Page 1 GROUP TAB LOCATOR Introduction Power Systems Lubrication & Maintenance Restraints Suspension Speed Control Differential & Driveline Vehicle Theft Security Brakes Wipers/Washers Clutch Wiring Cooling Engine Cooling - 2.5L Turbo Diesel Engine Audio Exhaust System Chime/Buzzer Exhaust System and Turbocharger Electronic Control Modules Frame &...
Page 2 5 - CAR LINE SHELL 6 - PAINT PROCEDURE DIGIT 20 7 - ENGINE Carline 8 - TRIM 9 - TRANSMISSION 10 - MARKET • K = Dodge 11 - VIN • Y = Chrysler • C = Chrysler • D = Dodge...
Page 3 INTRODUCTION BODY CODE PLATE (Continued) DIGIT 21 BODY CODE PLATE LINE 1 Price Class • H = Highline DIGITS 1, 2, AND 3 • L = Lowline Transaxle Codes • P = Premium • DGC = 31TH 3-Speed Automatic Transaxle •...
Page 4 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 2 FASTENER IDENTIFICATION...
Page 5 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 3 FASTENER STRENGTH...
Page 6 INTRODUCTION DESCRIPTION - THREADED HOLE REPAIR FASTENER USAGE Most stripped threaded holes can be repaired using a Helicoil . Follow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures. DESCRIPTION - FASTENER USAGE INTERNATIONAL SYMBOLS WARNING: USE OF AN INCORRECT FASTENER DESCRIPTION MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY.
Page 7 INTRODUCTION The following chart will assist in converting metric METRIC SYSTEM units to equivalent English and SAE units, or vise versa. DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY...
Page 8 INTRODUCTION METRIC SYSTEM (Continued) Fig. 5 METRIC CONVERSION CHART...
Page 9 INTRODUCTION tions Chart for torque references not listed in the TORQUE REFERENCES individual torque charts (Fig. 6). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- Fig. 6 TORQUE SPECIFICATIONS...
Page 10 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.) Car Line P = Chrysler, Town & Country - FWD P = Dodge, Caravan/Grand Caravan - FWD T = Chrysler, Town & Country - AWD T = Dodge, Grand Caravan - AWD...
Page 11 INTRODUCTION VEHICLE IDENTIFICATION NUMBER (Continued) POSITION INTERPRETATION CODE = DESCRIPTION Series 2 = Low Line 4 = High Line 5 = Premium 6 = Sport 7 = Special 6 - Export Series B = 4-Speed Automatic Transaxle N = 5-Speed Manual Transaxle Body Style 4 = Long Wheel Base 5 = Short Wheel Base...
Page 12 4 - AMENDMENT NUMBER VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifica- tions and vacuum hose routings.
Page 14: Table Of Contents
LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE DESCRIPTION - ENGINE OIL - DIESEL SPECIFICATIONS - FLUID CAPACITIES ..1 ENGINES ......6 INTERNATIONAL SYMBOLS FLUID FILL/CHECK LOCATIONS DESCRIPTION...
Page 15: Lubrication & Maintenance
This symbol means that the oil has been certified CENTER IN YOUR AREA. by the American Petroleum Institute (API). Diamler- Chrysler only recommend API Certified engine oils. When service is required, DaimlerChrysler Corpo- Use Mopar engine oil or equivalent. ration recommends that only Mopar brand parts, lubricants and chemicals be used.
Page 16: Description - Engine Coolant
LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) GEAR LUBRICANTS ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. SAE ratings also apply to multigrade gear lubri- cants. In addition, API classification defines the CAUTION: Use of Propylene Glycol based coolants lubricants usage.
Page 17: Description - Automatic Transmission Fluid
0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) WARNING: Ethanol vapors are extremely flammable DESCRIPTION - AUTOMATIC TRANSMISSION and could cause serious personal injury. Never FLUID have any smoking materials lit in or near the vehi- cle when removing the fuel filler tube cap (gas cap) NOTE: Refer to the maintenance schedules for the or filling the tank.
Page 18 LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) Light spark knock at low engine speeds is not levels higher than allowed in the United States. harmful to your engine. However, continued heavy MMT is prohibited in Federal and California refor- spark knock at high speeds can cause damage and mulated gasoline.
Page 19: Description - Fuel Requirements - Diesel Engine
LUBRICATION & MAINTENANCE FLUID TYPES (Continued) • The use of fuel additives which are now being that meet Chrysler material standard MS-6395, be sold as octane enhancers is not recommended. Most used. European Grade 10W-40 oils are also accept- of these products contain high concentrations of able.
Page 20: Jump Starting
LUBRICATION & MAINTENANCE 0 - 7 HOISTING (Continued) The hoisting points are identified by S.A.E. JUMP STARTING inverted triangle hoisting symbols (Fig. 5). The front hoisting points are at the bottom of the font rail STANDARD PROCEDURE - JUMP STARTING below the hoisting symbol approximately 250 mm behind the front suspension crossmember.
Page 21: Standard Procedure - Towing
0 - 8 LUBRICATION & MAINTENANCE JUMP STARTING (Continued) (2) When using another vehicle as a booster DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place ground on disabled vehicle.
Page 22 LUBRICATION & MAINTENANCE 0 - 9 TOWING (Continued) FLAT BED TOWING TIE DOWNS CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result. The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails, behind the front wheels.
Page 24 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page FRONT SUSPENSION ..... 1 WHEEL ALIGNMENT ..... 46 REAR SUSPENSION .
Page 25: Front Suspension
2 - 2 FRONT SUSPENSION strut assembly (through a pivot bearing in the upper FRONT SUSPENSION strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. DESCRIPTION - FRONT SUSPENSION This vehicle has a MacPherson Strut type front STANDARD PROCEDURE - LUBRICATION suspension (Fig.
Page 26: Specifications
FRONT SUSPENSION 2 - 3 SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE DESCRIPTION N·m Lbs. Lbs. Ball Joint Nut — Cradle Crossmember Mounting — Press, Ball Joint C-4212F Bolts Cradle Crossmember — Reinforcement Bolts - Size M-14 Cradle Crossmember — Reinforcement Bolt - Size M-12 Cradle Crossmember —...
Page 27: Front Suspension
2 - 4 FRONT SUSPENSION BUSHINGS REMOVAL - STABILIZER BAR CUSHION (1) Raise Vehicle. Refer to Hoisting in Lubrication and Maintenance. (2) Remove the 2 bolts fastening the emission leak detection pump to the cradle crossmember reinforce- ment. (3) Move the leak detection pump to the side allowing access to the stabilizer bar cushion retain- ers.
Page 28: Diagnosis And Testing - Hub And Bearing
FRONT SUSPENSION 2 - 5 HUB / BEARING (Continued) DIAGNOSIS AND TESTING - HUB AND BEARING The condition of the front hub and bearing assem- bly is diagnosed using the inspection and testing pro- cedure detailed below. The bearing contained in the Unit III front hub/ bearing assembly will produce noise and vibration when worn or damaged.
Page 29: Installation
2 - 6 FRONT SUSPENSION HUB / BEARING (Continued) (1) Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. (2) Install the 4 hub and bearing mounting bolts from the rear of the knuckle.
Page 30: Removal - Steering Knuckle
FRONT SUSPENSION 2 - 7 KNUCKLE (Continued) The center of the knuckle supports the hub and bearing and axle shaft. REMOVAL - STEERING KNUCKLE (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove the wheel and tire assembly from the vehicle.
Page 31: Inspection - Steering Knuckle
2 - 8 FRONT SUSPENSION KNUCKLE (Continued) Fig. 11 Removing Tie Rod End Attaching Nut Fig. 13 Front Wheel Speed Sensor 1 - TIE ROD END 1 - MOUNTING BOLT 2 - STEERING KNUCKLE 2 - WHEEL SPEED SENSOR 3 - WRENCH 3 - STEERING KNUCKLE 4 - SOCKET 5 - TIE ROD END STUD...
Page 32: Installation - Steering Knuckle
FRONT SUSPENSION 2 - 9 KNUCKLE (Continued) wrench, tighten the nut to a torque of 108 N·m (80 ft. lbs.). Fig. 15 Ball Joint Nut Installation 1 - KNUCKLE 2 - BALL JOINT STUD 3 - LOWER CONTROL ARM (4) Slide driveshaft stub axle into hub and bearing assembly.
Page 33: Lower Ball Joint Description
2 - 10 FRONT SUSPENSION KNUCKLE (Continued) LOWER BALL JOINT DESCRIPTION The ball joint is an integral part of the lower con- trol arm (Fig. 1). The ball joint has a tapered stud that is pressed into the aluminum knuckle. The ball joint stud is threaded on the end for a retainer nut.
Page 34: Removal
FRONT SUSPENSION 2 - 11 LOWER BALL JOINT SEAL BOOT (Continued) REMOVAL REMOVAL - BALL JOINT SEAL BOOT (1) Remove steering knuckle from vehicle. (Refer SUSPENSION/FRONT/KNUCKLE REMOVAL) (2) Using a screw driver or other suitable tool, pry the seal boot off of the ball joint (Fig. 17) Fig.
Page 35: Installation - Export
2 - 12 FRONT SUSPENSION LOWER BALL JOINT SEAL BOOT (Continued) (4) Wipe any grease off the ball joint stem using a CAUTION: Do not attempt to install a normal grease clean shop towel with Mopar Brake Parts Cleaner zirc in the ball joint and lubricate the joint through applied to it.
Page 36: Disassembly
FRONT SUSPENSION 2 - 13 LOWER CONTROL ARM (Continued) Fig. 21 Power Steering Cooler 1 - CRADLE CROSSMEMBER REINFORCEMENT 2 - POWER STEERING COOLER (5) Remove the lower control arm rear bushing retainer bolts located on each side of each lower con- trol arm rear bushing.
Page 37: Inspection - Lower Control Arm
2 - 14 FRONT SUSPENSION LOWER CONTROL ARM (Continued) Inspect and test the ball joint per the procedure listed in Lower Ball Joint. (Refer to 2 - SUSPEN- SION/FRONT/LOWER BALL JOINT - DIAGNOSIS AND TESTING) ASSEMBLY ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD) CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant specified...
Page 38: Assembly - Lower Control Arm (Rear Bushing - Hydro)
FRONT SUSPENSION 2 - 15 LOWER CONTROL ARM (Continued) ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO) CAUTION: Do not apply grease or any other type of lubricant to the arm stem where the bushing is to be mounted. Such action will reduce proper bush- ing adhesion to arm.
Page 39: Stabilizer Bar Description
2 - 16 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (2) Install NEW pivot bolt attaching front bushing of lower control arm to front suspension cradle cross- member (Fig. 29). Do not tighten or torque pivot bolt at this time. Fig. 30 Jack Stands Supporting Vehicle Weight 1 - LOWER CONTROL ARMS 2 - BALL JOINT 3 - JACK STANDS...
Page 40: Removal
FRONT SUSPENSION 2 - 17 STABILIZER BAR (Continued) to minimize the body roll of the vehicle during sus- pension movement. Connecting the stabilizer bar links to the strut assemblies helps reduce the fore-and-aft rate of the stabilizer bar from the rest of the front suspension. REMOVAL (1) Raise vehicle.
Page 41: Installation
2 - 18 FRONT SUSPENSION STABILIZER BAR (Continued) (1) If the stabilizer bar to front suspension cradle bushings require replacement at time of inspection, install new bushings before installing stabilizer bar. Bushings are replaced by opening slit on bushings and peeling them off stabilizer bar. Install new bush- ings on stabilizer bar by spreading bushing at slit and forcing them on the stabilizer bar.
Page 42: Strut
FRONT SUSPENSION 2 - 19 STABILIZER BAR (Continued) (6) Tighten the stabilizer bar bushing retainer to cradle attaching bolts (Fig. 34) to 68 N·m (50 ft. lbs.) torque. (7) Install the reinforcement on the front suspen- sion cradle crossmember and install the bolts attach- ing the reinforcement to the cradle crossmember (Fig.
Page 43: Diagnosis And Testing - Strut Assembly
2 - 20 FRONT SUSPENSION STRUT (Continued) Fig. 38 STRUT ASSEMBLY 1 - NUT 6 - COIL SPRING 2 - UPPER MOUNT 7 - DUST SHIELD 3 - PIVOT BEARING 8 - JOUNCE BUMPER 4 - UPPER SPRING SEAT 9 - LOWER SPRING ISOLATOR 5 - UPPER SPRING ISOLATOR 10 - STRUT (DAMPER) The coil spring controls ride quality and maintains...
Page 44 FRONT SUSPENSION 2 - 21 STRUT (Continued) open-end wrench on the flat machined into the link’s mounting stud, then remove the nut while holding the wrench in place. Push the stud out of the bracket. Fig. 39 Strut Assembly Leakage Inspection (Typical) 1 - DUST BOOT 2 - STRUT SHAFT 3 - STRUT FLUID RESERVOIR...
Page 45: Disassembly - Strut Assembly
2 - 22 FRONT SUSPENSION STRUT (Continued) (7) Remove the 3 nuts attaching the strut assem- end of the coil spring, so the strut is held in place bly upper mount to the strut tower (Fig. 43) and once the strut shaft nut is removed. remove the strut assembly from the vehicle.
Page 46: Assembly - Strut Assembly
FRONT SUSPENSION 2 - 23 STRUT (Continued) NOTE: Coil Springs on this vehicle are side-ori- ented. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom. Left and right springs must not be interchanged.
Page 47 2 - 24 FRONT SUSPENSION STRUT (Continued) slot on the jounce bumper. The jounce bumper will be at the top of the inner dust boot. Return the dust shield to its fully extended length. (9) Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring.
Page 48: Installation - Strut Assembly
FRONT SUSPENSION 2 - 25 STRUT (Continued) 43). Then using a crow foot. tighten the 3 attaching nuts to a torque of 28 N·m (250 in. lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation.
Page 49 2 - 26 REAR SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION ASSEMBLY - SHOCK ABSORBER (UPPER DESCRIPTION - REAR SUSPENSION ..26 BUSHING) ......38 OPERATION - REAR SUSPENSION .
Page 50: Operation - Rear Suspension
REAR SUSPENSION 2 - 27 REAR SUSPENSION (Continued) Fig. 1 Front-Wheel-Drive Rear Suspension 1 - SHACKLE 7 - LEAF SPRING (MONO-LEAF) 2 - REAR MOUNT (HANGER) 8 - ISOLATOR 3 - TRACK BAR 9 - FWD REAR AXLE 4 - SPRING PLATE 10 - STABILIZER BAR LINKS 5 - ISOLATOR 11 - STABILIZER BAR...
Page 51: Specifications
2 - 28 REAR SUSPENSION REAR SUSPENSION (Continued) SPECIFICATIONS SPECIAL TOOLS REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION DESCRIPTION N·m Lbs. Lbs. Hub And Bearing Mounting — Bolts Hub And Bearing Axle Hub — Jounce Bumper Mounting Bolt Remover, Hub/Bearing 8458 Leaf Spring Front Mount-To- —...
Page 52: Bushings
REAR SUSPENSION 2 - 29 it enough to allow access to spring pivot bolt. It may BUSHINGS be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring REMOVAL - LEAF SPRING FRONT BUSHING in place.
Page 53: Hub / Bearing Description
2 - 30 REAR SUSPENSION BUSHINGS (Continued) Fig. 5 TOOL 8459 MOUNTED FOR BUSHING Fig. 6 TOOL 8459 MOUNTED FOR BUSHING REMOVAL INSTALLATION 1 - BUSHING 1 - NUT 2 - BEARING 2 - WASHER 3 - WASHER 3 - BEARING 4 - NUT 4 - LEAF SPRING EYE 5 - BODY (8459-1)
Page 54: Operation
REAR SUSPENSION 2 - 31 HUB / BEARING (Continued) REMOVAL FRONT-WHEEL-DRIVE VEHICLES (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove wheel and tire. (Refer to 22 - TIRES/ WHEELS - REMOVAL) (3) Remove brake drum or disc brake caliper and rotor from hub and bearing.
Page 55 2 - 32 REAR SUSPENSION HUB / BEARING (Continued) (6) If hub and bearing cannot be removed from the (2) Raise vehicle. (Refer to LUBRICATION & axle by hand, use Remover, Special Tool 8458 (Fig. 9) MAINTENANCE/HOISTING - STANDARD PROCE- and following procedure to press the hub and bearing DURE) out of the axle.
Page 56: Installation
REAR SUSPENSION 2 - 33 HUB / BEARING (Continued) the outer joint of the driveshaft out of the hub/bear- INSTALLATION ing. (15) Remove the hub/bearing to axle mounting FRONT-WHEEL-DRIVE VEHICLES bolts (Fig. 13). (1) Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle.
Page 57 2 - 34 REAR SUSPENSION HUB / BEARING (Continued) Fig. 14 Removing/Installing Caliper (Left Side Shown) Fig. 12 Hub/Bearing Removal And Installation 1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST 1 - PARK BRAKE BRAKE SHOE 2 - DISC BRAKE CALIPER 2 - HUB/BEARING 3 - ADAPTER ABUTMENT 3 - PARK BRAKE BRAKE SHOE...
Page 58 REAR SUSPENSION 2 - 35 HUB / BEARING (Continued) (7) Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut (Fig. 16) on the stub shaft of the outer C/V joint.
Page 59: Jounce Bumper Description
2 - 36 REAR SUSPENSION HUB / BEARING (Continued) Fig. 19 Wheel Speed Sensor Fig. 20 Jounce Bumper 1 - MOUNTING BOLT 1 - JOUNCE BUMPER 2 - WHEEL SPEED SENSOR (19) Road test vehicle to ensure proper operation of the brake system. JOUNCE BUMPER DESCRIPTION There are two jounce bumpers used in the rear...
Page 60: Shock Absorber Description
REAR SUSPENSION 2 - 37 Tool 8526-2, on the tip of the Ball Joint Press screw SHOCK ABSORBER drive as shown (Fig. 22). DESCRIPTION There is one shock absorber on each side of the rear suspension. The top of each shock absorber is bolted to the frame rail.
Page 61: Assembly - Shock Absorber (Upper Bushing)
2 - 38 REAR SUSPENSION SHOCK ABSORBER (Continued) ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) NOTE: This procedure applies to load-leveling shock absorbers only. (1) Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw.
Page 62: Installation - Awd
REAR SUSPENSION 2 - 39 SPRING - AWD (Continued) (4) Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. (5) Loosen and remove the axle plate bolts from the rear axle (Fig.
Page 63: Spring - Fwd Description
2 - 40 REAR SUSPENSION SPRING - AWD (Continued) CAUTION: The following sequence must be fol- lowed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown below.
Page 64: Installation - Fwd
REAR SUSPENSION 2 - 41 SPRING - FWD (Continued) Fig. 33 Spring Plate Bolts 1 - SPRING PLATE Fig. 31 LIFTING POINT AND SPRING MOUNT 1 - BODY SILL AREA 2 - MOUNTING BOLTS 3 - SPRING MOUNTING BRACKET 4 - LEAF SPRING 5 - HOIST LIFT ARM 6 - WOODEN BLOCK Fig.
Page 65: Spring Mounts - Front Removal
2 - 42 REAR SUSPENSION SPRING - FWD (Continued) (8) Install spring plate bolts (Fig. 33). Tighten bolts to 95 N·m (70 ft. lbs.) torque. (9) Install lower shock absorber bolt. Do not tighten at this time. (10) Remove jack under axle. (11) Lower the vehicle and remove hoist arms and block of wood from under vehicle.
Page 66: Installation
REAR SUSPENSION 2 - 43 SPRING MOUNTS - FRONT (Continued) shock absorber lower mounting bolt. Do not fully tighten bolt at this time. (5) Lower the vehicle and remove hoist arms and block of wood from under vehicle. (6) Tighten the spring front pivot bolt to 156 N·m (115 ft.
Page 67: Installation
2 - 44 REAR SUSPENSION SPRING MOUNTS - REAR (Continued) (2) Install a jackstand under the side of the axle The stabilizer bar interconnects both sides of the having the leaf spring mount removed. Using the jack- rear axle and attaches to the rear frame rails using 2 stand, support the weight of the axle and leaf spring.
Page 68: Installation - Fwd
REAR SUSPENSION 2 - 45 STABILIZER BAR (Continued) • Stabilizer bar-to-link bolts — 61 N·m (45 ft. lbs.) (2) Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle. INSTALLATION - FWD Remove the track bar from the track bar mount.
Page 69 2 - 46 WHEEL ALIGNMENT WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT STANDARD PROCEDURE - CURB HEIGHT DESCRIPTION - WHEEL ALIGNMENT ..46 MEASUREMENT ..... . 54 DIAGNOSIS AND TESTING - SUSPENSION STANDARD PROCEDURE - CURB HEIGHT AND STEERING...
Page 70 WHEEL ALIGNMENT 2 - 47 WHEEL ALIGNMENT (Continued) CROSS CAMBER CROSS CASTER Cross camber is the difference between left and Cross caster is the difference between left and right camber. To achieve the cross camber reading, right caster. subtract the right side camber reading from the left. For example, if the left camber is +0.3°...
Page 71 2 - 48 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) TOE-OUT ON TURNS STEERING AXIS INCLINATION (S. A. I.) Toe-out on turns is the relative positioning of the Steering axis inclination is the angle between a front wheels while steering through a turn (Fig. 4). true vertical line starting at the center of the tire at This compensates for each front wheel’s turning the road contact point and a line drawn through the...
Page 72 WHEEL ALIGNMENT 2 - 49 WHEEL ALIGNMENT (Continued) THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle’s center line (Fig. 6). The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking).
Page 73 2 - 50 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Loose strut mount to body 7. Tighten strut attachment to specified attachment torque 8. Loose crossmember bolts 8. Tighten crossmember bolts to specified torque Front End Whine With 1.
Page 74 WHEEL ALIGNMENT 2 - 51 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Incorrect front wheel camber 3. Check and reset front wheel camber 4. Power steering gear imbalance 4. Replace power steering gear 5. Wheel braking 5. Correct braking condition causing lateral pull Excessive Steering Free 1.
Page 75 2 - 52 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) ment settings to the vehicle specifications for camber, assembly. If necessary use a wire hanger to sup- caster and toe-in. (Refer to 2 - SUSPENSION/ port the steering knuckle assembly or if required WHEEL ALIGNMENT - SPECIFICATIONS) remove the brake flex hose from the caliper assem- (4) If front camber and caster are not within spec-...
Page 76 WHEEL ALIGNMENT 2 - 53 WHEEL ALIGNMENT (Continued) (6) Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then install the nuts onto the bolts from the service pack- age (Fig. 10). Tighten the bolts just enough to hold the steering knuckle in position when adjusting cam- ber, while still allowing the steering knuckle to move in clevis bracket.
Page 77 2 - 54 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) Fig. 12 Front Wheel Toe Adjustment Fig. 11 Camber Adjustment Cam Bolt 1 - INNER TIE ROD SERRATION 1 - STEERING KNUCKLE 2 - OUTER TIE ROD JAM NUT 2 - CLEVIS BRACKET CAM STOP AREAS 3 - OUTER TIE ROD END 3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT 4 - INNER TIE ROD...
Page 78 WHEEL ALIGNMENT 2 - 55 WHEEL ALIGNMENT (Continued) CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES TIRE SALES CODE/TIRE SIZE FRONT REAR 754 mm ± 10 mm 770 mm ± 10 mm TM4 / 215/70 R 15 29.68 in. ± 0.39 in. 30.31 in.
Page 79 2 - 56 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) SPECIFICATIONS WHEEL ALIGNMENT NOTE: All specifications are given in degrees. NOTE: All wheel alignments are to be set at curb height. (Refer to 2 - SUSPENSION/WHEEL ALIGN- MENT - STANDARD PROCEDURE) FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER...
Page 80 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page HALF SHAFT - FRONT ..... 1 PROPELLER SHAFT .
Page 81: Half Shaft - Front
3 - 2 HALF SHAFT - FRONT HALF SHAFT - FRONT (Continued) Fig. 1 Unequal Length Half Shaft System 1 - STUB AXLE 8 - OUTER C/V JOINT 2 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT 3 - OUTER C/V JOINT BOOT 10 - INNER TRIPOD JOINT BOOT 4 - TUNED RUBBER DAMPER WEIGHT 11 - INNER TRIPOD JOINT...
Page 82 HALF SHAFT - FRONT 3 - 3 HALF SHAFT - FRONT (Continued) (3) Remove the wheel and tire assembly from the (7) Remove the disc brake caliper assembly from vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL) the steering knuckle. Caliper assembly is removed by (4) Remove the wave washer (Fig.
Page 83: Installation
3 - 4 HALF SHAFT - FRONT HALF SHAFT - FRONT (Continued) Fig. 6 Strut To Steering Knuckle Attaching Bolts Fig. 8 Tripod Joint Removal from Transaxle 1 - STRUT CLEVIS BRACKET 1 - INNER TRIPOD JOINT 2 - NUTS AND BOLTS 2 - TRANSAXLE 3 - STEERING KNUCKLE 3 - SPLINE...
Page 84 HALF SHAFT - FRONT 3 - 5 HALF SHAFT - FRONT (Continued) (9) Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper assembly under abutment steering knuckle, and then rotating top of caliper against top abutment.
Page 85: Specifications - Half Shaft - Front
3 - 6 HALF SHAFT - FRONT HALF SHAFT - FRONT (Continued) SPECIFICATIONS - HALF SHAFT - FRONT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolts, Caliper Adapter to Knuckle Nut, Hub Nuts, Front Wheel Lug Nut, Tie Rod End to Knuckle Nut, Strut Clevis to Knuckle 81 +90°...
Page 86 HALF SHAFT - FRONT 3 - 7 CV BOOT - INNER (Continued) (2) Install spider assembly onto interconnecting shaft (Fig. 16). Spider assembly must be installed on interconnecting shaft far enough to fully install spi- der retaining snap-ring. If the spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (Fig.
Page 87 3 - 8 HALF SHAFT - FRONT CV BOOT - INNER (Continued) (3) Install the spider assembly to interconnecting (6) Install inner CV joint seal boot to interconnect- shaft retaining snap-ring into groove on end of inter- ing shaft clamp evenly on sealing boot. connecting shaft (Fig.
Page 88 HALF SHAFT - FRONT 3 - 9 CV BOOT - INNER (Continued) CAUTION: Seal boot must not be dimpled, stretched joint housing. Remove the trim stick from between the or out of shape in any way. If seal boot is NOT sealing boot insert and the CV joint housing.
Page 89: Cv Boot - Outer Removal
3 - 10 HALF SHAFT - FRONT CV BOOT - INNER (Continued) LATCHING TYPE BOOT CLAMP CV BOOT - OUTER If seal boot uses low profile latching type boot clamp, use the following procedure to install the REMOVAL retaining clamp. (1) Remove half shaft assembly requiring boot (1) Place prongs of clamp locking tool in the holes replacement from vehicle.
Page 90 HALF SHAFT - FRONT 3 - 11 CV BOOT - OUTER (Continued) (3) Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly hous- ing. Put the remaining amount into the sealing boot. (4) Install outer CV joint seal boot retaining clamp, onto interconnecting shaft.
Page 91 3 - 12 HALF SHAFT - FRONT CV BOOT - OUTER (Continued) (6) Tighten nut on crimping tool C- 4975-A until jaws on tool are closed completely together, face to face (Fig. 32). Fig. 33 Crimping Tool Installed on Sealing Boot Clamp - Typical 1 - CLAMP Fig.
Page 92: Outer Cv Joint Bearing Shield Removal
HALF SHAFT - FRONT 3 - 13 OUTER CV JOINT BEARING SHIELD REMOVAL (1) Clamp half shaft in a vise by the interconnect- ing shaft. (2) Using a drift (Fig. 35) tap around the entire edge of the bearing shield until it is removed from the outer CV joint.
Page 93 3 - 14 HALF SHAFT - REAR HALF SHAFT - REAR TABLE OF CONTENTS page page HALF SHAFT - REAR SPECIFICATIONS - HALF SHAFT - FRONT . . . 16 DESCRIPTION ......14 CV BOOT - INNER/OUTER DIAGNOSIS AND TESTING - HALF SHAFT .
Page 94 HALF SHAFT - REAR 3 - 15 HALF SHAFT - REAR (Continued) REMOVAL (6) The half shaft is spring loaded. Compress inner half shaft joint slightly and pull downward to clear (1) Lift vehicle on hoist so that the wheels hang rear differential output flange.
Page 95 3 - 16 HALF SHAFT - REAR HALF SHAFT - REAR (Continued) Fig. 6 Cotter Pin, Nut Lock, And Wave Washer 1 - HUB NUT Fig. 5 Inner Half Shaft Bolts 2 - NUT LOCK 3 - COTTER PIN 1 - SHAFT 4 - SPRING WASHER 2 - FLANGE (6) Install rear wheel.
Page 96 HALF SHAFT - REAR 3 - 17 (4) Pull the boot back from the CV joint (Fig. 9). CV BOOT - INNER/OUTER REMOVAL (1) Remove half shaft from vehicle. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (2) Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft (Fig.
Page 97 3 - 18 HALF SHAFT - REAR CV BOOT - INNER/OUTER (Continued) (6) Remove the snap-ring holding the tripod (8) Remove the CV boot from the interconnecting assembly onto the interconnecting shaft (Fig. 11). shaft (Fig. 13). Fig. 13 Remove Boot Fig.
Page 98 HALF SHAFT - REAR 3 - 19 CV BOOT - INNER/OUTER (Continued) (4) Install the tripod assembly onto the intercon- (6) Install the new large diameter retaining clamp necting shaft (Fig. 15). onto the CV joint housing. (7) Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing.
Page 99 3 - 20 HALF SHAFT - REAR CV BOOT - INNER/OUTER (Continued) (10) Position the inner CV joint boot on intercon- necting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig.
Page 100 HALF SHAFT - REAR 3 - 21 CV BOOT - INNER/OUTER (Continued) CRIMP TYPE BOOT CLAMP LATCHING TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the fol- If seal boot uses low profile latching type boot lowing procedure to install the retaining clamp.
Page 101 3 - 22 PROPELLER SHAFT PROPELLER SHAFT TABLE OF CONTENTS page page PROPELLER SHAFT REMOVAL ......23 DESCRIPTION .
Page 102 PROPELLER SHAFT 3 - 23 PROPELLER SHAFT (Continued) to the rear driveline module of AWD equipped mod- (5) Lower propeller shaft assembly to ground, els. using care not to damage fore and aft flanges (Fig. The propeller shaft front half utilizes a CV joint at the PTU flange, and a plunging CV joint at the cen- INSTALLATION ter bearing location.
Page 103 3 - 24 REAR DRIVELINE MODULE REAR DRIVELINE MODULE TABLE OF CONTENTS page page REAR DRIVELINE MODULE OPERATION ......41 DESCRIPTION .
Page 104: Rear Driveline Module Description
REAR DRIVELINE MODULE 3 - 25 REAR DRIVELINE MODULE (Continued) Fig. 1 AWD Driveline Module Assembly 1 - TORQUE ARM 8 - WASHER 15 - PLUG-OVERRUNNING CLUTCH HOUSING DRAIN 2 - INPUT FLANGE 9 - BI-DIRECTIONAL OVERRUNNING CLUTCH (BOC) 16 - SNAP RING 3 - FLANGE NUT 10 - VISCOUS COUPLER 17 - BEARING...
Page 105 3 - 26 REAR DRIVELINE MODULE REAR DRIVELINE MODULE (Continued) • Wheel bearings Abnormal gear noise can be easily recognized. It • Engine produces a cycling tone that will be very pronounced • Transmission within a given speed range. The noise can occur dur- •...
Page 106: Diagnosis And Testing - Rear Driveline Module Operation
REAR DRIVELINE MODULE 3 - 27 REAR DRIVELINE MODULE (Continued) DIAGNOSIS AND TESTING - REAR DRIVELINE MODULE OPERATION Driveline module operation requires relatively straight-forward diagnosis. Refer to the following chart: DRIVELINE MODULE DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Rear wheels not 1) Bi-directional overrunning clutch 1) Replace overrunning clutch overrunning...
Page 107: Disassembly
3 - 28 REAR DRIVELINE MODULE REAR DRIVELINE MODULE (Continued) DISASSEMBLY (3) Remove input flange (Fig. 6). WARNING: Differential is only to be serviced as an assembly, and no disassembly is required. (1) Remove six torque arm-to-differential case bolts and remove torque arm assembly (Fig. 4). Fig.
Page 108 REAR DRIVELINE MODULE 3 - 29 REAR DRIVELINE MODULE (Continued) (5) Remove four overrunning clutch housing-to-dif- (10) Remove viscous coupler from differential pin- ferential assembly bolts (Fig. 8) and remove housing. ion shaft (Fig. 10). Fig. 8 Overrunning Clutch Housing Bolts Fig.
Page 109: Assembly
3 - 30 REAR DRIVELINE MODULE REAR DRIVELINE MODULE (Continued) (12) Remove overrunning clutch housing large (14) Remove output flange seals (Fig. 13). o-ring from differential assembly (Fig. 14). (13) Remove output flanges using suitable screw- drivers and wood blocks to protect casting (Fig. 12). Fig.
Page 110 REAR DRIVELINE MODULE 3 - 31 REAR DRIVELINE MODULE (Continued) Fig. 14 Drive Line Module 1 - NUT, INPUT FLANGE 6 - BEARING, FRONT 11 - VISCOUS COUPLER 2 - WASHER, INPUT FLANGE NUT 7 - SNAP RING, BEARING RETAINER 12 - O-RING, OVERRUNNING CLUTCH HOUSING 3 - INPUT FLANGE/SHIELD...
Page 111 3 - 32 REAR DRIVELINE MODULE REAR DRIVELINE MODULE (Continued) (4) Install viscous coupler to differential pinion (6) Install washer to overrunning clutch (Fig. 14). shaft (Fig. 17). (7) Install o-ring to overrunning clutch (Fig. 14). (8) Align overrunning clutch ground tab to 12 o’clock position (Fig.
Page 112 REAR DRIVELINE MODULE 3 - 33 REAR DRIVELINE MODULE (Continued) (10) Install and torque overrunning clutch hous- (12) Install flange/shield assembly (Fig. 23). ing-to-differential assembly bolts (Fig. 21) to 60 N·m (44 ft. lbs.). Fig. 23 Input Flange/Shield 1 - INPUT FLANGE/SHIELD Fig.
Page 113: Installation
3 - 34 REAR DRIVELINE MODULE REAR DRIVELINE MODULE (Continued) (14) Install torque arm assembly into position. (3) Remove transmission jack. Install and torque torque arm-to-differential assem- (4) Install and torque torque arm mount-to-body bly bolts (Fig. 25) to 60 N·m (44 ft. lbs.). bolts to 54 N·m (40 ft.
Page 114: Specifications - Rear Driveline Module
REAR DRIVELINE MODULE 3 - 35 REAR DRIVELINE MODULE (Continued) SPECIFICATIONS - REAR DRIVELINE MODULE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt, Driveline Module-to-Body — Bolt, Halfshaft-to-Ouput Flange — Bolt, Overrunning Clutch Housing-to-Differential — Bolt, Torque Arm-to-Differential Assembly —...
Page 115: Bi-Directional Overrunning Clutch Description
3 - 36 REAR DRIVELINE MODULE slippery surface. The BOC de-couples the rear driv- BI-DIRECTIONAL eline as soon the rear wheels begin to spin faster OVERRUNNING CLUTCH than the front wheels (front wheels locked) in order to provide increased braking stability. Furthermore DESCRIPTION the BOC also reduces the likelihood of throttle off The bi-directional overrunning clutch (BOC) (Fig.
Page 116 REAR DRIVELINE MODULE 3 - 37 BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) Fig. 28 Bi-directional Overrunning Clutch and Viscous Coupler 1 - POWERFLOW - BOC OVERUNNING 6 - VISCOUS COUPLER 2 - POWERFLOW - BOC LOCKED 7 - BOC ROLLER CAGE 3 - BOC GROUND TAB 8 - BOC INPUT SHAFT 4 - FRICTION BRAKE SHOES 9 - INPUT FLANGE...
Page 117 3 - 38 REAR DRIVELINE MODULE BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) OPERATION In order to achieve all-wheel drive operation in reverse, the overrunning clutch locking functional direc- tion must be reversible. The bi-directional overrunning clutch (BOC) changes the operational mode direction depending on the propeller shaft direction.
Page 118 REAR DRIVELINE MODULE 3 - 39 BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) STEADY STATE, HIGH SPEED, NO WHEEL SLIP The roller cage positions the rollers on the input shaft flats during low and high speed overrunning and during initial BOC lockup. The roller cage is rotating at input shaft (propeller shaft) speed at all times.
Page 119 3 - 40 REAR DRIVELINE MODULE BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) Fig. 34 BOC Operation During High Speed Lock-up Without High Speed Latch This lock-up is not desired, and requires the use of another mechanism to prevent the lock-up. The device that prevents undesired high-speed lock-up is called a high speed latch .
Page 120: Operation
REAR DRIVELINE MODULE 3 - 41 BI-DIRECTIONAL OVERRUNNING CLUTCH (Continued) At high speed, the rollers are forced outward to the outer race because of centrifugal force. At high speeds, the friction shoes can no longer prevent lock- up. When the teeth on the high-speed latch engage into the input shaft, it keeps the rollers centered above the flats because the tabs on the latch are locked into the cage.
Page 121: Standard Procedure - Differential
3 - 42 REAR DRIVELINE MODULE DIFFERENTIAL ASSEMBLY (Continued) When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns.
Page 122: Fluid
REAR DRIVELINE MODULE 3 - 43 FLUID - DIFFERENTIAL ASSEMBLY (Continued) (7) Using a suction gun (Fig. 42) or equivalent, fill (3) Remove overrunning clutch housing drain plug the differential assembly with 0.7 L (1.48 pts.) of and drain fluid (Fig. 43). Mopar Gear and Axle Lubricant (80W-90).
Page 123: Viscous Coupler Description
3 - 44 REAR DRIVELINE MODULE The inner plates are slotted around the radius and VISCOUS COUPLER the outer plates have holes in them. In the shear mode (normal operation), the plates are evenly DESCRIPTION spaced and the torque is created by the shearing of The heart of the all-wheel drive system is the the plates through the fluid and 90-100% of the inter-axle viscous coupling and bi-directional over-...
Page 124 REAR DRIVELINE MODULE 3 - 45 VISCOUS COUPLER (Continued) Fig. 46 Bi-directional Overrunning Clutch (BOC) and Viscous Coupler Powerflow 1 - POWERFLOW - BOC OVERUNNING 6 - VISCOUS COUPLER 2 - POWERFLOW - BOC LOCKED 7 - BOC ROLLER CAGE 3 - BOC GROUND TAB 8 - BOC INPUT SHAFT 4 - FRICTION BRAKE SHOES...
Page 125: Torque Arm Removal
3 - 46 REAR DRIVELINE MODULE TORQUE ARM REMOVAL (1) Raise vehicle on hoist. (2) Remove rear driveline module assembly. (Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR DRIV- ELINE MODULE - REMOVAL) (3) Remove six torque arm-to-differential assembly bolts (Fig. 47). Remove torque arm. Fig.
Page 126: Installation
REAR DRIVELINE MODULE 3 - 47 INPUT FLANGE SEAL (Continued) (5) Using suitable screwdriver, remove input (2) Install input flange (Fig. 52). flange seal from overrunning clutch housing (Fig. 50). Fig. 52 Input Flange 1 - INPUT FLANGE/SHIELD Fig. 50 Input Flange Seal Removal 1 - INPUT FLANGE SEAL (3) Install flange nut and washer.
Page 127: Output Flange Seal Removal
3 - 48 REAR DRIVELINE MODULE OUTPUT FLANGE SEAL REMOVAL (1) Raise vehicle on hoist. (2) Remove rear halfshaft inner joint at differen- tial output flange (Fig. 54). Fig. 55 Output Flange Removal Fig. 54 Inner Half Shaft Bolts 1 - WOOD BLOCK 1 - SHAFT 2 - PRYBAR 2 - FLANGE...
Page 128: Installation
REAR DRIVELINE MODULE 3 - 49 OUTPUT FLANGE SEAL (Continued) INSTALLATION (4) Install and torque bolts to 61 N·m (45 ft. lbs.) (Fig. 58). (1) Install output flange seal to differential hous- ing using tool C4171A and 8493 (Fig. 57). Fig.
Page 130 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 131 5 - 2 BRAKES - BASE DISC BRAKE CALIPER - FRONT DESCRIPTION - RHD ....38 REMOVAL OPERATION ......38 REMOVAL - FRONT DISC BRAKE CALIPER STANDARD PROCEDURE - MASTER (DISC/DISC BRAKES) .
Page 132: Brakes - Base
BRAKES - BASE 5 - 3 SUPPORT PLATE - DRUM BRAKE INSTALLATION REMOVAL ......64 INSTALLATION - PARKING BRAKE CABLE INSTALLATION .
Page 133: Warning
5 - 4 BRAKES - BASE BRAKES - BASE (Continued) come in contact with a hub mounted drum (drum for 1), for the installation of any metal fasteners into disc/drum brakes or drum-in-hat for disc/disc brakes) the shock tower. Because of the minimum clear- and hold it in place.
Page 134 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) RED BRAKE WARNING INDICATOR LAMP CONDITION POSSIBLE CAUSES CORRECTION RED BRAKE WARNING 1. Parking brake lever not fully 1. Release parking brake lever. LAMP ON released. 2. Parking brake warning lamp 2.
Page 135 5 - 6 BRAKES - BASE BRAKES - BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION SCRAPING (METAL-TO- 1. Foreign object interference with 1. Inspect brakes and remove foreign METAL). brakes. object. 2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and drums.
Page 136: Standard Procedure - Base Brake Bleeding
BRAKES - BASE 5 - 7 BRAKES - BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE PEDAL 1. One of the two hydraulic circuits 1. Inspect system for leaks. Check TRAVEL (ONE FRONT to the front brakes is malfunctioning. master cylinder for internal malfunction. WHEEL LOCKS UP DURING HARD BRAKING) PEDAL PULSATES/...
Page 137 5 - 8 BRAKES - BASE BRAKES - BASE (Continued) NOTE: The following wheel sequence should be CAUTION: “Just cracking” the bleeder screw often used when bleeding the brake hydraulic system. restricts fluid flow, allowing only a slow, weak fluid The use of this wheel sequence will ensure ade- discharge of fluid.
Page 138: Specifications
BRAKES - BASE 5 - 9 BRAKES - BASE (Continued) DESCRIPTION N·m Lbs. Lbs. Brake Tube Nuts — Brake Hose Intermediate — Bracket Bolt Brake Hose-To-Caliper — Mounting Bolt Disc Brake Caliper Guide — Pin Bolts Disc Brake Caliper Bleeder —...
Page 139: Brake Fluid Level Switch
5 - 10 BRAKES - BASE BRAKES - BASE (Continued) Installer, Dust Boot C-4689 or C-4842 BRAKE FLUID LEVEL SWITCH Tubes, Master Cylinder Bleed 8358 DESCRIPTION The brake fluid level switch is located in the brake fluid reservoir of the master cylinder (Fig. 4). OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the...
Page 140: Adjustable Pedal Switch
BRAKES - BASE 5 - 11 BRAKE FLUID LEVEL SWITCH (Continued) DIAGNOSIS AND TESTING - ADJUSTABLE PEDAL SWITCH Refer to Appropriate Diagnostic Information. REMOVAL NOTE: Before proceeding, review all Steering Col- umn and Airbag Warnings and Cautions. (Refer to 19 - STEERING/COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RESTRAINTS - WARNING) (1) Remove battery ground cable terminal from battery negative post and isolate.
Page 141: Installation
5 - 12 BRAKES - BASE ADJUSTABLE PEDAL SWITCH (Continued) Fig. 7 Steering Column Shrouds Fig. 9 Pedal Switch Retainers 1 - FIXED SHROUD 1 - LOWER SHROUD INTERIOR 2 - RETAINERS 2 - UPPER SHROUD 3 - CLOCKSPRING 4 - LOWER SHROUD (4) Install the lower shroud with adjustable pedal 5 - STEERING COLUMN switch.
Page 142: Diagnosis And Testing - Pedal Position Sensor
BRAKES - BASE 5 - 13 PEDAL POSITION SENSOR (Continued) (4) Move bulkhead connector toward left side of vehicle as far as its wires will allow. Do not over- stress wiring. (5) Remove two mounting screws securing pedal position sensor in place (Fig. 12). Fig.
Page 143: Hydraulic/Mechanical
5 - 14 BRAKES - BASE PEDAL POSITION SENSOR (Continued) (11) Turn key to OFF and remove scan tool from vehicle. (12) Road test the vehicle to ensure proper opera- tion of the adjustable brake system. HYDRAULIC/MECHANICAL DESCRIPTION DESCRIPTION - DISC BRAKES (FRONT) Each front disc brake consists of the following com- ponents: •...
Page 144: Description - Disc Brakes (Rear)
