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Chrysler PT Cruiser Service & Repair Manual

Chrysler PT Cruiser Service & Repair Manual

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Service & Repair Manual

Chrysler PT

Cruiser

GROUP TAB LOCATOR

Introduction

0

Lubrication & Maintenance

2

Suspension

3

Differential & Driveline

5

Brakes

6

Clutch

7

Cooling

8A

Audio

8B

Chime/Buzzer

8E

Electronic Control Modules

8F

Engine Systems

8G

Heated Systems

8H

Horn

8I

Ignition Control

8J

Instrument Cluster

8L

Lamps

8M

Message Systems

8N

Power Systems

8O

Restraints

8P

Speed Control

8Q

Vehicle Theft Security

8R

Wipers/Washers

8W

Wiring

9

Engine

11

Exhaust System and Turbocharger

13

Frame & Bumpers

14

Fuel System

19

Steering

21

Transaxle

22

Tires/Wheels

23

Body

24

Heating & Air Conditioning

25

Emissions Control

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

Table of Contents

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Chapters

Table of Contents

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Do you have a question about the PT Cruiser and is the answer not in the manual?

Questions and answers

Chris

April 19, 2025

My timing belt broke. How should I move the camshaft sprockets to align them? It says if I move them individually the valves may be damaged.

0

1 comments:

Mr. Anderson

May 10, 2025

After a timing belt break on a Chrysler PT Cruiser, the camshaft sprockets should be manually rotated to proper alignment with the timing marks. However, extreme caution is required. The factory service manual warns not to rotate the camshafts after the belt is removed, as it may cause valve damage. But in the case of a broken belt, manual rotation may be necessary to realign the camshafts. Always rotate the engine from the crankshaft and align all timing marks before belt installation.

This answer is automatically generated

0

Aaron Slaughter

February 28, 2025

Is there a diagram showing how the fuel injector harness runs?

0

1 comments:

Mr. Anderson

May 14, 2025

No, the provided information does not include a diagram for the fuel injector harness routing for a Chrysler PT Cruiser.

This answer is automatically generated

0

Jim Fleischer

May 22, 2025

My 2006 PT cruiser's glove compartment latch broke. Please send me a diagram of what the latch connects to on the inside of the glove box so that I can try to release it from the outside. Thanks

0

Marci Gregson

May 1, 2025

Is there a diagram of where the clutch pilot bearing and input shaft bearing are located?

