Page 1 SERVICE MANUAL 2000 JEEP CHEROKEE To order the special service tools used and illustrated, please refer to the instructions on inside back cover. NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR...
Page 2 FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups.
Page 3: Table Of Contents
GROUP TAB LOCATOR Introduction Lubrication and Maintenance Suspension Differential and Driveline Brakes Clutch Cooling System Battery Starting System Charging System Ignition System Instrument Panel Systems Audio Systems Horn Systems Vehicle Speed Control System Turn Signal and Hazard Warning Systems Wiper and Washer Systems Lamps Passive Restraint Systems Electrically Heated Systems...
Page 5: Table Of Contents
LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE TABLE OF CONTENTS page page LUBRICANTS ......1 JUMP STARTING, TOWING AND HOISTING .
Page 6: Lubrication And Maintenance
0 - 2 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) API QUALITY CLASSIFICATION LUBRICANTS AND GREASES This symbol (Fig. 2) on the front of an oil container Lubricating grease is rated for quality and usage means that the oil has been certified by the Ameri- by the NLGI.
Page 7 LUBRICATION AND MAINTENANCE 0 - 3 MANUAL TRANSMISSION SPECIFICATIONS FLUID CAPACITIES AX5 (4X2) ....3.5 L (3.7 qts.) AX5 (4X4) ....3.3 L (3.5 qts.) FUEL TANK AX15 (4X2) .
Page 8: Suspension
0 - 4 LUBRICATION AND MAINTENANCE MAINTENANCE SCHEDULES TABLE OF CONTENTS page page SERVICE PROCEDURES UNSCHEDULED INSPECTION ....4 DESCRIPTION ......4 •...
Page 9 LUBRICATION AND MAINTENANCE 0 - 5 SERVICE PROCEDURES (Continued) • Flush and replace engine coolant if it has been 30,000 Miles (48 000 km) or at 24 months • Change engine oil. 30,000 miles (48 000 km) or 24 months since last •...
Page 10 0 - 6 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) • Lubricate steering linkage. • Lubricate steering and suspension ball joints. • Drain and refill automatic transmission fluid. • Drain and refill manual transmission fluid. • Drain and refill transfer case fluid. •...
Page 11 LUBRICATION AND MAINTENANCE 0 - 7 SERVICE PROCEDURES (Continued) 45,000 Miles (72 000 km) 66,000 Miles (106 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Inspect engine air cleaner element, replace •...
Page 12 0 - 8 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) • Lubricate steering linkage. 87,000 Miles (139 000 km) • Drain and refill automatic transmission fluid. • Change engine oil. • Drain and refill front and rear axles.‡ • Replace engine oil filter. •...
Page 13 LUBRICATION AND MAINTENANCE 0 - 9 JUMP STARTING, TOWING AND HOISTING TABLE OF CONTENTS page page SERVICE PROCEDURES FOUR-WHEEL-DRIVE VEHICLE TOWING ..10 JUMP STARTING PROCEDURE....9 EMERGENCY TOW HOOKS .
Page 14 0 - 10 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) CAUTION: Do not crank starter motor on disabled TOWING-REAR END LIFTED (WHEEL LIFT) vehicle for more than 15 seconds, starter will over- (1) Raise front of vehicle off ground and install tow heat and could fail.
Page 15 When properly positioned, a floor jack can be used dollies under front wheels. to lift a Jeep vehicle (Fig. 2) and (Fig. 3). Support the (2) Attach wheel lift to rear wheels. vehicle in the raised position with jack stands at the (3) Place transmission in neutral.
Page 16 0 - 12 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) CAUTION: Do not attempt to lift a Jeep vehicle with a floor jack positioned under: • An axle tube. • A body side sill. • A steering linkage component. • A drive shaft.
Page 17 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE TABLE OF CONTENTS page page LUBRICANTS ......1 MAINTENANCE SCHEDULE.
Page 18 0 - 2 LUBRICATION AND MAINTENANCE MAINTENANCE SCHEDULE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SCHEDULE—B ......3 MAINTENANCE SCHEDULE—DIESEL ENGINE .
Page 19 LUBRICATION AND MAINTENANCE 0 - 3 SERVICE PROCEDURES (Continued) • Replace air filter element. 1 000 KM • Replace drive belt. • Change engine oil. • Check engine smoke. • Change engine oil filter. • Replace engine coolant. • Check all fluid levels. 70 000 KM 5 000 KM •...
Page 20 0 - 4 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) 55 000 KM 90 000 KM • Change engine oil. • Change engine oil. • Change engine oil filter. • Change engine oil filter. • Replace air filter element. 60 000 KM •...
Page 21 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page ALIGNMENT ......1 REAR SUSPENSION .
Page 22 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) • THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and exces- sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle.
Page 23 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING SUSPENSION AND STEERING SYSTEM CONDITION POSSIBLE CAUSES CORRECTION FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. 2. Loose or worn steering or 2. Tighten or replace components as suspension components.
Page 24 2 - 4 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock. OR SQUEAKING 2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components suspension components. as necessary. 3. Shock valve. 3.
Page 25 SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) bolts as shown (Fig. 4) and tighten to 49 N·m (36 ft. lbs.). NOTE: Make sure the toe setting does not change during clamp tightening. (4) Adjust the left wheel toe position with the tie rod.
Page 26 2 - 6 SUSPENSION SERVICE PROCEDURES (Continued) Fig. 5 Steering Linkage (RHD) 1 – PITMAN ARM 4 – TIE ROD 2 – DRAG LINK 5 – ADJUSTMENT SLEEVE 3 – STEERING DAMPNER (5) Verify the right toe setting and turn off engine. NOTE: Make sure the toe setting does not change during clamp tightening.
Page 27 SUSPENSION 2 - 7 FRONT SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COIL SPRING/JOUNCE BUMPER ... . . 9 SUSPENSION COMPONENTS ....7 STEERING KNUCKLE .
Page 28 2 - 8 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Suspension Components (LHD) 1 – LINKS 6 – JOUNCE BUMPER 2 – SHOCK ABSORBER 7 – LOWER SUSPENSION ARM 3 – UPPER SUSPENSION ARM 8 – TRACK BAR 4 – STABILIZER BAR 9 –...
Page 29 SUSPENSION 2 - 9 DESCRIPTION AND OPERATION (Continued) STABILIZER BAR ing components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be DESCRIPTION caused by the hydraulic valving and may be intermit- The spring steel bar extends across the underside tent.
Page 30 2 - 10 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 2 Coil Spring & Shock Absorber 1 – SPRING 9 – SPRING 2 – SCREW 10 – NUT 3 – SPRING RETAINER 11 – SCREW 4 – NUT 12 – SHOCK ABSORBER 5 –...
Page 31 SUSPENSION 2 - 11 REMOVAL AND INSTALLATION (Continued) (2) Position Spacer 7932-3 over the axle bushing on a 4x2 vehicle and right side on a 4x4 vehicle. (3) Place Receiver 7932-1 over flanged end of the bushing. (Fig. 4). (4) Place small end of Remover/Install 7932-2 against other side of the bushing.
Page 32 2 - 12 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 5 Bushing Installation 1 – REMOVER/INSTALLER 2 – AXLE BRACKET 3 – BOLT 4 – RECEIVER 5 – LONG NUT STABILIZER BAR Fig. 6 Stabilizer Bar (LHD) 1 – RETAINER 2 – GROMMET REMOVAL 3 –...
Page 33 SUSPENSION 2 - 13 REMOVAL AND INSTALLATION (Continued) (2) Install the hub bearing to knuckle bolts and tighten to 102 N·m (75 ft. lbs.). (3) Install the hub washer and nut. Tighten the hub nut to 237 N·m (175 ft. lbs.). Install the nut retainer and a new cotter pin.
Page 34 2 - 14 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 8 Hub Bearing & Knuckle 1 – BRAKE SHIELD 6 – HUB AND BEARING ASSEMBLY 2 – WASHER 7 – STEERING KNUCKLE 3 – RETAINER 8 – BOLT 4 – COTTER PIN 9 –...
Page 35 SUSPENSION 2 - 15 SPECIFICATIONS (Continued) DESCRIPTION TORQUE Track Bar Bracket Bolts ....125 N·m (92 ft. lbs.) Nut ....100 N·m (74 ft. lbs.) Support Bolts .
Page 36 2 - 16 SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION SUSPENSION COMPONENT ....16 SHOCK ABSORBER..... . . 17 SHOCK ABSORBERS .
Page 37 SUSPENSION 2 - 17 DESCRIPTION AND OPERATION (Continued) OPERATION tent. This condition is not repairable and the shock absorber must be replaced. The leaf springs control ride quality and maintain The shock absorbers are not refillable or adjust- proper ride height. The shackles allow the springs to able.
Page 38 2 - 18 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 1 Rear Suspension Components 1 – SHOCK ABSORBER 8 – RETAINER 2 – SPRING BRACKET 9 – SHOCK ABSORBER 3 – NUT 10 – SPRING 4 – BUSHING 11 – U-BOLTS 5 –...
Page 39 SUSPENSION 2 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 2 Stabilizer Bar Fig. 3 Spring Eye Bushing Removal 1 – LINK 1 – NUT 2 – BUSHING 2 – PIPE (RECEIVER) 3 – GROMMET 3 – SPRING EYE 4 – FRAME RAIL 4 –...
Page 41: Differential And Driveline
DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFTS ..... . . 1 194 RBI AXLE .
Page 42 3 - 2 PROPELLER SHAFTS DESCRIPTION AND OPERATION (Continued) Before undercoating a vehicle, the propeller shaft and the U-joints should be covered to pre- vent an out-of-balance condition and driveline vibration. CAUTION: Use original equipment replacement parts for attaching the propeller shafts. The speci- fied torque must always be applied when tightening the fasteners.
Page 43 PROPELLER SHAFTS 3 - 3 DESCRIPTION AND OPERATION (Continued) PROPELLER SHAFT JOINT ANGLE DESCRIPTION When two shafts come together at a common joint, the bend that is formed is called the operating angle. The larger the angle, the larger the amount of angu- lar acceleration and deceleration of the joint.
Page 44: Brakes
3 - 4 PROPELLER SHAFTS DESCRIPTION AND OPERATION (Continued) Propeller shaft speed (rpm) is the main factor in DIAGNOSIS AND TESTING determining the maximum allowable operating angle. As a guide to the maximum normal operating angles VIBRATION refer to (Fig. 5). Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration.
Page 45 PROPELLER SHAFTS 3 - 5 DIAGNOSIS AND TESTING (Continued) UNBALANCE NOTE: Removing and re-indexing the propeller shaft 180° relative to the yoke may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: (1) Raise the vehicle.
Page 46 3 - 6 PROPELLER SHAFTS DIAGNOSIS AND TESTING (Continued) (4) Refer to Runout Specifications chart. (2) Rotate the shaft until transmission/transfer (5) If the propeller shaft runout is out of specifica- case output yoke bearing is facing downward. tion, remove the propeller shaft, index the shaft 180°, Always make measurements from front to and re-install the propeller shaft.
Page 47 PROPELLER SHAFTS 3 - 7 SERVICE PROCEDURES (Continued) Fig. 10 Propeller Shaft Angle Measurement (C) 1 – SHAFT YOKE BEARING CAP Fig. 11 Rear (Input) Angle Measurement (B) 2 – SPECIAL TOOL 7663 (J23498–A) 1 – PINION YOKE BEARING CAP 2 –...
Page 48 3 - 8 PROPELLER SHAFTS SERVICE PROCEDURES (Continued) • Good cancellation of U–joint operating angles (within 1°). • Operating angles less than 3°. • At least 1/2 of one degree continuous operating (propeller shaft) angle. REMOVAL AND INSTALLATION FRONT PROPELLER SHAFT REMOVAL (1) Hoist and support vehicle on safety stands.
Page 49 PROPELLER SHAFTS 3 - 9 REMOVAL AND INSTALLATION (Continued) (4) Lower the vehicle. Fig. 15 Dust Boot Clamp Fig. 17 Crimping Dust Boot Clamp 1 – SLINGER 1 – SPECIAL TOOL C-4975–A 2 – BOOT 2 – SLINGER 3 – AWL 3 –...
Page 50 3 - 10 PROPELLER SHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (4) Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. (5) Position the yoke with the grease fitting, if equipped, pointing up.
Page 51 PROPELLER SHAFTS 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 23 Remove Snap Rings Fig. 22 Install Bearing On Trunnion 1 – BEARING CAP 2 – TRUNNION (4) Press the bearing cap into the yoke bore enough to install a snap ring. (5) Install a snap ring.
Page 52 3 - 12 PROPELLER SHAFTS DISASSEMBLY AND ASSEMBLY (Continued) Fig. 27 Install Cross In Yoke (3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 28). Keep the needle bearings upright in the bearing assembly. A Fig.
Page 53 PROPELLER SHAFTS 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) (7) Fit the link yoke on the remaining two trun- nions and press both bearing caps into place (Fig. 31). (8) Install snap rings. Fig. 29 Press In Bearing Cap (6) Flip the propeller shaft yoke and install the bearing cap onto the opposite trunnion.
Page 54 3 - 14 PROPELLER SHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (10) Place two bearing caps on opposite trunnions of the remaining cross. Fit the open trunnions into the link yoke bores and the bearing caps into the centering kit (Fig. 33). Fig.
Page 55 PROPELLER SHAFTS 3 - 15 ADJUSTMENTS REAR AXLE PINION INPUT ANGLE Adjust the rear axle pinion input angle on vehicles equipped with leaf springs with tapered shims (Fig. 37). Install tapered shims between the springs and axle pad to correct the angle. Refer to Group 2, Sus- pension, for additional information.
Page 56 3 - 16 TUBE, 181, AND 186 FBI AXLE TUBE, 181, AND 186 FBI AXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIFFERENTIAL SIDE BEARINGS ... . . 36 181 FBI AXLE.
Page 57 TUBE, 181, AND 186 FBI AXLE 3 - 17 DESCRIPTION AND OPERATION (Continued) OPERATION The differential case is a one–piece design. The dif- ferential pinion mate shaft is retained with a roll The axle receives power from the transfer case pin.
Page 58 3 - 18 TUBE, 181, AND 186 FBI AXLE DESCRIPTION AND OPERATION (Continued) STANDARD DIFFERENTIAL DESCRIPTION The differential gear system divides the torque between the axle shafts. It allows the axle shafts to rotate at different speeds when turning corners. Each differential side gear is splined to an axle shaft.
Page 59: Clutch
TUBE, 181, AND 186 FBI AXLE 3 - 19 • Incorrect or contaminated lubricant. DIAGNOSIS AND TESTING • Overloading (excessive engine torque) or exceed- ing vehicle weight capacity. GENERAL INFORMATION • Incorrect clearance or backlash adjustment. Axle bearing problem conditions are usually caused Axle component breakage is most often the result •...
Page 60 3 - 20 TUBE, 181, AND 186 FBI AXLE DIAGNOSIS AND TESTING (Continued) Condition Possible Causes Correction Differential 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the Gears Scored correct fluid type and quantity. 2. Improper grade of lubricant. 2.
Page 61 TUBE, 181, AND 186 FBI AXLE 3 - 21 DIAGNOSIS AND TESTING (Continued) GEAR NOISE VIBRATION Axle gear noise can be caused by insufficient lubri- Vibration at the rear of the vehicle is usually cant, incorrect backlash, tooth contact, worn/damaged caused by a: •...
Page 62 3 - 22 TUBE, 181, AND 186 FBI AXLE SERVICE PROCEDURES (Continued) (6) Apply a bead of Mopar Silicone Rubber Seal- (7) Disconnect the vent hose from the axle shaft ant, or equivalent, to the housing cover (Fig. 3). tube. (8) Mark the propeller shaft and yoke for installa- tion alignment reference.
Page 63 TUBE, 181, AND 186 FBI AXLE 3 - 23 REMOVAL AND INSTALLATION (Continued) (13) Align the previously made marks on the pro- (4) Position the upper and lower suspension arms peller shaft and the yoke. in the axle brackets. Loosely install bolts and nuts to (14) Install the straps and bolts to hold the propel- hold suspension arms to the axle brackets.
Page 64 3 - 24 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) (6) Compress the vise jaws to force the bearing cap into the larger socket (receiver). (7) Release the vise jaws. Remove the sockets and bearing cap that was partially forced out of the yoke. (8) Repeat the above procedure for the remaining bearing cap.
Page 65 TUBE, 181, AND 186 FBI AXLE 3 - 25 REMOVAL AND INSTALLATION (Continued) Fig. 8 Pinion Yoke Installation Fig. 6 Pinion Yoke Removal 1 – PINION YOKE 1 – SPECIAL TOOL C-3281 2 – AXLE HOUSING 2 – YOKE 3 – SPECIAL TOOL C-452 Fig.
Page 66 3 - 26 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) 186 FBI PINION SHAFT SEAL REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures. (4) Mark the propeller shaft and pinion yoke for installation reference.
Page 67 TUBE, 181, AND 186 FBI AXLE 3 - 27 REMOVAL AND INSTALLATION (Continued) (8) Install the brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures. (9) Install wheel and tire assemblies. (10) Lower the vehicle. COLLAPSIBLE SPACER REMOVAL W/PINION INSTALLED (1) Raise and support the vehicle.
Page 68 3 - 28 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) REMOVAL W/PINION REMOVED (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures. (4) Mark the propeller shaft and pinion yoke for installation reference.
Page 69 TUBE, 181, AND 186 FBI AXLE 3 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 19 Pinion Yoke Installation 1 – PINION YOKE 2 – AXLE HOUSING NOTE: If new pinion bearings were installed, do not install the differential assembly and axle shafts until Fig.
Page 70 3 - 30 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 22 Hub, Knuckle and Axle Shaft 1 – BRAKE SHIELD 6 – HUB AND BEARING ASSEMBLY 2 – WASHER 7 – STEERING KNUCKLE 3 – RETAINER 8 –...
Page 71 TUBE, 181, AND 186 FBI AXLE 3 - 31 REMOVAL AND INSTALLATION (Continued) STEERING KNUCKLE AND BALL STUDS Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289.
Page 72 3 - 32 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 26 Upper Ball Stud Remove/Install UPPER BALL STUD REPLACEMENT (2) Install and tighten the bottom retaining nut to 109 N·m (80 ft. lbs.) torque. Install new cotter pin. (1) Position tools as shown to remove and install (3) Install and tighten the top retaining nut to 101 ball stud (Fig.
Page 73 TUBE, 181, AND 186 FBI AXLE 3 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 27 Lower Ball Stud Remove/Install 1 – SPECIAL TOOL 6289–12 4 – SPECIAL TOOL 4212F 2 – SPECIAL TOOL 6289–4 5 – SPECIAL TOOL 6289–1 3 – SPECIAL TOOL 4212F 6 –...
Page 74 3 - 34 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 30 Install Dial Indicator 1 – SPECIAL TOOL C-3339 2 – DIAL INDICATOR 3 – LEVER ADAPTER 4 – SPECIAL TOOL Fig. 29 Install Axle Housing Spreader W-129–B 1 –...
Page 75 TUBE, 181, AND 186 FBI AXLE 3 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 32 Differential Case Removal 1 – AXLE HOUSING 2 – DIFFERENTIAL CASE 3 – BEARING CUPS INSTALLATION Fig. 33 Install Axle Housing Spreader If replacement differential bearings or differential 1 –...
Page 76 3 - 36 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) DIFFERENTIAL SIDE BEARINGS REMOVAL (1) Remove differential case from axle housing. (2) Remove the bearings from the differential case with Puller/Press C-293-PA, C-293-39 Adapter Blocks, and Plug SP-3289 (Fig. 35). Fig.
Page 77 TUBE, 181, AND 186 FBI AXLE 3 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 39 Remove Pinion Gear Fig. 37 Axle Seal Installation 1 – RAWHIDE HAMMER 1 – TURNBUCKLE 6797 2 – DISCS 8110 (7) Remove the front pinion bearing cup, bearing, (4) Using Holder 6958 to hold yoke, remove the oil slinger, if equipped, and pinion seal with Remover D-147 and Handle C–4171 (Fig.
Page 78 3 - 38 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) (8) Remove the rear pinion bearing cup and oil slinger from the axle housing (Fig. 41). Use Remover D-149 and Handle C–4171. Record the thickness of the oil slinger for future reference. Fig.
Page 79 TUBE, 181, AND 186 FBI AXLE 3 - 39 REMOVAL AND INSTALLATION (Continued) (3) Apply Mopar Door Ease, or equivalent, stick (6) Install the rear pinion bearing and pinion lubricant to outside surface of front pinion bearing depth shim/oil baffle onto the pinion gear with cup.
Page 80 3 - 40 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 47 Pinion Preload Shims–Typical 1 – PINION PRELOAD SHIMS 5 – WASHER 2 – FRONT BEARING CUP 6 – PINION NUT 3 – SLINGER 7 – PINION OIL SEAL 4 –...
Page 81 TUBE, 181, AND 186 FBI AXLE 3 - 41 REMOVAL AND INSTALLATION (Continued) (14) If the maximum tightening torque is reached (4) Using Holder 6958 to the hold yoke, remove prior to achieving the desired rotating torque, remove the pinion nut and washer (Fig. 50). the pinion yoke and decrease the thickness of the (5) Using Remover C–452 and Holder C-3281, preload shim pack.
Page 82 3 - 42 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) (6) Remove the pinion and collapsible spacer from (8) Remove the rear pinion bearing cup from axle housing (Fig. 52). Catch the pinion with your hand to housing (Fig.
Page 83 TUBE, 181, AND 186 FBI AXLE 3 - 43 REMOVAL AND INSTALLATION (Continued) (10) Remove the rear pinion bearing from the pin- with Puller/Press C–293-PA Adapters C–293–39 (Fig. 56). Place 4 adapter blocks so they do not damage the bearing cage. Fig.
Page 84 3 - 44 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 59 Pinion Seal Installation 1 – SPECIAL TOOL C-4171 2 – SPECIAL TOOL C-3972–A Fig. 61 Collapsible Preload Spacer 1 – COLLAPSIBLE SPACER 2 – SHOULDER 3 –...
Page 85 TUBE, 181, AND 186 FBI AXLE 3 - 45 REMOVAL AND INSTALLATION (Continued) bearing end play is taken up (Fig. 63). If more than 353 N·m (260 ft. lbs.) is needed to begin to collapse the spacer, the spacer is defective and must be replaced.
Page 86 3 - 46 TUBE, 181, AND 186 FBI AXLE REMOVAL AND INSTALLATION (Continued) (1) Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (2) Invert the differential case in the vise. (3) Install new ring gear bolts and alternately tighten to 95–122 N·m (70–90 ft.
Page 87 TUBE, 181, AND 186 FBI AXLE 3 - 47 DISASSEMBLY AND ASSEMBLY (Continued) (3) Install the pinion gear mate shaft. Align the roll pin holes in shaft and the differential case. (4) Install the roll pin to hold the pinion mate shaft in the differential case (Fig.
Page 88 3 - 48 TUBE, 181, AND 186 FBI AXLE CLEANING AND INSPECTION (Continued) • Wear and damage to pinion gear mate shaft, Compensation pinion depth variance pinion gears, side gears and thrust washers. Replace achieved with a select shim/oil baffle. The shims are as a matched set only.
Page 89 TUBE, 181, AND 186 FBI AXLE 3 - 49 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002...
Page 90 3 - 50 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) Fig. 75 Gauge Tools In Housing—Typical Fig. 76 Pinion Gear Depth Measurement—Typical 1 – ARBOR DISC 1 – ARBOR 2 – PINION BLOCK 2 – SCOOTER BLOCK 3 – ARBOR 3 –...
Page 91 TUBE, 181, AND 186 FBI AXLE 3 - 51 ADJUSTMENTS (Continued) PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the axle housing. Take measurements with Pinion Gauge Set 6774 and Dial Indicator C-3339 (Fig. 79). Fig.
Page 92 3 - 52 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) (1) Assemble Pinion Height Block 6739, Pinion Block 6733, and rear pinion bearing onto Screw 6741 (Fig. 79). (2) Insert assembled height gauge components, rear bearing and screw into axle housing through pinion bearing cups (Fig.
Page 93 TUBE, 181, AND 186 FBI AXLE 3 - 53 ADJUSTMENTS (Continued) differential side bearing cones. The proper shim (2) Remove factory installed shims from differen- thickness can be determined using slip-fit dummy tial case. bearings D-348 in place of the differential side bear- (3) Install ring gear on differential case and ings and a dial indicator C-3339.
Page 94 3 - 54 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) Fig. 88 Hold Differential Case and Zero Dial Fig. 86 Seat Ring Gear Side Differential Dummy Indicator Side Bearing 1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE 1 – AXLE HOUSING 2 –...
Page 95 TUBE, 181, AND 186 FBI AXLE 3 - 55 ADJUSTMENTS (Continued) (17) Install the pinion gear in axle housing. Install the pinion yoke and establish the correct pinion rotating torque. (18) Install differential case and dummy bearings D-348 in axle housing (without shims), install bear- ing caps and tighten bolts snug.
Page 96 3 - 56 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) proper pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differential side play is measured, the pinion is installed, and the gear backlash shim thickness is measured.
Page 97 TUBE, 181, AND 186 FBI AXLE 3 - 57 ADJUSTMENTS (Continued) (6) Install the marked bearing caps in their correct positions. Install and snug the bolts (Fig. 95). Fig. 97 Seat Ring Gear Side Differential Dummy Side Bearing Fig. 95 Tighten Bolts Holding Bearing Caps 1 –...
Page 98 3 - 58 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) (19) Seat ring gear side dummy bearing (Fig. 97). (20) Position the dial indicator plunger on a flat surface between the ring gear bolt heads. (Fig. 98). (21) Push and hold differential case toward pinion gear (Fig.
Page 99 TUBE, 181, AND 186 FBI AXLE 3 - 59 ADJUSTMENTS (Continued) (25) Subtract 0.002 in. (0.05 mm) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash. (26) Subtract the backlash shim thickness from the total preload shim thickness.
Page 100 3 - 60 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) Fig. 105 Gear Tooth Contact Patterns...
Page 101 TUBE, 181, AND 186 FBI AXLE 3 - 61 SPECIFICATIONS SPECIAL TOOLS 181 FBI AXLE 181 and 186 FBI AXLE Axle Type ......Hypoid Lubricant–Std.
Page 102 3 - 62 TUBE, 181, AND 186 FBI AXLE SPECIAL TOOLS (Continued) Dial Indicator—C-3339 Installer—W-162-D Driver—C-3716-A Cup—8109 Remover/Installer—6289 Handle—C-4171 Installer—6761 Installer—D-146 Installer—6752 Remover—D-149...
Page 103 TUBE, 181, AND 186 FBI AXLE 3 - 63 SPECIAL TOOLS (Continued) Installer Discs—8110 Installer—C-3972-A Turnbuckle—6797 Spreader—W-129-B Tool Set, Pinion Depth—6774 Adapter Kit—6987 Gauge Block—6733 Pilot Stud—C-3288-B Spanner—6958 Remover—D-147...
Page 104 3 - 64 TUBE, 181, AND 186 FBI AXLE SPECIAL TOOLS (Continued) Installer—D-144 Installer—W-262...
Page 105 194 RBI AXLE 3 - 65 194 RBI AXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIFFERENTIAL ......78 194 RBI AXLE .
Page 106 3 - 66 194 RBI AXLE DESCRIPTION AND OPERATION (Continued) OPERATION In operation, power flow occurs as follows: • The pinion gear rotates the ring gear • The ring gear (bolted to the differential case) rotates the case • The differential pinion gears (mounted on the pinion mate shaft in the case) rotate the side gears •...
Page 107 194 RBI AXLE 3 - 67 DESCRIPTION AND OPERATION (Continued) Fig. 3 Differential Operation—On Turns 1 – PINION GEARS ROTATE ON PINION SHAFT In the Trac-lok differential, part of the ring gear torque is transmitted through clutch packs which contain multiple discs. The clutches will have radial grooves on the plates, and concentric grooves on the discs or bonded fiber material that is smooth in appearance.
Page 108 3 - 68 194 RBI AXLE DIAGNOSIS AND TESTING (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. Misaligned axle tube. 1.
Page 109 194 RBI AXLE 3 - 69 DIAGNOSIS AND TESTING (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. Cracked differential housing. 3.
Page 110 3 - 70 194 RBI AXLE DIAGNOSIS AND TESTING (Continued) GEAR NOISE VIBRATION Axle gear noise can be caused by insufficient lubri- Vibration at the rear of the vehicle is usually cant, incorrect backlash, tooth contact, worn/damaged caused by a: •...
Page 111 194 RBI AXLE 3 - 71 DIAGNOSIS AND TESTING (Continued) TRAC–LOK TEST (3) Remove the differential housing cover and drain the lubricant from the housing. (4) Clean the housing cavity with a flushing oil, WARNING: WHEN SERVICING VEHICLES WITH A light engine oil, or lint free cloth.
Page 112 3 - 72 194 RBI AXLE (8) Connect the brake hose to the axle junction REMOVAL AND INSTALLATION block. Refer to Group 5, Brakes, for proper proce- dures. REAR AXLE (9) Install axle vent hose. (10) Align propeller shaft and pinion yoke refer- REMOVAL ence marks.
Page 113 194 RBI AXLE 3 - 73 REMOVAL AND INSTALLATION (Continued) (10) Use a suitable pry tool or slide hammer CAUTION: Never loosen pinion gear mounted screw to remove the pinion gear seal. decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload INSTALLATION torque or rotating torque is exceeded a new col- (1) Apply a light coating of gear lubricant on the...
Page 114 3 - 74 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 11 Tightening Pinion Shaft Nut–Typical Fig. 12 Pinion Yoke Removal 1 – SPECIAL TOOL 6958 1 – SPECIAL TOOL C-3281 2 – 1 in. PIPE 2 – YOKE 3 – 3/4 DRIVE TORQUE WRENCH 3 –...
Page 115 194 RBI AXLE 3 - 75 REMOVAL AND INSTALLATION (Continued) Fig. 15 Pinion Seal Installation 1 – SPECIAL TOOL C-4171 2 – SPECIAL TOOL C-3972–A Fig. 13 Remove Pinion Gear 1 – RAWHIDE HAMMER Fig. 16 Pinion Yoke Installation 1 – PINION YOKE 2 –...
Page 116 3 - 76 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) (10) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 18). Fig.
Page 117 194 RBI AXLE 3 - 77 REMOVAL AND INSTALLATION (Continued) AXLE SHAFT SEAL AND BEARING REMOVAL (1) Remove the axle shaft. (2) Remove the axle shaft seal from the end of the axle shaft tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool.
Page 118 3 - 78 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) (6) Loosen the differential bearing cap bolts. (7) Position Spreader W–129–B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 24). Install the hold- down clamps and tighten the tool turnbuckle finger–...
Page 119 194 RBI AXLE 3 - 79 REMOVAL AND INSTALLATION (Continued) Fig. 27 Differential Case Removal Fig. 25 Install Dial Indicator 1 – SPECIAL TOOLC-3339 1 – AXLE HOUSING 2 – DIAL INDICATOR 2 – DIFFERENTIAL CASE 3 – LEVER ADAPTER 3 –...
Page 120 3 - 80 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) (2) Remove the bearings from the differential case with Puller/Press C-293-PA, C-293-39 Blocks, and Plug SP-3289 (Fig. 30). Fig. 28 Install Axle Housing Spreader 1 – AXLE HOUSING 2 – DOWEL 3 –...
Page 121 194 RBI AXLE 3 - 81 REMOVAL AND INSTALLATION (Continued) (1) Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (2) Invert the differential case in the vise. (3) Install new ring gear bolts and alternately tighten to 95–122 N·m (70–90 ft.
Page 122 3 - 82 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 34 Pinion Yoke Removal 1 – SPECIAL TOOL C-3281 2 – YOKE 3 – SPECIAL TOOL C-452 Fig. 36 Front Bearing Cup Removal 1 – REMOVER 2 – HANDLE Fig.
Page 123 194 RBI AXLE 3 - 83 REMOVAL AND INSTALLATION (Continued) (13) Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION (1) Apply Mopar Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. (2) Install the pinion rear bearing cup with Installer D-146 and Driver Handle C–4171 (Fig.
Page 124 3 - 84 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 41 Pinion Front Bearing Cup Installation 1 – INSTALLER 2 – HANDLE Fig. 43 Shaft Rear Bearing Installation 1 – PRESS 2 – INSTALLATION TOOL 3 – DRIVE PINION GEAR 4 –...
Page 125 194 RBI AXLE 3 - 85 REMOVAL AND INSTALLATION (Continued) • Original Bearings — 1 to 2 N·m (10 to 20 in. lbs.). • New Bearings — 1.5 to 4 N·m (15 to 35 in. lbs.). Fig. 45 Pinion Yoke Installation 1 –...
Page 126 3 - 86 194 RBI AXLE REMOVAL AND INSTALLATION (Continued) Fig. 49 Pinion Mate Shaft Lock Screw 1 – LOCK SCREW 2 – PINION MATE SHAFT Fig. 48 Typical Housing Cover With Sealant 1 – SEALING SURFACE 2 – CONTOUR OF BEAD 3 –...
Page 127 194 RBI AXLE 3 - 87 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 51 Trac–lok Differential Components 1 – THRUST WASHER 6 – RETAINER 2 – PINION 7 – DISC 3 – SHAFT LOCK SCREW 8 – CLUTCH PACK 4 – PINION MATE SHAFT 9 –...
Page 128 3 - 88 194 RBI AXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Mate Shaft Lock Screw 1 – LOCK SCREW 2 – PINION GEAR MATE SHAFT Fig. 55 Step Plate Tool Installation 1 – LOWER SIDE GEAR 2 – DIFFERENTIAL CASE 3 –...
Page 129 194 RBI AXLE 3 - 89 DISASSEMBLY AND ASSEMBLY (Continued) (13) Rotate differential case until the pinion gears can be removed. (14) Remove pinion gears from differential case. Fig. 57 Tighten Belleville Spring Compressor Tool 1 – TORQUE WRENCH 2 – TOOL ASSEMBLED 3 –...
Page 130 3 - 90 194 RBI AXLE DISASSEMBLY AND ASSEMBLY (Continued) (17) Remove differential case from Side Gear Hold- ing Tool 6965. Remove side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal. ASSEMBLY NOTE: The clutch discs are replaceable as com- plete sets only.
Page 131 194 RBI AXLE 3 - 91 DISASSEMBLY AND ASSEMBLY (Continued) (11) Rotate case with Turning Bar C-6960-2 until TRAC-LOK the pinion mate shaft holes in pinion gears align Clean all components in cleaning solvent. Dry com- with holes in case. It may be necessary to slightly ponents with compressed air.
Page 132 3 - 92 194 RBI AXLE ADJUSTMENTS (Continued) Compensation pinion depth variance achieved with select shims. The shims are placed under the inner pinion bearing cone (Fig. 65). If a new gear set is being installed, note the depth variance etched into both the original and replace- ment pinion gear.
Page 133 194 RBI AXLE 3 - 93 ADJUSTMENTS (Continued) Fig. 68 Gauge Tools In Housing—Typical 1 – ARBOR DISC 2 – PINION BLOCK 3 – ARBOR 4 – PINION HEIGHT BLOCK (6) Place Scooter Block/Dial Indicator in position Fig. 66 Pinion Gear Depth Gauge Tools—Typical in axle housing so dial probe and scooter block are 1 –...
Page 134 3 - 94 194 RBI AXLE ADJUSTMENTS (Continued) Fig. 70 Axle Adjustment Shim Locations Fig. 69 Pinion Gear Depth Measurement—Typical 1 – PINION GEAR DEPTH SHIM 2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE 1 – ARBOR 3 – RING GEAR 2 –...
Page 135 194 RBI AXLE 3 - 95 ADJUSTMENTS (Continued) (6) Install the marked bearing caps in their correct positions. Install and snug the bolts. (7) Using a dead-blow type mallet, seat the differ- ential dummy bearings to each side of the axle hous- ing (Fig.
Page 136 3 - 96 194 RBI AXLE ADJUSTMENTS (Continued) (22) Zero dial indicator face to pointer. (23) Push and hold differential case to ring gear side of the axle housing. (24) Record dial indicator reading. (25) Subtract 0.002 in. (0.05 mm) from the dial indicator reading to compensate for backlash between ring and pinion gears.
Page 137 194 RBI AXLE 3 - 97 ADJUSTMENTS (Continued) (38) Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective.
Page 138 3 - 98 194 RBI AXLE ADJUSTMENTS (Continued) Fig. 79 Gear Tooth Contact Patterns...
Page 139 194 RBI AXLE 3 - 99 SPECIFICATIONS 194 RBI AXLE DESCRIPTION SPECIFICATION Axle Type ....Semi–Floating Hypoid Lubricant ..SAE Thermally Stable 80W–90 Lubricant Trailer Tow .
Page 140 3 - 100 194 RBI AXLE SPECIAL TOOLS (Continued) Installer—D-130 Spanner—6958 Installer—D-146 Installer Screw—8112 Cup—8109 Remover—C-4345 Remover—D-149 Handle—C-4171 Installer—W-262 Driver—C-3716-A...
Page 141 194 RBI AXLE 3 - 101 SPECIAL TOOLS (Continued) Installer—6436 Trac-lok Tool Set—6960 Holder—6965 Installer—6437 Puller—7794-A Disc, Axle Arbor—6732 Starting Point Shim—8107 Gauge Block—6735 Spreader—W-129-B Tool Set, Pinion Depth—6774...
Page 142 3 - 102 194 RBI AXLE SPECIAL TOOLS (Continued) Bearing Remover Tool Set—6310 Adapter Kit—6987 Guide Pin—C-3288-B Hub Puller—6790 Dial Indicator—C-3339...