BRAKES - BASE 5 - 15 HYDRAULIC/MECHANICAL (Continued) DESCRIPTION - DISC BRAKES (REAR) There are several distinctive features to the rear disc brakes on this vehicle (Fig. 17). The single pis- ton, floating caliper rear disc brake system includes a hub and bearing assembly, adapter, rotor, caliper, and brake shoes.
Page 145: Brakes - Base
5 - 16 BRAKES - BASE HYDRAULIC/MECHANICAL (Continued) DESCRIPTION - DRUM BRAKES (REAR) sary. Fluid level should always be checked after replacing shoes. This vehicle’s rear wheel drum brakes are a two- shoe, internal-expanding type with an automatic adjuster screw. The automatic adjuster screw is located directly below the wheel cylinder that is mounted near the top of the brake assembly (Fig.
Page 146: Brake Lines
BRAKES - BASE 5 - 17 BRAKE LINES BRAKE PADS/SHOES - FRONT DESCRIPTION - BRAKE TUBES AND HOSES REMOVAL The brake tubes are steel with a corrosion-resis- tant nylon coating applied to the external surfaces. REMOVAL - FRONT DISC BRAKE SHOES The flex hoses are made of reinforced rubber with fit- (DISC/DISC BRAKES) tings at each end.
Page 147: Removal - Front Disc Brake Shoes (Disc/Drum Brakes)
5 - 18 BRAKES - BASE BRAKE PADS/SHOES - FRONT (Continued) (4) Remove the disc brake caliper from the disc brake adapter and hang out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.
Page 148: Installation Installation - Front Disc Brake
BRAKES - BASE 5 - 19 BRAKE PADS/SHOES - FRONT (Continued) Replace both disc brake shoes (inboard and out- (12) Install the wheel and tire assemblies. Tighten board) on each caliper. It is necessary to replace the the wheel mounting nuts in proper sequence until all shoes on the opposite side of the vehicle as well as nuts are torqued to half specification, then repeat the the shoes failing inspection.
Page 149 5 - 20 BRAKES - BASE BRAKE PADS/SHOES - REAR DISC (Continued) (2) Remove rear wheel and tire assemblies from (5) Support caliper to prevent the weight of the vehicle. caliper from damaging the flexible brake hose (Fig. (3) Remove the caliper to adapter guide pin bolts 25).
Page 150: Cleaning - Disc Brake Shoes
BRAKES - BASE 5 - 21 BRAKE PADS/SHOES - REAR DISC (Continued) wear indicators on the shoes (if equipped) and the brake rotors. If a visual inspection does not adequately deter- mine the condition of the lining, a physical check will be necessary.
Page 151: Brake Pads/Shoes - Rear Drum
5 - 22 BRAKES - BASE BRAKE PADS/SHOES - REAR DISC (Continued) CAUTION: When installing the caliper guide pin (4) Create slack in the rear park brake cables. bolts extreme caution should be taken not to Slack is created by grabbing exposed section of front park brake cable and pulling it down and rearward.
Page 152 BRAKES - BASE 5 - 23 BRAKE PADS/SHOES - REAR DRUM (Continued) (6) Remove adjustment lever (Fig. 29) from leading brake shoe. Fig. 31 Brake Shoe Lower Return Spring 1 - TRAILING BRAKE SHOE Fig. 29 Adjustment Lever 2 - LEADING BRAKE SHOE 3 - RETURN SPRING 1 - AUTOMATIC ADJUSTER 2 - LEADING BRAKE SHOE...
Page 153 5 - 24 BRAKES - BASE BRAKE PADS/SHOES - REAR DRUM (Continued) (9) Remove the brake shoe to brake shoe upper (11) Remove the trailing brake shoe assembly from return spring (Fig. 33). the brake support plate, park brake actuating lever and park brake actuating strut (Fig.
Page 154: Inspection - Rear Drum Brake Shoe Lining
BRAKES - BASE 5 - 25 BRAKE PADS/SHOES - REAR DRUM (Continued) (13) Remove the park brake actuator (Fig. 37) from the leading brake shoe and transfer to the replacement brake shoe. Fig. 38 Brake Support Plate Contact Areas 1 - REAR BRAKE SUPPORT PLATE Fig.
Page 155: Adjustments Adjustment - Rear Drum Brake Shoes
5 - 26 BRAKES - BASE BRAKE PADS/SHOES - REAR DRUM (Continued) CAUTION: When installing the tension clip on the (1) Raise the vehicle. (Refer to LUBRICATION & automatic adjuster, it must be located on only the MAINTENANCE/HOISTING - STANDARD PROCE- DURE).
Page 156: Disassembly
BRAKES - BASE 5 - 27 DISC BRAKE CALIPER - FRONT (Continued) allow the brake fluid to drain out of the master cyl- DISASSEMBLY - CALIPER PISTON AND SEAL inder reservoir when the lines are opened. (2) Raise the vehicle. Refer to HOISTING in WARNING: UNDER NO CONDITION SHOULD HIGH LUBRICATION AND MAINTENANCE.
Page 157: Cleaning - Caliper
5 - 28 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) osene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These flu- ids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: •...
Page 158: Installation
BRAKES - BASE 5 - 29 DISC BRAKE CALIPER - FRONT (Continued) Fig. 42 Installing New Piston Seal 1 - CALIPER 2 - PISTON SEAL 3 - SEAL GROOVE Fig. 44 Installing Dust Boot 1 - HAMMER 2 - SPECIAL TOOL C-4171 3 - SPECIAL TOOL C-4689 or C-4842 4 - CALIPER INSTALLATION...
Page 159: Installation - Front Disc Brake Caliper (Disc/Drum Brakes)
5 - 30 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) should be taken not to cross thread the caliper (3) Align the caliper guide pin bolt holes with the guide pin bolts. guide pins. Install the caliper guide pin bolts and (4) Install the anti-rattle clip on the outboard side tighten them to a torque of 35 N·m (26 ft.
Page 160: Disassembly - Caliper Piston And Seal
BRAKES - BASE 5 - 31 DISC BRAKE CALIPER - REAR (Continued) NOTE: Before disassembling the brake caliper, clean and inspect it. Refer to CLEANING AND INSPECTION in this section. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle’s brake system.
Page 161: Cleaning - Caliper
5 - 32 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) osene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These flu- ids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: •...
Page 162: Installation - Rear Disc Brake Caliper
BRAKES - BASE 5 - 33 DISC BRAKE CALIPER - REAR (Continued) Fig. 49 Installing Piston Into Caliper Bore 1 - BOOT 2 - PISTON Fig. 50 Installing Dust Boot 3 - CALIPER 1 - HAMMER 2 - SPECIAL TOOL C-4171 (5) Position the dust boot into the counterbore of 3 - SPECIAL TOOL C-4689 or C-4842 the caliper assembly piston bore.
Page 163: Disc Brake Caliper Adapter Removal - Front Disc Brake Caliper Adapter
5 - 34 BRAKES - BASE DISC BRAKE CALIPER ADAPTER REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove front wheel and tire assembly, disc brake caliper and brake shoes. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - REMOVAL) (3) Remove two bolts fastening adapter to steering...
Page 164: Drum Removal
BRAKES - BASE 5 - 35 DISC BRAKE CALIPER GUIDE PINS (Continued) (3) Install the disc brake caliper over the brake FLUID shoes on the brake caliper adapter. (4) Align the caliper guide pin bolt holes with the DIAGNOSIS AND TESTING - BRAKE FLUID guide pins.
Page 165: Junction Block
5 - 36 BRAKES - BASE FLUID (Continued) CAUTION: Never use any type of a petroleum-based (c) Disconnect the vacuum hose connector at the fluid in the brake hydraulic system. Use of such tank built into the battery tray. (d) Remove the screw securing the coolant filler type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the neck to the battery tray.
Page 166: Master Cylinder Description Description
BRAKES - BASE 5 - 37 JUNCTION BLOCK (Continued) (3) Install the four chassis brake tubes into the outlet ports of the junction block. Tighten all 6 tube nuts to a torque of 17 N·m (145 in. lbs.). (4) If the vehicle is equipped with speed control, perform the following: (a) Install the speed control servo with its mounting nuts.
Page 167: Description - Rhd
5 - 38 BRAKES - BASE MASTER CYLINDER (Continued) CAUTION: Do not hone the bore of the cylinder as (1) Clamp master cylinder in a vise. this will remove the anodized surface from the bore. NOTE: Use correct bleeder tubes when bleeding DESCRIPTION - RHD master cylinder.
Page 168: Removal Removal - Lhd
BRAKES - BASE 5 - 39 MASTER CYLINDER (Continued) NOTE: Make sure open ends of bleeder tubes stay below surface of brake fluid once reservoir is filled to proper level. (3) Fill brake fluid reservoir with Mopar brake fluid or equivalent conforming to DOT 3 (DOT 4 and DOT 4+ are acceptable) specifications.
Page 169: Removal - Rhd
5 - 40 BRAKES - BASE MASTER CYLINDER (Continued) CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster.
Page 170: Assembly - Master Cylinder (Fluid Reservoir)
BRAKES - BASE 5 - 41 MASTER CYLINDER (Continued) (5) Using correct size pin punch, remove the two (2) Lubricate reservoir mounting area with fresh retaining pins between the fluid reservoir and master clean brake fluid. Place reservoir in position over cylinder housing (Fig.
Page 171: Installation - Rhd
5 - 42 BRAKES - BASE MASTER CYLINDER (Continued) (5) Install wiring harness connector to brake fluid (11) Road test vehicle to ensure proper operation of level switch mounted in brake fluid reservoir (Fig. brakes. 57). (6) Install battery, clamp and nut. PEDAL - ADJUSTABLE (7) Install battery shield.
Page 172: Diagnosis And Testing - Adjustable Pedal System
BRAKES - BASE 5 - 43 PEDAL - ADJUSTABLE (Continued) ing pedal adjustment, the APM will monitor pedal (4) Disconnect parking brake release link at position sensor voltage. If the APM does not detect release handle. expected voltage change within 3 seconds, it will cut (5) Compress tabs on sides of data link diagnostic power to the adjustable pedal motor.
Page 173 5 - 44 BRAKES - BASE PEDAL - ADJUSTABLE (Continued) Fig. 64 Steering Column Shrouds Fig. 66 Shift Cable At Steering Column 1 - FIXED SHROUD 1 - SHIFT LEVER MECHANISM 2 - UPPER SHROUD 2 - SHIFT CABLE 3 - CLOCKSPRING 3 - BRACKET 4 - LOWER SHROUD 4 - PRNDL CABLE...
Page 174: Installation
BRAKES - BASE 5 - 45 PEDAL - ADJUSTABLE (Continued) (19) Loosen two lower column mounting nuts. (24) Disconnect pedal wiring harness connector (20) Remove two upper column mounting nuts. (Fig. 69). (21) Remove the steering column. (25) Remove pedal wiring harness from clips along (22) Remove dash seal silencer shell over steering pedal bracket.
Page 175 5 - 46 BRAKES - BASE PEDAL - ADJUSTABLE (Continued) (9) Install dash seal silencer shell over steering column intermediate shaft and fasten in place (Fig. 68). (10) Install the steering column on the mounting studs. Install the two upper and two lower mounting nuts.
Page 176: Pedal Torque Shaft - Rhd Removal
BRAKES - BASE 5 - 47 PEDAL - ADJUSTABLE (Continued) (27) Install lower steering column cover/knee the link from the torque shaft. Discard the retaining blocker (Fig. 62). clip. It is not to be reused. Replace with a new clip (28) Install silencer panel below lower steering col- when reassembled.
Page 177: Power Brake Booster Description
5 - 48 BRAKES - BASE PEDAL TORQUE SHAFT - RHD (Continued) CAUTION: Do not reuse the original brake lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted.
Page 178: Operation
BRAKES - BASE 5 - 49 POWER BRAKE BOOSTER (Continued) All vehicles use a 270 mm single diaphragm vac- As the brake pedal is depressed, the power brake uum power brake booster. booster’s input rod moves forward (Fig. 75). This Vehicles equipped with Disc/Disc brakes use a dif- opens and closes valves in the power booster allowing ferent power brake booster than vehicles equipped...
Page 179: Removal Removal - Lhd
5 - 50 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (4) Using vacuum line pliers, close off the vacuum (a) Disconnect wiring harness connector from supply hose near the booster, but before the vacuum the speed control servo. gauge, then observe the vacuum gauge. (b) Remove the two servo mounting nuts.
Page 180 BRAKES - BASE 5 - 51 POWER BRAKE BOOSTER (Continued) Fig. 78 Master Cylinder Mounting Fig. 79 Vacuum Booster Input Rod Retaining Pin 1 - MASTER CYLINDER MOUNTING NUTS 1 - BRAKE PEDAL 2 - MASTER CYLINDER 2 - INPUT ROD 3 - SECONDARY TUBE NUT AT ICU 3 - SCREWDRIVER 4 - PRIMARY TUBE NUT AT ICU...
Page 181: Removal - Rhd
5 - 52 BRAKES - BASE POWER BRAKE BOOSTER (Continued) Fig. 81 Booster Removal/Installation Fig. 82 RHD Master Cylinder And Power Brake Booster REMOVAL - RHD 1 - POWER BRAKE BOOSTER 2 - BRAKE FLUID LEVEL SWITCH CAUTION: Reserve vacuum in power brake booster 3 - FLUID RESERVOIR must be pumped down (removed) before removing 4 - MASTER CYLINDER...
Page 182: Installation
BRAKES - BASE 5 - 53 POWER BRAKE BOOSTER (Continued) (19) Remove the three easily accessed mounting nuts attaching power brake booster to dash panel and loosen fourth (Fig. 85). As fourth nut is loosened, push the booster forward periodically until the nut can be completely removed.
Page 183 5 - 54 BRAKES - BASE POWER BRAKE BOOSTER (Continued) removed for some service, a new switch must be installed and adjusted. (5) Remove and replace the brake lamp switch with a NEW switch. (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING EXTERIOR/BRAKE LAMP SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/...
Page 184: Installation - Rhd
BRAKES - BASE 5 - 55 POWER BRAKE BOOSTER (Continued) (12) Connect wiring harness connector to brake fluid level switch in the master cylinder fluid reser- voir (Fig. 77). (13) Connect primary and secondary brake tubes to ABS ICU or non-ABS junction block (Fig. 78). Tighten the tube nuts to 17 N·m (145 in lbs.).
Page 185: Proportioning Valve Description - Proportioning Valve (Height Sensing)
5 - 56 BRAKES - BASE POWER BRAKE BOOSTER (Continued) PROPORTIONING VALVE DESCRIPTION - PROPORTIONING VALVE (HEIGHT SENSING) NOTE: Only vehicles without antilock brakes (ABS) have a proportioning valve. Vehicles with ABS uti- lize electronic brake distribution which is controlled through the ABS integrated control unit.
Page 186: Operation - Proportioning Valve (Height Sensing)
BRAKES - BASE 5 - 57 PROPORTIONING VALVE (Continued) OPERATION - PROPORTIONING VALVE propriate reduction in hydraulic pressure potentially could result in increased stopping distance of the (HEIGHT SENSING) vehicle. Vehicles not equipped with ABS use a height sens- When a premature rear wheel skid is obtained on a ing proportioning valve.
Page 187: Removal - Proportioning Valve (Height Sensing)
5 - 58 BRAKES - BASE PROPORTIONING VALVE (Continued) (8) With the aid of a helper, apply pressure to the (9) Remove the pressure test fittings and pressure brake pedal until a pressure of 6895 kPa (1000 psi) is gauges from the proportioning valve. obtained on the proportioning valve inlet gauge.
Page 188: Installation - Proportioning Valve (Height Sensing)
BRAKES - BASE 5 - 59 PROPORTIONING VALVE (Continued) INSTALLATION - PROPORTIONING VALVE Some discoloration or wear of the rotor surface is normal and does not require resurfacing when lin- (HEIGHT SENSING) ings are replaced. If cracks or burned spots are evi- (1) Install the end of the actuator rod through the dent, the rotor must be replaced.
Page 189 5 - 60 BRAKES - BASE ROTOR (Continued) Fig. 95 Checking Rotor Runout 1 - SPECIAL TOOL SP-1910 2 - 10 MILLIMETERS FROM EDGE 3 - DISC SURFACE 4 - SPECIAL TOOL C-3339 Fig. 94 Checking Rotor For Thickness 1 - CALIPER ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of...
Page 190: Standard Procedure - Brake Rotor Machining
BRAKES - BASE 5 - 61 ROTOR (Continued) Recheck brake rotor runout to see if the runout is now within specifications. (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/ROTOR SPECIFICA- TIONS) If runout is not within specifications, reface or replace the brake rotor. (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/ROTORS STANDARD PROCEDURE)
Page 191: Removal - Front Brake Rotor
5 - 62 BRAKES - BASE ROTOR (Continued) REMOVAL - FRONT BRAKE ROTOR (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. (2) Remove the front wheel and tire assembly. (3) Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Fig.
Page 192: Specifications Brake Rotor
BRAKES - BASE 5 - 63 ROTOR (Continued) tion, then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). (5) Lower vehicle to the ground. SPECIFICATIONS BRAKE ROTOR When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED.
Page 193: Support Plate - Drum Brake Removal
5 - 64 BRAKES - BASE (11) Remove the rear hub and bearing. (Refer to 2 SUPPORT PLATE - DRUM SUSPENSION/REAR/HUB BEARING BRAKE REMOVAL) (12) Remove the rear brake support plate from the REMOVAL rear axle. (1) Using a brake pedal depressor, move and INSTALLATION secure brake pedal to a position past its first 1 inch of travel.
Page 194: Wheel Cylinders Removal
BRAKES - BASE 5 - 65 SUPPORT PLATE - DRUM BRAKE (Continued) (11) Install wheel and tire. (3) Install brake tube into wheel cylinder. Tighten (12) Tighten wheel stud nuts to 135 N·m (100 ft. tube nut to a torque of 17 N·m (145 in. lbs.) torque. lbs.).
Page 195: Description - Export
5 - 66 BRAKES - BASE PARKING BRAKE (Continued) The vehicle has four flexible steel parking brake ing the parking brake lever (pedal) or the parking cables. They are: brake cables. • Front This parking brake lever (pedal) mechanism is •...
Page 196: Standard Procedure - Parking Brake Automatic Adjuster Tension Reset
BRAKES - BASE 5 - 67 PARKING BRAKE (Continued) CABLES - PARKING BRAKE REMOVAL REMOVAL - PARKING BRAKE CABLE (FRONT) (1) Raise vehicle on jackstands or centered on a hoist. (Refer to LUBRICATION & MAINTENANCE/ HOISTING - STANDARD PROCEDURE). (2) Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly.
Page 197: Removal - Parking Brake Cable (Intermediate)
5 - 68 BRAKES - BASE CABLES - PARKING BRAKE (Continued) REMOVAL - PARKING BRAKE CABLE (INTERMEDIATE) (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE). (2) Manually lock out the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly.
Page 198: Removal - Parking Brake Cable (Right Rear)
BRAKES - BASE 5 - 69 CABLES - PARKING BRAKE (Continued) Fig. 112 Intermediate Cable Attachment To Right Fig. 113 Locking Out Automatic Adjuster 1 - RIGHT REAR PARKING BRAKE CABLE 2 - LOCKING NUT 1 - PARK BRAKE CABLE 3 - INTERMEDIATE PARKING BRAKE CABLE 2 - REAR BODY OUTRIGGER BRACKET 3 - LOCKING PLIERS...
Page 199: Removal - Parking Brake Cable (Left Rear)
5 - 70 BRAKES - BASE CABLES - PARKING BRAKE (Continued) (4) Create slack in rear park brake cables by lock- ing out the automatic adjuster as described here. Grasp an exposed section of front park brake cable near the equalizer and pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body outrigger bracket (Fig.
Page 200: Installation - Parking Brake Cable
BRAKES - BASE 5 - 71 CABLES - PARKING BRAKE (Continued) INSTALLATION INSTALLATION - PARKING BRAKE CABLE (FRONT) (1) Pass front parking brake cable assembly through hole in floor pan from the inside of the vehi- cle. (2) Pass cable strand button through the hole in the lever (pedal) assembly bracket.
Page 201: Installation - Parking Brake Cable (Right Rear)
5 - 72 BRAKES - BASE CABLES - PARKING BRAKE (Continued) (7) Install and position the foam collar on the (7) Remove the locking pliers from the front park parking brake cable to prevent it from rattling brake cable. This will automatically adjust the park against the vehicle’s floor.
Page 202: Installation
BRAKES - BASE 5 - 73 LEVER - PARKING BRAKE (Continued) (3) Remove sill scuff plate from left door sill. (4) Remove the left side kick panel. (5) Remove the silencer panel under the instru- ment panel. (6) Remove the steering column cover from the lower instrument panel.
Page 203: Lever - Parking Brake (Export)
5 - 74 BRAKES - BASE LEVER - PARKING BRAKE (Continued) NOTE: If the original lever assembly is being used, the lever mechanism auto adjuster spring tension will need to be reset. (Refer to 5 - BRAKES/PARK- ING BRAKE - STANDARD PROCEDURE) (14) Lower vehicle.
Page 204: Installation - Parking Brake Lever And Front Cable
BRAKES - BASE 5 - 75 LEVER - PARKING BRAKE (EXPORT) (Continued) (12) Compress the parking brake cable retainer by (12) Remove the locking pliers from the front park- sliding a 14 mm wrench over the cable retainer and ing brake cable. This will allow the adjuster in the compress the three (3) retaining fingers.
Page 205 5 - 76 BRAKES - BASE SHOES - PARKING BRAKE (Continued) (5) AWD only - Remove the spring washer (Fig. ing pliers on the front park brake cable just rearward 126) from the stub shaft of the outer C/V joint. of the second body outrigger bracket (Fig.
Page 206 BRAKES - BASE 5 - 77 SHOES - PARKING BRAKE (Continued) Fig. 130 Removing/Installing Caliper Fig. 132 Park Brake Cable Attachment To Actuator 1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST 1 - ADAPTER 2 - DISC BRAKE CALIPER 2 - PARK BRAKE CABLE 3 - ADAPTER ABUTMENT 3 - ACTUATOR...
Page 207 5 - 78 BRAKES - BASE SHOES - PARKING BRAKE (Continued) (16) AWD only - Remove ABS wheel speed sensor head from hub/bearing (Fig. 134). Fig. 135 Sensor Connection At Hub And Bearing 1 - SECONDARY SENSOR RETAINING CLIP 2 - METAL SENSOR RETAINING CLIP Fig.
Page 208 BRAKES - BASE 5 - 79 SHOES - PARKING BRAKE (Continued) Fig. 137 Hub/Bearing Removal/Installation (AWD Fig. 138 Hub/Bearing Removal From Caliper Adapter Shown) 1 - SPECIAL TOOL 8214-1 2 - PARK BRAKE CABLE 1 - PARK BRAKE BRAKE SHOE 3 - DISC BRAKE CALIPER ADAPTER 2 - OUTER C/V JOINT 4 - HUB/BEARING...
Page 209 5 - 80 BRAKES - BASE SHOES - PARKING BRAKE (Continued) (22) Remove the lower return spring (Fig. 140) (24) Remove the adjuster (Fig. 142) from the lead- from the leading and trailing park brake shoes. ing and trailing park brake shoe. Fig.
Page 210: Installation
BRAKES - BASE 5 - 81 SHOES - PARKING BRAKE (Continued) (26) Remove the upper return springs (Fig. 144) (28) Remove the trailing park brake shoe from the from the trailing park brake shoe. adapter. (29) Remove the park brake shoe actuator from the adapter and inspect for signs of abnormal wear and binding at the pivot point.
Page 211 5 - 82 BRAKES - BASE SHOES - PARKING BRAKE (Continued) (15) Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on the park brake cable retainer are expanded out to ensure the cable will not pull out of the adapter.
Page 212: Adjustments
BRAKES - BASE 5 - 83 SHOES - PARKING BRAKE (Continued) (5) Using Brake Shoe Gauge, Special Tool C-3919, ADJUSTMENTS or equivalent, accurately measure the inside diam- eter of the park brake drum portion of the rotor (Fig. ADJUSTMENT - PARKING BRAKE SHOES 148).
Page 213 5 - 84 BRAKES - BASE SHOES - PARKING BRAKE (Continued) (7) Reduce the inside diameter measurement of (9) Using the star wheel adjuster, adjust the park the brake drum that was taken using Special Tool brake shoes until the lining on the park brake shoes C-3919 by 1/64 of an inch.
Page 214 BRAKES - ABS 5 - 85 BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS INSTALLATION ......90 DESCRIPTION REAR WHEEL SPEED SENSOR - FWD DESCRIPTION - ANTILOCK BRAKE...
Page 215: Brakes - Abs
5 - 86 BRAKES - ABS BRAKES - ABS (Continued) DESCRIPTION - ELECTRONIC VARIABLE ulated to prevent any wheel from locking. Each wheel circuit is designed with a set of electric sole- BRAKE PROPORTIONING noids to allow modulation, although for vehicle sta- Vehicles equipped with ABS use electronic variable bility, both rear wheel solenoids receive the same brake proportioning (EVBP) to balance front-to-rear...
Page 216: Operation - Electronic Variable Brake Proportioning
BRAKES - ABS 5 - 87 BRAKES - ABS (Continued) black tire marks since the wheel never reaches a pressure to the rear brakes. This back-and-forth pro- fully locked condition. However, tire marks may be cess will continue until the required slip difference is noticeable as light patched marks.
Page 217: Caution
5 - 88 BRAKES - ABS BRAKES - ABS (Continued) “thermo-protection mode,” the traction control func- CAUTION: An attempt to remove or disconnect cer- tion lamp illuminates TRAC OFF; note that no trou- tain system components may result in improper ble code is registered.
Page 218: Specifications
BRAKES - ABS 5 - 89 BRAKES - ABS (Continued) The ABS portion of the brake system must be bled TONE WHEEL RUNOUT separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. DESCRIPTION SPECIFICATION BLEEDING Front Tone Wheel 0.15 mm (0.006 in.)
Page 219: Rear Wheel Speed Sensor - Awd Removal
5 - 90 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) (2) Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips.
Page 220: Rear Wheel Speed Sensor - Fwd Removal
BRAKES - ABS 5 - 91 REAR WHEEL SPEED SENSOR - AWD (Continued) (5) Install metal routing clip on speed sensor cable the brake hose will require replacement of the brake and mount it to rear of axle with mounting bolt. hose if damaged during removal or installation of Tighten mounting bolt to 16 N·m (140 in.
Page 221: Tone Wheel
5 - 92 BRAKES - ABS REAR WHEEL SPEED SENSOR - FWD (Continued) Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. • missing, chipped, or broken teeth • contact with the wheel speed sensor •...
Page 222: Hydraulic/Mechanical
BRAKES - ABS 5 - 93 TRACTION CONTROL SWITCH (Continued) HYDRAULIC/MECHANICAL OPERATION - HYDRAULIC CIRCUITS AND VALVES The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The following paragraphs explain how this works.
Page 223 5 - 94 BRAKES - ABS HYDRAULIC/MECHANICAL (Continued) ABS PRIMARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 7) 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 224 BRAKES - ABS 5 - 95 HYDRAULIC/MECHANICAL (Continued) ABS SECONDARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 8) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding.
Page 225 5 - 96 BRAKES - ABS HYDRAULIC/MECHANICAL (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 9) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle.
Page 226 BRAKES - ABS 5 - 97 HYDRAULIC/MECHANICAL (Continued) • The pump/motor is switched on so that the ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID brake fluid from the low pressure accumulators is VALVE, AND SHUTTLE VALVE FUNCTION (ABS returned to the master cylinder circuits. WITH TRACTION CONTROL) •...
Page 227 5 - 98 BRAKES - ABS HYDRAULIC/MECHANICAL (Continued) ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 11) shows the vehicle in the ABS braking mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed.
Page 228: Hcu (Hydraulic Control Unit) Description
BRAKES - ABS 5 - 99 pressure that the HCU pump/motor is sending to the HCU (HYDRAULIC CONTROL front (driving) wheels when traction control is being UNIT) applied. The rear brakes need to be isolated from the master cylinder when traction control is being DESCRIPTION applied so the rear wheels do not drag.
Page 229: Icu (Integrated Control Unit) Description
5 - 100 BRAKES - ABS Two different ICU’s (HCU and CAB) are used on ICU (INTEGRATED CONTROL this vehicle depending on whether or not the vehicle UNIT) is equipped with traction control. The HCU on a vehicle equipped with traction control has a valve DESCRIPTION block that is approximately one inch longer than a The hydraulic control unit (HCU) and the control-...
Page 230: Removal - Rhd
BRAKES - ABS 5 - 101 ICU (INTEGRATED CONTROL UNIT) (Continued) (7) Using a brake pedal depressor, move and lock (16) Remove the pinch bolt and disconnect the the brake pedal to a position past the first inch of steering shaft coupling. pedal travel.
Page 231 5 - 102 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 17 CAB 24-Way Connector Fig. 16 ICU MOUNTING BOLTS 1 - CAB WIRING HARNESS 1 - ICU MOUNTING BOLTS 2 - 24–WAY CONNECTOR 2 - COUPLER 3 - FLOOR PAN 4 - HCU draining out of the master cylinder when the 5 - CAB...
Page 232: Disassembly - Icu
BRAKES - ABS 5 - 103 ICU (INTEGRATED CONTROL UNIT) (Continued) (7) Remove the brake tubes (6) from the inlet and (9) Remove ICU and the mounting bracket as a outlet ports on the HCU. (Fig. 19). unit from the vehicle. (10) Remove the 3 bolts (Fig.
Page 233: Installation Installation - Lhd
5 - 104 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) (Continued) Fig. 24 (TYPICAL) Remove/Install CAB Fig. 22 INTEGRATED CONTROL UNIT (ICU) 1 - CAB 1 - PUMP/MOTOR 2 - HCU VALVES 2 - HCU 3 - HCU VALVE BLOCK 3 - PUMP/MOTOR CONNECTOR 4 - CAB (4) Install the silencer on top of the dash seal (Fig.
Page 234: Installation - Rhd
BRAKES - ABS 5 - 105 ICU (INTEGRATED CONTROL UNIT) (Continued) NOTE: Before installing the 24–way connector in (2) Install the ICU and its mounting bracket as an the CAB be sure the seal is properly installed in the assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the connector.
Page 235 5 - 106 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) (Continued) (5) Clip the cab wiring harness (Fig. 17) to the ICU mounting bracket. (6) Install the routing clips (Fig. 25) on the brake tubes. (7) Lower the vehicle. (8) Connect negative cable back on negative post of the battery.
Page 236 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH INSTALLATION ......8 DESCRIPTION .
Page 237 6 - 2 CLUTCH CLUTCH (Continued) Fig. 2 Clutch Disc and Pressure Plate—2.5L TD Engines 1 - FLYWHEEL 3 - PRESSURE PLATE 2 - DISC RELEASE SYSTEM All models utilize a hydraulic clutch release sys- tem, conisting of a clutch master cylinder attached to the clutch pedal (Fig.
Page 238: Clutch
CLUTCH 6 - 3 CLUTCH (Continued) Fig. 5 Release Bearing and Lever 1 - RELEASE LEVER 2 - RELEASE BEARING Fig. 4 Slave Cylinder Removal/Installation 1 - MOUNTING HOLE inspection will then determine the problem after road 2 - SLAVE CYLINDER testing.
Page 239 6 - 4 CLUTCH CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc damaged or distorted. Replace modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD). Clutch misalignment. Verify modular clutch pilot plate alignment to crankshaft. Replace the modular clutch assembly (2.4L Gas) or clutch cover and disc (2.5L TD) if the pilot plate is loose or bent.
Page 240: Diagnosis And Testing - Drive Plate
CLUTCH 6 - 5 CLUTCH (Continued) SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON Clutch disc hub splines damaged Clean, smooth, and lubricate disc and shaft INPUT SHAFT SPLINES during installation splines. Replace modular clutch assembly, or clutch disc, and/or input shaft if splines are severely damaged.
Page 241: Diagnosis And Testing - Clutch Cover And Disc Runout
6 - 6 CLUTCH CLUTCH (Continued) DIAGNOSIS AND TESTING - CLUTCH COVER AND DISC RUNOUT Check condition of the clutch cover before installa- tion. A warped cover or diaphragm spring will cause grab and/or incomplete release or engagement. Use care when handling the clutch assembly. Impact can distort the cover, diaphragm spring, and release fin- gers.
Page 242 CLUTCH 6 - 7 CLUTCH RELEASE LEVER AND BEARING (Continued) (4) Separate release bearing from lever. NOTE: Remove release lever pivot ball(s) ONLY if replacement is necessary. (5) Remove pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig. 7). Fig.
Page 243: Removal
6 - 8 CLUTCH CLUTCH RELEASE LEVER AND BEARING (Continued) MASTER CYLINDER - RHD REMOVAL (1) Disconnect battery negative cable. (2) Remove master cylinder to clutch pedal pin retainer clip. Disengage pushrod from clutch pedal pin (Fig. 13). (3) Disengage master cylinder grommet from cowl panel.
Page 244: Master Cylinder - Lhd Removal
CLUTCH 6 - 9 MASTER CYLINDER - RHD (Continued) MASTER CYLINDER - LHD REMOVAL (1) Disconnect battery cables. (2) Remove instrument panel lower silencer (Fig. 14). Fig. 13 Clutch Master Cylinder at Pedal Bracket Fig. 14 Instrument Panel Lower Silencer 1 - CLUTCH MASTER CYLINDER 1 - INSTRUMENT PANEL LOWER SILENCER 2 - RETAINER CLIP...
Page 245: Installation
6 - 10 CLUTCH MASTER CYLINDER - LHD (Continued) (4) Remove clutch master cylinder pushrod retainer clip (Fig. 16). Fig. 17 Disconnect Quick-Connect Using Tool 6638A 1 - QUICK CONNECT FITTING 2 - TOOL 6638A Fig. 16 Master Cylinder Pushrod at Pedal 1 - MASTER CYLINDER PUSHROD 2 - CLUTCH/BRAKE PEDAL ASSEMBLY 3 - PUSHROD RETAINER...
Page 246: Modular Clutch Assy - 2.4L Gas Removal
CLUTCH 6 - 11 MASTER CYLINDER - LHD (Continued) (5) Install windshield wiper module assembly SLAVE CYLINDER (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER MODULE - INSTALLATION). REMOVAL (6) Install battery tray. (1) Raise vehicle on hoist. Diesel models: Remove (7) Install battery. underbody splash shield.
Page 247: Clutch Disc And Pressure Plate - 2.5L Td Removal
6 - 12 CLUTCH INSTALLATION CLUTCH DISC AND PRESSURE (1) Install clutch release bearing and lever (if PLATE - 2.5L TD removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE BEARING - INSTALLATION) REMOVAL (2) Install clutch disc and pressure plate to fly- (1) Remove transaxle assembly.
Page 248: Flywheel Removal
CLUTCH 6 - 13 FLYWHEEL REMOVAL (1) Remove transaxle assembly. (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Remove clutch pressure plate and disc. (Refer to 6 - CLUTCH/CLUTCH DISC - REMOVAL) (3) Remove flywheel assembly (Fig. 22). INSTALLATION (1) Install NEW flywheel-to-crankshaft bolts by hand.
Page 250 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE - COOLING DESCRIPTION SYSTEM FILLING ..... . 4 DESCRIPTION - COOLING SYSTEM .
Page 251: Cooling
7 - 2 COOLING COOLING (Continued) OPERATION - HOSE CLAMPS OPERATION The spring type hose clamp applies constant ten- OPERATION - COOLING SYSTEM sion on a hose connection. To remove a spring type hose clamp, use Special Tool 6094 or equivalent, con- The engine cooling systems primary purpose is to stant tension clamp pliers (Fig.
Page 252: Diagnosis And Testing - Cooling System Flow Check
COOLING 7 - 3 COOLING (Continued) If there are no external leaks, after the gauge dial shows a drop in pressure, detach the tester. Start engine and run until the thermostat opens, allowing the coolant to expand. Reattach the cooling system tester.
Page 253: Diagnosis And Testing - Cooling System Aeration
7 - 4 COOLING COOLING (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION Low coolant level in a cross flow radiator will equalize in both tanks with engine off. With engine at running and at operating temperature, the high pressure inlet tank runs full and the low pressure outlet tank drops, resulting in cooling system aera- tion.
Page 254: Standard Procedure - Coolant Level Check
COOLING 7 - 5 COOLING (Continued) Fig. 6 Cooling System Service Locations 1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK 2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP STANDARD PROCEDURE - COOLANT LEVEL CHECK NOTE: Do not remove radiator cap for routine cool- ant level inspections.
Page 255: Specifications Cooling System Capacity
7 - 6 COOLING COOLING (Continued) TORQUE SPECIFICATIONS COOLING SYSTEM CAPACITY DESCRIPTION N·m Lbs. Lbs. Engine Coolant Capacity* Accessory Drive Belt Tensioner — Assembly (3.3/3.8L)—Bolt 2.4L 10.7 L (11.4 qts.) Engine Coolant Temperature 3.3/3.8L (without 12.6 L (13.4 qts.) Sensor rear heater) 3.3/3.8L (with rear 15.4 L...
Page 256: Cooling System
COOLING 7 - 7 COOLING (Continued) SPECIAL TOOLS COOLING SYSTEM DRB III with PEP Module – OT-CH6010A Hose Clamp Pliers 6094 Belt Tension Gauge Adapter 8371 Hose Clamp Pliers 8495A Belt Tension Gauge 7198A Cooling System Tester 7700 Cooler Flusher 6906-C Coolant Refractometer 8286...
Page 257: Accessory Drive
7 - 8 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONER - 2.4L REMOVAL ......10 REMOVAL .
Page 258: Belt Tensioner - 3.3/3.8L
ACCESSORY DRIVE 7 - 9 BELT TENSIONER - 3.3/3.8L (Continued) DRIVE BELTS DESCRIPTION The drive belts are a Poly-V type belt. Belt widths vary depending on the various engine and accessory packages. Satisfactory performance of these belts depends on belt condition and proper belt tension. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accesso-...
Page 259: Removal
7 - 10 ACCESSORY DRIVE DRIVE BELTS (Continued) CONDITION POSSIBLE CAUSES CORRECTIONS BELT ROLLED OVER IN GROOVE 1. Broken cord in belt 1. Replace belt OR BELT JUMPS OFF 2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned belts.) (b) Adjust power steering belt tension (4 cyl.
Page 260: Cleaning
ACCESSORY DRIVE 7 - 11 DRIVE BELTS - 2.4L (Continued) CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and cool- ants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: •...
Page 261: Adjustments
7 - 12 ACCESSORY DRIVE DRIVE BELTS - 2.4L (Continued) DRIVE BELTS - 3.3/3.8L REMOVAL (1) Raise vehicle on hoist. (2) Remove the drive belt shield (Fig. 8). Fig. 7 Accessory Drive Belts - 2.4L 1 - POWER STEERING PUMP PULLEY 2 - BELT TENSIONER Fig.
Page 262: Cleaning
ACCESSORY DRIVE 7 - 13 DRIVE BELTS - 3.3/3.8L (Continued) (5) Remove the drive belt (Fig. 11). INSTALLATION (6) Carefully return tensioner to its relaxed posi- (1) Route and position the drive belt onto all pul- tion. leys, except for the crankshaft (Fig. 11). CLEANING Clean all foreign debris from belt pulley grooves.
Page 263 7 - 14 ENGINE ENGINE TABLE OF CONTENTS page page ENGINE REMOVAL ......25 DIAGNOSIS AND TESTING - ENGINE INSTALLATION .
Page 264: Diagnosis And Testing - Engine Cooling System
ENGINE 7 - 15 VISUAL INSPECTION ENGINE If the cooling system problem is not caused by a driving condition, perform a visual inspection to DIAGNOSIS AND TESTING - ENGINE COOLING determine if there was a recent service or accident SYSTEM repair, including the following: Establish what driving condition caused the cooling •...
Page 265 7 - 16 ENGINE ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION DETONATION OR PRE-IGNITION 1. Engine overheating. 1. Check reason for overheating (NOT CAUSED BY IGNITION and repair as necessary. SYSTEM). GAUGE MAY NOT BE 2. Freeze point of coolant not 2.
Page 266 ENGINE 7 - 17 ENGINE (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Obstructions in heater hose 3. Remove heater hoses at both fitting at engine or at heater core. ends and check for obstructions. Repair as necessary. 4. Heater hose kinked. 4.
Page 267 7 - 18 ENGINE 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 determining AND TESTING) Adjust the ethylene...
Page 268: Cleaning
ENGINE 7 - 19 ENGINE (Continued) Fig. 1 Temperature Gauge Indications CLEANING COOLANT Drain cooling system and refill with clean water. Refer to drain and fill procedures in this section. Run DIAGNOSIS AND TESTING - COOLANT engine with radiator cap installed until upper radia- CONCENTRATION TESTING tor hose is hot.
Page 269: Standard Procedure - Coolant Service
7 - 20 ENGINE COOLANT (Continued) higher the freeze protection (up to a maximum of and the coolant level in the container is at or above 60% by volume glycol). the MIN mark, there is an air leak in the coolant A refractometer (Special Tool 8286)(Refer to 7 - recovery system.
Page 270: Removal
ENGINE 7 - 21 ENGINE BLOCK HEATER ENGINE COOLANT TEMPERATURE SENSOR - 2.4L DESCRIPTION The engine block heater is available as an optional DESCRIPTION accessory on all models. The heater is operated by The engine coolant temperature sensor threads ordinary house current (110 Volt A.C.) through a into the top of the thermostat housing (Fig.
Page 271: Engine Coolant Temperature Sensor - 3.3/3.8L Description
7 - 22 ENGINE (3) Remove ignition coil and bracket (Fig. 5). ENGINE COOLANT TEMPERATURE SENSOR - 3.3/3.8L DESCRIPTION The engine coolant temperature sensor threads into a coolant passage on lower intake manifold near the thermostat (Fig. 6). New sensors have sealant applied to the threads.
Page 272: Installation
ENGINE 7 - 23 ENGINE COOLANT TEMPERATURE SENSOR - 3.3/3.8L (Continued) reaches a predetermined temperature, the wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT The thermostat is operated by a wax filled cham- ber (pellet) which is sealed.
Page 273: Installation
7 - 24 ENGINE ENGINE COOLANT THERMOSTAT - 2.4L (Continued) ENGINE COOLANT THERMOSTAT - 3.3/3.8L REMOVAL (1) Drain cooling system down below the thermo- stat level. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Remove radiator upper hose from coolant outlet connector (Fig.
Page 274: Radiator
ENGINE 7 - 25 ENGINE COOLANT THERMOSTAT - 3.3/3.8L (Continued) Fig. 10 THERMOSTAT - 3.3/3.8L ENGINE 1 - COOLANT OUTLET CONNECTOR 2 - BOLT Fig. 12 Thermostat Position In Outlet Connector 3 - THERMOSTAT 4 - GASKET 1 - LOCATING NOTCH 2 - THERMOSTAT 3 - COOLANT OUTLET CONNECTOR RADIATOR...
Page 275 7 - 26 ENGINE RADIATOR (Continued) (6) Remove vapor purge solenoid from mounting bracket. (7) Disconnect upper and lower hoses from the radiator (Fig. 13) or (Fig. 14). Fig. 13 Radiator Hoses to Radiator - 2.4L 1 - UPPER HOSE 2 - LOWER HOSE 3 - HOSE SUPPORT CLIP Fig.
Page 276: Removal
ENGINE 7 - 27 RADIATOR DRAINCOCK RADIATOR PRESSURE CAP REMOVAL DESCRIPTION The cooling system pressure cap is located on the CAUTION: Use of pliers on draincock is not recom- radiator. The cap construction includes; stainless mended. Damage may occur to radiator or drain- steel swivel top, rubber seals, and retainer, main cock.
Page 277: Diagnosis And Testing Diagnosis And Testing - Cooling System Pressure Cap Testing
