DaimlerChrysler LH New Yorker 1994 Electronic Service Manual

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Виктор Анатольевич

June 24, 2025

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Summary of Contents for DaimlerChrysler LH New Yorker 1994

Page 1 :HOFRPH WR WKH /+ 1HZ <RUNHU /+6 &RQFRUGH ,QWUHSLG 9LVLRQ DQG 6XSSOHPHQWV (OHFWURQLF 6HUYLFH 0DQXDO Click on logo to begin CLICK HERE FOR INSTRUCTIONS...
Page 2 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CONTENTS page page CHASSIS AND BODY ....15 GENERAL INFORMATION ....1 DRIVETRAIN .
Page 3: Engine Oil
0 - 2 LUBRICATION AND MAINTENANCE • Air Pump FLUID CAPACITIES • Generator Bushings Fuel Tank..........68 L (18 gal.) • Drive Belts Engine Oil • Drive Belt Idler/Tensioner Pulley 3.3L ............4.7L (5 qts.) • Wheel Bearings 3.5L ............5.2L (5.5 qts.) •...
Page 4 LUBRICATION AND MAINTENANCE 0 - 3 • Check and replace as needed all automatic tension- 45,000 MILES (72 500 KM) OR AT 36 MONTHS • Flush and replace engine coolant at 36 months, ing drive belts (see note 2 at the end of this chart). •...
Page 5 0 - 4 LUBRICATION AND MAINTENANCE SEVERE SERVICE MAINTENANCE 24,000 MILES (38 000KM) • Change engine oil. Follow the Severe Service recommendations if • Replace engine oil filter. you operate your vehicle under ANY of the fol- • Inspect CV joints and front suspension ball joints. lowing conditions •...
Page 6: Jump Starting, Hoisting And Towing
LUBRICATION AND MAINTENANCE 0 - 5 JUMP STARTING, HOISTING AND TOWING JUMP STARTING PROCEDURE jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 1). WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/START- ING/CHARGING SYSTEMS DIAGNOSTICS.
Page 7 0 - 6 LUBRICATION AND MAINTENANCE A towed vehicle should be raised until lifted wheels CAUTION: Do not position hoisting device on sus- are a minimum 100 mm (4 in) from the ground. Be pension components, damage to vehicle can result. sure there is adequate ground clearance at the oppo- site end of the vehicle, especially when towing over TO HOIST OR JACK VEHICLE SEE FIG.
Page 8: Table Of Contents
LUBRICATION AND MAINTENANCE 0 - 7 Use a flat bed towing device when wheel lift towing device is not available. REAR TOWING PROCEDURES CAUTION: Do not tow vehicle with the rear end lifted. If damage to the vehicle prevents front towing, use a flat bed towing device.
Page 9 0 - 8 LUBRICATION AND MAINTENANCE BREAK-IN PERIOD CAUTION: Wide open throttle operation in low gears, before engine break-in period is complete, can damage engine. On a Chrysler Corporation vehicle an extended break-in period is not required. Driving speeds of not over 80-90 km/h (50-55 mph) for the first 100 km (60 miles) is recommended.
Page 10: Engine Oil Filter
LUBRICATION AND MAINTENANCE 0 - 9 Fig. 2 Oil Level Indicator Dipstick—Typical (2) Hoist and support vehicle on safety stands. Re- fer to Hoisting and Jacking Recommendations in this Fig. 3 Remove Oil Filter group. (3) Place a suitable 3.8 liter (4 qt.) drain pan under crankcase drain.
Page 11: Engine Air Cleaner
0 - 10 LUBRICATION AND MAINTENANCE The engine cooling system will develop internal adequate protection. A mix table on the coolant con- pressure of 97 to 123 kPa (14 to 18 psi) at normal tainer indicates the amount of antifreeze required to operating temperature.
Page 12: Fuel Recommendations
LUBRICATION AND MAINTENANCE 0 - 11 (4) Clean inside of air cleaner lid and body with circuit. PCV system should be inspected at every oil change. Service PCV system if engine oil is dis- vacuum or compressed air. If oily, wash with solvent. charged into air cleaner.
Page 13: Ignition Cables
0 - 12 LUBRICATION AND MAINTENANCE age the engine. The cause of excessive spark knock nents will result. Methanol induced problems are not condition must be diagnosed and corrected. For diag- the responsibility of Chrysler Corporation and may nostic proedures refer to Group 14, Fuel System and not be covered by the vehicle warranty.
Page 14: Rubber And Plastic Component Inspection
LUBRICATION AND MAINTENANCE 0 - 13 RUBBER AND PLASTIC COMPONENT INSPECTION tion of rubber components, Chrysler Corporation rec- ommends Mopar Foamy Engine Degreaser or equiva- CAUTION: Plastic hoses or wire harness covers will lent be used to clean engine compartment of oil and melt or deform when exposed to heat from exhaust road grime.
Page 15 0 - 14 LUBRICATION AND MAINTENANCE Plus is not available use Dexron II or Dexron IIe Automatic Transmission Fluid or equivalent. Fig. 3 Differential Fill Plug Fig. 1 Transaxle Fill tube Fig. 2 Transaxle Dipstick—Typical DIFFERENTIAL The differential should be inspected for oil leaks and proper oil level when other under vehicle service is performed.
Page 16: Chassis And Body
LUBRICATION AND MAINTENANCE 0 - 15 rotation method can be used if the vehicle is equipped with a space saver spare tire. Fig. 5 Tire Rotation CHASSIS AND BODY INDEX page page Body Lubrication ......17 Steering Linkage .
Page 17 0 - 16 LUBRICATION AND MAINTENANCE and Maintenance Schedules. Refer to General Infor- CAUTION: Do not over fill power steering reservoir mation section of this group. A hose must be replaced when adding fluid, seal damage and leakage can if it has signs of cracking, chafing, fatigue or bulging. result.
Page 18 LUBRICATION AND MAINTENANCE 0 - 17 SUPPLEMENTAL AIRBAG SYSTEM During winter season, external lock cylinders should be lubricated with Mopar Lock Lubricant or WARNING: FAILURE TO HAVE THE AIRBAG SYS- equivalent to assure proper operation when exposed TEM PROMPTLY SERVICED BY AN AUTHORIZED to water and ice.
Page 20 SUSPENSION AND DRIVESHAFTS 2 - 1 SUSPENSION AND DRIVESHAFTS CONTENTS page page DRIVESHAFTS ......40 GENERAL INFORMATION .
Page 21 2 - 2 SUSPENSION AND DRIVESHAFTS...
Page 22 SUSPENSION AND DRIVESHAFTS 2 - 3 SUSPENSION/STEERING/DIAGNOSIS FRONT WHEEL DRIVE...
Page 23 2 - 4 SUSPENSION AND DRIVESHAFTS FRONT SUSPENSION FRONT SUSPENSION MAJOR COMPONENTS bolt clearance. The stud is clamped and locked into (FIG. 2) the steering knuckle leg with a clamp bolt. The ball joint used on the L.H. Platform vehicle is non- STRUT ASSEMBLY serviceable and if defective must be serviced as part The front strut and suspension of the vehicle is...
Page 24 SUSPENSION AND DRIVESHAFTS 2 - 5...
Page 25 2 - 6 SUSPENSION AND DRIVESHAFTS FRONT SUSPENSION SERVICE PROCEDURES INDEX page page Ball Joints ......20 Servicing Wheel Studs .
Page 26 SUSPENSION AND DRIVESHAFTS 2 - 7 to recommended pressures, full tank of fuel, no pas- senger or luggage compartment load and is on a level floor or alignment rack. Just prior to each alignment reading. The vehicle should be bounced (rear first, then front) by grasping bumper at center and jouncing each end an equal number of times.
Page 27 2 - 8 SUSPENSION AND DRIVESHAFTS some other method, do not let caliper assembly hang by brake hose (Fig. 4). Remove front braking disc from hub. Fig. 1 Stabilizer Bar Link Removed From Strut Fig. 4 Removal And Storage Of Front Caliper CAUTION: The strut assembly to steering knuckle bolts are serrated where they go through strut as- sembly and steering knuckle.
Page 28 SUSPENSION AND DRIVESHAFTS 2 - 9 (8) Remove the 3 strut assembly upper mount to bly to steering knuckle attaching bolts (Fig. 7). Torque the caliper assembly attaching bolts to 19 shock tower mounting nut and washer assemblies N m (192 in. lbs.). (Fig.
Page 29 2 - 10 SUSPENSION AND DRIVESHAFTS Fig. 9 Tightening Wheel Nuts DISASSEMBLY (STRUT DAMPER) The front strut is not serviced and must be replaced as an assembly if found to be defective. The strut is available with 2 calibrations, be sure strut is replaced Fig.
Page 30 SUSPENSION AND DRIVESHAFTS 2 - 11 (6) Remove the jounce bumper and the seat/bearing and dust shield as an assembly, from the strut assem- bly (Fig. 4). Fig. 6 Lower Spring Isolator (2) Install compressed coil spring onto strut assem- bly aligning paint mark on spring with paint mark on strut assembly (Fig.
Page 31 2 - 12 SUSPENSION AND DRIVESHAFTS (4) Lower seat/bearing and dust shield onto strut (7) Install Strut Rod Socket, Special Tool, L-4558 or assembly spring. Align paint mark L-4558A on strut shaft nut (Fig. 2). Using a 10 mm seat/bearing and dust shield, with paint mark on the socket on end of strut shaft to keep strut shaft from strut spring (Fig.
Page 32 SUSPENSION AND DRIVESHAFTS 2 - 13 REMOVAL (ASSEMBLY) (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrica- tion and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove the wheel and tire assembly from the vehicle.
Page 33 2 - 14 SUSPENSION AND DRIVESHAFTS (7) Separate lower control arm and tension strut CAUTION: Pulling steering knuckle out from vehicle from the cradle as an assembly. Lower control arm is after releasing from ball joint can separate inner C/V removed from cradle, by first removing pivot bushing joint.
Page 34 SUSPENSION AND DRIVESHAFTS 2 - 15 (7) Lower vehicle so the suspension is supporting vehicles weight (control arm at design height). Torque the lower control arm pivot bushing to cradle bracket attaching bolt (Fig. 9) to 123 N m (90 ft. lbs.). Fig.
Page 35 2 - 16 SUSPENSION AND DRIVESHAFTS Fig. 12 Tightening Wheel Nuts Fig. 14 Tension Strut Bushing Installed On Tension Strut Fig. 13 Lower Control Arm Pivot Bolt Fig. 15 Tension Strut Bushing Installed In Cradle an assembly from the vehicle. See Lower Control Arm When torquing tension strut nut, keep tension strut Removal in this section of the service manual for the from turning by holding tension strut at flat using an...
Page 36 SUSPENSION AND DRIVESHAFTS 2 - 17 (4) Tighten the wheel mounting stud nuts in (2) Separate the tension strut from the lower con- proper sequence (Fig. 17) until all nuts are torqued trol arm assembly (Fig. 19). to half specification. Then repeat the tightening se- quence to the full specified torque of 129 N m (95 ft.
Page 37 2 - 18 SUSPENSION AND DRIVESHAFTS (2) Install washer on end of tension strut (Fig. 21). Install a NEW tension strut to cradle bracket nut, on tension strut (Fig. 21). Torque the tension strut to cradle bracket retaining nut to 150 N m (110 ft. lbs.). When torquing tension strut nut, keep tension strut from turning by holding tension strut at flat using an open end wrench (Fig.
Page 38 SUSPENSION AND DRIVESHAFTS 2 - 19 Fig. 1 Lower Control Arm Pivot Bushing Removal Fig. 3 Pivot Bushing Installed In Lower Control Arm of Installer, Special Tool 6644-1 with end of ram on arbor press and start to press bushing into lower control arm.
Page 39 2 - 20 SUSPENSION AND DRIVESHAFTS bor press, press Remover, Special Tool, 6644-4 down through the tension strut bushing until the arbor press can push it no farther. As Remover, Special Tool, 6644-4 is pressed down through tension strut bushing it will cut the bushing into two pieces. Fig.
Page 40 SUSPENSION AND DRIVESHAFTS 2 - 21 (3) Using Installer, Special Tool MB-990800, press Attachment of stabilizer bar to cradle assembly, is seal onto ball joint housing until it is squarely seated through rubber-isolated bushings (Fig. 1). Stabilizer against top surface of control arm (Fig. 7). bar to strut assembly attachment is done utilizing a stabilizer bar link (Fig.
Page 41 2 - 22 SUSPENSION AND DRIVESHAFTS...
Page 42 SUSPENSION AND DRIVESHAFTS 2 - 23 STABILIZER BAR ISOLATOR BUSHING stabilizer bar, so lower part of stabilizer bar is cen- SERVICE tered in the middle of the cradle assembly. Failure to If only the stabilizer bar isolator bushings require do this may cause stabilizer bar to come in contact service without any service to the stabilizer bar.
Page 43 2 - 24 SUSPENSION AND DRIVESHAFTS material or equivalent, mount it to the following loca- tions on the 3.3 ltr. engine. (2) Remove bolt attaching A/C compressor bracket to front of engine. Install webbing material hook on A/C compressor bolt, install bolt and tighten (Fig. 5 and 6).
Page 44 SUSPENSION AND DRIVESHAFTS 2 - 25 CAUTION: When lower control is separated from steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steer- ing knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm to knuckle.
Page 45 2 - 26 SUSPENSION AND DRIVESHAFTS (6) Remove the 4 nuts attaching motor mounts to cradle assembly (Fig. 13). Fig. 15 Stabilizer Bar Isolator Bushing Attachment To Cradle MOVE CRADLE WITHOUT USING JACK STANDS TO SUPPORT COMPONENTS. (9) Position a jack stand under front of cradle and at center of transaxle to cradle assembly mount (Fig.
Page 46 SUSPENSION AND DRIVESHAFTS 2 - 27 • Slowly lower front jack stand until weight of en- bushing from around stabilizer bar. The stabilizer bar gine is supported by engine support fixture and motor to cradle assembly bushings, should be positioned on mount bolts are clear of cradle assembly.
Page 47 2 - 28 SUSPENSION AND DRIVESHAFTS • Using jack stand raise front of cradle assembly up against bottom of motor mounts. Be sure all 4 motor mount studs come through holes in cradle assembly. • Continue to raise cradle assembly and engine using jack stand until the 2 front cradle assembly to body attaching bolts (Fig.
Page 48 SUSPENSION AND DRIVESHAFTS 2 - 29 The front suspension knuckle is not a serviceable component. Do not attempt to straighten or repair the front suspension knuckle in any way. Service repair or replacement of the front (drive) hub and bearing, can be done with the front suspen- sion knuckle remaining on the vehicle.
Page 49 2 - 30 SUSPENSION AND DRIVESHAFTS Fig. 2 Disc Brake Caliper Mounting Fig. 4 Speed Sensor Head Removal (Typical) Fig. 5 Hub And Bearing To Stub Axle Retaining Nut Fig. 3 Removing Braking Disc DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and punch (Fig.
Page 50 SUSPENSION AND DRIVESHAFTS 2 - 31 Fig. 9 Prying Hub And Bearing Assembly From Steering Knuckle Fig. 7 Hub And Bearing Assembly Seal assembly and steering knuckle (Fig. 9) and gently pry hub and bearing from knuckle. If stub shaft is frozen to hub and bearing assembly tap end of stub shaft with soft face hammer to free it from hub and bearing spline.
Page 51 2 - 32 SUSPENSION AND DRIVESHAFTS (2) Position steering knuckle neck into strut assem- bly. CAUTION: The strut assembly to steering knuckle bolts are serrated where they go through strut as- sembly and steering knuckle. When installing bolts, turn nuts onto bolts DO NOT TURN BOLTS IN STEERING KNUCKLE.
Page 52 SUSPENSION AND DRIVESHAFTS 2 - 33 Fig. 15 Hub And Bearing Assembly Retaining Bolts CAUTION: The hub and bearing assembly to stub shaft retaining nut (Fig. 16) is a prevailing torque nut and can not be re-used. A NEW retaining nut MUST be used when assembled.
Page 53 2 - 34 SUSPENSION AND DRIVESHAFTS 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 02-13-94 September 23, 1994 (2) Remove the front wheel and tire assembly from the vehicle. (3) Remove the front caliper assembly from the front steering knuckle assembly (Fig.
Page 54 SUSPENSION AND DRIVESHAFTS 2 - 35 Fig. 3 Hub And Bearing To Stub Axle Retaining Nut Fig. 5 Hub And Bearing Assembly Seal and bearing assembly tap end of stub shaft with soft face hammer to free it from hub and bearing spline. Fig.
Page 55 2 - 36 SUSPENSION AND DRIVESHAFTS Fig. 9 Hub And Bearing Assembly Retaining Bolts Fig. 7 Prying Hub And Bearing Assembly From Steering Knuckle Fig. 10 Hub And Bearing To Stub Axle Retaining Nut Fig. 8 Hub And Bearing Assembly Mounting Surfaces (1) Install hub and bearing assembly onto stub shaft and into steering knuckle until squarely seated...
Page 56 SUSPENSION AND DRIVESHAFTS 2 - 37 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 02-13-94 September 23, 1994 (5) Install front brake caliper back over braking maximum torque of 176 N m (130 ft. lbs.). If the disc and align with caliper mounting holes on steer- maximum torque is exceeded this may result in a ing knuckle (Fig.
Page 57 2 - 38 SUSPENSION AND DRIVESHAFTS Front Disc Brake Service in the Brake Section of this service manual for caliper removal procedure. Fig. 1 Disc Brake Caliper Mounting (4) Remove front braking disk (rotor) from hub, by pulling it straight off wheel mounting studs (Fig. 2). Fig.
Page 58 SUSPENSION AND DRIVESHAFTS 2 - 39 (3) Install the braking disk back on the hub and bearing assembly (Fig. 5). Fig. 6 Disc Brake Caliper Mounting Fig. 5 Installing Braking Disc (4) Install front brake caliper back over braking disc and align with caliper mounting holes on steer- ing knuckle (Fig.
Page 59 2 - 40 SUSPENSION AND DRIVESHAFTS DRIVESHAFTS INDEX page page Driveshaft Reconditioning Procedure ..46 Outer C/V Joint Sealing Boot Service ..50 General Information .
Page 60 SUSPENSION AND DRIVESHAFTS 2 - 41 SUSPENSION/STEERING/DIAGNOSIS FRONT WHEEL DRIVE...
Page 61 2 - 42 SUSPENSION AND DRIVESHAFTS SERVICE PROCEDURES Procedures for removal and installation of drive- shafts on the L.H. platform vehicles are different and somewhat easier, then those on other front wheel drive vehicles. This new drive shaft design, allows both drive shafts to be removed from the vehicle without dismantling the transaxle.
Page 62 SUSPENSION AND DRIVESHAFTS 2 - 43 (7) Dislodge inner tripod joint from stub shaft re- CAUTION: When removing outer C/V joint from hub taining snap ring on transaxle assembly (Fig. 5). In- and bearing assembly, do not allow the flinger disk ner tripod joint is dislodged from stub shaft retaining (Fig.
Page 63 2 - 44 SUSPENSION AND DRIVESHAFTS Fig. 8 Inner Tripod Joint Removal From Stub Shaft Fig. 10 Grease Applied To Inner Tripod Joint Housing Spline Fig. 9 Tripod Joint Retaining Circlip And O-Ring Fig. 11 Inner Tripod Joint Installation On Stub Shaft Seal (2) Evenly apply a bead of grease, such as Mopar CAUTION: When installing outer C/V joint into the...
Page 64 SUSPENSION AND DRIVESHAFTS 2 - 45 Fig. 14 Hub And Bearing To Stub Axle Retaining Nut (9) Install speed sensor cable routing bracket on front strut assembly. Then install and securely tighten routing bracket attaching screw (Fig. 3). (10) Install the braking disk back on the hub and bearing assembly (Fig.
Page 65 2 - 46 SUSPENSION AND DRIVESHAFTS 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 02-13-94 September 23, 1994 Fig. 18 Tighten Hub And Bearing Retaining Nut DRIVESHAFT RECONDITIONING PROCEDURE The only service which is to be performed on the driveshaft assemblies is the replacement of the drive shaft seal boots.
Page 66 SUSPENSION AND DRIVESHAFTS 2 - 47 Fig. 1 L.H. Platform Driveshaft Components...
Page 67 2 - 48 SUSPENSION AND DRIVESHAFTS ing shaft (Fig. 2) and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. Fig. 4 Spider Assembly Retaining Snap Ring Removal (6) Thoroughly clean and inspect spider assembly, tripod joint housing and interconnecting shaft for any Fig.
Page 68 SUSPENSION AND DRIVESHAFTS 2 - 49 Fig. 5 Seal Boot Correctly Positioned On Fig. 7 Spider Assembly Installed In Housing Interconnecting Shaft Fig. 8 Crimping Tool Installed On Sealing Boot Fig. 6 Spider Assembly Retaining Snap Ring Clamp Installation (4) Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing.
Page 69 2 - 50 SUSPENSION AND DRIVESHAFTS (8) Position the sealing boot into the tripod housing OUTER C/V JOINT SEALING BOOT SERVICE retaining groove (Fig. 10). Install seal boot retaining REMOVE clamp evenly on sealing boot. To remove outer C/V joint sealing boot from a drive- shaft for replacement, the drive shaft assembly must be removed from the vehicle.
Page 70 SUSPENSION AND DRIVESHAFTS 2 - 51 Fig. 4 Seal Boot Correctly Positioned On Fig. 2 Outer C/V Joint Removal From Interconnecting Shaft Interconnecting Shaft clamp (Fig. 5). Then tighten nut on crimping tool shaft, by pushing interconnecting shaft into outer C-4975 until jaws on tool are closed completely to- C/V joint, until retaining snap ring is seated in gether, face to face (Fig.
Page 71 2 - 52 SUSPENSION AND DRIVESHAFTS CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. (6) Position outer C/V joint seal boot, into boot re- taining groove on outer C/V joint housing (Fig.
Page 72 SUSPENSION AND DRIVESHAFTS 2 - 53 REAR SUSPENSION INDEX page page General Information ..... . . 53 Rear Wheel Toe Setting Procedure ... . 55 Rear Crossmember .
Page 73 2 - 54 SUSPENSION AND DRIVESHAFTS...
Page 74 SUSPENSION AND DRIVESHAFTS 2 - 55 REAR WHEEL TOE SETTING PROCEDURE Rear Wheel alignment adjustments can only be made for the Toe In setting on the L.H. plat- form vehicles. Toe is measured in degrees or inches and is the distance the front edges of the tires are closer (or farther apart) than the rear edges.
Page 75 2 - 56 SUSPENSION AND DRIVESHAFTS taching link stud nut, at the stabilizer bar (Fig. 5). The attaching link does not have to be removed from strut assembly. Fig. 2 Brake Hose Bracket And Tube speed sensor cable attached damage to speed sensor cable may occur.
Page 76 SUSPENSION AND DRIVESHAFTS 2 - 57 Fig. 7 Center Punch Installed In Spindle Fig. 9 Spindle Assembly Removed From Strut Fig. 8 Removing Spindle From Strut Assembly NOTE: When removing rear strut assembly from vehicle, access for the 3 rear strut assem- bly to strut tower attaching nuts is through the trunk of the vehicle.
Page 77 2 - 58 SUSPENSION AND DRIVESHAFTS (5) Mount rear speed sensor cable routing tube to rear trailing arm (Fig. 14). Then mount speed sensor cable routing clip (Fig. 14) to the trailing arm to rear spindle bracket. Fig. 11 Spindle Mounted To Strut Assembly Fig.
Page 78 SUSPENSION AND DRIVESHAFTS 2 - 59 specification. Then repeat tightening sequence to full specified torque of 129 N m (95 ft. lbs.). Fig. 16 Tightening Wheel Nuts (10) Lower vehicle to the ground. (11) Check and reset rear wheel TOE to specifica- tions if required.
Page 79 2 - 60 SUSPENSION AND DRIVESHAFTS Fig. 3 Upper Strut Mount Removal Fig. 5 Plate, Dust Shield And Jounce Bumper Remove And Replace Fig. 4 Coil Spring Remove And Replace Fig. 6 Lower Spring Isolator body of strut and release, strut shaft should return to (5) Install the upper strut mount assembly onto the its fully extended position.
Page 80 SUSPENSION AND DRIVESHAFTS 2 - 61 Fig. 9 Identifying Coil Springs Fig. 7 Jounce Bumper Installed Into Dust Shield tion and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove the rear wheel and tire assembly from the vehicle.
Page 81 2 - 62 SUSPENSION AND DRIVESHAFTS Fig. 2 Brake Hose Bracket And Tube (4) If vehicle is equipped with rear disc brakes, remove rear braking disc from hub. If vehicle is equipped with rear drum brakes, remove the brake drum from the hub. (5) On all rear brake applications, remove rear hub Fig.
Page 82 SUSPENSION AND DRIVESHAFTS 2 - 63 (9) If vehicle is equipped with Anti-Lock brakes. Remove the speed sensor cable routing tube on trail- ing arm and the routing bracket on the trailing arm bracket to spindle (Fig. 7). If trailing arm is low- ered from strut with the speed sensor cable at- tached damage to speed sensor cable may occur.
Page 83 2 - 64 SUSPENSION AND DRIVESHAFTS Fig. 12 Removing Spindle From Strut Assembly Fig. 14 Lateral Links To Spindle Attaching Bolt remove center punch from hole in spindle. Install spindle to strut assembly pinch bolt into spindle (Fig. 13). Torque spindle to strut assembly pinch bolt to 55 N m (40 ft.
Page 84 SUSPENSION AND DRIVESHAFTS 2 - 65 (8) Install the rear hub and bearing assembly on the rear spindle. Install hub and bearing assembly retaining washer and nut on spindle (Fig. 20). Torque hub and bearing retaining nut to 168 N m (124 ft. lbs).
Page 85 2 - 66 SUSPENSION AND DRIVESHAFTS REAR CROSSMEMBER The L.H. platform vehicles are available with two different rear crossmembers depending on the sus- pension package the vehicle was built with. The crossmembers visually look the same between the standard and performance suspension packages, but the mounting location for the lateral links is differ- ent.
Page 86 SUSPENSION AND DRIVESHAFTS 2 - 67 (3) Align lateral links with spindles and install the lateral link to spindle attaching bolts (Fig. 2). Torque the lateral link to spindle attaching bolts to 140 N m (105 ft. lbs.). (4) Remove transmission jack supporting fuel tank. (5) Install wheel and tire assembly on vehicle.
Page 87 2 - 68 SUSPENSION AND DRIVESHAFTS REAR STABILIZER BAR SERVICE REMOVE (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrica- tion and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove both rear wheel and tire assemblies from the vehicle.
Page 88 SUSPENSION AND DRIVESHAFTS 2 - 69 Fig. 1 Rear Suspension Lateral Links SERVICING LATERAL LINKS (2) Remove left rear wheel and tire assembly from The lateral links are only serviced as complete as- the vehicle. semblies. The isolator bushings used in the lateral (3) Remove the nut and bolt attaching left lateral links are not serviced as separate components.
Page 89 2 - 70 SUSPENSION AND DRIVESHAFTS (2) Install the lateral link attaching bolt at the spindle and crossmember. Note: Both lateral link attaching bolts must be install, so head of bolt is facing front of vehicle (Fig. 2 and 3). (3) Torque both lateral link attaching bolts to 140 N m (105 ft.
Page 90 SUSPENSION AND DRIVESHAFTS 2 - 71 (6) Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper se- quence (Fig. 8) until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 N m (95 ft.
Page 91 2 - 72 SUSPENSION AND DRIVESHAFTS 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 02-13-94 September 23, 1994 SPECIFICATIONS ALIGNMENT SPECIFICATIONS AT CURB HEIGHT REAR SUSPENSION TORQUE SPECIFICATIONS FRONT SUSPENSION TORQUE SPECIFICATIONS...
Page 92 BRAKES 5 - 1 BRAKES CONTENTS page page ANTI-LOCK BRAKE SYSTEM—TEVES MARK IV MASTER CYLINDER ..... 69 SYSTEM ......75 PARKING BRAKES .
Page 93 5 - 2 BRAKES Fig. 2 Proper Tube Nut Thread Size And Tube Routing (Non-ABS Equipped) style tubing flares and fittings at all tubing joint lost or broken during servicing a vehicle, replace locations. See (Figs. 2 and 3) for specific joint loca- only with the equivalent part listed in the Mopar tions and tube fitting size.
Page 94 BRAKES 5 - 3 Fig. 3 Proper Nut Thread Size And Tube Routing (ABS Equipped) Fig. 4 Shock Tower To Spring Minimum Clearance Area...
Page 95 5 - 4 BRAKES SERVICE ADJUSTMENTS INDEX page page Adjusting Rear Service Brakes ....4 Road Wheel Stud Nut Tightening ....6 Bleeding Brake System .
Page 96 BRAKES 5 - 5 PRESSURE BLEEDING Before removing the master cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. CAUTION: Use bleeder tank Special Tool C-3496-B or equivalent, with Snap-On adapter BB400-9A or equivalent (Fig.
Page 97 5 - 6 BRAKES volume of brake fluid when bleeding the brakes. This Enough fluid has not passed through the system to will ensure all the air is bled from the brakes hydrau- expel all the trapped air. Be sure to monitor the fluid lic system.
Page 98 BRAKES 5 - 7 Fig. 5 Tightening Wheel Nuts Fig. 1 Anti-Lock Equipped Vehicle Flex Hoses BRAKE HOSE AND TUBING Banjo connector to the caliper assembly. Then attach the remaining hose end bracket to the vehicle frame INSPECTION OF BRAKE HOSE AND TUBING to minimize hose twisting.
Page 99: System
5 - 8 BRAKES into hot areas. All tubes should be properly attached with recommended retaining clips. Care must be taken during the removal and re- placement of components on a vehicle equipped with Anti-Lock brakes. To avoid damage to the flexible stainless steel hoses between the master cylinder and Anti-Lock hydraulic control unit.
Page 100 BRAKES 5 - 9 (3) Position tubing in jaws of the Flaring Tool so that it is flush with top surface of flaring tool bar assembly. (See Fig. 5). (4) Install the correct size adaptor for the brake tubing being flared, on the feed screw of the yoke assembly.
Page 101 5 - 10 BRAKES BASIC DIAGNOSIS GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 SYMPTOM MISC. COND. ACTUATION POWER BRAKES BRAKE NOISE WHEEL BRAKES BRAKE WARNING LIGHT ON EXCESSIVE PEDAL TRAVEL PEDAL GOES TO FLOOR STOP LIGHT ON WITHOUT BRAKES ALL BRAKES DRAG REAR BRAKES DRAG GRABBY BRAKES...
Page 102 BRAKES 5 - 11 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 05-12-93 August 13, 1993 BRAKE SYSTEM DIAGNOSTICS...
Page 103 5 - 12 BRAKES BRAKE SYSTEM DIAGNOSTICS...
Page 104 BRAKES 5 - 13 BRAKE SYSTEM DIAGNOSTICS...
Page 105 5 - 14 BRAKES BRAKE SYSTEM DIAGNOSTICS BRAKE SYSTEM DIAGNOSTICS...
Page 106 BRAKES 5 - 15 REAR WHEEL DRUM BRAKES INDEX page page Brake Drum Refacing ..... . 19 Description ......15 Brake Shoe Assemblies .
Page 107 5 - 16 BRAKES Fig. 4 Rear Hub And Bearing Dust Cap Removal Fig. 2 Tightening Wheel Nuts Fig. 5 Rear Hub And Bearing Retaining Nut Removal Fig. 3 Varga Rear Wheel Brake (Left Side Of Vehicle Shown) REMOVE (1) Remove rear hub and bearing assembly dust cap (Fig 4).
Page 108 BRAKES 5 - 17 (6) Remove both lower brake shoe assembly to an- chor plate springs (Fig. 9). Fig. 7 Expand or Retract Adjuster Screw (5) Disconnect parking brake cable from parking brake lever (Fig. 8). Note: Only disconnect the Fig.
Page 109 5 - 18 BRAKES (8) Remove brake shoe assemblies, upper shoe to shoe return spring, automatic adjuster and adjuster lever from brake shoe support plate as an assembly (Fig. 11) Fig. 13 Automatic Adjuster Lever Shoes with lack of contact at toe or heel maybe improperly ground.
Page 110 BRAKES 5 - 19 (2) Assemble leading and trailing brake shoe as- to half specification. Then repeat the tightening se- quence to the full specified torque of 129 N m (95 ft. semblies, top shoe to shoe spring, automatic adjuster lbs.).
Page 111 5 - 20 BRAKES WHEEL CYLINDERS INDEX page page General Information ..... . . 20 Service Procedures ..... . . 20 Installing Wheel Cylinders .
Page 112 BRAKES 5 - 21 Fig. 3 Rear Wheel Cylinder ASSEMBLING WHEEL CYLINDERS (6) Install the wheel and tire assembly. Tighten the Before assembling the pistons and new cups in the wheel mounting stud nuts in proper sequence (Fig. 4) wheel cylinders, dip them in clean brake fluid. If the until all nuts are torqued to half specification.
Page 113: Brake Support Assembly
5 - 22 BRAKES BRAKE SUPPORT ASSEMBLY REMOVAL (1) Remove rear tire and wheel assembly from ve- hicle. (2) Remove rear hub and bearing assembly dust cap (Fig 5). Then remove cotter pin and nut lock from spindle. Fig. 7 Remove or Install Automatic Adjuster Lever Fig.
Page 114 BRAKES 5 - 23 (2) Install support plate and gasket on rear suspen- until all nuts are torqued to half specification. This is sion knuckle casting. Torque support plate to knuckle important. Then repeat the tightening sequence to casting attaching bolts to 115 N m (85 ft. lbs). the full specified torque of 129 N m (95 ft.
