Page 1 SERVICE MANUAL 2005 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 manufactured.
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 Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Power Systems Restraints Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame &...
Page 5 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Power Systems Restraints Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame &...
Page 6 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATE MANUFACTURE PLATE DESCRIPTION ......1 DESCRIPTION .
Page 7 INTRODUCTION marks plus 2. The most commonly used metric bolt FASTENER IDENTIFICATION strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on DESCRIPTION the head of the bolt. The higher the class number, The SAE bolt strength grades range from grade 2 the greater the bolt strength.
Page 8 INTRODUCTION FASTENER IDENTIFICATION (Continued) FASTENER STRENGTH...
Page 9 INTRODUCTION FASTENER USAGE INTERNATIONAL SYMBOLS DESCRIPTION DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are FASTENER USAGE used to identify various instrument controls. The symbols correspond to the controls and displays that WARNING: USE OF AN INCORRECT FASTENER are located on the instrument panel.
Page 10 INTRODUCTION MANUFACTURE PLATE DESCRIPTION The Manufacturer Plate (Fig. 2) 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 11 INTRODUCTION METRIC SYSTEM (Continued) METRIC CONVERSION CHART...
Page 12 INTRODUCTION METRIC SYSTEM (Continued) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers TORQUE REFERENCES Refer to the Metric Conversion Chart to convert...
Page 13 INTRODUCTION TORQUE REFERENCES (Continued) TORQUE SPECIFICATIONS...
Page 14 POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = Manufactured By DaimlerChrysler Corpora- tion Make B = Dodge Vehicle Type 3 = Passenger Car Passenger Safety J = Restraint System Air Bags Front Next Gen- eration Multi-Stage Car Line...
Page 15 INTRODUCTION VEHICLE IDENTIFICATION NUMBER (Continued) All communications or inquiries regarding the VIN CHECK DIGIT vehicle should include the Month-Day-Hour and To protect the consumer from theft and possible Vehicle Identification Number. fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden- tification Number.
Page 16 LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS MAINTENANCE SCHEDULES DESCRIPTION ......1 DESCRIPTION PARTS &...
Page 17 0 - 2 LUBRICATION & MAINTENANCE PARTS & LUBRICANT RECOMMENDATION (Continued) FLUID TYPES Body Component Fluid, Lubricant, and Genuine DESCRIPTION Part ENGINE OIL Hinges: Door & Hood Mopar Engine Oil WARNING: NEW OR USED ENGINE OIL CAN BE Swing Gate Mopar Multi-Purpose Lube NLGI IRRITATING TO THE SKIN.
Page 18 LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) catalysts and hinder efforts to guarantee emissions performance to 100,000 miles. • Altering the viscosity characteristics of the engine oil so that it no longer meets the require- ments of the specified viscosity grade. •...
Page 19 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) The 5 Year/100,000 Mile Formula (orange in color) FLUID CAPACITIES - EXPORT and the Three Year Formula (green in color) MUST NOT BE MIXED. DESCRIPTION SPECIFICATION CAUTION: Mopar Antifreeze/Coolant, Fuel Tank 70.0 L (18.5 gal.) Year/100,000 Mile Formula (MS-9769) may not be Engine Oil with Oil Filter...
Page 20 LUBRICATION & MAINTENANCE 0 - 5 MAINTENANCE SCHEDULES (Continued) • If equipped for and operating with E-85 At Each Oil Change • Change the engine oil filter. (ethanol) fuel. • Inspect the exhaust system. NOTE: If ANY of these apply to you then change •...
Page 21 0 - 6 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 3,000 6,000 9,000 12,000 15,000 18,000 (Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) (29 000) Change engine oil and engine oil filter, if not replaced at 3 months. Inspect the brake linings.
Page 22 LUBRICATION & MAINTENANCE 0 - 7 MAINTENANCE SCHEDULES (Continued) Miles 57,000 60,000 63,000 66,000 69,000 72,000 (Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000) Change engine oil and engine oil filter, if not replaced at 3 months. Lubricate the front and rear sus- pension ball joints.
Page 23 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 93,000 96,000 99,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (163 000) (168 000) Change engine oil and engine oil filter, if not replaced at 3 months. Inspect the brake linings. Change the rear axle fluid.
Page 24 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 42,000 48,000 54,000 60,000 66,000 (Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) [Months] [42] [48] [54] [60] [66] Change engine oil and engine oil filter. Inspect the brake linings. Change the rear axle fluid.
Page 25 0 - 10 LUBRICATION & MAINTENANCE TOUCH EACH OTHER WHEN CONNECTED TO A HOISTING BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. STANDARD PROCEDURE - HOISTING REMOVE METALLIC JEWELRY WORN ON HANDS Refer to Owner’s Manual provided with vehicle for OR WRISTS TO AVOID INJURY BY ACCIDENTAL proper emergency jacking procedures.
Page 26 LUBRICATION & MAINTENANCE 0 - 11 JUMP STARTING (Continued) VENTURE UNDER A LIFTED VEHICLE IF NOT SUP- PORTED PROPERLY ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHI- CLE. CAUTION: Do not damage brake lines, exhaust sys- tem, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle.
Page 27 0 - 12 LUBRICATION & MAINTENANCE VEHICLE STORAGE (Continued) • Coat unpainted surfaces in engine compartment WHEELS AND TIRES PREPARATION with Mopar General Purpose Lube MP-50, or equiv- For short term storage refer to Owner’s Man- alent, to prevent corrosion. ual.
Page 28 LUBRICATION & MAINTENANCE 0 - 13 VEHICLE STORAGE (Continued) • If used, remove desiccant bag from interior of RETURNING VEHICLE FROM LONG TERM vehicle. STORAGE • Clean vehicle as necessary. For short term storage refer to Owner’s Man- It is possible for the clutch disc to adhere to the ual.
Page 30 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page SUSPENSION FRONT SUSPENSION ..... 3 WARNINGS AND CAUTIONS ....1 REAR SUSPENSION .
Page 31 2 - 2 SUSPENSION SUSPENSION (Continued) Fig. 1 Lubrication Points - Overhead View 1 - FRONT LOWER BALL JOINTS 3 - REAR LOWER BALL JOINTS 2 - FRONT UPPER BALL JOINTS 4 - REAR UPPER BALL JOINTS...
Page 32 FRONT SUSPENSION 2 - 3 FRONT SUSPENSION TABLE OF CONTENTS page page FRONT SUSPENSION INSTALLATION ......16 SPECIFICATIONS SHOCK ASSEMBLY FRONT SUSPENSION FASTENER TORQUE...
Page 33 2 - 4 FRONT SUSPENSION FRONT SUSPENSION SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE DESCRIPTION N·m Lbs. Lbs. ABS Tone Wheel Mounting Bolt Brake Caliper (Hydraulic) — Installer, Ball Joint 6761 Mounting Bolts Hub And Bearing Mounting — Bolts Lower Ball Joint Castle Nut —...
Page 34 FRONT SUSPENSION 2 - 5 FRONT SUSPENSION (Continued) HUB / BEARING DESCRIPTION The wheel bearing used on the front of this vehicle is a unit type combined hub and bearing assembly (Fig. 1). The hub and bearing is made up of the wheel mounting hub (flange) and the wheel bearing.
Page 35 2 - 6 FRONT SUSPENSION HUB / BEARING (Continued) To diagnose a bent hub, (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/ROTORS - DIAGNOSIS AND TESTING). REMOVAL NOTE: Review all Warnings and Cautions. (Refer to 2 - SUSPENSION - WARNING). (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove wheel and tire assembly.
Page 36 FRONT SUSPENSION 2 - 7 HUB / BEARING (Continued) INSTALLATION (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE). CAUTION: A special corrosion prevention gasket (2) Remove wheel and tire assembly. (Refer to 22 - must be installed between the hub and bearing and TIRES/WHEELS - REMOVAL) the steering knuckle (Fig.
Page 37 2 - 8 FRONT SUSPENSION KNUCKLE (Continued) Fig. 7 Puller Positioned To Release Tie Rod Fig. 9 Puller And Spacer Positioned To Release Ball Joint 1 - OUTER TIE ROD 2 - PULLER C-4150A 1 - SPACER 6983 3 - KNUCKLE 2 - PULLER C-4150A NOTE: Use of Spacer, Special Tool 6983, is neces- (11) Remove cotter pin and castle nut from upper...
Page 38 FRONT SUSPENSION 2 - 9 KNUCKLE (Continued) - SUSPENSION/FRONT/KNUCKLE / ABS TONE KNUCKLE/ABS TONE WHEEL WHEEL SEAL - INSTALLATION) SEAL (e) Install ABS wheel speed sensor tone wheel through seal on rear of knuckle and against rear of REMOVAL hub and bearing (Fig. 11). Install and tighten (1) Raise vehicle.
Page 39 2 - 10 FRONT SUSPENSION KNUCKLE/ABS TONE WHEEL SEAL (Continued) (5) Using hex wrench or driver socket, remove bolt retaining ABS tone wheel to hub and bearing (Fig. 11). Fig. 12 Seal Installation Using Special Tools 1 - STEERING KNUCKLE 2 - 6573 3 - C-4171 gasket must be used when installing a hub and...
Page 40 FRONT SUSPENSION 2 - 11 KNUCKLE/ABS TONE WHEEL SEAL (Continued) (9) Using same bolt or identical replacement bolt, preventative coating applied to it. A corrosion preven- mount tone wheel to hub and bearing. Tighten bolt to tion gasket is also used between the ball joint and 17 N·m (13 ft.
Page 41 2 - 12 FRONT SUSPENSION LOWER BALL JOINT SEAL BOOT (Continued) CAUTION: The nut must be positioned at the end of the stabilizer bar link stud to help prevent the end of the stud from being damaged when separating it from the lower control arm.
Page 42 FRONT SUSPENSION 2 - 13 LOWER BALL JOINT SEAL BOOT (Continued) (8) Install shock assembly into mounting bracket on lower control arm. Install shock assembly mount- ing bolt and nut (Fig. 17). DO NOT TIGHTEN MOUNTING BOLT AT THIS TIME. (9) Install stabilizer bar link into mounting hole on lower control arm (Fig.
Page 43 2 - 14 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (7) Remove bolt and nut attaching shock assembly to bracket on lower control arm (Fig. 17). (8) Remove cotter pin and nut from lower ball joint stud (Fig. 19). Fig. 20 Inserting Spacer Between Knuckle And Seal Fig.
Page 44 FRONT SUSPENSION 2 - 15 LOWER CONTROL ARM (Continued) CAUTION: Use a vise equipped with soft jaw caps CAUTION: Do not use any type of impact wrench on to protect the surface of the control arm from dam- Special Tool 6969B. Use only hand tools. age.
Page 45 2 - 16 FRONT SUSPENSION LOWER CONTROL ARM (Continued) CAUTION: Do not use any type of impact wrench on (11) Set vehicle to design height. (Refer to 2 - SUS- Special Tool 6969B. Use only hand tools. PENSION/WHEEL ALIGNMENT STANDARD PROCEDURE DESIGN HEIGHT...
Page 46 FRONT SUSPENSION 2 - 17 SHOCK ASSEMBLY (Continued) NOTE: If both front shock assemblies are being ser- viced at the same time, mark the coil spring and shock assembly according to which side of the vehicle the shock absorber was removed from, and which shock absorber the coil spring was removed from.
Page 47 2 - 18 FRONT SUSPENSION SHOCK ASSEMBLY (Continued) (6) Inspect the shock assembly components for the (5) Position the upper seat on the top of the coil following and replace as necessary: spring so the cutout in the upper seat is not posi- •...
Page 48 FRONT SUSPENSION 2 - 19 SHOCK ASSEMBLY (Continued) (8) Verify vehicle fuel tank is full of fuel. If tank is mounted against wheels) with notches against not full of fuel, reduction in weight will affect height locating pins in ends of Suspension Height Stands of vehicle and design height measurement.
Page 49 2 - 20 FRONT SUSPENSION SHOCK ASSEMBLY (Continued) (17) Add 150 pounds ballast weight to each seat (20) Compare recorded measurements to specifica- cushion of vehicle (300 pounds total) to lower vehicle tions. (Refer to 2 - SUSPENSION/WHEEL ALIGN- to specified design height (Fig. 33). MENT - SPECIFICATIONS) (21) If recorded height is higher than specifica- tions, jounce vehicle and remeasure.
Page 50 FRONT SUSPENSION 2 - 21 STABILIZER BAR (Continued) (4) Separate stabilizer bar from each link using (b) Remove each bushing from stabilizer bar by Remover, Special Tool MB991113 (Fig. 35). opening slit in bushing and peeling it off bar. INSTALLATION (1) Thoroughly clean stabilizer bar in area of bush- ing contact.
Page 51 2 - 22 FRONT SUSPENSION STABILIZER LINK REMOVAL NOTE: Review all Warnings and Cautions. (Refer to 2 - SUSPENSION - WARNING) (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE). (2) Remove wheel and tire assembly. (Refer to 22 - TIRES/WHEELS - REMOVAL) (3) Remove nut attaching stabilizer bar link to end of stabilizer bar (Fig.
Page 52 FRONT SUSPENSION 2 - 23 UPPER BALL JOINT (Continued) (2) Remove wheel and tire assembly (Refer to 22 - TIRES/WHEELS - REMOVAL). (3) Remove brake caliper from knuckle and hang out of the way, then remove brake rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR REMOVAL) (4) Remove bolt fastening wheel speed sensor head...
Page 53 2 - 24 FRONT SUSPENSION UPPER BALL JOINT SEAL BOOT (Continued) tighten wheel mounting nuts in proper sequence to 122 N·m (90 ft. lbs.) torque. (11) Lower vehicle. UPPER CONTROL ARM REMOVAL NOTE: Review all Warnings and Cautions. (Refer to 2 - SUSPENSION - WARNING).
Page 54 FRONT SUSPENSION 2 - 25 UPPER CONTROL ARM (Continued) Fig. 43 Knuckle Mounting 1 - UPPER BALL JOINT COTTER PIN 2 - LOWER BALL JOINT COTTER PIN Fig. 44 Front Suspension Mounting 3 - TIE ROD NUT 4 - LOWER BALL JOINT NUT 1 - UPPER CONTROL ARM 5 - KNUCKLE (WITH HUB AND BEARING) 2 - CAM BOLT...
Page 55 2 - 26 FRONT SUSPENSION UPPER CONTROL ARM (Continued) (2) Assemble pieces of Remover, Special Tool (2) Assemble pieces of Remover, Special Tool 6969B, through bushing as shown (Fig. 46). 6969B, through bushing and arm as shown (Fig. 47). Fig. 46 Tool 6969B Installed For Bushing Removal Fig.
Page 56 FRONT SUSPENSION 2 - 27 UPPER CONTROL ARM (Continued) (3) Install cotter pin through nut and stud of (8) Position vehicle on alignment rack/drive-on upper ball joint (Fig. 43). hoist. (4) Install ABS wheel speed sensor in steering (9) Set vehicle to design height. (Refer to 2 - SUS- knuckle (Fig.
Page 57 2 - 28 REAR SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION DISASSEMBLY ......42 SPECIFICATIONS ASSEMBLY .
Page 58 REAR SUSPENSION 2 - 29 REAR SUSPENSION SPECIAL TOOLS REAR SUSPENSION SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE DESCRIPTION N·m Lbs. Lbs. Brake Caliper (Hydraulic) — Mounting Bolts Hub And Bearing Mounting — Bolts Hub Nut — Lower Ball Joint Castle Nut —...
Page 59 2 - 30 REAR SUSPENSION REAR SUSPENSION (Continued) Remover, Tie Rod End MB991113 HUB / BEARING Wrench, Shock Absorber 9024 DESCRIPTION The wheel bearing used on the front of this vehicle is a unit type combined hub and bearing assembly (Fig.
Page 60 REAR SUSPENSION 2 - 31 HUB / BEARING (Continued) DIAGNOSIS AND TESTING - HUB AND BEARING (REAR) With the wheel, disc brake caliper, and brake rotor removed, rotate the wheel hub. Any roughness or resistance to rotation may indicate dirt intrusion or a failed wheel bearing.
Page 61 2 - 32 REAR SUSPENSION HUB / BEARING (Continued) (12) Install Puller, Special Tool C-4150A, over Spacer and lower control arm as shown (Fig. 6). Ball bearing in bolt of Special Tool C-4150A must be centered in end of lower ball joint stud. Fig.
Page 62 REAR SUSPENSION 2 - 33 HUB / BEARING (Continued) (17) Remove Puller from hub and bearing flange. (11) Install washer and hub nut on halfshaft yoke (18) Remove four bolts fastening hub and bearing (Fig. 3). Do not tighten at this time. to knuckle.
Page 63 2 - 34 REAR SUSPENSION KNUCKLE (Continued) (9) Release toe link from knuckle using Puller, Special Tool C-4150A (Fig. 5). Remove tool. (10) Remove cotter pin and castle nut from lower ball joint stud (Fig. 3). CAUTION: Do not strike or apply heat to steering knuckle in an effort to separate ball joint studs from knuckle.
Page 64 REAR SUSPENSION 2 - 35 KNUCKLE (Continued) INSTALLATION (19) Tighten hub nut on halfshaft yoke to 258 N·m (190 ft. lbs.) torque. (20) Install spring washer, nut lock and cotter pin CAUTION: A corrosion prevention gasket is used on end of halfshaft yoke (Fig. 3). between the hub and bearing and the knuckle (Fig.
Page 65 2 - 36 REAR SUSPENSION LOWER BALL JOINT (Continued) gasket is also used between the ball joint and the CAUTION: The nut must be positioned at the end of rear knuckle (Fig. 11). the stabilizer bar link stud when removing the link from the lower control arm.
Page 66 REAR SUSPENSION 2 - 37 LOWER BALL JOINT SEAL BOOT (Continued) (8) Lower vehicle. (9) Position vehicle on alignment rack/drive-on hoist. (10) Set vehicle to design height. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE DESIGN HEIGHT MEASURE- MENT) (11) Tighten shock assembly clevis bracket mount- ing bolt to 136 N·m (100 ft.
Page 67 2 - 38 REAR SUSPENSION LOWER CONTROL ARM (Continued) Fig. 14 Upper And Lower Control Arms Fig. 16 Knuckle Mounting 1 - UPPER CONTROL ARM 1 - UPPER CONTROL ARM 2 - LOWER CONTROL ARM 2 - HALFSHAFT 3 - STABILIZER LINK 3 - KNUCKLE (WITH HUB AND BEARING) 4 - NUT LOCK 5 - SPRING WASHER...
Page 68 REAR SUSPENSION 2 - 39 LOWER CONTROL ARM (Continued) (8) Release lower ball joint from lower control arm using Puller. Remove tools. Lift ball joint stud from lower control arm. (9) Remove nuts, cam bolts and washers fastening lower control arm to frame (Fig. 14). (10) Remove lower control arm.
Page 69 2 - 40 REAR SUSPENSION LOWER CONTROL ARM (Continued) ASSEMBLY - ISOLATOR BUSHINGS (5) Remove tools. (6) Install lower control arm on vehicle. (Refer to 2 - SUSPENSION/REAR/LOWER CONTROL ARM - NOTE: The following procedure can be used for INSTALLATION) either lower control arm isolator bushing.
Page 70 REAR SUSPENSION 2 - 41 SHOCK ASSEMBLY REMOVAL NOTE: Review all Warnings and Cautions. (Refer to 2 - SUSPENSION - WARNING). (1) Roll down both door windows. (2) Unlatch convertible top. (3) Disconnect rear window defroster electrical connectors. (4) Remove 14 tack strip nuts. (Fig. 21) Fig.
Page 71 2 - 42 REAR SUSPENSION SHOCK ASSEMBLY (Continued) (11) Remove nut and bolt fastening top of shock assembly to frame (Fig. 24). Fig. 25 Shock Service Access Hole 1 - SHOCK ACCESS HOLE 2 - SHOCK UPPER EYE (2) Position the shock absorber assembly in the strut coil spring compressor following the manufac- Fig.
Page 72 REAR SUSPENSION 2 - 43 SHOCK ASSEMBLY (Continued) Fig. 28 Upper Seat Removal/Installation 1 - COLLAR 2 - COIL SPRING 3 - UPPER SEAT 4 - JOUNCE BUMPER • Inspect the jounce bumper for cracks and signs of deterioration. • Inspect the plastic collar for cracks and signs of deterioration.
Page 73 2 - 44 REAR SUSPENSION SHOCK ASSEMBLY (Continued) Fig. 30 Coil Spring End Against Seat Step Fig. 29 Wrench 9024 Installed On Shock 1 - SHOCK ABSORBER 1 - NOTCH IN SHOCK BODY 2 - COIL SPRING END 2 - SHOCK ABSORBER BODY 3 - STEP IN LOWER SEAT 3 - CLEVIS BRACKET 4 - 1/2 SQUARE DRIVE HOLE...
Page 74 REAR SUSPENSION 2 - 45 SHOCK ASSEMBLY (Continued) (9) Install the shock assembly on the vehicle (13) Remove any load within passenger and lug- (Refer SUSPENSION/REAR/SHOCK gage compartments that is not factory equipment. INSTALLATION). (14) Position vehicle on alignment rack/drive-on lift equipped with front turntables and rear slip INSTALLATION plates.
Page 75 2 - 46 REAR SUSPENSION SHOCK ASSEMBLY (Continued) NOTE: When setting vehicle to design height while using Suspension Height Stands it is critically important to perform the following: • Make sure locating pins are inserted in correct wheel diameter holes in Height Stands or measure- ment will be incorrect.
Page 76 REAR SUSPENSION 2 - 47 SHOCK ASSEMBLY (Continued) (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE). (2) Remove both rear wheel and tire assemblies. (Refer to 22 - TIRES/WHEELS - REMOVAL) (3) Remove nuts attaching stabilizer bar links to each end of stabilizer bar.
Page 77 2 - 48 REAR SUSPENSION STABILIZER BAR (Continued) (3) Install stabilizer bar assembly back into vehicle STABILIZER LINK in reverse order of removal through wheel opening. (4) Position bushing retainers against frame rails, REMOVAL then install four retainer bolts (Fig. 37). DO NOT TIGHTEN AT THIS TIME.
Page 78 REAR SUSPENSION 2 - 49 STABILIZER LINK (Continued) (6) Position center punch in dimple on end of link stud (Fig. 39). Fig. 40 Rear Toe Link Assembly 1 - OUTER TIE ROD 2 - TOE PATTERN ADJUSTMENT HOLE 3 - MOUNTING HOLE 4 - FLEX JOINT BOOT 5 - JAM NUT steering attitude of the rear wheels.
Page 79 2 - 50 REAR SUSPENSION TOE LINK (Continued) Fig. 41 Upper Ball Joint And Toe Link Mounting 1 - UPPER BALL JOINT 2 - TOE LINK 3 - KNUCKLE Fig. 43 Toe Link Mounting To Frame 1 - OUTBOARD MOUNTING BOLT 2 - LEFT TOE LINK SHIM ORIENTATION 3 - RIGHT TOE LINK SHIM ORIENTATION 4 - ADJUSTMENT SHIM...
Page 80 REAR SUSPENSION 2 - 51 TOE LINK (Continued) Fig. 45 Upper Ball Joint 1 - TAPERED STUD 2 - GREASE FITTING 3 - THREADS FOR INSTALLING BALL JOINT IN CONTROL ARM Fig. 44 Stabilizer Bar And Toe Link Mounting To 4 - BALL JOINT Frame For this reason, the ball joint has a corrosion preven-...
Page 81 2 - 52 REAR SUSPENSION UPPER BALL JOINT (Continued) tire, look for any movement between the upper ball hand pressure to the rear of Installer until seal boot joint and the knuckle. flange is pressed squarely against control arm. (3) If any lateral movement is evident at the upper Remove tool.
Page 82 REAR SUSPENSION 2 - 53 UPPER CONTROL ARM (Continued) (1) Clamp upper control arm securely in vise so that bushing to be removed is closest to vise jaws (Fig. 48). Fig. 49 Tool 6969B Installed For Bushing Removal 1 - DOUBLE THREADED NUT 6969-4 2 - SPACER 6969-1 3 - RECEIVER 6969-2 Fig.
Page 83 2 - 54 REAR SUSPENSION UPPER CONTROL ARM (Continued) ASSEMBLY - ISOLATOR BUSHINGS NOTE: The following procedure can be used for either upper control arm isolator bushing. (1) Squarely position isolator bushing into control arm pivot end bore from outboard side. NOTE: Before using Special Tool 6969B, lubricate threads of Screw Assembly 6969-3 with appropriate lubricant.
Page 84 WHEEL ALIGNMENT 2 - 55 WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT DESIGN HEIGHT MEASUREMENT ..62 DESCRIPTION WHEEL ALIGNMENT ....65 WHEEL ALIGNMENT .
Page 85 2 - 56 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CAMBER CROSS CAMBER Camber is the inward or outward tilt of the top of Cross camber is the difference between left and the tire and wheel assembly (Fig. 1). Camber is mea- right camber.
Page 86 WHEEL ALIGNMENT 2 - 57 WHEEL ALIGNMENT (Continued) CROSS CASTER TOE-OUT ON TURNS Cross caster is the difference between left and Toe-out on turns is the relative positioning of the right caster. front wheels while steering through a turn (Fig. 4). This compensates for each front wheel’s turning radius.
Page 87 2 - 58 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) center of the upper ball joint (or strut) and the lower ball joint (Fig. 5). S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension compo- nent may be the cause.
Page 88 WHEEL ALIGNMENT 2 - 59 WHEEL ALIGNMENT (Continued) CAUTION: Design height must be correctly set after tightened and torqued with the vehicle at the cor- any rubber bushing-mounted suspension compo- rect design height. Otherwise, curb height is nent is installed on the vehicle. Rubber bushing- affected and the handling characteristics of the mounted suspension component fasteners must be vehicle are jeopardized.
Page 89 2 - 60 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Broken Or Weak Coil Spring(s). 3. Replace Coil Spring(s). 4. Shock Absorber Not Functioning 4. Replace Shock Absorber. Correctly . 5. Excessive Friction In Steering 5. Replace Steering Gear. Gear.
Page 90 WHEEL ALIGNMENT 2 - 61 WHEEL ALIGNMENT (Continued) (5) Remove belly pan from frame. (Refer to 23 - STANDARD PROCEDURE BODY/EXTERIOR/BELLY PAN - REMOVAL) (6) Place Adapter, Special Tool 8897, over smaller PRE-WHEEL ALIGNMENT INSPECTION end of one of two Suspension Height Gages, Special Before starting a wheel alignment on this vehicle, Tool 6914 (Fig.
Page 91 2 - 62 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) (b) Rubber bushing mounted suspension compo- nents may not be properly positioned and tight- ened at mounting locations. To correct this, (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE - DESIGN HEIGHT MEASUREMENT) Fig.
Page 92 WHEEL ALIGNMENT 2 - 63 WHEEL ALIGNMENT (Continued) (8) Install front and rear Suspension Height Gages on vehicle (Fig. 9) (Fig. 10). Ensure that gages are correctly attached to inner rim flange at very base of each wheel. Fig. 9 Height Gage Installed - Front Suspension 2 - WHEEL ALIGNMENT RACK 1 - HEIGHT GAGE 6914 WITH EXTENSION 8997...
Page 93 2 - 64 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) Fig. 10 Height Gage Installed - Rear Suspension 2 - WHEEL ALIGNMENT RACK 1 - HEIGHT GAGE 6914 (9) Add 150 pounds ballast weight to each seat (10) Jounce vehicle several times, each time pay- cushion of vehicle (300 pounds total) to lower vehicle ing special attention to release vehicle at very bot- to specified design height (Fig.
Page 94 WHEEL ALIGNMENT 2 - 65 WHEEL ALIGNMENT (Continued) NOTE: The mounting bolts must be loosened enough to allow the suspension of the vehicle to move without loading (twisting) the rubber insert of the isolator bushings. (15) Tighten previously loosened mounting bolts to specified torque values.
Page 95 2 - 66 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) (6) Proceed with Camber And Caster Angle. CAMBER ANGLE Camber angle adjustment involves the reposition- CAMBER AND CASTER ANGLE ing of the lower control arm pivot bolts using the Camber and caster angles on this vehicle are adjustment cams (Fig.
Page 96 WHEEL ALIGNMENT 2 - 67 WHEEL ALIGNMENT (Continued) INCLINOMETER SETUP FOR CASTER ANGLE VIEWING (2) Plug power cable (supplied with the DRBIII kit) into DRBIII power connector marked “VEHI- Both front and rear caster angle on this vehicle CLE” (Fig. 16). can be read.
Page 97 2 - 68 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) (9) Zero inclinometers (Fig. 17): (a) Place both inclinometers together on known flat, level surface, such as alignment rack, with knurled ends of fastening screws facing upward. (b) Press F2. (c) Follow directions on DRBIII screen to com- plete inclinometer zero.
Page 98 WHEEL ALIGNMENT 2 - 69 WHEEL ALIGNMENT (Continued) Fig. 19 Inclinometer Installed On Right Front Knuckle (Left Side Typical) 1 - UPPER SPRING-LOADED HOOK 4 - INCLINOMETER 6989 2 - BRAKE CALIPER 5 - ADAPTER 8995 3 - LOWER SPRING-LOADED HOOK...
Page 99 2 - 70 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) INCLINOMETER INSTALLATION ON REAR KNUCKLES inclinometer is mounted right-side-up on Adapter, upper mounting screw is larger diameter than lower. (1) Clean any dirt or debris off knuckles paying special attention to caster pads on trailing end of knuckles near ball joints.
Page 100 WHEEL ALIGNMENT 2 - 71 WHEEL ALIGNMENT (Continued) (4) Adjust caster using measurements viewed on DRBIII screen, and camber using measurements viewed on wheel alignment equipment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICA- TIONS) (5) When adjustments complete, remove Adapters/Inclinometers.
Page 101 2 - 72 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) sion is extended (rebound), wheel toe should move in (1) Raise vehicle by frame (near PLP holes (Fig. the opposite direction. Front suspension jounce 12) (Fig. 13), but allowing room for Suspension should cause the wheels to toe out;...
Page 102 WHEEL ALIGNMENT 2 - 73 WHEEL ALIGNMENT (Continued) (14) Plot toe readings for rear suspension on toe-in will increase on rebound and toe-out will Dynamic Toe Pattern Graph provided in this section increase on jounce. If the steering gear is lowered, (Fig.
Page 103 2 - 74 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued)
Page 104 WHEEL ALIGNMENT 2 - 75 WHEEL ALIGNMENT (Continued) NOTE: All wheel alignments are to be set with the SPECIFICATIONS vehicle at DESIGN HEIGHT. (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- WHEEL ALIGNMENT DURE). NOTE: All specifications are given in degrees. ADJUSTMENT FRONT SUSPENSION REAR SUSPENSION...
Page 105 2 - 76 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) SPECIAL TOOLS WHEEL ALIGNMENT Height Gages, Suspension 6914 Adapters, Rear Caster 8996 Adapters, Front Caster 8995 Extension, Height Gage 8997...
Page 106 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . 1 REAR AXLE - 226RIA .
Page 107 3 - 2 PROPELLER SHAFT PROPELLER SHAFT (Continued) CONDITION POSSIBLE CAUSE CORRECTION PROPELLER SHAFT VIBRATION 1. Undercoating or other foreign 1. Clean exterior of shaft and wash material on shaft. with solvent 2. Loose U-joint clamp screws. 2. Tighten screws properly. 3.
Page 108 PROPELLER SHAFT 3 - 3 PROPELLER SHAFT (Continued) (8) If the vibration decreased (but was not com- PROPELLER SHAFT RUNOUT pletely eliminated) install a second clamp (Fig. 2) (1) Remove dirt, rust, paint, and undercoating and repeat the vibration test. from the propeller shaft surface.
Page 109 3 - 4 PROPELLER SHAFT PROPELLER SHAFT (Continued) • Worn differential mounting bushings (3) Place inclinometer on yoke bearing cap (B) par- allel to the shaft (Fig. 6). Adjust bubble to center of PROPELLER SHAFT MEASUREMENT sight glass and record reading. To accurately check drive line alignment, raise and support the vehicle.
Page 110 PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) Fig. 7 BELLY PAN 1 - FRAME ASSEMBLY 3 - BELLY PAN 2 - BOLTS (20) 4 - REAR EXTENSION BELLY PAN Fig. 8 YOKE REFERENCE MARKS Fig. 9 PROPELLER SHAFT 1 - REFERENCE MARKS 1 - STRAPS 2 - PINION YOKE CAUTION: Propeller shaft universal joint straps...
Page 111 3 - 6 PROPELLER SHAFT PROPELLER SHAFT (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Axle Hub Nut U-Joint Strap Bolts SPECIAL TOOLS INCLINOMETER 7663 SINGLE CARDAN UNIVERSAL JOINTS REMOVAL (1) Remove the propeller shaft. (2) Mark the yokes and propeller shaft for instal- lation reference.
Page 112 PROPELLER SHAFT 3 - 7 SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 11 BEARING CAP INSTALLATION 1 - DRIVER SOCKET WRENCH 2 - YOKE 3 - VISE 4 - BEARING CAP CAUTION: The propeller shaft universal joint straps must be replaced. The straps slightly deform when torqued in place.
Page 113 3 - 8 HALF SHAFT HALF SHAFT TABLE OF CONTENTS page page HALF SHAFT INSTALLATION ......9 CAUTION .
Page 114 HALF SHAFT 3 - 9 HALF SHAFT (Continued) Fig. 2 TOE LINK Fig. 4 PULLER LOWER BALL JOINT 1 - PULLER 1 - SPACER 2 - TOE LINK STUD 2 - PULLER 3 - LOWER BALL JOINT STUD 4 - LOWER CONTROL ARM Fig.
Page 115 3 - 10 HALF SHAFT HALF SHAFT (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Half Shaft Nut SPECIAL TOOLS PULLER 9052...
Page 116 REAR AXLE - 226RIA 3 - 11 REAR AXLE - 226RIA TABLE OF CONTENTS page page REAR AXLE - 226RIA SPECIFICATIONS ..... . . 16 DESCRIPTION .
Page 117 3 - 12 REAR AXLE - 226RIA REAR AXLE - 226RIA (Continued) peak-noise range. If the noise stops or changes VIBRATION greatly: Vibration at the rear of the vehicle is usually • Check for insufficient lubricant. caused by a: • Incorrect ring gear backlash. •...
Page 118 REAR AXLE - 226RIA 3 - 13 REAR AXLE - 226RIA (Continued) Condition Possible Causes Correction Axle Shaft Broke 1.Vehicle overloaded. 1. Replace broken shaft and avoid excessive weight on vehicle. 2. Erratic clutch operation. 2. Replace broken shaft and avoid or correct erratic clutch operation.
Page 119 3 - 14 REAR AXLE - 226RIA REAR AXLE - 226RIA (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage.
Page 120 REAR AXLE - 226RIA 3 - 15 REAR AXLE - 226RIA (Continued) (3) Remove differential drain plug. (4) Remove lubricant from the axle assembly com- pletely. (5) Install drain plug and tighten to 20 N·m (15 ft lbs). (6) Remove fill plug and fill rear axle with 0.12 L (4 oz) of Mopar Limited Slip Additive and 1.21 L (41 oz) Mopar Synthetic Gear &...
Page 121 3 - 16 REAR AXLE - 226RIA REAR AXLE - 226RIA (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Differential Drain/Fill Plug Differential Cover Bolts Frame Mounting Bolts Pinion Mounting Bolts SPECIAL TOOLS INSTALLER C-3718 INSTALLER 6573 SPANNER WRENCH 6958 INSTALLER 8889 SEAL REMOVER 7794-A PULLER C-452...
Page 122 REAR AXLE - 226RIA 3 - 17 AXLE SHAFT SEALS REMOVAL (1) Remove axle assembly from the vehicle. (2) Remove rear cover. (3) Using a pair of 90 degree angled snap ring pli- ers, expand the snap ring while pulling outward on the output shaft.
Page 123 3 - 18 REAR AXLE - 226RIA PINION SEAL (Continued) Fig. 4 PINION YOKE REMOVER 1 - WRENCH 2 - YOKE 3 - REMOVER Fig. 6 PINION YOKE INSTALLER 1 - INSTALLER 2 - PINION YOKE 3 - SPANNER YOKE (5) Measure pinion rotating torque with an inch pound torque wrench (Fig.
Page 124 REAR AXLE - 226RIA 3 - 19 PINION SEAL (Continued) (6) If rotating torque is low, hold pinion yoke with Holder 6958 (Fig. 8) and tighten the pinion shaft nut in 6.8 N·m (5 ft. lbs.) increments until proper rotat- ing torque is achieved.
Page 126 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 127 5 - 2 BRAKES - BASE INSTALLATION - BRAKE ROTOR (REAR) . . . 35 INSTALLATION ......39 SPECIFICATIONS CALIPER - PARKING BRAKE BRAKE ROTOR LIMITS/SPECIFICATIONS .
Page 128 BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) DIAGNOSIS AND TESTING - BASE BRAKE LAMP, BRAKE NOISE and OTHER BRAKE CONDI- TIONS. SYSTEM DIAGNOSIS CHARTS NOTE: There are three diagnosis charts following that cover the RED BRAKE WARNING INDICATOR RED BRAKE WARNING INDICATOR LAMP CONDITION POSSIBLE CAUSES...
Page 129 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) OTHER BRAKE CONDITIONS CONDITION POSSIBLE CAUSES CORRECTION BRAKES CHATTER 1. Disc brake rotor has excessive 1. Isolate condition as rear or front. thickness variation. Reface or replace brake rotors as nec- essary.
Page 130 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes. 2. Power brake booster runout (vac- 2. Check booster vacuum hose and uum assist). engine tune for adequate vacuum sup- ply.
Page 131 5 - 6 BRAKES - BASE BRAKES - BASE (Continued) CAUTION: Use Bleeder Tank, Special Tool C-3496-B, (2) Open bleeder screw (Fig. 2) on inboard half of or equivalent, along with Cap, Master Cylinder the front caliper assembly at least ONE FULL TURN or more.
Page 132 BRAKES - BASE 5 - 7 BRAKES - BASE (Continued) Again attach clear hose to bleeder screw (5) Repeat the above steps until 4 to 8 ounces of located on the top of inboard half of front caliper brake fluid is bled through inboard half of front cal- assembly being bled (Fig.
Page 133 5 - 8 BRAKES - BASE BRAKES - BASE (Continued) SPECIAL TOOLS Actuation: Secondary Thread 7/16–24 UNS-28 BASE BRAKE SYSTEM Size Outlet Fitting Type 45° Double Wall Inverted Flare Power Brake Booster: Manufacturer/Type Bosch/Vacuum Assist Mounting Studs 3/8-16 UNRC-2A Type 205 mm Tandem Boost At 20 inches Of 4690 All...
Page 134 BRAKES - BASE 5 - 9 (3) Install lower steering column cover/knee ADJUSTABLE PEDALS blocker on instrument panel (Fig. 4). Install fasten- SWITCH ers. (4) Connect battery negative (-) cable to battery. DESCRIPTION (5) Check operation of adjustable pedals. The adjustable pedals switch is mounted on the lower steering column cover/knee blocker (Fig.
Page 135 5 - 10 BRAKES - BASE BRAKE FLUID LEVEL SWITCH (Continued) The disc brake caliper applies the brake pads to the brake rotor. This is done using a 4 piston opposed fixed caliper at each corner of the vehicle (Fig. 6). Each caliper body is cast aluminum, and is 2 individ- ual pieces which are held together by 4 bolts (ser- viced as one assembly).
Page 136 BRAKES - BASE 5 - 11 HYDRAULIC/MECHANICAL (Continued) Fig. 6 Disc Brake Caliper (Typical) 1 - PISTON SEAL 12 - SPRING CLIP 2 - LARGER PISTON – FRONT - 44 MM, REAR - 42 MM 13 - BRAKE SHOE SUPPORTS (4 PER CALIPER) 3 - BRAKE SHOE SUPPORT PINS 14 - TRANSFER BRAKE TUBE 4 - BLEEDER SCREW...
Page 137 5 - 12 BRAKES - BASE BRAKE PADS/SHOES - FRONT/REAR STANDARD PROCEDURE - BRAKE SHOE BURNISHING When new brake shoe and lining assemblies are installed on the vehicle, this procedure must be used to correctly burnish (seat) the brake lining to the brake rotor discs.
Page 138 BRAKES - BASE 5 - 13 BRAKE PADS/SHOES - FRONT/REAR (Continued) (7) Remove inboard and outboard brake shoes through opening in caliper (Fig. 11). Fig. 9 Removing Upper Support Pin 1 - HAMMER 2 - CALIPER ASSEMBLY 3 - SUPPORT PIN Fig.
Page 139 5 - 14 BRAKES - BASE BRAKE PADS/SHOES - FRONT/REAR (Continued) INSPECTION Visually inspect the condition of the brake shoe lin- ings (friction material) on the brake shoes through the caliper. If a more in-depth inspection needs to be made, removal of the brake shoes will be necessary. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ BRAKE PADS/SHOES - REMOVAL).
Page 140 BRAKES - BASE 5 - 15 BRAKE PADS/SHOES - FRONT/REAR (Continued) INSTALLATION (5) Press down on lower end of spring clip until it touches brake rotor. Then install lower brake shoe support pin through caliper and lower holes in both NOTE: Perform steps Step 1 through Step 8 on brake shoes in the same fashion the upper pin was each side of vehicle to complete shoe set removal...
Page 141 5 - 16 BRAKES - BASE BRAKE PADS/SHOES - FRONT/REAR (Continued) NOTE: When new brake shoes are installed they must be burnished (seated) to the rotor. This must be done to ensure the proper performance of the replacement brake shoe. (12) Road test vehicle making several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.
Page 142 BRAKES - BASE 5 - 17 DISC BRAKE CALIPER - FRONT (Continued) (1) Remove front disc brake caliper from vehicle. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ DISC BRAKE CALIPER - REMOVAL). (2) If brake shoes were not removed from caliper prior to removing caliper from vehicle, remove brake shoes.
Page 143 5 - 18 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) (5) Install C-clamp over inboard caliper piston (8) Remove block of wood from center area of cali- nearest to bleeder screw as follows: per. (a) Lay shop towel over outside of inboard cali- (9) Remove piston from caliper bore, but leave pis- per half to protect finish (Fig.
Page 144 BRAKES - BASE 5 - 19 DISC BRAKE CALIPER - FRONT (Continued) Fig. 26 Clamp Installed Over Outboard Piston Fig. 24 Removing Piston Dust Boot Nearest Bleeder Screw 1 - DUST BOOTS 2 - RETAINING GROOVE 1 - BLOCK OF WOOD 2 - C-CLAMP 3 - SHOP TOWEL 4 - INSTALLER 6454...
Page 145 5 - 20 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) CAUTION: Do not attempt to hone piston bores of this caliper. If bores cannot be cleaned using appro- priate solvents, caliper must be replaced. (35) Clean piston bores of caliper using Mopar Non-Clorinated Brake Parts Cleaner, alcohol or another suitable solvent saturated into a lint free towel.
Page 146 BRAKES - BASE 5 - 21 DISC BRAKE CALIPER - FRONT (Continued) CAUTION: When installing piston, force must be (2) Install brake caliper on steering knuckle (Fig. applied to the piston uniformly to avoid cocking 19). Install brake caliper mounting bolts and tighten to 115 N·m (85 ft.