7 - 28 ENGINE RADIATOR PRESSURE CAP (Continued) ket should relieve at 69-124 kPa (10-18 psi) and hold DIAGNOSIS AND TESTING pressure at 55 kPa (8 psi) minimum. DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP TESTING Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700 (Fig.
Page 278: Cleaning
ENGINE 7 - 29 RADIATOR PRESSURE CAP (Continued) CLEANING Use only a mild soap to clean the pressure cap. INSPECTION Hold the cap in your hand, top side up (Fig. 20). The vent valve at the bottom of the cap should open. If the rubber gasket has swollen, preventing the valve from opening, replace the cap.
Page 279: Diagnosis And Testing - Radiator Fan Motor
7 - 30 ENGINE RADIATOR FAN (Continued) DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR RADIATOR FAN DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL) 2.
Page 280: Installation
ENGINE 7 - 31 RADIATOR FAN (Continued) (4) Install the radiator upper support crossmem- (5) Remove the rivet attaching the relay to the ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN- front bumper beam (Fig. 22). ING REINFORCEMENT - INSTALLATION) (6) Remove the relay. (5) Install the upper radiator mounts to the cross- member bolts, if removed.
Page 281: Installation
7 - 32 ENGINE (7) Remove right engine mount bracket (Fig. 24). WATER PUMP - 2.4L (8) Remove the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKET(S) DESCRIPTION - REMOVAL). The water pump has a cast aluminum body and (9) Remove timing belt idler pulley.
Page 282 ENGINE 7 - 33 WATER PUMP - 2.4L (Continued) Fig. 24 Generator Bracket 1 - BRACKET - ENGINE MOUNT 5 - BOLT 2 - BOLT 6 - TENSIONER - DRIVE BELT 3 - GENERATOR 7 - BOLT 4 - BOLT 8 - BOLT Fig.
Page 283: Water Pump - 3.3/3.8L Description
7 - 34 ENGINE WATER PUMP - 2.4L (Continued) (7) Install the timing belt (Refer to 9 - ENGINE/ OPERATION VALVE TIMING/TIMING BELT AND SPROCKET(S) The water pump is the heart of the cooling system. - INSTALLATION). The coolant is pumped through the engine block, cyl- (8) Install the generator mount bracket.
Page 284: Cleaning
ENGINE 7 - 35 WATER PUMP - 3.3/3.8L (Continued) (9) Clean seal groove and sealing surfaces on pump and timing chain case cover. Take care not to scratch or gouge sealing surfaces. Fig. 30 Water Pump Inspection - 3.3/3.8L Engine Fig.
Page 285: Water Pump Inlet Tube - 2.4L Description
7 - 36 ENGINE WATER PUMP - 3.3/3.8L (Continued) (5) Rotate pump by hand to check for freedom of movement. (6) Install the accessory drive belt. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (7) Install drive belt shield. (8) Fill the cooling system.
Page 286 ENGINE 7 - 37 WATER PUMP INLET TUBE - 3.3/3.8L (Continued) Fig. 36 WATER PUMP INLET TUBE 1 - TIMING CHAIN COVER 2 - INLET TUBE Fig. 34 RAD HOSES TO ENGINE - 3.3/3.8L 3 - BOLT 4 - BOLT 1 - UPPER HOSE 5 - O-RING 2 - LOWER HOSE...
Page 287: Coolers And Tubes
7 - 38 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION CLEANING ......39 STANDARD PROCEDURE - FLUSHING INSPECTION .
Page 288: Transmission Oil Cooler Lines
TRANSMISSION 7 - 39 TRANSMISSION OIL COOLER (Continued) INSTALLATION (1) Install transaxle oil cooler and mounting screws (Fig. 2). NOTE: When replacing the transmission oil cooler, the cooler hoses must be replaced. (2) Connect the new cooler hoses and install clamps (Fig.
Page 289 7 - 40 TRANSMISSION TRANSMISSION OIL COOLER LINES (Continued) INSTALLATION NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses must be replaced.
Page 290 COOLING 2.5L TURBO DIESEL 7a - 1 COOLING 2.5L TURBO DIESEL TABLE OF CONTENTS page page COOLING 2.5L TURBO DIESEL CLEANING ......7 DESCRIPTION - COOLING SYSTEM .
Page 291 7a - 2 COOLING 2.5L TURBO DIESEL COOLING 2.5L TURBO DIESEL (Continued) COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Diesel engines, due to their 1. The low gauge reading may READS LOW inherent effiency are slower to warm be normal.
Page 292: Cooling 2.5L Turbo Diesel
COOLING 2.5L TURBO DIESEL 7a - 3 COOLING 2.5L TURBO DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION 6. Freeze point of antifreeze not 6. Check antifreeze. Adjust correct. Mixture may be too rich. antifreeze-to-water ratio as required. 7. Coolant not flowing through 7.
Page 293 7a - 4 COOLING 2.5L TURBO DIESEL COOLING 2.5L TURBO DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION 5. Coolant level low in the coolant 5. Check and correct coolant tank (air will build up in the cooling leaks. system causing the thermostat to open late).
Page 294 COOLING 2.5L TURBO DIESEL 7a - 5 COOLING 2.5L TURBO DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR 1. Radiator and/or A/C condensor is 1. Remove restriction or clean CONDITIONER restricted, obstructed or dirty debris from radiator or A/C PERFORMANCE (insects, leaves, etc.) condensor.
Page 295: Diagnosis And Testing - Cooling System Leak Test
7a - 6 COOLING 2.5L TURBO DIESEL COOLING 2.5L TURBO DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Has undercoating been applied to 4. Clean undercoating as any unnecessary components? necessary. STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting FRONT OF VEHICLE (snow, ice, or rain condensation) on from this area is normal.
Page 296: Diagnosis And Testing - Cooling System Flow Check
COOLING 2.5L TURBO DIESEL 7a - 7 COOLING 2.5L TURBO DIESEL (Continued) (2) Remove pressure/vent cap when engine is cold, idle engine until thermostat opens, you should observe coolant flow while looking down in the cool- ant recovery pressure container. Once flow is detected install the pressure/vent cap.
Page 297: Specifications Specifications - Torque
7a - 8 COOLING 2.5L TURBO DIESEL COOLING 2.5L TURBO DIESEL (Continued) SPECIFICATIONS SPECIFICATIONS - TORQUE 2.5L DIESEL - TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Water Pump Housing Nuts 24.4 Thermostat Housing Bolts 27.5 — Accessory Drive Belt 47.1 —...
Page 298: Accessory Drive
ACCESSORY DRIVE 7a - 9 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE DESCRIPTION - POWER STEERING BELT . . 10 SPECIFICATIONS - ACCESSORY BELT OPERATION TENSION ......9 OPERATION-ACCESSORY DRIVE BELT .
Page 299: Belt Tensioner
7a - 10 ACCESSORY DRIVE IDLER PULLEY DRIVE BELTS REMOVAL DESCRIPTION (1) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - DESCRIPTION - ACCESSORY DRIVE BELT REMOVAL). The accessory drive belt is a serpentine type belt (Fig.
Page 300: Diagnosis And Testing - Accessory Drive Belt
ACCESSORY DRIVE 7a - 11 DRIVE BELTS (Continued) DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT CONDITION POSSIBLE CAUSES CORRECTIONS INSUFFICIENT ACCESSORY 1. Belt too loose 1. (a) Replace belt (auto-tensioned OUTPUT DUE TO BELT SLIPPAGE belts) 2. Faulty belt tensioner 2.
Page 301 7a - 12 ACCESSORY DRIVE DRIVE BELTS (Continued) Fig. 6 POWER STEERING BELT REMOVAL TOOL Fig. 4 ACCESSORY DRIVE BELT REMOVAL 1 - VIBRATION DAMPER 1 - BELT TENSIONER 2 - POWER STEERING PULLEY 2 - ACCESSORY DRIVE BELT 3 - POWER STEERING BELT 3 - IDLER PULLEY 4 - POWER STEERING BELT REMOVER 4 - A/C COMPRESSOR CLUTCH...
Page 302: Installation
ACCESSORY DRIVE 7a - 13 DRIVE BELTS (Continued) INSTALLATION INSTALLATION-ACCESSORY DRIVE BELT (1) Install the accessory drive belt in proper popsi- tion (Fig. 8). Fig. 9 LOCKING/UNLOCKING BELT TENSIONER Fig. 8 ACCESSORY DRIVE BELT ROUTING 1 - GENERATOR 2 - IDLER PULLEY 3 - A/C COMPRESSOR CLUTCH 4 - POWER STEERING PUMP PULLEY 5 - POWER STEERING BELT...
Page 303 7a - 14 ENGINE ENGINE TABLE OF CONTENTS page page COOLANT OPERATION ......23 DESCRIPTION .
Page 304: Coolant Description
128 deg. C (263 deg. F) for ethylene-gly- col. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This...
Page 305: Standard Procedure Standard Procedure - Coolant Service
7a - 16 ENGINE STANDARD PROCEDURE - COOLANT LEVEL STANDARD PROCEDURE CHECK STANDARD PROCEDURE - COOLANT SERVICE For engine coolant recommended service schedule, NOTE: Do not remove pressure/vent cap for routine (Refer to LUBRICATION & MAINTENANCE/MAIN- coolant level inspections. TENANCE SCHEDULES - DESCRIPTION). The coolant reserve system provides a quick visual STANDARD PROCEDURE - ADDING method for determining the coolant level without...
Page 306: Standard Procedure - Cooling System Draining
ENGINE 7a - 17 COOLANT (Continued) (1) Without removing pressure/vent cap and with system not under pressure, open the drain- cock. The draincock is located on the lower right side of radiator (Fig. 3). (2) After the coolant recovery pressure container is empty, then remove coolant pressure/vent cap.
Page 307: Removal
7a - 18 ENGINE COOLANT RECOVERY PRESS CONTAINER (Continued) Fig. 4 COOLANT RECOVERY PRESSURE Fig. 5 COOLANT RECOVERY PRESSURE CONTAINER LOCATION CONTAINER LOCATION 1 - PRESSURE/VENT CAP 1 - PRESSURE/VENT CAP 2 - BRAKE MASTER CYLINDER 2 - BRAKE MASTER CYLINDER 3 - BATTERY 3 - BATTERY 4 - BATTERY SHIELD...
Page 308: Engine Coolant Temp Sensor Description
ENGINE 7a - 19 COOLANT RECOVERY PRESS CONTAINER (Continued) Fig. 6 COOLANT RECOVERY PRESSURE Fig. 7 COOLANT TEMPERATURE SENSOR CONTAINER LOCATION 1 - COOLANT RECOVERY PRESSURE CONTAINER 1 - EGR SOLENOID 2 - COOLANT BYPASS HOSE 2 - UPPER RADIATOR HOSE 3 - OUTLET HOSE 3 - COOLANT TEMPERATURE SENSOR 4 - PRESSURE/VENT CAP...
Page 309: Engine Coolant Thermostat Description
7a - 20 ENGINE ENGINE COOLANT THERMOSTAT (Continued) Fig. 8 COOLANT TEMPERATURE SENSOR Fig. 9 THERMOSTAT HOUSING LOCATION LOCATION 1 - CYLINDER HEAD COVER 2 - THERMOSTAT HOUSING 1 - EGR SOLENOID 3 - AIR BLEED 2 - UPPER RADIATOR HOSE 4 - WATER PUMP 3 - COOLANT TEMPERATURE SENSOR 5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING...
Page 310: Radiator Description
ENGINE 7a - 21 ENGINE COOLANT THERMOSTAT (Continued) REMOVAL (1) Disconnect negative cable from battery. (2) Remove radiator upper crossmember support. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REINFORCEMENT - REMOVAL) WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
Page 311: Installation
7a - 22 ENGINE RADIATOR (Continued) (8) Radiator can now be lifted free from engine RADIATOR DRAINCOCK compartment. Care should be taken not to dam- age radiator cooling fins or water tubes during REMOVAL removal. CAUTION: Use of pliers on draincock is not recom- mended.
Page 312: Water Pump Description
ENGINE 7a - 23 WATER PUMP DESCRIPTION The water pump on the 2.5L CRD diesel has a die cast aluminum housing. It bolts to a aluminum hous- ing which attaches to the engine block (Fig. 14). Fig. 15 WATER PUMP LOCATION 1 - CYLINDER HEAD 2 - ENGINE BLOCK 3 - OIL COOLER...
Page 313: Installation - Water Pump Housing
7a - 24 ENGINE WATER PUMP (Continued) Fig. 16 THERMOSTAT HOUSING LOCATION Fig. 17 WATER PUMP ASSEMBLY 1 - CYLINDER HEAD COVER 1 - WATER PUMP HOUSING STUDS 2 - THERMOSTAT HOUSING 2 - WATER PUMP 3 - AIR BLEED 3 - RETAINING NUTS 4 - WATER PUMP 4 - OIL COOLER RETAINING STUD...
Page 314: Radiator Pressure Cap Description
ENGINE 7a - 25 RADIATOR PRESSURE CAP DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM DESCRIPTION PRESSURE CAP The cooling system pressure cap is located on the radiator. The cap construction includes; stainless Dip the pressure cap in water. Clean any deposits steel swivel top, rubber seals, and retainer, main off the vent valve or its seat and apply cap to end of spring, and a spring loaded valve (Fig.
Page 315: Diagnosis And Testing - Pressure Relief Test
7a - 26 ENGINE RADIATOR PRESSURE CAP (Continued) DIAGNOSIS AND TESTING - PRESSURE WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN RELIEF TEST PLACE A SHOP TOWEL OVER THE CAP AND WITH- The pressure cap upper gasket (seal) pressure OUT PUSHING DOWN ROTATE COUNTERCLOCK- relief can be checked by removing the overflow hose WISE TO THE FIRST STOP.
Page 316: Operation
ENGINE 7a - 27 RADIATOR FAN (Continued) OPERATION RADIATOR FAN OPERATION CHART COOLANT TEMPERATURE A/C PRESSURE Fan Operation Initial Initial Speeds: Fan On: 104°C (220°F) 110°C (230°F) Fan 1,724 Kpa (250 psi) 2,068 Kpa (300 psi) Speed Duty-Cycles Fan Speed (Ramps-up) from Duty-Cycles 30% to 99%...
Page 317: Removal
7a - 28 ENGINE RADIATOR FAN (Continued) REMOVAL replace with the original Mopar equipment spring type clamp. There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or CAUTION: A number or letter is stamped into the otherwise damaged, it must be replaced as an assem- tongue of constant tension clamps.
Page 318: Radiator Fan Relay Description
ENGINE 7a - 29 (1) Remove engine cover (Refer to 9 - ENGINE - RADIATOR FAN RELAY REMOVAL). (2) Drain cooling system (Refer to 7 - COOLING/ DESCRIPTION ENGINE/COOLANT - STANDARD PROCEDURE). The low and high speed fan relays are mounted to (3) Remove upper radiator hose (Fig.
Page 319: Removal - Coolant Bypass Hose
7a - 30 ENGINE COOLANT SYSTEM HOSES (Continued) REMOVAL - COOLANT BYPASS HOSE (2) Refill cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE). (3) Install engine cover (Refer to 9 - ENGINE - WARNING: THE WARNING WORDS “DO NOT OPEN INSTALLATION).
Page 320 AUDIO 8A - 1 AUDIO TABLE OF CONTENTS page page AUDIO INSTALLATION ......8 DESCRIPTION .
Page 321 8A - 2 AUDIO AUDIO (Continued) information and location views for the various wire STEERING COLUMN, OR INSTRUMENT PANEL harness connectors, splices and grounds. COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD WARNING: ON VEHICLES EQUIPPED WITH AIR- RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT BAGS, REFER...
Page 322 AUDIO 8A - 3 AUDIO (Continued) CONDITION POSSIBLE CAUSE CORRECTION 2. GROUND FAULTY. 2. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND. THERE SHOULD BE CONTINUITY. REPAIR GROUND, IF REQUIRED. 3. RADIO FAULTY. 3. EXCHANGE OR REPLACE RADIO, IF REQUIRED. 4.
Page 323: Audio
8A - 4 AUDIO ANTENNA BODY AND CABLE DESCRIPTION All models use a fixed-length stainless steel rod- type antenna mast, installed at the right front fender of the vehicle. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle.
Page 324: Installation
AUDIO 8A - 5 ANTENNA BODY AND CABLE (Continued) (3) Disconnect antenna cable connector from exten- sion cable (Fig. 2). (4) Remove right kick trim panel. (5) Disengage rubber grommet insulator from door hinge pillar. (6) Pull antenna cable through hinge pillar into opening between door hinges.
Page 325: Antenna Module - Export Description
8A - 6 AUDIO ANTENNA BODY AND CABLE (Continued) (12) Install glove box to instrument panel. (13) Connect the battery negative cable. ANTENNA MODULE - EXPORT DESCRIPTION The antenna module is an electromagnetic circuit component designed to capture and enhance RF (Radio Frequency) signals in both the AM and FM broadcast bands.
Page 326: Removal
AUDIO 8A - 7 ANTENNA MODULE - EXPORT (Continued) REMOVAL you can not load a new disc while playing another at the same time. Each operation happens sequentially. (1) Disconnect and isolate the battery negative The radio unit provides control over all features of cable.
Page 327: Instrument Panel Antenna Cable Removal
8A - 8 AUDIO CD CHANGER (Continued) NOTE: Use care when inserting CD changer so that cable is not pinched or trapped against instrument panel. (3) Install screws holding CD changer. (4) Reconnect the battery negative cable. INSTRUMENT PANEL ANTENNA CABLE REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS,...
Page 328: Radio
AUDIO 8A - 9 (4) Turn the ignition switch to the OFF position. RADIO Remove the radio, but do not unplug the wire har- ness connectors. Check for continuity between the DIAGNOSIS AND TESTING - RADIO radio chassis and a good ground. There should be continuity.
Page 329: Installation
8A - 10 AUDIO RADIO (Continued) noise. This undesirable radio noise is generally man- ifested in the form of “buzzing,” “hissing,” “popping,” “clicking,” “crackling,” and/or “whirring” sounds. In most cases, RFI and EMI radio noise can be sup- pressed using a combination of vehicle and compo- nent grounding, filtering and shielding techniques.
Page 330: Operation
AUDIO 8A - 11 DIAGNOSIS AND TESTING - REMOTE REMOTE SWITCHES SWITCHES DESCRIPTION WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 331: Removal
8A - 12 AUDIO REMOTE SWITCHES (Continued) REMOTE RADIO SWITCH TEST (3) Remove the steering wheel from the steering column. Refer to STEERING/COLUMN/STEERING WHEEL. SWITCH POSITION RESISTANCE (4) Unplug the wire harness connector from the VOLUME UP 7320 OHMS remote radio switch (s). VOLUME DOWN 1210 OHMS (5) Remove three screws securing steering wheel...
Page 332: Removal
AUDIO 8A - 13 SPEAKER (Continued) Any diagnosis of the Audio system should (6) Partially remove quarter trim panel to access begin with the use of the DRB III diagnostic the D-pillar speaker. tool. For information on the use of the DRB (7) Slide the speaker from the retainer (Fig.
Page 333 8A - 14 AUDIO SPEAKER (Continued) INSTRUMENT PANEL SPEAKER (1) Disconnect and isolate the battery negative cable. (2) Remove the A-pillar trim. (Refer to 23 - BODY/ INTERIOR/A-PILLAR TRIM - REMOVAL). (3) Remove instrument panel top pad (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL TOP PAD - REMOVAL).
Page 334 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - LOW OIL DESCRIPTION ......1 PRESSURE CHIME .
Page 335: Chime/Buzzer
8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) (a) BCM has two battery feeds at pin 1 and pin When the ignition is OFF and the key is out of the 5 of the 6–way connector. ignition: • Driver’s door OPEN (door ajar switch is closed to (b) Pin 5 of the (BX2) 32 way connector of the BCM for ignition feed.
Page 336: Diagnosis And Testing - Low Oil
CHIME/BUZZER 8B - 3 CHIME/BUZZER (Continued) ignition switch. This chime will operate for all igni- led. The seat belt warning lamp should light and the tion positions except ON and START. chime should sound 4 to 8 seconds. With the ignition switch in the OFF position DIAGNOSIS AND TESTING - SEAT BELT LAMP ONLY: •...
Page 337: Diagnosis And Testing - Warning Lamp Announcement Chime
8B - 4 CHIME/BUZZER CHIME/BUZZER (Continued) • If hazard warning signals are pulsing, no chime are first illuminated, the chime will sound one tone. will sound. The door/liftgate ajar warning lamp announcement • If speed drops below 24 km/h (15 mph) before chime sounds only if the vehicle speed is above 4 the warning is issued, the warning will not be issued m.p.h.
Page 338 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES DIAGNOSTIC TROUBLE CODE ... 13 STANDARD PROCEDURE - PCM/SKIM OPERATION - SENSOR RETURN - PCM PROGRAMMING .
Page 339: Electronic Control Modules Standard Procedure - Pcm/Skim Programming
8E - 2 ELECTRONIC CONTROL MODULES (8) The DRB III will ask, Is odometer reading ELECTRONIC CONTROL between XX and XX? Select the YES or NO button on MODULES the DRB III. If NO is selected, the DRB III will read, Enter odometer Reading<From I.P.
Page 340: Adjustable Pedal Module
ELECTRONIC CONTROL MODULES 8E - 3 ELECTRONIC CONTROL MODULES (Continued) (5) Obtain ignition keys to be programmed from (4) Install adjustable pedal assembly. (Refer to 5 - customer (8 keys maximum). BRAKES/HYDRAULIC/MECHANICAL/PEDAL (6) Using the DRB III, erase all ignition keys by INSTALLATION) selecting MISCELLANEOUS and ERASE ALL CUR- RENT IGN.
Page 341 8E - 4 ELECTRONIC CONTROL MODULES BODY CONTROL MODULE (Continued) interior lamps after 15 minutes after the ignition is BCM does not receive any new inputs that would turned off, if they are not turned off by the driver. cause the interior lamps to remain on. •...
Page 342: Removal
ELECTRONIC CONTROL MODULES 8E - 5 BODY CONTROL MODULE (Continued) When replacing a BCM there are three modules CONTROLLER ANTILOCK available: BRAKE • Base • Midline DESCRIPTION • Highline The controller antilock brake (CAB) is a micropro- The Midline controller is used on vehicles that cessor-based device which monitors the antilock have Power Door Locks and the Highline controller is brake system (ABS) during normal braking and con-...
Page 343: Removal
8E - 6 ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE (Continued) • (with traction control only) Illuminate the TRAC (2) Remove the battery (Refer to 8 - ELECTRI- OFF lamp when the amber ABS warning indicator CAL/BATTERY SYSTEM/BATTERY - REMOVAL). lamp illuminates. (3) Disconnect the vacuum hose connector at the The CAB constantly monitors the antilock brake tank built into the battery tray.
Page 344 ELECTRONIC CONTROL MODULES 8E - 7 CONTROLLER ANTILOCK BRAKE (Continued) Module (PCM). Refer to On-Board Diagnostics in the General Diagnosis section of this group. FRONT CONTROL MODULE DESCRIPTION The Front Control Module (FCM) is a micro con- troller based module located in the engine compart- ment.
Page 345: Front Control Module
8E - 8 ELECTRONIC CONTROL MODULES FRONT CONTROL MODULE (Continued) • Back-Up switch • Brake Fluid Level • B+ Connection Detection • Engine Crank Signal (Diesel Engine Vehicles) • Horn Input • Ignition Switch Start Only • Ignition Switch Run and Start Only •...
Page 346: Heated Seat Module Description
ELECTRONIC CONTROL MODULES 8E - 9 FRONT CONTROL MODULE (Continued) (4) Install the battery in the vehicle. Refer to the The heated seat module is an electronic micropro- procedure in Battery Systems. cessor controlled device designed and programmed to (5) Connect the positive and negative battery use inputs from the ignition switch, heated seat cables.
Page 347: Removal
8E - 10 ELECTRONIC CONTROL MODULES HEATED SEAT MODULE (Continued) seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. (1) Check the heated seat element (Refer to 8 - ELECTRICAL/HEATED SEATS/HEATED...
Page 348: Installation
ELECTRONIC CONTROL MODULES 8E - 11 POWER LIFTGATE MODULE (Continued) POWERTRAIN CONTROL MODULE DESCRIPTION DESCRIPTION The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 11). The PCM receives input signals from various switches and sensors referred to as Powertrain Control Mod- ule Inputs.
Page 349 8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Ignition sense • Exhaust Gas Oxygen Content (heated oxygen • Intake Air Temperature Sensor sensors) • Knock Sensor • Manifold Absolute Pressure • Leak Detection Pump Feedback • Throttle Position •...
Page 350: Diagnostic Trouble Code
ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) DIAGNOSTIC TROUBLE CODE Remember that DTC’s are the results of a sys- tem or circuit failure, but do not directly iden- tify the failed component or components. DESCRIPTION A Diagnostic Trouble Code (DTC) indicates the NOTE: For a list of DTC’s, refer to the charts in this PCM has recognized an abnormal condition in the section.
Page 351 8E - 14 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0106 (M)
Page 352 ELECTRONIC CONTROL MODULES 8E - 15 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0138 (M)
Page 353 8E - 16 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0178...
Page 354 ELECTRONIC CONTROL MODULES 8E - 17 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0330...
Page 355 8E - 18 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0441 (M)
Page 356 ELECTRONIC CONTROL MODULES 8E - 19 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0522...
Page 357 8E - 20 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0660...
Page 358 ELECTRONIC CONTROL MODULES 8E - 21 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P0850...
Page 359 8E - 22 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P1298...
Page 360 ELECTRONIC CONTROL MODULES 8E - 23 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P1489 (M)
Page 361 8E - 24 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P1683...
Page 362: Operation - Sensor Return - Pcm Input
ELECTRONIC CONTROL MODULES 8E - 25 POWERTRAIN CONTROL MODULE (Continued) (M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded. (G) Generator Lamp Illuminated GENERIC DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE SCAN TOOL CODE P2008...
Page 363: Removal
8E - 26 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (2) Turn the ignition switch on and access the (4) Remove the 2 PCM connectors. “Read Fault” screen. (5) Remove the headlamp, refer to the Lamps sec- (3) Record all the DTC’s and “freeze frame” infor- tion for more information.
Page 364: Operation
ELECTRONIC CONTROL MODULES 8E - 27 SENTRY KEY IMMOBILIZER MODULE (Continued) (BCM), and the DRB III scan tool. The SKIM trans- The SKIM also sends indicator light status mes- mits and receives RF signals through a tuned sages to the BCM to operate the light. This is the antenna enclosed within a molded plastic ring forma- method used to turn the light ON solid or to flash it tion that is integral to the SKIM housing.
Page 365: Transmission Control Module Description
8E - 28 ELECTRONIC CONTROL MODULES Some examples of direct inputs to the TCM are: TRANSMISSION CONTROL • Battery (B+) voltage MODULE • Ignition “ON” voltage • Transmission Control Relay (Switched B+) DESCRIPTION • Throttle Position Sensor • Crankshaft Position Sensor (CKP) The Transmission Control Module (TCM) is located •...
Page 366 ELECTRONIC CONTROL MODULES 8E - 29 TRANSMISSION CONTROL MODULE (Continued) CLUTCH VOLUME INDEX (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the vol- ume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitor- ing the Input and Output Speed Sensors.
Page 367 8E - 30 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • Fluid temperature SHIFT SCHEDULES • Software level As mentioned earlier, the TCM has programming that As driving conditions change, the TCM appropri- allows it to select a variety of shift schedules. Shift ately adjusts the shift schedule.
Page 368: Standard Procedure Standard Procedure - Pinion Factor Setting
ELECTRONIC CONTROL MODULES 8E - 31 (1) Plug the DRBIII scan tool into the diagnostic STANDARD PROCEDURE connector. The connector is located under the instru- ment panel. STANDARD PROCEDURE - PINION FACTOR (2) Go to the Transmission screen. SETTING (3) Go to the Miscellaneous screen. (4) Select Quick Learn Procedure.
Page 369: Installation
8E - 32 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) (6) Remove three (3) TCM-to-rail screws and remove TCM from vehicle (Fig. 17). Fig. 18 Transmission Control Module Removal/ Installation 1 - SCREW Fig. 17 Transmission Control Module Removal/ 2 - TRANSMISSION CONTROL MODULE (TCM) Installation 3 - CLIP 1 - SCREW...
Page 370: Memory Seat/Mirror Module Description
ELECTRONIC CONTROL MODULES 8E - 33 the memory/mirror seat module. For complete circuit MEMORY SEAT/MIRROR diagrams, refer to Wiring Diagrams. MODULE REMOVAL DESCRIPTION (1) Disconnect and isolate the battery negative Vehicles equipped with the memory seat/mirror cable. option, utilize a memory module located under the (2) Remove the driver side front bucket seat drivers front seat.
Page 371: Operation
8E - 34 ELECTRONIC CONTROL MODULES SLIDING DOOR CONTROL MODULE (Continued) engage the clutch assembly and drive the door into the full open position. If an obstacle is felt during this power open cycle, the module will reverse direc- tion and close the door. This process is also enabled during a power close cycle.
Page 372 ELECTRONIC CONTROL MODULES 8Ea - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ENGINE CONTROL MODULE REMOVAL ......4 DESCRIPTION .
Page 373 8Ea - 2 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE (Continued) these sensor inputs to adjust fuel quantity and fuel INTERMITTENT CODE injector timing. A DTC that is not current every time the ECM/ SKIM checks the circuit or function is an intermit- Limp-In Mode tent code.
Page 374 ELECTRONIC CONTROL MODULES 8Ea - 3 ENGINE CONTROL MODULE (Continued) PCM/SKIM PROGRAMMING the battery state and connect a battery charger if necessary). When a PCM (JTEC) and the SKIM are replaced (6) Press ENTER to transfer the secret key (the at the same time perform the following steps in SKIM will send the secret key to the PCM).
Page 375 8Ea - 4 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE (Continued) Programming Key Failed (Possible Used Key From (4) Remove ECM upper mounting bolts (Fig. 3). Wrong Vehicle) - SKIM is unable to program key due to one of the following: •...
Page 376 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 377: Battery System
8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) • Battery Holddown - The battery holddown DIAGNOSIS AND TESTING - BATTERY SYSTEM hardware secures the battery in the battery tray in The battery, starting, and charging systems in the the engine compartment. vehicle operate with one another and must be tested •...
Page 378 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 379: System
8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 380: Cleaning
BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) CLEANING The following information details the recommended cleaning procedures for the battery and related com- ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
Page 381: Specifications
8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) SPECIFICATIONS The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment...
Page 382: Special Tools
BATTERY SYSTEM 8F - 7 BATTERY SYSTEM (Continued) SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS Fig. 4 MAINTENANCE-FREE DIESEL ENGINE BATTERY during normal charging and reunited to form the water within the electrolyte, eliminating the need to MICRO 420 BATTERY TESTER add distilled water.
Page 383 8F - 8 BATTERY SYSTEM BATTERY (Continued) CONVENTIONAL BATTERY - GASOLINE ENGINE Fig. 6 Maintenance-Free Battery 1 - POSITIVE POST 2 - VENT 3 - CELL CAP 4 - VENT 5 - CELL CAP 6 - VENT 7 - NEGATIVE POST 8 - INDICATOR EYE (if equipped) Fig.
Page 384: Operation
BATTERY SYSTEM 8F - 9 BATTERY (Continued) electrolyte can be caused by an overcharging condi- hydrogen gas is exposed to flame or sparks, it may tion. Be certain to diagnose the charging system after ignite. If the electrolyte level is low, the battery may replenishing the water in the battery for a low elec- arc internally and explode.
Page 385: Standard Procedure Standard Procedure - Spiral Plate Battery Charging
8F - 10 BATTERY SYSTEM BATTERY (Continued) NOTE: Completely discharged batteries may take tery System Inspection for the proper battery system several hours to accept a charge. Refer to Standard inspection procedures. Procedures for the proper battery charging proce- CHARGING A COMPLETELY DISCHARGED dures.
Page 386: Standard Procedure - Conventional Battery Charging
BATTERY SYSTEM 8F - 11 BATTERY (Continued) Battery charging is the means by which the bat- CHARGE RATE TABLE tery can be restored to its full voltage potential. A Voltage Hours battery is fully-charged when: • Micro 420 electrical system tester indicates bat- 14.4 volts maximum up to 4 hours tery is OK.
Page 387 8F - 12 BATTERY SYSTEM BATTERY (Continued) CAUTION: The battery should not be hot to the low for the polarity-sensing circuitry to detect, the touch. If the battery feels hot to the touch, turn off battery charger will not operate. This makes it appear that the battery will not accept charging cur- the charger and let the battery cool before continu- ing the charging operation.
Page 388: Standard Procedure - Open-Circuit Voltage Test
BATTERY SYSTEM 8F - 13 BATTERY (Continued) greater, it may be load tested to reveal its cranking CONVENTIONAL BATTERY CHARGING TIME TABLE capacity. Refer to Standard Procedures for the proper Charging battery load test procedures. 5 Amps 20 Amps Amperage Amps Open Circuit Hours Charging @ 21°...
Page 389: Standard Procedure - Checking Battery Electrolyte Level
8F - 14 BATTERY SYSTEM BATTERY (Continued) between the disconnected battery negative cable ter- STANDARD PROCEDURE - CHECKING BATTERY minal clamp and the battery negative terminal post. ELECTROLYTE LEVEL Make sure that the doors remain closed so that the The following procedure can be used to check the illuminated entry system is not activated.
Page 390: Installation
BATTERY SYSTEM 8F - 15 BATTERY (Continued) Fig. 11 HOOK INSIDE BATTERY CELLS - LOW- Fig. 12 BATTERY POSITION & ORIENTATION MAINTENANCE BATTERY ONLY 1 - BATTERY THERMOWRAP (IF EQUIPPED) 1 - TOP OF BATTERY 2 - INTEGRATED POWER MODULE 2 - HOOK INSIDE BATTERY CELLS 3 - FRONT CONTROL MODULE WARNING:...
Page 391: Installation
8F - 16 BATTERY SYSTEM BATTERY HOLDDOWN (Continued) (1) Turn the ignition switch to the Off position. Be current generated by the charging system for restor- certain that all electrical accessories are turned off. ing the voltage potential of the battery. The female (2) Remove the nut with washer that secures the battery terminal clamps on the ends of the battery battery hold down bracket to the battery tray and...
Page 392 BATTERY SYSTEM 8F - 17 BATTERY CABLES (Continued) VOLTAGE DROP TEST switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection The following operation will require a voltmeter between the battery positive cable terminal clamp accurate to 1/10 (0.10) volt.
Page 393: Removal
8F - 18 BATTERY SYSTEM BATTERY CABLES (Continued) (4) Connect the voltmeter to measure between the (2) One at a time, trace and install the battery battery negative cable terminal clamp and a good cable retaining fasteners and routing clips until the clean ground on the engine block (Fig.
Page 394: Operation
BATTERY SYSTEM 8F - 19 BATTERY TRAY (Continued) OPERATION (4) Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery The battery tray provides a secure mounting loca- tray mounted, vacuum reservoir. tion and supports the battery. The battery tray also (5) Remove the battery tray from the vehicle.
Page 395: Operation
8F - 20 BATTERY SYSTEM THERMOWRAP (Continued) OPERATION (2) Disconnect the positive battery cable. (3) Lift the battery thermowrap straight up to The thermowrap protects the battery from engine remove from the battery. compartment temperature extremes. The tempera- ture of the battery can affect battery life. The air INSTALLATION trapped in the padded material of the thermowrap (1) Position the thermowrap on the battery.
Page 396 CHARGING 8F - 21 CHARGING TABLE OF CONTENTS page page CHARGING REMOVAL DESCRIPTION - CHARGING SYSTEM ..21 REMOVAL - 2.4L ..... . 24 OPERATION - CHARGING SYSTEM .
Page 397: Charging
8F - 22 CHARGING CHARGING (Continued) The Check Gauges Lamp (if equipped) or Battery The following procedures may be used to diagnose Lamp monitors: charging system voltage, engine the charging system if: • the check gauges lamp or battery lamp is illumi- coolant temperature and engine oil pressure.
Page 398: Specifications
CHARGING 8F - 23 CHARGING (Continued) (6) Inspect decoupler pulley (if equipped). Ensure SPECIFICATIONS decoupler pulley is driving the alternator rotor. (7) Inspect automatic belt tensioner (if equipped). GENERATOR Refer to the Cooling System for more information. (8) Inspect generator electrical connections at gen- Type Engine Minimun Test...
Page 399: Battery Temperature Sensor
8F - 24 CHARGING current is delivered to the vehicles electrical system BATTERY TEMPERATURE through the generator, battery, and ground terminals. SENSOR Excessive or abnormal noise emitting from the gen- erator may be caused by: DESCRIPTION • Worn, loose or defective bearings •...
Page 400: Installation Installation - 2.4L
CHARGING 8F - 25 GENERATOR (Continued) INSTALLATION INSTALLATION - 2.4L (1) Install the generator. (2) Install the accessory drive belt, refer to the Cooling System section for proper procedures. (3) Connect B+ terminal to generator. (4) Install nut holding B+ wire terminal to back of generator.
Page 401: Operation
8F - 26 CHARGING GENERATOR DECOUPLER PULLEY (Continued) OPERATION The generator decoupler is a one way clutch and should be replaced as an assembly. It is designed to help reduce belt tension fluctuation, reduce fatigue loads, improve belt life, reduce hubloads on compo- nents, and reduce noise.
Page 402: Voltage Regulator Description
CHARGING 8F - 27 GENERATOR DECOUPLER PULLEY (Continued) Fig. 6 DECOUPLER REMOVAL (LITENS) Fig. 8 DECOUPLER INSTALLATION (Litens) VOLTAGE REGULATOR DESCRIPTION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulat- ing circuit located within the Powertrain Control Module (PCM).
Page 403 8F - 28 STARTING STARTING TABLE OF CONTENTS page page STARTING SPECIFICATIONS DESCRIPTION ......28 STARTER .
Page 404 STARTING 8F - 29 STARTING (Continued) • Starter - Visually inspect the starter for indica- tions of physical damage and loose or corroded wire harness connections. • Starter Solenoid - Visually inspect the starter solenoid for indications of physical damage and loose or corroded wire harness connections.
Page 405 8F - 30 STARTING STARTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS 1. BATTERY 1. REFER TO THE BATTERY SECTION FOR MORE TO ENGAGE. DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY, IF FAULTY. REQUIRED. 2. STARTING CIRCUIT 2.
Page 406: Circuit Test
STARTING 8F - 31 STARTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION STARTER 1. BROKEN TEETH ON 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE ENGAGES, STARTER RING GEAR. IF NECESSARY. SPINS OUT BEFORE ENGINE STARTS. 2. STARTER ASSEMBLY 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND FAULTY.
Page 407 8F - 32 STARTING STARTING (Continued) Remove the starter relay from the PDC as FUNCTION described in this group to perform the following tests: B (+) (1) A relay in the de-energized position should P/N POSITION SW.SENSE have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30.
Page 408: Diagnosis And Testing - Feed Circuit
STARTING 8F - 33 STARTING (Continued) tion. If that checks OK check for continuity between (c) Connect negative lead of voltmeter to battery PCM and the terminal 85. Repair open circuit as negative terminal, and positive lead to engine required. If OK, the PCM may be defective. block near the battery cable attaching point.
Page 409: Starter
8F - 34 STARTING STARTING (Continued) (3) To disable the ignition and fuel systems, dis- SPECIFICATIONS connect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Cen- STARTER ter (PDC). Refer to the PDC cover for proper relay location.
Page 410: Starter Motor
STARTING 8F - 35 STARTER MOTOR REMOVAL REMOVAL - 2.4L (1) Release hood latch and open hood (Fig. 4). Fig. 5 BATTERY CABLE AND FIELD WIRE 2.4L Fig. 4 STARTER 2.4L (2) Disconnect and isolate the battery negative cable. (3) Disconnect solenoid wire connector from termi- nal (Fig.
Page 411: Removal - 3.3/3.8L
8F - 36 STARTING STARTER MOTOR (Continued) REMOVAL - 3.3/3.8L (7) Remove starter from bellhousing (Fig. 9). (1) Release hood latch and open hood. (2) Disconnect and isolate the battery negative cable. (3) Hoist and support vehicle on safety stands. (4) Remove nut holding B+ terminal to starter solenoid (Fig.
Page 412 ENGINE SYSTEMS 8Fa - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 413: Battery System
8Fa - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) • Battery Holddown - The battery holddown DIAGNOSIS AND TESTING - BATTERY SYSTEM hardware secures the battery in the battery tray in The battery, starting, and charging systems in the the engine compartment. vehicle operate with one another and must be tested •...
Page 414: Battery System
BATTERY SYSTEM 8Fa - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 415 8Fa - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 416 BATTERY SYSTEM 8Fa - 5 BATTERY SYSTEM (Continued) ABNORMAL BATTERY DISCHARGING Any of the following conditions can result in abnor- mal battery discharging: 1. A faulty or incorrect charging system compo- nent. Refer to Charging System for additional charg- ing system diagnosis and testing procedures. 2.
Page 417: Inspection
8Fa - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) (4) Clean the battery thermowrap with a sodium battery terminal posts for looseness. Batteries with bicarbonate (baking soda) and warm water cleaning damaged cases or loose terminal posts must be solution using a soft bristle parts cleaning brush to replaced.
Page 418: Battery System Special Tools
BATTERY SYSTEM 8Fa - 7 BATTERY SYSTEM (Continued) BATTERY CLASSIFICATIONS & RATINGS BCI Group Size Cold Cranking Reserve Ampere - Load Test Part Number Classification Amperage Capacity Hours Amperage 4686158AB 110 Minutes 4727159AB 120 Minutes 4727242AB DIN H6 120 Minutes 5033235AA 95 Minutes SPECIAL TOOLS...
Page 419 8Fa - 8 BATTERY SYSTEM BATTERY (Continued) nal resistance and also increases the active material terminals made of a soft lead material protrude from surface area. the top of the molded plastic battery case (Fig. 6)to provide the means for connecting the battery to the WARNING: NEVER EXCEED 14.4 VOLTS WHEN vehicle electrical system.
Page 420: Operation
