Page 1 GROUP TAB LOCATOR Introduction Restraints Lubrication & Maintenance Restraints Suspension Speed Control Driveline Vehicle Theft Security Brakes Wipers/Washers Cooling Wiring Audio Engine Chime/Buzzer Exhaust System Clock Frame & Bumpers Electronic Control Modules Fuel System Engine Systems Steering Engine Systems Transaxle Heated Systems Tires/Wheels Horn...
Page 2: Location And Decoding
INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATES TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 3 INTRODUCTION BODY CODE PLATES (Continued) DIGITS 20 Carline • C = Chrysler • D = Dodge • Y = Chrysler DIGIT 21 Price Class • E = Economy • H = High Line • L = Low Line • M = Mid Line •...
Page 4: Description
INTRODUCTION FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2.
Page 5 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 3 FASTENER IDENTIFICATION...
Page 6 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 4 FASTENER STRENGTH...
Page 7: Description Description - Fastener Usage
INTRODUCTION DESCRIPTION - THREADED HOLE REPAIR FASTENER USAGE Most stripped threaded holes can be repaired using a Helicoil . Follow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures. DESCRIPTION - FASTENER USAGE INTERNATIONAL VEHICLE WARNING: USE OF AN INCORRECT FASTENER CONTROL &...
Page 8: Metric System Description
INTRODUCTION The following chart will assist in converting metric METRIC SYSTEM units to equivalent English and SAE units, or vise versa. DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY...
Page 9 INTRODUCTION METRIC SYSTEM (Continued) Fig. 6 METRIC CONVERSION CHART...
Page 10 INTRODUCTION tions Chart for torque references not listed in the TORQUE REFERENCES individual torque charts (Fig. 7). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- Fig. 7 TORQUE SPECIFICATIONS...
Page 11: Digit
Passenger Safety A = Restraint System - Active Driver and Side Airbags H = Restraint System - Active Driver and Passenger Airbags Car Line D = Intrepid (U.S.A. & Mexico) E = 300M H = Intrepid (Canada) Series 3 = Medium...
Page 12: Vehicle Safety Certification Label
INTRODUCTION VEHICLE IDENTIFICATION NUMBER (Continued) VIN CHECK DIGIT E-MARK LABEL DESCRIPTION DESCRIPTION To protect the consumer from theft and possible An E-mark Label (Fig. 10) is located on the rear fraud the manufacturer is required to include a shut face of the driver’s door. The label contains the Check Digit at the ninth position of the Vehicle Iden- following information: tification Number.
Page 13 INTRODUCTION MANUFACTURE PLATE DESCRIPTION The Manufacturer Plate (Fig. 11) is located in the engine compartment on the passenger side rear cor- ner of the hood. The plate contains five lines of infor- mation: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3.
Page 14 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Body Control Module ....8W-48-2 Power Distribution Center ... . . 8W-48-2 Driver Power Mirror .
Page 18 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Body Control Module ....8W-49-2 Junction Block ..... . 8W-49-2 Fuse 14 (JB) .
Page 20 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Accessory No. 1 ..... 8W-50-16 Headlamp Switch .
Page 36 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Automatic Day/Night Mirror ..8W-51-4, 5 Left Tail Lamp ....8W-51-8, 9 Brake Lamp Switch .
Page 46 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Left Side Repeater Lamp ....8W-52-4 Fuse 9 (JB) .
Page 52 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Body Control Module ... . . 8W-53-2, 4, 5 G106 ......8W-53-5 Front Washer Pump Motor .
Page 58 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 1 ....8W-60-2 Left Rear Power Window Switch ..8W-60-3, 4 Driver Power Window Motor .
Page 62 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Body Control Module ... 8W-61-2, 3, 4, 5 G301 ......8W-61-2, 4 Circuit Breaker No.
Page 68 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Automatic Day/Night Mirror ... 8W-62-7 Memory Heated Seat/Mirror Driver Power Mirror ... . 8W-62-2, 3, 5, 7 Module .
Page 76 8W-63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Body Control Module ....8W-63-8 Driver Power Seat Switch ... 8W-63-2, 4 Circuit Breaker No.
Page 84 8W-64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 14 (JB) ......8W-64-2 Sunroof Control Module .
Page 86 8W-65 SPEED PROPORTIONAL STEERING 8W - 65 - 1 8W-65 SPEED PROPORTIONAL STEERING Component Page Component Page Body Control Module ....8W-65-2 Junction Block ..... . 8W-65-2 Fuse 19 (JB) .
Page 88 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ....... 8W-15-4 S220 .
Page 94: Table Of Contents
C108 ......8W-80-14 C313 (Dodge/300M) ....8W-80-30 C109 .
Page 95 Front Wiper Motor ....8W-80-50 (Dodge) ......8W-80-38 Fuel Injector No.
Page 96 Memory Heated Seat/Mirror Module C3 . . 8W-80-71 (Dodge) ......8W-80-61 Memory Heated Seat/Mirror Module C4 . . 8W-80-71 Left Front Park/Turn Signal Lamp (Except Memory Set Switch .
Page 97 Right Front Park/Turn Signal Lamp (Dodge) ......8W-80-88 Right Tail/Stop Lamp No. 2 (Dodge) ..8W-80-96 Right Front Park/Turn Signal Lamp (Except Right Tail/Turn Signal Lamp (Concorde) .
Page 98 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C2 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 14BK GROUND A/C PRESSURE TRANSDUCER - GRAY 4 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K6 20VT/WT 5V SUPPLY C18 20DB...
Page 99 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K25 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL K4 20BK/LB SENSOR GROUND ANALOG CLOCK (LTD/300M) - NATURAL 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z2 20BK/LG GROUND E2 20OR...
Page 100 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AUTOSTICK SWITCH (DODGE/300M) - NATURAL 4 WAY CIRCUIT FUNCTION T44 20YL/LB AUTOSTICK DOWNSHIFT SWITCH SENSE T5 20LG/RD AUTOSTICK UPSHIFT SWITCH SENSE Z1 20BK GROUND F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) BLEND DOOR ACTUATOR - BLACK 5 WAY...
Page 101 MODE DOOR FEEDBACK SIGNAL C38 20DB (EXCEPT BASE) SUN SENSOR SIGNAL L99 20GY/BK(POLICE PACKAGE) FUSED B(+) C82 20YL/OR (MTC) TEMPERATURE SELECT E17 20YL/BK (BASE INTREPID) PARK LAMP RELAY OUTPUT C48 20VT/PK (MTC) A/C LED INDICATOR SIGNAL C26 22PK/DB 5V SUPPLY X920 20GY/OR...
Page 102 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 BODY CONTROL MODULE C4 - BLUE 16 WAY CIRCUIT FUNCTION G74 20TN/RD DOOR AJAR SWITCH SENSE (LR) G74 20TN/RD DOOR AJAR SWITCH SENSE (PASS) G72 20DG/OR PASSENGER CYLINDER LOCK SWITCH MUX G75 20TN DRIVER DOOR AJAR SWITCH SENSE P97 20WT/DG DRIVER DOOR SWITCH MUX...
Page 103: C101
8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE SWITCH SENSE G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) C101 - (HEADLAMP/DASH SIDE) CIRCUIT F42 16DG/LG K236 18GY/PK Z12 14BK/TN C2 14DB/BK Z1 14BK...
Page 104 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 C103 - GREEN (HEADLAMP AND DASH HARNESS SIDE) CIRCUIT V37 20RD/LG V32 20YL/RD V30 20DB/RD K29 20WT/PK G29 20BK/TN G6 20GY D21 20PK/TN D20 20LG G9 22GY/BK(POLICE PACKAGE/SPECIAL SERVICE) K4 20BK/LB L96 18LG/RD (BUILT-UP-EXPORT) A101 16RD/TN(POLICE PACKAGE) A105 18DB/RD(EXCEPT POLICE PACKAGE) A102 16RD/OR(POLICE PACKAGE)
Page 105: C104
C105 - YELLOW (HEADLAMP/DASH SIDE) CIRCUIT A4 10BK/PK A141 12DG/WT L13 18BR/YL C106 - NATURAL (BODY HARNESS SIDE) CIRCUIT B4 18LG B3 18LG/DB B2 18YL B1 18YL/DB K106 18WT/DG K107 20OR/RD Z1 18BK (EXCEPT 300M) L95 16DG/YL (300M/BUILT-UP-EXPORT) T44 20YL/LB (300M/DODGE) T5 20LG/RD (300M/DODGE)
Page 106: C106
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C106 - NATURAL (HEADLAMP/DASH SIDE) CIRCUIT B4 18LG (ABS) B3 18LG/DB (ABS) B2 18YL (ABS) B1 18YL/DB (ABS) K106 18WT/DG K107 18OR/RD F18 20LG/BK Z1 18BK (EXCEPT BUILT-UP-EXPORT) L95 18DG/YL (BUILT-UP-EXPORT) T44 20YL T5 20LG/RD C107 - LT.
Page 107 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C108 - LT. GRAY (HEADLAMP/DASH SIDE) CIRCUIT T9 16OR/BK T19 16WT Z1 18BK T60 16BR T59 16PK T50 16DG T47 16YL/BK K199 18BR/VT T20 16LB T16 16RD C108 - LT. GRAY (TRANSMISSION HARNESS SIDE) CIRCUIT T9 16OR/BK...
Page 108 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C109 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT L60 18TN L7 18BK/YL L61 18LG L39 20LB Z1 18BK C111 (BUILT-UP-EXPORT) - GRAY (HEADLAMP LEVELING SIDE) CIRCUIT L43 16VT L7 20BK/YL Z1 16BK L13 20BR/YL L33 20RD C111 (BUILT-UP-EXPORT) - GRAY (HEADLAMP...
Page 109: C120 (Police Package/Special Service)
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C112 (BUILT-UP-EXPORT) - GRAY (HEADLIGHT LEVELING SIDE) CIRCUIT L44 20VT L7 20BK/YL Z1 20BK L13 20BR/YL L34 20RD C115 (EXCEPT 2.7L BASE) - BLACK (ENGINE SIDE) CIRCUIT Z1 12BK Z1 12BK C23 12DG C25 12YL C115 (EXCEPT 2.7L BASE) - BLACK (RADIATOR MOTOR HARNESS)
Page 110: C200
C200 - BLUE (BODY HARNESS SIDE) CIRCUIT G78 20TN/BK Z2 20BK/LG L13 18BR/YL L95 16DG/YL (300M/BUILT-UP-EXPORT) F14 20LG/YL X60 20DG/RD (EXCEPT DODGE) P112 18TN/OR (EXCEPT DODGE) X12 18RD (POLICE PACKAGE) G9 20GY/BK (POLICE PACKAGE) P114 18TN/WT (EXCEPT DODGE) C80 20DB/WT F101 16YL/TN (POLICE PACKAGE)
Page 111: C201
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C201 - NATURAL (BODY HARNESS SIDE) CIRCUIT F62 16RD X51 18BR/YL X52 18DB/WT X53 18DG X54 18VT X55 18BR/RD X57 18BR/LB X58 18DB/OR X56 18DB/RD X88 18PK/RD X89 18PK/BK X60 20DG/RD F62 16RD/WT C201 - NATURAL (I/P HARNESS SIDE) CIRCUIT F62 16RD...
Page 112 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C202 (MTC) - NATURAL (I/P HARNESS SIDE) CIRCUIT C34 22BR/WT C35 22DG/YL C33 22DB/RD C32 22GY/DB C57 20DB/GY C26 22PK/DB C7 12BK/TN C1 12DG C12 22LG/BK C36 22RD/WT C37 22YL/WT C4 18TN C5 16LG C6 16LB C203 (ATC) - NATURAL (HVAC HARNESS SIDE)
Page 113: C204
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C203 (ATC) - NATURAL (I/P HARNESS SIDE) CIRCUIT C34 22BR/WT C35 22DG/YL C33 22DB/RD C32 22GY/DB C57 20DB/GY C26 22PK/DB C1 12DG C12 22LG/BK C36 22RD/WT C37 22YL/WT Z1 12BK C56 22RD/LG C204 - NATURAL (HEADLINER HARNESS SIDE) CIRCUIT Q41 20WT...
Page 114 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C205 (EXCEPT POLICE PACKAGE) - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT E2 20OR Z1 20BK A105 18DB/RD Z1 18BK C205 (EXCEPT POLICE PACKAGE) - NATURAL (POWERPOINT SIDE) CIRCUIT E2 20OR Z1 20BK A105 18DB/RD Z1 18BK C206 (EXCEPT POLICE PACKAGE) - NATURAL (HEADLINER SIDE)
Page 115: C300
X85 18LG/BK (MIDLINE AND PREMIUM AUDIO) Q28 14DG/WT P112 18TN/OR Q1 14YL Z1 14BK P114 18TN/WT L61 16LG (EXCEPT DODGE) C300 - NATURAL (LEFT FRONT DOOR SIDE) CIRCUIT Q17 14DB/WT X81 18YL/BK (MIDLINE AND PREMIUM AUDIO) P33 16OR Q26 14VT/WT...
Page 116: C301
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C301 - (LEFT FRONT DOOR SIDE) CIRCUIT G5 20DB/WT C16 20LB/YL M1 20PK P72 20YL/BK P70 20WT P74 20DB G73 20LG/OR P97 20WT/DG P64 20YL/OR P65 20DB/YL P69 20WT/RD P71 20YL (MEMORY) P75 20BK/WT (MEMORY) P73 20YL/PK (MEMORY) G75 20TN...
Page 117: C302
X80 18LB/BK (MIDLINE AND PREMIUM AUDIO) (POLICE PACKAGE) X56 18DB/RD (BASE) X86 18OR/RD (MIDLINE AND PREMIUM AUDIO) P34 16PK/BK Q16 14BR/WT M2 20YL Q1 14YL Z1 20BK X82 18LB/RD (MIDLINE AND PREMIUM AUDIO) X54 18VT (BASE) (POLICE PACKAGE) L60 16TN (EXCEPT DODGE)
Page 118: C303
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C303 - (RIGHT FRONT DOOR SIDE) CIRCUIT G5 20DB/WT C16 20LB/YL (MEMORY) M1 20PK P72 20YL/BK P70 20WT P74 20DB G72 20DG/OR P96 20WT/LG P67 20YL/RD (MEMORY) P68 20DG/RD (MEMORY) P66 20WT/BK (MEMORY) G74 20TN/RD P162 20GY/WT (MEMORY) C303 - NATURAL (BODY SIDE)
Page 119: C304
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C304 - NATURAL (BODY SIDE) CIRCUIT Z1 20BK P33 16OR P34 16PK/BK Q27 14RD/BK G74 20TN/RD Q1 14YL Q17 14DB/WT C304 - NATURAL (REAR DOOR SIDE) CIRCUIT Z1 20BK P33 16OR P34 16PK/BK Q27 14DG/WT G74 20TN/RD Q1 14YL...
Page 120: C306
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C305 - NATURAL (REAR DOOR SIDE) CIRCUIT Z1 20BK P33 16OR P34 16PK/BK Q28 14DG/WT G74 20TN/RD Q1 14YL Q18 14GY/BK C306 - BLACK (BODY SIDE) CIRCUIT Z1 16BK F35 16RD C306 - GREEN (POWER SEAT SIDE) CIRCUIT Z1 16BK F35 16RD...
Page 121: C308
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C307 - GREEN (POWER SEAT SIDE) CIRCUIT Z1 16BK F35 16RD C308 - BLACK (BODY SIDE) CIRCUIT K106 18WT/DG Z1 12BK G4 20DB K107 20OR/RD A141 12DG/WT C308 - BLACK (FUEL TANK JUMPER SIDE) CIRCUIT K106 18WT/DG (EXCEPT BUILT-UP-EXPORT)
Page 122: C310
P2 20BK/WT G71 18VT/WT Z1 16BK L50 16WT/TN (EXCEPT LTD/CONCORDE) C311 - RED (DECKLID SIDE) CIRCUIT G78 20TN/BK P2 20BK/WT G71 20VT/YL Z1 16BK L50 16WT/TN (DODGE) L50 18WT/TN (BUILT-UP-EXPORT) C312 - BLACK (BODY SIDE) CIRCUIT L7 18BK/YL Z1 18BK...
Page 123: C313 (Concorde/Dodge/300M)
C313 (CONCORDE/DODGE/300M) - GRAY (TAIL LAMP SIDE) CIRCUIT L50 18WT/TN L60 18LG/TN L7 18BK/YL L1 18VT/BK Z1 18BK C313 (DODGE/300M) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L60 16TN L7 18BK/YL L1 20VT/BK Z1 16BK C313 (LTD/BUILT-UP-EXPORT) - (TAIL LAMPS...
Page 124: C314 (Concorde/Dodge/300M)
C314 (CONCORDE/DODGE/300M) - GRAY (TAIL LAMP SIDE) CIRCUIT L50 16WT/TN L61 18LG/TN L7 18BK/YL L1 18VT/BK Z1 18BK C314 (DODGE/300M) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L61 16LG L7 18BK/YL L1 20VT/BK Z1 16BK C314 (LTD/BUILT-UP-EXPORT) - (TAILAMPS SIDE)
Page 125: C315 (Concorde/Ltd)
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C314 (LTD/CONCORDE/BUILT-UP-EXPORT) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L61 16LG L95 16DG/YL (BUILT-UP-EXPORT) L7 18BK/YL L1 20 VT/BK (BUILT-UP-EXPORT) Z1 16BK C315 (CONCORDE/LTD) - BLACK (BODY SIDE) CIRCUIT L1 18VT/BK Z1 18BK L7 18BK/YL C315 (CONCORDE/LTD) - BLACK (REAR FASCIA SIDE)
Page 126: C317
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C317 - NATURAL (BODY SIDE) CIRCUIT X98 18TN/VT (PREMIUM II AUDIO) X96 18TN/DG (PREMIUM II AUDIO) C317 - NATURAL (REAR DOOR SIDE) CIRCUIT X98 18TN/VT (PREMIUM II AUDIO) X96 18TN/DG (PREMIUM II AUDIO) C318 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT P130 16RD/TN...
Page 127 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C318 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT P130 16RD/TN P130 16RD/TN P142 20TN/DB P142 20TN/DB G5 20DB/WT G5 20DB/WT P138 20VT/LG P138 20VT/LG P140 20VT/BK P140 20VT/BK P134 20TN/LG P134 20TN/LG P144 20BK/LG P144 20BK/LG C319 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT...
Page 128: C319 (Memory)
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C319 (MEMORY) - NATURAL (POWER SEAT SIDE) CIRCUIT D25 20VT/YL G5 20DB/WT P70 20WT P72 20YL/BK P74 20DB P142 20TN/DB P130 16RD/TN P144 20BK/LG P134 20TN/LG P140 20VT/BK P138 20VT/LG P71 20YL P75 20BK/WT P73 20YL/PK P64 20YL/OR...
Page 129 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C321 (300M) - BLACK (CHMSL SIDE) CIRCUIT L50 18WT/TN Z1 18BK C321 (300M) - NATURAL (DECKLID SIDE) CIRCUIT L50 18WT/TN Z1 18BK C322 - BLACK (BODY SIDE) CIRCUIT F14 20LG/YL Z2 20BK/LG D25 20VT/YL C322 - BLACK (SAB JUMPER SIDE) CIRCUIT...
Page 130 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C325 (POLICE PACKAGE) - GREEN (BODY SIDE) CIRCUIT M1 20PK Z1 20BK C360 (POLICE PACKAGE/SPECIAL SERVICE) - BLACK (I/P HARNESS) CIRCUIT A101 16RD/TN A102 16RD/OR A103 16RD/YL F101 16YL/TN F102 16YL/OR F103 16YL/RD C360 (POLICE PACKAGE/SPECIAL SERVICE) - BLACK (POLICE ACCESSORY HARNESS SIDE) CIRCUIT...
Page 131 CENTER HIGH MOUNTED STOP LAMP NO. 1 (CONCORDE/LTD) - GRAY 2 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 18BK GROUND CENTER HIGH MOUNTED STOP LAMP NO. 1 (DODGE) - 2 WAY CIRCUIT FUNCTION L50 16WT/TN BRAKE LAMP SWITCH OUTPUT Z1 16BK GROUND CENTER HIGH MOUNTED STOP LAMP NO.
Page 132 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 CENTER HIGH MOUNTED STOP LAMP NO. 2 (DODGE) - 2 WAY CIRCUIT FUNCTION L50 16WT/TN BRAKE LAMP SWITCH OUTPUT Z1 16BK GROUND CENTER INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION...
Page 133 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS CLOCKSPRING C2 - YELLOW 2 WAY CIRCUIT FUNCTION R43 18BK/LB DRIVER SQUIB 1 LINE 2 R45 18DG/LB DRIVER SQUIB 1 LINE 1 CLOCKSPRING C3 - 4 WAY CIRCUIT FUNCTION V37 22RD/LG SPEED CONTROL SWITCH SIGNAL K4 22BK/LB SENSOR GROUND X920 22GY/OR...
Page 134 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 COIL ON PLUG NO. 4 - BLACK 2 WAY CIRCUIT FUNCTION F42 16DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K94 16TN/LG COIL ON PLUG DRIVER NO. 4 COIL ON PLUG NO. 5 - BLACK 2 WAY CIRCUIT FUNCTION F42 16DG/LG...
Page 135 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS COMPACT DISC CHANGER (MIDLINE/PREMIUM) - BLACK 8 WAY CIRCUIT FUNCTION X40 24GY/WT AUDIO OUT RIGHT E14 24OR/TN PANEL LAMPS DIMMER SIGNAL D25 24VT/YL PCI BUS X112 24RD FUSED IGNITION SWITCH OUTPUT X41 24DG/WT AUDIO OUT LEFT Z140 24BK/OR GROUND...
Page 136 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CRANKSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5V SUPPLY K4 20BK/LB SENSOR GROUND K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS Z1 20BK...
Page 137 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS DECKLID RELEASE SWITCH - BLACK 2 WAY CIRCUIT FUNCTION P1 20BK/WT DECKLID RELEASE SWITCH OUTPUT F30 20PK(POLICE PACKAGE BATTERY FUSED B(+) POSITION) M1 20PK FUSED B(+) F30 20PK(POLICE PACKAGE IGNITION FUSED IGNITION SWITCH OUTPUT (RUN-ACC) POSITION) DRIVER AIRBAG - YELLOW 2 WAY CIRCUIT...
Page 138 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 DRIVER HEATED SEAT BACK - GREEN 2 WAY CIRCUIT FUNCTION P88 16BR/BK HEATED SEAT DRIVER Z1 20BK GROUND DRIVER HEATED SEAT CUSHION - BLACK 4 WAY CIRCUIT FUNCTION P131 16RD/TN (EXCEPT MEMORY) DRIVER SEAT HEATER B(+) DRIVER P131 16RD/DG (MEMORY) DRIVER SEAT HEATER B(+) DRIVER...
Page 139 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS DRIVER POWER MIRROR (EXCEPT MEMORY) - NATURAL 3 WAY CIRCUIT FUNCTION P71 20YL DRIVER MIRROR UP DRIVER P73 20YL/PK DRIVER MIRROR COMMON DRIVER P75 20BK/WT DRIVER MIRROR LEFT DRIVER DRIVER POWER MIRROR (MEMORY) - WHITE 11 WAY CIRCUIT FUNCTION Z1 20BK...
Page 140 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 DRIVER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION P115 16YL/DB (MEMORY SEATS) DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 16YL/LB (EXCEPT MEMORY DRIVER SEAT HORIZONTAL REARWARD DRIVER SEATS) P117 16RD/LB (MEMORY SEATS) DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 16RD/LB (EXCEPT MEMORY DRIVER SEAT HORIZONTAL FORWARD DRIVER...
Page 141 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS DRIVER POWER SEAT RECLINER MOTOR SENSOR (MEMORY) - BLACK 3 WAY CIRCUIT FUNCTION P29 20BR/WT SEAT SENSOR 5V SUPPLY P47 20LB RECLINER POSITION SIGNAL P28 20BR/RD SEAT POSITION SENSOR GROUND DRIVER POWER SEAT SWITCH - BLUE 10 WAY CIRCUIT FUNCTION P9 20RD (MEMORY SEATS)
Page 142 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 DRIVER POWER WINDOW MOTOR - RED 2 WAY CIRCUIT FUNCTION Q21 16WT DRIVER WINDOW DRIVER (DOWN) Q11 16LB DRIVER WINDOW DOWN (UP) DRIVER POWER WINDOW SWITCH - BLUE 12 WAY CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) Q17 14DB/WT...
Page 143 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS EVAP/PURGE SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION K52 18PK/BK EVAPORATIVE EMISSION SOLENOID CONTROL K108 18DG/LG EVAPORATIVE EMISSION SOLENOID SENSE EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL C57 20DB/GY SENSOR GROUND FRONT WASHER PUMP MOTOR - BLACK 2 WAY...
Page 144 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 FUEL INJECTOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN/WT FUEL INJECTOR NO. 2 DRIVER F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 3 - BLACK 2 WAY CIRCUIT FUNCTION K13 18YL/WT...
Page 145 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS FUEL PUMP MODULE - GRAY 4 WAY CIRCUIT FUNCTION Z1 12BK GROUND Z1 18BK GROUND G4 18DB FUEL LEVEL SENSOR SIGNAL A141 12DG/WT FUEL PUMP RELAY OUTPUT GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION Z12 18BK/TN(3.5L)
Page 146 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 HEADLAMP SWITCH - BLUE 13 WAY CIRCUIT FUNCTION Z1 18BK/LB (BUILT-UP-EXPORT) GROUND L7 18BK/YL (BUILT-UP-EXPORT) HEADLAMP SWITCH OUTPUT E19 20RD PANEL LAMPS DIMMER SIGNAL Z1 20BK GROUND L95 18DG/YL (BUILT-UP-EXPORT) REAR FOG LAMP RELAY CONTROL L80 20WT HEADLAMP SWITCH RETURN L13 18BR/YL (BUILT-UP-EXPORT)
Page 147 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS IGNITION SWITCH - BLACK 10 WAY CIRCUIT FUNCTION A81 14DG/RD IGNITION SWITCH OUTPUT (OFF-RUN-START) G26 22LB KEY-IN IGNITION SWITCH SENSE Z2 20BK/LG GROUND A21 12DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) A1 12RD FUSED B (+) A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
Page 148 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 INTAKE AIR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K21 20BK/RD INTAKE AIR TEMPERATURE SIGNAL K4 20BK/LB SENSOR GROUND JUNCTION BLOCK BODY CONTROL MODULE-JB - 20 WAY CIRCUIT FUNCTION GROUND COURTESY LAMP DRIVER SPEED PROPORTIONAL STEERING SOLENOID (-) SPEED PROPORTIONAL STEERING SOLENOID (+) FUSED IGNITION SWITCH OUTPUT (RUN-START)
Page 149 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C10 - GRAY 13 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL L61 18LG LEFT TURN SIGNAL G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER L34 20RD/OR FUSED RIGHT HIGH BEAM OUTPUT L1 20VT/BK BACK-UP LAMP FEED F18 20LG/BK...
Page 150 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 JUNCTION BLOCK C3 - BLUE 15 WAY CIRCUIT FUNCTION A81 14DG/RD IGNITION SWITCH OUTPUT (OFF-RUN-START) X12 20RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z2 18BK/LG GROUND L99 20GY/BK(POLICE PACKAGE) FUSED B(+) G9 22GY/BK RED BRAKE WARNING INDICATOR DRIVER F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START)
Page 151 LOCK RELAY OUTPUT P33 16OR LOCK RELAY OUTPUT P55 16DB DRIVER DOOR UNLOCK RELAY OUTPUT M2 20YL COURTESY LAMPS DRIVER F11 20RD/WT (DODGE/300M) FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) L60 16TN RIGHT TURN SIGNAL L61 16LG LEFT TURN SIGNAL L1 18VT/BK (CONCORDE/LTD)
Page 152 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 JUNCTION BLOCK C9 - ORANGE 8 WAY CIRCUIT FUNCTION A13 12PK/WT FUSED B(+) A34 12LB/RD FUSED B(+) A7 14RD/BK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) F20 18WT/VT (ABS) FUSED IGNITION SWITCH OUTPUT (RUN) F13 20DB FUSED IGNITION SWITCH OUTPUT (RUN) F11 20RD/WT...
Page 153 LEFT BACK-UP LAMP (CONCORDE/LTD) - NATURAL 2 WAY CIRCUIT FUNCTION L1 18VT/BK BACK-UP LAMP FEED Z1 18BK GROUND LEFT BACK-UP LAMP (DODGE) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18VT/BK GROUND L1 18VT/BK BACK-UP LAMP FEED LEFT FOG LAMP (CONCORDE/LTD) - BLACK 2 WAY...
Page 154 FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT L61 18LG LEFT TURN SIGNAL LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L61 18LG LEFT TURN SIGNAL L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK...
Page 155 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+) B9 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L7 20BK/YL...
Page 156 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 LEFT LOW BEAM HEADLAMP - GRAY 2 WAY CIRCUIT FUNCTION L43 20VT (BUILT-UP-EXPORT) FUSED LEFT LOW BEAM OUTPUT L43 16VT (EXCEPT BUILT-UP-EXPORT) FUSED LEFT LOW BEAM OUTPUT Z1 16BK (EXCEPT BUILT-UP-EXPORT) GROUND Z1 20BK (BUILT-UP-EXPORT) GROUND LEFT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY...
Page 157 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS LEFT REAR POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q23 16DG LEFT REAR WINDOW DRIVER DOWN Q17 14GY/BK LEFT REAR WINDOW DRIVER (UP) Q27 14DG/WT LEFT REAR WINDOW DRIVER (DOWN) Q13 16GY WINDOW LEFT REAR B(+) UP Q1 14YL...
Page 158 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 LEFT REAR SIDE MARKER LAMP (DODGE) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT REAR TURN SIGNAL LAMP (300M/BUILT-UP-EXPORT) - 3 WAY CIRCUIT FUNCTION...
Page 159 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS LEFT REMOTE RADIO SWITCH - 2 WAY CIRCUIT FUNCTION X20 22GY/WT RADIO CONTROL MUX X920 22GY/OR RADIO CONTROL MUX RETURN LEFT SEAT AIRBAG - 2 WAY CIRCUIT FUNCTION R31 20LG/OR LEFT SEAT SQUIB LINE 1 R33 20LG/WT LEFT SEAT SQUIB LINE 2 LEFT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW 6 WAY...
Page 160 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 LEFT TAIL LAMP (300M/BUILT-UP-EXPORT) - GREEN 3 WAY CIRCUIT FUNCTION L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND LEFT TAIL LAMP (LTD) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT TAIL/STOP LAMP (CONCORDE) - BLACK 3 WAY...
Page 161 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS LEFT TAIL/STOP LAMP NO. 1 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND LEFT TAIL/STOP LAMP NO. 2 (300M) - 3 WAY...
Page 162 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 LEFT VISOR/VANITY LAMP - BLACK 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND LICENSE LAMP (EXCEPT BUILT-UP-EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR - GRAY 3 WAY...
Page 163 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS MANUAL TEMPERATURE CONTROL HEAD C2 - BLACK 10 WAY CIRCUIT FUNCTION C4 18TN LOW BLOWER MOTOR DRIVER C6 16LB M2 BLOWER MOTOR DRIVER Z1 12BK GROUND C5 16LG M1 BLOWER MOTOR DRIVER C7 12BK/TN HIGH BLOWER MOTOR DRIVER MEMORY HEATED SEAT/MIRROR MODULE C1 - 26 WAY...
Page 164 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 MEMORY HEATED SEAT/MIRROR MODULE C2 - 16 WAY CIRCUIT FUNCTION P139 20VT/WT DRIVER SEAT HIGH HEAT LED DRIVER P140 20VT/BK PASSENGER SEAT HIGH HEAT LED DRIVER P73 20YL/PK DRIVER MIRROR COMMON DRIVER-RIGHT/DOWN P75 20BK/WT DRIVER MIRROR LEFT DRIVER P71 20YL...
Page 165 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS MEMORY SET SWITCH - 6 WAY CIRCUIT FUNCTION Z1 18BK GROUND P24 18PK/WT MEMORY POSITION 2 SWITCH SENSE P22 18PK/BK MEMORY SET SWITCH SENSE P23 18PK/RD MEMORY POSITION SWITCH SENSE MODE DOOR ACTUATOR - BLACK 5 WAY CIRCUIT FUNCTION C35 22DG/YL...
Page 166 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 OVERHEAD TRAVEL INFORMATION SYSTEM (PREMIUM) - BLACK 6 WAY CIRCUIT FUNCTION G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) Z2 20BK/LG GROUND M1 20PK FUSED B(+) D25 20VT/YL PCI BUS OXYGEN SENSOR 1/1 RIGHT BANK UP - GRAY 4 WAY CIRCUIT FUNCTION Z1 18BK...
Page 167 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS OXYGEN SENSOR 2/2 LEFT BANK DOWN - BLACK 4 WAY CIRCUIT FUNCTION Z1 18BK GROUND K399 18BR/GY OXYGEN SENSOR 2/2 HEATER CONTROL K904 18DB/DG OXYGEN SENSOR RETURN (DOWN) K341 20PK/WT OXYGEN SENSOR 2/2 SIGNAL PASSENGER AIRBAG - YELLOW 2 WAY CIRCUIT FUNCTION...
Page 168 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 PASSENGER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G74 20TN/RD DOOR AJAR SWITCH SENSE Z1 20BK GROUND P34 16PK/BK UNLOCK RELAY OUTPUT P33 16OR LOCK RELAY OUTPUT PASSENGER HEATED SEAT BACK - GREEN 2 WAY CIRCUIT FUNCTION P88 16BR/BK...
Page 169 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS PASSENGER POWER DOOR LOCK SWITCH - NATURAL 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) Z1 20BK GROUND P96 20WT/LG PASSENGER DOOR MUX SWITCH PASSENGER POWER MIRROR (EXCEPT MEMORY) - NATURAL 3 WAY CIRCUIT FUNCTION P70 20WT...
Page 170 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 PASSENGER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION P14 16YL/LB PASSENGER SEAT HORIZONTAL FORWARD P16 16RD/LB PASSENGER SEAT HORIZONTAL FORWARD PASSENGER POWER SEAT REAR RISER MOTOR - 2 WAY CIRCUIT FUNCTION P10 16YL/WT...
Page 171 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS PASSENGER POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q22 16VT PASSENGER WINDOW DRIVER (DOWN) Q16 14BR/WT MASTER WINDOW SWITCH (RIGHT FRONT UP) Q26 14VT/WT MASTER WINDOW SWITCH (RIGHT FRONT DOWN) Q12 16BR PASSENGER WINDOW DRIVER (UP) Q1 14YL...
Page 172 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 POWER MIRROR SWITCH - BLACK 13 WAY CIRCUIT FUNCTION P73 20YL/PK DRIVER MIRROR COMMON DRIVER (RIGHT/DOWN) G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) P70 20WT PASSENGER MIRROR COMMON DRIVER (RIGHT/ DOWN) P74 20DB PASSENGER MIRROR LEFT DRIVER P75 20BK/WT DRIVER MIRROR LEFT DRIVER...
Page 173 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C1 - BLACK 38 WAY CIRCUIT FUNCTION Z12 16BK/TN GROUND F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) K236 18GY/PK (3.5L HIGH OUTPUT) SHORT RUNNER VALVE SOLENOID CONTROL Z12 16BK/TN GROUND...
Page 174 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 POWERTRAIN CONTROL MODULE C2 - 38 WAY CIRCUIT FUNCTION K96 16TN/LB COIL ON PLUG DRIVER NO. 6 K95 16TN/DG COIL ON PLUG DRIVER NO. 5 K94 16TN/LG COIL ON PLUG DRIVER NO. 4 K58 18BR/DB FUEL INJECTOR NO.
Page 175 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C3 - WHITE 38 WAY CIRCUIT FUNCTION K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL C27 20DB/PK HIGH SPEED RADIATOR FAN RELAY CONTROL V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL C24 20DB/PK LOW SPEED RADIATOR FAN RELAY CONTROL V32 20YL/RD...
Page 176 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 POWERTRAIN CONTROL MODULE C4 - GREEN 38 WAY CIRCUIT FUNCTION T60 16BR OVERDRIVE SOLENOID CONTROL T59 16PK UNDERDRIVE SOLENOID CONTROL T19 16WT 2-4 SOLENOID CONTROL T20 16LB LOW/REVERSE SOLENOID CONTROL Z14 16BK/YL GROUND Z13 16BK/RD GROUND...
Page 177 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS RADIATOR FAN - BLACK 4 WAY CIRCUIT FUNCTION Z1 12BK GROUND Z1 12BK GROUND C23 12DG LOW SPEED RADIATOR FAN RELAY OUTPUT C25 12YL HIGH SPEED RADIATOR FAN RELAY OUTPUT RADIATOR FAN MOTOR NO. 1 (EXCEPT 2.7L BASE) - 2 WAY CIRCUIT FUNCTION Z1 12BK...
Page 178 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 RADIATOR FAN RELAY NO. 2 (AT FAN) (EXCEPT 2.7L BASE) CIRCUIT FUNCTION 12BK GROUND C25 12RD HIGH SPEED RADIATOR RELAY OUTPUT C25 12RD HIGH SPEED RADIATOR RELAY OUTPUT Z1 12BK RADIATOR FAN MOTOR NO. 1 CONTROL Z1 12BK GROUND 12RD...
Page 179 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS RADIO C2 (BASE) - GRAY 7 WAY CIRCUIT FUNCTION X55 18BR/RD LEFT FRONT DOOR SPEAKER (-) X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-) E17 20YL/BK PARK LAMP RELAY OUTPUT E2 20OR PANEL LAMPS DRIVER X12 20RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) M1 20PK...
Page 180 Z1 18BK (BUILT-UP-EXPORT) GROUND RIGHT BACK-UP LAMP (CONCORDE/LTD) - NATURAL 2 WAY CIRCUIT FUNCTION L1 18VT/BK BACK-UP LAMP FEED Z1 18BK GROUND RIGHT BACK-UP LAMP (DODGE) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L1 18VT/BK BACK-UP LAMP FEED...
Page 181 X82 18LB/RD (NORMAL BUILD) AMPLIFIED RIGHT DOOR SPEAKER (+) X82 18LB/RD (EARLY BUILD) AMPLIFIED RIGHT DOOR SPEAKER (+) X80 18LB/BK AMPLIFIED RIGHT DOOR SPEAKER (-) RIGHT FRONT PARK/TURN SIGNAL LAMP (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL...
Page 182 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND RIGHT FRONT POSITION LAMP - GRAY 2 WAY...
Page 183 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS RIGHT HIGH BEAM HEADLAMP - BLACK 2 WAY CIRCUIT FUNCTION L34 20RD/OR (EXCEPT POLICE FUSED RIGHT HIGH BEAM OUTPUT PACKAGE/EXCEPT BUILT-UP-EXPORT) L34 20RD (BUILT-UP-EXPORT) FUSED RIGHT HIGH BEAM OUTPUT L34 20OR/WT (POLICE PACKAGE) FUSED RIGHT HIGH BEAM OUTPUT Z1 20BK GROUND...
Page 184 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 RIGHT REAR DOOR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X96 18TN/DG AMPLIFIED LOW RIGHT REAR SPEAKER (-) X98 18TN/VT AMPLIFIED LOW RIGHT REAR SPEAKER (+) RIGHT REAR FOG LAMP (BUILT-UP-EXPORT) - NATURAL 3 WAY CIRCUIT FUNCTION L95 18DG/YL...
Page 185 X52 18DB/WT (BASE NORMAL BUILD) RIGHT REAR SPEAKER (+) X94 18TN/RD (MIDLINE AND PREMIUM AMPLIFIED HIGH RIGHT REAR SPEAKER (+) AUDIO NORMAL BUILD) RIGHT REAR SIDE MARKER LAMP (DODGE) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL...
Page 186 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 RIGHT REAR TURN SIGNAL LAMP (DODGE) - 2 WAY CIRCUIT FUNCTION L60 18LG/TN RIGHT TURN SIGNAL Z1 18BK GROUND RIGHT REAR TURN SIGNAL LAMP (LTD) - 2 WAY CIRCUIT FUNCTION L60 18LG/TN...
Page 187 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW 6 WAY CIRCUIT FUNCTION F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) D25 20VT/YL PCI BUS R32 20LB/OR RIGHT SEAT SQUIB LINE 1 R34 20LB/WT RIGHT SEAT SQUIB LINE 2 Z2 20BK/LG GROUND...
Page 188 CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND RIGHT TAIL/STOP LAMP NO. 1 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT RIGHT TAIL/STOP LAMP NO.
Page 189 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS RIGHT TAIL/STOP LAMP NO. 2 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L7 18BK/YL PARK LAMP RELAY OUTPUT Z1 18BK GROUND RIGHT TAIL/TURN SIGNAL LAMP (CONCORDE) - BLACK 3 WAY...
Page 190 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 SHORT RUNNER VALVE SOLENOID (3.5L HIGH OUTPUT) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K236 18GY/PK SHORT RUNNER VALVE SOLENOID CONTROL SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 18TN/RD...
Page 191 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS SPOT LAMP NO. 2 (POLICE PACKAGE) - BLACK 2 WAY CIRCUIT FUNCTION SL2 18WT/DB FUSED B(+) SUN SENSOR/VTSS LED - BLACK 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) G69 22BK/OR VTSS INDICATOR DRIVER C57 20DB/GY SENSOR GROUND C38 20DB...
Page 192 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 SUNROOF MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q6 16DB SUNROOF MOTOR B(-) Q5 16DG SUNROOF MOTOR B(+) SUNROOF SWITCH - NATURAL 4 WAY CIRCUIT FUNCTION Q41 20WT SUNROOF OPEN Q42 20LB SUNROOF CLOSE Z1 20BK GROUND...
Page 193 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS TRANSMISSION RANGE INDICATOR ILLUMINATION (PRNDL) - 2 WAY CIRCUIT FUNCTION E2 20OR PANEL LAMPS FEED Z1 20BK GROUND TRANSMISSION RANGE SENSOR - LT. GREEN 10 WAY CIRCUIT FUNCTION F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) T13 20DB/BK SPEED SENSOR GROUND T54 20VT/PK...
Page 194 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 TRUNK LAMP - BLACK 2 WAY CIRCUIT FUNCTION G78 20TN/BK DECKLID AJAR SWITCH SENSE M1 20PK FUSED B(+) TURN SIGNAL/HAZARD SWITCH - BLACK 8 WAY CIRCUIT FUNCTION Z1 20BK GROUND L91 22DB/PK COMBINATION FLASHER SWITCHED GROUND L61 18LG LEFT TURN SIGNAL...
Page 195 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS WINDSHIELD WASHER PUMP MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Z1 20BK GROUND V10 20BR FRONT WASHER PUMP MOTOR CONTROL WINDSHIELD WIPER MOTOR - BLACK 5 WAY CIRCUIT FUNCTION V4 14RD/YL FRONT WIPER RELAY HIGH SPEED OUTPUT V3 14BR/WT FRONT WIPER RELAY LOW SPEED OUTPUT V55 20TN/RD...
Page 196 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 Use the wiring diagrams in each section for connec- CONNECTOR/GROUND/SPLICE tor, ground, and splice identification.
Page 197 Under Rear Seat C309 Under Driver Seat C310 Under Passenger Seat C311 Left Trunk Area C312 Left Trunk Area C313 (Dodge, 300M) Right Trunk Area C313 (LTD, Concorde, BUX) Right Trunk Area C314 Left Trunk Area C315 Left Trunk Area C316...
Page 198 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C318 Under Passenger Seat C319 Under Drivers Seat C320 Left Side Shelf Panel 20, 22 C321 (300M) Deck Lid C322 Left B Pillar C325 At Left C Pillar, Behind Sholder Belt Ancor C360 At bottom of I/P Center Stack...
Page 199 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Driver Power Seat Front Riser At Driver Seat Motor Driver Power Seat Front Riser At Driver Seat Sensor Driver Power Seat Horizontal Motor At Driver Seat Driver Power Seat Horizontal Motor At Driver Seat Sensor...
Page 200 Knock Sensor (2.7L) Under Intake Manifold Knock Sensor (3.5L) Under Intake Manifold Leak Detection Pump Center of Trunk Area Left Back-Up Lamp (Dodge) At Lamp Left Back-Up Lamp (300M, BUX) At Lamp Left Back-Up Lamp (LTD) At Lamp Left Fog Lamp...
Page 201 At Lamp Left Tail / Stop Lamp (Concorde) At Lamp Left Tail / Stop Lamp (LTD/BUX) At Lamp Left Tail / Stop Lamp No.1 (Dodge) At Lamp Left Tail / Stop Lamp No.1 (LTD, At Lamp 300M,BUX) Left Tail / Stop Lamp No.2 (300M) At Lamp Left Tail / Stop Lamp No.2 (Dodge)
Page 202 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Manual Temperature Control Head Center of I/P - C2 Memory Heated Seat / Mirror Under Driver Seat Module C1 Memory Heated Seat / Mirror Under Driver Seat Module C2 Memory Heated Seat / Mirror...
Page 203 Remote Rear Power Post In Trunk at Right Side Panel Right Back-Up Lamp (300M, BUX) At Lamp Right Back-Up Lamp (Concorde) At Lamp Right Back-Up Lamp (Dodge) At Lamp Right Back-Up Lamp (LTD) At Lamp Right Fog Lamp (300M, BUX, At Lamp...
Page 204 Right Front Door Right Front Park/Turn Signal Lamp At Lamp (Dodge) Right Front Park/Turn Signal Lamp At Lamp (Except Dodge) Right Front Position Lamp At Right Headlamp Right Front Side Marker Lamp At Lamp Right Front Wheel Speed Sensor Right Fender Side Shield...
Page 205: Grounds
FIG. Right Tail / Stop Lamp No.1 (LTD, At Lamp 300M, BUX) Right Tail / Stop Lamp No.2 At Lamp (Dodge) Right Tail / Stop Lamp No.2 (300M) At Lamp Right Tail / Turn Signal Lamp At Lamp (Concorde) Right Visor/Vanity Lamp...
Page 206: Splices
8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER LOCATION FIG. G105 Near Right Horn G106 Near Right Horn G108 Near Power Distribution Center G200 Lower Center of Instrument Panel G201 Lower Center of Instrument Panel G300 Under Driver Seat 15, 16...
Page 207 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S130 Front Lighting Near T/O for Left Front Lamps S131 Front Lighting Near T/O for Left Front Lamps S132 Front Lighting Near T/O for Left Front Lamps S133 Front Lighting Near T/O for Left Front Lamps S134...
