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Chrysler 1997 Stratus Convertible RHD Service Manual

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Table of Contents

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Welcome to the
1997 Stratus Convertible
(RHD & LHD)
Interactive Electronic Service Manual!
CLICK ON VEHICLE TO BEGIN
tweddle litho: dom parts cdrom demo 09/96
page 4 <output:0828 ET 02/25/97>

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Summary of Contents for Chrysler 1997 Stratus Convertible RHD

  • Page 1 Welcome to the 1997 Stratus Convertible (RHD & LHD) Interactive Electronic Service Manual! CLICK ON VEHICLE TO BEGIN tweddle litho: dom parts cdrom demo 09/96 page 4 <output:0828 ET 02/25/97>...
  • Page 2 GROUP TAB LOCATOR Introduction Lubrication and Maintenance Suspension Differential and Driveline Brakes Cooling System Battery Starting Charging System Ignition System Instrument Panel and Systems Audio System Horns Vehicle Speed Control System Turn Signal and Flashers Windshield Wipers and Washers Lamps Restraint System Electrically Heated Systems Power Door Locks...
  • Page 3 17 DIGITS V.I.N. PLATE WINDSHIELD OPENING DASH PANEL INTRODUCTION INTRODUCTION CONTENTS page page GENERAL INFORMATION STANDARD VEHICLE DIMENSIONS ..3 BODY CODE PLATE ..... 1 TORQUE REFERENCES .

  • Page 4: Body Code Plate

    SHELL TRIM INTRODUCTION GENERAL INFORMATION (Continued) VIN CODE BREAKDOWN POSITION INTERPRETATION CODE=DESCRIPTION Country of Origin 3=Built in Mexico by Chrysler of Mexico Make C=Chrysler Vehicle Type 3=Passenger Car Other E=Active Driver and Passenger Air Bag Car LIne L=Chrysler, Sebring Series...
  • Page 5 INTRODUCTION GENERAL INFORMATION (Continued) DIGIT 14— DIGIT 5— Open Space Market Code • U = United States DIGITS 15 THROUGH 18— • C = Canada • B = International Interior Trim Code • M = Mexico DIGIT 19— DIGIT 6— Open Space Open Space DIGITS 20, 21, AND 22—...

  • Page 6: Fastener Identification

    HEADLIGHTS, WINDSHIELD WINDSCREEN ENGINE COOLANT TEMPER- BATTERY CHARGING CON- REAR WINDOW DEFOGGER REAR WINDOW WASHER LIGHTS, PANEL LIGHTS REAR WINDOW WIPER WINDSHIELD WASHER REAR HOOD (TRUNK) WINDSHIELD WIPER HAZARD WARNING AND DEFROSTING VENTILATING FAN PARKING BRAKE BRAKE FAILURE TURN SIGNAL FRONT HOOD WIPER FOG LIGHTS...
  • Page 7 Bolt Markings and Torque — Metric Bolt Head Markings Bolt ings Torque Val- ues — U.S. Bolt Torque — Grade Customary Commercial Steel Class Mark- Bolt SAE Grade Number These are all SAE Grade 5 Bolt Head Markings (3) line Bolt Torque —...
  • Page 8 HOW TO DETERMINE BOLT STRENGTH No mark Welded bolt Three protrud- ing lines Two protruding lines Hexagon flange bolt Hexagon head bolt Hexagon head bolt Hexagon flange bolt w/washer hexagon bolt Hexagon head bolt Hexagon head bolt w/washer hexagon bolt Four protruding lines Bolt head No.

  • Page 9: Metric System

    INTRODUCTION GENERAL INFORMATION (Continued) METRIC SYSTEM The metric system is based on quantities of one, ten, one hundred, one thousand and one million (Fig. WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- Mega - (M) Million Deci - (D) Tenth SONAL INJURY.
  • Page 10 INTRODUCTION GENERAL INFORMATION (Continued) METRIC CONVERSION2 in-lbs to N·m N·m to in-lbs in-lb N·m N·m N·m N·m N·m N·m in-lb N·m in-lb N·m in-lb N·m in-lb N·m in-lb .2260 4.7453 9.2646 13.7839 18.3032 1.7702 37.1747 72.5792 12.2 107.9837 16.2 143.3882 .4519 4.9713 9.4906...
  • Page 11 INTRODUCTION GENERAL INFORMATION (Continued) in. to mm mm to in. .254 5.334 10.414 15.494 20.574 .00039 .00827 .01614 .02402 .03189 .508 5.588 10.668 15.748 20.828 .00079 .00866 .01654 .02441 .03228 .762 5.842 10.922 16.002 21.082 .00118 .00906 .01693 .02480 .03268 1.016 6.096 11.176...

  • Page 12: Torque References

    INTRODUCTION GENERAL INFORMATION (Continued) TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifi- cations Chart for torque references not listed in the individual torque charts. TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Class Diameter Pitch mm...

  • Page 13: Lubrication And Maintenance

    CLASSIFICATION OF LUBRICANTS PARTS AND LUBRICANT RECOMMENDATIONS Only lubricants that are endorsed by the following organization should be used to service a Chrysler When service is required, Chrysler Corporation Corporation vehicle. recommends that only Mopar brand parts, lubri- •...
  • Page 14 0 - 2 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 3) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter WHEEL BEARINGS...

  • Page 15: Maintenance Schedules

    • Check all lights and all other electrical items for There are two maintenance schedules that show correct operation. the proper service for Chrysler vehicles. Use the schedule that best describes the conditions under At Each Oil Change which the vehicle is operated. Where time and mile- •...
  • Page 16 0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Replace air cleaner air cleaner element. 37,500 Miles (60 000 km) or at 30 months • Replace spark plugs on 2.4L engines. • Change engine oil. • Replace engine oil filter on 2.4 liter engines. 97,500 Miles (156 000 km) or at 78 months •...
  • Page 17 LUBRICATION AND MAINTENANCE 0 - 5 GENERAL INFORMATION (Continued) 27,000 Miles (43 000 km) 60,000 Miles (96 000 km) • Change engine oil • Change engine oil. • Replace engine oil filter on 2.4 liter engines. • Replace engine oil filter on all engines. •...
  • Page 18 96,000 Miles (154 000 km) NOTE: **This maintenance is recommended by • Change engine oil. Chrysler to the owner but is not required to main- • Replace engine oil filter on all engines. tain the warranty on the PCV valve.

  • Page 19: Jump Starting, Hoisting And Towing

    BATTERY NEGATIVE CABLE BATTERY POSITIVE CABLE NEGATIVE JUMPER CABLE POSITIVE JUMPER CABLE ENGINE GROUND TEST INDICATOR BATTERY LUBRICATION AND MAINTENANCE 0 - 7 JUMP STARTING, HOISTING AND TOWING INDEX page page SERVICE PROCEDURES JUMP STARTING PROCEDURE ... . . 7 HOISTING RECOMMENDATIONS .
  • Page 20 DRIVE ON LIFT FRAME CONTACT LIFT (SINGLE POST) CHASSIS LIFT (DUAL POST) OUTBOARD LIFT (DUAL POST) FLOOR JACK 21’’ 23’’ WHEEL LIFT FLAT BED 0 - 8 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) DISCONNECT CABLE CLAMPS AS FOLLOWS: TOWING RECOMMENDATIONS •...
  • Page 21 VENTURE UNDER A LIFTED VEHICLE IF NOT SUP- PORTED PROPERLY ON SAFETY STANDS. DO NOT TOWING—FRONT WHEEL LIFT Chrysler Corporation recommends that a vehicle be ALLOW PASSENGERS TO RIDE IN A TOWED VEHI- CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT towed with the front end lifted, whenever possible.

  • Page 23: Wheel Alignment

    Toe and for ment being used should always be followed to ensure total Toe. accuracy of the alignment, except alignment specifi- cations recommended Chrysler Corporation MUST ALWAYS be used.
  • Page 24 TOE OUT FRONT LOOSEN NUT TO ADJUST ADJUST TOE NEGATIVE CAMBER POSITIVE TOE IN 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Alignment Camber/Toe (4) Toe is measured in degrees or inches and is (5) Thrust Angle is defined as the average of the the distance that the front edges of the tires are Toe settings on each rear wheel.
  • Page 25 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine On Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3. Worn Tires 3.
  • Page 26 2 - 4 SUSPENSION DIAGNOSIS AND TESTING (Continued) PRE-WHEEL ALIGNMENT INSPECTION Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification. Before any attempt is made to change or correct the wheel alignment factors. The following part CAUTION: Do not attempt to adjust the vehicles inspection and the necessary corrections should be...
  • Page 27 FORWARD LATERAL A RM REAR LATERAL LINK FORWARD LATERAL LINK ADJUSTING REAR LATERAL LINK 391mm 302mm (MAX) (MAX) SCREW JAM NUT 90mm (MAX) STABILIZER B AR ADJUSTING JAM NUTS SCREW SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) (5) Adjust the forward lateral link adjusting screw (Fig.
  • Page 28 2 - 6 SUSPENSION SPECIFICATIONS VEHICLE ALIGNMENT SPECIFICATIONS AT CURB HEIGHT ACCEPTABLE ALIGNMENT RANGE PREFERRED SETTING FENDER LIP TO FRONT WHEEL ALIGNMENT AT CURB HEIGHT (FULL FLUIDS NO GROUND HEIGHT (FULL FLUIDS NO PASSENGERS) PASSENGERS) CAMBER......-0.5° to +0.7° +0.1° 28.0 in.
  • Page 29 SHOCK COILSPRING TOWER NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER METAL FASTENERS ARE TO BE INSTALLED IN SHOCK TOWER AREA. ALSO, NO HOLES ARE TO BE DRILLED INTO SHOCK TOWER IN THIS SAME AREA. SUSPENSION 2 - 7 FRONT SUSPENSION INDEX page page...
  • Page 30 2 - 8 SUSPENSION DESCRIPTION AND OPERATION The top of each shock absorber assembly is bolted to the cast aluminum upper control arm bracket FRONT SUSPENSION SYSTEM DESCRIPTION which is then bolted to the shock tower of the vehicle using 4 mounting bolts. This vehicle’s front suspension is a short long arm The bottom of the shock absorber assembly design used in conjunction with a gas pressurized...
  • Page 31 SUSPENSION 2 - 9 DESCRIPTION AND OPERATION (Continued) Jounce and rebound movements affecting one attempt should be made to ever add any lubri- wheel are partially transmitted to the opposite wheel cation to the lower ball joint. of the vehicle to stabilize body roll. UPPER CONTROL ARM BALL JOINT Attachment of the stabilizer bar to the front sus- pension cradle is through 2 rubber-isolator bushings...
  • Page 32 SHOCK COILSPRING ABSORBER UPPER SPRING DUST BOOT SEAT 2 - 10 SUSPENSION DIAGNOSIS AND TESTING (Continued) any component of the upper control arm. Service pro- cedures to replace the serviceable components are detailed in the specific component sections of this group.
  • Page 33 BRAKE CALIPER FLEX WHEEL SPEED SEN- SOR CABLE SPEED HOSE SENSOR CABLE BRACKET ROUTING ATTACHINGBOLT STEERING KNUCKLE UPPER UPPER CASTLENUT CLEVIS UPPER CONTROL ARM SHOCK SHOCK ABSORBER STEERING BRACKET MOUNTING BRACKET KNUCKLE ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN BALL JOINT BRAKE FLEX HOSE STEERING...
  • Page 34 SHOCK CONTROL ARM MOUNTING ABSORBER/UPPER BRACKET BOLTS SHOCK TOWER SHOCK CLEVIS MUST BE INSTALLED FLUSH AGAINST LOCATING TAB HERE ORIENTATION TAB SHOCK CLEVIS LOCATING TAB CLEVIS SPLIT COVER THRU-BOLT SHOCK ABSORBER CLEVIS LOWER CONTROL SHOCK ABSORBER TIE ROD END 2 - 12 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 35 WHEEL SPEED CABLE BALL JOINT CAP SPEED SOR CABLE BRACKET ROUTING SENSOR SEN- STEERING KNUCKLE BRAKE CALIPER LOWER CONTROL ARM FLEX HOSE ATTACHING BOLT SHOCK ABSORBER CLEVIS UPPER UPPER CASTLENUT CLEVIS UPPER CONTROL ARM SHOCK SHOCK ABSORBER STEERING BRACKET MOUNTING BRACKET KNUCKLE ASSEMBLY CONTROL...
  • Page 36 SHOCK CONTROL ARM MOUNTING ABSORBER/UPPER BRACKET BOLTS SHOCK TOWER GP A20 GP C42 TOP SPRING SHOE BOTTOM SPRING SHOE COVER THRU-BOLT SHOCK ABSORBER CLEVIS LOWER CONTROL SPECIAL SHOCK ABSORBER GP-2020–C3.5 ASSEMBLY TOOL SHOCK ABSORBER VISE CLEVIS TIE ROD END 2 - 14 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 37 SHOCK TROL SHOCK CONTROL ABSORBER/CON- ABSORBER/UPPER MOUNTING BRACKET SPRING COMPRES- MOUNTING BRACKET WASHER CROW FOOT ISOLATOR BUSHING SHOCK SOCKET SNAP-ON A136 SHOCK ABSORBER ABSORBER LOWER SHOCK TROL ISOLATOR BUSHING ABSORBER/CON- MOUNTING BRACKET SHOCK UPPER ISOLATOR BUSHING ABSORBER SHOCK SLEEVE ABSORBER/CONTROL MOUNTING BRACKET UPPER SPRING ISO- LATOR...
  • Page 38 INSTALL ABSORBER ROD IN THIS UPPER SHOCK LOWER ISOLATOR BUSHING ABSORBER CONTROL DIRECTION SHOCK CONTROL ARM MOUNTING SHOCK UPPER ISOLATOR BUSHING INSTALL ABSORBER ROD IN THIS ABSORBER BOLTS UPPER CONTROL ARM MOUNTING BRACKET DIRECTION SHOCK 2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) ing bracket.
  • Page 39 SHOCK CLEVIS MUST BE INSTALLED FLUSH AGAINST LOCATING TAB HERE ORIENTATION TAB SHOCK CLEVIS LOCATING TAB CLEVIS SPLIT BALL JOINT CAP SHOCK ABSORBER LOWER CONTROL ARM SHOCK ABSORBER CLEVIS STEERING HEAT SHIELD KNUCKLE END STUD TIE ROD END SUSPENSION 2 - 17 REMOVAL AND INSTALLATION (Continued) (17) Tighten the shock absorber clevis to lower control arm bushing thru-bolt nut to a torque of 88...
  • Page 40 SHOCK ABSORBER CLEVIS LOWER CONTROL ARM HEAT SHIELD CASTLE NUT COTTER PIN STEERING KNUCKLE BOSS LOWER CONTROL ARM BALL JOINT STUD HEAT SHIELD LOWER CONTROL ARM DRIVESHAFT SPECIAL TOOL MB-991113 TIE ROD END STEERING HEAT SHIELD KNUCKLE HAMMER THRU-BOLT SHOCK ABSORBER CLEVIS LOWER CONTROL...
  • Page 41 FRONT ATTACHING BOLTS STABILIZER BAR CROSSMEMBER VEHICLE BODY SUSPENSION FRONT LOWER CONTROL ARM STABILIZER BAR CROSSMEMBER SHOCK CLEVIS SUSPENSION STABILIZER BAR BUSHING CLAMP WRENCH ALLEN WRENCH LOWER CONTROL ATTACHING BOLT AND NUT LOWER CONTROL LOWER ATTACHING BOLT AND NUT FRONT SUSPENSION CONTROL CROSSMEMBER STABILIZER BAR LINK ASSEMBLY...
  • Page 42 HEAT SHIELD CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH BALL JOINT CAP LOWER CONTROL ARM SHOCK ABSORBER CLEVIS TIE ROD END 2 - 20 SUSPENSION REMOVAL AND INSTALLATION (Continued) (3) Install the lower control arm ball joint stud into the steering knuckle. Install the steering knuckle to ball joint stud castle nut (Fig.
  • Page 43 CALIPER STEERING KNUCKLE GUIDE PIN BOLTS SPRING WASHER ASSEMBLY FRONT H UB DISC BRAKE CALI- COTTER PIN PER ASSEMBLY NUT LOCK DISC BRAKE CALI- LIFT THIS END OF CALIPER AWAY PER ASSEMBLY WIRE HANGER ROTOR FROM KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY UPPER CONTROL ARM...
  • Page 44 SHOCK ABSORBER CLEVIS STEERING KNUCKLE BOSS LOWER CONTROL ARM LOWER CONTROL ARM BALL JOINT STUD HEAT SHIELD HEAT SHIELD CASTLE NUT COTTER PIN STEERING WHEEL HEAT SHIELD SPEED CABLE KNUCKLE SPEED END STUD LOWER CONTROL ARM SOR CABLE BRACKET ROUTING SENSOR SEN- TIE ROD END...
  • Page 45 STEERING KNUCKLE OUTER JOINT BEARING SHIELD HUB/BEARING UPPER UPPER CASTLENUT UPPER CONTROL ARM SHOCK SHOCK ABSORBER MOUNTING BRACKET ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN BALL JOINT STEERING SHOCK ABSORBER KNUCKLE SPECIAL BALL JOINT STUD BALL JOINT ASSEMBLY C3894–A TOOL SUSPENSION 2 - 23 REMOVAL AND INSTALLATION (Continued) CAUTION: Pulling steering knuckle out from vehi-...
  • Page 46 INSTALL THIS END OF CALI OUTBOARD BRAKE SHOE DISC BRAKE CALIPER UNDER STEERING KNUCKLE KNUCKLE FIRST STEERING HEAT SHIELD ROTOR CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH HUB AND BEAR- STUB NUT LOCK AXLE WASHER “PULL” COTTER PIN THROUGH HUB NUT “WRAP”...
  • Page 47 FRONT ATTACHING BOLTS STABILIZER BAR CROSSMEMBER VEHICLE BODY SUSPENSION STABILIZER BAR BUSHING CLAMP WRENCH ALLEN WRENCH LOWER CONTROL STABILIZER BAR LINK ASSEMBLY SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) STABILIZER BAR front crossmember bushing replacement is required, bushing can be removed using the stabilizer bar bushing removal procedure in the Disassembly And REMOVE (1) Raise vehicle on jack stands or centered on a...
  • Page 48 SPRING WASHER FRONT H UB COTTER PIN NUT LOCK DISC BRAKE CALI- CALIPER STEERING LIFT THIS END OF CALIPER AWAY PER ASSEMBLY WIRE HANGER ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY UPPER CONTROL ARM STEERING KNUCKLE DISC BRAKE CALI-...
  • Page 49 DISC ASSEMBLY (STORED) STEERING KNUCKLE BRAKE CALIPER SHOCK ABSORBER CLEVIS LOWER CONTROL ARM HEAT SHIELD CASTLE NUT COTTER PIN STEERING HEAT SHIELD KNUCKLE END STUD LOWER CONTROL ARM BRAKING DISC TIE ROD END SPECIAL TOOL MB-991113 TIE ROD END STEERING HEAT SHIELD KNUCKLE WHEEL...
  • Page 50 HAMMER STEERING KNUCKLE OUTER STEERING KNUCKLE BOSS JOINT BEARING SHIELD LOWER STEERING KNUCKLE HUB/BEARING CONTROL UPPER UPPER CASTLENUT UPPER CONTROL ARM SHOCK SHOCK ABSORBER MOUNTING BRACKET ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN BALL JOINT STEERING SHOCK ABSORBER KNUCKLE SPECIAL BALL JOINT STUD BALL JOINT ASSEMBLY C3894–A...
  • Page 51 INSTALL THIS END OF CALI OUTBOARD BRAKE SHOE DISC BRAKE CALIPER UNDER STEERING KNUCKLE KNUCKLE FIRST STEERING HUB/BEARING STEERING KNUCKLE ATTACHING BOLTS HUB/BEARING ASSEMBLY HEAT SHIELD ROTOR CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH TIE ROD END SUSPENSION 2 - 29 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 52 HUB AND BEAR- BRAKING DISC STUB NUT LOCK AXLE TORQUE WRENCH WASHER “PULL” COTTER PIN THROUGH HUB NUT “WRAP” TIGHT CALIPER STEERING KNUCKLE GUIDE PIN BOLTS ASSEMBLY DISC BRAKE CALI- PER ASSEMBLY 2 - 30 SUSPENSION REMOVAL AND INSTALLATION (Continued) WHEEL MOUNTING STUDS CAUTION: If a wheel mounting stud needs to be...
  • Page 53 DISC ASSEMBLY (STORED) STEERING KNUCKLE BRAKE CALIPER DISC BRAKE CALI- LIFT THIS END OF CALIPER AWAY PER ASSEMBLY WIRE HANGER ROTOR BRAKING DISC FROM KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY UPPER CONTROL ARM STEERING KNUCKLE STEERING KNUCKLE OUTBOARD BRAKE SHOE ROTOR STEERING...
  • Page 54 INSTALL THIS END OF CALI OUTBOARD BRAKE SHOE DISC BRAKE CALIPER UNDER STEERING KNUCKLE KNUCKLE FIRST STEERING GP A20 GP C42 TOP SPRING SHOE BOTTOM SPRING SHOE ROTOR SPECIAL SHOCK ABSORBER GP-2020–C3.5 ASSEMBLY TOOL SHOCK ABSORBER VISE CLEVIS 2 - 32 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 55 SHOCK TROL SHOCK CONTROL ABSORBER/CON- ABSORBER/UPPER MOUNTING BRACKET SPRING COMPRES- MOUNTING BRACKET WASHER CROW FOOT ISOLATOR BUSHING SHOCK SOCKET SNAP-ON A136 SHOCK ABSORBER ABSORBER LOWER SHOCK TROL ISOLATOR BUSHING ABSORBER/CON- MOUNTING BRACKET SHOCK UPPER ISOLATOR BUSHING ABSORBER SHOCK SLEEVE ABSORBER/CONTROL MOUNTING BRACKET UPPER SPRING ISO- LATOR...
  • Page 56 SHOCK ABSORBER FLUID JOUNCE BUMPER RESERVOIR COLLAR SPRING COMPRESSOR S PRING SPRING COMPRESSOR SPRING WASHER SHOCK ABSORBER ASSEMBLY COIL SEATED AGAINST ISOLATOR SHOCK ABSORBER ASSEM- SHOCK ABSORBER ROD SPRING DUST SHIELD COIL SPRING DUST SHIELD MUST HERE SHOCK ABSORBER CLEVIS SHOCK ABSORBER ROD LOWER SPRING SEAT SHOCK ABSORBER FLUID...
  • Page 57 JOUNCE BUMPER SHOCK ABSORBER SHOCK ABSORBER ROD INSTALL ABSORBER ROD IN THIS SHOCK LOWER ISOLATOR BUSHING ABSORBER DIRECTION SHOCK SHOCK UPPER ISOLATOR BUSHING INSTALL ABSORBER ROD IN THIS ABSORBER DIRECTION SHOCK SUSPENSION 2 - 35 DISASSEMBLY AND ASSEMBLY (Continued) • Inspect jounce bumper for cracks and signs of CAUTION: The top and bottom shock absorber rod deterioration.
  • Page 58 SPECIAL TOOL MB-990799 SPECIAL TOOL C-4212–F LOWER CONTROL ARM FRONT ISOLATOR BUSHING SPECIAL TOOL 6602–5 SPECIAL TOOL 6876 ISOLATOR SPECIAL TOOL C-4212–F BUSH- MACHINED SURFACE SIDE OF LOWER CONTROL ARM SPECIAL TOOL 6758 2 - 36 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) LOWER CONTROL ARM FRONT ISOLATOR BUSHING To perform removal and replacement of the lower...
  • Page 59 FRONT ISOLATOR BUSHING SPECIAL TOOL C-4366–2 LOWER CONTROL ARM SPECIAL TOOL VOID IN BUSHING IN THIS C-4212–F REAR ISOLATOR BUSHING LOWER CONTROL ARM DIRECTION MACHINED SURFACE SPECIAL TOOL 6756 SPECIAL TOOL SPECIAL TOOL 6756 C-4212–F LOWER CONTROL ARM REAR BUSHING MACHINED SURFACE ON LOWER CONTROL ARM SPECIAL TOOL...
  • Page 60 MACHINED SUR- FACE SIDE OF LOWER TROL ARM LOWER CONTROL ARM SPECIAL TOOL 6876 CON- SPECIAL TOOL 6876 SPECIAL TOOL 6877 CLEVIS BUSHING SPECIAL TOOL C-4212–F SPECIAL LOWER SPECIAL TOOL TROL ARM C-4212–F TOOL CON- 6877 2 - 38 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Under no circumstances can a lower...
  • Page 61 BALL JOINT SEAL RETAIN- BALL UPPER SEAL BOOT BALL JOINT SEAL JOINT BOOT INSTALLATION SEC- SEALING UPPER SEALING RING TION Wipe off the grease. ING RING RING SCREW- DRIVERS LOWER CONTROL ARM GREASE BALL JOINT STUD TAPERED BOOT INSTALLATION SEC- TION Wipe off the grease.
  • Page 62 SEAL RETAINING R ING SPECIAL TOOL 6875 SPECIAL TOOL 6875 BOOT RETAINING RING LOWER CONTROL ARM LOWER CONTROL ARM SEAL BOOT RETAIN- SEAL BOOT BALL JOINT STUD BALL JOINT STUD CONTROL ARM ING RING LOWER BALL JOINT BALL JOINT SEAL BOOT CONTROL UPPER SEALING RING SCREWDRIVER...
  • Page 63 STABILIZER BAR BUSH- CONTROL ARM STABILIZER BAR BUSHING ING RETAINER SEAL BOOT CRIMPS BALL JOINT CRIMPS STABILIZER BAR SPECIAL TOOL 6758 SUSPENSION 2 - 41 DISASSEMBLY AND ASSEMBLY (Continued) SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE Shock Absorber To Clevis Pinch Bolt ..88 N·m (65 ft. lbs.) To Shock Tower Bolts .
  • Page 64 2 - 42 SUSPENSION SPECIAL TOOLS FRONT SUSPENSION Remover, Ball Joint MB-990799 Puller C-3894-A Remover/Installer Control Arm Bushing 6602–5 (In Tool Kit 6602) Installer, Ball Joint 6758 Installer/Receiver, Control Arm Bushing 6876 Press, Ball Joint Remover Installer C-4212F Installer, Ball Joint 6758...
  • Page 65 SUSPENSION 2 - 43 SPECIAL TOOLS (Continued) Remover / Installer C-4366-2 (In Tool Kit C-4366) Installer, Ball Joint Seal Boot Retainer 6875 Receiver, Ball Joint 6756 Remover, Tie Rod End MB-991113 or MB-990635 Installer, Bushing 6760 Remover, Lower Ball Joint C-4150A Remover/Installer Control Arm Clevis Bushing 6877...

  • Page 66: Rear Suspension

    2 - 44 SUSPENSION REAR SUSPENSION INDEX page page GENERAL INFORMATION SERVICE PROCEDURES GENERAL INFORMATION ....44 REAR WHEEL ALIGNMENT ....47 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION COIL SPRING...
  • Page 67 SUSPENSION 2 - 45 DESCRIPTION AND OPERATION (Continued)
  • Page 68 2 - 46 SUSPENSION DESCRIPTION AND OPERATION (Continued) The upper control arm is bolted to the rear suspen- ber. Fore and aft movement of the knuckle is con- sion crossmember using a pivot bar which is rubber trolled by a trailing link. isolated from the upper control arm.
  • Page 69 SUSPENSION 2 - 47 DIAGNOSIS AND TESTING (Continued) straighten the upper control arm. THE UPPER STABILIZER BAR ATTACHING LINKS CONTROL ARM MUST BE REPLACED IF Inspect the bushings and sleeves in the stabilizer FOUND TO BE DAMAGED OR DEFECTIVE IN bar attaching links for damage or deterioration.
  • Page 70 2 - 48 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 3 Shock Absorber Upper Mount Attaching Nuts Fig. 5 Shock Absorber Removal LATERAL LINK ATTACHING B OLT SHOCK CLEVIS BRACKET ABSORBER REAR KNUCKLE (4) Raise vehicle on jackstands or centered on a INSTALL frame contact type hoist.
  • Page 71 STABILIZER BAR ATTACHING FORWARD LATERAL LINK PARK BRAKE CABLE REAR LATERAL LINK STABILIZER BAR LINK ATTACHING BOLT ATTACHING BOLT CORRECTLY POSITION STABILIZER STABILIZER BAR ATTACH- REAR INSTALLED REAR STABILIZER CROSSMEMBER UP IN CAR SUSPENSION ING BRACKETS SIDE VIEW INCORRECTLY POSITION ATTACHING BOLT STABILIZER INSTALLED...
  • Page 72 2 - 50 SUSPENSION REMOVAL AND INSTALLATION (Continued) (6) Tighten the bolts attaching the stabilizer bar bushing clamps to the rear crossmember to a torque of 27 N·m (19 ft. lbs.) (Fig. 7). (7) Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica- tion.
  • Page 73 SUSPENSION 2 - 51 REMOVAL AND INSTALLATION (Continued) support plate, brake shoes and wheel cylinder as an assembly from rear knuckle. It is not necessary to BRAKE PLATE ATTACHING SUPPORT WIRE HANGER BOLTS REAR SHOCK ABSORBER REAR BRAKE SUP- REAR SUPPORT PLATE REAR KNUCKLE PORT PLATE...
  • Page 74 2 - 52 SUSPENSION REMOVAL AND INSTALLATION (Continued) (4) Install the front and rear lateral links and attaching nuts and bolts on the knuckle (Fig. 15) Tighten the lateral links to knuckle attaching bolts and nuts to 108 N·m (80 ft. lbs.). (5) Install rear brake support plate assembly onto the knuckle.
  • Page 75 SUSPENSION 2 - 53 REMOVAL AND INSTALLATION (Continued) UPPER CONTROL ARM The rear upper control arm, control arm bushings, and pivot bar are serviced as a complete assembly on this vehicle. Do not attempt to disassemble the con- trol arm from the pivot bar to service the rear control arm bushings.
  • Page 76 2 - 54 SUSPENSION REMOVAL AND INSTALLATION (Continued) UPPER CONTROL ARM SHOCK ABSORBER REAR SUSPENSION CROSS- ATTACHING BOLTS MEMBER UPPER CONTROL ARM PIVOT Fig. 27 Crossmember Attachment To Frame Rails Fig. 25 Lowering And Supporting Rear Suspension UPPER CONTROL BRAKE FLEX HOSE BRAKE DRUM BRACKET SPEED SENSOR CABLE ROUTING...
  • Page 77 SUSPENSION 2 - 55 REMOVAL AND INSTALLATION (Continued) Tighten the 2 pivot bar to crossmember attaching UPPER BALL JOINT bolts (Fig. 28) to a torque of 108 N·m (80 ft. lbs.). The ball joints are replaceable ONLY as an assem- (2) Using transmission jack, raise rear suspension bly, do not attempt any type of repair on the ball crossmember up to the rear frame rails and loosely...
  • Page 78 2 - 56 SUSPENSION REMOVAL AND INSTALLATION (Continued) (5) Position Receiving Cup, Special Tool 6758 over BALL JOINT SEAL SPECIAL TOOL 6758 CONTROL ARM sealing boot so it is aligned properly with bottom edge of sealing boot (Fig. 33). Apply pressure BY HAND to special tool 6758, until sealing boot is pressed squarely against surface of control arm.
  • Page 79 MUFFLER EXHAUST PIPE REAR FASCIA HANGER BOLT ATTACHING BOLTS BRACKET MUFFLER SUPPORT BRACKET UPPER CONTROL REAR SUSPENSION CROSS- BRAKE FLEX HOSE BRAKE DRUM ATTACHING BRACKET WOODEN BLOCK BOLTS MEMBER REAR SUSPENSION CROSS- SPEED SENSOR CABLE ROUTING BOLT MEMBER TRANSMISSION JACK SPEED SENSOR CABLE...
  • Page 80 2 - 58 SUSPENSION REMOVAL AND INSTALLATION (Continued) NOTE: One flat washer is used at each upper con- located between the pivot bar and the rear suspen- trol arm pivot bar attaching bolt. The flat washer is sion crossmember. Be sure 1 flat washer is used at located between the pivot bar and the rear suspen- each bolt attaching the pivot bar to the rear suspen- sion crossmember.
  • Page 81 SUSPENSION 2 - 59 REMOVAL AND INSTALLATION (Continued) tion. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (11) Lower vehicle to the ground. (12) Check and reset if required, rear wheel align- ment (camber and toe) to meet the preferred specifi- cations.
  • Page 82 2 - 60 SUSPENSION REMOVAL AND INSTALLATION (Continued) service manual for the required alignment setting INSTALL procedure. (1) Install the lateral link and the attaching nut and bolt at rear suspension crossmember (Fig. 46). REAR LATERAL LINK The rear lateral link is to be installed with the adjusting screw toward rear knuckle not rear REMOVE suspension crossmember (Fig.
  • Page 83 SUSPENSION 2 - 61 REMOVAL AND INSTALLATION (Continued) Do not reverse the position of the inner and outer trailing link bushing or retainers on the trailing link. NOTE: When installing trailing link into hanger bracket, the flat on the trailing link (Fig. 49) must be positioned at the hanger bracket.
  • Page 84 2 - 62 SUSPENSION REMOVAL AND INSTALLATION (Continued) SPRING SHOCK ABSORBER ASSEM- COMPRESSOR GP-2020–C3.5 COIL SPRING Fig. 51 Trailing Link Hanger Bracket Installation Fig. 52 Shock Absorber Correctly Mounted In Vise ing tighten the trailing link retaining nut (Fig. 47) to (3) Mark the coil spring and the shock absorber a torque of 99 N·m (73 ft.
  • Page 85 SUSPENSION 2 - 63 DISASSEMBLY AND ASSEMBLY (Continued) SHOCK ABSORBER SOCKET SNAP-ON A136 CROW FOOT (5) Hold the rod of the shock absorber from rotat- ing using Shock Absorber Socket, Snap-On A136 or SHOCK ABSORBER MOUNT SHOCK ABSORBER ROD WASHER an equivalent (Fig.
  • Page 86 COIL SPRING SPRING COMPRESSOR SPRING COMPRES- DUST SHIELD COIL SPRING COIL SPRING ISOLATOR SHOCK ABSORBER 2 - 64 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 59 Shock Absorber Dust Shield Fig. 62 Coil Spring Isolator (15) Inspect all disassembled components for signs of abnormal wear or failure, replacing any compo- nents as required.
  • Page 87 REAR SHOCK ABSORBER LOWER BUSHING MOUNT SHOCK ABSORBER JOUNCE SHOCK ABSORBER ROD SHOCK ABSORBER BUMPER COLLAR SUSPENSION 2 - 65 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 64 Shock Absorber Mount Lower Bushing Fig. 65 Jounce Bumper Installed On Shock Rod • Inspect jounce bumper for cracks and signs of (8) Install the isolator on the top of the coil spring.
  • Page 88 2 - 66 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) equivalent on end of shock rod to keep rod from turn- SPECIAL TOOLS ing (Fig. 54). Then tighten rod nut using a crowfoot (Fig. 54) to a torque of 55 N·m (40 ft. lbs.). REAR SUSPENSION (13) Relieve all tension from spring compressor.
  • Page 89 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CONTENTS page page GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY FRONT DRIVESHAFT IDENTIFICATION ..1 DRIVESHAFT RECONDITIONING FRONT DRIVESHAFTS ....1 PROCEDURE .
  • Page 90 INTERCONNECTING SHAFT TUNED DAMPER WEIGHT TRIPOD OUTER C/V JOINT BEARING SHIELD (THERMO PLASTIC) JOINT RIGHT SIDE DRIVESHAFT SEALING OUTER BOOT LEFT SIDE DRIVESHAFT (THERMO PLASTIC) JOINT TRIPOD JOINT SEALING BOOT SEALING BOOT OUTER C/V JOINT (THERMO PLASTIC) (SILICONE) SEALING BOOT INNER TRIPOD JOINT (IF ABS EQUIPPED) TONE WHEEL...
  • Page 91 SPRING WASHER COTTER PIN NUT LOCK HUB NUT FRONT H UB DIFFERENTIAL AND DRIVELINE 3 - 3 DIAGNOSIS AND TESTING (Continued) (1) Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint.
  • Page 92 DISC BRAKE CALI- CALIPER STEERING LIFT THIS END OF CALIPER AWAY PER ASSEMBLY WIRE HANGER ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY UPPER CONTROL ARM STEERING KNUCKLE DISC BRAKE CALI- PER ASSEMBLY STEERING KNUCKLE OUTBOARD...
  • Page 93 LOWER CONTROL CASTLENUT COTTER PIN BALL JOINT STUD STEERING KNUCKLE HAMMER STEERING KNUCKLE INNER PRYBAR OUTER STEERING KNUCKLE BOSS TRIPOD JOINT JOINT BEARING SHIELD TRANSAXLE C ASE LOWER STEERING KNUCKLE HUB/BEARING CONTROL BALL JOINT STUD DIFFERENTIAL AND DRIVELINE 3 - 5 REMOVAL AND INSTALLATION (Continued) (12) Remove cotter pin and castle nut (Fig.
  • Page 94 SPLINE OILSEAL SNAP RING INTERCON- NECTING S HAFT INNER TRANSAXLE TRIPOD JOINT 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (16) Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal (Fig.
  • Page 95 BRAKE CALIPER FLEX STEERING LOWER HEAT SHIELD WHEEL SPEED SEN- KNUCKLE END STUD CONTROL SOR CABLE SPEED HOSE CASTLENUT TIE ROD END SENSOR CABLE BRACKET ROUTING COTTER PIN ATTACHINGBOLT BALL JOINT STUD STEERING STEERING KNUCKLE KNUCKLE CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE...
  • Page 96 3 - 8 DIFFERENTIAL AND DRIVELINE HUB AND BEAR- BRAKING DISC STUB AXLE TORQUE WRENCH WASHER HUB NUT REMOVAL AND INSTALLATION (Continued) (13) Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of stub axle and tighten nut.
  • Page 97 RETAINING SPIDER ASSEM- SNAP RING INTERCONNECTING SHAFT INTERCONNECTING SEALING BOOT SHAFT TRIPOD ASSEMBLY WHEN REMOVING SPIDER SPIDER HOUSING SPIDER JOINT BRASS DRIFT ASSEMBLY BEARINGS ASSEM- SPIDER ASSEM- DIFFERENTIAL AND DRIVELINE 3 - 9 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: The only service which is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots on the inner tripod joints.
  • Page 98 BRASS INTERCONNECTING DRIFT SHAFT SPIDER ASSEMBLY DO NOT HIT BEARINGS WHEN INSTALLING THE INTERCONNECTING SPIDER ASSEMBLY SPIDER ASSEM- SHAFT 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) SEALING BOOT INTERCONNECTING SHAFT RAISED BEAD IN THIS AREA SEALING BOOT GROOVE (6) Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear.
  • Page 99 CLAMP JAWS OF SPECIAL TOOL C-4975A CLOSED INTERCONNECTING TOGETHER HERE COMPLETELY MUST SHAFT SEALING BOLT DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) SEALINGBOOT CLAMP INTERCON- NECTING SHAFT SPECIAL TOOL C-4975A SEALING BOOT TRIPOD SPIDER HOUSING JOINT ASSEM- Fig.
  • Page 100 INNER TRIPOD JOINT SEAL- TRIM STICK ING BOOT INNER JOINT HOUSING TRIPOD SEALINGBOOT JAWS OF SPE- CIAL C-4975A COMPLETELY TOGETHER HERE SPECIAL TOOL C -4975A CLOSED MUST TOOL TRIPOD HOUSING CLAMP SEALING BOOT CLAMP 3 - 12 DIFFERENTIAL AND DRIVELINE CLAMP SPECIAL YA3050...
  • Page 101 INNER JOINT HOUSING TRIPOD TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP SEALING BOOT BEARING OUTER SHIELD SPECIAL JOINT C-4698–2 TOOL OUTER C/V JOINT DRIFT BEARING SHIELD SPECIAL TOOL C-4698–1 DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 102 HAMMER SPECIAL C-4698–1 TOOL BEARING SEAL MUST BE FLUSH SPECIAL C-4698–2 WITH OUTER C/V JOINT TOOL FRONT BEARING SHIELD 3 - 14 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS DRIVESHAFT–SPECIAL TOOLS Tie Rod Remover MB-990635 Fig. 44 Correctly Installed Bearing Shield SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION TORQUE...
  • Page 103 BRAKES 5 - 1 BRAKES CONTENTS page page ANTILOCK BRAKE SYSTEM–ALLIED SIGNAL BASE BRAKE SYSTEM ....2 ABX-4 ......64 GENERAL INFORMATION .

  • Page 104: Table Of Contents

    5 - 2 BRAKES BASE BRAKE SYSTEM INDEX page page DESCRIPTION AND OPERATION PARK BRAKE LEVER OUTPUT CABLE ..46 CHASSIS TUBES AND HOSES ... . . 5 PARK BRAKE LEVER .

  • Page 105: Description And Operation

    BRAKE PADS AND LININGS CALIPER GUIDE PIN BOLT CALIPER GUIDE PIN BOLT OUTBOARD BRAKE SHOE INBOARD BRAKE SHOE STEERING KNUCKLE CALIPER ASSEMBLY WEAR INDICATOR BLEEDER SCREW GUIDE PIN BOLTS BRAKE ROTOR PISTON SEAL DRIVING HUB DUST SEAL BUSHING BUSHING CALIPER SLEEVE SLEEVE PISTON...
  • Page 106 5 - 4 BRAKES AUTOMATIC PARK PARK BRAKE BRAKE OUTPUT CABLE HAND LEVER MECHANISM EQUALIZER ADJUSTER ASSEMBLY CABLE LEVER REAR WHEEL BRAKE TUBES FROM MASTER CYLINDER FRONT CROSSMEMBER SUSPENSION BRAKE TUBE ASSEMBLY ROUT- NON-ABS EQUIPPED PROPOR- AUTOMATIC BRAKE BRAKE HUB/BEARING ASSEMBLY TRAILING BRAKE SHOE LEADING BRAKE SHOE AUTOMATIC ADJUSTER...

  • Page 107: Master Cylinder

    LEFT PORTIONING VALVE RIGHT TO REAR BRAKE LINE FRAME RAIL CODE REAR FRONT LABEL PRO- STAMP RIGHT REAR PROPORTION- HYDRAULIC TROL UNIT (HCU) ING VALVE O-RING SEAL TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT CON- RIGHT DRAFT SHAFT BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) CHASSIS TUBES AND HOSES The purpose of the chassis brake tubes and flex...

  • Page 108: Red Brake Warning Lamp

    MASTER DER FLUID RES- MASTER CYLINDER ASSEM- ERVOIR CYLIN- MASTER CYLINDER SEC- MASTER CYLINDER SEC- ONDARY PORTS ONDARY PORT MASTER CYLINDER PRI- BRAKE FLUID RES- ERVOIR MARY PORT MASTER CYL- I NDER MASTER CYLINDER MOUNT- MASTER CYLINDER PUSH VACUUM CHECK VALVE ING STUDS PART...
  • Page 109 MASTER MOUNTING STUDS (2) OUTPUT ROD VACUUM CHECK VALVE CYLINDER POWER BOOSTER ASSEM- MOUNTING STUDS (4) POWER BRAKE BOOSTER DASH PANEL INPUT ROD ASSEMBLY MASTER CYLINDER ASSEMBLY BRAKE TUBES MASTER CYLINDER FLUID LEVEL SENSOR LEFT SHOCK TOWER BRAKES 5 - 7 DESCRIPTION AND OPERATION (Continued) Fig.

  • Page 110: Diagnosis And Testing

    5 - 8 BRAKES DIAGNOSIS AND TESTING BRAKE SYSTEM BASIC DIAGNOSIS GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 SYMPTOM MISC. WARNING POWER BRAKE WHEEL COND. LIGHT BRAKES NOISE BRAKES Brake Warning Light On Excessive Pedal Travel Pedal Goes To The Floor Stop Light On Without Brakes All Brakes Drag...

  • Page 111: Brake System Diagnosis Charts

    CHECK OBSTRUCTION OF BRAKE INSPECT FOR AND COR- RECT STOP VERIFY THAT BRAKE PEDAL IS RETURNING FULLY TO APPLY RELEASE, WHEEL BY BLEEDER TURN WHEEL TURNS, HYDRAULIC PRESSURE WAS TRAPPED LOW ENGINE VACUUM SEE CONTAMINATED BINDING CALIPER PINS OR BUSHINGS REPLACE BUSH- BLOCKED OR PINCHED LINE LINING FRONT...
  • Page 112 CHECK FLUID LEVEL SWITCH AND MASTER CYLINDER FLOAT FOR REMOVE DER RESERVOIR CAP — CHECK FLUID LEVEL PROPER OPERATION MASTER FLUID LEVEL OK LIGHT CHECK BRAKE IS FULLY RELEASED CYLIN- “ON” THAT MALFUNCTION INDICATING PARKING REPAIR OR REPLACE AS CHECK FLUID LEVEL LOW ENTIRE CHECK WARNING LIGHT IGNITION...
  • Page 113 IF VACUUM SUPPLY IS BELOW 12 INCHES- REPLACE OR REPAIR VACUUM HOSE AND VACUUM FITTINGS. ALSO TUNE OR REPAIR IF PEDAL DOES NOT DROP, CONNECT VACUUM GAUGE TO SPEED CONTROL VACUUM PORT ON POWER UNIT. WITH ENGINE ENGINE OFF. DEPRESS AND RELEASE BRAKE PEDAL SEVERAL DEPRESS PEDAL AND HOLD WITH LIGHT EFFORT OF 15 TO 25 IF POWER UNIT IS OPERATING, PEDAL WILL FALL SLIGHTLY AND THEN HOLD.

  • Page 114: Brake Noise

    HIGH LOW SPEED, LIGHT PEDAL REPLACE BRAKE PADS PITCH SQUEAK AT DISC BRAKES FRONT BROKEN OR MISS- RATTLE SPRING OR CLIP ANTI-RATTLE CLUNKING PINS LOOSE SCRAPING (METAL TO AND REAR REPLACE WORN OUT INSPECT FERENCE OR FOREIGN DETERMINE NOISE LOCA- OBJECTS METAL) LININGS...