Page 115 5 - 24 BRAKES HYDRAULIC SYSTEM CONTROL VALVES INDEX page page ABS Brake Proportioning Valve Operation ..24 Non-ABS Proportioning Unit Operation ..24 General Information .
Page 116 BRAKES 5 - 25 Each rear brake circuit has its own screw-in propor- HYDRAULIC SYSTEM SERVICE PROCEDURES tioning valve which is attached to the rear brake BRAKE WARNING SYSTEM outlet ports of the hydraulic control unit (HCU). The valves limit brake pressure to rear brakes after a CHECKING BRAKE WARNING SWITCH UNIT certain pressure is reached.
Page 117 5 - 26 BRAKES To test the proportioning valve when the right rear wheel slides first, leave the front brakes connected to the valve, and proceed as follows: (1) Install one gauge and (TEE) of set C-4007-A between the brake line from the master cylinder sec- ondary port and the brake valve assembly (Fig.
Page 118 BRAKES 5 - 27 lowing chart, replace the valve. See (Fig. 4) for pro- portioning valve identification. Fig. 4 ABS Proportioning Valve Identification PROPORTIONING VALVE PRESSURES ABS-BRAKES PROPORTIONING VALVE PRESSURES NON-ABS BRAKES...
Page 119: Front Disc Brakes
5 - 28 BRAKES FRONT DISC BRAKES INDEX page page General Information ..... . . 28 Shoe and Lining Wear .
Page 120 BRAKES 5 - 29 Fig. 2 Disc Brake Caliper Mounting (Exploded View) The boot mounts in the cylinder bore opening and in a groove in the piston (Fig. 4). This prevents con- tamination in the bore area. As lining wears, master cylinder reservoir brake fluid level will go down.
Page 121 5 - 30 BRAKES If the brake shoe assemblies do not require replace- DISPOSE OF ALL DUST AND DIRT SUSPECTED ment. Reinstall, brake shoe assemblies making sure TO CONTAIN ANY ASBESTOS FIBERS IN SEALED each shoe assembly is returned to the original posi- BAGS OR CONTAINERS TO MINIMIZE DUST EXPO- tion on the vehicle.
Page 122: Kelsey Hayes Double Pin Caliper Assembly
BRAKES 5 - 31 KELSEY HAYES DOUBLE PIN CALIPER ASSEMBLY INDEX page page Brake Shoe Service Procedures ....31 Disc Brake Caliper Service ....33 Caliper Assembly Inspection .
Page 123 5 - 32 BRAKES Fig. 6 Removing Inboard Brake Shoe (3) Install the front braking disc (rotor) on the hub, making sure it is squarely seated on face of hub (Fig. (4) Remove the protective paper from the noise sup- pression gasket on both the inner and outer brake Fig.
Page 124 BRAKES 5 - 33 Fig. 8 Installing Inboard Brake Shoe Assembly Fig. 10 Installing Caliper Assembly On Steering Knuckle And Rotor Fig. 9 Installing Outboard Brake Shoe Assembly (7) Carefully position caliper and brake shoe as- semblies over braking disc (rotor) using the reversed required removal procedure (Fig.
Page 125 5 - 34 BRAKES (3) If both front caliper pistons are to be removed. Disconnect steel brake tube fitting from flexible brake line at frame bracket after removing piston. Plug brake tube and remove piston from opposite caliper. Using the same process as above for the first piston removal.
Page 126 BRAKES 5 - 35 (4) If the bore does not clean up within this specifi- cation, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid.
Page 127 5 - 36 BRAKES Fig. 4 Folded Caliper Guide Pin Bushing (2) Using your fingers insert the folded bushing into the caliper assembly (Fig. 5). Do not use a Fig. 2 Pushing Piston into Bore sharp object to perform this step do to possible (6) Position dust boot in counterbore of the caliper damage to the bushing.
Page 128 BRAKES 5 - 37 (3) Holding the sleeve in place work the other end of the bushing over the end of the sleeve and into the seal grove (Fig. 8). Be sure the other end of the bushing did not come out of the seal grove in the sleeve.
Page 129 5 - 38 BRAKES REAR DISC BRAKES INDEX page page Assembling Rear Disc Brake Caliper ..43 General Information ..... . . 38 Caliper Assembly Inspection .
Page 130 BRAKES 5 - 39 is returned to its original position on the wheel of (3) Remove the 2 caliper assembly to adapter guide the vehicle from which it was removed. (See Brake pin bolts (Fig. 1). Shoe Installation). SERVICE PRECAUTIONS WARNING: DUST AND DIRT ON BRAKE PARTS GENERATED DURING THE NORMAL USE AND WEAR OF MOTOR VEHICLE BRAKE SYSTEMS CAN...
Page 131 5 - 40 BRAKES Fig. 5 Removing Outboard Shoe Fig. 3 Storing Caliper Fig. 6 Removing Inboard Shoe place if they are damaged, dry, or found to be brittle. Refer to Cleaning And Inspection Of Brake Caliper. BRAKE SHOE INSTALLATION (1) Completely retract caliper piston back into pis- Fig.
Page 132 BRAKES 5 - 41 Fig. 9 Installing Outboard Brake Shoe Assembly Fig. 7 Installing Rear Braking Disc removal procedure (Fig. 10). Make sure that caliper (5) Install the new inboard brake shoe assembly guide pin bolts, bushings and sleeves are clear of the into the caliper piston by firmly pressing into piston adapter bosses.
Page 133 5 - 42 BRAKES CALIPER BORE. PERSONAL INJURY COULD RE- SULT FROM SUCH A PRACTICE. (4) Disconnect brake flexible hose from the caliper. To disassemble, mount caliper assembly in a vise equipped with protective jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
Page 134 BRAKES 5 - 43 The double pin caliper uses a sealed for life bushing CLEANING AND INSPECTION and sleeve assembly. If required this assembly can be Clean all parts using alcohol or a suitable non- serviced using the following procedure. petroleum based solvent and wipe dry.
Page 135 5 - 44 BRAKES (2) Dip new piston seal in clean brake fluid and (6) Position dust boot in counterbore of the caliper piston bore. install in the groove of the caliper bore. Seal should (7) Using a hammer and Installer Piston Caliper be positioned at one area in groove and gently worked Boot, Special Tool C-4383-7 and Handle, Special Tool around the groove (Fig.
Page 136 BRAKES 5 - 45 Fig. 12 Installing Caliper Sleeves Fig. 10 Installing Caliper Guide Pin Sleeve Bushings 13) until the one end of the bushing is fully seated the caliper assembly. Flanges should be seated evenly into the seal groove on the one end of the sleeve. on both sides of the bushing hole in the caliper as- (3) Holding the sleeve in place work the other end sembly (Fig.
Page 137 5 - 46 BRAKES tween your fingers and easily slid back and forth (7) Install brake hose onto caliper using banjo bolt. without the bushing seal unseating from the sleeve. Torque the brake hose to caliper assembly banjo bolt (5) Install the inboard and outboard brake shoes to 33 N m (24 ft.
Page 138 BRAKES 5 - 47 BRAKE DISC (ROTOR) INDEX page page Braking Disc Removal ..... 48 Installing Braking Disc ..... 48 General Information .
Page 139 5 - 48 BRAKES nuts in the proper sequence and torque to specifica- tions. Finally, check runout of disc to see if runout is now within specifications. Fig. 2 Marking Braking Disc and Wheel Stud Install Dial Indicator, Special Tool C-3339 and Mounting Adaptor, Special Tool SP-1910 on steering Fig.
Page 140 BRAKES 5 - 49 Fig. 5 Checking Disc for Thickness (2) Install caliper assembly, as described in Brake Shoe Installation paragraph. Fig. 6 Refacing Braking Disc REFINISHING BRAKING DISC REFACING BRAKING DISC Refacing of the braking disc is not required each time the shoe assemblies are replaced.
Page 141 5 - 50 BRAKES 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 05-12-94 June 10, 1994 All front braking discs have markings for able diameter cast on an un-machined surface of the braking disc (Fig. 9). The thickness mark- minimum allowable thickness cast on an un- ings may be located on the disc as shown in machined surface of the braking disc (Fig.
Page 142 BRAKES 5 - 51 PARKING BRAKES INDEX page page Front Park Brake Cable Service ....55 Parking Brake Shoe Service with Rear Disc General Information ..... . . 51 Brakes .
Page 143 5 - 52 BRAKES...
Page 144 BRAKES 5 - 53 SERVICE PROCEDURES ADJUSTING PARKING BRAKE The parking brake foot lever assembly used on all L.H. platform vehicles, with and without rear disc brakes contains a self adjuster for the cable system. Routine parking brake cable adjustment on all L.H. platform vehicles is not required.
Page 145 5 - 54 BRAKES Apply and release the park brake lever several times. The rear wheels should rotate freely without dragging. PARK BRAKE PEDAL MECHANISM REMOVE (1) Reload parking brake mechanism self adjuster using steps 3, 4, 5 and 6 listed under Reloading Self Adjuster in this section of the service manual.
Page 146 BRAKES 5 - 55 Fig. 11 Sill Molding And Cowl Area Molding Fig. 9 Park Brake Pedal Mechanism rapid pull. When locking pin is removed from park brake pedal mechanism, the park brake mechanism and park brake cables will automatically adjust. See parking brake adjustment procedure in this section of the service manual for complete park- ing brake adjustment procedure.
Page 147 5 - 56 BRAKES The throttle pedal and bracket have to be re- (3) Remove the front park brake cable to reaction bracket retaining clip, by prying it off cable using a moved from the dash panel to allow carpet to be screwdriver (Fig.
Page 148 BRAKES 5 - 57 Fig. 19 Park Brake Cable Removal From Park Brake Mechanism Fig. 17 Park Brake Mechanism Mounting Fig. 20 Park Brake Cable Installed On Pedal Assembly (3) Install park brake cable to park brake pedal mechanism retaining clip (Fig. 21). Be sure retaining clip is fully installed on park brake cable.
Page 149 5 - 58 BRAKES (4) Install park brake pedal mechanism onto the 2 (7) Install the park brake cable routing clip to floor loosened mounting bolt on cowl panel (Fig. 22). Install pan attaching screw (Fig. 24). Torque the routing clip the park brake pedal assembly retaining bolt into to floor pan attaching screw to 4 N m (35 in.
Page 150 BRAKES 5 - 59 5 PASSENGER MODELS (4) Install upper center console cover assembly back in vehicle. Refer to group 23 Body in this service (1) Fold carpeting back into position on left floor manual for required procedure to install upper center pan of vehicle.
Page 151 5 - 60 BRAKES parking brake adjustment procedure. On drum- in-hat type of rear disc brake adjust shoe diameter to 171.5 mm (6.75 inch). REAR PARK BRAKE CABLE SERVICE DRUM BRAKES Note: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required, to connect park brake cables to equalizer or park brake lever.
Page 152 BRAKES 5 - 61 (10) Remove rear seat lower cushion from vehicle. Refer to group 23 Body in this service manual for required lower seat cushion, removal procedure. (11) Remove both lower rear door opening sill mold- ings to allow rear section of carpeting to be folded forward.
Page 153 5 - 62 BRAKES 5 PASSENGER MODELS (5) Install upper center console cover assembly back in vehicle. Refer to group 23 Body in this service manual for required procedure to install upper center console. (6) Install shift knob on floor shifter (if equipped). Shift knob is installed by pushing shift knob down shift shaft until fully bottomed.
Page 154 BRAKES 5 - 63 adjustment procedure in this section of the service manual for complete parking brake adjustment proce- dure. DISC BRAKES Note: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required, to connect park brake cables to equalizer or park brake lever.
Page 155 5 - 64 BRAKES (13) Remove rear seat lower cushion from vehicle. Refer to Group 23 Body in this service manual for required lower seat cushion, removal procedure. (14) Remove both lower rear door opening sill mold- ings to allow rear section of carpeting to be folded forward.
Page 156 BRAKES 5 - 65 Fig. 7 Park Brake Cable Removal From Floor Pan Fig. 10 Park Brake Cables Connected To Equalizer (5) Install parking brake shoe assemblies on the rear disc brake adapter. See Removal And Installa- tion Parking Brake Shoes in this section of the ser- vice manual for the parking brake shoe assembly installation procedure.
Page 157 5 - 66 BRAKES Fig. 11 Park Brake Equalizer And Cover (16) Install drivers side seat assembly back in ve- hicle. (17) Return the driver and passenger side seats back to their original positions. (18) When repairs are complete, adjust rear brakes Fig.
Page 158 BRAKES 5 - 67 (9) Remove lower parking brake, shoe to shoe spring (Fig. 3). Fig. 5 Removing Front Holddown Clip And Shoe INSTALLING PARKING BRAKE SHOES Fig. 3 Removing Lower Spring (1) Install front parking brake shoe and holddown clip (Fig.
Page 159 5 - 68 BRAKES Fig. 7 Installing Upper Spring Fig. 9 Installing Adjuster Assembly (3) Pull rear parking brake shoe over anchor block until properly located on adapter. (4) Install lower parking brake, shoe to shoe return spring (Fig. 8). Fig.
Page 160 BRAKES 5 - 69 MASTER CYLINDER INDEX page page Brake Fluid Level Sensor ....69 Master Cylinder Service Procedures ... 70 General Information .
Page 161 5 - 70 BRAKES MASTER CYLINDER SERVICE PROCEDURES Do not pry off fluid reservoir using a tool, damage to reservoir may result. MASTER CYLINDER REMOVAL (1) Disconnect primary and secondary brake tubes from master cylinder housing. Install plugs at brake tube outlets.
Page 162 BRAKES 5 - 71 (2) Fill reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or Equivalent. (3) Using a wooden dowel per (Fig. 7). Depress master cylinder pistons slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled (Fig.
Page 163: Power Brakes
5 - 72 BRAKES POWER BRAKES GENERAL INFORMATION The purpose of the vacuum operated power brake booster. Is to reduce the amount of force applied to the brake pedal by the drivers foot. To obtain the required hydraulic pressure in the brake system to stop the vehicle.
Page 164 BRAKES 5 - 73 Fig. 3 Master Cylinder Mounting (7) From under instrument panel, position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. (8) Rotate screwdriver enough to allow retainer clip Fig.
Page 165: Rear Disc Brakes
5 - 74 BRAKES WHEEL BEARINGS FRONT WHEEL BEARINGS (2) Remove rear hub and bearing assembly cotter Front wheel drive vehicles are equipped with per- pin, nut retainer and hub/bearing assembly retaining manently sealed front wheel bearings. There is no nut and washer (Fig.
Page 166 ANTI-LOCK BRAKE SYSTEM 5 - 75 ANTI-LOCK BRAKE SYSTEM—TEVES MARK IV SYSTEM INDEX page page ABS Brake System Diagnosis ....89 Hydraulic Circuits and Valve Operation .
Page 167 5 - 76 ANTI-LOCK BRAKE SYSTEM hydraulic pressure at each wheel brake. Depending on signals generated by the wheel speed sensors (WSS) at each wheel and received at the Controller Anti-Lock Brake (CAB). MAJOR COMPONENTS The following is a list of major system components. Details of all components can be found later in this section.
Page 168 ANTI-LOCK BRAKE SYSTEM 5 - 77 The pump/motor assembly (Fig. 4) consists of an electric motor with a rotation sensor and a dual pis- ton pump. The motor shaft inside the pump is de- signed as a cam in order to drive both pistons. The rotation sensor is an inductive pick-up used by the (CAB) to monitor pump/motor operation.
Page 169 5 - 78 ANTI-LOCK BRAKE SYSTEM slip may result in some tire chirping, depending on the road surface. This sound should not be inter- preted as total wheel lock-up. Complete wheel lock up normally leaves black tire marks on dry pavement. The Anti-Lock Braking Sys- tem will not leave dark black tire marks since the wheel never reaches a locked condition.
Page 170 ANTI-LOCK BRAKE SYSTEM 5 - 79 • Pump Motor Running Without Command DIAGNOSTIC MODE • Pedal Travel Sensor Circuit To enter diagnostic mode, vehicle must be below 10 • Valve Fault (8/10) MPH. If vehicle speed is not below 10 MPH a no •...
Page 171 5 - 80 ANTI-LOCK BRAKE SYSTEM BRAKE WARNING LAMP block assembly, the pump/motor assembly, and a fluid reservoir with a fluid level switch. The red BRAKE Warning Lamp is located in the Instrument Panel. It can be activated in several ways.
Page 172 ANTI-LOCK BRAKE SYSTEM 5 - 81 Control (Isolation) valves. The Traction Control (Iso- PROPORTIONING VALVES lation) valves are spring loaded in the open position. Two Proportioning Valves (Fig. 2 and 3) are used in During traction control operation the traction control the system, one for each rear brake hydraulic circuit.
Page 173 5 - 82 ANTI-LOCK BRAKE SYSTEM duce inaccurate wheel speed signals. However, the system will continue to function correctly when using the mini-spare. Fig. 4 Wheel Speed Sensors Fig. 1 Controller Anti-Lock Brakes The (CAB) on the LH is located in the engine com- partment, on the left front inner frame rail (Fig.
Page 174 ANTI-LOCK BRAKE SYSTEM 5 - 83 • Store diagnostic information non-volatile The (CAB) Outputs include the following: • Eight Valve/Solenoid Drivers (Ten with Traction memory. Control) The (CAB) continuously monitors the speed of each • Main Relay Actuation wheel. When a wheel locking tendency is detected, •...
Page 175 5 - 84 ANTI-LOCK BRAKE SYSTEM lay. If either relay is defective both relays must be The following hydraulic circuit drawings are only a replaced. They are serviced as an assembly. representation of the actual hydraulic circuits. Note that only the valves for the right front wheel brake are shown actuated for the various modes.
Page 176 ANTI-LOCK BRAKE SYSTEM 5 - 85 Fig. 2 Baseline Brakes - Hydraulic Control Fig. 3 Pressure Hold - Hydraulic Control...
Page 177 5 - 86 ANTI-LOCK BRAKE SYSTEM Fig. 4 Pressure Decay - Hydraulic Control ABS BRAKING-PRESSURE DECAY tion is detected at the right front wheel only, the If the wheel locking tendency continues, the (CAB) (CAB) will close the left front inlet valve to prevent releases the pressure by opening the normally closed unneeded application of the brake at that wheel.
Page 178 ANTI-LOCK BRAKE SYSTEM 5 - 87 Fig. 5 Pressure Build - Hydraulic Control Fig. 6 Traction Control Pressure Build - Hydraulic Control...
Page 179 5 - 88 ANTI-LOCK BRAKE SYSTEM Fig. 7 Traction Control Pressure Hold - Hydraulic Control Fig. 8 Traction Control Pressure Decay - Hydraulic Control...
Page 180 ANTI-LOCK BRAKE SYSTEM 5 - 89 ABS BRAKE SYSTEM DIAGNOSIS DEFINITIONS Several abbreviations are used in this manual. GENERAL INFORMATION They are presented here for reference. • HCU—Hydraulic Control Unit WARNING: SOME OPERATIONS IN THIS SECTION • CAB—Controller Anti-Lock Brake REQUIRE THAT HYDRAULIC TUBES, HOSES AND •...
Page 181 5 - 90 ANTI-LOCK BRAKE SYSTEM Amber ABS Warning Lamp goes on refer to the 1994 Most intermittent faults are caused by faulty elec- M.Y. Teves Mark IV Anti-Lock Brakes Diagnostic trical connections or wiring. When an intermittent Manual. fault is encountered, check suspect circuits for: (3) If the Amber ABS Warning Lamp remains OUT, (1) Poor mating of connector halves or terminals drive the vehicle a short distance.
Page 182 ANTI-LOCK BRAKE SYSTEM 5 - 91 If any component exhibits a fault during system See testing procedures outlined in the Teves Mark IV initialization or dynamic check, the (CAB) will illumi- Anti-Lock Brakes Diagnostics Manual for 1994 M.Y. nate the Anti-Lock warning lamp and Traction Con- vehicles.
Page 183 5 - 92 ANTI-LOCK BRAKE SYSTEM During bleeding operations, be sure that the brake HYDRAULIC CONTROL UNIT (HCU) fluid level remains close to the FULL level in the REMOVE reservoir. Check the fluid level periodically during the (1) Center vehicle on hoist, or raise front of vehicle bleeding procedure and add DOT 3 brake fluid as on jack stands.
Page 184 ANTI-LOCK BRAKE SYSTEM 5 - 93 a screwdriver, lift connector latch away from connec- tor (Fig. 3) and rotate connector latch all the way back against (CAB). This will lift the (CAB) connec- tor away from (CAB) terminals. Fig. 5 Brake Tube Connections At Proportioning Valves Fig.
Page 185 5 - 94 ANTI-LOCK BRAKE SYSTEM (4) Remove plug from end of brake fluid supply hose going to reservoir at (HCU). Connect supply hose on (HCU) reservoir nipple and install hose clamp on hose. Be sure clamp is past bead on nipple of (HCU) fluid reservoir.
Page 186 ANTI-LOCK BRAKE SYSTEM 5 - 95 Fig. 14 Tightening Wheel Nuts CAUTION: Heat shield MUST be installed when ser- vicing of (HCU) is completed. Failure to install heat shield could result in a failure of the (CAB) due to high temperature. Fig.
Page 187 5 - 96 ANTI-LOCK BRAKE SYSTEM hole in fluid reservoir (Fig. 2). Note: If replacing reservoir on a (HCU) with traction control, drive pin completely out of pump housing. Fig. 4 Installing (HCU) Fluid Reservoir Fig. 2 Removing (HCU) Reservoir Retaining pin (4) Insert a screwdriver between pump housing and reservoir (Fig.
Page 188 ANTI-LOCK BRAKE SYSTEM 5 - 97 uum before pedal travel sensor can be removed. Failure to do this may result in the pedal travel sensor, sealing O-Ring being sucked into the brake vacuum booster. If the pedal travel sensor sealing O-Ring falls into the vacuum booster the booster will need to be replaced.
Page 189 5 - 98 ANTI-LOCK BRAKE SYSTEM (2) Remove required proportioning valve from valve block of (HCU) (Fig. 7). Fig. 5 Sealing O-Ring Location In Mounting Grommet MASTER CYLINDER AND POWER BOOSTER Fig. 7 Proportioning Valve Removal And REMOVAL AND INSTALLATION Replacement The power booster used on this vehicle with Anti- INSTALLATION...
Page 190 ANTI-LOCK BRAKE SYSTEM 5 - 99 (4) Bleed the air from brake hydraulic system. Re- fer to the Bleeding Teves Mark IV Anti-Lock Brake System in this section of the manual for proper bleed- ing procedure. When bleeding brake system visu- ally inspect all line fittings previously discon- nected for any signs of leakage.
Page 191 5 - 100 ANTI-LOCK BRAKE SYSTEM Fig. 4 System Relay/Warning Lamp Relay Location Fig. 5 Front Speed Sensor Cable Retaining Clip (2) Holding the relays with one hand, push the wiring harness connector strait onto the terminals of the relay. Make sure the connector is fully seated onto the terminals of the relay.
Page 192 ANTI-LOCK BRAKE SYSTEM 5 - 101 Fig. 8 Speed Sensor Head Removal (Typical) Fig. 9 Tightening Wheel Nuts CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers, as shown in this section, may result in contact with moving parts and/or over extension of cables, resulting in an open circuit.
Page 193 5 - 102 ANTI-LOCK BRAKE SYSTEM (5) Remove speed sensor head, attaching bolt from (7) Remove speed sensor cable assembly from ve- hicle. rear adapter (Fig. 12). Then remove rear speed sensor head from adapter. If the sensor has seized, due to INSTALLATION corrosion, DO NOT USE PLIERS ON SENSOR (1) Coat speed sensor where it slides into adapter...
Page 194 ANTI-LOCK BRAKE SYSTEM 5 - 103 SPECIFICATIONS BRAKE ACTUATION SYSTEM SPECIFICATIONS METRIC TIGHTENING REFERENCE...
Page 196 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page ACCESSORY DRIVE BELTS ....19 SERVICE PROCEDURES ....8 ENGINE BLOCK HEATER .
Page 197 7 - 2 COOLING SYSTEM COOLING SYSTEM DIAGNOSIS...
Page 198 COOLING SYSTEM 7 - 3 COOLING SYSTEM DIAGNOSIS...
Page 199 7 - 4 COOLING SYSTEM COOLING SYSTEM DIAGNOSIS...
Page 200 COOLING SYSTEM 7 - 5 COOLING SYSTEM DIAGNOSIS...
Page 201 7 - 6 COOLING SYSTEM COOLING SYSTEM DIAGNOSIS...
Page 202 COOLING SYSTEM 7 - 7 COOLING SYSTEM DIAGNOSIS...
Page 203 7 - 8 COOLING SYSTEM SERVICE PROCEDURES INDEX page page Automatic Transmission Oil Cooler ... . 18 Electric Fan Motor ......18 Coolant .
Page 204 COOLING SYSTEM 7 - 9 (5) Install drive belt. See Accessory Drive Belts this group. (6) Install right front lower fender shield. (7) Refill Cooling System. See Refilling Cooling System in this section. WATER PUMP—3.5L ENGINE The 3.5L pump bolts directly to the engine block, using a O-ring gasket for pump to block sealing (Fig.
Page 205 7 - 10 COOLING SYSTEM failed open, code 17 will be set. Do not change a COOLANT The cooling system is designed around the coolant. thermostat for lack of heat by gauge or heater perfor- The coolant must accept heat from engine metal, in mance, unless code 17 is present, see diagnosis for the cylinder head area near the exhaust valves.
Page 206 COOLING SYSTEM 7 - 11 SELECTION AND ADDITIVES the bleed valve in the thermostat. Route the hose The use of aluminum cylinder heads, intake mani- away from the accessory drive belt, drive pulleys and folds, and water pumps requires special corrosion pro- electric cooling fan.
Page 207 7 - 12 COOLING SYSTEM DEAERATION Air is removed from the system as it gathers in the coolant deaeration pressure bottle and is released into the atmosphere through the pressure valve located in the pressure cap when pressure reaches 97-124 kPa (16-18 psi.).
Page 208 COOLING SYSTEM 7 - 13 Fig. 2 Filling Cooling System (3) Attach one end of a 6.35 mm (.250 in.) ID clear hose that is approximately 1219 mm (48 in.) long, to the bleed valve in the thermostat (Fig. 3). Route the hose away from the accessory drive belt, drive pulleys and electric cooling fan.
Page 209 7 - 14 COOLING SYSTEM COOLANT DEAERATION PRESSURE BOTTLE This system works in conjunction with the coolant deaeration pressure bottle pressure cap to keep the coolant free of trapped air. It provides a volume for expansion and contraction and provides a convenient and safe method for checking coolant level and ad- justing level at atmospheric pressure.
Page 210 COOLING SYSTEM 7 - 15 RADIATORS The radiators are cross-flow types (horizontal tubes) with design features that provide greater strength as well as sufficient heat transfer capabilities to keep the engine satisfactorily cooled. CAUTION: Plastic tanks, while stronger than brass are subject to damage by impact, such as wrenches.
Page 211 7 - 16 COOLING SYSTEM the end of its threads, turn back 1/8 turn and pull the stem (Fig. 9) from the radiator tank. INSTALLATION (1) Push the draincock assembly body into the tank opening until it snaps into place. (2) Tighten the draincock stem by turning clock- wise until it stops.
Page 212 COOLING SYSTEM 7 - 17 clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended.
Page 213 7 - 18 COOLING SYSTEM not be damaged by excessive force. Surface or burr removal may be required to remove fan from motor shaft. (Fig. 14). Do not permit the fan blades to touch the bench. (2) To install fan on motor shaft, slide the fan over shaft.
Page 214 COOLING SYSTEM 7 - 19 ACCESSORY DRIVE BELTS INDEX page page 3.3/3.5L Engine Accessory Drive Belt Service ..19 General Information ..... . . 19 ACCESSORY DRIVE BELTS DIAGNOSIS GENERAL INFORMATION The Poly-V generator/power steering and water...
Page 215 7 - 20 COOLING SYSTEM Fig. 2 Accessory Drive— 3.3L Engine Fig. 4 Accessory Drive—3.5L Engine by loosening the tensioner pulley nut and adjustment bolt (Fig. 4). Reverse procedure to install and tighten belt to specified tension. AIR CONDITIONING BELT— 3.3/3.5L ENGINES (1) Remove the generator/power steering pump and water pump drive belt to gain access to the air condi- tioning drive belt.
Page 216 COOLING SYSTEM 7 - 21 ENGINE BLOCK HEATER DESCRIPTION AND OPERATION (2) Insert heater assembly with element loop posi- tioned upward. On all models an engine block heater is available as (3) With heater seated, tighten center screw se- an optional accessory. The heater, operated by ordinary curely to assure a positive seal.
Page 217 7 - 22 COOLING SYSTEM SPECIFICATIONS TORQUE COOLING SYSTEM CAPACITY...
Page 218 COOLING SYSTEM 7 - 1 COOLING SYSTEM RADIATOR (8) Disconnect automatic transmission hoses from cooler and plug off. REMOVAL (9) Disconnect the fan wiring connector from the (1) Disconnect negative battery cable from battery. RFI module. (10) Disconnect and cap A/C lines to condenser. (2) Remove the sight shield from the radiator Refer to Group 24 Heating and Air Conditioning for crossmember (Fig.
Page 220 ELECTRICAL 8A - 1 ELECTRICAL GROUP INDEX AUDIO SYSTEMS ......8F POWER MIRRORS ..... . . 8T BATTERY/STARTER/GENERATOR SERVICE .
Page 221 8A - 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS the powertrain control module. The powertrain con- trol module will store in electronic memory, any de- tectable failure within the monitored circuits. It will retain this information for a period of 50 engine starts, then erase the memory if the failure does not reoccur during that period.
Page 222 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3 BATTERY TEST PROCEDURES ON-VEHICLE INDEX page page Battery Charging ......7 General Information .
Page 223 8A - 4 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS It is important when using the Test Indicator that days the Main Fusible Link Connector (Fig. 6) should the battery be level and have a clean top to see the be disconnected. This is located near the battery on correct indications.
Page 224 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 5 Fig. 7 Battery Diagnostics...
Page 225 8A - 6 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 8 Testing Open Circuit Voltage Fig. 10 Volt-Ammeter-Load Tester (2) Using a voltmeter connected to the battery posts and measure the open circuit voltage (Fig. 8). This voltage reading will show the state of charge of the battery.
Page 226 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 7 WARNING: DO NOT CHARGE A BATTERY THAT HAS EXCESSIVELY LOW ELECTROLYTE LEVEL. BATTERY MAY SPARK INTERNALLY AND EX- PLODE. EXPLOSIVE GASES FORM OVER THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR BATTERY. DO NOT ASSIST BOOST OR CHARGE A FROZEN BATTERY.
Page 227 8A - 8 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Group. If the battery will endure a load test, return CHARGING COMPLETELY DISCHARGED BATTERY the battery to use. If battery will not endure a load The following procedure should be used to recharge test, it must be replaced. Properly clean and inspect a completely discharged battery.
Page 228 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 9 IGNITION OFF DRAW (IOD) GENERAL INFORMATION Each time the test light or milliamp meter is dis- A completely normal vehicle will have a small connected and connected, all electronic timer func- amount of current drain on the battery with the key tions will be activated for approximately one minute.
Page 229 8A - 10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS (9) Remove both fuses (J and A). • Interior/brake lamp fuse J (20 Amp) • Powertrain control module fuse A (20 Amp) If there is any reading, with fuses removed there is a short circuit in the wiring. Refer to Group 8W, wiring diagrams.
Page 230 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11 STARTER TEST PROCEDURES ON VEHICLE INDEX page page Diagnostic Preparation ..... 11 Starter Control Circuit Tests .
Page 231 8A - 12 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 3 Starter System Diagnostics Fig. 4 Volt Ampere Tester Fig. 5 Volt-Ampere Tester Connections • If voltage reads 12.4 volts or greater and amperage VEHICLES WITH DIRECT IGNITION SYSTEM: Disconnect the ignition coils electrical connector (Fig. reads 0 to 10 amps, go to starter control circuit test.
Page 232 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 13 Fig. 8 Starter Draw Tests Fig. 6 3.3L Engine Electrical Connection Fig. 9 Test Battery Connection Resistance Observe the voltmeter. If voltage is detected, correct Fig. 7 3.5L Engine Electrical Connection poor contact between cable clamp and post. coil connector.
Page 233 8A - 14 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 10 Test Ground Circuit Resistance Fig. 12 Test Positive Battery Cable Resistance STARTER SOLENOID TEST WARNING: CHECK TO ENSURE THAT THE TRANS- MISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED (1) Verify battery condition.
Page 234 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 15 (7) Remove the starter relay from the power distri- NEUTRAL STARTING AND BACK-UP SWITCH bution center. Refer to Starter Relay Tests for electrical diagnos- (8) Connect a remote starter switch or a jumper tics, when checking starter circuits (Fig. 14). wire between the battery positive post and terminal D For removal and installation of neutral switch, refer on the starter relay connector (Fig.
Page 235 8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 14 Starter Relay Tests...
Page 236 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 17 Fig. 15 Field Coil Wire Terminal—Melco Fig. 18 Continuity Test Between Solenoid Terminal and Field Coil Terminal—Nippondenso Fig. 19 Continuity Test Between Solenoid Terminal Fig. 16 Field Coil Wire Terminal—Nippondenso and Solenoid Case —Melco Fig.
Page 237 8A - 18 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS GENERATOR TEST PROCEDURES ON VEHICLE CHARGING SYSTEM DIAGNOSTICS (Fig. 1) test may be performed at each connection to locate a connection with excessive voltage drop. If voltage OUTPUT WIRE VOLTAGE DROP TEST drop tests are satisfactory, reduce engine speed, turn The generator output wire voltage drop test shows OFF blower motor, headlamps and ignition switch.
