Chrysler 300M 2002 Service Manual

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CHRYSLER/DODGE

SERVICE MANUAL

2002

300M, CONCORDE

AND INTREPID

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED,

STORED

RETRIEVAL

SYSTEM, OR TRANSMITTED, IN ANY FORM OR

BY ANY MEANS, ELECTRONIC, MECHANICAL,

PHOTOCOPYING, RECORDING, OR OTHERWISE,

WITHOUT THE PRIOR WRITTEN PERMISSION

OF DAIMLERCHRYSLER CORPORATION.

DaimlerChrysler Corporation reserves the right to make changes in design or

to make additions to or improvements in its products without imposing any

obligations upon itself to install them on its products previously manufac-

tured.

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Summary of Contents for Chrysler 300M 2002

Page 1 CHRYSLER/DODGE SERVICE MANUAL 2002 300M, CONCORDE AND INTREPID NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION.
Page 2 FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups.
Page 3 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Driveline Brakes Cooling Audio Chime/Buzzer Clock Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame &...
Page 4 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATES TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 5 INTRODUCTION BODY CODE PLATES (Continued) DIGITS 20 Carline • C = Chrysler • D = Dodge • Y = Chrysler DIGIT 21 Price Class • E = Economy • H = High Line • L = Low Line • M = Mid Line •...
Page 6: Fastener Identification Description
INTRODUCTION FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2.
Page 7 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 3 FASTENER IDENTIFICATION...
Page 8 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 4 FASTENER STRENGTH...
Page 9: Description Description - Fastener Usage
INTRODUCTION DESCRIPTION - THREADED HOLE REPAIR FASTENER USAGE Most stripped threaded holes can be repaired using a Helicoil . Follow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures. DESCRIPTION - FASTENER USAGE INTERNATIONAL VEHICLE WARNING: USE OF AN INCORRECT FASTENER CONTROL &...
Page 10: Metric System Description
INTRODUCTION The following chart will assist in converting metric METRIC SYSTEM units to equivalent English and SAE units, or vise versa. DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY...
Page 11 INTRODUCTION METRIC SYSTEM (Continued) Fig. 6 METRIC CONVERSION CHART...
Page 12: Torque References Description
INTRODUCTION tions Chart for torque references not listed in the TORQUE REFERENCES individual torque charts (Fig. 7). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- Fig. 7 TORQUE SPECIFICATIONS...
Page 13: Digit
CODE = DESCRIPTION Country of Origin 2 = Built in Canada by DaimlerChrysler Canada Inc. Make B = Dodge C = Chrysler Vehicle Type 3 = Passenger Car Passenger Safety A = Restraint System - Active Driver and Side Airbags...
Page 14: Vehicle Safety Certification Label Description
4 - AMENDMENT NUMBER VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifica- Fig.
Page 15: Manufacture Plate Description
INTRODUCTION MANUFACTURE PLATE DESCRIPTION The Manufacturer Plate (Fig. 11) is located in the engine compartment on the passenger side rear cor- ner of the hood. The plate contains five lines of infor- mation: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3.
Page 16 LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE FLUID FILL/CHECK LOCATIONS SPECIFICATIONS - FLUID CAPACITIES ..1 DESCRIPTION ......5 INTERNATIONAL SYMBOLS LUBRICATION POINTS DESCRIPTION...
Page 17 PROPERLY. CONTACT YOUR DEALER OR GOVERN- by the American Petroleum Institute (API). Diamler- MENT AGENCY FOR LOCATION OF COLLECTION Chrysler only recommend API Certified engine oils CENTER IN YOUR AREA. that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting When service is required, DaimlerChrysler Corpo- the specification MS-6395.
Page 18 LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solu- tion. The green coolant MUST NOT BE MIXED with the orange or magenta coolants.
Page 19 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) Exceptions to this policy are the use of special dyes GASOLINE/OXYGENATE BLENDS to aid in detecting fluid leaks. Some fuel suppliers blend unleaded gasoline with Various “special” additives and supplements exist oxygenates such as 10% ethanol, MTBE, and ETBE.
Page 20: Lubrication Points
LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) MATERIALS ADDED TO FUEL NOTE: The 42LE transaxle has separate transmis- sion and differential oil sumps, each requiring dif- All gasoline sold in the United States and Canada ferent fluids. are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions.
Page 21: Jump Starting
0 - 6 LUBRICATION & MAINTENANCE HOISTING JUMP STARTING STANDARD PROCEDURE - HOISTING STANDARD PROCEDURE - JUMP STARTING Refer to Owner’s Manual provided with vehicle for WARNING: proper emergency jacking procedures. REVIEW ALL SAFETY PRECAUTIONS AND WARN- WARNING: THE HOISTING AND JACK LIFTING INGS.
Page 22 LUBRICATION & MAINTENANCE 0 - 7 JUMP STARTING (Continued) (2) When using another vehicle as a booster source, park the booster vehicle within cable reach without allow vehicles to touch. (3) Turn off all accessories, set the parking brake, place the automatic transmission in PARK, and turn the ignition OFF in both vehicles.
Page 23 0 - 8 LUBRICATION & MAINTENANCE TOWING (Continued) be sure the rear end of disabled vehicle has at least Always tow vehicle with front wheels off the 100 mm (4 inches) ground clearance. If minimum ground as shown (Fig. 9). ground clearance cannot be reached, use a towing dolly.
Page 24 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page FRONT SUSPENSION ..... 1 WHEEL ALIGNMENT ..... 50 REAR SUSPENSION .
Page 25: Front Suspension
2 - 2 FRONT SUSPENSION tions without affecting the control of the vehicle. FRONT SUSPENSION Each side of the front suspension is allowed to move independently from the other. Both sides of the front DESCRIPTION - FRONT SUSPENSION suspension are allowed to pivot so the vehicle can be This vehicle uses a MacPherson strut type front steered in the direction preferred.
Page 26 FRONT SUSPENSION 2 - 3 FRONT SUSPENSION (Continued) CAUTION SPECIFICATIONS CAUTION: Only frame contact hoisting equipment FRONT SUSPENSION FASTENER TORQUE can be used on this vehicle. All vehicles have a fully independent rear suspension. The vehicles cannot be hoisted using equipment designed to lift DESCRIPTION N·m Lbs.
Page 27 2 - 4 FRONT SUSPENSION FRONT SUSPENSION (Continued) HUB / BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assem- bly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one piece unit.
Page 28 FRONT SUSPENSION 2 - 5 HUB / BEARING (Continued) (3) Remove the 2 guide pin bolts mounting the cal- (5) Remove the hub and bearing retaining nut iper assembly to the steering knuckle (Fig. 3). (Fig. 5). Remove the caliper from the front steering knuckle. Refer to Disc Brake Caliper in Brakes.
Page 29 2 - 6 FRONT SUSPENSION HUB / BEARING (Continued) bearing assembly will not slide out of knuckle, insert a pry bar between hub and bearing assembly and steering knuckle (Fig. 8) 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 30 FRONT SUSPENSION 2 - 7 HUB / BEARING (Continued) KNUCKLE DESCRIPTION - STEERING KNUCKLE The steering knuckle is a single casting with legs machined for attachment to the front strut assembly and lower control arm ball joint (Fig. 1). The steering knuckle also has machined abutments on the casting to support and align the front brake caliper.
Page 31 2 - 8 FRONT SUSPENSION KNUCKLE (Continued) Fig. 12 Disc Brake Caliper Mounting 1 - BRAKE LINE 2 - CALIPER GUIDE PIN BOLTS 3 - STEERING KNUCKLE 4 - BLEEDER SCREW 5 - CALIPER ASSEMBLY Fig. 11 Steering Knuckle 1 - STRUT ASSEMBLY 2 - STUB AXLE 3 - BRAKE CALIPER MOUNTING BOSSES 4 - HUB/BEARING ASSEMBLY...
Page 32 FRONT SUSPENSION 2 - 9 KNUCKLE (Continued) Fig. 14 Speed Sensor Head Removal Fig. 16 Hub And Bearing Retaining Bolts 1 - SENSOR EAR 1 - STEERING KNUCKLE 2 - PUNCH 2 - HUB/BEARING ATTACHING BOLTS 3 - SPEED SENSOR HEAD 3 - HALF SHAFT (7) Remove the hub and bearing to stub axle retaining nut (Fig.
Page 33 2 - 10 FRONT SUSPENSION KNUCKLE (Continued) assembly and steering knuckle (Fig. 19) 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 34 FRONT SUSPENSION 2 - 11 KNUCKLE (Continued) (12) Remove strut assembly steering knuckle attaching bolts (Fig. 22). Fig. 23 Hub And Bearing Assembly Mounting Surfaces 1 - BE SURE THESE SURFACES ARE CLEAN AND FREE OF Fig. 22 Strut To Steering Knuckle Attaching Bolts KNICKS BEFORE INSTALLING BEARINGS 2 - STEERING KNUCKLE 1 - STRUT ASSEMBLY...
Page 35 2 - 12 FRONT SUSPENSION KNUCKLE (Continued) sequence until all nuts are torqued to half specifica- through the center of the pivot bushing. The tension tion. Then repeat the tightening sequence to the full strut is fastened through the center of the tension specified torque of 135 N·m (100 ft.
Page 36 FRONT SUSPENSION 2 - 13 LOWER CONTROL ARM (Continued) CAUTION: When lower control arm is separated from steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assem- bling lower control arm to knuckle.
Page 37 2 - 14 FRONT SUSPENSION LOWER CONTROL ARM (Continued) Fig. 28 Lower Control Arm Removal/Installation 1 - ISOLATOR BUSHING 2 - TENSION STRUT 3 - CRADLE 4 - PIVOT BUSHING Fig. 30 Lower Control Arm Pivot Bushing 5 - LOWER CONTROL ARM BRACKET 1 - ARBOR PRESS RAM 6 - LOWER CONTROL ARM 2 - SPECIAL TOOL 6644-2...
Page 38 FRONT SUSPENSION 2 - 15 LOWER CONTROL ARM (Continued) Fig. 31 Removing Lower Control Arm Tension Strut Fig. 33 Pivot Bushing Bushing 1 - SPECIAL TOOL 6644-1 1 - ARBOR PRESS RAM 2 - SPECIAL TOOL MB990799 2 - SPECIAL TOOL 6644-4 3 - PRESS PIVOT BUSHING INTO LOWER CONTROL ARM 3 - SPECIAL TOOL MB990799 UNTIL INSTALLER TOUCHES THIS SURFACE OF CONTROL...
Page 39 2 - 16 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (2) Install the washer and a NEW retaining nut on the end of the tension strut at the control arm. Place an open end wrench on flat of tension strut to keep it from turning tension whilt tightening retain- ing nut.
Page 40 FRONT SUSPENSION 2 - 17 STABILIZER BAR DESCRIPTION The stabilizer bar interconnects both front struts of the vehicle and is attached to the front cradle/cross- member (Fig. 1) . Attachment of the stabilizer bar to the front cradle/ crossmember is through 2 rubber-isolator cushion bushings and retainers.
Page 41 2 - 18 FRONT SUSPENSION STABILIZER BAR (Continued) (4) Remove the right stabilizer bar link nut at the Puller, Special Tool C-3894A (Fig. 40), then remove strut assembly. Remove the link from the strut nut and tie rod from the steering arm. assembly (Fig.
Page 42 FRONT SUSPENSION 2 - 19 STABILIZER BAR (Continued) (8) Remove the 2 strut assembly to steering knuckle attaching bolts (Fig. 42). Fig. 44 Motor Mount To Cradle Assembly Attachment 1 - ENGINE OIL PAN Fig. 42 Strut Assembly To Steering Knuckle 2 - MOTOR MOUNT ATTACHING NUTS Attaching Bolts 3 - CRADLE ASSEMBLY...
Page 43 2 - 20 FRONT SUSPENSION STABILIZER BAR (Continued) the jack until the motor mounts clear the cradle assembly. It may be necessary to raise the jack further. Fig. 47 Stabilizer Bar Removal/Installation 1 - STABILIZER BAR 2 - HALFSHAFT Fig. 46 Jack Positioning Below Engine Oil Pan 3 - KNUCKLE 1 - TRANSAXLE 2 - RIGHT FRONT MOTOR MOUNT STUD...
Page 44 FRONT SUSPENSION 2 - 21 STABILIZER BAR (Continued) (16) Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specifica- tion. Repeat the tightening sequence to the full spec- ified torque of 135 N·m (100 ft. lbs.). (17) Lower vehicle to the ground.
Page 45 2 - 22 FRONT SUSPENSION STABILIZER BAR BUSHINGS (Continued) (2) Install the isolator bushing retainers back onto the stabilizer bar isolator bushings. CAUTION: When stabilizer bar is installed. Position stabilizer bar, so lower part of stabilizer bar is cen- tered in the middle of the cradle assembly. Failure to do this may cause stabilizer bar to come in con- tact with other suspension components.
Page 46 FRONT SUSPENSION 2 - 23 STRUT (Continued) (4) Inspect the upper strut mount assembly. Make sure the correct mount is on the correct side of the vehicle. Looking down at the top of the upper mount, 2 tabs can be seen, (Fig. 53) and (Fig. 54), down inside the mount center well.
Page 47 2 - 24 FRONT SUSPENSION STRUT (Continued) Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. Be sure that the springs meet the correct load rating for the vehicle and its specific options.
Page 48 FRONT SUSPENSION 2 - 25 STRUT (Continued) STEERING KNUCKLE. If bolts are turned damage to steering knuckle will result. (9) Remove the 2 strut assembly to steering knuckle attaching bolts (Fig. 60). Fig. 58 Caliper Guide Pin Bolts 1 - BRAKE LINE 2 - CALIPER GUIDE PIN BOLTS 3 - STEERING KNUCKLE 4 - BLEEDER SCREW...
Page 49 2 - 26 FRONT SUSPENSION STRUT (Continued) DISASSEMBLY - STRUT ASSEMBLY (FRONT) The Strut assembly must be removed from the vehicle for it to be disassembled and assembled. Refer to Removal in this section. For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Ser- vice Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring.
Page 50 FRONT SUSPENSION 2 - 27 STRUT (Continued) Fig. 63 Shaft Nut Removal/Installation 1 - SPRING COMPRESSOR 2 - SPECIAL TOOL 6864 3 - UPPER MOUNT Fig. 64 Strut Assembly Components 1 - SEAT AND BEARING bumper cup is not present, check inside the dust 2 - DUST SHIELD shield.
Page 51 2 - 28 FRONT SUSPENSION STRUT (Continued) NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, oth- erwise, proceed with step 5. (1) Place the coil spring in the compressor follow- ing the manufacturers instructions (Fig. 62). Before compressing the spring, rotate the spring to the posi- tion noted in the note between steps 7 and 8.
Page 52 FRONT SUSPENSION 2 - 29 STRUT (Continued) and bearing align properly. Verify the upper mount (7) Install stabilizer bar link on strut (Fig. 55). does not bind. Tighten the stabilizer link attaching nut to a torque (11) Remove the clamp from the lower end of the of 95 N·m (70 ft.
Page 53 2 - 30 FRONT SUSPENSION (3) Remove the remaining tension strut cradle TENSION STRUT CRADLE bushing halve from the engine cradle assembly (Fig. BUSHING 69). REMOVAL - TENSION STRUT CRADLE BUSHING (1) Remove lower control arm and tension strut as an assembly from the vehicle.
Page 54 REAR SUSPENSION 2 - 31 REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION REMOVAL - SPINDLE ....37 DESCRIPTION - REAR SUSPENSION .
Page 55 2 - 32 REAR SUSPENSION REAR SUSPENSION (Continued) Fig. 1 Rear Suspension 1 - STRUT ASSEMBLY 6 - STABILIZER BAR 2 - REAR SUSPENSION CROSSMEMBER 7 - TRAILING ARM 3 - REAR SUSPENSION CROSSMEMBER BUSHING 8 - SPINDLE 4 - LATERAL LINKS 5 - HUB AND BEARING CAUTION:: rear...
Page 56 REAR SUSPENSION 2 - 33 REAR SUSPENSION (Continued) SPECIFICATIONS HUB / BEARING REAR SUSPENSION FASTENER TORQUE DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one piece sealed unit or hub and bear- DESCRIPTION N·m ing unit type assembly.
Page 57 2 - 34 REAR SUSPENSION HUB / BEARING (Continued) INSTALLATION - HUB AND BEARING (REAR) (1) Install the rear hub and bearing assembly on the rear spindle. Install hub and bearing assembly retaining washer and nut on spindle (Fig. 3). Tighten the hub and bearing retaining nut to a torque of 168 N·m (124 ft.
Page 58 REAR SUSPENSION 2 - 35 LATERAL LINK (Continued) to remove the attaching bolt at the crossmember. See separate procedures below for the proper lateral link service procedure. LEFT FORWARD LATERAL LINK (1) Raise vehicle on jackstands or centered on a frame contact hoist.
Page 59 2 - 36 REAR SUSPENSION LATERAL LINK (Continued) CAUTION: The bolts attaching the forward lateral (8) Install the lateral links on the spindle. Install, links to the crossmember must be installed with the but DO NOT fully tighten the attaching bolt and nut at this time (Fig.
Page 60 REAR SUSPENSION 2 - 37 LATERAL LINK (Continued) (8) Tighten lateral arm to spindle attaching bolt and nut to 135 N·m (100 ft. lbs.). (9) Check and reset rear wheel toe to specifications if required. SPINDLE DESCRIPTION A forged rear spindle is mounted to each side of the rear suspension (Fig.
Page 61 2 - 38 REAR SUSPENSION SPINDLE (Continued) Fig. 8 Speed Sensor Head Fig. 10 Trailing Arm To Bracket Bolt 1 - STABILIZER BAR LINK 1 - SPINDLE 2 - STABILIZER BAR 2 - TRAILING ARM BRACKET 3 - LATERAL LINK 3 - TRAILING ARM 4 - BOLT 4 - BOLT...
Page 62 REAR SUSPENSION 2 - 39 SPINDLE (Continued) Fig. 12 Spindle Pinch Bolt Fig. 14 Removing Spindle From Strut 1 - PINCH BOLT 1 - BRASS DRIFT PUNCH 2 - STRUT ASSEMBLY 2 - STRUT ASSEMBLY 3 - REAR SPINDLE 3 - SPINDLE 4 - CENTER PUNCH 5 - HIT SPINDLE HERE 6 - LATERAL LINK...
Page 63 2 - 40 REAR SUSPENSION SPINDLE (Continued) (11) Tighten the lateral links to spindle attaching bar (Fig. 15). Remove the link from the stabilizer bar. bolt to a torque of 135 N·m (100 ft. lbs.). Repeat this procedure on the other side of the vehicle (12) Tighten the trailing arm to spindle bracket for the other attaching link.
Page 64 REAR SUSPENSION 2 - 41 STABILIZER BAR (Continued) rails (Fig. 16) (the 2 rearward attaching bolts also (3) Install the lower half of the retainer onto the attach the front corners of the rear suspension cross- bushing with the elongated mounting hole towards member in place).
Page 65 2 - 42 REAR SUSPENSION STABILIZER BAR (Continued) (9) Install both stabilizer bar attaching links onto stabilizer bar (Fig. 15). Install both stabilizer link to stabilizer bar attaching nuts (Fig. 15). Tighten the stabilizer link to stabilizer bar attaching nuts to a torque of 95 N·m (70 ft.
Page 66 REAR SUSPENSION 2 - 43 STRUT (Continued) NOTE: If the coils springs require replacement, be sure that the springs being replaced, are replaced with springs meeting the correct load and spring rate for the vehicle. Replacement of the coil spring requires removal and disassembly of the strut assembly.
Page 67 2 - 44 REAR SUSPENSION STRUT (Continued) Fig. 24 Spindle To Strut Attachment 1 - PINCH BOLT Fig. 22 Lateral Links To Spindle Attachment 2 - STRUT ASSEMBLY 1 - SPINDLE 3 - REAR SPINDLE 2 - LATERAL LINKS 3 - LATERAL LINK ATTACHING BOLT HEAD (15) Insert a center punch into the hole on the 4 - STRUT ASSEMBLY 5 - STABILIZER BAR ATTACHING LINK...
Page 68 REAR SUSPENSION 2 - 45 STRUT (Continued) Fig. 26 Removing Spindle From Strut Assembly Fig. 27 Strut Assembly Attaching Nuts 1 - BRASS DRIFT PUNCH 1 - FRONT OF CAR 2 - STRUT ASSEMBLY 2 - ATTACHING NUTS 3 - SPINDLE 3 - MOUNTING STUDS 4 - CENTER PUNCH 4 - STRUT ASSEMBLY...
Page 69 2 - 46 REAR SUSPENSION STRUT (Continued) • Inspect the strut for any condition of shaft bind- (3) Install the strut through the bottom of the coil ing over the full stroke of the shaft. spring until the lower spring seat contacts the lower •...
Page 70 REAR SUSPENSION 2 - 47 STRUT (Continued) INSTALLATION - STRUT ASSEMBLY (REAR) ft. lbs.) using a crow foot wrench and torque wrench in place of the wrench on the attaching nut. Be sure (1) Install the nut, washers, and rubber isolators to use a wrench to hold the link stud in place securing the stabilizer bar attaching link to the strut.
Page 71 2 - 48 REAR SUSPENSION TRAILING ARM/LINK (Continued) other damage to the trailing arm. If the trailing arm is bent or damaged the trailing arm will require replacement. attempt repair straighten a trailing arm. REMOVAL - TRAILING ARM (1) Raise vehicle on jackstands or centered on a frame contact hoist.
Page 72 REAR SUSPENSION 2 - 49 TRAILING ARM/LINK (Continued) (4) Install wheel and tire assembly on vehicle. (5) Lower vehicle to the ground. Tighten the wheel mounting stud nuts in proper (6) Tighten the trailing arm to spindle bracket sequence until all nuts are torqued to half specifica- attaching bolt to a torque of 100 N·m (75 ft.
Page 73 2 - 50 WHEEL ALIGNMENT WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT STANDARD PROCEDURE - WHEEL DESCRIPTION - WHEEL ALIGNMENT ..50 ALIGNMENT ......56 DIAGNOSIS AND TESTING STANDARD PROCEDURE - CURB HEIGHT DIAGNOSIS AND TESTING - SUSPENSION...
Page 74 WHEEL ALIGNMENT 2 - 51 WHEEL ALIGNMENT (Continued) Fig. 2 Caster TOE-OUT ON TURNS Toe-out on turns is the relative positioning of the front wheels while steering through a turn (Fig. 4). This compensates for each front wheel’s turning Fig. 1 Camber radius.
Page 75 2 - 52 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) Fig. 4 Toe-Out On Turns 1 - TOE-OUT ON TURNS Fig. 3 Toe 1 - TOE-IN 2 - TOE-OUT STEERING AXIS INCLINATION (S. A. I.) Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower...
Page 76 WHEEL ALIGNMENT 2 - 53 WHEEL ALIGNMENT (Continued) THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle’s center line (Fig. 6). The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking).
Page 77 2 - 54 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION Front End Clunk Or Snap 1. Loose lug nuts 1. Verify wheel lug nut torque On Turns 2. Worn or broken C/V joint 2. Replace C/V joint 3. Worn or loose tie rod 3.
Page 78 WHEEL ALIGNMENT 2 - 55 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure 2. Incorrect front or rear wheel toe 2. Check and reset wheel toe 3. Worn wheel bearings 3.
Page 79 2 - 56 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) symmetrical front caster or camber can sometimes by setting the front left camber to -0.3 degrees and cause a lead condition or can be used to fix a lead front right camber to +0.3 degrees. Do not exceed condition.
Page 80 WHEEL ALIGNMENT 2 - 57 WHEEL ALIGNMENT (Continued) (8) Check the vehicle’s curb height to verify it is within specifications. Refer to Curb Height Measure- ment. WHEEL ALIGNMENT SETUP (1) Position the vehicle on an alignment rack. (2) Install all required alignment equipment on the vehicle, per the alignment equipment manufac- turer’s instructions.
Page 81 2 - 58 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) If camber and caster do not meet required specifi- cations, the vehicles suspension components should be inspected for any signs of damage or bending. This inspection must be done before perform- ing the camber setting procedure. If a vehicle has a drift or lead condition, the front camber can be adjusted using the following camber adjustment procedure.
Page 82 WHEEL ALIGNMENT 2 - 59 WHEEL ALIGNMENT (Continued) CAUTION: When setting toe on vehicle, the maxi- (3) After completion of toe adjustment procedure, mum dimension of exposed threads allowed on tighten tie rod pinch bolt (Fig. 11) to a torque of 38 N·m (28 ft.
Page 83 2 - 60 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) NOTE: All wheel alignments are to be set with the SPECIFICATIONS vehicle at curb height. Refer to CURB HEIGHT MEA- SUREMENT. WHEEL ALIGNMENT NOTE: All specifications are given in degrees. FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER...
Page 84 DRIVELINE 3 - 1 DRIVELINE HALFSHAFT TABLE OF CONTENTS page page HALFSHAFT SPECIAL TOOLS DESCRIPTION ......1 DRIVELINE .
Page 85 3 - 2 HALFSHAFT HALFSHAFT (Continued) Fig. 1 Front Halfshaft Assemblies 1 - INNER BOOT 7 - INTERCONNECTING SHAFT 2 - INTERCONNECTING SHAFT 8 - OUTER RZEPPA JOINT 3 - OUTER BOOT 9 - INNER BOOT 4 - RIGHT HALF SHAFT 10 - LEFT HALF SHAFT 5 - TONE WHEEL 11 - OUTER BOOT...
Page 86 HALFSHAFT 3 - 3 HALFSHAFT (Continued) Fig. 2 Halfshaft Component Identification 1 - HOUSING ASM, RETAINER 11 - CLAMP, SEAL RETAINING 2 - RING, SPACER 12 - SHAFT, AXLE (RH SHOWN, LH SIMILAR) 3 - SPIDER, TRIPOD JOINT 13 - SEAL, DRIVE AXLE OUTBOARD 4 - RING, RETAINING 14 - CLAMP, SEAL RETAINING 5 - RETAINER, BALL &...
Page 87 3 - 4 HALFSHAFT HALFSHAFT (Continued) VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: (1) Foreign material (mud, snow, etc.) packed on the backside of the wheel(s). (2) Out of balance front tires or wheels. (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE) (3) Improper tire and/or wheel runout.
Page 88 HALFSHAFT 3 - 5 HALFSHAFT (Continued) Fig. 6 Hub And Bearing To Stub Axle Retaining Nut Fig. 8 Strut Assembly To Steering Knuckle Attaching Bolts 1 - HUB/BEARING ASSEMBLY 2 - NUT 1 - STRUT ASSEMBLY 2 - NUTS 3 - STRUT ASSEMBLY TO STEERING KNUCKLE ATTACHING BOLTS 4 - STEERING KNUCKLE Fig.
Page 89 3 - 6 HALFSHAFT HALFSHAFT (Continued) (11) Remove driveshaft inner tripod joint from transaxle stub shaft. When removing driveshaft, do not pull on interconnecting shaft to remove inner tripod joint from stub shaft. Removal in this manner will separate the spider assembly from the tripod joint housing.
Page 90 HALFSHAFT 3 - 7 HALFSHAFT (Continued) Fig. 13 Inner Tripod Joint Installation On Stub Shaft 1 - TRANSAXLE 2 - TRANSMISSION STUB SHAFT 3 - INNER TRIPOD JOINT Fig. 14 Outer C/V Joint Installation Into Hub and CAUTION: When installing outer C/V joint into the Bearing hub and bearing assembly, do not allow the flinger 1 - STRUT ASSEMBLY...
Page 91 3 - 8 HALFSHAFT HALFSHAFT (Continued) (8) Install retaining (Fig. 16). Tighten, but do not torque the hub nut at this time. Fig. 16 Hub And Bearing To Stub Axle Retaining Nut 1 - HUB/BEARING ASSEMBLY 2 - NUT Fig. 17 Installing Brake Rotor 1 - HUB (9) Install speed sensor cable routing bracket on 2 - STEERING KNUCKLE...
Page 92 HALFSHAFT 3 - 9 HALFSHAFT (Continued) Fig. 20 Tighten Hub And Bearing Retaining Nut 1 - HUB/BEARING 2 - TORQUE WRENCH SPECIAL TOOLS Fig. 18 Disc Brake Caliper Mounting DRIVELINE 1 - BRAKE SHOES 2 - STEERING KNUCKLE 3 - BRAKING DISC 4 - CALIPER ASSEMBLY 5 - MACHINED ABUTMENT Boot Clamp Installer C-4975A...
Page 93 3 - 10 HALFSHAFT CV BOOT-INNER REMOVAL To remove sealing boots from halfshafts for replacement, the halfshaft assemblies must be removed from the vehicle. (Refer to 3 - DIFFEREN- TIAL & DRIVELINE/HALF SHAFT - REMOVAL) (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) (1) Remove the halfshaft requiring boot replace- ment from the vehicle.
Page 94 HALFSHAFT 3 - 11 CV BOOT-INNER (Continued) INSTALLATION NOTE: The inner tripod joint sealing boots are made of silicone rubber which is soft and pliable. The replacement sealing boot MUST BE the same type of material as the sealing boot which was removed.
Page 95 3 - 12 HALFSHAFT CV BOOT-INNER (Continued) (7) Clamp sealing boot onto interconnecting shaft CAUTION: Seal must not be dimpled, stretched or using Crimper, Special Tool C-4975 and the following out of shape in any way. If seal is NOT shaped cor- procedure.
Page 96 HALFSHAFT 3 - 13 CV BOOT-OUTER (Continued) (4) Slide failed sealing boot off interconnecting shaft. (5) Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of exces- sive wear, the halfshaft assembly will require replacement.
Page 97 3 - 14 HALFSHAFT CV BOOT-OUTER (Continued) (4) Install outer C/V joint seal boot retaining clamp, onto interconnecting shaft. Install replace- ment outer C/V joint sealing boot onto interconnect- ing shaft. Outer C/V joint seal boot MUST be positioned on interconnecting shaft, so only the thinnest (sight) groove on interconnecting shaft is visible (Fig.
Page 98 HALFSHAFT 3 - 15 CV BOOT-OUTER (Continued) (7) Clamp sealing boot onto outer C/V joint hous- ing using Crimper, Special Tool C-4975 and the fol- lowing procedure. Place crimping tool C-4975 over bridge of clamp (Fig. 36). Tighten nut on crimping tool C-4975 until jaws on tool are closed completely together, face to face (Fig.
Page 100 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE BRAKE SYSTEM ... . . 1 BRAKES - ANTILOCK BRAKE SYSTEM ..61 BRAKES - BASE BRAKE SYSTEM TABLE OF CONTENTS page...
Page 101 5 - 2 BRAKES - BASE BRAKE SYSTEM INSPECTION - CALIPER ....32 OPERATION ......46 ASSEMBLY DIAGNOSIS AND TESTING - ASSEMBLY - CALIPER GUIDE PIN...
Page 102 BRAKES - BASE BRAKE SYSTEM 5 - 3 BRAKES - BASE BRAKE SYSTEM (Continued) hardware are described in detail in the Antilock CAUTION Brake System section. The parking brake on this vehicle is pedal-oper- CAUTION: Use only Mopar brake fluid or an equiv- ated.
Page 103 5 - 4 BRAKES - BASE BRAKE SYSTEM BRAKES - BASE BRAKE SYSTEM (Continued) NOTE: For bleeding this vehicles antilock brake hydraulic system, Refer to Antilock Brake System Bleeding. NOTE: Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process.
Page 104 BRAKES - BASE BRAKE SYSTEM 5 - 5 BRAKES - BASE BRAKE SYSTEM (Continued) the floor. Continue to hold the pedal all the way down. (5) Once the brake pedal has dropped, close the bleeder screw. The pedal can then be released. (6) Repeat steps (1) through (5) until all trapped air is removed from that wheel circuit (usually four or five times).
Page 105 5 - 6 BRAKES - BASE BRAKE SYSTEM BRAKES - BASE BRAKE SYSTEM (Continued) DESCRIPTION SPECIFICATION Master Cylinder Outlet Port Secondary Tube Nut M-12 Thread - W/O ABS Power Brake Booster 205 mm Vacuum Assist Type Power Brake Booster 4690 At 20 inches Boost Manifold Vacuum BRAKE FASTENER TORQUE...
Page 106 BRAKES - BASE BRAKE SYSTEM 5 - 7 BRAKES - BASE BRAKE SYSTEM (Continued) OPERATION The purpose of the brake fluid level switch is to provide the driver with early warning that brake fluid in the master cylinder is below a normal level. As the fluid drops below the designed level, the switch closes completing the red BRAKE warning indicator lamp circuit.
Page 107 5 - 8 BRAKES - BASE BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) Fig. 5 Front Disc Brake Caliper Assembly 1 - GUIDE PIN BOLT 10 - OUTBOARD BRAKE SHOE 2 - SLEEVE 11 - INBOARD BRAKE SHOE 3 - BUSHING 12 - ANTI-RATTLE CLIP 4 - CALIPER 13 - BUSHING 5 - PISTON SEAL...
Page 108 BRAKES - BASE BRAKE SYSTEM 5 - 9 HYDRAULIC/MECHANICAL (Continued) are attached to the adapter using threaded guide pin bolts (Fig. 8). The adapter and disc shield are mounted to the rear suspension knuckles of vehicle. The adapter is used to mount the brake shoes and actuating cables for the parking brake system.
Page 109 5 - 10 BRAKES - BASE BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) Although there are different disc brake systems available, they operate and are serviced in the same manner. A square-cut rubber piston seal is located in a machined groove in the cylinder bore. This provides a hydraulic seal between the piston and the cylinder wall (Fig.
Page 110 BRAKES - BASE BRAKE SYSTEM 5 - 11 HYDRAULIC/MECHANICAL (Continued) BRAKE NOISE CONDITION POSSIBLE CAUSES CORRECTION DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing. Correct as necessary. 2. Lack of lubricant on brake caliper 2.
Page 111 5 - 12 BRAKES - BASE BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Brake shoe lining transfer to 4. Reface or replace brake rotors as brake rotor. necessary. Replace brake shoes. EXCESSIVE PEDAL TRAVEL 1. Air in brake lines. 1.
Page 112: Brake Lines
BRAKES - BASE BRAKE SYSTEM 5 - 13 fittings and bolts at the caliper and must be replaced BRAKE LINES when the connection is broken. DESCRIPTION - BRAKE TUBES AND HOSES OPERATION - BRAKE TUBES AND HOSES The chassis brake tubes are steel with a corrosion The purpose of the chassis brake tubes and flex resistant coating applied to the external surfaces.
Page 113 5 - 14 BRAKES - BASE BRAKE SYSTEM BRAKE LINES (Continued) the rear proportioning valve and flex hose uses a SAE double inverted flare. Fig. 12 Cutting and Flaring of Brake 1 - SPECIAL TOOL TFM428 2 - SPECIAL TOOL C3478A Fig.
Page 114 BRAKES - BASE BRAKE SYSTEM 5 - 15 BRAKE LINES (Continued) all burrs on the inside of the tubing are removed brake hoses for severe surface cracking, scuffing, (Fig. 13). This preparation is essential to obtain worn spots or physical damage. If the fabric casing of the correct form of a (metric) ISO tubing flare.
Page 115 5 - 16 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - FRONT (Continued) machined abutment on steering knuckle (Fig. 16). Take care not to lose the two rail shims. Fig. 17 Supported Caliper 1 - WIRE HANGER 2 - FLEXIBLE BRAKE HOSE Fig.
Page 116 BRAKES - BASE BRAKE SYSTEM 5 - 17 BRAKE PADS/SHOES - FRONT (Continued) INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lin- ing wear. Also inspect for excessive lining deteriora- tion. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors.
Page 117 5 - 18 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - FRONT (Continued) (9) Repeat the preceding steps on the opposite side of the vehicle, installing the brake shoes on that side of the vehicle. (10) Install the wheel and tire assemblies. (11) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification.
Page 118 BRAKES - BASE BRAKE SYSTEM 5 - 19 BRAKE PADS/SHOES - FRONT (Continued) (7) Install the caliper guide pin bolts (Fig. 15). Tighten guide pin bolts to a torque of 22 N·m (192 in. lbs.). (8) Repeat the preceding steps on the opposite side of the vehicle, installing the brake shoes on that side of the vehicle.
Page 119 5 - 20 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - REAR (Continued) (5) Support caliper assembly firmly from rear strut to prevent weight of caliper from damaging the flex- ible brake hose (Fig. 24). Fig. 25 Removing / Installing Rear Rotor 1 - BRAKE ROTOR (DISC) 2 - DISC SHIELD 3 - HUB...
Page 120 BRAKES - BASE BRAKE SYSTEM 5 - 21 BRAKE PADS/SHOES - REAR (Continued) If a visual inspection does not adequately deter- mine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake shoes from the calipers.
Page 121 5 - 22 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - REAR (Continued) CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to cross thread the guide pin bolts. (8) Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 N·m (192 in.
Page 122 BRAKES - BASE BRAKE SYSTEM 5 - 23 DISC BRAKE CALIPER - FRONT (Continued) DISASSEMBLY DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING or INSPECTION in this section. (1) With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing (Fig.
Page 123 5 - 24 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) Fig. 32 Removing Bushing From Caliper Fig. 33 Removing Caliper/Piston Dust Boot 1 - CALIPER 1 - CALIPER 2 - BUSHING 2 - SCREWDRIVER 3 - BOOT NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of NOTE: Do not use a screw driver or other metal tool...
Page 124 BRAKES - BASE BRAKE SYSTEM 5 - 25 DISC BRAKE CALIPER - FRONT (Continued) (9) Inspect the caliper piston for pitting, scratches, or any physical damage. Replace the piston if there is evidence of scratches, pitting or physical damage. CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON- TAIN ASBESTOS FIBERS FROM PRODUCTION OR...
Page 125 5 - 26 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) Fig. 36 Folded Caliper Guide Pin Bushing 1 - CALIPER GUIDE PIN BUSHING (2) Insert the folded bushing into the caliper mounting boss using your fingers (Fig. 37). Fig.
Page 126 BRAKES - BASE BRAKE SYSTEM 5 - 27 DISC BRAKE CALIPER - FRONT (Continued) Fig. 41 Installing New Piston Seal 1 - CALIPER 2 - PISTON SEAL 3 - SEAL GROOVE CAUTION: Force applied to the piston to seat it in Fig.