  • Page 115: Drum Brake Automatic Adjuster Operation

    BRAKE ADJUSTER ACCESS BRAKE SUPPORT PLATE SHOCK ABSORBER HOLE PLUG KNUCKLE BRAKES 5 - 13 DIAGNOSIS AND TESTING (Continued) DRUM BRAKE AUTOMATIC ADJUSTER OPERATION properly, the respective brake drum must be removed for servicing of the adjuster mechanism. Place the vehicle on a frame contact hoist with a helper in the driver’s seat to apply the brakes.
  • Page 116 SPECIAL TOOL SPECIAL TOOL C-3339 SP-1910 MILLIMETERS FROM EDGE DISC SURFACE HUB SURFACE SPECIAL TOOL SP-1910 SPECIAL TOOL C-3339 5 - 14 BRAKES DIAGNOSIS AND TESTING (Continued) Fig. 19 Checking Rotor For Runout Fig. 21 Checking Hub for Runout Fig. 20 Marking Rotor and Wheel Stud Install Dial Indicator, Special Tool C-3339 and Mounting Adaptor, Special Tool SP-1910 on steering knuckle.

  • Page 117: Proportioning Valves

    TWELVE EQUAL POINTS ON CALIPER DISC BRAKES 5 - 15 DIAGNOSIS AND TESTING (Continued) cle, or in-line on the brake tube on non-antilock equipped vehicles. Fig. 24 Proportioning Valve Pressure Test Fittings The pressure gauges used with the pressure test SPECIAL TOOL C-4007–A fittings for testing the in-line proportioning valves on both non-ABS and ABS brakes, is the Pressure...
  • Page 118 5 - 16 BRAKES DIAGNOSIS AND TESTING (Continued) (7) Connect brake hydraulic line onto pressure test fitting installed in proportioning valve. (8) Install Pressure Gauge, Special Tool C-4007-A into each pressure test fitting. Bleed air out of hose from pressure test fitting to pressure gauge, at pressure gauge to remove all trapped air.
  • Page 119 LEFT PORTIONING VALVE RIGHT FRAME RAIL REAR FRONT PRO- RIGHT REAR PROPORTION- HYDRAULIC TROL UNIT (HCU) ING VALVE CON- RIGHT DRIVE SHAFT BRAKES 5 - 17 DIAGNOSIS AND TESTING (Continued) (6) Install Pressure Test Fitting, Special Tool 6805-3 or 6805-4 into the outlet of the proportioning valve.

  • Page 120: Red Brake Warning Lamp Test

    5 - 18 BRAKES DIAGNOSIS AND TESTING (Continued) BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar.
  • Page 121 BRAKES 5 - 19 SERVICE PROCEDURES (Continued) The following wheel sequence for bleeding the (4) Repeat the procedure at all the other remain- brake hydraulic system should be used to ensure ing bleeder screws. Then check the pedal for travel. adequate removal of all trapped air from the hydrau- If pedal travel is excessive or has not been improved, lic system.

  • Page 122: Brake Rotor Machining

    MASTER FLUID RESERVOIR MASTER CYLINDER CYLINDER SPECIAL TOOL 6802 SPECIAL TOOL 6802 MASTER CYLINDER ASSEMBLY 5 - 20 BRAKES SERVICE PROCEDURES (Continued) BRAKING DISC CUTTING TOOLS DAMPER Fig. 32 Bleeding Tubes Attached To Master Cylinder Fig. 34 Bleeding Master Cylinder With ABS BRAKE ROTOR MACHINING DISC BRAKE ROTOR TURNING PROCEDURES...
  • Page 123 BRAKING DISC GRINDER MINIMUM THICKNESS MARKINGS BRAKES 5 - 21 SERVICE PROCEDURES (Continued) Fig. 36 Resurfacing Brake Rotor (Final Finish) Fig. 37 Minimum Brake Rotor Thickness Markings The following chart shows the location of measure- (Example) ments and specifications when servicing the rotor. (0.0005 inch) thickness variation limits MUST BE NOTE: All rotors have markings for minimum...

  • Page 124: Brake Tube Repair

    5 - 22 BRAKES SERVICE PROCEDURES (Continued) exceed either 0.0635 mm (0.0025 inch) in 30° or 0.0889 mm (0.0035 inch) in 360°. All brake drums are marked with the maximum allowable brake drum diameter (Fig. 38). Fig. 38 Maximum Brake Drum Diameter Identification Fig.

  • Page 125: Removal And Installation

    INVERTED TUBE NUT FLARE TUBE INVERTED DOUBLE FLARE SEAT DOUBLE-INVERTED STYLE FLARE BRAKES 5 - 23 REMOVAL AND INSTALLATION (Continued) Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings.

  • Page 126: Brake Pedal

    5 - 24 BRAKES REMOVAL AND INSTALLATION (Continued) Support caliper from upper control arm (7) Remove jackstands or lower hoist. Before to prevent weight of caliper from being sup- moving vehicle, pump the brake pedal several ported by brake flex hose. Supporting disc times to insure the vehicle has a firm brake brake caliper from flex hose can damage the pedal.
  • Page 127 CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY STEERING KNUCKLE DISC BRAKE CALI- PER ASSEMBLY OUTBOARD BRAKE SHOE DISC DISC BRAKE CALI- PER ASSEMBLY WIRE HANGER ASSEMBLY (STORED) STEERING KNUCKLE BRAKE...
  • Page 128 BRAKE OUTBOARD BRAKE SHOE SHOE BRAKE CALIPER RETAINING PINS 5 - 26 BRAKES REMOVAL AND INSTALLATION (Continued) rect outer brake shoe is installed in the correct cal- iper. The left and right outer brake shoes are LEFT RIGHT OUTBOARD BRAKE INBOARD BRAKE SHOE OUTBOARD WEAR INDICATOR...
  • Page 129 INSTALL THIS END OF CALI- OUTBOARD BRAKE SHOE DISC BRAKE CALIPER UNDER STEERING KNUCKLE KNUCKLE FIRST STEERING ROTOR BRAKE ADJUSTER ACCESS BRAKE SUPPORT PLATE SHOCK ABSORBER HOLE PLUG KNUCKLE BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) (7) Carefully position brake caliper and brake shoes over brake rotor by first hooking top of brake shoes onto upper abutment on steering knuckle (Fig.
  • Page 130 5 - 28 BRAKES REMOVAL AND INSTALLATION (Continued) INSTALL (1) Install rear brake drum on rear hub and bear- ing assembly. (2) Install the wheel and tire assembly. (3) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification.
  • Page 131 PARK BRAKE SUPPORT PLATE BRAKE SUPPORT PLATE TRAILING BRAKE SHOE LEADING BRAKE SHOE AUTOMATIC ADJUSTER HOLD DOWN SPRING BRAKE ATTACHING PIN ACTUATING LEVER PARK PARK BRAKE LEVER PIN BRAKE SUPPORT PLATE BRAKE SUPPORT PLATE TRAILING BRAKE SHOE TRAILING BRAKE SHOE TRAILING BRAKE SHOE HOLD DOWN SPRING PARK BRAKE LEVER...
  • Page 132 PARK BRAKE SUPPORT PLATE BRAKE WAVE WASHER ACTUATING LEVER 5 - 30 BRAKES REMOVAL AND INSTALLATION (Continued) Shoes with lack of contact at toe or heel may be improperly ground. Clean and inspect support and adjusting screws. Apply a thin coat of Mopar Multi-Purpose Lubricant or equivalent to the threads of the self adjuster (Fig.
  • Page 133 BRAKES 5 - 31 REMOVAL AND INSTALLATION (Continued) specification. Then repeat the tightening sequence to Removal And Installation Section in this group of the the full specified torque of 135 N·m (100 ft. lbs.). service manual for the proper brake shoe assembly (16) Road test vehicle.
  • Page 134 5 - 32 BRAKES REMOVAL AND INSTALLATION (Continued) INSTALL (1) Install the gasket and brake support plate on rear suspension knuckle. Torque the brake support plate to knuckle attaching bolts to 75 N·m (55 ft. lbs.). (2) Insert parking brake cable end fitting into brake support plate.

  • Page 135: Master Cylinder

    HUB/BEARING REAR HUB/BEARING ASSEMBLY ASSEMBLY BRAKE DRUM DUST CAP REAR LATERAL REAR SUPPORTPLATE SHOCK ASSEMBLY BRAKE HUB/BEARING ASSEMBLY RETAINING NUT SPINDLE BRAKES 5 - 33 REMOVAL AND INSTALLATION (Continued) REAR HUB AND BEARING REMOVE (1) Raise vehicle on jackstands or centered on a frame contact type hoist.
  • Page 136 MASTER MASTER CYLINDER ASSEM- CYLIN- MASTER CYLINDER SEC- MASTER CYLINDER SEC- ONDARY PORTS ONDARY PORT MASTER CYLINDER PRI- BRAKE FLUID RES- ERVOIR MARY PORT MASTER CYL- I NDER BRAKE VACUUM BOOSTER BRAKE FLUID RESERVOIR MASTER FLUID RESERVOIR MASTER CYLINDER MOUNTING NUTS ROUTING CLIP MASTER CYLINDER CYLINDER...
  • Page 137 SPECIAL TOOL 6802 SPECIAL BRAKE FLUID RES- TOOL 6802 ERVOIR MASTER CLYINDER MASTER CYLINDER ASSEMBLY WOODEN DOWEL BRAKES 5 - 35 REMOVAL AND INSTALLATION (Continued) (2) Install the routing clip and chassis brake tubes (Fig. 84) on the inboard mounting stud for the mas- ter cylinder.
  • Page 138 MASTER MOUNTING ASSEMBLY CYLINDER ATTACHING NUTS BRACKET MASTER SPEED LEFT CYLIN- TOWER STRUT CONTROL SERVO ELECTRICAL LEFT PURGE SOLE- CONNECTOR VACUUM HARNESS TOWER STRUT NOID VACUUM HOSE FROM SPEED CONTROL SERVO AIR CLEANER HOUSING INTAKE MANIFOLD AIR INLET RESONATOR INLET LEFT SHOCK TOWER (ENGINE MOUNTING) AIR INLET HOSE...
  • Page 139 POWER UUM BOOSTER BRAKE VAC- TRANSAXLE MASTER CYLINDER AND LEFT STRUT TOWER BRAKE TUBES FRAME FRONT RAIL BRAKES 5 - 37 BRAKE PEDAL SCREWDRIVER INPUT ROD RETAINING CLIP BRAKE PEDAL PIN BRAKE VACUUM BOOSTER MASTER CYLINDER BRAKE FLUID RESERVOIR ASSEMBLY MASTER CYLINDER MOUNTING NUTS ROUTING CLIP...
  • Page 140 POWER BOOSTER ASSEMBLY BRAKE STRUT TOWER BRAKE P EDAL AIR CLEANER DASH PANEL VACUUM POWER BOOSTER MOUNTING BRAKE NUTS MASTER CYLINDER REMOTE GROUND CABLE LEFT AIR CLEANER GROUND TOWER STRUT STUD SPEED CONTROL SERVO 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) (6) Install the routing clip and chassis brake tubes (Fig.
  • Page 141 CHAM- ATTACHINGBOLT INTAKE MANIFOLD HOSE THROTTLE BODY GROUNDSTUD HOSE INLET CLEANER HOUSING LEFT STRUT TOWER AIR CLEANER LID BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) (2) Correctly isolate remote ground cable when ser- (4) Remove the throttle cable and if equipped the vicing vehicle by installing the ground cable insulator speed control cable from the throttle body (Fig.
  • Page 142 5 - 40 BRAKES REMOVAL AND INSTALLATION (Continued) (7) If equipped, remove the vehicle’s wiring har- ness connector from the speed control servo. Remove MOUNTING NUTS SPEED CONTROL SERVO STRUT TOWER AIR CLEANER the 2 speed control servo mounting bracket to strut tower attaching nuts (Fig.
  • Page 143 TRANSAXLE DIPSTICK TUBE DIPSTICK VACUUM HARNESS POWER BRAKE BOOSTER VACUUM ELECTRICAL CONNECTOR PURGE SOLENOID TRANSAXLE ATTACHING BOLT BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) (11) Remove the routing clip and chassis brake (16) Remove the vacuum hoses from the check tubes (Fig.
  • Page 144 POWER BRAKE BOOSTER VACUUM 5 - 42 BRAKES REMOVAL AND INSTALLATION (Continued) (19) Slide the vacuum booster straight forward brake tubes can not touch each other or other com- until mounting studs clear dash panel. Then lift the ponents or the body of the vehicle. vacuum booster strait up to remove it from the vehi- (9) Install the routing clip and chassis brake tubes on cle (Fig.
  • Page 145 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD STRIKER BRAKE LIGHT SWITCH BRAKE PEDAL BRAKE PEDAL PIN INPUT ROD BRAKE PEDAL RETAINING CLIP SCREWDRIVER SWITCH BRACKET LEFT STRUT TOWER SPEED CONTROL SERVO BRAKES 5 - 43 REMOVAL AND INSTALLATION (Continued) BRAKE PEDAL REMOVE...
  • Page 146 TRANSMISSION PARK BRAKE LEVER CENTER CONSOLE ALLEN WRENCH SHIFT KNOB INDICATOR RANGE 5 - 44 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: When installing the retaining clip on the chassis brake tube nut into the end of the flex hose. brake pedal pin a NEW retaining clip must be used Following this procedure will prevent twisting of the flex hose when the flex hose bracket is attached to to ensure the retention of the vacuum booster push...
  • Page 147 CENTER CONSOLE COVER ATTACHING SCREWS CENTER CONSOLE PARK CENTER CONSOLE WIRING VEHICLE WIRING HARNESS PARK BRAKE HAND LEVER GEARSHIFT MECHANISM 10–WAY CONNECTOR ATTACHING SCREWS CENTER CONSOLE CENTER CONSOLE PASSENGER SEAT BRAKE DRIVER SEAT ASSEMBLY HARNESS LEVER BRAKES 5 - 45 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 148 PARK AUTOMATIC PARK BRAKE LEVER OUT- PARK BRAKE LEVER MECH- USING PUSH DOWNWARD ON END PARK BRAKE LEVER OUT- OF CLUTCH SPRING HERE. PARK BRAKE HAND LEVER PARK BRAKE HAND LEVER CLUTCH SPRING END BRAKE CLUTCH SPRING 15/64 DRILL BIT SCREWDRIVER SCREWDRIVER MECHANISM...

  • Page 149: Park Brake Cables

    BRAKES 5 - 47 REMOVAL AND INSTALLATION (Continued) PARK BRAKE LEVER MOUNTING BOLTS MOUNTING BOLTS NOTE: The mounting holes in the park brake lever (3) Unload the adjuster mechanism on the park bracket are slotted, which requires the mounting brake lever using the following procedure. •...
  • Page 150 PARK BRAKE HAND LEVER CENTER CONSOLE COVER GEARSHIFT MECHANISM ATTACHING SCREWS ATTACHING SCREWS CENTER CONSOLE CENTER CONSOLE 5 - 48 BRAKES REMOVAL AND INSTALLATION (Continued) For servicing of either the left or right rear park SHIFT RANGE INDICATOR PARK BRAKE LEVER CENTER CONSOLE CENTER CONSOLE ALLEN WRENCH...
  • Page 151 PARK CENTER CONSOLE WIRING VEHICLE WIRING HARNESS 10–WAY CONNECTOR CENTER CONSOLE PASSENGER SEAT BRAKE DRIVER SEAT ASSEMBLY HARNESS LEVER PARK AUTOMATIC PARK BRAKE LEVER OUT- PARK BRAKE LEVER MECH- USING PUSH DOWNWARD ON END PARK BRAKE LEVER OUT- REAR WHEEL PARK BRAKE PARK BRAKE LEVER OUT- PARK PARK BRAKE CABLE TEN-...

  • Page 152: Rear Brake Drum

    REAR PARK BRAKE CABLES VEHICLE CARPETING ROUTING CLIP FLOOR PAN 5 - 50 BRAKES REMOVAL AND INSTALLATION (Continued) PARK BRAKE CABLE TEN- PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES HUB/BEARING REAR 1/2” BOX END WRENCH ASSEMBLY CONSOLE BRACKET SION EQUALIZER BRAKE DRUM PUT CABLE...
  • Page 153 HUB/BEARING ASSEMBLY HUB/BEARING ASSEMBLY RETAINING NUT DUST CAP SPINDLE PARK 1/2” FRAME PARK BRAKE CABLE PARK BRAKE CABLE BRAKE SUPPORT PLATE TRAILING BRAKE SHOE RAIL BRAKE PARK BRAKE CABLE PARK BRAKE CABLE RETAINER WRENCH ACTUATING LEVER ROUTING BRACKETS REAR SUPPORTPLATE FUEL TANK BRAKE BRAKES...
  • Page 154 5 - 52 BRAKES PARK BRAKE CABLE FUEL TANK SEALING GROMMET FUEL LINES VEHICLE FLOOR PLAN REMOVAL AND INSTALLATION (Continued) (29) Remove the park brake cable and sealing (11) Grasp park brake cable to floor pan seal grom- grommet (Fig. 146) from the floor pan of the vehicle. met by hand and pull it into the floor pan to ensure PARK PARK BRAKE CABLES...

  • Page 155: Disassembly And Assembly

    BRAKES 5 - 53 REMOVAL AND INSTALLATION (Continued) (18) Check the rear wheels of the vehicle with the park brake lever fully released, they should rotate freely without dragging. (19) Raise the park brake hand lever to approxi- mately a 45° angle. This is necessary for the required clearance to install the center console.

  • Page 156: Brake Fluid Level Switch

    MASTER CYLIN- FLUID MASTER FLUID RESER- BRAKE RESER- VOIR BRAKE CYLIN- VOIR FLUID LEVEL SWITCH RETAINING MASTER CYLIN- MASTER CYLINDER BRAKE FLUID RES- WIRING HARNESS CONNEC- TABS BRAKE ERVOIR BRAKE FLUID LEVEL LEVEL SWITCH MASTER CYL- I NDER SEN- FLUID 5 - 54 BRAKES DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 157 SLEEVE CALIPER BUSHING BRAKES 5 - 55 DISASSEMBLY AND ASSEMBLY (Continued) CALIPER BUSHING Caliper Disassembly And Re-Assembly Procedures in (3) Using your fingers, collapse one side of the Disc Brake Caliper Service in this section of the ser- bushing. Then pull on the opposite side to remove vice manual.
  • Page 158 5 - 56 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) CALIPER BUSHING (2) Insert the folded bushing into the caliper hous- (4) Lubricate the inside surfaces of the bushing ing (Fig. 156). Do not use a sharp object to per- using Mopar, Silicone Dielectric Compound or an CALIPER BUSHING SLEEVE...
  • Page 159 BRAKES 5 - 57 DISASSEMBLY AND ASSEMBLY (Continued) PISTON SEAL PLASTIC TRIM STICK PISTON SEAL GROOVE CALIPER Fig. 159 Correctly Installed Caliper Sleeve And Fig. 160 Removing Caliper/Piston Dust Boot Bushing Carefully depress brake pedal to hydrauli- cally push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel.
  • Page 160 CALIPER CALIPERBORE SPECIAL TOOL C-4095 CALIPER SEAL GROOVE PISTON SEAL 5 - 58 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) the bore is not increased more than 0.0254 mm (2) Dip new piston seal in clean brake fluid and (0.001 inch) (Fig. 162). install in the groove of the caliper bore.

  • Page 161: Wheel Cylinder Rear Drum Brake

    CALIPER SPECIAL C-4171 TOOL SPECIAL HAMMER C-4689 TOOL BRAKES 5 - 59 DISASSEMBLY AND ASSEMBLY (Continued) (6) Position dust boot into the counterbore of the (1) Pry boots away from cylinders and remove (Fig. caliper assembly piston bore. 166). (7) Using a hammer and Installer Piston Caliper (2) Press IN on one piston to force out opposite Boot, Special Tool C-4689 and Handle, Special Tool piston, cup and spring (Fig.
  • Page 162 PUSH-ON BOOT PISTON PISTON BLEEDER SCREW EXPANDERS SPRING CYLINDER PUSH-ON BOOT 5 - 60 BRAKES SELF ADJUSTER ACTUAT- OUTBOARD FORWARD OUTBOARD REAR SELF ADJUSTER STAR WHEEL ING LEVER CLEANING AND INSPECTION (Continued) Fig. 166 Rear Wheel Cylinder (Exploded View) When a set of brake shoes are worn to a total Clean and inspect the brake support plate and the thickness of approximately 9.0 mm (3/8 inch) they automatic self adjusting mechanism.

  • Page 163: Chassis Tubes And Hoses

    STRIKER BRAKE LIGHT SWITCH BRAKE PEDAL SWITCH BRACKET BRAKES 5 - 61 CLEANING AND INSPECTION (Continued) If any return, hold down, or actuating springs have ADJUSTMENTS overheated or are damaged, replace them. Overheat- STOP LAMP SWITCH ing indications are paint discoloration or distorted (1) Remove stop lamp switch from its bracket by end coils.

  • Page 164: Specifications

    5 - 62 BRAKES BRAKE ADJUSTER ACCESS BRAKE ADJUSTER ACCESS BRAKE SUPPORT PLATE BRAKE SUPPORT PLATE SHOCK ABSORBER SCREWDRIVER HOLE PLUG KNUCKLE HOSE ADJUSTMENTS (Continued) (1) Raise vehicle using a frame contact type hoist (5) Insert a thin screwdriver or a piece of welding or supported as required using jack stands.
  • Page 165 BRAKES 5 - 63 SPECIFICATIONS (Continued) BRAKE ACTUATING SYSTEM BRAKE FASTENER TORQUE SPECIFICATIONS ACTUATION: DESCRIPTION TORQUE Vacuum Operated Power Brakes ..Standard BRAKE TUBES: Hydraulic System ..Dual-Diagonally Split Tube Nuts To Fittings And Components .

  • Page 166: Special Tools

    5 - 64 BRAKES SPECIAL TOOLS BASE BRAKE SYSTEM Installer, Dust Boot C-4689 Adapters, Brake Pressure Test 6805 Dial Indicator C-3339 Gauge Set C-4007-A Tubes, Master Cylinder Bleeding 6802 Handle, Universal C-4171...
  • Page 167 BRAKES 5 - 65 ANTILOCK BRAKE SYSTEM–ALLIED SIGNAL ABX-4 INDEX page page DESCRIPTION AND OPERATION DIAGNOSTIC TROUBLE CODE ABS AMBER WARNING LAMP FUNCTION AND INFORMATION ..... . . 71 LOCATION .
  • Page 168 5 - 66 BRAKES DESCRIPTION AND OPERATION (Continued) ABS OPERATION AND VEHICLE PERFORMANCE steering maneuvers at high speed or high speed cor- nering beyond the limits of tire adhesion to the road This ABS System represents the current state-of- surface may cause vehicle skidding, independent of the-art in vehicle braking systems and offers the vehicle braking.
  • Page 169 FRONT SION CROSSMEM- DRIVESHAFT SUSPEN- RIGHT FRAME RAIL STEERING GEAR HCU MOUNTING HYDRAULIC CONTROL UNIT BRACKET BRAKES 5 - 67 DESCRIPTION AND OPERATION (Continued) ABS BRAKES HYDRAULIC CONTROL UNIT (HCU) This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the WARNING: THE ONLY PARTS OF THE HYDRAULIC CONTROL UNIT HCU THAT ARE SERVICEABLE...
  • Page 170 SYSTEM RELAY AND PUMP/ MOTOR RELAY BOX SYSTEM RELAY AND PUMP/MO- TOR RELAY BOX 10 WAY CON- NECTOR 6–WAY NECTOR CON- WHEEL SPEED SEN- BRAKE SUPPORT TO REAR BRAKE LINE STEERING WHEEL TONE WHEEL CODE PLATE KNUCKLE SENSOR SPEED LABEL STAMP TONE WHEEL ATTACHING...
  • Page 171 WINDSHIELD HOOD PROP ROD FLUID BOTTLE AIR CONDITION- WASHER ING HOSE CONTROLLER ANTILOCK BRAKES 60–WAY TRICAL NECTOR ELEC- CON- BRAKES 5 - 69 DESCRIPTION AND OPERATION (Continued) plate (Fig. 5) and the rear tone wheel is an integral hydraulic circuits until a locking tendency is no part of the rear wheel hub and bearing assembly.
  • Page 172 5 - 70 BRAKES DESCRIPTION AND OPERATION (Continued) ABS BRAKING MODE HYDRAULIC CIRCUIT Group 5 Brakes in this service manual. This includes brake noise, brake pulsation, lack of power assist, SOLENOID AND VALVE FUNCTION parking brake, Red Brake Warning Lamp lighting, or Through the following operation descriptions the vehicle vibration during normal braking.
  • Page 173 HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- BRAKES 5 - 71 DIAGNOSIS AND TESTING (Continued) peared. Other faults are non-latching, although a fault code will be set in most cases. INTERMITTENT DIAGNOSTIC TROUBLE CODES As with virtually any electronic system, intermit- tent faults in the ABS system may be difficult to accurately diagnose.
  • Page 174 TO REAR BRAKE LINE CODE LABEL STAMP O-RING SEAL TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT 5 - 72 BRAKES DIAGNOSIS AND TESTING (Continued) determine cause and correct before replacing the To test for contamination, put a small amount of wheel speed sensor.
  • Page 175 HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- BRAKES 5 - 73 DIAGNOSIS AND TESTING (Continued) Care must be taken to avoid overloading the CAB The Allied Signal ABX-4 Brake System must be circuits. In testing for open or short circuits, do bled as two independent braking systems.
  • Page 176 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD LEFT STRUT TOWER SPEED CONTROL SERVO 5 - 74 BRAKES SERVICE PROCEDURES (Continued) WARNING: WHEN BLEEDING THE BRAKE SYS- If welding work is to be performed on the vehicle, TEM WEAR SAFETY GLASSES.
  • Page 177 CLUTCH EQUIPPED REAR MUFFLER SUPPORT BRAKE P EDAL WITH PEDAL TRANSAXLE) THROTTLE PEDAL ISOLATORS MANUAL DRIVER’S SEAT STEERING FRONT MUFFLER SUPPORT WHEEL NUTS 32 N·M (24 SHOULDER BOLT ISOLATOR (250 IN. LBS.) SPRING FWD FT. LBS.) N·M GASKET NUTS 2.4/2.5L ENGINE 2.0L ENGINE RESONATOR PORT ISOLATORS...
  • Page 178 DRIVESHAFT FRONT SPLASH SHIELD CROSSMEMBER SUSPENSION MOUNTING BRACKET STEERING GEAR ATTACHING SHIELD HEAT BOLT 6–WAY RELAY BRAKE RIGHT FRONT BRAKE TOR CONNECTOR BRAKE TUBE PUMP/MO- TUBE TUBE ROUTING CLIP BRAKE TUBES FROM MASTER 10–WAY RELAY BOX CON- REAR BRAKE TUBES ATTACHING BOLT PROPORTIONING CYLINDER...
  • Page 179 REMOVE VEHICLE IS EQUIPPED WITH STEERINGGEAR THIS 2.5L ENGINE TUBE ASSEMBLY VEHICLE FLOOR PAN MOUNTING BRACKET BRAKES 5 - 77 DRIVESHAFT ING BOLT ATTACH- ISOLATOR/ WASHER VEHICLE FRAME MOUNTING BRACKET REMOVAL AND INSTALLATION (Continued) IF VEHICLE IS EQUIPPED REMOVE THIS TUBE FROM WITH A 2.5LTR ENGINE MOUNTINGBOLT STEERING GEAR...
  • Page 180 5 - 78 BRAKES REMOVAL AND INSTALLATION (Continued) PUMP MOTOR MOUNTING SCREWS (DO NOT REMOVE) RELAY MOUNTING SCREWS PUMP MOTOR RELAY BOX ASSEMBLY LEFT PORTIONING VALVE RIGHT TO REAR BRAKE LINE FRAME RAIL CODE REAR FRONT LABEL PRO- STAMP RIGHT REAR PROPORTION- HYDRAULIC TROL UNIT (HCU) ING VALVE...
  • Page 181 PULL RELAY BOX IN THIS DIRECTION RELAY BOX CONNECTOR RELAY BOX PUMP MOTOR CONNECTOR PUMP M OTOR AND SEAL BRAKES 5 - 79 REMOVAL AND INSTALLATION (Continued) PUMP MOTOR HOUSING PUMP MOTOR TO RELAY BOX ELECTRICAL CONNECTOR ELECTRICAL CONNECTOR PUMP MOTOR SEAL WINDSHIELD WINDOW...
  • Page 182 MOUNTING BOLT CAB AIR CONDITION- ING LINE MOUNTING BRACKET MOUNTING BOLT GROMMET RETAINER AND CABLE ROUTING BRACKET WHEEL SPEED SEN- SPEED ROUTING BRACKET SOR CABLE SENSOR BOLT STEERING KNUCKLE B OLT SHOCK ABSORBER WHEEL SPEED SEN- SEALING VEHICLE WIRING HARNESS INNER FENDER GROMMET SOR CABLE...
  • Page 183 BRAKES 5 - 81 REMOVAL AND INSTALLATION (Continued) CAUTION: If speed sensor head locating pin has sensor cable is not routed in this direction it will seized to the steering knuckle, do not attempt to rub against the tire or wheel, damaging the speed remove speed sensor head by grasping with pliers sensor cable.
  • Page 184 SEALING REAR VEHICLE WIRING HAR- REAR TRUNK FLOOR GROMMET FENDER SPEED INNER WHEEL SENSOR CABLE NESS SPEED SENSOR CABLE BRAKE SEALING BOLT HOSE FLEX GROMMET RETAINER REAR OF PASSEN- MENT BACK SEAT COMPART- UPPER CONTROL BRAKE FLEX HOSE BRAKE DRUM SPEED BRACKET SENSOR...
  • Page 185 BRAKES 5 - 83 REMOVAL AND INSTALLATION (Continued) (2) Install wheel speed sensor attaching bolt (Fig. BRAKE FASTENER TORQUE SPECIFICATIONS 40). Tighten the speed sensor head attaching bolt to 8 N·m (75 in. lbs.) DESCRIPTION TORQUE (3) Install speed sensor cable routing clips (Fig. BRAKE TUBES: 39) on the brake flex hose bracket and the bracket on Tube Nuts To Fittings And...
  • Page 187 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION TEMPERATURE GAUGE INDICATION ..17 ACCESSORY DRIVE BELTS ....2 TESTING SYSTEM FOR LEAKS .

  • Page 188: General Information

    THERMOSTAT HOUSING WATER PUMP COOL DOWN PRESSURE CAP COOLANT RECOVERY SYSTEM TANK ENGINE RADIATOR HEATUP HEATER 7 - 2 COOLING SYSTEM GENERAL INFORMATION Coolant flow circuits for 2.4L engine equipped vehi- cles are shown in (Fig. 1). The 2.5L engine coolant COOLING SYSTEM routing is shown in (Fig.
  • Page 189 THERMO- COOLANT RECOVERY SYSTEM TANK STAT GASKET THERMO- HEAT UPCOOLDOWN STAT HOUS- O-RING O-RING INLET PIPE COOLANT RADIATOR ELBOW INLET COOLANT GASKETS HEATER OUTLET O-RINGS TUBES CRANKSHAFT POWER HEATER DAMPER STEERING WATER PUMP PUMP THERMOSTAT HOUSING ENGINE AIR CONDITIONING COMPRESSOR PRESSURE CAP GENERATOR IDLER...

  • Page 190: Engine Thermostats

    7 - 4 COOLING SYSTEM GENERAL INFORMATION (Continued) COOLANT RECOVERY SYSTEM (CRS) This system works in conjunction with the pres- sure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air. It provides a volume for expansion and contraction, provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pres- COOLANT RECOVERY SYS-...

  • Page 191: Water Pump-2.5L Engine

    COOLING SYSTEM 7 - 5 INLET PIPE O-RING GASKET O-RING WATER PUMP GENERAL INFORMATION (Continued) The water pump is driven by the timing belt. See Timing System in Group 9, Engine for component removal providing access to water pump. TRANSMISSION FAN MODULE FASTENERS SINGLE FAN DRAINCOCK...

  • Page 192: Description And Operation

    7 - 6 COOLING SYSTEM GENERAL INFORMATION (Continued) AUXILIARY TRANSMISSION OIL COOLER—2.5L rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, TRANSMISSION Models equipped with 2.5L engine, have an auxil- COOLING MODULE OIL COOLER AUXILIARY and corrosion are added as follows:...

  • Page 193: Engine Block Heater

    THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR RUBBER SEALS VENT VALVE FILLER NECK OVERFLOW NIPPLE STAINLESS-STEEL SWIVEL TOP GASKET RETAINER MAIN SPRING COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) connecting hose. If valve is stuck shut, the radia- Spring type hose clamps are used in all applica- tor hoses will be collapsed on cool down.
  • Page 194 LEFT REAR SIDE VIEW CYLINDER BLOCK 2.5L ENGINE BLOCK HEATER F WD PUMP BODY BLOCK HEATER INLET PIPE O-RING GASKET RIGHT REAR SIDE VIEW LEFT REAR SIDE 2.04L ENGINE O-RING 2.04L ENGINE WATER PUMP VIEW 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Fig.

  • Page 195: Diagnosis And Testing

    COOLING SYSTEM 7 - 9 DIAGNOSIS AND TESTING COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On Board Diagnostic in (DTC) number 17 been set Group 25. Replace thermostat if indicating a stuck open engine necessary.
  • Page 196 7 - 10 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ENGINE THERMOSTAT TESTING COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 7. Coolant level low in radiator but 7. (a) Check condition of radiator HIGH OR ENGINE COOLANT not in coolant overflow/reserve cap and cap seals.
  • Page 197 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING 1. The gauge may cycle up and 1. A normal condition. No correction IS INCONSISTENT (FLUCTUATES, down. This is due to the cycling of is necessary.
  • Page 198 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leads in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT PRESSURE system hoses, water pump or necessary.
  • Page 199 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or air conditioning 1. Remove restriction and/or clean PERFORMANCE (COOLING condenser is restricted, obstructed as necessary. SYSTEM SUSPECTED) or dirty.
  • Page 200 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR - CONT. 2. Is temperature gauge reading 2. Refer to the previous above the normal range? Temperature Gauge Reads High in these Diagnosis Charts.

  • Page 201: Cooling System Flow Check

    COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) • When air conditioning system pressure reaches The thermostat is operated by a wax filled con- tainer (pellet) which is sealed so that when heated to 210 psi, fan will operate. •...

  • Page 202: Electric Fan Motor Test

    TRANSMISSION FAN MODULE FASTENERS SINGLE FAN DRAINCOCK COOLER 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) needle on the dial fluctuates it indicates a combus- tion leak, usually a head gasket leak. WARNING: WITH TOOL IN PLACE PRESSURE BUILDS UP FAST. ANY EXCESSIVE AMOUNT OF PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT.

  • Page 203: Pressure Testing Cooling System

    PRESSURE CAP PRESSURE TESTER COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) • Conducting service procedures • Checking for leaks WARNING: VEHICLE BEEN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTER- CLOCKWISE TO THE FIRST STOP.

  • Page 204: Service Procedures

    7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ACCESSORY DRIVE BELTS Satisfactory performance of the belt driven accesso- ries depends on belt condition and proper belt ten- sion. Condition Possible Cause Correction INSUFFICIENT ACCESSORY (a) Belt too loose. (a) Adjust belt tension. OUTPUT DUE TO BELT (b) Belt excessibely glazed or worn (b) Replace and tighten as...

  • Page 205: Removal And Installation

    COOLING SYSTEM 7 - 19 SERVICE PROCEDURES (Continued) WARNING: DO NOT REMOVE THE COOLING SYS- (2) Remove accessory drive belts and power steer- TEM PRESSURE CAP OR OPEN THE RADIATOR ing pump. Refer to Accessory Drive Belt service of this section. DRAINCOCK, WHEN SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM (3) Drain cooling system.
  • Page 206 7 - 20 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INLET PIPE O-RING GASKET ENGINE BLOCK WATER PUMP GASKET O-RING WATER PUMP (3) Rotate pump by hand to check for freedom of INSTALLATION PUMP HOUSING O-RING WATER PIPE movement. (1) Clean all gasket and O-ring surfaces on pump (4) Install inner timing belt cover.
  • Page 207 HEATER CORE WATER INLET TUBE PUMP ENGINE CONNECTOR OUTLET GASKET THERMOSTAT THERMOSTAT HOUSING VENT RECESS TO RADIATOR INLET COOLING SYSTEM 7 - 21 REMOVAL AND INSTALLATION (Continued) WATER PUMP INLET O-RING TUBE TO HEATER Fig. 27 Water Pump Inlet Tube Hose Connections Fig.
  • Page 208 7 - 22 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Remove hose clamps and hoses from the radia- tor. (5) Disconnect automatic transmission hoses from cooler and plug off. (6) Disconnect the fan wiring connector. CONDITIONING RADIATOR MOUNTING SCREWS CONDENSER (7) Disconnect the engine block heater wire, if equipped.

  • Page 209: Radiator Draincock

    DRAIN COCK BODY TRANSMISSION FAN MODULE FASTENERS MOTOR SHAFT SINGLE FAN DRAINCOCK COOLER SHROUD ASSEMBLY RETAINING CLIP COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) (8) Connect negative cable from auxiliary jumper terminal. (9) Fill cooling system with coolant. Refer to Refill- ing Cooling System in this group.
  • Page 210 LEFT REAR SIDE VIEW 2.5L ENGINE BLOCK HEATER F WD BLOCK HEATER RIGHT REAR SIDE VIEW LEFT REAR SIDE 2.4L ENGINE 2.0L ENGINE VIEW 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) ENGINE BLOCK HEATER GENERATOR, POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR DRIVE BELT—2.4L CRANKSHAFT POWER...
  • Page 211 SUPPORT LOCK NUT BRACKET ADJUSTING BOLT IDLER PIVOT BOLT LOCKING BOLT LOCKING BOLT LOCKING BOLT PIVOT BOLT ADJUSTING BOLT SQUARE OPENING INCH COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) (1) Loosen T-Bolt locking nut A and pivot bolt B to remove and install Poly V belt and/or adjust belt ten- sion (Fig.

  • Page 212: Water Pump-2.4L Engine

    ADJUSTMENT LOCKING BOLT (F) ADJUSTMENT SLOT SLOT LOCKING SQUARE OPENING PIVOT BOLT INCH BOLT PUMP HOUSING INLET 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) POWER STEERING PUMP BELT CLEANING AND INSPECTION (1) From the top of the vehicle loosen pivot bolt (Fig.

  • Page 213: Chemical Cleaning

    THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR NORMAL RUBBER SEALS VENT VALVE BELT OK NOT NORMAL CRACKS CRACKS FILLER NECK OVERFLOW NIPPLE REPLACE BELT STAINLESS-STEEL SWIVEL TOP GASKET RETAINER MAIN SPRING COOLING SYSTEM 7 - 27 CLEANING AND INSPECTION (Continued) dirty, fill, run and drain system again until water runs clear.

  • Page 214: Specifications

    7 - 28 COOLING SYSTEM SPECIFICATIONS ACCESSORY DRIVE GAUGE BELT COOLING SYSTEM CAPACITY 2.0/2.4L ENGINE ENGINE 2.4L 2.5L AIR CONDITIONING 150 LB. COMPRESSOR/ LITERS 8.5* 10.0* USED 80 LB. GENERATOR U.S. QUARTS 9.0* 10.5* POWER STEERING 130 LB. * CAPACITY, Includes Heater and Coolant Recovery PUMP USED 80 LB.
  • Page 215 This vehicle has an electronic voltage regulator posts, and cable terminals must be cleaned before which controls battery charging. ONLY CHRYSLER diagnostic procedures are performed. approved battery blanket/block heater combination should be used. It is designed to provide optimum charging system performance in very cold ambient temperatures below -17.8°C (0°F).

  • Page 216: Description And Operation

    BATTERY BLANKET HEATER 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) will adversely affect battery charging and will result STATE OF CHARGE in battery discharge or damage. A completely discharged battery requires more charging time than a partially charged battery. Elec- BATTERY IGNITION OFF DRAW (IOD) trolyte is nearly pure water in a completely dis- A completely normal vehicle will have a small...

  • Page 217: Battery Discharging

    BATTERY 8A - 3 DIAGNOSIS AND TESTING (Continued) (10) Check for a resistance value of 220 to 280 ABNORMAL BATTERY DISCHARGING • Corroded battery posts, cables or terminals. Ohms. If within the resistance value range the blan- • Loose or worn generator drive belt. ket is OK.
  • Page 218 8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) • Glove box, ensure that the glove box compart- ment lamp is off when the door is closed • All doors are closed • Sun visor vanity lamps are OFF • Allow the Illuminated Entry System to time out in approximately 30 seconds, if equipped.

  • Page 219: Battery Load Test

    BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) tor is located on the back of Junction Block below WARNING: IF BATTERY SHOWS SIGNS OF FREEZ- the fuses. ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY (I) If meter has no reading, replace the Sun LOW ELECTROLYTE LEVEL, DO NOT TEST.

  • Page 220: Battery Open Circuit Voltage Test

    8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) Battery Load Test Temperatures Temperature Minimum Voltage °F °C 9.6 volts 70° and 21° and above above 9.5 volts 60° 16° 9.4 volts 50° 10° 9.3 volts 40° 4° 9.1 volts 30° -1°...

  • Page 221: Service Procedures

    BATTERY BATTERY 8A - 7 Some battery chargers are equipped with polarity sensing devices to protect the charger or battery from being damaged if improperly connected. If the bat- tery state of charge is too low for the polarity sensor to detect, the sensor must be bypassed for charger to operate.

  • Page 222: Visual Inspection And Service

    8A - 8 BATTERY SERVICE PROCEDURES (Continued) WARM WATER AND BAKING CLEANING BRUSH SODA SOLUTION BATTERY (2) Connect charger leads to the remote cables. (5) Inspect cables for damage and broken termi- Some chargers feature polarity protection circuitry nals. Replace damaged, frayed cables and broken ter- that prevents operation unless charger is connected minal.

  • Page 223: Battery Tray

    BATTERYTRAY BATTERY STRAP BATTERY BLANKET HEATER RETAINER STRAP BATTERY 8A - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION SPECIFICATIONS For installation, reverse the above procedures. Tighten battery cables to 17 N·m (150 in. lbs.) BATTERY SPECIFICATIONS torque. Load Test Cold Cranking Reserve BATTERY TRAY (Amps)
  • Page 225 PARK/NEUTRAL IGNITION SWITCH NEGATIVE SWITCH (AUTO. TRANS. ONLY) CABLE POSITIVE CLUTCH SWITCH (MAN. TRANSMISSION BATTERY BATTERY POSITION CABLE SOLENOID TERMINAL PEDAL RELAY THIS CIRCUIT GROUNDED AT ALL TIMES (MAN. TRANS. ONLY) FEED IGNITION POSITION ONLY) FEED GROUND CIRCUIT STARTER SOLE- STARTER RELAY STARTER...

  • Page 226: Control Circuit Test

    RELAY CAVITIES RELAY TERMINALS 8B - 2 STARTING DIAGNOSIS AND TESTING STARTER RELAY WARNING: CHECK TO ENSURE THAT THE TRANS- CONTROL CIRCUIT TEST MISSION IS IN THE PARK POSITION/NEUTRAL The starter control circuit has: WITH THE PARKING BRAKE APPLIED • Starter solenoid •...

  • Page 227: Feed Circuit Resistance Test

    STARTING 8B - 3 DIAGNOSIS AND TESTING (Continued) continuity between the cavity for relay terminal 87 FEED CIRCUIT RESISTANCE TEST and the starter solenoid terminal at all times. If OK, Before proceeding with this operation, review go to Step 4. If not OK, repair the open circuit to the Starting System Test.

  • Page 228: Starting System Test

    POSITIVE CLAMP INDUCTION AMPME- TER CLAMP NEGATIVE CLAMP 8B - 4 STARTING DIAGNOSIS AND TESTING (Continued) Fig. 3 Test Battery Positive Cable Resistance Fig. 5 Volt-Ampere Tester Connections • Voltage above 12.4 volts and amperage reads 0 to 10 amps, check for corroded cables and/or bad con- nections.
  • Page 229 STARTING 8B - 5 DIAGNOSIS AND TESTING (Continued) • cable connections. Determine the state-of-charge and Starter Relay - Visually inspect the starter cranking capacity of the battery. Charge or replace relay for indications of physical damage and loose or the battery, if required. Refer to Group 8A, Battery corroded wire harness connections.
  • Page 230 8B - 6 STARTING STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty. 1. Refer to Group 8A, Battery. 2. Starting circuit wiring faulty. Charge or replace battery, if 3. Starter relay faulty. required.

  • Page 231: Removal And Installation

    BATTERY POSITIVE WIRE GENERATOR PUSH ON SOLENOID CONNEC- PUT WIRE OUT- VIEW A STARTING 8B - 7 REMOVAL AND INSTALLATION (5) Remove two bolts attaching starter to trans- mission housing and remove starter from vehicle. SAFETY SWITCHES INSTALLATION For Removal and Installation of the: •...

  • Page 232: Starter Relay

    PUSH ON SOLENOID CON- NECTOR BATTERY POSI- TIVE WIRE 8B - 8 STARTING REMOVAL AND INSTALLATION (Continued) 2.0L ENGINE WITH AUTOMATIC TRANSAXLE (7) Connect battery positive cable to solenoid post – 2.4L ENGINE (Fig. 8). (8) Connect the push-on solenoid connector. REMOVAL (9) Lower vehicle.

  • Page 233: Torque

    STARTING 8B - 9 SPECIFICATIONS (Continued) TORQUE Manufacturer BOSCH MELCO NIPPONDENSO Engine 2.0L 2.5L 2.4L DESCRIPTION TORQUE Application Starter Mounting Bolts ..54 N·m (40 ft. lbs.) Power rating 0 .95 Kw 1.2 Kw 1.4 Kw Starter Solenoid Battery Nut .
  • Page 235 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page GENERAL INFORMATION CHARGING SYSTEM ..... 2 OVERVIEW ......1 CURRENT OUTPUT TEST .