Page 147 5 - 22 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) DISASSEMBLY Except for piston size, rear calipers are same design as front calipers. (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DISC BRAKE CALIPER - FRONT - DISASSEMBLY) ASSEMBLY Except for piston size, rear calipers are same design as front calipers.
Page 148 BRAKES - BASE 5 - 23 FLUID DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over a period of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system.
Page 149 5 - 24 BRAKES - BASE FLUID (Continued) CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system.
Page 150 BRAKES - BASE 5 - 25 MASTER CYLINDER (Continued) (3) Position master cylinder on mounting studs of booster. Be sure push rod on booster is correctly aligned with piston of master cylinder. (4) Push master cylinder up against front of booster.
Page 151 5 - 26 BRAKES - BASE PEDALS - ADJUSTABLE (Continued) (4) Disconnect wiring connector at pedal motor (a) Position a small screwdriver under center (Fig. 35). tang on booster input rod retaining clip (Fig. 45) (b) Lift center tang high enough to clear end of pedal pin, then slide clip off pedal pin and discard.
Page 152 BRAKES - BASE 5 - 27 PEDALS - ADJUSTABLE (Continued) (11) Under hood, pull booster/master cylinder for- ward into engine compartment as far as possible by hand. (12) Reposition pedal assembly and remove wiring components clipped to bracket on left side of pedals assembly (Fig.
Page 153 5 - 28 BRAKES - BASE PEDALS - ADJUSTABLE (Continued) (8) Hold up accelerator pedal and install throttle cable and cable retainer in upper end of pedal shaft (Fig. 38). (9) Using lubriplate, or equivalent, coat contact surface of brake pedal pin (Fig. 37). (10) Slide power brake booster input rod onto brake pedal pin and install NEW retainer clip (Fig.
Page 154 BRAKES - BASE 5 - 29 POWER BRAKE BOOSTER (Continued) DIAGNOSIS AND TESTING - POWER BRAKE reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more BOOSTER than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test.
Page 155 5 - 30 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (4) Remove brake lamp switch and discard. Do not reuse switch. (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING EXTERIOR/BRAKE LAMP SWITCH - REMOVAL) (5) Disconnect brake booster input rod from brake pedal as follows: (a) Position a small screwdriver under center tang on booster input rod retaining clip (Fig.
Page 156 BRAKES - BASE 5 - 31 POWER BRAKE BOOSTER (Continued) (3) Using lubriplate, or equivalent, coat contact ROTOR MINIMUM THICKNESS surface of brake pedal pin. Measure rotor thickness at the center of the brake (4) Slide power brake booster input rod to brake shoe contact surface.
Page 157 5 - 32 BRAKES - BASE ROTOR (Continued) Fig. 50 Checking Rotor Runout 1 - SPECIAL TOOL SP-1910 Fig. 49 Checking Rotor Thickness 2 - ONE INCH FROM EDGE 3 - DISC SURFACE 1 - CALIPER 4 - SPECIAL TOOL C-3339 ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of...
Page 158 BRAKES - BASE 5 - 33 ROTOR (Continued) STANDARD PROCEDURE - BRAKE ROTOR Mount Dial Indicator, Special Tool C-3339, and MACHINING Mounting Adaptor, Special Tool SP-1910, to the steer- ing knuckle. Position the indicator stem so it contacts NOTE: Refacing the rotor is not required each time the hub face near the outer diameter.
Page 159 5 - 34 BRAKES - BASE ROTOR (Continued) Fig. 54 Minimum Brake Rotor Thickness Markings (Typical) 1 - ROTOR MINIMUM THICKNESS MARKING 2 - ROTOR Machine both sides of the brake rotor at the same Fig. 55 Front Brake Caliper And Rotor Mounting time.
Page 160 BRAKES - BASE 5 - 35 ROTOR (Continued) INSTALLATION INSTALLATION - BRAKE ROTOR (FRONT) (1) Install brake rotor on hub and bearing assem- bly. (Fig. 55) (2) Install brake caliper on steering knuckle (Fig. 55). Install brake caliper mounting bolts and tighten to 115 N·m (85 ft.
Page 161 5 - 36 BRAKES - BASE ROTOR (Continued) (4) Install parking brake caliper on knuckle (Fig. shoes. New brake shoes need to be properly bur- 56). Install brake caliper mounting bolts. Tighten nished. (Refer to 5 - BRAKES/HYDRAULIC/ME- upper mounting bolt to 32 N·m (24 ft. lbs.) torque. CHANICAL/BRAKE PADS/SHOES - STANDARD Tighten lower mounting bolt to 52 N·m (38 ft.
Page 162 BRAKES - BASE 5 - 37 PARKING BRAKE (Continued) The parking brake mechanism is self-adjusting to WARNING: THE AUTOMATIC ADJUSTING FEATURE compensate for lining wear. As wear occurs, drive-to- OF THIS PARKING BRAKE LEVER CONTAINS A driven disc clearance increases. This causes the drive CLOCKSPRING LOADED TO APPROXIMATELY 19 disc ball bearings to move farther up the cam ramps POUNDS.
Page 163 5 - 38 BRAKES - BASE CABLE - PARKING BRAKE (Continued) (4) Lower parking brake lever handle to released position. (5) Grasp parking brake lever output cable by hand and pull upward. Continue pulling on cable until a screwdriver (pin punch or appropriate pin) can be inserted through hole in left side of lever mechanism, behind sector gear and out hole in right side of lever (Fig.
Page 164 BRAKES - BASE 5 - 39 CABLE - PARKING BRAKE (Continued) (12) Remove cable end from apply lever on caliper (14) Remove screws from three cable routing (Fig. 61). clamps (Fig. 62). (15) Remove cable. INSTALLATION (1) Install cable through framework as shown (Fig. 62).
Page 165 5 - 40 BRAKES - BASE CABLE - PARKING BRAKE (Continued) (8) Install wheel and tire assembly (Refer to 22 - (4) Lower parking brake lever handle to released TIRES/WHEELS - INSTALLATION). Progressively position. tighten wheel mounting nuts in proper sequence to (5) Grasp parking brake lever output cable by 122 N·m (90 ft.
Page 166 BRAKES - BASE 5 - 41 CALIPER - PARKING BRAKE (Continued) (14) Using a pin punch, tap parking brake shoe retaining pin out of caliper (Fig. 64). Fig. 65 Guide Pin Bushing Components 1 - UPPER BUSHING COMPONENTS 2 - LOWER BUSHING COMPONENTS Fig.
Page 167 5 - 42 BRAKES - BASE CALIPER - PARKING BRAKE (Continued) (3) Install parking brake caliper on knuckle (Fig. 63). Install brake caliper mounting bolts. Tighten upper mounting bolt to 32 N·m (24 ft. lbs.) torque. Tighten lower mounting bolt to 52 N·m (38 ft. lbs.) torque.
Page 168 BRAKES - BASE 5 - 43 (6) Remove both rear parking brake cables from LEVER - PARKING BRAKE parking brake cable equalizer (Fig. 69). REMOVAL NOTE: Before proceeding, review Warnings and Cautions (Refer to 5 - BRAKES - WARNING). (1) Block tire and wheel assemblies so vehicle does not move once vehicle parking brake lever released.
Page 169 5 - 44 BRAKES - BASE LEVER - PARKING BRAKE (Continued) (8) Remove nut and bolt fastening lever in place nism. This action allows parking brake lever mecha- (Fig. 71). nism to automatically take up any slack. (6) Cycle parking brake lever once to position parking brake cables, then return lever its released position.
Page 170 BRAKES - BASE 5 - 45 PADS/SHOES - PARKING BRAKE (Continued) Fig. 72 Shoe Retaining Pin Removal Fig. 74 Using Piston Retractor To Seat Piston In Bore 1 - PIN PUNCH 2 - RETAINING PIN 1 - UPPER BUSHING 2 - LOWER BUSHING 3 - PISTON RETRACTOR 6366 Fig.
Page 171 5 - 46 BRAKES - ABS BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS INSPECTION - TONE WHEEL ....50 DESCRIPTION INSTALLATION - FRONT TONE WHEEL .
Page 172 BRAKES - ABS 5 - 47 BRAKES - ABS (Continued) NORMAL BRAKING TIRE NOISE AND MARKS Under normal braking conditions, the ABS func- Although the ABS system prevents complete wheel tions the same as a standard base brake system with lockup, some wheel slip is desired in order to achieve a vertically split (front-rear) master cylinder and con- optimum braking performance.
Page 173 5 - 48 BRAKES - ABS BRAKES - ABS (Continued) Check the following common causes when diagnos- CAUTION: These circuits should only be tested ing premature ABS cycling: damaged tone wheels; using a high impedance multi-meter or the DRBIII incorrect tone wheels; damaged steering knuckle scan tool as described in this section.
Page 174 BRAKES - ABS 5 - 49 BRAKES - ABS (Continued) CAUTION: Only the recommended jacking or hoist- WARNING: CONDITIONS THAT RESULT IN TURNING ing positions for this vehicle are to be used when- ON THE RED BRAKE WARNING INDICATOR LAMP ever it is necessary to lift a vehicle.
Page 175 5 - 50 BRAKES - ABS BRAKES - ABS (Continued) (1) Make sure all hydraulic fluid lines are installed TONE WHEEL RUNOUT and properly torqued. (2) Connect the DRBIII scan tool to the Data FRONT TONE WHEEL: Link Connector. The connector is located under the Maximum Runout 0.37 mm (0.015 in.) lower instrument panel to the left of the clutch pedal.
Page 176 BRAKES - ABS 5 - 51 TONE WHEEL (Continued) (4) Verify proper wheel speed sensor-to-tone wheel air gap. (Refer to 5 - BRAKES - ABS - SPECIFICA- TIONS) (5) Install brake caliper. (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/BRAKE PADS/SHOES - INSTALLATION) (6) Install tire and wheel assembly (Refer to 22 - TIRES/WHEELS - INSTALLATION).
Page 177 5 - 52 BRAKES - ABS WHEEL SPEED SENSOR - FRONT (Continued) (3) Disconnect vehicle wiring harness from wheel speed sensor wiring connector at frame rail. (4) Remove fastener clip securing sensor connector to frame rail. (5) Open routing clips along parking brake cable and remove sensor harness.
Page 178 BRAKES - ABS 5 - 53 WHEEL SPEED SENSOR - REAR (Continued) (3) Push sensor connector fastener clip into mount- ondary hydraulic circuit. Each hydraulic circuit uses ing hole in frame rail. a 3 cc accumulator. (4) Connect vehicle wiring harness to sensor con- The fluid accumulators temporarily store brake nector.
Page 179 5 - 54 BRAKES - ABS HCU (HYDRAULIC CONTROL UNIT) (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram (Fig. 4) shows the vehicle in the normal braking mode of the base brake hydraulic system. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle.
Page 180 BRAKES - ABS 5 - 55 HCU (HYDRAULIC CONTROL UNIT) (Continued) ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram (Fig. 5) 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 181 5 - 56 BRAKES - ABS The replaceable components of the ICU are the ICU (INTEGRATED CONTROL HCU and the CAB. No attempt should be made to UNIT) service any components of the HCU or CAB. For additional information on the CAB, (Refer to 8 DESCRIPTION - ELECTRICAL/ELECTRONIC CONTROL MOD- The hydraulic control unit (HCU) and the control-...
Page 182 BRAKES - ABS 5 - 57 ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 8 Brake Pedal Holding Tool Installed 1 - CLUTCH PEDAL 2 - THROTTLE PEDAL 3 - BRAKE PEDAL HOLDING TOOL Fig. 10 ICU Mounting 4 - STEERING WHEEL 5 - DRIVER’S SEAT 1 - FRAME MOUNTED BRACKET 6 - BRAKE PEDAL...
Page 183 5 - 58 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) (Continued) (3) Install primary and secondary brake tubes from the master cylinder at ICU hydraulic control unit (Fig. 9). Tighten primary and secondary brake tube nuts to 17 N·m (145 in. lbs.) torque. (4) Install three chassis brake tubes into their respective outlet ports in ICU hydraulic control unit.
Page 184 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH INSTALLATION ......9 DESCRIPTION .
Page 185 6 - 2 CLUTCH CLUTCH (Continued) OPERATION The clutch master cylinder push rod is connected to the clutch pedal. When the clutch pedal is Leverage, clamping force and friction are what depressed, the release bearing/slave cyclinder is oper- make the clutch work. The disc serves as the friction ated by the clutch master cylinder (Fig.
Page 186 CLUTCH 6 - 3 CLUTCH (Continued) WARNING like residue ranges in color from amber to black wil be noticed. Road splash contamination, dirt/water can entering WARNING: EXERCISE CARE WHEN SERVICING the clutch housing due to loose bolts, housing cracks CLUTCH COMPONENTS.
Page 187 6 - 4 CLUTCH CLUTCH (Continued) • Worn Disc Hub Splines CLUTCH DISC • Broken Springs Clutch disc runout should not exceed 0.5 mm • Lose Rivets (0.020 in.). Check runout 6 mm (0.25 in.) from the • Oil Soaked outer edge of the disc.
Page 188 CLUTCH 6 - 5 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc facing burnt. Flywheel 1. Frequent operation under high 1. Correct condition of flywheel and and pressure plate surfaces glazed. loads or hard acceleration pressure plate surface. Replace disc conditions.
Page 189 6 - 6 CLUTCH CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch master or slave cylinder 1. Master or slave cylinder 1. Replace clutch hydraulic linkage plunger dragging andør binding components worn or corroded. assembly. Release bearing is noisy. 1. Release bearing defective or 1.
Page 190 CLUTCH 6 - 7 CLUTCH (Continued) (2) Slowly depressing the clutch pedal while open- (5) Pump clutch pedal rapidly a minimum of 10 ing the clutch slave cylinder bleed screw (Fig. 6). times. If clutch pedal still feels spongy, repeat Step 2 (3) Holding down the clutch pedal and tighten through Step 5.
Page 191 6 - 8 CLUTCH CLEANING CLUTCH DISC Clean flywheel face with crocus cloth or 400-600 REMOVAL grade sandpaper, then wipe the surface with mineral spirits. If the surface is severely scored, heat checked (1) Remove transmission. or warped, replace the flywheel. (2) Remove clutch inspection cover 2 screws.
Page 192 CLUTCH 6 - 9 CLUTCH DISC (Continued) (2) To avoid distortion of the clutch cover (pressure plate), tighten bolts a few turns at a time in sequence (Fig. 9) until bolts are seated. Then tighten bolts in sequence to 30 N·m (270 in. lbs.). Remove clutch disc alignment tool.
Page 193 6 - 10 CLUTCH INSTALLATION LINKAGE (1) Twist clutch master cylinder a quarter turn DESCRIPTION clockwise to install into toe box. (2) Connect hydraulic line quick connector to The hydraulic linkage consists of a clutch master clutch bell housing. cylinder, reservoir, a clutch slave cylinder/release (3) Install clutch fluid reservoir mounting screws.
Page 194 CLUTCH 6 - 11 CLUTCH PEDAL POSITION SWITCH (Continued) WARNING: UNDER NO CIRCUMSTANCES SHOULD (5) Push the switch up the rod slightly. Then pull THE CLUTCH POSITION SWITCH BE DISCON- the bottom of the switch outward (Fig. 13). NECTED OR DISABLED. There is no adjustment on the clutch position switch.
Page 195 6 - 12 CLUTCH CLUTCH PEDAL POSITION SWITCH (Continued) INSTALLATION (1) Install new switch as shown in (Fig. 14). Be sure that the spring loaded plunger inside the switch is slightly compressed. The plunger inside the switch must go on the narrow section of the clutch master cylinder actuation rod.
Page 196 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING SPECIAL TOOLS WARNING COOLING ......2 COOLING SYSTEM WARNINGS .
Page 197 7 - 2 COOLING COOLING (Continued) SPECIAL TOOLS COOLING Coolant Refractometer 8286 Hose Clamp Pliers 8495 Pressure Tester Kit 7700...
Page 198 ACCESSORY DRIVE 7 - 3 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE BELT AND TENSIONER REMOVAL ......4 DIAGNOSIS AND TESTING - ACCESSORY INSPECTION .
Page 199 7 - 4 ACCESSORY DRIVE ACCESSORY DRIVE BELT AND TENSIONER (Continued) REMOVAL (1) Remove the air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL). (2) Release the belt tension by rotating the ten- sioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt.
Page 200 ACCESSORY DRIVE 7 - 5 ACCESSORY DRIVE BELT AND TENSIONER (Continued) INSTALLATION (2) Position the drive belt over all pulleys except for the water pump pulley (Fig. 1). (3) Rotate tensioner counterclockwise and slip NOTE: When installing accessory drive belt onto the belt over the water pump pulley.
Page 201 7 - 6 ENGINE ENGINE TABLE OF CONTENTS page page ENGINE INSTALLATION ......17 OPERATION ......6 ENGINE COOLANT TEMPERATURE SENSOR DIAGNOSIS AND TESTING DESCRIPTION...
Page 202 ENGINE 7 - 7 ENGINE (Continued) • Damaged hoses • Damaged radiator • Loose/damaged hose clamps • Damaged coolant recovery system • Damaged/incorrect engine thermostat • Damaged heater core • Damaged radiator hydraulic fan motor, fan blade If the visual inspection reveals none of the above and fan shroud as cause for a cooling system complaint, refer to the •...
Page 203 7 - 8 ENGINE ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER PERFOR- 1. Has a diagnostic trouble code 1. Refer to the appropriate Power- MANCE. (DTC) been set? train Diagnostic information. Repair as necessary. 2. Coolant level low. 2. Adjust coolant level as neces- sary.
Page 204 ENGINE 7 - 9 ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT COLOR. 1. Coolant color is not necessarily 1. Check the freeze point of the an indication of adequate corrosion coolant (Refer to 7 - COOLING/ or temperature protection. Do not ENGINE/COOLANT - DIAGNOSIS rely on coolant color for determin- AND TESTING - COOLANT CON-...
Page 205 7 - 10 ENGINE ENGINE (Continued) Fig. 1 Temperature Gauge Indications COOLING SYSTEM LEAK TEST Attach the Cooling System Tester 7700 or equiva- lent to the pressure bottle and apply 104 kPa (15 psi) pressure. If the pressure drops more than 13.8 kPa WARNING: THE WARNING WORDS “DO NOT OPEN (2 psi) in 2 minutes, inspect all points for external HOT”...
Page 206 ENGINE 7 - 11 ENGINE (Continued) WARNING: WITH TOOL IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). If the needle on the dial does not fluctuate, raise the engine rpm a few times.
Page 207 7 - 12 ENGINE ENGINE (Continued) ADDING ADDITIONAL COOLANT For coolant service schedules (Refer to LUBRICA- TION & MAINTENANCE/MAINTENANCE SCHED- ULES - DESCRIPTION). WARNING: THE WARNING WORDS “DO NOT OPEN (1) Try squeezing the upper radiator hose to deter- HOT” ON THE PRESSURE CAP IS A SAFETY PRE- mine if the cooling system is still pressurized.
Page 208 ENGINE 7 - 13 ENGINE (Continued) DRAINING COOLING SYSTEM FILLING COOLING SYSTEM WARNING: DO NOT REMOVE ENGINE BLOCK CAUTION: Do not use well water, or suspect water DRAIN PLUGS, COOLANT PRESSURE BOTTLE supply in cooling system. Use only a 50/50 mixture CAP, OR OPEN THE RADIATOR DRAINCOCK, of the specified ethylene glycol type antifreeze/cool- WHEN THE COOLING SYSTEM IS HOT AND UNDER...
Page 209 7 - 14 ENGINE ENGINE (Continued) NOTE: IT IS IMPERATIVE THAT THE COOLING SYS- TEM AIR BLEED SCREW BE OPENED BEFORE ANY COOLANT IS ADDED TO THE COOLING SYSTEM. FAILURE TO OPEN THE BLEED SCREW FIRST WILL RESULT IN AN INCOMPLETE FILL OF THE SYSTEM.
Page 210 ENGINE 7 - 15 ENGINE (Continued) (1) Drain cooling system (Refer to 7 - COOLING/ The use of aluminum cylinder blocks, cylinder heads, ENGINE - STANDARD PROCEDURE - DRAINING and water pumps requires special corrosion protection. COOLING SYSTEM). Mopar Antifreeze/Coolant, 5 Year/100,000 Mile For- (2) Refill cooling system with clean water (Refer to mula (MS-9769), or the equivalent ethylene glycol base 7 - COOLING/ENGINE - STANDARD PROCEDURE...
Page 211 7 - 16 ENGINE COOLANT (Continued) Because ethylene glycol and propylene glycol do CAUTION: The Cooling System Tester Tool is very not have the same specific gravities, the use of a sensitive to small air leaks that will not cause cool- hydrometer will be inaccurate.
Page 212 ENGINE 7 - 17 PRESSURE CAP (Continued) Fig. 10 Pressure Cap 1 - OVERFLOW NIPPLE 2 - MAIN SPRING 3 - GASKET RETAINER 4 - PLASTIC SWIVEL TOP 5 - RUBBER SEALS 6 - FILLER NECK 7 - DEAERATION PRESSURE BOTTLE 8 - SPRING LOADED VENT VALVE COOLANT PRESSURE BOTTLE Fig.
Page 213 7 - 18 ENGINE ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The engine coolant temperature sensor threads into the timing chain cover at the left front side of the engine (Fig. 13). OPERATION The PCM determines engine coolant temperature from the engine coolant temperature (ECT) sensor. The ECT sensor is a two wire Negative Temperature Coefficient (NTC) sensor.
Page 214 ENGINE 7 - 19 ENGINE COOLANT THERMOSTAT (Continued) REMOVAL (5) Tighten thermostat housing bolts sequence shown in (Fig. 16) to 11 N·m (95 in. lbs.). (1) Partially drain the cooling system below the (6) Connect upper radiator hose to thermostat thermostat level.
Page 215 7 - 20 ENGINE HOSE CLAMPS DESCRIPTION The cooling system uses constant tension spring type hose clamps. If a spring type clamp replacement is necessary, replace with the original Mopar equip- ment spring type clamp. CAUTION: A number or letter is stamped into the tongue of constant tension clamps.
Page 216 ENGINE 7 - 21 RADIATOR FAN (Continued) Fig. 19 Cooling System Hoses 1 - COOLANT BOTTLE INLET HOSE 4 - LOWER RADIATOR HOSE 2 - HEATER SUPPLY AND RETURN HOSE ASSY. 5 - UPPER RADIATOR HOSE 3 - OIL COOLER RETURN HOSE •...
Page 217 7 - 22 ENGINE RADIATOR FAN (Continued) ACTIVATING THE HYDRAULIC FAN WITH THE pressure delivery line to the vehicles steering gear to provide steering assist. Path two sends fluid back to DRBIII the power steering pump through a low pressure Under the Engine Systems test heading, there is a line.
Page 218 ENGINE 7 - 23 RADIATOR FAN (Continued) (3) Remove push pins from lower air dam that con- nect to radiator fan shroud (Fig. 21). Fig. 22 Hydraulic and Electrical Connections 1 - LOW PRESSURE RETURN HOSE 2 - HIGH PRESSURE LINE (OUTLET) Fig.
Page 219 7 - 24 ENGINE RADIATOR FAN (Continued) Fig. 23 Radiator and Fan 1 - RADIATOR MOUNTING FASTENERS 5 - LOWER RADIATOR HOSE 2 - COOLING MODULE 6 - FAN ELECTRICAL CONNECTOR 3 - FAN MOUNTING FASTENERS 7 - UPPER RADIATOR HOSE 4 - U - NUT 8 - DRAINCOCK (8) Install push pins that secure lower air dam to...
Page 220 ENGINE 7 - 25 RADIATOR (Continued) (6) Disconnect upper and lower radiator hoses. (9) Operate the engine until it reaches normal (7) Remove the radiator mounting bolts (Fig. 23). operating temperature. Check the cooling system for (8) Remove A/C condenser mounting fasteners correct fluid level.
Page 221 7 - 26 ENGINE WATER PUMP (Continued) (5) Erosion of the plastic impeller blades. INSTALLATION CAUTION: Do not use a metal scraper to clean alu- minum sealing surfaces, as damage to surfaces may occur. Use only a plastic scraper and Mopar Brake Parts Cleaner or the equivalent (1) Clean both sealing surfaces using a plastic scraper and Mopar...
Page 222 AUDIO/VIDEO 8A - 1 AUDIO/VIDEO TABLE OF CONTENTS page page AUDIO INSTALLATION ......6 DESCRIPTION .
Page 223 8A - 2 AUDIO/VIDEO AUDIO (Continued) WARNING: DISABLE AIRBAG SYSTEM TEM CAPACITOR TO DISCHARGE BEFORE PER- BEFORE ATTEMPTING ANY STEERING WHEEL, FORMING FURTHER DIAGNOSIS OR SERVICE. THIS STEERING COLUMN, SEAT BELT TENSIONER, SIDE IS THE ONLY SURE WAY TO DISABLE THE AIRBAG AIRBAG, OR INSTRUMENT PANEL COMPONENT SYSTEM.
Page 224 AUDIO/VIDEO 8A - 3 AUDIO (Continued) CONDITION POSSIBLE CAUSES CORRECTION POOR RADIO RECEPTION 1. Antenna faulty. 1. Refer to Antenna Diagnosis and Testing. 2. Radio ground faulty. 2. Check for continuity between radio chassis and a known good ground. There should be continuity.
Page 225 8A - 4 AUDIO/VIDEO AMPLIFIER (Continued) REMOVAL Refer to the appropriate wiring information. (1) Disconnect and isolate the battery negative WARNING: DISABLE AIRBAG SYSTEM cable. BEFORE ATTEMPTING ANY STEERING WHEEL, (2) Remove passenger seat (Refer to 23 - BODY/ STEERING COLUMN, SEAT BELT TENSIONER, SIDE SEATS/SEAT - REMOVAL).
Page 226 AUDIO/VIDEO 8A - 5 ANTENNA (Continued) (b) Connect antenna lead connector in the front DIAGNOSIS AND TESTING - ANTENNA of the instrument panel. Disconnect connector at MODULE antenna module. There should be a great drop in Any diagnosis of the Audio system should reception quality.
Page 227 8A - 6 AUDIO/VIDEO ANTENNA MODULE (Continued) (4) Disconnect antenna module cable and electrical (4) Disconnect the antenna cable by pulling the harness connector (Fig. 4). locking antenna connector away from the radio (Fig. Fig. 4 ANTENNA MODULE CABLE Fig. 5 ANTENNA TO RADIO 1 - ANTENNA MODULE ELECTRICAL CONNECTOR 2 - COAX CABLE 1 - RADIO...
Page 228 AUDIO/VIDEO 8A - 7 RADIO (Continued) OPERATION The radio receiver operates on ignition switched battery current that is available only when the igni- tion switch is in the On or Accessory positions. The electronic digital clock function of the radio operates on fused battery current supplied through a fuse in the Power Distribution Center (PDC), regardless of the ignition switch position.
Page 229 8A - 8 AUDIO/VIDEO RADIO NOISE SUPPRESSION COMPONENTS (Continued) Factory-installed radio noise suppression is accom- REMOVAL plished primarily through circuitry or devices that The underhood ground straps are integral to the are integral to the factory-installed radios, audio underhood silencer (Refer to 23 - BODY/HOOD/SI- power amplifiers and other on-board electrical com- LENCER PAD - REMOVAL).
Page 230 AUDIO/VIDEO 8A - 9 SPEAKER (Continued) CAUTION: The speaker output of the radio is a (6) Check for battery voltage at the two fused B(+) “floating ground” system. Do not allow any speaker circuit cavities of the power amplifier wire harness connector.
Page 231 8A - 10 AUDIO/VIDEO SPEAKER (Continued) REMOVAL (3) Remove the speaker fasteners. (4) Disconnect the wire harness connector and remove speaker. DOOR SPEAKER (1) Disconnect and isolate the battery negative REAR SPEAKER cable. (1) Disconnect and isolate the battery negative (2) Remove the speaker grill fasteners (Fig.
Page 232 AUDIO/VIDEO 8A - 11 SPEAKER (Continued) (3) Install the speaker grill. (4) Connect the battery negative cable. REAR SPEAKER (1) Connect wire harness connector and position speaker. (2) Install mounting fasteners. (3) Install the bulkhead quarter trim panel (Refer to 23 - BODY/INTERIOR/BULKHEAD TRIM PANEL - INSTALLATION).
Page 234 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - CHIME DESCRIPTION ......1 CONDITIONS .
Page 235 8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) ENHANCED SEAT BELT REMINDER the “enhanced seat belt warning” feature is currently sounding the chime and the “washer fluid low” fea- The enhanced seat belt reminder feature will ture becomes active. The warning announcement prompt the occupants to buckle their seat belt by chime associated with the washer fluid lamp activa- periodically flashing the seat belt indicator and...
Page 236 CHIME/BUZZER 8B - 3 CHIME/BUZZER (Continued) SERVICE ENGINE SOON WARNING WARNING LAMP ANNOUNCEMENT The EMIC monitors the Malfunction Indicator The BCM monitors critical engine system parame- Lamp (MIL) light message from the PCM and if bus ters. If any of the systems are out of their operating communication is lost from the PCM to the EMIC, parameters, the EMIC will illuminate a lamp and the EMIC will illuminate the MIL telltale and send a...
Page 238 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page BODY CONTROL MODULE OPERATION - DATA BUS COMMUNICATION DESCRIPTION ......1 RECEIVE - PCM INPUT .
Page 239 8E - 2 ELECTRONIC CONTROL MODULES BODY CONTROL MODULE (Continued) Entry (RKE) lock/unlock button under these condi- BATTERY SAVE MODE tions result in normal lock/unlock activation. • Exterior Lighting NORMAL OPERATING MODE The battery save mode is • Fade to Off Interior Lamps - This feature dims enabled by performing the following: (1) Insert the key into the ignition cylinder.
Page 240 ELECTRONIC CONTROL MODULES 8E - 3 BODY CONTROL MODULE (Continued) (4) Place ignition in the RUN position (this exits Battery save mode and places the BCM in the nor- mal powered state). REMOVAL (1) Open deck lid. (2) Remove four bolts to battery compartment cover and remove cover.
Page 241 8E - 4 ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE (Continued) CONTROLLER ANTILOCK BRAKE INPUTS (3) Connect pump/motor wiring connector (Fig. 1). • Wheel speed sensors (four) CAUTION: Before installing the 24-way connector in • Brake lamp switch the CAB, be sure the seal is properly installed in •...
Page 242 ELECTRONIC CONTROL MODULES 8E - 5 POWERTRAIN CONTROL MODULE (Continued) OPERATION - DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to per- form engine diagnostics and flash operations. The PCM uses the J1850 bus to communicate with vari- ous electronic modules within the vehicle.
Page 243 8E - 6 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) The PCM adjusts ignition timing based on the fol- pleted. If monitors have not been completed, then: lowing inputs. Key on: bulb check for approximately 14 seconds, • Coolant temperature lamp then flashes (once per second) for approxi- •...
Page 244 ELECTRONIC CONTROL MODULES 8E - 7 POWERTRAIN CONTROL MODULE (Continued) (1) Disconnect the negative battery cable. (2) Remove the air cleaner. (3) Disconnect the electrical connectors (Fig. 5). Fig. 7 PCM MOUNTING BOLTS Fig. 5 ELECTRICAL CONNECTIONS REMOVED (4) Remove the 2 mounting bolts (Fig. 6) and (Fig. Fig.
Page 246 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 247 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) battery system is also designed to provide a reserve as a complete system. In order for the engine to start of electrical energy to supplement the charging sys- and the battery to maintain its charge properly, all of tem for short durations while the engine is running the components that are used in these systems must and the electrical current demands of the vehicle...
Page 248 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system igni- 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN tion-off draw is excessive. Standard Procedure for the proper test proce- ATTEMPTING TO START dures.
Page 249 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an incor- 1. Refer to Battery System Specifications for the CHARGE CANNOT BE rect size or rating for this proper specifications.
Page 250 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) ponents. In addition to the maintenance schedules water cleaning solution using a stiff bristle parts found in this service manual and the owner’s man- cleaning brush to remove any acid film. ual, it is recommended that these procedures be per- (5) Clean any corrosion from the battery terminals formed any time the battery or related components with a wire brush or terminal cleaner, and a sodium...
Page 251 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) fall below 7.2 volts during or after the thirty second discharge period. The CCA required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. • Reserve Capacity - The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for bat- tery terminal voltage to fall below 10.5 volts, at a discharge rate of 25 amperes.
Page 252 BATTERY SYSTEM 8F - 7 BATTERY (Continued) lead dioxide, and the water back into sulfuric acid. AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT This action restores the difference in the electron OF THE REACH OF CHILDREN. charges deposited on the plates, and the voltage A battery that will not accept a charge is faulty, potential of the battery cells.
Page 253 8F - 8 BATTERY SYSTEM BATTERY (Continued) WARNING: THE BATTERY CONTAINS SULFURIC dure is properly followed, a good battery may be ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID needlessly replaced. (1) Measure the voltage at the battery posts with a CONTACT WITH THE SKIN, EYES, OR CLOTHING.
Page 254 BATTERY SYSTEM 8F - 9 BATTERY (Continued) Turn on the headlamps for fifteen seconds, then CHARGING TIME REQUIRED allow up to five minutes for the battery voltage to The time required to charge a battery will vary, stabilize. depending upon the following factors: (2) Disconnect and isolate both battery cables, neg- •...
Page 255 8F - 10 BATTERY SYSTEM BATTERY (Continued) A vehicle that has not been operated for approxi- test, the electronic timer function will be activated mately twenty days, may discharge the battery to an and all of the tests will have to be repeated. inadequate level.
Page 256 BATTERY SYSTEM 8F - 11 BATTERY (Continued) USING MICRO 420 BATTERY TESTER (3) Connect the tester (Fig. 5) to the battery or jumper posts, the red clamp to positive (+) and the black clamp to negative (–). NOTE: Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test.
Page 257 8F - 12 BATTERY SYSTEM BATTERY (Continued) REMOVAL (4) Remove the battery hold down from the vehi- cle. (1) Make sure ignition switch is in OFF position and all accessories are turned OFF. INSTALLATION (2) The battery is located in the trunk. (1) Install the battery hold down in the vehicle.
Page 258 BATTERY SYSTEM 8F - 13 BATTERY CABLES (Continued) • Fully engage the parking brake. The battery positive cable terminal is stamped onto • If the vehicle is equipped with an automatic the ends of two wires. One wire has an eyelet termi- nal that connects the battery positive cable to the transmission, place the gearshift selector lever in the B(+) terminal stud of the Power Distribution Center...
Page 259 8F - 14 BATTERY SYSTEM BATTERY CABLES (Continued) (2) Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the nega- tive lead of the voltmeter to the battery positive cable terminal clamp (Fig. 8). Rotate and hold the ignition switch in the Start position.
Page 260 BATTERY SYSTEM 8F - 15 BATTERY TRAY DESCRIPTION The battery is placed in a stamped metal tray located in the trunk. (Fig. 11). The battery tray is welded in place and cannot be removed from the vehicle. OPERATION The battery tray provides a secure mounting loca- tion and supports the battery.
Page 261 8F - 16 CHARGING CHARGING TABLE OF CONTENTS page page BATTERY TEMPERATURE SENSOR OPERATION ......17 OPERATION .
Page 262 CHARGING 8F - 17 GENERATOR (Continued) OPERATION (4) Disconnect the field connector (Fig. 4). As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a cur- rent into the windings of the stator coil. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification.
Page 263 8F - 18 CHARGING GENERATOR (Continued) (6) Remove the upper mounting bolt (Fig. 6). INSTALLATION (7) Remove the lower mounting bolt and nut (Fig. (1) Install generator. (2) Install the lower mounting bolt and nut (Fig. (3) Install the upper mounting bolt (Fig. 6). (4) Tighten the bolts to 55 N·m (41 ft.
Page 264 STARTING 8F - 19 STARTING TABLE OF CONTENTS page page STARTING SPECIFICATIONS DESCRIPTION ......19 STARTER .
Page 265 8F - 20 STARTING STARTING (Continued) • Starter Button - Visually inspect the starter button for indications of physical damage and loose or corroded wire harness connections. STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS 1. BATTERY DIS- 1. REFER TO THE BATTERY SECTION FOR MORE INFOR- TO ENGAGE.
Page 266 STARTING 8F - 21 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 ASSEM- 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND BLY FAULTY.
Page 267 8F - 22 STARTING STARTING (Continued) RELAY TEST RELAY CIRCUIT TEST The starter relay is located in the Power Distribu- (1) The relay common feed terminal cavity (30) is tion Center (PDC) in the engine compartment. Refer connected to battery voltage and should be hot at all to the PDC label for relay identification and location.
Page 268 STARTING 8F - 23 STARTING (Continued) DIAGNOSIS AND TESTING - FEED CIRCUIT tery cable blade terminal on starter solenoid. Rotate the ignition switch in the ON position after RESISTANCE TEST depressing the clutch pedal. If voltage reads above Before proceeding with this operation, review Diag- 0.2 volt, correct poor contact at battery cable to nostic Preparation and Starter Feed Circuit Tests.
Page 269 8F - 24 STARTING STARTER MOTOR REMOVAL (1) Disconnect the negative battery cable (Fig. 1). Fig. 3 STARTER BOLTS (5) Connect the solenoid connector. (6) Lower vehicle. (7) Connect the negative battery cable (Fig. 1). Fig. 1 BATTERY CONNECTION (2) Raise vehicle and support (Fig. 2). STARTER MOTOR RELAY DESCRIPTION The Starter Relay is an ISO (International Stan-...
Page 270 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS REMOVAL ......3 DESCRIPTION .
Page 271 8G - 2 HEATED SYSTEMS HEATED GLASS (Continued) ELECTRICAL/HEATED GLASS/REAR WINDOW partment. The relay and fuse must be tight in their DEFOGGER GRID - STANDARD PROCEDURE - receptacles and all electrical connections must be GRID LINE AND TERMINAL REPAIR). secure. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay.
Page 272 HEATED SYSTEMS 8G - 3 REAR WINDOW DEFOGGER RELAY (Continued) common physical dimensions, current capacities, ter- the fixed, normally closed contact point. The resistor minal functions and patterns. The ISO micro-relay or diode is connected in parallel with the relay coil, terminal functions are the same as a conventional and helps to dissipate voltage spikes and electromag- ISO relay.
Page 273 8G - 4 HEATED SYSTEMS REAR WINDOW DEFOGGER RELAY (Continued) OPERATION An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control operates the rear window defogger (EBL) relay. The EBL relay controls the current flow to the grids of the rear win- dow defogger.
Page 274 HEATED SYSTEMS 8G - 5 REAR WINDOW DEFOGGER GRID (Continued) neatly (Fig. 7). Extend the epoxy application onto the remove the portion of the clip remaining in the wire grid line or the bus bar on each side of the break. harness connector(s).
Page 276 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM REMOVAL ......2 DESCRIPTION .
Page 277 8H - 2 HORN (3) Disconnect electrical harness connectors (Fig. HORN DIAGNOSIS AND TESTING - HORN Any diagnosis of the Horn system should begin with the use of a scan tool and the appro- priate Diagnostic Service Manual. Refer to the appropriate wiring information. WARNING: DISABLE AIRBAG...
Page 278 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL IGNITION COIL DESCRIPTION - IGNITION SYSTEM ..1 OPERATION ......5 OPERATION - IGNITION SYSTEM .
Page 279 8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) SPARK PLUG Engine Spark Plug Thread Size 8.3L RC12ECC 0.033 TO 0.038 14mm (3/4 in.) reach CABLES RESISTANCE CHART MINIMUM MAXIMUM 250 Ohms Per Inch 750 Ohms Per Inch 3000 Ohms Per Foot 9,000 Ohms Per Foot IGNITION COIL RESISTANCE - 8.3L Primary Resistance at 21°C-27°C (70°F-...
Page 280 IGNITION CONTROL 8I - 3 CAMSHAFT POSITION SENSOR OPERATION - 8.3L The Camshaft Position Sensor is located above the water pump and under the throttle body (Fig. 1). Fig. 2 Camshaft Position Sensor 1 - CAMSHAFT POSITION SENSOR 2 - RIB MATERIAL (FOR SENSOR DEPTH POSITIONING) Fig.
Page 281 8I - 4 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) REPLACING OLD SENSOR WITH ORIGINAL Do not install sensor with gear positioned at low area. When the engine is started, the sensor The camshaft position sensor is located on the tim- will be broken.
Page 282 IGNITION CONTROL 8I - 5 CAMSHAFT POSITION SENSOR (Continued) (6) Install the sensor into the timing case/cover with a slight rocking action until the sensor is aligned to scribe line. The paper spacer can be used if reinstalling a used sensor. (7) Install sensor mounting bolt and tighten to 10.7 N·m (95 in.
