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Chrysler Stratus RHD 1999 Electronic Service Manual

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Summary of Contents for Chrysler Stratus RHD 1999

Page 2: Table Of Contents
Ameri- cants and chemicals be used. Mopar provides the can Petroleum Institute (API) to meet all the lubri- best engineered products for servicing Chrysler Cor- cation requirements specified Chrysler poration vehicles.
Page 3: Fluid Fill/Check Locations
Fuel Tank ....60.5 L (16.0 gal.) DESCRIPTION Engine Oil With Filter – 2.0 L, 2.5 L V6 ..4.25 L Chrysler Corporation uses international symbols to (4.5 qts.) identify engine compartment lubricant and fluid Engine Oil With Filter –...
Page 4 LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES INDEX page page DESCRIPTION AND OPERATION SCHEDULE – B ......4 MAINTENANCE SCHEDULES .
Page 5: Lubrication And Maintenance
0 - 4 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) • Replace the engine air cleaner element (fil- • Replace engine oil filter on 2.0 liter and 2.4 liter ter). engines. • Replace the spark plugs on 2.0 liter and 2.4 90,000 Miles (144 000 km) or at 72 months liter engines.
Page 6 LUBRICATION AND MAINTENANCE 0 - 5 SPECIFICATIONS (Continued) • Replace engine air cleaner element (filter) . 3,000 Miles (5 000 km) • Replace spark plugs on 2.0 liter and 2.4 liter • Change engine oil. • Replace engine oil filter on 2.0 liter and 2.4 liter engines.
Page 7 0 - 6 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) 60,000 Miles (96 000 km) 81,000 Miles (130 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter on all engines. • Replace engine oil filter on 2.0 liter and 2.4 liter •...
Page 8 • Replace the engine timing belt on 2.0 liter 2.4 liter engines (California emissions package.) • Change automatic transaxle fluid and filter.* NOTE: #1 This maintenance is recommended by Chrysler Corporation to the owner but is not required to maintain the emissions warranty.
Page 9: Jump Starting, Towing, And Hoisting
0 - 8 LUBRICATION AND MAINTENANCE JUMP STARTING, TOWING, AND HOISTING INDEX page page SERVICE PROCEDURES JUMP STARTING PROCEDURE ....8 HOISTING RECOMMENDATIONS ... 10 TOWING RECOMMENDATIONS .
Page 10: Towing Recommendations
Install lug nuts on wheel attaching studs to retain brake drums or rotors. TOWING—FRONT WHEEL LIFT Chrysler Corporation recommends that a vehicle be LOCKED VEHICLE TOWING towed with the front end lifted, whenever possible. A When a locked vehicle must be towed with the 90 cm (36 in.) length of 4x4 wood beam can be placed...
Page 11: Hoisting Recommendations
0 - 10 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) fascia to prevent damage to vehicle during the lifting operation. The beam can removed after lifting the front of the vehicle. TOWING—REAR WHEEL LIFT If a vehicle cannot be towed with the front wheels lifted, the rear wheels can be lifted provided the fol- lowing guide lines are observed.
Page 12: Service Procedures
• Thrust Angle is defined as the average of the toe accuracy of the alignment, except when alignment settings on each rear wheel. If this measurement is specifications recommended by Chrysler Corporation out of specification, readjust the rear wheel toe so differ.
Page 13 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Alignment Camber And Toe DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine On 1. Defective Wheel Bearing 1. Replace Wheel Bearing Turns 2. Incorrect Wheel Alignment 2.
Page 14 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine 1. Defective Wheel Bearing 1. Replace Wheel Bearing With Vehicle Going Straight At A Constant Speed 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3.
Page 15: Service Procedures
2 - 4 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Excessive Steering 1. Incorrect Steering Gear 1. Adjust Or Replace Steering Gear Free Play Adjustment 2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends 3.
Page 16: Service Procedures
SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) CURB HEIGHT SPECIFICATIONS VEHICLE FRONT REAR 694 mm 20 mm 693 mm 20 mm 27.32 in. 0.79 in. 27.28 in. 0.79 in. WHEEL ALIGNMENT adjusting screw located in the forward and rear lat- eral links of the vehicles rear suspension (Fig.
Page 17 2 - 6 SUSPENSION SERVICE PROCEDURES (Continued) procedure, inspect the suspension components for any signs of damage or bending. CAMBER ADJUSTMENT PROCEDURE (1) Open the hood and mark the position of all four shock assembly mounting bolts on the shock tower (Fig.
Page 18 SUSPENSION 2 - 7 SERVICE PROCEDURES (Continued) (8) Check and adjust the front camber as neces- sary. Refer to WHEEL ALIGNMENT SPECIFICA- TIONS in this group of the service manual for preferred specification. (9) If toe readings obtained are not within the required specification range, adjust toe to meet the preferred specification setting.
Page 19 2 - 8 SUSPENSION NOTE: All wheel alignments are to be set with the SPECIFICATIONS vehicle at its proper curb height. Refer to CURB HEIGHT MEASUREMENT in SERVICE PROCEDURES. WHEEL ALIGNMENT SPECIFICATIONS NOTE: All specifications are given in degrees. FRONT WHEEL ALIGNMENT ACCEPTABLE RANGE PREFERRED SETTING CAMBER...
Page 20: Front Suspension
SUSPENSION 2 - 9 FRONT SUSPENSION INDEX page page DESCRIPTION AND OPERATION LOWER CONTROL ARM ....25 BALL JOINT (FRONT UPPER) ....10 SERVICE WARNINGS AND CAUTIONS .
Page 21 2 - 10 SUSPENSION DESCRIPTION AND OPERATION (Continued) The shock absorber cushions the ride of the vehi- knuckle. The hub and bearing unit is not serviceable cle, controlling vibration, and jounce and rebound of and must be replaced as an assembly if the bearing the suspension.
Page 22 SUSPENSION 2 - 11 DESCRIPTION AND OPERATION (Continued) retained in the steering knuckle using a castle nut and a cotter pin. The cotter pin is used for positive retention of the castle nut. The lower ball joint is lubricated for life at the time it is assembled in the lower control arm.
Page 23 2 - 12 SUSPENSION DIAGNOSIS AND TESTING (Continued) cedures to replace the serviceable components are SERVICE PROCEDURES detailed in the specific component sections of this group. LUBRICATION The only serviceable lubrication points on the sus- BALL JOINT (FRONT UPPER) pension are the upper ball joints (Fig. 2). All other With the weight of the vehicle resting on the road joints are sealed for life.
Page 24 SUSPENSION 2 - 13 REMOVAL AND INSTALLATION (Continued) Fig. 2 Lubrication Points Fig. 4 Wheel Speed Sensor Cable Routing Bracket Fig. 3 Shock Tower To Spring Minimum Clearance (Fig. 6). Pull steering knuckle outward and position Area toward the rear of the front wheel opening. cation and Maintenance section of this manual, for (8) Remove pinch bolt attaching shock absorber the required lifting procedure to be used for this...
Page 25 2 - 14 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 8 Clevis To Lower Control Arm Attaching Bolt Fig. 5 Ball Joint Attachment To Steering Knuckle Fig. 9 Shock Assembly Attachment To Shock Tower Fig. 6 Ball Joint Stud Removal From Steering Knuckle INSTALLATION (1) Install the shock assembly, with the clevis...
Page 26 SUSPENSION 2 - 15 REMOVAL AND INSTALLATION (Continued) STEERING KNUCKLE REMOVE (1) Remove cotter pin, nut lock, and spring washer (Fig. 12) from the front stub axle. Fig. 10 Clevis Correctly Installed On Shock Absorber (5) Install the routing bracket for the speed control cable (Fig.
Page 27 2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) (5) Remove front disc brake caliper to steering knuckle guide pin attaching bolts (Fig. 14). Fig. 16 Correctly Supported Front Disc Brake Caliper Fig. 14 Front Disc Brake Caliper Mounting (6) Remove disc brake caliper assembly from steer- ing knuckle.
Page 28 SUSPENSION 2 - 17 REMOVAL AND INSTALLATION (Continued) (11) Remove the tie rod end from steering knuckle arm, using Remover, Special Tool MB-991113 (Fig. 19). Fig. 21 Lower Ball Joint Attachment To Steering Knuckle When striking steering knuckle care MUST be taken not to hit lower control arm or ball joint Fig.
Page 29 2 - 18 SUSPENSION REMOVAL AND INSTALLATION (Continued) steering knuckle away from the outer C/V joint (Fig. 23). Fig. 25 Ball Joint Stud Removal From Steering Knuckle Fig. 23 Separating Steering Knuckle From Outer C/V INSTALL Joint (1) If required install a hub/bearing assembly into steering knuckle before...
Page 30 SUSPENSION 2 - 19 REMOVAL AND INSTALLATION (Continued) (12) With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 244 N·m (180 ft. lbs.) of torque (Fig. 28). Fig. 26 Torquing Tie Rod End Attaching Nut CAUTION: The ball joint seal boot heat shield (Fig.
Page 31 2 - 20 SUSPENSION REMOVAL AND INSTALLATION (Continued) knuckle installed can result in damage to the tone (5) Remove front disc brake caliper to steering wheel teeth requiring replacement of the driveshaft. knuckle guide pin attaching bolts (Fig. 32). REMOVAL (1) Remove cotter pin, nut lock, and spring washer (Fig.
Page 32 SUSPENSION 2 - 21 REMOVAL AND INSTALLATION (Continued) (11) Remove the tie rod end from steering knuckle arm, using Remover, Special Tool MB-991113 (Fig. 37). Fig. 34 Correctly Supported Front Disc Brake Caliper Fig. 37 Tie Rod End Removal From Steering Knuckle (12) If equipped with antilock brakes remove the speed sensor cable routing bracket (Fig.
Page 33 2 - 22 SUSPENSION REMOVAL AND INSTALLATION (Continued) steering knuckle away from the outer C/V joint (Fig. 41). Fig. 39 Lower Ball Joint Attachment To Steering Knuckle When striking steering knuckle, care MUST be Fig. 41 Separating Steering Knuckle From Outer C/V taken not to hit lower control arm or ball joint Joint grease seal.
Page 34 SUSPENSION 2 - 23 REMOVAL AND INSTALLATION (Continued) (4) If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle (Fig. 38) and securely tighten attaching bolt. CAUTION: When installing tie rod on steering knuckle the heat shield (Fig. 45) must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor.
Page 35 2 - 24 SUSPENSION REMOVAL AND INSTALLATION (Continued) UPPER CONTROL ARM (FRONT) REMOVAL (1) Remove the front shock assembly from the vehicle. Refer to SHOCK ASSEMBLY (FRONT) in this section for the required procedure. (2) Disassemble the shock assembly until the upper (shock absorber/upper control arm) mounting bracket is removed from the coil spring.
Page 36 SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) (3) Install the control arm mounting bolt nuts. Position the control arm at a 90 degree angle to the mounting bracket and tighten the bolts to a torque of 90 N·m (66 ft. lbs.). (4) Reinstall the upper mounting bracket and con- trol arm on the coil spring.
Page 37 2 - 26 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 53 Lower Ball Joint To Steering Knuckle Fig. 55 Clevis To Lower Control Arm Attachment Attachment Fig. 56 Removing/ Installing Nut From Stud Of Fig. 54 Separating Lower Ball Joint Stud From Stabilizer Link Steering Knuckle CAUTION: Pulling the steering knuckle outward...
Page 38 SUSPENSION 2 - 27 REMOVAL AND INSTALLATION (Continued) INSTALL (1) Position rear of lower control arm into front suspension crossmember first. Then install front of lower control arm in front suspension crossmember. Install bolts and nuts (Fig. 58) and (Fig. 59) attach- ing the front and rear of lower control arm to front suspension crossmember.
Page 39 2 - 28 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 61 Stabilizer Bar Attaching Link Nut Removal Fig. 60 Supporting Lower Control Arm With Jack Stand (13) Install disc brake caliper on steering knuckle. Install and tighten the disc brake caliper mounting bolts (Fig.
Page 40 SUSPENSION 2 - 29 REMOVAL AND INSTALLATION (Continued) WHEEL MOUNTING STUDS (FRONT) CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly, DO NOT hammer the studs out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure.
Page 41 2 - 30 SUSPENSION REMOVAL AND INSTALLATION (Continued) (5) Install disc brake caliper assembly to steering knuckle attaching bolts (Fig. 63) and torque to 31 N·m (23 ft. lbs.). (6) Install front wheel and tire assembly. Install front wheel lug nuts and torque to 129 N·m (95 ft.lbs.).
Page 42 SUSPENSION 2 - 31 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 71 Retainer Nut Removal/Installation Fig. 69 Lower Hooks And Clamp Fig. 72 Washer NOTE: Before removing the coil spring from the spring compressor, note the position of the lower coil spring end to the spring compressor. The coil spring will need to be in this position on reassem- bly for proper coil spring-to-shock absorber and upper mounting bracket orientation.
Page 43 2 - 32 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 73 Shock Absorber Rod Upper Isolator Bushing (10) Remove the shock absorber rod lower isolator bushing and sleeve from the upper (shock absorber/ upper control arm) mounting bracket (Fig. 74). Remove upper coil spring isolator from mounting bracket.
Page 44 SUSPENSION 2 - 33 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: If installation of the upper control arm on the upper mounting bracket is necessary, refer to UPPER CONTROL ARM in the REMOVAL AND INSTALLATION section of this group to reinstall the upper control arm on the upper mounting bracket before proceeding.
Page 45 2 - 34 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (15) Install shock assembly on the vehicle. Refer to REMOVAL AND INSTALLATION in this section for the required procedure. BALL JOINT SEAL BOOT (FRONT UPPER) (1) Using a screw driver or other suitable tool, pry seal boot off of the ball joint assembly (Fig.
Page 46 SUSPENSION 2 - 35 DISASSEMBLY AND ASSEMBLY (Continued) lower control arm in area around ball joint and seal. (2) Slide ball joint seal boot with upper seal ring Then using a shop towel saturated with the engine installed, (Fig. 81) down tapered section of ball joint degreaser, carefully wipe off the ball joint seal boot.
Page 47 2 - 36 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (8) Remove Installer, Special Tool, 6875 from the ball joint seal boot. When removing tool from seal boot be careful not to damage the seal boot with the tool. (9) Check retaining ring installation on seal boot to ensure it is fully seated in seal boot groove and the ends are not twisted (Fig.
Page 48 SUSPENSION 2 - 37 DISASSEMBLY AND ASSEMBLY (Continued) machined surface of the lower control arm. This will correctly position front bushing in lower control arm. (5) Install lower control arm assembly back on vehicle. See Lower Control Arm Installation in this section of the service manual for the required instal- lation procedure.
Page 49 2 - 38 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) CONTROL ARM CLEVIS BUSHING To perform removal and replacement of the lower control arm clevis bushing, the lower control arm must be removed from the vehicle. DISASSEMBLE (1) Remove lower control arm assembly from vehi- cle.
Page 50 SUSPENSION 2 - 39 DISASSEMBLY AND ASSEMBLY (Continued) bar with slit in bushing facing front of vehicle when sway bar is installed. (5) Install bushing retainers back on stabilizer bar bushings. SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE Shock Assembly: Shock Tower Bolts .
Page 51 2 - 40 SUSPENSION SPECIAL TOOLS FRONT SUSPENSION Remover/Installer Control Arm Bushing 6602–5 (In Tool Kit 6602) Puller C-3894-A Installer/Receiver, Control Arm Bushing 6876 Installer, Ball Joint 6758 Remover / Installer C-4366-2 (In Tool Kit C-4366) Press, Ball Joint Remover Installer C-4212F Receiver, Ball Joint 6756 Remover, Ball Joint MB-990799...
Page 52 SUSPENSION 2 - 41 SPECIAL TOOLS (Continued) Installer, Bushing 6760 Installer, Ball Joint Seal Boot Retainer 6875 Remover/Installer Control Arm Clevis Bushing 6877 Remover, Tie Rod End MB-991113 or MB-990635 Remover, Lower Ball Joint C-4150A...
Page 53: Rear Suspension
2 - 42 SUSPENSION REAR SUSPENSION INDEX page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION HUB AND BEARING (REAR) ....44 HUB AND BEARING (REAR) ....50 KNUCKLE (REAR) .
Page 54 SUSPENSION 2 - 43 DESCRIPTION AND OPERATION (Continued)
Page 55 2 - 44 SUSPENSION DESCRIPTION AND OPERATION (Continued) HUB AND BEARING (REAR) lateral link attachment is done utilizing a rubber iso- lated stabilizer bar attaching link . All parts of the The hub and bearing is a combined rear wheel hub stabilizer bar are serviceable, and the stabilizer bar and wheel bearing unit.
Page 56 SUSPENSION 2 - 45 DIAGNOSIS AND TESTING (Continued) bent, the upper control arm must be replaced. The is bent or damaged the trailing link will require rear suspension upper control arm is not a repairable replacement. Do not ever attempt to repair or component and no attempt is to be made to repair or straighten a trailing link.
Page 57 2 - 46 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 2 Lubrication Points SHOCK ASSEMBLY (REAR) NOTE: Access for the nuts attaching the rear shock assembly upper mount to the vehicle is through the inside of the trunk. REMOVAL (1) Roll back carpeting on top of the rear shock tower to access shock mounting nuts.
Page 58 SUSPENSION 2 - 47 REMOVAL AND INSTALLATION (Continued) tion. Then repeat tightening sequence to full speci- fied torque of 129 N·m (95 ft. lbs.). (10) Lower vehicle to the ground. KNUCKLE (REAR) REMOVAL (1) Raise vehicle on jackstands or centered on a frame contact type hoist.
Page 59 2 - 48 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 11 Rear Brake Support Plate Mounting Bolts Fig. 8 Park Brake Cable Attachment To Actuating Lever Fig. 12 Correctly Stored Rear Brake Support Plate Fig. 9 Park Brake Cable Removal From Brake (8) Remove the nuts and bolts attaching the for- Support Plate ward and rear lateral links (Fig.
Page 60 SUSPENSION 2 - 49 REMOVAL AND INSTALLATION (Continued) (9) Remove cotter pin and castle nut attaching upper control arm ball joint to knuckle. (10) Remove ball joint stud from knuckle using Puller, Special Tool, CT-1106 (Fig. 14). When using puller, install castle nut on ball joint stud (Fig. 14) to protect threads from damage.
Page 61 2 - 50 SUSPENSION REMOVAL AND INSTALLATION (Continued) (3) Install upper ball joint stud in knuckle. Install Setting Procedure in the Wheel Alignment Check and tighten the ball joint stud castle nut to a torque And Adjustment section in this group of the service of 67 N·m (50 ft.
Page 62 SUSPENSION 2 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 21 Shock Absorber To Knuckle Attaching Fig. 20 Hub/Bearing Assembly Retaining Nut (3) Install the brake drum or brake rotor on the hub and bearing. (4) If equipped with rear disc brakes, install the rear caliper following the procedure found in REMOVAL AND INSTALLATION of the BASE BRAKE SYSTEM section of the group BRAKES.
Page 63 2 - 52 SUSPENSION REMOVAL AND INSTALLATION (Continued) (6) On only the side of the vehicle requiring con- trol arm removal, separate the control arm ball joint from the rear knuckle using following procedure. • Remove cotter pin and castle nut attaching upper control arm ball joint to knuckle.
Page 64 SUSPENSION 2 - 53 REMOVAL AND INSTALLATION (Continued) (6) Install muffler support bracket on rear frame rail (Fig. 22). Install rear exhaust pipe hanger on rear suspension crossmember (Fig. 23). (7) If vehicle is equipped with antilock brakes, install the wheel speed sensor cable routing clip on upper control arm mounting bracket.
Page 65 2 - 54 SUSPENSION REMOVAL AND INSTALLATION (Continued) (2) Remove the rear wheel and tire assembly from (3) Torque both lateral link attaching bolts to 95 the side of the vehicle requiring lateral link removal. N·m (70 ft. lbs.). (3) Remove the rear stabilizer bar attaching link (4) Install rear stabilizer bar attaching link, isola- from the forward lateral link (Fig.
Page 66 SUSPENSION 2 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 35 Trailing Link To Knuckle Attachment Fig. 34 Lateral Link Attachment To Rear Suspension Crossmember adjusting screw toward rear knuckle not rear suspension crossmember (Fig. 33). (2) Install the lateral link and the attaching bolt nut and washer at rear knuckle (Fig.
Page 67 2 - 56 SUSPENSION REMOVAL AND INSTALLATION (Continued) CAUTION: It is important that the following proce- dure be done when installing the trailing arm hanger bracket to the body of the vehicle. This pro- cedure will ensure that the hanger bracket is installed in the correct position on the vehicle.
Page 68 SUSPENSION 2 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 42 Installed Position Of Stabilizer Bar In Vehicle Fig. 40 Stabilizer Bar Attaching Link the stabilizer bar to attaching link bushings on (4) Remove the 4 bolts attaching the stabilizer bar attaching links.
Page 69 2 - 58 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) DISASSEMBLY WARNING: DO NOT REMOVE THE SHOCK ROD NUT BEFORE THE COIL SPRING IS COMPRESSED. (1) If both shocks are being serviced at the same THE COIL SPRING IS HELD UNDER PRESSURE time, mark the coil spring and shock assembly AND MUST BE COMPRESSED, REMOVING SPRING according to which side of the vehicle the shock was...
Page 70 SUSPENSION 2 - 59 DISASSEMBLY AND ASSEMBLY (Continued) (8) Remove the lower shock rod bushing washer from the top of the dust boot and shock absorber rod (Fig. 46). (9) Remove the dust shield and cup as an assem- bly from the shock absorber rod by pulling both straight up and off the shock rod (Fig.
Page 71 2 - 60 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) If the coil spring has been removed from the compressor, place the lower end (smaller diameter) of the coil spring in the spring compressor supported by the lower hooks at the same position as in disassem- bly (Fig.
Page 72 SUSPENSION 2 - 61 DISASSEMBLY AND ASSEMBLY (Continued) REMOVAL Special Tool 6804 on the top of the ball joint assem- bly (Fig. 55). (1) Using a screw driver or other suitable tool, pry seal boot up and off of ball joint assembly (Fig. 53). Fig.
Page 73 2 - 62 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) SPECIAL TOOLS REAR SUSPENSION Puller, Pitman Arm CT-1106 Fig. 56 Ball Joint Seal Boot Installation SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE Shock Assembly: Upper Mount To Body Nuts ..54 N·m (40 ft. lbs.) Knuckle Bolt/Nut .
Page 74 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CONTENTS page page GENERAL INFORMATION OUTER C/V JOINT BEARING SHIELD FRONT DRIVESHAFTS ....1 SERVICE .
Page 75 3 - 2 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: (1) A torn seal boot on the inner or outer joint of the driveshaft assembly. (2) A loose or missing clamp on the inner or outer joint of the driveshaft assembly.
Page 76 DIFFERENTIAL AND DRIVELINE 3 - 3 REMOVAL AND INSTALLATION (Continued) (6) Remove disc brake caliper assembly from steer- ing knuckle. Caliper is removed by first lifting bot- tom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle (Fig.
Page 77 3 - 4 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (12) Remove cotter pin and castle nut (Fig. 9) from stud of lower ball joint at the steering knuckle. Fig. 10 Separating Ball Joint Stud from Steering Knuckle Fig. 9 Lower Ball Joint to Steering Knuckle Attachment CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate...
Page 78 DIFFERENTIAL AND DRIVELINE 3 - 5 REMOVAL AND INSTALLATION (Continued) (16) Hold inner tripod joint and interconnecting (4) Clean all debris and moisture out of steering shaft of driveshaft assembly. Remove inner tripod knuckle, in the area were outer C/V joint will be joint from transaxle, by pulling it straight out of installed into steering knuckle.
Page 79 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (7) Install the steering knuckle to ball joint stud castle nut (Fig. 16). Tighten the castle nut to 95 N·m (70 ft. lbs.). Fig. 18 Installing Tie Rod End Nut Fig.
Page 80 DIFFERENTIAL AND DRIVELINE 3 - 7 REMOVAL AND INSTALLATION (Continued) Fig. 23 Torquing Front Hub Nut Fig. 21 Disc Brake Caliper Bolts (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 81 3 - 8 DIFFERENTIAL AND DRIVELINE (4) Remove snap ring which retains spider assem- DISASSEMBLY AND ASSEMBLY bly to interconnecting shaft (Fig. 27). Remove the spider assembly from interconnecting shaft. If spider INNER TRIPOD JOINT SEAL BOOT assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly REMOVAL with a brass drift (Fig.
Page 82 DIFFERENTIAL AND DRIVELINE 3 - 9 DISASSEMBLY AND ASSEMBLY (Continued) INSTALLATION NOTE: The inner tripod joint sealing boots are made from two different types of material. High temperature applications use silicone rubber where as standard temperature applications use hytrel plastic. The silicone sealing boots are soft and pli- able.
Page 83 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (5) Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 33). Fig. 35 Sealing Boot Retaining Clamp Installed CAUTION: The following positioning procedure determines the correct air pressure inside the inner...
Page 84 DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 38 Sealing Boot Retaining Clamp Installed Fig. 36 Trim Stick Inserted for Venting Tripod Joint LATCHING TYPE BOOT CLAMP (12) Clamp tripod joint sealing boot to tripod joint, If seal boot uses low profile latching type boot using required procedure for type of boot clamp clamp: application.
Page 85 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (3) Wipe away grease to expose outer C/V joint and interconnecting shaft. (4) Remove outer C/V joint from interconnecting shaft using the following procedure: Support inter- connecting shaft in a vise equipped with protec- tive caps on jaws of vise to prevent damage to interconnecting shaft.
Page 86 DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) sive wear, the driveshaft assembly will require replacement. Component parts of these drive- shaft assemblies are not serviceable. INSTALLATION (1) Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the inter- connecting shaft (Fig.
Page 87 3 - 14 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 50 Sealing Boot Retaining Clamp Installed Fig. 48 Sealing Boot Retaining Clamp Installed OUTER C/V JOINT BEARING SHIELD SERVICE CAUTION: Seal must not be dimpled, stretched, or out–of–shape in any way. If seal is NOT shaped cor- The front hub/bearing shield on the outer C/V joint rectly, equalize pressure in seal and shape it by is a serviceable component of the outer C/V.
Page 88 DIFFERENTIAL AND DRIVELINE 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) BEARING SHIELD INSTALLATION ON OUTER C/V SPECIFICATIONS JOINT TORQUE SPECIFICATIONS (1) Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint. (2) Position installer, Special Tool, C-4698-2 and DESCRIPTION TORQUE...
Page 90 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CONTENTS page page GENERAL INFORMATION OUTER C/V JOINT BEARING SHIELD FRONT DRIVESHAFTS ....1 SERVICE .
Page 91 3 - 2 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: (1) A torn seal boot on the inner or outer joint of the driveshaft assembly. (2) A loose or missing clamp on the inner or outer joint of the driveshaft assembly.
Page 92 DIFFERENTIAL AND DRIVELINE 3 - 3 REMOVAL AND INSTALLATION (Continued) (6) Remove disc brake caliper assembly from steer- ing knuckle. Caliper is removed by first lifting bot- tom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle (Fig.
Page 93 3 - 4 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (12) Remove cotter pin and castle nut (Fig. 9) from stud of lower ball joint at the steering knuckle. Fig. 10 Separating Ball Joint Stud from Steering Knuckle Fig. 9 Lower Ball Joint to Steering Knuckle Attachment CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate...
Page 94 DIFFERENTIAL AND DRIVELINE 3 - 5 REMOVAL AND INSTALLATION (Continued) (16) Hold inner tripod joint and interconnecting (4) Clean all debris and moisture out of steering shaft of driveshaft assembly. Remove inner tripod knuckle, in the area were outer C/V joint will be joint from transaxle, by pulling it straight out of installed into steering knuckle.
Page 95 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (7) Install the steering knuckle to ball joint stud castle nut (Fig. 16). Tighten the castle nut to 95 N·m (70 ft. lbs.). Fig. 18 Installing Tie Rod End Nut Fig.
Page 96 DIFFERENTIAL AND DRIVELINE 3 - 7 REMOVAL AND INSTALLATION (Continued) Fig. 23 Torquing Front Hub Nut Fig. 21 Disc Brake Caliper Bolts (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 3 - 8 DIFFERENTIAL AND DRIVELINE (4) Remove snap ring which retains spider assem- DISASSEMBLY AND ASSEMBLY bly to interconnecting shaft (Fig. 27). Remove the spider assembly from interconnecting shaft. If spider INNER TRIPOD JOINT SEAL BOOT assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly REMOVAL with a brass drift (Fig.
Page 98 DIFFERENTIAL AND DRIVELINE 3 - 9 DISASSEMBLY AND ASSEMBLY (Continued) INSTALLATION NOTE: The inner tripod joint sealing boots are made from two different types of material. High temperature applications use silicone rubber where as standard temperature applications use hytrel plastic. The silicone sealing boots are soft and pli- able.
Page 99 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (5) Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 33). Fig. 35 Sealing Boot Retaining Clamp Installed CAUTION: The following positioning procedure determines the correct air pressure inside the inner...
Page 100 DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 38 Sealing Boot Retaining Clamp Installed Fig. 36 Trim Stick Inserted for Venting Tripod Joint LATCHING TYPE BOOT CLAMP (12) Clamp tripod joint sealing boot to tripod joint, If seal boot uses low profile latching type boot using required procedure for type of boot clamp clamp: application.
Page 101 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (3) Wipe away grease to expose outer C/V joint and interconnecting shaft. (4) Remove outer C/V joint from interconnecting shaft using the following procedure: Support inter- connecting shaft in a vise equipped with protec- tive caps on jaws of vise to prevent damage to interconnecting shaft.
Page 102 DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) sive wear, the driveshaft assembly will require replacement. Component parts of these drive- shaft assemblies are not serviceable. INSTALLATION (1) Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the inter- connecting shaft (Fig.
Page 103 3 - 14 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 50 Sealing Boot Retaining Clamp Installed Fig. 48 Sealing Boot Retaining Clamp Installed OUTER C/V JOINT BEARING SHIELD SERVICE CAUTION: Seal must not be dimpled, stretched, or out–of–shape in any way. If seal is NOT shaped cor- The front hub/bearing shield on the outer C/V joint rectly, equalize pressure in seal and shape it by is a serviceable component of the outer C/V.
Page 104 DIFFERENTIAL AND DRIVELINE 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) BEARING SHIELD INSTALLATION ON OUTER C/V SPECIFICATIONS JOINT TORQUE SPECIFICATIONS (1) Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint. (2) Position installer, Special Tool, C-4698-2 and DESCRIPTION TORQUE...
Page 106 BRAKES 5 - 1 BRAKES CONTENTS page page ANTILOCK BRAKE SYSTEM ....73 BASE BRAKE SYSTEM ..... 1 BASE BRAKE SYSTEM INDEX page...
Page 107: Description And Operation
5 - 2 BRAKES cylinder is an anodized aluminum casting. It has a DESCRIPTION AND OPERATION machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake BASE BRAKE SYSTEM OPERATION line connections. The brake fluid reservoir of the When a vehicle needs to be stopped, the driver master cylinder assembly is made of a see through applies the brake pedal.
Page 108: Brake Tubes And Hoses
BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve (Fig. 4). As the brake pedal is depressed, the power boost- ers input rod moves forward (Fig.
Page 109: Disc Brakes (Front)
5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) PROPORTIONING VALVE brake system hydraulic pressure above a preset level (split point). Under light pedal application, the pro- This vehicle uses screw-in proportioning valves in- portioning valve allows full hydraulic pressure to be line with the rear brake tubes.
Page 110 BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 10 Front Disc Brake Caliper (Exploded View) which thread directly into bosses on the steering knuckle (Fig. 9), (Fig. 10) and (Fig. 11). Two machined abutments on the steering knuckle position the caliper. The guide pin bolts, sleeves and bushings control the side to side movement of the caliper.
Page 111: Disc Brakes (Rear)
5 - 6 BRAKES DESCRIPTION AND OPERATION (Continued) DISC BRAKES (REAR) cylinder in the area where the screw adjuster was located. The rear disc brakes are similar to the front disc The original equipment rear drum brake assem- brakes, however, there are several distinctive fea- blies used on this vehicle are supplied by Varga N.A.
Page 112 BRAKES 5 - 7 DESCRIPTION AND OPERATION (Continued) nating at the floor mounted, hand operated park sensor in the master cylinder reservoir, the ignition brake lever. switch in the crank position or the ABS CAB. On vehicles equipped with rear disc brakes, the The Brake Fluid Level sensor is located in the rear parking brakes have their own set of cable oper- brake fluid reservoir of the master cylinder assembly...
Page 113: Diagnosis And Testing
5 - 8 BRAKES DIAGNOSIS AND TESTING BRAKE SYSTEM DIAGNOSIS CHART GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 SYMPTOM MISC. WARNING POWER BRAKE NOISE WHEEL BRAKES COND. LIGHT BRAKES Brake Warning Light On Excessive Pedal Travel Pedal Goes To The Floor Stop Light On...
Page 114 BRAKES 5 - 9 DIAGNOSIS AND TESTING (Continued) BRAKE SYSTEM DIAGNOSIS CHARTS MISCELLANEOUS BRAKE SYSTEM CONDITIONS...
Page 115 5 - 10 BRAKES DIAGNOSIS AND TESTING (Continued) RED BRAKE WARNING LAMP FUNCTION...
Page 116 BRAKES 5 - 11 DIAGNOSIS AND TESTING (Continued) POWER BRAKE SYSTEM DIAGNOSTICS...
Page 117 5 - 12 BRAKES DIAGNOSIS AND TESTING (Continued) BRAKE NOISE...
Page 118 BRAKES 5 - 13 DIAGNOSIS AND TESTING (Continued) VEHICLE ROAD TEST PROPORTIONING VALVE NOTE: The following procedure is for the diagnosis and testing of the proportioning valve(s) on a vehi- cle without ABS. For diagnosis and testing of pro- portioning valves on a vehicle equipped with ABS, Refer to the ANTILOCK BRAKE SYSTEM section in this group.
Page 119 5 - 14 BRAKES DIAGNOSIS AND TESTING (Continued) (2) Remove hydraulic brake line (Fig. 18) from pro- portioning valve controlling the rear wheel of the vehicle which has premature wheel skid. (3) Remove the proportioning valve from the rear brake chassis tube. CAUTION: Be sure the pressure test fittings being installed into proportioning valve, have the correct thread sizes for installation into the proportioning...
Page 120: Brake Rotor
BRAKES 5 - 15 DIAGNOSIS AND TESTING (Continued) PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS Sales Inlet Brake System Type Split Point Slope Identification Outlet Pressure Code Pressure 14 Disc/Drum 500 psi 0.43 Bar Code 1000 psi 600-700 psi Label 14 Disc/Drum 500 psi 0.43 Bar Code...
Page 121 5 - 16 BRAKES DIAGNOSIS AND TESTING (Continued) Fig. 23 Checking Rotor For Thickness Fig. 24 Checking Rotor Runout the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adaptor, Special Tool SP- 1910 on steering arm.
Page 122 BRAKES 5 - 17 DIAGNOSIS AND TESTING (Continued) Fig. 27 Index Rotor And Wheel Stud Fig. 26 Checking Hub Runout DURES in this section of this group for information on brake rotor machining. BRAKE ROTOR LIMITS Minimum Rotor Rotor Rotor Micro Braking Rotor Rotor Thickness Rotor...
Page 123: Red Brake Warning Lamp
5 - 18 BRAKES DIAGNOSIS AND TESTING (Continued) Fully apply the brake pedal which will cause the brake shoes to leave the anchor. Upon application of the brake pedal, the adjuster quadrant should move. Thus, a definite rotation of the adjuster quadrant can be observed if the automatic adjuster is working properly.
Page 124: Base Brake Bleeding
BRAKES 5 - 19 SERVICE PROCEDURES (Continued) bringing it to the FULL mark on the side of the mas- MANUAL BLEEDING ter cylinder brake fluid reservoir. NOTE: To bleed the brakes manually, the aid of a helper will be required. (1) Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose...
Page 125 5 - 20 BRAKES SERVICE PROCEDURES (Continued) Use bleeder tank, Special Tool C-3496-B, with mas- ter cylinder reservoir adapter, Special Tool 8224, to pressurize the hydraulic system for bleeding. Following the same wheel circuit sequence as pre- scribed for manual bleeding. (1) Attach a clear plastic hose to the bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose...
Page 126 BRAKES 5 - 21 SERVICE PROCEDURES (Continued) Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas.
Page 127 5 - 22 BRAKES SERVICE PROCEDURES (Continued) BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action.
Page 128: Brake Drum Machining
BRAKES 5 - 23 SERVICE PROCEDURES (Continued) BRAKE DRUM MACHINING THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE If a brake drum is deeply scored or warped, it can PARTS USING ONLY WATER-DAMPENED SHOP be machined on a brake lathe equipped to machine TOWELS.
Page 129 5 - 24 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 46 Master Cylinder Mounting To Vacuum Fig. 43 Master Cylinder Fluid Level Sensor Booster BLEEDING MASTER CYLINDER (1) Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 to the master cyl- inder outlet ports (Fig.
Page 130: Brake Fluid Level Switch
BRAKES 5 - 25 REMOVAL AND INSTALLATION (Continued) BRAKE FLUID LEVEL SWITCH The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replace- ment of the brake fluid level sensor. (1) Remove wiring harness connector from brake fluid reservoir level sensor (Fig.
Page 131 5 - 26 BRAKES REMOVAL AND INSTALLATION (Continued) (3) If equipped, remove the vehicle’s wiring har- ness connector from the speed control servo. Remove the 2 speed control servo mounting bracket to strut tower attaching nuts (Fig. 55). Without removing speed control cable from servo, move speed control servo out of the way.