  • Page 236: Description And Operation

    BUMPER BEAM BATTERY TEMPERATURE SENSOR 8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) GENERATOR Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The The generator is belt-driven by the engine. It is ser- EVR circuitry monitors system line voltage and bat- viced only as a complete assembly.
  • Page 237 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued)
  • Page 238 CHECK TION. CHARGE BATTERY IF CHECK DRIVE BELT. REFER SYSTEM FOR ACCESSORY CHARGING SYSTEM RESIS- IS GROUND PATH VOLTAGE CLEAN TIGHTEN CHECK ON BOARD DIAG- NOSTIC TROUBLE CODES PERFORM OUTPUT VOLT- VOLTAGE OR DTC 41 OR REFER TO VOLTAGE DROP CHARGING CHARGING ABOVE MAXIMUM OR DTC...
  • Page 239 REPEAT OUTPUT VOLTAGE TEST REPAIR PINS DISCONNECT BOTH 40 WAY CONNEC- TORS ON POWERTRAIN CONTROL MOD- ULE — INSPECT FOR DAMAGE OR REPAIR DAMAGED PIN OR PINS ON POWER- TRAIN MODULE? TO GROUND SHORT DISCONNECT FIELD TERMINAL. MEASURE RESISTANCE FROM K20 CIRCUIT ON WIRING HAR- CORROSION.

  • Page 240: Charging System Resistance Tests

    TO PCM FEED TERMI- CASE GROUND TO POWERTRAIN CONTROL FEED CASE GROUND B+ TERMINAL MODULE BATTERY BATTERY REMOTE CABLE REMOTE CABLE VOLT METER NEGATIVE POSITIVE OHMMETER WIRE HARNESS CON- NECTOR 8C - 6 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) CHARGING SYSTEM RESISTANCE TESTS These tests will show the amount of voltage drop across the generator output wire from the generator output (B+) terminal to the battery positive post.

  • Page 241: Charging System

    CHARGING SYSTEM 8C - 7 DIAGNOSIS AND TESTING (Continued) (a) Touch the negative lead of voltmeter directly (6) A volt/amp tester equipped with both a battery to positive battery remote cable POST (Fig. 5). load control (carbon pile rheostat) and an inductive- (b) Touch the positive lead of voltmeter to the type pickup clamp (ammeter probe) will be used for B+ output terminal stud on the generator (not the...
  • Page 242 CHECK REPEAT OUTPUT VOLT- REPAIR FUSE LINK AND WIRE SHORT. REFER TO GROUP REPEAT CONNEC- TIONS GOOD? VOLTAGE TEST WIRING WIRE BROKEN? REPAIR WIRE BROKEN WIRE WIRING GRAMS. OUTPUT AGE TEST DIA- CHECK DISCONNECT CHECK SHORT CIRCUIT REPEAT CHECK TIONS STARTER MOTOR, BATTERY.

  • Page 243: On-Board Diagnostic System Test

    CHARGING SYSTEM 8C - 9 DIAGNOSIS AND TESTING (Continued) If minimum amperage could not be met, refer to to clear the memory after 50 engine starts if the the appropriate Powertrain Diagnostic Procedures problem does not occur again. manual for testing. DIAGNOSTIC TROUBLE CODES BATTERY TEMPERATURE SENSOR Diagnostic Trouble Codes (DTC) are two-digit num-...

  • Page 244: Removal And Installation

    8C - 10 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) An example of a DTC is as follows: (1) Lamp on for 2 seconds, then turns off. (2) Lamp flashes 4 times pauses and then flashes 1 time. (3) Lamp pauses for 4 seconds, flashes 4 times, pauses, then flashes 7 times.

  • Page 245: Specifications

    CHARGING SYSTEM 8C - 11 REMOVAL AND INSTALLATION (Continued) (8) Remove top mounting ear bolt. (9) Remove upper generator bracket. (10) Remove generator. INSTALLATION (1) For installation, reverse above procedures. Tighten all fasteners to the proper torque. Refer to the Torque Specifications chart at the rear Group 8C, Charging.
  • Page 247 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page GENERAL INFORMATION TESTING FOR SPARK AT COIL—2.4L ..9 INTRODUCTION ......2 TESTING FOR SPARK AT COIL—2.5L .

  • Page 248: General Information

    8D - 2 IGNITION SYSTEM GENERAL INFORMATION (2.4L). By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet INTRODUCTION changing engine operating conditions. On a 2.5L The PCM controls ignition timing by This group describes the ignition systems for the turning on and off a tranisistor in the distributor.

  • Page 249: Description And Operation

    IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) Replace spark plugs at the intervals recommended in Apply a very small amount of anti-seize compound Group O - Lubrication and Maintenance. to the threads when reinstalling the vehicle’s original Spark plugs that have low mileage may be cleaned spark plugs that have been determined good.
  • Page 250 PLATINUM SURFACE SPARK APPLY COMPOUND ANTI-SEIZE HERE ONLY 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) ELECTRONIC IGNITION COIL WARNING: THE DIRECT IGNITION SYSTEM GEN- ERATES APPROXIMATELY 40,000 VOLTS. PER- SONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM. IGNITION COILS The coil pack consists of 2 coils molded together.

  • Page 251: Automatic Shutdown Relay

    POWER DISTRIBUTION CENTER POWERTRAIN CON- TROL MODULE IGNITION SYSTEM 8D - 5 HIGH TENSION TOWER IGNITION COIL DESCRIPTION AND OPERATION (Continued) The ignition coil is located inside the distibutor. The distributor is mounted to the right end of the engine block behind the thermostat housing (Fig. 5). Fig.
  • Page 252 CRANKSHAFT MACHINED NOTCHES GENERATOR OIL FILTER POSITION SENSOR CRANKSHAFT PUSH ON CLIP ADJUSTMENT POSITION SENSOR HOLE PAPER SPACER CRANKSHAFT POSITION SEN- 8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 7 Timing Reference Notches The timing reference notches are machined at 20° position of the last slot in each group.

  • Page 253: Camshaft Position Sensor-2.4L

    CRANKSHAFT POSITION SENSOR TORQUE CONVERTER SLOTS PLATE DRIVE TRANSAXLE HOUSING CAMSHAFT POSITION SEN- IGNITION SYSTEM 8D - 7 DESCRIPTION AND OPERATION (Continued) Fig. 12 Camshaft Position Sensor—2.4L DOHC Fig. 10 Timing Slots The crankshaft sensor is located on the rear of the transmission housing, above the differential housing (Fig.

  • Page 254: Camshaft Position Sensor-2.5L

    8D - 8 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) The camshaft position sensor is mounted to the ENGINE COOLANT TEMPERATURE SENSOR rear of the cylinder head. The sensor also acts as a The Engine Coolant Temperature (ECT) sensor has thrust plate to control camshaft endplay. one element.

  • Page 255: Lock Key Cylinder

    SEN- INTAKE TURE SENSOR TEMPERA- ACCESSORY UNLOCK ON/RUN START IGNITION SYSTEM 8D - 9 DESCRIPTION AND OPERATION (Continued) from approximately 0.38 volts to 1.2 volts at mini- mum throttle opening (idle) to a maximum of 3.1 volts to 4.4 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine oper- ating conditions.

  • Page 256: Check Coil Test-2.4L

    8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) The coil pack contains independent coils. Each coil (5) Repeat the above test for the remaining coils. If must be checked individually. there is no spark during all cylinder tests, proceed to the Failure To Start Test.

  • Page 257: Check Coil Test-2.5L

    DISTRIBUTOR 6-WAY CON- NECTOR DISTRIBUTOR 2–WAY CON- NECTOR CHECK SECONDARY RESIS- TANCE ACROSS COIL TOW- COLOR IGNITION COIL DRIVER FUNCTION COLOR ASD RELAY OUTPUT FUNCTION GROUND CMP SENSOR SIGNAL IGNITION SYSTEM 8D - 11 FUSED IGN SWITCH OUTPUT SENSOR GROUND DIAGNOSIS AND TESTING (Continued) Fig.

  • Page 258: Failure To Start Test-2.5L

    8D - 12 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) IGNITION TIMING PROCEDURE The engines for this vehicle, use a fixed ignition system. The PCM regulates ignition timing. Basic ignition timing is not adjustable. CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR The output voltage of a properly operating cam- shaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts).
  • Page 259 IGNITION SYSTEM 8D - 13 DIAGNOSIS AND TESTING (Continued) Check for spread terminals at the sensor and PCM operating temperature during short operating peri- connections before replacing the TPS. ods. Replace carbon fouled plugs with new spark plugs. SPARK PLUG CONDITION FUEL FOULING NORMAL OPERATING CONDITIONS A spark plug that is coated with excessive wet fuel...
  • Page 260 GROUND ELECTRODE CENTER ELECTRODE DEPOSITS GROUND CENTER ELEC- ELECTRODE TRODE GROUND ELECTRODE COV- ERED WITH WHITE OR YEL- LOW DEPOSITS CENTER ELECTRODE CHIPPED INSULATOR 8D - 14 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) to take place gradually and avoid plug destroying splash fouling shortly after the plug change.

  • Page 261: Removal And Installation

    BLISTERED GRAY COLORED INSULATOR WHITE AUXILIARY JUMPER TERMINAL AIR CLEANER HOUSING POWERTRAIN CONTROL MODULE BRACKET SCREWS LEFT STRUT TOWER IGNITION SYSTEM 8D - 15 DIAGNOSIS AND TESTING (Continued) SPARK PLUG OVERHEATING (3) Remove screws attaching PCM to bracket (Fig. Overheating is indicated by a white or gray center 32).
  • Page 262 SUPPORT BRACKET BOLT MAP SENSOR INTAKE PERATURE TEM- SEN- 8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) SPARK PLUG—2.4L (2) Remove the spark plug using a quality socket with a rubber or foam insert. Failure to route the cables properly could cause the (3) Inspect the spark plug condition.
  • Page 263 SPEED CONTROL CABLE BOLTS TUBE EGR TUBE SUPPORT THROTTLE CABLE BRACKET BOLT RELEASE TANG IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) (6) Release snaps holding air cleaner housing cover to housing. (7) Remove air cleaner cover and inlet hoses from engine.

  • Page 264: Automatic Shutdown Relay

    ELECTRICAL CONNECTOR IGNITION COIL DISTRIBUTOR HOUSING COIL TOWER IGNITION COIL FAS- TENERS 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Install throttle and speed control (if equipped) cables. BATTERY POSITIVE BATTERY GROUND AIR CLEANER (8) Attach electrical connectors to sensors. (9) Tighten air inlet tube clamps to 3 N·m 1 (25 5 in.

  • Page 265: Camshaft Position Sensor-Dohc

    IGNITION SYSTEM 8D - 19 CAMSHAFT POSITION SEN- REMOVAL AND INSTALLATION (Continued) CAMSHAFT POSITION SENSOR—DOHC The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 42). MOUNTINGBOLT TARGET MAGNET CRANKSHAFT GENERATOR OIL FILTER POSITION- SENSOR Fig. 44 Target Magnet Installation (3) Carefully attach electrical connector to cam- shaft position sensor.

  • Page 266: Crankshaft Position Sensor-2.5L

    8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) CRANKSHAFT POSITION SENSOR—2.5L DISTRIBUTOR HOLD DOWN BOLT CRANKSHAFT POSITION SENSOR REMOVAL (1) Remove speed control servo from driver’s side strut tower. (2) Remove crankshaft position sensor retaining bolt (Fig. 46). Fig. 47 Crankshaft Position Sensor and Spacer DISTRIBUTOR SCREWS DISTRIBUTOR—2.5L...

  • Page 267: Distributor Cap-2.5L

    IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) SPARK PLUG CABLES (9) Mark the rotor position and remove rotor. The DISTRIBUTOR CONNEC- TORS (4) Install distributor holddown washers and nuts. mark indicates where to position the rotor when rein- Tighten nuts to 13 N·m (9 ft.

  • Page 268: Engine Coolant Temperature Sensor-2.5L

    ENGINE COOLANT TEMPER- ATURE SENSOR INLET COOLANT FILL TUBE NECK 8D - 22 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (5) Remove air inlet tube, resonator and air cleaner cover. (6) Remove EGR tube. INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR MAP SENSOR THROTTLE BODY (7) Remove spark plug cables from distributor cap.

  • Page 269: Sensor-2.5L

    SEN- INTAKE PERATURE SENSOR TEM- IGNITION SWITCH FUSE CENTER COVER PANEL BEZEL RETAINING TABS LOCK CYLINDER HOUSING SCREW COVER IGNITION SYSTEM 8D - 23 REMOVAL AND INSTALLATION (Continued) Fig. 53 Ignition Switch—Viewed From Below Fig. 52 Intake Air Temperature Sensor and MAP Column Sensor—2.5L REMOVAL...
  • Page 270 LOWER STEERING COLUMN SHROUD LOWER SCREW LOCATIONS SCREW LOCA- TIONS KEY CYLINDER LOWER SHROUD TILT LEVER LOWER SHROUD KNEE BOLSTER SCREW COVER LOCATIONS UNDER TOP SCREWS COVER 8D - 24 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Remove screws holding instrument panel top (8) Pull lower shroud to clear ignition cylinder and cover to center of instrument panel (Fig.
  • Page 271 LOCK RETAINING TAB CYLINDER ATTACHING SCREWS MULTI-FUNCTION SCREW- DRIVER SWITCH IGNITION SWITCH IGNITION SYSTEM 8D - 25 MULTI-FUNCTION IGNITION SWITCH SWITCH ATTACHING/GROUNDING KEY IN SWITCH SCREW PRNDL SWITCH LOCK HOUSING IGNITION SWITCH REMOVAL AND INSTALLATION (Continued) (11) Remove screws holding multi-function switch (13) Disconnect electrical connectors from ignition to lock housing (Fig.
  • Page 272 MOUNTINGBOLT TARGET MAGNET SOCKET LOCK CYLINDER RETAINING LOCK CYLINDER HOUSING 8D - 26 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Ensure the ignition switch is in the RUN posi- tion and the actuator shaft in the lock housing is in the RUN position.

  • Page 273: Specifications

    FIRING ORDER 1–3–4–2 FRONT IGNITION COIL VEHICLE FRONT OF ENGINE 1 - 2 - 3 - 4 - 5 - 6 FIRING ORDER CONNECTOR IGNITION SYSTEM 8D - 27 SPECIFICATIONS TORQUE SPECIFICATION VECI LABEL DESCRIPTION TORQUE If anything differs between the specifications found Air Inlet tube Clamp .

  • Page 274: Ignition Coils

    DIAMOND (BRASS TOWERS) WEASTEC (SILVER TOW- ERS) 8D - 28 IGNITION SYSTEM SPECIFICATIONS (Continued) SPARK PLUG CABLE RESISTANCE—2.4L SPARK PLUG CABLE RESISTANCE—2.5L CABLE RESISTANCE MINIMUM MAXIMUM #1,#4 3500 ohms— 250 Ohms Per Inch 560 Ohms Per 4900 ohms Inch #2,#3 2950 ohms—...
  • Page 275 INSTRUMENT PANEL AND SYSTEMS 8E - 1 INSTRUMENT PANEL AND SYSTEMS CONTENTS page page GENERAL INFORMATION GLOVE BOX DOOR HANDLE ....8 ELECTRO/MECHANICAL INSTRUMENT GLOVE BOX DOOR LOCK ....8 CLUSTER .

  • Page 276: General Information

    8E - 2 INSTRUMENT PANEL AND SYSTEMS GENERAL INFORMATION (Continued) TEMPERATURE/COMPASS MINI TRIP COMPUTER • Cruise • Estimated Range (RANGE) • Brake/park brake • Present Fuel Economy (ECO) • Anti-lock brake system • Trip Odometer (ODO) • High beam • Elapsed Ignition On Time (ET) •...
  • Page 277 INSTRUMENT PANEL AND SYSTEMS 8E - 3 DESCRIPTION AND OPERATION (Continued) AMBIENT TEMPERATURE continuously illuminated airbag indicator and NO The temperature is displayed in whole degrees Cel- BUS message displayed. sius or Fahrenheit. Temperatures greater than or If the cluster is not receiving CCD bus messages, equal to zero are displayed unsigned and tempera- refer to the pre-diagnostic test described in proper tures below zero are displayed signed (-).

  • Page 278: Autostick

    8E - 4 INSTRUMENT PANEL AND SYSTEMS DIAGNOSIS AND TESTING (Continued) CHEC 4 - AUTOMATIC TRANSMISSION CHEC 2 - WARNING LAMP DISPLAY If any V/F segment does not light, replace Odome- SERVICE ENGINE SOON ter/Transmission Range Indication. SEAT BELT CHEC 4 - TRANSMISSION RANGE INDICATOR AIRBAG V/F DISPLAY CHARGING SYSTEM...

  • Page 279: Service Procedures

    INSTRUMENT PANEL AND SYSTEMS 8E - 5 SERVICE PROCEDURES DIRECT METHOD Turn the vehicle to head in either a North or South COMPASS CALIBRATION PROCEDURE direction. The vehicle must be within 45 degrees of the North or South position or the SETTING the VARIANCE SETTING PROCEDURE VARIANCE will be ignored.

  • Page 280: Removal And Installation

    ATTACHINGSCREWS INSTRUMENT CLUS- TER HOOD 8E - 6 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION CENTER BEZEL REMOVAL Pull center bezel straight rearward along the sides of the radio and A/C control openings to disengage four clips (Fig. 6). INSTALLATION For installation, reverse the above procedures.

  • Page 281: Cubby Bin/Lamp

    VEHICLE THEFT SECURITY TRANSMISSION INDICATOR CONNECTOR *ILLUMINATION LAMP RETAINING SCREWS CHARGING SYSTEM MIL/CHECK ENGINE OIL PRESSURE SYSTEM LED RIGHT TURN HIGH BEAM LEFT TURN SEAT BELT FOG LAMP LOW FUEL NOT USED NOT USED VTSS LED AIR BAG HI TEMP CRUISE RANGE BRAKE...

  • Page 282: Fuel Gauge And Temperature Gauge

    CLUSTER ODOMETER/TRANSMISSION RANGE MASK/LENSSCREWS MASK/LENS SCREWS RETAINING SCREWS INDICATOR BACK VTSS LED CLUSTERSCREWS CLUSTER SCREWS NECTOR COVER CON- MASK/LENS SCREWS MASK/LENS SCREWS CLUSTERSCREWS CLUSTER SCREWS MASK/LENSSCREWS MASK/LENS SCREWS 8E - 8 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) FUEL GAUGE AND TEMPERATURE GAUGE REMOVAL (1) Remove mask/lens...
  • Page 283 END COVER KNEE BOLSTER SPEAKERS INSTRUMENT CLUSTER HVAC GLOVE BOX LOCK TOP COVER CUBBYBIN CENTER BEZEL SCREW CYLINDER PASSENGER BAG MODULE END COVER INSTRUMENT CLUS- AIR- RADIO TER HOOD INSTRUMENT PANEL AND SYSTEMS 8E - 9 REMOVAL AND INSTALLATION (Continued) (1) Remove instrument cluster hood, refer to Clus- FAILURE TO DISCONNECT BATTERY COULD ter Hood Removal and Installation procedures.

  • Page 284: Instrument Panel End Covers - Left And Right

    8E - 10 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove transmission range indicator bezel INSTALLATION from floor console. Use care not to mar the bezel or For installation, reverse the above procedures. DO console. NOT CONNECT battery negative remote cable. Refer (4) Remove floor center console.

  • Page 285: Junction Block/Body Control Module

    SPEAKER JUNCTION/BCM INSTRUMENT PANEL AND SYSTEMS 8E - 11 REMOVAL AND INSTALLATION (Continued) Fig. 16 Top Cover JUNCTION BLOCK/BODY CONTROL MODULE JUNCTION BLOCK REMOVAL The Junction Block and Body Control Module (BCM) are attached to each other. After removal they Fig.

  • Page 286: Odometer/Transmission Range Indicator

    8E - 12 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) ODOMETER/TRANSMISSION RANGE INDICATOR SPEEDOMETER/TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR REMOVAL (1) Remove speedometer/tachometer, refer REMOVAL Speedometer/Tachometer and Odometer Transmis- (1) Remove mask/lens retaining screws sion Range Indicator Removal and Installation remove mask/lens (Fig.
  • Page 287 AUDIO SYSTEM 8F - 1 AUDIO SYSTEM CONTENTS page page GENERAL INFORMATION REMOTE CD CHANGER TEST ... . 14 INTRODUCTION ......1 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION DOOR MOUNTED SPEAKER .

  • Page 288: Description And Operation

    8F - 2 AUDIO SYSTEM DESCRIPTION AND OPERATION (Continued) POWER ANTENNA REMOTE CD CHANGER The power operated radio antenna is a whip type The remote CD changer is located in the center antenna, extended and retracted by a reversible elec- console and is capable of holding up to six disc in a tric motor.
  • Page 289 1 — AMP ON-OFF SIGNAL/ANT UP SIGNAL 2 — LEFT REAR SPEAKER FEED (+) 3 — RIGHT REAR SPEAKER FEED (+) 4 — LEFT FRONT SPEAKER FEED (+) 5 — RIGHT FRONT SPEAKER FEED (+) 6 — LEFT REAR SPEAKER RETURN (-) 7 —...
  • Page 290 REPAIR AS NECES- REPAIR AS NECES- SARY CHECK SPEAKER CONNECTOR SARY (A) LOOSE CONNECTIONS CONDITION OK? REPAIR AS NECES- (B) BROKEN WIRES (C) CORROSION EXCHANGE RADIO CHECK RADIO CONNECTOR FOR: (A) LOOSE CONNECTIONS SARY TEST RESISTANCE BETWEEN THE SPEAKER PLUS AND MINUS TERMINALS FOR A READING FOR: TIONS OK? (B) BROKEN WIRES...
  • Page 291 START ENGINE. WITH ENGINE RUNNING, IF THERE IS STATIC/NOISE CHECK THE FOLLOW- CHECK CHECK ANY OTHER ELECTRICAL COM- PONENTS REPAIR AS NECES- ENGINE (B) CHECK GROUND CONNECTIONS REPAIR AS NEC- (C) CHECK ANTENNA MOUNTING (A) IGNITION SYSTEM FAULTS MOTORS GROUND ESSARY SARY CAUSE NOISE...
  • Page 292 EXCHANGE U NIT GOOD TAPE KNOWN CHECK OBSTRUCTION TAPE OBSTRUCTION PLAYER PLAYS OK? INOPERA- FOUND? TIVE BEHIND DOORS ADVISE WORN OR DEFECTIVE REPAIR AS NEC- SPOOL(S) OWNER CASE ESSARY EATS TAPES. (DIRTY CAPSTAN AND DRIVE TAPE SYSTEM) CLEAN EXCHANGE UNIT HEAD CLEANER WITH POOR...
  • Page 293 1 — AMP ON-OFF SIGNAL/ANT UP SIGNAL 2 — LEFT REAR SPEAKER FEED (+) 3 — RIGHT REAR SPEAKER FEED (+) 4 — LEFT FRONT SPEAKER FEED (+) 5 — RIGHT FRONT SPEAKER FEED (+) 6 — LEFT REAR SPEAKER RETURN (-) 7 —...
  • Page 294 CHECK RADIO CONNECTOR WITH IGNITION ON USING A VOLTMETER, CHECK FOR BATTERY VOLTAGE AT PIN 1 AND 2 OF THE GREY RADIO USING CHECK FOR BATTERY VOLT AGE AT AMPLIFIER. CHECK F30 CIRCUIT CAVITY 1 OF FOR A MINIMUM VOLTS. REFER TO GROUP CHECK FOR BATTERY VOLT AGE AT V+ TERMINALS AND CHECK...
  • Page 295 REPAIR REPLACE NECESSARY USING AN OHMMETER, WITH BOTH RADIO AND AMPLIFIER CONNEC- TORS DISCONNECTED, CHECK WIRES FROM THE RADIO CONNEC- TOR TO THE AMPLIFIER CONNECTOR FOR SHORT TO GROUND. REFER TO 8W, WIRING DIAGRAMS. PLACE ONE LEAD OF THE OHM- METER TO EACH TERMINAL AND THE OTHER LEAD TO BODY AMPLIFIER DISCONNECT...
  • Page 296 START ENGINE. WITH ENGINE RUNNING, IF THERE IS STATIC/NOISE CHECK THE FOLLOW- CHECK CHECK ANY OTHER ELECTRICAL COM- PONENTS REPAIR AS NECES- ENGINE (B) CHECK GROUND CONNECTIONS REPAIR AS NEC- (C) CHECK ANTENNA MOUNTING (A) IGNITION SYSTEM FAULTS MOTORS GROUND ESSARY SARY CAUSE NOISE...
  • Page 297 EXCHANGE U NIT GOOD TAPE KNOWN CHECK OBSTRUCTION TAPE OBSTRUCTION PLAYER PLAYS OK? INOPERA- FOUND? TIVE BEHIND DOORS ADVISE WORN OR DEFECTIVE REPAIR AS NEC- SPOOL(S) OWNER CASE ESSARY EATS TAPES. (DIRTY CAPSTAN AND DRIVE TAPE SYSTEM) CLEAN EXCHANGE UNIT HEAD CLEANER WITH POOR...
  • Page 298 NOTE: THE CD PLAYER WILL ONLY OPERATE BETWEEN APPROXIMATE TEMPERA- TURES OF −23°C AND +65°C (-10°F AND +145°F) INSERT GOOD CD LABEL SIDE EXCHANGE UNIT CD INOPERATIVE WILL BATTERY VOLT- AGE 11 VOLTS IS CD IN UNIT? OR MORE PLAY? KNOWN REPAIR AS NECES- WILL...

  • Page 299: Diagnostic Conditions

    AUDIO SYSTEM 8F - 13 DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CONDITIONS ALL SPEAKERS NON-OPERATIVE • Check radio for being ON, are the display lights NOISE DISTORTION IN ALL SPEAKERS • Radio not ON, refer to Radio Diagnosis Does the distortion occur through all operations: •...

  • Page 300: Power Antenna

    GROUND STRAP DRAIN HOSE ADAPTER ANTENNA NUT 8F - 14 AUDIO SYSTEM DIAGNOSIS AND TESTING (Continued) POWER ANTENNA (1) Antenna not operating check Fuse 5 in the Junction Block. If not OK, replace fuse. If OK, test for battery at the antenna wire connector. If OK, go to Step 2.

  • Page 301: Removal And Installation

    FRONT DOOR SPEAKER BRACKET SPEAKER GRILLE AUDIO SYSTEM 8F - 15 ERROR MESSAGES DIS- EXPLANATION WHAT TO DO PLAY nocd No disc or discs Load discs in in magazine magazine - - - - No magazine in Load magazine in player player Err HOT...

  • Page 302: Manual Antenna And Mast

    TOOTH MUST FACE TO FRONT OF (SERRATED) CONTACT SPRING ANTENNA MAST ADAPTER FRONT SIDE ANTENNA BASE MANUAL MAST ANTENNA NUT ADAPTER SPEAKER 8F - 16 AUDIO SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION POWER ANTENNA For installation, reverse the above procedures. REMOVAL (1) Disconnect battery negative cable.

  • Page 303: Radio

    MOUNTING SCREWS AUDIO SYSTEM 8F - 17 REMOVAL AND INSTALLATION (Continued) RADIO REAR QUARTER PANEL SPEAKER SPEAKER GRILLE REMOVAL CAUTION: Do not operate the radio with speaker (1) Remove center bezel by pulling straight back leads detached. Damage to the output devices may (Fig.

  • Page 304: Remote Amplifier

    8F - 18 AUDIO SYSTEM REMOVAL AND INSTALLATION (Continued) REMOTE AMPLIFIER REMOVAL (1) Loosen the two attaching screws and the nut (Fig. 11). (2) Disconnect the electrical connector and remove amplifier. INSTALLATION For installation, reverse the above procedure. Tighten fasteners to 4 N·m (40 in. lbs.) torque. REMOTE CD CHANGER AND MOUNTING BRACKET REMOVAL (1) Turn ignition switch to the OFF position.
  • Page 305 + POSITIVE − NEGATIVE HORNS 8G - 1 HORNS CONTENTS page page DESCRIPTION AND OPERATION HORNS WILL NOT SOUND ....2 INTRODUCTION ......1 SYSTEM TEST .

  • Page 306: Diagnosis And Testing

    HORN SWITCH AIRBAG MODULE H/LP RELAY CIRCUIT BREAKERS HORN RELAY 8G - 2 HORNS DIAGNOSIS AND TESTING (Continued) HORNS WILL NOT SOUND Check horn fuse 12 in the Power Distribution Cen- ter and fuse 8 in the Junction Block. If fuse is blown refer to Fuse Blown section.

  • Page 307: System Test

    HORNS 8G - 3 DIAGNOSIS AND TESTING (Continued) (b) If the horn does not sound, go to Step 4. (8) Using a voltmeter, with the horn switch (4) Remove driver airbag module from steering depressed test voltage across horn connector termi- wheel.

  • Page 308: Removal And Installation

    8G - 4 HORNS DIAGNOSIS AND TESTING (Continued) Refer to Group 8W, Wiring Diagrams for circuit and wiring information. REMOVAL AND INSTALLATION HORNS REMOVAL (1) Hoist and support front vehicle on safety stands. (2) The horns are located behind the front fascia on the right front frame rail.

  • Page 309: Vehicle Speed Control System

    SPEED RES ACCEL SET COAST SWITCHES CONTROL CANCEL VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page page GENERAL INFORMATION OVERSHOOT/UNDERSHOOT ON SPEED INTRODUCTION ......1 CONTROL SET .

  • Page 310: Description And Operation

    VACUUM VIEW Y RESER- VOIR 2.0L/2.4L THROTTLE BODY VIEW Z 2.5L SERVO NECTOR SPEED CON- TROL SERVO CON- 8H - 2 VEHICLE SPEED CONTROL SYSTEM Fig. 2 Speed Control System • Stepping on the brake pedal DESCRIPTION AND OPERATION • Depressing the OFF switch •...

  • Page 311: Automatic Speed Control Overspeed

    VEHICLE SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) If, while the speed control is engaged, the driver stop lamp switch, on the brake pedal mounting wishes to increase vehicle speed, the PCM is pro- bracket under the instrument panel. The PCM mon- grammed for an acceleration feature.

  • Page 312: Checking For Diagnostic Codes

    HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- 8H - 4 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) Instrument Panel and Gauges for speedometer diag- nosis. If a road test verifies an inoperative system, and the speedometer operates properly, check for: •...
  • Page 313 VEHICLE SPEED CONTROL SYSTEM 8H - 5 DIAGNOSIS AND TESTING (Continued) SPEED CONTROL DIAGNOSTIC TROUBLE CODES Diagnostic Hex Code DRB Scan Tool Display Description of Diagnostic Trouble Code Trouble Code 15** No Vehicle Speed Sensor Signal No vehicle distance (speed) sensor signal detected during road load conditions.
  • Page 314 POWERTRAIN SPEED SPEED CNT MODE SELECT K29 BRAKE SWITCH SIGNAL SPEED CONTROL VACUUM PARK/NEUTRAL SWITCH V35 SPEED CNT VENT BRAKE LAMP SWITCH VACUUM RESERVOIR V36 SPEED CNT VAC SENSOR VACUUM SOURCE THROTTLE BODY (INST. CLUSTER) RESUME/ACCEL CCD BUSS BAR CLOCK SPRING CRUISE LIGHT VACUUM LINE SET/COAST...

  • Page 315: Overshoot/Undershoot On Speed Control Set

    CONNECTORS FROM TERMINAL END SHOWN PIN 1 PIN 2 PIN 3 PIN 4 PIN 1 PIN 2 PIN 3 PIN 4 VEHICLE SPEED CONTROL SYSTEM 8H - 7 DIAGNOSIS AND TESTING (Continued) OVERSHOOT/UNDERSHOOT ON SPEED CONTROL If the operator repeatedly presses and releases the set button with their foot off of the accelerator (a “lift foot set”...

  • Page 316: Stop Lamp Switch Test

    8H - 8 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) contact closes to ground through a 6,650 ohm resis- tor. The 5-volt signal then passes through a higher resistance than that of the SET/COAST switch, caus- ing the voltage to be approximately 3.30 to 4.14 volts. When the OFF switch is depressed, the contacts close directly to ground, causing the 5-volt signal to drop to 0 volts.

  • Page 317: Vacuum Supply Test

    VEHICLE SPEED CONTROL SYSTEM 8H - 9 DIAGNOSIS AND TESTING (Continued) (10) Using an ohmmeter, touch one lead to a ground and touch the other lead to pin 76. The meter should show no continuity when transmission is in DRIVE and continuity when in PARK or NEUTRAL. If not, test Neutral Start and Back-Up switch using scan tool.

  • Page 318: Speed Control Servo Cable

    8H - 10 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Remove servo from the mounting bracket. the brake pedal. Once the switch is seated in the (3) Disconnect electrical connectors and vacuum hole, rotate clockwise approximately 30 degrees to hose.

  • Page 319: Vacuum Reservoir

    CABLE TABS CLASP VEHICLE SPEED CONTROL SYSTEM 8H - 11 REMOVAL AND INSTALLATION (Continued) VACUUM RESERVOIR The vacuum reservoir is located on the dash panel next to the brake booster. REMOVAL (1) 2.5L ONLY Remove the intake manifold, refer to Group 11 Exhaust System and Intake Manifold. (2) Disconnect vacuum hoses from reservoir.
  • Page 321 TURN SIGNAL AND FLASHERS 8J - 1 TURN SIGNAL AND FLASHERS CONTENTS page page GENERAL INFORMATION MULTI-FUNCTION SWITCH ....2 MULTI-FUNCTION SWITCH ....1 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION COMBINATION FLASHER...
  • Page 322 EXTERIOR LIGHTING CON- TURN SIGNAL TROL CONTROL STALK PANEL DIMMER SWITCH HAZARD WARNING BUTTON CANCELING CAM WINDSHIELD WASHER CONTROL WIPER/ 8J - 2 TURN SIGNAL AND FLASHERS DESCRIPTION AND OPERATION (Continued) Fig. 1 Multi-Function Switch • Fog lamps, pull switch outward with headlamps button will move out from the steering column in the on low beam ON position and will remain in toward the column in...
  • Page 323 TURN SIGNAL AND FLASHERS 8J - 3 DIAGNOSIS AND TESTING (Continued) COMBINATION FLASHER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT FLASH 1. Faulty external lamp. 1. Replace lamp. ON ONE SIDE, INDICATOR 2. Poor ground at lamp. 2. Check and/or replace wiring. LAMP FLASHES AT 3.
  • Page 324 10–WAY CONNECTOR-C 7–WAY CONNECTOR-B COMBO-FLASHER-A 8J - 4 TURN SIGNAL AND FLASHERS DIAGNOSIS AND TESTING (Continued) Fig. 3 Multi-Function Switch Continuity Test...
  • Page 325 MULTI-FUNCTION SWITCH COMBINATION FLASHER TURN SIGNAL AND FLASHERS 8J - 5 REMOVAL AND INSTALLATION INSTALLATION For installation, reverse the above procedures. MOUNTING SCREWS COMBINATION FLASHER (1) Tighten multi-function switch to column retain- ing screws to 2.3 N·m (20 in. lbs.) torque. The flasher is mounted to the back side of the (2) Tighten steering column cover retaining screws multi-function switch.

  • Page 327: Windshield Wipers And Washers

    WINDSHIELD WIPERS AND WASHERS 8K - 1 WINDSHIELD WIPERS AND WASHERS CONTENTS page page GENERAL INFORMATION WASHER RESERVOIR PUMP ....9 MULTI-FUNCTION SWITCH ....1 WASHER RESERVOIR .

  • Page 328: General Information

    EXTERIOR LIGHTING CON- TURN SIGNAL TROL CONTROL STALK PANEL DIMMER SWITCH HAZARD WARNING BUTTON CANCELING CAM WINDSHIELD WASHER CONTROL WIPER/ 8K - 2 WINDSHIELD WIPERS AND WASHERS GENERAL INFORMATION (Continued) Fig. 1 Multi-Function Switch The wiper motor and washer motor are designed to The electric pump assembly is mounted with a reduce radio frequency interference and provide elec- grommet directly to the reservoir.

  • Page 329: Diagnosis And Testing

    AIR FOIL WINDSHIELD WIPERS AND WASHERS 8K - 3 MOTOR WILL NOT RUN IN ANY SWITCH POSITION (1) Check fuse 15, in the Junction Block and fuse 8 and 18 in the Power Distribution Center (Fig. 4) and (Fig. 5). Refer to Group 8W, Wiring Diagrams for pin call outs.
  • Page 330 8K - 4 WINDSHIELD WIPERS AND WASHERS DIAGNOSIS AND TESTING (Continued) Fig. 6 Motor Wire Connector connector for continuity. If OK, go to Step 7. If not repair as necessary. (7) Using an ohmmeter, check for continuity between the HI-LO wiper relay and the intermittent wiper relay.
  • Page 331 WHITE CONNECTOR WINDSHIELD WIPERS AND WASHERS 8K - 5 DIAGNOSIS AND TESTING (Continued) (6) Check for faulty HI-LO wiper relay. WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION. WIPERS OPERATE IN INTERMITTENT MODE, BUT EACH WIPE IS AT HIGH SPEED.

  • Page 332: Wiper Motor System

    8K - 6 WINDSHIELD WIPERS AND WASHERS DIAGNOSIS AND TESTING (Continued) C and Pin D on the wiper motor connector. If contin- if it has 12 volts. If no voltage replace the BCM. If uous continuity, go to Step 3. If not OK, replace battery voltage, test for a wiring short refer to motor.
  • Page 333 WINDSHIELD WIPERS AND WASHERS 8K - 7 DIAGNOSIS AND TESTING (Continued) Fig. 9 Wiper Motor Test...

  • Page 334: Removal And Installation

    VIEW Y VIEW Z 8K - 8 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION MULTI-FUNCTION SWITCH REMOVAL (1) Disconnect battery negative cable. (2) Remove the upper steering column cover. Refer to steering column cover removal procedures below. (3) Remove multi-function switch mounting screws (Fig.

  • Page 335: Washer Reservoir Pump

    WINDSHIELD WIPERS AND WASHERS 8K - 9 REMOVAL AND INSTALLATION (Continued) WASHER RESERVOIR REMOVAL (1) Disconnect washer fluid hose at in-line connec- tor on top of the right shock tower. (2) Partially remove bumper facia as needed to gain access to the reservoir. Refer to Group 23, Body. (3) Remove carbon canister.

  • Page 336: Wiper Arm Linkage Or Cap

    VERTEBRA RUBBER ELEMENT CHANNEL CLAW TO GRASP AND SLOT PULL 8K - 10 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) INSTALLATION ARM RELEASE TAB VERTEBRA RUBBER ELEMENT RELEASE TAB For installation reverse the above procedures. When complete turn ignition switch ON. Turn wiper switch OFF allowing the wiper blades PARK, then turn ignition switch OFF.

  • Page 337: Wiper Motor Assembly Mounting Grommet

    WINDSHIELD WIPERS AND WASHERS 8K - 11 REMOVAL AND INSTALLATION (Continued) (4) Disconnect drive linkage from motor output crank. Using an ball joint/tie rod separator, separate the ball cap from the ball (Fig. 17). (5) Remove motor mounting nuts and remove motor.
  • Page 338 8K - 12 WINDSHIELD WIPERS AND WASHERS ADJUSTMENTS (Continued) (3) Use LOW speed setting and cycle the wiper motor to the PARK position. (4) Turn ignition OFF. (5) Carefully lower arm and blades to the wind- shield. (6) Measure the distance from the blade tip to the cowl screen edge.
  • Page 339 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... 19 LAMP BULB SERVICE ....8 EXTERIOR LAMP SWITCHES .
  • Page 340 8L - 2 LAMPS GENERAL INFORMATION (Continued) DIAGNOSTIC PROCEDURES When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, charging system, headlamp bulbs, wire connectors, relay, high beam dimmer switch and headlamp switch. Refer to Group 8W, Wiring Dia- grams for component locations and circuit informa- tion.
  • Page 341 LAMPS 8L - 3 GENERAL INFORMATION (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH 1. Loose or corroded battery cables. 1. Clean and secure battery cable ENGINE IDLING clamps and posts. OR IGNITION TURNED OFF. 2.
  • Page 342 ACCEPTABLE RANGE .75° UP TO .75° DOWN ADJUSTER GAUGE WHEEL BUBBLE LEVEL ZERO MARK 8L - 4 LAMPS HEADLAMP AND FOG LAMP ALIGNMENT INDEX page page GENERAL INFORMATION HEADLAMP ADJUSTMENT USING ALIGNMENT HEADLAMP ALIGNMENT PREPARATION ..4 SCREEN .
  • Page 343 CENTER OF HEADLAMPS 5 FRONT OF HEADLAMP CENTER OF VEHICLE 7.62 METERS (25 FT.) 7.5 5 RADIATOR CLOSURE PANEL LEFT/RIGHT ADJUSTER UP/DOWN ADJUSTER HEADLAMP MODULE GAUGE WHEEL BUBBLE VIAL LAMPS 8L - 5 ADJUSTMENTS (Continued) Fig. 3 Headlamp Alignment Screen HEADLAMP ADJUSTMENT A properly aimed low beam headlamp will project the center of the low beam hot spot on the alignment...
  • Page 344 TOP OF BEAM PATTERN 4 CENTER OF FOGLAMP FRONT OF FOGLAMP 7.62 METERS (25 FT.) UP/DOWN ADJUSTER FOGLAMP 8L - 6 LAMPS ADJUSTMENTS (Continued) Fig. 5 Fog Lamp Alignment FOG LAMP ALIGNMENT Prepare a alignment screen (Fig. 5). Refer to Align- ment Screen Preparation paragraph in this section.
  • Page 345 LAMPS 8L - 7 EXTERIOR LAMP SWITCHES INDEX page page REMOVAL AND INSTALLATION HEADLAMP SWITCH ..... 7 HEADLAMP DIMMER SWITCH ....7 HEADLAMP DIMMER SWITCH REMOVAL AND INSTALLATION The headlamp dimmer switch is incorporated into...
  • Page 346 8L - 8 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION FRONT MAP LAMP BULB ....9 ASH RECEIVER/CUP HOLDER LAMP BULB . . . 9 GLOVE BOX LAMP BULB .
  • Page 347 FASCIA FOGLAMP HOUSING HEADLAMP MODULE FOGLAMP BULB BULB LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Push bulb into map lamp. (2) Install map lamp lens. GLOVE BOX LAMP BULB REMOVAL (1) Open glove box door. (2) Pull downward on lamp/switch assembly to dis- engage tabs from instrument panel.
  • Page 348 FLOOR FLOOR CONSOLE CONSOLE FLOOR CONSOLE FLOOR CONSOLE TESY LAMP TESY LAMP COUR- COUR- BULB TAIL, STOP, TURN SIGNAL COURTESY LAMP HOUSING REAR CLOSURE PANEL DOOR TRIM PANEL LAMP BULB BULB 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 4 Floor Console Courtesy Lamp Fig.
  • Page 349 LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) (3) Remove plastic nuts holding tail lamp to rear (3) Rotate socket counterclockwise one quarter closure panel. turn. (4) Separate lamp from opening in quarter panel. (4) Pull socket from back of lamp (Fig. 8). (5) Rotate socket counterclockwise one quarter (5) Pull bulb from socket.
  • Page 350 FASCIA FOGLAMP HOUSING FOGLAMP HEADLAMP MODULE MODULE SCREWS 8L - 12 LAMPS LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION GLOVE BOX LAMP ..... 13 ASH RECEIVER/CUP HOLDER LAMP .
  • Page 351 RADIATOR CLOSURE PANEL FRONT BUMPER FASCIA HEADLAMP MODULE LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) FRONT MAP LAMP The front map lamp is not a serviceable compo- nent. If the front map lamp does not operate prop- erly, the rear view mirror assembly must be replaced. GLOVE BOX LAMP REMOVAL (1) Release glove box latch and open glove box.
  • Page 352 TAIL, STOP, TURN SIGNAL, BACKUP AND SIDEMARKER FLOOR CONSOLE FLOOR CONSOLE WIRE HARNESS TESY LAMP VIEW A VIEW A COUR- LAMP FLOOR CONSOLE FLOOR CONSOLE TESY LAMP COUR- BULB 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 4 Tail/Stop, Turn Signal, Backup and Side Marker Lamp Fig.
  • Page 353 COURTESY LAMP HOUSING COURTESY LAMP HOUSING COURTESY LAMP LENS DOOR TRIM PANEL DOOR TRIM PANEL UPPER DECK MOLDING WIRE CONNECTOR WIRE HARNESS CHMSL LAMPS 8L - 15 REMOVAL AND INSTALLATION (Continued) (2) Pull courtesy lamp from door trim panel (Fig. (2) Remove screws holding CHMSL assembly to upper deck molding (Fig.
  • Page 354 REAR BUMPER FASCIA LICENSE PLATE LAMP 8L - 16 LAMPS SPECIAL TOOLS (Continued) SPECIAL TOOLS LAMP SERVICE Trim Stick C-4755 Fig. 10 License Plate Lamp...
  • Page 355 FUSE BRACKET MULTI FUNCTION MODULE BLOCK DAYTIME RUNNING MODULE LAMP LAMPS 8L - 17 LAMP SYSTEMS INDEX page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING DAYTIME RUNNING LAMP (CANADA) ..17 GENERAL LAMP SYSTEM DIAGNOSTIC HEADLAMP TIME DELAY SYSTEM .
  • Page 356 8L - 18 LAMPS DIAGNOSIS AND TESTING (Continued) ILLUMINATED ENTRY DIAGNOSTIC PROCEDURES Refer to Group 8W, Wiring Diagrams for compo- nent location and circuit information. Refer to Body When testing the system, all doors must be closed Systems Diagnostic Procedures Manual for more to prevent courtesy lamps from lighting.
  • Page 357 LAMPS 8L - 19 BULB APPLICATION INDEX page page SPECIFICATIONS GENERAL INFORMATION ....19 EXTERIOR LAMPS ..... 19 INTERIOR LAMPS .

  • Page 359: Restraint System

    AWAY FROM THE BODY TO MINIMIZE POSSIBILITY ture deployment can result. INJURY ACCIDENTAL DEPLOYMENT If the Driver/Passenger Airbag Module is defective OCCURS. and not deployed, refer to Chrysler Corporation cur- REPLACE AIRBAG SYSTEM COMPONENTS WITH rent return list for proper handling procedures. MOPAR REPLACEMENT PARTS. SUBSTITUTE...

  • Page 360: Description And Operation

    PASSENGER AIRBAG MOD AIRBAG CONTROL MODULE DATA LINK CONNECTORS DRIVER AIRBAG MODULE 8M - 2 RESTRAINT SYSTEM DESCRIPTION AND OPERATION The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing AIRBAG CONTROL MODULE the passenger seat (Fig. 1). The passenger inflator assembly is within the mod- The Airbag Control Module (ACM) contains the ule housing.