Page 238 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 19 Fig. 1 Charging Diagnostics...
Page 239 8A - 20 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 4 Output Voltage Test Fig. 2 Wiring Connections Fig. 3 Voltage Drop Test...
Page 240 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 21 FAULT CODES—ON BOARD DIAGNOSTICS INDEX page page DRB Diagnostic Tester ..... 21 Testing Using Diagnostic Trouble Codes .
Page 241 8A - 22 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 6 Generator Diagnostic Trouble Codes...
Page 242 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 23 Fig. 7 Check For Inadequate/Low Charging...
Page 243 8A - 24 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 8 Check For Overcharging...
Page 244 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 25 Fig. 9 Powertrain Control Connector Fig. 11 Diagnostic Connector Location Fig. 10 Electrical Resistance Test...
Page 245 8A - 26 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS SPECIFICATIONS BATTERY TORQUE SPECIFICATIONS STARTER...
Page 246 BATTERY/STARTER/GENERATOR SERVICE 8B - 1 BATTERY/STARTER/GENERATOR SERVICE CONTENTS page page BATTERY ....... 1 STARTER .
Page 247 8B - 2 BATTERY/STARTER/GENERATOR SERVICE Fig. 3 Battery Heat Shield/Hold-Down/Tray Fig. 5 Cleaning Battery Posts Fig. 4 Cleaning Battery (9) Clean inside surfaces of battery terminal clamps with a suitable battery terminal cleaning tool Fig. 6 Cleaning Battery Cable Terminal (Fig.
Page 248 BATTERY/STARTER/GENERATOR SERVICE 8B - 3 Fig. 7 Battery Cables Disconnected STARTER INDEX page page General Information ......3 Starter Relay .
Page 249 8B - 4 BATTERY/STARTER/GENERATOR SERVICE (8) Remove the starter from vehicle. (9) For installation, reverse above procedures. Clean corrosion/dirt from the cable and wire termi- nals before installing wiring to the solenoid. MELCO STARTER SOLENOID REPLACEMENT (1) Disconnect field terminal (Fig. 3). (2) Remove wire terminal and battery cable nuts.
Page 250 BATTERY/STARTER/GENERATOR SERVICE 8B - 5 Fig. 6 Wire Terminal Connections Fig. 5 Starter—3.3L Engine GENERATOR INDEX page page General Information ......5 Generator Replacement—3.5L Engine .
Page 251 8B - 6 BATTERY/STARTER/GENERATOR SERVICE Fig. 2 Wire Terminal Connection Fig. 4 Generator—3.5L Engine Fig. 3 Generator—3.3L Engine (4) Loosen lower mounting bolt do not remove (Fig. 4). (10) Remove the B+ terminal nut and wire (Fig. 2). (5) Loosen pivot bolt, but do not remove. (11) For installation, reverse above procedures.
Page 252: Overhead Console
OVERHEAD CONSOLE 8C - 1 OVERHEAD CONSOLE CONTENTS page page AMBIENT TEMPERATURE SENSOR ..5 MINI CONSOLE ......4 BASE UNIT .
Page 253 8C - 2 OVERHEAD CONSOLE THERE ARE 6 DISPLAYS: SELF-DIAGNOSTIC TEST • Compass/Temperature (1) With the ignition switch in the OFF position • Average fuel economy simultaneously press the C/T and STEP buttons and • Distance to empty turn the ignition switch ON. •...
Page 254 OVERHEAD CONSOLE 8C - 3 TRIP ODOMETER netic tipped screwdriver, etc. If the roof becomes mag- netized use a demagnetizing Tool 6029 to demagne- OTIS receives trip odometer information from the tize the roof. body control module over the CCD lines. If OTIS In this demagnetizing procedure you will use the displays dashes -.- instead of the trip odometer value, demagnetizing tool to demagnetize the roof.
Page 255 8C - 4 OVERHEAD CONSOLE • The calibration procedure automatically sets the variance to 8. If you are in an area with a variance number other than 8 you must reset the variance. VARIANCE Variance is the difference between magnetic North and geographic North.
Page 256 OVERHEAD CONSOLE 8C - 5 (3) Remove lamp socket from mounting. (4) Remove switches by sliding them out of posi- tion. (5) For installation, reverse above procedures. OVERHEAD CONSOLE BASE REPLACEMENT (1) Remove overhead console, refer to above proce- dures. (2) Remove head liner refer to Group 23, Body.
Page 258: 3.3L And 3.5L Electronic Ignition System-System Operation
IGNITION SYSTEMS 8D - 1 IGNITION SYSTEMS CONTENTS page page 3.3L AND 3.5L ELECTRONIC IGNITION 3.3L AND 3.5L ELECTRONIC IGNITION SYSTEM—SYSTEM OPERATION ..1 SYSTEMS—SERVICE PROCEDURES ..10 3.3L AND 3.5L ELECTRONIC IGNITION IGNITION SWITCH AND INTERLOCK .
Page 259 8D - 2 IGNITION SYSTEMS POWERTRAIN CONTROL MODULE (PCM) when checked with at least a 1000 volt tester. For The powertrain control module (PCM) regulates the spark plug identification and specifications, Refer to ignition system (Fig. 2). The PCM supplies battery the Specifications section at the end of this group.
Page 260 IGNITION SYSTEMS 8D - 3 Fig. 4 Normal Operation and Cold (Carbon) Fouling Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 N m (20 ft. lbs.) torque.
Page 261 8D - 4 IGNITION SYSTEMS Fig. 8 Chipped Electrode Insulator Fig. 6 Electrode Gap Bridging Fig. 9 Preignition Damage Fig. 7 Scavenger Deposits PREIGNITION DAMAGE trodes (Fig. 6). Spark plugs with electrode gap bridg- Excessive combustion chamber temperature can ing can be cleaned and reused. cause preignition damage.
Page 262: Camshaft Position Sensor
IGNITION SYSTEMS 8D - 5 Fig. 10 Spark Plug Overheating Fig. 13 Camshaft Sprocket—3.3L Engine Fig. 11 Camshaft Position Sensor—3.3L Engine Fig. 12 Camshaft Position Sensor—3.5L Engine Fig. 14 Camshaft Sprocket—3.5L Engine CAMSHAFT POSITION SENSOR marks are next. After 3 camshaft pulses, the PCM The camshaft position sensor provides cylinder knows cylinder four crankshaft timing marks follow.
Page 263: Crankshaft Position Sensor
8D - 6 IGNITION SYSTEMS Fig. 17 Charge Air Temperature Sensor— Fig. 15 Camshaft Position Sensor Location— 3.5L Engine Only 3.3L Engine Fig. 18 Timing Slots FIg. 16 Camshaft Position Sensor Location— slots (Fig. 18). Basic timing is set by the position of 3.5L Engine the last slot in each group.
Page 264: Engine Coolant Temperature Sensor
IGNITION SYSTEMS 8D - 7 The PCM contains different spark advance sched- ules for cold and warm engine operation. The sched- ules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached.
Page 265: Manifold Absolute Pressure Sensor
8D - 8 IGNITION SYSTEMS Fig. 25 MAP Sensor—3.5L Engine Fig. 23 Knock Sensor Locations—3.5L Engine Only ground path for the solenoid side of the relays. Both MANIFOLD ABSOLUTE PRESSURE SENSOR relays turn on and off at the same time. The powertrain control module (PCM) supplies 5 The ASD relay connects battery voltage to the fuel volts to the MAP sensor.
Page 266 IGNITION SYSTEMS 8D - 9 3.3L AND 3.5L ELECTRONIC IGNITION SYSTEM—DIAGNOSTIC PROCEDURES INDEX page page Check Coil Test ......1 Engine Coolant Temperature Sensor Test .
Page 267 8D - 10 IGNITION SYSTEMS (Fig. 3). Secondary resistance should be 7,000 to MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST 15,800 ohms. Replace the coil if resistance is not Refer to the appropriate Powertrain Diagnostic Pro- within tolerance. cedure manual. ENGINE COOLANT TEMPERATURE SENSOR TEST CRANKSHAFT POSITION SENSOR AND CAMSHAFT Refer to the appropriate Powertrain Diagnostic Pro- POSITION SENSOR TESTS...
Page 268: Spark Plug Cables
IGNITION SYSTEMS 8D - 11 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-12-96 December, 1996 SPARK PLUG CABLE SERVICE—3.5L ENGINE The cables insulate the spark plugs and seal the top of the spark plug tube. A grooved tray routes the cables from the coil to each cylinder.
Page 269: Spark Plug Service
8D - 12 IGNITION SYSTEMS TESTING—ALL ENGINES conductive deposits. Conductive deposits can cause When testing cables for punctures and cracks with spark plug failure and engine misfire. Use a jewelers an oscilloscope, follow the instructions of the equip- file to remove deposits from the electrode gap. Use a ment manufacturers.
Page 270 IGNITION SYSTEMS 8D - 13 THROTTLE BODY MINIMUM AIR FLOW sprocket. While holding the sensor in this position, Refer to the General Diagnosis section of Group 14. install and tighten the retaining bolt to 12 N m (105 in. lbs.) torque. IGNITION TIMING PROCEDURE (2) Attach electrical connector to sensor.
Page 271 8D - 14 IGNITION SYSTEMS CRANKSHAFT POSITION SENSOR The crankshaft sensor is located on the passengers side of the transmission housing, above the differen- tial housing (Fig. 12). The bottom of the sensor sits abovethe drive plate. Fig. 14 Cylinder Identification (5) Reverse procedure for installation.
Page 272 IGNITION SYSTEMS 8D - 15 (4) Install intake manifold plenum. Refer to Intake Manifold Plenum in Group 11. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR On 3.3L engines, the MAP sensor threads into the rear of the intake manifold plenum (Fig. 18). On 3.5L engines, the MAP sensor threads into the left side of the intake manifold plenum (Fig.
Page 273 8D - 16 IGNITION SYSTEMS IGNITION SWITCH AND INTERLOCK INDEX page page Column Shift Interlock Service ....10 Ignition Interlock ......10 Floor Shift Interlock Adjustment .
Page 274 IGNITION SYSTEMS 8D - 17 Fig. 6 Ignition Lock Cylinder Detentes Fig. 4 Ignition Switch Removal/Installation Fig. 7 Lock Cylinder Removal Fig. 5 Ignition Switch Alignment (3) Remove the upper and lower covers from the LOCK KEY CYLINDER steering column. The lock cylinder is inserted in the end of the (4) Turn the ignition key to the run position.
Page 275 8D - 18 IGNITION SYSTEMS If the vehicle has column shift, install a new interlock cassette (column shift) when replacing the ignition lock cylinder. Adjust the system af- ter replacing the cassette. If the vehicle has floor shift, adjust the inter- lock cable after replacing the lock cylinder.
Page 276 IGNITION SYSTEMS 8D - 19 Fig. 10 Ignition Interlock Cassette—Column Shift Fig. 12 Ignition Interlock Adjustment Tab—Column Shift (4) Remove the tilt lever attaching screw. Remove lever. (5) Remove upper and lower covers from the steer- ing column. (6) Loosen the nut on the interlock adjustment le- ver in the floor shifter.
Page 277 8D - 20 IGNITION SYSTEMS Fig. 14 Interlock Cable at Ignition Switch Fig. 15 Interlock Cable at Floor Shifter Route the cable between the support strut and air (12) Install shifter handle. bag module mounting bracket and down to the (13) Install the lower silencer panel.
Page 278 IGNITION SYSTEMS 8D - 21 (11) Loosen the adjustment nut. Allow the cable to adjust itself to the correct position. Tighten the ad- justment nut. (12) Check the interlock adjustment: • With the ignition key in the OFF (lock) position, the shifter should be locked in the PARK position.
Page 279: Spark Plugs
8D - 22 IGNITION SYSTEMS 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-01-95 February, 1995 SPECIFICATIONS SPARK PLUG CABLE ROUTING—3.3L AND GENERAL INFORMATION 3.5L ENGINES The following specifications represent the latest in- formation available at the time of publication. If any- thing differs from the specifications on the Vehicle Emission Control Information Label, use the specifi- cations on the label.
Page 280 IGNITION SYSTEMS 8D - 1 IGNITION SYSTEMS IGNITION SWITCH AND INTERLOCK INDEX page page Column Shift Interlock Service ....3 Ignition Interlock ......3 Floor Shift Interlock Adjustment .
Page 281 8D - 2 IGNITION SYSTEMS Fig. 6 Ignition Lock Cylinder Detentes Fig. 4 Ignition Switch Removal/Installation cylinder is replaced. Refer to Floor Shift Interlock (2) Install and tighten ignition switch mounting Adjustment in this section. screws. (3) Attach electrical connector to ignition switch. REMOVAL (4) Install multi-function switch.
Page 282 IGNITION SYSTEMS 8D - 3 tion, the interlock system holds the transmission shifter in park. When the key is in the UNLOCK or RUN position the shifter unlocks and can be moved to any position. Also, if the shifter is not in PARK, the system prevents the operator from turning the ignition switch to the OFF or ACCESSORY positions.
Page 283 8D - 4 IGNITION SYSTEMS Fig. 10 Ignition Interlock Cassette—Column Shift Fig. 12 Ignition Interlock Adjustment Tab—Column Shift (3) Remove the cable from the locking arm on the If the system requires adjustment and not replace- shifter mechanism. ment, refer to the Floor Shift Interlock Adjustment INSTALLATION procedure in this section.
Page 284 IGNITION SYSTEMS 8D - 5 Fig. 14 Interlock Cable at Ignition Switch Fig. 15 Interlock Cable at Floor Shifter • Place the shifter in the PARK position. Turn the (10) Remove interlock cable. ignition key to the OFF (lock) position. You should INSTALLATION be able to remove the ignition key from the lock cyl- (1) Ensure ignition switch is in the On position.
Page 285 8D - 6 IGNITION SYSTEMS (10) Ensure the shift lever remains in PARK. Re- move the ignition key from the lock cylinder (switch in OFF position). When the adjustment nut on the interlock lever is loosened, the cable indexes itself to the correct posi- tion (Fig.
Page 286 INSTRUMENT PANEL AND GAUGES 8E - 1 INSTRUMENT PANEL AND GAUGES CONTENTS page page ASH RECEIVER/LAMP REMOVAL ... 11 INSTRUMENT PANEL END COVERS REMOVAL—RIGHT AND LEFT ... 10 ASH RECEIVER/LAMP REMOVAL—...
Page 287 8E - 2 INSTRUMENT PANEL AND GAUGES If the diagnostic procedure determines that a re- placement of an instrument cluster component is re- quired, refer to the Instrument Cluster Service Proce- dure. INSTRUMENT CLUSTER AND BEZEL REMOVAL To service any instrument cluster component, the instrument cluster must be removed from the instru- ment panel.
Page 288 INSTRUMENT PANEL AND GAUGES 8E - 3 Fig. 6 Cluster Bezel Fig. 7 Cluster Bezel—New Yorker imately 9 kilograms (20 lbs.) will be required to disen- SPEEDOMETER/TACHOMETER AND gage the cluster from the connectors. TRANSMISSION RANGE INDICATOR (8) For installation, reverse above procedures. REPLACEMENT—TYPE A AND C (1) Remove six cluster back cover retaining screws MASK/LENS REPLACEMENT—TYPE A AND C...
Page 289 8E - 4 INSTRUMENT PANEL AND GAUGES Fig. 8 Retaining Screws Fig. 10 Odometer (5) Remove speedometer/tachometer assembly from (4) Remove trip odometer reset knob by gently pull- cluster. The speedometer/tachometer assembly and ing rearward. the transmission range indicator is service as one (5) Remove screws attaching...
Page 290 INSTRUMENT PANEL AND GAUGES 8E - 5 (5) Remove tachometer and fuel/temperature gauge (2) Remove five cluster back cover retaining screws from the cluster. the remove cover (Fig. 11). (6) Remove speedometer from the cluster (Fig. 12). (3) Disconnect transmission range indicator and (7) For installation, reverse above procedures.
Page 291 8E - 6 INSTRUMENT PANEL AND GAUGES Fig. 16 Print Circuit Board—Type B Fig. 18 Lamp location—Type B Fig. 19 Message Center Module Fig. 17 Lamp location—Type A and C MESSAGE CENTER REMOVAL—NEW YORKER (1) Open front door and remove left end cover. (2) Remove headlamp switch bezel and center up- Fig.
Page 292 INSTRUMENT PANEL AND GAUGES 8E - 7 Fig. 23 Heater A/C Fan Relay TRACTION CONTROL SWITCH REMOVAL (1) Remove upper center outlet bezel (Figs. 24 and 25). (2) Press tabs at top and bottom of switch and remove switch from bezel. (3) Press retaining tab up and remove from wiring harness.
Page 293 8E - 8 INSTRUMENT PANEL AND GAUGES Fig. 24 Instrument Panel Breakdown...
Page 294 INSTRUMENT PANEL AND GAUGES 8E - 9 Fig. 25 Instrument Panel Breakdown—New Yorker...
Page 295 8E - 10 INSTRUMENT PANEL AND GAUGES Fig. 27 Top Cover and outlet to disengage end cover clips. Fuse Puller, Spare Fuses And Fuse Diagram Are Located On Left End Cover. Fuse Access Is Under Left End Cover (Figs. 24 and 25). (2) Open right door and remove right end cover by pulling from outlet vanes to disengage clips.
Page 296 INSTRUMENT PANEL AND GAUGES 8E - 11 CENTER UPPER OUTLET BEZEL REMOVAL (5) For installation, reverse above procedures. (1) Pull center bezel rearward and disengage the CIGAR LIGHTER REMOVAL two retaining clips and disconnect electrical connector (1) Remove lower slide out ash tray (Fig. 22). (Figs.
Page 297 8E - 12 INSTRUMENT PANEL AND GAUGES (2) Remove electrical connector and remove switch. When removing a passenger airbag module refer to (3) For installation, reverse above procedures. Group 8M, Passenger Airbag Module Removal. (1) Disconnect and isolate the battery negative HAZARD FLASHER RELAY REMOVAL cable.
Page 298 INSTRUMENT PANEL AND GAUGES 8E - 13 REMOTE KEYLESS ENTRY MODULE REMOVAL (1) Remove instrument panel top cover (Figs. 24, 25 and 27). (2) Remove two screws at each end of module, dis- connect two electrical connectors and remove module (Fig.
Page 299 8E - 14 INSTRUMENT PANEL AND GAUGES • Three ATC unit connectors at center of unit (8) Remove two screws at each end of instrument • Ground wire at left of center support panel at cowl sides, then detach lower instrument •...
Page 300: Audio System
AUDIO SYSTEM 8F - 1 AUDIO SYSTEM CONTENTS page page ANTENNAS ......13 SPEAKERS .
Page 301 8F - 2 AUDIO SYSTEM AM/FM STEREO—CASSETTE TAPE...
Page 302 AUDIO SYSTEM 8F - 3 AM/FM STEREO CONTINUED...
Page 303 8F - 4 AUDIO SYSTEM AM/FM STEREO CONTINUED AM/FM STEREO CONTINUED...
Page 304 AUDIO SYSTEM 8F - 5 INFINITY...
Page 305 8F - 6 AUDIO SYSTEM INFINITY CONTINUED...
Page 306 AUDIO SYSTEM 8F - 7 INFINITY CONTINUED...
Page 307 8F - 8 AUDIO SYSTEM INFINITY CONTINUED...
Page 308 AUDIO SYSTEM 8F - 9 INFINITY CONTINUED...
Page 309 8F - 10 AUDIO SYSTEM INFINITY CONTINUED...
Page 310 AUDIO SYSTEM 8F - 11 Fig. 1 Radio Connector Circuits...
Page 311 8F - 12 AUDIO SYSTEM RADIO REMOVAL (2) Remove two radio mounting screws (Fig. 3). (1) Remove center bezel by pulling straight back (Fig. 2). Fig. 3 Radio Assembly (3) Pull radio from panel and disconnect wiring, Fig. 2 Center Bezel Removal ground strap or wires and antenna lead from radio.
Page 312 AUDIO SYSTEM 8F - 13 ANTENNAS INDEX page page Manual Antennas Test ..... 13 Power Antenna Removal ....14 Power Antenna .
Page 313 8F - 14 AUDIO SYSTEM This antenna is actuated when the radio is switched fault. Remove the mast and verify that all the drive ON and with the ignition switch in ON or ACCESSORY teeth are intact. If not replace mast. position.
Page 314 AUDIO SYSTEM 8F - 15 grommets in use, check with parts catalog for proper POWER ANTENNA MAST REMOVAL grommet. If there is a water leak check for proper (1) Remove cap nut. grommet. (2) Turn ignition key to ACCESSORY position and (1) Disconnect battery negative cable.
Page 315 8F - 16 AUDIO SYSTEM SPEAKERS INDEX page page Amplifier Removal ......17 Door Mounted Speaker Replacement .
Page 316 AUDIO SYSTEM 8F - 17 (1) Remove parcel shelf panel, refer to Group 23, Body. Vehicles with grilles, pry up on grilles to re- move. (2) Remove four retaining screws (Fig. 13). Fig. 13 Rear Speakers (3) Disconnect wire connector and remove speaker. (4) For installation reverse above procedures.
Page 317 8F - 18 AUDIO SYSTEM • If resistance is less than two ohms, test speaker for CONDITION: ELECTRICAL NOISE DISTORTION ONE SPEAKER resistance. • Remove output signal connector from amplifier and • If OK repair wire. If not replace speaker. check for short to ground on the speaker with the CONDITION: ALL SPEAKERS NON-OPERATIVE distortion.
Page 318 HORNS 8G - 1 HORNS CONTENTS page page GENERAL INFORMATION ....1 HORN SWITCH TEST ..... 1 HORN RELAY REPLACEMENT .
Page 319 8G - 2 HORNS Fig. 2 Horn Diagnosis...
Page 320 HORNS 8G - 3 Fig. 3 Horn and Connector Fig. 5 Horn Relay Location HORN SWITCHES REPLACEMENT WARNING: BEFORE BEGINNING ANY AIRBAG SYS- TEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE CABLE FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS- TEM.
Page 322: Vehicle Speed Control System
VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page page CHECKING FOR DIAGNOSTIC TROUBLE CODE . 5 SERVO UNIT ......8 DIAGNOSIS PROCEDURES .
Page 323 8H - 2 VEHICLE SPEED CONTROL SYSTEM Fig. 3 Speed Control System—3.3L Engine gage the system. This will automatically maintain the A poor connection can cause a complete or intermittent desired speed. A CRUISE light in the instrument malfunction and is also the only connection in the cir- cluster will come on when the speed control is set.
Page 324 VEHICLE SPEED CONTROL SYSTEM 8H - 3 Fig. 4 System Diagnosis...
Page 325 8H - 4 VEHICLE SPEED CONTROL SYSTEM Fig. 5 System Diagnosis—Continued...
Page 326 VEHICLE SPEED CONTROL SYSTEM 8H - 5 • The Electrical Test at powertrain control module. Refer to the appropriate powertrain diagnostic manual. To determine the source of the problem. (3) If a diagnostic code 15 is observed, perform the test for a faulty vehicle speed sensor, refer to Group 8E, Instrument Panel.
Page 327 8H - 6 VEHICLE SPEED CONTROL SYSTEM Fig. 7 Servo Harness Connector (d) If voltage is OK, perform the speed control switch test. (e) If speed control switch is OK, test continuity across the clockspring. (f) If clockspring is OK, repair as wire between stop lamp switch and clockspring as necessary.
Page 328 VEHICLE SPEED CONTROL SYSTEM 8H - 7 pedal released, the meter should show continuity. If no continuity, perform the following test: (a) Check for continuity between pin 29 and pin 3 of the stop lamp switch connector. If no continuity, repair as necessary.
Page 329 8H - 8 VEHICLE SPEED CONTROL SYSTEM (3) If vacuum does not meet this requirement, check and correct the following vacuum leaks in the vacuum lines, check valve, vacuum reservoir or poor engine performance. SERVO VACUUM TEST (1) Remove the speed control cable at the throttle body end.
Page 330 TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1 TURN SIGNALS AND HAZARD WARNING FLASHER CONTENTS page page GENERAL INFORMATION ....1 MULTI-FUNCTION SWITCH TESTS ... 1 HAZARD WARNING SYSTEM .
Page 331 8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER Fig. 1 Turn Signal and Hazard Warning Flasher Diagnosis...
Page 332 TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3 To test the switch, first disconnect the negative battery cable, then remove the upper and lower col- umn covers to gain access to the switch connector. Remove switch connector. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts (Fig 2 or 3).
Page 334 WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 1 WINDSHIELD WIPER AND WASHER SYSTEMS CONTENTS page page GENERAL INFORMATION ....1 WASHER RESERVOIR PUMP ....11 INTERMITTENT WINDSHIELD WIPER SWITCH WASHER RESERVOIRS .
Page 335 8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS (2) Check the tips of the blades in blackout area. From the bottom edge of the windshield to the blade should be no closer than 24 mm (1 in.) (Fig. 4). Fig. 2 Remove Blade from Arm (2) Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip (Fig.
Page 336 WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 3 Fig. 5 Wiper Motor Runs Diagnosis...
Page 337 8K - 4 WINDSHIELD WIPER AND WASHER SYSTEMS Fig. 6 Wiper Motor Will Not Run Diagnosis...
Page 338 WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 5 The intermittent wiper function is controlled by the body control module, located in the passenger com- partment behind the right side kick panel (Fig. 7). If the body control module is determined to be the prob- lem, refer to Group 8E, Instrument Panels and Gauges, for replacement procedures.
Page 339 8K - 6 WINDSHIELD WIPER AND WASHER SYSTEMS C of the intermittent wiper relay. If OK, go to step 10. If not repair as necessary. (10) Using a voltmeter, connect positive lead to ter- minal 16 of the body control module J3 24-way con- nector.
Page 340 WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 7 Pin 2. Connect a second jumper wire between ground (3) Check circuit from intermittent relay cavity B and Pin 4 of the motor connector. to Hi/Low relay cavity B for short to battery or igni- (a) If motor runs, go to step 5.
Page 341 8K - 8 WINDSHIELD WIPER AND WASHER SYSTEMS Fig. 13 Wiper Motor and Linkage Module (2) Remove the rear hood seal with the cowl top plastic screen and disconnect the washer hose at in- line connector. Save in-line connector. (3) Disconnect motor connector at back side of housing.
Page 342 WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 9 Fig. 15 Cap Removal Fig. 17 Multi-Function Switch Fig. 16 Caps and Seals MULTI-FUNCTION INTERMITTENT WIPER SWITCH TEST To test the switch, first disconnect the switch wires from the body wiring in the steering column (Fig. 17). Using an ohmmeter, test for continuity between the terminals of the switch, as indicated in the following continuity chart.
Page 343 8K - 10 WINDSHIELD WIPER AND WASHER SYSTEMS button depressed when the switch is in the OFF position will operate the wipers and washer motor pump continuously until the washer button is re- leased. Releasing the button will stop the washer pump but the wipers will complete the current wipe cycle.
Page 344 WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 11 WASHER RESERVOIRS (3) Install reservoir retaining nuts and screw. Tighten to 9 to 14 N m (80 to 124 in. lbs.) torque. REMOVAL (4) Install battery tray and battery. Connect bat- (1) Disconnect the battery terminals. Remove bat- tery terminals.
Page 345 8K - 12 WINDSHIELD WIPER AND WASHER SYSTEMS WASHER FLUID LEVEL SENSOR (6) Connect wire connector to remote sensor. (1) Raise and support vehicle on safety stands. WASHER NOZZLE (2) Disconnect sensor wire connector. All models are equipped with the washer nozzles (3) Press up on the sensor lock and pull sensor out attached to the wiper arms.
Page 346 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 8 LAMP BULB SERVICE—CH OR CP VEHICLES . . 8 EXTERIOR LAMP SERVICE—CH OR CP LAMP BULB SERVICE—EXCEPT CH OR CP VEHICLES .
Page 347 8L - 2 LAMPS • Check for loose or corroded connector terminals or connectors, relay, high beam dimmer switch and headlamp switch. Refer to Group 8W, Wiring Dia- splices in headlamp circuits. Refer to Group 8W, Wir- grams for component locations and circuit informa- ing Diagrams for component and splice locations.
Page 348 LAMPS 8L - 3 is located on the top of the headlamp module to assist (4) Clean headlamp lenses. left/right alignment (Fig. 1). (5) Verify that luggage area is not heavily loaded. (6) Fuel tank should be FULL. Add 2.94 kg (6.5 lbs.) of weight over the fuel tank for each estimated gallon of missing fuel.
Page 349 8L - 4 LAMPS (6) Measure the distance from the center of head- lamp bulbs to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/down adjustment reference. (7) Measure distance from the centerline of the ve- hicle to the center of the headlamp bulbs.
Page 350 LAMPS 8L - 5 Fig. 5 Fog Lamp Alignment Screen Fig. 6 Headlamp Bubble Level Calibration...
Page 351 8L - 6 LAMPS LAMP BULB SERVICE—EXCEPT CH OR CP VEHICLES INDEX page page Center High Mounted Stop Lamp Bulb ..7 Side Marker, Park and Turn Signal Lamp Bulb ..6 Fog Lamp Bulb .
Page 352 LAMPS 8L - 7 INSTALLATION TAIL, STOP, BACK-UP AND TURN SIGNAL LAMP BULB CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced REMOVAL (FIG. 5) bulb life will result. (1) Remove tail lamp from vehicle. (2) Remove socket from lamp.
Page 353 8L - 8 LAMPS Fig. 6 License Plate Lamp Bulb—Typical LAMP BULB SERVICE—CH OR CP VEHICLES INDEX page page Back-Up Lamp Bulb ..... . . 10 License Plate Lamp Bulb .
Page 354 LAMPS 8L - 9 (5) Remove fog lamp wire connector cover. (6) Disengage wire connectors from fog lamp bulb. (7) Disengage retainer clip holding bulb to fog lamp. (8) Separate bulb from fog lamp. INSTALLATION (1) Place bulb in position in fog lamp. (2) Engage retainer clip to hold bulb to fog lamp.
Page 355 8L - 10 LAMPS BACK UP LAMP BULB REMOVAL (FIG. 5) (1) Release trunk latch and open trunk lid. (2) Remove trunk lining from rear closure panel as necessary to gain access to tail lamp fasteners. (3) Remove nuts holding tail lamp to rear closure panel.
Page 356 LAMPS 8L - 11 EXTERIOR LAMPS − EXCEPT CH OR CP VEHICLES INDEX page page Center High Mounted Stop Lamp (Chmsl) ..12 License Plate Lamp ..... . . 13 Fog Lamp .
Page 357 8L - 12 LAMPS Fig. 3 Side Marker, Park and Turn Signal Lamp Fig. 4 Front Lamp Module FRONT LAMP MODULE (4) Separate fog lamp from vehicle. REMOVAL (FIG. 4) INSTALLATION (1) Release hood latch and open hood. (1) Place fog lamp in position on vehicle. (2) Remove front bumper fascia.
Page 358 LAMPS 8L - 13 INSTALLATION (1) Place CHMSL in position on parcel shelf trim. (2) Install nuts to hold CHMSL to back of trim panel. (3) Engage CHMSL wire connector to body wire harness. (4) Install parcel shelf trim panel. Fig.
Page 359 8L - 14 LAMPS (3) Install screws to hold license plate lamp to trunk lid applique or fascia. Fig. 8 Trunk Lid Applique Lamp INSTALLATION (1) Install bulb socket into lamp. Fig. 9 License Plate Lamp (2) Place license plate lamp in position on vehicle. EXTERIOR LAMP SERVICE—CH OR CP VEHICLES INDEX page...
Page 360 LAMPS 8L - 15 INSTALLATION (1) Engage wire connectors to headlamp and fog lamp. (2) Place headlamp module in position on mount adapter. (3) Install screws to hold headlamp module to mount adapter. (4) Install radiator closure panel sight shield. (5) Verify headlamp alignment.
Page 361 8L - 16 LAMPS (2) Remove rear closure lining as necessary to gain (3) Install rear side marker lamp bulb and socket. access to tail lamp fasteners. (3) Remove wing nuts holding tail lamp to rear closure panel. (4) Disengage tail lamp wire connector from body wire harness.
Page 362 LAMPS 8L - 17 (2) Separate license plate lamp from rear bumper fascia. (3) Remove socket from lamp. (4) Separate license plate lamp from vehicle. INSTALLATION (1) Install socket into lamp. (2) Place license plate lamp in position on rear bumper fascia.
Page 363 8L - 18 LAMPS to control the system. Courtesy lamps will turn on for ULTRALIGHT SYSTEM 30 secontd (± 1 second) and fade to OFF over a five The Ultralight system turns the instrumentation second period. and exterior illumination lamps ON when the ambi- The Illuminated Entry System also turns ON the ent light levels are low and OFF when light levels are courtesy lamps (and ignition switch lamp) when door...
Page 364 LAMPS 8L - 19 BULB APPLICATION GENERAL INFORMATION Traction Control Switch The following Bulb Application Table lists the lamp All ..............4437661 title on the left side of the column and trade number INDICATOR LAMPS or part number on the right. Service procedures for most of the lamps in the in- strument panel, instrument cluster and switches are CAUTION: Do not use bulbs that have a higher...
Page 365 8L - 20 LAMPS nent is removed from the vehicle. Contact local dealer Overhead Console All ................192 for location of nearest ASC. Overhead Information Center Door Courtesy All ..............4437661 All .................212-2 Reading Lamp Engine Compartment Front or Rear............192 All ................105 Trunk Glove Compartment All ................98...
Page 366 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... 10 HEADLAMP ALIGNMENT ....1 EXTERIOR LAMP SERVICE .
Page 367 8L - 2 LAMPS Fig. 2 Headlamp Alignment Screen aero headlamps cannot be aligned. The high beam pattern should be correct when the low beams are aligned properly. To adjust headlamp alignment, rotate alignment screws to achieve the specified low beam hot spot pattern.