Page 283 8I - 6 IGNITION CONTROL IGNITION COIL (Continued) (8) Remove ignition coil. INSTALLATION The system uses two epoxy filled coil packs mounted on engine block post (Fig. 10) under the intake manifold. The rear coil pack, contains 3 sepa- rate coils and fires cylinders 1, 2, 3, 4, 6, and 7. The front coil pack, contains 2 individual coils and fires cylinders 5, 8, 9, and 10.
Page 284 IGNITION CONTROL 8I - 7 INSTALLATION SPARK PLUG Failure to route the cables properly could cause the DESCRIPTION radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. The 8.3L V-10 engine uses resistor spark plugs. (1) To avoid cross threading, start the spark plug They have resistance values of 6,000 to 20,000 ohms into the cylinder head by hand.
Page 285 8I - 8 IGNITION CONTROL SPARK PLUG CABLE (Continued) terminal as close as possible to the spark plug. (2) Connector coil insulator boots over respective Rotate the cover boot 1/2 turn slightly and pull ignition coil side post. Take care to match cylinder straight up in a steady motion.Do not use pliers number on ignition coil with cylinder number on and do not pull the cable at an angle.
Page 286 IGNITION CONTROL 8I - 9 SPARK PLUG CABLE (Continued) Fig. 15 IGNITION CABLE ROUTING Fig. 16 START BUTTON LOCATION 1 - Fuel Test Port 2 - Fuel Rail 3 - Fuel Injector 4 - Spark Plug Cables (5) Install Intake Manifold, refer to the Engine/ Manifolds/Intake Manifold for more information.
Page 287 8I - 10 IGNITION CONTROL STARTER BUTTON (Continued) (3) Remove the switch (Fig. 18). INSTALLATION (1) Install switch into center bezel (Fig. 18). (2) Install the center bezel (Fig. 16) (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION). Fig.
Page 288 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER OPERATION ......5 DESCRIPTION INSTRUMENT CLUSTER GAUGE PACK DESCRIPTION...
Page 289 8J - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) The purpose of the instrument cluster gauges, mes- The gauges are the magnetic air-core type. When sages, and indicator lamps is to keep the driver the ignition switch is OFF, the gauge pointers should informed about the operating condition of the vehicle.
Page 290 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) • Brake indicator: turned on if parking brake is is in the trip mode will reset the trip mileage. This ON, there is a brake failure due to loss of brake fluid button is also used to put the cluster in self-diagnos- pressure, or low fluid level.
Page 291 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) DIAGNOSIS AND TESTING - INSTRUMENT ELECTRICAL/INSTRUMENT CLUSTER - STANDARD PROCEDURE SELF-DIAGNOSTICS). This will CLUSTER WARNING/INDICATOR LAMPS “sweep” all the pointers to the correct side of the Every time the vehicle is switched to the START/ pointer stop.
Page 292 INSTRUMENT CLUSTER 8J - 5 airbag indicator illuminated. indicator AIRBAG INDICATOR remains illuminated until the cluster receives a sin- gle lamp-off message from the ORC. DESCRIPTION • Actuator Test - Each time the cluster is put An airbag indicator is standard equipment on all through the actuator test, the airbag indicator will be instrument clusters.
Page 293 8J - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER GAUGE PACK (Continued) (4) Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or instrument panel component service. (5) Remove center console (Refer to 23 - BODY/IN- TERIOR/CENTER CONSOLE - REMOVAL).
Page 294 INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER LENS (Continued) (8) Disconnect one electrical connector and remove specific recommendations on when to enable or dis- cluster bezel from vehicle. able the passenger airbag. The passenger airbag (9) Remove four screws and two electrical connec- ON/OFF switch allows the customer to turn the pas- tors to the instrument cluster and remove from senger airbag function ON or OFF to accommodate...
Page 296 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR STANDARD PROCEDURE - HEADLAMP WARNING ......2 UNIT AIMING - EXPORT .
Page 297 8L - 2 LAMPS Mopar Multi- purpose Grease or equivalent to avoid LAMPS/LIGHTING - EXTERIOR corrosion. Begin any electrical system failure diagnosis by WARNING testing all related fuses in the Power Distribution THIS VEHICLE CONTAINS MERCURY Center (PDC). Verify that bulbs are in good condition ADDED DEVICES ADDED BY THE MANUFAC- and test continuity of the circuit ground.
Page 298 LAMPS 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) BULB APPLICATION TABLE (3) Install the two Torx head retaining screws to the tail lamp access panel of the respective side of the vehicle. LAMP BULB (4) Connect the battery negative cable. Headlamp/Low-beam-HID (5) Place battery access cover into place and install Lamp/Igniter Assembly...
Page 299 8L - 4 LAMPS DIAGNOSIS AND TESTING - BRAKE LAMP BRAKE LAMP SWITCH SWITCH DESCRIPTION NOTE: Before proceeding with this diagnostic test, The brake lamp switch is located under the instru- verify the adjustment lever on the back of the ment panel, at the brake pedal arm.
Page 300 LAMPS 8L - 5 BRAKE LAMP SWITCH (Continued) (3) Disconnect wiring harness connector from switch (Fig. 3). (4) Discard brake lamp switch. It must not be reused. INSTALLATION CAUTION: Do not reuse the original brake lamp switch. This switch can only be adjusted once. That is during initial installation of the switch.
Page 301 8L - 6 LAMPS BRAKE LAMP SWITCH (Continued) (5) Check stop lamps to verify they are operating properly and not staying on when brake pedal is in released position. (6) Road test vehicle to ensure proper operation of brakes (including ABS) and lamps. CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL...
Page 302 LAMPS 8L - 7 FOG LAMP UNIT - FRONT (Continued) (2) Install three mounting screws attaching fog lamp unit to front bumper fascia. Torque screws to 4 N·m (35 in. lbs.). (3) Connect fog lamp connector. (4) Install fog lamp access panel (Fig. 5). (5) Connect the battery negative cable.
Page 303 8L - 8 LAMPS FOG LAMP UNIT - REAR (EXPORT) (Continued) (3) Route the harness along the backside of the rear fascia and secure with clips (Fig. 8). (4) Connect the rear fog lamp wiring harness con- nector behind the battery box, and clip the harness to the battery with the supplied clips (Fig.
Page 304 LAMPS 8L - 9 HEADLAMP (Continued) There are three components to each of the HID headlamps: • Ballast Module - The 12 volt Direct Current (DC) power supplied by the low beam relay is con- verted to Alternating Current (AC) power by the bal- last module (Fig.
Page 305 8L - 10 LAMPS HEADLAMP (Continued) module. If lamp still fails to light, replace lamp/ig- 14). Remove wheel and tire assembly if extra room is niter assembly. needed. (5) Remove the three nuts to the headlamp access REMOVAL panel and remove panel. (6) Remove the headlamp by turning 1/4 turn HIGH INTENSITY DISCHARGE (HID) HEADLAMPS - counterclockwise and pulling straight out.
Page 306 LAMPS 8L - 11 HEADLAMP (Continued) (6) Place battery access cover into place and install (3) Check tire inflation. Fill tires if necessary to four bolts. suggested specifications. Refer to vehicle Owner’s (7) Close deck lid. Manual or the vehicle Tire Placard inside the rear (8) Verify vehicle and system operation.
Page 307 8L - 12 LAMPS HEADLAMP UNIT (Continued) Fig. 12 HEADLAMP/FOG LAMP UNIT AIMING 1 - HORIZONTAL CENTERLINE OF HEADLAMP ON VEHICLE 9 - RIGHT TIRE 2 - VERTICAL CENTERLINE OF LEFT HEADLAMP 10 - FOG LAMP HORIZONTAL ALIGNMENT LINE 3 - CENTER OF VEHICLE HEADLAMP UNIT 11 - CENTER OF HORIZONTAL HEADLAMP LINE AND VEHICLE CENTERLINE 4 - 4 INCHES...
Page 308 LAMPS 8L - 13 HEADLAMP UNIT (Continued) Fig. 13 HEADLAMP AIMING - EXPORT 1 - HORIZONTAL CENTERLINE OF HEADLAMP ON VEHICLE 8 - FLOOR LEVEL 2 - VERTICAL CENTERLINE OF LEFT HEADLAMP 9 - TIRES 3 - CENTER OF VEHICLE HEADLAMP UNIT 10 - FOG LAMP HORIZONTAL ALIGNMENT LINE 4 - 100 MM (4 IN.) 11 - IMAGE BREAK POINT...
Page 309 8L - 14 LAMPS HEADLAMP UNIT (Continued) REMOVAL (11) Lift up on the front of the fender slightly, then lift the headlamp unit up and to the rear, into the (1) Open deck lid. wheel well. (2) Remove four bolts to battery compartment cover and remove cover.
Page 310 LAMPS 8L - 15 LICENSE PLATE LAMP (Continued) (2) Place the lamp socket into the license plate functions. An International Control and Display Sym- lamp unit and turn the respective bulb clockwise bol icon for “Hazard Warning” is applied to the top of until stops.
Page 311 8L - 16 LAMPS MULTI-FUNCTION SWITCH (Continued) Fig. 15 MULTI-FUNCTION SWITCH 1 - TURN SIGNAL CONTROL STALK 5 - CANCELLING CAM 2 - HAZARD WARNING SWITCH 6 - PANEL DIMMER/INTERIOR LIGHT SWITCH 3 - WINDSHIELD WIPER/WASHER CONTROL 7 - EXTERIOR LIGHTING CONTROL/FOG LAMP 4 - WINDSHIELD WIPER/WASHER SWITCH RETAINING SCREWS switch (Fig.
Page 312 LAMPS 8L - 17 MULTI-FUNCTION SWITCH (Continued) signal switch has a detent position in each direction portion of the wipe pattern When the control knob of that provides turn signals with automatic cancellation, the windshield wiper/washer control stalk on the and an intermediate, momentary position in each direc- right side of the multi-function switch is rotated to tion that provides turn signals only until the left multi-...
Page 313 8L - 18 LAMPS MULTI-FUNCTION SWITCH (Continued) TURN SIGNAL AND HAZARD WARNING FLASHER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION TURN SIGNAL FLASHES AT (1) FAULTY EXTERNAL LAMP. (1) REPLACE LAMP. TWICE THE NORMAL RATE. (2) POOR GROUND AT LAMP. (2) CHECK AND/OR REPAIR WIRING (3) OPEN CIRCUIT IN WIRING (3) CHECK AND/OR REPAIR WIRING TO EXTERNAL LAMP.
Page 314 LAMPS 8L - 19 MULTI-FUNCTION SWITCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT CANCEL (1) BROKEN CANCELLING FIN- (1) REPLACE MULTI FUNCTION AFTER COMPLETION OF THE GER ON SWITCH. SWITCH. TURN. (2) BROKEN OR MISSING (2) REPLACE CLOCK SPRING. CANCELLING CAM ON CLOCK SPRING.
Page 315 8L - 20 LAMPS MULTI-FUNCTION SWITCH (Continued) MULTI-FUNCTION SWITCH CONTINUITY TEST SWITCH POSITION MODE CONTINUITY BETWEEN TURN SIGNAL IN NEUTRAL B-1 AND B-4 HAZARD WARNING SWITCH OFF B-1 AND B-5 HAZARD OFF B-18 AND B-19 B-4 AND B-5 TURN SIGNAL ON A-2 AND B-2 HAZARD WARNING SWITCH OFF A-2 AND B-4...
Page 316 LAMPS 8L - 21 MULTI-FUNCTION SWITCH (Continued) MULTI-FUNCTION SWITCH DIMMER CONTROL RESISTANCE SWITCH POSITION RESISTANCE VALUE BETWEEN PINS 7 AND 8 DOME ON 150 OHMS PARADE MODE 411 OHMS DIM 6 (BRIGHTEST INTENSITY) 768 OHMS DIM 5 1221 OHMS DIM 4 1825 OHMS DIM 3 2593 OHMS...
Page 317 8L - 22 LAMPS MULTI-FUNCTION SWITCH (Continued) Fig. 20 MULTI-FUNCTION SWITCH - REMOVE/INSTALL 1 - MULTI-FUNCTION SWITCH CONNECTORS 3 - MULTI-FUNCTION SWITCH 2 - RETAINING SCREWS...
Page 318 LAMPS 8L - 23 switch housing and connects the switch to the vehicle MULTI-FUNCTION SWITCH - electrical system through a take out and connector of EXPORT the instrument panel wire harness. The multi-function switch supports the following DESCRIPTION functions and features: •...
Page 319 8L - 24 LAMPS MULTI-FUNCTION SWITCH - EXPORT (Continued) • Highbeam Flash-to-Pass - The internal cir- RUN only feeds, RUN/ACCESSORY feed, and the cuitry and hardware of the multi-function switch Ignition Off Draw (IOD) feed. includes momentary switching of the headlamp high The multi-function switch controls the follow- beam circuits to provide an input to the BCM and ing headlamp features and provides:...
Page 320 LAMPS 8L - 25 MULTI-FUNCTION SWITCH - EXPORT (Continued) the two turn signal cancel cam lobes will contact the to the Delay position, the circuitry within the switch turn signal cancel actuator. The cancel actuator connects the output of the wiper motor relay to the latches against the cancel cam rotation in the direc- low speed brush of the wiper motor and provides bat- tion opposite that which is signaled.
Page 321 8L - 26 LAMPS MULTI-FUNCTION SWITCH - EXPORT (Continued) TURN SIGNAL AND HAZARD WARNING FLASHER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION TURN SIGNAL FLASHES AT (1) FAULTY EXTERNAL LAMP. (1) REPLACE LAMP. TWICE THE NORMAL RATE. (2) POOR GROUND AT LAMP. (2) CHECK AND/OR REPAIR WIRING.
Page 322 LAMPS 8L - 27 MULTI-FUNCTION SWITCH - EXPORT (Continued) CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT CANCEL (1) BROKEN CANCELLING FIN- (1) REPLACE MULTI FUNCTION AFTER COMPLETION OF THE GER ON SWITCH. SWITCH. TURN. (2) BROKEN OR MISSING (2) REPLACE CLOCK SPRING. CANCELLING CAM ON CLOCK SPRING.
Page 323 8L - 28 LAMPS MULTI-FUNCTION SWITCH - EXPORT (Continued) MULTI-FUNCTION SWITCH CONTINUITY TEST SWITCH POSITION MODE CONTINUITY BETWEEN TURN SIGNAL IN NEUTRAL B-1 AND B-4 HAZARD WARNING SWITCH OFF B-1 AND B-5 HAZARD OFF B-18 AND B-19 B-4 AND B-5 TURN SIGNAL ON A-2 AND B-2 HAZARD WARNING SWITCH OFF...
Page 324 LAMPS 8L - 29 MULTI-FUNCTION SWITCH - EXPORT (Continued) SWITCH POSITION MODE CONTINUITY BETWEEN FRONT FOG B-13 AND B-14 B-9 AND B-20 B-16 AND B-18 B-16 AND B-19 REAR FOG B-13 AND B-14 B-9 AND B-20 B-16 AND B-18 B-16 AND B-19 B-18 AND B-19 B-12 AND B-13 MULTI-FUNCTION SWITCH DIMMER CONTROL RESISTANCE...
Page 325 8L - 30 LAMPS MULTI-FUNCTION SWITCH - EXPORT (Continued) REMOVAL (1) Open deck lid. (2) Remove four bolts to battery compartment cover and remove cover. (3) Disconnect and isolate the battery negative cable. (4) Remove both upper and lower steering column shrouds.
Page 326 LAMPS 8L - 31 MULTI-FUNCTION SWITCH - EXPORT (Continued) to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER/ (4) Remove the two Torx head retaining screws to WASHER SWITCH - INSTALLATION). the access panel of the respective side of the vehicle (2) Install the multi-function switch mounting and remove panel.
Page 327 8L - 32 LAMPS REPEATER LAMP - EXPORT (Continued) INSTALLATION (5) Close deck lid. (6) Verify vehicle and system operation. (1) Install bulb to socket. (2) Push lamp socket into the side repeater lamp. (3) Position side repeater lamp to hole in hinge TAIL LAMP UNIT cover.
Page 328 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER WINDOWS.
Page 329 8N - 2 POWER LOCKS POWER LOCKS (Continued) DOOR EXIT DOOR LOCK SWITCH The vehicle is exited by pulling the inside door When the Body Control Module (BCM) receives an handle. This will activate an electrical switch which input from the lock switch indicating a door lock/un- is received by the Body Control Module (BCM).
Page 330 POWER LOCKS 8N - 3 POWER LOCKS (Continued) REMOTE KEYLESS ENTRY EXTERIOR DOOR HANDLE The UNLOCK button will unlock either the drivers SWITCH door or both doors if pressed twice. When the Body Control Module (BCM) receives an DIAGNOSIS AND TESTING - EXTERIOR DOOR unlock input, the park/tail lamps will flash one time HANDLE SWITCH to indicate the drivers door is unlocked, or will flash...
Page 331 8N - 4 POWER LOCKS INTERIOR DOOR HANDLE SWITCH (Continued) (3) Use an ohmmeter to test switch resistance REMOVAL between pins. (1) Disconnect and isolate the battery negative (4) Pull handle. cable. (5) Test resistance between pins. Ohmmeter should (2) Remove the door trim panel (Refer to 23 - show 3.5K Ohm ±...
Page 332 POWER LOCKS 8N - 5 REMOTE KEYLESS ENTRY MODULE (Continued) INSTALLATION The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace (1) Connect wire harness connector and position the RKE transmitter batteries: module into place. (1) Using a thin coin, gently pry at the notch in (2) Install mounting fasteners.
Page 333 8N - 6 POWER LOCKS REMOTE KEYLESS ENTRY TRANSMITTER (Continued) UNLOCK SEQUENCE (6) Within 30 seconds of the chime, press and release the “LOCK” and “UNLOCK” buttons on the The unlock sequence can be toggled using a DRB transmitter at the same time. Then press and release or by using the Remote Keyless Entry (RKE) any button on the same transmitter and a chime will transmitter that is already programmed to the vehi-...
Page 334 POWER MIRRORS 8N - 7 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......8 DESCRIPTION .
Page 335 8N - 8 POWER MIRRORS POWER MIRROR SWITCH (Continued) POWER MIRROR SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN MIRROR SELECT SWITCH IN LEFT POSITION 3 AND 1 7 AND 8 DOWN 3 AND 8 1 AND 7 LEFT 7 AND 1 3 AND 4 RIGHT 3 AND 1...
Page 336 POWER WINDOWS 8N - 9 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS REMOVAL ......10 DESCRIPTION .
Page 337 8N - 10 POWER WINDOWS POWER WINDOW SWITCH CONTINUITY POWER WINDOW SWITCH DESCRIPTION SWITCH CONTINUITY RESISTANCE POSITION BETWEEN VALUE The driver and passenger power window switches are located on the center console bezel. The switches NEUTRAL Pins 2 and 3 4.8K Ohm ±...
Page 338 POWER WINDOWS 8N - 11 WINDOW MOTOR (Continued) OPERATION DIAGNOSIS AND TESTING - WINDOW MOTOR A positive and negative battery connection to the (1) Remove door trim panel two motor terminals will cause the power window (2) Connect positive (+) lead from a test battery to motor to rotate in one direction.
Page 340 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS OPERATION ......7 WARNING .
Page 341 8O - 2 RESTRAINTS TUTE FASTENERS, ONLY ORIGINAL RESTRAINTS EQUIPMENT FASTENERS LISTED IN THE PARTS CATALOG WHEN FASTENER WARNING REPLACEMENT IS REQUIRED. AIRBAGS SHOULD BE STORED IN A COOL, AIRBAG SYSTEM DRY PLACE, AWAY FROM EXCESSIVE HEAT THIS SYSTEM IS A SENSITIVE, COMPLEX AND STATIC ELECTRICAL ACTIVITY WITH ELECTRONIC UNIT.
Page 342 RESTRAINTS 8O - 3 RESTRAINTS (Continued) SEAT BELTS AND TENSIONERS STANDARD PROCEDURE After a frontal impact where an airbag has been STANDARD PROCEDURE - HANDLING deployed due to a collision. the following MUST be replaced: AIRBAGS • Front Seat Belt Retractors (driver and passen- ger) with integral Tensioners.
Page 343 8O - 4 RESTRAINTS CHILD TETHER (Continued) INSTALLATION removed from the steering column or if the steering shaft is disconnected from the steering gear, the clock (1) Install the child tether onto the rear bulkhead. spring spool can change position relative to the mov- Torque bolt to 40 N·m (30 ft.
Page 344 RESTRAINTS 8O - 5 CLOCKSPRING (Continued) (9) Connect the battery negative cable. (10) Place battery access cover into place and install four bolts. (11) Close deck lid. (12) Verify vehicle and system operation. REMOVAL (1) Place the front road wheels in the straight ahead position.
Page 345 8O - 6 RESTRAINTS shirt should be worn, as there may be deposits on DRIVER AIRBAG the surface which could irritate the skin and eyes. (1) Open deck lid. DESCRIPTION (2) Remove four bolts to battery compartment The driver airbag protective trim cover is the most cover and remove cover.
Page 346 RESTRAINTS 8O - 7 OCCUPANT RESTRAINT CONTROLLER (Continued) of the ORC housing with four screws to enclose and through a fuse in the Power Distribution Center protect the internal electronic circuitry and compo- (PDC), and a fused ignition switch output (START/ nents.
Page 347 8O - 8 RESTRAINTS OCCUPANT RESTRAINT CONTROLLER (Continued) (6) Remove shifter shaft with knob and body. PASSENGER AIRBAG (7) Remove floor console bezel and parking brake body. DESCRIPTION (8) Remove eight screws and disconnect one elec- The passenger airbag door is concealed behind the trical connector to center console and remove console instrument panel top pad and above the glove box from vehicle.
Page 348 RESTRAINTS 8O - 9 PASSENGER AIRBAG (Continued) ator, the initiator generates enough heat to ignite (18) Remove ground wire nuts at left floor tunnel. chemical pellets within the inflator. Once ignited, (19) Remove one bolt and one nut to the left brace these chemical pellets burn rapidly and produce the to instrument panel.
Page 349 8O - 10 RESTRAINTS PASSENGER AIRBAG (Continued) (43) Remove five screws and two electrical connec- (17) Connect the two occupant restraint controller tors to the instrument cluster gauge pack and electrical connectors. remove from panel. (18) Connect the occupant restraint controller (44) Remove two screws and one electrical connec- ground wires.
Page 350 RESTRAINTS 8O - 11 PASSENGER AIRBAG (Continued) (42) Place center console into position in vehicle indicator in the instrument cluster gauge pack will connect one electrical connector and install eight be illuminated whenever the switch is turned to the screws. OFF position and the ignition switch is in the RUN (43) Install parking brake body and floor console position.
Page 351 8O - 12 RESTRAINTS PASSENGER AIRBAG ON / OFF SWITCH (Continued) (4) Wait two minutes for the airbag system reserve (10) Remove the two bolts attaching the sport hoop capacitor to discharge before beginning any airbag to rear bulkhead. system or instrument panel component service. (11) Remove sport hoop from vehicle.
Page 352 RESTRAINTS 8O - 13 SEAT BELT BUCKLE REMOVAL (1) Open deck lid. (2) Remove four bolts to battery compartment cover and remove cover. (3) Disconnect and isolate the battery negative cable. (4) Move seat as needed to access seat retaining bolts (Fig.
Page 353 8O - 14 RESTRAINTS scan tool and the appropriate Body Diagnostic Proce- SEAT BELT SWITCH dures manual must be used. DESCRIPTION The Seat Belt Switch is a Hall Effect-type sensor. SEAT BELT TENSIONER This sensor consists of a fixed-position, Hall Effect Integrated Circuit (IC) chip and a small permanent DESCRIPTION magnet that is integral to the left seat belt buckle.
Page 354 RESTRAINTS 8O - 15 SEAT BELT TENSIONER (Continued) Removing excess slack from the front seat belts not nate the airbag indicator in the ElectroMechanical only keeps the occupants properly positioned for an Instrument Cluster (EMIC) and store a Diagnostic airbag deployment following a frontal impact of the Trouble Code (DTC) for any fault that is detected.
Page 356 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY INSTALLATION ......2 DESCRIPTION .
Page 357 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) NOTE: The VTSS will not disarm by opening the (2) Press the switch into position on the bracket. vehicle from the inside door handle. (3) Connect the battery negative cable. If the VTSS is triggered, the horn will pulse, fog VTSS DISARM SWITCH lamps/park lamps will flash and the VTSS warning...
Page 358 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS INSTALLATION ......8 DESCRIPTION .
Page 359 8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) Fig. 1 WINDSHIELD WIPER/WASHER SWITCH LOCATION 1 - TURN SIGNAL CONTROL STALK 5 - CANCELLING CAM 2 - HAZARD WARNING SWITCH 6 - PANEL DIMMER/INTERIOR LIGHT SWITCH 3 - WINDSHIELD WIPER/WASHER CONTROL 7 - EXTERIOR LIGHTING CONTROL/FOG LAMP 4 - WINDSHIELD WIPER/WASHER SWITCH RETAINING SCREWS The electric pump assembly is mounted directly to The wiper system completes the wipe cycle when...
Page 360 WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) DIAGNOSIS AND TESTING - WIPERS/ (5) Check terminal 2 of wiper switch connector for continuity to ground. If OK, go to Step 6. If not OK, WASHERS repair the ground circuit as necessary. The following is a list of general wiper motor sys- (6) Using a voltmeter, with wiper switch con- tem problems, the tests that are to be performed to nected, connect negative lead to terminal 1 of the...
Page 361 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) (2) Check for crossed wires in harness connector from wiper switch to motor. (3) If OK, replace wiper switch. WIPERS WILL OPERATE CONTINUOUSLY WITH THE SWITCH IN THE INTERMITTENT POSITION - WHEN WIPER SWITCH IS TURNED OFF, WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION.
Page 362 WIPERS/WASHERS 8R - 5 INSTALLATION WASHER HOSES / TUBES (1) Install pump to reservoir. REMOVAL (2) Connect wire harness connector and washer hose. (1) Disconnect and isolate the battery negative (3) Install washer reservoir (Refer to 8 - ELEC- cable. TRICAL/WIPERS/WASHERS/WASHER RESERVOIR (2) Remove washer reservoir (Refer to 8 - ELEC- - INSTALLATION).
Page 363 8R - 6 WIPERS/WASHERS WIPER ARMS (Continued) (2) Install the arm onto the pivot using a rocking OPERATION motion while the arm is in an over/centered position. When the wiper blade rubber element is exposed to (3) Install the wiper arm retaining nut. Torque nut the weather for a long period of time, it tends to lose to 19.7 - 21.5 N·m (175 - 190 in.
Page 364 WIPERS/WASHERS 8R - 7 WIPER BLADES (Continued) INSTALLATION INSTALLATION (1) Gently lift wiper arm tip off glass surface and (1) Connect wire harness connector. to the over center position. (2) Position wiper assembly. Install mounting fas- (2) Install the blade assembly onto the arm by teners.
Page 365 8R - 8 WIPERS/WASHERS WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION WIPER BLADES SLAP (1) WIPER ARMS ARE (1) PARK WIPER ARMS. REFER TO WIPER AGAINST COWL SCREEN PARKED INCORRECTLY. ARM ADJUSTMENT. OR WINDOW MOLDINGS. BLADES CHATTER. (1) FOREIGN SUBSTANCE (1) CLEAN GLASS AND BLADE ELEMENT SUCH AS POLISH ON GLASS WITH NON-ABRASIVE CLEANER.
Page 366 WIPERS/WASHERS 8R - 9 INSTALLATION WIPER/WASHER SWITCH (1) Attach the two switches. REMOVAL (2) Install the two retaining screws to the Wiper/ Washer Switch. (1) Remove the Multi-Function Switch from the (3) Install the Multi-Function Switch from the vehicle. Refer to Electrical, Lamps/Lighting - Exte- vehicle.
Page 367 8R - 10 WIPERS/WASHERS fascia, and extend out from the fascia when pressur- HEADLAMP WASHERS - ized with fluid (Fig. 8). EXPORT OPERATION DESCRIPTION The headlamp washer system utilizes a separate Headlamp washers on this vehicle work in conjunc- high pressure pump that is attached to the wind- tion with the windshield washers.
Page 368 WIPERS/WASHERS 8R - 11 HEADLAMP WASHERS - EXPORT (Continued) (1) Check the Export Accessory Fuse for continuity. check for leaks, or loose connections in the hose. If fuse is defective, repair the circuit as necessary. When reattaching the washer hose, push the connec- (2) If the headlamp washers do not pop up when a tor into the washer pump till you hear a snap.
Page 369 8R - 12 WIPERS/WASHERS HEADLAMP WASHERS - EXPORT (Continued) CONDITION POSSIBLE CAUSE CORRECTION ONE HEADLAMP WASHER 1. HEADLAMP WASHER 1. REPAIR OR REPLACE THE HEADLAMP NOZZLE WILL NOT FLOW HOSE NOT FLOWING WASHER HOSE. WASHER FLUID. FLUID. 2. PLUGGED HEADLAMP 2.
Page 370 WIPERS/WASHERS 8R - 13 HEADLAMP WASHER NOZZLE - EXPORT (Continued) INSTALLATION INSTALLATION - NOZZLE NOTE: Right side is shown. Left side is similar. (1) Position the washer nozzle and install the bolts. Torque the bolts to 8 N·m (71 in. lbs.). (2) Connect the hose and install the retaining clamp.
Page 371 8R - 14 WIPERS/WASHERS WASHER PUMP MOTOR - EXPORT REMOVAL (1) Remove the right front wheel and tire (Refer to 22 - TIRES/WHEELS - REMOVAL). (2) Remove the right headlamp access panel. (3) Disconnect the washer pump electrical connec- tor. (4) Disconnect the washer pump hose and remove the pump from the reservoir.
Page 372 WIPERS/WASHERS 8R - 15 HEADLAMP WASHER RESERVOIR - EXPORT (Continued) REMOVAL - UPPER RESERVOIR INSTALLATION (1) Disconnect and isolate the battery negative INSTALLATION - LOWER RESERVOIR cable. (2) Raise vehicle. (1) Position the lower washer reservoir in the vehi- (3) Remove right front tire. cle and install the lower mounting bolt.
Page 374 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 AUDIO SYSTEM ..... 8W-47-1 COMPONENT INDEX .
Page 376 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 377 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 378 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 379 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 380 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 381 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 382 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 383 8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 384 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL CONTINUITY (1) Connect the ground lead of a voltmeter to a (1) Remove the fuse for the circuit being checked known good ground (Fig.
Page 385 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 386 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 INSTALLATION CONNECTOR (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 387 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 388 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 389 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 390 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 392 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch ....8W-42 Fuel Pump Relay ..... . 8W-30 A/C Compressor Clutch Relay .
Page 393 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Remote Radio Switches Provision ..8W-47 Tail/Stop Lamps ..... . 8W-51 Reverse Lock-Out Solenoid .
Page 394 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-20 Fuse C4 ......8W-10-13 A/C Compressor Clutch Relay .
Page 414 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-3 Gauge Cluster ..... . 8W-15-9 A/C Low Pressure Switch .
Page 426 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page A/C-Heater Control ....8W-18-3 G201 ......8W-18-2 Airbag Control Module .
Page 430 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auto Shut Down Relay ....8W-20-2 G302 ......8W-20-2 Battery .
Page 434 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 Generator .
Page 438 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-8 Fuse B21 ......8W-30-15 A/C Low Pressure Switch .
Page 454 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Body Control Module ....8W-35-2 Power Distribution Center ... . . 8W-35-2 Brake Lamp Switch .
Page 458 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Ajar Switch-Decklid ....8W-39-6 Exterior Door Handle Switch-Driver .
Page 464 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Airbag Control Module ....8W-40-7 G202 ......8W-40-2, 7 Body Control Module .
Page 472 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 G202 ......8W-41-3 Cigar Lighter Outlet .
Page 476 8W-42 AIR CONDITIONING/HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING/HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-5 Fuse B20 ......8W-42-5 A/C Compressor Clutch Relay .
Page 484 8W-43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Component Page Component Page Airbag Control Module ... . 8W-43-2, 3, 4 Fuse C6 ......8W-43-2 Airbag On/Off Switch-Passenger .
Page 488: Table Of Contents
8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C-Heater Control ....8W-44-4 Illuminated Rear View Mirror ..8W-44-5 Body Control Module .
Page 494 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page A/C-Heater Control ....8W-45-15 Headlamp Relay ....8W-45-18 Airbag Control Module .
Page 512 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Amplifier Antenna ....8W-47-2 Radio ......8W-47-2, 3 Antenna .
Page 518 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C-Heater Control ....8W-48-2 Power Distribution Center ... . . 8W-48-2 Body Control Module .
Page 520 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Body Control Module ..8W-50-2, 3, 4, 5, 6 Headlamp Washer Pump Relay ..8W-50-6 Export Accessory Fuse .
Page 526 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-3, 4 License Lamp-Left ....8W-51-5 Back-Up Lamp-Left .
Page 532 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Body Control Module ....8W-52-2 Marker Lamp-Right Front ... . . 8W-52-4 Fuse B13 .
Page 536 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Fuse C8 ......8W-53-2 Power Distribution Center .
Page 540 8W-56 CONVENIENCE SYSTEMS 8W - 56 - 1 8W-56 CONVENIENCE SYSTEMS Component Page Component Page Adjustable Pedals Motor ....8W-56-2 G200 ......8W-56-2 Adjustable Pedals Switch .
Page 542 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Body Control Module ... . . 8W-60-2, 3, 4 Power Window Motor-Passenger ..8W-60-3, 4 Fuse B5 .
Page 546 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Ajar Switch-Decklid ....8W-61-5 Door Lock Switch-Passenger ... 8W-61-4 Ajar Switch-Driver Door .
Page 552 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Body Control Module ....8W-62-2 Power Mirror Switch ....8W-62-2 Fuse B18 .
Page 554 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-10-7 S204 .
Page 558 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-4 C201 ......8W-80-24 A/C Low Pressure Switch .
Page 559 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Footwell Lamp-Left ....8W-80-37 Oxygen Sensor 2/1 Right Bank Up ..8W-80-50 Footwell Lamp-Right .
Page 560 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Turn Signal Lamp-Left Rear ..8W-80-66 Wheel Speed Sensor-Right Rear ..8W-80-67 Turn Signal Lamp-Right Rear .
Page 561 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 18DB/YL A/C CLUTCH RELAY OUTPUT Z1 18BK GROUND A/C LOW PRESSURE SWITCH - DK. GREEN 2 WAY CIRCUIT FUNCTION C20 18DB/OR A/C SWITCH SENSE Z1 20BK GROUND A/C PRESSURE TRANSDUCER - BLACK 4 WAY...
Page 562 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C-HEATER CONTROL C2 - BLACK 16 WAY CIRCUIT FUNCTION F921 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN) Z2 20BK/LG GROUND C35 20LB/OR MODE DOOR 2 DRIVER E2 20OR/BR PANEL LAMPS DRIVER C33 20LB/BR BLEND DOOR DRIVER C801 20DB/OR MODE DOOR 1 DRIVER...
Page 563 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS AIRBAG CONTROL MODULE C1 (ORC) - YELLOW 32 WAY CIRCUIT FUNCTION R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R58 20LB/GY PASSENGER SEAT BELT SWITCH SENSE R60 20LB/TN PASSENGER SEAT BELT SWITCH GROUND R59 20LG/TN...
Page 564 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AIRBAG CONTROL MODULE C2 (ORC) - YELLOW 32 WAY CIRCUIT FUNCTION R45 20LG/OR DRIVER SQUIB 1 LINE 2 R43 20LG/BR DRIVER SQUIB 1 LINE 1 R42 20LB/BR PASSENGER SQUIB 1 LINE 2 R44 20LB/OR PASSENGER SQUIB 1 LINE 1 F100 20PK/VT...
Page 565 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS AIRBAG SQUIB 1-DRIVER - YELLOW/BLACK 2 WAY CIRCUIT FUNCTION R45 20LG/OR DRIVER SQUIB 1 LINE 2 R43 20LG/BR DRIVER SQUIB 1 LINE 1 AIRBAG SQUIB 2-DRIVER - YELLOW/GRAY 2 WAY CIRCUIT FUNCTION R63 20LG/WT DRIVER SQUIB 2 LINE 2 R61 20LG/VT...
Page 566 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AJAR SWITCH-DRIVER DOOR - BLACK 4 WAY CIRCUIT FUNCTION G75 20VT DRIVER DOOR AJAR SWITCH SENSE Z1 20BK GROUND AJAR SWITCH-HOOD - NATURAL 3 WAY CIRCUIT FUNCTION G70 20VT/LB HOOD AJAR SWITCH SENSE Z1 20BK GROUND AJAR SWITCH-PASSENGER DOOR - BLACK 4 WAY...
Page 567 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BACK-UP LAMP-LEFT - GRAY 3 WAY CIRCUIT FUNCTION L1 20WT/LG BACK-UP LAMP SWITCH OUTPUT Z1 20BK GROUND BACK-UP LAMP-RIGHT - GRAY 3 WAY CIRCUIT FUNCTION L1 20WT/LG BACK-UP LAMP SWITCH OUTPUT Z1 20BK GROUND BATTERY TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT...
Page 568 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 BATTERY-POSITIVE - 1 WAY CIRCUIT FUNCTION A0 2RD B(+) BLEND DOOR ACTUATOR - GRAY 2 WAY CIRCUIT FUNCTION C33 20LB/BR BLEND DOOR DRIVER C34 20DB/LB COMMON DOOR DRIVER BLOWER MOTOR - ORANGE 2 WAY CIRCUIT FUNCTION C7 12DB...
Page 569 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C1 - BLACK 6 WAY CIRCUIT FUNCTION A101 14VT/RD FUSED B(+) A102 12WT/RD FUSED B(+) Z103 12BK GROUND A101 14VT/RD FUSED B(+) BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY CIRCUIT FUNCTION L89 20WT...
Page 570 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY CIRCUIT FUNCTION J4 18OR (EXPORT) REAR FOG LAMP SWITCH SENSE D23 20WT/OR FLASH PROGRAM ENABLE G94 20LG LOW TIRE PRESSURE SIGNAL G75 20VT DRIVER DOOR AJAR SWITCH SENSE G96 20VT/DG REMOTE KEYLESS ENTRY INTERFACE G78 20VT/OR...
Page 571 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY CIRCUIT FUNCTION M26 20YL/DB HALO LAMP DRIVER M21 20YL/BR FOOTWELL LAMPS DRIVER D9 20WT/GY RKE MODULE PROGRAM ENABLE G150 20VT/YL INSTRUMENT CLUSTER WAKE UP SENSE J2 18DB/LG (EXPORT) EXHAUST SOLENOID RELAY CONTROL L124 20WT/DB...
Page 572 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BRAKE LAMP SWITCH - BLACK 6 WAY CIRCUIT FUNCTION A103 20GY/RD FUSED B(+) L50 20WT/TN BRAKE LAMP SWITCH OUTPUT Z1 20BK GROUND K29 20WT BRAKE LAMP SWITCH SENSE C100 - NATURAL (HEADLAMP AND DASH SIDE) CIRCUIT C7 12DB W4 16BR/OR...
Page 573 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C100 - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT C7 12DB W4 16BR/OR Q2 18WT/TN A105 18DB/RD A116 14YL/RD Z11 18BK/LG F13 18PK D25 20WT/VT D20 20WT/LG D21 20WT/BR D24 20DB/WT X4 20DG/WT G70 20VT/LB G11 20VT/TN L61 20LG A1 14RD...
Page 574 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C101 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT F20 18PK/WT F12 18PK J2 18DB/LG (EXPORT) F45 20PK/OR K29 18WT J3 18VT/WT (EXPORT) J5 18DB/WT (EXPORT) M28 20YL/TN (EXCEPT EXPORT) W3 16BR A102 12WT/RD A101 14VT/RD W5 16BR/LG W110 16BR/WT...
Page 575 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C101 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT F12 20PK F20 20PK/WT J2 18DB/LG (EXPORT) F45 20PK/OR K29 20WT J3 18VT/WT (EXPORT) J5 18DB/WT (EXPORT) M28 20YL/TN (EXCEPT EXPORT) W3 16BR A102 12WT/RD A101 14VT/RD W5 16BR/LG W110 16BR/WT...
Page 576 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C102 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT C15 16DB/WT L50 20WT/TN A141 16RD K900 18DB/DG M28 20YL/TN (EXCEPT EXPORT) J1 16WT/DB (EXPORT) B2 18DG/LB B1 18DG/OR B3 18DG/YL B4 18DG/GY F242 18PK C103 - LT.
Page 577 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C104 - BLACK (ENGINE SIDE) CIRCUIT G7 18VT/OR F888 18BR/PK K900 18DB/DG K136 18LB/BK K41 18DB/LB K141 18TN/WT C240 18LB/TN A14 16RD/YL K342 16BR/WT K43 18DB/LG K243 18BR K125 18BR/DG F202 18PK/GY C18 18LB/BR K42 18DB/YL K242 18BR/YL...
Page 578 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C106 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT L7 20WT/YL L61 20LG L43 18WT/DB L33 20LG/BR Z1 18BK C106 - BLACK (LEFT HEADLAMP JUMPER SIDE) CIRCUIT L7 20WT/YL L61 20LG L43 18WT/DB L33 20LG/BR Z1 18BK C107 - BLACK (HEADLAMP AND DASH SIDE)
Page 579 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C108 (EXPORT) - DK. GRAY (HEADLAMP AND DASH SIDE) CIRCUIT A128 14RD/OR J3 18VT/WT J1 16WT/DB J5 18DB/WT J12 18DG/RD J15 14TN J2 18DB/LG Z1 14BK C200 - BLACK (BODY SIDE) CIRCUIT R57 20LG/GY R59 20LG/TN R58 20LB/GY...
Page 580 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C200 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT R57 20LG/GY R59 20LG/TN R58 20LB/GY X209 18GY/OR X299 18GY R60 20LB/TN X51 20DG/DB X201 18GY/VT X291 18GY/YL X57 20DG/OR X53 20DG A116 14YL/RD X55 20DG/BR X54 20VT X208 18GY/DG X56 20GY/BR...
Page 581 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C201 - YELLOW (INSTRUMENT PANEL SIDE) CIRCUIT R53 20LG/YL R55 20LG/DG R54 20LB/YL R56 20LB/DG C202 - NATURAL (DRIVER DOOR SIDE) CIRCUIT G75 20VT F71 20PK/TN P97 20LG/YL P72 20TN/GY P74 20TN/OR P70 20TN/LB A114 20GY/RD Z1 20BK...
Page 582 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C203 - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT G74 20VT/WT F71 20PK/TN P96 20LG/LB P72 20TN/GY P74 20TN/OR P70 20TN/LB Z1 20BK M1 20YL/VT Q302 20OR/LG P900 20LG/OR Q112 14OR/BR C203 - NATURAL (PASSENGER DOOR SIDE) CIRCUIT G74 20VT/WT F71 20PK/TN...