Page 208 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S212 A/C Heater Harness Near T/O to Blend Door Actuator S214 Instrument Panel, Behind Cluster S215 Instrument Panel Left Side in T/O to C103 S216 In T/O to Right Radio Remote Switch S217 In T/O to Right Radio Remote Switch...
Page 209 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S331 Body Harness, Left Side Body S332 Body Harness, Right Side Body S334 Body Harness, Left Side Body S335 Body Harness, Left Side Body S336 Body Harness, Left Cowl S337 Body Harness, Body Rear...
Page 210 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 1 FRONT OF ENGINE Fig. 2 RIGHT FRONT ENGINE COMPARTMENT...
Page 211 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 212 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 213 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 214 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 215 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 216 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 217 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 218 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 10 LEFT INSTRUMENT PANEL END CAP Fig. 11 ACCESSORY EQUIPMENT CONNECTOR...
Page 219 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 12 HEADLAMP FLASHER - POLICE...
Page 220 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 221 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 14 LEFT SIDE BODY REAR...
Page 222 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 223 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 224 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 17 RIGHT FRONT DOOR Fig. 18 RIGHT FRONT DOOR PANEL...
Page 225 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 RIGHT REAR DOOR PANEL Fig. 20 SHELF PANEL...
Page 226 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 21 AUXILIARY LIGHT CONNECTOR Fig. 22 DECK LID...
Page 227 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 23 RIGHT TRUNK, REAR POWER AND ACCESSORIES...
Page 228 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 230 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......3 DESCRIPTION .
Page 231: Power Distribution
8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION (Continued) • Move the fuse slightly right and insert it in the The power distribution system for this vehicle con- sists of the following components: fuse #6 “BAT” location in the junction block. •...
Page 232: Operation
8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER/POWER OUTLET (Continued) IOD FUSE DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Junction Block when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the junction block as part of the preparation procedures performed just prior to new vehicle deliv- ery.
Page 233: Operation
8W - 97 - 4 8W-97 POWER DISTRIBUTION IOD FUSE (Continued) when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse.
Page 234: Operation
8W-97 POWER DISTRIBUTION 8W - 97 - 5 JUNCTION BLOCK (Continued) repaired and is only serviced as an assembly. If any POWER DISTRIBUTION internal circuit or the JB housing is faulty or dam- CENTER aged, the entire Junction Block assembly must be replaced.
Page 235: Removal
8W - 97 - 6 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) dards Organization (ISO) relays, and up to seven ISO INSTALLATION micro-relays. Internal connection of all the PDC cir- The Power Distribution Center (PDC) is serviced cuits is accomplished by an intricate network of hard as a unit with the engine compartment wire harness.
Page 236 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 2.7L......1 ENGINE 3.5L.
Page 237 9 - 2 ENGINE 2.7L INSTALLATION - OFF VEHICLE ... 36 VIBRATION DAMPER VALVE STEM SEALS REMOVAL ......54 REMOVAL .
Page 238: Engine 2.7L
ENGINE 2.7L 9 - 3 INSPECTION ......69 INSPECTION ......75 ASSEMBLY .
Page 239 9 - 4 ENGINE 2.7L ENGINE 2.7L (Continued) Fig. 1 2.7 Liter Engine Fig. 2 Cylinder Numbering and Firing Order...
Page 240: Diagnosis And Testing
ENGINE 2.7L 9 - 5 ENGINE 2.7L (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
Page 241: Diagnosis And Testing - Engine Diagnosis - Performance
9 - 6 ENGINE 2.7L ENGINE 2.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ BATTERY - DESCRIPTION) 2.
Page 242 ENGINE 2.7L 9 - 7 ENGINE 2.7L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Set gap as needed or replace plug(s). 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 243: Diagnosis And Testing - Engine Diagnosis - Mechanical
9 - 8 ENGINE 2.7L ENGINE 2.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 244 ENGINE 2.7L 9 - 9 ENGINE 2.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 245: Diagnosis And Testing - Cylinder Compression Pressure Test
9 - 10 ENGINE 2.7L ENGINE 2.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to Appropriate Diagnostic Manual) 2. Worn, scuffed or broken rings. 2.
Page 246: Standard Procedure Standard Procedure - Form-In- Place Gaskets And Sealers
ENGINE 2.7L 9 - 11 ENGINE 2.7L (Continued) Calibrate the tester according to the manufactur- will not cure if left in the uncovered tube. The er’s instructions. The shop air source for testing anaerobic material is for use between two machined should maintain 483 kPa (70 psi) minimum, 1,379 surfaces.
Page 247: Standard Procedure - Engine Core And Oil Gallery Plugs
9 - 12 ENGINE 2.7L ENGINE 2.7L (Continued) Never use the following to clean gasket surfaces: • Metal scraper • Abrasive pad or paper to clean cylinder block and head • High speed power tool with an abrasive pad or a wire brush (Fig.
Page 248: Standard Procedure - Hydrostatic Locked Engine
ENGINE 2.7L 9 - 13 ENGINE 2.7L (Continued) STANDARD PROCEDURE - HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.
Page 249 9 - 14 ENGINE 2.7L ENGINE 2.7L (Continued) (8) Remove air cleaner assembly and air inlet hose (Fig. 8). (9) Remove upper radiator crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REIN- FORCEMENT - REMOVAL) Fig. 8 Air Cleaner and Inlet Hose 1 - AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 - THROTTLE BODY (20) Disconnect throttle and speed control cables.
Page 250: Installation - Engine Assembly
ENGINE 2.7L 9 - 15 ENGINE 2.7L (Continued) (34) Lower vehicle. (12) Lower vehicle. (35) Remove screws attaching fuel line and electri- (13) Install rear throttle body support bracket. cal harness to the throttle body bracket. (14) Install electrical harness and fuel line support (36) Remove the fasteners attaching the following brackets to the throttle body support bracket.
Page 251 9 - 16 ENGINE 2.7L ENGINE 2.7L (Continued) Fig. 9 ENGINE LIFTING FIXTURE 1 - SPECIAL TOOL 8342 - ENGINE LIFTING FIXTURE 3 - ATTACHING LOCATION - REAR OF ENGINE 2 - ATTACHING LOCATION - FRONT OF ENGINE (39) Install right and left cowl screens. (Refer to 23 (42) Connect negative cable to remote jumper ter- - BODY/EXTERIOR/COWL GRILLE AND SCREEN - minal at right strut tower.
Page 252: Specifications
ENGINE 2.7L 9 - 17 ENGINE 2.7L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Piston Rings 2.7L ENGINE Ring Gap—Top 0.20–0.36 mm Compression Ring (0.008–0.014 in.) DESCRIPTION SPECIFICATION Ring Gap—2nd 0.37–0.63 mm General Specifications Compression Ring (0.0146–0.0249 in.) Type 60° DOHC V-6 24-Valve Ring Gap—Oil Control 0.25–0.76 mm Displacement...
Page 253 9 - 18 ENGINE 2.7L ENGINE 2.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Taper (Max.) 0.015 mm Intake Valve Seat Width 1.00–1.5 mm (0.0006 in.) (0.0394–0.0591 in.) End Play 0.0475–0.2725 mm Exhaust Valve Seat 1.25–1.75 mm Width (0.0019–0.0108 in.) (0.0492–0.0689 in.) End Play (Max.) 0.43 mm Guide Bore Diameter...
Page 254: Torque
ENGINE 2.7L 9 - 19 ENGINE 2.7L (Continued) TORQUE DESCRIPTION SPECIFICATION Valve Spring Free Length—Intake & 45.63 mm DESCRIPTION N·m Lbs. Lbs. Exhaust (Approx.) (1.7965 in.) A/C Compressor to — Spring Force—Intake & 249–284 N @ 38.0 mm Engine—Bolts Exhaust (Valve Closed) (56.0–64.0 lbs.
Page 255: Special Tools
9 - 20 ENGINE 2.7L ENGINE 2.7L (Continued) DESCRIPTION N·m Lbs. Lbs. Oil Pump Cover—Bolts — Oil Pump Pick Up — Tube—Bolt PCV Valve — Crankshaft Rear Seal — Retainer—Bolts Puller 1023 Spark Plugs — Starter Mounting—Bolts — Structural Collar (Refer to 9 - ENGINE/ ENGINE BLOCK/ STRUCTURAL COVER -...
Page 256 ENGINE 2.7L 9 - 21 ENGINE 2.7L (Continued) Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Crankshaft Seal Remover 6771 Crankshaft Seal & Sprocket Installer 6780-1 Driver Handle C-4171 Crankshaft Seal Protector 6780-2 Crankshaft Real Seal Retainer Alignment Fixture 8225 Puller 5048 Timing Chain Tensioner Resetting Gauge 8186 Puller Adaptor 8539...
Page 257 9 - 22 ENGINE 2.7L ENGINE 2.7L (Continued) Valve Spring Compressor 8215 Valve Spring Compressor MD-998772-A Adapter 8216 Valve Spring Adapter 6527 Valve Spring Compressor C-3422-D Indicator Bore Size C-119 Valve Spring Adapter 6526 Connecting Rod Installation Guides 8189 Valve Spring Tester C-647 Main Bearing Remover/Installer C-3059...
Page 258: Air Cleaner Element Removal
ENGINE 2.7L 9 - 23 ENGINE 2.7L (Continued) Cooling System Tester 7700 Pressure Gauge C-3292 Adapter 8406 Combustion Leak Tester C-3685-A AIR CLEANER ELEMENT REMOVAL (1) Remove air cleaner lid. Lift lid off of air cleaner housing. (2) Remove filter element (Fig. 10). DRBIII with PEP Module –...
Page 259: Cylinder Head
9 - 24 ENGINE 2.7L Possible indications of the cylinder head gasket CYLINDER HEAD leaking between a cylinder and an adjacent water jacket are: DESCRIPTION • Engine overheating The cylinder heads are made of an aluminum alloy • Loss of coolant (Fig.
Page 260: Removal
ENGINE 2.7L 9 - 25 CYLINDER HEAD (Continued) CYLINDER-TO-WATER JACKET LEAKAGE TEST (7) Remove water outlet connector (Fig. 12). (Refer COOLING/ENGINE/COOLANT OUTLET HOUSING - REMOVAL) WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED. VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap.
Page 261: Cleaning
9 - 26 ENGINE 2.7L CYLINDER HEAD (Continued) Fig. 14 CAMSHAFT & VALVETRAIN COMPONENTS 1 – CAMSHAFT BEARING CAP - INTAKE 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 2 – CAMSHAFT BEARING CAP - EXHAUST 8 – CYLINDER BLOCK 3 – CAMSHAFT - EXHAUST 9 –...
Page 262: Inspection
ENGINE 2.7L 9 - 27 CYLINDER HEAD (Continued) NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCE- DURE). Be careful not to gouge or scratch the alumi- num head sealing surface.
Page 263: Camshaft(S) Description
9 - 28 ENGINE 2.7L CYLINDER HEAD (Continued) (7) Install all valvetrain components and cam- OPERATION shafts. (Refer to 9 - ENGINE/CYLINDER HEAD/ The camshaft has precisely machined (egg shaped) CAMSHAFT(S) - INSTALLATION) Tighten camshaft lobes to provide accurate valve timing and duration. bearing caps in sequence shown in (Fig.
Page 264: Installation
ENGINE 2.7L 9 - 29 CAMSHAFT(S) (Continued) Fig. 20 Camshaft and Valvetrain Components 1 – CAMSHAFT BEARING CAP - INTAKE 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 2 – CAMSHAFT BEARING CAP - EXHAUST 8 – CYLINDER BLOCK 3 – CAMSHAFT - EXHAUST 9 –...
Page 265: Cylinder Head Cover(S) Removal
9 - 30 ENGINE 2.7L CAMSHAFT(S) (Continued) Fig. 23 Camshaft Inspection Fig. 21 Camshaft End Play Measuring 1 - ACTUAL WEAR 1 - DIAL INDICATOR 2 - BEARING JOURNAL 3 - EXHAUST CAMSHAFT 4 - INTAKE CAMSHAFT 5 - LOBE Fig.
Page 266: Installation
ENGINE 2.7L 9 - 31 CYLINDER HEAD COVER(S) (Continued) Fig. 27 Cylinder Head Cover Gasket and Spark Plug Seals 1 - ONE PIECE GASKET Fig. 25 Camshaft Chain Timing 2 - SPARK PLUG WELL SEALS 1 - PLATED CHAIN LINKS 2 - CAMSHAFT TIMING MARKS (4) Connect all electrical connectors and harness clips.
Page 267: Removal
9 - 32 ENGINE 2.7L INTAKE/EXHAUST VALVES & SEATS (Continued) VALVES Inspect the remaining margin after the valves are refaced. (Refer to 9 - ENGINE - SPECIFICATIONS) VALVE SEATS (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- ing stones.
Page 268: Inspection
ENGINE 2.7L 9 - 33 INTAKE/EXHAUST VALVES & SEATS (Continued) VALVE GUIDES (1) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. (2) Measure valve stem-to-guide clearance as fol- lows: (3) Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat.
Page 269: Valve Springs Description
9 - 34 ENGINE 2.7L INTAKE/EXHAUST VALVES & SEATS (Continued) (5) Remove cylinder head covers. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) (6) Remove crankshaft vibration damper (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL), timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL), and timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING...
Page 270: Installation
ENGINE 2.7L 9 - 35 VALVE SPRINGS (Continued) Fig. 34 VALVE, SPRING SEAT/SEAL, SPRING, REATINER AND LOCKS 1 - VALVE KEEPER 7 - VALVE-EXHAUST 2 - SPRING RETAINER 8 - VALVE-INTAKE 3 - VALVE KEEPER 9 - CYLINDER HEAD 4 - VALVE SPRING-EXHAUST 10 - VALVE STEM SEAL 5 - SPRING RETAINER 11 - VALVE SPRING-INTAKE...
Page 271: Installation - Off Vehicle
9 - 36 ENGINE 2.7L VALVE SPRINGS (Continued) - ENGINE/VALVE TIMING/TIMING BELT / CHAIN retainer. If height is greater than 38.75 mm (1.5256 COVER(S) - INSTALLATION). in.), install a 0.762 mm (0.030 in.) spacer in head (6) Install cylinder head covers. (Refer to 9 - counterbore under the valve spring seat to bring ENGINE/CYLINDER HEAD/CYLINDER...
Page 272: Installation
ENGINE 2.7L 9 - 37 VALVE STEM SEALS (Continued) INSTALLATION HYDRAULIC LASH (1) The valve stem seal/valve spring seat should be ADJUSTERS pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal DIAGNOSIS AND TESTING - HYDRAULIC LASH against top of guide.
Page 273: Removal
9 - 38 ENGINE 2.7L HYDRAULIC LASH ADJUSTERS (Continued) REMOVAL OPERATION (1) Remove cylinder head cover(s). (Refer to 9 - The rocker arm is the pivot point between the cam- ENGINE/CYLINDER HEAD/CYLINDER HEAD shaft lobe and the valve. COVER(S) - REMOVAL) REMOVAL (2) Remove rocker arm(s).
Page 274: Inspection
ENGINE 2.7L 9 - 39 ROCKER ARMS (Continued) INSPECTION STANDARD PROCEDURE - CYLINDER BORE Inspect the cam follower assembly for wear or HONING damage (Fig. 41). Replace as necessary. (1) Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure.
Page 275 9 - 40 ENGINE 2.7L ENGINE BLOCK (Continued) Fig. 42 ENGINE BLOCK AND CRANKSHAFT 1 - MAIN CAP BOLT—VERTICAL 5 - MAIN CAP BOLT —HORIZONTAL 2 - MAIN CAP 6 - CYLINDER BLOCK 3 - MAIN BEARING—LOWER 7 - CRANKSHAFT 4 - MAIN BEARING—UPPER (4) Check block deck surfaces for flatness.
Page 276: Connecting Rod Bearings
ENGINE 2.7L 9 - 41 ENGINE BLOCK (Continued) (1) For measuring Main Bearing Clearance and Connecting Rod Bearing Clearance use plastigage (Fig. 45). For more information on using plastigage (Refer to 9 - ENGINE - STANDARD PROCEDURE). Refer to Engine Specifications for bearing clearance specifications (Refer to 9 - ENGINE - SPECIFICA- TIONS).
Page 277: Crankshaft Description
9 - 42 ENGINE 2.7L CONNECTING ROD BEARINGS (Continued) ing rod throws are an even-firing design which reduces torque fluctuations while a vibration damper is used to control torsional vibration. The crankshaft oil seals are a one piece design. The front seal is retained by the timing chain cover, and the rear seal in a housing that attaches to the cylinder block.
Page 278: Installation
ENGINE 2.7L 9 - 43 CRANKSHAFT (Continued) (8) Remove timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL). (9) Remove primary timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN AND SPROCKETS - REMOVAL). (10) Remove crankshaft sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN AND...
Page 279 9 - 44 ENGINE 2.7L CRANKSHAFT (Continued) Fig. 51 CYLINDER BLOCK AND CRANKSHAFT 1 - MAIN CAP BOLT—VERTICAL 5 - MAIN CAP BOLT —HORIZONTAL 2 - MAIN CAP 6 - CYLINDER BLOCK 3 - MAIN BEARING—LOWER 7 - CRANKSHAFT 4 - MAIN BEARING—UPPER (3) Push crankshaft forward.
Page 280: Crankshaft Main Bearings Standard Procedure - Crankshaft Main Bearing Fitting
ENGINE 2.7L 9 - 45 CRANKSHAFT (Continued) (17) Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (18) Install idler pulley bracket for accessory drive belt. (19) Install oil pick-up tube and O-ring. (20) Install oil pan and oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION).
Page 281 9 - 46 ENGINE 2.7L CRANKSHAFT MAIN BEARINGS (Continued) Fig. 54 Crankshaft Main Journal Grade Marking Location Fig. 56 Main Bearing Grade Marks 1 - LOWER MAIN BEARING 2 - UPPER MAIN BEARING 3 - OIL FEED HOLE AND GROOVE 4 - GRADE SELECTION INK MARKS MAIN BEARING SELECTION CHART—2.7L Main Bearing Bore Grade...
Page 282: Crankshaft Oil Seal - Front
ENGINE 2.7L 9 - 47 CRANKSHAFT OIL SEAL - FRONT REMOVAL (1) Remove crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (2) Install Special Tool 8194, Insert into crankshaft nose. Remove seal using Special Tool 6771, Remover (Fig. 57). Fig.
Page 283: Crankshaft Oil Seal - Rear
9 - 48 ENGINE 2.7L INSTALLATION CRANKSHAFT OIL SEAL - REAR CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), clean surface using 400 REMOVAL grit sand paper to prevent seal damage during (1) Remove transaxle from vehicle. (Refer to 21 - installation.
Page 284: Crankshaft Rear Oil Seal Retainer
ENGINE 2.7L 9 - 49 CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL (1) Remove crankshaft rear oil seal and oil pan. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK- SHAFT OIL SEAL - REAR - REMOVAL) (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL) (2) Remove seal retainer attaching screws (Fig.
Page 285 9 - 50 ENGINE 2.7L FLEX PLATE (Continued) (3) Install flex plate bolts (Fig. 63). Tighten bolts OPERATION to 95 N·m (70 ft. lbs.). The piston and connecting rod is the link between (4) Install the transaxle. (Refer to 21 - TRANS- the combustion force to the crankshaft.
Page 286 ENGINE 2.7L 9 - 51 PISTON & CONNECTING ROD (Continued) CAUTION: DO NOT use a number stamp or a punch INSTALLATION to mark connecting rods. Damage to connecting (1) Install the piston rings. (Refer to 9 - ENGINE/ rod could occur. ENGINE BLOCK/PISTON RINGS - INSTALLA- TION) (2) Mark connecting rod and bearing cap positions...
Page 287 9 - 52 ENGINE 2.7L PISTON & CONNECTING ROD (Continued) (5) Position bearing onto connecting rod. Ensure (9) Tap the piston down in cylinder bore, using a that hole in bearing half is aligned to hole in con- hammer handle. At the same time, guide connecting necting rod.
Page 288 ENGINE 2.7L 9 - 53 PISTON RINGS (Continued) INSTALLATION (1) Measure clearance of piston rings to the cylin- der bore and piston. (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCE- DURE) (2) The No. 1 and No. 2 piston rings have a differ- ent cross section.
Page 289 9 - 54 ENGINE 2.7L PISTON RINGS (Continued) Fig. 75 PISTON RING END GAP POSITION Fig. 73 SIDE RAIL - INSTALLATION 1 - SIDE RAIL UPPER 1 - SIDE RAIL END 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO.
Page 290 ENGINE 2.7L 9 - 55 VIBRATION DAMPER (Continued) STRUCTURAL COLLAR / COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove bolts attaching structural collar to oil pan and transmission housing (Fig. 79). (3) Remove collar (Fig. 79). Fig. 77 VIBRATION DAMPER - REMOVAL 1 - SPECIAL TOOL 1023 2 - SPECIAL TOOL 8194 INSERT (3) Install accessory drive belts (Refer to 7 -...
Page 291 9 - 56 ENGINE 2.7L (2) Remove the isolator attaching nuts from top of ENGINE MOUNTING the mounting bracket (Fig. 80). (3) Support the engine with a jack and a block of DESCRIPTION wood across the full width of the oil pan. The engine mounting system consist of three (4) Remove the lower attaching nuts from the bot- mounts;...
Page 292 ENGINE 2.7L 9 - 57 (2) Remove the isolator attaching nuts from top of REAR MOUNT the mounting bracket (Fig. 81). (3) Support the engine with a jack and a block of REMOVAL wood across the full width of the oil pan. (1) Raise vehicle on hoist.
Page 293 9 - 58 ENGINE 2.7L OPERATION LUBRICATION Oil from the oil pan is pumped by a geroter type oil DESCRIPTION pump directly coupled to the crankshaft (Fig. 82). Oil pressure is controlled by a relief valve mounted The lubrication system is a full-flow filtration, inside the oil pump housing.
Page 294 ENGINE 2.7L 9 - 59 LUBRICATION (Continued) FROM: FROM: Oil Pump Oil Filter Mounting (inlet) Main Oil Gallery - Center 1. Crankshaft Main of Block Bearings Oil Filter Mounting (inlet) Oil Filter 2. Left Cylinder Head* Oil Filter Oil Filter Mounting (outlet) 3.
Page 295 9 - 60 ENGINE 2.7L LUBRICATION (Continued) FROM: Left Cylinder Head Oil Inlet Gallery (intake side of Oil Gallery and Accumulator – Rear of Head* head) Oil Gallery and Accumulator – Rear of Head* 1. Exhaust Camshaft Oil Passage 2. Intake Camshaft Oil Passage Left Exhaust Camshaft Oil Passage 1.
Page 296 ENGINE 2.7L 9 - 61 LUBRICATION (Continued) FROM: Right Cylinder Head Oil Inlet Gallery (intake side of Oil Gallery and Accumulator – Rear of Head* head) Oil Gallery and Accumulator – Rear of Head* 1. Exhaust Camshaft Oil Passage 2. Intake Camshaft Oil Passage Right Exhaust Camshaft Oil Passage 1.
Page 297 9 - 62 ENGINE 2.7L LUBRICATION (Continued) If the leakage occurs at the crankshaft rear oil seal (4) Oil Pressure (engine at operating temperature): area: Curb Idle 34.5 kPa (5 psi) minimum 3000 RPM (1) Disconnect the battery. 300–724 kPa (45–105 psi). (2) Raise the vehicle.
Page 298 ENGINE 2.7L 9 - 63 OIL (Continued) STANDARD PROCEDURE - ENGINE OIL AND OIL FILTER SPECIFICATION All engines are equipped with a high quality full- FILTER CHANGE flow, disposable type oil filter. When replacing oil fil- ter, use a Mopar filter or equivalent. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN.
Page 299 9 - 64 ENGINE 2.7L OIL COOLER & LINES (Continued) Fig. 86 ENGINE OIL COOLER - 2.7L ENGINE 1 - ENGINE OIL COOLER SUPPLY LINE 3 - ENGINE OIL COOLER FITTINGS 2 - RETAINER 4 - ENGINE OIL COOLER RETURN LINE Fig.
Page 300 ENGINE 2.7L 9 - 65 OIL COOLER & LINES (Continued) Fig. 88 ENGINE OIL COOLER - 2.7L 1 - ENGINE OIL COOLER SUPPLY LINE 3 - ENGINE OIL COOLER FITTINGS 2 - RETAINER 4 - ENGINE OIL COOLER RETURN LINE Fig.
Page 301 9 - 66 ENGINE 2.7L OIL COOLER & LINES (Continued) INSTALLATION ENGINE OIL COOLER (1) Install radiator assembly. (Refer to 7 - COOL- ING/ENGINE/RADIATOR - INSTALLATION) (2) Tighten oil cooler lines to radiator fittings to 18 N·m (160 in. lbs.). COOLER LINES (1) Connect cooler lines to radiator fittings and retainer clip (Fig.
Page 302 ENGINE 2.7L 9 - 67 OIL PAN (Continued) (a) Install oil pan bolts and nuts finger tight only—just tight enough to compress the gas- ket’s rubber seal. (b) Install timing chain cover to pan bolts and tighten to 12 N·m (105 in. lbs.). (c) Tighten oil pan bolts to 28 N·m (250 in.
Page 303 9 - 68 ENGINE 2.7L OIL PRESSURE RELIEF VALVE (Continued) OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light.
Page 304 ENGINE 2.7L 9 - 69 OIL PUMP (Continued) Fig. 94 Crankshaft Positioned At 60 DEGREES ATDC No.1 Cylinder 1 - CRANKSHAFT POSITION = 60° ATDC NO. 1 CYLINDER Fig. 96 Oil Pressure Relief Valve 1 - RELIEF VALVE 2 - SPRING 3 - RETAINER CAP (3) Remove oil pump cover screws and lift off cover plate (Fig.
Page 305 9 - 70 ENGINE 2.7L OIL PUMP (Continued) Fig. 99 MEASURING OUTER ROTOR THICKNESS Fig. 97 Oil Pump 1 - OIL PUMP COVER 2 - SCREWS (8) 3 - OIL PUMP INNER ROTOR 4 - OIL PUMP HOUSING 5 - OIL PUMP OUTER ROTOR Fig.
Page 306: Assembly
ENGINE 2.7L 9 - 71 OIL PUMP (Continued) Fig. 103 MEASURING CLEARANCE OVER ROTORS 1 - STRAIGHT EDGE 2 - FEELER GAUGE Fig. 101 MEASURING OUTER ROTOR CLEARANCE IN HOUSING (4) Prime oil pump before installation by filling 1 - FEELER GAUGE rotor cavity with engine oil.
Page 307: Intake Manifold Description
9 - 72 ENGINE 2.7L (1) File or sand the remaining port back until a INTAKE MANIFOLD flat surface is obtained (plane normal to nipple (port) axis). DESCRIPTION (2) Drill out the nipple (port) base using a 7/16” The two piece intake manifold is made of a com- drill bit (Fig.
Page 308: Inspection
ENGINE 2.7L 9 - 73 INTAKE MANIFOLD - UPPER (Continued) INSPECTION Check manifold for: • Damage and cracks • Gasket surface damage or warpage • Damaged or clogged EGR ports If the manifold exihibits any damaged or warped conditions, replace the manifold. Clean EGR ports as neccessary.
Page 309: Intake Manifold - Lower Removal
9 - 74 ENGINE 2.7L INTAKE MANIFOLD - UPPER (Continued) (6) Connect electrical connectors to the following NOTE: For ease of installing upper intake manifold, components: install a bolt 2 – 3 turns to the rearmost attaching • Manifold Absolute Pressure (MAP) Sensor hole of intake.
Page 310: Exhaust Manifold Description
ENGINE 2.7L 9 - 75 (7) Remove heat shield attaching screws and EXHAUST MANIFOLD remove heat shields (Fig. 110). (8) Remove exhaust manifold attaching bolts and DESCRIPTION remove manifold (Fig. 110). The exhaust manifolds are a log style design and made of cast nodular iron (Fig.
Page 311: Exhaust Manifold - Left Removal
9 - 76 ENGINE 2.7L EXHAUST MANIFOLD - RIGHT (Continued) (6) Install bolt attaching battery cable housing tube to transmission housing. Tighten bolt to 101 N·m (75 ft. lbs.). (7) Install air intake tube and air filter housing. (8) Connect negative cable. EXHAUST MANIFOLD - LEFT REMOVAL (1) Disconnect negative cable from remote jumper...
Page 312 ENGINE 2.7L 9 - 77 VALVE TIMING (Continued) side” of the primary chain, necessitating the double- The secondary timing chain drive system uses flexure type chain. two conventional roller-type chains, one at each cyl- The chain is controlled by three fixed chain guides inder bank (Fig.
Page 313: Standard Procedure Engine Timing - Verification
9 - 78 ENGINE 2.7L VALVE TIMING (Continued) STANDARD PROCEDURE TIMING CHAIN COVER ENGINE TIMING - VERIFICATION REMOVAL Correct timing is critical for the NON free-wheel- (1) Disconnect negative cable from remote jumper ing designed, 2.7L engine. Engine timing can be ver- terminal.
Page 314: Installation
ENGINE 2.7L 9 - 79 TIMING CHAIN COVER (Continued) INSTALLATION (1) Inspect and clean sealing surfaces. Inspect and replace gasket and seal as necessary. (2) If front crankshaft seal was bench installed, place Special Tool 6780-2, Sleeve over crankshaft nose to guide and protect seal lip. (3) Before installing timing cover gasket apply a 1/8 inch bead of Mopar Engine RTV GEN II to the parting lines between the oil pan and cylinder block...
Page 315: Removal - Crankshaft Sprocket
9 - 80 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage. (3) Align crankshaft sprocket timing mark to mark on oil pump housing (Fig.
Page 316 ENGINE 2.7L 9 - 81 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 118 TIMING DRIVE SYSTEM - PRIMARY 1 - CAMSHAFT DAMPER 7 - CHAIN GUIDE 2 - CHAIN GUIDE 8 - CHAIN TENSIONER ARM 3 - ACCESS PLUG 9 - CHAIN TENSIONER 4 - CAMSHAFT POSITION SENSOR 10 - CAMSHAFT SPROCKETS 5 - PRIMARY TIMING CHAIN...
Page 317: Installation Installation - Timing Chain
9 - 82 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) (7) Loosely position left side camshaft sprocket over camshaft hub. (8) Align timing (plated) link to the crankshaft sprocket timing mark (Fig. 120). (9) Position primary chain onto water pump drive sprocket.
Page 318 ENGINE 2.7L 9 - 83 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 120 TIMING CHAIN ALIGNMENT MARKS - PRIMARY 1 - CAMSHAFT TIMING MARKS 6 - CHAIN TENSIONER 2 - CHAIN GUIDE 7 - CAMSHAFT TIMING MARK 3 - CRANKSHAFT TIMING MARKS 8 - INTAKE CAMSHAFT SPROCKETS 4 - CRANKSHAFT SPROCKET 9 - CHAIN GUIDES...
Page 319 9 - 84 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 121 TIMING CHAIN TENSIONER - OIL PURGING 1 - TENSIONER 3 - SPECIAL TOOL 8186 2 - CHECK BALL 4 - PIN...
Page 320 ENGINE 2.7L 9 - 85 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 122 TIMING CHAIN TENSIONER - RESETTING 1 - TENSIONER 2 - SPECIAL TOOL 8186 (16) Install the reset chain tensioner into the right (19) Turn the left side camshaft by inserting a 3/8” cylinder head (Fig.
Page 321: Installation - Crankshaft Sprocket
9 - 86 ENGINE 2.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) INSTALLATION - CRANKSHAFT SPROCKET (1) Install crankshaft sprocket using Special Tools 6780-1 and 8179 (Fig. 124) until sprocket bottoms against crankshaft step flange. Use care not to rotate crankshaft. Fig. 123 TIMING CHAIN TENSIONER ACTIVATING (22) Install the timing chain cover, crankshaft Fig.
Page 322 ENGINE 3.5L 9 - 87 ENGINE 3.5L TABLE OF CONTENTS page page ENGINE 3.5L CAMSHAFT(S) DESCRIPTION ......90 DESCRIPTION .
Page 323 9 - 88 ENGINE 3.5L REMOVAL - CYLINDER HEAD ON ..125 ENGINE MOUNTING INSPECTION ......126 DESCRIPTION .
Page 324 ENGINE 3.5L 9 - 89 DIAGNOSIS AND TESTING - INTAKE TIMING BELT COVER(S) - REAR MANIFOLD LEAKS ....159 REMOVAL ......168 INTAKE MANIFOLD - UPPER INSTALLATION .
Page 325: The Cylinders Are Numbered From Front To Rear
9 - 90 ENGINE 3.5L ENGINE 3.5L DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DESCRIPTION DIAGNOSIS - INTRODUCTION The 3.5 Liter (214 Cubic Inches) 60 degree V-6 engines is a single overhead camshaft design with Engine diagnosis is helpful in determining the hydraulic lifters and four valves per cylinder (Fig.
Page 326 ENGINE 3.5L 9 - 91 ENGINE 3.5L (Continued) Fig. 2 Cylinder Numbering & Firing Order - 3.5L For fuel system diagnosis, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts.
Page 327: Diagnosis And Testing - Engine Diagnosis - Mechanical
9 - 92 ENGINE 3.5L ENGINE 3.5L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 328 ENGINE 3.5L 9 - 93 ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 329: Diagnosis And Testing - Engine Diagnosis - Performance
9 - 94 ENGINE 3.5L ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to Appropriate Diagnostic Manual) 2. Worn, scuffed or broken rings. 2.
Page 330 ENGINE 3.5L 9 - 95 ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer to ROUGH Appropriate Diagnostic Information) 2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic Information) 3.
Page 331: Diagnosis And Testing - Cylinder Compression Pressure Test
9 - 96 ENGINE 3.5L ENGINE 3.5L (Continued) • Leaks between adjacent cylinders or into water DIAGNOSIS AND TESTING - CYLINDER jacket. COMPRESSION PRESSURE TEST • Any causes for combustion/compression pressure The results of a cylinder compression pressure test loss. can be utilized to diagnose several engine malfunc- tions.
Page 332: Standard Procedure - Engine Gasket Surface Preparation
ENGINE 3.5L 9 - 97 ENGINE 3.5L (Continued) specially designed black silicone rubber RTV that may be removed with a shop towel. Components retains adhesion sealing properties when should be torqued in place while the sealant is still exposed to engine oil. Moisture in the air causes the wet to the touch (within 10 minutes).
Page 333: Standard Procedure - Hydrostatic Locked Engine
9 - 98 ENGINE 3.5L ENGINE 3.5L (Continued) (8) Install new spark plugs. (9) Drain engine oil and remove oil filter. (10) Install a new oil filter. (11) Fill engine with specified amount of approved oil. (12) Connect negative battery cable. (13) Start engine and check for any leaks.
Page 334: Standard Procedure - Measuring Bearing Clearance Using Plastigage
ENGINE 3.5L 9 - 99 ENGINE 3.5L (Continued) STANDARD PROCEDURE - MEASURING REMOVAL - ENGINE ASSEMBLY BEARING CLEARANCE USING PLASTIGAGE (1) Release fuel pressure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCE- Engine crankshaft bearing clearances can be deter- DURE) mined by use of Plastigage or equivalent.
Page 335: Installation - Engine Assembly
9 - 100 ENGINE 3.5L ENGINE 3.5L (Continued) (26) Disconnect coolant hoses at coolant recovery/ pressure container. (27) Disconnect all vacuum hoses. (28) Disconnect ground straps at both cylinder heads. CAUTION: Upper Intake manifold is a composite design. Therefore, manifold should be removed before lifting engine or damage to the manifold could occur.
Page 336 ENGINE 3.5L 9 - 101 ENGINE 3.5L (Continued) (4) Remove engine lifting device. (27) Install new V-Band clamp at right exhaust (5) Raise vehicle. manifold. Tighten V-Band clamp to 11 N·m (100 in. (6) Tighten engine mount fastener to 61 N·m (45 lbs.).
Page 337: Specifications
9 - 102 ENGINE 3.5L ENGINE 3.5L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Clearance in Rod 0.007–0.018 mm 3.5L ENGINE (0.0003–0.007 in.) DESCRIPTION SPECIFICATION Diameter 23.997–24.000 mm Type 60° SOHC V-6 24-Valve (0.9448–0.9449 in.) Displacement 3.5 Liters Piston Rings (214 Cubic Inches) Ring Gap—Top 0.20–0.36 mm Bore and Stroke...
Page 338 ENGINE 3.5L 9 - 103 ENGINE 3.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Taper (Max.) 0.015 mm Valve Seat Runout (Max.) 0.051 mm (0.0006 in) (0.002 in.) End Play 0.10–0.30 mm Valve Seat Width—Intake 0.75–1.25 mm (0.0295–0.0492 in.) (0.004–0.012 in.) Valve Seat Width— 1.25–1.75 mm —(Max.) 0.43 mm...
Page 339 9 - 104 ENGINE 3.5L ENGINE 3.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valve Stem Tip 42.366–43.655 mm Wire Diameter—Exhaust 4.16–4.22 mm Height—Intake (1.6680–1.7187 in.) (0.1638–0.1661 in.) Valve Stem Tip 44.705–45.986 mm Spring Installed Height 38.0 mm Height—Exhaust (Spring Seat to Bottom of (1.760–1.8105 in.) Retainer)—Intake &...
Page 340: Torque
ENGINE 3.5L 9 - 105 ENGINE 3.5L (Continued) TORQUE N·m DESCRIPTION Lbs. Lbs. N·m Engine Mount Isolator—Nuts — DESCRIPTION Lbs. Lbs. Generator Bracket—Bolts — A/C Compressor Bracket to — Intake Manifold Engine—Bolts —M6 Bolts — A/C Compressor to Bracket — —M8 Bolts —...
Page 341: Special Tools
9 - 106 ENGINE 3.5L ENGINE 3.5L (Continued) SPECIAL TOOLS 3.5L ENGINE Crankshaft Sprocket Puller L-4407A Puller Damper 1023 Crankshaft Seal Remover Crankshaft Damper Remover Insert C-4685-C2 Crankshaft Seal Installer 6342 Crankshaft Damper/Sprocket Installer Bolt C-4685-C1 Crankshaft Sprocket Installer 6641 Crankshaft Sprocket Installer 6641 Camshaft Alignment 6642 Crankshaft Damper Holder 8191...
Page 342 ENGINE 3.5L 9 - 107 ENGINE 3.5L (Continued) Camshaft Seal Protector 6788 Valve Spring Adapter 6526 Valve Spring Tester C-647 Camshaft Seal Remover C-3981B Valve Spring Compressor MD-998772-A Camshaft Seal Installer 6052 Valve Spring Adapter 6527 Dial Indicator C-3339 Valve Spring Compressor C-3422-D Indicator Bore Size C-119...
Page 343 9 - 108 ENGINE 3.5L ENGINE 3.5L (Continued) Main Bearing Remover/Installer C-3059 Release Probe 8351 Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Pressure Gauge C-3292 Adapter 8406 Driver Handle C-4171 DRBIII with PEP Module – OT-CH6010A Crankshaft Rear Seal Retainer Alignment Fixture 8225...
Page 344: Air Cleaner Element Removal
ENGINE 3.5L 9 - 109 ENGINE 3.5L (Continued) Pressure Transducer CH7059 Fig. 9 Air Cleaner Housing and Element 1 - AIR FILTER ELEMENT CYLINDER HEAD Adaptor 8116 DESCRIPTION The aluminum alloy cylinder heads feature cross- flow type intake and exhaust ports. Valve guides and seat inserts are powdered metal.
Page 345: Removal
9 - 110 ENGINE 3.5L CYLINDER HEAD (Continued) CYLINDER-TO-CYLINDER LEAKAGE TEST (5) Remove front timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN To determine if an engine cylinder head gasket is COVER(S) - REMOVAL) leaking between adjacent cylinders, follow the proce- (6) Remove camshaft sprockets.
Page 346: Inspection
ENGINE 3.5L 9 - 111 CYLINDER HEAD (Continued) Fig. 11 Right Side Timing Belt Cover Water Pump O-Rings Fig. 12 Checking Cylinder Head Flatness 1 - O-RINGS 2 - WATER PUMP IMPELLER NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. Remove all gasket material from cylinder head and block (Refer to 9 - ENGINE - STANDARD PROCE- DURE).
Page 347: Camshaft Oil Seal(S) Removal
9 - 112 ENGINE 3.5L CYLINDER HEAD (Continued) (8) Install rear timing belt covers (Fig. 10) and (Fig. 11). Tighten bolts to specified torque: • M10—54 N·m (40 ft. lbs.) • M8—28 N·m (20 ft. lbs.) • M6—12 N·m (105 in. lbs.) (9) Install camshaft sprockets and timing belt.
Page 348: Installation
ENGINE 3.5L 9 - 113 CAMSHAFT OIL SEAL(S) (Continued) INSTALLATION CAMSHAFT(S) (1) Apply light coat of engine oil to the camshaft DESCRIPTION oil seal lip. (2) Install the oil seal using Special Tool 6788 Seal A single overhead camshaft per cylinder head pro- Protector Sleeve (Fig.
Page 349: Removal
9 - 114 ENGINE 3.5L CAMSHAFT(S) (Continued) REMOVAL INSPECTION Camshafts are removed from the rear of each cyl- (1) Inspect camshaft bearing journals for damage inder head. The cylinder head must be removed. and binding (Fig. 21). If journals are binding, check (1) Remove camshaft sprocket(s).
Page 350: Cylinder Head Cover(S) Removal
ENGINE 3.5L 9 - 115 CYLINDER HEAD COVER(S) REMOVAL WARNING: DO NOT START OR RUN ENGINE WITH CYLINDER HEAD COVER REMOVED FROM THE ENGINE. DAMAGE OR PERSONAL INJURY MAY OCCUR. (1) Remove air cleaner assembly. (2) Remove upper intake manifold. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL)
Page 351: Intake/Exhaust Valves & Seats Description
9 - 116 ENGINE 3.5L CYLINDER HEAD COVER(S) (Continued) OPERATION The intake valve allows the air/fuel mixture to enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the com- bustion chamber. Also, the intake and exhaust valves seal the combustion chamber during the compression and power strokes.
Page 352: Removal
ENGINE 3.5L 9 - 117 INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 28 Valve Face and Seat 1 - SEAT WIDTH 2 - FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA the bottom edge of valve face, then raise valve seat Fig.
Page 353: Inspection Inspection - Valves