Page 368 LAMPS 8L - 3 Fig. 4 Fog Lamp Alignment Screen...
Page 369 8L - 4 LAMPS LAMP BULB SERVICE INDEX page page Back-Up Lamp Bulb ......5 License Plate Lamp Bulb .
Page 370 LAMPS 8L - 5 PARK AND TURN SIGNAL LAMP BULB (4) Install nuts to hold tail lamp to rear closure panel. REMOVAL (FIG. 3) (5) Install trunk lining. (1) Release hood latch and open hood. (6) Verify lamp operation. (2) Remove radiator closure panel sight shield as necessary to gain access to lamp.
Page 371 8L - 6 LAMPS LICENSE PLATE LAMP BULB REMOVAL (FIG. 7) (1) Remove screws holding license plate lamp to rear bumper fascia. (2) Separate license plate lamp from rear bumper fascia. (3) Remove socket from lamp. (4) Pull bulb from socket. INSTALLATION (1) Push bulb into socket.
Page 372 LAMPS 8L - 7 EXTERIOR LAMP SERVICE INDEX page page Center High Mounted Stop Lamp (CHMSL) ..9 Park and Turn Signal Lamp ....7 Headlamp Module .
Page 373 8L - 8 LAMPS (6) Separate park and turn signal lamp from vehi- (6) Install wing nuts to hold tail lamp to rear clo- sure panel. cle. (7) Install rear closure panel lining. INSTALLATION (8) Verify tail lamp operation. (1) Place park and turn signal lamp in position on vehicle.
Page 374 LAMPS 8L - 9 CENTER HIGH MOUNTED STOP LAMP (CHMSL) REMOVAL (FIG. 6) (1) Release trunk latch and open trunk. (2) From under rear deck panel, disengage CHMSL wire connector from body harness. (3) Remove rear deck upper panel. (4) Remove screws holding CHMSL to rear deck upper panel.
Page 375 8L - 10 LAMPS BULB APPLICATION GENERAL INFORMATION Ash Receiver............161 The following Bulb Applications list the lamp title Climate Control............330 on the left side of the column and trade number or Instrument Cluster ...........PC194 part number on the right. Radio..............ASC CAUTION: Do not use bulbs that have a higher can- INDICATOR LAMPS dle power than the bulb listed in the Bulb Applica-...
Page 376: Restraint Systems
RESTRAINT SYSTEMS 8M - 1 RESTRAINT SYSTEMS CONTENTS page page AIRBAG CONTROL MODULE (ACM) REMOVAL . 9 FRONT IMPACT SENSOR REMOVAL ..8 AIRBAG SERVICE AND TEST PROCEDURES . . . 1 GENERAL INFORMATION .
Page 377 8M - 2 RESTRAINT SYSTEMS mounted on the tunnel floor pan forward of the center console. The safing sensor provides confirma- tion of a crash, but does not discriminate severity. The ACM monitors the system to determine the system readiness. The ACM will store sufficient en- ergy to deploy the airbags for only two minutes after the battery is disconnected.
Page 378 RESTRAINT SYSTEMS 8M - 3 • Center distribution duct must be replaced because of visible or non visible structural damage. The lower instrument panel knee bolster, top cover, right trim bezel and any other components should be replaced if damaged. MAINTENANCE INSPECTION (1) Check that both front impact sensors are prop- erly installed to the headlamp carrier surface with...
Page 379 8M - 4 RESTRAINT SYSTEMS DRIVER AIRBAG MODULE REMOVAL (6) When replacing a deployed driver airbag mod- ule, the clockspring must also be replaced. Refer to WARNING: DISCONNECT AND ISOLATE THE BAT- Clockspring Removal and Installation for proper pro- TERY NEGATIVE (GROUND) CABLE BEFORE BE- cedure.
Page 380 RESTRAINT SYSTEMS 8M - 5 (13) Remove lower instrument panel assembly. (14) Remove left silencer/duct under instrument panel. (15) Remove instrument panel top cover, right and left A-pillar trim panels (Fig. 11). (16) Remove body control module at right end of instrument panel.
Page 381 8M - 6 RESTRAINT SYSTEMS Fig. 9 Instrument Panel Components...
Page 382 RESTRAINT SYSTEMS 8M - 7 Fig. 10 Instrument Panel Components—New Yorker...
Page 383 8M - 8 RESTRAINT SYSTEMS Fig. 11 Top Cover Fig. 13 Impact Sensor Location INSTALLATION (1) Connect sensor wiring lead from harness to con- nector on body of sensor. (2) Install left sensor (arrow pointed forward as shown in Fig. 14) to headlamp carrier surface, using three screws provided with new sensor and tighten to 3 to 5 N m (25 to 45 in.
Page 384 RESTRAINT SYSTEMS 8M - 9 AIRBAG CONTROL MODULE (ACM) REMOVAL (3) Connect ACM 4-way and 13-way connectors and ensure both connectors and all locking tabs are en- WARNING: THE ACM CONTAINS A SAFING SENSOR gaged. WHICH ENABLES THE SYSTEM TO DEPLOY THE (4) Install shifter bezel with screw located in ash AIRBAGS.
Page 385 8M - 10 RESTRAINT SYSTEMS CLOCKSPRING REMOVAL (12) Remove two mounting screws and pull clock- spring assembly from steering shaft. The clockspring WARNING: DISCONNECT AND ISOLATE THE BAT- cannot be repaired, and must be replaced if faulty. TERY NEGATIVE (GROUND) CABLE BEFORE BE- INSTALLATION GINNING ANY AIRBAG SYSTEM COMPONENT RE- (1) Confirm that:...
Page 386 RESTRAINT SYSTEMS 8M - 11 • Lock column with the ignition cylinder lock WARNING: DISCONNECT AND ISOLATE THE BAT- TERY NEGATIVE (GROUND) CABLE BEFORE BE- (2) Disconnect and isolate the battery negative GINNING ANY AIRBAG SYSTEM COMPONENT RE- cable. MOVAL OR INSTALLATION PROCEDURE. THIS WILL (3) Wait two minutes for the reserve capacitor to DISABLE THE AIRBAG SYSTEM.
Page 388: Rear Window Defogger
REAR WINDOW DEFOGGER 8N - 1 REAR WINDOW DEFOGGER CONTENTS page page A/C—HEATER—ATC CONTROL SWITCH ..1 REPAIR GRID LINES, TERMINALS AND PIGTAILS GENERAL INFORMATION ....1 SERVICE PROCEDURES .
Page 389 8N - 2 REAR WINDOW DEFOGGER (5) Using a DC voltmeter (Fig. 4) contact terminal abrasion. It is possible, however, that a break may B with the negative lead, and terminal A with the occur in an individual grid line resulting in no cur- positive lead.
Page 390 REAR WINDOW DEFOGGER 8N - 3 IN—VEHICLE TESTING (1) Remove the control switch from console and do not disconnect control switch (Fig. 6). Fig. 7 Grid Line Repair (3) Remove package separator clamp and mix plas- Fig. 6 A/C Heater Control Switch Connectors tic conductive epoxy thoroughly.
Page 392 POWER LOCKS 8P - 1 POWER LOCKS CONTENTS page page CHILD PROTECTION LOCK ....1 KEYLESS ENTRY SYSTEM ....3 DECK LID OPERATION .
Page 393: Deck Lid Operation
8P - 2 POWER LOCKS The power lock motors are also equipped with a shorted motor, or a bad switch. Disconnecting the thermal protection system which prevents the motors defective motor will allow the others to work. from burning out. The motors may chatter if they are To test an individual door lock motor, disconnect the continuously activated.
Page 394: Keyless Entry System
POWER LOCKS 8P - 3 (4) Insure that solenoid plunger travel is adequate and releasing the button two times, within five sec- approximately 16 mm (5/8 inch). onds interval, will unlock all doors. • Upon pressing the LOCK button, the horn will ADJUSTMENT sound a short CHIRP to notify that the all door lock Adjust deck lid latch and striker so that deck lid...
Page 395 8P - 4 POWER LOCKS (2) Locate the 2x3 traction control black connector (Fig. 4). The connector will either be connected to the switch or the back of the bezel housing. Disconnect the connector. (3) Turn ignition switch to the ON position. (4) Ground pin 4 of the traction control connector (Fig.
Page 396 POWER LOCKS 8P - 5 (10) Replace middle vent bezel, to the instrument (3) Check Pin 1 of the RKE module black connector panel. If the vehicle has a traction control switch for quick voltage pulse when the unlock button is check for functionality once the bezel is in place.
Page 397: Remote Keyless Entry Module
8P - 6 POWER LOCKS CONDITION: DOORS WILL LOCK WITH THE (7) Check Pin 5 of the RKE module black connector TRANSMITTER BUT THERE IS NO HORN for ground. Check Pin 4 of the black traction control CHIRP. connector for ground. If OK, replace the receiver mod- (1) Press horn button, listen horn sound.
Page 398: Vehicle Theft Security System
VEHICLE THEFT SECURITY SYSTEM 8Q - 1 VEHICLE THEFT SECURITY SYSTEM CONTENTS page page BODY CONTROL MODULE REMOVAL ..2 SECURITY SYSTEM TRUNK LOCK SWITCH GENERAL INFORMATION ....1 REPLACEMENT .
Page 399 8Q - 2 VEHICLE THEFT SECURITY SYSTEM timed-out for more than 18 minutes. This alert con- (4) Remove screw through oblong access hole at sists of 3 horn pulses when the vehicle is disarmed. right end of knee bolster (Fig. 2). The alarm system will not arm if the doors are locked manually with the ignition key or pushing.
Page 400: Replacement
VEHICLE THEFT SECURITY SYSTEM 8Q - 3 Fig. 4 Trunk Lock Switch Fig. 5 Trunk Lock Switch SECURITY SYSTEM TRUNK LOCK SWITCH (2) Remove security switch from cylinder or bracket REPLACEMENT and disconnect connector (Figs. 4 and 5). (1) Refer to Group 23, Body for trunk lock cylinder (3) For installation reverse above procedures.
Page 402: Power Seats
POWER SEATS 8R - 1 POWER SEATS CONTENTS page page CIRCUIT BREAKER TEST ....1 SEAT TRACK REMOVAL ....2 GENERAL INFORMATION .
Page 403: Switch Test
8R - 2 POWER SEATS Fig. 2 Switch Removal SWITCH TEST (1) Remove switch from mounting position (Fig. 2). (2) Using an ohmmeter, perform the switch conti- nuity tests in Fig. 3. If there is no continuity at any of the switch positions, replace switch.
Page 404 POWER SEATS 8R - 3 Fig. 4 Seat Track Removal...
Page 406: Power Windows
POWER WINDOWS 8S - 1 POWER WINDOWS CONTENTS page page GENERAL INFORMATION ....1 WINDOW LIFT MOTOR TEST ....2 MOTOR REPLACEMENT .
Page 407 8S - 2 POWER WINDOWS free to move up and down, the window lift motor will not be able to move the glass. To determine if the glass is free is to disconnect the regulator from the glass lift plate. Remove the two attaching screws, and slide the window up and down by hand.
Page 408 ELECTRICAL 8A - 1 ELECTRICAL GROUP INDEX IGNITION SYSTEM ..... . 8D WIRING DIAGRAMS ..... 8W LAMPS .
Page 409: Power Mirrors
POWER MIRRORS 8T - 1 POWER MIRRORS CONTENTS page page AUTOMATIC DAY/NIGHT INSIDE MIRROR ..2 MIRROR MOTOR TEST ....1 GENERAL INFORMATION .
Page 410 8T - 2 POWER MIRRORS MIRROR ASSEMBLY REPLACEMENT (1) For door trim panel and mirror removal, refer to Group 23, Body. (2) Test operation of mirror before installing door trim panel. AUTOMATIC DAY/NIGHT INSIDE MIRROR Operational test: • Turn ignition switch to the ON position with the vehicle in park (Fig.
Page 411 CHIME WARNING/REMINDER SYSTEM 8U - 1 CHIME WARNING/REMINDER SYSTEM CONTENTS page page BODY CONTROL MODULE REMOVAL ..1 HEADLAMP SWITCH REPLACEMENT ..3 CHIME SYSTEM DIAGNOSIS .
Page 412 8U - 2 CHIME WARNING/REMINDER SYSTEM (10) Replace the right side heat distribution duct under the instrument panel. (11) Replace the side cowl trim panel. (12) Replace the instrument panel end cover. CHIME SYSTEM DIAGNOSIS CONDITION No tone when ignition switch is turned on and drivers seat belt is unbuckled and fully retracted.
Page 413 CHIME WARNING/REMINDER SYSTEM 8U - 3 (3) Using the DRB, do the actuator test on cluster. (2) Use DRB to perform CCD diagnostics on body Refer to 1993 LH Body Diagnostic Manual. control module for battery, ignition switch input, key- (3) Check for battery feed at terminal J3-19 of the in-switch and driver’s door input and Chime Output module.
Page 415 WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page COMPONENT IDENTIFICATION ... . . 13 SPLICE LOCATIONS ..... 29 GENERAL INFORMATION .
Page 416 8W - 2 WIRING DIAGRAMS WIRE CODE IDENTIFICATION Each wire shown in the diagrams contains a code (Fig. 2) which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two letter code which can be identified by referring to the Wire Color Code Chart (Fig.
Page 417 WIRING DIAGRAMS 8W - 3 to a components name in the index if you are un- JUNCTION BLOCK The junction block, located at the left side of the clear as to what a system may be called. instrument panel, contains a series of connectors, Diagram sheets are arranged starting with the bat- fuses, and relays.
Page 418 8W - 4 WIRING DIAGRAMS FUSIBLE LINK REPLACEMENT CAUTION: Do not replace blown fusible links with a standard wire. Only use fusible type wire with hypa- lon insulation or damage to the electrical system could occur. Also make sure correct gauge of wiring is used.
Page 419 WIRING DIAGRAMS 8W - 5 Fig. 9 Stagger Cutting Wires (Typical) Fig. 7 Connector Locking Wedge Tab (Typical) (8) Place a piece of heat shrink tubing over one side (10) Connect battery and test all affected systems. of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.
Page 420 8W - 6 WIRING DIAGRAMS (10) Spread the strands of the wire apart on each part of the exposed wires (Fig. 6 example 1). (11) Push the two ends of wire together until the strands of wire are close to the insulation (Fig. 6 example 2).
Page 421 WIRING DIAGRAMS 8W - 7 Fig. 11 Symbol Identification...
Page 422 8W - 8 WIRING DIAGRAMS...
Page 423 WIRING DIAGRAMS 8W - 9...
Page 424 8W - 10 WIRING DIAGRAMS...
Page 425 WIRING DIAGRAMS 8W - 11 Fig. 15 Power Distribution Center Identification...
Page 426 8W - 12 WIRING DIAGRAMS Fig. 16 Junction Block Identification...
Page 427 WIRING DIAGRAMS 8W - 13 COMPONENT IDENTIFICATION Caption Fig. Caption Fig. ABS System Wiring (Rear) ......8 Engine Compartment Wiring (Right Rear) ... . .17 Battery Wiring .
Page 428 8W - 14 WIRING DIAGRAMS Fig. 1 Deck Lid Wiring Fig. 2 Trunk Area Wiring...
Page 429 WIRING DIAGRAMS 8W - 15 Fig. 3 Body Wiring (Right Rear) Fig. 4 Body Wiring (Left Rear)
Page 430 8W - 16 WIRING DIAGRAMS Fig. 5 Body Wiring (Right Front) Fig. 6 Body Wiring (Left Side)
Page 431 WIRING DIAGRAMS 8W - 17 Fig. 7 Body Wiring (Left Side) Fig. 8 ABS System Wiring (Rear)
Page 432 8W - 18 WIRING DIAGRAMS Fig. 9 Instrument Panel Wiring (Top) Fig. 10 Instrument Panel Wiring (Left Side)
Page 433 WIRING DIAGRAMS 8W - 19 Fig. 11 Instrument Panel Wiring (Center) Fig. 12 Instrument Panel Wiring (Right Side)
Page 434 8W - 20 WIRING DIAGRAMS Fig. 13 Steering Column Wiring Fig. 14 Door Wiring (Rear)
Page 435 WIRING DIAGRAMS 8W - 21 Fig. 15 Door Wiring (Front) Fig. 16 Engine Compartment Wiring (Right Front)
Page 436 8W - 22 WIRING DIAGRAMS Fig. 17 Engine Compartment Wiring (Right Rear) Fig. 18 Engine Compartment Wiring (Left Front)
Page 437 WIRING DIAGRAMS 8W - 23 Fig. 19 Engine Compartment Wiring (Left Rear) Fig. 20 Generator Wiring...
Page 438 8W - 24 WIRING DIAGRAMS Fig. 21 Battery Wiring Fig. 22 Starter and Transmission Wiring...
Page 439 WIRING DIAGRAMS 8W - 25...
Page 440 8W - 26 WIRING DIAGRAMS...
Page 441 WIRING DIAGRAMS 8W - 27 Fig. 25 Underhood Lamp Wiring...
Page 442 8W - 28 WIRING DIAGRAMS...
Page 443 WIRING DIAGRAMS 8W - 29 SPLICE LOCATIONS Splice Number Fig. Splice Number Fig. A1 ........13 K51 .
Page 444 8W - 30 WIRING DIAGRAMS Fig. 1 Deck Lid Splices Fig. 2 Trunk Area Splices...
Page 445 WIRING DIAGRAMS 8W - 31 Fig. 3 Body Splices (Left Side) Fig. 4 Headliner Splices...
Page 446 8W - 32 WIRING DIAGRAMS Fig. 5 Door Splices Fig. 6 HEVAC Splices...
Page 447 WIRING DIAGRAMS 8W - 33 Fig. 7 Instrument Panel Splices Fig. 8 Instrument Panel Splices...
Page 448 8W - 34 WIRING DIAGRAMS Fig. 9 Transmission Splices Fig. 10 Engine Compartment Splices (Right Front)
Page 449 WIRING DIAGRAMS 8W - 35 Fig. 11 Engine Compartment Splices (Right Rear) Fig. 12 Engine Compartment Splices (Left Front)
Page 450 8W - 36 WIRING DIAGRAMS Fig. 13 Engine Compartment Splices (Left Rear) Fig. 14 Engine Splices 3.3L...
Page 451 WIRING DIAGRAMS 8W - 37 Fig. 15 Engine Splices 3.5L...
Page 452 8W - 38 WIRING DIAGRAMS...
Page 453 WIRING DIAGRAMS 8W - 39 WIRING DIAGRAMS Index Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number A/C Climate Control Connectors ....129 Body Computer Connector (Bone) .
Page 454 8W - 40 WIRING DIAGRAMS Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number Right Front I.P. Speaker ..... . .85 Data Link Connector .
Page 455 WIRING DIAGRAMS 8W - 41 Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number Headlamp Switch ......57, 58 Lamps Headlamp and Front Fog Lamp Switch .
Page 456 8W - 42 WIRING DIAGRAMS Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number Daytime Running Lamp Module ....62 Relay 6 Intermittent Wiper ..... .3 Flex Fuel Sending Module .
Page 457 WIRING DIAGRAMS 8W - 43 Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number Right Tail/Turn Lamp ......108 Charge Air Temperature Sensor (3.3L ENG) .
Page 458 8W - 44 WIRING DIAGRAMS Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number Splice D2 ......19, 27 Splice P38 .
Page 459 WIRING DIAGRAMS 8W - 45 Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number Key In Switch ......11 Transmission Control System .
Page 504 1994 New Yorker, LHS, Concorde, Intrepid & Vision Publication No. 81-270-4140 TSB 26-10-95 December, 1995...
Page 505 1994 New Yorker, LHS, Concorde, Intrepid & Vision Publication No. 81-270-4140 TSB 26-10-95 December, 1995...
Page 622 1994 New Yorker, LHS, Concorde, Intrepid & Vision Publication No. 81-270-4140 TSB 26-04-95 June, 1995...
Page 625 WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS GENERAL INFORMATION This section covers the power sunroof system that is For information not contained in this section, refer to unique to this vehicle. For additional information on Group 8W-Wiring Diagrams in the 1993 Concorde, power sunroof operation, refer to Group 23 Body .
Page 627 ENGINE 9 - 1 ENGINE CONTENTS page page 3.3L ENGINE ......8 STANDARD SERVICE PROCEDURES .
Page 628: L Engine
9 - 2 ENGINE tinuous bead approximately 3 mm (0.120 inch.) in (j) If one or more cylinders have abnormally low compression pressures, repeat steps 4b through diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.) (k) If the same cylinder or cylinders repeat an drop is placed in the center of the gasket contact abnormally low reading on the second compression...
Page 629 ENGINE 9 - 3 When hone marks intersect at 50-60 degrees, the cross hatch angle is most satisfactory for proper seating of rings (Fig. 1). Fig. 3 Clearance Measurement MEASURING MAIN BEARING CLEARANCE AND CONNECTING ROD BEARING CLEARANCE PLASTIGAGE METHOD Engine crankshaft bearing clearances can be de- termined by use of Plastigage or equivalent.
Page 630: Hydraulic Lash Adjuster (Tappet) Noise Diagnosis
9 - 4 ENGINE amount of taper present. Record all readings taken. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several Refer to Engine Specifications. Plastigage gener- times after engine has reached normal operating ally is accompanied by two scales.
Page 631 ENGINE 9 - 5 (4) With all spark plugs removed, rotate engine (8) Install new spark plugs. crankshaft using a breaker bar and socket. (9) Drain engine oil and remove oil filter. (5) Identify the fluid in the cylinder(s) (i.e., coolant, (10) Fill engine with specified amount of approved fuel, oil or other).
Page 632 9 - 6 ENGINE ENGINE DIAGNOSIS—PERFORMANCE...
Page 633 ENGINE 9 - 7 ENGINE DIAGNOSIS—MECHANICAL...
Page 634 9 - 8 3.3L ENGINE 3.3L ENGINE INDEX page page Camshaft ....... 20 Engine Mounts .
Page 635 3.3L ENGINE 9 - 9 Fig. 1 3.3L V-6 Engine to the engine’s broad, flat torque curve, which was desired for excellent engine tractability, response and usable power output. The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution.
Page 636 9 - 10 3.3L ENGINE (3) Drain cooling system. Refer to Cooling System, Group 7 for procedure. (4) Disconnect all electrical connections. (5) Remove coolant hoses from radiator and en- gine. (6) Remove radiator and fan assembly. (7) See Fuel System, Group 14, to release fuel pressure.
Page 637 3.3L ENGINE 9 - 11 (13) Install radiator and fan assembly. Reconnect (2) Clean cylinder head cover gasket surface. In- fan motor electrical lead. Reinstall radiator hoses. Fill spect cover for distortion and straighten if necessary. cooling system. See Cooling System Group 7 for filling (3) Clean head rail if necessary.
Page 638 9 - 12 3.3L ENGINE Fig. 6 Cylinder Head Bolts Location Fig. 8 Head Gasket Installation lightly machine the head surface. As an example, if a 12 inch span is 1 mm (0.004 inch.) out of flat, allow- able is 12 x 0.019 mm (0.00075 inch.) equals 0.22 mm (0.009 in.) This amount of out of flat is accept- able.
Page 639 3.3L ENGINE 9 - 13 (3) Carefully install the intake manifold gasket (Fig. 13). Torque end seal retainer screws to 12 N m (105 in. lbs.). (4) Install intake manifold and (8) bolts and torque to 1 N m (10 in. lbs.). Then torque bolts to 22 N m (200 in.
Page 640 9 - 14 3.3L ENGINE REMOVAL (1) With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-B with adapter 6412 as shown in (Fig. 15). (2) Remove valve retaining locks, valve spring re- tainers, valve stem seals and valve springs. (3) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides.
Page 641 3.3L ENGINE 9 - 15 VALVE GUIDES Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch.) oversize reamer, or if guide is loose in cylinder head. Fig. 20 Valve Seats Fig. 19 Valve Dimensions REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 44-1/2 to 45 degree face angle.
Page 642 9 - 16 3.3L ENGINE ments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Fig. 24 Installing Valve, Cup Seal, Spring and Retainer (2) Disconnect negative battery cable. (3) Remove Air Cleaner Cover and hose assembly. Fig.
Page 643 3.3L ENGINE 9 - 17 (15) Install rocker arm covers tighten screws to 14 lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. N m (120 in. lbs.) and connector to ignition coils. When tappet noise is due to aeration, it may be inter- (16) Install Intake Manifold;...
Page 644 9 - 18 3.3L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 (2) Clean varnish deposits from inside of tappet (6) Remove dial indicator from spark plug hole. body above plunger cap. (7) Place a 5.08 mm (0.200 inch.) spacer between (3) Invert tappet body and remove plunger cap, the valve stem tip of #2 intake valve and rocker arm...
Page 645 3.3L ENGINE 9 - 19 MEASURING TIMING CHAIN FOR STRETCH (1) Place a scale next to timing chain so that any movement of chain may be measured. (2) Place a torque wrench and socket on camshaft sprocket attaching bolt and apply torque in direction of crankshaft rotation to take up slack;...
Page 646 9 - 20 3.3L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 (5) Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. (6) Install chain case cover screws (Fig.
Page 647 3.3L ENGINE 9 - 21 INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block. Whenever an engine has been rebuilt or a new camshaft or tappets have been installed, add one pint of Chrysler Crankcase Conditioner or equivalent to engine oil to aid in break in.
Page 648 9 - 22 3.3L ENGINE CAMSHAFT BEARINGS—ENGINE REMOVED FROM ENGINE CORE, OIL AND CAM PLUGS VEHICLE REMOVAL Using a blunt tool such as a drift and a hammer, REMOVAL (1) With engine completely disassembled, drive out strike the bottom edge of the cup plug. With the cup rear cam bearing core hole plug.
Page 649 3.3L ENGINE 9 - 23 CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly CYLINDER BLOCK (4) After removal, install bearing cap on the mat- ing rod. Fig. 2 Identify Connecting Rod to Cylinder PISTON—REMOVAL (1) Remove top ridge of cylinder bores with a reli- able ridge reamer before removing pistons from cylin-...
Page 650 9 - 24 3.3L ENGINE Fig. 5 Cylinder Bore and Piston Specifications Fig. 4 Checking Cylinder Bore Size and rings fitted. Whatever type of boring equipment Fig. 6 Piston Measurements is used, boring and honing operation should be removed damage to the piston may result. closely coordinated with the fitting of pistons and rings in order that specified clearances may be main- FITTING RINGS...
Page 651 3.3L ENGINE 9 - 25 Fig. 10 Piston Ring Installation Fig. 8 Piston Ring Specifications Fig. 11 Installing Side Rail Fig. 9 Measuring Piston Ring Side Clearance CAUTION: Install piston rings in the following or- der: (a) Oil ring expander. (b) Upper oil ring side rail.
Page 652 9 - 26 3.3L ENGINE (5) Position piston ring end gaps as shown in (Fig. 13). (6) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is impor- tant for oil control.
Page 653 3.3L ENGINE 9 - 27 CONNECTING RODS INSTALLATION OF CONNECTING ROD BEARINGS Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be marked at removal to insure correct assem- bly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps.
Page 654 9 - 28 3.3L ENGINE CRANKSHAFT SERVICE CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. (Fig. 1) Upper and lower bearing halves are NOT inter- changeable. Lower main bearing halves of 1, 3 and 4 are interchangeable.
Page 655 3.3L ENGINE 9 - 29 (4) Tighten number 1, 3 and 4 main cap bolts to 41 N m + 1/4 Turn (30 ft. lbs. + 1/4 Turn). (5) Rotate the crankshaft until number 6 piston is at TDC. (6) To ensure correct thrust bearing alignment the following procedure must be done: (a) Move crankshaft all the way to the rear of its travel.
Page 656 9 - 30 3.3L ENGINE clearance exceeds the specified limits. Replace the INSTALLATION main bearing(s) and if necessary have the crankshaft (1) Place Special Seal Pilot Tool C-4681 on crank- machined to next undersize. Also see Measuring Main shaft (Fig. 9). and Connecting Rod Bearing Clearance in Standard (2) Lightly coat seal O.D.
Page 657 3.3L ENGINE 9 - 31 Fig. 1 Engine Oiling System ENGINE LUBRICATION SYSTEM INSTALLATION The lubrication system is a full flow filtration pres- (1) Put a new o-ring on the oil pick-up tube and sure feed type. Oil from the oil pan is pumped by an install into Chain Case Cover tighten screw to 28 N m internal gear type oil pump directly coupled to the (250 in.
Page 658 9 - 32 3.3L ENGINE Fig. 3 Oil Pan Sealing Fig. 5 Oil Pressure Relief Valve OIL PUMP SERVICE INSPECTION AND REPAIR It is necessary to remove the oil pan, oil pickup and (1) Clean all parts thoroughly. Mating surface of chain case cover (CCC) to service the oil pump rotors.
Page 659 3.3L ENGINE 9 - 33 Fig. 9 Measuring Inner Rotor Thickness Fig. 7 Checking Oil Pump Cover Flatness (3) Prime oil pump before installation by filling (7) Place a straightedge across the face of the CCC, rotor cavity with engine oil. between bolt holes.
Page 660 9 - 34 3.3L ENGINE OIL FILTER When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock- seam. The lockseam joining the can to the base is reinforced by the base plate. (1) Using Tool C-4065, unscrew filter from base and discard (Fig.
Page 661 3.3L ENGINE 9 - 35 ENGINE SPECIFICATIONS...
Page 662 9 - 36 3.3L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 663 3.3L ENGINE 9 - 37 ENGINE SPECIFICATIONS (CONT.)
Page 664 9 - 38 3.3L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 665 3.3L ENGINE 9 - 39 TORQUE...
Page 666 9 - 40 3.5L ENGINE 3.5L ENGINE INDEX page page Camshaft Service ......50 Engine Specifications ..... . 70 Checking Engine Oil Pressure .
Page 667 3.5L ENGINE 9 - 41 SPECIFICATIONS retention and high resistance to scuffing. Piston pins are full-floating, join the pistons to the connecting rods. CYLINDER HEAD: The aluminum alloy cylinder heads feature cross-flow type intake and exhaust ports. Valve guides and inserts are powdered metal. Valves of heat resistance steel are arranged in a V with each camshaft on center.
Page 668 9 - 42 3.5L ENGINE • Drive shaft distress: Refer to Driveshafts in Sus- ENGINE MOUNTS pension, Group 2. • Any front end structural damage (after repair). • Insulator replacement. ENGINE ASSEMBLY REMOVAL (1) Disconnect battery. (2) Mark hood position at hinges and remove hood. (3) Drain cooling system.
Page 669 3.5L ENGINE 9 - 43 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 (5) Remove the cast cover (Fig. 2). (6) Remove the lower belt cover located behind the crankshaft damper. (7) To install reverse previous procedures. Fig.
Page 670 9 - 44 3.5L ENGINE TIMING BELT INSPECTION—IN VEHICLE (1) Drain cooling system and remove upper radia- tor hose for access to timing belt covers. Refer to Cooling Systems Group 7 for procedure. (2) Remove the accessory drive belts. Refer to Ac- cessory Drive System in Group 7 for service proce- dure.
Page 671 3.5L ENGINE 9 - 45 Fig. 7 Compressing Timing Belt Tensioner Fig. 8 Timing Belt Installation INSTALLATION CAUTION: This procedure can only be used when the camshaft sprockets have not been loosened or removed from the camshafts. (1) Align the crankshaft sprocket with the TDC mark on oil pump cover (Fig.
Page 672 9 - 46 3.5L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 09-05-94 April 15, 1994 (8) Install crankshaft sprocket using special tool CAMSHAFT SPROCKETS shown in (Fig. 13). REMOVAL CAUTION: When cam sprockets are loosened or removed, the camshafts must be timed to the en- gine.
Page 673 3.5L ENGINE 9 - 47 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 09-05-94 April 15, 1994 (13) Install crankshaft damper (Fig. 17). (14) Install accessory drive belts. Refer to Group 7 Cooling System for procedure. (15) Fill cooling system.
Page 674 9 - 48 3.5L ENGINE CYLINDER HEAD AND CAMSHAFT SERVICE (4) Loosen the A/C compressor mounting bracket and pull away from cylinder head. (5) Remove spark plug tube nut and o-ring (Fig. 3). (6) Remove rocker cover screws and remove cover (Fig.
Page 675 3.5L ENGINE 9 - 49 SPARK PLUG TUBE SERVICE (1) Remove valve cover. Refer to procedure outlined in this section for procedure. (2) Using locking pliers remove the tube from the cylinder head (Fig. 5). Discard old tube. (3) Clean area around spark plug with MOPAR parts cleaner or equivelant.
Page 676 9 - 50 3.5L ENGINE Tighten the screw into the pin, then loosen the nut on the screw. This will pull the dowel out of the shaft support. Remove the rocker arms and pedestals in order. (2) Check the rocker arm mounting portion of the shafts for wear or damage.
Page 677 3.5L ENGINE 9 - 51 CAMSHAFT INSPECTION Fig. 13 Remove Camshaft Oil Seal Fig. 12 Check Camshafts (1) Inspect camshaft bearing journals for damage and binding (Fig. 12). If journals are binding, also check the cylinder head for damage. Also check cylin- der head oil holes for clogging.
Page 678 9 - 52 3.5L ENGINE CYLINDER HEAD CLEANING (1) Use a gasket removal compound to soften the REMOVAL old gasket material. (1) Refer to Timing System Service in this group for disassembly and remove camshaft sprockets. The rear CAUTION: When cleaning the cylinder head and timing belt covers must be removed before the cylin- block mating surfaces, do not use a metal scraper der heads can be removed.
Page 679 3.5L ENGINE 9 - 53 • Fourth + 1/4 Turn Do not use a torque wrench for this step. Bolt torque after 1/4 turn should be over 90 ft. lbs. If not, replace the bolt. (5) Install rear timing belt covers. Use new o-ring on the water pump passages on the right side cover.
