Page 1 Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Power System Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame & Bumpers Fuel System Steering Transmission and Transfer Case Tires/Wheels Body Heating & Air Conditioning...
Page 2 DESCRIPTION A vehicle safety certification label (Fig. 1) is attached to every DaimlerChrysler Corporation vehi- cle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture.
Page 3 Vehicle Build Sequence VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. DaimlerChrysler permanently attaches the label in the engine compartment (Fig. 2). It cannot be removed without defacing informa- tion and destroying the label.
Page 4 5 - FLOOR PAN Price Class 6 - FRONT CARPET • L = Wrangler (All) The last code imprinted on a vehicle code plate will DIGITS 20 AND 21 be followed by the imprinted word END. When two Body Type vehicle code plates are required, the last available •...
Page 5 Open Space DIGIT 19 DIGITS 7 THROUGH 23 Open Space Vehicle Identification Number (VIN) DIGITS 20, 21, AND 22 (Refer to VEHICLE DATA/VEHICLE INFORMA- Engine Code TION/VEHICLE IDENTIFICATION NUMBER • ED1 = 2.4L 4 cyl. MPI Gasoline DESCRIPTION) for breakdown of VIN code.
Page 6 INTRODUCTION marks plus 2. The most commonly used metric bolt FASTENER IDENTIFICATION strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on DESCRIPTION the head of the bolt. The higher the class number, The SAE bolt strength grades range from grade 2 the greater the bolt strength.
Page 7 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 6 FASTENER IDENTIFICATION...
Page 8 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 7 FASTENER STRENGTH...
Page 9 INTRODUCTION DESCRIPTION - THREADED HOLE REPAIR FASTENER USAGE Most stripped threaded holes can be repaired using a Helicoil . Follow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures. DESCRIPTION - FASTENER USAGE METRIC SYSTEM WARNING: USE OF AN INCORRECT FASTENER...
Page 10 INTRODUCTION METRIC SYSTEM (Continued) Fig. 8 METRIC CONVERSION CHART...
Page 11 INTRODUCTION tions Chart for torque references not listed in the indi- TORQUE REFERENCES vidual torque charts (Fig. 9). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- Fig. 9 TORQUE SPECIFICATIONS...
Page 12: Lubrication & Maintenance
DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used to service a Chrysler Corporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) (Fig. 2) • National Lubricating Grease Institute (NLGI) (Fig.
Page 13 0 - 2 LUBRICATION & MAINTENANCE PARTS & LUBRICANT RECOMMENDATION (Continued) SAE VISCOSITY RATING An SAE viscosity grade is used to specify the vis- cosity of engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range.
Page 14 We recommend that ulations and provide excellent fuel economy and per- gasolines free of MMT be used in your vehicle. The formance when using high quality unleaded “regular” MMT content of gasoline may not be indicated on the gasoline having an octane rating of 87.
Page 15 • When pulling a heavy load or driving a fully lent ethylene-glycol base coolant with organic corro- loaded vehicle when the humidity is low and the tem- sion inhibitors (called HOAT, for Hybrid Organic perature is high, use a premium unleaded fuel to Additive Technology) is recommended.
Page 16 LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) centage of antifreeze can cause the engine to over- heat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyl- ene-glycol.
Page 17 DESCRIPTION - MANUAL TRANSMISSION ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or anti- NOTE: DaimlerChrysler recommends using Mopar freeze. The red color is not permanent and is not an lubricants or lubricants of equal quality.
Page 18: Fluid Capacities
1.0 L (2.2 pts.) NV241 2.0 L (4.2 pts.) CAUTION: Failure to perform the required mainte- nance items may result in damage to the vehicle. MANUAL TRANSMISSION NV1500 Approximate dry fill or fill to bottom edge of the 2.3 L (4.8 pts.) At Each Stop for Fuel fill plug hole.
Page 19: Suspension
• If equipped for and operated with E-85 underside of the vehicle should be thoroughly (ethanol) fuel. inspected. Examine threaded fasteners for looseness. Schedule “B” Follow this schedule if you usually operate your vehicle under one or more of the following conditions. Miles 3,000 6,000 9,000 12,000...
Page 20 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 33,000 36,000 39,000 42,000 45,000 (Kilometers) (53 000) (58 000) (62 000) (67 000) (72 000) Change the engine oil and engine oil filter. Lubricate the steering linkage tie rod ends. Lubricate the steering and suspension ball joints.
Page 21 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 63,000 66,000 69,000 72,000 75,000 (Kilometers) (101 000) (106 000) (110 000) (115 000) (120 000) Change the engine oil and engine oil filter. Lubricate the steering linkage tie rod ends. Lubricate the steering and suspension ball joints.
Page 22 Retain all receipts. service indicated with a ‡ in Schedule “B”. Perform ‡Off-highway operation, trailer towing, taxi, limou- these services if the vehicle is usually operated under sine, bus, snow plowing, or other types of commercial these conditions.
Page 23 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Schedule “A” Miles 6,000 12,000 18,000 24,000 30,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) [Months] [12] [18] [24] [30] Change the engine oil and engine oil filter. Lubricate the steering linkage joints and outer tie rod ends.
Page 24 LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) Miles 84,000 90,000 96,000 102, 000 (Kilometers) (134 000) (144 000) (154 000) (163 000) [Months] [84] [90] [96] [102] Change the engine oil and engine oil filter. Lubricate the steering linkage joints and outer tie rod ends.
Page 25 When properly positioned, a floor jack can be used WARNING: THE HOISTING AND JACK LIFTING to lift a Jeep vehicle (Fig. 6). Support the vehicle in POINTS PROVIDED ARE FOR A COMPLETE VEHI- the raised position with jack stands at the front and CLE.
Page 26 Fig. 8 Towing With Tow Dollies 1 - TOW DOLLY TOWING-FRONT END LIFTED (WHEEL LIFT) (1) Raise the rear of the vehicle off the ground and SAFETY PRECAUTIONS install tow dollies under rear wheels. • Secure loose and protruding parts.
Page 27: Jump Starting
1200 rpm. (3) On disabled vehicle, place gear selector in park or neutral and set park brake or equivalent. Turn JUMP STARTING OFF all accessories.
Page 28 LUBRICATION & MAINTENANCE 0 - 17 JUMP STARTING (Continued) (6) Allow battery in disabled vehicle to charge to DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 sec- ground on disabled vehicle.
Page 30 • Check the engine oil level about 5 minutes after a • If equipped for and operated with E-85 fully warmed engine is shut off. Checking the oil level (ethanol) fuel. while the vehicle is on level ground will improve the...
Page 31 0a - 2 MAINTENANCE SCHEDULES MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued) Kilometers 5 000 10 000 14 000 19 000 24 000 (Miles) (3,000) (6,000) (9,000) (12,000) (15,000) Change the engine oil and engine oil filter. Lubricate the steering linkage tie rod ends.
Page 32 MAINTENANCE SCHEDULES 0a - 3 MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued) Kilometers 77 000 82 000 86 000 91 000 96 000 (Miles) (48,000) (51,000) (54,000) (57,000) (60,000) Change the engine oil and engine oil filter. Lubricate the steering linkage tie rod ends.
Page 33 0a - 4 MAINTENANCE SCHEDULES MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued) Kilometers 125 000 130 000 134 000 139 000 144 000 (Miles) (78,000) (81,000) (84,000) (87,000) (90,000) Change the engine oil and engine oil filter. Lubricate the steering linkage tie rod ends.
Page 34 ‡ in Schedule “B”. Perform tain emissions warranty. these services if the vehicle is usually operated under these conditions.
Page 35 0a - 6 MAINTENANCE SCHEDULES MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued) Schedule “A” Kilometers 12 000 24 000 36 000 48 000 60 000 (Miles) (7,500) (15,000) (22,500) (30,000) (37,500) [Months] [12] [18] [24] [30] Change the engine oil and engine oil filter.
Page 36 MAINTENANCE SCHEDULES 0a - 7 MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued) Kilometers 120 000 132 000 144 000 156 000 (Miles) (75,000) (82,500) (90,000) (97,500) [Months] [60] [66] [72] [78] Change the engine oil and engine oil filter. Lubricate the steering linkage joints and outer tie rod ends.
Page 38 • CAMBER is the inward or outward tilt of the ity and to minimize tire wear. The most important wheel relative to the center of the vehicle. Tilting the measurements of an alignment are caster, camber top of the wheel inward provides negative camber.
Page 39 • THRUST ANGLE is the angle of the rear axle measured in degrees and is the angle that the steer- relative to the centerline of the vehicle. Incorrect ing knuckles are tilted. The inclination angle has a thrust angle can cause off-center steering and exces- fixed relationship with the camber angle.
Page 40 3. Tires worn or out of balance. 3. Replace or balance tires. 4. Alignment. 4. Align vehicle to specifications. 5. Leaking steering dampener. 5. Replace steering dampener. VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
Page 41 STANDARD PROCEDURE - CAMBER Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position.
Page 42: Specifications
WHEEL ALIGNMENT 2 - 5 WHEEL ALIGNMENT (Continued) SPECIFICATIONS ALIGNMENT SPECIFICATIONS NOTE: Alignment specifications are in degrees. SPECIFICATIONS DESCRIPTION SPECIFICATION PREFERRED CASTER CAMBER TOTAL + 7.0° (fixed TOE-IN angle) + 0.15° 0.25° (each front wheel) Fig. 4 Steering Linkage RANGE ±1.0°...
Page 43 CAUTION: Suspension components with rubber/ure- thane bushings (except stabilizer bar) should be FRONT SUSPENSION tightened with the vehicle at normal ride height. It is The front suspension is a link/coil design com- important to have the springs supporting the weight prised of: of the vehicle when the fasteners are torqued.
Page 44 FRONT 2 - 7 FRONT (Continued) SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Shock Absorber — Upper Nut Shock Absorber — Lower Nut Suspension Arm Lower — Axle Bracket Nut Suspension Arm Lower — Frame Bracket Nut Suspension Arm Upper —...
Page 45: Special Tools
REMOVAL (1) Remove the upper suspension arm from axle. (2) Position Spacer 7932-3 over the axle bushing on a 4x2 vehicle and right side on a 4x4 vehicle. (3) Place Receiver 7932-1 over flanged end of the bushing. (Fig. 1).
Page 46 HUB / BEARING KNUCKLE DESCRIPTION REMOVAL The bearing used on the front hub of this vehicle is Ball stud service procedures below require removal the combined hub and bearing unit type assembly. of the hub bearing and axle shaft. Removal and...
Page 47: Differential & Driveline
2 - 10 FRONT KNUCKLE (Continued) Fig. 3 Hub Bearing & Knuckle 1 - BRAKE SHIELD 6 - HUB AND BEARING ASSEMBLY 2 - WASHER 7 - STEERING KNUCKLE 3 - RETAINER 8 - BOLT 4 - COTTER PIN 9 - TONE WHEEL (ABS) 5 - NUT (5) Using special tool C-4150A seperate the ball joints from the steering knuckle.
Page 48: Brakes
FRONT AXLE - 181FBI/AXLE SHAFTS - REMOV- (3) If the vehicle is equipped with a cam bolt ser- AL). Removal and installation of upper and lower vice package paint or scribe alignment marks on the ball studs require the use of Tool Kit 6289.
Page 49 2 - 12 FRONT LOWER CONTROL ARM (Continued) (7) Tighten frame bracket nut to 176 N·m (130 ft. lbs.). (8) Align vehicle to specifications. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE). SHOCK DESCRIPTION The top of the shock absorbers are bolted to a frame bracket.
Page 50 (12) Install the wheel and tire assemblies, (Refer port it. to 22 - TIRES/WHEELS/WHEELS - STANDARD (4) Remove the front shocks at the lower mount- PROCEDURE). ings, (Refer to 2 - SUSPENSION/FRONT/SHOCK - (13) Remove the supports and lower the vehicle. REMOVAL).
Page 51 The stabilizer bar is used to control vehicle body roll during turns. The bar helps to control the vehicle OPERATION body in relationship to the suspension. The track bar is used to control front axle lateral...
Page 52 The upper suspension arms are steel and use rubber (4) Remove the supports and lower the vehicle. bushings at each end of the arm. The arms mount to (5) Tighten the bolt at the axle bracket to 47 N·m the frame rail bracket and the axle brackets.
Page 53 CAUTION: Suspension components with rubber/ure- REAR thane bushings (except stabilizer bar) should be tightened with the vehicle at normal ride height. It is DESCRIPTION important to have the springs supporting the weight of the vehicle when the fasteners are torqued. This...
Page 54 REAR 2 - 17 REAR (Continued) SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Shock Absorber — Upper Bolts Shock Absorber — Lower Nut Suspension Arm Lower — Axle Bracket Nut Suspension Arm Lower — Frame Bracket Nut Suspension Arm Upper —...
Page 55 The bottom of the shocks are bolted to the axle brackets. OPERATION The shock absorbers dampen jounce and rebound motion of the vehicle over various road conditions and limit suspension rebound travel. DIAGNOSIS AND TESTING - SHOCK ABSORBER Fig. 1 Upper & Lower Suspension Arms...
Page 56 DESCRIPTION REMOVAL The coil springs mount between the bottom of the (1) Raise and support the vehicle and the axle. frame rail and the top of the axle. A rubber doughnut (2) Remove the upper mounting bolts (Fig. 3) .
Page 57 OPERATION The stabilizer bar is used to control vehicle body roll during turns. The bar helps to control the vehicle body in relationship to the suspension. REMOVAL (1) Raise and support the vehicle.
Page 58 (3) Install the parking brake cable/bracket and ABS wiring bracket on the arm if equipped. (1) Install the track bar in the axle bracket and (4) Remove the supports and lower the vehicle. install the bolt loosely. (5) Tighten the upper suspension arm frame rail (2) Install the track bar in the frame rail bracket bracket bolt to 75 N·m (55 ft.
Page 60 Refer to Group 9 Engines for additional information. DIAGNOSIS AND TESTING Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a VIBRATION specific speed range is not usually caused by a pro- Tires that are out-of-round, or wheels that are peller shaft being unbalanced.
Page 61 2) Lack of lubrication. 2) Replace U-joints as necessary. BALANCE (8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration NOTE: Removing and re-indexing the propeller occurred. Stop the engine.
Page 62 0.020 in. (0.50 mm) for the full length of the tube. STANDARD PROCEDURE PROPELLER SHAFT ANGLE (1) Place transmission in netural. (2) Raise and support the vehicle at the axles as level as possible. (3) Remove any external bearing snap rings from universal joint so protractor base sits flat.
Page 63 3 - 4 PROPELLER SHAFT PROPELLER SHAFT (Continued) (5) Place Inclinometer 7663 (J-23498A) on yoke bearing (A) parallel to the shaft (Fig. 4). Center bub- ble in sight glass and record measurement. NOTE: This measurement will give you the Output Yoke Angle (A).
Page 64 PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) Fig. 7 U-JOINT ANGLE EXAMPLE 1 - 4.9° Angle (C) 4 - 3.0° Angle (A) 2 - 3.2° Angle (B) 5 - Output Yoke 3 - Input Yoke ADJUSTMENTS ADJUSTMENT The pinion angle of the front axle can be adjusted by the use of adjustment cams in the lower suspen- sion arms (Fig.
Page 65 (Fig. 10). (6) Remove transfer case yoke bolts. (7) Push rear of propeller shaft forward to clear transfer case yoke. (8) Remove propeller shaft from vehicle. INCLINOMETER 7663 PROPELLER SHAFT - FRONT REMOVAL (1) Shift transmission and transfer case into Neu- tral.
Page 66 (2) Tighten the U-joint strap/clamp bolts at the 3 - BOOT axle yoke to 19 N·m (14 ft. lbs.). 4 - CLAMP (3) Tighten clamp with Clamp Tool C-4975A to hold dust boot to propeller shaft yoke (Fig. 13). (4) Remove support and lower the vehicle.
Page 67 Fig. 14 TRANSFER CASE FLANGE 1 - REAR PROPELLER SHAFT 2 - REFERENCE MARK 3 - TRANSFER CASE FLANGE (5) Remove propeller shaft from the vehicle. INSTALLATION (1) Align installation reference marks at the pinion yoke, transfer case flange and propeller shaft.
Page 68 PROPELLER SHAFT 3 - 9 SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 17 PRESS OUT BEARING CAP Fig. 18 PRESS OUT BEARING CAP 1 - PRESS 1 - CROSS 2 - BEARING CAP 2 - SOCKET NOTE: If bearing cap will not come out, tap the yoke ear near the bearing cap to dislodge the cap.
Page 69 3 - 10 PROPELLER SHAFT SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 21 SNAP RINGS Fig. 20 BEARING AND TRUNNION (8) Press one bearing cap from the outboard side of 1 - BEARING CAP 2 - TRUNNION the link yoke enough to grasp the cap with vise jaws (Fig.
Page 70 PROPELLER SHAFT 3 - 11 DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. (2) Fit a cross into the propeller shaft yoke (Fig. 25). Fig. 23 REMOVE BEARING FROM YOKE Fig.
Page 71 3 - 12 PROPELLER SHAFT DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (4) Press bearing cap into the yoke bore enough to (7) Fit the link yoke onto the remaining trunnions clear snap ring groove (Fig. 27). and press both bearing caps into place and install (5) Install a snap ring.
Page 72 PROPELLER SHAFT 3 - 13 DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (9) Place two bearing caps on opposite trunnions of (11) Tap the snap rings to seat them into the the remaining cross. Fit the open trunnions into the grooves (Fig. 33). link yoke bores and the bearing caps into the center- ing kit (Fig.
Page 73 5 miles and then acceler- hub bearings. The hub bearings are bolted to the ate the vehicle to the speed range where the noise is steering knuckle at the outboard end of the axle tube the greatest.
Page 74: Clutch
Road test the vehicle. into gear (or the clutch engaged) can be caused by: Turn the vehicle sharply to the left and to the right. • High engine idle speed. This will load the bearings and change the noise •...
Page 75 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle. 3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Grabbing clutch.
Page 76 FRONT AXLE - 181FBI 3 - 17 FRONT AXLE - 181FBI (Continued) Condition Possible Causes Correction Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Improper grade of lubricant. 2.
Page 77 (1) Install springs and retainers and tighten retainer bolts to 21 N·m (16 ft. lbs.). (1) Raise and support the vehicle. (2) Position axle under the vehicle and align it (2) Position a lift under the axle and secure to the with the spring pads.
Page 78 FRONT AXLE - 181FBI 3 - 19 FRONT AXLE - 181FBI (Continued) ADJUSTMENTS Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are etched/marked onto each gear (Fig. 1). A plus (+) number, minus (–) number or zero (0) is etched/marked on the pinion gear.
Page 79 3 - 20 FRONT AXLE - 181FBI FRONT AXLE - 181FBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0.001 +0.006...
Page 80 FRONT AXLE - 181FBI 3 - 21 FRONT AXLE - 181FBI (Continued) DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side bearing cones. The proper shim thickness can be determined using slip-fit Dummy Bearings D-348 in place of the differential side bear- ings and a Dial Indicator C-3339.
Page 81 3 - 22 FRONT AXLE - 181FBI FRONT AXLE - 181FBI (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 82 FRONT AXLE - 181FBI 3 - 23 FRONT AXLE - 181FBI (Continued) (16) Install differential case and dummy bearings D-348 in the housing (without shims), install bearing caps and tighten bolts snug. (17) Seat ring gear side dummy bearing (Fig. 10). (18) Position the dial indicator plunger on a flat surface between the ring gear bolt heads (Fig.
Page 83 3 - 24 FRONT AXLE - 181FBI FRONT AXLE - 181FBI (Continued) (21) Subtract 0.05 mm (0.002 in.) 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. (22) Subtract the backlash shim thickness from the total preload shim thickness.
Page 84 FRONT AXLE - 181FBI 3 - 25 FRONT AXLE - 181FBI (Continued) Fig. 18 GEAR CONTACT PATTERNS...
Page 85 3 - 26 FRONT AXLE - 181FBI FRONT AXLE - 181FBI (Continued) DIFFERENTIAL BEARING PRELOAD CHECK Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.79-1.24 N·m The final check on the differential assembly before (7-11 in.
Page 86 FRONT AXLE - 181FBI 3 - 27 FRONT AXLE - 181FBI (Continued) WRENCH C-3281 REMOVER D-149 DIAL INDICATOR C-3339 INSTALLER W-162-D INSTALLER C-3716-A CUP 8109 INSTALLER 6761 HANDLE C-4171 INSTALLER D-146 INSTALLER 6752...
Page 87 3 - 28 FRONT AXLE - 181FBI FRONT AXLE - 181FBI (Continued) INSTALLER DISCS 8110 SPREADER W-129-B TURNBUCKLE 6797 ADAPTER KIT 6987B PINION DEPTH SET 6774 PILOT STUD C-3288-B SPANNER WRENCH 6958 REMOVER C-4345 INSTALLER C-3972-A INSTALLER D-130...
Page 88 (6) Install the brake rotor, caliper and wheel speed sensor, if equipped. (7) Install the wheel and tire assembly. (8) Remove support and lower the vehicle. SINGLE CARDAN UNIVERSAL Fig. 19 HUB BEARING BOLTS JOINT 1 - AXLE SHAFT...
Page 89 REMOVAL (4) Locate a socket with an outside diameter is (1) Raise and support the vehicle. smaller than the bearing cap. Place the socket (driv- (2) Remove wheel and tire assemblies. er) against the opposite bearing cap.
Page 90 FRONT AXLE - 181FBI 3 - 31 PINION SEAL (Continued) Fig. 23 PINION YOKE REMOVER 1 - WRENCH 2 - PINION YOKE 3 - REMOVER INSTALLATION (1) Apply a light coating of gear lubricant on the Fig. 25 PINION YOKE INSTALLER lip of pinion seal.
Page 91 (10) Install wheel and tire assemblies. installer (Fig. 29). (11) Lower the vehicle. COLLAPSIBLE SPACER REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake rotors and calipers. (4) Mark propeller shaft and pinion yoke for installation reference.
Page 92 0.56 N·m (5 in. Fig. 32 PINION ROTATING TORQUE lbs.). (8) Install propeller shaft with reference marks 1 - TORQUE WRENCH 2 - PINION YOKE aligned. (9) Install brake rotors and calipers. (10) Install wheel and tire assemblies. (11) Lower vehicle.
Page 93 This REMOVAL occurs because input torque applied to the gears is (1) Raise and support vehicle. divided and distributed equally between the two side (2) Remove the lubricant fill hole plug from the gears.
Page 94 FRONT AXLE - 181FBI 3 - 35 DIFFERENTIAL (Continued) (8) Position Spreader W-129-B, utilizing some items from Adapter Kit 6987, with the tool dowel pins seated in the locating holes (Fig. 36). Install the holddown clamps and tighten the tool turnbuckle fin- ger-tight.
Page 95 3 - 36 FRONT AXLE - 181FBI DIFFERENTIAL (Continued) (13) Remove differential from the housing. Ensure (3) Remove pinion gear mate shaft from the differ- that the differential bearing cups remain in position ential case and pinion mate gears. on the differential bearings (Fig. 39). (4) Rotate differential side gears and remove pin- ion mate gears and thrust washers (Fig.
Page 96 FRONT AXLE - 181FBI 3 - 37 DIFFERENTIAL (Continued) Fig. 43 SPREADER LOCATION Fig. 42 MATE SHAFT ROLL PIN 1 - AXLE HOUSING 1 - PUNCH 2 - DOWEL 2 - PINION MATE SHAFT 3 - SAFETY HOLD DOWN 3 - MATE SHAFT LOCKPIN 4 - SPREADER 5 - TURNBUCKLE (1) Position Spreader W-129-B, utilizing some...
Page 97 Refer to Lubricant Specifications for correct quantity and type. (14) Install fill hole plug and tighten to 34 N·m (25 ft. lbs.). (15) Remove support and lower vehicle. DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential case from the housing.
Page 98 NOTE: The ring and pinion gears are serviced as a matched set. Never replace one gear without replac- ing the other matched gear. (1) Raise and support the vehicle. (2) Mark pinion yoke and propeller shaft for installation reference. (3) Disconnect propeller shaft from pinion yoke and tie propeller shaft to underbody.
Page 99 3 - 40 FRONT AXLE - 181FBI PINION GEAR/RING GEAR (Continued) (9) Remove pinion yoke with Remover C-452 and (11) Remove front pinion bearing cup, bearing, oil Flange Wrench C-3281 (Fig. 51). slinger and pinion seal with Remover C-4345 and Handle C-4171 (Fig.
Page 100 FRONT AXLE - 181FBI 3 - 41 PINION GEAR/RING GEAR (Continued) (13) Remove collapsible spacer from pinion shaft (Fig. 55). Fig. 56 REAR PINION BEARING 1 - PULLER 2 - VISE 3 - ADAPTERS Fig. 55 COLLAPSIBLE SPACER 4 - PINION GEAR SHAFT 1 - COLLAPSIBLE SPACER 2 - SHOULDER 3 - PINION...
Page 101 3 - 42 FRONT AXLE - 181FBI PINION GEAR/RING GEAR (Continued) (2) Install front bearing cup with Installer D-130 and Handle C-4171 (Fig. 58) and verify cup is seated. Fig. 58 FRONT PINION BEARING CUP 1 - INSTALLER 2 - HANDLE Fig.
Page 102 FRONT AXLE - 181FBI 3 - 43 PINION GEAR/RING GEAR (Continued) (7) Install yoke with Installer W-162-B, Cup 8109 and Spanner Wrench 6958 (Fig. 62). Fig. 63 YOKE SPANNER WRENCH 1 - PINION YOKE 2 - SPANNER WRENCH Fig. 62 PINION YOKE INSTALLER 3 - PIPE 1 - INSTALLER 2 - PINION YOKE...
Page 103 (14) Install differential cover and fill with gear lubricate. (15) Install propeller shaft with reference marks aligned. (16) Remove supports and lower vehicle. Fig. 65 RING GEAR BOLT 1 - TORQUE WRENCH 2 - RING GEAR BOLT 3 - RING GEAR...
Page 104 5 miles and then acceler- hub bearings. The hub bearings are bolted to the ate the vehicle to the speed range where the noise is steering knuckle at the outboard end of the axle tube the greatest.
Page 105 (or the clutch engaged) can be caused by: when the bearings are loaded. Road test the vehicle. • High engine idle speed. Turn the vehicle sharply to the left and to the right. • Transmission shift operation. This will load the bearings and change the noise •...
Page 106 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle. 3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Grabbing clutch.
Page 107 3 - 48 FRONT AXLE - 216FBI FRONT AXLE - 216FBI (Continued) Condition Possible Causes Correction Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Improper grade of lubricant. 2.
Page 108 9. Replace housing. REMOVAL INSTALLATION (1) Raise and support the vehicle. CAUTION: The weight of the vehicle must be sup- (2) Position a lift under the axle and secure to the ported by the springs before suspension arms and axle.
Page 109 3 - 50 FRONT AXLE - 216FBI FRONT AXLE - 216FBI (Continued) (10) Connect the vent hose and pressure hose to Compensation pinion depth variance the axle. achieved with a select shim/oil slinger. The shims are (11) Connect wiring harness to locker indicator placed between the rear pinion bearing and the pin- switch.
Page 110 FRONT AXLE - 216FBI 3 - 51 FRONT AXLE - 216FBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0.001 +0.006...
Page 111 3 - 52 FRONT AXLE - 216FBI FRONT AXLE - 216FBI (Continued) (5) Install differential bearing caps on arbor discs and install bearing cap bolts. Tighten bearing cap bolts to 108 N·m (80 ft. lbs.). Fig. 6 PINION DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR...
Page 112 FRONT AXLE - 216FBI 3 - 53 FRONT AXLE - 216FBI (Continued) (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-345 on differen- tial case.
Page 113 3 - 54 FRONT AXLE - 216FBI FRONT AXLE - 216FBI (Continued) (18) Position the dial indicator plunger on a flat surface between the ring gear bolt heads (Fig. 11). (19) Push and hold differential case toward pinion gear and zero dial indicator (Fig. 14). Fig.
Page 114 FRONT AXLE - 216FBI 3 - 55 FRONT AXLE - 216FBI (Continued) (21) Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing. (22) Rotate dial indicator out of the way on pilot stud.
Page 115 3 - 56 FRONT AXLE - 216FBI FRONT AXLE - 216FBI (Continued) Fig. 18 GEAR TOOTH CONTACT PATTERNS...
Page 116 FRONT AXLE - 216FBI 3 - 57 FRONT AXLE - 216FBI (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 4.11 Ring Gear Diameter 216 mm (8.5 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Pinion Bearing Preload - Original Bearing 1-2 N·m (10-20 in.
Page 117 3 - 58 FRONT AXLE - 216FBI FRONT AXLE - 216FBI (Continued) DIAL INDICATOR C-3339 REMOVER D-148 INSTALLER D-145 INSTALLER D-156 REMOVER/INSTALLER D-354 HANDLE C-4171 INSTALLER W-162-D INSTALLER D-144 INSTALLER W-262 REMOVER D-147...
Page 118 FRONT AXLE - 216FBI 3 - 59 FRONT AXLE - 216FBI (Continued) INSTALLER 5041 HOLDER YOKE 6719A PULLER- C-293-PA PINION DEPTH SET 6730 ADAPTERS C-293-39 PULLER 6444 ADAPTER C-293-18 JAWS 6447 PLUG C-293-3...
Page 119 Refer to Brakes for proper procedures. (7) Install wheel and tire assembly. REMOVAL (8) Remove support and lower the vehicle. (1) Raise and support the vehicle. (2) Remove wheel and tire assembly. (3) Remove brake caliper, rotor and ABS wheel AXLE SHAFT SEALS speed sensor if equipped.
Page 120 FRONT AXLE - 216FBI 3 - 61 SINGLE CARDAN UNIVERSAL JOINT REMOVAL Single cardan U-joint components are not service- able. If defective they must be replaced as a unit. CAUTION: Clamp only the narrow forged portion of the yoke in the vise. To avoid distorting the yoke, do not over tighten the vise jaws.
Page 121 3 - 62 FRONT AXLE - 216FBI PINION SEAL (Continued) (4) Remove pinion yoke nut and washer with (2) Install yoke on the pinion gear with Installer Remover C-452 and Flange Wrench C-3281 (Fig. 23). W-162-D and Spanner Wrench 6958 (Fig. 25). Fig.
Page 122 1 - CONNECTOR 2 - DIFFERENTIAL COVER (1) Block tires opposite the axle to be tested to pre- vent the vehicle from rolling. (3) Measure electrical continuity across the switch (2) Place transfer case in 4WD Low and automan- terminals. Circuit should be closed (zero resistance).
Page 123 3 - 64 FRONT AXLE - 216FBI DIFFERENTIAL - LOCKER (Continued) (5) Remove locker pressure hose from actuator assembly (Fig. 30). Fig. 28 LOCKER PUMP CONNECTORS 1 - REAR PUMP CONNECTOR 2 - FRONT PUMP CONNECTOR Fig. 30 PRESSURE HOSE 3 - AXLE HARNESS 1 - PRESSURE HOSE 2 - BEARING CAP...
Page 124 FRONT AXLE - 216FBI 3 - 65 DIFFERENTIAL - LOCKER (Continued) CAUTION: Never spread the housing over 0.38 mm (0.015 in). If housing is over-spread, it could dis- torted and damaged the housing. (10) Spread housing enough to remove the differ- ential case from the housing.
Page 125 3 - 66 FRONT AXLE - 216FBI DIFFERENTIAL - LOCKER (Continued) DISASSEMBLY (1) Install Plug C-293-3 into the differential axle shaft hole. (2) Remove differential case bearings with Puller 6444, Puller Rods 6444-3 and Puller Flange 6444-1. Position puller (Fig. 37) on the differential. Fig.
Page 126 FRONT AXLE - 216FBI 3 - 67 DIFFERENTIAL - LOCKER (Continued) (3) Position Puller Jaws 6444-7 (Fig. 38) around the case bearing and puller flange. Fig. 39 PULLER AND COLLAR 1 - PULLER 2 - ROD Fig. 38 PULLER AND JAWS 3 - PLUG 4 - COLLAR 1 - PULLER...
Page 127 3 - 68 FRONT AXLE - 216FBI DIFFERENTIAL - LOCKER (Continued) ASSEMBLY (1) Verify pressure plate tabs (Fig. 41) are seated on the dog clutch slots. Fig. 42 ACTUATOR AND CASE BEARING 1 - CASE BEARING 2 - ACTUATOR Fig. 41 PRESSURE PLATE 1 - PLATE 2 - PLATE TABS (2) Place actuator on the pressure plate and case...
Page 128 FRONT AXLE - 216FBI 3 - 69 DIFFERENTIAL - LOCKER (Continued) CAUTION: Never spread over 0.38 mm (0.015 in). If (12) Install pressure hose on the actuator assem- the housing is over-spread, it could be distorted or bly. (13) Install the axle shafts. damaged.
Page 129 3 - 70 FRONT AXLE - 216FBI (4) Remove pumps and bracket assembly from the DIFFERENTIAL - LOCKER vehicle. PUMP (5) Remove pump connectors from the mounting bracket. REMOVAL (6) Remove pump mounting screws (Fig. 48) from (1) Disconnect locker pumps and axle harness con- the bracket and remove pump/pumps.
Page 130 FRONT AXLE - 216FBI 3 - 71 DIFFERENTIAL - LOCKER PUMP (Continued) (3) Install pump bracket assembly on the cross- PINION GEAR/RING GEAR member/skid plate and install pump bracket mount- ing bolts (Fig. 50). REMOVAL NOTE: The ring and pinion gears are serviced as a matched set.
Page 131 3 - 72 FRONT AXLE - 216FBI PINION GEAR/RING GEAR (Continued) Fig. 53 PINION YOKE REMOVAL 1 - FLANGER WRENCH 2 - YOKE 3 - PULLER Fig. 55 FRONT BEARING CUP REMOVAL 1 - REMOVER 2 - HANDLE Fig. 54 REMOVE PINION GEAR 1 - DEAD-BLOW HAMMER (13) Remove rear pinion bearing with Puller Fig.
Page 132 FRONT AXLE - 216FBI 3 - 73 PINION GEAR/RING GEAR (Continued) Fig. 57 REAR BEARING REMOVAL Fig. 58 REAR PINION BEARING CUP 1 - PULLER 2 - VISE 1 - INSTALLER 3 - ADAPTERS 2 - HANDLE 4 - PINION SHAFT INSTALLATION NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve...
Page 133 3 - 74 FRONT AXLE - 216FBI PINION GEAR/RING GEAR (Continued) (5) Install pinion seal with an appropriate installer (8) Install pinion gear in housing. (Fig. 60). (9) Install pinion preload shims (Fig. 62) Fig. 60 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER Fig.