0

Summary of Contents for Chrysler PT Cruiser

Page 1 Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Chrysler PT Engine Exhaust System and Turbocharger Frame & Bumpers Fuel System Cruiser Steering Transaxle Tires/Wheels Body Heating & Air Conditioning Emissions Control...
Page 3: Table Of Contents
INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATE VEHICLE IDENTIFICATION NUMBER DESCRIPTION ......1 DESCRIPTION - VEHICLE IDENTIFICATION FASTENER IDENTIFICATION NUMBER...
Page 4: Description
INTRODUCTION BODY CODE PLATE (Continued) DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number • (Refer to VEHICLE DATA/VEHICLE INFOR- MATION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for proper breakdown of VIN code.
Page 5 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 3 FASTENER IDENTIFICATION...
Page 6 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 4 FASTENER STRENGTH...
Page 7: 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 SYMBOLS WARNING: USE OF AN INCORRECT FASTENER DESCRIPTION MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY.
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: Torque References Description
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: Vehicle Identification Number
1 = Built in United States by DiamlerChrysler 3 = Built in Mexico by DiamlerChrysler De Mexico Make C = Chrysler 4 = Multi-purpose Passenger Vehicle Less Side Air Bags Vehicle Type 8 = Multi-purpose Passenger Vehicle with Side Air Bags Other F = 1815 - 2267 KG (4000 - 5000 lbs.)
Page 12: Vehicle Safety Certification Label
• Month-Day-Hour (MDH) • Vehicle Identification Number (VIN) • Country Codes • Regulation Number • Regulation Amendment Number • Approval Number VECI LABEL Fig. 11 MANUFACTURER PLATE DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches...
Page 13 LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS LUBRICATION POINTS DESCRIPTION ......1 DESCRIPTION .
Page 14: Fluid Types
This symbol means that the oil has been certified Fig. 4 NLGI SYMBOL by the American Petroleum Institute (API). Diamler- 1 - WHEEL BEARINGS Chrysler only recommends API Certified (GF-3) 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS engine oils that meet the requirements of Material Standard MS-6395.
Page 15: Description - Engine Coolant
LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) DESCRIPTION - ENGINE COOLANT emergency, it should be replaced with the specified coolant as soon as possible. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL DESCRIPTION - TRANSMISSION FLUID BASE COOLANT AND IS HARMFUL IF SWAL- LOWED OR INHALED.
Page 16 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) gasoline will provide no benefit over high quality reg- line retailer whether or not his/her gasoline contains ular gasoline, and in some circumstances may result MMT. in poorer performance. It is even more important to look for gasoline with- Light spark knock at low engine speeds is not out MMT in Canada because MMT can be used at harmful to your engine.
Page 17: Fluid Capacities
LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) perature is high, use a premium unleaded fuel to FLUID FILL/CHECK help prevent spark knock. If spark knock persists, LOCATIONS lighten the load, or engine piston damage may result. • The use of fuel additives which are now being DESCRIPTION sold as octane enhancers is not recommended.
Page 18 0 - 6 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Check the coolant level, hoses, and clamps. CAUTION: Failure to perform the required mainte- • Rotate the tires at each oil change interval nance items may result in damage to the vehicle. shown on Schedule “A”—NON TURBO CHARGED ENGINES 10 000 km (6,000 miles), Schedule “A”—...
Page 19 LUBRICATION & MAINTENANCE 0 - 7 MAINTENANCE SCHEDULES (Continued) Miles 21,000 24,000 27,000 30,000 33,000 36,000 (Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000) Change engine oil and engine oil filter. Inspect the brake linings. Replace the engine air cleaner filter.
Page 20 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 57,000 60,000 63,000 66,000 69,000 72,000 (Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000) Change engine oil and engine oil filter. Inspect the brake linings. Replace the engine air cleaner filter.
Page 21 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 93,000 96,000 99,000 100,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000) Change engine oil and engine oil filter. Inspect the brake linings. Change the brake fluid.
Page 22 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) SCHEDULE “A”—NON TURBO CHARGED ENGINES Miles 6,000 12,000 18,000 24,000 30,000 36,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000) [Months] [12] [18] [24] [30] [36] Change engine oil and engine oil filter.
Page 23 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) Miles 72,000 78,000 84,000 90,000 96,000 102,000 (Kilometers) (115 000) (125 000) (134 000) (144 000) (154 000) (163 000) [Months] [72] [78] [84] [90] [96] [102] Change engine oil and engine oil filter.
Page 24 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) SCHEDULE “A”—2.4L TURBO CHARGED ENGINES Miles 5,000 10,000 15,000 20,000 25,000 30,000 (Kilometers) (8 000) (16 000) (24 000) (32 000) (40 000) (48 000) [Months] [12] [18] [24] Change engine oil and engine oil filter.
Page 25 LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) Miles 90,000 95,000 100,000 105,000 (Kilometers) (144 000) (156 000) (160 000) (168 000) [Months] [72] [78] [84] Change engine oil and engine oil filter. Inspect the brake linings. Replace the engine air cleaner filter. Replace the spark plugs.
Page 26: Hoisting
0 - 14 LUBRICATION & MAINTENANCE HOISTING JUMP STARTING STANDARD PROCEDURE - HOISTING STANDARD PROCEDURE - JUMP STARTING Refer to Owner’s Manual provided with vehicle for WARNING: REVIEW ALL SAFETY PRECAUTIONS proper emergency jacking procedures. AND WARNINGS IN BATTERY/STARTING/CHARG- WARNING: THE HOISTING AND JACK LIFTING ING SECTIONS.
Page 27: Towing
LUBRICATION & MAINTENANCE 0 - 15 JUMP STARTING (Continued) trical arc will result. Review all warnings in this pro- TOWING cedure. (5) On disabled vehicle connect RED jumper cable STANDARD PROCEDURE - TOWING clamp to positive (+) remote terminal. Connect BLACK jumper cable clamp to engine ground as WARNING: DO NOT ALLOW TOWING ATTACHMENT close to the ground cable attaching point as possible...
Page 29 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page FRONT SUSPENSION ..... 1 WHEEL ALIGNMENT ..... 52 REAR SUSPENSION .
Page 30: Front Suspension
2 - 2 FRONT SUSPENSION AND HEALTH ADMINISTRATION (OSHA) AND THE FRONT SUSPENSION ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSI- DESCRIPTION - FRONT SUSPENSION TION OF DUST OR DEBRIS THAT MAY CONTAIN This vehicle has a gas pressurized MacPherson ASBESTOS FIBERS.
Page 31 FRONT SUSPENSION 2 - 3 FRONT SUSPENSION (Continued) Fig. 1 Front Suspension System...
Page 32: Specifications
2 - 4 FRONT SUSPENSION FRONT SUSPENSION (Continued) 1 - UPPER MOUNT 11 - HUB 2 - VEHICLE STRUT TOWER 12 - KNUCKLE 3 - OUTER TIE ROD 13 - STRUT 4 - JAM NUT 14 - LOWER SPRING ISOLATOR 5 - STEERING GEAR 15 - COIL SPRING 6 - CROSSMEMBER...
Page 33 FRONT SUSPENSION 2 - 5 FRONT SUSPENSION (Continued) Remover 6804 Remover C-4150A Socket/Wrench Strut Nut 6864 Press, Ball Joint C-4212F Remover/Installer 6908 (–2) Installer Adapter C-4698-2 Remover MB-990799 Remover/Installer 8373 Remover MB991113...
Page 34: Hub / Bearing Description
2 - 6 FRONT SUSPENSION and tapped legs on the leading end casting to support HUB / BEARING and align the front disc brake caliper adapter. The knuckle supports the wheel bearing and hub DESCRIPTION (Fig. 1). The wheel hub is pressed into a sealed-for- The wheel bearing and hub are pressed into the life wheel bearing that is pressed into the steering steering knuckle.
Page 35 FRONT SUSPENSION 2 - 7 KNUCKLE (Continued) Fig. 2 Hub Nut 1 - HUB NUT Fig. 4 Tie Rod Removal 2 - NUT LOCK 3 - COTTER PIN 1 - OUTER TIE ROD 4 - SPRING WASHER 2 - STEERING KNUCKLE (7) Remove the front disc brake caliper and (10) Remove the tie rod heat shield.
Page 36: Disassembly - Steering Knuckle (Wheel Bearing And Hub)
2 - 8 FRONT SUSPENSION KNUCKLE (Continued) (13) Separate the ball joint stud from the steering (1) Remove steering knuckle, hub, and wheel bear- knuckle by prying down on lower control arm and up ing as an assembly from the vehicle. (Refer to 2 - against the ball joint boss on the steering knuckle SUSPENSION/FRONT/KNUCKLE - REMOVAL) (Fig.
Page 37 FRONT SUSPENSION 2 - 9 KNUCKLE (Continued) (4) Install the Bearing Splitter, Special Tool 1130, (8) Remove the three bolts mounting the bearing between the hub and the bearing retainer plate as retainer plate to the steering knuckle (Fig. 11). shown (Fig.
Page 38: Assembly - Steering Knuckle (Wheel Bearing And Hub)
2 - 10 FRONT SUSPENSION KNUCKLE (Continued) Place Remover/Installer, Special Tool 6644-2 on end of hub. Press the hub out of the bearing race. Fig. 14 Wheel Bearing Installation 1 - PRESS RAM 2 - BEARING Fig. 13 Bearing Race Removal From Hub 1 - ARBOR PRESS (a) Place the studs in the three holes in the hub 2 - HUB...
Page 39: Installation - Steering Knuckle
FRONT SUSPENSION 2 - 11 KNUCKLE (Continued) (8) Place the steering knuckle with the wheel bear- once installed. Install the nuts. Holding the bolts in ing installed back in the arbor press with the smaller place tighten the nuts to a torque of 53 N·m (40 ft. end of Remover/Installer, Special Tool MB-990799, lbs.) plus an additional 90°...
Page 40: Lower Ball Joint
2 - 12 FRONT SUSPENSION LOWER BALL JOINT DIAGNOSIS AND TESTING - BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the headless grease fitting as shown (Fig. 18). With no mechanical assistance or added force, attempt to move the grease fitting.
Page 41: Lower Control Arm Description
FRONT SUSPENSION 2 - 13 LOWER BALL JOINT SEAL BOOT (Continued) CAUTION: It is important to lubricate the ball joint OPERATION before installation of steering knuckle to allow The lower control arm supports the lower end of proper venting when the seal is filled. If the ball the steering knuckle and allows for the up and down joint is lubricated after installation to knuckle, dam- movement of the suspension during the jounce and...
Page 42: 3 - Ball Joint
2 - 14 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (b) Remove the drive-belt splash shield fasteners (Fig. 23). Remove the shield. (c) Remove the pencil strut from the right front corner of the crossmember and body of the vehicle (Fig. 24). Remove the washer behind the strut from the torque strut bolt.
Page 43: Disassembly - Lower Control Arm (Rear Isolator Bushing)
FRONT SUSPENSION 2 - 15 LOWER CONTROL ARM (Continued) (8) Remove the front pivot bolt attaching the lower control arm to the front suspension crossmember (Fig. 25). Remove the rear pivot bolt attaching the lower control arm to the front suspension crossmem- ber and frame rail.
Page 44: Assembly
2 - 16 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (2) Place the lower control arm outer flange against the Receiver as shown (Fig. 28). Tighten the screw-drive until the Driver contacts the outer cir- cumference of the bushing evenly (Fig. 28). Continue to tighten the screw-drive until the bushing is pressed completely out of the lower control arm.
Page 45: Assembly - Lower Control Arm (Rear Isolator Bushing)
FRONT SUSPENSION 2 - 17 LOWER CONTROL ARM (Continued) ASSEMBLY - LOWER CONTROL ARM (REAR ISOLATOR BUSHING) (1) Back the ball joint press C-4212F set screw outward so it does not extend out into the cup area (Fig. 32). Fig. 31 Seal Boot Installation 1 - SEAL BOOT UPWARD LIP 2 - BALL JOINT (6) Place a new ball joint seal boot over the ball...
Page 46 2 - 18 FRONT SUSPENSION LOWER CONTROL ARM (Continued) Fig. 34 Installing Bushing 1 - LOWER CONTROL ARM FLANGE 2 - ISOLATOR BUSHING (b) Install the washer on the end of the stud extending from the torque strut bolt (Fig. 24). (c) Install the pencil strut to the right front cor- ner of the crossmember and body of the vehicle (Fig.
Page 47: Stabilizer Bar Description
FRONT SUSPENSION 2 - 19 LOWER CONTROL ARM (Continued) (11) If previously loosened, tighten the stabilizer (3) Remove the stabilizer bar cushion retainer bar cushion retainer bolts to a torque of 28 N·m (250 bolts and retainers (Fig. 35), and remove the stabi- in.
Page 48: Strut Assembly Description
2 - 20 FRONT SUSPENSION STABILIZER BAR (Continued) formed into the cushion retainers to the grooves OPERATION formed into the cushions. Install the cushion retainer The strut assembly cushions the ride of the vehicle, bolts, but do not completely tighten them at this controlling vibration, jounce and rebound of the sus- time.
Page 49: Disassembly
FRONT SUSPENSION 2 - 21 STRUT ASSEMBLY (Continued) (2) Remove tire and wheel assembly. (3) If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. (4) Remove the screw securing the ground strap to the rear of the strut (Fig.
Page 50 2 - 22 FRONT SUSPENSION STRUT ASSEMBLY (Continued) Fig. 40 Upper Mounting Nuts 1 - NUTS For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Ser- vice Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufactur- er’s instructions closely.
Page 51 FRONT SUSPENSION 2 - 23 STRUT ASSEMBLY (Continued) Fig. 42 Strut Assembly In Compressor (Upper) Fig. 44 Strut Assembly Components 1 - NOTCH IN UPPER SEAT 2 - UPPER MOUNT 1 - NUT 3 - UPPER HOOKS 2 - STRUT ASSEMBLY 4 - CLEVIS BRACKET 3 - STRUT 4 - LOWER SPRING ISOLATOR...
Page 52: Assembly
2 - 24 FRONT SUSPENSION STRUT ASSEMBLY (Continued) • Inspect the upper and lower spring isolators for on the lower end of the coil spring and strut, so the material deterioration and distortion. strut is held in place. • Inspect the coil spring for any sign of damage to (5) Install the jounce bumper on the strut shaft.
Page 53 FRONT SUSPENSION 2 - 25 STRUT ASSEMBLY (Continued) CAUTION: The strut assembly-to-steering knuckle of the strut (rearward ear) using its mounting screw attaching bolts are serrated and must not be turned (Fig. 39). Tighten the mounting screw to a torque of 13 N·m (120 in.
Page 54 2 - 26 REAR SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION REMOVAL ......41 DESCRIPTION - REAR SUSPENSION .
Page 55: Warning
REAR SUSPENSION 2 - 27 REAR SUSPENSION (Continued) Fig. 1 Rear Suspension System 1 - ISOLATORS 5 - WATTS LINK (LOWER) 2 - JOUNCE BUMPER 6 - BELL CRANK 3 - SHOCK ABSORBER 7 - AXLE 4 - WATTS LINK (UPPER) 8 - COIL SPRING COMPONENTS WITH A FINE MIST OF WATER, WARNING...
Page 56: Specifications
2 - 28 REAR SUSPENSION REAR SUSPENSION (Continued) DESCRIPTION N·m Lbs. Lbs. Shock Absorber Lower — Mounting Bolt Shock Absorber Upper — Mounting Bolt Stabilizer Bar Cushion — Retainer Bolt Stabilizer Bar Link Bolts And — Nuts Watts Link Bell Crank Pivot —...
Page 57: Axle - Front Wheel Drive Rear Description
REAR SUSPENSION 2 - 29 NEGATIVE CABLE. ALLOW THE SYSTEM CAPACI- AXLE - FRONT WHEEL DRIVE TOR TO DISCHARGE FOR TWO (2) MINUTES. FAIL- REAR URE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL DESCRIPTION INJURY. The steel rear axle on this vehicle is a twist beam NOTE: Before proceeding, (Refer to 2 - SUSPEN- design (Fig.
Page 58 2 - 30 REAR SUSPENSION AXLE - FRONT WHEEL DRIVE REAR (Continued) (11) On vehicles equipped with rear disc brakes: (a) Remove the bolts securing the disc brake flex hoses to the axle trailing arms. (b) Remove the disc brake caliper guide pin bolts, then the calipers from the disc brake adapt- ers (Fig.
Page 59 REAR SUSPENSION 2 - 31 AXLE - FRONT WHEEL DRIVE REAR (Continued) (b) Remove the actuating spring between the brake shoe adjustment lever and the brake shoe (Fig. 9). (c) Remove the parking brake cable from the rear brake support plate. The parking brake cable can be removed from brake support plate using a ⁄...
Page 60 2 - 32 REAR SUSPENSION AXLE - FRONT WHEEL DRIVE REAR (Continued) Fig. 10 Parking Brake Cable Removal Fig. 12 Parking Brake Cable Removal 1 - PARK BRAKE CABLE 1 - CABLE RETAINER 2 - 1/2 WRENCH 2 - OFFSET BOX WRENCH 3 - REAR BRAKE SUPPORT PLATE 3 - PARKING BRAKE CABLE 4 - PARK BRAKE CABLE RETAINER...
Page 61: Inspection
REAR SUSPENSION 2 - 33 AXLE - FRONT WHEEL DRIVE REAR (Continued) INSPECTION Verify proper torque of all axle fasteners. Inspect the axle looking for damage or bending. If damage is evident, the axle must be replaced. Inspect for broken or cracked welds at each end of the twist beam within the axle.
Page 62 2 - 34 REAR SUSPENSION AXLE - FRONT WHEEL DRIVE REAR (Continued) Fig. 15 Rear Suspension 1 - ISOLATORS 5 - WATTS LINK (LOWER) 2 - JOUNCE BUMPER 6 - BELL CRANK 3 - SHOCK ABSORBER 7 - AXLE 4 - WATTS LINK (UPPER) 8 - COIL SPRING NOTE: Both ends of the coil spring are identical.
Page 63 REAR SUSPENSION 2 - 35 AXLE - FRONT WHEEL DRIVE REAR (Continued) Fig. 18 Isolator Properly Installed 1 - ISOLATOR ABUTMENT 2 - FINGERS Fig. 16 Stabilizer Bar Mounting mounting bolt and tighten it to a torque of 149 N·m 1 - LINK (110 ft.
