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Jeep Wrangler 1999 Electronic Service Manual

Jeep Wrangler 1999 Electronic Service Manual

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Electronic service manual (1833 pages)

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Page 2 GROUP TAB LOCATOR Introduction Lamps Introduction Passive Restraint Systems Lubrication and Maintenance Electrically Heated System Suspension Power Distribution System Differential and Driveline Vehicle Theft/Security Systems Brakes Chime/Buzzer Warning Systems Clutch Wiring Diagrams Cooling System Engine Battery Exhaust System and Intake Manifold Starting Systems Frame and Bumpers Charging System...
Page 3 VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = United States Make J = Jeep Vehicle Type 4 = MPV Gross Vehicle Weight Rating E = 3001-4000 lbs. F = 4001-5000 lbs. Vehicle Line...
Page 4 INTRODUCTION GENERAL INFORMATION (Continued) Fig. 1 Vehicle Safety Certification Label—Typical VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 1) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all appli- cable Federal Motor Vehicle Safety Standards. The label also lists: •...
Page 5 INTRODUCTION GENERAL INFORMATION (Continued) BODY CODE PLATE—LINE 3 DIGIT 19 Open Space DIGITS 1 THROUGH 12 DIGITS 20, 21, AND 22 Vehicle Order Number Engine Code • EPE = 2.5 L 4 cyl. MPI Gasoline DIGITS 13, 14, AND 15 •...
Page 6 INTRODUCTION GENERAL INFORMATION (Continued) INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig. 4 FASTENER IDENTIFICATION strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are FASTENER IDENTIFICATION imprinted with a single-digit strength class on the nut face.
Page 7 INTRODUCTION GENERAL INFORMATION (Continued) FASTENER IDENTIFICATION...
Page 8 INTRODUCTION GENERAL INFORMATION (Continued) FASTENER STRENGTH...
Page 9 INTRODUCTION GENERAL INFORMATION (Continued) THREADED HOLE REPAIR The following chart will assist in converting metric units to equivalent English and SAE units, or vice Most stripped threaded holes can be repaired using versa. a Helicoil . Follow the manufactures recommenda- Refer to the Conversion Chart to convert torque tions for application and repair procedures.
Page 10 INTRODUCTION GENERAL INFORMATION (Continued) METRIC CONVERSION...
Page 11 INTRODUCTION GENERAL INFORMATION (Continued) TORQUE REFERENCES individual torque charts. Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifi- cations Chart for torque references not listed in the TORQUE SPECIFICATIONS...
Page 12 VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = United States Make J = Jeep Vehicle Type 4 = MPV Gross Vehicle Weight Rating E = 3001-4000 lbs. F = 4001-5000 lbs. Vehicle Line...
Page 13 INTRODUCTION GENERAL INFORMATION (Continued) Fig. 1 Vehicle Safety Certification Label—Typical VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 1) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all appli- cable Federal Motor Vehicle Safety Standards. The label also lists: •...
Page 14 INTRODUCTION GENERAL INFORMATION (Continued) BODY CODE PLATE—LINE 3 DIGITS 10 THROUGH 13 Secondary Paint DIGITS 1 THROUGH 12 DIGIT 14 Vehicle Order Number Open Space DIGITS 13, 14, AND 15 DIGITS 15 THROUGH 18 Roof • VJN = Soft Top White Interior Trim Code •...
Page 15 INTRODUCTION GENERAL INFORMATION (Continued) INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
Page 16 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CONTENTS page page GENERAL INFORMATION ....1 MAINTENANCE SCHEDULES ....3 JUMP STARTING, HOISTING AND TOWING .
Page 17 0 - 2 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) API QUALITY CLASSIFICATION FLUID CAPACITIES This symbol (Fig. 2) on the front of an oil container FUEL TANK means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by Chrysler Corpo- Standard .
Page 18 LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES INDEX page GENERAL INFORMATION MAINTENANCE SCHEDULES ....3 • Rotate the tires at each oil change interval GENERAL INFORMATION shown on Schedule “A”...
Page 19 0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Flush and replace engine coolant if it has been 30,000 Miles (48 000 km) or at 24 months • Change engine oil. 30,000 miles (48 000 km) or 24 months since last •...
Page 20 LUBRICATION AND MAINTENANCE 0 - 5 GENERAL INFORMATION (Continued) • Lubricate steering linkage. • Lubricate steering linkage. • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid. • Drain and refill transfer case fluid. • Drain and refill front and rear axles.‡ •...
Page 21 0 - 6 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Lubricate steering linkage. • Lubricate steering linkage. • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid. • Drain and refill front and rear axles.‡ • Drain and refill front and rear axles.‡ •...
Page 22 LUBRICATION AND MAINTENANCE 0 - 7 GENERAL INFORMATION (Continued) • Flush and replace engine coolant if it has been 96,000 Miles (154 000 km) • Change engine oil. 30,000 miles (48 000 km) since last change. • Lubricate steering linkage. •...
Page 23 0 - 8 LUBRICATION AND MAINTENANCE JUMP STARTING, HOISTING AND TOWING INDEX page page SERVICE PROCEDURES RECREATIONAL TOWING ....10 EMERGENCY TOW HOOKS ....10 TOWING RECOMMENDATIONS .
Page 24 LUBRICATION AND MAINTENANCE 0 - 9 SERVICE PROCEDURES (Continued) DISCONNECT CABLE CLAMPS AS FOLLOWS: SAFETY PRECAUTIONS • Disconnect BLACK cable clamp from engine • Secure loose and protruding parts. • Always use a safety chain system that is inde- ground on disabled vehicle. •...
Page 25 FLOOR JACK When properly positioned, a floor jack can be used to lift a Jeep vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails.
Page 26 LUBRICATION AND MAINTENANCE 0 - 11 SERVICE PROCEDURES (Continued) • An axle tube. • A ramp-type, drive-on hoist. • A body side sill. • A steering linkage component. NOTE: When a frame-contact type hoist is used, • A drive shaft. verify that the lifting pads are positioned properly.
Page 27 SUSPENSION 2 - 1 SUSPENSION CONTENTS page page ALIGNMENT ......1 REAR SUSPENSION ..... . 13 FRONT SUSPENSION .
Page 28 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Wheel Alignment Measurements...
Page 29 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING SUSPENSION AND STEERING SYSTEM CONDITION POSSIBLE CAUSES CORRECTION FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. 2. Loose or worn steering or 2. Tighten or replace components as suspension components.
Page 30 2 - 4 SUSPENSION SERVICE PROCEDURES PRE-ALIGNMENT Before starting wheel alignment, the following inspection and necessary corrections must be com- pleted. Refer to Suspension and Steering System Diagnosis Chart for additional information. (1) Inspect tires for size and tread wear. (2) Set tire air pressure.
Page 31 SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) (4) Adjust the left wheel toe position with the tie rod. Turn the sleeve until the left wheel is at the same TOE-IN position as the right wheel. Position the clamp bolts as shown (Fig. 3) and tighten to 27 N·m (20 ft.
Page 32 2 - 6 SUSPENSION FRONT SUSPENSION INDEX page page DESCRIPTION AND OPERATION SHOCK ABSORBER ..... . . 7 FRONT SUSPENSION ..... 6 STABILIZER BAR .
Page 33 SUSPENSION 2 - 7 DIAGNOSIS AND TESTING (Continued) ening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent.
Page 34 2 - 8 SUSPENSION REMOVAL AND INSTALLATION (Continued) (6) Install the front propeller shaft to the axle. (7) Install drag link to pit man arm. (8) Remove the supports and lower the vehicle. (9) Tighten all suspension components to proper torque.
Page 35 SUSPENSION 2 - 9 REMOVAL AND INSTALLATION (Continued) (5) Install bolt 7604 through remover, bushing and (5) Remove tools and install the upper suspension receiver. arm. (6) Install Long Nut 7603 and tighten nut too pull STABILIZER BAR bushing out of the axle bracket. REMOVAL (1) Remove upper link nuts (Fig.
Page 36 2 - 10 SUSPENSION REMOVAL AND INSTALLATION (Continued) HUB BEARING REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper, rotor and ABS wheel speed sensor, refer to Group 5 Brakes. (4) Remove the cotter pin, nut retainer and axle hub nut (Fig.
Page 37 SUSPENSION 2 - 11 REMOVAL AND INSTALLATION (Continued) WHEEL MOUNTING STUDS (6) Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. (7) Remove support and lower vehicle. REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly.
Page 38 2 - 12 SUSPENSION SPECIAL TOOLS FRONT SUSPENSION Bolt, Special 7604 Remover/Installer Suspension Bushing 7932 Remover C-4150A Nut, Long 7603...
Page 39 SUSPENSION 2 - 13 REAR SUSPENSION INDEX page page DESCRIPTION AND OPERATION SHOCK ABSORBER ..... . 14 REAR SUSPENSION ..... 13 STABILIZER BAR .
Page 40 2 - 14 SUSPENSION (3) Connect the stabilizer bar links and shock REMOVAL AND INSTALLATION absorbers to the axle bracket. Connect the track bar to the frame rail bracket. SHOCK ABSORBER (4) Remove the supports and lower the vehicle. (5) Tighten the stabilizer bar links, shock absorb- REMOVAL ers and track bar to specified torque.
Page 41 SUSPENSION 2 - 15 REMOVAL AND INSTALLATION (Continued) (3) Remove the supports and lower the vehicle. (4) Remove the stabilizer bar retainer bolts and (4) Tighten the lower suspension arm nuts to 177 retainers from the axle mounts (Fig. 6) and remove N·m (130 ft.
Page 42 2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) TRACK BAR SPECIFICATIONS REMOVAL TORQUE CHART (1) Raise and support the vehicle. (2) Remove the bolt and nut from the frame rail DESCRIPTION TORQUE bracket (Fig. 7). Shock Absorber (3) Remove the bolt from the axle bracket (Fig. 7) Upper Bolts .
Page 43 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CONTENTS page page 181 FBI AXLE ......15 216 RBI REAR AXLE .
Page 44 3 - 2 DIFFERENTIAL AND DRIVELINE GENERAL INFORMATION (Continued) Fig. 1 Propeller Shafts ensuring that the proper propeller shaft joint work- ing angles are maintained. A propeller shaft is properly phased when the yoke ends are in the same plane, or in line. A twisted shaft will make the yokes out of phase and cause a noticeable vibration.
Page 45 DIFFERENTIAL AND DRIVELINE 3 - 3 GENERAL INFORMATION (Continued) Fig. 3 Double Cardan U-Joint Fig. 4 Maximum Angles And Engine Speed PRECAUTIONS Use the exact replacement parts when installing the propeller shafts. The use of the correct replace- Fig. 5 Reference Marks on Yokes ment parts helps to ensure safe operation.
Page 46 3 - 4 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) Driveline vibration can also result from loose or specific speed range is not usually caused by a pro- damaged engine mounts. Refer to Group 9, Engines, peller shaft being unbalanced. Defective universal for additional information.
Page 47 DIFFERENTIAL AND DRIVELINE 3 - 5 DIAGNOSIS AND TESTING (Continued) Fig. 6 Clamp Screw At Position 1 Fig. 8 Clamp Screws Separated clamp to one of the other three positions. Repeat the RUNOUT vibration test. (1) Remove dirt, rust, paint, and undercoating (11) If there is no difference in vibration at the from the propeller shaft surface where the dial indi- other positions, the source of the vibration may not...
Page 48 3 - 6 DIFFERENTIAL AND DRIVELINE SERVICE PROCEDURES DRIVELINE ANGLE MEASUREMENT PREPARATION Before measuring universal joint angles, the fol- lowing must be done; • Inflate all tires to correct pressure. • Check the angles in the same loaded or unloaded condition as when the vibration occurred. Propeller shaft angles change according to the amount of load in the vehicle.
Page 49 DIFFERENTIAL AND DRIVELINE 3 - 7 SERVICE PROCEDURES (Continued) Fig. 11 Rear (Input) Angle Measurement (B) Fig. 12 Universal Joint Angle Example...
Page 50 3 - 8 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION FRONT PROPELLER SHAFT REMOVAL Fig. 14 Reference Marks on Yokes (7) Tighten the universal joint to transfer case bolts to 27 N·m (20 ft. lbs.) torque. (8) Lower the vehicle. REAR PROPELLER SHAFT Fig.
Page 51 DIFFERENTIAL AND DRIVELINE 3 - 9 REMOVAL AND INSTALLATION (Continued) (3) Remove snap rings from both sides of yoke (Fig. 18). Fig. 16 Rear Propeller Shaft INSTALLATION (1) Slide the slip yoke on the transmission/transfer case output shaft. Align the installation reference marks at the axle yoke and install the propeller shaft Fig.
Page 52 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. (8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole.
Page 53 DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (3) Remove all the bearing cap snap rings (Fig. (6) Grasp the protruding bearing by vise jaws. Tap 23). the link yoke with a mallet and drift to dislodge the bearing cap from the yoke (Fig.
Page 54 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (4) Press the bearing cap into the yoke bore enough to install a snap ring (Fig. 29). During assembly, ensure that the alignment (5) Install a snap ring. marks on the link yoke and propeller shaft yoke are aligned.
Page 55 DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 33 Install Remaining Cross Fig. 31 Install Link Yoke (9) Install the centering kit assembly inside the link yoke making sure the spring is properly posi- tioned (Fig. 32). Fig.
Page 56 3 - 14 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) adjustablity of the pinion angle. Follow the proce- dures supplied with the kit in order to ensure a safe installation. Fig. 35 Seat Snap Rings In Groove Fig. 37 Adjustment Cam SPECIFICATIONS TORQUE DESCRIPTION TORQUE...
Page 57 DIFFERENTIAL AND DRIVELINE 3 - 15 181 FBI AXLE INDEX page page GENERAL INFORMATION DRIVE AXLE ASSEMBLY ....20 181 FBI AXLE ......15 HUB BEARING AND AXLE SHAFT .
Page 58 3 - 16 DIFFERENTIAL AND DRIVELINE GENERAL INFORMATION (Continued) • Lubricant for axles intended for heavy-duty or complete a turn. The difference must be compensated trailer tow use is SAE 75W–140 SYNTHETIC gear for to prevent the tires from scuffing and skidding lubricant.
Page 59 DIFFERENTIAL AND DRIVELINE 3 - 17 DIAGNOSIS AND TESTING (Continued) The noise can also occur during a specific type of VIBRATION driving condition. These conditions are acceleration, Vibration at the rear of the vehicle is usually deceleration, coast, or constant load. caused by a: When road testing, accelerate the vehicle to the •...
Page 60 3 - 18 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) FRONT AXLES DIAGNOSIS...
Page 61 DIFFERENTIAL AND DRIVELINE 3 - 19 DIAGNOSIS AND TESTING (Continued) CONTINUED...
Page 62 3 - 20 DIFFERENTIAL AND DRIVELINE SERVICE PROCEDURES REMOVAL AND INSTALLATION LUBRICANT CHANGE DRIVE AXLE ASSEMBLY (1) Raise and support the vehicle. REMOVAL (2) Remove the lubricant fill hole plug from the differential housing cover. (1) Raise and support the vehicle. (3) Remove the differential housing cover and (2) Position a suitable lifting device under the drain the lubricant from the housing.
Page 63 DIFFERENTIAL AND DRIVELINE 3 - 21 REMOVAL AND INSTALLATION (Continued) (7) Install the shock absorbers and tighten the bolts to 23 N·m (17 ft. lbs.) torque. (8) Install the stabilizer bar links to the axle brackets. Tighten the nut to 95 N·m (70 ft. lbs.) torque.
Page 64 3 - 22 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) INSTALLATION INSTALLATION (1) Pack the bearing caps 1/3 full of wheel bearing (1) Apply a light coating of gear lubricant on the lubricant. Apply extreme pressure (EP), lithium–base lip of pinion seal. Install seal with Installer C-3972-A lubricant to aid in installation.
Page 65 DIFFERENTIAL AND DRIVELINE 3 - 23 REMOVAL AND INSTALLATION (Continued) (7) Check and fill the gear lubricant. Refer to the Lubricant Specifications for gear lubricant require- ments. (8) Install the brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures. (9) Install wheel and tire assemblies.
Page 66 3 - 24 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) REMOVAL W/PINION REMOVED (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake rotors and calipers. Refer to Group 5, Brakes, for proper procedures. (4) Mark the propeller shaft and pinion yoke for installation reference.
Page 67 DIFFERENTIAL AND DRIVELINE 3 - 25 REMOVAL AND INSTALLATION (Continued) (10) Check rotating torque with an inch pound torque wrench (Fig. 17). The torque necessary to rotate the pinion gear should be: • Original Bearings — The reading recorded dur- ing removal, plus an additional 0.56 N·m (5 in.
Page 68 3 - 26 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 18 Hub, Knuckle and Axle Shaft (6) Remove the hub to knuckle bolts (Fig. 19). (7) Remove the hub from the steering knuckle and axle shaft, if necessary. (8) Remove hub bearing and axle shaft assembly (Fig.
Page 69 DIFFERENTIAL AND DRIVELINE 3 - 27 REMOVAL AND INSTALLATION (Continued) STEERING KNUCKLE AND BALL STUDS (5) Connect the tie-rod or drag link end to the steering knuckle arm. Refer to Group 2, Suspension, Ball stud service procedures below require removal for proper procedures.
Page 70 3 - 28 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 22 Upper Ball Stud Remove/Install Fig. 23 Lower Ball Stud Remove/Install...
Page 71 DIFFERENTIAL AND DRIVELINE 3 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 26 Install Dial Indicator Fig. 24 Bearing Cap Identification Fig. 27 Spread Axle Housing Fig. 25 Install Axle Housing Spreader (3) Spread the housing enough to install the case (1) Position Spreader W-129-B, utilizing some in the housing.
Page 72 3 - 30 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 28 Differential Case Removal Fig. 30 Differential Bearing Cap Reference Letters Fig. 29 Install Axle Housing Spreader DIFFERENTIAL SIDE BEARINGS REMOVAL (1) Remove differential case from axle housing. (2) Remove the bearings from the differential case Fig.
Page 73 DIFFERENTIAL AND DRIVELINE 3 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 32 Differential Side Bearing Installation Fig. 33 Axle Seal Installation AXLE SHAFT OIL SEAL REMOVAL (1) Raise and support vehicle. (2) Remove differential assembly. (3) Remove the inner axle shaft seals with a pry bay.
Page 74 3 - 32 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 37 Pinion Yoke Removal (6) Remove the pinion gear and collapsible spacer from housing (Fig. 38). Catch the pinion with your hand to prevent it from falling and being damaged. Fig.
Page 75 DIFFERENTIAL AND DRIVELINE 3 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 39 Front Bearing Cup Removal Fig. 41 Collapsible Spacer NOTE: The pinion depth shims can be very thin. Verify that all shims have been removed before pro- ceeding. Fig. 42 Inner Bearing Removal INSTALLATION Fig.
Page 76 3 - 34 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (1) Place proper thickness depth shim in rear pin- (5) Apply a light coating of gear lubricant on the ion bearing cup bore in the axle housing. lip of pinion seal. Install seal with Installer C-3972-A (2) Apply Mopar Door Ease, or equivalent, stick and Handle C–4171 (Fig.
Page 77 DIFFERENTIAL AND DRIVELINE 3 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 49 Tightening Pinion Nut Fig. 47 Collapsible Preload Spacer (12) Check bearing rotating torque with an inch pound torque wrench (Fig. 50). The torque necessary to rotate the pinion gear should be: •...
Page 78 3 - 36 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLY (1) Remove the ring gear. (2) Using a suitable roll pin punch, drive out the roll pin holding pinion gear mate shaft in the differ- ential case (Fig. 51). Fig.
Page 79 DIFFERENTIAL AND DRIVELINE 3 - 37 DISASSEMBLY AND ASSEMBLY (Continued) • Bearing cups must not be distorted or cracked. • Machined surfaces should be smooth and with- out any raised edges. • Raised metal on shoulders of cup bores should be removed with a hand stone.
Page 80 3 - 38 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Compensation pinion depth variance (3) Install front pinion bearing and Cone-nut 6740 achieved with select shims. The shims are placed hand tight (Fig. 57). behind the rear pinion bearing cup (Fig. 56). (4) Place Arbor Disc 6732 on Arbor D-115-3 in posi- tion in axle housing side bearing cradles (Fig.
Page 81 DIFFERENTIAL AND DRIVELINE 3 - 39 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Fig. 58 Pinion Height Block—Typical determines the thickness of the shim used on the ring gear side of the differential case. Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear side of the differential (Fig.
Page 82 3 - 40 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) (1) Remove differential side bearings from differ- ential case. (2) Remove factory installed shims from differen- tial case. (3) Install ring gear on differential case and tighten bolts to specification. (4) Install dummy side bearings D-348 on differen- tial case.
Page 83 DIFFERENTIAL AND DRIVELINE 3 - 41 ADJUSTMENTS (Continued) Fig. 64 Seat Ring Gear Side Differential Dummy Fig. 66 Hold Differential Case and Zero Dial Side Bearing Indicator Fig. 67 Hold Differential Case and Read Dial Indicator (17) Install the pinion gear in axle housing. Install the pinion yoke and establish the correct pinion rotating torque.
Page 84 3 - 42 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) (35) Position the indicator plunger against a ring gear tooth (Fig. 70). (36) Push and hold ring gear upward while not allowing the pinion gear to rotate. (37) Zero dial indicator face to pointer. (38) Push and hold ring gear downward while not allowing the pinion gear to rotate.
Page 85 DIFFERENTIAL AND DRIVELINE 3 - 43 ADJUSTMENTS (Continued) GEAR CONTACT PATTERN ANALYSIS adjusted within specifications to achieve desired tooth contact patterns. (1) Apply a thin coat of hydrated ferric oxide, or equivalent, to the drive and coast side of the ring gear teeth.
Page 86 3 - 44 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 72 Gear Tooth Contact Patterns...
Page 87 DIFFERENTIAL AND DRIVELINE 3 - 45 SPECIFICATIONS 181 FBI AXLE Axle Type ......Hypoid Lubricant .
Page 88 3 - 46 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Dial Indicator—C-3339 Remover—D-149 Installer—W-162-D Driver—C-3716-A Cup—8109 Handle—C-4171 Remover/Installer—6289 Installer—D-146...
Page 89 DIFFERENTIAL AND DRIVELINE 3 - 47 SPECIAL TOOLS (Continued) Tool Set, Pinion Depth—6774 Installer—6761 Gauge Block—6733 Installer—6752 Installer Discs—8110 Spanner—6958 Turnbuckle—6797 Installer—C-3972-A...
Page 90 3 - 48 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Spreader—W-129-B Remover—C-4345 Adapter Kit—6987 Installer—D-130 Pilot Stud—C-3288-B Installer—W-262...
Page 91 DIFFERENTIAL AND DRIVELINE 3 - 49 194 RBI AXLE INDEX page page GENERAL INFORMATION DIFFERENTIAL SIDE BEARINGS ... . 63 194 RBI AXLE ......49 FINAL ASSEMBLY .
Page 92 3 - 50 DIFFERENTIAL AND DRIVELINE GENERAL INFORMATION (Continued) Fig. 2 Differential Operation—Straight Ahead Driving Fig. 1 Shim Locations allows the axle shafts to turn at unequal speeds (Fig. axle lubricant capacity is 1.66L (3.50 pts.) total, 3). In this instance, the input torque applied to the including the friction modifier if necessary.
Page 93 DIFFERENTIAL AND DRIVELINE 3 - 51 DESCRIPTION AND OPERATION (Continued) • Insufficient lubrication. forces generated by the side gears as torque is • Incorrect or contaminated lubricant. applied through the ring gear (Fig. 4). • Overloading (excessive engine torque) or exceed- ing vehicle weight capacity.
Page 94 3 - 52 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) Turn the vehicle sharply to the left and to the right. TRAC–LOK DIFFERENTIAL NOISE This will load the bearings and change the noise The most common problem is a chatter noise when level.
Page 95 DIFFERENTIAL AND DRIVELINE 3 - 53 DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART...
Page 96 3 - 54 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART — CONTINUED...
Page 97 DIFFERENTIAL AND DRIVELINE 3 - 55 DIAGNOSIS AND TESTING (Continued) (8) For Trac–lok differentials, quantity Mopar Trac–lok lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. Refer to the Lubricant Specifica- tions section of this group for the quantity necessary. (9) Fill differential with Mopar Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug...
Page 98 3 - 56 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (7) Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for instal- NOTE: The weight of the vehicle must be sup- ported by the springs before suspension arms and lation reference.
Page 99 DIFFERENTIAL AND DRIVELINE 3 - 57 REMOVAL AND INSTALLATION (Continued) CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke at this point. Damage to the collapsible spacer or bearings may result. (3) Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play.
Page 100 3 - 58 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (8) Using Holder 6958 to hold the pinion yoke, remove the pinion nut and washer. (9) Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig. 12). (10) Use a suitable pry tool or a slide hammer mounted screw to remove the pinion shaft seal.
Page 101 DIFFERENTIAL AND DRIVELINE 3 - 59 REMOVAL AND INSTALLATION (Continued) (9) Using yoke holder 6958 and a torque wrench set at 474 N·m (350 ft. lbs.), crush collapsible spacer until bearing end play is taken up (Fig. 17). NOTE: If more than 474 N·m (350 ft. lbs.) of torque is necessary to remove the bearing end play, the collapsible spacer...
Page 102 3 - 60 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 20 Axle Shaft C–Clip Lock (9) Inspect axle shaft seal for leakage or damage. (10) Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced.
Page 103 DIFFERENTIAL AND DRIVELINE 3 - 61 REMOVAL AND INSTALLATION (Continued) NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. (3) Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310 using Adapter Foot 6310-5 (Fig.
Page 104 3 - 62 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 26 Spread Axle Housing Fig. 24 Install Axle Housing Spreader Fig. 27 Differential Case Removal Fig. 25 Install Dial Indicator shim requirements may change. Refer to the Differ- (12) Remove the differential from the housing. ential Bearing Preload and Gear Backlash proce- Ensure that the differential bearing cups remain in dures in this section to determine the proper shim...
Page 105 DIFFERENTIAL AND DRIVELINE 3 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 29 Differential Bearing Cap Reference Letters Fig. 28 Install Axle Housing Spreader CAUTION: Do not spread over 0.38 mm (0.015 in). If the housing is over–spread, it could be distorted or damaged.
Page 106 3 - 64 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (1) Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (2) Invert the differential case in the vise. (3) Install new ring gear bolts and alternately tighten to 95–122 N·m (70–90 ft.
Page 107 DIFFERENTIAL AND DRIVELINE 3 - 65 REMOVAL AND INSTALLATION (Continued) Fig. 34 Pinion Yoke Removal Fig. 36 Front Bearing Cup Removal Fig. 35 Remove Pinion Gear (10) Remove the rear bearing cup from housing (Fig. 37). Use Remover D-149 and Handle C–4171. Fig.
Page 108 3 - 66 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 40 Pinion Rear Bearing Cup Installation Fig. 38 Collapsible Spacer Fig. 41 Pinion Front Bearing Cup Installation (7) Place the proper thickness depth shim on the pinion gear. (8) Install rear bearing slinger,...
Page 109 DIFFERENTIAL AND DRIVELINE 3 - 67 REMOVAL AND INSTALLATION (Continued) Fig. 42 Pinion Seal Installation Fig. 44 Collapsible Preload Spacer Fig. 43 Shaft Rear Bearing Installation Fig. 45 Pinion Yoke Installation CAUTION: Never loosen pinion gear (15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) decrease pinion gear bearing rotating torque and increments until the rotating torque is achieved.
Page 110 3 - 68 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 46 Tightening Pinion Nut Fig. 48 Typical Housing Cover With Sealant DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLY (1) Remove pinion gear mate shaft lock screw (Fig. 49). (2) Remove pinion gear mate shaft. (3) Rotate the differential side gears and remove the pinion mate gears and thrust washers (Fig.
Page 111 DIFFERENTIAL AND DRIVELINE 3 - 69 DISASSEMBLY AND ASSEMBLY (Continued) (4) Align the hole in the pinion gear mate shaft with the hole in the differential case and install the pinion gear mate shaft lock screw. (5) Lubricate all differential components with hypoid gear lubricant.
Page 112 3 - 70 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 54 Mate Shaft Removal Fig. 52 Differential Case Holding Tool Fig. 55 Step Plate Tool Installation Fig. 53 Mate Shaft Lock Screw (15) Remove Forcing Screw C-6960-4, Step Plate (9) Tighten forcing screw tool 122 N·m (90 ft.
Page 113 DIFFERENTIAL AND DRIVELINE 3 - 71 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 56 Threaded Adapter Installation Fig. 58 Remove Pinion Gear Thrust Washer Fig. 57 Tighten Belleville Spring Compressor Tool Fig. 59 Pinion Gear Removal Lubricate each component with gear lubricant (7) Hold assembly in position.
Page 114 3 - 72 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 60 Side Gear & Clutch Disc Removal Fig. 62 Clutch Discs & Lower Side Gear Installation Fig. 61 Clutch Disc Pack Fig. 63 Upper Side Gear & Clutch Disc Pack driver.
Page 115 DIFFERENTIAL AND DRIVELINE 3 - 73 CLEANING AND INSPECTION ADJUSTMENTS AXLE COMPONENTS PINION GEAR DEPTH Wash differential components with cleaning solvent GENERAL INFORMATION and dry with compressed air. Do not steam clean the differential components. Ring and pinion gears are supplied as matched Wash bearings with solvent and towel dry, or dry sets only.
Page 116 3 - 74 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE If a new gear set is being installed, note the depth variance etched into both the original and replace- ment pinion gear. Add or subtract the thickness of the original depth shims to compensate for the differ- ence in the depth variances.
Page 117 DIFFERENTIAL AND DRIVELINE 3 - 75 ADJUSTMENTS (Continued) crest of the arbor bar and record the highest reading. If the dial indicator can not achieve the zero reading, the rear bearing cup or the pinion depth gauge set is not installed correctly. (9) Select a shim equal to the dial indicator read- ing plus the drive pinion gear depth variance number etched in the face of the pinion gear (Fig.
Page 118 3 - 76 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) (7) Thread guide stud C-3288-B into rear cover bolt hole below ring gear (Fig. 72). (8) Attach dial indicator C-3339 to guide stud. Position the dial indicator plunger on a flat surface on a ring gear bolt head (Fig.
Page 119 DIFFERENTIAL AND DRIVELINE 3 - 77 ADJUSTMENTS (Continued) (23) Record dial indicator reading. (24) Subtract 0.002 in. (0.05 mm) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness of shim required to achieve proper backlash. (25) Subtract the backlash shim thickness from the total preload shim thickness.
Page 120 3 - 78 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 75 Gear Tooth Contact Patterns...
Page 121 DIFFERENTIAL AND DRIVELINE 3 - 79 SPECIFICATIONS 194 RBI AXLE DESCRIPTION SPECIFICATION Axle Type ....Semi–Floating Hypoid Lubricant ..SAE Thermally Stable 80W–90 Lubricant Trailer Tow .
Page 122 3 - 80 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Cup—8109 Wrench—C-3281 Installer—C-3972-A Handle—C-4171 Spanner—6958 Driver—C-3716-A Installer Screw—8112 Installer—D-130...
Page 123 DIFFERENTIAL AND DRIVELINE 3 - 81 SPECIAL TOOLS (Continued) Installer—6436 Installer—D-146 Remover—C-4345 Installer—6437 Remover—D-149 Disc, Axle Arbor—6732 Installer—W-262 Gauge Block—6735...
Page 124 3 - 82 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Tool Set, Pinion Depth—6774 Spreader—W-129-B Trac-lok Tool Set—6960 Adapter Kit—6987 Holder—6965 Guide Pin—C-3288-B Starting Point Shim—8107 Bearing Remover Tool Set—6310...
Page 125 DIFFERENTIAL AND DRIVELINE 3 - 83 SPECIAL TOOLS (Continued) Hub Puller—6790 Dial Indicator—C-3339...
Page 126 3 - 84 DIFFERENTIAL AND DRIVELINE 216 RBI REAR AXLE INDEX page page GENERAL INFORMATION FINAL ASSEMBLY ..... . 100 216 RBI AXLE .
Page 127 DIFFERENTIAL AND DRIVELINE 3 - 85 GENERAL INFORMATION (Continued) Fig. 2 Differential Operation—Straight Ahead Driving Fig. 1 Axle Adjustment Shims When turning corners, the outside wheel must • Lubricant for axles intended for heavy-duty or travel a greater distance than the inside wheel to trailer tow use is SAE 75W–140 SYNTHETIC gear complete a turn.
Page 128 3 - 86 DIFFERENTIAL AND DRIVELINE DESCRIPTION AND OPERATION (Continued) • Incorrect bearing preload torque adjustment. In operation, the Trac-lok clutches are engaged by • Incorrect backlash. two concurrent forces. The first being the preload force exerted through Belleville spring washers Axle gear problem conditions are usually the result within the clutch packs.
Page 129 DIFFERENTIAL AND DRIVELINE 3 - 87 DIAGNOSIS AND TESTING (Continued) tial bearing noise is also constant and varies only The source of a snap or a clunk noise can be deter- with vehicle speed. mined with the assistance of a helper. Raise the vehi- Axle shaft bearings produce noise and vibration cle on a hoist with the wheels free to rotate.
Page 130 3 - 88 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART...
Page 131 DIFFERENTIAL AND DRIVELINE 3 - 89 DIAGNOSIS AND TESTING (Continued) DIAGNOSIS CHART — CONTINUED...
Page 132 3 - 90 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) (8) For Trac–lok differentials, quantity Mopar Trac–lok lubricant (friction modifier), or equivalent, must be added after repair service or a lubricant change. Refer to the Lubricant Specifica- tions section of this group for the quantity necessary. (9) Fill differential with Mopar Hypoid Gear Lubricant, or equivalent, to bottom of the fill plug...
Page 133 DIFFERENTIAL AND DRIVELINE 3 - 91 REMOVAL AND INSTALLATION (Continued) INSTALLATION (7) Measure the amount of torque necessary to rotate the pinion gear with a (in. lbs.) dial-type torque wrench. Record the torque reading for instal- NOTE: The weight of the vehicle must be sup- ported by the springs before suspension arms and lation reference.
Page 134 3 - 92 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved. (7) Align the installation reference marks on the propeller shaft and yoke, and install the propeller shaft.
Page 135 DIFFERENTIAL AND DRIVELINE 3 - 93 REMOVAL AND INSTALLATION (Continued) (4) Install nuts to hold axle retaining plate to axle tube. (5) Through access hole in axle flange, tighten nuts to 61 N·m (45 ft. lbs.). (6) Install brake drum. (7) Install wheel and tire assembly.
Page 136 3 - 94 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 15 Axle Bearing and Seal Components Fig. 17 Press Bearing Retaining Ring On Axle Fig. 16 Press Bearing On Axle Fig. 18 Bearing Cap Identification DIFFERENTIAL against the opposite side of the housing (Fig. 19) and zero the indicator.