  • Page 361: Diagnosis And Testing

    RESTRAINT SYSTEM 8M - 3 DESCRIPTION AND OPERATION (Continued) seat belts are in lock or unlock position, an occupant Passive Restraint Diagnostic Test Manual to diag- can always release the seat belt and it will retract. nose the problem. To test the airbag warning lamp The Seat Belt Control Timer Module controls the operation in the cluster only, refer to Group 8E, power to the seat belt solenoids.

  • Page 362: Service Procedures

    8M - 4 RESTRAINT SYSTEM DIAGNOSIS AND TESTING (Continued) fuse blows check for shorts to ground between the SERVICE PROCEDURES module and the seat belt solenoid. Repair as neces- sary. CLEANUP PROCEDURE (4) If voltage is OK, go to Step 5. If no voltage Roll or fold the Passenger Airbag Module towards check for an open circuit between fuse and module.

  • Page 363: Handling Airbag Module

    (8) Do not connect battery negative remote cable. AIRBAG CONTROL MODULE (ACM) Refer above to Diagnosis and Testing for Airbag Sys- tem Test procedures. WARNING: REPLACE AIRBAG SYSTEM COMPO- NENTS WITH CHRYSLER MOPAR SPECIFIED REPLACEMENT PARTS. SUBSTITUTE PARTS MAY VISUALLY APPEAR INTERCHANGEABLE,...

  • Page 364: Clockspring

    RADIO ANTENNA CONNEC AIRBAG CONTROL MODULE ACM TROUGH SLIDE OVER TOP OF STUDS ON TOP OF AIRBAG CONTROL MODULE TO PARK BRAKE SWITCH INSTRUMENT HARNESS WIRE PARK BRAKE CONNECTOR PANEL NUTS SPEED CONTROL WIRES 2 WAY CONNECTOR 4 WAY CONNECTOR SQUIB WIRE HORN WIRE LOCK HOUSING LATCHES...

  • Page 365: Driver Airbag Module

    AIRBAG SQUIB WIRE AIRBAG MODULE HORN WIRE SPEED CONTROL CONNEC- TORS RESTRAINT SYSTEM 8M - 7 REMOVAL AND INSTALLATION (Continued) (10) Install the Driver Airbag Module bolts and (5) Do not connect the battery negative cable. tighten to 10 to 11 N·m (90 to 100 in. lbs.) torque. Refer to Diagnosis and Testing for Airbag System Tighten the left side first.
  • Page 366 END COVER KNEE BOLSTER SPEAKERS INSTRUMENT CLUSTER HVAC GLOVE BOX LOCK TOP COVER CUBBYBIN CENTER BEZEL SCREW CYLINDER PASSENGER BAG MODULE END COVER INSTRUMENT CLUS- AIR- RADIO TER HOOD 8M - 8 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 7 Instrument Panel Components (10) Remove the forward floor console nine attach- (16) Remove five screws attaching panel retainer ing screws and one push pin at forward driver’s side.

  • Page 367: Seat Belt Control Timer Module

    RESTRAINT SYSTEM 8M - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION For installation, reverse the above procedures. (1) Remove all of the instrument panel components that are not damaged and replace any components that are damaged. (2) Use a new instrument panel pad. (3) Install all of the components.

  • Page 368: Steering Wheel

    BELT CONTROL MODULE TIMER 8M - 10 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) care to feed the wires gently through the holes in the clockspring armature. INSTALLATION (1) Confirm that: • The steering wheel position is a half turn (180 degrees) to the right (clockwise) •...

  • Page 369: Introduction

    REAR WINDOW DEFOGGER SWITCH ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION SYSTEM TEST ......2 HVAC CONTROL MODULE .

  • Page 370: System Test

    PICK-UP VIEW FROM INSIDE VEHI- LEADS GROUND REAR WINDOW DEFOGGER VOLTAGE FEED VOLTMETER MID-POINT BUS BARS 8N - 2 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING SYSTEM TEST Electrically heated rear window defogger operation can be checked in vehicle in the following manner: (1) Turn ignition switch to the ON position.

  • Page 371: Service Procedures Repair Grid Lines, Terminals And Pigtails

    H/LP RELAY CIRCUIT BREAKERS HORN RELAY ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) (1) Remove the control switch from console and do not disconnect control switch (Fig. 4). (2) Using a ohmmeter, check leads between Pins 5 and 8 of the 8-way connector.

  • Page 372: Removal And Installation

    8N - 4 ELECTRICALLY HEATED SYSTEMS SERVICE PROCEDURES (Continued) (7) Apply a thin layer of conductive epoxy on ter- minal and place terminal on desired location. To pre- vent terminal from moving while the epoxy is curing, it must be wedged or clamped. (8) Carefully remove masking tape from grid line.
  • Page 373 POWER DOOR LOCKS 8P - 1 POWER DOOR LOCKS CONTENTS page page POWER DOOR LOCKS ....1 REMOTE KEYLESS ENTRY ....5 POWER DOOR LOCKS INDEX page...

  • Page 374: Power Door Locks

    LHVIEW + TO LOCK DIRECTION ARROW Z 8P - 2 POWER DOOR LOCKS DESCRIPTION AND OPERATION (Continued) DOOR LOCK INHIBIT With the key in the ignition switch in any position and the driver’s door open the Body Control Module will not allow the door locks switches to lock the doors.

  • Page 375: Service Procedures

    POWER DOOR LOCKS 8P - 3 LOCATION OF BEZEL TO DOOR TRIM CLIPS UNDER- LIFT UPWARD & INBOARD IN SWITCH & BEZEL ASSEMBLY DOOR THE DIRECTION OF ARROW TRIM DOOR TRIM LIFT POINT (ARMREST NEATH AREA) CLIPS AUTO DIAGNOSIS AND TESTING (Continued) not OK, check fuse 5 in the Junction Block, if fuse INSTALLATION is OK, repair wire as necessary.

  • Page 376: Remote Keyless Entry

    (2) 3 VOLT BATTERIES 8P - 4 POWER DOOR LOCKS REMOTE KEYLESS ENTRY INDEX page page GENERAL INFORMATION SYNCHRONIZATION OF ROLLING CODE ..7 INTRODUCTION ......4 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION DECK LID RELEASE RELAY .
  • Page 377 COURTESY DECK LID RELEASE RELAY ILLUMINATION LAMP RELAY RELAY CAVITIES RELAY TERMINALS POWER DOOR LOCKS 8P - 5 DESCRIPTION AND OPERATION (2) Resistance between terminals 85 and 86 (elec- tromagnet) should be 75 5 ohms. If OK, go to Step DECK LIP RELEASE RELAY 3.
  • Page 378 8P - 6 POWER DOOR LOCKS DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CONDITIONS Driver door will NOT unlock with the key fob transmitter, but passenger door will unlock. When trouble shooting problems with the Remote (1) Using a voltmeter, check Pin 4 of the BCM 20 Keyless Entry System, always verify that the power Pin connector for a voltage pulse (Fig.
  • Page 379 POWER DOOR LOCKS 8P - 7 SERVICE PROCEDURES (2) Grasp the relay and pull downward to discon- nect the relay. HORN CHIRP ENABLE/DISABLE INSTALLATION The scan tool (DRB) must be used to enable/disable Align the relay pins with the connector terminals the Horn Chirp.
  • Page 381 VEHICLE THEFT/SECURITY SYSTEM 8Q - 1 VEHICLE THEFT/SECURITY SYSTEM CONTENTS page page DESCRIPTION AND OPERATION HORN RELAY ......2 CENTRAL LOCK/UNLOCK SYSTEM .
  • Page 382 8Q - 2 VEHICLE THEFT/SECURITY SYSTEM DESCRIPTION AND OPERATION (Continued) NOTE: The ignition switch can be turned to the Activating the Remote Keyless Entry System accessory position without triggering alarm system. (RKE) to exercise any of the above inputs will also cause the horn to pulse.

  • Page 383: Power Seats

    POWER SEATS 8R - 1 POWER SEATS CONTENTS page page DESCRIPTION AND OPERATION TRACTION CONTROL SWITCH ... . . 1 INTRODUCTION ......1 VOLTAGE .
  • Page 384 MOUNTING SCREWS 8R - 2 POWER SEATS REMOVAL AND INSTALLATION (Continued) REMOVAL AND INSTALLATION SEAT ASSEMBLY REMOVAL (1) Remove adjuster attaching bolts from floor pan. Move seat as necessary for access. (2) Disconnect battery negative cable. (3) Disconnect wiring harness power lead at car- pet.
  • Page 385 VIEWED FROM TRACK SEAT BACK RECLINER SCREWS TRACK CUSHION SCREWS FRONT SEAT POWER SEATS 8R - 3 REMOVAL AND INSTALLATION (Continued) INSTALLATION For installation, reverse the above procedure. Fig. 4 Seat Track Removal...

  • Page 387: Power Windows

    POWER WINDOWS 8S - 1 POWER WINDOWS CONTENTS page page GENERAL INFORMATION WINDOW MOTOR ..... . . 2 INTRODUCTION ......1 WINDOW SWITCH .

  • Page 388: Window Drop Relay Assembly

    WINDOW MOTOR RELAYS CONTINUITY PIN 10 to 12 PIN 10 to 12 PIN 10 to 11 PIN 10 to 11 TERMINALS PIN 10 to 2 PIN 10 to 3 PIN 10 to 4 PIN 10 to 7 PIN 10 to 8 PIN 10 to 9 PIN 8 to 10 PIN 1 to 12...

  • Page 389: Window Motor

    CONTINUITY SWITCH POSITION TERMINALS BETWEEN PIN 2 to 5 PIN 1 to 4 PIN 1 to 4 PIN 5 to 6 PIN 2 to 5 PIN 1 to 6 DOWN MOTOR MOUNTING SCREWS CLAMP REGULATOR TO SEC- TOR GEAR POWER WINDOWS 8S - 3 REMOVAL AND INSTALLATION (Continued) (3) Disconnect wiring connector from motor.

  • Page 390: Window Switch And Bezel

    8S - 4 POWER WINDOWS REMOVAL AND INSTALLATION (Continued) WINDOW SWITCH AND BEZEL REMOVAL (1) Start at the rear center of the bezel. Using your fingers or a trim stick, lift the bezel upwards and slightly inboard to disconnect the two rear clips (Fig.

  • Page 391: Power Mirrors

    REMOVAL SLOT POWER MIRRORS 8T - 1 POWER MIRRORS CONTENTS page page DESCRIPTION AND OPERATION MIRROR SWITCH ..... . . 1 HEATED MIRROR .
  • Page 392 CONTINUITY Mirror in R Position Mirror in L Position SWITCH POSITION Move Button TERMINALS BETWEEN PIN 1 to 5 PIN 2 to 8 PIN 1 to 7 PIN 2 to 6 PIN 1 to 8 PIN 2 to 5 PIN 1 to 6 PIN 2 to 7 PIN 1 to 5 PIN 2 to 4...

  • Page 393: Introduction

    TRANSMISSION SEAT BELT WARNING LAMP INDICATOR DISPLAY DOOR KEY IN IGNITION SWITCH ALL OTHER DOORS SEAT BELT SWITCH AJAR SWITCH DRIVE DOOR PANEL LAMP CHIME UNIT BATTERY BATTERY GROUND IGNITION RANGE BUS + BODY CONTROL MODULE CHIME WARNING/REMINDER SYSTEM 8U - 1 CHIME WARNING/REMINDER SYSTEM CONTENTS page...

  • Page 394: Diagnosis And Testing

    BODY CONTROL MODULE H/LP RELAY HORNRELAY CIRCUIT HORN BREAK- 8U - 2 CHIME WARNING/REMINDER SYSTEM DIAGNOSIS AND TESTING Module. Refer to Group 8W, Wiring Diagrams for ter- minal location. CHIME CONDITIONS (5) If voltage not OK, repair as necessary. FASTEN SEAT BELT LAMP OR TONE NO TONE WHEN IGNITION SWITCH IS CONTINUE FOR MORE THAN 10 SECONDS TURNED ON AND DRIVERS SEAT BELT IS...

  • Page 395: Removal And Installation

    CHIME WARNING/REMINDER SYSTEM 8U - 3 DIAGNOSIS AND TESTING (Continued) NO TONE WHEN IGNITION KEY IS LEFT IN (2) Check wiring for a grounded condition between IGNITION SWITCH AND IT IS IN THE OFF key-in switch and Body Control Module. Check head- lamp switch to Body Control Module wiring for short POSITION WITH DRIVER’S DOOR IS OPEN (1) Check left door jamb switch for good ground...