Page 64 2 - 36 REAR SUSPENSION AXLE - FRONT WHEEL DRIVE REAR (Continued) Fig. 19 Coil Spring Orientation 1 - IMAGINARY LINE • Install the actuating spring to the brake shoe and the brake adjustment lever (Fig. 9). (21) On vehicles equipped with rear disc brakes, on each side of the vehicle: •...
Page 65: Axle Pivot Bushing Removal
REAR SUSPENSION 2 - 37 AXLE - FRONT WHEEL DRIVE REAR (Continued) (25) On vehicles equipped with rear disc brakes (39) Reinstall the air cleaner cover. (Fig. 6): (40) Place the vehicle on an alignment rack or (a) Install the brake rotors. drive-on hoist.
Page 66: Installation
2 - 38 REAR SUSPENSION AXLE PIVOT BUSHING (Continued) (12) Place Receiver, Special Tool 8405-1, on Press, (4) Place the Press, Special Tool C-4212F, with Special Tool C-4212F, and tighten the set screw (Fig. Receiver, Special Tool 8405-1, installed, over the arm, 21).
Page 67: Hub / Bearing Description
REAR SUSPENSION 2 - 39 AXLE PIVOT BUSHING (Continued) (c) Install the nut on the inboard end of the nut. HUB / BEARING Tighten the nut until the bracket has resistance when turned, but still moves independent of the DESCRIPTION axle bushing.
Page 68: Removal
2 - 40 REAR SUSPENSION HUB / BEARING (Continued) REMOVAL NOTE: Before proceeding, (Refer to 2 - SUSPEN- SION/REAR - WARNING). (1) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove the rear tire and wheel assembly. (3) On vehicles equipped with rear drum brakes, remove the brake drum retaining clips, then the drum (Fig.
Page 69: Installation
REAR SUSPENSION 2 - 41 HUB / BEARING (Continued) (6) Remove the hub and bearing retaining nut DIAGNOSIS AND TESTING - SHOCK from the spindle, then remove the hub and bearing ABSORBER (Fig. 23). Inspect the shock absorber for damage and evi- dence of fluid running from the upper end of the INSTALLATION fluid reservoir.
Page 70: Removal
2 - 42 REAR SUSPENSION SHOCK ABSORBER (Continued) (3) Install the washer and nut on the end of the (4) On vehicles equipped with rear disc brakes: shock absorber lower mounting bolt. Tighten the lower (a) Remove the bolts securing the disc brake flex mounting bolt to a torque of 88 N·m (65 ft.
Page 71: Installation
REAR SUSPENSION 2 - 43 SPINDLE (Continued) Fig. 27 Rear Disc Brakes 1 - DISC BRAKE ADAPTER 2 - GUIDE PIN BOLTS Fig. 29 Wheel Speed Sensor 3 - HUB AND BEARING 4 - BRAKE ROTOR 1 - SHOCK ABSORBER 5 - RETAINER CLIP 2 - RIGHT REAR WHEEL SPEED SENSOR 6 - DUST CAP...
Page 72: Spring Description
2 - 44 REAR SUSPENSION SPINDLE (Continued) (9) On vehicles equipped with rear disc brakes straight above the rear axle beam in line with the (Fig. 27): rear wheels. A spring isolator is attached to each end (a) Install the brake rotor. of the coil springs.
Page 73: Installation
REAR SUSPENSION 2 - 45 SPRING (Continued) (4) If equipped with a rear stabilizer bar, remove the bolts securing the stabilizer bar cushion retainers to the rear axle (Fig. 31), then remove the stabilizer bar from the axle. Fig. 32 Isolator Properly Installed 1 - ISOLATOR ABUTMENT 2 - FINGERS (3) The coil springs require proper orientation to...
Page 74 2 - 46 REAR SUSPENSION SPRING (Continued) Fig. 33 Coil Spring Orientation 1 - IMAGINARY LINE (8) Install the bolt from the front securing the watts link bell crank to the center of the axle (Fig. 30). Place the washer and nut on the end of the mounting bolt and tighten it to a torque of 149 N·m (110 ft.
Page 75: Stabilizer Bar Description
REAR SUSPENSION 2 - 47 STABILIZER BAR DESCRIPTION Some versions of this vehicle are equipped with a rear stabilizer bar. The stabilizer bar interconnects the rear axle with the frame rails of the vehicle (Fig. 35). Attachment of the stabilizer bar to the rear frame rails of the vehicle is through 2 rubber-isolator stabi- lizer bar links.
Page 76: Installation
2 - 48 REAR SUSPENSION STABILIZER BAR CUSHIONS (Continued) INSTALLATION (5) Tighten the stabilizer bar link upper bolt and lower nut to a torque of 65 N·m (48 ft. lbs.). (1) Install the cushions on the stabilizer bar by opening the slit in each cushion and wrapping it around the bar.
Page 77: Operation
REAR SUSPENSION 2 - 49 WATTS LINK ASSEMBLY (Continued) OPERATION WATTS BELL CRANK The watts link assembly serves the same purpose REMOVAL as a track bar. That is, it is used to control rear axle lateral movement and provides cross-car location of the axle.
Page 78 2 - 50 REAR SUSPENSION WATTS BELL CRANK (Continued) Fig. 37 Rear Suspension 1 - ISOLATORS 5 - WATTS LINK (LOWER) 2 - JOUNCE BUMPER 6 - BELL CRANK 3 - SHOCK ABSORBER 7 - AXLE 4 - WATTS LINK (UPPER) 8 - COIL SPRING (4) Slide the bell crank pivot bolt all the way through the axle.
Page 79: Watts Link Removal
REAR SUSPENSION 2 - 51 NOTE: The upper link extends from the right side of WATTS LINK the vehicle to the upper end of the bell crank while the lower link extends from the left side of the vehi- REMOVAL cle to the lower end of the bell crank.
Page 80 2 - 52 WHEEL ALIGNMENT WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT STANDARD PROCEDURE - WHEEL DESCRIPTION - WHEEL ALIGNMENT ..52 ALIGNMENT ......58 DIAGNOSIS AND TESTING - SUSPENSION SPECIFICATIONS AND STEERING...
Page 81 WHEEL ALIGNMENT 2 - 53 WHEEL ALIGNMENT (Continued) CROSS CAMBER Cross camber is the difference between left and Toe is the inward or outward angle of the wheels right camber. To achieve the cross camber reading, as viewed from above the vehicle (Fig. 3). •...
Page 82 2 - 54 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) TOE-OUT ON TURNS STEERING AXIS INCLINATION (S.A.I.) Toe-out on turns is the relative positioning of the Steering axis inclination is the angle between a front wheels while steering through a turn (Fig. 4). true vertical line starting at the center of the tire at This compensates for each front wheel’s turning the road contact point and a line drawn through the...
Page 83 WHEEL ALIGNMENT 2 - 55 WHEEL ALIGNMENT (Continued) THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle’s center line (Fig. 6). The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking).
Page 84 2 - 56 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine With 1. Defective Wheel Bearing 1. Replace Wheel Bearing Vehicle Going Straight At A Constant Speed 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3.
Page 85 WHEEL ALIGNMENT 2 - 57 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Excessive Steering Free 1. Incorrect Steering Gear 1. Adjust Or Replace Steering Gear Play Adjustment 2. Worn Or Loose Tie Rod Ends 2. Replace Or Tighten Tie Rod Ends 3.
Page 86 2 - 58 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) STANDARD PROCEDURE - WHEEL ALIGNMENT ment settings to the vehicle specifications for camber, caster and toe-in. (Refer to 2 - SUSPENSION/ WHEEL ALIGNMENT - SPECIFICATIONS) PRE-WHEEL ALIGNMENT INSPECTION REAR CAMBER AND TOE CAUTION: If during the inspection the front suspen- Rear camber and rear toe settings on this vehicle sion crossmember shows any sign of impact dam-...
Page 87 WHEEL ALIGNMENT 2 - 59 WHEEL ALIGNMENT (Continued) FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle’s suspension compo- nents. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components.
Page 88 2 - 60 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) FRONT TOE (1) Center the steering wheel and lock it in place using a steering wheel clamp. CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie rod during the front toe adjustment.
Page 89 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page HALF SHAFT ......1 HALF SHAFT TABLE OF CONTENTS page...
Page 90: Half Shaft
3 - 2 HALF SHAFT HALF SHAFT (Continued) Fig. 1 Unequal Length Halfshaft System 1 - STUB AXLE 8 - OUTER C/V JOINT 2 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT 3 - OUTER C/V JOINT BOOT 10 - INNER TRIPOD JOINT BOOT 4 - TUNED RUBBER DAMPER WEIGHT 11 - INNER TRIPOD JOINT 5 - INTERCONNECTING SHAFT - RH...
Page 91: Diagnosis And Testing - Halfshaft Diagnosis
HALF SHAFT 3 - 3 HALF SHAFT (Continued) Fig. 2 Halfshaft and Intermediate Shaft (2.2L TD Shown—2.4L Turbo Similar) 1 - HALFSHAFT (LH) 4 - BOLT (3) 2 - TRANSAXLE 5 - HALFSHAFT (RH) 3 - INTERMEDIATE SHAFT inner or outer joint seal boot or seal boot clamp dam- age.
Page 92: Removal-Except Diesel And Turbo Models
3 - 4 HALF SHAFT HALF SHAFT (Continued) (2) A loose or missing clamp on the inner or outer joint of the halfshaft assembly. This may be accom- panied by the visible loss of grease. (3) A damaged or worn halfshaft C/V joint. Isolate the noise to one side of the vehicle.
Page 93 HALF SHAFT 3 - 5 HALF SHAFT (Continued) Fig. 6 Steering Knuckle at Lower Control Arm Ball Joint 1 - NUT 2 - BOLT 3 - BALL JOINT Fig. 8 Separating Halfshaft from Hub/Bearing 1 - PULLER 1026 2 - HALFSHAFT sharply with a hammer to dislodge the right inner joint from the side gear.
Page 94: Removal-Diesel And Turbo Models
3 - 6 HALF SHAFT HALF SHAFT (Continued) CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER–SIZED BOLT AND NUT through front hub.
Page 95 HALF SHAFT 3 - 7 HALF SHAFT (Continued) (7) Remove nut and bolt (Fig. 13) retaining ball (9) Remove halfshaft from steering knuckle by joint stud into steering knuckle. pulling outward on knuckle while pressing in on half- shaft. Support outer end of halfshaft assembly. If dif- ficulty separating halfshaft...
Page 96: Installation Installation-Except Diesel And Turbo Models
3 - 8 HALF SHAFT HALF SHAFT (Continued) Fig. 16 Halfshaft and Intermediate Shaft—2.2L Turbo Diesel 1 - HALFSHAFT (LH) 4 - BOLT (3) 2 - TRANSAXLE 5 - HALFSHAFT (RH) 3 - INTERMEDIATE SHAFT diate shaft bearing-to-bracket bolts. Remove interme- (1) Thoroughly clean spline and oil seal sealing diate shaft bearing/shaft assembly from transaxle.
Page 97 HALF SHAFT 3 - 9 HALF SHAFT (Continued) Fig. 17 Halfshaft and Intermediate Shaft—2.4L Turbo Models 1 - HALFSHAFT (LH) 4 - INTERMEDIATE SHAFT 2 - TRANSAXLE 5 - HALFSHAFT (RH) 3 - BOLT 6 - BOLT (2) Fig. 18 Steering Knuckle to C/V Joint Sealing Area Fig.
Page 98: Installation-Diesel And Turbo Models
3 - 10 HALF SHAFT HALF SHAFT (Continued) Fig. 22 Wheel and Tire Installation 1 - WHEEL/TIRE ASSY. Fig. 20 Halfshaft Installation Into Hub And Knuckle 2 - LUG NUT (5) 3 - HUB 1 - NUT 2 - BOLT INSTALLATION—DIESEL AND TURBO MODELS 3 - BALL JOINT (8) Clean all foreign matter from threads of half-...
Page 99 HALF SHAFT 3 - 11 HALF SHAFT (Continued) (6) Install a NEW steering knuckle to ball joint stud bolt and nut (Fig. 25). Tighten the nut and bolt to 95 N·m (70 ft. lbs.). Fig. 23 Steering Knuckle to C/V Joint Sealing Area 1 - STEERING KNUCKLE 2 - WHEEL BEARING 3 - FRONT HUB...
Page 100: Specifications - Torque
3 - 12 HALF SHAFT HALF SHAFT (Continued) (11) Lower vehicle. (12) Connect battery negative cable. Fig. 27 Wheel and Tire Installation 1 - WHEEL/TIRE ASSY. 2 - LUG NUT (5) 3 - HUB (10) Check for correct fluid level in transaxle assembly.
Page 101: Cv Boot - Inner Removal
HALF SHAFT 3 - 13 (3) Slide the interconnecting shaft and spider CV BOOT - INNER assembly out of the tripod joint housing (Fig. 29). REMOVAL To remove sealing boot from halfshaft for replace- ment, the halfshaft assembly must be removed from the vehicle.
Page 102: Installation
3 - 14 HALF SHAFT CV BOOT - INNER (Continued) Fig. 32 Sealing Boot Installation on Interconnecting Fig. 31 Spider Assembly Removal from Shaft Interconnecting Shaft 1 - SEALING BOOT 1 - SPIDER ASSEMBLY 2 - RAISED BEAD IN THIS AREA OF SEALING BOOT 2 - DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN 3 - GROOVE REMOVING SPIDER ASSEMBLY...
Page 103 HALF SHAFT 3 - 15 CV BOOT - INNER (Continued) Fig. 34 Installing Spider Assembly On Fig. 36 Installing Tripod Housing on Spider Interconnecting Shaft Assembly 1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER 1 - TRIPOD JOINT HOUSING ASSEMBLY 2 - SPIDER ASSEMBLY 2 - SPIDER ASSEMBLY...
Page 104 3 - 16 HALF SHAFT CV BOOT - INNER (Continued) Fig. 38 Sealing Boot Retaining Clamp Installed Fig. 39 Trim Stick Inserted for Venting Tripod Joint 1 - CLAMP 1 - INNER TRIPOD JOINT SEALING BOOT 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED 2 - SEALING BOOT CLAMP COMPLETELY TOGETHER HERE 3 - INNER TRIPOD JOINT HOUSING...
Page 105 HALF SHAFT 3 - 17 CV BOOT - INNER (Continued) Fig. 41 Sealing Boot End to End Length with Fig. 43 Sealing Boot Retaining Clamp Installed Silicone Boot 1 - CLAMP 1 - 105 MILLIMETERS 2 - TRIPOD HOUSING 2 - SILICONE SEALING BOOT 3 - SPECIAL TOOL C-4975A 3 - CLAMP 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED...
Page 106: Cv Boot - Outer Removal
3 - 18 HALF SHAFT CV BOOT - INNER (Continued) (3) Wipe away grease to expose outer C/V joint and interconnecting shaft. (4) Remove outer C/V joint from interconnecting shaft using the following procedure: Support inter- connecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to intercon- necting shaft.
Page 107: Installation
HALF SHAFT 3 - 19 CV BOOT - OUTER (Continued) (6) Slide sealing boot off interconnecting shaft. (7) Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of exces- sive wear, the halfshaft assembly will require replacement.
Page 108 3 - 20 HALF SHAFT CV BOOT - OUTER (Continued) Fig. 54 Crimping Tool Installed on Sealing Boot Fig. 52 Crimping Tool Installed on Sealing Boot Clamp Clamp 1 - CLAMP 1 - SPECIAL TOOL C-4975A 2 - TRIPOD JOINT HOUSING 2 - INTERCONNECTING SHAFT 3 - SPECIAL TOOL C-4975A 3 - CLAMP...
Page 109 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 110: Brakes - Base
5 - 2 BRAKES - BASE DRUM INSTALLATION - RHD ....49 DIAGNOSIS AND TESTING - BRAKE DRUM . . . 35 PROPORTIONING VALVE STANDARD PROCEDURE - BRAKE DRUM DESCRIPTION .
Page 111: Operation - Base Brake System
BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) on one hydraulic circuit and the right front and left ING ASBESTOS FIBERS IN AN IMPERMEABLE rear are on the other. CONTAINER WITH THE APPROPRIATE LABEL. FOL- Front disc brakes control the braking of the front LOW PRACTICES PRESCRIBED BY THE OCCUPA- wheels;...
Page 112 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) RED BRAKE WARNING INDICATOR CONDITION POSSIBLE CAUSES CORRECTION RED BRAKE WARNING 1. Parking brake lever not fully 1. Release parking brake lever. INDICATOR ON released. 2. Parking brake warning switch on 2.
Page 113 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) OTHER BRAKE CONDITIONS CONDITION POSSIBLE CAUSES CORRECTION BRAKES CHATTER 1. Rear brake drum out of round or 1. Isolate condition as rear or front. disc brake rotor has excessive Reface or replace brake drums or thickness variation.
Page 114: Standard Procedure - Base Brake Bleeding
5 - 6 BRAKES - BASE BRAKES - BASE (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE PEDAL 1. One of the two hydraulic circuits is 1. Inspect system for leaks. Check TRAVEL (ONE FRONT malfunctioning. master cylinder for internal malfunction. WHEEL LOCKS UP DURING HARD BRAKING) PEDAL PULSATES/ 1.
Page 115 BRAKES - BASE 5 - 7 BRAKES - BASE (Continued) Do not allow the master cylinder reservoir to run (6) Bleed the remaining wheel circuits in the same out of brake fluid while bleeding the system. An manner until all air is removed from the brake sys- empty reservoir will allow additional air into the tem.
Page 116: Specifications Brake Actuation System
5 - 8 BRAKES - BASE BRAKES - BASE (Continued) (7) Check the brake pedal travel. If pedal travel is ACTUATION: excessive or has not been improved, some air may Outlet Port Threads- still be trapped in the system. Rebleed the brakes as Right Front and Right 7/16 in.–24 necessary.
Page 117: Special Tools Base Brake System
BRAKES - BASE 5 - 9 BRAKES - BASE (Continued) SPECIAL TOOLS BASE BRAKE SYSTEM Dial Indicator C-3339 Cap Adapter, Brake Pressure Bleeder 6921 Gauge Set C-4007-A Adapters, Brake Pressure 8187 Handle, Universal C-4171 Tubes, Master Cylinder Bleed 8358 Installer, Dust Boot C-4689 Adapter, Brake Pressure 8644...
Page 118: Brake Fluid Level Switch Removal
5 - 10 BRAKES - BASE INSTALLATION BRAKE FLUID LEVEL SWITCH (1) Align the brake fluid level switch with its REMOVAL mounting hole on the left side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until switch...
Page 119 BRAKES - BASE 5 - 11 HYDRAULIC/MECHANICAL (Continued) A square-cut rubber piston seal is located in a machined groove in the caliper cylinder bore. This seal provides a hydraulic seal between the piston and the cylinder wall (Fig. 6). Fig. 8 Adapter, Boots And Pins Fig.
Page 120 5 - 12 BRAKES - BASE HYDRAULIC/MECHANICAL (Continued) Fig. 11 Standard And BR4 Brake Calipers 1 - BRB/BRT FRONT BRAKE CALIPER 2 - ADAPTER Fig. 10 Brake Shoes Mounted In Adapter 3 - ADAPTER 4 - BR4 FRONT BRAKE CALIPER 1 - SPRINGS 2 - INBOARD SHOE 3 - OUTBOARD SHOE...
Page 121: Description - Disc Brakes (Rear)
BRAKES - BASE 5 - 13 HYDRAULIC/MECHANICAL (Continued) DESCRIPTION - DISC BRAKES (REAR) The adapter also mounts the parking brake shoes and actuating cables to the vehicle. All vehicles Rear disc brakes are optional equipment on some equipped with rear disc brakes have a small duo- models of this vehicle (Fig.