Page 137 DIFFERENTIAL AND DRIVELINE 3 - 95 REMOVAL AND INSTALLATION (Continued) against the opposite side of the housing (Fig. 19) and zero the indicator. (3) Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator (Fig.
Page 138 3 - 96 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 22 Differential Bearing Cap Reference Letters Fig. 24 Install Differential Side Bearings RING GEAR The ring and pinion gears are service in a matched set. Do not replace the ring gear without replacing the pinion gear.
Page 139 DIFFERENTIAL AND DRIVELINE 3 - 97 REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. (1) Invert the differential case and start two ring gear bolts.
Page 140 3 - 98 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 31 Rear Bearing Cup Removal Fig. 29 Remove Pinion Gear Fig. 32 Inner Bearing Removal Fig. 30 Front Bearing Cup Removal (1) Place proper thickness depth shim in rear pin- INSTALLATION ion bearing cup bore in the axle housing.
Page 141 DIFFERENTIAL AND DRIVELINE 3 - 99 REMOVAL AND INSTALLATION (Continued) Fig. 35 Pinion Seal Installation Fig. 33 Rear Pinion Bearing Cup Installation Fig. 36 Rear Pinion Bearing Installation Fig. 34 Pinion Outer Bearing Cup Installation (4) Install front pinion bearing, and oil slinger, if CAUTION: Never loosen pinion...
Page 142 3 - 100 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 37 Pinion Preload Shims–Typical Fig. 38 Pinion Yoke Installation (13) Tighten pinion shaft nut in 6.8 N·m (5 ft. lbs.) increments until the maximum tightening or desired rotating torque is reached. (14) If the maximum tightening torque is reached prior to achieving the desired rotating torque, remove Fig.
Page 143 DIFFERENTIAL AND DRIVELINE 3 - 101 REMOVAL AND INSTALLATION (Continued) CAUTION: Overfilling the differential can result in lubricant foaming and overheating. (3) Refill the differential housing with gear lubri- cant. Refer to the Lubricant Specifications section of this group for the gear lubricant requirements. (4) Install the fill hole plug.
Page 144 3 - 102 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 43 Pinion Mate Gear Removal Fig. 45 Differential Case Holding Tool Fig. 44 Trac–Lok Differential Components DISASSEMBLY (3) Remove ring gear, if necessary. Ring gear removal is necessary only if the ring gear is to be (1) Clamp Side Gear Holding Tool 6963–A in a replaced.
Page 145 DIFFERENTIAL AND DRIVELINE 3 - 103 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 46 Mate Shaft Lock Screw (5) Remove the pinion gear mate shaft. If neces- sary, use a drift and hammer (Fig. 47). Fig. 48 Step Plate Tool Installation Fig. 47 Mate Shaft Removal (6) Install and lubricate Step Plate C–4487–1 (Fig.
Page 146 3 - 104 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 50 Tighten Belleville Spring Compressor Tool Fig. 53 Side Gear & Clutch Disc Removal (17) Remove differential case from Side Gear Hold- ing Tool 6963-A. Remove side gear, clutch pack retainer, and clutch pack.
Page 147 DIFFERENTIAL AND DRIVELINE 3 - 105 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 56 Upper Side Gear & Clutch Disc Pack Installation (14) Remove forcing screw, threaded adapter, and Fig. 54 Clutch Disc Pack step plate. (15) Install pinion gear mate shaft and align holes in shaft and case.
Page 148 3 - 106 DIFFERENTIAL AND DRIVELINE CLEANING AND INSPECTION (Continued) • Wear and damage to pinion gear mate shaft, pinion gears, side gears and thrust washers. Replace as a matched set only. • Ring and pinion gear for worn and chipped teeth.
Page 149 DIFFERENTIAL AND DRIVELINE 3 - 107 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE PINION DEPTH MEASUREMENT AND ADJUSTMENT (2) Insert assembled height gauge components, rear bearing and screw into axle housing through Measurements are taken with pinion cups and pin- pinion bearing cups (Fig. 60). ion bearings installed in housing.
Page 150 3 - 108 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 61 Gauge Tools In Housing—Typical Fig. 62 Pinion Gear Depth Measurement—Typical (5) Assemble Dial Indicator C-3339 into Scooter ings and a dial indicator C-3339. Before proceeding Block D-115-2 and secure set screw. with the differential bearing preload and gear back- (6) Place Scooter Block/Dial Indicator in position lash measurements, measure the pinion gear depth...
Page 151 DIFFERENTIAL AND DRIVELINE 3 - 109 ADJUSTMENTS (Continued) DIFFERENTIAL PRELOAD AND GEAR BACHLASH SHIM SELECTION NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary. (1) Remove differential side bearings from differ- ential case.
Page 152 3 - 110 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 70 Hold Differential Case and Read Dial Indicator Fig. 68 Differential Side Play Measurement Fig. 71 Hold Differential Case and Zero Dial Indicator (24) Push and hold differential case to ring gear side of the axle housing (Fig.
Page 153 DIFFERENTIAL AND DRIVELINE 3 - 111 ADJUSTMENTS (Continued) (26) Subtract 0.002 in. (0.05 mm) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash. (27) Subtract the backlash shim thickness from the total preload shim thickness.
Page 154 3 - 112 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 75 Gear Tooth Contact Patterns...
Page 155 DIFFERENTIAL AND DRIVELINE 3 - 113 SPECIFICATIONS 216 RBI AXLE DESCRIPTION SPECIFICATION Axle Type ....Semi-floating Hypoid Lubricant ..SAE Thermally Stable 80W–90 Lubricant–Trailer Tow .
Page 156 3 - 114 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Trac-lok Tool Set—C-4487 Handle—C-4171 Installer—C-3972-A Installer—D-156 Installer—D-144 Pilot—C-3288-B Installer—D-145 Dial Indicator—C-3339...
Page 157 DIFFERENTIAL AND DRIVELINE 3 - 115 SPECIAL TOOLS (Continued) Cup—8109 Remover—D-147 Splitter—1130 Remover—D-148 Installer—W-262 Spreader—W-129-B Pinion Depth Set—6730 Installer—W-162–D...
Page 158 3 - 116 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Adapter—6790 Adapter Set—6987 Adapter Set—6956 Slide Hammer—7420 Holder—6958 Adapter—7420-8 Holder—6963-A Installer—7913-A...
Page 159 BRAKES 5 - 1 BRAKES CONTENTS page page ANTILOCK BRAKES ..... . 30 BASE BRAKE SYSTEM ..... 1 BASE BRAKE SYSTEM INDEX page...
Page 160 5 - 2 BRAKES fresh brake fluid or Mopar brake cleaner to clean or DESCRIPTION AND OPERATION flush brake system components. These are the only cleaning materials recommended. If system contam- BRAKE SYSTEM ination is suspected, check the fluid for dirt, discol- Power assist front disc and rear drum brakes are oration, or separation into distinct layers.
Page 161 BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 1 Power Brake Booster–Typical Two push rods are used in the booster. The pri- The chamber areas forward of the booster dia- mary push rod connects the booster to the brake phragms are exposed to vacuum from the intake pedal.
Page 162 5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) as an assembly. The reservoir and grommets are the only replaceable parts on the master cylinder. COMBINATION VALVE The combination valve contains a pressure differ- ential valve and switch and a rear brake proportion- ing valve.
Page 163 BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 4 Brake Components REAR DRUM BRAKE The brake systems use a leading shoe (primary) and trailing shoe (secondary). The mounting hard- ware is similar but not interchangeable (Fig. 4). When the brake pedal is depressed hydraulic pres- sure pushes the rear brake wheel cylinder pistons outward.
Page 164 5 - 6 BRAKES DESCRIPTION AND OPERATION (Continued) A parking brake switch is mounted on the parking (5) Check brake pedal operation. Verify that pedal brake lever and is actuated by movement of the does not bind and has adequate free play. If pedal lever.
Page 165 BRAKES 5 - 7 DIAGNOSIS AND TESTING (Continued) NOTE: Some pedal pulsation may be felt during A worn, damaged wheel bearing or suspension com- ABS activation. ponent are further causes of pull. A damaged front tire (bruised, ply separation) can also cause pull. A common and frequently misdiagnosed pull condi- BRAKE DRAG tion is where direction of pull changes after a few...
Page 166 5 - 8 BRAKES DIAGNOSIS AND TESTING (Continued) THUMP/CLUNK NOISE Thumping or clunk noises during braking are fre- quently not caused by brake components. In many cases, such noises are caused by loose or damaged steering, suspension, or engine components. However, calipers that bind on the slide surfaces can generate a thump or clunk noise.
Page 167 BRAKES 5 - 9 DIAGNOSIS AND TESTING (Continued) (3) Pump brake pedal until all vacuum reserve in booster is depleted. (4) Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leak- age).
Page 168 5 - 10 BRAKES DIAGNOSIS AND TESTING (Continued) DISC BRAKE ROTOR ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pul- The rotor braking surfaces should not be refinished sation, noise and shudder. unless necessary. Measure rotor thickness at 6-to-12 points around Light surface rust and scale can be removed with a the rotor face (Fig.
Page 169 BRAKES 5 - 11 DIAGNOSIS AND TESTING (Continued) PARKING BRAKE Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks NOTE: Parking brake adjustment is controlled by a or abrasions.
Page 170 5 - 12 BRAKES SERVICE PROCEDURES (Continued) hydraulic system. This will make additional bleeding operations necessary. Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed.
Page 171 BRAKES 5 - 13 SERVICE PROCEDURES (Continued) PRESSURE BLEEDING BRAKE TUBE FLARING Follow the manufacturers instructions carefully A preformed metal brake tube is recommended and when using pressure equipment. Do not exceed the preferred for all repairs. However, double-wall steel tank manufacturers pressure recommendations.
Page 172 5 - 14 BRAKES SERVICE PROCEDURES (Continued) Fig. 15 Inverted Flare Tools Fig. 16 ISO Flaring ISO FLARING To make a ISO flare use Snap-On Flaring Tool TFM-428 or equivalent. (1) Cut off damaged tube with Tubing Cutter. (2) Remove any burrs from the inside of the tube. (3) Install tube nut on the tube.
Page 173 BRAKES 5 - 15 REMOVAL AND INSTALLATION (Continued) BRAKE PEDAL Install retainer clip securing booster push rod to pedal (Fig. 18) and clutch rod retainer clip if equipped. REMOVAL (7) Install ABS controller if equipped. (1) Remove negative battery cable. (8) Install and connect stop lamp switch.
Page 174 5 - 16 BRAKES REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Use only original or factory replacement nuts. (4) Install combination valve onto brake booster (1) Position valve bracket on booster studs and studs and tighten mounting nuts to 24 N·m (18 ft. tighten bracket attaching nuts to 24 N·m (18 ft.
Page 175 BRAKES 5 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 23 Booster Mounting Nuts (5) Lubricate the pedal pin and bushing with Mopar multi-mileage grease. Then slid the booster push rod onto brake pedal pin and secure with retaining clip. (6) Tighten booster mounting nuts to 37 N·m (27 ft.
Page 176 5 - 18 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 27 Caliper Removal Fig. 29 Caliper Installation Fig. 28 Caliper Lubrication Points (3) Coat caliper mounting bolts with silicone grease. Then install and tighten bolts to 15 N·m (11 ft. lbs.). Fig.
Page 177 BRAKES 5 - 19 REMOVAL AND INSTALLATION (Continued) (6) Pump brake pedal until caliper pistons and brake shoes are seated. (7) Top off brake fluid level if necessary. DISC BRAKE ROTOR REMOVAL (1) Remove wheel and tire assemble. (2) Remove caliper. (3) Remove retainers securing rotor to hub studs (Fig.
Page 178 5 - 20 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 34 Drum Brake Components—Typical (6) Remove hold-down springs, retainers and pins with standard retaining spring tool. (7) Install spring clamps on wheel cylinders to hold pistons in place. (8) Remove adjuster lever, adjuster screw and spring.
Page 179 BRAKES 5 - 21 REMOVAL AND INSTALLATION (Continued) (5) Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION (1) Apply bead of silicone sealer around cylinder mounting surface of support plate. (2) Install cylinder mounting bolts and tighten to 10 N·m (7 ft.
Page 180 5 - 22 BRAKES REMOVAL AND INSTALLATION (Continued) (5) Remove secondary brake shoe and disconnect DISASSEMBLY AND ASSEMBLY cable from lever on brake shoe. (6) Compress cable retainer with worm drive hose MASTER CYLINDER RESERVOIR clamp (Fig. 40) and remove cable from backing plate. REMOVAL (1) Remove reservoir cap and empty fluid into drain container.
Page 181 BRAKES 5 - 23 DISASSEMBLY AND ASSEMBLY (Continued) (3) Install pins that retain reservoir to cylinder body. (4) Fill and bleed master cylinder on bench before installation in vehicle. DISC BRAKE CALIPER DISASSEMBLY (1) Remove brake shoes from caliper. (2) Drain brake fluid out of caliper. (3) Take a piece of wood and pad it with one-inch thickness of shop towels.
Page 182 5 - 24 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) Fig. 49 Piston Seal Removal Fig. 47 Caliper Piston Removal Fig. 50 Mounting Bolt Bushing And Boot Fig. 48 Caliper Piston Dust Boot Removal ASSEMBLY CAUTION: Dirt, oil, and solvents can damage cali- per seals.
Page 183 BRAKES 5 - 25 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 52 Piston Seal Installation Fig. 55 Piston Dust Boot Installation Fig. 53 Dust Boot On Piston Fig. 56 Wheel Cylinder Components–Typical ASSEMBLY (1) Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. (2) Install first piston in cylinder bore.
Page 184 5 - 26 BRAKES use any other cleaning agents. Remove light rust and CLEANING AND INSPECTION scale from the brake shoe contact pads on the sup- port plate with fine sandpaper. CALIPER INSPECTION CLEANING As a general rule, riveted brake shoes should be Clean the caliper components with clean brake replaced when worn to within 0.78 mm (1/32 in.) of fluid or brake clean only.
Page 185 BRAKES 5 - 27 CLEANING AND INSPECTION (Continued) INSPECTION (8) Raise vehicle and mark tensioner rod 6.5 mm (1/4 in.) from tensioner bracket (Fig. 59). Inspect the cylinder bore. Light discoloration and (9) Tighten adjusting nut at equalizer until mark dark stains in the bore are normal and will not on tensioner rod moves into alignment with tensioner impair cylinder operation.
Page 186 5 - 28 BRAKES ADJUSTMENTS (Continued) (4) Loosen parking brake cable adjustment nut until there is slack in front cable. (5) Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel (Fig. 62). Fig.
Page 187 BRAKES 5 - 29 SPECIFICATIONS (Continued) CAUTION: Never use reclaimed brake fluid or fluid SPECIAL TOOLS from an container which has been left open. An open container will absorb moisture from the air BASE BRAKES and contaminate the fluid. CAUTION: Never use any type of a petroleum- based fluid in the brake hydraulic system.
Page 188 5 - 30 BRAKES ANTILOCK BRAKES INDEX page page DESCRIPTION AND OPERATION SERVICE PROCEDURES ABS SYSTEM RELAYS ....33 BLEEDING ABS BRAKE SYSTEM ... 33 ABS WARNING LAMP .
Page 189 BRAKES 5 - 31 DESCRIPTION AND OPERATION (Continued) signals. These signals are processed and compared simultaneously. The CAB contains a self check program that illu- minates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool.
Page 190 5 - 32 BRAKES DESCRIPTION AND OPERATION (Continued) signal for each wheel. This voltage is generated by COMBINATION VALVE magnetic induction when a tone wheel passes by the The combination valve contains a pressure differ- stationary magnetic of the wheel speed sensor. ential valve and switch and a rear brake proportion- A gear type tone ring serves as the trigger mecha- ing valve.
Page 191 BRAKES 5 - 33 DESCRIPTION AND OPERATION (Continued) ABS SYSTEM RELAYS (1) Perform base brake bleeding. Refer to base brake section for procedure. The ABS brakes has two relays, which are the sys- (2) Connect scan tool to the Data Link Connector. tem and pump motor relays.
Page 192 5 - 34 BRAKES REMOVAL AND INSTALLATION (Continued) (3) Remove all the brake lines from the HCU (Fig. FRONT WHEEL SENSOR (4) Remove HCU mounting bolts and remove HCU REMOVAL (Fig. 7). (1) Raise vehicle and turn wheel outward to access (5) Remove bolts from mount and remove mount the sensor.
Page 193 BRAKES 5 - 35 REMOVAL AND INSTALLATION (Continued) REAR WHEEL SPEED SENSOR REMOVAL (1) Disconnect sensors at rear harness connectors. (2) Remove wheel and tire assembly. (3) Remove brake drum. (4) Remove clips securing sensor wires to brake lines, rear axle and, brake hose. (5) Unseat sensor wire support plate grommet.
Page 194 5 - 36 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 12 Combination Valve Brake Lines Fig. 14 Acceleration Switch ing arrow is pointing to the front of the vehicle (Fig. 15). (1) Position switch on mounting bracket. (2) Install mounting bolts and tighten to 4-5 N·m (35-45 in.
Page 195 BRAKES 5 - 37 SPECIFICATIONS T0RQUE CHART DESCRIPTION TORQUE Acceleration Sensor Sensor Bolt ... . 4-5 N·m (35-45 in. lbs.) Bracket Bolt ..8-13 N·m (75-115 in. lbs.) Hydraulic Control Unit Bracket to HCU Bolts .
Page 196 CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION CLUTCH LINKAGE FLUID ....9 CLUTCH COMPONENTS ....1 FLYWHEEL .
Page 197 6 - 2 CLUTCH DESCRIPTION AND OPERATION (Continued) phragm spring, pressure plate, and fulcrum compo- relieving clamp force on the disc. The clutch disc is dis- nents. The pressure plate clamps the clutch disc engaged and freewheeling at this point. against the flywheel and the spring provides the The process of clutch re-engagement is simply the clamping force.
Page 198 CLUTCH 6 - 3 DIAGNOSIS AND TESTING (Continued) Fig. 2 Clutch Components And Inspection...
Page 199 6 - 4 CLUTCH DIAGNOSIS AND TESTING (Continued) CLUTCH CONTAMINATION Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may Fluid contamination is a frequent cause of clutch cock the flywheel causing excessive runout. Use new malfunctions.
Page 200 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CHART...
Page 201 6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CHART...
Page 202 CLUTCH 6 - 7 DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CHART — CONTINUED...
Page 203 6 - 8 CLUTCH DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CHART — CONTINUED...
Page 204 CLUTCH 6 - 9 SERVICE PROCEDURES CLUTCH COMPONENT LUBRICATION Proper clutch component lubrication is important to satisfactory operation. Using the correct lubricant and not over lubricating are equally important. Apply recommended lubricant sparingly to avoid disc and pressure plate contamination. Clutch and transmission components requiring lubrication are: •...
Page 205 6 - 10 CLUTCH SERVICE PROCEDURES (Continued) • 68 N·m (50 ft. lbs.) plus an additional turn of REMOVAL AND INSTALLATION 60° for 4-cylinder flywheels Inspect the teeth on the starter ring gear. If the CLUTCH COVER AND DISC teeth are worn or damaged, the flywheel should be replaced as an assembly.
Page 206 CLUTCH 6 - 11 REMOVAL AND INSTALLATION (Continued) RELEASE BEARING REMOVAL (1) Remove transmission. (2) Disconnect release bearing from release lever and remove bearing (Fig. 6). (3) Inspect bearing slide surface of transmission front bearing retainer. Replace retainer if slide sur- face is scored, worn, or cracked.
Page 207 6 - 12 CLUTCH REMOVAL AND INSTALLATION (Continued) (2) Start new bearing into crankshaft by hand. Then seat bearing with clutch alignment tool (Fig. 7). Fig. 7 Pilot Bearing Installation (3) Lightly scuff sand flywheel surface with 180 grit emery cloth. Then clean surface with wax and grease remover.
Page 208 CLUTCH 6 - 13 REMOVAL AND INSTALLATION (Continued) (8) Install and tighten slave cylinder attaching nuts to 23 N·m (17 ft. lbs.) torque. (9) Secure clutch fluid line in body and transmis- sion clips. (10) Lower vehicle. (11) Connect clutch interlock safety switch wires. CLUTCH PEDAL REMOVAL (1) Remove steering column lower cover and knee...
Page 209 6 - 14 CLUTCH SPECIFICATIONS (Continued) SPECIFICATIONS TORQUE DESCRIPTION TORQUE Bolts, clutch cover 2.5 L ..31 N·m (23 ft. lbs) Bolts, clutch cover 4.0 L ..52 N·m (38 ft. lbs) Nut, clutch master cyl.
Page 210 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION SERVICE PROCEDURES ACCESSORY DRIVE BELTS ....3 COOLANT LEVEL—ROUTINE CHECK ..19 BLOCK HEATER .
Page 211 7 - 2 COOLING SYSTEM GENERAL INFORMATION (Continued) Fig. 1 Coolant Circulation—2.5L Engine COMPONENTS COOLANT The components of the cooling system are: The cooling system is designed around the coolant. • A heavy duty radiator Coolant flows through the engine water jackets •...
Page 212 COOLING SYSTEM 7 - 3 GENERAL INFORMATION (Continued) DESCRIPTION AND OPERATION TRANSMISSION OIL COOLER All models equipped with an automatic transmis- sion are equipped with a transmission oil cooler (water-to-oil) mounted internally within the radiator tank. This internal cooler is supplied as standard equipment on all models equipped with an automatic transmission.
Page 213 7 - 4 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) ence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plas- tic and soften solder.
Page 214 COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 5 Reverse Rotating Water Pump—Typical COOLING SYSTEM HOSES Rubber hoses route coolant to and from the radia- tor, intake manifold and heater core. Radiator lower hoses are spring-reinforced to pre- vent collapse from water pump suction at moderate and high engine speeds.
Page 215 7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) top speed of the fan to a predetermined maximum level at higher engine speeds. Fig. 6 Hose Clamp Tool—Typical Fig. 8 Water Pump Mounted Fan Drive A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown in (Fig.
Page 216 COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) bimetallic coil. It then increases fan speed to provide ACCESSORY DRIVE BELT DIAGNOSIS the necessary additional engine cooling. Once the engine has cooled, the radiator discharge VISUAL DIAGNOSIS temperature will drop. The bimetallic coil again When diagnosing serpentine accessory drive belts, reacts and the fan speed is reduced to the previous small cracks that run across the ribbed surface of the...
Page 217 7 - 8 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from has separated from belt body) pulley grooves. pulley grooves.
Page 218 COOLING SYSTEM 7 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE 1. Belt slippage 1. Adjust belt (Objectionable squeal, squeak, or 2. Bearing noise 2. Locate and repair rumble is heard or felt while drive belt is in operation) 3.
Page 219 7 - 10 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Has a Diagnostic Trouble Code 1. Refer to group 25, Emission Control READS LOW (DTC) been set indicating a stuck open Systems.
Page 220 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 6. Poor seals at radiator cap. 6. (a) Check condition of cap and cap READS HIGH OR ENGINE seals. Refer to Radiator Cap. Replace COOLANT WARNING LAMP cap if necessary.
Page 221 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 16. Thermal viscous fan drive not 16. Check fan drive operation and operating properly. replace if necessary. Refer to Viscous Fan Drive in this group. 17. Cylinder head gasket leaking. 17.
Page 222 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION PRESSURE CAP IS 1. Pressure relief valve in radiator cap 1. Check condition of radiator cap and BLOWING OFF STEAM is defective. cap seals. Refer to Radiator Caps in AND/OR COOLANT TO this group.
Page 223 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as CONDITIONER restricted, obstructed or dirty (insects, necessary. Refer to Radiator Cleaning PERFORMANCE (COOLING leaves etc.) in this group.
Page 224 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace certain drive line components. One or or repair as necessary. more of these shields may be missing. 2.
Page 225 ULTRAVIOLET LIGHT METHOD Inspect the cams on the outside part of the filler All Jeep models have a leak detection additive neck. If the cams are bent, seating of pressure cap added to the cooling system before they leave the fac- valve and tester seal will be affected.
Page 226 COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) leakage. If no leaks are visible, inspect for internal Drain sufficient coolant to allow for thermostat leakage. Large radiator leak holes should be repaired removal. Refer to Thermostat Replacement. Discon- by a reputable radiator repair shop. nect the water pump drive belt.
Page 227 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) (1) Drill a 3.18-mm (1/8-in) diameter hole in the RADIATOR CAP TO FILLER NECK SEAL— top center of the fan shroud. PRESSURE RELIEF CHECK (2) Obtain a dial thermometer with an 8 inch stem With radiator cap installed on filler neck, remove (or equivalent).
Page 228 COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, cooling system problems. A pressure cap that does WAIT AT LEAST 15 MINUTES BEFORE REMOVING not have a history of coolant loss should not be RADIATOR CAP.
Page 229 7 - 20 COOLING SYSTEM SERVICE PROCEDURES (Continued) for testing or when refilling system after service. Removing cap unnecessarily can cause loss of coolant and allow air to enter system, which produces corro- sion. SERVICE COOLANT LEVEL The cooling system is closed and designed to main- tain coolant level to top of radiator.
Page 230 COOLING SYSTEM 7 - 21 SERVICE PROCEDURES (Continued) ment. Have radiator cleaned more extensively by a radiator repair shop. REVERSE FLUSHING ENGINE Drain the cooling system. Remove the thermostat housing and thermostat. Install the thermostat hous- ing. Disconnect the radiator upper hose from the radiator and attach the flushing gun to the hose.
Page 231 7 - 22 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- ING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 21). If replacement is necessary, use only an original equipment clamp with matching number or letter.
Page 232 COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 19 Power Steering Pump Attachment Fig. 20 Hose Clamp Tool–Typical (8) Install and tension accessory drive belt. Refer to Accessory Drive Belt removal and installation in this group. (9) Fill cooling system with coolant and check for leaks.
Page 233 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) replacement is necessary, use only an original equipment clamp with matching number or letter. (2) Remove radiator upper hose and heater hose at thermostat housing. (3) Disconnect wiring connector at engine coolant temperature sensor.
Page 234 COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) (7) If equipped, disconnect and plug automatic transmission fluid cooler lines. (8) Remove six radiator mounting bolts. Position the front axle vent hose (Fig. 25) to the side. (9) Lift radiator straight up and out of vehicle tak- ing care not to damage radiator fins.
Page 235 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 25 Radiator—Remove/Install (3) Seat block heater flush against block face. VISCOUS FAN Tighten mounting screw to 4 N·m (31 in. lbs.) torque. (4) Fill cooling system with coolant. Pressurize system and inspect for leaks. (5) Plug power cord into block heater.
Page 236 COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) (2) Remove accessory drive belt. Refer to Belt Ser- VISCOUS FAN DRIVE vice in the Engine Accessory Drive Belt section of Refer to Cooling System Fan for removal and this group. installation procedures of the viscous drive unit.
Page 237 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 32 Power Steering Pump Bracket and Idler Pulley INSTALLATION Fig. 30 2.5L/4.0L Engines—Without A/C (1) Check condition of all pulleys. CAUTION: When installing the serpentine acces- sory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction.
Page 238 COOLING SYSTEM 7 - 29 CLEANING AND INSPECTION (Continued) COOLING SYSTEM driver or a hex socket. To prevent damage to hoses or clamps, the hose clamps should be tightened to 4 N·m (34 in. lbs.) torque. Do not CAUTION: The cooling system normally operates at over tighten hose clamps.
Page 239 7 - 30 COOLING SYSTEM ADJUSTMENTS (Continued) (5) Tighten idler pulley bolt and re-check belt ten- ACCESSORY DRIVE BELT TENSION sion. Adjust if necessary. BELT TENSION **NEW SERPENTINE 800-900 N (180-200 lbs.) BELT USED SERPENTINE 623-712 N (140-160 lbs.) BELT **Belt is considered new if it has been used 15 minutes or less.
Page 240 COOLING SYSTEM 7 - 31 SPECIAL TOOLS COOLING Cooling System Pressure Tester—7700–A Hose Clamp Pliers—6094 Quick Disconnect Tool—6935 Belt Tension Gauge —C-4162...
Page 241 BATTERY 8A - 1 BATTERY CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION BATTERY ....... 1 BATTERY .
Page 242 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) The diagnostic procedures used in each of these period. A battery must also be able to accept a groups include the most basic conventional diagnostic charge, so that its voltage potential may be restored. methods, to the more sophisticated On-Board Diag- In addition to producing and storing electrical nostics (OBD) built into the Powertrain Control Mod-...
Page 243 BATTERY 8A - 3 DESCRIPTION AND OPERATION (Continued) amperes. RC is determined with the battery fully- within this Service Manual. However, when attempt- charged at 26.7° C (80° F). This rating estimates how ing to diagnose any of these systems, it is important long the battery might last after a charging system that you keep their interdependency in mind.
Page 244 8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) checking the battery voltage (open-circuit voltage A battery that will not accept a charge is faulty, test). and must be replaced. Further testing is not 2. Cranking Capacity - This can be determined required.
Page 245 BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery seems weak or 1. The battery has an 1. Refer to Battery in the Specifications section of dead when attempting to start incorrect size or rating for this group.
Page 246 8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery state-of-charge 1. The battery has an 1. Refer to Battery in the Specifications section of cannot be maintained. incorrect size or rating for this group. Replace an incorrect battery with the this vehicle.
Page 247 BATTERY 8A - 7 DIAGNOSIS AND TESTING (Continued) Refer to Load Test in the Diagnosis and Testing sec- tery, the battery must be load tested. Refer to Load tion of this group for more information. Test in the Diagnosis and Testing section of this group for more information.
Page 248 8A - 8 BATTERY DIAGNOSIS AND TESTING (Continued) In a fully-charged battery the electrolyte will have a temperature-corrected specific gravity of 1.260 to 1.290. However, a specific gravity of 1.235 or above is satisfactory for battery load testing and/or return to service.
Page 249 BATTERY 8A - 9 DIAGNOSIS AND TESTING (Continued) the battery may be load tested to determine its (3) Using a voltmeter connected to the battery cranking capacity. Refer to Load Test in the Diagno- posts (see the instructions provided by the manufac- sis and Testing section of this group for more infor- turer of the voltmeter), measure the open-circuit volt- mation.
Page 250 8A - 10 BATTERY DIAGNOSIS AND TESTING (Continued) WARNING: • IF THE BATTERY SHOWS SIGNS OF FREEZ- ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHI- CLE DAMAGE MAY RESULT.
Page 251 BATTERY 8A - 11 DIAGNOSIS AND TESTING (Continued) CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHI- CLE DAMAGE MAY RESULT. • EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
Page 252 8A - 12 BATTERY DIAGNOSIS AND TESTING (Continued) Fig. 12 Test Battery Positive Cable Resistance - Typical Fig. 10 Test Battery Negative Connection Resistance - Typical Fig. 13 Test Ground Circuit Resistance - Typical to twenty-five milliamperes (0.005 to 0.025 ampere) with the ignition switch in the Off position, and all Fig.
Page 253 BATTERY 8A - 13 DIAGNOSIS AND TESTING (Continued) ing a battery. In most cases, the battery can be lowest milliampere scale of the multi-meter to check charged and returned to service after the excessive the low-amperage IOD. IOD condition has been corrected. CAUTION: Do not open any doors, or turn on any (1) Verify that all electrical accessories are off.
Page 254 8A - 14 BATTERY SERVICE PROCEDURES (Continued) CAUTION: • Always disconnect and isolate the battery neg- ative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may result. •...
Page 255 BATTERY 8A - 15 SERVICE PROCEDURES (Continued) tery, 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). • Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time.
Page 256 8A - 16 BATTERY REMOVAL AND INSTALLATION (Continued) Built-In Test Indicator in the Diagnosis and Test- ing section of this group for more information. Also refer to Battery Charging in the Service Procedures section of this group for more information. (9) If the battery is to be reinstalled, clean the out- side of the battery case and the top cover with a sodium bicarbonate (baking soda) and warm water...
Page 257 BATTERY 8A - 17 REMOVAL AND INSTALLATION (Continued) CAUTION: Be certain that the battery cables are connected to the correct battery terminals. Reverse polarity may damage electrical components. (4) Connect and tighten the battery positive cable terminal clamp. Then connect and tighten the bat- tery negative cable terminal clamp.
Page 258 8A - 18 BATTERY SPECIFICATIONS BATTERY Battery Classifications and Ratings BCI Group Size Cold Cranking Reserve Load Test Part Number Ampere-Hours Classification Amperage Capacity Amperage 56027960 110 Minutes 56041003 120 Minutes...
Page 259 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION STARTER RELAY ......9 STARTER MOTOR .
Page 260 8B - 2 STARTING SYSTEMS DESCRIPTION AND OPERATION (Continued) in the Diagnosis and Testing section of Group 8C - noid plunger hold-in coil. Current now flows between Charging System for more information. the solenoid battery terminal and the starter motor, energizing the starter.
Page 261 STARTING SYSTEMS 8B - 3 DESCRIPTION AND OPERATION (Continued) engagement with a larger gear that is splined to the relay contact is held against one of the fixed contacts input end of the starter pinion gear shaft. This fea- (normally closed) by spring pressure. When the elec- ture makes it possible to reduce the dimensions of tromagnetic coil is energized, it draws the movable the starter.
Page 262 8B - 4 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO 1. Battery discharged or 1. Refer to Battery in the Diagnosis and Testing section of OPERATE. faulty. Group 8A - Battery. Charge or replace the battery, if 2.
Page 263 STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) INSPECTION required. Refer to the proper section of Group 8W - Wiring Diagrams for complete service information For complete circuit diagrams, refer to Starting and circuit diagrams for the starting system wiring System in the Contents of Group 8W - Wiring Dia- components.
Page 264 8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) to Engine Diagnosis in the Diagnosis and Testing layout label affixed to the underside of the PDC cover section of Group 9 - Engine for further testing of for ASD relay identification and location. the engine.
Page 265 STARTING SYSTEMS 8B - 7 DIAGNOSIS AND TESTING (Continued) the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery cable connection at the solenoid. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable.
Page 266 8B - 8 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) Fig. 7 Starter Motor Noise Diagnosis gear by removing shims from both starter mounting NOTE: This is a condition that will generally cause pads on the engine block (Fig. 8). Refer to Starter broken starter (flywheel/torque converter drive Motor in the Removal and Installation section of plate) ring gear teeth or broken starter motor hous-...
Page 267 STARTING SYSTEMS 8B - 9 DIAGNOSIS AND TESTING (Continued) (3) Connect a suitable volt-ampere tester and a 12-volt battery to the starter motor in series, and set the ammeter to the 100 ampere scale. See the instructions provided by the manufacturer of the volt-ampere tester being used.
Page 268 8B - 10 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) (2) The relay normally closed terminal (87A) is REMOVAL AND INSTALLATION connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. STARTER MOTOR (3) The relay normally open terminal (87) is con- nected to the common feed terminal (30) in the ener- REMOVAL...