Page 143 8 1/4 REAR AXLE 3 - 103 8 1/4 REAR AXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIFFERENTIAL......114 8 1/4 AXLE .
Page 144 3 - 104 8 1/4 REAR AXLE DESCRIPTION AND OPERATION (Continued) Fig. 1 8 1/4 Axle LUBRICANT DESCRIPTION Multi-purpose, hypoid gear lubricant should be used for rear axles with a standard differential. The lubricant should have a MIL-L-2105C and API GL 5 quality specifications.
Page 145 8 1/4 REAR AXLE 3 - 105 DESCRIPTION AND OPERATION (Continued) STANDARD DIFFERENTIAL When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated DESCRIPTION for to prevent the tires from scuffing and skidding The differential gear system divides the torque through turns.
Page 146 3 - 106 8 1/4 REAR AXLE DESCRIPTION AND OPERATION (Continued) straight ahead during periods of unequal traction. When one wheel looses traction, the clutch packs transfer additional torque to the wheel having the most traction. Trac-lok differentials resist wheel spin on bumpy roads and provide more pulling power when one wheel looses traction.
Page 147 8 1/4 REAR AXLE 3 - 107 DIAGNOSIS AND TESTING (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. Misaligned axle tube. 1.
Page 148 3 - 108 8 1/4 REAR AXLE DIAGNOSIS AND TESTING (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. Cracked differential housing. 3.
Page 149 8 1/4 REAR AXLE 3 - 109 DIAGNOSIS AND TESTING (Continued) GEAR NOISE VIBRATION Axle gear noise can be caused by insufficient lubri- Vibration at the rear of the vehicle is usually cant, incorrect backlash, tooth contact, worn/damaged caused by a: •...
Page 150 3 - 110 8 1/4 REAR AXLE DIAGNOSIS AND TESTING (Continued) TRAC–LOK TEST (3) Remove the differential housing cover and drain the lubricant from the housing. (4) Clean the housing cavity with a flushing oil, WARNING: WHEN SERVICING VEHICLES WITH A light engine oil, or lint free cloth.
Page 151 8 1/4 REAR AXLE 3 - 111 AXLE SHAFT REMOVAL AND INSTALLATION REAR AXLE REMOVAL (1) Raise and support vehicle. Ensure that the REMOVAL transmission is in neutral. (2) Remove wheel and tire assembly. (1) Raise and support the vehicle. (3) Remove brake drum.
Page 152 3 - 112 8 1/4 REAR AXLE REMOVAL AND INSTALLATION (Continued) Fig. 9 Axle Shaft C–Lock Fig. 10 Axle Seal Removal 1 – C—LOCK 1 – AXLE TUBE 2 – AXLE SHAFT 2 – AXLE SEAL 3 – SIDE GEAR 3 –...
Page 153 8 1/4 REAR AXLE 3 - 113 REMOVAL AND INSTALLATION (Continued) (3) Install a new axle seal with Installer C-4076-B and Handle C-4735-1. When the tool contacts the axle tube, the seal is installed to the correct depth. (4) Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft.
Page 154 3 - 114 8 1/4 REAR AXLE REMOVAL AND INSTALLATION (Continued) (6) Position the pinion yoke on the end of the shaft with the reference marks aligned. (7) Seat yoke on pinion shaft with Installer C-3718 and Wrench 6719. (8) Remove the tools and install the pinion yoke washer.
Page 155 8 1/4 REAR AXLE 3 - 115 REMOVAL AND INSTALLATION (Continued) (2) Mark the differential housing and the differen- INSTALLATION tial bearing caps for installation reference (Fig. 17). (1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters.
Page 156 3 - 116 8 1/4 REAR AXLE REMOVAL AND INSTALLATION (Continued) Fig. 21 Install Differential Side Bearings 1 – HANDLE C-4171 2 – DIFFERENTIAL 3 – BEARING 4 – TOOL C-4340 Fig. 20 Differential Bearing Removal 1 – SPECIAL TOOL C-293–PA 2 –...
Page 157 8 1/4 REAR AXLE 3 - 117 REMOVAL AND INSTALLATION (Continued) Fig. 24 Pinion Yoke Removal 1 – PINION YOKE 2 – TOOL C452 Fig. 23 Ring Gear Bolt Installation 1 – TORQUE WRENCH 2 – RING GEAR BOLT 3 – RING GEAR 4 –...
Page 158 3 - 118 8 1/4 REAR AXLE REMOVAL AND INSTALLATION (Continued) Fig. 28 Collapsible Spacer Fig. 26 Front Bearing Cup Removal 1 – COLLAPSIBLE SPACER 1 – REMOVER 2 – SHOULDER 2 – HANDLE 3 – PINION 4 – PINION DEPTH SHIM 5 –...
Page 159 8 1/4 REAR AXLE 3 - 119 REMOVAL AND INSTALLATION (Continued) Fig. 32 Pinion Seal Installation 1 – SPECIAL TOOL C-4735 2 – DIFFERENTIAL HOUSING 3 – SPECIAL TOOL C-4076-A (8) Install rear bearing slinger, Fig. 30 Pinion Rear Bearing Cup Installation equipped, on the pinion (Fig.
Page 160 3 - 120 8 1/4 REAR AXLE REMOVAL AND INSTALLATION (Continued) Fig. 34 Collapsible Preload Spacer Fig. 35 Check Pinion Rotating Torque 1 – COLLAPSIBLE SPACER 1 – PINION YOKE 2 – SHOULDER 2 – INCH POUND TORQUE WRENCH 3 – PINION 4 –...
Page 161 8 1/4 REAR AXLE 3 - 121 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Install the differential side gears and thrust washers. (2) Install the differential pinion gears and thrust washers. (3) Install the pinion mate shaft. (4) Align the hole in the pinion mate shaft with the hole in the differential case and install the pinion mate shaft lock screw.
Page 162 3 - 122 8 1/4 REAR AXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 41 Mate Shaft Removal 1 – PINION MATE SHAFT 2 – SIDE GEAR 3 – DRIFT 4 – PINION MATE GEAR Fig. 39 Differential Case Holding Tool 1 – SIDE GEAR HOLDING TOOL 2 –...
Page 163 8 1/4 REAR AXLE 3 - 123 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 43 Threaded Adapter Installation 1 – SOCKET Fig. 45 Remove Pinion Thrust Washer 2 – SLOT IN ADAPTER 1 – THRUST WASHER 3 – SCREWDRIVER 2 – FEELER GAUGE 4 –...
Page 164 3 - 124 8 1/4 REAR AXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 48 Clutch Disc Pack Fig. 47 Side Gear & Clutch Disc Removal 1 – CLUTCH PACK 1 – DIFFERENTIAL CASE 2 – RETAINER 2 – RETAINER 3 – SIDE GEAR 3 –...
Page 165 8 1/4 REAR AXLE 3 - 125 DISASSEMBLY AND ASSEMBLY (Continued) Be sure that the axle tubes and oil channels are thoroughly cleaned in the housing. Inspect for: • Smooth appearance with no broken/dented sur- faces on the bearing rollers or the roller contact sur- faces.
Page 166 3 - 126 8 1/4 REAR AXLE ADJUSTMENTS 8 1/4 AXLE PINION GEAR DEPTH GENERAL INFORMATION Ring gears and pinions are supplied as matched sets only. The identifying numbers for the ring gear and pinion are etched into the face of each gear (Fig. 51).
Page 167 8 1/4 REAR AXLE 3 - 127 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 −0.001...
Page 168 3 - 128 8 1/4 REAR AXLE ADJUSTMENTS (Continued) NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments: • Maintain the gear teeth engaged (meshed) as marked.
Page 169 8 1/4 REAR AXLE 3 - 129 ADJUSTMENTS (Continued) pinion. This will provide a more distinct contact pat- tern. (3) Using a boxed end wrench on a ring gear bolt, Rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.
Page 170 3 - 130 8 1/4 REAR AXLE ADJUSTMENTS (Continued) Fig. 59 Gear Tooth Contact Patterns...
Page 171 8 1/4 REAR AXLE 3 - 131 ADJUSTMENTS (Continued) 8 1/4 INCH AXLE DESCRIPTION TORQUE Diff. Cover Bolt ... . . 41 N·m (30 ft. lbs.) Bearing Cap Bolt ..136 N·m (100 ft. lbs.) Pinion Nut–Minimum .
Page 172 3 - 132 8 1/4 REAR AXLE SPECIAL TOOLS (Continued) Puller—C-452 Handle—C-4171 Installer—C-3718 Installer—C-4076-B Adjustment Rod—C-4164 Handle—C-4735-1 Puller/Press—C-293–PA Holder—6719 Adapters—C-293-48...
Page 173 8 1/4 REAR AXLE 3 - 133 SPECIAL TOOLS (Continued) Plug—SP-3289 Installer—C-4345 Adapters—C-293-47 Remover—C-4307 Installer—C-4308 Installer—C-4340 Installer—D-130 Holder—8138 Installer—6448...
Page 174 3 - 134 8 1/4 REAR AXLE SPECIAL TOOLS (Continued) Trac-lok Tools—8140 Pinion Gauge Block—8540 Trac-lok Tools—6960 Arbor Discs—8541 Pinion Gauge Set...
Page 175 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BASE BRAKE SYSTEM ..... . 1 ANTILOCK BRAKES ..... . . 33 BASE BRAKE SYSTEM TABLE OF CONTENTS page...
Page 176 5 - 2 BRAKES CAUTION: Never use gasoline, kerosene, alcohol, DESCRIPTION AND OPERATION motor oil, transmission fluid, or any fluid containing mineral oil to clean the system components. These BRAKE SYSTEM fluids damage rubber cups and seals. Use only fresh brake fluid or Mopar brake cleaner to clean or DESCRIPTION flush brake system components.
Page 177 BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) RED BRAKE WARNING LAMP MASTER CYLINDER DESCRIPTION DESCRIPTION A red warning lamp is used for the service brake The master cylinder has a removable nylon reser- portion of the hydraulic system. The lamp is located voir.
Page 178 5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 1 Power Brake Booster–Typical 1 – VACUUM CHECK VALVE 7 – PRIMARY PUSH ROD (TO BRAKE PEDAL) 2 – FRONT DIAPHRAGM 8 – ATMOSPHERIC INLET VALVE ASSEMBLY 3 – REAR DIAPHRAGM 9 –...
Page 179 BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 3 Lining Wear Compensation By Piston Seal 1 – PISTON 2 – CYLINDER BORE 3 – PISTON SEAL BRAKE PRESSURE OFF 4 – CALIPER HOUSING 5 – DUST BOOT 6 – PISTON SEAL BRAKE PRESSURE ON REAR DRUM BRAKE Fig.
Page 180 5 - 6 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 4 Brake Components 1 – ADJUSTER LEVER 11 – PARK BRAKE STRUT AND SPRING 2 – ADJUSTER CABLE 12 – ADJUSTER SCREW ASSEMBLY 3 – HOLDDOWN SPRING AND RETAINERS 13 – HOLDDOWN SPRING AND RETAINERS 4 –...
Page 181 BRAKES 5 - 7 DESCRIPTION AND OPERATION (Continued) may be required if a new tensioner, or cables are (5) Check brake pedal operation. Verify that pedal installed, or disconnected. does not bind and has adequate free play. If pedal lacks free play, check pedal and power booster for BRAKE HOSES AND LINES being loose or for bind condition.
Page 182 5 - 8 BRAKES DIAGNOSIS AND TESTING (Continued) PEDAL PULSATION BRAKE PULL Pedal pulsation is caused by components that are Front brake pull condition could result from: • Contaminated lining in one caliper loose, or beyond tolerance limits. • Seized caliper piston The primary cause of pulsation are disc brake •...
Page 183 BRAKES 5 - 9 DIAGNOSIS AND TESTING (Continued) WHEEL AND TIRE PROBLEMS BRAKE LAMP SWITCH Some conditions attributed to brake components The brake lamp switch operation can be tested may actually be caused by a wheel or tire problem. with an ohmmeter. The ohmmeter is used to check A damaged wheel can cause shudder, vibration and continuity between the pin terminals (Fig.
Page 184 5 - 10 BRAKES DIAGNOSIS AND TESTING (Continued) ferential switch and valve have been actuated due to a leak in the hydraulic system. On models with ABS brakes, the amber warning lamp only illuminates during the self test and when an ABS malfunction has occurred.
Page 185 BRAKES 5 - 11 DIAGNOSIS AND TESTING (Continued) COMBINATION VALVE brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 in.) inward from the rotor edge. Maximum allowable rotor runout is 0.102 mm PRESSURE DIFFERENTIAL SWITCH (0.004 in.). (1) Have helper sit in drivers seat to apply brake pedal and observe red brake warning light.
Page 186 5 - 12 BRAKES DIAGNOSIS AND TESTING (Continued) BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar.
Page 187 BRAKES 5 - 13 SERVICE PROCEDURES (Continued) (3) Fill reservoir with fresh brake fluid. (3) Attach one end of bleed hose to bleed screw (4) Press cylinder pistons inward with wood dowel. and insert opposite end in glass container partially Then release pistons and allow them to return under filled with brake fluid (Fig.
Page 188 5 - 14 BRAKES SERVICE PROCEDURES (Continued) mounted on-vehicle lathe is recommended. This type of lathe trues the rotor to the vehicles hub/bearing. CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. BRAKE DRUM MACHINING The brake drums can be machined on a drum lathe when necessary.
Page 189 BRAKES 5 - 15 SERVICE PROCEDURES (Continued) (4) Position the tube in the flaring tool flush with the top of the tool bar (Fig. 16). Then tighten the tool bar on the tube. (5) Install the correct size adaptor on the flaring tool yoke screw.
Page 190 5 - 16 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 18 Booster Push Rod 1 – BRAKE PEDAL 2 – BOOSTER ROD 3 – BUSHING INSTALLATION Fig. 19 Differential Pressure Switch 1 – SWITCH TERMINAL (1) Install pedal and support bracket as an assem- 2 –...
Page 191: Cooling System
BRAKES 5 - 17 REMOVAL AND INSTALLATION (Continued) (3) Remove mounting nuts from the combination POWER BRAKE BOOSTER valve bracket and remove the valve (Fig. 20). (4) Remove mounting nuts from the master cylin- REMOVAL der (Fig. 21). (1) On RHD vehicles remove the coolant reserve/ (5) Remove master cylinder.
Page 192 5 - 18 BRAKES REMOVAL AND INSTALLATION (Continued) (3) Drain small amount of fluid from master cylin- der brake reservoir with suction gun. (4) Bottom caliper piston in bore with C-clamp. Position clamp screw on outboard brake shoe and clamp frame on rear of caliper (Fig. 24). Do not allow clamp screw to bear directly on outboard shoe retainer spring.
Page 193 BRAKES 5 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 26 Caliper Mounting Bolts 1 – CALIPER MOUNTING BOLT (2) Fig. 28 Caliper Lubrication Points 2 – CALIPER 1 – BUSHINGS 2 – CALIPER MOUNTING BOLTS (7) Tilt top of caliper outward with pry tool if nec- 3 –...
Page 194 5 - 20 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 30 Mounting Bolt Dimensions Fig. 31 Outboard Brake Shoe Removal 1 – 67 mm ( 0.6 mm) 2.637 in. ( 0.0236 in.) 1 – OUTBOARD BRAKESHOE 2 – 22 mm (0.866 in.) THREAD LENGTH 2 –...
Page 195 BRAKES 5 - 21 REMOVAL AND INSTALLATION (Continued) DISC BRAKE ROTOR (6) Remove hold-down springs, retainers and pins with standard retaining spring tool. (7) Install spring clamps on wheel cylinders to REMOVAL hold pistons in place. (1) Remove wheel and tire assemble. (8) Remove adjuster lever, adjuster screw and (2) Remove caliper.
Page 196 5 - 22 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 34 Drum Brake Components—Typical 1 – ADJUSTER LEVER 11 – PARK BRAKE STRUT AND SPRING 2 – ADJUSTER CABLE 12 – ADJUSTER SCREW ASSEMBLY 3 – HOLDDOWN SPRING AND RETAINERS 13 – HOLDDOWN SPRING AND RETAINERS 4 –...
Page 197 BRAKES 5 - 23 REMOVAL AND INSTALLATION (Continued) (5) Disconnect brake line at wheel cylinder. (6) Remove wheel cylinder from support plate. (7) Remove axle shaft, refer to Group 3 for proce- dures. (8) Remove bolts attaching support plate to axle and remove support plate.
Page 198 5 - 24 BRAKES REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Release parking brakes. (2) Raise vehicle. (3) Remove adjusting nut from tensioner rod at the equalizer (Fig. 38). Fig. 39 Parking Brake Lever Assembly 1 – MOUNTING BOLTS 2 – FRONT CABLE LEVER 3 –...
Page 199 BRAKES 5 - 25 DISASSEMBLY AND ASSEMBLY (Continued) (3) Clamp cylinder body in vise with brass protec- tive jaws. (4) Loosen reservoir from grommets with pry tool (Fig. 41). Fig. 43 Grommet Removal 1 – MASTER CYLINDER BODY 2 – GROMMETS (1) Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body (Fig.
Page 200 5 - 26 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) This will cushion and protect caliper piston during removal (Fig. 45). Fig. 45 Padding Caliper Interior 1 – SHOP TOWELS OR CLOTHS 2 – CALIPER (4) Remove caliper piston with short bursts of Fig.
Page 201 BRAKES 5 - 27 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 51 Piston Seal Installation Fig. 48 Piston Seal Removal 1 – SEAL GROOVE 1 – REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL 2 – PISTON SEAL 2 – PISTON SEAL Fig.
Page 202 5 - 28 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (8) Seat dust boot in caliper with Installer Tool C-4842 and Tool Handle C-4171 (Fig. 54). Fig. 55 Wheel Cylinder Components–Typical 1 – SPRING 2 – CYLINDER 3 – PISTON CLIP 4 – BOOT 5 –...
Page 203 BRAKES 5 - 29 CLEANING AND INSPECTION (Continued) Fig. 56 Polishing Piston Bore Fig. 57 Shoe Contact Surfaces 1 – SPECIAL HONE 1 – ANCHOR PIN 2 – CALIPER 2 – SUPPORT PLATE 3 – PISTON BORE 3 – SHOE CONTACT SURFACES REAR DRUM BRAKE WHEEL CYLINDER CLEANING...
Page 204 5 - 30 BRAKES (5) Reverse gauge and install it on brake shoes. ADJUSTMENTS Position gauge legs at shoe centers as shown (Fig. 59). If gauge does not fit (too loose/too tight), adjust BRAKE LAMP SWITCH shoes. (1) Press and hold brake pedal in applied position. (2) Pull switch plunger all the way out to fully extended position.
Page 205 BRAKES 5 - 31 ADJUSTMENTS (Continued) (4) Check rear brake shoe adjustment with stan- dard brake gauge. CAUTION: Excessive shoe-to-drum clearance, or worn brake components will result in faulty parking brake adjustment and operation. (5) Verify that parking brake cables operate freely and are not binding, or seized.
Page 206: Engine
5 - 32 BRAKES SPECIFICATIONS (Continued) only Mopar brake fluid or an equivalent from a SPECIAL TOOLS tightly sealed container. BASE BRAKES CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container will absorb moisture from the air and contaminate the fluid.
Page 207 BRAKES 5 - 33 ANTILOCK BRAKES TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION ANTILOCK BRAKE SYSTEM ....33 HYDRAULIC CONTROL UNIT/CONTROLLER CONTROLLER ANTILOCK BRAKES .
Page 208 5 - 34 BRAKES DESCRIPTION AND OPERATION (Continued) microprocessors. A logic block in each microprocessor power booster operate the same as a vehicle without receives identical sensor signals. These signals are an ABS brake system. processed and compared simultaneously. The CAB During antilock braking, solenoid valve pressure contains a self check program that illuminates the modulation occurs in three stages, pressure increase,...
Page 209 BRAKES 5 - 35 DESCRIPTION AND OPERATION (Continued) sensors have a resistance between 900 and 1300 OPERATION ohms. PRESSURE DIFFERENTIAL VALVE The pressure differential switch is connected to the brake warning light. The switch is actuated by move- ment of the switch valve. The switch monitors fluid pressure in the separate front/rear brake hydraulic circuits.
Page 210 5 - 36 BRAKES DESCRIPTION AND OPERATION (Continued) (3) Select ANTILOCK BRAKES, followed by MIS- CELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. (4) Perform base brake bleeding a second time. Refer to base brake section for procedure.
Page 211 BRAKES 5 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 5 HCU/CAB Mounting 1 – HCU 2 – CAB 3 – HCU/CAB BRACKET 4 – MOTOR Fig. 6 Front Wheel Speed Sensor FRONT WHEEL SPEED SENSOR 1 – WHEEL SPEED SENSOR PIGTAIL 2 –...
Page 212 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 8 Rear Wheel Speed Sensor 1 – TONE WHEEL 2 – WHEEL SPEED SENSOR Fig. 7 Acceleration Switch And Rear Sensor Connections 1 – REAR SEAT CROSSMEMBER 2 – ACCELERATION SENSOR 3 –...
Page 213 BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 10 New Rear Sensor Fig. 12 G-Switch 1 – REAR SENSOR 1 – SWITCH PART NUMBER 2 – AIR GAP SPACER ATTACHED TO SENSOR FACE 2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER MOUNTING (2) Disconnect switch harness.
Page 214 5 - 40 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY SPECIFICATIONS (1) Install the CAB onto the HCU. T0RQUE CHART (2) Install the CAB mounting screws and tighten to 1.8 N·m (16 in. lbs.). (3) Install pump motor connector to the CAB. DESCRIPTION TORQUE G-Sensor...
Page 215 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SPECIFICATIONS BRAKE BOOSTER – RHD DIESEL ... . 1 TORQUE SPECIFICATIONS ....4 MASTER CYLINDER –...
Page 216 5 - 2 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 5 Booster Mounting Fig. 3 Master Cylinder 1 – BOOSTER 1 – BOOSTER 2 – MASTER CYLINDER NOTE: If a new master cylinder is being installed, (11) Remove the retaining clip that secures the cylinder must be bench bleed prior to installation.
Page 217 BRAKES 5 - 3 REMOVAL AND INSTALLATION (Continued) (15) Adjust the brake lamp switch. Refer to the procedure in this group. WARNING: Be certain firm brake pedal achieved prior to attempting to operate the vehicle. MASTER CYLINDER – RHD DIESEL REMOVAL (1) Open hood and disconnect the negative battery cable...
Page 218 5 - 4 BRAKES REMOVAL AND INSTALLATION (Continued) (4) Install combination valve/bracket and retaining SPECIFICATIONS nuts. (5) Install brake lines on cylinder and valve. TORQUE SPECIFICATIONS Torque brake lines to 19 N·m (170 in. lbs.). (6) Connect differential pressure switch wire on DESCRIPTION TORQUE the combination valve.
Page 219 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUTCH FLYWHEEL RUNOUT ....6 CLUTCH ....... . 1 CLUTCH COVER AND DISC RUNOUT .
Page 220 6 - 2 CLUTCH DESCRIPTION AND OPERATION (Continued) The clutch master cylinder push rod is connected to the clutch pedal. When the clutch pedal is depressed, the slave cylinder is operated by the clutch master cylinder mounted on the dash panel. The release fork is actuated by the hydraulic slave cylinder mounted on the transmission housing.
Page 221 CLUTCH 6 - 3 DESCRIPTION AND OPERATION (Continued) OPERATION The clutch pressure plate assembly clamps the clutch disc against the flywheel. When the release bearing is depressed by the shift fork, the pressure exerted on the clutch disc by the pressure plate spring is decreased.
Page 222 6 - 4 CLUTCH DESCRIPTION AND OPERATION (Continued) HYDRAULIC CLUTCH LINKAGE COMPONENTS. BREATHING EXCESSIVE CONCEN- TRATIONS OF THESE FIBERS CAN CAUSE SERIOUS BODILY HARM. WEAR A RESPIRATOR DURING SER- DESCRIPTION VICE AND NEVER CLEAN CLUTCH COMPONENTS The hydraulic linkage consists of a clutch master WITH COMPRESSED AIR OR WITH A DRY BRUSH.
Page 223 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 8 Clutch Components And Inspection...
Page 224 6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) CLUTCH CONTAMINATION of any clutch component will cause grab, chatter and improper clutch release. Fluid contamination is a frequent cause of clutch malfunctions. Oil, water, or clutch fluid on the clutch CLUTCH HOUSING MISALIGNMENT disc and pressure plate surfaces will cause chatter, Clutch housing alignment is important to proper slip and grab.
Page 225 CLUTCH 6 - 7 DIAGNOSIS AND TESTING (Continued) CLUTCH COVER AND DISC RUNOUT CLUTCH DIAGNOSIS CHARTS Check the clutch disc before installation. Axial The clutch inspection chart (Fig. 8) outlines items (face) runout of a new disc should not exceed 0.50 to be checked before and during clutch installation.
Page 226 6 - 8 CLUTCH DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Facing on flywheel side of disc torn, 1. Flywheel surface scored or 2. Correct surface condition if gouged, or worn. nicked. possible. Replace flywheel and disc as necessary. 2.
Page 227 CLUTCH 6 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible. Replace clutch pedal if necessary. 2. Master cylinder bushing not 2. Lubricate master cylinder lubricated. bushing.
Page 228 6 - 10 CLUTCH SERVICE PROCEDURES (Continued) alent meeting standards SAE J1703 and DOT 3. Do cleanup of minor flywheel scoring can be performed not use any other type of fluid. by hand with 180 grit emery, or with surface grind- ing equipment.
Page 229 CLUTCH 6 - 11 SERVICE PROCEDURES (Continued) CAUTION: Do not use an oxy/acetylene torch to (a) Slide disc onto transmission input shaft remove the old gear, or to heat and expand a new splines. Disc should slide freely on splines. (b) Leave disc on shaft and check face runout gear.
Page 230 6 - 12 CLUTCH REMOVAL AND INSTALLATION (Continued) (2) Lubricate input shaft splines, bearing retainer slide surface, fork pivot and release fork pivot surface with Mopar high temperature grease. (3) Install new release bearing. Be sure bearing is properly secured to release fork. (4) Install transmission.
Page 231 CLUTCH 6 - 13 REMOVAL AND INSTALLATION (Continued) Fig. 13 Typical Method Of Installing Pilot Bearing 1 – PILOT BEARING 2 – ALIGNMENT TOOL 3 – BEARING SEAL MUST FACE TRANSMISSION Fig. 14 Clutch Housing Attachment 1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.) CLUTCH HOUSING 2 –...
Page 232 6 - 14 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 17 Right Hand Drive Clutch Master Cylinder 1 – CLUTCH MASTER CYLINDER Fig. 15 Slave Cylinder 1 – CLUTCH SLAVE CYLINDER Fig. 18 Clutch Pedal Attachment 1 – CLUTCH MASTER CYLINDER (3) Position clutch master cylinder on dash panel (Fig.
Page 233 CLUTCH 6 - 15 REMOVAL AND INSTALLATION (Continued) (9) Secure clutch fluid line in body and transmis- SPECIFICATIONS sion clips. (10) Lower vehicle. TORQUE (11) Connect clutch interlock safety switch wires. DESCRIPTION TORQUE Bolts, clutch cover 2.5 L ..31 N·m (23 ft. lbs) Bolts, clutch cover 4.0 L .
Page 235 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUTCH FLYWHEEL RUNOUT ....6 CLUTCH ....... . 1 CLUTCH COVER AND DISC RUNOUT .
Page 236 6 - 2 CLUTCH DESCRIPTION AND OPERATION (Continued) The clutch master cylinder push rod is connected to the clutch pedal. When the clutch pedal is depressed, the slave cylinder is operated by the clutch master cylinder mounted on the dash panel. The release fork is actuated by the hydraulic slave cylinder mounted on the transmission housing.
Page 237 CLUTCH 6 - 3 DESCRIPTION AND OPERATION (Continued) OPERATION The clutch pressure plate assembly clamps the clutch disc against the flywheel. When the release bearing is depressed by the shift fork, the pressure exerted on the clutch disc by the pressure plate spring is decreased.
Page 238 6 - 4 CLUTCH DESCRIPTION AND OPERATION (Continued) HYDRAULIC CLUTCH LINKAGE COMPONENTS. BREATHING EXCESSIVE CONCEN- TRATIONS OF THESE FIBERS CAN CAUSE SERIOUS BODILY HARM. WEAR A RESPIRATOR DURING SER- DESCRIPTION VICE AND NEVER CLEAN CLUTCH COMPONENTS The hydraulic linkage consists of a clutch master WITH COMPRESSED AIR OR WITH A DRY BRUSH.
Page 239 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 8 Clutch Components And Inspection...
Page 240 6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) CLUTCH CONTAMINATION of any clutch component will cause grab, chatter and improper clutch release. Fluid contamination is a frequent cause of clutch malfunctions. Oil, water, or clutch fluid on the clutch CLUTCH HOUSING MISALIGNMENT disc and pressure plate surfaces will cause chatter, Clutch housing alignment is important to proper slip and grab.
Page 241 CLUTCH 6 - 7 DIAGNOSIS AND TESTING (Continued) CLUTCH COVER AND DISC RUNOUT CLUTCH DIAGNOSIS CHARTS Check the clutch disc before installation. Axial The clutch inspection chart (Fig. 8) outlines items (face) runout of a new disc should not exceed 0.50 to be checked before and during clutch installation.
Page 242 6 - 8 CLUTCH DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Facing on flywheel side of disc torn, 1. Flywheel surface scored or 2. Correct surface condition if gouged, or worn. nicked. possible. Replace flywheel and disc as necessary. 2.
Page 243 CLUTCH 6 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible. Replace clutch pedal if necessary. 2. Master cylinder bushing not 2. Lubricate master cylinder lubricated. bushing.
Page 244 6 - 10 CLUTCH SERVICE PROCEDURES (Continued) alent meeting standards SAE J1703 and DOT 3. Do cleanup of minor flywheel scoring can be performed not use any other type of fluid. by hand with 180 grit emery, or with surface grind- ing equipment.
Page 245 CLUTCH 6 - 11 SERVICE PROCEDURES (Continued) CAUTION: Do not use an oxy/acetylene torch to (a) Slide disc onto transmission input shaft remove the old gear, or to heat and expand a new splines. Disc should slide freely on splines. (b) Leave disc on shaft and check face runout gear.
Page 246 6 - 12 CLUTCH REMOVAL AND INSTALLATION (Continued) (2) Lubricate input shaft splines, bearing retainer slide surface, fork pivot and release fork pivot surface with Mopar high temperature grease. (3) Install new release bearing. Be sure bearing is properly secured to release fork. (4) Install transmission.
Page 247 CLUTCH 6 - 13 REMOVAL AND INSTALLATION (Continued) Fig. 13 Typical Method Of Installing Pilot Bearing 1 – PILOT BEARING 2 – ALIGNMENT TOOL 3 – BEARING SEAL MUST FACE TRANSMISSION Fig. 14 Clutch Housing Attachment 1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.) CLUTCH HOUSING 2 –...
Page 248 6 - 14 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 17 Right Hand Drive Clutch Master Cylinder 1 – CLUTCH MASTER CYLINDER Fig. 15 Slave Cylinder 1 – CLUTCH SLAVE CYLINDER Fig. 18 Clutch Pedal Attachment 1 – CLUTCH MASTER CYLINDER (3) Position clutch master cylinder on dash panel (Fig.
Page 249 CLUTCH 6 - 15 REMOVAL AND INSTALLATION (Continued) (9) Secure clutch fluid line in body and transmis- SPECIFICATIONS sion clips. (10) Lower vehicle. TORQUE (11) Connect clutch interlock safety switch wires. DESCRIPTION TORQUE Bolts, clutch cover 2.5 L ..31 N·m (23 ft. lbs) Bolts, clutch cover 4.0 L .
Page 250 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FLYWHEEL ......5 CLUTCH COMPONENTS .
Page 251 6 - 2 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 2 Clutch Components (VM Diesel) 1 – ENGINE BLOCK 4 – CLUTCH COVER 2 – FLYWHEEL 5 – CLUTCH DISC 3 – CLUTCH HOUSING AND TRANSMISSION (3) Check free operation of clutch disc by sliding disc onto transmission output shaft splines.
Page 252 CLUTCH 6 - 3 REMOVAL AND INSTALLATION (Continued) PILOT BEARING REMOVAL (1) Remove the transmission and transfer case. Refer to Group 21, Transmission and Transfer Case for procedures. Fig. 4 Clutch Disc Alignment – Typical 1 – FLYWHEEL 2 – CLUTCH COVER AND DISC 3 –...
Page 253 6 - 4 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 9 Pilot Bearing Installation Fig. 7 Pilot Bearing Retainer Bolt Removal/ 1 – HOUSING Installation 2 – SPECIAL TOOL C-4171 1 – RETAINER 3 – BEARING 2 – PILOT BEARING 3 – FLYWHEEL Fig.
Page 254 CLUTCH 6 - 5 REMOVAL AND INSTALLATION (Continued) Fig. 11 Clutch Cover (Pressure Plate) View Fig. 12 Clutch Cover (Pressure Plate) View 1 – VEHICLE UNDERBODY 1 – VEHICLE UNDERBODY 2 – ENGINE SPEED SENSOR 2 – ENGINE SPEED SENSOR 3 –...
Page 255 6 - 6 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 13 Checking Flywheel Runout 1 – DIAL INDICATOR 2 – FLYWHEEL FACE Fig. 15 Cross Tightening Method (c) Loosen one bolt at a time and tighten to 19.6 N•m (14 ft. lbs.) plus 75° using the cross tighten- ing method until completion.
Page 256 CLUTCH 6 - 7 REMOVAL AND INSTALLATION (Continued) FLYWHEEL RING GEAR NOTE: The method of heating and expanding the new ring gear is extremely important. Every surface of the gear must be heated at the same time to pro- REMOVAL duce uniform expansion.
Page 257 6 - 8 CLUTCH REMOVAL AND INSTALLATION (Continued) SPECIFICATIONS SPECIFICATIONS DESCRIPTION TORQUE Clutch Cover to Flywheel Bolts ....50 N·m (37 ft. lbs.) Clutch Housing to Transmission Bolts .
Page 258 COOLING SYSTEM 7 - 1 COOLING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COOLANT—LEVEL CHECK ....21 COOLING SYSTEM ......1 COOLING SYSTEM—DRAINING AND AUTOMATIC TRANSMISSION OIL COOLER.
Page 259 7 - 2 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) • Fan shroud Transmission oil is cooled when it passes through • Radiator pressure cap this separate cooler. In case of a leak in the internal • Thermostat radiator mounted transmission oil cooler, engine cool- •...
Page 260 COOLING SYSTEM 7 - 3 DESCRIPTION AND OPERATION (Continued) The coolant reserve/overflow system consists of a radiator mounted pressurized cap, a plastic reserve/ overflow tank (Fig. 3) (Fig. 4), a tube (hose) connect- ing the radiator and tank, and an overflow tube on the side of the tank.
Page 261 7 - 4 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) BLOCK HEATER THERMOSTAT DESCRIPTION DESCRIPTION WARNING: DO NOT OPERATE ENGINE UNLESS CAUTION: Do not operate an engine without a ther- BLOCK HEATER CORD HAS BEEN DISCONNECTED mostat, except for servicing or testing. FROM POWER SOURCE AND SECURED IN PLACE.
Page 262 COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) RADIATOR A rubber gasket seals radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pres- DESCRIPTION sure. CAUTION: Plastic tanks, while stronger than brass, subject damage impact,...
Page 263 7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) WATER PUMP HOSE CLAMPS DESCRIPTION DESCRIPTION The cooling system utilizes both worm drive and CAUTION: All engines are equipped with a reverse spring type hose clamps. If a spring type clamp (counter-clockwise) rotating water pump and vis- replacement is necessary, replace with the original cous fan drive assembly.
Page 264 COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit. A typical viscous unit is shown in (Fig. 13). This spring coil reacts to the temperature of the radiator discharge air.
Page 265 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) ELECTRIC COOLING FAN OPERATION Electric cooling fan 2.5L: When air conditioning DESCRIPTION is not requested, the electric fan will not come on unless the coolant temperature is at least 103° C Vehicles equipped with a 2.5L/4.0L engine and air (218°...
Page 266 COOLING SYSTEM 7 - 9 DESCRIPTION AND OPERATION (Continued) to Group 25, Emission Control Systems for proper procedures) ACCESSING DIAGNOSTIC TROUBLE CODES To read DTC’s and to obtain cooling system data, refer to Group 25, Emission Control Systems for proper procedures. DRB SCAN TOOL For operation of the DRB scan tool, refer to the appropriate Powertrain Diagnostic Procedures ser-...
Page 267 7 - 10 COOLING SYSTEM DIAGNOSIS AND TESTING (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. pulley grooves.
Page 268 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE (Objectionable squeal, 1. Belt slippage 1. Adjust belt tension (2.5L) squeak, or rumble is heard or felt 2. Bearing noise 2. Locate and repair while drive belt is in operation) 3.
Page 269 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to Group 25, Emission (DTC) been set indicating a stuck Systems for On-Board Diagnostics open thermostat? and DTC information.
Page 270 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 6. Poor seals at the radiator cap. 6. (a) Check condition of cap and HIGH OR THE COOLANT cap seals. Refer to Radiator Cap. WARNING LAMP ILLUMINATES.
Page 271: Exhaust System
7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 17. Viscous fan drive not operating 17. Check fan drive operation and HIGH OR THE COOLANT properly. replace as necessary. Refer to WARNING LAMP ILLUMINATES. Viscous Fan Drive in this Group.
Page 272 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING 8. Water pump impeller loose on 8. Check water pump and replace IS INCONSISTENT (FLUCTUATES, shaft. as necessary. Refer to water Pumps CYCLES OR IS ERRATIC) in this group.