Page 134 FRONT AXLE - 216FBI 3 - 75 PINION GEAR/RING GEAR (Continued) (11) Install yoke washer and a new nut on the (13) Invert differential case in a vise and start two pinion gear. Tighten the nut to specification (Fig. 64). ring gear bolts.
Page 135 The axle shafts are retained by C-clips driving the vehicle at least 5 miles and then acceler- in the differential side gears. ate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the OPERATION peak-noise range.
Page 136 • High engine idle speed. when the bearings are loaded. Road test the vehicle. • Transmission shift operation. Turn the vehicle sharply to the left and to the right. • Loose engine/transmission/transfer case mounts. This will load the bearings and change the noise •...
Page 137 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle. 3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Grabbing clutch.
Page 138 INSTALLATION and lever. (7) Remove wheel speed sensors, if necessary. NOTE: The weight of the vehicle must be supported Refer to Group 5, Brakes, for proper procedures. by the springs before suspension arms and track (8) Disconnect the brake hose at the axle junction bar fasteners can be tightened.
Page 139 (11) Install the wheels and tires. (12) Add gear lubricant, if necessary. Refer to Lubricant Specifications in this section for lubricant requirements. (13) Remove lifting device from axle and lower the vehicle. (14) Tighten upper and lower control arms nuts to torque specification. ADJUSTMENTS ADJUSTMENT Fig.
Page 140 REAR AXLE - 194RBI 3 - 81 REAR AXLE - 194RBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0.001 +0.006...
Page 141 3 - 82 REAR AXLE - 194RBI REAR AXLE - 194RBI (Continued) NOTE: Arbor Discs 6732 have different step diame- ters to fit other axle sizes. Pick correct size step for axle being serviced. Fig. 6 PINION GEAR DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR...
Page 142 REAR AXLE - 194RBI 3 - 83 REAR AXLE - 194RBI (Continued) (1) Remove side bearings from differential case. (2) Install ring gear, if necessary, on differential case and tighten bolts to specification. (3) Install Dummy Bearings D-348 on differential case.
Page 143 3 - 84 REAR AXLE - 194RBI REAR AXLE - 194RBI (Continued) Fig. 13 RECORD DIAL INDICATOR READING 1 - READ DIAL INDICATOR 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING (24) Rotate dial indicator out of the way on pilot stud.
Page 144 REAR AXLE - 194RBI 3 - 85 REAR AXLE - 194RBI (Continued) (32) Push and hold ring gear upward while not GEAR CONTACT PATTERN allowing the pinion gear to rotate. The ring gear and pinion teeth contact patterns (33) Zero dial indicator face to pointer. will show if the pinion depth is correct in the hous- (34) Push and hold ring gear downward while not ing.
Page 145 3 - 86 REAR AXLE - 194RBI REAR AXLE - 194RBI (Continued) Fig. 16 GEAR TOOTH CONTACT PATTERNS...
Page 146 REAR AXLE - 194RBI 3 - 87 REAR AXLE - 194RBI (Continued) DIFFERENTIAL BEARING PRELOAD CHECK Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.79-1.24 N·m The final check on the differential assembly before (7-11 in.
Page 147 3 - 88 REAR AXLE - 194RBI REAR AXLE - 194RBI (Continued) PULLER C-452 HANDLE C-4171 WRENCH C-3281 INSTALLER D-130 WRENCH SPANNER 6958 INSTALLER D-146 INSTALLER SCREW 8112 REMOVER C-4345 CUP 8109 REMOVER D-149...
Page 148 REAR AXLE - 194RBI 3 - 89 REAR AXLE - 194RBI (Continued) Trac-lok Tools 6960 INSTALLER W-262 INSTALLER 6436 Holder Fixture 6965 Puller 7794-A INSTALLER 6437 Shim Dummy 8107 Pinion Depth 6774 Spreader W-129-B...
Page 149 (9) Inspect roller bearing contact surface on axle (1) Place transmission is in neutral. shaft for signs of brinelling, galling and pitting. If (2) Raise and support vehicle. any of these conditions exist, the axle shaft/bearing (3) Remove wheel and tire assembly.
Page 150 (6) Install brake drum. 2 - SEAL 3 - AXLE SHAFT TUBE (7) Install wheel and tire. 4 - HANDLE (8) Lower vehicle. AXLE SHAFT SEALS REMOVAL (1) Remove the axle shaft. (2) Remove axle shaft seal from the end of the axle shaft tube with a small pry bar.
Page 151 (Fig. 23). 4 - HANDLE (4) Install the axle shaft. PINION SEAL REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove the brake drums (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DRUM REMOVAL). (4) Mark propeller shaft and pinion yoke for Fig.
Page 152 REAR AXLE - 194RBI 3 - 93 PINION SEAL (Continued) (2) Install yoke on the pinion gear with Screw 8112, Cup 8109 and Spanner Wrench 6958 (Fig. 24). CAUTION: Do not exceed the minimum tightening torque 271 N·m (200 ft. lbs.) when installing the pin- ion yoke at this point.
Page 153 (Fig. 28). COLLAPSIBLE SPACER REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove rear brake drums. (4) Mark propeller shaft and pinion yoke for installation reference.
Page 154 (Fig. (8) Install propeller shaft with reference marks 32). aligned. (9) Install rear brake drums. (10) Add gear lubricant, if necessary. (11) Install wheel and tire assemblies. (12) Remove supports and lower vehicle.
Page 155 3 - 96 REAR AXLE - 194RBI DIFFERENTIAL (Continued) (4) Note the reference letters stamped on the bear- ing caps and housing machined sealing surface (Fig. 34). Fig. 32 STRAIGHT AHEAD DRIVING 1 - WHEELS ROTATE AT CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE Fig.
Page 156 REAR AXLE - 194RBI 3 - 97 DIFFERENTIAL (Continued) (7) Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 36) and zero the indicator.
Page 157 3 - 98 REAR AXLE - 194RBI DIFFERENTIAL (Continued) DISASSEMBLY the locating holes (Fig. 40). Install holddown clamps and tighten the tool turnbuckle finger-tight. (1) Remove pinion shaft. (2) Rotate differential side gears and remove the differential pinions and thrust washers (Fig. 39). Fig.
Page 158 2 - SEALANT vice or during a lubricant change. 3 - SEALANT THICKNESS After changing the lubricant, drive the vehicle and make 10 to 12 slow, figure-eight turns. This maneu- CAUTION: If housing cover is not installed within 3 ver will pump lubricant through the clutches. This to 5 minutes, the cover must be cleaned and new will correct the condition in most instances.
Page 159 3 - 100 REAR AXLE - 194RBI DIFFERENTIAL - TRAC-LOK (Continued) Fig. 44 ROTATING TORQUE TEST 1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE 2 - TORQUE WRENCH DISASSEMBLY (1) Clamp side gear Fixture 6965 in a vise and set differential case on the fixture (Fig.
Page 160 REAR AXLE - 194RBI 3 - 101 DIFFERENTIAL - TRAC-LOK (Continued) Fig. 46 MATE SHAFT LOCK SCREW 1 - LOCK SCREW 2 - PINION GEAR MATE SHAFT (5) Install and lubricate Step Plate C-6960-3 (Fig. 47). Fig. 48 THREAD ADAPTER DISC 1 - SOCKET 2 - SLOT IN ADAPTER 3 - SCREWDRIVER...
Page 161 3 - 102 REAR AXLE - 194RBI DIFFERENTIAL - TRAC-LOK (Continued) (9) With a feeler gauge remove thrust washers (14) Remove Forcing Screw, Step Plate from behind the pinion gears (Fig. 50). Threaded Adapter. (15) Remove top side gear, clutch pack retainer and clutch pack.
Page 162 REAR AXLE - 194RBI 3 - 103 DIFFERENTIAL - TRAC-LOK (Continued) Fig. 53 CLUTCH PACK 1 - DISCS 2 - DISHED PLATE 3 - RETAINER 4 - SIDE GEAR 5 - RETAINER 6 - PLATES Fig. 55 CLUTCH PACK AND UPPER SIDE GEAR 1 - SIDE GEAR AND CLUTCH PACK 2 - DIFFERENTIAL CASE 3 - STEP PLATE...
Page 163 3 - 104 REAR AXLE - 194RBI DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential from the housing. (2) Remove bearings from the differential case with Puller/Press C-293-PA , C-293-39 Blocks and Plug SP-3289 (Fig. 56). Fig. 57 DIFFERENTIAL CASE BEARINGS 1 - HANDLE C-4171 2 - DIFFERENTIAL 3 - BEARING...
Page 164 REAR AXLE - 194RBI 3 - 105 PINION GEAR/RING GEAR (Continued) (6) Remove pinion yoke from pinion shaft with Remover C-452 and Wrench C-3281 (Fig. 59). Fig. 59 PINION YOKE REMOVER 1 - WRENCH 2 - YOKE 3 - PULLER Fig.
Page 165 3 - 106 REAR AXLE - 194RBI PINION GEAR/RING GEAR (Continued) INSTALLATION NOTE: A pinion depth shim/oil slinger is placed between the rear pinion bearing cone and the pin- ion head to achieve proper ring gear and pinion mesh. If ring gear and pinion are reused, the pinion depth shim/oil slinger should not require replace- ment.
Page 166 REAR AXLE - 194RBI 3 - 107 PINION GEAR/RING GEAR (Continued) Fig. 66 FRONT PINION BEARING CUP 1 - INSTALLER 2 - HANDLE Fig. 68 REAR PINION BEARING 1 - PRESS 2 - INSTALLER 3 - DRIVE PINION GEAR 4 - REAR PINION BEARING Fig.
Page 167 3 - 108 REAR AXLE - 194RBI PINION GEAR/RING GEAR (Continued) (9) Install yoke with Installer Screw 8112, Cup 8109 and Wrench 6958 (Fig. 70). Fig. 71 PION YOKE WRENCH 1 - PINION YOKE 2 - SPANNER WRENCH Fig. 70 PINION YOKE INSTALLER 3 - PIPE 1 - INSTALLER 2 - PINION YOKE...
Page 168 (18) Install differential cover and fill with gear lubricant. (19) Install the propeller shaft with the reference marks aligned. (20) Remove supports and lower vehicle. Fig. 73 RING GEAR BOLTS 1 - TORQUE WRENCH 2 - RING GEAR BOLT 3 - RING GEAR...
Page 169 The driving the vehicle at least 5 miles and then acceler- axle shafts are retained a bearing and retainer plate. ate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the OPERATION peak-noise range.
Page 170 • High engine idle speed. when the bearings are loaded. Road test the vehicle. • Transmission shift operation. Turn the vehicle sharply to the left and to the right. • Loose engine/transmission/transfer case mounts. This will load the bearings and change the noise •...
Page 171 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle. 3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Grabbing clutch.
Page 172 INSTALLATION (7) Remove wheel speed sensors, if necessary. (8) Disconnect brake hose at the axle junction NOTE: The weight of the vehicle must be supported block. by the springs before suspension arms and track (9) Disconnect vent hose from the axle shaft tube.
Page 173 Note the etched number on the face of the drive (15) Remove lifting device from axle and lower the pinion gear (–1, –2, 0, +1, +2, etc.). The numbers rep- vehicle. resent thousands of an inch deviation from the stan- (16) Tighten lower suspension arm bolts to 177 dard.
Page 174 REAR AXLE - 216RBI 3 - 115 REAR AXLE - 216RBI (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0.001 +0.006...
Page 175 3 - 116 REAR AXLE - 216RBI REAR AXLE - 216RBI (Continued) NOTE: Arbor Discs 6732 have different step diame- ters to fit other axle sizes. Pick correct size step for axle being serviced. Fig. 6 PINION DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR Fig.
Page 176 REAR AXLE - 216RBI 3 - 117 REAR AXLE - 216RBI (Continued) (1) Remove differential side bearings from differ- (7) Using a dead-blow hammer seat the differen- ential case. tial dummy bearings to each side of the housing (Fig. (2) Remove factory installed shims from differen- 10) and (Fig.
Page 177 3 - 118 REAR AXLE - 216RBI REAR AXLE - 216RBI (Continued) Fig. 14 RECORD DIAL INDICATOR READING 1 - READ DIAL INDICATOR 2 - DIFFERENTIAL CASE TO RING GEAR SIDE 3 - DIFFERENTIAL HOUSING (15) Remove differential case and dummy bearings from the housing.
Page 178 REAR AXLE - 216RBI 3 - 119 REAR AXLE - 216RBI (Continued) (21) Push and hold differential case to ring gear (35) Push and hold ring gear upward while not side of the housing and record dial indicator reading allowing the pinion gear to rotate and zero dial indi- (Fig.
Page 179 3 - 120 REAR AXLE - 216RBI REAR AXLE - 216RBI (Continued) (3) Using a boxed end wrench on a ring gear bolt, Rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.
Page 180 REAR AXLE - 216RBI 3 - 121 REAR AXLE - 216RBI (Continued) Fig. 19 GEAR TOOTH CONTACT PATTERNS...
Page 181 3 - 122 REAR AXLE - 216RBI REAR AXLE - 216RBI (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.07, 3.73, 4.11 Differential Bearing Preload 0.1 mm (0.004 in.) Differential Side Gear Clearance 0.0-0.15 mm (0.0-0.006 in.) Ring Gear Diameter 216 mm (8.50 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Page 182 REAR AXLE - 216RBI 3 - 123 REAR AXLE - 216RBI (Continued) INSTALLER C-3972-A HANDLE C-4171 INSTALLER D-144 INSTALLER D-156 INSTALLER D-145 PILOT STUDS C-3288-B REMOVER D-147 DIAL INDICATOR C-3339 REMOVER D-148 TRAC-LOK TOOLS C-4487...
Page 183 3 - 124 REAR AXLE - 216RBI REAR AXLE - 216RBI (Continued) SPREADER W-129-B PINION DEPTH SET 6730 INSTALLER W-162-D PULLER 6790 DIFFERENTIAL TOOL SET 6956 CUP 8109 SPANNER WRENCH 6958 SPLITTER 1130 FIXTURE 6963-A INSTALLER W-262...
Page 184 REAR AXLE - 216RBI 3 - 125 REAR AXLE - 216RBI (Continued) JAWS 6447 ADAPTER KIT 6987B AXLE SHAFTS REMOVAL (1) Place transmission in neutral. (2) Remove brake caliper and rotor. (3) Remove axle retainer plate nuts through access hole in axle flange (Fig. 20). SLIDE HAMMER 7420 ADAPTER 7420-8 Fig.
Page 185 (5) Check and fill the differential with gear lubri- cant. AXLE BEARINGS REMOVAL Fig. 22 DRILL RETAINING RING (1) Remove axle shaft from vehicle. 1 - 3/8 in. DIA. DRILL BIT 2 - AXLE NOTE: It is normal that the axle bearing race is 3 - RETAINING PLATE loose in the axle tube.
Page 186 1 - PRESS RAM 2 - UNIT BEARING (7) Press soft metal retaining ring onto axle shaft 3 - INSTALLER with Installer 7913 and a press (Fig. 27). 4 - METAL RETAINING RING (8) Install axle in vehicle. 5 - AXLE...
Page 187 3 - 128 REAR AXLE - 216RBI PINION SEAL REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assemblies. (3) Remove brake drums. (4) Mark propeller shaft and pinion yoke for installation reference. (5) Remove propeller shaft from the yoke.
Page 188 This REMOVAL occurs because input torque applied to the gears is (1) Raise and support vehicle. divided and distributed equally between the two side (2) Remove fill hole plug from the differential gears.
Page 189 3 - 130 REAR AXLE - 216RBI DIFFERENTIAL (Continued) CAUTION: Never spread the housing over 0.38 mm (0.015 in). If housing is over-spread, it could dis- torted and damaged the housing. Fig. 34 BEARING CAP REFERENCE 1 - REFERENCE LETTERS 2 - REFERENCE LETTERS Fig.
Page 190 REAR AXLE - 216RBI 3 - 131 DIFFERENTIAL (Continued) (11) While holding the differential case in position, remove the differential bearing cap bolts and caps. (12) Remove differential from the housing and tag differential bearing cups to indicate location (Fig. 38). Fig.
Page 191 Gear Lubricant or equivalent to bottom of the fill plug hole. (14) Install the fill hole plug. (15) Install wheel and tire assemblies. (16) Remove support and lower the vehicle. DIFFERENTIAL - LOCKER Fig. 41 BEARING CAP REFERENCE DESCRIPTION 1 - REFERENCE LETTERS...
Page 192 DIAGNOSIS AND TESTING UNLOCKED (1) Block tires opposite the axle to be tested to pre- vent the vehicle from rolling. (2) Place transfer case in 4WD Low and automan- tic transmission in Park (1st gear if manual trans- mission).
Page 193 3 - 134 REAR AXLE - 216RBI DIFFERENTIAL - LOCKER (Continued) NOTE: If pump is not running, verify pump has (Fig. (3) Remove differential housing cover. 44) 12 volts and ground. (4) Remove axle shafts. (5) Remove locker pressure hose from actuator assembly (Fig.
Page 194 REAR AXLE - 216RBI 3 - 135 DIFFERENTIAL - LOCKER (Continued) (7) Loosen the differential bearing cap bolts. (8) Position Spreader W-129-B with Adapter Kit 6987B on differential locating holes (Fig. 48). Install hold down clamps and tighten the turnbuckle finger- tight.
Page 195 3 - 136 REAR AXLE - 216RBI DIFFERENTIAL - LOCKER (Continued) (11) Remove the dial indicator. (16) Clean the housing cavity with flushing oil, (12) Remove differential bearing cap bolts and ring light engine oil or lint free cloth. gear side bearing cap. NOTE: Do not use water, steam, kerosene or gaso- (13) Remove differential from housing with pinion line for cleaning.
Page 196 REAR AXLE - 216RBI 3 - 137 DIFFERENTIAL - LOCKER (Continued) (3) Position Puller Jaws 6444-7 (Fig. 54) around the case bearing and puller flange. Fig. 55 PULLER AND COLLAR 1 - PULLER 2 - ROD Fig. 54 PULLER AND JAWS 3 - PLUG 4 - COLLAR 1 - PULLER...
Page 197 3 - 138 REAR AXLE - 216RBI DIFFERENTIAL - LOCKER (Continued) (2) Position Spreader W-129-B and adapters from Adapter set 6987, with the tool dowel pins seated in the locating holes (Fig. 59). Install hold-down clamps and tighten the tool turnbuckle finger-tight. Fig.
Page 198 REAR AXLE - 216RBI 3 - 139 DIFFERENTIAL - LOCKER (Continued) (7) Install ring gear side bearing cap with refer- ence marks aligned (Fig. 60). Fig. 60 BEARING CAP REFERENCE MARKS 1 - REFERENCE MARKS 2 - REFERENCE MARKS Fig. 61 DIFFERENTIAL COVER (8) Loosely install differential bearing cap bolts.
Page 199 2 - CROSSMEMBER/SKID PLATE Fig. 65 PUMP SCREWS (4) Remove pumps and bracket assembly from the 1 - REAR PUMP SCREWS vehicle. 2 - FRONT PUMP SCREWS (5) Remove pump connectors from the mounting bracket. (3) Install pump bracket assembly on the cross- (6) Remove pump mounting screws (Fig.
Page 200 (Fig. 68). vice or during a lubricant change. This design provides the differential action needed After changing the lubricant, drive the vehicle and for turning corners and for driving straight ahead make 10 to 12 slow, figure-eight turns. This maneu- during periods of unequal traction.
Page 201 3 - 142 REAR AXLE - 216RBI DIFFERENTIAL -TRAC-LOK (Continued) DIFFERENTIAL TEST The differential can be tested without removing the differential case by measuring rotating torque. Make sure brakes are not dragging during this measure- ment. (1) Place blocks in front and rear of both front wheels.
Page 202 REAR AXLE - 216RBI 3 - 143 DIFFERENTIAL -TRAC-LOK (Continued) (6) Assemble Threaded Adapter C-4487-1 into top side gear. Thread Forcing Screw C-4487-4 into adapter until it becomes centered in adapter plate. (7) Position a small screw driver in slot of Threaded Adapter Disc C-4487-3 (Fig.
Page 203 3 - 144 REAR AXLE - 216RBI DIFFERENTIAL -TRAC-LOK (Continued) Fig. 75 PINION GEARS Fig. 77 CLUTCH PACK 1 - PINION GEARS 1 - DISCS 2 - TURNING BAR 2 - DISHED PLATE 3 - RETAINER 4 - SIDE GEAR 5 - RETAINER 6 - PLATES clutch pack retaining clips are in position and...
Page 204 REAR AXLE - 216RBI 3 - 145 DIFFERENTIAL -TRAC-LOK (Continued) (6) Install lubricated Step Plate C-4487-3 in lower (16) Install pinion mate shaft roll pin. Stake (peen) side gear (Fig. 79). case over pin in two places 180 degrees apart. (17) Lubricate all differential components with hypoid gear lubricant.
Page 205 NOTE: The ring gear and pinion are serviced as a matched set. Never replace one gear without replac- ing the other matched gear. (1) Raise and support vehicle (2) Mark pinion yoke and propeller shaft for installation reference. (3) Remove propeller shaft from pinion yoke and tie propeller shaft to underbody.
Page 206 REAR AXLE - 216RBI 3 - 147 PINION GEAR/RING GEAR/TONE RING (Continued) (9) Remove pinion yoke from pinion shaft with (11) Remove front pinion bearing cup, bearing and Remover C-452 and Flange Wrench C-3281 (Fig. 84). pinion seal with Remover D-147 and Handle C-4171 (Fig.
Page 207 3 - 148 REAR AXLE - 216RBI PINION GEAR/RING GEAR/TONE RING (Continued) (13) Remove rear pinion bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-39 (Fig. 88). Fig. 89 REAR BEARING CUP 1 - INSTALLER 2 - HANDLE Fig. 88 REAR PINION BEARING 1 - PULLER 2 - VISE 3 - ADAPTERS...
Page 208 REAR AXLE - 216RBI 3 - 149 PINION GEAR/RING GEAR/TONE RING (Continued) (5) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer 8681 (Fig. 91). Fig. 91 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER (6) Install pinion depth shim on the pinion shaft.
Page 209 3 - 150 REAR AXLE - 216RBI PINION GEAR/RING GEAR/TONE RING (Continued) (10) Check bearing preload torque with an inch CAUTION: Never reuse ring gear bolts, the bolts pound torque wrench (Fig. 95). The torque necessary can fracture causing extensive damage. to rotate the pinion gear should be: •...
Page 210 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 211 5 - 2 BRAKES - BASE STANDARD PROCEDURE - MASTER INSTALLATION - REAR ....32 CYLINDER BLEEDING ....24 WHEEL CYLINDERS REMOVAL .
Page 212 TOS FIBERS IN SEALED BAGS OR CONTAINERS check suspension components. Jounce front and rear TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- of vehicle and listen for noise that might be caused by loose, worn or damaged suspension or steering ERS. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINIS- components.
Page 213 In most cases, the rotors, drums, wheels and tires are quite warm to the touch after the vehicle is PEDAL FALLS AWAY stopped. A brake pedal that falls away under steady foot Severe drag can char the brake lining all the way pressure is generally the result of a system leak.
Page 214 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) As the dragging brake overheats, efficiency is so rotors and drums can become so scored that replace- reduced that fade occurs. Since the opposite brake ment is necessary. unit is still functioning normally, its braking effect is BRAKE CHATTER magnified.
Page 215 5 - 6 BRAKES - BASE BRAKES - BASE (Continued) Fill the bleeder tank with recommended fluid and STANDARD PROCEDURE purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylin- STANDARD PROCEDURE - MANUAL BLEEDING der adapter.
Page 216 BRAKES - BASE 5 - 7 BRAKES - BASE (Continued) TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Brake Pedal — Support Bolt Brake Booster — Mounting Nuts Master Cylinder — Mounting Nuts Master Cylinder — Brake Lines Combination Valve —...
Page 217 Flexible rubber hose is used at both front brakes and at the rear axle junction block. Inspect the hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle is in for service. Inspect the hoses for surface cracking, scuffing, or worn spots.
Page 218 BRAKES - BASE 5 - 9 BRAKE LINES (Continued) (7) Tighten the tool bar on the tube STANDARD PROCEDURE (8) Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flar- STANDARD PROCEDURE - BRAKE TUBE ing screw in recess of compression disc (Fig.
Page 219 When sufficient force is applied, friction 3 - PILOT will attempt to stop the rotors from turning and 4 - FLUSH WITH BAR bring the vehicle to a stop. 5 - TUBING 6 - BAR ASSEMBLY Application and release of the brake pedal gener-...
Page 220 6 - PISTON SEAL BRAKE PRESSURE ON REMOVAL REMOVAL - FRONT Fig. 8 Brake Hose And Bolt (1) Raise and support vehicle. 1 - FITTING WASHERS 2 - CALIPERS (2) Remove front wheel and tire assembly. (3) Drain small amount of fluid from master cylin- (6) Remove caliper mounting bolts (Fig.
Page 221 (5) Remove the caliper mounting slide pin bolts (Fig. 11). CAUTION: Do not blow the piston out of the bore (6) Remove the caliper from vehicle. with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out.
Page 222 BRAKES - BASE 5 - 13 DISC BRAKE CALIPERS (Continued) Fig. 15 Piston Seal Removal 1 - REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL 2 - PISTON SEAL Fig. 13 Caliper Piston Removal 1 - AIR GUN 2 - CALIPER PISTON 3 - PADDING MATERIAL (5) Remove caliper piston dust boot with suitable pry tool (Fig.
Page 223 5 - 14 BRAKES - BASE DISC BRAKE CALIPERS (Continued) The bore can be lightly polished with a brake (4) Install new piston seal into seal groove with hone to remove very minor surface imperfections finger (Fig. 19) . (Fig. 17) . The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch).
Page 224 BRAKES - BASE 5 - 15 DISC BRAKE CALIPERS (Continued) (6) Press piston into caliper bore by hand, use a INSTALLATION turn and push motion to work piston into seal (Fig. 21) . INSTALLATION - FRONT (1) Clean brake shoe mounting ledges with wire brush and apply light coat of Mopar multi-mileage grease to surfaces (Fig.
Page 225 Then install and tighten the bolts to (10) Remove the supports and lower the vehicle. 15 N·m (11 ft. lbs.). (11) Verify a firm pedal before moving the vehicle. (5) Install the brake hose banjo bolt if removed (Fig. 27).
Page 226 CAUTION: Do not use compressed air, this can the caliper adapter. unseat dust boot and force dirt into piston bore. NOTE: Do not allow brake hose to support caliper REMOVAL - DRUM BRAKE SHOES assembly. (1) Raise vehicle and remove rear wheels.
Page 227 TIRES/WHEELS/WHEELS - STANDARD PROCE- (10) Install guide plate and adjuster cable on DURE). anchor pin. (5) Remove support and lower vehicle. (11) Install primary and secondary return springs. (6) Pump brake pedal until caliper pistons and (12) Install adjuster cable guide on secondary brake shoes are seated.
Page 228 Measure drum diameter and runout with an accu- STANDARD PROCEDURE). rate gauge. The most accurate method of measure- (17) Verify firm brake pedal before moving vehicle. ment involves mounting the drum in a brake lathe and checking variation and runout with a dial indi- INSTALLATION - REAR DISC BRAKE PADS cator.
Page 229 ADJUSTMENT WITH BRAKE GAUGE (1) Be sure parking brakes are fully released. INSPECTION (2) Raise rear of vehicle and remove wheels and As a general rule, riveted brake shoes should be brake drums. replaced when worn to within 0.78 mm (1/32 in.) of (3) Verify that left and right automatic adjuster the rivet heads.
Page 230 ADJUSTMENT WITH ADJUSTING TOOL stop. Incomplete, rolling stops will not activate (1) Be sure parking brake lever is fully released. automatic adjusters. (2) Raise vehicle so rear wheels can be rotated freely. (3) Remove plug from each access hole in brake FLUID support plates.
Page 231 CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would Fig.
Page 232 (4) Press and hold brake pedal under light foot (4) Fill and bleed master cylinder on bench before pressure. The pedal should hold firm, if the pedal installation in vehicle. falls away master cylinder is faulty (internal leak- age). (5) Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm.
Page 233 STANDARD PROCEDURE - MASTER CYLINDER BLEEDING A new master cylinder should be bled before instal- lation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line.
Page 234 BRAKES - BASE 5 - 25 MASTER CYLINDER (Continued) (4) Install combination valve onto brake booster studs and tighten mounting nuts to 20 N·m (15 ft. lbs.). (5) Install brake lines to master cylinder and com- bination valve by hand to avoid cross threading. (6) Tighten master cylinder brake lines to 19 N·m (14 ft.
Page 235 5 - 26 BRAKES - BASE PEDAL (Continued) POWER BRAKE BOOSTER DESCRIPTION The booster assembly consists of a housing divided into separate chambers by two internal diaphragms. The outer edge of each diaphragm is attached to the booster housing. Two push rods are used in the booster. The pri- mary push rod connects the booster to the brake pedal.
Page 236 BRAKES - BASE 5 - 27 POWER BRAKE BOOSTER (Continued) Fig. 47 Power Brake Booster–Typical 1 - VACUUM CHECK VALVE 7 - PRIMARY PUSH ROD (TO BRAKE PEDAL) 2 - FRONT DIAPHRAGM 8 - ATMOSPHERIC INLET VALVE ASSEMBLY 3 - REAR DIAPHRAGM 9 - BOOSTER MOUNTING STUDS (4) 4 - HOUSING 10 - SECONDARY PUSH ROD (TO MASTER CYLINDER)
Page 237 5 - 28 BRAKES - BASE POWER BRAKE BOOSTER (Continued) REMOVAL INSTALLATION (1) Remove combination valve and master cylinder. (1) Clean the booster mounting surface. (2) Disconnect vacuum hose from booster check (2) Install dash seal on booster. valve. (3) Align and position booster on the front cowl (3) Remove retaining clip that secures booster panel.
Page 238 Pressure Differential Switch (1) Have helper sit in drivers seat to apply brake pedal and observe red brake warning light. (2) Raise vehicle on hoist. (3) Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid.
Page 239 5 - 30 BRAKES - BASE ROTORS DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining in a disc brake lathe if surface scoring and wear are light.
Page 240 Equipment capable of machining only one side at a time may produce a tapered rotor. NOTE: A hub mounted on-vehicle lathe is recom- mended. This type of lathe trues the rotor to the vehicles hub/bearing.
Page 241 Inspect the cylinder bore. Light discoloration and DURE). dark stains in the bore are normal and will not (4) Lower the vehicle. impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded.
Page 242 BRAKES - BASE 5 - 33 WHEEL CYLINDERS (Continued) corrosion. Replace the pistons if worn, scored, or cor- roded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition.
Page 243: Parking Brake
5 - 34 BRAKES - BASE SUPPORT PLATE (Continued) (2) Install the park brake shoes (Fig. 59)(Refer to 5 The rear cables are connected to the actuating - BRAKES/PARKING BRAKE/SHOES - INSTALLA- lever on each secondary brake shoe. The levers are TION).
Page 244 REMOVAL (1) Raise and support the vehicle. (2) Remove the tire and wheel assembly. (3) Remove the disc brake caliper, (Fig. 62)(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC Fig.
Page 245 INSTALLATION the brake shoe contact pads on the support plate with fine sandpaper. NOTE: On a new vehicle or after parking brake lin- ing replacement, it is recommended that the park- INSPECTION - REAR DRUM IN HAT BRAKE ing brake system be conditioned prior to use. This...
Page 246 If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. (1) Raise vehicle. Fig. 66 READING PARK BRAKE DRUM DIAMETER (2) Remove tire and wheel. 1 - SPECIAL TOOL C-3919...
Page 247 129 N·m (95 ft. lbs.). (16) Lower vehicle. Fig. 68 Brake Adjustment CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm 1 - STAR WHEEL 2 - LEVER enough pedal to stop the vehicle.
Page 248 BRAKES - BASE 5 - 39 CABLES REMOVAL REMOVAL - DRUM BRAKES (1) Raise vehicle and loosen equalizer nuts until rear cables are slack. (2) Disengage cable from equalizer and remove cable. (3) Remove cable bracket from upper suspension arm (Fig. 69).
Page 249 5 - 40 BRAKES - BASE CABLES (Continued) INSTALLATION INSTALLATION - DRUM BRAKES (1) Install new cable in backing plate. Be sure cable retainer is seated. (2) Attach cable to lever on brake shoe and install brake shoe on backing plate. (3) Adjust brake shoes to drum with brake gauge.
Page 250 During normal braking, the master cylinder, power DESCRIPTION booster and wheel brake units all function as they would in a vehicle without ABS. The HCU compo- The purpose of the antilock system is to prevent nents are not activated. wheel lockup during periods of high wheel slip. Pre-...
Page 251 Refer to base brake section for procedure. (5) Top off master cylinder fluid level and verify STANDARD PROCEDURE - BLEEDING ABS proper brake operation before moving vehicle. BRAKE SYSTEM ABS system bleeding requires conventional bleed- ing methods plus use of the DRB scan tool. The pro-...
Page 252 REMOVAL The sensors convert wheel speed into a small AC electrical signal. This signal is transmitted to the (1) Raise vehicle and turn wheel outward to access CAB. The CAB convert the AC signal into a digital the sensor. signal for each wheel. This voltage is generated by...
Page 253 G-switch), will not function properly if the switch is (3) Connect harness to switch. installed incorrectly. Verify that the switch locating (4) Place carpet back into position. arrow is pointing to the front of the vehicle (Fig. 3). (1) Position switch on mounting bracket.
Page 254 BRAKES - ABS 5 - 45 INSTALLATION REAR WHEEL SPEED SENSOR (1) If original sensor is being installed, remove DESCRIPTION any remaining pieces of cardboard spacer from sen- sor pickup face. Use dry shop towel only to remove A speed sensor is used at each wheel. The front old spacer material.
Page 255 During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease.
Page 256 BRAKES - ABS 5 - 47 HCU (HYDRAULIC CONTROL UNIT) (Continued) (4) Remove brake lines from the HCU. (5) Remove HCU/CAB mounting nuts and bolt (Fig. 9) and remove HCU/CAB. INSTALLATION (1) Install HCU/CAB on the mounting studs. (2) Install mounting nuts and bolt. Tighten to 11.5 N·m (102 in.
Page 258 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH INSTALLATION ......8 DESCRIPTION .
Page 259 DIAGNOSIS AND TESTING - CLUTCH (face) runout of a new disc should not exceed 0.50 Drive the vehicle at normal speeds. Shift the trans- mm (0.020 in.). Measure runout about 6 mm (1/4 in.) mission through all gear ranges and observe clutch from the outer edge of the disc facing.
Page 260 CLUTCH 6 - 3 CLUTCH (Continued) • heat warpage weaken the flywheel and interfere with proper clutch • improper machining release. • incorrect bolt tightening Clean the crankshaft flange before mounting the • improper seating on crankshaft flange shoulder flywheel. Dirt and grease on the flange surface may •...