Page 269 STARTING SYSTEMS 8B - 11 REMOVAL AND INSTALLATION (Continued) 4.0L ENGINE (1) Disconnect and isolate the battery negative cable. (2) Raise and support the vehicle. (3) Remove the lower (forward facing) mounting screw from the starter motor (Fig. 13). Fig. 14 Starter Wire Harness Remove/Install - 4.0L Engine (2) Install the battery cable and solenoid wire con- nector eyelets onto the solenoid terminal studs.
Page 270 8B - 12 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) motor during this process, do not let the starter (3) See the fuse and relay layout label affixed to motor hang from the wire harness. the underside of the PDC cover for starter relay iden- (4) Install and tighten the nut that secures the tification and location.
Page 271 STARTING SYSTEMS 8B - 13 SPECIFICATIONS STARTING SYSTEM Starter Motor and Solenoid Manufacturer Mitsubishi Engine Application 2.5L, 4.0L 2.5L - 1.2 Kilowatt (1.6 Horsepower) Power Rating 4.0L - 1.4 Kilowatt (1.9 Horsepower) Voltage 12 Volts Number of Fields Number of Poles Number of Brushes Drive Type Planetary Gear Reduction...
Page 272 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page DESCRIPTION AND OPERATION ON-BOARD DIAGNOSTIC TEST FOR BATTERY TEMPERATURE SENSOR ..2 CHARGING SYSTEM ....3 CHARGING SYSTEM OPERATION .
Page 273 8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) • an undercharged or overcharged battery condi- Although the generators appear the same exter- nally, different generators with different output rat- tion occurs. ings are used on this vehicle. Be certain that the Remember that an undercharged battery is often replacement generator has the same output rating caused by:...
Page 274 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued) (3) Remove generator pivot and mounting bolts/nut (Fig. 2). Position generator for access to wire connec- tors. (4) If equipped, unsnap plastic cover from B+ ter- minal. (5) Remove B+ terminal mounting nut at rear of generator (Fig.
Page 275 8C - 4 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 2 Generator Remove/Install Fig. 4 Battery Temperature Sensor Remove/Install INSTALLATION (1) Feed pigtail harness through hole in top of bat- Fig. 3 Generator Connectors (Typical) tery tray and press sensor into top of battery tray. (2) Connect pigtail harness.
Page 276 CHARGING SYSTEM 8C - 5 SPECIFICATIONS GENERATOR RATINGS TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS DENSO 56005684AB 2.5L/4.0L DENSO 56005685AB 2.5L/4.0L TORQUE CHART Description Torque Generator Upper Mounting Bolt/Nut— 2.5L/4.0L Engine ....55 N·m (41 ft.
Page 277 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page DESCRIPTION AND OPERATION SPARK PLUG CONDITIONS ....8 AUTOMATIC SHUTDOWN (ASD) RELAY ..2 REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR .
Page 278 8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) NOTE: Base ignition timing by rotation of distribu- Distributor position will have no effect on igni- tor is not adjustable. tion timing. The position of the distributor will determine fuel synchronization only. The PCM opens and closes the ignition coil ground All distributors contain an internal oil seal that circuit to operate the ignition coil.
Page 279 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT POSITION SENSOR The crankshaft position sensor is mounted to the transmission bellhousing at the left/rear side of the engine block (Fig. 3), (Fig. 4), or (Fig. 5). Fig. 5 Crankshaft Position Sensor—Manual Transmission (Typical) Fig.
Page 280 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 6 Sensor Operation—2.5L 4-Cyl. Engine Fig. 8 Sensor Operation—4.0L 6-Cyl. Engine— Automatic Transmission The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft.
Page 281 IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) On vehicles equipped with an automatic transmis- sion, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position.
Page 282 8D - 6 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) If the ignition coil is being replaced, the secondary spark plug cable must also be checked. Replace cable if it has been burned or damaged. Arcing at the tower will carbonize the cable boot, which if it is connected to a new ignition coil, will cause the coil to fail.
Page 283 IGNITION SYSTEM 8D - 7 DIAGNOSIS AND TESTING (Continued) CRANKSHAFT POSITION SENSOR (7) If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to To perform a complete test of this sensor and its Group 8W, Wiring Diagrams.
Page 284 8D - 8 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) With the engine running, remove spark plug cable ifications as found in the Spark Plug Cable from spark plug (one at a time) and hold next to a Resistance chart, replace the cable. Inspect the igni- good engine ground.
Page 285 IGNITION SYSTEM 8D - 9 DIAGNOSIS AND TESTING (Continued) WET FOULING OR GAS FOULING A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling.
Page 286 8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode (Fig.
Page 287 IGNITION SYSTEM 8D - 11 REMOVAL AND INSTALLATION (Continued) Fig. 22 Cable Removal (2) Prior to removing the spark plug, spray com- pressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber.
Page 288 8D - 12 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) On 2.5L 4-cylinder and 4.0L 6-cylinder engines with manual transmissions, the sensor is attached with two bolts. On 2.5L engines with automatic transmissions, the sensor is attached with two nuts. On 4.0L engines with automatic transmissions, the sensor is adjustable and is attached with one bolt.
Page 289 IGNITION SYSTEM 8D - 13 REMOVAL AND INSTALLATION (Continued) (5) Used Sensors: Clean bottom of sensor and install spacer PN05252229. (6) Install sensor into transmission bellhousing hole. (7) Push sensor against flywheel/drive plate. With sensor pushed against flywheel/drive plate, tighten mounting bolt to 7 N·m (60 in.
Page 290 8D - 14 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Factory replacement distributors are equipped with a plastic alignment pin already installed. The pin is located in an access hole on the bottom of the distrib- utor housing (Fig. 30). It is used to temporarily lock the rotor to the cylinder number 1 position during installation.
Page 291 IGNITION SYSTEM 8D - 15 REMOVAL AND INSTALLATION (Continued) Fig. 34 Slot At 11 O’clock Position—4.0L Engine (16) Remove and discard the old distributor-to-en- gine block gasket. INSTALLATION (1) If engine crankshaft has been rotated after dis- Fig. 32 Align Timing Marks tributor removal, cylinder number 1 must be (14) 2.5L 4-Cylinder Engine: Observe slot in oil returned to its proper firing stroke.
Page 292 8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Rotate distributor shaft and install pin punch slot in oil pump gear. The same may have to be done tool through proper alignment hole in plastic ring to engage distributor gear with camshaft gear. (Fig.
Page 293 IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before removing ignition switch. KEY CYLINDER REMOVAL (1) Disconnect negative battery cable at battery.
Page 294 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (6) Push the pin punch up while pulling key cylin- der from steering column. IGNITION SWITCH REMOVAL (1) Remove key cylinder. Refer to previous steps. (2) Remove lower steering column cover screws and remove cover (Fig.
Page 295 IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) SHIFTER/IGNITION INTERLOCK ENGINE FIRING ORDER—2.5L 4-CYLINDER On models equipped with an automatic transmis- ENGINE sion, a cable connects the ignition switch with the floor shift lever. The shifter will be locked in the PARK position when the ignition key is in the LOCK or ACCESSORY positions.
Page 296 8D - 20 IGNITION SYSTEM SPECIFICATIONS (Continued) SPARK PLUGS SPARK PLUG CABLE RESISTANCE ENGINE PLUG TYPE ELECTRODE GAP MINIMUM MAXIMUM 2.5L/4.0L RC12ECC 0.89 mm (0.035 in.) 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot IGNITION COIL RESISTANCE PRIMARY RESISTANCE SECONDARY RESISTANCE...
Page 297 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION GLOVE BOX COMPONENTS ....19 ACCESSORY RELAY ..... . 4 GLOVE BOX LATCH STRIKER .
Page 298 8E - 2 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) assembly allows access to the cluster illumination tioning the gauge needles at several predetermined and indicator lamp bulbs, and more of the instru- locations on the gauge faces in a prescribed sequence. ment panel wiring.
Page 299 INSTRUMENT PANEL SYSTEMS 8E - 3 DESCRIPTION AND OPERATION (Continued) tive scales after the ignition switch is turned to the instrument panel accessory switch bezel, which is Off position. located near the bottom of the instrument panel cen- ter bezel area, next to the ash receiver. A plastic cap INDICATOR LAMP snaps into the power outlet base when the power out- Indicator lamps are located in the instrument clus-...
Page 300 8E - 4 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) ACCESSORY RELAY RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR DESCRIPTION SERVICE. FAILURE TO TAKE THE PROPER PRE- The accessory relay is an electromechanical device CAUTIONS COULD RESULT IN ACCIDENTAL AIR- that switches fused battery current to the standard BAG DEPLOYMENT AND POSSIBLE PERSONAL...
Page 301 INSTRUMENT PANEL SYSTEMS 8E - 5 DIAGNOSIS AND TESTING (Continued) negative cable. Turn the ignition switch to the On (1) Begin the test with the ignition switch in the position. Check for battery voltage at the fused igni- Off position. tion switch output (run/start) circuit cavity of the (2) Depress the trip odometer reset button.
Page 302 8E - 6 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) Fig. 1 Instrument Cluster Actuator Test...
Page 303 INSTRUMENT PANEL SYSTEMS 8E - 7 DIAGNOSIS AND TESTING (Continued) OK, go to Step 3. If not OK, repair the open fused ignition switch output (run/start) circuit to the igni- ignition switch output (run/start) circuit to the igni- tion switch as required. tion switch as required.
Page 304 8E - 8 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) that system needs to be repaired first. If the exterior FOUR-WHEEL DRIVE INDICATOR LAMP lamps controlled by the headlamp switch are inoper- The diagnosis found here addresses an inoperative ative, refer to Headlamp Diagnosis in the Diagno- four-wheel drive indicator lamp condition.
Page 305 INSTRUMENT PANEL SYSTEMS 8E - 9 DIAGNOSIS AND TESTING (Continued) bulb. If not OK, repair the open part time four wheel ment panel, near the cowl side inner panel in the drive indicator lamp driver circuit as required. passenger compartment. For complete circuit dia- grams, refer to Horn/Cigar Lighter in the Contents HEADLAMP HIGH BEAM INDICATOR LAMP of Group 8W - Wiring Diagrams.
Page 306 8E - 10 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) (2) The relay normally closed terminal (87A) is (2) Turn the ignition switch to the On position. connected to terminal 30 in the de-energized position, Check for battery voltage at the insulated contact but is not used for this application.
Page 307 INSTRUMENT PANEL SYSTEMS 8E - 11 REMOVAL AND INSTALLATION (Continued) (3) Remove the four screws that secure the knee blocker to the instrument panel (Fig. 4). Fig. 3 Steering Column Opening Cover Remove/ Install (7) Remove the steering column opening cover Fig.
Page 308 8E - 12 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) REMOVAL (5) Install the knee blocker onto the instrument panel. Refer to Knee Blocker in the Removal and (1) Disconnect and isolate the battery negative Installation section of this group for the procedures. cable.
Page 309 INSTRUMENT PANEL SYSTEMS 8E - 13 REMOVAL AND INSTALLATION (Continued) (3) Remove the top cover from the instrument panel. INSTALLATION (1) Position the top cover onto the instrument panel. (2) Align the snap clips on the top cover with the snap clip receptacles in the instrument panel.
Page 310 8E - 14 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) REMOVAL lamp bulbs (including the integral bulb holders), the odometer reset knob boot, the cluster lens, the clus- (1) Disconnect and isolate the battery negative ter hood and mask unit, the instrument cluster hous- cable.
Page 311 INSTRUMENT PANEL SYSTEMS 8E - 15 REMOVAL AND INSTALLATION (Continued) CLUSTER HOOD AND MASK (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument cluster from the instru- ment panel. Refer to Instrument Cluster in the Removal and Installation section of this group for the procedures.
Page 312 8E - 16 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) CLUSTER HOUSING (2) Press firmly and evenly on the cluster lens to install it onto the cluster housing. (1) Disconnect and isolate the battery negative (3) Work around the perimeter of the cluster hous- cable.
Page 313 INSTRUMENT PANEL SYSTEMS 8E - 17 REMOVAL AND INSTALLATION (Continued) CLUSTER HOUSING (1) Install the rear cover onto the cluster housing. Refer to Instrument Cluster Components - Clus- ter Housing Rear Cover in the Removal and Installation section of this group for the procedures. (2) Install the cluster hood and mask unit onto the cluster housing.
Page 314 8E - 18 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL ACCESSORY SWITCH INSTALLATION (1) Position the accessory switch bezel to the BEZEL instrument panel. (2) Reconnect the instrument panel wire harness WARNING: ON VEHICLES EQUIPPED WITH AIR- connectors to the connector receptacles, the accessory BAGS, REFER GROUP...
Page 315 INSTRUMENT PANEL SYSTEMS 8E - 19 REMOVAL AND INSTALLATION (Continued) (3) Disconnect the accessory relay from the acces- sory relay wire harness connector. (4) Remove the accessory relay from under the instrument panel. INSTALLATION (1) Position the accessory relay to the accessory relay wire harness connector under the instrument panel.
Page 316 8E - 20 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Insert a small screwdriver into the retaining tumbler release slot and depress the retaining tum- bler (Fig. 17). Fig. 16 Glove Box Components (5) Remove the inner door and bin unit from the outer glove box door.
Page 317 INSTRUMENT PANEL SYSTEMS 8E - 21 REMOVAL AND INSTALLATION (Continued) (2) Install and tighten the four screws that secure (4) Remove the latch striker from the instrument the glove box latch and handle to the glove box door panel. from the inside of the glove box. Tighten the screws INSTALLATION to 2.2 N·m (20 in.
Page 318 8E - 22 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (3) Install the glove box latch striker onto the instrument panel. Refer to Glove Box Latch (1) Position the grab handle onto the instrument Striker in the Removal and Installation section of panel.
Page 319 INSTRUMENT PANEL SYSTEMS 8E - 23 REMOVAL AND INSTALLATION (Continued) (b) Disconnect the instrument panel wire har- ness connector from the heater-A/C system wire harness connector. (c) Disconnect the instrument panel wire har- ness connector from the passenger side airbag module wire harness connector.
Page 320 8E - 24 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (h) Reconnect the two halves of the heater-A/C (6) Remove the radio from the instrument panel. system vacuum harness connector. Refer to Radio in the Removal and Installation sec- (6) Install the glove box onto the instrument panel. tion of Group 8F - Audio Systems for the procedures.
Page 321 INSTRUMENT PANEL SYSTEMS 8E - 25 REMOVAL AND INSTALLATION (Continued) 24 - Heating and Air Conditioning Systems for the dle Bezel in the Removal and Installation section of procedures. this group for the procedures. (7) Install the heater-A/C control onto the instru- (11) Install the accessory switch bezel onto the ment panel.
Page 323 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS CONTENTS page page REMOVAL AND INSTALLATION REAR FOGLAMP SWITCH ....2 HEADLAMP LEVELING SWITCH ... . . 1 REMOVAL AND INSTALLATION (2) Disconnect the headlamp leveling switch elec- trical connector (Fig.
Page 324 8E - 2 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) REAR FOGLAMP SWITCH REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 325 INSTRUMENT PANEL SYSTEMS 8E - 3 REMOVAL AND INSTALLATION (Continued) (6) Remove the instrument panel center bezel. (7) Remove the screws attaching the accessory switch bezel to the instrument panel (Fig. 6). (8) Disconnect the rear foglamp switch electrical connector. (9) Remove the rear foglamp switch from the accessory switch bezel.
Page 326 AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS CONTENTS page page GENERAL INFORMATION AUDIO SYSTEM ......2 INTRODUCTION .
Page 327 8F - 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) • Radio receiver chassis ground wire or strap outer wire mesh of the cable) is grounded to the • Engine-to-body ground strap antenna base and the radio chassis. • Engine-to-frame ground strap The antenna coaxial cable has an additional dis- •...
Page 328 AUDIO SYSTEMS 8F - 3 DIAGNOSIS AND TESTING (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in Power Distribution Center. Replace fuses, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if required.
Page 329 8F - 4 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- CAUTION: The speaker output of the radio is a BAGS, REFER GROUP PASSIVE “floating ground” system. Do not allow any speaker RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY lead to short to ground, as damage to the radio STEERING WHEEL,...
Page 330 AUDIO SYSTEMS 8F - 5 DIAGNOSIS AND TESTING (Continued) ANTENNA (2) Connect one ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the antenna base. Check for continuity. WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) There should be no continuity.
Page 331 8F - 6 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) • The antenna and cable must be carefully RADIO FREQUENCY INTERFERENCE matched to ensure a low Standing Wave Ratio (SWR). WARNING: ON VEHICLES EQUIPPED WITH AIR- Fleet vehicles are available with an extra-cost RFI- BAGS, REFER GROUP...
Page 332 AUDIO SYSTEMS 8F - 7 REMOVAL AND INSTALLATION (Continued) Fig. 4 Radio Connections - Typical (1) Disconnect and isolate the battery negative cable. (2) Remove the two screws that secure the out- board end of the speaker bezel to the instrument panel (Fig.
Page 333 8F - 8 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Lift the left outboard end flap of the sound bar trim cover over the top of the sport bar far enough to access the wire harness connector (Fig. 7). Fig. 6 Instrument Panel Speaker Remove/Install (8) Unplug the wire harness connector from the speaker.
Page 334 AUDIO SYSTEMS 8F - 9 REMOVAL AND INSTALLATION (Continued) ANTENNA (7) Remove the three screws that secure the antenna body base to the right outer cowl side panel. (8) From the outside of the vehicle, pull the WARNING: ON VEHICLES EQUIPPED WITH AIR- antenna body base and cable assembly out through BAGS, REFER...
Page 335 8F - 10 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Remove the engine-to-body ground strap eyelet from the stud on the left upper rear corner of the engine cylinder head. (5) Remove the engine-to-body ground strap from the engine compartment. ENGINE-TO-FRAME GROUND STRAP (1) Remove the nut that secures the engine-to- frame ground strap eyelet to the forward ignition coil...
Page 336 HORN SYSTEMS 8G - 1 HORN SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION HORN RELAY ......3 HORN .
Page 337 8G - 2 HORN SYSTEMS DESCRIPTION AND OPERATION (Continued) field collapses allowing the plunger and diaphragm to back side of the driver side airbag module trim cover return to their relaxed positions and closing the con- in the center of the steering wheel (Fig. 1). The tact points again.
Page 338 HORN SYSTEMS 8G - 3 DIAGNOSIS AND TESTING HORN RELAY The horn relay (Fig. 2) is located in the Power Dis- tribution Center (PDC) behind the battery on the driver side of the engine compartment. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is com- pleted.
Page 339 8G - 4 HORN SYSTEMS DIAGNOSIS AND TESTING (Continued) Steering Column in the Removal and Installation REMOVAL AND INSTALLATION section of Group 19 - Steering for proper installation of the steering column. HORN RELAY (3) Remove the driver side airbag module from the steering wheel.
Page 340 HORN SYSTEMS 8G - 5 REMOVAL AND INSTALLATION (Continued) HORN REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Disconnect the wire harness connectors from the horn connector receptacles (Fig. 4). (3) Remove the two screws that secure the horn and mounting bracket units to the left front inner fender shield.
Page 341 SPEED CONTROL SYSTEM 8H - 1 SPEED CONTROL SYSTEM CONTENTS page page DESCRIPTION AND OPERATION ROAD TEST ......2 POWERTRAIN CONTROL MODULE .
Page 342 8H - 2 SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) • A Diagnostic Trouble Code (DTC). If a DTC throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo exists, conduct tests per the Powertrain Diagnostic diaphragm.
Page 343 SPEED CONTROL SYSTEM 8H - 3 DIAGNOSIS AND TESTING (Continued) VACUUM SUPPLY TEST stop lamp switch. Also check stop lamp switch adjustment. Refer to Group 5, Brakes for procedures. (1) Disconnect vacuum hose at speed control servo (5) Connect a small gauge jumper wire between and install a vacuum gauge into the disconnected the disconnected servo harness 4–way connector hose.
Page 344 8H - 4 SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) OFF position (or press the CANCEL button if equipped) after waiting 10 seconds. This procedure must be performed approximately 10–15 times to completely unlearn the overshoot/undershoot condi- tion. REMOVAL AND INSTALLATION SPEED CONTROL SERVO REMOVAL (1) Disconnect negative battery cable at battery.
Page 345 SPEED CONTROL SYSTEM 8H - 5 REMOVAL AND INSTALLATION (Continued) Fig. 4 Speed Control Switch Remove/Install (5) Connect negative battery cable to battery. STOP LAMP SWITCH Refer to Stop Lamp Switch in Group 5, Brakes for removal/installation and adjustment procedures. SERVO CABLE Fig.
Page 346 8H - 6 SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) VACUUM RESERVOIR REMOVAL (1) Remove battery and battery tray. Refer to The vacuum reservoir is located under the vehicle Group 8A, Battery for procedure. battery tray (Fig. 7). (2) Disconnect vacuum supply line at reservoir (Fig.
Page 347 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING COMBINATION FLASHER ....3 TURN SIGNAL AND HAZARD WARNING HAZARD WARNING SYSTEM .
Page 348 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) the hazard warning system is activated, the circuitry The information contained in this group addresses of the hazard warning switch and the combination only the multi-function switch turn signal and haz- flasher will cause both the right side and the left side ard warning functions.
Page 349 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DESCRIPTION AND OPERATION (Continued) module and speed control switches on the steering combination flasher with a known good unit to con- wheel and the instrument panel wire harness on the firm system operation. steering column.
Page 350 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) Likewise, pin 8 of the IC receives a sense voltage WARNING: ON VEHICLES EQUIPPED WITH AIR- from the turn signal circuits of the multi-function BAGS, REFER GROUP PASSIVE switch.
Page 351 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 DIAGNOSIS AND TESTING (Continued) nuity. If OK, go to Step 9. If not OK, repair the open ground circuit to ground as required. (9) Disconnect the instrument panel wire harness connector from the multi-function switch connector receptacle.
Page 352 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS REMOVAL AND INSTALLATION (Continued) TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 353 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7 REMOVAL AND INSTALLATION (Continued) (5) Remove both the upper and lower shrouds from (10) Disconnect the two instrument panel wire the steering column. harness connectors from the multi-function switch (6) Remove the two screws that secure the multi- connector receptacles.
Page 354 WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS CONTENTS page page GENERAL INFORMATION WIPER SWITCH AND WASHER SWITCH ..3 INTRODUCTION ......1 DIAGNOSIS AND TESTING DESCRIPTION AND OPERATION WASHER SYSTEM .
Page 355 8K - 2 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) • A park mode that operates the wiper motor until The driver side wiper pivot crank arm and the the blade reaches its park position when the rear wiper motor crank arm each have ball studs on their wiper switch is placed in the Off position.
Page 356 WIPER AND WASHER SYSTEMS 8K - 3 DESCRIPTION AND OPERATION (Continued) The rear wiper motor cannot be repaired. If faulty is pushed down to its detent to activate the rear or damaged, the entire rear wiper motor assembly wiper system, and down again to the momentary must be replaced.
Page 357 8K - 4 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) The nozzles are snapped into openings in the hood From the check valve, another single hose is routed panel below the windshield through the rear liftglass opening reinforcements of The two washer nozzles each emit two streams of the hardtop to the rear wiper motor cover.
Page 358 WIPER AND WASHER SYSTEMS 8K - 5 DIAGNOSIS AND TESTING (Continued) replace the faulty switch. If not OK, repair the open BAG DEPLOYMENT AND POSSIBLE PERSONAL circuit to ground as required. INJURY. (5) Turn the ignition switch to the Off position. (1) Check the fuse in the fuseblock module.
Page 359 8K - 6 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) WASHER SYSTEM REAR The diagnosis found here addresses an inoperative FRONT rear washer pump. If the washer pump operates, but no washer fluid is emitted from the washer nozzle, be The diagnosis found here addresses an inoperative certain to check the fluid level in the reservoir.
Page 360 WIPER AND WASHER SYSTEMS 8K - 7 DIAGNOSIS AND TESTING (Continued) WIPER SWITCH AND WASHER SWITCH REAR Perform the diagnosis for the rear wiper system FRONT and/or washer system as described in this group before testing the rear wiper and washer switch. For Perform the diagnosis for the front wiper system circuit descriptions and diagrams, see 8W-53 - Wip- and/or washer system as described in this group...
Page 361 8K - 8 WIPER AND WASHER SYSTEMS WIPER ARM REMOVAL AND INSTALLATION WIPER BLADE CAUTION: The use of a screwdriver or other prying tool to remove a wiper arm may distort it. This dis- tortion could allow the arm to come off of the pivot FRONT shaft, regardless of how carefully it is installed.
Page 362 WIPER AND WASHER SYSTEMS 8K - 9 REMOVAL AND INSTALLATION (Continued) Push the latch into the locked position and slowly (2) Remove the wiper arms from the wiper pivots. release the arm until the wiper blade rests on the See Wiper Arm in this group for the procedures. windshield.
Page 363 8K - 10 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 12 Rear Wiper and Washer System (7) Loosen, but do not remove, the right liftglass hinge nut. (8) From the inside of the liftglass, gently pull the rear wiper motor away from the liftglass until the output shaft clears the hole in the liftglass.
Page 364 WIPER AND WASHER SYSTEMS 8K - 11 REMOVAL AND INSTALLATION (Continued) (7) Remove the one screw located below the multi- function switch lever that secures the switch water shield and bracket to the steering column (Fig. 15). Fig. 15 Water Shield Lower Screw Remove/Install (8) Gently pull the lower mounting tab of the switch water shield bracket away from the steering column far enough to clear the screw boss below the...
Page 365 8K - 12 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) REAR bezel are fully engaged. Tighten the mounting screws to 2.2 N·m (20 in. lbs.). WARNING: ON VEHICLES EQUIPPED WITH AIR- WASHER SYSTEM BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY WASHER RESERVOIR STEERING WHEEL,...
Page 366 WIPER AND WASHER SYSTEMS 8K - 13 REMOVAL AND INSTALLATION (Continued) the washer pump out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. (5) Remove the rubber grommet seal from the res- ervoir and discard.
Page 367 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 16 LAMP DIAGNOSIS ......1 HEADLAMP ALIGNMENT .
Page 368 8L - 2 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING and posts. OR IGNITION TURNED 2. Loose or worn generator drive 2.
Page 369 LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) FOG LAMP FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts. IGNITION TURNED OFF.
Page 370 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) DAYTIME RUNNING LAMP DAYTIME RUNNING LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION DAYTIME RUNNING LAMPS DO 1. Poor connection at DRL module. 1. Secure connector on DRL NOT WORK 2. Parking brake engaged. module.
Page 371 LAMPS 8L - 5 HEADLAMP ALIGNMENT INDEX page page GENERAL INFORMATION LAMP ALIGNMENT SCREEN PREPARATION ..5 HEADLAMP ALIGNMENT ....5 VEHICLE PREPARATION FOR HEADLAMP SERVICE PROCEDURES ALIGNMENT .
Page 372 8L - 6 LAMPS SERVICE PROCEDURES (Continued) Fig. 1 Headlamp Alignment Screen—Typical • Adjust the beam vertical position is 25 mm (1 VEHICLE PREPARATION FOR HEADLAMP in) downward from the lamp horizontal centerline. ALIGNMENT (4) Rotate the lower, inboard (left/right) adjust- (1) Verify headlamp dimmer switch and high beam ment screw (Fig.
Page 373 LAMPS 8L - 7 SERVICE PROCEDURES (Continued) Fig. 3 Fog Lamp Alignment —Typical FOG LAMP ADJUSTMENT (3) Tighten the nut attaching the fog lamp to the mounting bracket. Prepare an alignment screen. A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp centerline SPECIAL TOOLS and straight ahead (Fig.
Page 374 8L - 8 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION FRONT PARK/TURN SIGNAL LAMP BULB ..8 BACK-UP LAMP BULB ..... 9 HEADLAMP BULB .
Page 375 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) (3) Push the bulb inward and rotate counter-clock- wise. (4) Remove the bulb from the lamp socket. Fig. 3 CHMSL Bulb Fig. 2 Lens Removal INSTALLATION (1) Install a replacement bulb in the lamp socket. (2) Position the lens on the lamp housing.
Page 376 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) (2) Depress the opposite terminal inward and (2) Remove the lens from the lamp housing. engage the remaining bulb wire loop. (3) Pull the bulb straight out to remove from the (3) Position the lamp lens on the lamp base and bulb holder.
Page 377 LAMPS 8L - 11 LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION FRONT PARK/TURN SIGNAL LAMP ..12 CENTER HIGH MOUNTED STOP LAMP HEADLAMP ......11 (CHMSL) .
Page 378 8L - 12 LAMPS REMOVAL AND INSTALLATION (Continued) (3) Connect the fog lamp wire harness connector. TAIL/STOP/TURN SIGNAL/BACK-UP LAMP FRONT PARK/TURN SIGNAL LAMP REMOVAL (1) From the underside of the vehicle, remove the REMOVAL push-in fastener attaching the bottom rear edge of (1) Remove the park/turn signal lamp housing the rear wheelhouse splash shield to the body.
Page 379 LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) (4) Carefully pull wire harness terminal ends from (4) Install the attaching screw through the lamp contact buttons (Fig. 6). flange and into the hood panel (Fig. 7). Tighten the (5) Route wire harness through tailgate and sepa- screw securely.
Page 380 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) CARGO AREA DOME LAMP INSTALLATION (1) Connect the lamp wire connector. (2) Position the lamp in the hardtop. (3) Install the screws that attach the lamp to the hardtop. (4) Install the bulb. (5) Position the lens on the lamp housing and press into place.
Page 381 LAMPS 8L - 15 LAMP SYSTEMS INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION DAYTIME RUNNING LIGHTS (CANADA ONLY) . . 15 DAYTIME RUNNING LAMP (DRL) MODULE ..15 GENERAL INFORMATION DAYTIME RUNNING LIGHTS (CANADA ONLY) The Daytime Running Lights (Headlamps) System is installed on vehicles manufactured for sale in Can- ada only.
Page 382 8L - 16 LAMPS BULB APPLICATION INDEX page page SPECIFICATIONS INTERIOR LAMPS ..... . . 16 EXTERIOR LAMPS ..... . . 16 SPECIFICATIONS INTERIOR LAMPS EXTERIOR LAMPS...
Page 383 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 11 LAMP DIAGNOSIS ......1 LAMP BULB SERVICE .
Page 384 8L - 2 LAMPS tions, charging system, headlamp bulbs, wire DIAGNOSIS AND TESTING connectors, relay, high beam dimmer switch and head- lamp switch. Refer to Group 8W, Wiring Diagrams, for DIAGNOSTIC PROCEDURES component locations and circuit information. When a vehicle experiences problems with the head- lamp system, verify the condition of the battery connec- HEADLAMP DIAGNOSIS CONDITION...
Page 385 LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts. IGNITION TURNED OFF. 2.
Page 386 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP LEVELING MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION ONE MOTOR DOES NOT 1. Poor connection at motor. 1. Secure connector on motor. OPERATE 2. No voltage at motor. 2. Repair circuit. Refer to Group 8W, Wiring.
Page 387 LAMPS 8L - 5 LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION HEADLAMP BULB ......5 CENTER HIGH MOUNTED STOP LAMP LICENSE PLATE LAMP BULB .
Page 388 8L - 6 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 4 Headlamp Bulb Retaining Ring Fig. 6 Citylight Lamp Bulb Housing Fig. 5 Headlamp Bulb INSTALLATION (1) Perform the removal procedure in reverse order. Fig. 7 Citylight Lamp Bulb CITYLIGHT LAMP BULB REMOVAL (1) Remove the headlamp from the vehicle.
Page 389 LAMPS 8L - 7 REMOVAL AND INSTALLATION (Continued) Fig. 9 Tail Lamp Bulbs Fig. 11 REAR FOG LAMP BULB REAR FOG LAMP BULB INSTALLATION (1) Perform the removal procedure in reverse REMOVAL order. (1) Remove the rear fog lamp lense attaching LICENSE PLATE LAMP BULB screws and lense (Fig.
Page 390 8L - 8 LAMPS LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION HEADLAMP LEVELING MOTOR ....8 CENTER HIGH MOUNTED STOP LAMP REAR FOG LAMP ..... . . 10 (CHMSL) .
Page 391 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) (2) Remove the tail lamp housing attaching bolts (Fig. 7). (3) Separate the lamp housing from the body. (4) Disconnect the tail lamp electrical connector and remove tail lamp housing. Fig. 4 Headlamp Housing Fig.
Page 392 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) CENTER HIGH MOUNTED STOP LAMP (CHMSL) REMOVAL NOTE: It may be necessary to remove the spare tire. (1) Remove the CHMSL housing to CHMSL bracket attaching screws. (2) Disconnect the CHMSL wire harness from the retaining clips.
Page 393 LAMPS 8L - 11 BULB APPLICATION INDEX page page GENERAL INFORMATION INTERIOR LAMPS ..... . . 11 GENERAL INFORMATION ....11 SPECIFICATIONS EXTERIOR LAMPS .
Page 394 PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION CLOCKSPRING ......15 AIRBAG CONTROL MODULE .
Page 395 8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) signals the inflator units of both airbag modules to GAS PRESSURIZED TO OVER 2500 PSI. DO NOT deploy the airbags. ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR An airbag indicator lamp in the instrument cluster TAMPER WITH ITS INFLATOR.
Page 396 PASSIVE RESTRAINT SYSTEMS 8M - 3 DESCRIPTION AND OPERATION (Continued) when supplied with the proper electrical signal. Fol- porous fabric material used on each end panel of the lowing an airbag deployment, the airbag cushion airbag cushion. quickly deflates by venting this gas towards the The molded plastic passenger side airbag door is instrument panel through the porous fabric material secured to the instrument panel at the upper and...
Page 397 8M - 4 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) AIRBAG CONTROL MODULE protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. DESCRIPTION The Airbag Control Module (ACM) is secured with CLOCKSPRING screws to a mounting bracket that is secured with four screws onto the floor panel transmission tunnel...
Page 398 PASSIVE RESTRAINT SYSTEMS 8M - 5 NOTE: If the airbag indicator lamp fails to light, or DIAGNOSIS AND TESTING lights and stays on, there is an airbag system mal- function. See the proper Diagnostic Procedures AIRBAG SYSTEM manual to diagnose the problem. A DRB scan tool is required for diagnosis of the airbag system.
Page 399 8M - 6 PASSIVE RESTRAINT SYSTEMS SERVICE PROCEDURES (Continued) STORAGE Begin the cleanup by removing the airbag modules from the vehicle. Refer to Driver Side Airbag Mod- An airbag module must be stored in its original, ule and Passenger Side Airbag Module in the special container until used for service.
Page 400 PASSIVE RESTRAINT SYSTEMS 8M - 7 REMOVAL AND INSTALLATION (Continued) WARNING: (5) The clockspring airbag wire harness connector • THE AIRBAG SYSTEM IS A SENSITIVE, COM- is a tight snap-fit into the airbag module connector receptacle, which is located on the airbag inflator on PLEX ELECTROMECHANICAL UNIT.