Page 680 9 - 54 3.5L ENGINE (3) Remove carbon and varnish deposits from in- side of valve guides with a reliable guide cleaner. (4) Measure valve stem guide clearance as follows: (a) Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat.
Page 681 3.5L ENGINE 9 - 55 VALVES (1) Inspect the remaining margin after the valves are refaced Refer to specifications (Fig. 26). VALVE SEATS (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones.
Page 682 9 - 56 3.5L ENGINE 100 psi air pressure (620.5 to 689 kPa). This is to hold valves into place while servicing components. Fig. 30 Checking Valve Tip Height and Valve Spring Installed Height (3) Install valve seal/spring seat assembly over valve guides on all valve stems (Fig.
Page 683 3.5L ENGINE 9 - 57 CYLINDER BLOCK, CRANKSHAFT, PISTON AND CONNECTING ROD ASSEMBLY SERVICE Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly CYLINDER BLOCK (3) Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 3). Push each piston and rod assembly out of cylinder bore.
Page 684 9 - 58 3.5L ENGINE Fig. 5 Cylinder Bore and Piston Specifications Fig. 4 Checking Cylinder Bore Size CYLINDER BORE INSPECTION The cylinder walls should be checked for out-of- round and taper with Tool C-119 (Fig. 4). If the cylinder walls are badly scuffed or scored, the cylin- der block should be rebored and honed, and new pistons and rings fitted.
Page 685 3.5L ENGINE 9 - 59 Refer to specifications (Fig. 8). firmly and press down the portion to be installed until side rail is in position. Do not use a piston (2) Check piston ring to groove clearance: (Fig. 9). ring expander. (Fig. 11). Refer to specification (Fig.
Page 686 9 - 60 3.5L ENGINE Fig. 12 Installing Upper and Intermediate Rings Fig. 15 Piston I.D. Marks (4) Install connecting rod bolt protectors on rod bolts. (Fig. 3) (5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
Page 687 3.5L ENGINE 9 - 61 Fig. 18 Checking Connecting Rod Side Clearance Fig. 16 Checking Connecting Rod Bearing Clearance—Typical (1) Follow procedure specified in the Standard Ser- vice Procedure Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance (Fig.
Page 688 9 - 62 3.5L ENGINE CRANKSHAFT SERVICE CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. (Fig. 1) Upper and lower bearing halves are NOT inter- changeable. Lower main bearing halves of 1, 2, 3 and 4 are interchangeable.
Page 689 3.5L ENGINE 9 - 63 (3) Install each main cap and tighten bolts finger tight. (4) Tighten number 1, 3 and 4 main cap bolts to 41 N m + 1/4 Turn (30 ft. lbs. + 1/4 Turn) (Fig. 1). Then tighten the #3 tie bolts to 54 N m (40 ft.
Page 690 9 - 64 3.5L ENGINE Fig. 7 Measure Crankshaft Journal O.D. Fig. 9 Removing Rear Crankshaft Oil Seal clearance exceeds the specified limits. Replace the (3) Place seal over Special Seal Pilot Tool C-4681 main bearing(s) and if necessary have the crankshaft and tap in place with a plastic hammer.
Page 691 3.5L ENGINE 9 - 65 lated by a relief valve. The oil is fed through an oil filter and to the crankshaft journals from the oil gallery in the cylinder block. This gallery also feeds oil under pressure to the cylinder heads. It then flows to each cylinder head through passages to camshaft journals, the rocker shafts to the rocker arms, hy- draulic lash adjusters (Fig.
Page 692 9 - 66 3.5L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 Fig. 2 Oil Pump Pick-up Tube Service Fig. 4 Windage Tray/Oil Pan Gasket (4) Clean oil screen and pipe in clean solvent. In- (8) Connect negative battery cable.
Page 693 3.5L ENGINE 9 - 67 (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.39 mm (0.3695 inch.) or less (Fig. 8), or if the diameter is 79.78 mm (3.141 inches.) or less, replace outer rotor. Fig.
Page 694 9 - 68 3.5L ENGINE Fig. 10 Measuring Outer Rotor Clearance in Fig. 12 Measuring Clearance Over Rotors Housing (3) Install crankshaft sprocket. Refer to front oil seal service procedure outlined in this section. (4) Install timing belt. Refer to procedure outlined in this section.
Page 695 3.5L ENGINE 9 - 69 OIL FILTER When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock- seam. The lockseam joining the can to the base is reinforced by the base plate. (1) Using Tool C-4065, unscrew filter from base and discard (Fig.
Page 696 9 - 70 3.5L ENGINE ENGINE SPECIFICATIONS...
Page 697 3.5L ENGINE 9 - 71 ENGINE SPECIFICATIONS (CONT.)
Page 698 9 - 72 3.5L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 699 3.5L ENGINE 9 - 73 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-06-95 August, 1995 TORQUE...
Page 701 ENGINE 9 - 1 ENGINE CONTENTS page page 3.3L ENGINE ......8 STANDARD SERVICE PROCEDURES .
Page 702 9 - 2 ENGINE tinuous bead approximately 3 mm (0.120 inch.) in (j) If one or more cylinders have abnormally low compression pressures, repeat steps 4b through diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.) (k) If the same cylinder or cylinders repeat an drop is placed in the center of the gasket contact abnormally low reading on the second compression...
Page 703 ENGINE 9 - 3 When hone marks intersect at 50-60 degrees, the cross hatch angle is most satisfactory for proper seating of rings (Fig. 1). Fig. 3 Clearance Measurement MEASURING MAIN BEARING CLEARANCE AND CONNECTING ROD BEARING CLEARANCE PLASTIGAGE METHOD Engine crankshaft bearing clearances can be de- termined by use of Plastigage or equivalent.
Page 704 9 - 4 ENGINE amount of taper present. Record all readings taken. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several Refer to Engine Specifications. Plastigage gener- times after engine has reached normal operating ally is accompanied by two scales.
Page 705 ENGINE 9 - 5 (4) With all spark plugs removed, rotate engine (8) Install new spark plugs. crankshaft using a breaker bar and socket. (9) Drain engine oil and remove oil filter. (5) Identify the fluid in the cylinder(s) (i.e., coolant, (10) Fill engine with specified amount of approved fuel, oil or other).
Page 706 9 - 6 ENGINE ENGINE DIAGNOSIS—PERFORMANCE...
Page 707 ENGINE 9 - 7 ENGINE DIAGNOSIS—MECHANICAL...
Page 708 9 - 8 3.3L ENGINE 3.3L ENGINE INDEX page page Camshaft ....... 20 Engine Mounts .
Page 709 3.3L ENGINE 9 - 9 Fig. 1 3.3L V-6 Engine to the engine’s broad, flat torque curve, which was desired for excellent engine tractability, response and usable power output. The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution.
Page 710 9 - 10 3.3L ENGINE (3) Drain cooling system. Refer to Cooling System, Group 7 for procedure. (4) Disconnect all electrical connections. (5) Remove coolant hoses from radiator and en- gine. (6) Remove radiator and fan assembly. (7) See Fuel System, Group 14, to release fuel pressure.
Page 711 3.3L ENGINE 9 - 11 (13) Install radiator and fan assembly. Reconnect (2) Clean cylinder head cover gasket surface. In- fan motor electrical lead. Reinstall radiator hoses. Fill spect cover for distortion and straighten if necessary. cooling system. See Cooling System Group 7 for filling (3) Clean head rail if necessary.
Page 712 9 - 12 3.3L ENGINE Fig. 6 Cylinder Head Bolts Location Fig. 8 Head Gasket Installation lightly machine the head surface. As an example, if a 12 inch span is 1 mm (0.004 inch.) out of flat, allow- able is 12 x 0.019 mm (0.00075 inch.) equals 0.22 mm (0.009 in.) This amount of out of flat is accept- able.
Page 713 3.3L ENGINE 9 - 13 (3) Carefully install the intake manifold gasket (Fig. 13). Torque end seal retainer screws to 12 N m (105 in. lbs.). (4) Install intake manifold and (8) bolts and torque to 1 N m (10 in. lbs.). Then torque bolts to 22 N m (200 in.
Page 714 9 - 14 3.3L ENGINE REMOVAL (1) With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-B with adapter 6412 as shown in (Fig. 15). (2) Remove valve retaining locks, valve spring re- tainers, valve stem seals and valve springs. (3) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides.
Page 715 3.3L ENGINE 9 - 15 VALVE GUIDES Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch.) oversize reamer, or if guide is loose in cylinder head. Fig. 20 Valve Seats Fig. 19 Valve Dimensions REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 44-1/2 to 45 degree face angle.
Page 716 9 - 16 3.3L ENGINE ments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Fig. 24 Installing Valve, Cup Seal, Spring and Retainer (2) Disconnect negative battery cable. (3) Remove Air Cleaner Cover and hose assembly. Fig.
Page 717 3.3L ENGINE 9 - 17 (15) Install rocker arm covers tighten screws to 14 lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. N m (120 in. lbs.) and connector to ignition coils. When tappet noise is due to aeration, it may be inter- (16) Install Intake Manifold;...
Page 718 9 - 18 3.3L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 (2) Clean varnish deposits from inside of tappet (6) Remove dial indicator from spark plug hole. body above plunger cap. (7) Place a 5.08 mm (0.200 inch.) spacer between (3) Invert tappet body and remove plunger cap, the valve stem tip of #2 intake valve and rocker arm...
Page 719 3.3L ENGINE 9 - 19 MEASURING TIMING CHAIN FOR STRETCH (1) Place a scale next to timing chain so that any movement of chain may be measured. (2) Place a torque wrench and socket on camshaft sprocket attaching bolt and apply torque in direction of crankshaft rotation to take up slack;...
Page 720 9 - 20 3.3L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 (5) Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. (6) Install chain case cover screws (Fig.
Page 721 3.3L ENGINE 9 - 21 INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block. Whenever an engine has been rebuilt or a new camshaft or tappets have been installed, add one pint of Chrysler Crankcase Conditioner or equivalent to engine oil to aid in break in.
Page 722 9 - 22 3.3L ENGINE CAMSHAFT BEARINGS—ENGINE REMOVED FROM ENGINE CORE, OIL AND CAM PLUGS VEHICLE REMOVAL Using a blunt tool such as a drift and a hammer, REMOVAL (1) With engine completely disassembled, drive out strike the bottom edge of the cup plug. With the cup rear cam bearing core hole plug.
Page 723 3.3L ENGINE 9 - 23 CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly CYLINDER BLOCK (4) After removal, install bearing cap on the mat- ing rod. Fig. 2 Identify Connecting Rod to Cylinder PISTON—REMOVAL (1) Remove top ridge of cylinder bores with a reli- able ridge reamer before removing pistons from cylin-...
Page 724 9 - 24 3.3L ENGINE Fig. 5 Cylinder Bore and Piston Specifications Fig. 4 Checking Cylinder Bore Size and rings fitted. Whatever type of boring equipment Fig. 6 Piston Measurements is used, boring and honing operation should be removed damage to the piston may result. closely coordinated with the fitting of pistons and rings in order that specified clearances may be main- FITTING RINGS...
Page 725 3.3L ENGINE 9 - 25 Fig. 10 Piston Ring Installation Fig. 8 Piston Ring Specifications Fig. 11 Installing Side Rail Fig. 9 Measuring Piston Ring Side Clearance CAUTION: Install piston rings in the following or- der: (a) Oil ring expander. (b) Upper oil ring side rail.
Page 726 9 - 26 3.3L ENGINE (5) Position piston ring end gaps as shown in (Fig. 13). (6) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is impor- tant for oil control.
Page 727 3.3L ENGINE 9 - 27 CONNECTING RODS INSTALLATION OF CONNECTING ROD BEARINGS Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be marked at removal to insure correct assem- bly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps.
Page 728 9 - 28 3.3L ENGINE CRANKSHAFT SERVICE CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. (Fig. 1) Upper and lower bearing halves are NOT inter- changeable. Lower main bearing halves of 1, 3 and 4 are interchangeable.
Page 729 3.3L ENGINE 9 - 29 (4) Tighten number 1, 3 and 4 main cap bolts to 41 N m + 1/4 Turn (30 ft. lbs. + 1/4 Turn). (5) Rotate the crankshaft until number 6 piston is at TDC. (6) To ensure correct thrust bearing alignment the following procedure must be done: (a) Move crankshaft all the way to the rear of its travel.
Page 730 9 - 30 3.3L ENGINE clearance exceeds the specified limits. Replace the INSTALLATION main bearing(s) and if necessary have the crankshaft (1) Place Special Seal Pilot Tool C-4681 on crank- machined to next undersize. Also see Measuring Main shaft (Fig. 9). and Connecting Rod Bearing Clearance in Standard (2) Lightly coat seal O.D.
Page 731 3.3L ENGINE 9 - 31 Fig. 1 Engine Oiling System ENGINE LUBRICATION SYSTEM INSTALLATION The lubrication system is a full flow filtration pres- (1) Put a new o-ring on the oil pick-up tube and sure feed type. Oil from the oil pan is pumped by an install into Chain Case Cover tighten screw to 28 N m internal gear type oil pump directly coupled to the (250 in.
Page 732 9 - 32 3.3L ENGINE Fig. 3 Oil Pan Sealing Fig. 5 Oil Pressure Relief Valve OIL PUMP SERVICE INSPECTION AND REPAIR It is necessary to remove the oil pan, oil pickup and (1) Clean all parts thoroughly. Mating surface of chain case cover (CCC) to service the oil pump rotors.
Page 733 3.3L ENGINE 9 - 33 Fig. 9 Measuring Inner Rotor Thickness Fig. 7 Checking Oil Pump Cover Flatness (3) Prime oil pump before installation by filling (7) Place a straightedge across the face of the CCC, rotor cavity with engine oil. between bolt holes.
Page 734 9 - 34 3.3L ENGINE OIL FILTER When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock- seam. The lockseam joining the can to the base is reinforced by the base plate. (1) Using Tool C-4065, unscrew filter from base and discard (Fig.
Page 735 3.3L ENGINE 9 - 35 ENGINE SPECIFICATIONS...
Page 736 9 - 36 3.3L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 737 3.3L ENGINE 9 - 37 ENGINE SPECIFICATIONS (CONT.)
Page 738 9 - 38 3.3L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 739 3.3L ENGINE 9 - 39 TORQUE...
Page 740 9 - 40 3.5L ENGINE 3.5L ENGINE INDEX page page Camshaft Service ......50 Engine Specifications ..... . 70 Checking Engine Oil Pressure .
Page 741 3.5L ENGINE 9 - 41 SPECIFICATIONS retention and high resistance to scuffing. Piston pins are full-floating, join the pistons to the connecting rods. CYLINDER HEAD: The aluminum alloy cylinder heads feature cross-flow type intake and exhaust ports. Valve guides and inserts are powdered metal. Valves of heat resistance steel are arranged in a V with each camshaft on center.
Page 742 9 - 42 3.5L ENGINE • Drive shaft distress: Refer to Driveshafts in Sus- ENGINE MOUNTS pension, Group 2. • Any front end structural damage (after repair). • Insulator replacement. ENGINE ASSEMBLY REMOVAL (1) Disconnect battery. (2) Mark hood position at hinges and remove hood. (3) Drain cooling system.
Page 743 3.5L ENGINE 9 - 43 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 (5) Remove the cast cover (Fig. 2). (6) Remove the lower belt cover located behind the crankshaft damper. (7) To install reverse previous procedures. Fig.
Page 744 9 - 44 3.5L ENGINE TIMING BELT INSPECTION—IN VEHICLE (1) Drain cooling system and remove upper radia- tor hose for access to timing belt covers. Refer to Cooling Systems Group 7 for procedure. (2) Remove the accessory drive belts. Refer to Ac- cessory Drive System in Group 7 for service proce- dure.
Page 745 3.5L ENGINE 9 - 45 Fig. 7 Compressing Timing Belt Tensioner Fig. 8 Timing Belt Installation INSTALLATION CAUTION: This procedure can only be used when the camshaft sprockets have not been loosened or removed from the camshafts. (1) Align the crankshaft sprocket with the TDC mark on oil pump cover (Fig.
Page 746 9 - 46 3.5L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 09-05-94 April 15, 1994 (8) Install crankshaft sprocket using special tool CAMSHAFT SPROCKETS shown in (Fig. 13). REMOVAL CAUTION: When cam sprockets are loosened or removed, the camshafts must be timed to the en- gine.
Page 747 3.5L ENGINE 9 - 47 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 09-05-94 April 15, 1994 (13) Install crankshaft damper (Fig. 17). (14) Install accessory drive belts. Refer to Group 7 Cooling System for procedure. (15) Fill cooling system.
Page 748 9 - 48 3.5L ENGINE CYLINDER HEAD AND CAMSHAFT SERVICE (4) Loosen the A/C compressor mounting bracket and pull away from cylinder head. (5) Remove spark plug tube nut and o-ring (Fig. 3). (6) Remove rocker cover screws and remove cover (Fig.
Page 749 3.5L ENGINE 9 - 49 SPARK PLUG TUBE SERVICE (1) Remove valve cover. Refer to procedure outlined in this section for procedure. (2) Using locking pliers remove the tube from the cylinder head (Fig. 5). Discard old tube. (3) Clean area around spark plug with MOPAR parts cleaner or equivelant.
Page 750 9 - 50 3.5L ENGINE Tighten the screw into the pin, then loosen the nut on the screw. This will pull the dowel out of the shaft support. Remove the rocker arms and pedestals in order. (2) Check the rocker arm mounting portion of the shafts for wear or damage.
Page 751 3.5L ENGINE 9 - 51 CAMSHAFT INSPECTION Fig. 13 Remove Camshaft Oil Seal Fig. 12 Check Camshafts (1) Inspect camshaft bearing journals for damage and binding (Fig. 12). If journals are binding, also check the cylinder head for damage. Also check cylin- der head oil holes for clogging.
Page 752 9 - 52 3.5L ENGINE CYLINDER HEAD CLEANING (1) Use a gasket removal compound to soften the REMOVAL old gasket material. (1) Refer to Timing System Service in this group for disassembly and remove camshaft sprockets. The rear CAUTION: When cleaning the cylinder head and timing belt covers must be removed before the cylin- block mating surfaces, do not use a metal scraper der heads can be removed.
Page 753 3.5L ENGINE 9 - 53 • Fourth + 1/4 Turn Do not use a torque wrench for this step. Bolt torque after 1/4 turn should be over 90 ft. lbs. If not, replace the bolt. (5) Install rear timing belt covers. Use new o-ring on the water pump passages on the right side cover.
Page 754 9 - 54 3.5L ENGINE (3) Remove carbon and varnish deposits from in- side of valve guides with a reliable guide cleaner. (4) Measure valve stem guide clearance as follows: (a) Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat.
Page 755 3.5L ENGINE 9 - 55 VALVES (1) Inspect the remaining margin after the valves are refaced Refer to specifications (Fig. 26). VALVE SEATS (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones.
Page 756 9 - 56 3.5L ENGINE 100 psi air pressure (620.5 to 689 kPa). This is to hold valves into place while servicing components. Fig. 30 Checking Valve Tip Height and Valve Spring Installed Height (3) Install valve seal/spring seat assembly over valve guides on all valve stems (Fig.
Page 757 3.5L ENGINE 9 - 57 CYLINDER BLOCK, CRANKSHAFT, PISTON AND CONNECTING ROD ASSEMBLY SERVICE Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly CYLINDER BLOCK (3) Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 3). Push each piston and rod assembly out of cylinder bore.
Page 758 9 - 58 3.5L ENGINE Fig. 5 Cylinder Bore and Piston Specifications Fig. 4 Checking Cylinder Bore Size CYLINDER BORE INSPECTION The cylinder walls should be checked for out-of- round and taper with Tool C-119 (Fig. 4). If the cylinder walls are badly scuffed or scored, the cylin- der block should be rebored and honed, and new pistons and rings fitted.
Page 759 3.5L ENGINE 9 - 59 Refer to specifications (Fig. 8). firmly and press down the portion to be installed until side rail is in position. Do not use a piston (2) Check piston ring to groove clearance: (Fig. 9). ring expander. (Fig. 11). Refer to specification (Fig.
Page 760 9 - 60 3.5L ENGINE Fig. 12 Installing Upper and Intermediate Rings Fig. 15 Piston I.D. Marks (4) Install connecting rod bolt protectors on rod bolts. (Fig. 3) (5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
Page 761 3.5L ENGINE 9 - 61 Fig. 18 Checking Connecting Rod Side Clearance Fig. 16 Checking Connecting Rod Bearing Clearance—Typical (1) Follow procedure specified in the Standard Ser- vice Procedure Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance (Fig.
Page 762 9 - 62 3.5L ENGINE CRANKSHAFT SERVICE CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. (Fig. 1) Upper and lower bearing halves are NOT inter- changeable. Lower main bearing halves of 1, 2, 3 and 4 are interchangeable.
Page 763 3.5L ENGINE 9 - 63 (3) Install each main cap and tighten bolts finger tight. (4) Tighten number 1, 3 and 4 main cap bolts to 41 N m + 1/4 Turn (30 ft. lbs. + 1/4 Turn) (Fig. 1). Then tighten the #3 tie bolts to 54 N m (40 ft.
Page 764 9 - 64 3.5L ENGINE Fig. 7 Measure Crankshaft Journal O.D. Fig. 9 Removing Rear Crankshaft Oil Seal clearance exceeds the specified limits. Replace the (3) Place seal over Special Seal Pilot Tool C-4681 main bearing(s) and if necessary have the crankshaft and tap in place with a plastic hammer.
Page 765 3.5L ENGINE 9 - 65 lated by a relief valve. The oil is fed through an oil filter and to the crankshaft journals from the oil gallery in the cylinder block. This gallery also feeds oil under pressure to the cylinder heads. It then flows to each cylinder head through passages to camshaft journals, the rocker shafts to the rocker arms, hy- draulic lash adjusters (Fig.
Page 766 9 - 66 3.5L ENGINE 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-08-95 October, 1995 Fig. 2 Oil Pump Pick-up Tube Service Fig. 4 Windage Tray/Oil Pan Gasket (4) Clean oil screen and pipe in clean solvent. In- (8) Connect negative battery cable.
Page 767 3.5L ENGINE 9 - 67 (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.39 mm (0.3695 inch.) or less (Fig. 8), or if the diameter is 79.78 mm (3.141 inches.) or less, replace outer rotor. Fig.
Page 768 9 - 68 3.5L ENGINE Fig. 10 Measuring Outer Rotor Clearance in Fig. 12 Measuring Clearance Over Rotors Housing (3) Install crankshaft sprocket. Refer to front oil seal service procedure outlined in this section. (4) Install timing belt. Refer to procedure outlined in this section.
Page 769 3.5L ENGINE 9 - 69 OIL FILTER When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock- seam. The lockseam joining the can to the base is reinforced by the base plate. (1) Using Tool C-4065, unscrew filter from base and discard (Fig.
Page 770 9 - 70 3.5L ENGINE ENGINE SPECIFICATIONS...
Page 771 3.5L ENGINE 9 - 71 ENGINE SPECIFICATIONS (CONT.)
Page 772 9 - 72 3.5L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 773 3.5L ENGINE 9 - 73 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-06-95 August, 1995 TORQUE...
Page 775: Exhaust System And Intake Manifold
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 EXHAUST SYSTEM AND INTAKE MANIFOLD CONTENTS page page GENERAL INFORMATION ....1 TORQUE SPECIFICATION ....12 SERVICE PROCEDURES .
Page 776 11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD car and the environment from the high temperatures developed in the vicinity of the catalytic converters and muffler. Each catalytic converter has a intergal heat shield attached to it and are not to be removed. Refer to Body and Sheet Metal, Group 23 for service procedures.
Page 777 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3 SERVICE PROCEDURES INDEX page page Exhaust Module ......4 Intake/Exhaust Manifold Service—3.3L Engines .
Page 778 11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD FRONT EXHAUST DOWN PIPES REMOVAL (1) Remove the exhaust system. Refer to procedure outlined in this section. (2) Apply penetrating oil and loosen the U-bolt clamps that fasten the front pipes to the inlet bush- ings of the underfloor convertor (Fig.
Page 779 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5 Fig. 8 Tailpipe/Resonator Support Brackets (5) Install exhaust system. Refer to procedure out- lined in this section. INTAKE/EXHAUST MANIFOLD SERVICE—3.3L ENGINES INTAKE MANIFOLD REMOVAL (1) Release fuel system pressure. Refer to Fuel Sys- tem Pressure Release Procedure in this section.
Page 780 11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD Fig. 2 Fuel Pressure Test Port—3.5L Engine Fig. 4 Removing Throttle Cable and Speed Control Cable Fig. 3 Releasing Fuel Pressure—Typical oline container. Connect the other end of hose Fig. 5 EGR Transducer C-4799-1 to the fuel pressure test port (Fig.
Page 781 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7 Fig. 9 Intake Manifold Removal and Installation Fig. 6 EGR Tube Fig. 7 Fuel Supply and Return Tubes Fig. 10 Intake Manifold Gasket (19) Remove intake manifold seal retainers screws (Fig. 14). Remove intake manifold gasket. INSPECTION Check for: •...
Page 782 11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD (3) Carefully install the intake manifold gasket (9) Remove cover from intake manifold. Place ple- (Fig. 14). Tighten end seal retainer screws to 12 N m num with new gasket on intake manifold. Loosely (105 in.
Page 783 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9 INSPECTION Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting sur- face mounting surface with a straightedge and thick- ness gauge. EXHAUST MANIFOLD INSTALLATION (1) Install exhaust manifold and tighten attaching bolts to 23 N m (200 in.
Page 784 11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD Fig. 3 MAP Sensor Fig. 6 EGR Tube Top Mounting Bolts Fig. 4 Throttle Position Sensor Fig. 7 Intake Manifold Plenum Support (Right Side) Fig. 5 Air Inlet Plenum (17) Remove intake manifold plenum. Discard gas- kets.
Page 785 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11 (4) Remove bolts attaching the manifold to cylinder head and remove manifold. Fig. 9 Intake Manifold Tightening Sequence INSTALLATION (1) Install intake manifold with new gaskets. Tighten in sequence shown in (Fig. 9) to 28 N m (250 in.
Page 786 11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD TORQUE SPECIFICATION...
Page 787: Frame And Bumpers
FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page page ENGINE CRADLE CROSSMEMBER ... 2 FRONT BUMPER REINFORCEMENT ..1 FRAME DIMENSIONS .
Page 788 13 - 2 FRAME AND BUMPERS REAR BUMPER FASCIA ENGINE CRADLE CROSSMEMBER REMOVAL (FIG. 3) REMOVAL (FIG. 4) (1) Release trunk latch and open trunk lid. WARNING: VERIFY THAT VEHICLE IS PROPERLY (2) Remove wheelhouse splash shields as necessary SUPPORTED AND SECURED TO THE LIFTING DE- to gain access to fascia fasteners.
Page 789 FRAME AND BUMPERS 13 - 3 INSTALLATION (10) Lower vehicle. If cradle replacement is required, transfer suspen- (11) Remove engine support device. sion components and body mount pads to replacement (12) Install nuts to hold engine mounts to cradle. cradle. (13) Align front suspension if necessary.
Page 790 13 - 4 FRAME AND BUMPERS Fig. 6 Engine Compartment Side View...
Page 791 FRAME AND BUMPERS 13 - 5...
Page 792 13 - 6 FRAME AND BUMPERS Fig. 8 Rear Frame Section...
Page 793 FUEL SYSTEMS 14 - 1 FUEL SYSTEMS CONTENTS page page ACCELERATOR PEDAL AND THROTTLE CABLE . . . 24 SEQUENTIAL MULTI-PORT FUEL INJECTION— FUEL DELIVERY SYSTEM ....3 SERVICE PROCEDURES .
Page 794 14 - 2 FUEL SYSTEMS gasoline blended and up to 15 percent MTBE. Gaso- ated materials such as ETBE, MTBE and ethanol. The line and ETBE (Ethyl Tertiary Butyl Ether) are use of gasoline blended with these materials also con- blends of gasoline and up to 17 percent ETBE.
Page 795 FUEL DELIVERY 14 - 3 FUEL DELIVERY SYSTEM INDEX page page Chassis Fuel Tubes ..... . . 18 Fuel System Pressure Release Procedure .
Page 796 14 - 4 FUEL DELIVERY The methanol concentration sensor output voltage INSTALLATION varies with the percent of methanol in the fuel sys- (1) Place sensor on bracket. Tighten mounting nut. tem. The sensor output voltage (input for PCM) (2) Attach electrical connector to sensor. ranges from 0.5 volts for pure gasoline to 4.75 volts (3) Connect fuel tubes to sensor.
Page 797 FUEL DELIVERY 14 - 5 (4) Place the open end of fuel pressure release hose, tool number C-4799-1, into an approved meth- anol/gasoline container. Connect the other end of hose C-4799-1 to the fuel pressure test port (Fig. 4). Fuel pressure will bleed off through the hose into the gasoline container.
Page 798 14 - 6 FUEL DELIVERY WARNING: THE FUEL PUMP RESERVOIR MAY CON- TAIN FUEL. DO NOT SPILL FUEL WHILE REMOVING THE MODULE. (10) To absorb possible fuel spillage, place shop towels around access opening. Without removing the module, tip it backwards to allow fuel in the reservoir to run down the side and back into the fuel tank.
Page 799 FUEL DELIVERY 14 - 7 (7) Install access cover and gasket. Tighten fasteners. (8) Install trunk liner. FLEXIBLE FUEL GAUGE MODULE On flexible fuel vehicles only, the fuel gauge circuit contains the Flexible Fuel Gauge Module. The module is a voltage convertor (AC to DC) that prevents fuel gauge corrosion.
Page 800 14 - 8 FUEL DELIVERY Fig. 12 Fuel Pump/Level Sensor Connector Fig. 15 Level Sensor Signal and Ground Wires Fig. 13 Wire Terminal Retaining Clip Fig. 16 Fuel Level Sensor Removal Fig. 14 Wire Terminal Identification Fig. 17 Standpipe Inside Module tool 7812 or an equivalent can cause terminal module and the top of the level sensor housing damage which will effect fuel gauge operation.
Page 801 FUEL DELIVERY 14 - 9 Fig. 19 Inlet Strainer Fig. 18 Level Sensor Installation INSTALLATION (1) Insert level sensor wires in bottom of standpipe. (2) Wrap wires into groove in back of level sensor (Fig. 18). (3) While feeding wires into standpipe, slide level sensor up into installation channel until it snaps into place.
Page 802 14 - 10 FUEL DELIVERY Fig. 21 Fuel Pressure Regulator—3.3L Engine Fig. 23 Fuel Pressure Regulator Operation the fuel return port. Manifold vacuum applied to the top of the diaphragm acts against the spring pressure while fuel pressure pushes on the bottom of the dia- phragm.
Page 803 FUEL DELIVERY 14 - 11 Fig. 24 Fuel Pressure Regulator Removal—3.3L Fig. 26 Fuel Pressure Regulator Installation Engine Fig. 25 Fuel Pressure Regulator—Typical (5) Using a thin flat screwdriver, pry the fuel pres- sure regulator out of the fuel rail (Fig. 24). (6) Ensure the upper O-ring, upper spacer, lower Fig.
Page 804 14 - 12 FUEL DELIVERY regulator. If not, remove them from the well in fuel rail (Fig. 25). INSTALLATION—3.5L ENGINE (1) Lightly lubricate the O-rings with a couple drops of clean engine oil. (2) Install fuel pressure regulator flush with fuel rail.
Page 805 FUEL DELIVERY 14 - 13 The 3.3L and 3.5L fuel systems operate at different not required. If pressure is not correct, record the pressures. Refer Fuel System Specifications for cor- pressure and remove gauge. rect system pressure. Ensure fuel does not leak from the fuel rail service (1) Release fuel system pressure before disconnect- valve.
Page 806 14 - 14 FUEL DELIVERY (a) Perform Fuel Pressure Release procedure. (b) Install Fuel Pressure Gauge C-4799 and Fuel Pressure Adapter 6631 in the fuel supply line (Fig. 33) between the fuel tank and fuel filter. (c) Remove the fuel return line hose from the fuel pump at fuel tank.
Page 807 FUEL DELIVERY 14 - 15 When disconnecting a quick-connect fitting, the re- CAUTION: When using the ASD Fuel System Test, the tainer will remain on the fuel tube nipple. Automatic Shut Down (ASD) Relay remains energized (1) Disconnect negative cable from the battery. for either 7 minutes, until the test is stopped, or until (2) Perform the Fuel Pressure Release Procedure.
Page 808 14 - 16 FUEL DELIVERY (1) Disconnect negative cable from the battery. (7) Inspect connection by pushing down on tool (2) Perform the Fuel Pressure Release Procedure. Re- 6751. When inspecting the connection, a slight fer to the Fuel Pressure Release Procedure in this sec- downward movement of the quick-connect fit- tion.
Page 809 FUEL DELIVERY 14 - 17 Fig. 40 Connecting Quick-Connect Fittings to Fuel Rail...
Page 810 14 - 18 FUEL DELIVERY CHASSIS FUEL TUBES The fuel tubes route from the fuel tank, along the frame rail to the fuel rail (Fig. 43). Plastic fuel tubes connect to the fuel pump module. Metal quick-connect fittings and braided tubes attach the fuel filter and fuel return circuit to the fuel rail.
Page 811 FUEL DELIVERY 14 - 19...
Page 812 14 - 20 FUEL TANK FUEL TANKS INDEX page page Flexible Fuel Components ....21 Fuel Tank Pressure Relief/Rollover Valve ..23 Flexible Fuel Vehicles (FFV) .