Page 273 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION ELECTRIC RADIATOR FAN WILL 1. Blown Fuse in Power Distribution 1. Determine reason for blown fuse NOT RUN AT ALL. GAUGE Center (PDC) and repair as necessary. READING HIGH OR HOT 2.
Page 274 COOLING SYSTEM—TESTING FOR LEAKS ULTRAVIOLET LIGHT METHOD All Jeep models have a leak detection additive added to the cooling system before they leave the fac- tory. The additive is highly visible under ultraviolet light (black light). If the factory original coolant has been drained, pour one ounce of additive into the cooling system.
Page 275 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) • Drops Slowly: Shows a small leak or seepage is PRESSURE TESTER METHOD occurring. Examine all connections for seepage or The engine should be at the normal operating tem- slight leakage with a flashlight. Inspect the radiator, perature.
Page 276 COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) COMBUSTION LEAKAGE TEST (WITHOUT 105°C (0°-to-220° F). Insert thermometer through the hole in the shroud. Be sure that there is adequate PRESSURE TESTER) clearance from the fan blades. DO NOT WASTE reusable coolant. If the solution (3) Connect a tachometer and an engine ignition is clean, drain the coolant into a clean container for timing light (timing light is to be used as a strobe...
Page 277 7 - 20 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) RADIATOR CAP-TO-FILLER NECK SEAL— There is no need to remove the radiator cap except for the following purposes: PRESSURE RELIEF CHECK (1) To check and adjust antifreeze freeze point. With radiator cap installed on filler neck, remove (2) To refill system with new antifreeze.
Page 278 COOLING SYSTEM 7 - 21 DIAGNOSIS AND TESTING (Continued) Operate the tester pump and observe the gauge The coolant reserve/overflow system provides a pointer at its highest point. The cap release pressure quick visual method for determining coolant level should be 83-to-110 kPa (12-to-16 psi). The cap is sat- without removing radiator pressure cap.
Page 279 7 - 22 COOLING SYSTEM SERVICE PROCEDURES (Continued) (2) For access to radiator draincock (Fig. 21), Reverse flushing of the cooling system is the forc- remove radiator grille mounting screws and remove ing of water through the cooling system. This is done grill.
Page 280 COOLING SYSTEM 7 - 23 SERVICE PROCEDURES (Continued) Remove the lead away hose, flushing gun, water supply hose and air supply hose. Remove the thermo- stat housing and install thermostat. Install the ther- mostat housing with a replacement gasket. Refer to Thermostat Replacement.
Page 281 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 25 Reverse Rotating Water Pump—Typical 1 – R STAMPED INTO IMPELLER Fig. 24 Reserve/Overflow Tank—With Right Hand Drive The water pump impeller is pressed on the rear of 1 – CLAMP 2 –...
Page 282 COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) CAUTION: After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. (9) Remove power steering pump and bracket (Fig.
Page 283 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) pump mating surfaces for erosion or damage from cavitation. (3) Install the gasket and water pump. The sili- cone bead on the gasket should be facing the water pump. Also, the gasket is installed dry. Tighten mounting bolts to 23 N·m (17 ft.
Page 284 COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 30 Power Steering Pump Attachment-4.0L 1 – PUMP ASSEMBLY 2 – PUMP BRACKET pump. Also, the gasket is installed dry. Tighten mounting bolts to 23 N·m (17 ft. lbs.) torque. Rotate the shaft by hand to be sure it turns freely.
Page 285 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (13) Fill cooling system with coolant and check for leaks. Refer to Refilling Cooling System in this group. (14) Connect battery negative cable. (15) Start and warm the engine. Check for leaks. THERMOSTAT REMOVAL WARNING: DO...
Page 286 COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) CAUTION: Tightening thermostat housing (7) Disconnect electric cooling fan electrical con- unevenly or with the thermostat out of its recess nector, if equipped. may result in a cracked housing. (3) Tighten the housing bolts to 20 N·m (15 ft. lbs.) torque.
Page 287 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (1) Lower radiator into engine compartment. Posi- tion alignment dowels into rubber grommets in radi- ator lower crossmember (Fig. 41). (2) If equipped with air conditioning, attach con- denser to radiator with mounting brackets (Fig. 35). (3) Install radiator upper crossmember and four mounting bolts.
Page 288 COOLING SYSTEM 7 - 31 REMOVAL AND INSTALLATION (Continued) CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 11). If replacement is necessary, use only an original equipment clamp with matching number or letter. REMOVAL (1) Disconnect battery negative cable.
Page 289 7 - 32 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 39 Radiator Removal/Installation—4.0L Engines 1 – (LHD) 6 – RADIATOR 2 – (RHD) 7 – LOWER CROSSMEMBER 3 – VISCOUS FAN SHROUD 8 – U-NUT 4 – ELECTRIC FAN MODULE 9 –...
Page 290 COOLING SYSTEM 7 - 33 REMOVAL AND INSTALLATION (Continued) (8) Install electric cooling fan (if equipped). Insert alignment tabs at bottom of fan shroud into slots in bracket at bottom of radiator. Tighten mounting bolts to 3 N·m (31 in. lbs.) torque. (9) Connect electric cooling fan electrical connector.
Page 291 7 - 34 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 42 Fan Shroud Removal/Installation 1 – ELECTRIC FAN/SHROUD ASSEMBLY 4 – RADIATOR 2 – UPPER CROSSMEMBER 5 – LOWER CROSSMEMBER 3 – ISOLATOR 6 – U-NUT (6) Connect fan electrical connector. (7) Install power steering reservoir to shoud.
Page 292 COOLING SYSTEM 7 - 35 REMOVAL AND INSTALLATION (Continued) (2) Insert block heater assembly into core hole with element loop pointing Up. (3) Seat block heater flush against block face. Tighten mounting screw to 3.6 N·m (32 in. lbs.) torque. (4) Fill cooling system with coolant.
Page 293 7 - 36 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) gauge. Use the correct gauge when checking belt ten- sion. Place gauge in the middle of the section of belt being tested (between two pulleys) to check tension. Do not allow the gauge (or gauge adapter) to contact anything but the belt.
Page 294 COOLING SYSTEM 7 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 52 Models With 4.0L Engine—Without A/C— Fig. 50 Models With 4.0L Engine—With A/C—Except With RHD Fig. 51 Models With 4.0L Engine—With A/C—With Fig. 53 Power Steering Pump Bracket and Idler Pulley 1 –...
Page 295 7 - 38 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 54 Generator Belt Tension Adjust Bracket 1 – TENSION ADJUSTMENT BOLT Fig. 55 Water Pump Mounted Cooling Fan 2 – UPPER ALTERNATOR NUT 1 – THERMAL VISCOUS FAN DRIVE 2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS CAUTION: When installing the serpentine acces- 3 –...
Page 296 COOLING SYSTEM 7 - 39 REMOVAL AND INSTALLATION (Continued) RADIATOR CLEANING Clean radiator fins With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C con- denser of debris. INSPECTION The radiator cooling fins should be checked for damage or deterioration.
Page 297 7 - 40 COOLING SYSTEM CLEANING AND INSPECTION (Continued) (3) Inspect fan assembly for cracks, bends, loose DESCRIPTION N·m rivets or broken welds. Replace fan if any damage is found. Lbs. Lbs. Water Pump or Hub — COOLING SYSTEM HOSES Bearing—Nuts Water Pump—Bolts —...
Page 298 BATTERY 8A - 1 BATTERY TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION BATTERY....... . 1 BATTERY CABLES .
Page 299 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) ing against one another. These dissimilar metal BATTERY SIZE AND RATINGS plates are submerged in a sulfuric acid and water The battery Group Size number, the Cold Cranking solution called an electrolyte. Amperage (CCA) rating, and the Reserve Capacity The factory-installed battery has a built-in test (RC) rating or Ampere-Hours (AH) rating can be...
Page 300 BATTERY 8A - 3 DESCRIPTION AND OPERATION (Continued) ment of excess or free electrons between the positive and negative plate groups. This movement of elec- trons produces a flow of electrical current through the load device attached to the battery terminals. As the plate materials become more similar chem- ically, and the electrolyte becomes less acid, the volt- age potential of each cell is reduced.
Page 301 8A - 4 BATTERY DESCRIPTION AND OPERATION (Continued) reliable connection of the battery to the vehicle elec- The battery hold down hardware (Fig. 3) includes trical system. two T-bolts with plastic push-on retainers, a hold The battery positive cable terminal clamp is die down bracket, a stamped steel battery support strap, cast onto the ends of two wires.
Page 302 BATTERY 8A - 5 DESCRIPTION AND OPERATION (Continued) BATTERY THERMOGUARD DESCRIPTION Fig. 4 Battery Thermoguard 1 – THERMOGUARD 2 – BATTERY A flexible plastic bubble-wrap style thermoguard (Fig. 4) slides over the battery case to enclose the Fig. 5 Battery Tray sides of the battery.
Page 303 8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) tested as a complete system. In order for the engine AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT to start and the battery to charge properly, all of the OF THE REACH OF CHILDREN. •...
Page 304 BATTERY 8A - 7 DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery seems weak or 1. The battery has an 1. Refer to Battery in the index of this service dead when attempting to start incorrect size or rating for manual for the location of the proper battery the engine.
Page 305 8A - 8 BATTERY DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery state-of-charge 1. The battery has an 1. Refer to Battery in the index of this service cannot be maintained. incorrect size or rating for manual for the location of the proper battery this vehicle.
Page 306 BATTERY 8A - 9 DIAGNOSIS AND TESTING (Continued) • IF THE BATTERY IS EQUIPPED WITH REMOV- 7. A faulty or incorrect starting system component. Refer to Starting System in the index of this ser- ABLE CELL CAPS, BE CERTAIN THAT EACH OF vice manual for the location of the proper starting THE CELL CAPS IS IN PLACE AND TIGHT BEFORE system diagnosis and testing procedures.
Page 307 8A - 10 BATTERY DIAGNOSIS AND TESTING (Continued) THE BATTERY IS RETURNED TO SERVICE. PER- SONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS. Before testing, visually inspect the battery for any damage (a cracked case or cover, loose posts, etc.) that would cause the battery to be faulty.
Page 308 BATTERY 8A - 11 DIAGNOSIS AND TESTING (Continued) rection factor is approximately a specific gravity PERSONAL INJURY AND/OR VEHICLE DAMAGE value of 0.004, which may also be identified as four MAY RESULT. • THE BATTERY CONTAINS SULFURIC ACID, points of specific gravity. For each 5.5° C above 26.7° C (10°...
Page 309 8A - 12 BATTERY DIAGNOSIS AND TESTING (Continued) age Test in this section for the proper battery open- Open Circuit Voltage circuit voltage test procedures. The battery open- Open Circuit Volts Charge Percentage circuit voltage must be 12.4 volts or greater. 11.7 volts or less 12.0 volts 12.2 volts...
Page 310 BATTERY 8A - 13 DIAGNOSIS AND TESTING (Continued) Load Test Temperature Temperature Minimum Voltage °F °C 9.6 volts 70° and above 21° and above 9.5 volts 60° 16° 9.4 volts 50° 10° 9.3 volts 40° 4° 9.1 volts 30° -1° 8.9 volts 20°...
Page 311 8A - 14 BATTERY DIAGNOSIS AND TESTING (Continued) Electronic Module Ignition-Off Draw (IOD) Time Out? IOD After Time Module (If Yes, Interval and Wake-Up Input) 1 to 3 Radio milliamperes Audio Power up to 1 Amplifier milliampere Central Timer Module 4.75 (CTM) milliamperes...
Page 312 BATTERY 8A - 15 DIAGNOSIS AND TESTING (Continued) • Fully engage the parking brake. battery cable connection and the battery cable again • If the vehicle is equipped with an automatic to confirm repair. When performing the voltage drop test, it is impor- transmission, place the gearshift selector lever in the tant to remember that the voltage drop is giving an Park position.
Page 313 8A - 16 BATTERY DIAGNOSIS AND TESTING (Continued) (4) Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 17). Rotate and hold the ignition switch in the Start position. Observe the voltmeter.
Page 314 BATTERY 8A - 17 SERVICE PROCEDURES (Continued) WARNING: cranking capacity. Refer to Battery in the index of • IF THE BATTERY SHOWS SIGNS OF FREEZ- this service manual for the location of the battery diagnosis and testing procedures for more informa- ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR tion on the proper battery load testing procedures.
Page 315 8A - 18 BATTERY SERVICE PROCEDURES (Continued) (3) Battery chargers vary in the amount of voltage Battery Charging Timetable and current they provide. The amount of time Charging required for a battery to accept measurable charging Amperage Amperes Amperes Amperes current at various voltages is shown in the Charge Open Rate chart.
Page 316 BATTERY 8A - 19 REMOVAL AND INSTALLATION (Continued) (10) Remove the screw that secures the battery (5) Install and tighten the nut that secures the negative cable eyelet terminal to the inner fender battery positive cable eyelet terminal to the B(+) ter- shield near the battery.
Page 317 8A - 20 BATTERY REMOVAL AND INSTALLATION (Continued) (20) Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.). (21) Reconnect the battery negative cable terminal clamp to the battery negative terminal post.
Page 318 BATTERY 8A - 21 REMOVAL AND INSTALLATION (Continued) BATTERY tion of the proper battery cleaning and inspection procedures. (2) Reinstall the battery thermoguard onto the REMOVAL battery case. Refer to Battery Thermoguard in the (1) Turn the ignition switch to the Off position. Be index of this service manual for the location of the certain that all electrical accessories are turned off.
Page 319 8A - 22 BATTERY REMOVAL AND INSTALLATION (Continued) (8) Apply a thin coating of petroleum jelly or chas- location of the proper battery temperature sensor sis grease to the exposed surfaces of the battery cable removal procedures. terminal clamps and the battery terminal posts. (3) Remove the three nuts with washers that secure the battery tray to the weld studs on the front BATTERY THERMOGUARD...
Page 320 BATTERY 8A - 23 REMOVAL AND INSTALLATION (Continued) (4) Position the battery tray onto the weld studs on the front extension of the right front wheelhouse inner panel. (5) Install and tighten the three nuts with washers that secure the battery tray to the weld studs on the front extension of the right front wheelhouse inner panel.
Page 321 8A - 24 BATTERY CLEANING AND INSPECTION (Continued) (5) Clean any corrosion from the battery terminal damaged cases or loose terminal posts must be posts with a wire brush or a post and terminal replaced. cleaner, and a sodium bicarbonate (baking soda) and (4) Inspect the battery thermoguard for tears, warm water cleaning solution (Fig.
Page 322 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STARTER RELAY ......10 STARTING SYSTEM .
Page 323 8B - 2 STARTING SYSTEMS DESCRIPTION AND OPERATION (Continued) engine, the park/neutral position switch is mounted by engaging the starter pinion gear with the starter on the right side of the automatic transmission case. ring gear. Once the engine starts, the ignition switch The switch is indexed to and driven by the transmis- key is released by the vehicle operator.
Page 324 STARTING SYSTEMS 8B - 3 DESCRIPTION AND OPERATION (Continued) Both starter motors use an overrunning clutch and STARTER RELAY starter pinion gear unit to engage and drive the starter ring gear, which is integral to the flywheel DESCRIPTION (manual transmission) or torque converter drive plate (automatic transmission) mounted on the rear crankshaft flange.
Page 325 8B - 4 STARTING SYSTEMS The diagnostic procedures used for the battery, DIAGNOSIS AND TESTING starting system and charging system include the most basic conventional diagnostic methods, to the STARTING SYSTEM more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an DIAGNOSIS induction-type milliampere ammeter, a volt/ohmme- The battery, starting system and charging system...
Page 326 STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) Starting System Diagnosis Condition Possible Cause Correction Starter engages, fails to 1. Battery discharged or 1. Refer to Battery in the index of this service manual for turn engine. faulty. the location of the proper battery diagnosis and testing 2.
Page 327 8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) • Fully engage the parking brake. (b) If the voltage reads above 9.6 volts and the • If the vehicle is equipped with an automatic current (amperage) draw reads below specifica- transmission, place the gearshift selector lever in the tions, refer to the Feed Circuit Test in this sec- Park position.
Page 328 STARTING SYSTEMS 8B - 7 DIAGNOSIS AND TESTING (Continued) • To prevent the engine from starting, remove the Automatic ShutDown (ASD) relay. The ASD relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay lay- out label affixed to the underside of the PDC cover for ASD relay identification and location.
Page 329 8B - 8 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) If the resistance tests detect no feed circuit prob- lems, refer to Starter Motor in the index of this ser- vice manual for the location of the proper starter motor diagnosis and testing procedures. CONTROL CIRCUIT TEST The starter control circuit components should be tested in the order in which they are listed, as fol-...
Page 330 STARTING SYSTEMS 8B - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 1. VERY HIGH FREQUENCY 1. Excessive distance between pinion 1. Move starter motor toward WHINE BEFORE ENGINE gear and flywheel/drive plate gear. flywheel/drive plate by removing STARTS; ENGINE STARTS OK. shim(s), if possible.
Page 331 8B - 10 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) STARTER MOTOR (1) Remove the starter motor from the vehicle. Refer to Starter Motor in the index of this service manual for the location of the proper starter motor removal and installation procedures. (2) Mount the starter motor securely in a soft- jawed bench vise.
Page 332 STARTING SYSTEMS 8B - 11 DIAGNOSIS AND TESTING (Continued) mission or if not OK with an automatic transmission, check for an open or shorted fused ignition switch output (start) circuit to the ignition switch and repair, as required. If the fused ignition switch out- put (start) circuit is OK, refer to Ignition Switch and Key Lock Cylinder in the index of this service manual for the location of the proper ignition switch...
Page 333 8B - 12 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) during this process. Do not let the starter motor hang from the wire harness. (7) Remove the starter motor and any starter motor shims (if used) from the engine block. 4.0L ENGINE (1) Disconnect and isolate the battery negative cable.
Page 334 STARTING SYSTEMS 8B - 13 REMOVAL AND INSTALLATION (Continued) starter solenoid. Always support the starter motor Always support the starter motor during this process. during this process. Do not let the starter motor Do not let the starter motor hang from the wire har- hang from the wire harness.
Page 335 8B - 14 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) • Ignition Switch Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness connections. Clean corroded connections as required. Refer to Wiring Diagrams in the index of this service manual for the location of the proper wiring repair or connector and terminal service procedures.
Page 336 STARTING SYSTEMS 8B - 15 CLEANING AND INSPECTION (Continued) • Wiring Visually inspect the starting system wire service manual for the location of the proper starter motor removal and installation procedures. harnesses for indications of physical damage. Repair • Starter Solenoid Visually inspect the starter or replace any faulty wiring, as required.
Page 337 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SPECIFICATIONS STARTER — LHD (DIESEL) ....1 STARTING SYSTEM ..... . . 3 STARTER —...
Page 338 8B - 2 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) (12) Remove the starter motor support bracket. (13) Disconnect the starter motor electrical connec- tors. CAUTION: Heatshields are very sharp. Wear gloves to prevent injury. (14) Remove the starter heatshield. (15) Remove the (3) starter motor retaining bolts. (16) Remove the starter motor from the vehicle.
Page 339 STARTING SYSTEMS 8B - 3 REMOVAL AND INSTALLATION (Continued) (2) Reconnect the starter motor electrical. Torque (13) Torque the engine mount throughbolt nut to (B+) nut to 27 N·m (20 ft. lbs.). 65 N·m (48 ft. lbs.). (14) Install the oil return line on the engine block CAUTION: Heatshield is very sharp.
Page 340 8B - 4 STARTING SYSTEMS SPECIFICATIONS STARTING SYSTEM Starter and Solenoid Engine Application 2.5L Diesel Power Rating 2.2 Kilowatt Voltage 12 Volts Number of Fields Number of Poles Number of Brushes Drive Type Planetary Gear Reduction Free Running Test Voltage 11.5 Volts Free Running Test Maximum 160 Amperes...
Page 341 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION CHARGING SYSTEM..... . . 1 GENERATOR .
Page 342 8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) generator begins producing sufficient current, it also OPERATION provides the current needed to energize the rotor. The amount of DC current produced by the gener- The Y type stator winding connections deliver the ator is controlled by EVR circuitry contained within induced AC current to 3 positive and 3 negative the PCM.
Page 343 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued) (3) Inspect all fuses in both the fuseblock and (1) Disconnect negative battery cable at battery. Power Distribution Center (PDC) for tightness in (2) Remove generator drive belt. Refer to Group 7, receptacles.
Page 344 8C - 4 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 4 Generator Connectors—Typical Denso 1 – FIELD WIRES 2 – B+ (OUTPUT TERMINAL) 3 – FIELD WIRE CONNECTOR Fig. 2 Remove/Install Generator—4.0L Engine—LHD 1 – UPPER MOUNTING BRACKET 2 – GENERATOR (3) If equipped, snap plastic cover to B+ terminal.
Page 345 CHARGING SYSTEM 8C - 5 REMOVAL AND INSTALLATION (Continued) BATTERY TEMPERATURE SENSOR REMOVAL (1) Remove battery. Refer to Group 8A, Battery for The battery temperature sensor is located under procedures. vehicle battery (Fig. 5) and is attached to a mounting (2) Disconnect sensor pigtail harness from engine hole on battery tray.
Page 346 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SPECIFICATIONS GENERATOR ......1 SPECIFICATIONS .
Page 347 8C - 2 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) SPECIFICATIONS SPECIFICATIONS Battery Terminal Nut ......8.5 N·m Lower Generator Mounting Bolt .
Page 348 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SPARK PLUGS ......10 IGNITION SYSTEM .
Page 349 8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) • Crankshaft Position Sensor SPARK PLUGS • Camshaft Position Sensor • The MAP, TPS, IAC and ECT also have an effect DESCRIPTION on the control of the ignition system. Resistor type spark plugs are used. Spark plug resistance values range from 6,000 to DISTRIBUTOR-2.5L ENGINE 20,000 ohms (when checked with at least a 1000 volt...
Page 350 OPERATION Although cylinder firing order is the same as 4.0L Jeep engines of previous years, spark plug firing is not. The 3 coils dual-fire the spark plugs on cylinders 1–6, 2–5 and/or 3–4. When one cylinder is being fired (on compression stroke), the spark to the opposite cylinder is being wasted (on exhaust stroke).
Page 351 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) advance. This is done to meet changing engine oper- ating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine.
Page 352 IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approxi- mately 5 volts.
Page 353 8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION DIAGNOSIS AND TESTING Vehicles equipped with an automatic trans- DISTRIBUTOR CAP-2.5L ENGINE mission and a floor mounted shifter: a cable is used to connect the interlock device in the steering Remove the distributor cap and wipe it clean with column assembly, to the transmission floor shift a dry lint free cloth.
Page 354 IGNITION SYSTEM 8D - 7 DIAGNOSIS AND TESTING (Continued) Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer.
Page 355 8D - 8 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) terminal at ignition coil end of cable. If resistance is two plugs in a set may be caused by sticking valves not within specifications as found in the Spark Plug or defective spark plug cables. Cold (carbon) fouling Cable Resistance chart, remove the cable from the of the entire set of spark plugs may be caused by a distributor cap.
Page 356 IGNITION SYSTEM 8D - 9 DIAGNOSIS AND TESTING (Continued) severe detonation can also separate the insulator from the center electrode (Fig. 15). Spark plugs with this condition must be replaced. Fig. 13 Electrode Gap Bridging 1 – GROUND ELECTRODE 2 – DEPOSITS 3 –...
Page 357 8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) Transmission Shift Interlock Cable Adjustment in Group 21, Transmissions for adjustment procedures. Vehicles equipped with an automatic trans- mission and a steering column mounted shifter: an interlock device is located within the steering col- umn.
Page 358 IGNITION SYSTEM 8D - 11 REMOVAL AND INSTALLATION (Continued) Fig. 18 Cable Removal 1 – SPARK PLUG CABLE AND BOOT 2 – SPARK PLUG BOOT PULLER 3 – TWIST AND PULL 4 – SPARK PLUG Fig. 19 Setting Spark Plug Gap—Typical any/all spark plug(s), refer to Ignition Coil-4.0L 1 –...
Page 359 8D - 12 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) IGNITION COIL—2.5L ENGINE ber boots (Fig. 21) to seal the 6 spark plugs to the coil. Inside each rubber boot is a spring. The spring REMOVAL is used for an electrical contact between the coil and The ignition coil is an epoxy filled type.
Page 360 IGNITION SYSTEM 8D - 13 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position ignition coil rubber boots to all spark plugs. Push down on coil assembly until bolt bases have contacted cylinder head (2) Install 4 coil mounting bolts. Loosely tighten 4 bolts just enough to allow bolt bases to contact cylin- der head.
Page 361 8D - 14 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 26 Crankshaft Position Sensor—Two-Bolt Fig. 25 Crankshaft Position Sensor—Two-Nut Mounting Mounting 1 – TRANSMISSION BELLHOUSING 1 – TRANSMISSION BELLHOUSING 2 – MOUNTING BOLTS (2) 2 – MOUNTING NUTS (2) 3 – CRANKSHAFT POSITION SENSOR 3 –...
Page 362 IGNITION SYSTEM 8D - 15 REMOVAL AND INSTALLATION (Continued) Fig. 27 Camshaft Position Sensor—2.5L Engine 1 – SYNC SIGNAL GENERATOR 2 – CAMSHAFT POSITION SENSOR 3 – PULSE RING 4 – DISTRIBUTOR ASSEMBLY (4) Remove distributor rotor from distributor shaft. (5) Lift camshaft position sensor assembly from distributor housing (Fig.
Page 363 8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 29 CMP Location—4.0L Engine Fig. 31 Align Timing Marks—4.0L Engine 1 – OIL FILTER 1 – CRANKSHAFT VIBRATION DAMPER TIMING MARK 2 – CAMSHAFT POSITION SENSOR 3 – CLAMP BOLT (4) Before proceeding to next step, mark and note 4 –...
Page 364 IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) (b) Remove cylinder number 1 spark plug. on ignition timing. All ignition timing values are con- (c) Hold a finger over the open spark plug hole. trolled by powertrain control module (PCM). Rotate engine at vibration dampener bolt until (15) Tighten hold-down clamp bolt to 23 N·m (17 compression (pressure) is felt.
Page 365 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Slowly continue to rotate engine. Do this until timing index mark on vibration damper pulley aligns with Top Dead Center (TDC) mark (0 degree) on tim- ing degree scale (Fig. 34). Always rotate engine in direction of normal rotation.
Page 366 IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) Fig. 35 Slot At 10 O’clock Position—2.5L Engine 1 – 10 0’CLOCK POSITION 2 – OIL PUMP SLOT INSTALLATION (1) If engine crankshaft has been rotated after dis- Fig. 36 Pin Alignment Holes—2.5L Engine tributor removal, cylinder number 1 must be 1 –...
Page 367 8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) The distributor is correctly installed when: • rotor is pointed at 3 o’clock position. • plastic alignment pin (or pin punch tool) is still installed to distributor. • number 1 cylinder piston is set at top dead cen- ter (TDC) (compression stroke).
Page 368 IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) Fig. 39 Key Cylinder Release Tang 1 – KEY CYLINDER 2 – RELEASE TANG Fig. 41 Ignition Switch Lock Tab 1 – LOCK TAB 2 – IGNITION SWITCH 3 – SCREWDRIVER Fig.
Page 369 8D - 22 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) KEY CYLINDER INSTALLATION (1) If equipped with an automatic transmission, place shifter in PARK position. (2) Position key cylinder into steering column as it would normally be in the ON position. (3) Press key cylinder into column until it snaps into position.
Page 370 IGNITION SYSTEM 8D - 23 ENGINE FIRING ORDER—4.0L 6-CYLINDER SPECIFICATIONS ENGINE IGNITION TIMING Ignition timing is not adjustable on any engine. ENGINE FIRING ORDER—2.5L 4-CYLINDER ENGINE SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 2.5L RC12ECC 0.89 mm (0.035 in.) 4.0L RC12ECC 0.89 mm (0.035 in.) SPARK PLUG CABLE RESISTANCE...
Page 371 8D - 24 IGNITION SYSTEM SPECIFICATIONS (Continued) TORQUE CHART DESCRIPTION TORQUE Camshaft Position Sensor–to–base bolts—4.0L ....28 N·m (15 in. lbs.) Crankshaft Position Sensor Bolts (sensor mounted with 2 bolts) ..19 N·m (14 ft.
Page 372 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION INSTRUMENT PANEL ACCESSORY SWITCH INSTRUMENT PANEL SYSTEM ....1 BEZEL ....... 15 INSTRUMENT PANEL .
Page 373 8E - 2 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) reduce buzzes, squeaks, and rattles even on the The low-line cluster includes the following analog bumpiest roads. gauges: • Fuel gauge This type of construction also provides improved • Speedometer. energy absorption which, in conjunction with the dual airbag modules and seat belts, helps to improve This cluster also includes provisions for the follow-...
Page 374 INSTRUMENT PANEL SYSTEMS 8E - 3 DESCRIPTION AND OPERATION (Continued) Electrically Heated Systems for more information on The seat belt reminder lamp is controlled by the the timer function of the instrument cluster. instrument cluster programming. The Malfunction The instrument clusters for this model are serviced Indicator Lamp (MIL) is normally controlled by CCD only as complete units.
Page 375 8E - 4 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) switch bezel unit must be replaced. The cigar lighter panel below the instrument panel in the passenger knob and heating element unit is available for ser- compartment. vice. This component cannot be repaired and, if The cigar lighter relay is a International Standards faulty or damaged, it must be replaced.
Page 376 INSTRUMENT PANEL SYSTEMS 8E - 5 DESCRIPTION AND OPERATION (Continued) spring-clip retainers inside the bottom of the recepta- (6) Turn the ignition switch to the On position and cle shell that are used to secure the cigar lighter check for battery voltage at the fused ignition switch heating element to the insulated contact.
Page 377 8E - 6 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) Successful completion of the actuator test will con- SERVICE. FAILURE TO TAKE THE PROPER PRE- firm that the instrument cluster is operational. How- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- ever, there may still be a problem with the CCD data BAG DEPLOYMENT AND POSSIBLE PERSONAL bus, the Powertrain Control Module (PCM), the Air- INJURY.
Page 378 INSTRUMENT PANEL SYSTEMS 8E - 7 DIAGNOSIS AND TESTING (Continued) Fig. 1 Low-Line Instrument Cluster Actuator Test...
Page 379 8E - 8 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) Fig. 2 High-Line Instrument Cluster Actuator Test...
Page 380 INSTRUMENT PANEL SYSTEMS 8E - 9 DIAGNOSIS AND TESTING (Continued) BRAKE WARNING LAMP ground. There should be continuity. If OK, go to Step 8. If not OK, repair the open red brake warning indi- The diagnosis found here addresses an inoperative cator driver circuit to the ignition switch as required.
Page 381 8E - 10 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) time four-wheel drive indicator lamp should light. If lamp driver circuit cavity of the transfer case switch OK, replace the faulty transfer case switch. If not wire harness connector and a good ground. The part OK, go to Step 5.
Page 382 INSTRUMENT PANEL SYSTEMS 8E - 11 DIAGNOSIS AND TESTING (Continued) proceed with lamp diagnosis. Refer to Washer Sys- ing Systems for further diagnosis. If no turn signal or tem in the Diagnosis and Testing section of Group hazard warning system problem is found, the follow- 8K - Wiper and Washer Systems for more informa- ing procedure will help locate a short or open in the tion.
Page 383 8E - 12 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) output circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter receptacle (instrument panel accessory switch bezel unit). If not OK, refer to Cigar Lighter Relay in the Diagnosis and Testing section of this group for further diagnosis.
Page 384 INSTRUMENT PANEL SYSTEMS 8E - 13 DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- REMOVAL BAGS, REFER GROUP PASSIVE (1) Disconnect and isolate the battery negative RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY cable. STEERING WHEEL, STEERING COLUMN, (2) If the vehicle is so equipped, move the tilt INSTRUMENT PANEL COMPONENT DIAGNOSIS OR steering column to the fully raised position.
Page 385 8E - 14 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) KNEE BLOCKER the mounting screws are located in the screw hole on each side of the steering column that is closest to the driver side front door of the vehicle (Fig. 6). WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER...
Page 386 INSTRUMENT PANEL SYSTEMS 8E - 15 REMOVAL AND INSTALLATION (Continued) Fig. 8 Instrument Panel Accessory Switch Bezel Remove/Install 1 – ACCESSORY SWITCH BEZEL 2 – SCREW (4) Pull the accessory switch bezel away from the instrument panel far enough to access the instru- Fig.
Page 387 8E - 16 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) CIGAR LIGHTER RELAY (4) Remove the screw located above the fuse access opening that secures the right cowl side trim to the right cowl side inner panel. WARNING: ON VEHICLES EQUIPPED WITH AIR- (5) Remove the screw that secures the right door BAGS, REFER...
Page 388 INSTRUMENT PANEL SYSTEMS 8E - 17 REMOVAL AND INSTALLATION (Continued) (2) Remove the knee blocker from the instrument (2) Align the snap clips on the cluster bezel with panel. Refer to Knee Blocker in the Removal and the receptacles in the instrument panel. Installation section of this group for the procedures.
Page 389 8E - 18 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Reach up under the instrument panel through (5) Insert the shaft of the headlamp switch control the outboard side of the steering column opening to knob and shaft unit through the opening in the span- access and depress the headlamp switch control knob ner nut and into the headlamp switch.
Page 390 INSTRUMENT PANEL SYSTEMS 8E - 19 REMOVAL AND INSTALLATION (Continued) receptacles on the back of the cluster housing. Do reinstalled in the correct position. Always use the not pull on the instrument cluster by the lens correct bulb size and type for replacement. An incor- or mask sections, or the cluster components rect bulb size or type may overheat and cause dam- may become separated.
Page 391 8E - 20 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 14 Instrument Cluster Components 1 – CLUSTER REAR COVER 4 – ODOMETER RESET KNOB BOOT 2 – CLUSTER HOOD AND MASK 5 – INSTRUMENT CLUSTER HOUSING 3 – CLUSTER LENS (4) Remove the odometer reset knob boot by pull- Removal and Installation section of this group for the ing it out of the cluster lens.
Page 392 INSTRUMENT PANEL SYSTEMS 8E - 21 REMOVAL AND INSTALLATION (Continued) (1) Insert the bulb and bulb holder unit straight Removal and Installation section of this group for the into the correct bulb mounting hole in the cluster procedures. electronic circuit board. (6) Reconnect the battery negative cable.
Page 393 8E - 22 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 15 Instrument Panel Top Cover Remove/Install Fig. 16 Glove Box Stop Bumpers Remove/Install 1 – INSTRUMENT PANEL 2 – TOP COVER 1 – GLOVE BOX OPENING UPPER REINFORCEMENT 3 – FRONT EDGE 2 –...
Page 394 INSTRUMENT PANEL SYSTEMS 8E - 23 REMOVAL AND INSTALLATION (Continued) Fig. 17 Glove Box Remove/Install 1 – GLOVE BOX 2 – LATCH 3 – SCREWS (4) Reconnect the battery negative cable. Fig. 18 Glove Box Components Remove/Install 1 – OUTER DOOR GLOVE BOX COMPONENTS 2 –...
Page 395 8E - 24 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL (1) Disconnect and isolate the battery negative cable.
Page 396 INSTRUMENT PANEL SYSTEMS 8E - 25 REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL END CAP Removal and Installation section of this group for the procedures. (3) Remove the top cover from the instrument WARNING: ON VEHICLES EQUIPPED WITH AIR- panel. Refer to Instrument Panel Top Cover in the BAGS, REFER GROUP...
Page 397 8E - 26 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL CENTER SUPPORT (6) Remove the two nuts that secure the instru- ment panel center support bracket to the studs on BRACKET the floor panel transmission tunnel. (7) Remove the center support bracket from the WARNING: ON VEHICLES EQUIPPED WITH AIR- instrument panel.
Page 398 INSTRUMENT PANEL SYSTEMS 8E - 27 REMOVAL AND INSTALLATION (Continued) (4) Remove the top cover from the instrument ness connector at the floor panel transmission tunnel panel. Refer to Instrument Panel Top Cover in the under the instrument panel. Removal and Installation section of this group for the (10) Roll down the glove box from the instrument procedures.
Page 399 8E - 28 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) studs. Then pull the lower instrument panel rear- ness connector at the floor panel transmission tunnel ward to clear the cowl side roll down screws. under the instrument panel. (16) Remove the instrument panel assembly from (8) Reconnect the instrument panel-to-floor wire the vehicle.
Page 400 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS TABLE OF CONTENTS page page REMOVAL AND INSTALLATION REAR FOG LAMP SWITCH....1 HEADLAMP LEVELING SWITCH....1 REMOVAL AND INSTALLATION INSTALLATION (1) Install the instrument panel center bezel on...
Page 401 8E - 2 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) receptacle on the back of the accessory switch bezel are fully engaged. Tighten the mounting screws to 2.2 N·m (20 in. lbs.). Fig. 2 Accessory Switch Bezel Remove/Install 1 – ACCESSORY SWITCH BEZEL 2 –...
Page 402 AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION SPEAKER ....... 4 INTRODUCTION .
Page 403 8F - 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) ignition switch in the Off position, will correct the nect allows the instrument panel assembly to be scrambled display condition. removed and installed without removing the radio. The IOD fuse should be checked if the radio is The factory-installed Electronically Tuned Radios inoperative.
Page 404 AUDIO SYSTEMS 8F - 3 DIAGNOSIS AND TESTING (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in junction block. Replace fuses, if required. 2. Radio connector 2. Check for loose or corroded radio connector. Repair, if faulty.