Page 401 8M - 8 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Do not reconnect the battery negative cable at this time. Refer to Airbag System in the Diagnosis and Testing section of this group for the proper pro- cedures. DRIVER SIDE AIRBAG MODULE TRIM COVER The horn switch is integral to the driver side air- bag module trim cover.
Page 402 PASSIVE RESTRAINT SYSTEMS 8M - 9 REMOVAL AND INSTALLATION (Continued) Fig. 9 Driver Side Airbag Trim Cover Remove/Install Fig. 7 Driver Side Airbag Trim Cover Retainers - w/o Speed Control Remove/Install - w/o Speed Control Fig. 10 Driver Side Airbag Trim Cover Remove/ Fig.
Page 403 8M - 10 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION (3) Install the horn switch ground wire eyelet over the upper airbag housing stud. (4) Install the upper and lower airbag trim cover WARNING: • USE EXTREME CARE TO PREVENT ANY FOR- retainers over the airbag housing studs.
Page 404 PASSIVE RESTRAINT SYSTEMS 8M - 11 REMOVAL AND INSTALLATION (Continued) (2) Remove the instrument panel assembly from PASSENGER SIDE AIRBAG DOOR the passenger compartment of the vehicle. Refer to Instrument Panel Assembly in the Removal and WARNING: • THE AIRBAG SYSTEM IS A SENSITIVE, COM- Installation section of Group 8E - Instrument Panel Systems for the procedures.
Page 405 8M - 12 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Remove the grab handle bezel from the instru- the passenger side airbag door bracket screws are ment panel. Refer to Instrument Panel Grab Han- removed. dle Bezel in the Removal and Installation section of (2) Position the passenger side airbag door to the Group 8E - Instrument Panel Systems for the proce- instrument panel and align the mounting holes in...
Page 406 PASSIVE RESTRAINT SYSTEMS 8M - 13 REMOVAL AND INSTALLATION (Continued) (3) Reach through the glove box opening to access and disconnect the two passenger side airbag on/off switch wire harness connectors from the instrument panel wire harness. These connectors are retained on a bracket located on the outboard glove box opening reinforcement (Fig.
Page 407 8M - 14 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) retained on a bracket located on the outboard glove IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE box opening reinforcement. Be certain that both con- OCCUPANT INJURIES. nectors are fully engaged and latched. (6) Install the glove box onto the instrument panel.
Page 408 PASSIVE RESTRAINT SYSTEMS 8M - 15 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Reconnect the cross-body wire harness connec- tor to the ACM connector receptacle. Be certain that the connector latches are fully engaged and that the white connector locks are pushed in. (2) Carefully position the ACM and mounting bracket unit to the floor panel transmission tunnel.
Page 409 8M - 16 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Remove the driver side airbag module from the (10) Remove both the upper and lower shrouds steering wheel. Refer to Driver Side Airbag Mod- from the steering column. ule in the Removal and Installation section of this (11) Disconnect the two instrument panel wire group for the procedures.
Page 410 PASSIVE RESTRAINT SYSTEMS 8M - 17 REMOVAL AND INSTALLATION (Continued) (14) If the removed clockspring is to be reused, (7) Install the steering column opening cover onto lock the clockspring rotor to the clockspring case to the instrument panel. Refer to Steering Column maintain clockspring centering until it is reinstalled Opening Cover in the Removal and Installation sec- on the steering column.
Page 411 8M - 18 PASSIVE RESTRAINT SYSTEMS ADJUSTMENTS (Continued) WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- BAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE.
Page 412 ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page page GENERAL INFORMATION DEFOGGER SWITCH ..... . 3 INTRODUCTION ......1 DEFOGGER SYSTEM .
Page 413 8N - 2 ELECTRICALLY HEATED SYSTEMS DESCRIPTION AND OPERATION (Continued) DEFOGGER SWITCH DEFOGGER RELAY The rear window defogger switch is installed in the The rear window defogger relay is a International instrument panel accessory switch bezel, which is Standards Organization (ISO)-type relay. The rear located near the bottom of the instrument panel cen- window defogger relay is a electromechanical device ter bezel area, next to the ash receiver.
Page 414 ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) midpoint C with the positive lead. A reading of approximately six volts indicates a line is good. A reading of zero volts indicates a break in the grid line between midpoint C and the left side bus bar. A reading of ten to fourteen volts indicates a break between midpoint C and the right side bus bar.
Page 415 8N - 4 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) Fig. 3 Defogger Relay rear glass heating grid and defogger switch connec- tors at all times. If OK, go to Step 4. If not OK, repair the open circuit(s) as required. (4) The coil battery terminal (86) is connected to the electromagnet in the relay.
Page 416 ELECTRICALLY HEATED SYSTEMS 8N - 5 DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- EYES. FOR SKIN CONTACT, WASH THE AFFECTED BAGS, REFER GROUP PASSIVE AREAS WITH SOAP AND WATER. FOR CONTACT RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY WITH THE EYES, FLUSH WITH PLENTY OF WATER. STEERING WHEEL, STEERING...
Page 417 8N - 6 ELECTRICALLY HEATED SYSTEMS SERVICE PROCEDURES (Continued) (9) Allow the epoxy to cure 24 hours at room tem- (4) Pull the accessory switch bezel out from the perature, or use a heat gun with a 260° to 371° C instrument panel far enough to access the wire har- (500°...
Page 418 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION FUSEBLOCK MODULE ....2 FUSEBLOCK MODULE .
Page 419 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) micro-type). Internal connection of all of the PDC cir- The fuses used in the fuseblock module are avail- cuits is accomplished by an intricate combination of able for service replacement. The fuseblock module is hard wiring and bus bars.
Page 420 POWER DISTRIBUTION SYSTEMS 8O - 3 REMOVAL AND INSTALLATION (Continued) Fig. 5 PDC Mounting Bracket Remove/Install (2) Install and tighten the three screws that secure the PDC mounting bracket to the right front inner Fig. 3 Power Distribution Center Connections fender.
Page 421 8O - 4 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) information on the locations of the affected connec- tors. (11) Reconnect the battery negative cable. FUSEBLOCK MODULE The fuseblock module is serviced as a unit with the cross body wire harness. If any internal circuit of the fuseblock module if the fuseblock module housing is faulty or damaged, the entire fuseblock module and the cross body wire harness unit must be replaced.
Page 422 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 SENTRY KEY IMMOBILIZER SYSTEM .
Page 423 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) technician to access the system for service. The Procedures manual are required. The SKIM cannot SKIM also stores in its memory the Vehicle Identifi- be repaired and, if faulty or damaged, the unit must cation Number (VIN), which it learns through a CCD be replaced.
Page 424 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) Key” code. The SKIM transceiver compares the tran- DIAGNOSIS AND TESTING sponder codes with the codes stored in its memory to determine whether a valid key is in the ignition lock SENTRY KEY IMMOBILIZER SYSTEM cylinder.
Page 425 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS If any of the above steps is not completed in the SERVICE PROCEDURES proper sequence, or within the allotted time, the SKIS will automatically exit the “Customer Learn” SENTRY KEY IMMOBILIZER SYSTEM programming mode. The SKIS will also automatically TRANSPONDER PROGRAMMING exit the “Customer Learn”...
Page 426 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 REMOVAL AND INSTALLATION (Continued) Fig. 3 Sentry Key Immobilizer Module Remove/Install (4) If the vehicle is equipped with a standard non- on the connector end of the SKIM mounting bracket tilt steering column, loosen the two upper steering to release this clip from the steering column jacket.
Page 427 CHIME/BUZZER WARNING SYSTEMS 8U - 1 CHIME/BUZZER WARNING SYSTEMS CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 DRIVER DOOR JAMB SWITCH .
Page 428 8U - 2 CHIME/BUZZER WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) DRIVER SEAT BELT SWITCH BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The driver seat belt switch is integral to the driver seat belt buckle-half assembly. The switch is nor- (1) Rotate the headlamp switch knob counterclock- mally closed, providing a ground path to the instru- wise to ensure that the dome lamps are not switched ment panel chime warning circuitry.
Page 429 CHIME/BUZZER WARNING SYSTEMS 8U - 3 DIAGNOSIS AND TESTING (Continued) KEY-IN IGNITION SWITCH between the left front door jamb switch sense circuit cavity of the headlamp switch wire harness connector For circuit descriptions and diagrams, refer to and a good ground. There should be no continuity 8W-40 - Instrument Cluster or 8W-44 - Interior with the driver door closed, and continuity with the Lighting in Group 8W - Wiring Diagrams.
Page 430 8U - 4 CHIME/BUZZER WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) • Driver door jamb switch - refer to Group 8L - OK, go to Step 5. If not OK, repair the short circuit as required. Lamps • Driver seat belt switch - refer to Group 23 - (5) Check for continuity between the seat belt switch sense circuit cavities of the right instrument Body...
Page 431 WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page AIR CONDITIONING-HEATER ..8W-42-1 HORN/CIGAR LIGHTER/POWER OUTLET . 8W-41-1 AIRBAG SYSTEM ....8W-43-1 INSTRUMENT CLUSTER .
Page 432: Table Of Contents
8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION TROUBLESHOOTING TESTS ....9 CIRCUIT FUNCTIONS ..... 4 TROUBLESHOOTING TOOLS .
Page 433: Description And Operation
8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 434 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 435: Circuit Functions
8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) CIRCUIT INFORMATION CIRCUIT FUNCTIONS Each wire shown in the diagrams contains a code All circuits in the diagrams use an alpha/numeric which identifies the main circuit, part of the main code to identify the wire and its function.
Page 436 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) SECTION IDENTIFICATION SYMBOLS The wiring diagrams are grouped into individual International symbols are used throughout the wir- sections. If a component is most likely found in a par- ing diagrams.
Page 437 8W - 01 - 6 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Symbols...
Page 438: Connector Information
8W - 01 GENERAL INFORMATION 8W - 01 - 7 DESCRIPTION AND OPERATION (Continued) TERMINOLOGY This a list of terms with there definitions used in the wiring diagrams. Built-Up-Export ..Vehicles Built For Sale In Markets Other Than North America Except-Built-Up-Export .
Page 439: Electrostatic Discharge (Esd) Sensitive Devices
8W - 01 - 8 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) WARNING: BE SURE THAT THE IGNITION SWITCH (3) When using a voltmeter, be sure to connect the ALWAYS IS IN THE OFF POSITION, UNLESS THE ground lead first. (4) Do not remove the part from its protective PROCEDURE REQUIRES IT TO BE ON.
Page 440: Intermittent And Poor Connections
8W - 01 GENERAL INFORMATION 8W - 01 - 9 DIAGNOSIS AND TESTING (Continued) • Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested.
Page 441: Troubleshooting Wiring Problems
8W - 01 - 10 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) TESTING FOR A SHORT TO GROUND TROUBLESHOOTING WIRING PROBLEMS (1) Remove the fuse and disconnect all items When troubleshooting wiring problems there are involved with the fuse. six steps which can aid in the procedure.
Page 442: Terminal/Connector Repair-Thomas
8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) Fig. 11 Using Special Tool 6742 (2) Disconnect the connector from its mating half/ component. (3) Push in the two lock tabs on the side of the connector (Fig.
Page 443 8W - 01 - 12 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (4) Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig.
Page 444 8W - 01 GENERAL INFORMATION 8W - 01 - 13 SERVICE PROCEDURES (Continued) (3) Cut off the existing wire connector directly (3) Remove connector locking wedge, if required behind the insulator. Remove six inches of tape from (Fig. 19). the harness. (4) Stagger cut all wires on the harness side at 1/2 inch intervals (Fig.
Page 445 8W - 01 - 14 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) DIODE REPLACEMENT (1) Disconnect the battery. (2) Locate the diode in the harness, and remove the protective covering. (3) Remove the diode from the harness, pay atten- tion to the current flow direction (Fig.
Page 446: Special Tools
8W - 01 GENERAL INFORMATION 8W - 01 - 15 SPECIAL TOOLS WIRING/TERMINAL Terminal Removing Tool 6932 Probing Tool Package 6807 Terminal Removing Tool 6934 Terminal Pick 6680...
Page 447 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch ....8W-42 Fuel Pump Relay ..... . 8W-30 A/C Compressor Clutch Relay .
Page 448 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Rear Window Defogger ....8W-48 Tail/Stop Lamps ..... . . 8W-51 Rear Window Defogger Relay .
Page 449 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-16 Fuse 14 (PDC) ....8W-10-7, 17 A/C Compressor Clutch Relay .
Page 450 8W - 10 - 2 8W-10 POWER DISTRIBUTION POWER DISTRIBUTION CENTER ENGINE REAR STARTER WINDOW MOTOR DEFOGGER RELAY RELAY PUMP SYSTEM MOTOR RELAY RELAY FUEL COMPRESSOR PUMP CLUTCH RELAY RELAY AUTOMATIC SHUT HORN DOWN RELAY RELAY FUSES J998W-5 TJI01002...
Page 451 8W-10 POWER DISTRIBUTION 8W - 10 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT A2 12PK/BK A0 6RD A2 12PK/BK A1 14RD A0 6RD A6 12RD/BK A0 6RD F30 12RD/PK A0 6RD A14 14RD/WT A0 6RD A14 14RD/WT A0 6RD A0 6RD L9 16BK/WT...
Page 452 8W - 10 - 4 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION A10 12RD/DG FUSED B (+) Z1 14BK GROUND PUMP B47 14RD/LB ABS SYSTEM RELAY OUTPUT MOTOR RELAY B47 14RD/LB ABS SYSTEM RELAY OUTPUT B116 20GY ABS PUMP MOTOR RELAY CONTROL B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT CAVITY...
Page 453 8W-10 POWER DISTRIBUTION 8W - 10 - 5 CAVITY CIRCUIT FUNCTION A2 12PK/BK FUSED B (+) ENGINE STARTER T141 14YL/RD FUSED IGNITION SWITCH OUTPUT (ST) MOTOR RELAY T41 20BR/LB PARK/NEUTRAL POSITION SWITCH SENSE T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT CAVITY CIRCUIT FUNCTION...
Page 454 8W - 10 - 6 8W-10 POWER DISTRIBUTION S136 FUSIBLE LINK BK/GY BATTERY (8W-20-2) GENERATOR (8W-20-2) ENGINE STARTER MOTOR (8W-21-2) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-2) (8W-10-8) (8W-10-9) (8W-10-10) (8W-10-10) PK/BK C106 C106 ENGINE RD/PK STARTER PK/BK RD/BK MOTOR RELAY S332...
Page 455 8W-10 POWER DISTRIBUTION 8W - 10 - 7 POWER DISTRIBUTION FROM FUSE CENTER 11 (PDC) (8W-10-2) (8W-10-6) FUSE FUSE FUSE FUSE FUSE (8W-10-17) (8W-10-17) (8W-10-14) (8W-10-16) (8W-10-16) RD/GY RD/DG BK/PK RD/DB HORN HORN REAR COMPRESSOR RELAY RELAY PUMP WINDOW CLUTCH (IN PDC) (IN PDC) MOTOR...
Page 456 8W - 10 - 8 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) (8W-10-9) PK/BK PK/BK ENGINE C106 STARTER MOTOR RELAY PK/BK (IN PDC) (8W-21-2) IGNITION SWITCH 1 START 2 RUN 0 OFF C104 C104 3 LOCK 4 ACC (8W-10-9) ENGINE...
Page 457 8W-10 POWER DISTRIBUTION 8W - 10 - 9 PARK BATT A0 (8W-10-6) BRAKE POWER SWITCH DISTRIBUTION (8W-40-6) CENTER (8W-10-2) BRAKE FUSE WARNING INDICATOR GY/BK SWITCH (8W-40-6) C322 C322 BATT A2 GY/BK C106 (8W-10-8) C106 GY/BK PK/BK GY/BK IGNITION SWITCH 1 START 2 RUN 0 OFF 3 LOCK...
Page 458 8W - 10 - 10 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER (8W-10-2) FUSE FUSE RD/BK RD/PK C106 RD/PK S332 C106 RD/PK CIGAR LIGHTER/ ACCESSORY RELAY (8W-41-2) RD/BK WT/PK RD/PK FUSE BLOCK (8W-11-2) FUSE FUSE FUSE FUSE (8W-11-4) (8W-11-4) (8W-11-10) (8W-11-10)
Page 459 8W-10 POWER DISTRIBUTION 8W - 10 - 11 BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER (8W-10-2) FUSE AUTOMATIC SHUT DOWN FUSE FUSE RELAY (8W-30-2) A142 A142 A142 F142 RD/WT RD/WT DG/PK DG/PK DG/PK OR/DG DG/LG S101 C103 C104 C104 A142 RD/WT DG/PK POWERTRAIN DG/LG...
Page 460 8W - 10 - 12 8W-10 POWER DISTRIBUTION FROM C104 (8W-10-11) DG/LG S126 DG/LG DG/LG FUEL INJECTOR NO. 6 (4.0L) DG/LG (8W-30-6) DG/LG FUEL IGNITION INJECTOR COIL NO. 5 (2.5L) DG/LG (4.0L) (8W-30-4) (8W-30-6) FUEL INJECTOR NO. 4 (8W-30-5) (8W-30-6) DG/LG S128 FUEL...
Page 461 8W-10 POWER DISTRIBUTION 8W - 10 - 13 BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) A111 RD/LB BK/WT RD/WT C106 A111 RD/LB C202 C108 C170 A111 RD/LB HVAC UNIT (8W-42-2) BK/WT RD/WT (8W-42-3) TURN HEADLAMP SIGNAL/ SWITCH HAZARD (8W-50-2) (8W-50-5)
Page 462 8W - 10 - 14 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) BK/PK DG/BK FUEL REAR PUMP WINDOW RELAY DEFOGGER (IN PDC) RELAY (8W-30-3) (IN PDC) A141 (8W-48-2) DG/WT BK/WT C103 C106 A141 DG/WT BK/WT S320 FUEL PUMP...
Page 463 8W-10 POWER DISTRIBUTION 8W - 10 - 15 BATT A0 (8W-10-6) INSTRUMENT POWER CLUSTER DISTRIBUTION (8W-40-2) CENTER FUSE (8W-10-2) LEFT COURTESY LAMP (8W-44-4) DATA LINK PK/WT CONNECTOR (8W-30-13) C108 C203 PK/WT PK/WT PK/WT PK/WT UNDERHOOD PK/WT LAMP S204 (8W-44-3) PK/WT PK/WT PK/WT HARD TOP...
Page 464 8W - 10 - 16 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER (8W-10-2) FUSE FUSE FUSE RD/GY WT/OR C108 COMPRESSOR CLUTCH RELAY WT/OR (IN PDC) (8W-42-4) DB/BK HORN RELAY LAMP C103 (IN PDC) RELAY (8W-41-3) NO. 1 (8W-50-7) DB/BK WT/RD C107...
Page 465 8W-10 POWER DISTRIBUTION 8W - 10 - 17 DIODE (8W-35-3) S146 RD/YL BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE (8W-10-2) FUSE FUSE RD/LB RD/DG RD/DB SYSTEM PUMP RELAY MOTOR (PDC) RELAY (8W-35-2) (PDC) (8W-35-2) B120 RD/LB RD/LB BR/WT RD/YL S114 S110 B120 B120...
Page 466 8W - 11 FUSE/FUSE BLOCK 8W - 11 - 1 8W-11 FUSE/FUSE BLOCK Component Page Component Page A/C Compressor Clutch Relay ... 8W-11-7 Fuse 14 (FB) ......8W-11-9 A/C Heater Control .
Page 467 8W - 11 - 2 8W-11 FUSE/FUSE BLOCK FRONT OF FUSE BLOCK FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE FUSE J998W-5 TJI01102...
Page 468 8W-11 FUSE/FUSE BLOCK 8W - 11 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT F34 18TN/BK A6 12RD/BK F32 18PK/DB E2 20OR E1 18TN E2 20OR Z1 20BK M23 20YL/BK Z1 20BK M23 20YL/BK F23 18DB/YL V23 18BR/PK A22 12BK/OR F20 20VT/WT F24 20RD/DG...
Page 469 8W - 11 - 4 8W-11 FUSE/FUSE BLOCK HEADLAMP SWITCH (8W-50-2) C202 BATT A6 (8W-10-10) FUSE BLOCK (8W-11-2) FUSE FUSE FUSE TN/BK PK/DB BRAKE PRNDL C202 LAMP LAMP SWITCH (8W-44-5) TN/BK (8W-51-6) TN/BK FRONT HEADLAMP SENTRY C202 SWITCH LAMP (8W-50-2) IMMOBILIZER SWITCH (8W-50-4)
Page 470 8W-11 FUSE/FUSE BLOCK 8W - 11 - 5 DRIVER PASSENGER DOOR DOOR AJAR AJAR SWITCH SWITCH (8W-44-4) (8W-44-4) YL/BK YL/BK FUSE BLOCK (8W-11-2) FUSE LAMP RELAY NO. 1 (EXCEPT BUILT- UP-EXPORT) (8W-50-7) REAR LAMP RELAY LAMP (BUILT-UP RELAY -EXPORT) NO. 2 (8W-51-7) (EXCEPT BUILT- (8W-51-8)
Page 471 8W - 11 - 6 8W-11 FUSE/FUSE BLOCK RUN A22 (8W-10-8) FUSE BLOCK (8W-11-2) FUSE FUSE DB/YL BR/PK SOFT TOP SOFT TOP HARD TOP BR/PK BR/PK BR/PK C323 C323 C323 C323 USED USED BR/PK C326 AIRBAG C331 CONTROL S401 MODULE (8W-43-2) C331 BR/PK...
Page 472 8W-11 FUSE/FUSE BLOCK 8W - 11 - 7 RUN A22 (8W-10-8) FUSE BLOCK (8W-11-2) FUSE FUSE VT/WT RD/DG C106 C202 VT/WT RD/DG RD/DG F24 20RD/DG HVAC A/C- UNIT HEATER (8W-42-2) CONTROL (8W-42-3) (8W-42-2) (8W-42-3) S108 VT/WT VT/WT VT/WT VT/WT VT/WT C104 SYSTEM RELAY...
Page 473 8W - 11 - 8 8W-11 FUSE/FUSE BLOCK ST-RUN A21 (8W-10-9) FUSE BLOCK (8W-11-2) FUSE FUSE FUSE FUSE RD/LG DB/WT LG/YL DB/WT C202 C106 SENTRY BRAKE C106 SHIFT IMMOBILIZER INTERLOCK MODULE LG/YL DB/WT SOLENOID (8W-30-14) (8W-31-2) S131 INSTRUMENT CLUSTER (8W-40-2) RD/LG S102 RD/LG...
Page 474 8W-11 FUSE/FUSE BLOCK 8W - 11 - 9 BATT A4 (8W-10-14) REAR WINDOW DEFOGGER RELAY (IN PDC) C106 (8W-48-2) BK/WT BK/WT S320 (8W-10-14) BK/WT RUN-ACC A31 ST A41 (8W-10-9) (8W-10-8) FUSE BLOCK (8W-11-2) FUSE FUSE FUSE FUSE FUSE (A/T) C202 T141 PK/BK YL/RD...
Page 475 8W - 11 - 10 8W-11 FUSE/FUSE BLOCK BATT A3 (8W-10-13) BATT F30 (8W-10-10) HEADLAMP CIGAR CIRCUIT SWITCH LIGHTER/ BREAKER 0 OFF ACCESSORY 1 PARK RELAY 2 HEAD (8W-41-2) (8W-50-2) WT/PK C202 L2 14LG HEADLAMP DIMMER SWITCH (8W-50-2) BATT F30 (8W-10-10) FUSE BLOCK...
Page 476 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-6 Ignition Switch ....8W-15-9, 10 A/C Heater Control .
Page 477 8W - 15 - 2 8W-15 GROUND DISTRIBUTION VEHICLE SPEED CONTROL DAYTIME UNDERHOOD SERVO RUNNING LAMP (8W-30-16) LAMP (8W-44-3) MODULE (8W-50-8) PUMP MOTOR (8W-35-2) PUMP MOTOR RELAY (IN PDC) (8W-35-2) SYSTEM RELAY (IN PDC) (8W-35-2) OTHER BASE S106 CONTROLLER ANTI-LOCK BRAKE (8W-35-3) G100...
Page 478 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 LEFT LEFT LEFT LEFT REPEATER FRONT FRONT LAMP LAMP PARK/ TURN (8W-50-7) (BUILT- TURN SIGNAL UP-EXPORT) SIGNAL LAMP (8W-52-3) LAMP (8W-52-3) LEFT (8W-50-4) (8W-52-3) FRONT PARK/ TURN FRONT FOG BUILT-UP- LAMPS EXPORT SIGNAL LAMP (EXCEPT...
Page 479 8W - 15 - 4 8W-15 GROUND DISTRIBUTION EXCEPT BUILT-UP-EXPORT RIGHT RIGHT GENERATOR FRONT (8W-20-2) LAMP PARK/ (8W-50-7) TURN SIGNAL LAMP (FRONT FOG LAMPS) (8W-50-4) (8W-52-3) S125 G104 RIGHT RIGHT FRONT HEADLAMP PARK/ (8W-50-2) TURN SIGNAL LAMP (EXCEPT FRONT FOG LAMPS) (8W-50-4) (8W-52-3) G103...
Page 480 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 BUILT-UP-EXPORT RIGHT RIGHT GENERATOR FRONT (8W-20-2) REPEATER TURN LAMP SIGNAL (8W-52-3) LAMP (8W-52-3) S125 G104 RIGHT RIGHT CITY HEADLAMP LAMP (8W-50-2) (8W-50-4) RIGHT HEADLAMP LEVELING MOTOR (8W-50-5) S150 G103 TJI01505 J998W-5...
Page 481 8W - 15 - 6 8W-15 GROUND DISTRIBUTION ENGINE STARTER MOTOR SENTRY RELAY (IN PDC) IMMOBILIZER (8W-21-2) MODULE POWERTRAIN (8W-30-14) C104 CONTROL MODULE DATA LINK BR/LB (8W-30-12) CONNECTOR BR/LB (8W-30-13) BK/LB C154 BR/LB MANUAL S134 TRANSMISSION BK/LB BK/TN JUMPER C202 C204 POWERTRAIN USED...
Page 482 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 REAR A/C- HEADLAMP REAR WIPER/ HEATER LEVELING WINDOW WASHER CONTROL SWITCH DEFOGGER SWITCH (8W-42-2) SWITCH (BUILT-UP (HARD TOP) (8W-42-3) (HARD -EXPORT) (8W-53-4) TOP) (8W-50-5) (8W-48-2) REAR CIGAR FRONT LIGHTER/ LAMP POWER LAMP SWITCH OUTLET SWITCH...
Page 483 8W - 15 - 8 8W-15 GROUND DISTRIBUTION REAR A/C- HEADLAMP REAR WIPER/ HEATER WINDOW SWITCH WASHER CONTROL DEFOGGER (8W-50-3) SWITCH (8W-42-2) SWITCH (HARD TOP) (8W-42-3) (HARD (8W-53-4) TOP) (8W-48-2) REAR CIGAR LIGHTER/ LAMP POWER SWITCH OUTLET (8W-41-2) (8W-51-7) (8W-51-8) BK/WT G202 S207...
Page 484 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 DRIVER PASSENGER LAMP DOOR DOOR RELAY AJAR AJAR NO. 1 SWITCH SWITCH (EXCEPT BUILT- (8W-44-4) (8W-44-4) UP-EXPORT) (8W-50-7) REAR LAMP YL/BK YL/BK RELAY LAMP NO. 2 RELAY (EXCEPT BUILT (BUILT-UP FUSE -UP-EXPORT) -EXPORT) BLOCK (8W-50-6)
Page 485 8W - 15 - 10 8W-15 GROUND DISTRIBUTION WINDSHIELD PASSENGER DRIVER WIPER DOOR DOOR SWITCH AJAR AJAR (8W-53-3) SWITCH SWITCH (8W-44-4) (8W-44-4) WINDSHIELD REAR WIPER MOTOR LAMP YL/BK YL/BK (8W-53-2) RELAY (8W-53-3) (8W-51-8) IGNITION FUSE SWITCH BLOCK (8W-10-9) (8W-11-2) FUSE (8W-11-5) PRNDL COMBINATION...
Page 486 8W-15 GROUND DISTRIBUTION 8W - 15 - 11 REAR REAR WIPER WINDOW MOTOR DEFOGGER (8W-53-4) (8W-48-2) S400 (HARD TOP) REAR LEFT RIGHT LICENSE LICENSE LAMP LAMP LAMP (8W-51-7) (8W-51-7) (8W-51-7) (8W-51-8) (8W-51-8) (8W-51-8) C331 S316 (BUILT-UP -EXPORT) CENTER SEAT REAR HIGH BELT WASHER...
Page 487 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... . 8W-20-2 G104 ......8W-20-2 Battery .
Page 488 8W - 20 - 2 8W-20 CHARGING SYSTEM ST-RUN A21 (8W-10-9) FUSIBLE LINK FUSE POWER BLOCK DISTRIBUTION (8W-11-2) FUSE CENTER FUSE (8W-10-2) (8W-11-8) (8W-10-11) BATTERY S136 C106 SENTRY RD/WT IMMOBILIZER MODULE BK/GY (8W-30-14) ENGINE B (+) S131 STARTER (8W-11-8) MOTOR (8W-21-2) AUTOMATIC SHUT...
Page 489 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 Fuse Block .
Page 490 8W - 21 - 2 8W-21 STARTING SYSTEM BATT A1 (8W-10-8) POWER IGNITION DISTRIBUTION SWITCH CENTER FUSE 1 START (8W-10-2) 2 RUN 0 OFF (8W-10-8) 3 LOCK 4 ACC (8W-10-9) PK/BK S331 C106 PK/BK CLUTCH PK/BK CLUTCH FUSE PEDAL PEDAL BLOCK POSITION POSITION...
Page 491 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEMS Component Page Component Page A/C Compressor Clutch Relay ... 8W-30-3 Fuse Block ....8W-30-2, 3, 11, 14 A/C Heater Control .
Page 492 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 BATT A0 (8W-10-9) (8W-10-6) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-2) (8W-11-8) (8W-10-11) C106 SENTRY FUSED IGNITION RD/WT RD/WT SWITCH IMMOBILIZER OUTPUT MODULE (ST-RUN) (8W-30-14) S131 (8W-11-8) C103 AUTOMATIC SHUT DOWN...
Page 493 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 ST-RUN A21 BATT A0 (8W-10-9) (8W-10-6) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-2) (8W-11-8) (8W-10-14) C106 S131 SENTRY FUSED (8W-11-8) IGNITION SWITCH IMMOBILIZER OUTPUT MODULE (ST-RUN) DG/BK (8W-30-14) FUEL PUMP RELAY (IN PDC) A141...
Page 494 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM BATT A14 (8W-10-11) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE (8W-10-2) DOWN RELAY (8W-30-2) (8W-10-11) A142 A142 DG/LG DG/PK DG/PK S129 (8W-70-4) S101 (8W-10-11) C104 C104 CRANKSHAFT POSITION SUPPLY SENSOR S126 CRANKSHAFT (8W-10-12) POSITION SENSOR SENSOR...
Page 495 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 2.5L BATT A14 (8W-10-11) POWER DISTRIBUTION CENTER AUTOMATIC SHUT (8W-10-2) FUSE DOWN RELAY (8W-30-2) (8W-10-11) A142 A142 DG/PK DG/PK DG/LG S101 (8W-10-11) C104 C104 DG/LG S126 (8W-10-12) DG/LG S128 (8W-10-12) DG/LG DG/LG DG/LG DG/LG FUEL...
Page 496 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM 4.0L BATT A14 (8W-10-11) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE (8W-10-2) DOWN RELAY (8W-30-2) (8W-10-11) A142 A142 DG/LG DG/PK DG/PK S101 (8W-10-11) C104 C104 DG/LG S126 (8W-10-12) DG/LG DG/LG DG/LG DG/LG S128 (8W-10-12) DG/LG DG/LG...
Page 497 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 2.5L S129 (8W-70-4) MANIFOLD ABSOLUTE PRESSURE SENSOR K167 BR/YL S127 (8W-70-3) K167 K167 K167 BR/YL BR/YL BR/YL K167 BR/YL ENGINE COOLANT ENGINE TEMPERATURE SENSOR PRESSURE SENSOR INTAKE TEMPERATURE VT/OR SENSOR S123 S133 (8W-70-4) (8W-70-3) K167...
Page 498 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM 4.0L S129 (8W-70-4) MANIFOLD ABSOLUTE PRESSURE SENSOR K167 BR/YL S127 (8W-70-3) K167 K167 K167 BR/YL BR/YL BR/YL S133 (8W-70-3) K167 BR/YL ENGINE COOLANT TEMPERATURE SENSOR INTAKE ENGINE TEMPERATURE PRESSURE SENSOR SENSOR VT/OR S123 (8W-70-4) K167...
Page 499 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 BATT A14 (8W-10-11) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE DOWN (8W-10-2) RELAY (8W-30-2) (8W-10-11) F142 A142 A142 OR/DG DG/PK DG/PK LEAK OTHER DETECTION S101 (8W-10-11) S107 (8W-10-11) F142 F142 OR/DG OR/DG C180 C103 LEAK S124...
Page 500 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM VEHICLE SPEED VEHICLE SENSOR SPEED SENSOR SENSOR SIGNAL S129 GROUND SUPPLY (8W-70-4) THROTTLE K167 POSITION SENSOR BR/YL K167 BR/YL VT/OR WT/OR S127 (8W-70-3) K167 BR/YL S133 (8W-70-3) C103 S123 S135 (8W-70-4) K167 BR/YL S147 WT/OR...
Page 501 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 FROM ST-RUN A21 (8W-10-9) S101 FUSE (8W-10-11) BLOCK (8W-11-2) FUSE POWER DISTRIBUTION CENTER (8W-11-8) FUSE (8W-10-2) (8W-10-11) RD/LG F142 C106 OR/DG S102 S107 (8W-11-8) (8W-10-11) C180 RD/LG F142 RD/LG C103 OR/DG C110 LEAK FUSED DETECTION...
Page 502 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM A/C- C21 20 DB/OR GENERATOR HEATER GENERATOR (8W-20-2) CONTROL VOLTAGE FIELD SELECT DRIVER REGULATOR (8W-42-3) INPUT HIGH SIGNAL PRESSURE PRESSURE SWITCH SWITCH C170 DB/WT C104 DG/OR C103 DB/WT S103 (8W-42-4) DG/OR POWERTRAIN VOLTAGE GENERATOR CONTROL...
