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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...
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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.
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...
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.
0 - 4 LUBRICATION AND MAINTENANCE MAINTENANCE SCHEDULES TABLE OF CONTENTS page page SERVICE PROCEDURES UNSCHEDULED INSPECTION ....4 DESCRIPTION ......4 •...
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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 •...
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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. •...
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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 •...
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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. •...
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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 .
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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SUSPENSION 2 - 7 FRONT SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COIL SPRING/JOUNCE BUMPER ... . . 9 SUSPENSION COMPONENTS ....7 STEERING KNUCKLE .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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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.
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.
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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.
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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.
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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.
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.
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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.
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.
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.
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 •...
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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.
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: •...
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.
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.
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.
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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.
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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.
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.
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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.
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.
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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.
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.
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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.
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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.
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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.
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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 –...
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.
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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.
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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.
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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 –...
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.
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.
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.
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.
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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.
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.
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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.
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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 –...
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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.
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.
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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 –...
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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.
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.
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 •...
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.
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: •...
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.
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.
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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...
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.
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.
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–...
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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 –...
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.
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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.
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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.
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 –...
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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 –...
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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.
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.
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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.
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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 –...
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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.
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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.
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.
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.
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.
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.
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: •...
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.
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.
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.
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.
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.
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.
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.
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).
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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.
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.
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.
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.
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.
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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 •...
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.
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.
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.
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.
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.
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.
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.
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.
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.
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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 –...
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.
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.
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.
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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.
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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.
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.
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.
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.
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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 .
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,...
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.
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.
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.
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...
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CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUTCH FLYWHEEL RUNOUT ....6 CLUTCH ....... . 1 CLUTCH COVER AND DISC RUNOUT .
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.
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.
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.
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CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 8 Clutch Components And Inspection...
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.
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.
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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.
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.
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.
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.
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.
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.
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CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 8 Clutch Components And Inspection...
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.
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.
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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.
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.
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.
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 .
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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.
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- •...
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.
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.
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,...
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.
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.
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°...
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-...
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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.
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.
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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.
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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.
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.
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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.
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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.
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.
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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.
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...
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.
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.
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.
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.
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 –...
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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.
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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.
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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.
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...
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.
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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.
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.
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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 –...
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.
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.
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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.
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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 –...
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.
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 —...
WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page AIR CONDITIONING-HEATER ... 8W-42-1 POWER DISTRIBUTION ....8W-10-1 AIRBAG SYSTEM .
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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 .
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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.
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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.
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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.
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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,...
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8W - 01 - 6 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Symbols...
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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.
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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 •...
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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.
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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.
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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 –...
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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.
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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 –...
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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 –...
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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.
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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 .
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8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Power Mirror Switch ....8W-62 Splice Information ..... 8W-70 Power Mirrors .
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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 .
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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...
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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)
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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)
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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...
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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...
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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...
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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)
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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)
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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...
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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)
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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)
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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 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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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 .
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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...
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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 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...
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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...
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)
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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...
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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...
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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...
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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...
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...
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...
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...
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 (-)
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...
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...
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...
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...
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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 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...
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 (-)
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...
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...
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...
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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)
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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...
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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.
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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...
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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...
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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...
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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...
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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 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.
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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...
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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...
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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...
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.
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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...
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 –...
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...
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 –...
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.
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.
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.
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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.
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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.
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.
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.
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)
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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.
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).
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...
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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...
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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 –...
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.
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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.
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.
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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.
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.
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.
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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.
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.
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.
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.
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.
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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).
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.
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.
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.
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...
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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 –...
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.
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.
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.
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.
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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.
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).
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.
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.
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.
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.
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.
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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°...
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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.
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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.)
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.
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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...
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 –...
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.
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...
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.
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.
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.
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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.
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.
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.
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.
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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.
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...
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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...
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 –...
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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.
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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.
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.
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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 –...
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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.
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.
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.
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(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...
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.
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.
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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.
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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.
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.
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.
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.
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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.
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.
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.
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.
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...
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.
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.
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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.
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.
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 –...
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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.
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.
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.
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.
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.
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.
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.)
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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.)
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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 &...
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 —...
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EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION EXHAUST SYSTEM......1 EXHAUST PIPE .
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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.
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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.
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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.
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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.
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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.
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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.
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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 .
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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 –...
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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.
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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.
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13 - 6 FRAME AND BUMPERS FRAME TABLE OF CONTENTS page page REMOVAL AND INSTALLATION TRAILER HITCH ......7 FRONT SKID PLATE .
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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.
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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 .
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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...
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.
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.
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.
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.
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”...
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.
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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.
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...
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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.
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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 –...
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.
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.
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.
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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.
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.
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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 –...
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.
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.
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...
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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 .
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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.
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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: •...
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.
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...
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.
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.
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.
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...
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- •...
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).
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.
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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.
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.
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.
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 –...
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.
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).
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...
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STEERING 19 - 1 STEERING TABLE OF CONTENTS page page POWER STEERING ......1 STEERING LINKAGE ..... . . 22 POWER STEERING PUMP .
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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.
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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.
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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.
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STEERING 19 - 5 POWER STEERING PUMP TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER STEERING PUMP ....5 POWER STEERING PUMP .
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.
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.
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.
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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 –...
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.
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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 –...
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.
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.
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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.
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.
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19 - 22 STEERING STEERING LINKAGE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DRAG LINK ......24 STEERING LINKAGE .
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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.
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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 –...
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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.
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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.
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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 .
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.
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- •...
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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.
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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.
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.
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.
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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.
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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 –...
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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 –...
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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 –...
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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 –...
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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 –...
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.
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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 –...
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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.
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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.
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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 –...
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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).
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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.
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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.
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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.
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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.
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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 –...
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.
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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.
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.
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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.
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 –...
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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 –...
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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 –...
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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.
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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.
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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 –...
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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.
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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 –...
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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 –...
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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.
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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.
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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 –...
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.
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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.
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 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.
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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.
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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.
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.
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.
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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.
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.
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 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.
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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.
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21 - 106 AUTOMATIC TRANSMISSION—30RH DESCRIPTION AND OPERATION (Continued) Fig. 22 Regulator Valve in Drive Position Fig. 23 Regulator Valve in Reverse Position...
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.
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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.
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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.
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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.
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.
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.
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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.