Page 261 1. Sand rusted surfaces with 180 pressure plate. period of time (e.g. long term grit sanding paper. Replace clutch vehicle storage). cover and flywheel if necessary. Pilot bearing seized, loose, or rollers 1. Bearing cocked during 1. Install and lubricate a new are worn.
Page 262 CLUTCH 6 - 5 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible. Replace clutch pedal if necessary. 2. Master cylinder bushing not 2. Lubricate master cylinder lubricated. bushing. 3. Pedal bushings worn out or 3.
Page 263 6 - 6 CLUTCH NOTE: If disc is not marked, flat side of disc hub CLUTCH DISC goes towards the flywheel. REMOVAL (4) Insert alignment tool through disc and into the (1) Remove transmission. Refer to 21 Transmission pilot bearing on the flywheel (Fig. 2). and Transfer Case for procedures.
Page 264 CLUTCH 6 - 7 CLUTCH RELEASE BEARING REMOVAL (1) Remove the transmission. (2) Disconnect release bearing from release lever and remove bearing (Fig. 3). (3) Inspect bearing slide surface of transmission front bearing retainer. Replace retainer if slide sur- face is scored, worn, or cracked. (4) Inspect release fork and fork pivot.
Page 265 6 - 8 CLUTCH FLYWHEEL (Continued) OPERATION Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may The flywheel serves to dampen the engine firing cock the flywheel causing excessive runout. Use new pulses. The heavy weight of the flywheel relative to bolts when remounting a flywheel and secure the the rotating mass of the engine components serves to bolts with Mopar Lock And Seal or equivalent.
Page 266 (1) Be sure reservoir cover on clutch master cylin- der is tight to avoid spills. (2) Position clutch linkage components in vehicle. Work connecting line and slave cylinder downward past engine and adjacent to clutch housing.
Page 267 (4) Remove nuts attaching pedal and bracket to dash panel and upper cowl support (Fig. 9) or (Fig. 10). (5) Separate pedal assemble from vehicle. INSTALLATION (1) Place clutch pedal and bracket over studs on dash panel and cowl support.
Page 268 It is attached to the clutch master cylinder push rod (Fig. 11). The wiring harness connection for the switch is made inside of the vehicle under the left side of the instrument panel (Fig. 12). Fig. 12 CPPS ELECTRICAL CONNECTION...
Page 270: Cooling
COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE - REFILLING DESCRIPTION COOLING SYSTEM - 2.4L ....11 DESCRIPTION - COOLING SYSTEM 2.4L STANDARD PROCEDURE—COOLANT ENGINE .
Page 271: Engine
7 - 2 COOLING COOLING (Continued) Fig. 3 Hose Clamp Tool 1 - HOSE CLAMP TOOL 6094 2 - HOSE CLAMP DIAGNOSIS AND TESTING ON-BOARD DIAGNOSTICS - OBD COOLING SYSTEM RELATED DIAGNOSTICS The Powertrain Control Module (PCM) has been programmed to monitor the certain following cooling system components: •...
Page 272 A maximum cooling package should have been plaint, refer to COOLING SYSTEM DIAGNOSIS ordered with vehicle if add-on or after market A/C is CHART BELOW. installed. If not, maximum cooling system compo-...
Page 273 TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep 1. This may be a temporary HIGH OR THE COOLANT hill is being climbed, vehicle is condition and repair is not WARNING LAMP ILLUMINATES. operated in slow moving traffic, or necessary.
Page 274 COOLING 7 - 5 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 8. Incorrect coolant concentration 8. Check coolant. (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION). 9. Coolant not flowing through 9. Check for coolant flow at radiator system filler neck with some coolant removed, engine warm and thermostat open.
Page 275 CLUSTER - DIAGNOSIS AND TESTING). 3. Gauge reading rises when 3. A normal condition. No correction vehicle is brought to a stop after is necessary. Gauge should return heavy use (engine still running) to normal range after vehicle is driven.
Page 276 COOLING 7 - 7 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT PRESSURE system hoses, water pump or necessary. (Refer to 7 - COOLING - CAP BLOWOFF.
Page 277 STEAM IS COMING FROM THE 1. During wet weather, moisture 1. Occasional steam emitting from FRONT OF VEHICLE NEAR THE (snow, ice or rain condensation) on this area is normal. No repair is GRILL AREA WHEN WEATHER IS the radiator will evaporate when the necessary.
Page 278 COOLING 7 - 9 COOLING (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM - Carefully remove the radiator pressure cap from the filler neck and check the coolant level. Push TESTING FOR LEAKS down on the cap to disengage it from the stop tabs. Wipe the inner part of the filler neck and examine ULTRAVIOLET LIGHT METHOD the lower inside sealing seat for nicks, cracks, paint,...
Page 279 PRESSURE TESTER) (1) DO NOT remove radiator cap first. With engine DO NOT WASTE reusable coolant. If the solution cold, raise vehicle on a hoist and locate radiator is clean, drain the coolant into a clean container for draincock. reuse.
Page 280 COOLING 7 - 11 COOLING (Continued) (2) Attach one end of a hose to the draincock. Put (3) With heater control unit in the HEAT position, the other end into a clean container. Open draincock operate engine with pressure bottle cap in place. and drain coolant from radiator.
Page 281 7 - 12 COOLING COOLING (Continued) (2) Drain coolant from engine block by removing Reverse flushing of the cooling system is the forc- drain plug at left rear side of block (Fig. 7). ing of water through the cooling system. This is done using air pressure in the opposite direction of normal coolant flow.
Page 282 COOLING 7 - 13 COOLING (Continued) Connect the water supply hose and air supply hose DESCRIPTION N·m to the flushing gun. Allow the engine to fill with water. When the engine is filled, apply air in short Lbs. Lbs. blasts, allowing the system to fill between air blasts. Fan Blade Assy.
Page 283 7 - 14 COOLING COOLING (Continued) Spanner Wrench 6958 with 8346 adapter pins Pressure Tester 7700–A Coolant Refractometer 8286...
Page 284 ACCESSORY DRIVE 7 - 15 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE INSTALLATION ..... . . 16 SPECIFICATIONS DRIVE BELTS - 2.4L BELT TENSION .
Page 285 7 - 16 ACCESSORY DRIVE BELT TENSIONERS (Continued) Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt ten- sioner. (1) Disconnect negative battery cable from battery. (2) Rotate belt tensioner until it contacts its stop. Remove belt, then slowly rotate the tensioner into the freearm position.
Page 286 ACCESSORY DRIVE 7 - 17 BELT TENSIONERS (Continued) Fig. 3 BELT ROUTING 2.4L WITH A/C Fig. 4 BELT ROUTING 2.4L WITHOUT A/C 1 - IDLER PULLEY 1 - IDLER PULLEY 2 - GENERATOR PULLEY 2 - GENERATOR PULLEY 3 - IDLER PULLEY 3 - IDLER PULLEY 4 - POWER STEERING PUMP PULLEY 4 - POWER STEERING PUMP PULLEY...
Page 287 7 - 18 ACCESSORY DRIVE DRIVE BELTS - 2.4L (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.
Page 288 ACCESSORY DRIVE 7 - 19 DRIVE BELTS - 2.4L (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE (Objectionable squeal, 1. Belt slippage 1. Adjust belt tension (2.5L) squeak, or rumble is heard or felt 2. Bearing noise 2. Locate and repair while drive belt is in operation) 3.
Page 289 7 - 20 ACCESSORY DRIVE DRIVE BELTS - 2.4L (Continued) INSTALLATION INSTALLATION NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these sche- matics and the Belt Routing Label, use the sche- matics on Belt Routing Label.
Page 290 ACCESSORY DRIVE 7 - 21 DRIVE BELTS - 2.4L (Continued) Fig. 10 4.0L Engines–With A/C Fig. 9 BELT ROUTING 2.4L WITHOUT A/C 1 - GENERATOR PULLEY 1 - IDLER PULLEY 2 - IDLER PULLEY 2 - GENERATOR PULLEY 3 - POWER STEERING PUMP PULLEY 3 - IDLER PULLEY 4 - AIR CONDITIONING COMPRESSOR PULLEY 4 - POWER STEERING PUMP PULLEY...
Page 291 7 - 22 ACCESSORY DRIVE DRIVE BELTS - 2.4L (Continued) Fig. 12 4.0L Engines–With A/C 1 - GENERATOR PULLEY 2 - IDLER PULLEY 3 - POWER STEERING PUMP PULLEY 4 - AIR CONDITIONING COMPRESSOR PULLEY 5 - CRANKSHAFT PULLEY 6 - WATER PUMP PULLEY 7 - TENSIONER PULLEY...
Page 292 ENGINE 7 - 23 ENGINE TABLE OF CONTENTS page page COOLANT RADIATOR DESCRIPTION DESCRIPTION ......33 DESCRIPTION - HOAT COOLANT .
Page 293 7 - 24 ENGINE be covered under the new vehicle warranty, and COOLANT decreased corrosion protection. COOLANT PERFORMANCE DESCRIPTION The required ethylene-glycol (antifreeze) and water DESCRIPTION - HOAT COOLANT mixture depends upon climate and vehicle operating conditions. The coolant performance of various mix-...
Page 294 The required ethylene-glycol (antifreeze) and water heat from the coolant to the atmosphere. During cold mixture depends upon the climate and vehicle oper- weather the ethylene-glycol coolant prevents water ating conditions. The recommended mixture of 50/50...
Page 295 7 - 26 ENGINE COOLANT RECOVERY CONTAINER (Continued) contraction of the coolant to keep the coolant free of ENGINE BLOCK HEATER trapped air. It provides: • A volume for coolant expansion and contraction. DESCRIPTION • A convenient and safe method for checking/ad- justing coolant level at atmospheric pressure.
Page 296 (1) Drain cooling system (Refer to 7 - COOLING/ securely to assure a positive seal. ENGINE - STANDARD PROCEDURE). (2) Raise vehicle on hoist. CAUTION: To prevent damage, the power cord must (3) Detach power cord plug from heater. be secured in it’s retaining clips, and not positioned (4) Loosen screw in center of heater.
Page 297 7 - 28 ENGINE ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases.
Page 298 ENGINE 7 - 29 OPERATION ENGINE COOLANT The wax pellet is located in a sealed container at THERMOSTAT the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension DESCRIPTION and water pump pressure to force the valve to open. CAUTION: Do not operate an engine without a ther- mostat, except for servicing or testing.
Page 299 7 - 30 ENGINE ENGINE COOLANT THERMOSTAT (Continued) Fig. 9 Thermostat Removal/Installation 1 - LONG BOLT 2 - GASKET 3 - THERMOSTAT 4 - THERMOSTAT HOUSING 5 - SHORT BOLT Fig. 10 Thermostat and Coolant Outlet Connector INSTALLATION 1 - TIMING BELT COVER 2 - OUTLET CONNECTOR 3 - THERMOSTAT INSTALLATION...
Page 300 ENGINE 7 - 31 ENGINE COOLANT THERMOSTAT (Continued) INSTALLATION The thermal viscous fan drive (Fig. 13) and (Fig. 14) is a silicone-fluid-filled coupling used to connect (1) Clean all gasket sealing surfaces. the fan blades to the water pump shaft. The coupling (2) Place a new gasket (dipped in clean water) on allows the fan to be driven in a normal manner.
Page 301 7 - 32 ENGINE FAN DRIVE VISCOUS CLUTCH (Continued) OPERATION 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. 15) (Fig. 16). This spring coil reacts to the temperature of the radiator discharge air.
Page 302 DESCRIPTION the removal of the fan shroud to remove the viscous fan drive. The fan shroud and fan blade/viscous fan CAUTION: Plastic tanks, while stronger than brass, drive should be removed from the vehicle as one subject damage impact, such assembly.
Page 303 (Fig. 20) to the side. temperature is reached. Then feel the upper radiator (10) Lift radiator straight up and out of vehicle hose. If hose is hot, the thermostat is open and water taking care not to damage radiator fins.
Page 304 ENGINE 7 - 35 RADIATOR (Continued) Fig. 20 Radiator - Remove/Install 1 - A/C CONDENSER SEALS 5 - COOLANT RECOVERY BOTTLE 2 - FAN SHROUD (4.0L) 6 - TRANSMISSION COOLER LINES (IF EQUIPPED) 3 - FAN SHROUD (2.5L) 7 - FRONT AXLE VENT HOSE 4 - TRANSMISSION OIL COOLER LINES RETAINER CLIPS REMOVAL CAUTION: A number or letter is stamped into the...
Page 305 7 - 36 ENGINE RADIATOR (Continued) Fig. 23 Air Seals - Typical 1 - AIR DAM 2 - RADIATOR 3 - AIR DAM Fig. 22 Clamp Number/Letter Location - Typical 4 - A/C CONDENSER 1 - TYPICAL CONSTANT TENSION HOSE CLAMP 5 - AIR SEAL 2 - CLAMP NUMBER/LETTER LOCATION 3 - TYPICAL HOSE...
Page 306 (1) Gently lower the radiator and fan shroud into (12) Gently lift up and remove radiator from vehi- the vehicle. Guide the two radiator alignment dowels cle. Be careful not to scrape the radiator fins against into the rubber grommets located in lower radiator any other component.
Page 307 7 - 38 ENGINE WATER PUMP - 2.4L (Continued) REMOVAL — 2.4L (1) Drain cooling system (Refer to 7 - COOLING/ ENGINE - STANDARD PROCEDURE). (2) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL).
Page 308 ENGINE 7 - 39 WATER PUMP - 2.4L (Continued) This aluminum water pump (Fig. 28) is the heart of the cooling system. The water pump is located at the front of the cylinder block, above the timing chain cover The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing.
Page 309 7 - 40 ENGINE WATER PUMP - 4.0L (Continued) Fig. 30 Fan and Fan Drive Mounting - 4.0L Engine 1 - FAN AND FAN DRIVE 2 - WATER PUMP PULLEY Fig. 29 Water Pump - 4.0L Engine WARNING: CONSTANT TENSION HOSE CLAMPS 1 - HEATER HOSE FITTING BORE 2 - WATER PUMP ARE USED ON MOST COOLING SYSTEM HOSES.
Page 310 (8) Remove the four pump mounting bolts (Fig. 33) and remove pump from vehicle. Discard old gasket. CAUTION: When installing the serpentine engine Note that one of the four bolts is longer than the accessory drive belt, the belt MUST be routed cor- other bolts.
Page 311 (2) Refill system with new antifreeze. (3) Conducting service procedures. (4) Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE.
Page 312 ENGINE 7 - 43 RADIATOR PRESSURE CAP (Continued) DIAGNOSIS AND TESTING - RADIATOR CAP CLEANING Remove cap from radiator. Be sure that sealing Use only a mild soap and water to clean the radi- surfaces are clean. Moisten rubber gasket with water ator cap.
Page 313 7 - 44 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION COOLER OPERATION ......44 DESCRIPTION .
Page 314: Table Of Contents
Junction Block modules in the vehicle over the Programmable Com- (JB) on a fused ignition switch output (run-acc) cir- munication Interface (PCI) bus network. The data...
Page 315: Audio Description
8A - 2 AUDIO AUDIO (Continued) DIAGNOSIS AND TESTING - AUDIO WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, (REFER ELECTRICAL/RESTRAINTS) Any diagnosis of the Audio system should BEFORE ATTEMPTING ANY STEERING WHEEL, begin with the use of the DRB III diagnostic STEERING COLUMN, OR INSTRUMENT PANEL tool.
Page 316: Amplified Subwoofer Description
DISC OPERATION 2. Foreign material on 2. Clean CD and test operation. 3. Condensation on CD 3. Allow temperature of vehicle interior to stabilize and test or optics. operation. 4. Faulty CD player. 4. Exchange or replace radio, if required.
Page 317: Removal
The antenna mast is con- nected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The antenna coaxial cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis.
Page 318: Removal
Replace the faulty base and cable, if required. TEST 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the bat- tery. Disconnect both battery cables, the negative cable first.
Page 319: Radio Description
(4) Remove the screws that secure the radio to the instrument panel. RADIO (5) If the vehicle is equipped with the CD radio, go to Step 6. If the vehicle is not equipped with the CD DESCRIPTION radio receiver, go to Step 8. Available factory-installed radio receivers for this...
Page 320: Installation
These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are used on this vehicle to control RFI or EMI noise include the fol- lowing: • Radio antenna base ground •...
Page 321: Removal
• The antenna should be mounted on the roof or toward the rear of the vehicle. Remember that mag- netic antenna mounts on the roof panel can adversely affect the operation of an overhead console compass, if the vehicle is so equipped.
Page 322: Installation
AUDIO 8A - 9 RADIO NOISE SUPPRESSION GROUND STRAP (Continued) ENGINE-TO-FRAME GROUND STRAP WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER-...
Page 323: Speaker Description
Base Cabin Equaliza- premium speaker system, the standard front speak- tion Curve programmed to the vehicle. If the vehicle ers are replace with an enclosure assembly that has a premium speaker system, make sure the Pre- includes a 4 inch speaker and a 1 inch tweeter.
Page 324: Removal
AUDIO 8A - 11 SPEAKER (Continued) REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 326 • Driver Door Ajar Warning - The instrument warning system components to each other through cluster chime tone generator will generate repetitive the electrical system of the vehicle. These hard wired chimes at a slow rate to announce that the hard...
Page 327 The chimes will continue to sage input received from the PCM over the PCI data...
Page 328 DIAGNOSIS AND TESTING - CHIME WARNING wired input for the right or left turn signal indicator as well as vehicle distance and speed message inputs SYSTEM received from the PCM over the PCI data bus indi-...
Page 329 8B - 4 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO SEAT BELT WARNING 1. Seat belt switch ground 1. Check for continuity between the ground circuit CHIME WITH SEAT BELT circuit open. of the floor wire harness connector for the seat UNBUCKLED, BUT OTHER belt switch and a good ground.
Page 330 CHIME/BUZZER 8B - 5 CHIME WARNING SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO HEADLAMPS-ON 1. Driver door ajar switch 1. Check for continuity between the driver door WARNING CHIME, BUT sense circuit open. ajar switch sense circuit of the connector for the OTHER CHIME FEATURES driver door ajar switch and the instrument panel wire harness instrument cluster connector.
Page 332 Standard for Class B Multiplexing. that it requires, it relays that message to its micro- Many of the electronic control modules in a vehicle processor. Each module ignores the messages on the require information from the same sensing device. In...
Page 333: Communication Description
DESCRIPTION The CAB operates the ABS system, and is separate from other vehicle electrical circuits. The CAB is located under the instrument panel to the right side of the steering column. It is mounted to bracket with one bolt. The bracket is mounted to the front upper...
Page 334: Operation
Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. REMOVAL (1) Remove the negative battery cable from the Fig.
Page 335: Fuel System
8E - 4 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • The PCM pre-positions the Idle Air Control (IAC) motor. • The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. • The PCM monitors the engine coolant tempera- ture sensor input.
Page 336: Steering
A/C compressor clutch relay. This is done • Air conditioning request signal (if equipped) if A/C has been selected by the vehicle operator and Based on these inputs the following occurs: specified pressures are met at the high and low–pres- •...
Page 337: Description - 5 Volt Supplies
• Vehicle speed sensor The Powertrain Control Module (PCM) has 2 main If the vehicle is under hard deceleration with the grounds. Both of these grounds are referred to as proper rpm and closed throttle conditions, the PCM power grounds.
Page 338: Operation
The PCM receives input signals from various NOTE: Powertrain Control Module (PCM) Outputs: switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations • A/C clutch relay through different system components. These compo- • Auto Shutdown (ASD) relay nents are referred to as PCM Outputs.
Page 339: Operation - Ignition Circuit Sense
NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. REMOVAL (1) Install PCM and mounting bolts to vehicle. USE THE DRB SCAN TOOL TO REPROGRAM (2) Tighten bolts to 4 N·m (35 in. lbs.). THE NEW POWERTRAIN CONTROL MODULE...
Page 340: Operation
SKIM sponder programming procedures. The SKIM also housing. If this antenna ring is not mounted properly stores the Vehicle Identification Number (VIN) in its around the ignition lock cylinder housing, communi- memory, which it learns through a PCI data bus cation problems between the SKIM and the transpon- message from the PCM during SKIS initialization.
Page 341: Standard Procedure - Pcm/Skim Programming
SKIM, then MISCELLANEOUS. invalid key or if a key transponder-related fault (3) Select PCM REPLACED (GAS ENGINE). exists, the SKIS indicator will flash. If the vehicle is (4) Enter secured access mode by entering the equipped with the Customer Learn transponder pro- vehicle four-digit PIN.
Page 342: Removal
BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle ignition keys will need to be (1) Disconnect and isolate the battery negative replaced and programmed to the new SKIM.
Page 343: Installation
8E - 12 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) (4) If the vehicle is equipped with the optional tilt (10) Remove the SKIM from the steering column. steering column, move the tilt steering column to the INSTALLATION fully lowered position and leave the tilt release lever in the released (down) position.
Page 344: Transmission Control Module Description
• Output Shaft Speed Sensor unit, the Sentry Key Immobilizer System (SKIS) Some examples of indirect inputs to the TCM MUST be initialized before the vehicle can be oper- are: ated. (Refer to 8 - ELECTRICAL/VEHICLE THEFT • Engine/Body Identification SECURITY - STANDARD PROCEDURE - SKIS INI- •...
Page 345 8E - 14 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibili- ties and functions: • Storing and maintaining Clutch Volume Indices (CVI) • Storing and selecting appropriate Shift Schedules •...
Page 346 ELECTRONIC CONTROL MODULES 8E - 15 TRANSMISSION CONTROL MODULE (Continued) • Fluid temperature SHIFT SCHEDULES • Software level As mentioned earlier, the TCM has programming As driving conditions change, the TCM appropri- that allows it to select a variety of shift schedules. ately adjusts the shift schedule.
Page 347: Standard Procedure - Tcm Quick Learn
8E - 16 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • The brakes must be applied STANDARD PROCEDURE - TCM QUICK LEARN • The engine speed must be above 500 rpm The quick learn procedure requires the use of the •...
Page 348 • Battery Holddown - The battery holddown engine compartment of the vehicle. The battery sys- hardware secures the battery in the battery tray in tem for this vehicle covers the following related com- the engine compartment. ponents, which are covered in further detail later in •...
Page 349: Battery System
(load sory systems for limited durations while the engine tester) and a 12-volt test lamp may be required.
Page 350 5. The battery has an 5. Refer to Battery System Specifications for the incorrect size or rating for proper size and rating. Replace an incorrect this vehicle. battery, as required. 6. The battery is faulty. 6. Determine the battery cranking capacity using the Micro 420 battery tester.
Page 351 Refer to Charging System for additional charging system diagnosis and testing procedures. Repair the faulty charging system, as required. 7. Electrical loads exceed the 7. Inspect the vehicle for aftermarket electrical output of the charging equipment which might cause excessive electrical system. loads.
Page 352: Cleaning
(baking performed any time the battery or related compo- soda) and warm water cleaning solution. Paint any nents must be removed for vehicle service. exposed bare metal. (1) Inspect the battery cable terminal clamps for (3) If the removed battery is to be reinstalled, damage.
Page 353: Specifications
Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment specification for the vehicle being serviced. Battery sizes and ratings are discussed in more detail below. • Group Size - The outside dimensions and ter-...
Page 354: Special Tools
The battery positive terminal post is physi- cally larger in diameter than the negative terminal post to ensure proper battery connection.
Page 355: Operation
This reaction causes the battery to dis- diagnose a vehicle. If the instruction manual is not charge electrical current from its terminals. As the available refer to the standard procedure in this sec-...
Page 356 CAUTION: Always disconnect and isolate the bat- tery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system compo- nents may result. Fig. 5 Voltmeter - Typical (2) Disconnect and isolate the battery negative CAUTION: Battery electrolyte will bubble inside the cable.
Page 357: Standard Procedure - Built-In Indicator Test
8F - 10 BATTERY SYSTEM BATTERY (Continued) appear that the battery will not accept charging cur- BATTERY CHARGING TIME TABLE rent. See the instructions provided by the manufac- Charging turer of the battery charger for details on how to 5 Amps 20 Amps Amperage Amps...
Page 358: Standard Procedure - Open-Circuit Voltage Test
Off position. A This test can be used in place of the hydrometer test normal vehicle electrical system will draw from five when a hydrometer is not available, or for mainte- to thirty-five milliamperes (0.005 to 0.035 ampere) nance-free batteries with non-removable cell caps.
Page 359: Battery System
When a vehicle will not be used for source of the high-amperage IOD. If the amperage twenty days or more (stored), remove the IOD fuse reading remains high after removing and replacing from the Power Distribution Center (PDC).
Page 360: Removal
Fig. 9 Micro 420 Battery Tester warranty claim submitted for battery replacement. (2) If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are OFF, including the ignition. The preferred test position REMOVAL is at the battery terminal. If the battery is not (1) Turn the ignition switch to the Off position.
Page 361: Installation
Refer to Battery Holddown for the proper bat- nal posts. Reversed battery polarity may damage tery holddown removal procedures. electrical components of the vehicle. WARNING: WEAR A SUITABLE PAIR OF RUBBER (5) Clean the battery cable terminal clamps and GLOVES (NOT THE HOUSEHOLD TYPE) WHEN the battery terminal posts.
Page 362: Operation
Improper hold down fastener tightness, whether too loose or too tight, can result in damage to the battery, the vehicle or both. (Refer to 8 Fig. 13 Battery Hold Downs Remove/Install ELECTRICAL/BATTERY...
Page 363: Battery Cables Description
Park position. If the vehicle is equipped with a man- wires from the female battery terminal clamps pro- ual transmission, place the gearshift selector lever in...
Page 364: Removal
BATTERY SYSTEM 8F - 17 BATTERY CABLES (Continued) • To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay is located in the Power Distribution Center (PDC), in the engine compartment. See the fuse and relay lay- out label affixed to the underside of the PDC cover for ASD relay identification and location.
Page 365: Installation
8F - 18 BATTERY SYSTEM BATTERY CABLES (Continued) (15) Remove the nut that secures the battery pos- itive cable eyelet terminal to the B(+) terminal stud on the starter solenoid. (16) Remove the battery positive cable eyelet ter- minal from the B(+) terminal stud on the starter solenoid.
Page 366: Battery Tray Description
Unrestrained battery movement during cable terminal clamps and the battery terminal vehicle operation could result in damage to the vehi- posts. cle, the battery, or both. REMOVAL...
Page 367: Installation
8F - 20 BATTERY SYSTEM BATTERY TRAY (Continued) INSTALLATION (4) Install the battery temperature sensor onto the battery tray (Refer to 8 - ELECTRICAL/CHARGING/ (1) Clean and inspect the battery tray (Refer to 8 - BATTERY TEMPERATURE SENSOR - INSTALLA- ELECTRICAL/BATTERY SYSTEM - CLEANING), TION).
Page 368 CHARGING 8F - 21 CHARGING TABLE OF CONTENTS page page CHARGING OPERATION ......24 DESCRIPTION .
Page 369 8F - 22 CHARGING CHARGING (Continued) DIAGNOSIS AND TESTING - CHARGING To perform a complete test of the charging system, refer to the appropriate Powertrain Diagnostic Proce- SYSTEM dures service manual and the DRB scan tool. Per- The following procedures may be used to diagnose form the following inspections before attaching the the charging system if: scan tool.
Page 370: Charging
20 degrees F. REMOVAL The battery temperature sensor is located under the vehicle battery (Fig. 1) and is attached to a mounting hole on battery tray. (1) Remove battery. Refer to 8, Battery for proce- dures.
Page 371: Generator
2 - UPPER BOLT nally, different generators with different output rat- 3 - LOWER BOLT ings are used on this vehicle. Be certain that the INSTALLATION replacement generator has the same output rating and part number as the original unit. Refer to Gen-...
Page 372 CHARGING 8F - 25 GENERATOR (Continued) Fig. 5 GENERATOR CONNECTORS - 4.0L Fig. 3 GENERATOR MOUNTING- 2.4L 1 - FIELD WIRE CONNECTOR 1 - UPPER MOUNTING BOLT 2 - B+ CABLE 2 - GENERTOR 3 - GENERATOR 3 - LOWER MOUNTING BOLT 4 - B+ CABLE MOUNTING NUT 5 - CABLE PROTECTOR Fig.
Page 373: Operation
8F - 26 CHARGING GENERATOR (Continued) CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cool- ing System.
Page 374 CHARGING 8F - 27 GENERATOR DECOUPLER PULLEY (Continued) (6) After breaking loose with tool, unthread decou- pler by hand from generator. Fig. 8 GENERATOR DECOUPLER PULLEY (INA) 1 - GENERATOR 2 - DECOUPLER (INA) 3 - MACHINED SPLINES Fig. 10 #8823 (VM.1048) TOOL AND INA DECOUPLER 1 - INA DECOUPLER 2 - TOOL #8823 (VM.1048)
Page 375 8F - 28 CHARGING GENERATOR DECOUPLER PULLEY (Continued) Fig. 12 END OF GENERATOR SHAFT (SPLINED) 1 - GENERATOR SHAFT 2 - SPLINES Fig. 14 DECOUPLER REMOVAL (INA-SPLINED) 1 - DRIVER 2 - TOOL #8823 (VM.1048) 3 - 17 MM WRENCH Fig.
Page 376 CHARGING 8F - 29 GENERATOR DECOUPLER PULLEY (Continued) Fig. 16 DECOUPLER REMOVAL (LITENS) Fig. 17 DECOUPLER INSTALLATION (INA-HEX) 1 - 10MM DEEP SOCKET INSTALLATION 2 - TOOL # 8823 (VM.1048) INA Decoupler (1) Thread decoupler pulley onto generator shaft by hand (right-hand threads). (2) Position Special Tool #8823 (VM.1048) into decoupler (Fig.
Page 377: Operation
8F - 30 CHARGING GENERATOR DECOUPLER PULLEY (Continued) (3) Do not use an adjustable, ratcheting “click VOLTAGE REGULATOR type” torque wrench. Most “click type” wrenches will only allow torque to be applied DESCRIPTION in a clockwise rotation. Use a dial-type or The Electronic Voltage Regulator (EVR) is not a beam-type wrench.
Page 378 If the vehicle is equipped with a manual transmis- tested as a complete system. For correct operation of sion, it has a clutch pedal position switch installed in...
Page 379: Starting Description
The battery, starting system and charging system selector is in the Neutral or Park positions. in the vehicle operate with one another, and must be When the starter relay coil is energized, the nor- tested as a complete system. In order for the engine mally open relay contacts close.
Page 380 Engine Diagnosis engine diagnosis and Park position. If the vehicle is equipped with a man- testing procedures. If the starter motor is not OK, ual transmission, place the gearshift selector lever in replace faulty starter motor.
Page 381 • If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a man- ual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position.
Page 382 STARTING 8F - 35 STARTING (Continued) eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Fig. 3 Test Battery Positive Connection Resistance - Typical 1 - VOLTMETER Fig.
Page 383: Inspection - Starting System
Park/Neutral Position Switch Clutch Pedal Position Switch • If vehicle is equipped with an automatic trans- • If the vehicle is equipped with a manual trans- mission, visually inspect park/neutral position switch mission, refer to Clutch Pedal Position Switch for...
Page 384: Specifications Starter
STARTING 8F - 37 STARTING (Continued) SPECIFICATIONS STARTER Starter Motor and Solenoid Manufacturer Mitsubishi Engine Application 2.4L, 4.0L 2.4L - 1.4 Kilowatt (1.9 Horsepower) Power Rating 4.0L - 1.4 Kilowatt (1.9 Horsepower) Voltage 12 Volts ** Number of Permanent Magnets Number of Brushes Drive Type Planetary Gear Reduction...
Page 385: Starter Motor Diagnosis And Testing - Starter Motor/Solenoid
Step 4. If not OK, replace faulty starter motor. by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to starter motor specifi- cations. CAUTION: Permanent magnets are used in the starter.
Page 386 1 - STARTER 2 - MOUNTING BOLTS (2) 4.0L (1) Disconnect and isolate negative battery cable. (2) Raise and support vehicle. (3) 4.0L With Manual Transmission: Remove lower bolt (forward facing) securing starter motor to transmission housing (Fig. 11). (4) 4.0L With Manual Transmission: While sup-...
Page 387: Installation
2 bolts. Refer to Torque Specifications. minal functions. The ISO micro-relay terminal (4) Lower vehicle. functions are the same as a conventional ISO relay. (5) Connect negative battery cable. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, 4.0L...
Page 388: Diagnosis And Testing - Starter Relay
STARTING 8F - 41 STARTER MOTOR RELAY (Continued) When the electromagnetic coil is de-energized, RELAY CIRCUIT TEST spring pressure returns the movable contact to the (1) The relay common feed terminal cavity (30) is normally closed position. The resistor or diode is con- connected to battery voltage and should be hot at all nected in parallel with the electromagnetic coil in the times.
Page 389: Removal
8F - 42 STARTING STARTER MOTOR RELAY (Continued) REMOVAL (1) Disconnect and isolate battery negative cable. (2) Unlatch and open cover on Power Distribution Center (PDC) (Fig. 15). (3) See fuse and relay layout label affixed to underside of PDC cover for starter relay identifica- tion and location.
Page 390 Refer to the own- Vehicles with the heated mirror options also have er’s manual in the vehicle glove box for more infor- heater grids located behind the outside rear view mation on the features, use and operation of the mirror glass.
Page 391: Window Defogger
(2) Using a 12-volt DC voltmeter, contact the ver- rear glass heating grid is still inoperative, one or tical bus bar on the right side of the vehicle with the more of the following is faulty: negative lead. With the positive lead, contact the ver- •...
Page 392: Standard Procedure
HEATED SYSTEMS 8G - 3 REAR WINDOW DEFOGGER GRID (Continued) (4) Connect the negative lead of the voltmeter to the right side bus bar and touch each grid line at 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.
Page 393: Rear Window Defogger Relay Description Defogger Relay
8G - 4 HEATED SYSTEMS REAR WINDOW DEFOGGER RELAY DESCRIPTION DEFOGGER RELAY The rear window defogger relay is a International Standards Organization (ISO)-type relay. The rear window defogger relay is a electromechanical device that switches fused battery current to the rear glass heating grid and the indicator lamp of the defogger switch, when the instrument cluster rear window defogger timer and logic circuitry grounds the relay...
Page 394: Removal
HEATED SYSTEMS 8G - 5 REAR WINDOW DEFOGGER RELAY (Continued) (5) The coil ground terminal (85) is connected to REAR WINDOW DEFOGGER the electromagnet in the relay. It is connected to SWITCH fused ignition switch output voltage and should be hot when the ignition switch is in the On position.