  • Page 397: Wiring Diagrams

    WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION ..8W-01-1 8W-46 TRAVELER ....8W-46-1 8W-02 COMPONENT INDEX .
  • Page 399 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION INTERMITTENT AND POOR CONNECTIONS ..6 CIRCUIT IDENTIFICATION ....2 TROUBLESHOOTING TESTS .
  • Page 400 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) NOTES are used to help describe how switches or WIRE CODE IDENTIFICATION components operate to complete a particular circuit. Each wire shown in the diagrams contains a code They are also used to indicate different conditions (Fig.
  • Page 401 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 4 Connector Identification tifies in-line connectors by number, and component connectors by name. If a component has two or more connectors they will be identified as C1, C2, C3...etc. This sections also provides terminal numbering, cir- cuit identification, wire colors, and functions.
  • Page 402 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Fig. 5 Symbol Identification...
  • Page 403 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When han- dling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inad- vertent discharge into the component.
  • Page 404 8W - 01 - 6 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) size tool from Special Tool Package 6807, and insert (2) Connect the other lead of the voltmeter to the it into the terminal being tested. Use the other end selected test point.
  • Page 405 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DIAGNOSIS AND TESTING (Continued) Fig. 10 Testing for Continuity Fig. 11 Testing for Voltage Drop (4) Start connecting the items in the fuse circuit (6) Verify proper operation. For this step check for one at a time.
  • Page 406 8W - 01 - 8 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (10) Connect battery and test all affected systems. Fig. 14 Using Special Tool 6742 CONNECTOR REPLACEMENT (1) Disconnect battery. (2) Disconnect the connector that is to be repaired from its mating half/component (3) Remove connector...
  • Page 407 8W - 01 - 10 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (10) Connect battery and test all affected systems. Fig. 18 Stagger Cutting Wires (9) Spread the strands of the wire apart on each Fig. 16 Terminal Removal part of the exposed wires.
  • Page 408 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 22) (Fig. 23). Fig. 19 Augat Connector Repair Fig. 22 Terminal Removal Fig.
  • Page 409 8W - 01 - 12 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (14) Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
  • Page 410 8W - 01 - 12 8W - 01 GENERAL INFORMATION SPECIAL TOOLS WIRING/TERMINAL Terminal Removing Tool 6932 Probing Tool Package 6807 Terminal Removing Tool 6934 Terminal Pick 6680...
  • Page 411 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX INDEX page GENERAL INFORMATION ..............3 COMPONENT INDEX Component Page...
  • Page 412 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page License Lamp .....8W-51, 51-2 Rear Window Defogger ....8W-47 Low Speed Radiator Fan Relay .
  • Page 413 8W - 02 COMPONENT INDEX 8W - 02 - 3 8W-02 COMPONENT INDEX GENERAL INFORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W. For information on system operation, refer to the appropriate section of the wiring diagrams.
  • Page 415 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 416 8W - 10 - 2 8W-10 POWER DISTRIBUTION POWER DISTRIBUTION CENTER HIGH SPEED LOW SPEED RADIATOR RADIATOR FAN RELAY FAN RELAY ENGINE AUTOMATIC SHUT STARTER MOTOR DOWN RELAY RELAY NOT USED A/C COMPRESSOR CLUTCH RELAY NOT USED INTERMITTENT WIPER RELAY WIPER HIGH/LOW RELAY...
  • Page 417 8W-10 POWER DISTRIBUTION 8W - 10 - 3 BATTERY (8W-20-2) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-4) (8W-10-5) (8W-10-5) (8W-10-6) FUSE FUSE FUSE FUSE (8W-10-4) (8W-10-5) (8W-10-9) RD/DB PK/YL PK/YL RD/BK RD/TN RD/LB FUSE S104 C126 USED S102 C121 SYSTEM CONTROL RELAY...
  • Page 418 8W - 10 - 4 8W-10 POWER DISTRIBUTION ST-RUN A142 BATT A0 (8W-10-5) (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-3) F142 OR/DG RD/DB PK/YL PK/YL TRANSMISSION RELAY (IN PDC) (8W-31-2) RD/BR S100 RD/BR C104 RD/BR TRANSMISSION SOLENOID AND PRESSURE DOWNSTREAM SWITCH HEATED...
  • Page 419 8W-10 POWER DISTRIBUTION 8W - 10 - 5 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-3) RD/BK RD/TN C126 JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) IMMOBILIZER COMBINATION FUSED (8W-12-6) (8W-61-5) FLASHER B(+) (8W-52-3) RD/BK S104 STOP (IN PDC) LAMP SWITCH (8W-33-3) RD/TN...
  • Page 420 8W - 10 - 6 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE INSTRUMENT (8W-10-3) CLUSTER BRAKE (8W-40-7) WARNING LAMP S102 GY/DB (IN PDC) C126 JUNCTION BLOCK (8W-12-16) (8W-12-3) ENGINE FUEL STARTER PUMP MOTOR RELAY RELAY (IN PDC) (IN PDC) (8W-30-3) (8W-21-2)
  • Page 421 8W-10 POWER DISTRIBUTION 8W - 10 - 7 BATT A1 BATT A1 (8W-10-6) (8W-10-6) IGNITION SWITCH (8W-10-6) 1 START 2 RUN 0 OFF 3 LOCK 4 ACC BK/WT DG/RD JUNCTION BLOCK (8W-12-2) BODY FUSE FUSE FUSE FUSED CONTROL IGN. MODULE (ST-RUN) (8W-45-2) (8W-12-12)
  • Page 422 8W - 10 - 8 8W-10 POWER DISTRIBUTION ST-RUN A21 (8W-10-7) POWER DISTRIBUTION FUSE CENTER (8W-10-3) LG/BK S106 (IN PDC) LG/BK LG/BK LG/BK LG/BK LG/BK HIGH SPEED RADIATOR RELAY (IN PDC) (8W-42-4) SPEED RADIATOR RELAY DUTY (IN PDC) CYCLE (8W-42-4) EVAP/ PURGE COMPRESSOR...
  • Page 423 8W-10 POWER DISTRIBUTION 8W - 10 - 9 ST-RUN A21 BATT A0 (8W-10-7) (8W-10-3) POWER DISTRIBUTION CENTER (8W-10-3) FUSE FUSE DB/WT C121 POWER DOWN RELAYS (8W-66-2) S105 (IN PDC) DB/WT DB/WT DB/WT C113 DB/WT POWERTRAIN CONTROLLER FUSED FUSED CONTROL ANTI-LOCK IGN.
  • Page 424 8W - 10 - 10 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-3) RD/GY PK/WT C121 SEAT FUSED BELT B(+) CONTROL MODULE (8W-67-2) INTERMITTENT WIPER RELAY (IN PDC) (8W-53-3) DG/VT WIPER JUNCTION HIGH/ BLOCK (8W-12-2) RELAY FUSE FUSE...
  • Page 425 8W-10 POWER DISTRIBUTION 8W - 10 - 11 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) RD/WT JUNCTION BLOCK (8W-12-2) HEADLAMP CIRCUIT FUSE (8W-12-3) DELAY BREAKER RELAY (8W-12-10) (8W-12-12) FUSE FUSE FUSE (8W-12-11) (8W-12-11) (8W-12-10) VT/WT RD/WT HEADLAMP SWITCH (8W-50-3) BODY CONTROL BEAM...
  • Page 426 8W - 10 - 12 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) BK/PK RD/LG S103 (IN PDC) JUNCTION BLOCK REAR (8W-12-2) RD/LG RD/LG RD/LG WINDOW DEFOGGER RELAY (8W-47-6) COMPRESSOR CLUTCH RELAY (IN PDC) (8W-42-3) FUSE SPEED RADIATOR DB/BK...
  • Page 427 8W-10 POWER DISTRIBUTION 8W - 10 - 13 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) BATT A1 (8W-10-6) PK/BK C126 PK/BK IGNITION SWITCH (8W-10-6) 1 START 2 RUN 0 OFF 3 LOCK 4 ACC DG/RD BK/WT BK/OR ST-RUN-OFF A81 ST-RUN A21 (8W-10-7) (8W-10-7)
  • Page 428 8W - 10 - 14 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER (8W-10-3) FUSE RD/DG RELAY PUMP (8W-35-3) MOTOR RELAY (8W-35-3) PUMP PUMP MOTOR MOTOR DRIVER (8W-35-3) B120 BR/RD CONTROLLER ANTI-LOCK PUMP MOTOR BRAKE SENSE (8W-35-3) 978W-14 JXI00141...
  • Page 429 8W-10 POWER DISTRIBUTION 8W - 10 - 15 FUSES FUSE AMPS FUSED CIRCUIT FEED CIRCUIT F142 18DG/OR A142 18DG/OR A20 16RD/DB A0 4RD A24 16PK/YL A0 4RD A24 16PK/YL A7 16RD/BK A0 4RD A14 16RD/TN A0 4RD A15 16PK A0 4RD A51 20RD/LB A0 4RD A1 16RD...
  • Page 430 8W - 10 - 16 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT (RUN/START) F12 18DB/WT FUEL PUMP K31 20BR/LG FUEL PUMP RELAY CONTROL RELAY A141 14DG/WT FUEL PUMP RELAY CONTROL FUSED B(+) A1 16RD CAVITY CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT (ACC/RUN) F13 18DB/GY WIPER...
  • Page 431 8W-10 POWER DISTRIBUTION 8W - 10 - 17 CAVITY CIRCUIT FUNCTION USED CAVITY CIRCUIT FUNCTION T40 14BR STARTER RELAY OUTPUT ENGINE IGNITION SWITCH OUTPUT (START) A41 26YL STARTER IGNITION SWITCH OUTPUT (START) T141 16YL/RD* MOTOR RELAY T41 20BK/WT PARK/NEUTRAL POSITON SWITCH SENSE T41 20BK/LB PARK/NEUTRAL POSITION SWITCH SENSE FUSED B(+)
  • Page 432 8W - 10 - 18 8W - 10 POWER DISTRIBUTION 8W-10 POWER DISTRIBUTION DESCRIPTION AND OPERATION mation on system operation, refer to the appropriate section of the wiring diagrams. INTRODUCTION This section covers the power distribution center and all circuits involved with it. For additional infor-...
  • Page 433 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 434 8W - 12 - 2 8W-12 JUNCTION BLOCK TOP OF JUNCTION BLOCK REAR WINDOW DEFOGGER RELAY HORN HEADLAMP RELAY DELAY RELAY BODY CONTROL MODULE SEE PAGE 8W-12-19 FOR JUNCTION BLOCK PIN-OUT INFORMATION 978W-14 JXI00142...
  • Page 435 8W-12 JUNCTION BLOCK 8W - 12 - 3 BOTTOM OF JUNCTION BLOCK MODULE JXI00143 978W-14...
  • Page 436 8W - 12 - 4 8W-12 JUNCTION BLOCK RUN A22 BATT A3 (8W-10-13) (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) RD/WT HEADLAMP SWITCH 1 HEAD 2 PARK 0 OFF BLOWER 3 LOW MOTOR 4 HIGH RESISTOR (8W-50-3) BLOCK (8W-42-2) RD/OR JUNCTION BLOCK (8W-12-2) FUSE...
  • Page 437 8W-12 JUNCTION BLOCK 8W - 12 - 5 RUN A22 (8W-10-13) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) DAYTIME FUSED RUNNING IGN. LAMP (RUN) MODULE (8W-50-5) WT/YL POWER LOCKS OTHERS S306 C342 C332 C342 C315 C105 POWER POWER C310 SWITCH WT/YL SWITCH BK/WT (8W-66-2) (8W-66-2)
  • Page 438 8W - 12 - 6 8W-12 JUNCTION BLOCK BATT A7 (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE BODY FUSED CONTROL MODULE (8W-45-2) PK/VT TRAVELER PK/OR PK/DB PK/WT FUSED (8W-46-2) B(+) TRUNK LAMP C310 C315 (8W-44-3) (8W-12-7) (8W-12-7) C332 S134 PK/WT PK/WT PK/WT PK/WT POWER ILLUMINATED...
  • Page 439 8W-12 JUNCTION BLOCK 8W - 12 - 7 FROM FROM FROM FUSE FUSE FUSE 5 (JB) 5 (JB) 5 (JB) (8W-12-6) (8W-12-6) (8W-12-6) C310 C315 VTSS OTHERS VTSS OTHERS S400 S401 RIGHT LEFT DOOR DOOR COURTESY COURTESY LAMP LAMP (8W-44-6) (8W-44-6) ILLUMINATED LEFT...
  • Page 440 8W - 12 - 8 8W-12 JUNCTION BLOCK BATT A4 BATT A13 (8W-10-12) (8W-10-10) JUNCTION BLOCK REAR (8W-12-2) WINDOW DEFOGGER RELAY (8W-47-6) FUSE FUSE LB/YL LB/OR LB/YL BK/LB BK/RD C310 C315 LB/OR LB/YL RIGHT HEADLAMP POWER SWITCH MIRROR (8W-50-3) (8W-47-6) LEFT POWER MIRROR...
  • Page 441 8W-12 JUNCTION BLOCK 8W - 12 - 9 BATT A13 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE HORN RELAY (8W-41-2) BODY HORN CONTROL RELAY MODULE CONTROL (8W-45-12) BK/RD DG/PK DG/PK CLOCKSPRING VEHICLE SPEED LEFT RIGHT CONTROL/ HORN HORN NOTE HORN SWITCH SWITCH HORN SWITCH (8W-41-2)
  • Page 442 8W - 12 - 10 8W-12 JUNCTION BLOCK BATT A3 ST-RUN-OFF A81 (8W-10-11) (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE BODY DAYTIME BODY FUSED FUSED FUSED CONTROL RUNNING CONTROL B(+) B(+) IGN. MODULE LAMP MODULE (ST-RUN-OFF) (8W-45-2) MODULE (8W-45-2) (8W-50-5) RD/VT RD/VT RD/VT...
  • Page 443 8W-12 JUNCTION BLOCK 8W - 12 - 11 BATT A3 RUN-ACC A31 (8W-10-11) (8W-10-7) JUNCTION BLOCK REAR (8W-12-2) WINDOW FUSE FUSE DEFOGGER RELAY (8W-47-6) RD/WT RD/WT DB/GY HEADLAMP C224 RADIO SWITCH (8W-47-2) 1 HEAD SEAT FUSED 2 PARK BELT IGN. 0 OFF (RUN-ACC) CONTROL...
  • Page 444 8W - 12 - 12 8W-12 JUNCTION BLOCK RUN A22 BATT A3 ST-RUN A21 (8W-10-13) (8W-10-11) (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE CIRCUIT FUSE BREAKER LG/YL S312 C309 DECKLID RELEASE RELAY LG/BK DECKLID POWER SOLENOID SEAT (8W-61-4) SWITCH (8W-63-2) AIRBAG FUSED FUSED CONTROL IGN.
  • Page 445 8W-12 JUNCTION BLOCK 8W - 12 - 13 RUN A22 (8W-10-13) JUNCTION BLOCK (8W-12-2) CIRCUIT (8W-12-3) BREAKER WINDOW TIMER TN/VT TN/WT MODULE C311 C316 (8W-60-4) TN/VT S410 MASTER POWER WINDOW SWITCH (8W-60-2) (8W-60-3) LEFT RIGHT DOOR DOOR WINDOW WINDOW MOTOR MOTOR RELAY RELAY...
  • Page 446 8W - 12 - 14 8W-12 JUNCTION BLOCK HEADLAMP AUTOMATIC OVERHEAD SWITCH DAY/ (8W-50-3) NIGHT LAMP MIRROR (8W-44-3) (8W-44-5) IGNITION SWITCH HEADLAMP (8W-10-6) LEVELING SWITCH (8W-50-4) AUTOMATIC OVERHEAD DAY/NIGHT MAP LAMP MIRROR ILLUMINATED ENTRY RELAY (8W-44-3) DATA LINK CONNECTOR (8W-30-17) C332 AUTOSTICK SWITCH...
  • Page 447 8W-12 JUNCTION BLOCK 8W - 12 - 15 JUNCTION BLOCK (8W-12-2) BODY (8W-12-3) CONTROL MODULE (8W-45-6) BK/YL BK/BR BK/BR BK/YL BK/YL BK/DG BK/YL LEFT RIGHT HEADLAMP PARK/ HEADLAMP SWITCH TURN LEVELING (8W-50-3) SIGNAL MOTOR LAMP (8W-50-4) (8W-50-4) LEFT RIGHT RADIO HEADLAMP PARK/ (8W-47-2)
  • Page 448 8W - 12 - 16 8W-12 JUNCTION BLOCK LEFT RIGHT LAMP SWITCH LAMP LAMP (8W-50-3) (8W-50-3) (8W-50-3) JUNCTION BLOCK (8W-12-3) DAYTIME RUNNING LAMP MODULE (8W-50-5) GY/DG GY/DB GY/DB GY/DB C224 BRAKE INSTRUMENT WARNING CLUSTER PRESSURE (8W-40-7) SWITCH (8W-40-7) CONTROLLER IGNITION PARK ANTI-LOCK SWITCH...
  • Page 449 8W-12 JUNCTION BLOCK 8W - 12 - 17 CONTROLLER STOP ANTI-LOCK LAMP BRAKE SWITCH (8W-35-6) (8W-33-3) WT/BR WT/TN JUNCTION BLOCK (8W-12-3) WT/TN S313 WT/TN WT/TN WT/TN C300 C305 C301 WT/TN BK/TN WT/TN LEFT CENTER RIGHT TAIL/ HIGH TAIL/ STOP MOUNTED STOP LAMP STOP...
  • Page 450 8W - 12 - 18 8W-12 JUNCTION BLOCK TURN SIGNAL/ HAZARD WARNING SWITCH (8W-52-2) JUNCTION BLOCK (8W-12-3) LG/TN LG/TN LG/TN TN/BR TN/BR C300 C301 LG/TN LEFT RIGHT REAR REAR TURN TURN SIGNAL SIGNAL LAMP LAMP (8W-52-4) (8W-52-4) S135 S136 LG/TN TN/BR LEFT INSTRUMENT...
  • Page 451 8W-12 JUNCTION BLOCK 8W - 12 - 19 FUSES FUSE AMPS COLOR FUSED CIRCUIT FEED CIRCUIT GREEN C1 DG A22 BK/OR BLUE L34 RD/OR L3 RD/OR BLUE L33 LG/BR L3 RD/OR F20 WT, F20 WT/YL A22 BK/OR BLUE M1 PK A7 RD/BK BLUE C16 LB/YL...
  • Page 452 8W-12 JUNCTION BLOCK DESCRIPTION AND OPERATION INTRODUCTION This section covers the junction block and all circuits involved with it. For additional information on system oper- ation, please refer to the appropriate section of the wiring diagrams. This section identifies the fuses, relays, modules, and internal circuity of the junction block. For additional infor- mation on system operation, refer to the appropriate group of the wiring diagrams.
  • Page 453 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 454 8W - 15 - 2 8W-15 GROUND DISTRIBUTION RADIATOR LEFT LEFT UPSTREAM PARK/ HEATED MOTOR LAMP TURN OXYGEN ASSEMBLY (8W-50-3) SIGNAL SENSOR (8W-42-4) LAMP (8W-30-10) (8W-50-4) LEFT LEFT HEADLAMP SIDE LEVELING REPEATER MOTOR (8W-52-2) (8W-50-4) C111 S109 VEHICLE SPEED CONTROL G102 SERVO (8W-15-3)
  • Page 455 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 TRANSMISSION POWERTRAIN TRANSMISSION CONTROL CONTROL RELAY MODULE MODULE (IN PDC) (8W-31-2) (8W-30-2) (8W-31-2) BRAKE WARNING PRESSURE BK/YL BK/RD BK/TN BK/TN BK/RD SWITCH (8W-40-7) C113 BK/TN S101 LEFT FROM HEADLAMP S109 (8W-50-2) (8W-15-2) BK/YL BK/RD G102...
  • Page 456 8W - 15 - 4 8W-15 GROUND DISTRIBUTION HIGH RIGHT WINDSHIELD DOWNSTREAM RIGHT NOTE PARK/ WASHER HEATED HEADLAMP HORN TURN PUMP OXYGEN LEVELING (8W-41-2) SIGNAL MOTOR SENSOR MOTOR LAMP (8W-53-2) (8W-30-10) (8W-50-4) (8W-50-4) RIGHT WASHER RIGHT NOTE FLUID SIDE HORN LAMP LEVEL REPEATER...
  • Page 457 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 GLOVE CIGAR TRAVELER DISTRIBUTOR LIGHTER/ (8W-46-2) (2.5L) LAMP POWER (8W-30-5) (8W-44-3) OUTLET (8W-41-2) RECEIVER LAMP (8W-44-4) S200 G105 JUNCTION BODY BLOCK CONTROL (8W-12-2) MODULE (8W-45-2) RADIO AIRBAG (8W-47-2) HEATER CONTROL CONTROL MODULE (8W-42-2) (8W-43-2) IMMOBILIZER...
  • Page 458 8W - 15 - 6 8W-15 GROUND DISTRIBUTION LEFT LEFT LEFT TAIL/ LICENSE REAR STOP LAMP LAMP LAMP (8W-51-2) (8W-51-2) (8W-51-4) LEFT LEFT RIGHT REAR BACK-UP LICENSE TURN LAMP LAMP SIGNAL (8W-51-3) (8W-51-2) LAMP (8W-52-4) S404 RIGHT RIGHT RIGHT TAIL/ REAR BACK-UP STOP...
  • Page 459 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 CENTER TRUNK FUEL DECKLID HIGH PUMP SOLENOID MOUNTED CYLINDER MODULE (8W-61-4) STOP LAMP SWITCH (8W-30-3) (8W-51-2) (VTSS) (8W-39-2) BK/LG C305 S301 G302 G300 (8W-15-6) REAR POWER SEAT WINDOW ANTENNA BELT DEFOGGER (8W-47-2) CONTROL (8W-47-6) (8W-47-6)
  • Page 460 8W - 15 - 8 8W-15 GROUND DISTRIBUTION WINDOW LEFT POWER MASTER TIMER POWER MIRROR POWER MODULE MIRROR SWITCH WINDOW (8W-60-4) (8W-47-6) (8W-62-2) SWITCH (8W-60-2) (8W-60-3) S402 C311 LEFT LEFT RIGHT POWER DOOR DOOR DOOR WINDOW WINDOW S308 LOCK MOTOR MOTOR (8W-15-9) SWITCH...
  • Page 461 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 RIGHT POWER PASSENGER DRIVER POWER SEAT SEAT MIRROR SWITCH BELT BELT (8W-47-6) (8W-66-2) SOLENOID SOLENOID (8W-67-2) (8W-67-2) RIGHT POWER DOOR LOCK SWITCH C342 (8W-61-2) C341 POWER SEAT SEAT BELT SWITCH SWITCH S403 (8W-63-2) (8W-40-4) (8W-45-9)
  • Page 462 8W - 15 - 10 8W-15 GROUND DISTRIBUTION HEADLAMP AUTOMATIC OVERHEAD SWITCH DAY/ (8W-50-3) NIGHT LAMP MIRROR (8W-44-3) (8W-44-5) IGNITION SWITCH (8W-10-6) AUTOMATIC OVERHEAD DAY/NIGHT MAP LAMP MIRROR ILLUMINATED AUTOSTICK ENTRY SWITCH RELAY (8W-31-3) (8W-44-3) DATA LINK CONNECTOR (8W-30-17) C332 BK/RD BK/TN JUNCTION...
  • Page 463 8W-15 GROUND DISTRIBUTION DESCRIPTION AND OPERATION INTRODUCTION This section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams. For an illustration of the physical location of each ground, refer to group 8W-90.
  • Page 465 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 466 8W - 20 - 2 8W-20 CHARGING SYSTEM FUSIBLE POWER LINK DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-5) RD/TN S104 (IN PDC) (8W-10-5) AUTOMATIC SHUT DOWN RELAY (IN PDC) BATTERY A142 A142 DG/OR DG/OR C111 S113 S118 FUSE (8W-70-5) (PDC) 2.5L 2.4L (8W-10-4) G100 A142...
  • Page 467 8W - 20 CHARGING SYSTEM 8W - 20 - 3 8W-20 CHARGING SYSTEM DESCRIPTION AND OPERATION generator field is controlled by the K20 circuit. Cir- cuit K20 connects to cavity 4 of the PCM. CHARGING SYSTEM When there is current present in the field, and the rotor is turning, the stator in the generator produces The charging system is an integral part of the bat- a B+ voltage that is supplied to the battery through...
  • Page 469 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 470 8W - 21 - 2 8W-21 STARTING SYSTEM BATT A1 (8W-10-6) IGNITION POWER SWITCH DISTRIBUTION 1 START CENTER FUSE 2 RUN (8W-10-3) 0 OFF 3 LOCK (8W-10-6) 4 ACC (8W-10-6) BATTERY (8W-20-2) C126 S102 (8W-10-6) CLUTCH TRANSMISSION INTER CONTROL LOCK MODULE IGN.
  • Page 471 8W - 21 STARTING SYSTEM 8W - 21 - 3 8W-21 STARTING SYSTEM DESCRIPTION AND OPERATION through circuit T40 when the coil side of the engine starter motor relay energizes. Circuit A1 contains a STARTING SYSTEM (MANUAL TRANSAXLE) 20 amp fuse, and feeds the contact side of the engine starter motor relay.
  • Page 473 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 474 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 BATT A0 (8W-10-7) (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-9) (8W-10-5) RD/TN DB/WT S105 S104 (IN PDC) (IN PDC) (8W-10-9) (8W-10-5) DB/WT C113 DB/WT RD/TN POWERTRAIN FUSED FUSED CONTROL IGN.
  • Page 475 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 ST-RUN A21 BATT A0 (8W-10-7) (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-9) (8W-10-6) DB/WT S105 S102 (8W-10-9) (8W-10-6) DB/WT FUEL PUMP RELAY (IN PDC) A141 DG/WT C121 FUEL BODY FUEL PUMP CONTROL LEVEL SENSOR...
  • Page 476 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM BATT A14 (8W-10-5) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-5) RD/TN S104 (IN PDC) (8W-10-5) AUTOMATIC SHUT DOWN RELAY (IN PDC) A142 A142 DG/OR DG/OR C111 S118 FUSE (8W-70-5) A142 (PDC) DG/OR (8W-10-4) S131 (8W-70-7) IGNITION...
  • Page 477 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 BATT A14 (8W-10-5) POWER DISTRIBUTION CENTER AUTOMATIC (8W-10-3) SHUT DOWN RELAY (8W-30-4) A142 A142 DG/OR DG/OR C111 A142 SPARK FUSE PLUGS DG/OR (PDC) (8W-10-4) S118 (8W-70-5) A142 DG/OR DISTRIBUTOR (2.5L) RELAY OUTPUT IGN COIL A142 SENSOR...
  • Page 478 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM 2.0L ENGINE BATT A14 (8W-10-5) POWER DISTRIBUTION CENTER AUTOMATIC SHUT (8W-10-3) DOWN RELAY (8W-30-4) A142 A142 DG/OR DG/OR C111 FUSE A142 DG/OR (PDC) (8W-10-4) S118 (8W-70-5) A142 DG/OR S114 (8W-70-3) A142 A142 A142 A142 DG/OR...
  • Page 479 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 2.5L ENGINE BATT A14 (8W-10-5) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-3) DOWN RELAY (8W-30-4) A142 18 DG/OR A142 C111 DG/OR S118 (8W-70-5) A142 DG/OR FUSE S114 (PDC) (8W-70-3) (8W-10-4) C165 A142 A142 A142 A142 DG/OR...
  • Page 480 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM CRANKSHAFT POSITION SENSOR SENSOR SENSOR SIGNAL GROUND SUPPLY GY/BK BK/LB OR/WT S117 (8W-70-4) S124 S120 (8W-70-6) (8W-31-4) BK/LB OR/WT BK/LB CAMSHAFT SENSOR POSITION GROUND SUPPLY SENSOR (2.0L) SENSOR SIGNAL C111 BK/LB OR/WT S110 (IN PDC) (8W-70-2)
  • Page 481 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 2.0L 2.5L THROTTLE BK/LB POSITION SENSOR S116 (8W-70-4) 2.0L 2.5L BK/LB BK/LB S130 (8W-70-7) VT/WT VT/WT BK/LB OR/LB S115 S121 S117 (8W-70-3) (8W-31-4) (8W-70-4) BK/LB 2.0L 2.5L VT/WT C111 C111 S110 (IN PDC) (8W-70-2) OR/LB OR/LB...
  • Page 482 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM BATT A14 (8W-10-5) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE (8W-10-3) DOWN RELAY (8W-10-4) (8W-30-4) A142 A142 18 DG/OR A142 OR/DG DG/OR POWERTRAIN C111 CONTROL UPSTREAM HEATED MODULE DOWNSTREAM S118 OXYGEN HEATED SENSOR (8W-70-5) OXYGEN SIGNAL...
  • Page 483 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 S116 (8W-70-4) BK/LB MANIFOLD ABSOLUTE PRESSURE SENSOR BK/LB S130 (8W-70-7) ELECTRONIC BK/LB BK/LB TRANSDUCER SOLENOID S117 (8W-70-4) INTAKE 2.0L 2.5L TEMPERATURE SENSOR VT/WT BK/LB A142 A142 S115 (8W-70-3) DG/OR DB/OR C111 VT/WT BK/LB C111 S110...
  • Page 484 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM S117 (8W-70-4) BK/LB BK/LB C111 ENGINE COOLANT TEMPERATURE BK/LB SENSOR S110 (IN PDC) (8W-70-2) TN/BK BK/LB POWERTRAIN SENSOR CONTROL SENSOR GROUND POWER SIGNAL STEERING MODULE KNOCK PRESSURE SENSOR SWITCH SIGNAL SENSE BK/LB DB/LG POWER STEERING...
  • Page 485 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 ST A41 (8W-10-7) POWER DISTRIBUTION ENGINE CENTER STARTER (8W-10-3) MOTOR RELAY (8W-21-2) T41 20 BK/LB VEHICLE SPEED CONTROL/ HORN SWITCH C104 (8W-33-3) 1 CANCEL 2 RESUME/ACCEL 3 SET/COAST BK/LB 4 ON/OFF TRANSMISSION RANGE CLOCKSPRING SWITCH...
  • Page 486 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM PRESSURE TRANSDUCER PRESSURE SENSOR SUPPLY SIGNAL GROUND BK/LB VT/WT DB/YL S116 (8W-70-4) S115 (8W-70-3) BK/LB S130 (8W-70-7) BK/LB S117 (8W-70-4) VT/WT BK/LB C111 C111 C113 BK/LB S110 (IN PDC) (8W-70-2) BK/LB BATTERY TEMPERATURE SENSOR VT/WT...
  • Page 487 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15 ST-RUN A21 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-8) LG/BK S106 (IN PDC) (8W-10-8) LG/BK LG/BK LG/BK HIGH COMPRESSOR SPEED SPEED CLUTCH RADIATOR RADIATOR RELAY FAN RELAY FAN RELAY (IN PDC) (IN PDC) (IN PDC) (8W-42-3) (8W-42-4)
  • Page 488 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 IDLE (8W-10-7) POWER CONTROL DISTRIBUTION MOTOR CENTER MOTOR MOTOR MOTOR MOTOR FUSE NO. 1 NO. 2 NO. 4 NO. 3 (8W-10-3) (8W-10-8) GY/RD YL/BK VT/GY BR/GY LG/BK C111 S106 (IN PDC) (8W-10-8) LG/BK DUTY...
  • Page 489 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17 BATT A7 (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-6) PK/WT S134 (8W-12-6) DATA LINK CONNECTOR BK/VT VT/BR WT/DB PK/LG PK/LB C126 S132 S133 C126 (8W-45-3) (8W-45-3) JUNCTION PK/LB PK/LB BLOCK (8W-12-14) (8W-12-2) (8W-12-3) BODY TRANSMISSION GROUND...
  • Page 490 8W - 30 - 18 8W - 30 FUEL/IGNITION SYSTEM 8W-30 FUEL/IGNITION SYSTEM INDEX page page DESCRIPTION AND OPERATION FUEL PUMP MOTOR ..... 19 AMBIENT (BATTERY) TEMPERATURE HEATED OXYGEN SENSORS .
  • Page 491 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 19 DESCRIPTION AND OPERATION (Continued) The universal data link connector is also interfaced nected from the relay to the fuel pump motor. with the CCD Bus. Circuit D1 is used for CCD (+) Ground for the fuel pump motor is provided on cir- and D2 is used for CCD (-).
  • Page 492 8W - 30 - 20 8W - 30 FUEL/IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Circuit Z1 provides the ground path for the heater sor. The K7 circuit connects to cavity 44 of the PCM circuits in the sensors. This ground terminates at the connector.
  • Page 493 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 21 DESCRIPTION AND OPERATION (Continued) THROTTLE POSITION SENSOR INTAKE AIR TEMPERATURE SENSOR From the Powertrain Control Module (PCM), cir- On the 2.0L engine the intake air temperature sen- cuit K6 supplies 5 volts to the Throttle Position Sen- sor is combination unit with the map sensor.
  • Page 494 8W - 30 - 22 8W - 30 FUEL/IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) • Manifold absolute pressure sensor side of the ASD relay on circuit K51. Circuit K51 con- • Throttle position sensor nects to cavity 67 of the PCM. •...
  • Page 495 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 23 DESCRIPTION AND OPERATION (Continued) HELPFUL INFORMATION ignition switch. Circuit A21 is HOT in the START • Refer to group 14 of the Service Manual or the and RUN positions only. appropriate Diagnostic Test Procedures Manual for The Powertrain Control Module (PCM) controls the additional information.
  • Page 497 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 498 8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM ST-RUN-OFF A81 (8W-10-7) BATT A0 (8W-10-3) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) FUSE CENTER FUSE (8W-10-3) (8W-12-10) (8W-10-4) PK/YL TRANSMISSION RELAY (IN PDC) BK/RD RD/BR S101 S100 (8W-15-3) (8W-10-4) BK/RD G102 (8W-15-3) RD/VT PK/YL LG/YL...
  • Page 499 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3 ST-RUN-OFF A81 (8W-10-7) OUTPUT TURBINE JUNCTION SHAFT SPEED BLOCK SPEED SENSOR (8W-12-2) FUSE SENSOR (8W-12-10) RD/VT RD/VT DB/BR DB/BR OR/YL INSTRUMENT CLUSTER (8W-40-2) AUTOSTICK S125 SWITCH (8W-70-6) HALL EFFECT SWITCH LG/VT DB/BR LG/LB YL/LB...
  • Page 500 8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM POWERTRAIN CONTROL MODULE VEHICLE CRANKSHAFT THROTTLE SPEED POSITION POSITION (8W-30-8) SENSOR SENSOR SENSOR SENSOR (8W-30-9) SIGNAL SIGNAL SIGNAL GROUND (8W-30-13) 2.4L 2.5L WT/OR GY/BK BK/LB OR/LB OR/LB S120 S121 S110 (8W-70-2) GY/BK OR/LB CRANKSHAFT...
  • Page 501 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5 RUN A22 BATT A1 (8W-10-13) C126 (8W-10-6) JUNCTION IGNITION BLOCK SWITCH (8W-12-2) 1 START FUSE 2 RUN CLUTCH 0 OFF INTER 3 LOCK (8W-12-5) LOCK 4 ACC SWITCH (8W-10-6) YL/RD WT/YL ENGINE C105 STARTER...
  • Page 502 8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM BATT A24 (8W-10-4) POWER DISTRIBUTION CENTER TRANSMISSION RELAY (8W-10-3) (8W-31-2) RD/BR S100 (8W-10-4) RD/BR C104 RD/BR TRANSMISSION SOLENOID AND LOW/ OVERDRIVE PRESSURE REVERSE PRESSURE PRESSURE SWITCH PRESSURE SWITCH SWITCH ASSEMBLY SWITCH DG/TN YL/GY OR/BK...
  • Page 503 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7 BATT A24 (8W-10-4) POWER DISTRIBUTION CENTER TRANSMISSION RELAY (8W-10-3) (8W-31-2) RD/BR S100 (8W-10-4) RD/BR C104 RD/BR TRANSMISSION SOLENOID AND PRESSURE LOW/ UNDERDRIVE OVERDRIVE REVERSE SOLENOID SOLENOID SOLENOID SWITCH SOLENOID ASSEMBLY LB/WT WT/PK PK/DB BR/TN...
  • Page 504 8W - 31 - 8 8W-31 TRANSMISSION CONTROL SYSTEM POWERTRAIN CONTROL TORQUE MODULE MANAGEMENT (8W-30-13) REQUIREMENT (8W-30-17) SENSE TRANSMIT PK/LG S127 (8W-30-17) PK/LG C126 PK/LG DATA LINK CONNECTOR (8W-30-17) S133 S132 (8W-45-3) (8W-45-3) WT/DB VT/BR PK/LB BODY CCD BUS CCD BUS CONTROL MODULE (IN JB)
  • Page 505 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 9 8W-31 TRANSMISSION CONTROL SYSTEM INDEX page page DESCRIPTION AND OPERATION TORQUE MANAGEMENT INPUT ... . 10 AUTO STICK ......10 TRANSMISSION CONTROL MODULE (TCM) .
  • Page 506 8W - 31 - 10 8W - 31 TRANSMISSION CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) transmission. The case ground supplies the ground path TRANSMISSION RANGE SENSOR for the pressure switches. The Transmission Range Sensor (TRS) is located The following circuits are controlled by the TCM internal to the transmission.
  • Page 507 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 508 8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL ST-RUN-OFF A81 (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-10) RD/VT INSTRUMENT CLUSTER CRUISE ENGAGED (8W-40-2) LAMP (8W-40-3) FUSED CRUISE ENGAGED IGN. LAMP CONTROL (ST-RUN-OFF) VT/BR WT/DB POWERTRAIN CONTROL MODULE (8W-30-17) S132 S133 (8W-45-3) (8W-45-3) VT/BR...
  • Page 509 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3 POWERTRAIN CONTROL SPEED SPEED SPEED MODULE CONTROL CONTROL CONTROL STOP SPEED VENT VACUUM ON/OFF LAMP CONTROL (8W-30-13) SOLENOID SOLENOID SWITCH SWITCH SWITCH CONTROL CONTROL SENSE SENSE SIGNAL YL/PK WT/RD RD/LG C113 C126 LG/RD WT/VT...
  • Page 510 8W - 33 - 4 8W - 33 VEHICLE SPEED CONTROL 8W-33 VEHICLE SPEED CONTROL INDEX page page DESCRIPTION AND OPERATION HELPFUL INFORMATION ....4 CRUISE (VEHICLE SPEED CONTROL) VEHICLE SPEED CONTROL .
  • Page 511 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 512 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES ST-RUN A21 BATT A0 (8W-10-7) (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-3) (8W-10-9) (8W-10-8) (8W-10-4) DB/WT LG/BK RD/DB S106 S105 (8W-10-8) (8W-10-9) LG/BK C126 DB/WT LG/BK INSTRUMENT CLUSTER (8W-40-6) WARNING LAMP LG/OG C126 LG/OR...
  • Page 513 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-14) RD/DG FROM RELAY SYSTEM RELAY (8W-35-2) PUMP PUMP MOTOR MOTOR RELAY DATA LINK CAPACITOR CONNECTOR (8W-30-17) PK/LG C126 B116 B120 GY/LB BR/RD PK/LG S112 (8W-15-4) S127...
  • Page 514 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES CONTROLLER LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR ANTI-LOCK DECAY DECAY DECAY DECAY BRAKE SOLENOID SOLENOID SOLENOID SOLENOID CONTROL CONTROL CONTROL CONTROL B142 B146 B143 B148 BR/YL BR/LB DG/YL DG/LB LEFT LEFT RIGHT RIGHT...
  • Page 515 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5 LEFT RIGHT FRONT FRONT WHEEL WHEEL SPEED SPEED SENSOR SENSOR LEFT RIGHT REAR REAR WHEEL WHEEL SPEED SPEED SENSOR SENSOR LG/DB YL/DB C121 C121 OR/DB WT/DB LG/DB YL/DB CONTROLLER LEFT LEFT LEFT LEFT RIGHT RIGHT...
  • Page 516 8W - 35 - 6 8W-35 ANTI-LOCK BRAKES ST-RUN-OFF A81 BATT A0 (8W-10-7) (8W-10-3) JUNCTION POWER BLOCK DISTRIBUTION FUSE (8W-12-2) CENTER FUSE (8W-10-3) (8W-12-10) (8W-10-5) RD/BK RD/VT JUNCTION INSTRUMENT (8W-10-5) BLOCK CLUSTER BRAKE (8W-12-3) (8W-40-7) WARNING LAMP RD/BK STOP LAMP GY/DB SWITCH (8W-33-3)
  • Page 517 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 7 8W-35 ANTI-LOCK BRAKES INDEX page page DESCRIPTION AND OPERATION BRAKE SWITCH INPUT ....8 ABS PUMP MOTOR RELAY .
  • Page 518 8W - 35 - 8 8W - 35 ANTI-LOCK BRAKES DESCRIPTION AND OPERATION (Continued) The solenoids use a common ground on the Z1 cir- CAB connector. Circuit L50 is spliced in with the cuit. There are two Z1 circuits from the modulator. stop lamps, and is used to provide the CAB with Both of these grounds terminate at the right frame information on when the brakes are being applied.
  • Page 519 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 520 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER BATT A13 ST-RUN-OFF A81 (8W-10-10) (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-6) (8W-12-10) PK/RD RD/VT INSTRUMENT CLUSTER FUSED FUSED B(+) IGN. (ST-RUN-OFF) GROUND GROUND VT/BR WT/DB S132 S133 (8W-45-3) (8W-45-3) BK/OR BK/LG VT/BR WT/DB JUNCTION...
  • Page 521 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 INSTRUMENT MALFUNCTION CRUISE CHARGING ENGINE COOLANT CLUSTER INDICATOR LAMP ENGAGED SYSTEM WARNING TEMPERATURE (CHECK ENGINE) LAMP LAMP LAMP MALFUNCTION CRUISE CHARGING ENGINE COOLANT INDICATOR (VEHICLE SPEED SYSTEM WARNING TEMPERATURE LAMP CONTROL CONTROL) LAMP CONTROL LAMP CONTROL (CHECK ENGINE)
  • Page 522 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER INSTRUMENT LOW FUEL SEAT BELT CLUSTER WARNING LAMP FUEL GAUGE INDICATOR LAMP LOW FUEL FUEL GAUGE SEAT BELT WARNING CONTROL INDICATOR LAMP CONTROL LAMP CONTROL VT/BR WT/DB S132 S133 (8W-45-3) (8W-45-3) VT/BR WT/DB BODY SEAT...
  • Page 523 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 INSTRUMENT CLUSTER PRNDL INDICATOR ODOMETER PRNDL CONTROL ODOMETER CONTROL TRIP AIRBAG HIGH BEAM DOOR AJAR ODOMETER WARNING INDICATOR INDICATOR CONTROL LAMP CONTROL LAMP CONTROL LAMP CONTROL AIRBAG HIGH BEAM DOOR AJAR WARNING INDICATOR INDICATOR LAMP...
  • Page 524 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER ST-RUN A21 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-8) LG/BK S106 (8W-10-8) TRAVELER (8W-46-2) FUSED LG/BK IGN. (ST-RUN) C126 LG/BK LG/BK WT/BK INSTRUMENT CLUSTER PRESSURE WARNING LAMP LAMP LG/OR C126 C111 LG/OR LG/OR GY/VT CONTROLLER...
  • Page 525 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7 ST-RUN-OFF A81 (8W-10-7) JUNCTION BLOCK FUSE (8W-12-2) (8W-12-10) RD/VT INSTRUMENT CLUSTER BRAKE WARNING LAMP GY/DB JUNCTION BLOCK (8W-12-3) GY/DB GY/DB IGNITION C224 SWITCH 1 START 2 RUN GY/DG 0 OFF 3 LOCK BRAKE PARK 4 ACC...
  • Page 526 8W - 40 - 8 8W-40 INSTRUMENT CLUSTER TURN REAR SIGNAL/ HAZARD LAMP WARNING SWITCH SWITCH (8W-51-4) (8W-52-2) JUNCTION BLOCK (8W-12-18) (8W-12-18) (8W-12-3) LG/TN TN/BR INSTRUMENT CLUSTER LEFT RIGHT TURN TURN LAMP SIGNAL SIGNAL INDICATOR INDICATOR INDICATOR CLUSTER ILLUMINATION LAMPS BK/OR BK/LG OR/YL...
  • Page 527 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9 INSTRUMENT DECKLID LOW WASHER CLUSTER AJAR FLUID LEVEL LAMP LAMP DECKLID LOW WASHER AJAR FLUID LEVEL LAMP CONTROL LAMP CONTROL TRUNK AJAR WASHER FLUID SWITCH SWITCH SENSE SENSE TN/BK BK/TN C224 C126 TN/BK S304 BK/TN...
  • Page 528 8W - 40 - 10 8W - 40 INSTRUMENT CLUSTER 8W-40 INSTRUMENT CLUSTER INDEX page page DESCRIPTION AND OPERATION HELPFUL INFORMATION ....13 ABS WARNING LAMP .
  • Page 529 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 11 DESCRIPTION AND OPERATION (Continued) the tachometer pointer based on the input from the Module (PCM) and the Transmission Control Module PCM and adjusts the position of the gauge pointer to (TCM) over the CCD Bus.
  • Page 530 8W - 40 - 12 8W - 40 INSTRUMENT CLUSTER DESCRIPTION AND OPERATION (Continued) above or fallen below the normal operating range. Power for the lamp is supplied on the F18 circuit. When the Powertrain Control Module (PCM) deter- This circuit also powers the Anti-Lock lamp, located mines a problem, a message is sent across the CCD internal to the cluster, high speed fan relay, A/C Bus to the Body Control Module (BCM).
  • Page 531 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 13 DESCRIPTION AND OPERATION (Continued) CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster.
  • Page 533 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 534 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET BATT A13 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE HORN RELAY (8W-12-9) BODY HORN CONTROL RELAY MODULE CONTROL (8W-45-12) BK/RD DG/PK DG/PK CIGAR LIGHTER/ POWER OUTLET CLOCKSPRING HIGH NOTE NOTE HORN HORN VEHICLE SPEED LEFT RIGHT...
  • Page 535 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET • Check the 40 amp fuse located in cavity 12 of DESCRIPTION AND OPERATION the PDC • Press the horn switch and listen for the horn HORNS relay to click.
  • Page 537 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 538 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER RUN A22 (8W-10-13) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-4) BLOWER MOTOR RESISTOR BLOCK BK/TN HEATER HEATER CONTROL CONTROL 1 DEFROST ILLUM. 2 MIX BLOWER 3 HEAT BLOWER SWITCH SWITCH MODE SWITCH SWITCH 4 BI-LEVEL ILLUM.
  • Page 539 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 ST-RUN A21 BATT A0 (8W-10-7) (8W-10-3) EVAPORATOR POWER TEMPERATURE DISTRIBUTION SENSOR FUSE FUSE CENTER (8W-10-3) (8W-10-8) (8W-10-12) LG/BK LG/BK RD/LG S106 S103 BODY EVAP. TEMP. SENSOR (8W-10-8) (8W-10-12) CONTROL SENSOR GROUND SIGNAL MODULE LG/BK RD/LG...
  • Page 540 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER BATT A0 ST-RUN A21 (8W-10-3) (8W-10-7) POWER DISTRIBUTION CENTER (8W-10-3) FUSE FUSE (8W-10-12) (8W-10-8) RD/LG LG/BK S103 (8W-10-12) S106 (8W-10-8) RD/LG LG/BK LG/BK RD/LG HIGH SPEED SPEED RADIATOR RADIATOR RELAY RELAY (IN PDC) (IN PDC) DG/LG DB/TN...
  • Page 541 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 5 8W-42 AIR CONDITIONING-HEATER INDEX page page DESCRIPTION AND OPERATION BLOWER MOTOR OPERATION ....6 A/C EVAPORATOR TEMPERATURE SENSOR . . . 5 HELPFUL INFORMATION .
  • Page 542 8W - 42 - 6 8W - 42 AIR CONDITIONING-HEATER DESCRIPTION AND OPERATION (Continued) The A/C compressor clutch receives this current When HIGH speed fan operation is required the and creates a magnetic field, energizing the clutch. PCM grounds circuit C27. This causes the contacts in The A/C compressor clutch is case grounded to the the relay to CLOSE connecting circuits A16 and C25.
  • Page 543 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 544 8W - 43 - 2 8W-43 AIRBAG SYSTEM RUN A22 ST-RUN A21 (8W-10-13) (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-12) (8W-12-12) DRIVER SIDE DRIVER DRIVER AIRBAG AIRBAG AIRBAG LINE 1 LINE 2 PASSENGER SIDE PASSENGER PASSENGER AIRBAG AIRBAG AIRBAG LINE 1 LINE 2 LG/YL BK/LB...
  • Page 545 8W-43 AIRBAG SYSTEM 8W - 43 - 3 ST-RUN-OFF A81 (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-10) RD/VT INSTRUMENT CLUSTER AIRBAG WARNING (8W-40-5) LAMP FUSED AIRBAG WARNING IGN. LAMP CONTROL (ST-RUN-OFF) DATA LINK CONNECTOR VT/BR WT/DB (8W-30-17) AIRBAG CONTROL VT/BR WT/DB MODULE S132 S133...
  • Page 546 8W - 43 - 4 8W - 43 AIRBAG SYSTEM 8W-43 AIRBAG SYSTEM INDEX page page DESCRIPTION AND OPERATION AIRBAG SQUIB (AIRBAG IGNITER) ... 4 AIRBAG CONTROL MODULE (ACM) ..4 AIRBAG WARNING LAMP .
  • Page 547 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 548 8W - 44 - 2 8W-44 INTERIOR LIGHTING BATT A7 (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-6) C332 PK/WT ILLUMINATED S302 ENTRY (8W-12-6) RELAY (8W-44-3) S134 (8W-12-6) LEFT RIGHT VISOR/ VISOR/ VANITY VANITY UNIVERSAL LAMP LAMP GARAGE DOOR OPENER C342 PK/WT KEY-IN REAR HALO...
  • Page 549 8W-44 INTERIOR LIGHTING 8W - 44 - 3 BATT A7 (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-6) PK/VT PK/WT TRUNK ILLUMINATED LAMP ENTRY C332 RELAY VISOR/ VANITY LAMPS OTHERS M112 BR/LG TN/BK S302 S304 S134 (8W-12-6) (8W-40-9) (8W-12-6) TRUNK C342 AJAR SWITCH S307 (8W-70-7)
  • Page 550 8W - 44 - 4 8W-44 INTERIOR LIGHTING BATT A13 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE INSTRUMENT CLUSTER CLUSTER ILLUMINATION LAMPS (8W-40-8) (8W-12-8) BK/RD HEADLAMP PANEL SWITCH LAMPS 1 HEAD DIMMER 2 PARK SWITCH 0 OFF (8W-50-3) BK/OR OR/YL BK/TN JUNCTION BLOCK (8W-12-2) BODY...
  • Page 551 8W-44 INTERIOR LIGHTING 8W - 44 - 5 BATT A7 RUN A22 (8W-10-13) (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-6) (8W-12-5) WT/YL C105 ILLUMINATED TRANSMISSION ENTRY RANGE RELAY SWITCH (8W-44-3) (8W-31-5) C332 VT/BK C105 S306 S307 (8W-12-5) C121 (8W-70-7) C342 VT/BK VT/BK C332...
  • Page 552 8W - 44 - 6 8W-44 INTERIOR LIGHTING BATT A7 (8W-10-5) JUNCTION BLOCK BODY (8W-12-2) CONTROL FUSE MODULE PANEL (8W-45-2) FUSED LAMPS (8W-45-7) B(+) DRIVER (8W-12-6) OR/BR C310 C315 RADIO (8W-47-2) ILLUMINATED S400 S401 C342 ENTRY (8W-12-7) (8W-12-7) RELAY (8W-44-3) REAR LEFT RIGHT...
  • Page 553 8W - 44 INTERIOR LIGHTING 8W - 44 - 7 8W-44 INTERIOR LIGHTING INDEX page page DESCRIPTION AND OPERATION ILLUMNATED ENTRY ..... . 7 ASH RECEIVER LAMP .
  • Page 554 8W - 44 - 8 8W - 44 INTERIOR LIGHTING DESCRIPTION AND OPERATION (Continued) Ground for the lamps is supplied on circuit M2. circuit is HOT when the operator has turned the This circuit connects from the lamps to the illumi- headlamp switch to the PARK or ON position.
  • Page 555 8W - 45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 556 8W - 45 - 2 8W-45 BODY CONTROL MODULE BATT A1 BATT A1 (8W-10-6) (8W-10-6) IGNITION SWITCH 1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-6) DG/RD BATT A3 BATT A7 (8W-10-11) (8W-10-5) JUNCTION BLOCK (8W-10-7) (8W-12-2) FUSE FUSE FUSE (8W-12-10)
  • Page 557 8W-45 BODY CONTROL MODULE 8W - 45 - 3 IMMOBILIZER (8W-61-5) INSTRUMENT CLUSTER (8W-40-2) VT/BR VT/BR WT/DB WT/DB DATA LINK CONNECTOR (8W-30-17) AIRBAG CONTROL MODULE VT/BR WT/DB (8W-43-2) S132 S133 VT/BR WT/DB VT/BR BK/VT WT/DB BODY GROUND CONTROL MODULE (IN JB) VT/BR WT/BK VT/DG...
  • Page 558 8W - 45 - 4 8W-45 BODY CONTROL MODULE RUN-ACC F13 DB/GY (8W-12-11) POWER DISTRIBUTION CENTER INTERMITTENT WIPER (8W-10-3) WIPER HIGH/ RELAY (8W-53-3) RELAY (8W-53-3) INTERMITTENT WIPER SWITCH (8W-53-2) BR/DB DG/RD PK/VT VT/PK BODY WASHER WINDSHIELD WIPER WIPER WIPER CONTROL WIPER ON/OFF PUMP...
  • Page 559 8W-45 BODY CONTROL MODULE 8W - 45 - 5 BATT M1 BATT A3 (8W-12-6) (8W-10-11) ILLUMINATED HEADLAMP ENTRY SWITCH RELAY (8W-50-3) 1 HEAD (8W-44-3) 2 PARK 3 LOW 4 HIGH 5 FLASH TO PASS 0 OFF VT/WT RD/OR M112 BR/LG BATT A3 (8W-10-11) JUNCTION...
  • Page 560 8W - 45 - 6 8W-45 BODY CONTROL MODULE BATT F33 (8W-12-8) HEADLAMP SWITCH 1 HEAD 2 PARK 0 OFF (8W-50-3) BK/YL JUNCTION BODY BLOCK PARK CONTROL (8W-12-2) LAMP MODULE (8W-12-3) SWITCH OUTPUT BK/DG BK/BR BK/YL BK/YL RADIO LEFT RIGHT C300 C301 (8W-47-2)
  • Page 561 8W-45 BODY CONTROL MODULE 8W - 45 - 7 BATT F33 (8W-12-8) INSTRUMENT HEADLAMP CLUSTER SWITCH PANEL (8W-40-8) 1 HEAD GENERAL LAMPS ILLUMINATION 2 PARK DIMMER 0 OFF SWITCH (8W-50-3) BK/LG OR/YL JUNCTION BLOCK (8W-12-2) BODY GROUND PANEL DIMMER CONTROL LAMPS SWITCH MODULE...
  • Page 562 8W - 45 - 8 8W-45 BODY CONTROL MODULE HEATER EVAPORATOR HVAC CONTROL TEMPERATURE MODE SWITCH (8W-42-2) SENSOR GROUND SENSE SENSE BK/PK DB/OR LG/BK BODY GROUND HVAC EVAP SENSOR MODE CONTROL MODE SWITCH TEMP GROUND DOOR MODE COMMON SENSE SENSE SENSOR MODULE SENSOR...
  • Page 563 8W-45 BODY CONTROL MODULE 8W - 45 - 9 BATT F35 (8W-12-12) UNIVERSAL LEFT GARAGE VISOR/ POWER DOOR VANITY DISTRIBUTION DECKLID OPENER LAMP CENTER RELEASE (8W-44-2) (8W-44-2) RELAY (8W-10-3) (8W-61-4) RIGHT VISOR/ VANITY VEHICLE Q33 18 BR/LB LAMP SPEED C342 (8W-44-2) CONTROL/ HORN...
  • Page 564 8W - 45 - 10 8W-45 BODY CONTROL MODULE LEFT RIGHT LEFT POWER POWER REMOTE DOOR DOOR KEYLESS LOCK LOCK ENTRY MOTOR MOTOR ANTENNA RIGHT REMOTE RIGHT LEFT KEYLESS POWER POWER ENTRY DOOR DOOR ANTENNA LOCK LOCK SWITCH SWITCH (8W-61-2) (8W-61-2) P158 OR/BK...
  • Page 565 8W-45 BODY CONTROL MODULE 8W - 45 - 11 LEFT RIGHT DOOR DOOR ARM/ ARM/ DISARM DISARM SWITCH SWITCH (8W-39-2) (8W-39-2) LG/OR DG/OR C310 C315 LG/OR DG/OR BODY LEFT RIGHT CONTROL VTSS VTSS LEFT ARM/ ARM/ MODULE DOOR DOOR TRUNK DOOR DISARM DISARM...
  • Page 566 8W - 45 - 12 8W-45 BODY CONTROL MODULE RUN-ACC A31 BATT A13 (8W-10-7) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-11) (8W-12-9) REAR HORN WINDOW RELAY DEFOGGER (8W-41-2) RELAY (8W-47-6) BODY REAR WINDOW HORN CONTROL DEFOGGER RELAY MODULE RELAY CONTROL CONTROL BK/RD VEHICLE...
  • Page 567 8W - 45 BODY CONTROL MODULE 8W - 45 - 13 8W-45 BODY CONTROL MODULE INDEX page page DESCRIPTION AND OPERATION ILLUMNATED ENTRY ..... 13 DOOR AJAR WARNING .
  • Page 568 8W - 45 - 14 8W - 45 BODY CONTROL MODULE DESCRIPTION AND OPERATION (Continued) DOOR LOCK INHIBIT INSTRUMENT PANEL LAMP DIMMING When the Key-In switch is CLOSED (circuit G26 The Body Control Module (BCM) controls the connected to circuit Z1) the Body Control Module instrument panel lamp intensity using input from (BCM) ignores the operators request for power door the dimmer switch, circuit E19.
  • Page 569 8W - 46 TRAVELER 8W - 46 - 1 8W-46 TRAVELER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 570 8W - 46 - 2 8W-46 TRAVELER BATT A7 ST-RUN A21 (8W-10-5) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-3) (8W-12-6) (8W-10-8) LG/BK S106 (IN PDC) (8W-10-8) LG/BK C126 LG/BK INSTRUMENT FUSED CLUSTER IGN. (ST-RUN) (8W-40-2) DATA LINK LG/BK WT/BK VT/BR...
  • Page 571 8W - 46 TRAVELER 8W - 46 - 3 8W-46 TRAVELER DESCRIPTION AND OPERATION Ground for the traveler is supplied on circuit Z1. To allow the traveler to send and receive informa- TRAVELER tion it is interfaced with the CCD Bus. Circuit D1 is used for CCD (+), and circuit D2 is used for CCD (-).
  • Page 573 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 574 8W - 47 - 2 8W-47 AUDIO SYSTEM STANDARD BATT F33 (8W-12-8) HEADLAMP SWITCH 1 HEAD 2 PARK 0 OFF (8W-50-3) BK/YL RUN-ACC A31 BATT A7 (8W-10-7) (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3) (8W-12-15) (8W-12-11) (8W-12-6) PK/WT PK/OR POWER ANTENNA S134 (8W-12-6)
  • Page 575 8W-47 AUDIO SYSTEM 8W - 47 - 3 STANDARD LEFT RIGHT REAR REAR SPEAKER SPEAKER BR/YL BR/LB DB/WT DB/OR C224 BR/YL BR/LB DB/WT DB/OR RADIO LEFT LEFT RIGHT RIGHT REAR REAR REAR REAR LEFT LEFT RIGHT RIGHT FRONT FRONT FRONT FRONT BR/RD DB/RD...
  • Page 576 8W - 47 - 4 8W-47 AUDIO SYSTEM PREMIUM BATT F33 (8W-12-8) HEADLAMP SWITCH (8W-50-3) 1 HEAD 2 PARK 0 OFF BK/YL BATT A7 RUN-ACC A31 (8W-10-5) (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3) (8W-12-15) (8W-12-6) (8W-12-11) PK/WT BODY CONTROL PANEL MODULE LAMPS...
  • Page 577 8W-47 AUDIO SYSTEM 8W - 47 - 5 PREMIUM LEFT LEFT DOOR FRONT SPEAKER INSTRUMENT PANEL SPEAKER RIGHT DOOR SPEAKER RIGHT FRONT INSTRUMENT PANEL SPEAKER C311 C316 C224 LG/VT LG/DG LB/VT LB/DG YL/RD YL/BK OR/RD OR/BK POWER LEFT LEFT RIGHT RIGHT AMPLIFIED AMPLIFIED...
  • Page 578 8W - 47 - 6 8W-47 AUDIO SYSTEM PREMIUM BATT A7 (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-14) (8W-12-6) WINDOW TIMER MODULE (8W-60-4) BK/LB PK/OR G301 YL/BK RD/WT (8W-15-9) POWER C342 GROUND AMPLIFIER POWER YL/BK RD/WT ANTENNA S310 S311 (8W-66-2) (8W-66-2) DG/RD C224...
  • Page 579 8W - 47 AUDIO SYSTEM 8W - 47 - 7 8W-47 AUDIO SYSTEM INDEX page page DESCRIPTION AND OPERATION RADIO ILLUMINATION ..... 7 CCD BUS .
  • Page 580 8W - 47 - 8 8W - 47 AUDIO SYSTEM DESCRIPTION AND OPERATION (Continued) SPEAKERS (PREMIUM SYSTEM) One is the M1 circuit. The M1 circuit is used to supply power to the Body Control Module (BCM), Circuit X53 is the feed for the left front speaker to Power Mirrors, and the Power Door Locks.
  • Page 581 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 582 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER BATT A0 (8W-10-3) POWER DISTRIBUTION FUSE CENTER (8W-10-3) (8W-10-12) A4 12 BK/PK RUN-ACC A31 (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-11) REAR WINDOW DEFOGGER RELAY BODY REAR CONTROL WINDOW FUSE MODULE DEFOGGER (8W-45-8) RELAY...
  • Page 583 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3 8W-48 REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION As current flows through the relay, contacts in the relay CLOSE connecting circuits A4 and C15. The A4 REAR WINDOW DEFOGGER circuit is protected by a 40 amp fuse located in cavity 16 of the PDC.
  • Page 585 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 586 8W - 50 - 2 8W-50 FRONT LIGHTING HEADLAMP BATT A0 (8W-10-3) SWITCH POWER (8W-50-3) 1 HEAD DISTRIBUTION FUSE 2 PARK CENTER 3 LOW (8W-10-3) 4 HIGH (8W-10-11) 5 FLASH TO PASS 0 OFF RD/WT RD/WT VT/WT RD/OR JUNCTION BLOCK (8W-12-2) HEADLAMP (8W-12-3)
  • Page 587 8W-50 FRONT LIGHTING 8W - 50 - 3 BATT F33 BATT A3 (8W-12-8) (8W-10-11) HEADLAMP SWITCH 1 HEAD 2 PARK 3 LOW 4 HIGH 5 FLASH TO PASS 0 OFF WT/VT RD/OR BK/YL BK/TN BK/YL FUSE 13 FUSE 2 HEADLAMP (JB) (JB) LEVELING...
  • Page 588 8W - 50 - 4 8W-50 FRONT LIGHTING FROM JUNCTION BLOCK (8W-50-3) FROM JUNCTION BLOCK (8W-50-3) FROM FROM LG/TN JUNCTION JUNCTION S135 BLOCK BLOCK (8W-50-3) (8W-50-3) (8W-12-18) BK/BR LG/TN LEFT PARK/ BK/BR BK/YL TURN SIGNAL LEFT RIGHT LAMP HEADLAMP HEADLAMP LEVELING LEVELING MOTOR...
  • Page 589 8W-50 FRONT LIGHTING 8W - 50 - 5 BATT A3 RUN A22 (8W-10-11) (8W-10-13) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-10) (8W-12-5) DAYTIME FUSED FUSED RUNNING B(+) IGN. (RUN) LAMP BRAKE LEFT RIGHT MODULE WARNING HIGH LAMP BEAM BEAM GROUND SENSE OUTPUT OUTPUT (8W-12-14)
  • Page 590 8W - 50 - 6 8W - 50 FRONT LIGHTING 8W-50 FRONT LIGHTING INDEX page page GENERAL INFORMATION HEADLAMP DELAY ..... . . 7 INTRODUCTION .
  • Page 591 8W - 50 FRONT LIGHTING 8W - 50 - 7 DESCRIPTION AND OPERATION (Continued) HELPFUL INFORMATION HEADLAMP DELAY • Check for a blown 40 amp fuse located in cavity The headlamp delay uses a relay located in the 15 of the PDC. junction block.
  • Page 593 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 594 8W - 51 - 2 8W-51 REAR LIGHTING BATT F33 BATT A0 (8W-10-3) (8W-12-8) HEADLAMP POWER SWITCH DISTRIBUTION STOP 1 HEAD CENTER LAMP FUSE 2 PARK (8W-10-3) SWITCH 0 OFF (8W-33-3) (8W-50-3) (8W-10-5) BK/YL WT/TN RD/BK RD/BK JUNCTION BLOCK (8W-12-15) (8W-12-2) BODY PARK...
  • Page 595 8W-51 REAR LIGHTING 8W - 51 - 3 RUN A22 (8W-10-13) JUNCTION BLOCK (8W-12-2) FUSE AUTOMATIC DAY/ (8W-12-5) NIGHT MIRROR REVERSE (8W-44-5) SENSE WT/YL VT/BK C105 TRANSMISSION RANGE SWITCH (M/T) (8W-31-5) C105 VT/BK C121 VT/BK C300 VT/BK LEFT RIGHT BACK-UP BACK-UP LAMP LAMP...
  • Page 596 8W - 51 - 4 8W-51 REAR LIGHTING BATT A3 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-10) REAR LAMP SWITCH 0. OFF 1. ON C224 C300 C301 INSTRUMENT REAR CLUSTER LAMP (8W-40-8) S407 LEFT RIGHT REAR REAR LAMP LAMP S404 S405 (8W-15-6) (8W-15-6) C301...
  • Page 597 8W - 51 REAR LIGHTING 8W - 51 - 5 8W-51 REAR LIGHTING INDEX page page DESCRIPTION AND OPERATION REAR FOG LAMPS ..... . . 5 BACK-UP LAMPS .
  • Page 599 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 600 8W - 52 - 2 8W-52 TURN SIGNALS TURN SIGNAL/ HAZARD WARNING SWITCH INSTRUMENT CLUSTER (8W-40-8) LEFT RIGHT TURN TURN SIGNAL SIGNAL INDICATOR INDICATOR LG/TN TN/BR JUNCTION BLOCK (8W-12-3) COMBINATION LG/TN LG/TN TN/BR FLASHER (8W-52-3) C300 C301 (8W-52-4) (8W-52-4) S135 S136 (8W-12-18) (8W-12-18)
  • Page 601 8W-52 TURN SIGNALS 8W - 52 - 3 TURN RUN-ACC A31 BATT A0 (8W-10-7) (8W-10-3) SIGNAL/ JUNCTION POWER HAZARD BLOCK DISTRIBUTION WARNING (8W-12-2) CENTER SWITCH FUSE FUSE (8W-10-3) (8W-52-2) (8W-12-11) (8W-10-5) C224 C126 SEAT FUSED BELT IGN. (RUN-ACC) CONTROL IMMOBILIZER MODULE (8W-61-5) (8W-67-2)
  • Page 602 8W - 52 - 4 8W-52 TURN SIGNALS FROM FROM JUNCTION JUNCTION BLOCK BLOCK (8W-52-2) (8W-52-2) LG/TN LG/TN C300 C301 LG/TN LEFT RIGHT REAR REAR TURN TURN SIGNAL SIGNAL LAMP LAMP S405 (8W-15-6) S404 (8W-15-6) C301 C300 G300 (8W-15-6) 978W-14 JXI00250...
  • Page 603 8W - 52 TURN SIGNALS 8W - 52 - 5 8W-52 TURN SIGNALS INDEX page page DESCRIPTION AND OPERATION TURN SIGNALS ......5 HAZARD FLASHERS .
  • Page 604 8W - 52 - 6 8W - 52 TURN SIGNALS DESCRIPTION AND OPERATION (Continued) Circuit L60 supplies voltage for the right front HELPFUL INFORMATION • Check the 20 amp fuses located in cavities 6, lamps and provides an input to the combined rear lighting module and side repeater lamp.
  • Page 605 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 606 8W - 53 - 2 8W-53 WIPERS RUN-ACC A31 (8W-10-7) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-11) C224 INTERMITTENT WIPER SWITCH 0 OFF SEAT FUSED 1 INT BELT IGN. (RUN-ACC) 2 LOW CONTROL 3 HIGH MODULE 4 WASH (8W-67-2) 5 MIST INSTRUMENT CLUSTER (8W-40-9) WASHER...
  • Page 607 8W-53 WIPERS 8W - 53 - 3 RUN-ACC A31 BATT A0 (8W-10-7) (8W-10-3) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-3) (8W-12-11) (8W-10-13) DB/GY RD/GY DB/GY DG/VT WIPER INTERMITTENT HIGH/ WIPER RELAY RELAY (IN PDC) (IN PDC) BR/OR VT/PK PK/VT RD/YL WINDSHIELD...
  • Page 608 8W - 53 - 4 8W - 53 WIPERS 8W-53 WIPERS INDEX page page DESCRIPTION AND OPERATION MIST FUNCTION ......4 HELPFUL INFORMATION .
  • Page 609 8W - 53 WIPERS 8W - 53 - 5 DESCRIPTION AND OPERATION (Continued) tent wipe relay to switch from its normally grounded circuit also is the feed for the wiper switch and the position and connect circuit A5 to circuit V5. The A5 intermittent wiper relay.
  • Page 611 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 612 8W - 60 - 2 8W-60 POWER WINDOWS RUN A22 (8W-10-13) JUNCTION BLOCK (8W-12-2) CIRCUIT (8W-12-3) BREAKER (8W-12-13) TN/VT C311 MASTER POWER WINDOW SWITCH 1 DOWN 2 UP FROM WINDOW TIMER MODULE S410 (8W-60-4) (8W-12-13) LG/RD LG/RD LEFT RIGHT DOOR DOOR WINDOW WINDOW...
  • Page 613 8W-60 POWER WINDOWS 8W - 60 - 3 RUN A22 (8W-10-13) JUNCTION BLOCK (8W-12-2) CIRCUIT (8W-12-3) BREAKER (8W-12-13) F21 14 TN MASTER POWER WINDOW SWITCH 1 DOWN 2 UP FROM WINDOW TN/VT TIMER MODULE C311 BR/WT (8W-60-4) C311 LG/RD S410 BR/WT (8W-12-13) TN/WT...
  • Page 614 8W - 60 - 4 8W-60 POWER WINDOWS RUN F21 (8W-12-13) MASTER POWER WINDOW SWITCH 1 DOWN 2 UP 14 DB/WT POWER GY/BK SWITCH (8W-66-2) RIGHT YL/BK RD/WT DOOR C342 WINDOW MOTOR S310 S311 FROM RELAY S410 (8W-66-2) (8W-66-2) (8W-60-2) (8W-60-2) (8W-60-3) YL/BK...
  • Page 615 8W - 60 POWER WINDOWS 8W - 60 - 5 8W-60 POWER WINDOWS INDEX page page DESCRIPTION AND OPERATION TOP OPERATION) ..... . . 6 HELPFUL INFORMATION .
  • Page 616 8W - 60 - 6 8W - 60 POWER WINDOWS DESCRIPTION AND OPERATION (Continued) Ground for the window motor is supplied on the top switch is activated. Refer to the following circuit Q17 circuit. Circuit Q17 connects from the left rear descriptions for operation in this mode.
  • Page 617 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 618 8W - 61 - 2 8W-61 POWER DOOR LOCKS BATT A7 RUN A22 (8W-10-5) (8W-10-13) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-6) (8W-12-5) C310 S306 C315 (8W-12-5) S400 S401 C310 C315 (8W-12-7) (8W-12-7) LEFT RIGHT POWER POWER DOOR DOOR LOCK LOCK SWITCH SWITCH WT/DG...
  • Page 619 8W-61 POWER DOOR LOCKS 8W - 61 - 3 LEFT RIGHT REMOTE REMOTE KEYLESS KEYLESS ENTRY ENTRY ANTENNA ANTENNA P158 BODY CONTROL ANTENNA ANTENNA LEFT WIRE WIRE MODULE FRONT DOOR DOOR DOOR DOOR (IN J/B) UNLOCK LOCK UNLOCK LOCK (8W-45-10) DRIVER DRIVER DRIVER...
  • Page 620 8W - 61 - 4 8W-61 POWER DOOR LOCKS BATT A3 (8W-10-11) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-12) S312 DECKLID RELEASE RELAY C309 UNIVERSAL LEFT GARAGE VISOR/ DOOR VANITY OPENER LAMP BR/LB BR/LB LG/BK RD/BK (8W-44-2) (8W-44-2) C342 RIGHT DECKLID POWER DECKLID VISOR/...
  • Page 621 8W-61 POWER DOOR LOCKS 8W - 61 - 5 BATT A0 ST-RUN A21 (8W-10-3) (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-5) (8W-10-8) LG/BK S106 (8W-10-8) LG/BK C126 A15 18 PK F18 18 LG/BK COMBINATION INSTRUMENT FLASHER CLUSTER (8W-52-3) (8W-40-2) LG/BK IMMOBILIZER FUSED...
  • Page 622 8W - 61 - 6 8W - 61 POWER DOOR LOCKS 8W-61 POWER DOOR LOCKS INDEX page page DESCRIPTION AND OPERATION POWER DOOR LOCKS ....6 DECK LID RELEASE .
  • Page 623 8W - 61 POWER DOOR LOCKS 8W - 61 - 7 DESCRIPTION AND OPERATION (Continued) When the RKE transmitter is activated the BCM provides a ground path for circuit Q33. This causes the contacts in the relay to CLOSE connecting cir- cuits F35 and Q2.
  • Page 625 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 626 8W - 62 - 2 8W-62 POWER MIRRORS BATT A7 (8W-10-5) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-6) C310 S400 (8W-12-7) POWER MIRROR SWITCH 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 LEFT MIRROR 6 RIGHT MIRROR WT/BK DB/WT WT/BK WT/YL LG/BK S402 (8W-15-8)
  • Page 627 8W - 62 POWER MIRRORS 8W - 62 - 3 8W-62 POWER MIRRORS INDEX page page DESCRIPTION AND OPERATION POWER MIRRORS ......3 HELPFUL INFORMATION .
  • Page 629 8W - 63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 630 8W - 63 - 2 8W-63 POWER SEAT BATT A3 (8W-10-11) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-12) S312 (8W-12-12) C309 RD/BK POWER SEAT SWITCH 1 VERTICAL 2 VERTICAL DOWN 3 UP 4 DOWN 5 FWD 6 BACK YL/LB RD/LB YL/LG RD/LG YL/WT RD/WT...
  • Page 631 8W - 63 POWER SEAT 8W - 63 - 3 8W-63 POWER SEAT INDEX page page DESCRIPTION AND OPERATION POWER HEATED SEATS ....3 HELPFUL INFORMATION .
  • Page 633 8W - 66 POWER TOP 8W - 66 - 1 8W-66 POWER TOP INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 634 8W - 66 - 2 8W-66 POWER TOPS BATT A0 RUN A22 (8W-10-3) (8W-10-13) POWER JUNCTION DISTRIBUTION BLOCK FUSE CENTER (8W-12-2) FUSE (8W-10-3) (8W-10-9) (8W-12-5) C121 POWER POWER OTHERS DOOR LOCKS S306 DOWN (8W-12-5) RELAYS RD/WT YL/BK POWER G300 C342 (8W-15-6) PUMP MOTOR...
  • Page 635 8W - 66 POWER TOP 8W - 66 - 3 8W-66 POWER TOP DESCRIPTION AND OPERATION age flowing through the coil side of the relay causes the contacts in the relay to CLOSE connecting cir- POWER TOP OPERATION W/POWER WINDOWS cuits A25 and P4.
  • Page 637 8W - 67 RESTRAINT SYSTEM 8W - 67 - 1 8W-67 RESTRAINT SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 638 8W - 67 - 2 8W-67 RESTRAINT SYSTEM RUN-ACC A31 BATT A0 (8W-10-7) (8W-10-3) JUNCTION POWER BLOCK DISTRIBUTION FUSE (8W-12-2) CENTER FUSE (8W-10-3) (8W-10-10) (8W-12-11) C121 C224 INTERMITTENT COMBINATION WIPER FLASHER SWITCH (8W-52-3) (8W-53-2) SEAT FUSED FUSED BELT IGN. B(+) (RUN-ACC) CONTROL LEFT FRONT...
  • Page 639 8W - 67 RESTRAINT SYSTEM 8W - 67 - 3 8W-67 RESTRAINT SYSTEM DESCRIPTION AND OPERATION located in cavity 13 of the Power Distribution Center (PDC). RESTRAINT SYSTEM Circuit F13 is HOT when the ignition switch is in the ACCESSORY and RUN position only. This circuit The seat belt system is used to lock and unlock the is protected by a 10 amp fuse located in cavity 15 of seat belts.
  • Page 641 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 642 8W - 70 - 2 8W-70 SPLICE INFORMATION DOWNSTREAM TRANSMISSION HEATED CONTROL OXYGEN MODULE SENSOR (8W-31-4) (8W-30-10) FROM S117 (8W-70-4) BK/LB BK/LB BK/LB C111 BK/LB S110 (IN PDC) BK/LB BK/LB BATTERY POWERTRAIN TEMPERATURE CONTROL SENSOR MODULE (8W-30-14) (8W-30-10) (8W-30-14) 978W-14 JXI00264...
  • Page 643 8W-70 SPLICE INFORMATION 8W - 70 - 3 FUEL FUEL FUEL FUEL FROM S118 INJECTOR INJECTOR INJECTOR INJECTOR (8W-70-5) NO. 1 NO. 2 NO. 3 NO. 4 (8W-30-6) (8W-30-6) (8W-30-6) (8W-30-6) A142 A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR DG/OR S114 (2.4L)
  • Page 644 8W - 70 - 4 8W-70 SPLICE INFORMATION INTAKE MANIFOLD UPSTREAM ABSOLUTE PRESSURE HEATED TEMPERATURE PRESSURE TRANSDUCER OXYGEN SENSOR SENSOR (8W-42-3) SENSOR (8W-30-11) (8W-30-11) (8W-30-10) 2.5L 2.0L BK/LB BK/LB BK/LB BK/LB BK/LB S116 BK/LB CRANKSHAFT S130 POSITION (8W-70-7) THROTTLE SENSOR POSITION (8W-30-8) SENSOR...
  • Page 645 8W-70 SPLICE INFORMATION 8W - 70 - 5 AUTOMATIC POWERTRAIN GENERATOR ELECTRONIC SHUT DOWN CONTROL (2.5L) RELAY MODULE (8W-20-2) TRANSDUCER (IN PDC) (8W-30-4) SOLENOID (8W-30-11) (8W-30-4) (8W-30-11) 2.4L 2.5L A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR A142 A142 C111 DG/OR DB/OR FUSE...
  • Page 646 8W - 70 - 6 8W-70 SPLICE INFORMATION DISTRIBUTOR CAMSHAFT CRANKSHAFT POWERTRAIN (8W-30-5) POSITION POSITION CONTROL MODULE SENSOR SENSOR (8W-30-8) (8W-30-8) (8W-30-5) (8W-30-8) OR/WT OR/WT OR/WT OR/WT C111 2.5L 2.0L OR/WT S124 TRANSMISSION TRANSMISSION TURBINE OUTPUT RANGE SPEED SHAFT CONTROL SWITCH SENSOR SPEED...
  • Page 647 8W-70 SPLICE INFORMATION 8W - 70 - 7 NOISE IGNITION FROM FROM S116 SUPPRESSOR COIL S118 (8W-70-4) (8W-30-4) PACK (8W-70-5) (8W-30-4) BK/LB S130 A142 A142 A142 DG/OR DG/OR DG/OR BK/LB S117 S131 (8W-70-4) (2.4L) LEFT RIGHT REAR DOOR DOOR FLOOR COURTESY COURTESY COURTESY...
  • Page 648 8W - 70 - 8 8W - 70 SPLICE INFORMATION 8W-70 SPLICE INFORMATION DESCRIPTION AND OPERATION INTRODUCTION This section identifies all splices shown in the dia- grams. It also shows the splices in there entirity. All circuits that are part of the splices are shown and the systems they affect are referanced.
  • Page 649 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 650 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Junction Block - C1 ....8W-80-26 Power Amplifier - C1 (Premium Sound)..8W-80-36 Junction Block - C2 .
  • Page 651 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Throttle Position Sensor ....8W-80-47 Vapor Canister Leak Detector Transmission Control Module ...8W-80-48 (2.0L Engine) .
  • Page 652 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 4 BLACK CIRCUIT FUNCTION C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT A/C COMPRESSOR CLUTCH BLACK CIRCUIT FUNCTION C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL C57 22GY SENSOR GROUND A/C EVAPORATOR TEMPERATURE SENSOR BLACK CIRCUIT FUNCTION C21 22DB/OR A/C SWITCH SENSE...
  • Page 653 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 BLACK CIRCUIT FUNCTION B142 20BR/YL LEFT FRONT DECAY SOLENOID CONTROL B143 20DG/YL RIGHT FRONT DECAY SOLENOID CONTROL B146 20BR/LB LEFT REAR DECAY SOLENOID CONTROL B148 20DG/LB RIGHT REAR DECAY SOLENOID CONTROL Z1 18BK GROUND Z1 18BK GROUND...
  • Page 654 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 6 YELLOW CIRCUIT FUNCTION R44 18DG/YL PASSENGER AIRBAG LINE 2 R42 18BK/YL PASSENGER AIRBAG LINE 1 R45 18DG/LB DRIVER AIRBAG LINE 2 AIRBAG CONTROL R43 18BK/LB DRIVER AIRBAG LINE 1 MODULE - C2 BLACK CIRCUIT FUNCTION...
  • Page 655 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 GRAY CIRCUIT FUNCTION K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL K4 18BK/LB SENSOR GROUND BATTERY TEMPERATURE SENSOR BLACK CIRCUIT FUNCTION C7 12BK/TN HI BLOWER MOTOR DRIVER C6 18LB M2 BLOWER MOTOR DRIVER C1 12DG FUSED IGNITION SWITCH OUTPUT (RUN) C4 18TN LO BLOWER MOTOR DRIVER...
  • Page 656 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 8 CIRCUIT FUNCTION WHITE C35 22DG/YL MODE DOOR DRIVER E2 18OR/YL PANEL LAMPS DRIVER E2 18OR/BR PANEL LAMPS DRIVER C26 20PK/DB 5 VOLT SUPPLY C34 22DB/YL COMMON DOOR DRIVER M50 20YL/RD KEY-IN LAMP DRIVER BODY CONTROL Z2 20BK/LG GROUND...
  • Page 657 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 CIRCUIT FUNCTION P34 16PK/BK RIGHT FRONT DOOR UNLOCK DRIVER P34 16DB/WT* LEFT FRONT DOOR UNLOCK DRIVER P55 16DB/WT** LEFT FRONT DOOR UNLOCK DRIVER G10 20LG/RD SEAT BELT SWITCH SENSE G74 18TN/RD LEFT REAR DOOR AJAR SWITCH SENSE BLACK G75 18TN LEFT FRONT DOOR AJAR SWITCH SENSE...
  • Page 658 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 10 CIRCUIT CIRCUIT F20 18WT/YL F20 18WT/YL BLACK T1 18LG/GY T1 20LG/GY BLACK T3 18VT T3 18VT T13 20DB/BR T13 20DB/BR T14 18LG/VT T14 20LG/VT T20 18LB/WT T20 20LB/WT T42 18VT/TN T42 18VT/TN C105 T47 18YL/GY C105...
  • Page 659 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 CIRCUIT CIRCUIT B1 20YL/DB B1 20YL/DB B2 20YL B2 20YL B3 20LG/DB GREEN B3 20LG/DB GREEN B4 20LG B4 20LG A141 14DG/WT A141 14DG/WT L1 18VT/BK L1 18VT/BK L1 18VT/BK A45 18BR A25 12DB A45 18BR Q33 18BR/LB...
  • Page 660 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 12 CIRCUIT CIRCUIT X52 18DB/WT X52 18DB/WT X56 20DB/RD* X80 18LB/DG X56 18DB/RD* X80 18LB/DG** X54 20VT* X82 18LB/VT X54 18VT* X82 18LB/VT** GRAY GRAY X58 18DB/OR X58 18DB/OR X51 18BR/YL 18BR/YL X55 20BR/RD* X85 18LG/DG X55 18BR/RD* X85 18LG/DG**...
  • Page 661 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 CIRCUIT CIRCUIT BLACK L1 18VT/BK L1 18VT/BK L50 18WT/TN L50 18WT/TN BLACK L60 18TN L60 18TN L7 18BK/YL L7 18BK/YL Z1 18BK Z1 18BK L36 18LG L36 18LG C301 C301 CIRCUIT CIRCUIT L50 18BK/TN L50 18WT/TN C305...
  • Page 662 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 14 CIRCUIT CIRCUIT X85 18LG/DG X85 18LG/DG X87 18LG/VT X87 18LG/VT Q17 14DB/WT Q17 14DB/WT Q18 14GY/BK Q18 14GY/BK BLUE Q27 14RD/BK Q27 14RD/BK BLUE Q28 14DG/WT Q28 14DG/WT Q16 14BR/WT Q16 14BR/WT Q26 14VT/WT Q26 14VT/WT C311...
  • Page 663 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 CIRCUIT CIRCUIT BLACK M1 18PK M1 18PK BLACK M2 18YL M2 18YL Z1 18BK Z1 18BK F20 20WT F20 20WT G38 18GY G38 18GY C332 C332 G38 18GY G38 18GY L1 18VT/BK L1 18VT/BK CIRCUIT CIRCUIT...
  • Page 664 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 16 BLACK CIRCUIT FUNCTION K7 20OR/WT 5 VOLT SUPPLY K4 20BK/LB SENSOR GROUND K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR (2.0L ENGINE ONLY) CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 18BK GROUND CENTER HIGH...
  • Page 665 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 CIRCUIT FUNCTION B1 20YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B2 20YL RIGHT REAR WHEEL SPEED SENSOR (+) B3 20LG/DB LEFT REAR WHEEL SPEED SENSOR (-) B4 20LG LEFT REAR WHEEL SPEED SENSOR (+) Z1 18BK GROUND B6 20WT/DB...
  • Page 666 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 18 (CONTINUED FROM PREVIOUS PAGE) CIRCUIT FUNCTION B146 20BR/LB LEFT REAR DECAY SOLENOID CONTROL B47 16RD/LB ABS SYSTEM RELAY OUTPUT B148 20DG/LB RIGHT REAR DECAY SOLENOID CONTROL D21 20PK/LG SCI TRANSMIT B57 20BR/BK ABS SYSTEM RELAY CONTROL F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN/START)
  • Page 667 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 CIRCUIT FUNCTION D1 20VT/BR CCD BUS (+) BLACK Z2 20BK/VT GROUND Z11 18BK GROUND D20 20LG SCI RECEIVE D21 20PK/LG SCI TRANSMIT DATA LINK D2 20WT/DB CCD BUS (-) CONNECTOR D6 20PK/LB SCI RECEIVE M1 18PK/WT FUSED B(+)
  • Page 668 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 20 BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT DISTRIBUTOR - C1 (2.5L ENGINE) CIRCUIT FUNCTION BLACK K4 18BK/LB SENSOR GROUND K7 18OR/WT 8 VOLT SUPPLY K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL Z1 16BK GROUND IGNITION COIL NO.
  • Page 669 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 GRAY CIRCUIT FUNCTION K52 20PK/GY EVAP/PURGE SOLENOID CONTROL F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (RUN/START) DUTY CYCLE EVAP/PURGE SOLENOID BLACK CIRCUIT FUNCTION K35 18GY/YL EGR SOLENOID CONTROL A142 18DG/OR* AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18DB/OR** AUTOMATIC SHUT DOWN RELAY OUTPUT ELECTRONIC EGR...
  • Page 670 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 22 BLACK CIRCUIT FUNCTION K12 18TN INJECTOR NO. 2 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 2 BLACK CIRCUIT FUNCTION K13 18YL/WT INJECTOR NO. 3 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO.
  • Page 671 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 BLACK CIRCUIT FUNCTION A141 14DG/WT FUEL PUMP RELAY OUTPUT G4 18DB FUEL LEVEL SENSOR SIGNAL Z1 16BK GROUND Z2 18BK/LG GROUND FUEL PUMP MODULE BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K20 18DG GENERATOR FIELD DRIVER GENERATOR...
  • Page 672 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 24 BLACK CIRCUIT FUNCTION K59 20VT/GY IAC MOTOR NO. 4 DRIVER K40 20BR/GY IAC MOTOR NO. 3 DRIVER K60 20YL/BK IAC MOTOR NO. 2 DRIVER K39 20GY/RD IAC MOTOR NO. 1 DRIVER IDLE AIR CONTROL MOTOR BLACK CIRCUIT FUNCTION...
  • Page 673 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 BLACK CIRCUIT FUNCTION Z1 18BK GROUND M1 18PK FUSED B(+) FUSED B(+) M1 18PK M112 20BR/LG ILLUMINATED ENTRY RELAY CONTROL ILLUMINATED ENTRY RELAY M2 18YL COURTESY LAMPS DRIVER BLACK CIRCUIT FUNCTION A15 18PK FUSED B(+) F18 20LG/BK FUSED IGNITION SWITCH OUTPUT...
  • Page 674 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 26 GRAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL INTAKE AIR TEMPERATURE SENSOR CIRCUIT FUNCTION G9 20GY/DB RED BRAKE WARNING LAMP DRIVER G9 20GY/DG RED BRAKE WARNING LAMP DRIVER L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT BLACK...
  • Page 675 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 WHITE CIRCUIT FUNCTION A7 16RD/BK FUSED B(+) A13 12PK/WT FUSED B(+) A3 12RD/WT FUSED B(+) A4 12BK/PK FUSED B(+) JUNCTION BLOCK - C3 CIRCUIT FUNCTION BLUE Z1 18BK/OR GROUND Z1 18BK/TN GROUND F23 18WT FUSED IGNITION SWITCH OUTPUT (RUN) G9 22GY/DB...
  • Page 676 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 28 CIRCUIT FUNCTION F13 18DB FUSED IGNITION SWITCH OUTPUT (RUN/ACC) F13 18DB FUSED IGNITION SWITCH OUTPUT (RUN/ACC) A81 18DG/RD IGNITION SWITCH OUTPUT (OFF/RUN/START) NATURAL L60 18TN/BR RIGHT TURN SIGNAL C16 22LB/YL REAR DEFOGGER LAMP DRIVER X12 18RD/WT FUSED IGNITION SWITCH OUTPUT (RUN/ACC) L61 18LG...
  • Page 677 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 CIRCUIT FUNCTION M112 20BR/LG ILLUMINATED ENTRY RELAY CONTROL BLACK Z1 18BK GROUND Z1 18BK GROUND JUNCTION BLOCK - C10 MI 18PK FUSED B(+) MI 18PK FUSED B(+) BLACK CIRCUIT FUNCTION L25 18BR** FUSED B(+) Z1 18BK GROUND...
  • Page 678 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 30 BLACK FUNCTION CIRCUIT M1 18PK FUSED B(+) M2 18YL COURTESY LAMPS DRIVER LEFT DOOR COURTESY LAMP BLACK FUNCTION CIRCUIT X85 18LG/DG LEFT FRONT (+) X87 18LG/VT LEFT FRONT (-) LEFT DOOR SPEAKER BLACK CIRCUIT FUNCTION...
  • Page 679 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 CIRCUIT FUNCTION Q21 14WT LEFT FRONT WINDOW DRIVER (DOWN) Q11 14LB LEFT FRONT WINDOW DRIVER (UP) LEFT FRONT POWER WINDOW MOTOR BLACK CIRCUIT FUNCTION B8 20OR/DB LEFT FRONT WHEEL SPEED SENSOR (-) B9 20OR LEFT FRONT WHEEL SPEED SENSOR (+) LEFT FRONT WHEEL...
  • Page 680 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION P55 16DB/WT LEFT FRONT DOOR UNLOCK DRIVER P33 16OR/BK LEFT FRONT DOOR LOCK DRIVER LEFT POWER DOOR LOCK MOTOR WHITE CIRCUIT FUNCTION M1 20 PK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT Z1 20BK GROUND...
  • Page 681 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 GRAY FUNCTION CIRCUIT L61 18LG/TN LEFT TURN SIGNAL Z1 18BK GROUND LEFT REAR TURN SIGNAL LAMP BLACK CIRCUIT FUNCTION B3 20LG/DB LR WHEEL SPEED SENSOR (-) B4 20LG LR WHEEL SPEED SENSOR (+) LEFT REAR WHEEL SPEED SENSOR GRAY...
  • Page 682 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND K6 18VT/WT 5-VOLT SUPPLY K1 18DG/RD MAP SENSOR SIGNAL MANIFOLD ABSOLUTE PRESSURE SENSOR CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) Q17 14DB/WT LEFT REAR WINDOW DRIVER (UP) Q31 14OR LEFT REAR WINDOW DRIVER (DOWN) BLUE...
  • Page 683 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 BLACK CIRCUIT FUNCTION G6 18GY/VT OIL PRESSURE SWITCH SENSE OIL PRESSURE SWITCH BLACK CIRCUIT FUNCTION T13 18DB/BR SPEED SENSOR GROUND T14 18LG/VT OUTPUT SHAFT SPEED SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR BLACK CIRCUIT FUNCTION M2 18YL...
  • Page 684 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION X91 20WT/BK LEFT REAR AMP INPUT (-) X92 20TN/BK RIGHT REAR AMP INPUT (-) X55 20BR/RD LEFT FRONT AMP INPUT (-) WHITE X60 20DG/RD REMOTE ON FOR AMP P5 20YL/BK POWER TOP SWITCH TO RELAY B(+) DOWN X93 20WT/RD LEFT REAR AMP INPUT (+)
  • Page 685 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 CIRCUIT FUNCTION Z1 20BK GROUND M1 20PK FUSED B(+) BLACK P94 20WT/YL POWER MIRROR HORIZONTAL (RIGHT) P92 20YL POWER MIRROR VERTICAL (RIGHT) P90 20LG/BK POWER MIRROR VERTICAL (LEFT/RIGHT) P90 20LG/BK POWER MIRROR VERTICAL (LEFT) P91 20WT/BK POWER MIRROR HORIZONTAL (LEFT/RIGHT) POWER MIRROR...
  • Page 686 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 38 BLACK CIRCUIT FUNCTION K10 18DB/LG POWER STEERING PRESSURE SWITCH SENSE Z1 18BK GROUND POWER STEERING PRESSURE SWITCH BLUE FUNCTION CIRCUIT P6 20RD/WT POWER TOP SIGNAL (UP) Z1 20BK GROUND Z1 20BK GROUND P5 20YL/BK POWER TOP SIGNAL (DOWN) POWER TOP...
  • Page 687 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 CIRCUIT FUNCTION V37 20RD/LG SPEED CONTROL SWITCH SIGNAL C18 20DB/YL A/C PRESSURE SIGNAL K4 20BK/LB SENSOR GROUND K7 18OR/WT 8 VOLT SUPPLY K10 18DB/LG POWER STEERING PRESSURE SWITCH SENSE A14 16RD/TN FUSED B(+) K40 20BR/GY IDLE AIR CONTROL MOTOR NO.
  • Page 688 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION K19 18BK/GY* IGNITION COIL NO. 1 DRIVER K17 18DB/DG* IGNITION COIL NO. 2 DRIVER K20 18DG GERNERATOR FIELD DRIVER V32 20YL/PK SPEED CONTROL ON/OFF SWITCH SENSE A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K13 18YL/WT INJECTOR NO.
  • Page 689 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 BLACK CIRCUIT FUNCTION A1 16RD FUSED B(+) A81 18DG/RD IGNITION SWITCH OUTPUT PRNDL FEED BROWN CIRCUIT FUNCTION E2 18OR/BK PANEL LAMPS DRIVER Z1 18BK GROUND PRNDL ILLUMINATION LED BLACK CIRCUIT FUNCTION Z1 12BK GROUND C23 12DG/LG LOW SPEED RADIATOR FAN RELAY OUTPUT...
  • Page 690 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION M1 18PK FUSED B(+) M2 18YL COURTESY LAMPS DRIVER REAR FLOOR COURTESY LAMP CIRCUIT FUNCTION P11 16YL/WT POWER SEAT REAR VERTICAL (UP) P13 16RD/WT POWER SEAT REAR VERTICAL (DOWN) REAR VERTICAL MOTOR GREEN...
  • Page 691 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 BLACK FUNCTION CIRCUIT X80 18LB/DG RIGHT FRONT (-) RIGHT DOOR SPEAKER X82 18LB/VT RIGHT FRONT (+) BLACK CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) G10 20LG/RD WINDOW MOTOR RELAY CONTROL G10 20LG/RD WINDOW MOTOR RELAY CONTROL Q30 14VT...
  • Page 692 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION Q22 14VT RIGHT FRONT WINDOW DRIVER (DOWN) Q12 14BR RIGHT FRONT WINDOW DRIVER (UP) RIGHT FRONT POWER WINDOW MOTOR BLACK CIRCUIT FUNCTION B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-) B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+) RIGHT FRONT WHEEL...
  • Page 693 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 WHITE FUNCTION CIRCUIT M1 20PK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT Z1 20BK GROUND RIGHT POWER P96 20WT/LG RIGHT FRONT DOOR SWITCH MUX DOOR LOCK SWITCH NATURAL CIRCUIT FUNCTION C16 20LB/YL REAR DEFOGGER LAMP DRIVER Z1 20BK GROUND...
  • Page 694 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION X58 18DB/OR RIGHT REAR (-) X52 18DB/WT RIGHT REAR (+) RIGHT REAR SPEAKER GRAY FUNCTION CIRCUIT L60 18TN BACK UP LAMP FEED Z1 18BK GROUND RIGHT REAR TURN SIGNAL LAMP BLACK CIRCUIT FUNCTION...
  • Page 695 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CIRCUIT FUNCTION G75 18TN LEFT FRONT DOOR AJAR SWITCH SENSE G74 18TN/RD DOOR AJAR SWITCH SENSE NATURAL F13 18DB FUSED IGNITION SWITCH OUTPUT (RUN/ACC) A45 18BR FUSED B(+) Z1 18BK GROUND R7 18OR/BK DRIVER LATCH SIGNAL R8 18OR/RD PASSENGER LATCH SIGNAL...
  • Page 696 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION T1 20LG/GY TRANSMISSION RANGE SWITCH T1 SENSE T3 18VT PARK/NEUTRAL POSITION SWITCH SENSE D2 20WT/DG CCD BUS(-) T5 20LG/LB AUTOSTICK UPSHIFT SWITCH SENSE K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL D21 20PK/LB SCI TRANSMIT BLACK 41 21 1...
  • Page 697 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 (CONTINUED) CIRCUIT FUNCTION T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE T42 18VT/TN TRANSMISSION RANGE SWITCH T42 SENSE D1 20VT/DG CCD BUS(+) T44 20YL/LB AUTOSTICK DOWNSHIFT SWITCH SENSE D6 20PK/LB SCI RECEIVE T47 20YL/GY 2-4 PRESSURE SWITCH SENSE T50 18DG/TN LOW/REVERSE PRESSURE SWITCH SENSE...
  • Page 698 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION T47 18YL/GY 2-4 PRESSURE SWITCH SENSE T50 18DG/TN LOW/REVERSE PRESSURE SWITCH SENSE T9 18OR/BK OVERDRIVE OFF SWITCH SENSE T16 16RD/BR TRANSMISSION CONTROL RELAY OUTPUT T59 18PK/DB UNDERDRIVE SOLENOID CONTROL T60 18BR/TN OVERDRIVE SOLENOID CONTROL T20 18LB/WT...
  • Page 699 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 BLACK CIRCUIT FUNCTION Z1 18BK GROUND A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K4 18BK/LB SENSOR GROUND K41 18BK/DG UPSTREAM OXYGEN SENSOR SIGNAL UPSTREAM HEATED OXYGEN SENSOR BLACK CIRCUIT FUNCTION F18 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN/START) K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL...
  • Page 700 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS FUNCTION CIRCUIT BLACK P5 20YL/BK POWER TOP SIGNAL (DOWN) F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) P6 20RD/WT POWER TOP SIGNAL (UP) Q27 14RD/BK LEFT REAR WINDOW DRIVER (DOWN) (MOTOR) Q32 14BR RIGHT REAR WINDOW DRIVER (DOWN) (SWITCH) Q28 14DG/WT RIGHT REAR WINDOW DRIVER (DOWN) (MOTOR)
  • Page 701 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 53 8W-80 CONNECTOR PIN-OUTS WIRING DIAGRAM INDEX DESCRIPTION AND OPERATION The following index covers all components found in INTRODUCTION this section of the wiring diagrams. If the component The pages refernced in this section show the con- you are looking for is not found here, refer to section nector, the circuits in the connector and what pin the 8W-02 for a complete list of all components shown in...
  • Page 703 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION number identification. Refer to the index for the proper figure number. INTRODUCTION CONNECTOR/GROUND LOCATIONS This section provides illustrations identifying the For items not shown in this section a N/S is placed general location of components, grounds, and connec- in the Fig.
  • Page 704 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C341 Under Engine Coolant At Sensor 4, 5 Passengers Temp Sensor Seat Front Vertical At Motor C342 Front of Floor Motor...
  • Page 705 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Generator Rear of Junction Block At Junction (2.0L/2.4L) Generator Block Generator Rear of Junction Block At Junction (2.5L) Generator Block...
  • Page 706 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Low Note Horn Right Front Radiator Fan Rear of Motor Fender Motor MAP Sensor Rear of Intake Radio C1 Rear of Radio (2.5L)
  • Page 707 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Right Rear At Motor Traveler Rear of Power Window Traveler Motor Trunk Key At Switch Right Rear At Speaker Cylinder Switch Speaker...
  • Page 708 8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 709 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 710 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 711 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
  • Page 712 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 713 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
  • Page 714 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 715 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued)
  • Page 716 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 717 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
  • Page 718 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 719 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
  • Page 720 8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 721 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued)
  • Page 722 8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 723 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued)
  • Page 724 8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 725 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23 DESCRIPTION AND OPERATION (Continued)
  • Page 727 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS DESCRIPTION AND OPERATION section for splice number identification. Refer to the index for the proper splice number. INTRODUCTION SPLICE LOCATIONS This section provides illustrations identifying the For splices not shown in this section a N/S is general location of the splices in this vehicle.
  • Page 728 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 1 Engine Compartment Splices Fig. 2 Engine Compartment Splices...
  • Page 729 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 3 Engine Compartment Splices Fig. 4 Transmission Splices...
  • Page 730 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 731 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
  • Page 732 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 733 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 734 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 735 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued)