Page 503 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-15) PK/WT PK/WT C108 HARD SOFT PK/WT C203 UNDERHOOD FUSED DOME SOUND LAMP B(+) LAMP S204 (8W-44-3) DOME (8W-10-15) SOUND LAMP (8W-44-2) PK/WT DOME LAMP DATA (8W-44-2)
Page 504 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM BATT A6 ST-RUN A21 (8W-10-9) (8W-10-10) INSTRUMENT CLUSTER FUSE (8W-40-3) BLOCK (8W-40-4) (8W-11-2) FUSE FUSE (8W-40-5) (8W-40-7) (8W-11-4) (8W-11-8) TN/BK C202 WT/BK VT/BR DATA TWISTED LINK PAIR CONNECTOR TN/BK (8W-30-13) HEADLAMP FUSED DATA SWITCH B(+)
Page 505 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15 POWERTRAIN CONTROL SPEED MODULE CONTROL SENSOR SWITCH GROUND SIGNAL POWER BATTERY K167 DISTRIBUTION HORN TEMPERATURE CENTER RELAY BR/YL SENSOR (8W-41-3) SENSOR (8W-10-2) (8W-30-10) S133 RETURN (8W-70-3) K167 BR/YL K167 K167 C103 BR/YL BR/YL RD/YL RD/LG...
Page 506 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM POWERTRAIN CONTROL SPEED SPEED SPEED CONTROL CONTROL CONTROL MODULE ON/OFF BRAKE VACUUM VENT SWITCH SWITCH SOLENOID SOLENOID SENSE SENSE CONTROL CONTROL BRAKE SHIFT BRAKE INTERLOCK YL/RD WT/PK SWITCH SOLENOID SENSE (8W-31-2) TN/RD LG/RD C108 WT/PK...
Page 507 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Brake Lamp Switch ....8W-31-2 G105 .
Page 508 8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM ST-RUN A21 (8W-10-9) FUSE BLOCK (8W-11-2) FUSE FUSE (8W-11-8) (8W-11-8) G5 20DB/WT C202 RD/LG DB/WT C106 DB/WT BRAKE INSTRUMENT RD/LG SHIFT CLUSTER INTERLOCK (8W-40-5) SOLENOID INDICATOR S102 (8W-11-8) G107 WT/PK RD/LG BK/RD C103 C108...
Page 509 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES Component Page Component Page ABS Diode ......8W-35-3 Fuse 21 (PDC) .
Page 510 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES FROM RUN A22 (8W-10-8) S146 FUSE (8W-35-3) BLOCK (8W-11-2) FUSE (8W-11-7) RD/YL BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER VT/WT (8W-10-2) FUSE C106 (8W-10-17) VT/WT S108 FUSE FUSE (8W-11-7) (8W-10-17) (8W-10-17) VT/WT RD/DB RD/LB RD/DG SYSTEM...
Page 511 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 RUN A22 ST-RUN A21 (8W-10-8) (8W-10-9) FUSE BLOCK (8W-11-2) FUSE FUSE (8W-11-7) (8W-11-8) VT/WT DB/WT C202 DB/WT C106 INSTRUMENT CLUSTER (8W-40-6) WARNING INDICATOR VT/WT C203 BRAKE FUSED SHIFT IGNITION C108 SWITCH INTERLOCK S108 OUTPUT SOLENOID...
Page 512 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES FROM FROM S114 S114 (8W-35-2) (8W-35-2) RD/LB RD/LB HYDRAULIC CONTROL UNIT B251 B254 B243 B245 B248 B249 WT/BK DG/OR DG/BK WT/LG DG/WT WT/DG CONTROLLER REAR REAR LEFT LEFT RIGHT RIGHT ANTI-LOCK INLET OUTLET FRONT FRONT...
Page 513 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5 BATT A6 (8W-10-10) FUSE BLOCK (8W-11-2) FUSE (8W-11-4) PK/DB BRAKE LAMP SWITCH DATA (8W-51-6) LINK CONNECTOR (8W-30-13) WT/TN POWERTRAIN CONTROL MODULE C203 (8W-30-13) C108 TRANSMIT G SWITCH C107 WT/TN PK/OR YL/VT TN/WT CONTROLLER BRAKE G-SWITCH...
Page 514 8W - 35 - 6 8W-35 ANTI-LOCK BRAKES LEFT RIGHT REAR FRONT WHEEL WHEEL SPEED SPEED SENSOR SENSOR LEFT RIGHT FRONT REAR WHEEL WHEEL SPEED SPEED SENSOR SENSOR LG/DB WT/DB RD/DB YL/DB C103 C104 C104 LG/DB WT/DB YL/DB CONTROLLER LEFT LEFT LEFT LEFT...
Page 515 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page ABS Diode ......8W-40-6 Headlamp Switch .
Page 516 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER BATT A0 ST-RUN A21 (8W-10-6) (8W-10-9) POWER FUSE DISTRIBUTION BLOCK CENTER (8W-11-2) FUSE FUSE (8W-10-2) (8W-10-15) (8W-11-8) PK/WT DB/WT C108 PK/WT HARD SOFT C202 UNDERHOOD FUSED LAMP B (+) (8W-44-3) PK/WT PK/WT PK/WT DB/WT DOME...
Page 517 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 BATT M1 ST-RUN G5 (8W-10-15) (8W-11-8) INSTRUMENT CLUSTER VOLT METER SPEEDOMETER PRESSURE GAUGE FUSED VOLT FUSED SPEEDOMETER B(+) METER IGNITION CONTROL PRESSURE CONTROL SWITCH GAUGE OUTPUT CONTROL (ST-RUN) ENGINE FUEL COOLANT GAUGE TEMPERATURE TACHOMETER CONTROL...
Page 518 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER BATT M1 ST-RUN G5 (8W-10-15) (8W-11-8) INSTRUMENT CLUSTER AIRBAG CHECK CHECK WARNING FUEL ENGINE GAUGES INDICATOR INDICATOR INDICATOR INDICATOR FUSED AIRBAG FUSED CHECK CHECK B(+) WARNING IGNITION FUEL ENGINE GAUGES INDICATOR SWITCH INDICATOR INDICATOR INDICATOR...
Page 519 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 BATT M1 ST-RUN G5 (8W-10-15) (8W-11-8) INSTRUMENT CLUSTER SENTRY SEAT UPSHIFT BELT INDICATOR INDICATOR IMMOBILIZER WARNING (M/T) MODULE INDICATOR INDICATOR FUSED SENTRY FUSED SEAT UPSHIFT B(+) IGNITION BELT INDICATOR IMMOBILIZER SWITCH WARNING DRIVER MODULE OUTPUT...
Page 520 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER ST-RUN G5 BATT M1 (8W-11-8) (8W-10-15) INSTRUMENT CLUSTER FUSED FUSED BRAKE IGNITION B(+) WARNING WARNING SWITCH INDICATOR INDICATOR OUTPUT (ST-RUN) GROUND GY/WT LG/OR BK/LG BK/LG C203 C170 OTHERS G201 (8W-15-7) C108 (8W-15-8) GY/WT BRAKE LG/OR...
Page 521 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7 BATT M1 ST-RUN G5 (8W-10-15) (8W-11-8) INSTRUMENT CLUSTER FUSED FUSED B(+) IGNITION SWITCH KEY-IN OUTPUT IGNITION (ST-RUN) SWITCH GROUND SENSE G26 20LB BK/LG BK/LG G26 20 LB VT/BR WT/BK C203 G201 HEADLAMP (8W-15-7) SWITCH (8W-15-8)
Page 522 8W - 40 - 8 8W-40 INSTRUMENT CLUSTER BATT F34 (8W-11-4) HEADLAMP SWITCH 0 HEAD 1 PARK 2 HEAD 3 DOME 4 MAX 5 MIN (8W-50-2) RUN F20 (8W-11-7) REAR C202 WINDOW DEFOGGER FUSE RELAY BLOCK (IN PDC) FUSE (8W-11-2) (8W-48-2) (8W-11-4) LB/WT...
Page 523 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9 HEADLAMP DIMMER DIMMER SWITCH SWITCH HIGH TURN (8W-50-2) BEAM SIGNAL/ OUTPUT HAZARD SWITCH LEFT RIGHT (8W-52-3) TURN TURN RD/OR SIGNAL SIGNAL C107 RD/OR S105 (8W-50-2) OTHER RD/OR RD/OR C203 C203 RD/GY DAYTIME HIGH DIMMER RUNNING...
Page 524 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Brake Lamp Switch ....8W-41-2 G200 .
Page 525 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET BATT A0 (8W-10-6) BRAKE LAMP POWER SWITCH DISTRIBUTION (8W-51-6) CENTER GROUND FUSE (8W-10-2) BATT A1 (8W-10-9) IGNITION (8W-10-10) SWITCH 1 START 2 RUN 0 OFF 3 LOCK RD/PK 4 ACC (8W-10-9) C106 S332 S307...
Page 526 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-16) HORN RELAY (IN PDC) WT/RD RD/YL C110 WT/RD BUILT- EXCEPT BUILT- C107 UP-EXPORT UP-EXPORT S115 RD/YL WT/RD WT/RD HIGH NOTE NOTE HORN HORN CLOCKSPRING (8W-30-15)
Page 527 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-4 Fuse 11 (PDC) ..... 8W-42-2, 3 A/C Compressor Clutch Relay .
Page 528 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER HEATER ONLY RUN A22 BATT A0 (8W-10-8) (8W-10-6) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-2) (8W-11-7) (8W-10-13) A111 RD/LB RD/DG C106 C202 F24 20RD/DG A111 RD/DG RD/DG RD/LB HVAC UNIT BLOWER BLOWER MOTOR...
Page 529 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 RUN A22 BATT A0 (8W-10-8) (8W-10-6) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-2) (8W-11-7) (8W-10-13) A111 RD/DG RD/LB C106 C202 F24 20RD/DG A111 RD/DG RD/DG RD/LB HVAC UNIT BLOWER BLOWER MOTOR M MOTOR RELAY...
Page 530 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER POWERTRAIN CONTROL MODULE COMPRESSOR CLUTCH (8W-30-3) SWITCH SELECT RELAY (8W-30-12) SENSE INPUT CONTROL RUN A22 (8W-10-9) FUSE BLOCK DB/WT DB/OR (8W-11-2) FUSE C104 (8W-11-7) DB/WT BATT A0 (8W-10-6) PRESSURE VT/WT SWITCH POWER C106 DISTRIBUTION CENTER...
Page 531 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ....8W-43-2, 3 Fuse 9 (FB) ......8W-43-2 Airbag Warning Indicator .
Page 532 8W - 43 - 2 8W-43 AIRBAG SYSTEM ST-RUN A21 RUN A22 (8W-10-9) (8W-10-8) FUSE BLOCK (8W-11-2) FUSE FUSE (8W-11-8) (8W-11-6) LG/YL DB/YL AIRBAG FUSED FUSED CONTROL IGNITION IGNITION SWITCH SWITCH MODULE OUTPUT OUTPUT (ST-RUN) (RUN) LG/YL PASSENGER PASSENGER DRIVER DRIVER AIRBAG SQUIB AIRBAG SQUIB...
Page 533 8W-43 AIRBAG SYSTEM 8W - 43 - 3 ST-RUN A21 (8W-10-9) FUSE AIRBAG BLOCK CONTROL (8W-11-2) MODULE FUSE (8W-11-8) DB/WT WT/BK VT/BR DB/WT C202 TWISTED PAIR BRAKE FUSED SHIFT IGNITION SWITCH INTERLOCK DB/WT OUTPUT SOLENOID (ST-RUN) S303 S302 (8W-31-2) (8W-30-14) (8W-30-14) INSTRUMENT CLUSTER...
Page 534 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C Heater Control ....8W-44-5 Key-In Switch .
Page 535 8W - 44 - 2 8W-44 INTERIOR LIGHTING BATT A0 (8W-10-6) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-15) PK/WT HARD SOFT PK/WT 4 SPEAKER LHD 2 RHD 2 SYSTEM SPEAKER SYSTEM SPEAKER SYSTEM C323 C323 C108 PK/WT PK/WT PK/WT PK/WT PK/WT PK/WT 2 SPEAKER 4 SPEAKER...
Page 536 8W-44 INTERIOR LIGHTING 8W - 44 - 3 FROM C108 (8W-44-2) PK/WT UNDERHOOD LAMP MERCURY SWITCH BASE OTHER S106 (8W-15-2) G100 G100 (8W-15-2) (8W-15-2) TJI04403 J998W-5...
Page 537 8W - 44 - 4 8W-44 INTERIOR LIGHTING BATT A0 (8W-10-6) UNDERHOOD INSTRUMENT POWER LAMP CLUSTER KEY-IN DISTRIBUTION (8W-44-3) (8W-40-7) IGNITION FUSED CENTER FUSE SWITCH B (+) (8W-10-2) SENSE (8W-10-15) G26 20LB PK/WT PK/WT G26 20LB C108 C203 HEADLAMP C203 SWITCH S204 HARD...
Page 538 8W-44 INTERIOR LIGHTING 8W - 44 - 5 BATT F34 (8W-11-4) HEADLAMP SWITCH 0 OFF S206 1 PARK (8W-11-4) 2 HEAD 3 DOME 4 MAX 5 MIN (8W-50-2) C202 FUSE BLOCK FRONT FUSE (8W-11-2) LAMP (8W-11-4) SWITCH (EXCEPT BUILT-UP -EXPORT) (8W-50-7) REAR A/C-...
Page 539 8W - 44 - 6 8W-44 INTERIOR LIGHTING BATT F34 (8W-11-4) HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 3 DOME 4 MAX 5 MIN (8W-50-2) C202 FUSE BLOCK FUSE (8W-11-2) (8W-11-4) C202 PRNDL LAMP (8W-44-5) S206 (8W-11-4) INSTRUMENT CLUSTER (8W-40-8) RADIO (8W-47-2)
Page 540 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Fuse 3 (FB) ......8W-47-2 Power Distribution Center .
Page 541 8W - 47 - 2 8W-47 AUDIO SYSTEM RUN-ACC A31 BATT A0 (8W-10-9) (8W-10-6) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE FUSE (8W-10-2) (8W-11-9) (8W-11-4) (8W-10-15) PK/WT C204 C108 C202 PK/WT PK/WT PK/WT HARD SOFT BATT F34 (8W-11-4) HEADLAMP UNDERHOOD SWITCH LAMP...
Page 542 8W-47 AUDIO SYSTEM 8W - 47 - 3 LEFT RIGHT REAR REAR SPEAKER SPEAKER (SOUND (SOUND LEFT RIGHT BAR) BAR) FRONT FRONT SPEAKER SPEAKER BR/LB BR/YL DB/PK DB/WT C330 BR/LB BR/YL DB/PK DB/WT C325 DB/PK DB/WT C323 C323 BR/LB BR/YL C323 C323 BR/LB...
Page 543 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Fuse 7 (FB) ......8W-48-2 Indicator Lamp .
Page 544 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER BATT A0 RUN A22 (8W-10-6) (8W-10-8) POWER FUSE DISTRIBUTION BLOCK CENTER (8W-11-2) FUSE FUSE (8W-10-2) (8W-10-14) (8W-11-7) F20 20VT/WT C106 BK/PK S108 (8W-11-7) REAR WINDOW DEFOGGER RELAY (PDC) BK/WT C106 S320 C323 C323 BK/WT...
Page 545 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Circuit Breaker ....8W-50-2, 5 Instrument Cluster .
Page 546 8W - 50 - 2 8W-50 FRONT LIGHTING DAYTIME BATT F34 BATT A3 (8W-11-4) (8W-10-13) RUNNING FUSED HEADLAMP LAMP B(+) CIRCUIT SWITCH MODULE OPTICAL BREAKER 0 OFF HORN (8W-50-8) 1 PARK FEED 2 HEAD 3 DOME 4 MAX 5 MIN LG/WT C108 LG/WT...
Page 547 8W-50 FRONT LIGHTING 8W - 50 - 3 INSTRUMENT KEY-IN CLUSTER IGNITION (8W-40-7) SWITCH SENSE FROM S202 C203 (8W-44-4) HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 3 DOME BK/LB C203 S207 (8W-15-8) BK/LB DRIVER DRIVER DOOR DOOR AJAR AJAR SWITCH SWITCH BK/LB...
Page 548 8W - 50 - 4 8W-50 FRONT LIGHTING INSTRUMENT TURN BATT F34 (8W-11-4) CLUSTER SIGNAL/ HEADLAMP (8W-40-9) RIGHT LEFT HAZARD TURN SWITCH TURN SWITCH TURN SIGNAL SIGNAL 1 PARK (8W-52-3) SIGNAL/ 2 HEAD LEFT HAZARD 3 OFF TURN SWITCH SIGNAL (8W-52-3) INSTRUMENT CLUSTER...
Page 549 8W-50 FRONT LIGHTING 8W - 50 - 5 BUILT-UP-EXPORT BATT A3 (8W-10-13) HEADLAMP CIRCUIT SWITCH BREAKER 0 OFF FUSE 1 PARK BLOCK 2 HEAD FUSE (8W-11-2) (8W-11-10) LG/DG C202 S330 (8W-11-10) LG/DG L22 20LG/DG C108 HEADLAMP HEADLAMP C204 DIMMER SWITCH OUTPUT SWITCH LG/DG...
Page 550 8W - 50 - 6 8W-50 FRONT LIGHTING FOG LAMPS HEADLAMP DIMMER DIMMER SWITCH HIGH BATT F34 SWITCH (8W-11-4) BEAM (8W-50-2) HEADLAMP OUTPUT SWITCH 0 OFF 1 PARK 2 HEAD RD/OR 3 DOME 4 MAX C107 5 MIN (8W-50-2) RD/OR S105 (8W-50-2) BK/YL...
Page 551 8W-50 FRONT LIGHTING 8W - 50 - 7 FOG LAMPS FROM FROM C202 C204 (8W-50-6) (8W-50-6) BATT A6 (8W-10-10) POWER FROM DISTRIBUTION CENTER LAMP (8W-10-2) RELAY FUSE DG/YL NO. 2 S206 (8W-50-6) (8W-11-4) (8W-10-16) FRONT LAMP SWITCH WT/OR C108 C203 WT/OR BR/WT S207...
Page 552 8W - 50 - 8 8W-50 FRONT LIGHTING VEHICLE ST-RUN A21 (8W-10-9) VEHICLE SPEED SPEED FUSE SENSOR SENSOR BLOCK (8W-30-10) SIGNAL (8W-11-2) FUSE HEADLAMP FUSED SWITCH B(+) (8W-50-2) OPTICAL (8W-11-8) WT/OR HORN FEED S135 RD/LG LG/WT WT/OR WT/OR C106 C202 L20 14LG/WT POWERTRAIN C103...
Page 553 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamps ....8W-51-2, 3 G302 .
Page 554 8W - 51 - 2 8W-51 REAR LIGHTING EXCEPT BUILT-UP-EXPORT RUN A22 BATT F34 (8W-10-8) (8W-11-4) FUSE HEADLAMP BLOCK SWITCH (8W-11-2) 0 OFF FUSE 1 PARK 2 HEAD (8W-50-4) (8W-11-7) TURN SIGNAL/ LEFT RIGHT HAZARD TURN TURN VT/WT SWITCH SIGNAL SIGNAL BK/YL C106...
Page 555 8W-51 REAR LIGHTING 8W - 51 - 3 BUILT-UP-EXPORT RUN A22 BATT F34 (8W-10-8) (8W-11-4) FUSE HEADLAMP BLOCK SWITCH (8W-11-2) 0 OFF FUSE 1 PARK 2 HEAD (8W-11-7) (8W-50-4) TURN C106 SIGNAL/ S108 LEFT RIGHT HAZARD BK/YL TURN TURN (8W-11-7) SWITCH SIGNAL SIGNAL...
Page 556 8W - 51 - 4 8W-51 REAR LIGHTING BATT A6 (8W-10-10) FUSE BLOCK (8W-11-2) FUSE (8W-11-4) CONTROLLER BRAKE ANTI-LOCK PK/DB LAMP BRAKE SWITCH (8W-35-5) OUTPUT BRAKE LAMP SWITCH (8W-51-6) WT/TN L50 18WT/TN EXCEPT WT/TN BUILT-UP- BUILT-UP- C108 EXPORT EXPORT C322 C322 C322 EXCEPT...
Page 557 8W-51 REAR LIGHTING 8W - 51 - 5 FROM C322 (8W-51-4) WT/TN TURN SIGNAL/ HAZARD SWITCH 1 LEFT 2 RIGHT 3 NORMAL 4 HAZARD DG/RD BR/RD EXCEPT EXCEPT BUILT-UP- BUILT-UP- BUILT-UP- BUILT-UP- EXPORT EXPORT EXPORT EXPORT C322 C322 C322 C322 C322 C322 DG/RD...
Page 558 8W - 51 - 6 8W-51 REAR LIGHTING POWERTRAIN BATT A6 (8W-10-10) CONTROL SPEED FUSE CONTROL MODULE ON/OFF BRAKE BLOCK (8W-30-16) SWITCH SWITCH (8W-11-2) FUSE SENSE SENSE BRAKE SHIFT BRAKE (8W-11-4) INTERLOCK SWITCH SOLENOID SENSE (8W-31-2) YL/RD WT/PK C108 WT/PK PK/DB YL/RD WT/PK...
Page 559 8W-51 REAR LIGHTING 8W - 51 - 7 LHD BUILT-UP-EXPORT BATT A3 BATT F34 (8W-10-13) (8W-11-4) HEADLAMP CIRCUIT SWITCH BREAKER 0 OFF HEADLAMP 1 PARK DIMMER 2 HEAD HEAD- 3 MAX SWITCH LAMP 4 MIN (8W-50-2) SWITCH (8W-50-2) OUTPUT (8W-50-4) C202 BK/YL L2 16LG...
Page 560 8W - 51 - 8 8W-51 REAR LIGHTING RHD BUILT-UP-EXPORT BATT A3 BATT F34 (8W-10-13) (8W-11-4) HEADLAMP CIRCUIT SWITCH BREAKER 0 OFF HEADLAMP 1 PARK DIMMER 2 HEAD HEAD- 3 MAX SWITCH LAMP 4 MIN (8W-50-2) SWITCH (8W-50-2) OUTPUT (8W-50-4) C202 BK/YL L2 16LG...
Page 561 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Left Repeater Lamp ....8W-52-3 Fuse 9 (PDC) .
Page 562 8W - 52 - 2 8W-52 TURN SIGNALS RUN-ACC A31 BATT A0 (8W-10-9) (8W-10-6) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-2) COMBINATION (8W-11-9) (8W-10-13) FLASHER COMBINATION COMBINATION FLASHER FLASHER INPUT OUTPUT GROUND BK/WT C108 S304 (8W-15-9) BK/GY RD/WT (8W-15-10) BK/WT G300...
Page 563 8W-52 TURN SIGNALS 8W - 52 - 3 TURN SIGNAL/ HAZARD SWITCH 1 LEFT 2 RIGHT 3 NORMAL 4 HAZARD C203 INSTRUMENT RIGHT LEFT CLUSTER TURN TURN SIGNAL SIGNAL (8W-40-9) C107 C110 EXCEPT EXCEPT BUILT- BUILT- BUILT- BUILT- UP-EXPORT UP-EXPORT UP-EXPORT UP-EXPORT S142...
Page 564 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Fuse 3 (FB) ......8W-53-4 Internal Delay Relay .
Page 565 8W - 53 - 2 8W-53 WIPERS STANDARD RUN-ACC A31 (8W-10-9) FUSE BLOCK (8W-11-2) FUSE (8W-11-9) PK/BK S306 PK/BK WINDSHIELD WIPER SWITCH 0 OFF 1 LOW 2 HIGH 3 WASH C107 PK/BK DG/YL BR/WT RD/YL WINDSHIELD C110 WIPER MOTOR 1 PARK 2 RUN 3 LOW 4 HIGH...
Page 566 8W-53 WIPERS 8W - 53 - 3 INTERMITTENT RUN-ACC A31 (8W-10-9) FUSE BLOCK (8W-11-2) FUSE (8W-11-9) PK/BK S306 WINDSHIELD WIPER SWITCH 0 OFF 1 DELAY 2 LOW 3 HIGH 4 WASH 5 MIN INTERNAL DELAY 6 MAX DELAY LOGIC AND RELAY RELAY CONTROL...
Page 567 8W - 53 - 4 8W-53 WIPERS HARD TOP BATT F34 RUN A22 (8W-11-4) (8W-10-8) HEADLAMP REAR FUSE SWITCH WIPER BLOCK 0 OFF MOTOR (8W-11-2) FUSE 1 PARK 1 PARK 2 HEAD 2 RUN 3 DOME (8W-11-6) 4 MAX 5 MIN (8W-50-2) C202 BR/PK...
Page 568 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S101 ......8W-10-11 S141 .
Page 569 8W - 70 - 2 8W-70 SPLICE INFORMATION LEFT RADIO HEADLAMP LICENSE SWITCH (8W-47-2) LAMP (8W-50-4) (BUILT-UP -EXPORT) (8W-51-7) (8W-51-8) RIGHT LICENSE BK/YL BK/YL LAMP (BUILT-UP -EXPORT) C203 (8W-51-7) (8W-51-8) LEFT RIGHT REAR REAR LAMP LAMP ASSEMBLY ASSEMBLY BK/YL BK/YL (8W-51-2) (8W-51-2) (8W-51-3)
Page 570 8W-70 SPLICE INFORMATION 8W - 70 - 3 OXYGEN MANIFOLD INTAKE SENSOR ABSOLUTE PRESSURE TEMPERATURE UPSTREAM SENSOR SENSOR (8W-30-7) (8W-30-7) (8W-30-9) (8W-30-8) (8W-30-8) ENGINE COOLANT TEMPERATURE SENSOR K167 K167 K167 (8W-30-7) (8W-30-8) BR/YL BR/YL BR/YL BATTERY K167 TEMPERATURE SENSOR BR/YL (8W-30-10) S127 K167...
Page 571 8W - 70 - 4 8W-70 SPLICE INFORMATION POWERTRAIN VEHICLE ENGINE CONTROL SPEED MODULE SENSOR PRESSURE (8W-30-7) SENSOR (8W-30-10) (8W-30-7) (8W-30-8) VT/OR VT/OR VT/OR S123 MANIFOLD ABSOLUTE PRESSURE SENSOR (8W-30-7) (8W-30-8) POWERTRAIN CAMSHAFT CRANKSHAFT THROTTLE CONTROL POSITION POSITION POSITION MODULE SENSOR SENSOR SENSOR...
Page 572 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-4 C322 ......8W-80-12 A/C Heater Controls .
Page 573 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Fuel Injector No. 1 ....8W-80-19 Left Fog Lamp ..... 8W-80-25 Fuel Injector No.
Page 574 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Radio ......8W-80-33 Right Rear Lamp Assemby .
Page 575 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND A/C COMPRESSOR CLUTCH BLACK CIRCUIT FUNCTION C7 12BR/TN HIGH SPEED BLOWER MOTOR M2 SPEED BLOWER MOTOR C6 14LB C5 16LG/LB M1 SPEED BLOWER MOTOR C4 16TN LOW SPEED BLOWER MOTOR...
Page 576 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 GRAY CIRCUIT FUNCTION C22 20DB/WT A/C SWITCH SENSE C21 20DB/OR A/C SWITCH SENSE A/C LOW PRESSURE SWITCH BLACK CIRCUIT FUNCTION B48 20RD/YL ABS MAIN RELAY OUTPUT G19 20LG/OR ABS WARNING INDICATOR DRIVER ABS DIODE BLACK CIRCUIT...
Page 577 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL K167 20BR/YL SENSOR GROUND K167 18BR/YL SENSOR GROUND BATTERY TEMPERATURE SENSOR GRAY CIRCUIT FUNCTION K29 20WT/PK BRAKE SWITCH SENSE Z1 20BK GROUND V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT...
Page 578 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 CIRCUIT CIRCUIT C90 20LG C90 20LG C22 18DB/WT C22 20DB/WT B4 18LG B4 18LG GREY B3 18LG/DB B3 18LG/DB GREY T41 20BR/LB T41 20BR/LB B2 18YL B2 18YL B1 18YL/DB B1 18YL/DB L1 20VT/BK L1 20VT/BK C104...
Page 579 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT L7 18BK/YL L7 18BK/YL L7 18BK/YL L60 18TN L60 18TN L61 18GY L61 18GY YELLOW YELLOW L3 16RD/OR L3 14RD/OR L4 16VT/WT L4 14VT/WT Z12 20BK/LB Z12 20BK/LB X3 20RD/YL X3 20RD/YL V10 18BR V10 18BR...
Page 580 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 CIRCUIT CIRCUIT L7 18BK/YL L7 18BK/YL L60 18TN L60 18TN BLACK BLACK L61 18GY L61 18GY L3 16RD/OR L3 16RD/OR L4 16VT/WT L4 16VT/WT X2 18WT/RD X2 18WT/RD V10 18BR V10 18BR L22 20LG/DG L22 20LG/DG C110...
Page 581 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT L13 20BR/YL L13 20BR/YL LIGHT BLACK GRAY C81 20LB/WT C81 20LB/WT G99 20GY/WT G99 20GY/WT A3 14RD/WT A3 14RD/WT G107 20BK/RD G107 20BK/RD C90 20LG C90 20LG C170 C170 BLACK BLACK CIRCUIT CIRCUIT...
Page 582 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 CIRCUIT CIRCUIT L60 18TN L60 18TN L60 18TN L61 18GY L61 18GY L61 18GY G26 20LB G26 20LB G26 20LB GREEN GREEN G16 20BK/LB G16 20BK/LB G16 20BK/LB G34 16RD/GY G34 16RD/GY G34 16RD/GY L7 18BK/YL L7 18BK/YL...
Page 583 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT L7 18BK/YL BLACK L7 18BK/YL BLACK L62 18BR/RD L62 18BR/RD L1 20VT/BK L1 20VT/BK L63 18DG/RD L63 18DG/RD Z1 12BK Z1 12BK G10 20LG/RD G10 20LG/RD C322 C322 L50 18WT/TN L50 18WT/TN (LHD) (LHD)
Page 584 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 CIRCUIT CIRCUIT C15 12BK/WT C15 12BK/WT Lt GRAY M1 20PK/WT M1 20PK/WT Lt GRAY M2 20YL M2 20YL V23 18BR/PK V23 18BR/PK V13 18BR/LG V13 18BR/LG V20 18VT/OR V20 18VT/OR X51 18BR/YL X51 18BR/YL C323 C323...
Page 585 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT L38 20BR/WT L38 18BR/WT L7 18BK/YL L7 18BK/YL Z1 20BK Z1 20BK C329 C329 BLACK CIRCUIT CIRCUIT WHITE X57 18BR/LB X57 20BR/LB X51 18BR/YL X51 20BR/YL M1 20PK/WT M1 20PK/WT M2 20YL M2 20YL...
Page 586 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BLACK CIRCUIT FUNCTION F30 12RD/PK FUSED B(+) A31 14BK/DG IGNITION SWITCH OUTPUT (RUN-ACC) F22 12WT/PK CIGAR LIGHTER/ACCESSORY RELAY OUTPUT Z1 20BK GROUND GROUND CIGAR LIGHTER/ Z1 20BK ACCESSORY RELAY CIRCUIT FUNCTION F38 16LB FUSED B (+) Z1 16BK GROUND...
Page 587 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION G19 20LG/OR ABS WARNING INDICATOR DRIVER B43 20PK/OR G-SWITCH TEST SIGNAL GRAY D21 20PK SCI TRANSMIT/ISO 9141K F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN) B41 20YL/VT G-SWITCH NO. 1 SENSE CONTROLLER B42 20TN/WT G-SWITCH NO.
Page 588 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 CIRCUIT FUNCTION D1 20VT/BR CCD BUS(+) Z12 20BK/LB GROUND Z12 20BK/TN GROUND BLACK D20 20LG SCI RECEIVE D21 20PK SCI TRANSMIT/ISO 9141K DATA LINK D2 20WT/BK CCD BUS(-) CONNECTOR M1 20PK/WT FUSED B(+) CIRCUIT FUNCTION L3 16RD/OR...
Page 589 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS NATURAL CIRCUIT FUNCTION M23 20YL/BK DOOR AJAR SWITCH OUTPUT M2 20YL COURTESY LAMPS DRIVER G16 20BK/LB DRIVER DOOR AJAR SWITCH SENSE DRIVER DOOR AJAR SWITCH BLACK CIRCUIT FUNCTION K52 20PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (ST-RUN) DUTY CYCLE...
Page 590 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 BLACK CIRCUIT FUNCTION L35 18BR/WT FOG LAMP SWITCH OUTPUT Z1 20BK GROUND F61 18WT/OR FUSED B(+) FOG LAMP L39 18LB FOG LAMP RELAY NO. 1 OUTPUT RELAY NO. 1 (EXCEPT BUILT- UP-EXPORT) BLACK CIRCUIT FUNCTION...
Page 591 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN FUEL INJECTOR NO. 2 DRIVER FUEL INJECTOR NO. 2 (2.5L) BLACK CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN FUEL INJECTOR NO.
Page 592 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 BLACK CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER FUEL INJECTOR NO. 4 (4.0L) BLACK CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K15 18PK/BK FUEL INJECTOR NO.
Page 593 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT L2 14LG HEADLAMP SWITCH OUTPUT L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT L20 14LG/WT FUSED B(+) OPTICAL HORN FEED HEADLAMP DIMMER SWITCH WHITE CIRCUIT FUNCTION...
Page 594 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 CIRCUIT FUNCTION BLACK B47 14RD/LB ABS SYSTEM RELAY OUTPUT B251 20WT/BK REAR INLET VALVE CONTROL B249 20WT/DG RIGHT FRONT INLET VALVE CONTROL B245 20WT/LG LEFT FRONT INLET VALVE CONTROL B254 20DG/OR REAR OUTLET VALVE CONTROL HYDRAULIC B248 20DG/WT RIGHT FRONT OUTLET VALVE CONTROL...
Page 595 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION D2 20WT/BK CCD BUS(-) GREEN D1 20VT/BR CCD BUS(+) C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL C80 20DB/LG REAR WINDOW DEFOGGER SWITCH SENSE G107 20BK/RD 4WD SENSE L60 18TN RIGHT TURN SIGNAL G26 20LB KEY-IN IGNITION SWITCH SENSE INSTRUMENT...
Page 596 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 BLACK CIRCUIT FUNCTION F142 20OR/DG FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT K106 20WT/DG LEAK DETECTION PUMP SOLENOID CONTROL K105 20WT/OR LEAK DETECTION PUMP SWITCH SENSE LEAK DETECTION PUMP (EXCEPT BUILT- UP-EXPORT) BLACK CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT...
Page 597: Left Front Turn Signal Lamp
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION L61 18GY LEFT TURN SIGNAL LEFT FRONT Z1 18BK GROUND TURN SIGNAL LAMP (BUILT-UP-EXPORT) BLACK CIRCUIT FUNCTION B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) LEFT FRONT WHEEL SPEED SENSOR...
Page 598: Left Repeater Lamp
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 BLACK CIRCUIT FUNCTION L1 20VT/BK BACK-UP LAMP FEED L63 18DG/RD LEFT TURN SIGNAL L63 18DG/RD LEFT TURN SIGNAL L1 20VT/BK BACK-UP LAMP FEED L7 18BK/YL HEADLAMP SWITCH OUTPUT LEFT REAR L50 18WT/TN BRAKE LAMP SWITCH OUTPUT LAMP ASSEMBLY L7 18BK/YL...