Page 132 BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 60 Master Cylinder Mounting Fig. 57 Vacuum Hose Attachment To Check Valve (9) Without removing the brake tubes from master cylinder, remove it from the power brake vacuum booster. Then carefully lower master cylinder and brake tubes as an assembly until it is positioned on top of the transaxle (Fig.
Page 133 5 - 28 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly. INSTALLATION (1) Position power brake booster onto dash panel. (2) Install and torque the 4 power brake vacuum booster mounting nuts (Fig.
Page 134 BRAKES 5 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 67 Engine Air Intake System Components Fig. 65 Ground Cable Attachment To Strut Tower (2) Correctly isolate remote ground cable when ser- vicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown (Fig. 66). This will prevent accidental grounding of the remote ground cable.
Page 135 5 - 30 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 69 EGR Tube Attachment To Intake Manifold Fig. 72 Primary And Secondary Brake Tubes And EGR Valve Without Antilock Brakes Fig. 70 Speed Control Servo Attachment To Strut Fig. 73 Master Cylinder Brake Fluid Level Sensor Tower Fig.
Page 136 BRAKES 5 - 31 REMOVAL AND INSTALLATION (Continued) Remove bracket and purge solenoid as an assembly from the vehicle. Fig. 77 Input Rod Retaining Pin Fig. 75 Purge Control Solenoid (12) Remove dipstick tube attaching bolt (Fig. 76). Then remove the dipstick tube and dipstick (Fig. 76) as an assembly from the transaxle.
Page 137: Brake Tubes And Hoses
5 - 32 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: Do not attempt to disassemble the AIS motor and the Throttle Position Sensor (Fig. 68) power brake vacuum booster it is to be serviced located on the throttle body. (16) Install the mounting bracket for the throttle ONLY as a complete assembly.
Page 138: Disc Brake Caliper (Front)
BRAKES 5 - 33 REMOVAL AND INSTALLATION (Continued) Only double wall 4.75mm (3/16 in.) steel brake line DISC BRAKE CALIPER (FRONT) tubing with Al- Rich/ZN-AL alloy coating should be used for replacement. Care must be taken when NOTE: Before proceeding, review SERVICE WARN- replacing brake tubing;...
Page 139 5 - 34 BRAKES REMOVAL AND INSTALLATION (Continued) by brake flex hose. Supporting disc brake cali- NOTE: Before vehicle is moved after any brake ser- per from flex hose can damage the hose (Fig. vice work, pump the brake pedal several times to 83).
Page 140 BRAKES 5 - 35 REMOVAL AND INSTALLATION (Continued) and out from the top machined abutment on steering knuckle (Fig. 85). Fig. 87 Removing / Installing Brake Rotor Fig. 85 Removing Brake Caliper (6) Support brake caliper from upper control arm to prevent weight of caliper from being supported by brake flex hose.
Page 141 5 - 36 BRAKES REMOVAL AND INSTALLATION (Continued) Check the caliper dust boot and caliper pin bush- ings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brit- tle. Refer to Guide Pin Bushing Service in Disc Brake Caliper Service in this section of the service manual.
Page 142: Disc Brake Caliper (Rear)
BRAKES 5 - 37 REMOVAL AND INSTALLATION (Continued) NOTE: Before vehicle is moved after any brake ser- vice work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. (13) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes.
Page 143 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication and Mainte- nance section of this manual. (2) Remove rear wheels and tires from vehicle. (3) Remove the 2 guide pin bolts mounting the cal- iper to the adapter (Fig.
Page 144 BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 101 Removing Outboard Brake Pad Fig. 99 Storing Caliper Fig. 102 Removing Inboard Brake Pad CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot.
Page 145 5 - 40 BRAKES REMOVAL AND INSTALLATION (Continued) INSTALLATION DRUM BRAKE WHEEL CYLINDER (REAR) (1) Completely retract the caliper piston back into NOTE: Before proceeding, review SERVICE WARN- the piston bore of the caliper. This is required for cal- INGS AND CAUTIONS at the beginning of REMOVAL iper installation when new brake pad assemblies are AND INSTALLATION in this section.
Page 146 BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 105 Adjuster Access Hole Plug Fig. 104 Wheel Cylinder Attaching Bolts so that teeth on quadrant, are moved toward the until all nuts are torqued to half specification. Then front of the vehicle. Continue moving quadrant repeat the tightening sequence to the full specified toward front of vehicle until it stops moving.
Page 147 5 - 42 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 110 Lower Brake Shoe Return Spring Fig. 107 Rear Brake Drum Assembly Fig. 111 Leading Brake Shoe Retainer Fig. 108 Adjuster Mechanism Actuating Spring Fig. 112 Leading Brake Shoe And Adjuster Fig.
Page 148 BRAKES 5 - 43 REMOVAL AND INSTALLATION (Continued) adjuster mechanism in the direction shown in (Fig. 115) to separate adjuster mechanism from leading brake shoe. Fig. 113 Trailing Brake Shoe To Support Plate Retainer CAUTION: On this vehicle, the park brake actuating Fig.
Page 149 5 - 44 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 116 Automatic Self Adjuster Mechanism Fig. 118 Shoe Contact Areas on Support Plate INSTALLATION will be positioned behind the brake shoe web (Fig. 113). NOTE: The leading rear brake shoes on this vehicle (3) Install the correctly handed trailing brake shoe are designated for which side of the vehicle they on the support plate so it is squarely seated on the...
Page 150 BRAKES 5 - 45 REMOVAL AND INSTALLATION (Continued) (6) Be sure leading brake shoe assembly is squarely seated on the brake support plate shoe con- tact areas. Then install the brake retainer on the retainer pin (Fig. 111). (7) Install the lower return spring onto the leading and trailing brake shoe assembly (Fig.
Page 151 5 - 46 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 122 Brake Drum And Hub And Bearing Fig. 124 Hub And Bearing Retaining Nut Assembly the Removal And Installation Section in this group of DRUM BRAKE SUPPORT PLATE (REAR) the service manual for the proper brake shoe assem- bly removal procedure.
Page 152 BRAKES 5 - 47 REMOVAL AND INSTALLATION (Continued) PARKING BRAKE LEVER REMOVAL (1) Remove the 2 screws (Fig. 127) attaching rear of center console assembly to console bracket. Fig. 126 Removing Park Brake Cable From Support Plate INSTALLATION (1) Install gasket and brake support plate on rear spindle.
Page 153 5 - 48 BRAKES REMOVAL AND INSTALLATION (Continued) • Remove the shifter boot from the center console. Shifter boot is removed by squeezing the bezel together at the base of the shifter boot and pulling upward on the boot (Fig. 131). Fig.
Page 154 BRAKES 5 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 134 Park Brake Lever Output Cable Adjustment Fig. 136 Wiring Harness Connection To Ground Switch (9) Using a screwdriver (Fig. 135) unlatch the park brake output cable retainer. Then remove cable retainer from park brake cable tension equalizer.
Page 155 5 - 50 BRAKES REMOVAL AND INSTALLATION (Continued) (2) Install the wiring harness (Fig. 137) on the park brake mechanism bracket. (3) Install the electrical connector on the ground switch of the park brake lever mechanism (Fig. 136). CAUTION: A new cable tension equalizer must be installed when replacing the park brake mechanism.
Page 156 BRAKES 5 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 142 Parking Brake Adjustment (Rear Disc Fig. 144 Shift Knob Retaining Screw Brakes) (3) If the vehicle is equipped with a manual trans- (11) Install screws attaching rear of center console mission remove the gearshift knob and shifter boot assembly to console bracket (Fig.
Page 157 5 - 52 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 149 Center Console Front Attaching Screws Fig. 146 Gearshift Knob Removal (Manual) brake cables, allowing rear park brake cables to be easily removed from tension equalizer. Fig. 147 Boot Removal Fig. 150 Park Brake Lever Output Cable Adjustment (9) Remove the rear park brake cable requiring service, from the park brake cable tension equalizer (Fig.
Page 158 BRAKES 5 - 53 REMOVAL AND INSTALLATION (Continued) (15) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubri- cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle.
Page 159 5 - 54 BRAKES REMOVAL AND INSTALLATION (Continued) (23) Raise vehicle. NOTE: The park brake cable routing and routing brackets are different on the right and left side of the vehicle. (24) Remove the 2 routing brackets attaching the right hand side (Fig. 159) or left hand side (Fig. 160) park brake cable to the frame rail.
Page 160 BRAKES 5 - 55 REMOVAL AND INSTALLATION (Continued) brake cable retainer, have expanded out to hold park brake cable in console bracket. Fig. 161 Park Brake Cable Removal / Installation At Floor Pan Fig. 162 Park Brake Cable Installed In Console are expanded to ensure park brake cable is securely Bracket held in the support plate.
Page 161 5 - 56 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: A new cable tension equalizer must be (16) Adjust cable tension for the parking brake installed when replacing a rear park brake cable . system using the following steps. • Position parking brake lever so it is in the fully The new cable tension equalizer is required to cor- rectly adjust park brake cable tension after install- released position.
Page 162: Brakes)
BRAKES 5 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 167 Parking Brake Adjustment (Rear Disc Brakes) (23) Install the shift knob on the shifter (Fig. 144) or (Fig. 146). (24) Install rear carpeting. (25) Install both rear door sill plate scuff moldings, Fig.
Page 163 5 - 58 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 170 Brake Shoe Lower Return Spring Fig. 172 Front Park Brake Shoe Hold Down Clip (12) Install rear disc brake caliper on adapter (See Brake Shoe Removal). (13) Install wheel and tire. (14) Tighten wheel stud nuts to 129 N·m (95 ft.lbs.).
Page 164: Disassembly And Assembly
BRAKES 5 - 59 REMOVAL AND INSTALLATION (Continued) (4) Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. CAUTION: Do not pry fluid reservoir off master cyl- inder using a tool, damage to the reservoir or mas- ter cylinder can result.
Page 165 5 - 60 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) CALIPER GUIDE PIN BUSHING REMOVAL (1) With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing (Fig.
Page 166 BRAKES 5 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 180 Installing Sleeve In Bushing Fig. 178 Installing Caliper Guide Pin Bushing Fig. 181 Correctly Installed Guide Pin Sleeve And Fig. 179 Bushing Correctly Installed In Caliper Bushing CALIPER PISTON AND SEALS NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of CALIPER PISTON REMOVAL...
Page 167 5 - 62 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. (2) Carefully depress the brake pedal to hydrauli- cally push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool.
Page 168 BRAKES 5 - 63 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: During the honing procedure, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. Use extreme care in cleaning the caliper after honing.
Page 169: Cleaning And Inspection
5 - 64 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) Fig. 188 Rear Wheel Cylinder (Exploded View) (1) Pry boots away from cylinders and remove (Fig. (4) Install piston in each end of cylinder having 188). the flat face of each piston contacting the flat face of (2) Press IN on one piston to force out opposite each cup, already installed (Fig.
Page 170: Disc Brakes (Rear)
BRAKES 5 - 65 CLEANING AND INSPECTION (Continued) CALIPER INSPECTION dry, or found to be brittle. Refer to Rear Disc Brake Caliper in the Disassembly And Assembly Section in Check caliper for piston seal leaks (brake fluid in this group of the service manual. and around boot area and inboard lining) and for any ruptures of the piston dust boot.
Page 171: Drum Brake Shoes
5 - 66 BRAKES CLEANING AND INSPECTION (Continued) • Ensure that the knurled pin (Fig. 190) is The steel brake tubing should be inspected period- securely attached to the adjuster mechanism and ically for evidence of corrosion, physical damage or that its teeth are not damaged.
Page 172 BRAKES 5 - 67 ADJUSTMENTS (Continued) brake cable tension. If the park brake cables require adjustment during the life of the vehicle, a NEW ten- sion equalizer MUST be installed before doing the park cable adjustment procedure. Fig. 194 Shift Knob Retaining Screw •...
Page 173 5 - 68 BRAKES ADJUSTMENTS (Continued) Fig. 199 Center Console Front Attaching Screws Fig. 196 Gearshift Knob Removal (Manual) Fig. 197 Boot Removal Fig. 200 Park Brake Lever Output Cable Adjustment installed when attaching output cable to tension equalizer. (9) Using a screwdriver (Fig. 201) unlatch the park brake output cable retainer.
Page 174 BRAKES 5 - 69 ADJUSTMENTS (Continued) Fig. 201 Output Cable To Equalizer Retaining Clip Fig. 203 Cable Retainer Installed On Tension Equalizer • Actuate the parking brake lever to its fully applied position (22 clicks) 1 time and then reposition the lever to its fully released position.
Page 175: Stop Lamp Switch
5 - 70 BRAKES ADJUSTMENTS (Continued) booster, stop lamp switch or striker (Fig. 206) can result. (5) Connect the wiring harness connector to the stop lamp switch. (6) Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger (Fig.
Page 176: Brake Actuating System
BRAKES 5 - 71 SPECIFICATIONS (Continued) BRAKE ACTUATING SYSTEM DESCRIPTION TORQUE Bleeder Screw ... . 10 N·m (80 in. lbs.) INTEGRATED CONTROL UNIT: ACTUATION: Mounting Bolts To Bracket . . . 11 N·m (97 in. lbs.) Vacuum Operated Power Brakes .
Page 177 5 - 72 BRAKES SPECIAL TOOLS (Continued) Installer, Dust Boot C-4689 Gauge Set C-4007-A Dial Indicator C-3339 Handle, Universal C-4171 Tubes, Master Cylinder Bleeding 6802...
Page 178: Antilock Brake System
BRAKES 5 - 73 ANTILOCK BRAKE SYSTEM INDEX page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION ANTILOCK BRAKE SYSTEM COMPONENTS . . . 74 INTEGRATED CONTROL ANTILOCK BRAKE SYSTEM OPERATION ..73 UNIT (HCU and CAB) ....86 HYDRAULIC CIRCUITS AND VALVE PROPORTIONING VALVE .
Page 179 5 - 74 BRAKES DESCRIPTION AND OPERATION (Continued) At the end of an ABS stop, ABS is turned off when Check the following common causes when diagnos- the vehicle is slowed to a speed of 3–4 mph. There ing premature ABS cycling: damaged tone wheels; may be a slight brake pedal drop anytime that the incorrect tone wheels;...
Page 180 BRAKES 5 - 75 DESCRIPTION AND OPERATION (Continued) INTEGRATED CONTROL UNIT (ICU) during normal braking and controls it when the vehi- cle is in an ABS stop. The CAB is mounted to the The hydraulic control unit (HCU) and the control- bottom of the HCU (Fig.
Page 181 5 - 76 BRAKES DESCRIPTION AND OPERATION (Continued) CONTROLLER ANTILOCK BRAKE OUTPUTS ondary hydraulic circuit (Fig. 4). Each hydraulic cir- • amber ABS warning lamp actuation cuit uses a 5 cc accumulator. • instrument cluster (MIC) The fluid accumulators temporarily store brake •...
Page 182 BRAKES 5 - 77 DESCRIPTION AND OPERATION (Continued) CAB. If either the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must be replaced. Refer to INTEGRATED CON- TROL UNIT in the DISASSEMBLY AND ASSEM- BLY section in this section of this service manual group for the procedure to remove the CAB from the HCU.
Page 183 5 - 78 BRAKES DESCRIPTION AND OPERATION (Continued) HYDRAULIC CIRCUITS AND VALVE OPERATION The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The following paragraphs explain how this works. For purposes of explanation only, it is assumed that only the right front wheel is experiencing antilock braking;...
Page 184 BRAKES 5 - 79 DESCRIPTION AND OPERATION (Continued) Fig. 11 Normal Braking Hydraulic Circuit Fig. 12 ABS Without Traction Control - Hydraulic Circuit...
Page 185 5 - 80 BRAKES GROUP 8W of this service manual. It will provide DIAGNOSIS AND TESTING you with the wiring diagrams and the circuit descrip- tion and operation information covering the antilock SERVICE WARNINGS AND CAUTIONS brake system. The ABS uses an electronic control module, the CAB.
Page 186 BRAKES 5 - 81 DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC TROUBLE CODES (DTC’s) Diagnostic trouble codes (DTC’s) are kept in the controller’s memory until either erased by the techni- cian using the DRB, or erased automatically after 3500 miles. DTC’s are retained by the controller even if the ignition is turned off or the battery is discon- nected.
Page 187 5 - 82 BRAKES DIAGNOSIS AND TESTING (Continued) (6) Look for poor terminal-to-wire connections. If a front tone wheel is found to need replacement, This requires removing the terminal from the connec- the drive shaft must be replaced. No attempt should tor body to inspect it.
Page 188 BRAKES 5 - 83 DIAGNOSIS AND TESTING (Continued) use the following procedure to diagnose the propor- tioning valve. Fig. 16 Brake Flex Hose Mounting Bracket CAUTION: Be sure the pressure test fittings being Fig. 14 Proportioning Valve Location installed into the proportioning valve have the cor- rect thread sizes and flares for installation into the The test procedure is the same for both rear wheel proportioning valve and for installation of the chas-...
Page 189 5 - 84 BRAKES DIAGNOSIS AND TESTING (Continued) Fig. 18 Proportioning Valve With Pressure Test Fig. 19 Pressure Gauges Installed On Pressure Test Fittings Installed Fittings chart, PROPORTIONING VALVE APPLICATIONS ing OEM brake lining material specifications. These AND PRESSURE SPECIFICATIONS. Then check conditions can also be a possible cause for a prema- the pressure reading on the proportioning valve out- ture rear wheel skid.
Page 190 BRAKES 5 - 85 SERVICE PROCEDURES (Continued) Refer to SERVICE PROCEDURES in the BASE (4) Bleed the base brake system using the stan- BRAKE SYSTEM section in this group for the proper dard pressure or manual bleeding procedure as out- procedure to check and adjust the brake fluid level in lined in SERVICE PROCEDURES in the BASE the master cylinder fluid reservoir.
Page 191 5 - 86 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: When performing any service procedure on a vehicle equipped with ABS do not apply a 12-volt power source to the ground circuit of the pump motor in the HCU. Doing this will damage the pump motor and will require replacement of the entire HCU.
Page 192 BRAKES 5 - 87 REMOVAL AND INSTALLATION (Continued) (5) Remove the splash shield (Fig. 23) from the right side of the engine compartment. Fig. 23 Right Side Splash Shield (6) Remove entire exhaust system from the vehicle as a complete assembly using the following steps. (a) Disconnect the oxygen sensor wiring har- nesses from the vehicle wiring harness.
Page 193 5 - 88 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 25 Exhaust System Support/Isolator Locations Fig. 26 HCU Heat Shield Fig. 27 Chassis Brake Tube Connections To HCU CAUTION: Before installing the 25 way connector (6) Install the bolt (Fig. 29) attaching the front leg in the CAB be sure that the seal is properly of the HCU mounting bracket to the front suspension crossmember.
Page 194 BRAKES 5 - 89 REMOVAL AND INSTALLATION (Continued) Fig. 28 Master Cylinder Brake Tube Connections To Fig. 31 HCU To Bracket Mounting Bolt Fig. 32 HCU To Bracket Mounting Bolt Fig. 29 HCU Mounting Bracket Front Bolt Fig. 33 Unlocked CAB Connector Fig.
Page 195 5 - 90 BRAKES REMOVAL AND INSTALLATION (Continued) (16) Install the remote ground cable onto the ground stud located on left shock tower (Fig. 20). Install the remote ground cable attaching nut and tighten to a torque of 28 N·m (250 in. lbs.). (17) Bleed the base brakes and the ABS brakes hydraulic system.
Page 196 BRAKES 5 - 91 REMOVAL AND INSTALLATION (Continued) Fig. 38 Proportioning Valve Removal Fig. 39 Speed Sensor Cable Routing Brackets INSTALLATION (1) Install proportioning valve on brake flex hose (Fig. 38). Tighten proportioning valve to a torque of 17 N·m (145 in. lbs.) (2) Install brake tube on proportioning valve (Fig.
Page 197 5 - 92 BRAKES REMOVAL AND INSTALLATION (Continued) speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly. Then insert a pin punch through hole in front steering knuckle (Fig.
Page 198 BRAKES 5 - 93 REMOVAL AND INSTALLATION (Continued) speed sensor cable to vehicle wiring harness connection is in the trunk of the vehicle. Fig. 47 Speed Sensor Cable Attachment To Rear Suspension Fig. 45 Rear Speed Sensor Cable Connection To Vehicle Wiring Harness (2) Raise vehicle on jack stands or centered on a frame contact type hoist.
Page 199 5 - 94 BRAKES REMOVAL AND INSTALLATION (Continued) (4) Install connector end of speed sensor cable through hole in inner fender and into trunk of vehi- cle. (5) Install speed control sealing grommet into hole in inner fender. Install the sealing grommet retainer and attaching bolt (Fig.
Page 200 BRAKES 5 - 95 BRAKE FASTENER TORQUE SPECIFICATIONS SPECIFICATIONS TONE WHEEL RUNOUT DESCRIPTION TORQUE MASTER CYLINDER: Mounting Nuts ... 28 N·m (250 in. lbs.) FRONT TONE WHEEL: Maximum Runout ..0.25 mm (0.009 in.) POWER BRAKE BOOSTER: REAR TONE WHEEL: Dash Panel Mounting Nuts .
Page 202 CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CLUTCH COMPONENTS ....1 CLUTCH ASSEMBLY ..... . 7 CLUTCH DISC AND COVER APPLICATION .
Page 203: Description And Operation
6 - 2 CLUTCH DESCRIPTION AND OPERATION CLUTCH CABLE The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear (Fig. 2). This adjuster mechanism is located within the clutch cable assembly. The preload spring maintains tension on the cable.
Page 204: Diagnosis And Testing
CLUTCH 6 - 3 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS–CLUTCH PEDAL POSITION SWITCH CONDITION POSSIBLE CAUSES CORRECTION ENGINE WON’T CRANK Switch does not have continuity Defective switch. Replace switch. WHEN CLUTCH PEDAL IS when plunger is depressed 1.25 mm PRESSED TO THE FLOOR Switch plunger is not depressed Floor mat interferes with clutch pedal when clutch pedal is pushed to the...
Page 205 6 - 4 CLUTCH DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear. Replace modular clutch assembly. Driver frequently rides (slips) clutch, Replace modular clutch assembly results in rapid wear overheating. Insufficient clutch cover diaphragm Replace modular clutch assembly spring tension CLUTCH DISC FACING...
Page 206: Clash-Into-Reverse Complaints
CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch cable binding or routed Check and correct cable routing incorrectly Self-adjuster in cable not functioning Pull on cable conduit at transaxle (as if properly, resulting in excess cable disconnecting cable) to check adjuster slack operation...
Page 207: Removal And Installation
6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) (3) Check the input shaft spline, clutch disc the pedal. Now remove the cable end from the splines, and release bearing for dry rust. If present, upstop/spacer. clean rust off and apply a light coat of bearing grease to the input shaft splines.
Page 208: Clutch Assembly
CLUTCH 6 - 7 REMOVAL AND INSTALLATION (Continued) determine if the mechanism is properly seated on the CLUTCH ASSEMBLY bracket. The transaxle must be removed to service the mod- (2) If the adjust mechanism functions properly, ular clutch disc assembly and lever. guide the cable through the slot in the transaxle housing.
Page 209: Release Bearing And Fork
6 - 8 CLUTCH REMOVAL AND INSTALLATION (Continued) RELEASE BEARING AND FORK OIL CONTAMINATION Oil contamination indicates a leak at the rear main Remove the transaxle from the vehicle. See Group seal and/or transaxle input shaft. Oil leaks produce a 21, Transaxle for removal and installation proce- residue of oil on the transaxle housing interior, clutch dures.
Page 210: Clutch Pedal Position Switch
CLUTCH 6 - 9 ADJUSTMENTS (Continued) Fig. 9 Cable at Transaxle Fig. 8 Clutch Cable Routing the clutch cable housing toward the dash panel. With less than 25 lbs. of effort the cable housing should move 30-50mm. This indicates proper adjuster mech- anism function.
Page 212 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION RADIATOR FAN CONTROL ....17 ACCESSORY DRIVE BELTS ....2 TEMPERATURE GAUGE INDICATION .
Page 213: General Information
7 - 2 COOLING SYSTEM WATER PIPES—2.5L GENERAL INFORMATION The 2.5L engine use metal piping beyond the lower COOLING SYSTEM radiator hose to route coolant to the suction side of water pump, located in the V of the cylinder banks. The cooling system consists of an engine cooling The pipes are also provided with inlet nipples for module, thermostat, coolant, a water pump to circu-...
Page 214 COOLING SYSTEM 7 - 3 GENERAL INFORMATION (Continued) Fig. 2 Cooling System Operation—2.5L Engine mostat housing/engine outlet connector (Fig. 7) and (Fig. 8). The thermostat has a air bleed located in the flange and a O-ring with a locating dimple incorpo- rate on it.
Page 215 7 - 4 COOLING SYSTEM GENERAL INFORMATION (Continued) coolant through the engine block, cylinder head, heater core, and radiator. Fig. 7 Thermostat/Engine Outlet Connector—2.0L Engine Fig. 5 Drive Belts—2.5L Engine Fig. 8 Thermostat and Engine Outlet Connector— 2.4L Engine Fig. 6 Coolant Recovery System NOTE: The water pump on all models can be replaced without discharging the air conditioning system.
Page 216: Automatic Transmission Oil Coolers
COOLING SYSTEM 7 - 5 GENERAL INFORMATION (Continued) WATER PUMP—2.5L ENGINE valve is stuck shut, the radiator hoses will col- lapse on cool-down. Clean the vent valve (Fig. The 2.5L pump bolts directly to the engine block 11) to ensure proper sealing when boiling point uses a gasket for pump to block sealing (Fig.
Page 217: Engine Block Heater
7 - 6 COOLING SYSTEM GENERAL INFORMATION (Continued) Fig. 12 Radiator Module Fig. 13 Fan Module EXTERNAL TRANSMISSION OIL COOLER An external oil-to-air type transmission oil cooler is mounted ahead of the cooling module (Fig. 15) and (Fig. 16). This style of cooler uses steel tubes and Fig.
Page 218: Coolant Performance
COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) (192 to 199°F). They also automatically reach wide COOLANT PERFORMANCE open so they do not restrict flow to the radiator as Performance is measurable. For heat transfer, one temperature of the coolant rises in hot weather to pound of pure water absorbs 1 btu for each degree of around 104°C (220°F).
Page 219: Engine Block Heater
7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting allowing coolant to return to radiator from coolant reserve system tank by vacuum through connecting hose.
Page 220: Water Pump-2.0/2.4L Engines
COOLING SYSTEM 7 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 20 Engine Block Heater exhaust manifolds and become damaged. For inder block. The water pump inlet is located at the removal procedures, refer to Removal and rear of the pump, a inlet tube located between the Installation in this section.
Page 221: Diagnosis And Testing
7 - 10 COOLING SYSTEM 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) been set indicating a stuck Group 25. Replace thermostat, if open engine thermostat? necessary.
Page 222 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 6. Poor seals at radiator cap. 6. (a) Check condition of cap and cap seals. Refer to Radiator cap Inspection. Replace cap if necessary. (b) Check condition of filler neck . If neck is bent or damaged, replace neck.
Page 223 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 16. Electric cooling fan not 16. Check electric fan operation and operating properly. repair as necessary. 17. Cylinder head gasket leaking. 17. Check cylinder head gasket for leaks.
Page 224 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 10. Air leak on the suction side of 10. Locate leak and repair as water pump allows air to build up in necessary. cooling system. This will cause the thermostat to open late.
Page 225 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ELECTRIC RADIATOR FAN WILL 1. Fan motor defective. 1. Refer to appropriate Powertrain NOT OPERATE. GAUGE READING Diagnostic Procedures manual for HIGH OR HOT operation of the DRB scan tool. Repair as necessary.
Page 226 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION INADEQUATE HEATER 1. Has a diagnostic trouble code 1. Refer to On-Board Diagnostic in PERFORMANCE. (DTC) been set? Group 25, Emission Control Systems. 2. Coolant level low. 2.
Page 227 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION STEAM IS COMING FROM FRONT 1. During wet weather, moisture 1. Occasional steam emitting from OF VEHICLE NEAR GRILL AREA (snow, ice or rain condensation) on this area is normal. No repair is WHEN WEATHER IS WET, the radiator will evaporate when the necessary.
Page 228: Electric Fan Motor Test
COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) RADIATOR FAN CONTROL RADIATOR FAN OPERATION—2.4L ENGINE Fan control is accomplished three ways. The fan runs when the air conditioning pressure reaches a Radiator Fan Control A/C Pressure set psi see charts below. In addition to this control, A/C Off High the fan is turned on by the temperature of the cool-...
Page 229: Pressure Cap To Filler Neck Seal Pressure Relief Check
7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) For wiring diagrams of the fan motor systems refer to Group, 8W Wiring Diagrams. COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill.
Page 230: Pressure Testing Cooling System
COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) ket for irregularities that may prevent the cap from sealing properly. Fig. 24 Cooling System Pressure Cap to Filler Neck There is no need to remove the pressure cap at any time except for the following purposes: •...
Page 231: Service Procedures
7 - 20 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION INSUFFICIENT ACCESSORY 1. Belt too loose. 1. Adjust belt tension. OUTPUT DUE TO BELT SLIPPAGE 2. Belt excessively glazed or worn. 2. Replace and tighten as specified. BELT SQUEAL WHEN 1.
Page 232: Cooling System-Draining
COOLING SYSTEM 7 - 21 SERVICE PROCEDURES (Continued) Fig. 26 Coolant Recovery Container and Pressure Cap Locations—2.0L Engine Fig. 27 Coolant Recovery Container and Pressure Cap Locations—2.4L Engine COOLING SYSTEM—DRAINING PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. NOTE: Drain, flush, and fill the cooling system at To drain cooling system move temperature selector the mileage or time intervals specified in the Main- for heater to full heat with engine running (to pro-...
Page 233: Cooling System-Refilling
7 - 22 COOLING SYSTEM SERVICE PROCEDURES (Continued) Fig. 28 Coolant Recovery Container and Pressure Cap Locations—2.5L Engine REMOVAL AND INSTALLATION WATER PUMP—2.0/2.4L ENGINES REMOVAL (1) Raise vehicle on a hoist. Remove right inner splash shield. (2) Remove accessory drive belts and power steer- ing pump.
Page 234 COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install new O-ring gasket in water pump body O-ring groove (Fig. 31). CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.
Page 235: Engines
7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Install pump to block mounting bolts and tighten to 27 N·m (20 ft. lbs.). (5) Install timing belt and right engine mount bracket and mount. Refer to Group 9, Engine for pro- cedure.
Page 236 COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) Fig. 38 Thermostat and Engine Outlet Connector— 2.4L Engine Fig. 40 Cooling Module Mounting WARNING: DO REMOVE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
Page 237: Radiator Draincock
7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (11) Remove screw attaching support bracket for (14) Operate engine until it reaches normal oper- air conditioning lines from right side of radiator. ating temperature. Check cooling system and auto- Remove support bracket. matic transmission for correct fluid levels.
Page 238 COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) retaining clip, so that the shaft and motor will not be INSTALLATION damaged by excessive force. Surface burr removal (1) Install fan module to radiator. Tighten shroud may be required to remove fan from motor to radiator fasteners to 7.5 N·m (65 in.
Page 239 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 45 Engine Block Heaters Accessory Drive Belt System—2.0/2.4L Engines (5) Tighten locking bolt E to 28 N·m (250 in. lbs.). (6) Tighten pivot bolt C to 54 N·m (40 ft. lbs.). ACCESSORY DRIVE BELTS—2.5L ENGINE Fig.
Page 240: Water Pump Inlet Tube-2.0/2.4L Engines
COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 48 Accessory Drive Belt Routing—2.5L Engine Fig. 47 Power Steering Belt Adjustment BELT TENSION CHART ACCESSORY DRIVE GAUGE BELTS 2.0/2.4L ENGINES 667 N (150 lbs.) Air Conditioning Belt: Compressor & Used Generator 356 N (80 lbs.)
Page 241: Water Pump-2.0/2.4L Engines
7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) BELT TENSION CHART ACCESSORY DRIVE GAUGE BELTS 2.5L ENGINE Air Conditioning Compressor & 667 N (150 lbs.) Belt: Generator Belt Used 356 N (80 lbs.) Belt: Power Steering Pump 578 N (130 lbs.) Belt Belt: Used...
Page 242: Accessory Drive Belt Inspection
COOLING SYSTEM 7 - 31 CLEANING AND INSPECTION (Continued) • Coolant leaks, if the shaft seal is leaking, evi- dent by traces of coolant leaks from vent hole A in (Fig. 52). • Impeller rubs inside of pump. • Excessively loose or rough turning bearing. ACCESSORY DRIVE BELT INSPECTION Belt replacement under any or all of the following conditions is required, excessive wear, frayed cords or...
Page 243: Belt Tension Gauge Method
7 - 32 COOLING SYSTEM CLEANING AND INSPECTION (Continued) CHEMICAL CLEANING SPECIFICATIONS One type of corrosion encountered with aluminum COOLING SYSTEM CAPACITY cylinder heads is aluminum hydroxide deposits. Cor- rosion products are carried to the radiator and depos- COOLING SYSTEM CAPACITY CHART ited when cooled off.
Page 244: Cooling
COOLING SYSTEM 7 - 33 SPECIAL TOOLS COOLING Hose Clamp Pliers 6094 Belt Tension Gauge 7198 Coolant Refractometer 8286...
Page 246 BATTERY 8A - 1 BATTERY CONTENTS page page GENERAL INFORMATION IGNITION OFF DRAW TESTS (IOD) ..4 INTRODUCTION ......1 SERVICE PROCEDURES SAFETY PRECAUTIONS AND WARNINGS .
Page 247: Description And Operation
This vehicle has an electronic voltage regulator A longer time will be needed to charge a battery at which controls battery charging. ONLY CHRYSLER -18°C (0°F) than at 27°C (80°F). When a fast charger approved battery blanket/block heater combination is connected to a cold battery, current accepted by should be used.
Page 248: Battery Discharging
BATTERY 8A - 3 DIAGNOSIS AND TESTING (Continued) (4) Inspect blanket heater for cuts, abrasion or BATTERY DISCHARGING other damage. If heater is damaged replace. If OK, go to Step 5. CAUSES OF BATTERY DISCHARGING (5) Lay heater flat and connect heater to vehicle’s It is normal to have up to a 30 milliamperes con- connector.
Page 249 8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) • Defective battery. Block that feed the modules with ignition off draw. Ensure that all electronic timer functions are timed IGNITION OFF DRAW TESTS (IOD) out before testing any of the components. High battery current draw when the ignition IN THE POWER DISTRIBUTION CENTER switch in the off position will discharge a battery.
Page 250: Battery Load Test
BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) MODULE AMPERAGE TABLE FUSE NO. MODULE INITIALIZER TIMEOUT DRAW DRAW DURING AFTER TIMEOUT TIMEOUT BCM - LAMPS RKE, DOOR AJAR, 0.5 MIN. 2.7 AMPS IGNITION KEY ON #5 & #10 IGNITION KEY ON 0.5 MIN.
Page 251: Battery Open Circuit Voltage Test
8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) (5) Rotate the load control knob on the tester to has open circuit voltage reading of 12.4 volts or maintain 50% (260) of the battery cold crank rating greater, and will not pass the load test, replace the for a minimum 15 seconds (Fig.
Page 252: Charging Completely Discharged Battery
BATTERY 8A - 7 SERVICE PROCEDURES (Continued) BATTERY OPEN CIRCUIT VOLTAGE CHARGING COMPLETELY DISCHARGED BATTERY Open Circuit Volts Charge Percentage The following procedure should be used to recharge a completely discharged battery. Unless procedure is 11.7 volts or less properly followed, a good battery may be needlessly 12.0 volts replaced.
Page 253: Visual Inspection And Service
8A - 8 BATTERY SERVICE PROCEDURES (Continued) the battery may be good, and charging should be (1) Make sure ignition switch completed in the normal manner. UNLOCKED position and all accessories are OFF. VISUAL INSPECTION AND SERVICE WARNING: NEVER GET UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS.
Page 254: Specifications
BATTERY 8A - 9 REMOVAL AND INSTALLATION (Continued) Fig. 11 Battery Tray Removal INSTALLATION COLD CRANK RATING For installation, reverse the above procedures. The current battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at –18°...
Page 256: Starting Systems
STARTING SYSTEMS 8B - 1 1999 JA Cirrus, Stratus and Breeze Publication No. 81-270-9121 TSB 26-09-98 September, 1998 STARTING SYSTEMS CONTENTS page page GENERAL INFORMATION FEED CIRCUIT TEST..... . . 3 GENERAL INFORMATION .
Page 257: Diagnosis And Testing
8B - 2 STARTING SYSTEMS STARTER RELAY DIAGNOSIS AND TESTING 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 • Starter relay •...
Page 258: Feed Circuit Resistance Test
STARTING SYSTEMS 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 259: Starting System Test
8B - 4 STARTING SYSTEMS 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 260 STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) • Battery - Visually inspect the battery for indi- tions of physical damage and loose or corroded wire cations of physical damage and loose or corroded harness connections. • Starter Relay - Visually inspect the starter cable connections.
Page 261: Removal And Installation
8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION STARTER DOES 1. STARTER 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING IMPROPERLY HARDWARE TO CORRECT TORQUE SPECIFICATIONS. DISENGAGE. INSTALLED. 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE 2.
Page 262 STARTING SYSTEMS 8B - 7 REMOVAL AND INSTALLATION (Continued) Fig. 7 Wire Terminal Connection – 2.0L Engine (6) Clean corrosion/dirt from wire terminals before installing wiring to the solenoid. (7) Connect battery positive cable to solenoid post (Fig. 8). (8) Connect the push-on solenoid connector. (9) Lower vehicle.