Page 122: Diagnosis And Testing - Drum Brake Automatic Adjuster
5 - 14 BRAKES - BASE HYDRAULIC/MECHANICAL (Continued) Fig. 16 Rear Drum Brakes 1 - WHEEL CYLINDER 2 - SEAL 3 - SUPPORT PLATE 4 - BRAKE SHOES 5 - RETAINER CLIP 6 - DUST CAP 7 - NUT 8 - DRUM 9 - HUB AND BEARING Fig.
Page 123: Brake Lines
BRAKES - BASE 5 - 15 HYDRAULIC/MECHANICAL (Continued) (3) Insert a thin screwdriver in the adjustment The steel brake tubing should be inspected period- slot and push back the adjustment lever. With the ically for evidence of corrosion, physical damage or lever in this position, back the star wheel adjustment contact with moving or hot components of the vehi- off approximately 10 notches.
Page 124: Cleaning - Disc Brake Shoes
5 - 16 BRAKES - BASE BRAKE PADS/SHOES - FRONT (Continued) (5) Remove the brake shoes from the disc brake INSPECTION - DISC BRAKE SHOES caliper adapter (Fig. 19). Visually inspect brake shoes (pads) for uneven lin- ing wear. Also inspect for excessive lining deteriora- tion.
Page 125: Brake Pads/Shoes - Rear Disc Removal
BRAKES - BASE 5 - 17 BRAKE PADS/SHOES - FRONT (Continued) (3) Install the disc brake caliper over the brake shoes on the brake caliper adapter. Make sure the springs on the shoes do not get caught in the hole formed into the center of the caliper housing.
Page 126: Cleaning - Disc Brake Shoes
5 - 18 BRAKES - BASE BRAKE PADS/SHOES - REAR DISC (Continued) (5) Hang the brake caliper from rear strut using wire or cord to prevent the weight of the caliper from damaging the brake hose (Fig. 22). Fig. 23 Outboard Brake Shoe 1 - CALIPER FINGERS 2 - RETAINING CLIP Fig.
Page 127: Inspection - Disc Brake Shoes
BRAKES - BASE 5 - 19 BRAKE PADS/SHOES - REAR DISC (Continued) INSPECTION - DISC BRAKE SHOES (4) Lubricate both adapter caliper slide abutments with a liberal amount of Mopar Multipurpose Lubri- Visually inspect brake shoes (pads) for uneven lin- cant, or an equivalent.
Page 128 5 - 20 BRAKES - BASE BRAKE PADS/SHOES - REAR DRUM (Continued) (3) Remove the brake drum retaining clips (if (6) Remove the automatic adjustment lever (Fig. equipped) (Fig. 25). 27)from the brake shoe. Fig. 27 Automatic Adjustment Lever Fig. 25 Drum Brakes 1 - AUTOMATIC ADJUSTMENT LEVER 1 - WHEEL CYLINDER 2 - FRONT BRAKE SHOE ASSEMBLY...
Page 129: Cleaning - Drum Brake Shoes
BRAKES - BASE 5 - 21 BRAKE PADS/SHOES - REAR DRUM (Continued) (8) Remove the lower brake shoe-to-shoe return spring (Fig. 29). Fig. 31 Brake Shoe Removal/Installation 1 - UPPER RETURN SPRING 2 - AUTOMATIC ADJUSTER SCREW Fig. 29 Shoe-To-Shoe Return Spring 3 - TRAILING BRAKE SHOE 4 - WHEEL MOUNTING STUDS 1 - ANCHOR PLATE...
Page 130: Installation
5 - 22 BRAKES - BASE BRAKE PADS/SHOES - REAR DRUM (Continued) Brake shoes with lack of contact at the toe or heel of the brake shoe lining may be improperly ground. Clean and inspect the brake support plate and shoe adjuster screw.
Page 131: Adjustment - Drum Brake Shoes
BRAKES - BASE 5 - 23 BRAKE PADS/SHOES - REAR DRUM (Continued) (12) Install the tire and wheel assemblies. Tighten (5) Remove the brake drum (Fig. 35). the wheel mounting nuts to a torque of 135 N·m (100 (6) Using a brake shoe gauge, Special Tool C-3919 ft.
Page 132: Disc Brake Caliper - Front Removal
5 - 24 BRAKES - BASE BRAKE PADS/SHOES - REAR DRUM (Continued) (9) Once the shoe diameter is set, reinstall the brake drum. (10) Turn the drum. A slight drag should be felt while rotating the drum. (11) Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 N·m (100 ft.
Page 133: Cleaning - Disc Brake Caliper
BRAKES - BASE 5 - 25 DISC BRAKE CALIPER - FRONT (Continued) Fig. 41 Piston Seal Removal 1 - TRIM STICK 2 - SEAL Fig. 40 Piston Removal PARTS. DO NOT SAND OR GRIND BRAKE LINING 1 - WOOD BLOCK UNLESS EQUIPMENT USED IS DESIGNED TO CON- TAIN THE DUST RESIDUE.
Page 134: Installation
5 - 26 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) NOTE: Never use an old piston seal. (6) Install the piston into the bore carefully push- ing it past the piston seal using hand pressure (Fig. (1) Dip the new piston seal in clean brake fluid 44).
Page 135: Disc Brake Caliper - Rear Removal
BRAKES - BASE 5 - 27 DISC BRAKE CALIPER - FRONT (Continued) (4) Install the banjo bolt connecting the brake hose (2) Raise the vehicle. (Refer to LUBRICATION & to the brake caliper (Fig. 39). Install NEW washers MAINTENANCE/HOISTING - STANDARD PROCE- on each side of the hose fitting as the banjo bolt is DURE) guided through the fitting.
Page 136: Disassembly
5 - 28 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) (1) With one hand, push the guide pin bushing sleeve towards the back of the caliper, and at the same time, pull the sleeve out the back of the caliper and bushing (Fig.
Page 137 BRAKES - BASE 5 - 29 DISC BRAKE CALIPER - REAR (Continued) Fig. 50 Removing Bushing From Caliper Fig. 51 Removing Caliper/Piston Dust Boot 1 - CALIPER 1 - CALIPER 2 - BUSHING 2 - SCREWDRIVER 3 - BOOT (1) Following the removal procedure in DISC BRAKE SHOES (Refer to 5 - BRAKES/HYDRAULIC/ NOTE: Do not use a screw driver or other metal tool MECHANICAL/BRAKE PADS/SHOES - REMOVAL),...
Page 138: Cleaning - Disc Brake Caliper
5 - 30 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) CLEANING - DISC BRAKE CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON- TAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS ASBESTOS...
Page 139 BRAKES - BASE 5 - 31 DISC BRAKE CALIPER - REAR (Continued) Fig. 54 Folded Caliper Guide Pin Bushing 1 - CALIPER GUIDE PIN BUSHING Fig. 56 Bushing Correctly Installed In Caliper 1 - BUSHING 2 - CALIPER 3 - BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED AROUND CALIPER BUSHING BORES.
Page 140: Assembly - Disc Brake Caliper (Piston And Seal)
5 - 32 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) (6) Holding the convoluted boot on the opposite end of the bushing, push the steel sleeve through the bushing until the bushing boot is fully seated into the seal groove on that end of sleeve (Fig. 57). Install the other end bushing boot into the groove on that end of the bushing sleeve.
Page 141: Installation
BRAKES - BASE 5 - 33 DISC BRAKE CALIPER - REAR (Continued) (6) Using a hammer and Installer, Special Tool (1) Completely retract the caliper piston back into C-4689, and Handle, Special Tool C-4171, drive the piston bore of the caliper. boot into the counterbore of the caliper (Fig.
Page 142: Installation
5 - 34 BRAKES - BASE DISC BRAKE CALIPER ADAPTER - FRONT (Continued) (2) Remove the front tire and wheel assembly. (6) Remove the abutment shims from the adapter (3) Remove the two brake caliper guide pin bolts (Fig. 63). (Fig.
Page 143: Installation
BRAKES - BASE 5 - 35 DISC BRAKE CALIPER GUIDE PINS (Continued) (1) Raise the vehicle. (Refer to LUBRICATION & INSTALLATION MAINTENANCE/HOISTING - STANDARD PROCE- (1) Lubricate the guide pins and inside the boots DURE) with the packet supplied with the service kit, Syth- (2) Remove the front tire and wheel assembly.
Page 144: Removal
5 - 36 BRAKES - BASE DRUM (Continued) Measure the brake drum diameter before machin- ing. If machining the drum will cause the drum to exceed maximum allowable diameter, do not machine the brake drum. It needs to be replaced. CAUTION: Do not machine the brake drum if it will cause the drum to exceed maximum allowable diameter.
Page 145: Fluid
BRAKES - BASE 5 - 37 CAUTION: Never use any type of a petroleum-based FLUID fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle DIAGNOSIS AND TESTING - BRAKE FLUID brake hydraulic system causing a failure of the CONTAMINATION vehicle brake system.
Page 146: Installation
5 - 38 BRAKES - BASE FLUID RESERVOIR (Continued) (5) Lift the reservoir from the master cylinder right side of the master cylinder housing while the casting. other is attached to the bottom (Fig. 75). (6) Remove the grommets (O-rings) sealing the The ABS master cylinder is a two-outlet design reservoir to the master cylinder housing (Fig.
Page 147: Removal
BRAKES - BASE 5 - 39 MASTER CYLINDER (Continued) inder and tighten in place (Fig. 71). Attach Master (6) Install the fill cap on the reservoir. Cylinder Bleed Tube, Special Tool 8358-2, to the (7) Remove the master cylinder from the vise. secondary port of the master cylinder and tighten in place.
Page 148: Removal - Lhd Without Abs
5 - 40 BRAKES - BASE MASTER CYLINDER (Continued) (7) Disconnect the two brake tubes from the mas- (6) Remove the vehicle wiring harness connector ter cylinder primary and secondary ports (Fig. 73). from brake fluid level switch in master cylinder Install plugs at all of the open brake tube outlets on brake fluid reservoir (Fig.
Page 149: Removal - Rhd
BRAKES - BASE 5 - 41 MASTER CYLINDER (Continued) (10) Slide the master cylinder straight out of the power brake booster with master cylinder piston power brake booster. push rod. Carefully push the master cylinder onto (11) To remove the proportioning valves, unthread the studs until it contacts the face of the booster.
Page 150: Installation - Rhd
5 - 42 BRAKES - BASE MASTER CYLINDER (Continued) (8) Install the power distribution center. PEDAL - WITH AUTOMATIC (9) Connect the negative (ground) cable on the bat- TRANSAXLE tery. (10) Install the air cleaner housing. REMOVAL (11) Reinstall the air cleaner cover (two clips). (12) Fill the master cylinder to the proper level.
Page 151: Installation
BRAKES - BASE 5 - 43 PEDAL - WITH AUTOMATIC TRANSAXLE (Continued) (10) Install the power brake booster input rod on the pin mounted on the side of the brake pedal. Install a new retaining clip on the end of the pin (Fig.
Page 152: Pedal - With Manual Transaxle Removal
5 - 44 BRAKES - BASE PEDAL - WITH MANUAL TRANSAXLE REMOVAL NOTE: Before proceeding, (Refer to 5 - BRAKES - WARNING). (1) Unclip the air cleaner cover (two clips) and move the cover aside. (2) Disconnect and isolate the battery negative cable from its post on the battery.
Page 153: Power Brake Booster Description
BRAKES - BASE 5 - 45 PEDAL - WITH MANUAL TRANSAXLE (Continued) (5) Install the pivot shaft nut (Fig. 81). Tighten (13) Road test the vehicle to ensure proper opera- the nut to a torque of 34 N·m (25 ft. lbs.). tion of the brakes and speed control (if equipped).
Page 154: Operation
5 - 46 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (3) Disconnect the vacuum hose on the side of the vacuum check valve that leads to the speed control, then connect a vacuum gauge to the open vacuum port on the valve. (4) Start the engine.
Page 155: Removal
BRAKES - BASE 5 - 47 POWER BRAKE BOOSTER (Continued) reading. The vacuum loss should be less than 3.0 (8) Disconnect the vacuum hoses from the check inches Hg in 15 seconds time span. If the loss is valve on the power brake booster (Fig. 86), but do not more than 3.0 inches Hg, replace the power brake remove the check valve from power brake booster.
Page 156: Removal - Rhd
5 - 48 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (12) Remove the four nuts attaching the power (10) Locate the brake pedal-to-power brake booster brake booster to the instrument panel (Fig. 88). The input rod attachment under the instrument panel. nuts are accessible from under the instrument panel Position a small screwdriver under the center tang of in the area of the brake pedal bracket.
Page 157: Installation - Rhd
BRAKES - BASE 5 - 49 POWER BRAKE BOOSTER (Continued) (5) Remove and replace the brake lamp switch CAUTION: Do not reuse the original brake lamp with a NEW switch. Discard the original brake lamp switch. The switch can only be adjusted once. That switch.
Page 158: Operation
5 - 50 BRAKES - BASE PROPORTIONING VALVE (Continued) OPERATION Before testing the proportioning valve in question, inspect the rear brake linings for contamination or Proportioning valves balance front to rear braking for replacement shoes not meeting the OEM brake by controlling the brake fluid hydraulic pressure to lining material specifications.
Page 159 BRAKES - BASE 5 - 51 PROPORTIONING VALVE (Continued) CAUTION: Be sure the pressure test fittings being installed into master cylinder and proportioning valve, have the correct thread sizes needed. (5) Install the Brake Pressure Adapters, Special Tool 8644 and 8187-2 onto the proportioning valve (Fig.
Page 160: Removal
5 - 52 BRAKES - BASE PROPORTIONING VALVE (Continued) REMOVAL (3) Unscrew the Proportioning valve from the mas- ter cylinder. NOTE: Before proceeding, (Refer to 5 - BRAKES - INSTALLATION WARNING)(Refer to 5 - BRAKES - CAUTION). (1) Lubricate the O-ring on the proportioning (1) Using a brake pedal holder, depress the brake valve.
Page 161 BRAKES - BASE 5 - 53 ROTOR (Continued) Fig. 95 Front Brake Rotor Comparison Fig. 96 Rear Brake Rotor Comparison 1 - BRB/BRT BRAKE ROTOR 1 - BRT BRAKE ROTOR 2 - STANDARD ROTOR THICKNESS 2 - STANDARD ROTOR THICKNESS 22.91-23.10 MM 8.75-9.25 MM 3 - PERFORMANCE ROTOR THICKNESS...
Page 162 5 - 54 BRAKES - BASE ROTOR (Continued) ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly.
Page 163: Standard Procedure - Brake Rotor Machining
BRAKES - BASE 5 - 55 ROTOR (Continued) Hub runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, the hub must be replaced. For front hub removal, (Refer to 2 - SUSPENSION/FRONT/KNUCKLE - REMOVAL). For rear hub removal, (Refer to 2 - SUSPENSION/ REAR/HUB / BEARING - REMOVAL).
Page 164: Removal
5 - 56 BRAKES - BASE ROTOR (Continued) If the rotor surface is deeply scored or warped, or Minimum allowable thickness is the minimum there is a complaint of brake roughness or brake thickness which the brake rotor machined surface pedal pulsation, the rotor should be refaced using a may be cut to.
Page 165: Installation
BRAKES - BASE 5 - 57 ROTOR (Continued) (3) Install the mounting bolts securing the caliper adapter to the steering knuckle (Fig. 105). Tighten the bolts to a torque of 104 N·m (77 ft. lbs.). (4) Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 N·m (100 ft.
Page 166: Support Plate - Drum Brakes Removal
5 - 58 BRAKES - BASE ROTOR (Continued) BRB/BRT SALES CODE Minimum Rotor Rotor Braking Rotor Rotor Thickness Rotor Thickness Runout* Thickness Variation 22.91–23.10 mm 21.40 mm 0.010 mm 0.13 mm Front Rotor 0.902–0.909 in. 0.843 in. 0.0004 in. 0.005 in. 8.75–9.25 mm 7.25 mm 0.013 mm...
Page 167: Installation
BRAKES - BASE 5 - 59 SUPPORT PLATE - DRUM BRAKES (Continued) Fig. 109 Removing Park Brake Cable From Support Fig. 108 Hub And Bearing/Rear Brakes Plate 1 - WHEEL CYLINDER 1 - WRENCH 2 - SEAL 2 - CABLE HOUSING RETAINER 3 - SUPPORT PLATE 3 - PARK BRAKE CABLE 4 - BRAKE SHOES...
Page 168: Wheel Cylinder - Drum Brake Removal
5 - 60 BRAKES - BASE SUPPORT PLATE - DRUM BRAKES (Continued) (8) Install the rear hub and bearing assembly on (4) Disconnect the rear brake flex hose from the the spindle. Install a new hub and bearing retaining wheel cylinder (Fig. 111). nut (Fig.
Page 169: Inspection
BRAKES - BASE 5 - 61 WHEEL CYLINDER - DRUM BRAKE (Continued) (7) Remove the brake wheel cylinder attaching PARKING BRAKE bolts (Fig. 111). (8) Remove the brake wheel cylinder from the DESCRIPTION brake support plate. The parking brakes consist of the following compo- (9) Remove old sealer from mounting surfaces.
Page 170: Operation
5 - 62 BRAKES - BASE PARKING BRAKE (Continued) The parking brakes on vehicles equipped with rear disc brakes consist of a small duo-servo brake assem- bly mounted to the disc brake caliper adapter (Fig. 114). The hat (center) section of the rear brake rotor serves as the braking surface (drum) for the parking brakes (Fig.
Page 171: Cable - Parking Brake Removal
BRAKES - BASE 5 - 63 PARKING BRAKE (Continued) (4) Remove the screws attaching the center con- (5) Cycle the parking brake lever once to position sole. the parking brake cables, then return the parking (5) Remove rear window switch panel from the brake lever to its released (full OFF) position.
Page 172 5 - 64 BRAKES - BASE CABLE - PARKING BRAKE (Continued) (2) Disconnect and isolate the battery negative cable from its post on the battery. (3) Block the tire and wheels so the vehicle does not move once the vehicle parking brake lever is released.
Page 173 BRAKES - BASE 5 - 65 CABLE - PARKING BRAKE (Continued) (16) Raise the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (17) Remove the rear tire and wheel assembly from the vehicle. (18) On vehicles equipped with rear drum brakes, remove the brake drum.
Page 174 5 - 66 BRAKES - BASE CABLE - PARKING BRAKE (Continued) Fig. 123 Actuating Spring 1 - BRAKE SHOE ADJUSTMENT LEVER 2 - ADJUSTMENT LEVER ACTUATING SPRING Fig. 125 Parking Brake Actuator Lever 3 - PARK BRAKE CABLE 1 - SHOE ACTUATOR LEVER 2 - SHIELD MOUNTING SCREWS 3 - REAR PARKING BRAKE CABLE Fig.
Page 175: Installation
BRAKES - BASE 5 - 67 CABLE - PARKING BRAKE (Continued) (25) Remove the two fasteners securing the cable (3) Align the cable routing brackets with their and routing brackets to the axle trailing arm (Fig. mounts on the trailing arm. Install the two fasteners 127).
Page 176: Lever - Parking Brake Removal