9 - 118 ENGINE 3.5L INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 32 Intake and Exhaust Valves 1 - MARGIN 2 - FACE 3 - STEM 4 - VALVE SPRING RETAINER LOCK GROOVES Fig. 31 Valve Seal and Spring - Installation 1 - VALVE 2 - VALVE RETAINING LOCKS 3 - VALVE SPRING RETAINER...
Page 354: Rocker Arm / Adjuster Assembly Description Description - Rocker Arm
ENGINE 3.5L 9 - 119 INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 34 Checking Valve Tip Height and Valve Spring Installed Height 1 - SPRING RETAINER 2 - GARTER SPRING 3 - VALVE SPRING SEAT TOP 4 - CYLINDER HEAD SURFACE Fig.
Page 355 9 - 120 ENGINE 3.5L ROCKER ARM / ADJUSTER ASSEMBLY (Continued) POSSIBLE NOISE SOURCES POSSIBLE NOISE MISDIAGNOSIS SOURCES Spongy/soft/aerated lash adjusters. SRV valve axle chatter. Missing lash adjuster swivel contact pads. Exhaust rocker arm-to-cylinder head cover contact. Intake rocker-to-camshaft bearing journal contact. Piston pin bore fit.
Page 356: Standard Procedure - Hydraulic Lash Adjuster Bleeding
ENGINE 3.5L 9 - 121 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) STANDARD PROCEDURE - HYDRAULIC LASH (e) Remove probes to allow check balls to seat. (f) Recheck for sponginess. If the lash adjuster ADJUSTER BLEEDING sponginess is not completely or nearly eliminated, Use this procedure to manually bleed aerated oil then repeat procedure.
Page 357: Disassembly
9 - 122 ENGINE 3.5L ROCKER ARM / ADJUSTER ASSEMBLY (Continued) Fig. 40 Rocker Arms and Shaft - Disassembly 1 - 4mm SCREW AND NUT 2 - 4mm SCREW AND NUT 3 - WASHER 4 - SPACER Fig. 38 Purging Air From Lash Adjuster 5 - DOWEL 1 - SPECIAL TOOL 8351 6 - DOWEL...
Page 358: Assembly
ENGINE 3.5L 9 - 123 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly (Fig. 41). Check rocker arms for wear or damage (Fig. 42): • Roller scuffing or wear •...
Page 359: Spark Plug Tube Removal
9 - 124 ENGINE 3.5L ROCKER ARM / ADJUSTER ASSEMBLY (Continued) (3) For spark plug tube seal replacement, (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (4) Install cylinder head cover(s). (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) VALVE STEM SEALS REMOVAL...
Page 360: Valve Springs Description
ENGINE 3.5L 9 - 125 VALVE STEM SEALS (Continued) OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. REMOVAL REMOVAL - CYLINDER HEAD OFF (1) Using Special Tool C-3422–D (valve spring compressor) with Adapter 6526 compress valve spring and remove valve retaining locks.
Page 361: Inspection
9 - 126 ENGINE 3.5L VALVE SPRINGS (Continued) INSPECTION counterbore under the valve spring seat to bring spring height back within specification. When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 50). As an example; the compression length of the spring to be tested is 38.00 mm (1.496 in.).
Page 362: Installation - Cylinder Head On
ENGINE 3.5L 9 - 127 VALVE SPRINGS (Continued) INSTALLATION - CYLINDER HEAD ON ENGINE BLOCK (1) Compress valve spring using Special Tool MD DESCRIPTION 998772A with Adaptor 6527 only enough to install retainer and locks. The cylinder block (Fig. 53) is made of heat treated (2) After installing locks, release tension on valve aluminum with cast-in-place iron liners.
Page 363: Cleaning
9 - 128 ENGINE 3.5L ENGINE BLOCK (Continued) (2) Deglazing of the cylinder walls may be done CLEANING using a cylinder surfacing hone, recommended tool Clean cylinder block thoroughly using a suitable C-3501 or equivalent, equipped with 280 grit stones, cleaning solvent.
Page 364: Connecting Rod Bearings
ENGINE 3.5L 9 - 129 CONNECTING ROD BOLTS CONNECTING ROD BEARINGS (1) Examine connecting rod bolts for stretching. Stretching can be checked by holding a scale or STANDARD PROCEDURE - CONNECTING RODS straight edge against the threads. If all the threads AND BEARINGS do not contact the scale the bolt must be replaced.
Page 365: Crankshaft Description
9 - 130 ENGINE 3.5L REMOVAL CRANKSHAFT (1) Remove engine from vehicle. (Refer to 9 - DESCRIPTION ENGINE - REMOVAL) (2) Remove oil pan. (Refer to 9 - ENGINE/LUBRI- The crankshaft (Fig. 53) is constructed of a forged CATION/OIL PAN - REMOVAL) micro alloy steel.
Page 366: Inspection
ENGINE 3.5L 9 - 131 CRANKSHAFT (Continued) INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.015 mm (0.0006 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter.
Page 367: Installation
9 - 132 ENGINE 3.5L CRANKSHAFT (Continued) INSTALLATION CAUTION: Main bearings are select fit. (Refer to 9 - ENGINE/ENGINE BLOCK/CONNECTING ROD BEAR- INGS - STANDARD PROCEDURE) (1) Install crankshaft main bearings (Fig. 63). (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK- SHAFT MAIN BEARINGS - STANDARD PROCE- DURE) Fig.
Page 368: Crankshaft Main Bearings Standard Procedure - Crankshaft Main Bearing Fitting
ENGINE 3.5L 9 - 133 CRANKSHAFT (Continued) (20) Install oil pickup tube and tighten bolt to 28 N·m (250 in. lbs.). (21) Install oil pan. (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - INSTALLATION) (22) Install engine assembly. (Refer to 9 - ENGINE - INSTALLATION) (23) Fill engine crankcase with proper amount of oil.
Page 369: Removal
9 - 134 ENGINE 3.5L CRANKSHAFT MAIN BEARINGS (Continued) REMOVAL Bearing caps are not interchangeable and are marked to insure correct assembly (Fig. 68). Upper and lower bearing halves are NOT interchangeable. (1) Remove oil pan. (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL) (2) Remove oil pick-up tube and windage tray.
Page 370: Installation
ENGINE 3.5L 9 - 135 CRANKSHAFT MAIN BEARINGS (Continued) INSTALLATION (b) Move crankshaft rearward to limit of travel. Lubricate and install the rear thrust washer by Bearing caps are not interchangeable and are rolling the washer onto the machined shelf marked to insure correct assembly.
Page 371: Crankshaft Oil Seal - Front Removal
9 - 136 ENGINE 3.5L CRANKSHAFT OIL SEAL - FRONT REMOVAL (1) Remove the crankshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (2) Tap the dowel pin out of the crankshaft (Fig. 72). Fig. 73 REMOVING CRANKSHAFT OIL SEAL WITH SPECIAL TOOL 1 - SPECIAL TOOL 6341A Fig.
Page 372: Crankshaft Oil Seal - Rear Removal
ENGINE 3.5L 9 - 137 INSTALLATION CRANKSHAFT OIL SEAL - REAR CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), clean surface using 400 REMOVAL grit sand paper to prevent seal damage during (1) Remove transaxle from vehicle. (Refer to 21 - installation.
Page 373: Crankshaft Rear Oil Seal Retainer Removal
9 - 138 ENGINE 3.5L (4) While applying firm pressure to the seal CRANKSHAFT REAR OIL SEAL retainer against Special Tools 8225 (Fig. 78), tighten RETAINER seal retainer screws to 12 N·m (105 in. lbs.). REMOVAL (1) Remove crankshaft rear oil seal. (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT SEAL - REAR - REMOVAL)
Page 374: Flex Plate Removal
ENGINE 3.5L 9 - 139 STANDARD PROCEDURE - FITTING PISTONS FLEX PLATE The pistons are machined to two different weight REMOVAL specifications and matched to rods based on weight. All piston and rod assemblies weigh the same to (1) Remove the transaxle. (Refer to 21 - TRANS- maintain engine balance.
Page 375: Installation
9 - 140 ENGINE 3.5L PISTON & CONNECTING ROD (Continued) Fig. 83 Check for Stretched Bolts Fig. 81 Connecting Rod to Cylinder Identification 1 - STRETCHED BOLT 1 - CYLINDER NUMBER 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT (3) Before installing pistons and connecting rod assemblies into the bore, ensure that compression...
Page 376 ENGINE 3.5L 9 - 141 PISTON & CONNECTING ROD (Continued) (4) Immerse the piston head and rings in clean (7) The arrow on top of piston must be pointing engine oil, slide the ring compressor over the piston toward front of engine (Fig. 86) and oil squirt hole on and tighten with the special wrench (Fig.
Page 377: Piston Rings
9 - 142 ENGINE 3.5L PISTON & CONNECTING ROD (Continued) Fig. 87 Piston and Connecting Rod Positioning (Front View of Engine) 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING (1) Wipe cylinder bore clean.
Page 378: Installation
ENGINE 3.5L 9 - 143 PISTON RINGS (Continued) Fig. 89 Measuring Piston Ring Side Clearance 1 - FEELER GAUGE Fig. 90 PISTON RING - INSTALLATION (2) Remove No. 1 and No.2 piston rings from pis- 1 - SIDE RAIL ton using a ring expander tool (Fig. 92). 2 - SPACER EXPANDER (3) Remove upper oil ring side rail (Fig.
Page 379: Structural Collar / Cover Removal
9 - 144 ENGINE 3.5L PISTON RINGS (Continued) STRUCTURAL COLLAR / COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove bolts attaching structural collar to oil pan and transmission housing (Fig. 94). (3) Remove collar (Fig. 94). Fig. 92 UPPER AND INTERMEDIATE RINGS (5) Install No.
Page 380: Vibration Damper Removal
ENGINE 3.5L 9 - 145 VIBRATION DAMPER REMOVAL (1) Disconnect negative cable at right strut tower. (2) Remove upper radiator crossmember. (Refer to 23 - BODY/EXTERIOR/GRILLE OPENING REIN- FORCEMENT - REMOVAL) (3) Remove radiator fan. (Refer to 7 - COOLING/ ENGINE/RADIATOR FAN - REMOVAL) (4) Remove the accessory drive belts.
Page 381: Removal
9 - 146 ENGINE 3.5L (2) Remove the isolator attaching nuts from top of ENGINE MOUNTING the mounting bracket (Fig. 98). (3) Support the engine with a jack and a block of DESCRIPTION wood across the full width of the oil pan. The engine mounting system consist of three (4) Remove the lower attaching nuts from the bot- mounts;...
Page 382: Rear Mount Removal
ENGINE 3.5L 9 - 147 (2) Remove the isolator attaching nuts from top of REAR MOUNT the mounting bracket (Fig. 99). (3) Support the engine with a jack and a block of REMOVAL wood across the full width of the oil pan. (1) Raise vehicle on hoist.
Page 383: Lubrication Description
9 - 148 ENGINE 3.5L through each cylinder heads oil passage to the rocker LUBRICATION shafts. Oil then feeds the camshaft journals, rocker arms, and hydraulic lash adjusters (Fig. 100). DESCRIPTION System is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. DIAGNOSIS AND TESTING The pump inner rotor is driven by the crankshaft.
Page 384: Diagnosis And Testing - Checking Engine Oil Pressure
ENGINE 3.5L 9 - 149 LUBRICATION (Continued) make sure the dye is thoroughly mixed as indicated If the leakage occurs at the crankshaft rear oil seal with a bright yellow color under a black light. area: (3) Using a black light, inspect the entire engine (1) Disconnect the battery.
Page 385: Oil Description
9 - 150 ENGINE 3.5L LUBRICATION (Continued) (5) If oil pressure is 0 at idle. Shut off engine, WARNING: NEW OR USED ENGINE OIL CAN BE check for pressure relief valve stuck open or a IRRITATING TO THE SKIN. AVOID PROLONGED OR clogged oil pickup screen.
Page 386: Oil Cooler & Lines Description
ENGINE 3.5L 9 - 151 REMOVAL OIL COOLER & LINES ENGINE OIL COOLER DESCRIPTION (1) The engine oil cooler is serviced with the radi- Vehicles equipped with the Heavy Duty Cooling ator (Refer to 7 - COOLING/ENGINE/RADIATOR - option (Sales Code NMC) or Severe Duty Cooling REMOVAL).
Page 387: Installation
9 - 152 ENGINE 3.5L OIL COOLER & LINES (Continued) INSTALLATION ENGINE OIL COOLER (1) Install radiator assembly (Refer to 7 - COOL- ING/ENGINE/RADIATOR INSTALLATION). Tighten lines to radiator fittings to 18 N·m (160 in. lbs.) (Fig. 102). COOLER LINES (1) Position cooler lines and connect lines to radia- tor fittings.
Page 388: Installation
ENGINE 3.5L 9 - 153 OIL PAN (Continued) (5) Disconnect engine oil cooler line from pan. (6) Disconnect transmission oil cooler line clips. (7) Remove oil pan (Fig. 105). (8) Remove oil pan gasket. (9) Clean oil pan and all gasket surfaces. INSTALLATION (1) Apply a 1/8 inch bead of Mopar Engine RTV GEN II at the parting line of the oil pump housing...
Page 389: Oil Pressure Relief Valve Removal
9 - 154 ENGINE 3.5L OIL PAN (Continued) Fig. 107 Oil Pressure Relief Valve Fig. 106 OIL PAN SEALING 1 - RELIEF VALVE (5) Lower vehicle and install dipstick and tube. 2 - SPRING (6) Fill engine crankcase with proper oil to correct 3 - RETAINER CAP level.
Page 390: Installation
ENGINE 3.5L 9 - 155 OIL PRESSURE SWITCH (Continued) (5) Unscrew oil pressure switch from fitting (Fig. (4) Remove the timing belt. (Refer to 9 - ENGINE/ 108). VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL) (5) Remove the crankshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN...
Page 391 9 - 156 ENGINE 3.5L OIL PUMP (Continued) Fig. 112 Checking Oil Pump Cover Flatness Fig. 110 Oil Pressure Relief Valve 1 - STRAIGHT EDGE 1 - RELIEF VALVE 2 - FEELER GAUGE 2 - SPRING 3 - OIL PUMP COVER 3 - RETAINER CAP 4 - COTTER PIN Fig.
Page 392 ENGINE 3.5L 9 - 157 OIL PUMP (Continued) Fig. 117 Measuring Clearance Over Rotors Fig. 115 Measuring Outer Rotor Clearance in Housing 1 - STRAIGHT EDGE 2 - FEELER GAUGES 1 - FEELER GAUGE 2 - OUTER ROTOR (9) Inspect oil pressure relief valve plunger for scoring and free operation in its bore.
Page 393: Assembly
9 - 158 ENGINE 3.5L OIL PUMP (Continued) ASSEMBLY INTAKE MANIFOLD (1) Assemble pump using parts DESCRIPTION required. (2) Tighten cover screws to 12 N·m (105 in. lbs.) The composite upper intake manifold is a cross- (Fig. 111). flow type with long runners to improve air charge (3) Prime oil pump before installation by filling inertia (Fig.
Page 394: Diagnosis And Testing - Intake Manifold Leaks
ENGINE 3.5L 9 - 159 INTAKE MANIFOLD (Continued) Fig. 120 LOWER INTAKE MANIFOLD 1 - BOLT 6 - GASKET 2 - HEATER SUPPLY TUBE 7 - BOLT 3 - BOLT 8 - O-RING 4 - BOLT 9 - INTAKE MANIFOLD-LOWER 5 - KNOCK SENSOR DIAGNOSIS AND TESTING - INTAKE INTAKE MANIFOLD - UPPER...
Page 395: Inspection
9 - 160 ENGINE 3.5L INTAKE MANIFOLD - UPPER (Continued) Fig. 123 INTAKE MANIFOLD SUPPORT - LEFT 1 - SUPPORT BRACKET (7) Remove support brackets at intake manifold front corners and at MTV (Fig. 124). Fig. 121 AIR CLEANER WITH INLET HOSE 1 - AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 - THROTTLE BODY •...
Page 396: Installation
ENGINE 3.5L 9 - 161 INTAKE MANIFOLD - UPPER (Continued) Fig. 126 UPPER INTAKE MANIFOLD TIGHTENING (9) Connect electrical connectors to the following: • Short Runner Valve (SRV)(If Equipped) • Manifold Tuning Valve (MTV)(If Equipped) • Throttle Position Sensor (TPS) •...
Page 397: Inspection
9 - 162 ENGINE 3.5L INTAKE MANIFOLD - LOWER (Continued) (6) Disconnect heater and coolant bottle supply INSPECTION hoses from coolant tube at rear of intake manifold Check manifold for: (Fig. 127). • Damage and cracks • Gasket surface damage or warpage •...
Page 398 ENGINE 3.5L 9 - 163 INTAKE MANIFOLD - LOWER (Continued) Fig. 128 LOWER INTAKE MANIFOLD 1 - BOLT 6 - GASKET 2 - HEATER SUPPLY TUBE 7 - BOLT 3 - BOLT 8 - O-RING 4 - BOLT 9 - INTAKE MANIFOLD-LOWER 5 - KNOCK SENSOR...
Page 399: Exhaust Manifold Description
9 - 164 ENGINE 3.5L INTAKE MANIFOLD - LOWER (Continued) EXHAUST MANIFOLD DESCRIPTION Both manifolds are a log style made of ductile cast iron (Fig. 130). The outlets are designed for V-Band clamp attachment of close coupled catalytic converters. Fig. 130 EXHAUST MANIFOLD 1 - BOLT - HEAT SHIELD 2 - HEAT SHIELD 3 - GASKET...
Page 400: Exhaust Manifold - Right Removal
ENGINE 3.5L 9 - 165 INSPECTION EXHAUST MANIFOLD - RIGHT (1) Inspect exhaust manifolds for damage or REMOVAL cracks. (2) Check manifold flatness. (1) Disconnect negative cable from remote jumper (3) Inspect the exhaust manifold gasket for obvi- terminal. ous discoloration or distortion. (2) Raise vehicle on hoist.
Page 401: Inspection
9 - 166 ENGINE 3.5L EXHAUST MANIFOLD - LEFT (Continued) (7) Remove electrical connector harness bracket. INSTALLATION (8) Disconnect oxygen sensor electrical connector (1) Install the exhaust manifold and gasket. and remove sensor from manifold. Tighten bolts starting at the center working outward (9) Remove heat shield attaching bolts and remove to 23 N·m (200 in.
Page 402: Timing Belt Cover(S) - Front Removal
ENGINE 3.5L 9 - 167 VALVE TIMING (Continued) Fig. 133 TIMING DRIVE SYSTEM 1 - TIMING BELT COVER - RIGHT REAR 8 - BOLT-CRANKSHAFT DAMPER 2 - TENSIONER-TIMING BELT 9 - TIMING BELT COVER-LOWER 3 - CAMSHAFT SPROCKET 10 - TIMING BELT COVER-RIGHT 4 - BOLT-CAMSHAFT SPROCKET 11 - TIMING BELT COVER-LEFT 5 - TIMING BELT...
Page 403: Timing Belt Cover(S) - Rear Removal
9 - 168 ENGINE 3.5L TIMING BELT COVER(S) - FRONT (Continued) Fig. 134 A/C BELT GUIDE/LIFT BRACKET Fig. 136 TIMING BELT COVER SEALER 1 - A/C BELT GUIDE/LIFT BRACKET 1 - SEALER 2 - NUT (5) Install the crankshaft vibration damper. (Refer (8) Remove the stamped steel cover (Fig.
Page 404 ENGINE 3.5L 9 - 169 TIMING BELT COVER(S) - REAR (Continued) (3) Position NEW O-rings on cover (Fig. 139). Fig. 139 Right Side Timing Belt Cover O-Rings 1 - O-RINGS 2 - WATER PUMP IMPELLER (4) Install rear timing belt covers (Fig. 140) and Fig.
Page 405: Timing Belt Tensioner & Pulley Removal Removal - Tensioner Pulley Assembly
9 - 170 ENGINE 3.5L TIMING BELT COVER(S) - REAR (Continued) • M6—12 N·m (105 in. lbs.) TIMING BELT TENSIONER & PULLEY REMOVAL REMOVAL - TENSIONER PULLEY ASSEMBLY (1) Remove the timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL - TIMING BELT) (2) Remove the timing belt tensioner pulley and bracket assembly by unscrewing the pivot bolt from...
Page 406: Installation - Tensioner
ENGINE 3.5L 9 - 171 TIMING BELT TENSIONER & PULLEY (Continued) INSTALLATION - TENSIONER (1) For timing belt tensioner installation procedure (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION - TIM- ING BELT). TIMING BELT AND SPROCKETS REMOVAL REMOVAL - TIMING BELT CAUTION: The following procedure can only be...
Page 407: Removal - Camshaft Sprockets
9 - 172 ENGINE 3.5L TIMING BELT AND SPROCKETS (Continued) CAUTION: Align the camshaft sprockets between the marks on rear belt covers before timing belt removal or damage to valve and/or pistons could occur. (9) Using a ink or paint marker; mark the exact position of the camshaft sprocket timing mark rela- tive to the two timing marks on the rear timing cover.
Page 408 ENGINE 3.5L 9 - 173 TIMING BELT AND SPROCKETS (Continued) CAUTION: When camshaft sprocket bolts are loos- ened or removed, the camshafts must be re-timed to the engine. Also, the camshaft sprocket bolts must NOT be reused. (1) Remove front timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (2) Position crankshaft sprocket to the TDC mark...
Page 409: Removal - Crankshaft Sprocket
9 - 174 ENGINE 3.5L TIMING BELT AND SPROCKETS (Continued) (8) Loosen and remove bolt and washer. To remove (h) Vehicle mileage or time at component main- the camshaft sprocket bolts with engine in the vehi- tenance requirement. (Refer to LUBRICATION & cle, it may be necessary to lift the engine to allow MAINTENANCE/MAINTENANCE SCHEDULES - bolt removal clearance.
Page 410: Installation - Camshaft Sprockets
ENGINE 3.5L 9 - 175 TIMING BELT AND SPROCKETS (Continued) (1) Align the crankshaft sprocket with the TDC (9) Install the accessory drive belts. (Refer to 7 - mark on oil pump cover (Fig. 152). COOLING/ACCESSORY DRIVE/DRIVE BELTS - (2) Align the camshaft sprockets (to reference INSTALLATION) mark made upon removal) between the marks on the (10) Instal the radiator fan.
Page 411 9 - 176 ENGINE 3.5L TIMING BELT AND SPROCKETS (Continued) (7) Hold the camshaft sprocket hex with a 36 mm (1 7/16 in.) wrench and tighten the camshaft bolts to the following: • Right side = 102 N·m (75 ft. lbs.) +90° turn •...
Page 412: Installation - Crankshaft Sprocket
ENGINE 3.5L 9 - 177 TIMING BELT AND SPROCKETS (Continued) (11) Install timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (12) Install crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) (13) Install accessory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (14) Fill cooling system.
Page 414 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page EXHAUST SYSTEM INSPECTION ......7 DESCRIPTION .
Page 415 11 - 2 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) Fig. 1 Exhaust System 1 - V-BAND CLAMPS 5 - MUFFLER 2 - BAND CLAMPS 6 - BAND CLAMP 3 - FRONT RESONATOR 7 - LEFT REAR RESONATOR/PIPE ASSEMBLY 4 - INTERMEDIATE PIPE 8 - CATALYTIC CONVERTERS Fig.
Page 416: Exhaust System
EXHAUST SYSTEM 11 - 3 EXHAUST SYSTEM (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - EXHAUST SYSTEM CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE EXHAUST NOISE 1. Exhaust manifold cracked or 1. Replace manifold. (UNDER HOOD) broken. 2. Manifold to cylinder head leak. 2.
Page 417: Removal - Exhaust System
11 - 4 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) (7) If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic converter inspection procedures, (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - INSPECTION). Replace component(s) as necessary. EXHAUST BACK PRESSURE LIMITS Exhaust Back Pressure Limit (Max) Vehicle in Park/Neutral 3.45 Kpa (0.5 psi)
Page 418: Adjustments
EXHAUST SYSTEM 11 - 5 EXHAUST SYSTEM (Continued) Fig. 4 Exhaust System Supports 1 - SUPPORTS 3 - ISOLATORS 2 - MUFFLER component to maintain position and proper clearance SPECIFICATIONS with underbody parts. (6) Tighten band clamps to 61 N·m (45 ft. lbs.). TORQUE (7) Lower the vehicle.
Page 419: Special Tools
11 - 6 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) SPECIAL TOOLS EXHAUST SYSTEM DRB III & PEP Module - OT-CH6010A Fig. 5 Catalytic Converters 1 - V-BAND CLAMPS 2 - BAND CLAMP 3 - EXTENSION PIPE 4 - CATALYTIC CONVERTERS verted into water (H2O) and carbon dioxide (CO2). Oxides of Nitrogen (NOx) are converted into elemen- tal Nitrogen (N) and water.
Page 420: Inspection
EXHAUST SYSTEM 11 - 7 CATALYTIC CONVERTER(S) (Continued) deterioration of the catalyst core can result in exces- CATALYTIC CONVERTER - sively high emission levels, noise complaints, and RIGHT exhaust restrictions. The use of catalysts also involves some non-auto- REMOVAL - RIGHT SIDE motive problems.
Page 421: Installation - Right Side
11 - 8 EXHAUST SYSTEM CATALYTIC CONVERTER - RIGHT (Continued) (8) Remove SRV (Short Runner Valve) vacuum res- CATALYTIC CONVERTER - ervoir and control valve assembly at right rear of LEFT engine (3.5L engine only). (9) Disconnect downstream oxygen sensor connec- REMOVAL - LEFT SIDE tor and remove sensor from converter pipe (Refer to (1) Loosen and remove V-Band clamp at exhaust...
Page 422: Muffler/Front Resonator Assembly Removal
EXHAUST SYSTEM 11 - 9 HEAT SHIELDS (Continued) CAUTION: Avoid application of rust prevention com- INSTALLATION pounds or undercoating materials to exhaust sys- (1) Install the left rear resonator/pipe assembly tem heat shields on cars if equipped. Light over onto the muffler/front resonator assembly and loose spray near the edges is permitted.
Page 424 ......4 REAR TOW EYE REAR FASCIA - INTREPID REMOVAL ......15 INSTALLATION - INTREPID .
Page 425: Installation
Fig. 2 ACCESS RUBBER GROMMET 1 - ACCESS RUBBER GROMMET INSTALLATION (1) Connect wire connectors. REMOVAL - INTREPID (2) Place fascia in position on vehicle, by fitting foam to bumper reinforcement. Use care not to (1) Release hood latch and open hood.
Page 426: Installation - Intrepid
(8) Install grommet. (9) Install the fasteners attaching the fascia to the lower crossmember. INSTALLATION - INTREPID Fig. 8 REAR BUMPER REINFORCEMENT (1) Connect fog lamp wire connectors, if equipped. (2) Place fascia pin position on vehicle, by fitting 1 - REAR BUMPER REINFORCEMENT foam to bumper beam.
Page 427: Installation
(6) Install trunk carpet back in position. (7) Install fasteners attaching fascia to rear quar- ter panel and splash shields. REAR FASCIA - INTREPID INSTALLATION - INTREPID Fig. 9 REAR BUMPER FASCIA (1) Connect the license plate lamp wire connector to the body harness.
Page 428: Frame Specifications Frame Dimensions
FRAME & BUMPERS 13 - 5 dimensions are from center to center of Principal FRAME Locating Point (PLP), or from center to center of PLP and fastener location. Vertical dimensions can be SPECIFICATIONS taken from the work surface to the locations indi- cated.
Page 429 13 - 6 FRAME & BUMPERS FRAME (Continued) Fig. 11 ENGINE COMPARTMENT TOP VIEW Fig. 12 ENGINE COMPARTMENT SIDE VIEW...
Page 430 FRAME & BUMPERS 13 - 7 FRAME (Continued)
Page 431 13 - 8 FRAME & BUMPERS FRAME (Continued) Fig. 14 REAR FRAME SECTION...
Page 432: Specifications - Torque
FRAME & BUMPERS 13 - 9 FRAME (Continued) SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Lbs. Lbs. Rear bumber reinforcement — attaching nut Front suspension crossmember — front attaching bolt Front suspension crossmember — rear attaching bolt Radiator support crossmember —...
Page 433: Front Tow Eye Removal
13 - 10 FRAME & BUMPERS FRONT TOW EYE REMOVAL (1) Unthread the front tow eye from the tow eye bracket (Fig. 16). Fig. 17 FRONT TOW EYE INSTALLATION 1 - NO SPACE 2 - TOW EYE INSTALLATION (1) Install the front tow eye bracket and fasteners. Torque bolts to 23 to 34 N·m (Fig.
Page 434 FRAME & BUMPERS 13 - 11 REAR CROSSMEMBER (Continued) Fig. 18 REAR SUSPENSION CROSSMEMBER 1 - LATERAL LINKS 3 - LATERAL LINKS 2 - REAR CROSSMEMBER ISOLATOR BUSHINGS REMOVAL (1) Open the fuel filler door. Remove the 3 fuel filler neck attaching screws. Remove the fuel filler cap.
Page 435: Disassembly
13 - 12 FRAME & BUMPERS REAR CROSSMEMBER (Continued) Remove the 4 bolts attaching both stabilizer bar isolator bushing retainers to the frame rails (the 2 rearward attaching bolts also attach the front cor- ners of the rear suspension crossmember in place). Allow the stabilizer bar to hang down.
Page 436: Assembly
FRAME & BUMPERS 13 - 13 REAR CROSSMEMBER (Continued) (3) Install Remover/Installer, Special Tool 8173–2, (5) Install Special Tool 8173–4 in the cup, Special on end of the threaded push rod on Special Tool Tool 8173–1 (Fig. 23). Install cup, Special Tool C-4212F.
Page 437 13 - 14 FRAME & BUMPERS REAR CROSSMEMBER (Continued) attaching the rear of the crossmember to the frame rails. Raise the exhaust into place. Reattach the 3 exhaust hangers previously removed from the muf- fler and resonator. (7) Remove transmission jack supporting muffler and exhaust system.
Page 438: Rear Tow Eye Removal
FRAME & BUMPERS 13 - 15 REAR CROSSMEMBER (Continued) CAUTION: Tightening the lateral link attaching bolts at this time will cause the bushings contort at curb riding height, leading to premature failure of the bushings. Tighten bolts only when vehicle is at curb riding height.
Page 440 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY ......1 FUEL INJECTION .
Page 441: Fuel Delivery
14 - 2 FUEL DELIVERY STANDARD PROCEDURE - DRAINING FUEL FUEL DELIVERY TANK DESCRIPTION Two different procedures may be used to drain fuel The front wheel drive car uses a plastic fuel tank tank (lowering tank or using DRB scan tool). located rear center of the vehicle.
Page 442: Torque
FUEL DELIVERY 14 - 3 FUEL DELIVERY (Continued) (10) Remove filler tube from fuel tank. Tank will IGNITION SOURCE IS PRESENT. NEVER DRAIN OR be drained through this fitting. STORE GASOLINE OR DIESEL FUEL IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF FIRE WARNING: WRAP SHOP TOWELS AROUND HOSES OR EXPLOSION.
Page 443: Flow Management Valve Description
14 - 4 FUEL DELIVERY FUEL DELIVERY (Continued) FUEL LEVEL SENDING UNIT / SENSOR DESCRIPTION The fuel gauge level sending unit is attached to the side of fuel pump module. The level sensor is a vari- able resistor. OPERATION Its resistance changes with the amount of fuel in Fuel Line Adapter 1/4 the tank.
Page 444 FUEL DELIVERY 14 - 5 FUEL LEVEL SENDING UNIT / SENSOR (Continued) (2) Remove wire terminal retaining clip from con- nector (Fig. 2). Note the location of terminals for the level sensor wires (Fig. 3). Fig. 4 Level Sensor Signal 1 - LEVEL SENSOR GROUND 2 - LEVEL SENSOR SIGNAL Fig.
Page 445: Installation
14 - 6 FUEL DELIVERY FUEL LEVEL SENDING UNIT / SENSOR (Continued) INSTALLATION The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the (1) Insert level sensor wires in bottom of stand- higher fuel pressures and the possibility of contami- pipe.
Page 446: Fuel Pressure Regulator Description
FUEL DELIVERY 14 - 7 through the pressure regulator. A separate fuel FUEL PRESSURE REGULATOR return line is not used with any gas powered engine. DESCRIPTION A combination fuel filter and fuel pressure regula- tor is used on all gas powered engines. It is located on the top of the fuel pump module.
Page 447: Fuel Pump Description
14 - 8 FUEL DELIVERY FUEL PRESSURE REGULATOR (Continued) put of approximately 880 kPa (130 psi). The regula- tor adjusts fuel system pressure to approximately 400 kpa ±34 kpa (58 psi ± 5 psi). NOTE: Checkvalve maintains volume of fuel in the rail and lines, not pressure.
Page 448: Removal
FUEL DELIVERY 14 - 9 FUEL PUMP MODULE (Continued) fuel filter return port. When pressure exceeds the calibrated amount, the diaphragm retracts, allowing excess pressure and fuel to vent into the tank. The maximum deadhead pressure is approximately 880 kPa (130 psi). The regulator adjusts fuel system pressure to approximately 400 ±34 kPa (58 ±...
Page 449: Fuel Rail Description
14 - 10 FUEL DELIVERY FUEL PUMP MODULE (Continued) (3) Position the locknut over the fuel pump mod- manifold to prevent foreign material from entering ule. engine. (4) Tighten the locknut using Special Tool #6856 to (5) Disconnect fuel supply tube quick connect fit- 55 N·m (40.5 ft.
Page 450: Installation - 3.5L
FUEL DELIVERY 14 - 11 FUEL RAIL (Continued) (7) Install intake manifold plenum. Refer to the are equipped with a self-diagnosing system using a Engine section for information. Natural Vacuum Leak Detection (NVLD). Refer to (8) Connect negative cable to battery. the Emission Control System for additional informa- tion.
Page 451 14 - 12 FUEL DELIVERY FUEL TANK (Continued) (4) Disconnect fuel pump electrical connector (Fig. (7) Loosen the rear stabilizer bar brackets from 17). body. Swing stabilizer bar toward rear of vehicle (Fig. 19) and (Fig. 20). Fig. 17 Electrical Connector Fig.
Page 452: Installation
FUEL DELIVERY 14 - 13 FUEL TANK (Continued) (8) Disconnect fuel and EVAP lines (Fig. 21). Fig. 23 HARNESS ON TANK PIN 1 - Pin 2 - Wiring Harness Fig. 21 Fuel and EVAP Lines (14) Remove wiring harness from body. (15) Remove NVLD filter from mounting location.
Page 453: Fuel Tank Filler Tube Removal
14 - 14 FUEL DELIVERY FUEL TANK (Continued) (9) Lower vehicle. INLET FILTER (10) Connect the fuel pump electrical connector that is under the rear seat (Fig. 17). REMOVAL (11) Install the rear seat, refer to the Body section (1) Remove fuel pump module. Refer to Fuel Pump for more information.
Page 454: Quick Connect Fitting Standard Procedure - Quick-Connect Fittings
FUEL DELIVERY 14 - 15 QUICK CONNECT FITTING STANDARD PROCEDURE - QUICK-CONNECT FITTINGS REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FIT- TINGS. REFER TO THE FUEL PRESSURE RELEASE Fig.
Page 455 14 - 16 FUEL DELIVERY QUICK CONNECT FITTING (Continued) WARNING: THE FUEL SYSTEM IS UNDER A CON- PLASTIC RETAINER RING TYPE FITTING STANT PRESSURE (EVEN WITH THE ENGINE OFF). This type of fitting can be identified by the use of a BEFORE SERVICING ANY FUEL SYSTEM HOSES, full-round plastic retainer ring (Fig.
Page 456 FUEL DELIVERY 14 - 17 QUICK CONNECT FITTING (Continued) DISCONNECTION/CONNECTION (5) After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. (1) Perform fuel pressure release procedure. Refer (6) Inspect fitting connector body, plastic retainer to Fuel Pressure Release Procedure in this section. ring and fuel system component for damage.
Page 457 14 - 18 FUEL INJECTION FUEL INJECTION TABLE OF CONTENTS page page FUEL INJECTION INSTALLATION ......30 OPERATION MANIFOLD TUNE VALVE OPERATION - INJECTION SYSTEM...
Page 458: Operation - Injection System
FUEL INJECTION 14 - 19 sensor diagnostics (they are checked for shorted con- FUEL INJECTION ditions at all times). During CLOSED LOOP modes the PCM monitors OPERATION the inputs from the upstream and downstream heated oxygen sensors. The upstream heated oxygen OPERATION - INJECTION SYSTEM sensor input tells the PCM if the calculated injector pulse width resulted in the ideal air-fuel ratio of 14.7...
Page 459 14 - 20 FUEL INJECTION FUEL INJECTION (Continued) • Knock sensor 1 second. Therefore, battery voltage is not supplied to • Throttle position the fuel pump, ignition coil, fuel injectors and heated • A/C switch oxygen sensors. • Battery voltage ENGINE START-UP MODE •...
Page 460: Fuel Correction Or Adaptive Memories
FUEL INJECTION 14 - 21 FUEL INJECTION (Continued) • Engine coolant temperature The PCM compares the upstream and downstream • Engine speed heated oxygen sensor inputs to measure catalytic • Knock sensor convertor efficiency. If the catalyst efficiency drops • Manifold absolute pressure below the minimum acceptable percentage, the PCM •...
Page 461: Programmable Communications Interface (Pci) Bus
14 - 22 FUEL INJECTION FUEL INJECTION (Continued) authority for short term memory is 25% (+/-) of base used. Because the goal is to keep short term at 0 (O2 pulse-width. Short term is violated and is lost when Sensor switching at 0.5 volt), long term will update ignition is turned OFF.
Page 462: Torque Management
FUEL INJECTION 14 - 23 FUEL INJECTION (Continued) • Transmission Control Module TROL MODULES/POWERTRAIN CONTROL MOD- • Powertrain Control Module ULE - DESCRIPTION). • Travel Module • SKIM TORQUE MANAGEMENT SYSTEM DIAGNOSIS OPERATION The PCM receives the torque management input OPERATION from the transmission control module.
Page 463: Special Tools
14 - 24 FUEL INJECTION FUEL INJECTION (Continued) SPECIAL TOOLS FUEL O2S (Oxygen Sensor) Remover/Installer—C-4907 Pressure Gauge Assembly C–4799–B O2S(Oxygen Sensor) Remover/Installer - 8439 ACCELERATOR PEDAL REMOVAL (1) Working from the engine compartment, hold the throttle body throttle lever in the wide open posi- tion.
Page 464: Installation
FUEL INJECTION 14 - 25 ACCELERATOR PEDAL (Continued) Fig. 4 CARPET AND INSULATION PLACEMENT 1 - PEDAL BASE 2 - CARPET 3 - INSULATION Fig. 2 RETAINER CLIP 4 - FLOOR PAN (3) Working from the passenger compartment, remove nuts from accelerator pedal base (Fig. 3). CRANKSHAFT POSITION Remove pedal and base from vehicle.
Page 465: Operation
14 - 26 FUEL INJECTION CRANKSHAFT POSITION SENSOR (Continued) OPERATION REMOVAL Engine speed and crankshaft position are provided The crankshaft sensor is located on the passengers through the crankshaft position sensor. The sensor side of the transmission housing, above the differen- generates pulses that are the input sent to the pow- tial housing.
Page 466: Fuel Injector Description
FUEL INJECTION 14 - 27 to flow out the orifice. Because the fuel is under high FUEL INJECTOR pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action DESCRIPTION atomizes the fuel, adding it to the air entering the The injectors are positioned in the cylinder heads combustion chamber.
Page 467: Removal - 3.5L
14 - 28 FUEL INJECTION FUEL INJECTOR (Continued) (7) Remove electrical connectors from the fuel (8) Install intake manifold plenum. Refer to the injectors. Engine section for information. (8) Remove fuel rail mounting bolts. (9) Connect negative cable to battery. (9) Lift fuel rail straight up off of the cylinder INSTALLATION - 3.5L head.
Page 468: Idle Air Control Motor Description
FUEL INJECTION 14 - 29 Target Idle IDLE AIR CONTROL MOTOR Target idle is determined by the following inputs: • Gear position DESCRIPTION • ECT Sensor The idle air control motor (IAC) attaches to the • Battery voltage throttle body (Fig. 10). It is an electric stepper motor. •...
Page 469: Installation - 3.5L
14 - 30 FUEL INJECTION IDLE AIR CONTROL MOTOR (Continued) INSTALLATION - 3.5L (1) Install the IAC to the throttle body (Fig. 12). (2) Tighten mounting screws to 7.3 N·m (65 in. lbs.) torque. (3) Attach electrical connector to the IAC. (4) Install air plenum and tighten the clamp.
Page 470: Operation
FUEL INJECTION 14 - 31 MAP SENSOR (Continued) it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on.
Page 471: Removal Removal - 2.7L
14 - 32 FUEL INJECTION MAP SENSOR (Continued) for your area. Always use the Diagnostic Test Proce- dures Manual for MAP sensor testing. REMOVAL REMOVAL - 2.7L (1) Remove the negative battery cable. (2) Disconnect the electrical connector from the MAP sensor (Fig.
Page 472: Operation
FUEL INJECTION 14 - 33 O2 SENSOR (Continued) The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indica-...
Page 473: Removal - Upstream 1/1, 2/1
14 - 34 FUEL INJECTION O2 SENSOR (Continued) fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element.
Page 474: Installation Installation - Upstream
FUEL INJECTION 14 - 35 O2 SENSOR (Continued) INSTALLATION INSTALLATION - UPSTREAM 1/1, 2/1 The engines uses two heated oxygen sensors, one in each exhaust manifold. (1) After removing the sensor, the exhaust mani- fold threads must be cleaned with an 18 mm X 1.5 + 6E tap.
Page 475: Throttle Body Description
14 - 36 FUEL INJECTION OPERATION THROTTLE BODY Filtered air from the air cleaner enters the intake DESCRIPTION manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle The throttle body is located on the intake manifold Air Control (IAC) motor.
Page 476: Installation Installation - 2.7L
FUEL INJECTION 14 - 37 THROTTLE BODY (Continued) (2) Install the cable housing (throttle body end) INSTALLATION into the cable mounting bracket on the engine. (3) From inside the vehicle, hold up the pedal and INSTALLATION - 2.7L install throttle cable and cable retainer in the upper (1) Install throttle body and bolts.
Page 477: Removal - 2.7L
14 - 38 FUEL INJECTION THROTTLE POSITION SENSOR (Continued) Fig. 28 THROTTLE POSITION SENSOR 3.2/3.5L Fig. 29 Throttle Position Sensor—2.7L Engine ENGINE 1 - TPS SENSOR 1 - THROTTLE BODY 2 - THROTTLE BODY 2 - TPS 3 - PCV VALVE 3 - IAC 4 - EGR TUBE opening (idle) to a maximum of 4.5 volts at wide open...