Page 395: Removal- Defogger Switch
8G - 6 HEATED SYSTEMS REAR WINDOW DEFOGGER SWITCH (Continued) sense circuit terminal on the back of the defogger (1) Disconnect and isolate the battery negative switch housing (Fig. 5). There should be momentary cable. continuity as the defogger switch button is depressed, (2) Remove the center bezel from the instrument and then no continuity.
Page 396: Installation
HEATED SYSTEMS 8G - 7 REAR WINDOW DEFOGGER SWITCH (Continued) INSTALLATION (1) Install the rear window defogger switch recep- tacle to the back of the accessory switch bezel and push switch into the bezel. (2) Plug the wire harness connectors to the rear of the accessory switches and the cigar lighter/power outlet.
Page 398 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM OPERATION ......2 DESCRIPTION .
Page 399 8H - 2 HORN HORN (Continued) should be continuity. If OK, go to Step 2. If not OK, switch grounds the relay coil. The horn relay is repair the open ground circuit to ground as required. located in the Power Distribution Center (PDC) in (2) Check for battery voltage at the horn relay out- the engine compartment.
Page 400 HORN 8H - 3 HORN RELAY (Continued) no continuity between terminals 87 and 30. If OK, go OK, go to Step 4. If not OK, repair the open circuit to to Step 3. If not OK, replace the faulty relay. the horn as required.
Page 401: Horn Switch
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS COMPONENT DIAGNOSIS OR SERVICE. FAILURE COMPONENT SHOULD BE PERFORMED ONLY BY TO TAKE THE PROPER PRECAUTIONS COULD CHRYSLER-TRAINED AND AUTHORIZED DEALER RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT SERVICE TECHNICIANS. FAILURE TO TAKE THE AND POSSIBLE PERSONAL INJURY.
Page 402 • THE HORN SWITCH IS INTEGRAL TO THE DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCI-...
Page 404 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL OPERATION - 4.0L ..... . . 8 DESCRIPTION .
Page 405: Ignition Control
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) primary transfers to the secondary causing a spark. ENGINE FIRING ORDER - 4.0L 6-CYLINDER The PCM will de-energize the ASD relay if it does ENGINE not receive inputs from either the crankshaft or cam- shaft position sensors.
Page 406: Ignition Coil Resistance - 4.0L Engine
IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) IGNITION COIL RESISTANCE - 4.0L ENGINE PRIMARY RESISTANCE 21-27°C (70-80°F) 0.71 - 0.88 Ohms IGNITION COIL - 2.4L SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 2.4L 4-Cylinder RE14MCC5 (Champion #) 1.24 to 1.37 mm (0.048 to 0.053 in.) 4.0L 6-Cylinder ZFR5N (NGK #) 1.00 mm (0.040 in.)
Page 407: Auto Shut Down Relay
(1) Remove relay from connector before testing. age. For both the ASD and fuel pump relays, termi- (2) With the relay removed from the vehicle, use nal 30 is connected to battery voltage at all times. an ohmmeter to check the resistance between termi- •...
Page 408: Removal
IGNITION CONTROL 8I - 5 AUTO SHUT DOWN RELAY (Continued) (4) Connect the ohmmeter between terminals 87 (4) Check for pin height (pin height should be the and 30. The ohmmeter should not show continuity at same for all terminals within the PDC connector). this time.
Page 409: Removal - 2.4L
8I - 6 IGNITION CONTROL CAMSHAFT POSITION SENSOR - 2.4L (Continued) When the leading edge of the target wheel cutout enters the tip of the CMP, the interruption of mag- netic field causes the voltage to switch high, result- ing in a sync signal of approximately 5 volts. When the trailing edge of the target wheel cutout leaves the tip of the CMP, the change of the magnetic field causes the sync signal voltage to switch low to 0...
Page 410: Camshaft Position Sensor - 4.0L Description - 4.0L
IGNITION CONTROL 8I - 7 CAMSHAFT POSITION SENSOR - 2.4L (Continued) Fig. 7 UPPER TIMING BELT COVER/BOLTS-2.4L Fig. 9 CMP ADJUSTMENT - 2.4L 1 - UPPER TIMING BELT COVER 1 - FACE OF SENSOR 2 - ELECTRICAL CONNECTOR (ECT) 2 - WIRE GAPPING TOOL 3 - MOUNTING BOLTS (3) Fig.
Page 411: Operation - 4.0L
8I - 8 IGNITION CONTROL CAMSHAFT POSITION SENSOR - 4.0L (Continued) REMOVAL - 4.0L The Camshaft Position Sensor (CMP) on the 4.0L 6–cylinder engine is bolted to the top of the oil pump drive shaft assembly (Fig. 12). The sensor and drive shaft assembly is located on the right side of the engine near the oil filter (Fig.
Page 412 IGNITION CONTROL 8I - 9 CAMSHAFT POSITION SENSOR - 4.0L (Continued) Fig. 13 CMP Location - 4.0L Engine Fig. 15 Align Timing Marks - 4.0L Engine 1 - OIL FILTER 1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK 2 - CAMSHAFT POSITION SENSOR 3 - CLAMP BOLT SENSOR ONLY - 4.0L 4 - HOLD-DOWN CLAMP...
Page 413: Installation - 4.0L
8I - 10 IGNITION CONTROL CAMSHAFT POSITION SENSOR - 4.0L (Continued) INSTALLATION - 4.0L (8) Connect electrical connector to CMP sensor. (9) If removed, install spark plug and ignition coil rail. SENSOR ONLY - 4.0L To verify correct rotational position of oil pump The Camshaft Position Sensor (CMP) on the 4.0L drive, the DRB scan tool must be used.
Page 414: Operation - 4.0L
Disconnect Fig. 17 Coil Location—4.0L Engine connector from coil by pushing slide tab outwards to right side of vehicle (Fig. 20). After slide tab has been 1 - COIL RAIL 2 - COIL MOUNTING BOLTS (4)
Page 415: Installation - 4.0L
8I - 12 IGNITION CONTROL COIL RAIL - 4.0L (Continued) Fig. 18 Ignition Coil Assembly—4.0L 6–Cylinder Engine Fig. 20 Ignition Coil Electrical Connector—4.0L 1 - CYL. #6 6–Cylinder Engine 2 - CYL. #5 3 - CYL. #4 1 - REAR OF VALVE COVER 4 - CYL.
Page 416: Ignition Coil - 2.4L Description - 2.4L
(2) Remove all secondary cables from coil. (3) Remove 4 coil mounting bolts (Fig. 22). The coil assembly consists of 2 different coils (4) Remove coil from vehicle. molded together. The assembly is mounted to the top of the engine (Fig. 21).
Page 417: Diagnosis And Testing - Spark Plug Conditions
8I - 14 IGNITION CONTROL SPARK PLUG (Continued) Remove the spark plugs and examine them for with a rust colored deposit. This rust color can be burned electrodes and fouled, cracked or broken por- misdiagnosed as being caused by coolant in the com- celain insulators.
Page 418 IGNITION CONTROL 8I - 15 SPARK PLUG (Continued) ELECTRODE GAP BRIDGING Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liq- uefy and bridge the gap between electrodes (Fig.
Page 419: Removal
8I - 16 IGNITION CONTROL SPARK PLUG (Continued) REMOVAL 2.4L If spark plug for #2 or #3 cylinder is being removed, throttle body must be removed. Refer to Throttle Body Removal. (1) Remove air cleaner tube and housing. (2) Twist secondary cable at cylinder head to break loose at spark plug.
Page 420: Installation
IGNITION CONTROL 8I - 17 SPARK PLUG (Continued) INSTALLATION SPARK PLUG CABLE Always tighten spark plugs to the specified torque. DESCRIPTION Over tightening can cause distortion. This may result in a change in the spark plug gap, or a cracked por- Spark plug cables are used only on the 2.4L 4–cyl- celain insulator.
Page 421: Removal - 2.4L
8I - 18 IGNITION CONTROL SPARK PLUG CABLE (Continued) words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, exces- sive resistance or loose terminals. Remove the cable at ignition coil, and from spark plug. Connect ohm- meter to each end of cable.
Page 422 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER OPERATION ......29 DESCRIPTION .
Page 423: Instrument Cluster Description
EMIC to the vehicle electrical serve as an electronic body control module. system through two take outs with color-coded con- The EMIC gauges and indicators are visible nectors from the instrument panel wire harness.
Page 424 • Rear Window Defogger Control - The EMIC modules in the vehicle over the PCI data bus. (Refer ELECTRICAL/ELECTRONIC CONTROL provides control and timer functions for the output to...
Page 425 • Seatbelt Indicator available option, the configurable indicators will not • Sentry Key Immobilizer System (SKIS) be functional in a vehicle that does not have the equipment that an indicator supports. The EMIC Indicator (with SKIS only) • Turn Signal (Right and Left) Indicators includes provisions for the following indicators (Fig.
Page 426: Operation
The EMIC is designed to allow the vehicle operator The EMIC also has a self-diagnostic actuator test to monitor the conditions of many of the vehicle com- capability, which will test each of the PCI bus mes- ponents and operating systems. The gauges and indi-...
Page 427 Therefore, the gauges do odometer switch on the EMIC circuit board is used to not accurately indicate any vehicle condition unless control some of the display modes. This switch is the ignition switch is in the On or Start positions.
Page 428 In addition, certain indicators in this instrument electronic dimming level message over the PCI data cluster are automatically configured or self-config- bus to illuminate all VFD units in the vehicle at full ured. This feature allows the configurable indicators (daytime) intensity for easier visibility when driving to be enabled by the EMIC circuitry for compatibility in daylight with the exterior lighting turned on.
Page 429 Upon receiving the proper moved out of the 4 X 4 Low range, or if the vehicle chime inputs, the EMIC activates an integral speed is greater than about 72 kilometers per hour on-board audible tone generator to provide audible (45 miles per hour).
Page 430 EMIC timer this vehicle, the electronic pinion factor needs to be and logic circuitry. If the input and output compo- considered for accurate processing of the vehicle nents and circuits of the interior lighting system test speed and distance information.
Page 431: Diagnosis And Testing - Instrument Cluster
8J - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) • Courtesy Lamp Feed window defogger switch a second time or by turning • Axle Lock Switch Enable 1 (w/Off-Road the ignition switch to the Off position. The timer function of the EMIC will also automat- Package Only) •...
Page 432 (run-start) circuit between the instrument cluster nation of the airbag indicator, the cruise indicator, and the fuse block as required. or the SKIM indicator when the vehicle does not (7) Check for continuity between the ground cir- have this equipment, the instrument cluster must cuit cavity of the instrument panel wire harness con- be replaced with a new unit.
Page 433 (e) The cluster will display the last six digits cluster circuitry, the gauges, the PCI data bus mes- (sequence number) of the Vehicle Identification sage controlled indicators, and the chime tone gener- Number (VIN) in the odometer/trip odometer VFD.
Page 434 AND POSSIBLE PERSONAL INJURY. to the Off position during the test, or if a vehicle NOTE: The following tests may not prove conclu- speed message indicating that the vehicle is moving sive in the diagnosis of this system.
Page 435 PDC as required. electronic vehicle speed and transfer case shift posi- (4) Check for continuity between the axle lock tion messages received by the cluster over the PCI...
Page 436 INSTRUMENT CLUSTER 8J - 15 INSTRUMENT CLUSTER (Continued) (5) Check for continuity between the axle lock dures, details of wire harness routing and retention, switch enable 1 and/or enable 2 circuit cavities of the connector pin-out information and location views for instrument panel wire harness connector (Connector the various wire harness connectors, splices and C1 for enable 1, Connector C2 for enable 2) for the...
Page 437: Removal
8J - 16 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) defogger relay receptacle in the PDC. There should (2) Remove the instrument cluster from the instru- be continuity. If OK, replace the faulty instrument ment panel. Disconnect the instrument panel wire cluster. If not OK, repair the open rear window harness connector (Connector C2) for the instrument defogger relay control circuit between the instrument cluster from the cluster connector receptacle.
Page 438: Disassembly
1 - WIRE HARNESS CONNECTORS 2 - INSTRUMENT CLUSTER 3 - SCREW (4) 4 - INSTRUMENT PANEL DISASSEMBLY Some of the components for the instrument cluster used in this vehicle are serviced individually. The serviced components include: incandescent Fig. 5 Cluster Bulb Locations...
Page 439: Assembly
INSTRUMENT CLUSTER (Continued) (6) Gently pull the cluster housing rear cover away from the back of the cluster housing. ASSEMBLY Some of the components for the instrument cluster used in this vehicle are serviced individually. The serviced components include: incandescent...
Page 440: Installation
(2) Press firmly and evenly on the cluster housing or the SKIM indicator when the vehicle does not rear cover to install it onto the back of the instru- have this equipment, the instrument cluster must ment cluster housing.
Page 441: Abs Indicator Description
8J - 20 INSTRUMENT CLUSTER cator on after the bulb test, it indicates that the CAB ABS INDICATOR has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will DESCRIPTION store a Diagnostic Trouble Code (DTC) for any mal- An Antilock Brake System (ABS) indicator is stan- function it detects.
Page 442: Airbag Indicator Description
The airbag indicator gives an indication to the bus, or the electronic message inputs to the instru- vehicle operator when the airbag system is faulty or ment cluster that control the airbag indicator, a inoperative. The airbag indicator is controlled by a DRBIII scan tool is required.
Page 443: Brake/Park Brake Indicator Description
NOSIS AND TESTING). If the brake indicator stays brake applied or not fully released) the brake indica- on with the ignition switch in the On position and tor is illuminated solid. If a vehicle speed message is the park brake released, or comes on while driving,...
Page 444: Check Gauges Indicator Description
OPERATION wire harness connector (Connector C2) for the instru- The check gauges indicator gives an indication to ment cluster from the connector receptacle on the the vehicle operator when certain instrument cluster back of the cluster housing. Disconnect the headlamp...
Page 445: Cruise Indicator Description
8J - 24 INSTRUMENT CLUSTER CHECK GAUGES INDICATOR (Continued) • System Voltage High Message - Each time gauge readings reflect a condition requiring immedi- ate attention. This indicator is controlled by a tran- the cluster receives a message from the PCM indicat- sistor on the instrument cluster circuit board based ing the electrical system voltage is greater than upon cluster programming and electronic messages...
Page 446: Operation
PCM or The engine coolant temperature gauge gives an until the ignition switch is turned to the Off position, indication to the vehicle operator of the engine cool- whichever occurs first. • Actuator Test - Each time the cluster is put ant temperature.
Page 447: Operation
Off position, whichever occurs first. After twelve sec- by the market for which the vehicle is manufactured. onds, the cluster will move the gauge needle to the This indicator is controlled by a hard wired input to left end of the gauge scale.
Page 448: Operation
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR The front lock indicator gives an indication to the THE SYSTEM CAPACITOR TO DISCHARGE BEFORE vehicle operator of the status of the locker mecha- PERFORMING FURTHER DIAGNOSIS OR SERVICE. nism in the front axle of vehicles equipped with the THIS IS THE ONLY SURE WAY TO DISABLE THE optional off-road package.
Page 449: Operation
An arrowhead pointed request circuit and from the front locker indicator toward the left side of the vehicle is imprinted on the switch (feedback) on the front locker indicator switch cluster overlay next to the “Fuel” icon in the fuel...
Page 450: Operation
The high beam indicator gives an indication to the the gauge scale and the low fuel indicator is illumi- vehicle operator whenever the headlamp high beams nated immediately. This message would indicate that are illuminated, or when the exterior lamps are inad- the fuel tank sender input to the PCM is an open cir- vertently left On.
Page 451: Diagnosis And Testing - High Beam Indicator
8J - 30 INSTRUMENT CLUSTER HIGH BEAM INDICATOR (Continued) illuminated regardless of the ignition switch position. cator bulb and the cluster control circuitry by per- The bulb only illuminates when it is provided a path forming the instrument cluster actuator test. (Refer to ground by the instrument cluster transistor.
Page 452: Low Fuel Indicator Description
The low fuel indicator gives an indication to the of the low fuel indicator or the instrument cluster cir- vehicle operator when the level of fuel in the fuel cuitry that controls the LED, (Refer to 8 - ELECTRI- tank becomes low. This indicator is controlled by a...
Page 453: Operation
MIL or the instrument cluster circuitry that con- The Malfunction Indicator Lamp (MIL) gives an trols the LED, (Refer to 8 - ELECTRICAL/INSTRU- indication to the vehicle operator when the Power- MENT CLUSTER - DIAGNOSIS AND TESTING). If train Control Module (PCM) has recorded a Diagnos-...
Page 454: Operation
The odometer and trip odometer give an indication SIS AND TESTING). For proper diagnosis of the to the vehicle operator of the distance the vehicle has vehicle speed sensor, the PCM, the PCI data bus, or traveled. This indicator is controlled by the instru-...
Page 455: Operation
The oil pressure gauge gives an indication to the left end of the gauge scale. vehicle operator of the engine oil pressure. This • Actuator Test - Each time the cluster is put gauge is controlled by the instrument cluster circuit...
Page 456: Operation
The rear lock indicator gives an indication to the sense circuit are mismatched, the rear lock indicator vehicle operator of the status of the locker mecha- flashes on and off at a slow rate. This condition nism in the rear axle of vehicles equipped with the occurs when the lock request is active but the axle optional off-road package.
Page 457: Operation
SHIFT INDICATOR (TRANSFER OPERATION CASE) The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor DESCRIPTION on the instrument cluster circuit board based upon...
Page 458: Diagnosis And Testing - 4Wd Indicator
Off-Road • Transfer Case Switch Input - Each time the Package. If the vehicle is equipped with the Off-Road cluster detects a ground on the 4WD switch sense Package, for proper diagnosis of the transfer case...
Page 459: Skis Indicator Description
The Sentry Key Immobilizer System (SKIS) indica- switch sense circuit cavities of the instrument panel tor gives an indication to the vehicle operator of the wire harness connector (Connector C2) for the instru- status of the SKIS. This indicator is controlled by the...
Page 460: Speedometer Description
The speedometer gives an indication to the vehicle tion of the test to confirm the functionality of the operator of the vehicle road speed. This gauge is con- LED and the cluster control circuitry. trolled by the instrument cluster circuit board based...
Page 461: Tachometer Description
The turn signal indicators give an indication to the new engine speed message and reposition the gauge vehicle operator that the turn signals (left or right pointer accordingly about every 86 milliseconds. The indicator flashing) or hazard warning (both left and...
Page 462: Upshift Indicator Description
The tronically disabled. The upshift indicator is located indicator will then remain off until the vehicle stops near the upper edge of the instrument cluster, to the accelerating and is brought back into the range of right of center.
Page 463: Voltage Gauge Description
8J - 42 INSTRUMENT CLUSTER UPSHIFT INDICATOR (Continued) • System Voltage Low (Charge Fail) Message cator, a DRBIII scan tool is required. Refer to the appropriate diagnostic information. - Each time the cluster receives a message from the PCM indicating the electrical system voltage is less than about 9.0 volts (charge fail condition), the gauge VOLTAGE GAUGE needle is moved to the 9 volt graduation on the far...
Page 464 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....35 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 465: Lamps/Lighting - Exterior
8L - 2 LAMPS/LIGHTING - EXTERIOR FRONT PARK/TURN SIGNAL LAMP REMOVAL ......29 REMOVAL .
Page 466: Description - Headlamp Leveling System
The left multi-function switch control stalk actuates the turn signal switch in the steering column. The turn signal system in this vehicle includes a turn signal-on warning chime feature. The EMIC electronic circuitry monitors the turn signal indica-...
Page 467: Warning
If this is a WARNING problem on the vehicle being diagnosed (Refer to 8 - ELECTRICAL/CHARGING DIAGNOSIS WARNING:: EYE PROTECTION SHOULD BE USED TESTING).
Page 468: Diagnosis And Testing - Headlamp System
LAMPS/LIGHTING - EXTERIOR 8L - 5 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION ONE TURN SIGNAL LAMP 1. Faulty or missing bulb 1. Test and replace turn signal DOES NOT ILLUMINATE bulb as required. 2. Faulty ground circuit. 2. Test and repair open ground circuit 3.
Page 469 8L - 6 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS 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. Loose or worn generator drive 2.
Page 470: Adjustments
10 meters (32.8 ft.), away from front of headlamp proper headlamp alignment. lens (Fig. 2). Fig. 2 Headlamp Alignment Screen -Typical 1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS 4 - FRONT OF HEADLAMP 2 - FLOOR TO CENTER OF HEADLAMP LENS 5 - VEHICLE CENTERLINE...
Page 471: Specifications Exterior Lamps
(3) Measure from the floor up 1.27 meters (5 ft.) and tape a vertical line on the wall at the centerline of the vehicle. Sight along the centerline of the vehi- cle (from rear of vehicle forward) to verify accuracy of the line placement.
Page 472: Special Tools
LAMPS/LIGHTING - EXTERIOR 8L - 9 LAMPS/LIGHTING - EXTERIOR (Continued) SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C-4466–A BRAKE LAMP SWITCH Fig. 4 Brake Lamp Switch Terminal Identification DESCRIPTION 1 - TERMINAL PINS The brake lamp switch consists of multiple switch 2 - PLUNGER TEST POSITIONS contacts either normally open or closed.
Page 473: Removal
BRAKE LAMP SWITCH (Continued) (5) Carefully pull wire harness terminal ends from contact buttons (Fig. 6). (6) Route wire harness through tailgate and sepa- rate CHMSL mounting bracket from vehicle. Fig. 5 Brake Lamp Switch 1 - RETAINER 2 - TERMINALS...
Page 474: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 11 CENTER HIGH MOUNTED STOP LAMP BULB (Continued) The combination flasher is located to the back of the left multi-function switch housing on the top of the steering column, where it is concealed beneath the upper steering column shroud (Fig. 8). The com- bination flasher is a smart relay that functions as both the turn signal system and the hazard warning system flasher.
Page 475: Removal
8L - 12 LAMPS/LIGHTING - EXTERIOR COMBINATION FLASHER (Continued) REMOVAL (4) Move the tilt steering column to the fully low- ered position and leave the tilt release lever in the released position. WARNING: ON VEHICLES EQUIPPED WITH AIR- (5) Remove the upper shroud from the steering col- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE umn.
Page 476: Daytime Running Lamp Module Description
BAG DEPLOYMENT AND POSSIBLE PERSONAL beam indicator driver. The DRL module is grounded INJURY. to the chassis. Once the vehicle reaches a speed of 3 CONDITION POSSIBLE CAUSES CORRECTION DAYTIME RUNNING LAMPS (DRL) 1.
Page 477: Removal
(2) Disconnect the wire harness connector from the module. (3) Remove the screws that attach the module to the cowl (Fig. 11). (4) Separate the module from the vehicle. INSTALLATION (1) Position the DRL module on the cowl. (2) Install the screws.
Page 478: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 15 FOG LAMP UNIT (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMP BULBS BURN 1. Charging system output too 1. Test and repair charging system. (Refer to OUT FREQUENTLY high. 8 - ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING) 2.
Page 479: Adjustments
4 - PIVOT NUT 5 - ADJUSTER Fig. 12 Fog Lamp Alignment - Typical (6) Remove the bulb/element from the reflector 1 - VEHICLE CENTERLINE (Fig. 14). 2 - CENTER OF FOG LAMP LENS 3 - HIGH - INTENSITY AREA 4 - FLOOR TO CENTER OF FOG LAMP LENS 5 - 100mm (4 in.)
Page 480: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 17 FOG LAMP (Continued) INSTALLATION rear fog lamp switch contacts within the multifunc- tion switch. Pulling the headlamp switch knob out- ward and then rotating the knob one detent CAUTION: Do not touch the bulb glass with fingers counterclockwise will activate the rear fog lamp and or other oily surfaces.
Page 481: Removal
8L - 18 LAMPS/LIGHTING - EXTERIOR REAR FOG LAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION REAR FOG LAMP 1. Poor lighting circuit ground. 1. Test for voltage drop across ground FLASHES RANDOMLY locations. 2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit. 3.
Page 482: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 19 REAR FOG LAMP (Continued) multifunction switch. Rotating the left lighting con- trol stalk to the headlamp on position then pulling outward on the stalk rotating the headlamp switch knob one detent counterclockwise will close the rear fog lamp contacts and illuminate the rear fog lamp.
Page 483: Front Park/Turn Signal Lamp Unit Description
8L - 20 LAMPS/LIGHTING - EXTERIOR FRONT PARK/TURN SIGNAL HEADLAMP UNIT LAMP UNIT DESCRIPTION The headlamps are sealed beam units. Each unit DESCRIPTION contains a high and low beam function. The front turn signal/parking lamp is a separate module. Each module contains a housing, a lens OPERATION assembly, and bulb.
Page 484: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 21 HEADLAMP UNIT (Continued) OPERATION With the rotation of the headlamp leveling switch control knob, voltage is adjusted at the headlamp lev- eling switch (rheostat). This signals the headlamp leveling motors (headlamp module mounted) to adjust the vertical headlamp beam pattern accord- ingly.
Page 485: Installation
8L - 22 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING SWITCH (Continued) REMOVAL HEADLAMP LEVELING 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. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 486 LAMPS/LIGHTING - EXTERIOR 8L - 23 HEADLAMP LEVELING MOTOR (Continued) NOTE: Headlamps must be operating properly and battery charger on the vehicles electrical system the battery must be completely charged (12.4v) when performing this test. Refer to the Battery sec- prior to testing.
Page 487: Installation
8L - 24 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING MOTOR (Continued) REMOVAL (1) Disconnect the negative battery cable. (2) Disconnect the headlamp and headlamp level- ing motor electrical connectors. (3) Remove the headlamp housing attaching nuts (Fig. 24). Fig. 25 HEADLAMP LEVELING MOTOR 1 - Headlamp Leveling Motor 2 - Headlamp Housing FRONT POSITION LAMP...
Page 488: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 25 FRONT POSITION LAMP (Continued) NOTE: The parking lamps must be on and opera- system when performing this test. Refer to the Bat- tional. The battery must be completely charged tery section of the service manual for detailed infor- (12v) prior to testing.
Page 489: Left Multi-Function Switch Description
A Power Distribution Center (PDC), a fused B(+) circuit second connector on the back of the switch housing and, when the ignition switch is in the Accessory or accepts the combination flasher.
Page 490 LAMPS/LIGHTING - EXTERIOR 8L - 27 LEFT MULTI-FUNCTION SWITCH (Continued) • Rear Fog Lamp(s) - The headlamp switch knob nal circuit then, based upon that input, provides a must be rolled to the headlamp on position. Pulling ground path to activate all interior courtesy lamps the headlamp switch knob outward and then rolling through a courtesy lamp feed circuit output.
Page 491: Diagnosis And Testing - Left Multi- Function Switch
8L - 28 LAMPS/LIGHTING - EXTERIOR LEFT MULTI-FUNCTION SWITCH (Continued) only momentary signaling is desired, the switch is (Fig. 28) and (Fig. 29) for connector terminal and actuated to a left or right intermediate detent posi- cavity identification. tion. In this position the signal lamps flash as described above, but the switch returns to the Off position as soon as the lever is released.
Page 492: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 29 LEFT MULTI-FUNCTION SWITCH (Continued) LEFT (LIGHTING) MULTI-FUNCTION SWITCH TEST TURN SIGNAL AND HAZARD WARNING SWITCH TESTS Headlamp Low Beams On B16 & B18, B16 & B19 Headlamp High Beams On B17 & B18, B17 & B19 Fog Lamps On B13 &...
Page 493: Installation
8L - 30 LAMPS/LIGHTING - EXTERIOR LEFT MULTI-FUNCTION SWITCH (Continued) (4) If the vehicle is equipped with the optional tilt INSTALLATION steering column, move the tilt steering column to the fully lowered position and leave the tilt release lever WARNING: ON VEHICLES EQUIPPED WITH AIR- in the released (down) position.
Page 494: Side Marker Lamp Unit Removal
ING COVER - INSTALLATION). lamps. One side repeater lamp can be found on each (13) Reconnect the battery negative cable. side of the vehicle just above the front wheel. On domestic vehicles, the side repeater lamp is know as SIDE MARKER LAMP UNIT the side marker lamp, they just operate differently.
Page 495: Removal- Side Repeater Lamp Unit
(1) Disconnect and isolate the battery negative cable. (1) Refer to Side Marker Lamp Bulb Removal (2) From the underside of the vehicle, remove the (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - push-in fastener attaching the bottom rear edge of EXTERIOR/MARKER LAMP - REMOVAL).
Page 496: Tail Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 33 TAIL LAMP UNIT (Continued) INSTALLATION (1) Install a replacement bulb in the lamp socket by pushing inward and rotating the bulb clockwise. (2) Position the lens on the lamp housing. (3) Install and tighten the screws. (4) Connect the battery negative cable.
Page 497: Installation
LAMPS/LIGHTING - EXTERIOR UNDERHOOD LAMP UNIT (Continued) (5) Remove screw attaching underhood lamp to the inner hood panel. (6) Separate underhood lamp from vehicle. INSTALLATION (1) Install bulb. (2) Install lamp lens. (3) Position the underhood lamp flange on the hood inner panel.
Page 498 Authorized Service Center (ASC) after NOTE: The dome lamp lens has a larger lens posi- the component is removed from the vehicle. tioning tab than the lens retaining tabs. The following Bulb Application Table lists the lamp (3) Separate lens from lamp (Fig.
Page 499: Removal
8L - 36 LAMPS/LIGHTING - INTERIOR DOME LAMP (Continued) (4) Position lamp lens on lamp housing and press into place. (5) Connect the battery negative cable. DOME LAMP BULB REMOVAL (1) Disconnect the battery negative cable. (2) Insert a small flat blade between the lamp housing and lamp lens.
Page 500: Diagnosis And Testing - Door Ajar Switch
LAMPS/LIGHTING - INTERIOR 8L - 37 DOOR AJAR SWITCH (Continued) DIAGNOSIS AND TESTING - DOOR AJAR REMOVAL SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE WARNING: ON VEHICLES EQUIPPED WITH AIR- ATTEMPTING ANY STEERING WHEEL, STEERING BAGS, DISABLE THE AIRBAG SYSTEM BEFORE COLUMN, OR INSTRUMENT PANEL COMPONENT ATTEMPTING ANY STEERING WHEEL, STEERING...
Page 501: Installation
8L - 38 LAMPS/LIGHTING - INTERIOR DOOR AJAR SWITCH (Continued) (4) Using hand pressure, press the door ajar switch housing into the mounting hole in the door hinge pillar until the snap features of the switch are fully engage in the mounting hole. (5) Slowly close the door and allow the door ajar switch plunger self-adjuster mechanism to ratchet to the proper position.
Page 502 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page AUTOMATIC DAY / NIGHT MIRROR STANDARD PROCEDURE DESCRIPTION ......1 STANDARD PROCEDURE - COMPASS OPERATION .
Page 503 CAL will be displayed. After completing one 360° Disconnect and isolate the battery negative cable. turn with the vehicle traveling less than 8 km/h (5 Check for continuity between the ground circuit cav- mph) in an area free from large metal or metallic...
Page 504 POWER SYSTEMS 8N - 3 AUTOMATIC DAY / NIGHT MIRROR (Continued) Fig. 1 Variance Settings To set the variance: Turn the ignition to the ON position. Press and hold the center button for 3 to 6 seconds. The last variance zone number will be dis- played.
Page 506 Active restraints are those which mounted turning loops, a fixed lower seat belt anchor require the vehicle occupants to take some action to secured with the retractor to the lower end of the employ, such as fastening a seat belt; while passive...
Page 507 8O - 2 RESTRAINTS RESTRAINTS (Continued) Fig. 1 Supplemental Restraint System 1 - AIRBAG CONTROL MODULE 3 - PASSENGER AIRBAG 2 - PASSENGER AIRBAG ON/OFF SWITCH (W/O REAR SEAT 4 - DRIVER AIRBAG ONLY) track. The front seat belt buckle for the driver side of fixed end-release seat belt buckle secured to the rear all models includes an integral seat belt switch that floor panel.
Page 508: Operation
PASSIVE RESTRAINTS glove box on the passenger side of the vehicle. • Passenger Airbag On/Off Switch - Models The passive restraints available for this model...
Page 509 See milliseconds. Within one to two seconds from the the owner’s manual in the vehicle glove box for more moment of impact, the airbags are almost entirely information on the features, use and operation of all deflated.
Page 510: Diagnosis And Testing - Supplemental Restraint System
RESTRAINTS 8O - 5 RESTRAINTS (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- WARNING: WHEN A STEERING COLUMN HAS AN BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT AIRBAG UNIT ATTACHED, NEVER PLACE THE COL- SYSTEM BEFORE ATTEMPTING ANY STEERING UMN ON THE FLOOR OR ANY OTHER SURFACE WHEEL, STEERING COLUMN, DRIVER AIRBAG, WITH THE STEERING WHEEL OR AIRBAG UNIT PASSENGER AIRBAG, OR INSTRUMENT PANEL...
Page 511: Standard Procedure - Service After Asupplemental Restraint Deployment
SUPPLEMENTAL RESTRAINT DEPLOYMENT Fig. 3 Wear Safety Glasses and Rubber Gloves - Typical Any vehicle which is to be returned to use follow- ing a supplemental restraint deployment, must have WARNING: IF YOU EXPERIENCE SKIN IRRITATION the deployed restraints replaced. In addition, if the...
Page 512: Standard Procedure - Verification Test
Refer to the appropriate service removal procedures. (4) You may need to vacuum the interior of the vehicle a second time to recover all of the powder. STANDARD PROCEDURE - VERIFICATION TEST The following procedure should be performed using...
Page 513: Airbag Control Module Description
On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRBIII scan tool using the Programma- ble Communications Interface (PCI) data bus net- work. This method of communication is used for...
Page 514: Removal
AND POSSIBLE PERSONAL INJURY. electronic impact sensor, and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which pro- WARNING: THE AIRBAG CONTROL MODULE CON- vides verification of the direction and severity of an TAINS THE IMPACT SENSOR, WHICH ENABLES impact.
Page 515: Installation
8O - 10 RESTRAINTS AIRBAG CONTROL MODULE (Continued) (4) Remove the four screws that secure the Airbag Control Module (ACM) to the mounting bracket on the floor panel transmission tunnel (Fig. 7). Fig. 7 Airbag Control Module Remove/Install 1 - SCREW (4) 2 - AIRBAG CONTROL MODULE 3 - WIRE HARNESS CONNECTOR 4 - MOUNTING BRACKET...
Page 516: Child Restraint Anchor Description
ACM label will be dard equipment seat belt provided for that seating pointed forward in the vehicle. Fig. 9 Child Restraint Anchor Locations 1 - LOWER ANCHOR (MODELS WITHOUT A REAR SEAT ONLY)
Page 517 8O - 12 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) position. All vehicles without a rear seat are equipped with a fixed-position child restraint upper tether anchor (Fig. 10) and two child restraint lower anchors (Fig. 11) for the front passenger seating posi- tion.