5 - 68 BRAKES - BASE CABLE - PARKING BRAKE (Continued) (17) Raise parking brake handle to full upright URE TO DO THIS COULD RESULT IN ACCIDENTAL (applied) position. AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL (18) Keeping your hands clear of the automatic INJURY.
Page 177: Installation
BRAKES - BASE 5 - 69 LEVER - PARKING BRAKE (Continued) KEEP HANDS OUT OF AUTOMATIC ADJUSTER SECTOR AND PAWL AREA. FAILURE TO OBSERVE CAUTION IN HANDLING THIS MECHANISM COULD LEAD TO SERIOUS INJURY. (1) Place the parking brake lever on the mounting studs on the vehicle floor.
Page 178: Installation
5 - 70 BRAKES - BASE SHOES - PARKING BRAKE (Continued) (4) Remove rear brake rotor. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR REMOVAL) (5) Remove the dust cap from the rear hub and bearing. (6) Remove the rear hub and bearing assembly retaining nut and washer.
Page 179: Adjustment
BRAKES - BASE 5 - 71 SHOES - PARKING BRAKE (Continued) (6) Adjust the parking brake shoes to a diameter of 171 mm (6.75 inch) (Fig. 136). Fig. 136 Measuring Brake Shoes Fig. 134 Brake Shoe and Upper Spring 1 - REAR PARKING BRAKE SHOES 1 - UPPER SPRING 2 - BRAKE SHOE GAUGE 2 - HOLD DOWN CLIP...
Page 180 5 - 72 BRAKES - BASE SHOES - PARKING BRAKE (Continued) • Insert a medium size screwdriver through NOTE: Before proceeding, (Refer to 5 - BRAKES - WARNING)(Refer to 5 - BRAKES - CAUTION). adjustment hole in the right backing plate. Position the screwdriver against the star wheel on the park- (1) Verify the parking brake lever is in the ing brake shoe adjuster.
Page 181 BRAKES - ABS 5 - 73 BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS OPERATION ......78 DESCRIPTION REMOVAL .
Page 182: Brakes - Abs
5 - 74 BRAKES - ABS BRAKES - ABS (Continued) DESCRIPTION - ELECTRONIC VARIABLE NORMAL BRAKING Under normal braking conditions, the ABS func- BRAKE PROPORTIONING tions the same as a standard base brake system with Vehicles equipped with ABS use electronic variable a diagonally split master cylinder and conventional brake proportioning (EVBP) to balance front-to-rear vacuum assist.
Page 183: Operation - Electronic Variable Brake Proportioning
BRAKES - ABS 5 - 75 BRAKES - ABS (Continued) TIRE NOISE AND MARKS diagnosing a vehicle exhibiting premature ABS cycling. Although the ABS system prevents complete wheel After diagnosing the defective component, repair or lockup, some wheel slip is desired in order to achieve replace it as required.
Page 184: Caution Cautions
5 - 76 BRAKES - ABS BRAKES - ABS (Continued) These valves are necessary because the pump/motor CAUTION: Use only factory wiring harnesses. Do supplies more volume than the system requires. not cut or splice wiring to the brake circuits. The If the brakes are applied at anytime during a trac- addition of aftermarket electrical equipment (car tion control cycle, the brake lamp switch triggers the...
Page 185: Standard Procedure - Antilock Brake System Bleeding
BRAKES - ABS 5 - 77 BRAKES - ABS (Continued) (3) Connect the DRBIII scan tool to the Data Before road testing a brake complaint vehicle, note Link Connector located under the instrument panel whether the red BRAKE warning indicator lamp, to the left of the steering column (Fig.
Page 186: Specifications Specifications - Abs Fastener Torque
5 - 78 BRAKES - ABS BRAKES - ABS (Continued) (2) Connect the DRBIII scan tool to the Data WHEEL SPEED SENSOR AIR GAP Link Connector. The connector is located under the lower steering column cover to the left of the steering DESCRIPTION SPECIFICATION column.
Page 187: Removal
BRAKES - ABS 5 - 79 FRONT WHEEL SPEED SENSOR (Continued) (2) Disconnect the wheel speed sensor cable con- nector from the wiring harness on the inside of the frame rail above the front suspension crossmember (Fig. 5). The connector has a locking tab which that must be pulled back before the connector release tang can be depressed, releasing the connection.
Page 188: Installation
5 - 80 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) (4) Remove the speed sensor cable grommet from the retaining bracket attached to the brake hose on the outside of the frame rail. (5) Remove the bolt mounting the wheel speed sen- sor head to the steering knuckle (Fig.
Page 189: Operation
BRAKES - ABS 5 - 81 REAR WHEEL SPEED SENSOR (Continued) The rear wheel speed sensors are mounted through OPERATION the disc brake adapter (Fig. 9) (Fig. 10). The rear The CAB sends 12 volts to power an Integrated tone wheels are mounted to and rotate with the hub Circuit (IC) in the sensor.
Page 190: Installation
5 - 82 BRAKES - ABS REAR WHEEL SPEED SENSOR (Continued) (2) Install the wheel speed sensor mounting bolt. Tighten the mounting bolt to a torque of 12 N·m (105 in. lbs.). (3) Install wheel speed sensor cable into the rout- ing clips on the brake tube, brake hose and axle trailing arm.
Page 191: Traction Control Switch Removal
BRAKES - ABS 5 - 83 TONE WHEEL (Continued) If wheel speed sensor to tone wheel contact is evi- (1) Remove the accessory switch bezel and then dent, determine the cause and correct it before remove the traction control switch from it. (Refer to replacing the wheel speed sensor or tone wheel.
Page 192: Operation - Hydraulic Circuits And Valves
5 - 84 BRAKES - ABS HCU - HYDRAULIC CONTROL UNIT (Continued) These TC valves are used to isolate the rear (non- The pump motor is also used to build pressure driving) wheels of the vehicle from the hydraulic when the system goes into traction control mode. pressure that the HCU pump/motor is sending to the The CAB may turn on the pump/motor when an front (driving) wheels when traction control is being...
Page 193 BRAKES - ABS 5 - 85 HCU - HYDRAULIC CONTROL UNIT (Continued) Fig. 14 Normal Braking Hydraulic Circuit (W/O Traction Control) 1 - OUTLET VALVE 6 - TO RIGHT FRONT WHEEL 2 - PUMP PISTON 7 - NORMALLY OPEN VALVE (OFF) 3 - PUMP MOTOR (OFF) 8 - MASTER CYLINDER PRESSURE 4 - LOW PRESSURE ACCUMULATOR...
Page 194 5 - 86 BRAKES - ABS HCU - HYDRAULIC CONTROL UNIT (Continued) • The normally open and normally closed valves ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE modulate (build/decay) the brake hydraulic pressure FUNCTION (ABS WITHOUT TRACTION CONTROL) as required. The hydraulic diagram (Fig. 15) shows the vehicle •...
Page 195 BRAKES - ABS 5 - 87 HCU - HYDRAULIC CONTROL UNIT (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 16) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle.
Page 196 5 - 88 BRAKES - ABS HCU - HYDRAULIC CONTROL UNIT (Continued) • The hydraulic shuttle valve closes upon brake ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID application so that the pump/motor cannot siphon VALVE, AND SHUTTLE VALVE FUNCTION (ABS brake fluid from the master cylinder. WITH TRACTION CONTROL) •...
Page 197 BRAKES - ABS 5 - 89 HCU - HYDRAULIC CONTROL UNIT (Continued) • The normally open TC (ASR) valve is energized ABS TRACTION CONTROL HYDRAULIC CIRCUIT, to isolate the brake fluid being pumped from the SOLENOID VALVE, AND SHUTTLE VALVE master cylinder and to isolate the driven wheel.
Page 198: Icu - Integrated Control Unit Description
5 - 90 BRAKES - ABS Two different ICU’s (HCU and CAB) are used on ICU - INTEGRATED CONTROL this vehicle depending on whether or not the vehicle UNIT is equipped with traction control. The HCU on a vehicle equipped with traction control has a valve DESCRIPTION block that is approximately one inch longer than a The hydraulic control unit (HCU) and the control-...
Page 199 BRAKES - ABS 5 - 91 ICU - INTEGRATED CONTROL UNIT (Continued) CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.
Page 200: Disassembly - Icu
5 - 92 BRAKES - ABS ICU - INTEGRATED CONTROL UNIT (Continued) (16) Remove the ICU from the vehicle. (3) Remove the CAB from the HCU (Fig. 26). (17) To separate the CAB from the HCU, (Refer to BRAKES/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT) - DISASSEMBLY). DISASSEMBLY - ICU (1) Disconnect the pump/motor wiring harness from the CAB (Fig.
Page 201 BRAKES - ABS 5 - 93 ICU - INTEGRATED CONTROL UNIT (Continued) (4) Install the four brake tubes going to the brakes not completely tighten the primary and secondary into their respective outlet ports on the ICU HCU tubes at this time. (Fig.
Page 203 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH OPERATION ......19 DESCRIPTION .
Page 204: Clutch Description
6 - 2 CLUTCH CLUTCH DESCRIPTION The typical clutch hydraulic system (Fig. 1) (Fig. 2) consists of a clutch master cylinder and integral res- ervoir, a clutch slave cylinder, and an interconnecting fluid line. LHD models have an adjustable pedal pushrod.
Page 205: Diagnosis And Testing Diagnosis And Testing-Clutch System Diagnosis
CLUTCH 6 - 3 CLUTCH (Continued) Slave cylinder spring force causes the release lever pressure plate rearward, relieving clamping force on to hold the release bearing in contact with the dia- the clutch disc. phragm spring, also known as bearing preload. Dur- ing a clutch pedal actuation, the hydraulic fluid DIAGNOSIS AND TESTING pressure applies additional force to the release lever.
Page 206 6 - 4 CLUTCH CLUTCH (Continued) SERVICE DIAGNOSIS - CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear. Replace clutch assembly. Driver frequently rides (slips) clutch, Replace clutch assembly. results in rapid wear, overheating. Insufficient clutch cover diaphragm Replace clutch assembly.
Page 207 CLUTCH 6 - 5 CLUTCH (Continued) SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON Clutch disc hub splines damaged Clean, smooth, and lubricate disc and shaft INPUT SHAFT SPLINES during installation splines. Replace modular clutch assembly, or clutch disc, and/or input shaft if splines are severely damaged.
Page 208: Diagnosis And Testing - Clutch Chatter Complaints
6 - 6 CLUTCH CLUTCH (Continued) DIAGNOSIS AND TESTING - CLUTCH CHATTER Use new bolts when mounting drive plate to crank- shaft. Tighten drive plate bolts to specified torque COMPLAINTS only. Over-tightening can distort the drive plate hub For all clutch chatter complaints, perform the fol- causing excessive runout.
Page 209 CLUTCH 6 - 7 CLUTCH (Continued) 1.6/2.0/2.4L MODELS (Except Turbo) From driver’s seat, actuate clutch pedal 60–100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Per- form the following procedure: (1) Verify fluid level in clutch master cylinder res- ervoir.
Page 210 6 - 8 CLUTCH CLUTCH (Continued) (6) Quickly attach hand operated bleed apparatus to bleed screw. Use care not to over-fill reservoir and spill fluid into engine compartment. (7) Operate bleed gun sufficiently to expel air upward through circuit and out of master cylinder reservoir.
Page 211: Specifications
CLUTCH 6 - 9 CLUTCH (Continued) SPECIFICATIONS CLUTCH/HYDRAULICS/PEDALS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Brake/Clutch Pedal & — Booster-to-Dash Nuts Brake/Clutch Pedal Assembly-to-Instrument — Panel Clutch Cover-to-Flywheel — Bolts Clutch Pedal Pivot Shaft — Damper-to-Transaxle Nuts — Driveplate-to-Crankshaft —...
Page 212: Clutch Disc And Pressure Plate Removal Removal-1.6L
6 - 10 CLUTCH CLUTCH DISC AND PRESSURE PLATE REMOVAL REMOVAL—1.6L (1) Remove transaxle. (Refer to 21 - TRANSMIS- SION/TRANSAXLE/MANUAL - REMOVAL) (2) Mark position of pressure plate on flywheel with paint or a scriber for assembly reference. (3) Loosen and remove six (6) pressure plate-to-fly- wheel bolts.
Page 213: Removal-2.2L Td
CLUTCH 6 - 11 CLUTCH DISC AND PRESSURE PLATE (Continued) REMOVAL—2.2L TD (1) Remove transaxle assembly. (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Mark position of pressure plate on flywheel with paint or a scriber for assembly reference. (3) Loosen and remove six (6) pressure plate-to-fly- wheel bolts.
Page 214: Installation-2.2L Td
6 - 12 CLUTCH CLUTCH DISC AND PRESSURE PLATE (Continued) (9) Tighten pressure plate bolts evenly and in rota- tion a few threads at a time The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate.. (10) Using a “criss-cross”...
Page 215: Operation
CLUTCH 6 - 13 CLUTCH INTERLOCK/UPSTOP SWITCH (Continued) CLUTCH PEDAL UPSTOP SWITCH NOTE: 2.0/2.4L-equipped models do not use the clutch pedal upstop switch/feature. These vehicles only utilize the starter inhibit (interlock) feature. 1.6L and 2.2L Turbo Diesel models: With the clutch pedal at rest, the clutch pedal upstop switch is closed, allowing speed control operation.
Page 216 6 - 14 CLUTCH CLUTCH INTERLOCK/UPSTOP SWITCH (Continued) CLUTCH INTERLOCK SWITCH Mechanical Test (1) With the park brake set and the transaxle IN NEUTRAL, turn the ignition key to the start posi- tion. The engine starter should not crank with the clutch pedal at rest (not depressed).
Page 217 CLUTCH 6 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH (Continued) (6) For RHD applications, disconnect the push rod control does not terminate, the upstop switch is from the pedal pin and actuate the push rod by hand defective or the related wiring is shorted. Proceed to to close the switch.
Page 218: Removal Removal - Lhd
6 - 16 CLUTCH CLUTCH INTERLOCK/UPSTOP SWITCH (Continued) REMOVAL REMOVAL - LHD NOTE: Depending on vehicle build date, some vehi- cles will not have the clutch pedal upstop switch included in the switch assembly. These vehicles will only utilize the starter inhibit (interlock) feature. (1) Disconnect and isolate battery negative cable.
Page 219: Removal - Rhd
CLUTCH 6 - 17 CLUTCH INTERLOCK/UPSTOP SWITCH (Continued) (11) Remove the interlock/upstop switch assembly (Fig. 23) from the brake/clutch pedal bracket assem- bly by depressing the four plastic wing tabs on each switch. Fig. 24 Lower Instrument Panel Bezel—Typical 1 - INSTRUMENT PANEL 2 - INSTRUMENT PANEL STEERING COLUMN COVER Fig.
Page 220: Installation - Rhd
6 - 18 CLUTCH CLUTCH INTERLOCK/UPSTOP SWITCH (Continued) (3) Install brake/clutch pedal bracket assembly location of fasteners intended to keep wires from into position. Install and tighten brake booster contacting pedals. mounting nuts to 34 N·m (300 in. lbs.). Install and (1) Install the clutch interlock/upstop switch onto tighten pedal bracket-to-instrument panel nuts to 34 the master cylinder push rod, making sure that the...
Page 221: Operation
CLUTCH 6 - 19 CLUTCH RELEASE BEARING (Continued) (3) As a unit, remove the lever from the bearing thrust plate. Be careful not to damage retention tabs on bearing. (4) Examine the condition of the bearing. It is pre-lubricated and sealed and should not be immersed in oil or solvent.
Page 222: Flywheel Description
6 - 20 CLUTCH FLYWHEEL DESCRIPTION 1.6L Equipped Models 1.6L Equipped Models utilize a conventional flywheel assembly, which is a solid rotating mass fastened to the rear of the crankshaft (Fig. 29). The flywheel also incor- porates an integral starter ring gear. 2.2L Turbo Diesel Equipped Models The Dual-Mass Flywheel (DMF) is utilized on 2.2L TD/5-speed models.
Page 223: Operation
CLUTCH 6 - 21 FLYWHEEL (Continued) OPERATION The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative to the rotating mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain.
Page 224: Master Cylinder - Lhd Description
6 - 22 CLUTCH MASTER CYLINDER - LHD DESCRIPTION CAUTION: The clutch master cylinder pushrod adjustment must not be used to change pedal free- play or pedal height. Using the adjustable pushrod for these reasons will result in premature clutch wear or system over/undertravel.
Page 225 CLUTCH 6 - 23 MASTER CYLINDER - LHD (Continued) (1) Remove air cleaner assembly (Fig. 35). Fig. 37 Clutch Slave Cylinder Hydraulic Connection—Diesel and Turbo Models 1 - MASTER CYLINDER TUBE 2 - SLAVE CYLINDER Fig. 35 Air Cleaner Assembly Removal/Installation— (5) 1.6/2.0/2.4L Non-Turbo Models:...
Page 226 6 - 24 CLUTCH MASTER CYLINDER - LHD (Continued) (10) Remove clip and disconnect the brake booster input rod from the brake pedal pin (Fig. 41). (11) Remove the brake booster mounting nuts (Fig. 41). Fig. 39 Clutch Slave Cylinder at Transaxle- 2.0L Models Fig.
Page 227: Installation
CLUTCH 6 - 25 MASTER CYLINDER - LHD (Continued) CAUTION: Use care when removing clutch master fluid and has ingested air into the master or slave cylinder from engine compartment. Aggressive han- cylinder assembly. (1) Install clutch master cylinder into position dling can result in a damaged hydraulic tube and improper clutch release operation upon reassembly.
Page 228: Master Cylinder - Rhd Description
6 - 26 CLUTCH MASTER CYLINDER - LHD (Continued) “click” should be heard. Verify connection by pulling outward on connection. (16) Lower vehicle. (17) Connect battery negative cable. (18) Install air cleaner assembly (Fig. 35). (19) Verify that reservoir is full. Top off with DOT 3 brake fluid if necessary.
Page 229 CLUTCH 6 - 27 MASTER CYLINDER - RHD (Continued) NOTE: Replacement master cylinder assemblies come pre-filled with fluid. No fluid service or sys- tem bleeding should be required, unless the hydraulic system has lost an excessive amount of fluid and has ingested air into the master or slave cylinder assembly.