Page 478 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page STEERING DIAGNOSIS AND TESTING - SPEED DESCRIPTION - POWER STEERING SYSTEM . . 1 PROPORTIONAL POWER STEERING ..9 OPERATION - POWER STEERING SYSTEM .
Page 479: Diagnosis And Testing Diagnosis And Testing - Power Steering Flow And Pressure Test
19 - 2 STEERING STEERING (Continued) CAUTION: If the vehicle is equipped with the Tire Install the following adapters from Adapter Set, Pressure Monitoring (TPM) System, the tire/wheel Special Tool 6893 (Fig. 2), on the analyzer hose ends: assembly needs to be reinstalled in the same loca- tion it is removed from or the TPM System (sen- sors) will need to be retrained.
Page 480 STEERING 19 - 3 STEERING (Continued) Fig. 3 Pressure Hose Connection To Power Steering Fig. 5 Analyzer Connected To Power Steering Pump Pump (2.7L Engine) (2.7L Engine) 1 - POWER STEERING FLUID PRESSURE HOSE 1 - POWER STEERING FLUID PRESSURE HOSE Fig.
Page 481: Diagnosis And Testing - Steering Diagnosis Charts
19 - 4 STEERING STEERING (Continued) NOTE: Power steering pump maximum relief pres- (12) Completely open the valve on the Power sure is 8275 to 8975 kPa (1250 to 1350 psi.). Steering Analyzer. Turn the steering wheel to the extreme left until the stop in the steering gear is •...
Page 482 STEERING 19 - 5 STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION POPPING NOISE 1. Worn outer tie rod. 1. Replace outer tie rod. CHIRP OR SQUEAL 1. Loose power steering pump drive 1. Check and adjust power steering pump (POWER STEERING belt.
Page 483 19 - 6 STEERING STEERING (Continued) * NOTE: There is some noise in all power steering ity fluid passes valve orifice edges. There is no systems. One of the most common is a hissing relationship between this noise and the perfor- sound evident when turning the steering wheel mance of the steering system.
Page 484 STEERING 19 - 7 STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 6. Loose power steering pump drive 6. Tighten the power steering pump drive belt. belt to specifications. If drive belt is worn or glazed, replace belt. 7. Faulty power steering pump flow 7.
Page 485 19 - 8 STEERING STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Steering column coupling joints 4. Realign steering column coupling joints. misaligned. 5. Steering wheel rubbing.** 5. Adjust steering column shrouds to eliminate rubbing condition. 6. Damaged, mis-positioned or 6. Replace, reposition, or lubricate dash un-lubricated steering column seal.
Page 486: Diagnosis And Testing - Speed Proportional Power Steering
STEERING 19 - 9 STEERING (Continued) ** NOTE: To evaluate this condition, it may be nec- steering wheel more than one revolution in either essary to disconnect the coupling at the base of the direction and place steering wheel in original loca- steering column.
Page 487: Special Tools
19 - 10 STEERING STEERING (Continued) STEERING COLUMN FASTENER TORQUE DESCRIPTION N·m Lbs. Lbs. Airbag Module Mounting — Bolts Speed Control Switch — Screws Puller C-4333 Steering Column Coupler Pinch Bolt Steering Column Mounting — Bolts Steering Column Mounting — Nuts Steering Wheel Retaining —...
Page 488 COLUMN 19 - 11 COLUMN TABLE OF CONTENTS page page COLUMN KEY/LOCK CYLINDER DESCRIPTION ......11 DESCRIPTION .
Page 489: Column
19 - 12 COLUMN COLUMN (Continued) Fig. 1 Steering Column 1 - SHIFT LEVER (COLUMN SHIFT ONLY) 4 - STEERING COLUMN MOUNTING BRACKET 2 - TILT HOUSING 5 - STEERING COLUMN COUPLER 3 - TILT LEVER 6 - STEERING COLUMN LOWER MOUNTING BRACKET WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, WARNING: WHEN HANDLING AN UNDEPLOYED COMPLEX ELECTRO-MECHANICAL UNIT.
Page 490 COLUMN 19 - 13 COLUMN (Continued) CAUTION CAUTIONS CAUTION: Disconnect the negative (ground) cable from the battery, before servicing any column com- ponent. CAUTION: Do not attempt to remove the pivot pins to disassemble the tilting mechanism. Damage will occur. DIAGNOSIS AND TESTING - STEERING COLUMN For diagnosis of conditions relating to the steering...
Page 491 19 - 14 COLUMN COLUMN (Continued) Fig. 4 Lower Instrument Panel Cover Mounting Fig. 6 Park Brake Release Cable Screws 1 - PARK BRAKE RELEASE CABLE 2 - PARK BRAKE RELEASE HANDLE 1 - MOUNTING SCREWS 3 - LOWER INSTRUMENT PANEL COVER 2 - INSTRUMENT PANEL BRACKET 3 - LOWER INSTRUMENT PANEL COVER Fig.
Page 492 COLUMN 19 - 15 COLUMN (Continued) Fig. 10 Driver Airbag Attaching Bolts Fig. 8 Diagnostic Connector 1 - DRIVER AIRBAG 1 - DIAGNOSTIC CONNECTOR 2 - STEERING WHEEL 2 - REINFORCEMENT PANEL 3 - MOUNTING SCREWS (11) Remove the driver airbag from the steering wheel.
Page 493 19 - 16 COLUMN COLUMN (Continued) (15) Remove the steering wheel attaching nut from CAUTION: Do not bump or hammer on steering the steering column shaft (Fig. 12). wheel or steering column shaft when removing steering wheel from steering column. (17) Remove steering wheel from steering column shaft.
Page 494 COLUMN 19 - 17 COLUMN (Continued) Fig. 15 Lower Shroud Attaching Screws Fig. 17 Clockspring Location 1 - LOWER SHROUD 1 - CLOCKSPRING 2 - MOUNTING SCREWS 2 - MOUNTING SCREWS (24) Remove the wiring harness from the routing clip on the top of the multi-function switch. Remove the 2 screws (Fig.
Page 495 19 - 18 COLUMN COLUMN (Continued) (25) Remove the 2 screws (Fig. 19) mounting the (27) If the vehicle is equipped with a steering col- ignition switch to the steering column. Remove the umn mounted shift lever, remove the brake transmis- ignition switch, with the wiring harness attached, sion shift interlock (BTSI) solenoid from the shift from the steering column.
Page 496 COLUMN 19 - 19 COLUMN (Continued) (28) If the vehicle is equipped with a steering col- (30) Remove the 2 air ducts (Fig. 25) from under umn mounted shift lever, remove the shift cable from the steering column. the shifter mechanism. Unlock the cable lock, then, the shift cable is removed by inserting a screwdriver between the shift cable and the shifter mechanism and prying the cable off the pin (Fig.
Page 497 19 - 20 COLUMN COLUMN (Continued) Fig. 27 Steering Column Mounting Fig. 28 Installed Shift Cable 1 - MOUNTING NUTS 1 - SHIFTER MECHANISM 2 - STEERING COLUMN UPPER MOUNTING BRACKET 2 - PIN 3 - STEERING COLUMN SUPPORT BRACKET 3 - SHIFT CABLE 4 - STEERING COLUMN LOWER MOUNTING BRACKET 5 - MOUNTING BOLTS...
Page 498 COLUMN 19 - 21 COLUMN (Continued) Fig. 32 Ignition Interlock Adjustment Tab 1 - LOCK CYLINDER HOUSING Fig. 30 Guide And Flange Alignment 2 - INTERLOCK CASSETTE 1 - BRACKET FLANGE 3 - ADJUSTMENT TAB 2 - GUIDE harness on the routing clip on the top of the multi- function switch.
Page 499 19 - 22 COLUMN COLUMN (Continued) • Keeping locking mechanism disengaged, rotate NOTE: Make sure steering wheel and airbag module the clockspring rotor in the CLOCKWISE DIREC- are in the right-side-up position before installing TION to the end of the travel. Do not apply excessive airbag module on steering wheel.
Page 500: Operation
COLUMN 19 - 23 COLUMN (Continued) eight seconds, then go out. This will indicate that the INSTALLATION airbag system is functioning normally. The ignition switch attaches to the lock cylinder • If airbag warning lamp fails to light, blinks on housing on the end opposite the lock cylinder.
Page 501: Key/Lock Cylinder Description
19 - 24 COLUMN INTERMEDIATE SHAFT (Continued) • If a vehicle is involved in an impact of the vehi- (3) Remove the upper and lower covers from the cle’s front suspension or undercarriage, which results steering column. in any type of damage to the front crossmember. (4) Turn the ignition key to the run position.
Page 502: Steering Coupling
COLUMN 19 - 25 KEY/LOCK CYLINDER (Continued) REMOVAL (1) Remove steering column assembly from vehicle. Refer to the Steering Column Removal. (2) Install Puller, Special Tool 6831-A, through center of roll pin in flex coupler and install knurled nut (Fig. 39). Fig.
Page 503: Steering Wheel Removal
19 - 26 COLUMN STEERING COUPLING (Continued) INSTALLATION (1) Confirm that: • The steering wheel position is a half turn (180 degrees) to the right (clockwise). • The column is locked with the ignition cylinder lock. • Check that the turn signal stalk is in the neu- tral position.
Page 504 COLUMN 19 - 27 STEERING COLUMN GEAR SHIFT LEVER (Continued) Fig. 41 Fuse Panel Cover 1 - FUSE PANEL COVER 2 - INSTRUMENT PANEL Fig. 43 Tilt Lever And Upper And Lower Shrouds 1 - UPPER SHROUD 2 - TILT LEVER 3 - LOWER SHROUD Fig.
Page 505 19 - 28 COLUMN STEERING COLUMN GEAR SHIFT LEVER (Continued) (4) Install the brake transmission interlock sole- noid on the shift lever mechanism. To do so, perform the following: (a) Align the flat inside the solenoid (Fig. 47) with the flat on the shift lever mounting stud. (b) Slide the solenoid completely onto the shift lever mounting stud aligning the plastic guide formed into the solenoid housing with the flange on...
Page 506 COLUMN 19 - 29 STEERING COLUMN GEAR SHIFT LEVER (Continued) adjustment tab will click as it moves into position. Ensure the tab fully depressed. Fig. 49 Solenoid Retainer Clip Installation 1 - SOLENOID Fig. 50 Ignition Interlock Adjustment Tab 2 - MOUNTING STUD 1 - LOCK CYLINDER HOUSING 3 - RETAINER CLIP 2 - INTERLOCK CASSETTE...
Page 507 19 - 30 GEAR GEAR TABLE OF CONTENTS page page GEAR OPERATION - SOLENOID CONTROL VALVE . . 40 DESCRIPTION REMOVAL - SOLENOID CONTROL VALVE ..40 DESCRIPTION - POWER STEERING GEAR . 30 INSTALLATION - SOLENOID CONTROL VALVE . 41 DESCRIPTION - SPEED PROPORTIONAL TIE ROD - INNER STEERING GEAR .
Page 508 GEAR 19 - 31 GEAR (Continued) Fig. 1 Power Steering Gear 1 - STEERING GEAR FLUID LINES 6 - ADJUSTMENT SLEEVE 2 - STEERING GEAR BOOT 7 - INNER TIE ROD 3 - RACK AND PINION STEERING GEAR 8 - ADJUSTMENT SLEEVE 4 - CLAMP 9 - TIE ROD END 5 - TIE ROD END...
Page 509: Steering Gear
19 - 32 GEAR GEAR (Continued) for controlling the variable effort of the power steer- OPERATION ing system. OPERATION - POWER STEERING GEAR REMOVAL - POWER STEERING GEAR Turning of the steering wheel is converted into lat- (1) Remove the battery ground cable from the eral (side-to side) travel through the meshing of the ground stud on the shock tower and isolate the helical pinion teeth with the rack teeth located in the...
Page 510 GEAR 19 - 33 GEAR (Continued) CAUTION: Before removing the steering column (7) Remove the wiper arms from the pivots. Wiper coupler from the intermediated steering shaft be arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled sure the steering wheel is locked from rotating (Fig.
Page 511 19 - 34 GEAR GEAR (Continued) (12) Remove the two nuts mounting the master cylinder to the vacuum booster (Fig. 11). Fig. 9 In-Line Resonator And Air Inlet Hose 1 - AIR INLET HOSE Fig. 11 Master Cylinder To Vacuum Booster 2 - THROTTLE BODY 3 - AIR INLET HOSE Mounting...
Page 512 GEAR 19 - 35 GEAR (Continued) Fig. 12 Tie Rod Attachment Bolt Retaining Tabs Fig. 14 Power Steering Hose Connections At Steering Gear 1 - STEERING GEAR 2 - TIE RODS 1 - POWER STEERING FLUID RETURN HOSE 3 - RETAINING TABS 2 - STEERING GEAR 4 - BOLTS 3 - MASTER CYLINDER FLUID RESERVIOR...
Page 513 19 - 36 GEAR GEAR (Continued) Fig. 16 Steering Gear Attachment To Crossmember Fig. 18 Steering Coupler Roll Pin (Right Side) 1 - SPECIAL TOOL 6831–A 2 - DASH PANEL SEAL & BOOT 1 - STEERING GEAR 3 - FLEX JOINT 2 - CROSSMEMBER 4 - KNURLED NUT 3 - MOUNTING BRACKET...
Page 514 GEAR 19 - 37 GEAR (Continued) (28) Remove the tie rod end from the steering arm (a) Slide the end of the steering gear through of the strut using Puller, Special Tool C-3894–A (Fig. the tie rod hole in the right side inner fender (Fig. 20).
Page 515: Disassembly - Power Steering Gear (Housing Bushings)
19 - 38 GEAR GEAR (Continued) DISASSEMBLY - POWER STEERING GEAR toms in the recessed area of the steering gear hous- ing. (HOUSING BUSHINGS) The power steering gear must be removed from the vehicle for the bushings to be serviced. Refer to REMOVAL in this section.
Page 516 GEAR 19 - 39 GEAR (Continued) (8) Using roll pin Installer, Special Tool 6831A, (12) Tighten the bolts mounting the left side of the install the roll pin in the flex joint of the intermedi- steering gear to the crossmember to a torque of 58 ate shaft (Fig.
Page 517: Speed Proportional Steering Solenoid
19 - 40 GEAR GEAR (Continued) (25) Remove the holding clamp from the steering wheel (Fig. 4). (26) Install the battery ground cable onto the ground stud on the shock tower. (27) Perform Power Steering Pump Initial Opera- tion procedure to properly refill and bleed power steering system.
Page 518: Installation - Solenoid Control Valve
GEAR 19 - 41 SPEED PROPORTIONAL STEERING SOLENOID (Continued) Fig. 31 Loosening Solenoid Control Valve 1 - SOLENOID CONTROL VALVE 2 - RETURN HOSE Fig. 29 Wiring Harness 3 - 15/16 CROW FOOT 1 - SPEED PROPORTIONAL STEERING SOLENOID 4 - STEERING GEAR CONNECTOR 2 - MASTER CYLINDER RESERVOIR (3) Using the 1–5/16 inch crow foot as shown (Fig.
Page 519: Tie Rod - Inner
19 - 42 GEAR SPEED PROPORTIONAL STEERING SOLENOID (Continued) (6) Connect the wiring harness connector. Be sure the wiring harness connector seal is in good condition before installing the connector in the control module. (7) Road test vehicle, referring to the test indi- cated in the Appropriate Diagnostic Information, to confirm correct operation of the variable-assist speed- proportional power steering gear.
Page 520 GEAR 19 - 43 TIE ROD - INNER (Continued) Fig. 39 Removing Outer Tie Rod From Steering Arm Fig. 37 In-Line Resonator And Air Inlet Hose 1 - TIE ROD END 1 - AIR INLET HOSE 2 - STEERING ARM 2 - THROTTLE BODY 3 - STRUT 3 - AIR INLET HOSE...
Page 521: Installation - Inner Tie Rod
19 - 44 GEAR TIE ROD - INNER (Continued) Fig. 42 Tie Rod Thread Engagement Requirements Fig. 41 Tie Rod To Steering Gear Attaching Bolts 1 - OUTER TIE ROD 2 - ADJUSTER 1 - TIE RODS 3 - PINCH BOLT 2 - BOLTS 4 - INNER TIE ROD 3 - MOUNTING PLATE...
Page 522: Tie Rod - Outer
GEAR 19 - 45 TIE ROD - INNER (Continued) tie rod attaching bolt through tie rod and washer (14) Install the battery ground cable onto the into steering gear. Be sure washer is installed ground stud on the shock tower and install nut. between tie rod and steering gear as shown (15) Adjust front toe.
Page 523: Removal - Outer Tie Rod
19 - 46 GEAR TIE ROD - OUTER (Continued) (6) Equally tighten both nuts on the U-bolt until a torque of 2.7 N·m (24 in. lbs.) is achieved on each nut. (7) Note the tie rod socket end play. New ball joint end play should not be greater then 0.100 inches.
Page 524: Bushing - Inner Tie Rod
GEAR 19 - 47 TIE ROD - OUTER (Continued) CAUTION: When setting the front Toe on the vehi- BUSHING - INNER TIE ROD cle, the maximum dimension of exposed threads allowed on the adjuster and outer tie rod cannot REMOVAL - INNER TIE ROD BUSHING exceed the distance shown in (Fig.
Page 525 19 - 48 GEAR BUSHING - INNER TIE ROD (Continued) (3) Remove the wiper arms from the pivots. Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots. (4) Remove the wiper module cover and cowl cover from the vehicle (Fig.
Page 526 GEAR 19 - 49 BUSHING - INNER TIE ROD (Continued) Fig. 56 Removing Outer Tie Rod From Steering Arm Fig. 58 Tie Rod To Steering Gear Attaching Bolts 1 - TIE ROD END 1 - TIE RODS 2 - STEERING ARM 2 - BOLTS 3 - STRUT 3 - MOUNTING PLATE...
Page 527: Installation - Inner Tie Rod Bushing
19 - 50 GEAR BUSHING - INNER TIE ROD (Continued) (a) Place the inner tie rod bushing end in the (a) Place the inner tie rod end in Receiver as Receiver as shown (Fig. 59). shown (Fig. 61). (b) Place Remover/Installer, Special Tool 8438–4, (b) Place the Sizer (with bushing) on top of the with the small end down on top of the bushing tie rod bushing bore with the tapered end facing...
Page 528 GEAR 19 - 51 BUSHING - INNER TIE ROD (Continued) (8) Align the inner tie rod with the mounting hole in the center take off on steering gear. Rotate the mounting plate into position over the tie rod. Install tie rod attaching bolt through tie rod and washer into steering gear.
Page 529 19 - 52 GEAR BUSHING - INNER TIE ROD (Continued) (16) Install the reinforcement on the vehicle (Fig. 53). Install the eight bolts attaching the cowl rein- forcement to the strut towers. Install the bolt attach- ing the wiper module to the reinforcement. (17) Install the covers over the wiper module and the cowl (Fig.
Page 530 PUMP 19 - 53 PUMP TABLE OF CONTENTS page page PUMP REMOVAL ......61 DESCRIPTION .
Page 531: Operation
19 - 54 PUMP PUMP (Continued) reduces pressure on the spring end of the flow con- trol valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the pump to a safe level.
Page 532: Removal - Pump (2.7L Engine)
PUMP 19 - 55 PUMP (Continued) REMOVAL REMOVAL - PUMP (2.7L ENGINE) (1) Remove the battery ground cable from the ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the ground stud (Fig. 3). Fig.
Page 533: Removal - Pump (3.5L Engine)
19 - 56 PUMP PUMP (Continued) (13) Remove the power steering pump, power steering fluid reservoir and pulley as an assembly from the engine. Power steering pump is removed from the top of the engine. (14) Transfer the required parts from the removed power steering pump to the replacement power steer- ing pump.
Page 534 PUMP 19 - 57 PUMP (Continued) Fig. 11 Drive Belt Tensioner Lock-Nut And Fig. 9 Power Steering Fluid Supply Hose At Power Adjustment Bolt Steering Pump 1 - ADJUSTMENT BOLT 1 - POWER STEERING FLUID SUPPLY HOSE 2 - POWER STEERING PUMP 2 - POWER STEERING PUMP 3 - LOCK-NUT 4 - DRIVE BELT...
Page 535: Disassembly - Pump (Pulley)
19 - 58 PUMP PUMP (Continued) (14) Transfer the required parts from the removed CAUTION: When installing the pulley on the power power steering pump to the replacement power steer- steering pump, Spacer, Special Tool 6936, MUST be ing pump. See Disassembly and Assembly in this sec- used.
Page 536: Installation - Pump (2.7L Engine)
PUMP 19 - 59 PUMP (Continued) the upset bead on the nipple of the power steer- ing fluid reservoir. (8) Connect the battery ground cable onto the ground stud located on the strut tower. (9) Perform Power Steering Pump Initial Opera- tion procedure to properly refill and bleed power steering system.(Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE)
Page 537: Standard Procedure - Power Steering Fluid Level Checking
19 - 60 PUMP FLUID STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. Wipe off the power steering fluid reservoir so that it is free of dirt (Fig. 16) (Fig. 17). Check the fill level of the fluid in the reservoir according to the mark- ings on the side of the reservoir.
Page 538: Removal
PUMP 19 - 61 FLUID COOLER (Continued) REMOVAL (1) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (2) Raise vehicle using a frame contact type hoist or supported using jack stands. See Hoisting in Lubrication And Maintenance.
Page 539: Hoses Description
19 - 62 PUMP (2) Position the front tires of the vehicle so that HOSES they are facing straight-ahead. (3) Raise the vehicle on a frame contact type hoist DESCRIPTION until the front tires of the vehicle are just off the The power steering fluid hoses connect the compo- floor.
Page 540 PUMP 19 - 63 HOSES (Continued) Fig. 26 Reinforcement Attachment To Vehicle 1 - RIGHT STRUT TOWER 2 - WIPER MODULE Fig. 28 Steering Wheel Lock Installed (Typical) 3 - LEFT STRUT TOWER 4 - ATTACHING BOLTS 1 - STEERING WHEEL 5 - ATTACHING BOLT 2 - STEERING WHEEL CLAMP 6 - REINFORCEMENT...
Page 541 19 - 64 PUMP HOSES (Continued) Fig. 32 Master Cylinder To Vacuum Booster Fig. 30 Tie Rod Attachment Bolt Retaining Tabs Mounting 1 - STEERING GEAR 2 - TIE RODS 1 - MOUNTING NUT 3 - RETAINING TABS 2 - MASTER CYLINDER 4 - BOLTS 3 - MOUNTING NUT 5 - PLATE...
Page 542 PUMP 19 - 65 HOSES (Continued) (18) Remove the 2 bolts attaching the left side of the steering gear to the crossmember (Fig. 34). Fig. 36 Power Steering Hose To Frame Rail Mounting 1 - COOLANT RECOVERY BOTTLE Fig. 34 Steering Gear Attachment To Crossmember 2 - FRAME RAIL (Left Side) 3 - POWER STEERING FLUID TUBES...
Page 543: Installation - Pressure And Return Hoses
19 - 66 PUMP HOSES (Continued) (Fig. 33). Tighten both power steering hose tube nuts to a torque of 47 N·m (35 ft. lbs.). CAUTION: Before installing tie rods on steering gear be sure the tie rod spacer block inside the steering gear bellows (Fig.
Page 544: Removal - Reservoir (2.7L Engine)
PUMP 19 - 67 HOSES (Continued) Fig. 41 Power Steering Fluid Reservoir (3.5L Fig. 40 Tie Rod Attachment Engine) 1 - RETAINING TABS 1 - SPEED CONTROL SERVO 2 - BOLTS 2 - POWER STEERING FLUID RESERVOIR 3 - RETAINING PLATE 4 - STEERING GEAR 5 - WASHER OPERATION...
Page 545: Installation - Reservoir
19 - 68 PUMP RESERVOIR (Continued) Fig. 42 Fluid Reservoir To Pump Mounting Fig. 44 Power Steering Fluid Reservoir (3.5L Engine) 1 - POWER STEERING FLUID RESERVOIR 2 - MOUNTING BOLTS 1 - SPEED CONTROL SERVO 3 - POWER STEERING PUMP 2 - POWER STEERING FLUID RESERVOIR 4 - MOUNTING BOLT Fig.
Page 546: Installation - Reservoir (3.5L Engine)
PUMP 19 - 69 RESERVOIR (Continued) INSTALLATION - RESERVOIR (3.5L ENGINE) hose clamps, being sure they are past the hose reten- tion beads on reservoir nipples. (1) Install the power steering fluid reservoir into (4) Lower vehicle. the mounting bracket. Be sure the retaining tab on (5) Fill the power steering pump reservoir to cor- the bracket is holding the reservoir in the bracket.
Page 548 TRANSAXLE 21 - 1 TRANSAXLE TABLE OF CONTENTS page page 42LE AUTOMATIC TRANSAXLE STANDARD PROCEDURE - FLUID/FILTER DESCRIPTION ......2 SERVICE .
Page 549 21 - 2 TRANSAXLE INSTALLATION ......135 INSTALLATION ......148 SHIFT INTERLOCK SOLENOID TORQUE CONVERTER REMOVAL...
Page 550: 42Le Automatic Transaxle
TRANSAXLE 21 - 3 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 1 42LE Transaxle 1 - DIFFERENTIAL 7 - OUTPUT GEAR 13 - UNDERDRIVE CLUTCH 2 - TRANSFER SHAFT 8 - OUTPUT SPEED SENSOR 14 - INPUT SPEED SENSOR 3 - TRANSFER GEAR 9 - LOW/REVERSE CLUTCH 15 - CONVERTER CLUTCH 4 - FRONT PLANET CARRIER...
Page 551: Operation
21 - 4 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 2 Transaxle Identification Label 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - IDENTIFICATION TAG Depending on date of manufacture, some transax- les will utilize a new identification label located in Fig.
Page 552: Diagnosis And Testing - Hydraulic
TRANSAXLE 21 - 5 42LE AUTOMATIC TRANSAXLE (Continued) • Diagnostic trouble code inspection running clutch may be slipping. If acceleration is nor- Then perform a road test to determine if the prob- mal, but high throttle opening is needed to maintain lem has been corrected or that more diagnosis is nec- highway speeds, the converter stator clutch may essary.
Page 553 21 - 6 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Install an engine tachometer, raise vehicle on hoist (3) Allow vehicle wheels to turn and increase which allows front wheels to turn, and position throttle opening to achieve an indicated vehicle speed tachometer so it can be read.
Page 554 TRANSAXLE 21 - 7 42LE AUTOMATIC TRANSAXLE (Continued) (1) Attach gauge to the torque converter clutch off (1) Attach gauge to the reverse and low/reverse pressure tap. clutch tap. (2) Move selector lever to the overdrive position. (2) Move selector lever to the reverse position. (3) Allow vehicle wheels to turn and increase (3) Read reverse clutch pressure with output sta- throttle opening to achieve an indicated vehicle speed...
Page 555: Pressure Tests
21 - 8 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - CLUTCH AIR UNDERDRIVE CLUTCH Because this clutch piston cannot be seen, its oper- PRESSURE TESTS ation is checked by function. Air pressure is applied Inoperative clutches can be located by substituting to the low/reverse or the 2/4 clutches.
Page 556: Diagnosis And Testing - Fluid Leakage
TRANSAXLE 21 - 9 42LE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - FLUID LEAKAGE The 42LE is a dual sump transaxle. The transaxle uses both automatic transaxle fluid (ATF) for the main sump and hypoid gear lube for the differential sump.
Page 557: Standard Procedure - Aluminum Thread Repair
21 - 10 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) COOLING/TRANSMISSION - STANDARD PROCE- DURE). The cooler bypass valve in the transaxle must be inspected and/or replaced also. The torque converter must also be replaced with an exchange unit. This will ensure that metal particles or sludged oil are not later transferred back into the recondi- tioned (or replaced) transaxle.
Page 558: Disassembly
TRANSAXLE 21 - 11 42LE AUTOMATIC TRANSAXLE (Continued) (23) Pull bottom of knuckles and drive shafts out- ward to allow clearance during transaxle removal. The drive shafts do not have to be completely removed from the vehicle. Do not allow the inner tripod joints to hang unsupported or joint dam- age may occur.
Page 559 21 - 12 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Before disassembling transaxle, move the shift (2) Remove input and output speed sensors (Fig. lever clockwise as far as it will go and then remove 13). the shift lever. NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.
Page 560 TRANSAXLE 21 - 13 42LE AUTOMATIC TRANSAXLE (Continued) (4) Remove transaxle oil filter (Fig. 15). (6) Remove valve body from transaxle (Fig. 17). Fig. 17 Remove Valve Body From Transaxle Fig. 15 Remove Transaxle Oil Filter 1 - VALVE BODY 1 - TRANSAXLE FILTER 2 - FILTER RETAINING CLIPS NOTE: For valve body recondition procedure, (Refer...
Page 561 21 - 14 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (8) Remove overdrive accumulator and springs (9) Remove the low/reverse accumulator snap ring (Fig. 19) (Fig. 20). (Fig. 21). Fig. 19 Remove Overdrive Accumulator and Springs Fig. 21 Remove Low/Reverse Accumulator 1 - OVERDRIVE ACCUMULATOR PISTON 1 - SNAP RING 2 - RETURN SPRINGS 2 - LOW/REVERSE ACCUMULATOR...
Page 562 TRANSAXLE 21 - 15 42LE AUTOMATIC TRANSAXLE (Continued) (11) Remove low/reverse accumulator piston and (12) Remove long stub shaft bearing snap ring springs (Fig. 23) (Fig. 24). (Fig. 25). Fig. 23 Remove Low/Reverse Accumulator Piston Fig. 25 Remove Long Stub Shaft Snap Ring 1 - SEAL RINGS 1 - SNAP RING 2 - PISTON...
Page 563 21 - 16 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (14) Remove oil pump-to-case bolts (Fig. 27). (16) Remove oil pump while pushing in on input shaft (Fig. 29). Fig. 27 Remove Oil Pump Attaching Bolts Fig. 29 Remove Oil Pump 1 - BELLHOUSING 1 - “PUSH IN”...
Page 564 TRANSAXLE 21 - 17 42LE AUTOMATIC TRANSAXLE (Continued) (18) Remove cooler by-pass valve (Fig. 31). (20) Remove input clutch assembly (Fig. 33). Fig. 31 Remove By-Pass Valve 1 - BYPASS VALVE (19) Remove #1 caged needle bearing (Fig. 32). Fig. 33 Remove Input Clutch Assembly 1 - INPUT CLUTCH ASSEMBLY (21) Remove #4 thrust plate (Fig.
Page 565 21 - 18 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (22) Remove front sun gear assembly and #4 (24) Remove rear sun gear and #7 needle bearing thrust washer (if still in place) (Fig. 35). (Fig. 37) (Fig. 38). Fig. 35 Remove Front Sun Gear Assembly Fig.
Page 566 TRANSAXLE 21 - 19 42LE AUTOMATIC TRANSAXLE (Continued) (25) Install and load Tool 5058 to remove 2/4 (27) Remove 2/4 clutch return spring (Fig. 42). clutch retainer snap ring (Fig. 39). Fig. 41 2/4 Clutch Retainer Fig. 39 Remove 2/4 Clutch Retainer Snap Ring 1 - 24 CLUTCH RETAINER 2 - 24 CLUTCH RETURN SPRING 1 - TOOL 5058...
Page 567 21 - 20 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (28) Remove 2/4 clutch pack (Fig. 43). (30) Remove low/reverse reaction plate (Fig. 45). Fig. 45 Remove Low/Reverse Reaction Plate Fig. 43 Remove 2/4 Clutch Pack 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP) 1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4) (31) Remove one (1) low/reverse clutch disc to facil-...
Page 568 TRANSAXLE 21 - 21 42LE AUTOMATIC TRANSAXLE (Continued) (32) Remove low/reverse reaction plate snap ring (34) Remove chain cover (Fig. 49). (Fig. 47). Fig. 49 Remove Chain Cover 1 - TRANSAXLE CASE Fig. 47 Remove Low/Reverse Reaction Plate Snap 2 - CHAIN COVER Ring 1 - SCREWDRIVER (35) Stand trans upright on bellhousing.
Page 569 21 - 22 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (37) Remove chain snubber (Fig. 51). Fig. 53 Remove Transfer Shaft Sprocket Snap Ring and Wave Washer Fig. 51 Remove Chain Snubber 1 - TRANSFER SHAFT 1 - CHAIN SNUBBER 2 - WAVE WASHER 3 - SNAP RING (38) Remove transfer and output shaft sprocket 4 - SNAP RING...
Page 570 TRANSAXLE 21 - 23 42LE AUTOMATIC TRANSAXLE (Continued) (40) Remove transfer chain and sprockets as an assembly (Fig. 55). Fig. 57 Main Sump Vent Baffle Location 1 - OUTPUT SHAFT NUT Fig. 55 Remove Chain and Both Sprockets as an 2 - MAIN SUMP VENT BAFFLE 3 - TRANSFER SHAFT NUT Assembly...
Page 571 21 - 24 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 59 Stake Grinding Pattern 1 - TRANSFER SHAFT 2 - TRANSFER SHAFT NUT (44) Using a small chisel, carefully open stakes on nut (Fig. 60). Fig. 61 Remove Output Shaft Nut 1 - SPECIAL TOOL 6497 2 - SPECIAL TOOL 6498 3 - BREAKER BAR...
Page 572 TRANSAXLE 21 - 25 42LE AUTOMATIC TRANSAXLE (Continued) (48) Remove rear carrier front bearing cone (Fig. 65). Fig. 63 Remove Front Bearing Cup 1 - ARBOR PRESS 2 - SPECIAL TOOL 6596 Fig. 65 Remove Rear Carrier Front Bearing Cone 1 - SPECIAL TOOL 5048–1 (47) Use special tool 6597 and handle C-4171 and 2 - SPECIAL TOOL 6545...
Page 573 21 - 26 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (51) Remove low/reverse piston belleville spring (Fig. 69). Fig. 67 Compressor Tool in Use 1 - LOW/REVERSE CLUTCH RETURN SPRING Fig. 69 Low/Reverse Piston Belleville Spring 2 - SNAP RING (INSTALL AS SHOWN) 3 - TOOL 5058A-3 1 - LOW/REVERSE PISTON RETURN SPRING 4 - TOOL 5059A...
Page 574 TRANSAXLE 21 - 27 42LE AUTOMATIC TRANSAXLE (Continued) (53) Drive out anchor shaft using suitable punch (Fig. 71). Fig. 71 Anchor Shaft Removal Fig. 73 Guide Bracket Disassembled 1 - PIN PUNCH 1 - ANTIRATCHET SPRING 2 - GUIDE BRACKET ASSEMBLY 2 - GUIDE BRACKET 3 - SPLIT SLEEVE (54) Remove guide bracket pivot shaft (Fig.
Page 575: Assembly
21 - 28 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (56) Remove low/reverse piston retainer screws (58) Remove low/reverse piston retainer gasket (Fig. 75). (Fig. 77). Fig. 75 Remove Piston Retainer-to-Case Screws Fig. 77 Remove Piston Retainer Gasket 1 - LOW/REVERSE CLUTCH PISTON RETAINER 1 - GASKET HOLES MUST LINE UP 2 - SCREWDRIVER 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET...
Page 576 TRANSAXLE 21 - 29 42LE AUTOMATIC TRANSAXLE (Continued) (2) Install low/reverse piston retainer gasket (Fig. (4) Install low/reverse piston retainer-to-case 79). screws (Fig. 81) and torque to 5 N·m (45 in. lbs.). Fig. 79 Install Piston Retainer Gasket Fig. 81 Install Retainer Attaching Screws 1 - LOW/REVERSE CLUTCH PISTON RETAINER 1 - GASKET HOLES MUST LINE UP 2 - SCREWDRIVER...
Page 577 21 - 30 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (6) Assemble guide bracket assembly as shown in (7) Install guide bracket pivot shaft (Fig. 85). (Fig. 83) (Fig. 84). Fig. 85 Install Guide Bracket Pivot Shaft 1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY Fig.
Page 578 TRANSAXLE 21 - 31 42LE AUTOMATIC TRANSAXLE (Continued) (9) Install low/reverse piston belleville spring into position (Fig. 87). Fig. 89 Compressor Tool Installed 1 - LOW/REVERSE CLUTCH RETURN SPRING Fig. 87 Install Low/Reverse Piston Return Spring 2 - SNAP RING (INSTALL AS SHOWN) 3 - TOOL 5058A-3 1 - LOW/REVERSE PISTON RETURN SPRING 4 - TOOL 5059A...
Page 579 21 - 32 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (12) Install rear carrier front bearing cone (Fig. (c) Turn case over on arbor press so that the 91). plate is resting on the press base. CAUTION: The output shaft will extend through the hole of tool 6618A.
Page 580 TRANSAXLE 21 - 33 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 93 Special Tool Installed 1 - SPECIAL TOOL 6618–A Fig. 95 Press Shaft Into Case 1 - SPECIAL TOOL C-4171 AND C-4171–2 2 - SPECIAL TOOL MD-998911 Fig. 94 Shim Installation 1 - SHIM 2 - OUTPUT SHAFT Fig.
Page 581 21 - 34 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (14) Apply Mopar ATF RTV (MS-GF41) as shown in (Fig. 99). Install main sump baffle to transaxle case (Fig. 100) and torque screw to 5 N·m (45 in. lbs.). Fig. 99 Properly Applied Sealant 1 - SEALANT Fig.
Page 582 TRANSAXLE 21 - 35 42LE AUTOMATIC TRANSAXLE (Continued) (17) Remove chain spreader (Fig. 103). Fig. 101 Output Sprocket Spacer Fig. 103 Remove Chain Spreader 1 - OUTPUT SPROCKET SPACER 2 - VENT BAFFLE 1 - OUTPUT SPROCKET 3 - OUTPUT SHAFT 2 - SPECIAL TOOL 6550 3 - TRANSFER SPROCKET CAUTION: The chain sprockets have a slip fit onto...
Page 583 21 - 36 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (20) Install chain oiler (Fig. 107) and torque screw to 5 N·m (45 in. lbs.). Fig. 105 Install Output Shaft Sprocket Snap Ring and Wave Washer 1 - WAVE WASHER Fig. 107 Install Chain Oiler 2 - SNAP RING 1 - CHAIN SNUBBER 2 - CHAIN OILER...
Page 584 TRANSAXLE 21 - 37 42LE AUTOMATIC TRANSAXLE (Continued) (23) Install low/reverse clutch pack (Fig. 109). (25) Install one low/reverse clutch disc (Fig. 111). Leave uppermost disc out to facilitate snap ring installation. Fig. 111 Install One Disc 1 - ONE DISC FROM LOW/REVERSE CLUTCH Fig.
Page 585 21 - 38 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (27) Install tapered snap ring (tapered side out) as shown in (Fig. 113) (Fig. 114). Fig. 115 Check Low/Reverse Clutch Clearance 1 - DIAL INDICATOR 2 - DIAL INDICATOR TIP TOOL 6268 3 - HOOK TOOL (29) Select the proper low/reverse reaction plate to achieve specifications:...
Page 586 TRANSAXLE 21 - 39 42LE AUTOMATIC TRANSAXLE (Continued) NOTE: When installing the 2-4 clutch plates and discs, the orientation should be alternated so the pilot pads of adjacent plates do not align, refer to (Fig. 117). Fig. 119 Proper Orientation of 2/4 Clutch 1 - NOTE POSITION 2 - RETURN SPRING 3 - 2/4 CLUTCH RETAINER...
Page 587 21 - 40 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (33) Set up Tool 5058 as shown in (Fig. 121). Com- (35) Install the #7 needle bearing to the rear sun press 2/4 clutch just enough to facilitate snap ring gear (Fig. 123). The number 7 needle bearing has installation.
Page 588 TRANSAXLE 21 - 41 42LE AUTOMATIC TRANSAXLE (Continued) (37) Install front carrier/rear annulus assembly (39) Determine proper #4 thrust plate thick- and #6 needle bearing (Fig. 125). ness. (a) Select the thinnest #4 thrust plate thickness. (b) Install #4 thrust plate (Fig. 127) using petro- latum to hold into position.
Page 589 21 - 42 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (i) Remove oil pump, gasket, and input clutch CAUTION: If view through input speed sensor hole assembly to gain access to and install proper #4 is not as shown in (Fig. 128), the input clutches thrust plate.
Page 590 TRANSAXLE 21 - 43 42LE AUTOMATIC TRANSAXLE (Continued) (40) Install input clutch assembly with proper (42) Replace cooler by-pass valve if transmission thrust plate (Fig. 131). failure has occurred (Fig. 133). CAUTION: By-pass valve must be replaced if trans- mission failure occurs. Fig.
Page 591 21 - 44 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (44) Install oil pump and torque oil pump-to-case NOTE: Install new halfshaft retainer clips. bolts to 28 N·m (250 in. lbs.) (Fig. 135). (46) Install long stub shaft bearing retaining snap ring (Fig. 137). Replace halfshaft retainer clips. Fig.
Page 592 TRANSAXLE 21 - 45 42LE AUTOMATIC TRANSAXLE (Continued) (48) Install low/reverse accumulator plug (Fig. (50) Install underdrive and overdrive accumulators 139). as shown in (Fig. 141) (Fig. 142) (Fig. 143). Fig. 141 Accumulator Locations Fig. 139 Install Low/Reverse Accumulator Plug (Cover) 1 - OVERDRIVE ACCUMULATOR LOCATION 2 - UNDERDRIVE ACCUMULATOR LOCATION...
Page 593 21 - 46 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 143 Install Overdrive Accumulator and Springs Fig. 145 Install Valve Body Bolts (7) 1 - OVERDRIVE ACCUMULATOR PISTON 1 - EXTENSION 2 - RETURN SPRINGS 2 - SOCKET 3 - SEAL RING 3 - VALVE BODY 4 - SEAL RING CAUTION: Do not handle the valve body by the...
Page 594: Installation
TRANSAXLE 21 - 47 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 147 Install Transaxle Oil Pan 1 - TRANSAXLE OIL PAN Fig. 149 Measure Input Shaft End Play Using Tool 8266—Typical 1 - TOOL 8266–8 2 - TOOL 8266–2 3 - TOOL C-3339 (2) If the torque converter is being replaced, apply a light coating of grease to the crankshaft pilot hole.
Page 595: Schematics And Diagrams - 42Le Transaxle
21 - 48 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) SCHEMATICS AND DIAGRAMS - 42LE TRANSAXLE...
Page 596 TRANSAXLE 21 - 49 42LE AUTOMATIC TRANSAXLE (Continued)
Page 597 21 - 50 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 598 TRANSAXLE 21 - 51 42LE AUTOMATIC TRANSAXLE (Continued)
Page 599 21 - 52 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 600 TRANSAXLE 21 - 53 42LE AUTOMATIC TRANSAXLE (Continued)
Page 601 21 - 54 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 602 TRANSAXLE 21 - 55 42LE AUTOMATIC TRANSAXLE (Continued)
Page 603 21 - 56 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 604 TRANSAXLE 21 - 57 42LE AUTOMATIC TRANSAXLE (Continued)
Page 605 21 - 58 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 606 TRANSAXLE 21 - 59 42LE AUTOMATIC TRANSAXLE (Continued)