Page 127 5 - 28 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) (6) Using a hammer and Installer, Special Tool (5) Carefully position caliper and brake shoes over C-4689 or C-4842 (depending on piston size), and rotor by reversing removal procedure (Fig. 29). Handle, Special Tool C-4171, drive the boot into the CAUTION: When being installed, extreme caution counterbore of the caliper as necessary (Fig.
Page 128 BRAKES - BASE BRAKE SYSTEM 5 - 29 DISC BRAKE CALIPER - FRONT (Continued) banjo bolt. Tighten banjo bolt to a torque of 48 N·m adapter. Then lift the caliper off the bottom abut- (35 ft. lbs.). ment on the adapter (Fig. 45). (7) Install the wheel and tire assembly.
Page 129 5 - 30 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - REAR (Continued) Fig. 48 Removing Sleeve From Bushing Fig. 46 Storing Caliper 1 - CALIPER 1 - FLEX HOSE 2 - SLEEVE 2 - STRUT 3 - BUSHING 3 - WIRE HANGER 4 - CALIPER ASSEMBLY Fig.
Page 130 BRAKES - BASE BRAKE SYSTEM 5 - 31 DISC BRAKE CALIPER - REAR (Continued) NOTE: The safest way to remove the piston from NOTE: Do not use a screw driver or other metal tool the caliper bore is to use the hydraulic pressure of for seal removal.
Page 131 5 - 32 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - REAR (Continued) AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar Non-Chlori- nated Brake Parts Cleaner.
Page 132 BRAKES - BASE BRAKE SYSTEM 5 - 33 DISC BRAKE CALIPER - REAR (Continued) (5) Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve (Fig. 56). Fig.
Page 133 5 - 34 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - REAR (Continued) (4) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 59). Fig. 57 Correctly Installed Guide Pin Sleeve And Fig.
Page 134 BRAKES - BASE BRAKE SYSTEM 5 - 35 DISC BRAKE CALIPER - REAR (Continued) FLUID DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar.
Page 135 5 - 36 BRAKES - BASE BRAKE SYSTEM FLUID (Continued) is permanently mounted to a bracket which fastens to the engine cradle crossmember. Later production junction blocks have the propor- tioning valves for the rear brakes mounted in them. One valve is mounted in each end (Fig. 62). The pro- portioning valves are not serviced separately from the junction block.
Page 136 BRAKES - BASE BRAKE SYSTEM 5 - 37 JUNCTION BLOCK (Continued) Fig. 63 Brake Pedal Holding Tool Installed Fig. 65 Transmission Control Module (TCM)— 1 - CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE) 2 - THROTTLE PEDAL Removal/Installation 3 - BRAKE PEDAL HOLDING TOOL 1 - RADIATOR UPPER SUPPORT 4 - STEERING WHEEL 2 - TCM...
Page 137: Master Cylinder
5 - 38 BRAKES - BASE BRAKE SYSTEM JUNCTION BLOCK (Continued) (10) There are two bolts fastening the junction (7) Install the four chassis brake tubes (going to block and mounting bracket to the engine cradle each brake) to the junction block (Fig. 66). Tighten crossmember.
Page 138 BRAKES - BASE BRAKE SYSTEM 5 - 39 MASTER CYLINDER (Continued) (2) Attach special tools for bleeding master cylin- der in the following fashion: (a) For non-ABS master cylinders, thread one Adapter, Special Tool 8822–2, into each outlet port. Tighten Adapters to 17 N·m (145 in. lbs.) torque. (b) For ABS master cylinders, thread one Adapter, Special Tools 8822–2, into the primary outlet port and one Adapter, Special Tool 8822–1,...
Page 139 5 - 40 BRAKES - BASE BRAKE SYSTEM MASTER CYLINDER (Continued) (6) Remove master cylinder from vise and install on power brake booster. (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/MASTER CYLINDER INSTALLATION) REMOVAL (1) Disconnect brake fluid level switch wire con- nector on the side of the master cylinder reservoir.
Page 140 BRAKES - BASE BRAKE SYSTEM 5 - 41 MASTER CYLINDER (Continued) PEDAL DESCRIPTION A suspended type brake pedal is used on this vehi- cle (Fig. 74). The pedal pivots on a shaft mounted in the pedal support bracket under the instrument panel.
Page 141: Power Brake Booster
5 - 42 BRAKES - BASE BRAKE SYSTEM PEDAL (Continued) pass over end of brake pedal pin, then pull retaining CAUTION: When installing the retaining clip on the clip off brake pedal pin. brake pedal pin, a NEW retaining clip must be used to ensure the retention of the power brake booster input rod.
Page 142 BRAKES - BASE BRAKE SYSTEM 5 - 43 POWER BRAKE BOOSTER (Continued) Fig. 77 Power Brake Booster Identification Fig. 76 Power Brake Booster 1 - VACUUM CHECK VALVE 1 - VACUUM CHECK VALVE 2 - MASTER CYLINDER PUSH ROD 2 - OUTPUT ROD 3 - POWER BRAKE BOOSTER ASSEMBLY 3 - POWER BRAKE BOOSTER ASSEMBLY 4 - MASTER CYLINDER MOUNTING STUDS...
Page 143 5 - 44 BRAKES - BASE BRAKE SYSTEM POWER BRAKE BOOSTER (Continued) then connect a vacuum gauge to the open vacuum more than 3.0 inches Hg, replace the power brake port on the valve. booster. If it is not, the booster is not defective. (4) Start the engine.
Page 144 BRAKES - BASE BRAKE SYSTEM 5 - 45 POWER BRAKE BOOSTER (Continued) Fig. 80 Wiper Module And Cowl Cover 1 - COWL COVER 2 - WIPER MODULE COVER (5) Remove the 8 bolts, attaching the reinforce- ment (Fig. 81) to the strut towers and the 1 bolt (Fig. Fig.
Page 145: Proportioning Valve
5 - 46 BRAKES - BASE BRAKE SYSTEM POWER BRAKE BOOSTER (Continued) (11) Install the covers over the wiper module and the cowl (Fig. 80). Install and securely tighten the attaching screws. (12) Reconnect the battery ground cable to the ground stud on the shock tower.
Page 146 BRAKES - BASE BRAKE SYSTEM 5 - 47 PROPORTIONING VALVE (Continued) portioning valves. Test the valve that controls the side of the vehicle on which the skid occurs. Both proportioning valves have the same pressure specifi- cations and are tested in the same way. (1) If the left rear proportioning valve is suspect, disconnect the tube nut fitting at the master cylinder primary port (port closest to power brake booster).
Page 147 5 - 48 BRAKES - BASE BRAKE SYSTEM PROPORTIONING VALVE (Continued) (14) Install Pressure Gauge, Special Tool (20) Install the transmission control module (with C-4007-A, to the Adapter. speed control servo attached) in its normal position (15) Tighten all tube nut fittings to 17 N·m (145 (Fig.
Page 148 BRAKES - BASE BRAKE SYSTEM 5 - 49 ROTOR (Continued) CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Minimum thickness specifications are cast on the rotor’s unmachined surface (Fig. 88). Limits can also be found in the table at the end of this brake rotor information.
Page 149 5 - 50 BRAKES - BASE BRAKE SYSTEM ROTOR (Continued) If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken.
Page 150 BRAKES - BASE BRAKE SYSTEM 5 - 51 ROTOR (Continued) BRAKE ROTOR LIMITS Minimum Rotor Rotor Run Rotor Micro Braking Rotor Rotor Thickness Rotor Thickness Out* Finish Thickness Variation 25.87–26.13 mm 24.4 mm 0.013 mm 0.08 mm Front Rotor 15-80 RMS 1.019 -1.029 in.
Page 151 5 - 52 BRAKES - BASE BRAKE SYSTEM ROTOR (Continued) When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the oper- ation of rotor turning equipment is required. Fig. 96 Rear Rotor Thickness Markings 1 - BRAKING DISC MINIMUM THICKNESS MARKING 2 - PARK BRAKE DRUM MAXIMUM DIAMETER MARKING BRAKE ROTOR REFINISHING LIMITS...
Page 152: Parking Brake
BRAKES - BASE BRAKE SYSTEM 5 - 53 ROTOR (Continued) INSTALLATION INSTALLATION - BRAKE ROTOR (FRONT) (1) Install brake rotor over the wheel mounting studs onto hub (Fig. 97). (2) Install disc brake caliper and shoes following the procedure found in Brake Pads/Shoes. (Refer to 5 - BRAKES - BASE/HYDRAULIC/MECHANICAL/ BRAKE PADS/SHOES - INSTALLATION) (3) Pump the brake pedal several times to ensure...
Page 153: Parking Brake Cable Tensioner
5 - 54 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE (Continued) NOTE: Leave park brakes applied until adjustment is complete. (11) Raise vehicle again. (12) Mark tensioner rod 6.35 mm (1/4 in.) from edge of tensioner bracket (Fig. 100). (13) Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket.
Page 154 BRAKES - BASE BRAKE SYSTEM 5 - 55 PARKING BRAKE CABLE TENSIONER (Continued) stud pointed towards the right side of the vehicle (Fig. 101) . (3) Connect the left rear park brake cable to the cable connector on the tensioner (Fig. 101) . (4) Attach the threaded end of the tensioner to the equalizer bracket (Fig.
Page 155 5 - 56 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE CABLE - INTERMEDIATE (Continued) (3) Disconnect the cable connector between the (5) Install the intermediate cable through the hole front and intermediate cable. in the body torque box (Fig. 103). Install the bolt (4) Remove the bolt attaching the intermediate attaching the intermediate cable retainer to the body cable retainer to the body torque box (Fig.
Page 156: Parking Brake Lever
BRAKES - BASE BRAKE SYSTEM 5 - 57 PARKING BRAKE CABLE - REAR (Continued) (7) Remove the rear wheel and tire assembly from (14) When repairs are complete, adjust parking the side of the vehicle requiring service to the park brake shoes, then adjust parking brake tensioner.
Page 157 5 - 58 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE LEVER (Continued) Fig. 106 Fuse Panel Cover Fig. 108 Trunk Release Wiring 1 - FUSE PANEL COVER 1 - WIRING HARNESS CONNECTOR 2 - INSTRUMENT PANEL 2 - TRUNK RELEASE SWITCH 3 - LOWER INSTRUMENT PANEL COVER Fig.
Page 158 BRAKES - BASE BRAKE SYSTEM 5 - 59 PARKING BRAKE LEVER (Continued) Fig. 110 Reinforcement Panel Fig. 112 Front Park Brake Cable At Rear Floor Pan 1 - REAR SEAT CUSHION 1 - REINFORCEMENT PANEL 2 - B-PILLAR 2 - MOUNTING BOLTS 3 - ROUTING BRACKET SCREW 4 - FRONT PARK BRAKE CABLE 5 - FLOOR PLAN...
Page 159 5 - 60 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE LEVER (Continued) tor. Remove the brake warning light ground wire from PARKING BRAKE SHOES the switch on the park brake lever assembly. (27) Continue to move parking brake lever, with REMOVAL - PARKING BRAKE SHOES front park brake cable attached, downward, and (1) Remove rear disc brake caliper assembly from...
Page 160 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 61 BRAKES - ANTILOCK BRAKE SYSTEM TABLE OF CONTENTS page page BRAKES - ANTILOCK BRAKE SYSTEM REAR WHEEL SPEED SENSOR DESCRIPTION DESCRIPTION ......68 DESCRIPTION - ANTILOCK BRAKES .
Page 161 5 - 62 BRAKES - ANTILOCK BRAKE SYSTEM BRAKES - ANTILOCK BRAKE SYSTEM (Continued) DESCRIPTION - ELECTRONIC VARIABLE speed sensors (WSS) at each wheel and received at the controller antilock brake (CAB). BRAKE PROPORTIONING Vehicles equipped with ABS use electronic variable NOISE AND BRAKE PEDAL FEEL brake proportioning (EVBP) to balance front-to-rear During ABS braking, some brake pedal movement...
Page 162 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 63 BRAKES - ANTILOCK BRAKE SYSTEM (Continued) 25–40 km/h (15–25 mph). This is caused by brief acti- released) the fluid in the LPA drains back to the vation of the ABS pump/motor and is a normal func- master cylinder by switching on the outlet valve and tion of ABS as part of the self-diagnosis check.
Page 163 5 - 64 BRAKES - ANTILOCK BRAKE SYSTEM BRAKES - ANTILOCK BRAKE SYSTEM (Continued) In the event that a system fault occurs thus illu- system operation. Only those components with minating the amber ABS warning lamp, the TRAC approved removal and installation procedures in OFF lamp will also illuminate.
Page 164 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 65 BRAKES - ANTILOCK BRAKE SYSTEM (Continued) (6) Turn the key to the OFF position and then back to the ON position. Note whether the amber ABS warning lamp continues to stay on. (7) If the amber ABS warning indicator lamp stays on, shift into gear and drive the car to a speed of approximately 25 km/h (15 mph) to complete the ABS...
Page 165: Digit
5 - 66 BRAKES - ANTILOCK BRAKE SYSTEM BRAKES - ANTILOCK BRAKE SYSTEM (Continued) (4) Bleed the base brake system using the stan- FRONT WHEEL SPEED dard pressure or manual bleeding procedure. (Refer SENSOR to 5 - BRAKES - BASE - STANDARD PROCEDURE) (5) Using DRBIII , select...
Page 166 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 67 FRONT WHEEL SPEED SENSOR (Continued) resulting signal is interpreted by the ABS CAB as the wheel speed. REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove the tire and wheel assembly from the vehicle.
Page 167 5 - 68 BRAKES - ANTILOCK BRAKE SYSTEM resulting signal is interpreted by the ABS CAB as REAR WHEEL SPEED SENSOR the wheel speed. DESCRIPTION REMOVAL This system uses two-wire wheel speed sensors known as active wheel speed sensors. One wheel NOTE: When removing rear wheel speed sensor speed sensor (WSS) and one tone wheel are located from vehicle, access to the wire harness connector...
Page 168 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 69 REAR WHEEL SPEED SENSOR (Continued) attaching bolt (Fig. 6) and tighten to 7 N·m (60 in. If wheel speed sensor to tone wheel contact is evi- lbs.). dent, determine the cause and correct it before (2) Install the sensor cable to the routing bracket replacing the wheel speed sensor or tone wheel.
Page 169 5 - 70 BRAKES - ANTILOCK BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 7) shows the vehicle in the normal braking mode of the base brake hydraulic system.
Page 170 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 71 HYDRAULIC/MECHANICAL (Continued) ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 8) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding.
Page 171 5 - 72 BRAKES - ANTILOCK BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 9) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle.
Page 172 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 73 HYDRAULIC/MECHANICAL (Continued) • The normally open and normally closed valves ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID modulate (build/decay) the brake hydraulic pressure VALVE, AND SHUTTLE VALVE FUNCTION (ABS as required. WITH TRACTION CONTROL) •...
Page 173 5 - 74 BRAKES - ANTILOCK BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 11) shows the vehicle in the traction control (TC) mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed.
Page 174 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 75 The fluid accumulators temporarily store brake HCU (HYDRAULIC CONTROL fluid that is removed from the wheel brakes during UNIT) an ABS cycle. This stored fluid is used by the pump/ motor to provide build pressure for the brake hydrau- DESCRIPTION lic system.
Page 175 5 - 76 BRAKES - ANTILOCK BRAKE SYSTEM ICU (INTEGRATED CONTROL UNIT) (Continued) The ABS-only ICU consists of the following compo- nents: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The ABS-with traction control ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet...
Page 176 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 77 ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 16 Transmission Controller Mounting Fig. 14 Correctly Isolated Remote Ground Cable 1 - POWER DISTRIBUTION CENTER 1 - CABLE ISOLATOR 2 - WASHER BOTTLE NECK 2 - GROUND STUD 3 - TRANSMISSION CONTROLLER MOUNTING BOLT AND NUT 3 - GROUND CABLE Fig.
Page 177 5 - 78 BRAKES - ANTILOCK BRAKE SYSTEM ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 18 24-way CAB Connector Lock Fig. 19 Integrated Control Unit (ICU) 1 - 24–WAY CAB CONNECTOR 1 - PUMP/MOTOR 2 - CONNECTOR LOCK 2 - HCU 3 - PUMP/MOTOR WIRING CONNECTOR 4 - CAB (12) Remove the left front tire and wheel assembly.
Page 178 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 79 ICU (INTEGRATED CONTROL UNIT) (Continued) ing procedure. Position the 24-way connector in the socket on the CAB and carefully push it onto CAB as far as it will go. When connector is fully seated into the CAB socket push in the connector lock (Fig.
Page 180 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE - COOLING DESCRIPTION - ENGINE COOLING SYSTEM . . 1 SYSTEM DRAINING ....8 OPERATION - ENGINE COOLING SYSTEM .
Page 181 7 - 2 COOLING COOLING (Continued) Fig. 1 COOLING SYSTEM FLOW 1 - BOTTLE SUPPLY HOSE 7 - RADIATOR LOWER OUTLET HOSE 2 - PRESSURE BOTTLE 8 - THERMOSTAT LOCATION 3 - HEATER SUPPLY TUBE 9 - BOTTLE RETURN 4 - RADIATOR UPPER INLET HOSE 10 - HEATER RETURN TUBE 5 - RADIATOR 11 - HEATER CORE...
Page 182 COOLING 7 - 3 COOLING (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING 1. During cold weather operation with 1. A normal condition. No correction is IS INCONSISTENT (FLUCTUATES, the heater blower in the high position, necessary.
Page 183 7 - 4 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE GROUND 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as WITHOUT PRESSURE CAP system hoses, water pump or engine. necessary. (Refer to 7 - COOLING - BLOWOFF.
Page 184 COOLING 7 - 5 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as PERFORMANCE (COOLING restricted, obstructed or dirty (insects, necessary. SYSTEM SUSPECTED). leaves, etc.). 2. Electrical radiator fan not operating 2.
Page 185 7 - 6 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace certain driveline components. One or or repair as necessary. more of these shields may be missing.
Page 186 COOLING 7 - 7 COOLING (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM internal leak in the engine. If there is an internal leak, the engine must be disassembled for repair. LEAK With engine not running, wipe the coolant bottle DIAGNOSIS AND TESTING - COOLING SYSTEM neck sealing seat clean.
Page 187 7 - 8 COOLING COOLING (Continued) (3) Remove the cylinder block drain plug(s) located below each exhaust manifold. Most service drains are about 80 percent of capac- ity because not all coolant is drained from system. For capacity specifications, (Refer to LUBRICATION &...
Page 188 COOLING 7 - 9 COOLING (Continued) WARNING: WHEN INSTALLING DRAIN HOSE TO AIR (4) Route hose away from the accessory drive belt, BLEED VALVE, ROUTE HOSE AWAY FROM ACCES- drive pulleys and electric cooling fan. Place the other end of hose into a clean container. The hose will pre- SORY DRIVE BELTS, ACCESSORY DRIVE PULLEYS, AND ELECTRIC COOLING FAN MOTORS.
Page 189 7 - 10 COOLING COOLING (Continued) 1 - 2.7L ENGINE 6 - COOLANT CONTAINER 2 - 3.5L ENGINE 7 - HOSE 3 - BLEED VALVE 8 - TO COOLANT CONTAINER 4 - TO COOLANT CONTAINER 9 - BLEED VALVE 5 - SPECIAL TOOL 8195 engine cooling system overheats and pushes cool- ant into the overflow side of the coolant bottle, this coolant will be sucked back into the cooling system...
Page 190 COOLING 7 - 11 COOLING (Continued) (1) Try squeezing the radiator upper hose to deter- mine if the system is still pressurized. DESCRIPTION N·m Lbs. Lbs. (2) Place a shop towel over the pressure cap and Engine Oil Cooler - Lines to —...
Page 191 7 - 12 COOLING COOLING (Continued) Cooling System Tester 7700 Hose Clamp Pliers 6094 Trans Cooler Flusher 6906 Filling Aid Funnel 8195 Coolant Refractometer 8286...
Page 192 ACCESSORY DRIVE 7 - 13 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE INSTALLATION ......15 DESCRIPTION .
Page 193 7 - 14 ACCESSORY DRIVE DRIVE BELTS - 2.7L REMOVAL GENERATOR/POWER STEERING BELT (1) Loosen tensioner pulley locking nut (Fig. 1). (2) Loosen belt adjusting bolt (Fig. 1). (3) Remove generator/power steering belt. Fig. 1 ACCESSORY DRIVE BELTS 1 - A/C DRIVE BELT 2 - LOCKING NUT 3 - GENERATOR/POWER STEERING DRIVE BELT 4 - ADJUSTING BOLT...
Page 194 ACCESSORY DRIVE 7 - 15 DRIVE BELTS - 2.7L (Continued) (7) Using a 1/2” drive breaker bar, apply counter- clockwise pressure until locking bolt can be installed. (8) Install the NEW belt by rotating the tensioner counterclockwise until the NEW belt can be installed on pulleys.
Page 195 7 - 16 ACCESSORY DRIVE DRIVE BELTS - 2.7L (Continued) (2) Carefully release the tension of spring on ten- BELT TENSION CHART—2.7/3.5L ENGINES sioner. (3) Remove pivot bolt, tensioner, and spring from POLY-V BELT GAUGE front cover. Generator/Power New Belt: 836 ±44 N (4) Insert spring into the USED belt position on Steering Belt (all (190 ±10 lbs.)
Page 196 ACCESSORY DRIVE 7 - 17 DRIVE BELTS - 3.5L (Continued) Fig. 7 Drive Belt Wear Pattern Fig. 6 ACCESSORY DRIVE BELTS 1 - NORMAL CRACKS - BELT OK 1 - V-BELT 2 - NOT NORMAL CRACKS - REPLACE BELT 2 - POLY-V BELT 3 - LOCKING NUT (1) Install generator/power steering belt.
Page 197 7 - 18 ENGINE ENGINE TABLE OF CONTENTS page page ENGINE HOSE CLAMPS CLEANING ......18 DESCRIPTION .
Page 198 ENGINE 7 - 19 ENGINE (Continued) glycol and distilled water (Refer to LUBRICATION & (1) Drain cooling system (Refer to 7 - COOLING - MAINTENANCE/FLUID TYPES - DESCRIPTION). STANDARD PROCEDURE). (2) Remove upper intake manifold (Refer to 9 - INSPECTION ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL).
Page 199: Engine Block Heater
7 - 20 ENGINE OPERATION COOLANT RECOVERY The pressure chamber keeps the coolant free of PRESSURE CONTAINER trapped air, provides a volume for expansion and con- traction, and provides a convenient and safe method DESCRIPTION for checking and adjusting coolant level at atmo- The coolant bottle consists of a pressure chamber spheric pressure.
Page 200: Engine Coolant Temperature Sensor
ENGINE 7 - 21 ENGINE BLOCK HEATER (Continued) Fig. 4 ENGINE BLOCK HEATER 1 - BLOCK HEATER 2 - ENGINE — RIGHT SIDE (5) Lower vehicle. Fig. 6 ENGINE COOLANT TEMPERATURE SENSOR - 3.5L ENGINE COOLANT 1 - CAMSHAFT POSITION SENSOR TEMPERATURE SENSOR 2 - ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION...
Page 201 7 - 22 ENGINE ENGINE COOLANT THERMOSTAT (Continued) stat flange. The air bleed allows internal trapped air engine operating temperature of 82°C (180°F). They during cooling system filling to be released. also automatically reach wide open at a temperature of approximately 95°C (203°F) so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F).
Page 202 ENGINE 7 - 23 ENGINE COOLANT THERMOSTAT - 2.7L (Continued) (8) Remove the transaxle dipstick tube bracket (12) Refill cooling system (Refer to 7 - COOLING - attaching bolt. STANDARD PROCEDURE). (9) Remove the lower heater hose tube bracket bolt. (13) Connect negative cable to remote jumper ter- (10) Remove the lower heater hose from thermo- minal.
Page 203 7 - 24 ENGINE ENGINE COOLANT THERMOSTAT - 3.5L (Continued) (2) Install thermostat and gasket into thermostat housing. For ease of installation, install bolts in housing for thermostat and gasket retention. (3) Install thermostat and housing to cylinder block (Fig. 10). Tighten bolts to 12 N·m (105 in. lbs.). (4) Connect heater and radiator hoses and install hose clamps.
Page 204: Hose Clamps
ENGINE 7 - 25 HEATER SUPPLY TUBE - 3.5L (Continued) (1) Drain cooling system. (Refer to 7 - COOLING - HOSE CLAMPS STANDARD PROCEDURE) (2) Remove upper and lower intake manifold. DESCRIPTION (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI- The cooling system utilizes both worm drive and FOLD - REMOVAL) spring type hose clamps.
Page 205 7 - 26 ENGINE HOSE CLAMPS (Continued) stant tension clamp pliers (Fig. 14) to compress the hose clamp. Fig. 14 HOSE CLAMP TOOL 1 - HOSE CLAMP TOOL 6094 Fig. 15 RADIATOR - TYPICAL 2 - HOSE CLAMP 1 - COOLING TUBES 2 - TANKS RADIATOR REMOVAL...
Page 206 ENGINE 7 - 27 RADIATOR (Continued) Fig. 16 RADIATOR 1 - ENGINE OIL COOLER FITTINGS (IF EQUIPPED) 2 - DRAINCOCK 3 - LOWER MOUNTING ISOLATORS 4 - TRANSMISSION COOLER LINE NIPPLES Fig. 18 A/C CONDENSER TO RADIATOR - 3.5L & 2.7L w/AUTO STICK 1 - TRANS COOLER LINE BRACKET SCREW 2 - SCREW - CONDENSER TO RADIATOR...
Page 207 7 - 28 ENGINE RADIATOR (Continued) (12) Radiator can now be lifted from engine com- RADIATOR DRAINCOCK partment. Care should be taken not to damage radiator cooling fins or water tubes during REMOVAL removal. WARNING: DO NOT REMOVE THE CYLINDER CLEANING BLOCK PLUG OR THE RADIATOR DRAINCOCK Clean radiator fins are necessary for good heat...
Page 208: Pressure Cap
ENGINE 7 - 29 ESCAPE THROUGH THE OVERFLOW TUBE AND PRESSURE CAP WHEN THE SYSTEM STOPS PUSHING OUT COOL- STEAM PRESSURE DROPS, DESCRIPTION REMOVE THE CAP COMPLETELY. SQUEEZING THE The cooling system cap is located on the coolant RADIATOR INLET HOSE WITH A SHOP TOWEL (TO pressure bottle.
Page 209: Radiator Fan
7 - 30 ENGINE PRESSURE CAP (Continued) There is no need to remove the pressure cap at any The cooling fans will operate based on inputs to time except for the following purposes: the Powertrain Control Module (PCM). When fan •...
Page 210 ENGINE 7 - 31 RADIATOR FAN (Continued) RADIATOR FAN OPERATION—2.7L ENGINE INTAKE (CHARGE) ENGINE COOLANT TEMPERATURE TEMPERATURE Engine @ Idle < 13 Km/h (8 Vehicle Speed < 45 Km/h (28 A/C Off A/C On MPH) Vehicle Speed MPH)** High High High High Speed...
Page 211 7 - 32 ENGINE RADIATOR FAN (Continued) REMOVAL each relay and fuse contained in the PDC. It is an ISO relay. (1) Remove radiator upper crossmember (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REIN- FORCEMENT - REMOVAL). (2) Disconnect radiator fan motor electrical connec- tor.
Page 212: Water Pump
ENGINE 7 - 33 RADIATOR FAN RELAY (Continued) Fig. 27 WATER PUMP - 2.7L ENGINE 1 - WATER PUMP BODY 2 - IMPELLER 3 - GASKET Fig. 26 Radiator Fan Relays - No. 1 & No. 2 (Except 2.7L Base) REMOVAL 1 - ELECTRICAL CONNECTOR 2 - RADIATOR FAN MOTOR NO.
Page 213 7 - 34 ENGINE WATER PUMP - 2.7L (Continued) (6) Remove bolts attaching water pump to block (Fig. 28). (7) Remove water pump and gasket. Fig. 29 WATER PUMP WEEP PASSAGE - 2.7L 1 - THERMOSTAT HOUSING/COOLANT INLET 2 - WATER PUMP WEEP PASSAGE (4) Install the timing chain cover (Refer to 9 - Fig.
Page 214 ENGINE 7 - 35 WATER PUMP - 3.5L (Continued) NOTE: It is normal for the water pump to weep a NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black small amount of coolant from the weep hole (black stain on water pump body).
Page 215 7 - 36 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION CLEANING ......37 STANDARD PROCEDURE - FLUSHING INSPECTION .
Page 216 TRANSMISSION 7 - 37 TRANSMISSION OIL COOLER (Continued) Fig. 1 TRANSMISSION OIL COOLER 1 - RADIATOR 4 - TRANSMISSION OIL RETURN LINE 2 - TRANSMISSION OIL COOLER SUPPLY LINE TO IN-TANK 5 - TRANSMISSION OIL SUPPLY LINE TO IN-TANK OIL COOLER COOLER 3 - FROM IN-TANK COOLER TO EXTERNAL OIL COOLER 6 - EXTERNAL TRANSMISSION OIL COOLER...
Page 217 7 - 38 TRANSMISSION TRANSMISSION OIL COOLER (Continued) (3) Reposition the A/C condenser to allow access to condenser rear surface. (4) Remove the previously cut-off cooler retaining straps. (5) Position and install the new retaining straps in the same locations on the condenser. (6) Reposition A/C condenser on the radiator upper retainers.
Page 218 TRANSMISSION 7 - 39 TRANSMISSION OIL COOLER (Continued) (16) Install the radiator upper support (Refer to 23 (2) Remove lines from transmission. BODY/EXTERIOR/GRILLE OPENING REIN- (3) Remove lines from supports. FORCEMENT - INSTALLATION). INSPECTION (17) Connect negative cable cable remote jumper terminal.
Page 220 AUDIO 8A - 1 AUDIO TABLE OF CONTENTS page page AUDIO SYSTEM OPERATION ......6 DESCRIPTION .
Page 221 8A - 2 AUDIO AUDIO SYSTEM (Continued) • Two 2.5 inch, coaxial speakers in the lower cor- Whenever a radio malfunction occurs; ners of the front door windows. (1) First check FUSES in the Junction Block: • Two 6.5 inch, round single-cone speakers in the (a) Radio power front doors.
Page 222 AUDIO 8A - 3 AUDIO SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO RADIO DISPLAY 1. Fuse faulty. 1. Check radio fuse and Ignition-Off Draw (IOD) fuse in Junction Block (JB). Replace fuses, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if required.
Page 223 8A - 4 AUDIO AMPLIFIER DESCRIPTION MIDLINE AND INFINITY l SYSTEM The amplifier is located in the right front cowl panel. INFINITY ll SYSTEM The amplifier is located beneath the trunk liner covering the right quarter inner panel. OPERATION For specific operation of each individual system, refer to the vehicles owners manual, Audio System Operation Manual.
Page 224 AUDIO 8A - 5 AMPLIFIER (Continued) INFINITY II SYSTEM The CD changer contains a Load/Eject button and an indicator light for each of the four disc positions. (1) Install remote amplifier into vehicle. The individual light indicates whether a CD is cur- (2) Connect two wire connectors.
Page 225 8A - 6 AUDIO RADIO (Continued) INSTALLATION (1) Remove upper quarter trim panel. (2) Disconnect the wire connectors from rear win- (1) Place radio near instrument panel opening. dow defogger, and rear window mounted radio (2) Connect wiring and antenna lead to radio and antenna, if so equipped.
Page 226 AUDIO 8A - 7 REAR WINDOW ANTENNA (Continued) Fig. 3 REAR WINDOW GLASS - TYPICAL 1 - REAR WINDOW GLASS 2 - URETHANE 3 - CLIP 4 - MOLDING Fig. 4 Rear Defogger/Antenna Module 1 - TO RADIO (12) After urethane has cured, water test rear win- 2 - TO BACKLITE dow to verify repair.
Page 227 8A - 8 AUDIO REAR WINDOW ANTENNA MODULE (Continued) (4) Reception degradation when the rear window defogger is actuated may indicate discontinuity in the heated grid lines. (5) Turn the radio and rear window defogger ON position. Using a voltmeter, test for battery voltage at the X60 and C15 circuit terminals of the rear win- dow antenna module wire harness connector (Fig.
Page 228 AUDIO 8A - 9 REAR WINDOW ANTENNA MODULE (Continued) INSTALLATION The two remote radio switch units are each retained in a mounting hole located on opposite sides (1) Install module from vehicle. of the rear steering wheel trim cover by four integral (2) Connect wire connectors and radio antenna snap features.
Page 229 8A - 10 AUDIO REMOTE SWITCHES (Continued) WARNING: DISABLE AIRBAG SYSTEM REMOTE RADIO SWITCH TEST BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE Switch Switch Position Resistance AIRBAG, OR INSTRUMENT PANEL COMPONENT Right DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- Volume Up 1.210 Kilohms (White)
Page 230 AUDIO 8A - 11 REMOTE SWITCHES (Continued) REMOVAL WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 231 8A - 12 AUDIO (2) Open rear door. SPEAKER (3) Using a trim stick (special tool #C-4755), care- fully pry speaker grille away from door trim panel REMOVAL (Fig. 11). FRONT DOOR - LOWER (1) Disconnect and isolate the battery negative cable.
Page 232 AUDIO 8A - 13 SPEAKER (Continued) INSTRUMENT PANEL (4) Connect battery negative cable. (1) Place speaker into position on instrument REAR SHELF panel. (1) Connect wire connector and place speaker into (2) connect wiring connector, install two retaining speaker opening. screws to center speaker.
Page 234 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - EXTERIOR DESCRIPTION ......1 LAMPS ON .
Page 235 8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) No tone when key is left in ignition. Ignition door open. Chime should sound until headlamps are turned off or drivers door is closed. switch is in the OFF position and driver’s door is Refer to Electrical, Lamps/Lighting - Exterior, open.
Page 236 CLOCK 8C - 1 CLOCK TABLE OF CONTENTS page page CLOCK REMOVAL ......1 DESCRIPTION .
Page 238 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES DIAGNOSTIC TROUBLE CODE ... 12 STANDARD PROCEDURE - PCM/SKIM OPERATION - SENSOR RETURN - PCM PROGRAMMING .
Page 239: Body Control Module
8E - 2 ELECTRONIC CONTROL MODULES ELECTRONIC CONTROL MODULES (Continued) (2) Use the DRB III and select THEFT ALARM, (2) Use the DRB III and select THEFT ALARM, SKIM then MISCELLANEOUS. SKIM then MISCELLANEOUS. (3) Select PCM REPLACED (GAS ENGINE). (3) Select PROGRAM IGNITION KEY’S.
Page 240 Block, Removal and Installation. lated (VPWM) signals. The PCI data bus speed is an average 10.4 Kilo-bits per second (Kbps). By compar- COMMUNICATION ison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kbps. DESCRIPTION...
Page 241 8E - 4 ELECTRONIC CONTROL MODULES COMMUNICATION (Continued) resistor and a terminating capacitor. There are two the bus. When two modules are transmitting simul- types of nodes on the bus. The dominant node termi- taneously on the bus, there must be some form of nates the bus through a 1 KW resistor and a 3300 pF arbitration to determine which module will gain con- capacitor.
Page 242 ELECTRONIC CONTROL MODULES 8E - 5 • (with traction control only) Illuminate the TRAC CONTROLLER ANTILOCK OFF lamp when the amber ABS warning indicator BRAKE lamp illuminates. The CAB constantly monitors the antilock brake DESCRIPTION system for proper operation. If the CAB detects a The controller antilock brake (CAB) is a micropro- fault, it will turn on the amber ABS warning indica- cessor-based device which monitors the antilock...
Page 243: Data Link Connector
8E - 6 ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE (Continued) BRAKES - ABS/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) - REMOVAL) INSTALLATION To install the CAB, it must be attached to the HCU, forming the ICU. (Refer to 5 - BRAKES - ABS/ HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) - ASSEMBLY)
Page 244 ELECTRONIC CONTROL MODULES 8E - 7 MEMORY HEATED SEAT/MIRROR MODULE (Continued) ule (PCM) (vehicle speed status). The programming (2) Position the drivers seat as far upward and in the MSM allows it to process the information from rearward as possible. these inputs and send control outputs to each of the (3) Remove the two module attaching screws (Fig.
Page 245 8E - 8 ELECTRONIC CONTROL MODULES • Natural Vacuum Leak Detection POWERTRAIN CONTROL • PCI Bus MODULE • Power Steering Pressure Switch • Proportional Purge Sense • SCI Receive DESCRIPTION • Speed Control • Throttle Position Sensor DESCRIPTION • Torque Management Input (Integral to PCM) The Powertrain Control Module (PCM) is a digital •...
Page 246 ELECTRONIC CONTROL MODULES 8E - 9 POWERTRAIN CONTROL MODULE (Continued) The PCM adjusts injector pulse width (air-fuel The PCM engine control strategy prevents reduced ratio) based on the following inputs. idle speeds until after the engine operates for 320 km •...
Page 247 8E - 10 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) Gear ratios can be determined by using the DRB The volume of transmission fluid needed to apply Scan Tool and reading the Input/Output Speed Sen- the friction elements are continuously updated for sor values in the “Monitors”...
Page 248 ELECTRONIC CONTROL MODULES 8E - 11 POWERTRAIN CONTROL MODULE (Continued) • Throttle position TRANSMISSION CONTROL • Engine load • Fluid temperature SHIFT SCHEDULES • Software level As mentioned earlier, the PCM has programming As driving conditions change, the PCM appropri- that allows it to select a variety of shift schedules.
Page 249 8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) DIAGNOSTIC TROUBLE CODE Remember that DTC’s are the results of a sys- tem or circuit failure, but do not directly iden- tify the failed component or components. DESCRIPTION A Diagnostic Trouble Code (DTC) indicates the NOTE: For a list of DTC’s, refer to the charts in this PCM or TCM has recognized an abnormal condition section.
Page 250 ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE Ambient temp.
Page 251 8E - 14 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE P0135 (M) 1/1 O2 Sensor Heater Failure...
Page 252 ELECTRONIC CONTROL MODULES 8E - 15 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE A rich air/fuel mixture has been indicated by an P0172 (M)
Page 253 8E - 16 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE P0307 (M) CYLINDER #7 MISFIRE...