Page 405 8F - 4 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) RADIO WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE For circuit descriptions and diagrams, refer to RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY 8W-47 - Audio System in Group 8W - Wiring Dia- STEERING WHEEL, STEERING...
Page 406 AUDIO SYSTEMS 8F - 5 DIAGNOSIS AND TESTING (Continued) OK, replace the faulty speaker. If not OK, repair the the amplified return (–) circuit cavities of the speaker open circuit(s) as required. wire harness connector and the amplifier wire har- (6) For each inoperative speaker location, check for ness connector.
Page 407 8F - 6 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) TEST 1 RADIO FREQUENCY INTERFERENCE Test 1 determines if the antenna mast is insulated WARNING: ON VEHICLES EQUIPPED WITH AIR- from the base. Proceed as follows: BAGS, REFER GROUP PASSIVE (1) Unplug the antenna coaxial cable connector RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY from the radio chassis and isolate.
Page 408 AUDIO SYSTEMS 8F - 7 DIAGNOSIS AND TESTING (Continued) • The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio (SWR). Fleet vehicles are available with an extra-cost RFI- suppressed Powertrain Control Module (PCM). This unit reduces interference generated by the PCM on some radio frequencies used in two-way radio com- munications.
Page 409 8F - 8 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 6 Window Regulator Crank Handle Remove - Fig. 4 Radio Connections - Typical Typical 1 – ANTENNA CABLE 1 – DOOR HANDLE REMOVAL TOOL 2 – RADIO 2 – WINDOW CRANK 3 –...
Page 410 AUDIO SYSTEMS 8F - 9 REMOVAL AND INSTALLATION (Continued) Fig. 8 Front Door Trim Panel Remove/Install - Power Fig. 9 Front Door Lower Speaker Remove/Install Window 1 – SPEAKER 1 – U-NUT 2 – WIRE HARNESS CONNECTORS 2 – DOOR 3 –...
Page 411 8F - 10 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) (6) Reverse the removal procedures to install. ANTENNA Tighten the mounting screw to 2.2 N·m (20 in. lbs.). WARNING: ON VEHICLES EQUIPPED WITH AIR- REAR HEADLINER BAGS, REFER GROUP PASSIVE The rear headliner speakers can be serviced with- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY out removing the headliner using the procedures that STEERING...
Page 412 AUDIO SYSTEMS 8F - 11 REMOVAL AND INSTALLATION (Continued) (4) Unscrew the antenna mast from the antenna body (Fig. 13). Fig. 13 Antenna Mast Remove/Install - Typical 1 – ANTENNA MAST 2 – ADAPTER 3 – CAP NUT (5) Remove the antenna cap nut and adapter using an antenna nut wrench (Special Tool C-4816) (Fig.
Page 413 8F - 12 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Remove the engine-to-body ground strap from the engine compartment. INSTALLATION ENGINE-TO-BODY GROUND STRAP (1) Position the engine-to-body ground strap in the engine compartment. (2) Position the engine-to-body ground strap eyelet over the stud on the left upper rear corner of the engine cylinder head.
Page 414 HORN SYSTEMS 8G - 1 HORN SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION HORN SWITCH ......4 HORN SYSTEM.
Page 415 8G - 2 HORN SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the Within the two halves of the molded plastic horn normally closed position. The resistor or diode is con- housing are a flexible diaphragm, a plunger, an elec- nected in parallel with the electromagnetic coil in the tromagnetic coil and a set of contact points.
Page 416 HORN SYSTEMS 8G - 3 DESCRIPTION AND OPERATION (Continued) trim cover and horn switch must be replaced as a unit. OPERATION When the center area of the driver side airbag trim cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes contact each other, closing the switch circuit.
Page 417 8G - 4 HORN SYSTEMS DIAGNOSIS AND TESTING (Continued) HORN SWITCH HORN For complete circuit diagrams, refer to Horn/Ci- For complete circuit diagrams, refer to Horn/Ci- gar Lighter in the Contents of Group 8W - Wiring gar Lighter in the Contents of Group 8W - Wiring Diagrams.
Page 418 HORN SYSTEMS 8G - 5 REMOVAL AND INSTALLATION (Continued) HORN REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Raise and support the vehicle. (3) Remove the front underbody splash shield. NOTE: Remove the horn and its mounting bracket from the vehicle as a unit.
Page 419 8G - 6 HORN SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION sure panel brace. Tighten the screw to 28.5 N·m (21 ft. lbs.). (1) Position the horn and mounting bracket unit (5) Install the front underbody splash shield. behind the front bumper. (6) Lower the vehicle.
Page 420 SPEED CONTROL SYSTEM 8H - 1 SPEED CONTROL SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING SPEED CONTROL SYSTEM ....1 ROAD TEST .
Page 421 8H - 2 SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) A “tap down” feature is used to decelerate without SPEED CONTROL SOLENOID CIRCUITS disengaging the speed control system. To decelerate from an existing recorded target speed, momentarily OPERATION depress the COAST switch. For each switch activa- When all of the speed control parameters are met, tion, speed will be lowered approximately 1 mph.
Page 422 SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) The previous disengagement conditions are pro- Refer to the Brake section for more information on grammed for added safety. brake lamp switch service and adjustment proce- Once the speed control has been disengaged, dures.
Page 423 8H - 4 SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) • Smooth operation of throttle linkage and throttle ing/air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. body air valve. • Failed speed control servo. Do the servo vacuum VEHICLE SPEED SENSOR (SPEED CONTROL test.
Page 424 SPEED CONTROL SYSTEM 8H - 5 REMOVAL AND INSTALLATION SPEED CONTROL SERVO REMOVAL (1) Disconnect negative battery cable at battery. (2) Disconnect vacuum line at servo (Fig. 1). (3) Disconnect electrical connector at servo. (4) Disconnect servo cable at throttle body. Refer to Servo Cable Removal/Installation.
Page 425 8H - 6 SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL (5) Disconnect servo cable at servo. Refer to Speed Control Servo Removal/Installation. (1) Disconnect and isolate negative battery cable from battery. (2) Remove airbag module. Refer to Group 8M, Passive Restraint Systems.
Page 426 SPEED CONTROL SYSTEM 8H - 7 REMOVAL AND INSTALLATION (Continued) (3) Remove 2 reservoir mounting screws. (4) Remove reservoir from bumper bar. Fig. 6 Vacuum Reservoir Removal/Installation 1 – VACUUM LINE 2 – RESERVOIR SCREWS Fig. 5 Vacuum Reservoir Location 3 –...
Page 427 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM TABLE OF CONTENTS page DESCRIPTION AND OPERATION DIESEL ENGINE SPEED CONTROL SYSTEM ..1 DESCRIPTION AND OPERATION speed control functions are used. The outputs from these switches are filtered into one input. The MSA determines which output has been applied through DIESEL ENGINE SPEED CONTROL SYSTEM resistive multiplexing.
Page 428 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION TURN SIGNAL SWITCH AND HAZARD TURN SIGNAL SYSTEM ....1 WARNING SWITCH .
Page 429 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION With the hazard warning switch in the On posi- tion, the hazard warning system is activated. When the hazard warning system is activated, the circuitry of the hazard warning switch and the combination flasher will cause both the right side and the left side turn signal indicator lamps, front park/turn signal lamps, front side marker lamps and rear tail/stop/...
Page 430 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DESCRIPTION AND OPERATION (Continued) TURN SIGNAL CANCELLING CAM outputs or functions. The combination flasher should never be substituted for an ISO-relay or replaced with an ISO-relay, or else component and vehicle DESCRIPTION damage may occur.
Page 431 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) If the problem being diagnosed is related to a fail- ure of the turn signals to automatically cancel follow- ing completion of a turn, inspect the multi-function switch for a faulty or damaged cancel actuator and inspect the turn signal cancelling cam lobes on the clockspring mechanism for damage or improper...
Page 432 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 DIAGNOSIS AND TESTING (Continued) (7) Turn the ignition switch to the Off position. shown in the Multi-Function Switch Continuity chart Place the hazard warning switch in the On position. (Fig. 3). Check for battery voltage again at the fused B+ cir- SWITCH POSITION CONTINUITY...
Page 433 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS REMOVAL AND INSTALLATION (Continued) the instrument panel diagnostics mounting bracket TURN SIGNAL SWITCH AND HAZARD (Fig. 4). WARNING SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 434 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7 REMOVAL AND INSTALLATION (Continued) with the optional tilt steering column, move the tilt (8) Gently pull the lower mounting tab of the steering column to the fully lowered position. multi-function switch water shield bracket away from (5) Remove both the upper and lower shrouds from the steering column far enough to clear the screw the steering column.
Page 435 8J - 8 TURN SIGNAL AND HAZARD WARNING SYSTEMS REMOVAL AND INSTALLATION (Continued) (9) Install and tighten the three screws that secure (11) Install the knee blocker onto the instrument the lower steering column shroud to the upper panel. Refer to Knee Blocker in the Removal and shroud.
Page 436 WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION WASHER NOZZLE AND PLUMBING ... 4 INTRODUCTION ......1 DIAGNOSIS AND TESTING WINDSHIELD WIPER SYSTEM .
Page 437 8K - 2 WIPER AND WASHER SYSTEMS GENERAL INFORMATION (Continued) the driver when the washer fluid level needs to be The blades are mounted to spring-loaded wiper checked. Refer to Group 8E - Instrument Panel Sys- arms. The spring tension of the wiper arms controls tems for more information on this feature.
Page 438 WIPER AND WASHER SYSTEMS 8K - 3 DESCRIPTION AND OPERATION (Continued) wipe cycle when the windshield wiper switch stalk is moved to the Off position, and parks the blades in the lowest portion of the wipe pattern. The windshield wiper motor cannot be repaired. If faulty or damaged, the entire wiper linkage and pivot module unit must be replaced.
Page 439 8K - 4 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) WASHER PUMP Located at the highest point of the supply hose routing, beneath the liftgate opening upper header The washer pumps and motors are mounted near garnish moulding, the hose connects to a check valve. the bottom of the washer reservoir.
Page 440 WIPER AND WASHER SYSTEMS 8K - 5 DIAGNOSIS AND TESTING (Continued) (4) Turn the ignition switch to the Off position. STEERING WHEEL, STEERING COLUMN, Disconnect and isolate the battery negative cable. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR Check for continuity between the ground circuit cav- SERVICE.
Page 441 8K - 6 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) be continuity. If OK, replace the faulty rear wiper tinuity. If OK, replace the faulty switch. If not OK, motor. If not OK, repair the open circuit as required. repair the open circuit as required.
Page 442 WIPER AND WASHER SYSTEMS 8K - 7 DIAGNOSIS AND TESTING (Continued) be continuity. If OK, replace the faulty switch. If not the wiper system and/or washer system wire harness OK, repair the open circuit as required. circuits as required. WIPER SWITCH AND WASHER SWITCH REAR Perform the diagnosis for the rear wiper system FRONT...
Page 443 8K - 8 WIPER AND WASHER SYSTEMS (3) To install the wiper blade on the wiper arm, REMOVAL AND INSTALLATION slide the blade retainer into the U-shaped formation on the tip of the wiper arm until the release tab WIPER BLADE snaps into its locked position.
Page 444 WIPER AND WASHER SYSTEMS 8K - 9 REMOVAL AND INSTALLATION (Continued) Fig. 7 Rear Wiper Arm Remove/Install 1 – PIVOT COVER Fig. 6 Front Wiper Arm Installation 2 – WIPER ARM RETAINING NUT • 33 to 62 mm (1.29 to 2.44 inch) on the passenger side.
Page 445 8K - 10 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Remove the wiper arms from the wiper pivots. See Wiper Arm in this group for the procedures. (3) Remove the eight screws that secure the cowl plenum cover/grille panel and screen to the cowl top panel (Fig.
Page 446 WIPER AND WASHER SYSTEMS 8K - 11 REMOVAL AND INSTALLATION (Continued) (3) Remove the three screws that secure the lower steering column shroud to the upper shroud (Fig. 12). Fig. 11 Rear Wiper Motor Remove/Install 1 – LIFTGATE 2 – ARM 3 –...
Page 447 8K - 12 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (13) Reverse the removal procedures to install. Tighten the upper switch mounting screws to 2.2 N·m (20 in. lbs.). Tighten the lower switch water shield and bracket screw to 1.1 N·m (10 in. lbs.). Tighten the non-tilt steering column mounting nuts to 22 N·m (200 in.
Page 448: Fuel System
WIPER AND WASHER SYSTEMS 8K - 13 REMOVAL AND INSTALLATION (Continued) wiper and washer switch receptacle on the back of the accessory switch bezel and pull the switch out of the bezel. (8) Reverse the removal procedures to install. Be certain that both of the switch snap clip retainers in the receptacle on the back of the accessory switch bezel are fully engaged.
Page 449 8K - 14 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (8) Reverse the removal procedures to install. (3) Carefully lift the cowl plenum cover/grille panel Always use a new rubber grommet seal on the reser- and screen from the vehicle far enough to access the voir.
Page 450 WIPER AND WASHER SYSTEMS 8K - 15 REMOVAL AND INSTALLATION (Continued) (2) Disconnect the washer supply hose from the (7) When reinstalling the check valve, be certain barbed rear washer nozzle nipple. the valve is properly oriented within the system flow (3) Reverse the removal procedures to install.
Page 451: Steering
LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMP SYSTEMS ......1 LAMP SERVICE.
Page 452 8L - 2 LAMPS DESCRIPTION AND OPERATION (Continued) used for tail light and stop lamp functions. One sin- ada only. A separate module, mounted on the cowl, gle filament bulb is for turn signal functions. The controls the DRL. other bulb is a single filament bulb used for back-up OPERATION light illumination.
Page 453 LAMPS 8L - 3 LAMP DIAGNOSIS TABLE OF CONTENTS page page DIAGNOSIS AND TESTING SYSTEM DIAGNOSIS ..... . 3 DIAGNOSTIC PROCEDURES ....3 DIAGNOSIS AND TESTING SYSTEM DIAGNOSIS DIAGNOSTIC PROCEDURES...
Page 454 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground RANDOMLY locations, refer to Group 8W. 2. High resistance in headlamp 2. Test amperage draw of headlamp circuit. circuit.
Page 455: Body
LAMPS 8L - 5 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground RANDOMLY locations. Refer to Group 8W. 2. High resistance in fog lamp circuit. 2.
Page 456 8L - 6 LAMPS HEADLAMP ALIGNMENT TABLE OF CONTENTS page page SERVICE PROCEDURES HEADLAMP ADJUSTMENT ....6 HEADLAMP ALIGNMENT ....6 FOG LAMP ADJUSTMENT .
Page 457 LAMPS 8L - 7 SERVICE PROCEDURES (Continued) Fig. 1 Headlamp Alignment Screen—Typical 1 – CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS 4 – FRONT OF HEADLAMP 2 – FLOOR TO CENTER OF HEADLAMP LENS 5 – VEHICLE CENTERLINE 3 – 7.62 METERS (25 FEET) (8) Cover front of headlamp that has been adjusted and adjust the other headlamp beam as instructed above.
Page 458 8L - 8 LAMPS SERVICE PROCEDURES (Continued) Fig. 4 Fog Lamp Alignment —Typical 1 – VEHICLE CENTERLINE 5 – 100 mm (4 in.) 2 – CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 6 – 7.62 METERS (25 FEET) 3 –...
Page 459 LAMPS 8L - 9 SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C-4466–A...
Page 460 8L - 10 LAMPS LAMP BULB SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION LICENSE PLATE LAMP BULB ....12 HEADLAMP BULB ......10 CENTER HIGH MOUNTED STOP LAMP FOG LAMP BULB.
Page 461 LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) (2) Connect bulb wire connector. (3) Install spring clip securing bulb to fog lamp. (4) Install screws attaching the access cover to the bottom of the fog lamp. FRONT PARK/TURN SIGNAL LAMP BULB REMOVAL (1) Remove headlamp bezel.
Page 462 8L - 12 LAMPS REMOVAL AND INSTALLATION (Continued) LICENSE PLATE LAMP BULB UNDERHOOD LAMP BULB REMOVAL REMOVAL (1) Remove screws attaching license plate lamp (1) Insert a small flat blade in the access slot housing to liftgate. between the lamp base and lamp lens. (2) Rotate bulb socket...
Page 463 LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) (2) Depress the opposite terminal inward and MAP READING LAMP BULB engage the remaining bulb wire loop. (3) Position the lamp lens on the lamp base and REMOVAL press into place. (1) Insert a flat blade screwdriver in slot at front of lens (Fig.
Page 464 8L - 14 LAMPS LAMP SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION CENTER HIGH MOUNTED STOP LAMP HEADLAMP ......14 (CHMSL) .
Page 465 LAMPS 8L - 15 REMOVAL AND INSTALLATION (Continued) FOG LAMP REMOVAL (1) Disconnect the fog lamp wire harness connec- tor. (2) Remove the screws attaching the fog lamp to the support (Fig. 3). (3) Separate the fog lamp from the vehicle. Fig.
Page 466 8L - 16 LAMPS REMOVAL AND INSTALLATION (Continued) BACK-UP/BRAKE/REAR TURN SIGNAL/TAIL LAMP REMOVAL (1) Open the liftgate. (2) Remove the bolts attaching the tail lamp hous- ing to the quarter panel (Fig. 6). (3) Grasp the lamp and pull to disengage it from the grommet at the base of the lamp.
Page 467 LAMPS 8L - 17 REMOVAL AND INSTALLATION (Continued) Fig. 9 Cargo Lamp Fig. 8 Underhood Lamp 1 – HOUSING 2 – SCREWDRIVER SLOTS 1 – HOOD 3 – CARGO LAMP 2 – UNDERHOOD LAMP/SWITCH 4 – LENS INSTALLATION (1) Position underhood lamp on hood inner panel. Ensure anti-rotation tab is positioned in slot on hood inner panel.
Page 468 8L - 18 LAMPS REMOVAL AND INSTALLATION (Continued) VISOR VANITY LAMP INSTALLATION (1) Position visor lamp at visor and connect visor REMOVAL lamp wire connector. (2) Position visor lamp in visor and press into (1) Fold down sunvisor. place. (2) Starting at the base of the lamp assembly and working right-to-left, use a small flat blade, carefully pry lamp from visor.
Page 469 LAMPS 8L - 19 LAMP SYSTEMS TABLE OF CONTENTS page page REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP MODULE ..19 SENTINEL HEADLAMP DELAY MODULE ..19 REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP MODULE SENTINEL HEADLAMP DELAY MODULE...
Page 470 8L - 20 LAMPS BULB APPLICATION TABLE OF CONTENTS page page SPECIFICATIONS INTERIOR LAMPS ......20 EXTERIOR LAMPS......20 SPECIFICATIONS LAMP BULB...
Page 471 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMP DIAGNOSIS ......1 LAMP SERVICE......8 HEADLAMP AND FOG LAMP ALIGNMENT.
Page 472 8L - 2 LAMPS DIAGNOSIS AND TESTING (Continued) DIAGNOSIS AND TESTING HEADLAMP LEVELING MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION ONE MOTOR DOES NOT 1. Poor connection at motor. 1. Secure connector on motor. OPERATE 2. No voltage at motor. 2. Repair circuit. Refer to Group 8W, Wiring.
Page 473 LAMPS 8L - 3 HEADLAMP AND FOG LAMP ALIGNMENT TABLE OF CONTENTS page page SERVICE PROCEDURES ADJUSTMENTS HEADLAMP ALIGNMENT PREPARATION..3 HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN ....3 SERVICE PROCEDURES (5) Rock vehicle side-to-side three times and allow suspension to stabilize.
Page 474 8L - 4 LAMPS ADJUSTMENTS (Continued) Fig. 1 Headlamp Alignment Screen—Typical 1 – CENTER OF VEHICLE 5 – 10 METERS (32.8 ft.) 2 – CENTER OF HEADLAMPS 6 – HORIZONTAL CUT-OFF LINE 3 – 15° CUT-OFF LINE 7 – 130mm 4 –...
Page 475 LAMPS 8L - 5 ADJUSTMENTS (Continued) Fig. 3 Fog Lamp Alignment-Typical 1 – HIGH INTENSITY AREA 5 – 200mm (8 in.) 2 – CENTER OF VEHICLE 6 – FRONT OF FOG LAMP 3 – VERTICAL CENTER OF FOG LAMP 7 – 10 METERS (32.8 ft.) 4 –...
Page 476 8L - 6 LAMPS LAMP BULB SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION REAR FOG LAMP BULB ....7 FRONT POSITION LAMP BULB .
Page 477 LAMPS 8L - 7 REMOVAL AND INSTALLATION (Continued) Fig. 4 Side Repeater Lamp Fig. 5 Rear Lamp Replacement INSTALLATION (3) Install the remaining three lamp sockets in the taillamp assembly. (1) Align the side repeater lamp bulb to the socket (4) Position the taillamp assembly and install the (Fig.
Page 478 8L - 8 LAMPS LAMP SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION FRONT FOG LAMP ......9 HEADLAMP .
Page 479 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) (4) Disconnect the headlamp leveling motor electri- FRONT FOG LAMP cal connector. (5) Rotate the leveling motor 90 degrees until REMOVAL motor is loose in mounting bracket. 1. Remove the 2 screws from the bottom cover of (6) Tilt motor upwards to disconnect motor push the lamp body.
Page 480 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install lamp socket in lamp housing. (2) Verify lamp operation. (3) Install license plate lamp assembly in liftgate and install retaining screws.
Page 481 Underhood Retractable Lamp ....105 that can be purchased from your local Jeep dealer. Front Fog ......H3...
Page 482 PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DRIVER SIDE AIRBAG MODULE TRIM AIRBAG SYSTEM ......1 COVER .
Page 483 8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) Module (ACM). The ACM also contains an impact WITH ACID, WATER, OR HEAVY METALS MAY PRO- sensor and a safing sensor, which are monitored by DUCE HARMFUL AND IRRITATING GASES (SODIUM the ACM to determine when an impact occurs that is HYDROXIDE IS FORMED IN THE PRESENCE OF severe enough to require airbag system protection.
Page 484 PASSIVE RESTRAINT SYSTEMS 8M - 3 DESCRIPTION AND OPERATION (Continued) unit are attached and sealed. The conventional pyro- charge the gas it produces directly into the cushion technic-type inflator assembly is mounted to studs on when supplied with the proper electrical signal. Fol- the back of the airbag module housing.
Page 485 8M - 4 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) ACM. A pre-programmed decision algorithm in the However, if the clockspring is removed for service or ACM microprocessor determines when the decelera- if the steering column is disconnected from the steer- tion rate as signaled by the impact sensor indicates ing gear allowing the clockspring tape to change posi- an impact that is severe enough to require airbag...
Page 486 PASSIVE RESTRAINT SYSTEMS 8M - 5 DIAGNOSIS AND TESTING (Continued) DRB contains the latest version of the proper DRB DISPOSAL OF NON-DEPLOYED AIRBAG MODULES software. All damaged or faulty and non-deployed driver side (3) Using the DRB, read and record the active or passenger side airbag modules which are replaced Diagnostic Trouble Code (DTC) data.
Page 487 8M - 6 PASSIVE RESTRAINT SYSTEMS SERVICE PROCEDURES (Continued) driver side airbag has been deployed, the clockspring must also be replaced. Refer to Clockspring in the Removal and Installation section of this group for the additional service procedures for the clockspring. WARNING: •...
Page 488 PASSIVE RESTRAINT SYSTEMS 8M - 7 REMOVAL AND INSTALLATION (Continued) (2) Reconnect the clockspring horn switch wire harness connector to the horn switch feed wire con- nector, which is located on the back of the airbag module. (3) Carefully position the driver side airbag mod- ule in the steering wheel.
Page 489 8M - 8 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Remove the driver side airbag module from the steering wheel. Refer to Driver Side Airbag Mod- ule in the Removal and Installation section of this group for the procedures. (3) Remove the plastic horn switch feed wire retainer from the stud on the back of the driver side airbag housing (Fig.
Page 490 PASSIVE RESTRAINT SYSTEMS 8M - 9 REMOVAL AND INSTALLATION (Continued) feed and ground wires are not pinched between the the passenger side airbag module has been deployed, airbag housing and the trim cover locking blocks. the passenger side airbag door must also be replaced. (2) Engage the upper and lower trim cover locking Refer to Passenger Side Airbag Door in the blocks with the lip of the driver side airbag housing,...
Page 491 8M - 10 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (11) Remove the passenger side airbag door from the airbag module. Refer to Passenger Side Airbag Door in the Removal and Installation section of this group for the procedures. INSTALLATION WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOM-...
Page 492 PASSIVE RESTRAINT SYSTEMS 8M - 11 REMOVAL AND INSTALLATION (Continued) Removal and Installation section of Group 8E - Instrument Panel Systems for the procedures. (11) Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing section of this group for the proper pro- cedures.
Page 493 8M - 12 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) AIRBAG CONTROL MODULE (a) Squeeze connector latch tabs between the thumb and forefinger. (b) Pull the connector straight away from the WARNING: • THE AIRBAG CONTROL MODULE CONTAINS ACM connector receptacle. THE IMPACT SENSOR, WHICH ENABLES THE SYS- TEM TO DEPLOY THE AIRBAG.
Page 494 PASSIVE RESTRAINT SYSTEMS 8M - 13 REMOVAL AND INSTALLATION (Continued) (6) Install the console rear duct onto the floor (5) Pull the steering wheel off of the steering col- panel transmission tunnel. Refer to Ducts And Out- umn upper shaft spline using a steering wheel puller lets in the index of this service manual for the loca- (Special Tool C-3428-B).
Page 495 8M - 14 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) replaced if faulty or damaged, or if the driver side airbag has been deployed. (14) If the removed clockspring is to be reused, lock the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column.
Page 496 PASSIVE RESTRAINT SYSTEMS 8M - 15 REMOVAL AND INSTALLATION (Continued) tion of Group 8E - Instrument Panel Systems for the AND ISOLATE THE BATTERY NEGATIVE (GROUND) procedures. CABLE. THEN WAIT TWO MINUTES FOR THE SYS- (8) Install the steering wheel onto the steering col- TEM CAPACITOR TO DISCHARGE BEFORE FUR- umn upper shaft.
Page 497 8M - 16 PASSIVE RESTRAINT SYSTEMS ADJUSTMENTS (Continued) until the rotor flats are horizontal. If the upper clock- SPECIAL TOOLS spring wire harnesses are not oriented towards the bottom of the clockspring, rotate the rotor another PASSIVE RESTRAINT SYSTEMS one-half turn in the counterclockwise direction. (6) The clockspring is now centered.
Page 498 ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS TABLE OF CONTENTS page page REAR WINDOW DEFOGGER SYSTEM ..1 HEATED SEAT SYSTEM ..... 8 REAR WINDOW DEFOGGER SYSTEM TABLE OF CONTENTS page...
Page 499 8N - 2 ELECTRICALLY HEATED SYSTEMS GENERAL INFORMATION (Continued) the defogger switch is turned on again during the window heating grid is operating as designed, refer same ignition cycle, the defogger system will auto- to Power Mirror in the Diagnosis and Testing section matically turn off after about five minutes.
Page 500 ELECTRICALLY HEATED SYSTEMS 8N - 3 DESCRIPTION AND OPERATION (Continued) control output signal at the defogger relay. For diag- nosis of the CCD data bus and the data bus message inputs, a DRB scan tool and the proper Diagnostic Procedures manual are recommended. Refer to Instrument Cluster in Group 8E - Instru- ment Panel Systems for the service procedures for the instrument cluster.
Page 501 8N - 4 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) REAR GLASS HEATING GRID (3) Check for continuity between the ground cir- cuit terminal and the rear window defogger switch For circuit descriptions and diagrams, refer to sense circuit terminal on the back of the defogger 8W-48 - Rear Window Defogger in Group 8W - Wir- switch housing (Fig.
Page 502 ELECTRICALLY HEATED SYSTEMS 8N - 5 DIAGNOSIS AND TESTING (Continued) (3) Connect a battery to terminals 85 and 86. is turned On. Be certain that you depress the defog- There should now be continuity between terminals ger switch at least twice to confirm that the system 30 and 87, and no continuity between terminals 87A is turned on during this test.
Page 503 8N - 6 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) (6) Check for continuity between the rear window (2) Follow the instructions in the repair kit for defogger relay control circuit cavities of the right preparing the damaged area. instrument cluster wire harness connector (connector (3) Remove the package separator clamp and mix B) and the defogger relay receptacle (the cavity for the two conductive epoxy components thoroughly...
Page 504 ELECTRICALLY HEATED SYSTEMS 8N - 7 REMOVAL AND INSTALLATION (Continued) (2) Remove the center bezel from the instrument (3) Remove the stamped nut that secures the right panel. See Instrument Panel Center Bezel in Group cowl side trim to the junction block stud (Fig. 6). 8E - Instrument Panel Systems for the procedures.
Page 505 8N - 8 ELECTRICALLY HEATED SYSTEMS HEATED SEAT SYSTEM TABLE OF CONTENTS page page GENERAL INFORMATION HEATED SEAT SWITCH ....10 INTRODUCTION .
Page 506 ELECTRICALLY HEATED SYSTEMS 8N - 9 DESCRIPTION AND OPERATION (Continued) HEATED SEAT ELEMENT and SENSOR Two heated seat heating elements are used in each front seat, one for the seat cushion and the other for the seat back. The two elements for each seat are connected in series with the SHIM.
Page 507 8N - 10 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) SEAT HEAT INTERFACE MODULE DIAGNOSTIC ROUTINES FAILURE MODE SWITCH “HI” TELLTALE SWITCH “LO” TELLTALE Shorted Heating Element Flashing Flashing Open Heating Element Flashing NTC Value Out of Range Flashing Before testing the individual components in the suspect switch.
Page 508 ELECTRICALLY HEATED SYSTEMS 8N - 11 DIAGNOSIS AND TESTING (Continued) of the switch. The resistance reading should be about (1) Disconnect and isolate the battery negative 32.5 Ohms. If OK, see Heated Seat Relay in the cable. Unplug the 4-way heated seat cushion wire Diagnosis and Testing section of this group.
Page 509 8N - 12 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) SEAT HEAT INTERFACE MODULE (4) Pull back the seat cushion to allow access to the Seat Heat Interface Module (SHIM). Before testing the seat heat interface module, test (5) Pull the SHIM upward to release the two the heated seat switch, the heated seat elements, and mounting fasteners from either the module or the the heated seat sensor as described in the Diagnosis...
Page 510 ELECTRICALLY HEATED SYSTEMS 8N - 13 REMOVAL AND INSTALLATION (Continued) (5) Cut the Christmas tree fastener to remove the Heated Seat Relay fastener from the mounting bracket. Unplug the wire harness connector from the relay (Fig. 3). (6) Reverse the removal procedures to install. A new Christmas tree fastener must be used to mount the relay.
Page 511 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION IGNITION-OFF DRAW FUSE ....5 POWER DISTRIBUTION SYSTEM... . . 1 JUNCTION BLOCK .
Page 512 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) POWER DISTRIBUTION CENTER replacement. The PDC main housing unit, the fuse wedges, the fuse cassette and the bus bars cannot be repaired and are only serviced as a unit with the DESCRIPTION headlamp and dash wire harness.
Page 513 POWER DISTRIBUTION SYSTEMS 8O - 3 DESCRIPTION AND OPERATION (Continued) sonnel are to remove the IOD fuse from the storage Battery in the index of this service manual for the location and install it into PDC fuse cavity 16 as part location of additional service information covering of the preparation procedures performed just prior to the battery.
Page 514 8O - 4 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) access panel for easy removal, and a fuse puller and spare fuse holders are located on the back of the fuse access panel. The JB unit cannot be repaired and is only ser- viced as an assembly.
Page 515 POWER DISTRIBUTION SYSTEMS 8O - 5 REMOVAL AND INSTALLATION (Continued) (5) Install the eyelets of the battery wire harness PDC take outs onto the PDC B(+) terminal stud. (6) Install and tighten the nut that secures the eyelet of the battery wire harness PDC take outs to the B(+) terminal stud.
Page 516 8O - 6 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the fuse access panel by unsnapping it from the right cowl side inner trim panel (Fig. 8). Fig. 7 Ignition-Off Draw Fuse 1 –...
Page 517 POWER DISTRIBUTION SYSTEMS 8O - 7 REMOVAL AND INSTALLATION (Continued) (9) Remove the three nuts that secure the JB to sill trim to the door opening sill. Tighten the screw to the mounting studs on the right cowl side inner 2.2 N·m (20 in.
Page 518 8O - 8 POWER DISTRIBUTION SYSTEMS DISASSEMBLY AND ASSEMBLY (Continued) Fig. 11 PDC Housing Lower Cover Remove/Install Fig. 10 Power Distribution Center Components 1 – PDC HOUSING 1 – LATCH 2 – TAB 2 – COVER 3 – PDC HOUSING LOWER COVER 3 –...
Page 519 POWER DISTRIBUTION SYSTEMS 8O - 9 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY PDC RELAY CASSETTE (1) Move the faulty PDC relay cassette with its wiring away from the bottom of the PDC housing far enough to allow the replacement relay cassette to be installed into the PDC.
Page 520 8O - 10 POWER DISTRIBUTION SYSTEMS DISASSEMBLY AND ASSEMBLY (Continued) (2) Press the PDC housing lower cover gently and evenly onto the PDC until each of the latches that secure the cover to the PDC is fully engaged. (3) Engage the mounting slots on the PDC housing with the stanchions of the PDC mounting bracket and push the unit downward until the mounting bracket latches fully engage the mounting tabs on...
Page 521 POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION POWER LOCK MOTOR ..... 4 INTRODUCTION .
Page 522 8P - 2 POWER LOCK SYSTEMS GENERAL INFORMATION (Continued) (about thirty seconds), when the power locks are PDM contains the control circuitry and the power unlocked using the RKE transmitter. lock and unlock relays for the entire power lock sys- The RKE system for this vehicle also features a tem.
Page 523 POWER LOCK SYSTEMS 8P - 3 DESCRIPTION AND OPERATION (Continued) headliner. The RKE receiver is a radio frequency unit transmitter, see the Power Lock Motor diagnosis in that also contains the RKE system program logic. this group. • If the RKE and power lock systems are function- The RKE receiver also performs as a smart relay for the illuminated entry feature.
Page 524 8P - 4 POWER LOCK SYSTEMS DIAGNOSIS AND TESTING (Continued) request circuit between the DDM and the PDM as to Step 5. Connect the battery negative cable. Turn required. If not OK, replace the faulty DDM. the ignition switch to the Accessory or On positions. Check for battery voltage at both sides of the power window circuit breaker in the junction block.
Page 525 POWER LOCK SYSTEMS 8P - 5 DIAGNOSIS AND TESTING (Continued) (3) Once it is determined which power lock motor is inoperative, that motor can be tested as follows. Unplug the wire harness connector at the inoperative power lock motor. Apply 12 volts to the motor termi- nals to check its operation in one direction.
Page 526 8P - 6 POWER LOCK SYSTEMS DIAGNOSIS AND TESTING (Continued) If not OK, repair the shorted circuit or component as no continuity. If OK, go to Step 11. If not OK, repair required and replace the faulty fuse. the short circuit to the horn relay as required. (2) Disconnect and isolate the battery negative (11) Check for continuity between the horn relay cable.
Page 527 POWER LOCK SYSTEMS 8P - 7 SERVICE PROCEDURES (Continued) To program the Remote Keyless Entry (RKE) (5) Pull the front door trim panel away from the receiver so that the horn chirp feature is disabled, inner door panel far enough to access the inside door proceed as follows: latch release and lock linkage rods near the back of (1) While within the reception range of the RKE...
Page 528 8P - 8 POWER LOCK SYSTEMS REMOVAL AND INSTALLATION (Continued) LIFTGATE cotton clothing, not synthetic fabric clothing; and, should ground themselves before and during all (1) Disconnect and isolate the battery negative handling and service procedures. Electrically con- cable. ductive wrist or heel straps are recommended, or (2) Open the liftgate.
Page 529 POWER LOCK SYSTEMS 8P - 9 REMOVAL AND INSTALLATION (Continued) OVERHEAD CONSOLE MOUNTED TYPE (1) Disconnect and isolate the battery negative cable. (2) Remove the overhead console from the head- liner. Refer to Overhead Console in Group 8V - Over- head Console Systems for the procedures.
Page 530 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 SENTRY KEY IMMOBILIZER SYSTEM .
Page 531 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) SKIM also transfers the “Secret Key” code to the For diagnosis or initialization of the SKIM and the memory of each of the Sentry Key transponders dur- PCM, a DRBIII scan tool and the proper Diagnostic ing new key programming.
Page 532 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) The Sentry Key transponder is within the range of DIAGNOSIS AND TESTING the SKIM transceiver antenna ring when it is inserted in the ignition lock cylinder. When the ignition switch is SENTRY KEY IMMOBILIZER SYSTEM turned to the Start or On positions, the SKIM trans- ceiver issues a Radio Frequency (RF) signal that excites...
Page 533 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS “Customer Learn” programming mode if it sees a non- SERVICE PROCEDURES blank Sentry Key transponder when it should see a blank, if it has already programmed eight valid Sentry SENTRY KEY IMMOBILIZER SYSTEM Keys, or if the ignition switch is turned to the Off posi- TRANSPONDER PROGRAMMING tion for more than about fifty seconds.
Page 534 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 REMOVAL AND INSTALLATION (Continued) Fig. 3 Sentry Key Immobilizer Module Remove/Install 1 – UPPER SHROUD 5 – IGNITION LOCK CYLINDER 2 – STEERING COLUMN 6 – SCREW 3 – WIRE HARNESS CONNECTOR 7 – LOWER SHROUD 4 –...