Page 263: Starter Relay
8B - 8 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) (6) Remove three bolts attaching starter to trans- SPECIFICATIONS mission housing and remove starter from vehicle. STARTER INSTALLATION For installation, reverse the above procedures. Manufacturer BOSCH MELCO NIPPONDENSO Clean corrosion/dirt from wire terminals before Engine 2.0L 2.5L...
Page 264 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page DESCRIPTION AND OPERATION ON-BOARD DIAGNOSTIC SYSTEM TEST ..5 BATTERY TEMPERATURE SENSOR ..2 REMOVAL AND INSTALLATION CHARGING SYSTEM .
Page 265: Description And Operation
8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) • Misaligned drive pulley regulates generator current output accordingly. Also • Defective stator or diode refer to Charging System Operation for additional • Damaged internal fins information. BATTERY TEMPERATURE SENSOR DIAGNOSIS AND TESTING DESCRIPTION CHARGING SYSTEM The sensor is located on the rear side of the front...
Page 266 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued) They will also show the amount of voltage drop from the ground (-) terminal on the generator (Fig. 2) or (Fig. 3) to the battery negative post. Fig. 4 Electrical Resistance Test Fig.
Page 267: Current Output Test
8C - 4 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) (3) Turn on headlamps and place in high-beam (3) Check condition of battery cables at battery. position. Clean if necessary. (4) Turn vehicle interior lamps on. (4) Be sure the generator drive belt is properly (5) Bring engine speed up to 2400 rpm and hold.
Page 268: On-Board Diagnostic System Test
CHARGING SYSTEM 8C - 5 DIAGNOSIS AND TESTING (Continued) lighting off, this could take several minutes of engine ERASING DIAGNOSTIC TROUBLE CODES operation. If amperage did not drop, refer to the The DRB Scan Tool must be used to erase a DTC. appropriate Powertrain Diagnostic Procedures man- ual for testing.
Page 269: Generator-2.4L (Nippondenso)
8C - 6 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) (5) Loosen adjusting T-bolt, but do not remove (Fig. 8). Fig. 9 Battery Cable at Shock Tower Fig. 8 Generator—2.0L Engine (6) Loosen pivot bolt, but do not remove. (7) Loosen adjusting bolt to allow removal of the generator drive belt.
Page 270 CHARGING SYSTEM 8C - 7 REMOVAL AND INSTALLATION (Continued) (6) Loosen adjusting bolt on idler to allow removal of the generator drive belt. Refer to the Cooling Sys- tem. (7) Remove pivot bolt, do not drop spacer. (8) Remove top mounting ear bolt. (9) Remove upper generator bracket.
Page 271: Specifications
8C - 8 CHARGING SYSTEM SPECIFICATIONS GENERATOR RATINGS TYPE ENGINES MINIMUM TEST AMPS DENSO 2.0L 74 amps DENSO 2.4L 74 amps MELCO 2.5L 74 amps The Test Specifications are: 1. 2500 20 RPMS 2. Voltage Output 15V 3. Field Current 5amps .1amp TORQUE DESCRIPTION...
Page 272 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION AUTOMATIC SHUTDOWN RELAY ... . 4 AUTOMATIC SHUTDOWN RELAY ... 16 CAMSHAFT POSITION SENSOR—2.0/2.4L .
Page 273: Description And Operation
8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) sensors, refer to Camshaft Position Sensor and to both electrode ends as show in (Fig. 1). Extreme Crankshaft Position Sensor in this section. care must be used to prevent spark plug cross threading, mis-gaping and ceramic insulator damage SPARK PLUGS—2.0/2.4L during plug removal and installation.
Page 274 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) pression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil and distributor cap towers and at the spark plugs. Terminals should be fully seated. The nipples and spark plug covers should be in good condition.
Page 275: Automatic Shutdown Relay
8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION The Automatic Shutdown (ASD) relay supplies bat- tery voltage to the fuel injectors, generator field, elec- tronic ignition coil and the heating elements in the oxygen sensors. Refer to the Wiring Diagrams for circuit informa- tion.
Page 276 IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) Fig. 8 Timing Reference Notches The notches generate pulses from high to low in OPERATION the crankshaft position sensor output voltage. When The crankshaft position sensor (Fig. 10) detects a metal portion of the counterweight aligns with the slots cut into the transmission driveplate extension.
Page 277: Camshaft Position Sensor-2.0/2.4L
8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 13 Camshaft Position Sensor—2.4L DOHC Fig. 11 Timing Slots CAMSHAFT POSITION SENSOR—2.0/2.4L DESCRIPTION The camshaft position sensor is mounted to the rear of the cylinder head. The sensor also acts as a thrust plate to control camshaft endplay (Fig.
Page 278 IGNITION SYSTEM 8D - 7 DESCRIPTION AND OPERATION (Continued) Fig. 15 Target Magnet Polarity Fig. 16 Camshaft Position Sensor—2.5L Engine OPERATION Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage The PCM determines fuel injection synchronization (signal) to the PCM while the engine operates.
Page 279: Diagnosis And Testing
8D - 8 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 17 Ignition Lock Cylinder Detents DIAGNOSIS AND TESTING Fig. 18 Testing For Spark TESTING FOR SPARK AT COIL—2.0/2.4L (4) Crank the engine and look for spark across the WARNING: THE DIRECT IGNITION SYSTEMS GEN- electrodes of the spark plug.
Page 280: Check Coil Test-2.0/2.4L
IGNITION SYSTEM 8D - 9 DIAGNOSIS AND TESTING (Continued) (3) Plug test spark plug cable onto coil tower. (4) Crank engine and look for spark across the electrodes of the spark plug. If there is no spark, check for: (Fig. 19) •...
Page 281: Distributor Cap Resistance Test-2.5L
8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) ply circuit shorts to ground, neither sensor will pro- tion before cranking. Wait for the test light to flash duce a signal (output voltage to the PCM). once, then crank the engine.) When the ignition key is turned and left in the On (6) If the test light momentarily flashes during position, the PCM automatically energizes the Auto...
Page 282 IGNITION SYSTEM 8D - 11 DIAGNOSIS AND TESTING (Continued) that a problem exists in the corresponding cylinder. FUEL FOULING Replace spark plugs at the intervals recommended in A spark plug that is coated with excessive wet fuel the - Lubrication and Maintenance section. is called fuel fouled.
Page 283 8D - 12 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) ELECTRODE GAP BRIDGING CHIPPED ELECTRODE INSULATOR Loose deposits in the combustion chamber can A chipped electrode insulator usually results from cause electrode gap bridging. The deposits accumu- bending the center electrode while adjusting the late on the spark plugs during continuous stop- spark plug electrode gap.
Page 284: Removal And Installation
IGNITION SYSTEM 8D - 13 DIAGNOSIS AND TESTING (Continued) This suggests that a plug with a cooler heat range Special care should be used when installing spark rating should be used. Over advanced ignition tim- plugs in the 2.0/2.4L cylinder head spark plug wells. ing, detonation and cooling system malfunctions also Be sure the plugs do not drop into the wells, damage can cause spark plug overheating.
Page 285 8D - 14 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) 2.5L SPARK PLUG GAP MEASUREMENT CAUTION: The Platinum pads can be damaged dur- ing the measurement of checking the gap if extreme care is not used. • Use only a taper gap gauge (Fig. 2) •...
Page 286 IGNITION SYSTEM 8D - 15 REMOVAL AND INSTALLATION (Continued) Fig. 32 Throttle Position Sensor Fig. 35 EGR Tube and Right Manifold Support Bolt (15) Prior to removing the spark plug spray com- pressed air around the spark plug hole and the area around the spark plug.
Page 287: Automatic Shutdown Relay
8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install coil pack on valve cover. (2) Transfer spark plug cables to new coil pack. The coil pack towers are numbered with the cylinder identification. Be sure the ignition cables snap onto the towers.
Page 288: Camshaft Position Sensor-Dohc
IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Disconnect the filtered air tube from the throt- tle body and air cleaner housing. Remove filtered air tube. (2) Remove the air cleaner inlet tube. (3) Disconnect electrical connectors from engine coolant sensor and camshaft position sensor.
Page 289: Crankshaft Position Sensor-2.0/2.4L
8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 46 Crankshaft Position Sensor Fig. 44 Target Magnet Installation (4) (Disconnect crankshaft position sensor electri- CRANKSHAFT POSITION SENSOR—2.0/2.4L cal connector from the wiring harness connector. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil INSTALLATION—ADJUSTABLE filter (Fig.
Page 290 IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) (4) Install speed control servo. Tighten nuts to 9 N·m (80 in. lbs.) torque. DISTRIBUTOR—2.5L REMOVAL (1) Remove bolt holding air inlet resonator to intake manifold. (2) Loosen clamps holding air cleaner cover to air cleaner housing.
Page 291: Distributor Cap-2.5L
8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) DISTRIBUTOR CAP—2.5L INSTALLATION (1) Install rotor on shaft. REMOVAL (2) Install distributor cap. (3) Install spark plug cables onto distributor cap. (1) Remove bolt holding air inlet resonator to The cap is numbered as well as the cables. Ensure intake manifold.
Page 292 IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) Fig. 54 Knee Bolster Attaching Points Fig. 51 Instrument Panel Top Cover—Left End Fig. 55 Lower Steering Column Shroud Screw Locations Fig. 52 Center Bezel Fig. 56 Remove Lower Shroud From Ignition Cylinder Fig.
Page 293 8D - 22 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 57 Lower Shroud Removal (11) Remove screws holding multi-function switch to lock housing (Fig. 58). Fig. 59 Lock Cylinder Removal Fig. 58 Multi-Function Switch Removal/Installation (12) Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder (Fig.
Page 294: Ignition Interlock
IGNITION SYSTEM 8D - 23 REMOVAL AND INSTALLATION (Continued) Fig. 63 Lock Cylinder Retaining Tab (2) The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig.
Page 295: Specifications
8D - 24 IGNITION SYSTEM TORQUE SPECIFICATION SPECIFICATIONS DESCRIPTION TORQUE VECI LABEL Air Inlet tube Clamp ..3 N·m (25 in. lbs.) Always use the information found on the Vehicle Camshaft Position Sensor Screw ..12 N·m Emission Control Information (VECI) label.
Page 296 IGNITION SYSTEM 8D - 25 SPECIFICATIONS (Continued) IGNITION COILS Primary Resistance at Secondary Resistance at 21°C-27°C Engines Coil Manufacture 21°C-27°C (70°F-80°F) (70°F-80°F) Toyodenso/ 2.0/2.4L 0.51 TO 0.61 Ohms 11,500 to 13,500 Ohms Diamond 2.5L Melco 0.6 TO 0.8 Ohms 12,500 to 18,000 Ohms Coil Polarity Coil Polarity...
Page 298 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page DESCRIPTION AND OPERATION SPECIFICATIONS SPARK PLUGS — 2.5L With Leaded Fuel SPARK PLUGS ......1 Option .
Page 300 INSTRUMENT PANEL AND SYSTEMS 8E - 1 INSTRUMENT PANEL AND SYSTEMS CONTENTS page page GENERAL INFORMATION HVAC CONTROL ......6 ELECTRO/MECHANICAL INSTRUMENT INSTRUMENT CLUSTER .
Page 301: Data Link Connector
8E - 2 INSTRUMENT PANEL AND SYSTEMS tion. This will cycle an electronic display segment DESCRIPTION AND OPERATION check and illumination in sequence of all CCD bus activated cluster warning indicators. There are four AUTOSTICK Check (CHEC) functions: Vehicles with Autostick will have a unique Trans- (1) CHEC 1, checks the gauges.
Page 302: Body Control Module (Bcm)
INSTRUMENT PANEL AND SYSTEMS 8E - 3 DIAGNOSIS AND TESTING (Continued) CHEC 2 - WARNING LAMP DISPLAY CHEC 4 - AUTOMATIC TRANSMISSION If any V/F segment does not light, replace Odome- ter/Transmission Range Indication. CHECK ENGINE TRANSMISSION RANGE (VF) DISPLAY - SEAT BELT AUTOSTICK AIRBAG...
Page 303: Center Bezel
8E - 4 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (b) Remove screw at left end of panel. (c) Pull hood straight back to disengage the For installation, reverse the above procedures. eight clips. If equipped with a Compass/Tempera- CENTER BEZEL ture Mini Trip Computer pull rearward about 3 inches and stop.
Page 304: Cubby Bin/Lamp
INSTRUMENT PANEL AND SYSTEMS 8E - 5 REMOVAL AND INSTALLATION (Continued) Fig. 5 Lamp Location INSTALLATION For installation, reverse the above procedures. The cubby bin must engage the console at its forward edge prior to installing the mounting screws. FUEL GAUGE AND TEMPERATURE GAUGE REMOVAL (1) Remove mask/lens...
Page 305: Glove Box Door Lock
8E - 6 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 10 Fuel Gauge and Temperature Gauge (3) Rotate the key clockwise to disengage cylinder from housing. INSTALLATION Fig. 7 Mask/Lens Retaining Screws For installation, reverse the above procedures. HVAC CONTROL REMOVAL (1) Remove center bezel by pulling rearward to...
Page 306: Instrument Panel
INSTRUMENT PANEL AND SYSTEMS 8E - 7 REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL (b) Lift rear edge and slide top cover rearward disengaging angular clips and remove cover. (15) Remove HVAC control attaching screws. WARNING: DISCONNECT AND ISOLATE THE BAT- (16) Remove center distribution duct screws from TERY NEGATIVE...
Page 307: Instrument Panel Top Cover
8E - 8 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 11 Instrument Panel Breakdown (2) Remove two screws on each speaker and lift (4) Lift the right rear edge of top cover to disen- up, disconnect wiring connector and remove speaker. gage the clips along the rear edge.
Page 308: Left Under Instrument Panel Silencer/Duct
INSTRUMENT PANEL AND SYSTEMS 8E - 9 REMOVAL AND INSTALLATION (Continued) RIGHT UNDER INSTRUMENT PANEL SILENCER/DUCT REMOVAL (1) Remove push-in fastener under right end of instrument panel. (2) Maneuver part off center floor distribution duct to remove. INSTALLATION For installation, reverse the above procedures. SPEEDOMETER/TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR Fig.
Page 310 INSTRUMENT PANEL AND GAUGE 8E - 1 INSTRUMENT PANEL AND GAUGE CONTENTS page page GENERAL INFORMATION HEADLAMP LEVELING SWITCH ... . . 2 ELECTRO/MECHANICAL INSTRUMENT SPEEDOMETER/TACHOMETER AND CLUSTER ......1 ODOMETER TRANSMISSION RANGE DIAGNOSIS AND TESTING INDICATOR .
Page 311 8E - 2 INSTRUMENT PANEL AND GAUGE DIAGNOSIS AND TESTING (Continued) (3) Connect the ground lead to a good ground, if no voltage, refer to Wiring Diagrams and test circuit back to headlamp switch. If battery voltage, repair Pin 2 ground circuit as necessary. (4) Turn headlamps OFF.
Page 312 INSTRUMENT PANEL AND GAUGE 8E - 3 REMOVAL AND INSTALLATION (Continued) SPEEDOMETER/TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR REMOVAL (1) Remove mask/lens retaining screws remove mask/lens (Fig. 3). (2) Disconnect odometer/transmission range indi- cator connector from the printed circuit board (Fig. (3) Remove screws attaching speedometer/tachom- eter to housing.
Page 314 INSTRUMENT PANEL AND GAUGE 8E - 1 INSTRUMENT PANEL AND GAUGE CONTENTS page page GENERAL INFORMATION HEADLAMP LEVELING SWITCH ... . . 2 ELECTRO/MECHANICAL INSTRUMENT SPEEDOMETER/TACHOMETER AND CLUSTER ......1 ODOMETER TRANSMISSION RANGE DIAGNOSIS AND TESTING INDICATOR .
Page 315 8E - 2 INSTRUMENT PANEL AND GAUGE DIAGNOSIS AND TESTING (Continued) (3) Connect the ground lead to a good ground, if no voltage, refer to Wiring Diagrams and test circuit back to headlamp switch. If battery voltage, repair Pin 2 ground circuit as necessary. (4) Turn headlamps OFF.
Page 316 INSTRUMENT PANEL AND GAUGE 8E - 3 REMOVAL AND INSTALLATION (Continued) SPEEDOMETER/TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR REMOVAL (1) Remove mask/lens retaining screws remove mask/lens (Fig. 3). (2) Disconnect odometer/transmission range indi- cator connector from the printed circuit board (Fig. (3) Remove screws attaching speedometer/tachom- eter to housing.
Page 318: Audio Systems
AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS CONTENTS page page GENERAL INFORMATION REMOTE CD CHANGER TEST ... . . 13 INTRODUCTION ......1 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION DOOR MOUNTED SPEAKER .
Page 319: Description And Operation
8F - 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) refer to the diagnostic tests. Refer to Group 8W, Wir- ELECTRICAL NOISE DISTORTION ONE SPEAKER • Remove output signal connector from amplifier ing Diagrams for Pin numbers and location. and check for short to ground on the speaker with REMOTE CD CHANGER the distortion.
Page 320 AUDIO SYSTEMS 8F - 3 DIAGNOSIS AND TESTING (Continued) BASE 6 SPEAKER SYSTEM...
Page 321 8F - 4 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) BASE 6 SPEAKER SYSTEM CONTINUED...
Page 322 AUDIO SYSTEMS 8F - 5 DIAGNOSIS AND TESTING (Continued) BASE 6 SPEAKER SYSTEM CONTINUED...
Page 323 8F - 6 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) BASE 6 SPEAKER SYSTEM CONTINUED...
Page 324 AUDIO SYSTEMS 8F - 7 DIAGNOSIS AND TESTING (Continued) AMPLIFIED...
Page 325 8F - 8 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 326 AUDIO SYSTEMS 8F - 9 DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 327 8F - 10 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 328 AUDIO SYSTEMS 8F - 11 DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 329 8F - 12 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 330: Manual Antenna
AUDIO SYSTEMS 8F - 13 DIAGNOSIS AND TESTING (Continued) NO BASS FREQUENCIES, HIGH AND MID POWER ANTENNA FREQUENCIES OK (1) To extend antenna, using jumper wires, attach • Check radio for being ON, are the display lights one end to a battery positive source and the other to the red and green wire terminals for up direction.
Page 331: Door Mounted Speaker
8F - 14 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) DIN CABLE PIN-OUTS PIN 1 DATA BUS (-) PIN 5 AUDIO IN PIN 2 AUDIO GRD PIN 6 BATTERY PIN 3 DATA BUS (+) PIN 7 IGNITION PIN 4 AUDIO IN (R) PIN 8 GROUND ERROR MESSAGES...
Page 332: Instrument Panel Speaker
AUDIO SYSTEMS 8F - 15 REMOVAL AND INSTALLATION (Continued) Fig. 4 Instrument Panel Top Cover Fig. 3 Door Mounted Speaker INSTRUMENT PANEL SPEAKER CAUTION: Do not operate the radio with speaker leads detached. Damage to the output devices may Fig. 5 Instrument Panel Speakers result.
Page 333: Power Antenna
8F - 16 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) POWER ANTENNA REMOVAL (1) Disconnect battery negative cable. (2) Inside trunk, pull trunk liner aside. (3) Unplug antenna lead from pigtail connector, disconnect wire connector, remove drain tube from grommet (Fig. 2). (4) Remove screws attaching ground strap and antenna brace.
Page 334: Rear Speaker
AUDIO SYSTEMS 8F - 17 REMOVAL AND INSTALLATION (Continued) REAR SPEAKER INSTALLATION For installation, reverse the above procedures. CAUTION: Do not operate the radio with speaker Tighten fasteners to 4 N·m (40 in. lbs.) torque. leads detached. Damage to the output devices may result.
Page 336 HORNS 8G - 1 HORNS CONTENTS page page DESCRIPTION AND OPERATION HORNS WILL NOT SOUND ....3 HORN RELAY ......1 SYSTEM TEST .
Page 337: Horn Relay
8G - 2 HORNS (1) Ground horn wire (Fig. 2). DIAGNOSIS AND TESTING (2) If horn does not sound, check for corrosion on wire, bracket or airbag contact ring and ensure horn HORN wire is properly connected. (1) Disconnect wire connector at horn. (3) If bracket needs to be replaced, the steering (2) Using a voltmeter, connect one lead to ground wheel must be replaced.
Page 338: Horns Will Not Sound
HORNS 8G - 3 DIAGNOSIS AND TESTING (Continued) (a) When the horn contact is not depressed, no (7) Using a continuity tester, with the horns dis- continuity. connected test continuity of the X2 cavity of the horn (b) Continuity to ground when horn contact is relay to ground.
Page 339 8G - 4 HORNS DIAGNOSIS AND TESTING (Continued) HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION HORN SOUNDS (1) FAULTY HORN RELAY. (1) REFER TO HORN RELAY TEST. CONTINUOUSLY. (2) HORN CONTROL (2) CHECK HORN RELAY TERMINAL 8 IN NOTE: IMMEDIATELY CIRCUIT TO RELAY THE JUNCTION BLOCK FOR CONTINUITY UNPLUG HORN RELAY IN...
Page 340: Removal And Installation
HORNS 8G - 5 HORN CONTACT SWITCH REMOVAL AND INSTALLATION HORNS WARNING: BEFORE BEGINNING ANY AIRBAG SYS- TEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE REMOVAL CABLE FROM THE VEHICLE BATTERY. THIS IS THE (1) Hoist and support front vehicle on safety ONLY SURE WAY TO DISABLE THE AIRBAG SYS- stands.
Page 342: Vehicle Speed Control System
VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page page DESCRIPTION AND OPERATION OVERSHOOT/UNDERSHOOT FOLLOWING AUTOMATIC SPEED CONTROL OVERSPEED SPEED CONTROL SET ....5 REDUCTION .
Page 343: Description And Operation
8H - 2 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 2 Speed Control System • Depressing the OFF switch While the speed control is engaged, the driver can • Depressing the CANCEL switch. increase the vehicle speed by depressing the ACCEL •...
Page 344: Automatic Speed Control Overspeed Reduction
VEHICLE SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) SPEED CONTROL SWITCHES OPERATION Vehicles equipped with the speed control option use DESCRIPTION a dual function stop lamp switch. The PCM monitors the state of the dual function stop lamp switch. Refer There are two separate switch pods that operate to the Brake section for more information on stop the speed control system.
Page 345: Diagnosis And Testing
8H - 4 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) trol software in the PCM uses vehicle speed and CHECKING FOR DIAGNOSTIC CODES acceleration to control to the set speed. When trying to verify a speed control system elec- Vehicles with a 3 speed automatic or manual trans- tronic malfunction: Connect a DRB scan tool if avail- mission have a Vehicle Speed Sensor (VSS) mounted...
Page 346: Overshoot/Undershoot Following Speed Control Set
VEHICLE SPEED CONTROL SYSTEM 8H - 5 DIAGNOSIS AND TESTING (Continued) OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET If the operator repeatedly presses and releases the set button with their foot off of the accelerator (a “lift foot set” to begin speed control operation), the vehicle may accelerate and exceed the desired set speed by up to 5 MPH (8 km/h) and then decelerate to less than the desired set speed before finally achieving...
Page 347 8H - 6 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) (2) With switch plunger released, there should be continuity between Pin 5 and Pin 6. (3) With switch plunger depressed, there should be continuity: • Between Pin 1 and Pin 2. •...
Page 348: Vacuum Supply Test
VEHICLE SPEED CONTROL SYSTEM 8H - 7 DIAGNOSIS AND TESTING (Continued) (5) Using an ohmmeter, check continuity from cav- ity 62 of the PCM connector to ground. If continuity is OK with brake pedal in unpressed position, pro- ceed to Step 6. (a) If no continuity, perform the Stop Lamp switch test.
Page 349: Speed Control Servo Cable
8H - 8 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION INSTALLATION (1) Install servo cable to servo and install clip. Before installing the switch, reset the adjustable (2) Install speed control cable to throttle cam. switch plunger by pulling on the plunger head until (3) Connect vacuum hose to servo.
Page 350: Vacuum Reservoir
VEHICLE SPEED CONTROL SYSTEM 8H - 9 REMOVAL AND INSTALLATION (Continued) (6) Rotate the throttle cam forward to the wide open position and install throttle cable clasp. (7) Install throttle control shield, if equipped. Fig. 9 Disconnecting Throttle Cable—Typical REMOVAL (1) 2.5L ONLY Remove the intake manifold, refer to the Engine section.
Page 352 TURN SIGNAL AND FLASHERS 8J - 1 TURN SIGNAL AND FLASHERS CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING MULTI-FUNCTION SWITCH ....1 COMBINATION FLASHER ....2 DESCRIPTION AND OPERATION MULTI-FUNCTION SWITCH .
Page 353 8J - 2 TURN SIGNAL AND FLASHERS DESCRIPTION AND OPERATION (Continued) Fig. 1 Multi-Function Switch are nine detentes (steps) of density. Detent 1 is full panel. The hazard switch is identified with a double brightness and each detent thereafter is lower. Test- triangle on top of the button.
Page 354 TURN SIGNAL AND FLASHERS 8J - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HAZARD WARNING 1) FAULTY FUSE. 1) REPLACE FUSE. MALFUNCTION/SYSTEM 2) FAULTY FLASHER. 2) REPLACE FLASHER. DOES NOT FLASH 3) OPEN CIRCUIT IN FEED 3) REPLACE WIRING/HARNESS. CHECK WIRE TO SWITCH.
Page 355 8J - 4 TURN SIGNAL AND FLASHERS DIAGNOSIS AND TESTING (Continued) Fig. 2 Multi-Function Switch Continuity Test...
Page 356 TURN SIGNAL AND FLASHERS 8J - 5 INSTALLATION REMOVAL AND INSTALLATION For installation, reverse the above procedures. 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 358 TURN SIGNAL AND FLASHERS 8J - 1 TURN SIGNAL AND FLASHERS CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING MULTI-FUNCTION SWITCH ....1 MULTI-FUNCTION SWITCH ....2 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION EXTERIOR LAMPS .
Page 359 8J - 2 TURN SIGNAL AND FLASHERS GENERAL INFORMATION (Continued) • Panel dimmer, rotating dimmer switch regulates cancel actuator and returns the switch to the off posi- tion. intensity of the instrument panel illumination. There If only momentary signaling such as indication of a are nine detentes (steps) of intensity.
Page 360 TURN SIGNAL AND FLASHERS 8J - 3 REMOVAL AND INSTALLATION (Continued) Fig. 2...
Page 362: Windshield Wipers And Washers
WINDSHIELD WIPERS AND WASHERS 8K - 1 WINDSHIELD WIPERS AND WASHERS CONTENTS page page GENERAL INFORMATION WASHER RESERVOIR ....8 MULTI-FUNCTION SWITCH ....1 WASHER RESERVOIR PUMP .
Page 363: General Information
8K - 2 WINDSHIELD WIPERS AND WASHERS GENERAL INFORMATION (Continued) Fig. 1 Multi-Function Switch has a range of 1/2 to 18 seconds when the vehicle wipe cycles ( 1) before the wipers park and the mod- speed is over 10 m.p.h.. The wiper delay times will ule turns off.
Page 364: Diagnosis And Testing
WINDSHIELD WIPERS AND WASHERS 8K - 3 DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING MULTI-FUNCTION SWITCH – WINDSHIELD WIPER To test the multi-function windshield wiper switch, refer to Group 8J Turn Signals and Hazard Warning Flashers, for diagnosis and testing of the Multi-Func- tion Switch.
Page 365 8K - 4 WINDSHIELD WIPERS AND WASHERS DIAGNOSIS AND TESTING (Continued) Fig. 5 Motor Wire Connector tion Center. If no voltage check fuse 18 (Fig. 4). If OK, go to Step 6. If not repair as necessary. (6) Using an ohmmeter, check from terminal 28 of the HI-LO wiper relay to Pin A of the motor wire connector for continuity.
Page 366 WINDSHIELD WIPERS AND WASHERS 8K - 5 DIAGNOSIS AND TESTING (Continued) wiper motor wire harness connector for continuity. If OK, go to Step 5. If not repair as necessary. (5) If wiper will not run at the high speed, using an ohmmeter, check for an open circuit.
Page 367: Wiper Motor System
8K - 6 WINDSHIELD WIPERS AND WASHERS DIAGNOSIS AND TESTING (Continued) WIPER WILL RUN CONTINUOUSLY WITH SWITCH (a) If the voltage is zero, check the wiring between the washer motor and the BCM. Repair as IN THE INTERMITTENT POSITION. WHEN COLUMN necessary.
Page 368: Removal And Installation
WINDSHIELD WIPERS AND WASHERS 8K - 7 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION MOTOR STOPS IN ANY 1) OPEN PARK CIRCUIT. 1) CHECK PARK SWITCH BY DISCONNECTING POSITION WHEN THE WIRE CONNECTOR AND APPLY BATTERY SWITCH IS TURNED OFF VOLTAGE TO PIN A.
Page 369: Washer Reservoir
8K - 8 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) INSTALLATION For installation, reverse the above procedures. Fig. 8 Multi-Function Switch hose. If no washer spray, check fluid hoses kinks or leaks (Fig. 9). Fig. 10 Reservoir Removal WASHER RESERVOIR PUMP REMOVAL (1) Partially remove the bumper fascia as needed to gain access to the reservoir pump.
Page 370: Wiper Arm And Blade
WINDSHIELD WIPERS AND WASHERS 8K - 9 REMOVAL AND INSTALLATION (Continued) WIPER ARM AND BLADE REMOVAL (1) Place the wiper arm/blades in the PARK posi- tion and turn ignition OFF. (2) Unsnap arm cover. By hand rock gently side to side and slide away from arm pivot.
Page 371: Wiper Motor
8K - 10 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) WIPER ARM LINKAGE OR CAP WIPER MOTOR ASSEMBLY REMOVAL REMOVAL (1) Remove wiper arms and blades. (1) Remove wiper arms and blades (Fig. 16). (2) Remove the cowl screen. (2) Remove the cowl screen.
Page 372: Cleaning And Inspection
WINDSHIELD WIPERS AND WASHERS 8K - 11 REMOVAL AND INSTALLATION (Continued) INSTALLATION ADJUSTMENTS For installation, reverse the above procedures. WIPER ARM Ensure proper position of grommets when installing: (1) The right inboard grommet is installed with High speed, wet windshield operation, the right insert flat facing down.
Page 374: Wiper And Washer Systems
WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS CONTENTS page HEADLAMP WASHERS ..... 1 HEADLAMP WASHERS INDEX page page GENERAL INFORMATION...
Page 375 8K - 2 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) HEADLAMP WASHER NOZZLE (2) Remove the right headlamp assembly. Refer to Group 8L, Lamps. (3) Partially remove the inner fender well as Removal needed to gain access to the reservoir. (1) Remove the headlamp assembly.
Page 376 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 18 LAMP BULB SERVICE ..... 8 EXTERIOR LAMP SWITCHES .
Page 377 8L - 2 LAMPS GENERAL INFORMATION (Continued) SYSTEM DIAGNOSTIC PROCEDURES connectors, relay, high beam dimmer switch and headlamp switch. Refer to Group 8W, Wiring Dia- When a vehicle experiences problems with the grams for component locations and circuit informa- headlamp system, verify the condition of the battery tion.
Page 378 LAMPS 8L - 3 GENERAL INFORMATION (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING and posts. OR IGNITION TURNED 2. Loose or worn generator drive 2.
Page 379 8L - 4 LAMPS HEADLAMP AND FOG LAMP ALIGNMENT INDEX page page GENERAL INFORMATION ADJUSTMENTS HEADLAMP ALIGNMENT ....4 FOG LAMP ALIGNMENT ....6 HEADLAMP ALIGNMENT PREPARATION .
Page 380 LAMPS 8L - 5 ADJUSTMENTS (Continued) (4) Rock vehicle side-to-side three times to allow NOTE: The bubble level and gauge wheel is cali- suspension to stabilize. brated before the headlamp is installed in the vehi- (5) Jounce front suspension three times by pushing cle.
Page 381 8L - 6 LAMPS ADJUSTMENTS (Continued) FOG LAMP ALIGNMENT Prepare a alignment screen (Fig. 5). Refer to Align- ment Screen Preparation paragraph in this section. A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp center line and straight ahead.
Page 382 LAMPS 8L - 7 EXTERIOR LAMP SWITCHES INDEX page page REMOVAL AND INSTALLATION HEADLAMP SWITCH ..... . 7 HEADLAMP DIMMER SWITCH ....7 REMOVAL AND INSTALLATION HEADLAMP DIMMER SWITCH The headlamp dimmer switch is incorporated into...
Page 383 8L - 8 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION FOG LAMP BULB ......9 ASH RECEIVER/CUP HOLDER LAMP BULB .
Page 384 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION Reverse the preceding operation. FOG LAMP BULB REMOVAL (1) Remove fog lamp from front bumper fascia. (2) Disengage wire connector from back of fog lamp. (3) Rotate bulb base counterclockwise one quarter turn.
Page 385 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) (5) Rotate socket counterclockwise one quarter INSTALLATION turn. Reverse the preceding operation. (6) Pull socket from back of lamp (Fig. 7). (7) Pull bulb from socket. LICENSE PLATE LAMP BULB REMOVAL (1) Remove screws attaching license plate lamp to rear bumper fascia.
Page 386 LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) (2) Pull lamp reflector from lamp assembly by (3) Push bezel and lamp assembly into cubby bin grasping lamp reflector opposite lamp bulbs and pull- to engage tabs. ing upward. GLOVE BOX LAMP BULB (3) Pull bulbs from socket as necessary.
Page 387 8L - 12 LAMPS LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION GLOVE BOX LAMP ..... . 14 ASH RECEIVER/CUP HOLDER LAMP ..14 HEADLAMP MODULE .
Page 388 LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) (4) Rotate socket counterclockwise one quarter TAIL, STOP, TURN SIGNAL, AND BACK-UP turn. LAMP (5) Pull socket from back of lamp (Fig. 3). (6) Pull bulb from socket. REMOVAL (1) Release decklid latch and open decklid. (2) Remove wing-nuts attaching tail lamp to rear closure panel (Fig.
Page 389 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) TAIL LAMP CIRCUIT BOARD (2) Disconnect wire connector from dome lamp. (3) Remove dome lamp from vehicle. REMOVAL INSTALLATION (1) Remove tail lamp. (1) Position dome lamp to vehicle. (2) Remove bulb sockets. (2) Connect wire connector to dome lamp.
Page 390 LAMPS 8L - 15 REMOVAL AND INSTALLATION (Continued) INSTALLATION (2) Connect wire connector to lamp assembly. (3) Engage tabs on transmission range indicator (1) Position lamp/switch assembly from vehicle. bezel to slots in rear floor console bezel. (2) Engage wire connector to assembly. (4) Push downward on transmission range indica- (3) Push upward on lamp/switch assembly to tor bezel to engage to bezel to floor console.
Page 391 8L - 16 LAMPS LAMP SYSTEMS INDEX page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING DAYTIME RUNNING LAMP (CANADA) ..16 GENERAL LAMP SYSTEM DIAGNOSTIC HEADLAMP TIME DELAY SYSTEM ..16 PROCEDURES .
Page 392 LAMPS 8L - 17 DIAGNOSIS AND TESTING (Continued) ILLUMINATED ENTRY DIAGNOSTIC controller uses input from the remote keyless entry system to switch ON the courtesy lamps. PROCEDURES Refer to Group 8W, Wiring Diagrams for compo- When testing the system, all doors must be closed nent location and circuit information.
Page 393 8L - 18 LAMPS BULB APPLICATION INDEX page page SPECIFICATIONS INTERIOR LAMPS ..... . . 18 EXTERIOR LAMPS ..... . . 18 SPECIFICATIONS A/C Heater Control .
Page 394 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 11 LAMP DIAGNOSIS ......1 HEADLAMP AND FOG LAMP ALIGNMENT .
Page 395 8L - 2 LAMPS HEADLAMP AND FOG LAMP ALIGNMENT INDEX page page GENERAL INFORMATION ADJUSTMENTS HEADLAMP ALIGNMENT PREPARATION ..2 HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN ....2 GENERAL INFORMATION (2) Place 75 kg in the driver’s seat to simulate the ride height of the vehicle when driven.
Page 396 LAMPS 8L - 3 ADJUSTMENTS (Continued) Fig. 1 Headlamp Alignment Screen—Typical HEADLAMP ADJUSTMENT headlamp horizontal centerline. The high beams on a vehicle with aero headlamps cannot be aligned. The A properly aimed low beam headlamp will project a high beam pattern should be correct when the low high intensity light pattern on the screen with the beams are aligned properly.
Page 397 8L - 4 LAMPS ADJUSTMENTS (Continued) Fig. 2 Fog Lamp Alignment-Typical FOG LAMP ALIGNMENT centerline and straight ahead (Fig. 2). To improve visual interpretation of the fog lamp pattern on the alignment Prepare an alignment screen. Refer to the Alignment screen, disable the headlamps by disengaging the wire Screen Preparation paragraph in this section.
Page 398 LAMPS 8L - 5 LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION PARK LAMP BULB ......6 CENTER HIGH MOUNTED STOP LAMP REAR FOG LAMP BULB .
Page 399 8L - 6 LAMPS REMOVAL AND INSTALLATION (Continued) TURN SIGNAL LAMP BULB REMOVAL (1) Release hood latch and open hood. (2) Remove screws holding headlamp module to radiator closure panel. (3) Separate headlamp module from radiator clo- sure panel. (4) Rotate socket counterclockwise one quarter turn. (5) Pull socket from back of lamp (Fig.
Page 400 LAMPS 8L - 7 REMOVAL AND INSTALLATION (Continued) REAR FOG LAMP BULB INSTALLATION Reverse the preceding operation. Removal CENTER HIGH MOUNTED STOP LAMP (1) Remove screws holding rear fog lamp to rear bumper fascia. (CHMSL) BULB (2) Separate rear fog lamp from rear bumper fas- cia (Fig.
Page 401 8L - 8 LAMPS LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION HEADLAMP MODULE ..... 8 CENTER HIGH MOUNTED STOP LAMP LICENSE PLATE LAMP .