BATTERY SYSTEM 8Fa - 9 BATTERY (Continued) tive plates to prevent them from contacting or short- charging the battery with a voltage higher than that ing against one another. These dissimilar metal of the battery itself, the battery discharging process plates are submerged in a sulfuric acid and water is reversed.
Page 421: Standard Procedure Standard Procedure - Spiral Plate Battery Charging
8Fa - 10 BATTERY SYSTEM BATTERY (Continued) WARNING: THE BATTERY CONTAINS SULFURIC ing the charging operation. Damage to the battery ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID may result. After the battery has been charged to 12.6 volts or CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT, FLUSH WITH WATER greater, perform a load test to determine the battery AND CALL A PHYSICIAN IMMEDIATELY.
Page 422: Standard Procedure - Conventional Battery Charging
BATTERY SYSTEM 8Fa - 11 BATTERY (Continued) turer of the battery charger for details on how to BATTERY CHARGING TIME TABLE bypass the polarity-sensing circuitry. Charging (3) Battery chargers vary in the amount of voltage 5 Amps 8 Amps Amperage and current they provide.
Page 423 8Fa - 12 BATTERY SYSTEM BATTERY (Continued) WARNING: IF THE BATTERY IS EQUIPPED WITH peres. Such low current may not be detectable on the REMOVABLE CELL CAPS, BE CERTAIN THAT EACH ammeters built into many battery chargers. OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SER- VICE.
Page 424: Standard Procedure - Open-Circuit Voltage Test
BATTERY SYSTEM 8Fa - 13 BATTERY (Continued) F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage). •...
Page 425: Standard Procedure - Checking Battery Electrolyte Level
8Fa - 14 BATTERY SYSTEM BATTERY (Continued) • Intermittent shorts in the wiring. CAUTION: Do not open any doors, or turn on any If the IOD is over twenty-five milliamperes, the electrical accessories with the lowest milliampere problem must be found and corrected before replac- scale selected, or the multi-meter may be damaged.
Page 426: Battery System
BATTERY SYSTEM 8Fa - 15 BATTERY (Continued) (2) Wearing safety glasses, look through the bat- tery cell cap holes to determine the level of the elec- trolyte in the battery. The electrolyte should be above the hooks inside the battery cells (Fig. 11). Fig.
Page 427: Removal
8Fa - 16 BATTERY SYSTEM BATTERY HOLDDOWN (Continued) battery movement during the most extreme vehicle service replacement only as a unit with the battery operation conditions. Periodic removal and lubrica- wire harness, which may include portions of the wir- tion of the battery holddown hardware is recom- ing circuits for the generator and other components mended to prevent hardware seizure at a later date.
Page 428 BATTERY SYSTEM 8Fa - 17 BATTERY CABLES (Continued) PLE: When testing the resistance of the battery pos- itive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery pos- itive cable eyelet terminal at the starter solenoid B(+) terminal stud.
Page 429: Removal
8Fa - 18 BATTERY SYSTEM BATTERY CABLES (Continued) (3) Remove the battery thermowrap (if equipped) from the battery tray. (4) Remove the tape from the engine wire harness assembly, to access the desired battery cable. (5) One at a time, trace and disconnect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle.
Page 430: Operation
BATTERY SYSTEM 8Fa - 19 BATTERY TRAY (Continued) directly under the battery and the other is located on the right side of the tray which also serves as a cool- ant bottle neck retaining bolt. An additional bolt is located directly under the battery. The battery tray and support unit also includes a engine vacuum reservoir, located in the rear of the unit (Fig.
Page 431 8Fa - 20 CHARGING CHARGING TABLE OF CONTENTS page page CHARGING REMOVAL - 2.5L ..... . 24 DESCRIPTION - CHARGING SYSTEM .
Page 432: Diagnosis And Testing - On-Board Diagnostic System
CHARGING 8Fa - 21 CHARGING (Continued) ULES/POWERTRAIN CONTROL MODULE ERASING DIAGNOSTIC TROUBLE CODES DESCRIPTION) section for more DTC information. The DRBIII Scan Tool must be used to erase a The Check Gauges Lamp (if equipped) or Battery DTC. Lamp monitors: charging system voltage, engine The following procedures may be used to diagnose coolant temperature and engine oil pressure.
Page 433: Specifications
8Fa - 22 CHARGING CHARGING (Continued) (5) Inspect generator drive belt condition and ten- SPECIFICATIONS sion. Tighten or replace belt as required. Refer to Belt Tension Specifications(Refer to 7 - COOLING/ GENERATOR ACCESSORY DRIVE - SPECIFICATIONS). (6) Inspect decoupler pulley (if equipped). Ensure Type Engine Minimun Test...
Page 434: Battery Temperature Sensor
CHARGING 8Fa - 23 OPERATION BATTERY TEMPERATURE As the energized rotor begins to rotate within the SENSOR generator, the spinning magnetic field induces a cur- rent into the windings of the stator coil. Once the DESCRIPTION generator begins producing sufficient current, it also The PCM incorporates a Battery Temperature Sen- provides the current needed to energize the rotor.
Page 435: Removal - 2.5L
8Fa - 24 CHARGING GENERATOR (Continued) REMOVAL - 2.5L (3) Raise vehicle and support. (4) Turn wheels to the right. Remove the right (1) Disconnect the negative battery cable (Fig. 1). front splash shield (Fig. 3). Fig. 1 BATTERY CONNECTION Fig.
Page 436: Removal - 3.3/3.8L
CHARGING 8Fa - 25 GENERATOR (Continued) (6) Lower vehicle. (7) Disconnect the generator battery connection (Fig. 5). Fig. 7 AIR BOX REMOVED Fig. 5 GENERATOR CONNECTIONS 1 - Battery Connection 2 - Field Connection (8) Disconnect the field connection (Fig. 5). (9) Relocate the wiring harness on upper generator bracket (Fig.
Page 437: Removal - 3.5L
8Fa - 26 CHARGING GENERATOR (Continued) (9) Remove the lower oil dip stick tube bolt (Fig. REMOVAL - 3.5L (1) Disconnect the negative battery cable. (10) Remove wiring harness from the oil dip stick (2) Turn wheels to the right. tube (3) Raise and support the vehicle.
Page 438: Installation
CHARGING 8Fa - 27 GENERATOR (Continued) (7) Remove the 2 upper clevies bolts. (8) Remove axle from knuckle (Fig. 13). Fig. 15 GENERATOR CONNECTORS (13) Disconnect the field connector. Fig. 13 AXLE AND KNUCKLE (14) Remove the axle from vehicle, oil will leak from transmission.
Page 439: Installation - 2.5L
8Fa - 28 CHARGING GENERATOR (Continued) (5) Connect the push-in field wire connector to (5) Install axle to steering knuckle (Fig. 13). back of generator. (6) Install the 2 upper clevies bolts and tighten, (6) Install the EVAP Purge solenoid to its bracket. refer to the Suspension section.
Page 440 CHARGING 8Fa - 29 GENERATOR DECOUPLER PULLEY (Continued) DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY CONDITION POSSIBLE CAUSES CORRECTION Does not drive generator Clutch failure Replace Decoupler (Generator not Charging) REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable. (3) Raise vehicle and support.
Page 441: Description
8Fa - 30 CHARGING GENERATOR DECOUPLER PULLEY (Continued) INSTALLATION VOLTAGE REGULATOR (1) Install the Generator Decoupler to the genera- DESCRIPTION tor shaft. (2) Use Special Tool #8433 (Fig. 20) to tighten the The Electronic Voltage Regulator (EVR) is not a Generator Decoupler (Fig.
Page 442 STARTING 8Fa - 31 STARTING TABLE OF CONTENTS page page STARTING Torques ......37 DESCRIPTION .
Page 443 8Fa - 32 STARTING STARTING (Continued) INSPECTION Before removing any unit from the starting system for repair or diagnosis, perform the following inspec- tions: • Battery - Visually inspect the battery for indi- cations of physical damage and loose or corroded cable connections.
Page 444 STARTING 8Fa - 33 STARTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS 1. BATTERY 1. REFER TO THE BATTERY SECTION FOR MORE TO ENGAGE. DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY, IF FAULTY. REQUIRED. 2. STARTING CIRCUIT 2.
Page 445: Starting
8Fa - 34 STARTING STARTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION STARTER 1. BROKEN TEETH ON 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE ENGAGES, STARTER RING GEAR. IF NECESSARY. SPINS OUT BEFORE ENGINE STARTS. 2. STARTER ASSEMBLY 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND FAULTY.
Page 446 STARTING 8Fa - 35 STARTING (Continued) Remove the starter relay from the PDC as FUNCTION described in this group to perform the following tests: B (+) (1) A relay in the de-energized position should P/N POSITION SW.SENSE have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30.
Page 447: Diagnosis And Testing - Feed Circuit
8Fa - 36 STARTING STARTING (Continued) tion. If that checks OK check for continuity between (c) Connect negative lead of voltmeter to battery PCM and the terminal 85. Repair open circuit as negative terminal, and positive lead to engine required. If OK, the PCM may be defective. block near the battery cable attaching point.
Page 448 STARTING 8Fa - 37 STARTING (Continued) (3) To disable the ignition and fuel systems, dis- SPECIFICATIONS connect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Cen- STARTER ter (PDC). Refer to the PDC cover for proper relay location.
Page 449: Starter Motor Removal Removal - 2.4L
8Fa - 38 STARTING STARTER MOTOR REMOVAL REMOVAL - 2.4L (1) Release hood latch and open hood (Fig. 4). Fig. 5 BATTERY CABLE AND FIELD WIRE 2.4L Fig. 4 STARTER 2.4L (2) Disconnect and isolate the battery negative cable. (3) Disconnect solenoid wire connector from termi- nal (Fig.
Page 450: Removal - 3.3/3.8L
STARTING 8Fa - 39 STARTER MOTOR (Continued) REMOVAL - 3.3/3.8L (7) Remove starter from bellhousing (Fig. 9). (1) Release hood latch and open hood. (2) Disconnect and isolate the battery negative cable. (3) Hoist and support vehicle on safety stands. (4) Remove nut holding B+ terminal to starter solenoid (Fig.
Page 451: Removal - 2.5L
8Fa - 40 STARTING STARTER MOTOR (Continued) (4) Disconnect the solenoid connector (Fig. 10). (9) Remove the lower mounting bolt (Fig. 13). (5) Turn front wheels to the left and use long extension to reach the upper mounting bolt (Fig. 11). Fig.
Page 452: Installation
STARTING 8Fa - 41 STARTER MOTOR (Continued) (5) Remove the starter mounting bolts (Fig. 15). (8) Verify starter operation. INSTALLATION - 3.3/3.8L (1) Place starter spacer in position on transaxle bellhousing, flange toward flywheel. (2) Place starter in position on bellhousing. (3) Install bolts and ground wire (Fig.
Page 454 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEAT SYSTEM .
Page 455: Heated Glass
8G - 2 HEATED GLASS HEATED GLASS (Continued) The electrically heated Rear Window Defogger (Fig. REAR WINDOW DEFOGGER 1), Heated Power Side View Mirrors, and Heated GRID Windshield Wiper De-icer (Fig. 2)is available on select models. STANDARD PROCEDURE - GRID LINE REPAIR OPERATION REAR The Rear Window Defogger(Refer to 8 - ELECTRI-...
Page 456: Windshield Grid
HEATED GLASS 8G - 3 WINDSHIELD GRID DIAGNOSIS AND TESTING - SYSTEM TEST Electrically heated rear window defogger or the heated windshield wiper deicer operation can be checked on the vehicle in the following manner: (1) Turn the ignition switch to the ON position. (2) Using a ammeter on the battery, turn the rear defogger control switch to the ON position, a distinct increase in amperage draw should be noted.
Page 457 8G - 4 HEATED GLASS WINDSHIELD GRID (Continued) (4) For grid line, mark off area to be repaired with (10) After epoxy is properly cured remove wedge masking tape (Fig. 5). from terminal and check the operation of the rear (5) Apply conductive epoxy through slit in masking window defogger.
Page 458: Heated Mirrors Description
HEATED MIRRORS 8G - 5 HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS OPERATION ......6 DESCRIPTION .
Page 459: Operation
8G - 6 HEATED MIRRORS MIRROR SWITCH (Continued) OPERATION RELAY A LED indicator will illuminate when the switch is DESCRIPTION activated. The switch energizes the HVAC control assembly when it requests the Front Control Module There is no heated mirror relay it is integrated (FCM) to activate the rear window defogger relay.
Page 460 HEATED SEAT SYSTEM 8G - 7 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM REMOVAL ......12 DESCRIPTION .
Page 461: Heated Seat System
8G - 8 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) • Heated Seat Switch - Two heated seat only operate when the ignition switch is in the On or switches are used per vehicle, one for the driver and Accessory positions. The heated seat system will be one for the passenger side front seats.
Page 462: Driver Heated Seat Switch
HEATED SEAT SYSTEM 8G - 9 cator illuminates. When the switch rocker is moved DRIVER HEATED SEAT to its neutral position (middle), Off is selected and SWITCH both LED indicators are extinguished. Both switches provide separate resistor multi- DESCRIPTION plexed hard wire inputs to the Heated Seat Module (HSM) to indicate the selected switch position.
Page 463: Removal
8G - 10 HEATED SEAT SYSTEM DRIVER HEATED SEAT SWITCH (Continued) CHECKING SWITCH ONLY If the system is still inoperative proceed with check- ing remaining components. (1) Disconnect and isolate the battery negative cable. Remove the center bezel from the instrument REMOVAL panel (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - REMOV-...
Page 464: Heated Seat Element Description
HEATED SEAT SYSTEM 8G - 11 DRIVER HEATED SEAT SWITCH (Continued) (2) Install and tighten the three screws that secure NOTE: WHEN CHECKING HEATED SEAT ELE- the heated seat switch to the back of the instrument MENTS FOR CONTINUITY, BE CERTAIN TO MOVE panel center bezel.
Page 465: Removal
8G - 12 HEATED SEAT SYSTEM HEATED SEAT ELEMENT (Continued) REMOVAL Do not remove the OEM heating element from the seat or seat back cushion/trim covers. The original element is permanently attached and cannot be removed without permanent damage. The service replacement heating element is designed to be applied directly on the seat cushion.
Page 466: Passenger Heated Seat Switch Description
HEATED SEAT SYSTEM 8G - 13 cator illuminates. When the switch rocker is moved PASSENGER HEATED SEAT to its neutral position (middle), Off is selected and SWITCH both LED indicators are extinguished. Both switches provide separate resistor multi- DESCRIPTION plexed hard wire inputs to the Heated Seat Module (HSM) to indicate the selected switch position.
Page 467: Removal
8G - 14 HEATED SEAT SYSTEM PASSENGER HEATED SEAT SWITCH (Continued) CHECKING SWITCH ONLY (4) Reconnect the instrument panel switch bank and test the heated seat system for proper operation. (1) Disconnect and isolate the battery negative If the system is still inoperative proceed with check- cable.
Page 468: Installation
HEATED SEAT SYSTEM 8G - 15 PASSENGER HEATED SEAT SWITCH (Continued) INSTALLATION (3) Install the center bezel onto the instrument panel. Refer to Instrument Panel Center Bezel in (1) Position the heated seat switch onto the back the Body section for the procedure. of the instrument panel center bezel.
Page 470 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM INSTALLATION ......4 DESCRIPTION .
Page 471 8H - 2 HORN HORN SYSTEM (Continued) HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION HORN SOUNDS CONTINUOUSLY. (1) FAULTY HORN RELAY. (1) REFER TO HORN RELAY TEST. NOTE: IMMEDIATELY UNPLUG HORN RELAY IN THE IPM. (2) HORN CONTROL (2) CHECK TERMINAL 85 IN IPM CIRCUIT TO RELAY FOR CONTINUITY TO GROUND.
Page 472 HORN 8H - 3 HORN SYSTEM (Continued) CONDITION POSSIBLE CAUSE CORRECTION (5) FAULTY HORN SWITCH. (5) REPLACE DRIVER AIRBAG MODULE TRIM COVER. (6) FAULTY CLOCKSPRING. (6) REPLACE CLOCKSPRING. (7) FAULTY FRONT (7) REFER TO ELECTRONIC CONTROL MODULE. CONTROL MODULES/FRONT CONTROL MODULE. FUSE BLOWS WHEN HORN SOUNDS (1) SHORT CIRCUIT IN (1) REMOVE HORN RELAY, CHECK...
Page 473 8H - 4 HORN HORN (Continued) FUSE BLOWN (b) If NO continuity, replace airbag trim cover. (6) Install horn relay into intelligent power mod- (1) Verify condition of battery terminals and volt- ule. age, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM (7) Disengage wire connectors from horns.
Page 474 HORN 8H - 5 (b) If the horn does not sound, install horn relay HORN RELAY and refer to Horn Test. DIAGNOSIS AND TESTING - HORN RELAY REMOVAL (1) Remove horn relay. (1) Disconnect and isolate the battery negative (2) Using ohmmeter, test between relay connector cable.
Page 476 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL REMOVAL - 3.3/3.8L ....7 DESCRIPTION - IGNITION SYSTEM .
Page 477: Specifications
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) SPECIFICATIONS TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. 2.4L Target Magnet Screw 2.4L Camshaft Sensor 12.9 Screw 3.3/3.8L Camshaft Sensor 14.1 Screw 2.4L Ignition coil bolts 11.8 3.3/3.8LIgnition coil bolts 11.8 Spark Plugs 17.5 Knock Sensor SPARK PLUG CABLE RESISTANCE...
Page 478: Firing Order
IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) FIRING ORDER AUTO SHUT DOWN RELAY DESCRIPTION The relay is located in the Power Distribution Cen- ter (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check elec- trical terminals for corrosion and repair as necessary OPERATION The ASD sense circuit informs the PCM when the...
Page 479: Operation
8I - 4 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) OPERATION with the particular cylinder. The arrows and cylinder call outs on (Fig. 2) represent which cylinder the flat The camshaft position sensor provides cylinder spot and notches identify, they do not indicate TDC identification to the Powertrain Control Module position.
Page 480 IGNITION CONTROL 8I - 5 CAMSHAFT POSITION SENSOR (Continued) Fig. 3 EGR/CAM SENSOR 2.4L Fig. 5 AIR BOX COVER Fig. 4 Target Magnet Removal/Installation 1 - TARGET MAGNET 2 - MOUNTING BOLT 3 - REAR OF CYLINDER HEAD (6) Pull sensor up out of the chain case cover. Do Fig.
Page 481: Installation Installation - 2.4L
8I - 6 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) INSTALLATION INSTALLATION - 2.4L The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 7). Fig. 8 Camshaft Position Sensor and Spacer 1 - ELECTRICAL CONNECTOR 2 - O-RING 3 - PAPER SPACER...
Page 482: Removal Removal - 2.4L
IGNITION CONTROL 8I - 7 IGNITION COIL (Continued) (3) Remove coil pack mounting bolts. (4) Remove coil pack and heat shield (Fig. 9). REMOVAL - 3.3/3.8L (1) Disconnect the negative battery cable. (2) Remove the throttle and speed control cables from clip.
Page 483: Installation - 3.3/3.8L
8I - 8 IGNITION CONTROL IGNITION COIL (Continued) INSTALLATION - 3.3/3.8L long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond (1) Install coil over studs on bracket. quickly to retard timing when engine knock is (2) Install 2 bolts to ignition coil.
Page 484: Spark Plug
IGNITION CONTROL 8I - 9 KNOCK SENSOR (Continued) spark plug identification and specifications, Refer to the Specifications section. Do not use an ohm meter to check the resis- tance of the spark plugs. This will give an inac- curate reading. When the spark plugs use a single or double plat- inum tips and they have a recommended service life of 100,000 miles for normal driving conditions per...
Page 485: Installation
8I - 10 IGNITION CONTROL SPARK PLUG (Continued) SPARK PLUG CABLE DESCRIPTION Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electri- cal current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction.
Page 486 IGNITION CONTROL 8Ia - 1 IGNITION CONTROL TABLE OF CONTENTS page page GLOW PLUG CAMSHAFT POSITION SENSOR DESCRIPTION ......1 DESCRIPTION .
Page 487: Glow Plug
8Ia - 2 IGNITION CONTROL GLOW PLUG RELAY (Continued) The Glow Plug lamp is tied to this circuit. Lamp OPERATION operation is also controlled by the ECM. The CMP sensor is a hall effect switch. A tooth With a cold engine, the glow plug relays and glow made of a ferromagnetic material is attached to the plugs may be activated for a maximum time of 200 camshaft.
Page 488 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER CLUSTER LENS DESCRIPTION ......1 REMOVAL .
Page 489 8J - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) CLUSTER CALIBRATION DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - SELF- SPEEDOMETER CALIBRATION POINT DIAGNOSTICS 0 MPH (0 KM/H) The instrument clusters are equipped with a self 20 MPH (40 KM/H) diagnostic test feature to help identify electronic 60 MPH (100 KM/H) problems.
Page 490 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) NOTE: Always check the functionality of the cluster by running the self test prior to troubleshooting. INSTRUMENT CLUSTER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION INSTRUMENT CLUSTER NO PCI BUS MESSAGES USE A DRB III SCAN TOOL TO CHECK THE BCM. INOPERATIVE.
Page 491 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) SPEEDOMETER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO POINTER 1. INTERNAL CLUSTER 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST MOVEMENT. FAILURE. AND CHECK FOR FAULT CODES. • IF SPEEDOMETER POINTER MOVES TO CALIBRATION POINTS DURING TEST LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
Page 492 INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION ERRATIC POINTER 1. ERRATIC MESSAGE 1.A. CHECK THE BCM USING A DRB III SCAN TOOL MOVEMENT. FROM ANOTHER IF OK, GO TO STEP 1.B. IF NOT OK, REFER TO THE MODULE.
Page 493 8J - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION SPEEDOMETER 1. SPEEDOMETER OUT 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. INACCURATE. OF CALIBRATION. • IF SPEEDOMETER IS ACCURATE TO THE CALIBRATION POINTS THEN LOOK FOR ANOTHER POSSIBLE CAUSE OF INACCURACY. •...
Page 494 INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION ERRATIC POINTER 1. BAD PCI BUS 1. CHECK THE PCM USING A DRB III SCAN TOOL. MOVEMENT. MESSAGE FROM REFER TO THE PROPER POWERTRAIN DIAGNOSTIC PCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND REPAIR.
Page 495 8J - 8 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION ERRATIC POINTER 1. BAD PCI FUEL 1. USE A DRB III SCAN TOOL TO CHECK THE BCM. MOVEMENT. MESSAGE FROM THE IF OK, GO TO STEP 2. IF NOT OK, REFER TO THE BODY CONTROLLER.
Page 496 INSTRUMENT CLUSTER 8J - 9 INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION ERRATIC POINTER 1. BAD PCI BUS 1.A. CHECK PCM FAULT CODES USING A DRB III MOVEMENT. MESSAGE FROM THE SCAN TOOL. IF THERE ARE NO FAULTS, GO TO POWERTRAIN CONTROL STEP 1.B.
Page 497 8J - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION ERRATIC DISPLAY 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST FAILURE. AND CHECK FOR FAULT CODES. • IF ODOMETER PASSES THE SEGMENT TEST, FAILURE MAY NOT BE IN THE CLUSTER. LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
Page 498 INSTRUMENT CLUSTER 8J - 11 INSTRUMENT CLUSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION ALL SEGMENTS ARE ON. 1. NO PCI BUS 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. MESSAGE FROM THE IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED) TCM. PASSES TEST GO TO STEP 1.B. IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST, REPLACE CLUSTER ASSEMBLY.
Page 499 8J - 12 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) (3) Remove the plastic knee blocker reinforcement. (9) Connect the transmission range indicator cable Refer to Body, Instrument Panel, Knee Blocker Rein- end to the shift lever by flexing the HOOP on the forcement, Removal.
Page 500 INSTRUMENT CLUSTER 8J - 13 OPERATION RED BRAKE WARNING The red BRAKE warning indicator (lamp) is sup- INDICATOR plied a 12-volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by com- DESCRIPTION pleting the ground circuit either through the switch The red BRAKE warning indicator (lamp) is on the parking brake lever, the brake fluid level located in the instrument panel cluster and is used to...
Page 502 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....25 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 503 8L - 2 LAMPS/LIGHTING - EXTERIOR OPERATION - TURN SIGNAL SYSTEM ..21 REPEATER LAMP - EXPORT DIAGNOSIS AND TESTING - MULTI- REMOVAL ......23 FUNCTION SWITCH .
Page 504: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) sage transmitted by the BCM to the FCM to turn off urable) before they automatically turn off (If the key the headlamps. is in the ignition during the headlamp time delay mode, then both the headlamps and park lamps OPERATION (including panel dimming) will be ON).
Page 505: Specifications
8L - 4 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) OPERATION SPECIFICATIONS When the brake pedal is pressed, the plunger on EXTERIOR LAMPS the outside of the brake lamp switch extends out- ward. This action opens or closes the contacts of the BULB APPLICATION TABLE three switches inside the brake lamp switch.
Page 506: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 5 BRAKE LAMP SWITCH (Continued) (1) Remove the switch from the vehicle. (Refer to 8 If the switch is found to be operating properly, it - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ may be misadjusted. Do not reinstall the switch, BRAKE LAMP SWITCH - REMOVAL) replace it.
Page 507: Installation
8L - 6 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) INSTALLATION CENTER HIGH MOUNTED STOP LAMP CAUTION: Do not reuse the original brake lamp switch. The switch can only be adjusted once. That REMOVAL is during initial installation of the switch. If the (1) Disconnect and isolate the battery negative switch is not adjusted properly or has been cable.
Page 508: Fog Lamp
LAMPS/LIGHTING - EXTERIOR 8L - 7 CENTER HIGH MOUNTED STOP LAMP UNIT (Continued) FOG LAMP DIAGNOSIS AND TESTING - FOG LAMP When a vehicle experiences problems with the fog lamp system, verify the condition of the battery con- nections, fuses, charging system, fog lamp bulbs, wire connectors, relay, high beam switch, and headlamp switch.
Page 509 8L - 8 LAMPS/LIGHTING - EXTERIOR FOG LAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. Refer to WITH ENGINE Electrical, Charging. RUNNING ABOVE IDLE 2. Poor lighting circuit Z349/Z248 2.
Page 510: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 9 FOG LAMP (Continued) REMOVAL FOG LAMP - EXPORT (1) Disconnect and isolate the battery negative REMOVAL cable. (2) From behind the bumper fascia, twist bulb (1) Disconnect and isolate the battery negative counter-clockwise, and remove bulb. (Fig. 7). cable.
Page 511: Fog Lamp Unit Standard Procedure Standard Procedure - Fog Lamp Unit Alignment
8L - 10 LAMPS/LIGHTING - EXTERIOR on the alignment screen, the headlamps should be in FOG LAMP UNIT the “off” position. The fog lamps are adjusted by a adjustment screw STANDARD PROCEDURE located through the lens on Dodge vehicles, and by a knob on the back of the lamp.
Page 512: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 11 FOG LAMP UNIT (Continued) The fog lamps are adjusted by a adjustment screw FRONT POSITION LAMP - located on the underside of the fog lamp unit. EXPORT REMOVAL REMOVAL (1) Disconnect and isolate the battery negative (1) Disconnect and isolate the battery negative cable.
Page 513: Lamps/Lighting - Exterior
8L - 12 LAMPS/LIGHTING - EXTERIOR FRONT POSITION LAMP - EXPORT (Continued) HEADLAMP DIAGNOSIS AND TESTING - HEADLAMP When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, fuses, charging system, headlamp bulbs, wire connectors, relay, high beam switch, dimmer switch, and headlamp switch.
Page 514 LAMPS/LIGHTING - EXTERIOR 8L - 13 HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer to WITH ENGINE Electrical, Wiring Information. RUNNING ABOVE IDLE. 2. Poor lighting circuit Z343/Z344- 2.
Page 515: Removal
8L - 14 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) REMOVAL HEADLAMP - EXPORT (1) Disconnect and isolate the battery negative REMOVAL cable. (2) Remove headlamp unit retaining screws. (1) Disconnect and isolate the battery negative (3) Remove headlamp unit to expose back of unit. cable.
Page 516: Headlamp Leveling Motor - Export
LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP LEVELING MOTOR - EXPORT DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT HEADLAMP LEVELING MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION ONE MOTOR DOES NOT 1. Poor electrical connection at 1. Check for proper electrical connection at OPERATE.
Page 517: Headlamp Leveling Switch - Export Description
8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING HEADLAMP SWITCH SWITCH - EXPORT DIAGNOSIS AND TESTING DESCRIPTION Some vehicles are equipped with a remote head- DIAGNOSIS AND TESTING - HEADLAMP lamp leveling system. This system allows the driver SWITCH to adjust the vertical headlamp aim from the interior Using a Digital Multi-meter, perform the HEAD- of the vehicle to compensate for passenger or cargo LAMP SWITCH CONTINUITY test and refer to (Fig.
Page 518: Diagnosis And Testing - Headlamp Switch - Export
LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP SWITCH (Continued) 13 - WAY 13 - WAY DIMMER DIMMER CONNECTOR RESISTANCE CONNECTOR RESISTANCE POSITION POSITION TERMINAL TERMINAL DOME 12 TO 6 15568 - 23357 DOME 12 TO 6 15568 - 23357 PARADE 12 TO 6 5168 - 7757 PARADE...
Page 519 8L - 18 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) (3) Verify proper tire inflation. (2) If necessary, tape a line on the floor 7.62 (4) Clean headlamp lenses. meters (25 ft.) away from and parallel to the wall. (5) Verify that luggage area is loaded as the vehi- (3) Rock vehicle side-to-side three times and allow cle is routinely used.
Page 520: Standard Procedure - Headlamp Unit Alignment - Export
LAMPS/LIGHTING - EXTERIOR 8L - 19 HEADLAMP UNIT (Continued) HEADLAMP ADJUSTMENT (4) Verify proper tire inflation. (5) Clean headlamp lenses. The low beam headlamp will project on the screen (6) Verify that luggage area is loaded as the vehi- upper edge of the beam (cut-off) at the horizontal cle is routinely used.
Page 521: Installation
8L - 20 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) Fig. 20 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT 1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.) 2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE 3 - 15° CUT-OFF LINE 7 - 110 mm (4.3 in.) 4 - FRONT OF HEADLAMP Fig.
Page 522: License Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 21 HEADLAMP UNIT (Continued) Fig. 25 LICENSE PLATE LAMP - REMOVE/INSTALL 1 - LICENSE PLATE LAMP UNIT 2 - BULB Fig. 23 HEADLAMP UNIT INSTALLATION 1 - HEADLAMP UNIT 2 - HEADLAMP (1) Push bulb into socket. 3 - PARK/TURN SIGNAL LAMP (2) Install socket into lamp.
Page 523: Diagnosis And Testing - Multi-Function Switch
8L - 22 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) DIAGNOSIS AND TESTING - MULTI-FUNCTION SWITCH To test turn signal, headlamp beam select and opti- cal horn portion of the multi-function switch: (1) Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation.
Page 524: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 23 PARK/TURN SIGNAL LAMP - EXPORT (Continued) INSTALLATION (1) Install bulb to bulb socket. (2) Install bulb socket to headlamp unit. (3) Install headlamp unit. (4) Connect battery negative cable. REAR FOG LAMP - EXPORT DESCRIPTION The rear fog lamps are incorporated into the tail lamp unit.
Page 525: Installation
8L - 24 LAMPS/LIGHTING - EXTERIOR TAIL LAMP - EXPORT (Continued) INSTALLATION (4) Disengage hook attaching forward end of lamp to quarter panel opening. (1) Install bulbs by turning clockwise. (5) Disconnect wire harness connector from tail (2) Install housing to tail lamp unit. lamp unit by sliding the red lock, then pressing (3) Install the tail lamp unit (Refer to 8 - ELEC- release tab (Fig.
Page 526 LAMPS/LIGHTING - INTERIOR 8L - 25 LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR INSTALLATION ......26 SPECIFICATIONS GLOVE BOX LAMP SWITCH INTERIOR LAMPS...
Page 527: Center Console Lamp Switch Removal
8L - 26 LAMPS/LIGHTING - INTERIOR CENTER CONSOLE LAMP SWITCH REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Open console lid and remove tray. (3) Using a flat bladed tool, pry up on the switch. (4) Remove bulb from switch. INSTALLATION (1) Install bulb into switch.
Page 528: Installation
LAMPS/LIGHTING - INTERIOR 8L - 27 GLOVE BOX LAMP SWITCH (Continued) INSTALLATION READING LAMP (1) Push bulb into switch. REMOVAL (2) Connect wire harness to switch. (3) Push switch into instrument panel. The front reading lamps are incorporated into the (4) Close glove box door.
Page 529: Installation
8L - 28 LAMPS/LIGHTING - INTERIOR READING LAMP (Continued) (3) Remove bulb from lamp (Fig. 6), (Fig. 7). Fig. 5 COURTESY/READING LAMP 1 - HVAC LOUVER Fig. 7 COURTESY/READING LAMP 2 - ASSIST HANDLE 1 - COURTESY/READING LAMP 3 - LAMP LENS (1) Disconnect and isolate the battery negative cable.
Page 530 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE REMOVAL ......8 DESCRIPTION .
Page 531: Overhead Console
8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) from Fahrenheit to Celsius by selecting the desired (3) Check the fused ignition switch output (run/ U.S./Metric option from the customer programmable start) fuse in the integrated power module. If OK, go features.
Page 532: Standard Procedure
MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) ure. The electronics module is faulty and must be This allows the compass unit to compensate for small replaced. changes in the residual magnetism that the vehicle c. Failed J1850 Communication (EVIC only), may acquire during normal use.
Page 533: Standard Procedure - Compass Demagnetizing
8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) STANDARD PROCEDURE - COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console for- ward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz.
Page 534: Removal - Overhead Console
MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) Fig. 2 Variance Settings down until “VAR = XX” appears in the display. This (2) Remove the overhead console retaining screw, takes about five seconds. located in the front of console. (4) Release the push button(s). “VAR =XX ” will (3) Using your fingertips, grasp the sides of the remain in the display.
Page 535: Electronic Vehicle Info Center Description
8M - 6 MESSAGE SYSTEMS OPERATION ELECTRONIC VEHICLE INFO The EVIC has access to both non-switched and CENTER ignition switched sources of battery current so that some of its features remain operational at any time, DESCRIPTION while others may only operate with the ignition The Electronic Vehicle Information Center (EVIC) switch in the On position.
Page 536: Standard Procedure - Electronic Vehicle Information Center Programming
MESSAGE SYSTEMS 8M - 7 ELECTRONIC VEHICLE INFO CENTER (Continued) • LANGUAGE? - The options include English, nications and the BCM. If the brightness level is improper check the J1850 Data Bus circuit. Francaise, Deutsch, Italiana, or Espanol. The default The DRB III is recommended for checking the is English.
Page 537: Removal
8M - 8 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) driver door unlocks when the Unlock button of the only turn on if manually selected or if the Auto mode Remote Keyless Entry (RKE) transmitter is selected and the outside ambient light levels dic- depressed once.
Page 538: Compass/Mini-Trip Computer Description
MESSAGE SYSTEMS 8M - 9 ELECTRONIC VEHICLE INFO CENTER (Continued) NOTE: IF A NEW EVIC MODULE HAS BEEN DIAGNOSIS AND TESTING - COMPASS INSTALLED, THE COMPASS WILL HAVE TO BE MINI-TRIP COMPUTER CALIBRATED AND THE VARIANCE SET. REFER TO Compass Mini-Trip Computer (CMTC) and Com- COMPASS VARIATION ADJUSTMENT AND COM- pass Temperature (CT) data is obtained from the PASS CALIBRATION IN THE SERVICE PROCE-...
Page 539: Operation
8M - 10 MESSAGE SYSTEMS UNIVERSAL TRANSMITTER (Continued) ules push buttons located just rearward of the dis- test the universal transmitter operation again. If the play screen in the overhead console. The three unit is still inoperative, replace the faulty universal universal transmitter push buttons are identified transmitter and EVIC/CMTC module as a unit.
Page 540: Diagnosis And Testing Diagnosis And Testing - Ambient Temperature Sensor
MESSAGE SYSTEMS 8M - 11 AMBIENT TEMP SENSOR (Continued) firmed to be OK, but the temperature display is circuit cavities of the Front Control Module wire har- inoperative or incorrect, refer to Diagnosis and ness connector. There should be continuity. If OK, go Testing - Overhead Console in this group.
Page 542 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LIFTGATE SYSTEM ....1 POWER MIRRORS ......46 POWER SLIDING DOOR SYSTEM .
Page 543: Power Liftgate System
8N - 2 POWER LIFTGATE SYSTEM POWER LIFTGATE SYSTEM DESCRIPTION Fig. 1 POWER LIFTGATE INTRODUCTION Some vehicles are equipped with an automatic The pinch sensor or sensors are located along the opening and closing power liftgate system (Fig. 1). right and left sides of the power liftgate, just above This power liftgate system is a complex system con- the body line.
Page 544: Operation
POWER LIFTGATE SYSTEM 8N - 3 POWER LIFTGATE SYSTEM (Continued) the power liftgate control module via the PCI bus cir- cuit. A diagnostic scan tool, such as the DRB III is used to read and troubleshoot these Diagnostic Trou- ble Codes (DTC). Refer to the Body Diagnostic Man- ual for a complete list of diagnostic routines.
Page 545: Diagnosis And Testing - Power Liftgate System
8N - 4 POWER LIFTGATE SYSTEM POWER LIFTGATE SYSTEM (Continued) The power liftgate system is designed with a num- TEM AND/OR COMPONENTS AND/OR CAUSE PER- ber of system inhibitors. These inhibitors are neces- SONAL INJURY. sary for safety and / or feasibility of the power WARNING: NEVER STICK OBJECTS IN THE POWER liftgate system.
Page 546 POWER LIFTGATE SYSTEM 8N - 5 POWER LIFTGATE SYSTEM (Continued) LIFTGATE SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION Liftgate opens unexpectedly Failure of Power Liftgate or Body Disconnect then reconnect battery to reset Control module module, function liftgate, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures...
Page 547 8N - 6 POWER LIFTGATE SYSTEM POWER LIFTGATE SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Binding or sticking of components Establish location of binding and replace necessary components Wiring problems (system or vehicle) Troubleshoot using electrical schematics. Refer to wiring diagrams Power loss during Liftgate Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Page 548 POWER LIFTGATE SYSTEM 8N - 7 POWER LIFTGATE SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Key fob, Outside Handle or Blown Fuse Check fuse and replace overhead console switches do not power operate liftgate Battery voltage low Charge or replace battery in key fob or vehicle Failure of latch assembly Check for foreign matter preventing the...
Page 549: Standard Procedure Standard Procedure - Liftgate Adjustment
8N - 8 POWER LIFTGATE SYSTEM POWER LIFTGATE SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Liftgate continues to cinch Failure of latch assembly Check wire connections and for blown fuse closed during power mode Check for foreign matter preventing the operation of latch assembly Troubleshoot using Body Diagnostic Manual Replace components, if necessary Failure of Power Liftgate or Body...
Page 550: Standard Procedure - Power Liftgate Learn Cycle
POWER LIFTGATE SYSTEM 8N - 9 POWER LIFTGATE SYSTEM (Continued) STANDARD PROCEDURE - POWER LIFTGATE LEARN CYCLE Any time a power liftgate component is removed, replaced or a liftgate adjustment is performed a learn cycle must be performed. This learn cycle enables the power liftgate control module to learn or relearn information (travel limits, resistance to door travel, etc.) which allows it to perform properly and safely.
Page 551: Full Open Switch Description
8N - 10 POWER LIFTGATE SYSTEM PINCH SENSOR (Continued) WARNING: USE EXTREME CAUTION WHEN TEST- (2) Remove the lift gear and link rod assembly ING PINCH SENSOR OPERATION. from the vehicle(Refer to 8 - ELECTRICAL/POWER DOORS/CONTROL ROD - REMOVAL). (3) Cut the two wires leading to the full open switch or back the wires out of the electrical connec- FULL OPEN SWITCH tor (Fig.
Page 552: Operation
POWER LIFTGATE SYSTEM 8N - 11 LIFTGATE MOTOR (Continued) fer the remaining components (engage actuator, full open switch, transverse bracket and lift gear and rod) to the replacement motor assembly. (1) Disconnect and isolate the negative battery cable. (2) Remove the left rear D-pillar trim panel from the vehicle.
Page 553: Removal
8N - 12 POWER LIFTGATE SYSTEM ENGAGE ACTUATOR (Continued) Fig. 7 LIFTGATE GEAR MOTOR ASSEMBLY Fig. 8 LIFTGATE GEAR MOTOR ASSEMBLY 1 - TRANSVERSE BRACKET 1 - ENGAGE ACTUATOR RETAINING SCREWS 2 - ENGAGE ACTUATOR 2 - LIFT GEAR RETAINING BOLTS 3 - LIFT GEAR AND ROD ASSEMBLY 4 - LIFTGATE MOTOR (4) Install the left rear D-pillar trim on the vehi-...
