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: Lubricants
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: Specifications
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 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page ALIGNMENT ......1 REAR SUSPENSION .
Page 18 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 19 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 20 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 21 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 22 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 23 SUSPENSION 2 - 7 FRONT SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COIL SPRING/JOUNCE BUMPER ... . . 9 SUSPENSION COMPONENTS ....7 STEERING KNUCKLE .
Page 24: Description And Operation
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 25: Stabilizer Bar
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 26: Steering Knuckle
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 27: Upper Suspension Arm
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 28: Stabilizer Bar
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 29: Wheel Mounting Studs
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 30: Specifications
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 31: Special Tools
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 32 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 33: Description And Operation
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 34: Leaf Spring
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 35: Specifications
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 37: Differential And Driveline
DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFTS ..... . . 1 194 RBI AXLE .
Page 38: Propeller Shafts
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 39: Propeller Shaft Joint Angle
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 40: Diagnosis And Testing Vibration
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 41: Unbalance
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 42: Service Procedures Driveline Angle Measurement Preparation
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 43 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 44: Removal And Installation
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 45: Disassembly And Assembly
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 46 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 47: Double Cardan Joint
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 48 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 49 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 50 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 51: Adjustments
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 52 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 53: Description And Operation
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 54: Standard Differential
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 55: Diagnosis And Testing General Information
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 56 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 57: Gear Noise
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 58: Removal And Installation
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 59: Tube Axle Assembly
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 60: 181 Fbi Pinion Shaft Seal
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 61 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 62 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 63 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 64: Collapsible Spacer
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 65 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 66: Hub Bearing And Axle Shaft
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 67: Steering Knuckle And Ball Studs
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 68 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 69: Axle Bushing Replacement
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 70 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 71 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 72: Differential
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 73 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 74 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 75 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 76 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 77: 186 Fbi Pinion
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 78 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 79 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 80 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 81: Ring Gear
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 82: Disassembly And Assembly
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 83: Final Assembly
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 84: Adjustments
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 85 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 86 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 87 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 88: Fbi Differential Bearing Preload And Gear Backlash
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 89 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 90 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 91 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 92: Fbi Differential Bearing Preload And Gear Backlash
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 93 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 94 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 95: Gear Contact Pattern Analysis
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 96 3 - 60 TUBE, 181, AND 186 FBI AXLE ADJUSTMENTS (Continued) Fig. 105 Gear Tooth Contact Patterns...
Page 97: Specifications
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 98 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 99 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 100 3 - 64 TUBE, 181, AND 186 FBI AXLE SPECIAL TOOLS (Continued) Installer—D-144 Installer—W-262...
Page 101 194 RBI AXLE 3 - 65 194 RBI AXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIFFERENTIAL ......78 194 RBI AXLE .
Page 102: Description And Operation
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 103: Diagnosis And Testing General Information
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 104 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 105 194 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 106: Gear Noise
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 107: Trac-Lok Test
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 108: Removal And Installation Rear Axle
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 109 194 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 110: Collapsible Spacer
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 111 194 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 112: Axle Shaft
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 113: Axle Shaft Seal And Bearing
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 114: Differential
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 115 194 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 116: Differential Side Bearings
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 117: Pinion Gear
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 118 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 119 194 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 120 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 121: Final Assembly
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 122: Disassembly And Assembly Standard Differential
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 123: Trac-Lok Differential
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 124 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 125 194 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 126 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 127: Cleaning And Inspection Axle Components
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 128 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 129 194 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 130: Differential Bearing Preload And Gear Backlash
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 131 194 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 132 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 133: Gear Contact Pattern Analysis
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 134: 194 Rbi Axle
3 - 98 194 RBI AXLE ADJUSTMENTS (Continued) Fig. 79 Gear Tooth Contact Patterns...
Page 135 194 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 136 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 137 194 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 138 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 139 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 140: Description And Operation
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 141: Standard Differential
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 142: Diagnosis And Testing General Information
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 143 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 144 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 145: Gear Noise
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 146: Trac-Lok Test
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 147: Removal And Installation Rear Axle
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 148: Axle Seal And Bearing
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 149: Pinion Seal
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 150: Differential
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 151: Differential Side Bearings
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 152: Ring Gear
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 153: Pinion Gear
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 154 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 155 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 156: Disassembly And Assembly Standard Differential
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 157: Trac-Lok Differential
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 158 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 159 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 160 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 161: Cleaning And Inspection
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 162: 1/4 Axle Pinion Gear Depth
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 163: Differential Bearing Preload And Gear Backlash
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 164 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 165: Gear Contact Pattern Analysis
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 166 3 - 130 8 1/4 REAR AXLE ADJUSTMENTS (Continued) Fig. 59 Gear Tooth Contact Patterns...
Page 167: Specifications
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 168 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 169 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 170 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 171 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BASE BRAKE SYSTEM ..... . 1 ANTILOCK BRAKES ..... . . 33 BASE BRAKE SYSTEM TABLE OF CONTENTS page...
Page 172: Description And Operation Brake System
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 173: Red Brake Warning Lamp
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 174: Front Disc Brakes
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 175: Rear Drum Brake
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 176 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 177: Brake Hoses And Lines
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 178 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 179: Brake Lamp Switch
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 180: Master Cylinder/Power Booster
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 181: Combination Valve
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 182: Brake Line And Hoses
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 183: Base Brake Bleeding
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 184: Brake Drum Machining
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 185: Removal And Installation Brake Lamp Switch
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 186: Combination Valve
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 187: Power Brake Booster
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 188: Front Disc Brake Caliper
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 189 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 190: Front Disc Brake Shoes
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 191: Disc Brake Rotor
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 192: Brake Support Plate
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 193: Rear Parking Brake Cables
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 194: Disassembly And Assembly
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 195: Disc Brake Caliper
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 196 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 197 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 198: Wheel Cylinder
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 199: Rear Drum Brake
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 200: Adjustments Brake Lamp Switch
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 201: Parking Brake Cable Tensioner
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 202: Brake Components
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 203 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 204: Description And Operation
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 205: Combination Valve
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 206: Diagnosis And Testing Antilock Brakes
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 207: Front Wheel Speed Sensor
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 208: G-Switch
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 209: Disassembly And Assembly Hydraulic Control Unit/Controller Antilock Brake
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 210: Specifications T0Rque Chart
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 211 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUTCH FLYWHEEL RUNOUT ....6 CLUTCH ....... . 1 CLUTCH COVER AND DISC RUNOUT .
Page 212: Description And Operation
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 213: Clutch Release Bearing
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 214: Hydraulic Clutch Linkage
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 215 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 8 Clutch Components And Inspection...
Page 216: Clutch Contamination
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 217: Clutch Cover And Disc Runout
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 218 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 219: Service Procedures
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 220: Clutch Fluid Level
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 221: Removal And Installation
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 222: Release Bearing
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 223: Clutch Housing
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 224 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 225: Specifications
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 227 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUTCH FLYWHEEL RUNOUT ....6 CLUTCH ....... . 1 CLUTCH COVER AND DISC RUNOUT .
Page 228: Description And Operation
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 229: Clutch Release Bearing
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 230: Hydraulic Clutch Linkage
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 231 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 8 Clutch Components And Inspection...
Page 232: Clutch Contamination
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 233: Clutch Cover And Disc Runout
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 234 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 235: Service Procedures
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 236: Clutch Fluid Level
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 237: Removal And Installation
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 238: Release Bearing
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 239: Clutch Housing
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 240 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 241: Specifications
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 243 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 244: Description And Operation
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 245: Cooling System Fans
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 246: Block Heater
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 247: Radiator
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 248: Water Pump
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 249: Viscous Fan Drive
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 250: Electric Cooling Fan
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 251: Diagnosis And Testing
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 252 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 253: Preliminary Checks
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 254 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 255 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 256: 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 257 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 258 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 259: Radiator Coolant Flow Check
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 260 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 261: Viscous Fan Drive
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 262: Radiator Cap-To-Filler Neck Seal-Pressure Relief Check
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 263: Coolant-Low Level Aeration
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 264: Cooling System-Reverse Flushing