Page 535 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE PROCEDURES SENTRY KEY IMMOBILIZER SYSTEM ..1 SENTRY KEY IMMOBILIZER SYSTEM SENTRY KEY IMMOBILIZER MODULE..1 TRANSPONDER PROGRAMMING .
Page 536 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) units will require a system initialization procedure to restore system operation. When the ignition switch is turned to the On or Start positions, the SKIM transmits an RF signal to excite the Sentry Key transponder.
Page 537 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) The SKIM sends messages to the instrument clus- work should be diagnosed using a DRB scan tool. ter to turn the lamp on for about three seconds when The DRB will allow confirmation that the CCD data the ignition switch is turned to the On position as a bus is functional, that the Sentry Key Immobilizer bulb test.
Page 538 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS (5) While holding the retaining tumbler depressed, REMOVAL AND INSTALLATION pull the ignition lock cylinder and key out of the igni- tion lock housing. SENTRY KEY IMMOBILIZER MODULE (6) Remove the three screws that secure the lower steering column shroud to the upper shroud.
Page 539 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 REMOVAL AND INSTALLATION (Continued) Fig. 3 Sentry Key Immobilizer Module Remove/Install 1 – UPPER SHROUD 5 – IGNITION LOCK CYLINDER 2 – STEERING COLUMN 6 – SCREW 3 – WIRE HARNESS CONNECTOR 7 – LOWER SHROUD 4 –...
Page 540 POWER SEAT SYSTEMS 8R - 1 POWER SEAT SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 POWER SEAT SYSTEM .
Page 541 8R - 2 POWER SEAT SYSTEMS DESCRIPTION AND OPERATION (Continued) moved in the opposite direction, the battery feed and from the Power Distribution Center (PDC) as ground path to the motor(s) are reversed through the required. switch contacts. This causes the motor to run in the POWER SEAT ADJUSTER AND MOTORS opposite direction.
Page 542 POWER SEAT SYSTEMS 8R - 3 DIAGNOSIS AND TESTING (Continued) REMOVAL AND INSTALLATION POWER SEAT SWITCH (1) Disconnect and isolate the battery negative cable. (2) Remove the three screws that secure the seat cushion side shield to the outboard seat cushion frame.
Page 543 8R - 4 POWER SEAT SYSTEMS REMOVAL AND INSTALLATION (Continued) (7) Remove the nut that secures the inboard rear of the seat adjuster frame to the stud on the floor panel. (8) Remove the seat and the power seat adjuster and motors assembly from the vehicle as a unit.
Page 544 POWER WINDOW SYSTEMS 8S - 1 POWER WINDOW SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION CIRCUIT BREAKER ......3 INTRODUCTION .
Page 545 8S - 2 POWER WINDOW SYSTEMS DESCRIPTION AND OPERATION (Continued) between the terminals of the power window motor. In addition, each power window motor is equipped The passenger side front door and, on four-door mod- with an integral self-resetting circuit breaker to pro- els, both rear door power window switches receive tect the motor from overloads.
Page 546 POWER WINDOW SYSTEMS 8S - 3 DIAGNOSIS AND TESTING (Continued) the glass can be moved slightly from side to side, the passenger side front door power window switch front to rear, and up and down. Then check that the and, on four-door models, the rear door power win- glass is not bound tight in the tracks.
Page 547 8S - 4 POWER WINDOW SYSTEMS DIAGNOSIS AND TESTING (Continued) POWER WINDOW MOTOR For circuit descriptions and diagrams, refer to 8W-60 - Power Windows in Group 8W - Wiring Dia- grams. Before you proceed with this diagnosis, con- firm proper switch operation. See the Door Module and/or Power Window Switch diagnosis in this group.
Page 548 POWER WINDOW SYSTEMS 8S - 5 REMOVAL AND INSTALLATION (Continued) (2) Remove the screws that secure the door trim panel to the inner door panel (Fig. 6). Fig. 4 Front Door Trim Panel Remove/Install 1 – U-NUT 2 – DOOR Fig.
Page 549 8S - 6 POWER WINDOW SYSTEMS REMOVAL AND INSTALLATION (Continued) ulator unit. If the front door power window motor or mechanism is faulty or damaged, the entire power window regulator unit must be replaced. Refer to Group 23 - Body for the front door window regulator service procedures.
Page 550 POWER MIRROR SYSTEMS 8T - 1 POWER MIRROR SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 POWER MIRROR SYSTEM.
Page 551 8T - 2 POWER MIRROR SYSTEMS DESCRIPTION AND OPERATION (Continued) selector switch is moved right (right mirror control), (4) Turn the ignition switch to the Off position. left (left mirror control), or center to turn the power Disconnect and isolate the battery negative cable. mirrors off.
Page 552 POWER MIRROR SYSTEMS 8T - 3 DIAGNOSIS AND TESTING (Continued) Check for continuity between the ground circuit cav- ity of the stand-alone switch wire harness connector or the 8-way DDM wire harness connector and a good ground. There should be continuity. If OK, go to Step 10.
Page 553 8T - 4 POWER MIRROR SYSTEMS REMOVAL AND INSTALLATION (Continued) POWER MIRROR TEST 12 VOLTS GROUND MIRROR REACTION PIN 1 PIN 4 PIN 4 PIN 1 DOWN PIN 2 PIN 3 LEFT Fig. 5 Front Door Trim Panel Remove/Install PIN 3 PIN 2 RIGHT 1 –...
Page 554 POWER MIRROR SYSTEMS 8T - 5 REMOVAL AND INSTALLATION (Continued) Fig. 6 Door Module Remove/Install 1 – INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS 2 – CONNECTOR 1 RECEPTACLE 3 – DOOR MODULE Fig. 8 Front Door Trim Panel Remove/Install - 4 –...
Page 555 8T - 6 POWER MIRROR SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 11 Power Mirror Remove/Install 1 – SIDE VIEW MIRROR 2 – WIRE HARNESS Fig. 10 Front Door Flag Trim Panel Remove/Install 3 – SEAL 1 – FRONT DOOR 4 – GROMMET 2 –...
Page 556 CHIME/BUZZER WARNING SYSTEMS 8U - 1 CHIME/BUZZER WARNING SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 DRIVER DOOR JAMB SWITCH .
Page 557 8U - 2 CHIME/BUZZER WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) data bus message inputs, a DRB scan tool and the door is open). The headlamp switch opens the ground proper Diagnostic Procedures manual are recom- path when the headlamp switch is turned off. mended.
Page 558 CHIME/BUZZER WARNING SYSTEMS 8U - 3 DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Check for continuity between the left front door BAGS, REFER GROUP PASSIVE jamb switch sense circuit cavity of the key-in ignition switch wire harness connector and a good ground. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL,...
Page 559 8U - 4 CHIME/BUZZER WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- belt switch sense circuit cavity of the right instru- BAGS, REFER GROUP PASSIVE ment cluster wire harness connector (connector B) and a good ground. There should be no continuity. If RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL,...
Page 560 OVERHEAD CONSOLE SYSTEMS 8V - 1 OVERHEAD CONSOLE SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION COMPASS CALIBRATION ....5 INTRODUCTION ......1 COMPASS DEMAGNETIZING .
Page 561 8V - 2 OVERHEAD CONSOLE SYSTEMS DESCRIPTION AND OPERATION (Continued) Some of the functions and features that the trip cession flag can exceed the compensating ability of computer supports and/or controls, include the fol- the compass unit if placed on the roof panel. Mag- lowing display options: netic bit drivers used on the fasteners that hold the •...
Page 562 OVERHEAD CONSOLE SYSTEMS 8V - 3 DESCRIPTION AND OPERATION (Continued) When a door is open, depressing the lamp lens message inputs being received from the instrument switches will not turn the lamps off. Refer to Group cluster over the Chrysler Collision Detection (CCD) 8L - Lamps, for diagnosis of the reading and courtesy data bus.
Page 563 8V - 4 OVERHEAD CONSOLE SYSTEMS DIAGNOSIS AND TESTING (Continued) a. In the display segment test, if any segment SENSOR TEST should fail to light the unit is faulty and must be (1) Turn the ignition switch to the Off position. replaced.
Page 564 OVERHEAD CONSOLE SYSTEMS 8V - 5 SERVICE PROCEDURES (Continued) Fig. 1 Variance Settings (2) Turn the ignition switch to the On position. If This allows the compass unit to compensate for small the compass/temperature data is not currently being changes in the residual magnetism that the vehicle displayed, momentarily depress and release the Step may acquire during normal use.
Page 565 8V - 6 OVERHEAD CONSOLE SYSTEMS SERVICE PROCEDURES (Continued) NOTE: If the “CAL” message remains in the dis- play, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the demagne- tizing and calibration procedures at least one more time.
Page 566 OVERHEAD CONSOLE SYSTEMS 8V - 7 REMOVAL AND INSTALLATION (Continued) Fig. 3 Overhead Console Remove/Install Fig. 4 Trip Computer, Compass, and Thermometer 1 – HEADLINER Display Module Remove/Install 2 – REAR BRACKET 1 – TRIP COMPUTER, COMPASS AND THERMOMETER 3 – REAR MOUNTING TAB DISPLAY MODULE 4 –...
Page 567 8V - 8 OVERHEAD CONSOLE SYSTEMS REMOVAL AND INSTALLATION (Continued) SUNGLASSES STORAGE BIN The sunglasses storage bin door and bin, housing, damper, spring and latch are serviced only as a unit. Remove the sunglasses storage bin module from the overhead console as follows: (1) Remove the overhead console from the vehicle.
Page 568 OVERHEAD CONSOLE SYSTEMS 8V - 9 REMOVAL AND INSTALLATION (Continued) SPECIAL TOOLS COMPASS Degaussing Tool 6029 Fig. 7 Ambient Temperature Sensor Remove/Install 1 – WIRE HARNESS 2 – SCREW 3 – SENSOR 4 – RADIATOR SUPPORT CROSSMEMBER 5 – CLIPS 6 –...
Page 569: Wiring Diagrams
WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page AIR CONDITIONING-HEATER ... 8W-42-1 POWER DISTRIBUTION ....8W-10-1 AIRBAG SYSTEM .
Page 570 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION TROUBLESHOOTING WIRING PROBLEMS ..9 CIRCUIT FUNCTIONS ..... . 4 SERVICE PROCEDURES CIRCUIT INFORMATION .
Page 571 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 572 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 573 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) CIRCUIT INFORMATION CIRCUIT FUNCTIONS Each wire shown in the diagrams contains a code All circuits in the diagrams use an alpha/numeric which identifies the main circuit, part of the main code to identify the wire and its function.
Page 574 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) SECTION IDENTIFICATION GROUP TOPIC The wiring diagrams are grouped into individual 8W-01 thru General Information and Diagram sections. If a component is most likely found in a par- 8W-09 Overview ticular group, it will be shown complete (all wires,...
Page 575 8W - 01 - 6 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Symbols...
Page 576 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DESCRIPTION AND OPERATION (Continued) CONNECTOR INFORMATION that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that CAUTION: Not all connectors are serviced. Some could prevent making an error that may damage the connectors are serviced only with a harness.
Page 577 8W - 01 - 8 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) ELECTROSTATIC DISCHARGE (ESD) SENSITIVE voltages in these circuits use a meter with a 10-me- gohm or greater impedance rating. DEVICES All ESD sensitive components are solid state and a •...
Page 578 8W - 01 GENERAL INFORMATION 8W - 01 - 9 DIAGNOSIS AND TESTING (Continued) TROUBLESHOOTING TESTS Before beginning any tests on a vehicles electrical system use the Wiring Diagrams and study the cir- cuit. Also refer to the Troubleshooting Wiring Prob- lems in this section.
Page 579 8W - 01 - 10 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) (7) Solder the connection together using rosin core type solder only. Do not use acid core solder. (8) Center the heat shrink tubing over the joint, and heat using a heat gun.
Page 580 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) Fig. 8 Molex Connector Repair Fig. 10 Thomas and Betts Connector Lock Release 1 – CONNECTOR Tabs 2 – SPECIAL TOOL 6742 1 – LOCK TABS Fig. 9 Using Special Tool 6742 1 –...
Page 581 8W - 01 - 12 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) Fig. 12 Single Lock Tab Fig. 14 Using Special Tool 6932 1 – SINGLE LOCK TAB 1 – SPECIAL TOOL 6932 2 – CONNECTOR Fig. 13 Augat Connector Repair Fig.
Page 582 8W - 01 GENERAL INFORMATION 8W - 01 - 13 SERVICE PROCEDURES (Continued) Fig. 16 Terminal Removal Fig. 18 Stagger Cutting Wires 1 – CONNECTOR 2 – FROM SPECIAL TOOL KIT 6680 1 – REPAIR SIDE WIRES 2 – STAGER CUTS 3 –...
Page 583 8W - 01 - 14 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) Fig. 21 Terminal Removal Using Special Tool Fig. 19 Connector Locking Wedge Tab (Typical) 1 – FROM SPECIAL TOOL KIT 6680 1 – CONNECTOR 2 – CONNECTOR 2 –...
Page 584 8W - 01 GENERAL INFORMATION 8W - 01 - 15 SERVICE PROCEDURES (Continued) (4) Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. (5) Install the new diode in the harness, making sure current flow is correct.
Page 586 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 1-2 And 3-4 Solenoid ....8W-31 Fog Lamp Relays .
Page 587 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Power Mirror Switch ....8W-62 Splice Information ..... 8W-70 Power Mirrors .
Page 588 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-14 Fuse 18 (JB) ......8W-10-9 A/C Compressor Clutch Relay .
Page 589 8W - 10 - 2 8W-10 POWER DISTRIBUTION POWER DISTRIBUTION CENTER AUTOMATIC RADIATOR SHUT DOWN RELAY RELAY OXYGEN ENGINE SENSOR STARTER DOWNSTREAM MOTOR RELAY RELAY OXYGEN FUEL SENSOR PUMP UPSTREAM RELAY RELAY CONTROLLER LAMP ANTI-LOCK RELAY BRAKE NO. 1 RELAY COMPRESSOR LAMP CLUTCH...
Page 590 8W-10 POWER DISTRIBUTION 8W - 10 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT A1 12RD A0 6RD A2 12PK/BK A0 6RD A7 10RD/BK A0 6RD F141 12LG/RD A0 6RD A111 12RD/LG A0 6RD A3 14RD/WT A0 6RD A3 14RD/WT A16 14RD/LG A0 6RD...
Page 591 8W - 10 - 4 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION A17 16RD/BK FUSED B(+) C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT COMPRESSOR C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL CLUTCH RELAY F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) CAVITY CIRCUIT FUNCTION A16 14RD/LG...
Page 592 8W-10 POWER DISTRIBUTION 8W - 10 - 5 CAVITY CIRCUIT FUNCTION L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT LAMP RELAY NO. 1 Z1 20BK GROUND Z1 20BK GROUND L139 20VT FOG LAMP RELAY OUTPUT NO. 1 L33 20RD/WT FUSED B(+) G34 16RD/GY...
Page 593 8W - 10 - 6 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION F99 18RD FUSED B(+) F99 18RD FUSED B(+) OXYGEN A242 18VT/OR OXYGEN SENSOR 1/2 DOWNSTREAM SENSOR DOWNSTREAM F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) RELAY F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) (GAS) F26 18PK/OR FUSED IGNITION SWITCH OUTPUT (ST-RUN)
Page 594 8W-10 POWER DISTRIBUTION 8W - 10 - 7 S118 FUSIBLE BATTERY LINK BK/WT (8W-20-2) ENGINE GENERATOR STARTER (8W-20-2) MOTOR (8W-21-2) (8W-21-3) (8W-21-4) (8W-21-5) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE FUSE (8W-10-2) (8W-10-9) (8W-10-9) (8W-10-12) (8W-10-13) (8W-10-13) A111 RD/LG F141 C100 PK/BK RD/BK...
Page 595 8W - 10 - 8 8W-10 POWER DISTRIBUTION POWER FROM DISTRIBUTION FUSE 11 CENTER (PDC) (8W-10-2) (8W-10-7) FUSE FUSE FUSE (8W-10-17) (8W-10-18) (ABS) (8W-10-16) FUSE FUSE (ABS) (4.0L) (8W-10-17) (8W-10-16) TN/BK C100 RD/DG RD/DB HEADLAMP S218 CONTROLLER CONTROLLER S135 OXYGEN SWITCH ANTI-LOCK ANTI-LOCK...
Page 596 8W-10 POWER DISTRIBUTION 8W - 10 - 9 BATT A0 (8W-10-7) POWER BRAKE DISTRIBUTION WARNING CENTER PRESSURE FUSE FUSE (8W-10-2) SWITCH (8W-40-7) GY/BK C100 S211 PK/BK GY/BK C201 C203 C100 FROM S210 (8W-10-10) GY/BK PARK BRAKE PK/BK GY/BK SWITCH (8W-40-7) IGNITION SWITCH KEY-IN...
Page 597 8W - 10 - 10 8W-10 POWER DISTRIBUTION INSTRUMENT PASSENGER PASSENGER CLUSTER POWER POWER (8W-40-8) LOCK/ LOCK/ WINDOW WINDOW SWITCH SWITCH BATT A1 (FULL (FULL (8W-10-9) OPTIONS) OPTIONS) (8W-61-2) (8W-61-3) C300 C306 C201 C203 S210 IGNITION HEADLAMP SWITCH SWITCH KEY-IN 1 START 0 OFF SWITCH...
Page 598 8W-10 POWER DISTRIBUTION 8W - 10 - 11 BATT A2 (8W-10-9) PK/BK IGNITION SWITCH 1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-9) BK/OR C201 BK/OR JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE (8W-12-15) (8W-12-20) (8W-12-20) (8W-12-17) (8W-12-16) (8W-12-21) (8W-12-21) (8W-12-18)
Page 599 8W - 10 - 12 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-2) RD/BK JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE FUSE (8W-12-5) (8W-12-5) (8W-12-17) (8W-12-19) (8W-12-19) (8W-12-18) CIGAR HORN CIRCUIT LIGHTER RELAY BREAKER RELAY (8W-41-2) (8W-41-2) (8W-41-3) (8W-41-3) (8W-12-25)
Page 600 8W-10 POWER DISTRIBUTION 8W - 10 - 13 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) F141 A111 LG/RD RD/LG RADIATOR C100 RELAY A111 (IN PDC) RD/LG (8W-42-8) C201 C202 C209 A111 RD/LG BLOWER RADIATOR MOTOR RELAY MOTOR (8W-42-2) (8W-42-8) (8W-42-3) (8W-42-4)
Page 601 8W - 10 - 14 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) RD/WT RD/WT RD/BK RD/BK DB/GY COMPRESSOR CLUTCH RELAY (IN PDC) (8W-42-7) DB/BK 4.0L C100 OTHER C108 C100 DB/BK DB/GY COMPRESSOR CLUTCH (8W-42-7) RD/WT HEADLAMP SWITCH...
Page 602 8W-10 POWER DISTRIBUTION 8W - 10 - 15 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) A142 RD/LG DG/OR C107 AUTOMATIC A999 A142 SHUT DOWN DG/OR RELAY (IN PDC) S109 (8W-30-2) A999 4.0L 2.5L A142 A142 POWER DISTRIBUTION DG/OR DG/OR FUSE CENTER...
Page 603 8W - 10 - 16 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-2) (ABS) (ABS) BK/PK RD/DG RD/DB ENGINE CONTROLLER STARTER ANTI-LOCK MOTOR BRAKE RELAY (8W-35-2) (IN PDC) (8W-21-2) JUNCTION (8W-21-3) BLOCK (8W-21-4) (8W-12-2) (8W-21-5) REAR WINDOW...
Page 604 8W-10 POWER DISTRIBUTION 8W - 10 - 17 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) (4.0L) S135 OXYGEN SENSOR DOWNSTREAM JUNCTION RELAY BLOCK (IN PDC) (8W-12-2) (8W-30-9) UNDERHOOD LAMP/ MERCURY SWITCH (8W-44-5) C314 TRANSMISSION C201 OXYGEN CONTROL SENSOR MODULE UPSTREAM (4.0L)
Page 605 8W - 10 - 18 8W-10 POWER DISTRIBUTION BATT A0 FROM (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-10-17) CENTER FUSE (8W-10-2) TN/BK C100 C100 TN/BK TN/BK HEADLAMP S218 SWITCH (8W-50-2) TN/BK TN/BK TN/BK SKIM OTHERS DATA HEADLAMP DATA S361 LINK SWITCH LINK (8W-50-2) CONNECTOR...
Page 606 8W-10 POWER DISTRIBUTION 8W - 10 - 19 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) DG/BK FUEL PUMP RELAY (IN PDC) (8W-30-3) (8W-30-4) A141 BK/PK DG/WT DG/BK C107 C100 A141 DG/WT C200 C204 A141 BK/PK DG/WT DG/BK COMBINATION FUEL POWERTRAIN FLASHER...
Page 607 8W - 10 - 20 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) PK/DB C100 WT/OR PK/DB LAMP RELAY BRAKE NO. 2 LAMP (IN PDC) SWITCH (8W-50-9) (8W-33-3) (8W-50-10) C100 C106 WT/TN WT/TN S106 S203 C100 C100 LEFT...
Page 608 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ... . . 8W-12-12 Headlamp Delay Module ....8W-12-11 A/C- Heater Control .
Page 609 8W - 12 - 2 8W-12 JUNCTION BLOCK SPARE RELAY CIGAR LIGHTER RELAY HORN RELAY REAR WINDOW DEFOGGER RELAY FRONT OF JUNCTION BLOCK J008W-7 XJD01202...
Page 610 8W-12 JUNCTION BLOCK 8W - 12 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT F38 16RD/LB A7 10RD/BK INTERNAL A7 10RD/BK L33 20RD L3 16RD/OR L43 20VT L4 16VT/WT L44 20VT/RD L4 16VT/WT E2 20OR E1 20TN INTERNAL L7 18BK/YL A21 12DB F87 20WT/BK...
Page 611 8W - 12 - 4 8W-12 JUNCTION BLOCK CIRCUIT BREAKERS CB NO. AMPS FUSED CIRCUIT FEED CIRCUIT INTERNAL A31 12BK/WT F37 14RD/LB A7 10RD/BK V6 16DB A31 12BK/WT CAVITY CIRCUIT FUNCTION INTERNAL FUSED B(+) CIGAR INTERNAL GROUND LIGHTER A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) RELAY F30 16RD...
Page 612 8W-12 JUNCTION BLOCK 8W - 12 - 5 (8W-10-12) BATT A7 JUNCTION BLOCK (8W-12-2) FUSE FUSE CIGAR LIGHTER RELAY (8W-41-2) (8W-41-3) RD/LB C201 C201 RD/LB POWER CIGAR OUTLET LIGHTER (8W-41-2) (8W-41-2) (8W-41-3) (8W-41-3) XJD01205 J008W-7...
Page 613 8W - 12 - 6 8W-12 JUNCTION BLOCK HEADLAMP BEAM SELECT SWITCH (8W-50-3) (8W-50-4) RD/OR S213 (8W-50-3) (8W-50-4) RD/OR C201 RD/OR JUNCTION BLOCK (8W-12-2) FUSE FUSE RD/OR C106 RD/OR LEFT RIGHT HEADLAMP HEADLAMP C106 (8W-50-3) (8W-50-3) (8W-50-4) (8W-50-4) RD/WT LAMP RELAY NO.
Page 614 8W-12 JUNCTION BLOCK 8W - 12 - 7 HEADLAMP BEAM SELECT SWITCH (8W-50-3) (8W-50-4) VT/WT VT/WT C201 VT/WT VT/WT VT/WT JUNCTION BLOCK (8W-12-2) FUSE FUSE VT/RD S133 C106 OTHER VT/RD VT/RD C100 DAYTIME VT/RD RUNNING LAMP MODULE LEFT RIGHT (8W-50-11) HEADLAMP HEADLAMP (8W-50-3)
Page 615 8W - 12 - 8 8W-12 JUNCTION BLOCK HEADLAMP SWITCH (8W-50-2) C201 JUNCTION BLOCK FUSE (8W-12-2) S315 C206 C201 PRNDL TRANSFER ILLUMINATION CASE (A/T) SWITCH (8W-44-2) ILLUMINATION (8W-44-2) S215 A/C- POLICE PACKAGE OTHERS HEATER CONTROL RADIO (8W-42-4) EXTENDED (8W-47-2) (8W-47-8) IDLE HEATER SWITCH...
Page 616 8W-12 JUNCTION BLOCK 8W - 12 - 9 HEADLAMP SWITCH (8W-50-2) JUNCTION BLOCK FUSE (8W-12-2) S215 C203 RADIO REAR (8W-47-3) WINDOW (8W-47-9) DEFOGGER SWITCH (8W-48-3) OR/BK INSTRUMENT FRONT CLUSTER (8W-40-12) LAMP SWITCH (8W-44-3) C206 A/C- PRNDL TRANSFER REAR HEATER ILLUMINATION CASE WIPER/ CONTROL...
Page 617 8W - 12 - 10 8W-12 JUNCTION BLOCK HEADLAMP SWITCH (8W-50-2) BK/YL S206 C201 JUNCTION BK/YL BLOCK (8W-12-2) FUSE RADIO (8W-47-2) (8W-47-3) (8W-47-8) (8W-47-9) BR/YL BR/YL S311 LAMP TRAILER RELAY BR/YL NO. 1 C106 CONNECTOR BR/YL BR/YL (IN PDC) (8W-54-2) (8W-50-8) L139 C327...
Page 618 8W-12 JUNCTION BLOCK 8W - 12 - 11 ST-RUN A21 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE SPARE WT/BK WT/BK FULL OPTIONS BASE S225 WT/BK WT/BK C201 WT/BK WT/BK S216 WT/BK WT/BK WT/BK WT/BK SENTRY HEADLAMP DELAY WT/BK IMMOBILIZER MODULE C301 MODULE (8W-50-5) (8W-39-4)
Page 619 8W - 12 - 12 8W-12 JUNCTION BLOCK RADIATOR ST-RUN A21 (8W-10-10) JUNCTION RELAY BLOCK (IN PDC) (8W-12-2) (4.0L M/T) FUSE TRANSMISSION (4.0L A/T DRL) RANGE (4.0L A/T SENSOR EXCEPT FOG) (4.0L A/T) (8W-42-8) (8W-31-6) DAYTIME RUNNING LAMP MODULE (8W-50-11) C201 COMPRESSOR DUTY...
Page 620 8W-12 JUNCTION BLOCK 8W - 12 - 13 2.5L ST-RUN A21 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE DB/WT S130 DB/WT DB/WT DB/WT FUEL PUMP RELAY (IN PDC) (8W-30-3) (8W-30-4) C107 AUTOMATIC SHUT DOWN DB/WT RELAY (IN PDC) (8W-30-2) POWERTRAIN CONTROL MODULE (8W-30-2) XJD01213 J008W-7...
Page 621 8W - 12 - 14 8W-12 JUNCTION BLOCK 4.0L ST-RUN A21 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE DB/WT S130 DB/WT DB/WT DB/WT DB/WT TRANSMISSION CONTROL MODULE (RHD) DB/WT DB/WT (8W-31-4) AUTOMATIC FUEL S136 SHUT PUMP DOWN RELAY RELAY (IN PDC) (IN PDC) (8W-30-3) DB/WT DB/WT...
Page 622 8W-12 JUNCTION BLOCK 8W - 12 - 15 (8W-10-16) RUN A22 BATT A4 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE REAR WINDOW DEFOGGER RELAY (8W-48-2) FUSE FUSE SPARE LB/WT LB/YL BK/WT BK/WT C201 PASSENGER POWER C326 MIRROR LB/YL (8W-48-2) LB/WT BK/WT C312 INSTRUMENT C310 CLUSTER...
Page 623 8W - 12 - 16 8W-12 JUNCTION BLOCK (8W-10-16) RUN A22 BATT A4 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE REAR WINDOW DEFOGGER RELAY (8W-48-3) FUSE FUSE SPARE LB/WT BK/WT LB/YL BK/WT BK/WT C204 DRIVER C326 POWER MIRROR (8W-48-3) LB/YL REAR WINDOW INSTRUMENT DEFOGGER CLUSTER...
Page 624 8W-12 JUNCTION BLOCK 8W - 12 - 17 (8W-10-12) (8W-10-9) BATT A7 RUN-ACC A31 ST A41 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE 2.5L A/T 4.0L A/T RD/WT YL/DG C201 YL/RD YL/RD YL/RD RD/WT CLUTCH CLUTCH INTERLOCK INTERLOCK RADIO SWITCH SWITCH (8W-47-2)
Page 625 8W - 12 - 18 8W-12 JUNCTION BLOCK (8W-10-12) (8W-10-9) BATT A7 RUN-ACC A31 ST A41 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE RD/WT YL/DG YL/RD C204 C100 C300 RADIO (8W-47-3) YL/RD (8W-47-9) YL/DG C306 POWER MIRRORS FULL OPTIONS S352 YL/RD YL/RD...
Page 626 8W-12 JUNCTION BLOCK 8W - 12 - 19 (8W-10-12) BATT A7 JUNCTION BLOCK (8W-12-2) FUSE FUSE HORN RELAY (8W-41-2) (8W-41-3) BK/RD BK/RD C201 RD/OR BK/RD DG/RD C301 C323 S131 BK/RD RD/OR BK/RD DG/RD DG/RD CLOCKSPRING (8W-41-2) (8W-41-3) OVERHEAD HORN MODULE SWITCH (8W-49-4) (8W-41-2)
Page 627 8W - 12 - 20 8W-12 JUNCTION BLOCK RUN A22 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE SPARE BR/PK DB/WT DB/WT S219 C201 S134 DB/WT DB/WT BR/PK C209 DB/WT DB/WT REAR BLOWER WIPER/ MOTOR WASHER RELAY SWITCH CONTROLLER (8W-42-2) (8W-53-3) ANTI-LOCK (8W-42-4) BRAKE...
Page 628 8W-12 JUNCTION BLOCK 8W - 12 - 21 RUN A22 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE SPARE BR/PK DB/WT DB/WT REAR S134 WIPER/ WASHER SWITCH DB/WT DB/WT (8W-53-4) CONTROLLER ANTI-LOCK BRAKE BR/PK RELAY C203 FULL (IN PDC) OPTIONS BASE (8W-35-3) S324 CONTROLLER...
Page 629 8W - 12 - 22 8W-12 JUNCTION BLOCK HEADLAMP SWITCH HEADLAMP (8W-50-2) SWITCH OUTPUT BK/YL S206 (8W-12-10) C201 BK/YL JUNCTION BLOCK (8W-12-2) FUSE DG/YL DG/YL C321 C106 DG/YL DG/YL S101 DG/YL DG/YL DG/YL RIGHT RIGHT RIGHT FRONT FRONT SIDE RIGHT PARK/ PARK/ MARKER...
Page 630 8W-12 JUNCTION BLOCK 8W - 12 - 23 (8W-10-9) RUN A22 ST-RUN A21 RUN-ACC A31 (8W-10-11) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE CIRCUIT BREAKER LG/YL DB/YL C201 C200 C307 AIRBAG DRIVER PASSENGER CONTROL POWER POWER MODULE LOCK/ LOCK/ (8W-43-2) WINDOW WINDOW SWITCH SWITCH...
Page 631 8W - 12 - 24 8W-12 JUNCTION BLOCK (8W-10-9) RUN A22 ST-RUN A21 RUN-ACC A31 (8W-10-11) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE CIRCUIT BREAKER LG/YL DB/YL C204 C202 C307 LG/YL DB/YL AIRBAG PASSENGER DRIVER CONTROL POWER POWER MODULE LOCK/ LOCK/ (8W-43-3) WINDOW WINDOW...
Page 632 8W-12 JUNCTION BLOCK 8W - 12 - 25 (8W-10-12) (8W-10-9) BATT A7 RUN-ACC A31 JUNCTION BLOCK (8W-12-2) CIRCUIT CIRCUIT BREAKER BREAKER RD/LB C201 FRONT WIPER MOTOR (8W-53-2) C316 WIPE/ WASH SWITCH (8W-53-2) RD/LB S356 RD/LB RD/LB RD/LB C362 C329 C363 RD/LB LEFT HEATED...
Page 633 8W - 12 - 26 8W-12 JUNCTION BLOCK BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-17) S135 JUNCTION UNDERHOOD BLOCK LAMP/ (8W-12-2) MERCURY SWITCH (8W-44-5) C314 OTHERS SKIM TRANSMISSION C201 CONTROL MODULE (4.0L) S347 S361 (8W-31-4) (8W-10-18) (8W-10-18) S214 CARGO RADIO C208...
Page 634 8W-12 JUNCTION BLOCK 8W - 12 - 27 HEADLAMP LEFT RIGHT SWITCH COURTESY COURTESY LAMP LAMP (8W-50-2) (8W-44-5) (8W-44-5) BK/WT BK/WT C208 C207 S201 C201 JUNCTION BLOCK (8W-12-2) OVERHEAD MODULE BASE/POLICE S345 FULL OPTIONS MIDLINE DOME LAMP OVERHEAD (8W-44-4) MODULE (8W-49-4) (8W-49-5) COMPASS...
Page 635 8W - 12 - 28 8W-12 JUNCTION BLOCK PASSENGER PASSENGER POWER DOOR LOCK/ LOCK WINDOW MOTOR SWITCH (8W-61-4) (FULL OPTIONS) (8W-61-4) PK/BK OR/BK OR/BK PK/BK S317 S316 PK/BK OR/BK JUNCTION BLOCK (8W-12-2) PK/BK OR/BK S307 S306 PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK...
Page 636 8W-12 JUNCTION BLOCK 8W - 12 - 29 PASSENGER POWER LOCK/ WINDOW SWITCH (FULL OPTIONS) (8W-61-5) PK/BK OR/BK S323 S322 PK/BK OR/BK PK/BK OR/BK PASSENGER DOOR C305 LOCK MOTOR (8W-61-5) PK/BK OR/BK S307 S306 PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK C309...
Page 637 8W - 12 - 30 8W-12 JUNCTION BLOCK LHD EXCEPT FULL OPTIONS RUN-ACC F83 (8W-12-17) POWER MIRROR SWITCH (8W-62-6) 1 RIGHT 2 UP 3 LEFT 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR YL/BK DB/WT OR/YL WT/BK DRIVER POWER MIRROR (8W-62-6) JUNCTION BLOCK...
Page 638 8W-12 JUNCTION BLOCK 8W - 12 - 31 LHD FULL OPTIONS DRIVER DRIVER POWER POWER LOCK/ MIRROR WINDOW (8W-62-2) SWITCH (8W-62-3) OR/YL OR/YL OR/YL S328 YL/BK OR/YL C305 YL/BK OR/YL C200 YL/BK OR/YL C201 YL/BK OR/YL JUNCTION BLOCK (8W-12-2) YL/BK OR/YL S318 OR/YL...
Page 639 8W - 12 - 32 8W-12 JUNCTION BLOCK RHD EXCEPT FULL OPTIONS RUN-ACC F83 (8W-12-18) POWER MIRROR SWITCH (8W-62-7) 1 RIGHT 2 UP 3 LEFT 4 DOWN 5 DRIVER MIRRIOR 6 PASSENGER MIRROR DB/WT YL/LB YL/BK S319 DRIVER (8W-15-7) POWER MIRROR OR/YL WT/BK...
Page 640 8W-12 JUNCTION BLOCK 8W - 12 - 33 RHD FULL OPTIONS PASSENGER POWER MIRROR (8W-62-5) DB/RD OR/YL OR/YL S328 OR/YL C305 YL/BK OR/YL C204 YL/BK OR/YL JUNCTION BLOCK (8W-12-2) DB/WT YL/LB OR/YL S318 OR/YL OR/YL OR/YL DRIVER DRIVER POWER POWER LOCK/ MIRROR WINDOW...
Page 641 8W - 12 - 34 8W-12 JUNCTION BLOCK PASSENGER POWER DRIVER POWER MIRROR POWER MIRROR SWITCH MIRROR (LHD) (8W-62-7) (8W-48-3) (8W-48-2) PASSENGER POWER LOCK/ WINDOW S319 SWITCH (8W-15-7) (LHD) (8W-61-2) PASSENGER POWER MIRROR S319 (8W-48-2) (8W-15-7) FULL OPTIONS POWER POWER MIRRORS MIRRORS JUNCTION...
Page 642 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C- Heater Control ....8W-15-8, 9 Left Turn Signal Lamp ... . 8W-15-10, 11 Airbag Control Module .
Page 643 8W - 15 - 2 8W-15 GROUND DISTRIBUTION TRANSFER TRANSFER OXYGEN OXYGEN CASE CASE SENSOR SENSOR SWITCH SWITCH (8W-40-7) (8W-40-7) DOWNSTREAM DOWNSTREAM (8W-30-8) (4.0L (8W-30-10) CALIFORNIA) POWERTRAIN (8W-30-11) CONTROL MODULE 4.0L A/T OTHER (2.5L M/T) C112 (8W-30-14) C112 ENGINE OXYGEN STARTER SENSOR 242 4WD...
Page 644 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 LHD 2.5L REAR WINDSHIELD WASHER WASHER LAMP LAMP PUMP PUMP RELAY RELAY NO. 2 NO. 1 (8W-53-3) (8W-53-2) (IN PDC) (IN PDC) (DRL) (DRL) (8W-50-10) (8W-50-10) UNDERHOOD LAMP/ MERCURY SWITCH (8W-44-5) VEHICLE SPEED CONTROL SERVO...
Page 645 8W - 15 - 4 8W-15 GROUND DISTRIBUTION LHD 4.0L REAR WINDSHIELD WASHER WASHER PUMP PUMP (8W-53-2) (8W-53-3) WASHER FRONT TRANSMISSION FLUID WIPER RANGE LEVEL MOTOR SENSOR SWITCH (8W-53-2) (A/T) (8W-40-5) (8W-31-6) S141 UNDERHOOD LAMP/ LAMP LAMP MERCURY RELAY RELAY SWITCH NO.