Page 583 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C204 - LT. GRAY (INSTRUMENT PANEL SIDE) CIRCUIT C7 12DB C34 20DB/RD C73 14DB/VT C32 20DB/TN C71 16DB/BR C35 20LB/OR C75 12DB/GY C801 20DB/OR C72 16OR C33 20LB/BR C205 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT Z1 20BK M24 20BK/BR...
Page 584 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C206 - RED (INSTRUMENT PANEL SIDE) CIRCUIT A105 18DB/RD R4 20OR/LB R6 20VT/LB Z1 16BK C207 - GREEN (INSTRUMENT PANEL SIDE) CIRCUIT P128 18LG/DG Q122 14OR/YL P126 18LG/OR X202 18DG/VT X292 18DG/YL C207 - NATURAL (PASSENGER DOOR SIDE) CIRCUIT P128 18LG/DG...
Page 585 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C208 - NATURAL (DRIVER DOOR SIDE) CIRCUIT P125 20LG/YL P129 18LG/TN Q21 18OR/WT P127 18OR/LG X201 18GY/VT X291 18GY/YL C300 - BLACK (BODY SIDE) CIRCUIT F20 20PK/WT L1 20WT/LG K33 20DB/LG F242 20PK K136 20LB/BK C300 - BLACK (TRANSMISSION SIDE) CIRCUIT...
Page 586 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C301 - BLACK (LEFT TAIL LAMP SIDE) CIRCUIT Z1 18BK L7 20WT/YL L50 20WT/TN L63 20WT/DG L1 20WT/LG C302 - BLACK (BODY SIDE) CIRCUIT Z1 18BK L7 20WT/YL L50 20WT/TN L62 20WT/RD L1 20WT/LG C302 - BLACK (RIGHT TAIL LAMP SIDE) CIRCUIT...
Page 587 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C303 - BLACK (DECKLID JUMPER SIDE) CIRCUIT G78 20VT/OR L50 20WT/TN L7 20WT/YL Z1 20BK Q2 18WT C304 (EXPORT) - BLACK (REAR FOG LAMP SIDE) CIRCUIT J1 18WT Z1 18BK C304 (EXPORT) - BLACK (BODY SIDE) CIRCUIT J1 16WT/DB Z1 16BK/DG...
Page 588 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 CENTER HIGH MOUNTED STOP LAMP - GRAY 2 WAY CIRCUIT FUNCTION L50 20WT/TN BRAKE LAMP SWITCH OUTPUT Z1 20BK GROUND CIGAR LIGHTER OUTLET - GRAY 3 WAY CIRCUIT FUNCTION A105 16DB/RD FUSED B(+) Z1 16BK GROUND CLOCKSPRING - WHITE 8 WAY...
Page 589 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY CIRCUIT FUNCTION Z107 12BK/DB GROUND B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12V SUPPLY D25 20WT/VT PCI BUS B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B7 18DG/VT...
Page 590 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20WT/VT PCI BUS Z2 20BK/LG GROUND Z11 18BK/LG GROUND D20 20WT/LG SCI RECEIVE D21 20WT/BR SCI TRANSMIT D23 20WT/OR FLASH PROGRAM ENABLE D24 20DB/WT FLASH ABS A105 18DB/RD...
Page 591 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS DOOR LATCH MOTOR-PASSENGER - BLUE 2 WAY CIRCUIT FUNCTION P128 18LG/DG PASSENGER DOOR UNLATCH RETURN P126 18LG/OR PASSENGER DOOR UNLATCH DRIVER DOOR LOCK SWITCH-DRIVER - BLACK 3 WAY CIRCUIT FUNCTION F71 20PK/TN IGNITION FEED P97 20LG/YL DRIVER DOOR SWITCH MUX...
Page 592 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 ENGINE OIL TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION G24 18VT/BR OIL TEMPERATURE SENSOR SIGNAL K900 20DB/DG SENSOR GROUND EVAP/PURGE SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION K52 18DB/WT EVAP/PURGE SOLENOID CONTROL F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) EXHAUST SOLENOID (EXPORT) - BLACK 2 WAY...
Page 593 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS EXPORT ACCESSORY FUSE CIRCUIT FUNCTION A1 10RD B(+) A104 10RD FUSED B(+) EXTERIOR DOOR HANDLE SWITCH-DRIVER - BLACK 2 WAY CIRCUIT FUNCTION P125 20LG/YL DRIVER EXTERIOR DOOR HANDLE SWITCH SENSE P901 20OR/LB DRIVER DOOR SWITCH RETURN EXTERIOR DOOR HANDLE SWITCH-PASSENGER - BLACK 2 WAY CIRCUIT...
Page 594 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 FOG LAMP-RIGHT FRONT - BLACK 2 WAY CIRCUIT FUNCTION L90 20WT/OR RIGHT FOG LAMP OUTPUT Z1 20BK GROUND FOG LAMP-RIGHT REAR (EXPORT) - 2 WAY CIRCUIT FUNCTION J1 20WT REAR FOG LAMP RELAY OUTPUT Z1 20BK GROUND FOOTWELL LAMP-LEFT - BLACK 2 WAY...
Page 595 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 1 - BLACK 2 WAY CIRCUIT FUNCTION K11 18BR/YL FUEL INJECTOR NO. 1 DRIVER K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K12 18BR/DB...
Page 596 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 FUEL INJECTOR NO. 6 - BLACK 2 WAY CIRCUIT FUNCTION K58 18BR/VT FUEL INJECTOR NO. 6 DRIVER K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 7 - BLACK 2 WAY CIRCUIT FUNCTION K26 18BR/OR...
Page 597 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS FUEL TANK MODULE - GRAY 4 WAY CIRCUIT FUNCTION Z1 18BK GROUND Z2 20BK/LG GROUND G4 20LB/VT FUEL LEVEL SENSOR SIGNAL A141 16RD FUEL PUMP RELAY OUTPUT GAUGE CLUSTER C1 - WHITE 3 WAY CIRCUIT FUNCTION R166 20LG/TN...
Page 598 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 GENERATOR - GRAY 2 WAY CIRCUIT FUNCTION K125 18BR/DG GENERATOR SOURCE K20 18BR/GY GENERATOR FIELD DRIVER GENERATOR-EYELET - 1 WAY CIRCUIT FUNCTION A11 8LB FUSED B(+) GLOVE BOX LAMP - BLACK 2 WAY CIRCUIT FUNCTION M28 20YL/TN...
Page 599 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS HID LAMP-LEFT - GRAY 2 WAY CIRCUIT FUNCTION L43 18WT/DB FUSED HEADLAMP RELAY OUTPUT Z1 20BK GROUND HID LAMP-RIGHT - GRAY 2 WAY CIRCUIT FUNCTION L44 18WT/TN FUSED HEADLAMP RELAY OUTPUT Z1 20BK GROUND HIGH BEAM HEADLAMP-LEFT - BLACK 2 WAY CIRCUIT...
Page 600 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 HORN-HIGH NOTE - BLACK 2 WAY CIRCUIT FUNCTION X2 18DG/OR HORN RELAY OUTPUT Z1 18BK GROUND HORN-LOW NOTE - BLACK 2 WAY CIRCUIT FUNCTION X2 18DG/OR HORN RELAY OUTPUT Z1 18BK GROUND HYDRAULIC COOLING MODULE - BLACK 3 WAY CIRCUIT FUNCTION...
Page 601 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS IGNITION COIL PACK-LEFT - BLACK 4 WAY CIRCUIT FUNCTION K19 18DG/DB IGNITION COIL NO. 1 DRIVER K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT K32 18DB/WT IGNITION COIL NO. 4 DRIVER K134 18DB/YL IGNITION COIL NO.
Page 602 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 INSTRUMENT CLUSTER C1 - BLACK 16 WAY CIRCUIT FUNCTION M1 20YL/VT IOD-B(+) G11 20VT/TN BRAKE WARNING INDICATOR DRIVER D23 20WT/OR FLASH PROGRAM ENABLE D25 20WT/VT PCI BUS Z2 20BK/LG GROUND Z1 20BK GROUND G150 20VT/YL INSTRUMENT CLUSTER WAKE UP SENSE...
Page 603 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS INTAKE AIR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K21 18LG/DB INTAKE AIR TEMPERATURE SENSOR SIGNAL K900 20DB/DG SENSOR GROUND INTERIOR DOOR HANDLE SWITCH-DRIVER - BLACK 2 WAY CIRCUIT FUNCTION P97 20LG/YL DRIVER DOOR SWITCH MUX P901 20OR/LB DRIVER DOOR SWITCH RETURN...
Page 604 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 KNOCK SENSOR NO. 1 - BLACK 2 WAY CIRCUIT FUNCTION K42 18DB/YL KNOCK SENSOR NO. 1 SIGNAL K900 18DB/DG SENSOR GROUND KNOCK SENSOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K242 18BR/YL KNOCK SENSOR NO.
Page 605 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS MANIFOLD ABSOLUTE PRESSURE SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K900 20DB/DG SENSOR GROUND F855 20PK/YL 5V SUPPLY MARKER LAMP-LEFT FRONT - DK. GRAY 2 WAY CIRCUIT FUNCTION L7 20WT/YL...
Page 606 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 MARKER LAMP-RIGHT REAR - LT. GRAY 2 WAY CIRCUIT FUNCTION L7 20WT/YL PARK LAMP SWITCH OUTPUT Z1 20BK GROUND MODE DOOR ACTUATOR 1 (DEFROST TO FLOOR) - GRAY 2 WAY CIRCUIT FUNCTION C801 20DB/OR MODE DOOR 1 DRIVER C34 20DB/RD...
Page 607 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS OXYGEN SENSOR 1/1 LEFT BANK UP - BLACK 4 WAY CIRCUIT FUNCTION K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT K79 18BR/LB OXYGEN SENSOR 1/1 HEATER CONTROL K900 20DB/DG SENSOR GROUND K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL OXYGEN SENSOR 1/2 LEFT BANK DOWN - BLACK 4 WAY CIRCUIT...
Page 608 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 PARK BRAKE SWITCH - NATURAL 1 WAY CIRCUIT FUNCTION G11 20VT/TN BRAKE WARNING INDICATOR DRIVER PARK/TURN LAMP-LEFT - BLACK 3 WAY CIRCUIT FUNCTION L61 20LG LEFT TURN SIGNAL L7 20WT/YL PARK LAMP SWITCH OUTPUT Z1 20BK GROUND PARK/TURN LAMP-RIGHT - BLACK 3 WAY...
Page 609 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS POWER AMPLIFIER C1 - DK. GRAY 14 WAY CIRCUIT FUNCTION Z514 16BK/LG GROUND X53 20DG LEFT FRONT SPEAKER (+) X51 20DG/DB LEFT REAR SPEAKER (+) X52 20GY/DB RIGHT REAR SPEAKER (+) X54 20VT RIGHT FRONT SPEAKER (+) X60 20DG/RD RADIO 12V OUTPUT...
Page 610 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 POWER MIRROR SWITCH - BLACK 10 WAY CIRCUIT FUNCTION P73 20TN/VT DRIVER MIRROR COMMON DRIVER (LEFT/DOWN) P72 20TN/GY PASSENGER MIRROR UP DRIVER Z1 20BK GROUND P75 20TN/LG DRIVER MIRROR RIGHT DRIVER F71 20PK/TN IGNITION FEED A114 20GY/RD FUSED B(+) (I.O.D.)
Page 611 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS POWER WINDOW MOTOR-DRIVER - BLACK 6 WAY CIRCUIT FUNCTION M1 20YL/VT IOD-B(+) Q301 20WT DRIVER WINDOW HALL SIGNAL Z1 20BK GROUND Q21 18OR/WT DRIVER WINDOW DOWN DRIVER Q11 18OR/DB DRIVER WINDOW UP DRIVER POWER WINDOW MOTOR-PASSENGER - BLACK 6 WAY CIRCUIT FUNCTION...
Page 612 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 POWERTRAIN CONTROL MODULE C1 - BLACK/BLACK 32 WAY CIRCUIT FUNCTION K32 18DB/WT IGNITION COIL NO. 4 DRIVER F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) K18 18DB/OR IGNITION COIL NO. 3 DRIVER K900 18DB/DG SENSOR GROUND K134 18DB/YL IGNITION COIL NO.
Page 613 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C2 - BLACK/WHITE 32 WAY CIRCUIT FUNCTION K26 18BR/OR FUEL INJECTOR NO. 7 DRIVER K115 18BR FUEL INJECTOR NO. 9 DRIVER K11 18BR/YL FUEL INJECTOR NO. 1 DRIVER K13 18BR/DG FUEL INJECTOR NO.
Page 614 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 POWERTRAIN CONTROL MODULE C3 - BLACK/GRAY 32 WAY CIRCUIT FUNCTION C13 18LB/OR A/C CLUTCH RELAY CONTROL K51 18BR/GY AUTOMATIC SHUT DOWN RELAY CONTROL K33 18DB/LG SKIP SHIFT SOLENOID CONTROL K42 18DB/YL KNOCK SENSOR NO. 1 SIGNAL K79 18BR/LB OXYGEN SENSOR 1/1 HEATER CONTROL K127 18BR/OR...
Page 615 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS RADIO - GRAY 22 WAY CIRCUIT FUNCTION A114 20GY/RD FUSED B(+) (I.O.D.) F89 20RD/WT RUN/ACC RELAY CONTROL E2 20OR/BR PANEL LAMPS DRIVER X54 20VT RIGHT FRONT SPEAKER (+) X56 20GY/BR RIGHT FRONT SPEAKER (-) X55 20DG/BR LEFT FRONT SPEAKER (-) X53 20DG...
Page 616 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 REAR WINDOW DEFOGGER-GROUND - BLACK 1 WAY CIRCUIT FUNCTION Z1 18BK GROUND RECIRCULATION DOOR ACTUATOR - GRAY 2 WAY CIRCUIT FUNCTION C32 20DB/TN RECIRCULATION DOOR DRIVER C34 20DB/RD COMMON DOOR DRIVER REMOTE KEYLESS ENTRY MODULE - BLACK 6 WAY CIRCUIT FUNCTION G96 20VT/DG...
Page 617 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS REMOTE RADIO SWITCH-RIGHT PROVISION - BLACK 2 WAY CIRCUIT FUNCTION X20 20GY/WT RADIO CONTROL MUX X920 20GY/OR RADIO CONTROL MUX RETURN REVERSE LOCK-OUT SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION F242 20PK FUSED B(+) K136 20LB/BK REVERSE LOCK-OUT SOLENOID CONTROL...
Page 618 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 SEAT BELT TENSIONER-DRIVER - YELLOW 2 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 SEAT BELT TENSIONER-PASSENGER - YELLOW 2 WAY CIRCUIT FUNCTION R54 20LB/YL...
Page 619 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS SIDE REPEATER LAMP-RIGHT (EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L60 20TN RIGHT FRONT TURN SIGNAL CONTROL Z1 18BK GROUND SKIP SHIFT SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION F242 20PK FUSED B(+) K33 20DB/LG SKIP SHIFT SOLENOID CONTROL SPEAKER-LEFT DOOR - BLACK 2 WAY...
Page 620 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 SPEAKER-LEFT REAR - WHITE 3 WAY CIRCUIT FUNCTION X303 18DG/TN AMPLIFIED LEFT REAR SPEAKER (+) X393 18DG/GY AMPLIFIED LEFT REAR SPEAKER (-) SPEAKER-REAR WOOFER - GRAY 4 WAY CIRCUIT FUNCTION X300 18GY/BR AMPLIFIED LEFT REAR WOOFER (+) X390 18DG/BR AMPLIFIED LEFT REAR WOOFER (-)
Page 621 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS STARTER MOTOR - NATURAL 1 WAY CIRCUIT FUNCTION T40 12YL/TN STARTER MOTOR RELAY OUTPUT STARTER MOTOR-BATTERY EYELET - 1 WAY CIRCUIT FUNCTION A0 2RD B(+) STARTER MOTOR-GENERATOR EYELET - 1 WAY CIRCUIT FUNCTION A11 4BK/GY FUSED B(+)
Page 622 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 TAIL LAMP-RIGHT - LT. GRAY 2 WAY CIRCUIT FUNCTION L7 20WT/YL PARK LAMP SWITCH OUTPUT Z1 20BK GROUND TAIL/STOP LAMP-LEFT - DK. GRAY 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 20WT/YL PARK LAMP SWITCH OUTPUT L50 20WT/TN BRAKE LAMP SWITCH OUTPUT...
Page 623 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS TIRE PRESSURE MONITOR MODULE - BLUE 6 WAY CIRCUIT FUNCTION D21 20WT/BR SCI TRANSMIT Z2 20BK/LG GROUND G5 20OR FUSED IGNITION SWITCH OUTPUT (RUN-START) G94 20LG LOW TIRE PRESSURE SIGNAL TURN SIGNAL LAMP-LEFT REAR - BLACK 3 WAY CIRCUIT FUNCTION L63 20WT/DG...
Page 624 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 WHEEL SPEED SENSOR-LEFT FRONT - LT. GRAY 2 WAY CIRCUIT FUNCTION B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR 12V SUPPLY B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL WHEEL SPEED SENSOR-LEFT REAR - LT. GRAY 2 WAY CIRCUIT FUNCTION B4 18DG/GY...
Page 625 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS WINDOW UP RELAY-PASSENGER - BLACK 5 WAY CIRCUIT FUNCTION Q12 20BR/OR PASSENGER WINDOW UP RELAY CONTROL Z1 20BK GROUND Q112 14OR/BR PASSENGER WINDOW UP RELAY OUTPUT Z1 16BK/WT GROUND A128 14RD/OR FUSED B(+) WIPER CONTROL MODULE - GRAY 7 WAY CIRCUIT FUNCTION...
Page 626 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 Connector, ground and splice indexes are provided.
Page 627 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Color Location Fig. Blend Door Actuator Behind Right Side of Instrument Panel Blower Motor Behind Right Side of Instrument Panel 16, 17 Blower Motor Resistor Behind Right Side of Instrument Panel Block Body Control Module C1 Behind Left Side of Instrument Panel...
Page 628: Door Lock Switch-Driver
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Color Location Fig. Decklid Release Motor In Decklid Door Latch Motor - Driver Rear of Left Door Door Latch Motor - Passen- Rear of Right Door Door Lock Switch - Driver Left Door Door Lock Switch - Passen- Right Door...
Page 629: Instrument Cluster
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Color Location Fig. Headlamp Washer Pump Left Rear Engine Compartment Relay Motor (Export) HID Lamp - Left Left Front Corner of Vehicle HID Lamp - Right Right Front Corner of Vehicle High Beam Headlamp - Left Left Front Corner of Vehicle High Beam Headlamp -...
Page 630: Power Mirror Switch
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Color Location Fig. Oxygen Sensor 1/2 Left Left Rear of Engine Compartment Bank Down Oxygen Sensor 2/1 Right Right Rear Engine Compartment Bank Up Oxygen Sensor 2/2 Right Right Rear Engine Compartment Bank Down Park Brake Switch...
Page 631: Vtss Led
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Color Location Fig. Remote Radio Switch - In Steering Wheel Right Provision Reverse Lock-Out Solenoid Rear of Transmission Seat Belt Switch - Driver Under Driver Seat Seat Belt Switch - Passen- Under Passenger Seat Seat Belt Tensioner - Driver Behind Driver Seat...
Page 632: Wheel Speed Sensor-Left Rear
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Color Location Fig. Wheel Speed Sensor - LT GY Right Rear Frame Rail 28, 29 Right Rear Window Up Relay - Pas- Behind Instrument Panel Near Steering senger Column Window Down Relay - Pas- Behind Instrument Panel Near Steering...
Page 633 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICES Splice No. Location Fig. S100 Near T/O for Wheel Speed Sensor - Right Front S101 In Power Distribution Center S102 In Power Distribution Center S103 In Power Distribution Center S104 In T/O for Controller Antilock Brake S106...
Page 634 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Splice No. Location Fig. S142 (Export) In PDC S143 (Export) Near T/O for G100 S144 (Export) Left Rear Engine Compartment S146 Near T/O for Park/Turn Lamp - Right S147 Near T/O for Park/Turn Lamp - Right S148 Near T/O for Park/Turn Lamp - Right...
Page 635 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Splice No. Location Fig. S305 Center Chassis Behind Seats S307 Near T/O for C302 S309 Near T/O for License Lamp - Right S310 Near T/O for Decklid Release Motor/Ajar Switch S311 Near T/O for Tail Lamp - Left S312...
Page 636 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 637 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 638 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 639 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 4 RIGHT ENGINE COMPARTMENT Fig. 5 RIGHT FRONT ENGINE COMPARTMENT...
Page 640 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 6 POWERTRAIN CONTROL MODULE Fig. 7 LEFT REAR ENGINE COMPARTMENT...
Page 641 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 8 LEFT FRONT ENGINE COMPARTMENT (EXPORT) Fig. 9 LEFT FRONT ENGINE...
Page 642 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 643 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 644 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 12 RIGHT FRONT ENGINE Fig. 13 REAR ENGINE COMPARTMENT...
Page 645 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 14 LEFT REAR TRANSMISSION Fig. 15 RIGHT TRANSMISSION...
Page 646 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 16 HVAC TOP Fig. 17 HVAC SIDE...
Page 647 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 648 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 649 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 20 LEFT KICK PANEL Fig. 21 CLOCKSPRING...
Page 650 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 22 RIGHT KICK PANEL Fig. 23 FRONT CENTER BODY...
Page 651 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 652 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 653 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 654 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 655 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 656 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 657 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 30 RIGHT REAR BODY Fig. 31 REAR LIGHTING...
Page 658 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 32 DECKLID...
Page 660 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION POWER DISTRIBUTION CENTER DESCRIPTION ......1 REMOVAL .
Page 661 8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) damaged, the entire PDC and body wire harness unit must be replaced. NOTE: If the power distribution center (PDC) is being replaced with a new unit, be certain to trans- fer each of the fuses and relays from the old PDC to the proper cavities of the new PDC.
Page 662 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE - 8.3L INSTALLATION ......34 DESCRIPTION .
Page 663 9 - 2 ENGINE OIL PRESSURE SENSOR INSTALLATION ......60 REMOVAL ......53 CONNECTING ROD BEARINGS INSTALLATION .
Page 664 ENGINE 9 - 3 ENGINE - 8.3L DESCRIPTION The engine is an 8.3 Liter (505 CID), 10-cylinder, 90° V-type, lightweight, single-cam, overhead valve engine (Fig. 1). This engine is designed for premium unleaded fuel. The crankshaft is forged steel. The cylinder block and cylinder heads are aluminum.
Page 665 9 - 4 ENGINE ENGINE - 8.3L (Continued) ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT 1. Weak or discharged battery. 1. Charge or replace battery as necessary. CRANK (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING). Check charging system.
Page 666 ENGINE 9 - 5 ENGINE - 8.3L (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE STALLS OR 1. Carbon buildup on throttle plate. 1. Remove throttle body and de-carbon. ROUGH IDLE 2. Engine idle speed too low. 2. Check Idle Air Control circuit. Refer to the appropriate Diagnostic Information for IAC motor testing.
Page 667 9 - 6 ENGINE ENGINE - 8.3L (Continued) CONDITION POSSIBLE CAUSES CORRECTION CONNECTING ROD 1. Insufficient oil supply. 1. Check engine oil level. NOISE 2. Low oil pressure. 2. Check engine oil level. If OK, perform oil pressure test. Inspect oil pump relief valve and spring.
Page 668 ENGINE 9 - 7 ENGINE - 8.3L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Misaligned or deteriorated gas- 1. Replace gaskets. kets. 2. Loose fastener, broken or porous 2. Tighten, repair or replace component. component. EXCESSIVE OIL CON- 1. PCV system malfunction. 1.
Page 669 9 - 8 ENGINE ENGINE - 8.3L (Continued) (1) Check the coolant level and fill as required. DO CYLINDER-TO-WATER JACKET LEAKAGE TEST NOT install the pressure cap. (2) Start and operate the engine until it attains WARNING: USE EXTREME CAUTION WHEN THE normal operating temperature, then turn the engine ENGINE IS OPERATING WITH COOLANT PRES- OFF.
Page 670 ENGINE 9 - 9 ENGINE - 8.3L (Continued) HYDRAULIC TAPPET NOISE DIAGNOSIS Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by exces- sive leak-down around the unit plunger which will PRELIMINARY STEP TO CHECKING THE necessitate replacing the tappet, or by the plunger HYDRAULIC TAPPETS partially sticking in the tappet body cylinder.
Page 671 9 - 10 ENGINE ENGINE - 8.3L (Continued) (6) If no leaks are detected, turn off the air supply. (7) After the oil leak root cause and appropriate Remove the air hose, all plugs, and caps. Connect the corrective action have been identified, replace compo- PCV hoses.
Page 672 ENGINE 9 - 11 ENGINE - 8.3L (Continued) place gasket material unless specified. Bead size, MOPAR GASKET SEALANT continuity, and location are of great importance. Too Mopar Gasket Sealant is a slow drying, perma- thin a bead can result in leakage while too much can nently soft sealer.
Page 673 9 - 12 ENGINE ENGINE - 8.3L (Continued) ENGINE GASKET SURFACE PREPARATION 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 674 ENGINE 9 - 13 ENGINE - 8.3L (Continued) (6) Discharge air conditioning system using a suit- able refrigerant recovery machine (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/RE- FRIGERANT - STANDARD PROCEDURE). (7) Remove front strut tower to tower brace (Fig. 5) (Refer to 23 - BODY/EXTERIOR/FRONT STRUT TOWER TO TOWER BRACE - REMOVAL).
Page 675 9 - 14 ENGINE ENGINE - 8.3L (Continued) (24) Disconnect exhaust system at left and right (35) Lower transmission jack to gain access to exhaust manifolds. Do not reuse V-band clamps. transmission to bellhousing bolts. Remove transmis- (25) Remove left and right catalytic converter sup- sion to bell housing bolts (Fig.
Page 676 ENGINE 9 - 15 ENGINE - 8.3L (Continued) (38) Remove left and right engine mount to frame (41) Install Special Tool 9057 - Engine Lifting nuts (Fig. 10). Bracket to left front cylinder head boss (Fig. 11) and (Fig. 13). Fig.
Page 677 9 - 16 ENGINE ENGINE - 8.3L (Continued) (42) Attach an appropriate chain to engine lifting (13) Connect oil cooler lines (Refer to 9 - ENGINE/ brackets. Remove engine with an engine hoist (Fig. LUBRICATION/OIL COOLER & LINES - STAN- 14).
Page 678 ENGINE 9 - 17 ENGINE - 8.3L (Continued) (41) Install air cleaner housing assembly, connect CYLINDER BLOCK throttle body air inlet hose (Refer to 9 - ENGINE/ AIR INTAKE SYSTEM - INSTALLATION). SPECIFICATION (42) Install hood (Refer to 23 - BODY/HOOD/ DESCRIPTION Metric Standard...
Page 679 9 - 18 ENGINE ENGINE - 8.3L (Continued) CONNECTING RODS PISTON PINS SPECIFICATION SPECIFICATION DESCRIPTION DESCRIPTION Metric Standard Metric Standard Bearing Clear- 0.005-0.074 0.0002-0.0029 Clearance in 0.009-0.022 0.0004-0.0009 ance Piston Desired 0.0381 mm 0.0015 in. Clearance in 0.017-0.061 0.0007-0.0024 Connecting Rod Wear Limit 0.0889 mm 0.0035 in.
Page 680 ENGINE 9 - 19 ENGINE - 8.3L (Continued) CAMSHAFT CYLINDER HEAD VALVE SEAT SPECIFICATION SPECIFICATION DESCRIPTION DESCRIPTION Metric Standard Metric Standard Lift 8.13 mm 0.320 in. Seat Angle 44°-44.5° Journal Diameter Runout (Max.) 0.038 mm 0.002 in. 53.09-53.11 mm 2.090-2.091 in. Width (Finish) Boar Diameter Intake and...
Page 681 9 - 20 ENGINE ENGINE - 8.3L (Continued) VALVE SPRING SPECIFICATION DESCRIPTION Metric Standard SPECIFICATION Inner Rotor DESCRIPTION Thickness 18.92 mm 0.744 in. Metric Standard (Min.) Free Length - 55.0 mm 2.165 in. Clearance Spring 0.19 mm 0.007 in. (Max.) Free Length - 47 mm 1.850 in.
Page 682 ENGINE 9 - 21 ENGINE - 8.3L (Continued) DESCRIPTION N·m Lbs. Lbs. 1/4–20 — 5/16–18 — Oil Pan Drain—Plug — Oil Pressure Relief Valve—Plug — Oil Pump Cover—Bolts — Crankshaft Insert 8194 Oil Pump Pick-up Tube Bolt 1/4–20 — Nut 5/16–18 —...
Page 683 9 - 22 ENGINE ENGINE - 8.3L (Continued) Front Crankshaft Seal Remover C-4679A Bearing/Seal Remover Adapter - 8990 Front Crankshaft Seal Installer MD-998306 Puller, Slide Hammer C-3752 Rear Crankshaft Seal Installation Guide 9060 Crankshaft Pilot Bearing Installer 9058 Valve Spring Compressor MD998772A Driver Handle C-4171...
Page 684 ENGINE 9 - 23 ENGINE - 8.3L (Continued) Valve Spring Tester C-647 DRB III with PEP Module – OT-CH6010A Pressure Tester Kit 7700 Pressure Transducer OT-CH7059 Bloc–Chek–Kit C-3685–A Clutch Hydraulic Line Disconnect Tool 6638A Adaptor 8116 Disconnect Tool 9005...
Page 685 9 - 24 ENGINE (2) Pull the air filter element up and off of the noz- AIR CLEANER ELEMENT zle assembly (Fig. 17), the assembly is held in by the lips in the housing (Fig. 18) for the filter element. REMOVAL The air intake system does not preheat ambient air.
Page 686 ENGINE 9 - 25 AIR CLEANER HOUSING REMOVAL The air intake system does not preheat ambient air. The majority of the inlet air is directed into the air cleaner front housing from the hood duct (Fig. 19). The incoming ambient air passes through two fil- ter elements in the air cleaner.
Page 687 9 - 26 ENGINE ENGINE MOUNTS REMOVAL NOTE: This procedure covers either the left or right engine mount. (1) Raise vehicle on hoist. (2) Support oil pan with suitable jack. (3) Loosen engine mount to block bolts (Fig. 22) or (Fig.
Page 688 ENGINE 9 - 27 ENGINE MOUNTS (Continued) Fig. 24 Engine Mount to Frame Nuts (Left Side Shown - Right Side Typical) 2 - NUT 1 - ENGINE MOUNT STUD (3) Install engine mount to frame nut (Fig. 24). (1) Perform the fuel system pressure release proce- Tighten nut to 102 N·m (75 ft.
Page 689 9 - 28 ENGINE INTAKE MANIFOLD (Continued) (4) Disconnect throttle cable from throttle cam. (7) Remove the wiper arms (Refer to 8 - ELECTRI- Remove throttle cable from bracket and set aside. CAL/WIPERS/WASHERS/WIPER ARMS (Fig. 25). REMOVAL). (8) Remove the wiper cowl (Refer to 8 - ELECTRI- CAL/WIPERS/WASHERS/WIPER MODULE REMOVAL).
Page 690 ENGINE 9 - 29 INTAKE MANIFOLD (Continued) (13) Remove the intake manifold bolts and intake manifold (Fig. 28). (14) Cover the intake manifold openings with a suitable cover when servicing to prevent any debris from entering cylinder heads. Fig. 29 Intake Manifold Gaskets Installation 1 - ALIGNMENT PINS 2 - INTAKE MANIFOLD GASKET Fig.
Page 691 9 - 30 ENGINE INTAKE MANIFOLD (Continued) • MAP sensor • Idle Speed Control • Throttle Position Sensor • Right cylinder head fuel injectors (10) Install air cleaner housing assembly, connect throttle body air inlet hose and connect the Intake Air Temperature Sensor (Refer to 9 - ENGINE/AIR INTAKE SYSTEM - INSTALLATION).
Page 692 ENGINE 9 - 31 EXHAUST MANIFOLD (Continued) INSTALLATION CYLINDER HEAD(S) NOTE: Care must be taken to protect the cylinder REMOVAL - CYLINDER HEAD(S) head covers powder coating from scrapes and abrasions. This procedure covers either the left or NOTE: Care must be taken to protect the intake right exhaust manifold.
Page 693 9 - 32 ENGINE CYLINDER HEAD(S) (Continued) NOTE: Do not reuse V-Band clamp. (2) Clean cylinder head and oil passages. (3) Check cylinder head for flatness (Fig. 34). (7) Lower the vehicle. (4) Inspect all surfaces with a straightedge (2) if (8) Remove intake manifold (Refer to 9 - ENGINE/ there is any reason to suspect leakage.
Page 694 ENGINE 9 - 33 CYLINDER HEAD(S) (Continued) DESCRIPTION), (Refer to LUBRICATION & MAIN- TENANCE/FLUID TYPES - SPECIFICATIONS). (19) Fill the cooling system (Refer to 7 - COOL- ING/ENGINE - STANDARD PROCEDURE - FILL- ING COOLING SYSTEM). (20) Connect negative battery cable. Install battery cover.
Page 695 9 - 34 ENGINE CYLINDER HEAD COVER(S) (Continued) (4) Remove cylinder head cover from engine (Fig. (3) Connect spark plug wires. Position spark plug 37). wire retainers onto cylinder head cover studs. (4) Connect CCV hose to cylinder head cover. Fig.
Page 696 ENGINE 9 - 35 ROCKER ARMS (Continued) (4) If rocker arm assemblies are disassembled for right while the damper is wound downward and to cleaning or replacement, reassemble rocker arms in the left. The valve spring is serviced as an assembly their original position.
Page 697 9 - 36 ENGINE VALVE SPRINGS/SEALS (Continued) (1) Obtain specifications for spring tension at spec- (4) Rotate crankshaft until No. 1 piston is at TDC ified spring length (Refer to 9 - ENGINE - SPECIFI- on compression stroke. CATIONS). (5) Remove rocker arms with pivots. The rocker (2) Turn table of Special Tool C-647 (2) until the arms should not be disturbed and remain on pivot surface is in line with the spring length specification...
Page 698 ENGINE 9 - 37 VALVE SPRINGS/SEALS (Continued) REMOVAL (2) Remove valve retaining locks (Fig. 45). (3) Slowly release valve spring compressor. (4) Remove valve spring retainer and valve spring (Fig. 45). (5) Before removing the valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides.
Page 699 9 - 38 ENGINE VALVE SPRINGS/SEALS (Continued) Fig. 47 Measuring Valve Tip Height and Valve Spring Installed Height 1 - VALVE SEAL 2 - VALVE SPRING SEAT 3 - CYLINDER HEAD SURFACE (5) Compress valve springs with a valve spring compressor.
Page 700 ENGINE 9 - 39 INTAKE/EXHAUST - VALVES/SEATS/GUIDES (Continued) a 30° stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 75° stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained.
Page 701 9 - 40 ENGINE TIMING CHAIN COVER REMOVAL (1) Open trunk lid. Remove battery cover. Discon- nect negative battery cable. (2) Disconnect throttle body air inlet hose, remove air cleaner housing assembly (Refer to 9 - ENGINE/ AIR INTAKE SYSTEM - REMOVAL). (3) Drain cooling system (Refer to 7 - COOLING/ ENGINE - STANDARD PROCEDURE - DRAINING COOLING SYSTEM).
Page 702 ENGINE 9 - 41 TIMING CHAIN COVER (Continued) (3) Position the oil pump inner rotor mating flats (18) Install crankshaft damper and pulley (Refer in the same position as the crankshaft drive flats. ENGINE/ENGINE BLOCK/VIBRATION (4) Install timing chain cover onto crankshaft. DAMPER - INSTALLATION).
Page 703 9 - 42 ENGINE TIMING CHAIN AND SPROCKETS REMOVAL TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL (1) Remove timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL). (2) Rotate crankshaft until timing marks are aligned (Fig. 60). (3) Remove the camshaft sprocket attaching bolts (Fig.
Page 704 ENGINE 9 - 43 TIMING CHAIN AND SPROCKETS (Continued) INSTALLATION CRANKSHAFT SPROCKET INSTALLATION Fig. 60 Alignment of Timing Marks (6) Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign. Fig.
Page 705 9 - 44 ENGINE LUBRICATION (Continued) leak is detected and identified, repair per service DIAGNOSIS AND TESTING manual procedures. (4) If the leakage occurs at the rear oil seal area, CHECKING ENGINE OIL PRESSURE refer to the section, Inspection for Rear Seal Area (1) Remove oil pressure sensor (Refer to 9 - Leak.
Page 706 ENGINE 9 - 45 STANDARD PROCEDURE CHECKING ENGINE OIL LEVEL The best time to check engine oil level is after the vehicle has sat overnight. If the engine has been run- Fig. 62 Engine Oil Level ning, allow the engine to be shut off for at least 5 1 - ENGINE OIL DIPSTICK minutes before checking oil level.
Page 707 9 - 46 ENGINE OIL (Continued) ENGINE OIL AND FILTER CHANGE USED ENGINE OIL DISPOSAL Care should be exercised when disposing used WARNING: NEW OR USED ENGINE OIL CAN BE engine oil after it has been drained from a vehicle IRRITATING TO THE SKIN.
Page 708 ENGINE 9 - 47 OIL COOLER & LINES (Continued) Fig. 64 Oil Cooler Line Quick Connect Fitting - Assembly 1 - QUICK CONNECT FITTING 2 - CLIP 3 - OIL COOLER LINE 4 - DUST CAP Fig. 63 Oil Cooler Line Quick Connect Fitting - (3) Slide dust cap (4) down the oil cooler line (3) Disassembly and snap it over the quick connect fitting (1) until it...
Page 709 9 - 48 ENGINE OIL COOLER & LINES (Continued) REMOVAL (1) Disconnect throttle body air inlet hose, remove air cleaner housing assembly (Refer to 9 - ENGINE/ AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL). (2) Drain cooling system (Refer to 7 - COOLING/ ENGINE - STANDARD PROCEDURE).
Page 710 ENGINE 9 - 49 OIL PAN REMOVAL (1) Raise vehicle on hoist. (2) Drain engine oil. (3) Remove flywheel inspection cover. (4) Remove fasteners securing A/C line to oil pan. (5) Remove transmission to oil pan fasteners (Fig. 68). (6) Remove oil pan bolts and remove oil pan (Fig. 69). NOTE: Clean and inspect oil pan gasket.
Page 711 9 - 50 ENGINE OIL PAN (Continued) (4) Run the transmission to oil pan bolts in finger DISASSEMBLY tight (Fig. 68). (5) Torque 5/16–18 oil pan bolts to 23 N·m (200 in. lbs.). Torque 1/4–20 oil pan bolts to 11 N·m (95 in lbs.).
Page 712 ENGINE 9 - 51 OIL PUMP (Continued) (3) Remove oil pressure relief valve (1) and spring (2) (Fig. 72). (4) Wash all parts in a suitable solvent and inspect carefully for damage or wear. CLEANING Clean all parts thoroughly. Mating surface of the chain case cover should be smooth.
Page 713 9 - 52 ENGINE OIL PUMP (Continued) Fig. 78 Oil Pressure Relief Valve INSTALL Fig. 77 Measuring Clearance Between Rotors 1 - OIL PRESSURE RELIEF VALVE 2 - SPRING 1 - FEELER GUAGE 3 - PLUG WITH O-RING 2 - OUTER ROTOR 3 - INNER ROTOR (5) Measure clearance between the outer rotor (2) and inner rotor (3) (Fig.
Page 714 ENGINE 9 - 53 OIL PUMP (Continued) INSTALLATION INSTALLATION (1) Assemble oil pump (Refer to 9 - ENGINE/LU- (1) Apply thread sealer to oil temperature sensor BRICATION/OIL PUMP - ASSEMBLY). threads. (2) Prime oil pump before installation by filling (2) Install oil temperature sensor (Fig. 80). rotor cavity with engine oil.
Page 715 9 - 54 ENGINE ENGINE BLOCK (Continued) scuffing, scoring and scratches. Usually, a few strokes (3) Use a wooden or plastic scraper and Mopar will clean up a bore and maintain the required lim- Brake Parts Cleaner or the equivalent to remove the its.
Page 716 ENGINE 9 - 55 HYDRAULIC TAPPETS DESCRIPTION Fig. 84 Hydraulic Tappets 1 - BOLT 2 - ALIGNING YOKE 3 - HYDRAULIC TAPPET Fig. 83 Hydraulic Tappets 1 - BOLT 2 - ALIGNING YOKE 3 - HYDRAULIC TAPPET The roller type design hydraulic tappets (3) are positioned in the cylinder block.
Page 717 9 - 56 ENGINE HYDRAULIC TAPPETS (Continued) (3) With roller tappets in proper position, install aligning yoke assemblies. Apply Mopar Lock & Seal Adhesive (Medium Strength Threadlocker) to the screws and tighten to 11 N·m (95 in. lbs.) (Fig. 84). (4) Install cylinder heads (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION).
Page 718 ENGINE 9 - 57 PISTON & CONNECTING ROD DESCRIPTION The pistons are made of cast aluminum. Three pis- ton rings are used; two compression and one three- piece oil control ring. The piston pin (press-fit into the rods) joins the piston to a forged steel, fractured cap, designed connecting rod.
Page 719 9 - 58 ENGINE PISTON & CONNECTING ROD (Continued) REMOVAL NOTE: Pistons and connecting rods are to be removed as an assembly from top of cylinder block. (1) Remove cylinder heads (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL). (2) Remove oil pan (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL).
Page 720 ENGINE 9 - 59 PISTON & CONNECTING ROD (Continued) INSPECTION (9) Install oil pump pick up tube using a new o-ring. Torque 1/4–20 bolt to 11 N·m (95 in. lbs.). Torque 5/16–18 nut to 23 N·m (200 in. lbs.) (Fig. 90). CONNECTING ROD (10) Install oil pan (Refer to 9 - ENGINE/LUBRI- (1) Check the connecting rods for twist or bend.
Page 721 9 - 60 ENGINE REMOVAL PISTON RINGS STANDARD PROCEDURE - MEASURING PISTON RING CLEARANCES Fig. 97 Piston Rings—Removing and Installing (1) Using a suitable ring expander, remove upper and intermediate piston rings (Fig. 97). (2) Remove the upper oil ring side rail, lower oil Fig.
Page 722 ENGINE 9 - 61 PISTON RINGS (Continued) CAUTION: Install piston rings in the following order: • Oil ring expander • Lower oil ring side rail • Upper oil ring side rail • No. 2 intermediate piston ring • No. 1 upper piston ring (1) Install oil ring expander.
Page 723 9 - 62 ENGINE CONNECTING ROD BEARINGS (Continued) The bearing shells must be installed so that the the top of the engine. Only then should the cap be tangs are in the machined grooves in the rods and assembled and torqued to specifications. Do not caps.
Page 724 ENGINE 9 - 63 CRANKSHAFT DAMPER (Continued) Fig. 104 Engine Mount to Frame Nuts (Left Side Shown - Right Side Typical) 2 - NUT 1 - ENGINE MOUNT STUD (10) Using bolt-grip type universal puller, remove the crankshaft damper (Fig. 106). Fig.
Page 725 9 - 64 ENGINE CRANKSHAFT DAMPER (Continued) INSTALLATION CRANKSHAFT OIL SEAL - FRONT NOTE: Lubricate the threads of Special Tool 9055 using Mopar Nickel Anti-seize Compound or equiv- REMOVAL alent, before beginning crankshaft damper installa- (1) Remove air cleaner housing (Refer to 9 - tion.
Page 726 ENGINE 9 - 65 CRANKSHAFT OIL SEAL - FRONT (Continued) (5) Install air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION). Fig. 109 Crankshaft Oil Seal—Installation 1 - SEAL 2 - CRANKSHAFT SEAL INSTALLING TOOL MD 998306 Fig.
Page 727 9 - 66 ENGINE CRANKSHAFT MAIN BEARINGS DESCRIPTION Fig. 113 Placement of Plastigage in Bearing Shell 1 - PLASTIGAGE crankshaft. This can be accomplished by either of two methods: PREFERRED METHOD (1) Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance Fig.
Page 728 ENGINE 9 - 67 CRANKSHAFT MAIN BEARINGS (Continued) (3) Zero the dial indicator. (4) Move crankshaft all the way to the front and read the dial indicator. (Refer to 9 - ENGINE - SPECIFICATIONS) for crankshaft end-play specifica- tions. CRANKSHAFT END PLAY CHECK - OPTIONAL (1) Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage...
Page 729 9 - 68 ENGINE CRANKSHAFT (Continued) REMOVAL (1) Remove engine assembly from vehicle (Refer to 9 - ENGINE - REMOVAL). (2) Mount engine on a suitable repair stand. (3) Remove oil pan (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL). (4) Remove crankshaft rear oil seal retainer (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT REAR OIL SEAL RETAINER - REMOVAL).
Page 730 ENGINE 9 - 69 CRANKSHAFT (Continued) (11) Remove connecting rod bolts and caps. lets. After grinding, remove rough edges from crank- (12) Main bearing caps are not interchangeable shaft oil holes and clean out all passages. and should be marked before removal to ensure cor- CAUTION: With the forged crankshafts it is impor- rect reassembly.