Page 813 FUEL TANK 14 - 21 sciousness could result from breathing these vapors. CAUTION: Remove the fuel filler cap to release fuel Serious injury, blindness and even death could result tank pressure before disconnecting any fuel system from ingesting methanol. component. Methanol vapors are extremely flammable and can travel along the ground.
Page 814 14 - 22 FUEL TANK Fig. 4 Fuel Filler and Vent Hoses Fig. 6 Crossmember Bolts (9) Disconnect both ends of the sway bar from the stabilizer links (Fig. 5). (10) Use a grease pencil or marker to outline the position of the crossmember ends on the frame rail.
Page 815 FUEL TANK 14 - 23 (16) Center transmission jack. Lower jack enough (10) Install exhaust system on hangers. (11) Connect fuel supply, return and vent tubes. to provide access to the fuel line and electrical connec- Refer to Quick-Connect Fittings in the Fuel Delivery tions on the fuel pump module at the top of the tank.
Page 816 14 - 24 ACCELERATOR PEDAL AND THROTTLE CABLE ACCELERATOR PEDAL AND THROTTLE CABLE ACCELERATOR PEDAL SERVICE CAUTION: When servicing the accelerator pedal or throttle cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL (1) Working from the engine compartment, hold the throttle body throttle lever in the wide open position.
Page 817 ACCELERATOR PEDAL AND THROTTLE CABLE 14 - 25 (3) From inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of the pedal shaft. (4) At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet (Fig.
Page 818 14 - 26 FUEL INJECTION—SYSTEM OPERATION SEQUENTIAL MULTI-PORT FUEL INJECTION—SYSTEM OPERATION INDEX page page 5 Volt Supply—PCM Output ....39 Ignition Coil—PCM Output ....37 8-Volt Supply—PCM OUtput .
Page 819 FUEL INJECTION—SYSTEM OPERATION 14 - 27 Fig. 1 Sequential Multi-Port Fuel Injection Components RPM (speed) and manifold absolute pressure (air den- sity) are the primary inputs that determine injector pulse width. SYSTEM DIAGNOSIS The powertrain control module (PCM) can test many of its own input and output circuits.
Page 820 14 - 28 FUEL INJECTION—SYSTEM OPERATION • High Speed Fan Relay the Air Conditioning select input, transaxle gear • Idle Air Control Motor position input and speed control engage inputs over • Ignition Coils the CCD Bus. The PCM also receives the air condi- •...
Page 821 FUEL INJECTION—SYSTEM OPERATION 14 - 29 The PCM contains a voltage converter that changes the data link connector. The data link connector con- tains 6 terminals. Terminal 3 is the SCI Receive battery voltage to a regulated 8.0 volts. The 8.0 volts circuit.
Page 822 14 - 30 FUEL INJECTION—SYSTEM OPERATION marks are next. After 3 camshaft pulses, the PCM knows cylinder four crankshaft timing marks follow. One camshaft pulse after the three pulses indicates cylinder five. The two camshaft pulses after cylinder 5 signals cylinder six (Fig. 5 or Fig. 6). The PCM can synchronize on cylinders 1 or 4.
Page 823 FUEL INJECTION—SYSTEM OPERATION 14 - 31 Fig. 10 Intake Air Temperature Sensor— Fig. 7 Camshaft Position Sensor Location— 3.3L FFV Engine 3.3L Engine FIg. 8 Camshaft Position Sensor Location— 3.5L Engine Fig. 11 Timing Slots The crankshaft sensor is located on the passengers side of the transmission housing, above the differen- tial housing (Fig.
Page 824 14 - 32 FUEL INJECTION—SYSTEM OPERATION ENGINE COOLANT TEMPERATURE SENSOR—PCM knock sensor detects a knock in one of the cylinders, INPUT it sends an input signal to the PCM. In response, the The engine coolant temperature sensor threads into PCM retards ignition timing by a scheduled amount. the water jacket next to thermostat housing (Fig.
Page 825 FUEL INJECTION—SYSTEM OPERATION 14 - 33 Fig. 18 Methanol Concentration Sensor Fig. 16 MAP Sensor—3.3L Engine HEATED OXYGEN SENSORS—PCM INPUT The fuel injection system uses two heated oxygen sensors, one in the outlet of each exhaust manifold (Fig. 19 or Fig. 20). Both sensors monitor the amount of oxygen in the exhaust gas stream.
Page 826 14 - 34 FUEL INJECTION—SYSTEM OPERATION 3.5L engine has two throttle bodies, it only uses one TPS. On 3.5L engines, the TPS is mounted on the right side throttle body. Fig. 20 Heated Oxygen Sensor—3.5L Engine The oxygen sensors are equipped with a heating element.
Page 827 FUEL INJECTION—SYSTEM OPERATION 14 - 35 AIR CONDITIONING COMPRESSOR CLUTCH the ignition switch is in the Run position, it de- energizes both relays. When the relays are de- RELAY—PCM OUTPUT energized, battery voltage is not supplied to the fuel The powertrain control module (PCM) operates the injectors, ignition coil and fuel pump.
Page 828 14 - 36 FUEL INJECTION—SYSTEM OPERATION vides the correct amount of exhaust gas recirculation for different operating conditions. DUTY CYCLE EVAP PURGE SOLENOID—PCM OUTPUT The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body.
Page 829 FUEL INJECTION—SYSTEM OPERATION 14 - 37 Fig. 28 Fuel Injector—3.3L Engine Fig. 29 Ignition Coil Pack The PCM determines injector synchronization from IDLE AIR CONTROL MOTOR—PCM OUTPUT the camshaft position sensor and crankshaft position 3.3L ENGINE sensor inputs. The PCM grounds the ASD and fuel The idle air control motor attaches to the throttle pump relays after receiving the camshaft position body (Fig.
Page 830 14 - 38 FUEL INJECTION—SYSTEM OPERATION Fig. 30 Idle Air Control Motor—3.3L Engine Fig. 33 Idle Air Passage—3.5L Engine MALFUNCTION INDICATOR (CHECK ENGINE) LAMP—PCM OUTPUT The PCM transmits the signal for the malfunction indicator lamp (instrument panel Check Engine light) over the CCD Bus.
Page 831 FUEL INJECTION—SYSTEM OPERATION 14 - 39 to On Board Diagnostics in the General Diagnosis When the PCM receives an input from the A/C pressure transducer indicating high side pressure is section of this Group for Diagnostic Trouble Code approximately 1448 kPa (210 PSI), it energizes the Descriptions.
Page 832 14 - 40 FUEL INJECTION—SYSTEM OPERATION MODES OF OPERATION When the key is in the ON position and the engine As input signals to the powertrain control module is not running (zero rpm), the automatic shut down (PCM) change, the PCM adjusts its response to out- (ASD) relay and fuel pump relay are not energized.
Page 833 FUEL INJECTION—SYSTEM OPERATION 14 - 41 ENGINE WARM-UP MODE DECELERATION MODE This is an OPEN LOOP mode. The following inputs This is a CLOSED LOOP mode. During decelera- are received by the PCM: tion the following inputs are received by the PCM: •...
Page 834 14 - 42 FUEL INJECTION—SYSTEM OPERATION Fig. 34 Throttle Body—3.3L Engine Fig. 35 Throttle Bodies—3.5L Engine position sensor (TPS) attaches to the right throttle FUEL PRESSURE REGULATOR body. Because the shaft maintains throttle body syn- The powertrain control module (PCM) does not con- chronization, the fuel injection system uses only one trol the fuel pressure regulator.
Page 835 FUEL INJECTION—GENERAL DIAGNOSIS 14 - 43 SEQUENTIAL MULTI-PORT FUEL INJECTION—GENERAL DIAGNOSIS INDEX page page ASD and Fuel Pump Relays ....47 Throttle Body Minimum Air Flow—3.3L Engine .
Page 836 14 - 44 FUEL INJECTION—GENERAL DIAGNOSIS Fig. 5 Idle Air Control Motor—3.3L Engine Fig. 2 Power Distribution Center Fig. 6 Idle Air Control Motor—3.5L Engine Fig. 3 MAP Sensor—3.3L Engine Fig. 7 Throttle Position Sensor—3.5L Engine (3) Check the MAP sensor electrical connection Fig.
Page 837 FUEL INJECTION—GENERAL DIAGNOSIS 14 - 45 Fig. 8 Engine Coolant Temperature Sensor— Fig. 11 Manifold Tuning Valve 3.3L Engine Fig. 9 Engine Coolant Temperature Sensor— Fig. 12 Fuel Pressure Regulator—3.3L Engine 3.5L Engine ensure the PCV hose is connected to the PCV valve, not the idle air control motor.
Page 838 14 - 46 FUEL INJECTION—GENERAL DIAGNOSIS Fig. 16 Generator Fig. 13 Fuel Pressure Regulator—3.5L Engine Fig. 17 Crankshaft Position Sensor Fig. 14 EVAP Purge and MTV Solenoids Fig. 18 Heated Oxygen Sensor—3.3L Engine Fig. 15 EVAP Canister Hose Connections (17) Check for loose or corroded connections at the generator (Fig.
Page 839 FUEL INJECTION—GENERAL DIAGNOSIS 14 - 47 FUEL INJECTORS For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts. For poor fuel economy diagnosis or engine miss, also refer to Transmission Driveplate in this section. TRANSMISSION DRIVEPLATE A cracked transmission driveplate could cause poor fuel economy and an engine miss.
Page 840 14 - 48 FUEL INJECTION—GENERAL DIAGNOSIS 3.3L FUEL INJECTOR DIAGNOSIS...
Page 841 FUEL INJECTION—GENERAL DIAGNOSIS 14 - 49 3.5L FUEL INJECTOR DIAGNOSIS...
Page 842 14 - 50 FUEL INJECTION—GENERAL DIAGNOSIS Fig. 22 ASD and Fuel Pump Relay Terminals (6) Connect one end of another jumper wire (16 should be greater than 0.6 volts. At wide open gauge or smaller) to the power side of the 12 volt throttle, TPS output voltage should be less than 4.5 power source.
Page 843 FUEL INJECTION—GENERAL DIAGNOSIS 14 - 51 Fig. 23 PCV Valve—3.3L Engine Fig. 25 Orifice 6457 Attached to Purge Nipple— 3.3L Engine 3.3L MINIMUM AIR FLOW IDLE SPECIFICATIONS WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN.
Page 844 14 - 52 FUEL INJECTION—GENERAL DIAGNOSIS THROTTLE BODY MINIMUM AIR FLOW—3.5L ENGINE If the vehicle has a low idle speed condition, first use the DRB scan tool to check for proper operation of the idle air control motor. Refer to the DRB scan tool and the appropriate Powertrain Diagnostic Manual.
Page 845 FUEL INJECTION—GENERAL DIAGNOSIS 14 - 53 (11) If idle RPM is within the range shown in the (12) Shut off engine. Idle Specification chart, throttle body minimum air- (13) Remove orifice 6457 from each throttle body. flow is set correctly. Install purge hoses.
Page 846 14 - 54 FUEL INJECTION—ON-BOARD DIAGNOSTICS SEQUENTIAL MULTI-PORT FUEL INJECTION—ON-BOARD DIAGNOSTICS INDEX page page Circuit Actuation Test Mode ....56 Monitored Circuits ......54 Diagnostic Trouble Codes .
Page 847 FUEL INJECTION—ON-BOARD DIAGNOSTICS 14 - 55 Fuel Pressure - The vacuum assisted fuel pressure input voltages from other sensors or switches that must be present before verifying a diagnostic trouble regulator controls fuel system pressure. The PCM code condition. cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply or return DIAGNOSTIC TROUBLE CODES line.
Page 848 14 - 56 FUEL INJECTION—ON-BOARD DIAGNOSTICS • RPM STATE DISPLAY TEST MODE • Speed Control Target The switch inputs to the powertrain control module • Speed Control Status (PCM) have two recognized states; HIGH and LOW. • Target RPM For this reason, the PCM cannot recognize the differ- •...
Page 849 FUEL INJECTION—ON-BOARD DIAGNOSTICS 14 - 57 (b) Relays POWERTRAIN CONTROL MODULE 60-WAY • Auto Shutdown CONNECTOR • Radiator Fan Check the powertrain control module (PCM) 60-way connector for the following. (c) All Sol/Rel • Spread terminals (7) IAC Motor (idle air control motor) •...
Page 850 14 - 58 FUEL INJECTION—ON-BOARD DIAGNOSTICS...
Page 851 FUEL INJECTION—ON-BOARD DIAGNOSTICS 14 - 59 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS Diagnostic Trouble DRB Scan Tool Display Description of Diagnostic Trouble Code Code 11* ..No Crank Reference No crank reference signal detected during engine cranking. Signal at PCM 12* .
Page 852 14 - 60 FUEL INJECTION—ON-BOARD DIAGNOSTICS DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED Diagnostic Trouble DRB Scan Tool Display Description of Diagnostic Trouble Code Code 25** ..Idle Air Control Motor A shorted condition detected in one or more of the idle air control Circuits motor circuits.
Page 853 FUEL INJECTION—ON-BOARD DIAGNOSTICS 14 - 61 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED Diagnostic Trouble DRB Scan Tool Display Description of Diagnostic Trouble Code Code 42* ..Auto Shutdown Relay An open or shorted condition detected in the automatic shut down Control Circuit relay circuit.
Page 854 14 - 62 FUEL INJECTION—ON-BOARD DIAGNOSTICS DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED Diagnostic Trouble DRB Scan Tool Display Description of Diagnostic Trouble Code Code 63* ..PCM Failure EEPROM Unsuccessful attempt to write to an EEPROM location by the PCM. Write Denied 64** .
Page 855 FUEL INJECTION—SERVICE PROCEDURES 14 - 63 SEQUENTIAL MULTI-PORT FUEL INJECTION—SERVICE PROCEDURES INDEX page page Camshaft Position Sensor—3.3L Engine ..73 Idle Air Control Motor—3.5L Engine ... 76 Camshaft Position Sensor—3.5L Engine .
Page 856 14 - 64 FUEL INJECTION—SERVICE PROCEDURES THROTTLE BODY—3.3L ENGINE REMOVAL (1) Disconnect PCV make-up air hose from cylinder head cover. Remove air cleaner tube from throttle body (Fig. 4). Fig. 6 Throttle Position Sensor (2) Attach electrical connectors to throttle position sensor and idle air control motor.
Page 857 FUEL INJECTION—SERVICE PROCEDURES 14 - 65 blade and portions of the throttle bore that are closest to the throttle blade when it is closed, must be free of deposits. (4) Use compressed air to dry the throttle bodies. (5) Inspect throttle bodies for foreign material. (6) Install throttle bodies on manifold.
Page 858 14 - 66 FUEL INJECTION—SERVICE PROCEDURES THROTTLE BODY SYNCHRONIZATION—3.5L ENGINE Synchronize the throttle bodies if there is a gap between the adjustment screw and the linkage lever (Fig. 12 and Fig. 13). Also, synchronize the throttle bodies after removing and installing the throttle bod- ies.
Page 859 FUEL INJECTION—SERVICE PROCEDURES 14 - 67 FUEL RAIL—3.3L ENGINE REMOVAL WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL. WHEN SERVICING FLEXIBLE FUEL VEHICLES, WEAR METHANOL RE- SISTANT GLOVES AND EYE PROTECTION AND AVOID BREATHING FUMES. DO NOT ALLOW METHANOL/GASOLINE MIXTURES TO CONTACT SKIN.
Page 860 14 - 68 FUEL INJECTION—SERVICE PROCEDURES (10) Attach electrical connectors to the MAP sensor and EGR transducer solenoid. (11) Attach electrical connectors to throttle position sensor and idle air control motor. (12) Install throttle cable and speed control cable in bracket.
Page 861 FUEL INJECTION—SERVICE PROCEDURES 14 - 69 INTAKE MANIFOLD PLENUM—3.5L ENGINE (7) Disconnect electrical connector from manifold absolute pressure (MAP) sensor (Fig. 21). REMOVAL (1) Release fuel system pressure. Refer to Fuel Sys- tem Pressure Release Procedure in this section. (2) Remove engine cover from top of intake mani- fold plenum.
Page 862 14 - 70 FUEL INJECTION—SERVICE PROCEDURES Fig. 23 Air Inlet Plenum—3.5L Engine Fig. 26 Intake Manifold Plenum—3.5L Engine (2) Install and tighten support bracket bolts. (3) Attach electrical connectors to MAP Sensor, TPS, idle air control motor and intake air tempera- ture sensor.
Page 863 FUEL INJECTION—SERVICE PROCEDURES 14 - 71 (4) Using tool 6751, disconnect the fuel supply and return tubes from the fuel rail (Fig. 27). Refer to Metal Quick-Connect Fittings in the Fuel Delivery section of this group. Fig. 29 Fuel Injector Clamp—3.5L Engine (2) Position fuel rail over openings in intake mani- fold plenum.
Page 864 14 - 72 FUEL INJECTION—SERVICE PROCEDURES Fig. 30 Purging Fuel From Rail Fig. 32 Fuel Injector Removal—3.5L Engine (7) Remove the vacuum tube from the fuel pressure regulator (Fig. 28). (8) Remove fuel rail mounting bolts (Fig. 29). (9) Remove injector clamp screw (Fig. 29). (10) Slide the injector clamp toward the rear of the engine, then lift the clamp off of the rail (Fig.
Page 865 FUEL INJECTION—SERVICE PROCEDURES 14 - 73 (8) Install intake manifold plenum. Refer to Intake CAMSHAFT POSITION SENSOR—3.5L ENGINE Manifold Plenum—3.5L Engine in this section. The camshaft position sensor is installed in the timing case cover above the left camshaft sprocket CAMSHAFT POSITION SENSOR—3.3L ENGINE (Fig.
Page 866 14 - 74 FUEL INJECTION—SERVICE PROCEDURES INTAKE AIR TEMPERATURE SENSOR—3.3L FFV INSTALLATION ENGINE (1) Install sensor. Tighten sensor to 28 N m (20 ft. The intake air temperature sensor threads into the lbs.) torque. rear of the intake manifold plenum (Fig. 39). (2) Attach electrical connector to sensor.
Page 867 FUEL INJECTION—SERVICE PROCEDURES 14 - 75 Fig. 44 Duty Cycle EVAP Purge Solenoid Fig. 43 Engine Coolant Temperature Sensor— and MTV Solenoid 3.5L Engine HEATED OXYGEN SENSORS—3.3L ENGINE REMOVAL (1) With the engine cold, disconnect coolant sensor The 3.3L engine uses two heated oxygen sensors, electrical connector.
Page 868 14 - 76 FUEL INJECTION—SERVICE PROCEDURES REMOVAL (3) Remove idle air control motor mounting screws. (1) To access the heated oxygen sensor on the right (4) Remove idle air control motor. Ensure O-ring is exhaust manifold, remove the air cleaner tube. removed with the motor.
Page 869 FUEL INJECTION—SERVICE PROCEDURES 14 - 77 ELECTRONIC IGNITION COIL PACK—3.3L ENGINE The electronic ignition coil pack attaches to the a bracket mounted on the left cylinder head (Fig. 49). Fig. 51 Electronic Ignition Coil Pack—3.5L Engine (4) Remove coil. The spark plug cables are num- bered for cylinder identification (Fig.
Page 870 14 - 78 FUEL INJECTION—SERVICE PROCEDURES Fig. 53 Knock Sensor Location Fig. 55 MAP Sensor—3.5L Engine INSTALLATION INSTALLATION (1) Install knock sensor. Tighten knock sensor to 10 (1) Thread sensor into intake manifold plenum. N m (7 ft. lbs) torque. Over or under tightening Tighten sensor to 10 N m (90 in.
Page 871 FUEL INJECTION—SERVICE PROCEDURES 14 - 79 MANIFOLD TUNING VALVE—3.5L ENGINE POWERTRAIN CONTROL MODULE (PCM) The PCM engine control strategy prevents reduced REMOVAL idle speeds until after the engine operates for 320 km (1) Remove engine cover. (200 miles). If the PCM is replaced after 320 km (200 (2) Disconnect vacuum hose from manifold tuning miles) of usage, update the milage in new PCM.
Page 872 14 - 80 FUEL INJECTION—SERVICE PROCEDURES (3) Install PCM. Tighten stud bolt to 10 N m (7 ft. lbs.) torque. Install push pin. Push down on center lock of pushpin. (4) Install air cleaner. (5) Using DRB scan tool, program milage into PCM.
Page 873 FUEL INJECTION—SERVICE PROCEDURES 14 - 81 Fig. 65 Throttle Position Sensor Installation— Fig. 66 Rotate TPS Clockwise For Alignment— 3.5L Engine 3.5L Engine REMOVAL holes with the screw holes in the throttle body (Fig. (1) Disconnect the TPS electrical connector (Fig. 64). 66).
Page 874 14 - 82 FUEL INJECTION—SERVICE PROCEDURES SPECIFICATIONS TORQUE...
Page 875 FUEL SYSTEMS 14 - 1 FUEL SYSTEMS GENERAL INFORMATION During Limp-In mode, the PCM attempts to keep the This section describes Fuel System differences be- system operational and leaves the lamp on. In Limp-In tween the Chrysler New Yorker and the 1993 Chrysler mode, the PCM compensates for the failure of certain Concorde, Eagle Vision and Dodge Intrepid.
Page 876 14 - 2 FUEL SYSTEMS DIAGNOSTIC TROUBLE CODE DESCRIPTION...
Page 877 FUEL SYSTEMS 14 - 3 DIAGNOSTIC TROUBLE CODE DESCRIPTION (CONTINUED)
Page 878 14 - 4 FUEL SYSTEMS DIAGNOSTIC TROUBLE CODE DESCRIPTION (CONTINUED)
Page 879 STEERING 19 - 1 STEERING CONTENTS page page GENERAL INFORMATION ....1 SPECIFICATIONS AND TIGHTENING POWER STEERING GEAR ....19 REFERENCE .
Page 880 19 - 2 STEERING POWER STEERING PUMPS INDEX page page Checking Power Steering Fluid Level ... 9 Power Steering Pump Removal ....13 Flow Control Valve Fitting O-Ring Seal .
Page 881 STEERING 19 - 3 STEERING COMPONENTS SERVICE DIAGNOSIS POWER STEERING SERVICE DIAGNOSIS...
Page 882 19 - 4 STEERING POWER STEERING SERVICE DIAGNOSIS...
Page 883 STEERING 19 - 5 POWER STEERING SERVICE DIAGNOSIS...
Page 884 19 - 6 STEERING POWER STEERING SERVICE DIAGNOSIS...
Page 885 STEERING 19 - 7 POWER STEERING SERVICE DIAGNOSIS...
Page 886 19 - 8 STEERING POWER STEERING SERVICE DIAGNOSIS...
Page 887 STEERING 19 - 9 POWER STEERING PUMP SERVICE When the high pressure area of the power steering The service procedures for the Saginaw power steer- pump is filled with power steering fluid. Power ing pump are limited to the areas and components steering fluid then flows under the vanes in the rotor listed below.
Page 888 19 - 10 STEERING Power steering pump maximum relief pres- sure is 8275 to 8975 kPa (1200 to 1300 psi.). • Power steering pump pressures above specifica- tions but not within 345 kPa (50 psi) of each other, replace pump. •...
Page 889 STEERING 19 - 11 (2) Install new O-rings and/or washer seals on the ends of the power steering hoses. Lubricate O-rings or washer seals using fresh clean power steering fluid. (3) Install power steering pressure hose into outlet fitting of the power steering pump (Fig. 2). Do not tighten power steering pressure hose to power steering pump fitting at this time.
Page 890 19 - 12 STEERING CAUTION: On 3.5 ltr engine applications, correct orientation of power steering pressure hose at power steering pump must be maintained. Be sure power steering hose is installed in orientation clip (Fig. 6) at generator, prior to tightening tube fitting. This will maintain required clearance between power steering pressure hose and throttle body cam.
Page 891 STEERING 19 - 13 (4) Install power steering return hose into steering gear return port and loosely install fitting. Do not tighten power steering return hose to steering gear fitting at this time. (5) Install power steering return hose, onto remote power steering fluid reservoir (Fig.
Page 892 19 - 14 STEERING Fig. 3 Power Steering Fluid Hose From Remote Fig. 6 Power Steering Pump Mounting Bolts Reservoir Fig. 7 Power Steering Pump Removal And Installation Fig. 4 Power Steering Pressure Hose Routing Clip INSTALL (1) Install power steering pump back in vehicle from the bottom of the engine compartment (Fig.
Page 893 STEERING 19 - 15 Fig. 7 Power Steering Pressure Hose Routing Clip (4) Install hose from remote power steering fluid reservoir, on low pressure port of power steering pump (Fig. 3). (5) Install the serpentine drive power steering belt on the power steering pump drive pulley. Fig.
Page 894 19 - 16 STEERING CAUTION: When installing the pulley on the Sagi- naw T/C style power steering pump. The spacer that is provided with either the replacement power steer- ing pump or pulley MUST be used when the pulley is installed on the pump. The spacer provides for the correct pulley location on the power steering pump to provide correct accessory drive belt align- ment.
Page 895 STEERING 19 - 17 Fig. 8 Battery Tray Mounting Fig. 6 Power Steering Fluid Reservoir Location (2) Position drain pan under vehicle for leaking power steering fluid. Loosen and remove power steer- ing return hose (Fig. 7) from side of power steering fluid reservoir.
Page 896 19 - 18 STEERING FLOW CONTROL VALVE FITTING O-RING SEAL INSTALLATION (1) If necessary, clean and install flow control valve REMOVAL and spring in pump housing bore (Fig. 10). Be sure (1) Remove power steering pressure hose from the hex nut end of the valve is facing in toward the pump.
Page 897 STEERING 19 - 19 POWER STEERING GEAR INDEX page page General Information ..... . . 19 Steering Gear Service ..... 19 Outer Tie Rod .
Page 898 19 - 20 STEERING cation and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (3) Remove gear shift cable, from shift lever on transaxle. Loosen bolt (Fig. 2) at gear shift cable to transaxle mount.
Page 899 STEERING 19 - 21 • Remove wiring harness connector from travel sen- ing column shaft rotates beyond normal num- ber of turns in either direction clock spring sor. • Using a small screwdriver lift retaining ring from damage will occur. (13) Using paint mark steering coupler and steer- notch (Fig.
Page 900 19 - 22 STEERING (21) Slide steering gear forward in vehicle to disen- gage steering coupler from steering gear shaft. After steering gear is disengaged from steering cou- pler, do not rotate steering gear shaft. (22) Remove steering gear assembly from vehicle through area in cowl that the windshield wiper mod- ule was previously removed from (Fig.
Page 901 STEERING 19 - 23 (4) Install the steering coupler to steering gear shaft retaining roll pin (Fig. 14). Roll pin must be installed until it is flush with top edge of steering coupler (Fig. 7). Fig. 16 Power Steering Fluid Line Connections At Steering Gear CAUTION: After tie rod attaching bolts are torqued, bend attaching bolt retaining tabs against heads of...
Page 902 19 - 24 STEERING (7) Install pedal travel sensor retaining ring on (11) Install vacuum supply hose for power brake booster back on intake manifold vacuum port. Install travel sensor grommet in the vacuum booster (Fig. hose clamp on vacuum hose. 19).
Page 903 STEERING 19 - 25 (19) Raise vehicle. (20) Install gear shift cable onto shift lever on tran- saxle. Install gear shift cable on cable mounting bracket of transaxle and securely tighten bolt (Fig. 26). Fig. 23 Air Intake Plenum Installation Fig.
Page 904 19 - 26 STEERING OUTER TIE ROD (3) Install outer tie rod into steering arm on front strut assembly. Install tie rod to steering arm attach- REMOVAL ing nut and torque to 37 N m (27 ft.lbs.). (1) Raise vehicle on jackstands or centered on a (4) Install and tighten wheel mounting stud nuts in frame contact type hoist.
Page 905 STEERING 19 - 27 SPEED PROPORTIONAL POWER STEERING GEAR INDEX page page General Information ..... . . 27 Solenoid Control Valve Service ....29 Solenoid Control Valve Control Module Service .
Page 906 19 - 28 STEERING using the DRB scan tool, to create an electronically simulated vehicle speed of 0 and 60 mph. Refer to the 1994 M.Y. Chassis Daignostic Procedures Manual for the specific testing procedure. The solenoid control valve and solenoid control module are both serviceable components of the variable-assist speed-proportional...
Page 907 STEERING 19 - 29 INSTALL (1) Insert tabs on solenoid control module (Fig. 5) into steering gear end cap. Then rotate module down- ward until locking tabs on module (Fig. 4) are en- gaged with steering gear end cap. (2) Connect wiring harness connectors onto sole- noid control module (Fig.
Page 908 19 - 30 STEERING Fig. 10 Loosening Solenoid Control Valve From Fig. 12 Solenoid Control Valve Wiring Harness Steering Gear Routing At Steering Gear (3) Using the 1 5/16 inch crow foot as shown in (5) Connect wiring harness connector from solenoid control valve onto solenoid control module (Fig.
Page 909 STEERING 19 - 31 SAGINAW TILT STEERING COLUMN INDEX page page General Information ..... . . 31 Steering Column Service Procedures .
Page 910 19 - 32 STEERING...
Page 911 STEERING 19 - 33 The Saginaw tilt steering column (Fig. 1) has been (1) Lock steering column by turning steering wheel designed to be serviced as an assembly; less wiring, 1/2 turn (180°) clockwise from the straight ahead switches, shifter assembly, ignition park interlock, position of the front wheels (Fig.
Page 912 19 - 34 STEERING Fig. 7 Removing Steering Wheel From Shaft Fig. 4 Air Bag Module Attaching Bolts (8) Remove instrument panel left and right end covers (Fig. 8). Refer to Group 8 Electrical in this service manual for the required removal procedure. Fig.
Page 913 STEERING 19 - 35 (10) Remove left and right lower cowl area trim panels (Fig. 10). Fig. 10 Lower Cowl Area Trim Panels (Left Side Shown) (11) Remove ash receiver (Fig. 11) from lower knee bolster panel. Fig. 12 Center Bezel Removal From Instrument Panel Fig.
Page 914 19 - 36 STEERING (15) Remove screw attaching lower knee bolster panel to upper instrument panel (Fig. 15). Fig. 17 Lower Knee Bolster Attaching Screws At Glove Box Fig. 15 Lower Knee Bolster To Upper Instrument Panel Attachment (16) Remove vehicle wiring harness connectors from cigar lighter and ash receiver assembly (Fig.
Page 915 STEERING 19 - 37 (22) Remove the 2 under steering column, heat and A/C ducts (Fig. 20). Fig. 22 Shroud To Steering Column Attaching Screws Fig. 20 Under Steering Column Heat And A/C Ducts ing column (Fig. 23). Then remove shift cable retain- ing clip at shift cable support bracket, (Fig.
Page 916 19 - 38 STEERING Fig. 27 Lower Steering Column Mounting Bracket Fig. 24 Shift Cable Bracket And Retaining Clip Fig. 25 Shifter Interlock Cable Removal Fig. 28 Upper Steering Column Assembly Mounting (32) Remove steering column assembly from mounting brackets and lay on floor of vehicle (Fig. 29).
Page 917 STEERING 19 - 39 clips on multi function switch and on side of clock spring (Fig. 28 and 29). Be sure wiring is taut and free of interference with column shifter assembly actuator in low gear. (3) Install steering column assembly back on mounting bracket, by first sliding lower steering col- umn bracket onto bolts in mounting bracket (Fig.
Page 918 19 - 40 STEERING full up. Then tighten upper and lower steering col- umn assembly fasteners to hold steering column in place. Then again remove upper and lower steering column shrouds and the center instrument panel be- zel. (6) Be sure both breakaway capsules are fully seated in the slots of the steering column upper support bracket.
Page 919 STEERING 19 - 41 (17) Install lower knee bolster panel onto upper instrument panel. Ensure the 3 tabs on knee bolster panel are installed into mating slots in upper instru- ment panel. (18) Install but do not tighten, the 6 bolts (3 each side) attaching lower knee bolster panel to cowl panel (Fig.
Page 920 19 - 42 STEERING Fig. 41 Knee Bolster Panel Attachment At Ash Receiver Fig. 43 Radio And Heater A/C Control Attachment To Knee Bolster Panel Fig. 42 Lower Knee Bolster To Upper Instrument Panel Attachment (24) Install center upper air outlet bezel, back in Fig.
Page 921 STEERING 19 - 43 Fig. 47 Air Bag Module Attaching Bolts Fig. 45 Wire Routing Through Steering Wheel Fig. 48 Instrument Panel End Covers servicing adjustment shifter/ignition interlock system on either a floor or column shift vehicle. Refer to the Ignition Switch And Interlock Section of Group 8 for the required opera- tion check and adjustment of the interlock system.
Page 922 19 - 44 STEERING (4) Install the gear shift cable onto the cable at- taching pin on shifter assembly. (5) Adjust interlock cassette. Refer to the Ignition Switch And Interlock Section of Group 8 for the re- quired operation check and adjustment procedure of the interlock system.
Page 923 STEERING 19 - 45 1994 New Yorker, LHS, Concorde, Intrepid and Vision Publication No. 81-270-4140 TSB 26-12-96 December, 1996 INSTALL (1) Install steering coupler on steering shaft until correctly positioned to allow spring pin to be installed CAUTION: Steering column shaft must be supported in coupler.
Page 925 TRANSAXLE 21 - 1 TRANSAXLE CONTENTS page page 42LE FOUR SPEED AUTOMATIC TRANSAXLE . . 1 42LE ON-BOARD DIAGNOSTICS ... 84 42LE HYDRAULIC SCHEMATICS ..101 42LE SPECIFICATIONS .
Page 926 21 - 2 TRANSAXLE 2nd, and direct gears with 2nd-direct shift delayed to 40 mph or greater. When operating in 3 or L posi- tions torque converter clutch application occurs in direct gear. This improves transmission cooling when towing trailers and/or driving on steep grades. If high engine coolant temperature occurs, the torque converter clutch will also engage in 2nd gear.