Page 599: Oxygen Sensor 1/1 Upstream
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K7 20OR 5V SUPPLY MANIFOLD ABSOLUTE PRESSURE SENSOR GRAY CIRCUIT FUNCTION F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT Z1 18BK GROUND K167 20BR/YL...
Page 600: Power Steering Pressure Switch
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 LIGHT GRAY CIRCUIT FUNCTION F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (ST-RUN) Z6 20BK/PK GROUND PASSENGER AIRBAG ON/OFF SWITCH - C1 YELLOW CIRCUIT FUNCTION R142 18BR/YL PASSENGER AIRBAG SQUIB LINE 1 R144 18VT/YL PASSENGER AIRBAG SQUIB LINE 2 R42 18BK/YL PASSENGER AIRBAG LINE 1...
Page 601 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION F15 18DB FUSED IGNITION SWITCH OUTPUT (ST-RUN) K167 18BR/YL SENSOR GROUND T41 18BR/LB PARK/NEUTRAL POSITION SWITCH SENSE K19 18GY IGNITION COIL NO. 1 DRIVER BLACK K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL K60 18YL/BK IDLE AIR CONTROL NO.
Page 602 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 CIRCUIT FUNCTION K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER WHITE K20 18DG GENERATOR FIELD DRIVER (+) T23 18OR/LG TRANSMISSION LOW/OVERDRIVE SOLENOID K16 18LG/BK FUEL INJECTOR NO.
Page 603: Powertrain Control Module
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL GRAY K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL V32 18YL/RD SPEED CONTROL ON/OFF SWITCH SENSE...
Page 604: Rear Fog Lamp
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 CIRCUIT FUNCTION GRAY X55 18BR/RD LEFT FRONT SPEAKER(-) X56 18DB RIGHT FRONT SPEAKER(-) L7 18BK/YL HEADLAMP SWITCH OUTPUT RADIO - C1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL X12 20PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC) M1 20PK/WT FUSED B(+) CIRCUIT...
Page 605: Rear Washer Pump
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION V20 18VT/OR REAR WASHER MOTOR CONTROL Z1 18BK GROUND REAR WASHER PUMP (HARD TOP) GRAY CIRCUIT FUNCTION Z1 20BK GROUND C80 20DB/LG REAR WINDOW DEFOGGER SWITCH SENSE F81 20DB/RD FUSED REAR WINDOW DEFOGGER RELAY OUTPUT E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL...
Page 606: Right City Lamp
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 BLACK CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 20BK GROUND RIGHT CITY LAMP (BUILT-UP-EXPORT) BLACK CIRCUIT FUNCTION M1 20PK/WT FUSED B(+) M2 20YL COURTESY LAMPS DRIVER RIGHT COURTESY LAMP BLACK CIRCUIT FUNCTION Z1 18BK GROUND...
Page 607: Right Headlamp
8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-) B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) RIGHT FRONT WHEEL SPEED SENSOR BLACK CIRCUIT FUNCTION L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT Z1 18BK...
Page 608: Right Repeater Lamp
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 BLACK CIRCUIT FUNCTION B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+) RIGHT REAR WHEEL SPEED SENSOR GRAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL Z1 18BK GROUND RIGHT REPEATER...
Page 609 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS NATURAL CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL K7 20OR 5V SUPPLY THROTTLE POSITION SENSOR BLACK CIRCUIT FUNCTION F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (ST-RUN) T23 18OR/LG TRANSMISSION LOW/OVERDRIVE SOLENOID TORQUE CONVERTOR CLUTCH SOLENOID...
Page 610 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 BLACK CIRCUIT FUNCTION V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT Z1 18BK GROUND VEHICLE SPEED CONTROL SERVO BLACK CIRCUIT FUNCTION K6 20VT/OR...
Page 611 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS each section for connector number identification. DESCRIPTION AND OPERATION Refer to the index for the proper figure number. INTRODUCTION CONNECTOR/GROUND LOCATIONS This section provides illustrations identifying com- For items that are not shown in this section a N/S ponent and connector locations in the vehicle.
Page 612 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C323 (RHD) LT GY Left Kick Panel Data Link Bottom Left of Connector Instrument C325 (4 Spkr Left Side of 22, 23 (LHD)
Page 613 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number G100 Rear Center of 2, 3 G Switch Near T/O for Engine Controller Compartment Anti-Lock Brake G101 Rear Center of Generator...
Page 614 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Left Courtesy Left Side of 17, 18 Low Note Horn Left Front Lamp Instrument (Except Fender Side Panel Built-Up-Export) Shield...
Page 615: Seat Belt Switch
8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Rear Fog Lamp LT GN Near Fuse Right License At Lamp 24, 25 Relay Block T/O Lamp (Built-Up- (Built-Up-...
Page 616: Windshield Washer Pump
8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Windshield Under Washer Windshield At Steering Washer Pump Fluid Reservoir Wiper Switch Column Windshield Center of Cowl 7, 8 Wiper Motor Panel...
Page 617 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued)
Page 618 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 619 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
Page 620 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 621 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
Page 622 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 6 ABS Hydraulic Control Unit Fig. 7 Windshield Wiper Motor—LHD...
Page 623 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued) Fig. 8 Windshield Wiper Motor—RHD...
Page 624 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 625 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
Page 626 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 627 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
Page 628 8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 629 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued)
Page 630 8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 631 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued)
Page 632 8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 633 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23 DESCRIPTION AND OPERATION (Continued)
Page 634 8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 635 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25 DESCRIPTION AND OPERATION (Continued)
Page 636 8W - 90 - 26 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 21 Instrument Panel Connectors—Right Side, LHD...
Page 637 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 27 DESCRIPTION AND OPERATION (Continued)
Page 638 8W - 90 - 28 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 639 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 29 DESCRIPTION AND OPERATION (Continued) Fig. 24 Rear Under Body Wiring Connectors—LHD Fig. 25 Rear Under Body Wiring Connectors—RHD...
Page 640 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS section for splice number identification. Refer to the DESCRIPTION AND OPERATION index for proper splice number. INTRODUCTION SPLICE LOCATIONS This section provides illustrations identifying the For splices that are not shown in the figures in general location of the splices in this vehicle.
Page 641: Windshield Wiper Motor
8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S127 Between Fuel Injector NO. 2 S144 Near T/O for Right Front (2.5L) and Fuel Injector NO. 3 Park/Turn Signal Lamp (RHD) S146...
Page 642 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S316 In T/O for Rear Fog Lamp 12, 13 S331 Near T/O for Airbag Control 8, 9 Module S317 Near T/O for Left License 12, 13...
Page 643 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 644 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
Page 645 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 646 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
Page 647 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 648 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued)
Page 649 8W - 95 - 10 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 650 8W - 95 SPLICE LOCATIONS 8W - 95 - 11 DESCRIPTION AND OPERATION (Continued)
Page 651 8W - 95 - 12 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 652 8W - 95 SPLICE LOCATIONS 8W - 95 - 13 DESCRIPTION AND OPERATION (Continued)
Page 653 8W - 95 - 14 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 654 8W - 95 SPLICE LOCATIONS 8W - 95 - 15 DESCRIPTION AND OPERATION (Continued)
Page 655 8W - 95 - 16 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 656 ENGINE 9 - 1 ENGINE CONTENTS page page 2.5L ENGINE ......14 ENGINE DIAGNOSIS ..... . . 7 4.0L ENGINE .
Page 657 9 - 2 ENGINE GENERAL INFORMATION (Continued) inch) drop is placed in the center of the gasket con- taper and out-of-round as well as removing light tact area. Uncured sealant may be removed with a scuffing, scoring or scratches. Usually a few strokes shop towel.
Page 658 ENGINE 9 - 3 GENERAL INFORMATION (Continued) MEASURING WITH PLASTIGAGE CRANKSHAFT MAIN BEARING CLEARANCE Engine crankshaft bearing clearances can be deter- mined by use of Plastigage, or equivalent. The follow- ing is the recommended procedures for the use of Plastigage: (1) Remove oil film from surface to be checked.
Page 659 9 - 4 ENGINE GENERAL INFORMATION (Continued) Plastigage in place be assembled. Tighten the rod cap (1) Perform the Fuel Pressure Release Procedure nuts to required torque. (Refer to the torque specifi- (refer to Group 14, Fuel System). cations at the rear of the engine’s section). DO NOT (2) Disconnect the negative cable from the battery.
Page 660 ENGINE 9 - 5 GENERAL INFORMATION (Continued) API SERVICE GRADE CERTIFIED The engine oil level indicator (Dipstick) is located at the right rear of both 2.5L engines and 4.0L In gasoline engines. use an engine oil that is API engines. Inspect engine oil level approximately every Service Grade Certified (Fig.
Page 661 The proper oil filter has SAE type 3/4 X 16 threads. An oil filter with metric threads can result in oil leaks and engine failure. All Jeep engines are equipped with a high quality full-flow, throw-away type oil filter. Chrysler Corpo- ration recommends a Mopar or equivalent oil filter be used.
Page 662 ENGINE 9 - 7 ENGINE DIAGNOSIS INDEX page page DIAGNOSIS AND TESTING ENGINE OIL PRESSURE ....10 CYLINDER COMBUSTION PRESSURE GENERAL INFORMATION ....7 LEAKAGE TEST .
Page 663 9 - 8 ENGINE DIAGNOSIS AND TESTING (Continued) INTAKE MANIFOLD LEAKAGE DIAGNOSIS CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is An intake manifold air leak is characterized by leaking between adjacent cylinders; follow the proce- lower than normal manifold vacuum. Also, one or dures outlined in Cylinder Compression Pressure more cylinders may not be functioning.
Page 664 ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) All gauge pressure indications should be equal, Refer to the Cylinder Combustion Pressure Leak- with no more than 25% leakage. age Test Diagnosis chart. FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder.
Page 665 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) If the leakage occurs at the crankshaft rear oil seal slowly turning the crankshaft, it is possible the area: crankshaft seal surface is damaged. The seal area on (1) Disconnect the battery. the crankshaft could have minor nicks or scratches (2) Raise the vehicle.
Page 666 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE LOSS OF POWER 1. Worn or burned distributor 1. Install new distributor rotor rotor 2. Worn distributor shaft 2. Remove and repair distributor (Refer to group 8D, Ignition System 3.
Page 667 9 - 12 ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—MECHANICAL ENGINE MECHANICAL DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES/LIFTERS 1. High or low oil level in 1. Check for correct oil level. Adjust oil level by crankcase draining or adding as needed 2.
Page 668 ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Loose flywheel or torque 7. Inspect crankshaft, flexplate/flywheel and converter bolts for damage. Tighten to correct torque LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary 2.
Page 669 9 - 14 2.5L ENGINE 2.5L ENGINE INDEX page page DESCRIPTION AND OPERATION OIL PUMP ......45 ENGINE DESCRIPTION .
Page 670 2.5L ENGINE 9 - 15 DESCRIPTION AND OPERATION (Continued) Galleries extend downward from the main oil gal- lery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals (except number 4 main bear- ing journal) to the connecting rod journals.
Page 671 9 - 16 2.5L ENGINE DESCRIPTION AND OPERATION (Continued) Oil Lubrication System—2.5L Engine...
Page 672 2.5L ENGINE 9 - 17 vide accurate results (Fig. 3). Therefore measuring SERVICE PROCEDURES the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY . To correctly select VALVE TIMING the proper size piston, a cylinder bore gauge capable Disconnect the spark plug wires and remove the of reading in 0.003 mm (.0001 in.) increments is spark plugs.
Page 673 9 - 18 2.5L ENGINE SERVICE PROCEDURES (Continued) PISTON SIZE CHART CYLINDER BORE SIZE PISTON LETTER SIZE 98.438 to 98.448 mm (3.8755 to 3.8759 in.) ..A 98.448 to 98.458 mm (3.8759 to 3.8763 in.) ..B 98.458 to 98.468 mm (3.8763 to 3.8767 in.) .
Page 674 2.5L ENGINE 9 - 19 SERVICE PROCEDURES (Continued) (7) The second compression ring has a slight chamfer on the bottom of the inside edge and a dot on the top for correct installation (Fig. 9). (8) Using a ring installer, install the second com- pression ring with the dot facing up (Fig.
Page 675 9 - 20 2.5L ENGINE SERVICE PROCEDURES (Continued) FITTING CONNECTING ROD BEARINGS INSPECTION BEARINGS Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 13) (Fig. 14). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 15). Replace any bearing that shows abnormal wear.
Page 676 2.5L ENGINE 9 - 21 SERVICE PROCEDURES (Continued) tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod. (8) If the correct clearance is indicated, replace- ment of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert.
Page 677 9 - 22 2.5L ENGINE SERVICE PROCEDURES (Continued) SIDE CLEARANCE MEASUREMENT FITTING BEARINGS (CRANKSHAFT INSTALLED) Slide snug-fitting feeler gauge between the con- The main bearing caps, numbered (front to rear) necting rod and crankshaft journal flange (Fig. 18). from 1 through 5 have an arrow to indicate the for- Refer to Engine Specifications for the proper clear- ward position.
Page 678 2.5L ENGINE 9 - 23 SERVICE PROCEDURES (Continued) Install the bearing cap and tighten the bolts to 108 this insert size or some other combination will pro- N·m (80 ft. lbs.) torque. vide the specified clearance. FOR EXAMPLE: If the clearance was 0.0762 mm (0.003 inch) originally, a NOTE: DO NOT rotate the crankshaft.
Page 679 9 - 24 2.5L ENGINE SERVICE PROCEDURES (Continued) MAIN BEARING FITTING CHART CRANKSHAFT JOURNALS #1 - 4 CORRESPONDING CRANKSHAFT BEARING INSERT Color Code Diameter Upper Insert Size Lower Insert Size 63.5025 - 63.4898 mm Yellow - Standard Yellow - Standard Yellow (2.5001 - 2.4996 in.) 63.4898 - 63.4771mm...
Page 680 2.5L ENGINE 9 - 25 REMOVAL AND INSTALLATION ENGINE MOUNTS—FRONT The front mounts support the engine at each side. These supports are made of resilient rubber. REMOVAL (1) Disconnect negative cable from battery. (2) Raise the vehicle. (3) Support the engine. Fig.
Page 681 9 - 26 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION MANUAL TRANSMISSION: (1) Position the transmission mount bracket to the transmission and install the bolts (Fig. 24). (2) Tighten the bolts to 54 N·m (40 ft. lbs.) torque. (3) Position the support cushion to the transmis- sion mount bracket and install nuts (Fig.
Page 682 2.5L ENGINE 9 - 27 REMOVAL AND INSTALLATION (Continued) (6) Remove upper radiator hose. (a) Disconnect the hoses from the fittings at the (7) Remove the viscous fan/drive assembly. steering gear. (8) Remove accessory drive belt. (Refer to Group 7, (b) Drain the pump reservoir.
Page 683 9 - 28 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 28 Manual Transmission to Engine—2.5L (12) Remove the engine lifting device. (13) Raise the vehicle. Fig. 26 Air Cleaner Resonator and Duct Work (14) Install inspection cover and tighten bolts/nuts to 16 N·m (138 in.
Page 684 2.5L ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) • Oxygen sensor (24) Install the engine ground strap. (25) Connect heater hoses to thermostat housing and water pump inlet tube. (26) Connect accelerator cable, transmission line pressure cable (if equipped), and speed control cable (if equipped) to bracket and throttle body.
Page 685 9 - 30 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Loosen the accessory drive belt tension and remove the belt from the power steering pump. (Refer to Group 7, Cooling for correct procedure). (4) Remove the power steering pump and brackets from the water pump and intake manifold.
Page 686 2.5L ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) (6) Pull out on fuel supply line to verify that it is properly connected. Install latch clip. (7) Connect the molded vacuum hoses to the vac- uum port on the intake manifold and the cylinder head cover.
Page 687 9 - 32 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) REMOVAL bridge. Tighten the capscrews to 28 N·m (21 ft. lbs.) torque. (1) Remove the engine cylinder head cover. (Refer (5) Install the engine cylinder head cover. to procedure in this section) (2) Check for rocker arm bridges which are caus- VALVE SPRINGS AND OIL SEALS ing misalignment of the rocker arm to valve tip area.
Page 688 2.5L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) (2) Drain the coolant and disconnect the hoses at the engine thermostat housing. DO NOT waste reus- able coolant. If the solution is clean and is being drained only to service the engine or cooling system, drain the coolant into a clean container for reuse.
Page 689 9 - 34 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (12) Remove the intake and engine exhaust mani- folds from the engine cylinder head (refer to Group 11, Exhaust System and Intake Manifold for the proper procedures). (13) Number and disconnect the ignition wires and remove the spark plugs.
Page 690 2.5L ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) (b) Tighten all bolts in sequence (1 through 10) CAUTION: The accessory drive belt must be routed to 61 N·m (45 ft. lbs.) torque. correctly. Incorrect routing can cause the water (c) Check all bolts to verify they are set to 61 pump to turn in the opposite direction causing the N·m (45 ft.
Page 691 9 - 36 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 41 Vibration Damper Removal Tool 7697 TIMING CASE COVER OIL SEAL REMOVAL This procedure is done with the timing case cover Fig. 40 Hydraulic Valve Tappet Removal/Installation installed. Tool (1) Disconnect negative cable from battery. (4) Install the rocker arms and bridge and pivot (2) Remove the serpentine drive belt.
Page 692 2.5L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Clean the timing case cover, oil pan and cylin- der block gasket surfaces. (2) Install a new crankshaft oil seal in the timing case cover. The open end of the seal should be toward the inside of the cover.
Page 693 9 - 38 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) TIMING CHAIN AND SPROCKETS The timing chain tensioner reduces noise and pro- longs timing chain life. In addition, it compensates for slack in a worn or stretched chain and maintains the correct valve timing. REMOVAL (1) Disconnect negative cable from battery.
Page 694 2.5L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) (2) Drain the cooling system. DO NOT waste reus- (9) Pull the tensioner block toward the tensioner able coolant. If the solution is clean, drain it into a lever to compress the spring. Hold the block and turn clean container for reuse.
Page 695 9 - 40 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (19) Position the oil pump gear. Refer to Distribu- tor in the Component Removal/Installation section of Group 8D, Ignition Systems. (20) Install the distributor and ignition wires. Refer to Distributor in the Component Removal/In- stallation section of Group 8D, Ignition Systems.
Page 696 2.5L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) (4) Install camshaft sprocket, crankshaft (18) Install the radiator. Connect the radiator sprocket and timing chain with the timing marks hoses and automatic transmission fluid cooler pipes, aligned (Fig. 51). if equipped. Fill the cooling system. (5) Install the crankshaft oil slinger.
Page 697 9 - 42 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (6) Apply Mopar Gasket Maker, or equivalent on the rear bearing cap (Fig. 56). The bead should be 3 mm (0.125 in) thick. DO NOT apply Mopar Gasket Maker, or equivalent to the lip of the seal. (7) Install the rear main bearing cap.
Page 698 2.5L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) Fig. 56 Location of Mopar Gasket Maker OIL PAN REMOVAL (1) Disconnect negative cable from battery. (2) Raise the vehicle. (3) Remove the oil pan drain plug and drain the engine oil. (4) Remove the engine starter motor.
Page 699 9 - 44 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (11) Remove the oil pan fasteners. Carefully remove the oil pan and gasket. INSTALLATION (1) Clean the block and pan gasket surfaces. (2) Fabricate 4 alignment dowels from 1/4 x 1 1/2 inch bolts.
Page 700 2.5L ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
Page 701 9 - 46 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (11) Have an assistant push the piston and con- necting rod assemblies up and through the top of the cylinder bores (Fig. 64). Fig. 65 Rod and Piston Assembly Installation (9) The rod journal is identified during the engine production by a color-coded paint mark on the adja- cent cheek or counterweight toward the flange (rear) end of the crankshaft.
Page 702 2.5L ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) ASSEMBLY (1) Thoroughly clean the valve stems and the valve guide bores. (2) Lightly lubricate the stem. (3) Install the valve in the original valve guide bore. (4) Install the replacement valve stem oil seals on the valve stems.
Page 703 9 - 48 2.5L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) mm (0.015 inch) oversize stems, 0.076mm (.003in.) oversize stems do not require oversize seals. NOTE: If the valve guides are reamed oversize, the valve seats must be ground to ensure that the valve seat is concentric to the valve guide.
Page 704 2.5L ENGINE 9 - 49 DISASSEMBLY AND ASSEMBLY (Continued) by more than 0.076 mm (0.003 inch), ream the guide bore to accommodate an oversize valve stem. ALTERNATIVE METHOD: (1) Use a dial indicator to measure the lateral movement of the valve stem (stem-to-guide clear- ance).
Page 705 9 - 50 2.5L ENGINE INSPECTION CLEANING AND INSPECTION Use a straightedge and feeler gauge to check the ROCKER ARMS AND PUSH RODS flatness of the engine cylinder head and block mating surfaces. CLEANING CYLINDER BLOCK Clean all the components with cleaning solvent. Use compressed air to blow out the oil passages in CLEANING the rocker arms and push rods.
Page 706 2.5L ENGINE 9 - 51 CLEANING AND INSPECTION (Continued) (4) Determine taper by subtracting the smaller diameter from the larger diameter. (5) Rotate measuring device 90° and repeat steps above. (6) Determine out-of-roundness by comparing the difference between each measurement. (7) If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can...
Page 707 9 - 52 2.5L ENGINE SPECIFICATIONS (Continued) Base Circle Runout ... 0.03 mm - max. Cylinder Bore Diameter— (0.001 in. - max.) Out-of-Round (Max.) ..0.025 mm (0.001 in.) Camshaft Lobe Lift Tappet Bore Diameter .
Page 708 2.5L ENGINE 9 - 53 SPECIFICATIONS (Continued) Rocker Arms, Push Rods & Tappets Ring Side Clearance—Oil Control Ring ..0.06 to 0.21 mm (0.0024 to 0.0083 in.) Rocker Arm Ratio ..... 1.6:1 Piston Ring Groove Height—Compression Push Rod Length .
Page 709 9 - 54 2.5L ENGINE SPECIFICATIONS (Continued) DESCRIPTION TORQUE DESCRIPTION TORQUE Drain Plug ....34 N·m (25 ft. lbs.) Connecting Rod Cap Nuts ....45 N·m (33 ft. lbs.) Oil Pressure Sending Unit Cylinder Block Sending Unit .
Page 710 2.5L ENGINE 9 - 55 SPECIAL TOOLS (Continued) Fig. 79 Timing Case Cover Alignment and Seal Tool 6139 Fig. 78 Vibration Damper Removal Tool 7697...
Page 711 9 - 56 4.0L ENGINE 4.0L ENGINE INDEX page page DESCRIPTION AND OPERATION OIL PAN ....... . 83 ENGINE DESCRIPTION .
Page 712 4.0L ENGINE 9 - 57 DESCRIPTION AND OPERATION (Continued) Galleries extend downward from the main oil gal- lery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals (except number 4 main bear- ing journal) to the connecting rod journals.
Page 713 9 - 58 4.0L ENGINE DESCRIPTION AND OPERATION (Continued) Oil Lubrication System—4.0L Engine...
Page 714 4.0L ENGINE 9 - 59 the inside diameter of the cylinder bore with a dial SERVICE PROCEDURES Bore Gauge is MANDATORY . To correctly select the proper size piston, a cylinder bore gauge capable VALVE TIMING of reading in 0.003 mm (.0001 in.) increments is Disconnect the spark plug wires and remove the required.
Page 715 9 - 60 4.0L ENGINE SERVICE PROCEDURES (Continued) PISTON SIZE CHART CYLINDER BORE SIZE PISTON LETTER SIZE 98.438 to 98.448 mm (3.8755 to 3.8759 in.) ..A 98.448 to 98.458 mm (3.8759 to 3.8763 in.) ..B 98.458 to 98.468 mm (3.8763 to 3.8767 in.) .
Page 716 4.0L ENGINE 9 - 61 SERVICE PROCEDURES (Continued) (7) The second compression ring has a slight chamfer on the bottom of the inside edge and a dot on the top for correct installation (Fig. 9). (8) Using a ring installer, install the second com- pression ring with the dot facing up (Fig.
Page 717 9 - 62 4.0L ENGINE SERVICE PROCEDURES (Continued) FITTING CONNECTING ROD BEARINGS INSPECTION BEARINGS Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 13) (Fig. 14). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 15). Replace any bearing Fig.
Page 718 4.0L ENGINE 9 - 63 SERVICE PROCEDURES (Continued) necting rod or foreign material trapped between (8) If the correct clearance is indicated, replace- the insert and cap or rod. ment of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert.
Page 719 9 - 64 4.0L ENGINE SERVICE PROCEDURES (Continued) Each bearing insert pair is selectively fitted to its respective journal to obtain the specified operating clearance. In production, the select fit is obtained by using various-sized color-coded bearing insert pairs as listed in the Main Bearing Fitting Chart. The bearing color code appears on the edge of the insert.
Page 720 4.0L ENGINE 9 - 65 SERVICE PROCEDURES (Continued) Fig. 20 Crankshaft Journal Size Paint I.D. Location If the clearance exceeds specification, install a pair of 0.025 mm (0.001 inch) undersize bearing inserts and measure the clearance as described in the previ- ous steps.
Page 721 9 - 66 4.0L ENGINE SERVICE PROCEDURES (Continued) Once the proper clearances have been obtained, proceed to Crankshaft Main Bearing—Installation. MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) Remove the crankshaft from the cylinder block (refer to Cylinder Block - Disassemble). Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer.
Page 722 4.0L ENGINE 9 - 67 SERVICE PROCEDURES (Continued) MAIN BEARING FITTING CHART Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert Color Code Diameter Upper Insert Size Lower Insert Size 63.5025 -63.4898 mm Yellow - Standard Yellow - Standard Yellow (2.5001 - 2.4996 in.) 63.4898 - 63.4771 mm (2.4996 - 2.4991 in.) Blue - Undersize...
Page 723 9 - 68 4.0L ENGINE REMOVAL AND INSTALLATION ENGINE MOUNTS—FRONT The front mounts support the engine at each side. These supports are made of resilient rubber. REMOVAL (1) Disconnect negative cable from battery. (2) Raise the vehicle. (3) Support the engine. (4) Remove the nut from the through bolt (Fig.
Page 724 4.0L ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued) INSTALLATION MANUAL TRANSMISSION: (1) Position the transmission mount bracket to the transmission and install the bolts (Fig. 25). (2) Tighten the bolts to 54 N·m (40 ft. lbs.) torque. (3) Position the support cushion to the transmis- sion mount bracket and install nuts (Fig.
Page 725 9 - 70 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (6) Remove upper radiator hose. (a) Disconnect the hoses from the fittings at the (7) Remove the viscous fan/drive assembly. Refer steering gear. to Group 7, Cooling for procedure. (b) Drain the pump reservoir. (8) Remove accessory drive belt.
Page 726 4.0L ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) Fig. 29 Automatic Transmission to Engine—4.0L the bolt holes are aligned. Install the thru-bolts and nuts and tighten to 81 N·m (60 ft. lbs.). Fig. 27 Air Cleaner Resonator and Duct Work (7) Remove the engine lifting device.
Page 727 9 - 72 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) • MAP sensor (4) Disconnect the following electrical connectors: • Crankshaft position sensor • Map Sensor • Oxygen sensor • Idle Air Control Motor • Intake Manifold Air Temperature Sensor (19) Install the engine ground strap. •...
Page 728 4.0L ENGINE 9 - 73 REMOVAL AND INSTALLATION (Continued) line to the fuel rail assembly. (Refer to Group 14, Fuel System for the correct procedure). (11) Connect all sensor electrical connections on the intake manifold. • Map Sensor • Idle Air Control Motor •...
Page 729 9 - 74 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (5) Remove the three bolts that fasten the control ROCKER ARMS AND PUSH RODS cable bracket to the intake manifold. This procedure can be done with the engine in or (6) Remove control cables from cylinder head cover out of the vehicle.
Page 730 4.0L ENGINE 9 - 75 REMOVAL AND INSTALLATION (Continued) VALVE SPRINGS AND OIL SEALS This procedure can be done with the engine cylin- der head installed on the block. REMOVAL Inspect the valve stems, especially the grooves. An Arkansas smooth stone should be used to remove nicks and high spots.
Page 731 9 - 76 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Remove the air cleaner assembly. (4) Remove the engine cylinder head cover. (5) Remove the capscrews, bridge and pivot assem- blies and rocker arms . (6) Remove the push rods . Retain the push rods, bridges, pivots and rocker arms in the same order as removed.
Page 732 4.0L ENGINE 9 - 77 REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD BOLTS pump to turn in the opposite direction causing the engine to overheat. POSITION DESCRIPTION (16) Install the accessory drive belt and correctly 1,4,5,12,13 1/2 in.-13 BOLT tension the belt (refer to Group 7, Cooling System for the proper procedure).
Page 733 9 - 78 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 38 Hydraulic Valve Tappet Removal— Installation Tool INSTALLATION Fig. 39 Vibration Damper Removal Tool 7697 It is not necessary to charge the tappets with vibration damper hub with the crankshaft key and engine oil.
Page 734 4.0L ENGINE 9 - 79 REMOVAL AND INSTALLATION (Continued) Lubricate and tighten the bolt to 108 N·m (80 ft. lbs.) torque. (10) Install the A/C compressor (if equipped) and generator bracket assembly. (11) Install the engine fan and hub assembly and shroud.
Page 735 9 - 80 4.0L ENGINE 1999 TJ Wrangler REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-9148 TSB 26-11-98 November, 1998 (2) Drain the cooling system. DO NOT waste reus- able coolant. If the solution is clean, drain it into a clean container for reuse. (3) Remove the radiator or radiator and condenser, if equipped with A/C (refer to Group 7, Cooling Sys- tem for the proper procedure).
Page 736 4.0L ENGINE 9 - 81 1999 TJ Wrangler REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-9148 TSB 26-11-98 November, 1998 (9) Position thrust plate and install retaining (22) Install the A/C condenser and receiver/drier screws. Tighten screws to 24 N m (18 ft. lbs.). assembly, if equipped (refer to Group 24, Heating and (10) Install the camshaft sprocket bolt/cup washer.
Page 737 9 - 82 4.0L ENGINE 1999 TJ Wrangler REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-9148 TSB 26-11-98 November, 1998 CAMSHAFT BEARINGS (10) To verify correct installation of the timing chain, turn the crankshaft two full revolutions then position the camshaft sprocket timing mark as shown REMOVAL in Fig.
Page 738 4.0L ENGINE 9 - 83 REMOVAL AND INSTALLATION (Continued) (15) Install the vibration damper on the crank- shaft. (16) Lubricate and tighten the damper bolt to 108 N·m (80 ft. lbs.) torque. (17) If equipped with air conditioning: (a) Install the A/C compressor serpentine drive belt idler pulley.
Page 739 9 - 84 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) Oil pump removal or replacement will not affect the distributor timing because the distributor drive gear remains in mesh with the camshaft gear. REMOVAL (1) Drain the engine oil. (2) Remove the oil pan. (3) Remove the pump-to-cylinder block attaching bolts.
Page 740 4.0L ENGINE 9 - 85 REMOVAL AND INSTALLATION (Continued) (9) Using the same procedure described above, remove the remaining bearing inserts one at a time for inspection. Fig. 53 Main Bearing Caps and Brace. Fig. 55 Removing Upper Inserts INSTALLATION (1) Lubricate the bearing surface of each insert with engine oil.
Page 741 9 - 86 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) (b) Position the dial indicator rod so that it is (4) Remove the engine cylinder head. parallel to the center line of the crankshaft. (5) Position the pistons one at a time near the bot- (c) Pry the crankshaft forward, position the dial tom of the stroke.
Page 742 4.0L ENGINE 9 - 87 REMOVAL AND INSTALLATION (Continued) CAUTION: Ensure that the connecting rod bolts DO NOT scratch the crankshaft journals or cylinder walls. Short pieces of rubber hose, slipped over the rod bolts will provide protection during removal. (12) Have an assistant push the piston and con- necting rod assemblies up and through the top of the cylinder bores (Fig.
Page 743 9 - 88 4.0L ENGINE REMOVAL AND INSTALLATION (Continued) CRANKSHAFT OIL SEALS—REAR (7) Apply Mopar Gasket Maker sealer on both sides of cylinder block as shown in (Fig. 62). The dab The crankshaft rear main bearing oil seal consists of sealer should be 3 mm (0.125 in.) in diameter. of two half pieces of viton with a single lip that effec- (8) Position the lower seal into the bearing cap tively seals the rear of the crankshaft.
Page 744 4.0L ENGINE 9 - 89 REMOVAL AND INSTALLATION (Continued) Fig. 62 Location of Sealer (6) Install the radiator shroud. (7) Connect negative cable to battery. DISASSEMBLY AND ASSEMBLY VALVES AND VALVE SPRINGS This procedure is done with the engine cylinder head removed from the block.
Page 745 9 - 90 4.0L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) (5) Remove the valves, and place them in a rack in the same order as removed. INSTALLATION (1) Thoroughly clean the valve stems and the valve guide bores. (2) Lightly lubricate the stem. (3) Install the valve in the original valve guide bore.
Page 746 4.0L ENGINE 9 - 91 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: If the valve guides are reamed oversize, the ALTERNATIVE METHOD valve seats must be ground to ensure that the valve (1) Use a dial indicator to measure the lateral seat is concentric to the valve guide. movement of the valve stem (stem-to-guide clear- ance).
Page 747 9 - 92 4.0L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) CYLINDER BLOCK CLEANING AND INSPECTION DISASSEMBLY CYLINDER HEAD Refer to the applicable sections for detailed CLEANING instructions. (1) Drain the engine oil. Remove and discard the Thoroughly clean the engine cylinder head and cylin- oil filter.
Page 748 4.0L ENGINE 9 - 93 CLEANING AND INSPECTION (Continued) concave, the corresponding lobe on the camshaft is also the measurement near the middle of the bore, then worn. Replace the camshaft and defective tappets. repeat the measurement near the bottom of the bore. (4) Determine taper by subtracting the smaller CYLINDER BLOCK diameter from the larger diameter.
Page 749 9 - 94 4.0L ENGINE SPECIFICATIONS (Continued) Camshaft Camshaft Flatness ....0.05 mm per 152 mm No. 3 ..51.03 to 51.05 mm (2.009 to 2.010 in.) (0.002 in.
Page 750 4.0L ENGINE 9 - 95 SPECIFICATIONS (Continued) Camshaft Camshaft Piston Ring Groove Diameter—No.1 Compression Push Rod Diameter ... 7.92 to 8.00 mm (0.312 to 0.315 in.) Ring ..88.39 to 88.65 mm (3.48 to 3.49 in.) Hydraulic Tappet Diameter .