Page 518: Operation
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. OPERATION See the owner’s manual in the vehicle glove box for more information on the proper use of all of the fac- tory-installed child restraint anchors. Fig. 14 Rear Upper Tether Anchor Remove/Install...
Page 519: Clockspring Description
8O - 14 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) WARNING: DURING AND FOLLOWING ANY SEAT The clockspring assembly is secured with two inte- BELT OR CHILD RESTRAINT ANCHOR SERVICE, gral plastic latches onto the steering column lock housing near the top of the steering column behind CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER the steering wheel (Fig.
Page 520: Operation
The clock- clockspring tape. spring case is positioned and secured to the upper...
Page 521: Removal
(Fig. 18). reinstalled on the steering column. (7) If the vehicle is equipped with the optional tilt (6) The front wheels should still be in the straight- steering column, move the tilt steering column to the ahead position.
Page 522: Installation
RESTRAINTS 8O - 17 CLOCKSPRING (Continued) (12) Remove the clockspring from the steering col- umn upper housing. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. (13) If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clock- spring case to maintain clockspring centering until it is reinstalled on the steering column.
Page 523: Driver Airbag Description
2 N·m (18 in. lbs.). cushion, the airbag cushion retainer, the airbag hous- (6) If the vehicle is equipped with the optional tilt ing, the airbag inflator, and the retainers that secure steering column, move the tilt steering column to the the inflator to the airbag housing.
Page 524: Operation
(Refer to harness of the clockspring. The driver airbag cannot 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-...
Page 525: Disassembly
8O - 20 RESTRAINTS DRIVER AIRBAG (Continued) WARNING: WHEN REMOVING A DEPLOYED AIR- pigtail wire connector insulator and pull the insula- BAG, RUBBER GLOVES, EYE PROTECTION, AND A tor straight out from the airbag inflator to disconnect it from the connector receptacle. LONG-SLEEVED SHIRT SHOULD BE WORN.
Page 526: Assembly
RESTRAINTS 8O - 21 DRIVER AIRBAG (Continued) WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COL- ORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT.
Page 527 8O - 22 RESTRAINTS DRIVER AIRBAG (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- (1) Place the new driver airbag trim cover on a BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT suitable work surface with the airbag receptacle fac- ing up. Be certain to take the proper precautions to SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, prevent the trim cover from receiving cosmetic dam-...
Page 528 (1) Position the driver airbag close enough to the service after a supplemental restraint deployment steering wheel to reconnect the two electrical connec- before removing the airbag from the vehicle. (Refer to tions at the back of the airbag housing. 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-...
Page 529: Installation
8O - 24 RESTRAINTS (3) Remove the screw that secures the shoulder FRONT SEAT BELT & belt turning loop to the adjuster. RETRACTOR (4) Remove the shoulder belt turning loop and the support/guide washer from the adjuster. REMOVAL (5) Remove the screw that secures the retractor and lower seat belt anchor to the lower sport bar WARNING: DURING AND FOLLOWING ANY SEAT (Fig.
Page 530: Front Seat Belt Buckle Removal
RESTRAINTS 8O - 25 FRONT SEAT BELT & RETRACTOR (Continued) (1) Position the front seat belt and retractor and the lower seat belt anchor to the lower sport bar (Fig. 28). Be certain to engage the locator tab on the retractor in the locator hole on the sport bar.
Page 531: Installation
The inflator initiator is connected to molded, thermoplastic passenger airbag door is the the vehicle electrical system through a yellow connec- most visible part of the passenger airbag (Fig. 31). tor on the end of a short, two-wire pigtail harness The passenger airbag door is located above the glove and a take out of the body wire harness.
Page 532: Operation
(2) Remove the instrument panel from the passen- inert gas canister. ger compartment of the vehicle. (Refer to 23 - BODY/ The inflator is sealed to the airbag cushion so that INSTRUMENT PANEL - REMOVAL).
Page 533: Passenger Airbag Door Removal
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- (3) Reinstall the instrument panel into the passen- CEDURE - SERVICE AFTER A SUPPLEMENTAL ger compartment of the vehicle. (Refer to 23 - BODY/ RESTRAINT DEPLOYMENT). INSTRUMENT PANEL - INSTALLATION). When installing the instrument panel, be certain the pas-...
Page 534: Installation
RESTRAINTS 8O - 29 PASSENGER AIRBAG DOOR (Continued) RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PAS- SENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR.
Page 535: Passenger Airbag On/Off Switch Description
A molded plastic connector receptacle on the back of the switch hous- ing connects the switch to the vehicle electrical sys- tem through a dedicated take out of the body wire harness. The molded plastic harness connector insu- lator is keyed and latched to ensure proper and secure switch electrical connections.
Page 536: Removal
RESTRAINTS 8O - 31 PASSENGER AIRBAG ON/OFF SWITCH (Continued) not applied. To actuate the passenger airbag on/off (2) Remove the passenger airbag on/off switch and switch, insert the ignition key into the switch key accessory switch bezel from the instrument panel as actuator far enough to fully depress the plunger, then a unit.
Page 537: Rear Seat Belt & Retractor Removal
8O - 32 RESTRAINTS PASSENGER AIRBAG ON/OFF SWITCH (Continued) (3) Reinstall the passenger airbag on/off switch and accessory switch bezel unit to the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ ACCESSORY SWITCH BEZEL - INSTALLATION). (4) Do not reconnect the battery negative cable at this time.
Page 538: Installation
RESTRAINTS 8O - 33 REAR SEAT BELT & RETRACTOR (Continued) (8) Remove the screw that secures the rear seat (8) Tumble the folded rear seat cushion and back belt retractor to the lower sport bar near the top of unit rearward onto the rear floor panel. the inner rear wheel house panel.
Page 539: Installation
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR switch. Only one seat belt switch is installed in the DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT vehicle, and it is integral to the buckle of the driver BELT CHILD RESTRAINT COMPONENT.
Page 540: Diagnosis And Testing - Seat Belt Switch
RESTRAINTS 8O - 35 SEAT BELT SWITCH (Continued) ground; and, when the driver side front seat belt tip- (2) Check for continuity between the ground cir- half is removed from the seat belt buckle, the switch cuit cavity in the body wire harness connector for the closes the ground path.
Page 541: Installation
8O - 36 RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER (Continued) (1) Unsnap and lift the trim cover from the front MOUNTING HARDWARE, RETRACTORS, TETHER seat belt turning loop to access the screw that STRAPS, AND ANCHORS FOR PROPER INSTALLA- secures the turning loop to the height adjuster on the TION, OPERATION, OR DAMAGE.
Page 542 RES/ACCEL switch (when speed is When speed control is selected by depressing the greater than 30 mph) restores the vehicle to the tar- ON switch, the PCM allows a set speed to be stored get speed that was stored in the PCM.
Page 543: Speed Control
When the speed con- tions at the servo. Corrosion should be removed from trol is set with the vehicle operators foot off of the electrical terminals and a light coating of Mopar accelerator pedal, the speed control thinks there is MultiPurpose Grease, or equivalent, applied.
Page 544: Cable Description
6 - BELLCRANK it will be broken. To remove throttle cable from throttle body bracket, slide cable towards front of vehicle. (4) After removing throttle control cable at throttle body, slide servo cable from throttle body. (5) If necessary, disconnect opposite end of servo cable at servo.
Page 545: Operation
When (4) Clip cable to cable guide at valve cover. the brake is released, if vehicle speed exceeds 30 (5) Connect negative battery cable to battery. mph to resume, 35 mph to set, and the RES/ACCEL...
Page 546: Description
ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph.
Page 547: Removal
SPEED CONTROL SWITCH (Continued) released. The PCM also has a tap-up feature in which vehicle speed increases at a rate of approxi- mately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate with- out disengaging speed control.
Page 548: Diagnosis And Testing - Vacuum Reservoir
8P - 7 VACUUM RESERVOIR (Continued) DIAGNOSIS AND TESTING - VACUUM REMOVAL RESERVOIR The vacuum reservoir is located under the vehicle battery tray (Fig. 6). (1) Disconnect vacuum hose at speed control servo and install a vacuum gauge into the disconnected hose.
Page 550 VEHICLE THEFT SECURITY are routed throughout the vehicle and retained by many different methods. These circuits may be con- nected to each other, to the vehicle electrical system DESCRIPTION and to the SKIS components through the use of a The Sentry Key Immobilizer System (SKIS) is combination of soldered splices, splice block connec- available as a factory-installed option on this model.
Page 551 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) SKIM in the vehicle in order for the system to recognize DIAGNOSIS AND TESTING - SENTRY KEY them as valid keys. This can be done by the dealer IMMOBILIZER SYSTEM...
Page 552 SKIM when you first go to Step 4. If not OK, repair the shorted circuit or begin your diagnosis of the vehicle. It is important to component as required and replace the faulty fuse.
Page 553 Keys. If two valid Sentry Keys are not available, cle were being started with an invalid key. In other or if the vehicle does not have a U.S. country code words, the engine will stall after about two seconds designator, the Secured Access Method must be used of operation.
Page 554 NOTE: Once a Sentry Key has been programmed as tated by the SKIM message. For more information on a valid key to a vehicle, it cannot be programmed the SKIS and the SKIS indicator control parameters, (Refer to 8 - ELECTRICAL/VEHICLE THEFT SECU- as a valid key for use on any other vehicle.
Page 555 Therefore, once a Sentry Key has been programmed to a particular vehicle, it When the ignition switch is turned to the On posi- cannot be used on any other vehicle. (Refer to 8 - tion, the Sentry Key Immobilizer Module (SKIM) ELECTRICAL/VEHICLE...
Page 556 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page FRONT WIPERS/WASHERS ....1 REAR WIPERS/WASHERS ....24 FRONT WIPERS/WASHERS TABLE OF CONTENTS page...
Page 557: Front Wipers/Washers
8R - 2 FRONT WIPERS/WASHERS FRONT WIPERS/WASHERS (Continued) Fig. 1 Front Wiper & Washer System 1 - WASHER RESERVOIR, PUMP/MOTOR 4 - FRONT WIPER ARM & BLADE (2) 2 - FRONT WASHER NOZZLE 5 - RIGHT MULTI-FUNCTION SWITCH 3 - FRONT WIPER MODULE •...
Page 558: Operation
These hard wired circuits are integral to for as long as the washer system is activated, then several wire harnesses, which are routed throughout provide one or two additional wipe cycles after the the vehicle and retained by many different methods.
Page 559 8R - 4 FRONT WIPERS/WASHERS FRONT WIPERS/WASHERS (Continued) tain clear visibility for the vehicle operator by remov- Delay mode, the faulty right multi-function switch ing excess accumulations of rain, snow, bugs, mud, or must be replaced. Refer to the appropriate diagnostic other minor debris from the outside windshield glass information.
Page 560: Diagnosis And Testing - Front Wiper & Washer System
FRONT WIPERS/WASHERS 8R - 5 FRONT WIPERS/WASHERS (Continued) val. The logic circuit then energizes the wiper motor DIAGNOSIS AND TESTING - FRONT WIPER & relay by pulling the relay control coil to ground. The WASHER SYSTEM energized wiper motor relay directs battery current from the normally open relay terminal through the WIPER SYSTEM common feed relay terminal and the Delay mode...
Page 561 8R - 6 FRONT WIPERS/WASHERS FRONT WIPERS/WASHERS (Continued) (4) Reconnect the battery negative cable. Turn the WASHER SYSTEM ignition switch to the On position. Check for battery The diagnosis found here addresses an electrically voltage at the fused ignition switch output (run-acc) inoperative front washer system.
Page 562: Cleaning - Front Wiper & Washer System
FRONT WIPERS/WASHERS 8R - 7 FRONT WIPERS/WASHERS (Continued) harness connector for the front washer pump/motor. abrasive cleaner. Flush foreign material from the If OK, replace the faulty front washer pump/motor. If washer system plumbing by first disconnecting the not OK, go to Step 4. washer hoses from the front washer nozzle, then run- (4) Turn the ignition switch to the Off position.
Page 563: Front Check Valve Description
8R - 8 FRONT WIPERS/WASHERS FRONT WIPERS/WASHERS (Continued) (3) Once proper hinge action of the wiper arm is WASHER SYSTEM confirmed, check the hinge for proper spring tension. washer system components should Remove the wiper blade from the wiper arm. Either inspected periodically, not just when washer perfor- place a small postal scale between the blade end of mance problems are experienced.
Page 564: Operation
FRONT WIPERS/WASHERS 8R - 9 FRONT CHECK VALVE (Continued) barbed hose nipple is formed on each side of the raised center section of the valve body. Within the check valve body, a small diaphragm is held against the lip of an integral sump well by a small plastic piston and a coiled spring.
Page 565: Installation
8R - 10 FRONT WIPERS/WASHERS FRONT CHECK VALVE (Continued) INSTALLATION (1) Position the front check valve in the engine compartment. (2) With the directional arrow on the check valve pointed in the direction of the system flow, reconnect the washer supply hose from the reservoir to the barbed inlet nipple of the front check valve (Fig.
Page 566: Operation
FRONT WIPERS/WASHERS 8R - 11 FRONT WASHER NOZZLE (Continued) Fig. 8 Front Washer Nozzle 1 - HOOD 2 - LATCH 3 - ORIFICE (FLUIDIC INSERT) 4 - NIPPLE barbed inlet nipple which are concealed below the Fig. 9 Front Washer Nozzle Remove/Install hood panel.
Page 567: Front Washer Pump Motor Description
The front washer pump/motor unit features a small Direct Current (DC) electric motor. The motor is con- nected to the vehicle electrical system through a sin- gle take out and two-cavity connector of the headlamp and dash wire harness. The motor is...
Page 568: Installation
FRONT WIPERS/WASHERS 8R - 13 FRONT WASHER PUMP MOTOR (Continued) Fig. 11 Washer Pump/Motor Remove/Install Fig. 12 Wiper Arm 1 - REAR BODY WIRE HARNESS 1 - LATCH 2 - WASHER RESERVOIR 2 - WIPER ARM PIVOT END 3 - REAR WASHER PUMP/MOTOR 4 - HEADLAMP &...
Page 569: Removal
8R - 14 FRONT WIPERS/WASHERS FRONT WIPER ARM (Continued) removal and installation. The spring-loaded wiper (1) The front wiper arms must be indexed to the arm hinge controls the down-force applied through wiper pivots with the wiper motor in the park posi- the tip of the wiper arm to the wiper blade on the tion to be properly installed (Fig.
Page 570: Front Wiper Blade
FRONT WIPERS/WASHERS 8R - 15 FRONT WIPER BLADE (Continued) Each front wiper blade is secured by an integral (2) To remove the wiper blade from the wiper arm, latching pivot block to the hook formation on the tip depress the pivot block latch release tab under the of each front wiper arm, and rests on the glass near tip of the arm and slide the blade away from the tip the base of the windshield when the wipers are not...
Page 571: Front Wiper Module Description
The wiper motor is connected to the are the only visible components of the front wiper vehicle electrical system through a dedicated take module. The front wiper module consists of the fol- out and wire harness connector of the body wire har- lowing major components: ness.
Page 572: Removal
FRONT WIPERS/WASHERS 8R - 17 FRONT WIPER MODULE (Continued) two wiper pivots mechanically convert the rotary out- (1) Remove the front wiper module from the cowl put of the wiper motor to the back and forth wiping plenum. (Refer to 8 - ELECTRICAL/FRONT WIP- motion of the wiper arms and blades on the glass.
Page 573: Right Multi-Function Switch Description
FRONT WIPERS/WASHERS FRONT WIPER MODULE (Continued) (7) Reinstall the front wiper arms onto the wiper housing and connects the switch to the vehicle elec- pivots. (Refer to 8 - ELECTRICAL/FRONT WIPERS/ trical system through a dedicated take out and con- WASHERS/FRONT WIPER ARM - INSTALLATION).
Page 574: Operation
WHEEL, STEERING COLUMN, DRIVER AIRBAG, operated to control the functions and features they PASSENGER AIRBAG, OR INSTRUMENT PANEL provide. Refer to the owner’s manual in the vehicle COMPONENT DIAGNOSIS OR SERVICE. DISCON- glove box for more information on the features, use NECT AND ISOLATE THE BATTERY NEGATIVE and operation of the right multi-function switch.
Page 575: Removal
7 - SCREW (2) REMOVAL (4) If the vehicle is equipped with the optional tilt steering column, move the tilt steering column to the WARNING: ON VEHICLES EQUIPPED WITH AIR- fully lowered position and leave the tilt release lever BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT in the released (down) position.
Page 576: Installation
2 N·m (18 in. lbs.). enough to engage the alignment pins on the top (1 (10) If the vehicle is equipped with the optional tilt pin) and bottom (2 pins) of the right switch housing steering column, move the tilt steering column to the...
Page 577: Washer Reservoir Description
On models not equipped with the optional rear compartment (Fig. 25). washer system, the rear washer pump/motor mount- (2) If the vehicle is so equipped, reconnect the rear ing hole in the washer reservoir is sealed with a body wire harness connector for the rear washer plastic plug.
Page 578 FRONT WIPERS/WASHERS 8R - 23 WASHER RESERVOIR (Continued) (3) Reconnect the headlamp and dash wire harness connector for the front washer pump/motor to the connector receptacle on the motor. (4) Reconnect the washer supply hose(s) to the barbed outlet nipple(s) of the washer pump/motor unit(s).
Page 579 The plumbing is routed along washer system is optional factory-installed equip- the left side of the vehicle with the body wire har- ment on this model when it is also equipped with the ness from the washer reservoir in the engine com- optional hardtop roof (Fig.
Page 580 REAR WIPERS/WASHERS 8R - 25 REAR WIPERS/WASHERS (Continued) Fig. 1 Rear Wiper & Washer System 1 - WIPER ARM & BLADE 4 - REAR WIPER/WASHER SWITCH 2 - WIPER MOTOR 5 - REAR WASHER PUMP/MOTOR 3 - WASHER NOZZLE 6 - REAR WASHER HOSE CAP/CHECK VALVE •...
Page 581: Rear Wipers/Washers
These hard wired circuits are integral to accumulations of rain, snow, bugs, mud, or other several wire harnesses, which are routed throughout minor debris that might be encountered while driv- the vehicle and retained by many different methods.
Page 582: Diagnosis And Testing - Rear Wiper
REAR WIPERS/WASHERS 8R - 27 REAR WIPERS/WASHERS (Continued) CONTINUOUS WIPE MODE information. The wiring information includes wiring diagrams, proper wire and connector repair proce- When the Wipe position of the rear wiper and dures, details of wire harness routing and retention, washer switch rocker is selected, the Wipe mode cir- connector pin-out information and location views for cuitry within the switch directs battery current...
Page 583 8R - 28 REAR WIPERS/WASHERS REAR WIPERS/WASHERS (Continued) (5) Test the rear wiper and washer switch continu- WARNING: ON VEHICLES EQUIPPED WITH AIR- ity. (Refer to 8 - ELECTRICAL/REAR WIPERS/ BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT WASHERS/REAR WIPER/WASHER SWITCH SYSTEM BEFORE ATTEMPTING ANY STEERING DIAGNOSIS AND TESTING).
Page 584: Cleaning - Rear Wiper & Washer System
REAR WIPERS/WASHERS 8R - 29 REAR WIPERS/WASHERS (Continued) (5) Test the rear wiper and washer switch continu- CAUTION: Never use compressed air to flush the ity. (Refer to 8 - ELECTRICAL/REAR WIPERS/ washer system plumbing. Compressed air pres- WASHERS/REAR WIPER/WASHER SWITCH sures are too great for the washer system plumbing DIAGNOSIS AND TESTING).
Page 585: Rear Check Valve Description
6 - DAMAGED SUPPORT COMPONENTS hose in the hardtop wire harness, near the belt line WASHER SYSTEM in the left rear corner of the vehicle. The check valve consists of a molded plastic valve body with a raised washer system...
Page 586: Removal
(3) Remove the rear check valve from the left rear The rear washer plumbing consists of small diam- corner of the vehicle near the belt line. eter rubber hose that is integral to and routed with the body wire harness from the barbed outlet nipple...
Page 587: Operation
8R - 32 REAR WIPERS/WASHERS REAR WASHER HOSES/TUBES (Continued) The body wire harness and washer hose are routed OPERATION from the left cowl side inner panel, along the left Washer fluid in the washer reservoir is pressurized door opening sill, then up the B-pillar and along the and fed by the rear washer pump/motor through the upper inner edge of the left rear fender panel to the rear washer system plumbing and fittings to the rear...
Page 588: Operation
REAR WIPERS/WASHERS 8R - 33 REAR WASHER NOZZLE (Continued) OPERATION INSTALLATION The rear washer nozzle is designed to dispense (1) Position the rear washer nozzle and rubber washer fluid into the wiper pattern area on the out- gasket to the outside of the liftglass with the orifice side of the liftglass.
Page 589: Operation
An integral connector receptacle between the motor housing and the pump housing connects the unit to the vehicle electrical system. A small capacitor internal to the connector receptacle insulator is connected in parallel with the motor leads to control ElectroMagnetic Interference (EMI) Fig.
Page 590: Rear Wiper Arm Description
REAR WIPERS/WASHERS 8R - 35 REAR WASHER PUMP MOTOR (Continued) (6) Refill the washer reservoir with the washer A wiper arm cannot be adjusted or repaired. If fluid drained from the reservoir during the removal damaged or faulty, the entire wiper arm unit must be procedure.
Page 591: Installation
8R - 36 REAR WIPERS/WASHERS REAR WIPER ARM (Continued) (4) If necessary, use a battery terminal puller to disengage the wiper arm from the rear wiper motor output shaft splines (Fig. 14). Fig. 15 Rear Wiper Arm Installation 1 - LIFTGLASS BLACKOUT AREA (4) Gently lower the wiper arm until the wiper blade rests on the glass.
Page 592: Operation
REAR WIPERS/WASHERS 8R - 37 REAR WIPER BLADE (Continued) • Superstructure - The superstructure includes a stamped steel bridge and plastic links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm.
Page 593: Rear Wiper Motor Description
The end of the motor tem has been turned Off, and to park the wiper blade output shaft that protrudes through a large rubber in the uppermost portion of the wipe pattern.
Page 594: Installation
REAR WIPERS/WASHERS 8R - 39 REAR WIPER MOTOR (Continued) output shaft clears the rubber grommet in the lift- glass output shaft hole. (10) Remove the rear wiper motor and mounting bracket from the liftglass as a unit. (11) Remove the rubber grommet from the outside of the liftglass output shaft hole.
Page 595: Installation
The rear dimmer controlled illumination lamp with the exte- wiper and washer switch contains switches and cir-...
Page 596: Operation
Refer to the owner’s manual in the vehicle glove box for more information on the fea- tures, use and operation of the rear wiper and washer switch.
Page 597: Removal
8R - 42 REAR WIPERS/WASHERS REAR WIPER/WASHER SWITCH (Continued) (3) If the switch fails any of the continuity checks, replace the faulty switch. If the switch checks OK, repair the open or shorted rear wiper and/or rear washer system circuits as required. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT...
Page 598 SPLICE INFORMATION ....8W-70-1 VEHICLE SPEED CONTROL ... . 8W-33-1 CONNECTOR PIN-OUTS ....8W-80-1 ANTILOCK BRAKES.
Page 600 DaimlerChrysler Corporation wiring diagrams are as they appear on the vehicle. For example, a short designed to provide information regarding the vehi- piece of wire is treated the same as a long one. In cles wiring content.
Page 601: Wiring Diagram Information
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 602 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 603 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 604: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 605: Description - Circuit Functions
NOT USED 8W-01 thru General information and Diagram OPEN 8W-09 Overview POWERTRAIN CONTROL 8W-10 thru Main Sources of Power and 8W-19 Vehicle Grounding MODULE EXTERIOR LIGHTING 8W-20 thru Starting and Charging 8W-29 INTERIOR LIGHTING 8W-30 thru Powertrain/Drivetrain Systems NOT USED...
Page 606: Description - Connector, Ground And Splice Information
BETWEEN A BATTERY FEED AND GROUND. WARNINGS provide information to prevent per- sonal injury and vehicle damage. Below is a list of • Voltmeter - Used to check for voltage on a cir- general warnings that should be followed any time a cuit.
Page 607: Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis. If the vehicle is equipped with these items, in a circuit means good continuity.
Page 608: Standard Procedure - Testing Of Voltage Potential
(2) Connect the other lead of the voltmeter to the (2) Connect one lead of the ohmmeter to one side selected test point. The vehicle ignition may need to of the circuit being tested (Fig. 8). be turned ON to check voltage. Refer to the appropri- (3) Connect the other lead to the other end of the ate test procedure.
Page 609: Standard Procedure - Testing For Ashort To Ground On Fuses Powering Several Loads
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS SHORT TO GROUND ON FUSES POWERING WIRING/TERMINAL SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse.
Page 610: Connector Removal
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 CONNECTOR REMOVAL (1) Disconnect battery. (2) Release Connector Lock (Fig. 10). (3) Disconnect the connector being repaired from its mating half/component. (4) Remove the dress cover (if applicable) (Fig. 10). (5) Release the Secondary Terminal Lock, if required (Fig.
Page 611 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 612 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 613: Diode Removal
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 614: Standard Procedure - Wire Splicing
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 616 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 4WD Indicator ......8W-31 Fuses .
Page 617 Transfer Case Switch ....8W-31 Vehicle Speed Sensor ....8W-30 Transmission Control Module .
Page 618 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-19 Fuse 19 ......8W-10-9, 19 A/C Compressor Clutch Relay .
Page 640 8W-11 FUSE BLOCK 8W - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page A/C Compressor Clutch Relay ... 8W-11-8 Fuse 12 ......8W-11-7 A/C-Heater Control .
Page 652 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ... 8W-15-7, 8, 9 Ignition Switch ..... 8W-15-13 A/C-Heater Control .
Page 666 8W-18 BUS COMMUNICATION 8W - 18 - 1 8W-18 BUS COMMUNICATION Component Page Component Page Airbag Control Module ....8W-18-2 Power Distribution Center ... . . 8W-18-3 Controller Antilock Brake .
Page 670 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... 8W-20-2 Fusible Link ......8W-20-2 Battery .
Page 674 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2, 3 Fuse Block .
Page 678 Fuse 11 ......8W-30-11, 17 Vehicle Speed Sensor ... . . 8W-30-10, 16 Fuse 12 .
Page 702 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-31-2 Input Speed Sensor ....8W-31-9 Axle Lock Switch .
Page 718 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-2 Left Speed Control Switch ... . . 8W-33-3 Brake Transmission Shift Interlock Powertrain Control Module .
Page 722 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Antilock Brake Relay ....8W-35-2 G-Switch ......8W-35-3 Brake Lamp Switch .
Page 726 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Data Link Connector ....8W-39-2 G302 .
Page 728 Fuse Block ..... . . 8W-40-2, 8 Vehicle Speed Sensor ....8W-40-3 G105 .
Page 738 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter/Power Outlet ... . 8W-41-2 Horn ......8W-41-3 Clockspring .
Page 742 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ... . . 8W-42-6, 8 Fuse 21 ......8W-42-6, 7 A/C Compressor Clutch Relay .
Page 752 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ....8W-43-2, 3 Fuse 10 ......8W-43-3 Brake Transmission Shift Interlock Fuse Block .
Page 756 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C-Heater Control ....8W-44-5 Instrument Cluster ... . . 8W-44-3, 4, 5, 7 Ambient Temperature Sensor .
Page 764 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Fuse 3 ......8W-47-5 Left Rear Speaker .
Page 770 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Fuse 2 ......8W-48-2 Instrument Cluster .
Page 774 Left Front Park/Turn Signal Lamp ..8W-50-4 Vehicle Speed Sensor ....8W-50-11 Left Front Position Lamp ....8W-50-6...
Page 786 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-2, 4 Instrument Cluster ....8W-51-2, 4, 8 Brake Lamp Switch .
Page 794 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Brake Lamp Switch ....8W-52-2 Left Side Marker Lamp ....8W-52-4 Fuse 13 .
Page 800 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Front Washer Pump ....8W-53-2 G302 ......8W-53-4 Front Wiper Motor .
Page 804 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S101 ......8W-10-9, 16 S163 .
Page 814 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-3 C205 ......8W-80-19 A/C High Pressure Switch (4.0L) .
Page 815 (Except Export/Japan Low Torque Converter Clutch Solenoid ..8W-80-48 Emission Vehicle) ....8W-80-37 Transfer Case Switch (Except Off-Road Passenger Airbag On-Off Switch (LHD) . . 8W-80-37 Package) .
Page 816 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK (4.0L) A/C COMPRESSOR CLUTCH RELAY OUTPUT C3 18DB/BK (2.4L) A/C COMPRESSOR CLUTCH RELAY OUTPUT Z246 18BK/OR (2.4L) GROUND Z1 20BK (4.0L) GROUND A/C HIGH PRESSURE SWITCH (4.0L) - BLACK 2 WAY CIRCUIT...
Page 817 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS A/C-HEATER CONTROL C1 - 5 WAY CIRCUIT FUNCTION C7 12BR/TN BLOWER MOTOR HIGH SPEED C6 14LB BLOWER MOTOR M2 SPEED C5 16LG/LB BLOWER MOTOR M1 SPEED C4 18TN BLOWER MOTOR LOW SPEED C1 12DG BLOWER MOTOR FEED A/C-HEATER CONTROL C2 - 5 WAY...
Page 818 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 AMBIENT TEMPERATURE SENSOR - GRAY 2 WAY CIRCUIT FUNCTION G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL G32 20BK/LB SENSOR GROUND AXLE LOCK SWITCH (OFF-ROAD PACKAGE) - 8 WAY CIRCUIT FUNCTION Z1 20BK GROUND E2 20OR PANEL LAMPS FEED M1 20PK/WT...
Page 819 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS BLEND DOOR ACTUATOR - 6 WAY CIRCUIT FUNCTION Z11 20DB/WT GROUND C36 20YL BLEND DOOR FEEDBACK SIGNAL F24 20OR FUSED IGNITION SWITCH OUTPUT (RUN) BLOWER MOTOR - 2 WAY CIRCUIT FUNCTION C1 12DG BLOWER MOTOR RELAY OUTPUT C7 12BK/TN BLOWER MOTOR HIGH DRIVER...
Page 820 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE LAMP SWITCH SENSE G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G9 20GY/BK...
Page 821 C90 20LG (4.0L) K6 20VT/WT (2.4L) K99 18BR/OR K299 18BR/WT K173 18LG (2.4L) A242 18VT/OR (4.0L EXCEPT BUILT-UP-EXPORT/4.0L JAPAN LOW EMISSION VEHICLE) K4 20BK/LB F15 18DB/WT Z12 20BK/TN G7 20WT/OR (DRL) T141 18YL/RD C3 20DB/BK C104 (LHD) - (ENGINE SIDE)
Page 822 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 C104 (LHD) - GRAY (DASH SIDE) CIRCUIT A14 14RD/WT C21 18DB/OR (4.0L) C18 18DB (2.4L A/C) B1 18YL/DB (ABS) G301 20VT/LB (OFF-ROAD PACKAGE) A850 18RD/WT (OFF-ROAD PACKAGE) B2 18YL (ABS) T41 20BR/LB B3 18LG/DB (ABS) G300 20VT/WT (OFF-ROAD PACKAGE) B4 18LG (ABS)
Page 823 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS C107 - (BODY SIDE) CIRCUIT V32 20YL/RD B41 20YL/VT (LHD) L3 14RD/OR L4 14VT/WT F3 14LB/OR F30 12RD/PK K125 18WT/DB K4 20BK/LB V37 20RD/LG L9 18BK/WT M1 20PK/WT K29 20WT/PK G107 20BK/RD L60 18TN A1 18RD L1 20VT/BK...
Page 824 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 C107 - (DASH SIDE) CIRCUIT V32 18YL/RD (SPEED CONTROL) B41 18YL/VT (ABS) L3 14RD/OR L4 14VT/WT F3 14LB/OR (DRL) F30 12RD/PK K125 18WT/DB K4 20 BK/LB V37 18RD/LB (SPEED CONTROL) L9 18BK/WT M1 20PK/WT M1 20PK/WT (ABS EXCEPT CANADA) K29 18WT/PK...
Page 825 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS C109 (A/T) - LT GRAY (DASH SIDE) CIRCUIT A30 16RD/WT K30 18PK T16 16RD D21 18PK D20 18LG/PK D25 18VT/YL T56 18DG/LB T10 18YL/DG T6 18OR/WT C109 (A/T) - LT GRAY (ENGINE SIDE) CIRCUIT A30 16RD/WT K30 18PK...
Page 826 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C110 - BLACK (HEADLAMP SIDE) CIRCUIT L7 18BK/YL L60 18TN L61 18GY L3 14RD/OR L4 14VT/WT X2 18WT/RD V10 16BR L22 20LG/DG (EXPORT) G31 20VT/LG G32 20BK/LB L39 16LB (FRONT FOG LAMPS) L13 20BR/YL (EXPORT) C115 (OFF-ROAD PACKAGE) - BLACK (ENGINE SIDE)
Page 827 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C116 (OFF-ROAD PACKAGE) - LT GRAY (REAR FEEDBACK OVERLAY SIDE) CIRCUIT Z1 20BK G301 20VT/LB C120 (2.4L) - (DASH SIDE) CIRCUIT C25 12YL Z213 12BK C120 (2.4L) - (ELECTRIC FAN JUMPER) CIRCUIT C25 12YL Z213 12BK C170 - BLACK (I/P SIDE)
Page 828 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C170 - NATURAL (DASH SIDE) CIRCUIT L13 20BR/YL (HEADLAMP LEVELING) C81 20LB/WT G99 20GY/WT D20 18LG/PK (A/T) T56 18DG/LB (A/T) C90 20LG (A/C) T6 18OR/WT (A/T) G31 20VT/LG D32 18LG/WT D21 18PK G304 20VT/DB (OFF-ROAD PACKAGE) F60 16RD/WT G305 20VT/LG (OFF-ROAD PACKAGE)
Page 829 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C181 (2.4L) - BLACK (ENGINE SIDE) CIRCUIT F42 18DG/LG C3 20DB/BK Z1 20BK K11 18WT/DB K12 18TN K13 18YL/WT K14 18LB/BR K44 18TN/YL K4 18TN/YL C182 (2.4L) - BLACK (ENGINE INTAKE SIDE) CIRCUIT K59 18VT/BK K40 18BR/WT...
Page 830 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C202 - (BODY SIDE) CIRCUIT F24 20RD/DG G75 20TN F38 16LB L61 18GY L61 18 GY L7 18BK/YL L7 18BK/YL L1 20VT/BK X53 18DG (SUBWOOFER) X55 18BR/RD (SUBWOOFER) F14 18LG/YL G5 20DB/WT X54 18VT (SUBWOOFER) X56 18DB (SUBWOOFER) L60 18TN...