Page 230 6 - 28 CLUTCH MASTER CYLINDER - RHD (Continued) (5) 1.6/2.0/2.4L Non-Turbo Models: Remove slave cylinder from transaxle (Fig. 50) (Fig. 51). Fig. 50 Clutch Slave Cylinder at Transaxle- 1.6L Models 1 - SLAVE CYLINDER 2 - BOLT Fig. 52 Master Cylinder Pipe at Left Rail 1 - RETAINER 2 - MASTER CYLINDER PIPE Fig.
Page 231: Installation
CLUTCH 6 - 29 MASTER CYLINDER - RHD (Continued) (11) Remove clutch master cylinder reservoir (Fig. 54). assemblies. If the master cylinder requires replace- (12) Disengage master cylinder hydraulic pipe ment, the master AND slave cylinders must be from dash panel retainer (Fig. 52). replaced with a two-piece “quick-connect”...
Page 232: Modular Clutch Description
6 - 30 CLUTCH OPERATION MODULAR CLUTCH The modular clutch assembly is designed to trans- DESCRIPTION mit power from the engine to the manual transaxle. This is accomplished by the friction and clamping force generated when the spring loaded pressure 2.0/2.4L MODELS (Except Turbo) plate locks the clutch disc to the flywheel (Fig.
Page 233: Removal
CLUTCH 6 - 31 MODULAR CLUTCH (Continued) REMOVAL (1) Remove transaxle from vehicle. (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL REMOVAL) (2) Remove modular clutch assembly (Fig. 58) from transaxle input shaft. (3) 2.4L Turbo models: Disassemble modular clutch assembly. Remove six (6) pressure plate-to-fly- wheel bolts (Fig.
Page 234: Installation
6 - 32 CLUTCH MODULAR CLUTCH (Continued) (6) pressure plate-to-flywheel bolts to 28 N·m (250 in. lbs.). Visually verify clutch disc alignment. Fig. 59 Pressure Plate-to-Flywheel Bolts—Turbo 1 - BOLT (6) 2 - PRESSURE PLATE Fig. 60 Clutch Disc-to-Flywheel Orientation 3 - DOWEL 1 - FLYWHEEL 2 - CLUTCH DISC...
Page 235: Removal-1.6/2.0/2.4L (Except Diesel And Turbo)
CLUTCH 6 - 33 SLAVE CYLINDER (Continued) Fig. 61 Clutch Slave Cylinder at Transaxle- 1.6L Models 1 - SLAVE CYLINDER 2 - BOLT Fig. 63 Slave Cylinder Location—Diesel and Turbo Models 1 - CONCENTRIC SLAVE CYLINDER (CSC) Fig. 62 Clutch Slave Cylinder at Transaxle- 2.0L Models 1 - SLAVE CYLINDER 2 - BRACKET...
Page 236: Removal-Diesel And Turbo Models
6 - 34 CLUTCH SLAVE CYLINDER (Continued) (5) Remove slave cylinder from transaxle and sep- arate from hydraulic tube. Allow brake fluid to drain into suitable container. Fig. 65 Clutch Slave Cylinder at Transaxle—1.6L Models 1 - SLAVE CYLINDER 2 - BOLT Fig.
Page 237 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING ACCESSORY DRIVE - 1.6L SOHC ... . 3 WARNING ACCESSORY DRIVE - 2.0/2.4L DOHC ..6 COOLING SYSTEM WARNINGS .
Page 238: Torque - 2.0/2.4L
7 - 2 COOLING COOLING (Continued) TORQUE - 2.0/2.4L DESCRIPTION N·m Lbs. Lbs. A/C Condenser to Radiator— — Screws Automatic Belt Tensioner — Pulley—Bolt Automatic Belt Tension — Hose Clamp Pliers 8495 Assembly—Bolt Charge Air Cooler to Radiator — (Turbo Equipped)—Screws Coolant Recovery Bottle—Nut/ —...
Page 239 ACCESSORY DRIVE - 1.6L SOHC 7 - 3 ACCESSORY DRIVE - 1.6L SOHC TABLE OF CONTENTS page page ACCESSORY DRIVE - 1.6L SOHC INSTALLATION ......4 DESCRIPTION .
Page 240 7 - 4 ACCESSORY DRIVE - 1.6L SOHC ACCESSORY DRIVE BELT REMOVAL (1) Disconnect negative battery cable. (2) Insert a 1/2” drive breaker bar into the square opening of the accessory drive belt tensioner. (3) Rotate accessory drive belt tensioner counter- clockwise until accessory drive belt can be removed from pulleys (Fig.
Page 241: Accessory Drive - 1.6L Sohc
ACCESSORY DRIVE - 1.6L SOHC 7 - 5 ACCESSORY DRIVE BELT (Continued) (1) Install belt around all the pulleys except for (2) Install accessory drive belt (Refer to 7 - COOL- the generator pulley (Fig. 1) or (Fig. 2). ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- (2) Rotate accessory drive belt tensioner counter- LATION).
Page 242 7 - 6 ACCESSORY DRIVE - 2.0/2.4L DOHC ACCESSORY DRIVE - 2.0/2.4L DOHC TABLE OF CONTENTS page page DRIVE BELTS INSTALLATION ......10 DESCRIPTION .
Page 243: Drive Belts
ACCESSORY DRIVE - 2.0/2.4L DOHC 7 - 7 DRIVE BELTS (Continued) DIAGNOSIS AND TESTING ACCESSORY DRIVE BELTS CONDITION POSSIBLE CAUSE CORRECTION BELT SLIPPAGE 1. Belt slipping because of 1. Retension generator belt. insufficient tension. Replace the power steering belt’s automatic belt tensioner. 2.
Page 244: Removal
7 - 8 ACCESSORY DRIVE - 2.0/2.4L DOHC DRIVE BELTS (Continued) REMOVAL POWER STEERING PUMP/AIR CONDITIONING COMPRESSOR BELT (1) Remove belt splash shield (Fig. 2). (2) Using a wrench, rotate belt tensioner clockwise (Fig. 3) until belt can be removed from power steer- ing pump pulley.
Page 245 ACCESSORY DRIVE - 2.0/2.4L DOHC 7 - 9 DRIVE BELTS (Continued) Fig. 4 Power Steering/Air Conditioning Belt 1 - POWER STEERING PUMP PULLEY 5 - BELT 2 - POWER STEERING PUMP PULLEY 6 - IDLER PULLEY 3 - AIR CONDITIONING COMPRESSOR PULLEY 7 - CRANKSHAFT PULLEY 4 - CRANKSHAFT PULLEY 8 - BELT...
Page 246: Installation
7 - 10 ACCESSORY DRIVE - 2.0/2.4L DOHC DRIVE BELTS (Continued) INSTALLATION BELT TENSION CHART GENERATOR BELT Accessory Belt Tension Drive Belt NOTE: When installing drive belt onto pulleys, make Power Steering Dynamic Tensioner sure that belt is properly routed and all V-grooves Pump and A/C make proper contact with pulley grooves.
Page 247: Adjustments Belt Tension
ACCESSORY DRIVE - 2.0/2.4L DOHC 7 - 11 DRIVE BELTS (Continued) ADJUSTMENTS BELT TENSION For belt tension adjustment procedure, (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). AUTOMATIC BELT TENSIONER AND PULLEY DESCRIPTION The automatic belt tensioner (Fig. 9) maintains proper tension on the power steering and air condi- tioning belt.
Page 248 7 - 12 ENGINE - 1.6L SOHC ENGINE - 1.6L SOHC TABLE OF CONTENTS page page ENGINE - 1.6L SOHC ENGINE COOLANT TEMP SENSOR DESCRIPTION ......13 DESCRIPTION .
Page 249: Engine - 1.6L Sohc Description
ENGINE - 1.6L SOHC 7 - 13 OPERATION ENGINE - 1.6L SOHC The primary purpose of a cooling system is to DESCRIPTION maintain engine temperature in a range that will provide satisfactory engine performance and emission The cooling system consists of an engine cooling levels under all expected driving conditions.
Page 250: Diagnosis And Testing Diagnosis And Testing - Cooling System Aeration
7 - 14 ENGINE - 1.6L SOHC ENGINE - 1.6L SOHC (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS AND TESTING LEAK TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING PRESSURE If coolant level drops below a certain point, aera- CAP.
Page 251: Standard Procedure Standard Procedure - Draining Cooling System
ENGINE - 1.6L SOHC 7 - 15 ENGINE - 1.6L SOHC (Continued) If there are no external leaks after the gauge dial (1) Position a clean collecting container under shows a drop in pressure, detach the tester. Start draincock location. engine and run the engine to normal operating tem- (2) Without removing the pressure cap and with perature in order to open the thermostat and allow...
Page 252: Cleaning
7 - 16 ENGINE - 1.6L SOHC ENGINE - 1.6L SOHC (Continued) (1) Close radiator draincock. Hand tighten only. (10) Slowly fill the coolant recovery container to (2) Remove cooling system pressure cap. Install the FULL HOT mark with the recommended coolant. Special Tool 8195 Filling Aid Funnel (Fig.
Page 253: Coolant Description
ENGINE - 1.6L SOHC 7 - 17 COOLANT STANDARD PROCEDURE STANDARD PROCEDURE - COOLANT SERVICE DESCRIPTION For engine coolant recommended service schedule, CAUTION: Use of Propylene Glycol based coolants (Refer to LUBRICATION & MAINTENANCE/MAIN- TENANCE SCHEDULES - DESCRIPTION). is not recommended, as they provide less freeze protection and less corrosion protection.
Page 254: Hose Clamps
7 - 18 ENGINE - 1.6L SOHC HOSE CLAMPS COOLANT RECOVERY CONTAINER DESCRIPTION - HOSE CLAMPS The cooling system uses spring type hose clamps. If a DESCRIPTION spring type clamp replacement is necessary, replace The coolant recovery system consists of a coolant with the original Mopar equipment spring type clamp.
Page 255: Engine Block Heater Description
ENGINE - 1.6L SOHC 7 - 19 COOLANT RECOVERY CONTAINER (Continued) ENGINE BLOCK HEATER DESCRIPTION The heater is mounted in a core hole (in place of a core hole plug) in the engine block near the starter mounting location. The heating element immersed in coolant (Fig.
Page 256: Engine Coolant Temp Sensor Description
7 - 20 ENGINE - 1.6L SOHC ENGINE BLOCK HEATER (Continued) Fig. 12 Engine Coolant Temperature Sensor 1 - ENGINE COOLANT TEMPERATURE SENSOR Fig. 11 Engine Block Heater INSTALLATION 1 - BLOCK HEATER (1) Install coolant temperature sensor (Fig. 12). 2 - SCREW Tighten sensor to 17 N·m (150 in.
Page 257: Radiator Pressure Cap Description
ENGINE - 1.6L SOHC 7 - 21 ENGINE COOLANT THERMOSTAT AND HOUSING (Continued) RADIATOR PRESSURE CAP DESCRIPTION The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97-124 kPa (14-18 psi). There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant recovery container by vacuum through...
Page 258: Diagnosis And Testing - Cooling System Pressure Relief Testing
7 - 22 ENGINE - 1.6L SOHC RADIATOR PRESSURE CAP (Continued) CAUTION: The Cooling System Tester Tool is very BUILDS UP PRESSURE. TO PREVENT SCALDING sensitive to small air leaks that will not cause cool- OR OTHER INJURY, THE PRESSURE CAP SHOULD ing system problems.
Page 259: Installation
ENGINE - 1.6L SOHC 7 - 23 RADIATOR DRAINCOCK (Continued) Fig. 17 Draincock 1 - RADIATOR TANK 2 - DRAINCOCK INSTALLATION Fig. 18 Radiator Fan (1) Align draincock stem to radiator tank opening. 1 - RADIATOR FAN SHROUD (2) Push draincock into the radiator tank opening. 2 - SCREWS (3) Tighten the draincock by turning clockwise 3 - SCREWS...
Page 260: Diagnosis And Testing - Radiator Fan
7 - 24 ENGINE - 1.6L SOHC RADIATOR FAN (Continued) RADIATOR FAN OPERATION CHART Radiator Fan Control Low Speed High Speed A/C Off –vehicle speed < 70.8 km/h (44 mph) Fan On: 96.6° C (206° 103° C (219° F) 92.7° C (199° 98.8°...
Page 261: Installation
ENGINE - 1.6L SOHC 7 - 25 RADIATOR FAN (Continued) INSTALLATION (1) Install the radiator fan into position on the radiator. (2) Install the upper and right side radiator fan retaining screws and tighten to 6 N·m (55 in. lbs.) (Fig.
Page 262: Radiator Removal
7 - 26 ENGINE - 1.6L SOHC RADIATOR (Continued) CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and air conditioning fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.
Page 263: Heater Return Tube Removal
ENGINE - 1.6L SOHC 7 - 27 HEATER RETURN TUBE WATER PUMP/POWER STEERING PUMP ASSEMBLY REMOVAL (1) Disconnect negative battery cable. DESCRIPTION (2) Disconnect positive battery cable. The water pump on this vehicle is attached to the (3) Remove battery. rear of the power steering pump to form an assembly (4) Drain cooling system (Refer to 7 - COOLING/ (Fig.
Page 264: Disassembly
7 - 28 ENGINE - 1.6L SOHC WATER PUMP/POWER STEERING PUMP ASSEMBLY (Continued) REMOVAL DISASSEMBLY (1) Remove the three hex drive bolts and washers NOTE: Before proceeding, review all Warnings and that attach the power steering pump to the water Cautions (Refer to 7 - COOLING - WARNING) and pump (Fig.
Page 265: Assembly
ENGINE - 1.6L SOHC 7 - 29 WATER PUMP/POWER STEERING PUMP ASSEMBLY (Continued) Fig. 28 Hoses, Reservoir And Pump - 1.6L Engine 1 - RETURN HOSE 4 - 1.6L ENGINE 2 - FLUID RESERVOIR 5 - COOLER OUTLET TUBE 3 - SUPPLY HOSE 6 - PRESSURE HOSE ASSEMBLY (b) Holding the socket in this position, insert a...
Page 266: Installation
7 - 30 ENGINE - 1.6L SOHC WATER PUMP/POWER STEERING PUMP ASSEMBLY (Continued) (1) Install water pump/power steering pump assembly into engine compartment in reverse of how it was removed. (2) Install all four power steering pump mounting bolts (Fig. 29). Tighten bolts to 28 N·m (21 ft. lbs.) torque.
Page 267 ENGINE - 2.0/2.4L DOHC 7 - 31 ENGINE - 2.0/2.4L DOHC TABLE OF CONTENTS page page ENGINE - 2.0/2.4L DOHC OPERATION ......48 DESCRIPTION .
Page 268: Engine - 2.0/2.4L Dohc Description
7 - 32 ENGINE - 2.0/2.4L DOHC ENGINE - 2.0/2.4L DOHC DESCRIPTION Non-Turbo The cooling system consists of an engine cooling module, thermostat, coolant recovery/reserve system, coolant, and a water pump. The engine cooling mod- ule (Fig. 1) consists of a radiator, electric fan motor, fan, shroud, transmission oil cooler, hoses, clamps, air conditioning condenser and transmission oil lines.
Page 269 ENGINE - 2.0/2.4L DOHC 7 - 33 ENGINE - 2.0/2.4L DOHC (Continued) Fig. 3 Cooling System Operation DIAGNOSIS AND TESTING COOLING SYSTEM CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Diagnostic Trouble Code (DTC) 1. Replace thermostat, if necessary. has been set indicating a stuck If a (DTC) has not been set, the open engine thermostat.
Page 270 7 - 34 ENGINE - 2.0/2.4L DOHC ENGINE - 2.0/2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Trailer being towed, a steep hill 1. This may be a temporary HIGH OR ENGINE COOLANT being climbed, vehicle being condition and repair is not WARNING LAMP ILLUMINATES.
Page 271 ENGINE - 2.0/2.4L DOHC 7 - 35 ENGINE - 2.0/2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION 8. Freeze point of coolant not 8. Check coolant concentration correct. Mixture ratio may be too (Refer to 7 - COOLING/ENGINE/ rich. COOLANT - DIAGNOSIS AND TESTING).
Page 272 7 - 36 ENGINE - 2.0/2.4L DOHC ENGINE - 2.0/2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION 3. Temperature gauge or Engine 3. Check gauge operation (Refer to Coolant Temperature Sensor is 8 - ELECTRICAL/INSTRUMENT defective or shorted. CLUSTER - DIAGNOSIS AND TESTING).
Page 273 ENGINE - 2.0/2.4L DOHC 7 - 37 ENGINE - 2.0/2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. (a) Pressure cap relief valve WHEN ENGINE IS COOLING system on engine cool-down is not stuck (Refer to 7 - COOLING/ being relieved through coolant ENGINE/RADIATOR PRESSURE...
Page 274 7 - 38 ENGINE - 2.0/2.4L DOHC ENGINE - 2.0/2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION INADEQUATE AIR CONDITIONER 1. Electric radiator fan not operating 1. Refer to appropriate Powertrain PERFORMANCE (COOLING when A/C is on. Diagnostic Procedures manual for SYSTEM SUSPECTED) operation of the DRB III scan tool.
Page 275: Diagnosis And Testing Cooling System
ENGINE - 2.0/2.4L DOHC 7 - 39 ENGINE - 2.0/2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION POOR DRIVEABILITY 1. Has a diagnostic trouble code 1. Refer to the Powertrain (THERMOSTAT POSSIBLY STUCK (DTC ) been set? Diagnostic Procedure manual for OPEN).
Page 276: Diagnosis And Testing - Cooling System Flow Check
7 - 40 ENGINE - 2.0/2.4L DOHC ENGINE - 2.0/2.4L DOHC (Continued) while looking down the filler neck. Once flow is detected install the pressure cap. Replace removed coolant into coolant recovery container. ALTERNATIVE METHOD • If engine is cold, idle engine until normal oper- ating temperature is reached.
Page 277: Standard Procedure - Filling Cooling System
ENGINE - 2.0/2.4L DOHC 7 - 41 ENGINE - 2.0/2.4L DOHC (Continued) (1) Position a clean collecting container under draincock location. (2) Without removing the pressure cap and with system not under pressure, turn draincock counter- clockwise to open (Fig. 5). (3) The coolant reserve bottle should empty first, then remove the pressure cap.
Page 278: Cleaning
7 - 42 ENGINE - 2.0/2.4L DOHC ENGINE - 2.0/2.4L DOHC (Continued) (11) Slowly fill coolant reserve/recovery bottle to at COOLANT least the FULL HOT mark with the recommended coolant. It may be necessary to add additional cool- DESCRIPTION ant to the reserve/recovery bottle after three or four warm-up/cool down cycles to maintain coolant level CAUTION: Use of Propylene Glycol based coolants between the FULL HOT and ADD marks.This is due...
Page 279: Standard Procedure Standard Procedure - Routine Coolant Level Check
ENGINE - 2.0/2.4L DOHC 7 - 43 COOLANT (Continued) STANDARD PROCEDURE - ADDING STANDARD PROCEDURE ADDITIONAL COOLANT STANDARD PROCEDURE - ROUTINE COOLANT LEVEL CHECK NOTE: The radiator cap should not be removed. When additional coolant is needed, it should be NOTE: Do not remove pressure cap for routine added to the coolant recovery container (Fig.
Page 280 7 - 44 ENGINE - 2.0/2.4L DOHC COOLANT (Continued) Fig. 9 Coolant Recovery Container and Pressure Cap 1 - ENGINE OIL FILL 3 - ENGINE OIL DIPSTICK 2 - COOLANT RECOVERY CONTAINER 4 - COOLANT PRESSURE CAP Fig. 10 Coolant Recovery Container and Pressure Cap - 2.4L Turbo 1 - ENGINE OIL FILL 3 - ENGINE OIL DIPSTICK 2 - COOLANT RECOVERY CONTAINER...
Page 281: Coolant Recovery Container Description
ENGINE - 2.0/2.4L DOHC 7 - 45 COOLANT RECOVERY CONTAINER DESCRIPTION The coolant recovery system consists of a coolant recovery container mounted to the dash panel, a vent hose for the coolant recovery container, a hose con- necting the container to the coolant outlet connector on the engine, and a pressure cap (Fig.
Page 282: Cooling System Pressure Cap Description
7 - 46 ENGINE - 2.0/2.4L DOHC COOLANT RECOVERY CONTAINER (Continued) Turbo (1) Install coolant recovery container and tighten fasteners to 4 N·m (35 in. lbs.) (Fig. 14). (2) Connect throttle and speed control cables to throttle body. (3) Install throttle cable shield to throttle body. (4) Connect overflow hose to coolant outlet connec- tor (Fig.