Page 646 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 REAR WINDSHIELD WASHER WASHER LAMP LAMP PUMP PUMP RELAY RELAY (8W-53-2) NO. 2 NO. 1 (8W-53-4) (IN PDC) (IN PDC) (8W-50-9) (8W-50-8) (8W-50-10) (8W-50-10) UNDERHOOD LAMP/ MERCURY SWITCH (8W-44-5) CONTROLLER ANTI-LOCK OTHER BRAKE RELAY VEHICLE...
Page 647 8W - 15 - 6 8W-15 GROUND DISTRIBUTION LEFT LEFT LEFT LEFT HEADLAMP FRONT FRONT (8W-50-3) LAMP PARK/ PARK/ (8W-50-4) (8W-50-9) TURN TURN (8W-50-10) SIGNAL SIGNAL LAMP LAMP NO. 1 NO. 2 (8W-50-6) (8W-50-6) (8W-52-3) (8W-52-3) S103 S158 RIGHT RIGHT RIGHT RIGHT FRONT...
Page 648 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 OVERHEAD LEFT PASSENGER POWER MODULE VISOR/ POWER MIRROR (8W-49-2) VANITY MIRROR SWITCH (8W-49-3) LAMP (LHD) (8W-62-7) (8W-44-4) (8W-48-2) DRIVER COMPASS RIGHT PASSENGER POWER (8W-49-2) VISOR/ POWER MIRROR (8W-49-3) VANITY LOCK/ (8W-48-3) LAMP WINDOW (8W-44-4) SWITCH...
Page 649 8W - 15 - 8 8W-15 GROUND DISTRIBUTION FROM FROM JUNCTION EXTENDED FRONT C201 BLOCK IDLE (8W-15-7) (8W-15-7) SWITCH LAMP (8W-30-17) SWITCH (8W-44-2) (8W-44-3) POLICE OTHERS PACKAGE REAR COMBINATION REAR WINDOW FLASHER WIPER/ DEFOGGER (8W-52-2) WASHER SWITCH SWITCH (8W-48-2) (8W-53-3) (8W-48-3) (8W-53-4) S208...
Page 650 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 WIPE/ BRAKE HEADLAMP IGNITION WASH LAMP DELAY SWITCH SWITCH SWITCH MODULE (8W-10-9) (8W-53-2) (8W-33-3) (8W-50-5) HEADLAMP SWITCH (8W-50-2) S207 BLOWER MOTOR RELAY SENTRY (8W-42-2) (8W-42-3) IMMOBILIZER (8W-42-4) (8W-42-5) MODULE COMPASS (8W-39-4) (8W-49-2) (8W-39-5) (8W-49-3) C209...
Page 651 8W - 15 - 10 8W-15 GROUND DISTRIBUTION LEFT LEFT DRIVER LEFT TAIL/ BACK-UP POWER TURN STOP LAMP MIRROR SIGNAL LAMP (8W-51-7) (8W-48-2) LAMP (8W-51-3) (8W-52-3) DRIVER POWER POWER MIRROR LOCK/ SWITCH WINDOW (8W-62-6) SWITCH (8W-60-2) (8W-61-2) DRIVER S341 POWER MIRROR (8W-48-2) TRAILER...
Page 652 8W-15 GROUND DISTRIBUTION 8W - 15 - 11 LEFT LEFT LEFT TAIL/ TURN BACK-UP STOP SIGNAL LAMP LAMP LAMP (8W-51-7) (8W-51-3) (8W-52-3) S341 TRAILER PRNDL ILLUMINATION CONNECTOR (A/T) TRANSFER (8W-54-2) (8W-44-2) CASE SWITCH PASSENGER ILLUMINATION PASSENGER POWER (8W-44-3) POWER MIRROR LOCK/ (8W-48-3) WINDOW...
Page 653 8W - 15 - 12 8W-15 GROUND DISTRIBUTION RIGHT RIGHT RIGHT TAIL/ TURN BACK-UP STOP SIGNAL LAMP LAMP LAMP (8W-51-7) (8W-51-3) (8W-52-4) S348 RIGHT PASSENGER REAR DOOR DOOR JAMB JAMB SWITCH SWITCH (8W-39-6) (8W-39-6) C319 C318 C321 S310 G303 J008W-7 XJD01512...
Page 654 8W-15 GROUND DISTRIBUTION 8W - 15 - 13 RIGHT RIGHT RIGHT TAIL/ TURN BACK-UP STOP SIGNAL LAMP LAMP LAMP (8W-51-7) (8W-51-3) (8W-52-4) S348 DRIVER DRIVER DRIVER DOOR POWER POWER JAMB LOCK/ MIRROR SWITCH WINDOW (FULL (8W-39-7) SWITCH OPTIONS) (8W-48-3) (FULL OPTIONS) (8W-60-3) (8W-61-3)
Page 655 8W - 15 - 14 8W-15 GROUND DISTRIBUTION LICENSE LIFTGATE REAR LAMP SWITCH WIPER (8W-51-4) (8W-44-6) MOTOR (8W-44-7) (8W-53-3) (8W-53-4) C330 S334 CENTER HIGH MOUNTED STOP LAMP (8W-51-4) REAR WINDOW C310 DEFOGGER C311 (8W-48-2) (8W-48-3) C333 C310 C312 G304 J008W-7 XJD01514...
Page 656 8W-15 GROUND DISTRIBUTION 8W - 15 - 15 LEFT RIGHT HEATED HEATED HEATED SEAT SEAT SEAT RELAY BACK BACK (8W-63-6) (8W-63-5) (8W-63-5) S354 LEFT RIGHT HEATED HEATED SEAT SEAT SWITCH SWITCH C332 C329 (8W-63-4) (8W-63-4) S355 LEFT RIGHT SEAT POWER POWER HEAT SEAT...
Page 658 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... . 8W-20-2 Fuse 22 (PDC) ..... . 8W-20-3 Battery .
Page 659 8W - 20 - 2 8W-20 CHARGING SYSTEM POWER FUSIBLE LINK DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-15) S118 RD/LG BK/WT AUTOMATIC BATTERY SHUT DOWN GENERATOR RELAY (IN PDC) (8W-30-2) A999 A999 ENGINE B(+) STARTER MOTOR (8W-21-2) (8W-21-3) (8W-21-4) FUSE (8W-21-5) 18 (PDC) (8W-10-15) POWER DISTRIBUTION...
Page 660 8W-20 CHARGING SYSTEM 8W - 20 - 3 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-19) S138 (8W-70-3) K167 BR/YL DG/BK C107 K167 FUEL K167 FUSED PUMP B(+) BR/YL BR/YL RELAY (IN PDC) S111 (8W-30-3) (8W-70-3) (8W-30-4) 4.0L CALIFORNIA OTHER BATTERY TEMPERATURE...
Page 662 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ..... . 8W-21-2, 3, 4, 5 G101 .
Page 663 8W - 21 - 2 8W-21 STARTING SYSTEM 2.5L A/T ST A41 (8W-10-11) JUNCTION POWER BLOCK FUSE DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) (8W-12-17) (8W-12-18) (8W-10-16) YL/RD C100 YL/RD YL/RD CLUTCH CLUTCH INTERLOCK INTERLOCK SWITCH SWITCH JUMPER JUMPER T141 T141 C100 ENGINE STARTER BATTERY...
Page 664 8W-21 STARTING SYSTEM 8W - 21 - 3 4.0L A/T ST A41 (8W-10-11) JUNCTION POWER BLOCK FUSE DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) (8W-12-17) (8W-12-18) (8W-10-16) YL/RD C100 YL/RD CLUTCH INTERLOCK SWITCH YL/RD JUMPER T141 C100 ENGINE STARTER MOTOR BATTERY RELAY (8W-20-2) (IN PDC) BK/WT...
Page 665 8W - 21 - 4 8W-21 STARTING SYSTEM 2.5L M/T ST A41 (8W-10-11) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-2) (8W-12-17) (8W-10-16) (8W-12-18) YL/RD C100 CLUTCH CLUTCH INTERLOCK INTERLOCK SWITCH SWITCH BATTERY (8W-20-2) C100 T141 ENGINE STARTER MOTOR RELAY (IN PDC) BK/WT...
Page 666 8W-21 STARTING SYSTEM 8W - 21 - 5 4.0L M/T ST A41 (8W-10-11) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-2) (8W-12-17) (8W-10-16) (8W-12-18) YL/RD C100 CLUTCH CLUTCH INTERLOCK INTERLOCK SWITCH SWITCH BATTERY (8W-20-2) C100 T141 ENGINE STARTER MOTOR RELAY (IN PDC) LAMP...
Page 668 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-9, 18 G101 ....8W-30-2, 8, 10, 11, 14, 17 A/C High Pressure Switch .
Page 669 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 BATT A0 (8W-10-10) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE FUSE (8W-10-2) (8W-12-13) (8W-10-15) (8W-10-19) (8W-12-14) RD/LG DG/BK DB/WT S130 FUEL FUSED (8W-12-13) PUMP B(+) (8W-12-14) RELAY (IN PDC) DB/WT DB/WT (8W-30-3)
Page 670 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 ST-RUN A21 BATT A0 (8W-10-10) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-2) (8W-12-13) (8W-10-19) (8W-12-14) F12 18DB/WT DG/BK S130 (8W-12-13) (8W-12-14) FUEL PUMP RELAY (IN PDC) A141 14DG/WT C100 A141 DG/WT C200...
Page 671 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 BATT A0 (8W-10-10) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-2) (8W-12-13) (8W-10-19) (8W-12-14) F12 18DB/WT DB/BK S130 (8W-12-13) (8W-12-14) FUEL PUMP RELAY (IN PDC) A141 14DG/WT C100 A141 DG/WT C204...
Page 672 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 BATT A16 (8W-10-15) POWER DISTRIBUTION AUTOMATIC CENTER SHUT DOWN (8W-10-2) RELAY (8W-30-2) A999 16RD A999 POWER FUSE DISTRIBUTION 21 (PDC) FUSE CENTER (8W-10-15) (8W-10-2) (8W-10-15) S115 (8W-70-2) A142 DG/OR CRANKSHAFT POSITION SUPPLY CRANKSHAFT SENSOR POSITION...
Page 673 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM BATT A16 (8W-10-15) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE DOWN (8W-10-2) RELAY (8W-30-2) (8W-10-15) A142 A999 A999 DG/OR C107 A142 DG/OR FUSE S109 21 (PDC) (8W-10-15) (8W-10-15) A142 DG/OR S113 (8W-10-15) A142 A142 A142 A142...
Page 674 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 THROTTLE POSITION SENSOR OTHER 4.0L A/T K167 BR/YL OR/DB S112 OR/DB OR/DB C107 OR/DB TRANSMISSION THROTTLE CONTROL POSITION MODULE SENSOR SIGNAL (8W-31-5) S114 S115 (8W-70-3) (8W-70-2) K167 K167 K167 BR/YL BR/YL BR/YL S111 (8W-70-3) ENGINE...
Page 675 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM 2.5L BATT A16 (8W-10-15) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE DOWN (8W-10-2) RELAY (8W-30-2) (8W-10-15) F142 A999 DG/WT S168 (8W-10-15) F142 DG/WT C107 F142 DG/WT S110 (8W-10-15) F142 F142 DG/WT DG/WT OXYGEN OXYGEN SENSOR SENSOR...
Page 676 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 4.0L ST-RUN A21 BATT A0 (8W-10-10) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-12) (8W-10-17) C201 OXYGEN EXCEPT OTHER SENSOR C100 UPSTREAM RELAY (IN PDC) PK/OR S159 (8W-12-12) FUSED A/T FOG COMPRESSOR IGNITION...
Page 677 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM 4.0L FROM OXYGEN OXYGEN SENSOR SENSOR UPSTREAM DOWNSTREAM RELAY RELAY (8W-30-9) (8W-30-9) A242 VT/OR C107 CALIFORNIA CALIFORNIA OTHER OTHER A242 A242 S121 VT/OR DG/OR A242 (8W-30-11) VT/OR S122 (8W-30-11) A242 VT/OR OXYGEN OXYGEN SENSOR SENSOR...
Page 678 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 4.0L CALIFORNIA FROM FROM OXYGEN OXYGEN SENSOR SENSOR UPSTREAM DOWNSTREAM RELAY RELAY (8W-30-9) (8W-30-9) A242 VT/OR C107 A242 A242 VT/OR DG/OR S121 S122 A242 A242 VT/OR VT/OR OXYGEN OXYGEN SENSOR SENSOR UPSTREAM DOWNSTREAM (8W-30-10) (8W-30-10)
Page 679 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM MANIFOLD ABSOLUTE PRESSURE SENSOR K167 BR/YL S114 (8W-70-3) K167 BR/YL S111 S115 (8W-70-3) 4.0L (8W-70-2) CALIFORNIA OTHER K167 K167 K167 BR/YL BR/YL BR/YL K167 S123 VEHICLE SENSOR BR/YL VEHICLE (8W-70-2) SPEED GROUND K167 SPEED SENSOR...
Page 680 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 LEFT RIGHT SPEED SPEED CONTROL CONTROL SWITCH SWITCH 1 SET 1 RESUME/ACCEL 2 ON/OFF 2 CANCEL (8W-33-2) 3 COAST (8W-33-2) K167 K167 RD/LG BR/YL RD/LG BR/YL S221 S222 CLOCKSPRING BK/RD RD/LG C100 K167 BR/YL S138...
Page 681 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM (8W-12-17) (8W-12-17) ST T141 ST F45 (8W-12-18) (8W-12-18) POWER DISTRIBUTION OTHER 4.0L A/T CENTER ENGINE (8W-10-2) STARTER MOTOR YL/RD YL/RD RELAY (8W-21-2) (8W-21-3) (8W-21-4) (8W-21-5) BRAKE LAMP SWITCH (8W-33-3) BK/WT S132 (8W-15-4) TRANSMISSION RANGE BK/WT...
Page 682 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15 ST-RUN A21 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-13) (8W-12-12) (8W-12-14) DB/WT S130 (8W-12-13) (8W-12-14) C201 OTHER 4.0L LHD A/T C100 DB/WT C100 S136 (8W-12-14) DB/WT S159 (8W-12-12) C107 S161 (8W-51-6) DUTY CYCLE EVAP/ PURGE...
Page 683 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM POWERTRAIN CONTROL MODULE IDLE AIR IDLE AIR IDLE AIR IDLE AIR BRAKE CONTROL CONTROL CONTROL CONTROL LAMP NO. 3 NO. 2 NO. 1 NO. 4 SWITCH DRIVER DRIVER DRIVER DRIVER SENSE WT/PK 4.0L A/T OTHER S140...
Page 684 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17 POWERTRAIN HEADLAMP PANEL CONTROL POWER SWITCH LAMPS MODULE STEERING DIMMER (8W-50-2) PRESSURE SWITCH IDLE SWITCH SIGNAL ACTUATOR SIGNAL C201 4.0L A/T 2.5L 4.0L A/T 2.5L RUN A22 (8W-10-11) JUNCTION BLOCK DB/BR (8W-12-2) FUSE FUSE (8W-12-8)
Page 685 8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM GENERATOR (8W-12-12) ST-RUN F20 (8W-20-2) POWER GENERATOR GENERATOR FIELD DISTRIBUTION SOURCE CENTER RADIATOR COMPRESSOR (8W-10-2) CLUTCH RELAY DG/OR RELAY (8W-42-8) (8W-42-7) C108 DG/OR S166 DG/OR EVAP LEAK DETECTION C107 PUMP K106 K105 DB/OR DB/PK WT/DG...
Page 686 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 19 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-18) TN/BK C100 HEADLAMP S218 FUSED SWITCH (8W-10-18) B(+) (8W-50-2) TN/BK DATA LINK CONNECTOR BK/TN LG/BK C100 2.5L 4.0L S139 BK/TN CONTROLLER ANTI-LOCK TRANSMIT/ ISO 9141K BRAKE LG/BK...
Page 687 8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM DATA SENTRY LINK CONNECTOR IMMOBILIZER TWISTED MODULE PAIR VT/BR WT/BK (8W-39-8) TWISTED PAIR VT/BR WT/BK S238 S239 TWISTED TWISTED PAIR PAIR VT/BR WT/BK VT/BR WT/BK VT/BR WT/BK C201 VT/BR WT/BK VT/BR WT/BK INSTRUMENT CLUSTER AIRBAG...
Page 688 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 21 DATA SENTRY LINK CONNECTOR IMMOBILIZER TWISTED MODULE PAIR VT/BR WT/BK (8W-39-9) TWISTED PAIR VT/BR WT/BK S238 S239 TWISTED TWISTED PAIR PAIR VT/BR WT/BK VT/BR WT/BK VT/BR WT/BK C204 VT/BR WT/BK VT/BR WT/BK INSTRUMENT CLUSTER AIRBAG...
Page 690 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Brake Lamp Switch ....8W-31-3, 7 Lock-Up Solenoid .
Page 691 8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM 2.5L (8W-12-17) ST-RUN A21 ST T141 (8W-10-10) (8W-12-18) JUNCTION POWER BLOCK DISTRIBUTION ENGINE (8W-12-2) CENTER STARTER FUSE FUSE (8W-10-2) MOTOR RELAY (8W-21-2) (8W-12-13) (8W-12-12) BK/WT C201 DB/WT C100 C107 C100 S159 S130 (8W-12-12) (8W-12-13)
Page 692 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3 2.5L RUN A22 (8W-10-11) JUNCTION BLOCK FUSE (8W-12-2) (8W-12-20) (8W-12-21) DB/WT S219 (8W-12-20) (8W-12-21) C201 DB/WT DB/WT S217 (8W-12-20) SHIFT LOCK SOLENOID WT/PK WT/PK S204 WT/PK BRAKE WT/PK WT/PK LAMP SWITCH (8W-33-3) C100 WT/PK...
Page 693 8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM 4.0L ST-RUN A21 BATT A0 (8W-10-10) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-2) (8W-12-14) (8W-10-17) DB/WT S130 (8W-12-14) DB/WT S135 (8W-10-17) S136 (8W-12-14) DB/WT TRANSMISSION FUSED FUSED CONTROL IGNITION B(+) SWITCH...
Page 694 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5 4.0L POWERTRAIN CONTROL MODULE SENSOR (8W-30-7) SUPPLY GROUND 4.0L CALIFORNIA OTHER K167 BR/YL K167 S123 BR/YL (8W-70-2) K167 BR/YL S111 (8W-70-3) K167 K167 BR/YL BR/YL S115 S114 (8W-70-2) (8W-70-3) C107 K167 BR/YL K167 OR/DB...
Page 695 8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM 4.0L ST-RUN A21 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FROM ENGINE STARTER (8W-12-12) MOTOR RELAY (8W-21-3) C201 BK/WT C100 S159 (8W-12-12) TRANSMISSION RANGE SENSOR BR/LG LG/BK VT/WT S141 (8W-15-4) (8W-15-5) S142 (8W-51-6) BR/LG G106 (8W-15-6)
Page 696 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7 4.0L RUN A22 (8W-10-11) DATA JUNCTION TWISTED LINK BLOCK PAIR CONNECTOR (8W-12-2) (8W-30-20) FUSE (8W-30-21) (8W-12-20) (8W-12-21) VT/BR WT/BK DB/WT S219 (8W-12-20) (8W-12-21) S239 S238 (8W-30-20) (8W-30-20) C201 (8W-30-21) (8W-30-21) DB/WT DB/WT S217 (8W-12-20)
Page 698 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-3 Left Speed Control Switch .
Page 699 8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL LEFT RIGHT SPEED SPEED CONTROL CONTROL SWITCH SWITCH 1 SET 1 RESUME/ACCEL 2 ON/OFF 2 CANCEL 3 COAST K167 K167 RD/LG BR/YL RD/LG BR/YL S221 S222 CLOCKSPRING BK/RD RD/LG C100 K167 BR/YL S138 (8W-70-3)
Page 700 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-20) YL/RD YL/RD WT/PK C100 PK/DB S204 (8W-31-3) (8W-31-7) BRAKE C100 LAMP SWITCH WT/PK WT/PK DB/RD WT/TN S207 C100 (8W-15-9) S203 DB/RD C100 (8W-10-20) G108 (8W-15-9)
Page 702 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES Component Page Component Page ABS Indicator ..... . . 8W-35-3 G Switch .
Page 703 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) (8W-10-16) (8W-10-16) (8W-10-20) DATA LINK CONNECTOR PK/DB (8W-30-19) C100 PK/DB C100 BRAKE LAMP 4.0L 2.5L SWITCH (8W-33-3) SWITCH WT/TN S139 S203 (8W-30-19) (8W-10-20) WT/TN PK/OR...
Page 704 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 RUN A22 ST-RUN A21 (8W-10-11) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-11) (8W-12-20) (8W-12-21) DB/WT WT/BK FULL BASE OPTIONS S225 (8W-12-11) C201 S216 (8W-12-11) WT/BK INSTRUMENT S134 CLUSTER (8W-12-20) (8W-40-5) (8W-12-21) INDICATOR LAMP RELAY DB/WT...
Page 705 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES LEFT RIGHT FRONT FRONT WHEEL WHEEL SPEED SPEED SENSOR SENSOR LEFT RIGHT REAR REAR WHEEL WHEEL SPEED SPEED SENSOR SENSOR LG/DB YL/DB TWISTED TWISTED TWISTED TWISTED PAIR PAIR PAIR PAIR C109 C109 RD/DB LG/DB WT/DB...
Page 706 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Cargo Lamp/Switch ....8W-39-6 Horn Relay .
Page 707 8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM (8W-10-7) BATT A0 POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-17) PASSENGER DOOR POWER DOOR UNLOCK LOCK/ LOCK RELAY WINDOW CONTROL CONTROL SWITCH (8W-61-2) S135 LB/RD DB/PK (8W-10-17) JUNCTION C300 BLOCK (8W-12-2) LB/RD DB/PK OTHERS...
Page 708 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3 (8W-10-7) BATT A0 PASSENGER POWER DOOR POWER DISTRIBUTION DOOR UNLOCK LOCK/ CENTER LOCK RELAY WINDOW FUSE CONTROL CONTROL (8W-10-2) SWITCH (8W-61-3) (8W-10-17) LB/RD C305 S135 (8W-10-17) LB/RD DB/PK C203 JUNCTION BLOCK (8W-12-2) LB/RD...
Page 709 8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM (8W-10-14) BATT A17 ST-RUN A21 (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-14) (8W-12-11) DB/GY WT/BK BASE FULL OPTIONS S225 (8W-12-11) WT/BK C100 C201 WT/BK S216 (8W-12-11) DB/GY WT/BK SENTRY...
Page 710 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5 (8W-10-14) BATT A17 ST-RUN A21 (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-14) (8W-12-11) DB/GY WT/BK C100 S216 (8W-12-11) DB/GY WT/BK SENTRY FUSED FUSED B(+) IGNITION IMMOBILIZER SWITCH OUTPUT MODULE...
Page 711 8W - 39 - 6 8W-39 VEHICLE THEFT SECURITY SYSTEM HEADLAMP OVERHEAD DOOR CARGO SWITCH MODULE JAMB COURTESY (8W-49-4) LAMP/ (8W-50-2) SWITCH LAMPS SWITCH SENSE DRIVER (8W-44-6) IGNITION SWITCH DRIVER DOOR (8W-10-9) AJAR S345 SWITCH (8W-12-27) SENSE C314 JUNCTION BLOCK (8W-12-2) BK/LB BK/LB...
Page 712 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 7 OVERHEAD HEADLAMP DOOR MODULE SWITCH JAMB CARGO COURTESY SWITCH (8W-49-5) (8W-50-2) LAMP/ LAMP SENSE IGNITION DOOR SWITCH CONTROL SWITCH JAMB (8W-44-7) SWITCH (8W-10-9) SENSE S345 C314 (8W-12-27) BK/LB BK/LB S200 (8W-10-10) JUNCTION BLOCK...
Page 713 8W - 39 - 8 8W-39 VEHICLE THEFT SECURITY SYSTEM DATA LINK INSTRUMENT SENTRY CONNECTOR CLUSTER (8W-30-20) (8W-40-3) IMMOBILIZER MODULE VT/BR WT/BK WT/BK VT/BR WT/BK VT/BR TWISTED TWISTED TWISTED PAIR PAIR PAIR S238 (8W-30-20) S239 (8W-30-20) TWISTED PAIR TWISTED (8W-10-12) BATT A7 PAIR JUNCTION...
Page 714 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 9 DATA LINK INSTRUMENT SENTRY CONNECTOR CLUSTER (8W-30-21) (8W-40-3) IMMOBILIZER MODULE WT/BK VT/BR WT/BK VT/BR VT/BR WT/BK TWISTED TWISTED TWISTED PAIR PAIR PAIR S238 (8W-30-21) S239 TWISTED (8W-30-21) TWISTED PAIR PAIR (8W-10-12) BATT A7 JUNCTION...
Page 716 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page ABS Indicator ..... 8W-40-5, 6 Junction Block .
Page 717 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER (8W-10-7) BATT A0 ST-RUN A21 (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-17) (8W-12-11) WT/BK S135 (8W-10-17) FULL OPTIONS BASE JUNCTION WT/BK BLOCK S225 (8W-12-2) (8W-12-11) C201 C201 WT/BK S214 S216 (8W-10-17)
Page 718 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 (8W-12-11) ST-RUN F87 INSTRUMENT CLUSTER CHECK UPSHIFT FUEL GAUGES INDICATOR WARNING WARNING (M/T) INDICATOR INDICATOR FUSED LOW FUEL CHECK GAUGES UPSHIFT IGN. WARNING WARNING INDICATOR (ST-RUN) INDICATOR INDICATOR CONTROL CONTROL CONTROL FUEL GAUGE TACHOMETER SPEEDOMETER...
Page 719 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER (8W-12-11) ST-RUN F87 INSTRUMENT CLUSTER CHECK ENGINE WARNING INDICATOR FUSED CHECK ENGINE ENGINE IGNITION WARNING COOLANT SWITCH INDICATOR TEMPERATURE PRESSURE OUTPUT CONTROL GAUGE GAUGE (ST-RUN) CONTROL CONTROL ENGINE COOLANT PRESSURE TEMPERATURE GAUGE GAUGE VT/BR WT/BK...
Page 720 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 ST-RUN F87 (8W-12-11) INSTRUMENT CLUSTER AIRBAG SEAT WARNING BELT WASHER INDICATOR INDICATOR WARNING FLUID INDICATOR INDICATOR FUSED AIRBAG SEAT IGNITION WARNING BELT WASHER SWITCH INDICATOR WARNING FLUID OUTPUT CONTROL INDICATOR INDICATOR CONTROL CONTROL (ST-RUN) SEAT...
Page 721 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER ST-RUN F87 (8W-12-11) INSTRUMENT CLUSTER AIRBAG SEAT WARNING BELT WASHER INDICATOR INDICATOR WARNING FLUID INDICATOR INDICATOR FUSED AIRBAG SEAT IGNITION WARNING BELT WASHER SWITCH INDICATOR WARNING FLUID OUTPUT CONTROL INDICATOR INDICATOR (ST-RUN) CONTROL CONTROL SEAT...
Page 722 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7 (8W-12-11) ST-RUN F87 INSTRUMENT CLUSTER FULL PART BRAKE TIME TIME WARNING INDICATOR INDICATOR INDICATOR G106 G107 BK/WT BK/RD GY/WT C100 G106 G107 BK/WT BK/RD GY/WT C107 G106 G107 BRAKE WARNING BK/WT BK/RD PRESSURE 242 4WD 231 4WD...
Page 723 8W - 40 - 8 8W-40 INSTRUMENT CLUSTER (8W-10-17) BATT M1 (8W-10-18) INSTRUMENT CLUSTER FUSED B(+) CHIME CONTROL S210 (8W-10-10) IGNITION HEADLAMP SWITCH SWITCH KEY-IN (8W-10-9) 0 OFF SWITCH 1 PARK 2 HEAD (8W-50-2) BK/LB BK/LB S200 (8W-10-10) C200 C203 BK/LB BK/LB C317...
Page 724 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9 OVERHEAD RUN A22 (8W-10-11) MODULE JUNCTION (8W-49-6) BLOCK (8W-12-2) SENTRY FUSE TWISTED PAIR IMMOBILIZER VT/BR WT/BK (8W-12-15) MODULE (8W-39-8) COMPASS OTHER COMPASS OTHER S344 S346 REAR TWISTED (8W-30-20) (8W-30-20) WINDOW DEFOGGER PAIR RELAY C301 (8W-48-2)
Page 725 8W - 40 - 10 8W-40 INSTRUMENT CLUSTER OVERHEAD RUN A22 (8W-10-11) MODULE JUNCTION (8W-49-6) BLOCK (8W-12-2) SENTRY FUSE TWISTED PAIR IMMOBILIZER VT/BR WT/BK (8W-12-16) MODULE (EXCEPT COMPASS OTHER COMPASS OTHER POLICE/ REAR S344 S346 POSTAL) TWISTED WINDOW (8W-30-21) (8W-30-21) (8W-39-9) DEFOGGER PAIR...
Page 726 8W-40 INSTRUMENT CLUSTER 8W - 40 - 11 DAYTIME HEADLAMP DIMMER HIGH SWITCH RUNNING BEAM BEAM HIGH TURN LAMP SELECT INDICATOR BEAM SIGNAL/ MODULE SWITCH DRIVER OUTPUT HAZARD LEFT RIGHT (8W-50-11) (8W-50-3) TURN TURN (8W-50-4) SWITCH SIGNAL SIGNAL (8W-52-2) RD/GY RD/OR HIGH LAMP...
Page 727 8W - 40 - 12 8W-40 INSTRUMENT CLUSTER (8W-10-18) BATT F34 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 3 DIM 4 BRIGHT LIFTGATE LIFTGATE (8W-50-2) SWITCH AJAR (8W-44-6) SWITCH (8W-44-7) SENSE C201 TN/BK JUNCTION BLOCK C310 (8W-12-2) FUSE C311 (8W-12-8) (8W-12-9) TN/BK...
Page 728 8W-40 INSTRUMENT CLUSTER 8W - 40 - 13 (8W-12-11) ST-RUN F87 INSTRUMENT CLUSTER CRUISE ENGAGED INDICATOR FUSED CRUISE IGNITION ENGAGED SWITCH INDICATOR OUTPUT CONTROL (ST-RUN) VT/BR WT/BK TWISTED PAIR S239 S238 (8W-30-20) (8W-30-20) (8W-30-21) (8W-30-21) VT/BR WT/BK C100 4.0L A/T OTHER OTHER 4.0L A/T...
Page 730 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter ..... 8W-41-2, 3 High Note Horn .
Page 731 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET (8W-10-9) (8W-10-12) RUN-ACC A31 BATT A7 JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-5) (8W-12-5) (8W-12-19) CIGAR HORN LIGHTER RELAY RELAY RD/LB BK/RD BK/RD DG/RD S131 S314 (8W-12-19) C301 (8W-15-7) DG/RD DG/RD C201 HIGH NOTE...
Page 732 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 (8W-10-9) (8W-10-12) RUN-ACC A31 BATT A7 JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-5) (8W-12-5) (8W-12-19) CIGAR HORN LIGHTER RELAY RELAY RD/LB BK/RD BK/RD DG/RD C301 S131 (8W-12-19) S208 (8W-15-8) DG/RD DG/RD CIGAR POWER HIGH...
Page 734 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-7 Fuse 25 (JB) ....8W-42-2, 3, 4, 5, 7 A/C Compressor Clutch Relay .
Page 735 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER LHD HEATER ONLY (8W-10-7) RUN A22 BATT A0 (8W-10-11) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) FUSE (8W-12-20) (8W-10-13) FROM S215 (8W-12-8) A111 RD/LG DB/WT C100 S219 HEATER (8W-12-20) CONTROL 1 HIGH 2 MEDIUM 2 A111 3 MEDIUM 1...
Page 736 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 RHD HEATER ONLY (8W-10-7) RUN A22 BATT A0 (8W-10-11) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) FUSE FROM (8W-12-21) S215 (8W-10-13) (8W-12-9) A111 RD/LG C100 DB/WT HEATER S219 CONTROL (8W-12-21) 1 HIGH 2 MEDIUM 2 A111 3 MEDIUM 1...
Page 737 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER (8W-10-7) RUN A22 BATT A0 (8W-10-11) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) FUSE (8W-12-20) (8W-10-13) FROM S215 (8W-12-8) A111 RD/LG DB/WT S219 C100 (8W-12-20) A/C- HEATER CONTROL 1 HIGH MODE 2 MEDIUM 2 3 MEDIUM 1 4 LOW...
Page 738 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5 (8W-10-7) RUN A22 BATT A0 (8W-10-11) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) FUSE (8W-12-21) FROM (8W-10-13) S215 (8W-12-9) A111 RD/LG DB/WT S219 C100 (8W-12-21) A/C- DB/WT HEATER CONTROL 1 HIGH MODE C204 2 MEDIUM 2...
Page 739 8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER FROM A/C- HEATER CONTROL (8W-42-4) (8W-42-5) C100 S143 4.0L 2.5L HIGH PRESSURE PRESSURE SWITCH SWITCH DB/PK DB/PK HIGH PRESSURE PRESSURE SWITCH SWITCH DB/WT POWERTRAIN RADIATOR CONTROL SWITCH SWITCH SENSE REQUEST SENSE MODULE (8W-30-18) J008W-7 XJD04206...
Page 740 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7 (8W-12-12) (8W-10-14) ST-RUN F20 BATT A17 RUN A22 (8W-10-11) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE COMPRESSOR (8W-10-2) CLUTCH RELAY (8W-12-20) (8W-12-21) BLEND FUSED DOOR DB/WT BLEND IGNITION ACTUATOR DOOR SWITCH FEEDBACK OUTPUT S219 GROUND...
Page 741 8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER (8W-12-12) ST-RUN F20 BATT F141 (8W-10-13) POWER DISTRIBUTION RADIATOR CENTER (8W-10-2) RELAY DB/PK POWERTRAIN RADIATOR RADIATOR CONTROL RELAY MODULE MOTOR CONTROL (8W-30-18) G106 (8W-15-6) J008W-7 XJD04208...
Page 742 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ... . 8W-43-2, 3, 4 Fuse 27 (JB) ..... . 8W-43-2, 3 Clockspring .
Page 743 8W - 43 - 2 8W-43 AIRBAG SYSTEM RUN A22 ST-RUN A21 (8W-10-11) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-23) (8W-12-23) LG/YL DB/YL AIRBAG FUSED FUSED CONTROL IGNITION IGNITION SWITCH SWITCH MODULE OUTPUT OUTPUT (RUN) (ST-RUN) GROUND WT/BK VT/BR TWISTED BASE FULL OPTIONS PAIR...
Page 744 8W-43 AIRBAG SYSTEM 8W - 43 - 3 RUN A22 ST-RUN A21 (8W-10-11) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-24) (8W-12-24) LG/YL DB/YL C204 LG/YL DB/YL AIRBAG FUSED FUSED CONTROL IGNITION IGNITION SWITCH SWITCH MODULE OUTPUT OUTPUT (RUN) (ST-RUN) GROUND WT/BK VT/BR TWISTED...
Page 745 8W - 43 - 4 8W-43 AIRBAG SYSTEM AIRBAG CONTROL MODULE DRIVER DRIVER PASSENGER PASSENGER AIRBAG AIRBAG AIRBAG AIRBAG LINE 1 LINE 2 LINE 2 LINE 1 DG/LB BK/LB BK/YL DG/YL TWISTED TWISTED PAIR PAIR C205 DG/LB BK/LB BK/YL DG/YL TWISTED TWISTED PAIR...
Page 746 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C- Heater Control ....8W-44-2, 3 Instrument Cluster ... . . 8W-44-2, 3, 6, 7 Cargo Lamp/Switch .
Page 747 8W - 44 - 2 8W-44 INTERIOR LIGHTING HEADLAMP C206 PANEL SWITCH LAMPS (8W-50-2) DIMMER PRNDL SWITCH ILLUMINATION SIGNAL JUNCTION (A/T) BLOCK TRANSFER FUSE (8W-12-2) CASE SWITCH ILLUMINATION (8W-12-8) C201 C206 S315 (8W-12-8) C201 S314 (8W-15-7) S215 (8W-12-8) C201 POLICE PACKAGE OTHERS RADIO...
Page 748 8W-44 INTERIOR LIGHTING 8W - 44 - 3 HEADLAMP PANEL C206 SWITCH LAMPS (8W-50-2) DIMMER SWITCH SIGNAL PRNDL TRANSFER ILLUMINATION ILLUMINATION CASE (A/T) SWITCH ILLUMINATION JUNCTION OR/BK BLOCK FUSE (8W-12-2) (8W-12-9) C203 C206 S313 (8W-15-11) S215 S309 (8W-12-9) (8W-15-11) G302 (8W-15-11) A/C- RADIO...
Page 749 8W - 44 - 4 8W-44 INTERIOR LIGHTING (8W-10-17) BATT M1 (8W-10-18) JUNCTION BLOCK (8W-12-2) M1 20PK SKIM OTHERS S361 (8W-10-18) S347 (8W-10-18) FULL OPTIONS OTHERS MIDLINE BASE/POLICE COMPASS (8W-49-2) DOME (8W-49-3) LAMPS SWITCH DOME LAMP LEFT VISOR/ VANITY LAMP S342 S345 (8W-15-7)
Page 750 8W-44 INTERIOR LIGHTING 8W - 44 - 5 BATT A0 (8W-10-7) POWER DISTRIBUTION FROM DOME CENTER FUSE LAMPS (8W-10-2) FROM SWITCH COMPASS (8W-10-17) FULL MIDLINE (8W-44-4) OPTIONS S135 (8W-10-17) JUNCTION BLOCK (8W-12-2) C201 C314 S214 (8W-10-17) C208 C207 S304 S304 (8W-44-6) (8W-44-7) CARGO...