  • Page 737: L Engine

    ENGINE 9 - 1 ENGINE CONTENTS page page 2.4L ENGINE ......12 ENGINE DIAGNOSIS ..... . 7 2.5L ENGINE .

  • Page 738: General Information

    9 - 2 ENGINE GENERAL INFORMATION (Continued) instances, it may be necessary to lightly tap the part CYLINDER CUP PLUG BLOCK DRIFT SECOND REMOVE PLUG FIRST STRIKE HERE WITH HAMMER WITH PLIERS with a mallet or other suitable tool to break the seal between the mating surfaces.

  • Page 739: General Information

    CROSS-HATCH PATTERN ENGINE 9 - 3 GENERAL INFORMATION (Continued) ing a fire (Conventional Ignition System). For Direct (2) Deglazing of the cylinder walls may be done Ignition System DIS disconnect the coil connector. using a cylinder surfacing hone, Tool C-3501, (5) Be sure throttle blade is fully open during the equipped with 280 grit stones, if the cylinder bore is compression check.
  • Page 740 9 - 4 ENGINE PLASTIGAGE GENERAL INFORMATION (Continued) • When checking #3 main bearing shim #2 & #4 MEASURING MAIN BEARING AND CONNECTING main bearing. ROD BEARING CLEARANCES • When checking #4 main bearing shim #3 main bearing. NOTE: REMOVE ALL SHIMS BEFORE REASSEM- BLING ENGINE Fig.

  • Page 741: Hydrostatic Locked Engine

    ENGINE 9 - 5 GENERAL INFORMATION (Continued) (1) Rotate the crankshaft until the connecting rod (2) Remove negative battery cable. to be checked is at the bottom of its stroke. (3) Place a shop towel around the spark plugs ENGINE LEVEL STICK DIP-...
  • Page 742 All engines are equipped with a high quality full- An Energy Conserving type oil is recommended for flow, disposable type oil filter. Chrysler Corporation gasoline engines. They are designated as either recommends a Mopar or equivalent oil filter be used.
  • Page 743 ENGINE 9 - 7 ENGINE DIAGNOSIS INDEX page page DIAGNOSIS AND TESTING GENERAL INFORMATION ....7 CYLINDER COMBUSTION PRESSURE INSPECTION (ENGINE OIL LEAKS IN LEAKAGE TEST .
  • Page 744 9 - 8 ENGINE DIAGNOSIS AND TESTING (Continued) cause of low compression unless some malfunc- Perform the test procedures on each cylinder tion is present. according to the tester manufacturer’s instructions. (11) Clean or replace spark plugs as necessary While testing, listen for pressurized air escaping and adjust gap as specified in Group 8, Electrical.
  • Page 745 ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) (2) Add an oil soluble dye (use as recommended by INSPECTION FOR REAR SEAL AREA LEAKS manufacturer). Start the engine and let idle for Since it is sometimes difficult to determine the approximately 15 minutes.
  • Page 746 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery specific gravity. Charge or replace as necessary. 2. Corroded or loose battery 2. Clean and tighten battery connections.
  • Page 747 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in crankcase. 1. Checkfor correct oil level (refer to Group 0, Lubrication and Maintenance). 2. Thin or diluted oil. 2.
  • Page 748 9 - 12 2.4L ENGINE 2.4L ENGINE INDEX page page DESCRIPTION AND OPERATION LEFT SIDE MOUNT ..... 20 ENGINE COMPONENTS .
  • Page 749 ENGINE IDENTIFICATION LOCATION 2.4L ENGINE 9 - 13 DESCRIPTION AND OPERATION ENGINE Engine—2.4L ENGINE IDENTIFICATION GENERAL SPECIFICATIONS The engine identification number is located on the Type ..... In-Line OHV, DOHC rear of the cylinder block (Fig.
  • Page 750 9 - 14 2.4L ENGINE DESCRIPTION AND OPERATION (Continued) ENGINE COMPONENTS the intake camshaft at the rear of cylinder head. A hydrodynamic oil seal is used for oil control at the BALANCE SHAFTS: 2.4L engines are equipped front of the camshaft. with two balance shafts installed in a carrier VALVES: 4 valves per cylinder are actuated by attached to the lower crankcase.
  • Page 751 Correct piston to bore clearance must be established in order to assure quiet and economical operation. FITTING PISTON RINGS Chrysler engines use pistons designed specifically (1) Wipe cylinder bore clean. Insert ring and push for each engine model. Clearance and sizing locations down with piston to ensure it is square in bore.
  • Page 752 9 - 16 2.4L ENGINE SERVICE PROCEDURES (Continued) positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 5). Refer to specification in piston ring specifications table. SPACER EXPANDER NO. 2 PISTON RING NO.
  • Page 753 NO. 2 RING GAP AND SPACER GAP OF LOWER SIDE RAIL EXPANDER FRONT OF ENGINE NO. 1 RING GAP GAP OF UPPER SIDE RAIL SIDE RAIL END 2.4L ENGINE 9 - 17 SERVICE PROCEDURES (Continued) Fig. 10 Measuring Plastigage Width (5) Remove the bearing cap and compare the width Fig.
  • Page 754 FRONT OIL GROOVES LOWER BEARINGS UPPER BEAR- OIL HOLES INGS 9 - 18 2.4L ENGINE SERVICE PROCEDURES (Continued) CRANKSHAFT MAIN BEARINGS (2) Make certain oil holes in block line up with oil The crankshaft is supported in five main bearings. holes in bearings.
  • Page 755 2.4L ENGINE 9 - 19 SERVICE PROCEDURES (Continued) seated into the bedplate slots. Install the main bear- cap and a crankshaft cheek, using care not to dam- ing/bedplate into engine block. age any bearing surface. DO NOT loosen main bear- (6) Before installing the bolts the threads should ing cap.
  • Page 756 9 - 20 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 17 Engine Support Module INSTALLATION (1) Install thru bolt at front mount. Do not tighten at this time. (2) Install lower radiator support. (3) Install attaching bolts from support module to lower radiator support.
  • Page 757 STRUT A/C COMPRESSOR ENGINE ENGINE SUPPORT MOD- STRUT (SOME MODELS) FRONT BRACKET FRONT TORQUE MOUNT 2.4L ENGINE 9 - 21 REMOVAL AND INSTALLATION (Continued) (5) Remove coolant recovery system tank. Refer to Group 7, Cooling System for procedure. (6) Remove right engine support. (7) Remove the three bolts attaching the engine support bracket to the cylinder block.
  • Page 758 9 - 22 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) (16) Remove engine support module. (2) Align engine and transmission mounts to (17) Remove front and rear mount brackets from attaching points. Install mounting bolts at the right the engine and transmission. engine and left transmission mounts.
  • Page 759 SPECIAL TOOLS POST 6848 SPECIAL TOOL 6710 CRA- SPECIAL TOOL 6135 DOLLY WITH ADAPTERS 6909 SPECIAL TOOLS FRONT VIEW REAR VIEW POST 6848 2.4L ENGINE 9 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 23 Positioning Engine Cradle SupportPost Mounts...
  • Page 760 ONE PIECE RUBBER GAS- SPARK PLUG WELL SEALS IGNITION COIL FASTENERS GROUND STRAP 9 - 24 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD COVER (b) Tighten all fasteners to 9.0 N·m (80 in. lbs.) (c) Tighten all fasteners to 12 N·m (105 in. lbs.) REMOVAL (1) Remove ignition coil pack and plug wires (Fig.
  • Page 761 REMOVE OUTSIDE BEARING CAPS FIRST 2.4L ENGINE 9 - 25 REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: Ensure that NONE of the pistons are at top dead center when installing the camshafts. FRONT CAM CAP LEFT REAR CAM CAP 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET MAKER (1) Remove camshaft retaining caps and lubricate...
  • Page 762 CHAIN (CUTAWAY) COVER GUIDE STUD PIVOT SCREW ADJUST SCREW TENSIONER GEAR COVER (ADJUSTER) 9 - 26 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) CAMSHAFT FOLLOWER BALANCE SHAFTS CARRIER ASSEMBLY REMOVAL BALANCE SHAFTS Remove cylinder head cover using procedure ROLLER LASH ADJUSTER POCKET REMOVAL outlined in this section.
  • Page 763 NICKEL PLATED LINK AND MARK GEAR COVER STUD (DOU- BLE ENDED) NICKEL LINK AND DOT PLATED DRIVE GEAR GEAR(S) GEAR/SPROCKET CARRIERDOWEL DRIVEN GEAR SCREWS REAR COVER BALANCESHAFT CARRIER 2.4L ENGINE 9 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 37 Balance Shaft(s)—Removal/Installation Fig.
  • Page 764 9 - 28 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance. DRIVE SPROCKET ALIGN FLAT ON SPROCKET WITH FLAT SPROCKET FACING FRONT CRANKSHAFT SPECIAL NO.
  • Page 765 PIVOT B OLT TENSIONER (0.039 (ADJUSTER) SHIM IN.) BOLT AIR HOSE VALVE SPRING COMPRES- SOR MD 998772A 2.4L ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (4) With the load applied, tighten top tensioner VALVE SPRINGS AND VALVE SEALS IN VEHICLE bolt first, then bottom pivot bolt.
  • Page 766 VALVE RETAINER SPRING VALVE RETAINING LOCKS VALVE VALVE SPRING SEAT VALVESPRING SEAL ASSEMBLY 9 - 30 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION STRETCHED UNSTRETCHED BOLT BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE NOTE: The Cylinder head bolts should be exam- ined BEFORE reuse.
  • Page 767 VALVE SEAL TOOL VALVE STEM 2.4L ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) (5) Install rear timing belt cover and timing belt idler pulley. Install timing belt and camshaft sprocket. Refer to procedure outlined in this section. (7) Install cam sensor and fuel injectors wiring connectors.
  • Page 768 9 - 32 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) VIBRATION DAMPER (3) Remove engine mount bracket (Fig. 51). REMOVAL Remove crankshaft vibration damper bolt. Remove damper by using Special Tool 1026 and Insert 6827–A (Fig. 49). Fig. 49 Crankshaft Vibration Damper—Removal Fig.
  • Page 769 REAR COVER TO CYLINDER REAR COVER TO ENGINE BLOCK FASTENERS HEAD FASTENERS BELT TENSIONER UPPER TIMING BOLT COVER ENGINE SUPPORT BRACKET LOWER CAMSHAFT TIMING MARKS CRANKSHAFT AT TDC COVER FASTENERS TIMING FASTENERS FASTENERS TOGETHER BELT 2.4L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 770 6mm ALLEN WRENCH BELT TENSIONER WRENCH ALLEN TENSIONER BRACKET ALIGNMENT FLATS BELT TENSIONER 9 - 34 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 56 Tensioner to Bracket Alignment Fig. 55 Locking Timing Belt Tensioner (4) Move the exhaust camshaft sprocket counter- (9) Install 6 mm Allen wrench into belt tensioner.
  • Page 771 CAMSHAFT CAMSHAFT MOVE SPROCKET CAMSHAFT TIMING MARKS INSTALL 1/2 NOTCH LOCATION 1/2 NOTCH LOCATION CRANKSHAFT AT TDC BELT BELT SLACK DIRECTION SPROCKET SPROCKET CAMSHAFT TAKE EXHAUST INTAKE THIS PLACE A 3 MM (1/8 INCH) BEAD OF SEALANT AT THE PARTING LINE OF THE OIL PICK-UP TUBE OIL PUMP BODY TO ENGINE BLOCK SEALER...
  • Page 772 ADAPTER SPECIAL TOOL C-4679 C-4687–1 SPECIAL TOOL C-4687 SPECIAL MD 998306 TOOL 9 - 36 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) FRONT CAMSHAFT OIL SEAL REMOVAL (1) Remove front timing belt cover and timing belt. Refer to procedure outlined in this section. (2) Hold camshaft sprocket with Special Tool C-4687 and adapter C-4687-1 while removing center bolt (Fig.
  • Page 773 TIGHTEN NUT TO INSTALL SPECIAL TOOL SEAL 6780 SPECIAL TOOL PROTECTOR 6792 2.4L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 65 Crankshaft Sprocket—Removal Fig. 67 Front Crankshaft Oil Seal—Installation Fig. 66 Front Crankshaft Oil Seal—Removal (2) Place seal into opening with seal spring towards the inside of engine.
  • Page 774 SPECIAL 6792–2 INSTALLER SPECIAL TOOL 6926–1 PILOT TOOL REAR CRANKSHAFT M12–1.75 WASHER BEARING SCREW- DRIVER FROM 150 MM BOLT, SEAL TOOL 6792 SPECIAL THRUST ENGINE BLOCK REAR CRANKSHAFT SEAL ENGINE BLOCK CRANK- REAR SHAFT SHAFT SCREW- METAL CASE DUST LIP PRY IN THIS DIRECTION CRANK-...
  • Page 775 2.4L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) (7) Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when remov- ing the crankshaft. INSTALLATION Fig. 74 Installing Main Bearing Upper Shell (1) Install the main bearing shells with the lubri- cation groove in the cylinder block (Fig.
  • Page 776 FRONT OF ENGINE CRANKSHAFT SPROCKET SPECIAL TOOL 6793 9 - 40 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) filter on until the gasket contacts base. Tighten to 21 N·m (15 ft. lbs.). OIL PUMP REMOVAL (1) Disconnect negative battery cable. (2) Remove Timing Belt. Refer to Timing Belt Removal in this section.
  • Page 777 APPLY GASKET MAKER TO OIL PUMP BODY FLANGE OIL PICK-UP TUBE OIL PUMP BODY GASKET WINDAGE TRAY DRAIN PLUG OIL PAN COLLAR O-RING FILTER WITH 2.4L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) SPECIAL TOOL PROTECTOR SEAL 6780 Fig. 78 Oil Pump and Pick-up Tube Fig.
  • Page 778 DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA TIGHTEN NUT TO INSTALL SPECIAL TOOL 6792 9 - 42 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) (6) Install crankshaft sprocket, using Special Tool covered during this operation . Mark piston with 6792 (Fig. 81). matching cylinder number (Fig.
  • Page 779 2.4L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) Fig. 85 Piston—Installation Fig. 86 Checking Connecting Rod Side Clearance Immerse the piston head and rings in clean (3) Remove pump rotors. engine oil, slide the ring compressor, over the piston Wash all parts in a suitable solvent and (Fig.
  • Page 780 FEELER GAUGE OIL PICK-UP TUBE OIL PUMP BODY GASKET WINDAGE TRAY DRAIN PLUG OIL PAN COLLAR O-RING FILTER WITH STRAIGHT EDGE MIDDLE BOTTOM CUT AWAY VIEW OF VALVE SUREMENT GUIDE LOCA- TIONS MEA- 9 - 44 2.4L ENGINE CLEANING AND INSPECTION (Continued) Fig.
  • Page 781 SPRING HEAT 13.25 - 13.75 MM (.521 - .541 IN.) VALVE GUIDE INNER ROTOR ROTOR OIL PUMP COVER OIL PUMP BODY OUTER ROTOR FASTENER O-RING SEAL OIL PUMP COVER STRAIGHT EDGE FEELER GAUGE 2.4L ENGINE 9 - 45 CLEANING AND INSPECTION (Continued) Fig.
  • Page 782 FEELER GAUGE OUTER ROTOR STRAIGHT EDGE FEELER GAUGE INNER R OTOR 9 - 46 2.4L ENGINE OUTER FEELER GAUGE ROTOR CLEANING AND INSPECTION (Continued) Fig. 94 Measuring Outer Rotor Thickness Fig. 97 Measuring Clearance Between Rotors Fig. 95 Measuring Inner Rotor Thickness Fig.
  • Page 783 FRONT MIDDLE OF BORE SIZING PISTON 2.4L ENGINE 9 - 47 CLEANING AND INSPECTION (Continued) 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. Refer to (Fig. 101) for specifications. Fig.
  • Page 784 9 - 48 2.4L ENGINE ADJUSTMENTS (Continued) (4) Pry the engine right or left as required to achieve Piston Ring Gap the proper drive shaft assembly length. Refer to Group Top Compression Ring ..0.25 - 0.51 mm 2, Suspension and Driveshaft for driveshaft identifica- (0.0098 - 0.020 in.) tion and related assembly length measuring.
  • Page 785 2.4L ENGINE 9 - 49 SPECIFICATIONS (Continued) Camshaft Bearing Bore Diameter No. 1-6 ........26.020 - 26.041 mm (1.024 - 1.025 in.) Diametrical Bearing Clearance .
  • Page 786 9 - 50 2.4L ENGINE SPECIFICATIONS (Continued) TORQUE CHART 2.4L DESCRIPTION ....TORQUE DESCRIPTION ....TORQUE Balance Shaft Carrier to Block Exhaust Manifold Heat Shield Bolts .
  • Page 787 2.4L ENGINE 9 - 51 SPECIAL TOOLS ENGINE 2.4L Cradle 6710 Puller 1026 Post Kit Engine Cradle 6848 Crankshaft Damper Removal Insert6827-A Camshaft Sprocket Remover C-4687 Dolly 6135 Camshaft Seal Remover C-4679-A...
  • Page 788 9 - 52 2.4L ENGINE SPECIAL TOOLS (Continued) Camshaft Seal Installer MD-998306 Cylinder Bore Gage C-119 Crankshaft Damper Installer 6792 Crankshaft Sprocket Remover 6793 Valve Spring Compressor MD-998772-A Crankshaft Sprocket Remover InsertC-4685-C2 Valve Spring Compressor Adapter 6779 Crankshaft Seal Remover 6771...
  • Page 789 2.4L ENGINE 9 - 53 SPECIAL TOOLS (Continued) Post Adapter 8130 Oil Pressure Gage C-3292 Front Crankshaft Oil Seal Installer6780 Rear Crankshaft Seal Guide and Installer6926-1 and 6926-2 Balance Shaft Sprocket Installer6052 Post Kit Engine Cradle 6848...
  • Page 790 9 - 54 2.5L ENGINE 2.5L ENGINE INDEX page page DESCRIPTION AND OPERATION OIL FILTER ......79 ENGINE COMPONENTS .
  • Page 791 AND VIN NUMBER SERIAL NUMBER ENGINE FILTER 2.5L ENGINE 9 - 55 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION The engine identification number is located on the rear of the cylinder block just below the cylinder head (Fig. 1). Fig. 1 Engine Identification ENGINE—2.5L...
  • Page 792 CYLINDER WALLS SPLASH LUBRI- CATED FROM DIRECTED HOLES IN * NO. 2 CAMSHAFT CAP (FRONT AND REAR) RECEIVES OIL FROM CYLINDER HEAD TO SUPPLY ROCKERS, LASH ADJUSTERS, CAMSHAFT JOURNALS CONNECTING RODS CYLINDER CAMSHAFT BOLTS HEAD JOUR- NALS PICKUP CAMSHAFT JOURNALS PUMP RELIEF VALVE MAIN...
  • Page 793 2.5L ENGINE 9 - 57 DESCRIPTION AND OPERATION (Continued) the oil pump case and the rear is retained in a die- adjusters assemblies which pivot on rocker arm cast aluminum block-mounted housing. shafts. All valves have 6 mm diameter chrome plated valve stems.
  • Page 794 PISTON O.D. MENT LOCATION MEASURE- FEELER GAUGE 9 - 58 2.5L ENGINE SERVICE PROCEDURES (Continued) Fig. 5 Measuring Piston for Clearance andWear Fig. 3 Measure Cylinder Bore cylinder bore. Check gap with feeler gauge (Fig. 6). Refer to (Fig. 7) for specification. Fig.
  • Page 795 2.5L ENGINE 9 - 59 SERVICE PROCEDURES (Continued) SPACER EXTENDER NO. 2 PISTON RING PISTON RING OIL RING SIDE RAIL NO. 2 RING GAP AND SPACER RING SIDE EXPANDER GAP UPPER RAIL NO. 2 RING - INSTALL FIRST SIDE LOWER NO.
  • Page 796 9 - 60 2.5L ENGINE SERVICE PROCEDURES (Continued) (11) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin cen- ter or on the thrust direction. CONNECTING ROD CLEARANCE (1) Follow the procedures outlined in the Standard Service Procedures Section for Measuring Main Bear- ing and Connecting Rod Bearing Clearances.
  • Page 797 2.5L ENGINE 9 - 61 SERVICE PROCEDURES (Continued) PLASTIGAGE MEASUREMENT (1) Measure the crankshaft journal diameter and (1) Remove oil from journal and bearing shell. confirm its classification from the following (Fig. 20). (2) Install crankshaft. In the case of a bearing supplied as a service part, its (3) Cut plastigage to same length as width of the identification color is painted at the position show in bearing and place it in parallel with the journal axis...
  • Page 798 IDENTIFICATION COLOR 9 - 62 2.5L ENGINE SERVICE PROCEDURES (Continued) CAMSHAFT END PLAY (1) Oil camshaft journals and install camshaft without rocker arm assemblies. (2) Using a suitable tool, move camshaft as far rearward as it will go. (3) Zero dial indicator (Fig. 24). (4) Move camshaft as far forward as it will go.
  • Page 799 2.5L ENGINE 9 - 63 REMOVAL AND INSTALLATION (Continued) ENGINE MOUNT—RIGHT/ENGINE SUPPORT BRACKET NOTE: The right side engine mount is a Hydro- Mount and may show surface cracks this will not effect it’s performance and should not be replaced. Only replace the Hydro-Mount when it’s leaking fluid.
  • Page 800 9 - 64 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (1) Support the transmission with a transmission (15) Disconnect exhaust pipe from manifold. jack. (16) Remove front and rear engine mount brackets (2) Remove the three vertical bolts, from the from the body. mount to the transmission.
  • Page 801 SPECIAL ADJUSTABLE SPECIAL TOOL SUP- PORT BARS 6810-3A NO. 6848 POSTS TOOL SPECIAL SPECIAL SPECIAL ENGINE CRADLE NO. 6810 TOOL DOLLY NO. 6135 TOOL NO. 6810 CRADLE ENGINE ENGINE TOOL 2.5L ENGINE 9 - 65 REMOVAL AND INSTALLATION (Continued) (7) Install power steering pump and reservoir. Refer to Group 7, Cooling System Accessory Drive Section for belt tension adjustment.
  • Page 802 INTAKE CAMSHAFT INTAKE ROCKER ARM ROCKER ARMS CYLINDER (RIGHT SIDE) COVER SHAFT HEAD SEAL SPRINGCAP GASKET BREATHER HOSE VALVE STEM SEAL SPRING SEAT HEAD GASKETS WASHER SPRING VALVE CYLINDER HEAD BOLT SPRING PCV VALVE RETAINER LOCKS SEAL O-RINGEXHAUST CYLINDER HYDRAULIC LASH CAMSHAFT EXHAUST CAMSHAFT (LEFT...
  • Page 803 SPECIAL TOOL MD998443 2.5L ENGINE 9 - 67 REMOVAL AND INSTALLATION (Continued) TIMING BELT END CYLINDER HEAD BOLT AND WASHER 1 0 mm ALLEN (3) Remove upper intake manifold assembly. Refer EXHAUST ROCKER INTAKE ROCKER ARMS ARMS ROCKER SHAFT RETAINERS ROCKER SPRINGS SHAFT...
  • Page 804 ROCKER EXHAUST INTAKE SPRING ORIENTATION ROCKER ROCKER TIGHTEN SEQUENCE TIGHTEN SEQUENCE SHAFT DIRECTIONAL SHAFT SHAFT FLAT HYDRAULIC ADJUSTER EXHAUST LASH INTAKE ROCKER ROCKER TIGHTEN SEQUENCE SPECIAL TIGHTEN SEQUENCE MD998443 TOOL SHAFT SHAFT ROLLER ROCKER ARM 9 - 68 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 805 MOUNTING ADAPTER 6865 POST 6886 FORCING FORCING ARM 6887 SCREW 6765 SCREW SPECIAL MD998774 TOOL 2.5L ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued) (2) Using a suitable tool, move camshaft as far INSTALLATION rearward as it will go. (1) Install valve seal (Fig. 43) as outlined in valve (3) Zero dial indicator (Fig.
  • Page 806 WHEELHOUSE SPLASH SHIELD PUSH IN FASTENER NUT SNAP FENDER ACCESSORY BELT SPLASH SHIELD PUSH IN FAS TENER FASCIA DRIVE SILVER INTAKE SPECIAL MD998774 TOOL EXHAUST BLACK ENAMELED END SPRING SPRING SEAT RETAINER STEM SEAL VALVE STEM SEAL 9 - 70 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (2) Remove valve stem seals with suitable tool...
  • Page 807 BOLT 182 N·m (134 FT. TORQUE CRANKSHAFT BOLT LBS.) SQUARE WASHER 1/2” CRANKSHAFT SPROCKET RUBBER 2.5L ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) ENGINE BRACKET UPPER BELT COVER FASTENERS LOWER TIMING BELT COVER FASTENERS TENERS RIGHT FAS- TIMING UPPER LEFT COVER FASTENERS TIMING...
  • Page 808 ENGINE 45 N·m (33 ft. lbs.) BRACKETTENSIONER MOUNT 23 N·m (17 ft. CAMSHAFT SPROCKET BOLT PULLEY TENSIONER UPPER RIGHT TIMING lbs.) 48 N·m (35 ft. 88 N·m (65 ft. lbs.) BELT COVER lbs.) 44 N·m (33 ft. CAMSHAFT SPROCKET TENSIONER lbs.) TIMING BELT CRANKSHAFT...
  • Page 809 LOCKING PIN SOFT JAW VISE TIMING MARKS 2.5L ENGINE 9 - 73 REMOVAL AND INSTALLATION (Continued) (3) Install timing belt on rear camshaft sprocket first and install a binder clip on the belt and sprocket so the belt will not slip out of position. Keeping the RIGHT SPROCKET ALIGN TIMING MARKS...
  • Page 810 SPECIAL TOOL 6847 9 - 74 2.5L ENGINE SPECIAL MD-998713 TOOL SPECIAL TOOL 6863 SEAL CAMSHAFT REMOVAL AND INSTALLATION (Continued) (8) Pull tensioner plunger pin. CAMSHAFT OIL SEAL (9) Rotate crankshaft 2 revolutions in a clockwise (1) Apply light coat of engine oil to the camshaft direction ONLY and check the alignment of the tim- oil seal lip.
  • Page 811 OIL PICKUP GASKET DRAIN PLUG BOLT GASKET SCREW 2.5L ENGINE 9 - 75 REMOVAL AND INSTALLATION (Continued) OIL PAN (3) Remove engine support module. Refer to proce- dure in this section. (4) Remove dipstick tube. REMOVAL (1) Disconnect battery negative remote cable (Fig. (5) Remove starter motor.
  • Page 812 FASTENER LENGTH OIL PUMP ASSEM- SEAL TORQUE GASKET THRUST BEARINGS MAIN (2 PAIRS) UPPER ING (GROOVED) BEARING BEAR- LOCK CAP MONOB- CASE SEAL 25 mm (.984 INCH) 10 N·m (88 IN. LBS.) 55 mm (2.165 INCH) 15 N·m (130 IN. LBS.) 60 mm (2.362 INCH) 83 N·m (61 FT.
  • Page 813 25 MM (1 IN.) 30 MM (1 3/16 IN.) 60 MM (2 3/8 IN.) 10mm (104 IN. 31/32 IN.) 50 MM (1 LBS.) 2.5L ENGINE 9 - 77 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install upper main bearing shells making cer- tain oil holes are in alignment, and bearing tabs seat in block tabs.
  • Page 814 GROOVED THRUST WITHOUT TAB BEARING THRUST BEAR- ING WITH TAB FRONT MONOBLOCK BEARING CAP MAIN PLAIN 9 - 78 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) CRANKSHAFT FRONT BEARING CAP BEARING BOLT CYLINDER BLOCK TIMING BELT END Fig. 69 Install Main Bearings Fig.
  • Page 815 2.5L ENGINE 9 - 79 REMOVAL AND INSTALLATION (Continued) CHECKING CRANKSHAFT END PLAY (1) Mount a dial indicator to front of engine, locat- ing probe on nose of crankshaft (Fig. 71). (2) Move crankshaft all the way to the rear of its travel.
  • Page 816 9 - 80 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) “L” ARROW TOWARD FRONT OF FORWARD CYLINDERS 2-4-6 ENGINE FACE CYLINDER NUM- Fig. 77 Oil Pump Sealing 25 MM (1 IN.) 30 MM (1 3/16 IN.) 60 MM (2 3/8 IN.) 31/32 IN.) 50 MM (1 Fig.
  • Page 817 2.5L ENGINE 9 - 81 REMOVAL AND INSTALLATION (Continued) (3) Upper oil ring side rail. (4) Lower oil ring side rail. (5) No. 2 Intermediate piston ring. (6) No. 1 Upper piston ring. (7) Install the side rail by placing one end between the piston ring groove and the expander.
  • Page 818 9 - 82 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLING PISTON AND CONNECTING ROD (1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.
  • Page 819 2.5L ENGINE 9 - 83 DISASSEMBLY AND ASSEMBLY (Continued) ROCKER ARM SHAFTS The rocker arm shafts is hollow and is used as a lubrication oil duct. (1) Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or worn.
  • Page 820 MIDDLE OF BORE FRONT USE FOR SIZ- ING PISTON 9 - 84 2.5L ENGINE MIDDLE BOTTOM CUT AWAY VIEW OF VALVE SUREMENT GUIDE LOCA- TIONS MEA- CLEANING AND INSPECTION (Continued) CYLINDER HEAD Fig. 94 Checking Cylinder Head Flatness (1) Before cleaning, check for leaks, damage and cracks.
  • Page 821 2.5L ENGINE 9 - 85 CLEANING AND INSPECTION (Continued) HYDRAULIC GASKET BRACKET ADJUSTER LASH SPECIAL FILTER MD998443 TOOL ROLLER 23 N·m (17 IN. LBS.) ROCKER ARM ROCKER ARM Inspect the rocker arm/hydraulic lash adjuster assembly for wear or damage (Fig. 98). Replace assembly as necessary.
  • Page 822 (0.0015 TO 0.0035 INCH) 0.04 TO 0.09 mm 9 - 86 2.5L ENGINE CLEANING AND INSPECTION (Continued) ALIGNMENT MARKS OIL PUMP OIL PUMP BODY SEAL INNER R OTOR OUTER PLUG ROTOR RELIEF PUMP COVER SPRING VALVE PRESSURE RELIEF VALVE O-RINGS SCREW PLUG (1) Check oil pump case for damage and remove...
  • Page 823 ENGINE BRACKET UPPER BELT COVER FASTENERS LOWER TIMING BELT COVER FASTENERS TENERS RIGHT FAS- TIMING UPPER LEFT COVER FASTENERS TIMING BELT MARK AND IS NOT FULL WIDTH OF THE FACE SEAT CONTACT MARGIN 2.5L ENGINE 9 - 87 CLEANING AND INSPECTION (Continued) VALVES, SPRINGS, SEATS AND GUIDES TOOTH CANVAS...
  • Page 824 9 - 88 2.5L ENGINE CLEANING AND INSPECTION (Continued) (7) Measure valve stem to guide clearance. Refer ADJUSTMENTS to specification (Fig. 109). (8) Measure Valve spring free length and if the ENGINE SUPPORT ADJUSTMENT spring is square (Fig. 108). Refer to (Fig. 109) for The right and left support assemblies are slotted to specifications.
  • Page 825 2.5L ENGINE 9 - 89 SPECIFICATIONS ENGINE 2.5L DESCRIPTION STANDARD DIMENSION DESCRIPTION STANDARD DIMENSION AND SERVICE LIMIT AND SERVICE LIMIT Valve Timing Valve Guide Intake—Open ....19° BTDC Height .
  • Page 826 9 - 90 2.5L ENGINE SPECIFICATIONS (Continued) ENGINE SPECIFICATIONS (CONT.) Description Standard Dimension Service Limit Piston O.D. 83.5 mm — (3.29 inches) Piston to Cylinder Clearance 0.02 to 0.04 mm — (0.0008 to 0.0016 inch) Ring End Gap 0.25 to 0.40 mm 0.8 mm No.
  • Page 827 2.5L ENGINE 9 - 91 SPECIFICATIONS (Continued) TORQUE CHART 2.5L DESCRIPTION TORQUE Intake Manifold Plenum Bolt ..........18 N·m (13 ft. lbs.) Intake Manifold Plenum Support Bolt M8 .
  • Page 828 9 - 92 2.5L ENGINE SPECIAL TOOLS ENGINE 2.5L Installer MD-998713 Remover C-4679-A Installer MD-998718 Insert C-4685-C2 Compressor C-3422-B Installer MD-998717 Adapter 6526 Holders MD-998443...
  • Page 829 2.5L ENGINE 9 - 93 SPECIAL TOOLS (Continued) Wrench MD-998767 Installer 6052 Compressor MD-998772-A Dolly 6135 Installer MD-998774 Fixture Engine 6710 Puller 1026 Screw 6765...
  • Page 830 9 - 94 2.5L ENGINE SPECIAL TOOLS (Continued) Adapter 6779 Adapter 6885 Support Bar Cradle 6710-3A Posts 6886 Holder 6847 Adapter 6887 Engine Cradle Posts 6848 Camshaft Seal Installer 6863 Bracket Cradle Post Support 6973...