Page 831 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C202 - (I/P SIDE) CIRCUIT F24 20RD/DG F24 20RD/DG G75 20TN F38 16LB/WT L61 18GY L7 18BK/YL L1 20VT/BK X53 18DG X55 18BR/RD F14 18LG/YL (LHD) G5 20DB/WT X54 18VT X56 18DB L60 18TN G26 20LB R166 18LG/BR (LHD)
Page 832 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C203 - (I/P SIDE) CIRCUIT G5 20DB/WT Z10 20BK L1 20VT/BK G31 20VT/LG G32 20BK/LB M2 20YL M1 20PK/WT C203 - (MIRROR SIDE) CIRCUIT G5 20DB/WT Z2 20BK/LG L1 20VT/BK G31 20VT/LG G32 20BK/LB M2 20YL M1 20PK/WT...
Page 833 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C324 - (BODY SIDE) CIRCUIT M1 20PK/WT M2 20YL X58 18DB/PK X52 18GY/DB C324 - BLACK (SPEAKER POD JUMPER) CIRCUIT M1 20PK/WT M2 20YL X58 18DB/PK X52 18GY/DB C325 - BLACK (SPEAKER POD JUMPER) CIRCUIT M1 20PK/WT M2 20YL...
Page 834 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C326 (HARD TOP) - BLACK (HARD TOP SIDE) CIRCUIT C15 12BK/WT V13 18BR/LG V23 18BR/PK V23 18BR/PK Z1 12BK C329 (EXPORT) - BLACK (BODY SIDE) CIRCUIT L38 18BR/WT L7 18BK/YL Z1 20BK C329 (EXPORT) - BLACK (BUMPER SIDE) CIRCUIT L38 18BR/WT...
Page 835 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS CIGAR LIGHTER/POWER OUTLET - RED 3 WAY CIRCUIT FUNCTION F38 16LB/WT FUSED CIGAR LIGHTER/ACCESSORY RELAY OUTPUT Z1 16BK/WT GROUND CIRCUIT BREAKER - GRAY 2 WAY CIRCUIT FUNCTION A3 12RD/WT HEADLAMP SWITCH RELAY FEED F3 14LB/OR DAYTIME RUNNING LAMP MODULE CLOCKSPRING C1 - NATURAL 4 WAY...
Page 836 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 CONTROLLER ANTILOCK BRAKE - 25 WAY CIRCUIT FUNCTION B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-) B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) B41 18YL/VT...
Page 837 HIGH BEAM INDICATOR DRIVER F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) F3 14LB/OR FUSED B(+) G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL Z1 18BK GROUND L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT DRIVER AIRBAG SQUIB 1 - YELLOW 2 WAY CIRCUIT...
Page 838 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 DRIVER DOOR AJAR SWITCH - NATURAL 3 WAY CIRCUIT FUNCTION M23 20YL/BK DOOR AJAR SWITCH OUTPUT G75 20TN DRIVER DOOR AJAR SWITCH SENSE ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K4 20BK/LB (4.0L) SENSOR GROUND...
Page 839 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS FRONT LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND A750 18TN/RD FRONT LOCKER RELAY OUTPUT FRONT WASHER PUMP - BLACK 2 WAY CIRCUIT FUNCTION V10 16BR WASHER PUMP CONTROL SWITCH OUTPUT Z1 18BK GROUND...
Page 840 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 FUEL INJECTOR NO. 2 (2.4L) - 2 WAY CIRCUIT FUNCTION F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN FUEL INJECTOR NO. 2 DRIVER FUEL INJECTOR NO. 2 (4.0L) - 2 WAY CIRCUIT FUNCTION F42 18DG/LG...
Page 841 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 5 (4.0L) - 2 WAY CIRCUIT FUNCTION F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K38 18GY FUEL INJECTOR NO. 5 DRIVER FUEL INJECTOR NO. 6 (4.0L) - 2 WAY CIRCUIT FUNCTION F42 18DG/LG...
Page 842 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 HEADLAMP LEVELING SWITCH (EXPORT) - 6 WAY CIRCUIT FUNCTION L22 20LG/DG FUSED HEADLAMP SWITCH OUTPUT Z1 20BK GROUND L13 20BR/YL HEADLAMP ADJUST SIGNAL HORN - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND X2 18WT/RD HORN RELAY OUTPUT...
Page 843 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS IGNITION SWITCH - 10 WAY CIRCUIT FUNCTION A1 18RD FUSED B(+) A21 18DB IGNITION SWITCH OUTPUT (RUN-START) F22 12WT/PK IGNITION SWITCH OUTPUT (RUN-ACC) F30 12RD/PK FUSED B(+) G26 20LB KEY-IN IGNITION SWITCH SENSE A41 18YL IGNITION SWITCH OUTPUT (START) A31 18BK/DG...
Page 844 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 INSTRUMENT CLUSTER C2 - 16 WAY CIRCUIT FUNCTION C80 20DB/WT (HARD TOP) REAR WINDOW DEFOGGER SWITCH SENSE G10 20LG/RD SEAT BELT SWITCH SENSE G76 20TN/YL PASSENGER DOOR AJAR SWITCH SENSE G75 20TN DRIVER DOOR AJAR SWITCH SENSE M2 20YL COURTESY LAMP FEED...
Page 845 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS LEFT DOME LAMP - WHITE 2 WAY CIRCUIT FUNCTION M1 20PK/WT FUSED B(+) M2 20YL COURTESY LAMPS DRIVER LEFT FOG LAMP (EXCEPT EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L39 16LB FOG LAMP RELAY NO.
Page 846 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 LEFT FRONT WHEEL SPEED SENSOR - 2 WAY CIRCUIT FUNCTION B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) LEFT HEADLAMP - BLACK 3 WAY CIRCUIT FUNCTION L3 14RD/OR...
Page 847 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS LEFT REAR SPEAKER - BLACK 3 WAY CIRCUIT FUNCTION X57 20BR/LB LEFT REAR SPEAKER (-) X51 18BR/YL LEFT REAR SPEAKER (+) LEFT REAR WHEEL SPEED SENSOR - 2 WAY CIRCUIT FUNCTION B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-) B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
Page 848 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 MANIFOLD ABSOLUTE PRESSURE SENSOR (4.0L) - 3 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K7 20OR 5V SUPPLY MULTI-FUNCTION SWITCH C1 - GRAY 20 WAY CIRCUIT FUNCTION L50 18WT/TN (EXCEPT EXPORT)
Page 849 GROUND EMISSIONS VEHICLE) K4 20BK/LB SENSOR GROUND K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/JAPAN LOW EMISSION VEHICLE) - 4 WAY CIRCUIT FUNCTION F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT K299 18BR/WT O2 SENSOR 2/1 HEATER CONTROL...
Page 850 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/JAPAN LOW EMISSION VEHICLE) - 4 WAY CIRCUIT FUNCTION A242 18VT/OR OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT Z1 18BK GROUND K4 20BK/LB SENSOR GROUND K341 18TN/WT OXYGEN SENSOR 2/2 SIGNAL...
Page 851 OXYGEN SENSOR 1/1 SIGNAL K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL K241 18LG/RD (4.0L EXCEPT OXYGEN SENSOR 2/1 SIGNAL BUILT-UP-EXPORT/4.0L JAPAN LOW EMMISION VEHICLE) K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K341 18TN/WT (4.0L EXCEPT OXYGEN SENSOR 2/2 SIGNAL BUILT-UP-EXPORT/4.0L JAPAN LOW...
Page 852 FUEL INJECTOR NO. 2 DRIVER K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER K173 18LG (2.4L) HIGH SPEED RADIATOR RELAY INPUT C18 18DB (2.4L) A/C PRESSURE SIGNAL G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL K6 18VT/WT 5V SUPPLY...
Page 853 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY CIRCUIT FUNCTION C13 18DB/OR (A/C) A/C COMPRESSOR CLUTCH RELAY CONTROL K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL V36 18TN/RD (SPEED CONTROL) SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD (SPEED CONTROL) SPEED CONTROL VENT SOLENOID CONTROL K99 18BR/OR...
Page 854 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 RADIATOR FAN MOTOR CIRCUIT BREAKER (2.4L) - 2 WAY CIRCUIT FUNCTION C25 12YL HIGH SPEED RADIATOR RELAY OUTPUT C23 12DB FUSED HIGH SPEED RADIATOR RELAY OUTPUT RADIATOR FAN MOTOR RELAY (2.4L) - 4 WAY CIRCUIT FUNCTION C24 12DB/PK...
Page 855 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS REAR FOG LAMP (EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L38 18BR/WT REAR FOG LAMP FEED Z1 20BK GROUND REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY CIRCUIT FUNCTION Z1 20BK GROUND G301 20VT/LB REAR LOCKER INDICATOR SWITCH SENSE...
Page 856 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 REAR WINDOW DEFOGGER SWITCH (HARD TOP) - 4 WAY CIRCUIT FUNCTION Z1 20BK GROUND C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE F81 20DB/RD FUSED REAR WINDOW DEFOGGER RELAY OUTPUT E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL REAR WIPER MOTOR (HARD TOP) - BLACK 3 WAY CIRCUIT FUNCTION...
Page 857 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS RIGHT FOG LAMP (EXCEPT EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L39 16LB FOG LAMP RELAY NO. 1 OUTPUT RIGHT FRONT PARK/ TURN SIGNAL LAMP (EXCEPT EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L60 18TN...
Page 858 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-) B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) RIGHT HEADLAMP - BLACK 3 WAY CIRCUIT FUNCTION L3 14RD/OR...
Page 859 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS RIGHT REAR SPEAKER - BLACK 3 WAY CIRCUIT FUNCTION X58 20DB/PK RIGHT REAR SPEAKER (-) X52 20DB/WT RIGHT REAR SPEAKER (+) RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-) B2 18YL...
Page 860 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START) Z1 20BK GROUND F33 20PK/RD FUSED B(+) SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 18TN/RD...
Page 861 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS THROTTLE POSITION SENSOR (4.0L) - 3 WAY CIRCUIT FUNCTION K7 20OR 5-VOLT SUPPLY K4 20BK/LB SENSOR GROUND K22 18OR/DB THROTTLE POSITION SENSOR #1 SIGNAL TORQUE CONVERTER CLUTCH SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION F12 20RD/LG...
Page 862 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 TRANSMISSION CONTROL MODULE - 60 WAY CIRCUIT FUNCTION T1 18LG/BK TRS T1 SENSE T3 18VT TRS T3 SENSE K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL D21 18PK SCI TRANSMIT T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START) T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE T10 18YL/DG...
Page 863 LOW/REVERSE PRESSURE SWITCH SENSE UNDERHOOD LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND M1 20PK/WT FUSED B(+) VEHICLE SPEED SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 18VT/WT 5V SUPPLY K4 20BK/LB SENSOR GROUND G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL...
Page 864 For items that are not shown in this section N/S is placed in the DESCRIPTION Fig. column. This section provides illustrations identifying con- nector, ground, and splice locations in the vehicle. Connector, ground, and splice indexes are provided. CONNECTORS Connector Name/Number Color Location Fig.
Page 865 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. C107 (RHD) Right Kick Panel, see LHD Similar C109 (A/T) LT-GY Rear of Engine Compartment 7, 8, 15 C110 Left Fender Side Shield 1, 7 C115 (Off Road) Top of Locker Pump Bracket C116 (Off Road)
Page 866 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Engine Coolant Temperature On Thermostat Housing 4, 15 Sensor Engine Oil Pressure Switch Right Side of Engine Block (4.0L) Engine Oil Pressure Switch Below A/C Compressor (2.4L) Evap/Purge Solenoid Left Fender Side Shield...
Page 867 At Lamp Left Rear Lamp Assembly At Lamp Left Rear Speaker In Left Speaker/lamp Pod Left Rear Wheel Speed Near Vehicle Speed Sensor T/O Sensor Left Side Marker Lamp At Lamp, See Right Left Side Repeater Lamp At Lamp, See Right...
Page 868 Rear of Lamp Right Headlamp Leveling Near Headlamp at Motor Motor (Export) Right License Lamp At Lamp Right Rear Lamp Assembly At Lamp Right Rear Speaker In Right Speaker/lamp Pod Right Rear Wheel Speed Near Vehicle Speed Sensor T/O Sensor...
Page 869 Transmission Range Sensor Left Center of Transmission Transmission Solensid/ Right Center of Transmission Pressure Switch Assembly Underhood Lamp Under Hood 7, 8, 15 Vehicle Speed Sensor Left Rear of Transfer Case GROUNDS Connector Name/ Location Fig. Number G100 Rear Center of Engine Compartment...
Page 870 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/ Location Fig. Number G204 (RHD) Center of Instrument Panel G300 (LHD) Left Kick Panel G300 (RHD) Right Kick Panel G301 (LHD) Between Front Seats G301 (RHD) Left Kick Panel G302 (LHD) Left Kick Panel G302 (RHD)
Page 871 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Splice Number Location Fig. S133 (2.4L) Near T/O for Input Speed Sensor, See 4.0L S134 (4.0L) Near T/O for C154 S134 (2.4L) Between Engine Starter Solenoid and C182 S135 (4.0L) Near T/O for Oxygen Sensor 1/2 Downstream S135 (2.4L) Between Engine Starter Solenoid and C182...
Page 872 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Splice Number Location Fig. S208 Near Blower Motor S209 Near T/O for C202, C203, and C204 20, 23, 24 S210 Near T/O for A/C Heater Control C3 22, 25 S211 Near T/O for C202 20, 23...
Page 873 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 874 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 875 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 876 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 877 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 878 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 879 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 880 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 881 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 882 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 10 2.4 LITER RIGHT FENDER SHIELD Fig. 11 FRONT WIPER MOTOR...
Page 883 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 884 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 885 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 14 2.4 LITER ENGINE PCM Fig. 15 2.4 LITER REAR ENGINE...
Page 886 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 16 4.0 LITER ENGINE REAR...
Page 887 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 888 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 889 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 LEFT COWL PANEL LHD...
Page 890 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 891 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 892 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 893 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 894 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 895 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 896 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 26 STEERING COLUMN CONNECTIONS...
Page 897 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 898 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 28 FRONT LOCKER INDICATOR SWITCH Fig. 29 REAR LOCKER INDICATOR SWITCH...
Page 899 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 30 MANUAL TRANSMISSION BUX Fig. 31 MANUAL TRANSMISSION...
Page 900 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 32 MANUAL TRANS 2.4L...
Page 901 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 902 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 34 FUEL PUMP Fig. 35 LEAK DETECTION PUMP...
Page 903 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 36 REAR LAMPS...
Page 904 The power distribution system can components in the power distribution system. See the also prove useful for the sourcing of additional elec- owner’s manual in the vehicle glove box for more trical circuits that may be required to provide the...
Page 905: Operation
POWER DISTRIBUTION (Continued) electrical current needed to operate many accessories shield slides up toward the knob exposing the heat- that the vehicle owner may choose to have installed ing element, and the heating element extends from in the aftermarket. the housing toward the insulated contact in the bot- tom of the receptacle shell.
Page 906: Fuse Block Description
An electrical fuseblock module is mounted on the dash panel in the passenger compartment of the vehicle (Fig. 1). The fuseblock module serves to dis- tribute electrical current to many of the accessory systems in the vehicle. The fuseblock module houses up to twenty blade-type mini fuses.
Page 907: Operation
(4) Remove all of the fasteners that secure each of (1) Position the fuseblock module and the body the body wire harness ground eyelets to the vehicle wire harness onto the dash panel as a unit. body and chassis components. Refer to Connector...
Page 908: Iod Fuse Description
The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days.
Page 909: Micro-Relay Description
8W - 97 - 6 8W-97 POWER DISTRIBUTION IOD FUSE (Continued) vehicle is being prepared for delivery in order to OPERATION restore full electrical system operation. A micro-relay is an electromechanical switch that (1) Turn the ignition switch to the Off position.
Page 910: Power Distribution Center Description
2 - LATCHES (3) Remove all of the fasteners that secure each of 3 - PDC COVER the dash wire harness ground eyelets to the vehicle 4 - RIGHT FRONT FENDER body and chassis components. Refer to Connector The PDC housing is secured in the engine compart- Locations in the Wiring section of this service man- ment at four points.
Page 911 8W - 97 - 8 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) (2) Unlatch and remove the cover from the PDC. (3) Unlatch and remove the B(+) terminal stud cover from the PDC. (4) Remove the two nuts that secure the eyelet ter- minal to the two B(+) terminal studs of the PDC.
Page 912 8W-97 POWER DISTRIBUTION 8W - 97 - 9 POWER DISTRIBUTION CENTER (Continued) PDC B(+) TERMINAL MODULE REMOVAL (1) Remove the PDC housing lower cover. (2) From the top of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches that secure the B(+) terminal module in the PDC (Fig.
Page 913: Power Distribution Center Assembly
8W - 97 - 10 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) NOTE: It may be necessary to remove relay cas- settes that are not being serviced from the PDC housing in order to obtain sufficient clearance to service the faulty relay cassette. The same service procedure is repeated as necessary to remove each of the interfering relay wedges and relay cassettes from the PDC housing.
Page 914: Installation
8W-97 POWER DISTRIBUTION 8W - 97 - 11 POWER DISTRIBUTION CENTER (Continued) (2) Gently and evenly press the PDC relay wedge down into the relay cassette until both of the latches are fully engaged. (3) Install each of the removed relays into the proper cavities of the PDC relay wedge.
Page 915: Power Distribution Center Support
PDC housing. (6) Engage each of the retainers that secure the dash wire harness to the vehicle body and chassis components. Refer to Connector Locations in the index of this service manual for the location of more information on the dash wire harness retainer loca- tions.
Page 916: Removal
8W-97 POWER DISTRIBUTION 8W - 97 - 13 POWER OUTLET (Continued) (1) Check the fused B(+) fuse in the Power Distri- bution Center. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
Page 917: Relay Description
8W - 97 - 14 8W-97 POWER DISTRIBUTION DIAGNOSIS AND TESTING - RELAY RELAY The relays are located in the junction block or DESCRIPTION power distribution center. For complete circuit dia- grams, refer to Wiring Diagrams. (1) Remove the relay from its mounting location. (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30.
Page 918: Removal
8W-97 POWER DISTRIBUTION 8W - 97 - 15 RELAY (Continued) REMOVAL INSTALLATION (1) Disconnect and isolate the negative battery (1) Position the relay to the proper receptacle. cable. (2) Align the relay terminals with the terminal (2) Remove the relay by grasping it firmly and cavities in the receptacle.
Page 920 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 2.4L......1 ENGINE 4.0L.
Page 921 9 - 2 ENGINE 2.4L HYDRAULIC LIFTERS REAR MOUNT DIAGNOSIS AND TESTING - LASH ADJUSTER REMOVAL ......46 (TAPPET) NOISE DIAGNOSIS .
Page 922: Engine 2.4L
ENGINE 2.4L 9 - 3 TIMING BELT TENSIONER & PULLEY BALANCE SHAFT CARRIER REMOVAL ......60 REMOVAL .
Page 923: Diagnosis And Testing - Engine Oil Leak Inspection
ENGINE 2.4L ENGINE 2.4L (Continued) (2) Drive the vehicle until engine reaches normal (4) If dye is not observed, drive the vehicle at var- operating temperature. Select a route free from traf- ious speeds for approximately 24 km (15 miles), and fic and other forms of congestion, observe all traffic repeat inspection.
Page 924: Diagnosis And Testing - Engine
ENGINE 2.4L 9 - 5 ENGINE 2.4L (Continued) present in this area, remove transmission for further DIAGNOSIS AND TESTING - ENGINE inspection. Engine diagnosis is helpful in determining the (a) Circular spray pattern generally indicates causes of malfunctions not detected and remedied by seal leakage or crankshaft damage.
Page 925: Diagnosis And Testing - Engine Diagnosis - Performance
9 - 6 ENGINE 2.4L ENGINE 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 926 ENGINE 2.4L 9 - 7 ENGINE 2.4L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter. 3.
Page 927: Diagnosis And Testing - Engine Mechanical
9 - 8 ENGINE 2.4L ENGINE 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 928 ENGINE 2.4L 9 - 9 ENGINE 2.4L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 929: Standard Procedure
It is not necessary to wait for curing of the sealant. CAUTION: Do not drive cup plug into the casting as The cooling system can be refilled and the vehicle restricted cooling can result and cause serious placed in service immediately.
Page 930: Standard Procedure - Measuring Bearing Clearance Using Plastigage
ENGINE 2.4L 9 - 11 ENGINE 2.4L (Continued) • Metal scraper holes (Fig. 4). (In addition, suspected areas can be • Abrasive pad or paper to clean cylinder block checked by placing the Plastigage in the suspected and head area). Torque the bearing cap bolts of the bearing •...
Page 931: Standard Procedure - Hydrostatic Locked Engine
9 - 12 ENGINE 2.4L ENGINE 2.4L (Continued) result in spill-over which can break off and obstruct ily be wiped off. Components should be torqued in fluid feed lines. A continuous bead of the proper place within 15 minutes. The use of a locating dowel width is essential to obtain a leak-free gasket.
Page 932: Removal - Engine Assembly
INSTALLATION - ENGINE ASSEMBLY (16) Remove lower radiator hose from engine. (17) Disconnect the engine to body ground straps (1) Position the engine in the vehicle. at the left side of cowl. CAUTION: Use caution when installing 2.4L engine (18) Disconnect the engine wiring harness at the...
Page 933 (12) Install the exhaust pipe. (24) Connect upper radiator hose. (13) Connect the oxygen sensors. (25) Connect throttle and speed control cables. (14) Lower vehicle. (26) Install the heater hose assembly. (15) Connect the knock sensors. (27) Install coolant recovery bottle.
Page 934: Specifications
ENGINE 2.4L 9 - 15 ENGINE 2.4L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Piston Ring Groove 4.097–4.236 mm SPECIFICATIONS - 2.4L ENGINE Depth No. 3 (0.161–0.166 in.) Piston Pins DESCRIPTION SPECIFICATION Clearance in Piston 0.005–0.018 mm General Specification (0.0002–0.0008 in.) Type In-Line OHV, DOHC Clearance in Connecting Interference Number of Cylinders...
Page 935 9 - 16 ENGINE 2.4L ENGINE 2.4L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Bore Diameter— 53.007–52.993 mm Exhaust 6.60 mm Crankshaft End (2.0868–2.0863 in.) (0.259 mm) Side Clearance 0.13–0.38 mm Intake Valve Timing* (0.005–0.015 in.) Closes (ABDC) 51° Wear Limit 0.40 mm Opens (BTDC) 1°...
Page 936 ENGINE 2.4L 9 - 17 ENGINE 2.4L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Head Diameter—Intake 34.67–34.93 mm Valve Springs 1.364–1.375 in.) Free Length (Approx.) 48.4 mm Head Diameter—Exhaust 28.32–28.52 mm (1.905 in.) (1.114–1.122 in.) Nominal Force (Valve 338 N @ 38.0 mm Closed) Valve Length (Overall) (75.98 lbs.
Page 937: Specifications - Torque
9 - 18 ENGINE 2.4L ENGINE 2.4L (Continued) SPECIFICATIONS - TORQUE DESCRIPTION N·m DESCRIPTION N·m Lbs. Lbs. Lbs. Lbs. Balance Shaft Carrier to — Engine Mount Bracket — Block—Bolts Right—Bolts Balance Shaft Gear — Engine Mounting—Bolts (Refer to 9 ENGINE/ Cover—Double Ended ENGINE MOUNTING) Fastener...
Page 938: 2.4L Engine
ENGINE 2.4L 9 - 19 ENGINE 2.4L (Continued) SPECIAL TOOLS 2.4L ENGINE Crankshaft Damper Installer 6792 Puller 1026 Valve Spring Compressor 8215 Crankshaft Damper Removal Insert 6827-A Camshaft Sprocket Holder 6847 Adaptor 8436 Camshaft Seal Remover C-4679-A Valve Spring Compressor MD998772A Camshaft Seal Installer MD-998306 Valve Spring Compressor Adapter 6779...
Page 939 9 - 20 ENGINE 2.4L ENGINE 2.4L (Continued) Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Cylinder Bore Gage C-119 Crankshaft Sprocket Remover 6793 Balance Shaft Sprocket Installer 6052 Crankshaft Sprocket Remover Insert C-4685-C2 Front Crankshaft Oil Seal Installer 6780 Crankshaft Seal Remover 6771 Combustion Leak Tester C-3685-A Oil Pressure Gauge C-3292...
Page 940: Air Cleaner Element - 2.4L Removal - 2.4L
The intake valves face toward the left (4) Remove air cleaner element (filter) from hous- side of the vehicle. The exhaust valves face the right ing. side. The cylinder head incorporates powdered metal (5) Clean inside of housing before replacing ele- valve guides and seats.
Page 941: Diagnosis And Testing - Cylinder Head Gasket
REMOVAL) dures in Cylinder Compression Pressure Test (Refer (9) Raise vehicle and remove exhaust pipe from to 9 - ENGINE - DIAGNOSIS AND TESTING). An manifold. engine cylinder head gasket leaking between adja- (10) Remove power steering pump and set aside.
Page 942: Cleaning
ENGINE 2.4L 9 - 23 CYLINDER HEAD (Continued) CLEANING To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Page 943: Camshaft Oil Seal(S)
(12) Install accessary drive bracket. (13) Install power steering pump to cylinder head. (14) Raise vehicle and install the exhaust pipe to the manifold. (15) Install accessory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -...
Page 944: Description
ENGINE 2.4L 9 - 25 CAMSHAFT OIL SEAL(S) (Continued) Fig. 15 Camshaft Seal - Installation 1 - SPECIAL TOOL MD 998306 Fig. 13 Camshaft Sprocket - Removal/Installation (6) Install camshaft sprockets. Hold each sprocket 1 - SPECIAL TOOL 6847 with Special Tool 6847 and tighten center bolt to 101 N·m (75 ft.
Page 945: Removal
9 - 26 ENGINE 2.4L CAMSHAFT(S) (Continued) TION CONTROL/CAMSHAFT POSITION SENSOR - REMOVAL) (3) Remove timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL) (4) Remove camshaft sprockets and timing belt rear cover. (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT / CHAIN COVER(S) - REMOVAL) (5) Bearing caps...
Page 946: Installation
ENGINE 2.4L 9 - 27 CAMSHAFT(S) (Continued) (4) Apply Mopar Gasket Maker to No. 1 and No. 6 bearing caps (Fig. 22). Install bearing caps and tighten M8 fasteners to 28 N·m (250 in. lbs.). Fig. 19 Camshaft Bearing Cap - Removal Fig.
Page 947: Cylinder Head Cover Removal
9 - 28 ENGINE 2.4L CYLINDER HEAD COVER REMOVAL (1) Remove intake manifold. (Refer ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) (2) Remove ignition coil and spark plug wires. (3) Disconnect PCV and make-up air hoses from cylinder head cover. (4) Remove cylinder head cover bolts. (5) Remove cylinder head cover from cylinder head.
Page 948: Intake/Exhaust Valves & Seats
ENGINE 2.4L 9 - 29 CYLINDER HEAD COVER (Continued) (4) Install cylinder head cover assembly to cylin- CLEANING der head. Install all bolts, ensuring the two (2) bolts (1) Clean valves thoroughly discard containing the sealing washer are located in the cen- burned, warped and cracked valves.
Page 949: Inspection
9 - 30 ENGINE 2.4L VALVE SPRINGS (Continued) INSPECTION Install new valve stem seals on all valves using a valve stem seal tool (Fig. 29). The valve stem (1) Whenever valves have been removed for inspec- seals should be pushed firmly and squarely over tion, reconditioning or replacement, valve springs valve guide.
Page 950: Removal
Spongy adjusters can be bottomed out easily. b. Remove suspected lash adjusters, and replace as REMOVAL necessary. NOTE: This procedure is for in-vehicle service with REMOVAL camshafts installed. NOTE: This procedure is for in-vehicle service with (1) Remove cylinder head cover. (Refer to 9 - camshafts installed.
Page 951: Inspection
9 - 32 ENGINE 2.4L ROCKER ARMS (Continued) CAUTION: If cam follower assemblies are to be INSTALLATION reused, always mark position for reassembly in (1) Lubricate rocker arm with clean engine oil. their original positions. (2) Using Special Tools 8215 and 8436 slowly depress valve assembly until rocker arm can be (5) Using Special Tools 8215 and 8436 slowly installed on the hydraulic lifter and valve stem.
Page 952: Standard Procedure - Cylinder Bore Honing
ENGINE 2.4L 9 - 33 ENGINE BLOCK (Continued) piston to bore clearance must be established in order strokes depending on the bore condition, will be suf- to assure quiet and economical operation. ficient to provide a satisfactory surface. Use a light honing oil.
Page 953: Inspection
9 - 34 ENGINE 2.4L ENGINE BLOCK (Continued) INSPECTION Measure the cylinder bore at three levels in direc- tions A and B (Fig. 38). Top measurement should be 10 mm (3/8 in.) down and bottom measurement ENGINE BLOCK should be 10 mm (3/8 in.) up from bottom of bore. (1) Clean cylinder block thoroughly and check all (Refer to 9 - ENGINE - SPECIFICATIONS).
Page 954: Crankshaft Description
To optimize bear- ing loading, eight counterweights are used. Fig. 41 CHECKING CRANKSHAFT END PLAY (1) Remove engine assembly from vehicle. (Refer to 9 - ENGINE - REMOVAL) (2) Remove flex plate and crankshaft rear oil seal.
Page 955: Installation
9 - 36 ENGINE 2.4L CRANKSHAFT (Continued) Fig. 42 Bedplate Bolt Tightenening Sequence exceed 0.305 mm (0.012 in.) under the standard jour- nal diameter. DO NOT grind thrust faces of No. 3 Fig. 44 Installing Main Bearing Upper Shell main bearing. DO NOT nick crank pin or bearing fil- lets.
Page 956: Crankshaft Main Bearings
ENGINE 2.4L 9 - 37 CRANKSHAFT (Continued) (18) Install the oil pan. (Refer to 9 - ENGINE/LU- BRICATION/OIL PAN - INSTALLATION) (19) Install the oil filter. (20) Install crankshaft rear oil seal. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT SEAL - REAR - INSTALLATION) (21) Install flex plate.
Page 957 9 - 38 ENGINE 2.4L CRANKSHAFT MAIN BEARINGS (Continued) Fig. 49 Main Bearing Caps/Bedplate Sealing Fig. 47 Main Bearing Identification 1 - OIL GROOVE 2 - MAIN BEARINGS 3 - OIL HOLE Fig. 50 Main Bearing Caps/Bedplate Tightening Sequence (8) Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight.
Page 958: Crankshaft Oil Seal - Front
ENGINE 2.4L 9 - 39 CRANKSHAFT MAIN BEARINGS (Continued) (11) Install main bearing bedplate to engine block bolts (11–20), and torque each bolt to 28 N·m (20 ft. lbs.) in sequence shown in (Fig. 50). (12) After the main bearing bedplate is installed, check the crankshaft turning torque.
Page 959 9 - 40 ENGINE 2.4L CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 56 Crankshaft Vibration Damper - Installation - Typical 1 - M12–1.75 × 150 MM BOLT, WASHER AND THRUST BEARING FROM SPECIAL TOOL 6792 CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface.
Page 960: Installation
ENGINE 2.4L 9 - 41 CRANKSHAFT OIL SEAL - REAR (Continued) INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installa- tion of new seal. NOTE: When installing seal, no lube on seal is needed.
Page 961: Installation
9 - 42 ENGINE 2.4L PISTON & CONNECTING ROD (Continued) (5) Remove Balance Shaft Assembly. Refer to Bal- ance Shaft Removal in this section. (6) Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals.
Page 962: Piston Rings
ENGINE 2.4L 9 - 43 PISTON & CONNECTING ROD (Continued) PISTON RINGS STANDARD PROCEDURE PISTON RING - FITTING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore.
Page 963 9 - 44 ENGINE 2.4L PISTON RINGS (Continued) PISTON RINGS - INSTALLATION Fig. 69 Installing Side Rail - Typical 1 - SIDE RAIL END Fig. 68 Piston Ring Installation Position oil ring expander gap at least 45° 1 - NO. 1 PISTON RING from the side rail gaps but not on the piston pin cen- 2 - NO.
Page 964: Vibration Damper Removal
The engine mounting system consist of three mounts; right and a left side support the powertrain, REMOVAL and rear mount to control powertrain torque. The (1) Raise vehicle on hoist. mounts are of molded rubber material. (2) Remove structural collar attaching bolts. (3) Remove collar.
Page 965: Front Mount Removal
(1) Disconnect negative cable from battery. (2) Raise the vehicle and support the transmission. (3) Remove the nuts holding the support cushion to the crossmember. Remove the crossmember. MANUAL TRANSMISSION a.
Page 966: Installation
ENGINE 2.4L 9 - 47 REAR MOUNT (Continued) INSTALLATION (2) Position the crossmember in the vehicle. Install the crossmember to mount through bolt and nut. (3) Install crossmember-to-sill bolts and tighten to MANUAL TRANSMISSION: 41 N·m (30 ft. lbs.) torque.
Page 967: Description
Drilled pas- before checking oil level. sages within the crankshaft route oil from main bear- Checking the oil while the vehicle is on level ing journals to connecting rod journals. Balance shaft ground will improve the accuracy of the oil level lubrication is provided through an oil passage from reading.
Page 968: Standard Procedure - Engine Oil And Filter Change
(Fig. 80). CENTER IN YOUR AREA. Run engine until achieving normal operating tem- perature. (1) Position the vehicle on a level surface and turn engine off. (2) Hoist and support vehicle on safety stands. Refer to Hoisting and Jacking Recommendations.
Page 969: Oil Pan Removal
ENGINE 2.4L OIL PAN REMOVAL (1) Remove air cleaner assembly. (2) Raise vehicle on hoist and drain engine oil. (3) Loosen the engine mount thru bolts. (4) Disconnect exhaust pipe at manifold. (5) Remove structural collar, if equipped. (6) Remove front axle mounting bolts, and lower axle as far possible, if equipped.
Page 970: Oil Pump Removal
ENGINE 2.4L 9 - 51 (8) Remove oil pump (Fig. 84) and front crankshaft OIL PUMP seal. REMOVAL (1) Disconnect negative cable from battery. (2) Remove timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL) (3) Remove timing belt rear cover. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (4) Remove oil pan.
Page 971: Assembly
9 - 52 ENGINE 2.4L OIL PUMP (Continued) (4) If inner rotor measures 9.40 mm (0.370 in.) or less replace inner rotor (Fig. 87). Fig. 87 Measuring Inner Rotor Thickness INSTALLATION Fig. 85 Checking Oil Pump Cover Flatness (1) Make sure all surfaces are clean and free of oil and dirt.