Page 927 TRANSAXLE 21 - 3 dirt particles. For that reason hardened-steel poppet This method achieves more precision than would be and ball valves are used. These are free from any possible with exacting tolerances. It can also adapt to close operating clearances, and the solenoids operate any changes that occur with age or environment.
Page 928 21 - 4 TRANSAXLE After noting all conditions, check the easily acces- Then perform a road test to determine if the prob- sible variables: lem has been corrected or that more diagnosis is • Fluid level and condition necessary. If the problem exists after the preliminary •...
Page 929 TRANSAXLE 21 - 5 DIAGNOSIS GUIDE-VEHICLE WILL NOT MOVE...
Page 930 21 - 6 TRANSAXLE DIAGNOSIS GUIDE-FLUID LEAKS...
Page 931 TRANSAXLE 21 - 7 DIAGNOSTIC TROUBLE CODE CHART A...
Page 932 21 - 8 TRANSAXLE DIAGNOSIS CHART B...
Page 933 TRANSAXLE 21 - 9 FLUID LEVEL AND CONDITION The transmission fluid level should be inspected at The transmission and differential have separate least every six months. oil sumps. The transmission sump requires auto- DIFFERENTIAL SUMP matic transmission fluid. The differential sump re- The differential sump is checked separately from quires petroleum based hypoid gear lube.
Page 934 21 - 10 TRANSAXLE at the time of the oil change. The magnet (on (3) Remove differential fill plug located on the dif- ferential side cover. This will assist the flow of fluid the inside of the oil pan) should also be cleaned from the drain plug hole.
Page 935 TRANSAXLE 21 - 11 (2) Remove column cover screws (Fig. 2). Fig. 5 Lower Column Cover Removal Fig. 2 Lower Column Cover Screw Removal (6) Remove cable from shift pin (Fig. 6). (3) Tilt column down and remove upper half of column cover (Fig.
Page 936 21 - 12 TRANSAXLE (8) From underhood side of dash panel, unseat grommet and pull cable from interior of vehicle. (9) Raise vehicle on hoist and unbolt fill tube bracket. Rotate fill tube to gain access to shift cable clamp (Fig. 8). Fig.
Page 937 TRANSAXLE 21 - 13 (12) Adjust cable by rotating the adjuster into lock (4) Tilt the steering column to the full down posi- position (Fig. 12). The adjuster will click when lock is tion. fully adjusted. (5) Place shifter in the park position with the key removed.
Page 938 21 - 14 TRANSAXLE (8) Loosen bolt that clamps shift cable to transaxle. (9) Disconnect shifter cable from shift lever assem- bly at transaxle. (10) Remove cable from underneath vehicle. INSTALLATION (1) Reroute new cable from underside of vehicle. The cable must be routed between the engine block and the heater return tube (Fig.
Page 939 TRANSAXLE 21 - 15 FLOOR SHIFTER REMOVAL (1) Remove shifter handle and console bezel. (2) Loosen adjuster nuts on interlock adjuster and shifter adjuster. (3) Disconnect shifter cable from cable attaching stud (pin). (4) Disconnect interlock cable from shifter base slot.
Page 940 21 - 16 TRANSAXLE ROAD TEST HYDRAULIC PRESSURE TESTS Pressure testing is a very important step in the Prior to performing a road test, verify that the fluid diagnostic procedure. These tests usually reveal the level, fluid condition, and linkage adjustment have cause of most transaxle problems.
Page 941 TRANSAXLE 21 - 17 TEST ONE-SELECTOR IN L (3) Allow vehicle wheels to turn and increase This test checks pump output, pressure regu- throttle opening to achieve an indicated vehicle speed lation and condition of the low/reverse clutch of 50 mph. hydraulic circuit and shift schedule.
Page 942 21 - 18 TRANSAXLE 42LE PRESSURE CHECK SPECIFICATIONS OVERDRIVE CLUTCH Apply air pressure to the overdrive clutch apply passage and watch for the push/pull piston to move forward. The piston should return to its starting posi- tion when the air pressure is removed. UNDERDRIVE CLUTCH Because this clutch piston cannot be seen, its opera- tion is checked by function.
Page 943 TRANSAXLE 21 - 19 Fig. 3 Testing Underdrive Clutch Fig. 4 Weep Hole Location carefully for the 2/4 piston to move rearward. The (2) Prior to removing the transaxle, perform the piston should return to its original position after the following checks: air pressure is removed.
Page 944 21 - 20 TRANSAXLE (4) Run engine at approximately 2,500 rpm with (3) Clean the suspect area of the transaxle with transaxle in neutral, for about 2 minutes. Transaxle solvent. must be at operating temperature. (4) Road test the vehicle until the leak reoccurs. (5) Stop engine and carefully remove tool.
Page 945 TRANSAXLE 21 - 21 (1) Plug dipstick tube and plug oil cooler line fit- procedure. If any of the items listed above require tings. replacement, this procedure cannot be used. Refer to Differential Recondition section of this manual. CAUTION: Prevent manual shaft rotation during in- (1) Remove transaxle from vehicle.
Page 946 21 - 22 TRANSAXLE Fig. 3 Indexing Outer Adjuster Fig. 4 Indexing Outer Adjuster CAUTION: Keep the inner adjuster for reinstallation. (6) Lube inner adjuster threads with gear oil and reinstall to the cross haired index marks. (7) Install the differential carrier. Then install stub shaft seal protector.
Page 947 TRANSAXLE 21 - 23 cooler (Fig. 8). Catch the exiting spirits from the To Cooler line. Observe for the presence of debris in the exiting fluid. Continue until fluid exiting is clear and free from debris. Fig. 7 Stub Shaft Corrosion (9) Install outer adjuster into transaxle case and tighten adjuster within 10 ft.
Page 948 21 - 24 TRANSAXLE formation is sent to the transmission control module. (2) Remove valve body assembly from transaxle. Refer Also the MVLPS provides for Park/Neutral only to Valve Body in this section for removal procedure. starter operation and back-up lamp operation. (3) Remove solenoid retaining screws from solenoid The MVLPS connector extends outside the tran- (Fig.
Page 949 TRANSAXLE 21 - 25 (2) Remove power distribution center plastic cover. If the transmission control module has been replaced, refer to Quick Learn Procedure. This (3) Pull relay out of power distribution center (Fig. program will allow the transmission control module to learn the characteristics of the ve- hicle.
Page 950 21 - 26 TRANSAXLE...
Page 951 TRANSAXLE 21 - 27 SPEED SENSOR-INPUT The solenoid pack and MVLPS can only be removed from the valve body after the valve body is removed The input speed sensor can be serviced without from the transaxle. having to remove the transaxle from the vehicle. REMOVAL AND INSTALLATION CAUTION: When disconnecting speed sensor con- (1) Disconnect the MVLPS wiring connector.
Page 952 21 - 28 TRANSAXLE (6) Remove oil filter from valve body (Fig. 3). It is held in place by two clips. Fig. 5 Remove Valve Body From Transaxle Fig. 3 Remove Transaxle Oil Filter CAUTION: The 42LE transaxle oil filter is not inter- changeable with the 41TE transaxle filter.
Page 953 TRANSAXLE 21 - 29 Fig. 8 Accumulator Locations Fig. 11 Stiffener Plate Location RECONDITION (5) Remove 2/4 accumulator retaining plate screws. (1) Remove manual shaft screw (Fig. 9) (6) Remove thermal valve (Fig. 12). Fig. 9 Manual Shaft Screw Fig. 12 Thermal Valve Location (2) Remove Manual Valve Lever Position Sensor (MVLPS) and manual shift lever.
Page 954 21 - 30 TRANSAXLE (8) Remove dual retainer plate from valve body. without having to set backlash and measure differen- tial bearing turning torque. Use special tool 6301 to remove plate (Fig. 14). CAUTION: The transfer shaft rear shim, bearing cups and cones, differential bearings and the differ- ential adjusters must be reused to use this proce- dure.
Page 955 TRANSAXLE 21 - 31 Fig. 16 Valve Body Components Fig. 18 Indexing Inner Adjuster Fig. 17 Long Stub Shaft Removal turns in both directions. Finish tightening the ad- juster 1/4 turn to its index mark (original location). (16) Reinstall the outer adjuster locking bracket.
Page 956 21 - 32 TRANSAXLE Fig. 19 Indexing Outer Adjuster Fig. 2 Wiring Connector Location TRANSAXLE REMOVAL AND INSTALLATION The transaxle can be removed without having to remove the engine. (1) Disconnect battery. (2) Remove engine air inlet tube. (3) Disconnect crankshaft position sensor connector and remove sensor (Fig.
Page 957 TRANSAXLE 21 - 33 Inspect the driveplate for cracks before reinstalling transaxle. If any cracks are found replace the drive- plate. Do not attempt to repair a cracked driveplate. Always use new torque converter to driveplate bolts. If the torque converter has been replaced, re- fer to Torque Converter Clutch Break-in Proce- dure in this section.
Page 958 21 - 34 TRANSAXLE INSTALLATION If a new transmission control module is put on the (1) Clean and inspect oil pump seal seat. Then vehicle, the status will be at the start of break-in. install seal using special tool C-4193A (Fig. 6). This status is acceptable regardless of the mileage on the torque converter.
Page 959 TRANSAXLE 21 - 35 Break-in Status has been RESET to Start. This (8) Press the number 1 on the DRB scan tool key screen will indicate that the reset procedure has been pad (Quick Learn). Then follow the instructions on successfully completed.
Page 960 21 - 36 TRANSAXLE Fig. 6 Remove Valve Body From Transaxle Fig. 3 Remove Transaxle Oil Pan For valve body recondition procedure, refer to Valve Body in this section. Fig. 4 Remove Transaxle Oil Filter Fig. 7 Remove Underdrive Accumulator and Spring Fig.
Page 961 TRANSAXLE 21 - 37 CAUTION: Tag the springs for the Overdrive Accu- mulator so that they are not confused with the springs in the Low/Reverse Accumulator. Fig. 12 Low/Reverse Accumulator Piston Fig. 9 Accumulator Locations Fig. 13 Low/Reverse Accumulator Fig. 10 Remove Low/Reverse Accumulator Fig.
Page 962 21 - 38 TRANSAXLE Fig. 18 Remove Oil Pump Fig. 15 Remove Long Stub Shaft From Bell-housing CAUTION: Drive shaft retainer clips and seals lo- cated on the stub shafts must be replaced before reinstalling drive shafts. Fig. 19 Remove Oil Pump Gasket CAUTION: By-pass valve must be replaced trans- mission failure occurs.
Page 963 TRANSAXLE 21 - 39 Fig. 21 Remove No. 1 Caged Needle Bearing Fig. 23 Remove Front Sun Gear Assembly Fig. 24 Remove Front Carrier and Rear Annulus Assembly Fig. 22 Remove Input Clutch Assembly Fig. 25 Remove Rear Sun Gear...
Page 964 21 - 40 TRANSAXLE The number 7 needle bearing has antireversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 26). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
Page 965 TRANSAXLE 21 - 41 Fig. 31 2/4 Retainer and Spring Indexed Fig. 34 Tapered Snap Ring Instructions Fig. 32 Remove 2/4 Clutch Pack Fig. 35 Snap Ring Installed Fig. 33 Remove Tapered Snap Ring...
Page 966 21 - 42 TRANSAXLE Fig. 36 Low/Reverse Reaction Plate Fig. 39 Remove Low/Reverse Clutch Pack Stand Trans Upright on Bell-housing Fig. 40 Remove Chain Cover Fig. 37 Remove One Disc Chain cover must be free of old sealant, dirt and oil before applying new sealant.
Page 967 TRANSAXLE 21 - 43 CAUTION: Be sure to reinstall the chain snubber CAUTION: The chain sprockets have a slip fit onto there shafts. Apply only a slight amount of pressure and chain oiler when reassembling. to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly removal or installation will be difficult.
Page 968 21 - 44 TRANSAXLE CAUTION: When reinstalling drive chain, the blue link must face outward. Fig. 49 Correctly Applied Sealant Fig. 47 Output Sprocket Spacer When reinstalling transaxle drive chain and sprock- ets, sprocket height must be checked. Refer to Drive Sprocket Height Adjustment Procedure in this group.
Page 969 TRANSAXLE 21 - 45 Using a small chisel, carefully open stakes on nut (Fig. 52). Fig. 54 Use Arbor Press to Remove Output Shaft from Case Fig. 52 Opening Nut Stakes Use special tool 6497 and 6498 to remove the trans- fer shaft nut or the output shaft nut (Fig.
Page 970 21 - 46 TRANSAXLE Use special tool 6597 and handle C-4171 and C-4171-2 to press rear output shaft bearing cup rear- ward (Fig. 56). Fig. 58 Remove Rear Carrier Front Bearing Cone Fig. 56 Remove Rear Bearing Cup Use special tool 5050A to install both front and rear bearing cups (Fig.
Page 971 TRANSAXLE 21 - 47 Fig. 63 Remove Parking Sprag Pivot Retaining Fig. 60 Compressor Tool in Use Screw CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle case. Fig. 61 Remove Snap Ring Fig.
Page 972 21 - 48 TRANSAXLE Fig. 66 Guide Bracket Assembled Fig. 69 Piston Retainer Attaching Screws Fig. 67 Guide Bracket Disassembled Fig. 70 Piston Retainer Fig. 68 Low/Reverse Clutch Piston Fig. 71 Piston Retainer Gasket AT THIS POINT the Centerline of the transaxle shaft seal.
Page 973 TRANSAXLE 21 - 49 OUTPUT SHAFT BEARING PRELOAD SHIM (2) Install special tool 6618A (Fig. 3). Lightly tighten retaining screws. Screws should be below the SELECTION plate surface, but do not snug screws. When assembling, the output bearing preload must be checked and/or adjusted if any of the following items have been replaced: •...
Page 974 21 - 50 TRANSAXLE OUTPUT SHAFT REAR SHIM CHART 8 in. lbs., install a thicker shim. If the turning torque is less than 1 in. lb., install a thinner shim. Make sure there is no end play. (5) Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position.
Page 975 TRANSAXLE 21 - 51 LOW/REVERSE REACTION PLATE CHART Fig. 8 Correctly Staked Nut LOW/REVERSE CLUTCH CLEARANCE Fig. 10 Check 2/4 Clutch Clearance INPUT CLUTCHES-RECONDITION DISASSEMBLY Fig. 9 Check Low/Reverse Clutch Clearance Press down clutch pack with finger and zero dial indicator.
Page 976 21 - 52 TRANSAXLE Fig. 5 Reverse Clutch Pack Fig. 2 Reverse Clutch Snap Ring Tag reverse clutch pack for reassembly identi- fication. Fig. 3 Pry Reverse Clutch Reaction Plate Fig. 6 OD/Reverse Pressure Plate Snap Ring Fig. 4 Reverse Clutch Reaction Plate Fig.
Page 977 TRANSAXLE 21 - 53 Tag overdrive clutch pack for reassembly identification. Fig. 8 Waved Snap Ring Fig. 11 Overdrive Shaft Assembly Fig. 9 Remove OD Clutch Pack Fig. 12 Underdrive Shaft Assembly Fig. 13 No. 2 Needle Bearing Fig. 10 Overdrive Clutch Pack...
Page 978 21 - 54 TRANSAXLE Fig. 14 OD/UD Reaction Plate Tapered Snap Ring Fig. 17 UD Clutch Flat Snap Ring Fig. 15 OD/UD Reaction Plate Fig. 18 Underdrive Clutch Pack CAUTION: Compress return spring just enough to remove or install snap ring. Fig.
Page 979 TRANSAXLE 21 - 55 Fig. 20 UD Return Spring and Retainer Fig. 23 Tap on Input Hub Fig. 21 Underdrive Clutch Piston Fig. 24 Input Hub Removed Fig. 22 Input Hub Tapered Snap Ring Fig. 25 Pull Retainer from Piston...
Page 980 21 - 56 TRANSAXLE Fig. 26 Install Snap Ring Fig. 29 Remove Input Shaft ASSEMBLY Use petrolatum on all seals to ease assembly of components. Fig. 27 Snap Ring and Return Spring Fig. 1 Install Input Shaft Fig. 28 Remove Input Shaft Snap Ring Fig.
Page 981 TRANSAXLE 21 - 57 Fig. 6 Install Input Shaft Hub Assembly Fig. 3 Return Spring and Snap Ring Fig. 4 Install Snap Ring Fig. 7 Input Hub Tapered Snap Ring Fig. 5 Install OD/Reverse Piston Fig. 8 Underdrive Clutch Piston...
Page 982 21 - 58 TRANSAXLE Fig. 9 Seal Compressor Special Tool 5067 Fig. 12 Underdrive Clutch Pack Fig. 10 UD Return Spring and Retainer Fig. 13 UD Clutch Flat Snap Ring CAUTION: Compress return spring just enough to remove or install snap ring. Fig.
Page 983 TRANSAXLE 21 - 59 Fig. 15 OD/UD Reaction Plate Fig. 18 Set Up Dial Indicator for Clutch Clearance Fig. 16 Tapered Snap Ring Snap ring ends must be located within one Fig. 19 Use Hook Tool to Raise One Clutch Disc finger of the input clutch hub.
Page 984 21 - 60 TRANSAXLE Fig. 23 Pressure Plate Installed Fig. 20 Install OD Clutch Pack Fig. 24 Install Flat Snap Ring Fig. 21 Install Waved Snap Ring Fig. 25 Check OD Clutch Pack Clearance Fig. 22 OD/Reverse Pressure Plate...
Page 985 TRANSAXLE 21 - 61 The overdrive (OD) clutch pack clearance is .965 to 2.26 mm (.038 to .089 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance. Fig. 29 Seating Snap Ring to Determine Reverse Clutch Clearance Fig.
Page 986 21 - 62 TRANSAXLE CAUTION: Do not intermix clutch parts. Keep in exact same order. Now proceed with the next phase of the assembly: Fig. 34 Install No. 3 Thrust Plate Fig. 31 Install No. 2 Needle Bearing Fig. 35 Install Overdrive Shaft Assembly Reinstall overdrive clutch and reverse clutch as shown in Figures 20 through 28.
Page 987 TRANSAXLE 21 - 63 DETERMINING No. 4 THRUST PLATE THICKNESS (Input Shaft End Play) The input clutch assembly must be completed prior to performing this step. To determine the proper thickness of the No. 4 thrust plate, select the thinnest No. 4 thrust plate (Fig.
Page 988 21 - 64 TRANSAXLE NO. 4 THRUST PLATE CHART Fig. 3 Screwdriver Placement (6) Butt a scale against the snubber and place a second mark on the scale at the bottom of the chain (Fig. 4). Fig. 1 Screwdriver Placement Fig.
Page 989 TRANSAXLE 21 - 65 If the transfer chain was replaced, refer to Snubber 33 teeth. Check the height difference using a straight edge (special tool 6311 or equivalent) and a set of Gap Measurement in this section to verify correct feeler gauges.
Page 990 21 - 66 TRANSAXLE DIFFERENTIAL RECONDITION The valve body and solenoid wiring connector must be removed from the transaxle in order to recondition the transaxle differential. The transfer shaft cannot be removed with the valve body in place. Refer to Valve Body Recondition for removal procedure.
Page 991 TRANSAXLE 21 - 67 CAUTION: The chain sprockets have a slip fit onto there shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly removal or installation will be difficult.
Page 992 21 - 68 TRANSAXLE Fig. 11 Remove Outer Adjuster Fig. 13 Remove Differential Side Cover, Carrier and Ring Gear Assembly If the carrier requires reconditioning, refer to Dif- ferential Carrier Recondition. Fig. 12 Loosen Outer Adjuster Fig. 14 Remove Inner Adjuster By Turning Clockwise CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to...
Page 993 TRANSAXLE 21 - 69 Using a small chisel, carefully open stakes on nut (Fig. 18). Fig. 15 Remove Differential Vent Baffle Using a die grinder or equivalent, grind the stakes Fig. 18 Opening Nut Stakes in the shoulder of the shaft nut as shown in figure 16 and 17.
Page 994 21 - 70 TRANSAXLE Install special tool 6577 to remove rear transfer bearing cup (Fig. 20). Fig. 22 Remove Transfer Shaft Assembly From Case Remove transfer shaft seals (Fig. 23) using special tool 6310 and foot 6310-9 (Tar 960). Do not reuse old seals.
Page 995 TRANSAXLE 21 - 71 Support special tool P-334 on press table so that pinion head of transfer shaft can be pressed through table (Fig. 25). Fig. 25 Remove Front Transfer Shaft Bearing And Pinion Depth Shim ASSEMBLE AND BEARING ADJUSTMENT Fig.
Page 996 21 - 72 TRANSAXLE Fig. 3 Gauge Disc and Bearing Fig. 6 Installing Centering Nut Fig. 7 Dial indicator, Locating Block and Extension tion. If the dial indicator being used is a 0-100 reading face, take the reading obtained and subtract it from 100.
Page 997 TRANSAXLE 21 - 73 Fig. 9 Zero Dial Indicator Fig. 11 Pivot Dial Indicator the shim that will be installed between the transfer shaft pinion head and the front transfer shaft bear- ing. Refer to the following examples for further expla- nation: Example 1 in (MM): •...
Page 998 21 - 74 TRANSAXLE PINION HEAD SHIM CHART Fig. 13 Bearing Installation The following steps will determine how many foot pounds are required on the outer differential adjuster to obtain the correct turning torque. CAUTION: Failure to set differential bearing preload correctly may cause bearing failure, gear noise and/or axle shaft seal failure.
Page 999 TRANSAXLE 21 - 75 (17) Remove old stub shaft seals. Press inner ad- juster seal out with special tool 6502B. Press outer adjuster seal out with special tool 6558. (18) Install new stub shaft seals in both adjusters using special tool 6558 (Fig. 15). Fig.
Page 1000 21 - 76 TRANSAXLE Fig. 20 Outer Adjuster Installation Fig. 21 Special Tool 6548 CAUTION: Lube threads and o-ring on adjuster be- CAUTION: Turning torque of 19 to 23 in. lbs. can fore installing. Failure to due so will result in thread only be obtain when using new bearings.
Page 1001 TRANSAXLE 21 - 77 (27) Remove the differential cover, differential car- (30) Install transfer shaft seal protector (special tool 6592) (Fig. 25). Apply thin film of gear oil to rier assembly and inner adjuster. protector. At this point the amount of torque required on the outer differential adjuster has been determined.
Page 1002 21 - 78 TRANSAXLE CAUTION: Properly seated cups are essential in cor- rectly setting bearing preload. (35) Use special tool 6560 to press cup into case (Fig. 30). FIg. 27 Seal Installation Fig. 30 Rear Transfer Shaft Cup Installation (36) Install Transfer shaft preload shim (Fig. 31). Use the original shim that was taken out of transaxle if possible.
Page 1003 TRANSAXLE 21 - 79 TRANSFER SHAFT REAR SHIM CHART Fig. 33 Transfer Shaft Nut Installation or seals to fail. Be sure transfer shaft does not have end play. If end play exists, install a thinner preload shim. (40) Check the turning torque of the transfer shaft using a torque wrench (Fig.
Page 1004 21 - 80 TRANSAXLE Fig. 37 Baffle Installation Fig. 35 Staking New Nuts Fig. 38 Differential Assembly Installation Fig. 36 Correctly Staked Nut (45) Transfer shaft to ring gear backlash should be CAUTION: Failure to stake the transfer shaft nut 0.006 to 0.009 thousands of an inch.
Page 1005 TRANSAXLE 21 - 81 Fig. 39 Rocking Ring Gear Back and Forth Fig. 41 Seal Protector (46) Apply a 1/8 inch bead of sealant to differential cover flange. Then install differential cover with seal- ant (Fig. 40) and tighten cover bolts. Fig.
Page 1006 21 - 82 TRANSAXLE If there is too much backlash, loosen the outer adjuster with special tool 6503. Then turn the inner adjuster so that it moves away from the ring gear. After adjusting the inner adjuster, retighten the outer adjuster to the torque recorded in step 26.
Page 1007 TRANSAXLE 21 - 83 Fig. 5 Remove Pinion Shaft Roll Pin Fig. 7 Carrier Bearing Removal Fig. 6 Slide Out Differential Pinion Shaft and Remove Pinion Gears and Side Gears If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.
Page 1008 21 - 84 TRANSAXLE 42LE ON-BOARD DIAGNOSTICS INDEX page page CCD Bus ....... 84 General Information .
Page 1009 TRANSAXLE 21 - 85 • Reverse instrument panel. Refer to the Using the DRB scan • Second Gear tool manual or the Diagnostic Procedures Manual for No upshifts or downshifts are allowed while in the information. Limp-in mode. The position of the manual valve alone DIAGNOSTIC TROUBLE CODE CHARTS allows the three ranges that are available.
Page 1010 21 - 86 TRANSAXLE DIAGNOSTIC TROUBLE CODE 12 DIAGNOSTIC TROUBLE CODE 13...
Page 1011 TRANSAXLE 21 - 87 DIAGNOSTIC TROUBLE CODE 14 DIAGNOSTIC TROUBLE CODE 15...
Page 1012 21 - 88 TRANSAXLE DIAGNOSTIC TROUBLE CODE 16 DIAGNOSTIC TROUBLE CODE 17...
Page 1013 TRANSAXLE 21 - 89 DIAGNOSTIC TROUBLE CODE 18 DIAGNOSTIC TROUBLE CODE 19...
Page 1014 21 - 90 TRANSAXLE DIAGNOSTIC TROUBLE CODE 20...
Page 1015 TRANSAXLE 21 - 91 DIAGNOSTIC TROUBLE CODE 21-27...
Page 1016 21 - 92 TRANSAXLE DIAGNOSTIC TROUBLE CODE 28...
Page 1017 TRANSAXLE 21 - 93 DIAGNOSTIC TROUBLE CODE 29 DIAGNOSTIC TROUBLE CODE 31-32...
Page 1018 21 - 94 TRANSAXLE DIAGNOSTIC TROUBLE CODE 35 DIAGNOSTIC TROUBLE CODE 36...
Page 1019 TRANSAXLE 21 - 95 DIAGNOSTIC TROUBLE CODE 37 DIAGNOSTIC TROUBLE CODE 38...
Page 1020 21 - 96 TRANSAXLE DIAGNOSTIC TROUBLE CODE 41-44...
Page 1021 TRANSAXLE 21 - 97 DIAGNOSTIC TROUBLE CODE 45 DIAGNOSTIC TROUBLE CODE 46...
Page 1022 21 - 98 TRANSAXLE DIAGNOSTIC TROUBLE CODE 47 DIAGNOSTIC TROUBLE CODE 48 DIAGNOSTIC TROUBLE CODE: 48 Torque Management BACKGROUND: Engine torque management is used during high-torque, high-speed 1-2, 2-3, 4-2, and 3-1 shifts in order to reduce the energy dissipation in the 2-4 clutch and the OD clutch to an acceptable level.
Page 1023 TRANSAXLE 21 - 99 DIAGNOSTIC TROUBLE CODE 50-58...
Page 1024 21 - 100 TRANSAXLE DIAGNOSTIC TROUBLE CODE 60-62...
Page 1025 TRANSAXLE 21 - 101 42LE HYDRAULIC SCHEMATICS...
Page 1026 21 - 102 TRANSAXLE...
Page 1027 TRANSAXLE 21 - 103...
Page 1028 21 - 104 TRANSAXLE...
Page 1029 TRANSAXLE 21 - 105...
Page 1030 21 - 106 TRANSAXLE...
Page 1031 TRANSAXLE 21 - 107...
Page 1032 21 - 108 TRANSAXLE...
Page 1033 TRANSAXLE 21 - 109...
Page 1034 21 - 110 TRANSAXLE...
Page 1035 TRANSAXLE 21 - 111...
Page 1036 21 - 112 TRANSAXLE...
Page 1037 TRANSAXLE 21 - 113...
Page 1038 21 - 114 TRANSAXLE 42LE SPECIFICATIONS 42LE FOUR SPEED AUTOMATIC TRANSAXLE...
Page 1039 TRANSAXLE 21 - 115 42LE TORQUE SPECIFICATIONS...
Page 1040 21 - 116 TRANSAXLE MASTER SHIM CHART...
Page 1041 WHEELS—TIRES 22 - 1 WHEELS—TIRES CONTENTS page page SPECIFICATIONS ......8 WHEELS SERVICE PROCEDURES ... 6 TIRE SERVICE PROCEDURES .
Page 1042 22 - 2 WHEELS—TIRES TIRE INFLATION PRESSURES Inflation pressures specified on the placard are al- Under inflation (Fig. 1) causes rapid shoulder wear ways cold inflation pressure. Cold inflation pres- and tire flexing and can result in tire failure. sure is obtained after the vehicle has not been operated for 3 hours.
Page 1043 WHEELS—TIRES 22 - 3 ROTATION DIRECTIONAL TREAD PATTERN TIRES Some vehicles fitted with special high- performance tires having a directional tread pattern designed to improve traction on wet pavement. To obtain the full benefits of this design, the tires must be installed so that they rotate in the correct direc- tion.
Page 1044 22 - 4 WHEELS—TIRES Fig. 4 Tire Wear Patterns...
Page 1045 WHEELS—TIRES 22 - 5 LEAD CORRECTION CHART LEAD CORRECTION CHART...
Page 1046 22 - 6 WHEELS—TIRES WHEELS SERVICE PROCEDURES INDEX page page General Information ......6 Wheel Installation ......6 Tire and Wheel Balance .
Page 1047 WHEELS—TIRES 22 - 7 sembly require balancing. Static balancing should be Use run out gauge D-128-TR to determine run out (Fig. 4). used only when two plane dynamic balancing is not available. For static imbalance, find location of heavy spot causing imbalance.
Page 1048 22 - 8 WHEELS—TIRES Fig. 6 Checking Wheel Run out SPECIFICATIONS TIRE SPECIFICATIONS TORQUE SPECIFICATIONS...
Page 1049 BODY 23 - 1 BODY CONTENTS page page BODY COMPONENT SERVICE— GENERAL SERVICE INFORMATION ..1 LH/D-L-X BODY ..... . . 15 PAINT .
Page 1050 23 - 2 BODY BODY DIAGNOSTIC PROCEDURES WATER LEAKS vehicle. For hoisting recommendations refer to Group Water leaks can be caused by poor sealing, im- 0, Lubrication and Maintenance, General Information proper body component alignment, body seam poros- section. ity, missing plugs, or blocked drain holes. Centrifugal WATER LEAK DETECTION and gravitational force can cause water to drip from a To detect a water leak point of entry, do a water test...
Page 1051 BODY 23 - 3 soft bristle brush. If soap bubbles occur at a body VISUAL INSPECTION BEFORE TESTS seam, joint, seal or gasket the leak entry point could Verify that floor and body plugs are in place and be at that location. body components are aligned and sealed.
Page 1052 23 - 4 BODY PAINT INTRODUCTION TOUCH-UP PROCEDURE A paint code is provided on the body code plate (1) Scrape loose paint and corrosion from inside located in the engine compartment. Refer to the In- scratch or chip. troduction section at the front of this manual for body (2) Clean affected area with Mopar Tar/Road Oil code plate description.
Page 1053 BODY 23 - 5 AFTERMARKET PAINT REPAIR PRODUCTS...
Page 1054 23 - 6 BODY WINDSHIELD SAFETY PRECAUTIONS AND WARNINGS WARNING: DO NOT OPERATE VEHICLE FOR AT LEAST 24 HOURS AFTER WINDSHIELD INSTALLA- TION. WINDSHIELD MAY NOT PERFORM PROPERLY IN THE EVENT OF A COLLISION IF URETHANE ADHESIVE IS NOT SUFFICIENTLY CURED. REFER TO MANUFAC- TURER OF URETHANE BEING USED FOR CURING TIME SPECIFICATIONS.
Page 1055 BODY 23 - 7 Fig. 5 Position Urethane Compression Spacers Fig. 3 Center Windshield and Mark at Support Spacers Fig. 6 Lower Windshield Into Position (8) With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers.
Page 1056 23 - 8 BODY SUNROOF INDEX page page Diagnostic Procedures ..... . 8 Sunroof Guide and Cam ....11 Glass Panel Seal .
Page 1057 BODY 23 - 9 SYMPTOM—I SUNROOF MODULE Sunroof water leak. REMOVAL (FIG. 1) POSSIBLE CAUSE (1) Operate glass panel to open position. • Drain tubes clogged or kinked. (2) Disconnect battery negative cable. • Glass panel improperly adjusted. (3) Remove left A-pillar molding. •...
Page 1058 23 - 10 BODY SUNROOF POSITION SENSOR INSTALLATION (1) Place drive motor in position on sunroof module. REMOVAL (FIG. 2) (2) Install bolts to hold drive motor to sunroof mod- (1) Remove headlining as necessary to gain access ule. to sensor on driver side of vehicle. (3) Engage drive motor wire connector into sunroof (2) Disengage sensor wire connector from sunroof controller.
Page 1059 BODY 23 - 11 SUNROOF REAR TROUGH (9) Actuate sunroof switch closed until cam stops. (10) Remove screws holding guide link (2) to guide REMOVAL (FIG.2) (1). (1) Remove sunroof glass panel. (11) Separate front guide (1) from sunroof module. (2) Remove screws (26) holding trough guide links (12) Intermittently actuate the sunroof switch vent to rear trough.
Page 1060 23 - 12 BODY SUNROOF CABLE SYNCHRONIZATION strip compression. A 0.13 mm (0.003 in.) thick paper After cables, cams or guides have been replaced card can be used as a gauge to measure the fit around both of the cables must be synchronized. If the the roof opening to the glass panel.
Page 1061 BODY 23 - 13 Fig. 2 Sunroof Components...
Page 1062 23 - 14 BODY SUNROOF COMPONENT LEGEND...