Page 554: Transverse Bracket
POWER LIFTGATE SYSTEM 8N - 13 TRANSVERSE BRACKET (Continued) (5) Connect the gear motor assembly electrical con- nector and engage retaining pushpin. (6) Install the appropriate D-pillar trim from the vehicle. Refer to Body for the procedure. LIFT GEAR & LINK ROD DESCRIPTION Fig.
Page 555: Description
8N - 14 POWER LIFTGATE SYSTEM LIFT GEAR & LINK ROD (Continued) OPERATION LATCH One end of the rod assembly is attached to the lift- DESCRIPTION gate, the other attached to the lift gear. When the lift gear is driven by the gear motor assembly the lift- gate is moved to the open or closed position.
Page 556: Description
POWER LIFTGATE SYSTEM 8N - 15 LATCH (Continued) OPERATION On the power cinch/release latch, the latch mounted actuator provides the torque required to close the power liftgate from the secondary to the pri- mary closed and latched position. On the power cinch/release latch and the power release only latch, the actuator releases the liftgate from the primary closed and latched position to the fully unlatched and...
Page 557: Operation
8N - 16 POWER LIFTGATE SYSTEM LATCH ACTUATOR (Continued) (5) Grab the latch assembly and unhook the key The exterior handle switch is a serviceable compo- cylinder link rod from the key cylinder (Fig. 13). nent. Consult your Mopar™ parts catalog for a spe- (6) Place the latch assembly on a bench and locate cific part number.
Page 558: Exterior Handle Switch
POWER LIFTGATE SYSTEM 8N - 17 EXTERIOR HANDLE SWITCH (Continued) chime/thermistor assembly is hardwired to the power liftgate module. Second the thermistor provides a outside temperature reading by way of a resistance reading ( - ohms) supplied to the power liftgate module.
Page 559 8N - 18 POWER SLIDING DOOR SYSTEM POWER SLIDING DOOR SYSTEM TABLE OF CONTENTS page page POWER SLIDING DOOR SYSTEM RIGHT B-PILLAR SWITCH DESCRIPTION ......18 DESCRIPTION .
Page 560 POWER SLIDING DOOR SYSTEM 8N - 19 POWER SLIDING DOOR SYSTEM (Continued) Fig. 1 Power Sliding Door Introduction referred to, is an open and close command switch located on the vehicles interior body side B-pillar trim. The overhead console switch, is an open and close command switch located in the vehicle’s over- head console.
Page 561 8N - 20 POWER SLIDING DOOR SYSTEM POWER SLIDING DOOR SYSTEM (Continued) During the door open cycle, if the power sliding door module detects sufficient resistance to door travel, such as an obstruction in the door’s path, the power sliding door module will immediately stop door movement and reverse door travel to the full open or closed position.
Page 562: Power Sliding Door System
POWER SLIDING DOOR SYSTEM 8N - 21 POWER SLIDING DOOR SYSTEM (Continued) with the open fuel tank filler door, mechanical link- ING DOOR SYSTEM OR COMPONENTS AND/OR age prevents the side door from opening and striking CAUSE PERSONAL INJURY. the fuel door. Refer to the Body section of this man- DIAGNOSIS AND TESTING - POWER SLIDING ual for detailed information on the fuel door lockout feature.
Page 563 8N - 22 POWER SLIDING DOOR SYSTEM POWER SLIDING DOOR SYSTEM (Continued) POWER SLIDING DOOR SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION Door opens unexpectedly Failure of sliding door control or Disconnect then reconnect battery to reset body control module module, function door, if no function exists check for loose wire connections, Refer to the Body Diagnostic Manual for detailed procedures...
Page 564 POWER SLIDING DOOR SYSTEM 8N - 23 POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Replace the handle if necessary Failure of latch assembly Check cable connections Check for foreign matter preventing the operation of latch assembly Replace latch assembly, if necessary Failure of outside handle cable Check cable for binding assembly...
Page 565 8N - 24 POWER SLIDING DOOR SYSTEM POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Low battery voltage Charge battery Failure of sliding door control or Disconnect then reconnect battery to reset body control module module, function door, if no function exists check for loose wire connections, see Body Diagnostic Manual for detailed procedures Failure of drive assembly...
Page 566 POWER SLIDING DOOR SYSTEM 8N - 25 POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Striker damaged Replace striker if necessary Cables worn and stretched Replace cables as necessary Binding or sticking of components Establish location of binding and replace necessary components Key fob, B-pillar or Blown Fuse...
Page 567 8N - 26 POWER SLIDING DOOR SYSTEM POWER SLIDING DOOR SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION Check for foreign matter preventing the operation of latch assembly Troubleshoot using body diagnostic manual Replace latch assembly, if necessary Failure of inside/outside handle Go to that POSSIBLE CAUSE and review assembly CORRECTIONS...
Page 568: Standard Procedure - Power Door
POWER SLIDING DOOR SYSTEM 8N - 27 POWER SLIDING DOOR SYSTEM (Continued) CAUTION: Be certain to use the correct torque STANDARD PROCEDURE specification (35 in.lbs.) when installing the door motor retaining screws. STANDARD PROCEDURE - WELLNUT REPLACEMENT Vehicles equipped with a power sliding door utilize STANDARD PROCEDURE - POWER DOOR wellnuts.
Page 569: Description
8N - 28 POWER SLIDING DOOR SYSTEM POWER SLIDING DOOR SYSTEM (Continued) Use a known good vehicle for side door comparison OPERATION data. Refer to the Side Door Adjustment procedure in The power latch performs the same operation as a the Body section of the service manual for detailed full manual door latch as well as power cinch, instructions.
Page 570: Installation
POWER SLIDING DOOR SYSTEM 8N - 29 LATCH (Continued) (5) Partially close the door and pull the latch assembly out of the side door inner panel. (6) Disconnect all electrical connectors leading to the latch assembly. (7) Disconnect the inside and outside handle cables from the latch assembly.
Page 571: Installation
8N - 30 POWER SLIDING DOOR SYSTEM SLIDING DOOR MOTOR (Continued) (2) Remove the door trim panel from the appropri- FULL OPEN SWITCH ate side door. Refer to the Body section for the pro- cedure. DESCRIPTION (3) Remove water shield as necessary to gain access to motor assembly.
Page 572: Description
POWER SLIDING DOOR SYSTEM 8N - 31 OPERATION LEFT B-PILLAR SWITCH When the Pillar switch is depressed a signal is DESCRIPTION sent to the Body Control Module (BCM), this signal is then sent to the Power Sliding Door Module, tell- Vehicles equipped with power sliding side door/s ing it to start a power open or close cycle.
Page 573: Removal
8N - 32 POWER SLIDING DOOR SYSTEM LOWER DRIVE UNIT (Continued) Fig. 10 Lower Drive Unit Fig. 11 Sliding Door Lower Hinge Assembly 1 - Lower Drive Unit 1 - Lower Drive Unit Cover 2 - Flex Drive Assembly 2 - Lower Drive Unit Cover Retaining Screws 3 - Sliding Door 4 - Lower Hinge Arm Bracket REMOVAL...
Page 574: Lower Drive Unit Track & Rack Description
POWER SLIDING DOOR SYSTEM 8N - 33 REMOVAL LOWER DRIVE UNIT TRACK & (1) Disconnect and isolate the negative battery RACK cable. (2) Remove the side door sill plate from the lower DESCRIPTION of the door opening. Refer to the Body section for the procedure.
Page 575: Wiring Harness
8N - 34 POWER SLIDING DOOR SYSTEM LOWER DRIVE UNIT TRACK & RACK (Continued) Fig. 15 Lower Track Retaining Bolts Fig. 16 Wire Harness Position and Orientation 1 - Lower Track Retaining Bolts 1 - Lower Door Track and Rack Assembly 2 - Lower Door Track 2 - Wire Harness 3 - Rack Access Hole Sealing Patches...
Page 576: Installation
POWER SLIDING DOOR SYSTEM 8N - 35 WIRING HARNESS (Continued) (9) Install the appropriate door trim panel on the sliding side door. Refer to the Body section for the procedure. (10) Connect the negative battery cable. FLEX DRIVE DESCRIPTION Fig. 17 Lower Hinge/Drive Assembly 1 - Lower Drive Unit Cover 2 - Lower Drive Unit Cover Retaining Screws 3 - Sliding Door...
Page 577: Operation
8N - 36 POWER SLIDING DOOR SYSTEM FLEX DRIVE (Continued) OPERATION With one end of the flex drive attached to the door motor and the other attached to the lower drive unit, the flex drive transfers the power and torque from the motor to the drive unit.
Page 578: Sliding Door Module
POWER SLIDING DOOR SYSTEM 8N - 37 FLEX DRIVE (Continued) Fig. 22 Side Door Components Fig. 21 Flex Drive Cable 1 - Sliding Door Control Module 1 - Door Motor 2 - Module Retaining Screw 2 - Flex Drive Collar 3 - Module Electrical Connectors 3 - Flex Drive Inner Shaft 4 - Door Motor Assembly...
Page 579: Removal
8N - 38 POWER SLIDING DOOR SYSTEM SLIDING DOOR MODULE (Continued) REMOVAL INSTALLATION (1) Disconnect and isolate the negative battery (1) Position the control module and install the cable. retaining screw. (2) Remove the appropriate door trim panel from (2) Connect the control module electrical connec- the vehicle.
Page 580 POWER LOCKS 8N - 39 POWER LOCKS TABLE OF CONTENTS page page POWER LOCKS STANDARD PROCEDURE - BATTERY DESCRIPTION ......39 REPLACEMENT .
Page 581: Power Locks
8N - 40 POWER LOCKS POWER LOCKS (Continued) REMOTE KEYLESS ENTRY SYSTEM AUTOMATIC DOOR LOCKS The BCM is equipped with a disable feature to stop the speed sensitive automatic door locks from functioning. The DISABLE feature can be switched ON or OFF as desired. When the system is DIS- ABLED the door locks will operate normally, but will not lock automatically when the vehicle is rolling.
Page 582: Operation
POWER LOCKS 8N - 41 POWER LOCKS (Continued) DOOR LOCK CIRCUIT PROTECTION DOOR CYLINDER LOCK The BCM controls the door lock output drivers. If SWITCH the door lock switch is actuated continuously for more than one second the BCM will turn the output DESCRIPTION driver OFF (the BCM would consider the switch The Door Cylinder Lock Switch is used to:...
Page 583: Removal
8N - 42 POWER LOCKS DOOR CYLINDER LOCK SWITCH (Continued) CAUTION: Do not disconnect the switch from the To test an individual door lock motor, disconnect rear of the door key cylinder. This switch is a one the electrical connector from the motor. To lock the door, connect a 12 volt power source to the positive time use switch.
Page 584: Removal
POWER LOCKS 8N - 43 DOOR LOCK SWITCH (Continued) REMOVAL age the rubber gasket during separation of the hous- ing halves. (1) Disconnect and isolate the battery negative cable. (2) Remove door trim panel. Refer to Body, Door - Front, Trim Panel, Removal. (3) Disconnect wire connector from back of door lock switch.
Page 585: Remote Keyless Entry Module Description
8N - 44 POWER LOCKS abbreviated chime to acknowledge that the program- REMOTE KEYLESS ENTRY ming of the transmitter has been completed and was MODULE successful. (7) Repeat step 6 for all transmitters that will be DESCRIPTION used with this vehicle (up to 4 total). The RKE module is capable of retaining up to four (8) Programming mode will last for 30 seconds.
Page 586: Installation
POWER LOCKS 8N - 45 REMOTE KEYLESS ENTRY MODULE (Continued) INSTALLATION (1) Position the RKE module and install the screws. (2) Connect the wire connector to the RKE module (Fig. 4). (3) Install the instrument panel top pad. (4) Connect the battery negative cable. SLIDING DOOR LOCK MOTOR REMOVAL (1) Disconnect and isolate the negative battery...
Page 587 8N - 46 POWER MIRRORS POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......49 DESCRIPTION .
Page 588 POWER MIRRORS 8N - 47 POWER MIRRORS (Continued) Fig. 1 Power Mirror Connector POWER MIRROR MOTOR TEST SWITCH CONNECTOR 12 Volts Ground MIRROR REACTION Right Left PIN 12 PIN 6 — PIN 7 PIN 6 — LEFT PIN 6 PIN 12 —...
Page 589: Power Mirrors
8N - 48 POWER MIRRORS AUTOMATIC DAY / NIGHT MIRROR (Continued) The mirror switch allows the driver a manual con- (5) Turn the ignition switch to the On position. Set trol of whether the automatic dimming feature is the parking brake. Place the transmission gear selec- operational.
Page 590: Remote Switch
POWER MIRRORS 8N - 49 (4) If results shown in the table are not obtained, REMOTE SWITCH replace the switch. DIAGNOSIS AND TESTING - REMOTE SWITCH REMOVAL (1) Remove power mirror switch. (Refer to 8 - (1) Disconnect and isolate the battery negative ELECTRICAL/POWER MIRRORS/POWER MIRROR cable.
Page 591 8N - 50 POWER MIRRORS POWER FOLDAWAY MIRROR SWITCH - EXPORT (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the upper and lower steering column shroud (Refer to 19 - STEERING/COLUMN/LOWER SHROUD - REMOVAL). (3) Disconnect electrical harness connector. Fig.
Page 592 POWER SEAT SYSTEM 8N - 51 POWER SEAT SYSTEM TABLE OF CONTENTS page page POWER SEAT SYSTEM OPERATION ......57 DESCRIPTION DIAGNOSIS AND TESTING - PASSENGER DESCRIPTION .
Page 593: Power Seat System
8N - 52 POWER SEAT SYSTEM POWER SEAT SYSTEM (Continued) DESCRIPTION - MEMORY SYSTEM An electronic memory system is available on some models. The memory system is able to store and recall the driver side power seat positions (including the power recliner position) and both outside side view mirrors positions for two drivers.
Page 594: Operation - Power Seat System
POWER SEAT SYSTEM 8N - 53 POWER SEAT SYSTEM (Continued) • Body Control Module (BCM) - Refer to Body • Seat Front Down or Up • Seat Rear Down or Up Control Module in Electronic Control Modules for • Recliner Rearward or Forward more information.
Page 595: Diagnosis And Testing - Memory System
8N - 54 POWER SEAT SYSTEM POWER SEAT SYSTEM (Continued) system is receiving the proper hard wired inputs and DRB III scan tool and the proper Diagnostic Proce- relaying the proper hard wired outputs to perform its dures manual. The DRB III scan tool can provide driver side power seat functions.
Page 596: Diagnosis And Testing - Driver Seat
POWER SEAT SYSTEM 8N - 55 DRIVER SEAT SWITCH (Continued) The switch is secured to the back of the seat cush- DRIVER SEAT SWITCH CONTINUITY TEST ion side shield with two screws. However, the control TABLE knobs for the seat switch unit must be removed before the seat switch can be removed from the side SWITCH CONTINUITY BETWEEN...
Page 597: Installation
8N - 56 POWER SEAT SYSTEM DRIVER SEAT SWITCH (Continued) MEMORY SET SWITCH DESCRIPTION Fig. 4 Removing Switch Control Knobs - Typical (3) Remove the screws that secure the outboard seat cushion side shield to the seat cushion frame. Refer to the Body section of the service manual for Fig.
Page 598: Diagnosis And Testing - Memory Switch
POWER SEAT SYSTEM 8N - 57 MEMORY SET SWITCH (Continued) See the owner’s manual in the vehicle glove box for INSTALLATION more information on the features, use and operation (1) Position the memory switch and install and of the memory switch. tighten the two screws that secure the memory switch to the back of the driver side front door trim DIAGNOSIS AND TESTING - MEMORY SWITCH...
Page 599 8N - 58 POWER SEAT SYSTEM PASSENGER SEAT SWITCH (Continued) DIAGNOSIS AND TESTING - PASSENGER SEAT REMOVAL SWITCH (1) Remove the power seat switch, refer to the Switch Removal and Installation procedures in this section. (2) Using an ohmmeter, check pin #1 of the power seat switch connector for continuity to ground.
Page 600: Installation
POWER SEAT SYSTEM 8N - 59 PASSENGER SEAT SWITCH (Continued) (7) Remove the power seat switch from the out- OPERATION board seat cushion side shield. When memory system operation is requested (depressing of the memory switch), a resistor multi- INSTALLATION plexed signal is sent from the memory switch to the (1) Position the power seat switch onto the out- body control module (BCM).
Page 601: Driver Power Seat Track Description
8N - 60 POWER SEAT SYSTEM ground path to the motor are reversed through the DRIVER POWER SEAT TRACK switch contacts. This causes the adjuster motor to run in the opposite direction. DESCRIPTION No power seat switch should be held applied in any The eight-way power seat option includes a electri- direction after the adjuster has reached its travel cally operated power seat track located under each...
Page 602: Removal
POWER SEAT SYSTEM 8N - 61 DRIVER POWER SEAT TRACK (Continued) cle. Check for battery voltage at the fused B(+) INSTALLATION circuit cavity of the power seat wire harness connec- (1) Position the seat cushion on the seat track. tor for the power seat switch. If OK, go to Step 4. If (2) Install the four seat track retaining bolts in the not OK, repair the open fused B(+) circuit to the seat cushion pan.
Page 603: Operation
8N - 62 POWER SEAT SYSTEM PASSENGER POWER SEAT TRACK (Continued) The power seat track unit cannot be repaired, and at its travel limit. If the power seat track adjuster is serviced only as a complete unit. If any component still fails to operate in only one direction, refer to in this unit is faulty or damaged, the entire power Diagnosis and Testing Power Seat Switch in this...
Page 604 POWER SEAT SYSTEM 8N - 63 PASSENGER POWER SEAT TRACK (Continued) (1) Remove the appropriate seat from the vehicle INSTALLATION (Refer to 23 - BODY/SEATS/SEAT - REMOVAL). (1) Position the seat cushion on the seat track. (2) Remove the rear fabric blocker trim panel from (2) Install the four seat track retaining bolts in the the rear of the front seat.
Page 605 8N - 64 POWER WINDOWS POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS INSTALLATION ......65 DESCRIPTION .
Page 606 POWER WINDOWS 8N - 65 POWER WINDOWS (Continued) If window moved completely up or down, reverse (2) Disconnect power vent window motor wire con- the jumper probes and cycle window to the opposite nector from body harness. position to verify full operation. (3) Using two jumper wires, connect one to a bat- If motor grunts and does not move, verify that reg- tery (+) source and the other to a good ground (-).
Page 607 8N - 66 POWER WINDOWS VENT WINDOW MOTOR (Continued) POWER WINDOW MASTER SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN 13 and 1 13 and 2 13 and 3 13 and 4 13 and 5 13 and 6 13 and 7 13 and 8 UP DRIVER 11 and 8 *DOWN DRIVER...
Page 608 POWER WINDOWS 8N - 67 WINDOW SWITCH (Continued) PASSENGER WINDOW SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN 3 AND 8 2 AND 5 1 AND 8 DOWN 1 AND 5 (5) If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature.
Page 610 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS SEAT BELT FIRST ROW OUTBOARD - SWB DESCRIPTION ......2 FOUR DOOR OPERATION .
Page 611: Restraints Description
8O - 2 RESTRAINTS FROM THE BODY TO MINIMIZE POSSIBILITY OF RESTRAINTS INJURY IF ACCIDENTAL DEPLOYMENT OCCURS. REPLACE AIRBAG SYSTEM COMPONENTS WITH DESCRIPTION MOPAR REPLACEMENT PARTS. SUBSTITUTE This vehicle is equipped with a Frontal Impact Air- PARTS MAY APPEAR INTERCHANGEABLE, BUT bag System, which utilizes the driver/passenger air- INTERNAL DIFFERENCES MAY RESULT IN INFE- bags and seatbelt pretensioners.
Page 612: Clock Spring Description
RESTRAINTS 8O - 3 RESTRAINTS (Continued) (6) Refer to the proper Body Diagnostic Procedures REMOVAL manual if any diagnostic codes are found in Step 4 or (1) Position steering wheel and front wheels Step 5. straight ahead. (7) Erase stored diagnostic codes if there are no (2) Release hood latch and open hood.
Page 613: Standard Procedure - Clean Up
8O - 4 RESTRAINTS DRIVER AIRBAG (Continued) When the front airbag system is deployed, the fol- (7) Remove upper and lower steering column lowing MUST be replaced: shrouds. • Complete Steering Column Assembly. (8) Remove clock spring from the housing assem- •...
Page 614: Installation
RESTRAINTS 8O - 5 DRIVER AIRBAG TRIM COVER (Continued) (2) Remove the driver airbag from the steering just forward of the storage bin. The ORC monitors wheel (Refer to 8 - ELECTRICAL/RESTRAINTS/ the system to determine the system readiness. The DRIVER AIRBAG - REMOVAL).
Page 615: Passenger Airbag Description
8O - 6 RESTRAINTS CARE OF UNDEPLOYED AIRBAGS PASSENGER AIRBAG Airbags must be stored in their original special container until used for service. At no time should a DESCRIPTION source of electricity be permitted near the inflator on the back of an airbag. When carrying or handling an WARNING: NEVER DISASSEMBLE THE PASSEN- undeployed airbag, the trim side of the airbag should GER AIRBAG, THE PASSENGER AIRBAG HAS NO...
Page 616: Seat Airbag Description
RESTRAINTS 8O - 7 PASSENGER AIRBAG (Continued) (2) Install airbag attaching bolts to the instrument One in each front seat. The seat airbag inflator panel. assembly is within the airbag housing (Fig. 1). Each (3) Connect yellow wire connector from passenger airbag is mounted to the seat back frame.
Page 617: Seat Belt First Row Anchor Bracket - Lwb Removal
8O - 8 RESTRAINTS SEAT BELT OUTBOARD FRONT (Continued) SEAT BELT LEFT FIRST ROW OUTBOARD - SWB THREE DOOR REMOVAL (1) Remove first and second row seats. Refer to Owner’s manual for proper procedures. (2) Remove shoulder harness height adjuster knob by pulling it straight away from adjuster.
Page 618: Seat Belt First Row Outboard - Swb Four Door Removal
RESTRAINTS 8O - 9 SEAT BELT LEFT FIRST ROW OUTBOARD - SWB THREE DOOR (Continued) (11) Remove bolt attaching seat belt retractor to quarter panel (Fig. 4). (12) Lift retractor upward and disengage arrow head retainer holding retractor to quarter panel. (13) Remove seat belt from vehicle.
Page 619: Seat Belt First Row Outboard - Lwb Four Door Removal
8O - 10 RESTRAINTS SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR (Continued) (10) Install floor anchor bolt. Tighten seat belt NOTE: The tightening specification for all seat belt anchor bolts to 39 N·m (29 ft. lbs.) torque. anchor bolts is 39 N·m (29 ft. lbs.) torque. (11) Slide floor anchor cover over the anchor bolt.
Page 620: Seat Belt Second Right Row Outboard - Lbw With Rear Hvac Removal
RESTRAINTS 8O - 11 SEAT BELT SECOND RIGHT ROW OUTBOARD - LWB (Continued) (10) Remove quarter trim panel as necessary to gain access to HVAC unit. (11) Route seat belt webbing and turning loop through access hole in quarter trim. (12) Loosen HVAC unit enough to gain access to seat belt retractor fasteners.
Page 621: Seat Belt Second Row Outboard - Swb Removal
8O - 12 RESTRAINTS SEAT BELT SECOND RIGHT ROW OUTBOARD - LBW WITH REAR HVAC (Continued) (13) Install D-pillar trim panel. (14) Position turning loop to extension bracket. (15) Install bolt attaching turning loop to exten- sion bracket above quarter glass. Tightening seat belt bolt to 39 N·m (29 ft.
Page 622: Seat Belt Buckle - Front Inboard Removal
RESTRAINTS 8O - 13 SEAT BELT SECOND ROW OUTBOARD - SWB (Continued) Fig. 10 SEAT BELT BUCKLE - FRONT INBOARD 1 - SEAT CUSHION Fig. 9 SEAT BELT SECOND ROW OUTBOARD - 2 - SEAT BELT BUCKLE 3 - SEAT TRACK 1 - QUARTER PANEL 2 - RETRACTOR SEAT BELT BUCKLE FIRST...
Page 623: Seat Belt Buckle First Row - Two Passenger Bench Removal
8O - 14 RESTRAINTS SEAT BELT BUCKLE FIRST ROW - TWO PASSENGER BENCH REMOVAL (1) Remove seat from vehicle. (2) Remove bolt attaching inboard seat belt buckle to seat frame (Fig. 11). (3) Remove belt from seat. Fig. 12 SEAT BELT BUCKLE SECOND ROW - THREE PASSENGER BENCH 1 - ANCHOR BOLT 2 - SEAT BELTS...
Page 624: Shoulder Belt Height Adjuster Removal
RESTRAINTS 8O - 15 SEAT BELT TENSIONER (Continued) Once a vehicle has been in an accident, the ten- SHOULDER BELT HEIGHT sioner must be replaced along with any deployed air- ADJUSTER KNOB bags and broken or damaged parts. Refer to the proper Body Diagnostic Procedures manual for diag- REMOVAL nosis and testing.
Page 625: Side Impact Airbag Control Module Description
8O - 16 RESTRAINTS REMOVAL SIDE IMPACT AIRBAG CONTROL MODULE NOTE: Diagnose the SIACM using the service/diag- nostic manual. DESCRIPTION The side airbag system is a safety devise designed (1) Disconnect and isolate the battery negative to reduce the risk of fatality or serious injury, caused cable terminal.
Page 626 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL OPERATION ......4 DESCRIPTION .
Page 627: Speed Control
8P - 2 SPEED CONTROL SPEED CONTROL (Continued) NOTE: Turning the system off by depressing the throttle opening, while inhibiting/delaying down- OFF switch or turning off the ignition switch will shifts. erase the set speed stored in the PCM. OPERATION For added safety, the speed control system is pro- If opening the throttle alone cannot maintain the grammed to disengage for any of the following condi-...
Page 628: Diagnosis And Testing - Road Test
SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) OPERATION tem. The cause of any speedometer problems should be corrected before proceeding. Refer to the Instru- The Transmission Control Module (TCM) first ment Cluster for speedometer diagnosis. senses that the speed control is set. If the set speed If a road test verifies an inoperative system, and is exceeded by more than 4 mph (6.5 km/hr) and the the speedometer operates properly, check for:...
Page 629: Cable Description
8P - 4 SPEED CONTROL OPERATION CABLE The PCM controls the solenoid valve body. The DESCRIPTION solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum The speed control servo cable is connected between servo.
Page 630: Installation
SPEED CONTROL 8P - 5 SERVO (Continued) (4) Depress lock tabs holding speed control and (1) Install retaining clip to cable at servo. throttle cable casing to cable mount bracket. (2) Install 2 nuts at cable to servo and servo (5) Disconnect vacuum line from speed control bracket, tighten to 7 N·m (60 ins.
Page 631: Installation
8P - 6 SPEED CONTROL SWITCH (Continued) (2) Turn off ignition. OPERATION (3) Remove the air bag, refer to the restraint sec- The reservoir stores engine vacuum. Manifold vac- tion for more information. uum is supplied from the brake booster check valve. (4) Remove the screw from bottom of the switch.
Page 632 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY INSTALLATION ......3 DESCRIPTION .
Page 633 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) Passive disarming occurs upon normal vehicle ond time-out will restart from the time of the second entry by unlocking either door with the ignition key/ actuation. remote transmitter. This disarming will also halt the If the security lamp does not illuminate at all upon alarm once it has been activated.
Page 634 VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) DIAGNOSIS AND TESTING - VEHICLE THEFT DIAGNOSIS AND TESTING SECURITY SYSTEM DIAGNOSIS AND TESTING - SENTRY KEY Refer to the appropriate wiring information. The IMMOBILIZER SYSTEM wiring information includes wiring diagrams, proper wire and connector repair procedures, further details WARNING: ON VEHICLES EQUIPPED WITH AIR- on wire harness routing and retention, as well as...
Page 635 8Q - 4 VEHICLE THEFT SECURITY TRANSPONDER KEY (Continued) STANDARD PROCEDURE - TRANSPONDER PROGRAMMING USING A DRB III SCAN TOOL All Sentry Keys included with the vehicle are pre- programmed to work with the Sentry Key Immobi- lizer System (SKIS) when it is shipped from the factory.
Page 636 VEHICLE THEFT SECURITY 8Q - 5 TRANSPONDER KEY (Continued) able, Sentry Key programming will require the use of NOTE: If you attempt to start the vehicle while in a DRB III scan tool. “Customer Learn” mode (LED flashing), the vehicle The steps required to program Sentry Keys with will behave as though an invalid key is being used two valid Sentry Keys follows:...
Page 638 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS HEADLAMP WASHER PUMP MOTOR - EXPORT DESCRIPTION ......1 REMOVAL .
Page 639: Wipers/Washers
8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) • Speed sensitive intermittent wipe OPERATION • Wipe after wash • Park (switch OFF) FRONT WIPER/WASHER SYSTEM The windshield wiper circuits are continuously The windshield washer circuit is protected by a 15 monitored and controlled by the Body Control Mod- amp Cartridge Fuse located in the IPM.
Page 640: Diagnosis And Testing - Failed Park Switch
WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) • HIGH SPEED - Wipers operate at high speed. DIAGNOSIS AND TESTING - FAILED PARK • WIPE AFTER WASH - Wipers operate at low SWITCH speed in any mode setting. Wipers operate only while If the wiper park switch has failed, the windshield the wash button is depressed with switch in the OFF wipers will operate as follows:...
Page 641 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. BLADE STRUCTURE BENT. 3. REPLACE BLADE. 4. BLADE ELEMENT HAS 4. REPLACE BLADE. PERMANENT SET. WIPER KNOCK AT 1. LINKAGE BUSHINGS WORN. 1. REPLACE WORN LINK. REFER TO REVERSAL WIPER LINKAGE REMOVAL AND INSTALLATION.
Page 642: Diagnosis And Testing - Rear Wiper System
WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) DIAGNOSIS AND TESTING - REAR WIPER ule (BCM). If a problem occurs in the electronic com- ponents, wiring, switch (except integral motor park SYSTEM switch) and wiper motor a Diagnostic Trouble Code The rear window wiper system operates in several (DTC) will be stored in the BCM memory.
Page 643 8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSES CORRECTION WASHER SYSTEM WILL 1. NO WASHER FLUID IN 1. FILL WASHER RESERVOIR. NOT FLOW WASHER RESERVOIR. FLUID. 2. IPM FUSE #33 BLOWN. 2. SHORT OR DEFECTIVE CIRCUIT BETWEEN IPM PIN 11 AND WASHER PUMP MOTOR CONNECTOR POSITIVE TERMINAL 2.
Page 644 WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSES CORRECTION COWL GRILLE NOZZLE 1. FROZEN NOZZLE. 1. MOVE VEHICLE INTO HEATED AREA TO WILL NOT FLOW. ALLOW TIME TO THAW NOZZLE. ASSURE WASHER FLUID IS PROPERLY BLENDED FOR AMBIENT OUTSIDE TEMPERATURES. 2.
Page 645 8R - 8 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSES CORRECTION LOW WASHER FLUID 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO LOW LEVEL INDICATOR SENSOR CONNECTOR. FLUID LEVEL SENSOR AND LOCK. INOPERATIVE. 2. OPEN POWER CIRCUIT TO 2. OPEN OR DEFECTIVE CIRCUIT FLUID LEVEL SENSOR.
Page 646: Front Washer Pump Motor Removal
WIPERS/WASHERS 8R - 9 against the reservoir and that pump connector is fac- FRONT WASHER PUMP ing up in the fully seated position. Assure the pump MOTOR is aligned to and fully seated in the reservoir cavity. (3) Push filler neck and front washer hose through REMOVAL the opening in the front fender side shield.
Page 647: Removal
8R - 10 WIPERS/WASHERS FRONT WIPER ARMS (Continued) (4) Repeat Step 1, and align as necessary until wiper stops chattering and wipes the windshield clear. REMOVAL CAUTION: The driver side wiper arm must be parked above the passenger side. Failure to do so will result in damage to the arms, blades or system.
Page 648: Headlamp Washers - Export Description
WIPERS/WASHERS 8R - 11 will spray its two timed pulses every fourth request HEADLAMP WASHERS - from the washer control. EXPORT DESCRIPTION The headlamp washers (Fig. 3) work in conjunction with the windshield washers. The headlamp washers are enabled with the headlamps ON and the wind- shield washers activated.
Page 649 8R - 12 WIPERS/WASHERS HEADLAMP WASHERS - EXPORT (Continued) HEADLAMP WASHER TEST CONDITION POSSIBLE CAUSE CORRECTION HEADLAMP WASHER 1. NO WASHER FLUID IN 1. FILL RESERVOIR. SYSTEM WILL NOT FLOW RESERVOIR. WASHER FLUID. 2. JUNCTION BLOCK FUSE 2. SHORT CIRCUIT BETWEEN JUNCTION BLOCK #5 BLOWN.
Page 650: Removal
WIPERS/WASHERS 8R - 13 HEADLAMP WASHERS - EXPORT (Continued) REMOVAL HEADLAMP WASHER HOSE - (1) Disconnect and isolate the battery negative EXPORT cable. (2) Hoist vehicle or support on jack stands. REMOVAL (3) Disconnect the hose from the nozzle inlet. To The headlamp washer hose is a special high pres- disconnect the headlamp washer hose, push down on sure hose with specific fittings, and must be replaced...
Page 651: Installation
8R - 14 WIPERS/WASHERS HEADLAMP WASHER PUMP MOTOR - EXPORT (Continued) (9) Drain washer fluid from the reservoir and into (9) Install the right front wheel and tire assembly a suitable clean container. This can be done by dis- (Refer to 22 - TIRES/WHEELS - INSTALLATION). connecting the windshield washer hose from the (10) lower vehicle from hoist or jack stands.
Page 652: Installation
WIPERS/WASHERS 8R - 15 REAR WASHER PUMP MOTOR (Continued) (12) Disconnect the reservoir from the body mount (13) Install the engine fresh air housing inside the by raising the reservoir upward slightly and then engine compartment (Refer to 9 - ENGINE/AIR down so that the reservoir filler neck and front INTAKE SYSTEM/AIR...
Page 653: Rear Wiper Motor Removal
8R - 16 WIPERS/WASHERS REAR WIPER MOTOR REAR WIPER/WASHER SWITCH REMOVAL (1) Disconnect and isolate the battery negative DESCRIPTION cable. The rear window wiper/washer switches are (2) Remove rear wiper arm. (Refer to 8 - ELEC- located on the center bezel with the hazard and TRICAL/WIPERS/WASHERS/REAR WIPER ARM - heated seat switches (Fig.
Page 654: Installation
WIPERS/WASHERS 8R - 17 WASHER FLUID LEVEL SWITCH (Continued) (6) Hoist and support vehicle on hoist or jack (5) Connect the electrical body harness connectors stands. to the washer pump motors and the fluid level sen- (7) Remove the right front wheel and tire assembly sor.
Page 655: Washer Reservoir Removal
8R - 18 WIPERS/WASHERS (5) Connect the left right front wheelhouse splash WASHER RESERVOIR shield and move aside (Refer to 23 - BODY/EXTERIOR/ WHEELHOUSE SPLASH SHIELD - INSTALLATION). REMOVAL (6) Install the right front wheel and tire assembly (1) Disconnect and isolate the battery negative (Refer to 22 - TIRES/WHEELS - INSTALLATION).
Page 656: Cleaning
WIPERS/WASHERS 8R - 19 WIPER BLADES (Continued) CLEANING (6) Install the cowl cover. (7) Install the wiper arms and blades. Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended WIPER MODULE to remove the accumulation of salt and road grime.
Page 657: Installation
8R - 20 WIPERS/WASHERS WIPER MODULE (Continued) INSTALLATION (1) Position the wiper module into the cowl. (2) Install the bolts that secure the wiper module to the dash (Fig. 11). (3) Install the nuts that retain the wiper module. (4) Connect the drain tubes to the nipples on the wiper module.
Page 658 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 MESSAGE CENTER ....8W-46-1 COMPONENT INDEX .
Page 660: Wiring Diagram Information
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 661 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 662 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 663 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 664: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 665: Description - Circuit Functions
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 666: Description - Connector, Ground And Splice Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 667: Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance are listed and explained below. Always check for non- between two points of a circuit. Low or no resistance factory items added to the vehicle before doing any in a circuit means good continuity.
Page 668: Standard Procedure - Testing Of Voltage Potential
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (2) Connect the other lead of the voltmeter to the selected test point.
Page 669: Standard Procedure - Testing For Ashort To Ground On Fuses Powering Several Loads
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS SHORT TO GROUND ON FUSES POWERING WIRING/TERMINAL SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse.
Page 670: Connector Removal
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 671 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 672 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 8 - SPECIAL TOOL 6742 2 - PICK FROM SPECIAL TOOL KIT 6680 9 - THOMAS AND BETTS CONNECTOR 3 - APEX CONNECTOR 10 - SPECIAL TOOL 6934 4 - PICK FROM SPECIAL TOOL KIT 6680 11 - TYCO CONNECTOR...
Page 673: Diode Removal
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 674: Wire
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 676 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... . 8W-42 Fog Lamps ......8W-50 A/C Compressor Clutch .
Page 677 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Mid Reading Lamps ....8W-44 Rear Lamp Assemblies ....8W-51 Mode Door Actuator .
Page 678 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ..8W-10-22, 24, 45, 47 Front Washer Pump Motor ..8W-10-16, 31, 68 A/C Compressor Clutch Front Wiper Hi/Low Relay .
Page 679 8W - 10 - 2 8W-10 POWER DISTRIBUTION Component Page Component Page Headlamp Washer Pump Motor ..8W-10-26, 52 Power Seat Circuit Breaker ..8W-10-25, 49 Headlamp Washer Relay .
Page 746 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-7, 8 Left Sliding Door Lock Motor/Ajar Switch ..8W-15-14 A/C- Heater Control .
Page 772 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page A/C- Heater Control ....8W-18-4 Integrated Power Module ... . 8W-18-2, 3 Adjustable Pedals Module .
Page 778 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auto Shut Down Relay ....8W-20-2 Fuselink ......8W-20-2, 3 Battery .
Page 782 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2, 3 G101 .
Page 786 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch ....8W-30-18 Fuse 18 ......8W-30-18, 17 A/C Compressor Clutch Relay .
Page 818 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Autostick Switch ..... 8W-31-5 Input Speed Sensor .
Page 828 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-3 Left Speed Control Switch ... 8W-33-2, 4 Clockspring .
Page 832 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Body Control Module ....8W-35-2 G200 ......8W-35-2 Brake Lamp Switch .
Page 836 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Body Control Module ..8W-39-2, 4, 7, 8, 9, Left Sliding Door Latch Sensing Switch . . . 8W-39-9 10, 11, 12, 13, 14, 15 Left Sliding Door Lock Motor .
Page 852 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Airbag Control Module ....8W-40-2 Left Sliding Door Lock Motor/Ajar Body Control Module .
Page 864 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Accessory Relay ....8W-41-3, 4 G302 .
Page 868 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ... . 8W-42-14, 16 G103 ......8W-42-14, 16 A/C Compressor Clutch Relay .
Page 869 2002 RS Service Manual Publication No. 81-370-02062 TSB 26-12-01 December, 2001...
Page 873 2002 RS Service Manual Publication No. 81-370-02062 TSB 26-12-01 December, 2001...
Page 886 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ..8W-43-2, 3, 4, 5 Instrument Cluster ....8W-43-2 Body Control Module .
Page 894 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C- Heater Control ....8W-44-8 Instrument Cluster ....8W-44-7 Accessory Relay .
Page 902 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page A/C- Heater Control ....8W-45-16, 19 Left Stop/Turn Signal Relay ... . 8W-45-5 Auto Temp Control .
Page 922 8W-46 MESSAGE CENTER 8W - 46 - 1 8W-46 MESSAGE CENTER Component Page Component Page Body Control Module ....8W-46-2 Integrated Power Module ....8W-46-2 Fuse 24 .
Page 924 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Accessory Relay ....8W-47-2, 5 Left Instrument Panel Speaker ..8W-47-3, 8 Antenna .
Page 936 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C- Heater Control ....8W-48-2 G200 ......8W-48-3 Accessory Relay .
Page 940 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temp Sensor ....8W-49-2 G301 ......8W-49-4 Automatic Day/Night Mirror .
Page 944 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Body Control Module ... . . 8W-50-2, 4, 5 Left Headlamp ..... . 8W-50-3 Diagnostic Junction Port .
Page 956 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-5 G302 ......8W-51-2, 3, 4, 5 Battery .
Page 962 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Body Control Module ... . 8W-52-2, 3, 4, 6 Left Repeater Lamp ....8W-52-6 Brake Lamp Switch .
Page 968 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Accessory Relay ..... 8W-53-3 G200 ......8W-53-6 Body Control Module .
Page 974 8W-54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Body Control Module ....8W-54-2 Left Rear Lamp Assembly ....8W-54-2 Brake Lamp Switch .
Page 978 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Accessory Relay ..... 8W-60-2 Integrated Power Module ....8W-60-2 Driver Power Window Motor .
Page 986 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Accessory Relay ....8W-61-2, 3, 4, 7 Left Sliding Door Lock Motor/Ajar Body Control Module .
Page 1006 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Automatic Day/Night Mirror ... . 8W-62-8 Memory Seat/Mirror Module ..8W-62-3, 6, 7, 8 Body Control Module .
Page 1016 8W-63 POWER SEATS 8W - 63 - 1 8W-63 POWER SEATS Component Page Component Page Body Control Module ....8W-63-5, 9 Driver Power Seat Switch ... . 8W-63-2, 6 Diagnostic Junction Port .
Page 1026 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S101 ....... 8W-42-15 S212 .
Page 1032 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-6 C202 ......8W-80-24 A/C Pressure Sensor .