Page 607 21 - 60 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 608: Specifications
TRANSAXLE 21 - 61 42LE AUTOMATIC TRANSAXLE (Continued) SPECIFICATIONS 42LE AUTOMATIC TRANSAXLE GENERAL SPECIFICATIONS Four-Speed Automatic, Longitudinally Mounted, Electronically Controlled, Fully Adaptive, Electronically Transaxle Type Modulated Torque Converter, Integrated Differential with Unique Oil Sump Lubrication Method Pump (internal - external gear-type) Water Heat Exchanger and/or Air-to-Oil Heat Cooling Method Exchanger...
Page 609 21 - 62 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) FLUID, TRANSMISSION & DIFFERENTIAL Location Type Metric Capacity Standard Capacity Transmission Sump Mopar ATF+4 Type 9602 9.29L 9.81 Qts. Differential Sump Mopar Fuel Saving 0.95L 32 oz. 75W-90 Petroleum-Based Hypoid Gear Lube INPUT SHAFT Description Metric...
Page 610: Special Tools
TRANSAXLE 21 - 63 42LE AUTOMATIC TRANSAXLE (Continued) Description N·m Ft. Lbs. In. Lbs. Bolt, Solenoid/Pressure Switch Assy-to- Valve Body Bolt, Valve Body-to-Case Bolt, Valve Body-to-Transfer Plate Connector, Solenoid/Pressure Switch Assembly Fitting, Cooler Line Nut, Output Shaft Nut, Transfer Shaft Stake Plug, Differential Drain Plug, Differential Fill Plug, Pressure Tap...
Page 611 21 - 64 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Seal Puller C-3981B Adapter C-4996 Adapter Set L-4559 Universal Handle C-4171 Bearing Splitter P-334 Handle Extension C-4171-2 Seal Installer C-4193A Puller Set 5048 Installer 5050A Installer C-4340...
Page 612 TRANSAXLE 21 - 65 42LE AUTOMATIC TRANSAXLE (Continued) Compressor 5058A Disk 6057 Compressor 5059-A Tip 6268 Installer 5067 Remover/Installer 6301 Installer 6052 Remover/Installer 6302...
Page 613 21 - 66 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Remover 6502B Remover 6310 Installer 6494 Wrench 6503 Remover 6495 Installer 6522 Wrench 6497 Puller Jaws 6545 Wrench 6498 Turning Fork 6548...
Page 614 TRANSAXLE 21 - 67 42LE AUTOMATIC TRANSAXLE (Continued) Pinion Gauge Tool Set 6549 Remover 6577 Remover 6550 Staking Tool 6589 Installer 6558 Seal Protector 6591 Installer 6560 Seal Protector 6592 Seal Installer 6567A Fixture 6595...
Page 615 21 - 68 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Remover 6596 Cooler Flusher 6906 Remover 6597 End Play Set 8266 Plate Set 6599 Support Plate 6618A Pressure Fixture 8391 Staking Tool 6639 Remover 8420A...
Page 616: Accumulator Description
TRANSAXLE 21 - 69 ACCUMULATOR DESCRIPTION The 42LE underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumu- lator. An accumulator assembly typically consists of a piston, seals, return spring(s), and a cover or plug (Fig. 150). Fig. 151 Overdrive, Underdrive and Low/Reverse Accumulator Location 1 - OVERDRIVE ACCUMULATOR LOCATION 2 - UNDERDRIVE ACCUMULATOR LOCATION...
Page 617: Autostick Switch Description
21 - 70 TRANSAXLE stick mode. Speed control will be deactivated if the AUTOSTICK SWITCH transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the trans- DESCRIPTION axle resumes the OD shift schedule. Autostick is a driver-interactive transmission fea- ture that offers manual gear shifting capability to DEACTIVATION provide you with more control.
Page 618: Bearing Adjustment Procedures
TRANSAXLE 21 - 71 NOTE: Bearing end play and drag torque specifica- BEARINGS tions must be maintained to avoid premature bear- ing failures. ADJUSTMENTS Used (original) bearing may lose up to 50 percent of the original drag torque after break-in. BEARING ADJUSTMENT PROCEDURES Take extreme care when removing and installing NOTE: All bearing adjustments must be made with...
Page 619 21 - 72 TRANSAXLE BEARINGS (Continued) Master Shim Chart...
Page 620: Driving Clutches Description
TRANSAXLE 21 - 73 NOTE: (Refer to 21 - TRANSMISSION/TRANSAXLE/ DRIVING CLUTCHES AUTOMATIC - 42LE - DIAGNOSIS AND TESTING) for a collective view of which clutch elements are DESCRIPTION applied at each position of the selector lever. Three hydraulically applied input clutches are used to drive planetary components.
Page 621 21 - 74 TRANSAXLE FINAL DRIVE (Continued) (2) Remove chain oiler (Fig. 156). Fig. 156 Remove Chain Oiler 1 - CHAIN SNUBBER 2 - CHAIN OILER (3) Remove chain snubber (Fig. 157). Fig. 154 Differential Assembly 1 - PINION GEAR 2 - RING GEAR 3 - SHORT STUB SHAFT 4 - DIFFERENTIAL CASE ASSEMBLY...
Page 622 TRANSAXLE 21 - 75 FINAL DRIVE (Continued) (6) Install chain spreader 6550 and expand to facilitate sprocket and chain removal (Fig. 160). Fig. 158 Remove Output Shaft Sprocket Snap Ring and Wave Washer 1 - WAVE WASHER Fig. 160 Install Chain Spreader 2 - SNAP RING 1 - OUTPUT SPROCKET 2 - SPECIAL TOOL 6550...
Page 623 21 - 76 TRANSAXLE FINAL DRIVE (Continued) (8) Using suitable snap ring pliers, remove long CAUTION: Driveshaft retainer clips and seals stub shaft snap ring (Fig. 162). located on the stub shafts must be replaced before reinstalling halfshafts. (10) Remove inner differential adjuster lock (Fig. 164).
Page 624 TRANSAXLE 21 - 77 FINAL DRIVE (Continued) (12) Loosen outer adjuster (Fig. 166). DIFFERENTIAL DISASSEMBLY (1) Remove ring gear-to-carrier bolts (Fig. 168). Fig. 166 Loosen Outer Adjuster Fig. 168 Remove Ring Gear Bolts 1 - OUTER ADJUSTER 1 - RING GEAR BOLTS 2 - SPECIAL TOOL 6503 2 - RING GEAR (13) Remove differential side cover, and carrier/...
Page 625 21 - 78 TRANSAXLE FINAL DRIVE (Continued) (3) Using suitable pry tools, pry differential carrier (5) Using a suitable punch, remove pinion shaft apart (Fig. 170). roll pin (Fig. 172). Fig. 170 Pry Differential Carrier Apart 1 - DIFFERENTIAL CARRIER 2 - PRY TOOL 3 - PRY TOOL (4) Remove stub shaft C-clip (Fig.
Page 626 TRANSAXLE 21 - 79 FINAL DRIVE (Continued) (7) Using tool C-293-PA, adapters C-293-48, and adapter C-4996, remove differential carrier bearings (Fig. 174). Fig. 176 Differential Vent Baffle 1 - RETAINING SCREWS 2 - VENT BAFFLE W/SHIELD CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to transfer shaft during nut removal.
Page 627 21 - 80 TRANSAXLE FINAL DRIVE (Continued) Fig. 178 Stake Grinding Pattern 1 - TRANSFER SHAFT 2 - TRANSFER SHAFT NUT (17) Using a small chisel, carefully open stakes on nut (Fig. 179) Fig. 180 Press Transfer Shaft Downward to Remove Rear Cone 1 - TRANSFER SHAFT 2 - ARBOR PRESS...
Page 628: Assembly / Bearing Adjustment Procedure
TRANSAXLE 21 - 81 FINAL DRIVE (Continued) (20) Remove transfer shaft preload shim (Fig. (22) Remove transfer shaft seals using special tool 182). If transfer shaft bearings are to be reused, the 6310 and foot 6310-9 (Fig. 184). Do not reuse old original shim must also be reused.
Page 629 21 - 82 TRANSAXLE FINAL DRIVE (Continued) Fig. 186 Remove Front Transfer Shaft Bearing And Pinion Depth Shim 1 - ARBOR PRESS 2 - TRANSFER SHAFT 3 - SPECIAL TOOL P-334 4 - FRONT TRANSFER SHAFT BEARING Fig. 187 Install Front Transfer Shaft CAUTION: Failure to adjust pinion depth correctly 1 - SPECIAL TOOL 6494 could cause gear noise or transaxle failure.
Page 630 TRANSAXLE 21 - 83 FINAL DRIVE (Continued) (3) Install new front bearing (actual bearing to be (5) Install centering disc (special tool 6494-2) onto used during reassembly) onto gauge disc (special tool gauge disc rod (Fig. 191). 6549-3) (Fig. 189). Fig.
Page 631 21 - 84 TRANSAXLE FINAL DRIVE (Continued) (7) Hand tighten centering nut until all play in the (9) Before making a pinion depth measurement tool has been removed. the dial indicator must be zeroed. This is done by (8) Install dial indicator into locating block Tool placing the dial indicator in the zeroing fixture (spe- 6549-1.
Page 632 TRANSAXLE 21 - 85 FINAL DRIVE (Continued) • Shim size needed: 0.032+0.001= 0.033in (11) Pivot dial indicator back and forth (Fig. 197)on centering pin to obtain the shortest distance measurement. This will be the lowest number reading on dial indicator. Record the number obtained.
Page 633 21 - 86 TRANSAXLE FINAL DRIVE (Continued) (19) The following steps will determine how many foot pounds are required on the outer differential adjuster to obtain the correct turning torque. CAUTION: Failure to set differential bearing preload correctly may cause bearing failure, gear noise and/or axle shaft seal failure.
Page 634 TRANSAXLE 21 - 87 FINAL DRIVE (Continued) Fig. 201 Axle Shaft Seal Installation 1 - ARBOR PRESS 2 - OUTER DIFFERENTIAL ADJUSTER 3 - O-RING 4 - SPECIAL TOOL 6558 If differential was not disassembled, refer to Step Fig. 203 Carrier Bearing Installation 1 - ARBOR PRESS 2 - HANDLE C-4171 3 - SPECIAL TOOL C-4340...
Page 635 21 - 88 TRANSAXLE FINAL DRIVE (Continued) Fig. 207 Install Ring Gear Bolts 1 - RING GEAR BOLTS 2 - RING GEAR Fig. 205 Install Pinion Shaft Roll Pin 1 - HAMMER 2 - PIN PUNCH 3 - PINION SHAFT 4 - DIFFERENTIAL CARRIER 5 - DIFFERENTIAL BEARING Fig.
Page 636 TRANSAXLE 21 - 89 FINAL DRIVE (Continued) Fig. 211 Outer Adjuster Installation Fig. 209 Differential Cover Installation 1 - O-RING 1 - SIDE COVER 2 - OUTER ADJUSTER Fig. 210 Seal Protector Fig. 212 Special Tool 6548 1 - SEAL PROTECTOR (6591) 1 - SPECIAL TOOL 6548 2 - SIDE COVER ⁄...
Page 637 21 - 90 TRANSAXLE FINAL DRIVE (Continued) Fig. 213 Determining Turning Torque 1 - FT. LBS. TORQUE WRENCH 3 - IN. LBS. TORQUE WRENCH 2 - SPECIAL TOOL 6548 4 - SPECIAL TOOL 6503 (33) Install transfer shaft into transaxle case (Fig. CAUTION: Bottom of support fixture must be flush 214).
Page 638 TRANSAXLE 21 - 91 FINAL DRIVE (Continued) Fig. 217 Correct Seal Orientation 1 - SEAL PROTECTOR 2 - FRONT TRANSFER SHAFT SEAL 3 - SERRATED SIDE REARWARD Fig. 215 Transfer Shaft Support Fixture 1 - SUPPORT FIXTURE (6595) Fig. 218 Seal Installation 1 - ARBOR PRESS 2 - SEAL INSTALLER (6567A) 3 - TRANSAXLE CASE...
Page 639 21 - 92 TRANSAXLE FINAL DRIVE (Continued) (38) Install rear transfer shaft seal. The seal must CAUTION: Properly seated cups are essential in be installed so that the spring side of the seal faces correctly setting bearing preload. the installation tool (Fig. 219). Use the same special (40) Use special tool 6560 to press cup into case tool (6567A) to install the seal.
Page 640 TRANSAXLE 21 - 93 FINAL DRIVE (Continued) CAUTION: Failure to set the transfer shaft turning torque correctly may cause transfer shaft bearings or seals to fail. Be sure transfer shaft does not have end play. If end play exists, install a thinner preload shim.
Page 641 21 - 94 TRANSAXLE FINAL DRIVE (Continued) Fig. 227 Vent Baffle Installation Fig. 225 Staking New Nuts 1 - NO SEALER ON THIS EDGE 1 - ARBOR PRESS 2 - APPLY SEALER 2 - STAKING TOOL (6589) 3 - VENT BAFFLE (49) Install new inner adjuster O-ring.
Page 642 TRANSAXLE 21 - 95 FINAL DRIVE (Continued) (51) Transfer shaft to ring gear backlash should be (53) Install seal protector (special tool 6591) on 0.006 to 0.009 thousands of an inch. To get the shaft (Fig. 231). backlash close enough to measure, perform the fol- lowing steps.
Page 643 21 - 96 TRANSAXLE FINAL DRIVE (Continued) (55) To check and/or adjust backlash, remove the FLUID inspection plug from the top of the differential. Install dial indicator as shown in (Fig. 233). The tip STANDARD PROCEDURE of the dial indicator must be perpendicular against one of the ring gear teeth.
Page 644 TRANSAXLE 21 - 97 FLUID (Continued) Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly.
Page 645: Standard Procedure - Fluid/Filter Service
21 - 98 TRANSAXLE FLUID (Continued) Be sure to examine the fluid on the dipstick closely. FLUID/FILTER SERVICE (RECOMMENDED) If there is any doubt about its condition, drain out a (1) Raise vehicle on a hoist (Refer to LUBRICA- sample for a double check. TION &...
Page 646: Standard Procedure - Differential Sump Drain And Refill
TRANSAXLE 21 - 99 FLUID (Continued) ALTERNATIVE MAINTENANCE METHODS (4) Follow the manufacturers recommended proce- dure and evacuate the fluid from the transaxle. TRANSAXLE FLUID EXCHANGER METHOD (5) Remove the suction line from the dipstick tube. (6) Pour four quarts of Mopar ATF+4 (Automatic CAUTION: The use of any fluid exchanger that Transmission Fluid—Type 9602) through the dipstick introduces additives into the transaxle is not rec-...
Page 647: Gear Shift Cable - Column Removal
21 - 100 TRANSAXLE GEAR SHIFT CABLE - COLUMN REMOVAL (1) Place vehicle in park, and turn ignition key to the “LOCK” position (Fig. 237) . Fig. 239 Lower Column Cover Screw Removal 1 - LOWER COLUMN COVER 2 - STEERING WHEEL Fig.
Page 648 TRANSAXLE 21 - 101 GEAR SHIFT CABLE - COLUMN (Continued) Fig. 241 Tilt Lever Screw Removal/Install 1 - STEERING WHEEL 2 - TURN SIGNAL LEVER 3 - TILT LEVER 4 - SCREWDRIVER Fig. 243 Column Gear Shift Cable—Re 1 - CONDUIT BRACKET (6) Remove the ignition key and remove lower col- 2 - RETAINER CLIP umn cover (Fig.
Page 649: Installation
21 - 102 TRANSAXLE GEAR SHIFT CABLE - COLUMN (Continued) (13) Remove shift cable retaining nut and slide cable assy. off of mounting stud (Fig. 246) . (14) Disconnect shifter cable from shift lever assembly at transaxle (Fig. 246) . (15) Remove cable from vehicle.
Page 650: Adjustment
TRANSAXLE 21 - 103 GEAR SHIFT CABLE - COLUMN (Continued) (13) Move the steering column to full tilt downward. Put the column shifter in park with key removed. (14) Adjust cable by rotating the adjuster into lock position (Fig. 248) . The adjuster will click when lock is fully adjusted.
Page 651: Gear Shift Cable - Floor Removal
21 - 104 TRANSAXLE GEAR SHIFT CABLE - COLUMN (Continued) (8) Check shifter for proper operation. It should (5) Remove retaining clip from shift cable conduit operate smoothly without binding. The vehicle should bracket (Fig. 253) . crank in Park or Neutral only. (6) Disconnect shifter cable from cable attach stud (pin) (Fig.
Page 652 TRANSAXLE 21 - 105 GEAR SHIFT CABLE - FLOOR (Continued) Fig. 256 Cable Routing Bracket—(3.2 Fig. 254 Throttle/Gearshift Cable Bracket 1 - BRACKET 1 - CABLE BRACKET 2 - CABLE 2 - GEARSHIFT CABLE 3 - THROTTLE CABLE (5) Install cable “push pin” into bracket as shown in (Fig.
Page 653: Adjustment
21 - 106 TRANSAXLE GEAR SHIFT CABLE - FLOOR (Continued) (10) Route cable through hole in shifter conduit (3) Make sure that the transaxle shift lever (at bracket and attach to cable attaching shift pin by transaxle) is in the Park position. This is the most snapping into place (Fig.
Page 654: Input Clutch Assembly Disassembly
TRANSAXLE 21 - 107 HOLDING CLUTCHES (Continued) INPUT CLUTCH ASSEMBLY DISASSEMBLY (1) Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391). (2) Tap down reverse clutch reaction plate to release pressure from snap ring (Fig. 260). Fig. 260 Tapping Reaction Plate Fig.
Page 655 21 - 108 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (4) Pry up and remove reverse clutch reaction (5) Remove the reverse clutch pack (two fibers/one plate (Fig. 262) (Fig. 263). steel) (Fig. 264). NOTE: Tag reverse clutch pack for reassembly iden- tification.
Page 656 TRANSAXLE 21 - 109 INPUT CLUTCH ASSEMBLY (Continued) (7) Remove OD/Reverse pressure plate (Fig. 266). (9) Remove OD shaft/hub and OD clutch pack (Fig. 268) (Fig. 269). NOTE: Tag overdrive clutch pack for reassembly identification. Fig. 266 OD/Reverse Reaction Plate 1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN) 2 - (STEP SIDE DOWN) Fig.
Page 657 21 - 110 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (10) Remove and inspect #3 & #4 thrust washers (12) Remove the #2 needle bearing (Fig. 272). (Fig. 270). Fig. 272 No. 2 Needle Bearing Fig. 270 #3 & 4 Thrust Washers 1 - #2 NEEDLE BEARING (NOTE 3 TABS) 1 - #3 THRUST PLATE (3 TABS) 2 - OD SHAFT ASSEMBLY...
Page 658 TRANSAXLE 21 - 111 INPUT CLUTCH ASSEMBLY (Continued) NOTE: The OD/UD clutch reaction plate has a step (16) Remove the UD clutch flat snap ring (Fig. on both sides. Install the OD/UD clutches reaction 276). plate tapered step side up. (14) Remove the OD/UD reaction plate (Fig.
Page 659 21 - 112 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) CAUTION: Compress return spring just enough to (20) Remove UD clutch piston (Fig. 280). remove or install snap ring. (18) Using Tool 5059A and an arbor press, com- press UD clutch piston enough to remove snap ring (Fig.
Page 660 TRANSAXLE 21 - 113 INPUT CLUTCH ASSEMBLY (Continued) (22) Tap on input hub with soft faced hammer and (23) Separate clutch retainer from OD/Reverse pis- separate input hub from OD/Reverse piston and ton (Fig. 284). clutch retainer (Fig. 282) (Fig. 283). Fig.
Page 661: Assembly
21 - 114 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (26) Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub (Fig. 288). Fig. 286 Return Spring and Snap Ring 1 - OD/REVERSE PISTON 2 - RETURN SPRING 3 - SNAP RING Fig.
Page 662 TRANSAXLE 21 - 115 INPUT CLUTCH ASSEMBLY (Continued) (2) Install input shaft snap ring (Fig. 290). Fig. 292 Install Snap Ring 1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST Fig. 290 Install Input Shaft Snap Ring ENOUGH TO REMOVE OR INSTALL SNAP RING) 1 - INPUT SHAFT 2 - SCREWDRIVER 2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
Page 663 21 - 116 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (5) Install the input hub/shaft assembly. to the (7) Install UD clutch piston (Fig. 296). OD/Reverse piston/clutch retainer ashy. (Fig. 294). Fig. 296 Underdrive Clutch Piston Fig. 294 Install Input Shaft Hub Assembly 1 - PISTON 1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY (ROTATE TO ALIGN SPLINES)
Page 664 TRANSAXLE 21 - 117 INPUT CLUTCH ASSEMBLY (Continued) (9) Using Tool 5059A and an arbor press, install (10) Install the UD clutch pack (four fibers/four the UD spring retainer and snap ring. (Fig. 298) (Fig. steels) (Fig. 300). Leave the top disc out until after 299) Compress just enough to install snap ring.
Page 665 21 - 118 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (12) Install the last UD clutch disc (Fig. 302). Fig. 304 Tapered Snap Ring Fig. 302 Install Last UD Clutch Disc 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 1 - ONE UNDERDRIVE CLUTCH DISC 2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE) (13) Install the OD/UD clutch reaction plate and snap ring (Fig.
Page 666 TRANSAXLE 21 - 119 INPUT CLUTCH ASSEMBLY (Continued) Fig. 306 Input Clutch Assembly on Pressure Fixture Fig. 308 Press Down on UD Clutch Pack and Zero Tool 8391 Dial Indicator 1 - INPUT CLUTCH ASSEMBLY 1 - DIAL INDICATOR 2 - INPUT CLUTCH PRESSURE FIXTURE 8391 2 - UNDERDRIVE CLUTCH (19) Take average of four measurements and com- pare with UD clutch pack clearance specification.
Page 667 21 - 120 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) (22) Install OD reaction plate waved snap ring (24) Install OD reaction plate flat snap ring (Fig. (Fig. 310). 312). Fig. 310 Install Waved Snap Ring Fig. 312 Install Flat Snap Ring 1 - ARBOR PRESS RAM 1 - OVERDRIVE REACTION PLATE WAVED SNAP RING 2 - TOOL 5059A...
Page 668 TRANSAXLE 21 - 121 INPUT CLUTCH ASSEMBLY (Continued) (26) Zero dial indicator and apply 30 psi (206 kPa) (30) Tap reaction plate down to allow installation air pressure to the overdrive clutch hose on Tool of the reverse clutch snap ring. Install reverse clutch 8391.
Page 669 21 - 122 TRANSAXLE INPUT CLUTCH ASSEMBLY (Continued) reverse clutch pack measurement in four (4) places, 90° apart. (35) Take average of four measurements and com- pare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.).
Page 670 TRANSAXLE 21 - 123 INPUT CLUTCH ASSEMBLY (Continued) (41) Install the overdrive shaft assembly (Fig. 324). Fig. 322 Install No. 3 Thrust Washer 1 - #3 THRUST WASHER (NOTE 5 TABS) 2 - UNDERDRIVE SHAFT ASSEMBLY Fig. 324 Install Overdrive Shaft Assembly 1 - OVERDRIVE SHAFT ASSEMBLY (40) Install the #3 thrust plate to the bottom of the 2 - #3 THRUST PLATE...
Page 671: Oil Pump Description
21 - 124 TRANSAXLE STANDARD PROCEDURE - OIL PUMP VOLUME OIL PUMP CHECK DESCRIPTION Measuring oil pump output volume will determine The oil pump is located in the pump housing inside if sufficient flow to the transmission oil cooler exists, the bell housing of the transaxle case.
Page 672: Disassembly
TRANSAXLE 21 - 125 OIL PUMP (Continued) DISASSEMBLY (4) Re-install the gears and check clearances. (5) Measure the clearance between the outer gear When disassembling the transaxle it is necessary and the pump pocket (Fig. 330). Clearance should be to inspect the oil pump for wear and damage. 0.089–0.202 mm (0.0035-0.0079 in.).
Page 673: Assembly
21 - 126 TRANSAXLE OIL PUMP (Continued) ASSEMBLY PLANETARY GEARTRAIN (1) Assemble oil pump as shown in (Fig. 331) DESCRIPTION (2) Install and torque reaction shaft support-to-oil pump housing bolts to 28 N·m (20 ft. lbs.) torque. The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case.
Page 674: Seal - Stub Shaft (Long) Removal
TRANSAXLE 21 - 127 To replace the long stub shaft bearing, install stub SEAL - STUB SHAFT (LONG) shaft in soft-jawed vise. Remove the stub shaft bear- ing C-clip (Fig. 334). Install bearing splitter onto the REMOVAL shaft. Install Special Tool # P-334 under the bearing. If it has been diagnosed that the long stub shaft Using a shop press, remove the bearing from the seal is leaking, the following procedure can be used...
Page 675: Installation
21 - 128 TRANSAXLE SEAL - STUB SHAFT (LONG) (Continued) CAUTION: If short stub shaft has corrosion, use caution when removing differential cover. Inspect seal and shaft for damage after removal of cover. Replace shaft and/or seal as required. (4) Index outer adjuster (Fig. 338). Remove lock bracket and back out adjuster exactly one revolution.
Page 676: Seal - Stub Shaft (Short) Removal
TRANSAXLE 21 - 129 SEAL - STUB SHAFT (SHORT) REMOVAL The following procedure can be used to replace the short stub shaft seal without having to remove the transaxle from the vehicle. If the adjuster or bearing located behind the adjuster require replacement, do not use this procedure.
Page 677 21 - 130 TRANSAXLE SEAL - STUB SHAFT (SHORT) (Continued) (3) Remove solenoid connector from transaxle case. (4) Remove long stub shaft from transaxle (Fig. 343). Fig. 342 Stub Shaft Corrosion 1 - STUB SHAFT 2 - CORROSION AREA INSTALLATION (1) Lube O-ring, threads on adjuster, seal protector and seal lips with gear oil before installing.
Page 678: Seal - Oil Pump
TRANSAXLE 21 - 131 SEAL - TRANSFER SHAFT (Continued) (6) Index outer adjuster (Fig. 345). Remove lock (7) Tighten the outer adjuster 3/4 of a turn. Seat bracket and back out adjuster exactly one revolution. bearings by turning differential carrier three or four Then remove differential cover.
Page 679: Shift Interlock Cable Removal
21 - 132 TRANSAXLE SEAL - OIL PUMP (Continued) (2) Remove gearshift knob from shifter assy. (3) Remove console bezel from vehicle. (4) Remove under panel silencer/duct assembly (Fig. 349). (5) Remove column cover screws. (6) Tilt column down and remove upper half of col- umn cover.
Page 680: Installation
TRANSAXLE 21 - 133 SHIFT INTERLOCK CABLE (Continued) (8) Remove the ignition key and remove lower col- umn cover (Fig. 351). Fig. 353 Interlock Cable Locking Tab 1 - TAB 2 - INTERLOCK CABLE Fig. 351 Lower Column Cover Removal/Installation 3 - LOCK CYLINDER HOUSING 1 - LOWER COLUMN COVER (9) Remove the interlock cable from the shifter...
Page 681: Adjustment - Interlock Cable
21 - 134 TRANSAXLE SHIFT INTERLOCK CABLE (Continued) (3) Move the gear shifter to PARK and the ignition key to the LOCK position (Fig. 356). (4) If the interlock cable is being replaced, remove the pin to allow cable to “self adjust.” Press locking clip (Fig.
Page 682: Shift Interlock Mechanism Removal
TRANSAXLE 21 - 135 SHIFT INTERLOCK CABLE (Continued) ACTION EXPECTED RESPONSE 1. Turn key to the OFF 1. Shifter CAN be shifted position. out of park. 2. Turn key to the 2. Shifter CANNOT be ON/RUN position. shifted out of park. 3.
Page 683: Shift Interlock Solenoid Removal
21 - 136 TRANSAXLE SHIFT INTERLOCK MECHANISM (Continued) Fig. 360 Ignition Interlock Adjustment Tab 1 - LOCK CYLINDER HOUSING Fig. 362 Lower Instrument Panel Cover Mou 2 - INTERLOCK CASSETTE 1 - MOUNTING SCREWS 3 - ADJUSTMENT TAB 2 - INSTRUMENT PANEL BRACKET 3 - LOWER INSTRUMENT PANEL COVER SHIFT INTERLOCK SOLENOID from the steering column lower shroud, DO NOT...
Page 684: Installation
TRANSAXLE 21 - 137 SHIFT INTERLOCK SOLENOID (Continued) (6) Remove the 2 screws attaching the lower shroud to the steering column (Fig. 364) . Remove the lower shroud from the steering column. Fig. 366 Solenoid Retainer Clip 1 - SOLENOID 2 - MOUNTING STUD 3 - RETAINER CLIP Fig.
Page 685 21 - 138 TRANSAXLE SHIFT INTERLOCK SOLENOID (Continued) (7) Install the lower shroud (Fig. 364) on the steer- ing column. Install and securely tighten the 2 screws attaching the lower shroud to the steering column. (8) Install the tilt lever (Fig. 363) on the steering column.
Page 686: Operation
TRANSAXLE 21 - 139 SHIFT INTERLOCK SYSTEM (Continued) COLUMN Vehicles equipped with a column shifter utilize a brake transmission shift interlock (BTSI) solenoid, which prevents the transmission gear shifter from being moved out of PARK without a driver in place (Fig.
Page 687: Diagnosis And Testing - Brake/ Transmission Shift Interlock System
21 - 140 TRANSAXLE SHIFT INTERLOCK SYSTEM (Continued) DIAGNOSIS AND TESTING - BRAKE/ If the floor shifter cannot be moved out of the PARK position, refer to Shifter Locked In Place TRANSMISSION SHIFT INTERLOCK SYSTEM below. If the shift lever can be shifted out of PARK without the brake pedal depressed, refer to Circuit FLOOR SHIFT MODELS Test below.
Page 688 TRANSAXLE 21 - 141 SHIFT INTERLOCK SYSTEM (Continued) circuit or brake lamp switch. Repair the short or ACTION EXPECTED RESPONSE replace brake lamp switch as necessary. 6. With the key removed, 6. Shifter cannot be (8) Reconnect the wire connector to the solenoid. try to shift out of PARK .
Page 689: Shift Mechanism
21 - 142 TRANSAXLE SHIFT INTERLOCK SYSTEM (Continued) lamp switch. Repair the open or replace brake lamp switch as necessary. (7) Depress the brake pedal. The test light should go out. If it does not, there is a short in the ground circuit or brake lamp switch.
Page 690: Solenoid/Pressure Switch Assy
TRANSAXLE 21 - 143 SHIFT MECHANISM (Continued) (6) Remove the five floor pan attaching nuts from SOLENOID/PRESSURE the shifter base and shift cable bracket (Fig. 378). SWITCH ASSY (7) Remove shifter assembly from vehicle (Fig. 378). DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 379) is inside the transaxle and mounted to the valve body assembly.
Page 691 21 - 144 TRANSAXLE SOLENOID/PRESSURE SWITCH ASSY (Continued) needed. When a solenoid is energized, the solenoid The PCM also tests the 2/4 and OD pressure valve shifts, and a fluid passage is opened or closed switches when they are normally off (OD and 2/4 are (vented or applied), depending on its default operat- tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd ing state.
Page 692: Speed Sensor - Input Description
TRANSAXLE 21 - 145 SOLENOID/PRESSURE SWITCH ASSY (Continued) (4) Remove Solenoid/Pressure Switch Assembly and screen from valve body (Fig. 381). Fig. 382 Transaxle Identification Label 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - IDENTIFICATION TAG Fig. 381 Solenoid/Pressure Switch Assembly and Screen 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY 2 - VALVE BODY...
Page 693: Speed Sensor - Output Description
21 - 146 TRANSAXLE SPEED SENSOR - INPUT (Continued) Fig. 384 Sensor Relation to Input Clutch Fig. 386 O-Ring Location 1 - INPUT SPEED SENSOR 1 - INPUT SPEED SENSOR 2 - TRANSAXLE CASE 2 - O-RING 3 - INPUT CLUTCH HUB INSTALLATION REMOVAL (1) Verify o-ring is installed into position (Fig.
Page 694 TRANSAXLE 21 - 147 SPEED SENSOR - OUTPUT (Continued) Fig. 387 Speed Sensor Location 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - IDENTIFICATION TAG Fig. 389 Sensor Relation to Planet Carrier Park Pawl Lugs 1 - OUTPUT SPEED SENSOR 2 - REAR PLANET CARRIER/OUTPUT SHAFT ASSEMBLY 3 - TRANSAXLE CASE REMOVAL...
Page 695: Torque Converter
21 - 148 TRANSAXLE SPEED SENSOR - OUTPUT (Continued) Fig. 391 O-Ring Location 1 - OUTPUT SPEED SENSOR 2 - O-RING INSTALLATION (1) Verify o-ring is installed into position (Fig. 391) Fig. 392 Torque Converter Assembly 1 - TURBINE (2) Install and tighten output speed sensor to 27 2 - IMPELLER N·m (20 ft.
Page 696 TRANSAXLE 21 - 149 TORQUE CONVERTER (Continued) REMOVAL (3) Align torque converter to oil pump seal open- ing. (4) Insert torque converter hub into oil pump. NOTE: If torque conveter assembly is being (5) While pushing torque converter inward, rotate replaced, it is necessary to restart the TCC Break-In converter until converter is fully seated in the oil Strategy.
Page 697: Transfer System Inspection
21 - 150 TRANSAXLE (4) Insert a screwdriver into the 18 mm hole with TRANSFER SYSTEM the screwdriver BELOW the chains (Fig. 396). An assistant may be needed to perform this step. INSPECTION The need to replace the transfer chains because of excessive wear is unlikely.
Page 698: Drive Sprocket Height Adjustment Procedure
TRANSAXLE 21 - 151 TRANSFER SYSTEM (Continued) Fig. 398 Measuring Marks on Scale 1 - SCALE 2 - RULER 3 - MARKS PLACED ON SCALE Fig. 399 Checking Sprocket Height ADJUSTMENTS 1 - STRAIGHT EDGE 2 - FEELER GAUGE DRIVE SPROCKET HEIGHT ADJUSTMENT PROCEDURE A spacer beneath the output sprocket is used to position the output sprocket in line with the transfer...
Page 699: Transmission Control Relay
21 - 152 TRANSAXLE TRANSMISSION CONTROL TRANSMISSION RANGE RELAY SENSOR DESCRIPTION DESCRIPTION The transmission control relay is located in the The Transmission Range Sensor (TRS) is mounted Power Distribution Center (PDC) on the left side of to the top of the valve body inside the transaxle and the engine compartment (Fig.
Page 700: Removal
TRANSAXLE 21 - 153 TRANSMISSION RANGE SENSOR (Continued) TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 403) that the PCM uses to monitor the transmission’s sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM requires this information to determine which shift schedule to operate in.
Page 701: Valve Body Description
21 - 154 TRANSAXLE TRANSMISSION RANGE SENSOR (Continued) (4) Remove manual shaft/TRS retaining screw (Fig. 405) . Fig. 406 Valve Body Assembly Fig. 405 Manual Shaft Retaining Screw 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY 1 - SCREW 2 - TRS 2 - TRS 3 - TRANSFER PLATE 4 - SEPARATOR PLATE (5) Slide TRS off of manual valve shaft.
Page 702 TRANSAXLE 21 - 155 VALVE BODY (Continued) Fig. 407 Valve Body—Exploded 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE SOLENOID SWITCH VALVE...
Page 703: Removal
21 - 156 TRANSAXLE VALVE BODY (Continued) REMOVAL NOTE: If valve body is being reconditioned or replaced, it is necessary to perform the Quick Learn Procedure. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/POWERTRAIN CONTROL MODULE - STANDARD PROCEDURE) (1) Disconnect the TRS wiring connector. The sole- noid wiring connector can remain attached to the case.
Page 704 TRANSAXLE 21 - 157 VALVE BODY (Continued) (7) Remove valve body bolts-to-case (Fig. 411). Fig. 413 Accumulator Assembly—Typical 1 - ACCUMULATOR PISTON (UNDERDRIVE) Fig. 411 Valve Body Bolts 2 - RETURN SPRINGS 3 - SEAL RING 1 - EXTENSION 4 - SEAL RING 2 - SOCKET 3 - VALVE BODY (8) Carefully remove valve body assembly from...
Page 705: Disassembly
21 - 158 TRANSAXLE VALVE BODY (Continued) (3) Remove Transmission Range Sensor (TRS) and manual shaft (Fig. 417). Fig. 415 Overdrive, Underdrive and Low/Reverse Accumulator Location 1 - OVERDRIVE ACCUMULATOR LOCATION 2 - UNDERDRIVE ACCUMULATOR LOCATION 3 - LOW/REVERSE ACCUMULATOR Fig.
Page 706 TRANSAXLE 21 - 159 VALVE BODY (Continued) (5) Remove valve body stiffener plate (Fig. 419). (7) Remove transfer/separator plate from valve body (Fig. 421) Fig. 419 Remove Stiffener Plate 1 - STIFFENER PLATE Fig. 421 Remove Transfer Plate to Valve Body 1 - TRANSFER PLATE (6) Invert valve body assembly and remove trans- 2 - VALVE BODY...
Page 707 21 - 160 TRANSAXLE VALVE BODY (Continued) (9) Remove separator plate from transfer plate (11) Remove thermal valve (Fig. 425) from transfer (Fig. 423). plate. Fig. 425 Remove Thermal Valve to Transfer Plate Fig. 423 Remove Separator Plate to Transfer Plate 1 - THERMAL VALVE 1 - SEPARATOR PLATE 2 - TRANSFER PLATE...
Page 708 TRANSAXLE 21 - 161 VALVE BODY (Continued) Fig. 426 Ball Check Location 1 - (#4) BALL CHECK LOCATION 3 - (#5) BALL CHECK LOCATION 2 - (#2) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION Fig. 427 2/4 Accumulator Assembly 1 - VALVE BODY Fig.
Page 709 21 - 162 TRANSAXLE VALVE BODY (Continued) (15) Remove regulator valve spring retainer (Fig. (17) Remove valves and springs as shown in (Fig. 429). 431). (18) Cleanliness through entire disassembly and assembly of the valve body cannot be overempha- sized. When disassembling, each part should be washed in a suitable solvent, then dried by com- pressed air.
Page 710 TRANSAXLE 21 - 163 VALVE BODY (Continued) Fig. 431 Valve Body Assembly 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE Fig.
Page 711 21 - 164 TRANSAXLE VALVE BODY (Continued) (2) Install regulator valve spring retainer (Fig. 433). Fig. 435 Valve Retainer Location 1 - RETAINER Fig. 433 Install Regulator Valve Spring Retainer 2 - RETAINER using Tool 6302 1 - TOOL 6302 (5) Install 2/4 Accumulator components as shown 2 - RETAINER in (Fig.
Page 712 TRANSAXLE 21 - 165 VALVE BODY (Continued) Fig. 437 Ball Check Location 1 - (#4) BALL CHECK LOCATION 3 - (#5) BALL CHECK LOCATION 2 - (#2) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION (7) Install thermal valve to the transfer plate (Fig. (8) Install oil screen to transfer plate (Fig.
Page 713 21 - 166 TRANSAXLE VALVE BODY (Continued) (9) Install separator plate to transfer plate (Fig. (11) Install the transfer plate to the valve body 440). (Fig. 442). Fig. 442 Install Transfer Plate to Valve Body Fig. 440 Install Separator Plate to Transfer Plate 1 - TRANSFER PLATE 1 - SEPARATOR PLATE 2 - VALVE BODY...
Page 714 TRANSAXLE 21 - 167 VALVE BODY (Continued) (13) Install the stiffener plate (Fig. 444). (15) Install the manual shaft/rooster comb and transmission range sensor to the valve body (Fig. 446). Fig. 444 Install Stiffener Plate 1 - STIFFENER PLATE Fig. 446 Manual Shaft/Rooster Comb and (14) Install the solenoid/pressure switch assembly Transmission Range Sensor and to the transfer plate (Fig.
Page 715: Installation
21 - 168 TRANSAXLE VALVE BODY (Continued) INSTALLATION (1) Install valve body into position and start bolts. Torque valve body to transaxle case bolts (Fig. 448) to 12 N·m (105 in. lbs.) torque. Fig. 449 Transaxle Oil Filter 1 - TRANSAXLE FILTER 2 - FILTER RETAINING CLIPS Fig.
Page 716 TIRES/WHEELS 22 - 1 TIRES/WHEELS TABLE OF CONTENTS page page TIRES/WHEELS DESCRIPTION - RADIAL-PLY TIRES ..15 DIAGNOSIS AND TESTING - TIRE AND DESCRIPTION - REPLACEMENT TIRES ..15 WHEEL VIBRATION .
Page 717 22 - 2 TIRES/WHEELS • Visual Buzziness (high frequency, rapid vibra- TIRES/WHEELS tion up and down) To rule out vibrations due to brakes or powertrain: DIAGNOSIS AND TESTING - TIRE AND WHEEL • Lightly apply brakes at speed; if vibration occurs VIBRATION or is enhanced, vibration is likely due to causes other Tire and wheel imbalance, runout and force varia-...
Page 718 TIRES/WHEELS 22 - 3 TIRES/WHEELS (Continued) assembly from vehicle and install it back on the hub two studs over from original mounting posi- tion. If re-indexing the tire and wheel assembly corrects or reduces system runout, check hub runout and repair as necessary (Refer to 5 - BRAKES BASE/HYDRAULIC/MECHANICAL/ ROTORS - DIAGNOSIS AND TESTING).
Page 719 22 - 4 TIRES/WHEELS TIRES/WHEELS (Continued) Fig. 4 Checking Radial Runout Of Wheel 1 - MOUNTING CONE 2 - SPINDLE SHAFT 3 - WING NUT 4 - PLASTIC CUP Fig. 6 Remount Tire 180 Degrees 5 - DIAL INDICATOR 1 - VALVE STEM 6 - WHEEL 2 - REFERENCE MARK 7 - DIAL INDICATOR...
Page 720 TIRES/WHEELS 22 - 5 TIRES/WHEELS (Continued) (6) Once back together, road test the vehicle for at STANDARD PROCEDURE least 5 miles, following the format described in Road Test. If vibration persists, and all components tested STANDARD PROCEDURE - TIRE AND WHEEL are within specification, the tires may have an exces- BALANCE sive radial force condition.
Page 721 22 - 6 TIRES/WHEELS TIRES/WHEELS (Continued) Fig. 8 Static Unbalance & Balance 1 - HEAVY SPOT 4 - CORRECTIVE WEIGHT LOCATION 2 - CENTER LINE OF SPINDLE 5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP 3 - ADD BALANCE WEIGHTS HERE Fig.
Page 722 TIRES/WHEELS 22 - 7 TIRES/WHEELS (Continued) NON-DIRECTIONAL TREAD PATTERN TIRES Tires on the front and rear axles operate at differ- ent loads and perform different functions. For these reasons, they wear at unequal rates, and tend to develop irregular wear patterns. These effects can be reduced by timely rotation of tires.
Page 723 22 - 8 TIRES/WHEELS TIRES/WHEELS (Continued) in damage to the wheel cover. The wheel cover is REMOVAL removed by pulling it off the wheel by hand. (3) Grasp the wheel cover at the edges in line with REMOVAL - TIRE AND WHEEL ASSEMBLY the remaining installed wheel mounting nuts and (ALUMINUM WHEEL) pull straight outward from the wheel.
Page 724 TIRES/WHEELS 22 - 9 TIRES/WHEELS (Continued) Fig. 13 Tightening Sequence Fig. 14 Two Wheel Mounting Nuts Installed INSTALLATION - TIRE AND WHEEL ASSEMBLY 1 - VALVE STEM 2 - NUTS (STEEL WHEEL) 3 - HUB 4 - WHEEL NOTE: Never use oil or grease on studs or wheel mounting nuts.
Page 725: Tire Pressure Monitoring