Page 731 9 - 70 ENGINE CRANKSHAFT (Continued) INSTALLATION For proper main bearing size selection, refer to MAIN BEARING SELECT FIT CHART. MAIN BEARING SELECT FIT CHART Engine Block Crankshaft Main Bearing Mark Mark Color White White Orange White Black White Black White White Black...
Page 732 ENGINE 9 - 71 CRANKSHAFT (Continued) Fig. 123 Main Bearing Cap Torque Sequence (13) Install timing chain (Refer to 9 - ENGINE/ (15) Install oil pan (Refer to 9 - ENGINE/LUBRI- VALVE TIMING/TIMING CHAIN AND SPROCKETS CATION/OIL PAN - INSTALLATION). - INSTALLATION).
Page 733 9 - 72 ENGINE CRANKSHAFT PILOT BEARING REMOVAL Fig. 125 Crankshaft Pilot Bearing 1 - MARKINGS ON BEARING FACE OUT FOR INSTALLATION Fig. 124 Crankshaft Pilot Bearing Removal 1 - SPECIAL TOOL 8990 2 - SPECIAL TOOL C-3752 (1) Remove transmission (Refer to 21 - TRANS- MISSION/TRANSAXLE/MANUAL - REMOVAL).
Page 734 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page EXHAUST SYSTEM INSTALLATION - AUXILIARY RESONATOR DESCRIPTION - EXPORT ....1 HEAT SHIELD .
Page 735 11 - 2 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) Valves use a butterfly style valve to restrict exhaust TAKEN WHEN WORKING NEAR THE CATALYTIC from exiting the side of the vehicle. The diverted CONVERTER. THE TEMPERATURE OF THE CON- exhaust is then carried to the Auxiliary Resonator VERTER RISES TO A HIGH LEVEL AFTER A SHORT where it is exhausted to the atmosphere (Fig.
Page 736 EXHAUST SYSTEM 11 - 3 EXHAUST SYSTEM (Continued) Fig. 2 VACUUM DIAGRAM ACTIVATED (7) If pressure exceeds maximum limits, inspect ADJUSTMENTS exhaust system for restricted component. For further catalytic converter inspection procedures, (Refer to 11 EXHAUST SYSTEM ALIGNMENT - EXHAUST SYSTEM/CATALYTIC CONVERTER - A misaligned exhaust system is usually indicated INSPECTION).
Page 737 11 - 4 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) SPECIFICATIONS PIPE CLAMPS TORQUE DESCRIPTION A V-band clamp (Fig. 3) secures the catalytic con- verter to exhaust manifold connection. When the DESCRIPTION N·m V-band clamp is tightened, it forces the flared mating Lbs.
Page 738 EXHAUST SYSTEM 11 - 5 Proper catalyst operation is dependent on its abil- HEAT SHIELDS ity to store and release the oxygen needed to com- plete the emissions-reducing chemical reactions. As a DESCRIPTION catalyst deteriorates, its ability to store oxygen is High temperatures can develop around the cata- reduced.
Page 739 11 - 6 EXHAUST SYSTEM CATALYTIC CONVERTER(S) (Continued) Fig. 6 Inner Sill Heat Shield (Right Side Shown - Left Side Typical) 1 - SCREW(S) 3 - U NUT 2 - INNER SILL HEAT SHIELD 4 - PEEL AND STICK HEAT SHIELD (3) Apply penetrating oil to catalytic converter (8) Loosen band clamp at resonator (Fig.
Page 740 EXHAUST SYSTEM 11 - 7 CATALYTIC CONVERTER(S) (Continued) Fig. 7 Sill Panel (Right Side Shown - Left Side Typical) 3 - FENDER ASSEMBLY 1 - FRAME ASSEMBLY 2 - SILL PANEL Fig. 8 Catalytic Converter (Right Side Shown - Left Fig.
Page 741 11 - 8 EXHAUST SYSTEM CATALYTIC CONVERTER(S) (Continued) INSPECTION (7) Tighten “A” and “B” pillar support isolators to 28 N·m (250 in. lbs.). (8) Tighten resonator band clamp to 54 N·m (40 ft. WARNING: THE NORMAL OPERATING TEMPERA- lbs.). TURE OF THE EXHAUST SYSTEM IS VERY HIGH. (9) Connect downstream oxygen sensor connector THEREFORE, NEVER ATTEMPT TO SERVICE ANY (Fig.
Page 742 EXHAUST SYSTEM 11 - 9 RESONATOR(S) (Continued) (3) Apply penetrating oil to spout assembly and H-pipe band clamps (Fig. 11) and (Fig. 12). (4) Loosen spout assembly and H-Pipe band clamps (Fig. 11) and (Fig. 12). (5) Remove “B” pillar support isolator (Fig. 11). (6) Separate spout assembly from resonator.
Page 743 11 - 10 EXHAUST SYSTEM SPOUT ASSEMBLY - LEFT/RIGHT (Continued) Fig. 12 H-Pipe and Spout Assemblies 1 - H-PIPE 3 - BAND CLAMP 2 - RIGHT SIDE SPOUT ASSEMBLY 4 - LEFT SIDE SPOUT ASSEMBLY (7) Start the engine and inspect for exhaust leaks. (8) Check the exhaust system for contact with the Repair exhaust leaks as necessary.
Page 744 EXHAUST SYSTEM 11 - 11 H-PIPE HEAT SHIELDS - EXPORT REMOVAL REMOVAL - AUXILIARY RESONATOR HEAT (1) Raise vehicle on hoist (Refer to LUBRICATION SHEILD & MAINTENANCE/HOISTING - STANDARD PRO- (1) Remove the auxiliary resonator (Refer to 11 - CEDURE). EXHAUST SYSTEM/RESONATOR - REMOVAL).
Page 745 11 - 12 EXHAUST SYSTEM (1) Raise the vehicle on a hoist (Refer to LUBRI- RESONATOR(S) - EXPORT CATION & MAINTENANCE/HOISTING - STAN- DARD PROCEDURE). REMOVAL (2) Remove the sill panel (Refer to 23 - BODY/EX- (1) Raise the vehicle on a hoist (Refer to LUBRI- TERIOR/ROCKER PANEL COVER - REMOVAL).
Page 746 EXHAUST SYSTEM 11 - 13 SPOUT ASSEMBLY - EXPORT (Continued) Fig. 15 DIVERTER TO SPOUT MOUNTING 1 - BAND CLAMP 4 - LEFT SIDE DIVERTER PIPE 2 - RIGHT SIDE SPOUT ASSEMBLY 5 - BAND CLAMP 3 - RIGHT SIDE DIVERTER PIPE 6 - LEFT SIDE SPOUT ASSEMBLY (1) Connect the spout assembly to the diverter H-PIPE - EXPORT...
Page 747 11 - 14 EXHAUST SYSTEM H-PIPE - EXPORT (Continued) Fig. 16 H-PIPE Fig. 17 H-PIPE EXTENSION PIPE 1 - DIFFERENTIAL (for reference) 1 - BAND CLAMP 2 - BAND CLAMP 2 - H-PIPE EXTENSION PIPE 3 - H-PIPE 3 - BAND CLAMP 4 - BAND CLAMP 4- H-PIPE 5- DIFFERENTIAL (for reference)
Page 748 EXHAUST SYSTEM 11 - 15 NOTE: Do not tighten the band clamps until all of EXHAUST PIPE - EXPORT the exhaust connections are in place. REMOVAL - DIVERTER PIPE (1) Connect the diverter pipe to the spout assem- bly (Fig. 18). Loosely install the band clamp. NOTE: This procedure covers removal of either the (2) Connect the vacuum line to the diverter valve.
Page 749 11 - 16 EXHAUST SYSTEM SUPPORT BRACKET AND ISOLATOR - EXPORT REMOVAL REMOVAL - AUXILIARY RESONATOR - UPPER LEFT Fig. 20 AUXILIARY RESONATOR LOWER LEFT HANGER 1 - NUTS 2 - HANGER INSTALLATION INSTALLATION - AUXILIARY RESONATOR - UPPER LEFT Fig.
Page 750 EXHAUST SYSTEM 11 - 17 EXHAUST SOLENOID - EXPORT REMOVAL (1) Disconnect the negative battery cable. (2) Disconnect the exhaust solenoid electrical con- nector. (3) Disconnect the inlet and outlet vacuum hoses at the solenoid. (4) Remove the retaining screw and remove the solenoid from the bracket (Fig.
Page 752 FRAME & BUMPERS 13 - 1 FRAME & BUMPERS TABLE OF CONTENTS page page FRAME & BUMPERS INSTALLATION ......7 SPECIFICATIONS - TORQUE .
Page 753 13 - 2 FRAME & BUMPERS FRONT FASCIA (Continued) Fig. 1 FASCIA TO FENDER ATTACHMENT 1 - PUSH ON SPRING NUT 6 - SPRING NUT 2 - STUD PLATE 7 - HEADLAMP MOUNT SUPPORT 3 - FASCIA, FRONT 8 - STUD WITH FENDER ASSEMBLY 4 - FOG LAMP 9 - FASCIA TO FENDER NUT 5 - SCREW...
Page 754 FRAME & BUMPERS 13 - 3 FRONT FASCIA (Continued) INSTALLATION (5) Remove the remaining wheel opening fasten- ers. (1) Position the fascia and connect the fog lamp (6) Remove the upper screws and remove the fas- electrical connectors. cia. (2) Install the upper screws. (7) Disconnect the fog lamps.
Page 755 13 - 4 FRAME & BUMPERS FRONT FASCIA - EXPORT (Continued) Fig. 4 FRONT FASCIA 1 - PUSH ON SPRING NUT 6 - BUMPER REINFORCEMENT 2 - FRAME ASSEMBLY 7 - FRONT FASCIA 3 - RIVET NUT 8 - FRONT BUMPER 4 - NUT 9 - SQUARE NECK BOLT 5 - BOLTS...
Page 756 FRAME & BUMPERS 13 - 5 FRONT BUMPER REINFORCEMENT - EXPORT REMOVAL - EXPORT (1) Remove the fascia (Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT FASCIA REMOVAL). (2) Remove the bolts and remove the hood release handle. (Fig. 6) (3) Disconnect the headlamp washer main hose from the lower washer reservoir (Fig.
Page 757 13 - 6 FRAME & BUMPERS REAR FASCIA (Continued) Fig. 8 REAR FASCIA TO REAR QUARTER PANEL 1 - FASCIA TO REAR QUARTER PANEL NUT 4 - REAR FASCIA 2 - REAR QUARTER PANEL RETAINER 5 - ROUND SPRING NUT 3 - BODY ASSEMBLY 6 - FASCIA RETAINER Fig.
Page 758 FRAME & BUMPERS 13 - 7 REAR BUMPER FOAM REMOVAL (1) Remove the rear fascia. (Refer to 13 - FRAME & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL) (2) Remove the push pin fasteners and remove the foam (Fig. 11). INSTALLATION (1) Install the foam and install the push pin fas- teners.
Page 759 13 - 8 FRAME & BUMPERS FRONT TOW EYE BRACKET - BRACKET - REAR LICENSE EXPORT PLATE EXPORT REMOVAL - EXPORT REMOVAL - EXPORT (1) Remove the front fascia (Refer to 13 - FRAME (1) Remove the license plate. & BUMPERS/BUMPERS/FRONT FASCIA NOTE: Lift the license plate flap up to access the...
Page 760 FRAME & BUMPERS 13 - 9 • Do not anchor or support vehicle on powertrain FRAME components during frame straightening operations. Damage to powertrain can result. WARNING • Protect wire harness and plastic components from excessive heat or sparks during frame repair WARNING: USE EYE PROTECTION WHEN GRIND- operations.
Page 761 13 - 10 FRAME & BUMPERS FRAME (Continued) The frame is constructed with mild and high BUMPERS/FRAME - SPECIFICATIONS - WELD- strength low alloy steel tubing. The frame is held ING). rigid by cross braces and stringers. The datum plane (3) Measure and recheck alignments (Refer to 13 - is defined by the bottom of the frame rails under the FRAME &...
Page 762 FRAME & BUMPERS 13 - 11 FRAME (Continued) (1) The frame should be straightened and squared Installation before removing the front frame assembly (Refer to (1) Fit the new side sill assembly into place, and 13 - FRAME & BUMPERS/FRAME - SPECIFICA- check for fit and alignment.
Page 763 13 - 12 FRAME & BUMPERS FRAME (Continued) (2) If sectioning, refer to front upper frame rail lines that make up the grid run in three planes assembly in this section. defined as X, Y, and Z. The X-plane extends from the (3) Double check all measurements (Refer to 13 - front to the rear of the vehicle.
Page 764 FRAME & BUMPERS 13 - 13 FRAME (Continued) Fig. 15 X, Y, AND Z PLANES...
Page 765 13 - 14 FRAME & BUMPERS FRAME (Continued)
Page 766 FRAME & BUMPERS 13 - 15 FRAME (Continued)
Page 767 13 - 16 FRAME & BUMPERS FRAME (Continued)
Page 768 FRAME & BUMPERS 13 - 17 FRAME (Continued)
Page 769 13 - 18 FRAME & BUMPERS FRAME (Continued)
Page 770 FRAME & BUMPERS 13 - 19 FRAME (Continued)
Page 771 13 - 20 FRAME & BUMPERS FRAME (Continued) SPECIFICATIONS - WELDING CAUTION: All welds should conform to DaimlerChrysler vehi- cle engineering process standard “PS 9472”. WELD PROCESS SPECIFICATIONS WELDING FLUX SHIELDED PROCESS CORED METAL METAL (MIG)* (STICK) Material 3.7 mm to 3.7 mm to 3.7 mm to Thickness...
Page 772 FRAME & BUMPERS 13 - 21 FRAME (Continued) WELDING FLUX SHIELDED PROCESS CORED METAL METAL (MIG)* (STICK) Direction of Welding Vertical Vertical Vertical Vertical - Down Hill Down Hill Up Hill (only) (only) (only) Flat & Flat - Flat - Flat - Drag Overhead Push or...
Page 774 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY ......1 FUEL INJECTION .
Page 775 14 - 2 FUEL DELIVERY FUEL DELIVERY STANDARD PROCEDURE FUEL SYSTEM PRESSURE RELEASE DESCRIPTION PROCEDURE (1) Remove Fuel Pump relay from Power Distribu- FUEL DELIVERY SYSTEM tion Center (PDC). For location of relay, refer to label The fuel delivery system consists of: the electric on underside of PDC cover.
Page 776 FUEL DELIVERY 14 - 3 FUEL DELIVERY (Continued) SPECIAL TOOLS FUEL O2S (OXYGEN SENSOR) REMOVAL/INSTALLER- C4907 Test Kit, Fuel Oxygen sensor tool FUEL FILTER DESCRIPTION The fuel filter mounts inside frame rail on the Adapters, Fuel Pressure Test—6539 and/or 6631 drivers side of vehicle near the rear tire.
Page 777 14 - 4 FUEL DELIVERY FUEL FILTER (Continued) Fig. 2 Fuel Pump Module Fig. 1 FUEL FILTER LOCATION FUEL LEVEL SENSOR DESCRIPTION The level sensor is attached to the side of the fuel pump module. The level sensor consists of a float, an arm, and a variable resistor.
Page 778 FUEL DELIVERY 14 - 5 FUEL LEVEL SENSOR (Continued) Fig. 7 Groove in Back Side of Level Sensor Fig. 4 Wedge Lock 1 - WIRING GROOVE (6) Push connector up into bottom of fuel pump module electrical connector. (7) Install fuel pump module. Refer to Fuel Pump Module in this section.
Page 779 14 - 6 FUEL DELIVERY FUEL TUBES/LINES/HOSES AND CLAMPS (Continued) STANDARD PROCEDURE - HOSES AND Fuel is supplied to the regulator by the electric fuel pump through an opening tube at the bottom of reg- CLAMPS ulator. Inspect all hose connections (clamps and quick con- The fuel pump module contains a check valve to nect fittings) for completeness and leaks.
Page 780 FUEL DELIVERY 14 - 7 FUEL PRESSURE REGULATOR (Continued) FUEL PUMP ELECTRICAL CONTROL Voltage to operate the electric pump is supplied through the fuel pump relay. For an electrical opera- tional description of the fuel pump refer to fuel Pump Relay—PCM Output.
Page 781 14 - 8 FUEL DELIVERY FUEL PUMP MODULE (Continued) Fig. 11 CONVERTIBLE FASTENER Fig. 13 FUEL PUMP MODULE COVER (4) Lift the top up and disconnect the heated back glass electrical connector (Fig. 12) from both sides of the glass. Fig.
Page 782 FUEL DELIVERY 14 - 9 FUEL PUMP MODULE (Continued) Fig. 15 PUMP MODULE FOAM BLOCK Fig. 17 ELECTRICAL & FUEL CONNECTION Fig. 16 FOAM BLOCK REMOVAL/INSTALL Fig. 18 FUEL PUMP MODULE LOCK RING INSTALLATION (6) Connect and lock the electrical connector to the fuel pump module.
Page 783 14 - 10 FUEL DELIVERY FUEL PUMP MODULE (Continued) (15) Pull top back and install the heated back (5) Disconnect the electrical connector to the TPS glass electrical connector (Fig. 12) and Idle Air Control (Fig. 20). (16) Install the convertible top fasteners (15 nuts) (Fig.
Page 784 FUEL DELIVERY 14 - 11 FUEL RAIL (Continued) (7) Disconnect the electrical connector from the (9) Remove the bolts for the fuel rail (Fig. 24). fuel injectors (Fig. 22). Fig. 24 FUEL RAIL Fig. 22 FUEL INJECTOR CONNECTOR (10) Pull fuel rail and injectors straight up and out (8) Disconnect the fuel line quick connector (Fig.
Page 785 14 - 12 FUEL DELIVERY FUEL RAIL (Continued) (11) Move the fuel rail forward (Fig. 26) and out from under the intake manifold and throttle body (Fig. 27). Fig. 28 FUEL INJECTOR & CLIP (4) Insert fuel injector nozzles into openings in intake manifold (Fig.
Page 786 FUEL DELIVERY 14 - 13 FUEL TANK (Continued) An evaporation control system restricts fuel evapo- (4) Cut on the 1/2 inch line marked IN from out- ration into the atmosphere and reduces unburned line of panel. hydrocarbons. Vapors from the fuel tank are collected (5) Cut clearance notch for fuel pump module as in a charcoal filled canister.
Page 787 14 - 14 FUEL DELIVERY FUEL TANK (Continued) (3) Put access panel in place and scribe the outline of the panel (Fig. 31). Mark the hole for the rivet that hold the panel in place. Fig. 33 CUTTING PANEL Fig. 31 REPLACEMENT PANEL MARKING (4) Remove the panel and scribe a line about a 1/2 inch in from the panel outline.
Page 788 FUEL DELIVERY 14 - 15 FUEL TANK (Continued) Fig. 37 CONVERTIBLE FASTENER Fig. 35 FUEL TANK & EVAP CANISTER Fig. 38 BACK GLASS ELECTRICAL CONNECTOR Fig. 36 CONVERTIBLE TOP ATTACHMENT (11) Roll deck lid carpet forward and out of the (9) Lift the top up and disconnect the heated back way.
Page 789 14 - 16 FUEL DELIVERY FUEL TANK (Continued) (12) Remove the 4 rivets from the fuel pump mod- (13) Using a scraper or long knife cut the sealer ule cover (Fig. 39) and (Fig. 40). You may have to under the cover to remove it from the vehicle. knock out the center pin with a punch.
Page 790 FUEL DELIVERY 14 - 17 FUEL TANK (Continued) (15) Clean the area round the fuel pump module (19) Use Special Tool #6856 to remove fuel pump (Fig. 43). module locknut (Fig. 45). (16) Mark fuel pump module location on tank. Fig.
Page 791 14 - 18 FUEL DELIVERY FUEL TANK (Continued) (22) Raise and support the vehicle. (26) Disconnect the vapor line at fuel filler tube (23) Remove the right rear tire. (Fig. 49). (24) Remove the right rear splash shield. (25) Remove the fuel filler tube from fuel tank (Fig.
Page 792 FUEL DELIVERY 14 - 19 FUEL TANK (Continued) (30) Disconnect the ground strap from frame (Fig. (32) Remove the liquid separator (Fig. 53) from the 51). top of the EVAP canister. Fig. 51 GROUND STRAP Fig. 53 LIQUID SEPARATOR (31) Disconnect the LDP electrical connector from (33) Pull wiring harness (Fig.
Page 793 14 - 20 FUEL DELIVERY FUEL TANK (Continued) (34) Pull fuel tank to the rear of vehicle (Fig. 55) and disconnect the vapor lines from the top of the fuel tank (Fig. 56). Fig. 57 TANK REMOVAL Fig. 55 FUEL TANK REMOVAL/INSTALL Fig.
Page 794 FUEL DELIVERY 14 - 21 FUEL TANK (Continued) (4) Connect the LDP electrical connector to pump (Fig. 52). (5) Connect the vapor lines to the tank (Fig. 55). (6) Slide tank forward. (7) Install the liquid separator (Fig. 53) to the top of the EVAP canister.
Page 795 14 - 22 FUEL DELIVERY FUEL FILLER TUBE QUICK CONNECT FITTING REMOVAL STANDARD PROCEDURE - QUICK-CONNECT (1) Loosen fuel filler tube cap. FITTINGS (2) Remove fuel filler neck screws (Fig. 61). (3) Raise vehicle on hoist. REMOVAL (4) Remove right rear tire. When disconnecting a quick-connect fitting, the (5) Remove inner splash shields.
Page 796 FUEL DELIVERY 14 - 23 QUICK CONNECT FITTING (Continued) WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRES- SURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE...
Page 797 14 - 24 FUEL DELIVERY QUICK CONNECT FITTING (Continued) PLASTIC RETAINER RING TYPE FITTING (3) Clean fitting of any foreign material before dis- assembly. This type of fitting can be identified by the use of a (4) To release fuel system component from quick- full-round plastic retainer ring (Fig.
Page 798 FUEL INJECTION 14 - 25 FUEL INJECTION TABLE OF CONTENTS page page FUEL INJECTION INLET AIR TEMPERATURE SENSOR OPERATION DESCRIPTION ......35 OPERATION - INJECTION SYSTEM .
Page 799 14 - 26 FUEL INJECTION FUEL INJECTION (Continued) The PCM adjusts injector pulse width by opening The multi-port fuel injection systems has the fol- and closing the ground path to the injector. Engine lowing modes of operation: • Ignition switch ON (Zero RPM) RPM (speed) and manifold absolute pressure (air •...
Page 800 FUEL INJECTION 14 - 27 FUEL INJECTION (Continued) • After determining crankshaft position, the PCM The PCM adjusts injector pulse width and controls begins energizing the injectors in sequence. It adjusts injector synchronization by turning the individual injector pulse width and controls injector synchroni- ground paths to the injectors On and Off.
Page 801 14 - 28 FUEL INJECTION FUEL INJECTION (Continued) • Battery voltage OPERATION • Inlet/Intake air temperature • Engine coolant temperature Short Term • Crankshaft position (engine speed) The first fuel correction program that begins func- • Exhaust gas oxygen content (upstream heated tioning is the short term fuel correction.
Page 802 FUEL INJECTION 14 - 29 FUEL INJECTION (Continued) Long term adaptive memory can change the pulse- that would drive long term to 33% and short term to width by as much as 33%, which means it can correct another 33% for a total change of 66% away from for all of short term.
Page 803 14 - 30 FUEL INJECTION FUEL INJECTION (Continued) SPECIAL TOOLS FUEL O2S (OXYGEN SENSOR) REMOVAL/INSTALLER- C4907 Test Kit, Fuel Oxygen sensor tool ACCELERATOR PEDAL DESCRIPTION CAUTION: When servicing the accelerator pedal, do Adapters, Fuel Pressure Test—6539 and/or 6631 not damage or kink the core wire inside the cable sheathing.
Page 804 FUEL INJECTION 14 - 31 CRANKSHAFT POSITION SENSOR DESCRIPTION The crankshaft position sensor is located in the passengers side of the engine block, below the exhaust manifold at the rear of the engine (Fig. 1). OPERATION There are 5 sets of slots on flywheel ring gear. Each set contains 2 slots, for a total of 10 slots.
Page 805 14 - 32 FUEL INJECTION FUEL INJECTORS (Continued) OPERATION The injector contains a pintle that closes off an ori- fice at the nozzle end. When electric current is sup- plied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice.
Page 806 FUEL INJECTION 14 - 33 FUEL INJECTORS (Continued) (7) Disconnect the electrical connector from the (9) Remove the bolts for the fuel rail (Fig. 9). fuel injectors (Fig. 7). Fig. 9 FUEL RAIL Fig. 7 FUEL INJECTOR CONNECTOR (10) Pull fuel rail and injectors straight up and out (8) Disconnect the fuel line quick connector (Fig.
Page 807 14 - 34 FUEL INJECTION FUEL INJECTORS (Continued) (12) Remove the fuel injector from the fuel rail FUEL PUMP RELAY (Fig. 11). DESCRIPTION The relay is located in the PDC. Check electrical terminals for corrosion and repair as necessary. OPERATION The fuel pump relay supplies battery voltage to the fuel pump.
Page 808 FUEL INJECTION 14 - 35 IDLE AIR CONTROL MOTOR (Continued) OPERATION (3) Remove sensor from inlet hose. The motor controls air flow through a passage con- nected to both intake manifold plenums. The PCM operates the idle air control motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load or ambient conditions.
Page 809 14 - 36 FUEL INJECTION metric goes down. The first thing that happens as MAP SENSOR the key is rolled on, before reaching the crank posi- tion, the PCM powers up, comes around and looks at DESCRIPTION the MAP voltage, and based upon the voltage it sees, The MAP sensor (Fig.
Page 810 FUEL INJECTION 14 - 37 MAP SENSOR (Continued) altitude. You should make a habit of knowing what OPERATION the average pressure and corresponding barometric A single sensor ground is used for all O2 sensors (4 pressure is for your area. Always use the Diagnostic sensors, 2 upstream and 2 downstream of the catay- Test Procedures Manual for MAP sensor testing.
Page 811 14 - 38 FUEL INJECTION O2 SENSOR (Continued) UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depend- ing upon the oxygen content of the exhaust gas in the exhaust manifold.
Page 812 FUEL INJECTION 14 - 39 (4) Disconnect the TPS electrical connector (Fig. THROTTLE BODY 19). DESCRIPTION The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors.
Page 813 14 - 40 FUEL INJECTION THROTTLE BODY (Continued) Fig. 21 WIRING CLIP Fig. 22 THROTTLE CABLE AT THROTTLE BODY INSTALLATION (1) Mount throttle body (Fig. 20) and wiring clips (Fig. 21), tighten bolts to 12 N.m (105 in. lbs.). (2) Connect electrical connector to throttle position sensor (Fig.
Page 814 FUEL INJECTION 14 - 41 THROTTLE CABLE (Continued) Fig. 25 TPS & IDLE AIR CONTROL Fig. 24 THROTTLE CABLE ROUTING 1 - Throttle Position Sensor INSTALLATION 2 - Idle Air Control Motor 3 - Fuel Rail (1) Insert cable assembly through opening in dash 4 - Connector Fuel Line for Fuel Rails panel (Fig.
Page 815 14 - 42 FUEL INJECTION THROTTLE POSITION SENSOR (Continued) INSTALLATION The TPS is attached to the throttle body (Fig. 25). The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 26). When indexed cor- rectly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body.
Page 816 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page STEERING SPECIFICATIONS WARNINGS AND CAUTIONS ....1 POWER STEERING FASTENER TORQUE . . . 8 DIAGNOSIS AND TESTING SPECIAL TOOLS DIAGNOSIS AND TESTING - HYDRAULIC POWER STEERING...
Page 817 19 - 2 STEERING STEERING (Continued) Fig. 1 Analyzer Setup To Test At Pump Fig. 2 Analyzer Setup To Test At Gear 1 - HOSE 6959 1 - HOSE 6905 2 - ADAPTER FITTING 9091-3 2 - HOSE 6713 3 - FLOW METER AND GAUGE 6800 3 - FLOW METER AND GAUGE 6800 4 - HOSE 6713 4 - ADAPTER FITTING 9091-4...
Page 818 STEERING 19 - 3 STEERING (Continued) PUMP OUTLET SPECIFICATIONS DIAGNOSIS AND TESTING - STEERING SYSTEM DIAGNOSIS CHARTS FLOW RATE RELIEF ENGINE (GPM) @ 1100 NOTE: There are three diagnosis charts following PRESSURE that cover POWER STEERING NOISE, STEERING WHEEL FEEL, and POWER STEERING FLUID. 9653 kPa ±...
Page 819 19 - 4 STEERING STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION CHIRP OR SQUEAL 1. Loose power steering pump drive 1. Check and replace automatic belt (POWER STEERING belt. tensioner as necessary. Replace belt if PUMP) worn or glazed. WHINE OR GROWL 1.
Page 820 STEERING 19 - 5 STEERING (Continued) STEERING WHEEL FEEL CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL/ 1. Steering column bearings. 1. Replace steering column. COLUMN CLICKING, CLUNKING OR RATTLING. STEERING WHEEL HAS 1. Steering wheel retaining bolt not 1. Tighten the steering wheel retaining bolt FORE AND AFT properly tightened and torqued.
Page 821 19 - 6 STEERING STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 9. Binding upper or lower control arm 9. Replace the ball joint or control arm as ball joint. necessary. 10. Excessive friction in power 10. Replace power steering gear. steering gear. STIFF, HARD TO TURN, 1.
Page 822 STEERING 19 - 7 STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING 1. Air in the fluid of the power 1. Bleed air from system following the WHEEL KICKBACK OR steering system. power steering pump initial operation TOO MUCH STEERING service procedure.* WHEEL FREE PLAY.
Page 823 19 - 8 STEERING STEERING (Continued) POWER STEERING FLUID CONDITION POSSIBLE CAUSES CORRECTION LOW FLUID LEVEL WITH 1. Loose power steering hose tube 1. Tighten the tube nut to its specified VISIBLE LEAK. nut. torque. 2. Damaged or missing fitting seal, 2.
Page 824 STEERING 19 - 9 STEERING (Continued) SPECIAL TOOLS POWER STEERING Adapters, Power Steering 9091 Analyzer, Power Steering 6815 Remover, Ball Joint C-4150A Adapters, Power Steering 6893 Hose, Power Steering Analyzer 6959 Disconnect, Cooler Line 8875...
Page 825 19 - 10 COLUMN COLUMN TABLE OF CONTENTS page page COLUMN REMOVAL ......17 WARNINGS AND CAUTIONS .
Page 826 COLUMN 19 - 11 COLUMN (Continued) REMOVAL CAUTION: When installing a wheel puller on the steering wheel, be sure the puller bolts are fully seated in the threaded holes on the steering wheel. NOTE: Before proceeding, review Warnings and If the bolts are not fully seated in the threaded Cautions.
Page 827 19 - 12 COLUMN COLUMN (Continued) Fig. 2 Steering Column And Components 1 - STEERING WHEEL 5 - INTERMEDIATE SHAFT EXTENSION 2 - CLOCKSPRING 6 - BEARING 3 - STEERING COLUMN 7 - INTERMEDIATE SHAFT 4 - UPPER SHROUD 8 - LOWER SHROUD Fig.
Page 828 COLUMN 19 - 13 COLUMN (Continued) 7). Pull switch straight away from column to remove it. (d) Disconnect wiring connector and remove halo lamp from the column by unclipping it from igni- tion cylinder housing. (e) If necessary, remove ignition switch from steering column by first removing mounting screw (Fig.
Page 829 19 - 14 COLUMN COLUMN (Continued) (2) Install steering column into opening in lower (14) Install steering wheel retaining bolt and instrument panel. tighten it until wheel is fully installed on shaft. (3) Align slots in mounting brackets on steering Tighten steering wheel retaining bolt to 54 N·m (40 column with studs in instrument panel.
Page 830 COLUMN 19 - 15 COLUMN (Continued) (23) Verify tilt mechanism operates properly. (2) Place key cylinder in RUN position. Through (24) Road test vehicle to ensure proper operation the hole in the lower shroud, depress lock cylinder of steering. retaining tab and remove key cylinder (Fig. 10). SPECIFICATIONS STEERING COLUMN FASTENER TORQUE DESCRIPTION...
Page 831 19 - 16 COLUMN IGNITION SWITCH (Continued) Fig. 12 Multi-Function Switch Fig. 14 Removing Ignition Switch (3) Install electrical connectors to ignition switch. (4) Install the multi-function switch and tighten the 2 screws (Fig. 12). (5) Install upper and lower shrouds. (6) Install key cylinder (cylinder retaining tab will depress only in the RUN position).
Page 832 COLUMN 19 - 17 START BUTTON REMOVAL (1) Remove the center bezel (Fig. 16) (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL). Fig. 18 START BUTTON REMOVED INTERMEDIATE SHAFT DIAGNOSIS AND TESTING - STEERING COLUMN INTERMEDIATE SHAFT The steering column intermediate shaft and its Fig.
Page 833 19 - 18 COLUMN INTERMEDIATE SHAFT (Continued) (2) Secure steering wheel in STRAIGHT-AHEAD (6) Install air cleaner housing. (Refer to 9 - position using a steering wheel holder. ENGINE/AIR INTAKE SYSTEM/AIR CLEANER (3) Remove air cleaner housing. (Refer to 9 - HOUSING - INSTALLATION) ENGINE/AIR INTAKE...
Page 834 COLUMN 19 - 19 INTERMEDIATE SHAFT - EXTENSION (Continued) Fig. 21 Airbag Mounting To Steering Wheel 1 - DRIVER AIRBAG 2 - HORN WIRING CONNECTION 3 - LEFT WIRING CLIP Fig. 20 Steering Column Intermediate Shaft 4 - RIGHT WIRING CLIP Extension 5 - STEERING WHEEL 6 - SQUIB WIRING CONNECTION...
Page 835 19 - 20 COLUMN STEERING WHEEL (Continued) Fig. 22 Steering Column And Components 1 - STEERING WHEEL 5 - INTERMEDIATE SHAFT EXTENSION 2 - CLOCKSPRING 6 - BEARING 3 - STEERING COLUMN 7 - INTERMEDIATE SHAFT 4 - UPPER SHROUD 8 - LOWER SHROUD from steering column shaft using puller.
Page 836 COLUMN 19 - 21 STEERING WHEEL (Continued) go on for six to eight seconds, then go out. This will indicate that airbag system is functioning nor- mally. If airbag indicator lamp fails to light, blinks on and off, or goes on and stays on, there is an air- bag system malfunction.
Page 837 19 - 22 GEAR GEAR TABLE OF CONTENTS page page GEAR TIE ROD - OUTER REMOVAL ......22 REMOVAL .
Page 838 GEAR 19 - 23 GEAR (Continued) Fig. 2 Power Steering Gear Mounting 1 - MOUNTING BOLT 5 - INSULATOR 2 - WASHER 6 - SHIM 3 - INSULATOR 7 - STEERING GEAR 4 - O-RING (a) Remove nut from outer tie rod (Fig. 3). maximum of 11 mm (0.43 in.
Page 839 19 - 24 GEAR GEAR (Continued) wheel mounting nuts in proper sequence to 122 N·m (90 ft. lbs.) torque. (8) Lower vehicle. (9) Install power steering pressure hose and return hose in steering gear fluid ports. Tighten hose tube nuts to 28 N·m (21 ft. lbs.) torque. (10) Align intermediate shaft with steering gear shaft.
Page 840 GEAR 19 - 25 TIE ROD - OUTER (Continued) Fig. 5 Tie Rod Jam Nut (Typical) 1 - INNER TIE ROD 2 - JAM NUT 3 - OUTER TIE ROD (5) Release outer tie rod from knuckle using Puller, Special Tool C-4150A (Fig. 4). Remove tool. (6) Remove outer tie rod by unthreading it from inner tie rod.
Page 841 19 - 26 PUMP PUMP TABLE OF CONTENTS page page PUMP INSTALLATION ......30 STANDARD PROCEDURE - POWER HOSE - PRESSURE - FAN TO GEAR STEERING PUMP INITIAL OPERATION .
Page 842 PUMP 19 - 27 PUMP (Continued) • Smooth power assist • Noiseless operation • Proper fluid level • No system leaks • Proper fluid condition (18) Stop the engine. If all the proper conditions exist, the procedure is complete. REMOVAL NOTE: Review all Warnings and Cautions.
Page 843 19 - 28 PUMP PUMP (Continued) (3) Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts.
Page 844 PUMP 19 - 29 FLUID (Continued) CAUTION: Do not use automatic transmission fluid (Refer to 19 - STEERING/PUMP - STANDARD PRO- in this power steering system. CEDURE). (9) Start the engine and allow it to run for fifteen The fluid level should be within the “COLD minutes, then stop the engine.
Page 845 19 - 30 PUMP FLUID COOLER (Continued) CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar Power Steering Fluid or equivalent. (7) Fill power steering pump reservoir to correct fluid level. (Refer to 19 - STEERING/PUMP/FLUID - STANDARD PROCEDURE) (8) Perform Power Steering Pump Initial Opera- tion procedure.
Page 846 PUMP 19 - 31 HOSE - PRESSURE - PUMP TO FAN (Continued) Fig. 7 Power Steering Hoses 1 - PRESSURE HOSE - PUMP TO FAN 9 - RETURN HOSE - FAN TO PUMP 2 - PRESSURE HOSE - FAN TO GEAR 10 - QUICK-CONNECT FITTING 3 - POWER STEERING PUMP 11 - POWER STEERING GEAR...
Page 847 19 - 32 PUMP HOSE - PRESSURE - FAN TO GEAR (Continued) CAUTION: Cap all open ends of power steering (8) Check for leaks at all hose connections. hoses, power steering pump fittings and steering gear ports when disconnected. This will prevent the HOSE - RETURN - FAN TO entry of foreign material into the components dur- PUMP...
Page 848 PUMP 19 - 33 HOSE - RETURN - FAN TO PUMP (Continued) (7) Fill power steering pump reservoir to correct CAUTION: Cap all open ends of power steering fluid level. (Refer to 19 - STEERING/PUMP/FLUID - hoses, power steering pump fittings and steering STANDARD PROCEDURE) gear ports when disconnected.
Page 849 19 - 34 PUMP HOSE - RETURN - GEAR TO COOLER (Continued) (6) Reposition radiator upward. It will move about (9) Fill power steering pump reservoir to correct 1/4 inch. fluid level. (Refer to 19 - STEERING/PUMP/FLUID - (7) Raise vehicle. (Refer to LUBRICATION & STANDARD PROCEDURE) MAINTENANCE/HOISTING - STANDARD PROCE- (10) Perform Power Steering Pump Initial Opera-...
Page 850 PUMP 19 - 35 HOSE - RETURN - COOLER TO PUMP (Continued) (5) Remove clamp, then return hose at reservoir CAUTION: Do not use automatic transmission fluid (Fig. 7). in power steering system. Use only Mopar Power (6) Remove two radiator mounting screws (Fig. 8). Steering Fluid or equivalent.
Page 851 19 - 36 PUMP RESERVOIR (Continued) (3) Install reservoir onto housing. (6) Fill power steering pump reservoir to correct (4) Slide and tap in NEW reservoir retainer clips fluid level. (Refer to 19 - STEERING/PUMP/FLUID - making sure each tab locks into place on housing. STANDARD PROCEDURE) (5) Install power steering pump on vehicle.
Page 852 TRANSMISSION/TRANSAXLE 21 - 1 TRANSMISSION/TRANSAXLE TABLE OF CONTENTS page MANUAL TRANSMISSION - T56 ....1 MANUAL TRANSMISSION - T56 TABLE OF CONTENTS page page MANUAL TRANSMISSION - T56 EXTENSION HOUSING SEAL DESCRIPTION .
Page 853 21 - 2 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) 1ST GEAR The 1-2 synchronizer sleeve shifts rearward to engage with the clutch teeth on the first speed gear (Fig. 3). In this condition, the power from the input gear is transmitted through the cluster gear to the first speed gear.
Page 854 MANUAL TRANSMISSION - T56 21 - 3 MANUAL TRANSMISSION - T56 (Continued) REVERSE DIAGNOSIS AND TESTING - MANUAL The reverse gear synchronizer moves rearward to TRANSMISSION engage with the reverse speed gear (Fig. 3). Input power from the input gear travels through the clus- LOW LUBRICANT LEVEL ter gear to the cluster gear extension.
Page 855 21 - 4 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) A leak at the front of the transmission will be from (3) Remove drain plug located on the right side of either the front bearing retainer or retainer seal. the transmission tail housing.
Page 856 MANUAL TRANSMISSION - T56 21 - 5 MANUAL TRANSMISSION - T56 (Continued) (10) Disconnect reverse lamp switch and skip shift solenoid main connector at left side frame rail. Dis- connect reverse lamp switch connector on the right side of the transmission. (11) Remove upper transmission to bell housing bolts.
Page 857 21 - 6 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (5) Remove six tail housing bolts (Fig. 8). (7) Remove mainshaft roller bearing snap ring, roller bearing and spacers (Fig. 10). Fig. 8 TAIL HOUSING BOLT 1 - TAIL HOUSING 2 - BOLTS Fig.
Page 858 MANUAL TRANSMISSION - T56 21 - 7 MANUAL TRANSMISSION - T56 (Continued) (9) Remove reverse gear, bearing, wave washer (11) Remove reverse shift fork snap ring (Fig. 14) and brass reverse blocker ring from mainshaft (Fig. and discard snap ring. 12).
Page 859 21 - 8 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (13) Remove shift fork and synchronizer sleeve as (15) Remove reverse gear from countershaft with an assembly (Fig. 16). three jaw puller (Fig. 18). Fig. 16 REVERSE SHIFT FORK AND Fig.
Page 860 MANUAL TRANSMISSION - T56 21 - 9 MANUAL TRANSMISSION - T56 (Continued) (17) Remove fifth gear thrust washer from coun- (19) Remove 5-6 gear from mainshaft with Puller tershaft (Fig. 20). 9379, Bolts 9378 and Bridge 9382 (Fig. 22). Fig. 20 FIFTH GEAR THRUST WASHER Fig.
Page 861 21 - 10 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (21) Remove 5-6 synchronizer snap ring and syn- (23) Remove sixth gear, bearing and thrust washer chronizer hub (Fig. 24) from countershaft. from countershaft (Fig. 26). Fig. 24 5-6 SYNCHRONIZER Fig.
Page 862 MANUAL TRANSMISSION - T56 21 - 11 MANUAL TRANSMISSION - T56 (Continued) (25) Remove shift detent assembly (Fig. 28). Check (29) Remove two torx screws located on the top of O-ring, replace if required. the transmission case (Fig. 30). Fig. 28 SHIFT DETENT ASSEMBLY Fig.
Page 863 21 - 12 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (34) Remove remaining adapter bolt and pry trans- (35) Remove reverse rail assembly (Fig. 33). mission case upward. Remove offset lever from shift rail and case from adapter plate (Fig. 32). Fig.
Page 864 MANUAL TRANSMISSION - T56 21 - 13 MANUAL TRANSMISSION - T56 (Continued) (36) Tilt countershaft sideways and lift mainshaft (37) Remove countershaft assembly (Fig. 35). and shift rail assemblies out of adapter plate (Fig. 34). Fig. 35 COUNTERSHAFT 1 - COUNTERSHAFT Fig.
Page 865 21 - 14 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (38) Remove input shaft from adapter (Fig. 36). Fig. 37 MAINSHAFT O-RING 1 - BEARING 2 - MAIN SHAFT 3 - O-RING 4 - FIRST GEAR Fig. 36 INPUT SHAFT 1 - BEARING 2 - INPUT SHAFT 3 - ADAPTER...
Page 866 MANUAL TRANSMISSION - T56 21 - 15 MANUAL TRANSMISSION - T56 (Continued) (3) Remove first gear and bearing from mainshaft (Fig. 39). Fig. 41 1-2 THRUST WASHER & BLOCKER RING 1 - THRUST WASHER/BLOCKER RING 2 - SYNCHRONIZER Fig. 39 FIRST GEAR 3 - SECOND GEAR 1 - FIRST GEAR 2 - BEARING...
Page 867 21 - 16 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (7) Remove 3-4 synchronizer snap ring (Fig. 43). (9) Remove third gear bearing and spacer from mainshaft (Fig. 45). Fig. 43 3-4 SYNCHRONIZER SNAP RING Fig. 45 THIRD GEAR BEARING 1 - SYNCHRONIZER 2 - SNAP RING 1 - SPACER...
Page 868 MANUAL TRANSMISSION - T56 21 - 17 MANUAL TRANSMISSION - T56 (Continued) COUNTERSHAFT INPUT SHAFT (1) Remove countershaft adapter plate bearing (1) Remove input shaft bearing with Splitter 9384 with Splitter 9388 and Press Adapter 9377 (Fig. 47). and a press (Fig. 49). Fig.
Page 869 21 - 18 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) EXTENSION HOUSING (3) Remove gear shaft. (4) Remove mainshaft bearing race snap ring (Fig. (1) Remove idler gear bracket bolts (Fig. 51) and 53). bracket. Fig. 53 MAINSHAFT RACE SNAP RING 1 - RACE 2 - SNAP RING Fig.
Page 870 MANUAL TRANSMISSION - T56 21 - 19 MANUAL TRANSMISSION - T56 (Continued) (6) Remove countershaft bearing plastic bearing cage and remove roller bearings (Fig. 55). Fig. 57 SHIFT RAIL BUSHING 1 - REMOVER 2 - SLIDE HAMMER Fig. 55 COUNTERSHAFT BEARING CAGE 1 - RACE TRANSMISSION CASE 2 - CAGE...
Page 871 21 - 20 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) CLEANING Clean the gears, bearings shafts, extension/adapter housing and gear case with solvent. Dry all parts except the bearings with compressed air. Allow the bearings to either air dry or wipe them dry with clean shop towels.
Page 872 MANUAL TRANSMISSION - T56 21 - 21 MANUAL TRANSMISSION - T56 (Continued) (2) Install input shaft seal with Installer 9366. TRANSMISSION CASE (3) Install countershaft and mainshaft select shims (1) Install shift rail bushings with Installer 9368 (Fig. 62) and bearing cups (Fig. 63). and Handle C-4171.
Page 873 21 - 22 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) EXTENSION HOUSING (3) Install mainshaft roller bearing race snap ring. (4) Install shift rail bushings with Installer 9368 (1) Install countershaft bearing with Installer 9394 and Handle C-4171. and Handle C-4171 (Fig.