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 265: Removal And Installation
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 266: Water Pump
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 267 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 268 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 269 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 270: Thermostat
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 271: Radiator-2.5L
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 272 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 273: Radiator-4.0L
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 274 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 275: Electric Cooling Fan-2.5L
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 276: Electric Cooling Fan-4.0L
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 277: Block Heater
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 278 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 279 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 280: Cooling System Fans
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 281: Viscous Fan Drive Removal/Installation
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 282: Cooling System Hoses
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 283: 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 285 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 286 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 287 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 288 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 289 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 290 8W - 01 - 6 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Symbols...
Page 291 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 292 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 293 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 294 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 295 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 296 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 297 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 298 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 299 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 301 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 302 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Power Mirror Switch ....8W-62 Splice Information ..... 8W-70 Power Mirrors .
Page 303 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 304 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 305 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 306 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 307 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 308 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 309 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 310 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 311 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 312 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 313 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 314 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 315 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 316 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 317 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 318 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 319 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 320 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 321 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 322 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 323 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 324 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 325 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 326 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 327 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 328 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 329 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 330 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 331 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 332 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 333 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 334 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 335 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 336 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 337 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 338 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 339 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 340 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 341 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 342 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 343 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 344 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 345 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 346 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 347 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 348 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 349 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 350 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 351 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 352 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 353 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 354 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 355 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 356 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 357 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 358 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 359 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 360 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 361 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 362 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 363 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 364 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 365 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 366 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 367 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 368 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 369 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 370 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 371 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 373 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 374 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 375 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 377 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ..... . 8W-21-2, 3, 4, 5 G101 .
Page 378 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 379 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 380 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 381 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 383 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 384 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 385 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 386 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 387 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 388 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 389 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 390 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 391 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 392 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 393 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 394 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 395 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 396 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 397 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 398 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 399 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 400 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 401 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 402 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 403 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 405 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 406 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 407 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 408 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 409 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 410 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 411 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 413 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 414 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 415 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 417 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 418 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 419 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 420 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 421 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 422 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 423 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 424 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 425 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 426 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 427 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 428 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 429 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 431 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page ABS Indicator ..... 8W-40-5, 6 Junction Block .
Page 432 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 433 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 434 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 435 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 436 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 437 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 438 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 439 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 440 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 441 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 442 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 443 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 445 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 446 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 447 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 449: A/C Compressor Clutch Relay
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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457: Airbag Control Module
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 458 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 459 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 460 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 461 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 462 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 463 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 464 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 465 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 466: Cargo Lamp/Switch
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 467 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 469 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 470 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 471 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 472 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 473 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 474 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 475 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 476 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 477 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 478 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 479 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 480 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 481 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 483 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 484 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 485 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 486 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 487 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 488 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 489 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 490 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 491 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 492 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 493 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 494 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 495 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 496 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 497 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 498 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 499 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 501 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 502 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 503 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 504 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 505 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 506 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 507 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 509 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 510 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 511 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 512 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 513 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 514 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 515 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 516 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 517 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 518 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 519 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 521: Circuit Breaker 28 (Jb)
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 522 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 523 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 524 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 525 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 527 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 528 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 529 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 530 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 531 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 533 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 534 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 535 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 536 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 537 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 538 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 539 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 541: Circuit Breaker 29
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 542: Circuit Breaker 30
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 543 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 544: 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 545 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 546 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 547 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-50-7 S219 .
Page 548 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 549: Clockspring
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 551 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 552 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Ignition Coil ..... . . 8W-80-42 Passenger Power Window Motor .
Page 553 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 554 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 555 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 556 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 557 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 558 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 559 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 560 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 561 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 562 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 563 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 564 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 565 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 566 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 567 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 568 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 569 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 570 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 571 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 572 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 573 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 574 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 575 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 576 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 577 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 578 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 579 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 580 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 581: Clutch Interlock Switch Jumper
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 582: Controller Anti-Lock Brake
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 583: Daytime Running Lamp Module
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 584: Driver Door Jamb Switch
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 585: Driver Power Lock/Window Switch
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 586: Duty Cycle Evap/Purge Solenoid
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 587: Extended Idle Switch
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 588 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 589 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 590: Headlamp Beam Select Switch
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 591: Heated Seat Relay
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 592 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 593 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 594: Horn Relay
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 595 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 596 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 597 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 598: Left Courtesy Lamp