22 - 10 TIRES/WHEELS TIRES/WHEELS (Continued) tire that is low or high. This will be displayed for the rest of the ignition cycle, or until either the C/T, MENU, STEP or RESET button is pressed. If a road tire is replaced by the spare, the TPM system will detect the swap automatically (after the ignition has been cycled) and display SPARE SWAP DETECTED along with a chime (This could take up...
Page 726 TIRES/WHEELS 22 - 11 CAUTION: Do not reuse the original Sensor-To- SENSOR - TPM Wheel Grommet when installing a pressure sensor. Always use a new grommet and properly torque the DESCRIPTION sensor nut to specifications. (Refer to 22 - TIRES/ On vehicles equipped with Tire Pressure Monitor- WHEELS/TIRE PRESSURE MONITORING/SENSOR - ing, one tire pressure sensor is mounted to each...
Page 727 22 - 12 TIRES/WHEELS SENSOR - TPM (Continued) CAUTION: Never attempt to train more than one vehicle at a time. System is capable of reading tire pressure sensor transmissions from other nearby vehicles while in train mode. Each time a wheel rotation or tire pressure sensor replacement occurs the tire pressure sensors must be retrained.
Page 728 TIRES/WHEELS 22 - 13 SENSOR - TPM (Continued) INSTALLATION NOTE: Before reinstalling a tire pressure sensor, replace sealing grommet at base of valve stem. (1) Wipe area clean where sensor sealing grommet contacts wheel. Make sure surface of wheel is not damaged.
Page 729 22 - 14 TIRES/WHEELS SENSOR - TPM (Continued) TIRES DESCRIPTION DESCRIPTION - TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling charac- teristics match the vehicle’s requirements. With proper care they will give excellent reliability, trac- tion, skid resistance, and tread life.
Page 730 TIRES/WHEELS 22 - 15 TIRES (Continued) TIRE IDENTIFICATION DESCRIPTION - RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. TIRE TYPE (Not P - Passenger Radial-ply tires must always be used in sets of present on all tires) four.
Page 731 22 - 16 TIRES/WHEELS TIRES (Continued) DESCRIPTION - SPARE TIRE (TEMPORARY) DIAGNOSIS AND TESTING - TREAD WEAR The compact temporary spare tire is designed for INDICATORS emergency use only. The original tire should be Tread wear indicators are molded into the bottom repaired or replaced at the first opportunity, then of the tread grooves.
Page 732 TIRES/WHEELS 22 - 17 TIRES (Continued) STANDARD PROCEDURE STANDARD PROCEDURE - TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle (usually on the rear face of the driv- er’s door).
Page 733 22 - 18 TIRES/WHEELS TIRES (Continued) Install wheel on vehicle, and progressively tighten the 5 wheel nuts to a torque of 135 N·m (100 ft. lbs.). Fig. 28 Safety Rim 1 - FLANGE 2 - RIDGE 3 - WELL Fig. 27 Tire Repair Area 1 - REPAIRABLE AREA The wheel studs and nuts are designed for specific wheel applications and must be replaced with equiv-...
Page 734: Wheel Cover
TIRES/WHEELS 22 - 19 WHEELS (Continued) WARNING: FAILURE EQUIVALENT WHEEL COVER REPLACEMENT WHEELS ADVERSELY AFFECT THE SAFETY AND HANDLING OF THE DESCRIPTION VEHICLE. This vehicle uses a bolt-on type wheel cover (Fig. 29). This bolt-on wheel cover cannot be removed from WARNING: REPLACEMENT WITH USED WHEELS IS the wheel until three of the five wheel mounting nuts NOT RECOMMENDED.
Page 735 22 - 20 TIRES/WHEELS WHEEL COVER (Continued) (2) Install and lightly tighten the three remain- ing wheel mounting nuts, securing the wheel cover in place (Fig. 29). (3) Tighten all five wheel mounting nuts in the proper sequence (Fig. 32). Tighten wheel nuts to a torque of 135 N·m (100 ft.
Page 736 TIRES/WHEELS 22 - 21 WHEEL MOUNTING STUDS - FRONT (Continued) Fig. 33 Caliper Guide Pin Bolts 1 - BRAKE LINE 2 - CALIPER GUIDE PIN BOLTS 3 - STEERING KNUCKLE 4 - BLEEDER SCREW 5 - CALIPER ASSEMBLY Fig. 35 Removing Wheel Stud From Hub And Bearing 1 - HUB/BEARING ASSEMBLY 2 - WHEEL STUD...
Page 737 22 - 22 TIRES/WHEELS WHEEL MOUNTING STUDS - FRONT (Continued) (3) Install the rotor on the hub and bearing assem- bly (Fig. 34). (4) Install disc brake caliper back over brake rotor and align with caliper mounting holes on steering knuckle.
Page 738 BODY 23 - 1 BODY TABLE OF CONTENTS page page BODY DECKLID ......13 DESCRIPTION - VEHICLE IDENTIFICATION .
Page 739 23 - 2 BODY BODY (Continued) the vehicle should not enter the passenger or luggage Some water leaks must be tested for a considerable compartment. Moving sealing surfaces will not length of time to become apparent. When a leak always seal water tight under all conditions. At appears, find the highest point of the water track or times, side glass or door seals will allow water to drop.
Page 740 BODY 23 - 3 BODY (Continued) noticed in the passenger compartment during high Semi-Rigid Plastics: cross winds. Over compensating on door or glass Examples of semi-rigid plastic use: Interior Panels, adjustments to stop wind noise that occurs under Under Hood Panels, and other Body Trim Panels. severe conditions can cause premature seal wear and Flexible Plastics: excessive closing or latching effort.
Page 741 23 - 4 BODY BODY (Continued) RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION ACRYLONITRILE STYRENE LURAN S CONSOLES, GRILLES ACRYLITE ACRYLONITRILE TERLURAN A PILLARS, CONSOLES, BUTADIENE STYRENE GRILLES ABS/PC ABS/PC ALLOY PULSE, PROLOY, DOORS, INSTRUMENT BAYBLEND PANELS...
Page 742 BODY 23 - 5 BODY (Continued) CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION UNSATURATED SMC, BMC, TMC, ZMC, IMC, GRILLE OPENING PANEL, POLYESTER XSMC, UP LIFTGATES, FLARESIDE (THERMOSETTING) FENDERS, FENDER EXTENSIONS EEBC ETHER/ESTER BLOCKED EEBC BUMPERS CO-POLYMER EEBC/PBTP EEBC/POLYBUTYLENE EEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS TEREPTHALATE...
Page 743 23 - 6 BODY BODY (Continued) PANEL SECTIONING backing. Reinforcements can be made with several applications of glass cloth saturated with structural If it is required to section a large panel for a plas- adhesive. Semi-rigid or flexible repair materials tic repair, it will be necessary to reinforce the panel should be used for semi-rigid or flexible backing rein- (Fig.
Page 744 BODY 23 - 7 BODY (Continued) Fig. 4 BEVELING ANGLE - 20 DEGREE • Panel repair for both flexible and rigid panels are basically the same. The primary difference Fig. 6 DAMAGE COMPONENT between flexible panel repair and rigid panel repair 1 - PUNCTURE is in the adhesive materials used (Fig.
Page 745 23 - 8 BODY BODY (Continued) Fig. 8 FABRICATED PANEL Fig. 7 DAMAGED PANEL CUTOUT AND PATCH 1 - STRUCTURAL ADHESIVE 1 - CUTOUT 2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE 2 - DAMAGED BODY PANEL 3 - WIDTH OF V-GROOVE 3 - 4 MM (0.160 IN.) HOLES 4 - WAXED PAPER 4 - PATCH CUT TO SIZE...
Page 746 BODY 23 - 9 BODY (Continued) (12) Position patch in cutout against support (15) Install screws to hold the patch to support squares and adjust patch until the gap is equal along squares (Fig. 12). Tighten screws until patch surface all sides (Fig.
Page 747 23 - 10 BODY BODY (Continued) (18) Apply adhesive backed nylon mesh (dry wall apply a coat of high quality rigid plastic body filler. tape) over gaps around patch (Fig. 14). Prime, block sand, and paint as required. (19) Mix enough adhesive to cover the entire patch STANDARD PROCEDURE - HEAT STAKING area.
Page 748 BODY 23 - 11 BODY (Continued) (3) Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position. DESCRIPTION N·m Lbs. Lbs. Front seat back to seat cushion NOTE: Do not add more lubricant. Front seat arm rest - 60/40 (4) Cycle the lock cylinder mechanism several Front arm rest - 50/50 split times to allow the lubricant to flow throughout the...
Page 749 23 - 12 BODY BODY (Continued) SPECIAL TOOLS BODY Stick, Trim C-4755 Remover, Moldings C-4829 Pliers, Headliner Clip C–6967...
Page 750 DECKLID 23 - 13 DECKLID TABLE OF CONTENTS page page COVER INSTALLATION ......16 REMOVAL ......13 LOCK CYLINDER INSTALLATION .
Page 751 23 - 14 DECKLID DECKLID HINGE REMOVAL REMOVAL (1) Release decklid latch and open decklid. (1) Open decklid. (2) Mark hinge locations on inside of decklid to aid (2) Support decklid with a suitable prop device or installation. block. (3) Disconnect the wire harness connector, if (3) Remove hinge bolts (Fig.
Page 752 (5) Disconnect power lock connector from latch solenoid. (6) Disconnect decklid ajar switch connector from latch. (7) Remove latch from vehicle. Fig. 5 DECK LID LATCH - INTREPID 1 - LOCK CYLINDER BRACKET 2 - LOCK SET 3 - TRUNK LID 4 - TRUNK LID LATCH 5 - TRUNK LOCK CYLINDER Fig.
Page 753: Lock Cylinder
23 - 16 DECKLID INSTALLATION LATCH STRIKER (1) Install decklid lock cylinder. REMOVAL (2) Install decklid lock set. (3) Place latch in position on vehicle. (1) Open decklid. (4) Connect decklid ajar switch connector on latch. (2) Remove trunk liner as necessary. (5) Connect power lock connector on latch solenoid.
Page 754 DECKLID 23 - 17 SLAM BUMPER REMOVAL (1) Open decklid. (2) Pull slam bumper from decklid. (3) Remove slam bumper from decklid. INSTALLATION (1) Place slam bumper in position on decklid. (2) Push slam bumper into decklid. (3) Verify decklid alignment. SUPPORT CYLINDER REMOVAL Fig.
Page 755 23 - 18 DOOR - FRONT DOOR - FRONT TABLE OF CONTENTS page page DOOR - FRONT INSTALLATION ......22 DESCRIPTION .
Page 756: Door Glass
DOOR - FRONT 23 - 19 CHECK STRAP (Continued) INSTALLATION INSTALLATION (1) Place check strap in position on vehicle. (1) Place door in position on vehicle. (2) Install bolts attaching check strap to door end (2) Engage door onto pin on upper door hinge. frame and body.
Page 757 23 - 20 DOOR - FRONT DOOR GLASS (Continued) (5) Remove glass from roller channel. EXTERIOR HANDLE (6) Raise glass upward and out of the opening at top of door. REMOVAL (1) Remove door trim panel. (Refer to 23 - BODY/ INSTALLATION DOOR - FRONT/TRIM PANEL - REMOVAL) (1) Lower glass into opening at top of door.
Page 758 DOOR - FRONT 23 - 21 REMOVAL - DOOR HINGE DOUBLE ENDED HINGE STUD (1) Remove door hinge. REMOVAL (2) To remove double ended stud, double nut stud and back stud out of door frame. If stud is broken, REMOVAL use locking pliers on the shoulder of the double (1) Mark location of hinge on hinge pillar.
Page 759 23 - 22 DOOR - FRONT LATCH LATCH STRIKER REMOVAL REMOVAL (1) Close door glass. (1) Open front door. (2) Remove door trim panel. (Refer to 23 - BODY/ (2) Mark location of door latch striker on B-pillar DOOR - FRONT/TRIM PANEL - REMOVAL) to assist installation alignment.
Page 760 DOOR - FRONT 23 - 23 LOCK CYLINDER SIDE VIEW MIRROR FLAG REMOVAL REMOVAL (1) Remove door trim panel. (Refer to 23 - BODY/ (1) Pull cover, release clips and remove (Fig. 11). DOOR - FRONT/TRIM PANEL - REMOVAL) (2) Remove the bolts and remove the bracket, if (2) Remove water shield, as necessary necessary.
Page 761 23 - 24 DOOR - FRONT (3) Open trim plug from the pull cup and remote SIDE VIEW MIRROR FLAG bezel by inserting a small flat blade tool into the notch and lifting up. REMOVAL - WITH SPEAKER (4) Remove three screws from bottom of door. (1) Open the front door.
Page 762 DOOR - FRONT 23 - 25 TRIM PANEL (Continued) (16) Install three screws to the bottom of the door. Tighten all screws to 1.3 to 1.9 N·m (12 to 17 in. lbs.) torque. (17) Place speaker grille in position on trim panel. TRIM PANEL - WOOD TRIM REMOVAL - WOOD TRIM (1) Remove door trim panel.
Page 763: Window Regulator
23 - 26 DOOR - FRONT TRIM PANEL - WOOD TRIM (Continued) fer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL) (2) Slide glass from regulator roller channel. (3) Disconnect power window motor wire connector. (4) Loosen bolt attaching regulator support brace to door panel.
Page 764 DOORS - REAR 23 - 27 DOORS - REAR TABLE OF CONTENTS page page DOORS - REAR INSTALLATION ......30 DESCRIPTION .
Page 765 23 - 28 DOORS - REAR (6) Connect door wire harness to instrument panel DOOR wire harness. (7) Attach check strap. REMOVAL (8) Align door to achieve equal spacing to sur- (1) Open rear door. rounding body panels. Panels should be flush across (2) Mark location of hinge on door end frame.
Page 766 DOORS - REAR 23 - 29 DOOR GLASS (Continued) (4) Tighten nuts to attach regulator roller channel to glass and lift plate. (5) Install upper trim retainer channel. (6) Install watershield. (7) Install door trim panel. (Refer to 23 - BODY/ DOORS - REAR/TRIM PANEL - INSTALLATION) ADJUSTMENTS ADJUSTMENT...
Page 767 23 - 30 DOORS - REAR LATCH (Continued) Fig. 6 REAR DOOR LATCH 1 - TO LOCK BUTTON 4 - REAR DOOR LATCH 2 - CLIPS 5 - TO DOOR HANDLE 3 - WIRE CONNECT INSTALLATION (1) Place latch in position in door. (2) Install screws attaching door latch to door end frame.
Page 768 DOORS - REAR 23 - 31 TRIM PANEL REMOVAL CAUTION: Do not pry on door trim panel, damage to trim panel will result. (1) Open trim plug from the pull cup and remote bezel by inserting a small flat blade tool into the notch and lifting up.
Page 769 23 - 32 DOORS - REAR TRIM PANEL - WOOD TRIM REMOVAL - WOOD TRIM (1) Remove door trim panel. (Refer to 23 - BODY/ DOORS - REAR/TRIM PANEL - REMOVAL) (2) Remove and discard the retainer clips (Fig. 10) (3) Remove the wood trim from the trim panel.
Page 770 DOORS - REAR 23 - 33 WINDOW REGULATOR REMOVAL (1) Remove flag cover, door trim panel, water shield as necessary, and pull cup support bracket. (Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - REMOVAL) (2) Slide glass from regulator roller channel (Fig. 12).
Page 771 23 - 34 EXTERIOR EXTERIOR TABLE OF CONTENTS page page BODY SIDE MOLDINGS INSTALLATION - 300 M - UPPER ..36 REMOVAL ......34 INSTALLATION - 300 M - LOWER .
Page 772 EXTERIOR 23 - 35 COWL GRILLE AND SCREEN EXTERIOR NAME PLATES REMOVAL REMOVAL (1) Release hood latch and open hood. (2) Remove wiper arms. (Refer to 8 - ELECTRI- REMOVAL - DOUBLE SIDED TAPE CAL/WIPERS/WASHERS/WIPER ARMS (1) Mark reference points before removing. REMOVAL) (2) Using a heat gun gently apply heat in a circu- (3) Remove screws attaching cowl screen at the...
Page 773 23 - 36 EXTERIOR REMOVAL - 300 M - UPPER FRONT STRUT TOWER TO (1) Open hood. TOWER BRACE (2) Remove fascia. (3) Drill out rivets attaching cross bracket to REMOVAL grille. (1) Open hood. (4) Remove upper grille six attaching clips. (2) Remove the cowl screen.
Page 774: Front Fender
EXTERIOR 23 - 37 GRILLE OPENING FRONT FENDER REINFORCEMENT REMOVAL (1) Remove headlamp housing. REMOVAL (2) Remove splash shield to fascia plastic rivets. (1) Open hood. (3) Remove splash shield to sill cladding. (2) Mark bolt locations on the upper radiator clo- (4) First remove fender bolt to lower cowl.
Page 775 23 - 38 EXTERIOR FRONT FENDER (Continued) (8) Install splash shield plastic rivets to sill clad- REAR WHEELHOUSE SPLASH ding. SHIELD (9) Install splash shield plastic rivets to fascia. (10) Install headlamp assembly. REMOVAL (11) Check fender for flush and gap. (1) Hoist and support vehicle on safety stands.
Page 776 EXTERIOR 23 - 39 SIDE VIEW MIRROR (Continued) INSTALLATION to glass holder attachment, otherwise the glass holder could be installed incorrectly causing poor (1) Feed power mirror wire harness through hole retention and possible repeat failure. in mirror flag and seat grommet. Do not pull on wire (1) Position the new mirror glass holder to the harness to seat grommet.
Page 777 23 - 40 HOOD HOOD TABLE OF CONTENTS page page HINGE INSTALLATION ......41 REMOVAL ......40 LATCH RELEASE CABLE INSTALLATION .
Page 778 HOOD 23 - 41 be aligned to 4 mm (0.160 in.) gap to the front fenders HOOD and flush across the top surfaces along fenders. (4) Verify hood operation and alignment. REMOVAL (1) Raise hood to full up position. (2) Mark all bolt and hinge attachment locations LATCH with a grease pencil or other suitable device to pro- vide reference marks for installation.
Page 779 (9) Release the rubber grommet from the dash panel. Pull cable through the dash panel access hole. (10) Remove cable from vehicle. Fig. 6 HOOD RELEASE CABLE - INTREPID Fig. 4 HOOD LATCH - INTREPID 1 - HOOD LATCH 1 - HOOD BUMPER ADJUSTER...
Page 780 HOOD 23 - 43 LATCH RELEASE CABLE (Continued) INSTALLATION (1) Place cable in position on vehicle. (2) Push cable through access hole in dash panel. (3) Install release cable rubber grommet into access hole in dash panel. (4) Install screws attaching hood latch release cable handle to the cowl side.
Page 781 23 - 44 INSTRUMENT PANEL INSTRUMENT PANEL TABLE OF CONTENTS page page CLUSTER BEZEL INSTRUMENT PANEL SILENCER REMOVAL ......44 REMOVAL .
Page 782 INSTRUMENT PANEL 23 - 45 CLUSTER BEZEL (Continued) (3) Install the items covering the bezel mounting REMOVAL), (Refer to 23 - BODY/INTERIOR/CROSS screws. CAR BEAM - REMOVAL) and etc. (4) Install the one screw (Concorde/300M) to clus- (2) Feed electrical wires back through the silencer ter bezel wiring pass through holes (Fig.
Page 783: Glove Box
23 - 46 INSTRUMENT PANEL INSTALLATION GLOVE BOX (1) Install latch from outer door. REMOVAL (2) Install one screw to the latch. (3) Place teh the inner and outer door together. (1) Remove the four screws at bottom of glove box (4) Install the nine screws to the backside of the door.
Page 784 INSTRUMENT PANEL 23 - 47 INSTRUMENT PANEL ASSEMBLY (Continued) - BODY/INSTRUMENT PANEL/STORAGE BIN - REMOVAL). (10) Disconnect wire connectors to the HVAC con- trol and traction control switch and remove bezel from vehicle. (11) Remove two screws to left console side cover, pull outboard and remove from vehicle.
Page 785 23 - 48 INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY (Continued) Fig. 5 INSTRUMENT PANEL REMOVAL 1 - INSTRUMENT PANEL 4 - STEERING COLUMN MOUNTING PLATE 2 - ATTACHING SCREWS 5 - INSTRUMENT PANEL COLUMN BRACKET 3 - CROSS CAR BEAM INSTALLATION and two ground eyelets left of the floor tunnel near the bulkhead.
Page 786 INSTRUMENT PANEL 23 - 49 INSTRUMENT PANEL ASSEMBLY (Continued) (20) Place the right console side cover into position the left lower instrument panel cover into position and firmly snap into place. Install the two screws to and firmly snap into place. Install the two screws to right console side cover.
Page 787 23 - 50 INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY (Continued) Fig. 6 INSTRUMENT PANEL COMPONENTS - 300M...
Page 788: Instrument Panel
INSTRUMENT PANEL 23 - 51 INSTRUMENT PANEL ASSEMBLY (Continued) 1 - BEZEL, INSTRUMENT PANEL END CAP 9 - BEZEL, INSTRUMENT PANEL TRIM-CENTER 2 - COVER, UPPER INSTRUMENT PANEL 10 - BEZEL, INSTRUMENT PANEL AIR DISTRIBUTION OUTLET 3 - LOUVER, AIR OUTLET 11 - BEZEL, INSTRUMENT CLUSTER 4 - LOUVER/DEMISTER SIDE WINDOW 12 - STORAGE COMPARTMENT CUBBY BOX...
Page 789 23 - 52 INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY (Continued) Fig. 7 INSTRUMENT PANEL COMPONENTS - INTREPID...
Page 790 INSTRUMENT PANEL 23 - 53 INSTRUMENT PANEL ASSEMBLY (Continued) 1 - SPEAKER, INSTRUMENT PANEL CENTER 11 - BEZEL INSTRUMENT CLUSTER 2 - INSTRUMENT PANEL ASSEMBLY 12 - SWITCH HEADLAMP 3 - BEZEL, INSTRUMENT PANEL END CAP 13 - LOUVER, AIR OUTLET 4 - LOUVER, AIR OUTLET 14 - COVER, INSTRUMENT PANEL CENTER SUPPORT/BIN (6 PASS.
Page 791 23 - 54 INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY (Continued) Fig. 8 INSTRUMENT PANEL COMPONENTS - CONCORDE...
Page 792 INSTRUMENT PANEL 23 - 55 INSTRUMENT PANEL ASSEMBLY (Continued) 1 - SPEAKER, INSTRUMENT PANEL CENTER 10 - BEZEL, INSTRUMENT CLUSTER 2 - COVER, UPPER INSTRUMENT PANEL 11 - SWITCH, HEADLAMP 3 - INSTRUMENT PANEL ASSEMBLY 12 - LOUVER, AIR OUTLET 4 - BEZEL, INSTRUMENT PANEL END CAP 13 - COVER, INSTRUMENT PANEL CENTER SUPPORT/BIN (6 PASS.
Page 793 23 - 56 INSTRUMENT PANEL INSTRUMENT PANEL END CAP (Continued) (3) Engage weatherstrip along the header and down the A-pillar. (4) Verify weatherstrip sealing. (5) Close door. INSTRUMENT PANEL SILENCER REMOVAL (1) Remove the retaining screw to the instrument panel. (2) Maneuver part and bracket off of the center floor distribution duct.
Page 794 INSTRUMENT PANEL 23 - 57 UPPER RIGHT TRIM BEZEL(300M) (Continued) INSTALLATION (1) Position upper right trim bezel over slots in instrument panel and firmly snap into place. If equipped with traction control, connect connector. (2) Tighten the lower right edge of steering column cover, then tighten upper right corner of steering col- umn cover.
Page 795 23 - 58 INSTRUMENT PANEL STEERING COLUMN COVER (Continued) INSTALLATION (1) Place steering column cover into position (Fig. 14). (2) Push on steering column cover till retaining clips lock into position. (3) Install two attaching screws to the side of the steering column cover.
Page 796 INTERIOR 23 - 59 INTERIOR TABLE OF CONTENTS page page A-PILLAR TRIM DOOR SILL TRIM REMOVAL ......60 REMOVAL .
Page 797 23 - 60 INTERIOR A-PILLAR TRIM REMOVAL (1) Remove instrument panel end cap. (2) Disengage clips attaching trim to A-pillar by pulling on trim (Fig. 1). (3) Slide A-pillar trim rearward, to disengaging from instrument panel top cover. (4) Remove A-pillar trim from vehicle. Fig.
Page 798 INTERIOR 23 - 61 B-PILLAR LOWER TRIM B-PILLAR UPPER TRIM REMOVAL REMOVAL (1) Remove seat belt height adjuster knob. (1) Disengage shoulder belt turning loop cover. (2) Remove upper B-pillar trim. (2) Remove bolt attaching turning loop to shoulder (3) Remove bolt attaching seat belt to floor below belt height adjuster.
Page 799 23 - 62 INTERIOR INSTALLATION CROSS CAR BEAM (1) Place cross car beam in position in vehicle. REMOVAL (2) Install right side fasteners attaching the cross car beam to cowl side panels. (1) Remove steering column and instrument panel (3) Install left side fasteners attaching the cross from vehicle.
Page 800 INTERIOR 23 - 63 CARPETS REMOVAL (1) Remove floor mats. (2) Remove door sill trim covers. (3) Remove cowl side trim covers. (4) Remove front seats. (5) Remove bolts attaching front seat belt lower anchors to floor below B-pillar trim panels. (6) Remove center console, if equipped.
Page 801 (6) Disconnect the power outlet, if equipped. (7) Disconnect the transmission range indicator Fig. 8 FRONT FLOOR CONSOLE SIDE PANELS - illumination connector. INTREPID SHOWN - 300M SIMILAR (8) Remove bezel from vehicle. 1 - INSTRUMENT PANEL 2 - FLOOR CONSOLE BEZEL...
Page 802 INTERIOR 23 - 65 CENTER CONSOLE BEZEL (Continued) (5) Install instrument panel center bezel. (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION) (6) Push gear shift knob onto gear shift. (7) Tighten set screw attaching gear shift knob to gear shift.
Page 803 23 - 66 INTERIOR CENTER CONSOLE CENTER CONSOLE REAR CUPHOLDER ASSEMBLY BEZEL REMOVAL - CONCORD REMOVAL (1) Remove shift knob. (1) Disengage tabs on sides at bottom (Fig. 12) (2) Remove floor console shift bezel (Fig. 7). (2) Open arm rest lid and remove rear end cap (3) Raise console armrest lid.
Page 804 INTERIOR 23 - 67 CENTER CONSOLE SIDE PANELS (Continued) REMOVAL DOOR SILL TRIM (1) Remove shift knob. REMOVAL (2) Remove console shift bezel (Fig. 8). (3) To remove right side panel, open glove box and The door sills are attached with push pin fasteners remove side panel attaching screws.
Page 805 23 - 68 INTERIOR FLOOR CONSOLE REMOVAL (1) Remove shift knob. (2) Remove floor console shift bezel. (3) Remove side panels (Fig. 14), or (Fig. 15). (4) Disconnect the electrical connectors. (5) Remove fasteners attaching forward bracket to instrument panel. (6) Remove fasteners attaching bottom of console storage bin to rear mounting bracket (Fig.
Page 806 INTERIOR 23 - 69 FLOOR CONSOLE (Continued) Fig. 16 FLOOR CONSOLE 1 - CONSOLE BRACKET 4 - FLOOR CONSOLE DUCT 2 - FASTENERS 5 - SHIFTER ASSEMBLY 3 - FLOOR CONSOLE (5) Install fasteners attaching bottom of console storage bin to rear mounting bracket. (6) Connect the electrical connectors.
Page 807 23 - 70 INTERIOR HEADLINER REMOVAL (1) Remove front passenger seat for ease of removal of headliner. (2) Remove right and left A-pillar trim panels. (3) Remove right and left sun visors and retainers. (4) Remove overhead console or front interior lights.
Page 808 INTERIOR 23 - 71 ROOF STRUCTURAL MEMBRANE REMOVAL (1) Remove headliner. (2) Remove roof support membrane, using a Mold- ing Removal Tool, 3-M p/n 08978. (3) Carefully pull down corner of roof structural membrane enough to insert molding removal tool between roof panel and adhesive.
Page 809: Rear View Mirror
23 - 72 INTERIOR LOWER QUARTER TRIM (Continued) INSTALLATION (7) Install center seat belt anchor bolt. Tighten to 40 N·m (29 ft. lbs.) torque. (1) Place quarter trim in position on vehicle. (8) Install seat back and cushion. (2) Engage clips attaching lower quarter trim to inner quarter panel.
Page 810 INTERIOR 23 - 73 REAR VIEW MIRROR (Continued) (4) Apply accelerator to the surface on the bracket (3) Pull and hold assist handle down. according to the following instructions: (4) Remove front screw attaching assist handle to (a) Crush the vial to saturate the felt applicator. roof (Fig.
Page 811: Sun Visor
23 - 74 INTERIOR SUN VISOR TRUNK LINING REMOVAL REMOVAL All vehicles with driver and passenger side air (1) Remove rear seat cushion and back. bags must have a colored coded five Bullet point air- (2) Remove fasteners at forward edge along wheel- bag warning label applied to the sun visor, verify housing label availability and ensure the label is installed.
Page 812 INTERIOR 23 - 75 (2) Remove lower quarter trim (Refer to 23 - UNDER REAR SHELF BODY/INTERIOR/LOWER QUARTER TRIM SILENCER REMOVAL). (3) Remove front trunk push pin and fold trunk REMOVAL carpet down. (1) Remove fasteners attaching silencer to lower (4) Remove fasteners attaching silencer to wheel shelf sheet metal (Fig.
Page 813 23 - 76 PAINT PAINT TABLE OF CONTENTS page page PAINT PAINT SURFACE TOUCH-UP SPECIFICATIONS - COLOR CODE CHARTS . . 76 DESCRIPTION ......77 BASECOAT/CLEARCOAT FINISH FINESSE SANDING/BUFFING &...
Page 814 PAINT 23 - 77 TOUCH UP PROCEDURE BASECOAT/CLEARCOAT (1) Scrape loose paint and corrosion from inside FINISH scratch or chip. (2) Clean affected area with Mopar Tar/Road Oil DESCRIPTION Remover, and allow to dry. On most vehicles a two-part paint application (3) Fill the inside of the scratch or chip with a coat (basecoat/clearcoat) is used.
Page 815 23 - 78 SEATS SEATS TABLE OF CONTENTS page page SEATS SEAT SIDE SHIELD SPECIFICATIONS - TORQUE ....79 REMOVAL FRONT ARMREST REMOVAL - NON AIRBAG ....90 REMOVAL - 50/50 SPLIT .
Page 816: Front Armrest
SEATS 23 - 79 SEATS SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Lbs. Lbs. Front seat track to floor pan bolts — Front seat inboard and outboard — pivot bolts Front seat recliner to seat cushion — frame Front seat track to cushion frame —...
Page 817 23 - 80 SEATS (1) Disconnect the remote negative battery cable. HEADREST (2) If fully extended, lower head restraint slightly. (3) Insert a stiff wire into the hole on the right REMOVAL hand side head restraint sleeve/guide and push to release latch (Fig.
Page 818: Front Seat
SEATS 23 - 81 INSTALLATION - AIRBAG EQUIPPED HEADREST SLEEVE - AIRBAG EQUIPPED NOTE: The head restraint guide sleeve equipped with height adjustment button is always installed on REMOVAL - AIRBAG EQUIPPED the left side of the seat back. WARNING: DISCONNECT AND ISOLATE THE NEGA- (1) Install guides in seat back making sure they TIVE BATTERY CABLE REMOTE TERMINAL BEFORE are snapped in place.
Page 819 23 - 82 SEATS FRONT SEAT (Continued) REMOVAL - AIRBAG EQUIPPED WARNING: DISCONNECT AND ISOLATE THE NEGA- TIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY FRONT SEAT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DIS- ABLE THE AIRBAG SYSTEM. FAILURE TO DISCON- NECT BATTERY COULD...
Page 820 SEATS 23 - 83 FRONT SEAT (Continued) (6) Connect the remote negative battery cable. (7) Using the DRB III Scan Tool erase all DTC’s and perform airbag system diagnostics. (8) Verify front seat operation. FRONT SEAT BACK REMOVAL REMOVAL (1) Remove front seat from vehicle (Refer to 23 - BODY/SEATS/FRONT SEAT - REMOVAL).
Page 821 23 - 84 SEATS FRONT SEAT BACK (Continued) INSTALLATION - AIRBAG EQUIPPED (1) Position the assembled seat back and feed wire harness down into lower seat cushion (Fig. 13). Be certain harness is routed along the leading edge of seat frame. (2) Install inboard and outboard pivot bolts.
Page 822 SEATS 23 - 85 (1) Disconnect and isolate the negative battery FRONT SEAT BACK COVER cable (Fig. 15). REMOVAL REMOVAL (1) Remove head restraint (Refer to 23 - BODY/ SEATS/ARMREST - FRONT - REMOVAL). (2) Remove front seat back (Refer to 23 - BODY/ SEATS/FRONT SEAT BACK - REMOVAL).
Page 823 23 - 86 SEATS FRONT SEAT BACK COVER (Continued) (13) Disengage velcro from cover. With one hand, hold velcro that is glued to seat back foam. With the other hand, grasp opposite velcro strip and pull apart to separate. This will prevent tearing velcro out of seat back foam.
Page 824 SEATS 23 - 87 FRONT SEAT BACK COVER (Continued) CAUTION: Seat Airbag Module Must Be Installed IN SEAT BACK PANEL Nylon Sleeve. Failure To Do So Will Adversely Affect Function Of Airbag System. REMOVAL - AIRBAG EQUIPPED (5) Carefully slide the seat airbag module in nylon WARNING: DISCONNECT AND ISOLATE THE NEGA- sleeve (Fig.
Page 825 23 - 88 SEATS SEAT BACK PANEL (Continued) INSTALLATION - AIRBAG EQUIPPED CAUTION: Always install new push pins in the upper mounting location of back panel. Failure to do so could adversely affect the airbag system. (1) Starting at the bottom, line up back panel retaining tabs and new push pins.
Page 826 SEATS 23 - 89 FRONT SEAT CUSHION COVER (Continued) (1) Remove track and recliner assembly (Refer to INSTALLATION - HEATED 23 - BODY/SEATS/SEAT TRACK & RECLINER (1) Position seat cover on cushion. Ensure to repo- ASSEMBLY - REMOVAL). sition seat anti squeak sheet to frame, if equipped. (2) Disconnect seat cushion heater element har- (2) Route seat function switches through access ness connectors from seat pan.
Page 827: Lumbar Support
23 - 90 SEATS WARNING: IF EQUIPPED WITH AIRBAG, AFTER SEAT SIDE SHIELD THE NEGATIVE CABLE IS DISCONNECTED WAIT FOR 2 MINUTES BEFORE DISCONNECTING OR REMOVAL REMOVING ANY AIRBAG SYSTEM COMPONENTS. (1) Disconnect and isolate the remote negative bat- REMOVAL - NON AIRBAG tery cable.
Page 828 SEATS 23 - 91 SEAT TRACK & RECLINER ASSEMBLY REMOVAL WARNING: DISCONNECT AND ISOLATE THE NEGA- TIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY FRONT SEAT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DIS- ABLE THE AIRBAG SYSTEM. FAILURE TO DISCON- NECT BATTERY COULD...
Page 829: Rear Armrest
23 - 92 SEATS (3) Remove silencer panel. REAR ARMREST (4) Remove fasteners attaching arm rest to seat back (Fig. 33). REMOVAL (5) Remove arm rest (Fig. 34). REMOVAL - 60/40 (1) Fold down 40 side rear seat back. (2) Remove arm rest bolt (Fig. 30). (3) Remove retaining C-clip.
Page 830 SEATS 23 - 93 REAR ARMREST (Continued) (3) Pull bottom of seat back out to slide rear seat back mounts off studs. Push rear seat back upward to disengage hooks at top of seat back. (4) Remove rear seat back from vehicle. REMOVAL - 40 SECTION (1) Remove seat back collar assembly (Refer to 23 - BODY/SEATS/REAR...
Page 831 23 - 94 SEATS REAR SEAT BACK (Continued) (5) Remove the 60 seat section from the rear seat back collar assembly (Fig. 40). Fig. 38 40 Section Pivot Pin 1 - PIN Fig. 40 REAR SEAT BACK COLLAR REMOVAL - 60 SECTION 1 - PIVOT BRACKET (1) Remove seat back collar assembly (Refer to 23 - BODY/SEATS/REAR SEAT BACK COLLAR ASSEM-...
Page 832: Rear Seat Cushion
SEATS 23 - 95 REAR SEAT BACK (Continued) INSTALLATION - 60/40 SEAT COLLAR ASSEMBLY (1) Install the 60 seat section from the rear seat back collar assembly. (2) Install the 40 seat section from the rear seat back collar assembly. (3) Place the rear seat back collar assembly in position in vehicle.
Page 833 23 - 96 SEATS REAR SEAT CUSHION COVER (Continued) (2) Remove the front seat back. Refer to the proce- dure in this group. (3) Remove bolts attaching seat adjuster to cush- ion pan (Fig. 44). (4) Disconnect wire harness from cushion pan. (5) Remove seat adjuster from seat cushion.
Page 834 STATIONARY GLASS 23 - 97 STATIONARY GLASS TABLE OF CONTENTS page page STATIONARY GLASS WINDSHIELD DESCRIPTION ......97 DESCRIPTION .
Page 835 BACKLITE (Continued) push rear window inward till flush to roof line and CAUTION: Protect all painted and trimmed surfaces C-pillars (Intrepid). from coming in contact with urethane or primers. (9) Clean excess urethane from exterior with Be careful not to damage painted surfaces when Mopar Super Kleen or equivalent.
Page 836 STATIONARY GLASS 23 - 99 WINDSHIELD (Continued) (2) Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. (3) Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig.
Page 837 23 - 100 STATIONARY GLASS WINDSHIELD (Continued) (11) Apply pinch weld primer 15 mm (.75 in.) wide (19) Install cowl cover (Refer to 23 - BODY/EXTE- around the windshield fence. Allow at least three RIOR/COWL GRILLE AND SCREEN - INSTALLA- minutes drying time.
Page 838 SUNROOF 23 - 101 SUNROOF TABLE OF CONTENTS page page SUNROOF ADJUSTMENT - SUNROOF GLASS PANEL DESCRIPTION ......101 TIMING .
Page 839 23 - 102 SUNROOF SUNROOF (Continued) However, when some type of drying blower system is ing. This causes the water to blow over the edge of used, like those found in automatic car washes, the the module and onto the headlining. water may not have a chance to drain before the Refer to (Fig.
Page 840 SUNROOF 23 - 103 SUNROOF (Continued) Fig. 1 SUNROOF ASSEMBLY 1 - SUNSHADE 2 - EXPRESS MODULE 3 - DRIVE MOTOR 4 - FRAME ASSEMBLY 5 - WIND DEFLECTOR 6 - GLASS PANEL 7 - DRAIN CHANNEL...
Page 841 23 - 104 SUNROOF (4) Connect the drain tubes to the sunroof housing. HOUSING ASSEMBLY (5) With the aid of a helper move the headliner through the rear door into position. REMOVAL (6) Engage headliner rear locating clip. (1) Remove headliner (Refer to 23 - BODY/INTE- (7) Connect sunroof harness connector at the RIOR/HEADLINER - REMOVAL).
Page 842: Glass Panel
SUNROOF 23 - 105 (3) Set headliner into position. DRIVE MOTOR (4) Connect express module, drive motor, and con- trol switch wire connectors. REMOVAL (5) Test sunroof operation, adjust as necessary. (6) Finish installing the headliner (Refer to 23 - NOTE: BODY/INTERIOR/HEADLINER - INSTALLATION).
Page 843 23 - 106 SUNROOF GLASS PANEL (Continued) (4) Adjust the front of the sunroof glass panel 1 HOUSING DRAIN HOSE mm (1/32 inch) below the top surface of the roof panel. REMOVAL (5) Tighten the front two screws. (6) Loosen the rear screws on each side enough to FRONT HOSES make the rear adjustment.
Page 844 SUNROOF 23 - 107 HOUSING DRAIN HOSE (Continued) (3) Remove headliner as necessary (Refer to 23 - BODY/INTERIOR/HEADLINER - REMOVAL). (4) Remove rear shelf panel (Refer to 23 - BODY/IN- TERIOR/REAR SHELF TRIM PANEL - REMOVAL). (5) Disconnect the end of the drain tube from the rubber grommet at the end of the drain tube closest to the rear window of the vehicle (Fig.
Page 845 23 - 108 SUNROOF HOUSING DRAIN HOSE (Continued) (3) Connect the lower end of the drain tube to the (4) Using a flat blade tool, remove front guide rubber grommet near the rear window of the vehicle. blocks from track. By pushing block toward the cen- (4) Connect the drain hose to the sunroof housing ter of the vehicle (Fig.
Page 846: Wind Deflector
SUNROOF 23 - 109 WIND DEFLECTOR REMOVAL (1) Open sunroof glass panel. (2) Push down one corner of the wind deflector and let the other corner rise up (Fig. 10). (3) Push the low corner towards the opposite side of the vehicle until tab on sunshade clears the body. Then raise the corner up.
Page 847 23 - 110 WEATHERSTRIP/SEALS WEATHERSTRIP/SEALS TABLE OF CONTENTS page page DOOR OPENING WEATHERSTRIP INSTALLATION ......112 REMOVAL .
Page 848 WEATHERSTRIP/SEALS 23 - 111 DRIP RAIL WEATHERSTRIP REMOVAL (1) Open front and rear doors. (2) Remove fasteners attaching drip rail weather- strip to body and fender tip. (Fig. 2). (3) Remove drip rail weatherstrip from vehicle. INSTALLATION (1) Place drip rail weatherstrip in position on vehi- cle.
Page 849 23 - 112 WEATHERSTRIP/SEALS FRONT DOOR GLASS RUN WEATHERSTRIP (Continued) INSTALLATION REAR DOOR BODY MOUNTED (1) Clean butyl material from door flange area. WEATHERSTRIP (2) Place door run weatherstrip in position on win- dow frame channel. REMOVAL (3) Push door run weatherstrip into window frame (1) Remove door opening sill plate (Refer to 23 - channel.
Page 850 WEATHERSTRIP/SEALS 23 - 113 INSTALLATION REAR DOOR GLASS RUN (1) Clean butyl material from door flange area. WEATHERSTRIP (2) Place door run weatherstrip in position on win- dow frame channel. REMOVAL (3) Push door run weatherstrip in position on win- (1) Remove door glass (Refer to 23 - BODY/ dow frame channel.
Page 851 23 - 114 WEATHERSTRIP/SEALS INSTALLATION REAR DOOR MOUNTED (1) Place door mount weatherstrip in position on WEATHERSTRIP door with the paint dot in the upper corner of the B-pillar. REMOVAL (2) Install push pin fasteners to attach door (1) Using a fork type prying tool, disengage push mounted weatherstrip to lower door.
Page 852 ....124 GAP AND FLUSH SPECIFICATIONS BODY GAP AND FLUSH MEASUREMENTS INDEX DESCRIPTION FIGURE BODY GAP AND FLUSH – INTREPID BODY GAP AND FLUSH – CONCORDE AND 300M...
Page 853 23 - 116 BODY STRUCTURE GAP AND FLUSH (Continued) Fig. 1 BODY GAP AND FLUSH - INTREPID LOCATION FLUSH Hood to Fender 4.0 +/- 1.0 0 - 1.0 Hood to Fender Fore and Aft 0 +/- 1.0 0 +/- 1.0 Front Door to Fender 5.0 +/- 1.5...
Page 854 BODY STRUCTURE 23 - 117 GAP AND FLUSH (Continued) Fig. 2 BODY GAP AND FLUSH - CONCORDE AND 300M LOCATION FLUSH Hood to Fender 4.0 +/- 1.5 0 +/- 1.5 Hood to Fender Fore and Aft 0 +/- 1.0 0 +/- 2.0 Front Door to Fender 5.0 +/- 1.5 0 - 1.0...
Page 855: Opening Dimensions