Page 751 8W - 44 - 6 8W-44 INTERIOR LIGHTING FROM JUNCTION FROM BLOCK C314 (8W-44-5) (8W-44-5) S304 C314 C317 C320 C318 C319 CARGO LAMP/ SWITCH LEFT RIGHT REAR REAR DOOR DOOR GY/BK JAMB JAMB C314 SWITCH SWITCH C326 GY/BK C311 C310 DRIVER PASSENGER DOOR...
Page 752 8W-44 INTERIOR LIGHTING 8W - 44 - 7 FROM JUNCTION FROM BLOCK C314 (8W-44-5) (8W-44-5) S304 C314 C317 C320 C318 C319 CARGO LAMP/ SWITCH LEFT RIGHT REAR REAR DOOR DOOR GY/BK JAMB JAMB C314 SWITCH SWITCH C326 GY/BK PASSENGER DRIVER C311 DOOR DOOR...
Page 754 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Antenna ..... . 8W-47-2, 3, 8, 9 Left Front Door Speaker .
Page 755 8W - 47 - 2 8W-47 AUDIO SYSTEM LHD 6 SPEAKER SYSTEM (8W-10-18) (8W-10-7) BATT F34 BATT A0 HEADLAMP POWER SWITCH DISTRIBUTION 0 OFF CENTER 1 PARK FUSE (8W-10-2) 2 HEAD FUSE 3 DIM 4 BRIGHT (8W-10-17) (8W-50-2) (8W-10-20) C201 S135 (8W-10-17) BK/YL...
Page 756 8W-47 AUDIO SYSTEM 8W - 47 - 3 RHD 6 SPEAKER SYSTEM (8W-10-18) (8W-10-7) BATT F34 BATT A0 HEADLAMP POWER SWITCH DISTRIBUTION 0 OFF CENTER 1 PARK FUSE (8W-10-2) 2 HEAD FUSE 3 DIM 4 BRIGHT (8W-50-2) (8W-10-20) BK/YL S135 (8W-10-17) (8W-10-9) RUN-ACC A31...
Page 757 8W - 47 - 4 8W-47 AUDIO SYSTEM LHD 6 SPEAKER SYSTEM RADIO LEFT LEFT LEFT LEFT REAR REAR FRONT FRONT RADIO SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT BR/YL BR/LB BR/RD DG/RD C200 BR/YL BR/LB BR/RD DG/RD POWER LEFT LEFT LEFT LEFT RADIO AMPLIFIER...
Page 758 8W-47 AUDIO SYSTEM 8W - 47 - 5 RHD 6 SPEAKER SYSTEM RADIO LEFT LEFT LEFT LEFT FRONT FRONT REAR REAR RADIO SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT BR/YL BR/LB BR/RD DG/RD C203 BR/YL BR/LB BR/RD DG/RD POWER LEFT LEFT LEFT LEFT RADIO AMPLIFIER...
Page 759 8W - 47 - 6 8W-47 AUDIO SYSTEM LHD 6 SPEAKER SYSTEM RADIO RIGHT RIGHT RIGHT RIGHT REAR REAR FRONT FRONT SPEAKER SPEAKER SPEAKER SPEAKER DB/WT DB/OR DB/RD C200 DB/WT DB/OR DB/RD POWER RIGHT RIGHT RIGHT RIGHT AMPLIFIER REAR REAR FRONT FRONT SPEAKER...
Page 760 8W-47 AUDIO SYSTEM 8W - 47 - 7 RHD 6 SPEAKER SYSTEM RADIO RIGHT RIGHT RIGHT RIGHT REAR REAR FRONT FRONT SPEAKER SPEAKER SPEAKER SPEAKER DB/WT DB/OR DB/RD C203 DB/WT DB/OR DB/RD POWER RIGHT RIGHT RIGHT RIGHT AMPLIFIER REAR REAR FRONT FRONT SPEAKER...
Page 761 8W - 47 - 8 8W-47 AUDIO SYSTEM LHD 4 SPEAKER SYSTEM (8W-10-18) BATT F34 HEADLAMP SWITCH 0 OFF C201 1 PARK 2 HEAD 3 DIM 4 BRIGHT (8W-50-2) (8W-10-17) (8W-10-9) BATT M1 RUN-ACC A31 (8W-10-18) JUNCTION BLOCK (8W-12-2) FUSE FUSE BK/YL (8W-12-17)
Page 762 8W-47 AUDIO SYSTEM 8W - 47 - 9 RHD 4 SPEAKER SYSTEM (8W-10-18) BATT F34 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 3 DIM 4 BRIGHT (8W-50-2) BK/YL S206 (8W-12-10) (8W-10-17) (8W-10-9) BATT M1 RUN-ACC A31 (8W-10-18) JUNCTION BLOCK (8W-12-2) FUSE FUSE...
Page 763 8W - 47 - 10 8W-47 AUDIO SYSTEM 4 SPEAKER SYSTEM RADIO LEFT LEFT RIGHT RIGHT REAR REAR REAR REAR SPEAKER(+) SPEAKER(-) SPEAKER(+) SPEAKER(-) BR/YL BR/LB DB/WT DB/OR C200 C203 C200 C203 C200 C203 C200 C203 BR/YL BR/LB DB/WT DB/OR C314 DB/WT DB/OR...
Page 764 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Driver Power Mirror ....8W-48-2, 3 Instrument Cluster .
Page 765 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER (8W-10-16) RUN A22 BATT A4 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-15) REAR FUSE WINDOW DEFOGGER RELAY (8W-12-15) C201 LB/WT BK/WT BK/WT C201 LB/YL C326 PASSENGER INSTRUMENT C312 POWER REAR WINDOW C310 CLUSTER DEFOGGER MIRROR...
Page 766 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 3 (8W-10-16) RUN A22 BATT A4 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-16) FUSE REAR WINDOW (8W-12-16) DEFOGGER RELAY C16 20BK/WT C204 LB/WT BK/WT BK/WT LB/YL C326 C305 FULL POWER DRIVER C312 INSTRUMENT OPTIONS MIRRORS REAR WINDOW...
Page 768 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temperature Sensor ..8W-49-4, 5 G108 ......8W-49-2, 3 Compass .
Page 769 8W - 49 - 2 8W-49 OVERHEAD CONSOLE (8W-10-7) BATT A0 ST-RUN A21 (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK FUSE CENTER (8W-12-2) FUSE (8W-10-2) (8W-12-11) (8W-10-17) WT/BK S135 S225 (8W-10-17) (8W-12-11) JUNCTION WT/BK BLOCK (8W-12-2) C301 OTHERS SKIM WT/BK S361 (8W-10-18) S347 (8W-10-18) COMPASS...
Page 770 8W-49 OVERHEAD CONSOLE 8W - 49 - 3 (8W-10-7) BATT A0 ST-RUN A21 (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-17) (8W-12-11) WT/BK S216 S135 (8W-12-11) (8W-10-17) JUNCTION BLOCK WT/BK (8W-12-2) OTHERS SKIM S361 C301 (8W-10-18) WT/BK S347 (8W-10-18) COMPASS...
Page 771 8W - 49 - 4 8W-49 OVERHEAD CONSOLE (8W-10-12) BATT A7 JUNCTION AMBIENT AMBIENT BLOCK TEMPERATURE TEMPERATURE (8W-12-2) SENSOR SENSOR SENSOR HORN SIGNAL GROUND RELAY (8W-41-2) VT/LG BK/LB C100 PASSENGER DOOR POWER DOOR UNLOCK LOCK/ LOCK RELAY VT/LG BK/LB BK/RD WINDOW CONTROL CONTROL...
Page 772 8W-49 OVERHEAD CONSOLE 8W - 49 - 5 (8W-10-12) BATT A7 JUNCTION AMBIENT AMBIENT BLOCK TEMPERATURE TEMPERATURE (8W-12-2) SENSOR HORN SENSOR SENSOR RELAY SIGNAL GROUND (8W-41-3) VT/LG BK/LB PASSENGER C100 DOOR POWER BK/RD DOOR UNLOCK LOCK/ LOCK RELAY WINDOW CONTROL CONTROL SWITCH (8W-61-3)
Page 773 8W - 49 - 6 8W-49 OVERHEAD CONSOLE DATA LINK CONNECTOR (8W-30-20) (8W-30-21) TWISTED VT/BR WT/BK PAIR S239 S238 (8W-30-20) (8W-30-20) (8W-30-21) (8W-30-21) VT/BR WT/BK C201 C201 TWISTED PAIR VT/BR WT/BK C301 VT/BR WT/BK OTHER COMPASS COMPASS OTHER S344 S346 (8W-30-20) (8W-30-20) (8W-30-21)
Page 774 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Controller Anti-Lock Brake Relay ..8W-50-8 Headlamp Beam Select Switch ..8W-50-3, 4, 5 Daytime Running Lamp Headlamp Delay Module .
Page 775 8W - 50 - 2 8W-50 FRONT LIGHTING BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE RD/WT (8W-10-2) HEADLAMP (8W-10-18) (8W-10-14) DAYTIME FUSED DELAY RUNNING B(+) MODULE LAMP (8W-50-5) MODULE GROUND (8W-50-11) TN/BK RD/WT C100 FROM S218 FROM S201 S210 (8W-10-18) RD/WT (8W-12-27)
Page 776 8W-50 FRONT LIGHTING 8W - 50 - 3 INSTRUMENT DAYTIME FROM DIMMER HEADLAMP CLUSTER RUNNING FROM HIGH SWITCH DELAY HEADLAMP (8W-40-11) LAMP BEAM HIGH INDICATOR MODULE SWITCH BEAM MODULE DRIVER OUTPUT (8W-50-11) (8W-50-2) (8W-50-2) RD/GY HEADLAMP C100 BEAM SELECT SWITCH RD/GY 1 FLASH 2 LOW...
Page 777 8W - 50 - 4 8W-50 FRONT LIGHTING FROM HEADLAMP FROM DELAY HEADLAMP MODULE SWITCH (8W-50-2) (8W-50-2) HEADLAMP INSTRUMENT BEAM DIMMER CLUSTER SELECT SWITCH (8W-40-11) HIGH SWITCH BEAM 1 FLASH OUTPUT 2 LOW 3 HIGH VT/WT RD/OR RD/OR S213 RD/OR JUNCTION BLOCK (8W-12-2)
Page 778 8W-50 FRONT LIGHTING 8W - 50 - 5 BATT A0 ST-RUN A21 (8W-10-7) (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-11) (8W-10-14) WT/BK RD/WT RD/WT C100 DAYTIME FUSED BASE FULL OPTIONS RUNNING B(+) LAMP MODULE S225 RD/WT (8W-50-11) WT/BK (8W-12-11)
Page 779 8W - 50 - 6 8W-50 FRONT LIGHTING TURN BATT F34 (8W-10-18) SIGNAL/ LEFT HEADLAMP HAZARD TURN SWITCH SIGNAL SWITCH 1 PARK (PART OF 2 HEAD MULTI- 0 OFF FUNCTION (8W-50-2) SWITCH) LG/WT (8W-52-2) S209 (8W-52-3) BK/YL LG/WT S206 C100 (8W-12-10) BK/YL LG/WT...
Page 780 8W-50 FRONT LIGHTING 8W - 50 - 7 BATT F34 (8W-10-18) TURN SIGNAL/ HEADLAMP RIGHT HAZARD SWITCH TURN SWITCH SIGNAL 1 PARK (8W-52-2) 2 HEAD 0 OFF (8W-50-2) S212 BK/YL (8W-52-4) S206 (8W-12-10) C100 BK/YL C201 C106 BK/YL JUNCTION S100 BLOCK (8W-12-2) FUSE...
Page 781 8W - 50 - 8 8W-50 FRONT LIGHTING EXCEPT DRL (8W-10-18) S206 BATT F34 (8W-12-10) HEADLAMP SWITCH BK/YL 1 PARK 2 HEAD 0 OFF C201 (8W-50-2) FROM C106 (8W-50-3) BK/YL (8W-50-4) BK/YL JUNCTION BLOCK (8W-12-2) FUSE FROM (8W-12-10) LAMP RD/WT RELAY NO.
Page 782 8W-50 FRONT LIGHTING 8W - 50 - 9 EXCEPT DRL BATT F61 (8W-10-20) POWER FROM FOG LAMP DISTRIBUTION RELAY NO. 1 CENTER (IN PDC) (8W-10-2) (8W-50-8) LAMP RELAY NO. 2 L139 FRONT C100 C106 LAMP SWITCH SWITCH ILLUM. INDICATOR FOG LAMP RELAY NO.
Page 783 8W - 50 - 10 8W-50 FRONT LIGHTING INSTRUMENT BATT F34 (8W-10-18) HIGH CLUSTER JUNCTION BEAM HEADLAMP (8W-40-11) INDICATOR BLOCK SWITCH DRIVER (8W-12-2) 1 PARK FUSE 2 HEAD DAYTIME 0 OFF BK/YL HIGH RUNNING (8W-50-2) BEAM (8W-12-10) LAMP C201 INDICATOR RD/GY MODULE DRIVER...
Page 784 8W-50 FRONT LIGHTING 8W - 50 - 11 (8W-10-10) BATT A0 ST-RUN A21 (8W-10-7) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE (8W-10-2) FUSE RIGHT FUSED VEHICLE HEADLAMP RIGHT (8W-12-12) VEHICLE SPEED (8W-10-14) (8W-50-3) SPEED SENSOR BEAM SENSOR (8W-30-12) SIGNAL OUTPUT VT/RD WT/OR C201...
Page 786 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-6 Left Turn Signal Lamp ....8W-51-5 Brake Lamp Switch .
Page 787 8W - 51 - 2 8W-51 REAR LIGHTING (8W-10-7) BATT A0 (8W-10-18) BATT F34 POWER DISTRIBUTION HEADLAMP CENTER FUSE SWITCH (8W-10-2) 1 PARK 2 HEAD (8W-10-20) 0 OFF (8W-50-2) BK/YL PK/DB S206 C100 (8W-12-10) PK/DB BK/YL BRAKE LAMP SWITCH (8W-33-3) C201 WT/TN BK/YL...
Page 788 8W-51 REAR LIGHTING 8W - 51 - 3 FROM FROM FUSE S203 (8W-51-2) 7 (JB) (8W-51-2) WT/TN BR/YL S302 (8W-10-20) S311 FROM (8W-12-10) FUSE OTHER TRAILER TOW WT/TN 23 (JB) BR/YL C323 (8W-51-2) C321 TRAILER TOW OTHERS S336 (8W-54-3) C323 DG/YL WT/TN BR/YL...
Page 789 8W - 51 - 4 8W-51 REAR LIGHTING FROM FUSE FROM S203 7 (JB) (8W-51-2) (8W-51-2) BR/YL WT/TN S311 S302 (8W-12-10) (8W-10-20) BR/YL WT/TN C327 C326 BR/YL WT/TN C311 C310 C333 BR/YL C330 DG/WT BK/YL CENTER HIGH MOUNTED LICENSE STOP LAMP LAMP C330...
Page 790 8W-51 REAR LIGHTING 8W - 51 - 5 TURN SIGNAL/ LEFT RIGHT HAZARD TURN TURN SWITCH SIGNAL SIGNAL (8W-52-2) DG/RD BR/RD C200 C204 C200 C204 TRAILER TOW OTHERS S312 C323 (8W-70-2) S335 (8W-54-3) BR/RD C321 DG/RD C322 BR/RD RIGHT DG/RD TURN LEFT SIGNAL...
Page 791 8W - 51 - 6 8W-51 REAR LIGHTING ST-RUN A21 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) C201 C100 S159 (8W-12-12) 4.0L A/T 4.0L M/T 2.5L M/T 2.5L A/T C113 C107 C107 TRANSMISSION RANGE SENSOR S161 (8W-31-6) BACK-UP PARK/ LAMP NEUTRAL SWITCH POSITION BR/LG...
Page 792 8W-51 REAR LIGHTING 8W - 51 - 7 FROM FROM C200 C204 (8W-51-6) (8W-51-6) S303 BR/LG BR/LG TRAILER OTHERS C321 C323 S339 (8W-54-2) BR/LG C322 BR/LG LEFT RIGHT BACK-UP BACK-UP LAMP LAMP S341 S348 (8W-15-10) (8W-15-12) (8W-15-11) (8W-15-13) TRAILER CONNECTOR C322 (8W-54-2) TRAILER...
Page 794 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Left Front Park/Turn Signal Lamp No. 2 . . 8W-52-3 Fuse 12 (JB) .
Page 795 8W - 52 - 2 8W-52 TURN SIGNALS RUN A22 BATT A0 (8W-10-11) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-2) (8W-12-15) (8W-10-19) (8W-12-16) BK/PK C100 C201 BK/PK COMBINATION FUSED FUSED FLASHER IGNITION B(+) SWITCH HAZARD OUTPUT FLASHER (RUN) FLASHER SELECT...
Page 796 8W-52 TURN SIGNALS 8W - 52 - 3 FROM FROM TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD TRAILER SWITCH SWITCH OTHER (8W-52-2) (8W-52-2) C323 S335 DG/RD DG/RD (8W-54-3) LG/WT DG/RD C200 C204 S209 DG/RD DG/RD DG/RD C322 LG/WT LG/WT C100 DG/RD INSTRUMENT LEFT LEFT...
Page 797 8W - 52 - 4 8W-52 TURN SIGNALS FROM FROM TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD SWITCH SWITCH (8W-52-2) (8W-52-2) BR/RD S212 C200 C204 C100 INSTRUMENT BR/RD RIGHT CLUSTER TURN S312 SIGNAL (8W-40-11) C106 (8W-70-2) BR/RD S100 C321 (8W-50-7) BR/RD RIGHT RIGHT SIDE...
Page 798 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page A/C- Heater Control ....8W-53-4 Headlamp Switch ....8W-53-3, 4 Circuit Breaker 30 (JB) .
Page 799 8W - 53 - 2 8W-53 WIPERS RUN-ACC A31 (8W-10-9) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-25) C201 WIPE/ WASH SWITCH 0 OFF 1 DELAY 2 LOW 3 HIGH 4 WASH INTERMITTENT WIPER 5 INTERMITTENT LOGIC WIPER MOTOR RELAY DG/YL BR/VT BR/WT C100 C100...
Page 800 8W-53 WIPERS 8W - 53 - 3 HEADLAMP RUN A22 (8W-10-11) PANEL JUNCTION SWITCH JUNCTION LAMPS BLOCK (8W-50-2) DIMMER BLOCK FUSE (8W-12-2) SWITCH (8W-12-2) SIGNAL FUSE (8W-12-8) (8W-12-20) E2 20OR S315 (8W-12-8) BR/PK C201 C201 S215 (8W-12-8) BR/PK REAR WIPER/ WASHER SWITCH 0 OFF...
Page 801 8W - 53 - 4 8W-53 WIPERS HEADLAMP RUN A22 (8W-10-11) PANEL JUNCTION SWITCH JUNCTION LAMPS BLOCK (8W-50-2) BLOCK DIMMER FUSE (8W-12-2) SWITCH (8W-12-2) SIGNAL FUSE (8W-12-9) (8W-12-21) S215 (8W-12-9) A/C- FUSED HEATER PANEL BR/PK LAMPS CONTROL DIMMER (8W-42-5) SWITCH SIGNAL REAR WIPER/...
Page 802 8W - 54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Brake Lamp Switch ....8W-54-3 Left Turn Signal Lamp ....8W-54-3 Fuse 7 (JB) .
Page 803 8W - 54 - 2 8W-54 TRAILER TOW (8W-10-18) BATT F34 S206 HEADLAMP (8W-12-10) SWITCH 1 PARK 2 HEAD C201 BK/YL 0 OFF (8W-50-2) BK/YL JUNCTION BLOCK (8W-12-2) FUSE FROM S303 (8W-12-10) (8W-51-7) BR/YL BR/LG S311 C323 (8W-12-10) BR/YL BR/LG C323 S339 BR/YL...
Page 804 8W-54 TRAILER TOW 8W - 54 - 3 (8W-10-12) BATT A7 JUNCTION BLOCK (8W-12-2) FUSE (8W-12-19) RD/OR C323 S338 TURN BRAKE TURN (8W-12-19) BRAKE SIGNAL/ LAMP SIGNAL/ LEFT RIGHT LAMP HAZARD SWITCH HAZARD TURN TURN SWITCH SWITCH (8W-33-3) SWITCH SIGNAL SIGNAL OUTPUT (8W-52-2)
Page 806 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker 28 (JB) ....8W-60-2, 3 Left Rear Window Motor ... . . 8W-60-4, 5 Driver Power Lock/Window Left Rear Window Switch .
Page 807 8W - 60 - 2 8W-60 POWER WINDOWS (8W-10-9) RUN-ACC A31 JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-23) F81 12TN C201 C200 C307 F81 14TN DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK BR/WT VT/WT C306 S329 C303 (8W-15-10)
Page 808 8W-60 POWER WINDOWS 8W - 60 - 3 (8W-10-9) RUN-ACC A31 JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-24) DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK BR/WT VT/WT S319 C303 (8W-15-13) C307 C303 BR/WT VT/WT C306 S305 PASSENGER POWER...
Page 809 8W - 60 - 4 8W-60 POWER WINDOWS RUN-ACC F81 (8W-12-23) DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK S329 (8W-15-10) DB/WT RD/BK GY/BK DG/WT C307 C306 S309 (8W-15-10) DB/WT RD/BK GY/BK DG/WT S305 G302 (8W-60-2) (8W-15-10) C309...
Page 810 8W-60 POWER WINDOWS 8W - 60 - 5 RUN-ACC F81 (8W-12-24) DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK S319 (8W-15-13) DB/WT RD/BK GY/BK DG/WT C303 DB/WT RD/BK GY/BK DG/WT S305 (8W-60-3) C309 C304 LEFT RIGHT REAR REAR...
Page 812 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Circuit Breaker 28 (JB) ....8W-61-2, 3 Junction Block ....8W-61-2, 3, 4, 5 Driver Door Lock Motor .
Page 813 8W - 61 - 2 8W-61 POWER DOOR LOCKS (8W-10-12) (8W-10-9) OVERHEAD BATT A7 RUN-ACC A31 DOOR MODULE JUNCTION UNLOCK DOOR (8W-49-4) BLOCK RELAY LOCK CONTROL CONTROL (8W-12-2) FUSE CIRCUIT BREAKER (8W-12-17) (8W-12-23) LB/RD C301 DB/PK LB/RD C300 DB/PK LB/RD PASSENGER FUSED FUSED...
Page 814 8W-61 POWER DOOR LOCKS 8W - 61 - 3 (8W-10-12) (8W-10-9) BATT A7 RUN-ACC A31 JUNCTION OVERHEAD DOOR BLOCK MODULE UNLOCK DOOR (8W-12-2) (8W-49-5) FUSE CIRCUIT RELAY LOCK BREAKER CONTROL CONTROL (8W-12-18) (8W-12-24) LB/RD C301 DB/PK LB/RD C204 C202 C203 DB/PK LB/RD C305...
Page 815 8W - 61 - 4 8W-61 POWER DOOR LOCKS PASSENGER POWER DOOR DOOR LOCK/ LOCK UNLOCK WINDOW DRIVER DRIVER SWITCH OR/BK PK/BK S317 S316 (8W-12-28) (8W-12-28) OR/BK OR/BK PK/BK PK/BK PASSENGER DOOR LOCK MOTOR JUNCTION BLOCK (8W-12-2) OR/BK PK/BK S307 (8W-12-28) S306 (8W-12-28)
Page 816 8W-61 POWER DOOR LOCKS 8W - 61 - 5 PASSENGER POWER DOOR DOOR LOCK/ LOCK UNLOCK WINDOW DRIVER DRIVER SWITCH OR/BK PK/BK S323 S322 (8W-12-29) (8W-12-29) OR/BK OR/BK PK/BK PK/BK PASSENGER DOOR LOCK MOTOR C305 OR/BK PK/BK S306 (8W-12-29) S307 (8W-12-29) PK/BK OR/BK...
Page 818 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Driver Power Lock/Window G302 ......8W-62-2, 3, 6 Switch .
Page 819 8W - 62 - 2 8W-62 POWER MIRRORS LHD FULL OPTIONS RUN-ACC A31 (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-17) YL/DG C201 YL/DG C200 YL/DG C305 YL/DG DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR OR/YL...
Page 820 8W-62 POWER MIRRORS 8W - 62 - 3 LHD FULL OPTIONS RUN-ACC F83 (8W-12-17) DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR OR/YL YL/BK S329 S328 (8W-15-10) (8W-12-31) C305 OR/YL...
Page 821 8W - 62 - 4 8W-62 POWER MIRRORS RHD FULL OPTIONS RUN-ACC A31 (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-18) YL/DG C300 YL/DG S352 (8W-12-18) YL/DG DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR OR/YL...
Page 822 8W-62 POWER MIRRORS 8W - 62 - 5 RHD FULL OPTIONS RUN-ACC F83 (8W-12-18) DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR OR/YL DB/WT YL/LB S319 S318 (8W-15-13) (8W-12-33) OR/YL...
Page 823 8W - 62 - 6 8W-62 POWER MIRRORS LHD EXCEPT FULL OPTIONS RUN-ACC F83 (8W-12-17) POWER MIRROR SWITCH 1 RIGHT 2 UP 3 LEFT 4 DOWN YL/BK DB/WT OR/YL WT/BK S329 DRIVER (8W-15-10) POWER MIRROR JUNCTION BLOCK (8W-12-2) WT/BK OR/YL C307 JUNCTION BLOCK...
Page 824 8W-62 POWER MIRRORS 8W - 62 - 7 RHD EXCEPT FULL OPTIONS RUN-ACC F83 (8W-12-18) POWER MIRROR SWITCH 1 RIGHT 2 UP 3 LEFT 4 DOWN DB/WT YL/LB YL/BK S319 DRIVER (8W-15-13) POWER MIRROR OR/YL WT/BK JUNCTION BLOCK OR/YL WT/BK (8W-12-2) YL/BK C204...
Page 826 8W - 63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Circuit Breaker 29 (JB) ... . 8W-63-2, 3, 6 Left Power Seat Motors ....8W-63-2 Forward/Rearward Motor .
Page 827 8W - 63 - 2 8W-63 POWER SEAT (8W-10-12) BATT A7 JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-25) RD/LB C316 S356 (8W-12-25) RD/LB C362 LEFT POWER SEAT SWITCH 1 FRONT DOWN 2 FRONT UP 3 REAR DOWN 4 REAR UP 5 FORWARD 6 REARWARD C362 RD/LG...
Page 828 8W-63 POWER SEAT 8W - 63 - 3 (8W-10-12) BATT A7 JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-25) RD/LB C316 S356 (8W-12-25) RD/LB RD/LB C362 C363 LEFT FUSED POWER B(+) SEAT SWITCH (8W-63-2) RIGHT POWER SEAT SWITCH 1 FRONT UP 2 FRONT DOWN 3 REAR UP 4 REAR DOWN 5 FORWARD...
Page 829: Heated Seats
8W - 63 - 4 8W-63 POWER SEAT HEATED SEATS (8W-10-9) RUN-ACC A31 JUNCTION BLOCK (8W-12-2) FUSE (8W-12-17) (8W-12-18) YL/DG YL/DG C300 C201 HEATED FUSED SEAT IGNITION SWITCH RELAY OUTPUT (8W-63-6) (RUN-ACC) YL/DG YL/DG S352 C200 (8W-12-18) C324 S351 YL/DG (8W-12-17) C316 C329...
Page 830 8W-63 POWER SEAT 8W - 63 - 5 HEATED SEATS SEAT HEAT INTERFACE LEFT LEFT RIGHT RIGHT HEATED HEAT HEAT HEATED MODULE SEAT SENSE SENSOR SENSE SEAT GROUND DRIVER INPUT FEED INPUT DRIVER P143 P144 BK/OR BK/DG BK/YL PK/BK BK/LG C329 C329 P143...
Page 831 8W - 63 - 6 8W-63 POWER SEAT HEATED SEATS (8W-10-9) (8W-10-12) RUN-ACC A31 BATT A7 JUNCTION BLOCK (8W-12-2) FUSE CIRCUIT BREAKER (8W-12-17) (8W-12-18) (8W-12-25) YL/DG YL/DG RD/LB C300 C201 S352 (8W-12-18) YL/DG C200 YL/DG C324 YL/DG S351 YL/DG (8W-12-17) YL/DG C316 YL/DG...
Page 832 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-50-7 S219 .
Page 833 8W - 70 - 2 8W-70 SPLICE INFORMATION POWERTRAIN CAMSHAFT CRANKSHAFT THROTTLE CONTROL POSITION POSITION POSITION MODULE SENSOR SENSOR SENSOR (8W-30-5) (8W-30-5) (8W-30-5) (8W-30-7) (8W-30-7) (8W-30-12) MANIFOLD ABSOLUTE PRESSURE SENSOR (8W-30-12) S115 OXYGEN OXYGEN POWERTRAIN SENSOR SENSOR CONTROL MODULE TURN UPSTREAM UPSTREAM (8W-30-10)
Page 834 8W-70 SPLICE INFORMATION 8W - 70 - 3 FUEL CLOCKSPRING PUMP (8W-33-2) MODULE (8W-30-3) (8W-30-4) BATTERY K167 TEMPERATURE BR/YL SENSOR (4.0L) BK/RD (8W-30-13) C204 C200 TRANSMISSION CONTROL K167 MODULE C100 K167 (4.0L) BR/YL (8W-31-5) BR/YL K167 K167 C100 BR/YL BR/YL S138 INTAKE MANIFOLD...
Page 836 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Heater Control ....8W-80-4 C326 .
Page 837 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Ignition Coil ..... . . 8W-80-42 Passenger Power Window Motor .
Page 838 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Throttle Position Sensor ....8W-80-70 Transmission Range Sensor ... 8W-80-72 Torque Converter Clutch Solenoid .
Page 839 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION BLACK Z8 12BK/VT GROUND C7 12BK/TN BLOWER MOTOR HIGH DRIVER C6 14LB BLOWER MOTOR M2 DRIVER C5 14LG BLOWER MOTOR M1 DRIVER C4 14TN BLOWER MOTOR LOW DRIVER A/C-HEATER C90 20LG A/C SWITCH SENSE CONTROL-C1 E2 20OR...
Page 840 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 CIRCUIT FUNCTION C21 20DB/PK A/C SWITCH SENSE C22 18DB/WT PRESSURE SWITCH OUTPUT C90 20LG A/C SWITCH SENSE A/C LOW C21 20DB/PK A/C SWITCH SENSE PRESSURE SWITCH CIRCUIT FUNCTION R45 18DG/LB DRIVER AIRBAG LINE 1 R43 18BK/LB DRIVER AIRBAG LINE 2 YELLOW...
Page 841 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL G32 20BK/LB SENSOR GROUND AMBIENT TEMPERATURE SENSOR BLACK CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) L10 18BR/LG BACK UP LAMP FEED BACK-UP LAMP SWITCH BLACK...
Page 842 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 CIRCUIT FUNCTION C1 12DG BLOWER MOTOR RELAY OUTPUT C7 12BK/TN BLOWER MOTOR HIGH DRIVER BLOWER MOTOR BLACK CIRCUIT FUNCTION C1 12DG BLOWER MOTOR RELAY OUTPUT Z1 20BK GROUND A111 12RD/LG FUSED B(+) BLOWER F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
Page 843 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT Z1 18BK Z1 18BK G106 20BK/WT G106 20BK/WT G107 20BK/RD G107 20BK/RD L92 20PK L39 20LB L139 20VT L139 20VT C90 20LG C90 20LG BLACK BLACK C100 C100 (LHD) (LHD) V3 16BR/WT V3 16BR/WT A1 12RD...
Page 844 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 (CONTINUED) CIRCUIT CIRCUIT L50 20WT/TN L50 20WT/TN G9 20GY/BK G9 20GY/BK L10 18BR/LG L10 18BR/LG V10 18BR V10 18BR V20 18BK/WT V20 18BK/WT F34 18TN/BK F34 18TN/BK Z12 18BK/TN Z12 18BK/TN G29 20BK/LB G29 20BK/LB F20 18WT F20 18WT...
Page 845 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT Z1 18BK Z1 18BK G106 20BK/WT G106 20BK/WT G107 20BK/RD G107 20BK/RD L39 20LB L92 20PK L139 20VT L139 20VT C90 20LG C90 20LG Z12 18BK/TN Z12 18BK/TN G29 20BK/LB G29 20BK/LB F20 18WT F20 18WT...
Page 846 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 (CONTINUED) CIRCUIT CIRCUIT F45 20YL/RD F45 20YL/RD T141 20YL T141 20YL F1 20DB/GY F1 20DB/GY D20 18LG/BK V30 20DB/RD V30 20DB/RD F32 20PK/DB F32 20PK/DB V32 18YL/RD V32 20YL/RD G19 20LG/OR G19 20LG/OR G31 20VT/LG G31 20VT/LG G32 20BK/LB...
Page 847 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT L33 20RD L33 18RD BLACK BLACK L61 20LG/WT L61 20LG Z1 20BK Z1 18BK L34 20RD/OR L34 18RD/OR L77 20BR/YL L77 20BR L39 20LB L39 20LB L43 20VT L43 18VT L60 20TN L60 20TN C106...
Page 848 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 CIRCUIT CIRCUIT A142 18DG/OR A142 18DG/OR K20 18DG K20 18DG BLACK BLACK K167 20BR/YL K167 20BR/YL G7 20WT/OR G7 20WT/OR T41 20BK/WT T41 18BK/WT Z1 18BK K22 20OR/DB K22 20OR/DB A42 18DG A42 20DG G107 20BK/RD G107 20BK/RD...
Page 849 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT A142 18DG/OR A142 18DG/OR K20 18DG K20 18DG K167 20BR/YL K167 20BR/YL G7 20WT/OR G7 20WT/OR BLACK BLACK T41 20BK/WT T41 18BK/WT Z1 18BK K22 20OR/DB K22 20OR/DB A42 20DG A42 18DG G107 20BK/RD G107 20BK/RD...
Page 850 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 CIRCUIT CIRCUIT X53 18DG X53 16DG X55 18BR/RD X55 16BR/RD X54 18VT X54 16VT X56 18DB/RD X56 16DB/RD X51 18BR/YL X51 16BR/YL GRAY X57 18BR/LB X57 16BR/LB GRAY X52 18DB/WT X52 16DB/WT X58 18DB/OR X58 16DB/OR X60 18DG/RD...
Page 851 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT F20 18WT F20 18WT C16 20LB/YL C16 20LB/YL L5 20BK L5 20BK C36 20RD/WT C36 20RD/WT F87 20WT/BK F87 20WT/BK M1 20PK M1 20PK Z1 20BK Z1 20BK V6 16DB V6 16DB P36 20PK/VT P36 20PK/VT...
Page 852 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 (CONTINUED) CIRCUIT CIRCUIT F83 18YL/DG F83 18YL/DG L7 18BK/YL L7 18BK/YL M2 20YL M2 20YL F30 16RD F30 16RD D1 18VT/BR D1 20VT/BR D2 18WT/BK D2 20WT/BK X12 16RD/WT X12 16RD/WT D1 20VT/BR D1 20VT/BR D2 20WT/BK D2 20WT/BK...
Page 853 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT C7 12BK/TN C7 12BK/TN GRAY GRAY F81 12TN F81 12TN Z8 16BK/VT Z8 12BK/VT A111 12RD/LG A111 12RD/LG C6 14LB C6 14LB C5 14LG C5 14LG C202 C202 C4 14TN C4 14TN (RHD) (RHD)
Page 854 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 CIRCUIT CIRCUIT F15 20DB/WT F15 20DB/WT WHITE C16 20BK/WT C16 20LB/YL WHITE P35 20OR/VT P35 20OR/VT P36 20PK/VT P36 20PK/VT G78 20TN/BK G78 20TN/BK K226 20DB/LG K226 20DB/LG K167 20BR/YL K167 20BR/YL P72 20YL/BK P72 20YL/BK C204...
Page 855 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT E2 20OR E2 20OR E2 20OR/BK Z1 20BK C206 C206 Z1 20BK (M/T) (M/T) BLACK BLACK CIRCUIT CIRCUIT M1 20PK M1 18PK M2 20YL M2 18BK/WT C207 C207 BLACK BLACK CIRCUIT...
Page 856 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 WHITE WHITE CIRCUIT CIRCUIT P35 18OR/VT P35 20OR/VT P36 18PK/VT P36 20PK/VT F83 18YL/DG F83 18YL/DG C300 C300 (RHD) (RHD) CIRCUIT CIRCUIT D1 20VT/BR D1 20VT/BR WHITE D2 20WT/BK D2 20WT/BK WHITE G32 20BK/LB G32 20BK/LB G31 20VT/LG...
Page 857 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT Q18 14GY/BK Q18 14GY/BK Q28 14DG/WT Q28 14DG/WT Q1 14YL Q1 14YL P33 16OR/BK P33 16OR/BK P34 16PK/BK P34 16PK/BK C304 C304 (LHD) (LHD) BLACK BLACK CIRCUIT CIRCUIT Q18 14GY/BK Q18 14GY/BK Q28 14DG/WT...
Page 858 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 CIRCUIT CIRCUIT X85 18BR/RD X85 18BR/RD X55 18LG/RD X55 18BR/RD X87 18DG X87 18LG/VT X53 18LG/BK X53 18DG P59 20LB/RD P59 20LB/RD P33 16OR/BK P33 16OR/BK WHITE WHITE P34 16PK/BK P34 16PK/BK P35 20OR/VT P35 18OR/VT P36 20PK/VT...