Page 402 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Make sure headlamp leveling motor ball stud lines up with socket in headlamp module. (1) Insert and rotate headlamp leveling motor into the headlamp module. (2) With a flat blade screwdriver gently pry on headlamp reflector mechanism and fully seat head- lamp leveling motor ball stud into the socket (Fig.
Page 403 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) CENTER HIGH MOUNTED STOP LAMP (CHMSL) REMOVAL (1) Release trunk latch and open trunk lid. (2) Disengage wire connector from CHMSL harness. (3) Remove nuts holding CHMSL to trunk lid. (4) Separate CHMSL from trunk lid. INSTALLATION Reverse the preceding operation.
Page 404 LAMPS 8L - 11 BULB APPLICATION INDEX page SPECIFICATIONS EXTERIOR LAMPS ..... . . 11 SPECIFICATIONS EXTERIOR LAMPS Back-up ......P21–5W Fog .
Page 406: Passive Restraint Systems
PARTS MAY APPEAR INTERCHANGEABLE, BUT If the Driver/Passenger Airbag Module is defective INTERNAL DIFFERENCES MAY RESULT IN INFE- and not deployed, refer to Chrysler Corporation cur- RIOR OCCUPANT PROTECTION. rent return list for proper handling procedures.
Page 407: Description And Operation
8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION AIRBAG CONTROL MODULE (ACM) The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The impact sensor acts as a threshold sensitive switch that completes a circuit when an impact provides suf- ficient deceleration.
Page 408: Service Procedures
PASSIVE RESTRAINT SYSTEMS 8M - 3 PASSENGER AIRBAG SERVICE PROCEDURES After a Passenger Airbag Module has been CLEANUP PROCEDURE deployed: • Passenger Airbag Module • Instrument panel and pad assembly CAUTION: When working around deployed Airbags, The components above must be replaced because of rubber gloves, eye protection and long sleeves visible or non visible structural damage.
Page 409: Removal And Installation
8M - 4 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION AIRBAG CONTROL MODULE (ACM) WARNING: REPLACE AIRBAG SYSTEM COMPO- NENTS WITH CHRYSLER MOPAR SPECIFIED REPLACEMENT PARTS. SUBSTITUTE PARTS MAY VISUALLY APPEAR INTERCHANGEABLE, INTERNAL DIFFERENCES MAY RESULT IN INFE- RIOR OCCUPANT PROTECTION.
Page 410: Driver Airbag Module
PASSIVE RESTRAINT SYSTEMS 8M - 5 REMOVAL AND INSTALLATION (Continued) DRIVER AIRBAG MODULE REMOVAL CAUTION: When removing a deployed Driver Air- bag Module, rubber gloves, eye protection and long sleeves should be worn. There may be deposits on the surface that could irritate the skin and eyes. (1) Disconnect and isolate the battery negative remote cable (Fig.
Page 411: Passenger Airbag Module
8M - 6 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Install the two module bolts and tighten to 9 to 10 N·m (80 to 90 in. lbs.) torque. (3) Connect wire connectors to the speed control switches and install the switches. Tighten the screws to 0.7 to 2.7 N·m (6 to 24 in lbs.).
Page 412: Clockspring Centering Procedure
PASSIVE RESTRAINT SYSTEMS 8M - 7 REMOVAL AND INSTALLATION (Continued) (6) Remove the steering wheel retaining nut. (8) Install the airbag module bolts and tighten the (7) Remove the steering wheel with wheel puller left side first. Tighten to 9 to 10 N·m (80 to 90 in. tool.
Page 414: Description And Operation
ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION SYSTEM TEST ......2 HVAC CONTROL MODULE .
Page 415: Diagnosis And Testing
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. (2) Make sure defogger switch is OFF. (3) Remove the battery negative remote cable from the terminal.
Page 416: Service Procedures
ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) TESTING WITH SCAN TOOL If using the scan tool, refer to the proper Body Diagnostic Procedures Manual. TESTING WITHOUT SCAN TOOL (1) Remove the control switch from console and do not disconnect control switch (Fig.
Page 417: Removal And Installation
8N - 4 ELECTRICALLY HEATED SYSTEMS SERVICE PROCEDURES (Continued) (4) Apply conductive epoxy through slit in masking tape. Overlap both ends of the break by 19 mm (3/4 inch). (5) For a terminal or pigtail replacement, mask adjacent areas so epoxy can be extended onto line as well as bus bar.
Page 418: Heated Seats
ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page HEATED SEATS ......1 HEATED SEATS INDEX page...
Page 419 8N - 2 ELECTRICALLY HEATED SYSTEMS DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING HEATED SEAT SWITCH HEATED SEAT SYSTEM The heated seat switch is located in the floor con- For circuit descriptions and diagrams, refer to sole. The two six-position rotating-type switches, one 8W-63 - Power Seat With Heated Seats in Group 8W switch for each front seat, provide a voltage signal to - Wiring Diagrams.
Page 420 ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) (2) Disconnect the green 4–way heated seat cush- ion connector and check for continuity between pins A and B of the heated seat cushion connector. There should be continuity, if OK, test the heated seat back for continuity.
Page 421 8N - 4 ELECTRICALLY HEATED SYSTEMS REMOVAL AND INSTALLATION (Continued) HEATED SEAT CONTROL MODULE (1) Move the power seat adjuster to its upper-most and rearward-most stop positions. (2) Disconnect and isolate the battery negative cable. (3) Reach under the front of the seat cushion and separate the heated seat control module from the seat cushion frame (Fig.
Page 422 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION JUNCTION BLOCK (JB) ....2 JUNCTION BLOCK (JB) .
Page 423 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) JUNCTION BLOCK (JB) in the Component Index of Group 8W - Wiring Dia- grams for complete circuit diagrams. An electrical Junction Block (JB) is located in the The fuses, circuit breakers, relays, and are avail- left endcap of the instrument panel.
Page 424 POWER DISTRIBUTION SYSTEMS 8O - 3 REMOVAL AND INSTALLATION (Continued) (1) Open hood then disconnect and isolate the bat- REMOVAL tery negative remote cable from the remote terminal (1) Open hood then disconnect and isolate the bat- on the left shock tower (Fig. 3). tery negative remote cable from the remote terminal on the left shock tower (Fig.
Page 425 8O - 4 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Install and tighten the fasteners that secure (6) Reconnect each of the engine compartment each of the engine compartment wire harness ground wire harness connectors. Refer to 8W-90 - Connec- eyelets to the vehicle body and chassis components.
Page 426: Power Lock Systems
POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS CONTENTS page page POWER DOOR LOCKS ..... 1 REMOTE KEYLESS ENTRY ....4 POWER DOOR LOCKS INDEX page...
Page 427: Description And Operation
8P - 2 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) er’s or passenger door cylinder lock to the lock posi- tion, all doors will lock. This feature operates differently on each door. Turn key in the driver’s door to the unlock position once will unlock driver’s door only.
Page 428: Voltage
POWER LOCK SYSTEMS 8P - 3 DIAGNOSIS AND TESTING (Continued) VOLTAGE (2) Disconnect motor/latch wire connector (Fig. 1). (3) Disconnect linkage from: The following circuit test sequence determines • Outside door handle whether or not voltage is continuous through the •...
Page 429 8P - 4 POWER LOCK SYSTEMS REMOTE KEYLESS ENTRY INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION INTRODUCTION ......4 JUNCTION BLOCK (JB) .
Page 430 POWER LOCK SYSTEMS 8P - 5 (2) If the RKE still doesn’t function. Check the key DIAGNOSIS AND TESTING fob transmitter battery(s) for 3 Volts each. If less than 3 Volts, replace the battery(s). DIAGNOSTIC CONDITIONS (3) If the system still does not work, replace the Refer to (Fig.
Page 431 8P - 6 POWER LOCK SYSTEMS DIAGNOSIS AND TESTING (Continued) (4) If no voltage pulse measured, replace the BCM. If voltage is measured, repair the Junction Block as nec- essary. Unable to program BCM with a new key fob transmitter, door locks will not cycle. Check BCM country code setting and refer to the proper Body Diagnostic Procedure Manual.
Page 432 REMOTE KEYLESS ENTRY 8P - 1 REMOTE KEYLESS ENTRY CONTENTS page REMOTE KEYLESS ENTRY ....1 REMOTE KEYLESS ENTRY INDEX page page GENERAL INFORMATION SYNCHRONIZATION OF ROLLING CODE .
Page 433: Remote Keyless Entry
8P - 2 REMOTE KEYLESS ENTRY GENERAL INFORMATION (Continued) Each Remote Keyless Entry Module must have at least one and no more than four key fob transmit- ters. Fig. 1 Remote Keyless Entry (RKE) Transmitter DESCRIPTION AND OPERATION DECK LID RELEASE RELAY The Deck Lid Release circuit works in conjunction Fig.
Page 434: Diagnostic Conditions
REMOTE KEYLESS ENTRY 8P - 3 DIAGNOSIS AND TESTING (Continued) when energized supplies battery voltage to the deck All doors will not unlock with the key fob lid release solenoid. If OK, go to Step 3. If not OK, transmitter. repair the open circuit to the deck lid release sole- (1) Using a voltmeter, check Pin 4 of the BCM 20 noid as required.
Page 435: Service Procedures
8P - 4 REMOTE KEYLESS ENTRY DIAGNOSIS AND TESTING (Continued) Doors will lock with the key fob transmitter but neously for at lease five seconds. Then wait until the doors unlock indicating that the code has been syn- there is no horn CHIRP. chronized.
Page 436 VEHICLE THEFT / SECURITY SYSTEM 8Q - 1 VEHICLE THEFT / SECURITY SYSTEM CONTENTS page page GENERAL INFORMATION VEHICLE THEFT / SECURITY SYSTEM (VTSS) INTRODUCTION ......1 SELF - TESTS .
Page 437: Description And Operation
The SKIS programming also enables three seconds when the ignition switch is turned to the SKIM to communicate over the Chrysler Collision the ON position as a bulb test. After completion of Detection (CCD) data bus network with the Power-...
Page 438: Sentry Key Immobilizer System Indicator Lamp
DESCRIPTION AND OPERATION (Continued) sages received from the Sentry Key Immobilizer Module (SKIM) through the Body Control Module (BCM) on the Chrysler Collision Detection (CCD) data bus. The SKIM sends messages to the instrument clus- ter, via the BCM, to turn the LED on for about three seconds when the ignition switch is turned to the ON position as a bulb test.
Page 439: Diagnosis And Testing
The Sentry Key Immobilizer System (SKIS) and • The Remote Keyless Entry the Chrysler Collision Detection (CCD) data bus net- • The Central Lock Feature. work should be diagnosed using a DRB lll scan tool. If the LED lamp does not illuminate at all upon...
Page 440: Vehicle Theft / Security System (Vtss) Self - Tests
(1) Obtain vehicles unique number assigned to it’s original SKIM module from the vehi- cle owner, the vehicle’s invoice or from Chrysler’s Customer Center. (2) With the DRB lll scan tool, select “Theft Alarm,” “SKIM,” Miscellaneous.” Select “SKIM Mod- ule Replaced” function and the DRB lll will prompt you through the following steps.
Page 441: Removal And Installation
8Q - 6 VEHICLE THEFT / SECURITY SYSTEM SERVICE PROCEDURES (Continued) requires access to at least two of the valid Sentry PROGRAMMING BLANK SENTRY KEY Keys. If two valid Sentry Keys are not available, Sen- TRANSPONDERS WITH A DRB lll SCAN TOOL try Key programming will require the use of a DRB When programming a blank Sentry Key transpon- lll scan tool.
Page 442: Junction Block (Jb)
VEHICLE THEFT / SECURITY SYSTEM 8Q - 7 REMOVAL AND INSTALLATION (Continued) JUNCTION BLOCK (JB) (5) Remove the two screws securing the SKIM module to the top of the steering column. Refer to Group 8O, Power Distribution Systems for (6) Rotate the SKIM and its mounting bracket Removal and Installation.
Page 444: Description And Operation
POWER SEATS 8R - 1 POWER SEATS CONTENTS page page DESCRIPTION AND OPERATION SEAT SWITCH ......2 INTRODUCTION .
Page 445: Seat Switch
8R - 2 POWER SEATS DIAGNOSIS AND TESTING (Continued) SWITCH HARNESS CONNECTOR CIRCUIT TEST CAVITY TEST FUNCTION (–) GROUND SEATBACK RECLINER UP SEAT BACKWARD SEATBACK RECLINER DOWN BATTERY SEAT FORWARD FRONT RISER UP REAR RISER UP REAR RISER DOWN FRONT RISER DOWN SEAT SWITCH (1) Remove switch from mounting position Refer to (Fig.
Page 446: Voltage
POWER SEATS 8R - 3 DIAGNOSIS AND TESTING (Continued) (1) Remove the four screws retaining the left and right seat cushion side shields. (2) Disconnect the power seat switch connectors from the seat cushion side shield and remove side shield. (3) Remove the four bolts retaining the power seat adjuster to the seat assembly and remove.
Page 448: Power Windows
POWER WINDOWS 8S - 1 POWER WINDOWS CONTENTS page page GENERAL INFORMATION WINDOW SWITCH ..... . . 1 INTRODUCTION ......1 REMOVAL AND INSTALLATION DIAGNOSIS AND TESTING WINDOW MOTOR .
Page 449 8S - 2 POWER WINDOWS DIAGNOSIS AND TESTING (Continued) REMOVAL (1) Move the window to the full-up position, if pos- sible. (2) Remove door trim panel and window regulator, refer to Group 23 Body for removal procedures. WARNING: FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOV- ING THE MOTOR CAN RESULT IN INJURY.
Page 450 POWER WINDOWS 8S - 3 REMOVAL AND INSTALLATION (Continued) WINDOW SWITCH MASTER SWITCH REMOVAL (1) Remove driver’s door trim panel, refer to Group 23, Body for removal procedures. (2) Remove three mounting screws. (3) Remove switch and disconnect wire connector. INSTALLATION For installation, reverse the above procedures.
Page 452: Power Mirrors
POWER MIRRORS 8T - 1 POWER MIRRORS CONTENTS page page DESCRIPTION AND OPERATION MIRROR MOTOR ......2 HEATED MIRROR .
Page 453 8T - 2 POWER MIRRORS DIAGNOSIS AND TESTING (Continued) MIRROR MOTOR (1) Remove door trim panel. Refer to Group 23, Body. (2) Disconnect wire connector from the switch. (3) Using two jumper wires, one connected to a 12 volt battery source, and the other connected to a good body ground.
Page 454 CHIME WARNING / REMINDER SYSTEM 8U - 1 CHIME WARNING / REMINDER SYSTEM CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION INTRODUCTION ......1 BODY CONTROL MODULE (BCM) .
Page 455: Exterior Lamps Left On
8U - 2 CHIME WARNING / REMINDER SYSTEM DESCRIPTION AND OPERATION DOOR AJAR CHIME An audible chime will sound when the vehicle begins to move and the transmission range indicator display will indicate DOOR. EXTERIOR LAMPS LEFT ON To test the headlamps left on function, turn igni- tion off, turn exterior lamps on with driver’s door open.
Page 456: Removal And Installation
CHIME WARNING / REMINDER SYSTEM 8U - 3 DIAGNOSIS AND TESTING (Continued) (1) Check all door jamb switches. (5) Remove Body Control Module from Junction (2) Use DRB lll scan tool to perform CCD diag- Block. Check for battery voltage at terminal JB-12 nostics on Body Control Module for battery and igni- and ignition feed at terminal JB-6 of Body Control tion switch input...
Page 458 CHIME WARNING/REMINDER SYSTEM 8U - 1 CHIME WARNING/REMINDER SYSTEM CONTENTS page page GENERAL INFORMATION HIGH SPEED WARNING CHIME ... . . 1 INTRODUCTION ......1 DIAGNOSIS AND TESTING DESCRIPTION AND OPERATION CHIME CONDITIONS .
Page 459 8U - 2 CHIME WARNING/REMINDER SYSTEM DIAGNOSIS AND TESTING (Continued) (3) Use scan tool to perform actuator diagnostics (1) Use scan tool to perform CCD diagnostics on on Body Control Module Chime. Body Control Module for battery and ignition switch (4) Check for tone in any other function.
Page 460 CHIME WARNING/REMINDER SYSTEM 8U - 3 DIAGNOSIS AND TESTING (Continued) (4) Inspect Body Control Module connectors and (2) Check wiring for a grounded condition between wires for proper connection. key-in switch and Body Control Module. Check head- (5) Remove Body Control Module from Junction lamp switch to Body Control Module wiring for short Block.
Page 462 The SKIS programming also enables operating while the system is armed. The primary the SKIM to communicate over the Chrysler Collision components of this system are the Sentry Key Immo- Detection (CCD) data bus network with the Power-...
Page 463 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) access the SKIS for initialization, or by the dealer SENTRY KEY IMMOBILIZER TRANSPONDER technician to access the system for service. The The Sentry Key Immobilizer System (SKIS) uses a SKIM also stores in its memory the Vehicle Identifi- transponder that is integral to each of the two igni- cation Number (VIN), which it learns through a CCD tion keys that are supplied with the vehicle when it...
Page 464 The Sentry Key Immobilizer System (SKIS) and tion of about one second. Then the SKIM sends mes- the Chrysler Collision Detection (CCD) data bus net- sages to the instrument cluster circuitry to turn the work should be diagnosed using a DRB scan tool.
Page 465 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DIAGNOSIS AND TESTING (Continued) (4) Turn the ignition switch to the On position. REMOVAL AND INSTALLATION Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the SKIM wire SENTRY KEY IMMOBILIZER MODULE harness connector.
Page 466 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 REMOVAL AND INSTALLATION (Continued) (6) Remove both the upper and lower shrouds from (7) Unplug the wire harness connector from the the steering column. SKIM receptacle. (8) Remove the screw securing the SKIM module to the steering column.
Page 468: Wiring Diagrams
WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page AIR CONDITIONING-HEATER ..8W-42-1 POWER DISTRIBUTION ....8W-10-1 AIRBAG SYSTEM .
Page 470 Chrysler wiring diagrams to shown complete. diagnose and repair a Chrysler vehicle, it is impor- It is important to realize that no attempt is made tant to understand all of their features and charac- on the diagrams to represent components and wiring teristics.
Page 471 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 472 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 473 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) CIRCUIT INFORMATION CIRCUIT FUNCTIONS Each wire shown in the diagrams contains a code All circuits in the diagrams use an alpha/numeric which identifies the main circuit, part of the main code to identify the wire and its function.
Page 474 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) SECTION IDENTIFICATION SYMBOLS The wiring diagrams are grouped into individual International symbols are used throughout the wir- sections. If a component is most likely found in a par- ing diagrams.
Page 475 8W - 01 - 6 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Symbols...
Page 476 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DESCRIPTION AND OPERATION (Continued) TERMINOLOGY This a list of terms with there definitions used in the wiring diagrams. Built-Up-Export ..Vehicles Built For Sale In Markets Other Than North America Except-Built-Up-Export .
Page 477 8W - 01 - 8 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) WARNING: BE SURE THAT THE IGNITION SWITCH (3) When using a voltmeter, be sure to connect the ALWAYS IS IN THE OFF POSITION, UNLESS THE ground lead first. (4) Do not remove the part from its protective PROCEDURE REQUIRES IT TO BE ON.
Page 478 8W - 01 GENERAL INFORMATION 8W - 01 - 9 DIAGNOSIS AND TESTING (Continued) • Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested.
Page 479 8W - 01 - 10 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) TESTING FOR A SHORT TO GROUND TROUBLESHOOTING WIRING PROBLEMS (1) Remove the fuse and disconnect all items When troubleshooting wiring problems there are involved with the fuse. six steps which can aid in the procedure.
Page 480 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) (9) Connect connector to its mating half/compo- nent. (10) Connect battery and test all affected systems. Fig. 11 Terminal Removal CONNECTOR AND TERMINAL REPLACEMENT Fig. 9 Wire Repair (3) Remove connector locking...
Page 481 8W - 01 - 12 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) Fig. 13 Stagger Cutting Wires Fig. 14 Augat Connector Repair (8) Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Page 482 8W - 01 GENERAL INFORMATION 8W - 01 - 13 SERVICE PROCEDURES (Continued) (13) Solder the connection together using rosin core type solder only. Do not use acid core solder. (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 483 8W - 01 - 14 8W - 01 GENERAL INFORMATION SPECIAL TOOLS WIRING/TERMINAL Terminal Removing Tool 6932 Probing Tool Package 6807 Terminal Removing Tool 6934 Terminal Pick 6680...
Page 484 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 2-4 Pressure Switch ....8W-31 Fusible Link .
Page 485 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Power Mirrors ..... 8W-48, 62 Sunroof Position Sensor ....8W-64 Power Seat Switch .
Page 486 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-17 Fuse 13 (PDC) ....8W-10-7, 14 A/C Compressor Clutch Relay .
Page 487 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 488 8W-10 POWER DISTRIBUTION 8W - 10 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT F142 18OR/DG A142 18DG/OR A20 12RD/DB A0 4RD A0 4RD A24 16PK/YL A24 16PK/YL A0 4RD A7 16RD/BK A0 4RD A14 16RD/TN A0 4RD A15 16PK A0 4RD A51 20RD/LB...
Page 489 8W - 10 - 4 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN) COMPRESSOR CLUTCH C28 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL RELAY C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT A16 12RD/LG FUSED B(+) CAVITY CIRCUIT FUNCTION A142 18 DG/OR...
Page 490 8W-10 POWER DISTRIBUTION 8W - 10 - 5 CAVITY CIRCUIT FUNCTION F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) FUEL PUMP K31 20BR/LG FUEL PUMP RELAY CONTROL RELAY A141 14DG/WT FUEL PUMP RELAY OUTPUT A1 16RD FUSED B(+) CAVITY CIRCUIT FUNCTION C25 12YL/VT HIGH SPEED RADIATOR FAN RELAY OUTPUT HIGH...
Page 491 8W - 10 - 6 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION T15 20LG/YL 12V SUPPLY TRANSMISSION CONTROL RELAY Z13 20BK/RD GROUND T16 16RD/BR TRANSMISSION CONTROL RELAY OUTPUT A24 16PK/YL FUSED B(+) CAVITY CIRCUIT FUNCTION F13 20DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC) WIPER V3 14BR/OR WIPER HIGH/LOW RELAY LOW SPEED OUTPUT...
Page 492 8W-10 POWER DISTRIBUTION 8W - 10 - 7 BATTERY (8W-20-2) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-8) (8W-10-9) (8W-10-9) (8W-10-13) FUSE FUSE FUSE FUSE (8W-10-8) (8W-10-9) (8W-10-10) (8W-10-10) RD/BK PK/YL RD/DB PK/YL RD/TN RD/LB PK/BK JUNCTION TRANSMISSION BLOCK CONTROL S104 C126 S102...
Page 493 8W - 10 - 8 8W-10 POWER DISTRIBUTION BATT A14 (8W-10-9) AUTOMATIC SHUT DOWN RELAY (IN PDC) (8W-30-4) A142 A142 DG/OR BATT A0 (8W-10-7) DG/OR POWER DISTRIBUTION C111 CENTER FUSE FUSE FUSE (8W-10-7) A142 DG/OR S118 (8W-70-5) F142 RD/DB PK/YL PK/YL OR/DG TRANSMISSION...
Page 494 8W-10 POWER DISTRIBUTION 8W - 10 - 9 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-7) RD/BK RD/TN C126 JUNCTION BLOCK COMBINATION (8W-12-2) FLASHER FUSE (8W-12-3) (PART OF MULTI-FUNCTION (8W-12-8) SWITCH) SENTRY (8W-52-2) IMMOBILIZER S104 MODULE (IN PDC) (8W-39-3) RD/BK RD/TN...
Page 495 8W - 10 - 10 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE INSTRUMENT (8W-10-7) CLUSTER (8W-40-7) RD/LB GY/DB S102 (IN PDC) JUNCTION BLOCK (8W-12-18) C126 (8W-12-2) ENGINE FUEL (8W-12-3) STARTER PUMP MOTOR RELAY RD/LB RELAY (IN PDC) (IN PDC) (8W-30-3) GY/DB...
Page 496 8W-10 POWER DISTRIBUTION 8W - 10 - 11 BATT A51 BATT A1 (8W-10-10) (8W-10-10) IGNITION SWITCH 0 OFF 1 START 2 RUN 3 LOCK 4 ACC (8W-10-10) DG/RD BK/WT JUNCTION BLOCK (8W-12-2) BODY FUSE FUSE FUSE (8W-12-3) CONTROL MODULE (8W-12-14) (8W-12-13) (8W-12-13) (8W-45-2)
Page 497 8W - 10 - 12 8W-10 POWER DISTRIBUTION ST-RUN A21 (8W-10-11) POWER DISTRIBUTION FUSE CENTER (8W-10-7) LG/BK S106 (IN PDC) LG/BK LG/BK LG/BK LG/BK HIGH SPEED LG/BK RADIATOR RELAY (IN PDC) (8W-42-4) SPEED RADIATOR C121 RELAY (IN PDC) (8W-42-4) LG/BK LG/BK COMPRESSOR CLUTCH...
Page 498 8W-10 POWER DISTRIBUTION 8W - 10 - 13 ST-RUN A21 BATT A0 (8W-10-11) (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-7) DB/WT PK/BK C126 PK/BK S105 (IN PDC) C225 DB/WT DB/WT DB/WT PK/BK S310 (BUILT-UP C113 -EXPORT) CONTROLLER PK/BK PK/BK ANTI-LOCK BRAKE (8W-35-2) DB/WT...
Page 499 8W - 10 - 14 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-7) FUSE FUSE BK/PK RD/DG PK/WT JUNCTION BLOCK REAR (8W-12-2) WINDOW (8W-12-3) DEFOGGER RELAY (8W-48-2) CONTROLLER ANTI-LOCK BRAKE (8W-35-3) FUSE (8W-12-10) BK/WT JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3)
Page 500 8W-10 POWER DISTRIBUTION 8W - 10 - 15 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER (8W-10-7) FUSE RD/WT JUNCTION BLOCK (8W-12-2) HEADLAMP CIRCUIT (8W-12-3) FUSE DELAY BREAKER RELAY (8W-50-2) (8W-12-12) (8W-12-14) (8W-12-13) FUSE EXCEPT FUSE FUSE BUILT-UP BUILT-UP (8W-12-12) -EXPORT -EXPORT BODY CONTROL (8W-12-13)
Page 501 8W - 10 - 16 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-7) PK/BK C126 PK/BK IGNITION SWITCH 0 OFF 1 START 2 RUN 3 LOCK 4 ACC (8W-10-10) BK/OR JUNCTION BLOCK (8W-12-2) (8W-12-3) CIRCUIT FUSE FUSE FUSE BREAKER (8W-12-6)
Page 502 8W-10 POWER DISTRIBUTION 8W - 10 - 17 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-7) RD/GY RD/YL RD/LG S103 (IN PDC) HEADLAMP WASHER MODULE RD/LG (8W-53-4) COMPRESSOR CLUTCH RD/LG RD/LG INTERMITTENT RELAY WIPER (IN PDC) RELAY (8W-42-3) SPEED (IN PDC) RADIATOR...
Page 504 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C- Heater Control ....8W-12-8, 10 Left Headlamp ..... 8W-12-6, Airbag Control Module .
Page 505 8W - 12 - 2 8W-12 JUNCTION BLOCK TOP OF JUNCTION BLOCK FUSE 8 FUSE 17 FUSE 7 FUSE 16 FUSE 6 FUSE 15 C.B. 2 FUSE 5 FUSE 14 C.B. 1 FUSE 13 REAR WINDOW FUSE 4 DEFOGGER FUSE 12 RELAY FUSE 3 FUSE 11...
Page 506 8W-12 JUNCTION BLOCK 8W - 12 - 3 BOTTOM OF JUNCTION BLOCK DAYTIME RUNNING LAMP MODULE JAI01203 J998W-16...
Page 507 8W - 12 - 4 8W-12 JUNCTION BLOCK FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT C1 12DG INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL L92 18LG * INTERNAL INTERNAL INTERNAL INTERNAL A81 20DG/RD...
Page 508 8W-12 JUNCTION BLOCK 8W - 12 - 5 CAVITY CIRCUIT FUNCTION INTERNAL HEADLAMP DELAY RELAY CONTROL HEADLAMP INTERNAL FUSED B (+) DELAY RELAY INTERNAL FUSED B (+) INTERNAL HEADLAMP DELAY RELAY OUTPUT CAVITY CIRCUIT FUNCTION INTERNAL FUSED B(+) HORN INTERNAL HORN RELAY CONTROL RELAY INTERNAL...
Page 509 8W - 12 - 6 8W-12 JUNCTION BLOCK RUN A22 BATT A3 (8W-10-16) (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) RD/WT HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) RESISTOR 0 OFF 1 PARK BLOCK 2 HEAD (8W-42-2) 3 REAR FOG 4 LOW 5 HIGH (8W-50-6) RD/OR...
Page 510 8W-12 JUNCTION BLOCK 8W - 12 - 7 RUN A22 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) DAYTIME RUNNING LAMP MODULE (8W-50-6) WT/YL EATX C311 C316 WT/YL WT/YL C105 C169 WT/YL WT/YL BACK-UP RIGHT LAMP FRONT SWITCH POWER (8W-51-3) DOOR LOCK SWITCH (8W-61-2) TRANSMISSION...
Page 511 8W - 12 - 8 8W-12 JUNCTION BLOCK BATT A7 (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) BODY CONTROL MODULE (8W-45-2) PK/VT PK/WT PK/OR POWER GLOVE PK/TN ANTENNA (BUILT-UP LAMP -EXPORT) (8W-44-2) (8W-47-4) TRUNK LAMP (8W-44-3) C310 C315 (8W-12-9) (8W-12-9) RADIO RD/BK (8W-47-2) (8W-47-5)
Page 512 8W-12 JUNCTION BLOCK 8W - 12 - 9 FROM FROM FUSE FUSE 5 (JB) 5 (JB) (8W-12-8) (8W-12-8) C310 C315 OTHER VTSS S400 S401 LEFT RIGHT FRONT CYLINDER POWER LOCK DOOR SWITCH LOCK POWER LEFT (8W-39-2) SWITCH MIRROR CYLINDER (8W-61-2) SWITCH LOCK (8W-62-2)
Page 513 8W - 12 - 10 8W-12 JUNCTION BLOCK BATT A4 BATT A13 (8W-10-14) (8W-10-14) JUNCTION BLOCK REAR (8W-12-2) WINDOW (8W-12-3) DEFOGGER RELAY (8W-48-2) FUSE FUSE LB/YL LB/OR LB/YL BK/WT PK/RD BK/RD C311 C315 LB/OR LB/YL RIGHT HEADLAMP POWER SWITCH MIRROR (PART OF (HEATED MIRRORS) MULTI-FUNCTION...
Page 514 8W-12 JUNCTION BLOCK 8W - 12 - 11 BATT A13 (8W-10-14) JUNCTION BLOCK (8W-12-2) FUSE HORN (8W-12-3) RELAY (8W-41-2) BODY CONTROL MODULE (8W-45-7) RD/PK BK/RD DG/PK DG/PK CLOCKSPRING POWER NO. 1 AMPLIFIER (8W-41-2) (8W-47-4) VEHICLE SPEED CONTROL NOTE SWITCH HORN (8W-41-2) (8W-41-2) PREMIUM...
Page 515: Autostick Switch
8W - 12 - 12 8W-12 JUNCTION BLOCK BATT A3 ST-RUN-OFF A81 (8W-10-15) (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-3) BUILT-UP EXCEPT BUILT- -EXPORT UP-EXPORT BODY BODY CONTROL CONTROL MODULE MODULE DAYTIME (8W-45-2) (8W-45-2) RUNNING LAMP MODULE (8W-50-6) RD/VT RD/VT RD/VT REAR...
Page 516 8W-12 JUNCTION BLOCK 8W - 12 - 13 BATT A3 RUN-ACC A31 (8W-10-15) (8W-10-11) JUNCTION BLOCK REAR (8W-12-2) WINDOW FUSE FUSE (8W-12-3) DEFOGGER RELAY (8W-48-2) RD/WT RD/WT HEADLAMP INTERMITTENT SWITCH WIPER (PART OF RELAY MULTI-FUNCTION (IN PDC) SWITCH) (8W-53-3) RADIO 0 OFF 1 PARK (8W-47-2)
Page 517: Circuit Breaker 1
8W - 12 - 14 8W-12 JUNCTION BLOCK ST-RUN A21 BATT A3 RUN A22 (8W-10-11) (8W-10-15) (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE CIRCUIT FUSE CIRCUIT (8W-12-3) BREAKER BREAKER LG/YL C309 C311 POWER MASTER SEAT POWER SWITCH WINDOW (8W-63-2) SWITCH (8W-60-2) SUNROOF CONTROL MODULE (8W-64-2)
Page 518: Dome Lamp
8W-12 JUNCTION BLOCK 8W - 12 - 15 DATA HEADLAMP LINK LEVELING CONNECTOR SEAT SWITCH (8W-30-18) BELT (BUILT-UP-EXPORT) SWITCH (8W-50-3) (EXCEPT BUILT- IGNITION UP-EXPORT) SWITCH DOME (8W-40-4) (8W-10-10) LAMP (8W-44-2) S303 POWER (8W-15-8) AMPLIFIER (PREMIUM) (8W-47-4) PREMIUM BASE BK/LB JUNCTION DAYTIME BODY BLOCK...
Page 519: 12 Junction Block 8W
8W - 12 - 16 8W-12 JUNCTION BLOCK BATT F33 (8W-12-10) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 PARK 2 HEAD 3 REAR FOG (8W-50-3) BK/YL JUNCTION BODY BLOCK CONTROL (8W-12-2) MODULE (8W-12-3) (8W-45-7) BK/YL L7 18BK/YL HEADLAMP LEVELING BK/BR RIGHT...
Page 520: 12 Junction Block
8W-12 JUNCTION BLOCK 8W - 12 - 17 MASTER LEFT DOME POWER REAR LAMP WINDOW POWER (8W-44-2) SWITCH WINDOW (8W-60-2) SWITCH (8W-60-3) RIGHT RIGHT FRONT REAR POWER POWER WINDOW WINDOW SWITCH SWITCH (8W-60-2) (8W-60-3) YL/VT BASE PREMIUM S307 (8W-44-2) C311 C316 C308 C318...
Page 521 8W - 12 - 18 8W-12 JUNCTION BLOCK LEFT CONTROLLER LAMP ANTI-LOCK SWITCH LAMP BRAKE (PART OF (8W-50-4) (8W-35-5) (8W-50-5) MULTI-FUNCTION SWITCH) (8W-50-4) S300 RIGHT STOP (8W-50-5) (8W-51-2) LAMP INSTRUMENT LAMP SWITCH CLUSTER (8W-50-4) (8W-51-5) (EXCEPT (8W-50-5) BUILT-UP -EXPORT) (8W-40-8) LB/OR WT/BR WT/TN...
Page 522 8W-12 JUNCTION BLOCK 8W - 12 - 19 TURN SIGNAL/ HAZARD WARNING SWITCH (PART OF MULTI-FUNCTION SWITCH) (8W-52-2) (8W-52-3) JUNCTION BLOCK (8W-12-2) (8W-12-3) LG/TN LG/TN TN/BR TN/BR C301 LEFT INSTRUMENT RIGHT C300 PARK/ CLUSTER PARK/ TURN (8W-40-8) TURN SIGNAL SIGNAL LAMP LAMP (8W-50-3)
Page 524: Component Page
8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C- Heater Control ....8W-15-5 Left Headlamp ..... . 8W-15-2 Airbag Control Module .
Page 525 8W - 15 - 2 8W-15 GROUND DISTRIBUTION RADIATOR LEFT LEFT OXYGEN PARK/ SENSOR MOTOR LAMP TURN ASSEMBLY (8W-50-4) SIGNAL UPSTREAM (8W-50-5) LAMP (MTX) (8W-42-4) (8W-50-3) (8W-30-10) LEFT ENGINE HEADLAMP STARTER LEVELING MOTOR MOTOR RELAY C111 (BUILT-UP (MTX) -EXPORT) (IN PDC) LEFT (8W-50-3) (8W-21-2)
Page 526 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 TRANSMISSION OXYGEN CONTROL SENSOR MODULE UPSTREAM (8W-31-2) (EATX) (8W-30-10) POWERTRAIN CONTROL MODULE (8W-30-2) BK/YL BK/RD BK/TN BK/TN C111 C113 BK/TN S101 BK/RD POWERTRAIN CONTROL MODULE (8W-30-2) BRAKE TRANSMISSION WARNING CONTROL PRESSURE RELAY SWITCH (IN PDC) (8W-35-5)
Page 527 8W - 15 - 4 8W-15 GROUND DISTRIBUTION HIGH RIGHT WINDSHIELD OXYGEN NOTE PARK/ WASHER SENSOR HORN TURN PUMP (8W-53-2) (8W-41-2) SIGNAL DOWNSTREAM LAMP (8W-30-10) (8W-50-3) RIGHT NOTE HEADLAMP HORN LEVELING (8W-41-2) MOTOR (BUILT-UP -EXPORT) (8W-50-3) S111 DISTRIBUTOR HEADLAMP HEADLAMP (2.5L) WASHER WASHER...
Page 528 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 GLOVE BODY AIRBAG RECEIVER CONTROL CONTROL LAMP LAMP MODULE MODULE (8W-44-2) (8W-44-4) (8W-43-2) (8W-45-2) BK/LG BK/LG G200 G201 CIGAR A/C- LIGHTER/ HEATER POWER CONTROL OUTLET (8W-42-2) (8W-41-2) G202 JAI01505 J998W-16...