Page 751 9 - 96 4.0L ENGINE SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Adaptor Bolts ... . 102 N·m (50 ft. lbs.) Connecting Rod Nuts ....45 N·m (33 ft. lbs.) Oil Galley Cylinder Block Plug .
Page 752 4.0L ENGINE 9 - 97 SPECIAL TOOLS (Continued) Timing Case Cover Alignment and Seal installation Tool 6139 Vibration Damper Removal Tool 7697 Hydraulic Valve Tappet Removal/Installation Tool C-4129–A...
Page 753 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CATALYTIC CONVERTER ....1 CATALYTIC CONVERTER/EXHAUST PIPE ..3 EXHAUST HEAT SHIELDS .
Page 754 11 - 2 EXHAUST SYSTEM GENERAL INFORMATION (Continued) Fig. 1 Exhaust System—2.5L Engine Fig. 2 Exhaust System—4.0L Engine...
Page 755 EXHAUST SYSTEM 11 - 3 DIAGNOSIS AND TESTING EXHAUST SYSTEM EXHAUST SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE EXHAUST NOISE OR 1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking LEAKING EXHAUST GASES joints. 2. Rusted or blown out muffler. 2.
Page 756 11 - 4 EXHAUST SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. MUFFLER AND TAILPIPE ASSEMBLY WARNING: THE NORMAL OPERATING TEMPERA- TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
Page 757 EXHAUST SYSTEM 11 - 5 REMOVAL AND INSTALLATION (Continued) Fig. 6 Muffler and Tailpipe Assembly (3) Remove the tailpipe hangers from the insula- SPECIFICATIONS tors (Fig. 6). (4) Heat the catalytic converter-to-muffler connec- TORQUE SPECIFICATIONS tion with an oxyacetylene torch until the metal becomes cherry red.
Page 758 Tighten the bolts to 108 N·m (80 ft. lbs.) torque. FRONT TOW HOOK Some Jeep vehicles are equipped with front emer- FRONT BUMPER EXTENSION gency tow hooks. The tow hooks should be used for EMERGENCY purposes only.
Page 759 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) FRONT BUMPER REMOVAL (1) If equipped, disconnect the fog lamp harness connector. (2) Remove the screws that attach the bumper to the frame rail (Fig. 3). (3) If equipped, remove the tow hook. (4) Separate the bumper from the vehicle.
Page 760 N·m (35 ft. lbs.) torque. GENERAL INFORMATION The frame is constructed of mild-strength rectan- The Jeep TJ frame is the structural center of the gular tubing and crossmembers. The crossmembers vehicle. In addition to supporting the body and pay- join the siderails and retain them in alignment in load, the frame provides a station for the engine.
Page 761 13 - 4 FRAME AND BUMPERS FRAME REPAIRS SERVICE PROCEDURES DRILLING HOLES FRAME SERVICE Do not drill holes in the top and bottom of frame rail, metal fatigue can result causing frame failure. SAFETY PRECAUTIONS AND WARNINGS Holes drilled in the side of the frame rail must be at least 38 mm (1.5 in.) from the top and bottom WARNING: USE EYE PROTECTION WHEN GRIND- flanges.
Page 762 FRAME AND BUMPERS 13 - 5 SERVICE PROCEDURES (Continued) Fig. 4 Transmission Mount—Automatic Transmission Fig. 3 Energy Management Holes FRAME FASTENERS Bolts and nuts and can be used to repair frames or to install a reinforcement section on the frame. Conical-type washers are preferred over the split- ring type lock washers.
Page 763 13 - 6 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) (3) Install the nuts attaching the transmission mount to the skid plate. Tighten the nuts to 28 N·m (21 ft. lbs.) torque. (4) Remove the support under the transmission. (5) Remove the support from under the vehicle and lower the vehicle.
Page 764 FRAME AND BUMPERS 13 - 7 SPECIFICATIONS FRAME DIMENSIONS FRAME SIDE VIEW...
Page 765 13 - 8 FRAME AND BUMPERS SPECIFICATIONS (Continued) FRAME TOP VIEW...
Page 766 FRAME AND BUMPERS 13 - 9 SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION TORQUE Front Bumper Screw ..104 N·m (77 ft. lbs.) Front Tow Hook Screw ..108 N·m (80 ft. lbs.) Fuel Tank Skid Plate Nuts .
Page 767 FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page BUMPERS ....... 1 BUMPERS INDEX page...
Page 768 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) FRONT LICENSE PLATE BRACKET REAR LICENSE PLATE BRACKET REMOVAL REMOVAL (1) Remove the front license plate bracket attach- (1) Remove the rear license plate bracket attach- ing bolts and bracket (Fig. 3). ing screws (Fig.
Page 769 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....1 FUEL INJECTION SYSTEM ....23 FUEL DELIVERY SYSTEM INDEX page...
Page 770 14 - 2 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) vehicle. Chrysler recommends the use of gasoline Illumination of either light while operating on high that meet the AAMA specifications if they are avail- sulfur gasoline does not necessarily mean your emis- able.
Page 771 FUEL SYSTEM 14 - 3 DESCRIPTION AND OPERATION (Continued) gauge sending unit (fuel level sensor) and a separate fuel filter located at bottom of pump module • fuel tubes/lines/hoses • quick-connect fittings • fuel injector rail • fuel injectors • fuel tank •...
Page 772 14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition.
Page 773 FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) ROLLOVER VALVE(S) FUEL RAIL/FUEL DAMPER—2.5L ENGINE Refer to Group 25, Emission Control System for The fuel rail supplies the necessary fuel to each information. individual fuel injector and is mounted to the intake manifold (Fig.
Page 774 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING FUEL PUMP PRESSURE TEST—ALL ENGINES WITH PRESSURE TEST PORT Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere in this group.
Page 775 FUEL SYSTEM 14 - 7 DIAGNOSIS AND TESTING (Continued) (2) Start and warm engine and note pressure to Fuel Filter/Fuel Pressure Regulator Removal/In- gauge reading. Fuel pressure should be 339 kPa stallation for additional information. kPa (49.2 psi 5 psi) at idle. (c) If both fuel pressure and capacity are low, (3) If engine runs, but pressure is below 44.2 psi, replace fuel pump module assembly.
Page 776 14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) check valves in either the electric fuel pump or filter/ regulator may be leaking. Note: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump.
Page 777 FUEL SYSTEM 14 - 9 DIAGNOSIS AND TESTING (Continued) (8) Press ENTER three times. (9) Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). (10) Press ENTER to change 2 amp scale to 10 amp scale.
Page 778 14 - 10 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (18) Disconnect test leads from relay cavities Leak Detection Pump (LDP). The vehicle may be immediately after testing. equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP FUEL GAUGE SENDING UNIT and EVAP monitor system.
Page 779 FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) Inspect all hose connections such as clamps, cou- plings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of deg- radation that could result in failure.
Page 780 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) (6) Raise pull tab until it separates from quick- connect fitting (Fig. 17). Discard old pull tab. Fig. 18 Typical Two-Tab Type Quick-Connect Fitting WARNING: THE FUEL SYSTEM IS UNDER A CON- Fig.
Page 781 FUEL SYSTEM 14 - 13 SERVICE PROCEDURES (Continued) (7) Insert quick-connect fitting to component being (3) Clean fitting of any foreign material before dis- serviced and into plastic retainer. When a connection assembly. is made, a click will be heard. (4) To release fuel system component from quick- (8) Verify a locked condition by firmly pulling on connect fitting, firmly push fitting towards compo-...
Page 782 14 - 14 FUEL SYSTEM SERVICE PROCEDURES (Continued) properly installed to fuel rail. Recheck fuel line connection. (12) Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). (13) Connect negative battery cable to battery. (14) Start engine and check for leaks. REMOVAL AND INSTALLATION FUEL FILTER/FUEL PRESSURE REGULATOR The combination Fuel Filter/Fuel Pressure Regula-...
Page 783 FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) (6) The molded arrow (Fig. 22) on top of fuel pump module should be pointed towards front of vehicle (12 o’clock position). (7) Rotate filter/regulator until fuel supply tube (fitting) is pointed to 10 o’clock position. (8) Install new retainer clamp (clamp snaps over top of filter/regulator and locks to flanges on pump module).
Page 784 14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 26 Locknut Removal/Installation—Typical INSTALLATION Fig. 27 Fuel Pump Inlet Filter CAUTION: Whenever the fuel pump module is ser- FUEL GAUGE SENDING UNIT viced, the module gasket must be replaced. The fuel gauge sending unit (fuel level sensor) and (1) Using a new gasket, position fuel pump module float assembly is located on the side of fuel pump into opening in fuel tank.
Page 785 FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 30 Fuel Rail Mounting—2.5L Engine Fig. 29 Fuel Gauge Sending Unit Release Tab (9) Disconnect automatic transmission cable at (2) Connect electrical connector to terminals. throttle body (if equipped). (3) Install fuel pump module. Refer to Fuel Pump (10) Remove cable routing bracket (Fig.
Page 786 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (9) Install cable routing bracket to intake mani- (6) Disconnect fuel supply line latch clip and fuel fold. line at fuel rail. Refer to Quick-Connect Fittings in (10) Connect throttle cable at throttle body. this group for procedures.
Page 787 FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) FUEL INJECTORS FUEL TANK REMOVAL WARNING: THE FUEL SYSTEM IS UNDER CON- STANT FUEL PRESSURE EVEN WITH THE ENGINE (1) Remove fuel rail. Refer to Fuel Injector Rail OFF. THIS PRESSURE MUST RELEASED Removal in this section.
Page 788 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (12) Remove four skid plate-to-body nuts at rear of tank (Fig. 36). Do not loosen tank strap nuts (Fig. 36). (13) Lower the tank assembly. (14) If fuel pump module is to be removed, refer to Fuel Pump Module Removal/Installation.
Page 789 FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) Fig. 37 Fuel Tank Mounting Nuts—Front FUEL TANK FILLER TUBE CAP If replacement of the fuel tank filler tube cap is Fig. 38 Accelerator Pedal Mounting necessary, it must be replaced with an identical cap INSTALLATION to be sure of correct system operation.
Page 790 14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Snap cable into clip guides on engine cylinder head (valve) cover. (3) Push other end of cable through opening in dash panel until retaining tabs lock into panel. (4) From inside drivers compartment, slide throttle cable core wire into opening in top of accelerator pedal arm.
Page 791 FUEL SYSTEM 14 - 23 FUEL INJECTION SYSTEM INDEX page page GENERAL INFORMATION MANIFOLD ABSOLUTE PRESSURE (MAP) INTRODUCTION ......24 SENSOR—PCM INPUT .
Page 792 14 - 24 FUEL SYSTEM POWER STEERING PRESSURE SWITCH—2.5L VEHICLE SPEED SENSOR ....49 ENGINE ......46 SPECIFICATIONS POWERTRAIN CONTROL MODULE (PCM) .
Page 793 FUEL SYSTEM 14 - 25 GENERAL INFORMATION (Continued) ENGINE START-UP MODE sure A/C switches. Refer to Group 24, Heating and Air Conditioning for additional information. This is an Open Loop mode. The following actions • When engine has reached operating tempera- occur when the starter motor is engaged.
Page 794 14 - 26 FUEL SYSTEM GENERAL INFORMATION (Continued) • Air conditioning select signal (if equipped) If the vehicle is under hard deceleration with the • Air conditioning request signal (if equipped) proper rpm and closed throttle conditions, the PCM • Battery voltage will ignore the oxygen sensor input signal.
Page 795 FUEL SYSTEM 14 - 27 DESCRIPTION AND OPERATION (Continued) • Vehicle speed sensor The PCM can adapt its programming to meet chang- ing operating conditions. NOTE: Powertrain Control Module (PCM) Outputs: The PCM receives input signals from various switches and sensors. Based on these inputs, the •...
Page 796 FIVE VOLT SENSOR SUPPLY—PRIMARY and fuel injectors to the 12 volt + power supply. Jeep Supplies the required 5 volt power source to the models of previous years had used the ASD relay to...
Page 797 FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) Fig. 3 Camshaft Position Sensor—Typical The sensor is bolted to the transmission bellhous- ing. Fig. 4 Engine Coolant Temperature Sensor—Typical Refer to Group 8D, Ignition System for more crankshaft position sensor information. present (caused by a lean air/fuel mixture), the sen- The engine will not operate if the PCM does not sors produces a low voltage.
Page 798 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) tor (MIL) (or Check Engine) lamp. For more informa- tion, refer to Group 25, Emission Control Systems. The downstream sensor input is also used to adjust the upstream O2S goal voltage. This allows a better control of the exhaust gases as the catalytic conver- tor ages.
Page 799 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) POWER STEERING PRESSURE SWITCH—PCM INPUT A pressure sensing switch is included in the power steering system (mounted on the high-pressure line). This switch will be used only on vehicles equipped with a 2.5L engine and power steering. The switch (Fig.
Page 800 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus.
Page 801 FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) Fig. 11 Power Distribution Center (PDC) clutch. This is based on changes in engine operating conditions. The PCM will also de-energize the relay if Fig. 12 Data Link Connector Location coolant temperature exceeds 125°C (257°F). DUTY CYCLE EVAP PURGE SOLENOID AUTO SHUTDOWN (ASD) RELAY—PCM VALVE-PCM OUTPUT...
Page 802 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) engine idle speed by moving the IAC motor pintle in and out of the air control passage. The IAC motor is positioned when the ignition key is turned to the On position.
Page 803 FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) Fig. 14 Throttle Body (4.0L Engine Shown) The Throttle Position Sensor (TPS), IAC motor and Manifold Absolute Pressure sensor (MAP) Fig. 15 Powertrain Control Module (PCM) attached to the throttle body. The accelerator pedal cable, speed control cable (when equipped) and auto- matic transmission control cable (when equipped) are connected to the throttle arm.
Page 804 14 - 36 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (13) Inspect air cleaner inlet and air cleaner ele- ment for dirt or restrictions. (14) Inspect radiator grille area, radiator fins and air conditioning condenser for restrictions. (15) Verify intake manifold air temperature sensor wire connector is firmly connected to harness connec- tor (Fig.
Page 805 FUEL SYSTEM 14 - 37 DIAGNOSIS AND TESTING (Continued) Fig. 21 Rubber L-Shaped Fitting—MAP Sensor-to- Fig. 23 Upstream Oxygen Sensor Throttle Body with injector number (INJ 1, INJ 2 etc.) of its corre- sponding fuel injector and cylinder number. (18) Verify harness connectors are firmly con- nected to Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) (Fig.
Page 806 14 - 38 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 27 ASD and Fuel Pump Relay Terminals OPERATION • Terminal number 30 is connected to battery volt- age. For both the ASD and fuel pump relays, termi- nal 30 is connected to battery voltage at all times. •...
Page 807 FUEL SYSTEM 14 - 39 DIAGNOSIS AND TESTING (Continued) power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CON- TACT TERMINALS 85 OR 86 DURING THIS TEST. (7) Attach the other end of the jumper wire to relay terminal 86.
Page 808 14 - 40 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) priate Powertrain Diagnostics Procedures manual. To ENGINE COOLANT TEMPERATURE SENSOR test the O2S sensors only, refer to the following: To perform a complete test of the engine coolant The upstream O2S sensor is located on the exhaust temperature sensor and its circuitry, refer to DRB downpipe (Fig.
Page 809 FUEL SYSTEM 14 - 41 DIAGNOSIS AND TESTING (Continued) SENSOR RESISTANCE (OHMS)—COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR TEMPERATURE RESISTANCE (OHMS) °CEL. °FAHR. MIN. MAX. 291,490 381,710 85,850 108,390 49,250 61,430 29,330 35,990 17,990 21,810 11,370 13,610 9,120 10,880 7,370 8,750 4,900 5,750 Fig.
Page 810 14 - 42 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (2) Connect a pair of jumper wires to switch termi- voltage must be less than 4.49 volts. The output volt- nals. Route and secure jumper wires away from fan age should increase gradually as the throttle plate is blades and fan belt.
Page 811 FUEL SYSTEM 14 - 43 DIAGNOSIS AND TESTING (Continued) (10) Remove orifice tool and connect CCV tube to engine. (11) Install air duct to throttle body. REMOVAL AND INSTALLATION AUTOMATIC SHUTDOWN (ASD) RELAY The ASD relay is located in the Power Distribution Center (PDC) (Fig.
Page 812 14 - 44 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install relay to PDC. (2) Install cover to PDC. THROTTLE BODY A (factory adjusted) set screw is used to mechani- cally limit the position of the throttle body throttle plate.
Page 813 FUEL SYSTEM 14 - 45 REMOVAL AND INSTALLATION (Continued) throttle shaft on the other side of the socket tangs). (2) Install and tighten two mounting bolts (screws) The TPS will be under slight tension when rotated. to 7 N·m (60 in. lbs.) torque. (3) Install electrical connector.
Page 814 14 - 46 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) POWERTRAIN CONTROL MODULE (PCM) POWER STEERING PRESSURE SWITCH—2.5L The PCM is located in the engine compartment ENGINE (Fig. 47). This switch is not used with 4.0L six-cylinder engines. The power steering pressure switch is installed in the power steering high-pressure hose (Fig.
Page 815 FUEL SYSTEM 14 - 47 REMOVAL AND INSTALLATION (Continued) (3) Remove O2S sensor. Snap-On oxygen sensor wrench number YA 8875 (or equivalent) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor.
Page 816 14 - 48 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION INTAKE MANIFOLD AIR TEMPERATURE (1) Install air cleaner element into housing. SENSOR (2) Install housing cover to housing. Be sure cover The intake manifold air temperature (IAT) sensor is properly seated to air cleaner housing. is installed into intake manifold plenum near throttle (3) Connect air tube at cover.
Page 817 FUEL SYSTEM 14 - 49 REMOVAL AND INSTALLATION (Continued) VEHICLE SPEED SENSOR REMOVAL (1) Raise and support vehicle. The vehicle speed sensor is located on the speed- (2) Disconnect electrical connector from sensor. ometer pinion gear adapter. The pinion gear adapter (3) Remove sensor mounting bolt (Fig.
Page 818 14 - 50 FUEL SYSTEM SPECIAL TOOLS FUEL SYSTEM O2S (Oxygen Sensor) Remover/Installer—C-4907 Spanner Wrench—6856 Adapters, Fuel Pressure Test—6539 and/or 6631 Test Kit, Fuel Pressure—5069 Fitting, Air Metering—6714 Test Kit, Fuel Pressure—C-4799-B Fuel Line Removal Tool—6782...
Page 819 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page GENERAL INFORMATION FUEL REQUIREMENTS—LEADED FUEL VEHICLES ......1 GENERAL INFORMATION Engine damage resulting from operating with a heavy spark knock may not be covered by the new...
Page 820 STEERING 19 - 1 STEERING CONTENTS page page POWER STEERING ......1 STEERING COLUMN ..... . 25 POWER STEERING GEAR .
Page 821 19 - 2 STEERING DIAGNOSIS AND TESTING POWER STEERING SYSTEM DIAGNOSIS CHARTS STEERING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound evident at a standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar to that of a water tap being closed slowly.
Page 822 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) BINDING AND STICKING CONDITION POSSIBLE CAUSE CORRECTION 1. Low fluid level. 1. Fill to proper level. DIFFICULT TO TURN WHEEL STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure. 3. Steering component. 3.
Page 823 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION VEHICLE PULLS OR LEADS TO 1. Tire Pressure. 1. Adjust tire pressure. ONE SIDE 2. Radial tire lead. 2. Cross front tires. 3. Brakes dragging. 3. Repair as necessary. 4.
Page 824 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) CAUTION: Do not force the pump to operate against the stops for more than 2 to 4 seconds at a time because, pump damage will result. PUMP SPECIFICATIONS ENGINE RELIEF PRESSURE FLOW RATE (GPM) 2.5L 9653 kPa (1400 psi) 1500 RPM 2.4 - 2.8 GPM...
Page 825 19 - 6 STEERING POWER STEERING PUMP INDEX page page DESCRIPTION AND OPERATION PUMP REMOTE RESERVOIR – 2.5L ..7 POWER STEERING PUMP ....6 DISASSEMBLY AND ASSEMBLY DIAGNOSIS AND TESTING FLOW CONTROL VALVE .
Page 826 STEERING 19 - 7 (7) Lower the vehicle, start the engine and turn DIAGNOSIS AND TESTING the steering wheel slowly from lock to lock. (8) Stop the engine and check the fluid level and PUMP LEAKAGE DIAGNOSIS refill as required. (9) If the fluid is extremely foamy or milky look- ing, allow the vehicle to stand a few minutes and repeat the procedure.
Page 827 19 - 8 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 2 Pump Mounting DISASSEMBLY AND ASSEMBLY PUMP PULLEY DISASSEMBLY (1) Remove pump assembly. (2) Remove pulley from pump with Puller C-4333 (Fig. 4). Fig. 3 Pump Reservoir – 2.5L (4) Fill reservoir to proper level, refer to Power Steering Pump Initial Operation.
Page 828 STEERING 19 - 9 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Replace pulley if bent, cracked, or loose. (2) Install pulley on pump with Installer C-4063-B (Fig. 5) flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. Fig.
Page 829 19 - 10 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (2) Install O-ring seal onto fitting. (3) Install flow control valve in pump housing and tighten to 75 N·m (55 ft. lbs.). (4) Install pressure hose to valve. SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Adapters, Power Steering Flow/Pressure Tester Power Steering Pump...
Page 830 STEERING 19 - 11 POWER STEERING GEAR INDEX page page DESCRIPTION AND OPERATION RACK PISTON AND WORM SHAFT ..17 POWER STEERING GEAR ....11 SPOOL VALVE .
Page 831 19 - 12 STEERING DESCRIPTION AND OPERATION (Continued) Fig. 1 Recirculating Ball Type Gear...
Page 832 STEERING 19 - 13 DIAGNOSIS AND TESTING POWER STEERING GEAR LEAKAGE DIAGNOSIS Fig. 2 Steering Gear Mounting (5) Install power steering hoses/tubes to power steering pump. (6) Fill power steering system to proper level, refer to Steering Pump Initial Operation. DISASSEMBLY AND ASSEMBLY HOUSING END PLUG DISASSEMBLY...
Page 833 19 - 14 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (2) Slowly rotate stub shaft with 12 point socket PITMAN SHAFT/SEALS/BEARING COUNTER-CLOCKWISE to force the end plug out from housing. DISASSEMBLY (1) Clean exposed end of pitman shaft and housing CAUTION: Do not turn stub shaft any further than with a wire brush.
Page 834 STEERING 19 - 15 DISASSEMBLY AND ASSEMBLY (Continued) (9) Install preload adjuster nut. Do not tighten nut until after Over-Center Rotation Torque adjustment has been made. (10) Install gasket to side cover and bend tabs around edges of side cover (Fig. 6). (11) Install pitman shaft assembly and side cover to housing.
Page 835 19 - 16 STEERING DISASSEMBLY AND ASSEMBLY (Continued) Fig. 10 Thrust Support Assembly Fig. 12 Stub Shaft Fig. 11 Valve Assembly With Stub Shaft ASSEMBLY NOTE: Clean and dry all components, then lubri- cate with power steering fluid. Fig. 13 Spool Valve (1) Install spool valve spool O-ring.
Page 836 STEERING 19 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 16 Stub Shaft Cap O-Ring Fig. 14 Valve Seals Fig. 17 Rack Piston End Plug (6) Turn the stub shaft with a 12 point socket COUNTERCLOCKWISE, this will force the rack pis- ton onto the tool and hold the rack piston balls in place.
Page 837 19 - 18 STEERING DISASSEMBLY AND ASSEMBLY (Continued) Fig. 18 Rack Piston with Arbor Fig. 20 Rack Piston Teflon Ring and O-Ring Fig. 19 Rack Piston (14) Remove the worm shaft from the housing (Fig. 21). ASSEMBLY Fig. 21 Worm Shaft (4) Lubricate and install rack piston balls through NOTE: Clean and dry all components and lubricate return guide hole while turning worm shaft COUN-...
Page 838 STEERING 19 - 19 DISASSEMBLY AND ASSEMBLY (Continued) ADJUSTMENTS STEERING GEAR CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result. NOTE: Adjusting the steering gear in the vehicle is not recommended.
Page 839 19 - 20 STEERING ADJUSTMENTS (Continued) Fig. 25 Alignment Marking On Housing Fig. 27 Aligning To The Second Mark Fig. 26 Second Marking On Housing OVER-CENTER Fig. 28 Steering Gear Centered NOTE: Before performing this procedure, the worm bearing preload adjustment must be performed. NOTE: The stub shaft must rotate smoothly without sticking or binding.
Page 840 STEERING 19 - 21 ADJUSTMENTS (Continued) (6) If an adjustment to the Over-Center Rotating TORQUE CHART Torque is necessary, first loosen the adjuster lock nut. Then turn the pitman shaft adjuster screw back DESCRIPTION TORQUE (COUNTERCLOCKWISE) until fully extended, then Power Steering Gear turn back in (CLOCKWISE) one full turn.
Page 841 19 - 22 STEERING STEERING LINKAGE INDEX page page DESCRIPTION AND OPERATION PITMAN ARM ......23 STEERING LINKAGE .
Page 842 STEERING 19 - 23 REMOVAL AND INSTALLATION (Continued) (2) Install the washer and nut on the shaft and tighten the nut to 251 N·m (185 ft. lbs.). (3) Install drag link ball stud to pitman arm. Install nut and tighten to 81 N·m (60 ft. lbs.). Install a new cotter pin.
Page 843 19 - 24 STEERING SPECIFICATIONS SPECIAL TOOLS TORQUE CHART STEERING LINKAGE DESCRIPTION TORQUE Pitman Arm Shaft ....251 N·m (185 ft. lbs.) Drag Link Ball Studs .
Page 844 STEERING 19 - 25 STEERING COLUMN INDEX page page DESCRIPTION AND OPERATION SPECIFICATIONS STEERING COLUMN ..... 25 TORQUE CHART ......27 REMOVAL AND INSTALLATION STEERING COLUMN .
Page 845 19 - 26 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 1 Steering Wheel Fig. 3 Column Shrouds Fig. 2 Key Cylinder Release Access Hole (8) Remove the steering coupler bolt and column mounting nuts (Fig. 4) then lower column off the mounting studs.
Page 846 STEERING 19 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 5 Steering Column Harness Fig. 7 Clock Spring (10) Install lower column shrouds and install mounting screws. (11) Install ignition cylinder. (12) Install knee blocker and knee blocker cover, refer to Group 8E Instrument Panel Systems. (13) Install steering wheel and tighten nut to 54 N·m (40 ft.
Page 847 TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE CONTENTS page page AUTOMATIC TRANSMISSION—30/32RH ..75 AX5 MANUAL TRANSMISSION ....1 AX15 MANUAL TRANSMISSION .
Page 848: General Information
21 - 2 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) Fig. 1 AX5 Manual Transmission Fig. 3 Fill Plug Location TRANSMISSION ASSEMBLY INFORMATION Lubricate transmission components with Fig. 2 Transmission Identification Mopar 75W–90, GL 3 gear lubricant during assem- The fill plug is on the passenger side of the bly.
Page 849: Diagnosis And Testing
TRANSMISSION AND TRANSFER CASE 21 - 3 GENERAL INFORMATION (Continued) Fig. 4 Geartrain Components avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid DIAGNOSIS AND TESTING an incorrect lubricant level condition. LOW LUBRICANT LEVEL HARD SHIFTING A low transmission lubricant level is generally the...
Page 850: Transmission Noise
21 - 4 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) TRANSMISSION NOISE (13) Secure transfer case, if equipped, to jack with safety chains. Most manual transmissions make some noise dur- (14) Disconnect transfer case shift linkage at ing normal operation. Rotating gears generate a mild transfer case, if equipped.
Page 851 TRANSMISSION AND TRANSFER CASE 21 - 5 REMOVAL AND INSTALLATION (Continued) CAUTION: It is important that the crankshaft posi- tion sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations. (18) Support engine with adjustable jack stand.
Page 852 21 - 6 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (11) Install rear crossmember. Tighten crossmem- (28) Install and tighten propeller shaft U–joint ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque. clamp bolts to 19 N·m (170 in. lbs.) torque. (12) Install fasteners to hold rear cushion and (29) Install slave cylinder in clutch housing.
Page 853: Adapter Housing Seal
TRANSMISSION AND TRANSFER CASE 21 - 7 REMOVAL AND INSTALLATION (Continued) (3) Install new front bearing retainer gasket to the front bearing retainer. (4) Install the front bearing retainer onto the transmission case. (5) Install the bolts to hold the bearing retainer onto the transmission case.
Page 854: Disassembly And Assembly Adapter/Extension Housing And Front Bearing Retainer
21 - 8 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (7) Remove shift tower gasket from shift tower or transmission case (Fig. 17). Fig. 16 Remove Shift Tower Fig. 15 Install Adapter Housing Seal (3) Install transfer case. (4) Check and add fluid to transmission as neces- sary.
Page 855 TRANSMISSION AND TRANSFER CASE 21 - 9 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 20 Remove Detent Spring Fig. 18 Clutch Housing Fig. 21 Remove Detent Ball (15) Remove adapter/extension housing bolts. (16) Loosen adapter/extension housing by tapping it loose with plastic mallet (Fig. 26). (17) Remove adapter/extension housing (Fig.
Page 856 21 - 10 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 22 Shift Arm Retainer Bolt Removal Fig. 24 Removing Shift Lever Shaft Plug Fig. 23 Shift Arm Rstrictor Pins (c) Remove speedometer drive gear locating snap-ring (Fig. 28). (19) Remove the bolts holding the front bearing retainer to the transmission case.
Page 857 TRANSMISSION AND TRANSFER CASE 21 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (21) Remove input shaft bearing snap-ring (Fig. 30). (22) Remove countershaft front bearing snap-ring. Fig. 26 Loosen Adapter/Extension Housing Fig. 29 Remove Front Bearing Retainer Fig. 27 Remove Adapter/Extension Housing–Typical Fig.
Page 858 21 - 12 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 31 Separate Intermediate Plate and Fig. 34 Install Transmission Gear Case to the Transmission Case Intermediate Plate (4) Install new front bearing snap rings (Fig. 35). Fig. 32 Remove Intermediate Plate from Transmission Case (3) Align geartrain and shift rails with mating holes in transmission case and install transmission...
Page 859 TRANSMISSION AND TRANSFER CASE 21 - 13 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 36 Install Front Bearing Retainer Fig. 38 Install Adapter/Extension Housing–Typical (8) Apply a 1/8 to 3/16 inch wide bead of Threeb- ond Liquid Gasket TB1281, P/N 83504038, to seal- ing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes.
Page 860 21 - 14 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (14) Install and tighten shifter arm shaft plug to 18 N·m (13 ft. lbs.) torque (Fig. 42). Fig. 42 Shifter Arm Shaft Plug Installation Fig. 40 Install Shifter Arm Shaft Fig.
Page 861 TRANSMISSION AND TRANSFER CASE 21 - 15 DISASSEMBLY AND ASSEMBLY (Continued) (18) Install detent plug and tighten to 19 N·m (14 ft. lbs.) (Fig. 46). Fig. 46 Install Detent Ball Plug Fig. 44 Install Detent Ball Fig. 47 Install Shift Tower Fig.
Page 862 21 - 16 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) SHIFT MECHANISM AND GEARTRAIN (3) Remove bolt holding fifth gear shift fork to shift rail (Fig. 51). DISASSEMBLY (1) Install suitable bolts and washers in intermedi- ate plate (Fig. 49). Then clamp plate and gear assem- bly in vise.
Page 863 TRANSMISSION AND TRANSFER CASE 21 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Remove Fifth Gear Synchro Ring Fig. 55 Remove Fifth Gear Thrust Ring Fig. 54 Remove Fifth Gear and Synchro Assembly Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball NOTE: There are many lock balls, check balls, interlock balls, and interlock pins used in various places in the transmission.
Page 864 21 - 18 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 58 Remove Output Shaft Rear Bearing Retainer Fig. 60 Remove Reverse Shift Arm Bracket Bolts Fig. 59 Remove Shift Fork To Shift Rail Bolts (14) Remove snap-ring holding output shaft rear bearing into the intermediate plate (Fig.
Page 865 TRANSMISSION AND TRANSFER CASE 21 - 19 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 62 Remove Countershaft and Countershaft Rear Bearing Fig. 64 Remove 3–4 Shift Fork Fig. 63 Remove Mainshaft (20) Remove the 1–2 shift fork from the 1–2 and the 3–4 shift rails (Fig. 65). (21) Remove threaded plugs from intermediate plate.
Page 866 21 - 20 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 68 Remove Fifth Gear Check Ball Fig. 66 Remove Lock Ball And Spring (23) Remove fifth gear shift rail (Fig. 67). Fig. 69 Remove Reverse Shift Head And Rail Assembly Fig.
Page 867 TRANSMISSION AND TRANSFER CASE 21 - 21 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 71 Remove Interlock Pin From Reverse Shift Rail Fig. 73 Remove 1–2 Shift Rail Interlock Pin Fig. 74 Remove 1–2 Check Ball ASSEMBLY Refer to (Fig. 75) while assembling and installing the shift rail components.
Page 868 21 - 22 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 75 Shift Rail Components Fig. 76 Install 1–2 Check Ball Fig. 77 Install 1–2 Shift Rail Interlock Pin (4) Install the 1–2 shift rail into the intermediate (6) Install the reverse check ball into the interme- plate.
Page 869 TRANSMISSION AND TRANSFER CASE 21 - 23 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 80 Install Reverse Arm Bracket to Fork Fig. 78 Install Reverse Check Ball (8) Assemble the reverse arm bracket to the reverse fork (Fig. 80). Fig. 81 Install Reverse Shift Rail Fig.
Page 870 21 - 24 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 83 Install Fifth Gear Check Ball Fig. 85 Install 1–2 Shift Fork Fig. 84 Install Fifth Gear Shift Rail (15) Install the shift rail detent balls in the inter- mediate plate.
Page 871 TRANSMISSION AND TRANSFER CASE 21 - 25 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 87 Install Shift Fork Bolts Fig. 89 Install Compression Spring And Pin (28) Position the mainshaft rear bearing retainer over the output shaft and onto the intermediate plate. (29) Install new bolts to hold the bearing retainer to the intermediate plate.
Page 872 21 - 26 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 91 Align Idler Shaft Pin Fig. 94 Install Fifth Gear Thrust Ring (43) Position the countershaft fifth gear assembly on the countershaft. Ensure that the fifth gear fork is installed onto the fifth gear shift rail.
Page 873: Countershaft
TRANSMISSION AND TRANSFER CASE 21 - 27 DISASSEMBLY AND ASSEMBLY (Continued) COUNTERSHAFT DISASSEMBLY (1) Remove select fit snap-ring holding the coun- tershaft front bearing onto the countershaft (Fig. 96). (2) Using Bearing Splitter P-334, a suitable spacer on center of countershaft, and a shop press, remove the countershaft front bearing from the countershaft.