Page 859 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS WHITE WHITE CIRCUIT CIRCUIT F81 14TN F81 12TN Q1 14YL Q1 14YL Z1 12BK Z1 12BK Z1 16BK C307 C307 BLACK BLACK CIRCUIT CIRCUIT Q17 14DB/WT Q17 14DB/WT Q27 14RD/BK Q27 14RD/BK Q1 14YL Q1 14YL P33 16OR/BK...
Page 860 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 WHITE WHITE CIRCUIT CIRCUIT X92 16TN/BK X92 18TN/BK X52 18DB/WT X52 18DB/WT X94 16TN/RD X94 18TN/RD X58 18DB/OR X58 18DB/OR C314 C314 X91 16BR/DB X91 18WT/BK X51 18BR/YL X51 18BR/YL X93 18WT/RD X93 16BR/YL X57 18BR/LB X57 18BR/LB...
Page 861 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT M2 18YL M2 20YL G16 18BK/LB G16 20BK/LB Z1 18BK 20BK C318 C318 BLACK BLACK CIRCUIT CIRCUIT M2 18YL M2 20YL Z1 18BK Z1 20BK C319 C319 BLACK BLACK CIRCUIT CIRCUIT...
Page 862 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 CIRCUIT CIRCUIT BLACK BLACK L63 18DG/RD L63 20DG/RD Z1 18BK Z1 18BK L38 18BR/WT L10 18BR/LG L10 18BR/LG L50 18WT/TN L50 20WT/TN C322 C322 L77 18BR L77 18BR/YL (TRAILER TOW) (TRAILER TOW) CIRCUIT CIRCUIT BLACK...
Page 863 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT P133 18TN/DG P133 18TN/DG P134 18TN/RD P134 18TN/RD NATURAL P137 18VT NATURAL P137 18VT P138 18VT/LG P138 18VT/LG P139 18VT/WT P139 18VT/WT P140 18VT/BK P140 18VT/BK P87 18BK/OR P87 18BK/OR P141 18TN/LB P141 18TN/LB P143 18BK/DG...
Page 864 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 BLACK BLACK CIRCUIT CIRCUIT F37 14RD/LB F37 14RD Z1 14BK Z1 14BK C362 C362 BLACK BLACK CIRCUIT CIRCUIT F37 14RD/LB F37 14RD Z1 14BK Z1 14BK C363 C363 GRAY CIRCUIT FUNCTION K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL K167 20BR/YL SENSOR GROUND...
Page 865 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION Z1 18BK GROUND L50 18DG/WT BRAKE LAMP SWITCH OUTPUT CENTER HIGH MOUNTED STOP LAMP CIRCUIT FUNCTION F30 16RD CIGAR LIGHTER RELAY OUTPUT Z1 16BK GROUND CIGAR LIGHTER CIRCUIT FUNCTION NATURAL X3 20BK/RD HORN RELAY CONTROL...
Page 866 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 GREEN CIRCUIT FUNCTION T141 20YL IGNITION SWITCH OUTPUT (START) FUSED B(+) ENGINE STARTER MOTOR RELAY F45 20YL/RD CLUTCH INTERLOCK SWITCH BLACK CIRCUIT FUNCTION F45 18YL FUSED B(+) ENGINE STARTER MOTOR RELAY F45 18YL FUSED B(+) ENGINE STARTER MOTOR RELAY CLUTCH INTERLOCK SWITCH JUMPER...
Page 867 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-) BLACK B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) B41 18YL/VT G SWITCH NO.
Page 868 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 CIRCUIT FUNCTION L3 16RD DIMMER SWITCH HIGH BEAM OUTPUT BLACK G34 16RD/GY HIGH BEAM INDICATOR DRIVER F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) A3 14RD/WT FUSED B(+) G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL DAYTIME RUNNING Z12 16BK/TN...
Page 869 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION M2 18YL COURTESY LAMPS DRIVER G16 18BK/LB DRIVER DOOR AJAR SWITCH SENSE Z1 18BK GROUND DRIVER DOOR JAMB SWITCH CIRCUIT FUNCTION P34 16PK/BK DOOR UNLOCK DRIVER P33 16OR/BK DOOR LOCK DRIVER DRIVER DOOR LOCK MOTOR CIRCUIT...
Page 870 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 CIRCUIT FUNCTION WHITE P71 20YL LEFT POWER MIRROR VERTICAL DRIVER P71 20YL/LB LEFT POWER MIRROR VERTICAL DRIVER P76 20OR/YL MIRROR COMMON DRIVER F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER Z1 14BK GROUND DRIVER POWER...
Page 871 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION Q11 14LB LEFT FRONT WINDOW DRIVER UP Q21 14WT LEFT FRONT WINDOW DRIVER DOWN DRIVER POWER WINDOW MOTOR (LHD) BLACK CIRCUIT FUNCTION Q11 14BR LEFT WINDOW DRIVER UP Q21 14VT LEFT FRONT WINDOW DRIVER DOWN DRIVER POWER WINDOW MOTOR...
Page 872 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 BLACK CIRCUIT FUNCTION K72 18DG/OR GENERATOR DRIVER EVAP LEAK K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL DETECTION K105 18WT/OR LEAK DETECTION PUMP SWITCH SENSE PUMP WHITE CIRCUIT FUNCTION Z1 20BK GROUND K78 20GY IDLE ACTUATOR F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
Page 873 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER FUEL INJECTOR NO. 1 (2.5L) BLACK CIRCUIT FUNCTION A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN FUEL INJECTOR NO.
Page 874 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 BLACK CIRCUIT FUNCTION A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER FUEL INJECTOR NO. 1 (4.0L) BLACK CIRCUIT FUNCTION A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN FUEL INJECTOR NO.
Page 875 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION A141 16DG/WT FUEL PUMP RELAY OUTPUT K226 20DB/LG FUEL LEVEL SENSOR SIGNAL K167 20BR/YL SENSOR GROUND Z1 16BK GROUND FUEL PUMP MODULE BLACK CIRCUIT FUNCTION B42 20TN/WT G SWITCH NO. 2 SENSE B41 20YL/VT G SWITCH NO.1 SENSE B43 20PK/OR...
Page 876 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 BLACK CIRCUIT FUNCTION E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL L2 14LG HEADLAMP SWITCH OUTPUT M2 20YL COURTESY LAMPS DRIVER F34 18TN/BK FUSED B(+) F34 18TN/BK FUSED B(+) G26 20LB KEY-IN IGNITION SWITCH SENSE G16 20BK/LB DRIVER DOOR AJAR SWITCH SENSE L20 14LG/WT...
Page 877 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT IGNITION COIL NO. 1 DRIVER K19 18GY IGNITION COIL (2.5L) CIRCUIT FUNCTION Z1 20BK GROUND BLACK G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER A2 12PK/BK FUSED B(+) A22 12BK/OR...
Page 878 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CIRCUIT FUNCTION G78 20TN/BK LIFTGATE AJAR SWITCH SENSE BLACK G99 20GY/WT RED BRAKE WARNING INDICATOR DRIVER E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL G19 20LG/OR ABS WARNING INDICATOR DRIVER G34 16RD/GY HIGH BEAM INDICATOR DRIVER Z2 20BK/LG GROUND...
Page 879 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL INTAKE AIR TEMPERATURE SENSOR CIRCUIT FUNCTION L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT NATURAL F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY L78 20DG/YL FUSED HEADLAMP SWITCH OUTPUT F15 20DB/WT...
Page 880 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 NATURAL CIRCUIT FUNCTION M2 20YL COURTESY LAMPS DRIVER Z1 20BK GROUND M1 20PK FUSED B(+) JUNCTION BLOCK - C3 CIRCUIT FUNCTION A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC) A21 12DB IGNITION SWITCH OUTPUT (ST-RUN) A41 14YL IGNITION SWITCH OUTPUT (ST) A22 12BK/OR...
Page 881 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION X3 20BK/RD HORN RELAY CONTROL WHITE P76 20OR/YL MIRROR COMMON DRIVER P91 20WT/BK MIRROR COMMON DRIVER C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT F35 16RD FUSED B(+) F81 12TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC) JUNCTION P74 20DB...
Page 882 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 NATURAL CIRCUIT FUNCTION F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC) JUNCTION BLOCK - C8 CIRCUIT FUNCTION P33 16OR/BK DOOR LOCK DRIVER P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT NATURAL P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER...
Page 883 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION M1 18PK FUSED B(+) M2 18BK/WT COURTESY LAMPS DRIVER LEFT COURTESY LAMP GRAY CIRCUIT FUNCTION Z1 20BK GROUND L39 20LB FOG LAMP RELAY OUTPUT LEFT FOG LAMP BLACK CIRCUIT FUNCTION X85 18BK/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
Page 884 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 GRAY CIRCUIT FUNCTION L61 18LG LEFT TURN SIGNAL L77 18BR FUSED HEADLAMP SWITCH OUTPUT Z1 18BK GROUND LEFT FRONT PARK/TURN SIGNAL LAMP NO. 2 GRAY CIRCUIT FUNCTION B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) LEFT FRONT...
Page 885 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION P137 18VT LEFT SEAT LOW HEAT LED DRIVER Z1 18BK GROUND F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) LEFT HEATED P139 18VT/WT LEFT SEAT HIGH HEAT LED DRIVER SEAT SWITCH P133 18TN/DG LEFT SEAT HEATER SWITCH MUX YELLOW...
Page 886 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 BLACK CIRCUIT FUNCTION F37 14RD FUSED B(+) Z1 14BK GROUND P13 14RD/WT LEFT POWER SEAT REAR DOWN LEFT POWER SEAT REAR UP P11 14YL/WT P17 14RD/LB LEFT POWER SEAT HORIZONTAL REARWARD P15 14YL/LB LEFT POWER SEAT HORIZONTAL FORWARD LEFT POWER P19 14YL/LG...
Page 887 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS BLUE CIRCUIT Q13 14DB POWER WINDOW LEFT REAR B(+) UP Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN Q17 14DB/WT LEFT REAR WINDOW DRIVER UP Q23 14RD/WT LEFT REAR WINDOW DRIVER DOWN Q1 14YL POWER WINDOW SWITCH FEED LEFT REAR WINDOW SWITCH...
Page 888 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 CIRCUIT FUNCTION Z1 18BK GROUND LEFT TURN L63 18DG/RD LEFT TURN SIGNAL SIGNAL LAMP BLACK CIRCUIT FUNCTION M1 20PK FUSED B(+) LEFT VISOR/ Z1 20BK GROUND VANITY LAMP CIRCUIT FUNCTION L78 18BK/YL FUSED HEADLAMP SWITCH OUTPUT Z1 18BK GROUND...
Page 889 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K7 20OR 5V SUPPLY MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT FUNCTION M2 20YL COURTESY LAMPS DRIVER M1 20PK FUSED B(+) Z1 20BK GROUND BLACK...
Page 890 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 GRAY CIRCUIT FUNCTION A42 20DG OXYGEN SENSOR RELAY OUTPUT Z1 20BK GROUND K167 20BR/YL SENSOR GROUND OXYGEN K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL SENSOR 2/1 UPSTREAM (4.0L CALIFORNIA) BLACK CIRCUIT FUNCTION A242 20VT/OR OXYGEN SENSOR RELAY OUTPUT GROUND Z1 20BK...
Page 891 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION P34 16PK/BK DOOR UNLOCK DRIVER P33 16OR/BK DOOR LOCK DRIVER PASSENGER DOOR LOCK MOTOR CIRCUIT FUNCTION P34 16PK/BK DOOR UNLOCK DRIVER Q22 14VT PASSENGER FRONT WINDOW DRIVER DOWN Q26 14VT/WT MASTER WINDOW SWITCH PASSENGER FRONT DOWN BLUE Q16 14BR/WT...
Page 892 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 CIRCUIT FUNCTION P71 20YL LEFT POWER MIRROR VERTICAL DRIVER LEFT POWER MIRROR HORIZONTAL DRIVER P75 20DB/WT MIRROR COMMON DRIVER P76 20OR/YL MIRROR COMMON DRIVER P91 20WT/BK P75 20DB/RD LEFT POWER MIRROR HORIZONTAL DRIVER P76 20OR/YL MIRROR COMMON DRIVER C16 20BK/WT...
Page 893 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION Z1 20BK GROUND Z1 14BK GROUND F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER P76 20OR/YL MIRROR COMMON DRIVER P76 20OR/YL MIRROR COMMON DRIVER POWER...
Page 894 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 CIRCUIT FUNCTION K18 18RD/YL IGNITION COIL NO. 3 DRIVER F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) K167 18BR/YL SENSOR GROUND T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE Z1 18BK GROUND K19 18GY IGNITION COIL NO. 1 DRIVER K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL K60 18YL/BK...
Page 895 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER K17 18DB/TN IGNITION COIL NO. 2 DRIVER K20 18DG GENERATOR FIELD WHITE TORQUE CONVERTER CLUTCH SOLENOID CONTROL...
Page 896 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 CIRCUIT FUNCTION C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL C27 18DB/PK RADIATOR FAN RELAY CONTROL K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL GRAY OXYGEN SENSOR UPSTREAM RELAY CONTROL K73 18BR/OR...
Page 897 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL Z1 20BK GROUND PRNDL ILLUMINATION (A/T) LT.GRAY CIRCUIT FUNCTION C25 12LB RADIATOR FAN RELAY OUTPUT Z1 12BK GROUND RADIATOR FAN MOTOR CIRCUIT FUNCTION BLACK X60 16DG/RD...
Page 898 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 BLACK CIRCUIT FUNCTION V20 18BK/WT REAR WASHER MOTOR CONTROL Z1 18BK GROUND REAR Z1 18BK GROUND WASHER PUMP GRAY CIRCUIT FUNCTION Z1 20BK GROUND C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT REAR E2 20OR...
Page 899 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION M1 18PK FUSED B(+) M2 18BK/WT COURTESY LAMPS DRIVER RIGHT COURTESY LAMP GRAY CIRCUIT FUNCTION Z1 20BK GROUND L39 20LB FOG LAMP RELAY OUTPUT RIGHT FOG LAMP BLACK CIRCUIT FUNCTION X80 18LB/BK AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
Page 900 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 CIRCUIT FUNCTION B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-) B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT FUNCTION L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT Z1 18BK...
Page 901 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS YELLOW CIRCUIT FUNCTION P16 14RD/LB RIGHT POWER SEAT HORIZONTAL REARWARD P14 14YL/LB RIGHT POWER SEAT HORIZONTAL FORWARD RIGHT POWER SEAT HORIZONTAL MOTOR YELLOW CIRCUIT FUNCTION P10 14YL/WT RIGHT POWER SEAT REAR UP P12 14RD/WT RIGHT POWER SEAT REAR DOWN RIGHT POWER...
Page 902 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 CIRCUIT FUNCTION B1 20YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B2 20YL RIGHT REAR WHEEL SPEED SENSOR (+) RIGHT REAR WHEEL SPEED SENSOR BLACK CIRCUIT FUNCTION Q14 14GY POWER WINDOW RIGHT REAR B(+) UP Q24 14DG RIGHT REAR WINDOW DRIVER DOWN RIGHT REAR...
Page 903 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND RIGHT SPEED V37 20RD/LG SPEED CONTROL SWITCH SIGNAL CONTROL SWITCH CIRCUIT FUNCTION Z1 18BK GROUND L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT RIGHT TAIL/ STOP LAMP CIRCUIT...
Page 904 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 CIRCUIT FUNCTION P133 18TN/DG LEFT SEAT HEATER SWITCH MUX P141 18TN/LB SENSOR FEED BLACK P86 18PK/BK RIGHT HEAT ELEMENT OUTPUT F235 16RD HEATED SEAT RELAY OUTPUT P87 18BK/OR LEFT HEAT ELEMENT OUTPUT HEATED SEAT RELAY OUTPUT F235 16RD RIGHT HEAT SENSE INPUT...
Page 905 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS WHITE CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL THROTTLE K7 20OR 5V SUPPLY POSITION SENSOR CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) TORQUE CONVERTER K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL...
Page 906 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 BLACK CIRCUIT FUNCTION G107 20BK/RD 4WD SWITCH SENSE (PART-TIME) Z1 20BK GROUND TRANSFER CASE SWITCH (231 4WD) BLACK CIRCUIT FUNCTION Z1 20BK GROUND G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME) G107 20BK/RD 4WD SWITCH SENSE (PART-TIME) TRANSFER CASE SWITCH (242 4WD)
Page 907 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION T31 20VT/LG INPUT SPEED SENSOR GROUND T52 20RD/BK INPUT SPEED SENSOR SIGNAL T13 20DB/BK OUTPUT SPEED SENSOR GROUND T14 20LG/WT OUTPUT SPEED SENSOR SIGNAL D2 20WT/BK CCD BUS (-) BLACK CCD BUS (+) D1 20VT/BR T3 18VT...
Page 908 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 CIRCUIT FUNCTION BLACK L60 20TN RIGHT TURN SIGNAL L62 20BR/RD RIGHT TURN SIGNAL L55 20RD/WT COMBINATION FLASHER INPUT L6 20RD/WT FLASHER OUTPUT L12 20VT/TN HAZARD FLASHER SELECT SIGNAL L63 20DG/RD LEFT TURN SIGNAL TURN SIGNAL/ L61 20LG/WT LEFT TURN SIGNAL...
Page 909 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION Z1 20BK GROUND G29 20BK/LB LOW WASHER FLUID SENSE WASHER FLUID LEVEL SWITCH BLACK CIRCUIT FUNCTION V10 18BR WASHER PUMP CONTROL Z1 18BK GROUND WINDSHIELD WASHER PUMP NATURAL CIRCUIT FUNCTION Z1 16BK GROUND...
Page 910 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR LOCATIONS each section for connector number identification. DESCRIPTION AND OPERATION Refer to the index for the proper figure number. INTRODUCTION CONNECTOR/GROUND LOCATIONS This section provides illustrations identifying com- For items that are not shown in this section N/S is ponent and connector locations in the vehicle.
Page 911 8W - 90 - 2 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C106 Left Front 1, 6, C207 Right Lower Engine Instrument Compartment Panel C208 Left Lower C107 (2.5L) Rear of 2, 3, Instrument...
Page 912 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C318 Right Lower A Clutch Interlock At Clutch Pillar Switch Pedal C319 Right Lower B Pillar Clutch Interlock Lower Switch Jumper...
Page 913 8W - 90 - 4 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Duty Cycle Left Rear of 3, 11 G102 Rear of 2, 3, EVAP/Purge Engine Engine 4, 5, Solenoid (RHD) Compartment Compartment...
Page 914 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number HeadLamp Delay Lower Left of Junction Block - At Right Kick Module (LHD) Instrument Panel Area Panel Junction Block - At Right Kick...
Page 915 8W - 90 - 6 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Left Rear Wheel Under Rear Oxygen Sensor Left Side of Speed Sensor Seat 2/2 Downstream Engine (California) Left Rear Window In Left Rear...
Page 916 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number PRNDL At Center Right Heated Seat At Right Seat Illumination (A/T) Console Back Radiator Fan LT GY Front of 2, 3, Right Heated Seat...
Page 917 8W - 90 - 8 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Sentry Key At Steering Transmission BK/GY Rear of Immobilizer Column Range Sensor Engine Module (4.0L A/T) Compartment Shift Lock At Steering...
Page 918 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
Page 919 8W - 90 - 10 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 920 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
Page 921 8W - 90 - 12 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 4 Right Engine Compartment 2.5L Engine LHD Fig. 5 Right Engine Compartment 2.5L Engine RHD...
Page 922 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued)
Page 923 8W - 90 - 14 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 924 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
Page 925 8W - 90 - 16 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 926 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
Page 927 8W - 90 - 18 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 928 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued)
Page 929 8W - 90 - 20 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 930 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued)
Page 931 8W - 90 - 22 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 932 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 23 DESCRIPTION AND OPERATION (Continued)
Page 933 8W - 90 - 24 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 934 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 25 DESCRIPTION AND OPERATION (Continued) Fig. 18 4.0L Engine...
Page 935 8W - 90 - 26 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 936 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 27 DESCRIPTION AND OPERATION (Continued)
Page 937 8W - 90 - 28 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 938 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 29 DESCRIPTION AND OPERATION (Continued)
Page 939 8W - 90 - 30 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 940 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 31 DESCRIPTION AND OPERATION (Continued)
Page 941 8W - 90 - 32 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 942 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 33 DESCRIPTION AND OPERATION (Continued)
Page 943 8W - 90 - 34 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 944 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 35 DESCRIPTION AND OPERATION (Continued)
Page 945 8W - 90 - 36 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 946 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 37 DESCRIPTION AND OPERATION (Continued)
Page 947 8W - 90 - 38 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 31 Liftgate...
Page 948 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 39 DESCRIPTION AND OPERATION (Continued)
Page 949 8W - 90 - 40 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 33 Trailer Tow Fig. 34 Headliner...
Page 950 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 41 DESCRIPTION AND OPERATION (Continued)
Page 952 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS section for splice number identification. Refer to the DESCRIPTION AND OPERATION index for proper splice number. INTRODUCTION SPLICE LOCATIONS This section provides illustrations identifying the For splices that are not shown in the figures in general location of the splices in this vehicle.
Page 953 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S135 (LHD) Near T/O for A/C High S161 (A/T) Near T/O for Vehicle Speed (2.5L) Pressure Switch Sensor S135 (LHD) Near T/O for C107 S166...
Page 954 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S216 (LHD) Near T/O for Instrument S312 (LHD Near T/O for C304 and C319 Cluster - C2 with Power Amplifier, S216 (RHD) Near T/O for Junction Block...
Page 955 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S342 (With In T/O for Overhead Module S348 In Right Tail Lamp Harness Remote near C322 Keyless S349 (RHD) In T/O for C209 Entry) S351...
Page 956 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
Page 957 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 958 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
Page 959 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 960 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued)
Page 961 8W - 95 - 10 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 962 8W - 95 SPLICE LOCATIONS 8W - 95 - 11 DESCRIPTION AND OPERATION (Continued)
Page 963 8W - 95 - 12 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 964 8W - 95 SPLICE LOCATIONS 8W - 95 - 13 DESCRIPTION AND OPERATION (Continued)
Page 965 8W - 95 - 14 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 966 8W - 95 SPLICE LOCATIONS 8W - 95 - 15 DESCRIPTION AND OPERATION (Continued)
Page 967 8W - 95 - 16 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 968 8W - 95 SPLICE LOCATIONS 8W - 95 - 17 DESCRIPTION AND OPERATION (Continued)
Page 969 8W - 95 - 18 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 970 8W - 95 SPLICE LOCATIONS 8W - 95 - 19 DESCRIPTION AND OPERATION (Continued)
Page 971 8W - 95 - 20 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 972 8W - 95 SPLICE LOCATIONS 8W - 95 - 21 DESCRIPTION AND OPERATION (Continued) Fig. 17 Left Side Body Harness Splices Fig. 18 Trailer Tow Splices...
Page 973 8W - 95 - 22 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 19 Power Seat Splices Fig. 20 Right Front Door Splices...
Page 974 8W - 95 SPLICE LOCATIONS 8W - 95 - 23 DESCRIPTION AND OPERATION (Continued) Fig. 21 Left Front Door Splices Fig. 22 Liftgate Splices...
Page 975 8W - 95 - 24 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 23 Headliner Splices...
Page 976 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page 2.5L ENGINE......1 4.0L ENGINE.
Page 977 9 - 2 2.5L ENGINE DESCRIPTION AND OPERATION ENGINE DESCRIPTION The 2.5 liter (150 CID) four-cylinder engine is an In-line, lightweight, overhead valve engine. This engine is designed for unleaded fuel. The engine cylinder head has dual quench-type combustion cham- bers that create turbulence and fast burning of the air/ fuel mixture.
Page 978 2.5L ENGINE 9 - 3 DESCRIPTION AND OPERATION (Continued) sprocket to the timing chain. Oil drains back to the hole in the corresponding rocker arm. Oil from the oil pan under the number one main bearing cap. rocker arm lubricates the valve train components, The oil supply for the rocker arms and bridged then passes down through the push rod guide holes pivot assemblies is provided by the hydraulic valve...
Page 979 9 - 4 2.5L ENGINE DESCRIPTION AND OPERATION (Continued) Oil Lubrication System—2.5L Engine 1 – CAM/CRANK MAIN GALLERY (7) 5 – NUMBER 1 CAMSHAFT BEARING JOURNAL 2 – TAPPET GALLERY 6 – CAMSHAFT SPROCKET 3 – TAPPET GALLERY 7 – TAPPET GALLERY 4 –...
Page 980 2.5L ENGINE 9 - 5 DESCRIPTION AND OPERATION (Continued) CYLINDER BLOCK DESCRIPTION The cylinder block is a cast iron inline four cylin- der design. The cylinder block is drilled forming gal- leries for both oil and coolant. Fig. 4 Cylinder Head 1 –...
Page 981 9 - 6 2.5L ENGINE DESCRIPTION AND OPERATION (Continued) PISTON AND CONNECTING ROD OPERATION When the camshaft rotates, the lobes actuate the DESCRIPTION tappets and push rods forcing upward on the rocker arms which applies downward force on the valves. The pistons are made of a high strength aluminum alloy, the piston skirts are coated with a solid lubri- ROCKER ARM...
Page 982 2.5L ENGINE 9 - 7 DESCRIPTION AND OPERATION (Continued) VALVE SPRING DESCRIPTION The valve springs are made of high strength chrome silicon steel. The springs are common for both intake and exhaust valves. Fig. 10 Cylinder Head Cover 1 – AIR INLET FITTING 2 –...
Page 983 9 - 8 2.5L ENGINE DESCRIPTION AND OPERATION (Continued) VALVE STEM SEAL EXHAUST MANIFOLD DESCRIPTION DESCRIPTION The valve stem seals are made of rubber and incor- The exhaust manifold is log style and is made of porate a garter spring to maintain consistent lubrica- high silicon molybdenum cast iron.
Page 984 2.5L ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—PERFORMANCE ENGINE PERFORMANCE DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A, Battery, for correct procedures. Check charging system. Refer to Group 8C, Charging Systems, for correct procedures.
Page 985: Emission Control Systems
9 - 10 2.5L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 12. Faulty ignition coil 12. Test and replace, as necessary (Refer to Group 8D, ignition system) ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1.
Page 986 2.5L ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic tappets/lash adjusters 5. Bent push rod(s) 5. Install new push rods 6. Worn rocker arms 6. Inspect oil supply to rocker arms and replace worn arms as needed 7.
Page 987 9 - 12 2.5L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary 2. Faulty oil pressure sending unit 2. Install new sending unit 3. Clogged oil filter 3.
Page 988 2.5L ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) INTAKE MANIFOLD LEAKAGE DIAGNOSIS dures outlined in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between An intake manifold air leak is characterized by adjacent cylinders will result in approximately a lower than normal manifold vacuum.
Page 989 9 - 14 2.5L ENGINE DIAGNOSIS AND TESTING (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 AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
Page 990 2.5L ENGINE 9 - 15 DIAGNOSIS AND TESTING (Continued) filter runoff, and main bearing cap to cylinder pointer indicates 0.305 mm (0.012 inch) travel dis- block mating surfaces. tance (lift). • The timing notch index on the vibration damper (4) If no leaks are detected, pressurize the crank- case as outlined in the, Inspection (Engine oil Leaks should be aligned with the TDC mark on the timing in general)
Page 991 9 - 16 2.5L ENGINE SERVICE PROCEDURES (Continued) NOTE: If the valve guides are reamed oversize, the valve seats must be ground to ensure that the valve seat is concentric to the valve guide. VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT Valve stem-to-guide clearance may be measured by either of the following two methods.
Page 992 2.5L ENGINE 9 - 17 SERVICE PROCEDURES (Continued) inch). If the measurement differs from specification by more than 0.076 mm (0.003 inch), ream the guide bore to accommodate an oversize valve stem. ALTERNATIVE METHOD: (1) Use a dial indicator to measure the lateral movement of the valve stem (stem-to-guide clear- ance).
Page 993 9 - 18 2.5L ENGINE SERVICE PROCEDURES (Continued) PISTON SIZE CHART CYLINDER BORE SIZE PISTON LETTER SIZE 98.438 - 98.448 mm (3.8755 - 3.8759 in.) 98.448 - 98.458 mm (3.8759 - 3.8763 in.) 98.458 - 98.468 mm (3.8763 - 3.8767 in.) 98.468 - 98.478 mm (3.8767 - 3.8771 in.) 98.478 - 98.488 mm...
Page 994 2.5L ENGINE 9 - 19 SERVICE PROCEDURES (Continued) Fig. 22 Gap Measurement 1 – FEELER GAUGE RING GAP MEASUREMENT CHART Fig. 21 Ring Side Clearance Measurement ITEM SPECIFICATION 1 – FEELER GAUGE Top Compression Ring 0.229 - 0.610 mm (0.0090 - 0.0240 in.) RING SIDE CLEARANCE CHART Second Compression 0.483 - 0.965 mm...
Page 995 9 - 20 2.5L ENGINE SERVICE PROCEDURES (Continued) Fig. 23 Top Compression ring identification 1 – TOP COMPRESSION RING Fig. 26 Compression Ring Installation 1 – COMPRESSION RING 2 – RING EXPANDER RECOMMENDED Fig. 24 Second Compression Ring Identification 1 – SECOND COMPRESSION RING 2 –...
Page 996 2.5L ENGINE 9 - 21 SERVICE PROCEDURES (Continued) CONNECTING ROD BEARINGS—FITTING Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 28) (Fig. 29). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 30). Replace any bearing that shows abnormal wear.
Page 997 9 - 22 2.5L ENGINE SERVICE PROCEDURES (Continued) Engine Specifications for the proper clearance. Plas- tigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
Page 998 2.5L ENGINE 9 - 23 SERVICE PROCEDURES (Continued) (11) FOR EXAMPLE: If the initial clearance was 0.0762 mm (0.003 inch), 0.025 mm (0.001 inch) undersize inserts would reduce the clearance by 0.025 mm (0.001 inch). The clearance would be 0.002 inch and within specification.
Page 999 9 - 24 2.5L ENGINE SERVICE PROCEDURES (Continued) NOTE: When replacing inserts, the odd size inserts ing inserts is not necessary. Remove the Plastigage must be either all on the top (in cylinder block) or from the crankshaft journal and bearing insert. Pro- ceed to Crankshaft Main Bearing—Installation.
Page 1000 2.5L ENGINE 9 - 25 SERVICE PROCEDURES (Continued) MAIN BEARING FITTING CHART CRANKSHAFT JOURNALS CORRESPONDING CRANKSHAFT BEARING INSERT Color Code Diameter Upper Insert Size Lower Insert Size 63.5025 - 63.4898 mm Yellow - Standard Yellow - Standard Yellow (2.5001 - 2.4996 in.) 63.4898 - 63.4771mm (2.4996 - 2.4991 in.) Blue- Undersize 0.025 mm...
Page 1001 9 - 26 2.5L ENGINE SERVICE PROCEDURES (Continued) Mopar Silicone Rubber Adhesive Sealant should be abrasive materials from entering the crankshaft applied in a continuous bead approximately 3 mm area. (0.12 inch) in diameter. All mounting holes must be (1) Used carefully, the Cylinder Bore Sizing Hone circled.
Page 1002: Lubricants
2.5L ENGINE 9 - 27 SERVICE PROCEDURES (Continued) to wash parts with a solution of hot water and deter- (7) Make sure all fluid has been removed from the gent. Dry parts thoroughly. Use a clean, white, lint- cylinders. free cloth to check that the bore is clean. Oil the (8) Repair engine or components as necessary to bores after cleaning to prevent rusting.
Page 1003: Maintenance Schedules
9 - 28 2.5L ENGINE SERVICE PROCEDURES (Continued) (5) Remove dipstick, with handle held above the tip, note oil level reading (Fig. 39). (6) Add oil only if level is below the ADD mark on dipstick. Fig. 37 Engine Oil Container Standard Notations suited to your area’s particular ambient temperature range and variation (Fig.
Page 1004 The proper oil filter has SAE type 3/4 X 16 threads. An oil filter with metric threads can result in oil leaks and engine failure. All Jeep engines are equipped with a high quality full-flow, throw-away type oil filter. Chrysler Corpo- ration recommends a Mopar or equivalent oil filter be used.
Page 1005 9 - 30 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 43 Engine Support Bracket—Right Side 1 – ENGINE SUPPORT BRACKET Fig. 42 Front Mounts 1 – ENGINE SUPPORT BRACKET 2 – THROUGH BOLT 3 – RETAINING BOLT 4 – SUPPORT CUSHION 5 –...
Page 1006 2.5L ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 45 Rear Mount (Manual Transmission) 1 – TRANSMISSION SUPPORT BRACKET 2 – SUPPORT CUSHION AUTOMATIC TRANSMISSION: a. Remove the support cushion bolts and remove the cushion and the transmission support bracket. b.
Page 1007 9 - 32 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (9) Remove fan assembly and install a 5/16 x 1/2- inch SAE capscrew through fan pulley into water pump flange. This will maintain the pulley and water pump in alignment when crankshaft is rotated. (10) Disconnect the heater hoses.
Page 1008 2.5L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) (32) Raise the engine slightly off the front sup- (25) Connect all the vacuum hoses and wire con- ports. nectors. (33) Place a support stand under the converter or (26) Connect suction/discharge hose to compressor. flywheel housing.
Page 1009 9 - 34 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (5) Perform fuel system pressure release procedure (refer to Group 14, Fuel System for correct proce- dure). (6) Disconnect fuel supply tube from the fuel rail. Some fuel lines require a special tool for removal/in- stallation (refer to Group 14, Fuel System - Quick Connect Fittings).
Page 1010 2.5L ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) (10) Install the power steering pump and bracket assembly to the water pump and intake manifold. Hand start the three (3) tensioner bracket to p/s pump to intake manifold bolts and the two (2) ten- sioner bracket to water pump bolts.
Page 1011 9 - 36 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove the engine cylinder head cover. (Refer to procedure in this section) (2) Check for rocker arm bridges which are caus- ing misalignment of the rocker arm to valve tip area. (3) Remove the capscrews at each bridge and pivot assembly (Fig.
Page 1012 2.5L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) pivot contacts. Install rocker arms, pivots and bridge above each cylinder in their original position. (3) Loosely install the capscrews through each bridge. (4) At each bridge, tighten the capscrews alter- nately, one turn at a time, to avoid damaging the bridge.
Page 1013 9 - 38 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (9) Install the engine cylinder head cover. CYLINDER HEAD This procedure can be done with the engine in or out of the vehicle. REMOVAL (1) Disconnect negative cable from battery. WARNING: DO REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR...
Page 1014 2.5L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 58 Alignment Dowel Locations 1 – ALIGNMENT DOWEL 2 – ALIGNMENT DOWEL Fig. 56 Engine Cylinder Head Assembly CAUTION: Engine cylinder head bolts should be 1 – BRIDGE reused only once. Replace the head bolts if they 2 –...
Page 1015 9 - 40 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) LINE WITH THE FAN. DO NOT PUT HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING. (27) Operate the engine with the radiator cap off. Inspect for leaks and continue operating the engine until the thermostat opens.
Page 1016 2.5L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 61 Vibration Damper Removal Tool 7697 1 – VIBRATION DAMPER REMOVAL TOOL 2 – WRENCH Fig. 60 Hydraulic Valve Tappet Removal/Installation With the key in position, align the keyway on the Tool vibration damper hub with the crankshaft key and 1 –...
Page 1017 9 - 42 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 63 Timing Case Cover Components 1 – TIMING CASE COVER Fig. 62 Timing Case Cover Oil Seal Installation 2 – OIL SLINGER 3 – CRANKSHAFT OIL SEAL 1 – SEAL INSTALLATION TOOL 4 –...
Page 1018 2.5L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (6) Install the timing case cover-to-cylinder block and the oil pan-to-timing case cover bolts. (7) Tighten the 1/4 inch cover-to-block bolts to 7 N·m (60 in. lbs.) torque. Tighten the 5/16 inch front cover-to-block bolts to 22 N·m (192 in.
Page 1019 9 - 44 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) CAMSHAFT REMOVAL WARNING: THE COOLANT IN A RECENTLY OPER- ATED ENGINE PRESSURIZED. RELEASE THE PRESSURE BEFORE REMOVING THE DRAIN COCK, CAP AND DRAIN PLUGS. (1) Disconnect negative cable from battery. (2) Drain the cooling system. DO NOT waste reus- able coolant.
Page 1020 2.5L ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) (2) Inspect the bearing journals for uneven wear pattern or finish. (3) Inspect the bearings for wear. (4) Inspect the distributor drive gear for wear. (5) If the camshaft appears to have been rubbing against the timing case cover, examine the oil pres- sure relief holes in the rear cam journal.
Page 1021 9 - 46 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (a) Remove the A/C compressor serpentine drive belt idler pulley. (b) Disconnect and remove the generator. (c) Remove the A/C condenser attaching bolts and move the condenser and receiver/drier assem- bly up and out of the way. (7) Remove the serpentine drive belt.
Page 1022 2.5L ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) (17) If equipped with air conditioning: (a) Install the A/C compressor serpentine drive belt idler pulley. (b) Install the generator. (c) Install the A/C condenser and receiver/drier assembly. (18) Install the serpentine drive belt on the pulleys and tighten (refer to Group 7, Cooling System for the specifications and procedures).
Page 1023 9 - 48 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 77 Removing Upper Inserts Fig. 76 Removing Main Bearing Caps and Lower 1 – COTTER PIN Inserts 2 – FABRICATED TOOL 1 – CONNECTING ROD JOURNAL 3 – BEARING INSERT 2 –...

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