Page 254 ELECTRONIC CONTROL MODULES 8E - 17 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE An open or shorted condition detected in the EGR P0403 (M)
Page 255 8E - 18 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE Vehicle Speed Sensor #1 A rationality error has been detected for no vehicle speed...
Page 256 ELECTRONIC CONTROL MODULES 8E - 19 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE No communication detected between co-processors in the P0600 (M)
Page 257 8E - 20 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE P0720 (M) Output Speed Sensor Error...
Page 258 ELECTRONIC CONTROL MODULES 8E - 21 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE LR pressure switch open or closed at wrong time in given P0841 (M)
Page 259 8E - 22 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE Radiator Temperature Sensor Volts Radiator coolant temperature sensor input above the...
Page 260 ELECTRONIC CONTROL MODULES 8E - 23 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE An open or shorted condition detected in the Wait to Start P1399...
Page 261 8E - 24 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE Leak Detection Pump Solenoid An open or shorted condition detected in the Leak...
Page 262 ELECTRONIC CONTROL MODULES 8E - 25 POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE No BUS messages received from the Mechanical P1687...
Page 263 8E - 26 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Malfunction Indicator Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC SCAN TOOL DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE CODE TCM detects LR pressure switch close while in PEMCC/ Solenoid Switch Valve Latched in the...
Page 264 ELECTRONIC CONTROL MODULES 8E - 27 POWERTRAIN CONTROL MODULE (Continued) • Manifold absolute pressure sensor be calibrated to the different combinations of equip- • Throttle position sensor ment available. Pinion Factor allows the technician • Linear EGR solenoid to set the Powertrain Control Module initial setting •...
Page 265 8E - 28 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (3) View or Start TCC Break-In as prompted by Refer to the appropriate Powertrain Diagnostic Man- DRBIII menu. ual and the DRBIII scan tool. To avoid possible voltage spike damage to PCM, STANDARD PROCEDURE - TRANSAXLE QUICK ignition key must be off, and the negative battery cable must be disconnected before unplugging the...
Page 266 ELECTRONIC CONTROL MODULES 8E - 29 POWERTRAIN CONTROL MODULE (Continued) (4) Remove the 3 fasteners from PCM mounting the PCM. If this step is not done a diagnostic trouble (Fig. 8). code (DTC) may be set and SKIM must be done or car will not start if it is a SKIM equipped car.
Page 267 8E - 30 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) OPERATION helps to reduce the possibility of unauthorized SKIS disarming. The rolling code algorithm ensures secu- The SKIM transmits and receives RF signals rity by preventing an override of the SKIS through through a tuned antenna enclosed within a molded the unauthorized substitution of the SKIM or the plastic ring formation that is integral to the SKIM...
Page 268 ELECTRONIC CONTROL MODULES 8E - 31 SENTRY KEY IMMOBILIZER MODULE (Continued) REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO ELECTRICAL, RESTRAINTS, WARNINGS, BEFORE ATTEMPTING COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCI- DENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 270 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 271 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) • Battery Tray - The battery tray provides a as a complete system. In order for the engine to start secure mounting location in the vehicle for the bat- and the battery to maintain its charge properly, all of tery and an anchor point for the battery holddown the components that are used in these systems must hardware.
Page 272 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 273 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 274 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) CLEANING (4) If equipped, clean the battery heater blanket with a sodium bicarbonate (baking soda) and warm The following information details the recommended water cleaning solution using a stiff bristle parts cleaning procedures for the battery and related com- cleaning brush to remove any acid film.
Page 275 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) • Cold Cranking Amperage - The Cold Crank- discharge rate of 25 amperes. RC is determined with ing Amperage (CCA) rating specifies how much cur- the battery fully-charged at 26.7° C (80° F). This rat- rent (in amperes) the battery can deliver for thirty ing estimates how long the battery might last after a seconds at -18°...
Page 276 BATTERY SYSTEM 8F - 7 BATTERY (Continued) charged plate groups made of lead oxide, and nega- DIAGNOSIS AND TESTING - BATTERY tively charged plate groups made of sponge lead. The The battery must be completely charged and the dissimilar metal plates are submerged in a sulfuric terminals should be properly cleaned and inspected acid and water solution called an electrolyte.
Page 277 8F - 8 BATTERY SYSTEM BATTERY (Continued) accessible, you may test using both the positive and STANDARD PROCEDURE negative jumper posts. Select TESTING AT JUMPER POST when connecting to that location. STANDARD PROCEDURE - USING MICRO 420 (3) Connect the tester (Fig. 3) to the battery or ELECTRICAL TESTER jumper posts, the red clamp to positive (+) and the black clamp to negative (–).
Page 278 BATTERY SYSTEM 8F - 9 BATTERY (Continued) STANDARD PROCEDURE - BATTERY vents indicates a battery overcharging condition. Immediately reduce the charging rate or turn off the CHARGING charger to evaluate the battery condition. Damage Battery charging is the means by which the bat- to the battery may result from overcharging.
Page 279 8F - 10 BATTERY SYSTEM BATTERY (Continued) tery chargers are equipped with polarity-sensing cir- BATTERY CHARGING TIME TABLE cuitry. This circuitry protects the battery charger and Charging the battery from being damaged if they are improp- 5 Amps 20 Amps Amperage Amps erly connected.
Page 280 BATTERY SYSTEM 8F - 11 BATTERY (Continued) an open-circuit voltage reading of 12.4 volts or A vehicle that has not been operated for approxi- greater, it may be load tested to reveal its cranking mately twenty days, may discharge the battery to an capacity (Refer to 8 - ELECTRICAL/BATTERY SYS- inadequate level.
Page 281 8F - 12 BATTERY SYSTEM BATTERY (Continued) (4) Set an electronic digital multi-meter to its peres (0.035 ampere). If the current draw exceeds highest amperage scale. Connect the multi-meter thirty-five milliamperes, isolate each circuit using the between the disconnected battery negative cable ter- fuse and circuit breaker remove-and-replace process minal clamp and the battery negative terminal post.
Page 282: Battery Cables
BATTERY SYSTEM 8F - 13 BATTERY HOLDDOWN BATTERY CABLES DESCRIPTION DESCRIPTION The battery holddown includes two bolts and a The battery cables are large gauge, stranded cop- holddown bracket. The battery holddown bracket con- per wires sheathed within a heavy plastic or syn- sists of a formed steel bracket with holes on each thetic rubber insulating jacket.
Page 283 8F - 14 BATTERY SYSTEM BATTERY CABLES (Continued) The battery positive cable terminal clamp is die the Neutral position and block the clutch pedal in the cast onto the ends of two wires. One wire has an eye- fully depressed position. •...
Page 284 BATTERY SYSTEM 8F - 15 BATTERY CABLES (Continued) Fig. 9 TEST GROUND CIRCUIT RESISTANCE - Fig. 7 TEST BATTERY POSITIVE CONNECTION TYPICAL RESISTANCE - TYPICAL 1 - VOLTMETER 1 - VOLTMETER 2 - BATTERY 2 - BATTERY 3 - ENGINE GROUND REMOVAL (1) Turn the ignition switch to the Off position.
Page 285: Battery Tray
8F - 16 BATTERY SYSTEM OPERATION BATTERY TRAY The temperature of the battery can affect battery DESCRIPTION performance. Only DAIMLERCHRYSLER approved battery blanket/block heater combination should be The battery is placed in a steel tray located in the used. The battery blanket heater is designed to pro- right front corner of the vehicle.
Page 286 CHARGING 8F - 17 CHARGING TABLE OF CONTENTS page page CHARGING OPERATION ......19 DESCRIPTION - CHARGING SYSTEM .
Page 287 8F - 18 CHARGING CHARGING (Continued) The ambient temperature sensor is used to control INSPECTION the battery voltage based upon ambient temperature The Powertrain Control Module (PCM) monitors (approximation of battery temperature). The PCM critical input and output circuits of the charging sys- maintains the optimal output of the generator by tem, making sure they are operational.
Page 288 CHARGING 8F - 19 CHARGING (Continued) SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage Denso 2.7L 105 Amp Denso 3.5L 125 Amps Test Specification: 1. Engine RPM : 2500 RPM ±20 RPM 2. Voltage Output : 14.0 V ± 0.5 V 3.
Page 289 8F - 20 CHARGING GENERATOR (Continued) REMOVAL REMOVAL - 2.7L (1) Disconnect negative battery cable. (2) Raise and support vehicle. (3) Remove lower plastic splash shield (Fig. 1). Fig. 2 GENERATOR 3.5L (12) Remove generator. INSTALLATION INSTALLATION - 2.7L Fig. 1 GENERATOR 2.7L (1) Install generator.
Page 290: Voltage Regulator
CHARGING 8F - 21 GENERATOR (Continued) (9) Install the upper radiator support and tighten the generators second rotor field terminal and its bolts. ground. (10) Connect the negative battery cable. Tighten Voltage is regulated by cycling the ground path to all fasteners to the proper torque.
Page 291 8F - 22 STARTING STARTING TABLE OF CONTENTS page page STARTING DESCRIPTION - 3.5L ....28 DESCRIPTION ......22 OPERATION OPERATION .
Page 292 STARTING 8F - 23 STARTING (Continued) • Transmission Range Sensor - Visually inspect the transmission range sensor for indications of phys- ical damage and loose or corroded wire harness con- nections. • Starter Relay - Visually inspect the starter relay for indications of physical damage and loose or corroded wire harness connections.
Page 293 8F - 24 STARTING STARTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS 1. BATTERY 1. REFER TO THE BATTERY SECTION FOR MORE TO ENGAGE. DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY, IF FAULTY. REQUIRED. 2. STARTING CIRCUIT 2.
Page 294 STARTING 8F - 25 STARTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION STARTER 1. BROKEN TEETH ON 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE ENGAGES, STARTER RING GEAR. IF NECESSARY. SPINS OUT BEFORE ENGINE STARTS. 2. STARTER ASSEMBLY 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND FAULTY.
Page 295 8F - 26 STARTING STARTING (Continued) Remove the starter relay from the PDC as described in this group to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2.
Page 296 STARTING 8F - 27 STARTING (Continued) to the transmission range sensor and repair. It is ignition switch in the START position. Observe the grounded by the PCM if the conditions are right to voltmeter. If voltage is detected, correct poor con- start the car.
Page 297: Starter Motor
8F - 28 STARTING STARTING (Continued) SPECIFICATIONS - TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Starter Mounting Bolts – Starter Solenoid Battery Nut – STARTER MOTOR DESCRIPTION DESCRIPTION - 2.7L The Melco is a permanent magnet starter motor. DESCRIPTION - 3.5L The Nippondenso is a reduction gear-field coil starter motor.
Page 298: Starter Motor Relay
STARTING 8F - 29 STARTER MOTOR (Continued) no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (elec- tromagnet) should be 75 ±5 ohms. If OK, go to Step 3.
Page 299: Starter Solenoid
8F - 30 STARTING STARTER MOTOR RELAY (Continued) Check for battery voltage at the cavity for relay ter- DIAGNOSIS AND TESTING - STARTER minal 86 with the ignition switch in the Start posi- SOLENOID tion, and no voltage when the ignition switch is released to the On position.
Page 300 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEAT SYSTEM .
Page 301 8G - 2 HEATED GLASS HEATED GLASS (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - WINDOW DEFOGGER Electrically Heated Rear Window Defogger opera- tion can be easily checked in three steps: (1) Use ATC or MTC self diagnostics, or the DRB III scan tool to check fault codes and control button operation.
Page 302 HEATED GLASS 8G - 3 HEATED GLASS (Continued) window defogger grid is shorting to the vehicle ground and must be replaced. If the ohmmeter indi- cates more than 100 ohms of resistance with the grid voltage feed wire disconnected, then go to Step 6. (6) There is a problem with the circuits that con- nect to the rear window defogger relay.
Page 303: Rear Window Defogger Relay
8G - 4 HEATED GLASS REAR WINDOW DEFOGGER GRID (Continued) epoxy to the area where the terminal was fastened and to the adjacent line. (7) Apply a thin layer of conductive epoxy on the terminal and place terminal on desired location. To prevent the terminal from moving while the epoxy is curing, it must be wedged or clamped.
Page 304 HEATED GLASS 8G - 5 REAR WINDOW DEFOGGER RELAY (Continued) The rear window defogger relay cannot be repaired nected in parallel with the electromagnetic coil in the or adjusted and, if faulty or damaged, it must be relay, and helps to dissipate voltage spikes that are replaced.
Page 305: Rear Window Defogger Switch
8G - 6 HEATED GLASS REAR WINDOW DEFOGGER RELAY (Continued) REMOVAL must be replaced. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CON- (1) Disconnect the battery negative remote cable TROL - REMOVAL) from the remote ground post (Fig. 6). OPERATION On Manual Temperature Control systems when the rear...
Page 306 HEATED MIRRORS 8G - 7 HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS DIAGNOSIS AND TESTING - HEATED DESCRIPTION ......7 MIRRORS .
Page 307: Table Of Contents
8G - 8 HEATED SEAT SYSTEM HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM REMOVAL ......12 DESCRIPTION .
Page 308: Heated Seat System Description
HEATED SEAT SYSTEM 8G - 9 HEATED SEAT SYSTEM (Continued) The heated seat switches are hard wired to the all of the electronic modules are sending and receiv- Body Control Module (BCM). The BCM monitors the ing the proper messages on the PCI data bus, and heated seat switch inputs, then sends heated seat that the Heated Seat Module (HSM) or Memory switch status messages to the HSM or MHSM over...
Page 309: Operation
8G - 10 HEATED SEAT SYSTEM DRIVER HEATED SEAT SWITCH (Continued) switch inputs and sends heated seat switch status messages to the Heated Seat Module (HSM) or the Memory Heated Seat Module (MHSM) over the Pro- grammable Communications Interface (PCI) data bus.
Page 310: Removal
HEATED SEAT SYSTEM 8G - 11 DRIVER HEATED SEAT SWITCH (Continued) HEATED SEAT SWITCH CONTINUITY (3) Working from the underside of the switch, gen- tly rock the switch back and forth out of its mounting location. CONTINUITY SWITCH READING BETWEEN POSITION INSTALLATION PIN 4 AND 6...
Page 311: Operation
8G - 12 HEATED SEAT SYSTEM PASSENGER HEATED SEAT SWITCH (Continued) The heated seat switches are located on the out- board cushion side shield of the driver and passenger seats (Fig. 6) (Fig. 7). The two, three-position rocker type switches provide a resistor multiplexed signal to the Body Control Module (BCM) through separate hard wired circuits.
Page 312: Installation
HEATED SEAT SYSTEM 8G - 13 PASSENGER HEATED SEAT SWITCH (Continued) The seat heating elements are sewn into the seat cushion cover trim and seat back cover trim units. The heated seat elements and the temperature sen- sor cannot be adjusted or repaired and, if faulty or damaged, the seat element assembly must be replaced.
Page 313: Removal
8G - 14 HEATED SEAT SYSTEM HEATED SEAT ELEMENT (Continued) SEAT BACK (1) Unplug the 2–way heated seat back wire har- ness connector. (2) Check the continuity between the heated seat driver circuit cavity and the ground cavity of the seat back cover half of the heated seat cushion wire har- ness connector.
Page 314: Diagnosis And Testing - Heated Seat Sensor
HEATED SEAT SYSTEM 8G - 15 HEATED SEAT SENSOR (Continued) DIAGNOSIS AND TESTING - HEATED SEAT (2) Using an ohmmeter, measure the resistance through the heated seat sensor. The sensor resistance SENSOR should be between 2 and 200 kiloohms. If OK, test For complete circuit diagrams, refer to the WIR- the memory heated seat mirror module.
Page 316 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM HORN RELAY DESCRIPTION ......1 DIAGNOSIS AND TESTING - HORN RELAY .
Page 317 8H - 2 HORN HORN SYSTEM (Continued) Check fuse 18 in the Junction Block and fuse L in the Power Distribution Center. Refer to Horn System Test table. HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION HORN SOUNDS 1. FAULTY HORN RELAY. 1.
Page 318 HORN 8H - 3 HORN SYSTEM (Continued) CONDITION POSSIBLE CAUSE CORRECTION FUSE BLOWS WHEN HORN IS 1. SHORT CIRCUIT IN HORN OR 1. REMOVE HORN RELAY, CHECK BLOWN HORN WIRING FOR SHORTED HORN OR HORN WIRING. DISCONNECT HORN WIRE HARNESS TO ISOLATE SHORT AND REPAIR AS NECESSARY.
Page 319 8H - 4 HORN (c) If incorrect voltage, repair as necessary. Refer HORN RELAY to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire DIAGNOSIS AND TESTING - HORN RELAY and connector repair procedures, details of wire (1) Remove horn relay.
Page 320: Horn Switch
HORN 8H - 5 (2) Depress horn switch, continuity should be HORN SWITCH present. Repeat for other switch. If no continuity, replace switches. DIAGNOSIS AND TESTING - HORN SWITCH REMOVAL WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, WARNING: DISABLE AIRBAG SYSTEM...
Page 322: Description - Ignition System
IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL IGNITION COIL DESCRIPTION - IGNITION SYSTEM ..1 DESCRIPTION ......4 OPERATION - IGNITION SYSTEM .
Page 323: Spark Plugs
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. 3.5L Crankshaft Position Sensor Screw 2.7L Ignition Coil 3.5L Ignition Coil Knock Sensor 2.7L Map Sensor 3.5L Map Sensor 17.7 2.7L Spark Plugs 17.6 3.5L Spark Plugs SPARK PLUGS Engine Spark Plug...
Page 324: Camshaft Position Sensor Description
IGNITION CONTROL 8I - 3 OPERATION CAMSHAFT POSITION The camshaft position sensor contains a hall effect SENSOR device that provide cylinder identification to the Pow- ertrain Control Module (PCM) (Fig. 4) or (Fig. 5). DESCRIPTION The sensor generates pulses as groups of notches on The camshaft position sensor is mounted in the the camshaft sprocket pass underneath it.
Page 325: Installation Installation - 2.7L
8I - 4 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) Fig. 6 Paper Spacer 3.5L 1 - CAMSHAFT POSITION SENSOR 2 - PAPER SPACER (4) Connect the negative battery cable. Fig. 5 Camshaft Position Sensor 3.5L IGNITION COIL (2) Loosen the upper intake plenum, refer to the Intake System section.
Page 326: Removal
IGNITION CONTROL 8I - 5 IGNITION COIL (Continued) (2) Remove electrical connector from ignition coil. On 3.5L engines, it is necessary to loosen the screws by alternating back and forth. Do not lose the spacers under the coil when loosening the screws. (3) Remove 2 fasteners from ignition coil assembly.
Page 327: Removal
8I - 6 IGNITION CONTROL IGNITION COIL CAPACITOR (Continued) REMOVAL sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a (1) Remove the negative battery cable. selective cylinder retard. (2) Disconnect the electrical connector (Fig. 11). The PCM ignores knock sensor input during engine (3) Remove nut and capacitor.
Page 328: Installation
IGNITION CONTROL 8I - 7 KNOCK SENSOR (Continued) driving conditions per schedule B in this manual. A thin platinum pad is welded to both or center elec- trode end(s) as show in (Fig. 14). Extreme care must be used to prevent spark plug cross threading, mis- gaping (Fig.
Page 329: Removal
8I - 8 IGNITION CONTROL SPARK PLUG (Continued) REMOVAL INSTALLATION Always remove the ignition coil assembly by grasp- Always remove the ignition coil assembly by grasp- ing at the spark plug boot, turning the assembly 1/2 ing at the spark plug boot, turning the assembly 1/2 turn and pulling straight back in a steady motion.
Page 330 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER INSTALLATION ......4 DESCRIPTION .
Page 331 8J - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) OPERATION attaching screws (four on Intrepid, Limited, and 300M, and five on Concorde). The gauges are the magnetic air-core type. When (8) Using a trim stick (special tool #C-4755), gently the ignition switch is OFF, the gauge pointers should pry out on the instrument panel cluster bezel, discon- rest at or below the low graduation.
Page 332 INSTRUMENT CLUSTER 8J - 3 NOTE: Tilt steering wheel down to gain access for ANTI-LOCK BRAKE SYSTEM instrument cluster removal. INDICATOR (10) Remove the instrument cluster from panel. DESCRIPTION The instrument panel wiring harness connectors are self-aligning, mounted directly to the rear panel. A The amber Anti-Lock Brake System (ABS) warning force of approximately 9 kilograms (30 lbs.) will be indicator lamp is located on the instrument panel in...
Page 333 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER MASK/LENS (Continued) (13) Separate mask/lens from instrument cluster (4) Unplug connectors from printed circuit board. and remove. (5) Remove cluster mask/lens from instrument cluster. Refer to Mask/Lens Removal and Installa- INSTALLATION tion. (6) Remove two screws to Vacuum Fluorescent (1) Align mask/lens with instrument cluster and (VF) display Odometer and remove from cluster.
Page 334 INSTRUMENT CLUSTER 8J - 5 TRANSMISSION RANGE CONDITION POSSIBLE CAUSE INDICATOR (PRNDL) ALL DISPLAY LIGHTS Normal transient condition between P&R and R&N gear positions DESCRIPTION The shift position indicator is located in the instru- Check shift lever linkage ment cluster. It indicates the position of the manual BCM malfunction valve lever by illuminating an LED located under the Check wiring and...
Page 336 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....36 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 337: Lamps/Lighting - Exterior
8L - 2 LAMPS/LIGHTING - EXTERIOR HEADLAMP SWITCH PARK/TURN SIGNAL LAMP DIAGNOSIS AND TESTING - HEADLAMP REMOVAL ......31 SWITCH .
Page 338: Brake Lamp Switch
LAMPS/LIGHTING - EXTERIOR 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) BULB APPLICATION TABLE LAMP BULB Rear Fog P27/7W LAMP MODEL BULB Rear Tail/Stop P27/7W Back up Concorde/ Rear Turn Signal P27/7W Limited Side Repeater Intrepid/300M 3157K Underhood CHMSL Concorde/ Underhood Retractable Limited/300M Intrepid BRAKE LAMP SWITCH...
Page 339: Diagnosis And Testing - Brake Lamp Switch
8L - 4 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) open while the electrical contacts for other two inter- nal switches are closed. When the brake pedal is pressed, the plunger on the outside of the brake lamp switch extends out- ward.
Page 340: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 5 BRAKE LAMP SWITCH (Continued) INSTALLATION CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If to much force is used, damage to the NOTE: Prior to installing the brake lamp switch into brake lamp switch or striker can result.
Page 341: Installation
8L - 6 LAMPS/LIGHTING - EXTERIOR CENTER HIGH MOUNTED STOP LAMP (Continued) INSTALLATION CONCORDE (1) Install the bulb into the socket. (2) Install socket into CHMSL housing. (3) Connect the battery negative cable and close the hood. (4) Verify CHMSL operation. INTREPID (1) Install bulb into socket.
Page 342: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 7 CENTER HIGH MOUNTED STOP LAMP UNIT (Continued) COMBINATION FLASHER DESCRIPTION The Combination Flasher, also refered to as the combo-flasher, is mounted to the in-line bracket which is located to the right of the Junction Block. The flasher can be removed by pulling in a rearward direction.
Page 343: Installation
8L - 8 LAMPS/LIGHTING - EXTERIOR COMBINATION FLASHER (Continued) (2) Remove the left instrument panel silencer. DECKLID/TRUNK LAMP Refer to Body, Instrument Panel Silencer, Removal. (3) The flasher can be removed by pulling in a REMOVAL rearward direction. (1) Open hood, disconnect and isolate the battery negative cable.
Page 344: Lamps/Lighting - Exterior
LAMPS/LIGHTING - EXTERIOR 8L - 9 FOG LAMP (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts. IGNITION TURNED OFF. 2.
Page 345 8L - 10 LAMPS/LIGHTING - EXTERIOR FOG LAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS DO NOT 1. Blown fuse for fog lamps. 1. Replace fuse, refer to Wiring Diagrams. ILLUMINATE 2. No Z1-ground at fog lamps. 2. Repair circuit ground, refer to Wiring Diagrams.
Page 346: Fog Lamp Unit
LAMPS/LIGHTING - EXTERIOR 8L - 11 FOG LAMP (Continued) FOG LAMP UNIT STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT Prepare an alignment screen (Fig. 14). Refer to Electrical, Lamps/Lighting - Exterior, Headlamp, Adjustments for Alignment Screen Preparation. A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp center line and straight ahead.
Page 347: Front Position Lamp - Export Description
8L - 12 LAMPS/LIGHTING - EXTERIOR FOG LAMP UNIT (Continued) Fig. 17 FOG LAMP UNIT ADJUSTER SCREW - 300M 1 - UP/DOWN ADJUSTER SCREW 2 - FOG LAMP UNIT Fig. 15 FOG LAMP UNIT ADJUSTER SCREW - INTREPID 1 - FOG LAMP UNIT 2 - UP/DOWN ADJUSTER SCREW Fig.
Page 348: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 13 FRONT POSITION LAMP - EXPORT (Continued) OPERATION The front position lamps are turned on or off with the headlamp switch. These lamps function in the same way that the parking lamps do on other market built vehicles.
Page 349: Installation
8L - 14 LAMPS/LIGHTING - EXTERIOR FRONT POSITION LAMP - EXPORT (Continued) AUTO HEADLAMP SYSTEM The Automatic Headlamp system turns the instru- mentation and exterior illumination lamps ON when the ambient light levels are low and OFF when light levels are high. HEADLAMPS ON WITH WIPERS For vehicles equipped with the Automatic Head- lamp System, the instrumentation and exterior illu-...
Page 350: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP (Continued) OPERATION Ambient light levels are monitored by the BCM using the automatic temperature control system Sun Sen- sor, located on the top of the instrument panel cover. HEADLAMP SYSTEM Ambient light readings are averaged to limit cycling The headlamp system will default to the head- the lamps ON and OFF when passing through areas lamps ON position when the ignition switch is ON,...
Page 351 8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer WITH ENGINE RUNNING to Electrical, Battery. ABOVE IDLE 2. Poor lighting circuit Z1 ground. 2.
Page 352: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION INSTRUMENT PANEL 1. No voltage to dimmer switch. 1. Check fuse. If good repair open LAMPS DO NOT DIM OR headlamp circuit, refer to Wiring ILLUMINATE Diagrams. 2. No Z1-ground at headlamps. 2.
Page 353: Installation
8L - 18 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) INSTALLATION HEADLAMP LEVELING MOTOR - EXPORT CONCORDE/300M DESCRIPTION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced HEADLAMP LEVELING SYSTEM bulb life will result. The Remote Headlamp Leveling System allows the (1) Install the headlamp wiring connector.
Page 354: Diagnosis And Testing Diagnosis And Testing - Headlamp Leveling Motor - Export
LAMPS/LIGHTING - EXTERIOR 8L - 19 HEADLAMP LEVELING MOTOR - EXPORT (Continued) HEADLAMP LEVELING MOTOR headlamp leveling motors. This signal voltage (typi- cally 2 – 9 volts) tells the headlamp leveling motors The headlamp leveling motors move the headlamp where to position the headlamps. The headlamp lev- and beam pattern according to the signal received eling motors are attached to the headlamps with a from the headlamp leveling switch.
Page 355: Installation
8L - 20 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING MOTOR - EXPORT (Continued) (5) Using an appropriate prying tool, place the edge of tool between leveling motor gasket and head- lamp assembly. Pry the leveling motor up and out. NOTE: Significant force will be required to unsnap the leveling motor pushrod from the headlamp reflector mechanism.
Page 356: Switch
LAMPS/LIGHTING - EXTERIOR 8L - 21 HEADLAMP LEVELING SWITCH - EXPORT (Continued) HEADLAMP LEVELING SWITCH CONTINUITY POSITION TERMINALS RESISTANCE RHEOSTAT 6 & 3 - 1870 RESISTANCE (THUMBWHEEL) (POT) SWITCH POSITION BETWEEN PINS 1&2 DIM POSITION 0.752 RHEOSTAT 6 & 3 2280 - 2520 0.564...
Page 357: Headlamp Unit
8L - 22 LAMPS/LIGHTING - EXTERIOR ALIGNMENT SCREEN PREPARATION HEADLAMP UNIT (1) Position vehicle on a level surface perpendicu- lar to a flat wall 7.62 meters (25 ft.) away from front STANDARD PROCEDURE of headlamp lens. (2) If necessary, tape a line on the floor 7.62 STANDARD PROCEDURE - HEADLAMP UNIT meters (25 ft.) away from and parallel to the wall.
Page 358 LAMPS/LIGHTING - EXTERIOR 8L - 23 HEADLAMP UNIT (Continued) Fig. 27 HEADLAMP UNIT ALIGNMENT SCREEN 1 - LOW BEAM CENTER LINE TO GROUND 4 - PREFERRED CUT OFF LOCATION ± 2 INS. 2 - FRONT OF HEADLAMP 5 - CENTER OF VEHICLE 3 - 7.26 METERS (25 ft.) 6 - CENTER OF HEADLAMP Fig.
Page 359: Standard Procedure - Headlamp Unit Alignment - Export
8L - 24 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) STANDARD PROCEDURE - HEADLAMP UNIT mm (4 in.) below the headlamp centerline (Fig. 30). The intersection of the horizontal and 15 degree cut- ALIGNMENT - EXPORT off lines in the projected pattern should align to the intersection of the headlamp centerline vertical tape VEHICLE PREPARATION FOR HEADLAMP UNIT line and the tape line 100 mm (4 in.) below the head-...
Page 360 LAMPS/LIGHTING - EXTERIOR 8L - 25 HEADLAMP UNIT (Continued) Fig. 30 HEADLAMP ALIGNMENT SCREEN - EXPORT 1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.) 2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE 3 - 15° CUT-OFF LINE 7 - 100 MM 4 - FRONT OF HEADLAMP Fig.
Page 361: Installation
8L - 26 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) INSTALLATION CONCORDE/300M CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. NOTE: If replacing complete headlamp unit, transfer halogen bulb to new unit. (1) Put headlamp under crossmember to install it into the vehicle.
Page 362: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 27 LICENSE PLATE LAMP UNIT (Continued) INSTALLATION INSTALLATION (1) Place license plate lamp in position on vehicle. (1) Place lamp in position on fascia. (2) Install screws to attach license plate lamp to (2) Install lamp fasteners. fascia.
Page 363: Operation
8L - 28 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) OPERATION HAZARD WARNING SYSTEM Push and release the button to turn the hazard MULTI-FUNCTION SWITCH function ON or OFF. The button will move out from the steering column in the ON position and will When the driver wishes to signal his intentions to remain in toward the column in the OFF position.
Page 364 LAMPS/LIGHTING - EXTERIOR 8L - 29 MULTI-FUNCTION SWITCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION HAZARD WARNING 1. FAULTY FUSE. 1. REPLACE FUSE. MALFUNCTION/SYSTEM 2. FAULTY FLASHER UNIT. 2. REPLACE FLASHER UNIT. DOES NOT FLASH. 3. OPEN CIRCUIT IN FEED 3. REPLACE WIRING HARNESS. CHECK WIRE TO SWITCH.
Page 365: Removal
8L - 30 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) TURN SIGNAL AND HAZARD SWITCH Fig. 37 TURN SIGNAL AND HAZARD SWITCH CONNECTOR PIN CALL OUT CONTINUITY SWITCH POSITION CONTINUITY TURN HAZARD SIGNAL WARNING NEUTRAL 1 AND 2 LEFT 7 AND 6 RIGHT 7 AND 8 NEUTRAL...
Page 366: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 31 MULTI-FUNCTION SWITCH (Continued) (3) Install both upper and lower steering column shrouds. Refer to Body, Instrument Panel, Steering Column Shrouds, Installation. (4) Install the tilt lever. (5) Connect the negative battery cable remote ter- minal to the remote battery post.
Page 367: Installation
8L - 32 LAMPS/LIGHTING - EXTERIOR (1) Remove the rear fog lamp bulb and check for REAR FOG LAMP - EXPORT burned out condition, replace bulb if necessary. (2) If bulb appears OK, reinstall the bulb in its DESCRIPTION socket and turn fog lamps ON and check for proper operation.
Page 368: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 33 REAR FOG LAMP SWITCH - EXPORT (Continued) OPERATION One Side Repeater Lamp can be found on each side of the vehicle just behind the front wheel (Fig. 44). With the rotation of the rear fog lamp switch, volt- The side repeater lamp utilizes an amber colored age is sent through the rear fog lamp switch.
Page 369: Installation
8L - 34 LAMPS/LIGHTING - EXTERIOR SIDE REPEATER LAMP - EXPORT (Continued) INSTALLATION (1) Install the side repeater lamp bulb in the socket. (2) Verify lamp operation. (3) Install the side repeater lamp socket into the lamp unit. (4) Install the side repeater lamp in the front fender.
Page 370: Tail Lamp Unit Removal
LAMPS/LIGHTING - EXTERIOR 8L - 35 INSTALLATION TAIL LAMP UNIT (1) Connect tail lamp unit wire connector to body REMOVAL wire harness. (2) Place tail lamp unit in position on vehicle. (1) Release decklid latch and open decklid. (3) Install nuts to attach tail lamp unit to lower (2) Remove fasteners attaching trunk lining to trunk and quarter panel.
Page 371 8L - 36 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR GLOVE BOX LAMP SWITCH SPECIFICATIONS REMOVAL ......38 INTERIOR LAMPS .
Page 372 LAMPS/LIGHTING - INTERIOR 8L - 37 LAMPS/LIGHTING - INTERIOR (Continued) INTERIOR LAMPS INDICATOR COLOR BULB #/LED Service procedures for most of the lamps in the fol- TURN SIGNALS GREEN lowing list can be found in Body. Some components CRUISE GREEN have lamps that can only be serviced by an Autho- rized Service Center (ASC) after the component is TRAC ON...
Page 373: Courtesy Lamp
8L - 38 LAMPS/LIGHTING - INTERIOR COURTESY LAMP DESCRIPTION The Body Control Module (BCM) illuminates the courtesy lamps whenever a door is opened. When the last door is closed, the BCM “fades-to-OFF” the cour- tesy lamps in five seconds if not in illuminated entry mode.
Page 374 LAMPS/LIGHTING - INTERIOR 8L - 39 ILLUMINATED ENTRY (Continued) DIAGNOSIS AND TESTING - ILLUMINATED TRANSMISSION RANGE ENTRY INDICATOR ILLUMINATION When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that DESCRIPTION remote keyless entry system is operating properly The floor console mounted Transmission Range before testing illuminated entry circuits.
Page 376 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE OPERATION ......10 DESCRIPTION .
Page 377: Overhead Console
8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) Fig. 1 Overhead Console Without Universal Transmitter Fig. 4 Top of Overhead Console 1 - OVERHEAD CONSOLE HOUSING 2 - EVIC MODULE 3 - ILLUMINATION LAMPS 4 - SCREWS (4) (2) Remove the overhead console from the head- liner (Refer to 8 - ELECTRICAL/OVERHEAD CON- SOLE - REMOVAL).
Page 378: Standard Procedure - Compass Demagnetizing
MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) cedure. This feature automatically updates the must also have a field strength of over 350 gauss at 7 compass calibration while the vehicle is being driven. millimeters (0.25 inch) beyond the tip of the probe. This allows the compass unit to compensate for small To demagnetize the roof panel and the overhead changes in the residual magnetism that the vehicle...
Page 379: Standard Procedure - Compass Variation Adjustment
8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) (7) Connect the degaussing tool to an electrical STANDARD PROCEDURE - ELECTRONIC outlet, while keeping the tool at least 61 centimeters VEHICLE INFORMATION CENTER (2 feet) away from the compass unit. PROGRAMMING (8) Slowly approach the center line of the roof panel at the windshield header, with the degaussing EVIC PROGRAMMING MODE...
Page 380 MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) Fig. 6 Variance Settings again include Yes and No. The default is No. When confirmation when the RKE receiver recognizes a Yes is selected, following each Auto Door Lock event valid Lock signal from an RKE transmitter. When No all doors will automatically unlock when the driver is selected, no horn chirp will occur with the RKE door is opened, if the vehicle is stopped and the...
Page 381: Removal - Overhead Console
8M - 6 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) • TRAIN REMOTE - When this feature is when the windshield wipers are turned on. The head- lamps will turn off when the wipers are turned off, selected the driver can choose to train up to four as long as the headlamp switch is in the Auto or Off remote keyless entry transmitters.
Page 382: Compass/Mini-Trip Computer Description
MESSAGE SYSTEMS 8M - 7 OVERHEAD CONSOLE (Continued) (4) Install the overhead console retaining screw, 3. US/M (ENGLISH/METRIC MEASUREMENT) located in the front of console near the windshield. BUTTON Torque the screw to 1.2 N·m (10 in. lbs.). Pressing the US/M button switches the display (5) Connect the remote negative battery cable.
Page 383: Removal
8M - 8 MESSAGE SYSTEMS COMPASS/MINI-TRIP COMPUTER (Continued) the PCI bus line. If Compass Mini-Trip Computer (4) If Compass Mini-Trip Computer displays PASS, displays a dash (-) instead of an instantaneous fuel the module is OK. economy value, it is not receiving a PCI bus message (5) If Compass Mini-Trip Computer displays FAIL, for the instantaneous fuel economy from the BCM.
Page 384: Electronic Vehicle Info Center
MESSAGE SYSTEMS 8M - 9 If the vehicle is equipped with the optional Univer- ELECTRONIC VEHICLE INFO sal Transmitter, the EVIC will also display messages CENTER and an icon indicating when the Universal Transmit- ter is being trained, which of the three transmitter DESCRIPTION - ELECTRONIC VEHICLE buttons is transmitting, and when the transceiver is INFORMATION CENTER (EVIC)
Page 385: Operation
8M - 10 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) The compass unit also will compensate for magne- position, momentarily depressing and releasing the tism the body of the vehicle may acquire during nor- C/T (compass/temperature) push button switch will mal use.
Page 386: Standard Procedure - Tire Pressure System Test
MESSAGE SYSTEMS 8M - 11 ELECTRONIC VEHICLE INFO CENTER (Continued) (2) Check for battery voltage at the fused B(+) fuse (4) Following completion of these tests, the EVIC in the junction block. If OK, go to Step 3. If not OK, module will display one of the following messages: repair the open fused B(+) circuit to the fused B(+) a.
Page 387: Removal
8M - 12 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) (3) Upon entering the test mode, the EVIC will (4) Remove the EVIC module from the overhead clear the sensor counter and each time a sensor sig- console housing. nal for a road tire is received, the EVIC will update NOTE: IF THE EVIC MODULE IS BEING REPLACED, the counter value (vehicle must be driven at 25 mph THE TIRE PRESSURE MONITORING SYSTEM MUST...
Page 388: Universal Transmitter Description
MESSAGE SYSTEMS 8M - 13 transmitter, see the owner’s manual in the vehicle UNIVERSAL TRANSMITTER glove box. DESCRIPTION DIAGNOSIS AND TESTING - UNIVERSAL On some LH models a Universal Transmitter is TRANSMITTER standard factory-installed equipment. The universal If the Universal Transmitter is inoperative, but the transmitter transceiver is integral to the Electronic Electronic Vehicle Information Center (EVIC) is oper- Vehicle Information Center (EVIC), which is located...
Page 389: Ambient Temp Sensor Description
8M - 14 MESSAGE SYSTEMS AMBIENT TEMP SENSOR DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - AMBIENT DESCRIPTION TEMPERATURE SENSOR Ambient air temperature is monitored by the Elec- tronic Vehicle Information Center (EVIC) through (1) Turn the ignition switch to the Off position. ambient temperature messages received from the Disconnect and isolate the battery negative cable.
Page 390: Removal
MESSAGE SYSTEMS 8M - 15 AMBIENT TEMP SENSOR (Continued) REMOVAL (3) From behind front bumper fascia, remove the screw attaching the ambient temperature sensor to (1) Open hood, disconnect and isolate the negative radiator closure panel (Fig. 10). battery cable remote terminal from the remote bat- tery post (Fig.
Page 392 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEATS .
Page 393: Power Locks
8N - 2 POWER LOCKS POWER LOCKS (Continued) CENTRAL LOCKING OPERATION The Central Locking System is part of the Vehicle POWER DOOR LOCKS Theft Security System (VTSS). The Body Control Module (BCM) actuates the CHILD PROTECTION LOCK power door lock relays when a door lock switch is The child protection locks are on the rear doors activated.
Page 394: Diagnosis And Testing - Power Locks
POWER LOCKS 8N - 3 POWER LOCKS (Continued) DOOR LOCK INHIBIT A blown fuse is the probable cause. The remote keyless entry fuse 13 is located in the Junction With the key in the ignition switch and the driver’s Block. If neither terminal measures battery voltage, door open, the Body Control Module (BCM) will check for an open or shorted circuit to the Junction ignore the command to lock the power door locks.
Page 395: Deck Lid Release Solenoid
8N - 4 POWER LOCKS POWER LOCKS (Continued) REMOVAL (1) Disconnect and isolate the negative battery cable remote terminal from the remote battery post. (2) Raise deck lid to the full up position. (3) Remove latch cover attaching screws then remove cover.
Page 396: Power Locks
POWER LOCKS 8N - 5 DOOR CYLINDER LOCK SWITCH (Continued) Fig. 4 DOOR CYLINDER LOCK SWITCH 1 - DOOR CYLINDER LOCK SWITCH 2 - LOCK CYLINDER 3 - DOOR HANDLE 4 - PIGTAIL CONNECTOR 5 - CLIP Fig. 5 DOOR LOCK MOTOR/LATCH 1 - PASSENGER SIDE CONNECTOR INSTALLATION 2 - + TO LOCK...
Page 397: Keyless Entry Transmitter
8N - 6 POWER LOCKS DOOR LOCK SWITCH (Continued) DOOR LOCK SWITCH CONTINUITY SPECIFICATIONS TRANSMITTER SWITCH CONTINUITY RESISTANCE POSITION BETWEEN VALUE BATTERY LOCK 1 AND 4 2700 ± 10% The transmitter has two 3 volt batteries, which can UNLOCK 1 AND 4 ±...
Page 398: Power Mirrors Description
POWER MIRRORS 8N - 7 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS POWER MIRROR SWITCH DESCRIPTION ......7 DESCRIPTION .
Page 399: Operation
8N - 8 POWER MIRRORS POWER MIRRORS (Continued) and retention, connector pin-out information and AUTOMATIC DAY / NIGHT location views for the various wire harness connec- MIRROR tors, splices and grounds. (1) Remove the power mirror switch. DESCRIPTION (2) Disconnect wire harness connector to power The automatic day/night mirror uses a thin layer mirror switch (Fig.
Page 400: Diagnosis And Testing - Power Mirrors
POWER MIRRORS 8N - 9 AUTOMATIC DAY / NIGHT MIRROR (Continued) Unplug the wire harness connector from the auto- POWER MIRROR SWITCH matic day/night mirror. Connect the battery negative cable. Turn the ignition switch to the On position. DESCRIPTION Check for battery voltage at the fused ignition switch The mirror switch on the door trim panel operates output (run/start) circuit cavity of the automatic day/ both the outside rear view mirrors.
Page 401: Removal
8N - 10 POWER MIRRORS POWER MIRROR SWITCH (Continued) MIRROR SWITCH TEST REMOVAL (1) Disconnect and isolate the battery negative cable. SWITCH POSITION CONTINUITY BETWEEN (2) Using a trim stick, remove power mirror switch MOVE BUTTON TERMINALS from mounting position. MIRROR IN L POSITION (3) Disconnect wire connector.
Page 402 POWER SEATS 8N - 11 POWER SEATS TABLE OF CONTENTS page page POWER SEATS DRIVER POWER SEAT SWITCH DESCRIPTION DESCRIPTION ......15 DESCRIPTION - POWER SEAT SYSTEM .
Page 403: Power Seats
8N - 12 POWER SEATS POWER SEATS (Continued) • Programmable Communications Interface (PCI) provides increased reliability, enhanced diagnostics, data bus network and allows the addition of many new feature capabil- Refer to Wiring Diagrams for complete circuit dia- ities. For diagnosis of these electronic modules or of grams.
Page 404: Diagnosis And Testing Diagnosis And Testing - Power Seats
POWER SEATS 8N - 13 POWER SEATS (Continued) DESCRIPTION - ELECTRONIC VEHICLE The most reliable, efficient, and accurate means to diagnose the driver side power seat with the memory INFORMATION CENTER system option requires the use of a DRB III scan The Electronic Vehicle Information Center (EVIC) tool and the proper Diagnostic Procedures manual.
Page 405: Standard Procedure - Memory System Programming
8N - 14 POWER SEATS POWER SEATS (Continued) The most reliable, efficient, and accurate means to MEMORY SET SWITCH diagnose the memory system requires the use of a DRB III scan tool and the proper Diagnostic Proce- DESCRIPTION dures manual. The DRB III scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic modules are sending and receiv-...
Page 406: Operation
POWER SEATS 8N - 15 MEMORY SET SWITCH (Continued) OPERATION RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. When the memory set switch is depressed, a resis- (2) Remove the drivers seat cushion side shield tance multiplexed signal is sent to the memory/ from the seat (Fig.
Page 407: Diagnosis And Testing - Driver Power Seat Switch
8N - 16 POWER SEATS DRIVER POWER SEAT SWITCH (Continued) tion until the switch is released, or until the travel CENTER PIN 5 & 3 limit of the adjuster is reached. When the switch is SWITCH PIN 1 & 10 moved in the opposite direction, the battery feed and FORWARD ground path to the motor are reversed through the...
Page 408: Installation
POWER SEATS 8N - 17 DRIVER POWER SEAT SWITCH (Continued) WARNING: SOME VEHICLES ARE EQUIPPED WITH power rear seat riser motor. Vehicles with the six- SEATBACK MOUNTED AIRBAGS. BEFORE way do not. The switch is secured to the back of the seat cush- ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT ion side shield with two screws.
Page 409: Removal
8N - 18 POWER SEATS PASSENGER POWER SEAT SWITCH (Continued) PASSENGER SEAT SWITCH CONTINUITY TEST TABLE SWITCH CONTINUITY BETWEEN POSITION PINS PASSENGER PIN 5 & 4 PIN 5 & 3 PIN 5 & 2 PIN 5 & 10 PIN 5 & 9 PIN 5 &...
Page 410: Installation
POWER SEATS 8N - 19 PASSENGER POWER SEAT SWITCH (Continued) INSTALLATION DIAGNOSIS AND TESTING - POWER SEAT (1) Position the switch and install the switch TRACK attaching screws. (1) Remove power seat switch from seat. Refer to (2) Install the knobs on the switch. the procedure in this section.
Page 411: Removal
8N - 20 POWER SEATS POWER SEAT TRACK (Continued) REMOVAL Fig. 10 Power Seat Wire Harness Pin Call-Out 1 - BLUE 2 - VIEWED FROM BODY HARNESS END WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE Fig.
Page 412 POWER WINDOWS 8N - 21 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS INSTALLATION ......22 DESCRIPTION .
Page 413 8N - 22 POWER WINDOWS POWER WINDOWS (Continued) POWER WINDOWS/WINDOW MOTOR - REMOV- AL). (5) If window moved completely up or down, the test leads should be reversed one more time to com- plete a full window travel inspection. (6) If window does not move, check to make sure that it is free.
Page 414 POWER WINDOWS 8N - 23 WINDOW SWITCH (Continued) Fig. 2 Master Window Switch PIN 8 to 10 PIN 8 to 11 PIN 8 to 7 PIN 8 to 6 PIN 8 to 3 PIN 8 to 4 PIN 8 to 9 Fig.
Page 415 8N - 24 POWER WINDOWS WINDOW SWITCH (Continued) INSTALLATION (3) Connect negative battery cable remote termi- nal. MASTER SWITCH PASSENGER SWITCH (1) Install switch and wire connector. INTREPID AND CONCORDE (2) Install door trim panel. (Refer to 23 - BODY/ (1) Install switch and wire connector.
Page 416 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS OPERATION ......11 DESCRIPTION - SIDE IMPACT AIRBAG OCCUPANT RESTRAINT CONTROLLER - 5 SYSTEM...
Page 417 8O - 2 RESTRAINTS RESTRAINTS (Continued) Fig. 1 SIDE AIRBAG LOCATION - TYPICAL...
Page 418: Operation - Side Impact Airbag System
THIS WILL DISABLE THE AIRBAG SYSTEM. FAIL- IF THE DRIVER/PASSENGER AIRBAG IS DEFEC- URE TO DISCONNECT THE BATTERY COULD TIVE AND DEPLOYED, REFER TO CHRYSLER COR- RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT PORATIONS CURRENT RETURN LIST FOR PROPER AND POSSIBLE PERSONAL INJURY.
Page 419: Standard Procedure
8O - 4 RESTRAINTS RESTRAINTS (Continued) of airbag deployment. Sodium hydroxide powder can irritate the skin, eyes, nose and throat. Wear safety glasses, rubber gloves, and long sleeved clothing when cleaning any of the powder residue from the vehicle. If you find that the cleanup is irritating your skin, run cool water over the affected area.
Page 420: Child Tether Cup Removal
RESTRAINTS 8O - 5 RESTRAINTS (Continued) SERVICE OF DEPLOYED AIRBAG INSTALLATION (1) Place the Child Tether Cup cover into position DRIVER AIRBAG on top of the rear shelf trim panel. After a Driver Airbag has been deployed due to a (2) Push downward on the Child Tether Cup Cover collision, the following must be replaced: until it locks into position (you will hear it click into...
Page 421: Removal
8O - 6 RESTRAINTS CLOCK SPRING (Continued) • The front wheels were moved with the steering (11) Remove two mounting screws and pull clock wheel off. spring assembly from steering shaft. The clock spring • The steering wheel was moved from the half cannot be repaired, and must be replaced if faulty.
Page 422: Driver Airbag Description
RESTRAINTS 8O - 7 the airbag nylon housing. A stamped metal retainer DRIVER AIRBAG is placed over the inflator mounting studs on the back of the airbag nylon housing. A stamped metal DESCRIPTION retainer is placed over the inflator mounting studs The trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch and tray unit upon airbag deployment.
Page 423: Driver Airbag Trim Cover Removal
8O - 8 RESTRAINTS Make sure that neither horn wire is trapped between DRIVER AIRBAG TRIM COVER the airbag housing and the trim cover locking blocks. (3) Engage the upper and lower trim cover locking REMOVAL blocks with the lip of the driver airbag housing. Then To replace the Driver Airbag Trim Cover, you must engage the locking blocks on each side of the trim first remove the driver airbag (Refer to 8 - ELECTRI-...
Page 424 RESTRAINTS 8O - 9 DRIVER AIRBAG TRIM COVER (Continued) Fig. 7 DRIVER AIRBAG TRIM COVER INSULATOR CONNECTOR - REMOVAL 1 - HORN SWITCH FEED WIRE 4 - NUTS 2 - HORN SWITCH GROUND WIRE 5 - WIRE RETAINER 3 - TRIM COVER RETAINER BRACKET Fig.
Page 425: Front Seat Belt & Retractor Removal
8O - 10 RESTRAINTS DRIVER AIRBAG TRIM COVER (Continued) Fig. 9 DRIVER AIRBAG TRIM COVER 1 - LOCKING BLOCKS 3 - HORN GROUND WIRE 2 - TRIM COVER RETAINER BRACKET 4 - LOCKING BLOCKS For airbags with a blade style horn switch feed wire: (6) Route the horn switch feed wire between the inflator housing and the upper airbag housing stud...
Page 426: Installation
RESTRAINTS 8O - 11 FRONT SEAT BELT & RETRACTOR (Continued) (3) Detach the turning loop cover from the upper (7) Install the upper anchor bolt. Tighten to 40 anchor bolt. N·m (30 ft. lbs.) torque. (4) Remove the upper anchor bolt (Fig. 11). (8) Close the turning loop covers.
Page 427: Installation
8O - 12 RESTRAINTS CAUTION: USE SUPPLIED SCREWS ONLY. OCCUPANT RESTRAINT CONTROLLER - 5 PASSENGER (2) Tighten the top screw on the drivers side. VEHICLES (3) Install the two side ORC mounting screws on the drivers side. (4) Connect ORC 23-way connector and slide the REMOVAL red Connector Position Assurance (CPA) tab in.
Page 428: Installation
RESTRAINTS 8O - 13 OCCUPANT RESTRAINT CONTROLLER - 6 PASSENGER VEHICLES (Continued) (6) Remove the instrument panel center bezel. The (10) Install the two screws to steering column temperature control module, power outlet and trac- cover. tion control switch will pop out with the center bezel. (11) Install the left end cover at the junction block.
Page 429: Operation
8O - 14 RESTRAINTS PASSENGER AIRBAG (Continued) Following a passenger airbag deployment, the pas- senger side airbag, instrument panel, and instrument panel wiring harness must be replaced. The passen- ger side airbag cannot be repaired, and must be replaced if deployed or in any way damaged. OPERATION The passenger inflator assembly is within the air- bag housing.
Page 430: Installation
RESTRAINTS 8O - 15 PASSENGER AIRBAG (Continued) (26) Pull the right side of the instrument panel back and set on right (passenger side) seat to access the passenger airbag module. NOTE: The instrument panel does not have to be removed any more than this for passenger airbag service.
Page 431 8O - 16 RESTRAINTS PASSENGER AIRBAG (Continued) (6) Install the right and left pencil strut to Passen- (32) If equipped with center console: • Install the right console side trim panel. ger Airbag screws (45 in. lbs. torque) (Fig. 14). •...
Page 432: Rear Seat Belt & Retractor Removal
RESTRAINTS 8O - 17 (4) Route the anchor end of the seat belt through REAR SEAT BELT & the upper quarter trim opening. Tighten to 40 N·m RETRACTOR (30 ft. lbs.). (5) Install the nut to attach the lower seat belt REMOVAL anchor to the floor.
Page 433: Installation
8O - 18 RESTRAINTS REAR SEAT BELT & RETRACTOR - CENTER (Continued) INSTALLATION WARNING: INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR IF THE BELT IS CUT, FRAYED, TORN, OR DAM- AGED IN ANY WAY. (1) Install the center rear seat belt retractor assembly on the rear shelf.
Page 434: Installation
RESTRAINTS 8O - 19 SEAT AIRBAG (Continued) (3) Remove the plastic back panel from the seat INSTALLATION back (Fig. 20). Refer to Body, Seats, Seat Back, Removal. WARNING: DO NOT REPLACE A DEPLOYED AIR- BAG. IF SEAT AIRBAG HAS BEEN DEPLOYED, THE ENTIRE SEAT BACK AND ALL DAMAGED PARTS MUST BE REPLACED.
Page 435: Seat Airbag Wiring Harness Removal
8O - 20 RESTRAINTS SEAT AIRBAG WIRING HARNESS REMOVAL WARNING: DISCONNECT AND ISOLATE THE BAT- TERY NEGATIVE CABLE REMOTE TERMINAL BEFORE BEGINNING SEAT AIRBAG REMOVAL. THIS WILL DISABLE THE SIDE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL SIDE AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 436: Seat Belt Buckle - Rear Seat Removal
RESTRAINTS 8O - 21 SEAT AIRBAG WIRING HARNESS (Continued) (4) Install the plastic back panel on the seat back. INSTALLATION Install new push pins in the upper mounting location (1) Place the seat belt buckle anchor over stud on of the back cover. Refer to Body, Seats, Front Seat floor.
Page 437: Side Impact Airbag Control Module Description
8O - 22 RESTRAINTS OPERATION SIDE IMPACT AIRBAG Each Side Impact Airbag Control Module (SIACM) CONTROL MODULE serves as the impact sensor for its seat mounted air- bag. The right side SIACM controls the right seat DESCRIPTION airbag (Fig. 26). The left side SIACM controls the left seat airbag (Fig.
Page 438 RESTRAINTS 8O - 23 SIDE IMPACT AIRBAG CONTROL MODULE (Continued) Fig. 26 SIDE IMPACT AIRBAG SYSTEM COMPONENT LOCATION 1 - RIGHT SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) 4 - LEFT SEAT AIRBAG MODULE 2 - VEHICLE BODY B-PILLAR 5 - LEFT SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) 3 - RIGHT SEAT AIRBAG MODULE 6 - OCCUPANT RESTRAINT CONTROLLER...
Page 440 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL INSTALLATION - 3.5L ....4 DESCRIPTION ......1 SERVO OPERATION DESCRIPTION...
Page 441: Speed Control Description
8P - 2 SPEED CONTROL SPEED CONTROL (Continued) NOTE: Turning the system off by depressing the throttle opening, while inhibiting/delaying down- OFF switch or turning off the ignition switch will shifts. erase the set speed stored in the PCM. OPERATION For added safety, the speed control system is pro- If opening the throttle alone cannot maintain the grammed to disengage for any of the following condi-...
Page 442: Diagnosis And Testing - Road Test
SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) OPERATION tem. The cause of any speedometer problems should be corrected before proceeding. Refer to the Instru- The Powertrain Control Module (PCM) first senses ment Cluster for speedometer diagnosis. that the speed control is set. If the set speed is If a road test verifies an inoperative system, and exceeded by more than 4 mph (6.5 km/hr) and the the speedometer operates properly, check for:...
Page 443: Removal Removal - 2.7L
8P - 4 SPEED CONTROL CABLE (Continued) REMOVAL REMOVAL - 2.7L (1) Disconnect the negative battery cable. (2) Remove speed control cable from throttle cam by sliding clasp out hole used for throttle cable. (3) Compress the retaining tabs on the cable and slide cable out of bracket.
Page 444: Operation
SPEED CONTROL 8P - 5 SERVO (Continued) OPERATION SWITCH The PCM controls the solenoid valve body. The DESCRIPTION solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum There are two separate switch pods that operate servo.
Page 445: Vacuum Reservoir
8P - 6 SPEED CONTROL REMOVAL VACUUM RESERVOIR (1) Disconnect the negative battery cable. DESCRIPTION (2) Remove the Powertrain Control Module (PCM) refer to the Fuel Injection System section. The vacuum reservoir is located in the engine com- (3) Remove and reposition coolant reservoir. partment.
Page 446 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY OPERATION ......4 DESCRIPTION .
Page 447: Vehicle Theft Security Description
8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) OPERATION ignition key, but the engine will not start unless the key transponder is also programmed to the vehicle. The SKIS will recognize no more than eight valid VEHICLE THEFT SECURITY SYSTEM Sentry Key transponders at any one time.
Page 448: Decklid Security Switch Removal
VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) (4) Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the SKIM wire harness connector. If OK, use a DRBIII scan tool and the proper Body Diagnostic Procedures Manual to complete the diagnosis of the SKIS.
Page 449: Skis Indicator Lamp Description
8Q - 4 VEHICLE THEFT SECURITY SKIS INDICATOR LAMP DESCRIPTION The Sentry Key Immobilizer System (SKIS) uses the Vehicle Theft Security System (VTSS) indicator LED to give an indication when the SKIS is faulty or when the vehicle has been immobilized due to the use of an invalid ignition key.
Page 450: Operation
VEHICLE THEFT SECURITY 8Q - 5 TRANSPONDER KEY (Continued) The Sentry Key transponder cannot be repaired If any of the above steps is not completed in the and, if faulty or damaged, it must be replaced. proper sequence, or within the allotted time, the SKIS will automatically exit the “Customer Learn”...
Page 452 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS WASHER PUMP MOTOR DESCRIPTION ......1 REMOVAL .
Page 453: Operation
8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) has a range of 1/2 to 18 seconds. The wiper delay times will double to a range of 1 to 36 seconds when the vehicle speed is less than 10 mph. The delay is controlled by a variable resistor in the wiper switch and the Body Control Module (BCM).
Page 454: Diagnosis And Testing Diagnosis And Testing - Intermittent Wipers
WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - INTERMITTENT WIPERS The intermittent wiper function is controlled by the Body Control Module (BCM), located in the left side of the instrument panel, attached to the Junc- tion Block (Fig.
Page 455 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER SYSTEM WILL 1. NO WASHER FLUID IN 1. FILL RESERVOIR. NOT FLOW WASHER RESERVOIR. FLUID. 2. JUNCTION BLOCK FUSE 2. SHORT CIRCUIT BETWEEN JUNCTION #5 BLOWN. BLOCK FUSE #5 AND WIPER SWITCH TERMINAL #1.
Page 456 WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSE CORRECTION HOOD NOZZLE WILL NOT 1. FROZEN NOZZLE. 1. DE-ICE NOZZLE BY ALLOWING TIME FOR FLOW. UNDERHOOD ENGINE HEAT TO THAW NOZZLE. IF NOT OK, MOVE VEHICLE INTO HEATED AREA. ASSURE WASHER FLUID IS PROPERLY BLENDED FOR AMBIENT OUTSIDE TEMPERATURES.
Page 457: Diagnosis And Testing - Wiper System Conditions
8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER FLUID LEVEL 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO SWITCH. INDICATOR INOPERATIVE. SENSOR CONNECTOR. 2. OPEN POWER CIRCUIT 2. OPEN OR DEFECTIVE CIRCUIT BETWEEN TO SWITCH. INSTRUMENT CLUSTER CONNECTOR TERMINAL #B4 AND LOW FLUID LEVEL SENSOR CONNECTOR TERMINAL.
Page 458 WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) Power Distribution Center. If no voltage check fuse M. (b) If motor runs and average ammeter reading If OK, go to Step 6. If not OK, repair as necessary. is less than 10 amps, go to Step 2. (6) Using an ohmmeter, check from terminal D of (2) Check to see if wiper linkage or pivots are the HI-LO wiper relay to Pin 1 of the motor wire con-...
Page 459: Headlamp Washers - Export Description
8R - 8 WIPERS/WASHERS WIPERS/WASHERS (Continued) WIPERS RUN AT LOW SPEED WITH SWITCH IN Check for continuity between Pin 1 of the wiper motor wire harness connector and terminal 3 of the HIGH SPEED POSITION BCM C3 bone 12-way connector. If no continuity, (1) Check for faulty HI-LO wiper relay.
Page 460 WIPERS/WASHERS 8R - 9 HEADLAMP WASHERS - EXPORT (Continued) WINDSHIELD/HEADLAMP WASHER TEST CONDITION POSSIBLE CAUSE CORRECTION WASHER POWER FEED 1. JUNCTION BLOCK FUSE 1. CHECK FUSE #5. REPLACE IF NOT OK. FUSE OPEN. #5 BLOWN. BLOWN FUSE WHEN 1. SHORT IN WIPER/ 1.
Page 461 8R - 10 WIPERS/WASHERS HEADLAMP WASHERS - EXPORT (Continued) CONDITION POSSIBLE CAUSE CORRECTION HOOD NOZZLE WILL NOT 1. PINCHED NOZZLE 1. ASSURE NOZZLE HOSE IS NOT PINCHED, FLOW. HOSE. LOOSE, BROKEN, OR DISCONNECTED. IF NOT OK, PROPERLY ROUTE OR REPAIR NOZZLE HOSE.
Page 462 WIPERS/WASHERS 8R - 11 HEADLAMP WASHERS - EXPORT (Continued) CONDITION POSSIBLE CAUSE CORRECTION HEADLAMP WASHER 1. NO WASHER FLUID IN 1. FILL RESERVOIR. SYSTEM WILL NOT FLOW RESERVOIR. WASHER FLUID. 2. JUNCTION BLOCK FUSE 2. SHORT CIRCUIT BETWEEN JUNCTION #5 BLOWN. BLOCK FUSE #5 AND WIPER SWITCH TERMINAL #1.
Page 463: Standard Procedure - Headlamp Washer System Priming - Export
8R - 12 WIPERS/WASHERS HEADLAMP WASHERS - EXPORT (Continued) STANDARD PROCEDURE - HEADLAMP WASHER SYSTEM PRIMING - EXPORT The headlamp washer system may loose it’s prime when the system is serviced. The following procedure must be used to prime the headlamp washer system. A DRB III scan tool must be used for this priming procedure.
Page 464: Headlamp Washer Nozzle - Export Removal
WIPERS/WASHERS 8R - 13 Standard Procedures - Headlamp Washer System HEADLAMP WASHER NOZZLE Priming. - EXPORT HEADLAMP WASHER PUMP - REMOVAL (1) Hoist vehicle. EXPORT (2) Partially remove the front fascia to gain access to the headlamp assembly. Refer to Body for Removal REMOVAL procedures.
Page 465: Installation
8R - 14 WIPERS/WASHERS HEADLAMP WASHER PUMP - EXPORT (Continued) INSTALLATION (6) Connect the negative battery cable remote ter- minal to the remote battery post. (1) Install the headlamp washer motor in the windshield/headlamp washer pump. (2) Connect the headlamp washer pump hose and WASHER FLUID LEVEL electrical connector.
Page 466: Installation
WIPERS/WASHERS 8R - 15 WASHER HOSES (Continued) INSTALLATION (1) Route washer hose up through engine compart- ment. (2) Connect washer hose to top of reservoir and to washer pump discharge port. (3) Connect hose clips to hood, tower to tower beam, and fender beam.
Page 467: Installation
8R - 16 WIPERS/WASHERS WASHER PUMP MOTOR (Continued) (4) Disconnect the wire connectors from the reser- (2) Position pump motor over grommet and firmly voir pump. snap into place. (5) Gently pry pump away from reservoir and out (3) Place reservoir into position in engine compart- of grommet.
Page 468: Washer Reservoir - Intrepid Removal
WIPERS/WASHERS 8R - 17 WASHER RESERVOIR (Continued) WASHER RESERVOIR - INTREPID REMOVAL (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. (2) Remove the left headlamp assembly and set aside. Refer to Electrical, Lamps/Lighting - Exterior, Headlamp Unit (Intrepid), Removal.
Page 469: Installation
8R - 18 WIPERS/WASHERS WASHER RESERVOIR FILLER TUBE (Continued) (3) Remove front fascia as necessary (left side only WIPER ARMS and use a 2x4 to prop left edge of fascia away from body). Refer to Body for Removal. STANDARD PROCEDURE - WIPER ARM (4) Reach up behind the washer reservoir and pull ALIGNMENT the filler tube off the rear of the reservoir.
Page 470: Wiper Blades Description
WIPERS/WASHERS 8R - 19 WIPER BLADES DESCRIPTION The wiper blades are a rubber element with a steel vertebrae that are mounted on the end of the wind- shield wiper arm and sweep across the front wind- shield to clear it of water, snow, and debris. OPERATION When the wiper blade rubber element is exposed to the weather for a long period of time, it tends to lose...
Page 471: Wiper Linkage Removal
8R - 20 WIPERS/WASHERS WIPER BLADE ELEMENT (Continued) the stopper. Assure element locked end is closest to INSTALLATION wiper system pivot. NOTE: Grommet eyelet may have been removed from rubber isolator on rear inboard and forward WIPER LINKAGE outboard mounting grommets during disassembly. Install if removed.
Page 472: Installation
WIPERS/WASHERS 8R - 21 WIPER MODULE (Continued) INSTALLATION (1) Install the wiper motor onto the wiper module assembly. Refer to Electrical, Wipers and Washers, Wiper Motor, Removal. (2) Install the three retaining bolts to the wiper motor (Fig. 19). (3) Install the crank arm and install the one nut to crank arm (Fig.
Page 473 8R - 22 WIPERS/WASHERS WIPER MOTOR (Continued) WIPER MOTOR TEST CONDITION POSSIBLE CAUSE CORRECTION WIPER OPERATES IN LOW 1. HI/LO RELAY 1. CHECK HI/LO RELAY WITH KNOWN GOOD SPEED OR INTERMITTENT DEFECTIVE. RELAY. IF NOT OK, REPLACE HI/LO RELAY. ONLY. 2.
Page 474 WIPERS/WASHERS 8R - 23 WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER WILL NOT PARK. 1. OPEN WIPER MOTOR 1. OPEN OR DEFECTIVE CIRCUIT BETWEEN PARK CIRCUIT. WIPER MOTOR CONNECTOR TERMINAL #4 AND BCM TERMINAL #3C. IF NOT OK, REPAIR CIRCUIT.
Page 475 8R - 24 WIPERS/WASHERS WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER SYSTEM WILL NOT 1. PDC FUSE M BLOWN. 1. SHORT CIRCUIT BETWEEN PDC FUSE M AND RUN. ON/OFF RELAY CAVITY A OR D OR HI/LO RELAY CAVITY A . SHORT CIRCUIT IN ON/OFF RELAY OR HI/LO RELAY.
Page 476 WIPERS/WASHERS 8R - 25 WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER SYSTEM MAKES 1. LOOSE ARM TO BLADE 1. INSPECT CONNECTION FOR DAMAGE, REVERSAL NOISE. CONNECTION. BENDING, EXCESSIVE WARE. REPLACE ARM OR BLADE IF NOT OK. 2. LOOSE MASTER LINK. 2.
Page 477: Removal
8R - 26 WIPERS/WASHERS WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION POOR COLD 1. NO WASHER FLUID FOR 1. ADD WASHER FLUID TO RESERVOIR. TEMPERATURE WIPE WASH/WIPE CYCLE. QUALITY. 2. POOR WINDSHIELD 2. CHECK WINDSHIELD DEFROSTER FOR DEFROST PERFORMANCE. PROPER FUNCTION AND PERFORMANCE. 3.
Page 478 WIPERS/WASHERS 8R - 27 WIPER SWITCH (Continued) Fig. 21 MULTI-FUNCTION/WIPER SWITCH PIN CALL Fig. 20 WIPER SWITCH LOCATION 1 - WINDSHIELD WASHER BUTTON 2 - CONTROL STALK (BEAM SELECT) 3 - HAZARD WARNING BUTTON 4 - MULTI-FUNCTION SWITCH 5 - WINDSHIELD WIPER CONTROL WIPER/WASHER SWITCH RESISTANCE SWITCH POSITION TERMINALS...
Page 480 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 BODY CONTROL MODULE ... . . 8W-45-1 COMPONENT INDEX ....8W-02-1 AUDIO SYSTEM .
Page 482: Diagrams
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 483: Wiring Diagram Information
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 484 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 485 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 486: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 487: Description - Circuit Functions
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 488: Description - Connector, Ground And Splice Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 489: Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance are listed and explained below. Always check for non- between two points of a circuit. Low or no resistance factory items added to the vehicle before doing any in a circuit means good continuity.
Page 490: Standard Procedure - Testing Of Voltage Potential
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (2) Connect the other lead of the voltmeter to the selected test point.
Page 491: Standard Procedure - Testing For Ashort To Ground On Fuses Powering Several Loads
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS SHORT TO GROUND ON FUSES POWERING WIRING/TERMINAL SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse.
Page 492: Connector Removal
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 CONNECTOR REMOVAL (1) Disconnect battery. (2) Release Connector Lock (Fig. 10). (3) Disconnect the connector being repaired from its mating half/component. (4) Remove the dress cover (if applicable) (Fig. 10). (5) Release the Secondary Terminal Lock, if required (Fig.
Page 493 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 494 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 495: Diode Removal
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 496: Wire
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 498 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... . 8W-42 Front Wiper High/Low Relay ... . . 8W-53 A/C Compressor Clutch .
Page 499 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Overhead Travel Information System ..8W-49 Seat Belt Switch ..... . 8W-40 Oxygen Sensors .
Page 500 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-12 Fuse M (PDC) ..... . 8W-10-8, 19 A/C Compressor Clutch Relay .
Page 530 8W-11 FUSE BLOCK 8W - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page Fuse 1 (RFB) ..... . . 8W-11-5 ISO Relay No.
Page 536 8W-12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ....8W-12-25 Left Fog Lamp ......8W-12-18 Airbag Control Module (ORC) .
Page 572 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-5 Left Rear Turn Signal Lamp ... . . 8W-15-16, 17 Airbag Control Module (ORC) .
Page 594 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Airbag Control Module (ORC) ..8W-18-3 Instrument Cluster ....8W-18-3 Automatic Temperature Control Head .
Page 598 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auto Shut Down Relay ....8W-20-3 Generator ......8W-20-2 Battery .
Page 602 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 Powertrain Control Module .
Page 604 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-16 Fuse T (PDC) ..... . . 8W-30-2 A/C Pressure Transducer .
Page 630 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Automatic Day/Night Mirror ... 8W-31-5 Input Speed Sensor ....8W-31-3 Autostick Switch .