Page 972: Intake Manifold Description
ENGINE 2.4L 9 - 53 OIL PUMP (Continued) (5) Install new front crankshaft seal using Special Tool 6780 (Fig. 89). Fig. 90 Crankshaft Sprocket - Installation 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL INTAKE MANIFOLD DESCRIPTION The intake manifold is a one piece composite mod- ule that attaches to the cylinder head with fasteners.
Page 973: Removal
9 - 54 ENGINE 2.4L INTAKE MANIFOLD (Continued) REMOVAL (4) Install and tighten intake manifold fasteners to 28 N·m (250 in. lbs.) in the sequence shown (Fig. 91). (1) Disconnect negative cable from battery. Repeat procedure until all bolts are at specified (2) Disconnect connector from inlet air tempera- torque.
Page 974: Exhaust Manifold Description
REMOVAL (1) Clean the manifold mating surfaces. (2) Install exhaust manifold with a new gasket. (1) Raise vehicle and disconnect exhaust pipe from Tighten attaching nuts to 20 N·m (175 in. lbs.). the exhaust manifold. (3) Attach exhaust pipe to exhaust manifold and (2) Lower the vehicle.
Page 975 9 - 56 ENGINE 2.4L TIMING BELT COVER(S) (Continued) Fig. 94 ACCESSORY DRIVE BRACKET Fig. 93 TIMING BELT REAR COVER FASTENERS 1- UPPER TIMING BELT COVER 1 - OUTER COVER TO REAR COVER FASTENERS (3) 2- LOWER TIMING BELT COVER 2 - REAR COVER TO CYLINDER HEAD FASTENERS 3- BELT TENSIONER 3 - OUTER COVER TO REAR COVER FASTENERS (3)
Page 976: Timing Belt And Sprocket(S)
TIMING BELT AND SPROCKET(S) REMOVAL REMOVAL - TIMING BELT (1) Remove air cleaner upper cover, housing, and clean air tube. (2) Raise vehicle on hoist. (3) Remove accessory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSION- ERS - REMOVAL) (4) Remove crankshaft vibration damper.
Page 977: Removal - Crankshaft Sprocket
9 - 58 ENGINE 2.4L TIMING BELT AND SPROCKET(S) (Continued) REMOVAL - CRANKSHAFT SPROCKET (1) Disconnect negative battery cable. (2) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL). (3) Remove crankshaft sprocket using Special Tools 6793 and insert C-4685-C2 (Fig.
Page 978 ENGINE 2.4L 9 - 59 TIMING BELT AND SPROCKET(S) (Continued) (3) Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Fig. 101). (4) Move the exhaust camshaft sprocket counter- clockwise (Fig.
Page 979: Timing Belt Tensioner & Pulley
9 - 60 ENGINE 2.4L TIMING BELT AND SPROCKET(S) (Continued) SORY DRIVE/BELT TENSIONERS INSTALLATION) (11) Install crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) (12) Install accessory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (13) Install drive belt splash shield.
Page 980: Balance Shaft Description
ENGINE 2.4L 9 - 61 TIMING BELT TENSIONER & PULLEY (Continued) the engine bracket mounting bolts (M10) 5 to 7 turns into the tensioner’s upper mounting location. (2) Torque the tensioner’s lower mounting bolt to 61 N·m (45 ft. lbs.). Remove the upper bolt used for tensioner alignment.
Page 981: Operation
9 - 62 ENGINE 2.4L BALANCE SHAFT (Continued) OPERATION The balance shafts are driven by the crankshaft via a roller chain and sprockets. The balance shafts are connected by helical gears. The dual counter rotating shafts decrease second order vertical shak- ing forces caused by component movement.
Page 982: Balance Shaft Timing
ENGINE 2.4L 9 - 63 BALANCE SHAFT (Continued) (2) Turn balance shafts until both shaft key ways are up, parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After instal- lation gear and balance shaft keyways must be up with gear timing marks meshed as shown in (Fig.
Page 983 9 - 64 ENGINE 2.4L BALANCE SHAFT (Continued) Fig. 114 Balance Shaft Drive 1 - SPROCKET 2 - SPECIAL TOOL 6052 (6) Turn crankshaft until number 1 cylinder is at top dead center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap.
Page 984: Balance Shaft Carrier Removal
ENGINE 2.4L 9 - 65 BALANCE SHAFT (Continued) BALANCE SHAFT CARRIER (10) If the sprockets are timed correctly, install the balance shaft bolts and tighten to 28 N·m (250 in. REMOVAL lbs.). A wood block placed between crankcase and (Refer to 9 - ENGINE/VALVE TIMING/BALANCE crankshaft counterbalance will prevent crankshaft SHAFT - REMOVAL) and gear rotation.
Page 985: Introduction
9 - 66 ENGINE 4.0L ENGINE 4.0L TABLE OF CONTENTS page page ENGINE 4.0L INTAKE/EXHAUST VALVES & SEATS DESCRIPTION DESCRIPTION ......88 DESCRIPTION - ENGINE BLOCK .
Page 986 ENGINE 4.0L 9 - 67 HYDRAULIC LIFTERS DESCRIPTION ......107 STANDARD PROCEDURE - ENGINE OIL REMOVAL ......107 SERVICE .
Page 987: Description - Engine Block
9 - 68 ENGINE 4.0L ENGINE 4.0L DESCRIPTION DESCRIPTION - ENGINE BLOCK The cylinder block is a cast iron inline six cylinder design. The cylinder block is drilled forming galleries for both oil and coolant (Fig. 1). Fig. 2 Engine Firing Order Fig.
Page 988: Diagnosis And Testing
ENGINE 4.0L 9 - 69 ENGINE 4.0L (Continued) DIAGNOSIS AND TESTING) (MECHANICAL) for DIAGNOSIS AND TESTING possible causes and corrections of malfunctions. Additional tests and diagnostic procedures may be DIAGNOSIS AND TESTING - ENGINE necessary for specific engine malfunctions that can DIAGNOSIS - INTRODUCTION not be isolated with the Service Diagnosis charts.
Page 989 9 - 70 ENGINE 4.0L ENGINE 4.0L (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE CRANKS BUT WILL NOT 1. No spark 1. Check for spark. (Refer to 8 - START ELECTRICAL/IGNITION CONTROL - SPECIFICATIONS), for correct procedures. 2. No fuel 2. Perform fuel pressure test (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING), and if...
Page 990: Diagnosis And Testing- Engine Diagnosis - Mechanical
ENGINE 4.0L 9 - 71 ENGINE 4.0L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 2. Engine idle speed too low 2. Check Idle Air Control circuit. 3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap plugs spark plugs. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING) 4.
Page 991 9 - 72 ENGINE 4.0L ENGINE 4.0L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash adjusters 8. Worn valve guides 8. Inspect all valve guides and replace as necessary 9. Excessive runout of valve seats 9.
Page 992: Diagnosis And Testing-Cylinder Compression Pressure
ENGINE 4.0L 9 - 73 ENGINE 4.0L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Oil pump relief valve stuck 7. Remove valve to inspect, clean and reinstall 8. Oil pump suction tube loose, 8. Inspect suction tube and clean or broken, bent or clogged replace if necessary 9.
Page 993: Standard Procedure
9 - 74 ENGINE 4.0L ENGINE 4.0L (Continued) • Any causes for combustion/compression pressure kPa (200 psi) maximum and 552 kPa (80 psi) recom- loss. mended. (1) Check the coolant level and fill as required. DO (7) Perform the test procedures on each cylinder NOT install the radiator cap.
Page 994: Standard Procedure - Hydrostatic Lock
The sealant diameter should installed in the vehicle. be 1.00 mm (0.04 inch) or less. Be certain the mate- A short block is identified with the letter “S”...
Page 995: Standard Procedure - Engine Performance
ENGINE/RADIATOR - REMOVAL) or radiator/con- PERFORMANCE denser (if equipped with A/C). It is important that the vehicle is operating to its (13) Disconnect the heater hoses at the engine optimum performance level to maintain fuel economy thermostat housing and water pump (Fig. 4).
Page 996: Installation
(27) Disconnect the wires from the engine starter motor solenoid. INSTALLATION (28) Remove the engine starter motor (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR CAUTION: When installing the engine into a vehicle REMOVAL). equipped with an automatic transmission, be care- (29) Disconnect oxygen sensor...
Page 997 - HEATING & AIR CONDITIONING/PLUMBING - (15) Tighten the engine mount-to-bracket bolts. STANDARD PROCEDURE). (16) Connect the vehicle speed sensor wire connec- (38) Connect the radiator hoses and automatic tions and tighten the screws. transmission fluid cooler pipes, if equipped.
Page 998: Specifications
ENGINE 4.0L 9 - 79 ENGINE 4.0L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION ENGINE - 4.0L Base Circle Runout 0.03 mm (MAX) (0.001 in.) DESCRIPTION SPECIFICATION Valve Lift Engine Type In-line 6 Cylinder Intake 10.350 mm (0.4075 in.) Bore and Stroke 98.4 x 86.69 mm Exhaust 10.528 mm (0.4145 in.) (3.88 x 3.413 in.)
Page 999: Engine 4.0L
9 - 80 ENGINE 4.0L ENGINE 4.0L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Connecting Rod Journal Piston Pin Bore Diameter 23.59 to 23.62 mm Diameter 53.17 to 53.23 mm (0.9288 to 0.9298 in.) (2.0934 to 2.0955 in.) Bore (Less Bearings) 56.08 to 56.09 mm Connecting Rod Journal 27.18 to 27.33 mm (2.2080 to 2.2085 in.)
Page 1000 ENGINE 4.0L 9 - 81 ENGINE 4.0L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Flatness 0.03 mm per 25 mm Tip Refinishing (Max. 0.25 mm (0.010 in.) Allowable) (0.001 in. per 1 in.) 0.05 mm per 152 mm VALVE SPRINGS (0.002 in. per 6 in.) Free Length (Approx.) 47.65 mm (1.876 in.) Flatness Max.
Page 1001: Torque - 4.0L Engine
9 - 82 ENGINE 4.0L ENGINE 4.0L (Continued) TORQUE - 4.0L ENGINE DESCRIPTION SPECIFICATION Oil Control Ring 4.035 to 4.060 mm DESCRIPTION N·m (0.1589 to 0.1598 in.) Lbs. Lbs. Piston Ring Groove A/C Compressor—Bolts — Diameter Block Heater—Nut — No.1 Compression Ring 88.39 to 88.65 mm Camshaft Sprocket—Bolt —...
Page 1002: Air Cleaner Element Removal
ENGINE 4.0L 9 - 83 ENGINE 4.0L (Continued) AIR CLEANER ELEMENT DESCRIPTION N·m Lbs. Lbs. REMOVAL Fasteners #1-5 — (1) Loosen air tube clamp at housing cover (Fig. 7) . (2) Disconnect air tube at cover. Fasteners #6 and 7 —...
Page 1003: Cylinder Head Description
REMOVAL NOTE: This procedure can be done with the engine in or out of the vehicle. (1) Disconnect the battery negative cable. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRES- Fig.
Page 1004: Cleaning
NOTE: This procedure can be done with the engine ward (Fig. 9). Pull bolt No.14 out as far as it will go in or out of the vehicle. and then suspend the bolt in this position (tape around the bolt).
Page 1005 9 - 86 ENGINE 4.0L CYLINDER HEAD (Continued) CAUTION: During the final tightening sequence, (13) Install the engine cylinder head cover (Refer bolt No.11 will be tightened to a lower torque than ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). the rest of the bolts. DO NOT overtighten bolt No.11.
Page 1006: Cylinder Head Cover(S) Description
ENGINE 4.0L 9 - 87 (9) Remove the engine cylinder head cover and CYLINDER HEAD COVER(S) gasket. DESCRIPTION The cylinder head cover (Fig. 11) is made of stamped steel and incorporates the Crankcase Venti- lation (CCV) Hoses and the oil fill opening. Fig.
Page 1007: Installation
9 - 88 ENGINE 4.0L CYLINDER HEAD COVER(S) (Continued) INSTALLATION The cylinder head cover is isolated from the cylin- der head via grommets and a reusable molded rubber gasket. The grommet and limiter are retained in the cylinder head cover. (1) If a replacement cover is installed, transfer the CCV valve grommet and oil filler cap from the origi- nal cover to the replacement cover.
Page 1008 ENGINE 4.0L 9 - 89 INTAKE/EXHAUST VALVES & SEATS (Continued) angle with a good dressing stone. Remove only enough metal to provide a smooth finish. (2) Use tapered stones to obtain the specified seat width when required. (3) Control valve seat runout to a maximum of 0.0635 mm (0.0025 in.) (Fig.
Page 1009: Removal
9 - 90 ENGINE 4.0L INTAKE/EXHAUST VALVES & SEATS (Continued) REMOVAL INSTALLATION NOTE: This procedure is done with the engine cyl- NOTE: This procedure is done with the engine cyl- inder head removed from the block. inder head removed from the block. (1) Remove the engine cylinder head (Refer to 9 - (1) Thoroughly clean the valve stems and the valve ENGINE/CYLINDER HEAD - REMOVAL) from the...
Page 1010: Rocker Arm / Adjuster Assembly
NOTE: This procedure can be done with the engine pitted. in or out of the vehicle. Inspect each push rod end for excessive wear and replace as required. If any push rod is excessively...
Page 1011: Installation
VALVE STEM SEALS NOTE: This procedure can be done with the engine DESCRIPTION in or out of the vehicle. The valve stem seals (Fig. 24) are made of rubber and incorporate a garter spring to maintain consis- (1) Lubricate the ball ends of the push rods with tent lubrication control.
Page 1012: Valve Springs Description
ENGINE 4.0L 9 - 93 VALVE SPRINGS DESCRIPTION The valve springs (Fig. 25) are made of high strength silicon chrome spring steel. The springs are common for both intake and exhaust valves. Fig. 26 Valve Spring Tester 1 - TORQUE WRENCH 2 - VALVE SPRING TESTER Each valve spring is held in place by a retainer and a set of conical valve locks.
Page 1013: Installation
9 - 94 ENGINE 4.0L VALVE SPRINGS (Continued) Fig. 27 Valve and Valve Components Fig. 28 Valve and Valve 1 - VALVE LOCKS (3–BEAD) 1 - VALVE LOCKS (3–BEAD) 2 - RETAINER 2 - RETAINER 3 - VALVE STEM OIL SEAL 3 - VALVE STEM OIL SEAL 4 - INTAKE VALVE 4 - INTAKE VALVE...
Page 1014: Engine Block Cleaning
ENGINE 4.0L 9 - 95 (5) Rotate measuring device 90° and repeat steps ENGINE BLOCK above. (6) Determine out-of-roundness by comparing the CLEANING difference between each measurement. Thoroughly clean the oil pan and engine block gas- (7) If cylinder bore taper does not exceed 0.025 ket surfaces.
Page 1015: Removal - Camshaft Bearings
9 - 96 ENGINE 4.0L CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (10) Remove the timing case cover (Refer to 9 - REMOVAL ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). REMOVAL - CAMSHAFT BEARINGS (11) Rotate the crankshaft until the crankshaft The camshaft rotates within four steel-shelled, sprocket timing mark is aligned on centerline with babbitt-lined bearings that are pressed into the cyl-...
Page 1016 ENGINE 4.0L 9 - 97 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) Fig. 33 Crankshaft / Camshaft Chain Drive Fig. 32 Crankshaft / Camshaft Sprocket Timing Mark Installation—Typical Alignment 1 - CAMSHAFT SPROCKET 2 - TIMING MARKS 1 - CAMSHAFT SPROCKET 3 - CRANKSHAFT SPROCKET 2 - TIMING MARKS 3 - CRANKSHAFT SPROCKET...
Page 1017: Connecting Rod Bearings
9 - 98 ENGINE 4.0L CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (16) Install the serpentine drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). NOTE: During installation, lubricate the hydraulic valve tappets and all valve components with Mopar Engine Oil Supplement, or equivalent.
Page 1018 ENGINE 4.0L 9 - 99 CONNECTING ROD BEARINGS (Continued) Fig. 38 Rod and Piston Assembly Installation torque. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication. Fig. 39 Measuring Bearing Clearance with (7) Remove the bearing cap and determine amount Plastigage of bearing-to- journal clearance by measuring the 1 - PLASTIGAGE SCALE...
Page 1019: Description
9 - 100 ENGINE 4.0L CONNECTING ROD BEARINGS (Continued) (11) FOR EXAMPLE: If the initial clearance was 0.0762 mm (0.003 inch), 0.025 mm (0.001 inch) undersize inserts would reduce the clearance by 0.025 mm (0.001 inch). The clearance would be 0.002 inch and within specification.
Page 1020 ENGINE 4.0L 9 - 101 CRANKSHAFT MAIN BEARINGS (Continued) Fig. 42 Crankshaft Journal Size Paint I.D. Location 1 - NO. 7 MAIN JOURNAL SIZE PAINT MARK 3 - NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK 2 - NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK 4 - NO.
Page 1021 9 - 102 ENGINE 4.0L CRANKSHAFT MAIN BEARINGS (Continued) inch). The clearance would then be 0.0508 mm (0.002 MAIN BEARING FITTING CHART inch) and within the specification. A 0.051 mm (0.002 inch) undersize bearing insert and a 0.0254 mm Corresponding Crankshaft Journals (0.001 inch) undersize insert would reduce the origi- Crankshaft Bearing...
Page 1022: Removal
TRICAL/IGNITION CONTROL/SPARK PLUG Code Insert Size Insert Size REMOVAL). 63.4873 - (3) Raise the vehicle. 63.4746 (4) Remove the oil pan (Refer to 9 - ENGINE/LU- Yellow - Yellow - Yellow BRICATION/OIL PAN - REMOVAL) and oil pump Standard Standard (2.4995 -...
Page 1023: Inspection
9 - 104 ENGINE 4.0L CRANKSHAFT MAIN BEARINGS (Continued) imbedded in the lining. Normal main bearing insert wear patterns are illustrated (Fig. 47). In general the lower bearing half will have a heaver wear pattern. Fig. 47 Main Bearing Wear Patterns 1 - UPPER INSERT Fig.
Page 1024: Crankshaft Oil Seal - Front
95 N·m (70 ft. lbs.) torque and finally tighten to N·m (25 ft. lbs.) torque. 108 N·m (80 ft. lbs.) torque. (16) Lower the vehicle. (9) Rotate the crankshaft after tightening each (17) Install the spark plugs. Tighten the plugs to main bearing cap to ensure the crankshaft rotates 37 N·m (27 ft.
Page 1025: Installation
9 - 106 ENGINE 4.0L CRANKSHAFT OIL SEAL - FRONT (Continued) INSTALLATION CRANKSHAFT OIL SEAL - This procedure is done with the timing case cover REAR installed. (1) Position the replacement oil seal on Timing REMOVAL Case Cover Alignment and Seal Installation Tool The crankshaft rear main bearing oil seal consists 6139 with seal open end facing inward.
Page 1026: Hydraulic Lifters Description
ENGINE 4.0L 9 - 107 CRANKSHAFT OIL SEAL - REAR (Continued) HYDRAULIC LIFTERS DESCRIPTION Valve lash is controlled by hydraulic tappets located inside the cylinder block, in tappet bores above the camshaft. REMOVAL NOTE: Retain all the components in the same order as removed.
Page 1027: Installation
9 - 108 ENGINE 4.0L HYDRAULIC LIFTERS (Continued) (2) Lift the ram and position the tappet (with the (1) Dip each tappet in Mopar Engine Oil Supple- ball bearing) inside the tester cup. ment, or equivalent. (3) Lower the ram, then adjust the nose of the ram (2) Use Hydraulic Valve Tappet Removal/Installa- until it contacts the ball bearing.
Page 1028: Standard Procedure - Piston Fitting
ENGINE 4.0L 9 - 109 PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE - PISTON FITTING PISTON SIZE CHART (1) To correctly select the proper size piston, a cyl- inder bore gauge, capable of reading in 0.003 mm CYLINDER BORE SIZE PISTON LETTER SIZE (.0001 in.) INCREMENTS is required.
Page 1029: Installation
ENGINE 4.0L PISTON & CONNECTING ROD (Continued) ridge from the top end of the cylinder walls. Use a (11) Lower the vehicle until it is about 2 feet from protective cloth to collect the cuttings. the floor. (6) Raise the vehicle.
Page 1030 (11) Install main bearing cap brace (Fig. 58). Tighten nuts to 47 N·m (35 ft. lbs.). (6) Raise the vehicle. (12) Install the oil pan and gasket (Refer to 9 - (7) Each bearing insert is fitted to its respective...
Page 1031: Piston Rings
9 - 112 ENGINE 4.0L PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING (1) Carefully clean the carbon from all ring grooves. Oil drain openings in the oil ring groove and pin boss must be clear. DO NOT remove metal from the grooves or lands.
Page 1032 ENGINE 4.0L 9 - 113 PISTON RINGS (Continued) (5) The oil control rings are symmetrical, and can be installed with either side up. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails. (6) The two compression rings are different and cannot be interchanged.
Page 1033: Vibration Damper Removal
9 - 114 ENGINE 4.0L PISTON RINGS (Continued) Ring Gap Orientation VIBRATION DAMPER • Position the gaps on the piston as shown (Fig. 69). REMOVAL • Oil spacer - Gap on center line of piston skirt. (1) Disconnect negative cable from battery. •...
Page 1034: Structural Support Removal
NOTE: Before the engine or the transmission can be removed the engine bending braces must be removed. (1) Raise and support vehicle. NOTE: Both left and right side bending braces are removed the sameway. Only the right side is shown.
Page 1035: Front Mount Removal
INSTALLATION (1) Disconnect negative cable from battery. The front mounts support the engine at each side. (2) Raise the vehicle and support the transmission. These supports are made of resilient rubber. (3) Remove the nuts holding the support cushion (1) If the engine support bracket was removed, to the skid plate (Fig.
Page 1036: Installation
(2) Remove the bolts holding the transmission sup- tighten to 75 N·m (55 ft. lbs.) torque. port bracket to transmission. (3) Remove the transmission support. (3) Remove the transmission support bracket. (4) Lower the vehicle. (5) Connect negative cable to battery. INSTALLATION MANUAL TRANSMISSION LUBRICATION (1) Position the transmission mount bracket to the transmission and install the bolts (Fig.
Page 1037: Diagnosis And Testing
ENGINE 4.0L LUBRICATION (Continued) channels the oil up to the main gallery which (4) If dye is not observed, drive the vehicle at var- extends the entire length of the block. ious speeds for approximately 24km (15 miles), and Galleries extend downward from the main oil gal- repeat inspection.If the oil leak source is not pos-...
Page 1038 ENGINE 4.0L 9 - 119 LUBRICATION (Continued) Fig. 77 Oil Lubrication System—4.0L Engine 1 - CAM/CRANK MAIN GALLERY (7) 5 - NUMBER 1 CAMSHFT BEARING JOURNAL 2 - TAPPET GALLERY 6 - CAMSHAFT SPROCKET 3 - TAPPET GALLERY 7 - TAPPET GALLERY 4 - CAMSHAFT BEARING...
Page 1039: Standard Procedure - Engine Oil Service
Run engine until achieving normal operating tem- perature. CAUTION: Do not exceed 20.6 kPa (3 psi). (1) Position the vehicle on a level surface and turn engine off. (5) If the leak is not detected, very slowly turn the (2) Hoist and support vehicle on safety stands.
Page 1040: Oil Filter
(6) Add oil only if level is below the ADD mark on dipstick. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this Fig. 81 Oil Filter—4.0L Engine procedure.
Page 1041: Installation
REMOVAL With a wiping cloth, clean the gasket sealing surface (1) Disconnect negative cable from battery. (Fig. 79) of oil and grime. (2) Raise the vehicle. (3) Remove the oil pan drain plug and drain the INSTALLATION engine oil. (1) Lightly lubricate oil filter gasket with engine (4) Disconnect the exhaust pipe at the exhaust oil or chassis grease.
Page 1042 9.5 N·m (84 in. lbs.) torque. Install the 5/16 Tighten the plug to 34 N·m (25 ft. lbs.) torque. inch oil pan bolts (Fig. 87). Tighten these bolts to 15 (17) Lower the vehicle. N·m (132 in. lbs.) torque. (18) Connect negative cable to battery.
Page 1043: Engine Oil Pressure Sensor
4 - OIL INLET TUBE instrument panel on either a CCD or PCI bus circuit 5 - OIL PUMP (depending on vehicle line) to operate the oil pressure 6 - STRAINER ASSEMBLY gauge and the check gauges lamp. Ground for the...
Page 1044: Timing Belt / Chain Cover(S)
ENGINE 4.0L 9 - 125 VALVE TIMING (Continued) (9) Rotate the crankshaft clockwise (viewed from the front of the engine) until the dial indicator pointer indicates 0.305 mm (0.012 inch) travel dis- tance (lift). (10) The timing notch index on the vibration damper should be aligned with the TDC mark on the timing degree scale.
Page 1045: Timing Belt/Chain And Sprockets
9 - 126 ENGINE 4.0L TIMING BELT / CHAIN COVER(S) (Continued) crankshaft, install the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION). (10) Install the A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION) (if equipped) and generator bracket assembly.
Page 1046: Intake Manifold Description
(9) Install the fan, hub assembly and shroud (3) Remove the air cleaner assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - (4) Remove the throttle cable, vehicle speed control INSTALLATION). cable (if equipped) and the transmission line pres- (10) Connect negative cable to battery.
Page 1047: Exhaust Manifold Description
(11) Connect the vacuum hoses previously removed. (4) Install washer and fastener Numbers 1, 2, 4, 5, (12) Install throttle cable, vehicle speed control 8, 9, 10 and 11 (Fig. 94). cable (if equipped). (5) Install washer and fastener Numbers 6 and 7 (13) Install the transmission line pressure cable (if (Fig.
Page 1048 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page EXHAUST SYSTEM REMOVAL — 4.0L ..... . 7 DESCRIPTION .
Page 1049: Exhaust System
11 - 2 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) Fig. 1 Exhaust system - 2.4L Engine 1 - CATALYTIC CONVERTER 4 - EXHAUST PIPE TO EXHAUST MANIFOLD FLANGE 2 - TAILPIPE 5 - MINI CATALYTIC CONVERTER 3 - MUFFLER...
Page 1050 EXHAUST SYSTEM 11 - 3 EXHAUST SYSTEM (Continued) Fig. 2 Exhaust System - 4.0L 1 - TAILPIPE 4 - EXHAUST PIPE TO CATALYTIC CONVERTER FLANGE 2 - MUFFLER 5 - MINI CATALYTIC CONVERTER 3 - CATALYTIC CONVERTER 6 - EXHAUST PIPE...
Page 1051: Description
11 - 4 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) 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 to specified LEAKING EXHAUST GASES torque at leaking joints. 2.
Page 1052: Removal - 2.4L
CATALYTIC CONVERTER (Continued) The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but exces- sive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur.
Page 1053: Installation - 2.4L
11 - 6 EXHAUST SYSTEM CATALYTIC CONVERTER (Continued) (1) Raise and support the vehicle. (3) Install exhaust pipe onto exhaust manifold DO (2) Saturate the studs and nuts with a Mopar NOT tighten bolts at this time. rust penetrant. Allow 5 minutes for penetration.
Page 1054: Removal - 4.0L
(6) Tighten muffler to catalytic converter flange sor. retaining nuts to 28.5 N·m (21 ft. lbs.). (1) Raise and support the vehicle. (7) Tighten exhaust pipe to exhaust manifold (2) Saturate the studs and nuts with a Mopar mounting bolts to 31 N·m (23 ft. lbs.).
Page 1055: Installation - 4.0L
Heat shields (Fig. 7) are made of stamped/formed steel, or metal foil. Exhaust heat shields are needed to protect both the vehicle and the environment from the high tem- Fig. 8 Muffler Heat Shield - Rear peratures developed by the catalytic converter. The...
Page 1056: Installation
(1) Raise the vehicle and support the rear of the DESCRIPTION vehicle by the side rails and allow the axle to hang Both the 2.4L and 4.0L engines use a galvanized free. steel muffler (Fig. 10) to control exhaust noise levels (2) Remove the tailpipe hangers from the insula- and exhaust back pressure.
Page 1057 6 - MUFFLER TO CATALYTIC CONVERTER FLANGE 3 - TAILPIPE HANGERS 7 - NUTS 4 - TAILPIPE 8 - CATALYTIC CONVERTER (5) Tighten muffler to catalytic converter flange nuts to 28.5 N·m (21 ft. lbs.). (6) Lower vehicle. (7) Start engine check for leaks.
Page 1058: Tailpipe
The tailpipe (Fig. 12) is made of galvanized steel OPERATION The tailpipe channels the exhaust out of the muf- fler and out from under the vehicle to control noise and prevent exhaust gas fumes from entering the passenger compartment. Fig. 12 Tailpipe - Typical...
Page 1060 FRAME & BUMPERS 13 - 1 FRAME & BUMPERS TABLE OF CONTENTS page page FRAME & BUMPERS SPECIFICATIONS SPECIFICATIONS FRAME DIMENSIONS ....5 TORQUE SPECIFICATIONS .
Page 1061: Frame & Bumpers
(Fig. 2). (3) If equipped, remove the tow hook. (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT TOW HOOK - REMOVAL) (4) Separate the bumper from the vehicle. Fig. 1 BUMPER EXTENSION 1 - BUMPER EXTENSION 2 - FRONT BUMPER...
Page 1062: Rear Extension Removal
ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VER- IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. DO NOT ALLOW OPEN FLAME TO CONTACT PLASTIC BODY PANELS.
Page 1063 Use MIG, TIG or arc welding equipment to repair welded frame components. Frame components that have been damaged should be inspected for cracks before returning the vehicle to use. If cracks are found in accessible frame com- ponents perform the following procedures.
Page 1064: Specifications
Locating Point (PLP), or from center to center of PLP and fastener location. VEHICLE PREPARATION Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface.
Page 1065 13 - 6 FRAME & BUMPERS FRAME (Continued)
Page 1066: Transfer Case Skid Plate Removal
SION ARE SUPPORTED BY THE TRANSFER CASE SKID PLATE. BEFORE REMOVING THE TRANSFER CASE SKID PLATE, ENSURE THAT THE TRANSMIS- SION IS PROPERLY SUPPORTED. (1) Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - Fig. 8 TRANSMISSION MOUNT - AUTOMATIC STANDARD PROCEDURE)
Page 1067: Installation
(1) Attach the skid plate to the fuel tank strap. INSTALLATION (2) Position and support the skid plate under the (1) Position the skid plate on the vehicle. fuel tank. (2) Install the bolts attaching the skid plate to the (3) Install the nuts to attach the skid plate to the frame and tighten to 74 N·m (55 ft.
Page 1068: Front Tow Hook Removal
(1) Position the skid plate in place and support. REMOVAL (2) Install the bolts and tighten the plate to frame (1) Raise and support the vehicle. (Refer to bolts to 68 N·m (50 ft. lbs.). LUBRICATION & MAINTENANCE/HOISTING - (3) Tighten the plate to transfer case skid plate STANDARD PROCEDURE) bolts to 29 N·m (21 ft.
Page 1070 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY ......1 FUEL INJECTION .
Page 1071: Fuel Delivery
14 - 2 FUEL DELIVERY FUEL DELIVERY (Continued) • fuel tank filler tube cap (4) Attempt restarting engine until it will no • check valve(s) longer run. • accelerator pedal (5) Turn ignition key to OFF position. • throttle cable CAUTION: Steps 1, 2, 3 and 4 must be performed to OPERATION relieve high pressure fuel from within fuel rail.
Page 1072: Description
FUEL DELIVERY 14 - 3 FUEL DELIVERY (Continued) TORQUE - FUEL DELIVERY DESCRIPTION Ft. Lbs. In. Lbs. Accelerator Pedal Bracket Mounting Nuts Fuel Hose Clamps Fuel Rail Mounting Bolts - 2.4L Fuel Rail Mounting Bolts or Nuts - 4.0L Fuel Tank Mounting Strap Refer to service manual Bolts text.
Page 1073: Fuel Filter/Pressure Regulator
14 - 4 FUEL DELIVERY FUEL DELIVERY (Continued) through the pressure regulator. A separate fuel return line is not used with any engine. REMOVAL The combination Fuel Filter/Fuel Pressure Regula- tor is located on the fuel pump module. The fuel pump module is located on top of fuel tank.
Page 1074: Fuel Level Sending Unit / Sensor Description
14 - 5 FUEL FILTER/PRESSURE REGULATOR (Continued) (6) The molded arrow (Fig. 1) 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.
Page 1075: Removal
14 - 6 FUEL DELIVERY FUEL LEVEL SENDING UNIT / SENSOR (Continued) the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level.
Page 1076: Fuel Pump Description
FUEL PUMP injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a DESCRIPTION normal condition. Refer to the Fuel Pressure Leak The electric fuel pump is located inside of the fuel Down Test for more information.
Page 1077: Operation
(5) Rotate module until arrow (Fig. 1) is pointed STANT PRESSURE (EVEN WITH THE ENGINE OFF). toward front of vehicle (12 o’clock position). This step BEFORE SERVICING THE FUEL PUMP MODULE, must be done to prevent float/float rod assembly from...
Page 1078: Fuel Rail/Fuel Damper - 2.4L
FUEL DELIVERY 14 - 9 REMOVAL - 2.4L FUEL RAIL/FUEL DAMPER - 2.4L WARNING: THE FUEL SYSTEM IS UNDER CON- STANT PRESSURE EVEN WITH ENGINE OFF. DESCRIPTION - 2.4L BEFORE SERVICING FUEL RAIL, FUEL SYSTEM The fuel injector rail is used to mount the fuel PRESSURE MUST BE RELEASED.
Page 1079 14 - 10 FUEL DELIVERY FUEL RAIL/FUEL DAMPER - 2.4L (Continued) Fig. 10 MAP SENSOR LOCATION - 2.4L 1 - REAR OF INTAKE MANIFOLD 2 - MAP SENSOR 3 - ALIGNMENT PIN 4 - MOUNTING BOLT (TORX) 5 - ELECTRICAL CONNECTOR 6 - MAIN ENGINE HARNESS CONNECTORS Fig.
Page 1080: Fuel Rail - 4.0L Engine Description - 4.0L
FUEL DELIVERY 14 - 11 OPERATION - 4.0L FUEL RAIL - 4.0L ENGINE The fuel injector rail supplies the necessary fuel to DESCRIPTION - 4.0L each individual fuel injector. The fuel damper is used only to help control fuel The fuel rail is mounted to the intake manifold pressure pulsations.
Page 1081: Installation - 4.0L
14 - 12 FUEL DELIVERY FUEL RAIL - 4.0L ENGINE (Continued) (9) Disconnect automatic transmission cable at throttle body (if equipped). (10) Remove cable routing bracket at intake man- ifold. (11) If equipped, remove wiring harnesses at injec- tion rail studs by removing nuts. (12) Clean dirt/debris from each fuel injector at intake manifold.