Page 1033 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C322 (Memory) ..... 8W-80-39 Driver Power Seat Front Riser Position Sensor .
Page 1034 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Glove Box Lamp ....8W-80-63 Left Instrument Panel Speaker ..8W-80-75 Glow Plug Relay (Diesel) .
Page 1035 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Memory Set Switch ....8W-80-84 Rear A/C-Heater Unit (3 Zone HVAC) ..8W-80-99 Message Center (High Line) .
Page 1036 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 Component Page Component Page Right Rear Lamp Assembly ... 8W-80-107 Right Turn Signal Lamp (Built-Up-Export) ....8W-80-111 Right Rear Pillar Speaker .
Page 1037 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY CIRCUIT FUNCTION C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT Z153 18BK/GY GROUND A/C PRESSURE SENSOR - GRAY 4 WAY CIRCUIT FUNCTION C918 20BK/LB (DIESEL) A/C PRESSURE SENSOR GROUND K900 18DB/DG (GAS) SENSOR GROUND...
Page 1038 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAY CIRCUIT FUNCTION C75 12DB/GY BLOWER MOTOR HIGH DRIVER C74 12DB/WT BLOWER MOTOR M3 DRIVER Z134 12BK/OR GROUND C71 16DB/BR BLOWER MOTOR LOW DRIVER C73 14DB/VT BLOWER MOTOR M2 DRIVER C72 16DB/OR BLOWER MOTOR M1 DRIVER...
Page 1039 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS AIRBAG CONTROL MODULE (ORC) - YELLOW/RED 23 WAY CIRCUIT FUNCTION R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R62 18LB/PK PASSENGER SQUIB 2 LINE 2 R64 18LB/WT PASSENGER SQUIB 2 LINE 1 R42 18LB/BR...
Page 1040 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AUTO TEMP CONTROL C1 - WHITE 13 WAY CIRCUIT FUNCTION C161 20LB/WT DRIVER BLEND DOOR DRIVER (B) C61 20DB/LG DRIVER BLEND DOOR DRIVER (A) C133 20DB/WT PASSENGER BLEND DOOR DRIVER (B) C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A) C132 20DB/YL RECIRCULATION DOOR DRIVER (B)
Page 1041 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS AUTOSTICK SWITCH (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION T55 20YL/VT AUTOSTICK/OVERDRIVE OFF MUX INPUT Z65 20BK/YL GROUND BACK-UP LAMP SWITCH (MTX) - BLACK 2 WAY CIRCUIT FUNCTION T2 18DG/WT TRS REVERSE SENSE Z252 18BK/WT GROUND BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY...
Page 1042 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 BODY CONTROL MODULE C1 - BLACK/BLACK 6 WAY CIRCUIT FUNCTION A102 12WT/RD FUSED B(+) A701 16BR/RD FUSED B(+) (HAZARD) Z100 12BK/TN GROUND A101 12VT/RD FUSED B(+) BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY CIRCUIT FUNCTION L61 18WT/LB (BUILT-UP-EXPORT)
Page 1043 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY CIRCUIT FUNCTION G23 20VT/DB (POWER SLIDING DOOR) SLIDING DOORS OVERHEAD SWITCH MUX D23 20WT/BR FLASH PROGRAM ENABLE G152 20VT/GY (POWER SLIDING RIGHT SLIDING DOOR WAKE UP SIGNAL DOOR) G151 20VT/BR (POWER SLIDING LEFT SLIDING DOOR WAKE UP SIGNAL...
Page 1044 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY CIRCUIT FUNCTION E18 20OR/LB (POWER MIRRORS) PANEL LAMPS DRIVER (MIRROR SWITCH) E12 20OR/GY PANEL LAMPS DRIVER (HVAC) E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH) D9 20WT/GY RKE MODULE PROGRAM ENABLE G150 20VT/BR...
Page 1045 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C5 - BLACK/BLACK 34 WAY CIRCUIT FUNCTION L91 20WT/DB HAZARD SWITCH SENSE G20 20VT/BR IGNITION SWITCH SENSE G926 20VT/WT REAR WIPER SWITCH MUX RETURN L900 20WT/YL HEADLAMP SWITCH MUX RETURN L307 20WT/BR HEADLAMP SWITCH MUX L36 20WT/DB (BUILT-UP-EXPORT)
Page 1046 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BRAKE LAMP SWITCH - BLACK 6 WAY CIRCUIT FUNCTION A103 18GY/RD FUSED B(+) L50 18WT/TN BRAKE LAMP SWITCH OUTPUT V30 20VT/WT (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE Z429 20BK/OR GROUND B29 20DG/WT...
Page 1047 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C100 - BLACK (POWERTRAIN SIDE) CIRCUIT D21 18WT/BR D16 18WT/OR (EATX) K119 20DB/LG (DIESEL) D20 18WT/LG (GAS) D25 20WT/VT (DIESEL) D25 18WT/VT (GAS) Z111 18BK/WT N1 18DB/OR (DIESEL) N2 18DB/YL (DIESEL) K22 20OR/DB (DIESEL) V32 18VT/YL (GAS) B29 18DG/WT (GAS) B29 20DG/WT (DIESEL)
Page 1048 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C102 (2.4L) - BLACK (FUEL RAIL SIDE) CIRCUIT K11 16BR/YL K12 16BR/DB K13 16BR/LB K14 16BR/TN K342 16BR/WT K900 18DB/DG K2 18VT/OR K1 18VT/BR F855 18OR/PK (EXCEPT BUILT-UP-EXPORT) F855 18PK/YL (BUILT-UP-EXPORT) C102 (2.4L) - BLACK (POWERTRAIN SIDE) CIRCUIT K11 16BR/YL K12 16BR/DB...
Page 1049 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C102 (3.3L/3.8L) - BLACK (POWERTRAIN SIDE) CIRCUIT K342 16BR/WT K1 18VT/BR K11 16BR/YL K12 16BR/DB K13 16BR/LB K14 16BR/TN K900 18DB/DG K38 16BR/OR K58 16BR/VT F855 18PK/YL C103 (DIESEL) - BLACK (POWERTRAIN SIDE) CIRCUIT K342 16BR/WT K342 16BR/WT...
Page 1050 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C106 (BUILT-UP-EXPORT) - BLACK/YELLOW (COMPONENT SIDE) CIRCUIT L43 16WT L33 16GY L77 16BK L61 16YL Z343 16BR L13 16RD Z203 16BR C107 (BUILT-UP-EXPORT) - BLACK (FRONT END LIGHTING SIDE) CIRCUIT L44 16WT/TN L34 16WT/GY L78 18WT/OR L60 16WT/TN...
Page 1051 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C200 - GRAY (BODY SIDE) CIRCUIT C151 18LB/DG (3 ZONE HVAC) C200 20LB/DG (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) A106 20LB/RD A108 18LG/RD C152 16LB/LG (3 ZONE HVAC) C59 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) P159 20TN/DG (BUILT-UP-EXPORT) C200 20LB/DG (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) K32 18DB/YL (GAS)
Page 1052 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C200 - GRAY (BODY SIDE) CIRCUIT P66 20TN/LG (MEMORY) P67 20TN/OR (MEMORY) P68 20TN/YL (MEMORY) P69 20TN/WT (EXCEPT BUILT-UP-EXPORT) (MEMORY) P69 20TN/DB (BUILT-UP-EXPORT) (MEMORY) P70 18TN/LB (MEMORY) P71 18TN/GY (BUILT-UP-EXPORT) (MEMORY) P71 18TN/DG (EXCEPT BUILT-UP-EXPORT) (MEMORY) P72 18TN/GY (MEMORY) P73 18TN/VT (EXCEPT BUILT-UP-EXPORT) (MEMORY) P73 18TN/YL (BUILT UP-EXPORT) (MEMORY)
Page 1053 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C200 - GRAY (INSTRUMENT PANEL SIDE) CIRCUIT C200 20LB/DG (BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL) C151 18LB/DG (3 ZONE HVAC) A106 20LB/RD A108 18LG/RD C59 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) C152 16LB/LG (3 ZONE HVAC) P159 20TN/DG (BUILT-UP-EXPORT) C200 20LB/DG (EXCEPT BUILT-UP-EXPORT) (AUTOMATIC TEMPERATURE CONTROL)
Page 1054 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C200 - GRAY (INSTRUMENT PANEL SIDE) CIRCUIT P69 20TN/WT (MEMORY) P70 18TN/LB (MEMORY) P71 18TN/DG (MEMORY) P72 18TN/GY (MEMORY) P73 18TN/VT (MEMORY) P74 18TN/DB (MEMORY) P75 18TN/LG (MEMORY) D23 20WT/BR (RHD) P112 20TN/OR (EXCEPT BUILT-UP-EXPORT) (MEMORY POWER MIRRORS) B25 20DG/WT (BUILT-UP-EXPORT) P114 20TN/WT (EXCEPT BUILT-UP-EXPORT) (MEMORY POWER MIRRORS) C154 20LB/OR (AUTOMATIC TEMPERATURE CONTROL) (3 ZONE HVAC)
Page 1055 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C201 - YELLOW (BODY SIDE) CIRCUIT R53 18LG/YL R55 18LG/DG R54 18LB/YL R56 18LB/DG C202 - GRAY (INSTRUMENT PANEL SIDE) CIRCUIT Z134 12BK/OR (AUTOMATIC TEMPERATURE CONTROL) C34 20DB/LB (MANUAL TEMPERATURE CONTROL) C56 20DB/LB (AUTOMATIC TEMPERATURE CONTROL) C32 20DB/TN C33 20LB/BR C61 20DB/LG...
Page 1056 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C203 (UNITED KINGDOM) - WHITE (INSTRUMENT PANEL SIDE) CIRCUIT D97 20WT/OR D96 20WT/LB A600 20RD/LB G944 20LB/BR C300 (LHD) - BLACK (LEFT DOOR SIDE) CIRCUIT G75 20VT Z75 20BK/VT (EXCEPT POWER LOCKS) Z821 12BK/BR (POWER LOCKS) X53 20DG X55 20DG/BR...
Page 1057 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C300 (RHD) - BLACK (LEFT DOOR SIDE) CIRCUIT G75 20VT Z822 20BK/BR X53 20DG X55 20DG/BR G161 20VT/DG P1 20TN/LG P3 20TN/WT F304 12WT/PK C300 (RHD) - BLACK (BODY SIDE) CIRCUIT G75 20VT Z822 20BK/BR X53 20DG X55 20DG/BR...
Page 1058 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C302 - LT. GRAY (RIGHT DOOR SIDE) CIRCUIT M21 20YL/BR X13 16DG/GY X15 16GY/DG X154 20GY/YL X156 20GY/LB G162 20VT/WT (POWER LOCKS) G200 20VT/BR (RHD) (MEMORY) G920 20VT/YL (RHD) (MEMORY) Q16 12OR/TN Q26 12OR/GY C302 - LT.
Page 1059 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C303 (LHD) - BLACK (BODY SIDE) CIRCUIT G74 20VT/WT Z822 20BK/BR X54 20GY X56 20GY/BR G160 20VT/LG P2 20TN/GY P4 20TN/BR F304 18GY/PK (EXCEPT POWER WINDOWS) F304 12WT/PK (POWER WINDOWS) C303 (RHD) - BLACK (RIGHT DOOR SIDE) CIRCUIT G74 20VT/WT Z821 12BK/BR...
Page 1060 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C304 - YELLOW (BODY SIDE) CIRCUIT R54 18LB/YL (RHD) R53 18LG/YL (LHD) R56 18LB/DG (RHD) R55 18LG/DG (LHD) R31 18LG/OR R33 18LG/WT C304 - YELLOW (SEAT SIDE) CIRCUIT R54 18LB/YL (RHD) R53 18LG/YL (LHD) R56 18LB/DG (RHD) R55 18LG/DG (LHD) R31 18LG/OR...
Page 1061 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C306 - YELLOW (BODY SIDE) CIRCUIT R53 18LG/YL (RHD) R54 18LB/YL (LHD) R55 18LG/DG (RHD) R56 18LB/DG (LHD) R32 18LB/OR R34 18LB/WT C306 - YELLOW (SEAT SIDE) CIRCUIT R53 18LG/YL (RHD) R54 18LB/YL (LHD) R55 18LG/DG (RHD) R56 18LB/DG (LHD) R32 18LB/OR...
Page 1062 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C308 - BLUE (LEFT DOOR WIRE TRACK ASSEMBLY SIDE) CIRCUIT Z77 20BK (MANUAL SLIDING DOOR) Z825 14BK (POWER SLIDING DOOR) P32 20BK/TN G77 20BK/DG P5 20BK/DB G151 20BK/GY (POWER SLIDING DOOR) D25 20BK/VT (POWER SLIDING DOOR) A113 14BK/RD (POWER SLIDING DOOR) C308 - BLUE (BODY SIDE)
Page 1063 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C309 - GREEN (BODY SIDE) CIRCUIT Z76 20BK/YL (EXCEPT BUILT-UP-EXPORT MANUAL SLIDING DOOR) Z824 14BK/WT (EXCEPT BUILT-UP-EXPORT / POWER SLIDING DOORS) (BUILT-UP-EXPORT) P34 20TN/LB G76 20VT/YL P38 20TN/DB G152 20VT/GY (POWER SLIDING DOOR) D25 20WT/VT (POWER SLIDING DOOR) A113 12WT/RD (POWER SLIDING...
Page 1064 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C311 - GRAY (BODY SIDE) CIRCUIT C153 12DB/BR (3 ZONE HVAC) F850 20LB/PK (3 ZONE HVAC) F504 20GY/PK (AUTOMATIC TEMPERATURE CONTROL) C121 20DB/DG (3 ZONE HVAC) D22 20WT/TN (AUTOMATIC TEMPERATURE CONTROL) C22 20LB/WT (3 ZONE HVAC) D17 20WT/DG (AUTOMATIC TEMPERATURE CONTROL) C151 18LB/DG (3 ZONE HVAC)
Page 1065 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C312 - GRAY (BODY SIDE) CIRCUIT M27 20YL/LB M22 20YL/OR G23 20VT/DB G25 20VT/TN D25 20WT/VT A114 20GY/RD F503 20WT/PK P112 20TN/OR (EXCEPT BUILT-UP-EXPORT/POWER MIRRORS) (EXCEPT TOWN & COUNTRY) P112 20BK/OR (EXCEPT BUILT-UP-EXPORT/POWER MIRRORS) (TOWN &...
Page 1066 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C314 (HIGH LINE) - BLACK (BODY SIDE) CIRCUIT G32 20VT/LB (POWER LIFTGATE) L77 18WT/BR L50 18WT/TN P30 20TN/DG P31 20TN/DG (POWER RELEASE/ BUILT-UP-EXPORT LHD SWB GAS) P31 20TN/YL (POWER RELEASE/ EXCEPT BUILT-UP-EXPORT LHD SWB GAS) Q60 20OR/YL (POWER LIFTGATE) Q84 18TN/GY (POWER LIFTGATE)
Page 1067 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C315 (HIGH LINE) - BLACK (LIFTGATE SIDE) CIRCUIT C15 12DB/WT Q76 20OR/LB (POWER LIFTGATE) G78 20VT/OR M11 20YL/VT G165 20VT/GY Q85 18TN/WT (POWER LIFTGATE) Q94 20TN/LG (POWER LIFTGATE) W13 18BR/LG F302 18GY/PK Z245 18BK/GY (POWER LIFTGATE) C316 (POWER SLIDING DOOR) - BLACK (LEFT DOOR WIRE TRACK ASSEMBLY SIDE)
Page 1068 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C317 (POWER SLIDING DOOR) - BLACK (RIGHT SLIDING DOOR SIDE) CIRCUIT P38 20TN/DB P34 20TN/LB G76 20TN/OR Z824 14BK/WT G152 20VT/GY D25 20WT/VT A113 14WT/RD C318 (TRAILER TOW) - BLACK (BODY SIDE) CIRCUIT L63 18WT/DG L62 18WT/BR...
Page 1069 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C319 (EXCEPT BUILT-UP-EXPORT/LOW LINE) - BLACK (LIFTGATE SIDE) CIRCUIT C15 12DB/WT L77 18WT/BR L50 18WT/TN P30 20TN/DG P31 20TN/YL G78 20VT/OR M11 20YL/VT W13 18BR/LG F302 18GY/PK Z800 12BK C320 - DK. GRAY (SEAT SIDE) CIRCUIT Z849 14BK/OR A210 14OR/RD...
Page 1070 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 C322 (MEMORY) - BLACK (BODY SIDE) CIRCUIT P69 20TN/DB (BUILT-UP-EXPORT) P69 20TN/WT (EXCEPT BUILT-UP-EXPORT) P67 20TN/OR P64 20TN P66 20TN/LG P68 20TN/YL P65 20TN/VT D25 20WT/VT P73 18TN/YL (BUILT-UP-EXPORT) P73 18TN/VT (EXCEPT BUILT-UP-EXPORT) P75 18TN/DB (BUILT-UP-EXPORT) P75 18TN/LG (EXCEPT...
Page 1071 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS C324 (MANUAL SLIDING DOOR) - BLACK (LEFT MANUAL SLIDING DOOR SIDE) CIRCUIT P5 20BK/DB P32 20BK/TN G77 20BK/DG Z77 20BK C325 (MANUAL SLIDING DOOR) - BLACK (RIGHT DOOR WIRE TRACK ASSEMBLY SIDE) CIRCUIT P38 20BK/DB P34 20BK/TN...
Page 1072 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 C327 - YELLOW (SAFETY SEAT SIDE) CIRCUIT R34 18LB/WT (EXCEPT BUILT-UP-EXPORT) R34 18WT/BK (BUILT-UP-EXPORT) R32 18LB/OR (EXCEPT BUILT-UP-EXPORT) R32 18DG/WT (BUILT-UP-EXPORT) C329 (DIESEL) - BLACK (BODY SIDE) CIRCUIT N2 18DB/YL Z201 18BK/OR N1 16DB/OR Z201 18BK/OR F853 20LG/PK...
Page 1073 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS C331 (DIESEL) - BLACK (CABIN HEATER JUMPER SIDE) CIRCUIT A119 16RD/OR C41 20LB/DG D21 20WT/BR Z149 16BK/DB C331 (DIESEL) - GRAY (CABIN HEATER COMPONENT SIDE) CIRCUIT A119 14RD/OR C41 20DB/OR D21 20WT/DB Z149 14BK/DB C332 (ATC) - LT.
Page 1074 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION A119 14RD/OR FUSED B(+) Z149 14BK/DB GROUND CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION K944 20BK/GY CAMSHAFT POSITION SENSOR GROUND K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL K342 16BR/WT...
Page 1075 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z350 20BK/TN GROUND L50 18WT/TN BRAKE LAMP SWITCH OUTPUT CLOCKSPRING C1 - WHITE 6 WAY CIRCUIT FUNCTION X920 20GY/OR RADIO CONTROL MUX RETURN X20 20GY/WT RADIO CONTROL MUX X3 20DG/VT...
Page 1076 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 CLOCKSPRING C5 - YELLOW 4 WAY CIRCUIT FUNCTION R45 18OR/LB DRIVER SQUIB 1 LINE 2 R43 18BK/LB DRIVER SQUIB 1 LINE 1 R63 18TN/LB DRIVER SQUIB 2 LINE 2 R61 18OR/LB DRIVER SQUIB 2 LINE 1 CLUTCH PEDAL INTERLOCK SWITCH (MTX) - BLACK 2 WAY CIRCUIT FUNCTION...
Page 1077 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY CIRCUIT FUNCTION Z107 12BK/DG GROUND B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY D25 18WT/VT PCI BUS B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL...
Page 1078 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY CIRCUIT FUNCTION F888 18BR/PK 8 VOLT SUPPLY K900 18DB/DG SENSOR GROUND K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20WT/VT...
Page 1079 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS DOSING PUMP (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION 18RD DOSING PUMP CONTROL Z149 18BK/DB GROUND DRIVER AIRBAG C1 - BROWN 2 WAY CIRCUIT FUNCTION R43 18BK/LB DRIVER SQUIB 1 LINE 1 R45 18OR/LB DRIVER SQUIB 1 LINE 2 DRIVER AIRBAG C2 - BLACK 2 WAY...
Page 1080 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 DRIVER DOOR COURTESY LAMP - GRAY 3 WAY CIRCUIT FUNCTION Z322 20BK/BR (RHD) GROUND Z321 20BK/BR (LHD) GROUND M21 20YL/BR COURTESY LAMPS DRIVER DRIVER DOOR LOCK SWITCH - BLACK 3 WAY CIRCUIT FUNCTION F304 16WT/PK (EXCEPT POWER FUSED ACCESSORY RELAY OUTPUT...
Page 1081 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS DRIVER HEATED SEAT MODULE C2 - GRAY 2 WAY CIRCUIT FUNCTION S2 18DG (LHD) DRIVER SEAT BACK HEATER GROUND S2 18BK (RHD) DRIVER SEAT BACK HEATER GROUND S1 18DB (LHD) DRIVER SEAT BACK HEATER B(+) DRIVER S1 18RD (RHD) DRIVER SEAT BACK HEATER B(+) DRIVER DRIVER HEATED SEAT MODULE C3 - GREEN 4 WAY...
Page 1082 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 DRIVER POWER SEAT HORIZONTAL POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY P25 20LG/VT SEAT HORIZONTAL POSITION SIGNAL P28 20LG/BR SEAT POSITION SENSOR GROUND DRIVER POWER SEAT REAR RISER MOTOR - RED 2 WAY CIRCUIT FUNCTION P11 14LG/YL...
Page 1083 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS DRIVER POWER SEAT SWITCH - GREEN 10 WAY CIRCUIT FUNCTION Z849 20BK/OR (MEMORY) GROUND Z849 14BK/OR GROUND P43 14LG/VT DRIVER SEAT RECLINER UP SWITCH SENSE P43 14LG/VT (MEMORY) RECLINER UP SWITCH SENSE P17 14LG/DG DRIVER SEAT HORIZONTAL REARWARD SWITCH SENSE...
Page 1084 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 DRIVER POWER WINDOW SWITCH (LOWLINE) - LT. GRAY 8 WAY CIRCUIT FUNCTION F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT Z421 12BK/BR GROUND Z421 12BK/BR GROUND Q21 16OR/WT MASTER WINDOW SWITCH DRIVER DOWN F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT Z421 20BK/BR...
Page 1085 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY CIRCUIT FUNCTION K35 20GY/YL EGR SOLENOID CONTROL K342 16BR/WT ECM/PCM RELAY OUTPUT EGR SOLENOID (GAS) - GRAY 2 WAY CIRCUIT FUNCTION K35 18DB/VT EGR SOLENOID CONTROL F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY...
Page 1086 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY CIRCUIT FUNCTION Z130 14BK/BR GROUND Z131 14BK/DG GROUND K20 14BR/GY GENERATOR FIELD CONTROL K342 14BR/WT ECM/PCM RELAY OUTPUT K342 14BR/WT ECM/PCM RELAY OUTPUT D25 20WT/VT PCI BUS K944 20BK/GY...
Page 1087 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY CIRCUIT FUNCTION N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL C918 20BK/LB A/C PRESSURE SENSOR GROUND K4 20BK/LB LOW IDLE POSITION SWITCH GROUND K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY K51 20BR/WT ECM/PCM RELAY CONTROL...
Page 1088 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY CIRCUIT FUNCTION T753 20DG/YL FUSED IGNITION SWITCH OUTPUT (START) K35 20GY/YL EGR SOLENOID CONTROL K35 20GY/YL EGR SOLENOID CONTROL K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE K14 14LB/BR FUEL INJECTOR NO.
Page 1089 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K900 18DB/DG SENSOR GROUND K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION F855 20PK/YL SENSOR REFERENCE VOLTAGE A...
Page 1090 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL C121 20DB/DG SENSOR GROUND FLOOR CONSOLE LAMP - BLACK 2 WAY CIRCUIT FUNCTION F307 18OR (REAR CONSOLE) FUSED ACCESSORY RELAY OUTPUT (ACCESSORY RELAY POSITION) F307 18OR (REAR CONSOLE)
Page 1091 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS FRONT CIGAR LIGHTER - RED/NATURAL 3 WAY CIRCUIT FUNCTION F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT E14 20OR/TN (BUILT-UP-EXPORT) PANEL LAMPS DRIVER Z736 16BK/YL GROUND FRONT READING LAMPS/SWITCH - BLACK 6 WAY CIRCUIT FUNCTION E15 20OR/DB (EXCEPT BASE)
Page 1092 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K111 14DB/LB COMMON INJECTOR DRIVER K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL FUEL INJECTOR NO. 2 (2.4L/3.3L/3.8L) - BLACK 2 WAY CIRCUIT FUNCTION K342 16BR/WT...
Page 1093 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 4 (2.4L/3.3L/3.8L) - BLACK 2 WAY CIRCUIT FUNCTION K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K111 14DB/LB...
Page 1094 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K342 16BR/WT ECM/PCM RELAY OUTPUT K87 16BR FUEL PRESSURE SOLENOID CONTROL FUEL PUMP MODULE - LT. GRAY 4 WAY CIRCUIT FUNCTION Z201 16BK/OR (GAS) GROUND Z201 18BK/OR (RHD/DIESEL) GROUND...
Page 1095 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS HEADLAMP SWITCH - BLACK 13 WAY CIRCUIT FUNCTION Z403 20BK/YL (BUILT-UP-EXPORT) GROUND L78 20WT/OR (BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT Z407 18BK/OR GROUND L36 20WT/DB (BUILT-UP-EXPORT) REAR FOG LAMP INDICATOR DRIVER L900 20WT/YL HEADLAMP SWITCH MUX RETURN L13 20WT/YL (BUILT-UP-EXPORT) HEADLAMP ADJUST SIGNAL...
Page 1096 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 IDLE AIR CONTROL MOTOR (3.3L/3.8L) - BLACK 2 WAY CIRCUIT FUNCTION K39 18VT/DG IDLE AIR CONTROL NO. 1 DRIVER K60 18VT/LG IDLE AIR CONTROL NO. 2 DRIVER IGNITION COIL (2.4L) - BLACK 3 WAY CIRCUIT FUNCTION K17 16DB/TN...
Page 1097 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS INPUT SPEED SENSOR (EATX) - GRAY 2 WAY CIRCUIT FUNCTION T13 18DG/VT SPEED SENSOR GROUND T52 18DG/WT INPUT SPEED SENSOR SIGNAL INSTRUMENT CLUSTER - BLACK 13 WAY CIRCUIT FUNCTION E13 20OR/YL PANEL LAMPS DRIVER L160 20WT/TN (LOW LINE) RIGHT TURN INDICATOR DRIVER G7 20VT/GY (HIGH LINE)
Page 1098 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 INTEGRATED POWER MODULE C1 - LT. GREEN/RED 20 WAY CIRCUIT FUNCTION F301 18VT/PK FUSED ACCESSORY RELAY OUTPUT L43 18WT/DB LEFT LOW BEAM DRIVER Z344 16BK/TN GROUND L34 16WT/GY RIGHT HIGH BEAM DRIVER W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE L33 18WT/LG...
Page 1099 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS INTEGRATED POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAY CIRCUIT FUNCTION N21 20DB/TN LIFT PUMP RELAY CONTROL T751 20YL FUSED IGNITION SWITCH OUTPUT (START) T2 18DG/WT TRS REVERSE SENSE N2 18DB/YL LIFT PUMP RELAY OUTPUT F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) C3 18DB/YL...
Page 1100 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 INTEGRATED POWER MODULE C4 - BLUE 10 WAY CIRCUIT FUNCTION Z127 12BK/DG (GAS) GROUND T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT K342 16BR/WT (GAS) AUTOMATIC SHUT DOWN RELAY OUTPUT F500 16DG/PK (EXCEPT MTX) FUSED IGNITION SWITCH OUTPUT (RUN) D25 16WT/VT (ANTILOCK BRAKES)
Page 1101 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS INTEGRATED POWER MODULE C7 - BLACK/RED 20 WAY CIRCUIT FUNCTION C16 20DB/GY (EXCEPT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT BUILT-UP-EXPORT) C16 18DB/GY (BUILT-UP-EXPORT) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT T141 20YL/OR (BUILT-UP-EXPORT) FUSED IGNITION SWITCH OUTPUT (START) T751 20YL (EXCEPT FUSED IGNITION SWITCH OUTPUT (START)
Page 1102 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 INTEGRATED POWER MODULE C9 - BLACK 10 WAY CIRCUIT FUNCTION A102 12WT/RD FUSED B(+) F20 18PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) C15 12DB/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT A105 18DB/RD FUSED B(+) L61 18WT/LB (BUILT-UP-EXPORT) LEFT FRONT TURN SIGNAL DIVER L61 18WT/LG (EXCEPT...
Page 1103 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS LEFT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY CIRCUIT FUNCTION Z61 20BK/DG GROUND F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT G41 20VT/DG LEFT SLIDING DOOR PILLAR SWITCH MUX LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY CIRCUIT FUNCTION Q49 18TN/WT...
Page 1104 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 LEFT FOG LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY CIRCUIT FUNCTION L89 18WT/YL FRONT FOG LAMP RELAY OUTPUT Z349 18BK/YL GROUND LEFT FOG LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L89 18WT/YL FRONT FOG LAMP RELAY OUTPUT Z349 18BK/YL GROUND...
Page 1105 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 18DG/LG (EXCEPT 3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL...
Page 1106 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X153 20DG/YL LEFT FRONT I/P SPEAKER (+) X155 20DG/LB LEFT FRONT I/P SPEAKER (-) LEFT LIFTGATE FLOOD LAMP - GRAY 3 WAY CIRCUIT FUNCTION Z312 20BK/YL...
Page 1107 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS LEFT POWER MIRROR - BLACK 12 WAY CIRCUIT FUNCTION P171 20TN/YL (BUILT-UP-EXPORT) LEFT FOLDING MIRROR UNFOLD DRIVER P112 20TN/OR (EXCEPT MIRROR B(+) BUILT-UP-EXPORT/MEMORY) P114 20TN/WT (EXCEPT MIRROR B(-) BUILT-UP-EXPORT/MEMORY) P65 20TN/VT (MEMORY) LEFT MIRROR HORIZONTAL POSITION SIGNAL P69 20TN/WT (MEMORY) LEFT MIRROR SENSOR GROUND...
Page 1108 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 LEFT REAR SPEAKER - BLACK/RED 6 WAY CIRCUIT FUNCTION X151 20DG/WT (HIGH LINE) LEFT REAR PILLAR SPEAKER (-) X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND X157 20DG (HIGH LINE) LEFT REAR PILLAR SPEAKER (+) X51 20DG/DB LEFT REAR SPEAKER (+) X13 16DG/GY (HIGH LINE)
Page 1109 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS LEFT SEAT AIRBAG - YELLOW 2 WAY CIRCUIT FUNCTION R31 18LG/OR (EXCEPT LEFT SEAT SQUIB LINE 1 BUILT-UP-EXPORT) R33 18WT/BK (BUILT-UP-EXPORT) LEFT SEAT SQUIB LINE 2 R33 18LG/WT (EXCEPT LEFT SEAT SQUIB LINE 2 BUILT-UP-EXPORT) R31 18DG/WT (BUILT-UP-EXPORT) LEFT SEAT SQUIB LINE 1...
Page 1110 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 LEFT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY CIRCUIT FUNCTION Z77 20BK/GY GROUND Q59 20OR/YL LEFT PAWL SWITCH SENSE G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE Z77 20BK/GY GROUND Q55 20OR/BR...
Page 1111 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS LEFT STOP/TURN SIGNAL RELAY (TRAILER TOW) - BLACK 5 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 18BK/DG GROUND Z1 18BK/DG GROUND L73 18YL LEFT STOP SIGNAL L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER...
Page 1112 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 LICENSE LAMP (POWER RELEASE) - DK. GRAY 4 WAY CIRCUIT FUNCTION L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT) Z367 20BK/BR GROUND P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE Z430 20BK/LG GROUND LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION N2 18OR...
Page 1113 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS LIFTGATE CYLINDER LOCK SWITCH - BLACK 2 WAY CIRCUIT FUNCTION Z465 20BK/GY GROUND G165 20VT/GY LIFTGATE CYLINDER LOCK SWITCH MUX LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY CIRCUIT FUNCTION Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL Q76 20OR/LB...
Page 1114 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY CIRCUIT FUNCTION K342 16BR/WT ECM/PCM RELAY OUTPUT K957 20BK/OR MASS AIR FLOW SENSOR GROUND F855 20PK/YL SENSOR REFERENCE VOLTAGE A K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL MEMORY SEAT/MIRROR MODULE C1 - GRAY 26 WAY CIRCUIT FUNCTION...
Page 1115 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS MEMORY SEAT/MIRROR MODULE C2 - GRAY 16 WAY CIRCUIT FUNCTION P73 18TN/LB LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P75 18DB LEFT MIRROR LEFT DRIVER P71 18TN/GY LEFT MIRROR UP DRIVER P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY P70 18LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) P74 18TN/DB...
Page 1116 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 MESSAGE CENTER (HIGH LINE) - WHITE 14 WAY CIRCUIT FUNCTION L160 20WT/TN (LHD) RIGHT TURN INDICATOR DRIVER G3 20VT/LB (LHD) MALFUNCTION INDICATOR LAMP DRIVER L134 20WT/GY (RHD) HIGH BEAM INDICATOR DRIVER G69 20VT/WT (LHD) VTSS INDICATOR DRIVER L160 20WT/TN (RHD) RIGHT TURN INDICATOR DRIVER...
Page 1117 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS OUTPUT SPEED SENSOR (EATX) - GRAY 2 WAY CIRCUIT FUNCTION T13 18DG/VT SPEED SENSOR GROUND T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY CIRCUIT FUNCTION G23 20VT/DB SLIDING DOORS OVERHEAD SWITCH MUX G25 20VT/TN LIFTGATE SWITCH MUX...
Page 1118 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) - BLACK 4 WAY CIRCUIT FUNCTION Z43 18BK/DB GROUND K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT K902 18BR/DG OXYGEN SENSOR 1/2 GROUND K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL PARK/NEUTRAL POSITION SWITCH (ATX) - BLACK 3 WAY CIRCUIT FUNCTION...
Page 1119 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS PASSENGER DOOR COURTESY LAMP - GRAY 3 WAY CIRCUIT FUNCTION Z321 20BK/BR (RHD) GROUND Z322 20BK/BR (LHD) GROUND M21 20YL/BR COURTESY LAMPS DRIVER PASSENGER DOOR LOCK SWITCH - BLACK 3 WAY CIRCUIT FUNCTION F304 16WT/PK (EXCEPT POWER FUSED ACCESSORY RELAY OUTPUT...
Page 1120 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 PASSENGER HEATED SEAT MODULE C1 - GRAY 4 WAY CIRCUIT FUNCTION Z848 18BK/OR GROUND P8 20LG/WT PASSENGER HEATED SEAT SWITCH MUX F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN) A210 14OR/RD FUSED B(+) PASSENGER HEATED SEAT MODULE C2 - GRAY 2 WAY CIRCUIT FUNCTION...
Page 1121 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS PASSENGER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH SENSE PASSENGER POWER SEAT REAR RISER MOTOR - RED 2 WAY CIRCUIT FUNCTION P10 14LG/TN...
Page 1122 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 PASSENGER POWER WINDOW SWITCH - BLACK 8 WAY CIRCUIT FUNCTION F304 12WT/PK (EXCEPT FUSED WINDOW CIRCUIT BREAKER OUTPUT BUILT-UP-EXPORT RHD) F304 16WT/PK (BUILT-UP-EXPORT FUSED WINDOW CIRCUIT BREAKER OUTPUT LHD) Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP Q22 14OR/VT...
Page 1123 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS POWER LIFTGATE MODULE C1 - BLACK 8 WAY CIRCUIT FUNCTION Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER Q88 16TN/BR (EXCEPT LIFTGATE OPEN DRIVER BUILT-UP-EXPORT) Q88 14TN/BR (BUILT-UP-EXPORT) LIFTGATE OPEN DRIVER Q89 16TN/OR (EXCEPT LIFTGATE CLOSE DRIVER BUILT-UP-EXPORT) Q89 14TN/OR (BUILT-UP-EXPORT)
Page 1124 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 POWER MIRROR SWITCH - BLACK 13 WAY CIRCUIT FUNCTION P70 18TN/LB (MEMORY) RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN) E18 20OR/LB PANEL LAMPS DRIVER P73 20TN/VT LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P73 18TN/VT (MEMORY) LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P75 18TN/LG (MEMORY)
Page 1125 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS POWER WINDOW SWITCH (LOWLINE) - BLACK 8 WAY CIRCUIT FUNCTION F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT Z421 12BK/BR GROUND Z421 12BK/BR GROUND Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT Z421 20BK/BR GROUND...
Page 1126 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 POWERTRAIN CONTROL MODULE C2 (GAS) - GRAY/GRAY 40 WAY CIRCUIT FUNCTION V37 18VT SPEED CONTROL SWITCH SIGNAL C18 18LB/BR A/C PRESSURE SENSOR SIGNAL K900 18DB/DG SENSOR GROUND F888 18BR/PK 8 VOLT SUPPLY A109 18OR/RD FUSED B(+) K40 18BR/LG (2.4L)
Page 1127 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY CIRCUIT FUNCTION N202 12DB/OR RADIATOR FAN NO. 1 CONTROL N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT RADIATOR FAN NO. 1 (GAS) - BLACK 2 WAY CIRCUIT FUNCTION N23 12DB/DG...
Page 1128 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY CIRCUIT FUNCTION N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT K342 16BR/WT ECM/PCM RELAY OUTPUT N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL A201 12RD/LG FUSED B(+) RADIATOR FAN RELAY NO.
Page 1129 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS RADIO C1 - 22 WAY CIRCUIT FUNCTION A114 16GY/RD FUSED B(+) (I.O.D.) F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT E14 20OR/TN PANEL LAMPS DRIVER X56 20GY/BR (EXCEPT RIGHT FRONT SPEAKER (-) BUILT-UP-EXPORT) X54 20GY (BUILT-UP-EXPORT) RIGHT FRONT SPEAKER (-) X156 20GY/LB (LOW LINE) RIGHT FRONT I/P SPEAKER (-)
Page 1130 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 RADIO CHOKE - LT. GRAY 2 WAY CIRCUIT FUNCTION X1 16DG/BR NAME BRAND SPEAKER RELAY OUTPUT X13 16DG/GY RADIO CHOKE OUTPUT REAR A/C-HEATER UNIT (3 ZONE HVAC) - LT. GREEN 10 WAY CIRCUIT FUNCTION C53 20LB...
Page 1131 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS REAR BLOWER MOTOR POWER MODULE C1 (ATC) - RED/BLACK 4 WAY CIRCUIT FUNCTION C51 18DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT C51 12DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT C59 18DB/LB BLOWER MOTOR CONTROL Z135 12BK/LB GROUND REAR BLOWER MOTOR POWER MODULE C2 (ATC) - BLACK 2 WAY...
Page 1132 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 REAR MODE MOTOR (ATC) - GRAY 2 WAY CIRCUIT FUNCTION C154 18LB/GY REAR MODE DOOR DRIVER (B) C53 18LB REAR MODE DOOR DRIVER (A) REAR POWER OUTLET - RED 3 WAY CIRCUIT FUNCTION F307 16LB/PK (ACCESSORY RELAY FUSED ACCESSORY RELAY OUTPUT...
Page 1133 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS RECIRCULATION DOOR ACTUATOR (ATC) - GRAY 2 WAY CIRCUIT FUNCTION C132 20DB/YL RECIRCULATION DOOR DRIVER (B) C32 20DB/TN RECIRCULATION DOOR DRIVER (A) RECIRCULATION DOOR ACTUATOR (MTC) - GRAY 2 WAY CIRCUIT FUNCTION C32 20DB/TN (RHD) RECIRCULATION DOOR DRIVER (A) C34 20DB/LB (LHD)
Page 1134 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 103 RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY CIRCUIT FUNCTION Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER Z248 18BK/WT GROUND Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER RIGHT COMBINATION RELAY (TRAILER TOW) - BLACK 5 WAY CIRCUIT FUNCTION...
Page 1135 8W - 80 - 104 8W-80 CONNECTOR PIN-OUTS RIGHT FOG LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L90 18WT/OR FRONT FOG LAMP RELAY OUTPUT Z348 18BK/OR GROUND RIGHT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CIRCUIT FUNCTION G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE...
Page 1136 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 105 RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY CIRCUIT FUNCTION Q52 20OR RIGHT FULL OPEN SWITCH SENSE Z76 20BK/YL GROUND RIGHT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L44 16WT/TN RIGHT LOW BEAM DRIVER...
Page 1137 8W - 80 - 106 8W-80 CONNECTOR PIN-OUTS RIGHT LIFTGATE FLOOD LAMP - GRAY 3 WAY CIRCUIT FUNCTION Z312 20BK/YL GROUND M11 20YL/VT COURTESY LAMPS DRIVER RIGHT LOW BEAM LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION Z344 16BR GROUND L44 16WT RIGHT LOW BEAM DRIVER RIGHT MID READING LAMP (PREMIUM/LUXURY) - GRAY 3 WAY...
Page 1138 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 107 RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY CIRCUIT FUNCTION L62 18WT/BR (EXCEPT RIGHT REAR TURN SIGNAL DRIVER BUILT-UP-EXPORT) Z362 18BK/BR (BUILT-UP-EXPORT) GROUND L62 18WT/BR (BUILT-UP-EXPORT) RIGHT REAR TURN SIGNAL DRIVER L78 18WT/OR (EXCEPT FUSED PARK LAMP RELAY OUTPUT (RIGHT) BUILT-UP-EXPORT) L50 18WT/TN (BUILT-UP-EXPORT)
Page 1139 8W - 80 - 108 8W-80 CONNECTOR PIN-OUTS RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY CIRCUIT FUNCTION X20 20RD/BK...
Page 1140 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 109 RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY CIRCUIT FUNCTION Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER A113 14WT/RD FUSED B(+) Z124 14BK...
Page 1141 8W - 80 - 110 8W-80 CONNECTOR PIN-OUTS RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY CIRCUIT FUNCTION P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER Q34 20OR/GY RIGHT DOOR LOCK SENSE Z76 20BK/YL GROUND RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY...
Page 1142 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 111 RIGHT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - ORANGE 2 WAY CIRCUIT FUNCTION Z344 16BR GROUND L60 16YL RIGHT FRONT TURN SIGNAL DRIVER RIGHT VISOR/VANITY LAMP (PREMIUM/LUXURY) - BLACK 2 WAY CIRCUIT FUNCTION Z327 20BK/OR GROUND M27 20YL/LB READING LAMPS DRIVER...
Page 1143 8W - 80 - 112 8W-80 CONNECTOR PIN-OUTS SPEED CONTROL SERVO (GAS) - BLACK 4 WAY CIRCUIT FUNCTION V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL V30 18VT/WT SPEED CONTROL BRAKE SWITCH OUTPUT Z155 18BK/LG GROUND THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAY CIRCUIT...
Page 1144 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 113 TORQUE CONVERTER CLUTCH SOLENOID (ATX) - BLACK 3 WAY CIRCUIT FUNCTION F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) K54 18DB/WT TORQUE CONVERTER CLUTCH SOLENOID CONTROL TRACTION CONTROL SWITCH - BLACK 2 WAY CIRCUIT FUNCTION B27 20DG/WT...
Page 1145 8W - 80 - 114 8W-80 CONNECTOR PIN-OUTS TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY CIRCUIT FUNCTION T1 18DG/LB TRS T1 SENSE T3 18DG/DB TRS T3 SENSE K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL D21 18WT/BR SCI TRANSMIT T751 18YL FUSED IGNITION SWITCH OUTPUT (START) T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE...
Page 1146 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 115 TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY CIRCUIT FUNCTION T55 18YL/VT (AUTOSTICK) AUTOSTICK/OVERDRIVE OFF MUX INPUT A104 18YL/RD FUSED B(+) Z133 16BK/LG GROUND N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL T59 18YL/LB UNDERDRIVE SOLENOID CONTROL T60 18YL/GY OVERDRIVE SOLENOID CONTROL...
Page 1147 8W - 80 - 116 8W-80 CONNECTOR PIN-OUTS WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION F853 20RD WATER IN FUEL SENSOR SIGNAL K900 18RD SENSOR GROUND WIPER MODULE - DK. GRAY 4 WAY CIRCUIT FUNCTION W3 12BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT W7 20BR/GY...
Page 1148 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 1149 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Boost Pressure Sensor (Diesel) Top Left of Engine Brake Fuid Level Switch On Master Cylinder Brake Lamp Switch At Top Of Brake Pedal 35, 36 Brake Transmission Shift Interlock Near Steering Column 15, 16, 17, 26...
Page 1150 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C325 Right Sliding Door C326 At Driver Side Airbag C327 At Passenger Side Airbag C329 (Diesel) Left Rear Engine Compartment C330 (Diesel) LTGY Left Rear Engine Compartment C331 (Diesel) Left Rear Engine Compartment Cabin Heater Assist C1 (Diesel)
Page 1151 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Driver Power Seat Front Riser At Seat Motor Driver Power Seat Horizontal Motor At Seat Driver Power Seat Rear Riser At Seat Motor Driver Power Seat Recliner Motor At Seat Driver Power Seat Switch At Switch...
Page 1152 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Fuel Injector No.3 At Fuel Injector Fuel Injector No.3 (Diesel) At Fuel Injector Fuel Injector No.4 At Fuel Injector Fuel Injector No.4 (Diesel) At Fuel Injector Fuel Injector No.5 At Fuel Injector Fuel Injector No.6...
Page 1153 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Left Cylinder Lock Switch At Switch Left Door Speaker At Speaker Left Fog Lamp At Lamp Left Front Door Ajar Switch At Switch Left Front Door Lock Motor/Ajar Left Door Switch Left Front Park/Turn Signal Lamp...
Page 1154 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Liftgate Ajar Switch (Manual At Latch Release) Liftgate Ajar Switch (Power Lower Liftgate Release) Liftgate Cinch/Release Motor Liftgate Liftgate Cylinder Lock Switch At Switch Liftgate Left Pinch Sensor Left Side of Liftgate Liftgate Right Pinch Sensor...
Page 1155 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Passenger Heated Seat Module C2 At Heated Seat Back Passenger Heated Seat Module C3 At Heated Seat Passenger Power Seat Front Riser Under Seat Motor Passenger Power Seat Horizontal Under Seat...
Page 1156 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Rear Blower Motor Power Module Right Quarter Rear Blower Rear Control Switch Overhead Rear Blower Rear Control Switch Overhead Rear Power Outlet Left Quarter Panel Rear Temperature Motor Right Quarter Rear Washer Pump Motor...
Page 1157 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Right Seat Airbag At Passenger Seat Right Side Impact Airbag Control YL/RD Right B Pillar Module Right Sliding Door Control Module Rear of Door 38, 39 Right Sliding Door Control Module BK/RD...
Page 1158 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS GROUND NUMBER LOCATION FIG. G100 Body Ground Near Powertrain Control Module G101 Above Starter G102 Left Headlamp Area G103 Above Starter G200 Right Side of Instrument Panel 15, 19, 24 G201 Right Side of Instrument Panel 15, 19, 24...
Page 1159 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S117 (2.4L) Neat T/O for G101 and G103 S117 (3.3L/3.8L) Near T/O for Output Speed Sensor S118 (2.4L) Near T/O for Knock Sensor S119 (2.5L) Near T/O for Engine Starter Motor S120 (2.4L) Near T/O for Oxygen Sensors...
Page 1160 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S177 In Right Headlamp Wiring Assembly S179 In Left Headlamp Wiring Assembly S187 (2.5L) Near T/O for Engine Control Module C1 S188 (2.5L) Near T/O for Radiator Fan Relay No.1 S201 In T/O to Instrument Panel Speaker 15, 21...
Page 1161 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S327 Near Left Side Impact Airbag Module S328 (RS) In Floor Pan Track Wiring S329 Near T/O to Left Rear Pillar Speaker S330 Near T/O for Power Liftgate Module S331 Near T/O for Power Liftgate Motor S332...
Page 1162 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1163 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 2 LEFT FRONT ENGINE COMPARTMENT Fig. 3 WASHER PUMP CONNECTORS...
Page 1164 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 4 LEFT REPEATER LAMP Fig. 5 LEFT FENDER SHIELD...
Page 1165 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1166 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 7 INTEGRATED POWER MODULE...
Page 1167 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1168 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1169 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1170 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1171 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1172 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1173 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1174 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1175 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1176 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 17 STEERING COLUMN...