Page 638 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Ambient Temperature Sensor ... 8W-33-2 G104 ......8W-33-3 Body Control Module .
Page 642 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Body Control Module ....8W-35-2 Junction Block ..... . 8W-35-2 Brake Lamp Switch .
Page 646 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Body Control Module ..8W-39-2, 3, 4, 5, 6 Ignition Switch ..... . 8W-39-2 Driver Cylinder Lock Switch .
Page 652 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page ABS Warning Indicator ....8W-40-3 G300 ......8W-40-10 Analog Clock .
Page 662 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Body Control Module ....8W-41-2 G200 ......8W-41-2 Cigar Lighter .
Page 666 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-6 G105 ......8W-42-7, 8 A/C Compressor Clutch Relay .
Page 676 8W-43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Component Page Component Page Airbag Control Module (ORC) ..8W-43-2 Instrument Cluster ....8W-43-2 Body Control Module .
Page 680 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Analog Clock ..... . . 8W-44-6 Left Rear Reading/Courtesy Lamp .
Page 688 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page Airbag Control Module (ORC) ..8W-45-15 Left Rear Door Lock Motor/Ajar Switch . . 8W-45-10 Automatic Temperature Left Rear Reading/Courtesy Lamp .
Page 704 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Body Control Module ..8W-47-2, 4, 5, 9, 10 Left Rear Shelf Speaker ..8W-47-3, 6, 10 Center Instrument Panel Speaker .
Page 716 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Body Control Module ....8W-48-2 Power Distribution Center ... . . 8W-48-2 Driver Power Mirror .
Page 720 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Body Control Module ....8W-49-2 Junction Block ..... . 8W-49-2 Fuse 14 (JB) .
Page 722 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Accessory No. 1 ..... 8W-50-16 Headlamp Switch .
Page 738 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Automatic Day/Night Mirror ..8W-51-4, 5 Left Tail Lamp ....8W-51-8, 9 Brake Lamp Switch .
Page 748 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Left Side Repeater Lamp ....8W-52-4 Fuse 9 (JB) .
Page 754 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Body Control Module ... . . 8W-53-2, 4, 5 G106 ......8W-53-5 Front Washer Pump Motor .
Page 760 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 1 ....8W-60-2 Left Rear Power Window Switch ..8W-60-3, 4 Driver Power Window Motor .
Page 764 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Body Control Module ... 8W-61-2, 3, 4, 5 G301 ......8W-61-2, 4 Circuit Breaker No.
Page 770 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Automatic Day/Night Mirror ... 8W-62-7 Memory Heated Seat/Mirror Driver Power Mirror ... . 8W-62-2, 3, 5, 7 Module .
Page 778 8W-63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Body Control Module ....8W-63-8 Driver Power Seat Switch ... 8W-63-2, 4 Circuit Breaker No.
Page 786 8W-64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 14 (JB) ......8W-64-2 Sunroof Control Module .
Page 788 8W-65 SPEED PROPORTIONAL STEERING 8W - 65 - 1 8W-65 SPEED PROPORTIONAL STEERING Component Page Component Page Body Control Module ....8W-65-2 Junction Block ..... . 8W-65-2 Fuse 19 (JB) .
Page 790 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ....... 8W-15-4 S220 .
Page 796 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-5 C204 ......8W-80-20 A/C Pressure Transducer .
Page 797 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C321 (300M) ..... . . 8W-80-36 Driver Power Seat Recliner Motor ..8W-80-47 C322 .
Page 798 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Left Front Door Sail Speaker ..8W-80-60 Memory Heated Seat/Mirror Module C1 . . 8W-80-70 Left Front Door Speaker ....8W-80-61 Memory Heated Seat/Mirror Module C2 .
Page 799 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Rear Window Defogger/Antenna Module . 8W-80-87 Right Side Repeater Lamp (Built-Up- Export) ......8W-80-94 Recirculation Door Actuator .
Page 800 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C2 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 14BK GROUND A/C PRESSURE TRANSDUCER - GRAY 4 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K6 20VT/WT 5V SUPPLY C18 20DB...
Page 801 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K25 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL K4 20BK/LB SENSOR GROUND ANALOG CLOCK (LTD/300M) - NATURAL 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z2 20BK/LG GROUND E2 20OR...
Page 802 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AUTOSTICK SWITCH (DODGE/300M) - NATURAL 4 WAY CIRCUIT FUNCTION T44 20YL/LB AUTOSTICK DOWNSHIFT SWITCH SENSE T5 20LG/RD AUTOSTICK UPSHIFT SWITCH SENSE Z1 20BK GROUND F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) BLEND DOOR ACTUATOR - BLACK 5 WAY CIRCUIT FUNCTION C33 22DB/RD...
Page 803 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C2 - BLACK 24 WAY CIRCUIT FUNCTION C36 22RD/WT BLEND DOOR FEEDBACK SIGNAL G52 20YL HEADLAMP SWITCH MUX X20 20GY/WT RADIO CONTROL MUX D19 20VT/OR SCI RECEIVE (TCM/BCM) C9 22YL/DG (ATC) ASPIRATOR MOTOR DRIVER C56 22RD/LG (ATC) BLOWER MOTOR CONTROL...
Page 804 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 BODY CONTROL MODULE C4 - BLUE 16 WAY CIRCUIT FUNCTION G74 20TN/RD DOOR AJAR SWITCH SENSE (LR) G74 20TN/RD DOOR AJAR SWITCH SENSE (PASS) G72 20DG/OR PASSENGER CYLINDER LOCK SWITCH MUX G75 20TN DRIVER DOOR AJAR SWITCH SENSE P97 20WT/DG DRIVER DOOR SWITCH MUX...
Page 805 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE SWITCH SENSE G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) C101 - (HEADLAMP/DASH SIDE) CIRCUIT F42 16DG/LG K236 18GY/PK Z12 14BK/TN C2 14DB/BK Z1 14BK...
Page 806 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 C103 - GREEN (HEADLAMP AND DASH HARNESS SIDE) CIRCUIT V37 20RD/LG V32 20YL/RD V30 20DB/RD K29 20WT/PK G29 20BK/TN G6 20GY D21 20PK/TN D20 20LG G9 22GY/BK(POLICE PACKAGE/SPECIAL SERVICE) K4 20BK/LB L96 18LG/RD (BUILT-UP-EXPORT) A101 16RD/TN(POLICE PACKAGE) A105 18DB/RD(EXCEPT POLICE PACKAGE) A102 16RD/OR(POLICE PACKAGE)
Page 807 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS C104 - ORANGE (HEADLAMP/DASH SIDE) CIRCUIT A1 12RD A2 12PK/BK A41 12YL C104 - ORANGE (I/P HARNESS SIDE) CIRCUIT A1 12RD A2 12PK/BK A41 14YL C105 - YELLOW (BODY HARNESS SIDE) CIRCUIT L13 18BR/YL A141 12DG/WT A4 10BK/PK...
Page 808 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C106 - NATURAL (HEADLAMP/DASH SIDE) CIRCUIT B4 18LG (ABS) B3 18LG/DB (ABS) B2 18YL (ABS) B1 18YL/DB (ABS) K106 18WT/DG K107 18OR/RD F18 20LG/BK Z1 18BK (EXCEPT BUILT-UP-EXPORT) L95 18DG/YL (BUILT-UP-EXPORT) T44 20YL T5 20LG/RD C107 - LT.
Page 809 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C108 - LT. GRAY (HEADLAMP/DASH SIDE) CIRCUIT T9 16OR/BK T19 16WT Z1 18BK T60 16BR T59 16PK T50 16DG T47 16YL/BK K199 18BR/VT T20 16LB T16 16RD C108 - LT. GRAY (TRANSMISSION HARNESS SIDE) CIRCUIT T9 16OR/BK...
Page 810 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C109 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT L60 18TN L7 18BK/YL L61 18LG L39 20LB Z1 18BK C111 (BUILT-UP-EXPORT) - GRAY (HEADLAMP LEVELING SIDE) CIRCUIT L43 16VT L7 20BK/YL Z1 16BK L13 20BR/YL L33 20RD C111 (BUILT-UP-EXPORT) - GRAY (HEADLAMP...
Page 811 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C112 (BUILT-UP-EXPORT) - GRAY (HEADLIGHT LEVELING SIDE) CIRCUIT L44 20VT L7 20BK/YL Z1 20BK L13 20BR/YL L34 20RD C115 (EXCEPT 2.7L BASE) - BLACK (ENGINE SIDE) CIRCUIT Z1 12BK Z1 12BK C23 12DG C25 12YL C115 (EXCEPT 2.7L BASE) - BLACK (RADIATOR MOTOR HARNESS)
Page 812 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C200 - BLUE (BODY HARNESS SIDE) CIRCUIT G78 20TN/BK Z2 20BK/LG L13 18BR/YL L95 16DG/YL (300M/BUILT-UP-EXPORT) F14 20LG/YL X60 20DG/RD (EXCEPT DODGE) P112 18TN/OR (EXCEPT DODGE) X12 18RD (POLICE PACKAGE) G9 20GY/BK (POLICE PACKAGE) P114 18TN/WT (EXCEPT DODGE) C80 20DB/WT F101 16YL/TN (POLICE PACKAGE)
Page 813 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C201 - NATURAL (BODY HARNESS SIDE) CIRCUIT F62 16RD X51 18BR/YL X52 18DB/WT X53 18DG X54 18VT X55 18BR/RD X57 18BR/LB X58 18DB/OR X56 18DB/RD X88 18PK/RD X89 18PK/BK X60 20DG/RD F62 16RD/WT C201 - NATURAL (I/P HARNESS SIDE) CIRCUIT F62 16RD...
Page 814 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C202 (MTC) - NATURAL (I/P HARNESS SIDE) CIRCUIT C34 22BR/WT C35 22DG/YL C33 22DB/RD C32 22GY/DB C57 20DB/GY C26 22PK/DB C7 12BK/TN C1 12DG C12 22LG/BK C36 22RD/WT C37 22YL/WT C4 18TN C5 16LG C6 16LB C203 (ATC) - NATURAL (HVAC HARNESS SIDE)
Page 815 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C203 (ATC) - NATURAL (I/P HARNESS SIDE) CIRCUIT C34 22BR/WT C35 22DG/YL C33 22DB/RD C32 22GY/DB C57 20DB/GY C26 22PK/DB C1 12DG C12 22LG/BK C36 22RD/WT C37 22YL/WT Z1 12BK C56 22RD/LG C204 - NATURAL (HEADLINER HARNESS SIDE) CIRCUIT Q41 20WT...
Page 816 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C205 (EXCEPT POLICE PACKAGE) - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT E2 20OR Z1 20BK A105 18DB/RD Z1 18BK C205 (EXCEPT POLICE PACKAGE) - NATURAL (POWERPOINT SIDE) CIRCUIT E2 20OR Z1 20BK A105 18DB/RD Z1 18BK C206 (EXCEPT POLICE PACKAGE) - NATURAL (HEADLINER SIDE)
Page 817 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C300 - NATURAL (BODY HARNESS SIDE) CIRCUIT Q17 14DB/WT X81 18YL/BK (MIDLINE AND PREMIUM AUDIO) P33 16OR Q26 14VT/WT Q18 14GY/BK X53 18DG (BASE AUDIO) (POLICE PACKAGE) X87 18LG/VT (MIDLINE AND PREMIUM AUDIO) X83 18YL/RD (MIDLINE AND PREMIUM AUDIO) P55 16DB Q16 14BR/WT...
Page 818 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C301 - (LEFT FRONT DOOR SIDE) CIRCUIT G5 20DB/WT C16 20LB/YL M1 20PK P72 20YL/BK P70 20WT P74 20DB G73 20LG/OR P97 20WT/DG P64 20YL/OR P65 20DB/YL P69 20WT/RD P71 20YL (MEMORY) P75 20BK/WT (MEMORY) P73 20YL/PK (MEMORY) G75 20TN...
Page 819 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C302 - (RIGHT FRONT DOOR SIDE) CIRCUIT X84 18OR/BK (MIDLINE AND PREMIUM AUDIO) P33 16OR Q26 14VT/WT X80 18LB/BK X86 18OR/RD (MIDLINE AND PREMIUM AUDIO) P34 16PK/BK Q16 14BR/WT M2 20YL Q1 14YL Z1 20BK X82 18LB/RD L60 18TN...
Page 820 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C303 - (RIGHT FRONT DOOR SIDE) CIRCUIT G5 20DB/WT C16 20LB/YL (MEMORY) M1 20PK P72 20YL/BK P70 20WT P74 20DB G72 20DG/OR P96 20WT/LG P67 20YL/RD (MEMORY) P68 20DG/RD (MEMORY) P66 20WT/BK (MEMORY) G74 20TN/RD P162 20GY/WT (MEMORY) C303 - NATURAL (BODY SIDE)
Page 821 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C304 - NATURAL (BODY SIDE) CIRCUIT Z1 20BK P33 16OR P34 16PK/BK Q27 14RD/BK G74 20TN/RD Q1 14YL Q17 14DB/WT C304 - NATURAL (REAR DOOR SIDE) CIRCUIT Z1 20BK P33 16OR P34 16PK/BK Q27 14DG/WT G74 20TN/RD Q1 14YL...
Page 822 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C305 - NATURAL (REAR DOOR SIDE) CIRCUIT Z1 20BK P33 16OR P34 16PK/BK Q28 14DG/WT G74 20TN/RD Q1 14YL Q18 14GY/BK C306 - BLACK (BODY SIDE) CIRCUIT Z1 16BK F35 16RD C306 - GREEN (POWER SEAT SIDE) CIRCUIT Z1 16BK F35 16RD...
Page 823 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C307 - GREEN (POWER SEAT SIDE) CIRCUIT Z1 16BK F35 16RD C308 - BLACK (BODY SIDE) CIRCUIT K106 18WT/DG Z1 12BK G4 20DB K107 20OR/RD A141 12DG/WT C308 - BLACK (FUEL TANK JUMPER SIDE) CIRCUIT K106 18WT/DG (EXCEPT BUILT-UP-EXPORT)
Page 824 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C310 - YELLOW (BODY SIDE) CIRCUIT R32 20LB/OR R34 20LB/WT C310 - YELLOW (RIGHT SEAT SIDE) CIRCUIT R32 20LB/OR R34 20LB/WT C311 - RED (BODY SIDE) CIRCUIT G78 20TN/BK P2 20BK/WT G71 18VT/WT Z1 16BK L50 16WT/TN (EXCEPT LTD/CONCORDE) C311 - RED (DECKLID SIDE)
Page 825 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C312 - BLACK (REAR FASCIA SIDE) CIRCUIT L7 18BK/YL Z1 18BK C313 (CONCORDE/DODGE/300M) - GRAY (TAIL LAMP SIDE) CIRCUIT L50 18WT/TN L60 18LG/TN L7 18BK/YL L1 18VT/BK Z1 18BK C313 (DODGE/300M) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L60 16TN...
Page 826 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C313 (LTD/CONCORDE/BUILT-UP-EXPORT) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L60 16TN L95 16DG/YL (BUILT-UP-EXPORT) L7 18BK/YL L1 20VT/BK (BUILT-UP-EXPORT) Z1 16BK C314 (CONCORDE/DODGE/300M) - GRAY (TAIL LAMP SIDE) CIRCUIT L50 16WT/TN L61 18LG/TN L7 18BK/YL L1 18VT/BK Z1 18BK...
Page 827 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C314 (LTD/CONCORDE/BUILT-UP-EXPORT) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L61 16LG L95 16DG/YL (BUILT-UP-EXPORT) L7 18BK/YL L1 20 VT/BK (BUILT-UP-EXPORT) Z1 16BK C315 (CONCORDE/LTD) - BLACK (BODY SIDE) CIRCUIT L1 18VT/BK Z1 18BK L7 18BK/YL C315 (CONCORDE/LTD) - BLACK (REAR FASCIA SIDE)
Page 828 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C317 - NATURAL (BODY SIDE) CIRCUIT X98 18TN/VT (PREMIUM II AUDIO) X96 18TN/DG (PREMIUM II AUDIO) C317 - NATURAL (REAR DOOR SIDE) CIRCUIT X98 18TN/VT (PREMIUM II AUDIO) X96 18TN/DG (PREMIUM II AUDIO) C318 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT P130 16RD/TN...
Page 829 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C318 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT P130 16RD/TN P130 16RD/TN P142 20TN/DB P142 20TN/DB G5 20DB/WT G5 20DB/WT P138 20VT/LG P138 20VT/LG P140 20VT/BK P140 20VT/BK P134 20TN/LG P134 20TN/LG P144 20BK/LG P144 20BK/LG C319 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT...
Page 830 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C319 (MEMORY) - NATURAL (POWER SEAT SIDE) CIRCUIT D25 20VT/YL G5 20DB/WT P70 20WT P72 20YL/BK P74 20DB P142 20TN/DB P130 16RD/TN P144 20BK/LG P134 20TN/LG P140 20VT/BK P138 20VT/LG P71 20YL P75 20BK/WT P73 20YL/PK P64 20YL/OR...
Page 831 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C321 (300M) - BLACK (CHMSL SIDE) CIRCUIT L50 18WT/TN Z1 18BK C321 (300M) - NATURAL (DECKLID SIDE) CIRCUIT L50 18WT/TN Z1 18BK C322 - BLACK (BODY SIDE) CIRCUIT F14 20LG/YL Z2 20BK/LG D25 20VT/YL C322 - BLACK (SAB JUMPER SIDE) CIRCUIT...
Page 832 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C325 (POLICE PACKAGE) - GREEN (BODY SIDE) CIRCUIT M1 20PK Z1 20BK C360 (POLICE PACKAGE/SPECIAL SERVICE) - BLACK (I/P HARNESS) CIRCUIT A101 16RD/TN A102 16RD/OR A103 16RD/YL F101 16YL/TN F102 16YL/OR F103 16YL/RD C360 (POLICE PACKAGE/SPECIAL SERVICE) - BLACK (POLICE ACCESSORY HARNESS SIDE) CIRCUIT...
Page 833 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS CENTER HIGH MOUNTED STOP LAMP (300M) - 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L50 18WT/TN BRAKE LAMP SWITCH OUTPUT CENTER HIGH MOUNTED STOP LAMP NO. 1 (CONCORDE/LTD) - GRAY 2 WAY CIRCUIT FUNCTION L50 18WT/TN...
Page 834 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 CENTER HIGH MOUNTED STOP LAMP NO. 2 (DODGE) - 2 WAY CIRCUIT FUNCTION L50 16WT/TN BRAKE LAMP SWITCH OUTPUT Z1 16BK GROUND CENTER INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X89 18PK/BK AMPLIFIED CENTER INSTRUMENT PANEL SPEAKER X88 18PK/RD...
Page 835 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS CLOCKSPRING C2 - YELLOW 2 WAY CIRCUIT FUNCTION R43 18BK/LB DRIVER SQUIB 1 LINE 2 R45 18DG/LB DRIVER SQUIB 1 LINE 1 CLOCKSPRING C3 - 4 WAY CIRCUIT FUNCTION V37 22RD/LG SPEED CONTROL SWITCH SIGNAL K4 22BK/LB SENSOR GROUND X920 22GY/OR...
Page 836 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 COIL ON PLUG NO. 4 - BLACK 2 WAY CIRCUIT FUNCTION F42 16DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K94 16TN/LG COIL ON PLUG DRIVER NO. 4 COIL ON PLUG NO. 5 - BLACK 2 WAY CIRCUIT FUNCTION F42 16DG/LG...
Page 837 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS COMPACT DISC CHANGER (MIDLINE/PREMIUM) - BLACK 8 WAY CIRCUIT FUNCTION X40 24GY/WT AUDIO OUT RIGHT E14 24OR/TN PANEL LAMPS DIMMER SIGNAL D25 24VT/YL PCI BUS X112 24RD FUSED IGNITION SWITCH OUTPUT X41 24DG/WT AUDIO OUT LEFT Z140 24BK/OR GROUND...
Page 838 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CRANKSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5V SUPPLY K4 20BK/LB SENSOR GROUND K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS Z1 20BK...
Page 839 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS DECKLID RELEASE SWITCH - BLACK 2 WAY CIRCUIT FUNCTION P1 20BK/WT DECKLID RELEASE SWITCH OUTPUT F30 20PK(POLICE PACKAGE BATTERY FUSED B(+) POSITION) M1 20PK FUSED B(+) F30 20PK(POLICE PACKAGE IGNITION FUSED IGNITION SWITCH OUTPUT (RUN-ACC) POSITION) DRIVER AIRBAG - YELLOW 2 WAY CIRCUIT...
Page 840 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 DRIVER HEATED SEAT BACK - GREEN 2 WAY CIRCUIT FUNCTION P88 16BR/BK HEATED SEAT DRIVER Z1 20BK GROUND DRIVER HEATED SEAT CUSHION - BLACK 4 WAY CIRCUIT FUNCTION P131 16RD/TN (EXCEPT MEMORY) DRIVER SEAT HEATER B(+) DRIVER P131 16RD/DG (MEMORY) DRIVER SEAT HEATER B(+) DRIVER...
Page 841 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS DRIVER POWER MIRROR (EXCEPT MEMORY) - NATURAL 3 WAY CIRCUIT FUNCTION P71 20YL DRIVER MIRROR UP DRIVER P73 20YL/PK DRIVER MIRROR COMMON DRIVER P75 20BK/WT DRIVER MIRROR LEFT DRIVER DRIVER POWER MIRROR (MEMORY) - WHITE 11 WAY CIRCUIT FUNCTION Z1 20BK...
Page 842 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 DRIVER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION P115 16YL/DB (MEMORY SEATS) DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 16YL/LB (EXCEPT MEMORY DRIVER SEAT HORIZONTAL REARWARD DRIVER SEATS) P117 16RD/LB (MEMORY SEATS) DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 16RD/LB (EXCEPT MEMORY DRIVER SEAT HORIZONTAL FORWARD DRIVER...
Page 843 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS DRIVER POWER SEAT RECLINER MOTOR SENSOR (MEMORY) - BLACK 3 WAY CIRCUIT FUNCTION P29 20BR/WT SEAT SENSOR 5V SUPPLY P47 20LB RECLINER POSITION SIGNAL P28 20BR/RD SEAT POSITION SENSOR GROUND DRIVER POWER SEAT SWITCH - BLUE 10 WAY CIRCUIT FUNCTION P9 20RD (MEMORY SEATS)
Page 844 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 DRIVER POWER WINDOW MOTOR - RED 2 WAY CIRCUIT FUNCTION Q21 16WT DRIVER WINDOW DRIVER (DOWN) Q11 16LB DRIVER WINDOW DOWN (UP) DRIVER POWER WINDOW SWITCH - BLUE 12 WAY CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) Q17 14DB/WT...
Page 845 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS EVAP/PURGE SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION K52 18PK/BK EVAPORATIVE EMISSION SOLENOID CONTROL K108 18DG/LG EVAPORATIVE EMISSION SOLENOID SENSE EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL C57 20DB/GY SENSOR GROUND FRONT WASHER PUMP MOTOR - BLACK 2 WAY...
Page 846 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 FUEL INJECTOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN/WT FUEL INJECTOR NO. 2 DRIVER F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 3 - BLACK 2 WAY CIRCUIT FUNCTION K13 18YL/WT...
Page 847 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS FUEL PUMP MODULE - GRAY 4 WAY CIRCUIT FUNCTION Z1 12BK GROUND Z1 18BK GROUND G4 18DB FUEL LEVEL SENSOR SIGNAL A141 12DG/WT FUEL PUMP RELAY OUTPUT GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION Z12 18BK/TN(3.5L)
Page 848 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 HEADLAMP SWITCH - BLUE 13 WAY CIRCUIT FUNCTION Z1 18BK/LB (BUILT-UP-EXPORT) GROUND L7 18BK/YL (BUILT-UP-EXPORT) HEADLAMP SWITCH OUTPUT E19 20RD PANEL LAMPS DIMMER SIGNAL Z1 20BK GROUND L95 18DG/YL (BUILT-UP-EXPORT) REAR FOG LAMP RELAY CONTROL L80 20WT HEADLAMP SWITCH RETURN L13 18BR/YL (BUILT-UP-EXPORT)
Page 849 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS IGNITION SWITCH - BLACK 10 WAY CIRCUIT FUNCTION A81 14DG/RD IGNITION SWITCH OUTPUT (OFF-RUN-START) G26 22LB KEY-IN IGNITION SWITCH SENSE Z2 20BK/LG GROUND A21 12DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) A1 12RD FUSED B (+) A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
Page 850 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 INTAKE AIR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K21 20BK/RD INTAKE AIR TEMPERATURE SIGNAL K4 20BK/LB SENSOR GROUND JUNCTION BLOCK BODY CONTROL MODULE-JB - 20 WAY CIRCUIT FUNCTION GROUND COURTESY LAMP DRIVER SPEED PROPORTIONAL STEERING SOLENOID (-) SPEED PROPORTIONAL STEERING SOLENOID (+) FUSED IGNITION SWITCH OUTPUT (RUN-START)
Page 851 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C10 - GRAY 13 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL L61 18LG LEFT TURN SIGNAL G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER L34 20RD/OR FUSED RIGHT HIGH BEAM OUTPUT L1 20VT/BK BACK-UP LAMP FEED F18 20LG/BK...
Page 852 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 JUNCTION BLOCK C3 - BLUE 15 WAY CIRCUIT FUNCTION A81 14DG/RD IGNITION SWITCH OUTPUT (OFF-RUN-START) X12 20RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z2 18BK/LG GROUND L99 20GY/BK(POLICE PACKAGE) FUSED B(+) G9 22GY/BK RED BRAKE WARNING INDICATOR DRIVER F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START)
Page 853 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C6 - BROWN 12 WAY CIRCUIT FUNCTION P33 16OR LOCK RELAY OUTPUT P33 16OR LOCK RELAY OUTPUT P33 16OR LOCK RELAY OUTPUT P55 16DB DRIVER DOOR UNLOCK RELAY OUTPUT M2 20YL COURTESY LAMPS DRIVER F11 20RD/WT (DODGE/300M) FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START)
Page 854 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 JUNCTION BLOCK C9 - ORANGE 8 WAY CIRCUIT FUNCTION A13 12PK/WT FUSED B(+) A34 12LB/RD FUSED B(+) A7 14RD/BK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) F20 18WT/VT (ABS) FUSED IGNITION SWITCH OUTPUT (RUN) F13 20DB FUSED IGNITION SWITCH OUTPUT (RUN) F11 20RD/WT...
Page 855 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS LEFT BACK-UP LAMP (CONCORDE/LTD) - NATURAL 2 WAY CIRCUIT FUNCTION L1 18VT/BK BACK-UP LAMP FEED Z1 18BK GROUND LEFT BACK-UP LAMP (DODGE) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18VT/BK GROUND L1 18VT/BK BACK-UP LAMP FEED LEFT FOG LAMP (CONCORDE/LTD) - BLACK 2 WAY CIRCUIT...
Page 856 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 LEFT FRONT DOOR SPEAKER - 3 WAY CIRCUIT FUNCTION X87 18LG/VT (NORMAL BUILD) AMPLIFIED LEFT DOOR SPEAKER (+) X87 18LG/VT (EARLY BUILD) AMPLIFIED LEFT DOOR SPEAKER (+) X85 18LG/BK AMPLIFIED LEFT DOOR SPEAKER (-) LEFT FRONT PARK/TURN SIGNAL LAMP (DODGE) - 3 WAY CIRCUIT FUNCTION...
Page 857 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) B9 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L7 20BK/YL...
Page 858 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 LEFT LOW BEAM HEADLAMP - GRAY 2 WAY CIRCUIT FUNCTION L43 20VT (BUILT-UP-EXPORT) FUSED LEFT LOW BEAM OUTPUT L43 16VT (EXCEPT BUILT-UP-EXPORT) FUSED LEFT LOW BEAM OUTPUT Z1 16BK (EXCEPT BUILT-UP-EXPORT) GROUND Z1 20BK (BUILT-UP-EXPORT) GROUND LEFT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY...
Page 859 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS LEFT REAR POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q23 16DG LEFT REAR WINDOW DRIVER DOWN Q17 14GY/BK LEFT REAR WINDOW DRIVER (UP) Q27 14DG/WT LEFT REAR WINDOW DRIVER (DOWN) Q13 16GY WINDOW LEFT REAR B(+) UP Q1 14YL...
Page 860 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 LEFT REAR SIDE MARKER LAMP (DODGE) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT REAR TURN SIGNAL LAMP (300M/BUILT-UP-EXPORT) - 3 WAY CIRCUIT FUNCTION L61 18LG/TN LEFT TURN SIGNAL Z1 18BK...
Page 861 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS LEFT REMOTE RADIO SWITCH - 2 WAY CIRCUIT FUNCTION X20 22GY/WT RADIO CONTROL MUX X920 22GY/OR RADIO CONTROL MUX RETURN LEFT SEAT AIRBAG - 2 WAY CIRCUIT FUNCTION R31 20LG/OR LEFT SEAT SQUIB LINE 1 R33 20LG/WT LEFT SEAT SQUIB LINE 2 LEFT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW 6 WAY...
Page 862 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 LEFT TAIL LAMP (300M/BUILT-UP-EXPORT) - GREEN 3 WAY CIRCUIT FUNCTION L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND LEFT TAIL LAMP (LTD) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT TAIL/STOP LAMP (CONCORDE) - BLACK 3 WAY...
Page 863 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS LEFT TAIL/STOP LAMP NO. 1 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND LEFT TAIL/STOP LAMP NO. 2 (300M) - 3 WAY CIRCUIT FUNCTION L50 18WT/TN...
Page 864 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 LEFT VISOR/VANITY LAMP - BLACK 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND LICENSE LAMP (EXCEPT BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR - GRAY 3 WAY...
Page 865 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS MANUAL TEMPERATURE CONTROL HEAD C2 - BLACK 10 WAY CIRCUIT FUNCTION C4 18TN LOW BLOWER MOTOR DRIVER C6 16LB M2 BLOWER MOTOR DRIVER Z1 12BK GROUND C5 16LG M1 BLOWER MOTOR DRIVER C7 12BK/TN HIGH BLOWER MOTOR DRIVER MEMORY HEATED SEAT/MIRROR MODULE C1 - 26 WAY...
Page 866 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 MEMORY HEATED SEAT/MIRROR MODULE C2 - 16 WAY CIRCUIT FUNCTION P139 20VT/WT DRIVER SEAT HIGH HEAT LED DRIVER P140 20VT/BK PASSENGER SEAT HIGH HEAT LED DRIVER P73 20YL/PK DRIVER MIRROR COMMON DRIVER-RIGHT/DOWN P75 20BK/WT DRIVER MIRROR LEFT DRIVER P71 20YL...
Page 867 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS MEMORY SET SWITCH - 6 WAY CIRCUIT FUNCTION Z1 18BK GROUND P24 18PK/WT MEMORY POSITION 2 SWITCH SENSE P22 18PK/BK MEMORY SET SWITCH SENSE P23 18PK/RD MEMORY POSITION SWITCH SENSE MODE DOOR ACTUATOR - BLACK 5 WAY CIRCUIT FUNCTION C35 22DG/YL...
Page 868 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 OVERHEAD TRAVEL INFORMATION SYSTEM (PREMIUM) - BLACK 6 WAY CIRCUIT FUNCTION G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) Z2 20BK/LG GROUND M1 20PK FUSED B(+) D25 20VT/YL PCI BUS OXYGEN SENSOR 1/1 RIGHT BANK UP - GRAY 4 WAY CIRCUIT FUNCTION Z1 18BK...
Page 869 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS OXYGEN SENSOR 2/2 LEFT BANK DOWN - BLACK 4 WAY CIRCUIT FUNCTION Z1 18BK GROUND K399 18BR/GY OXYGEN SENSOR 2/2 HEATER CONTROL K904 18DB/DG OXYGEN SENSOR RETURN (DOWN) K341 20PK/WT OXYGEN SENSOR 2/2 SIGNAL PASSENGER AIRBAG - YELLOW 2 WAY CIRCUIT FUNCTION...
Page 870 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 PASSENGER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G74 20TN/RD DOOR AJAR SWITCH SENSE Z1 20BK GROUND P34 16PK/BK UNLOCK RELAY OUTPUT P33 16OR LOCK RELAY OUTPUT PASSENGER HEATED SEAT BACK - GREEN 2 WAY CIRCUIT FUNCTION P88 16BR/BK...
Page 871 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS PASSENGER POWER DOOR LOCK SWITCH - NATURAL 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) Z1 20BK GROUND P96 20WT/LG PASSENGER DOOR MUX SWITCH PASSENGER POWER MIRROR (EXCEPT MEMORY) - NATURAL 3 WAY CIRCUIT FUNCTION P70 20WT...
Page 872 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 PASSENGER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION P14 16YL/LB PASSENGER SEAT HORIZONTAL FORWARD P16 16RD/LB PASSENGER SEAT HORIZONTAL FORWARD PASSENGER POWER SEAT REAR RISER MOTOR - 2 WAY CIRCUIT FUNCTION P10 16YL/WT...
Page 873 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS PASSENGER POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q22 16VT PASSENGER WINDOW DRIVER (DOWN) Q16 14BR/WT MASTER WINDOW SWITCH (RIGHT FRONT UP) Q26 14VT/WT MASTER WINDOW SWITCH (RIGHT FRONT DOWN) Q12 16BR PASSENGER WINDOW DRIVER (UP) Q1 14YL...
Page 874 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 POWER MIRROR SWITCH - BLACK 13 WAY CIRCUIT FUNCTION P73 20YL/PK DRIVER MIRROR COMMON DRIVER (RIGHT/DOWN) G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) P70 20WT PASSENGER MIRROR COMMON DRIVER (RIGHT/ DOWN) P74 20DB PASSENGER MIRROR LEFT DRIVER P75 20BK/WT DRIVER MIRROR LEFT DRIVER...
Page 875 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C1 - BLACK 38 WAY CIRCUIT FUNCTION Z12 16BK/TN GROUND F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) K236 18GY/PK (3.5L HIGH OUTPUT) SHORT RUNNER VALVE SOLENOID CONTROL Z12 16BK/TN GROUND...
Page 876 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 POWERTRAIN CONTROL MODULE C2 - 38 WAY CIRCUIT FUNCTION K96 16TN/LB COIL ON PLUG DRIVER NO. 6 K95 16TN/DG COIL ON PLUG DRIVER NO. 5 K94 16TN/LG COIL ON PLUG DRIVER NO. 4 K58 18BR/DB FUEL INJECTOR NO.
Page 877 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C3 - WHITE 38 WAY CIRCUIT FUNCTION K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL C27 20DB/PK HIGH SPEED RADIATOR FAN RELAY CONTROL V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL C24 20DB/PK LOW SPEED RADIATOR FAN RELAY CONTROL V32 20YL/RD...
Page 878 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 POWERTRAIN CONTROL MODULE C4 - GREEN 38 WAY CIRCUIT FUNCTION T60 16BR OVERDRIVE SOLENOID CONTROL T59 16PK UNDERDRIVE SOLENOID CONTROL T19 16WT 2-4 SOLENOID CONTROL T20 16LB LOW/REVERSE SOLENOID CONTROL Z14 16BK/YL GROUND Z13 16BK/RD GROUND...
Page 879 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS RADIATOR FAN - BLACK 4 WAY CIRCUIT FUNCTION Z1 12BK GROUND Z1 12BK GROUND C23 12DG LOW SPEED RADIATOR FAN RELAY OUTPUT C25 12YL HIGH SPEED RADIATOR FAN RELAY OUTPUT RADIATOR FAN MOTOR NO. 1 (EXCEPT 2.7L BASE) - 2 WAY CIRCUIT FUNCTION Z1 12BK...
Page 880 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 RADIATOR FAN RELAY NO. 2 (AT FAN) (EXCEPT 2.7L BASE) CIRCUIT FUNCTION 12BK GROUND C25 12RD HIGH SPEED RADIATOR RELAY OUTPUT C25 12RD HIGH SPEED RADIATOR RELAY OUTPUT Z1 12BK RADIATOR FAN MOTOR NO. 1 CONTROL Z1 12BK GROUND 12RD...
Page 881 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS RADIO C2 (BASE) - GRAY 7 WAY CIRCUIT FUNCTION X55 18BR/RD LEFT FRONT DOOR SPEAKER (-) X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-) E17 20YL/BK PARK LAMP RELAY OUTPUT E2 20OR PANEL LAMPS DRIVER X12 20RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) M1 20PK...
Page 882 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 REAR WINDOW DEFOGGER/ANTENNA MODULE - BLACK 3 WAY CIRCUIT FUNCTION X60 20DG/RD RADIO 12V OUTPUT C15 10BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT RECIRCULATION DOOR ACTUATOR - NATURAL 5 WAY CIRCUIT FUNCTION C32 20GY/DB RECIRCULATION DOOR DRIVER C34 20BR/WT COMMON DOOR DRIVER...
Page 883 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS RIGHT FOG LAMP (CONCORDE/LTD) - BLACK 2 WAY CIRCUIT FUNCTION L39 20LB FOG LAMP RELAY OUTPUT Z1 20BK GROUND RIGHT FOG LAMP (DODGE/300M/BUILT-UP-EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION L39 20LB FOG LAMP SWITCH OUTPUT Z1 20BK GROUND RIGHT FRONT DOOR SAIL SPEAKER - BLACK 2 WAY...
Page 884 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND RIGHT FRONT POSITION LAMP - GRAY 2 WAY CIRCUIT FUNCTION L7 20BK/YL...
Page 885 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS RIGHT HIGH BEAM HEADLAMP - BLACK 2 WAY CIRCUIT FUNCTION L34 20RD/OR (EXCEPT POLICE FUSED RIGHT HIGH BEAM OUTPUT PACKAGE/EXCEPT BUILT-UP-EXPORT) L34 20RD (BUILT-UP-EXPORT) FUSED RIGHT HIGH BEAM OUTPUT L34 20OR/WT (POLICE PACKAGE) FUSED RIGHT HIGH BEAM OUTPUT Z1 20BK GROUND...
Page 886 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 RIGHT REAR DOOR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X96 18TN/DG AMPLIFIED LOW RIGHT REAR SPEAKER (-) X98 18TN/VT AMPLIFIED LOW RIGHT REAR SPEAKER (+) RIGHT REAR FOG LAMP (BUILT-UP-EXPORT) - NATURAL 3 WAY CIRCUIT FUNCTION L95 18DG/YL...
Page 887 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS RIGHT REAR READING/COURTESY LAMP - BLACK 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) M42 20LG (EXCEPT BASE) COURTESY LAMPS DRIVER RIGHT REAR READING/COURTESY LAMP SWITCH - WHITE 3 WAY CIRCUIT FUNCTION Z1 20BK COURTESY LAMPS DRIVER M42 20LG...
Page 888 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 RIGHT REAR TURN SIGNAL LAMP (DODGE) - 2 WAY CIRCUIT FUNCTION L60 18LG/TN RIGHT TURN SIGNAL Z1 18BK GROUND RIGHT REAR TURN SIGNAL LAMP (LTD) - 2 WAY CIRCUIT FUNCTION L60 18LG/TN RIGHT TURN SIGNAL Z1 18BK GROUND...
Page 889 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW 6 WAY CIRCUIT FUNCTION F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) D25 20VT/YL PCI BUS R32 20LB/OR RIGHT SEAT SQUIB LINE 1 R34 20LB/WT RIGHT SEAT SQUIB LINE 2 Z2 20BK/LG GROUND...
Page 890 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 RIGHT TAIL/STOP LAMP (CONCORDE) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND RIGHT TAIL/STOP LAMP (LTD/BUILT-UP-EXPORT)) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN...
Page 891 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS RIGHT TAIL/STOP LAMP NO. 2 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND RIGHT TAIL/TURN SIGNAL LAMP (CONCORDE) - BLACK 3 WAY CIRCUIT FUNCTION L60 18LG/TN...
Page 892 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 SHORT RUNNER VALVE SOLENOID (3.5L HIGH OUTPUT) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K236 18GY/PK SHORT RUNNER VALVE SOLENOID CONTROL SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 18TN/RD...
Page 893 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS SPOT LAMP NO. 2 (POLICE PACKAGE) - BLACK 2 WAY CIRCUIT FUNCTION SL2 18WT/DB FUSED B(+) SUN SENSOR/VTSS LED - BLACK 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) G69 22BK/OR VTSS INDICATOR DRIVER C57 20DB/GY SENSOR GROUND C38 20DB...
Page 894 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 SUNROOF MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q6 16DB SUNROOF MOTOR B(-) Q5 16DG SUNROOF MOTOR B(+) SUNROOF SWITCH - NATURAL 4 WAY CIRCUIT FUNCTION Q41 20WT SUNROOF OPEN Q42 20LB SUNROOF CLOSE Z1 20BK GROUND...
Page 895 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS TRANSMISSION RANGE INDICATOR ILLUMINATION (PRNDL) - 2 WAY CIRCUIT FUNCTION E2 20OR PANEL LAMPS FEED Z1 20BK GROUND TRANSMISSION RANGE SENSOR - LT. GREEN 10 WAY CIRCUIT FUNCTION F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) T13 20DB/BK SPEED SENSOR GROUND T54 20VT/PK...
Page 896 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 TRUNK LAMP - BLACK 2 WAY CIRCUIT FUNCTION G78 20TN/BK DECKLID AJAR SWITCH SENSE M1 20PK FUSED B(+) TURN SIGNAL/HAZARD SWITCH - BLACK 8 WAY CIRCUIT FUNCTION Z1 20BK GROUND L91 22DB/PK COMBINATION FLASHER SWITCHED GROUND L61 18LG LEFT TURN SIGNAL...
Page 897 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS WINDSHIELD WASHER PUMP MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Z1 20BK GROUND V10 20BR FRONT WASHER PUMP MOTOR CONTROL WINDSHIELD WIPER MOTOR - BLACK 5 WAY CIRCUIT FUNCTION V4 14RD/YL FRONT WIPER RELAY HIGH SPEED OUTPUT V3 14BR/WT FRONT WIPER RELAY LOW SPEED OUTPUT V55 20TN/RD...
Page 898 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 Use the wiring diagrams in each section for connec- CONNECTOR/GROUND/SPLICE tor, ground, and splice identification.
Page 899 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C103 Left Side Instrument Panel 8, 15 C104 Left Side Instrument Panel 8, 15 C105 Left Side Instrument Panel C106 Left Side Instrument Panel C107 LTGY Rear of Engine...
Page 900 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C318 Under Passenger Seat C319 Under Drivers Seat C320 Left Side Shelf Panel 20, 22 C321 (300M) Deck Lid C322 Left B Pillar C325 At Left C Pillar, Behind Sholder Belt Ancor C360 At bottom of I/P Center Stack...