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 599: Left Headlamp
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 600: Left Heated Seat Switch
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 601: Left Rear Door Jamb Switch
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 602: Left Tail/Stop Lamp
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 603: Left Visor/Vanity Lamp
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 604: Overhead Module
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 605 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 606: Passenger Power Lock/Window Switch
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 607 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 608: Power Mirror Switch
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 609 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 610: Powertrain Control Module
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 611 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 612: Prndl Illumination
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 613: Rear Window Defogger Switch
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 614: Right Courtesy Lamp
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 615: Right Headlamp
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 616: Right Rear Door Jamb Switch
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 617 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 618: Right Tail/Stop Lamp
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 619: Sentry Key Immobilizer Module
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 620: Trailer Tow Left Turn Relay
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 621 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 622 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 623 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 624 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 625 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 626 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 627 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 628 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 629 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 630 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 631 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 632: Transfer Case Switch Illumination
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 633 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
Page 634 8W - 90 - 10 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 635 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
Page 636 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 637 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued)
Page 638 8W - 90 - 14 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 639 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
Page 640 8W - 90 - 16 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 641 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
Page 642 8W - 90 - 18 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 643 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued)
Page 644 8W - 90 - 20 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 645 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued)
Page 646 8W - 90 - 22 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 647 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 23 DESCRIPTION AND OPERATION (Continued)
Page 648 8W - 90 - 24 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 649 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 25 DESCRIPTION AND OPERATION (Continued) Fig. 18 4.0L Engine...
Page 650 8W - 90 - 26 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 651 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 27 DESCRIPTION AND OPERATION (Continued)
Page 652 8W - 90 - 28 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 653 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 29 DESCRIPTION AND OPERATION (Continued)
Page 654 8W - 90 - 30 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 655 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 31 DESCRIPTION AND OPERATION (Continued)
Page 656 8W - 90 - 32 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 657 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 33 DESCRIPTION AND OPERATION (Continued)
Page 658 8W - 90 - 34 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 659 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 35 DESCRIPTION AND OPERATION (Continued)
Page 660 8W - 90 - 36 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 661 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 37 DESCRIPTION AND OPERATION (Continued)
Page 662 8W - 90 - 38 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 31 Liftgate...
Page 663 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 39 DESCRIPTION AND OPERATION (Continued)
Page 664 8W - 90 - 40 8W - 90 CONNECTOR LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 33 Trailer Tow Fig. 34 Headliner...
Page 665 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 41 DESCRIPTION AND OPERATION (Continued)
Page 667 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 668 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 669 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 670 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 671 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
Page 672 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 673 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
Page 674 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 675 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued)
Page 676 8W - 95 - 10 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 677 8W - 95 SPLICE LOCATIONS 8W - 95 - 11 DESCRIPTION AND OPERATION (Continued)
Page 678 8W - 95 - 12 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 679 8W - 95 SPLICE LOCATIONS 8W - 95 - 13 DESCRIPTION AND OPERATION (Continued)
Page 680 8W - 95 - 14 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 681 8W - 95 SPLICE LOCATIONS 8W - 95 - 15 DESCRIPTION AND OPERATION (Continued)
Page 682 8W - 95 - 16 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 683 8W - 95 SPLICE LOCATIONS 8W - 95 - 17 DESCRIPTION AND OPERATION (Continued)
Page 684 8W - 95 - 18 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 685 8W - 95 SPLICE LOCATIONS 8W - 95 - 19 DESCRIPTION AND OPERATION (Continued)
Page 686 8W - 95 - 20 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 687 8W - 95 SPLICE LOCATIONS 8W - 95 - 21 DESCRIPTION AND OPERATION (Continued) Fig. 17 Left Side Body Harness Splices Fig. 18 Trailer Tow Splices...
Page 688 8W - 95 - 22 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 19 Power Seat Splices Fig. 20 Right Front Door Splices...
Page 689 8W - 95 SPLICE LOCATIONS 8W - 95 - 23 DESCRIPTION AND OPERATION (Continued) Fig. 21 Left Front Door Splices Fig. 22 Liftgate Splices...
Page 690 8W - 95 - 24 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 23 Headliner Splices...
Page 691 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page 2.5L ENGINE......1 4.0L ENGINE.
Page 692: L Engine
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 693 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 694 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 695: Cylinder Block
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 696: Piston And Connecting Rod
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 697: Valve Spring
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 698: Valve Stem Seal
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 699: Service Diagnosis-Performance
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 700: Service Diagnosis-Mechanical
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 701 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 702 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 703: Intake Manifold Leakage Diagnosis
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 704: Engine Oil Leak Inspection
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 705: Engine Oil Pressure
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 706 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 707: Piston-Fitting
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 708: Piston Ring-Fitting
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 709 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 710 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 711: Connecting Rod Bearings-Fitting
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 712 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 713: Fitting Crankshaft Main Bearings
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 714 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 715: Form-In-Place Gaskets
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 716: Engine Performance
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 717: Repair Damaged Or Worn Threads
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 718 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 719: Removal And Installation
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 720: Engine Mount-Rear
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 721: Engine
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 722: Steering
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 723: Intake Manifold
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 724 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 725: Exhaust Manifold
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 726: Rocker Arms And Push Rods
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 727: Valve Spring And Seal
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 728: Cylinder Head
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 729 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 730: Cylinder Head
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 731: Vibration Damper
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 732: Timing Case Cover
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 733: Timing Chain And Sprockets
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 734: Camshaft
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 735: Camshaft Pin Replacement
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 736 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 737: Camshaft Bearings
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 738 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 –...
Page 739: Oil Pan
2.5L ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) (9) Push the crankshaft forward and backward. (14) Install the drain plug. Tighten the plug to 34 Load the crankshaft front or rear and tighten cap N·m (25 ft. lbs.) torque. bolt No.2 to 54 N·m (40 ft.
Page 740: Oil Pump
9 - 50 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 80 Fabrication of Alignment Dowels Fig. 82 Location of Mopar Silicone Adhesive 1 – 1/4 1 1/2 BOLT Sealant on Cylinder Block 2 – DOWEL 1 – SEALER LOCATIONS 3 – SLOT Fig.
Page 741: Piston And Connecting Rod
2.5L ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) through an inlet tube and strainer assembly that is INSTALLATION pressed into the pump body. (1) Install the oil pump on the cylinder block using The pump incorporates a nonadjustable pressure a replacement gasket.
Page 742: Rear Main Oil Seal
9 - 52 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 87 Rod and Piston Assembly Installation the bearing insert. The size is not stamped on inserts used for production of engines. (9) The rod journal is identified during the engine production by a color-coded paint mark on the adja- cent cheek or counterweight toward the flange (rear) end of the crankshaft.
Page 743: Disassembly And Assembly
2.5L ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) (2) Pry out the seal from around the crankshaft (4) Remove the vibration damper. flange, making sure not to scratch or nick the crank- (5) Remove the timing case cover and lay the cover shaft.
Page 744: Engine Cylinder Head
9 - 54 2.5L ENGINE CLEANING AND INSPECTION (Continued) Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted. Inspect each push rod end for excessive wear and replace as required. If any push rod is excessively worn because of lack of oil, replace it and inspect the corresponding hydraulic tappet for excessive wear.
Page 745: Specifications
2.5L ENGINE 9 - 55 SPECIFICATIONS DESCRIPTION SPECIFICATION ENGINE SPECIFICATIONS Bearing Journal Diameter ENGINE DESCRIPTION No. 1 51.54 - 51.56 mm (2.029 - 2.030 in.) DESCRIPTION SPECIFICATION No. 2 51.28 - 51.31 mm (2.019 - 2.020 in.) Engine Type In-line 4 Cylinder No.
Page 746 9 - 56 2.5L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Stem to Guide Clearance 0.025 - 0.076 mm Main Bearing Journal Width (0.001 - 0.003 in.) No. 1 27.58 to 27.89 mm ValveFace Angle (1.086 to 1.098 in.) Intake 46.5°...
Page 747 2.5L ENGINE 9 - 57 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Flatness Max 0.20 mm for total length Valve Seat Runout 0.064 mm (0.008 in. for total length) (0.0025 in.) Main Bearing Bore 68.3514 to 68.3768 mm Flatness 0.03 mm per 25 mm Diameter (0.001 in.
Page 748 9 - 58 2.5L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Oil Control Ring 89.66 to 89.92 mm OIL PUMP AND OIL PRESSURE (3.53 to 3.54 in.) Gear to Body Clearance Piston Pin Bore Diameter 23.650 to 23.658 mm (Radial) 0.051 to 0.102 mm (0.9312 to 0.9315 in.) (0.002 to 0.004 in.)
Page 749: Specifications-Torque
2.5L ENGINE 9 - 59 SPECIFICATIONS (Continued) SPECIFICATIONS—TORQUE DESCRIPTION N·m In. Lbs TORQUE CHART 2.5L ENGINE Lbs. Exhaust Manifold DESCRIPTION N·m In. Lbs Bolt #1 — Lbs. Bolts #2-5 — A/C Compressor Bracket — Nuts 6 and 7 — to Engine—Bolts Flywheel/Converter —...
Page 750: Special Tools
9 - 60 2.5L ENGINE SPECIAL TOOLS 2.5L ENGINE SPECIAL TOOLS Vibration Damper Removal Tool 7697 Valve Spring Compressor Tool MD-998772A Rear Main Seal Installer Tool 6271A Timing Case Cover Alignment and Seal installation Tool 6139 Hydraulic Valve Tappet Removal/Installation Tool C-4129–A...
Page 751 4.0L ENGINE 9 - 61 4.0L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE ENGINE ASSEMBLY (SHORT ENGINE ....... . 62 BLOCK).
Page 752: Description And Operation
9 - 62 4.0L ENGINE DESCRIPTION AND OPERATION ENGINE DESCRIPTION The 4.0 Liter (242 CID) six-cylinder engine is an In-line, lightweight, overhead valve engine. This engine is designed for unleaded fuel. The engine cylinder head has dual quench-type combus- tion chambers that create turbulence and fast burn- ing of the air/fuel mixture.
Page 753 4.0L ENGINE 9 - 63 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 754 9 - 64 4.0L ENGINE DESCRIPTION AND OPERATION (Continued) Oil Lubrication System—4.0L 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 755: Cylinder Block
4.0L ENGINE 9 - 65 DESCRIPTION AND OPERATION (Continued) CYLINDER BLOCK DESCRIPTION The cylinder block is a cast iron inline six cylinder design. The cylinder block is drilled forming galleries for both oil and coolant (Fig. 3). Fig. 4 Cylinder Head 4.0L Engine 1 –...
Page 756: Piston And Connecting Rod
9 - 66 4.0L ENGINE DESCRIPTION AND OPERATION (Continued) PISTON AND CONNECTING ROD DESCRIPTION The pistons are made of a high strength aluminum alloy with an anodized top ring groove and crown. Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resis- tance.
Page 757: Valves
4.0L ENGINE 9 - 67 DESCRIPTION AND OPERATION (Continued) VALVES DESCRIPTION The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing. All valves use three bead locks to promote valve rotation (Fig. 9). Fig. 10 Cylinder Head Cover HYDRAULIC TAPPET DESCRIPTION Valve lash is controlled by hydraulic tappets...
Page 758: Exhaust Manifold
9 - 68 4.0L ENGINE DESCRIPTION AND OPERATION (Continued) exhaust manifolds share a common gasket with the intake manifold. The exhaust manifolds also incorpo- rate ball flange outlets for improved sealing and strain free connections. DIAGNOSIS AND TESTING ENGINE DIAGNOSIS—INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance.
Page 759: Service Diagnosis-Performance
4.0L ENGINE 9 - 69 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 760: Service Diagnosis-Mechanical
9 - 70 4.0L 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 761 4.0L ENGINE 9 - 71 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 762: Intake Manifold Leakage Diagnosis
9 - 72 4.0L 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 763: Cylinder Compression Pressure Test
4.0L ENGINE 9 - 73 DIAGNOSIS AND TESTING (Continued) (1) Start the engine. CYLINDER-TO-WATER JACKET LEAKAGE TEST (2) Spray a small stream of water at the suspected leak area. WARNING: USE EXTREME CAUTION WHEN THE (3) If a change in RPM is observed the area of the ENGINE IS OPERATING.
Page 764: Engine Oil Leak Inspection
9 - 74 4.0L 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 765: Engine Oil Pressure
4.0L ENGINE 9 - 75 DIAGNOSIS AND TESTING (Continued) filter runoff, and main bearing cap to cylinder The timing notch index on the vibration damper block mating surfaces. should be aligned with the TDC mark on the timing (4) If no leaks are detected, pressurize the crank- degree scale.
Page 766 9 - 76 4.0L ENGINE SERVICE PROCEDURES (Continued) VALVE SEAT REFACING VALVE STEM-TO-GUIDE CLEARANCE (1) Install a pilot of the correct size in the valve MEASUREMENT guide bore. Reface the valve seat to the specified Valve stem-to-guide clearance may be measured by angle with a good dressing stone.
Page 767: Piston Fitting
4.0L ENGINE 9 - 77 SERVICE PROCEDURES (Continued) ALTERNATIVE METHOD (1) Use a dial indicator to measure the lateral movement of the valve stem (stem-to-guide clear- ance). This must be done with the valve installed in its guide and just off the valve seat (Fig. 17). (2) Correct clearance 0.025-0.0762...
Page 768 9 - 78 4.0L 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 769 4.0L ENGINE 9 - 79 SERVICE PROCEDURES (Continued) Fig. 23 Gap Measurement 1 – FEELER GAUGE RING GAP MEASUREMENT CHART Fig. 22 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 770: Fitting Connecting Rod Bearings
9 - 80 4.0L ENGINE SERVICE PROCEDURES (Continued) Fig. 25 Second Compression Ring Identification 1 – SECOND COMPRESSION RING 2 – CHAMFER 3 – ONE DOT Fig. 28 Ring Gap Orientation 1 – TOP COMPRESSION RING 2 – BOTTOM COMPRESSION RING 3 –...