Page 1082: Fuel Tank Description
(22) Remove both straps and remove tank from On this model, the fuel tank is mounted to the skid plate. vehicle skid plate. The skid plate is mounted to vehi- cle body. The tank and skid plate are removed as 1 INSTALLATION assembly.
Page 1083 (17) Fill fuel tank. Install filler cap. (18) Connect negative battery cable to battery. (19) Start vehicle and inspect for leaks. Fig. 17 EVAP CANISTER / LDP LOCATION 1 - RIGHT / REAR FENDER (WHEELHOUSE) 2 - BRACKET...
Page 1084 FUEL DELIVERY 14 - 15 FUEL TANK (Continued) Fig. 19 FUEL TANK/FUEL PUMP MODULE (TOP VIEW) 1 - VAPOR LINES (2) 8 - CHECK VALVE 2 - FUEL SUPPLY LINE 9 - FUEL MANAGEMENT VALVE 3 - ELECTRICAL CONNECTOR 10 - SKID PLATE 4 - MODULE LOCKNUT 11 - CHECK VALVE 5 - FUEL PUMP MODULE ASSEMBLY...
Page 1085: Inlet Filter Removal
14 - 16 FUEL DELIVERY INLET FILTER REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of fuel pump module (Fig. 22). The fuel pump module is located on top of fuel tank. Fig. 23 Fuel Pump Inlet Filter 1 - FUEL PUMP MODULE 2 - FUEL PUMP INLET FILTER cial tool for disconnection and removal.
Page 1086 FUEL DELIVERY 14 - 17 QUICK CONNECT FITTING (Continued) CAUTION: The interior components (o-rings, spac- ers) of some types of quick-connect fitting are not serviced separately. If service parts are not avail- able, do not attempt to repair a damaged fitting or fuel line.
Page 1087 14 - 18 FUEL DELIVERY QUICK CONNECT FITTING (Continued) Fig. 29 TYPICAL 2–TAB TYPE FITTING Fig. 27 DISCONNECTING SINGLE-TAB TYPE 1 - TAB(S) FITTING 2 - QUICK-CONNECT FITTING 1 - PULL TAB 2 - SCREWDRIVER 3 - QUICK-CONNECT FITTING Fig. 28 REMOVING PULL TAB 1 - FUEL TUBE OR FUEL SYSTEM COMPONENT 2 - PULL TAB 3 - QUICK-CONNECT FITTING...
Page 1088 (c) Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. (9) Latch Clips: Depending on vehicle model and engine, 2 different types of safety latch clips are used (Fig. 31) or (Fig. 32). Type-1 is tethered to fuel line and type-2 is not.
Page 1089: Flow Management Valve Description
EVAP canister. During tem component for damage. Replace as necessary. vehicle run, the vapors are metered through an ori- (2) Prior to connecting quick-connect fitting to fice to the EVAP canister. It is also used as a liquid...
Page 1090 FUEL INJECTION 14 - 21 FUEL INJECTION TABLE OF CONTENTS page page FUEL INJECTION OPERATION ......29 DESCRIPTION .
Page 1091: Fuel Injection
Throttle Position Sensor Mounting Screws - 2.4L/4.0L Vehicle Speed Sensor Mounting Bolt (1) From inside vehicle, hold up accelerator pedal. ACCELERATOR PEDAL Remove plastic cable retainer (clip) and throttle cable core wire from upper end of accelerator pedal arm REMOVAL (Fig.
Page 1092: Crankshaft Position Sensor
FUEL INJECTION 14 - 23 ACCELERATOR PEDAL (Continued) The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel (targetwheel) is a part of the engine crankshaft (Fig.
Page 1093: Removal
14 - 24 FUEL INJECTION CRANKSHAFT POSITION SENSOR (Continued) Fig. 4 CKP SENSOR LOCATION - 2.4L 1 - RIGHT FRONT ENGINE MOUNT 2 - CKP SENSOR Fig. 3 CKP OPERATION - 4.0L 3 - MOUNTING BOLT 4 - ELECTRICAL CONNECTOR 1 - CRANKSHAFT POSITION SENSOR 2 - FLYWHEEL 3 - FLYWHEEL NOTCHES...
Page 1094 FUEL INJECTION 14 - 25 CRANKSHAFT POSITION SENSOR (Continued) Fig. 8 CKP - TWO-NUT MOUNTING Fig. 6 CKP (WITH 42RLE AUTO. TRANS.) 1 - TRANSMISSION BELLHOUSING 1 - CKP SENSOR 2 - MOUNTING NUTS (2) 2 - MOUNTING BOLT 3 - CRANKSHAFT POSITION SENSOR 3 - ELEC.
Page 1095: Fuel Injector
If installing (PCM). The PCM will adjust injector pulse width by (returning) a used sensor to vehicle, a new paper switching the ground path to each individual injector spacer must be installed to bottom of sensor. This on and off.
Page 1096: Operation - Fuel Injector
FUEL INJECTION 14 - 27 FUEL INJECTOR (Continued) OPERATION - FUEL INJECTOR The top (fuel entry) end of the injector (Fig. 10) is attached into an opening on the fuel rail. The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end.
Page 1097: Installation
14 - 28 FUEL INJECTION FUEL PUMP RELAY (Continued) IAC opens an air passage around the throttle blade which increases RPM. The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP dur- ing decel (keep engine from stalling).
Page 1098: Removal
FUEL INJECTION 14 - 29 IDLE AIR CONTROL MOTOR (Continued) per motor control engine rpm, is the recording of the (4) Remove IAC motor from throttle body. last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accom- plished by delaying compressor operation for approx- imately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded...
Page 1099: Removal
14 - 30 FUEL INJECTION INTAKE AIR TEMPERATURE SENSOR (Continued) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. REMOVAL 2.4L The intake manifold air temperature (IAT) sensor is installed into the intake manifold plenum at the rear end of the intake manifold (Fig.
Page 1100: Map Sensor
Tighten sensor to 28 N·m (20 ft. lbs.) torque. As the altitude increases, the air becomes thinner (2) Connect electrical connector to sensor. (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, MAP SENSOR the barometric pressure needs to be updated.
Page 1101: Removal
14 - 32 FUEL INJECTION MAP SENSOR (Continued) REMOVAL 2.4L The Manifold Absolute Pressure (MAP) sensor is mounted into the rear of the intake manifold (Fig. 18). An o-ring is used to seal the sensor to the intake manifold (Fig. 19). (1) Disconnect electrical connector at sensor.
Page 1102: O2 Heater Relay
Depending Open Loop operation, the PCM ignores the O2 sensor on the engine or emission package, the vehicle may input. The PCM adjusts injector pulse width based use a total of either 2 or 4 sensors.
Page 1103: Removal
SENSOR. The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. (1) Raise and support vehicle. Upstream Sensors - Engine Equipped With 4 (2) Disconnect wire connector from O2S sensor. Sensors: Two upstream sensors are used (1/1 and 2/1).
Page 1104: Installation
PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. (1) Raise and support vehicle. (2) Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor.
Page 1105: Removal
14 - 36 FUEL INJECTION THROTTLE BODY (Continued) A (factory adjusted) set screw is used to mechani- speed using this screw. All idle speed functions are cally limit the position of the throttle body throttle controlled by the Powertrain Control Module (PCM). plate.
Page 1106: Throttle Control Cable
Plastic cable retainer snaps into top of pedal arm. (2) Remove cable core wire at pedal arm. (3) From inside vehicle, pinch both sides of cable housing retainer tabs (Fig. 26) at dash panel. Remove cable housing from dash panel and pull into engine compartment.
Page 1107 (Fig. 28). Plastic cable retainer (clip) snaps into pedal arm. (2) Remove cable core wire at pedal arm. (3) From inside vehicle, pinch both sides of cable housing retainer tabs (Fig. 28) at dash panel. Remove cable housing from dash panel and pull into engine compartment.
Page 1108: Installation
This information is dash panel until retaining tabs lock into panel. needed to assist in performing the following calcula- (5) From inside vehicle, slide throttle cable core tions: wire into opening (slot) in top of pedal arm.
Page 1109 14 - 40 FUEL INJECTION THROTTLE POSITION SENSOR (Continued) Fig. 32 TPS MOUNTING SCREWS - 4.0L 1 - MOUNTING SCREWS 2 - TPS Fig. 31 TPS/IAC MOTOR - 2.4L 1 - THROTTLE POSITION SENSOR (TPS) 2 - MOUNTING SCREWS 3 - IDLE AIR CONTROL MOTOR (IAC) 4 - MOUNTING SCREWS (4) Manually operate throttle (by hand) to check for any TPS binding before starting engine.
Page 1110 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page STEERING DIAGNOSIS AND TESTING - POWER DESCRIPTION ......1 STEERING FLOW AND PRESSURE .
Page 1111 19 - 2 STEERING STEERING (Continued) OPERATION The gear acts as a rolling thread between the worm shaft and rack piston. The worm shaft is sup- ported by a thrust bearing at the upper end. When the worm shaft is turned from input from the steer- ing column the rack piston moves.
Page 1112 4. High friction in steering gear. 4. Test and adjust as necessary. 5. Ball joints binding. 5. Inspect and repair as necessary. NOTE: Some roads will cause a vehicle to drift, due to the crown in the road.
Page 1113 FLOW AND PRESSURE The following procedure is used to test the opera- tion of the power steering system on the vehicle. This test will provide the gallons per minute (GPM) or flow rate of the power steering pump along with the maximum relief pressure.
Page 1114 STEERING 19 - 5 STEERING (Continued) • Pressures within 345 kPa (50 psi) of each other (8) Start engine and let idle long enough to circu- late power steering fluid through flow/pressure test but below specifications, replace pump. gauge. (13) Open the test valve and turn the steering (9) Shut off the engine and check the fluid level, wheel to the extreme left and right positions against add fluid as necessary.
Page 1115 19 - 6 COLUMN COLUMN TABLE OF CONTENTS page page COLUMN INSTALLATION ......10 DESCRIPTION ......6 KEY-IN IGNITION SWITCH OPERATION - SERVICE PRECAUTIONS .
Page 1116 COLUMN 19 - 7 COLUMN (Continued) (4) Remove the steering wheel with an appropriate (5) Turn ignition cylinder to the on position and puller (Fig. 1). remove cylinder by pressing release through lower shroud access hole (Fig. 3) (Refer to 19 - STEERING/ NOTE: Ensure the puller jaws are seated in the COLUMN/LOCK CYLINDER HOUSING - REMOV- pockets (Fig.
Page 1117 (10) Disconnect and remove the wiring harness 5 - SKIM from the column (Fig. 6). INSTALLATION NOTE: If vehicle is equipped with automatic trans- (1) Align and install column into the steering cou- mission, remove shifter interlock cable from the pler.
Page 1118: Description
COLUMN 19 - 9 COLUMN (Continued) (10) Install the ignition lock cylinder. (Refer to 19 - NOTE: If equipped with cruise control, connect STEERING/COLUMN/LOCK CYLINDER HOUSING clock spring harness to cruise switch harness on - INSTALLATION). the steering wheel. (11) Install the knee blocker and the knee blocker (12) Install the steering wheel and tighten bolt to cover, (Refer to 23 - BODY/INSTRUMENT PANEL/ 54 N·m (40 ft.
Page 1119: Removal
19 - 10 COLUMN IGNITION SWITCH (Continued) REMOVAL The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before removing ignition switch. (1) Remove key cylinder. (Refer to 19 - STEER- ING/COLUMN/LOCK CYLINDER HOUSING...
Page 1120: Diagnosis And Testing - Key-In Ignition Switch
COLUMN 19 - 11 KEY-IN IGNITION SWITCH (Continued) DIAGNOSIS AND TESTING - KEY-IN IGNITION SWITCH For circuit descriptions and diagrams, Refer to the appropriate sections on the individual components. WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER ELECTRICAL PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING...
Page 1121: Steering Wheel Removal
19 - 12 COLUMN STEERING WHEEL REMOVAL (1) Disable and remove the drivers side airbag.(Re- fer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIR- BAG - REMOVAL). (2) Partially remove the steering wheel bolt and leave the bolt in the column. (3) Install puller C-3894–A or equivalent using the top of the bolt to push on.
Page 1122 GEAR 19 - 13 GEAR TABLE OF CONTENTS page page GEAR ADJUSTMENTS ......15 DESCRIPTION ......13 SPECIFICATIONS OPERATION .
Page 1123 19 - 14 GEAR GEAR (Continued) Fig. 4 STEERING GEAR Fig. 3 POWER STEERING GEAR & PUMP - 2.4L 1 - VALVE HOUSING O-RING 1 - REMOTE RESERVOIR 2 - ADJUSTER NUT 2 - POWER STEERING PUMP 3 - POWER STEERING LINE FITTINGS 3 - PUMP MOUNT BRACKET 4 - INPUT SHAFT HOUSING GASKET 4 - MOUNTING BOLTS (3)
Page 1124 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. Remove gear from the vehicle and drain the fluid. Then mount gear in a vise to perform adjustments.
Page 1125 19 - 16 GEAR GEAR (Continued) SPECIFICATIONS POWER STEERING GEAR SPECIFICATIONS DESCRIPTION SPECIFICATION Steering Gear Recirculating Ball Type Steering Gear 15:24 Gear Ratio Worm Shaft Bearing 0.53–.93 N·m (3.5–8 in. Preload lbs.) Pitman Shaft Over- .133 N·m (1.17 in. lbs.) + Center Drag Worm Shaft Preload New Gear (under 400...
Page 1126 CAUTION: If any steering components are replaced or serviced an alignment must be performed, to ensure the vehicle meets all alignment specifica- tions. Fig. 1 Steering Linkage CAUTION: Components attached with a nut and cot- 1 - COTTER PIN ter pin must be torqued to specification.
Page 1127: Description
19 - 18 LINKAGE LINKAGE (Continued) SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Pitman Arm — Shaft Drag Link — Ball Studs Drag Link — Clamp Tie Rod Ends — Ball Studs Tie Rod Ends — Clamp Tie Rod —...
Page 1128: Damper Removal
LINKAGE 19 - 19 DAMPER PITMAN ARM REMOVAL REMOVAL (1) Place the front wheels in a straight ahead posi- (1) Remove the cotter pin and nut from the drag tion. link at the pitman arm. (2) Remove the steering dampener retaining nut (2) Remove the drag link ball stud from the pit- and bolt from the axle bracket (Fig.
Page 1129: Tie Rod End Removal
19 - 20 LINKAGE TIE ROD END REMOVAL (1) Remove the cotter pins and nuts at the steer- ing knuckle and drag link (Fig. 1). (2) Remove ball studs with puller tool C-4150R. (3) If necessary, loosen the end clamp bolts and remove the tie rod ends from the tube.
Page 1130 PUMP 19 - 21 PUMP TABLE OF CONTENTS page page PUMP OPERATION - RETURN LINE ... . 25 DESCRIPTION ......21 FLUID OPERATION .
Page 1131 (8) Stop the engine and check the fluid level and 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. CAUTION: Do not run a vehicle with foamy fluid for an extended period.
Page 1132 PUMP 19 - 23 PUMP (Continued) INSTALLATION INSTALLATION - 4.0L (1) Install pulley on pump. (Refer to 19 - STEER- ING/PUMP/PULLEY - INSTALLATION). (2) Install pump on the engine mounting bracket. (3) Install 3 pump mounting bolts and tighten to 27 N·m (20 ft.
Page 1133: Torque Chart
19 - 24 PUMP PUMP (Continued) SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Power Steering Pump — Bracket to Pump Power Steering Pump — Bracket to 4.0L Engine Power Steering Pump — Bracket to 2.4L Engine Power Steering Pump —...
Page 1134: Description - Pressure Line
ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or anti- freeze. The red color is not permanent and is not an...
Page 1135: Removal
19 - 26 PUMP POWER STEERING PRESSURE SWITCH (Continued) When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the normally closed switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling.
Page 1136: Removal - 4.0L
PUMP 19 - 27 RESERVOIR REMOVAL REMOVAL - 4.0L (1) Remove power steering pump. (Refer to 19 - STEERING/PUMP - REMOVAL). (2) Clean exterior of pump. (3) Clamp the pump body in a soft jaw vice. (4) Pry up tab and slide the retaining clips off (Fig. NOTE: Use new retaining clips for installation.
Page 1138 TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page page MANUAL - NV1500 ......1 TRANSFER CASE - NV231 .
Page 1139 (7) Remove propeller shafts. A correct lubricant level check can only be made (8) Remove transfer case shift linkage and vent when the vehicle is level. Also allow the lubricant to hose. settle for a minute or so before checking. These rec-...
Page 1140 MANUAL - NV1500 21 - 3 MANUAL - NV1500 (Continued) (17) Remove clutch release bearing, release fork (4) Remove shift tower bolts and remove tower and and retainer clip (Fig. 2). lever assembly (Fig. 4). Fig. 4 SHIFT TOWER Fig. 2 CLUTCH RELEASE BEARING 1 - SHIFT TOWER AND LEVER ASSEMBLY 1 - FORK 2 - SHIFT SOCKET...
Page 1141 21 - 4 MANUAL - NV1500 MANUAL - NV1500 (Continued) (6) Remove shift shaft detent plug with Remover 8117A (Fig. 6). Fig. 6 DETENT PULLER Fig. 8 INPUT SHAFT BEARING RETAINER 1 - REMOVER 1 - BEARING RETAINER 2 - OIL FEED 2 - DETENT PLUG (7) Remove shift shaft detent plunger and spring with a pencil magnet.
Page 1142 MANUAL - NV1500 21 - 5 MANUAL - NV1500 (Continued) Fig. 12 GEARTRAIN AND SHIFT COMPONENT 1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER AND SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT 7 - 1-2 FORK Fig.
Page 1143 21 - 6 MANUAL - NV1500 MANUAL - NV1500 (Continued) (2) Position shift socket off to the side so roll pin removal does not interfere with gears. (3) Drive out shift socket roll pin with a hammer and punch. NOTE: Use proper size punch to prevent damage to the shift shaft.
Page 1144 MANUAL - NV1500 21 - 7 MANUAL - NV1500 (Continued) (11) Remove reverse idler shaft, idler gear, bearing and thrust washer (Fig. 19). Fig. 21 REAR HOUSING GEARTRAIN Fig. 19 REVERSE IDLER ASSEMBLY (1) Remove 1-2 and fifth-reverse forks from syn- 1 - SUPPORT chro sleeves.
Page 1145 21 - 8 MANUAL - NV1500 MANUAL - NV1500 (Continued) (3) Remove third gear needle bearing (Fig. 22). Fig. 24 SECOND GEAR AND NEEDLE BEARING Fig. 22 THIRD GEAR NEEDLE BEARING 1 - SECOND GEAR 1 - THIRD GEAR NEEDLE BEARING 2 - SECOND GEAR NEEDLE BEARING (4) Remove retaining ring that secures two-piece thrust washer on shaft.
Page 1146 MANUAL - NV1500 21 - 9 MANUAL - NV1500 (Continued) (12) Remove output shaft bearing snap ring (Fig. 27). Fig. 29 FIFTH GEAR NEEDLE BEARING 1 - FIFTH GEAR NEEDLE BEARING Fig. 27 OUTPUT SHAFT BEARING SNAP RING 1 - OUTPUT SHAFT BEARING 2 - BEARING SNAP RING 3 - SNAP RING PLIERS (13) Remove output shaft bearing from shaft with...
Page 1147 21 - 10 MANUAL - NV1500 MANUAL - NV1500 (Continued) (17) Remove fifth-reverse synchro hub and sleeve Clean the shaft bearings with a mild solvent such with shop press (Fig. 31). as Mopar degreasing solvent, Gunk, or similar sol- vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry, or wipe them dry with clean shop towels.
Page 1148 MANUAL - NV1500 21 - 11 MANUAL - NV1500 (Continued) Fig. 33 SHIFT FORKS AND SHAFT 1 - SHIFT SHAFT 4 - 3-4 SHIFT FORK 2 - SHAFT LEVER 5 - 1-2 SHIFT FORK 3 - SHAFT LEVER BUSHING 6 - FIFTH-REVERSE SHIFT FORK NOTE: The front housing contains the countershaft front bearing race.
Page 1149 21 - 12 MANUAL - NV1500 MANUAL - NV1500 (Continued) Shift Socket Inspect shift socket for wear or damage. Replace socket if the roll pin or shift shaft bores are dam- aged. Replace socket if the ball seat is worn, or cracked.
Page 1150 MANUAL - NV1500 21 - 13 MANUAL - NV1500 (Continued) Fig. 37 REVERSE GEAR 1 - REVERSE GEAR Fig. 39 FIFTH-REVERSE SYNCHRO ASSEMBLY 1 - SPACER 2 - PRESS RAM 3 - REVERSE GEAR 4 - FIFTH-REVERSE SYNCHRO ASSEMBLY Fig. 38 REVERSE GEAR SYNCHRO RING 5 - CUP 6 - PRESS BLOCKS 1 - REVERSE GEAR...
Page 1151 21 - 14 MANUAL - NV1500 MANUAL - NV1500 (Continued) (6) Install fifth gear synchro ring in synchro hub and sleeve (Fig. 41). Fig. 43 FIFTH GEAR 1 - FIFTH GEAR 2 - BEARING Fig. 41 FIFTH GEAR SYNCHRO RING (10) Install output shaft bearing snap ring, spread 1 - FIFTH-SPEED SYNCHRO RING snap ring only enough to install it (Fig.
Page 1152 MANUAL - NV1500 21 - 15 MANUAL - NV1500 (Continued) (13) Install synchro cone onto first gear. Verify (15) Install first gear synchro ring (Fig. 47). synchro cone locating tabs are properly located to the recesses in first gear. Fig. 47 FIRST GEAR SYNCHRO RING 1 - FIRST GEAR SYNCHRO RING 2 - CUP 3 - FIRST GEAR...
Page 1153 21 - 16 MANUAL - NV1500 MANUAL - NV1500 (Continued) (17) Press 1-2 synchro onto output shaft with suit- able size pipe and shop press (Fig. 49). CAUTION: Align synchro ring and sleeve as hub is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.
Page 1154 MANUAL - NV1500 21 - 17 MANUAL - NV1500 (Continued) (21) Install second gear needle bearing on shaft (23) Install thrust washer pin to shaft and install (Fig. 52). two-piece thrust washer (Fig. 54). Verify washer halves are seated in shaft groove and pin reliefs are positioned at washer locating pin.
Page 1155 21 - 18 MANUAL - NV1500 MANUAL - NV1500 (Continued) (26) Install third gear on shaft and bearing (Fig. 56). Fig. 58 START 3-4 SYNCHRO HUB ON OUTPUT SHAFT 1 - GROOVED SIDE OF SLEEVE (TO FRONT) Fig. 56 THIRD GEAR 2 - 3-4 SYNCHRO ASSEMBLY 1 - THIRD GEAR (29) Press 3-4 synchro assembly onto output shaft...
Page 1156 MANUAL - NV1500 21 - 19 MANUAL - NV1500 (Continued) GEARTRAIN (1) Install input shaft into Support Stand 8355 (Fig. 62). (2) Install pilot bearing in input shaft (Fig. 62). (3) Install fourth gear synchro ring on input shaft (Fig. 63). Fig.
Page 1157 21 - 20 MANUAL - NV1500 MANUAL - NV1500 (Continued) (4) Install assembled output shaft and geartrain in input shaft (Fig. 64). Rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve. Fig. 62 INPUT SHAFT AND PILOT BEARING 1 - PILOT BEARING 2 - INPUT SHAFT 3 - STAND...
Page 1158 MANUAL - NV1500 21 - 21 MANUAL - NV1500 (Continued) Fig. 67 SHIFT FORKS AND SYNCHROS 1 - FIFTH REVERSE SHIFT FORK 2 - 1-2 SHIFT FORK Fig. 65 COUNTERSHAFT ON SUPPORT STAND REAR HOUSING 1 - COUNTER SHAFT (1) Lubricate countershaft rear bearing race. 2 - MAIN SHAFT 3 - SUPPORT STAND (2) Install rear housing onto geartrain (Fig.
Page 1159 21 - 22 MANUAL - NV1500 MANUAL - NV1500 (Continued) (4) Apply Mopar Gasket Maker or equivalent to REVERSE IDLER bolt threads, bolt shanks and under bolt heads (Fig. (1) Remove geartrain and housing assembly from 69). support stand with aid of helper. (2) Assemble shaft, gear and washer (without bearing or support) and install into housing (Fig.
Page 1160 MANUAL - NV1500 21 - 23 MANUAL - NV1500 (Continued) SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET (1) Verify all synchro sleeves are in Neutral posi- tion (centered on hub). CAUTION: Synchros must all be in Neutral position to prevent damage to the housings, shift forks and gears during installation of the two housings.
Page 1161 21 - 24 MANUAL - NV1500 MANUAL - NV1500 (Continued) (10) Align roll pin holes in shift shaft, lever and bushing, then start roll pin into shaft lever by hand (Fig. 79). Fig. 76 LEVER OPENING IN HOUSING 1 - SHIFT SHAFT Fig.
Page 1162 MANUAL - NV1500 21 - 25 MANUAL - NV1500 (Continued) and use plastic mallet to seat bearing. Bearing goes in from front side of housing only. Fig. 81 STARTING ROLL PIN IN SHIFT SOCKET 1 - ROLL PIN 2 - SHIFT SOCKET Fig.
Page 1163 21 - 26 MANUAL - NV1500 MANUAL - NV1500 (Continued) (4) Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain. (5) Work front housing downward onto geartrain until seated on rear housing. CAUTION: If the front housing will not seat on the rear housing, the shift components are not in Neu- tral, or one or more components are misaligned.
Page 1164 MANUAL - NV1500 21 - 27 MANUAL - NV1500 (Continued) (18) Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 90). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer. NOTE: Be sure that no sealer gets into the oil feed hole in the transmission case or bearing retainer.
Page 1165 (Fig. 92). Verify shift ball is seated in socket and offset in the tower is toward the passenger side of INSTALLATION the vehicle before installing tower bolts. (1) Install clutch housing on transmission and (4) Install shift tower bolts (Fig. 93) and tighten tighten housing bolts to 46 N·m (34 ft.
Page 1166 MANUAL - NV1500 21 - 29 MANUAL - NV1500 (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. lbs. Back up Lamp Switch Coutershaft Bearing Shim Bearing Retainer - Front Bearing Retainer - Rear Drain/Fill Plug Shift Shaft Lock Bolt Idler Shaft Bolts - M8 Idler Shaft Bolts - M10 Shift Tower Bolts...
Page 1167 21 - 30 MANUAL - NV1500 MANUAL - NV1500 (Continued) STUD ALIGNMENT 8120 REMOVER 8117A REMOVER 8356 REMOVER L-4454 SPLITTER BEARING 1130 CUP 6310-1...
Page 1168 DIAGNOSIS AND TESTING ....31 VEHICLE SPEED SENSOR REMOVAL ......32 DESCRIPTION .
Page 1169 (8) Disconnect necessary exhaust system compo- A correct lubricant level check can only be made nents. when the vehicle is level. Also allow the lubricant to (9) Remove slave cylinder (Fig. 2) from clutch settle for a minute or so before checking. These rec- housing.
Page 1170 21 - 33 MANUAL - NV3550 (Continued) (24) Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle. (25) Remove clutch release bearing, release fork and retainer clip. (26) Remove clutch housing from transmission.
Page 1171 21 - 34 MANUAL - NV3550 MANUAL - NV3550 (Continued) Fig. 9 PULL DETENT PLUG Fig. 7 SHAFT LOCK BOLT 1 - NUT 1 - SHIFT SHAFT LOCK BOLT 2 - REMOVER 2 - SHAFT SOCKET (7) Remove shift shaft detent plug with Remover 8117A.
Page 1172 MANUAL - NV3550 21 - 35 MANUAL - NV3550 (Continued) (11) Remove snap ring that secures input shaft in front bearing (Fig. 12). Fig. 12 INPUT SHAFT SNAP RING Fig. 14 INPUT AND COUNTERSHAFT BEARING 1 - INPUT SHAFT SNAP RING RACE 2 - OIL FEED 1 - INPUT SHAFT BEARING...
Page 1173 21 - 36 MANUAL - NV3550 MANUAL - NV3550 (Continued) (16) Note the location of the input shaft, shift shaft, shift forks and geartrain (Fig. 16). Fig. 17 SHIFT SOCKET ROLL PIN 1 - REMOVER 2 - SHIFT SOCKET NOTE: Place shop towel over shaft to contain detent ball and spring.
Page 1174 MANUAL - NV3550 21 - 37 MANUAL - NV3550 (Continued) Fig. 21 SHIFT SOCKET AND ROLL PIN 1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET Fig. 19 SHIFT SHAFT LEVER AND BUSHING ROLL 1 - LEVER AND BUSHING 2 - SHIFT SHAFT (4) Pull shift shaft straight (Fig.
Page 1175 21 - 38 MANUAL - NV3550 MANUAL - NV3550 (Continued) (8) Remove the reverse idler shaft support bolt (d) Stand geartrain and rear housing upright on (front bolt) (Fig. 24). fixture (Fig. 27). Have helper hold fixture tool in (9) Loosen rear reverse idler shaft bolt (rear bolt) place while housing and geartrain is being rotated (Fig.
Page 1176 MANUAL - NV3550 21 - 39 MANUAL - NV3550 (Continued) REAR ADAPTER HOUSING (1) Locate rear seal dimples (Fig. 28). With slide hammer mounted screw, remove rear seal by insert- ing screw into one of the seal dimples (Fig. 29). Fig.
Page 1177 21 - 40 MANUAL - NV3550 MANUAL - NV3550 (Continued) (4) Remove retaining ring that secures two-piece thrust washer on shaft (Fig. 34). Use a small pry tool to remove retaining ring. Fig. 34 THRUST WASHER Fig. 32 REAR ADAPTER HOUSING COMPONENTS 1 - PRY TOOL 2 - THRUST WASHER RETAINING RING 1 - BEARING RETAINER...
Page 1178 MANUAL - NV3550 21 - 41 MANUAL - NV3550 (Continued) (11) Remove first gear needle bearing (Fig. 39). Fig. 36 SECOND GEAR AND NEEDLE BEARING 1 - SECOND GEAR Fig. 39 FIRST GEAR NEEDLE BEARING 2 - SECOND GEAR NEEDLE BEARING 1 - FIRST GEAR NEEDLE BEARING (12) Remove fifth gear (Fig.
Page 1179 21 - 42 MANUAL - NV3550 MANUAL - NV3550 (Continued) (14) Remove fifth-reverse synchro hub snap ring (16) Remove reverse gear and needle bearing (Fig. (Fig. 42). 44). Fig. 44 REVERSE GEAR AND NEEDLE BEARING 1 - REVERSE GEAR AND NEEDLE BEARING REVERSE IDLER (1) Remove idler gear snap rings (Fig.
Page 1180 MANUAL - NV3550 21 - 43 MANUAL - NV3550 (Continued) Fig. 45 REVERSE IDLER COMPONENTS 1 - SNAP RING 6 - IDLER GEAR BEARING 2 - FLAT WASHER 7 - IDLER SHAFT 3 - WAVE WASHER 8 - THRUST WASHER 4 - THRUST WASHER 9 - SNAP RING 5 - REVERSE IDLER GEAR...
Page 1181 21 - 44 MANUAL - NV3550 MANUAL - NV3550 (Continued) Fig. 46 SHIFT FORKS & SHAFT 1 - SHIFT SHAFT 4 - 3-4 SHIFT FORK 2 - SHAFT LEVER 5 - 1-2 SHIFT FORK 3 - SHAFT LEVER BUSHING 6 - FIFTH-REVERSE SHIFT FORK Replace the thrust washer, wave washer, or thrust plate if cracked, chipped, or worn.
Page 1182 MANUAL - NV3550 21 - 45 MANUAL - NV3550 (Continued) ASSEMBLY Sealers are used at all case joints. Usea Mopar Gasket Maker for all case joints and Mopar silicone sealer or equivalent, for the input shaft bearing retainer. Apply these products as indicated in the assembly procedures.
Page 1183 21 - 46 MANUAL - NV3550 MANUAL - NV3550 (Continued) (6) Install new fifth-reverse hub snap ring (Fig. 53) and verify the snap ring is seated. Fig. 51 REVERSE SYNCHRO 1 - REVERSE GEAR 2 - SYNCHRO RING (4) Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.
Page 1184 MANUAL - NV3550 21 - 47 MANUAL - NV3550 (Continued) Fig. 55 FIFTH GEAR BEARING 1 - SHAFT SHOULDER 2 - FIFTH GEAR BEARING Fig. 57 FIRST GEAR BEARING 1 - FIRST GEAR BEARING 2 - SHAFT SHOULDER 3 - CUP 4 - PRESS BLOCKS Fig.
Page 1185 21 - 48 MANUAL - NV3550 MANUAL - NV3550 (Continued) (13) Install first gear synchro ring (Fig. 59). (16) Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 61). CAUTION: Align the synchro ring and sleeve as hub the is being pressed onto the shaft.
Page 1186 MANUAL - NV3550 21 - 49 MANUAL - NV3550 (Continued) (17) Install interm ring. (21) Install second gear needle bearing on shaft (18) Install new 1-2 synchro hub snap ring (Fig. (Fig. 64). 62) and verfiy the snap ring is seated. Fig.
Page 1187 21 - 50 MANUAL - NV3550 MANUAL - NV3550 (Continued) (23) Install two-piece thrust washer (Fig. 66). Ensure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores. NOTE: Dot or markings on the two-piece thrust washer go toward 3rd gear.
Page 1188 MANUAL - NV3550 21 - 51 MANUAL - NV3550 (Continued) Fig. 72 3-4 SYNCHRO HUB ON OUTPUT SHAFT Fig. 69 THIRD GEAR BEARING 1 - GROOVED SIDE OF SLEEVE (TO FRONT) 1 - THIRD GEAR BEARING 2 - 3-4 SYNCHRO ASSEMBLY (31) With the lug on the ring aligned with the slot on the synchro, press 3-4 synchro assembly onto out- put shaft with shop press and suitable size pipe tool...
Page 1189 21 - 52 MANUAL - NV3550 MANUAL - NV3550 (Continued) REVERSE IDLER ASSEMBLY (1) Lubricate idler components with Mopar Man- ual Transmission lubricant or equivalent. (2) Slide idler gear bearing on shaft (Fig. 76). Bearing fits either way on shaft. (3) Slide gear onto shaft.
Page 1190 MANUAL - NV3550 21 - 53 MANUAL - NV3550 (Continued) Fig. 76 IDLER GEAR AND BEARING 1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT Fig. 78 IDLER GEAR AND SHAFT ASSEMBLY 1 - REAR OF SHAFT 2 - GEAR 3 - THRUST WASHER AND BALL 4 - WAVE WASHER...

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