Page 874 MANUAL TRANSMISSION - T56 21 - 23 MANUAL TRANSMISSION - T56 (Continued) Fig. 71 INPUT SHAFT BEARING 1 - TUBE 2 - INSTALLER Fig. 69 IDLER GEAR BRACKET BOLTS 3 - BEARING 1 - TAIL HOUSING 2 - BRACKET BOLTS Fig.
Page 875 21 - 24 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) MAINSHAFT (3) Press third gear and 3-4 synchronizer hub (Fig. 75) onto the mainshaft with Splitter 9375. CAUTION: Mainshaft snap rings are not inter- changeable. (1) Install mainshaft tapered bearing with...
Page 876 MANUAL TRANSMISSION - T56 21 - 25 MANUAL TRANSMISSION - T56 (Continued) (6) Press second gear and synchronizer hub onto (8) Install original or new 1-2 snap ring on main main shaft with Splitter 9375 (Fig. 77). shaft (Fig. 79). Fig.
Page 877 21 - 26 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (10) Install rear main shaft tapered bearing (Fig. (3) Install countershaft assembly into adapter (Fig. 81). 83). Fig. 81 MAINSHAFT BEARING 1 - BEARING 2 - FIRST GEAR TRANSMISSION HOUSING NOTE: During assembly refer to Adjustments for Mainshaft and Countershaft End Play...
Page 878 MANUAL TRANSMISSION - T56 21 - 27 MANUAL TRANSMISSION - T56 (Continued) (4) Tilt countershaft sideways then install main- (5) Install reverse rail assembly (Fig. 85). shaft and shift rail assemblies into adapter (Fig. 84). Fig. 85 REVERSE SHAFT RAIL ASSEMBLY Fig.
Page 879 21 - 28 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (8) Install transmission case on gear set untill (10) Install two torx screws on top of transmission shift rail through the guide plate. Then install offset case (Fig. 88). lever sping, ball and lever on shift rail and seat transmission case on adapter (Fig.
Page 880 MANUAL TRANSMISSION - T56 21 - 29 MANUAL TRANSMISSION - T56 (Continued) (12) Apply Loctite 242 to shift detente threads. (17) Install sixth gear stop ring (Fig. 92). Install shift detente assembly with new O-ring and tighten to 34 N·m (25 ft. lbs.) (Fig. 90). Fig.
Page 881 21 - 30 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (20) Install 5-6 shift fork and synchronizer sleeve (Fig. 94). Fig. 94 5-6 SYNCHRONIZER SLEEVE 1 - SHIFT FORK 2 - SYNCHRONIZER SLEEVE (21) Install new 5-6 gear shift fork snap ring (Fig. 95).
Page 882 MANUAL TRANSMISSION - T56 21 - 31 MANUAL TRANSMISSION - T56 (Continued) (25) Install fifth gear thrust washer (Fig. 98). (27) Install reverse shift fork and synchronizer sleeve onto main shaft (Fig. 100). Fig. 98 FIFTH GEAR THRUST WASHER Fig. 100 REVERSE SHIFT FORK AND 1 - FIFTH GEAR SYNCHRONIZER 2 - THRUST WASHER...
Page 883 21 - 32 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (29) Install reverse gear snap ring on countershaft. (32) Install reverse gear, bearing, wave washer (30) Install reverse synchronizer snap ring (Fig. and brass synchronizer ring (Fig. 104). 102).
Page 884 MANUAL TRANSMISSION - T56 21 - 33 MANUAL TRANSMISSION - T56 (Continued) (34) Install main shaft roller bearing, spacers and (37) Install two tail housing nuts on top of trans- snap ring (Fig. 106). mission tail housing (Fig. 108). Fig. 108 TAIL HOUSING NUT 1 - VENT 2 - TAIL HOUSING NUTS Fig.
Page 885 21 - 34 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) (39) Install offset lever roll pin (Fig. 110). Fig. 111 TRANSMISSION BOLTS 1 - TRANS TO TOP OF ENGINE Fig. 110 ROLL PIN 2 - 7/16 BOLTS 1 - HAMMER 3 - TRANS TO OIL PAN 2 - PIN PUNCH 3 - OFFSET LEVER...
Page 886 MANUAL TRANSMISSION - T56 21 - 35 MANUAL TRANSMISSION - T56 (Continued) (3) Install case and bolt together using all bolts. COUNTERSHAFT BEARINGS PRELOAD (4) Rotate input shaft and mainshaft to seat bear- (1) Install countershaft with original shim into ings.
Page 887 21 - 36 MANUAL TRANSMISSION - T56 MANUAL TRANSMISSION - T56 (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Adapter Bolts Back-up Lamp Switch Dust Shield Bolts Clutch Release Bearing Drain Plug Fill Plug Flywheel Bolts Guide Plate Bolts Inspection Plug Interlock Bolt *Reverse Idler Brkt.
Page 888 MANUAL TRANSMISSION - T56 21 - 37 EXTENSION HOUSING SEAL (Continued) Fig. 115 SEAL REMOVAL 1 - REMOVER 2 - SEAL CAUTION: Replace drive shaft joint straps when- Fig. 116 ADAPTER BOLTS ever they are removed. The straps slightly deform when torqued in place.
Page 889 21 - 38 MANUAL TRANSMISSION - T56 INPUT SHAFT (Continued) (9) Lift cluster shaft slightly and remove input shaft from transmission (Fig. 118). Fig. 118 INPUT SHAFT Fig. 120 INPUT SHAFT BEARING 1 - TRANSMISSION CASE 1 - Installer 6052 and MB-991317 2 - INPUT SHAFT 2 - Bearing (10) Remove input shaft bearing (Fig.
Page 890 MANUAL TRANSMISSION - T56 21 - 39 INSTALLATION SHIFT MECHANISM (1) Clean sealing surfaces of transmission. Then REMOVAL apply a bead of Mopar Gasket Maker. (2) Install shifter onto transmission. Make sure that the ball on the bottom of the shifter is in the off- NOTE: The gear shift lever bolts directly to the set lever.
Page 892 TIRES/WHEELS 22 - 1 TIRES/WHEELS TABLE OF CONTENTS page page TIRES/WHEELS TIRES DIAGNOSIS AND TESTING - TIRE AND DESCRIPTION - TIRES ....12 WHEEL RUNOUT .
Page 893 22 - 2 TIRES/WHEELS TIRES/WHEELS (Continued) Fig. 1 Wheel Nut Tightening Sequence Fig. 3 Marking Tire, Wheel And Stud 1 - TIRE AND WHEEL ASSEMBLY 2 - TYPICAL LOCATION MARKS Fig. 2 Runout Gauge Retighten wheel nuts until all are properly torqued.
Page 894 TIRES/WHEELS 22 - 3 TIRES/WHEELS (Continued) Fig. 6 Wheel Weight Locations Fig. 5 Checking Lateral Runout Of Wheel 1 - WHEEL 2 - CLIP-ON WHEEL WEIGHT (FRONT WHEELS ONLY) 1 - MOUNTING CONE 3 - INNER FACE OF WHEEL 2 - SPINDLE SHAFT 4 - STICK-ON WHEEL WEIGHT (INNER LOCATION) 3 - WING NUT 5 - STICK-ON WHEEL WEIGHT (OUTER LOCATION)
Page 895 22 - 4 TIRES/WHEELS TIRES/WHEELS (Continued) Fig. 7 Static Unbalance & Balance 1 - HEAVY SPOT 4 - CORRECTIVE WEIGHT LOCATION 2 - CENTER LINE OF SPINDLE 5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP 3 - ADD BALANCE WEIGHTS HERE Fig.
Page 896 TIRES/WHEELS 22 - 5 TIRES/WHEELS (Continued) (1) Measure the total indicator runout on the cen- ter of the tire tread rib. Record the indicator reading. Mark the tire to indicate the high spot. Place a mark on the tire at the valve stem location (Fig. 9). Fig.
Page 897 22 - 6 TIRES/WHEELS TIRES/WHEELS (Continued) REMOVAL - TIRE AND WHEEL ASSEMBLY TIRE PRESSURE MONITORING (1) Raise the vehicle. (Refer to LUBRICATION & (TPM) MAINTENANCE/HOISTING - STANDARD PROCE- DURE) DESCRIPTION (2) Remove the 6 wheel mounting nuts securing This vehicle has a tire pressure monitoring (TPM) the wheel to the hub.
Page 898 TIRES/WHEELS 22 - 7 TIRE PRESSURE MONITORING (TPM) (Continued) TIRE DIAGNOSTIC FAULT The tire pressure sensors/transmitters and TPM module are not repairable components. If either of Once the RUN/START cycle and initialization of these components are found to be at fault or dam- the TPM is complete, a tire diagnostic fault will be aged, the component must be replaced.
Page 899 22 - 8 TIRES/WHEELS MODULE - TPM (Continued) • Program Module (4 Sensors) OPERATION • Monitor The tire pressure monitoring (TPM) module has a (5) Place a magnet, special tool 8821, at the valve microprocessor controller that can monitor the trans- stem for that wheel as directed by the DRBIII.
Page 900 TIRES/WHEELS 22 - 9 MODULE - TPM (Continued) (6) Verify that the module has been programmed the original valve stem core must be reinstalled. If with the identification code of all four of the tire the valve stem core needs to be replaced, it must be pressure sensor/transmitters using the DRBIII scan replaced with an original equipment valve stem core.
Page 901 22 - 10 TIRES/WHEELS SENSOR - TPM (Continued) REMOVAL CAUTION: pressure transmitter must removed from the wheel and dropped into the tire (1) Remove the tire and wheel assembly from the prior to breaking the bead and dismounting the tire. vehicle.
Page 902 TIRES/WHEELS 22 - 11 SENSOR - TPM (Continued) (9) Pull upward on the tire (Fig. 17). Reach inside (2) Install the special sensor mounting nut. When the tire and remove the pressure sensor/transmitter. tightening the tire pressure sensor/transmitter nut, hold the sensor so it does not rotate. Once tightened, the gap between the sensor and the wheel must be even on both sides as shown (Fig.
Page 903 22 - 12 TIRES/WHEELS SENSOR - TPM (Continued) (9) Verify that the TPM module has been pro- TIRE IDENTIFICATION grammed with the identification code from the new tire pressure sensor/transmitter using the DRBIII TIRE TYPE (Not P - Passenger scan tool. If the identification code and tire pressure present on all tires) thresholds from the new tire pressure transmitter T - Temporary...
Page 904 TIRES/WHEELS 22 - 13 TIRES (Continued) DIAGNOSIS AND TESTING TIRE NOISE AND VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing a noise or vibration, drive the vehicle over a smooth road at varying speeds.
Page 905 22 - 14 TIRES/WHEELS TIRES (Continued) Rapid wear from the tire tread shoulders (Fig. 22) An incorrect wheel toe position will cause the tire is usually caused by under- inflation. If this type of tread surface to develop a feathered edge (Fig. 22). wear occurs and the tires are serviceable, inflate the One side of the tread will be rounded while the oppo- tires to their recommended cold inflation pressure.
Page 906 TIRES/WHEELS 22 - 15 TIRES (Continued) Vehicle Lead Correction Diagnosis Chart...
Page 907 22 - 16 TIRES/WHEELS TIRES (Continued) • The vehicle to drift. STANDARD PROCEDURE For proper tire pressure specification refer to the Tire Inflation Pressure Chart Placard provided with TIRE INFLATION PRESSURES the vehicle. Tire pressures have been chosen to provide safe WARNING: OVER OR UNDER INFLATED TIRES CAN operation, vehicle stability, and a smooth ride.
Page 908 TIRES/WHEELS 22 - 17 TIRES (Continued) Install the wheel and tire on the vehicle, and pro- gressively tighten all 6 wheel nuts to a torque of 122 N·m (90 ft. lbs.). Fig. 26 Safety Rim 1 - TIRE 2 - WELL 3 - SAFETY HUMPS 4 - FLANGE Initial inflation of the tire forces the bead over...
Page 909 22 - 18 TIRES/WHEELS WHEELS (Continued) Original equipment replacement wheels for this WHEEL MOUNTING STUDS - vehicle are available through your dealer and should FRONT always be used if a wheel requires replacement. If a replacement wheel is obtained through a source other REMOVAL than a dealer, the wheel must be equivalent in load carrying capacity.
Page 910 TIRES/WHEELS 22 - 19 WHEEL MOUNTING STUDS - FRONT (Continued) INSTALLATION WHEEL MOUNTING STUDS - (1) Install the replacement wheel mounting stud REAR through rear of hub/bearing flange. Install a stack of washers approximately 1/2 inch (13 mm) thick on the REMOVAL stud, then install a standard type wheel mounting nut with its flat side toward the washers (Fig.
Page 912 BODY 23 - 1 BODY TABLE OF CONTENTS page page BODY SPECIAL TOOLS WARNING BODY ......12 SAFETY PRECAUTIONS AND WARNINGS .
Page 913 23 - 2 BODY BODY (Continued) VISUAL INSPECTION BEFORE WATER LEAK TESTS MIRROR INSPECTION METHOD When a leak point area is visually obstructed, use Verify that floor and body plugs are in place, body a suitable mirror to gain visual access. A mirror can drains are clear, and body components are properly aligned and sealed.
Page 914 BODY 23 - 3 BODY (Continued) ROAD TESTING WIND NOISE Repair Procedure: (1) Drive the vehicle to verify the general location The repair procedure for all three categories of of the wind noise. plastics is basically the same. The one difference is (2) Apply 50 mm (2 in.) masking tape in 150 mm the material used for the repair.
Page 915 23 - 4 BODY BODY (Continued) RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION ACRYLONITRILE STYRENE LURANS CONSOLES, GRILLES ACRYLITE ACRYLONITRILE BUTADI- TERLURAN A PILLARS, CONSOLES, ENE STYRENE GRILLES ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAY- DOORS, INSTRUMENT PAN- BLEND ABS/PVC...
Page 916 BODY 23 - 5 BODY (Continued) CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION UNSATURATED POLYES- SMC, BMC, TMC, ZMC, IMC, GRILLE OPENING PANEL, TER (THERMOSETTING) XSMC, UP LIFTGATES, FLARESIDE FENDERS, FENDER EXTEN- SIONS EEBC ETHER/ESTER BLOCKED EEBC BUMPERS CO-POLYMER EEBC/PBTP EEBC/POLYBUTYLENE EEBC, PBTP, BEXLOY...
Page 917 23 - 6 BODY BODY (Continued) PANEL REINFORCEMENT PANEL SECTIONING Structural repair procedures for rigid panels with If it is required to section a large panel for a plas- large cracks and holes will require a reinforcement tic repair, it will be necessary to reinforce the panel backing.
Page 918 BODY 23 - 7 BODY (Continued) Fig. 4 BEVELING ANGLE - 20 DEGREE • Panel repair for both flexible and rigid panels are basically the same. The primary difference Fig. 6 DAMAGE COMPONENT between flexible panel repair and rigid panel repair 1 - PUNCTURE is in the adhesive materials used (Fig.
Page 919 23 - 8 BODY BODY (Continued) PANEL PATCH INSTALLATION (1) Make a paper or cardboard pattern the size and shape of the cutout hole in the panel. (2) Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting surfaces. (3) Using the pattern as a guide, cut the patch to size.
Page 920 BODY 23 - 9 BODY (Continued) (15) Install screws to hold the patch to support squares (Fig. 12). Tighten screws until patch surface is flush with panel surface. (16) Allow adhesive to cure, and remove all screws. (17) Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2 mm (0.080 in.) deep path across the gaps around the patch (Fig.
Page 921 23 - 10 BODY BODY (Continued) SPECIFICATIONS BODY PANELS AND MATERIALS Most body panels are made of plastic type materi- als. Different processes are used to create and shape the panels. Flexible panels are produced from the rim process. All panels are fastened with adhesive, rivets, bolts, and screws or a combination of these fasteners.
Page 922 BODY 23 - 11 BODY (Continued) (3) Insert key into lock cylinder and cycle the (5) Wipe all lubricant from exterior of lock cylinder mechanism from the locked to the unlocked position. and key. ALL OTHER BODY MECHANISMS NOTE: Do not add more lubricant. (1) Clean component as described above.
Page 923 23 - 12 BODY BODY (Continued) Description N·m Ft. Lbs. In. Lbs. Door window regulator nuts — Fender support fasteners — Fuel filler door screws — Hood hinge to body bolts — Hood hinge to hood bolts — Hood latch nuts —...
Page 924 CONVERTIBLE TOP 23 - 13 CONVERTIBLE TOP TABLE OF CONTENTS page page CONVERTIBLE TOP INSTALLATION ......18 DESCRIPTION .
Page 925 23 - 14 CONVERTIBLE TOP CONVERTIBLE TOP (Continued)
Page 926 CONVERTIBLE TOP 23 - 15 FOLDING TOP COVER (Continued) 1 = TOP COVER ASSEMBLY 2 = BACKLITE ASSEMBLY 3 = REAR/#4 BOW ASSEMBLY 4 = CENTER/#3 BOW ASSEMBLY 5 = HEADER ASSEMBLY 6 = SCREWS (14) 7 = CLOTH SUPPORT PANEL 8 = LATCH ASSEMBLY 9 = SEAL COMPRESSION PANEL 10 = SCREWS (11)
Page 927 23 - 16 CONVERTIBLE TOP FOLDING TOP COVER (Continued) (11) Tighten the tack strip nuts to 12 N·m (9 ft. lbs.). (12) Connect the rear window defroster electrical connectors. (13) Position the trim welt and staple into place. (14) Position the tension cable through the cover assembly and replace the rivets.
Page 928 CONVERTIBLE TOP 23 - 17 FOLDING TOP - ASSEMBLY (Continued) (13) Close and latch the convertible top and check for fit. REAR WINDOW REMOVAL (1) Roll down both door windows. (2) Unlatch the convertible top. (3) Remove the front and rear weatherstrip retain- ers.
Page 929 23 - 18 CONVERTIBLE TOP STAY PADS - STRAPS (Continued) (5) Drill out the tension cable rivets. (6) Pull tension cable through the cover assembly. (7) Remove the 11 screws and remove the seal compression panel. (8) Remove the staples from the cover assembly to the header assembly.
Page 930 CONVERTIBLE TOP 23 - 19 BOW - REAR/4 (Continued) (5) Staple the side panels into place. (2) Remove the cover assembly rivets to the rear of (6) Install the tack strips over the studs and the header assembly. install the nuts. (3) Remove the rivets attaching the stay pad (7) Tighten the tack strip nuts to 12 N·m (9 ft.
Page 931 23 - 20 CONVERTIBLE TOP TACK STRIP (Continued) TENSION CABLE REMOVAL (1) Remove the header support panel. (Refer to 23 - BODY/CONVERTIBLE TOP/HEADER SUPPORT PANEL - REMOVAL) (2) Remove the rivets (two per side) at the bottom of cover assembly to the linkage. (3) Remove the tension cable rivet.
Page 932 CONVERTIBLE TOP 23 - 21 TENSION CABLE (Continued) INSTALLATION HINGE - SIDEARM/LINKAGE (1) Position the cable through the top cover. ASSEMBLY (2) Install new upper anchor and guide rivets. (3) Position the lower anchor and install a new REMOVAL rivet. (1) Remove the bulkhead trim panel.
Page 933 23 - 22 CONVERTIBLE TOP HINGE - SIDEARM/LINKAGE ASSEMBLY (Continued) (5) Tighten the bolts to 12 N·m (9 ft. lbs.). (6) Position the tension cable through the cover assembly and replace the rivet. (7) Position the cover assembly side panel at the door opening and install new rivets attaching it to the sidearm/linkage.
Page 934 DECKLID 23 - 23 DECKLID TABLE OF CONTENTS page page GAS PROP LATCH STRIKER REMOVAL ......23 REMOVAL .
Page 935 23 - 24 DECKLID HINGE (Continued) Fig. 2 UPPER SUPPORT CYLINDER RETAINING Fig. 4 GAS PROP CLIP 1 - DECKLID HINGE ASSEMBLY 2 - GAS PROP 1 - RETAINING CLIP 2 - BALL SOCKET 3 - BALL STUD Fig. 3 LOWER GAS PROP Fig.
Page 936 DECKLID 23 - 25 INSTALLATION LATCH (1) Position latch to vehicle. REMOVAL (2) Loosely install bolts attaching latch to decklid. (3) Using previously made marks, align decklid (1) Remove the three screws and remove the key latch to outline on decklid. cylinder cable bracket.
Page 937 23 - 26 DECKLID LOCK CYLINDER SLAM BUMPER REMOVAL REMOVAL (1) Remove the three screws and position aside the (1) Release decklid latch and open decklid. lock cylinder cable bracket. (Fig. 6) (2) Rotate slam bumper counterclockwise and (2) Remove the nut and remove the lock cylinder. remove the slam bumper from the decklid.
Page 938 DOOR - FRONT 23 - 27 DOOR - FRONT TABLE OF CONTENTS page page DOOR INSTALLATION ......33 REMOVAL .
Page 939 23 - 28 DOOR - FRONT DOOR (Continued) (3) Loosen the hinge to hinge pillar fasteners. (Refer to 23 - BODY/DOOR - FRONT/HINGE - REMOVAL) (4) Adjust the door to the correct position. (Refer BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS) (5) Tighten the hinge pillar fasteners to 37 N·m (27 ft.
Page 940 DOOR - FRONT 23 - 29 DOOR (Continued) (7) Install the latch striker. (Refer to 23 - BODY/ DOOR - FRONT/LATCH STRIKER - INSTALLA- TION) (8) Install the door hinge cover and install the three screws to the fender. Fig. 4 DOOR GLASS 1 - DOOR GLASS ATTACHING SCREW 2 - REGULATOR ASSEMBLY 3 - DOOR GLASS...
Page 941 23 - 30 DOOR - FRONT DOOR GLASS (Continued) Fig. 5 FRONT DOOR GLASS ADJUSTMENT SPECIFICATIONS NOTE: Remove only one weatherstrip section at a (4) Using a 3 mm allen wrench, rotate the jack time or the glass to weatherstrip retainer measure- screw to achieve the proper gap between the door glass and the weatherstrip retainer (Fig.
Page 942 DOOR - FRONT 23 - 31 DOOR GLASS (Continued) (3) Remove the two bolts. (Fig. 10) (4) Depress the lever on the handle assembly and back out the shipping screw to secure the lever in the depressed position. (5) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL) (6) Disconnect the electrical connector.
Page 943 23 - 32 DOOR - FRONT OUTSIDE DOOR HANDLE (Continued) Fig. 10 DOOR HANDLE ASSEMBLY Fig. 11 DOOR HINGE COVER 1 - SHIPPING SCREW 1 - U-NUTS (3 PER SIDE) 2 - BOLTS 2 - U-NUTS (2 PER SIDE) 3 - HANDLE ASSEMBLY 3 - SCREW (1 PER SIDE) 4 - ELECTRICAL CONNECTOR 4 - FENDER GRILLE...
Page 944 DOOR - FRONT 23 - 33 HINGE (Continued) Fig. 14 DOOR LOCK CYLINDER ASSEMBLY 1 - WIRE CONNECTOR 2 - LATCH/LOCK CABLE 3 - DOOR ASSEMBLY Fig. 13 FRONT DOOR HINGE 4 - LOCK SET & LOCK CYLINDER BRACKET 1 - FRONT DOOR HINGE ASSEMBLY 2 - ACCESS PANEL 3 - FRONT DOOR 4 - FRONT DOOR WATERSHIELD...
Page 945 23 - 34 DOOR - FRONT LATCH (Continued) (4) Install the watershield. (5) Install the trim panel. (Refer to 23 - BODY/ DOOR - FRONT/TRIM PANEL - INSTALLATION) LATCH STRIKER REMOVAL (1) Open the door and using a grease pencil or equivalent, mark the position of the striker to aid installation.
Page 946 DOOR - FRONT 23 - 35 TRIM PANEL REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the speaker. (3) Remove the three trim panel screws in the speaker opening. (4) Using a trim stick C-4755 or equivalent, remove the trim plug at the interior release handle and remove the screw.
Page 947 23 - 36 DOOR - FRONT TRIM PANEL (Continued) (10) Install the two push pins at the rear of the trim panel and one at the front of the trim panel (Fig. 27). To install the push pin fastener, first push the center pin back through the push pin to the open position.
Page 948 DOOR - FRONT 23 - 37 TRIM PANEL (Continued) Fig. 28 PUSH PIN FASTENER 1 - OPEN POSITION 2 - LOCK POSITION 3 - RELEASE POSITION Fig. 26 DOOR TRIM PANEL 1 - DOOR ASSEMBLY WINDOW REGULATOR 2 - SPRING NUT 3 - DOOR TRIM PANEL 4 - TRIM PLUG SCREW CAP REMOVAL...
Page 949 23 - 38 DOOR - FRONT WINDOW REGULATOR (Continued) INSTALLATION INSTALLATION (1) Install the regulator and install the nuts. (1) Cut a hole for the side repeater lamp using the (2) Tighten the nuts to 12 N·m (9 ft. lbs.). supplied template.
Page 950 EXTERIOR 23 - 39 EXTERIOR TABLE OF CONTENTS page page BELLY PAN REAR WHEELHOUSE SPLASH SHIELD REMOVAL REMOVAL ......46 REMOVAL .
Page 951 23 - 40 EXTERIOR BELLY PAN (Continued) Fig. 2 BELLY PAN 1 - FRAME ASSEMBLY 3 - BELLY PAN 2 - BOLTS (20) 4 - REAR EXTENSION BELLY PAN Fig. 3 FRONT EXTENSION BELLY PAN 1 - FRAME ASSEMBLY 5 - FASCIA BOLTS (9) 2 - FRAME BOLTS (4) 6 - HEADLAMP MOUNT SUPPORT 3 - FRONT EXTENSION BELLY PAN...
Page 952 EXTERIOR 23 - 41 BELLY PAN (Continued) Fig. 4 REAR EXTENSION BELLY PAN 1 - LOWER REAR SPLASH SHIELD 4 - BOLTS (17) 2 - REAR FASCIA 5 - REAR EXTENSION BELLY PAN 3 - SPRING NUT REMOVAL - REAR EXTENSION BELLY PAN INSTALLATION - REAR EXTENSION BELLY PAN (1) Raise and support the vehicle.
Page 953 23 - 42 EXTERIOR COWL SCREEN PANEL (Continued) Fig. 7 FUEL FILLER DOOR 1 - FUEL FILLER CAP 2 - REAR QUARTER PANEL 3 - FUEL FILLER DOOR Fig. 5 WINDSHIELD WIPER ARMS 4 - FUEL FILLER DOOR BUMPER 1 - WINDSHIELD WIPER ARM & BLADE 2 - WIPER ARM NUT CAP INSTALLATION 3 - WIPER ARM NUT...
Page 954 EXTERIOR 23 - 43 FRONT WHEELHOUSE SPLASH SHIELD (Continued) INSTALLATION (1) Install the rear splash shield and loosely install the six screws. (2) Install the three push pin fasteners and tighten the screws. (3) Install the front splash shield and loosely install the screws.
Page 955 23 - 44 EXTERIOR REAR QUARTER PANEL (Continued) Fig. 10 REAR FASCIA TO REAR QUARTER PANEL 1 - FASCIA TO REAR QUARTER PANEL NUT 4 - REAR FASCIA 2 - REAR QUARTER PANEL RETAINER 5 - ROUND SPRING NUT 3 - BODY ASSEMBLY 6 - FASCIA RETAINER (6) Install the adjustment bracket screw.
Page 956 EXTERIOR 23 - 45 REAR QUARTER PANEL (Continued) Fig. 12 REAR QUARTER PANEL MOUNTING BRACKET 1 - REAR QUARTER PANEL MOUNTING BRACKET 4 - REAR QUARTER PANEL TO REAR CLIP BRACKET 2 - FRAME ASSEMBLY 5 - REAR CLIP 3 - REAR QUARTER PANEL Fig.
Page 957 23 - 46 EXTERIOR REAR WHEELHOUSE SPLASH SILL PANEL SHIELD REMOVAL (1) Remove the three screws and remove the door REMOVAL hinge cover. (Fig. 16) (1) Remove the rear wheel. (Refer to 22 - TIRES/ (2) Remove the screws attaching the fender grille WHEELS - REMOVAL) to the fender and the sill.
Page 958 EXTERIOR 23 - 47 SILL PANEL (Continued) INSTALLATION (1) Position the sill onto the vehicle. (2) Tighten the sill to fender support nuts. (3) Install the screws into the door surround panel. (4) Install the rear screw into the frame near the quarter panel.
Page 959 23 - 48 EXTERIOR SILL PANEL (Continued) Fig. 18 SILL PANEL 3 - FENDER ASSEMBLY 1 - FRAME ASSEMBLY 2 - SILL PANEL SILL PANEL - EXPORT REMOVAL (1) Remove the side repeater lamp (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/RE- PEATER LAMP - REMOVAL).
Page 960 EXTERIOR 23 - 49 SILL PANEL - EXPORT (Continued) Fig. 20 SILL PANEL BOLTS 1 - SILL PANEL 3 - FENDER GRILLE 2 - SPLASH SHIELD 4 - FRAME ASSEMBLY Fig. 21 SILL PANEL 3 - FENDER ASSEMBLY 1 - FRAME ASSEMBLY 2 - SILL PANEL (10) Install the side repeater lamp (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/RE-...
Page 961 23 - 50 EXTERIOR SIDE VIEW MIRROR REMOVAL (1) Open deck lid. (2) Remove four bolts to battery compartment cover and remove cover. (3) Disconnect and isolate the battery negative cable. (4) Remove the access panel at the front of door. (Fig.
Page 962 EXTERIOR 23 - 51 GLASS-OUTSIDE REARVIEW MIRROR (Continued) NOTE: Pressure must be applied equally over the center portion of the mirror to engage the mirror glass holder’s attaching fingers to the correspond- ing fingers on the housing assembly. One or more clicks may be heard when finger engagement takes place.
Page 963 23 - 52 EXTERIOR TRUNK PAN (Continued) Fig. 25 TRUNK PAN ASSEMBLY 4 - FRAME RAIL NUT/RIVET 1 - TRUNK PAN ASSEMBLY 2 - TAIL LAMP COVER PANEL (RIGHT/LEFT) 5 - FRAME ASSEMBLY 3 - SHOCK SERVICE PLUG FRONT FENDER REMOVAL Fender (1) Remove the sill panel.
Page 964 EXTERIOR 23 - 53 FRONT FENDER (Continued) Fig. 29 FENDER PANEL 1 - NUTS 2 - BOLTS (8) 3 - FENDER 4 - SCREWS 5 - WINDSHIELD SURROUND Fig. 27 DOOR HINGE COVER Fender Support (1) Remove the bolts attaching the support to the 1 - U-NUTS (3 PER SIDE) 2 - U-NUTS (2 PER SIDE) frame.
Page 965 23 - 54 EXTERIOR FRONT FENDER (Continued) Fig. 30 FENDER INNER SUPPORT ASSEMBLY 1 - FENDER INNER SUPPORT ASSEMBLY 4 - WINDSHIELD SURROUND COMPLETE FRAME 2 - SPRING NUT 5 - FRAME ASSEMBLY 3 - FRONT OF DASH PANEL (3) Using a heat gun, heat attachment area to at (3) Install the fender support and align with least 121°C (250°F) to soften adhesive attaching marks made previously.
Page 966 EXTERIOR 23 - 55 FRONT FENDER (Continued) Fig. 31 ADHESIVE LOCATIONS 1 - SEALER LOCATIONS - FRAME 3 - FRONT OF DASH PANEL 2 - SEALER LOCATIONS - FRAME/FRONT OF DASH PANEL 4 - FRAME FRONT FENDER - EXPORT REMOVAL Fender (1) Remove the sill panel (Refer to 23 - BODY/EX- TERIOR/ROCKER PANEL COVER - REMOVAL).
Page 967 23 - 56 EXTERIOR FRONT FENDER - EXPORT (Continued) Fig. 33 NEW FRONT FENDER 6 - FENDER 1 - RIVETS 2 - FENDER SUPPORT 7 - NUTS 3 - WINDSHIELD SURROUND 8 - U-NUTS 4 - BOLTS 9 - SILL/FENDER BRACKET 5 - SCREWS (4) Using a flat blade scraper, cut adhesive from between fender support and frame.
Page 968 EXTERIOR 23 - 57 FRONT FENDER - EXPORT (Continued) Fig. 35 FENDER INNER SUPPORT ASSEMBLY 1 - FENDER INNER SUPPORT ASSEMBLY 4 - WINDSHIELD SURROUND COMPLETE FRAME 2 - SPRING NUT 5 - FRAME ASSEMBLY 3 - FRONT OF DASH PANEL (3) Install the fender support and align with FRONT STRUT TOWER TO marks made previously.
Page 969 23 - 58 EXTERIOR FRONT STRUT TOWER TO TOWER BRACE (Continued) Fig. 36 ADHESIVE LOCATIONS 1 - SEALER LOCATIONS - FRAME 3 - FRONT OF DASH PANEL 2 - SEALER LOCATIONS - FRAME/FRONT OF DASH PANEL 4 - FRAME Fig. 38 Front Strut Tower to Tower Brace Fig.
Page 970 HOOD 23 - 59 HOOD TABLE OF CONTENTS page page ADJUSTMENT BUMPER INSTALLATION ......60 REMOVAL ......59 HOOD LATCH AND SAFETY CATCH INSTALLATION .
Page 971 23 - 60 HOOD HINGE (Continued) ADJUSTMENTS ADJUSTMENT (1) If hood is low in relation to the rear of fender, insert shims between hinge and body. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS) (2) Adjust hood bumper in or out to adjust hood- to-fender height alignment.
Page 972 HOOD 23 - 61 HOOD LATCH AND SAFETY CATCH (Continued) (3) Install and tighten the nuts to 12 N·m (9 ft. lbs.) (4) Check the hood fit and adjust if required. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS) LATCH RELEASE HANDLE REMOVAL (1) Remove the hood latch.
Page 973 23 - 62 HOOD INSTALLATION SILENCER PAD (1) Install the silencer pad and install the push REMOVAL pin fasteners. (2) Install the ground wires and install the bolts. (1) Open the hood and remove the bolts and dis- connect the ground wires. (Fig. 7) (2) Remove the push pin fasteners and remove the silencer pad.
Page 974 HOOD 23 - 63 GAS PROP REMOVAL (1) Open the hood and support. NOTE: The gas props have an integral secondary service position. This wider open position is achieved by physically pushing the front of the hood up lightly. (2) Using a small flat bladed tool, or equivalent, release the retaining clips while pulling the ball socket away from the ball stud.
Page 975 23 - 64 INSTRUMENT PANEL INSTRUMENT PANEL TABLE OF CONTENTS page page CLUSTER BEZEL INSTALLATION ......66 REMOVAL .
Page 976 INSTRUMENT PANEL 23 - 65 GLOVE BOX (Continued) (1) Disconnect the check straps to the door. (6) Remove the glove box. (Refer to 23 - BODY/IN- (2) Remove three screws retaining glove box STRUMENT PANEL/GLOVE BOX - REMOVAL) assembly and remove from panel. (7) Remove the glove box striker.
Page 977 23 - 66 INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL (Continued) (4) Wait two minutes for the airbag system reserve (1) Connect the adjustable pedal switch electrical capacitor to discharge before beginning any airbag connector. system or instrument panel component service. (2) Position the cover into place and seat the right (5) Remove the console bezel.
Page 978 INSTRUMENT PANEL 23 - 67 INSTRUMENT PANEL & PAD ASSEMBLY (Continued) Fig. 1 INSTRUMENT PANEL STEERING COLUMN COVER 1 - WINDSHIELD SURROUND FRAME 4 - INSTRUMENT PANEL CENTER BRACKET 2 - INSTRUMENT PANEL & PAD ASSEMBLY 5 - INSTRUMENT PANEL BRACKET 3 - INSTRUMENT PANEL STEERING COLUMN COVER Fig.
Page 979 23 - 68 INSTRUMENT PANEL INSTRUMENT PANEL & PAD ASSEMBLY (Continued) (13) Disconnect the brake lamp switch. (Fig. 3) (16) Remove ground wire nuts at left floor tunnel. (Fig. 5) Fig. 3 BRAKE LAMP SWITCH MOUNTING Fig. 5 TUNNEL GROUNDS 1 - ADJUSTABLE PEDALS ASSEMBLY 2 - SWITCH BRACKET 1 - NUTS...
Page 980 INSTRUMENT PANEL 23 - 69 INSTRUMENT PANEL & PAD ASSEMBLY (Continued) Fig. 7 INSTRUMENT PANEL FASTENERS Fig. 8 PASSENGER SIDE ELECTRICAL CONNECTORS 1 - LEFT BOLTS 2 - INSTRUMENT PANEL ASSEMBLY 1 - DOOR HARNESS ELECTRICAL CONNECTOR 3 - RIGHT BOLTS 2 - GROUND WIRES 3 - BOLT (20) Using a trim stick (special tool #C-4755) or...
Page 981 23 - 70 INSTRUMENT PANEL INSTRUMENT PANEL & PAD ASSEMBLY (Continued) Fig. 10 INSTRUMENT PANEL & PAD ASSEMBLY 1 - FRONT OF DASH PANEL 5 - INSTRUMENT PANEL STUD (10) 2 - INSTRUMENT PANEL DEFROSTER DUCT 6 - FLOOR AIR DUCT 3 - INSTRUMENT PANEL &...
Page 982 INSTRUMENT PANEL 23 - 71 INSTRUMENT PANEL & PAD ASSEMBLY (Continued) CAUTION: The brake lamp switch can only be (4) Wait two minutes for the airbag system reserve adjusted once. That is during initial installation of capacitor to discharge before beginning any airbag system or instrument panel component service.
Page 983 23 - 72 INTERIOR INTERIOR TABLE OF CONTENTS page page A-PILLAR TRIM INSTALLATION REMOVAL ......72 INSTALLATION .
Page 984 INTERIOR 23 - 73 BULKHEAD QUARTER TRIM PANEL (Continued) (17) Pull back panel up and route the seat belt through the panel. (18) Remove the trim panel. (19) Disconnect the speaker electrical connectors. (20) Remove the nuts and remove the convertible top latch assembly.
Page 985 23 - 74 INTERIOR CARPETS REMOVAL Floor Carpets (1) Disconnect and isolate the battery negative cable. (2) Remove the seat. (Refer to 23 - BODY/SEATS/ SEAT - REMOVAL) (3) Remove the lower seat belt anchor. (4) For the passenger side carpet, remove the radio amplifier.
Page 986 INTERIOR 23 - 75 CARPETS (Continued) Fig. 6 TOP STACK CARPET WELL 3 - PUSH IN PIN 1 - BULKHEAD QUARTER TRIM 2 - TOP STACK CARPET WELL CENTER CONSOLE BEZEL REMOVAL (1) Using a trim stick C-4755 or equivalent, pry up the bezel.
Page 987 23 - 76 INTERIOR DOOR SURROUND PANEL REMOVAL (1) Using a trim stick C-4755 or equivalent, remove the door sill. (2) Separate the primary door seal from the sur- round. (3) Remove the front screws. (Fig. 8) (4) Remove the side and top screws. (Fig. 9) (5) Using a flat blade scraper, cut the sealant from between surround panel, frame and front of dash panel.
Page 988 INTERIOR 23 - 77 REAR VIEW MIRROR (Continued) (8) Allow the adhesive to cure for an additional 8-10 minutes before installing the mirror. SIDE COWL TRIM REMOVAL (1) Using a trim stick C-4755 or equivalent, scuff plate. (Fig. 11) (2) Remove the rear screw. (3) Remove the two push pin fasteners.
Page 989 23 - 78 INTERIOR SPORT HOOP (Continued) (2) Remove the fasteners and remove the mount- ing brackets. (Fig. 13) INSTALLATION Sport Hoop Mounting Brackets (1) Install the bracket and install the fasteners. (2) Tighten the bolts to 39 N·m (29 ft. lbs.). (3) Install the bulkhead quarter trim panels.
Page 990 INTERIOR 23 - 79 SUN VISOR (Continued) Fig. 14 SUN VISOR 1 - WINDSHIELD SURROUND ASSEMBLY 2 - SUN VISOR Fig. 15 FRONT TUNNEL CONSOLE BEZEL INSTALLATION 1 - CONSOLE INSULATOR (1) Install the visor and install the mounting 2 - FRONT TUNNEL CONSOLE 3 - CONSOLE WIRING HARNESS screw.
Page 991 23 - 80 PAINT PAINT TABLE OF CONTENTS page page PAINT PAINT TOUCH-UP SPECIFICATIONS - PAINT CODES ..80 DESCRIPTION ......81 PAINT CODE FINESSE SANDING/BUFFING &...
Page 992 PAINT 23 - 81 BASE COAT/CLEAR COAT FINISH (Continued) CAUTION: Do not use abrasive chemicals or com- (5) On vehicles without clearcoat, the touch up pounds on painted surfaces. Damage to finish can color can be lightly finesse sanded (1500 grit) and polished with rubbing compound.
Page 993 23 - 82 SEATS SEATS TABLE OF CONTENTS page page SEAT INSTALLATION ......85 REMOVAL ......82 SEAT BACK RECLINER INSTALLATION .
Page 994 SEATS 23 - 83 SEAT (Continued) Fig. 2 SEAT ELECTRICAL CONNECTOR Fig. 3 RECLINER HANDLE 1 - SEAT BACK 1 - SEAT CUSHION 2 - WIRE CONNECTOR 2 - SEAT CUSHION COVER 3 - SCREW 4 - RECLINER HANDLE (7) Place battery access cover into place and install four bolts.
Page 995 23 - 84 SEATS SEAT ADJUSTERS (Continued) Fig. 5 REAR ADJUSTER BOLTS 1 - SEAT ADJUSTER 2 - SEAT CUSHION 3 - REAR ADJUSTER BOLTS Fig. 7 SEAT BACK 1 - SEAT BACK 2 - SEAT BACK RECLINER BOLTS 3 - RECLINER 4 - SEAT BACK CUSHION/COVER INSTALLATION (1) Install the seat back onto the recliners and...
Page 996 SEATS 23 - 85 SEAT BACK COVER (Continued) (6) Position the seat back cover/cushion aside and release the seat belt pass through bezel locking tabs. (Fig. 9) (7) Remove the seat belt pass through bezel. (8) Remove the seat back cushion cover and cush- ion.
Page 997 23 - 86 SEATS SEAT BACK RECLINER (Continued) (3) Remove the seat belt buckle bolt and buckle. (Fig. 13) Fig. 12 RECLINER HANDLE 1 - SEAT CUSHION 2 - SEAT CUSHION COVER 3 - SCREW 4 - RECLINER HANDLE Fig. 11 SEAT BACK 1 - SEAT BACK 2 - SEAT BACK RECLINER BOLTS 3 - RECLINER...
Page 998 SEATS 23 - 87 SEAT CUSHION ASSEMBLY (Continued) (7) Separate seat cushion from seat back. SEAT CUSHION COVER REMOVAL (1) Remove the seat adjuster. (Refer to 23 - BODY/ SEATS/SEAT ADJUSTERS - REMOVAL) (2) Unclip the recliner cable and remove the seat back assembly.
Page 999 23 - 88 STATIONARY GLASS STATIONARY GLASS TABLE OF CONTENTS page page WINDSHIELD REMOVAL ......88 WARNING INSTALLATION .
Page 1000 STATIONARY GLASS 23 - 89 WINDSHIELD (Continued) INSTALLATION (5) Apply black out primer 15 mm (.75 in.) wide on top and sides of windshield and 25 mm (1 in.) on bot- tom of windshield. Allow at least three minutes dry- CAUTION: Allow the urethane at least 24 hours to ing time.
Page 1001 23 - 90 STATIONARY GLASS WINDSHIELD (Continued) Fig. 3 WINDSHIELD 1 - WINDSHIELD GLASS 3 - WINDSHIELD GLASS SPACERS 2 - WINDSHIELD SURROUND FRAME 4 - WINDSHIELD GLASS SHIMS (14) Install inside rear view mirror. (15) After urethane has cured, remove tape strips and water test windshield to verify repair.
Page 1002 WEATHERSTRIP/SEALS 23 - 91 WEATHERSTRIP/SEALS TABLE OF CONTENTS page page DOOR INNER BELT WEATHERSTRIP INSTALLATION ......92 REMOVAL .
Page 1003 23 - 92 WEATHERSTRIP/SEALS DOOR OUTER BELT WEATHERSTRIP REMOVAL (1) Remove the door glass. (Refer to 23 - BODY/ DOOR - FRONT/DOOR GLASS - REMOVAL) (2) Remove the screws and remove the weather strip. (Fig. 2) Fig. 3 DOOR SECONDARY SEAL WEATHERSTRIP 1 - FRONT DOOR INNER BELT WEATHERSTRIP 2 - FRONT DOOR 3 - SECONDARY SEAL WEATHERSTRIP...
Page 1004 WEATHERSTRIP/SEALS 23 - 93 SIDE RAIL WEATHERSTRIP (Continued) DECKLID OPENING WEATHERSTRIP REMOVAL (1) Open the decklid and Using a grease pencil or equivalent, mark the position of the seal seam to aid installation. (2) Remove the weatherstrip. (Fig. 6) Fig. 4 WINDSHIELD HEADER & A-PILLAR WEATHERSTRIP 1 - WINDSHIELD HEADER &...
Page 1005 23 - 94 BODY STRUCTURE BODY STRUCTURE TABLE OF CONTENTS page page GAP AND FLUSH STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS ..... . . 94 SPECIFICATIONS OPENING DIMENSIONS STRUCTURAL ADHESIVE LOCATIONS...
Page 1006 BODY STRUCTURE 23 - 95 GAP AND FLUSH (Continued) O/F = Over Flush NOTE: All measurements are in mm. U/F = Under Flush LEFT FRONT GAP & FLUSH MEASUREMENTS O/F = Over Flush U/F = Under Flush DIMEN- DESCRIP- FLUSH SION TION RIGHT REAR GAP &...
Page 1007 23 - 96 BODY STRUCTURE OPENING DIMENSIONS SPECIFICATIONS OPENING DIMENSIONS OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING DIMENSIONS DOOR OPENING DIMENSIONS CROSS BODY DIMENSIONS TRUNK OPENING DIMENSIONS Fig. 3 WINDSHIELD OPENING DIMENSIONS...
Page 1008 BODY STRUCTURE 23 - 97 OPENING DIMENSIONS (Continued) Fig. 4 DOOR OPENING DIMENSIONS Fig. 5 CROSS BODY DIMENSIONS...
Page 1009 23 - 98 BODY STRUCTURE OPENING DIMENSIONS (Continued) Fig. 6 TRUNK OPENING DIMENSIONS...
Page 1010 BODY STRUCTURE 23 - 99 SEALER LOCATIONS SPECIFICATIONS SEALER LOCATIONS SEALER LOCATION INDEX DESCRIPTION FIGURE DOOR SURROUND AND DASH ASSEMBLY FRONT OF DASH PANEL AND FRAME REAR CLIP & FRAME REAR QUARTER PANEL & FRAME WINDSHIELD SURROUND AND DASH ASSEMBLY Fig.
Page 1011 23 - 100 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 8 FRONT OF DASH PANEL AND FRAME...
Page 1012 BODY STRUCTURE 23 - 101 SEALER LOCATIONS (Continued) Fig. 9 REAR CLIP & FRAME...
Page 1013 BODY STRUCTURE 23 - 101 SEALER LOCATIONS (Continued) Fig. 10 REAR QUARTER PANEL & FRAME Fig. 11 WINDSHIELD SURROUND AND DASH ASSEMBLY...
Page 1014 23 - 102 BODY STRUCTURE STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS STRUCTURAL ADHESIVE LOCATION INDEX DESCRIPTION FIGURE FRONT FENDER SUPPORTS Fig. 12 FRONT FENDER SUPPORTS...
Page 1015 BODY STRUCTURE 23 - 103 WELD LOCATIONS DESCRIPTION FIGURE FLOOR PAN (1 OF 5) FLOOR PAN (2 OF 5) SPECIFICATIONS FLOOR PAN (3 OF 5) WELD LOCATIONS FLOOR PAN (4 OF 5) WELD LOCATION INDEX FLOOR PAN (5 OF 5) REAR FRAME (1 OF 5) DESCRIPTION FIGURE...
Page 1016 23 - 104 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1017 BODY STRUCTURE 23 - 105 WELD LOCATIONS (Continued)
Page 1018 23 - 106 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1019 BODY STRUCTURE 23 - 107 WELD LOCATIONS (Continued)
Page 1020 23 - 108 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1021 BODY STRUCTURE 23 - 109 WELD LOCATIONS (Continued)