BODY OPENING DIMENSION INDEX DESCRIPTION FIGURE WINDSHIELD AND FRONT DOOR OPENINGS REAR DOOR OPENINGS - CONCORDE/300M REAR DOOR OPENINGS - INTREPID REAR WINDOW AND TRUNK OPENING - CONCORDE REAR WINDOW AND TRUNK OPENINGS - INTREPID REAR WINDOW AND TRUNK OPENINGS - 300M...
Page 856 BODY STRUCTURE 23 - 119 OPENING DIMENSIONS (Continued) Fig. 3 WINDSHIELD AND FRONT DOOR OPENINGS...
Page 857 BODY STRUCTURE OPENING DIMENSIONS (Continued) Fig. 4 REAR DOOR OPENINGS - CONCORDE/300M Fig. 5 REAR DOOR OPENINGS - INTREPID A - Center of radius at top to door latch hole. A - Center of radius at top to door latch hole.
Page 858 BODY STRUCTURE 23 - 121 OPENING DIMENSIONS (Continued) Fig. 6 REAR WINDOW AND TRUNK OPENING - CONCORDE...
Page 859 23 - 122 BODY STRUCTURE OPENING DIMENSIONS (Continued) Fig. 7 REAR WINDOW AND TRUNK OPENINGS - INTREPID...
Page 860 BODY STRUCTURE 23 - 123 OPENING DIMENSIONS (Continued) Fig. 8 REAR WINDOW AND TRUNK OPENINGS - 300M...
Page 861 23 - 124 BODY STRUCTURE SEALER LOCATIONS SPECIFICATIONS SEALER LOCATIONS INDEX DESCRIPTION FIGURE METHODS OF APPLYING AUTO BODY SEALANT STRUT TOWER AND COWL AREA LOAD BEAM AND COWL AREA BODY SIDE APERTURE FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN REAR TRUNK AREA INNER WHEELHOUSE REAR QUARTER PANE...
Page 862 BODY STRUCTURE 23 - 125 SEALER LOCATIONS (Continued) Fig. 9 METHODS OF APPLYING AUTO BODY SEALANT...
Page 863 23 - 126 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 10 STRUT TOWER AND COWL AREA 1 - SEALER TO BE BRUSHED INTO SEAMS 4 - SEALER TO BE BRUSHED INTO SEAMS 2 - SEALER TO BE BRUSHED INTO SEAMS 5 - SEALER TO BE BRUSHED INTO SEAMS 3 - SEALER TO BE BRUSHED INTO SEAMS...
Page 864 BODY STRUCTURE 23 - 127 SEALER LOCATIONS (Continued) Fig. 11 LOAD BEAM AND COWL AREA...
Page 865 23 - 128 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 12 BODY SIDE APERTURE...
Page 866 BODY STRUCTURE 23 - 129 SEALER LOCATIONS (Continued) Fig. 13 FLOOR PAN 1 - SEALER TO BE BRUSHED INTO SEAMS...
Page 867 23 - 130 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 14 FLOOR PAN...
Page 868 BODY STRUCTURE 23 - 131 SEALER LOCATIONS (Continued) Fig. 15 FLOOR PAN...
Page 869 23 - 132 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 16 FLOOR PAN...
Page 870 BODY STRUCTURE 23 - 133 SEALER LOCATIONS (Continued) Fig. 17 REAR TRUNK AREA...
Page 871 23 - 134 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 18 INNER WHEELHOUSE...
Page 872 BODY STRUCTURE 23 - 135 SEALER LOCATIONS (Continued) Fig. 19 REAR QUARTER PANE...
Page 873 23 - 136 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 20 DECKLID...
Page 874 BODY STRUCTURE 23 - 137 SEALER LOCATIONS (Continued) Fig. 21 FRONT DOORS...
Page 875 23 - 138 BODY STRUCTURE SEALER LOCATIONS (Continued) Fig. 22 REAR DOORS...
Page 876 BODY STRUCTURE 23 - 139 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS INDEX DESCRIPTION FIGURE HOOD - CONCORDE AND 300M HOOD - INTREPID FRONT FENDER ROOF SUNROOF DOORS DECKLID Fig. 23 HOOD - CONCORDE AND 300M...
Page 877 23 - 140 BODY STRUCTURE STRUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 24 HOOD - INTREPID Fig. 25 FRONT FENDER...
Page 878 BODY STRUCTURE 23 - 141 STRUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 26 ROOF Fig. 27 SUNROOF...
Page 879 23 - 142 BODY STRUCTURE STRUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 28 DOORS...
Page 880 BODY STRUCTURE 23 - 143 STRUCTURAL ADHESIVE LOCATIONS (Continued) Fig. 29 DECKLID...
Page 881 23 - 144 BODY STRUCTURE WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS INDEX DESCRIPTION FIGURE ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT ENGINE COMPARTMENT DASH AND COWL DASH AND COWL DASH AND COWL DASH AND COWL DASH AND COWL...
Page 882 BODY STRUCTURE 23 - 145 WELD LOCATIONS (Continued) DESCRIPTION FIGURE FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN FLOOR PAN REAR SHELF REAR SHELF...
Page 883 23 - 146 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 30 ENGINE COMPARTMENT...
Page 884 BODY STRUCTURE 23 - 147 WELD LOCATIONS (Continued) Fig. 31 ENGINE COMPARTMENT...
Page 885 23 - 148 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 32 ENGINE COMPARTMENT...
Page 886 BODY STRUCTURE 23 - 149 WELD LOCATIONS (Continued) Fig. 33 ENGINE COMPARTMENT...
Page 887 23 - 150 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 34 ENGINE COMPARTMENT...
Page 888 BODY STRUCTURE 23 - 151 WELD LOCATIONS (Continued) Fig. 35 ENGINE COMPARTMENT...
Page 889 23 - 152 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 36 ENGINE COMPARTMENT...
Page 890 BODY STRUCTURE 23 - 153 WELD LOCATIONS (Continued) Fig. 37 ENGINE COMPARTMENT...
Page 891 23 - 154 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 38 ENGINE COMPARTMENT...
Page 892 BODY STRUCTURE 23 - 155 WELD LOCATIONS (Continued) Fig. 39 ENGINE COMPARTMENT...
Page 893 23 - 156 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 40 ENGINE COMPARTMENT...
Page 894 BODY STRUCTURE 23 - 157 WELD LOCATIONS (Continued) Fig. 41 DASH AND COWL...
Page 895 23 - 158 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 42 DASH AND COWL...
Page 896 BODY STRUCTURE 23 - 159 WELD LOCATIONS (Continued) Fig. 43 DASH AND COWL...
Page 897 23 - 160 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 44 DASH AND COWL...
Page 898 BODY STRUCTURE 23 - 161 WELD LOCATIONS (Continued) Fig. 45 DASH AND COWL...
Page 899 23 - 162 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 46 DASH AND COWL...
Page 900 BODY STRUCTURE 23 - 163 WELD LOCATIONS (Continued) Fig. 47 ROOF PANEL AND ROOF BOWS...
Page 901 23 - 164 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 48 ROOF PANEL AND ROOF BOWS...
Page 902 BODY STRUCTURE 23 - 165 WELD LOCATIONS (Continued) Fig. 49 ROOF PANEL AND ROOF BOWS...
Page 903 23 - 166 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 50 ROOF PANEL AND ROOF BOWS Fig. 51 BODY SIDE APERTURE...
Page 904 BODY STRUCTURE 23 - 167 WELD LOCATIONS (Continued) Fig. 52 BODY SIDE APERTURE...
Page 905 23 - 168 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 53 BODY SIDE APERTURE...
Page 906 BODY STRUCTURE 23 - 169 WELD LOCATIONS (Continued) Fig. 54 BODY SIDE APERTURE...
Page 907 23 - 170 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 55 BODY SIDE APERTURE...
Page 908 BODY STRUCTURE 23 - 171 WELD LOCATIONS (Continued) Fig. 56 BODY SIDE APERTURE...
Page 909 23 - 172 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 57 BODY SIDE APERTURE...
Page 910 BODY STRUCTURE 23 - 173 WELD LOCATIONS (Continued) Fig. 58 BODY SIDE APERTURE...
Page 911 23 - 174 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 59 BODY SIDE APERTURE...
Page 912 BODY STRUCTURE 23 - 175 WELD LOCATIONS (Continued) Fig. 60 BODY SIDE APERTURE...
Page 913 23 - 176 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 61 BODY SIDE APERTURE...
Page 914 BODY STRUCTURE 23 - 177 WELD LOCATIONS (Continued) Fig. 62 BODY SIDE APERTURE...
Page 915 23 - 178 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 63 BODY SIDE APERTURE...
Page 916 BODY STRUCTURE 23 - 179 WELD LOCATIONS (Continued) Fig. 64 FLOOR PAN...
Page 917 23 - 180 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 65 FLOOR PAN...
Page 918 BODY STRUCTURE 23 - 181 WELD LOCATIONS (Continued) Fig. 66 FLOOR PAN...
Page 919 23 - 182 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 67 FLOOR PAN...
Page 920 BODY STRUCTURE 23 - 183 WELD LOCATIONS (Continued) Fig. 68 FLOOR PAN...
Page 921 23 - 184 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 69 FLOOR PAN...
Page 922 BODY STRUCTURE 23 - 185 WELD LOCATIONS (Continued) Fig. 70 FLOOR PAN...
Page 923 23 - 186 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 71 FLOOR PAN...
Page 924 BODY STRUCTURE 23 - 187 WELD LOCATIONS (Continued) Fig. 72 FLOOR PAN...
Page 925 23 - 188 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 73 FLOOR PAN...
Page 926 BODY STRUCTURE 23 - 189 WELD LOCATIONS (Continued) Fig. 74 FLOOR PAN...
Page 927 23 - 190 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 75 FLOOR PAN...
Page 928 BODY STRUCTURE 23 - 191 WELD LOCATIONS (Continued) Fig. 76 FLOOR PAN...
Page 929 23 - 192 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 77 FLOOR PAN...
Page 930 BODY STRUCTURE 23 - 193 WELD LOCATIONS (Continued) Fig. 78 FLOOR PAN...
Page 931 23 - 194 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 79 FLOOR PAN...
Page 932 BODY STRUCTURE 23 - 195 WELD LOCATIONS (Continued) Fig. 80 FLOOR PAN Fig. 81 REAR SHELF...
Page 933 23 - 196 BODY STRUCTURE WELD LOCATIONS (Continued) Fig. 82 REAR SHELF...
Page 934 BODY STRUCTURE 23 - 197 WELD LOCATIONS (Continued) Fig. 83 REAR SHELF...
Page 936 CABLE - REMOTE LOCK ACTUATOR 23s - 1 CABLE - REMOTE LOCK ACTUATOR TABLE OF CONTENTS page page CABLE - REMOTE LOCK ACTUATOR INSTALLATION ......1 REMOVAL .
Page 938 HEATING & AIR CONDITIONING 24 - 1 HEATING & AIR CONDITIONING TABLE OF CONTENTS page page HEATING & AIR CONDITIONING DIAGNOSIS AND TESTING - ERRATIC DESCRIPTION - ENGINE COOLING SYSTEM OPERATION OF HVAC SYSTEM ... 6 REQUIREMENTS .
Page 939 24 - 2 HEATING & AIR CONDITIONING HEATING & AIR CONDITIONING (Continued) • Set temperature to the LO position PERFORMANCE TEST PROCEDURE • Push panel mode button Before performing the following procedure, (Refer • Push RECIRC (Recirculation) button (A/C and to 24 - HEATING &...
Page 940 HEATING & AIR CONDITIONING 24 - 3 HEATING & AIR CONDITIONING (Continued) TEMPERATURE REFERENCE TABLE tool or the vehicles own control head display. Refer to the DRBIII menu for checking Diagnostic Trouble Codes (DTC’s). Note that there are three DTC tables. Ambient Temp.
Page 941 24 - 4 HEATING & AIR CONDITIONING HEATING & AIR CONDITIONING (Continued) ATC AND MTC DTC’S ATC DTC’S CODE DESCRIPTION CODE DESCRIPTION BLEND DOOR ACTUATOR FEEDBACK ATC IN-CAR TEMPERATURE FAILURE THERMISTER FAILURE MODE DOOR ACTUATOR FEEDBACK ATC IN-CAR SENSOR FAILURE FAILURE ENGINE TEMPERATURE MESSAGE AMBIENT SENSOR...
Page 942 HEATING & AIR CONDITIONING 24 - 5 HEATING & AIR CONDITIONING (Continued) Diagnostic trouble codes related to the MTC head and the climate control unit will appear on the odom- eter display in numerical form after the letters “AC”. The diagnostic trouble codes are stored in the BCM and can range between 23 and 51.
Page 943 A/C APPLICATION TABLE-ATC Erratic operation of the A/C and heater systems including: Item Description Notes • Lack of cold air Vehicle LH - Intrepid, Automatic • Lack of hot air Concorde, Temperature • Unrequested mode change (ATC only) 300M, LHS Control (ATC) •...
Page 944 A/C APPLICATION TABLE-MTC Item Description Notes Mode Door Electric BCM controlled Item Description Notes actuator actuators use a common ground Vehicle LH - Intrepid, manual A/C Blend Door Electric Concorde, control actuator 300M, LHS Recirculation Electric System R134a Door actuator...
Page 945 24 - 8 CONTROLS CONTROLS TABLE OF CONTENTS page page A/C COMPRESSOR CLUTCH OPERATION ......15 DESCRIPTION .
Page 946 CONTROLS 24 - 9 A/C COMPRESSOR CLUTCH (Continued) The compressor clutch engagement is controlled by STANDARD PROCEDURE several components: the a/c heater control head (ATC or MTC), the evaporator temperature sensor, the a/c INSPECTION pressure transducer, the compressor clutch relay, and Examine the friction surfaces of the clutch pulley the Powertrain Control Module (PCM).
Page 947 24 - 10 CONTROLS A/C COMPRESSOR CLUTCH (Continued) (8) Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor (Fig. 3). Fig. 3 REMOVING PULLEY SNAP RING 1 - SNAP RING Fig. 1 COMPRESSOR SHAFT BOLT AND CLUTCH PLATE 1 - COMPRESSOR SHAFT BOLT 2 - COMPRESSOR CLUTCH PLATE...
Page 948 CONTROLS 24 - 11 A/C COMPRESSOR CLUTCH (Continued) INSTALLATION (1) Align pin in back of field coil with hole in com- pressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw.
Page 949 24 - 12 CONTROLS A/C COMPRESSOR CLUTCH RELAY (Continued) DIAGNOSIS AND TESTING - A/C COMPRESSOR pressor clutch relay output circuit cavity of the com- pressor clutch coil wire harness connector. If OK, go CLUTCH RELAY to Step 4. If not OK, repair the open circuit as required.
Page 950 CONTROLS 24 - 13 A/C COMPRESSOR CLUTCH RELAY (Continued) INSTALLATION (1) Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. (2) Install the PDC cover. (3) Connect the battery negative cable. (4) Test the relay operation.
Page 951 24 - 14 CONTROLS A/C PRESSURE TRANSDUCER (Continued) Fig. 10 NEGATIVE BATTERY CABLE REMOTE Fig. 11 AMBIENT TEMPERATURE SENSOR TERMINAL LOCATION 1 - RIGHT STRUT TOWER 1 - AMBIENT TEMPERATURE SENSOR 2 - AIR CLEANER INLET TUBE 2 - FRONT FASCIA 3 - REMOTE TERMINAL 3 - POWER STEERING COOLER INSTALLATION...
Page 952 CONTROLS 24 - 15 POWER MODULE (Continued) REMOVAL ground path through the correct resistor wire to obtain the selected blower motor speed. The blower motor resistor cannot be repaired and, WARNING: ON VEHICLES EQUIPPED WITH AIR- if faulty or damaged, it must be replaced. BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING OPERATION...
Page 953 24 - 16 CONTROLS BLOWER MOTOR RESISTOR BLOCK (Continued) REMOVAL mistor in the tube will detect the temperature of the evaporator. The thermistor will change resistance as the temperature changes. WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE OPERATION ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT...
Page 954 CONTROLS 24 - 17 EVAPORATOR TEMPERATURE SENSOR (Continued) REMOVAL (6) Connect the negative battery cable remote termi- nal to the remote battery post(Refer to 8 - ELECTRI- (1) Open the hood and disconnect the negative bat- CAL/BATTERY SYSTEM/CABLES - INSTALLATION). tery cable remote terminal from the remote battery post (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ CABLES - REMOVAL).
Page 955 24 - 18 CONTROLS IN-CAR TEMPERATURE SENSOR (Continued) REMOVAL IN-CAR SENSOR ASPIRATOR MOTOR OPERATION CONDITION MOTOR OPERATION WARNING: ON VEHICLES EQUIPPED WITH AIR- IGNITION SWITCH IS MOTOR ALWAYS BAGS, DISABLE THE AIRBAG SYSTEM BEFORE OPERATES, EVEN ATTEMPTING ANY STEERING WHEEL, STEERING WHEN ATC CONTROL COLUMN, OR INSTRUMENT PANEL COMPONENT HEAD OFF BUTTON IS...
Page 956 CONTROLS 24 - 19 BLEND DOOR ACTUATOR (Continued) (2) Remove the left and right underpanel silencer/ MODE DOOR ACTUATOR ducts. (3) Remove the two screws from the actuator DESCRIPTION which are accessible from the right side of the center The mode door actuator is an electric motor. It stack (Fig.
Page 957 24 - 20 CONTROLS MODE DOOR ACTUATOR (Continued) RECIRCULATION DOOR ACTUATOR 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-...
Page 958 CONTROLS 24 - 21 RECIRCULATION DOOR ACTUATOR (Continued) (2) Remove the instrument panel(Refer to 23 - responds to sun light intensity rather than tempera- BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ture. It is used to aid in determining proper mode ASSEMBLY - REMOVAL). door position, temperature door position and blower (3) Remove the actuator retaining screws.
Page 959 24 - 22 CONTROLS SUN SENSOR (Continued) REMOVAL INSTALLATION (1) Connect the wiring harness connector to the WARNING: ON VEHICLES EQUIPPED WITH AIR- sensor and position in the vehicle. BAGS, DISABLE THE AIRBAG SYSTEM BEFORE (2) Install the two sensor fasteners. ATTEMPTING ANY STEERING WHEEL, STEERING (3) Install the instrument panel top cover(Refer to COLUMN, OR INSTRUMENT PANEL COMPONENT...
Page 960 DISTRIBUTION 24 - 23 DISTRIBUTION TABLE OF CONTENTS page page DISTRIBUTION INSTALLATION ......24 DESCRIPTION HVAC HOUSING DESCRIPTION - HVAC SYSTEM AIRFLOW .
Page 961 24 - 24 DISTRIBUTION BLOWER MOTOR (Continued) REMOVAL TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG WARNING: ON VEHICLES EQUIPPED WITH AIR- SYSTEM. FAILURE TO TAKE THE PROPER PRE- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE CAUTIONS COULD RESULT IN AN ACCIDENTAL ATTEMPTING ANY STEERING WHEEL, STEERING...
Page 962 DISTRIBUTION 24 - 25 HVAC HOUSING (Continued) (12) Remove the rear seat heat duct elbow push (21) Using a flat blade screwdriver, pinch in the pin fastener. retaining tab at the base of the vent door. Pull up on (13) Disconnect the HVAC harness connector. door and remove it from the HVAC housing.
Page 963 24 - 26 DISTRIBUTION HVAC HOUSING (Continued) (17) Thread the blower motor wiring through the (7) Install the nuts on the HVAC housing mount- blower motor cover, and install the blower motor ing studs on the engine compartment side of the housing cover.
Page 964 PLUMBING 24 - 27 PLUMBING TABLE OF CONTENTS page page PLUMBING INSTALLATION ......36 DESCRIPTION - REFRIGERANT LINE .
Page 965 24 - 28 PLUMBING PLUMBING (Continued) OPERATION - REFRIGERANT LINE KEEP OUT OF REACH OF CHILDREN AND PETS. DO NOT OPEN A COOLING SYSTEM WHEN THE High pressures are produced in the refrigerant sys- ENGINE IS AT RUNNING TEMPERATURE. PER- tem when the air conditioning compressor is operat- SONAL INJURY CAN RESULT.
Page 966 PLUMBING 24 - 29 PLUMBING (Continued) • A/C in the ON position High pressures are produced in the system when it • Open all windows is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and CAUTION: A leak detector designed for R-12 refrig- moisture can enter the system when it is opened for erant may not detect leaks in a R-134a refrigerant...
Page 967 24 - 30 PLUMBING PLUMBING (Continued) A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrig- erant system. Refer to the operating instructions sup- plied by the equipment manufacturer for the proper care and use of this equipment.
Page 968 PLUMBING 24 - 31 PLUMBING (Continued) valves. Then allow the system to evacuate an addi- A/C COMPRESSOR tional 10 minutes. (3) Close all valves. Turn off and disconnect the DESCRIPTION vacuum pump. The air conditioning system uses a Nippondenso (4) The refrigerant system is prepared to be 10PA17 ten cylinder, double-acting swash plate-type charged with refrigerant.
Page 969 24 - 32 PLUMBING A/C COMPRESSOR (Continued) REMOVAL The A/C compressor may be unbolted and reposi- tioned without discharging the refrigerant system. Discharging is not necessary if removing the com- pressor clutch/coil assembly, engine, cylinder head, or alternator. WARNING: REVIEW THE WARNINGS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.
Page 970 PLUMBING 24 - 33 A/C COMPRESSOR (Continued) (1) Position the a/c compressor in the vehicle and install the attaching bolts. Torque the a/c compressor mounting bolts to 28 N·m (21 ft. lbs.) (2) Remove the plug or cap from the opened refrig- erant line fittings.
Page 971 24 - 34 PLUMBING A/C CONDENSER (Continued) (9) Separate the condenser from the radiator. (8) Install the upper radiator core support(Refer to (10) Remove the condenser (with auxiliary trans- 7 - COOLING/ENGINE/RADIATOR - INSTALLA- mission cooler attached) from the vehicle. TION).
Page 972 PLUMBING 24 - 35 A/C DISCHARGE LINE (Continued) ing. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.
Page 973 24 - 36 PLUMBING LIQUID LINE (Continued) (5) Disconnect receiver/drier bracket fastener and Any kinks or sharp bends in the refrigerant plumb- separate the bracket from the strut panel (there are ing will reduce the capacity of the entire air condi- two hidden plastic fasteners to pry out).
Page 974 PLUMBING 24 - 37 SUCTION LINE REMOVAL WARNING: REVIEW THE WARNINGS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) (1) Recover the refrigerant from the system. (Refer to 24 - HEATING &...
Page 975 24 - 38 PLUMBING SUCTION LINE (Continued) (3) Install the engine air inlet tube and air distri- bution duct(Refer to 9 - ENGINE/AIR INTAKE SYS- TEM/AIR CLEANER ELEMENT - INSTALLATION). (4) Connect the suction line to the expansion valve. Tighten the retaining nut to 23 N·m (17 ft. lbs.).
Page 976 PLUMBING 24 - 39 A/C EVAPORATOR (Continued) (6) At the center of the HVAC housing, locate the (7) Install the recirculation door actuator. (Refer to evaporator probe access plate. Using a flat blade pry 24 - HEATING & AIR CONDITIONING/CONTROLS/ tool, pull back on the locking tab.
Page 977: Heater Core
24 - 40 PLUMBING A/C EXPANSION VALVE (Continued) In a Closed Position: There will be low suction be routed so they are at least 80 millimeters (3 pressure and no cooling. This may be caused by a inches) from the exhaust manifold. failed power dome or excessive moisture in the A/C High pressures are produced in the refrigerant sys- system.
Page 978 PLUMBING 24 - 41 HEATER CORE (Continued) (1) Open the hood and disconnect the negative bat- FOLLOWING OPERATION. (Refer to 24 - HEATING & tery cable remote terminal from the remote battery AIR CONDITIONING/PLUMBING - WARNING) post. (1) Recover the refrigerant from the system. (Refer (2) Remove the HVAC unit housing from vehicle.
Page 979 24 - 42 PLUMBING RECEIVER / DRIER (Continued) (1) Install the small line from the receiver/drier to REFRIGERANT OIL expansion valve on the new receiver/drier. (2) Install the reveiver/drier in the vehicle. DESCRIPTION (3) Install the a/c line at the receiver/drier. Tighten The refrigerant oil used in R-134a refrigerant sys- the fastener to 13.6 N·m (10 ft.
Page 980 PLUMBING 24 - 43 REFRIGERANT OIL (Continued) oil in the compressor is dispersed through the lines (4) From the suction and discharge ports on top of and components. The evaporator, condenser, and the compressor, drain the lubricant from the com- receiver/drier will retain a significant amount of oil.
Page 981 24 - 44 PLUMBING SERVICE PORT VALVE CORE (Continued) INSTALLATION NOTE: When assembling the new valve core into the fitting, the core should be oiled with clean ND8 PAG compressor oil. (1) Install the new valve core into the fitting. (2) Evacuate the refrigerant system.
Page 982 EMISSIONS CONTROL 25 - 1 EMISSIONS CONTROL TABLE OF CONTENTS page page EMISSIONS CONTROL DESCRIPTION - HIGH AND LOW LIMITS ..9 DESCRIPTION OPERATION DESCRIPTION - MONITORED COMPONENT OPERATION - SYSTEM ....9 DESCRIPTION - VEHICLE EMISSION DRB III STATE DISPLAY TEST MODE .
Page 983 25 - 2 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) • Intake/inlet Air Temperature (IAT) Sensor • Heater Performance • Throttle Position (TPS) Sensor Slow Response Rate (Big Slope)—Response rate • Ambient/Battery Temperature Sensors is the time required for the sensor to switch from •...
Page 984 EMISSIONS CONTROL 25 - 3 EMISSIONS CONTROL (Continued) • Fuel level above 15% internal circuit decreases. The PCM sends a 5 volts • Ambient air temperature biased signal through the oxygen sensors to ground • Barometric pressure this monitoring circuit. As the temperature increases, •...
Page 985 25 - 4 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) Normal vehicle miles or engine misfire can cause a below the lean threshold to above the rich threshold. catalyst to decay. A meltdown of the ceramic core can The number of Rear O2 sensor switches is divided by cause a reduction of the exhaust passage.
Page 986 EMISSIONS CONTROL 25 - 5 EMISSIONS CONTROL (Continued) • Vehicle Speed Sensor • A rise of 40°F in engine temperature must occur • Brake switch (auto trans only) from the time when the engine was started • Intake air temperature •...
Page 987 25 - 6 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) • Misfire Monitor FUEL INJECTOR MECHANICAL MALFUNCTIONS • Fuel System Monitor The PCM cannot determine if a fuel injector is • Oxygen Sensor Monitor clogged, the needle is sticking or if the wrong injector •...
Page 988 EMISSIONS CONTROL 25 - 7 EMISSIONS CONTROL (Continued) Effective control of exhaust emissions is achieved FUEL SYSTEM MONITOR by an oxygen feedback system. The most important To comply with clean air regulations, vehicles are element of the feedback system is the O2S. The O2S equipped with catalytic converters.
Page 989 25 - 8 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) chemical reaction takes place. This means the con- The spring in the pump is set so that the system centration of oxygen will be the same downstream as will achieve an equalized pressure of about 7.5” upstream.
Page 990 EMISSIONS CONTROL 25 - 9 EMISSIONS CONTROL (Continued) nation by this diagnostic. When the vacuum in the DESCRIPTION - HIGH AND LOW LIMITS system exceeds about 1 H2O (0.25 KPA), a vacuum The PCM compares input signal voltages from each switch closes.
Page 991 25 - 10 EMISSIONS CONTROL EMISSIONS CONTROL (Continued) Technicians can display stored DTC’s. Refer to Diagnostic Trouble Codes (Refer to 8 - ELECTRICAL/ ELECTRONIC CONTROL MODULES/POWER- TRAIN CONTROL MODULE - DESCRIPTION). For obtaining the DTC information, use the Data Link Connector with the DRBIII scan tool (Fig.
Page 992 EVAPORATIVE EMISSIONS 25 - 11 EVAPORATIVE EMISSIONS TABLE OF CONTENTS page page EVAPORATIVE EMISSIONS ORVR OPERATION - EVAPORATION CONTROL DESCRIPTION ......15 SYSTEM .
Page 993 25 - 12 EVAPORATIVE EMISSIONS EVAPORATIVE EMISSIONS (Continued) Fig. 1 ORVR SYSTEM SCHEMATIC 1 - FUEL CAP 7 - BREATHER ELEMENT 2 - RECIRCULATION TUBE 8 - CANISTER 3 - CONTROL VALVE 9 - ROLLOVER VALVE 4 - FLOW MANAGEMENT VALVE 10 - FUEL TANK 5 - PURGE 11 - CHECK VALVE...
Page 994: Fuel Filler Cap
EVAPORATIVE EMISSIONS 25 - 13 EVAP/PURGE SOLENOID (Continued) Fig. 2 UPSTREAM HEATED OXYGEN SENSOR 1/1 Fig. 3 NVLD ASSEMBLY 1 - PROPORTIONAL PURGE SOLENOID OPERATION 2 - O2 SENSOR The Natural Vacuum Leak Detection (NVLD) sys- tem is the next generation evaporative leak detection FUEL FILLER CAP system that will first be used on vehicles equipped with the Next Generation Controller (NGC) starting...
Page 995 25 - 14 EVAPORATIVE EMISSIONS NATURAL VAC LEAK DETECTION ASSY (Continued) The NVLD device is designed with a normally open (4) Disconnect the hoses from the NVLD assembly vacuum switch, a normally closed solenoid, and a (Fig. 5). seal, which is actuated by both the solenoid and a (5) Lift tab on NVLD assembly (Fig.
Page 996 EVAPORATIVE EMISSIONS 25 - 15 NATURAL VAC LEAK DETECTION ASSY (Continued) OPERATION The emission control principle used in the ORVR system is that the fuel flowing into the filler tube (approx. 1” I.D.) creates an aspiration effect which draws air into the fill tube (Fig. 7). During refueling, the fuel tank is vented to the vapor canister to cap- ture escaping vapors.
Page 997 25 - 16 EVAPORATIVE EMISSIONS ORVR (Continued) Fig. 7 ORVR System Schematic 1 - FUEL CAP 7 - BREATHER ELEMENT 2 - RECIRCULATION TUBE 8 - CANISTER 3 - CONTROL VALVE 9 - ROLLOVER VALVE 4 - FLOW MANAGEMENT VALVE 10 - FUEL TANK 5 - PURGE 11 - CHECK VALVE...
Page 998: Pcv Valve
EVAPORATIVE EMISSIONS 25 - 17 PCV HOSE (Continued) Fig. 9 PCV - 3.2/3.5L Fig. 11 PCV Valve—3.2/3.5L (4) Fill coolant system, refer to the Cooling system 1 - THROTTLE BODY for more information. 2 - PCV VALVE PCV VALVE OPERATION When the engine is not operating or during an DESCRIPTION engine backfire, the spring forces the plunger back...
Page 999 25 - 18 EVAPORATIVE EMISSIONS PCV VALVE (Continued) VAPOR CANISTER OPERATION All vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the can- ister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber.
Page 1000 EVAPORATIVE EMISSIONS 25 - 19 VAPOR CANISTER (Continued) Fig. 16 EVAP CANISTER BOTTOM TABS Fig. 18 EVAP CANISTER TOP MOUNTING (5) Swing the EVAP canister away from the lower INSTALLATION bracket. (1) Install the EVAP canister to the upper mount- (6) Lift the EVAP canister up and off the upper ing bracket (Fig.
Page 1001 25 - 20 EXHAUST GAS RECIRCULATION EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page page EXHAUST GAS RECIRCULATION REMOVAL - 3.5L ......20 SPECIFICATIONS INSTALLATION - 3.5L .
Page 1002 EXHAUST GAS RECIRCULATION 25 - 21 EGR VALVE (Continued) (3) Disconnect electrical connector from (3) Remove EGR tube mounting clips at intake valve. manifold plenum (Fig. 3). (4) Remove EGR tube mounting screws at EGR valve (Fig. 1). The EGR valve attaches to the rear of the right cylinder head.
Page 1003 25 - 22 EXHAUST GAS RECIRCULATION EGR TUBE - 3.5L (Continued) (5) Remove EGR tube mounting screws at EGR valve. When removing EGR upper tube assembly being careful not to drop the silicone rubber seals in the intake manifold. Clean gasket surfaces on the EGR valve.
Page 1004 ON-BOARD DIAGNOSTICS 25 - 23 ON-BOARD DIAGNOSTICS TABLE OF CONTENTS page page TASK MANAGER OPERATION ......23 DESCRIPTION .
Page 1005 25 - 24 ON-BOARD DIAGNOSTICS TASK MANAGER (Continued) The Task Manager Screen shows both a Requested ditions Window is when engine RPM is within ±375 MIL state and an Actual MIL state. When the MIL is RPM and load is within ±20% of when the fault illuminated upon completion of a test for a good trip, occurred.
Page 1006 ON-BOARD DIAGNOSTICS 25 - 25 TASK MANAGER (Continued) Alternate Good Trip FUEL SYSTEM • Fuel System Similar Conditions Window — Alternate Good Trips are used in place of Global Good Trips for Comprehensive Components and An indicator that ’Absolute MAP When Fuel Sys Fail’ Major Monitors.
Page 1007 25 - 26 ON-BOARD DIAGNOSTICS TASK MANAGER (Continued) • Absolute MAP — A live reading of engine load tive to calculate the Adaptive Memory Factor for to aid the user in accessing the Similar Conditions total fuel correction. • 200 Rev Counter — Counts 0–100 720 degree Window.
Page 1008 INDEX Description Group-Page Description Group-Page Description Group-Page ABS FASTENER TORQUE, ADJUSTERS - INSTALLATION, AIRBAG WIRING HARNESS - SPECIFICATIONS ..... . 5-66 HYDRAULIC LASH .
Page 1009 INDEX Description Group-Page Description Group-Page Description Group-Page ARM - REMOVAL, LOWER CONTROL ..2-12 ASSEMBLY (FRONT) - OPERATION, BACKLITE - REMOVAL ....23-97 ARM - REMOVAL, TRAILING .
Page 1010 BLOCK - DESCRIPTION, ENGINE ..9-127,9-39 BOX - REMOVAL, GLOVE ....23-46 OCCUPIED - CONCORDE/INTREPID - BLOCK - DESCRIPTION, JUNCTION ..8W-97-4 BOX LAMP - INSTALLATION, GLOVE .
Page 1011 DISTRIBUTION ....8W-97-6 OCCUPIED - CONCORDE/INTREPID - CALIPER - REMOVAL, REAR ... . . 5-29 INSTALLATION, SEAT BELT .
Page 1012 LINES/HOSES ......14-6 CODES - STANDARD PROCEDURE, INTREPID - INSTALLATION, SEAT BELT CLAMPS - DESCRIPTION, HOSE ..7-25 SETTING UNIVERSAL TRANSMITTER .
Page 1013 Group-Page Description Group-Page COMBINATION FLASHER - DESCRIPTION . . . 8L-7 CONCORDE/INTREPID - REMOVAL, SEAT CONTROL ARM (TENSION STRUT COMBINATION FLASHER - DIAGNOSIS BELT BUCKLE - FRONT SEAT CENTER BUSHING) - ASSEMBLY, LOWER ..2-15 AND TESTING .
Page 1014 INDEX Description Group-Page Description Group-Page Description Group-Page COOLANT OUTLET CONNECTOR - 2.7L - CORE AND OIL GALLERY PLUGS - CRANKSHAFT OIL SEAL - REAR - INSTALLATION ......7-19 STANDARD PROCEDURE, ENGINE .
Page 1015 INDEX Description Group-Page Description Group-Page Description Group-Page CYLINDER HEAD COVER(S) - REMOVAL . . 9-115, DEMISTER DUCTS - DESCRIPTION, DESCRIPTION, DATA LINK CONNECTOR ..8E-6 9-30 INSTRUMENT PANEL ....24-26 DESCRIPTION, DAYTIME RUNNING CYLINDER HEAD GASKET - DIAGNOSIS DEMISTER DUCTS - OPERATION,...
Page 1016: Torque References Description
INDEX Description Group-Page Description Group-Page Description Group-Page DESCRIPTION, HEATED SEAT ELEMENT . . . 8G-13 DESCRIPTION, PLANETARY GEARTRAIN . . 21-126 DESCRIPTION, STRUT ASSEMBLY DESCRIPTION, HEATED SEAT SENSOR ..8G-14 DESCRIPTION, PLATINUM PLUGS ..8I-7 (FRONT) .
Page 1017 INDEX Description Group-Page Description Group-Page Description Group-Page DIAGNOSIS AND TESTING - DIAGNOSIS AND TESTING, COOLING DIAGNOSIS AND TESTING, HUB AND DISASSEMBLY ..... . . 21-11 SYSTEM DEAERATION .
Page 1018 INDEX Description Group-Page Description Group-Page Description Group-Page DIAGNOSIS AND TESTING, STABILIZER DIFFERENTIAL LUBRICANT - DOOR ACTUATOR - REMOVAL, BLEND ..24-18 BAR (FRONT) ......2-17 DESCRIPTION .
Page 1019 INDEX Description Group-Page Description Group-Page Description Group-Page DRIVE BELTS - 2.7L - REMOVAL ..7-14 EMERGENCY RELEASE CABLE - ENGINE OIL AND LUBRICANTS - DRIVE BELTS - 3.5L - CLEANING ..7-16 INSTALLATION .
Page 1020 WASHER HOSES ..... 8R-12 FILL/CHECK LOCATIONS - DESCRIPTION, FLUID LEVEL SWITCH - INTREPID - EXPORT - INSTALLATION, HEADLAMP FLUID ....... 0-5 INSTALLATION, WASHER .
Page 1021 . . 14-14 REMOVAL, REAR SEAT ....23-73 CONCORDE/INTREPID - INSTALLATION, FUEL TANK VENT TUBE - REMOVAL ..14-14 GRID - DIAGNOSIS AND TESTING, REAR SEAT BELT BUCKLE .
Page 1022 INDEX Description Group-Page Description Group-Page Description Group-Page HANDLE/READING LAMP - REMOVAL, HEAT STAKING - STANDARD HIGH MOUNTED STOP LAMP UNIT - REAR SEAT GRAB ....23-73 PROCEDURE .
Page 1023 INDEX Description Group-Page Description Group-Page Description Group-Page HUB AND BEARING (REAR) - IMPACT AIRBAG CONTROL MODULE - INSPECTION, BATTERY SYSTEM ..8F-5 INSTALLATION ......2-34 DESCRIPTION, SIDE .
Page 1024 INDEX Description Group-Page Description Group-Page Description Group-Page INSTALLATION, ANTENNA BODY & INSTALLATION, DECK LID RELEASE INSTALLATION, FRONT SEAT BELT & CABLE ......8A-5 SWITCH .
Page 1025 SWITCH ......8N-10 CONCORDE/INTREPID ....8O-21...
Page 1026 KEY IMMOBILIZER MODULE - REMOVAL, - INTREPID ......8R-16 CLEANING ......9-117 SENTRY .
Page 1027 ... 8L-34 LATCH - REMOVAL, CENTER CONSOLE LEVEL SWITCH - INTREPID - REMOVAL, LAMP - OPERATION, SKIS INDICATOR ..8Q-4 LID ....... . 23-66 WASHER FLUID .
Page 1028 INDEX Description Group-Page Description Group-Page Description Group-Page LID RELEASE SOLENOID - REMOVAL, LOWER BALL JOINT - DESCRIPTION ..2-12 MARKER LAMP - CONCORDE - DECK ....... 8N-4 LOWER BALL JOINT - OPERATION .
Page 1029 NIGHT MIRROR - OPERATION, MODULE - DIAGNOSIS AND TESTING, MOTOR - INTREPID - INSTALLATION, AUTOMATIC DAY ..... . 8N-8 REAR WINDOW ANTENNA ....8A-7 WASHER PUMP .
Page 1030 Group-Page Description Group-Page Description Group-Page OCCUPIED - CONCORDE/INTREPID - OIL SEAL - FRONT - INSTALLATION, OPERATION, BRAKE TUBES AND HOSES . . . 5-13 INSTALLATION, SEAT BELT BUCKLE - CRANKSHAFT ....9-136,9-47 OPERATION, CABLE .
Page 1031 INDEX Description Group-Page Description Group-Page Description Group-Page OPERATION, HEADLAMP WASHERS - OPERATION, POWER SEAT TRACK ..8N-19 OPERATION, TRANSMISSION RANGE EXPORT ......8R-8 OPERATION, POWER STEERING GEAR .
Page 1032 INDEX Description Group-Page Description Group-Page Description Group-Page PANEL TOP COVER - REMOVAL, PERFORMANCE - DIAGNOSIS AND POSITION SENSOR - DESCRIPTION, INSTRUMENT ..... . . 23-56 TESTING, ENGINE DIAGNOSIS .
Page 1033 OPERATION ......19-1 PRESSURE TRANSDUCER - PUMP MOTOR - INTREPID - REMOVAL, POWER WINDOWS - DESCRIPTION .
Page 1034 INDEX Description Group-Page Description Group-Page Description Group-Page REAR - INSTALLATION, CRANKSHAFT REAR SEAT BELT & RETRACTOR - RECIRCULATION DOOR ACTUATOR - OIL SEAL ..... . . 9-137,9-48 REMOVAL .
Page 1035 INDEX Description Group-Page Description Group-Page Description Group-Page RELAY - INSTALLATION, A/C REMOVAL, A/C PRESSURE REMOVAL, DECK LID RELEASE SWITCH . . . 8N-4 COMPRESSOR CLUTCH ....24-13 TRANSDUCER .
Page 1036 REMOVAL, PCV HOSE ....25-16 CONCORDE/INTREPID ....8O-21...
Page 1037 REMOVAL, STANDARD PROCEDURE ..8E-28 INTREPID ......8R-17 ODOMETER ......8J-5 REMOVAL, STANDARD PROCEDURE .
Page 1038 SEAT SYSTEM - DIAGNOSIS AND INTREPID - REMOVAL ....8O-21 WHEEL ......5-66 TESTING, MEMORY .
Page 1039 INDEX Description Group-Page Description Group-Page Description Group-Page SEATS - DIAGNOSIS AND TESTING, SENSOR - INSTALLATION, EVAPORATOR SENTRY KEY IMMOBILIZER MODULE - POWER ......8N-13 TEMPERATURE .
Page 1040 INDEX Description Group-Page Description Group-Page Description Group-Page SHOES - INSTALLATION, FRONT DISC SKI/PASS - REMOVAL, REAR ... 23-92 SPECIFICATIONS - EXTERIOR LAMPS ..8L-2 BRAKE ......5-17 SKIS INDICATOR LAMP - DESCRIPTION .
Page 1041 INDEX Description Group-Page Description Group-Page Description Group-Page SPEED SENSOR - REMOVAL, REAR STANDARD PROCEDURE, BRAKE ROTOR STANDARD PROCEDURE, HYDROSTATIC WHEEL ......5-68 MACHINING .
Page 1042 INDEX Description Group-Page Description Group-Page Description Group-Page STANDARD PROCEDURE, TOGGLING STEERING GEAR - OPERATION, SPEED STRUT ASSEMBLY (REAR) - REMOVAL ..2-43 CUSTOMER PREFERENCES ....8N-3 PROPORTIONAL .
Page 1043 ..8N-24 SYSTEM - DESCRIPTION, MEMORY SEAT . 8N-12 9-68 SWITCH - INTREPID - INSTALLATION, SYSTEM - DESCRIPTION, METRIC ..Intro.-7 SWITCH - DESCRIPTION, PASSENGER WASHER FLUID LEVEL ....8R-14 SYSTEM - DESCRIPTION, POWER SEAT .
Page 1044 INDEX Description Group-Page Description Group-Page Description Group-Page SYSTEM CALIBRATION - STANDARD TEMP SENSOR - INSTALLATION, TEST - STANDARD PROCEDURE, TIRE PROCEDURE, HVAC ....24-6 AMBIENT .
Page 1045 INDEX Description Group-Page Description Group-Page Description Group-Page TESTING, COOLING SYSTEM AERATION - TESTING, HEATER PERFORMANCE TEST TESTING, SIDE REPEATER LAMP - DIAGNOSIS ......7-7 - DIAGNOSIS .
Page 1046 INDEX Description Group-Page Description Group-Page Description Group-Page THERMOSTAT - DESCRIPTION, ENGINE TIRE PRESSURE SENSOR - DIAGNOSIS TOW EYE - INSTALLATION, FRONT ..13-10 COOLANT ......7-21 AND TESTING .
Page 1047 INDEX Description Group-Page Description Group-Page Description Group-Page TRANSMISSION OIL COOLER LINES - TUBE - 2.7L - REMOVAL, HEATER UPPER - REMOVAL, 300 M ... . . 23-36 INSTALLATION ......7-39 SUPPLY .
Page 1048 DOOR BODY MOUNTED ....23-112 VEHICLE INFO CENTER - INSTALLATION, INTREPID - REMOVAL ....8R-14 WEATHERSTRIP - REMOVAL, REAR ELECTRONIC .
Page 1049 INDEX Description Group-Page Description Group-Page Description Group-Page WHEEL ROTATION - STANDARD WINDOW ANTENNA MODULE - WINDSHIELD - REMOVAL ....23-98 PROCEDURE, TIRE ....22-7 OPERATION, REAR .
Page 1050 INDEX Description Group-Page Description Group-Page Description Group-Page ACTUATOR - INSTALLATION, CABLE - LAMP - POLICE - REMOVAL, SPOT ..8L-2 REMOTE LOCK ACTUATOR - REMOTE LOCK ..... . . 23-1 LAMP - POLICE - REMOVAL, INSTALLATION, CABLE .