Page 901 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Driver Power Seat Front Riser At Driver Seat Motor Driver Power Seat Front Riser At Driver Seat Sensor Driver Power Seat Horizontal Motor At Driver Seat Driver Power Seat Horizontal Motor At Driver Seat Sensor...
Page 902 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. High Beam Headlamp Relay In Junction Block High Speed Radiator Fan Relay In Power Distribution Center Horn Relay In Junction Block Idle Air Control Motor On Throttle Body 5, 6 Ignition Switch...
Page 903 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Left License Lamp At Lamp Left Low Beam Headlamp At Lamp Left Rear Courtesy Reading Lamp At Switch Switch Left Rear Courtesy Reading Lamp Near Switch Left Rear Door Lock Motor/Ajar At Left Rear Door...
Page 904 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Manual Temperature Control Head Center of I/P - C2 Memory Heated Seat / Mirror Under Driver Seat Module C1 Memory Heated Seat / Mirror Under Driver Seat Module C2 Memory Heated Seat / Mirror...
Page 905 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Passenger Power Seat Switch At Seat Passenger Power Window Motor Passenger Door Passenger Power Window Switch Passenger Door Passenger Side Airbag At Seat Power Amplifier C1 (Front) At Amplifier Right Cowl Power Amplifier C2 (Front) At Amplifier Right Cowl...
Page 906 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Right Front Door Speaker Right Front Door Right Front Park/Turn Signal Lamp At Lamp (Dodge) Right Front Park/Turn Signal Lamp At Lamp (Except Dodge) Right Front Position Lamp At Right Headlamp Right Front Side Marker Lamp...
Page 907 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Right Tail / Stop Lamp No.1 (LTD, At Lamp 300M, BUX) Right Tail / Stop Lamp No.2 At Lamp (Dodge) Right Tail / Stop Lamp No.2 (300M) At Lamp Right Tail / Turn Signal Lamp At Lamp...
Page 908 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER LOCATION FIG. G105 Near Right Horn G106 Near Right Horn G108 Near Power Distribution Center G200 Lower Center of Instrument Panel G201 Lower Center of Instrument Panel G300 Under Driver Seat 15, 16...
Page 909 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S130 Front Lighting Near T/O for Left Front Lamps S131 Front Lighting Near T/O for Left Front Lamps S132 Front Lighting Near T/O for Left Front Lamps S133 Front Lighting Near T/O for Left Front Lamps S134...
Page 910 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S212 A/C Heater Harness Near T/O to Blend Door Actuator S214 Instrument Panel, Behind Cluster S215 Instrument Panel Left Side in T/O to C103 S216 In T/O to Right Radio Remote Switch S217 In T/O to Right Radio Remote Switch...
Page 911 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S331 Body Harness, Left Side Body S332 Body Harness, Right Side Body S334 Body Harness, Left Side Body S335 Body Harness, Left Side Body S336 Body Harness, Left Cowl S337 Body Harness, Body Rear...
Page 912 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 1 FRONT OF ENGINE Fig. 2 RIGHT FRONT ENGINE COMPARTMENT...
Page 913 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 914 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 915 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 916 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 917 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 918 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 919 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 920 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 10 LEFT INSTRUMENT PANEL END CAP Fig. 11 ACCESSORY EQUIPMENT CONNECTOR...
Page 921 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 12 HEADLAMP FLASHER - POLICE...
Page 922 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 923 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 14 LEFT SIDE BODY REAR...
Page 924 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 925 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 926 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 17 RIGHT FRONT DOOR Fig. 18 RIGHT FRONT DOOR PANEL...
Page 927 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 RIGHT REAR DOOR PANEL Fig. 20 SHELF PANEL...
Page 928 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 21 AUXILIARY LIGHT CONNECTOR Fig. 22 DECK LID...
Page 929 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 23 RIGHT TRUNK, REAR POWER AND ACCESSORIES...
Page 930 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 932 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......3 DESCRIPTION .
Page 933 8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION (Continued) • Move the fuse slightly right and insert it in the The power distribution system for this vehicle con- sists of the following components: fuse #6 “BAT” location in the junction block. •...
Page 934 8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER/POWER OUTLET (Continued) IOD FUSE DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the junction block as part of the preparation procedures performed just prior to new vehicle deliv- ery.
Page 935 8W - 97 - 4 8W-97 POWER DISTRIBUTION IOD FUSE (Continued) when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse.
Page 936: Power Distribution Center
8W-97 POWER DISTRIBUTION 8W - 97 - 5 JUNCTION BLOCK (Continued) repaired and is only serviced as an assembly. If any POWER DISTRIBUTION internal circuit or the JB housing is faulty or dam- CENTER aged, the entire Junction Block assembly must be replaced.
Page 937 8W - 97 - 6 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) dards Organization (ISO) relays, and up to seven ISO INSTALLATION micro-relays. Internal connection of all the PDC cir- The Power Distribution Center (PDC) is serviced cuits is accomplished by an intricate network of hard as a unit with the engine compartment wire harness.
Page 938 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 2.7L......1 ENGINE 3.5L.
Page 939 9 - 2 ENGINE 2.7L INSTALLATION - OFF VEHICLE ... 36 VIBRATION DAMPER VALVE STEM SEALS REMOVAL ......54 REMOVAL .
Page 940 ENGINE 2.7L 9 - 3 INSPECTION ......69 INSPECTION ......75 ASSEMBLY .
Page 941 9 - 4 ENGINE 2.7L ENGINE 2.7L (Continued) Fig. 1 2.7 Liter Engine Fig. 2 Cylinder Numbering and Firing Order...
Page 942 ENGINE 2.7L 9 - 5 ENGINE 2.7L (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
Page 943 9 - 6 ENGINE 2.7L ENGINE 2.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ BATTERY - DESCRIPTION) 2.
Page 944 ENGINE 2.7L 9 - 7 ENGINE 2.7L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Set gap as needed or replace plug(s). 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 945 9 - 8 ENGINE 2.7L ENGINE 2.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 946 ENGINE 2.7L 9 - 9 ENGINE 2.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 947 9 - 10 ENGINE 2.7L ENGINE 2.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to Appropriate Diagnostic Manual) 2. Worn, scuffed or broken rings. 2.
Page 948 ENGINE 2.7L 9 - 11 ENGINE 2.7L (Continued) Calibrate the tester according to the manufactur- will not cure if left in the uncovered tube. The er’s instructions. The shop air source for testing anaerobic material is for use between two machined should maintain 483 kPa (70 psi) minimum, 1,379 surfaces.
Page 949 9 - 12 ENGINE 2.7L ENGINE 2.7L (Continued) Never use the following to clean gasket surfaces: • Metal scraper • Abrasive pad or paper to clean cylinder block and head • High speed power tool with an abrasive pad or a wire brush (Fig.
Page 950 ENGINE 2.7L 9 - 13 ENGINE 2.7L (Continued) STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.
Page 951 9 - 14 ENGINE 2.7L ENGINE 2.7L (Continued) (8) Remove air cleaner assembly and air inlet hose (Fig. 8). (9) Remove upper radiator crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REIN- FORCEMENT - REMOVAL) Fig. 8 Air Cleaner and Inlet Hose 1 - AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 - THROTTLE BODY (20) Disconnect throttle and speed control cables.
Page 952 ENGINE 2.7L 9 - 15 ENGINE 2.7L (Continued) (34) Lower vehicle. (12) Lower vehicle. (35) Remove screws attaching fuel line and electri- (13) Install rear throttle body support bracket. cal harness to the throttle body bracket. (14) Install electrical harness and fuel line support (36) Remove the fasteners attaching the following brackets to the throttle body support bracket.
Page 953 9 - 16 ENGINE 2.7L ENGINE 2.7L (Continued) Fig. 9 ENGINE LIFTING FIXTURE 1 - SPECIAL TOOL 8342 - ENGINE LIFTING FIXTURE 3 - ATTACHING LOCATION - REAR OF ENGINE 2 - ATTACHING LOCATION - FRONT OF ENGINE (39) Install right and left cowl screens. (Refer to 23 (42) Connect negative cable to remote jumper ter- - BODY/EXTERIOR/COWL GRILLE AND SCREEN - minal at right strut tower.
Page 954 ENGINE 2.7L 9 - 17 ENGINE 2.7L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Piston Rings 2.7L ENGINE Ring Gap—Top 0.20–0.36 mm Compression Ring (0.008–0.014 in.) DESCRIPTION SPECIFICATION Ring Gap—2nd 0.37–0.63 mm General Specifications Compression Ring (0.0146–0.0249 in.) Type 60° DOHC V-6 24-Valve Ring Gap—Oil Control 0.25–0.76 mm Displacement...
Page 955 9 - 18 ENGINE 2.7L ENGINE 2.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Taper (Max.) 0.015 mm Intake Valve Seat Width 1.00–1.5 mm (0.0006 in.) (0.0394–0.0591 in.) End Play 0.0475–0.2725 mm Exhaust Valve Seat 1.25–1.75 mm Width (0.0019–0.0108 in.) (0.0492–0.0689 in.) End Play (Max.) 0.43 mm Guide Bore Diameter...
Page 956 ENGINE 2.7L 9 - 19 ENGINE 2.7L (Continued) TORQUE DESCRIPTION SPECIFICATION Valve Spring Free Length—Intake & 45.63 mm DESCRIPTION N·m Lbs. Lbs. Exhaust (Approx.) (1.7965 in.) A/C Compressor to — Spring Force—Intake & 249–284 N @ 38.0 mm Engine—Bolts Exhaust (Valve Closed) (56.0–64.0 lbs.
Page 957 9 - 20 ENGINE 2.7L ENGINE 2.7L (Continued) DESCRIPTION N·m Lbs. Lbs. Oil Pump Cover—Bolts — Oil Pump Pick Up — Tube—Bolt PCV Valve — Crankshaft Rear Seal — Retainer—Bolts Puller 1023 Spark Plugs — Starter Mounting—Bolts — Structural Collar (Refer to 9 - ENGINE/ ENGINE BLOCK/ STRUCTURAL COVER -...
Page 958 ENGINE 2.7L 9 - 21 ENGINE 2.7L (Continued) Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Crankshaft Seal Remover 6771 Crankshaft Seal & Sprocket Installer 6780-1 Driver Handle C-4171 Crankshaft Seal Protector 6780-2 Crankshaft Real Seal Retainer Alignment Fixture 8225 Puller 5048 Timing Chain Tensioner Resetting Gauge 8186 Puller Adaptor 8539...
Page 959 9 - 22 ENGINE 2.7L ENGINE 2.7L (Continued) Valve Spring Compressor 8215 Valve Spring Compressor MD-998772-A Adapter 8216 Valve Spring Adapter 6527 Valve Spring Compressor C-3422-D Indicator Bore Size C-119 Valve Spring Adapter 6526 Connecting Rod Installation Guides 8189 Valve Spring Tester C-647 Main Bearing Remover/Installer C-3059...
Page 960 ENGINE 2.7L 9 - 23 ENGINE 2.7L (Continued) Cooling System Tester 7700 Pressure Gauge C-3292 Adapter 8406 Combustion Leak Tester C-3685-A AIR CLEANER ELEMENT REMOVAL (1) Remove air cleaner lid. Lift lid off of air cleaner housing. (2) Remove filter element (Fig. 10). DRBIII with PEP Module –...
Page 961 9 - 24 ENGINE 2.7L Possible indications of the cylinder head gasket CYLINDER HEAD leaking between a cylinder and an adjacent water jacket are: DESCRIPTION • Engine overheating The cylinder heads are made of an aluminum alloy • Loss of coolant (Fig.
Page 962 ENGINE 2.7L 9 - 25 CYLINDER HEAD (Continued) CYLINDER-TO-WATER JACKET LEAKAGE TEST (7) Remove water outlet connector (Fig. 12). (Refer COOLING/ENGINE/COOLANT OUTLET HOUSING - REMOVAL) WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED. VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap.
Page 963 9 - 26 ENGINE 2.7L CYLINDER HEAD (Continued) Fig. 14 CAMSHAFT & VALVETRAIN COMPONENTS 1 – CAMSHAFT BEARING CAP - INTAKE 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 2 – CAMSHAFT BEARING CAP - EXHAUST 8 – CYLINDER BLOCK 3 – CAMSHAFT - EXHAUST 9 –...
Page 964 ENGINE 2.7L 9 - 27 CYLINDER HEAD (Continued) NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCE- DURE). Be careful not to gouge or scratch the alumi- num head sealing surface.
Page 965 9 - 28 ENGINE 2.7L CYLINDER HEAD (Continued) (7) Install all valvetrain components and cam- OPERATION shafts. (Refer to 9 - ENGINE/CYLINDER HEAD/ The camshaft has precisely machined (egg shaped) CAMSHAFT(S) - INSTALLATION) Tighten camshaft lobes to provide accurate valve timing and duration. bearing caps in sequence shown in (Fig.
Page 966 ENGINE 2.7L 9 - 29 CAMSHAFT(S) (Continued) Fig. 20 Camshaft and Valvetrain Components 1 – CAMSHAFT BEARING CAP - INTAKE 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 2 – CAMSHAFT BEARING CAP - EXHAUST 8 – CYLINDER BLOCK 3 – CAMSHAFT - EXHAUST 9 –...
Page 967 9 - 30 ENGINE 2.7L CAMSHAFT(S) (Continued) Fig. 23 Camshaft Inspection Fig. 21 Camshaft End Play Measuring 1 - ACTUAL WEAR 1 - DIAL INDICATOR 2 - BEARING JOURNAL 3 - EXHAUST CAMSHAFT 4 - INTAKE CAMSHAFT 5 - LOBE Fig.
Page 968 ENGINE 2.7L 9 - 31 CYLINDER HEAD COVER(S) (Continued) Fig. 27 Cylinder Head Cover Gasket and Spark Plug Seals 1 - ONE PIECE GASKET Fig. 25 Camshaft Chain Timing 2 - SPARK PLUG WELL SEALS 1 - PLATED CHAIN LINKS 2 - CAMSHAFT TIMING MARKS (4) Connect all electrical connectors and harness clips.
Page 969 9 - 32 ENGINE 2.7L INTAKE/EXHAUST VALVES & SEATS (Continued) VALVES Inspect the remaining margin after the valves are refaced. (Refer to 9 - ENGINE - SPECIFICATIONS) VALVE SEATS (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- ing stones.
Page 970 ENGINE 2.7L 9 - 33 INTAKE/EXHAUST VALVES & SEATS (Continued) VALVE GUIDES (1) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. (2) Measure valve stem-to-guide clearance as fol- lows: (3) Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat.
Page 971 9 - 34 ENGINE 2.7L INTAKE/EXHAUST VALVES & SEATS (Continued) (5) Remove cylinder head covers. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) (6) Remove crankshaft vibration damper (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL), timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL), and timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING...
Page 972 ENGINE 2.7L 9 - 35 VALVE SPRINGS (Continued) Fig. 34 VALVE, SPRING SEAT/SEAL, SPRING, REATINER AND LOCKS 1 - VALVE KEEPER 7 - VALVE-EXHAUST 2 - SPRING RETAINER 8 - VALVE-INTAKE 3 - VALVE KEEPER 9 - CYLINDER HEAD 4 - VALVE SPRING-EXHAUST 10 - VALVE STEM SEAL 5 - SPRING RETAINER 11 - VALVE SPRING-INTAKE...
Page 973 9 - 36 ENGINE 2.7L VALVE SPRINGS (Continued) - ENGINE/VALVE TIMING/TIMING BELT / CHAIN retainer. If height is greater than 38.75 mm (1.5256 COVER(S) - INSTALLATION). in.), install a 0.762 mm (0.030 in.) spacer in head (6) Install cylinder head covers. (Refer to 9 - counterbore under the valve spring seat to bring ENGINE/CYLINDER HEAD/CYLINDER...
Page 974: Hydraulic Lash Adjusters
ENGINE 2.7L 9 - 37 VALVE STEM SEALS (Continued) INSTALLATION HYDRAULIC LASH (1) The valve stem seal/valve spring seat should be ADJUSTERS pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal DIAGNOSIS AND TESTING - HYDRAULIC LASH against top of guide.
Page 975: Rocker Arms
9 - 38 ENGINE 2.7L HYDRAULIC LASH ADJUSTERS (Continued) REMOVAL OPERATION (1) Remove cylinder head cover(s). (Refer to 9 - The rocker arm is the pivot point between the cam- ENGINE/CYLINDER HEAD/CYLINDER HEAD shaft lobe and the valve. COVER(S) - REMOVAL) REMOVAL (2) Remove rocker arm(s).
Page 976 ENGINE 2.7L 9 - 39 ROCKER ARMS (Continued) INSPECTION STANDARD PROCEDURE - CYLINDER BORE Inspect the cam follower assembly for wear or HONING damage (Fig. 41). Replace as necessary. (1) Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure.
Page 977 9 - 40 ENGINE 2.7L ENGINE BLOCK (Continued) Fig. 42 ENGINE BLOCK AND CRANKSHAFT 1 - MAIN CAP BOLT—VERTICAL 5 - MAIN CAP BOLT —HORIZONTAL 2 - MAIN CAP 6 - CYLINDER BLOCK 3 - MAIN BEARING—LOWER 7 - CRANKSHAFT 4 - MAIN BEARING—UPPER (4) Check block deck surfaces for flatness.
Page 978 ENGINE 2.7L 9 - 41 ENGINE BLOCK (Continued) (1) For measuring Main Bearing Clearance and Connecting Rod Bearing Clearance use plastigage (Fig. 45). For more information on using plastigage (Refer to 9 - ENGINE - STANDARD PROCEDURE). Refer to Engine Specifications for bearing clearance specifications (Refer to 9 - ENGINE - SPECIFICA- TIONS).
Page 979 9 - 42 ENGINE 2.7L CONNECTING ROD BEARINGS (Continued) ing rod throws are an even-firing design which reduces torque fluctuations while a vibration damper is used to control torsional vibration. The crankshaft oil seals are a one piece design. The front seal is retained by the timing chain cover, and the rear seal in a housing that attaches to the cylinder block.
Page 980 ENGINE 2.7L 9 - 43 CRANKSHAFT (Continued) (8) Remove timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL). (9) Remove primary timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN AND SPROCKETS - REMOVAL). (10) Remove crankshaft sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN AND...
Page 981 9 - 44 ENGINE 2.7L CRANKSHAFT (Continued) Fig. 51 CYLINDER BLOCK AND CRANKSHAFT 1 - MAIN CAP BOLT—VERTICAL 5 - MAIN CAP BOLT —HORIZONTAL 2 - MAIN CAP 6 - CYLINDER BLOCK 3 - MAIN BEARING—LOWER 7 - CRANKSHAFT 4 - MAIN BEARING—UPPER (3) Push crankshaft forward.
Page 982 ENGINE 2.7L 9 - 45 CRANKSHAFT (Continued) (17) Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (18) Install idler pulley bracket for accessory drive belt. (19) Install oil pick-up tube and O-ring. (20) Install oil pan and oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION).
Page 983 9 - 46 ENGINE 2.7L CRANKSHAFT MAIN BEARINGS (Continued) Fig. 54 Crankshaft Main Journal Grade Marking Location Fig. 56 Main Bearing Grade Marks 1 - LOWER MAIN BEARING 2 - UPPER MAIN BEARING 3 - OIL FEED HOLE AND GROOVE 4 - GRADE SELECTION INK MARKS MAIN BEARING SELECTION CHART—2.7L Main Bearing Bore Grade...
Page 984 ENGINE 2.7L 9 - 47 CRANKSHAFT OIL SEAL - FRONT REMOVAL (1) Remove crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (2) Install Special Tool 8194, Insert into crankshaft nose. Remove seal using Special Tool 6771, Remover (Fig. 57). Fig.
Page 985 9 - 48 ENGINE 2.7L INSTALLATION CRANKSHAFT OIL SEAL - REAR CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), clean surface using 400 REMOVAL grit sand paper to prevent seal damage during (1) Remove transaxle from vehicle. (Refer to 21 - installation.
Page 986 ENGINE 2.7L 9 - 49 CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL (1) Remove crankshaft rear oil seal and oil pan. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK- SHAFT OIL SEAL - REAR - REMOVAL) (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (2) Remove seal retainer attaching screws (Fig.
Page 987 9 - 50 ENGINE 2.7L FLEX PLATE (Continued) (3) Install flex plate bolts (Fig. 63). Tighten bolts OPERATION to 95 N·m (70 ft. lbs.). The piston and connecting rod is the link between (4) Install the transaxle. (Refer to 21 - TRANS- the combustion force to the crankshaft.
Page 988 ENGINE 2.7L 9 - 51 PISTON & CONNECTING ROD (Continued) CAUTION: DO NOT use a number stamp or a punch INSTALLATION to mark connecting rods. Damage to connecting (1) Install the piston rings. (Refer to 9 - ENGINE/ rod could occur. ENGINE BLOCK/PISTON RINGS - INSTALLA- TION) (2) Mark connecting rod and bearing cap positions...
Page 989 9 - 52 ENGINE 2.7L PISTON & CONNECTING ROD (Continued) (5) Position bearing onto connecting rod. Ensure (9) Tap the piston down in cylinder bore, using a that hole in bearing half is aligned to hole in con- hammer handle. At the same time, guide connecting necting rod.
Page 990 ENGINE 2.7L 9 - 53 PISTON RINGS (Continued) INSTALLATION (1) Measure clearance of piston rings to the cylin- der bore and piston. (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCE- DURE) (2) The No. 1 and No. 2 piston rings have a differ- ent cross section.
Page 991 9 - 54 ENGINE 2.7L PISTON RINGS (Continued) Fig. 75 PISTON RING END GAP POSITION Fig. 73 SIDE RAIL - INSTALLATION 1 - SIDE RAIL UPPER 1 - SIDE RAIL END 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO.
Page 992 ENGINE 2.7L 9 - 55 VIBRATION DAMPER (Continued) STRUCTURAL COLLAR / COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove bolts attaching structural collar to oil pan and transmission housing (Fig. 79). (3) Remove collar (Fig. 79). Fig. 77 VIBRATION DAMPER - REMOVAL 1 - SPECIAL TOOL 1023 2 - SPECIAL TOOL 8194 INSERT (3) Install accessory drive belts (Refer to 7 -...
Page 993 9 - 56 ENGINE 2.7L (2) Remove the isolator attaching nuts from top of ENGINE MOUNTING the mounting bracket (Fig. 80). (3) Support the engine with a jack and a block of DESCRIPTION wood across the full width of the oil pan. The engine mounting system consist of three (4) Remove the lower attaching nuts from the bot- mounts;...
Page 994 ENGINE 2.7L 9 - 57 (2) Remove the isolator attaching nuts from top of REAR MOUNT the mounting bracket (Fig. 81). (3) Support the engine with a jack and a block of REMOVAL wood across the full width of the oil pan. (1) Raise vehicle on hoist.
Page 995 9 - 58 ENGINE 2.7L OPERATION LUBRICATION Oil from the oil pan is pumped by a geroter type oil DESCRIPTION pump directly coupled to the crankshaft (Fig. 82). Oil pressure is controlled by a relief valve mounted The lubrication system is a full-flow filtration, inside the oil pump housing.
Page 996 ENGINE 2.7L 9 - 59 LUBRICATION (Continued) FROM: FROM: Oil Pump Oil Filter Mounting (inlet) Main Oil Gallery - Center 1. Crankshaft Main of Block Bearings Oil Filter Mounting (inlet) Oil Filter 2. Left Cylinder Head* Oil Filter Oil Filter Mounting (outlet) 3.
Page 997 9 - 60 ENGINE 2.7L LUBRICATION (Continued) FROM: Left Cylinder Head Oil Inlet Gallery (intake side of Oil Gallery and Accumulator – Rear of Head* head) Oil Gallery and Accumulator – Rear of Head* 1. Exhaust Camshaft Oil Passage 2. Intake Camshaft Oil Passage Left Exhaust Camshaft Oil Passage 1.
Page 998 ENGINE 2.7L 9 - 61 LUBRICATION (Continued) FROM: Right Cylinder Head Oil Inlet Gallery (intake side of Oil Gallery and Accumulator – Rear of Head* head) Oil Gallery and Accumulator – Rear of Head* 1. Exhaust Camshaft Oil Passage 2. Intake Camshaft Oil Passage Right Exhaust Camshaft Oil Passage 1.
Page 999 9 - 62 ENGINE 2.7L LUBRICATION (Continued) If the leakage occurs at the crankshaft rear oil seal (4) Oil Pressure (engine at operating temperature): area: Curb Idle 34.5 kPa (5 psi) minimum 3000 RPM (1) Disconnect the battery. 300–724 kPa (45–105 psi). (2) Raise the vehicle.
Page 1000 ENGINE 2.7L 9 - 63 OIL (Continued) STANDARD PROCEDURE - ENGINE OIL AND OIL FILTER SPECIFICATION All engines are equipped with a high quality full- FILTER CHANGE flow, disposable type oil filter. When replacing oil fil- ter, use a Mopar filter or equivalent. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN.
Page 1001 9 - 64 ENGINE 2.7L OIL COOLER & LINES (Continued) Fig. 86 ENGINE OIL COOLER - 2.7L ENGINE 1 - ENGINE OIL COOLER SUPPLY LINE 3 - ENGINE OIL COOLER FITTINGS 2 - RETAINER 4 - ENGINE OIL COOLER RETURN LINE Fig.
Page 1002 ENGINE 2.7L 9 - 65 OIL COOLER & LINES (Continued) Fig. 88 ENGINE OIL COOLER - 2.7L 1 - ENGINE OIL COOLER SUPPLY LINE 3 - ENGINE OIL COOLER FITTINGS 2 - RETAINER 4 - ENGINE OIL COOLER RETURN LINE Fig.
Page 1003 9 - 66 ENGINE 2.7L OIL COOLER & LINES (Continued) INSTALLATION ENGINE OIL COOLER (1) Install radiator assembly. (Refer to 7 - COOL- ING/ENGINE/RADIATOR - INSTALLATION) (2) Tighten oil cooler lines to radiator fittings to 18 N·m (160 in. lbs.). COOLER LINES (1) Connect cooler lines to radiator fittings and retainer clip (Fig.
Page 1004 ENGINE 2.7L 9 - 67 OIL PAN (Continued) (a) Install oil pan bolts and nuts finger tight only—just tight enough to compress the gas- ket’s rubber seal. (b) Install timing chain cover to pan bolts and tighten to 12 N·m (105 in. lbs.). (c) Tighten oil pan bolts to 28 N·m (250 in.
Page 1005 9 - 68 ENGINE 2.7L OIL PRESSURE RELIEF VALVE (Continued) OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light.
Page 1006 ENGINE 2.7L 9 - 69 OIL PUMP (Continued) Fig. 94 Crankshaft Positioned At 60 DEGREES ATDC No.1 Cylinder 1 - CRANKSHAFT POSITION = 60° ATDC NO. 1 CYLINDER Fig. 96 Oil Pressure Relief Valve 1 - RELIEF VALVE 2 - SPRING 3 - RETAINER CAP (3) Remove oil pump cover screws and lift off cover plate (Fig.
Page 1007 9 - 70 ENGINE 2.7L OIL PUMP (Continued) Fig. 99 MEASURING OUTER ROTOR THICKNESS Fig. 97 Oil Pump 1 - OIL PUMP COVER 2 - SCREWS (8) 3 - OIL PUMP INNER ROTOR 4 - OIL PUMP HOUSING 5 - OIL PUMP OUTER ROTOR Fig.
Page 1008 ENGINE 2.7L 9 - 71 OIL PUMP (Continued) Fig. 103 MEASURING CLEARANCE OVER ROTORS 1 - STRAIGHT EDGE 2 - FEELER GAUGE Fig. 101 MEASURING OUTER ROTOR CLEARANCE IN HOUSING (4) Prime oil pump before installation by filling 1 - FEELER GAUGE rotor cavity with engine oil.
Page 1009 9 - 72 ENGINE 2.7L (1) File or sand the remaining port back until a INTAKE MANIFOLD flat surface is obtained (plane normal to nipple (port) axis). DESCRIPTION (2) Drill out the nipple (port) base using a 7/16” The two piece intake manifold is made of a com- drill bit (Fig.
Page 1010 ENGINE 2.7L 9 - 73 INTAKE MANIFOLD - UPPER (Continued) INSPECTION Check manifold for: • Damage and cracks • Gasket surface damage or warpage • Damaged or clogged EGR ports If the manifold exihibits any damaged or warped conditions, replace the manifold. Clean EGR ports as neccessary.
Page 1011 9 - 74 ENGINE 2.7L INTAKE MANIFOLD - UPPER (Continued) (6) Connect electrical connectors to the following NOTE: For ease of installing upper intake manifold, components: install a bolt 2 – 3 turns to the rearmost attaching • Manifold Absolute Pressure (MAP) Sensor hole of intake.
Page 1012 ENGINE 2.7L 9 - 75 (7) Remove heat shield attaching screws and EXHAUST MANIFOLD remove heat shields (Fig. 110). (8) Remove exhaust manifold attaching bolts and DESCRIPTION remove manifold (Fig. 110). The exhaust manifolds are a log style design and made of cast nodular iron (Fig.
Page 1013 9 - 76 ENGINE 2.7L EXHAUST MANIFOLD - RIGHT (Continued) (6) Install bolt attaching battery cable housing tube to transmission housing. Tighten bolt to 101 N·m (75 ft. lbs.). (7) Install air intake tube and air filter housing. (8) Connect negative cable. EXHAUST MANIFOLD - LEFT REMOVAL (1) Disconnect negative cable from remote jumper...
Page 1014 ENGINE 2.7L 9 - 77 VALVE TIMING (Continued) side” of the primary chain, necessitating the double- The secondary timing chain drive system uses flexure type chain. two conventional roller-type chains, one at each cyl- The chain is controlled by three fixed chain guides inder bank (Fig.
Page 1015: Timing Chain Cover
9 - 78 ENGINE 2.7L VALVE TIMING (Continued) STANDARD PROCEDURE TIMING CHAIN COVER ENGINE TIMING - VERIFICATION REMOVAL Correct timing is critical for the NON free-wheel- (1) Disconnect negative cable from remote jumper ing designed, 2.7L engine. Engine timing can be ver- terminal.
Page 1016 ENGINE 2.7L 9 - 79 TIMING CHAIN COVER (Continued) INSTALLATION (1) Inspect and clean sealing surfaces. Inspect and replace gasket and seal as necessary. (2) If front crankshaft seal was bench installed, place Special Tool 6780-2, Sleeve over crankshaft nose to guide and protect seal lip. (3) Before installing timing cover gasket apply a 1/8 inch bead of Mopar Engine RTV GEN II to the parting lines between the oil pan and cylinder block...
Page 1017 9 - 80 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. (3) Align crankshaft sprocket timing mark to mark on oil pump housing (Fig.
Page 1018 ENGINE 2.7L 9 - 81 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 118 TIMING DRIVE SYSTEM - PRIMARY 1 - CAMSHAFT DAMPER 7 - CHAIN GUIDE 2 - CHAIN GUIDE 8 - CHAIN TENSIONER ARM 3 - ACCESS PLUG 9 - CHAIN TENSIONER 4 - CAMSHAFT POSITION SENSOR 10 - CAMSHAFT SPROCKETS 5 - PRIMARY TIMING CHAIN...
Page 1019 9 - 82 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) (7) Loosely position left side camshaft sprocket over camshaft hub. (8) Align timing (plated) link to the crankshaft sprocket timing mark (Fig. 120). (9) Position primary chain onto water pump drive sprocket.
Page 1020 ENGINE 2.7L 9 - 83 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 120 TIMING CHAIN ALIGNMENT MARKS - PRIMARY 1 - CAMSHAFT TIMING MARKS 6 - CHAIN TENSIONER 2 - CHAIN GUIDE 7 - CAMSHAFT TIMING MARK 3 - CRANKSHAFT TIMING MARKS 8 - INTAKE CAMSHAFT SPROCKETS 4 - CRANKSHAFT SPROCKET 9 - CHAIN GUIDES...
Page 1021 9 - 84 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 121 TIMING CHAIN TENSIONER - OIL PURGING 1 - TENSIONER 3 - SPECIAL TOOL 8186 2 - CHECK BALL 4 - PIN...
Page 1022 ENGINE 2.7L 9 - 85 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 122 TIMING CHAIN TENSIONER - RESETTING 1 - TENSIONER 2 - SPECIAL TOOL 8186 (16) Install the reset chain tensioner into the right (19) Turn the left side camshaft by inserting a 3/8” cylinder head (Fig.
Page 1023 9 - 86 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) INSTALLATION - CRANKSHAFT SPROCKET (1) Install crankshaft sprocket using Special Tools 6780-1 and 8179 (Fig. 124) until sprocket bottoms against crankshaft step flange. Use care not to rotate crankshaft. Fig. 123 TIMING CHAIN TENSIONER ACTIVATING (22) Install the timing chain cover, crankshaft Fig.
Page 1024 ENGINE 3.5L 9 - 87 ENGINE 3.5L TABLE OF CONTENTS page page ENGINE 3.5L CAMSHAFT(S) DESCRIPTION ......90 DESCRIPTION .
Page 1025 9 - 88 ENGINE 3.5L REMOVAL - CYLINDER HEAD ON ..125 ENGINE MOUNTING INSPECTION ......126 DESCRIPTION .
Page 1026 ENGINE 3.5L 9 - 89 DIAGNOSIS AND TESTING - INTAKE TIMING BELT COVER(S) - REAR MANIFOLD LEAKS ....159 REMOVAL ......168 INTAKE MANIFOLD - UPPER INSTALLATION .
Page 1027 9 - 90 ENGINE 3.5L ENGINE 3.5L DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DESCRIPTION DIAGNOSIS - INTRODUCTION The 3.5 Liter (214 Cubic Inches) 60 degree V-6 engines is a single overhead camshaft design with Engine diagnosis is helpful in determining the hydraulic lifters and four valves per cylinder (Fig.
Page 1028 ENGINE 3.5L 9 - 91 ENGINE 3.5L (Continued) Fig. 2 Cylinder Numbering & Firing Order - 3.5L For fuel system diagnosis, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts.
Page 1029 9 - 92 ENGINE 3.5L ENGINE 3.5L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1030 ENGINE 3.5L 9 - 93 ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1031 9 - 94 ENGINE 3.5L ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to Appropriate Diagnostic Manual) 2. Worn, scuffed or broken rings. 2.
Page 1032 ENGINE 3.5L 9 - 95 ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer to ROUGH Appropriate Diagnostic Information) 2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic Information) 3.
Page 1033 9 - 96 ENGINE 3.5L ENGINE 3.5L (Continued) • Leaks between adjacent cylinders or into water DIAGNOSIS AND TESTING - CYLINDER jacket. COMPRESSION PRESSURE TEST • Any causes for combustion/compression pressure The results of a cylinder compression pressure test loss. can be utilized to diagnose several engine malfunc- tions.
Page 1034 ENGINE 3.5L 9 - 97 ENGINE 3.5L (Continued) specially designed black silicone rubber RTV that may be removed with a shop towel. Components retains adhesion sealing properties when should be torqued in place while the sealant is still exposed to engine oil. Moisture in the air causes the wet to the touch (within 10 minutes).
Page 1035 9 - 98 ENGINE 3.5L ENGINE 3.5L (Continued) (8) Install new spark plugs. (9) Drain engine oil and remove oil filter. (10) Install a new oil filter. (11) Fill engine with specified amount of approved oil. (12) Connect negative battery cable. (13) Start engine and check for any leaks.
Page 1036 ENGINE 3.5L 9 - 99 ENGINE 3.5L (Continued) STANDARD PROCEDURE - MEASURING REMOVAL - ENGINE ASSEMBLY BEARING CLEARANCE USING PLASTIGAGE (1) Release fuel pressure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCE- Engine crankshaft bearing clearances can be deter- DURE) mined by use of Plastigage or equivalent.
Page 1037 9 - 100 ENGINE 3.5L ENGINE 3.5L (Continued) (26) Disconnect coolant hoses at coolant recovery/ pressure container. (27) Disconnect all vacuum hoses. (28) Disconnect ground straps at both cylinder heads. CAUTION: Upper Intake manifold is a composite design. Therefore, manifold should be removed before lifting engine or damage to the manifold could occur.
Page 1038 ENGINE 3.5L 9 - 101 ENGINE 3.5L (Continued) (4) Remove engine lifting device. (27) Install new V-Band clamp at right exhaust (5) Raise vehicle. manifold. Tighten V-Band clamp to 11 N·m (100 in. (6) Tighten engine mount fastener to 61 N·m (45 lbs.).
Page 1039 9 - 102 ENGINE 3.5L ENGINE 3.5L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Clearance in Rod 0.007–0.018 mm 3.5L ENGINE (0.0003–0.007 in.) DESCRIPTION SPECIFICATION Diameter 23.997–24.000 mm Type 60° SOHC V-6 24-Valve (0.9448–0.9449 in.) Displacement 3.5 Liters Piston Rings (214 Cubic Inches) Ring Gap—Top 0.20–0.36 mm Bore and Stroke...
Page 1040 ENGINE 3.5L 9 - 103 ENGINE 3.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Taper (Max.) 0.015 mm Valve Seat Runout (Max.) 0.051 mm (0.0006 in) (0.002 in.) End Play 0.10–0.30 mm Valve Seat Width—Intake 0.75–1.25 mm (0.0295–0.0492 in.) (0.004–0.012 in.) Valve Seat Width— 1.25–1.75 mm —(Max.) 0.43 mm...
Page 1041 9 - 104 ENGINE 3.5L ENGINE 3.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valve Stem Tip 42.366–43.655 mm Wire Diameter—Exhaust 4.16–4.22 mm Height—Intake (1.6680–1.7187 in.) (0.1638–0.1661 in.) Valve Stem Tip 44.705–45.986 mm Spring Installed Height 38.0 mm Height—Exhaust (Spring Seat to Bottom of (1.760–1.8105 in.) Retainer)—Intake &...
Page 1042 ENGINE 3.5L 9 - 105 ENGINE 3.5L (Continued) TORQUE N·m DESCRIPTION Lbs. Lbs. N·m Engine Mount Isolator—Nuts — DESCRIPTION Lbs. Lbs. Generator Bracket—Bolts — A/C Compressor Bracket to — Intake Manifold Engine—Bolts —M6 Bolts — A/C Compressor to Bracket — —M8 Bolts —...
Page 1043 9 - 106 ENGINE 3.5L ENGINE 3.5L (Continued) SPECIAL TOOLS 3.5L ENGINE Crankshaft Sprocket Puller L-4407A Puller Damper 1023 Crankshaft Seal Remover Crankshaft Damper Remover Insert C-4685-C2 Crankshaft Seal Installer 6342 Crankshaft Damper/Sprocket Installer Bolt C-4685-C1 Crankshaft Sprocket Installer 6641 Crankshaft Sprocket Installer 6641 Camshaft Alignment 6642 Crankshaft Damper Holder 8191...
Page 1044 ENGINE 3.5L 9 - 107 ENGINE 3.5L (Continued) Camshaft Seal Protector 6788 Valve Spring Adapter 6526 Valve Spring Tester C-647 Camshaft Seal Remover C-3981B Valve Spring Compressor MD-998772-A Camshaft Seal Installer 6052 Valve Spring Adapter 6527 Dial Indicator C-3339 Valve Spring Compressor C-3422-D Indicator Bore Size C-119...
Page 1045 9 - 108 ENGINE 3.5L ENGINE 3.5L (Continued) Main Bearing Remover/Installer C-3059 Release Probe 8351 Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Pressure Gauge C-3292 Adapter 8406 Driver Handle C-4171 DRBIII with PEP Module – OT-CH6010A Crankshaft Rear Seal Retainer Alignment Fixture 8225...