Page 1177 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1178 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 RIGHT SIDE INSTRUMENT PANEL...
Page 1179 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1180 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 21 INSTRUMENT PANEL RHD Fig. 22 LEFT SIDE INSTRUMENT PANEL UPPER RHD...
Page 1181 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 23 RIGHT SIDE INSTRUMENT PANEL UPPER RHD Fig. 24 LEFT SIDE INSTRUMENT PANEL LOWER RHD...
Page 1182 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 25 RIGHT SIDE INSTRUMENT PANEL LOWER RHD Fig. 26 STEERING COLUMN CONNECTORS RHD...
Page 1183 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1184 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 28 RIGHT SIDE BODY RHD...
Page 1185 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1186 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 30 BODY HARNESS SPLICES Fig. 31 LEFT FRONT BODY SPLICES...
Page 1187 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1188 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 33 RIGHT B PILLAR Fig. 34 LEFT B PILLAR...
Page 1189 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1190 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1191 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 37 PASSENGER DOOR Fig. 38 RIGHT SLIDING DOOR...
Page 1192 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1193 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1194 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 41 RIGHT QUARTER...
Page 1195 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1196 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 1 8W-97 POWER DISTRIBUTION SYSTEM TABLE OF CONTENTS page page POWER DISTRIBUTION SYSTEM OPERATION ......3 DESCRIPTION .
Page 1197 8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEM POWER DISTRIBUTION SYSTEM (Continued) SPECIAL TOOLS DIAGNOSIS AND TESTING POWER DISTRIBUTION SYSTEMS DIAGNOSIS & TESTING - ACCESSORY RELAY The accessory relay (Fig. 1) is located in the Inte- grated Power Module (IPM), in the engine compart- ment.
Page 1198 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 3 ACCESSORY RELAY (Continued) (4) The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the accessory relay when the ignition switch is in the Accessory or On positions. Turn the ignition switch to the On position.
Page 1199 8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEM INTEGRATED POWER MODULE (Continued) tion of the service manual for complete IPM circuit schematics. REMOVAL (1) Disconnect the negative and positive battery cables. (2) Remove the battery thermal guard from the vehicle.
Page 1200 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 5 IOD FUSE (Continued) tion. The IOD fuse is a 15 ampere blade-type car- INSTALLATION tridge fuse and, when removed, it is stored in a fuse (1) Be certain the ignition switch is in the Off posi- cavity adjacent to the washer fuse within the IPM.
Page 1201 8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEM POWER OUTLET (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT- ING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAG- NOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCI- DENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 1202 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 2.4L......1 ENGINE 3.3/3.8L .
Page 1203 9 - 2 ENGINE 2.4L VALVE SPRINGS & SEALS STRUCTURAL COLLAR REMOVAL REMOVAL ......49 REMOVAL - CYLINDER HEAD ON .
Page 1204 ENGINE 2.4L 9 - 3 EXHAUST MANIFOLD REMOVAL - CRANKSHAFT SPROCKET ..66 DESCRIPTION ......62 CLEANING .
Page 1205 9 - 4 ENGINE 2.4L ENGINE 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1206 ENGINE 2.4L 9 - 5 ENGINE 2.4L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter. 3.
Page 1207 9 - 6 ENGINE 2.4L ENGINE 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1208 ENGINE 2.4L 9 - 7 ENGINE 2.4L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1209 9 - 8 ENGINE 2.4L ENGINE 2.4L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1210 ENGINE 2.4L 9 - 9 ENGINE 2.4L (Continued) (3) Remove torque converter or clutch housing (4) Remove the Auto Shutdown (ASD) relay from cover and inspect rear of block for evidence of oil. the PDC. Use a black light to check for the oil leak. If a leak is (5) Be sure throttle blade is fully open during the present in this area, remove transmission for further compression check.
Page 1211 9 - 10 ENGINE 2.4L ENGINE 2.4L (Continued) Calibrate the tester according to the manufactur- Thoroughly clean inside of cup plug hole in cylin- er’s instructions. The shop air source for testing der block or head. Be sure to remove old sealer. should maintain 483 kPa (70 psi) minimum, 1,379 Lightly coat inside of cup plug hole with Mopar kPa (200 psi) maximum, with 552 kPa (80 psi) rec-...
Page 1212 ENGINE 2.4L 9 - 11 ENGINE 2.4L (Continued) CAUTION: Squirt approximately one teaspoon of oil plate and cylinder block without disturbing the bear- into the cylinders, rotate engine to lubricate the cyl- ing clearance or alignment of these components. The material cures slowly in the absence of air when inder walls to prevent damage on restart.
Page 1213 9 - 12 ENGINE 2.4L ENGINE 2.4L (Continued) NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Only use the following for cleaning gasket surfaces: • Solvent or a commercially available gasket remover • Plastic or wood scraper (Fig. 3) •...
Page 1214 ENGINE 2.4L 9 - 13 ENGINE 2.4L (Continued) NOTE: When the transaxle cooler lines are removed (14) Discharge air conditioning system. (Refer to from the rolled-groove type fittings at the transaxle, 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) damage to the inner wall of the hose will occur.
Page 1215 9 - 14 ENGINE 2.4L ENGINE 2.4L (Continued) (22) Remove engine front mount and bracket from engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/ FRONT MOUNT - REMOVAL) (23) Remove structural collar. (Refer to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL COVER - REMOVAL) (24) Remove rear engine mount bracket.
Page 1216 ENGINE 2.4L 9 - 15 ENGINE 2.4L (Continued) Fig. 8 Positioning Engine Cradle Support Post Mounts 1 - SPECIAL TOOL POSTS 6848 4 - SPECIAL TOOL 6710 CRADLE 2 - SPECIAL TOOL 6135 DOLLY 5 - SPECIAL TOOL 6848 - POST CONTACT ON PAN RAIL 3 - SPECIAL TOOL POSTS 6848...
Page 1217 9 - 16 ENGINE 2.4L ENGINE 2.4L (Continued) INSTALLATION - ENGINE ASSEMBLY (1) Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission. (2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right (Fig.
Page 1218 ENGINE 2.4L 9 - 17 ENGINE 2.4L (Continued) (32) Fill engine crankcase with proper oil to cor- DESCRIPTION SPECIFICATION rect level. Piston Ring Groove 4.640–4.784 mm (33) Start engine and run until operating temper- Depth No. 1 ature is reached. (0.182–0.188 in.) (34) Adjust transmission linkage, if necessary.
Page 1219 9 - 18 ENGINE 2.4L ENGINE 2.4L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Wear Limit 0.075 mm Lift (Zero Lash) (0.003 in.) Intake 8.25 mm Bore Diameter—Piston 20.96–20.98 mm (0.324 in.) (0.8252–0.8260 in.) Exhaust 6.60 mm Bore Diameter— 53.007–52.993 mm (0.259 in.) Crankshaft End (2.0868–2.0863 in.) Intake Valve Timing*...
Page 1220 ENGINE 2.4L 9 - 19 ENGINE 2.4L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Service Limit 0.25 mm Valves (0.010 in.) Face Angle—Intake and 44.5—45° Exhaust Valve Springs Head Diameter—Intake 34.67–34.93 mm Free Length (Approx.) 48.4 mm 1.364–1.375 in.) (1.905 in.) Head Diameter—Exhaust 28.32–28.52 mm Nominal Force (Valve 338 N @ 38.0 mm...
Page 1221 9 - 20 ENGINE 2.4L ENGINE 2.4L (Continued) SPECIFICATIONS - TORQUE DESCRIPTION N·m Lbs. Lbs. DESCRIPTION N·m Exhaust Manifold to — Lbs. Lbs. Cylinder Head—Bolts Balance Shaft Carrier to — Exhaust Manifold Heat — Block—Bolts Shield—Bolts Balance Shaft Gear — Intake Manifold - Lower —...
Page 1222 ENGINE 2.4L 9 - 21 ENGINE 2.4L (Continued) SPECIAL TOOLS 2.4L ENGINE Post Kit Engine Cradle 6848 Puller 1026 Camshaft Sprocket Holder 6847 Crankshaft Damper Removal Insert 6827A Camshaft Seal Remover C-4679A Dolly 6135 Camshaft Seal Installer MD-998306 Cradle 6710A Crankshaft Damper/Sprocket Installer 6792...
Page 1223 9 - 22 ENGINE 2.4L ENGINE 2.4L (Continued) Indicator, Cylinder Bore C-119 Valve Spring Compressor 8215-A Connecting Rod Guides 8189 Adaptor 8436 Crankshaft Sprocket Remover 6793 Valve Spring Compressor MD998772A Crankshaft Sprocket Remover Insert C-4685-C2 Valve Spring Compressor Adapter 6779 Front Crankshaft Oil Seal Remover 6771...
Page 1224 ENGINE 2.4L 9 - 23 ENGINE 2.4L (Continued) Front Crankshaft Oil Seal Installer 6780 Balance Shaft Sprocket Installer 6052 Combustion Leak Tester C-3685-A Oil Pressure Gauge C-3292 Adapter 8406 Pressure Transducer CH7059 Rear Crankshaft Oil Seal Installer 6926 Cylinder Compression Pressure Adaptor 8116 Driver Handle C-4171 DRB III with PEP Module OT-CH6010A...
Page 1225 9 - 24 ENGINE 2.4L AIR CLEANER ELEMENT REMOVAL (1) Unsnap 2 clips. (2) Lift cover and pull toward the engine and remove cover tabs from air box. (3) Lift cover and remove the element (Fig. 11). Fig. 12 IAT SENSOR 2.4L (2) Install bolt to hold air box to the upper radia- tor cross member.
Page 1226 ENGINE 2.4L 9 - 25 CYLINDER HEAD (Continued) VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST.
Page 1227 9 - 26 ENGINE 2.4L CYLINDER HEAD (Continued) (13) Remove timing belt and camshaft sprockets. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (14) Remove timing belt idler pulley and rear tim- ing belt cover. (Refer to 9 - ENGINE/VALVE TIM- ING/TIMING BELT CHAIN...
Page 1228 ENGINE 2.4L 9 - 27 CYLINDER HEAD (Continued) • Second All to 68 N·m (50 ft. lbs.) • Third All to 68 N·m (50 ft. lbs.) CAUTION: Do not use a torque wrench for the fol- lowing step. • Fourth Turn an additional 1/4 Turn, Fig.
Page 1229 9 - 28 ENGINE 2.4L CYLINDER HEAD (Continued) (19) Install air inlet tube and housing. (20) Connect all vacuum lines, electrical wiring, ground straps and fuel line. (21) Fill cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (22) Connect battery negative cable. CAMSHAFT OIL SEAL(S) REMOVAL (1) Remove timing belt (Refer to 9 - ENGINE/...
Page 1230 ENGINE 2.4L 9 - 29 (5) Record reading on dial indicator. For end play CAMSHAFT(S) specification, (Refer to 9 - ENGINE - SPECIFICA- TIONS). DESCRIPTION (6) If end play is excessive, check cylinder head Both camshafts have six bearing journal surfaces and camshaft for wear;...
Page 1231 9 - 30 ENGINE 2.4L CAMSHAFT(S) (Continued) Fig. 25 Camshaft Bearing Cap Identification Fig. 27 Checking Camshaft(s) for Wear 1 - UNWORN AREA 2 - ACTUAL WEAR 3 - BEARING JOURNAL 4 - LOBE 5 - WEAR ZONE (1) Lubricate all camshaft bearing journals, rocker arms and camshaft lobes.
Page 1232 ENGINE 2.4L 9 - 31 CAMSHAFT(S) (Continued) (1) Install new cylinder head cover gaskets and spark plug well seals (Fig. 30). Fig. 29 Camshaft Bearing Cap Sealing 1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET MAKER (7) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD...
Page 1233 9 - 32 ENGINE 2.4L CYLINDER HEAD COVER (Continued) INTAKE/EXHAUST VALVES & SEATS DESCRIPTION The valves are made of heat resistant steel. They have chrome plated stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats.
Page 1234 ENGINE 2.4L 9 - 33 VALVE SPRINGS & SEALS (Continued) REMOVAL - CYLINDER HEAD OFF (1) With cylinder head removed from cylinder block, compress valve springs using a universal valve spring compressor. (2) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. (3) Before removing valves, remove any burrs from valve stem lock grooves to prevent dam- age to the valve guides.
Page 1235 9 - 34 ENGINE 2.4L VALVE SPRINGS & SEALS (Continued) (4) Check the valve spring installed height B after a. Check lash adjusters for sponginess while refacing the valve and seat (Fig. 36). Make sure mea- installed in cylinder head. Depress part of rocker surements are taken from top of spring seat to the arm over adjuster.
Page 1236 ENGINE 2.4L 9 - 35 INSPECTION ROCKER ARMS Inspect the rocker arm for wear or damage (Fig. REMOVAL 39). Replace as necessary. NOTE: This procedure is for in-vehicle service with camshafts installed. (1) Remove cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD...
Page 1237 9 - 36 ENGINE 2.4L ENGINE BLOCK (Continued) Fig. 40 Cylinder Block and Bedplate 1 - CYLINDER BLOCK 2 - BEDPLATE STANDARD PROCEDURE STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING Piston and cylinder wall must be clean and dry. Fig.
Page 1238 ENGINE 2.4L 9 - 37 ENGINE BLOCK (Continued) The cylinder walls should be checked for out-of- round and taper with Tool C119 or equivalent (Fig. 44) (Refer to 9 - ENGINE - SPECIFICATIONS). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.
Page 1239 9 - 38 ENGINE 2.4L CONNECTING ROD BEARINGS (Continued) (4) Tighten the bolts to 27 N·m PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Do not use a torque wrench for last step. (5) Using a feeler gauge, check connecting rod side clearance (Fig.
Page 1240 ENGINE 2.4L 9 - 39 CRANKSHAFT (Continued) (10) Remove the crankshaft sprocket and oil pump. should within specitifications. (Refer to 9 - ENGINE - (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - SPECIFICATIONS) Journal grinding should not REMOVAL) exceed 0.305 mm (0.012 in.) under the standard jour- (11) Remove balance shafts and housing assembly.
Page 1241 9 - 40 ENGINE 2.4L CRANKSHAFT (Continued) (2) Make certain oil holes in block line up with oil (7) Install main bearing bedplate to engine block hole in bearings and bearing tabs seat in the block bolts 11, 17, and 20 finger tight. Tighten these bolts tab slots.
Page 1242 ENGINE 2.4L 9 - 41 CRANKSHAFT (Continued) (21) Install the timing belt front covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (22) Install engine mount support bracket. (23) Install the oil pan. (Refer to 9 - ENGINE/LU- BRICATION/OIL PAN - INSTALLATION) (24) Install the oil filter.
Page 1243 9 - 42 ENGINE 2.4L CRANKSHAFT MAIN BEARINGS (Continued) • Step 6: Remove wedge tool used to hold crank- shaft. (10) Tighten bolts (1–10) again to 41 N·m (30 ft. lbs.) in sequence shown in (Fig. 56). CAUTION: Do Not use a torque wrench for the fol- lowing step.
Page 1244 ENGINE 2.4L 9 - 43 CRANKSHAFT OIL SEAL - FRONT (Continued) (4) Using Tool 6771 to remove front crankshaft oil seal (Fig. 58). Be careful not to damage the seal sur- face of cover. Fig. 58 Front Crankshaft Oil Seal - Removal 1 - SPECIAL TOOL 6771 2 - REAR TIMING BELT COVER INSTALLATION...
Page 1245 9 - 44 ENGINE 2.4L CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 62 Rear Crankshaft Seal and Special Tool Fig. 61 Rear Crankshaft Oil Seal—Removal 6926-1 1 - REAR CRANKSHAFT SEAL 1 - SPECIAL TOOL 6926–1 PILOT 2 - ENGINE BLOCK 2 - SEAL 3 - ENGINE BLOCK 4 - REAR CRANKSHAFT SEAL METAL CASE...
Page 1246 ENGINE 2.4L 9 - 45 CRANKSHAFT OIL SEAL - REAR (Continued) REMOVAL Fig. 65 Piston Markings 1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA NOTE: Cylinder Head must be removed before Pis- tons and Rods (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL).
Page 1247 9 - 46 ENGINE 2.4L PISTON & CONNECTING ROD (Continued) (9) After removal, install bearing cap on the mat- ing rod. (10) Repeat procedure for each piston and connect- ing rod assembly. (11) Piston and connecting rods are serviced as an assembly.
Page 1248 ENGINE 2.4L 9 - 47 PISTON & CONNECTING ROD (Continued) Fig. 69 Checking Connecting Rod Side Clearance PISTON RINGS Fig. 71 Piston Ring Side Clearance 1 - FEELER GAUGE STANDARD PROCEDURE PISTON RING - FITTING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
Page 1249 9 - 48 ENGINE 2.4L PISTON RINGS (Continued) (3) Install upper side rail first and then the lower VIBRATION DAMPER side rail. (4) Install No. 2 piston ring and then No. 1 piston REMOVAL ring. (1) Remove accesory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) (2) Remove crankshaft damper bolt.
Page 1250 ENGINE 2.4L 9 - 49 • Step 4: Final torque collar to oil pan bolts to 54 STRUCTURAL COLLAR N·m (40 ft. lbs.). (2) Install engine front mount bracket and insula- REMOVAL tor. (Refer to 9 - ENGINE/ENGINE MOUNTING/ (1) Raise vehicle on hoist. FRONT MOUNT - INSTALLATION) (2) Remove engine front mount bracket and front (3) Lower vehicle.
Page 1251 9 - 50 ENGINE 2.4L FRONT MOUNT (Continued) Fig. 80 LEFT MOUNT TO BRACKET 1 - BOLT - BRACKET TO FRAME RAIL 68 N·m (50 ft. lbs.) 2 - BOLT - MOUNT TO RAIL THRU 75 N·m (55 ft. lbs.) Fig.
Page 1252 ENGINE 2.4L 9 - 51 LEFT MOUNT (Continued) Fig. 82 UNDER CONSTRUCTION Fig. 83 REAR MOUNT HEAT SHIELD 1 - LEFT MOUNT ASSEMBLY 1 - BOLT - HEAT SHIELD 11 N·m (100 in. lbs.) 2 - BOLT - 54 N·m (40 ft. lbs.) 2 - HEAT SHIELD 3 - TRANSAXLE - 41TE 3 - CLIP...
Page 1253 9 - 52 ENGINE 2.4L REAR MOUNT (Continued) Fig. 85 REAR MOUNT BRACKET - (all engines) 1 - BOLT - VERTICAL 102 N·m (75 ft. lbs.) 3 - BOLT - HORIZONTAL 102 N·m (75 ft. lbs.) 2 - BRACKET - REAR MOUNT INSTALLATION RIGHT MOUNT (1) Position right engine mount and install frame...
Page 1254 ENGINE 2.4L 9 - 53 RIGHT MOUNT (Continued) running the length of the cylinder head. The cam- shaft journals are partially slotted to allow a prede- termined amount of pressurized oil to pass into the bearing cap cavities. Lubrication of the camshaft lobes are provided by small holes in the camshaft bearing caps that are directed towards each lobe.
Page 1255 9 - 54 ENGINE 2.4L OIL (Continued) (12) Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Fig. 87 Oil Level OIL FILTER 1 - ENGINE OIL LEVEL DIPSTICK DESCRIPTION...
Page 1256 ENGINE 2.4L 9 - 55 OIL FILTER (Continued) INSTALLATION OIL PRESSURE SWITCH (1) Clean and check filter mounting surface. The REMOVAL surface must be smooth, flat and free of debris or pieces of gasket. (1) Raise vehicle. (2) Lubricate new oil filter gasket with clean (2) Position oil collecting container under pressure engine oil.
Page 1257 9 - 56 ENGINE 2.4L OIL PUMP (Continued) Fig. 91 Crankshaft Sprocket - Removal 1 - SPECIAL TOOL 6793 2 - SPECIAL TOOL C-4685–C2 3 - CRANKSHAFT SPROCKET Fig. 93 Oil Pump 1 - BOLTS 2 - BOLTS 3 - OIL PUMP Fig.
Page 1258 ENGINE 2.4L 9 - 57 OIL PUMP (Continued) Fig. 95 Oil Pump Fig. 96 Oil Pump 1 - O-RING 1 - O-RING 2 - SEAL 2 - SEAL 3 - INNER ROTOR 3 - INNER ROTOR 4 - OIL PUMP COVER 4 - OIL PUMP COVER 5 - FASTENER 5 - FASTENER...
Page 1259 9 - 58 ENGINE 2.4L OIL PUMP (Continued) (2) Apply Mopar Gasket Maker to oil pump as shown in (Fig. 100). Install O-ring into oil pump body discharge passage. Fig. 98 Measuring Outer Rotor Thickness Fig. 100 Oil Pump Sealing 1 - O-RING 2 - SEALER LOCATION (3) Prime oil pump with engine oil before installa-...
Page 1260 ENGINE 2.4L 9 - 59 OIL PUMP (Continued) INTAKE MANIFOLD DESCRIPTION The intake manifold is a two piece aluminum cast- ing (Fig. 103) that attaches to the cylinder head with fasteners. The manifold is a long branch design to enhance low and mid-range torque Fig.
Page 1261 9 - 60 ENGINE 2.4L INTAKE MANIFOLD - UPPER REMOVAL (1) Disconnect negative cable from battery. (2) Disconnect connector from inlet air tempera- ture sensor (Fig. 104). Fig. 106 Throttle Body Electrical Connectors - Typical 1 - IDLE AIR CONTROL MOTOR CONNECTOR 2 - TPS CONNECTOR (8) Remove vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum res-...
Page 1262 ENGINE 2.4L 9 - 61 INTAKE MANIFOLD - UPPER (Continued) (12) Remove engine oil dipstick from tube. (11) Connect electrical connectors for MAP sensor, (13) Remove upper intake manifold bolts (Fig. throttle position sensor (TPS), and idle air control 108). Remove upper intake manifold. (IAC) motor.
Page 1263 9 - 62 ENGINE 2.4L INTAKE MANIFOLD - LOWER (Continued) (5) Connect the fuel line. (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY/QUICK CONNECT FIT- TING - STANDARD PROCEDURE) (6) Connect coolant temperature sensor/fuel injec- tor wiring harness electrical connector. (7) Install the radiator upper and heater supply hoses.
Page 1264 ENGINE 2.4L 9 - 63 EXHAUST MANIFOLD (Continued) (2) Attach exhaust pipe to exhaust manifold and tighten fasteners to 37 N·m (27 ft. lbs.). (3) Install and connect the oxygen sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR - COMPONENT LOCATION) Fig.
Page 1265 9 - 64 ENGINE 2.4L TIMING BELT COVER(S) (Continued) Fig. 113 ENGINE FRONT MOUNT BRACKET Fig. 115 Timing Belt Rear Cover 1 - ENGINE MOUNT BRACKET 1 - BOLTS - REAR COVER 12 N·m (105 in. lbs.) 2 - BOLTS - 61 N·m (45 ft. lbs.) 2 - BOLTS - REAR COVER 28 N·m (250 in.
Page 1266 ENGINE 2.4L 9 - 65 TIMING BELT AND SPROCKET(S) (Continued) (7) Remove crankshaft vibration damper. (Refer to CAUTION: When aligning crankshaft and camshaft ENGINE/ENGINE BLOCK/VIBRATION timing marks always rotate engine from crankshaft. DAMPER - REMOVAL) Camshaft should not be rotated after timing belt is (8) Remove air conditioner/generator belt tensioner removed.
Page 1267 9 - 66 ENGINE 2.4L TIMING BELT AND SPROCKET(S) (Continued) CLEANING Do Not attempt to clean a timing belt. If contami- nation from oil, grease, or coolants have occurred, the timing belt should be replaced. Clean all sprockets using a suitable solvent. Clean all sprocket grooves of any debris.
Page 1268 ENGINE 2.4L 9 - 67 TIMING BELT AND SPROCKET(S) (Continued) INSTALLATION - TIMING BELT NOTE: A new tensioner is held in the wound posi- tion by a pull pin. CAUTION: The crankshaft sprocket is set to a pre- determined depth from the factory for correct tim- ing belt tracking.
Page 1269 9 - 68 ENGINE 2.4L TIMING BELT AND SPROCKET(S) (Continued) (5) Remove the pull pin or Allen wrench from the (11) Install crankshaft vibration damper. (Refer to belt tensioner. ENGINE/ENGINE BLOCK/VIBRATION (6) Once the timing belt has been installed and DAMPER - INSTALLATION) tensioner released, rotate the crankshaft two (2) com- (12) Install accessory drive belts.
Page 1270 ENGINE 2.4L 9 - 69 TIMING BELT TENSIONER & PULLEY (Continued) Fig. 126 Timing Belt Tensioner Assembly—Removal/ Installation 1 - TIMING BELT TENSIONER ASSEMBLY 2 - TENSIONER ASSEMBLY UPPER BOLT 3 - TENSIONER ASSEMBLY LOWER BOLT Fig. 125 Rear Timing Belt Cover Fasteners (3) Install rear timing belt cover and fasteners 1 - BOLTS - REAR COVER 12 N·m (105 in.
Page 1271 9 - 70 ENGINE 2.4L BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 127 Balance Shafts and Carrier Assembly 1 - SPROCKET 7 - GEARS 2 - TENSIONER 8 - GEAR COVER 3 - PLUG 9 - CHAIN COVER 4 - CARRIER 10 - SPROCKET 5 - REAR COVER 11 - GUIDE...
Page 1272 ENGINE 2.4L 9 - 71 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 128 Chain Cover, Guide and Tensioner Fig. 129 Drive Chain and Sprockets 1 - STUD 1 - NICKEL PLATED LINK AND MARK 2 - TENSIONER (ADJUSTER) 2 - GEAR/SPROCKET SCREWS 3 - GEAR COVER 3 - NICKEL PLATED LINK AND DOT 4 - ADJUST SCREW...
Page 1273 9 - 72 ENGINE 2.4L BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 133 Balance Shaft Sprocket Alignment to Fig. 131 Balance Shaft - Removal/Installation Crankshaft 1 - REAR COVER 1 - ALIGN FLATS 2 - CARRIER 3 - BALANCE SHAFT Fig.
Page 1274 ENGINE 2.4L 9 - 73 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) (9) With balance shaft keyways pointing up (12 (11) CHAIN TENSIONING: o’clock) slide the balance shaft sprocket onto the nose (a) Install chain tensioner loosely assembled. of the balance shaft. The balance shaft may have to (b) Position guide on double ended stud making be pushed in slightly to allow for clearance.
Page 1275 9 - 74 ENGINE 3.3/3.8L ENGINE 3.3/3.8L TABLE OF CONTENTS page page ENGINE 3.3/3.8L INSPECTION ......101 DESCRIPTION .
Page 1276 ENGINE 3.3/3.8L 9 - 75 CLEANING ......113 PISTON RINGS INSPECTION ......113 STANDARD PROCEDURE - PISTON RING CAMSHAFT &...
Page 1277 9 - 76 ENGINE 3.3/3.8L OIL PUMP OPERATION ......152 DESCRIPTION ......143 EXHAUST MANIFOLD - RIGHT REMOVAL .
Page 1278 ENGINE 3.3/3.8L 9 - 77 ENGINE 3.3/3.8L (Continued) Fig. 1 3.3/3.8L V-6 Engines DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
Page 1279 9 - 78 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1280 ENGINE 3.3/3.8L 9 - 79 ENGINE 3.3/3.8L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter. 3.
Page 1281 9 - 80 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1282 ENGINE 3.3/3.8L 9 - 81 ENGINE 3.3/3.8L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1283 9 - 82 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1284 ENGINE 3.3/3.8L 9 - 83 ENGINE 3.3/3.8L (Continued) (3) Remove torque converter or clutch housing (4) Remove the Auto Shutdown (ASD) relay from cover and inspect rear of block for evidence of oil. the PDC. Use a black light to check for the oil leak. If a leak is (5) Be sure throttle blade is fully open during the present in this area, remove transmission for further compression check.
Page 1285 9 - 84 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) Calibrate the tester according to the manufactur- Remove the bearing cap and compare the er’s instructions. The shop air source for testing width of the flattened Plastigage with the metric should maintain 483 kPa (70 psi) minimum, 1,379 scale provided on the package.
Page 1286 ENGINE 3.3/3.8L 9 - 85 ENGINE 3.3/3.8L (Continued) MOPAR GASKET MAKER is an anaerobic type STANDARD PROCEDURE - ENGINE GASKET gasket material. The material cures in the absence of SURFACE PREPARATION air when squeezed between two metallic surfaces. It To ensure engine gasket sealing, proper surface will not cure if left in the uncovered tube.
Page 1287 9 - 86 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) STANDARD PROCEDURE - HYDROSTATIC CAUTION: Be sure that the tapped holes maintain the original center line. LOCKED ENGINE When an engine is suspected to be hydrostatically Heli-Coil tools and inserts are readily available locked, regardless of what caused the problem, the from automotive parts jobbers.
Page 1288 ENGINE 3.3/3.8L 9 - 87 ENGINE 3.3/3.8L (Continued) REMOVAL - ENGINE ASSEMBLY (24) Disconnect the A/C lines from compressor. Cover and seal all openings of hoses and compressor. (1) Perform fuel pressure release procedure (Refer (25) Remove the radiator upper hose. to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN- (26) Disengage electrical harness clip at transaxle DARD PROCEDURE).
Page 1289 9 - 88 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) (33) AWD equipped: Remove the power transfer unit (PTU) (Refer to 21 - TRANSMISSION/TRANS- AXLE/POWER TRANSFER UNIT - REMOVAL). (34) Disconnect exhaust pipe from the manifold (Fig. 7). Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER 1 - BRACKET - ENGINE REAR MOUNT 2 - BOLT - TRANSAXLE CASE COVER 3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL...
Page 1290 ENGINE 3.3/3.8L 9 - 89 ENGINE 3.3/3.8L (Continued) (48) Remove the water pump pulley attaching bolts and position pulley between pump hub and housing. (49) Disconnect the oil pressure switch electrical connector. (50) Disconnect wiring harness support clip from engine oil dipstick tube. (51) Install Special Tools 6912 and 8444 Adapters on the right side (rear) of engine block (Fig.
Page 1291 9 - 90 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) Fig. 12 Positioning Engine Cradle Support Post Mounts 1 - SPECIAL TOOL 8444 5 - SPECIAL TOOLS 6848 2 - SPECIAL TOOLS 6848 6 - SAFETY STRAPS 3 - SPECIAL TOOL 6912 7 - SPECIAL TOOLS 6909 4 - SPECIAL TOOLS 6135 &...
Page 1292 ENGINE 3.3/3.8L 9 - 91 ENGINE 3.3/3.8L (Continued) (25) Connect exhaust pipe to manifold (Fig. 7). (26) Install crossmember cradle plate (Fig. 6). (27) Lower vehicle. (28) Connect transaxle shift linkage. (29) Connect transaxle electrical connectors. (30) Remove plugs from transmission cooler hoses and install transaxle oil cooler line service splice kit.
Page 1293 9 - 92 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Out-of-Round (Service 0.076 mm 3.3/3.8L ENGINE Limits) (0.003 in.) Taper (Service Limits) 0.051 mm DESCRIPTION SPECIFICATION (0.002 in.) General Specification Lifter Bore Diameter 22.980–23.010 mm Type 60° V-6 Engine (0.905–0.906 in.) Number of Cylinders Deck Surface Flatness...
Page 1294 ENGINE 3.3/3.8L 9 - 93 ENGINE 3.3/3.8L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Ring End Gap—2nd 0.28–0.57 mm (0.017–0.020 in.) Compression Ring (0.011–0.022 in.) Connecting Rod Wear Limit 1.0 mm Bearing Clearance 0.019–0.065 mm (0.039 in.) (0.0008–0.0026 in.) Ring End Gap—Oil 0.23–0.78 mm Wear Limit 0.074 mm...
Page 1295 9 - 94 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Bearing Clearance (Max. 0.127 mm Valve Seat allowable) (0.005 in.) Angle 44.5–45° End Play 0.254–0.508 mm Valve Seat Runout 0.0762 mm (Service Limits) (0.010–0.020 in.) (0.003 in.) (Max. allowable) 0.304 mm Valve Seat Width—Intake 1.50–2.00 mm...
Page 1296 ENGINE 3.3/3.8L 9 - 95 ENGINE 3.3/3.8L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Exhaust (Standard) 6.906–6.924 mm (3.148 in.) (0.2718–0.2725 in.) Tip Clearance Between 0.20 mm Rotors (Max.) (0.008 in.) Valve Stem to Guide Clearance Intake 0.025–0.065 mm Oil Pressure (0.001–0.0025 in.) At Curb Idle Speed* 34.47 kPa (Minimum with engine at...
Page 1297 9 - 96 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) SPECIAL TOOLS DESCRIPTION N·m Lbs. Lbs. 3.3/3.8L ENGINE Exhaust Crossover — Pipe—Bolts Intake Manifold - — Lower—Bolts Intake Manifold - Lower — Gasket Retainer—Bolts Intake Manifold — Upper—Bolts Lifter Yoke Retainer— — Bolts Dolly 6135 Oil Filter Attaching Fitting...
Page 1298 ENGINE 3.3/3.8L 9 - 97 ENGINE 3.3/3.8L (Continued) Indicator, Cylinder Bore C-119 Adapter 6912 Tester - Valve Spring C-647 Puller 1026 Compressor, Valve Spring In-vehicle 8453 Insert, Crankshaft 8450 Valve Spring Compressor Off-vehicle C-3422-D Crankshaft Damper/Sprocket Installer 8452...
Page 1299 9 - 98 ENGINE 3.3/3.8L ENGINE 3.3/3.8L (Continued) Remover and Installer, Crankshaft Main Bearing C-3059 Adapter, Valve Spring Compressor Off-vehicle 8464 Rear Crankshaft Oil Seal Installer 6926 Remover, Valve Tappet C-4129-A Oil Pressure Gauge C-3292 Remover, Crankshaft Front Seal 6341A Adapter 8406 Installer, Crankshaft Front Seal C-4992 Cooling System Tester 7700...
Page 1300 ENGINE 3.3/3.8L 9 - 99 ENGINE 3.3/3.8L (Continued) Pressure Transducer CH7059 Fig. 15 AIR BOX COVER AIR CLEANER HOUSING Compression Test Adapter 8116 REMOVAL (1) Disconnect the negative battery cable. (2) Disconnect the inlet air temperature sensor (Fig. 16). DRB III with PEP Module OT-CH6010A AIR CLEANER ELEMENT REMOVAL (1) Unsnap 2 clips.
Page 1301 9 - 100 ENGINE 3.3/3.8L AIR CLEANER HOUSING (Continued) INSTALLATION CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is (1) Install air box into vehicle and onto the locat- leaking between adjacent cylinders, follow the proce- ing pin. dures in Cylinder Compression Pressure Test (Refer (2) Install bolt to hold air box to the upper radia- to 9 - ENGINE - DIAGNOSIS AND TESTING).
Page 1302 ENGINE 3.3/3.8L 9 - 101 CYLINDER HEAD (Continued) Fig. 17 Cylinder Head and Components 1 - VALVE LOCKS 5 - SPRING SEATS 2 - RETAINERS 6 - CYLINDER HEAD 3 - VALVE SPRINGS 7 - VALVE - EXHAUST 4 - VALVE STEM SEALS 8 - VALVE - INTAKE (4) Remove the cylinder head covers.
Page 1303 9 - 102 ENGINE 3.3/3.8L CYLINDER HEAD (Continued) (2) Position new gasket(s) on engine block (Fig. 20). The left bank gasket is identified with the “L” stamped in the exposed area of the gasket located at front of engine (shown in (Fig. 20)). The right bank gasket is identified with a “R”...
Page 1304 ENGINE 3.3/3.8L 9 - 103 CYLINDER HEAD (Continued) • Step 2: Bolts 1 – 8 to 88 N·m (65 ft. lbs.) AND TESTING) for determining the source of a • Step 3: Bolts 1 – 8 (again) to 88 N·m (65 ft. lbs.) leak.
Page 1305 9 - 104 ENGINE 3.3/3.8L CYLINDER HEAD COVER - RIGHT (Continued) Fig. 26 CYLINDER HEAD COVER GASKET 1 - CYLINDER HEAD COVER 2 - BOLT Fig. 24 P/S Supply Hose 3 - SEAL (SERVICED WITH BOLT) 4 - GASKET 1 - POWER STEERING RESERVOIR 2 - CLAMP 3 - SUPPLY HOSE (5) Tighten cylinder head cover bolts to 12 N·m...
Page 1306 ENGINE 3.3/3.8L 9 - 105 CYLINDER HEAD COVER - LEFT REMOVAL (1) Disconnect spark plug wires from spark plugs. (2) Disconnect crankcase vent hose from cylinder head cover. (3) Remove cylinder head cover bolts. (4) Remove cylinder head cover and gasket. Fig.
Page 1307 9 - 106 ENGINE 3.3/3.8L INTAKE/EXHAUST VALVES & SEATS (Continued) (2) Measure the concentricity of valve seat using 0.794 mm (0.0312 in.) spacer in head counter- dial indicator (Fig. 31). Total runout should not bore to bring spring height back within specifi- exceed 0.051 mm (0.002 in.) total indicator reading.
Page 1308 ENGINE 3.3/3.8L 9 - 107 INTAKE/EXHAUST VALVES & SEATS (Continued) INSTALLATION (1) Coat valve stems with clean engine oil and insert them in cylinder head. (2) Install valve spring seat on head (Fig. 36). (3) Install new seals on all valve stems and over valve guides (Fig.
Page 1309 9 - 108 ENGINE 3.3/3.8L VALVE SPRINGS (Continued) Fig. 36 VALVE COMPONENTS 1 - VALVE LOCKS 5 - SPRING SEATS 2 - RETAINERS 6 - CYLINDER HEAD 3 - VALVE SPRINGS 7 - VALVE - EXHAUST 4 - VALVE STEM SEALS 8 - VALVE - INTAKE (4) Remove rocker arms and shaft.
Page 1310 ENGINE 3.3/3.8L 9 - 109 VALVE SPRINGS (Continued) spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length.
Page 1311 9 - 110 ENGINE 3.3/3.8L VALVE SPRINGS (Continued) (2) Follow the same procedure on the remaining 5 REMOVAL - ROCKER ARMS AND SHAFT cylinders using the firing sequence 1-2-3-4-5-6. Make (1) Remove the cylinder head cover(s). (Refer to 9 - sure piston in cylinder is at TDC on the valve ENGINE/CYLINDER HEAD/CYLINDER...
Page 1312 ENGINE 3.3/3.8L 9 - 111 ROCKER ARMS (Continued) Fig. 41 ROCKER ARM RETAINER - REMOVAL 1 - ADJUSTABLE PLIERS 3 - ROCKER ARM RETAINER 2 - ROCKER SHAFT BOLT ASSEMBLY - ROCKER ARMS AND SHAFT (1) Position the rocker arm and shaft assemblies on the pedestal mounts.
Page 1313 9 - 112 ENGINE 3.3/3.8L ROCKER ARMS (Continued) Fig. 42 ROCKER ARMS AND SHAFT 1 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH) 5 - ROCKER ARM - EXHAUST 2 - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.) 6 - WASHER 3 -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.) 7 - ROCKER ARM - INTAKE (LARGER OFFSET) 4 - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.)
Page 1314 ENGINE 3.3/3.8L 9 - 113 VALVE STEM SEALS (Continued) REMOVAL (1) Remove the valve springs. (Refer to 9 - ENGINE/CYLINDER HEAD/VALVE SPRINGS REMOVAL) (2) Remove the valve stem seal (Fig. 44). INSTALLATION (1) Install the valve stem seal squarely over the valve guide, using the valve stem as a guide (Fig.
Page 1315 9 - 114 ENGINE 3.3/3.8L ENGINE BLOCK (Continued) The cylinder walls should be checked for out-of- round and taper with Tool C119 or equivalent (Fig. 46) (Refer to 9 - ENGINE - SPECIFICATIONS). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.
Page 1316 ENGINE 3.3/3.8L 9 - 115 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (4) Remove camshaft thrust plate (Fig. 47). (6) Install the timing chain and sprockets. (Refer (5) Install a long bolt into front of camshaft to to 9 - ENGINE/VALVE TIMING/TIMING BELT/ facilitate removal of the camshaft.
Page 1317 9 - 116 ENGINE 3.3/3.8L CONNECTING ROD BEARINGS (Continued) (3) Place a piece of Plastigage across the entire CRANKSHAFT width of the bearing shell in the bearing cap approx- imately 6.35 mm (1/4 in.) off center and away from DESCRIPTION the oil hole.
Page 1318 ENGINE 3.3/3.8L 9 - 117 CRANKSHAFT (Continued) DESCRIPTION - 3.8L STANDARD PROCEDURE - MEASURING The nodular iron crankshaft is supported by four CRANKSHAFT END PLAY main bearings, with number two position providing (1) Mount a dial indicator to front of engine with thrust bearing location (Fig.
Page 1319 9 - 118 ENGINE 3.3/3.8L CRANKSHAFT (Continued) (13) Remove and discard the main bearing cross INSTALLATION bolts and washers (3.8L engine only). (1) Lubricate with engine oil and install the crank- shaft main bearing halves in the engine block. NOTE: Install new cross bolt and washer assembly (2) Position the crankshaft in engine block (Fig.
Page 1320 ENGINE 3.3/3.8L 9 - 119 CRANKSHAFT (Continued) Fig. 56 CRANKSHAFT AND BLOCK - 3.3L Fig. 57 CRANKSHAFT AND BLOCK - 3.8L 1 - MAIN BEARING CAP No. 4 1 - MAIN BEARING CAP No. 4 2 - MAIN BEARING CAP No. 3 2 - MAIN BEARING CAP No.
Page 1321 9 - 120 ENGINE 3.3/3.8L CRANKSHAFT MAIN BEARINGS (Continued) lowing is the recommended procedures for the use of Plastigage with the engine in the vehicle or engine on a repair stand. PLASTIGAGE METHOD—ENGINE IN-VEHICLE NOTE: The total clearance of the main bearings can only be determined with the engine in the vehicle by removing the weight of the crankshaft.
Page 1322 ENGINE 3.3/3.8L 9 - 121 CRANKSHAFT MAIN BEARINGS (Continued) NOTE: Plastigage is available in a variety of clear- REMOVAL - CRANKSHAFT MAIN BEARINGS ance ranges. Use the most appropriate range for (1) Remove the oil pan. (Refer to 9 - ENGINE/LU- the specifications you are checking.
Page 1323 9 - 122 ENGINE 3.3/3.8L CRANKSHAFT MAIN BEARINGS (Continued) NOTE: The main cap bolts should be examined (3) Remove accessory drive belt. (Refer to 7 - before reuse. Bolt stretch can be checked by hold- COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) ing a scale or straight edge against the threads.
Page 1324 ENGINE 3.3/3.8L 9 - 123 CRANKSHAFT OIL SEAL - FRONT (Continued) INSTALLATION CAUTION: Do not permit the pry tool blade to con- tact crankshaft seal surface. Contact of the pry tool (1) Position Special Tool C-4992-2 Guide, on the blade against crankshaft edge (chamfer) is permit- crankshaft nose (Fig.
Page 1325 9 - 124 ENGINE 3.3/3.8L CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 69 CRANKSHAFT REAR OIL SEAL 1 - OIL SEAL 2 - BOLT 3 - RETAINER - OIL SEAL 4 - GASKET FLEX PLATE REMOVAL Fig. 68 Rear Crankshaft Oil Seal—Installation (1) Remove the transaxle (Refer to 21 - TRANS- 1 - SPECIAL TOOLS: MISSION/TRANSAXLE/AUTOMATIC...
Page 1326 ENGINE 3.3/3.8L 9 - 125 FLEX PLATE (Continued) (3) Install flex plate bolts (Fig. 70). Tighten bolts DIAGNOSIS AND TESTING - HYDRAULIC to 95 N·m (70 ft. lbs.). LIFTERS (4) Install the transaxle (Refer to 21 - TRANSMIS- SION/TRANSAXLE/AUTOMATIC - 41TE - INSTAL- HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY LATION).
Page 1327 9 - 126 ENGINE 3.3/3.8L HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued) the plunger and the lifter body causing the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, lifter assembly should be removed for inspec- tion.
Page 1328 ENGINE 3.3/3.8L 9 - 127 PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE STANDARD PROCEDURE - FITTING CONNECTING RODS The bearing caps are not interchangeable or reversible, and should be marked at removal to ensure correct reassembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps.
Page 1329 9 - 128 ENGINE 3.3/3.8L PISTON & CONNECTING ROD (Continued) Fig. 79 Connecting Rod Protectors 1 - COVER ROD BOLTS WITH A SUITABLE COVERING WHEN REMOVING OR INSTALLING PISTON ASSEMBLY Fig. 77 Checking Cylinder Bore Size (5) Inspect connecting rods and connecting rod caps for cylinder identification.
Page 1330 ENGINE 3.3/3.8L 9 - 129 PISTON & CONNECTING ROD (Continued) (6) The pistons are marked with a “F” located near (8) Tap the piston down in cylinder bore, using a the piston pin. Install piston with this mark posi- hammer handle. At the same time, guide connecting tioned to front of engine on both cylinder banks.
Page 1331 9 - 130 ENGINE 3.3/3.8L PISTON & CONNECTING ROD (Continued) Fig. 82 Piston and Connecting Rod Positioning (Front View of Engine) 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE (11) Install the cylinder heads. (Refer to 9 - PISTON RINGS ENGINE/CYLINDER HEAD - INSTALLATION) (12) Install the oil pan.
Page 1332 ENGINE 3.3/3.8L 9 - 131 PISTON RINGS (Continued) CAUTION: Install piston rings in the following order: a. Oil ring expander. b. Upper oil ring side rail. c. Lower oil ring side rail. d. No. 2 Intermediate piston ring. e. No. 1 Upper piston ring. Fig.
Page 1333 9 - 132 ENGINE 3.3/3.8L PISTON RINGS (Continued) (4) Install No. 2 piston ring and then No. 1 piston VIBRATION DAMPER ring (Fig. 87). REMOVAL (1) Disconnect negative cable from battery. (2) Raise vehicle on hoist. (3) Remove the right front wheel and inner splash shield.
Page 1334 ENGINE 3.3/3.8L 9 - 133 VIBRATION DAMPER (Continued) Fig. 90 Vibration Damper - Installation 1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452 2 - VIBRATION DAMPER 3 - THRUST BEARING / WASHER Fig. 91 Engine Hydro-type Mount - Right Side 1 - BOLT (6) Install the accessory drive belt.