Page 529 8W - 15 - 6 8W-15 GROUND DISTRIBUTION LEFT TAIL/ STOP LAMP (8W-51-2) LICENSE RIGHT LAMP LICENSE (8W-51-4) LAMP (BUILT-UP LEFT LEFT -EXPORT) BACK-UP LICENSE (8W-51-4) LAMP LAMP LEFT (8W-51-3) (BUILT-UP REAR -EXPORT) (8W-51-4) LAMP LEFT (BUILT-UP TURN -EXPORT) LAMP (8W-51-4) (8W-52-2) S410...
Page 530 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 HEATED DRIVER PASSENGER SEAT HEATED HEATED SWITCH SEAT SEAT (8W-63-3) MODULE MODULE (8W-63-3) (8W-63-3) S311 (BUILT-UP -EXPORT) C225 PRNDL ILLUMINATION (8W-15-8) JAI01507 J998W-16...
Page 531 8W - 15 - 8 8W-15 GROUND DISTRIBUTION OVERHEAD DOME SUNROOF RIGHT LEFT LAMP CONTROL VISOR/ VISOR/ LAMPS (8W-44-2) MODULE VANITY VANITY (8W-44-2) (8W-64-2) LAMPS LAMPS (8W-44-3) (8W-44-3) S303 IGNITION SEAT SWITCH BELT (8W-10-10) DOME SWITCH LAMP (EXCEPT HEADLAMP DATA (8W-44-2) BUILT-UP LEVELING...
Page 532 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 RIGHT RIGHT LEFT POWER LEFT FRONT POWER FRONT MIRROR POWER POWER MIRROR POWER SWITCH MIRROR (HEATED (HEATED DOOR DOOR (8W-62-2) MIRRORS) MIRRORS) LOCK LOCK (8W-48-2) (8W-48-2) SWITCH SWITCH (8W-61-2) (8W-61-2) C316 RIGHT MASTER SIDE POWER...
Page 534 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... 8W-20-2 Fusible Link ..... . . 8W-20-2 Battery .
Page 535 8W - 20 - 2 8W-20 CHARGING SYSTEM POWER DISTRIBUTION CENTER FUSE (8W-10-7) (8W-10-9) ENGINE STARTER BK/GY MOTOR RD/TN (8W-21-2) S104 (IN PDC) 2.0L 2.4L 2.5L (8W-10-9) AUTOMATIC FUSIBLE SHUT LINK DOWN RELAY (IN PDC) BATTERY (8W-30-4) A142 A142 2.0L 2.4L 2.5L DG/OR...
Page 536 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 Ignition Switch .
Page 537 8W - 21 - 2 8W-21 STARTING SYSTEM BATT A1 (8W-10-10) IGNITION POWER SWITCH DISTRIBUTION 0 OFF CENTER 1 START FUSE (8W-10-7) 2 RUN 3 LOCK 4 ACC (8W-10-10) (8W-10-10) BATTERY (8W-20-2) C126 EATX S102 YL/OR (IN PDC) (8W-10-10) CLUTCH YL/OR PEDAL POSITION...
Page 538 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-16 G110 ......8W-30-2 A/C Pressure Transducer .
Page 539 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 BATT A0 (8W-10-11) (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-7) (8W-10-13) (8W-10-9) RD/TN DB/WT S105 S104 (IN PDC) (IN PDC) (8W-10-13) (8W-10-9) DB/WT C113 DB/WT RD/TN POWERTRAIN FUSED FUSED CONTROL IGNITION B(+) SWITCH...
Page 540 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 ST-RUN A21 BATT A0 ST-RUN A21 (8W-10-11) (8W-10-7) (8W-10-11) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-7) (8W-10-13) (8W-10-10) (8W-10-12) POWERTRAIN CONTROL LEAK LEAK LG/BK MODULE DETECTION DETECTION PUMP PUMP S106 SOLENOID SWITCH DB/WT (IN PDC) CONTROL...
Page 541 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-7) (8W-10-9) RD/TN S104 (IN PDC) (8W-10-9) AUTOMATIC SHUT DOWN RELAY (IN PDC) A142 A142 DG/OR DG/OR C111 S118 FUSE (8W-70-5) 1 (PDC) A142 (8W-10-8) DG/OR S133 (2.0L/2.4L)
Page 542 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 BATT A14 (8W-10-9) POWER DISTRIBUTION CENTER AUTOMATIC (8W-10-7) SHUT DOWN RELAY (8W-30-4) A142 A142 DG/OR DG/OR C111 SPARK S118 FUSE PLUGS (8W-70-5) 1 (PDC) (8W-10-8) A142 DG/OR DISTRIBUTOR AUTOMATIC (2.5L) SHUT CAMSHAFT IGNITION DOWN POSITION...
Page 543 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM 2.0L/2.4L BATT A14 (8W-10-9) POWER DISTRIBUTION CENTER AUTOMATIC SHUT (8W-10-7) DOWN RELAY (8W-30-4) A142 A142 DG/OR DG/OR C111 FUSE A142 1 (PDC) DG/OR (8W-10-8) S118 (8W-70-5) A142 DG/OR S114 (8W-70-3) A142 A142 A142 A142 DG/OR...
Page 544 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 2.5L BATT A14 (8W-10-9) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-7) DOWN RELAY (8W-30-4) A142 A142 DG/OR C165 A142 DG/OR DG/OR A142 C111 FUSE DG/OR 1 (PDC) A142 (8W-10-8) DG/OR S123 S118 (8W-70-3) (8W-70-5) A142 A142...
Page 545 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM CRANKSHAFT POSITION CRANKSHAFT SENSOR POSITION SENSOR SENSOR SIGNAL SUPPLY GROUND GY/BK BK/LB S124 S117 (8W-70-6) (8W-70-4) S120 (8W-31-4) BK/LB BK/LB CAMSHAFT SENSOR POSITION SUPPLY GROUND SENSOR CAMSHAFT (2.0L/2.4L) POSITION SENSOR 2.5L/2.4L 2.0L SIGNAL C111 C111...
Page 546 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 THROTTLE POSITION SENSOR BK/LB 2.0L/2.4L 2.5L OR/DB 2.5L 2.0L/2.4L VT/WT VT/WT BK/LB S116 BK/LB (8W-70-4) S115 S121 (8W-70-2) (8W-31-4) BK/LB 2.0L/2.5L 2.4L S117 (8W-70-4) BK/LB VT/WT OR/DB OR/DB C111 C111 BK/LB S110 (IN PDC) (8W-70-2) VT/WT...
Page 547 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM BATT A14 (8W-10-9) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE DOWN (8W-10-7) RELAY (8W-30-4) (8W-10-8) F142 A142 18 DG/OR A142 OR/DG DG/OR POWERTRAIN C111 CONTROL MODULE OXYGEN OXYGEN S118 SENSOR SENSOR (8W-70-5) SIGNAL 2.0L/ DOWNSTREAM 2.5L...
Page 548 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 2.0L INTAKE AIR TEMPERATURE/ MANIFOLD MANIFOLD INTAKE ABSOLUTE PRESSURE ABSOLUTE SENSOR TEMPERATURE SENSOR PRESSURE GROUND SIGNAL SUPPLY SIGNAL SENSOR BK/LB VT/WT S116 (8W-70-4) ELECTRONIC TRANSDUCER SOLENOID BK/LB S117 S115 (8W-70-4) (8W-70-2) BK/LB VT/WT A142 C111...
Page 549 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM 2.4L/2.5L MANIFOLD ABSOLUTE PRESSURE SENSOR 2.4L 2.5L BK/LB VT/WT VT/WT S116 (8W-70-4) BK/LB BK/LB S117 S115 (8W-70-4) (8W-70-2) INTAKE ELECTRONIC TEMPERATURE TRANSDUCER SENSOR SOLENOID BK/LB VT/WT A142 C111 C111 DG/OR BK/LB S118 (8W-70-5) S110 (IN PDC)
Page 550 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 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 ENGINE SENSOR CONTROL COOLANT GROUND TEMPERATURE MODULE SENSOR KNOCK SIGNAL SENSOR SIGNAL DB/LG KNOCK SENSOR (2.0L/ 2.4L) JAI03013...
Page 551 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM ST A41 (8W-10-11) POWER DISTRIBUTION CENTER ENGINE (8W-10-7) STARTER MOTOR RELAY (EATX) (8W-21-2) T41 18 BK/WT VEHICLE SPEED SPEED C104 CONTROL CONTROL SWITCH SWITCH SIGNAL (8W-33-3) BK/LB CLOCKSPRING NO. 1 TRANSMISSION (8W-33-3) RANGE SENSOR (8W-31-5)
Page 552 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15 PRESSURE TRANSDUCER PRESSURE SENSOR SUPPLY SIGNAL GROUND VT/WT BK/LB S115 S116 (8W-70-2) (8W-70-4) BK/LB S117 (8W-70-4) AMBIENT TEMPERATURE SENSOR BK/LB VT/WT C111 C113 C111 BK/LB BK/LB S110 (IN PDC) (8W-70-2) VT/WT DB/YL BK/LB VT/LG POWERTRAIN...
Page 553 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 (8W-10-11) POWER DISTRIBUTION CENTER FUSE (8W-10-7) (8W-10-12) LG/BK S106 (IN PDC) (8W-10-12) LG/BK LG/BK LG/BK COMPRESSOR SPEED CLUTCH RADIATOR RELAY FAN RELAY (IN PDC) (IN PDC) (8W-42-3) (8W-42-4) HIGH SPEED RADIATOR FAN RELAY (IN PDC)
Page 554 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17 IDLE IDLE IDLE IDLE IDLE CONTROL CONTROL CONTROL CONTROL CONTROL MOTOR MOTOR MOTOR MOTOR MOTOR NO. 1 NO. 2 NO. 4 NO. 3 DRIVER DRIVER DRIVER DRIVER GY/RD YL/BK VT/BK BR/WT DUTY CYCLE EVAP/ PURGE...
Page 555 8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM BATT A7 (8W-10-9) TRANSMISSION CONTROL JUNCTION MODULE BLOCK (8W-31-2) (8W-12-2) RECEIVE FUSE (8W-12-3) (8W-12-8) PK/DG C126 PK/DG DATA LINK CONNECTOR TRANSMISSION CONTROL MODULE VT/GY WT/DG BK/VT PK/LB TRANSMIT (8W-31-8) JUNCTION BLOCK C126 (8W-12-2) TWISTED (8W-12-3)
Page 556 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 19 VEHICLE POWERTRAIN POWER SPEED CONTROL STEERING SENSOR MODULE VEHICLE PRESSURE SPEED (MTX) SWITCH SENSOR SENSOR SENSE SUPPLY GROUND SIGNAL BK/LB WT/OR DB/LG TRANSMISSION CONTROL MODULE VEHICLE SPEED (8W-31-4) SENSOR SIGNAL C169 WT/OR POWER STEERING PRESSURE...
Page 558 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Autostick Switch ....8W-31-8, 9 Output Shaft Speed Sensor .
Page 559 8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM ST-RUN-OFF A81 (8W-10-11) BATT A0 (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) FUSE CENTER (8W-12-3) FUSE (8W-10-7) (8W-12-12) (8W-10-8) PK/YL TRANSMISSION CONTROL RELAY (IN PDC) DATA LINK CONNECTOR (8W-30-18) BK/RD RD/BR PK/DG S101 S100 (8W-15-3)
Page 560 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3 ST-RUN A21 (8W-10-11) POWER OUTPUT DISTRIBUTION SHAFT CENTER SPEED FUSE (8W-10-7) SENSOR TRANSMISSION (8W-10-12) TURBINE RANGE SPEED SPEED SENSOR SENSOR SENSOR (8W-31-5) GROUND LG/BK S106 (IN PDC) (8W-10-12) LG/BK DB/BR DB/BR DB/BR OR/YL C121...
Page 561 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 GROUND SIGNAL SIGNAL (8W-30-19) 2.4L 2.0L/2.5L WT/OR 2.4L/2.5L 2.0L GY/BK GY/BK OR/DB OR/DB BK/LB S110 S120 S121 (IN PDC)
Page 562 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5 RUN A22 BATT A1 (8W-10-16) (8W-10-10) JUNCTION IGNITION BLOCK SWITCH (8W-12-2) 0 OFF/LOCK FUSE (8W-12-3) 1 START C126 2 RUN 3 UNLOCK 4 ACC (8W-12-7) (8W-10-10) YL/OR WT/YL ENGINE STARTER MOTOR RELAY C105 (IN PDC)
Page 563 8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM BATT A24 (8W-10-8) POWER DISTRIBUTION CENTER TRANSMISSION CONTROL (8W-10-7) RELAY (8W-31-2) RD/BR S100 (8W-10-8) RD/BR C104 RD/BR TRANSMISSION SOLENOID AND LOW/ OVERDRIVE PRESSURE REVERSE PRESSURE PRESSURE SWITCH PRESSURE SWITCH SWITCH ASSEMBLY SWITCH DG/TN YL/GY...
Page 564 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7 BATT A24 (8W-10-8) POWER DISTRIBUTION CENTER TRANSMISSION CONTROL (8W-10-7) RELAY (8W-31-2) RD/BR S100 (8W-10-8) RD/BR C104 RD/BR TRANSMISSION SOLENOID AND PRESSURE LOW/ UNDERDRIVE OVERDRIVE SWITCH REVERSE SOLENOID SOLENOID SOLENOID ASSEMBLY SOLENOID LB/WT WT/PK PK/DB...
Page 565 8W - 31 - 8 8W-31 TRANSMISSION CONTROL SYSTEM ST-RUN-OFF A81 (8W-10-11) JUNCTION TRANSMISSION BLOCK CONTROL (8W-12-15) (8W-12-2) MODULE FUSE (8W-12-3) RECEIVE (8W-12-12) PK/DG INSTRUMENT FUSED C126 IGNITION CLUSTER SWITCH (8W-40-2) OUTPUT BK/RD (ST-RUN-OFF) PK/DG G301 (8W-15-9) DATA LINK RD/VT RD/VT CONNECTOR (8W-30-18)
Page 566 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 9 WITHOUT ABS ST-RUN-OFF A81 (8W-10-11) JUNCTION TRANSMISSION BLOCK CONTROL (8W-12-15) (8W-12-2) MODULE FUSE (8W-12-3) RECEIVE (8W-12-12) PK/DG INSTRUMENT FUSED C126 IGNITION CLUSTER SWITCH (8W-40-2) OUTPUT BK/RD (ST-RUN-OFF) PK/DG G301 (8W-15-9) DATA LINK RD/VT RD/VT...
Page 568 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Autostick Switch ....8W-33-2 Instrument Cluster .
Page 569 8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL ST-RUN-OFF A81 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-12) RD/VT INSTRUMENT CLUSTER CRUISE ENGAGED (8W-40-2) LAMP RD/VT FUSED CRUISE ENGAGED AUTOSTICK FUSED IGNITION LAMP CONTROL SWITCH IGNITION SWITCH SWITCH (8W-31-8) OUTPUT OUTPUT (ST-RUN-OFF) (ST-RUN-OFF)
Page 570 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3 POWERTRAIN CONTROL SPEED SPEED SPEED MODULE CONTROL CONTROL CONTROL SPEED VENT VACUUM ON/OFF BRAKE CONTROL (8W-30-14) SOLENOID SOLENOID SWITCH SWITCH SWITCH CONTROL CONTROL SENSE SENSE SIGNAL YL/RD WT/RD RD/LG C113 C126 LG/RD WT/VT YL/PK...
Page 572 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES Component Page Component Page ABS Warning Lamp ....8W-35-2 G113 ......8W-35-3 Autostick Switch .
Page 573 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES ST-RUN A21 BATT A0 (8W-10-11) (8W-10-7) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-7) (8W-10-13) (8W-10-12) (8W-10-8) DB/WT LG/BK S106 S105 (IN PDC) RD/DB (IN PDC) (8W-10-12) (8W-10-13) LG/BK C126 DB/WT LG/BK INSTRUMENT CLUSTER (8W-40-6) WARNING...
Page 574 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER (8W-10-7) FUSE (8W-10-14) BODY CONTROL MODULE (8W-45-3) (8W-45-4) RD/DG TWISTED WT/BK WT/BK VT/BR VT/BR PAIR TWISTED S142 S132 PAIR (8W-45-4) (8W-45-4) EXCEPT BUILT-UP BUILT-UP EXCEPT BUILT-UP -EXPORT -EXPORT BUILT-UP...
Page 575 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES LEFT LEFT RIGHT RIGHT FRONT REAR FRONT REAR WHEEL WHEEL WHEEL WHEEL SPEED SPEED SPEED SPEED SENSOR SENSOR SENSOR SENSOR LG/DB YL/DB C121 C121 OR/DB WT/DB LG/DB YL/DB CONTROLLER LEFT LEFT LEFT LEFT RIGHT RIGHT...
Page 576 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5 ST-RUN-OFF A81 BATT A0 (8W-10-11) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION FUSE (8W-12-2) CENTER FUSE (8W-12-3) (8W-10-7) (8W-12-12) (8W-10-9) RD/BK RD/VT JUNCTION F11 20 RD/VT BLOCK (8W-12-2) INSTRUMENT (8W-12-3) CLUSTER BRAKE (8W-40-7) WARNING INDICATOR RD/BK AUTOSTICK...
Page 578 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Body Control Module ... 8W-39-2, 3, 4, 5, Junction Block ....8W-39-2, 3, 4, 5 Combination Flasher .
Page 579 8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM BATT A7 (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-8) C315 C310 S400 S401 (8W-12-9) (8W-12-9) LEFT RIGHT CYLINDER CYLINDER LOCK LOCK SWITCH SWITCH 0 OFF 0 OFF 1 DISARM 1 DISARM 2 ARM 2 ARM C311...
Page 580 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3 BATT A0 ST-RUN A21 (8W-10-7) (8W-10-11) POWER DISTRIBUTION FUSE FUSE CENTER (8W-10-7) (8W-10-9) (8W-10-12) INSTRUMENT FUSED CLUSTER IGNITION SWITCH (8W-40-6) LG/BK OUTPUT (ST-RUN) C126 S106 (IN PDC) (8W-10-12) LG/BK LG/BK COMBINATION C126 FLASHER...
Page 581 8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM BATT A13 (8W-10-14) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-10) PK/RD INSTRUMENT CLUSTER (8W-40-7) VTSS BK/OR BODY VTSS LEFT CONTROL INDICATOR FRONT DRIVER MODULE DOOR DOOR DOOR AJAR AJAR AJAR (8W-45-12) SWITCH SWITCH SWITCH...
Page 582 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5 POWERTRAIN CONTROL LEFT HEAD- MODULE PARK/ LAMP (8W-30-18) TURN SWITCH SIGNAL OUTPUT LAMP TWISTED (8W-50-3) PAIR VT/BR WT/BK RIGHT HEAD- PARK/ LAMP EXCEPT EXCEPT TURN SWITCH BUILT-UP BUILT-UP BUILT-UP BUILT-UP SIGNAL OUTPUT -EXPORT...
Page 584 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page ABS Warning Lamp ....8W-40-6 Ignition Switch ..... 8W-40-7 Airbag Control Module .
Page 585 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER BATT A13 ST-RUN-OFF A81 (8W-10-14) (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3) (8W-12-10) (8W-12-12) PK/RD RD/VT RD/VT AUTOSTICK FUSED SWITCH IGNITION SWITCH (8W-31-8) OUTPUT (8W-31-9) (ST-RUN-OFF) INSTRUMENT CLUSTER FUSED FUSED B (+) IGNITION SWITCH OUTPUT...
Page 586 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 INSTRUMENT MALFUNCTION CHARGING ENGINE COOLANT CLUSTER INDICATOR LAMP SYSTEM WARNING TEMPERATURE (CHECK ENGINE) LAMP LAMP MALFUNCTION CHARGING ENGINE COOLANT INDICATOR SYSTEM WARNING TEMPERATURE LAMP CONTROL LAMP CONTROL LAMP CONTROL (CHECK ENGINE) ENGINE COOLANT SPEEDOMETER TACHOMETER TEMPERATURE...
Page 587 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER INSTRUMENT CRUISE SEAT BELT LOW FUEL CLUSTER ENGAGED INDICATOR WARNING LAMP LAMP LAMP FUEL GAUGE CRUISE SEAT BELT LOW FUEL FUEL GAUGE (VEHICLE SPEED INDICATOR WARNING CONTROL CONTROL) LAMP CONTROL LAMP CONTROL ENGAGED LAMP CONTROL TWISTED...
Page 588 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 INSTRUMENT CLUSTER PRNDL/AUTOSTICK INDICATOR ODOMETER/TRIP PRNDL/AUTOSTICK CONTROL ODOMETER/TRIP CONTROL AIRBAG HIGH BEAM WARNING INDICATOR LAMP CONTROL LAMP CONTROL AIRBAG HIGH WARNING BEAM LAMP INDICATOR AIRBAG CONTROL MODULE (8W-43-3) VT/BR WT/DB TWISTED PAIR TWISTED PAIR WT/BK...
Page 589 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER ST-RUN A21 (8W-10-11) POWER DISTRIBUTION CENTER FUSE (8W-10-7) (8W-10-12) SENTRY FUSED IGNITION IMMOBILIZER SWITCH LG/BK OUTPUT MODULE (ST-RUN) (8W-39-3) S106 (IN PDC) (8W-10-12) LG/BK LG/BK C126 LG/BK INSTRUMENT CLUSTER PRESSURE WARNING INDICATOR INDICATOR LG/OR C126...
Page 590 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7 (8W-10-14) (8W-10-11) BATT A13 ST-RUN-OFF A81 JUNCTION BLOCK FUSE (8W-12-2) FUSE (8W-12-3) (8W-12-12) (8W-12-10) PK/RD RD/VT INSTRUMENT RD/VT CLUSTER BRAKE AUTOSTICK FUSED WARNING SWITCH IGNITION INDICATOR SWITCH (8W-31-8) VTSS OUTPUT (8W-31-9) (ST-RUN-OFF) JUNCTION GY/DB DAYTIME...
Page 591 8W - 40 - 8 8W-40 INSTRUMENT CLUSTER TURN REAR SIGNAL/ LAMP LEFT RIGHT REAR LAMP HAZARD LAMP SWITCH TURN TURN SWITCH WARNING SWITCH (PART OF SIGNAL SIGNAL LAMP OUTPUT SWITCH (PART OF MULTI- (PART OF MULTI-FUNCTION FUNCTION MULTI-FUNCTION SWITCH) SWITCH) SWITCH) (BUILT-UP...
Page 592 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Body Control Module ....8W-41-2 Horn Relay .
Page 593 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET BATT A13 (8W-10-14) JUNCTION BLOCK (8W-12-2) (8W-12-3) FUSE HORN RELAY (8W-12-11) BODY HORN CONTROL RELAY MODULE CONTROL (8W-45-10) BK/RD DG/PK DG/PK CLOCKSPRING NO. 1 HIGH NOTE NOTE VEHICLE HORN HORN SPEED LEFT RIGHT CONTROL...
Page 594 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-3 G111 ......8W-42-4 A/C Compressor Clutch Relay .
Page 595 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER BATT A7 BATT A4 RUN A22 (8W-10-9) (8W-10-14) (8W-10-16) JUNCTION BLOCK REAR (8W-12-2) FUSE WINDOW FUSE FUSE (8W-12-3) DEFOGGER RELAY (8W-12-6) (8W-48-2) (8W-12-10) (8W-12-8) RESISTOR RADIO BLOCK (8W-47-2) (8W-47-5) FUSED B(+) BLOWER PK/TN LB/YL MOTOR...
Page 596 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 ST-RUN A21 BATT A0 (8W-10-11) (8W-10-7) EVAPORATOR POWER TEMPERATURE DISTRIBUTION SENSOR FUSE FUSE CENTER (8W-10-7) (8W-10-12) LG/BK (8W-10-17) BODY EVAPORATOR SENSOR S106 S103 CONTROL TEMPERATURE GROUND (IN PDC) (IN PDC) SENSOR MODULE SIGNAL (8W-10-12) (8W-10-17)
Page 597 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER BATT A0 ST-RUN A21 (8W-10-7) (8W-10-11) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-7) (8W-10-17) (8W-10-12) RD/LG LG/BK S103 (IN PDC) (8W-10-17) S106 (IN PDC) (8W-10-12) RD/LG LG/BK LG/BK RD/LG HIGH SPEED SPEED RADIATOR RADIATOR RELAY RELAY...
Page 598 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ....8W-43-2, 3 Fuse 11 (JB) ......8W-43-3 Airbag Warning Lamp .
Page 599 8W - 43 - 2 8W-43 AIRBAG SYSTEM RUN A22 ST-RUN A21 (8W-10-16) (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3) (8W-12-14) (8W-12-14) DRIVER SIDE DRIVER DRIVER AIRBAG AIRBAG AIRBAG SQUIB LINE 1 LINE 2 CLOCKSPRING NO. 2 PASSENGER SIDE PASSENGER PASSENGER AIRBAG AIRBAG...
Page 600 8W-43 AIRBAG SYSTEM 8W - 43 - 3 ST-RUN-OFF A81 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-12) RD/VT INSTRUMENT CLUSTER AIRBAG WARNING (8W-40-2) RD/VT INDICATOR (8W-40-5) AUTOSTICK FUSED FUSED AIRBAG WARNING SWITCH IGNITION IGNITION INDICATOR CONTROL SWITCH (8W-31-8) SWITCH OUTPUT (8W-31-9) OUTPUT (ST-RUN-OFF)
Page 602 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C- Heater Control ....8W-44-4 Instrument Cluster ....8W-44-4 Ash Receiver Lamp .
Page 603 8W - 44 - 2 8W-44 INTERIOR LIGHTING BATT A7 (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-8) PREMIUM BASE S302 PK/WT (8W-12-8) OVERHEAD DOME GLOVE LAMP 0 OFF LAMPS LAMP 1 ON 2 DOOR PREMIUM BASE S303 (8W-15-8) G200 (8W-15-5) PREMIUM BASE S307...
Page 604 8W-44 INTERIOR LIGHTING 8W - 44 - 3 BATT A7 (8W-10-9) JUNCTION BLOCK (8W-12-2) (8W-12-3) FUSE (8W-12-8) PK/OR S302 (PREMIUM) (8W-12-8) TRUNK LAMP LEFT RIGHT VISOR/ VISOR/ VANITY VANITY LAMPS LAMPS TN/BK TRUNK AJAR SWITCH S303 (PREMIUM) (8W-15-8) JUNCTION BLOCK (8W-12-15) (8W-12-2) (8W-12-3)
Page 605 8W - 44 - 4 8W-44 INTERIOR LIGHTING BATT A13 (8W-10-14) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-10) INSTRUMENT CLUSTER CLUSTER ILLUMINATION LAMPS (8W-40-8) BK/RD HEADLAMP SWITCH PANEL (PART OF LAMPS MULTI-FUNCTION DIMMER SWITCH) SWITCH 1 HEAD 2 PARK 0 OFF BK/OR OR/YL (8W-50-4)
Page 606 8W - 45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page A/C Evaporator Temperature Sensor ..8W-45-9 Left Horn Switch ....8W-45-7 A/C- Heater Control .
Page 607 8W - 45 - 2 8W-45 BODY CONTROL MODULE BATT A1 BATT A51 (8W-10-10) (8W-10-10) IGNITION SWITCH 1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-10) DG/RD BATT A3 BATT A7 (8W-10-15) (8W-10-9) JUNCTION BLOCK (8W-12-2) (8W-12-3) FUSE FUSE FUSE (8W-12-12)
Page 608 8W-45 BODY CONTROL MODULE 8W - 45 - 3 EXCEPT BUILT-UP-EXPORT INSTRUMENT CLUSTER (8W-40-3) AIRBAG TRANSMISSION CONTROL CONTROL MODULE MODULE (8W-43-3) TWISTED (8W-31-8) PAIR TWISTED PAIR TWISTED VT/BR WT/DB VT/DG WT/DG PAIR WT/BK BODY CONTROL MODULE GROUND TWISTED TWISTED PAIR PAIR VT/GY WT/DG...
Page 609 8W - 45 - 4 8W-45 BODY CONTROL MODULE BUILT-UP-EXPORT INSTRUMENT CLUSTER (8W-40-3) AIRBAG TRANSMISSION CONTROL CONTROL MODULE TWISTED MODULE (8W-43-3) PAIR (8W-31-8) (8W-31-9) TWISTED TWISTED PAIR PAIR VT/BR WT/DB VT/DG WT/DG WT/BK BODY CONTROL MODULE GROUND TWISTED PAIR TWISTED PAIR VT/BR WT/BK...
Page 610 8W-45 BODY CONTROL MODULE 8W - 45 - 5 RUN-ACC F13 (8W-12-13) WIPER POWER SWITCH DISTRIBUTION (PART OF CENTER INTERMITTENT WIPER MULTI- (8W-10-7) WIPER HIGH/LOW WASHER FUNCTION RELAY RELAY PUMP WINDSHIELD (8W-53-3) (8W-53-3) CONTROL WIPER SWITCH) SWITCH SWITCH (8W-53-2) OUTPUT BR/DB DG/YL PK/VT...
Page 611 8W - 45 - 6 8W-45 BODY CONTROL MODULE BATT A3 (8W-10-15) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 PARK 2 HEAD 3 REAR FOG 4 LOW 5 HIGH 6 FLASH TO PASS (8W-50-2) VT/WT RD/OR BATT A3 (8W-10-15) JUNCTION BLOCK...
Page 612 8W-45 BODY CONTROL MODULE 8W - 45 - 7 BATT F33 (8W-12-10) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 HEAD 2 PARK 3 REAR FOG * (8W-50-3) BK/YL RUN-ACC A31 BATT A13 (8W-10-11) (8W-10-14) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3) (8W-12-13)
Page 613 8W - 45 - 8 8W-45 BODY CONTROL MODULE BATT F33 (8W-12-10) INSTRUMENT HEADLAMP CLUSTER SWITCH PANEL PANEL (PART OF LAMPS (8W-40-2) LAMPS GROUND DRIVER (8W-40-8) MULTI-FUNCTION DIMMER SWITCH) SWITCH 0 OFF 1 HEAD 2 PARK (8W-50-4) (8W-50-5) BK/LG OR/YL BODY GROUND PANEL...
Page 614 8W-45 BODY CONTROL MODULE 8W - 45 - 9 A/C- EVAPORATOR HEATER EVAPORATOR MODE TEMPERATURE CONTROL TEMPERATURE SWITCH SWITCH SENSOR SENSOR (8W-42-2) SENSOR GROUND SENSE SENSE SIGNAL GROUND BK/PK DB/OR LG/BK BODY GROUND MODE EVAPORATOR SENSOR CONTROL SWITCH SWITCH TEMPERATURE GROUND SENSE SENSE...
Page 615 8W - 45 - 10 8W-45 BODY CONTROL MODULE VEHICLE SPEED CONTROL SWITCH GROUND (8W-33-3) CLOCKSPRING NO. 1 (8W-33-3) LEFT RIGHT REMOTE REMOTE KEYLESS KEYLESS ENTRY ENTRY ANTENNA ANTENNA (8W-61-3) (8W-61-3) P158 BK/TN BODY GROUND CONTROL EXTERNAL EXTERNAL MODULE ANTENNA ANTENNA KEY-IN FUEL...
Page 616 8W-45 BODY CONTROL MODULE 8W - 45 - 11 LEFT RIGHT LEFT FRONT FRONT FRONT POWER POWER LEFT POWER DOOR DOOR FRONT DOOR LOCK LOCK DOOR SWITCH LOCK MOTOR MOTOR SWITCH (8W-61-2) RIGHT FRONT RIGHT POWER FRONT DOOR DOOR OR/BK DB/WT OR/BK PK/LB...
Page 617 8W - 45 - 12 8W-45 BODY CONTROL MODULE SEAT LEFT SEAT LEFT BELT CYLINDER BELT DOOR SWITCH LOCK SWITCH SENSE (8W-40-4) CYLINDER SWITCH SWITCH (8W-39-2) SENSE INSTRUMENT TRUNK RIGHT RIGHT CLUSTER CYLINDER TRUNK VTSS DOOR (8W-40-7) CYLINDER LOCK INDICATOR CYLINDER SWITCH SWITCH...
Page 618 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page A/C- Heater Control ....8W-47-2, 5 Left Front Door Speaker ... . 8W-47-2, 6 Antenna .
Page 619 8W - 47 - 2 8W-47 AUDIO SYSTEM STANDARD BATT F33 (8W-12-10) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 PARK 2 HEAD 3 REAR FOG (8W-50-3) BK/YL RUN-ACC A31 BATT A7 (8W-10-11) (8W-10-9) JUNCTION (8W-12-16) BLOCK (8W-12-2) BODY FUSE FUSE (8W-12-3)
Page 620 8W-47 AUDIO SYSTEM 8W - 47 - 3 STANDARD BATT A7 (8W-10-9) JUNCTION BLOCK (8W-12-2) (8W-12-3) FUSE (8W-12-8) ANTENNA PK/VT POWER FUSED ANTENNA B(+) (BUILT- RADIO UP-EXPORT) OUTPUT DG/RD ANTENNA CABLE C224 RADIO RADIO OUTPUT RIGHT RIGHT RIGHT RIGHT FRONT FRONT REAR REAR...
Page 621 8W - 47 - 4 8W-47 AUDIO SYSTEM PREMIUM BATT A13 BATT A7 (8W-10-14) (8W-10-9) JUNCTION BLOCK (8W-12-2) (8W-12-3) FUSE FUSE (8W-12-11) (8W-12-8) ANTENNA PK/VT POWER FUSED ANTENNA B(+) (BUILT- RADIO UP-EXPORT) RD/PK OUTPUT ANTENNA CABLE DG/RD POWER FUSED RADIO AMPLIFIER B(+) OUTPUT...
Page 622 8W-47 AUDIO SYSTEM 8W - 47 - 5 PREMIUM BATT F33 (8W-12-10) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 PARK 2 HEAD 3 REAR FOG (8W-50-3) BK/YL RUN-ACC A31 BATT A7 (8W-10-11) (8W-10-9) JUNCTION (8W-12-16) BLOCK (8W-12-2) BODY FUSE FUSE (8W-12-3)
Page 623 8W - 47 - 6 8W-47 AUDIO SYSTEM PREMIUM POWER AMPLIFIER AMPLIFIED AMPLIFIED AMPLIFIED AMPLIFIED AMPLIFIED AMPLIFIED HIGH HIGH LEFT LEFT LEFT LEFT LEFT LEFT DOOR DOOR REAR REAR REAR REAR SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER LG/DG LG/VT WT/RD WT/DG WT/VT WT/BK...
Page 624 8W-47 AUDIO SYSTEM 8W - 47 - 7 PREMIUM POWER AMPLIFIER AMPLIFIED AMPLIFIED AMPLIFIED AMPLIFIED HIGH HIGH AMPLIFIED AMPLIFIED RIGHT RIGHT RIGHT RIGHT RIGHT RIGHT REAR REAR REAR REAR DOOR DOOR SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER TN/RD TN/DG TN/VT TN/BK LB/DG LB/VT...
Page 626 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C- Heater Control ....8W-48-2 Left Front Power Door Lock Switch .
Page 627 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-7) (8W-10-14) RUN-ACC A31 A4 12 BK/PK (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-13) REAR WINDOW DEFOGGER RELAY BODY REAR CONTROL WINDOW FUSE MODULE DEFOGGER (8W-45-7) RELAY...
Page 628: Body Control Module
8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Body Control Module ... 8W-50-2, 3, 4, 5 Headlamp Switch ... . 8W-50-2, 3, 4, 5, 6 Daytime Running Lamp Module .
Page 629 8W - 50 - 2 8W-50 FRONT LIGHTING HEADLAMP BATT A0 (8W-10-7) SWITCH POWER (PART OF DISTRIBUTION MULTI-FUNCTION CENTER SWITCH) FUSE 0 OFF (8W-10-7) 1 PARK 2 HEAD (8W-10-15) 3 FOG 4 LOW 5 HIGH 6 FLASH TO PASS RD/WT RD/WT VT/WT RD/OR...
Page 630 8W-50 FRONT LIGHTING 8W - 50 - 3 BATT F33 (8W-12-10) HEADLAMP HEADLAMP LEVELING SWITCH (PART OF SWITCH MULTI-FUNCTION (BUILT-UP -EXPORT) SWITCH) 0 OFF 1 PARK 2 HEAD 3 REAR FOG* BR/VT BK/YL TURN SIGNAL/ LEFT RIGHT HAZARD TURN TURN WARNING SIGNAL SIGNAL...
Page 631 8W - 50 - 4 8W-50 FRONT LIGHTING BUILT-UP-EXPORT SENTRY IMMOBILIZER MODULE GROUND BATT F33 (8W-12-10) (8W-39-3) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 PARK 2 HEAD 3 REAR FOG 4 LOW 5 HIGH 6 FLASH TO PASS BK/TN BATT A3 (8W-10-15)
Page 632 8W-50 FRONT LIGHTING 8W - 50 - 5 EXCEPT BUILT-UP-EXPORT BATT F33 BATT A3 (8W-12-10) (8W-10-15) HEADLAMP SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 PARK 2 HEAD 3 LOW 4 HIGH 5 FLASH TO PASS BK/TN VT/WT JUNCTION BODY BLOCK PANEL CONTROL...
Page 633 8W - 50 - 6 8W-50 FRONT LIGHTING HEADLAMP DIMMER SWITCH SWITCH HIGH (PART OF BEAM MULTI-FUNCTION OUTPUT SWITCH) RD/OR BATT A3 RUN A22 (8W-10-15) (8W-10-16) JUNCTION BLOCK (8W-12-2) (8W-12-3) FUSE FUSE FUSE (8W-12-6) (8W-12-12) (8W-12-7) DAYTIME FUSED FUSED IGNITION RUNNING B(+) SWITCH OUTPUT...
Page 634 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-3, 5 Left Tail/Stop Lamp ....8W-51-2, 5 Center High Mounted Stop Lamp .