Page 283: Operation
ENGINE - 2.0/2.4L DOHC 7 - 47 COOLING SYSTEM PRESSURE CAP (Continued) OPERATION The pressure cap allows the cooling system to oper- ate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point, allowing increased radiator cooling capacity. The pressure cap will release cooling system pressure in a range of 97–124 kPa (14–18 psi).
Page 284: Cleaning
7 - 48 ENGINE - 2.0/2.4L DOHC COOLING SYSTEM PRESSURE CAP (Continued) WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, If any light can be seen between vent valve and WAIT 15 MINUTES BEFORE REMOVING CAP. the rubber gasket, replace the cap. Use only a replacement cap that has a spring to hold the PLACE A SHOP TOWEL OVER THE CAP, AND WITH- OUT PUSHING DOWN, ROTATE IT COUNTER-...
Page 285: Removal
ENGINE - 2.0/2.4L DOHC 7 - 49 ENGINE BLOCK HEATER (Continued) (5) Connect power cord to block heater (Fig. 19). (6) Fill cooling system (Refer to 7 - COOLING/EN- GINE - STANDARD PROCEDURE - FILLING COOLING SYSTEM). ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The engine coolant temperature (ECT) sensor threads into the thermostat housing just below the...
Page 286: Removal
7 - 50 ENGINE - 2.0/2.4L DOHC ENGINE COOLANT TEMPERATURE SENSOR (Continued) (3) Install upper torque strut (Refer to 9 - ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION). (4) Fill cooling system (Refer to 7 - COOLING/EN- GINE - STANDARD PROCEDURE). (5) Connect negative battery cable. ENGINE COOLANT THERMOSTAT DESCRIPTION...
Page 287: Operation
ENGINE - 2.0/2.4L DOHC 7 - 51 ENGINE COOLANT THERMOSTAT (Continued) ertrain Diagnostic Procedures manual for further information and diagnostics provided. DIAGNOSIS AND TESTING - ENGINE COOLANT THERMOSTAT The thermostat is operated by a wax filled cham- ber (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open.
Page 288: Hose Clamps
7 - 52 ENGINE - 2.0/2.4L DOHC ENGINE COOLANT THERMOSTAT (Continued) Fig. 26 Spring Clamp Size Location 1 - SPRING CLAMP SIZE LOCATION OPERATION The worm type hose clamp uses a specified torque value to maintain proper tension on a hose connec- tion.
Page 289: Operation
ENGINE - 2.0/2.4L DOHC 7 - 53 RADIATOR FAN (Continued) OPERATION RADIATOR FAN OPERATION CHART Non-Turbo Radiator Fan Control Radiator fan operation is control by the Powertrain Low Speed High Speed Control Module (PCM) with inputs from the temper- A/C Off –vehicle speed < 70.8 km/h (44 mph) ature of the coolant, which is sensed by the coolant Fan On: 96.6°...
Page 290: Diagnosis And Testing
7 - 54 ENGINE - 2.0/2.4L DOHC RADIATOR FAN (Continued) DIAGNOSIS AND TESTING RADIATOR FAN MOTOR TEST Refer to Powertrain Diagnostic Manual for proce- dure. REMOVAL NOTE: The fan motor, fan, and the shroud are ser- viced as an assembly. WARNING: DO NOT OPEN THE RADIATOR DRAIN- COCK WITH THE SYSTEM HOT AND UNDER PRES- SURE...
Page 291: Installation
ENGINE - 2.0/2.4L DOHC 7 - 55 RADIATOR FAN (Continued) (12) Remove radiator fan by lifting up from the INSTALLATION engine compartment. (1) Install the radiator fan into position on the radiator. (2) Hand start all radiator fan fasteners. (3) Tighten all radiator fan retaining screws to 6 N·m (55 in.
Page 292: Radiator Removal
7 - 56 ENGINE - 2.0/2.4L DOHC RADIATOR (Continued) (9) Remove radiator assembly (Fig. 36) by lifting it up from the engine compartment. Care should be taken not to damage the cooling fins and tubes during removal. (10) Non-Turbo Vehicles: Remove the lower air seal from radiator (Fig.
Page 293: Cleaning
ENGINE - 2.0/2.4L DOHC 7 - 57 RADIATOR (Continued) CLEANING (6) Torque all condenser fasteners to 8 N·m (70 in. lbs.). Clean radiator fins are necessary for good heat (7) Torque all radiator fan fasteners to 6 N·m (55 transfer. The radiator and air conditioning fins in.
Page 294: Installation
7 - 58 ENGINE - 2.0/2.4L DOHC RADIATOR DRAINCOCK (Continued) • Disconnect A/C suction line from A/C compressor (1) Drain the cooling system (Refer to 7 - COOL- ING/ENGINE - STANDARD PROCEDURE). (Refer to 24 - HEATING & AIR CONDITIONING/ (2) Open the draincock by turning it counterclock- PLUMBING/SUCTION LINE - REMOVAL).
Page 295: Water Pump
ENGINE - 2.0/2.4L DOHC 7 - 59 WATER PUMP DIAGNOSIS AND TESTING WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the sys- tem.
Page 296: Water Pump Inlet Tube Removal
7 - 60 ENGINE - 2.0/2.4L DOHC WATER PUMP (Continued) Fig. 42 Water Pump Inlet Tube Fasteners 1 - BOLTS 2 - HOSE - HEATER RETURN 3 - WATER PUMP INLET TUBE Fig. 41 Water Pump Body 1 - IMPELLER 2 - WATER PUMP BODY 3 - O-RING LOCATING GROOVE WATER PUMP INLET TUBE...
Page 297 TRANSMISSION 7 - 61 TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION COOLER HOSES REMOVAL ......61 DESCRIPTION .
Page 298: Transmission
7 - 62 TRANSMISSION AUTOMATIC TRANSMISSION OIL COOLER (Continued) Turbo NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur. To prevent potential leakage, the cooler hoses and clamps must be replaced.
Page 299 TRANSMISSION 7 - 63 AUTOMATIC TRANSMISSION OIL COOLER (Continued) INSTALLATION Non - Turbo (1) Install transmission oil cooler and tighten screws to 8 N·m (70 in. lbs.) (Fig. 3). NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the cooler and transaxle, damage to the inner wall of hose will occur.
Page 301 AUDIO 8A - 1 AUDIO TABLE OF CONTENTS page page AUDIO INSTALLATION ......7 DESCRIPTION .
Page 302: Audio Description
8A - 2 AUDIO AUDIO (Continued) DIAGNOSIS AND TESTING - AUDIO WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING Any diagnosis of the Audio system should COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR begin with the use of the DRB III diagnostic INSTRUMENT PANEL COMPONENT DIAGNOSIS OR tool.
Page 303: Antenna Body & Cable Description
AUDIO 8A - 3 AUDIO (Continued) CONDITION POSSIBLE CAUSES CORRECTION CLOCK WILL NOT KEEP 1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the SET TIME Junction Block (JB). Replace fuse, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if required.
Page 304: Diagnosis And Testing - Antenna Body And Cable
8A - 4 AUDIO ANTENNA BODY & CABLE (Continued) shielding the radio waves as they are conducted to the radio. The radio then tunes and amplifies the weak radio signals into stronger electrical signals in order to operate the audio system speakers. DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE The following four tests are used to diagnose the...
Page 305: Removal
AUDIO 8A - 5 ANTENNA BODY & CABLE (Continued) TEST 3 (4) Remove antenna nut and adapter (Fig. 2). Test 3 checks the condition of the vehicle body ground connection. To begin this test, proceed as fol- lows: (1) This test must be performed with the battery positive cable disconnected from the battery.
Page 306: Antenna - Satellite Radio Description
8A - 6 AUDIO ANTENNA BODY & CABLE (Continued) (3) Seat the grommet in the side panel and connect the cable to the instrument panel harness connector. (4) Install antenna nut and adapter. (5) Install shroud (if equipped). (6) Install the inner fender shield. (7) Install antenna mast.
Page 307: Antenna Cable - Satellite Radio Description
AUDIO 8A - 7 INSTALLATION ANTENNA CABLE - SATELLITE (1) Secure the antenna cable to the body harness. RADIO Connect the wire harness connectors at each end of the antenna. DESCRIPTION (2) Install the headliner (Refer to 23 - BODY/IN- The satellite radio antenna connects the roof TERIOR/HEADLINER - INSTALLATION).
Page 308: Removal
8A - 8 AUDIO RADIO (Continued) REMOVAL RADIO NOISE SUPPRESSION (1) Disconnect and isolate the battery negative cable. COMPONENTS (2) Remove instrument panel center bezel. (3) Remove mounting fasteners and remove radio DESCRIPTION from instrument panel (Fig. 6). Radio noise suppression devices are factory-in- stalled standard equipment on this vehicle.
Page 309: Removal
AUDIO 8A - 9 RADIO NOISE SUPPRESSION COMPONENTS (Continued) electromagnetic signals by the audio system compo- nents. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, igni- tion, engine control and transmission control sys-...
Page 310 8A - 10 AUDIO RADIO NOISE SUPPRESSION COMPONENTS (Continued) HOOD HINGE GROUND STRAP RADIO NOISE SUPPRESSION CAPACITOR (1) Disconnect and isolate the battery negative (1) Disconnect and isolate the battery negative cable. cable. (2) Remove bolt from fender (Fig. 12). (2) Disconnect electrical harness connector from capacitor (Fig.
Page 311: Installation
AUDIO 8A - 11 RADIO NOISE SUPPRESSION COMPONENTS (Continued) INSTALLATION REMOVAL (1) Disconnect and isolate the battery negative ENGINE GROUND STRAP cable. (1) Install strap and bolt to strut tower. Tighten (2) Remove the left rear quarter trim panel (Refer bolt to 12 N·m (105 in.
Page 312: Speaker Removal
8A - 12 AUDIO SPEAKER (Continued) Fig. 17 Front Door Speaker Remove/Install INSTRUMENT PANEL SPEAKER (1) Disconnect and isolate the battery negative cable. (2) Remove instrument panel top cover (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL TOP COVER - REMOVAL). Fig.
Page 313 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - CHIME DESCRIPTION ......1 CONDITIONS .
Page 314 8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) RUN position, the chime will sound six times (about NO TONE WHEN HEADLAMPS ARE ON AND 2 seconds). The chime will be a “fast” chime (same as DRIVERS DOOR IS OPEN door ajar). The transmission has reverse gear adja- (1) Remove the key from the ignition.
Page 315 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page CONTROLLER ANTILOCK BRAKE STANDARD PROCEDURE DESCRIPTION ......1 STANDARD PROCEDURE - OBTAINING OPERATION .
Page 316: Controller Antilock Brake
8E - 2 ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE (Continued) When a fault is detected, the amber ABS warning lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. These DTC’s will remain in the CAB mem- ory even after the ignition has been turned off.
Page 317: Description
ELECTRONIC CONTROL MODULES 8E - 3 CONTROLLER ANTILOCK BRAKE (Continued) (4) Remove four screws securing CAB to HCU half HEATED SEAT MODULE of ICU (Fig. 3). Remove CAB from HCU. (5) Pull outward on CAB connector lock and dis- DESCRIPTION connect 24–way wiring connector.
Page 318: Operation
8E - 4 ELECTRONIC CONTROL MODULES HEATED SEAT MODULE (Continued) The heated seat module cannot be adjusted or If the heated seat module detects a heated seat repaired. If a module is damaged or faulty, the entire sensor value input that is out of range or a shorted module must be replaced.
Page 319: Removal
ELECTRONIC CONTROL MODULES 8E - 5 HEATED SEAT MODULE (Continued) REMOVAL harness connector are aligned with the terminals in the heated seat module connector receptacle before pushing the connector firmly into place. WARNING: THERE ARE MANY SHARP METAL (3) Install the heated seat module on the power EDGES ON THE SEAT CUSHION FRAME AND SEAT seat cushion pan.
Page 320: Operation
8E - 6 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Power Steering Pressure Switch OPERATION • SCI Receive • Speed Control Switches OPERATION • Throttle Position Sensor (1.6L has 2 TPS Sen- The PCM receives input signals from various sors) switches and sensors that are referred to as PCM •...
Page 321 ELECTRONIC CONTROL MODULES 8E - 7 POWERTRAIN CONTROL MODULE (Continued) • Coolant temperature harness connectors to receive and send engine and • Exhaust gas content (oxygen sensor) transmission data. To ease assembly, the mating wir- • Engine speed (crankshaft position sensor) ing harness connector is color-coded.
Page 322 8E - 8 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions.
Page 323 ELECTRONIC CONTROL MODULES 8E - 9 POWERTRAIN CONTROL MODULE (Continued) • Fluid temperature TRANSMISSION SHIFT SCHEDULES • Software calibration level The PCM is programmed to allow it to select a As driving conditions change, the PCM appropri- variety of shift schedules. Shift schedule selection is ately adjusts the shift schedule.
Page 324: Operation - 5 Volt Supply - Pcm Output
8E - 10 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) OPERATION - 5 VOLT SUPPLY - PCM OUTPUT The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM/TCM The PCM supplies 5 volts to the following sensors: must be calibrated to the different combinations of •...
Page 325: Removal - 1.6L
ELECTRONIC CONTROL MODULES 8E - 11 POWERTRAIN CONTROL MODULE (Continued) REMOVAL REMOVAL - 1.6L The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle iden- tification number (VIN) in the new PCM.
Page 326: Removal - 2.0, 2.4, And 2.4L Turbo
8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (3) Unlock the PCM connector by pulling on the (5) Remove attaching nuts for PCM to bracket tab on the end of the PCM connector (Fig. 12). (Fig. 14). (6) Lift PCM up to remove it from vehicle. Fig.
Page 327 ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) (4) Remove the clutch reservoir and relocate (Fig. 18). Fig. 16 VACUUM LINES (3) Unlock and disconnect the 3 or 4 electrical con- nectors (Fig. 17) from the Powertrain Control Module Fig.
Page 328: Installation Installation - 1.6L
8E - 14 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (6) Remove the 3 screws from the PCM bracket to PCM (Fig. 22). Fig. 20 PCM MOUNTING Screw AND LOCATION TAB Fig. 22 PCM AND MOUNTING BRACKET INSTALLATION INSTALLATION - 1.6L The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles).
Page 329: Installation - 2.0, 2.4, And 2.4L Turbo
ELECTRONIC CONTROL MODULES 8E - 15 POWERTRAIN CONTROL MODULE (Continued) INSTALLATION - 2.0, 2.4, and 2.4L TURBO (1) Install the PCM bracket and 3 screws to the PCM (Fig. 22) and tighten to 11.8 N·m (105 in. lbs.). (2) Install the PCM and bracket assembly and locate the bracket on the tab (Fig.
Page 330: Operation
(Fig. 25). assigned to its original SKIM from the vehicle owner, (6) Rotate the SKIM and its mounting bracket the vehicle’s invoice, or from Chrysler’s Customer upwards and then to the side away from the steering Center.
Page 331: Installation
ELECTRONIC CONTROL MODULES 8E - 17 SENTRY KEY IMMOBILIZER MODULE (Continued) TRANSMISSION CONTROL MODULE DESCRIPTION The Transmission Control Module (TCM) is located behind the left fender and is fastened to the left frame rail forward of the suspension (Fig. 26). It mounts on a bracket that is fastened to the rail.
Page 332 8E - 18 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: • Engine/Body Identification • Manifold Pressure • Target Idle • Torque Reduction Confirmation • Speed Control ON/OFF Switch •...
Page 333 ELECTRONIC CONTROL MODULES 8E - 19 TRANSMISSION CONTROL MODULE (Continued) CLUTCH VOLUMES When Updated Proper Clutch Clutch Volume Shift Sequence Oil Temperature Throttle Angle 2-1 or 3-1 coast > 70° < 5° 35 to 83 downshift 1-2 shift 20 to 77 5 - 54°...
Page 334: Removal
8E - 20 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) Schedule Condition Expected Operation Super Overheat Oil temperature above 260° F – All Overheat shift schedule features apply – 2nd gear PEMCC above 22 mph – Above 22 mph the torque converter will not unlock unless the throttle is closed or if a wide open throttle 2nd PEMCC to 1 kickdown...
Page 335 ELECTRONIC CONTROL MODULES 8E - 21 TRANSMISSION CONTROL MODULE (Continued) CAUTION: TCM 60-way connector must be torqued (5) Install left front wheel/tire assembly (Fig. 28). within 30-40 in. lbs. Improper torque may result in Torque lug nuts to 135 N·m (100 ft. lbs.) torque. (6) Lower vehicle.
Page 337 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 338: Battery System
8F - 2 BATTERY SYSTEM battery system is also designed to provide a reserve BATTERY SYSTEM of electrical energy to supplement the charging sys- tem for short durations while the engine is running DESCRIPTION and the electrical current demands of the vehicle A single 12-volt battery is standard factory-in- that exceed the output of the charging system.
Page 339 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 340: Cleaning
8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 341 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
Page 342: Inspection
8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) INSPECTION ratings that equal or exceed the original equipment specification for the vehicle being serviced. Battery The following information details the recommended sizes and ratings are discussed in more detail below. inspection procedures for the battery and related components.
Page 343: Torque Specifications
BATTERY SYSTEM 8F - 7 BATTERY SYSTEM (Continued) TORQUE SPECIFICATIONS power and service life than conventional batteries the same size. The spiral plate battery is completely, per- manently sealed. Through gas recombination, hydro- DESCRIPTION ....TORQUE gen and oxygen within the battery are captured Battery Hold Down Bolt .
Page 344: Diagnosis And Testing - Battery