Page 874: Output Shaft
21 - 28 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 100 Install Output Shaft Pilot Bearing Rollers OUTPUT SHAFT DISASSEMBLY (1) Remove input shaft and output shaft pilot bearing rollers from output shaft. (2) Measure and note thrust clearance of output shaft gears (Fig.
Page 875 TRANSMISSION AND TRANSFER CASE 21 - 29 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 102 Remove Fifth Gear Snap-ring Fig. 104 Remove First Gear Bearing Inner Race Lock Ball Fig. 103 Remove Fifth Gear, First Gear Bearing, And Fig. 105 Remove Second Gear, Reverse Gear, And Race 1–2 Synchronizer (5) Remove first gear needle roller bearing from...
Page 876 21 - 30 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 106 Remove 3–4 Synchronizer Snap Ring Fig. 108 Synchronizer Identification (4) Install third gear over bearing and onto output shaft flange. (5) Install third gear synchronizer ring to third gear.
Page 877 TRANSMISSION AND TRANSFER CASE 21 - 31 DISASSEMBLY AND ASSEMBLY (Continued) (9) Install snap-ring to hold 3–4 synchronizer onto output shaft. (10) Verify third gear thrust clearance with feeler gauge (Fig. 110). Clearance should be 0.10 – 0.25 mm (0.004 – 0.010 in.). If clearance is out of specification, refer to Cleaning and Inspection section within this group.
Page 878: Semi-Synchronized Reverse Idler Gear
21 - 32 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 113 Check First–Second Gear Thrust Clearance (25) Position fifth gear onto output shaft with the gear’s short shoulder toward the rear of shaft. Ensure that the gear and output shaft splines are aligned.
Page 879 TRANSMISSION AND TRANSFER CASE 21 - 33 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 115 Remove Reverse Idler Gear Snap-ring Fig. 118 Remove Reverse Idler Gear Synchronizer Ring CLEANING AND INSPECTION AX5 MANUAL TRANSMISSION COMPONENTS GENERAL INFORMATION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air.
Page 880 21 - 34 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Fig. 120 Check Output Shaft Runout GEAR AND SYNCHRONIZER Install the needle bearing and inner race in the first gear. Then check oil clearance between the gear and inner race (Fig. 121). Clearance should be 0.009 –...
Page 881 TRANSMISSION AND TRANSFER CASE 21 - 35 CLEANING AND INSPECTION (Continued) Fig. 122 Check Gear–To–Shaft Oil Clearance Fig. 124 Check Fork–To–Hub Clearance SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plugs, Access ....19 N·m (14 ft.lbs.) Bolts, Adapter Housing .
Page 882 21 - 36 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS 8212 Installer, Seal C-3339 Dial Indicator Set 8208 Installer, Seal C-3995-A Installer, Extension Housing Seal P-334 Splitter, Bearing 8109 Cup, Installer C-4171 Handle, Universal Tool 8211 Installer, Seal L-4507 Tube, Driver...
Page 883 TRANSMISSION AND TRANSFER CASE 21 - 37 SPECIAL TOOLS (Continued) 6747–1A Adapter, Fixture MD-998805 Installer, Seal...
Page 884 21 - 38 TRANSMISSION AND TRANSFER CASE AX15 MANUAL TRANSMISSION INDEX page page GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY AX15 MANUAL TRANSMISSION ... . . 38 ADAPTER/EXTENSION HOUSING AND FRONT RECOMMENDED LUBRICANT ....39 BEARING RETAINER .
Page 885 TRANSMISSION AND TRANSFER CASE 21 - 39 GENERAL INFORMATION (Continued) Fig. 2 Identification Code Number Location Fig. 3 Fill Plug Location TRANSMISSION GEAR RATIOS Gear ratios for the AX15 manual transmission are as follows: • First gear: 3.83:1 • Second gear: 2.33:1 •...
Page 886 21 - 40 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) Fig. 5 Output Shaft and Gears avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid DIAGNOSIS AND TESTING an incorrect lubricant level condition. LOW LUBRICANT LEVEL HARD SHIFTING A low transmission lubricant level is generally the...
Page 887 TRANSMISSION AND TRANSFER CASE 21 - 41 DIAGNOSIS AND TESTING (Continued) TRANSMISSION NOISE (13) Secure transfer case, if equipped, to jack with safety chains. Most manual transmissions make some noise dur- (14) Disconnect transfer case shift linkage at ing normal operation. Rotating gears generate a mild transfer case, if equipped.
Page 888 21 - 42 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) CAUTION: It is important that the crankshaft posi- tion sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations. (18) Support engine with adjustable jack stand.
Page 889 TRANSMISSION AND TRANSFER CASE 21 - 43 REMOVAL AND INSTALLATION (Continued) (11) Install rear crossmember. Tighten crossmem- (27) Align marks on front propeller shaft, axle, ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque. and transfer case yokes, if equipped. (12) Install fasteners to hold rear cushion and (28) Install and tighten propeller shaft U–joint bracket to transmission.
Page 890 21 - 44 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (2) Remove any residual gasket material from the sealing surfaces of the bearing retainer and the transmission case. (3) Install new front bearing retainer gasket to the front bearing retainer. (4) Install the front bearing retainer onto the transmission case.
Page 891 TRANSMISSION AND TRANSFER CASE 21 - 45 REMOVAL AND INSTALLATION (Continued) (7) Remove shift tower gasket from shift tower or transmission case (Fig. 18). Fig. 17 Remove Shift Tower Fig. 16 Install Adapter Housing Seal (3) Install transfer case. (4) Check and add fluid to transmission as neces- sary.
Page 892 21 - 46 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 21 Remove Detent Spring Fig. 19 Clutch Housing Fig. 22 Remove Detent Ball Fig. 20 Remove Detent Ball Plug (14) Remove the shift arm from the adapter hous- ing.
Page 893 TRANSMISSION AND TRANSFER CASE 21 - 47 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 24 Shift Arm Rstrictor Pins Fig. 25 Removing Shift Lever Shaft Plug Fig. 26 Remove Shifter Shaft Fig. 27 Adapter/Extension Housing Bolts...
Page 894 21 - 48 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 30 Speedometer Drive Gear Assembly Fig. 28 Loosen Adapter/Extension Housing Fig. 31 Remove Front Bearing Retainer Fig. 29 Remove Adapter/Extension Housing (18) On 4x2 transmissions; (a) Remove speedometer gear retaining snap- ring from output shaft.
Page 895 TRANSMISSION AND TRANSFER CASE 21 - 49 DISASSEMBLY AND ASSEMBLY (Continued) shown, making sure to keep sealer bead to inside of bolt holes (Fig. 36). (3) Align geartrain and shift rails with mating holes in transmission case and install transmission case to the intermediate plate (Fig.
Page 896 21 - 50 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 40 Speedometer Drive Gear Assembly Fig. 38 Install Front Bearing Snap-rings Fig. 41 Install Adapter/Extension Housing Fig. 39 Install Front Bearing Retainer (8) Apply a 1/8 to 3/16 inch wide bead of Threeb- ond Liquid Gasket TB1281, P/N 83504038, to seal- ing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes.
Page 897 TRANSMISSION AND TRANSFER CASE 21 - 51 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 43 Install Shifter Arm Shaft Fig. 45 Shifter Arm Shaft Plug Installation Fig. 44 Install Shift Arm Retainer Bolt Fig. 46 Install Shifter Restrictor Pins (15) Install shifter restrictor pins in shift tower and tighten to 27 N·m (20 ft.
Page 898: Shift Mechanism And Geartrain
21 - 52 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (17) Install detent spring (Fig. 48). (20) Install new metal o-ring to the backup lamp (18) Install detent plug and tighten to 19 N·m (14 switch. ft. lbs.) (Fig. 49). (21) Install backup lamp switch (Fig.
Page 899 TRANSMISSION AND TRANSFER CASE 21 - 53 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 51 Positioning Intermediate Plate In Vise Fig. 54 Remove Fifth Gear Shift Fork Fig. 52 Remove Fifth Gear Snap-ring Fig. 55 Remove Reverse Shift Head Assembly Fig. 53 Remove Fifth Gear Shift Fork Retainer Bolt...
Page 900 21 - 54 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 58 Remove Fifth Gear And Synchro Assembly Fig. 56 Remove Fifth Gear Blocker Ring Fig. 59 Remove Fifth Gear Thrust Ring Fig. 57 Remove Fifth Gear Synchro Ring (10) Remove the countershaft fifth gear assembly from countershaft (Fig.
Page 901 TRANSMISSION AND TRANSFER CASE 21 - 55 DISASSEMBLY AND ASSEMBLY (Continued) (13) Remove bolts holding output shaft rear bear- ing retainer to intermediate plate (Fig. 61). Fig. 63 Remove Reverse Idler Shaft And Gear Fig. 61 Remove Output Shaft Rear Bearing Retainer Bolts (14) Remove rear bearing retainer (Fig.
Page 902 21 - 56 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 68 Remove Fifth Gear Shift Rail Lock Ball (21) Remove the 1–2 and 3–4 shift rail c-rings using two equally sized screwdrivers (Fig. 69). (22) Remove bolts holding 1–2 and 3–4 shift forks to the shift rails (Fig.
Page 903 TRANSMISSION AND TRANSFER CASE 21 - 57 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 71 Remove 3–4 Shift Rail Fig. 69 Remove Shift Rail C-rings Fig. 72 Remove 3–4 Shift Rail Interlock Plug (27) Remove the 1–2 shift rail interlock pin from the 1–2 shift rail (Fig.
Page 904 21 - 58 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 75 Remove 1–2 Shift Rail Interlock Pin Fig. 73 Remove Shift Forks Fig. 76 Remove 1–2 Shift Rail Interlock Plug (32) Remove the interlock pin from the reverse shift rail (Fig.
Page 905 TRANSMISSION AND TRANSFER CASE 21 - 59 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 79 Remove Reverse Shift Rail Interlock Pin Fig. 77 Remove Reverse Shift Rail C-ring Fig. 80 Remove Output Shaft Rear Bearing Snap-ring Fig. 78 Remove Reverse Shift Rail (36) Remove the countershaft by moving the coun- tershaft rearward until the countershaft is clear of the intermediate plate.
Page 906 21 - 60 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Align and mesh the mainshaft and counter- (12) Install c-ring to hold the reverse shift rail into shaft gears as much as possible. the intermediate plate. (6) Install the countershaft bearing over the coun- (13) Install the 1–2 and 3–4 shift forks into the tershaft bearing boss and into the intermediate plate.
Page 907 TRANSMISSION AND TRANSFER CASE 21 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 86 Install 1–2 Shift Rail Interlock Pin Fig. 89 Install 3–4 Shift Rail (17) Install 3–4 shift rail interlock plug into the (19) Install new bolts to hold the shift forks to the intermediate plate (Fig.
Page 908 21 - 62 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (21) Install the fifth gear shift rail lock ball in the intermediate plate (Fig. 94). (22) Install the fifth gear shift rail into the inter- mediate plate. (23) Install reverse idler gear and idler gear shaft (Fig.
Page 909 TRANSMISSION AND TRANSFER CASE 21 - 63 DISASSEMBLY AND ASSEMBLY (Continued) (31) Position fifth gear blocker ring onto counter- shaft. Verify that blocker ring and countershaft splines are aligned. (32) Using a suitable driver and mallet, seat the blocker ring onto the countershaft. (33) Select the thickest snap-ring the will fit into the snap–ring groove of the countershaft.
Page 910 21 - 64 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 101 Install Reverse Shift Head And Rail Assembly Fig. 104 Install Detent Balls And Springs COUNTERSHAFT DISASSEMBLY (1) Remove select fit snap-ring holding the coun- Fig. 102 Install Fifth Gear Shift Fork tershaft front bearing onto the countershaft (Fig.
Page 911 TRANSMISSION AND TRANSFER CASE 21 - 65 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 107 Remove Output Shaft Pilot Bearing Fig. 105 Countershaft Front Bearing Snap-ring INPUT SHAFT DISASSEMBLY (1) Verify that the 3–4 synchronizer is in the neu- tral position. (2) Separate input shaft from output shaft (Fig. 106).
Page 912 21 - 66 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) DISASSEMBLY (1) Remove input shaft and output shaft pilot bearing from output shaft (Fig. 111), if necessary. (2) Measure and note thrust clearance of output shaft gears (Fig. 112). First gear clearance should be 0.10 –...
Page 913 TRANSMISSION AND TRANSFER CASE 21 - 67 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 112 Check Output Shaft Gear Thrust Clearance Fig. 114 Remove Fifth Gear, First Gear Bearing, And (3) Remove output shaft fifth gear snap ring with Thrust Washer two screwdrivers (Fig. 113). (5) Remove first gear thrust washer locating pin from output shaft.
Page 914 21 - 68 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 117 Remove 3–4 Synchronizer And Third Gear Fig. 115 Remove Second Gear And 1–2 Synchronizer/Reverse Gear Fig. 118 Synchronizer Identification (4) Install third gear over bearing and onto output shaft flange.
Page 915 TRANSMISSION AND TRANSFER CASE 21 - 69 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 119 Select 3–4 Synchronizer Snap-ring Fig. 121 Second Gear And Synchronizer Assembly (17) Install snap-ring to hold 1–2 synchronizer/re- verse gear onto output shaft. (18) Install first gear synchronizer ring into 1–2 synchronizer/reverse gear.
Page 916: Cleaning And Inspection
21 - 70 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 122 First And Fifth Gear Components Fig. 124 Select/Install Fifth Gear Snap Ring CLEANING AND INSPECTION AX15 MANUAL TRANSMISSION COMPONENTS GENERAL INFORMATION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air.
Page 917 TRANSMISSION AND TRANSFER CASE 21 - 71 CLEANING AND INSPECTION (Continued) Inspect the threads in the case, housing, and plate. Minor thread damage can be repaired with steel thread inserts, if necessary. Do not attempt to repair any threads which show evidence of cracks around the threaded hole.
Page 918: Specifications
21 - 72 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plugs, Access ....19 N·m (14 ft.lbs.) Bolts, Adapter Housing ..34 N·m (25 ft.lbs.) Switch, Back-up Light .
Page 919: Special Tools Ax5
TRANSMISSION AND TRANSFER CASE 21 - 73 SPECIAL TOOLS AX15 8208 Installer, Seal C-3339 Dial Indicator Set L-4407A Puller, Gear C-4171 Handle, Universal Tool P-334 Splitter, Bearing 8209 Installer, Seal 8109 Cup, Installer 8212 Installer, Seal...
Page 920 21 - 74 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) 6052 Tube, Driver MD-998805 Tube, Driver 6761 Adapter, Installer L-4507 Tube, Driver...
Page 921 TRANSMISSION AND TRANSFER CASE 21 - 75 AUTOMATIC TRANSMISSION—30/32RH INDEX page page GENERAL INFORMATION PARK LOCK ......105 30/32RH AUTOMATIC TRANSMISSION .
Page 922 21 - 76 TRANSMISSION AND TRANSFER CASE (1) A result of restricted fluid flow through the GENERAL INFORMATION main and/or auxiliary cooler. This condition is usu- ally the result of a faulty or improperly installed 30/32RH AUTOMATIC TRANSMISSION drainback valve, a damaged main cooler, or severe The 30RH automatic transmission is used with the restrictions in the coolers and lines caused by debris 2.5L engine.
Page 923 TRANSMISSION AND TRANSFER CASE 21 - 77 GENERAL INFORMATION (Continued) Fig. 1 30/32 RH Automatic Transmission...
Page 924 21 - 78 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) GEARSHIFT MECHANISM The shift mechanism is cable operated and pro- vides six shift positions. The shift indicator is located on the console next to the gear shift. The shift posi- tions are: •...
Page 925 TRANSMISSION AND TRANSFER CASE 21 - 79 DESCRIPTION AND OPERATION (Continued) The 1-2 shift valve provide 1-2 and 2-1 shifts and CONVERTER CLUTCH ENGAGEMENT the 2-3 shift valve provide 2-3 and 3-2 shifts. Converter clutch engagement in third gear is con- The 1-2 shift control valve transmits 1-2 shift pres- trolled by sensor inputs to the powertrain control sure to the accumulator piston.
Page 926 21 - 80 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION (Continued) Fig. 3 Ignition Interlock Cable Routing PRELIMINARY DIAGNOSIS Two basic procedures are required. One procedure for vehicles that are drivable and an alternate proce- dure for disabled vehicles (will not back up or move forward).
Page 927 TRANSMISSION AND TRANSFER CASE 21 - 81 DIAGNOSIS AND TESTING (Continued) (3) Check for cracked, leaking cooler lines, or loose (d) NEUTRAL position—Engine running and or missing pressure-port plugs. brakes applied, apply forward force on center of (4) Raise and support vehicle on safety stands, shift handle.
Page 928 21 - 82 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) required, the 300 psi gauge can be used at any of the other test ports. Pressure Test Port Locations Pressure test ports locations are provided at the accumulator, front servo, and rear servo, governor passage, and overdrive clutch pressure passage (Fig.
Page 929 TRANSMISSION AND TRANSFER CASE 21 - 83 DIAGNOSIS AND TESTING (Continued) PRESSURE TEST PROCEDURE (4) Read pressures on both gauges as transmission throttle lever is moved from full forward to full rear- Test One - Transmission In 1 Range ward position. (5) Line pressure should be 54-60 psi (372-414 This test checks pump output, pressure regulation, kPa) with throttle lever forward and gradually...
Page 930 21 - 84 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CAUTION: Stalling the converter causes a rapid increase in fluid temperature. To avoid fluid over- heating, hold the engine at maximum rpm for no more than 5 seconds. If engine exceeds 2500 rpm during the test, release the accelerator pedal imme- diately;...
Page 931 TRANSMISSION AND TRANSFER CASE 21 - 85 DIAGNOSIS AND TESTING (Continued) Some suspected converter housing fluid leaks may not be leaks at all. They may only be the result of residual fluid in the converter housing, or excess fluid spilled during factory fill or fill after repair. Converter housing leaks have several potential sources.
Page 932 21 - 86 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONVERTER HOUSING AREA LEAK CORRECTION (7) Adjust front band. (8) Lubricate pump seal and converter hub with (1) Remove converter. transmission fluid or petroleum jelly and install con- (2) Tighten front band adjusting screw until band verter.
Page 933 TRANSMISSION AND TRANSFER CASE 21 - 87 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION DELAYED ENGAGEMENT 1. Fluid Level Low. 1. Correct level and check for leaks. FROM NEUTRAL TO 2. Filter Clogged. 2. Change filter. DRIVE OR REVERSE 3.
Page 934 21 - 88 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE OR REVERSE 1. Fluid Level Low. 1. Add fluid and check for leaks if drive is (VEHICLE WILL NOT restored. MOVE) 2. Gearshift Linkage/Cable 2.
Page 935 TRANSMISSION AND TRANSFER CASE 21 - 89 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION SHIFTS DELAYED OR 1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if ERRATIC (SHIFTS ALSO low. HARSH AT TIMES) 2. Throttle Linkage Misadjusted. 2.
Page 936 21 - 90 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO LOW GEAR (MOVES 1. Governor Valve Sticking. 1. Remove governor, clean, inspect and IN 2ND OR 3RD GEAR repair as required. ONLY) 2. Valve Body Malfunction. 2.
Page 937 TRANSMISSION AND TRANSFER CASE 21 - 91 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION BUZZING NOISE 1. Fluid Level Low. 1. Add fluid and check for leaks. 2. Shift Cable Misassembled. 2. Route cable away from engine and bell housing.
Page 938 21 - 92 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION GROWLING, GRATING OR 1. Drive Plate Broken. 1. Replace. SCRAPING NOISES 2. Torque Converter Bolts Hitting 2. Dust shield bent. Replace or repair. Dust Shield. 3.
Page 939 TRANSMISSION AND TRANSFER CASE 21 - 93 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO START IN PARK OR 1. Gearshift Linkage/Cable 1. Adjust linkage/cable. NEUTRAL Misadjusted. 2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair as required.
Page 940 21 - 94 TRANSMISSION AND TRANSFER CASE REMOVAL SERVICE PROCEDURES (1) Hoist and support vehicle on safety stands. FLUID LEVEL CHECK (2) Place a large diameter shallow drain pan beneath the transmission pan. Transmission fluid level should be checked monthly (3) Remove bolts holding front and sides of pan to under normal operation.
Page 941 TRANSMISSION AND TRANSFER CASE 21 - 95 SERVICE PROCEDURES (Continued) INSPECTION is equal on both sides of the dipstick. If one side is noticably higher than the other, the dipstick has Inspect bottom of pan and magnet for excessive picked up some oil from the dipstick tube. Allow the amounts of metal or fiber contamination.
Page 942 21 - 96 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES (Continued) (1) Disconnect the From cooler line at the trans- nents. DO NOT use solvents containing acids, water, mission and place a collecting container under the gasoline, or any other corrosive liquids. disconnected line.
Page 943 TRANSMISSION AND TRANSFER CASE 21 - 97 SERVICE PROCEDURES (Continued) Heli-Coil, or equivalent, tools and inserts are readily available from most automotive parts suppli- ers. REMOVAL AND INSTALLATION TRANSMISSION CAUTION: The transmission and torque converter must be removed as an assembly to avoid compo- nent damage.
Page 944 21 - 98 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (21) Remove bolts attaching crossmember to frame (8) Position transmission on jack and secure it and remove crossmember. with safety chains. (22) Disconnect transfer case vent hose. Then dis- (9) Check condition converter...
Page 945 TRANSMISSION AND TRANSFER CASE 21 - 99 REMOVAL AND INSTALLATION (Continued) Fig. 19 Transmission Attachment (32) Adjust gearshift linkage and throttle valve (3) Pull the torque converter forward until the cen- cable if necessary. ter hub clears the oil pump seal. (33) Align and connect propeller shaft(s).
Page 946 21 - 100 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (6) Check converter seating with a scale and straightedge (Fig. 20). Surface of converter lugs should be 1/2 in. to rear of straightedge when con- verter is fully seated. (7) If necessary, temporarily secure converter with C-clamp attached to the converter housing.
Page 947 TRANSMISSION AND TRANSFER CASE 21 - 101 REMOVAL AND INSTALLATION (Continued) Fig. 22 Speedometer Pinion Adapter Components (2) Install new O-rings on speed sensor and speed- ometer adapter if necessary (Fig. 22). (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter.
Page 948 21 - 102 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (2) Remove lower steering column shroud. Refer to Group 19, Steering, for proper procedure. (3) Remove tie strap near the solenoid retaining the brake transmission interlock cable to the steering column.
Page 949 TRANSMISSION AND TRANSFER CASE 21 - 103 REMOVAL AND INSTALLATION (Continued) Fig. 26 Cable and Shifter (11) Install lower steering column shroud and igni- tion lock. (12) Install lower steering column cover. VALVE BODY REMOVAL (1) Raise vehicle. (2) Remove oil pan and drain fluid. (3) Loosen clamp bolts and remove throttle and manual valve levers from manual lever shaft.
Page 950 21 - 104 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (14) Connect park/neutral position switch and con- verter clutch solenoid wires. (15) Install speedometer pinion gear, adapter and speed sensor. (16) Lower vehicle. (17) Fill transmission with Mopar ATF Plus 3, Type 7176 fluid.
Page 951 TRANSMISSION AND TRANSFER CASE 21 - 105 REMOVAL AND INSTALLATION (Continued) Fig. 31 Governor Valve Fig. 33 Governor Body (10) Remove governor valve and shaft from gover- (a) Install thin snap ring first. Then install nor body (Fig. 31). thrust washer second, and thick snap ring last (11) Remove snap rings and spacer that retain (Fig.
Page 952 21 - 106 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) end of control rod for wear grooves, or being seized on rod. Replace rod if bent, if knob is worn/grooved, or it has seized on rod. Replace park gear if lugs are damaged.
Page 953 TRANSMISSION AND TRANSFER CASE 21 - 107 DISASSEMBLY AND ASSEMBLY (Continued) VALVE BODY DISASSEMBLY Position the valve body on a clean work surface to avoid contamination. CAUTION: Do not clamp any part of the valve body assembly (Fig. 39) in a vise. This practice will dis- tort the valve body and transfer plate resulting in valve bind.
Page 954 21 - 108 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 40 Adjusting Screw Bracket, Springs, Valve Fig. 43 Manual Valve Removal (13) Remove screws attaching end cover plate to torque converter module (Fig. 47). (14) Remove converter clutch valve, fail safe valve, and springs (Fig.
Page 955 TRANSMISSION AND TRANSFER CASE 21 - 109 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 45 Converter Clutch Solenoid Fig. 48 Valve Body Transfer Plate Screws (20) Note position of filter, rear clutch servo and rear servo check balls for assembly reference (Fig. 49) and (Fig.
Page 956 21 - 110 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (23) Remove governor plug end plate (Fig. 53). (24) Remove 1-2 and 2-3 shift valve governor plugs from valve body (Fig. 53). (25) Remove shuttle valve throttle plug, primary spring and shuttle valve from valve body (Fig.
Page 957 TRANSMISSION AND TRANSFER CASE 21 - 111 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Control Valves, Shift Valves, And Governor Plugs (5) Compress spring into kickdown limit valve (18) Assemble shuttle valve spring and guides body. (Fig. 53). Place spring and guides in position on shut- (6) Install retainer in grooves at end of kickdown tle valve stem.
Page 958 21 - 112 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 55 Shuttle Valve End Plate Fig. 57 Transfer And Separator Plates (22) Install rear clutch servo and rear servo check balls in proper cavities in transfer plate (Fig. 56). (23) Insert filter into opening in separator plate (Fig.
Page 959 TRANSMISSION AND TRANSFER CASE 21 - 113 DISASSEMBLY AND ASSEMBLY (Continued) (38) Install screw to attach solenoid to transfer plate (Fig. 62). (39) If necessary, insert park rod end into manual lever and install E-clip (Fig. 63). Fig. 62 Converter Clutch Solenoid Fig.
Page 960 21 - 114 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 64 Securing Detent Ball And Spring With Retainer Tool Fig. 67 Manual Valve And Throttle Lever Alignment Fig. 65 Manual Valve Fig. 68 Adjusting Screw Bracket, Springs, and Valves (3) Clean exterior of transmission with suitable solvent or pressure washer.
Page 961 TRANSMISSION AND TRANSFER CASE 21 - 115 DISASSEMBLY AND ASSEMBLY (Continued) (14) Thread bolts of Slide Hammer Tools C-3752 into threaded holes in pump body flange (Fig. 73). (15) Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case (Fig.
Page 962 21 - 116 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 74 Front Band Strut (21) Remove output shaft thrust plate and washer from output shaft hub (Fig. 77). (22) Remove front band from case (Fig. 78). (23) Remove extension housing from transmission case.
Page 963 TRANSMISSION AND TRANSFER CASE 21 - 117 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 78 Front Band Fig. 80 Rear Band Adjuster Location Fig. 79 Planetary Geartrain Fig. 81 Low-Reverse Drum Snap Ring (28) Remove bolts attaching rear support to trans- mission case and pull support from low-reverse drum (Fig.
Page 964 21 - 118 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 85 Rear Band and Link—30RH Fig. 83 Overrunning Clutch Cam Bolt Locations Fig. 86 Rear Band and Link—30RH (d) Using snap-ring plier, pull rear band lever pivot from transmission case (Fig. 90). (e) Separate rear band servo lever from trans- mission.
Page 965 TRANSMISSION AND TRANSFER CASE 21 - 119 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 89 Front Band Lever Fig. 91 Compressing Front Servo Fig. 90 Rear Band Servo Lever Pin (33) Compress front servo rod guide about 1/8 in. with large C-clamp and Tool C-4470, or Spring Com- pressor Tool C-3422-B (Fig.
Page 966 21 - 120 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (a) Assemble link bar to band. Notched side of link toward band (Fig. 90). (b) Insert rear band through pan opening in transmission case. (c) Insert hook on band onto adjuster lever. (d) Align holes in link bar with hole in transmis- sion case outboard of rear support opening (Fig.
Page 967 TRANSMISSION AND TRANSFER CASE 21 - 121 DISASSEMBLY AND ASSEMBLY (Continued) (22) Align drive lugs on rear planetary gear with slots in low-reverse drum (Fig. 96). Then seat plane- tary assembly in drum. (23) Install governor on output shaft. Fig. 98 Front and Rear Clutches (26) Install output shaft thrust plate on shaft hub in planetary geartrain driving shell (Fig.
Page 968 21 - 122 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) annulus gear. Verify that front clutch drive lugs are fully engaged in slots of driving shell after installa- tion. Fig. 100 Assembling Front And Rear Clutch Units Fig. 103 Front Band Fig.
Page 969 TRANSMISSION AND TRANSFER CASE 21 - 123 DISASSEMBLY AND ASSEMBLY (Continued) (40) Lubricate oil pump seals with Mopar Door- Ease, or Ru-Glyde, Door Eze, or ATF Plus 3. (41) Install oil pump (Fig. 109). Align and position pump on pilot studs. Slide pump down studs and work it into front clutch hub and case by hand.
Page 970 21 - 124 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) NOTE: If end play is incorrect, transmission is incorrectly assembled, output shaft thrust washer and/or thrust plate are worn and need to be changed. (a) Attach dial indicator (C-3339) to converter housing.
Page 971 TRANSMISSION AND TRANSFER CASE 21 - 125 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 113 Assembling Overrunning Clutch And Cam Fig. 115 Assembled Overrunning Clutch Fig. 114 Temporary Assembly Of Clutch And Drum Fig. 116 Front Servo To Check Operation REAR SERVO PISTON (3) Remove and discard servo component O-ring and seal rings.
Page 972 21 - 126 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (6) If pump seal was not removed during transmis- sion disassembly, remove seal with punch and ham- mer. (7) Remove front clutch thrust washer from sup- port hub (Fig. 122). Fig.
Page 973 TRANSMISSION AND TRANSFER CASE 21 - 127 DISASSEMBLY AND ASSEMBLY (Continued) (3) Stake new pump bushing in two places with (4) Lightly grip old bushing in vise or with pliers blunt punch (Fig. 124). Remove burrs from stake and back remover tool out of bushing. points with knife blade afterward.
Page 974 21 - 128 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (8) Install reaction shaft support on pump housing (Fig. 129). (9) Align reaction support on pump housing. Use alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing are all aligned (holes are offset for one-way fit).
Page 975 TRANSMISSION AND TRANSFER CASE 21 - 129 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 131 Front Clutch Components FRONT CLUTCH DISASSEMBLY (1) Remove waved snap ring and remove pressure plate, clutch plates and clutch discs (Fig. 131). (2) Compress clutch piston spring with Compressor Tool C-3575-A (Fig.
Page 976 21 - 130 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Never push the clutch piston straight in. (7) Compress piston spring and retainer with Com- This will fold the seals over causing leakage and pressor Tool C-3575-A (Fig. 132). Then install new snap ring to secure spring retainer and spring.
Page 977 TRANSMISSION AND TRANSFER CASE 21 - 131 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 137 Rear Clutch Components ASSEMBLY (6) Remove and discard piston seals. (7) Remove input shaft snap-ring (Fig. 138). It (1) Soak clutch discs in transmission fluid while may be necessary to press the input shaft in slightly assembling other clutch parts.
Page 978 21 - 132 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.
Page 979 TRANSMISSION AND TRANSFER CASE 21 - 133 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 144 Installing Rear Clutch Thrust Washer Fig. 142 Piston Spring/Wave Spring Position (6) Remove front planetary gear front thrust • .083–.085 in. washer from annulus gear hub. • .076–.078 in. (7) Separate and remove driving shell, rear plane- •...
Page 980 21 - 134 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Install assembled rear planetary and annulus gear on output shaft (Fig. 150). Verify that assembly is fully seated on shaft. (6) Install front thrust washer on rear planetary gear (Fig.
Page 981 TRANSMISSION AND TRANSFER CASE 21 - 135 DISASSEMBLY AND ASSEMBLY (Continued) (11) Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig. 156). (12) Install assembled driving shell and sun gear on output shaft (Fig.
Page 982 21 - 136 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (19) Install thrust washer in front annulus (Fig. 161). Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up. (20) Install front annulus snap ring (Fig. 162). Use snap ring pliers to avoid distorting ring during installation.
Page 983 TRANSMISSION AND TRANSFER CASE 21 - 137 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 161 Installing Front Annulus Thrust Washer Fig. 164 Checking Planetary Geartrain End Play CLEANING AND INSPECTION GOVERNOR AND PARK GEAR Thoroughly clean all the governor parts in a suit- able cleaning solution but do not use any type of caustic cleaning agents.
Page 984 21 - 138 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Fig. 165 Governor Weights Fig. 166 Governor Components and reaction plug (Fig. 168). Compress the reac- and install it. Do not distort the clip during tion plug spring clip only enough to remove removal or installation.
Page 985 TRANSMISSION AND TRANSFER CASE 21 - 139 CLEANING AND INSPECTION (Continued) Be sure a replacement sprag is installed so the sprag locking lug will face the park gear (Fig. 169). Also be sure the spring is correctly positioned as shown (Fig. 169). The sprag may not retract if the spring is improperly installed.
Page 986 21 - 140 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) or any surfaces are heavily scored, the valve body scored. Inspect all of the valve body springs. The will have to be replaced. springs must be free of distortion, warpage or broken coils.
Page 987 TRANSMISSION AND TRANSFER CASE 21 - 141 CLEANING AND INSPECTION (Continued) Inspect the case for cracks, porous spots, worn Replace the low-reverse drum if the clutch race, servo bores, or damaged threads. However, the case roller surface or inside diameter is scored, worn or will have to be replaced if it exhibits damage or wear.
Page 988 21 - 142 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) FRONT CLUTCH Clean and inspect the front clutch components. Replace the clutch discs if warped, worn, scored, burned or charred, or if the facing is flaking off. Replace the steel plates if heavily scored, warped, or broken.
Page 989 TRANSMISSION AND TRANSFER CASE 21 - 143 CLEANING AND INSPECTION (Continued) planetary thrust plates and the tabbed thrust wash- ers if cracked, scored or worn. Inspect the machined surfaces of the output shaft. Be sure the oil passages are open and clear. Replace the shaft if scored, pitted, or damaged.
Page 990 21 - 144 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) (7) Check adjustment as follows: (a) Check movement of release shift handle but- ton (floor shift) or release lever (column shift). You should not be able to press button inward or move column lever.
Page 991 TRANSMISSION AND TRANSFER CASE 21 - 145 ADJUSTMENTS (Continued) Checking Throttle Valve Cable Adjustment (5) Insert a small screwdriver under edge of retaining clip and remove retaining clip. (1) Turn ignition key to OFF position. (6) Center cable end on attachment stud to within (2) Remove air cleaner.
Page 992 21 - 146 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) Fig. 180 Band Adjustment Adapter Tool REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw. (1) Raise vehicle. (2) Remove transmission oil pan and drain fluid. (3) Loosen band adjusting screw locknut 5-6 turns.
Page 993 TRANSMISSION AND TRANSFER CASE 21 - 147 ADJUSTMENTS (Continued) Push the gauge tool inward to compress the kick- down valve against the spring and bottom the throt- tle valve. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool.
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