Page 771 4.0L ENGINE 9 - 81 SERVICE PROCEDURES (Continued) alignment. Replace misaligned, bent or twisted con- necting rods. BEARING-TO-JOURNAL CLEARANCE (1) Wipe the oil from the connecting rod journal. (2) Use short rubber hose sections over rod bolts during installation. (3) Lubricate the upper bearing insert and install in connecting rod.
Page 772 9 - 82 4.0L ENGINE SERVICE PROCEDURES (Continued) (9) If bearing-to-journal clearance exceeds the specification, install a pair of 0.0254 mm (0.001 inch) undersize bearing inserts. All the odd size inserts must be on the bottom. The sizes of the service replacement bearing inserts are stamped on the backs of the inserts.
Page 773: Fitting Crankshaft Main Bearings
4.0L ENGINE 9 - 83 SERVICE PROCEDURES (Continued) FITTING BEARINGS (CRANKSHAFT INSTALLED) The main bearing caps, numbered (front to rear) from 1 through 7 have an arrow to indicate the for- ward position. The upper main bearing inserts are grooved to provide oil channels while the lower inserts are smooth.
Page 774 9 - 84 4.0L ENGINE SERVICE PROCEDURES (Continued) Fig. 36 Crankshaft Journal Size Paint I. D. Location 1 – NO. 7 MAIN JOURNAL SIZE PAINT MARK 3 – NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK 2 – NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK 4 –...
Page 775 4.0L ENGINE 9 - 85 SERVICE PROCEDURES (Continued) If the clearance exceeds specification using a pair MAIN BEARING JOURNAL DIAMETER of 0.051 mm (0.002 inch) undersize bearing inserts, (CRANKSHAFT REMOVED) measure crankshaft journal diameter with Remove the crankshaft from the cylinder block micrometer.
Page 776: Form-In-Place Gaskets
9 - 86 4.0L ENGINE SERVICE PROCEDURES (Continued) Crankshaft Journal #7 Only Corresponding Bearing Insert Color Code Diameter Upper Insert Size Lower Insert Size 63.4873 - 63.4746 mm Yellow - Standard Yellow - Standard Yellow (2.4995 - 2.4990 in.) 63.4746 - 63.4619 mm (2.4996 - 2.4991 in.) Blue - Undersize Yellow - Standard...
Page 777: Engine Performance
4.0L ENGINE 9 - 87 SERVICE PROCEDURES (Continued) tact area. Uncured sealant may be removed with a scuffing, scoring or scratches. Usually a few strokes shop towel. Components should be torqued in place will clean up a bore and maintain the required lim- while the sealant is still wet to the touch (within 10 its.
Page 778: Repair Damaged Or Worn Threads
9 - 88 4.0L ENGINE SERVICE PROCEDURES (Continued) REPAIR DAMAGED OR WORN THREADS (9) Squirt engine oil into the cylinders to lubricate the walls. This will prevent damage on restart. (10) Install new spark plugs. Tighten the spark CAUTION: Be sure that the tapped holes maintain plugs to 37 N·m (27 ft.
Page 779 (5) Remove dipstick, with handle held above the All Jeep engines are equipped with a high quality tip, take oil level reading (Fig. 41). full-flow, throw-away type oil filter. DaimlerChrysler (6) Add oil only if level is below the ADD mark on...
Page 780: Removal And Installation
9 - 90 4.0L ENGINE SERVICE PROCEDURES (Continued) Corporation recommends a Mopar or equivalent oil filter be used. OIL FILTER REMOVAL (1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss or filter adapter housing (Fig.
Page 781: Engine Mount-Rear
4.0L ENGINE 9 - 91 REMOVAL AND INSTALLATION (Continued) Fig. 45 Support Cushion Bracket Fig. 44 Front Mounts 1 – SUPPORT CUSHION BRACKET 2 – SUPPORT CUSHION BRACKET 1 – ENGINE SUPPORT BRACKET 2 – THROUGH BOLT 3 – SUPPORT CUSHION MANUAL TRANSMISSION 4 –...
Page 782: Engine Assembly
9 - 92 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 46 Rear Mount(Manual Transmission) 1 – TRANSMISSION SUPPORT BRACKET 2 – SUPPORT CUSHION 3 – CROSSMEMBER ASSEMBLY b. Install the support cushion to the support Fig. 47 Rear Mount(Automatic Transmission) bracket.
Page 783 4.0L ENGINE 9 - 93 REMOVAL AND INSTALLATION (Continued) (10) Disconnect radiator fan switch wire connector. (11) Vehicles with Air Conditioning: (a) Discharge A/C system (refer to group 24, Heating and Air Conditioning for proper proce- dures) (b) Disconnect the suction/discharge hose and cap off compressor ports to prevent foreign mate- rial and refrigerant oil loss.
Page 784 9 - 94 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (39) Remove the remaining converter (or flywheel) (17) Lower the vehicle. housing bolts. (18) Connect all the vacuum hoses and wire con- (40) Lift the engine out of the engine compart- nectors identified during engine removal.
Page 785: Intake And Exhaust Manifold
4.0L ENGINE 9 - 95 REMOVAL AND INSTALLATION (Continued) INTAKE AND EXHAUST MANIFOLD (3) Install intake manifold on the cylinder head dowels. (4) Install washer and fastener Numbers 1, 2, 4, 5, REMOVAL 8, 9, 10 and 11 (Fig. 50). (5) Install washer and fastener Numbers 6 and 7 NOTE: THE ENGINE INTAKE AND EXHAUST MANI- (Fig.
Page 786: Exhaust Manifold-4.0L Engine
9 - 96 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (18) Lower the vehicle. (19) Connect the battery negative cable. (20) Start the engine and check for leaks. EXHAUST MANIFOLD—4.0L ENGINE The intake and engine exhaust manifolds on the 4.0L engine must be removed and installed together. The manifolds use a common gasket at the cylinder head.
Page 787: Valve Springs And Oil Seals
4.0L ENGINE 9 - 97 REMOVAL AND INSTALLATION (Continued) (2) Remove cap screws, bridge and pivot assem- blies and rocker arms for access to each valve spring to be removed. (3) Remove push rods. Retain the push rods, bridges, pivots and rocker arms in the same order and position as removed.
Page 788: Cylinder Head
9 - 98 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (7) Loosen the accessory drive belt at the power steering pump. (Refer to Group 7, Cooling System for the correct procedure). Slip the belt off of the power CAUTION: Install oil seals carefully to prevent dam- age from the sharp edges of the valve spring lock steering pulley.
Page 789 4.0L ENGINE 9 - 99 REMOVAL AND INSTALLATION (Continued) • Bolts 12 through 14 to 149 N·m (110 ft. lbs.) torque. CYLINDER HEAD BOLTS POSITION DESCRIPTION 1,4,5,12,13 1/2 in.-13 BOLT 1/2 in.-13 BOLT WITH DOWEL POINT 2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD All bolts are 12 point drives for rocker cover clearance (e) Check all bolts in sequence to verify the cor- rect torque.
Page 790: Valves And Valve Springs
9 - 100 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: The serpentine drive belt must be routed (4) Install the replacement valve stem oil seals on correctly. Incorrect routing can cause the water the valve stems. If the 0.381 mm (0.015 inch) over- size valve stems are used, oversize oil seals are pump to turn in the opposite direction causing the engine to overheat.
Page 791: Vibration Damper
4.0L ENGINE 9 - 101 REMOVAL AND INSTALLATION (Continued) (5) Install the rocker arms and bridge and pivot (3) Tighten the damper retaining bolt to 108 N·m assemblies at their original locations. Loosely install (80 ft. lbs.) torque. the capscrews at each bridge. (4) Install the serpentine drive belt.
Page 792: Timing Chain And Sprockets
9 - 102 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Position the timing case cover on the oil pan (6) Rotate crankshaft until the “0” timing mark is gasket and the cylinder block. closest to and on the center line with camshaft (4) Insert Timing Case Cover Alignment and Seal sprocket timing mark (Fig.
Page 793: Camshaft
4.0L ENGINE 9 - 103 REMOVAL AND INSTALLATION (Continued) (10) Installation of the timing chain with the tim- (9) Remove the vibration damper. ing marks on the crankshaft and camshaft sprockets (10) Remove the timing case cover. properly aligned ensures correct valve timing. A worn (11) Rotate the crankshaft until the crankshaft or stretched timing chain will adversely affect valve sprocket timing mark is aligned on centerline with...
Page 794: Camshaft Bearings
9 - 104 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Install the cylinder head and head bolts (Refer to cylinder head R&I in this section for torque values and tightening sequence). (16) Install the push rods. (17) Install the rocker arms and pivot and bridge assemblies.
Page 795: Crankshaft Main Bearings
4.0L ENGINE 9 - 105 REMOVAL AND INSTALLATION (Continued) (3) Inspect the camshaft thrust plate for wear. If the plate shows excessive wear inspect the camshaft oil pressure relief holes in the rear cam jounral. The relief holes must be clean and free of debris. CAUTION: Make sure outside diameter of number 1 bearing is clean.
Page 796 9 - 106 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (2) Loosen all the main bearing caps. Install the main bearing upper inserts. (3) Install the lower bearing inserts into the main bearing caps. (4) On the rear main cap, apply Mopar Gasket Maker sealer on both sides of cylinder block as shown in (Fig.
Page 797: Oil Pan
4.0L ENGINE 9 - 107 REMOVAL AND INSTALLATION (Continued) (a) Attach a magnetic base dial indicator to the OIL PAN cylinder block at either the front or rear of the engine. REMOVAL (b) Position the dial indicator rod so that it is (1) Disconnect negative cable from battery.
Page 798: Pistons And Connecting Rods
9 - 108 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Install two dowels in the timing case cover. Install the other two dowels in the cylinder block (Fig. 73). Fig. 75 Position of 5/16 inch Oil Pan Bolts 1 – OIL PAN 2 –...
Page 799 4.0L ENGINE 9 - 109 REMOVAL AND INSTALLATION (Continued) ridge from the top end of the cylinder walls. Use a (11) Lower the vehicle until it is about 2 feet from protective cloth to collect the cuttings. the floor. (6) Raise the vehicle. CAUTION: Ensure that the connecting rod bolts DO (7) Drain the engine oil.
Page 800: Crankshaft Oil Seals-Rear
9 - 110 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (4) Use a piston ring compressor to install the con- (12) Install the oil pan and gaskets as outlined in necting rod and piston assemblies through the top of the installation procedure. the cylinder bores (Fig.
Page 801: Oil Pump
4.0L ENGINE 9 - 111 REMOVAL AND INSTALLATION (Continued) The pump incorporates a nonadjustable pressure relief valve to limit maximum pressure to 517 kPa (75 psi). In the relief position, the valve permits oil to bypass through a passage in the pump body to the inlet side of the pump.
Page 802: Timing Case Cover Oil Seal
9 - 112 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Apply Mopar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key. (1) Install the oil pump on the cylinder block using With the key inserted in the keyway in the crank- a replacement gasket.
Page 803: Cleaning And Inspection
4.0L ENGINE 9 - 113 DISASSEMBLY AND ASSEMBLY (Continued) (12) Lubricate the oil filter seal with clean engine INSPECTION oil. Tighten oil filter to 18 N·m (156 in. lbs.) torque. Inspect the pivot surface area of each rocker arm. (13) Install the engine into the vehicle. Replace any that are scuffed, pitted, cracked or (14) Fill the engine with clean lubrication oil (refer excessively worn.
Page 804: Cylinder Block
9 - 114 4.0L ENGINE CLEANING AND INSPECTION (Continued) (7) Slowly swing the weighted arm onto the push INSPECTION rod. (1) It is mandatory to use a dial bore gauge to (8) Rotate the cup by turning the handle at the measure each cylinder bore diameter (Fig.
Page 805: Specifications
4.0L ENGINE 9 - 115 SPECIFICATIONS DESCRIPTION SPECIFICATION SPECIFICATIONS Base Circle Runout 0.03 mm (MAX) 4.0L ENGINE (0.001 in.) Valve Lift DESCRIPTION SPECIFICATION Intake 10.350 mm (0.4075 in.) Engine Type In-line 6 Cylinder Exhaust 10.528 mm (0.4145 in.) Bore and Stroke 98.4 x 86.69 mm Valve Timing (3.88 x 3.413 in.)
Page 806 9 - 116 4.0L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Connecting Rod Journal Bore (Less Bearings) 56.08 to 56.09 mm Diameter 53.17 to 53.23 mm (2.2080 to 2.2085 in.) (2.0934 to 2.0955 in.) Bearing Clearance 0.025 to 0.076 mm Connecting Rod Journal 27.18 to 27.33 mm (0.001 to 0.003 in.)
Page 807 4.0L ENGINE 9 - 117 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Flatness Max. 0.20 mm - max. for total VALVE SPRINGS length Free Length (Approx.) 47.65 mm (1.876 in.) (0.008 in. max. for total Spring Load length) Valve Closed 316 to 351 N @ 41.656 ROCKER ARMS, PUSH RODS &...
Page 808: Torque Specifications
9 - 118 4.0L ENGINE SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION SPECIFICATION 4.0L ENGINE Piston Ring Groove Diameter DESCRIPTION N·m No.1 Compression Ring 88.39 to 88.65 mm Lbs. Lbs. (3.48 to 3.49 in.) A/C Compressor—Bolts — No.2 Compression Ring 87.63 to 87.88 mm Block Heater—Nut —...
Page 809: Special Tools
4.0L ENGINE 9 - 119 SPECIFICATIONS (Continued) SPECIAL TOOLS DESCRIPTION N·m Lbs. Lbs. 4.0L ENGINE Intake/Exhaust Manifold Fasteners #1-5 — Fasteners #6 and 7 — Fasteners #8-11 — Flywheel to Converter — Housing—Bolts Flywheel to Crankshaft—Bolts — Front Cover to Block—Bolts 1/4-20 —...
Page 811 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION EXHAUST SYSTEM......1 EXHAUST PIPE .
Page 812 11 - 2 EXHAUST SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 3 Exhaust System—Typical 1 – STUD 7 – NUT 2 – TAIL PIPE HANGER 8 – MUFFLER 3 – CLAMP 9 – CLAMP 4 – ISOLATOR 10 – CATALYTIC CONVERTER 5 –...
Page 813 EXHAUST SYSTEM 11 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 4 4.0L Catalytic Converter and O2 Sensor Configuration—(California Emissions only) 1 – O2 SENSOR 4 – O2 SENSOR 2 – O2 SENSOR 5 – O2 SENSOR 3 – O2 SENSOR 6 –...
Page 814 11 - 4 EXHAUST SYSTEM DESCRIPTION AND OPERATION (Continued) TAILPIPE DESCRIPTION The tail pipe is also made of galvanized steel. OPERATION The tailpipe channels the exhaust out of the muf- fler and out from under the vehicle to control noise and prevent exhaust gas fumes from entering the passenger compartment.
Page 815 EXHAUST SYSTEM 11 - 5 REMOVAL AND INSTALLATION EXHAUST PIPE WARNING: IF TORCHES ARE USED WHEN WORK- ING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing exhaust system compo- nents, disconnect the oxygen sensor connector. Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sen- sor.
Page 816 11 - 6 EXHAUST SYSTEM REMOVAL AND INSTALLATION (Continued) CATALYTIC CONVERTER WARNING: IF TORCHES ARE USED WHEN WORK- ING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES. CAUTION: When servicing exhaust system compo- nents, disconnect the oxygen sensor connector. Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sen- sor.
Page 817 EXHAUST SYSTEM 11 - 7 REMOVAL AND INSTALLATION (Continued) • To remove an original equipment exhaust muf- fler/tailpipe combination, cut the exhaust tailpipe close to the muffler. Collapse the part remaining in the muffler and remove. • To remove a service exhaust tailpipe/muffler combination, apply heat until the metal becomes cherry red.
Page 818 11 - 8 EXHAUST SYSTEM REMOVAL AND INSTALLATION (Continued) (9) Start the engine and inspect for exhaust leaks SPECIFICATIONS and exhaust system contact with the body panels. Adjust the alignment, if needed. TORQUE SPECIFICATIONS HEAT SHIELDS DESCRIPTION N·m Lbs. Lbs. REMOVAL Catalytic Converter/Exhaust (1) Raise and support the vehicle.
Page 819 BUMPERS DESCRIPTION AND OPERATION DESCRIPTION FRAME AND BUMPERS The bumpers on the Jeep Cherokee are made up of the main bumper beam, the end caps, air deflector FRAME (front bumper) and mounting brackets. Some Chero- kee models also have a tow hook support bracket.
Page 820 13 - 2 FRAME AND BUMPERS BUMPERS TABLE OF CONTENTS page page REMOVAL AND INSTALLATION REAR BUMPER END CAP ....4 FRONT BUMPER END CAP ....2 REAR BUMPER .
Page 821 FRAME AND BUMPERS 13 - 3 REMOVAL AND INSTALLATION (Continued) Fig. 2 Bumper End Cap 1 – RETAINER TAB 2 – BUMPER END CAP 3 – BUMPER 4 – GRILLE Fig. 3 Vacuum Reservoir 1 – VACUUM LINE 2 – RESERVOIR SCREWS (4) Install the rivet attaching the end cap to air 3 –...
Page 822 13 - 4 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) REAR BUMPER END CAP refer to removal procedure within Group 13, Frame and Bumpers. (2) Remove bumper end caps. REMOVAL (3) Remove upper nuts that attach bumper to (1) Remove the screws attaching the bumper end bumper support brackets (Fig.
Page 823 FRAME AND BUMPERS 13 - 5 REMOVAL AND INSTALLATION (Continued) REAR TOW HOOK REMOVAL (1) Remove bolts that attach tow hook bracket and tow hook to frame rail (Fig. 6). (2) Remove bracket and tow hook from frame rail. INSTALLATION (1) Position bracket and tow hook on frame rail.
Page 824 13 - 6 FRAME AND BUMPERS FRAME TABLE OF CONTENTS page page REMOVAL AND INSTALLATION TRAILER HITCH ......7 FRONT SKID PLATE .
Page 825 FRAME AND BUMPERS 13 - 7 REMOVAL AND INSTALLATION (Continued) FUEL TANK SKID PLATE REMOVAL (1) Position a support under skid plate. (2) Remove bolts that attach skid plate to under- body side rails (Fig. 3). (3) Remove support and skid plate from vehicle. Fig.
Page 826 13 - 8 FRAME AND BUMPERS SPECIFICATIONS (Continued) Fig. 6 Frame Dimensions...
Page 827 FRAME AND BUMPERS 13 - 9 SPECIFICATIONS (Continued) FRAME TORQUE SPECIFICATIONS DESCRIPTION TORQUE Front Skid Plate Screw ..42 N·m (31 ft. lbs.) Front Skid Plate Nut ..17 N·m (125 in. lbs.) Transfer Case Skid Plate Bolt .
Page 829 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY SYSTEM....1 FUEL INJECTION SYSTEM ....25 FUEL DELIVERY SYSTEM TABLE OF CONTENTS page...
Page 830: Description And Operation
14 - 2 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • fuel tubes/lines/hoses • quick-connect fittings • fuel injector rail • fuel injectors • fuel tank • fuel tank filler/vent tube assembly • fuel tank filler tube cap • accelerator pedal •...
Page 831: Fuel Pump
FULL, to about 8.6 volts at The regulator acts as a check valve to maintain EMPTY (about 8.6 volts at EMPTY for Jeep some fuel pressure when the engine is not operating. models, and about 7.0 volts at EMPTY for This will help to start the engine.
Page 832: Fuel Tank
14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) into the intake manifold. Certain models are also equipped with a self-diagnosing system using a Leak Detection Pump (LDP). Refer to Emission Control System for additional information. FUEL INJECTORS DESCRIPTION An individual fuel injector (Fig. 4) is used for each individual cylinder.
Page 833: Fuel Injector Rail/Fuel Damper-2.5L Engine
FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) injector pulse width based on various inputs it FUEL RAIL/FUEL DAMPER—4.0L ENGINE receives. Battery voltage is supplied to the injectors through DESCRIPTION the ASD relay. The fuel rail is mounted to the intake manifold The PCM determines injector pulse width based on (Fig.
Page 834: Fuel Tank Filler Tube Cap