Page 635 8W - 51 - 2 8W-51 REAR LIGHTING BATT F33 BATT A0 (8W-12-10) (8W-10-7) HEADLAMP POWER SWITCH DISTRIBUTION (PART OF CENTER FUSE MULTI-FUNCTION (8W-10-7) SWITCH) (8W-10-9) 0 OFF 1 PARK 2 HEAD 3 REAR FOG (8W-50-3) BK/YL RD/BK JUNCTION BLOCK (8W-12-2) (8W-12-3) BK/YL...
Page 636 8W-51 REAR LIGHTING 8W - 51 - 3 RUN A22 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-7) WT/YL EATX C169 C105 BACK-UP TRANSMISSION LAMP RANGE SWITCH SENSOR (8W-31-5) VT/BK VT/BK C105 C169 VT/BK VT/BK C121 VT/BK L1 18 VT/BK C300 C301 VT/BK VT/BK...
Page 637 8W - 51 - 4 8W-51 REAR LIGHTING BATT A3 (8W-10-15) JUNCTION FROM BLOCK C300 (8W-12-2) FUSE (8W-51-2) (8W-12-3) (8W-12-12) LG/DG INSTRUMENT BK/YL REAR REAR CLUSTER C121 (8W-40-8) LAMP LAMP INDICATOR SWITCH C320 (PART OF MULTI- C300 EXCEPT FUNCTION BUILT-UP BUILT-UP SWITCH) -EXPORT...
Page 638: Controller Anti-Lock Brake
8W-51 REAR LIGHTING 8W - 51 - 5 BATT A0 (8W-10-7) POWER DISTRIBUTION CENTER FUSE (8W-10-7) (8W-10-9) RD/BK JUNCTION BLOCK (8W-12-2) (8W-12-3) BODY CONTROL MODULE (8W-45-5) GROUND WT/TN WT/BR WT/TN RD/BK BK/LG DB/RD STOP LAMP CONTROLLER BRAKE SWITCH ANTI-LOCK LAMP SWITCH BRAKE OUTPUT...
Page 640: Fuse 10 (Pdc)
8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Junction Block ....8W-52-2, 3 Fuse 6 (PDC) .
Page 641: G301
8W - 52 - 2 8W-52 TURN SIGNALS TURN SIGNAL/ HAZARD WARNING SWITCH (PART OF MULTI-FUNCTION SWITCH) INSTRUMENT CLUSTER BATT A0 LEFT (8W-10-7) (8W-40-8) TURN POWER SIGNAL DISTRIBUTION CENTER (8W-10-7) FUSE LG/TN RUN-ACC A31 (8W-10-11) (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-13) C126...
Page 642 8W-52 TURN SIGNALS 8W - 52 - 3 TURN SIGNAL/ HAZARD WARNING SWITCH (PART OF MULTI-FUNCTION SWITCH) INSTRUMENT CLUSTER RIGHT (8W-40-8) TURN SIGNAL TN/BR JUNCTION BLOCK (8W-12-2) (8W-12-3) TN/BR C344 C301 LG/TN RIGHT PARK/ RIGHT RIGHT TURN TURN SIDE SIGNAL LAMP REPEATER LAMP...
Page 644 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Body Control Module ... . . 8W-53-2, 3, 4 Headlamp Washer Pump ....8W-53-4 Fuse 15 (JB) .
Page 645 8W - 53 - 2 8W-53 WIPERS RUN-ACC A31 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-3) (8W-12-13) WIPER SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 INTERMITTENT 3 INTERMITTENT 4 INTERMITTENT 5 INTERMITTENT 6 LOW 7 HIGH 8 MIST 9 WASH BR/DB DG/YL BODY...
Page 646 8W-53 WIPERS 8W - 53 - 3 RUN-ACC A31 BATT A0 (8W-10-11) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE (8W-12-3) (8W-10-7) FUSE (8W-12-13) (8W-10-17) RD/GY DG/VT WIPER INTERMITTENT HIGH/LOW WIPER RELAY RELAY (IN PDC) (IN PDC) BR/OR VT/PK PK/VT RD/YL WINDSHIELD WIPER...
Page 647 8W - 53 - 4 8W-53 WIPERS BUILT-UP-EXPORT BATT A0 BATT F33 (8W-10-7) (8W-12-10) POWER HEADLAMP DISTRIBUTION SWITCH CENTER (PART OF FUSE MULTI-FUNCTION (8W-10-7) SWITCH) 0 OFF (8W-10-17) BODY WASHER 1 PARK CONTROL PUMP 2 HEAD CONTROL 3 REAR FOG MODULE SWITCH (8W-53-4)
Page 648 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker 2 (JB) ....8W-60-2 Master Power Window Switch ..8W-60-2 G306 .
Page 649: Junction Block
8W - 60 - 2 8W-60 POWER WINDOWS RUN A22 (8W-10-16) JUNCTION BLOCK (8W-12-2) CIRCUIT (8W-12-3) BREAKER (8W-12-14) C311 MASTER POWER WINDOW SWITCH 1 DOWN 2 UP 3 LOCK 4 UNLOCK AUTODOWN VT/WT BR/WT DB/WT DG/WT GY/BK RD/BK C311 C310 S402 C316 C316...
Page 650 8W-60 POWER WINDOWS 8W - 60 - 3 FROM FROM FROM FROM MASTER MASTER MASTER MASTER POWER POWER POWER POWER WINDOW WINDOW WINDOW WINDOW SWITCH SWITCH SWITCH SWITCH (8W-60-2) (8W-60-2) (8W-60-2) (8W-60-2) RD/BK DB/WT DG/WT GY/BK C310 C311 C311 JUNCTION FROM BLOCK JUNCTION...
Page 652 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Body Control Module ....8W-61-2, 3 Left Rear Power Door Lock Motor ..8W-61-3 Fuse 4 (JB) .
Page 653 8W - 61 - 2 8W-61 POWER DOOR LOCKS BATT A7 RUN A22 (8W-10-9) (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-3) (8W-12-8) (8W-12-7) POWER LEFT MIRROR POWER SWITCH MIRROR (8W-62-2) (HEATED MIRRORS) GROUND GROUND (8W-48-2) C315 C310 Z1 18BK C316 S402 (8W-15-9) OTHER...
Page 654 8W-61 POWER DOOR LOCKS 8W - 61 - 3 LEFT RIGHT REMOTE REMOTE KEYLESS KEYLESS ENTRY ENTRY ANTENNA ANTENNA P158 BODY CONTROL EXTERNAL EXTERNAL ANTENNA ANTENNA MODULE (8W-45-10) (8W-45-11) LEFT FRONT DOOR DOOR DOOR DOOR DOOR DOOR DOOR DOOR UNLOCK LOCK UNLOCK LOCK...
Page 656 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Fuse 5 (JB) ......8W-62-2 Left Power Mirror .
Page 657 8W - 62 - 2 8W-62 POWER MIRRORS BATT A7 (8W-10-9) JUNCTION BLOCK (8W-12-2) LEFT FUSE (8W-12-3) POWER MIRROR (8W-12-8) (HEATED GROUND MIRRORS) (8W-48-2) LEFT FRONT C310 POWER S402 DOOR GROUND (8W-15-9) LOCK SWITCH (8W-61-2) S400 C311 (8W-12-9) G306 (8W-15-9) POWER MIRROR SWITCH...
Page 658 8W - 63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Circuit Breaker 1 (JB) ....8W-63-2 Junction Block ....8W-63-2, 3 Driver Heated Seat Module .
Page 659 8W - 63 - 2 8W-63 POWER SEAT BATT A3 (8W-10-15) JUNCTION BLOCK (8W-12-2) CIRCUIT (8W-12-3) BREAKER (8W-12-14) C309 POWER SEAT SWITCH 1 BACK 2 FORWARD 3 UP 4 DOWN YL/LG RD/LG YL/LB RD/LB YL/WT RD/WT GY/WT GY/LB C309 REAR VERTICAL G301 MOTOR...
Page 660: Heated Seat
8W-63 POWER SEAT 8W - 63 - 3 HEATED SEAT HEATED ST-RUN-OFF A81 (8W-10-11) FUSED SEAT IGNITION DRIVER JUNCTION SWITCH SWITCH HEATED BLOCK OUTPUT SEAT FUSE (8W-12-2) (ST-RUN-OFF) SWITCH (8W-12-3) (8W-12-12) BATT A0 (8W-10-7) POWER DISTRIBUTION FUSE CENTER (8W-10-7) RD/VT (8W-10-13) C225 RD/WT...
Page 662 8W - 64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Circuit Breaker 2 (JB) ....8W-64-2 Sunroof Motor ..... . 8W-64-2 G301 .
Page 663 8W - 64 - 2 8W-64 POWER SUNROOF RUN A22 (8W-10-16) JUNCTION BLOCK (8W-12-2) CIRCUIT (8W-12-3) BREAKER (8W-12-14) SUNROOF SUNROOF SWITCH POSITION 1 OPEN SENSOR 2 CLOSE STOP VENT GROUND 3 VENT SUNROOF POWER POWER POWER POWER FUSED STOP VENT GROUND CONTROL SUNROOF...
Page 664 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-10-8 S133 .
Page 665 8W - 70 - 2 8W-70 SPLICE INFORMATION INTAKE AIR THROTTLE TEMPERATURE/ POSITION MANIFOLD SENSOR ABSOLUTE (8W-30-9) PRESSURE SENSOR (8W-30-11) 2.5L POWERTRAIN MANIFOLD CONTROL ABSOLUTE MODULE PRESSURE (8W-30-9) SENSOR VT/WT VT/WT (8W-30-12) 2.4L 2.5L PRESSURE TRANSDUCER VT/WT VT/WT (8W-30-15) VT/WT VT/WT C111 VT/WT...
Page 666 8W-70 SPLICE INFORMATION 8W - 70 - 3 FROM S118 FUEL FUEL FUEL FUEL (8W-70-5) INJECTOR INJECTOR INJECTOR INJECTOR 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 (2.0L/...
Page 667 8W - 70 - 4 8W-70 SPLICE INFORMATION INTAKE AIR MANIFOLD TEMPERATURE/ ABSOLUTE MANIFOLD PRESSURE ABSOLUTE SENSOR PRESSURE (8W-30-12) SENSOR (8W-30-11) PRESSURE 2.0L 2.4L/ TRANSDUCER 2.5L (8W-30-15) BK/LB BK/LB S116 THROTTLE BK/LB BK/LB POSITION SENSOR CRANKSHAFT INTAKE AIR (8W-30-9) POSITION TEMPERATURE SENSOR SENSOR...
Page 668 8W-70 SPLICE INFORMATION 8W - 70 - 5 AUTOMATIC DISTRIBUTOR GENERATOR ELECTRONIC SHUT DOWN (2.5L) (2.5L) RELAY (8W-30-5) (8W-20-2) TRANSDUCER (IN PDC) SOLENOID (8W-30-4) (8W-30-11) (8W-30-12) A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR A142 DG/OR C111 FUSE A142 1 (PDC) (8W-10-8) DG/OR S118...
Page 669 8W - 70 - 6 8W-70 SPLICE INFORMATION VEHICLE SPEED SENSOR (8W-30-19) POWERTRAIN CONTROL MODULE (8W-30-19) C169 OR/WT OR/WT S130 (MTX) POWERTRAIN CONTROL DISTRIBUTOR CAMSHAFT CRANKSHAFT MODULE (2.5L) POSITION POSITION OR/WT (8W-30-8) (8W-30-5) SENSOR SENSOR (8W-30-8) (8W-30-8) EATX OR/WT C111 2.5L 2.0L/ 2.4L...
Page 670 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-4 Clockspring No. 1 ....8W-80-17 A/C Evaporator Temperature Sensor .
Page 671 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Left Back - Up Lamp ....8W-80-30 Oil Pressure Switch ....8W-80-38 Left Cylinder Lock Switch .
Page 672 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Right Headlamp Leveling Motor ..8W-80-46 Shift Interlock Solenoid ....8W-80-49 Right License Lamp .
Page 673 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT COMPRESSOR CLUTCH BLACK CIRCUIT FUNCTION C57 22GY SENSOR GROUND C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL EVAPORATOR TEMPERATURE SENSOR NATURAL CIRCUIT FUNCTION M1 20PK/DB FUSED B(+) C21 22DB/OR A/C SWITCH SENSE...
Page 674 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 GRAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K6 20VT/WT 5 VOLT SUPPLY C18 20DB A/C PRESSURE SIGNAL A/C PRESSURE TRANSDUCER CIRCUIT FUNCTION F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (ST-RUN) F23 18WT FUSED IGNITION SWITCH OUTPUT (RUN) D1 18VT CCD BUS (+) GRAY...
Page 675 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS YELLOW CIRCUIT FUNCTION R44 18LG/YL PASSENGER AIRBAG LINE 1 R42 18RD/WT PASSENGER AIRBAG LINE 2 R45 18DG/LB DRIVER AIRBAG LINE 1 R43 18BK/LB DRIVER AIRBAG LINE 2 AIRBAG CONTROL MODULE - C2 BLACK CIRCUIT FUNCTION...
Page 676 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 GRAY CIRCUIT FUNCTION F20 18WT/YL FUSED IGNITION SWITCH OUTPUT (RUN) L1 18VT/BK BACK-UP LAMP FEED BACK-UP LAMP SWITCH (MTX) CIRCUIT FUNCTION V55 20TN/RD WIPER PARK SWITCH SENSE D1 18VT/BR CCD BUS (+) Z1 18BK GROUND BLACK...
Page 677 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION G69 20BK/OR VTSS INDICATOR DRIVER NATURAL C35 20DG/YL MODE DOOR DRIVER (+) E2 18OR/YL PANEL LAMPS DRIVER E2 18OR/BR PANEL LAMPS DRIVER C26 20PK/DB 5 VOLT SUPPLY C34 20DB/YL MODE DOOR DRIVER (-) Z2 18BK/LG GROUND BODY...
Page 678 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 CIRCUIT FUNCTION P34 16PK/LB DOOR UNLOCK DRIVER P34 16PK/DB DOOR UNLOCK DRIVER P34 16PK/BK DOOR UNLOCK DRIVER P55 16DB/WT DOOR UNLOCK DRIVER G10 20LG/RD SEAT BELT SWITCH SENSE G74 20TN/RD LEFT REAR DOOR AJAR SWITCH SENSE BLACK G75 20TN DOOR AJAR SWITCH SENSE...
Page 679 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT F20 18WT/YL F20 18WT/YL BLACK T1 20LG/BK T1 18LG/GY BLACK T3 18VT T3 18VT T13 20DB/BK T13 18DB/BR T14 20LG/WT T14 18LG/VT T20 20LB T20 18LB/WT T42 18VT/TN T42 18VT/TN T47 20YL/BK T47 18YL/GY C105...
Page 680 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 CIRCUIT CIRCUIT A141 14DG/WT A141 14DG/WT BLACK L1 18VT/BK BLACK L1 18VT/BK L36 18LB L36 18LG/DG G74 20TN/RD B1 20YL/DB B1 18YL/DB B2 20YL B2 18YL B3 20LG/DB B3 18LG/DB B4 20LG B4 18LG C121 C121...
Page 681 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT A142 18DG/OR A142 18DG/OR K11 18WT/DB K11 18WT/DB K13 18YL/WT K13 18YL/WT K38 18GY K38 18GY C165 C165 (2.5L) (2.5L) BLACK CIRCUIT CIRCUIT BLACK K7 18OR/WT K7 18OR K4 18BK/LB K4 18BK/LB G7 18WT/OR...
Page 682 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 BLACK CIRCUIT CIRCUIT BLACK L1 18VT/BK L1 18VT/BK L50 18WT/TN L50 18WT/TN L60 18TN L60 18TN L7 18BK/YL L7 18BK/YL Z1 18BK Z1 18BK C301 C301 BLACK BLACK CIRCUIT CIRCUIT L50 16WT/TN L50 18BK/TN Z1 18BK Z1 18BK...
Page 683 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT Z1 16BK F35 16RD F35 16RD Z1 16BK C309 C309 (POWER SEAT) (POWER SEAT) CIRCUIT CIRCUIT M1 20PK M1 20PK P97 22WT/DG P97 22WT/DG P91 22WT/BK P91 22WT/BK P92 22YL P92 22YL BROWN...
Page 684 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 CIRCUIT CIRCUIT M1 20PK M1 20PK P96 22WT/LG P96 22WT/LG BROWN P90 22LG/BK P90 22LG/BK BROWN P92 22YL P92 22YL C315 C315 P91 22WT/BK P91 22WT/BK C16 20LB/YL C16 20LB/YL P94 22WT/YL P94 22WT/YL CIRCUIT CIRCUIT...
Page 685 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT L7 18BK/YL L7 18BK/YL Z1 18BK Z1 18BK L36 18LG L36 18LB C320 C320 BLACK BLACK CIRCUIT CIRCUIT L61 18LG/TN L61 18LG Z1 18BK Z1 18BK Z1 18BK C343 C343 (BUILT-UP-EXPORT)
Page 686 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 BLACK CIRCUIT FUNCTION Z1 18BK GROUND L50 18BK/TN BRAKE LAMP SWITCH OUTPUT CENTER HIGH MOUNTED STOP LAMP NATURAL CIRCUIT FUNCTION X3 18BK/RD HORN RELAY CONTROL V37 20PK/LG SPEED CONTROL SWITCH SIGNAL Z2 18BK/TN GROUND CLOCKSPRING NO.
Page 687 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-) B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) BLACK Z1 12BK GROUND...
Page 688 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 BLACK CIRCUIT FUNCTION K7 20OR 8 VOLT SUPPLY K4 20BK/LB SENSOR GROUND CRANKSHAFT K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL POSITION SENSOR (2.0L/2.4L) BLACK CIRCUIT FUNCTION K7 20OR 8 VOLT SUPPLY K4 20BK/LB SENSOR GROUND K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL...
Page 689 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUTDOWN RELAY OUTPUT DISTRIBUTOR - C1 (2.5L) CIRCUIT FUNCTION BLACK K4 18BK/LB SENSOR GROUND K7 20OR 8 VOLT SUPPLY K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL Z1 16BK GROUND K19 18BK/GY IGNITION COIL NO.
Page 690 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 BLACK CIRCUIT FUNCTION K52 20PK/GY EVAPORATIVE EMISSION SOLENOID CONTROL K108 18WT/TN EVAPORATIVE SOLENOID SENSE DUTY CYCLE EVAP/PURGE SOLENOID BLACK CIRCUIT FUNCTION K35 18GY/YL EGR SOLENOID CONTROL A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT ELECTRONIC EGR TRANSDUCER SOLENOID...
Page 691 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K12 18TN INJECTOR NO. 2 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 2 (2.0L/2.4L) BLACK CIRCUIT FUNCTION K12 18TN INJECTOR NO. 2 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO.
Page 692 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 BLACK CIRCUIT FUNCTION K38 18GY INJECTOR NO. 5 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 5 (2.5L) BLACK CIRCUIT FUNCTION INJECTOR NO. 6 DRIVER K58 18BR/DB AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18DG/OR FUEL INJECTOR NO.
Page 693 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION HEADLAMP SWITCH OUTPUT L7 18BK/YL GROUND Z1 18BK HEADLAMP ADJUST SIGNAL L13 18BR/VT HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) BLACK CIRCUIT FUNCTION V53 14YL/RD WASHER RELAY OUTPUT Z1 18BK GROUND L7 18BK/YL HEADLAMP SWITCH OUTPUT A53 14RD/YL FUSED B(+)
Page 694 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 GRAY CIRCUIT FUNCTION P15 16YL/LB LEFT POWER SEAT HORIZONTAL REARWARD P17 16RD/LB LEFT POWER SEAT HORIZONTAL FORWARD HORIZONTAL MOTOR CIRCUIT FUNCTION K39 20GY/RD IDLE AIR CONTROL NO. 1 DRIVER IDLE AIR CONTROL NO. 2 DRIVER K60 20YL/BK IDLE AIR K40 20BR/WT...
Page 695 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION A51 20RD/LB FUSED B(+) A81 20DG/RD FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF) IGNITION SWITCH - C1 CIRCUIT FUNCTION Z1 20BK GROUND G9 22GY/DB RED BRAKE WARNING INDICATOR DRIVER BLACK A2 12PK/BK FUSED B(+) A22 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN)
Page 696 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 GRAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL K6 20VT/WT 5 VOLT SUPPLY K1 18DG/RD MAP SENSOR SIGNAL INTAKE AIR TEMPERATURE/MANIFOLD ABSOLUTE PRESSURE SENSOR (2.0L) GRAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND...
Page 697 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS 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 698 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 WHITE CIRCUIT FUNCTION A22 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN) L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT A3 14RD/WT FUSED B(+) C1 12DG BLOWER MOTOR FEED JUNCTION BLOCK - C6 CIRCUIT...
Page 699 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS NATURAL CIRCUIT FUNCTION M2 20YL COURTESY LAMPS DRIVER F21 18TN FUSED IGNITION SWITCH OUTPUT (RUN) Z1 20BK GROUND Z1 18BK GROUND JUNCTION BLOCK - C10 M1 20PK FUSED B (+) CIRCUIT FUNCTION BLACK L92 18LG FUSED B(+)
Page 700 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 BLACK CIRCUIT FUNCTION G73 18 LG/OR LEFT DOOR KEY CYLINDER SWITCH SENSE M1 20PK FUSED B(+) LEFT CYLINDER LOCK SWITCH (VTSS) GRAY CIRCUIT FUNCTION L39 18LB/OR FOG LAMP SWITCH OUTPUT Z1 18BK GROUND LEFT FOG LAMP...
Page 701: Left Front Wheel Speed Sensor
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION P55 16DB/WT LEFT FRONT DOOR UNLOCK DRIVER P33 16OR/BK DOOR LOCK DRIVER LEFT FRONT POWER DOOR LOCK MOTOR NATURAL CIRCUIT FUNCTION M1 20PK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) Z1 20BK GROUND LEFT FRONT...
Page 702 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 BLACK CIRCUIT FUNCTION L43 18VT/OR FUSED LEFT LOW BEAM OUTPUT Z1 18BK GROUND L33 18LG/BR FUSED LEFT HIGH BEAM OUTPUT LEFT HEADLAMP (EXCEPT BUILT- UP-EXPORT) BLACK CIRCUIT FUNCTION L7 18BK/BR HEADLAMP SWITCH OUTPUT L13 18BR/VT HEADLAMP ADJUST SIGNAL LEFT HEADLAMP...
Page 703 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION L36 18LG REAR FOG LAMP Z1 18BK GROUND LEFT REAR FOG LAMP (BUILT-UP-EXPORT) GRAY CIRCUIT FUNCTION P34 16PK/BK DOOR UNLOCK DRIVER P33 16OR/BK DOOR LOCK DRIVER LEFT REAR POWER DOOR LOCK MOTOR BLACK FUNCTION...
Page 704: Left Rear Wheel Speed Sensor
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 BLACK CIRCUIT FUNCTION B3 20LG/DB LEFT REAR WHEEL SPEED SENSOR (-) B4 20LG LEFT REAR WHEEL SPEED SENSOR (+) LEFT REAR WHEEL SPEED SENSOR CIRCUIT FUNCTION L61 18LG/TN LEFT TURN SIGNAL Z1 18BK GROUND LEFT SIDE REPEATER...
Page 705 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND LEFT VISOR/ VANITY LAMPS CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK GROUND LICENSE LAMP (EXCEPT BUILT- UP-EXPORT) CIRCUIT FUNCTION Z1 18BK GROUND X2 18DG/PK HORN RELAY OUTPUT...
Page 706 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) Q17 14DB/WT LEFT REAR WINDOW DRIVER (UP) Q27 14RD/BK LEFT REAR WINDOW DRIVER (DOWN) BLUE Q18 14GY/BK RIGHT REAR WINDOW DRIVER (UP) Q1 14YL POWER WINDOW SWITCH FEED Q11 16LB LEFT FRONT WINDOW DRIVER (UP)
Page 707 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS GREEN CIRCUIT FUNCTION G6 18GY/VT ENGINE OIL PRESSURE SWITCH SENSE G6 18GY ENGINE OIL PRESSURE SWITCH SENSE OIL PRESSURE SWITCH GRAY CIRCUIT FUNCTION T13 18DB/BR SPEED SENSOR GROUND T14 18LG/VT OUTPUT SPEED SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR BLACK...
Page 708 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 YELLOW CIRCUIT FUNCTION R42 18RD/WT PASSENGER AIRBAG LINE 2 R44 18LG/YL PASSENGER AIRBAG LINE 1 PASSENGER SIDE AIRBAG SQUIB GRAY CIRCUIT FUNCTION F30 18RD/PK FUSED B(+) Z1 18BK/LB GROUND POWER AMPLIFIER - C1 (PREMIUM) CIRCUIT FUNCTION...
Page 709 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION X93 20WT/VT AMPLIFIED LOW LEFT REAR SPEAKER (+) X91 20WT/DG AMPLIFIED LOW LEFT REAR SPEAKER (-) X60 22DG/RD RADIO 12 VOLT OUTPUT BLUE X96 20TN/BK AMPLIFIED HIGH RIGHT REAR SPEAKER (-) X98 20TN/RD AMPLIFIED HIGH RIGHT REAR SPEAKER (+) X95 20WT/RD...
Page 710 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 CIRCUIT FUNCTION K17 18DB/TN IGNITION COIL NO. 2 DRIVER K19 18BK/GY IGNITION COIL NO. 1 DRIVER V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K13 18YL/WT INJECTOR NO.
Page 711 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS 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(+) Z1 18BK GROUND K40 20BR/WT...
Page 712 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 BLACK CIRCUIT FUNCTION Z1 12BK GROUND Z1 12BK GROUND C23 12DG/LG LOW SPEED RADIATOR FAN RELAY OUTPUT C25 12YL/VT HIGH SPEED RADIATOR FAN RELAY OUTPUT RADIATOR FAN MOTOR ASSEMBLY CIRCUIT FUNCTION BLACK X60 22DG/RD RADIO 12 VOLT OUTPUT X51 22BR/YL...
Page 713 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION BACK-UP LAMP FEED L1 18VT/BK RIGHT Z1 18BK GROUND BACK-UP LAMP BLACK CIRCUIT FUNCTION G72 18DG/OR RIGHT DOOR KEY CYLINDER SWITCH SENSE M1 20PK FUSED B(+) RIGHT CYLINDER LOCK SWITCH (VTSS) GRAY CIRCUIT...
Page 714: Right Front Wheel Speed Sensor
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 GRAY CIRCUIT FUNCTION P34 16PK/LB DOOR UNLOCK DRIVER P33 16OR/BK DOOR LOCK DRIVER RIGHT FRONT POWER DOOR LOCK MOTOR NATURAL FUNCTION CIRCUIT M1 20PK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) Z1 20BK GROUND RIGHT FRONT...
Page 715 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT Z1 18BK GROUND L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT RIGHT HEADLAMP (EXCEPT BUILT-UP -EXPORT) BLACK CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT L13 18BR/VT HEADLAMP ADJUST SIGNAL RIGHT HEADLAMP...
Page 716 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CIRCUIT FUNCTION GRAY C16 20LB/YL* FUSED REAR WINDOW DEFOGGER RELAY OUTPUT Z1 18BK* GROUND Z1 20BK* GROUND P94 22WT/YL RIGHT POWER MIRROR VERTICAL P91 22WT/BK LEFT/RIGHT POWER MIRROR HORIZONTAL SUPPLY RIGHT POWER P90 22LG/BK POWER MIRROR FEED MIRROR...
Page 717: Right Rear Wheel Speed Sensor
8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION X98 20TN/RD AMPLIFIED HIGH RIGHT REAR SPEAKER (+) X92 20TN/DG AMPLIFIED LOW RIGHT REAR SPEAKER (-) RIGHT REAR X94 20TN/VT AMPLIFIED LOW RIGHT REAR SPEAKER (+) SPEAKER X96 20TN/BK AMPLIFIED HIGH RIGHT REAR SPEAKER (-) (PREMIUM) BLACK...
Page 718 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 GRAY CIRCUIT FUNCTION BRAKE LAMP SWITCH OUTPUT L50 18WT/TN L7 18BK/YL HEADLAMP SWITCH OUTPUT RIGHT TAIL/STOP Z1 18BK GROUND LAMP CIRCUIT FUNCTION RIGHT TURN SIGNAL L60 18TN Z1 18BK GROUND RIGHT TURN LAMP BLACK CIRCUIT...
Page 719 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION GRAY K29 18WT/RD BRAKE SWITCH SENSE Z2 20BK/LG GROUND V32 20YL/PK SPEED CONTROL ON/OFF SWITCH SENSE V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT L50 16WT/TN BRAKE LAMP SWITCH OUTPUT STOP LAMP A7 16RD/BK FUSED B(+) SWITCH...
Page 720 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 BLACK 3 2 1 CIRCUIT FUNCTION THROTTLE K4 18BK/LB SENSOR GROUND POSITION K6 18VT/WT 5 VOLT SUPPLY SENSOR K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL (2.0L) K6 20VT/WT 5 VOLT SUPPLY NATURAL K4 18BK/LB SENSOR GROUND THROTTLE POSITION...
Page 721 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS (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/DG SCI RECEIVE T47 20YL/BK 2-4 PRESSURE SWITCH SENSE T50 18DG/TN LOW/REVERSE PRESSURE SWITCH SENSE...
Page 722 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 BLACK CIRCUIT FUNCTION T47 18YL/GY 2-4 PRESSURE SWITCH SENSE T50 18DG/TN LOW/REVERSE PRESSURE SWITCH SENSE T9 18OR/BK OVERDRIVE PRESSURE 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 723 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION V36 20WT/VT SPEED CONTROL VACUUM SOLENOID CONTROL V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT VEHICLE SPEED Z1 20BK GROUND CONTROL SERVO BLACK CIRCUIT FUNCTION K7 18OR...
Page 724 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS INDEX page page DESCRIPTION AND OPERATION INTRODUCTION ......1 CONNECTOR/GROUND LOCATIONS .
Page 725 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C301 Right Rear Downstream Rear of Engine Quarter Panel Heated Oxygen Sensor C305 Near Trunk Latch Driver Heated At Center Seat Module...
Page 726 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number G107 Right Strut Horizontal Motor At Motor Tower Idle Air Control On Throttle G110 Left Strut Tower Motor Body G111...
Page 727 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Key-In Halo At Lamp Left Rear At Speaker Lamp Speaker Key-In Switch At Switch Left Rear Wheel Left Quarter Speed Sensor Panel...
Page 728 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Power Antenna Right Rear Right Front At Switch Quarter Panel Power Window Switch Power Mirror At Switch Switch Right Front Right Fender...
Page 729 8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Sunroof Switch At Switch Turbine Speed Front of Sensor Transmission Throttle Position On Throttle 4, 5 Sensor Body Upstream...
Page 730 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued)
Page 731 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 732 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
Page 733 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 734 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
Page 735 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 736 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued)
Page 737 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 738 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
Page 739 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 740 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
Page 741 8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 742 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued)
Page 743 8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 744 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued)
Page 745 8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 746 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23 DESCRIPTION AND OPERATION (Continued) Fig. 17 Door Connections (Front) Fig. 18 Door Connections (Rear)
Page 747 8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 19 Deck Lid Connections...
Page 748 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS INDEX page page DESCRIPTION AND OPERATION SPLICE LOCATIONS ..... . 1 INTRODUCTION .
Page 749 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S302 Between LT and RT Visor S312 Near T/O for Junction Block Lamps Connectors S303 Between LT and RT Visor S400 Near Left Door Speaker Lamps...
Page 750 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 1 Engine Compartment Splices Fig. 2 Engine Compartment Splices...
Page 751 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 3 Engine Compartment Splices Fig. 4 Transmission Splices...
Page 752 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
Page 753 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 754 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
Page 755 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 8 Deck Lid Splices Fig. 9 Door Splices...
Page 756: L Engine
ENGINE 9 - 1 ENGINE CONTENTS page page 2.0L SOHC ENGINE ..... . 14 ENGINE DIAGNOSIS ..... . . 9 2.4L ENGINE .
Page 757: Engine Core Plugs
9 - 2 ENGINE GENERAL INFORMATION (Continued) GASKET DISASSEMBLY Only use the following for cleaning gasket surfaces: • use Mopar Brake and Parts Cleaner Parts assembled with form-in-place gaskets may be • use only a plastic or wood scraper (Fig. 1) disassembled without unusual...
Page 758: Engine Performance
ENGINE 9 - 3 GENERAL INFORMATION (Continued) INSTALLATION equipped with 280 grit stones, if the cylinder bore is straight and round. 20-60 strokes depending on the Thoroughly clean all debris/rust from inside of cup bore condition, will be sufficient to provide a satisfac- plug hole in cylinder block or head.
Page 759 9 - 4 ENGINE GENERAL INFORMATION (Continued) Fig. 5 Clearance Measurement Fig. 4 Plastigage Placed in Lower Shell ALTERNATIVE METHOD NOTE: The total clearance of the main bearings can only be determined by removing the weight of the The weight of the crankshaft can be supported by a crankshaft.
Page 760: Hydrostatic Locked Engine
ENGINE 9 - 5 GENERAL INFORMATION (Continued) the oil hole (Fig. 4). In addition, suspect areas can be (4) With all spark plugs removed, rotate engine checked by placing plastigage in the suspect area. crankshaft using a breaker bar and socket. (4) Assemble the rod cap with Plastigage in place.
Page 761 9 - 6 ENGINE GENERAL INFORMATION (Continued) Fig. 6 Dipstick and Engine Oil Fill Locations—2.0L Fig. 7 Dipstick and Engine Oil Fill Locations—2.4L SAE VISCOSITY CONTAINER IDENTIFICATION An SAE viscosity grade is used to specify the vis- Standard engine oil identification notations have cosity of engine oil.
Page 762 ENGINE 9 - 7 GENERAL INFORMATION (Continued) Fig. 8 Dipstick and Engine Oil Fill Locations—2.5L Fig. 9 Oil Level Fig. 11 Engine Oil Container Standard Notations Run engine until achieving normal operating tem- perature. (1) Position the vehicle on a level surface and turn engine off.
Page 763 All engines are equipped with a high quality full- engine. Refer to the WARNING listed above. flow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used.
Page 764 ENGINE 9 - 9 ENGINE DIAGNOSIS INDEX page page DIAGNOSIS AND TESTING GENERAL INFORMATION ....9 CYLINDER COMBUSTION PRESSURE INSPECTION (ENGINE OIL LEAKS IN LEAKAGE TEST .
Page 765 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) should not be disassembled to determine the kPa (200 psi) maximum, with 552 kPa (80 psi) rec- cause of low compression unless some malfunc- ommended. tion is present. Perform the test procedures on each cylinder (11) Clean or replace spark plugs as necessary and according to the tester manufacturer’s instructions.
Page 766 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) make sure the dye is thoroughly mixed as indicated present in this area remove transmission for further with a bright yellow color under a black light. inspection. (3) Using a black light, inspect the entire engine (a) Circular spray pattern generally indicates for fluorescent dye, particularly at the suspected area seal leakage or crankshaft damage.
Page 767 9 - 12 ENGINE DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. Refer to Group 8A, Battery. 2. Corroded or loose battery 2. Clean and tighten battery connections.
Page 768 ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in crankcase. 1. Check and correct engine oil level. 2. Thin or diluted oil. 2. Change oil to correct viscosity. 3.
Page 769 9 - 14 2.0L SOHC ENGINE 2.0L SOHC ENGINE INDEX page page DESCRIPTION AND OPERATION OIL PAN ....... 46 2.0L SOHC ENGINE .
Page 770 2.0L SOHC ENGINE 9 - 15 DESCRIPTION AND OPERATION 2.0L SOHC ENGINE 2.0L SOHC Engine ENGINE IDENTIFICATION The engine identification number is located on the left rear of the cylinder block behind starter (Fig. 1). Fig. 1 Engine Identification SOHC...
Page 771 9 - 16 2.0L SOHC ENGINE DESCRIPTION AND OPERATION (Continued) GENERAL SPECIFICATION toward the radiator. The exhaust valves facing toward the dash panel. Rocker arm shafts mount directly to the cylinder head. It incorporates powder Type ... . . In-Line OHV, DOHC & SOHC metal valve guides and seats.
Page 772 2.0L SOHC ENGINE 9 - 17 DESCRIPTION AND OPERATION (Continued) Engine Lubrication Components MAIN/ROD BEARINGS A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to connecting rod journals.
Page 773 Fig. 4 Piston Measurements nomical operation. Chrysler engines use pistons designed specifically NOTE: Pistons and cylinder bores should be mea- for each engine model. Clearance and sizing locations sured at normal room temperature, 21°C (70°F).
Page 774 2.0L SOHC ENGINE 9 - 19 SERVICE PROCEDURES (Continued) FITTING PISTON RINGS (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore.
Page 775 9 - 20 2.0L SOHC ENGINE SERVICE PROCEDURES (Continued) (4) Tighten the bolts to 27 N·m PLUS 1/4 turn (20 CRANKSHAFT SPECIFICATION CHART ft. lbs. PLUS 1/4 turn) Do not use a torque Crankshaft End-Play wrench for last step. New Part: 0.09 - 0.24 mm (5) Using a feeler gauge, check connecting rod side (0.0035 - 0.0094 in.)
Page 776 2.0L SOHC ENGINE 9 - 21 SERVICE PROCEDURES (Continued) CAMSHAFT END PLAY NOTE: It may be necessary to tilt engine for rear mount removal clearance. (1) Oil camshaft journals and remove rocker arm assemblies. Cam sensor installed and fastener (6) Remove rear mount. tighten to specified torque.
Page 777 9 - 22 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 14 Engine Mounting—Rear ITEM DESCRIPTION TORQUE Bolt 61 N·m (45 ft. lbs.) Bolt—w/Auto. 110 N·m (80 ft. B & C Transaxle lbs.) Fig. 13 Engine Mounting—Front 2.0L Bolt—w/Manual 61 N·m (45 ft. Transaxle lbs.) (2) Install bolts attaching rear mount to front sus-...