Chrysler Dodge Caravan 2002 Manual

Lubrication & Maintenance

International Symbols

Lubrication & Maintenance

Hoisting

Description - Engine Oil - Diesel Engines

Lubrication & Maintenance

Fluid Fill/Check Locations Description

Lubrication Points Description

Maintenance Schedules Description

Jump Starting

Towing

Suspension

Front Suspension

Bushings

Hub / Bearing Description

Knuckle Description

Lower Ball Joint Description

Lower Ball Joint Seal Boot

Front Suspension

Lower Control Arm Description

Stabilizer Bar

Strut

Rear Suspension

Bushings

Hub / Bearing Description

Jounce Bumper Description

Rear Suspension

Shock Absorber Description

Spring - Awd Description

Spring - Fwd Description

Spring Mounts - Front Removal

Spring Mounts - Rear Removal

Stabilizer Bar Description

Track Bar Description

Differential & Driveline

Half Shaft - Front Description

Half Shaft - Front

CV Boot - Inner

Half Shaft - Front

CV Boot - Outer Removal

Outer CV Joint Bearing Shield Removal

Rear Driveline Module

Rear Driveline Module Description

Bi-Directional Overrunning Clutch Description

Differential Assembly Description

Fluid - Differential Assembly

Fluid

Viscous Coupler Description

Torque Arm Removal

Input Flange Seal Removal

Output Flange Seal Removal

Brakes

Brakes - Base

Brake Fluid Level Switch

Adjustable Pedal Switch

Pedal Position Sensor Description

Hydraulic/Mechanical

Brakes - Base

Brake Pads/Shoes - Front

Brake Lines

Brake Pads/Shoes - Rear Disc

Brake Pads/Shoes - Rear Drum

Disc Brake Caliper - Front

Disc Brake Caliper - Rear

Disc Brake Caliper Guide Pins

Disc Brake Caliper Adapter Removal - Front Disc Brake Caliper Adapter

Fluid

Drum Removal

Junction Block

Master Cylinder Description Description

Pedal - Adjustable Description

Pedal Torque Shaft - Rhd Removal

Power Brake Booster Description

Proportioning Valve Description - Proportioning Valve (Height Sensing)

Rotor

Support Plate - Drum Brake Removal

Wheel Cylinders Removal

Cables - Parking Brake Removal Removal - Parking Brake Cable (Front)

Lever - Parking Brake Removal