Page 1046 ENGINE 3.5L 9 - 109 ENGINE 3.5L (Continued) Pressure Transducer CH7059 Fig. 9 Air Cleaner Housing and Element 1 - AIR FILTER ELEMENT CYLINDER HEAD Adaptor 8116 DESCRIPTION The aluminum alloy cylinder heads feature cross- flow type intake and exhaust ports. Valve guides and seat inserts are powdered metal.
Page 1047 9 - 110 ENGINE 3.5L CYLINDER HEAD (Continued) CYLINDER-TO-CYLINDER LEAKAGE TEST (5) Remove front timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN To determine if an engine cylinder head gasket is COVER(S) - REMOVAL) leaking between adjacent cylinders, follow the proce- (6) Remove camshaft sprockets.
Page 1048 ENGINE 3.5L 9 - 111 CYLINDER HEAD (Continued) Fig. 11 Right Side Timing Belt Cover Water Pump O-Rings Fig. 12 Checking Cylinder Head Flatness 1 - O-RINGS 2 - WATER PUMP IMPELLER NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCE- DURE).
Page 1049 9 - 112 ENGINE 3.5L CYLINDER HEAD (Continued) (8) Install rear timing belt covers (Fig. 10) and (Fig. 11). Tighten bolts to specified torque: • M10—54 N·m (40 ft. lbs.) • M8—28 N·m (20 ft. lbs.) • M6—12 N·m (105 in. lbs.) (9) Install camshaft sprockets and timing belt.
Page 1050 ENGINE 3.5L 9 - 113 CAMSHAFT OIL SEAL(S) (Continued) INSTALLATION CAMSHAFT(S) (1) Apply light coat of engine oil to the camshaft DESCRIPTION oil seal lip. (2) Install the oil seal using Special Tool 6788 Seal A single overhead camshaft per cylinder head pro- Protector Sleeve (Fig.
Page 1051 9 - 114 ENGINE 3.5L CAMSHAFT(S) (Continued) REMOVAL INSPECTION Camshafts are removed from the rear of each cyl- (1) Inspect camshaft bearing journals for damage inder head. The cylinder head must be removed. and binding (Fig. 21). If journals are binding, check (1) Remove camshaft sprocket(s).
Page 1052 ENGINE 3.5L 9 - 115 CYLINDER HEAD COVER(S) REMOVAL WARNING: DO NOT START OR RUN ENGINE WITH CYLINDER HEAD COVER REMOVED FROM THE ENGINE. DAMAGE OR PERSONAL INJURY MAY OCCUR. (1) Remove air cleaner assembly. (2) Remove upper intake manifold. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL)
Page 1053 9 - 116 ENGINE 3.5L CYLINDER HEAD COVER(S) (Continued) OPERATION The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the com- bustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes.
Page 1054 ENGINE 3.5L 9 - 117 INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 28 Valve Face and Seat 1 - SEAT WIDTH 2 - FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA the bottom edge of valve face, then raise valve seat Fig.
Page 1055 9 - 118 ENGINE 3.5L INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 32 Intake and Exhaust Valves 1 - MARGIN 2 - FACE 3 - STEM 4 - VALVE SPRING RETAINER LOCK GROOVES Fig. 31 Valve Seal and Spring - Installation 1 - VALVE 2 - VALVE RETAINING LOCKS 3 - VALVE SPRING RETAINER...
Page 1056 ENGINE 3.5L 9 - 119 INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 34 Checking Valve Tip Height and Valve Spring Installed Height 1 - SPRING RETAINER 2 - GARTER SPRING 3 - VALVE SPRING SEAT TOP 4 - CYLINDER HEAD SURFACE Fig.
Page 1057 9 - 120 ENGINE 3.5L ROCKER ARM / ADJUSTER ASSEMBLY (Continued) POSSIBLE NOISE SOURCES POSSIBLE NOISE MISDIAGNOSIS SOURCES Spongy/soft/aerated lash adjusters. SRV valve axle chatter. Missing lash adjuster swivel contact pads. Exhaust rocker arm-to-cylinder head cover contact. Intake rocker-to-camshaft bearing journal contact. Piston pin bore fit.
Page 1058 ENGINE 3.5L 9 - 121 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) STANDARD PROCEDURE - HYDRAULIC LASH (e) Remove probes to allow check balls to seat. (f) Recheck for sponginess. If the lash adjuster ADJUSTER BLEEDING sponginess is not completely or nearly eliminated, Use this procedure to manually bleed aerated oil then repeat procedure.
Page 1059 9 - 122 ENGINE 3.5L ROCKER ARM / ADJUSTER ASSEMBLY (Continued) Fig. 40 Rocker Arms and Shaft - Disassembly 1 - 4mm SCREW AND NUT 2 - 4mm SCREW AND NUT 3 - WASHER 4 - SPACER Fig. 38 Purging Air From Lash Adjuster 5 - DOWEL 1 - SPECIAL TOOL 8351 6 - DOWEL...
Page 1060 ENGINE 3.5L 9 - 123 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly (Fig. 41). Check rocker arms for wear or damage (Fig. 42): • Roller scuffing or wear •...
Page 1061 9 - 124 ENGINE 3.5L ROCKER ARM / ADJUSTER ASSEMBLY (Continued) (3) For spark plug tube seal replacement, (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (4) Install cylinder head cover(s). (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) VALVE STEM SEALS REMOVAL...
Page 1062 ENGINE 3.5L 9 - 125 VALVE STEM SEALS (Continued) OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. REMOVAL REMOVAL - CYLINDER HEAD OFF (1) Using Special Tool C-3422–D (valve spring compressor) with Adapter 6526 compress valve spring and remove valve retaining locks.
Page 1063 9 - 126 ENGINE 3.5L VALVE SPRINGS (Continued) INSPECTION counterbore under the valve spring seat to bring spring height back within specification. When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 50). As an example; the compression length of the spring to be tested is 38.00 mm (1.496 in.).
Page 1064 ENGINE 3.5L 9 - 127 VALVE SPRINGS (Continued) INSTALLATION - CYLINDER HEAD ON ENGINE BLOCK (1) Compress valve spring using Special Tool MD DESCRIPTION 998772A with Adaptor 6527 only enough to install retainer and locks. The cylinder block (Fig. 53) is made of heat treated (2) After installing locks, release tension on valve aluminum with cast-in-place iron liners.
Page 1065 9 - 128 ENGINE 3.5L ENGINE BLOCK (Continued) (2) Deglazing of the cylinder walls may be done CLEANING using a cylinder surfacing hone, recommended tool Clean cylinder block thoroughly using a suitable C-3501 or equivalent, equipped with 280 grit stones, cleaning solvent.
Page 1066 ENGINE 3.5L 9 - 129 CONNECTING ROD BOLTS CONNECTING ROD BEARINGS (1) Examine connecting rod bolts for stretching. Stretching can be checked by holding a scale or STANDARD PROCEDURE - CONNECTING RODS straight edge against the threads. If all the threads AND BEARINGS do not contact the scale the bolt must be replaced.
Page 1067 9 - 130 ENGINE 3.5L REMOVAL CRANKSHAFT (1) Remove engine from vehicle. (Refer to 9 - DESCRIPTION ENGINE - REMOVAL) (2) Remove oil pan. (Refer to 9 - ENGINE/LUBRI- The crankshaft (Fig. 53) is constructed of a forged CATION/OIL PAN - REMOVAL) micro alloy steel.
Page 1068 ENGINE 3.5L 9 - 131 CRANKSHAFT (Continued) INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.015 mm (0.0006 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter.
Page 1069 9 - 132 ENGINE 3.5L CRANKSHAFT (Continued) INSTALLATION CAUTION: Main bearings are select fit. (Refer to 9 - ENGINE/ENGINE BLOCK/CONNECTING ROD BEAR- INGS - STANDARD PROCEDURE) (1) Install crankshaft main bearings (Fig. 63). (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK- SHAFT MAIN BEARINGS - STANDARD PROCE- DURE) Fig.
Page 1070 ENGINE 3.5L 9 - 133 CRANKSHAFT (Continued) (20) Install oil pickup tube and tighten bolt to 28 N·m (250 in. lbs.). (21) Install oil pan. (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - INSTALLATION) (22) Install engine assembly. (Refer to 9 - ENGINE - INSTALLATION) (23) Fill engine crankcase with proper amount of oil.
Page 1071 9 - 134 ENGINE 3.5L CRANKSHAFT MAIN BEARINGS (Continued) REMOVAL Bearing caps are not interchangeable and are marked to insure correct assembly (Fig. 68). Upper and lower bearing halves are NOT interchangeable. (1) Remove oil pan. (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL) (2) Remove oil pick-up tube and windage tray.
Page 1072 ENGINE 3.5L 9 - 135 CRANKSHAFT MAIN BEARINGS (Continued) INSTALLATION (b) Move crankshaft rearward to limit of travel. Lubricate and install the rear thrust washer by Bearing caps are not interchangeable and are rolling the washer onto the machined shelf marked to insure correct assembly.
Page 1073 9 - 136 ENGINE 3.5L CRANKSHAFT OIL SEAL - FRONT REMOVAL (1) Remove the crankshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (2) Tap the dowel pin out of the crankshaft (Fig. 72). Fig. 73 REMOVING CRANKSHAFT OIL SEAL WITH SPECIAL TOOL 1 - SPECIAL TOOL 6341A Fig.
Page 1074 ENGINE 3.5L 9 - 137 INSTALLATION CRANKSHAFT OIL SEAL - REAR CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), clean surface using 400 REMOVAL grit sand paper to prevent seal damage during (1) Remove transaxle from vehicle. (Refer to 21 - installation.
Page 1075 9 - 138 ENGINE 3.5L (4) While applying firm pressure to the seal CRANKSHAFT REAR OIL SEAL retainer against Special Tools 8225 (Fig. 78), tighten RETAINER seal retainer screws to 12 N·m (105 in. lbs.). REMOVAL (1) Remove crankshaft rear oil seal. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT SEAL - REAR - REMOVAL)
Page 1076 ENGINE 3.5L 9 - 139 STANDARD PROCEDURE - FITTING PISTONS FLEX PLATE The pistons are machined to two different weight REMOVAL specifications and matched to rods based on weight. All piston and rod assemblies weigh the same to (1) Remove the transaxle. (Refer to 21 - TRANS- maintain engine balance.
Page 1077 9 - 140 ENGINE 3.5L PISTON & CONNECTING ROD (Continued) Fig. 83 Check for Stretched Bolts Fig. 81 Connecting Rod to Cylinder Identification 1 - STRETCHED BOLT 1 - CYLINDER NUMBER 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT (3) Before installing pistons and connecting rod assemblies into the bore, ensure that compression...
Page 1078 ENGINE 3.5L 9 - 141 PISTON & CONNECTING ROD (Continued) (4) Immerse the piston head and rings in clean (7) The arrow on top of piston must be pointing engine oil, slide the ring compressor over the piston toward front of engine (Fig. 86) and oil squirt hole on and tighten with the special wrench (Fig.
Page 1079 9 - 142 ENGINE 3.5L PISTON & CONNECTING ROD (Continued) Fig. 87 Piston and Connecting Rod Positioning (Front View of Engine) 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING (1) Wipe cylinder bore clean.
Page 1080 ENGINE 3.5L 9 - 143 PISTON RINGS (Continued) Fig. 89 Measuring Piston Ring Side Clearance 1 - FEELER GAUGE Fig. 90 PISTON RING - INSTALLATION (2) Remove No. 1 and No.2 piston rings from pis- 1 - SIDE RAIL ton using a ring expander tool (Fig. 92). 2 - SPACER EXPANDER (3) Remove upper oil ring side rail (Fig.
Page 1081 9 - 144 ENGINE 3.5L PISTON RINGS (Continued) STRUCTURAL COLLAR / COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove bolts attaching structural collar to oil pan and transmission housing (Fig. 94). (3) Remove collar (Fig. 94). Fig. 92 UPPER AND INTERMEDIATE RINGS (5) Install No.
Page 1082 ENGINE 3.5L 9 - 145 VIBRATION DAMPER REMOVAL (1) Disconnect negative cable at right strut tower. (2) Remove upper radiator crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REIN- FORCEMENT - REMOVAL) (3) Remove radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL) (4) Remove the accessory drive belts.
Page 1083 9 - 146 ENGINE 3.5L (2) Remove the isolator attaching nuts from top of ENGINE MOUNTING the mounting bracket (Fig. 98). (3) Support the engine with a jack and a block of DESCRIPTION wood across the full width of the oil pan. The engine mounting system consist of three (4) Remove the lower attaching nuts from the bot- mounts;...
Page 1084 ENGINE 3.5L 9 - 147 (2) Remove the isolator attaching nuts from top of REAR MOUNT the mounting bracket (Fig. 99). (3) Support the engine with a jack and a block of REMOVAL wood across the full width of the oil pan. (1) Raise vehicle on hoist.
Page 1085 9 - 148 ENGINE 3.5L through each cylinder heads oil passage to the rocker LUBRICATION shafts. Oil then feeds the camshaft journals, rocker arms, and hydraulic lash adjusters (Fig. 100). DESCRIPTION System is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. DIAGNOSIS AND TESTING The pump inner rotor is driven by the crankshaft.
Page 1086 ENGINE 3.5L 9 - 149 LUBRICATION (Continued) make sure the dye is thoroughly mixed as indicated If the leakage occurs at the crankshaft rear oil seal with a bright yellow color under a black light. area: (3) Using a black light, inspect the entire engine (1) Disconnect the battery.
Page 1087 9 - 150 ENGINE 3.5L LUBRICATION (Continued) (5) If oil pressure is 0 at idle. Shut off engine, WARNING: NEW OR USED ENGINE OIL CAN BE check for pressure relief valve stuck open or a IRRITATING TO THE SKIN. AVOID PROLONGED OR clogged oil pickup screen.
Page 1088 ENGINE 3.5L 9 - 151 REMOVAL OIL COOLER & LINES ENGINE OIL COOLER DESCRIPTION (1) The engine oil cooler is serviced with the radi- Vehicles equipped with the Heavy Duty Cooling ator (Refer to 7 - COOLING/ENGINE/RADIATOR - option (Sales Code NMC) or Severe Duty Cooling REMOVAL).
Page 1089: Oil Filter
9 - 152 ENGINE 3.5L OIL COOLER & LINES (Continued) INSTALLATION ENGINE OIL COOLER (1) Install radiator assembly (Refer to 7 - COOL- ING/ENGINE/RADIATOR INSTALLATION). Tighten lines to radiator fittings to 18 N·m (160 in. lbs.) (Fig. 102). COOLER LINES (1) Position cooler lines and connect lines to radia- tor fittings.
Page 1090 ENGINE 3.5L 9 - 153 OIL PAN (Continued) (5) Disconnect engine oil cooler line from pan. (6) Disconnect transmission oil cooler line clips. (7) Remove oil pan (Fig. 105). (8) Remove oil pan gasket. (9) Clean oil pan and all gasket surfaces. INSTALLATION (1) Apply a 1/8 inch bead of Mopar Engine RTV GEN II at the parting line of the oil pump housing...
Page 1091 9 - 154 ENGINE 3.5L OIL PAN (Continued) Fig. 107 Oil Pressure Relief Valve Fig. 106 OIL PAN SEALING 1 - RELIEF VALVE (5) Lower vehicle and install dipstick and tube. 2 - SPRING (6) Fill engine crankcase with proper oil to correct 3 - RETAINER CAP level.
Page 1092 ENGINE 3.5L 9 - 155 OIL PRESSURE SWITCH (Continued) (5) Unscrew oil pressure switch from fitting (Fig. (4) Remove the timing belt. (Refer to 9 - ENGINE/ 108). VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL) (5) Remove the crankshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN...
Page 1093 9 - 156 ENGINE 3.5L OIL PUMP (Continued) Fig. 112 Checking Oil Pump Cover Flatness Fig. 110 Oil Pressure Relief Valve 1 - STRAIGHT EDGE 1 - RELIEF VALVE 2 - FEELER GAUGE 2 - SPRING 3 - OIL PUMP COVER 3 - RETAINER CAP 4 - COTTER PIN Fig.
Page 1094 ENGINE 3.5L 9 - 157 OIL PUMP (Continued) Fig. 117 Measuring Clearance Over Rotors Fig. 115 Measuring Outer Rotor Clearance in Housing 1 - STRAIGHT EDGE 2 - FEELER GAUGES 1 - FEELER GAUGE 2 - OUTER ROTOR (9) Inspect oil pressure relief valve plunger for scoring and free operation in its bore.
Page 1095 9 - 158 ENGINE 3.5L OIL PUMP (Continued) ASSEMBLY INTAKE MANIFOLD (1) Assemble pump using parts DESCRIPTION required. (2) Tighten cover screws to 12 N·m (105 in. lbs.) The composite upper intake manifold is a cross- (Fig. 111). flow type with long runners to improve air charge (3) Prime oil pump before installation by filling inertia (Fig.
Page 1096 ENGINE 3.5L 9 - 159 INTAKE MANIFOLD (Continued) Fig. 120 LOWER INTAKE MANIFOLD 1 - BOLT 6 - GASKET 2 - HEATER SUPPLY TUBE 7 - BOLT 3 - BOLT 8 - O-RING 4 - BOLT 9 - INTAKE MANIFOLD-LOWER 5 - KNOCK SENSOR DIAGNOSIS AND TESTING - INTAKE INTAKE MANIFOLD - UPPER...
Page 1097 9 - 160 ENGINE 3.5L INTAKE MANIFOLD - UPPER (Continued) Fig. 123 INTAKE MANIFOLD SUPPORT - LEFT 1 - SUPPORT BRACKET (7) Remove support brackets at intake manifold front corners and at MTV (Fig. 124). Fig. 121 AIR CLEANER WITH INLET HOSE 1 - AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 - THROTTLE BODY •...
Page 1098 ENGINE 3.5L 9 - 161 INTAKE MANIFOLD - UPPER (Continued) Fig. 126 UPPER INTAKE MANIFOLD TIGHTENING (9) Connect electrical connectors to the following: • Short Runner Valve (SRV)(If Equipped) • Manifold Tuning Valve (MTV)(If Equipped) • Throttle Position Sensor (TPS) •...
Page 1099 9 - 162 ENGINE 3.5L INTAKE MANIFOLD - LOWER (Continued) (6) Disconnect heater and coolant bottle supply INSPECTION hoses from coolant tube at rear of intake manifold Check manifold for: (Fig. 127). • Damage and cracks • Gasket surface damage or warpage •...
Page 1100 ENGINE 3.5L 9 - 163 INTAKE MANIFOLD - LOWER (Continued) Fig. 128 LOWER INTAKE MANIFOLD 1 - BOLT 6 - GASKET 2 - HEATER SUPPLY TUBE 7 - BOLT 3 - BOLT 8 - O-RING 4 - BOLT 9 - INTAKE MANIFOLD-LOWER 5 - KNOCK SENSOR...
Page 1101 9 - 164 ENGINE 3.5L INTAKE MANIFOLD - LOWER (Continued) EXHAUST MANIFOLD DESCRIPTION Both manifolds are a log style made of ductile cast iron (Fig. 130). The outlets are designed for V-Band clamp attachment of close coupled catalytic converters. Fig. 130 EXHAUST MANIFOLD 1 - BOLT - HEAT SHIELD 2 - HEAT SHIELD 3 - GASKET...
Page 1102 ENGINE 3.5L 9 - 165 INSPECTION EXHAUST MANIFOLD - RIGHT (1) Inspect exhaust manifolds for damage or REMOVAL cracks. (2) Check manifold flatness. (1) Disconnect negative cable from remote jumper (3) Inspect the exhaust manifold gasket for obvi- terminal. ous discoloration or distortion. (2) Raise vehicle on hoist.
Page 1103 9 - 166 ENGINE 3.5L EXHAUST MANIFOLD - LEFT (Continued) (7) Remove electrical connector harness bracket. INSTALLATION (8) Disconnect oxygen sensor electrical connector (1) Install the exhaust manifold and gasket. and remove sensor from manifold. Tighten bolts starting at the center working outward (9) Remove heat shield attaching bolts and remove to 23 N·m (200 in.
Page 1104 ENGINE 3.5L 9 - 167 VALVE TIMING (Continued) Fig. 133 TIMING DRIVE SYSTEM 1 - TIMING BELT COVER - RIGHT REAR 8 - BOLT-CRANKSHAFT DAMPER 2 - TENSIONER-TIMING BELT 9 - TIMING BELT COVER-LOWER 3 - CAMSHAFT SPROCKET 10 - TIMING BELT COVER-RIGHT 4 - BOLT-CAMSHAFT SPROCKET 11 - TIMING BELT COVER-LEFT 5 - TIMING BELT...
Page 1105 9 - 168 ENGINE 3.5L TIMING BELT COVER(S) - FRONT (Continued) Fig. 134 A/C BELT GUIDE/LIFT BRACKET Fig. 136 TIMING BELT COVER SEALER 1 - A/C BELT GUIDE/LIFT BRACKET 1 - SEALER 2 - NUT (5) Install the crankshaft vibration damper. (Refer (8) Remove the stamped steel cover (Fig.
Page 1106 ENGINE 3.5L 9 - 169 TIMING BELT COVER(S) - REAR (Continued) (3) Position NEW O-rings on cover (Fig. 139). Fig. 139 Right Side Timing Belt Cover O-Rings 1 - O-RINGS 2 - WATER PUMP IMPELLER (4) Install rear timing belt covers (Fig. 140) and Fig.
Page 1107 9 - 170 ENGINE 3.5L TIMING BELT COVER(S) - REAR (Continued) • M6—12 N·m (105 in. lbs.) TIMING BELT TENSIONER & PULLEY REMOVAL REMOVAL - TENSIONER PULLEY ASSEMBLY (1) Remove the timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL - TIMING BELT) (2) Remove the timing belt tensioner pulley and bracket assembly by unscrewing the pivot bolt from...
Page 1108 ENGINE 3.5L 9 - 171 TIMING BELT TENSIONER & PULLEY (Continued) INSTALLATION - TENSIONER (1) For timing belt tensioner installation procedure (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION - TIM- ING BELT). TIMING BELT AND SPROCKETS REMOVAL REMOVAL - TIMING BELT CAUTION: The following procedure can only be...
Page 1109 9 - 172 ENGINE 3.5L TIMING BELT AND SPROCKETS (Continued) CAUTION: Align the camshaft sprockets between the marks on rear belt covers before timing belt removal or damage to valve and/or pistons could occur. (9) Using a ink or paint marker; mark the exact position of the camshaft sprocket timing mark rela- tive to the two timing marks on the rear timing cover.
Page 1110 ENGINE 3.5L 9 - 173 TIMING BELT AND SPROCKETS (Continued) CAUTION: When camshaft sprocket bolts are loos- ened or removed, the camshafts must be re-timed to the engine. Also, the camshaft sprocket bolts must NOT be reused. (1) Remove front timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (2) Position crankshaft sprocket to the TDC mark...
Page 1111 9 - 174 ENGINE 3.5L TIMING BELT AND SPROCKETS (Continued) (8) Loosen and remove bolt and washer. To remove (h) Vehicle mileage or time at component main- the camshaft sprocket bolts with engine in the vehi- tenance requirement. (Refer to LUBRICATION & cle, it may be necessary to lift the engine to allow MAINTENANCE/MAINTENANCE SCHEDULES - bolt removal clearance.
Page 1112 ENGINE 3.5L 9 - 175 TIMING BELT AND SPROCKETS (Continued) (1) Align the crankshaft sprocket with the TDC (9) Install the accessory drive belts. (Refer to 7 - mark on oil pump cover (Fig. 152). COOLING/ACCESSORY DRIVE/DRIVE BELTS - (2) Align the camshaft sprockets (to reference INSTALLATION) mark made upon removal) between the marks on the (10) Instal the radiator fan.
Page 1113 9 - 176 ENGINE 3.5L TIMING BELT AND SPROCKETS (Continued) (7) Hold the camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the camshaft bolts to the following: • Right side = 102 N·m (75 ft. lbs.) +90° turn •...
Page 1114 ENGINE 3.5L 9 - 177 TIMING BELT AND SPROCKETS (Continued) (11) Install timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (12) Install crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) (13) Install accessory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (14) Fill cooling system.
Page 1116 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page EXHAUST SYSTEM INSPECTION ......7 DESCRIPTION .
Page 1117 11 - 2 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) Fig. 1 Exhaust System 1 - V-BAND CLAMPS 5 - MUFFLER 2 - BAND CLAMPS 6 - BAND CLAMP 3 - FRONT RESONATOR 7 - LEFT REAR RESONATOR/PIPE ASSEMBLY 4 - INTERMEDIATE PIPE 8 - CATALYTIC CONVERTERS Fig.
Page 1118 EXHAUST SYSTEM 11 - 3 EXHAUST SYSTEM (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - EXHAUST SYSTEM CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE EXHAUST NOISE 1. Exhaust manifold cracked or 1. Replace manifold. (UNDER HOOD) broken. 2. Manifold to cylinder head leak. 2.
Page 1119 11 - 4 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) (7) If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic converter inspection procedures, (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - INSPECTION). Replace component(s) as necessary. EXHAUST BACK PRESSURE LIMITS Exhaust Back Pressure Limit (Max) Vehicle in Park/Neutral 3.45 Kpa (0.5 psi)
Page 1120 EXHAUST SYSTEM 11 - 5 EXHAUST SYSTEM (Continued) Fig. 4 Exhaust System Supports 1 - SUPPORTS 3 - ISOLATORS 2 - MUFFLER component to maintain position and proper clearance SPECIFICATIONS with underbody parts. (6) Tighten band clamps to 61 N·m (45 ft. lbs.). TORQUE (7) Lower the vehicle.
Page 1121 11 - 6 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) SPECIAL TOOLS EXHAUST SYSTEM DRB III & PEP Module - OT-CH6010A Fig. 5 Catalytic Converters 1 - V-BAND CLAMPS 2 - BAND CLAMP 3 - EXTENSION PIPE 4 - CATALYTIC CONVERTERS verted into water (H2O) and carbon dioxide (CO2). Oxides of Nitrogen (NOx) are converted into elemen- tal Nitrogen (N) and water.
Page 1122 EXHAUST SYSTEM 11 - 7 CATALYTIC CONVERTER(S) (Continued) deterioration of the catalyst core can result in exces- CATALYTIC CONVERTER - sively high emission levels, noise complaints, and RIGHT exhaust restrictions. The use of catalysts also involves some non-auto- REMOVAL - RIGHT SIDE motive problems.
Page 1123 11 - 8 EXHAUST SYSTEM CATALYTIC CONVERTER - RIGHT (Continued) (8) Remove SRV (Short Runner Valve) vacuum res- CATALYTIC CONVERTER - ervoir and control valve assembly at right rear of LEFT engine (3.5L engine only). (9) Disconnect downstream oxygen sensor connec- REMOVAL - LEFT SIDE tor and remove sensor from converter pipe (Refer to (1) Loosen and remove V-Band clamp at exhaust...
Page 1124 EXHAUST SYSTEM 11 - 9 HEAT SHIELDS (Continued) CAUTION: Avoid application of rust prevention com- INSTALLATION pounds or undercoating materials to exhaust sys- (1) Install the left rear resonator/pipe assembly tem heat shields on cars if equipped. Light over onto the muffler/front resonator assembly and loose spray near the edges is permitted.
Page 1126 FRAME & BUMPERS 13 - 1 FRAME & BUMPERS TABLE OF CONTENTS page page FRONT BUMPER REINFORCEMENT SPECIFICATIONS - TORQUE ... . . 9 REMOVAL ......1 ENGINE CRADLE CROSSMEMBER INSTALLATION .
Page 1127 13 - 2 FRAME & BUMPERS FRONT FASCIA REMOVAL REMOVAL (1) Release hood latch and open hood. (2) Remove large rubber grommet (70 mm x 168 mm) from splash shield to gain access to fascia fas- teners (Fig. 2). (3) Remove fasteners attaching fascia to the front fender and splash shield.
Page 1128: Rear Bumper
FRAME & BUMPERS 13 - 3 FRONT FASCIA (Continued) Fig. 7 FRONT BUMPER FASCIA Fig. 5 FRONT BUMPER FASCIA 1 - FRONT FASCIA 1 - BODY & FASCIA WIRE CONNECTORS 2 - FOG LAMP CONNECTORS 2 - FRONT FASCIA 3 - FRONT FENDER 4 - PUSH PIN FASTENER (5) Install fasteners attaching fascia to splash shields.
Page 1129 13 - 4 FRAME & BUMPERS REAR BUMPER (Continued) INSTALLATION (5) Pull fascia rearward to expose license plate lamp wire connector. Disconnect wire harness connector. The (1) Place reinforcement in position on rear of vehicle. connector is located on the left side of vehicle. (2) Install bracket to rails attaching bolts and nuts.
Page 1130 FRAME & BUMPERS 13 - 5 dimensions are from center to center of Principal FRAME Locating Point (PLP), or from center to center of PLP and fastener location. Vertical dimensions can be SPECIFICATIONS taken from the work surface to the locations indi- cated.
Page 1131 13 - 6 FRAME & BUMPERS FRAME (Continued) Fig. 11 ENGINE COMPARTMENT TOP VIEW Fig. 12 ENGINE COMPARTMENT SIDE VIEW...
Page 1132 FRAME & BUMPERS 13 - 7 FRAME (Continued)
Page 1133 13 - 8 FRAME & BUMPERS FRAME (Continued) Fig. 14 REAR FRAME SECTION...
Page 1134 FRAME & BUMPERS 13 - 9 FRAME (Continued) SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Lbs. Lbs. Rear bumber reinforcement — attaching nut Front suspension crossmember — front attaching bolt Front suspension crossmember — rear attaching bolt Radiator support crossmember —...
Page 1135 13 - 10 FRAME & BUMPERS FRONT TOW EYE REMOVAL (1) Unthread the front tow eye from the tow eye bracket (Fig. 16). Fig. 17 FRONT TOW EYE INSTALLATION 1 - NO SPACE 2 - TOW EYE INSTALLATION (1) Install the front tow eye bracket and fasteners. Torque bolts to 23 to 34 N·m (Fig.
Page 1136 FRAME & BUMPERS 13 - 11 REAR CROSSMEMBER (Continued) Fig. 18 REAR SUSPENSION CROSSMEMBER 1 - LATERAL LINKS 3 - LATERAL LINKS 2 - REAR CROSSMEMBER ISOLATOR BUSHINGS REMOVAL (1) Open the fuel filler door. Remove the 3 fuel filler neck attaching screws. Remove the fuel filler cap.
Page 1137 13 - 12 FRAME & BUMPERS REAR CROSSMEMBER (Continued) Remove the 4 bolts attaching both stabilizer bar isolator bushing retainers to the frame rails (the 2 rearward attaching bolts also attach the front cor- ners of the rear suspension crossmember in place). Allow the stabilizer bar to hang down.
Page 1138 FRAME & BUMPERS 13 - 13 REAR CROSSMEMBER (Continued) (3) Install Remover/Installer, Special Tool 8173–2, (5) Install Special Tool 8173–4 in the cup, Special on end of the threaded push rod on Special Tool Tool 8173–1 (Fig. 23). Install cup, Special Tool C-4212F.
Page 1139 13 - 14 FRAME & BUMPERS REAR CROSSMEMBER (Continued) attaching the rear of the crossmember to the frame rails. Raise the exhaust into place. Reattach the 3 exhaust hangers previously removed from the muf- fler and resonator. (7) Remove transmission jack supporting muffler and exhaust system.
Page 1140 FRAME & BUMPERS 13 - 15 REAR CROSSMEMBER (Continued) CAUTION: Tightening the lateral link attaching bolts at this time will cause the bushings contort at curb riding height, leading to premature failure of the bushings. Tighten bolts only when vehicle is at curb riding height.
Page 1142 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY ......1 FUEL INJECTION .
Page 1143: Fuel Delivery
14 - 2 FUEL DELIVERY STANDARD PROCEDURE - DRAINING FUEL FUEL DELIVERY TANK DESCRIPTION Two different procedures may be used to drain fuel The front wheel drive car uses a plastic fuel tank tank (lowering tank or using DRB scan tool). located rear center of the vehicle.
Page 1144 FUEL DELIVERY 14 - 3 FUEL DELIVERY (Continued) (10) Remove filler tube from fuel tank. Tank will IGNITION SOURCE IS PRESENT. NEVER DRAIN OR be drained through this fitting. STORE GASOLINE OR DIESEL FUEL IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF FIRE WARNING: WRAP SHOP TOWELS AROUND HOSES OR EXPLOSION.
Page 1145 14 - 4 FUEL DELIVERY FUEL DELIVERY (Continued) FUEL LEVEL SENDING UNIT / SENSOR DESCRIPTION The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a vari- able resistor. OPERATION Its resistance changes with the amount of fuel in Fuel Line Adapter 1/4 the tank.
Page 1146 FUEL DELIVERY 14 - 5 FUEL LEVEL SENDING UNIT / SENSOR (Continued) (2) Remove wire terminal retaining clip from con- nector (Fig. 2). Note the location of terminals for the level sensor wires (Fig. 3). Fig. 4 Level Sensor Signal 1 - LEVEL SENSOR GROUND 2 - LEVEL SENSOR SIGNAL Fig.
Page 1147: Fuel Lines
14 - 6 FUEL DELIVERY FUEL LEVEL SENDING UNIT / SENSOR (Continued) INSTALLATION The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the (1) Insert level sensor wires in bottom of stand- higher fuel pressures and the possibility of contami- pipe.
Page 1148: Fuel Pressure Regulator
FUEL DELIVERY 14 - 7 through the pressure regulator. A separate fuel FUEL PRESSURE REGULATOR return line is not used with any gas powered engine. DESCRIPTION A combination fuel filter and fuel pressure regula- tor is used on all gas powered engines. It is located on the top of the fuel pump module.
Page 1149: Fuel Pump
(14) Fill fuel tank. Use the DRB III scan tool to OPERATION pressurize the fuel system. Check for leaks. The Chrysler fuel pump modul is an in-tank unit with an integral fuel level sensor and pressure regu- FUEL PUMP lator (Fig. 12). The pump is driven by a 12 volt DC motor any time the fuel pump relay is energized.
Page 1150 FUEL DELIVERY 14 - 9 FUEL PUMP MODULE (Continued) fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess pressure and fuel to vent into the tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The regulator adjusts fuel system pressure to approximately 400 ±34 kPa (58 ±...
Page 1151: Fuel Rail
14 - 10 FUEL DELIVERY FUEL PUMP MODULE (Continued) (3) Position the locknut over the fuel pump mod- manifold to prevent foreign material from entering ule. engine. (4) Tighten the locknut using Special Tool #6856 to (5) Disconnect fuel supply tube quick connect fit- 55 N·m (40.5 ft.
Page 1152: Fuel Tank
FUEL DELIVERY 14 - 11 FUEL RAIL (Continued) (7) Install intake manifold plenum. Refer to the are equipped with a self-diagnosing system using a Engine section for information. Natural Vacuum Leak Detection (NVLD). Refer to (8) Connect negative cable to battery. the Emission Control System for additional informa- tion.
Page 1153 14 - 12 FUEL DELIVERY FUEL TANK (Continued) (4) Disconnect fuel pump electrical connector (Fig. (7) Loosen the rear stabilizer bar brackets from 17). body. Swing stabilizer bar toward rear of vehicle (Fig. 19) and (Fig. 20). Fig. 17 Electrical Connector Fig.
Page 1154 FUEL DELIVERY 14 - 13 FUEL TANK (Continued) (8) Disconnect fuel and EVAP lines (Fig. 21). Fig. 23 HARNESS ON TANK PIN 1 - Pin 2 - Wiring Harness Fig. 21 Fuel and EVAP Lines (14) Remove wiring harness from body. (15) Remove NVLD filter from mounting location.
Page 1155 14 - 14 FUEL DELIVERY FUEL TANK (Continued) (9) Lower vehicle. INLET FILTER (10) Connect the fuel pump electrical connector that is under the rear seat (Fig. 17). REMOVAL (11) Install the rear seat, refer to the Body section (1) Remove fuel pump module. Refer to Fuel Pump for more information.
Page 1156 FUEL DELIVERY 14 - 15 QUICK CONNECT FITTING STANDARD PROCEDURE - QUICK-CONNECT FITTINGS REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FIT- TINGS. REFER TO THE FUEL PRESSURE RELEASE Fig.
Page 1157 14 - 16 FUEL DELIVERY QUICK CONNECT FITTING (Continued) WARNING: THE FUEL SYSTEM IS UNDER A CON- PLASTIC RETAINER RING TYPE FITTING STANT PRESSURE (EVEN WITH THE ENGINE OFF). This type of fitting can be identified by the use of a BEFORE SERVICING ANY FUEL SYSTEM HOSES, full-round plastic retainer ring (Fig.
Page 1158 FUEL DELIVERY 14 - 17 QUICK CONNECT FITTING (Continued) DISCONNECTION/CONNECTION (5) After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. (1) Perform fuel pressure release procedure. Refer (6) Inspect fitting connector body, plastic retainer to Fuel Pressure Release Procedure in this section. ring and fuel system component for damage.
Page 1159 14 - 18 FUEL INJECTION FUEL INJECTION TABLE OF CONTENTS page page FUEL INJECTION INSTALLATION ......30 OPERATION MANIFOLD TUNE VALVE OPERATION - INJECTION SYSTEM...
Page 1160 FUEL INJECTION 14 - 19 sensor diagnostics (they are checked for shorted con- FUEL INJECTION ditions at all times). During CLOSED LOOP modes the PCM monitors OPERATION the inputs from the upstream and downstream heated oxygen sensors. The upstream heated oxygen OPERATION - INJECTION SYSTEM sensor input tells the PCM if the calculated injector pulse width resulted in the ideal air-fuel ratio of 14.7...
Page 1161 14 - 20 FUEL INJECTION FUEL INJECTION (Continued) • Knock sensor 1 second. Therefore, battery voltage is not supplied to • Throttle position the fuel pump, ignition coil, fuel injectors and heated • A/C switch oxygen sensors. • Battery voltage ENGINE START-UP MODE •...
Page 1162 FUEL INJECTION 14 - 21 FUEL INJECTION (Continued) • Engine coolant temperature The PCM compares the upstream and downstream • Engine speed heated oxygen sensor inputs to measure catalytic • Knock sensor convertor efficiency. If the catalyst efficiency drops • Manifold absolute pressure below the minimum acceptable percentage, the PCM •...
Page 1163 14 - 22 FUEL INJECTION FUEL INJECTION (Continued) authority for short term memory is 25% (+/-) of base used. Because the goal is to keep short term at 0 (O2 pulse-width. Short term is violated and is lost when Sensor switching at 0.5 volt), long term will update ignition is turned OFF.
Page 1164 FUEL INJECTION 14 - 23 FUEL INJECTION (Continued) • Transmission Control Module TROL MODULES/POWERTRAIN CONTROL MOD- • Powertrain Control Module ULE - DESCRIPTION). • Travel Module • SKIM TORQUE MANAGEMENT SYSTEM DIAGNOSIS OPERATION The PCM receives the torque management input OPERATION from the transmission control module.
Page 1165: Accelerator Pedal
14 - 24 FUEL INJECTION FUEL INJECTION (Continued) SPECIAL TOOLS FUEL O2S (Oxygen Sensor) Remover/Installer—C-4907 Pressure Gauge Assembly C–4799–B O2S(Oxygen Sensor) Remover/Installer - 8439 ACCELERATOR PEDAL REMOVAL (1) Working from the engine compartment, hold the throttle body throttle lever in the wide open posi- tion.
Page 1166 FUEL INJECTION 14 - 25 ACCELERATOR PEDAL (Continued) Fig. 4 CARPET AND INSULATION PLACEMENT 1 - PEDAL BASE 2 - CARPET 3 - INSULATION Fig. 2 RETAINER CLIP 4 - FLOOR PAN (3) Working from the passenger compartment, remove nuts from accelerator pedal base (Fig. 3). CRANKSHAFT POSITION Remove pedal and base from vehicle.
Page 1167 14 - 26 FUEL INJECTION CRANKSHAFT POSITION SENSOR (Continued) OPERATION REMOVAL Engine speed and crankshaft position are provided The crankshaft sensor is located on the passengers through the crankshaft position sensor. The sensor side of the transmission housing, above the differen- generates pulses that are the input sent to the pow- tial housing.
Page 1168: Fuel Injector