Page 1022 23 - 110 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1023 BODY STRUCTURE 23 - 111 WELD LOCATIONS (Continued)
Page 1024 23 - 112 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1025 BODY STRUCTURE 23 - 113 WELD LOCATIONS (Continued)
Page 1026 23 - 114 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1027 BODY STRUCTURE 23 - 115 WELD LOCATIONS (Continued)
Page 1028 23 - 116 BODY STRUCTURE WELD LOCATIONS (Continued)
Page 1029 BODY STRUCTURE 23 - 117 WELD LOCATIONS (Continued)
Page 1030 HEATING & AIR CONDITIONING 24 - 1 HEATING & AIR CONDITIONING TABLE OF CONTENTS page page HEATING & AIR CONDITIONING SPECIFICATIONS DESCRIPTION ......1 HEATING-A/C SYSTEM .
Page 1031 24 - 2 HEATING & AIR CONDITIONING HEATING & AIR CONDITIONING (Continued) end of the instrument panel facing the rear of the humidity from the air before it is directed through or vehicle and two located near the top of the instru- around the heater core.
Page 1032 HEATING & AIR CONDITIONING 24 - 3 HEATING & AIR CONDITIONING (Continued) perform a double duty. It must lower the air temper- tions could result in possible personal injury or ature, and it must lower the temperature of the death. moisture in the air that condenses on the evaporator NOTE: When connecting the service equipment fins.
Page 1033 24 - 4 HEATING & AIR CONDITIONING HEATING & AIR CONDITIONING (Continued) PRESSURE DIAGNOSIS Condition Possible Causes Correction Rapid compressor clutch 1. Low refrigerant system 1. See Refrigerant System Leaks in this group. cycling (ten or more cycles charge. Test the refrigerant system for leaks. Repair, per minute).
Page 1034 HEATING & AIR CONDITIONING 24 - 5 HEATING & AIR CONDITIONING (Continued) Condition Possible Causes Correction The low side pressure is 1. Low refrigerant system 1. See Refrigerant System Leaks in this group. normal or slightly low, and charge. Test the refrigerant system for leaks. Repair, the high side pressure is too evacuate and charge the refrigerant system, if low.
Page 1035 24 - 6 HEATING & AIR CONDITIONING HEATING & AIR CONDITIONING (Continued) HEATER PERFORMANCE MAXIMUM HEATER OUTPUT Engine coolant is delivered to the heater core Before performing the following tests, refer to through two heater hoses. With the engine idling at Group 7 - Cooling for the procedures to check the normal operating temperature, set the temperature engine coolant level and flow, engine coolant reserve/...
Page 1036 HEATING & AIR CONDITIONING 24 - 7 HEATING & AIR CONDITIONING (Continued) SPECIFICATIONS HEATING-A/C SYSTEM A/C SYSTEM Item Description Notes A/C Compressor Denso 10S17C ND-8 PAG oil Freeze–up Control A/C low pressure switch Accumulator mounted - input to powertrain control module (PCM) - PCM opens compressor clutch relay below 131-141 kPa (19-21 psi), closes relay above 241-269...
Page 1037 24 - 8 HEATING & AIR CONDITIONING HEATING & AIR CONDITIONING (Continued) FASTENER TORQUE Description N·m Ft. Lbs. In. Lbs. All Screws NOT Listed – Below A/C Compressor Clutch 17.5 – Bolt A/C Compressor Mount- – ing Bolts A/C Condenser to Radia- –...
Page 1038 CONTROLS 24 - 9 CONTROLS TABLE OF CONTENTS page page A/C COMPRESSOR CLUTCH REMOVAL ......18 DESCRIPTION .
Page 1039 24 - 10 CONTROLS A/C COMPRESSOR CLUTCH (Continued) (2) If the A/C compressor clutch still will not engage, disconnect the wire harness connector for the A/C pressure transducer and check for battery cur- rent at the connector with the engine running and the A/C-heater control set to the A/C mode.
Page 1040 CONTROLS 24 - 11 A/C COMPRESSOR CLUTCH (Continued) A/C CLUTCH COIL SPECIFICATIONS A/C CLUTCH BREAK-IN After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately Compressor Current Draw Coil Resis- twenty times (five seconds on, then five seconds off). tance During this procedure, set the A/C-heater controls to Denso 10S17...
Page 1041 24 - 12 CONTROLS A/C COMPRESSOR CLUTCH (Continued) (7) Tap the clutch plate lightly with a plastic mal- let to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft (Fig. 4). NOTE: Use care not to lose any of the shim(s).
Page 1042 CONTROLS 24 - 13 A/C COMPRESSOR CLUTCH (Continued) INSTALLATION (1) Align the dowel pin on the back of the clutch coil with the hole in the compressor front cover and position the clutch coil onto the compressor. Be cer- tain that the clutch coil pigtail wires are properly ori- ented and routed so that they are not pinched between the compressor front cover and the clutch coil.
Page 1043 24 - 14 CONTROLS When the relay coil is de-energized, spring pres- A/C COMPRESSOR CLUTCH sure returns the movable relay contact back against RELAY the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, DESCRIPTION and helps to dissipate voltage spikes and electromag- The A/C clutch relay (Fig.
Page 1044 CONTROLS 24 - 15 A/C COMPRESSOR CLUTCH RELAY (Continued) minates when the rear window defogger (EBL) system is in operation. The A/C-heater control cannot be repaired and, if faulty or damaged, it must be replaced. The illumi- nation lamps are available for service replacement. Fig.
Page 1045 24 - 16 CONTROLS A/C HEATER CONTROL (Continued) (3) Connect the wire harness connectors to the due to the pressure/temperature relationship of the back of the A/C-heater control and install instrument refrigerant. panel center bezel (Refer to 23 - BODY/INSTRU- Before performing diagnosis of the A/C low pres- MENT PANEL/INSTRUMENT...
Page 1046 CONTROLS 24 - 17 A/C LOW PRESSURE SWITCH (Continued) (3) Remove the A/C low pressure switch from the charge line. An internally threaded fitting on the A/C fitting on the top of the accumulator and remove and pressure transducer connect it to the externally discard the O-ring seal.
Page 1047 24 - 18 CONTROLS A/C PRESSURE TRANSDUCER (Continued) 110 kPa (16 psi) and will re-engage the clutch when REMOVAL the high side pressure rises above 220 kPa (32 psi). If the refrigerant pressure rises above 1654 kPa (240 NOTE: Note: It is not necessary to discharge the psi), the PCM will actuate the cooling fan.
Page 1048 CONTROLS 24 - 19 NOTE: If battery voltage is low or not sensed at the BLEND DOOR ACTUATOR blend door actuator for less than a 60 second inter- val, the blend door actuator will be out of calibra- DESCRIPTION tion. Remove fuse #3 BCM1 (I.O.D. fuse) for a The blend door actuator is a reversible, 12-volt minimum of 60 seconds.
Page 1049 24 - 20 CONTROLS BLEND DOOR ACTUATOR (Continued) BLOWER MOTOR RELAY DESCRIPTION The blower motor relay (Fig. 16) is a International Standards Organization (ISO)-type relay. Relays con- forming to the ISO specifications have common phys- ical dimensions, current capacities, terminal functions and patterns.
Page 1050 CONTROLS 24 - 21 BLOWER MOTOR RELAY (Continued) netic interference that can be generated as the elec- tromagnetic field of the relay coil collapses. The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC).
Page 1051 24 - 22 CONTROLS BLOWER MOTOR RESISTOR BLOCK (Continued) information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin- out and location views for the various wire harness connectors, splices and grounds.
Page 1052 CONTROLS 24 - 23 BLOWER MOTOR RESISTOR BLOCK (Continued) indexing to the mode-air doors, as they are electron- ically calibrated by the A/C-heater control. OPERATION The floor/defrost and the panel mode door actua- tors are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire take out and connector of the HVAC wire harness.
Page 1053 24 - 24 CONTROLS MODE DOOR ACTUATORS (Continued) (1) Disconnect and isolate the negative battery (2) Install the three screws that secure each mode cable. door actuator to the HVAC housing, as required. (2) Remove the instrument panel (Refer to 23 - Tighten the screws to 2 N·m (17 in.
Page 1054 CONTROLS 24 - 25 RECIRCULATION DOOR ACTUATOR (Continued) trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. NOTE: If battery voltage is low or not sensed at the recirculation door actuator for less than a 60 sec- ond interval, the recirculation door actuator will be out of calibration.
Page 1055 24 - 26 DISTRIBUTION DISTRIBUTION TABLE OF CONTENTS page page AIR OUTLETS INSTALLATION ......29 DESCRIPTION .
Page 1056 DISTRIBUTION 24 - 27 BLOWER MOTOR DIAGNOSIS AND TESTING BLOWER MOTOR DESCRIPTION The blower motor (Fig. 2) is a 12-volt, direct cur- WARNING: On vehicles equipped with airbags, dis- rent (DC) motor mounted within a plastic housing able the airbag system before attempting any steer- with an integral wire connector and squirrel cage- ing wheel, steering column, or instrument panel type blower wheel that is secured to the blower...
Page 1057 24 - 28 DISTRIBUTION BLOWER MOTOR (Continued) REMOVAL WARNING: On vehicles equipped with airbags, dis- able the airbag system before attempting any steer- ing wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service.
Page 1058 DISTRIBUTION 24 - 29 DEFROSTER DUCTS (Continued) UPPER DEFROSTER DUCT (1) Using a trim stick C-4755 or equivalent, gently pry the defroster grille from the instrument panel top pad (Fig. 4). (1) Remove the two screws that secure the upper defroster duct to the top of the instrument panel and remove the duct.
Page 1059 24 - 30 DISTRIBUTION (2) Connect the floor distribution duct to the FLOOR DISTRIBUTION DUCT HVAC housing. (3) Install the one screw and one nut that secure REMOVAL the floor distribution duct to the dash panel. Tighten the screw and nut to 2 N·m (17 in. lbs.). WARNING: On vehicles equipped with airbags, dis- (4) Install the instrument panel (Refer to 23 - able the airbag system before attempting any steer-...
Page 1060 DISTRIBUTION 24 - 31 HVAC HOUSING (Continued) Fig. 7 Air Inlet Plenum Fig. 8 HVAC Housing - Engine Compartment 1 - AIR INLET PLENUM 1 - NUT (2) 2 - SCREW (4) 2 - DASH PANEL 3 - DASH PANEL 3 - HVAC HOUSING 4 - BOLT CONDITIONING/PLUMBING/HEATER...
Page 1061 24 - 32 DISTRIBUTION HVAC HOUSING (Continued) (3) Remove the HVAC wiring harness from the (b) That the evaporator drain opening is clean HVAC housing. and the evaporator seal is properly installed. If necessary, remove the blower motor from (2) Install the screws that secure the upper and the HVAC housing (Refer to 24 - HEATING &...
Page 1062 DISTRIBUTION 24 - 33 HVAC HOUSING (Continued) (2) Install the one nut that secures the HVAC INSTRUMENT PANEL DUCTS housing to the dash panel in the passenger compart- ment. Tighten the nut to 7 N·m (60 in. lbs.). REMOVAL (3) Connect lower defroster duct and the floor dis- (1) Disconnect the negative battery cable.
Page 1063 24 - 34 PLUMBING PLUMBING TABLE OF CONTENTS page page PLUMBING OPERATION ......47 DESCRIPTION .
Page 1064 PLUMBING 24 - 35 PLUMBING (Continued) system and can reduce the flow of refrigerant in the WARNING: The evaporation rate of R-134a refriger- system. The radius of all bends in the flexible hose ant at average temperature and altitude is extremely refrigerant lines should be at least ten times the high.
Page 1065 24 - 36 PLUMBING PLUMBING (Continued) CAUTION: The use of A/C system sealers may CAUTION: Do not overcharge the refrigerant sys- result in damage to A/C refrigerant recovery/evacu- tem. Overcharging will cause excessive compressor ation/recharging equipment and/or A/C system. head pressure and can cause compressor noise Many federal, state/provincial and local regulations and A/C system failure.
Page 1066 PLUMBING 24 - 37 PLUMBING (Continued) SYSTEM LOW (1) Position the vehicle in a wind-free work area. This will aid in detecting small leaks. (2) Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run at idle under the following condi- tions for five minutes, then turning the engine off.
Page 1067 24 - 38 PLUMBING PLUMBING (Continued) Fig. 3 Refrigerant Recovery/Recycling Station - Typical 1 - R-134a REFRIGERANT STATION If an A/C compressor designed to use R-134a refrig- erant is left open to the atmosphere for an extended Fig. 2 Manifold Gauge Set - Typical period of time.
Page 1068 PLUMBING 24 - 39 PLUMBING (Continued) STANDARD PROCEDURE - REFRIGERANT SYS- oil lost during the recovery process. Refer the TEM RECOVERY). equipment manufacturer instructions for more infor- (3) Open the suction and discharge valves and mation. start the vacuum pump. The vacuum pump should (1) Evacuate the refrigerant system (Refer to 24 - run a minimum of 45 minutes prior to charge to HEATING &...
Page 1069 24 - 40 PLUMBING A/C COMPRESSOR (Continued) A label identifying the use of R-134a refrigerant is HIGH PRESSURE RELIEF VALVE located on the A/C compressor. The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached.
Page 1070 PLUMBING 24 - 41 A/C COMPRESSOR (Continued) (3) To duplicate a high-ambient temperature condi- (5) Remove the bolts that secure the suction and tions (high head pressure), restrict the air flow discharge lines to the A/C compressor (Fig. 5). through the A/C condenser. Install a manifold gauge (6) Disconnect the suction and discharge lines set or a scan tool to be certain that the discharge from the A/C compressor and remove and discard the...
Page 1071 24 - 42 PLUMBING A/C COMPRESSOR (Continued) (5) Lubricate new rubber O-ring seals with clean REMOVAL refrigerant oil and install them on the suction and discharge line fittings. Use only the specified O-rings WARNING: Refer to the applicable warnings and as they are made of a special material for the R-134a cautions for this system before performing the fol- system.
Page 1072 PLUMBING 24 - 43 A/C CONDENSER (Continued) (7) Remove the bolt that secures the discharge line INSTALLATION to the A/C condenser (Fig. 7) (8) Disconnect the discharge line from the A/C con- NOTE: If the A/C condenser is being replaced, add denser and remove and discard the O-ring seal.
Page 1073 24 - 44 PLUMBING A/C DISCHARGE LINE DESCRIPTION The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser. The A/C discharge line has a fitting for the A/C pres- sure transducer. The A/C discharge line has no ser- viceable parts except the rubber O-ring seals.
Page 1074 PLUMBING 24 - 45 A/C DISCHARGE LINE (Continued) Fig. 9 A/C Dischgarge Line - Condenser Fig. 10 A/C Discharge Line – Compressor 1 - RADIATOR 1 - SUCTION LINE 2 - MOUNTING BRACKET 2 - BOLT (2) 3 - COOLING FAN 3 - A/C COMPRESSOR CLUTCH 4 - A/C DISCHARGE LINE 4 - UPPER MOUNTING BOLT...
Page 1075 24 - 46 PLUMBING A/C EVAPORATOR (Continued) the refrigerant to boil and vaporize. The refrigerant type recommended for the A/C compressor in the becomes a low-pressure gas before it leaves the A/C vehicle. evaporator. (1) Install the A/C evaporator into the lower half of The A/C evaporator cannot be repaired and, if the HVAC housing.
Page 1076 PLUMBING 24 - 47 A/C VARIABLE ORFICE TUBE (Continued) tem contaminants. The outlet end of the tube has a ACCUMULATOR nylon mesh diffuser screen. The O-rings on the plas- tic body of the VOV seal the tube to the inside of the DESCRIPTION liquid line and prevent refrigerant from bypassing The accumulator (Fig.
Page 1077 24 - 48 PLUMBING ACCUMULATOR (Continued) canister, which acts as a separator. A desiccant bag is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system A filter is also mounted inside the canister to trap any foreign mate- rial that may have entered the refrigerant system during assembly.
Page 1078 PLUMBING 24 - 49 ACCUMULATOR (Continued) STANDARD PROCEDURE - REFRIGERANT SYS- bag system. Failure to take the proper precautions TEM EVACUATE). could result in accidental airbag deployment and (13) Charge the refrigerant system (Refer to 24 - possible personal injury or death. HEATING &...
Page 1079 24 - 50 PLUMBING HEATER CORE (Continued) Fig. 15 HVAC Housing - Disassembled 1 - PANEL MODE DOOR ACTUATOR 10 - BLOWER MOTOR AND WHEEL 2 - FLOOR/DEFROST MODE DOOR ACTUATOR 11 - BLOWER MOTOR RESISTOR BLOCK 3 - UPPER HVAC HOUSING 12 - HEATER CORE 4 - RECIRCULATION-AIR DOOR 13 - BLEND-AIR DOOR...
Page 1080 PLUMBING 24 - 51 HEATER INLET HOSE (Continued) (6) Remove the heater inlet hose from the engine (7) Refill the engine cooling system (Refer to 7 - compartment. COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL). HEATER RETURN HOSE REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the fol- lowing operation (Refer to 24 - HEATING &...
Page 1081 24 - 52 PLUMBING HEATER RETURN HOSE (Continued) LIQUID LINE DESCRIPTION The liquid line is the refrigerant line that goes from the A/C condenser to the A/C evaporator. The liquid line contains the A/C variable orifice valve (VOV) and includes the high side service port. The liquid line has no serviceable parts except the rubber O-ring seals and the service port valve core.
Page 1082 PLUMBING 24 - 53 LIQUID LINE (Continued) Fig. 18 Liquid Line Fig. 19 Liquid Line - A/C Condenser 1 - A/C CONDENSER 1 - UPPER MOUNTING BOLT 2 - HIGH SIDE SERVICE PORT 2 - A/C CONDENSER 3 - LIQUID LINE 3 - LOWER MOUNTING BOLT 4 - SUCTION LINE 4 - RIGHT FRAME RAIL...
Page 1083 24 - 54 PLUMBING LIQUID LINE (Continued) (9) Install the bolt that secures the liquid line to REFRIGERANT OIL the A/C condenser. Tighten the bolt to 18 N·m (13 ft. lbs.). DESCRIPTION (10) Install the bolt that secures the liquid line The refrigerant oil used in R-134a refrigerant sys- bracket to the right inner front fender.
Page 1084 PLUMBING 24 - 55 REFRIGERANT OIL (Continued) CAUTION: The oil used in the Denso 10S17 A/C SERVICE PORT VALVE CORE compressor is ND-8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be DESCRIPTION used to service the A/C system. Do not use any Refrigerant system service ports are used to other refrigerant oil.
Page 1085 24 - 56 PLUMBING SERVICE PORT VALVE CORE (Continued) REMOVAL tem refrigerant while uncoupling the charge adapt- ers. (3) Using a Schrader-type valve core tool, install WARNING: Refer to the applicable warnings and and tighten the valve core into the service port(s). cautions for this system before performing the fol- (4) Evacuate the refrigerant system (Refer to 24 - lowing operation (Refer to 24 - HEATING &...
Page 1086 PLUMBING 24 - 57 SUCTION LINE (Continued) NOTE: The A/C suction line is serviced in two sec- (4) Remove the bolt that secures the suction line to tions. The front section connects between the accu- the A/C compressor (Fig. 24). (5) Disconnect the suction line from the A/C com- mulator and the A/C compressor.
Page 1087 24 - 58 PLUMBING SUCTION LINE (Continued) (11) Remove the bolt that secures the front section of the suction line to the accumulator outlet port (Fig. 25). (12) Disconnect the suction line from the accumu- lator and remove and discard the O-ring seal. (13) Install plugs in, or tape over the opened suc- tion line fitting and the accumulator port.
Page 1088 PLUMBING 24 - 59 SUCTION LINE (Continued) refrigerant oil of the type recommended for the A/C (2) Remove the tape or plugs from the suction line compressor in the vehicle. fitting and the accumulator port. (4) Connect the front section of the suction line to (3) Lubricate a new rubber O-ring seal with clean the accumulator.
Page 1090 EMISSIONS CONTROL 25 - 1 EMISSIONS CONTROL TABLE OF CONTENTS page page EMISSIONS CONTROL DESCRIPTION - MONITORED SYSTEMS ..6 DESCRIPTION DESCRIPTION - HIGH AND LOW LIMITS ..8 DESCRIPTION - MONITORED COMPONENT OPERATION DESCRIPTION - VEHICLE EMISSION OPERATION - SYSTEM .
Page 1091 25 - 2 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) mands the Idle Air Control (IAC) Motor to a specific difficulty changing beyond the threshold value. Each position under certain operating conditions, it expects time the voltage signal surpasses the threshold, a to see a specific (target) idle speed (RPM).
Page 1092 EMISSIONS CONTROL 25 - 3 EMISSIONS CONTROL (Continued) Conflict—The Task Manager does not run the sor. Each time the signal is biased, the PCM reads a Oxygen Sensor Monitor if any of the following condi- voltage decrease. When the PCM detects a voltage tions are present: decrease of a predetermined value for several biased •...
Page 1093 25 - 4 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) oxygen downstream of the converter. The output of Enabling Conditions—The following conditions the downstream O2S will indicate limited activity in must typically be met before the PCM runs the cat- this condition. alyst monitor.
Page 1094 EMISSIONS CONTROL 25 - 5 EMISSIONS CONTROL (Continued) The label contains the vehicle’s emission specifica- FUEL PRESSURE tions and vacuum hose routings. All hoses must be The fuel pressure regulator controls fuel system connected and routed according to the label. pressure.
Page 1095 25 - 6 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) • Reduced output voltage PCM CONNECTOR ENGAGEMENT • Dynamic shift The PCM may not be able to determine spread or • Shorted or open circuits damaged connector pins. However, it might store Response rate is the time required for the sensor to diagnostic trouble codes as a result of spread connec- switch from lean to rich once it is exposed to a richer...
Page 1096 EMISSIONS CONTROL 25 - 7 EMISSIONS CONTROL (Continued) (positive torque) by looking at changes in the crank- the downstream O2S will indicate limited activity in shaft speed. If a misfire occurs the speed of the this condition. crankshaft will vary more than normal. As the converter loses the ability to store oxygen, the condition can be detected from the behavior of FUEL SYSTEM MONITOR...
Page 1097 25 - 8 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) Pump Mode: The pump is cycled at a fixed rate to OPERATION achieve a rapid pressure build in order to shorten the overall test length. OPERATION - SYSTEM Test Mode: The solenoid is energized with a fixed The Powertrain Control Module (PCM) monitors duration pulse.
Page 1098 EMISSIONS CONTROL 25 - 9 EMISSIONS CONTROL (Continued) Technicians can display stored DTC’s. Refer to Diagnostic Trouble Codes (Refer to 8 - ELECTRICAL/ ELECTRONIC CONTROL MODULES/POWER- TRAIN CONTROL MODULE - DESCRIPTION). For obtaining the DTC information, use the Data Link Connector with the DRBIII scan tool (Fig.
Page 1099 25 - 10 EVAPORATIVE EMISSIONS EVAPORATIVE EMISSIONS TABLE OF CONTENTS page page EVAPORATIVE EMISSIONS OPERATION ......13 OPERATION - EVAPORATION CONTROL LEAK DETECTION PUMP SYSTEM...
Page 1100 EVAPORATIVE EMISSIONS 25 - 11 CCV SYSTEM (Continued) CCV HOSE CONNECTION AT THROTTLE BODY CCV HOSE (2) Disconnect each CCV tube. (3) Blow compressed air through each tube and check for blockage or restrictions. If cleaning is nec- essary, spray a soapy-type all-purpose cleaner into each component and blow out.
Page 1101 25 - 12 EVAPORATIVE EMISSIONS EVAP/PURGE SOLENOID (Continued) REMOVAL (3) Remove the vacuum lines (Fig. 4). The EVAP/Purge solenoid is located near the PCM on the driver side of vehicle (Fig. 2). Fig. 4 VACUUM CONNECTION (4) Pull solenoid up and off the mounting bracket Fig.
Page 1102 EVAPORATIVE EMISSIONS 25 - 13 EVAP/PURGE SOLENOID (Continued) INSTALLATION OPERATION (1) Make sure that you have the proper orientation The fuel filler tube cap seals the fuel tank when of the EVAP/Purge solenoid (Fig. 6). threaded onto the filler neck. For safety, the cap con- tains pressure-vacuum relief valves.
Page 1103 25 - 14 EVAPORATIVE EMISSIONS LEAK DETECTION PUMP (Continued) (3) Cut closeout panel hole for fuel tank and remove panel (Fig. 9). Fig. 10 FUEL TANK CONNECTORS Fig. 9 CUTTING PANEL (4) Drill holes (11 holes). (5) Disconnect the LDP electrical connector from pump (Fig.
Page 1104 EVAPORATIVE EMISSIONS 25 - 15 stops, either following shut-off or by having the fuel ORVR level in the tank rise high enough to close the control valve. The control valve contains a float that rises to DESCRIPTION seal the large diameter vent path to the canister. At ORVR System Schematic and components (Fig.
Page 1105 25 - 16 EVAPORATIVE EMISSIONS VAPOR CANISTER DESCRIPTION All vehicles use a sealed, maintenance free, char- coal filled EVAP canister. The canister mounts to fuel tank with the LDP attached to it. OPERATION All vehicles use a maintenance free, evaporative (EVAP) canister.
Page 1106 EVAPORATIVE EMISSIONS 25 - 17 VAPOR CANISTER (Continued) (5) Disconnect the LDP electrical connector from pump (Fig. 15). Fig. 16 LIQUID SEPARATOR will cause the Check Engine Lamp to illumi- Fig. 15 FUEL TANK CONNECTORS nate. Connect lines to the LDP. (3) Install electrical connector to pump and push (6) Remove the liquid separator from the canister locking tab to lock (Fig.
Page 1107 25 - 18 ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS TABLE OF CONTENTS page page TASK MANAGER OPERATION ......18 DESCRIPTION .
Page 1108 ON-BOARD DIAGNOSTICS 25 - 19 TASK MANAGER (Continued) The Task Manager Screen shows both a Requested ditions Window is when engine RPM is within ±375 MIL state and an Actual MIL state. When the MIL is RPM and load is within ±20% of when the fault illuminated upon completion of a test for a good trip, occurred.
Page 1109 25 - 20 ON-BOARD DIAGNOSTICS TASK MANAGER (Continued) • Fuel System Similar Conditions Window — Alternate Good Trips are used in place of Global Good Trips for Comprehensive Components and An indicator that ’Absolute MAP When Fuel Sys Fail’ Major Monitors. If the Task Manager cannot run a and ’RPM When Fuel Sys Failed’...
Page 1110 ON-BOARD DIAGNOSTICS 25 - 21 TASK MANAGER (Continued) • Absolute MAP — A live reading of engine load tive to calculate the Adaptive Memory Factor for to aid the user in accessing the Similar Conditions total fuel correction. • 200 Rev Counter — Counts 0–100 720 degree Window.
Page 1112 INDEX Description Group-Page Description Group-Page Description Group-Page INDEX A-PILLAR TRIM ..... . 23-72 CRANKSHAFT OIL SEAL - FRONT ..9-64 FUEL RAIL .
Page 1113 INDEX Description Group-Page Description Group-Page Description Group-Page LATCH RELEASE HANDLE ....23-61 RADIO ......8A-6 STAY PADS - STRAPS .
Page 1114 SERVICE MANUAL COMMENTS What errors(s) have you found? ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ In order for us to assist you, please include as much details as possible when reporting an error Comments / Suggestions ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ □ □ Dealership Technician Retail Customer Dealer Code: Manual Title, Year, Number and Page: _________________________________________________...
Page 1115 DaimlerChrysler Corporation Attn. Publications Dept. CIMS 486-02-70 800 Chrysler Drive Auburn Hills, MI 48326-2757...
Page 1116 TABLE OF CONTENTS INTRODUCTION ............1 SYSTEM COVERAGE .
Page 1117 TABLE OF CONTENTS - Continued P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH ......23 P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE .
Page 1118 TABLE OF CONTENTS - Continued P0307-CYLINDER #7 MISFIRE ..........89 P0308-CYLINDER #8 MISFIRE .
Page 1119 TABLE OF CONTENTS - Continued *BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIII ...186 *CANNOT SHIFT INTO 2ND AND 3RD GEARS ......188 *CANNOT SHIFT INTO REVERSE .
Page 1120 TABLE OF CONTENTS - Continued GENERATOR - GRAY 2 WAY ..........230 HYDRAULIC COOLING MODULE - BLACK 3 WAY .
Page 1121 NOTES...
Page 1122 GENERAL INFORMATION • 1.0 INTRODUCTION repair of isolated problem • verification of proper operation The procedures contained in this manual include specifications, instructions, and graphics needed to 2.0 IDENTIFICATION OF diagnose the PCM Powertrain System. The diag- SYSTEM nostics in this manual are based on the failure condition or symptom being present at the time of diagnosis.
Page 1123 GENERAL INFORMATION PCM memory. The criteria may range from engine The On Board Diagnostics have evolved to the rpm, engine temperature, and/or input voltage to second Generation of Diagnostics referred to as the PCM. If a problem is detected with a monitored OBDII.
Page 1124 GENERAL INFORMATION OBD II Monitor Operation Comprehensive Major Monitors Major Monitors Components Non Fuel Control Fuel Control Monitor & Non Misfire & Misfire Run constantly Run Once Per Trip Run constantly Includes All Engine Hardware Monitors Entire Emission Monitors Entire System •Sensors, Switches, System Solenoids, etc.
Page 1125 GENERAL INFORMATION 3.2.3 JTEC CONTROLLED REAR WHEEL *NOTE: The most efficient order has been outlined below. The first two monitors have DRIVE VEHICLES very similar enable criteria. It is possible that The following procedure has been established to the Evaporative Leak Detection Monitor will assist Dealer Technicians in the field with enabling run during the O2 Sensor Heater Monitor.
Page 1126 GENERAL INFORMATION Throttle Closure. If all of the parameters are met EVAP Purge Solenoid: The PCM uses the EVAP and it still does not run, with your foot firmly on purge solenoid to control purging of excess fuel the Service Brake, slightly (1/4) open the Throt- vapors stored in the EVAP canister.
Page 1127 GENERAL INFORMATION spring force. This upward movement closes the vent valve. It also causes low pressure below the dia- phragm, unseating the inlet check valve and allow- ing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open (Figure the switch is open, and there is no voltage sent to the PCM.
Page 1128 GENERAL INFORMATION The pumping cycle is repeated as the solenoid is NOTE: If battery voltage drops below 10 volts turned on and off. When the evaporative system for more than 5 seconds during engine begins to pressurize, the pressure on the bottom of cranking, the evap leak detection test will not the diaphragm will begin to oppose the spring run.
Page 1129 GENERAL INFORMATION system has residual pressure, the LDP diaphragm done by monitoring the time required for the LDP to may be up. This could result in the LDP reed switch pump air into the EVAP system during two to three being open when the key is turned to “ON”...
Page 1130 GENERAL INFORMATION MIL will illuminate and a DTC will be stored based take the place of the ultrasonic leak detector 6917A. on the size of leak detected. If no leak is detected The EELD utilizes shop air and a smoke generator during the next test, the temporary fault will be to visually detect leaks down to 0.020 or smaller.
Page 1131 GENERAL INFORMATION Cylinder Compression − The PCM cannot de- conditions that cause them. The following proce- tect uneven, low, or high engine cylinder compres- dures may assist you in identifying a possible sion.(*) intermittent problem: Excessive Oil Consumption − Although the •...
Page 1132 GENERAL INFORMATION 3.5.1 DRBIII DOES NOT POWER UP access mode will be locked out for one hour. To exit this lock out mode, leave the ignition key in If the LED’s do not light or no sound is emitted at the Run/Start position for one hour.
Page 1133 GENERAL INFORMATION 4.2 SAFETY • Do not use the DRBIII if it has been damaged. • Do not use the test leads if the insulation is damaged or if metal is exposed. 4.2.1 TECHNICIAN SAFETY INFORMATION • To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
Page 1134 GENERAL INFORMATION CAUTION: Before road testing a vehicle, be 6.0 ACRONYMS sure that all components are reassembled. During the test drive, do not try to read the Air Conditioning DRBIII screen while in motion. Do not hang Anti-Lock Brake System the DRBIII from the rear view mirror or operate...
Page 1135 GENERAL INFORMATION Engine Position Pulse OBD II On-Board Diagnostics – 2nd Gener- ation European Union ORVR On-Board Refueling Vapor Recovery EVAP Evaporative Emission System PCI Bus Programmable Communications In- Electronic Voltage Regulator terface BUS (J1850) EWMA Exponentially Weighted Moving Powertrain Control Module Average Positive Crankcase Ventilation Federal Test Procedure...
Page 1136 DIAGNOSTIC INFORMATION AND PROCEDURES...
Page 1137 COMMUNICATION Symptom: *NO RESPONSE FROM PCM (PCI BUS) POSSIBLE CAUSES PCM PCI NO RESPONSE PCI BUS CIRCUIT OPEN POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY Turn the ignition on. NOTE: As soon as one or more module communicates with the DRB, answer the question.
Page 1138 COMMUNICATION Symptom: *NO RESPONSE FROM PCM (SCI ONLY) POSSIBLE CAUSES CHECK PCM POWERS AND GROUNDS SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE TIRE PRESSURE MONITOR MODULE SCI RECEIVE CIRCUIT SHORTED TO VOLTAGE SCI CIRCUITS SHORTED TOGETHER SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI RECEIVE CIRCUIT SHORTED TO GROUND SCI RECEIVE CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN...
Page 1139 COMMUNICATION *NO RESPONSE FROM PCM (SCI ONLY) — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the DRBIII from the DLC. Disconnect the PCM harness connectors. Turn the ignition on. Disconnect the Low Tire Pressure Warning Module harness connector (if equipped). Measure the voltage of the SCI Transmit circuit at the DLC.
Page 1140 COMMUNICATION *NO RESPONSE FROM PCM (SCI ONLY) — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the PCM C3 harness connector. Disconnect the DRBIII from the DLC. Measure the resistance of the SCI Transmit circuit between the PCM C3 connector and the DLC.
Page 1141 COMMUNICATION Symptom: *PCI BUS COMMUNICATION FAILURE POSSIBLE CAUSES WIRING HARNESS INTERMITTENT OPEN PCI BUS CIRCUIT AT THE DATA LINK CONNECTOR (DLC) PCI BUS CIRCUIT SHORTED TO VOLTAGE MODULE SHORT TO VOLTAGE PCI BUS CIRCUIT SHORTED TO GROUND MODULE SHORT TO GROUND TEST ACTION APPLICABILITY...
Page 1142 COMMUNICATION *PCI BUS COMMUNICATION FAILURE — Continued TEST ACTION APPLICABILITY NOTE: Reconnect the PCM harness connector and the negative battery cable. Turn the ignition on. Measure the voltage of the PCI Bus circuit at the Data Link Connector (DLC). Is the voltage above 7.0 volts? Yes →...
Page 1143 DRIVEABILITY - GAS Symptom: INTERMITTENT CONDITION POSSIBLE CAUSES INTERMITTENT CONDITION TEST ACTION APPLICABILITY NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN.
Page 1144 DRIVEABILITY - GAS Symptom List: P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW.
Page 1145 DRIVEABILITY - GAS P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW — Continued TEST ACTION APPLICABILITY Ignition on, engine not running. With the DRBIII , read DTCs and record the related Freeze Frame data. With the DRBIII , actuate the O2 Heater test. Monitor the O2 Heater Voltage for 5 minutes.
Page 1146 DRIVEABILITY - GAS P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW — Continued TEST ACTION APPLICABILITY NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.
Page 1147 DRIVEABILITY - GAS Symptom: P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE When Monitored and Set Condition: P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE When Monitored: With the ignition on and no Battery Temperature Sensor Open or Short Faults present. Set Condition: After 5 warm cycles have occurred (coolant increases at least 22°C (40°F) to a minimum of 71°C (160°F) and the odometer mileage has increased 196.6 miles and the Battery Temperature has changed less than 4°C (7.2°F) change in temperature.
Page 1148 DRIVEABILITY - GAS P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE — Continued TEST ACTION APPLICABILITY With the DRBIII , read the Battery Temp Sensor voltage with the Batt Temp Sensor still disconnected. Is the voltage above 4.6 volts? Yes → Go To 4 →...
Page 1149 DRIVEABILITY - GAS P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Battery Temp Sensor harness connector. Disconnect the PCM harness connectors. Measure the resistance between ground and the (K25) Battery Temp Signal circuit. Is the resistance below 100 ohms? Yes →...
Page 1150 DRIVEABILITY - GAS Symptom: P0107-MAP SENSOR VOLTAGE TOO LOW When Monitored and Set Condition: P0107-MAP SENSOR VOLTAGE TOO LOW When Monitored: With the engine RPM above 416 but less than 1500, the TPS voltage less than 1.13 volts, and battery voltage greater than 10.4 volts. Set Condition: The MAP Sensor signal voltage is below 0.1 of a volt for 2.0 seconds with the engine running.
Page 1151 DRIVEABILITY - GAS P0107-MAP SENSOR VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY With the DRBIII , monitor the MAP Sensor voltage with the Sensor still discon- nected. Is the voltage above 1.2 volts? Yes → Replace the MAP Sensor. Perform POWERTRAIN VERIFICATION TEST VER - 5.
Page 1152 DRIVEABILITY - GAS Symptom: P0108-MAP SENSOR VOLTAGE TOO HIGH When Monitored and Set Condition: P0108-MAP SENSOR VOLTAGE TOO HIGH When Monitored: With the engine RPM above 400, the TPS voltage less than 1.13 volts, and battery voltage greater than 10.4 volts Set Condition: The MAP Sensor signal voltage is greater than 4.88 volts at start or with the engine running for 2.2 seconds.
Page 1153 DRIVEABILITY - GAS P0108-MAP SENSOR VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the PCM harness connectors. Ignition on, engine not running. Measure the voltage on the (K1) MAP Sensor Signal circuit at the MAP Sensor harness connector.
Page 1154 DRIVEABILITY - GAS Symptom: P0111-INTAKE AIR TEMP PERFORMANCE When Monitored and Set Condition: P0111-INTAKE AIR TEMP PERFORMANCE When Monitored: With the ignition on and no Intake Air Temperature Sensor open/ shorted faults present. Set Condition: After 5 warm cycles have occurred (coolant increases at least 22°C (40°F) to a minimum of 71°C (160°F) and the odometer mileage has increased 196.6 miles and the Intake Air Temperature has had less than 5°C (9°F) change in temperature.
Page 1155 DRIVEABILITY - GAS P0111-INTAKE AIR TEMP PERFORMANCE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Connect a jumper wire across the IAT Sensor harness connector. Ignition on, engine not running. With the DRBIII , read the IAT voltage. Is the voltage below 1.0 volt? Yes →...
Page 1156 DRIVEABILITY - GAS Symptom: P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW When Monitored and Set Condition: P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW When Monitored: With the ignition on and battery voltage greater than 10.4 volts. Set Condition: The Intake Air Temperature (IAT) Sensor circuit voltage at the PCM goes below 0.8 of a volt.
Page 1157 DRIVEABILITY - GAS P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Measure the resistance between the (K21) IAT Sensor Signal circuit and the (K900) Sensor ground circuit at the IAT Sensor harness connector. Is the resistance below 100 ohms? Yes →...
Page 1158 DRIVEABILITY - GAS Symptom: P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH When Monitored and Set Condition: P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH When Monitored: With the ignition on and battery voltage greater than 10.4 volts. Set Condition: The Intake Air Temperature (IAT) Sensor circuit voltage at the PCM goes above 4.9 volts.
Page 1159 DRIVEABILITY - GAS P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the PCM harness connectors. Ignition on, engine not running. Measure the voltage on the (K21) IAT Sensor Signal circuit. Is the voltage above 5.3 volts? Yes →...