  • Page 831: Exhaust System And Intake Manifold

    CATALYTIC CONVERTER OXYGEN SENSOR 2.5 L TAILPIPE 2.5 L TAILPIPE RESONATOR FLEX JOINT FLEX JOINT SUPPORT SUPPORT MUFFLER CLAMP CLAMP EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 EXHAUST SYSTEM AND INTAKE MANIFOLD CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CATALYTIC CONVERTERS .

  • Page 832: General Information

    GENERAL INFORMATION (Continued) Fig. 2 Band Clamp CATALYTIC CONVERTERS There is no regularly scheduled maintenance on any Chrysler catalytic converter. If damaged, the con- verter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts.
  • Page 833 RESONATOR HEAT SHIELD HEAT SHIELD EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3 GENERAL INFORMATION (Continued) FLANGE BELLOWS END CAPS Fig. 4 Heat Shield—JX ing temperature increases in the area of the catalytic engine moves, preventing breakage that could occur convertor under severe operating conditions.

  • Page 834: Description And Operation Intake/Exhaust Manifold-2.4L Engine

    REAR EXHAUST MANIFOLD REAR HEAT SHIELD EXHAUST MANIFOLD 30 N·m (22 ft. lbs.)13 N·m (10 ft. lbs.) RIGHT SIDE MANIFOLD SUP- UPPER INTAKE MANIFOLD 18 N·m (13 ft. lbs.) LOWER MANIFOLD LOWER INTAKE MANIFOLD PORT NUT 59 N·m (43 ft. INTAKE 18 N·m (13 ft.

  • Page 835: Diagnosis And Testing Exhaust System

    EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5 DIAGNOSIS AND TESTING EXHAUST SYSTEM CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE EXHAUST NOISE (a) Exhaust manifold cracked or (a) Replace manifold (UNDER HOOD) broken (b) Manifold to cylinder head leak (b) Tighten manifold and/or replace gasket (c) EGR Valve to manifold gasket (c) Tighten fasteners or replace...

  • Page 836: Removal And Installation

    CATALYTIC CONVERTER OXYGEN SENSOR 2.5 L TAILPIPE 2.4 L TAILPIPE RESONATOR FLEX JOINT FLEX JOINT SUPPORT SUPPORT MUFFLER CLAMP CLAMP 11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (6) Vehicle equipped with 2.5L engine disconnect upstream heated oxygen sensor. EXHAUST PIPE AND MUFFLER (7) Remove catalytic converter to exhaust manifold attaching fasteners (Fig.
  • Page 837 OXYGEN SENSORS OXYGEN SENSORS SHOULDER BOLT 2.4L ENGINE 2.5L ENGINE 2.0L ENGINE SEAL RING GASKET GASKET SPRING BOLT EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7 REMOVAL AND INSTALLATION (Continued) (2) Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody (Fig. 9). (3) Install the muffler to resonator pipe and attach to the supports on the underbody (Fig.
  • Page 838 REAR MUFFLER SUPPORT RESONATOR SUPPORT ISO- MUFFLER/FRONT PIPE SUP- TORQUE SPECI- PORT ISOLATOR GROUND STRAP ISOLATORS FICATION FASTENER LATORS AUXILIARY JUMPER TERMINAL AIR CLEANER HOUSING CLAMP SIZE LEFT STRUT TOWER 11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) INTAKE AIR TEMPERATURE TO LEAK DETECTION PUMP THROTTLE BODY...
  • Page 839 VACUUM SOURCE VAPOR VACUUM SOURCE BRAKE IDLE CONTROL MOTOR MAP SENSOR CANISTER BOOSTER THROTTLE POSITION SENSOR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9 REMOVAL AND INSTALLATION (Continued) Fig. 15 Tube Assembly—Typical Fig. 13 Idle Air Control (IAC) Motor and Throttle Position Sensor (TPS) Wiring Connectors and Vacuum Hose Connection.

  • Page 840: Exhaust Manifold-2.4L Engine

    HEATED OXYGEN SENSOR HEAT SHIELD ATTACHING SCREWS 11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) teners at the EGR valve first to 11 N·m (95 in. lbs.) INSTALLATION then, tighten the intake manifold side fasteners to 11 (1) Install new manifold gasket.

  • Page 841: Intake Manifold/Plenum-2.5L Engine

    REAR EXHAUST MANIFOLD REAR HEAT SHIELD EXHAUST MANIFOLD 30 N·m (22 ft. lbs.)13 N·m (10 ft. lbs.) RIGHT SIDE MANIFOLD SUP- UPPER INTAKE MANIFOLD 18 N·m (13 ft. lbs.) LOWER MANIFOLD LOWER INTAKE MANIFOLD PORT NUT 59 N·m (43 ft. INTAKE 18 N·m (13 ft.
  • Page 842 11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) SPEED CONTROL CABLE THROTTLE CABLE THROTTLE BODY SUPPORT BRACKET BOLT THROTTLE POSITION SENSOR MAP SENSOR INTAKE PERATURE TEM- SEN- RELEASE TANG BOLTS TUBE EGR TUBE SUPPORT BRACKET BOLT Fig.
  • Page 843 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13 REMOVAL AND INSTALLATION (Continued) (15) Remove 7 bolts holding upper intake plenum (3) Insert fuel injector nozzles into openings in and remove plenum (Fig. 19). intake manifold. Seat the injectors in place. Tighten (16) Disconnect electrical connectors from fuel fuel rail bolts to 12 N·m (8 ft.

  • Page 844: Exhaust Manifold-2.5L Engine

    REAR OF INTAKE MANI- REAR EXHAUST MANIFOLD FOLD FLANGE HEAT SHIELD 11 - 14 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) (3) Inspect manifolds for cracks or distortion. Replace manifold if necessary. INTAKE MANIFOLD—2.5L ENGINE (1) Discard gasket and clean all gasket surfaces of manifold to cylinder heads.
  • Page 845 HEADLAMP FRONT BUMPER FORCEMENT ASSEMBLY ADAPTER FENDER GRILLE FASCIA REIN- BUMPERS AND FRAME 13 - 1 BUMPERS AND FRAME CONTENTS page page BUMPERS ......1 FRAME .
  • Page 846 UPPER RADIATOR SUPPORT HEADLAMP CROSSMEMBER FRONT FASCIA ASSEMBLY ADAPTER REAR BUMPER FASCIA QUARTER PANEL TRUNK FRONT BUMPER ENERGY FRONT MANAGEMENT FOAM BUMPER FORCEMENT REIN- REAR BUMPER REINFORCE- MENT 13 - 2 BUMPERS AND FRAME REMOVAL AND INSTALLATION (Continued) (3) Remove screws holding fascia to rear closure panel and nuts securing to inner quarter panel (Fig.
  • Page 847 ENERGY REAR BUMPER FASCIA MANAGEMENT FOAM BUMPERS AND FRAME 13 - 3 REMOVAL AND INSTALLATION (Continued) (7) Install push-in fasteners holding rear fascia to (2) Support bumper reinforcement on a suitable rear bumper reinforcement. lifting device. (8) Install nuts holding rear fascia to inner quarter (3) Mark position of nuts on frame rail to aid in panel.
  • Page 848 FRONT CROSSMEMBER SUSPENSION ENGINE RADIATOR CLOSURE PANEL PORT MODULE R ADIATOR SUPPORT SUP- CROSSMEMBER 13 - 4 BUMPERS AND FRAME FRAME INDEX page page REMOVAL AND INSTALLATION SPECIFICATIONS ENGINE SUPPORT MODULE ....4 FRAME DIMENSIONS .
  • Page 849 STEERING GEAR FRONT CROSSMEMBER SUSPENSION ISOLATOR CLAMP BUMPERS AND FRAME 13 - 5 REMOVAL AND INSTALLATION (Continued) (12) Remove bolts holding rear of crossmember to SPECIFICATIONS frame rail torque boxes. (13) Lower front suspension crossmember away TORQUE SPECIFICATIONS from bottom of vehicle. DESCRIPTION TORQUE Rear Bumper Reinforcement...
  • Page 850 D = STRUT FORWARD NUT E = STRUT REARWARD NUT A = RADIATOR INSULATOR B = FENDER FRONT BOLT C = HOOD SLAM BUMPER OUTBOARD INBOARD 13 - 6 BUMPERS AND FRAME SPECIFICATIONS (Continued) VEHICLE PREPARATION Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface.
  • Page 851 A = BOTTOM OF EXTENSION C = ENGINE COMPARTMENT B = ENGINE COMPARTMENT B = BOTTOM OF RADIATOR C = FRONT MID PLP TO REAR MID PLP A = FRONT PLP REAR PLP REAR PLP D = PLP BUMPERS AND FRAME 13 - 7 SPECIFICATIONS (Continued) Fig.
  • Page 852 B = CENTER OF TRACK BAR CENTER A = REAR MID PLP CROSSMEMBER D = REAR PLP ZERO PLANE MOUNT REAR 13 - 8 BUMPERS AND FRAME SPECIFICATIONS (Continued) Fig. 6 Rear Frame Section Side View...
  • Page 853 B = REAR RAIL TO FLOOR C = CENTER OF TRACK BAR CENTER OF RADIUS AT TOP CORNER TO CENTER OF RADIUS AT BOTTOM COR- CENTER TO FRONT MID PLP A = REAR MID PLP CROSSMEMBER E = REAR PLP LOCATOR MOUNT REAR...
  • Page 854 CENTER OF MASTER GAGE A. DOOR OPENING PLP TO TOP CORNER OF OPPOSITE B. DOOR OPENING PLP TO OPPOSITE DOOR OPENING C. CENTER OF 25 mm SUN- VISOR HOLE TO OPPOSITE DOOR OPENING PLP. B-PILLAR. VIEW A VIEW A SLOT PLP.
  • Page 855 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....3 GENERAL INFORMATION ....1 FUEL INJECTION SYSTEM .
  • Page 856 Problems that are the result of using methanol/ mance and lowest emissions operating on high qual- gasoline blends are not the responsibility of Chrysler ity unleaded gasoline, it will perform equally well Corporation and may not be covered by the vehicle and produce even lower emissions when operating on warranty.
  • Page 857 INLET STRAINER FUEL RESERVOIR FUEL LEVEL SENSOR FUEL PRESSURE REGULATOR FUEL SYSTEM 14 - 3 FUEL DELIVERY SYSTEM INDEX page page DESCRIPTION AND OPERATION FUEL TANK DRAINING ....10 FUEL DELIVERY SYSTEM .
  • Page 858 FUEL TANK The fuel tanks of all Chrysler Motors built vehicles are equipped with fuel and vapor controls that allow the vehicle to pass a full 360° rollover without fuel leakage.
  • Page 859 RETAINER “EAR” CASING WINDOW WINDOW RETAINER TAB O RINGS NIPPLE FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pres- sure required to open the return port. The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine vacuum.
  • Page 860 14 - 6 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (3) Place ignition key in the ON position. Using DRB scan tool, access ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. •...
  • Page 861 FUEL RELEASE ADAPTER 6539 BETWEEN FUEL PUMP AND FUEL FIL- TER. CONNECT GAUGE C-4799B TO ADAPTER. PRES- PRESSURE SPECIFICATIONS FUEL RESTRICTION BETWEEN FUEL PUMP INLET AND FUEL SUPPLY NIP- FUEL INLET STRAINER PLUGGED REPLACE INLET STRAINER FUEL PRESSURE STILL LOW BELOW SURIZE SYSTEM.
  • Page 862 LEVEL SENSOR FULL STOP 50 OHMS MINIMUM SENSOR EMPTY STOP 1050 GROUND SENSOR FUEL PUMP MODULE CONNECTOR TER- FLOAT POSITION (HEIGHT) FUEL PUMP GROUND 10 OHMS FLOAT POSITION FLOAT MINAL PIN-OUTS LEVEL SENSOR SIGNAL FUEL PUMP VOLTAGE SUP- FUEL LEVEL SENSOR RESISTANCE 6539 FUEL...
  • Page 863 CHECK POWER FEED AND GROUND BETWEEN PCM AND THE INJECTOR REFER GRAMS FOR COLOR CODES AND PIN TERMINAL NUM- TEST THE ENGINE CON- TROL SYSTEM WITH THE CIRCUIT IS OK. CHECK FOR FUEL DELIVERY AT SUS- PECT INJECTOR BY REMOV- ING THE INJECTOR FROM THE RAIL AND OBSERVING RESTRICTIONS IN THE RAIL...
  • Page 864 FUEL TANK DRAIN PLUG 14 - 10 FUEL SYSTEM SERVICE PROCEDURES FUEL SYSTEM PRESSURE RELEASE PROCEDURE—2.5L FUEL SYSTEM PRESSURE RELEASE PROCEDURE—2.4L CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. WARNING: RELEASE FUEL SYSTEM PRESSURE (1) Disconnect the fuel rail electrical harness from BEFORE SERVICING FUEL SYSTEM COMPONENTS.
  • Page 865 SHOULDER (ON TUBE) WINDOW TAB (2) FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) HOSES AND CLAMPS (4) The plastic quick-connect fitting has windows in the sides of the casing. When the fitting com- Inspect all hose connections (clamps and quick con- pletely attaches to the fuel tube, the retainer locking nect fittings) for completeness and leaks.
  • Page 866 BATTERY POSITIVE BATTERY GROUND AIR CLEANER 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) CAUTION: The interior components (o-rings, spac- REMOVAL AND INSTALLATION ers, retainers) of this type of quick-connect fitting AUTOMATIC SHUTDOWN RELAY are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes.
  • Page 867 FUEL PUMP MOD- O-RING FUEL SYSTEM 14 - 13 REMOVAL AND INSTALLATION (Continued) (6) Using Special Tool #6856 Fuel Pump Module ule flange sits in the corresponding notch in the fuel Ring Spanner, remove locknut to release pump mod- tank. ule (Fig.
  • Page 868 TABS (4) PRY BETWEEN REGULATOR AND HOUSING FUEL REGULATOR PRESSURE FUEL FILTER FUEL PUMP MODULE LOCK FUEL LINES RING 14 - 14 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) WARNING: WRAP SHOP TOWELS AROUND (2) Install fuel tank, filter and tank straps, install HOSES TO CATCH ANY GASOLINE SPILLAGE.
  • Page 869 UPPER O-RING LOWER 0-RING TABS INLET STRAINER FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) (4) Install fuel pump module. Refer to Fuel Pump Module Installation in this section. FUEL LEVEL SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module in this section.
  • Page 870 WRAP PUMP MODULE WIRES GROOVE CHANNEL LEVEL SENSOR REAR VIEW SENSOR LEVEL 14 - 16 FUEL SYSTEM OPENING IN MODULE FUEL LEVEL SENSOR REMOVAL AND INSTALLATION (Continued) (3) Insert a screwdriver between the fuel pump module and the top of the level sensor housing (Fig. 23).
  • Page 871 FUEL SYSTEM 14 - 17 IGNITION COIL FUEL RAIL FUEL QUICK- CONNECTS LINE SUPPORT BRACKET BOLT MAP SENSOR INTAKE PERATURE TEM- SEN- FUEL SUP- FUEL INJEC- PLY LINE REMOVAL AND INSTALLATION (Continued) (7) Install fuel pump module. Refer to Fuel Pump (4) Connect fuel supply tube to fuel rail.
  • Page 872 FUEL RAIL THROTTLE POSITION SEN- SPEED CONTROL THROTTLE CABLE BODY THROTTLE POSITION SENSOR THROTTLEBODY IDLE THROTTLE CABLE CONTROL MOTOR BOLTS TUBE EGR TUBE SUPPORT BRACKET BOLT BOLTS RELEASE TANG 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (10) Unplug TPS and idle air control motor con- (12) Slide Speed control cable out of bracket, if nectors (Fig.
  • Page 873 INJECTOR CLIP FUEL INJECTOR FUEL RAIL FUEL RAIL PLIERS FUEL INJECTOR INJECTOR CLIP FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. CAUTION: Make sure spacers are located under each fuel rail mounting position.
  • Page 874 FUEL FILLER HOSE FUEL TANK DRAIN PLUG HOSE CLAMP FUEL INLET TANK FUEL PUMP MODULE REAR CROSS MEM- FUEL TANK VAPOR FUEL FILTER FUEL TANK LINE 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Remove drain plug and allow fuel to drain (Fig. 38).
  • Page 875 FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) FUEL FILLER NECK INSTALLATION (1) Install rubber gromment in body housing (Fig. REMOVAL 43). Make sure chamfer is in the proper location (Fig. (1) Loosen fuel filler tube cap (Fig. 41). 44).
  • Page 876 DASHPANEL PEDAL S HAFT CABLE SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE CABLE TABS CLASP 14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) ACCELERATOR PEDAL REMOVAL (1) Remove the throttle cable from the throttle body cam as described in Throttle Cable of this sec- tion.
  • Page 877 THROTTLE CABLE THROTTLE LEVER FUEL SYSTEM 14 - 23 REMOVAL AND INSTALLATION (Continued) THROTTLE CABLE—2.5L REMOVAL (1) Working from the engine compartment, remove throttle cable from the throttle body lever (Fig. 48). Fig. 49 Throttle Cable Attachment (2) Install cable housing (throttle body end) into the cable mounting bracket on the engine.
  • Page 878 14 - 24 FUEL SYSTEM FUEL INJECTION SYSTEM INDEX page page GENERAL INFORMATION RADIATOR FAN RELAYS—PCM OUTPUT ..39 INTRODUCTION ..... . . 25 SCI RECEIVE—PCM INPUT .
  • Page 879 FUEL SYSTEM 14 - 25 SPECIFICATIONS (Continued) THROTTLE POSITION SENSOR (TPS)—2.4L . . 49 VEHICLE SPEED SENSOR ....56 THROTTLE POSITION SENSOR (TPS)—2.5L . . 50 SPECIFICATIONS UPSTREAM HEATED OXYGEN SENSOR—2.0/ TORQUE .
  • Page 880 14 - 26 FUEL SYSTEM GENERAL INFORMATION (Continued) • The number of engine revolutions since cranking IGNITION SWITCH ON (ZERO RPM) MODE When the ignition switch activates the fuel injec- was initiated tion system, the following actions occur: During Start-up the PCM maintains ignition tim- •...
  • Page 881 FUEL SYSTEM 14 - 27 GENERAL INFORMATION (Continued) instrument panel). Also, the PCM stores an engine The PCM may receive a closed throttle input from misfire DTC in memory. the Throttle Position Sensor (TPS) when it senses an The PCM performs several diagnostic routines. abrupt decrease in manifold pressure.
  • Page 882 BATTERY POSITIVE BATTERY GROUND AIR CLEANER 14 - 28 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) POWER DISTRIBUTION CENTER NOTE: PCM Inputs: The Power Distribution Center (PDC) is located • Air Conditioning Controls next to the battery (Fig. 1). The PDC contains the •...
  • Page 883 CAMSHAFT POSITION SEN- FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) • Engine speed (crankshaft position sensor) does not receive 12 volts from this input after • Knock sensor grounding the ASD relay, it sets a Diagnostic Trouble • Manifold absolute pressure Code (DTC).
  • Page 884 DISTRIBUTOR PULSE RING SYNC GENERATOR SIGNAL 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) 2.5L ENGINE The crankshaft position sensor mounts to the The 2.5L engine is equipped with a camshaft engine block behind the generator, just above the oil driven mechanical distributor.
  • Page 885 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) ENGINE COOLANT TEMPER- ATURE SENDING UNIT COOLANT FILLER CAP Fig. 8 Engine Coolant Temperature Sensor—2.5L Fig. 6 Crankshaft Position Sensor—2.5L Engine HEATED OXYGEN SENSORS—PCM INPUT As coolant temperature varies, the coolant temper- ature sensor resistance changes resulting in a differ- As vehicles accumulate mileage, the catalytic con- ent current draw from the PCM.
  • Page 886 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The heating element in the sensor provides heat to paring the downstream heated oxygen sensor input the sensor ceramic element. Heating the sensor to the input from the upstream sensor, the PCM cal- allows the system to enter into closed loop operation culates catalytic convertor efficiency.
  • Page 887 INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR MAP SENSOR SEN- INTAKE PERATURE SENSOR THROTTLE BODY TEM- STARTER MOTOR KNOCK SEN- FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) Fig. 15 Knock Sensor Fig. 13 Intake Air Temperature Sensor and MAP MAP sensor voltage decreases proportionately. Also, Sensor—2.4L as vacuum decreases, MAP sensor voltage increases proportionately.
  • Page 888 TROL MOTOR 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) SENSOR RETURN—PCM INPUT THROTTLE POSITION SENSOR—PCM INPUT The sensor return circuit provides a low electrical The throttle position sensor mounts to the side of noise ground reference for all of the systems sensors. the throttle body (Fig.
  • Page 889 BATTERY POSITIVE BATTERY GROUND AIR CLEANER FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) VEHICLE SPEED AND DISTANCE—PCM INPUT On-Board Diagnostics. When the ignition switch is in the On or Crank position, the PCM monitors the The transaxle output speed sensor supplies the crankshaft position sensor and camshaft position sen- vehicle speed and distance inputs to the PCM.
  • Page 890 ELECTRICAL CONNECTION EGR VALVE ELECTRICAL CONNECTION DRIVER’S MASTER CYLINDER SIDE TOWER STRUT EXHAUST VACUUM SUPPLY PRESSURE BACK VACUUM INLET EGR SOLENOID PRESSURE TRANSDUCER BACK BACK VACUUM TO EGR VALVE PRESSURE OUTLET HOSE DUTY CYCLE PURGE SOLENOID 14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure),...
  • Page 891 HOOD RELEASE THROTTLE POSITION SEN- DIAGNOSTIC DRIVER’S THROTTLEBODY IDLE KICK PANEL NECTOR SIDE CON- CONTROL MOTOR FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) IDLE AIR CONTROL MOTOR—PCM OUTPUT The Idle Air Control (IAC) motor is mounted on the throttle body.
  • Page 892 IGNITION COIL NOZZLE FUEL INJECTOR SPARK PLUG CABLE AND BOOT TOP (FUEL ENTRY) IGNITION COIL DISTRIBUTOR HOUSING COIL TOWER 14 - 38 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The PCM energizes the injectors in a sequential order during all engine operating conditions except start-up.
  • Page 893 FUEL SYSTEM 14 - 39 DESCRIPTION AND OPERATION (Continued) the PCM will be displayed. Refer to On-Board Diag- 5 VOLT SUPPLY—PCM OUTPUT nostics in Group 25, Emission Control Systems Diag- The PCM supplies 5 volts to the following sensors: nostic Trouble Code Descriptions. •...
  • Page 894 14 - 40 FUEL SYSTEM are fully seated in the PDC (Fig. 33). A label on the underside of the PDC cover shows the locations of each relay and fuse. (4) Inspect accelerator cable, and cruise control cable (if equipped) connections. Check their connec- tions to the throttle arm of the throttle body for any THROTTLE POSITION SEN- IDLE AIR CONTROL...
  • Page 895 INTAKE PCV VALVE MANI- FOLD FRONT COVER VALVE PCVVALVE INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR IGNITION COIL MAP SENSOR FUEL RAIL FUEL QUICK- CONNECTS LINE SEN- INTAKE PERATURE SENSOR THROTTLE BODY TEM- FUEL SUP- FUEL INJEC- PLY LINE FUEL SYSTEM 14 - 41 DIAGNOSIS AND TESTING (Continued) (6) Check hose connections between the PCV valve, vacuum port-intake manifold (Fig.
  • Page 896 SPARK PLUG CABLES DISTRIBUTOR SPARK CONNEC- INSULATOR TORS PLUG SPARK PLUG CABLE IGNITION COILS CAMSHAFT POSITION SEN- ELECTRICAL CONNECTION DRIVER’S MASTER CYLINDER STARTER MOTOR SIDE KNOCK TOWER STRUT SEN- DUTY CYCLE PURGE SOLENOID 14 - 42 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig.
  • Page 897 ENGINE COOLANT TEMPER- ATURE SENSOR INLET COOLANT FILL TUBE NECK ENGINE COOLANT TEMPER- ATURE SENDING UNIT COOLANT FILLER CAP FUEL SYSTEM 14 - 43 DIAGNOSIS AND TESTING (Continued) Fig. 46 Engine Coolant Temperature Sensor—2.4L Fig. 49 Electronic EGR Transducer—2.5L Engine Engine DISTRIBUTOR HOLD DOWN BOLT...
  • Page 898 OUTPUT SPEED SENSOR POWER PRESSURE SWITCH STEERING MANUAL VALVE LEVER DOWNSTREAM HEATED OXYGEN SENSOR EXHAUST MANIFOLD OXYGEN CATALYTIC RUBBER GROMMET UPSTREAM SORS SEN- VERTOR CON- CATALYTIC HEATED GEN SENSOR OXY- VERTER CON- 14 - 44 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (19) Check electrical connection at the vehicle speed sensor (Fig.
  • Page 899 REAR SEAT BACK FUEL PUMP MODULE CON- TRUNK FLOOR NUMBER TERMINAL LEGEND NECTOR COMMON FEED IDENTIFICATION COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED FUEL SYSTEM 14 - 45 DIAGNOSIS AND TESTING (Continued) (2) With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86.
  • Page 900 TER- MINAL 1 TER- MINAL 3 TER- MINAL 2 14 - 46 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) connector terminal 43 and the sensor harness con- (2) Test PCM terminal 29 for the same voltage nector. Refer to Group 8W, Wiring diagrams for cir- described in the previous step to verify wire harness cuit information.
  • Page 901 SPECIAL PURGE NIP- PURGE HOSE THROTTLE BODY #6457 TOOL FUEL SYSTEM 14 - 47 DIAGNOSIS AND TESTING (Continued) 2.4L Minimum Air Flow Idle Specifications 2.5L Minimum Air Flow Idle Specifications Fig. 61 Purge Hose—2.5L Engine tion. If idle air control motor is OK, replace throttle (4) Use a piece of hose to attach Air Metering Ori- body.
  • Page 902 SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE 14 - 48 FUEL SYSTEM SERVICE PROCEDURES CLEANING COKED THROTTLE BODIES Coked throttle bodies will cause low idle speed and poor idle quality. Also, if the vehicle has low idle and the idle air control motor operates normally, clean the throttle body before checking throttle body mini- mum air flow.
  • Page 903 SPEED CONTROL CABLE THROTTLE CABLE RELEASE TANG FUEL SYSTEM 14 - 49 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Attach electrical connectors to idle air control motor and throttle position sensor. (2) Install paper gasket. (3) Position throttle body on intake and install mounting bolts.
  • Page 904 14 - 50 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Remove throttle body. Refer to Throttle Body in (5) Remove throttle position sensor. this section. (3) Disconnect electrical connector from idle air control motor and throttle position sensor. (4) Remove throttle position sensor mounting screws.
  • Page 905 THROTTLE POSITION SENSOR THROTTLE SHAFT TABS RETAINER SCREWS IDLE AIR CONTROL MOTOR IDLE AIR CON- TROL MOTOR FUEL SYSTEM 14 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 71 Indexing Throttle Position Sensor—2.5L Engine Fig. 74 Throttle Position Sensor and Idle Air Control Motor—2.5L INSTALLATION (1) The new idle air control motor has a new...
  • Page 906 INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR MAP SENSOR SEN- INTAKE PERATURE SENSOR THROTTLE BODY TEM- 14 - 52 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Disconnect electrical connector from sensor. (2) Remove sensor. INSTALLATION (1) Install sensor. Tighten sensor to 28 N·m (20 ft. lbs.) torque.
  • Page 907 AUXILIARY JUMPER TERMINAL AIR CLEANER HOUSING POWERTRAIN CONTROL MODULE BRACKET SCREWS EXHAUST PIPE FLANGE CROW UPSTREAM OXYGEN SEN- WRENCH FOOT LEFT STRUT TOWER FUEL SYSTEM 14 - 53 REMOVAL AND INSTALLATION (Continued) (3) Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equiva- lent (Fig.
  • Page 908 DOWNSTREAM HEATED MOUNTING BOLTS OXYGEN SENSOR CATALYTIC AIR INLET RES- CONVERTOR ONATOR 14 - 54 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 80 Upstream Heated Oxygen Sensor Removal/ Fig. 81 Downstream Heated Oxygen Sensor Removal/Installation Installation REMOVAL (1) Raise vehicle. (2) Disconnect electrical connector from sensor.
  • Page 909 AIR INLET RESONA- RESONATOR B OLT AIR INLET RES- CLEANER ONATOR HOUSING COVER CLEANER HOUSING CLASPS FUEL SYSTEM 14 - 55 REMOVAL AND INSTALLATION (Continued) 2.4L REMOVAL (1) Loosen screw holding resonator to throttle body (Fig. 83). (2) Loosen clamp holding resonator to air inlet tube.
  • Page 910 ENGINE COOLANT TEMPER- HOUSING ATURE SENDING UNIT AIR CLEANER ELEMENT ENGINE COOLANT TEMPER- ATURE SENSOR COOLANT HOUSING INLET COOLANT FILL FILLER CAP COVER TUBE NECK 14 - 56 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 89 Engine Coolant Temperature Sensor—2.5L Engine INSTALLATION (1) Install coolant sensor.
  • Page 911 TRANSAXLE SPEED SENSOR RETAINING BOLT SPEED SENSOR FUEL SYSTEM 14 - 57 SPECIFICATIONS (Continued) TORQUE DESCRIPTION TORQUE Camshaft Position Semsor ..12 N·m (105 in. lbs.) Crankshaft Position Sensor . . . 12 N·m (105 in. lbs.) Engine Coolant Temperature Sensor .
  • Page 912 14 - 58 FUEL SYSTEM SPECIAL TOOLS FUEL Spanner Wrench 6856 Extractor C–4334 Metering Orifice Pressure Gauge Assembly C–4799–B Fuel Line Tool Fuel Pressure Test Adapter 6539 Fuel Line Adapter...
  • Page 913 FUEL SYSTEM 14 - 59 SPECIAL TOOLS (Continued) Fuel Line Adapter 1/4...
  • Page 915 STEERING 19 - 1 STEERING CONTENTS page page GENERAL INFORMATION ....1 POWER STEERING PUMP ....8 POWER STEERING GEAR .
  • Page 916 19 - 2 STEERING DIAGNOSIS AND TESTING noise similar to that experienced while slowly closing a water tap. The noise is present in every valve and STEERING DIAGNOSIS CHARTS results from high velocity fluid passing over the edges of the valve orifice. There is no relationship STEERING NOISE between this noise and the performance of the vehi- There is some noise in all power steering systems.
  • Page 917 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose touching the vehicle body, can create a noise level that could bring com- plaints.
  • Page 918 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) BINDING STICKING SEIZED CONDITION POSSIBLE CAUSES CORRECTION CATCHES, STICKS IN CERTAIN 1. Low power steering fluid level. 1. Fill power steering fluid reservoir to POSITIONS OR IS DIFFICULT TO specified level and perform leakage TURN.
  • Page 919 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) LOW ASSIST, NO ASSIST, HARD STEERING CONDITION POSSIBLE CAUSES CORRECTION STIFF, HARD TO TURN, SURGES, 1. Tires not properly inflated. 1. Inflate tires to specified pressure. MOMENTARY INCREASE IN EFFORT WHEN TURNING. 2.
  • Page 920 19 - 6 STEERING DIAGNOSIS AND TESTING (Continued) LOOSE STEERING CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING WHEEL 1. Air in the fluid of the power steering 1. Fill power steering fluid reservoir to KICKBACK OR TOO MUCH system. the specified level. Perform procedure STEERING WHEEL FREE PLAY.
  • Page 921 STEERING 19 - 7 DIAGNOSIS AND TESTING (Continued) POWER STEERING FLUID LEAK CONDITION POSSIBLE CAUSES CORRECTION LOW FLUID LEVEL WITH: NO 1. Overfilled power steering pump 1. Adjust the power steering fluid fill VISIBLE SIGNS OF A LEAK ON fluid reservoir. to the correct level.