Page 778 2.0L SOHC ENGINE 9 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 16 Left Side Mount—Typical Fig. 15 Engine Mounting—Right Side ENGINE MOUNT—LEFT ITEM DESCRIPTION TORQUE NOTE: If centering or adjusting the engine/trans- Bolt 61 N·m mission assembly is needed refer to Adjustments, (45 ft.
Page 779 9 - 24 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: The torque procedure for the structural collar must be followed, as damage to oil pan or collar could occur. (1) Install the structural collar (Fig. 17) using the following 3 step torque sequence: •...
Page 780 2.0L SOHC ENGINE 9 - 25 REMOVAL AND INSTALLATION (Continued) (18) Install battery tray and battery. Set Power- train Control Module (PCM) into place. (19) Install air cleaner and hoses. (20) Evacuate and charge air conditioning system. Refer to Group 24, Heating and Air Conditioning for procedures.
Page 781 9 - 26 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (5) Remove fuel rail assembly attaching screws (10) Remove transaxle to throttle body support and remove fuel rail assembly from engine. Cover bracket fasteners at the throttle body and loosen the injector holes with a suitable covering.
Page 782 2.0L SOHC ENGINE 9 - 27 REMOVAL AND INSTALLATION (Continued) CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain ener- gized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.
Page 783 9 - 28 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD COVER REMOVAL (1) Remove ignition coil pack (Fig. 28). (2) Remove the cylinder head cover bolts. (3) Remove cylinder head cover from cylinder head. Fig. 29 Servicing Spark Plug Tubes SPARK PLUG TUBE SEALS The spark plug tube seals are located in the cylin- der head cover (Fig.
Page 784 2.0L SOHC ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (4) Remove rocker arm shaft bolts. Refer to proce- dure outlined in this section. (5) Remove timing belt, timing belt tensioner, and camshaft sprocket. Refer to procedures outlined in this section. (6) Remove rear timing belt cover.
Page 785 9 - 30 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (3) Loosen the attaching fasteners. Remove rocker arm shaft assemblies from cylinder head. (4) Identify the rocker arms spacers and retainers for reassembly. Disassemble the rocker arm assem- blies by removing the attaching bolts from the shaft (Fig.
Page 786 2.0L SOHC ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 38 Valve Stem Oil Seal Tool ment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC. Fig. 36 Rocker Arm Shaft Tightening Sequence VALVE SEALS AND SPRINGS—IN VEHICLE REMOVAL (1) Remove rocker arm shafts assemblies.
Page 787 9 - 32 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Cylinder Head and Valve Assembly (7) Remove power brake vacuum hose from intake manifold. (8) Raise vehicle and remove exhaust pipe from manifold. (9) Remove power steering fluid reservoir and set aside.
Page 788 2.0L SOHC ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt(s) should be replaced. Fig. 41 Checking Bolts for Streching (Necking) Fig.
Page 789 9 - 34 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) VALVE INSPECTION (1) Clean valves thoroughly and discard burned, warped and cracked valves. (2) Measure valve stems for wear. Measure stem about 60 mm beneath the valve lock grooves. (3) If valve stems are worn more than 0.05 mm (.002 in.), replace valve.
Page 790 2.0L SOHC ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) (2) Inspect the remaining margin after the valves then set valve in place. Rotate the valve with light are refaced (Fig. 47). Intake valves with less than pressure. If the blue is transferred to the center of 0.95 mm (1/32 inch.) margin and Exhaust valves valve face, contact is satisfactory.
Page 791 9 - 36 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (5) Install rocker shafts previously described in this section. (6) Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed.
Page 792 2.0L SOHC ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 54 Generator and Brackets Fig. 52 Crankshaft Damper—Removal (3) Raise vehicle on hoist and install right inner splash shield. Fig. 55 Right Engine Mount Bracket INSTALLATION Fig. 53 Crankshaft Damper—Installation (1) Install front timing cover.
Page 793 9 - 38 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) CHECKING BELT TIMING—COVER INSTALLED • Remove number one spark plug. • Using a dial indicator, set number one cylinder to TDC on the compression stroke. • Remove the access plug from the outer timing belt cover (Fig.
Page 794 2.0L SOHC ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) REMOVAL—TIMING BELT (5) Lower vehicle and place a jack under engine. (6) Remove right engine mount. Refer to procedure (1) Disconnect negative cable from auxiliary in this section. jumper terminal. (7) Remove generator and bracket (Fig.
Page 795 9 - 40 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 63 Timing Belt Cover Fig. 65 Remove Timing Belt (3) When plunger is compressed into the tensioner body install a 1.9 mm (5/64) Allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed.
Page 796 2.0L SOHC ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 67 Crankshaft Sprocket Timing Fig. 70 Adjusting Timing Belt Tension pulley bracket and tighten fasteners to 31 N·m (23 ft. lbs.) (Fig. 70). (11) Pull tensioner plunger pin. Pretension is cor- rect when pin can be removed and installed.
Page 797 9 - 42 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) • Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover (Fig. 73). Fig. 73 Camshaft Timing Marks Fig. 71 Crankshaft Damper—Installation REMOVAL—TIMING BELT TIMING BELT—WITH MECHANICAL (1) Disconnect...
Page 798 2.0L SOHC ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (12) Remove front timing belt cover (Fig. 78). CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft. (13) Install a 8 mm Allen wrench into the belt ten- sioner.
Page 799 9 - 44 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 80 Crankshaft Sprocket Timing Fig. 78 Timing Belt Cover Fig. 81 Camshaft Timing Mark (2) Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover (Fig.
Page 800 2.0L SOHC ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) (4) Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket. (5) Move crankshaft sprocket to TDC to take up belt slack. (6) Remove the 1/8”...
Page 801 9 - 46 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install timing belt tensioner assembly. Tighten attaching bolts to 31 N·m (275 in. lbs.). (2) Install timing belt. Refer to procedure in this section. OIL PAN REMOVAL (1) Drain engine oil. (2) Remove front engine mount bracket.
Page 802 2.0L SOHC ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) (3) Install camshaft sprocket retaining bolt. Hold camshaft sprocket with Special Tool C-4687-1 (Fig. 88) and tighten bolt to 115 N·m (85 ft. lbs.). (4) Install timing belt tensioner, timing belt, and front cover.
Page 803 9 - 48 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (4) Using Tool 6771 to remove front crankshaft oil seal (Fig. 93). Do not damage the seal contact area on the crankshaft. Fig. 95 Crankshaft Sprocket—Installation (4) Install timing belt and covers. Refer to Timing Belt System in this section for installation.
Page 804 2.0L SOHC ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 97 Rear Crankshaft Oil Seal—Removal Fig. 98 Rear Crankshaft Seal and Special Tool 6926-1 INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installa- tion of new seal.
Page 805 9 - 50 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) CRANKSHAFT MAIN BEARINGS LOCATION The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bed- plate) main bearing cap are plain.
Page 806 2.0L SOHC ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 101 Cylinder Block and Components Fig. 102 Bedplate Bolts Fig. 103 Main Bearing Identification...
Page 807 9 - 52 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 106 Main Bearing Caps/Bedplate Torque Fig. 104 Installing Main Bearing Upper Shell Sequence CAUTION: Use only the specified anaerobic sealer (9) Install main bearing bedplate to engine block on the bedplate or damage may occur to the bolts (11 –...
Page 808 2.0L SOHC ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) OIL FILTER REMOVE AND INSTALL CAUTION: When servicing the oil filter (Fig. 108) avoid deforming the filter, install tool band strap against the seam at the base of the filter. The seam, joining the can to the base is reinforced by the base plate.
Page 809 9 - 54 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 110 Oil Pump and Tube Fig. 111 Oil Pump Sealing (4) Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. (5) Remove connecting rod cap bolts.
Page 810 2.0L SOHC ENGINE 9 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 116 Piston Rings—Removing and Installing Fig. 113 Crankshaft Sprocket—Installation PISTON RINGS—INSTALLATION (1) Install rings with manufacturers I.D. mark fac- ing up, to the top of the piston (Fig. 117). Fig.
Page 811 9 - 56 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 118 Installing Side Rail Fig. 120 Installing Piston (4) Position piston ring end gaps as shown in (Fig. should face toward the front of the engine for DOHC 119). engine (Fig.
Page 812 2.0L SOHC ENGINE 9 - 57 CLEANING AND INSPECTION (Continued) (2) Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. (3) Inspect manifolds for cracks or distortion. Replace manifold as necessary.
Page 813 9 - 58 2.0L SOHC ENGINE CLEANING AND INSPECTION (Continued) Fig. 125 Checking Oil Pump Cover Flatness Fig. 127 Measuring Inner Rotor Thickness (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 inch.) or less (Fig. 126), or if the diameter is 79.95 mm (3.148 inches) or less, replace outer rotor.
Page 814 2.0L SOHC ENGINE 9 - 59 CLEANING AND INSPECTION (Continued) Fig. 130 Measuring Clearance Over Rotors (9) The relief valve spring has a free length of approximately 60.7 mm (2.39 inches) it should test between 18 and 19 pounds when compressed to 40.5 mm (1.60 inches).
Page 815 9 - 60 2.0L SOHC ENGINE ADJUSTMENTS (Continued) ENGINE SUPPORT ADJUSTMENT DESCRIPTION SPECIFICATION Piston Pins (1) Remove the load on the engine motor mounts Clearance in Piston ..0.008 - 0.020 mm by carefully supporting the engine and transmission (0.0003 - 0.0008 in.) assembly with a floor jack.
Page 816 2.0L SOHC ENGINE 9 - 61 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valve Seat Rocker Arm Shaft Retainers (Width) Intake (All) ....28.46 mm (1.12 in.) Angle ....... . 45° Exhaust .
Page 817 9 - 62 2.0L SOHC ENGINE SPECIFICATIONS (Continued) TORQUE CHART 2.0L SOHC DESCRIPTION TORQUE Rear Torque Bracket—2.0L Engine Bolts w/Auto. Transaxle ..110 N·m (80 ft. lbs.) DESCRIPTION TORQUE Bolts w/Manual Transaxle . . . 61 N·m (45 ft. lbs.) Camshaft Sensor Pick Up Rocker Arm Shaft Bolts .
Page 818 2.0L SOHC ENGINE 9 - 63 SPECIAL TOOLS (Continued) Camshaft Sprocket Remover/Installer C-4687 Crankshaft Damper Installer 6792 Camshaft Sprocket Remover/Installer Adapter Valve Spring Compressor MD-998772-A C-4687-1 Spring Compressor Adapter 6779 Camshaft Seal Remover C-4679-A Valve Spring Compressor C-3422-B Camshaft Seal Installer MD-998306...
Page 819 9 - 64 2.0L SOHC ENGINE SPECIAL TOOLS (Continued) Cylinder Bore Indicator C-119 Crankshaft Sprocket Remover Insert C-4685-C2 Front Crankshaft Seal Remover 6771 Crankshaft Sprocket Installer 6792 Front Crankshaft Seal Installer 6780 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Crankshaft Sprocket Remover 6793 Pressure Gauge C-3292...
Page 820 2.0L SOHC ENGINE 9 - 65 SPECIAL TOOLS (Continued) Dial Indicator C-3339 Driver Handle C-4171 Valve Spring Tester C-647...
Page 821 9 - 66 2.4L ENGINE 2.4L ENGINE INDEX page page DESCRIPTION AND OPERATION HYDRAULIC LASH ADJUSTER ....85 ENGINE ....... 67 INTAKE MANIFOLD .
Page 822 2.4L ENGINE 9 - 67 Engine—2.4L GENERAL SPECIFICATIONS DESCRIPTION AND OPERATION ENGINE 2.4L ENGINE Type ....In-Line OHV, DOHC ENGINE IDENTIFICATION Bore ....87.5 mm (3.444 in.) The engine identification number is located on the Stroke .
Page 823 9 - 68 2.4L ENGINE DESCRIPTION AND OPERATION (Continued) have undercut fillets that are deep rolled for added ENGINE LUBRICATION: Refer to Group 0 strength. To evenly distribute bearing loads and min- Lubrication and Maintenance for recommended oil to imize internal stress, 8 counterweights are used. be used in various engine application.
Page 824 Piston To Bore Clearance economical operation. 0.024 - 0.057 mm (0.0009 - 0.0022 in.) Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations Measurements taken at Piston Size Location. vary with respect to engine model.
Page 825 9 - 70 2.4L ENGINE SERVICE PROCEDURES (Continued) Fig. 4 Piston Ring Gap Fig. 5 Piston Ring Side Clearance PISTON RING SPECIFICATION CHART Ring Ring Gap Wear Limit Position Upper Ring 0.025 to 0.51 mm 0.8 mm (0.0098 to 0.020 in.) (0.031 in.) Intermediate 0.23 to 0.48 mm...
Page 826 2.4L ENGINE 9 - 71 SERVICE PROCEDURES (Continued) Fig. 9 Measuring Plastigage Width ences in readings between the ends indicate the amount of taper present. Record all readings taken. Fig. 7 Installing Side Rail Refer to Engine Specifications. Plastigage gener- ally is accompanied by two scales.
Page 827 9 - 72 2.4L ENGINE SERVICE PROCEDURES (Continued) CRANKSHAFT SPECIFICATION CHART Crankshaft End-Play New Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.) Wear Limit: 0.37 mm (0.015 in.) Main Bearing Clearance New Part: 0.018 - 0.058 mm (0.0007 - 0.0023 in.) Connecting Rod Bearing Clearance New Part: 0.025 - 0.071 mm (0.001 - 0.003 in.) Wear Limit: 0.075 mm (0.003 in.)
Page 828 2.4L ENGINE 9 - 73 SERVICE PROCEDURES (Continued) (5) Install lower main bearings into main bearing (2) Move crankshaft all the way to the rear of its cap/bedplate. Make certain the bearing tabs are travel. seated into the bedplate slots. Install the main bear- (3) Zero the dial indicator.
Page 829 9 - 74 2.4L ENGINE REMOVAL AND INSTALLATION ENGINE MOUNTS—FRONT AND REAR REMOVAL FRONT MOUNT (1) Raise vehicle on hoist. (2) Remove through bolt at front mount (Fig. 17). (3) Remove attaching bolts from mount to lower radiator support. NOTE: It may be necessary to tilt engine for front mount removal clearance.
Page 830 2.4L ENGINE 9 - 75 REMOVAL AND INSTALLATION (Continued) • Bolts attaching strut bracket to front suspension crossmember: 61 N·m (45 ft. lbs.) • Nut attaching support bracket to front suspen- sion crossmember: 108 N·m (80 ft. lbs.) • Bolt attaching support bracket to rear strut: 61 N·m (45 ft.
Page 831 9 - 76 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) ENGINE ASSEMBLY (26) Remove engine and transmission mount bolts. (27) Raise vehicle slowly. It may be necessary to move the engine/transmission assembly on the cradle REMOVAL to allow for removal around body flanges. (1) Perform fuel pressure release procedure.
Page 832 2.4L ENGINE 9 - 77 REMOVAL AND INSTALLATION (Continued) Fig. 21 Positioning Engine Cradle Support Post Mounts...
Page 833 9 - 78 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) To release fuel pressure, refer to Group 14, Fuel System for procedure. REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. (2) Disconnect negative cable from auxiliary jumper terminal (Fig. 22). (3) Remove Air Inlet Resonator.
Page 834 2.4L ENGINE 9 - 79 REMOVAL AND INSTALLATION (Continued) Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position. (4) Install throttle body. Tighten fastener to 22 N·m (200 in. lbs.). Install transaxle to throttle body support bracket and tighten to 12 N·m (105 in.
Page 835 9 - 80 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 28 Exhaust Manifold Heat Shield Fig. 30 Ignition Coil Pack and Ground Strap Fig. 29 Exhaust Manifold both directions to 23 N·m (200 in. lbs.). Repeat this Fig. 31 Cylinder Head Cover Gasket and Spark Plug procedure until all fasteners are at specified torque.
Page 836 2.4L ENGINE 9 - 81 REMOVAL AND INSTALLATION (Continued) (4) Install ignition coil pack and plug wires. Tighten fasteners to 12 N·m (105 in. lbs.). (5) Install ground strap. CAMSHAFT REMOVAL (1) Remove cylinder head cover using procedure in this section. (2) Remove timing belt, sprockets and covers.
Page 837 9 - 82 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 38 Cam Follower Assembly INSTALLATION Fig. 36 Camshaft Bearing Cap Tightening Sequence (1) Lubricate with clean oil and install cam fol- lower assemblies in their original position on the hydraulic adjuster and valve stem (Fig. 39). (2) Install the camshafts.
Page 838 2.4L ENGINE 9 - 83 REMOVAL AND INSTALLATION (Continued) Fig. 42 Gear Cover and Gears Fig. 40 Chain Cover, Guide and Tensioner Fig. 43 Balance Shaft(s)—Removal/Installation BALANCE SHAFT CARRIER REMOVAL The following components will remain intact dur- ing carrier removal. Gear cover, gears, balance shafts Fig.
Page 839 9 - 84 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) BALANCE SHAFT INSTALLATION (3) Install gear cover and tighten double ended stud/washer fastener to 12 N·m (105 in. lbs.). Balance shaft and carrier assembly installation is (4) Install crankshaft sprocket using Special Tool the reverse of the removal procedure.
Page 840 2.4L ENGINE 9 - 85 REMOVAL AND INSTALLATION (Continued) (9) If the sprockets are timed correctly install the section to gain access to cam followers and lash balance shaft bolts and tighten to 28 N·m (250 in. adjusters. lbs.). A wood block placed between crankcase and (3) Mark hydraulic lash adjusters for reassembly crankshaft counterbalance will prevent crankshaft in their original position.
Page 841 9 - 86 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) (2) Install valve spring and retainer, use Special (14) Raise vehicle and remove exhaust pipe from Tool MD-998772-A with adapter 6779 to compress manifold. valve springs only enough to install locks (Fig. 48). (15) Remove power steering pump reservoir and Correct alignment of tool is necessary to avoid nick- line support bracket from cylinder head and set...
Page 842 2.4L ENGINE 9 - 87 REMOVAL AND INSTALLATION (Continued) VALVES AND VALVE SPRINGS REMOVAL (1) With cylinder head removed, compress valve springs using a universal valve spring compressor. (2) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. (3) Before removing valves, remove any burrs from valve stem lock grooves to prevent dam- age to the valve guides.
Page 843 9 - 88 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) in.) spacer under the valve spring seat to bring spring height back within specification. Fig. 53 Checking Spring Installed Height and Valve Tip Height Dimensions Fig. 55 Crankshaft Damper—Installation CRANKSHAFT DAMPER (4) Remove engine mount bracket (Fig.
Page 844 2.4L ENGINE 9 - 89 REMOVAL AND INSTALLATION (Continued) (3) Remove timing belt idler pulley. (5) Remove generator belt idler pulley. (4) Remove both camshaft sprockets. Refer to pro- (6) Remove lower timing belt cover fasteners and cedure in the section. remove cover (Fig.
Page 845 9 - 90 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. (2) Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Fig.
Page 846 2.4L ENGINE 9 - 91 REMOVAL AND INSTALLATION (Continued) Fig. 61 Camshaft Sprocket Alignment For Timing Belt Installation Fig. 63 Crankshaft and Camshaft Timing Fig. 64 Camshaft Sprockets—Removal/Installation Fig. 62 Timing Belt—Installation...
Page 847 9 - 92 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 66 Timing Belt Tensioner Assembly—Removal/ Installation OIL PAN REMOVAL (1) Raise vehicle on hoist and drain engine oil. Fig. 65 Rear Timing Belt Cover Fasteners (2) Remove right inner splash shield. (5) Remove lower bolt attaching timing belt ten- (3) Remove bolts attaching dust shield to transaxle sioner assembly to engine and remove tensioner as...
Page 848 2.4L ENGINE 9 - 93 REMOVAL AND INSTALLATION (Continued) Fig. 68 Oil Pan Gasket Installation Fig. 70 Camshaft Oil Seal—Removal With C-4679–A (2) Install the oil pan gasket to the block (Fig. 68). CAUTION: Do not nick shaft seal surface or seal (3) Install pan and tighten the screws to 12 N·m bore (105 in.
Page 849 9 - 94 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) CRANKSHAFT OIL SEAL—FRONT REMOVAL (1) Using Special Tool 1026 and Insert 6827-A, remove crankshaft damper (Fig. 72). (2) Remove timing belt. Refer to procedures in this section. (3) Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig.
Page 850 2.4L ENGINE 9 - 95 REMOVAL AND INSTALLATION (Continued) Fig. 76 Crankshaft Sprocket—Installation Fig. 78 Rear Crankshaft Oil Seal—Removal NOTE: When installing seal, no lube on seal is needed. (1) Place Special Tool 6926-1 on crankshaft. This is a pilot tool with a magnetic base (Fig. 79). (2) Position seal over pilot tool.
Page 851 9 - 96 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 79 Rear Crankshaft Seal and Special Tool 6926-1 Fig. 81 Rear Crankshaft Seal—Installation CAUTION: Do not pry up on one side of the bed- plate. Damage may occur to cylinder block to bed- plate alignment and thrust bearing.
Page 852 2.4L ENGINE 9 - 97 REMOVAL AND INSTALLATION (Continued) seated into the bedplate slots. Install the main bear- ing/bedplate into engine block. (6) Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil. (7) Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight.
Page 853 9 - 98 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) OIL PUMP REMOVAL (1) Disconnect negative cable from battery. (2) Remove Timing Belt. Refer to procedure in this section. (3) Remove Oil Pan. Refer to procedure in this sec- tion. (4) Remove Crankshaft Sprocket using Special Tool 6793 and insert C-4685-C2 (Fig.
Page 854 2.4L ENGINE 9 - 99 REMOVAL AND INSTALLATION (Continued) Fig. 87 Oil Pump Sealing Fig. 89 Crankshaft Sprocket—Installation Fig. 90 Piston Markings inder block. Be sure to keep tops of pistons covered during this operation . Mark piston with matching cylinder number (Fig. 90). (2) Remove oil pan.
Page 855 9 - 100 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 91 Identify Connecting Rod to Cylinder INSTALLATION (1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression Fig. 93 Piston—Installation ring gaps are staggered so that neither is in line with (6) Tap the piston down in cylinder bore, using a oil ring rail gap.
Page 856 2.4L ENGINE 9 - 101 (4) Install relief valve, spring, gasket and cap as DISASSEMBLY AND ASSEMBLY shown in (Fig. 95). Tighten cap to 41 N·m (30 ft. lbs.). OIL PUMP CLEANING AND INSPECTION DISASSEMBLY (1) To remove the relief valve, proceed as follows: INTAKE MANIFOLD (a) Remove the threaded plug and gasket from (1) Discard gasket and clean all surfaces of mani-...
Page 857 9 - 102 2.4L ENGINE CLEANING AND INSPECTION (Continued) CYLINDER HEAD VALVE GUIDE SPECIFICATION CHART CLEANING Valve Guide Diameter Remove all gasket material from cylinder head and Intake and 5.975 - 6.000 mm block. Be careful not to gouge or scratch the alumi- Exhaust (0.2352 - 0.2362 in.) num head sealing surface.
Page 858 2.4L ENGINE 9 - 103 CLEANING AND INSPECTION (Continued) OIL PUMP (6) Install inner rotor into pump housing. If clear- ance between inner and outer rotors (Fig. 104) is (1) Clean all parts thoroughly. Mating surface of 0.203 mm (0.008 in.) or more, replace both rotors. the oil pump should be smooth (Fig.
Page 859 9 - 104 2.4L ENGINE CLEANING AND INSPECTION (Continued) (10) If oil pressure is low and pump is within spec- ifications, inspect for worn engine bearings or other reasons for oil pressure loss. Fig. 105 Measuring Clearance Over Rotors Fig. 103 Measuring Outer Rotor Clearance in Housing Fig.
Page 860 2.4L ENGINE 9 - 105 CLEANING AND INSPECTION (Continued) Fig. 108 Cam Follower Assembly ADJUSTMENTS ENGINE SUPPORT ADJUSTMENT The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right and left engine support assemblies as required.
Page 861 9 - 106 2.4L ENGINE SPECIFICATIONS DESCRIPTION SPECIFICATION Oil Ring (Pack) ... . . 0.012 - 0.178 mm 2.4L ENGINE (0.0004 - 0.0070 in.) Piston Ring Width Compression Rings ... . 1.47 - 1.50 mm DESCRIPTION SPECIFICATION (0.057 - 0.059 in.)
Page 862 2.4L ENGINE 9 - 107 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valve Timing – Exhaust Valve Valve Springs Closes (ATDC) ......8° Free Length (Approx.) .
Page 863 9 - 108 2.4L ENGINE SPECIFICATIONS (Continued) DESCRIPTION TORQUE SPECIAL TOOLS Crankshaft Damper Bolt ....135 N·m (100 ft. lbs.) 2.4L ENGINE Cylinder Head Bolts .
Page 864 2.4L ENGINE 9 - 109 SPECIAL TOOLS (Continued) Post Kit Engine Cradle 6848 Crankshaft Damper Installer 6792 Camshaft Sprocket Holder 6847 Valve Spring Compressor MD-998772-A Camshaft Seal Remover C-4679-A Valve Spring Compressor Adapter 6779 Camshaft Seal Installer MD-998306 Cylinder Bore Gage C-119...
Page 865 9 - 110 2.4L ENGINE SPECIAL TOOLS (Continued) Crankshaft Sprocket Remover 6793 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Crankshaft Sprocket Remover Insert C-4685-C2 Balance Shaft Sprocket Installer 6052 Crankshaft Seal Remover 6771 Post Adapter 8130 Oil Pressure Gage C-3292 Front Crankshaft Oil Seal Installer 6780...
Page 866 2.5L ENGINE 9 - 111 2.5L ENGINE INDEX page page DESCRIPTION AND OPERATION INTAKE MANIFOLD/PLENUM ....123 ENGINE COMPONENTS ....112 OIL FILTER .
Page 867 9 - 112 2.5L ENGINE GENERAL SPECIFICATION DESCRIPTION AND OPERATION ENGINE IDENTIFICATION 2.5L V-6 ENGINE Type ....60° V SOHC (Per Bank) The engine identification number is located on the Bore .
Page 868 2.5L ENGINE 9 - 113 DESCRIPTION AND OPERATION (Continued) while a dynamic damper is used to control torsional VALVES vibration of the crankshaft. Rubber lipped seals are Four valves per cylinder are actuated by die-cast used at front and rear. The front seal is retained in aluminum roller rocker arms and hydraulic lash the oil pump case and the rear is retained in a die- adjusters assemblies which pivot on rocker arm...
Page 869 9 - 114 2.5L ENGINE DIAGNOSIS AND TESTING (Continued) Fig. 2 Engine Oiling CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM. (2) Warm engine at high idle until thermostat opens. SERVICE PROCEDURES BORING CYLINDER Examine cylinder walls for scuffs, scoring and mea- sure cylinder bore for out-of-round or taper.
Page 870 2.5L ENGINE 9 - 115 SERVICE PROCEDURES (Continued) Fig. 4 Measure Piston FITTING PISTONS Measure approximately 2mm (.080 inch) above the bottom of the piston skirt and across the thrust face Fig. 6 Check Gap on Piston Rings (Fig. 5). See Boring Cylinder Block. FITTING PISTON RINGS (1) Wipe cylinder bore clean.
Page 871 9 - 116 2.5L ENGINE SERVICE PROCEDURES (Continued) Fig. 7 Piston Ring Groove Clearance Fig. 9 Side Rail—Installation (2) Check piston ring to groove clearance (Fig. 7); (3) Using a piston ring expander, install No. 2 pis- Refer to Piston Ring Specification Chart. ton ring and then No.
Page 872 2.5L ENGINE 9 - 117 SERVICE PROCEDURES (Continued) (5) Position oil ring expander gap at least 45° from CONNECTING ROD SPECIFICATION CHART the side rail gaps but not on the piston pin center or on the thrust direction. Connecting Rod Bearing Oil Clearance New Part: 0.016 - 0.046 mm CONNECTING ROD CLEARANCE...
Page 873 9 - 118 2.5L ENGINE SERVICE PROCEDURES (Continued) CRANKSHAFT SPECIFICATION CHART CRANKSHAFT BEARING INSTALLATION When the bearings need replacing, select and install the proper bearing by the following procedure. Crankshaft End-Play (1) Measure the crankshaft journal diameter and New Part: 0.05 - 0.25 mm confirm its classification from the Crankshaft Size (0.002 - 0.010 in.)
Page 874 2.5L ENGINE 9 - 119 SERVICE PROCEDURES (Continued) CRANKSHAFT END PLAY CRANKSHAFT SPECIFICATION CHART Crankshaft End-Play New Part: 0.05 - 0.25 mm (0.002 - 0.010 in.) Wear Limit: 0.30 mm (0.012 in.) Main Bearing Oil Clearance New Part: 0.018 - 0.036 mm (0.0007 - 0.0014 in.) Wear Part: 0.10 mm (0.0039 in.)
Page 875 9 - 120 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) REAR MOUNT (1) Raise vehicle on hoist. (2) Remove through bolt (A) from rear engine mount and bracket (Fig. 23). (3) Remove rear strut bracket (Fig. 21). (4) Remove bolts attaching rear mount to cross- member.
Page 876 2.5L ENGINE 9 - 121 REMOVAL AND INSTALLATION (Continued) NOTE: If centering or adjusting the engine/trans- mission assembly is needed refer to Adjustments, in this section. (8) Reverse removal procedure for installation. Refer to (Fig. 24) for bolt tightening specifications. Fig.
Page 877 9 - 122 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (19) Remove power steering pump and reservoir and set them aside. (20) Remove A/C compressor. (21) Remove ground straps to body. (22) Mount Special Tool 6973 bracket, to the right side of the cylinder block (Fig. 26). Align the front adjustable post with the hole in the bracket.
Page 878 2.5L ENGINE 9 - 123 REMOVAL AND INSTALLATION (Continued) Fig. 28 Intake and Exhaust Manifolds—2.5L Engine (20) Install oil filter. Fill engine crankcase with (3) Disconnect fuel supply tube from rail. Refer to proper oil to correct level. Group 14, Fuel System for procedure. (21) Evacuate and charge air conditioning system.
Page 879 9 - 124 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 32 Throttle Position Sensor Fig. 30 Air Inlet Resonator Fig. 33 Idle Air Control Motor Fig. 31 Intake Manifold Sensors and Left Manifold Support Bolt (8) Release snaps holding air cleaner housing cover to housing.
Page 880 2.5L ENGINE 9 - 125 REMOVAL AND INSTALLATION (Continued) Fig. 38 Intake Manifold Tightening Sequence (6) Install new gasket and position upper intake plenum to lower manifold. Install plenum bolts and tighten to 18 N·m (13 ft. lbs.). (7) Install bolts at plenum support brackets. Fig.
Page 881 9 - 126 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD COVERS FRONT CYLINDER HEAD COVER REMOVAL (1) Disconnect and relocate spark plug cables and wiring harness. (2) Remove cylinder head cover fasteners and remove cover (Fig. 41). INSTALLATION NOTE: Before installation, clean cylinder head and cover mating surfaces.
Page 882 2.5L ENGINE 9 - 127 REMOVAL AND INSTALLATION (Continued) Fig. 41 Cylinder Head Components (6) Remove exhaust manifolds and cross-under pipe. Refer to procedure in this section. (7) Remove cylinder head bolts and remove cylin- der head(s). INSTALLATION CAUTION: When cleaning cylinder head surfaces, DO NOT use a metal scraper because the surfaces could be cut or ground, Use ONLY a wooden or plastic scraper.
Page 883 9 - 128 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 43 Cylinder Head Bolt Washer Fig. 45 Auto Lash Adjuster Retainers retainers hold the lash adjusters into position when the rocker arms are serviced. (4) Loosen the attaching fasteners. Remove rocker arm shaft assemblies from cylinder head.
Page 884 2.5L ENGINE 9 - 129 REMOVAL AND INSTALLATION (Continued) Fig. 49 Retainer Auto Lash Adjuster Fig. 47 Rocker Arm Shaft Flat (3) Mark rocker arm shaft assemblies for installa- Install the retainers and spring clips in their original tion. positions on the exhaust and intake shafts (Fig. 46). (4) Remove rocker arm shaft bolts.
Page 885 9 - 130 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 50 Cylinder Head Components Fig. 51 Rocker Arm Shaft Tightening Sequence Fig. 52 Camshaft End Play (2) Using a suitable tool, move camshaft as far VALVE SPRINGS AND SEALS—IN VEHICLE rearward as it will go.
Page 886 2.5L ENGINE 9 - 131 REMOVAL AND INSTALLATION (Continued) (3) Rotate crankshaft until piston is at TDC on 6765 and Adapter 6885 (Fig. 53) to compress valve compression stroke. springs only enough to install locks. Correct align- (4) Remove spark plug from applicable cylinder. ment of tool is necessary to avoid nicking valve (5) Using a air hose attached to an adapter tool, stems.
Page 887 9 - 132 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) NOTE: To remove engine mount bracket the lower timing belt cover must be removed first. Fig. 57 Belt Splash Shield Fig. 59 Timing Belt Covers (6) Remove power steering pump bracket. Refer to Group 19, Steering for procedure.
Page 888 2.5L ENGINE 9 - 133 REMOVAL AND INSTALLATION (Continued) Fig. 60 Timing Belt System TIMING BELT CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE CAUTION: The 2.5L engine is a Non-freewheeling design. When the timing belt is removed, DO NOT TIMING BELT TENSIONER rotate the camshafts or crankshaft without first (1) When tensioner is removed from the engine it locating the proper crankshaft position.
Page 889 9 - 134 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper locking pin orientation when tensioner is installed on the engine. (3) When plunger is compressed into the tensioner body, install a locking pin through the body and plunger (Fig.
Page 890 2.5L ENGINE 9 - 135 REMOVAL AND INSTALLATION (Continued) (2) Install bolt and washer to camshaft. Using Spe- cial Tool 6847, hold camshaft sprocket and torque bolt to 88 N·m (65 ft. lbs.) (Fig. 68). (3) Install timing belt. Refer to procedure in this section.
Page 891 9 - 136 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (7) Remove engine to transaxle struts/bending braces. (8) Remove transaxle inspection cover. (9) Remove oil pan. INSTALLATION NOTE: Oil pan to cylinder block sealing is provided with Mopar Silicone Rubber Adhesive Sealant or equivalent gasket material.
Page 892 2.5L ENGINE 9 - 137 REMOVAL AND INSTALLATION (Continued) (4) Pry out the front seal with a flat tip screw- (4) Mount engine on a suitable engine repair driver. Cover the end of the screwdriver with a shop stand. towel. (5) Remove oil pan.
Page 893 9 - 138 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 75 Crankshaft and Cylinder Block Fig. 76 Oil Pump Fig. 77 Rear Seal Assembly...
Page 894 2.5L ENGINE 9 - 139 REMOVAL AND INSTALLATION (Continued) Fig. 78 Main Bearings Installation Fig. 79 Crankshaft Main Bearing Cap...
Page 895 9 - 140 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 81 Crankshaft Oil Seal Retainer—Rear Fig. 80 Crankshaft End Play—Typical INSTALLATION (13) Install rear oil seal and retainer. (14) Install flex plate. Apply Mopar Lock & Seal (1) Inspect and clean all sealing surfaces. Adhesive to bolt threads and tighten to 95 N·m (70 (2) Install rear crankshaft oil seal in housing with ft.
Page 896 2.5L ENGINE 9 - 141 REMOVAL AND INSTALLATION (Continued) Fig. 83 Apply Sealant to Oil Seal Housing OIL FILTER CAUTION: When servicing the oil filter (Fig. 84) avoid deforming the filter can by installing the Fig. 85 Oil Pump Assembly remove/install tool band strap against the can-to- base lockseam.
Page 897 9 - 142 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) PISTON AND CONNECTING ROD REMOVAL (1) Remove oil pan and cylinder head(s). Refer to procedures in this section. (2) Identify pistons with matching cylinder. The pistons are not interchangeable from bank to bank (Fig.
Page 898 2.5L ENGINE 9 - 143 REMOVAL AND INSTALLATION (Continued) CAUTION: Install piston rings in the following INSTALLATION order: (1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression a. Oil ring expander. ring gaps are staggered so that neither is in line with b.
Page 899 9 - 144 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 97 Valve Stem Seals—Removal Fig. 95 Connecting Rod and Cap guide (Fig. 98). Using Special Tool MD-998774 install DISASSEMBLY AND ASSEMBLY seal by tapping lightly until seal is in place (Fig. 99). CYLINDER HEAD DISASSEMBLY CAUTION: Before disassembly, mark each valve’s...
Page 900 2.5L ENGINE 9 - 145 DISASSEMBLY AND ASSEMBLY (Continued) result from misalignment of the valve spring com- pressor. CAUTION: When depressing valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool.
Page 901 9 - 146 2.5L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 105 Checking Camshafts for Wear lobes show signs of pitting on the nose, flank or base circle; replace the camshaft. CYLINDER BORE AND BLOCK (1) Measure the cylinder bore at three levels in Fig.
Page 902 2.5L ENGINE 9 - 147 CLEANING AND INSPECTION (Continued) CYLINDER BLOCK CAUTION: This is a combined total dimension of stock removal from cylinder head if any and block Inspect cylinder block for scratches, cracks and top surface is 0.2 mm (0.0079 in.). rust or corrosion, and repair or replace as required.
Page 903 9 - 148 2.5L ENGINE CLEANING AND INSPECTION (Continued) VALVE SPECIFICATION CHART Valve Dimensions INTAKE VALVE (MINIMUM) Stem 6.00 mm (0.236 in.) Diameter: Face Angle: 45° Valve 1.0 mm (0.039 in.) Margin: EXHAUST VALVE (MINIMUM) Stem 6.00 mm (0.236 in.) Diameter: Face Angle: 45°...