14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Refer to Fuel Filter/Fuel Pressure Regulator in this QUICK-CONNECT FITTINGS group for information. The fuel rail is not repairable. DESCRIPTION Different types of quick-connect fittings are used to FUEL TANK FILLER TUBE CAP attach various fuel system components, lines and tubes.
Page 835: Fuel Pump Capacity Test
FUEL SYSTEM 14 - 7 DIAGNOSIS AND TESTING (Continued) (from gauge set 5069) to test port pressure fitting on (3) Obtain correct Fuel Line Pressure Test Adapter fuel rail (Fig. 7). The DRB III Scan Tool along Tool Hose. Tool number 6539 is used for 5/16” fuel with the PEP module, the 500 psi pressure lines and tool number 6631 is used for 3/8”...
Page 836: Fuel Pump Amperage Test
14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) cleaner housing removal may be necessary before (9) If pressure falls below 30 psi, it must be deter- fuel line disconnection. mined if a fuel injector, the check valve within the (2) Obtain correct Fuel Line Pressure Test Adapter fuel pump module, or a fuel tube/line is leaking.
Page 837 FUEL SYSTEM 14 - 9 DIAGNOSIS AND TESTING (Continued) Depending upon vehicle model, year or engine con- figuration, three different types of relays may be used: Type-1, type-2 and type–3. (14) If equipped with type–1 relay (Fig. 10), attach test leads from LCS adapter into PDC relay cavities number 30 and 87.
Page 838: Fuel Gauge Sending Unit
14 - 10 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) electrical terminals (pins). Place an ohmmeter across the terminals. Resistance reading should be approxi- mately 12 ohms 1.2 ohms at 20°C (68°F). SERVICE PROCEDURES FUEL SYSTEM PRESSURE RELEASE PROCEDURE TERMINAL LEGEND Use following procedure if the fuel injector NUMBER IDENTIFICATION...
Page 839 FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) used on certain components/lines. Certain fittings may require use of a special tool for disconnection. DISCONNECTING WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED.
Page 840 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) Fig. 15 Removing Pull Tab 1 – FUEL TUBE OR FUEL SYSTEM COMPONENT 2 – PULL TAB 3 – QUICK-CONNECT FITTING 4 – FUEL TUBE STOP Fig. 17 Plastic Retainer Ring Type Fitting 1 –...
Page 841: Removal And Installation
FUEL SYSTEM 14 - 13 SERVICE PROCEDURES (Continued) (8) Disconnect quick-connect fitting from fuel sys- tem component being serviced. CONNECTING (1) Inspect quick-connect fitting body and fuel sys- tem component for damage. Replace as necessary. (2) Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component.
Page 842: Fuel Pump Module
14 - 14 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings Fig. 21 Fuel Filter/Fuel Pressure Regulator 1 – FUEL FILTER/FUEL PRESSURE REGULATOR 1 – RETAINER CLAMP 2 – TO FUEL INJECTORS 2 – FUEL FILTER/FUEL PRESSURE REGULATOR 3 –...
Page 843: Fuel Pump Inlet Filter
FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) (1) Drain fuel tank and remove tank. Refer to the Fuel Tank Removal/Installation section of this group. (2) Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. (3) Disconnect fuel line at filter/regulator.
Page 844: Fuel Gauge Sending Unit
14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 26 Fuel Pump Inlet Filter Fig. 28 Fuel Gauge Sending Unit Release Tab 1 – FUEL PUMP MODULE 1 – ELECTRICAL CONNECTOR 2 – FUEL PUMP INLET FILTER 2 – FUEL GAUGE SENDING UNIT 3 –...
Page 845: Fuel Injector Rail/Fuel Damper-4.0L Engine
FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) (4) Remove air tube at top of throttle body. Note: (13) Remove fuel rail mounting nuts/bolts (Fig. Some engine/vehicles may require removal of air 29). cleaner ducts at throttle body. (14) Remove fuel rail by gently rocking until all (5) Remove injector harness electrical connectors the fuel injectors are out of intake manifold.
Page 846 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (5) Disconnect electrical connectors at all 6 fuel injectors. To remove connector refer to (Fig. 30). Push red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector.
Page 847: Fuel Injectors
FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) (8) Install protective cap to pressure test port fit- FUEL TANK ting (if equipped). (9) Install cable routing bracket to intake mani- WARNING: THE FUEL SYSTEM IS UNDER CON- fold. STANT FUEL PRESSURE EVEN WITH THE ENGINE (10) Connect throttle cable at throttle body.
Page 848 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 35 Fuel Tank Connections at Front of Fuel Tank Fig. 33 Fuel Hose Shield 1 – FUEL PUMP MODULE CONNECTOR 1 – FUEL HOSE SHIELD 2 – LEFT-REAR SHOCK ABSORBER 2 –...
Page 849: Fuel Tank Filler Tube Cap
FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) (10) Connect fuel pump module pigtail harness electrical connector near front of tank. (11) Connect fuel pump module supply line near front of tank. Refer to Quick-Connect Fittings for procedures. (12) Connect EVAP hose near front of tank. (13) Install exhaust tailpipe heat shield.
Page 850: Throttle Cable
14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 38 Accelerator Pedal Mounting—Typical Fig. 39 Throttle Cable at Throttle Body 1 – RETAINER TABS 1 – ACCELERATOR CABLE 2 – CLIP 2 – OFF 3 – MOUNTING NUTS 3 – OFF 4 –...
Page 851: Specifications
FUEL SYSTEM 14 - 23 during the winter months to reduce carbon monoxide SPECIFICATIONS emissions. Fuels blended with these oxygenates may be used in your vehicle. FUEL TANK CAPACITY CAUTION: DO NOT use gasoline containing METH- Models Liters U. S. Gallons ANOL.
Page 852: Torque Chart
14 - 24 FUEL SYSTEM SPECIFICATIONS (Continued) Use of additional detergents or other additives is not of these products contain high concentrations of needed under normal conditions. methanol. Fuel system damage or vehicle perfor- mance problems resulting from the use of such fuels FUEL SYSTEM CAUTIONS or additives is not the responsibility of Daimler- Chrysler Corporation and may not be covered under...
Page 853 FUEL SYSTEM 14 - 25 FUEL INJECTION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FUEL INJECTORS—PCM OUTPUT ... 35 POWERTRAIN CONTROL MODULE (PCM) ..25 FUEL PUMP RELAY-PCM OUTPUT .
Page 854: Battery
14 - 26 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • Manifold absolute pressure (MAP) sensor • Oil pressure • Oxygen sensors • Park/neutral switch (auto. trans. only) • Power ground • Power steering pressure switch (2.5L engine only) • Sensor return •...
Page 855 FUEL SYSTEM 14 - 27 DESCRIPTION AND OPERATION (Continued) • Crankshaft position sensor to the PCM whether or not the calculated injector • Intake manifold air temperature sensor pulse width results in the ideal air-fuel ratio. This • Manifold absolute pressure (MAP) sensor ratio is 14.7 parts air-to-1 part fuel.
Page 856 14 - 28 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) IDLE MODE CRUISE MODE When the engine is at operating temperature, this When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM is a Closed Loop mode. At cruising speed, the PCM receives inputs from: receives inputs from: •...
Page 857: Automatic Shutdown (Asd) Relay Sense-Pcm Input
FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) If the vehicle is under hard deceleration with the connect the oxygen sensor heater element, ignition proper rpm and closed throttle conditions, the PCM coil and fuel injectors to 12 volt + power supply. will ignore the oxygen sensor input signal.
Page 858: Fuel Level Sensor-Pcm Input
14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • supply the 5 volt power source to the transmis- EXTENDED IDLE SWITCH—PCM INPUT sion pressure sensor (if equipped with an RE auto- matic transmission). DESCRIPTION USED ONLY WITH OPTIONAL POLICE FUEL LEVEL SENSOR—PCM INPUT PACKAGE WHEN EQUIPPED WITH A 4.0L ENGINE: The extended idle switch is a rocker-type...
Page 859: Ignition Circuit Sense-Pcm Input
FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) nia emission package, the heaters on both sensors Upstream Sensors (California Emissions): Two are fed battery voltage from the two O2S heater upstream sensors are used (1/1 and 2/1). The 1/1 sen- relays.
Page 860: Intake Manifold Air Temperature Sensor-Pcm Input
14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) INTAKE MANIFOLD AIR TEMPERATURE The MAP sensor input is the number one contrib- utor to fuel injector pulse width. The most important SENSOR—PCM INPUT function of the MAP sensor is to determine baromet- ric pressure.
Page 861: Oil Pressure Sensor-Pcm Input
FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) • Generator field winding The range of voltage output from the sensor is usu- • Fuel injectors ally between 4.6 volts at sea level to as low as 0.3 • Ignition coil(s) volts at 26 in.
Page 862: Sensor Return-Pcm Input
14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) When pump pressure drops to approximately 1379 VEHICLE SPEED AND DISTANCE SENSOR— kPa (200 psi), the switch circuit will re-close and PCM INPUT engine idle speed will return to its previous setting. DESCRIPTION SENSOR RETURN—PCM INPUT The 3–wire Vehicle Speed Sensor (VSS) is located...
Page 863: Ccd Bus (+/-) Circuits-Pcm Outputs
FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) • the ignition key is left in the ON position. This injector pulse width based on various inputs it is if the engine has not been running for approxi- receives. mately 1.8 seconds. Battery voltage (12 volts +) is supplied to the injec- •...
Page 864: Radiator Fan Relay-Pcm Output
14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The PCM uses the IAC motor to control idle speed can anticipate A/C compressor loads. This is accom- (along with timing) and to reach a desired MAP dur- plished by delaying compressor operation for approx- ing decel (keep engine from stalling).
Page 865: Power Distribution Center
FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) transmission control cable (when equipped) are con- nected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechani- cally limit the position of the throttle body throttle plate.
Page 866 14 - 38 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) intake manifold. Also check connection to brake vac- uum booster. (15) Inspect air cleaner inlet and air cleaner ele- ment for dirt or restrictions. (16) Inspect radiator grille area, radiator fins and air conditioning condenser for restrictions.
Page 867 FUEL SYSTEM 14 - 39 DIAGNOSIS AND TESTING (Continued) Fig. 10 Engine Coolant Temperature Sensor— Typical 1 – THERMOSTAT HOUSING Fig. 8 Sensor Locations—4.0L Engine 2 – ENGINE COOLANT TEMPERATURE SENSOR 1 – MOUNTING BOLTS (4) 3 – ELECTRICAL CONNECTOR 2 –...
Page 868 14 - 40 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 14 Rear Oxygen Sensor—2.5L/4.0L—Federal Emissions 1 – 1/2 O2S Fig. 12 Oxygen Sensors—4.0L—California Emissions (24) Inspect for pinched or leaking fuel tubes. 1 – 1/1 O2S Inspect for pinched, cracked or leaking fuel hoses. 2 –...
Page 869: Asd And Fuel Pump Relays
FUEL SYSTEM 14 - 41 DIAGNOSIS AND TESTING (Continued) Fig. 17 Fuel Tank Connections at Front of Fuel Tank 1 – FUEL PUMP MODULE CONNECTOR 2 – LEFT-REAR SHOCK ABSORBER Fig. 15 Vehicle Speed Sensor—Typical— 3 – EVAP CANISTER VENT LINE CONNECTION 4WD Shown 4 –...
Page 870: Throttle Body Minimum Air Flow Check Procedure
14 - 42 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (5) Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source.
Page 871: Removal And Installation
FUEL SYSTEM 14 - 43 DIAGNOSIS AND TESTING (Continued) (1) Start the engine and bring to operating tem- perature. Be sure all accessories are off before per- forming this test. (2) Shut off engine and remove air duct at throttle body.
Page 872: Fuel Pump Relay
14 - 44 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 23 Power Distribution Center (PDC) Fig. 24 Throttle Body and Sensor Locations—4.0L 1 – POWER DISTRIBUTION CENTER (PDC) Engine 1 – MOUNTING BOLTS (4) 2 – THROTTLE BODY FUEL PUMP RELAY 3 –...
Page 873: Throttle Position Sensor (Tps)
FUEL SYSTEM 14 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 26 TPS Mounting Screws 1 – MOUNTING SCREWS 2 – TPS Fig. 25 Throttle Body and Sensor Locations—2.5L Engine 1 – IDLE AIR CONTROL MOTOR 2 – IAT SENSOR 3 – THROTTLE BODY 4 –...
Page 874: Powertrain Control Module
14 - 46 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (3) While removing MAP sensor, slide the rubber L-shaped fitting (Fig. 29) from throttle body. (4) Remove rubber L-shaped fitting from MAP sen- sor. INSTALLATION (1) Install rubber L-shaped fitting to MAP sensor. (2) Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple.
Page 875: Power Steering Pressure Switch-2.5L Engine
FUEL SYSTEM 14 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 32 Power Steering Pressure Switch 1 – POWER STEERING PRESSURE SWITCH Fig. 31 PCM Mounting 2 – ELECTRICAL CONNECTOR 1 – PCM 3 – POWER STEERING PUMP 2 – L. F. FENDER 3 –...
Page 876 14 - 48 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 33 Front Oxygen Sensor—4.0L—Federal Fig. 35 Front Oxygen Sensor—2.5L—Federal Emissions Emissions 1 – 1/1 O2S 1 – 1/1 O2S Fig. 36 Rear Oxygen Sensor—2.5L/4.0L—Federal Emissions 1 – 1/2 O2S Fig. 34 Oxygen Sensors—4.0L—California Emissions INSTALLATION 1 –...
Page 877: Air Cleaner Element (Filter)
FUEL SYSTEM 14 - 49 REMOVAL AND INSTALLATION (Continued) (1) Install O2S sensor. Tighten to 30 N·m (22 ft. lbs.) torque. (2) Connect O2S sensor wire connector. (3) Lower vehicle. AIR CLEANER ELEMENT (FILTER) REMOVAL (1) Unlock air tube clamp (Fig. 37) at air cleaner cover.
Page 878: Intake Manifold Air Temperature Sensor
14 - 50 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 40 Engine Coolant Temperature Sensor— Typical 1 – THERMOSTAT 2 – ENGINE COOLANT TEMPERATURE SENSOR Fig. 41 IAT Sensor Location—4.0L Engine 3 – ELECTRICAL CONNECTOR 1 – MOUNTING BOLTS (4) 2 –...
Page 879: Vehicle Speed Sensor
FUEL SYSTEM 14 - 51 REMOVAL AND INSTALLATION (Continued) VEHICLE SPEED SENSOR The Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the transfer case extension (left side) (Fig. 43). If equipped with 2WD, this adapter is located on the extension housing of the transmission (left side).
Page 880: Special Tools
14 - 52 FUEL SYSTEM SPECIAL TOOLS FUEL SYSTEM O2S (Oxygen Sensor) Remover/Installer—C-4907 Spanner Wrench—6856 Test Kit, Fuel Pressure—5069 Adapters, Fuel Pressure Test—6539 and/or 6631 Test Kit, Fuel Pressure—C-4799-B Fitting, Air Metering—6714 Fuel Line Removal Tool—6782...
Page 881 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page POWER STEERING ......1 STEERING LINKAGE ..... . . 22 POWER STEERING PUMP .
Page 882 19 - 2 STEERING DIAGNOSIS AND TESTING POWER STEERING SYSTEM DIAGNOSIS CHARTS STEERING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound evident at a standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar to that of a water tap being closed slowly.
Page 883 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) BINDING AND STICKING CONDITION POSSIBLE CAUSE CORRECTION 1. Low fluid level. 1. Fill to proper level. DIFFICULT TO TURN WHEEL STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure. 3. Steering component. 3.
Page 884 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) LOOSE STEERING AND VEHICLE LEADS/DRIFTS CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Repair as necessary. WHEEL steering components. 2. Worn or loose wheel bearings. 2.
Page 885 STEERING 19 - 5 POWER STEERING PUMP TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER STEERING PUMP ....5 POWER STEERING PUMP .
Page 886: Description And Operation
19 - 6 STEERING DESCRIPTION AND OPERATION (Continued) POWER STEERING RETURN LINE (4) Disconnect high pressure hose at the pump. Use a container for dripping fluid. (5) Connect Tube 6865 to the pump hose fitting. DESCRIPTION (6) Connect the power steering hose from the Power steering return line is a hose which is steering gear to Adapter 6826.
Page 887: Pump Leakage Diagnosis
STEERING 19 - 7 DIAGNOSIS AND TESTING (Continued) PUMP LEAKAGE DIAGNOSIS (8) Stop the engine and check the fluid level and refill as required. (9) If the fluid is extremely foamy or milky look- ing, allow the vehicle to stand a few minutes and repeat the procedure.
Page 888: Disassembly And Assembly
19 - 8 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 3 Pump Mounting LHD 1 – PUMP BRACKET 3 – PUMP ASSEMBLY 4.0L 2 – PUMP ASSEMBLY 2.5L (3) Install the pump hoses. (4) With Serpentine Belt, run engine until warm (5 (4) Fill reservoir to proper level.
Page 889 STEERING 19 - 9 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 4 Pump Mounting 4.0L RHD 1 – BRACKET 2 – PUMP ASSEMBLY Fig. 6 Pulley Installation Fig. 5 Pulley Removal 1 – POWER STEERING PUMP DRIVE PULLEY 1 – POWER STEERING PUMP DRIVE PULLEY 2 –...
Page 890: Specifications
19 - 10 STEERING DISASSEMBLY AND ASSEMBLY (Continued) SPECIAL TOOLS POWER STEERING PUMP Analyzer Set, Power Steering Flow/Pressure 6815 Fig. 7 Pump Reservoir Clips 1 – RESERVOIR 2 – RETAINING CLIPS Adapters, Power Steering Flow/Pressure Tester SPECIFICATIONS 6893 TORQUE CHART DESCRIPTION TORQUE Power Steering Pump...
Page 891 STEERING 19 - 11 POWER STEERING GEAR TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SPOOL VALVE ......14 POWER STEERING GEAR .
Page 892: Steering Gear
19 - 12 STEERING REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY STEERING GEAR HOUSING END PLUG REMOVAL DISASSEMBLY (1) Place the front wheels in the straight ahead (1) Unseat and remove retaining ring from groove position with the steering wheel centered. with a punch through the hole in the end of the (2) Disconnect and cap the fluid hoses from steer- housing (Fig.
Page 893 STEERING 19 - 13 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: The pitman shaft will not clear the housing if it is not centered. Fig. 3 End Plug Components 1 – HOUSING ASSEMBLY 2 – HOUSING END PLUG O-RING SEAL 3 – HOUSING END PLUG 4 –...
Page 894: Spool Valve
19 - 14 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (9) Install preload adjuster nut. Do not tighten nut until after Over-Center Rotation Torque adjustment has been made. (10) Install gasket to side cover and bend tabs around edges of side cover (Fig. 5). (11) Install pitman shaft assembly and side cover to housing.
Page 895 STEERING 19 - 15 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 9 Thrust Support Assembly 1 – STUB SHAFT 2 – HOUSING 3 – THRUST SUPPORT ASSEMBLY Fig. 11 Stub Shaft 1 – STUB SHAFT 2 – VALVE BODY 3 – HOLE IN SPOOL 4 –...
Page 896: Rack Piston And Worm Shaft
19 - 16 STEERING DISASSEMBLY AND ASSEMBLY (Continued) Fig. 15 Stub Shaft Cap O-Ring 1 – VALVE BODY 2 – STUB SHAFT CAP 3 – O-RING (6) Install stub shaft and valve assembly in the housing. Line up worm shaft to slots in the valve Fig.