Dodge Intrepid Service Manual

Table of Contents

8W-97 Power Distribution

Cigar Lighter/Power Outlet Description

Power Distribution

Iod Fuse Description

Junction Block Description

Power Distribution Center Description

Engine

Engine 2.7L

Air Cleaner Element Removal

Engine 3.5L

Cylinder Head

Camshaft(S) Description

Cylinder Head Cover(S) Removal

Intake/Exhaust Valves & Seats Description

Valve Springs Description

Valve Stem Seals Removal

Hydraulic Lash Adjusters

Rocker Arms Description

Engine Block Description

Connecting Rod Bearings

Crankshaft Description

Crankshaft Main Bearings Standard Procedure - Crankshaft Main Bearing Fitting

Crankshaft Oil Seal - Front

Crankshaft Oil Seal - Rear

Crankshaft Rear Oil Seal Retainer

Intake Manifold Description

Intake Manifold - Upper

Intake Manifold - Lower Removal

Exhaust Manifold Description

Exhaust Manifold - Right Removal

Exhaust Manifold - Left Removal

Valve Timing

Timing Chain Cover Removal

Engine 3.5L

Description

Timing Belt/Chain and Sprockets Removal Removal - Timing Chain

Air Cleaner Element Removal

Cylinder Head Description

Camshaft Oil Seal(S) Removal

Camshaft(S) Description

Cylinder Head Cover(S) Removal

Intake/Exhaust Valves & Seats Description

Rocker Arm / Adjuster Assembly Description Description - Rocker Arm

Spark Plug Tube Removal

Valve Stem Seals Removal

Valve Springs Description

Engine Block Description

Connecting Rod Bearings

Crankshaft Description

Crankshaft Main Bearings Standard Procedure - Crankshaft Main Bearing Fitting

Crankshaft Oil Seal - Front Removal

Crankshaft Oil Seal - Rear Removal

Crankshaft Rear Oil Seal Retainer Removal

Flex Plate Removal

Piston & Connecting Rod Description

Piston Rings

Structural Collar / Cover Removal

Vibration Damper Removal

Engine Mounting Description

Left Mount Removal

Rear Mount Removal

Right Mount Removal

Lubrication Description

Oil Description

Oil Cooler & Lines Description

Oil Filter Removal

Oil Pan Removal

Oil Pressure Relief Valve Removal

Oil Pressure Switch Description

Oil Pump Removal

Intake Manifold Description

Intake Manifold - Upper Removal

Intake Manifold - Lower Removal

Exhaust Manifold Description

Exhaust Manifold - Right Removal

Exhaust Manifold - Left Removal

Timing Belt Cover(S) - Front Removal

Timing Belt Cover(S) - Rear Removal