Page 904 2.5L ENGINE 9 - 149 CLEANING AND INSPECTION (Continued) (3) Insert the rotor into the oil pump case (Fig. 114) and measure clearance with a feeler gauge as indicated. Replace if out of limits. Fig. 116 Measuring Clearance Over Rotors Fig.
Page 905 9 - 150 2.5L ENGINE CLEANING AND INSPECTION (Continued) Fig. 120 Valve Inspection (3) Measure the clearance between the valve guide and valve stem. If the service limit is exceeded, replace the valve guides, valves or both. (4) Check for even contact (at face center) with valve seat, Point C.
Page 906 2.5L ENGINE 9 - 151 CLEANING AND INSPECTION (Continued) VALVE SPECIFICATION CHART Valve Dimensions INTAKE VALVE (MINIMUM) Stem 6.00 mm (0.236 in.) Diameter: Face Angle: 45° Valve Margin: 1.0 mm (0.039 in.) EXHAUST VALVE (MINIMUM) Stem 6.00 mm (0.236 in.) Fig.
Page 907 9 - 152 2.5L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION No. 2 ..0.002 - 0.06 mm (0.0007 - 0.0024 in.) Cylinder Head Flatness of Gasket Surface . . 0.03 mm (0.0012 in.) Service Limit ... . 0.1 mm (0.004 in.) Service Limit .
Page 908 2.5L ENGINE 9 - 153 SPECIFICATIONS (Continued) DESCRIPTION TORQUE DESCRIPTION TORQUE Bolt ..... 44 N·m (33 ft. lbs.) Crankshaft Pulley Bolt .
Page 909 9 - 154 2.5L ENGINE SPECIAL TOOLS (Continued) Holders MD-998443 Adapter 6526 Installer MD-998713 Wrench MD-998767 Installer MD-998718 Compressor MD-998772-A Compressor C-3422-B Installer MD-998774...
Page 910 2.5L ENGINE 9 - 155 SPECIAL TOOLS (Continued) Puller 1026 Screw 6765 Installer 6052 Adapter 6779 Dolly 6135 Support Bar Cradle 6710-3A Fixture Engine 6710 Holder 6847...
Page 911 9 - 156 2.5L ENGINE SPECIAL TOOLS (Continued) Engine Cradle Posts 6848 Posts 6886 Bracket Cradle Post Support 6973 Adapter 6887 Adapter 6885 Camshaft Seal Installer 6863...
Page 912 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION CATALYTIC CONVERTERS ....1 EXHAUST SYSTEM ..... . . 4 EXHAUST FLEX-JOINT COUPLING .
Page 913: Exhaust Flex-Joint Coupling
11 - 2 EXHAUST SYSTEM DESCRIPTION AND OPERATION (Continued) EXHAUST GAS RECIRCULATION (EGR) erwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other To assist in the control of oxides of nitrogen (NOx) means short out cylinders if exhaust system is in engine exhaust, all engines are equipped with an equipped with catalytic converter.
Page 914: Diagnosis And Testing Exhaust System
EXHAUST SYSTEM 11 - 3 DESCRIPTION AND OPERATION (Continued) CAUTION: When servicing, care must be exercised not to dent or bend the bellows or bellows cover of the flex-joint. Should this occur, the flex-joint will eventually fail and require the catalytic converter be replaced.
Page 915 11 - 4 EXHAUST SYSTEM (6) Remove clamp and supports at the resonator REMOVAL AND INSTALLATION pipe to catalytic converter slip joint (Fig. 5). Separate at slip joint and remove the resonator assembly. EXHAUST SYSTEM (7) Disconnect downstream heated oxygen sensor from the catalytic converter pipe (Fig.
Page 916 EXHAUST SYSTEM 11 - 5 REMOVAL AND INSTALLATION (Continued) (1) Assemble catalytic convertor to exhaust mani- fold connection (Fig. 6). (2) Assemble resonator pipe to catalytic convertor. Attach isolators to the supports on the underbody (Fig. 7). (3) Install the muffler to resonator pipe. Attach isolators to the supports on the underbody (Fig.
Page 917: Exhaust System Alignment
11 - 6 EXHAUST SYSTEM CLEANING AND INSPECTION (Continued) Fig. 7 Exhaust System Support Isolators—Typical (1) Loosen clamps and support brackets. (2) Align the exhaust system starting at the front, working rearward. (3) Tighten all clamps and brackets once align- ment and clearances are achieved.
Page 918: Exhaust System And Intake Manifold
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 EXHAUST SYSTEM AND INTAKE MANIFOLD CONTENTS page GENERAL INFORMATION EXHAUST SYSTEM ..... . . 1 GENERAL INFORMATION EXHAUST SYSTEM The exhaust system is produced in two configura-...
Page 919 11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD GENERAL INFORMATION (Continued) Fig. 2 Exhaust System—Leaded Fuel...
Page 920: Frame And Bumpers
FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page page BUMPERS ....... 1 FRAME .
Page 921 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) Fig. 1 Front Bumper Fascia (4) Remove nuts holding rear bumper reinforce- ment to frame rail (Fig. 3). (5) Separate bumper reinforcement from vehicle. Fig. 2 Rear Bumper Fascia (9) Install tail lamps. Refer to Group 8L, Lamps, for proper procedures.
Page 922 FRAME AND BUMPERS 13 - 3 FRAME INDEX page page DESCRIPTION AND OPERATION REAR SUSPENSION CROSSMEMBER ..4 REAR SUSPENSION CROSSMEMBER ..3 SPECIFICATIONS REMOVAL AND INSTALLATION FRAME DIMENSIONS .
Page 923 13 - 4 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) REAR SUSPENSION CROSSMEMBER (5) Remove the rear exhaust pipe hanger from the rear suspension crossmember (Fig. 4). Let exhaust system drop down as far as possible. REMOVE (1) Raise vehicle on jackstands or centered on a frame contact type hoist.
Page 924 FRAME AND BUMPERS 13 - 5 REMOVAL AND INSTALLATION (Continued) (7) If vehicle is equipped with antilock brakes, remove routing clips for wheel speed sensor cable from brackets on upper control arm (Fig. 6). Fig. 8 Upper Control Arm Attachment To Crossmember NOTE: When installing the lateral links on the crossmember, the lateral link attaching bolts must...
Page 925 13 - 6 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) (5) Position a drift of the appropriate size into the positioning hole in each side of rear suspension cross- member and locating holes in the frame rail of the body. (Fig. 9). This is required to properly position rear suspension crossmember side-to-side and front- to-rear in the body of the vehicle.
Page 926 FRAME AND BUMPERS 13 - 7 VEHICLE PREPARATION SPECIFICATIONS Position the vehicle on a level work surface. Using FRAME DIMENSIONS screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface. Frame dimensions are listed in metric scale. All Vertical dimensions can be taken from the work sur- dimensions are from center to center of Principal face to the locations indicated were applicable (Fig.
Page 927 13 - 8 FRAME AND BUMPERS SPECIFICATIONS (Continued) Fig. 11 Engine Compartment Side View Fig. 12 Forward Frame Section Bottom View...
Page 928 FRAME AND BUMPERS 13 - 9 SPECIFICATIONS (Continued) Fig. 13 Rear Frame Section Side View...
Page 929 13 - 10 FRAME AND BUMPERS SPECIFICATIONS (Continued) Fig. 14 Rear Frame Section Bottom View TORQUE SPECIFICATIONS DESCRIPTION TORQUE Rear Bumper Reinforcement Attaching Nut ... . . 28 N·m (21 ft. lbs.) Front Suspension Crossmember Attaching Bolt Front .
Page 930 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....1 FUEL INJECTION SYSTEM ....26 FUEL DELIVERY SYSTEM INDEX page...
Page 931 MMT in Canada because MMT can be used at or additives is not the responsibility of Chrysler Cor- levels higher than allowed in the United States. poration and may not be covered under the new vehi- MMT is prohibited in Federal and California refor- cle warranty.
Page 932: Fuel Delivery System
Problems that are the result of using methanol/ Relieve fuel system pressure before servicing fuel gasoline blends are not the responsibility of Chrysler system components. Refer to the Fuel System Pres- Corporation and may not be covered by the vehicle sure Release Procedure and follow all Cautions and warranty.
Page 933: Fuel Injectors
14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The fuel pump module contains the following: FUEL TANK • Electric fuel pump • Fuel pump reservoir OPERATION • Inlet strainer All models pass a full 360 degree rollover test • Fuel pressure regulator without fuel leakage.
Page 934: Fuel Pressure Regulator
FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) Fuel injectors are not interchangeable between tank is vented to the vapor canister to capture escap- engines. ing vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the canister, the vehicle’s computer controlled purge system draws vapor out of the canister for the engine to burn.
Page 935 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) ORVR System Schematic CAUTION: The interior components (o-rings, spac- ers) of quick-connect fitting are not serviced sepa- rately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
Page 936: Fuel Tubes/Lines/Hoses And Clamps
FUEL SYSTEM 14 - 7 DESCRIPTION AND OPERATION (Continued) Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources.
Page 937 14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (3) Place ignition key in the ON position. Using pump module). If the fuel return tube is not pinched DRB scan tool, access ASD Fuel System Test. The or restricted, replace the fuel pressure regulator. •...
Page 938 FUEL SYSTEM 14 - 9 DIAGNOSIS AND TESTING (Continued)
Page 939: Fuel Injectors
14 - 10 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) FUEL PUMP PRESSURE TEST—2.5L ENGINE The level sensor is a variable resistor. Its resis- tance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the WARNING: FUEL SYSTEM PRESSURE MUST BE fuel level changes.
Page 940 FUEL SYSTEM 14 - 11 DIAGNOSIS AND TESTING (Continued) FUEL INJECTOR DIAGNOSIS...
Page 941: Fuel Tank Draining
14 - 12 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) VEHICLE DOES NOT FILL Pre-Mature Nozzle Defective fuel tank assembly Fill tube improperly installed (sump). Shut-Off. components. Fill tube hose pinched. Check valve stuck shut. Control valve stuck shut. Defective vapor/vent Vent line from control valve to canister pinched components.
Page 942: Hoses And Clamps
FUEL SYSTEM 14 - 13 SERVICE PROCEDURES (Continued) WARNING: DRAIN PLUG MUST BE INSTALLED AT (1) Using a clean lint free cloth, clean the fuel tube THIS TIME AS THERE WILL BE 1 TO 2 GALLONS nipple and retainer. (2) Prior to connecting the fitting to the fuel tube, OF FUEL LEFT IN THE TANK.
Page 943 14 - 14 FUEL SYSTEM SERVICE PROCEDURES (Continued) (7) Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. (8) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (9) Connect negative cable to battery or auxiliary jumper terminal.
Page 944: Removal And Installation
FUEL SYSTEM 14 - 15 SERVICE PROCEDURES (Continued) (2) Disconnect negative battery cable from battery or auxiliary jumper terminal. (3) Clean fitting of any foreign material before dis- assembly. (4) To release fuel system component from quick- connect fitting, firmly push fitting towards compo- nent being serviced while firmly pushing plastic retainer ring into fitting (Fig.
Page 945: Fuel Filter
14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) REFER TO THE FUEL PRESSURE RELEASE PRO- CEDURE (1) Remove rear seat. (2) Disconnect fuel pump electrical connector. Push grommet out and feed jumper completely through hole in body. (3) Remove fuel cap slowly to release tank pres- sure.
Page 946 FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Spread tangs on pressure regulator retainer (Fig. 17). (2) Pry fuel pressure regulator out of housing. (3) Ensure both upper and lower O-rings were removed with regulator. INSTALLATION (1) Lightly lubricate the O-rings with clean engine oil and place them into opening in pump module (Fig.
Page 947 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 21 Terminal Removal Tool Fig. 19 Inlet Strainer Removal FUEL LEVEL SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module in this section. (1) Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector (Fig.
Page 948 FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) (2) Wrap wires into groove in back of level sensor (Fig. 24). Fig. 26 Fuel/Pump/Level Sensor Electrical Connector FUEL RAIL—2.0/2.4L Fig. 24 Groove in Back Side of Level Sensor (3) While feeding wires into guide grooves, slide REMOVAL level sensor up into channel until it snaps into place (1) Disconnect...
Page 949: Fuel Injectors
14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Lift fuel rail off engine. There are spacers under each fuel rail bolt (Fig. 29). Fig. 29 Fuel Rail Spacers INSTALLATION Fig. 27 Fuel Rail and Injectors (1) Apply a light coating of clean engine oil to the FUEL RAIL—2.5L O-ring on the nozzle end of each injector.
Page 950 FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) Push grommet out and feed jumper completely through hole in body. (4) Remove fuel cap slowly to release tank pres- sure. (5) With vehicle on a hoist, drain fuel from tank. Support fuel tank with a support such as a transmis- sion jack stand.
Page 951 14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 33 Fuel Filler Hose Clamp Fig. 35 Fuel Tank Removal (9) Position fuel filter and fuel tank straps. Install the front bolts first and then the rear bolts. Tighten fuel tank strap bolts to 23 N·m (250 in. lbs.) torque. Remove transmission jack.
Page 952: Throttle Cable-2.0/2.4L
FUEL SYSTEM 14 - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 N·m (105 in. lbs.) torque. (2) Place cable through slot in top of pedal shaft. (3) Step on pedal and retainer will snap into place.
Page 953: Throttle Cable-2.5L
14 - 24 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Lift cable up through slot in top of pedal shaft. THROTTLE CABLE—2.5L (5) From the engine compartment, pull the throttle cable and grommet out of the dash panel. REMOVAL (1) Working from the engine compartment, remove INSTALLATION throttle cable from the throttle body lever (Fig.
Page 954: Specifications
FUEL SYSTEM 14 - 25 REMOVAL AND INSTALLATION (Continued) (3) Place cable through slot in top of pedal shaft. SPECIFICATIONS (4) Step on pedal and retainer will snap into place. TORQUE DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts ..12 N·m (105 in. lbs.) Fuel Filter Mounting Screw .
Page 955 14 - 26 FUEL SYSTEM FUEL INJECTION SYSTEM INDEX page page DESCRIPTION AND OPERATION SCI RECEIVE—PCM INPUT ....37 5 VOLT SUPPLY—PCM OUTPUT ... . 43 SENSOR RETURN—PCM INPUT .
Page 956 FUEL SYSTEM 14 - 27 There are two different areas of operation, OPEN DESCRIPTION AND OPERATION LOOP and CLOSED LOOP. During OPEN LOOP modes the PCM receives INJECTION SYSTEM input signals and responds according to preset PCM All engines used in this section have a sequential programming.
Page 957 14 - 28 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) PCM determines basic fuel injector pulse width from During Start-up the PCM maintains ignition tim- this input. ing at 9° BTDC. • The PCM determines atmospheric air pressure ENGINE WARM-UP MODE from the MAP sensor input to modify injector pulse This is an OPEN LOOP mode.
Page 958 FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (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 959 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) POWERTRAIN CONTROL MODULE OPERATION The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sen- sors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs.
Page 960 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) Based on inputs it receives, the PCM adjusts fuel current to power the camshaft position sensor, crank- injector pulse width, idle speed, ignition spark shaft position sensor and vehicle speed sensor. The advance, ignition coil dwell and EVAP canister purge PCM also provides a 5 volt direct current supply for operation.
Page 961 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) BRAKE SWITCH—PCM INPUT OPERATION When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through control of the idle air control motor.
Page 962 FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) OPERATION The PCM determines engine coolant temperature from the coolant temperature sensor. The coolant temperature sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD Bus to the Body Control Module (BCM) for the instrument panel gauge clus- ter.
Page 963 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 7 Timing Reference Notches Fig. 8 Engine Coolant Temperature Sensor—2.0L Fig. 10 Engine Coolant Temperature Sensor—2.5L Fig. 11 Oxygen Sensor 1/1 Upstream—2.0/2.4L Fig. 9 Engine Coolant Temperature Sensor—2.4L Engines...
Page 964 FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.
Page 965 14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 15 Intake Air Temperature Sensor and MAP Fig. 17 Knock Sensor Sensor—2.4L Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases.
Page 966 FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) SCI RECEIVE—PCM INPUT OPERATION SCI Receive is the serial data communication receive circuit for the DRB scan tool. The Powertrain Control Module (PCM) receives data from the DRB through the SCI Receive circuit. TRANSAXLE PARK/NEUTRAL SWITCH—PCM INPUT DESCRIPTION...
Page 967 14 - 38 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 22 Vehicle Speed Sensor—Manual Transmission OPERATION Fig. 20 Throttle Position Sensor—2.0/2.4L Engines AUTOMATIC The transaxle control module (TCM) supplies the vehicle speed signal to the PCM based on the output shaft speed.
Page 968 FUEL SYSTEM 14 - 39 DESCRIPTION AND OPERATION (Continued) • Speedometer • Speed control • Daytime Running Lights (Canadian Vehicles only). AIR CONDITIONING CLUTCH RELAY—PCM OUTPUT DESCRIPTION The air conditioning clutch relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location.
Page 969 14 - 40 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 26 EGR Control Valve—2.5L Engine Fig. 24 Proportional Purge Solenoid ELECTRIC EGR TRANSDUCER—PCM OUTPUT— 2.4/2.5L ENGINES DESCRIPTION The solenoid/transducer and EGR valve mount to the rear of the cylinder head (Fig. 25) or (Fig. 26). Fig.
Page 970 FUEL SYSTEM 14 - 41 DESCRIPTION AND OPERATION (Continued) IDLE AIR CONTROL MOTOR—PCM OUTPUT various switch operations (brake, park/neutral, air conditioning). DESCRIPTION DATA LINK CONNECTOR The Idle Air Control (IAC) motor is mounted on the throttle body. The PCM operates the idle air control DESCRIPTION motor (Fig.
Page 971 14 - 42 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION The Automatic Shutdown (ASD) relay supplies bat- tery voltage to the fuel injectors. The PCM controls the ground path for each injector in sequence. By switching the ground paths on and off, the PCM fine- tunes injector pulse width.
Page 972 FUEL SYSTEM 14 - 43 DESCRIPTION AND OPERATION (Continued) cations port. Various modules use the CCD Bus to TACHOMETER—PCM OUTPUT exchange information. The Check Engine lamp comes on each time the OPERATION ignition key is turned ON and stays on for 3 seconds The tachometer receives its information across the as a bulb test.
Page 973 14 - 44 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING VISUAL INSPECTION Before diagnosing or servicing the fuel injection system, perform a visual inspection for loose, discon- nected, or misrouted wires and hoses. A thorough visual inspection that includes the following checks saves unnecessary test and diagnostic time.
Page 974 FUEL SYSTEM 14 - 45 DIAGNOSIS AND TESTING (Continued) (6) Check hose connections between the PCV valve, vacuum port-intake manifold (Fig. 39), (Fig. 40) or (Fig. 41). Fig. 41 PCV Valve—2.5L Engine Fig. 39 PCV Valve—2.0L Engine Fig. 42 MAP/ Air Temperature Sensor—2.0L Engine Fig.
Page 975 14 - 46 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 44 MAP Sensor and Intake Air Temperature Fig. 46 Ignition Coil and Spark Plugs Sensor—2.5L Engine Fig. 45 Fuel Injectors—2.0/2.4L Engines 2.0/2.4L (a) Inspect the ignition coil electrical connector. Ensure the spark plug insulators are firmly seated over the spark plugs (Fig.
Page 976 FUEL SYSTEM 14 - 47 DIAGNOSIS AND TESTING (Continued) Fig. 51 Camshaft Position Sensor—2.4L Engine Fig. 48 Proportional Purge Solenoid Fig. 52 Engine Coolant Temperature Sensor—2.4L Engine Fig. 49 Knock Sensor—2.0/2.4L Fig. 53 Engine Coolant Temperature Sensor—2.5L Engine Fig. 50 Camshaft Position Sensor and Engine Coolant Temperature Sensor—2.0L Engine...
Page 977 14 - 48 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (18) Check electrical connector at Electronic EGR Transducer. Inspect vacuum and back pressure hoses at the solenoid and transducer for leaks (Fig. 54) or (Fig. 55). Fig. 56 Crankshaft Position Sensor—2.0/2.4L Engines-Typical Fig.
Page 978 FUEL SYSTEM 14 - 49 DIAGNOSIS AND TESTING (Continued) Fig. 59 Vehicle Speed Sensor—Manual Fig. 62 Upstream Heated Oxygen Sensor—2.5L Transmission Engine Fig. 60 Power Steering Pressure Switch Fig. 63 Rear Heated Oxygen Sensor (24) Inspect the electrical connections at the (25) Inspect the fuel pump module electrical con- upstream and downstream heated oxygen sensors nection in the trunk for corrosion or damage (Fig.
Page 979 14 - 50 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (26) Inspect the connections to the speed control voltage is not supplied to the rest of the circuit. Ter- servo, if equipped. Refer to the Vehicle Speed Control minal 87A is the center terminal on the relay. •...
Page 980 FUEL SYSTEM 14 - 51 DIAGNOSIS AND TESTING (Continued) • Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. • Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. (4) Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor har- ness connector.
Page 981 14 - 52 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at wide-open-throttle (WOT). At idle, TPS output volt- age should be greater than 0.6 volts.
Page 982 FUEL SYSTEM 14 - 53 DIAGNOSIS AND TESTING (Continued) 2.0/2.4L MINIMUM AIR FLOW IDLE REMOVAL AND INSTALLATION THROTTLE BODY—2.0/2.4L ENGINES Odometer Idle RPM Below 1000 Miles 550-1300 RPM REMOVAL Above 1000 Miles 600-1300 RPM (1) Remove air inlet resonator as described in this section.
Page 983 14 - 54 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (9) Lift throttle body far enough to remove connec- tors from the throttle position sensor and idle air control motor. Remove throttle body. (10) 2.0L The rubber O-ring gasket on the intake manifold is reusable.
Page 984 FUEL SYSTEM 14 - 55 REMOVAL AND INSTALLATION (Continued) THROTTLE POSITION SENSOR (TPS)—2.0/ 2.4L The throttle position sensor attaches to the side of the throttle body (Fig. 78). Fig. 79 Throttle Position Sensor Installation REMOVAL (1) Remove throttle body. Refer to Throttle Body in this section.
Page 985 14 - 56 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (3) Attach electrical connectors to idle air control motor and throttle position sensor. (4) Install throttle body to intake manifold. Refer to throttle body in this section. Fig. 83 Throttle Position Sensor and Idle Air Control Fig.
Page 986 FUEL SYSTEM 14 - 57 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove air inlet resonator. (2) Reaching through intake manifold from throttle body end, disconnect sensor connector. (3) Remove sensor. INSTALLATION (1) Install sensor. Tighten sensor to 28 N·m (20 ft. lbs.) torque.
Page 987 14 - 58 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Insert sensor into intake manifold while mak- ing sure not to damage O-ring seal. (2) Tighten mounting screws to: 2.4L (3) 2 N·m (20 in. lbs.) torque. 2.5L (4) 3.4 N·m (30 in. lbs) torque. (5) Attach electrical connector to sensor.
Page 988 FUEL SYSTEM 14 - 59 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) After removing the sensor, the exhaust mani- fold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent.
Page 989 14 - 60 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Loosen clamp holding resonator to air inlet (3) Install bolt holding resonator to intake mani- tube. Remove resonator. fold. Tighten to 5 .5 N·m (45 5 in. lbs.) torque. INSTALLATION AIR CLEANER (1) Install air inlet resonator to throttle body.
Page 990 FUEL SYSTEM 14 - 61 REMOVAL AND INSTALLATION (Continued) (2) Remove filter element (Fig. 97). 2.4L (3) If necessary, clean the inside of the air cleaner The engine coolant temperature sensor threads housing. into the front of the cylinder head (Fig. 99). INSTALLATION (1) Install new filter element.
Page 991 14 - 62 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) VEHICLE SPEED SENSOR SPECIFICATIONS The vehicle speed sensor is located in the transmis- VECI LABEL sion extension housing (Fig. 101). Always use the information found on the Vehicle REMOVAL Emission Control Information (VECI) label. The (1) Disconnect electrical connector from sensor.
Page 992 FUEL SYSTEM 14 - 63 SPECIAL TOOLS (Continued) Metering Orifice Fuel Pressure Test Adapter 6539 Fuel Line Adapter 1/4 Spanner Wrench 6856 O2S (Oxygen Sensor) Remover/Installer—C-4907...
Page 994 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....1 FUEL INJECTION SYSTEM ....26 FUEL DELIVERY SYSTEM INDEX page...
Page 995 MMT in Canada because MMT can be used at or additives is not the responsibility of Chrysler Cor- levels higher than allowed in the United States. poration and may not be covered under the new vehi- MMT is prohibited in Federal and California refor- cle warranty.
Page 996: Fuel Delivery System
Problems that are the result of using methanol/ Relieve fuel system pressure before servicing fuel gasoline blends are not the responsibility of Chrysler system components. Refer to the Fuel System Pres- Corporation and may not be covered by the vehicle sure Release Procedure and follow all Cautions and warranty.
Page 997: Fuel Injectors
14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The fuel pump module contains the following: FUEL TANK • Electric fuel pump • Fuel pump reservoir OPERATION • Inlet strainer All models pass a full 360 degree rollover test • Fuel pressure regulator without fuel leakage.
Page 998: Onboard Refueling Vapor Recovery
FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) Fuel injectors are not interchangeable between tank is vented to the vapor canister to capture escap- engines. ing vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the canister, the vehicle’s computer controlled purge system draws vapor out of the canister for the engine to burn.
Page 999 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) ORVR System Schematic CAUTION: The interior components (o-rings, spac- ers) of quick-connect fitting are not serviced sepa- rately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
Page 1000: Rollover Valves
FUEL SYSTEM 14 - 7 DESCRIPTION AND OPERATION (Continued) Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources.
Page 1001 14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (3) Place ignition key in the ON position. Using pump module). If the fuel return tube is not pinched DRB scan tool, access ASD Fuel System Test. The or restricted, replace the fuel pressure regulator. •...
Page 1002 FUEL SYSTEM 14 - 9 DIAGNOSIS AND TESTING (Continued)
Page 1003: Fuel Injectors
14 - 10 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) FUEL PUMP PRESSURE TEST—2.5L ENGINE The level sensor is a variable resistor. Its resis- tance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the WARNING: FUEL SYSTEM PRESSURE MUST BE fuel level changes.
Page 1004 FUEL SYSTEM 14 - 11 DIAGNOSIS AND TESTING (Continued) FUEL INJECTOR DIAGNOSIS...
Page 1005: Vehicle Does Not Fill
14 - 12 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) VEHICLE DOES NOT FILL Pre-Mature Nozzle Defective fuel tank assembly Fill tube improperly installed (sump). Shut-Off. components. Fill tube hose pinched. Check valve stuck shut. Control valve stuck shut. Defective vapor/vent Vent line from control valve to canister pinched components.
Page 1006: Hoses And Clamps
FUEL SYSTEM 14 - 13 SERVICE PROCEDURES (Continued) WARNING: DRAIN PLUG MUST BE INSTALLED AT (1) Using a clean lint free cloth, clean the fuel tube THIS TIME AS THERE WILL BE 1 TO 2 GALLONS nipple and retainer. (2) Prior to connecting the fitting to the fuel tube, OF FUEL LEFT IN THE TANK.
Page 1007 14 - 14 FUEL SYSTEM SERVICE PROCEDURES (Continued) (7) Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. (8) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (9) Connect negative cable to battery or auxiliary jumper terminal.
Page 1008: Removal And Installation
FUEL SYSTEM 14 - 15 SERVICE PROCEDURES (Continued) (2) Disconnect negative battery cable from battery or auxiliary jumper terminal. (3) Clean fitting of any foreign material before dis- assembly. (4) To release fuel system component from quick- connect fitting, firmly push fitting towards compo- nent being serviced while firmly pushing plastic retainer ring into fitting (Fig.
Page 1009: Fuel Filter
14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) REFER TO THE FUEL PRESSURE RELEASE PRO- CEDURE (1) Remove rear seat. (2) Disconnect fuel pump electrical connector. Push grommet out and feed jumper completely through hole in body. (3) Remove fuel cap slowly to release tank pres- sure.
Page 1010 FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Spread tangs on pressure regulator retainer (Fig. 17). (2) Pry fuel pressure regulator out of housing. (3) Ensure both upper and lower O-rings were removed with regulator. INSTALLATION (1) Lightly lubricate the O-rings with clean engine oil and place them into opening in pump module (Fig.
Page 1011 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 21 Terminal Removal Tool Fig. 19 Inlet Strainer Removal FUEL LEVEL SENSOR REMOVAL Remove fuel pump module. Refer to Fuel Pump Module in this section. (1) Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector (Fig.
Page 1012 FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) (2) Wrap wires into groove in back of level sensor (Fig. 24). Fig. 26 Fuel/Pump/Level Sensor Electrical Connector FUEL RAIL—2.0/2.4L Fig. 24 Groove in Back Side of Level Sensor (3) While feeding wires into guide grooves, slide REMOVAL level sensor up into channel until it snaps into place (1) Disconnect...
Page 1013: Fuel Rail-2.5L
14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Lift fuel rail off engine. There are spacers under each fuel rail bolt (Fig. 29). Fig. 29 Fuel Rail Spacers INSTALLATION Fig. 27 Fuel Rail and Injectors (1) Apply a light coating of clean engine oil to the FUEL RAIL—2.5L O-ring on the nozzle end of each injector.
Page 1014 FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) Push grommet out and feed jumper completely through hole in body. (4) Remove fuel cap slowly to release tank pres- sure. (5) With vehicle on a hoist, drain fuel from tank. Support fuel tank with a support such as a transmis- sion jack stand.
Page 1015 14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 33 Fuel Filler Hose Clamp Fig. 35 Fuel Tank Removal (9) Position fuel filter and fuel tank straps. Install the front bolts first and then the rear bolts. Tighten fuel tank strap bolts to 23 N·m (250 in. lbs.) torque. Remove transmission jack.
Page 1016: Throttle Cable-2.0/2.4L
FUEL SYSTEM 14 - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 N·m (105 in. lbs.) torque. (2) Place cable through slot in top of pedal shaft. (3) Step on pedal and retainer will snap into place.
Page 1017: Throttle Cable-2.5L
14 - 24 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Lift cable up through slot in top of pedal shaft. THROTTLE CABLE—2.5L (5) From the engine compartment, pull the throttle cable and grommet out of the dash panel. REMOVAL (1) Working from the engine compartment, remove INSTALLATION throttle cable from the throttle body lever (Fig.
Page 1018: Specifications
FUEL SYSTEM 14 - 25 REMOVAL AND INSTALLATION (Continued) (3) Place cable through slot in top of pedal shaft. SPECIFICATIONS (4) Step on pedal and retainer will snap into place. TORQUE DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts ..12 N·m (105 in. lbs.) Fuel Filter Mounting Screw .
Page 1019 14 - 26 FUEL SYSTEM FUEL INJECTION SYSTEM INDEX page page DESCRIPTION AND OPERATION SCI RECEIVE—PCM INPUT ....37 5 VOLT SUPPLY—PCM OUTPUT ... . 43 SENSOR RETURN—PCM INPUT .
Page 1020 FUEL SYSTEM 14 - 27 There are two different areas of operation, OPEN DESCRIPTION AND OPERATION LOOP and CLOSED LOOP. During OPEN LOOP modes the PCM receives INJECTION SYSTEM input signals and responds according to preset PCM All engines used in this section have a sequential programming.
Page 1021 14 - 28 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) PCM determines basic fuel injector pulse width from During Start-up the PCM maintains ignition tim- this input. ing at 9° BTDC. • The PCM determines atmospheric air pressure ENGINE WARM-UP MODE from the MAP sensor input to modify injector pulse This is an OPEN LOOP mode.
Page 1022 FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (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 1023 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) POWERTRAIN CONTROL MODULE OPERATION The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sen- sors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs.
Page 1024 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) Based on inputs it receives, the PCM adjusts fuel current to power the camshaft position sensor, crank- injector pulse width, idle speed, ignition spark shaft position sensor and vehicle speed sensor. The advance, ignition coil dwell and EVAP canister purge PCM also provides a 5 volt direct current supply for operation.
Page 1025 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) BRAKE SWITCH—PCM INPUT OPERATION When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through control of the idle air control motor.
Page 1026 FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) OPERATION The PCM determines engine coolant temperature from the coolant temperature sensor. The coolant temperature sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD Bus to the Body Control Module (BCM) for the instrument panel gauge clus- ter.
Page 1027 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 7 Timing Reference Notches Fig. 8 Engine Coolant Temperature Sensor—2.0L Fig. 10 Engine Coolant Temperature Sensor—2.5L Fig. 11 Oxygen Sensor 1/1 Upstream—2.0/2.4L Fig. 9 Engine Coolant Temperature Sensor—2.4L Engines...
Page 1028 FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.
Page 1029 14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 15 Intake Air Temperature Sensor and MAP Fig. 17 Knock Sensor Sensor—2.4L Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases.
Page 1030 FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) SCI RECEIVE—PCM INPUT OPERATION SCI Receive is the serial data communication receive circuit for the DRB scan tool. The Powertrain Control Module (PCM) receives data from the DRB through the SCI Receive circuit. TRANSAXLE PARK/NEUTRAL SWITCH—PCM INPUT DESCRIPTION...
Page 1031 14 - 38 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 22 Vehicle Speed Sensor—Manual Transmission OPERATION Fig. 20 Throttle Position Sensor—2.0/2.4L Engines AUTOMATIC The transaxle control module (TCM) supplies the vehicle speed signal to the PCM based on the output shaft speed.
Page 1032 FUEL SYSTEM 14 - 39 DESCRIPTION AND OPERATION (Continued) • Speedometer • Speed control • Daytime Running Lights (Canadian Vehicles only). AIR CONDITIONING CLUTCH RELAY—PCM OUTPUT DESCRIPTION The air conditioning clutch relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location.
Page 1033 14 - 40 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 26 EGR Control Valve—2.5L Engine Fig. 24 Proportional Purge Solenoid ELECTRIC EGR TRANSDUCER—PCM OUTPUT— 2.4/2.5L ENGINES DESCRIPTION The solenoid/transducer and EGR valve mount to the rear of the cylinder head (Fig. 25) or (Fig. 26). Fig.
Page 1034 FUEL SYSTEM 14 - 41 DESCRIPTION AND OPERATION (Continued) IDLE AIR CONTROL MOTOR—PCM OUTPUT various switch operations (brake, park/neutral, air conditioning). DESCRIPTION DATA LINK CONNECTOR The Idle Air Control (IAC) motor is mounted on the throttle body. The PCM operates the idle air control DESCRIPTION motor (Fig.
Page 1035 14 - 42 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION The Automatic Shutdown (ASD) relay supplies bat- tery voltage to the fuel injectors. The PCM controls the ground path for each injector in sequence. By switching the ground paths on and off, the PCM fine- tunes injector pulse width.
Page 1036 FUEL SYSTEM 14 - 43 DESCRIPTION AND OPERATION (Continued) cations port. Various modules use the CCD Bus to TACHOMETER—PCM OUTPUT exchange information. The Check Engine lamp comes on each time the OPERATION ignition key is turned ON and stays on for 3 seconds The tachometer receives its information across the as a bulb test.
Page 1037 14 - 44 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING VISUAL INSPECTION Before diagnosing or servicing the fuel injection system, perform a visual inspection for loose, discon- nected, or misrouted wires and hoses. A thorough visual inspection that includes the following checks saves unnecessary test and diagnostic time.
Page 1038 FUEL SYSTEM 14 - 45 DIAGNOSIS AND TESTING (Continued) (6) Check hose connections between the PCV valve, vacuum port-intake manifold (Fig. 39), (Fig. 40) or (Fig. 41). Fig. 41 PCV Valve—2.5L Engine Fig. 39 PCV Valve—2.0L Engine Fig. 42 MAP/ Air Temperature Sensor—2.0L Engine Fig.
Page 1039 14 - 46 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 44 MAP Sensor and Intake Air Temperature Fig. 46 Ignition Coil and Spark Plugs Sensor—2.5L Engine Fig. 45 Fuel Injectors—2.0/2.4L Engines 2.0/2.4L (a) Inspect the ignition coil electrical connector. Ensure the spark plug insulators are firmly seated over the spark plugs (Fig.
Page 1040 FUEL SYSTEM 14 - 47 DIAGNOSIS AND TESTING (Continued) Fig. 51 Camshaft Position Sensor—2.4L Engine Fig. 48 Proportional Purge Solenoid Fig. 52 Engine Coolant Temperature Sensor—2.4L Engine Fig. 49 Knock Sensor—2.0/2.4L Fig. 53 Engine Coolant Temperature Sensor—2.5L Engine Fig. 50 Camshaft Position Sensor and Engine Coolant Temperature Sensor—2.0L Engine...
Page 1041 14 - 48 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (18) Check electrical connector at Electronic EGR Transducer. Inspect vacuum and back pressure hoses at the solenoid and transducer for leaks (Fig. 54) or (Fig. 55). Fig. 56 Crankshaft Position Sensor—2.0/2.4L Engines-Typical Fig.
Page 1042 FUEL SYSTEM 14 - 49 DIAGNOSIS AND TESTING (Continued) Fig. 59 Vehicle Speed Sensor—Manual Fig. 62 Upstream Heated Oxygen Sensor—2.5L Transmission Engine Fig. 60 Power Steering Pressure Switch Fig. 63 Rear Heated Oxygen Sensor (24) Inspect the electrical connections at the (25) Inspect the fuel pump module electrical con- upstream and downstream heated oxygen sensors nection in the trunk for corrosion or damage (Fig.
Page 1043 14 - 50 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (26) Inspect the connections to the speed control voltage is not supplied to the rest of the circuit. Ter- servo, if equipped. Refer to the Vehicle Speed Control minal 87A is the center terminal on the relay. •...

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