Page 897 STEERING 19 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 18 Rack Piston 1 – CLAMP 2 – BALLS 3 – RACK PISTON 4 – BALL GUIDE Fig. 16 Rack Piston End Plug 1 – EXTENSION 2 – END PLUG 3 – RACK PISTON 4 –...
Page 898 19 - 18 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (5) Install remaining balls in guide using grease to hold the balls in place (Fig. 22). Fig. 20 Worm Shaft 1 – GEAR HOUSING 2 – BEARING RACE 3 – WORM SHAFT 4 –...
Page 899: Steering Gear
STEERING 19 - 19 ADJUSTMENTS STEERING GEAR CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result. NOTE: Adjusting the steering gear in the vehicle is not recommended.
Page 900 19 - 20 STEERING ADJUSTMENTS (Continued) Fig. 26 Aligning To The Second Mark Fig. 27 Steering Gear Centered 1 – FIRST MARK 1 – ADJUSTMENT SCREW 2 – SECOND MARK 2 – MASTER SPLINE 3 – SPANNER WRENCH (COUNTERCLOCKWISE) until fully extended, then OVER-CENTER turn back in (CLOCKWISE) one full turn.
Page 901: Specifications
STEERING 19 - 21 ADJUSTMENTS (Continued) surement until correct Over-Center Rotating Torque SPECIAL TOOLS is reached. POWER STEERING GEAR NOTE: To increase the Over-Center Rotating Torque turn the screw CLOCKWISE. (8) Prevent the adjuster screw from turning while tightening adjuster lock nut. Tighten the adjuster lock nut to 49 N·m (36 ft.
Page 902 19 - 22 STEERING STEERING LINKAGE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DRAG LINK ......24 STEERING LINKAGE .
Page 903 STEERING 19 - 23 DESCRIPTION AND OPERATION (Continued) Fig. 2 Steering Linkage—RHD 1 – PITMAN ARM 4 – TIE ROD 2 – DRAG LINK 5 – ADJUSTMENT SLEEVE 3 – STEERING DAMPNER SERVICE PROCEDURES REMOVAL AND INSTALLATION STEERING LINKAGE TIE ROD The tie rod end and ball stud seals should be CAUTION: Use a Puller tool C-3894-A for tie rod inspected during all oil changes.
Page 904 19 - 24 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 3 Ball Stud Puller 1 – CLAMP 2 – ADJUSTMENT SLEEVE 3 – PULLER TOOL C-3894–A 4 – SEAL Fig. 5 Pitman Arm Puller 5 – TIE-ROD END 1 – PITMAN ARM 2 –...
Page 905 STEERING 19 - 25 REMOVAL AND INSTALLATION (Continued) (5) Install steering damper onto drag link and SPECIAL TOOLS install nut. Tighten nut to 74 N·m (55 ft. lbs.) and install a new cotter pin. STEERING LINKAGE STEERING DAMPER REMOVAL (1) Remove the steering damper retaining bolt from the axle bracket.
Page 906 19 - 26 STEERING STEERING COLUMN TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SPECIFICATIONS STEERING COLUMN ..... . 26 TORQUE CHART .
Page 907: Transmission And Transfer Case
STEERING 19 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 3 Column Shrouds Fig. 1 Steering Wheel 1 – UPPER SHROUD 1 – PULLER 2 – LOWER SHROUD 2 – STEERING WHEEL Fig. 4 Tilt Steering Column Mounting Fig. 2 Key Cylinder Release Access Hole 1 –...
Page 908 19 - 28 STEERING REMOVAL AND INSTALLATION (Continued) (4) Install column harness and connect harness to switches. NOTE: If vehicle is equipped with automatic trans- mission install shifter interlock cable. Refer to Group 21 Transmission and Transfer Case for installation and adjustment. (5) Install upper column shrouds.
Page 909 TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page page AX5 MANUAL TRANSMISSION ....1 AW–4 AUTOMATIC TRANSMISSION ..217 NV3550 MANUAL TRANSMISSION .
Page 910: Ax5 Manual Transmission
21 - 2 AX5 MANUAL TRANSMISSION DESCRIPTION AND OPERATION (Continued) Fig. 1 AX5 Manual Transmission nents to begin the shift sequence. As the shift lever moves the selected shift rail, the shift fork attached to that rail begins to move. The fork is positioned in a groove in the outer circumference of the synchro- nizer sleeve.
Page 911: Diagnosis And Testing
AX5 MANUAL TRANSMISSION 21 - 3 DESCRIPTION AND OPERATION (Continued) Approximate dry fill lubricant capacity is: HARD SHIFTING • 3.3 liters (3.49 quarts) for 4–wheel drive applica- Hard shifting is usually caused by a low lubricant tions. level, improper, or contaminated lubricants. The con- •...
Page 912 21 - 4 AX5 MANUAL TRANSMISSION REMOVAL AND INSTALLATION (Continued) (16) Disconnect transfer case shift linkage at transfer case, if equipped. (17) Remove nuts attaching transfer case to trans- mission, if equipped. (18) Remove transfer case, if equipped. (19) Remove crankshaft position sensor (Fig. 6). Fig.
Page 913 AX5 MANUAL TRANSMISSION 21 - 5 REMOVAL AND INSTALLATION (Continued) sole shifter boots. Leave the lever in place for transmission installation. Fig. 7 Removing/Installing Shift Lever 1 – SHIFT LEVER RETAINER 2 – DUST BOOT 3 – SHIFT TOWER (26) Remove clutch housing brace rod. (27) Remove clutch housing-to-engine bolts.
Page 914: Front Bearing Retainer Seal
21 - 6 AX5 MANUAL TRANSMISSION REMOVAL AND INSTALLATION (Continued) (18) Slide transfer case forward until case is FRONT BEARING RETAINER SEAL seated on transmission, if necessary. (19) Install nuts to attach transfer case to trans- REMOVAL mission, if equipped. Tighten transfer case-to-trans- (1) Remove release bearing and lever from the mission nuts to 35 N·m (26 ft.
Page 915: Extension Housing Seal
AX5 MANUAL TRANSMISSION 21 - 7 REMOVAL AND INSTALLATION (Continued) EXTENSION HOUSING SEAL REMOVAL (1) Raise and support vehicle. (2) Remove propeller shaft. Refer to Group 3, Dif- ferential and Driveline, for proper procedures. (3) Using a suitable seal puller or screw with a slide hammer, remove the extension housing seal (Fig.
Page 916: Disassembly And Assembly
21 - 8 AX5 MANUAL TRANSMISSION REMOVAL AND INSTALLATION (Continued) Fig. 15 Remove Shift Tower 1 – SHIFT TOWER 2 – ADAPTER/EXTENSION HOUSING Fig. 14 Install Adapter Housing Seal 1 – SPECIAL TOOL 8208 2 – ADAPTER HOUSING 3 – SPECIAL TOOL C-4171 DISASSEMBLY AND ASSEMBLY ADAPTER/EXTENSION HOUSING AND FRONT BEARING RETAINER...
Page 917 AX5 MANUAL TRANSMISSION 21 - 9 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 19 Remove Detent Spring 1 – PENCIL MAGNET 2 – DETENT BALL SPRING Fig. 17 Clutch Housing 1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.) 2 – CLUTCH HOUSING 3 –...
Page 918 21 - 10 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (10) Remove shift arm retainer bolt (Fig. 21). (11) Remove shift arm restrictor pins (Fig. 22). NOTE: The restrictor pins are not interchangeable and are color coded. Note which color restrictor pin is removed from each side of the transmission and be sure to install it into the same location.
Page 919: Front Bearing Retainer
AX5 MANUAL TRANSMISSION 21 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (17) Remove adapter/extension housing (Fig. 26). Fig. 27 Speedometer Drive Gear Assembly 1 – SNAP RING 2 – LOCK BALL Fig. 25 Loosen Adapter/Extension Housing 3 – SNAP RING 1 – INTERMEDIATE PLATE 4 –...
Page 920 21 - 12 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 31 Remove Intermediate Plate from Fig. 29 Remove Input Shaft Bearing Snap-ring Transmission Case 1 – SNAP RING PLIERS 1 – GEAR CASE 2 – INPUT SHAFT 2 – INTERMEDIATE PLATE 3 –...
Page 921 AX5 MANUAL TRANSMISSION 21 - 13 DISASSEMBLY AND ASSEMBLY (Continued) (5) Install front bearing retainer gasket to front bearing retainer. (6) Install the front bearing retainer (Fig. 35) and tighten bolts to 17 N·m (12 ft. lbs.). Fig. 33 Install Transmission Gear Case to the Intermediate Plate 1 –...
Page 922 21 - 14 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 36 Speedometer Drive Gear Assembly Fig. 38 Position Shift Arm in Adapter or Extension 1 – SNAP RING Housing 2 – LOCK BALL 1 – SHIFT ARM 3 – SNAP RING 4 –...
Page 923 AX5 MANUAL TRANSMISSION 21 - 15 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: The restrictor pins are not interchangeable and are color coded. Be sure to install the pin into the same location from which it was removed. Fig. 40 Install Shift Arm Retainer Bolt 1 –...
Page 924 21 - 16 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 46 Install Shift Tower 1 – SHIFT TOWER 2 – ADAPTER/EXTENSION HOUSING Fig. 44 Install Detent Spring 1 – PENCIL MAGNET (23) Install new metal o-ring onto the backup lamp 2 –...
Page 925: Shift Mechanism And Geartrain
AX5 MANUAL TRANSMISSION 21 - 17 DISASSEMBLY AND ASSEMBLY (Continued) SHIFT MECHANISM AND GEARTRAIN DISASSEMBLY (1) Install suitable bolts and washers in intermedi- ate plate (Fig. 48). Then clamp plate and gear assem- bly in vise. Use enough washers to prevent bolts from touching.
Page 926 21 - 18 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (4) Remove fifth gear blocker ring from counter- shaft assembly with Puller L-4407 (Fig. 51). Fig. 53 Remove Fifth Gear and Synchro Assembly 1 – FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY 2 –...
Page 927 AX5 MANUAL TRANSMISSION 21 - 19 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 57 Remove Output Shaft Rear Bearing Retainer Fig. 55 Remove Fifth Gear Thrust Ring Lock Ball 1 – OUTPUT SHAFT REAR BEARING RETAINER 1 – PENCIL MAGNET 2 – CLUSTER GEAR 3 –...
Page 928 21 - 20 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) from the intermediate plate. The countershaft will release from the countershaft bearing first and can be removed by moving the countershaft rearward and downward (Fig. 61). (17) Remove the mainshaft by moving the main- shaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks (Fig.
Page 929 AX5 MANUAL TRANSMISSION 21 - 21 DISASSEMBLY AND ASSEMBLY (Continued) (20) Remove the 1–2 shift fork from the 1–2 and (21) Remove threaded plugs from intermediate the 3–4 shift rails (Fig. 64). plate. Then remove lock ball and spring from plug holes with pencil magnet (Fig.
Page 930 21 - 22 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (23) Remove fifth gear shift rail (Fig. 66). Fig. 68 Remove Reverse Shift Head And Rail Fig. 66 Remove Fifth Gear Shift Rail Assembly 1 – INTERMEDIATE PLATE 1 – REVERSE SHIFT HEAD AND RAIL ASSEMBLY 2 –...
Page 931 AX5 MANUAL TRANSMISSION 21 - 23 DISASSEMBLY AND ASSEMBLY (Continued) (28) Remove interlock pin from reverse shift rail (30) Remove snap-ring on 3–4 shift rail. (Fig. 70). (31) Remove 1–2 shift rail from intermediate plate. (32) Remove interlock pin from 1–2 shift rail (Fig. 72).
Page 932 21 - 24 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 74 Shift Rail Components 1 – 3–4 FORK 5 – FIFTH GEAR FORK 2 – 3–4 SHIFT RAIL 6 – FIFTH GEAR SHIFT RAIL 3 – 1–2 FORK 7 – 1–2 SHIFT RAIL 4 –...
Page 933 AX5 MANUAL TRANSMISSION 21 - 25 DISASSEMBLY AND ASSEMBLY (Continued) (7) Install the interlock pin into the reverse shift rail (Fig. 78). (8) Assemble the reverse arm bracket to the reverse fork (Fig. 79). Fig. 76 Install 1–2 Shift Rail Interlock Pin 1 –...
Page 934 21 - 26 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 82 Install Fifth Gear Check Ball Fig. 80 Install Reverse Shift Rail 1 – FIFTH GEAR CHECK BALL 1 – REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY (13) Install fifth gear shift rail (Fig. 83). (10) Install snap-ring onto reverse shift rail (Fig.
Page 935 AX5 MANUAL TRANSMISSION 21 - 27 DISASSEMBLY AND ASSEMBLY (Continued) (16) Install the shift rail detent springs in the (21) Install mainshaft into the intermediate plate intermediate plate. Note that the bottom detent by guiding the output shaft through opening in inter- spring is shorter than the others.
Page 936 21 - 28 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (32) Install the compression spring and pin into the reverse idler gear shaft (Fig. 88). (33) Install the reverse idler shaft through the intermediate plate and reverse idler gear assembly (Fig.
Page 937 AX5 MANUAL TRANSMISSION 21 - 29 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 91 Depress Pin In Reverse Idler Gear Shaft Fig. 93 Install Fifth Gear Thrust Ring 1 – LOCK BALL NOTCH 1 – DEPRESS PIN 2 – FIFTH GEAR THRUST RING (37) Position the reverse idler gear shaft lock plate (44) Install the fifth gear synchro ring.
Page 938 21 - 30 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (51) Remove intermediate plate from vise and remove bolts and washers from intermediate. COUNTERSHAFT DISASSEMBLY (1) Remove select fit snap-ring holding the coun- tershaft front bearing onto the countershaft (Fig. 95). (2) Using Bearing Splitter P-334, a suitable spacer on center of countershaft, and a shop press, remove the countershaft front bearing from the countershaft.
Page 939 AX5 MANUAL TRANSMISSION 21 - 31 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 99 Install Output Shaft Pilot Bearing Rollers 1 – INPUT SHAFT 2 – BEARING ROLLERS (6) Install the fourth gear synchronizer ring onto the input shaft. (7) Install input shaft to output shaft. Use care when mating the two shafts not to displace any out- put shaft pilot bearing rollers.
Page 940 21 - 32 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (3) Remove output shaft fifth gear snap ring with two screwdrivers (Fig. 101). Fig. 102 Remove Fifth Gear, First Gear Bearing, And Race 1 – PRESS RAM Fig. 101 Remove Fifth Gear Snap-ring 2 –...
Page 941 AX5 MANUAL TRANSMISSION 21 - 33 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 106 Remove 3–4 Synchronizer And Third Gear Fig. 104 Remove Second Gear, Reverse Gear, And 1 – 3–4 SYNCHRONIZER 1–2 Synchronizer 2 – THIRD GEAR 1 – PRESS RAM 2 –...
Page 942 21 - 34 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 107 Geartrain Components Fig. 108 Synchronizer Identification 1 – SNAP RING 1 – SLEEVES 2 – FIFTH GEAR 2 – HUBS 3 – COUNTER GEAR 4 – BEARING 5 – LOCK BALL 6 –...
Page 943 AX5 MANUAL TRANSMISSION 21 - 35 DISASSEMBLY AND ASSEMBLY (Continued) (23) Install snap-ring onto output shaft rear bear- ing outer race. Fig. 110 Check Third Gear Clearance 1 – FEELER GAUGE 2 – THIRD GEAR Fig. 112 First Gear Components 1 –...
Page 944: Semi-Synchronized Reverse Idler Gear
21 - 36 AX5 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (28) Install snap-ring to hold fifth gear onto output shaft. SEMI-SYNCHRONIZED REVERSE IDLER GEAR DISASSEMBLY (1) Remove snap-ring holding the reverse idler gear onto the reverse idler gear hub/race (Fig. 115). (2) Remove the plate washer from the reverse idler gear hub/race (Fig.
Page 945: Cleaning And Inspection
AX5 MANUAL TRANSMISSION 21 - 37 DISASSEMBLY AND ASSEMBLY (Continued) CLEANING AND INSPECTION AX5 MANUAL TRANSMISSION COMPONENTS GENERAL INFORMATION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air. Dry the bearings with clean, dry shop towels only.
Page 946 21 - 38 AX5 MANUAL TRANSMISSION CLEANING AND INSPECTION (Continued) COUNTERSHAFT Inspect the countershaft gear teeth. Replace the countershaft if any teeth are worn or damaged. Inspect the bearing surfaces and replace shaft if any surface shows damage or wear. Check condition of the countershaft front bearing.
Page 947: Specifications
AX5 MANUAL TRANSMISSION 21 - 39 CLEANING AND INSPECTION (Continued) Fig. 122 Check Gear–To–Shaft Oil Clearance Fig. 124 Check Fork–To–Hub Clearance 1 – GEAR BEING CHECKED 1 – SHIFT FORK 2 – OUTPUT SHAFT 2 – FEELER GAUGE 3 – SYNCHRONIZER SLEEVE SPECIFICATIONS TORQUE DESCRIPTION...
Page 948: Special Tools
21 - 40 AX5 MANUAL TRANSMISSION SPECIAL TOOLS 8212 Installer, Seal C-3339 Dial Indicator Set 8208 Installer, Seal C-3995-A Installer, Extension Housing Seal P-334 Splitter, Bearing C-4171 Handle, Universal Tool 8109 Cup, Installer 8211 Installer, Seal L-4507 Tube, Driver...
Page 949 AX5 MANUAL TRANSMISSION 21 - 41 SPECIAL TOOLS (Continued) 6747–1A Adapter, Fixture MD-998805 Installer, Seal...
Page 950 21 - 42 NV3550 MANUAL TRANSMISSION NV3550 MANUAL TRANSMISSION TABLE OF CONTENTS page page GENERAL INFORMATION YOKE SEAL—2WD ..... . . 47 NV3550 MANUAL TRANSMISSION.
Page 951: General Information
NV3550 MANUAL TRANSMISSION 21 - 43 GENERAL INFORMATION (Continued) Fig. 1 NV3550 Shift Mechanism 1 – 3-4 FORK 7 – ROLL PIN 2 – SHIFT SHAFT LEVER AND BUSHING 8 – SHIFT LEVER SOCKET 3 – 1-2 FORK 9 – SHAFT RAIL DETENTS 4 –...
Page 952: Diagnosis And Testing
21 - 44 NV3550 MANUAL TRANSMISSION GENERAL INFORMATION (Continued) A correct lubricant level check can only be made when the vehicle is level; use a drive–on hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These recommenda- tions will ensure an accurate check and avoid an under-or-overfill condition.
Page 953 NV3550 MANUAL TRANSMISSION 21 - 45 REMOVAL AND INSTALLATION (Continued) (3) Install nuts on two M6X1.0 bolts and thread the bolts into the threaded holes at the base of the shift lever. (4) Tighten the nuts equally until the shift lever loosens on the shift tower stub shaft.
Page 954 21 - 46 NV3550 MANUAL TRANSMISSION REMOVAL AND INSTALLATION (Continued) (24) Support engine with adjustable jack stand. (5) Lightly lubricate pilot bearing and transmis- Position wood block between jack and oil pan to sion input shaft splines with Mopar high temp avoid damaging pan.
Page 955: Shift Tower
NV3550 MANUAL TRANSMISSION 21 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 9 Remove Shift Tower Fig. 8 Align Propeller Shaft And Rear Axle Yokes 1 – SHIFT TOWER AND LEVER ASSEMBLY Alignment Marks 2 – SHIFT SOCKET 1 – REFERENCE MARKS 3 –...
Page 956: Rear Housing Yoke Bushing
21 - 48 NV3550 MANUAL TRANSMISSION REMOVAL AND INSTALLATION (Continued) (3) Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. (4) Align marks made at removal and connect pro- peller shaft to rear axle pinion yoke. Fig.
Page 957 NV3550 MANUAL TRANSMISSION 21 - 49 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 15 Shift Tower Removal Fig. 17 Detent Plunger And Spring Removal 1 – SHIFT TOWER AND LEVER ASSEMBLY 1 – FRONT HOUSING 2 – SHIFT SOCKET 2 – PLUG 3 –...
Page 958 21 - 50 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (10) Remove input shaft bearing retainer. Use pry tool to carefully lift retainer and break sealer bead (Fig. 19). Fig. 21 Input Shaft Snap Ring Removal—Typical 1 – INPUT SHAFT SNAP RING 2 –...
Page 959 NV3550 MANUAL TRANSMISSION 21 - 51 DISASSEMBLY AND ASSEMBLY (Continued) (14) Separate front housing from rear housing (Fig. 23). Use plastic mallet to tap front housing off alignment dowels. Fig. 23 Front Housing Removal Fig. 25 Geartrain And Shift Component 1 –...
Page 960 21 - 52 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 28 Shift Shaft Removal Fig. 26 Removing the Shift Socket Roll Pin 1 – SHIFT SHAFT 1 – SPECIAL TOOL 2 – 3–4 FORK 6858 3 – SHAFT DETENT NOTCHES 2 –...
Page 961 NV3550 MANUAL TRANSMISSION 21 - 53 DISASSEMBLY AND ASSEMBLY (Continued) place while housing and geartrain is being rotated into upright position. Fig. 31 Removing 3-4 Shift Fork 1 – 3–4 FORK 2 – 1–2 AND 5TH-REVERSE FORK ARMS 3 – 3–4 SYNCHRO SLEEVE Fig.