Page 1063 LH/D-L-X BODY 23 - 15 BODY COMPONENT SERVICE INDEX page page A-Pillar Trim ......35 Hood Latch .
Page 1064 23 - 16 LH/D-L-X BODY Fig. 1 Grille Fig. 3 Hood Latch Fig. 4 Hood Release Cable Fig. 2 Hood Safety Catch HOOD RELEASE CABLE (3) Install screw to hold safety catch release handle to inside of hood. REMOVAL (FIG. 4) (1) Release hood latch and open hood.
Page 1065 LH/D-L-X BODY 23 - 17 Fig. 5 Hood Release Handle Fig. 6 Hood partment. Rout cable assembly through engine com- (3) Position bolts at marks and tighten bolts. The partment toward the latch. hood should be aligned to 4 mm (0.160 in.) gap to the (3) Install release cable rubber grommet into access front fenders and flush across the top surfaces along hole in dash panel.
Page 1066 23 - 18 LH/D-L-X BODY (4) Remove bolts holding hood hinge to front fender (5) Install wiper arms, refer to Group 8K, Wind- flange and separate hinge from vehicle. If necessary, shield Wiper and Washer Systems. paint new hinge before installation. WHEELHOUSE SPLASH SHIELD INSTALLATION REMOVAL (FIG.
Page 1067 LH/D-L-X BODY 23 - 19 INSTALLATION (1) Place fender in position on vehicle. (2) From inside engine compartment, install bolts to hold fender to inner wheelhouse panel. (3) Install bolts to hold fender to radiator closure panel. (4) From inside door opening, install bolts to hold fender to hinge pillar brackets.
Page 1068 23 - 20 LH/D-L-X BODY Fig. 13 Front Door Trim Panel—Typical Fig. 15 Front Door Panel Hooks and Lock Bottom (14) Disengage wire connector from power door lock motor located on door latch. (15) From behind door silencer pad, disengage push-in retainers holding wire harness to trim panel.
Page 1069 LH/D-L-X BODY 23 - 21 (12) Install screw to hold pull cup to trim panel (Fig. 13). (13) Install screws to hold trim panel to door inside speaker opening (Fig. 13). (14) Place speaker grille in position on trim panel. Engage clips to hold door speaker grille to trim panel (Fig.
Page 1070 23 - 22 LH/D-L-X BODY (7) Disengage push-in fastener holding run weath- erstrip to window frame. (8) Pull run weatherstrip from window frame chan- nel. INSTALLATION (1) Push run weatherstrip into window frame chan- nel. (2) Engage push-in fastener to hold run weather- strip to window frame.
Page 1071 LH/D-L-X BODY 23 - 23 FRONT DOOR GLASS REGULATOR FRONT DOOR LATCH Power and manual door glass regulators are ser- REMOVAL (FIG. 23) viced using the same procedures. For power window (1) Close door glass. motor service procedures refer to Group 8S, Power (2) Remove door trim panel.
Page 1072 23 - 24 LH/D-L-X BODY FRONT DOOR CHECK STRAP REMOVAL (FIG. 26) (1) Close door glass. (2) Remove door trim panel. (3) Remove bolts holding check strap to door end frame. (4) Remove retainer holding check strap to door hinge. (5) Disengage check strap from pin on upper door hinge.
Page 1073 LH/D-L-X BODY 23 - 25 Fig. 29 Front Door and Hinge Fig. 27 Side View Mirror (4) Disengage clip holding wire connector together (7) Verify Mirror operation. on hinge pillar side of the connector. (8) Install door trim panel. (5) Separate door harness from instrument panel harness.
Page 1074 23 - 26 LH/D-L-X BODY Fig. 32 Front Door Latch Striker Fig. 30 Front Door Upper Hinge FRONT DOOR PRIMARY WEATHERSTRIP REMOVAL (FIG. 33) (1) Open front door. (2) Pull primary weatherstrip from channel around upper window frame. (3) Using a fork-type prying tool, disengage push-in fasteners holding weatherstrip to lower door end frames and bottom panel.
Page 1075 LH/D-L-X BODY 23 - 27 Fig. 35 Window Crank Fig. 34 Front Door Secondary Weatherstrip FRONT DOOR SECONDARY WEATHERSTRIP REMOVAL (FIG. 34) (1) Open front door. (2) Loosen door opening sill plate. (3) Pull secondary weatherstrip from fence around door opening. INSTALLATION (1) Position splice in weatherstrip at center of door opening sill.
Page 1076 23 - 28 LH/D-L-X BODY Fig. 37 Door Latch Handle Rod (3) Engage channel retainer at top of trim (Fig. 36). (4) Insert pull cup into door arm rest and install screw to hold pull cup to door panel (Fig. 36). (5) Install screw to hold trim panel to door behind inside latch handle (Fig.
Page 1077 LH/D-L-X BODY 23 - 29 Fig. 41 Door Inner Belt Weatherstrip—Typical REAR DOOR GLASS REMOVAL (FIG. 42) (1) Remove door trim panel and upper trim re- tainer channel. Fig. 39 Rear Door Forward Applique (2) Remove window frame applique. (3) Raise door glass to gain access to roller channel to glass fasteners through holes in inner door panel.
Page 1078 23 - 30 LH/D-L-X BODY Fig. 43 Rear Door Glass Alignment Fig. 44 Rear Door Glass Run Weatherstrip (4) Tighten screws to hold regulator roller channel REAR DOOR GLASS REGULATOR to glass. Power and manual door glass regulators are ser- (5) Install upper trim retainer channel and install viced using the same procedures.
Page 1079 LH/D-L-X BODY 23 - 31 INSTALLATION (1) Insert roller channel through access hole in door panel. (2) Insert bolt heads on regulator through key hold slots in door panel. (3) Tighten bolts to hold regulator to door panel. (4) Insert bolt heads on support brace and scissor channel into key hole slot on door panel.
Page 1080 23 - 32 LH/D-L-X BODY (7) Hold door up and release door latch. INSTALLATION (1) Place check strap in position on vehicle. (8) Separate door from vehicle. (2) Engage check strap onto pin on upper door INSTALLATION hinge. (1) Place door in position on vehicle. (3) Install bushing over pin on door hinge.
Page 1081 LH/D-L-X BODY 23 - 33 Fig. 53 Rear Door Secondary Weatherstrip DRIP RAIL MOLDING REMOVAL (FIG. 54) (1) Release front door latch and open door. (2) Release rear door latch and open door. Fig. 52 Door Primary Weatherstrip—Typical (3) Remove screws holding drip rail molding to roof FRONT DOOR PRIMARY WEATHERSTRIP rail.
Page 1082 23 - 34 LH/D-L-X BODY Fig. 55 Center Console Bezel—Typical Fig. 56 Center Console CENTER CONSOLE BEZEL INSTALLATION (1) Place center console in position on vehicle. REMOVAL (FIG. 55) (2) Install screws to hold bottom of glove compart- (1) Place gear selector in neutral. ment to rear mounting bracket.
Page 1083 LH/D-L-X BODY 23 - 35 Fig. 58 A-pillar Trim A-PILLAR TRIM REMOVAL (FIG. 58) (1) Remove screw holding bottom of A-pillar trim to cowl panel. Fig. 59 Side Cowl Trim (2) Disengage clips holding trim to A-pillar. (3) Separate A-pillar trim from vehicle. INSTALLATION (1) Place B-pillar trim in position on vehicle.
Page 1084 23 - 36 LH/D-L-X BODY LOWER QUARTER TRIM REMOVAL (FIG. 62) (1) Remove upper quarter trim. (2) Remove rear seat cushion and back. (3) Remove bolt holding rear seat shoulder harness to floor at bottom of quarter trim. (4) Remove sill trim as necessary to clear quarter trim removal path.
Page 1085 LH/D-L-X BODY 23 - 37 Fig. 63 Parcel Shelf Trim Panel Fig. 65 Rear Seat Back Fig. 64 Rear Seat Cushion Fig. 66 Front Seat—Typical (4) Push parcel shelf trim rearward toward rear (3) Push rear seat back upward to disengage hooks glass and engage clips.
Page 1086 23 - 38 LH/D-L-X BODY Fig. 67 Recliner Pivot Bolt Fig. 68 Front Seat Track—Typical INSTALLATION FRONT SEAT BELT BUCKLE (1) Place front seat in position in vehicle. REMOVAL (FIG. 69) (2) Install bolts to hold rear of seat track to floor. (1) Remove front seat as necessary to gain access to (3) Install bolts to hold front of the seat track to seat belt buckle anchor bolt.
Page 1087 LH/D-L-X BODY 23 - 39 Fig. 70 Front Shoulder Belt Turning Loop Fig. 71 Front Shoulder Belt Adjuster FRONT SHOULDER BELT TURNING LOOP INSTALLATION (1) Place seat belt retractor in position on vehicle. REMOVAL (FIG. 70) (2) Install push-in fastener to hold seat belt retrac- (1) On back of turning loop cover, disengage clips tor to floor kick-up below B-pillar.
Page 1088 23 - 40 LH/D-L-X BODY REAR SEAT BELT BUCKLE REMOVAL (FIG. 73) (1) Remove rear seat cushion. (2) Remove rear seat back. (3) Separate seat belt buckle or belt from stud on floor. INSTALLATION (1) Place seat belt buckle or belt anchor over stud on floor.
Page 1089 LH/D-L-X BODY 23 - 41 SUN VISOR REMOVAL (FIG. 76) (1) Remove screw holding inboard visor pivot to windshield header. (2) Remove screws holding outboard visor pivot base to windshield header. (3) Separate visor from header. (4) Disconnect visor vanity lamp wire connector, if equipped.
Page 1090 23 - 42 LH/D-L-X BODY HEADLINING INSTALLATION (1) Place splash shield in position on vehicle. REMOVAL (FIG. 79) (2) Install screws to hold splash shield to rear (1) Remove A-pillar trim panels. bumper fascia. (2) Remove sun visors. (3) Install screw to hold splash shield to quarter (3) Remove overhead console, refer to Group 8C, panel.
Page 1091 LH/D-L-X BODY 23 - 43 Fig. 81 Body Vent Fig. 83 Trunk Lid Torsion Bars TRUNK LID WEATHERSTRIP REMOVAL (FIG. 84) (1) Release trunk lid latch and open trunk lid. (2) Pull trunk lid weatherstrip form trunk opening fence. (3) Separate weatherstrip from vehicle. INSTALLATION (1) Place weatherstrip in position on vehicle.
Page 1092 23 - 44 LH/D-L-X BODY (2) Position splice in weatherstrip above the trunk latch striker. (3) Push trunk lid weatherstrip onto trunk opening fence. (4) Verify trunk lid operation and sealing. TRUNK LATCH STRIKER REMOVAL (FIG. 85) (1) Release trunk lid latch and open trunk lid. (2) Remove push-in fasteners holding trunk lining to tail panel.
Page 1093 LH/D-L-X BODY 23 - 45 INSTALLATION TRUNK LID SLAM BUMPER (1) Place trunk lock remote adapter in position on REMOVAL vehicle. (1) Release trunk lid latch and open trunk lid. (2) Engage clips to hold lock cable to trunk lid. (2) Unscrew slam bumper from trunk lid.
Page 1094 23 - 46 LH/D-L-X BODY (5) Cut the urethane around the perimeter of the rear window glass. Refer to Windshield section of this group for proper procedures. (6) Separate the rear window from the vehicle. INSTALLATION (1) Prepare the work area, window fence, and glass the same way as described in the Windshield section of this group.
Page 1095 LH/CH-CP BODY 23 - 47 BODY COMPONENTS—LH/CH-CP BODY INDEX page page Child Seat Module ......49 Rear Seat Back with Child Seat .
Page 1096 23 - 48 LH/CH-CP BODY (3) Apply 8 mm (5/16 in.) round butyl tape to the fence area on the stationary glass. (4) Place stationary glass in position on vehicle. (5) Install bolt to hold bottom of stationary glass to inner door panel.
Page 1097 LH/CH-CP BODY 23 - 49 (3) Install screws to hold top of child seat module to seat back frame from behind shoulder belts. (4) Engage push-in fasteners to hold upper bolster to child seat module above shoulder belts. (5) Install liner in child seat module. (6) Place lower bolster in position on seat child seat.
Page 1098 23 - 50 LH/CH-CP BODY TRUNK LOCK BRACKET REMOVAL (FIG. 8) (1) Remove trunk latch. (2) Remove bolts holding trunk lock bracket to trunk lid. (3) Separate trunk lock bracket from vehicle. INSTALLATION (1) Place trunk lock bracket in position on trunk lid.
Page 1099 LH/CH-CP BODY 23 - 51 TRUNK LID APPLIQUE MOLDING REMOVAL (FIG. 11) (1) Release trunk latch and open trunk. (2) Remove screws holding molding to applique. (3) Separate molding from applique. INSTALLATION (1) Place molding in position on applique. (2) Install screws to hold molding to applique. REAR DECK UPPER PANEL REMOVAL (1) Release trunk latch and open trunk.
Page 1101 BODY 23 - 1 BODY CONTENTS page page BODY COMPONENTS ..... 1 SUNROOF ......6 BODY COMPONENTS INDEX page...
Page 1102 23 - 2 BODY (3) Apply 8 mm (5/16 in.) round butyl tape to the fence area on the stationary glass. (4) Place stationary glass in position on vehicle. (5) Install bolt to hold bottom of stationary glass to inner door panel. (6) Install nut to hold rear of stationary glass to door frame.
Page 1103 BODY 23 - 3 Fig. 5 Rear Seat Back with Child Seat CHILD SEAT MODULE REMOVAL (FIG. 6) (1) Remove rear seat back from vehicle. (2) Slide lower bolster cushion retainer from chan- nel on child seat cushion. (3) Separate lower bolster from child seat. (4) Remove liner from child seat module.
Page 1104 23 - 4 BODY Fig. 7 Trunk Latch Fig. 9 Trunk Lock Cylinder (2) Install bolts to hold trunk lock bracket to trunk INSTALLATION lid. (1) Place applique in position on trunk lid. (3) Install trunk latch. (2) Install nuts to hold applique to trunk lid. Fig.
Page 1105 BODY 23 - 5 (4) Push wiring grommet through hole in deck panel. (5) Disengage clips holding upper deck panel to rear deck below rear window. (6) Separate rear deck upper panel from vehicle. INSTALLATION (1) Place rear deck upper panel in position on vehicle. (2) Engage clips to hold upper deck panel to rear deck below rear window.
Page 1106 23 - 6 BODY SUNROOF INDEX page page Diagnostic Procedures ..... . 6 Sunroof Guide and Cam ....9 Glass Panel Alignment .
Page 1107 BODY 23 - 7 • Faulty opening weatherstrip. (4) Disengage hose clamps and separate drain • Glass panel leaks at molding. tubes from sunroof module. (5) Using a suitable marking device, mark outline SYMPTOM of sunroof module on inside of roof panel to aid in- Wind noise from sunroof stallation.
Page 1108 23 - 8 BODY (2) Disengage sensor wire connector from sunroof INSTALLATION controller. (1) Place wind deflector in position on vehicle. (3) Using a small screw driver, pry downward on (2) Install screws to hold track access plugs to sun- inner lip of sensor retainer bracket.
Page 1109 BODY 23 - 9 INSTALLATION (3) Place cam spring (16) into side of cam. Slide (1) Place rear trough in position on vehicle. cam rearward into end of track. (2) Install screws to hold trough to rear shoe (17). (4) Insert guide and link rearward into end of (3) Install screws (26) to hold guide links to rear track.
Page 1110 23 - 10 BODY SUNROOF COMPONENT CALL OUTS...
Page 1111 BODY 23 - 11 Fig. 2 Sunroof Components...
Page 1112 23 - 12 BODY (4) Clean edge molding around glass panel with (3) Loosen nuts (21) holding glass panel (18) to mounting brackets (19). Mopar, Super Kleen solvent or equivalent. Wipe sur- (4) Shift glass panel on mounting brackets to face dry with lint free cloth.
Page 1113 HEATING AND AIR CONDITIONING 24 - 1 HEATING AND AIR CONDITIONING CONTENTS page page AUTOMATIC TEMPERATURE CONTROL (ATC) MANUAL AIR CONDITIONING SYSTEM SELF-DIAGNOSTICS ....34 SELF-DIAGNOSTICS .
Page 1114 24 - 2 HEATING AND AIR CONDITIONING in a recirculation setting. Recirculation is prevented/ The use of a bug screen is not recommended. Any disabled when the system is in DEFROST, MIX or obstructions in front of the radiator or condenser can FLOOR mode.
Page 1115 HEATING AND AIR CONDITIONING 24 - 3 REFRIGERANT SERVICE PROCEDURES INDEX page page A/C Performance Test ..... . . 8 System Leak Checking .
Page 1116 24 - 4 HEATING AND AIR CONDITIONING SYSTEM LEAK CHECKING (2) Position the vehicle in a wind free work area. This will aid in detecting small leaks. WARNING: R-134A SERVICE EQUIPMENT OR VE- (3) Bring the refrigerant system up to operating HICLE A/C SYSTEM SHOULD NOT BE PRESSURE temperature and pressure.
Page 1117 HEATING AND AIR CONDITIONING 24 - 5 WARNING: R-134A SERVICE EQUIPMENT OR VE- HICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRES- SURES.
Page 1118 24 - 6 HEATING AND AIR CONDITIONING Fig. 5 Charge Determination Graph • Temperature to full cold PERFORMANCE TEST PROCEDURE • High blower Review safety precautions and warnings in this group before proceeding with this procedure. Air tem- ATC (Automatic Temperature Control) System perature in the test room and vehicle must be 70°F •...
Page 1119 HEATING AND AIR CONDITIONING 24 - 7 A/C PERFORMANCE TEMPERATURES...
Page 1120 24 - 8 HEATING AND AIR CONDITIONING COMPONENT SERVICE PROCEDURES INDEX page page A/C Pressure Transducer ....8 Compressor Manifold Valve Cores ... . . 16 A/C Refrigerant Lines .
Page 1121 HEATING AND AIR CONDITIONING 24 - 9 (2) Remove floor console or instrument panel center TEMPERATURE DOOR ACTUATOR lower cover. The blend-air (temperature) door actuator is an (3) Remove lower instrument panel assembly. electric motor which mechanically positions the tem- (4) Remove body controller at right side of instru- perature door.
Page 1122 24 - 10 HEATING AND AIR CONDITIONING Fig. 5 Blend-Air Door Spline Fig. 7 Nameplate Fig. 8 In-Car Temperature Sensor Fig. 6 Ambient Sensor ATC system then makes adjustments to maintain the TEST optimum passenger compartment comfort. To test Ambient Temperature Sensor refer to 1993 The In-Car sensor will automatically turn on when LH Body Diagnostic Manual.
Page 1123 HEATING AND AIR CONDITIONING 24 - 11 (a) Turn ignition to the ON position and push the (3) Remove sensor retaining screws. OFF button to stop the ATC system airflow. This (4) Pull out sensor from instrument panel and dis- will make it easier to observe paper in the next connect wiring.
Page 1124 24 - 12 HEATING AND AIR CONDITIONING Fig. 14 Wiring Grommet Fig. 12 Blower Motor Resistor BLOWER MOTOR The blower motor is located on the right side of the heater housing. The blower motor the and blower motor wheel must be replaced as an assembly. REMOVAL AND INSTALLATION (1) Disconnect battery.
Page 1125 HEATING AND AIR CONDITIONING 24 - 13 • Apply strip caulking (Dum-Dum) to all seam areas pressor is dispersed through the lines and compo- around the blower wheel housing and evaporator nents. The evaporator, condenser, and filter-drier will housing. The seams can be reached from the blower retain a significant amount of lubricant.
Page 1126 24 - 14 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION The A/C compressor may be unbolted and reposi- tioned without discharging the refrigerant system. Discharging is not necessary if removing the compres- sor clutch/coil assembly, engine, cylinder head, or gen- erator.
Page 1127 HEATING AND AIR CONDITIONING 24 - 15 (3) Install pulley assembly to compressor. If neces- sary, tap gently with a block of wood on the friction surface (Fig. 5). Fig. 3 Removing Pulley Snap Ring Fig. 5 Installing Pulley Assembly (4) Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574).
Page 1128 24 - 16 HEATING AND AIR CONDITIONING dure, set the system to the A/C mode, engine rpm at COMPRESSOR MANIFOLD VALVE CORES 1500-2000, and high blower speed. This procedure The compressor manifold valve cores are located on (burnishing) will seat the opposing friction surfaces the top of the manifold (High Side) and front side of and provide a higher clutch torque capability.
Page 1129 HEATING AND AIR CONDITIONING 24 - 17 (3) Remove condenser mounting bolts and unscrew CAUTION: Never attempt to remove a clip or discon- 3/4 inch nut at receiver/drier. nect a quick connect without reclaiming all refriger- (4) Remove screw from condenser inlet tube ant from the air conditioning system.
Page 1130 24 - 18 HEATING AND AIR CONDITIONING CAUTION: Cap all lines that are not being replaced and cap all condenser tubes. (6) Remove the liquid line from the vehicle. To install, reverse the removal procedure. DISCHARGE LINE REMOVAL AND INSTALLATION (1) Remove refrigerant from the A/C system using a refrigerant recovery machine.
Page 1131 HEATING AND AIR CONDITIONING 24 - 19 (3) Disconnect wiring connector for evaporator probe. (4) At center of heater housing, locate evaporator probe access plate. Using a flat blade pry tool, pull back on the locking tab. Twist the access plate counter clockwise one-quarter turn and remove plate (Fig.
Page 1132 24 - 20 HEATING AND AIR CONDITIONING EXPANSION VALVE The expansion valve is located on the engine side of the dash panel, near the right shock tower. The expansion valve can fail in three different posi- tions (open, closed or restricted). In a Open Position: this will result in a noisy com- pressor or no cooling.
Page 1133 HEATING AND AIR CONDITIONING 24 - 21 pull back carpet and use caution when removing unit. Keep the heater tubes elevated to prevent spill- age of coolant. (6) Remove both A/C lines from expansion valve. Use special tool 7193 to disconnect quick connectors on A/C lines.
Page 1134 24 - 22 HEATING AND AIR CONDITIONING (22) Remove instrument panel ground strap. This (3) With the heater housing out of the vehicle, pull strap is located on the lower left side of the center back heater core retaining clips. Then pull the heater console.
Page 1135 HEATING AND AIR CONDITIONING 24 - 23 (3) Remove recirculation door actuator wiring (Fig. 1). Remove actuator from recirculation housing (Fig. Fig. 4 Mode Door Actuator (5) Remove blend air door actuator (Fig. 5). Fig. 1 Recirculation Door Actuator Wiring Fig.
Page 1136 24 - 24 HEATING AND AIR CONDITIONING (7) Remove blower motor wiring at resistor (Fig. 7). (10) Remove screws at blower motor mounts. Re- move motor (Fig. 10). Fig. 7 Blower Motor Wiring (8) Squeeze blower motor wiring grommet and Fig.
Page 1137 HEATING AND AIR CONDITIONING 24 - 25 Fig. 12 Evaporator Probe Fig. 15 Evaporator Seal Fig. 16 A/C Housing Screws Fig. 13 Evaporator Probe Needle Fig. 17 Lower Housing Fig. 14 Vent Door Seal...
Page 1138 24 - 26 HEATING AND AIR CONDITIONING (19) Remove evaporator assembly from lower hous- (21) Using a flat blade screwdriver, pinch in the ing (Fig. 18). retaining tab at the base of the vent door (Fig. 20). Pull up on door and remove from housing (Fig. 21). Fig.
Page 1139 HEATING AND AIR CONDITIONING 24 - 27 (23) Remove screw at defrost door actuating arm (24) Remove defrost door arm from lower housing (Fig. 24). Remove defrost door link from arm. (Fig. 25). (25) Remove link and defrost door from housing (Fig.
Page 1140 24 - 28 HEATING AND AIR CONDITIONING ASSEMBLE (1) Install vent door actuating arm to lower hous- ing. (2) Install defrost door link to defrost door. (3) Install door and link into A/C housing (Fig. 1). Fig. 3 Mode Door Cam Fig.
Page 1141 HEATING AND AIR CONDITIONING 24 - 29 Fig. 8 Blower Motor Cover Fig. 6 Probe Needle Into Evaporator (16) Install blower motor resistor. (17) Install blower motor into housing (Fig. 7). In- stall blower motor mounting screws. Fig. 9 Blower Wiring Grommet Fig.
Page 1142 24 - 30 HEATING AND AIR CONDITIONING (22) Install blend-air door actuator (Fig. 11). (25) Install recirculation door actuator and wiring (Fig. 14). Fig. 11 Blend-Air Door Actuator Fig. 14 Recirculation Door Actuator (23) Install mode door actuator (Fig. 12). (26) Install heater core into A/C housing (Fig.
Page 1143 HEATING AND AIR CONDITIONING 24 - 31 RECEIVER/DRIER The receiver/drier is a receiver for reserve refriger- ant. It also has a desiccant bag and a filter. This is used to absorb moisture and filter the refrigerant as it passes through the receiver/drier. The receiver/drier is located left of the A/C con- denser.
Page 1144 24 - 32 HEATING AND AIR CONDITIONING MANUAL AIR CONDITIONING SYSTEM SELF-DIAGNOSTICS GENERAL INFORMATION (2) The left knob (Blower control) must be placed to any speed setting. Do not place the knob to the off The system uses three rotary knobs to control the position.
Page 1145 HEATING AND AIR CONDITIONING 24 - 33 • Place the mode actuator knob in the Recirculate CAUTION: Step 10 (mode actuator knob test) and step 11 (temperature knob test) can not be per- Panel mode. The rear window defogger switch light formed if test in step 8 (unsuccessful calibration) should flash six times and then pause.
Page 1146 24 - 34 HEATING AND AIR CONDITIONING AUTOMATIC TEMPERATURE CONTROL (ATC) SELF-DIAGNOSTICS GENERAL INFORMATION The ATC system allows the operator to manually con- trol the passenger compartment environment. The con- trol head, located in the instrument panel is used to control the desired temperature, air flow direction and blower speed (Fig.
Page 1147 HEATING AND AIR CONDITIONING 24 - 35 DRB SCAN TOOL FLOW CHART—MANUAL/ATC...
Page 1148 24 - 36 HEATING AND AIR CONDITIONING...
Page 1149 HEATING AND AIR CONDITIONING 24 - 37 DRB SCAN TOOL FLOW CHART—SYSTEM TESTS...
Page 1151 HEATING AND AIR CONDITIONING 24 - 1 HEATING AND AIR CONDITIONING INDEX page page Air Conditioner Condenser ....1 ATC In-Car Temperature Sensor ....2 AIR CONDITIONER CONDENSER The cooling module assembly must be removed to service the condenser.
Page 1152 24 - 2 HEATING AND AIR CONDITIONING ATC IN-CAR TEMPERATURE SENSOR (b) Place a small piece of tissue paper in front of The In-Car Temperature Sensor is part of a motor- the sensor opening. If the tissue sticks to the open- ized aspirator assembly that is mounted in the in- ing, the In-Car sensor is aspirating properly.
Page 1153 EMISSION CONTROL SYSTEMS 25 - 1 EMISSION CONTROL SYSTEMS CONTENTS page page EVAPORATIVE EMISSION CONTROLS ..1 EXHAUST EMISSION CONTROLS ... . 9 EVAPORATIVE EMISSION CONTROLS INDEX page...
Page 1154 25 - 2 EMISSION CONTROL SYSTEMS CANADA VEHICLE EMISSION CONTROL CALIFORNIA VEHICLE EMISSION CONTROL INFORMATION LABEL—TYPICAL INFORMATION LABEL—TYPICAL...
Page 1155 EMISSION CONTROL SYSTEMS 25 - 3...
Page 1156 25 - 4 EMISSION CONTROL SYSTEMS...
Page 1157 EMISSION CONTROL SYSTEMS 25 - 5 VACUUM HARNESS purge solenoid turns the vacuum signal to the canis- When installing a new vacuum harness, follow the ter on and off. The PCM purges the EVAP canister schematics for correct routing. On 3.5L engines, at during certain operating conditions.
Page 1158 25 - 6 EMISSION CONTROL SYSTEMS The solenoid will not operate unless it is installed correctly. If the vehicle has a 3.5L engine, the EVAP purge solenoid shares a bracket with the MTV sole- noid. Fig. 5 EVAP Canister Bracket Fig.
Page 1159 EMISSION CONTROL SYSTEMS 25 - 7 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEMS Intake manifold vacuum removes crankcase vapors and piston blow-by from the engine. Emissions pass through the PCV valve into the intake manifold ple- num (Fig. 9 or Fig. 10). The vapors become part of the calibrated air-fuel mixture, are burned and expelled with the exhaust gases.
Page 1160 25 - 8 EMISSION CONTROL SYSTEMS (3) After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. If the en- gine does not draw the paper against the grommet after installing a new valve, replace the PCV valve hose.
Page 1161 EMISSION CONTROL SYSTEMS 25 - 9 EXHAUST EMISSION CONTROLS INDEX page page Air Cleaner ......9 EGR Tube—3.5L Engine .
Page 1162 25 - 10 EMISSION CONTROL SYSTEMS Fig. 6 Heated Oxygen Sensor—3.5L Engine proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain Fig.
Page 1163 EMISSION CONTROL SYSTEMS 25 - 11 • EGR tube (connects a passage in the intake mani- fold to the exhaust manifold) • EGR valve • Electronic EGR Transducer (EET) • Connecting hoses The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig.
Page 1164 25 - 12 EMISSION CONTROL SYSTEMS varies the strength of vacuum applied to the EGR EGR valve stem should move when accelerating the valve. Varying the strength of the vacuum changes engine (the relative position of the groove on the EGR the amount of EGR supplied to the engine.
Page 1165 EMISSION CONTROL SYSTEMS 25 - 13 EGR DIAGNOSIS CHART—3.3L ENGINE...
Page 1166 25 - 14 EMISSION CONTROL SYSTEMS minimum of 15 inches of vacuum supplied to the should remain open for approximately 30 seconds or solenoid. If vacuum is low, check for kinked or twisted more. If the valve leaks, replace the EGR valve and hoses and leaking hoses or hose connections.
Page 1167 EMISSION CONTROL SYSTEMS 25 - 15 Fig. 15 EGR Valve—3.5L Engine Fig. 13 Electronic EGR Transducer—3.5L Engine (5) Slide transducer into bracket. (4) Loosen, but do not remove, the EGR tube to (6) Attach electrical connector to solenoid. intake manifold screws (Fig. 14). EGR TUBE—3.3L ENGINE The EGR tube attaches to the intake manifold ple- num below the throttle body and the right exhaust...
Page 1168 25 - 16 EMISSION CONTROL SYSTEMS Fig. 17 EGR Tube Upper Mounting Screws Fig. 18 EGR Tube—3.5L Engine EGR TUBE—3.5L ENGINE (4) Ensure the insulation on the EGR tube aligns The EGR tube attaches to the both sides of the with and contacts the insulation on the vacuum har- ness at the rear of the engine (Fig.
Page 1169 EMISSION CONTROL SYSTEMS 25 - 1 EMISSION CONTROL SYSTEMS EVAPORATIVE EMISSION CONTROLS INDEX page page Vacuum Schematic ......1 Vehicle Emission Control Information Label .
Page 1170 25 - 2 EMISSION CONTROL SYSTEMS...
Page 1171 EMISSION CONTROL SYSTEMS 25 - 3 EXHAUST EMISSION CONTROLS EGR SYSTEM ON-BOARD DIAGNOSTICS the Malfunction Indicator Lamp (instrument Check The powertrain control module (PCM) performs an Engine light). The lamp indicates the need for imme- on-board diagnostic check of the EGR system. The diate service.
Page 1173 CHRYSLER CORPORATION SERVICE MANUAL and SUPPLEMENT 1994 NEW YORKER, LHS CONCORDE, INTREPID AND VISION To order the special service tools used and illustrated, please refer to the instructions on inside back cover. NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, ME- CHANICAL, PHOTOCOPYING, RECORDING,...
Page 1174 FOREWORD The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle.
Page 1175 GROUP TAB LOCATOR PAGE NOTE: Groups with the suffix “-S” are supplements to Introduction the original service manual publication. IN-S Introduction Lubrication and Maintenance Front Suspension and Axle Brakes Cooling System Cooling System Electrical Electrical Engines Exhaust System and Intake Manifold Frame and Bumpers Fuel System 14-S...
Page 1177 CHRYSLER CORPORATION 1994 SERVICE MANUAL SUPPLEMENT CHRYSLER LHS & NEW YORKER This publication contains preliminary service information for the 1994 Chrysler LHS and New Yorker. It must be used along with the 1993 Concorde, Intrepid, Vision Service Manual, 81- 270-3140, for full vehicle coverage. Complete ser- vice information will be contained in a final service manual which, includes all 1994 LH mod- els, to be released July, 1993.
Page 1178 FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle.
Page 1179 GROUP TAB LOCATOR Introduction Cooling System Ignition Systems Lamps Wiring Diagrams Fuel System Body Heating and Air Conditioning Emission Control Systems Component and System Index Service Manual Comment Forms (Rear of Manual)
Page 1181 INTRODUCTION INTRODUCTION CONTENTS page page BODY CODE PLATE LOCATION AND DECODING METRIC THREAD AND GRADE IDENTIFICATION . . . 3 INFORMATION ......1 TORQUE REFERENCES .
Page 1182 INTRODUCTION BODY CODE PLATE DIGITS 5 THROUGH 8— Primary Paint See Group 23, Body for color codes DIGIT 9— Open Space DIGITS 10 THROUGH 13— Secondary Paint DIGIT 14— Open Space DIGITS 15 THROUGH 18— Interior Trim Code DIGIT 19— Open Space BODY CODE PLATE LINE 3 DIGITS 20, 21, AND 22—...

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