FUEL INJECTION 14 - 27 to flow out the orifice. Because the fuel is under high FUEL INJECTOR pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action DESCRIPTION atomizes the fuel, adding it to the air entering the The injectors are positioned in the cylinder heads combustion chamber.
Page 1169: Fuel Pump Relay
14 - 28 FUEL INJECTION FUEL INJECTOR (Continued) (7) Remove electrical connectors from the fuel (8) Install intake manifold plenum. Refer to the injectors. Engine section for information. (8) Remove fuel rail mounting bolts. (9) Connect negative cable to battery. (9) Lift fuel rail straight up off of the cylinder INSTALLATION - 3.5L head.
Page 1170 FUEL INJECTION 14 - 29 Target Idle IDLE AIR CONTROL MOTOR Target idle is determined by the following inputs: • Gear position DESCRIPTION • ECT Sensor The idle air control motor (IAC) attaches to the • Battery voltage throttle body (Fig. 10). It is an electric stepper motor. •...
Page 1171 14 - 30 FUEL INJECTION IDLE AIR CONTROL MOTOR (Continued) INSTALLATION - 3.5L (1) Install the IAC to the throttle body (Fig. 12). (2) Tighten mounting screws to 7.3 N·m (65 in. lbs.) torque. (3) Attach electrical connector to the IAC. (4) Install air plenum and tighten the clamp.
Page 1172 FUEL INJECTION 14 - 31 MAP SENSOR (Continued) it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on.
Page 1173 14 - 32 FUEL INJECTION MAP SENSOR (Continued) for your area. Always use the Diagnostic Test Proce- dures Manual for MAP sensor testing. REMOVAL REMOVAL - 2.7L (1) Remove the negative battery cable. (2) Disconnect the electrical connector from the MAP sensor (Fig.
Page 1174 FUEL INJECTION 14 - 33 O2 SENSOR (Continued) The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indica-...
Page 1175 14 - 34 FUEL INJECTION O2 SENSOR (Continued) fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element.
Page 1176 FUEL INJECTION 14 - 35 O2 SENSOR (Continued) INSTALLATION INSTALLATION - UPSTREAM 1/1, 2/1 The engines uses two heated oxygen sensors, one in each exhaust manifold. (1) After removing the sensor, the exhaust mani- fold threads must be cleaned with an 18 mm X 1.5 + 6E tap.
Page 1177: Throttle Body
14 - 36 FUEL INJECTION OPERATION THROTTLE BODY Filtered air from the air cleaner enters the intake DESCRIPTION manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle The throttle body is located on the intake manifold Air Control (IAC) motor.
Page 1178: Throttle Position Sensor
FUEL INJECTION 14 - 37 THROTTLE BODY (Continued) (2) Install the cable housing (throttle body end) INSTALLATION into the cable mounting bracket on the engine. (3) From inside the vehicle, hold up the pedal and INSTALLATION - 2.7L install throttle cable and cable retainer in the upper (1) Install throttle body and bolts.
Page 1179 14 - 38 FUEL INJECTION THROTTLE POSITION SENSOR (Continued) Fig. 28 THROTTLE POSITION SENSOR 3.2/3.5L Fig. 29 Throttle Position Sensor—2.7L Engine ENGINE 1 - TPS SENSOR 1 - THROTTLE BODY 2 - THROTTLE BODY 2 - TPS 3 - PCV VALVE 3 - IAC 4 - EGR TUBE opening (idle) to a maximum of 4.5 volts at wide open...
Page 1180 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page STEERING DIAGNOSIS AND TESTING - SPEED DESCRIPTION - POWER STEERING SYSTEM . . 1 PROPORTIONAL POWER STEERING ..9 OPERATION - POWER STEERING SYSTEM .
Page 1181 19 - 2 STEERING STEERING (Continued) CAUTION: If the vehicle is equipped with the Tire Install the following adapters from Adapter Set, Pressure Monitoring (TPM) System, the tire/wheel Special Tool 6893 (Fig. 2), on the analyzer hose ends: assembly needs to be reinstalled in the same loca- tion it is removed from or the TPM System (sen- sors) will need to be retrained.
Page 1182 STEERING 19 - 3 STEERING (Continued) Fig. 3 Pressure Hose Connection To Power Steering Fig. 5 Analyzer Connected To Power Steering Pump Pump (2.7L Engine) (2.7L Engine) 1 - POWER STEERING FLUID PRESSURE HOSE 1 - POWER STEERING FLUID PRESSURE HOSE Fig.
Page 1183 19 - 4 STEERING STEERING (Continued) NOTE: Power steering pump maximum relief pres- (12) Completely open the valve on the Power sure is 8275 to 8975 kPa (1250 to 1350 psi.). Steering Analyzer. Turn the steering wheel to the extreme left until the stop in the steering gear is •...
Page 1184 STEERING 19 - 5 STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION POPPING NOISE 1. Worn outer tie rod. 1. Replace outer tie rod. CHIRP OR SQUEAL 1. Loose power steering pump drive 1. Check and adjust power steering pump (POWER STEERING belt.
Page 1185 19 - 6 STEERING STEERING (Continued) * NOTE: There is some noise in all power steering ity fluid passes valve orifice edges. There is no systems. One of the most common is a hissing relationship between this noise and the perfor- sound evident when turning the steering wheel mance of the steering system.
Page 1186 STEERING 19 - 7 STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 6. Loose power steering pump drive 6. Tighten the power steering pump drive belt. belt to specifications. If drive belt is worn or glazed, replace belt. 7. Faulty power steering pump flow 7.
Page 1187 19 - 8 STEERING STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Steering column coupling joints 4. Realign steering column coupling joints. misaligned. 5. Steering wheel rubbing.** 5. Adjust steering column shrouds to eliminate rubbing condition. 6. Damaged, mis-positioned or 6. Replace, reposition, or lubricate dash un-lubricated steering column seal.
Page 1188 STEERING 19 - 9 STEERING (Continued) ** NOTE: To evaluate this condition, it may be nec- steering wheel more than one revolution in either essary to disconnect the coupling at the base of the direction and place steering wheel in original loca- steering column.
Page 1189 19 - 10 STEERING STEERING (Continued) STEERING COLUMN FASTENER TORQUE DESCRIPTION N·m Lbs. Lbs. Airbag Module Mounting — Bolts Speed Control Switch — Screws Puller C-4333 Steering Column Coupler Pinch Bolt Steering Column Mounting — Bolts Steering Column Mounting — Nuts Steering Wheel Retaining —...
Page 1190 COLUMN 19 - 11 COLUMN TABLE OF CONTENTS page page COLUMN KEY/LOCK CYLINDER DESCRIPTION ......11 DESCRIPTION .
Page 1191 19 - 12 COLUMN COLUMN (Continued) Fig. 1 Steering Column 1 - SHIFT LEVER (COLUMN SHIFT ONLY) 4 - STEERING COLUMN MOUNTING BRACKET 2 - TILT HOUSING 5 - STEERING COLUMN COUPLER 3 - TILT LEVER 6 - STEERING COLUMN LOWER MOUNTING BRACKET WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, WARNING: WHEN HANDLING AN UNDEPLOYED COMPLEX ELECTRO-MECHANICAL UNIT.
Page 1192 COLUMN 19 - 13 COLUMN (Continued) CAUTION CAUTIONS CAUTION: Disconnect the negative (ground) cable from the battery, before servicing any column com- ponent. CAUTION: Do not attempt to remove the pivot pins to disassemble the tilting mechanism. Damage will occur. DIAGNOSIS AND TESTING - STEERING COLUMN For diagnosis of conditions relating to the steering...
Page 1193 19 - 14 COLUMN COLUMN (Continued) Fig. 4 Lower Instrument Panel Cover Mounting Fig. 6 Park Brake Release Cable Screws 1 - PARK BRAKE RELEASE CABLE 2 - PARK BRAKE RELEASE HANDLE 1 - MOUNTING SCREWS 3 - LOWER INSTRUMENT PANEL COVER 2 - INSTRUMENT PANEL BRACKET 3 - LOWER INSTRUMENT PANEL COVER Fig.
Page 1194 COLUMN 19 - 15 COLUMN (Continued) Fig. 10 Driver Airbag Attaching Bolts Fig. 8 Diagnostic Connector 1 - DRIVER AIRBAG 1 - DIAGNOSTIC CONNECTOR 2 - STEERING WHEEL 2 - REINFORCEMENT PANEL 3 - MOUNTING SCREWS (11) Remove the driver airbag from the steering wheel.
Page 1195 19 - 16 COLUMN COLUMN (Continued) (15) Remove the steering wheel attaching nut from CAUTION: Do not bump or hammer on steering the steering column shaft (Fig. 12). wheel or steering column shaft when removing steering wheel from steering column. (17) Remove steering wheel from steering column shaft.
Page 1196 COLUMN 19 - 17 COLUMN (Continued) Fig. 15 Lower Shroud Attaching Screws Fig. 17 Clockspring Location 1 - LOWER SHROUD 1 - CLOCKSPRING 2 - MOUNTING SCREWS 2 - MOUNTING SCREWS (24) Remove the wiring harness from the routing clip on the top of the multi-function switch. Remove the 2 screws (Fig.
Page 1197 19 - 18 COLUMN COLUMN (Continued) (25) Remove the 2 screws (Fig. 19) mounting the (27) If the vehicle is equipped with a steering col- ignition switch to the steering column. Remove the umn mounted shift lever, remove the brake transmis- ignition switch, with the wiring harness attached, sion shift interlock (BTSI) solenoid from the shift from the steering column.
Page 1198 COLUMN 19 - 19 COLUMN (Continued) (28) If the vehicle is equipped with a steering col- (30) Remove the 2 air ducts (Fig. 25) from under umn mounted shift lever, remove the shift cable from the steering column. the shifter mechanism. Unlock the cable lock, then, the shift cable is removed by inserting a screwdriver between the shift cable and the shifter mechanism and prying the cable off the pin (Fig.
Page 1199 19 - 20 COLUMN COLUMN (Continued) Fig. 27 Steering Column Mounting Fig. 28 Installed Shift Cable 1 - MOUNTING NUTS 1 - SHIFTER MECHANISM 2 - STEERING COLUMN UPPER MOUNTING BRACKET 2 - PIN 3 - STEERING COLUMN SUPPORT BRACKET 3 - SHIFT CABLE 4 - STEERING COLUMN LOWER MOUNTING BRACKET 5 - MOUNTING BOLTS...
Page 1200 COLUMN 19 - 21 COLUMN (Continued) Fig. 32 Ignition Interlock Adjustment Tab 1 - LOCK CYLINDER HOUSING Fig. 30 Guide And Flange Alignment 2 - INTERLOCK CASSETTE 1 - BRACKET FLANGE 3 - ADJUSTMENT TAB 2 - GUIDE harness on the routing clip on the top of the multi- function switch.
Page 1201 19 - 22 COLUMN COLUMN (Continued) • Keeping locking mechanism disengaged, rotate NOTE: Make sure steering wheel and airbag module the clockspring rotor in the CLOCKWISE DIREC- are in the right-side-up position before installing TION to the end of the travel. Do not apply excessive airbag module on steering wheel.
Page 1202: Ignition Switch
COLUMN 19 - 23 COLUMN (Continued) eight seconds, then go out. This will indicate that the INSTALLATION airbag system is functioning normally. The ignition switch attaches to the lock cylinder • If airbag warning lamp fails to light, blinks on housing on the end opposite the lock cylinder.
Page 1203 19 - 24 COLUMN INTERMEDIATE SHAFT (Continued) • If a vehicle is involved in an impact of the vehi- (3) Remove the upper and lower covers from the cle’s front suspension or undercarriage, which results steering column. in any type of damage to the front crossmember. (4) Turn the ignition key to the run position.
Page 1204 COLUMN 19 - 25 KEY/LOCK CYLINDER (Continued) REMOVAL (1) Remove steering column assembly from vehicle. Refer to the Steering Column Removal. (2) Install Puller, Special Tool 6831-A, through center of roll pin in flex coupler and install knurled nut (Fig. 39). Fig.
Page 1205: Steering Wheel
19 - 26 COLUMN STEERING COUPLING (Continued) INSTALLATION (1) Confirm that: • The steering wheel position is a half turn (180 degrees) to the right (clockwise). • The column is locked with the ignition cylinder lock. • Check that the turn signal stalk is in the neu- tral position.
Page 1206 COLUMN 19 - 27 STEERING COLUMN GEAR SHIFT LEVER (Continued) Fig. 41 Fuse Panel Cover 1 - FUSE PANEL COVER 2 - INSTRUMENT PANEL Fig. 43 Tilt Lever And Upper And Lower Shrouds 1 - UPPER SHROUD 2 - TILT LEVER 3 - LOWER SHROUD Fig.
Page 1207 19 - 28 COLUMN STEERING COLUMN GEAR SHIFT LEVER (Continued) (4) Install the brake transmission interlock sole- noid on the shift lever mechanism. To do so, perform the following: (a) Align the flat inside the solenoid (Fig. 47) with the flat on the shift lever mounting stud. (b) Slide the solenoid completely onto the shift lever mounting stud aligning the plastic guide formed into the solenoid housing with the flange on...
Page 1208 COLUMN 19 - 29 STEERING COLUMN GEAR SHIFT LEVER (Continued) adjustment tab will click as it moves into position. Ensure the tab fully depressed. Fig. 49 Solenoid Retainer Clip Installation 1 - SOLENOID Fig. 50 Ignition Interlock Adjustment Tab 2 - MOUNTING STUD 1 - LOCK CYLINDER HOUSING 3 - RETAINER CLIP 2 - INTERLOCK CASSETTE...
Page 1209 19 - 30 GEAR GEAR TABLE OF CONTENTS page page GEAR OPERATION - SOLENOID CONTROL VALVE . . 40 DESCRIPTION REMOVAL - SOLENOID CONTROL VALVE ..40 DESCRIPTION - POWER STEERING GEAR . 30 INSTALLATION - SOLENOID CONTROL VALVE . 41 DESCRIPTION - SPEED PROPORTIONAL TIE ROD - INNER STEERING GEAR .
Page 1210 GEAR 19 - 31 GEAR (Continued) Fig. 1 Power Steering Gear 1 - STEERING GEAR FLUID LINES 6 - ADJUSTMENT SLEEVE 2 - STEERING GEAR BOOT 7 - INNER TIE ROD 3 - RACK AND PINION STEERING GEAR 8 - ADJUSTMENT SLEEVE 4 - CLAMP 9 - TIE ROD END 5 - TIE ROD END...
Page 1211 19 - 32 GEAR GEAR (Continued) for controlling the variable effort of the power steer- OPERATION ing system. OPERATION - POWER STEERING GEAR REMOVAL - POWER STEERING GEAR Turning of the steering wheel is converted into lat- (1) Remove the battery ground cable from the eral (side-to side) travel through the meshing of the ground stud on the shock tower and isolate the helical pinion teeth with the rack teeth located in the...
Page 1212 GEAR 19 - 33 GEAR (Continued) CAUTION: Before removing the steering column (7) Remove the wiper arms from the pivots. Wiper coupler from the intermediated steering shaft be arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled sure the steering wheel is locked from rotating (Fig.
Page 1213 19 - 34 GEAR GEAR (Continued) (12) Remove the two nuts mounting the master cylinder to the vacuum booster (Fig. 11). Fig. 9 In-Line Resonator And Air Inlet Hose 1 - AIR INLET HOSE Fig. 11 Master Cylinder To Vacuum Booster 2 - THROTTLE BODY 3 - AIR INLET HOSE Mounting...
Page 1214 GEAR 19 - 35 GEAR (Continued) Fig. 12 Tie Rod Attachment Bolt Retaining Tabs Fig. 14 Power Steering Hose Connections At Steering Gear 1 - STEERING GEAR 2 - TIE RODS 1 - POWER STEERING FLUID RETURN HOSE 3 - RETAINING TABS 2 - STEERING GEAR 4 - BOLTS 3 - MASTER CYLINDER FLUID RESERVIOR...
Page 1215 19 - 36 GEAR GEAR (Continued) Fig. 16 Steering Gear Attachment To Crossmember Fig. 18 Steering Coupler Roll Pin (Right Side) 1 - SPECIAL TOOL 6831–A 2 - DASH PANEL SEAL & BOOT 1 - STEERING GEAR 3 - FLEX JOINT 2 - CROSSMEMBER 4 - KNURLED NUT 3 - MOUNTING BRACKET...
Page 1216 GEAR 19 - 37 GEAR (Continued) (28) Remove the tie rod end from the steering arm (a) Slide the end of the steering gear through of the strut using Puller, Special Tool C-3894–A (Fig. the tie rod hole in the right side inner fender (Fig. 20).
Page 1217 19 - 38 GEAR GEAR (Continued) DISASSEMBLY - POWER STEERING GEAR toms in the recessed area of the steering gear hous- ing. (HOUSING BUSHINGS) The power steering gear must be removed from the vehicle for the bushings to be serviced. Refer to REMOVAL in this section.
Page 1218 GEAR 19 - 39 GEAR (Continued) (8) Using roll pin Installer, Special Tool 6831A, (12) Tighten the bolts mounting the left side of the install the roll pin in the flex joint of the intermedi- steering gear to the crossmember to a torque of 58 ate shaft (Fig.
Page 1219 19 - 40 GEAR GEAR (Continued) (25) Remove the holding clamp from the steering wheel (Fig. 4). (26) Install the battery ground cable onto the ground stud on the shock tower. (27) Perform Power Steering Pump Initial Opera- tion procedure to properly refill and bleed power steering system.
Page 1220 GEAR 19 - 41 SPEED PROPORTIONAL STEERING SOLENOID (Continued) Fig. 31 Loosening Solenoid Control Valve 1 - SOLENOID CONTROL VALVE 2 - RETURN HOSE Fig. 29 Wiring Harness 3 - 15/16 CROW FOOT 1 - SPEED PROPORTIONAL STEERING SOLENOID 4 - STEERING GEAR CONNECTOR 2 - MASTER CYLINDER RESERVOIR (3) Using the 1–5/16 inch crow foot as shown (Fig.
Page 1221 19 - 42 GEAR SPEED PROPORTIONAL STEERING SOLENOID (Continued) (6) Connect the wiring harness connector. Be sure the wiring harness connector seal is in good condition before installing the connector in the control module. (7) Road test vehicle, referring to the test indi- cated in the Appropriate Diagnostic Information, to confirm correct operation of the variable-assist speed- proportional power steering gear.
Page 1222 GEAR 19 - 43 TIE ROD - INNER (Continued) Fig. 39 Removing Outer Tie Rod From Steering Arm Fig. 37 In-Line Resonator And Air Inlet Hose 1 - TIE ROD END 1 - AIR INLET HOSE 2 - STEERING ARM 2 - THROTTLE BODY 3 - STRUT 3 - AIR INLET HOSE...
Page 1223 19 - 44 GEAR TIE ROD - INNER (Continued) Fig. 42 Tie Rod Thread Engagement Requirements Fig. 41 Tie Rod To Steering Gear Attaching Bolts 1 - OUTER TIE ROD 2 - ADJUSTER 1 - TIE RODS 3 - PINCH BOLT 2 - BOLTS 4 - INNER TIE ROD 3 - MOUNTING PLATE...
Page 1224 GEAR 19 - 45 TIE ROD - INNER (Continued) tie rod attaching bolt through tie rod and washer (14) Install the battery ground cable onto the into steering gear. Be sure washer is installed ground stud on the shock tower and install nut. between tie rod and steering gear as shown (15) Adjust front toe.
Page 1225 19 - 46 GEAR TIE ROD - OUTER (Continued) (6) Equally tighten both nuts on the U-bolt until a torque of 2.7 N·m (24 in. lbs.) is achieved on each nut. (7) Note the tie rod socket end play. New ball joint end play should not be greater then 0.100 inches.
Page 1226 GEAR 19 - 47 TIE ROD - OUTER (Continued) CAUTION: When setting the front Toe on the vehi- BUSHING - INNER TIE ROD cle, the maximum dimension of exposed threads allowed on the adjuster and outer tie rod cannot REMOVAL - INNER TIE ROD BUSHING exceed the distance shown in (Fig.
Page 1227 19 - 48 GEAR BUSHING - INNER TIE ROD (Continued) (3) Remove the wiper arms from the pivots. Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots. (4) Remove the wiper module cover and cowl cover from the vehicle (Fig.
Page 1228 GEAR 19 - 49 BUSHING - INNER TIE ROD (Continued) Fig. 56 Removing Outer Tie Rod From Steering Arm Fig. 58 Tie Rod To Steering Gear Attaching Bolts 1 - TIE ROD END 1 - TIE RODS 2 - STEERING ARM 2 - BOLTS 3 - STRUT 3 - MOUNTING PLATE...
Page 1229 19 - 50 GEAR BUSHING - INNER TIE ROD (Continued) (a) Place the inner tie rod bushing end in the (a) Place the inner tie rod end in Receiver as Receiver as shown (Fig. 59). shown (Fig. 61). (b) Place Remover/Installer, Special Tool 8438–4, (b) Place the Sizer (with bushing) on top of the with the small end down on top of the bushing tie rod bushing bore with the tapered end facing...
Page 1230 GEAR 19 - 51 BUSHING - INNER TIE ROD (Continued) (8) Align the inner tie rod with the mounting hole in the center take off on steering gear. Rotate the mounting plate into position over the tie rod. Install tie rod attaching bolt through tie rod and washer into steering gear.
Page 1231 19 - 52 GEAR BUSHING - INNER TIE ROD (Continued) (16) Install the reinforcement on the vehicle (Fig. 53). Install the eight bolts attaching the cowl rein- forcement to the strut towers. Install the bolt attach- ing the wiper module to the reinforcement. (17) Install the covers over the wiper module and the cowl (Fig.
Page 1232 PUMP 19 - 53 PUMP TABLE OF CONTENTS page page PUMP REMOVAL ......61 DESCRIPTION .
Page 1233 19 - 54 PUMP PUMP (Continued) reduces pressure on the spring end of the flow con- trol valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the pump to a safe level.
Page 1234 PUMP 19 - 55 PUMP (Continued) REMOVAL REMOVAL - PUMP (2.7L ENGINE) (1) Remove the battery ground cable from the ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the ground stud (Fig. 3). Fig.
Page 1235 19 - 56 PUMP PUMP (Continued) (13) Remove the power steering pump, power steering fluid reservoir and pulley as an assembly from the engine. Power steering pump is removed from the top of the engine. (14) Transfer the required parts from the removed power steering pump to the replacement power steer- ing pump.
Page 1236 PUMP 19 - 57 PUMP (Continued) Fig. 11 Drive Belt Tensioner Lock-Nut And Fig. 9 Power Steering Fluid Supply Hose At Power Adjustment Bolt Steering Pump 1 - ADJUSTMENT BOLT 1 - POWER STEERING FLUID SUPPLY HOSE 2 - POWER STEERING PUMP 2 - POWER STEERING PUMP 3 - LOCK-NUT 4 - DRIVE BELT...
Page 1237 19 - 58 PUMP PUMP (Continued) (14) Transfer the required parts from the removed CAUTION: When installing the pulley on the power power steering pump to the replacement power steer- steering pump, Spacer, Special Tool 6936, MUST be ing pump. See Disassembly and Assembly in this sec- used.
Page 1238 PUMP 19 - 59 PUMP (Continued) the upset bead on the nipple of the power steer- ing fluid reservoir. (8) Connect the battery ground cable onto the ground stud located on the strut tower. (9) Perform Power Steering Pump Initial Opera- tion procedure to properly refill and bleed power steering system.(Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE)
Page 1239 19 - 60 PUMP FLUID STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. Wipe off the power steering fluid reservoir so that it is free of dirt (Fig. 16) (Fig. 17). Check the fill level of the fluid in the reservoir according to the mark- ings on the side of the reservoir.
Page 1240 PUMP 19 - 61 FLUID COOLER (Continued) REMOVAL (1) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (2) Raise vehicle using a frame contact type hoist or supported using jack stands. See Hoisting in Lubrication And Maintenance.
Page 1241 19 - 62 PUMP (2) Position the front tires of the vehicle so that HOSES they are facing straight-ahead. (3) Raise the vehicle on a frame contact type hoist DESCRIPTION until the front tires of the vehicle are just off the The power steering fluid hoses connect the compo- floor.
Page 1242 PUMP 19 - 63 HOSES (Continued) Fig. 26 Reinforcement Attachment To Vehicle 1 - RIGHT STRUT TOWER 2 - WIPER MODULE Fig. 28 Steering Wheel Lock Installed (Typical) 3 - LEFT STRUT TOWER 4 - ATTACHING BOLTS 1 - STEERING WHEEL 5 - ATTACHING BOLT 2 - STEERING WHEEL CLAMP 6 - REINFORCEMENT...
Page 1243 19 - 64 PUMP HOSES (Continued) Fig. 32 Master Cylinder To Vacuum Booster Fig. 30 Tie Rod Attachment Bolt Retaining Tabs Mounting 1 - STEERING GEAR 2 - TIE RODS 1 - MOUNTING NUT 3 - RETAINING TABS 2 - MASTER CYLINDER 4 - BOLTS 3 - MOUNTING NUT 5 - PLATE...
Page 1244 PUMP 19 - 65 HOSES (Continued) (18) Remove the 2 bolts attaching the left side of the steering gear to the crossmember (Fig. 34). Fig. 36 Power Steering Hose To Frame Rail Mounting 1 - COOLANT RECOVERY BOTTLE Fig. 34 Steering Gear Attachment To Crossmember 2 - FRAME RAIL (Left Side) 3 - POWER STEERING FLUID TUBES...
Page 1245 19 - 66 PUMP HOSES (Continued) (Fig. 33). Tighten both power steering hose tube nuts to a torque of 47 N·m (35 ft. lbs.). CAUTION: Before installing tie rods on steering gear be sure the tie rod spacer block inside the steering gear bellows (Fig.
Page 1246 PUMP 19 - 67 HOSES (Continued) Fig. 41 Power Steering Fluid Reservoir (3.5L Fig. 40 Tie Rod Attachment Engine) 1 - RETAINING TABS 1 - SPEED CONTROL SERVO 2 - BOLTS 2 - POWER STEERING FLUID RESERVOIR 3 - RETAINING PLATE 4 - STEERING GEAR 5 - WASHER OPERATION...
Page 1247 19 - 68 PUMP RESERVOIR (Continued) Fig. 42 Fluid Reservoir To Pump Mounting Fig. 44 Power Steering Fluid Reservoir (3.5L Engine) 1 - POWER STEERING FLUID RESERVOIR 2 - MOUNTING BOLTS 1 - SPEED CONTROL SERVO 3 - POWER STEERING PUMP 2 - POWER STEERING FLUID RESERVOIR 4 - MOUNTING BOLT Fig.
Page 1248 PUMP 19 - 69 RESERVOIR (Continued) INSTALLATION - RESERVOIR (3.5L ENGINE) hose clamps, being sure they are past the hose reten- tion beads on reservoir nipples. (1) Install the power steering fluid reservoir into (4) Lower vehicle. the mounting bracket. Be sure the retaining tab on (5) Fill the power steering pump reservoir to cor- the bracket is holding the reservoir in the bracket.
Page 1250 TRANSAXLE 21 - 1 TRANSAXLE TABLE OF CONTENTS page page 42LE AUTOMATIC TRANSAXLE STANDARD PROCEDURE - FLUID/FILTER DESCRIPTION ......2 SERVICE .
Page 1251 21 - 2 TRANSAXLE INSTALLATION ......135 INSTALLATION ......148 SHIFT INTERLOCK SOLENOID TORQUE CONVERTER REMOVAL...
Page 1252 TRANSAXLE 21 - 3 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 1 42LE Transaxle 1 - DIFFERENTIAL 7 - OUTPUT GEAR 13 - UNDERDRIVE CLUTCH 2 - TRANSFER SHAFT 8 - OUTPUT SPEED SENSOR 14 - INPUT SPEED SENSOR 3 - TRANSFER GEAR 9 - LOW/REVERSE CLUTCH 15 - CONVERTER CLUTCH 4 - FRONT PLANET CARRIER...
Page 1253 21 - 4 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 2 Transaxle Identification Label 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - IDENTIFICATION TAG Depending on date of manufacture, some transax- les will utilize a new identification label located in Fig.
Page 1254 TRANSAXLE 21 - 5 42LE AUTOMATIC TRANSAXLE (Continued) • Diagnostic trouble code inspection running clutch may be slipping. If acceleration is nor- Then perform a road test to determine if the prob- mal, but high throttle opening is needed to maintain lem has been corrected or that more diagnosis is nec- highway speeds, the converter stator clutch may essary.
Page 1255 21 - 6 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Install an engine tachometer, raise vehicle on hoist (3) Allow vehicle wheels to turn and increase which allows front wheels to turn, and position throttle opening to achieve an indicated vehicle speed tachometer so it can be read.
Page 1256 TRANSAXLE 21 - 7 42LE AUTOMATIC TRANSAXLE (Continued) (1) Attach gauge to the torque converter clutch off (1) Attach gauge to the reverse and low/reverse pressure tap. clutch tap. (2) Move selector lever to the overdrive position. (2) Move selector lever to the reverse position. (3) Allow vehicle wheels to turn and increase (3) Read reverse clutch pressure with output sta- throttle opening to achieve an indicated vehicle speed...
Page 1257 21 - 8 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - CLUTCH AIR UNDERDRIVE CLUTCH Because this clutch piston cannot be seen, its oper- PRESSURE TESTS ation is checked by function. Air pressure is applied Inoperative clutches can be located by substituting to the low/reverse or the 2/4 clutches.
Page 1258 TRANSAXLE 21 - 9 42LE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - FLUID LEAKAGE The 42LE is a dual sump transaxle. The transaxle uses both automatic transaxle fluid (ATF) for the main sump and hypoid gear lube for the differential sump.
Page 1259 21 - 10 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) COOLING/TRANSMISSION - STANDARD PROCE- DURE). The cooler bypass valve in the transaxle must be inspected and/or replaced also. The torque converter must also be replaced with an exchange unit. This will ensure that metal particles or sludged oil are not later transferred back into the recondi- tioned (or replaced) transaxle.
Page 1260 TRANSAXLE 21 - 11 42LE AUTOMATIC TRANSAXLE (Continued) (23) Pull bottom of knuckles and drive shafts out- ward to allow clearance during transaxle removal. The drive shafts do not have to be completely removed from the vehicle. Do not allow the inner tripod joints to hang unsupported or joint dam- age may occur.
Page 1261 21 - 12 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Before disassembling transaxle, move the shift (2) Remove input and output speed sensors (Fig. lever clockwise as far as it will go and then remove 13). the shift lever. NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.
Page 1262 TRANSAXLE 21 - 13 42LE AUTOMATIC TRANSAXLE (Continued) (4) Remove transaxle oil filter (Fig. 15). (6) Remove valve body from transaxle (Fig. 17). Fig. 17 Remove Valve Body From Transaxle Fig. 15 Remove Transaxle Oil Filter 1 - VALVE BODY 1 - TRANSAXLE FILTER 2 - FILTER RETAINING CLIPS NOTE: For valve body recondition procedure, (Refer...
Page 1263 21 - 14 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (8) Remove overdrive accumulator and springs (9) Remove the low/reverse accumulator snap ring (Fig. 19) (Fig. 20). (Fig. 21). Fig. 19 Remove Overdrive Accumulator and Springs Fig. 21 Remove Low/Reverse Accumulator 1 - OVERDRIVE ACCUMULATOR PISTON 1 - SNAP RING 2 - RETURN SPRINGS 2 - LOW/REVERSE ACCUMULATOR...
Page 1264 TRANSAXLE 21 - 15 42LE AUTOMATIC TRANSAXLE (Continued) (11) Remove low/reverse accumulator piston and (12) Remove long stub shaft bearing snap ring springs (Fig. 23) (Fig. 24). (Fig. 25). Fig. 23 Remove Low/Reverse Accumulator Piston Fig. 25 Remove Long Stub Shaft Snap Ring 1 - SEAL RINGS 1 - SNAP RING 2 - PISTON...
Page 1265 21 - 16 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (14) Remove oil pump-to-case bolts (Fig. 27). (16) Remove oil pump while pushing in on input shaft (Fig. 29). Fig. 27 Remove Oil Pump Attaching Bolts Fig. 29 Remove Oil Pump 1 - BELLHOUSING 1 - “PUSH IN”...
Page 1266 TRANSAXLE 21 - 17 42LE AUTOMATIC TRANSAXLE (Continued) (18) Remove cooler by-pass valve (Fig. 31). (20) Remove input clutch assembly (Fig. 33). Fig. 31 Remove By-Pass Valve 1 - BYPASS VALVE (19) Remove #1 caged needle bearing (Fig. 32). Fig. 33 Remove Input Clutch Assembly 1 - INPUT CLUTCH ASSEMBLY (21) Remove #4 thrust plate (Fig.
Page 1267 21 - 18 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (22) Remove front sun gear assembly and #4 (24) Remove rear sun gear and #7 needle bearing thrust washer (if still in place) (Fig. 35). (Fig. 37) (Fig. 38). Fig. 35 Remove Front Sun Gear Assembly Fig.
Page 1268 TRANSAXLE 21 - 19 42LE AUTOMATIC TRANSAXLE (Continued) (25) Install and load Tool 5058 to remove 2/4 (27) Remove 2/4 clutch return spring (Fig. 42). clutch retainer snap ring (Fig. 39). Fig. 41 2/4 Clutch Retainer Fig. 39 Remove 2/4 Clutch Retainer Snap Ring 1 - 24 CLUTCH RETAINER 2 - 24 CLUTCH RETURN SPRING 1 - TOOL 5058...
Page 1269 21 - 20 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (28) Remove 2/4 clutch pack (Fig. 43). (30) Remove low/reverse reaction plate (Fig. 45). Fig. 45 Remove Low/Reverse Reaction Plate Fig. 43 Remove 2/4 Clutch Pack 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP) 1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4) (31) Remove one (1) low/reverse clutch disc to facil-...
Page 1270 TRANSAXLE 21 - 21 42LE AUTOMATIC TRANSAXLE (Continued) (32) Remove low/reverse reaction plate snap ring (34) Remove chain cover (Fig. 49). (Fig. 47). Fig. 49 Remove Chain Cover 1 - TRANSAXLE CASE Fig. 47 Remove Low/Reverse Reaction Plate Snap 2 - CHAIN COVER Ring 1 - SCREWDRIVER (35) Stand trans upright on bellhousing.
Page 1271 21 - 22 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (37) Remove chain snubber (Fig. 51). Fig. 53 Remove Transfer Shaft Sprocket Snap Ring and Wave Washer Fig. 51 Remove Chain Snubber 1 - TRANSFER SHAFT 1 - CHAIN SNUBBER 2 - WAVE WASHER 3 - SNAP RING (38) Remove transfer and output shaft sprocket 4 - SNAP RING...
Page 1272 TRANSAXLE 21 - 23 42LE AUTOMATIC TRANSAXLE (Continued) (40) Remove transfer chain and sprockets as an assembly (Fig. 55). Fig. 57 Main Sump Vent Baffle Location 1 - OUTPUT SHAFT NUT Fig. 55 Remove Chain and Both Sprockets as an 2 - MAIN SUMP VENT BAFFLE 3 - TRANSFER SHAFT NUT Assembly...
Page 1273 21 - 24 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 59 Stake Grinding Pattern 1 - TRANSFER SHAFT 2 - TRANSFER SHAFT NUT (44) Using a small chisel, carefully open stakes on nut (Fig. 60). Fig. 61 Remove Output Shaft Nut 1 - SPECIAL TOOL 6497 2 - SPECIAL TOOL 6498 3 - BREAKER BAR...
Page 1274 TRANSAXLE 21 - 25 42LE AUTOMATIC TRANSAXLE (Continued) (48) Remove rear carrier front bearing cone (Fig. 65). Fig. 63 Remove Front Bearing Cup 1 - ARBOR PRESS 2 - SPECIAL TOOL 6596 Fig. 65 Remove Rear Carrier Front Bearing Cone 1 - SPECIAL TOOL 5048–1 (47) Use special tool 6597 and handle C-4171 and 2 - SPECIAL TOOL 6545...
Page 1275 21 - 26 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (51) Remove low/reverse piston belleville spring (Fig. 69). Fig. 67 Compressor Tool in Use 1 - LOW/REVERSE CLUTCH RETURN SPRING Fig. 69 Low/Reverse Piston Belleville Spring 2 - SNAP RING (INSTALL AS SHOWN) 3 - TOOL 5058A-3 1 - LOW/REVERSE PISTON RETURN SPRING 4 - TOOL 5059A...
Page 1276 TRANSAXLE 21 - 27 42LE AUTOMATIC TRANSAXLE (Continued) (53) Drive out anchor shaft using suitable punch (Fig. 71). Fig. 71 Anchor Shaft Removal Fig. 73 Guide Bracket Disassembled 1 - PIN PUNCH 1 - ANTIRATCHET SPRING 2 - GUIDE BRACKET ASSEMBLY 2 - GUIDE BRACKET 3 - SPLIT SLEEVE (54) Remove guide bracket pivot shaft (Fig.
Page 1277 21 - 28 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (56) Remove low/reverse piston retainer screws (58) Remove low/reverse piston retainer gasket (Fig. 75). (Fig. 77). Fig. 75 Remove Piston Retainer-to-Case Screws Fig. 77 Remove Piston Retainer Gasket 1 - LOW/REVERSE CLUTCH PISTON RETAINER 1 - GASKET HOLES MUST LINE UP 2 - SCREWDRIVER 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET...
Page 1278 TRANSAXLE 21 - 29 42LE AUTOMATIC TRANSAXLE (Continued) (2) Install low/reverse piston retainer gasket (Fig. (4) Install low/reverse piston retainer-to-case 79). screws (Fig. 81) and torque to 5 N·m (45 in. lbs.). Fig. 79 Install Piston Retainer Gasket Fig. 81 Install Retainer Attaching Screws 1 - LOW/REVERSE CLUTCH PISTON RETAINER 1 - GASKET HOLES MUST LINE UP 2 - SCREWDRIVER...
Page 1279 21 - 30 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (6) Assemble guide bracket assembly as shown in (7) Install guide bracket pivot shaft (Fig. 85). (Fig. 83) (Fig. 84). Fig. 85 Install Guide Bracket Pivot Shaft 1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY Fig.
Page 1280 TRANSAXLE 21 - 31 42LE AUTOMATIC TRANSAXLE (Continued) (9) Install low/reverse piston belleville spring into position (Fig. 87). Fig. 89 Compressor Tool Installed 1 - LOW/REVERSE CLUTCH RETURN SPRING Fig. 87 Install Low/Reverse Piston Return Spring 2 - SNAP RING (INSTALL AS SHOWN) 3 - TOOL 5058A-3 1 - LOW/REVERSE PISTON RETURN SPRING 4 - TOOL 5059A...
Page 1281 21 - 32 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (12) Install rear carrier front bearing cone (Fig. (c) Turn case over on arbor press so that the 91). plate is resting on the press base. CAUTION: The output shaft will extend through the hole of tool 6618A.
Page 1282 TRANSAXLE 21 - 33 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 93 Special Tool Installed 1 - SPECIAL TOOL 6618–A Fig. 95 Press Shaft Into Case 1 - SPECIAL TOOL C-4171 AND C-4171–2 2 - SPECIAL TOOL MD-998911 Fig. 94 Shim Installation 1 - SHIM 2 - OUTPUT SHAFT Fig.
Page 1283 21 - 34 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (14) Apply Mopar ATF RTV (MS-GF41) as shown in (Fig. 99). Install main sump baffle to transaxle case (Fig. 100) and torque screw to 5 N·m (45 in. lbs.). Fig. 99 Properly Applied Sealant 1 - SEALANT Fig.
Page 1284 TRANSAXLE 21 - 35 42LE AUTOMATIC TRANSAXLE (Continued) (17) Remove chain spreader (Fig. 103). Fig. 101 Output Sprocket Spacer Fig. 103 Remove Chain Spreader 1 - OUTPUT SPROCKET SPACER 2 - VENT BAFFLE 1 - OUTPUT SPROCKET 3 - OUTPUT SHAFT 2 - SPECIAL TOOL 6550 3 - TRANSFER SPROCKET CAUTION: The chain sprockets have a slip fit onto...
Page 1285 21 - 36 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (20) Install chain oiler (Fig. 107) and torque screw to 5 N·m (45 in. lbs.). Fig. 105 Install Output Shaft Sprocket Snap Ring and Wave Washer 1 - WAVE WASHER Fig. 107 Install Chain Oiler 2 - SNAP RING 1 - CHAIN SNUBBER 2 - CHAIN OILER...

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