Page 962 21 - 54 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) REAR HOUSING REMOVAL—2WD (1) On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (Fig. 35). Bolts are rear of shift tower open- ing. Fig.
Page 963 NV3550 MANUAL TRANSMISSION 21 - 55 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 39 Location Of Dimples In Seal Face—4WD 1 – LOCATION OF DIMPLES 2 – SEAL FACE Fig. 37 Rear Housing Removal—2WD 1 – REAR HOUSING 2 – SHIFT FORKS AND GEARTRAIN Fig.
Page 964 21 - 56 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 41 Rear Bearing Snap Ring Removal—4WD 1 – HEAVY DUTY SNAP RING PLIERS 2 – REAR BEARING SNAP RING 3 – OUTPUT SHAFT Fig. 43 Rear Adapter Housing Components 1 –...
Page 965 NV3550 MANUAL TRANSMISSION 21 - 57 DISASSEMBLY AND ASSEMBLY (Continued) OUTPUT SHAFT (5) Remove two-piece thrust washer (Fig. 46). Note position of washer locating lugs in shaft notches for NOTE: The synchronizer hubs and sleeves are dif- installation reference. ferent and must not be intermixed. It is recom- mended that each synchronizer unit be removed as an assembly to avoid intermixing parts.
Page 966 21 - 58 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 50 First Gear Needle Bearing Removal 1 – FIRST GEAR NEEDLE BEARING Fig. 48 Second Gear Synchro Ring And Cones Removal 1 – 1–2 SYNCHRO HUB AND SLEEVE 2 – INTERM RING 3 –...
Page 967 NV3550 MANUAL TRANSMISSION 21 - 59 DISASSEMBLY AND ASSEMBLY (Continued) (15) Remove fifth gear needle bearing. Spread bearing apart just enough to clear shoulder on output shaft (Fig. 53). Fig. 53 Fifth Gear Needle Bearing Removal 1 – FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO CLEAR SHOULDER ON SHAFT) (16) Remove fifth-reverse synchro hub snap ring (Fig.
Page 968 21 - 60 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 57 Reverse Idler Components 1 – SNAP RING 6 – IDLER GEAR BEARING 2 – FLAT WASHER 7 – IDLER SHAFT 3 – WAVE WASHER 8 – THRUST WASHER 4 –...
Page 969 NV3550 MANUAL TRANSMISSION 21 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 59 Reverse Gear Bearing Installation 1 – REVERSE GEAR BEARING 2 – SHOULDER Fig. 58 Assembled View Of Synchro Components 1 – SLEEVE 2 – HUB SHOULDER 3 – SPRING (3) 4 –...
Page 970 21 - 62 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (7) Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done. CAUTION: The fifth-reverse synchro sleeve can be installed backwards if care is not exercised. One side of the hub has shoulders around the hub bore.
Page 971 NV3550 MANUAL TRANSMISSION 21 - 63 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 65 Installing Fifth Gear Bearing 1 – SHAFT SHOULDER 2 – FIFTH GEAR BEARING Fig. 67 First Gear Bearing Installation 1 – FIRST GEAR BEARING 2 – SHAFT SHOULDER 3 –...
Page 972 21 - 64 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (16) Install first gear synchro ring (Fig. 69). (19) Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 71). CAUTION: Take time to align the synchro ring and sleeve as hub the is being pressed onto the shaft.
Page 973 NV3550 MANUAL TRANSMISSION 21 - 65 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 72 Installing 1-2 Synchro Hub Snap Ring Fig. 74 Second Gear Bearing Installation 1 – 1–2 SYNCHRO 1 – SECOND GEAR BEARING 2 – SPECIAL TOOL 2 – SPECIAL TOOL 6310–1 6310–1 3 –...
Page 974 21 - 66 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (26) Install two-piece thrust washer (Fig. 76). Be sure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. Also, ensure that the i.d. grooves and markings noted dur- ing removal are facing the correct direction.
Page 975 NV3550 MANUAL TRANSMISSION 21 - 67 DISASSEMBLY AND ASSEMBLY (Continued) (29) Install third gear needle bearing on shaft (Fig. 79). Fig. 81 Third Speed Synchro Ring Installation 1 – THIRD SPEED SYNCHRO RING 2 – THIRD GEAR Fig. 79 Third Gear Bearing Installation (33) Start 3-4 synchro hub on output shaft splines 1 –...
Page 976 21 - 68 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (36) Install output shaft bearing. (37) Install output shaft bearing snap ring (Fig. 85). Use heavy duty snap ring pliers and spread snap ring only enough to install it. Be sure snap ring is completely seated in shaft groove before proceeding.
Page 977 NV3550 MANUAL TRANSMISSION 21 - 69 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 86 Correct Synchro Sleeve Position 1 – DOUBLE GROOVE FORWARD 5 – GROOVE FORWARD 2 – GROOVE FORWARD 6 – 5TH-REV SYNCHRO SLEEVE 3 – FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 7 –...
Page 978 21 - 70 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (c) Attach a slide hammer or suitable puller to the bolt and remove the bearing. (d) Use the short end of Installer 8119 to install the new bearing. (e) The bearing is correctly installed if the bear- ing is flush with the transmission case.
Page 979 NV3550 MANUAL TRANSMISSION 21 - 71 DISASSEMBLY AND ASSEMBLY (Continued) (4) Install fourth gear synchro ring on input shaft (Fig. 92). Fig. 92 Installing Fourth Gear Synchro Ring On Input Shaft 1 – FOURTH GEAR SYNCHRO RING 2 – INPUT SHAFT Fig.
Page 980 21 - 72 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (9) Check alignment of countershaft and output shaft gear teeth. Note that gears may not align per- fectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This difference will not interfere with assembly.
Page 981 NV3550 MANUAL TRANSMISSION 21 - 73 DISASSEMBLY AND ASSEMBLY (Continued) (10) Position reverse idler in support cup of assem- bly fixture (Fig. 96). Be sure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain. Adjust pedestal up or down if necessary.
Page 982 21 - 74 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (13) Install assembled shift forks in synchro (2) Apply liberal quantity of petroleum jelly to sleeves (Fig. 99). Be sure forks are properly seated in countershaft rear bearing and bearing race. sleeves.
Page 983 NV3550 MANUAL TRANSMISSION 21 - 75 DISASSEMBLY AND ASSEMBLY (Continued) (9) Install the three bolts that secure rear bearing retainer to rear housing as follows: (a) Apply Mopar Gasket Maker, or equivalent, to bolt threads, bolt shanks and under bolt heads (Fig.
Page 984 21 - 76 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) ADAPTER HOUSING—4WD (9) Install rear bearing snap ring on output shaft (Fig. 107). (1) Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place.
Page 985 NV3550 MANUAL TRANSMISSION 21 - 77 DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: The transmission synchros must all be (4) Assemble shift shaft shift lever and bushing in Neutral position for proper reassembly. Other- (Fig. 111). Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft.
Page 986 21 - 78 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 115 Roll Pin Identification—Shaft Lever And Shift Socket 1 – SHAFT LEVER ROLL PIN 2 – SHIFT SOCKET ROLL PIN (10) Align roll pin holes in shift shaft, lever and Fig.
Page 987 NV3550 MANUAL TRANSMISSION 21 - 79 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 117 Correct Seating Of Shift Shaft Lever Roll 1 – BUSHING LOCK PIN SLOT 2 – SEAT ROLL PIN FLUSH WITH LEVER Fig. 119 Seating Shift Socket Roll Pin 1 –...
Page 988 21 - 80 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) (2) Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (Fig. 120). Large diameter side of bearing cage goes toward countershaft (Fig. 121). Small diameter side goes toward bearing race in housing.
Page 989 NV3550 MANUAL TRANSMISSION 21 - 81 DISASSEMBLY AND ASSEMBLY (Continued) (12) Install shift shaft bushing lock bolt (Fig. 124). (14) Install detent spring inside plunger (Fig. 125). Apply Mopar Gasket Maker, or equivalent, to bolt (15) Install detent plug as follows: threads, shank and underside of bolt head before (a) Install detent plug in end of Installer 8123.
Page 990 21 - 82 NV3550 MANUAL TRANSMISSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 128 Installing Oil Seal In Front Bearing Retainer Fig. 130 Installing Input Shaft Bearing Retainer— 1 – SPECIAL TOOL Typical 6448 1 – INPUT SHAFT 2 – FRONT BEARING RETAINER 2 –...
Page 991: Cleaning And Inspection
NV3550 MANUAL TRANSMISSION 21 - 83 DISASSEMBLY AND ASSEMBLY (Continued) (4) Install shift tower bolts (Fig. 133). Tighten CLEANING AND INSPECTION bolts to 8.5 N·m (75.2 in. lbs.) torque. TRANSMISSION COMPONENTS Clean the gears, shafts, shift components and transmission housings with a standard parts clean- ing solvent.
Page 992 21 - 84 NV3550 MANUAL TRANSMISSION CLEANING AND INSPECTION (Continued) Fig. 134 Shift Forks And Shaft 1 – SHIFT SHAFT 4 – 3-4 SHIFT FORK 2 – SHAFT LEVER 5 – 1-2 SHIFT FORK 3 – SHAFT LEVER BUSHING 6 – FIFTH-REVERSE SHIFT FORK NOTE: The front housing contains the countershaft ing race becomes damaged, it will be necessary to front bearing race.
Page 993: Specifications
NV3550 MANUAL TRANSMISSION 21 - 85 CLEANING AND INSPECTION (Continued) SPECIFICATIONS TORQUE Description Torque Clutch Housing Bolts . . . 54–61 N·m (40–45 ft. lbs.) Crossmember-To-Frame Bolts ..61–75 N·m (44–55 ft. lbs.) Crossmember-To-Insulator Nuts .
Page 994 21 - 86 NV3550 MANUAL TRANSMISSION SPECIAL TOOLS (Continued) Remover, Bushing—6957 Remover/Installer, NV3550 Shift Rail Roll Pin—6858 Installer, Bushing—6951 Fixture, NV3550—6747 Adapter, Fixture—6747-1A Handle—C-4171 Adapter, Fixture—6747-2A Remover—8117 Cup, Fixture—8115...
Page 995 NV3550 MANUAL TRANSMISSION 21 - 87 SPECIAL TOOLS (Continued) Stud, Alignment—8120 Splitter, Bearing—1130 Tube—6310-1 Installer, Seal—C-3860-A Installer—8118 Installer—8123 Remover/Installer—8119 Installer, Bearing Cone—6448...
Page 996 21 - 88 AUTOMATIC TRANSMISSION—30RH AUTOMATIC TRANSMISSION—30RH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ADAPTER HOUSING ..... 147 30RH AUTOMATIC TRANSMISSION... 89 SPEEDOMETER ADAPTER .
Page 997: Description And Operation
AUTOMATIC TRANSMISSION—30RH 21 - 89 DESCRIPTION AND OPERATION 30RH AUTOMATIC TRANSMISSION DESCRIPTION The 30RH automatic transmission is used with the 2.5L engine (Fig. 1). The 30RH is three speed trans- missions with a lock-up clutch in the torque con- verter. The transmissions contain a front and rear clutch which function as the input driving compo- nents.
Page 998 21 - 90 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 1 30RH Automatic Transmission...
Page 999 AUTOMATIC TRANSMISSION—30RH 21 - 91 DESCRIPTION AND OPERATION (Continued) TRANSMISSION IDENTIFICATION OPERATION Transmission identification numbers are stamped The application of each driving or holding compo- on the left side of the case just above the oil pan gas- nent is controlled by the valve body based upon the ket surface (Fig.
Page 1000 21 - 92 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) PARK POWERFLOW NEUTRAL POWERFLOW As the engine is running and the crankshaft is With the gear selector in the neutral position (Fig. rotating, the flexplate and torque converter, which 4), the power flow of the transmission is essentially are also bolted to it, are all rotating in a clockwise the same as in the park position.
Page 1001 AUTOMATIC TRANSMISSION—30RH 21 - 93 DESCRIPTION AND OPERATION (Continued) REVERSE POWERFLOW When the gear selector is moved into the reverse position (Fig. 5), the front clutch and the rear band are applied. With the application of the front clutch, engine torque is applied to the sun gear, turning it in a clockwise direction.
Page 1002 21 - 94 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) FIRST GEAR POWERFLOW When the gearshift lever is moved into the drive position the transmission goes into first gear (Fig. 6). As soon as the transmission is shifted from park or neutral to drive, the rear clutch applies, applying the rear clutch pack to the front annulus gear.
Page 1003 AUTOMATIC TRANSMISSION—30RH 21 - 95 DESCRIPTION AND OPERATION (Continued) SECOND GEAR POWERFLOW In drive–second (Fig. 7), the same elements are applied as in manual–second. Therefore, the power flow will be the same, and both gears will be discussed as one in the same. In drive–second, the transmission has proceeded from first gear to its shift point, and is shift- ing from first gear to second.
Page 1004: Fluid
21 - 96 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) DIRECT DRIVE POWERFLOW FLUID The vehicle has accelerated and reached the shift NOTE: Refer to the maintenance schedules in point for the 2–3 upshift into direct drive (Fig. 8). Group 0, Lubrication and Maintenance for the rec- When the shift takes place, the front band is released, and the front clutch is applied.
Page 1005: Torque Converter
AUTOMATIC TRANSMISSION—30RH 21 - 97 DESCRIPTION AND OPERATION (Continued) fluid condition. As the vehicle is driven, the ATF will TORQUE CONVERTER begin to look darker in color and may eventually become brown. This is normal. A dark brown/black DESCRIPTION fluid accompanied with a burnt odor and/or deterio- The torque converter (Fig.
Page 1006 21 - 98 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) IMPELLER TURBINE The impeller (Fig. 10) is an integral part of the The turbine (Fig. 11) is the output, or driven, mem- converter housing. The impeller consists of curved ber of the converter. The turbine is mounted within blades placed radially along the inside of the housing the housing opposite the impeller, but is not attached on the transmission side of the converter.
Page 1007 AUTOMATIC TRANSMISSION—30RH 21 - 99 DESCRIPTION AND OPERATION (Continued) Fig. 11 Turbine 1 – TURBINE VANE 4 – PORTION OF TORQUE CONVERTER COVER 2 – ENGINE ROTATION 5 – ENGINE ROTATION 3 – INPUT SHAFT 6 – OIL FLOW WITHIN TURBINE SECTION STATOR The stator assembly (Fig.
Page 1008 21 - 100 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 14 Torque Converter Clutch (TCC) Fig. 13 Stator Location 1 – IMPELLER FRONT COVER 1 – STATOR 2 – THRUST WASHER ASSEMBLY 2 – IMPELLER 3 – IMPELLER 3 – FLUID FLOW 4 –...
Page 1009: Oil Pump
AUTOMATIC TRANSMISSION—30RH 21 - 101 DESCRIPTION AND OPERATION (Continued) Fig. 15 Torque Converter Fluid Operation 1 – APPLY PRESSURE 3 – RELEASE PRESSURE 2 – THE PISTON MOVES SLIGHTLY FORWARD 4 – THE PISTON MOVES SLIGHTLY REARWARD is a direct 1:1 mechanical link between the engine and the transmission.
Page 1010: Valve Body
21 - 102 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches.
Page 1011 AUTOMATIC TRANSMISSION—30RH 21 - 103 DESCRIPTION AND OPERATION (Continued) Fig. 18 Valve Body Assembly 1 – GOVERNOR PLUG END PLATE 11 – KICKDOWN LIMIT VALVE 2 – SHUTTLE VALVE 12 – END PLATE 3 – 1–2 GOVERNOR PLUG 13 – THROTTLE PRESSURE PLUG 4 –...
Page 1012 21 - 104 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Meanwhile, the torque converter is filled slowly. In all other gear positions (Fig. 21), fluid flows between two right side lands to the switch valve and torque converter. At low pump speeds, the flow is controlled by the pressure valve groove to reduce pressure to the torque converter.
Page 1013 AUTOMATIC TRANSMISSION—30RH 21 - 105 DESCRIPTION AND OPERATION (Continued) Fig. 21 Regulator Valve in Neutral Position 1 – MANUAL VALVE 4 – REGULATOR VALVE 2 – TO SHIFT VALVE 5 – THROTTLE PRESSURE PLUG 3 – FROM THROTTLE VALVE The metering at land #2 establishes the line pres- sure throughout the transmission.
Page 1014 21 - 106 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 22 Regulator Valve in Drive Position Fig. 23 Regulator Valve in Reverse Position...
Page 1015 AUTOMATIC TRANSMISSION—30RH 21 - 107 DESCRIPTION AND OPERATION (Continued) Fig. 24 Kickdown Valve 1 – GOVERNOR PLUG 6 – THROTTLE VALVE 2 – 2-3 SHIFT VALVE 7 – MANUAL VALVE 3 – KICKDOWN VALVE 8 – 1-2 SHIFT VALVE 4 – THROTTLE VALVE 9 –...
Page 1016 21 - 108 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 25 Kickdown Limit Valve-Low Speeds Fig. 26 Kickdown Limit Valve-High Speeds 1 – GOVERNOR PRESSURE CLOSES LIMIT VALVE 4 – 2-3 SHIFT VALVE 2 – THROTTLE PRESSURE 5 – GOVERNOR PLUG 3 –...
Page 1017 AUTOMATIC TRANSMISSION—30RH 21 - 109 DESCRIPTION AND OPERATION (Continued) Fig. 27 1–2 Shift Valve-Before Shift 1 – TO FRONT SERVO AND 2-3 SHIFT VALVE 3 – LINE PRESSURE 2 – THROTTLE PRESSURE 4 – LINE PRESSURE PASSAGE FOR MANUAL LOW POSITION 1–2 SHIFT VALVE The 1–2 shift valve assembly (Fig.
Page 1018 21 - 110 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 28 1–2 Shift Valve-After Shift 1 – TO FRONT SERVO AND 2-3 SHIFT VALVE 3 – LINE PRESSURE 2 – THROTTLE PRESSURE 4 – LINE PRESSURE PASSAGE FOR MANUAL LOW POSITION When governor pressure builds to a point where it plate overcoming governor pressure.
Page 1019 AUTOMATIC TRANSMISSION—30RH 21 - 111 DESCRIPTION AND OPERATION (Continued) shift control valve. This additional pressure is fluid discharge from the front clutch and servo directed to the 1–2 shift control’s spring cavity, add- release circuits. During a 3–2 kickdown, fluid dis- ing to the spring load on the valve.
Page 1020 21 - 112 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) 2–3 valve is ready to make its shift. Now that the of the 2–3 governor plug. This line pressure at the vehicle is in motion and under acceleration, there is governor plug locks the shift valve into the second throttle pressure being applied to the spring side of gear position, preventing an upshift into direct drive.
Page 1021 AUTOMATIC TRANSMISSION—30RH 21 - 113 DESCRIPTION AND OPERATION (Continued) Fig. 31 2–3 Shift Valve-After Shift Fig. 32 Throttle Valve...
Page 1022 21 - 114 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) The higher engine speed and line pressure would pressure to the switch valve. The switch valve directs open the vent too far and reduce line pressure too this pressure through the transmission input shaft, much.
Page 1023 AUTOMATIC TRANSMISSION—30RH 21 - 115 DESCRIPTION AND OPERATION (Continued) Fig. 33 Switch Valve-Torque Converter Unlocked...
Page 1024 21 - 116 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 34 Switch Valve-Torque Converter Locked...
Page 1025: Accumulator
AUTOMATIC TRANSMISSION—30RH 21 - 117 DESCRIPTION AND OPERATION (Continued) MANUAL VALVE The manual valve (Fig. 35) is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range.
Page 1026: Pistons
21 - 118 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) NOTE: The accumulator is shown in the inverted PISTONS position for illustrative purposes. DESCRIPTION There are several sizes and types of pistons used in an automatic transmission. Some pistons are used to apply clutches, while others are used to apply bands.
Page 1027 AUTOMATIC TRANSMISSION—30RH 21 - 119 DESCRIPTION AND OPERATION (Continued) pressure will be created if the fluid is not confined. It using a difference of area to create a difference in will simply “leak” past the piston. There must be a pressure to move an object.