Dodge ZB 2005 Service Manual

W-44 Interior Lighting

Vtss Led/Wheel Speed Sensor-Left Rear

- Continued

Tire Pressure Monitoring System (Tpms)

Power Door Entry System

Power Windows

Electrically Heated Systems

Vehicle Theft Security System

Using the Drbiii

Drbiii Error Messages

Drbiii Does Not Power up (Blank Screen)

Safety

Disclaimers, Safety, Warnings

Display Is Not Visible

Disclaimers

Glossary of Terms

Required Tools and Equipment

Warnings

Diagnostic Information and Procedures

Airbag

Quick Links

Chapters

Summary of Contents for Dodge ZB 2005

Page 488: Table Of Contents

Page 628: Door Lock Switch-Driver

Page 629: Instrument Cluster

Page 630: Power Mirror Switch

Page 631: Vtss Led

Page 632: Wheel Speed Sensor-Left Rear

Dodge ZB 2005 Service Manual

W-44 Interior Lighting

Vtss Led/Wheel Speed Sensor-Left Rear

- Continued

Tire Pressure Monitoring System (Tpms)

Power Door Entry System

Power Windows

Electrically Heated Systems

Vehicle Theft Security System

Using the Drbiii

Drbiii Error Messages

Drbiii Does Not Power up (Blank Screen)

Safety

Disclaimers, Safety, Warnings

Display Is Not Visible

Disclaimers

Glossary of Terms

Required Tools and Equipment

Warnings

Diagnostic Information and Procedures

Airbag

Quick Links

Chapters

Related Manuals for Dodge ZB 2005

Summary of Contents for Dodge ZB 2005

Page 488: Table Of Contents

Page 628: Door Lock Switch-Driver

Page 629: Instrument Cluster

Page 630: Power Mirror Switch

Page 631: Vtss Led

Page 632: Wheel Speed Sensor-Left Rear

Table of Contents