  • Page 922: Power Steering Pump

    POWER POWER POWER POWER FLOW CONTROL VALVE FIT- FLUID SUPPLY FITTING STEERING STEERING STEERING STEERING SHAFT SEAL HOUSING SHAFT PUMP PUMP PUMP PUMP TING 19 - 8 STEERING POWER STEERING PUMP INDEX page page DESCRIPTION AND OPERATION POWER STEERING FLUID SUPPLY POWER STEERING FLUID PRESSURE HOSE–RESERVOIR TO POWER STEERING SWITCH .
  • Page 923 STEERING 19 - 9 DESCRIPTION AND OPERATION (Continued) • Power steering fluid reservoir filler cap/dipstick POWER STEERING FLUID PRESSURE SWITCH assemblies. On all vehicles, a power steering pressure switch WIRING HARNESS CONNEC- POWER STEERING PRES- POWER STEERING GEAR SURE SWITCH Because of unique shaft bearings, flow control lev- (Fig.
  • Page 924 POWER STEERING PRES- FLOW CONTROL VALVE FIT- POWER STEERING PUMP SURE HOSE ADAPTER TING TINGS FIT- SPECIAL TOOL 6815 19 - 10 STEERING DIAGNOSIS AND TESTING (Continued) flow test is performed using Pressure/Flow Tester, (5) Start engine and let idle long enough to circu- Special Tool 6815 (Fig.
  • Page 925 POWER FLOW CONTROL VALVE FIT- ABS HYDRAULIC CONTROL POWER STEERING PRES- POWER FLOW CONTROL VALVE FIT- POWER STEERING PRES- POWER STEERING PUMP UNIT HEAT SHIELD STEERING STEERING BANJO FITTING SUPPLY HOSE SURE HOSE SURE HOSE HOUSING FLUID PUMP TING TING STEERING 19 - 11 SERVICE PROCEDURES (Continued)
  • Page 926 POWER SUCTION FITTING ATTACH- POWER STEERING PUMP STEERING SUCTION FITTING ING BOLT PUMP WIRING HARNESS CONNEC- POWER STEERING PRES- POWER STEERING GEAR SURE SWITCH 19 - 12 STEERING SERVICE PROCEDURES (Continued) DISASSEMBLE (1) Remove power steering fluid supply hose from power steering pump suction port fitting.
  • Page 927 POWER STEERING RETURN HOSE POWER POWER STEERING PRES- EGR VALVE CYLINDER HEAD POWER BOLT TO BE REMOVED ROUTING BRACKET PRESSURE HOSE STEERING POWER STEERING GEAR SURE HOSE RESERVOIR STEERING BRACKET ROUTING FLUID BOLT POWER RETURN HOSE STEERING POWER STEERING RETURN POWER STEERING PRES- SURE HOSE HOSE...
  • Page 928 POWER STEERING PRES- FLOW CONTROL VALVE FIT- POWER STEERING PUMP POWER RETURN HOSE ROUTING SURE HOSE STEERING TING ROUTING ATTACHING BOLTS ROUTING BRACKETS BRACK- BRACKET POWER PRESSURE HOSE STEERING POWER STEERING PRES- SURE HOSE BANJO FITTING POWER STEERING PRES- SURE HOSE BANJO FITTING BANJO BOLT BANJO BOLT O-RING...
  • Page 929 POWER STEERING PRES- SURE HOSE TORQUE WRENCH POWER STEERING RETURN STEERINGGEAR HOSE STEERING 19 - 15 REMOVAL AND INSTALLATION (Continued) power steering pressure hose routing brackets and (14) Start the engine and let run for a few seconds. attaching bolts on engine (Fig. 12), (Fig. 11) and (Fig. then turn the engine off.
  • Page 930 POWER POWER STEERING STEERING SUPPLY HOSE RESERVOIR FLUID FLUID POWER STEERING RETURN HOSE POWER POWER STEERING PRES BOLT TO BE REMOVED STEERING SURE HOSE RESERVOIR BRACKET ROUTING FLUID BOLT POWER POWER HOSE CLAMP STEERING RETURN HOSE STEERING POWER STEERING PRES- RETURN HOSE FLUID FLUID...
  • Page 931 POWER RETURN HOSE ROUTING STEERING ROUTING ATTACHING BOLTS ROUTING BRACKETS BRACK- BRACKET POWER PRESSURE HOSE STEERING STEERING 19 - 17 REMOVAL AND INSTALLATION (Continued) (9) Raise the front suspension crossmember and steering gear back up into the vehicle. Refer to the steering gear service procedure in this group of the service manual for the required procedure to install the front suspension crossmember.
  • Page 932 POWER POWER STEERING PUMP STEERING SUPPLY HOSE FLUID POWER STEERING RESERVOIR FLUID 19 - 18 STEERING REMOVAL AND INSTALLATION (Continued) (2) Remove the tie-strap (Fig. 22) holding the CAUTION: The tie strap must be installed on the power steering fluid supply hose to the power steer- power steering pressure hose and supply hose to ing pressure hose.
  • Page 933 POWER STEERING PRES FLOW CONTROL VALVE FIT POWER STEERING PUMP SURE HOSE TING POWER INTAKE MANIFOLD STEERING SUPPLY HOSE FLUID POWER STEERING FLUID POWER STEERING POWER FLUID STEERING FLUID SUPPLY HOSE (TO PUMP) RESERVOIR RETURN HOSE STEERING 19 - 19 REMOVAL AND INSTALLATION (Continued) hose clamp on power steering fluid supply hose at power steering fluid reservoir.
  • Page 934 POWER FLOW CONTROL VALVE FIT ABS HYDRAULIC CONTROL POWER STEERING PRES UNIT HEAT SHIELD STEERING SUPPLY HOSE SURE HOSE FLUID TING CAST ALUMINUM POWER FRONT POWER STEERING PRES STEERING ING BRACKET BRAKE TUBE SURE HOSE MOUNTING BRACKET MOUNT PUMP BOLT POWER STEERING PUMP SPLASH SHIELD...
  • Page 935 BANJO BOLT O RING WHEEL SPEED SEN- WHEEL SEALING VEHICLE WIRING HARNESS CABLE ROUTING HOLE INNER FENDER GROMMET EXTENSION RATCHET SOR CABLE SPEED SENSOR GROMMET RETAINING BRACKET FRONT SHOCK STEERING KNUCKLE ABSORBER POWER STEERING PRES- SURE HOSE BANJO FITTING STEERING 19 - 21 REMOVAL AND INSTALLATION (Continued) (12) Remove the speed sensor cable sealing grom-...
  • Page 936 POWER FRONT POWER STEERING STEERING ADJUSTING HOLE BANJO BOLT DRIVE BELT MOUNTING BRACKET O RING PUMP PUMP BOLT POWER STEERING PRES- SURE HOSE BANJO FITTING POWER STEERING PRES- SURE HOSE 19 - 22 STEERING REMOVAL AND INSTALLATION (Continued) hose, being sure hose clamp is installed on hose past upset bead on power steering pump tube.
  • Page 937 POWER STEERING PRES POWER FLOW CONTROL VALVE FIT ABS HYDRAULIC CONTROL POWER STEERING PRES POWER STEERING PUMP UNIT HEAT SHIELD STEERING ADJUSTING SLOT SUPPLY HOSE SURE HOSE SURE HOSE FLUID BOLT TING SPLASH SHIELD ACCESSORY DRIVE MOUNT- POWER STEERING PUMP POWER STEERING PUMP ING BRACKET STEERING...
  • Page 938 BANJO BOLT BANJO BOLT O RING O RING POWER ING PUMP STEER- ADJUSTING SLOT BOLT POWER PUMP MOUNTINGBRACKET STEERING FRONT POWER STEERING PRES- SURE HOSE BANJO FITTING POWER STEERING PRES- SURE HOSE BANJO FITTING ENGINE ACCESSORY DRIVE BOLT BRACKET 19 - 24 STEERING REMOVAL AND INSTALLATION (Continued) steering front mounting bracket, attaching it to the...
  • Page 939 POWER RADIATOR LOWER CROSS STEERING HOSE CLAMPS RADIATOR MEMBER HOSES FLUID POWER STEERING PUMP POWER MOUNTING BRACKET ADJUSTING HOLE STEERING PUMP POWER STEERING COOLER STEERING 19 - 25 REMOVAL AND INSTALLATION (Continued) (23) Add power steering fluid if necessary. (24) Lower the vehicle. Start engine again and turn the steering wheel slowly from lock to lock.
  • Page 940 POWER RADIATOR LOWER CROSS COOLER STEERING ATTACHING MEMBER COOLER BOLTS RADIATOR RETAINING PIN INTERMEDIATE SHAFT STEERING BRAKE P EDAL SHAFT GEAR COUPLER PINCH BOLT 19 - 26 STEERING REMOVAL AND INSTALLATION (Continued) POWER STEERING FLUID COOLER LINES REMOVE (1) Remove the intermediate steering shaft coupler (Fig.
  • Page 941 POWER RADIATOR LOWER CROSS STEERING HOSE CLAMPS RADIATOR MEMBER HOSES FLUID POWER RETURN HOSE BRACKET LEFT FRAME RAIL TRANSAXLE STEERING LEFT FRAME RAIL HOSE COOLER CLAMP POWER STEERING COOLER BOLT CLIP LINES ROUTING CLIP POWER STEERING COOLER LINES FLUID POWER PRESSURE HOSE POWER STEERING GEAR STEERING...
  • Page 942 POWER STEERING PRES- SURE HOSE TORQUE WRENCH POWER STEERING RETURN STEERINGGEAR HOSE POWER FLUID RESERVOIR STEERING ATTACHING B OLTS 19 - 28 STEERING REMOVAL AND INSTALLATION (Continued) (19) Add fluid if necessary. Repeat the above pro- cedure until the fluid level remains constant after running the engine.
  • Page 943 POWER STEERING RESERVOIR FLUID MOUNTING BOLTS POWER SPECIAL TOOL C-4333 PUMP PULLEY STEERING OR C-4068 VISE STEERING 19 - 29 REMOVAL AND INSTALLATION (Continued) DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DRIVE PULLEY The power steering pump must be removed from the vehicle for removal of the power steering pump pulley.
  • Page 944 POWER POWER STEERING PUMP STEERING PULLEY PUMP POWER POWER SPECIAL TOOL 6936 STEERING STEERING PUMP PULLEY PUMP POWER STEERING PUMP PULLEY MUST BE STARTED SQUARELY ON SHAFT OF POWER STEERING PUMP AS SHOWN SPECIAL C-4063 TOOL WRENCHES POWER STEERING PUMP POWER STEERING PUMP...
  • Page 945 POWER POWER POWER SPECIAL TOOL C-4333 PUMP PULLEY STEERING STEERING STEERING PUMP OR C-4068 PULLEY PUMP POWER STEERING PUMP PULLEY MUST BE STARTED SQUARELY ON SHAFT OF POWER STEERING PUMP AS SHOWN VISE POWER POWER STEERING PUMP SPECIAL SPECIAL TOOL 6936 STEERING C-4063 TOOL...
  • Page 946 19 - 32 STEERING SPECIFICATIONS (Continued) POWER STEERING PUMP FASTENER TORQUE SPECIAL TOOLS SPECIFICATIONS POWER STEERING PUMP DESCRIPTION TORQUE POWER STEERING PUMP: Discharge Fitting ..75 N·m (55 ft. lbs.) To Rear Bracket Mounting Bolts ..54 N·m (40 ft.

  • Page 947: Power Steering Gear

    STEERING 19 - 33 POWER STEERING GEAR INDEX page page DESCRIPTION AND OPERATION OUTER TIE ROD END ....42 POWER STEERING GEAR ....33 STEERING GEAR MOUNTING BOLT DIAGNOSIS AND TESTING ISOLATOR...
  • Page 948 POWER STEERING PRES FLOW CONTROL VALVE FIT SURE HOSE TING JAM NUT ADAPTER INNER TIE ROD TINGS FIT- STEERING STEERING GEAR BOOT SPECIAL SHAFT GEAR STEERING TOOL 6815 FLUID LINES MOUNTING BUSHING GEAR POWER POWER PRESSURE SWITCH GEAR HOUSING POWER STEERING PUMP STEERING STEERING STEERING GEAR BOOT...
  • Page 949 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD STEERING HEAT SHIELD RETAINING PIN INTERMEDIATE KNUCKLE END STUD SHAFT TIE ROD END STEERING BRAKE P EDAL SHAFT GEAR COUPLER LEFT STRUT TOWER SPEED CONTROL SERVO PINCH BOLT STEERING 19 - 35 REMOVAL AND INSTALLATION...
  • Page 950 FRONT FRAME RAIL TO CROSS MEMBER LOWER CONTROL ARM OUTER TIE ROD CROSSMEMBER INNER TIE ROD SUSPENSION DRIVESHAFT ATTACHING BRACKET LOWER CONTROL ARM SPECIAL TOOL MB–991113 TIE ROD END STEERING HEAT SHIELD KNUCKLE FRONT CROSSMEMBER TO BODY, FRONT TO BACK LOCATING FRONT LOWER CON- FRAME CROSSMEMBER...
  • Page 951 FRONT ATTACHING BOLTS STABILIZER BAR CROSSMEMBER VEHICLE BODY SUSPENSION STABILIZER BAR BUSHING FRAME CROSSMEMBER LOWER RAIL BRACKET CONTROL CLAMP FRONT CROSSMEMBER SUSPENSION FRONT CROSSMEMBER TO BODY SIDE TO SIDE LOCATING SUSPENSION MARK FRONT ENGINE CROSSMEMBER SUSPENSION THRU-BOLT SUPPORT BRACKET SHOCK ABSORBER ATTACHING B OLTS CLEVIS LOWER...
  • Page 952 ENGINE FRONT TRANSAXLE CROSSMEMBER CROSSMEMBER FRONT REAR SUPPORT BRACKET SUSPENSION MOUNTING BRACKET MOUNTING ATTACHING BOLTS SUPPORT BRACKET BOLT BOLT CROSSMEMBER STABILIZER BAR LOWER CONTROL ARM STABILIZER BAR FRONT SUSPENSION MOUNTING BOLT CROSS- CROSSMEMBER MEMBER STEERING REAR GEAR POWER PRESSURE HOSE POWER STEERING GEAR STEERING REAR MOUNTING BOLT...
  • Page 953 FRONT STEERING GEAR FRONT CROSSMEMBER SUSPENSION MOUNTING ISOLATOR BOLT ATTACHING BOLTS (2) SADDLE BRACKET FRONT SUPPORTED ANTILOCK BRAKES STEERING GEAR CROSSMEMBER CONTROL UNIT SUSPENSION HYDRAULIC STEERING 19 - 39 REMOVAL AND INSTALLATION (Continued) CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribed into body of vehicle.
  • Page 954 BALL JOINT CAP HEAT SHIELD CROWFOOT 11/32 SOCKET LOWER CONTROL ARM STEERING KNUCKLE TORQUE SHOCK ABSORBER WRENCH CLEVIS TIE ROD END 19 - 40 STEERING REMOVAL AND INSTALLATION (Continued) lbs.). Be sure to install the upper to lower steer- ing coupler retaining bolt, retention pin. CAUTION: Do not use automatic transmission fluid.
  • Page 955 STEERING SCREWDRIVER STEERING ING BOLT ISOLATOR BUSH- GEAR ING BRACKET MOUNT- GEAR MOUNT- STEERING GEAR ISOLATOR STEERING MOUNTINGBRACKET BUSHING GEAR SLEEVE STEERING OUTER TIE ROD GEAR ING BRACKET MOUNT- JAM NUT STEERING ING BOLT ISOLATOR BUSH- INNER TIE ROD ISOLATOR GEAR MOUNT- BUSHING...
  • Page 956 STEERING GEAR INNER TIE ROD CLAMP INNER TIE ROD BOOT BOOT CLAMP STEERING GEAR OUTER TIE ROD CLAMP SPECIAL JAM NUT C-4975A INNER TIE ROD TOOL WHEN INSTALLING CLAMP TIGHTEN THERE IS NO GAP HERE TOOL UNTIL TIE ROD BOOT 19 - 42 STEERING DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 957 STEERING HEAT SHIELD KNUCKLE END STUD LOWER CONTROL ARM TIE ROD END SPECIAL TOOL MB-991113 TIE ROD END STEERING HEAT SHIELD KNUCKLE STEERING 19 - 43 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 32 Removing Tie Rod End Nut Fig. 34 Torquing Tie Rod End Attaching Nut (3) Remove tie rod end stud, from steering CAUTION: During this procedure do not allow the knuckle, using Remover, Special Tool MB-991113...
  • Page 958 19 - 44 STEERING SPECIAL TOOLS POWER STEERING GEAR Installer Boot Clamp C-4975A Remover Tie Rod End MB–990635 P/S System Analyzer 6815...

  • Page 959: Steering Column

    STEERING 19 - 45 STEERING COLUMN INDEX page page DESCRIPTION AND OPERATION WARNINGS ......45 STEERING COLUMN ASSEMBLY .
  • Page 960 INTERMEDIATE SHAFT COU- PLER INTERMEDIATE INTERMEDIATE SHAFT LOWER STEERING COLUMN MOUNTING BRACKET SHAFT JOINT STEERING COLUMN UPPER MOUNTING BRACKET TILT TORSION SPRING TILT LEVER SHIPPING PIN LOCK CYLINDER HOUSING IGNITION SWITCH SWITCH HOUSING HALO LIGHT 19 - 46 STEERING SERVICE PROCEDURES (Continued) Fig.
  • Page 961 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD FUSE CLIMATE CONTROL PANEL COVER PANEL CENTER BEZEL DASH PANEL TRIM STICK RADIO SCREW COVER LEFT STRUT TOWER SPEED CONTROL SERVO COVER SCREWS STEERING 19 - 47 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 962 SPEED MOUNTING SCREWS STEERING WHEEL SWITCHES CONTROL AIRBAG LOWER SCREW LOCATIONS ELECTRICAL STEERING COLUMN STEERING WHEEL STEERING WHEEL ATTACHING BOLT AIRBAG MODULE AIRBAG MODULE LOCKING TAB LEAD NECTOR CON- KNEE BOLSTER SCREW LOCATIONS UNDER TOP COVER 19 - 48 STEERING REMOVAL AND INSTALLATION (Continued) MODULE ACCIDENTLY DEPLOYS.
  • Page 963 ELECTRICAL HORN SWITCH STEERING WHEEL STEERING WHEEL AIRBAG MODULE AIRBAG MODULE CLOCKSPRING LEAD NECTOR WIRING LEAD CON- SPEED CONTROL SWITCH STEERING WHEEL ATTACH- (SHOWN IN LOCKED POSI- AIRBAG ELECTRICAL LEAD STEERING WHEEL PULLER STEERING WHEEL STEERING WHEEL ING NUT WIRING TION) STEERING 19 - 49...
  • Page 964 TILT LEVER WIRING HARNESS CON- CLOCKSPRING CLOCKSPRING NECTORS ATTACHINGSCREWS STEERING WIRING HARNESS CONNEC- HALO LIGHT SHROUDS COLUMN MULTI-FUNCTION IGNITION SWITCH HOUSING LOCK SWITCH MULTI-FUNCTION SWITCH WIRING HARNESS MULTI-FUNCTION SWITCH WIRING HAR- MULTI-FUNCTION SWITCH NESS CONNECTOR LOCKING TAB CONNECTOR KEY CYL- INDER SHIFTER IGNITION INTERLOCK CABLE 19 - 50...
  • Page 965 UPPER RETAINING PIN INTERMEDIATE MOUNTING BRACKET SHAFT LOCKING HOLES DRILL BITS STEERING BRAKE P EDAL SHAFT GEAR COUPLER MOUNTING STEERING COLUMN TILT LEVER SUPPORT BRACKET MOUNTINGNUTS DRILL BITS UPPER MOUNTING MOUNTING NUT LOWER MOUNT- BRACKET ING BRACKET PINCH BOLT STEERING 19 - 51 REMOVAL AND INSTALLATION (Continued) remove the 2 lower steering column assembly mount-...
  • Page 966 STEERING MOUNTING BRACKET COLUMN THESE 2 MOUNTING STUDS MUST BE IN THE CENTER OF THE MOUNTING CAPSULES AS SHOWN BEFORE TIGHT- ENING AND TORQUING THE UPPER UPPER MOUNTING NUTS. STEERING COLUMN ASSEMBLY 19 - 52 STEERING REMOVAL AND INSTALLATION (Continued) arrow on the clockspring rotor will be pointing at yel- low window on clock spring.
  • Page 967 CENTER BEZEL STEERING COLUMN LOWER SPECIAL MOUNTING BRACKET 6831–A TOOL FLEX JOINT INTERMEDIATE S HAFT ROLL PIN K NURLED NUT STEERING 19 - 53 REMOVAL AND INSTALLATION (Continued) (21) Install screw behind fuse panel cover holding (25) If airbag warning lamp fails to light, dash panel top cover (Fig.
  • Page 968 STEERING COLUMN SHAFT FLEX JOINT SCREW- DRIVER STEERING COLUMN LOWER MOUNTING BRACKET INTERMEDIATE SHAFT 19 - 54 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 26 Removing Flex Joint From Steering Column Fig. 27 Tool Set-Up For Installing Flex Joint Roll Pin Shaft SPECIFICATIONS INSTALL...
  • Page 969 TRANSAXLE 21 - 1 TRANSAXLE CONTENTS page page GENERAL INFORMATION PINION FACTOR PROCEDURE ... . 13 41TE FOUR SPEED AUTOMATIC TRANSAXLE . 1 TRANSAXLE QUICK LEARN PROCEDURE . . . 13 FLUID LEVEL AND CONDITION .
  • Page 970 IDENTIFICATION TAG 21 - 2 TRANSAXLE GENERAL INFORMATION (Continued) FLUID LEVEL AND CONDITION NOTE: The transmission and differential sump have a common oil sump with an opening between the two. The torque converter fills in both the (P) Park and (N) Neutral positions.

  • Page 971: Special Additives

    SPECIAL ADDITIVES operating clearances. The solenoids operate the valves directly without any intermediate element. Chrysler Corporation does not recommend the Direct operation means that these units must have addition of any fluids to the transaxle, other than the very high output. They must close against the size- fluid listed above.

  • Page 972: Shifter/Ignition Interlock

    21 - 4 TRANSAXLE DESCRIPTION AND OPERATION (Continued) fied terms, the upshift logic allows the releasing ele- trol Module (dependent on which fault is set), the ment to slip backwards slightly. This ensures that it powertrain control module will turn on a MIL (Mal- does not have excess capacity.

  • Page 973: Transmission Range Sensor

    TRANSAXLE 21 - 5 DESCRIPTION AND OPERATION (Continued) LOCK or ACCESSORY position, unless shifter is in AUTOMATIC SHIFTS WILL OCCUR UNDER the PARK position. THE FOLLOWING CONDITIONS GEARSHIFT AND PARKING LOCK CONTROLS TYPE OF SHIFT APPROXIMATE SPEED The transaxle is controlled by a lever type gear- 4-3 coast downshift 13 mph shift incorporated within the floor shift mechanism.
  • Page 974 21 - 6 TRANSAXLE DIAGNOSIS AND TESTING (Continued) • Improper adjustments Attach 150 psi gauges to ports required for test • Hydraulic malfunctions being conducted. A 300 psi gauge (C-3293) is required • Mechanical malfunctions for reverse pressure test. • Electronic malfunctions Test port locations are shown in (Fig.
  • Page 975 TORQUE CONVERTER OFF LOW/REVERSE CLUTCH UNDERDRIVE CLUTCH OVERDRIVE CLUTCH REVERSE CLUTCH 2/4 CLUTCH TRANSAXLE 21 - 7 DIAGNOSIS AND TESTING (Continued) Shift Lever Position Start Park CLUTCHES Safety Sprag Underdrive Overdrive Reverse Low/ Reverse P — PARK R — REVERSE N —...

  • Page 976: Clutch Air Pressure Tests

    21 - 8 TRANSAXLE DIAGNOSIS AND TESTING (Continued) (4) Reverse and LR clutch pressure should read LOW/REVERSE CLUTCH 165 to 235 psi. Apply air pressure to the low/reverse clutch feed (5) This test checks the reverse clutch hydraulic hole (rear of case, between 2 bolt holes). Then, look circuit.

  • Page 977: Interlock System Operation Check

    TRANSAXLE 21 - 9 DIAGNOSIS AND TESTING (Continued) TOOL 6056 AIR NOZZLE TOOL 6056 ACCUMULATORS Fig. 4 PRESSURE CHECK SPECIFICATIONS Fig. 5 Air Pressure Test Plate Fig. 6 Testing Reverse Clutch INTERLOCK SYSTEM OPERATION CHECK PARK position should not be possible, when the igni- (1) Place shifter in PARK, the Ignition switch tion switch is in the LOCK or ACCESSORY position.

  • Page 978: Service Procedures

    21 - 10 TRANSAXLE DIAGNOSIS AND TESTING (Continued) transaxle manual valve lever. The TCM receives the AUTOSTICK switch signal and processes the data. The TCM sends The autostick feature will be deactivated if one of the Shift Lever Position (SLP) information to the the following conditions or Trouble Codes occur: BCM via the CCD bus.

  • Page 979: Flushing Coolers And Tubes

    TRANSAXLE 21 - 11 TRANSAXLE DIPSTICK DIPSTICK SERVICE PROCEDURES (Continued) (7) Add sufficient fluid to bring level to 1/8 inch (6) Adjust transmission fluid level shown on the below the ADD mark. dipstick according to the chart. (7) Check transmission for leaks. CAUTION: Do not overfill transaxle.
  • Page 980 ADD WARM HOT Temperature (°F) NOMINAL FILL LINE 21 - 12 TRANSAXLE SERVICE PROCEDURES (Continued) Transmission Fluid Temperature Chart (3) Verify pump power switch is turned OFF. Con- (11) Place CLEAR suction line into a one quart nect red alligator clip to positive (+) battery post. container of Mopar type 7176 automatic transmis- Connect black (-) alligator clip to a good ground.

  • Page 981: Oil Cooler Flow Check

    TO COOLER FROM COOLER TRANSAXLE 21 - 13 SERVICE PROCEDURES (Continued) • Valve Body Replacement or Recondition To perform the Quick Learn Procedure, follow the instructions from the DRB scan tool. PINION FACTOR PROCEDURE The vehicle speed readings for the speedometer are taken from the output speed sensor.

  • Page 982: Gearshift Mechanism

    ADJUSTMENT SHIFTER/IGNITION INTERLOCKCABLE GEARSHIFT MECHANISM CABLE END 21 - 14 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (3) Remove battery positive cable. (4) Remove Transmission Control Module (TCM) connector. Remove TCM. (5) Pull Power Distribution Center (PDC) up and out of the way. (6) Using a pry tool, pry up on cable at manual valve lever and remove cable from lever.
  • Page 983 FUSE CENTER COVER PANEL BEZEL SCREW COVER LOWER STEERING COLUMN SHROUD LOWER SCREW LOCATIONS SCREW LOCA- TIONS KNEE BOLSTER SCREW COVER LOCATIONS UNDER TOP SCREWS COVER TRANSAXLE 21 - 15 REMOVAL AND INSTALLATION (Continued) (6) Pull cable up and out of the gearshift mecha- nism.
  • Page 984 KEY CYLINDER LOWER SHROUD TILT LEVER LOWER SHROUD INTERLOCK CABLE IGNITION SWITCH INTERLOCK CABLE IGNITION LOCK CYL- INDER 21 - 16 TRANSAXLE REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: When installing interlock cable assem- bly, care must be taken not to bend exposed cable wire and slug at shifter end of cable.

  • Page 985: Interlock Mechanism

    MOUNTING SCREW INTERLOCK MECHANISM INPUT INPUT (TURBINE) SPEED (TURBINE) SENSOR SPEED SENSOR SOLENOID ASSEMBLY SOUND COVER OUTPUT SPEED SENSOR TRANSAXLE 21 - 17 REMOVAL AND INSTALLATION (Continued) (17) Install screw holding end of instrument panel SOLENOID ASSEMBLY-REPLACE top cover. Install fuse panel cover from left end of instrument panel.
  • Page 986 TRANSMISSION RANGE RETAINING SEN- SCREW SOCKET SOUND COVER ATTACHING PLATE SOUND 8-WAY WRENCH SOLENOID ATTACHING PLATE ASSEMBLY NECTOR CON- COVER SOLENOID ASSEMBLY GAS- ATTACHING KETS SCREWS TRANSMISSION RANGE SENSOR MANUAL SHAFT SEAL VALVE BODY 21 - 18 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (12) Remove TRS retaining screw (Fig.

  • Page 987: Speed Sensor-Input

    INPUT VALVE BODY (TURBINE) SENSOR SPEED TRANSMISSION RANGE SEN- OUTPUT SPEED SENSOR TRANSAXLE 21 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 30 Remove Transmission Range Sensor Fig. 32 Output Speed Sensor TRANSMISSION CONTROL MODULE INSTALLATION (1) For installation, reverse removal procedure. Do not interchange transmission control modules Tighten TRS retaining screw to 5 N·m (45 in.

  • Page 988: Valve Body

    21 - 20 TRANSAXLE REMOVAL AND INSTALLATION (Continued) O-RING VALVE ATTACHING BOLTS BODY OIL FIL- (18) VALVE BODY Fig. 33 Transmission Control Module Fig. 35 Oil Pan 2.5 LITER ENGINE REMOVAL (1) Disconnect battery negative cable at the left strut tower. (2) Remove TCM 60 way connector.
  • Page 989 TRANSMISSION SCREWDRIVER VALVE BODY VALVE BODY SENSOR RANGE PARK SPRAG PARK SPRAG TRANSMISSION GUIDE ROLLERS CONTROL MODULE BRACKET TRANSAXLE 21 - 21 REMOVAL AND INSTALLATION (Continued) TRANSAXLE REMOVAL Transaxle removal does NOT require engine removal. The transaxle and torque converter must be removed as an assembly;...
  • Page 990 SOLENOID PACK NECTOR CON- 21 - 22 TRANSAXLE REMOVAL AND INSTALLATION (Continued) TRANSAXLE COOLER LINES (4) Remove solenoid pack connector (Fig. 43). ENGINE BRIDGE FIXTURE SHIFT CABLE CLAMP Fig. 45 Shift Cable at Lever Fig. 43 Solenoid Pack Connector (5) Remove dipstick tube. (6) Remove transaxle cooler lines (Fig.
  • Page 991 STARTER TRANSAXLE 21 - 23 REMOVAL AND INSTALLATION (Continued) UPPER TRANSAXLE MOUNT SPLASH SHIELD Fig. 48 Upper Transaxle Mount Fig. 51 Starter (16) Remove front motor mount bracket. (17) Remove rear mount bracket through-bolt. (18) Remove center member bolts. (19) Remove rear mount bracket bolts, and remove rear mount bracket.
  • Page 992 DRIVE PLATE LOWER ENGINE PULLEY TRANSMISSION TRANSAXLE JACK K-FRAME MOUNT STEERING RACK MOUNT DRIVE PLATE TURN CLOCKWISE SWAY BOLT MOUNT 21 - 24 TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 54 Steering Gear and K-frame Bolts Fig. 52 Rotate Engine Clockwise Fig.

  • Page 993: Disassembly And Assembly

    OIL PUMP SEAL TOOL C-3981-B TRANSAXLE 21 - 25 REMOVAL AND INSTALLATION (Continued) OIL PUMP SEAL DISASSEMBLY AND ASSEMBLY VALVE BODY RECONDITION REMOVAL TRANSMISSION RETAINING SCREW ROOSTER COMB MANUAL SHAFT VALVE BODY SENSOR RANGE HANDLE TOOL C-4193 C-4171 TOOL Fig. 57 Remove Oil Pump Seal Fig.
  • Page 994 2–4 ACCUMULATOR RETAIN- 2–4 ACCUMULATOR PISTON VALVE BODY SCREWS VALVE BODY SCREWS VALVE BODY SCREWS VALVE BODY SCREWS RETAINER PLATE ROOSTER COMB DETENT SPRING DETENT SPRING MANUAL SHAFT VALVE BODY ING PLATE SPRINGS OVERDRIVE OVERDRIVE SEPARATOR PLATE SEPARATOR PLATE TRANSFER PLATE TRANSFER PLATE THERMAL VALVE CLUTCH...
  • Page 995 (#4) BALL CHECK LOCATION (#2) BALL CHECK LOCATION (#3) BALL CHECK LOCATION LOW/REVERSE TORQUE CONVERTER CON- TORQUE SOLENOID SWITCH VALVE 2–4 ACCUMULATOR REGULATOR VALVE T/C LIMIT VALVE MANUAL VALVE CLUTCH VALVE CONVERTER TROL VALVE RETAINER SWITCH VALVE SPECIAL TOOL 6301 TRANSAXLE 21 - 27 DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 996 (USE RTV UNDER BOLT HEADS) BOLTS VALVE BODY REGULATOR VALVE TOOL 6302 SPRING OIL PAN O-RING 1/8 INCH BEAD OF RTV VALVE ATTACHING OIL FILTER BOLTS SEALANT BODY OIL FIL- (18) REGULATOR VALVE VALVE BODY SPRING RETAINER 21 - 28 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 997 TRANSMISSION SCREWDRIVER VALVE BODY VALVE BODY SENSOR RANGE ACCUMULATOR ACCUMULATOR RETURN SPRINGS SEAL RING (2) RETURN SPRING (UNDERDRIVE) (OVERDRIVE) SEAL RING SEAL RING SEAL RING SEAL RING PISTON PISTON RETURNSPRING PARK SPRAG PARK SPRAG OVERDRIVE UNDERDRIVE CLUTCH ACCUMU- GUIDE ROLLERS CLUTCH LATOR BRACKET...
  • Page 998 PISTON SNAP RING SUITABLE TOOL PISTON PETROLATUM ADJUSTABLE SEAL RINGS PLIERS PLUG PLUG RETURN ACCUMULATOR PIS- SPRINGS (NOTE NOTCH) SEAL RINGS 21 - 30 TRANSAXLE INPUT SHAFT DISASSEMBLY AND ASSEMBLY (Continued) DIAL INDICATOR Fig. 84 Low/Reverse Accumulator Fig. 81 Low/Reverse Accumulator Snap Ring Attach a dial indicator to transaxle bell housing with its plunger seated against end of input shaft (Fig.
  • Page 999 “PUSH IN” ON INPUT SHAFT PUMP HOUS- PUMP WHILE REMOVING PUMP PUMP PULLERS ATTACHING BOLTS C-3752 TOOL GASKET PUMP GAS- OIL PUMP TRANSAXLE 21 - 31 DISASSEMBLY AND ASSEMBLY (Continued) Record indicator reading for reference when reas- sembling the transaxle. Fig.
  • Page 1000 #1 CAGED NEEDLE #4 THRUST WASHER WASHER THRUST BEARING FRONT INPUT CLUTCHES ASSEMBLY ASSEMBLY GEAR #6 NEEDLE BEAR- FRONT CARRIER AND REAR ANNULUS (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL). ASSEMBLY NOTE: TANGED SIDE OUT 21 - 32 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: The cooler bypass valve must be replaced if...
  • Page 1001 24 CLUTCH RETURN SPRING RETURNSPRING CLUTCH RETAINER RETAINER CLUTCH CLUTCH CLUTCH CAUTION: IDENTIFY PACKS ORIGINAL PLACEMENT PLATE (4) RETAINER CLUTCH ASSURE CLUTCH NOTE POSITION RETURN SPRING CLUTCH DISC (4) TRANSAXLE 21 - 33 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 98 Remove 2/4 Clutch Retainer Fig.
  • Page 1002 21 - 34 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) NOTE: Tag 2/4 clutch pack for reassembly identifi- cation. ONE DISC FROM LOW/REVERSE CLUCTH LOW/REVERSE REACTION PLATE (FLAT SIDE UP) A THRU H INSTALLATION TAPERED SNAP ENDS BETWEEN 9:00 & 10:00 SEQUENCE RING TRANSAXLE CASE OIL PAN FACE VIEW FROM BELLHOUSING...
  • Page 1003 DO NOT SCRATCH REAR SCREWDRIVER CLUTCH PLATE CAUTION: TAG AND IDEN- TIFY PACKS TO ASSURE ORIGINAL PLACEMENT. COVER BOLTS TRANSFER SHAFT GEAR TRANSFER S HAFT SPECIAL TOOL 6259 REAR COVER LOCK WASHER 1/8 INCH BEAD OF MOPAR SILI- CONE RUBBER ADHESIVE SEAL- ANT AS SHOWN OUTPUT GEAR CLUTCH PLATES (5)
  • Page 1004 TRANSFER TRANSFER SHAFTGEAR SPECIAL WRENCHES SPECIAL L-4407 TOOL SHAFT GEAR L-4407–6 TOOL 200 FT. LBS. SPECIAL TOOL 6259 SPECIAL TOOL 6261 TORQUE WRENCH OUTPUT GEAR TRANSFER TRANSFER SHAFT GEAR WRENCHES SHIM (SELECT) BEARING CUP RETAINER SHAFT GEAR ALIGN INDEXING TAB TO TOOL WITH TOOL...
  • Page 1005 TRANSFER USE REMOVED BEARING CUP SHAFT GEAR TRANSFER BEARING TO SUPPORT RETAINER TOOL 5052 RETAINER WRENCHES ARBOR PRESS RAM SHAFT ARBOR PRESS RAM BEARING CONE HANDLE C-4171 TRANSFER BEARING HANDLE C-4171 TOOL 6062 TOOL 6061 RETAINER SHAFT SPECIAL TOOL 5049–A SNAP RING PLIERS TOOL 6051 ARBOR...
  • Page 1006 OUTPUT GEAR- BOLT RETAINING S TRAP STIRRUP TRANSFER SHAFT BAF- OUTPUT GEAR BEARING CUP TOOL 6052 TOOL 6259 BEARING CONE TRANSFER SHAFT NEW BEARING CONE ARBOR PRESS R AM O-RING OUTPUT RETAINING BOLT GEAR STIRRUP 21 - 38 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out.
  • Page 1007 STIRRUP RETAINING STRAP STIRRUP RETAINING STRAP RETAINING STRAP TABS STIRRUP RETAINING S TRAP CONED LOCK WASHER TOOL L-4407 BOLT BOLTS TOOL L-4407–6 BUTTON TOOL 6055 WRENCHES TURN CLOCKWISE TURN CLOCKWISE OUTPUT GEAR OUTPUT GEAR TRANSAXLE 21 - 39 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 1008 21 - 40 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 141 Install New Bearing Cone Fig. 138 Tighten Output Gear to 271 N·m (200 ft. lbs.) REAR CAR- RIER ASSEMBLY WRENCHES TOOL 5048–3 AND BUTTON 6055 5048 WITH JAWS OUTPUT GEAR WRENCHES TOOL JAWS 5048–5 AND...
  • Page 1009 LOW/REVERSE REAR TOOL 6057 TOOL 5058–3 ARBOR PRESS RAM ASSEMBLY RETURN SPRING CARRIER CLUTCH TOOL 5059 SNAP (INSTALL SHOWN) RING TOOL 5058–3 TOOL 5059 TOOL 6053 TOOL 6057 BEARING CONE PARK SPRAG GUIDE BRACKET SNAP RING OPENING MUST LOW/REVERSE HAMMER PISTON DRIFT TOOL 6057...
  • Page 1010 PIVOT ANCHOR SHAFT PLUG SHAFT ANTIRATCHET GUIDE ANCHOR SHAFT SPRING BRACKET PAWL GUIDE PLIERS BRACKET SHAFT PIVOT GUIDE BRACKET PIVOT SHAFT PAWL SPACER STEPPED SPACER GUIDE BRACKET ANTIRATCHET SPRING ANTIRATCHET (MUST BE ASSEMBLED AS GUIDE BRACKET SPLIT SLEEVE SHOWN) SPRING PAWL 21 - 42 TRANSAXLE...
  • Page 1011 LOW/REVERSE CLUTCH GASKET HOLES GASKET MUST LINE UP TORX-LOC SCREWS RETAINER PISTON LOW/REVERSE CLUTCH PIS- TON RETAINER GASKET SCREW- DRIVER STEELDRIFT OUTPUT BEARING TOOL 5050 CUPS HAMMER TOOL 6062 OUTPUT CUPS (REPLACE IN WRENCHES BEARING PAIRS) LOW/REVERSE CLUTCH PISTON RETAINER TRANSAXLE 21 - 43 DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 1012 OUTPUT GEAR OUTPUT GEAR TOOL L-4432 INCH-POUND WRENCH TORQUE SPECIAL SCREWS TOOL 6260 DIAL INDICATOR DIAL INDICATOR USE HOOK TOOL TO RAISE TIP TOOL 6268 HOOK TOOL ONE CLUTCH DISC DIAL INDICATOR DIAL INDICATOR DIAL INDICATOR TIP TOOL 6268 HOOK TOOL 21 - 44 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 1013 INPUT CLUTCHES 3 DABS OF PETROLA- RETAINER OVERDRIVE SHAFT ASSEM- RETEN- TION THINNEST #4 THRUST PLATE (SELECT) INPUT (TURBINE) SENSOR HOLE SPEED ASSEMBLY PUMP O-RING OIL COOLER NIPPLES TRANSAXLE 21 - 45 DISASSEMBLY AND ASSEMBLY (Continued) DETERMINING No. 4 THRUST PLATE INPUT SHAFT USE A SMALL BOLT DIAL INDICATOR...
  • Page 1014 REACTION PLATE inch SCREWDRIVER R EVERSE SNAP (SELECT) CLUTCH RING REVERSE REACTION (INSTALL FLAT SIDE REVERSE SCREW- REACTION PLATE DRIVER CLUTCH CLUTCH DOWN) PLATE SCREW- DRIVER 21 - 46 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) See chart below to select the proper No. 4 thrust plate. Fig.
  • Page 1015 OVERDRIVE OVERDRIVE CLUTCH PLATE CLUTCH DISC OVERDRIVE SHAFT ASSEM- CAUTION: TAG AND IDEN- TIFY CLUTCH PACKS TO ASSURE ORIGINAL PLACE- MENT OD/REVERSE OD/REVERSE PRESSURE PLATE OVERDRIVE SHAFT ASSEM- SIDE DOWN) OD/REVERSE CLUTCH WAVED SNAP (STEP SURE PLATE PRES- RING SCREWDRIVER SCREWDRIVER OD/REVERSE PRESSURE...
  • Page 1016 NEEDLE (NOTE 3 TABS) BEARING WASHER UNDERDRIVE SHAFT ASSEMBLY THRUST TABS) 21 - 48 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 184 OD/UD Reaction Plate Fig. 181 Underdrive Shaft Assembly UNDERDRIVE REACTION PLATE SNAP RING CLUTCH FLAT SCREWDRIVER Fig. 185 Remove One UD Clutch Disc Fig.
  • Page 1017 CAUTION: TAG AND IDENTIFY PACKS TO ASSURE ORIGINAL CLUTCHPLATE REPLACEMENT CLUTCH CLUTCH DISC ONE UD CLUTCH DISC TRANSAXLE 21 - 49 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 187 Underdrive Clutch Pack Fig. 190 Underdrive Clutch Piston NOTE: Tag underdrive clutch pack for reassembly identification.
  • Page 1018 OD/RE- VERSE PISTON ARBOR (COMPRESS SPRING TO REMOVE OR INSTALL SPECIAL TOOL 6057 OVERDRIVE/RE- OVERDRIVE/REVERSE PISTON VERSE PISTON O-RING JUST PRESS SNAP RING) ENOUGH RETURN LIP SEAL SNAP RING SCREW- INPUT DRIVER RETURNSPRING INPUT CLUTCHES RETAINER CLUTCHES RETAINER INPUT SHAFT AND HUB OD/REVERSE O-RING SNAP...
  • Page 1019 INPUT CLUTCHES RETAINER PUSH DOWN TO INSTALL OVERDRIVE/RE- OD/REVERSE O-RING INPUT SHAFT INPUT SHAFT PIS- O-RINGS RETURNSPRING SCREWDRIVER (DO NOT SCRATCH ARBOR PRESS RAM INPUT SNAP RING SHAFT SNAP RING ASSEMBLY LIP SEALS SURFACE) BEARING OD/RE- VERSE PISTON ARBOR (COMPRESS SPRING TO REMOVE OR INSTALL SPECIAL TOOL 6057...
  • Page 1020 INPUT SHAFT PISTON RETURNSPRING INPUT CLUTCHES PISTON ASSEMBLY RETAINER SHAFT INPUT (TAPERED SIDE UP WITH SPECIAL TABS IN CAVITY) SNAP TOOL 5067 SNAP RING PLIERS RING PISTON UNDERDRIVE LIP SEAL RETURN SPRING RETAINER SPRING SNAP RING 21 - 52 TRANSAXLE OD/REVERSE CAUTION: TAG AND IDENTIFY...
  • Page 1021 ONE UNDERDRIVE CLUTCH UNDERDRIVE REACTION OD/UD REACTION (STEP SIDE DOWN) CLUTCH PLATE PLATE SNAP RING CLUTCH FLAT DISC SCREWDRIVER CAUTION: TAPERED SNAP OVERDRIVE/UNDERDRIVE CLUTCHES PLATE TAPERED REUSE RING REACTION SNAP RING SCREWDRIVER NOT SCRATCH REAC- TION PLATE) TRANSAXLE 21 - 53 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 1022 OVERDRIVE CLUTCH PACK OVERDRIVE/REVERSE (STEP PRESSURE PLATE DOWN) SIDE HOOK TOOL OVERDRIVE PLATE WAVED SNAP RING REACTION SCREWDRIVER 21 - 54 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 219 Install Waved Snap Ring Fig. 217 Use Hook Tool to Raise One Clutch Disc Underdrive clutch pack clearance must be 0.91 to 1.47 mm (.036 to .058 inch).
  • Page 1023 REVERSE DIAL FLAT CLUTCH PLATE HOOK T OOL ARBOR PRESS RAM INDICA- C-3339 SNAP RING OVERDRIVE/REVERSE TOOL 5059A CAUTION: PRESS JUST SNAP REVERSE CLUTCH DISCS PRESSURE ENOUGH GROOVE EXPOSE PLATE DOWN RING REVERSE CLUTCH REAC- REVERSE SNAP MUST REVERSE TION REVERSE CLUTCH REAC- TION...
  • Page 1024 HOOK T OOL BEARING (NOTE SMALL TABS) NEEDLE COMPRESS CLUTCH PACK WITH FINGER INDICATOR ZERO TABS UP OVERDRIVE SHAFT ASSEMBLY WASHER (NOTE 5 UNDERDRIVE #3 THRUST PLATE (NOTE 3 BEARING NEEDLE THRUST ASSEMBLY TABS) SHAFT TABS) DABS UNDERDRIVE (FOR RETENTION) PETROLATUM ASSEMBLY SHAFT...

  • Page 1025: Differential Repair

    OVERDRIVE SHAFT DIFFERENTIAL COVER BOLTS ASSEMBLY WASHER THRUST OVERDRIVE ASSEMBLY DIFFERENTIAL #3 THRUST PLATE SHAFT COVER DIFFERENTIAL TOOL L-4435 ASSEMBLY DIFFERENTIAL COVER 1/8 INCH BEAD OF MOPAR SILICONE RUBBER ADHE- DIFFERENTIAL DIFFERENTIAL BEARING RETAINER RETAINER BOLTS SIVE SEALANT TRANSAXLE 21 - 57 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 1026 DIFFERENTIAL SPECIAL SPECIAL TOOL C-293 SPECIAL TOOL C-293-3 DIFFERENTIAL ASSEMBLY ASSEMBLY C-4171 TOOL DIFFERENTIAL SPECIAL BEARING SPECIAL C-293-36 TOOL TOOL 6536 SPECIAL SPECIAL SPECIAL 5048-4 TOOL SPECIAL TO0L 5048 SPECIAL TOOL 5048 L-4539-2 5048-4 TOOL TOOL SPECIAL DIFFERENTIAL RING GEAR TOOL 5048 21 - 58...
  • Page 1027 DIFFERENTIAL MOVE SIDE GEAR MOVE SIDE GEAR SPECIAL TOOL C-4996 SIDE GEAR ASSEMBLY UP AND DOWN UP AND DOWN SPECIAL C-4996 (NOTE POSI- (NOTE POSITION) TION) TOOL DIFFERENTIAL DIAL INDICATOR DIAL INDICATOR SET ASSEMBLY DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL BEARING RETAINER SPECIAL RETAINER 6062A RETAINER...

  • Page 1028: Cleaning And Inspection

    DIFFERENTIAL BEARING RETAINER SPECIAL C-4171 TOOL SPECIAL TOOL 5052 21 - 60 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) ADJUSTMENTS GEARSHIFT LINKAGE ADJUSTMENT Normal operation of the Park/Neutral Position Switch provides a quick check to confirm proper link- age adjustment. Move the selector level slowly forward until it clicks into the (P) Park position.
  • Page 1029 SHIFTER/IGNITION SHIFTER CABLE ADJUSTMENT SHIFTER/IGNITION INTERLOCKCABLE INTERLOCK CABLE ADJUSTMENT CABLE END TRANSAXLE 21 - 61 ADJUSTMENTS (Continued) (4) Loosen the adjustment nut on the interlock (10) Slip the cable into the housing until it snaps lever (Fig. 251). in place. (11) Ensure the shift lever remains in PARK.

  • Page 1030: Output Gear Bearing

    21 - 62 TRANSAXLE ADJUSTMENTS (Continued) OUTPUT GEAR BEARING DIFFERENTIAL BEARING With output gear removed: (1) Position the transaxle assembly vertically on (1) Install a 4.50 mm (0.177 inch) gauging shim on the support stand, differential bearing retainer side the rear carrier assembly hub, using grease to hold the shim in place.
  • Page 1031 TRANSAXLE 21 - 63 ADJUSTMENTS (Continued) (c) Remove the existing shim from under the DIFFERENTIAL BEARING SHIM CHART cup. (d) Measure the existing shim. THICKNESS INCH NOTE: If the turning torque was too high when measured, install a .05 mm (.002 inch) thinner shim. .980 0.0386 If the turning torque is was too low, install a .05 mm...

  • Page 1032: Transfer Shaft Bearing

    21 - 64 TRANSAXLE ADJUSTMENTS (Continued) TRANSFER SHAFT BEARING (1) Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L-4407. (2) Install a 4.66 mm (.184 inch) gauging shim on the transfer shaft. (3) Install transfer shaft gear and bearing assem- bly and torque the nut to 271 N·m (200 ft.

  • Page 1033: Schematics

    TRANSAXLE 21 - 65 SCHEMATICS AND DIAGRAMS (Continued)

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1997 stratus convertible lhd

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