Jeep cherokee 2000 Service Manual

Group Tab Locator

Front Suspension

Description and Operation

Diagnosis and Testing Shock Diagnosis

Description and Operation

Removal and Installation Shock Absorber

Specifications

Special Tools

Rear Suspension

Diagnosis and Testing

Removal and Installation Shock Absorber

Description and Operation

Specifications

Differential and Driveline

Description and Operation

Propeller Shafts

Diagnosis and Testing Vibration

Service Procedures Driveline Angle Measurement Preparation

Removal and Installation

Disassembly and Assembly

Cleaning and Inspection

Special Tools Propeller Shaft

Specifications

Adjustments

Tube, 181, and 186 Fbi Axle

Description and Operation

Diagnosis and Testing General Information

Service Procedures Lubricant Change

Removal and Installation

Disassembly and Assembly

Cleaning and Inspection

Adjustments

Special Tools

Specifications

194 Rbi Axle

Description and Operation

Diagnosis and Testing General Information

Service Procedures Lubricant Change

Removal and Installation Rear Axle

Disassembly and Assembly Standard Differential

Cleaning and Inspection Axle Components

Adjustments

Specifications

8 1/4 Rear Axle

Description and Operation

Diagnosis and Testing General Information

Service Procedures Lubricant Change

Removal and Installation Rear Axle

Disassembly and Assembly Standard Differential

Cleaning and Inspection

Adjustments

Special Tools

Specifications

Brakes

Description and Operation Brake System

Diagnosis and Testing Base Brake System

Service Procedures

Removal and Installation Brake Lamp Switch

Disassembly and Assembly

Cleaning and Inspection Caliper

Adjustments Brake Lamp Switch

Specifications Brake Fluid

Special Tools

Antilock Brakes

Description and Operation

Removal and Installation Hydraulic Control Unit/Controller Antilock Brakes

Service Procedures

Diagnosis and Testing Antilock Brakes

Disassembly and Assembly Hydraulic Control Unit/Controller Antilock Brake

Specifications T0Rque Chart

Section 10

Description and Operation

Diagnosis and Testing Safety Precautions

Service Procedures

Removal and Installation

Specifications

Section 11

Description and Operation

Diagnosis and Testing