8F - 8 BATTERY SYSTEM BATTERY (Continued) tion occurs. This reaction causes the battery to dis- IN THE EVENT OF CONTACT, FLUSH WITH WATER charge electrical current from its terminals. As the AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT battery discharges, a gradual chemical change takes OF THE REACH OF CHILDREN.
Page 345 BATTERY SYSTEM 8F - 9 BATTERY (Continued) cranking capacity. Refer to Battery Diagnosis and appear that the battery will not accept charging cur- Testing for the proper battery test procedures. If the rent. See the instructions provided by the manufac- battery will endure a load test, return the battery to turer of the battery charger for details on how to service.
Page 346: Standard Procedure - Conventional Battery Charging
8F - 10 BATTERY SYSTEM BATTERY (Continued) AGE MAY RESULT FROM LOOSE OR MISSING SPIRAL-PLATE BATTERY CHARGING TIME CELL CAPS. TABLE Charging CAUTION: Always disconnect and isolate the bat- 5 Amps 8 Amps Amperage tery negative cable before charging a battery. Do not exceed sixteen volts while charging a battery.
Page 347: Standard Procedure - Using Micro 420
BATTERY SYSTEM 8F - 11 BATTERY (Continued) charging time. A battery charger that supplies twenty amperes or more will require a shorter charg- ing time. • State-Of-Charge - A completely discharged bat- tery requires more charging time than a partially discharged battery.
Page 348: Standard Procedure - Open-Circuit Voltage Test
(2) Disconnect and isolate both battery cables, neg- NOTE: When testing the battery in a PT Cruiser, ative cable first. always test at the battery terminals (3) Using a voltmeter connected to the battery...
Page 349: Standard Procedure - Ignition-Off Draw Test
BATTERY SYSTEM 8F - 13 BATTERY (Continued) See the Open-Circuit Voltage Table. This voltage (2) Determine that the underhood lamp is operat- reading will indicate the battery state-of-charge, but ing properly, then disconnect the lamp wire harness will not reveal its cranking capacity. If a battery has connector or remove the lamp bulb.
Page 350: Removal - Gasoline Engine
8F - 14 BATTERY SYSTEM BATTERY (Continued) in Step 5. The multi-meter reading will drop to within the acceptable limit when the source of the excessive current draw is disconnected. Repair this circuit as required; whether a wiring short, incorrect switch adjustment, or a component failure is at fault.
Page 351 BATTERY SYSTEM 8F - 15 BATTERY (Continued) Fig. 10 Battery Temperature Sensor Location Fig. 12 Battery Remove/Install - Diesel Engine Only 1 - BOTTOM OF BATTERY 1 - PASSENGER SEAT 2 - BATTERY TEMPERATURE SENSORS 2 - BATTERY Fig. 11 Removing Battery Temperature Sensor Fig.
Page 352: Installation - Gasoline Engine
8F - 16 BATTERY SYSTEM BATTERY (Continued) WARNING: DO NOT USE A CONVENTIONAL LEAD- (3) Install battery cables on battery posts. Install ACID BATTERY IN PLACE OF THE FACTORY battery positive cable first. (4) Torque clamp nuts to 110 in. lbs. ± 20 in. lbs. EQUIPPED SPIRAL-PLATE BATTERY.
Page 353: Battery Holddown Description
BATTERY SYSTEM 8F - 17 BATTERY (Continued) CAUTION: Vehicles equipped with the diesel engine use a unique battery hold down. If the replacement battery is not identical, in size to the original, it may be necessary to use non-corrosive spacers in between the hold down retainer to properly secure the battery in the battery tray.
Page 354: Battery Cables Description
8F - 18 BATTERY SYSTEM DIAGNOSIS AND TESTING - BATTERY CABLES BATTERY CABLES A voltage drop test will determine if there is exces- DESCRIPTION sive resistance in the battery cable terminal connec- tions or the battery cable. If excessive resistance is The battery cables are large gauge, stranded cop- found in the battery cable connections, the connec- per wires sheathed within a heavy plastic or syn-...
Page 355: Removal
BATTERY SYSTEM 8F - 19 BATTERY CABLES (Continued) Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. Fig. 17 Testing Battery Negative Connection Resistance Fig. 19 Testing Battery Positive Cable Resistance 1 - VOLTMETER 2 - BATTERY 1 - BATTERY 2 - VOLTMETER...
Page 356: Installation
8F - 20 BATTERY SYSTEM BATTERY CABLES (Continued) (3) Remove the battery from the vehicle. Refer to OPERATION the procedure in this group. The battery tray provides a secure mounting loca- (4) One at a time, trace the battery cable retaining tion and supports the battery.
Page 357: Thermal Guard Description
BATTERY SYSTEM 8F - 21 OPERATION THERMAL GUARD The thermal guard protects the battery from DESCRIPTION engine compartment temperature extremes. The tem- perature of the battery can affect battery perfor- On gasoline engine equipped vehicles, a flexible mance. The air trapped in the thermal guard creates thermal guard wraps around the battery case to a dead air space, which helps to insulate the sides of enclose the sides of the battery (Fig.
Page 358: Battery Tray Support Bracket Removal
8F - 22 BATTERY SYSTEM INSTALLATION BATTERY TRAY SUPPORT (1) Position the battery tray support bracket and BRACKET install the two battery tray support bracket retaining bolts. REMOVAL (2) Raise the vehicle on the hoist. (1) Disconnect and isolate the negative battery (3) Working under the vehicle, install the two bat- cable.
Page 359 CHARGING 8F - 23 CHARGING TABLE OF CONTENTS page page CHARGING REMOVAL DESCRIPTION - CHARGING SYSTEM ..23 REMOVAL - 2.0/2.4L ....27 OPERATION - CHARGING SYSTEM .
Page 360: Diagnosis And Testing - On-Board Diagnostic System
8F - 24 CHARGING CHARGING (Continued) • loose generator belt. ture and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is INSPECTION done as reminder to check the three gauges. The sig- The Powertrain Control Module (PCM) monitors nal to activate the lamp is sent via the PCI bus cir- critical input and output circuits of the charging sys- cuits.
Page 361: Battery Temperature Sensor Operation
CHARGING 8F - 25 BATTERY TEMPERATURE SENSOR OPERATION The battery temperature sensor is used to deter- mine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate.
Page 362: Installation - 2.0, 2.4, And 2.4L Turbo
8F - 26 CHARGING BATTERY TEMPERATURE SENSOR (Continued) Fig. 4 LOCKING TABS Fig. 6 AIR CLEANER BOX LOCATOR PINS GENERATOR DESCRIPTION The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the genera- tor fails for any reason, the entire assembly must be replaced.
Page 363: Removal Removal - 2.0/2.4L
CHARGING 8F - 27 GENERATOR (Continued) (7) Remove the pencil strut (Fig. 9). REMOVAL REMOVAL - 2.0/2.4L (1) Remove the air cleaner lid, disconnect the inlet air sensor and makeup air hose. (2) Disconnect the negative battery cable. (3) Loosen the upper generator T-bolt lock nut (Fig.
Page 364: Removal - 2.4L Turbo
8F - 28 CHARGING GENERATOR (Continued) (9) Loosen the accessory drive belt t-bolt. REMOVAL - 2.4L TURBO (10) Unplug field circuit from generator (Fig. 11). The generator is located above the oil filter and axle shaft (Fig. 13). Fig. 11 Battery Connection 1 - FIELD CONNECTOR Fig.
Page 365 CHARGING 8F - 29 GENERATOR (Continued) (3) Remove nut from the upper T-bolt adjustment (7) Remove the lower heat shield bolt. bracket (Fig. 15). (8) Remove the generator heat shield. (9) Unplug the field circuit from the generator (Fig. 17). Fig.
Page 366 8F - 30 CHARGING GENERATOR (Continued) (13) Loosen the lower generator pivot bolt (Fig. (17) Remove the 2 bolts for the axle shaft bearing 19). support. (18) Remove the axle shaft assembly (Fig. 20). Put a container under the transmission to catch the transmission fluid from the transmission.
Page 367: Removal - 2.2 Diesel
CHARGING 8F - 31 GENERATOR (Continued) REMOVAL - 2.2 DIESEL (1) Disconnect the negative battery cable. (2) Remove the front grill, refer to the Body sec- tion for more information. (3) Remove the hood seal, refer to the Body section for more information.
Page 368: Installation - 2.4L Turbo
8F - 32 CHARGING GENERATOR (Continued) (14) Tighten the T-bolt locknut (Fig. 7) and tighten INSTALLATION - 2.2 DIESEL to 54 N·m (40 ft. lbs.) (15) Connect the negative battery cable. NOTE: The orientation of the generator (Fig. 25), it (16) Install the air cleaner lid and connect the will fit onto the bracket backwards.
Page 369: Voltage Regulator Description
CHARGING 8F - 33 GENERATOR (Continued) (17) Install the underbody plate (skid plate), refer OPERATION to the Body section for more information. The amount of DC current produced by the gener- (18) Lower vehicle. ator is controlled by EVR circuitry contained within (19) Install ambient temperature sensor.
Page 370 8F - 34 STARTING STARTING TABLE OF CONTENTS page page STARTING TORQUE ......40 DESCRIPTION .
Page 371 STARTING 8F - 35 STARTING (Continued) • Starter Solenoid - Visually inspect the starter cranking capacity of the battery. Charge or replace the battery, if required. Refer to the Battery section solenoid for indications of physical damage and loose for more information. or corroded wire harness connections.
Page 372: Diagnosis And Testing - Control Circuit Test
8F - 36 STARTING STARTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 2. STARTING CIRCUIT 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND WIRING FAULTY. THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS NECESSARY. 3. STARTER ASSEMBLY 3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND FAULTY.
Page 373 STARTING 8F - 37 STARTING (Continued) (3) Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. (4) Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location.
Page 374: Diagnosis And Testing - Feed Circuit
8F - 38 STARTING STARTING (Continued) RELAY CIRCUIT TEST IGNITION SWITCH (1) The relay common feed terminal cavity (30) is After testing starter solenoid and relay, test igni- connected to battery voltage and should be hot at all tion switch and wiring. Refer to the Ignition Section times.
Page 375: Diagnosis And Testing - Feed Circuit
STARTING 8F - 39 STARTING (Continued) the START position. If voltage reads above 0.2 volt, (4) Verify that all lights and accessories are OFF, correct poor starter to engine ground. and the transmission shift selector is in the PARK (a) Connect the positive voltmeter lead to the and SET parking brake.
Page 376: Torque
8F - 40 STARTING STARTING (Continued) TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Starter Mounting Bolts Starter Solenoid Battery STARTER MOTOR REMOVAL REMOVAL - 1.6L (1) Turn wheels to the left. (2) Remove air cleaner cover. (3) Disconnect the negative battery cable. (4) Raise vehicle and support.
Page 377: Removal - 2.2 Diesel
STARTING 8F - 41 STARTER MOTOR (Continued) (7) Push up the spring clip that holds the heat REMOVAL - 2.2 DIESEL shield for the starter (Fig. 5). (1) Disconnect the negative battery cable. (2) Remove the front grill, refer to the Body sec- tion for more information.
Page 378: Removal - 2.0/2.4L
8F - 42 STARTING STARTER MOTOR (Continued) (16) Remove the radiator from vehicle (Fig. 8). Fig. 10 Battery Negative Cable Remove/Install (4) Raise vehicle on hoist. Fig. 8 STARTER LOCATION (5) Remove Engine Structural Collar. Refer to Engine, Structural Collar Removal and Installation. (17) Disconnect the electrical connectors from the (6) Disconnect starter motor wiring (Fig.
Page 379 STARTING 8F - 43 STARTER MOTOR (Continued) (3) Pushing the inner cooler hose up and out of the (6) Remove the nuts that hold the lower inner way and remove the upper starter bolt (Fig. 12) and cooler tube (Fig. 14). ground wire.
Page 380: Installation Installation - 1.6L
8F - 44 STARTING STARTER MOTOR (Continued) (9) Remove the Structural Collar (Fig. 16), refer to INSTALLATION the Engine, Structural Collar Removal and Installa- tion section. INSTALLATION - 1.6L (1) Install the starter through the wheel well (Fig. (2) Install the lower mounting bolt. (3) Install the upper mounting bolts.
Page 381: Installation - 2.0/2.4L
STARTING 8F - 45 STARTER MOTOR (Continued) INSTALLATION - 2.0/2.4L (3) Connect the positive battery cable and tighten nut to 10 N·m ( 90 in. lbs.). (1) Reinstall starter motor into vehicle lower (4) Connect and lock the solenoid electrical connec- engine compartment.
Page 383 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED SEAT SYSTEM ..... 1 HEATED WINDOW DEFOGGER ....10 HEATED SEAT SYSTEM TABLE OF CONTENTS page...
Page 384: Heated Seat System
8G - 2 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) the vehicle electrical system and to the heated seat system components through the use of a combination of soldered splices, splice block connectors and differ- ent types of wire harness terminal connectors. Refer to the appropriate wiring information.
Page 385 HEATED SEAT SYSTEM 8G - 3 HEATED SEAT SYSTEM (Continued) HEATED SEAT SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO HEATED SEAT SWITCH 1. Faulty fuse. 1. Check heated seat fuse in Junction Block (JB). ILLUMINATION WITH Replace fuse, if required. IGNITION ON 2.
Page 386: Driver Heated Seat Switch Description
8G - 4 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) HEATED SEAT SYSTEM SELF-DIAGNOSTIC TABLE SWITCH HI LED FAILURE MODE SWITCH LO LED INDICATOR INDICATOR Shorted Heating Element Flashing Flashing Open Heating Element Flashing NTC Sensor Value Out of Range Flashing OPERATION DRIVER HEATED SEAT...
Page 387: Removal
HEATED SEAT SYSTEM 8G - 5 DRIVER HEATED SEAT SWITCH (Continued) INSTALLATION (1) Gently rock the switch back and forth in to its mounting location. (2) Install the appropriate seat cushion side shield. Refer to the Body section of this manual for the pro- cedure.
Page 388: Operation
8G - 6 HEATED SEAT SYSTEM HEATED SEAT ELEMENT (Continued) OPERATION (2) Remove the appropriate seat cushion or seat back trim cover. Refer to the Body section of the ser- The heated seat elements resist the flow of electri- vice manual for the procedures. cal current.
Page 389: Heated Seat Relay Description
HEATED SEAT SYSTEM 8G - 7 HEATED SEAT ELEMENT (Continued) terns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base.
Page 390: Installation
8G - 8 HEATED SEAT SYSTEM HEATED SEAT RELAY (Continued) INSTALLATION (3) Test the seat wire harness between the heated seat module connector and the heated seat wire har- (1) Align the micro-relay terminals with the termi- ness connector for shorted or open circuits. If OK, nal cavities in the receptacle.
Page 391: Diagnosis And Testing - Passenger Heated Seat Switch
HEATED SEAT SYSTEM 8G - 9 PASSENGER HEATED SEAT SWITCH (Continued) DIAGNOSIS AND TESTING - PASSENGER HEATED SEAT SWITCH PIN CALL-OUT HEATED SEAT SWITCH FUNCTION For circuit description and diagrams, refer to Wir- ing Diagrams. LO LED Inspect the Heated Seat Switches for apparent OPEN damage or sticking/binding and replace as required.
Page 392 8G - 10 HEATED WINDOW DEFOGGER HEATED WINDOW DEFOGGER TABLE OF CONTENTS page page HEATED WINDOW DEFOGGER DIAGNOSIS AND TESTING DESCRIPTION ......10 REAR WINDOW DEFOGGER SWITCH .
Page 393: Defogger Switch
HEATED WINDOW DEFOGGER 8G - 11 HEATED WINDOW DEFOGGER (Continued) (2) Connect an ammeter in series with the battery. (7) When the above steps have been completed and Push the rear window defogger switch to the ON the system is still inoperative, one or more of the fol- position.
Page 394 8G - 12 HEATED WINDOW DEFOGGER DEFOGGER SWITCH (Continued) (3) Using a voltmeter, check for battery voltage at Refer to (Fig. 4) and the Rear Window Defogger Pin 1 and 2 (Fig. 3). Switch and Harness Connector Pin Call-Out table. Fig.
Page 395 HEATED WINDOW DEFOGGER 8G - 13 REAR WINDOW DEFOGGER GRID (Continued) • 10-14 volts indicates a break between Mid-Point (C) and terminal (B). Move the lead toward the break and voltage will change as soon as the break is crossed. STANDARD PROCEDURE GRID LINE AND TERMINAL REPAIR WARNING:...
Page 397 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM HORN RELAY DESCRIPTION ......1 DIAGNOSIS AND TESTING - HORN RELAY .
Page 398 8H - 2 HORN HORN SYSTEM (Continued) CONDITION POSSIBLE CAUSE CORRECTION HORN SOUND INTERMITTENTLY AS 1. HORN RELAY CONTROL 1. REMOVE DRIVER AIRBAG THE STEERING WHEEL IS TURNED. CIRCUIT X3 IS SHORTED MODULE AND CHECK FOR TO GROUND INSIDE RUBBING OR LOOSE WIRE/ STEERING WHEEL.
Page 399 HORN 8H - 3 HORN DIAGNOSIS AND TESTING - HORN (1) Disconnect wire connector at horn. (2) Using a voltmeter, connect one lead to ground terminal and the other lead to the positive wire ter- minal (Fig. 1). HORN CONNECTOR PIN CALL-OUT PIN # CIRCUIT NAME GROUND...
Page 400: Horn Switch
8H - 4 HORN HORN RELAY (Continued) (3) Test for continuity between ground and termi- nal 85 of horn relay. (a) When the horn switch is not depressed, no continuity should be present. (b) Continuity to ground when horn switch is depressed.
Page 401 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL INSTALLATION- 2.0/2.4L ....10 DESCRIPTION - IGNITION SYSTEM ..1 INSTALLATION - 2.4L TURBO .
Page 402: Ignition Control
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) SPECIFICATIONS FIRING ORDER—1.6/2.0L TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. 2.0/2.4L Camshaft Position Sensor Screw Cam Magnet/Target 2.0/2.4L Crankshaft Position Sensor Screw 1.6L Cam/Crank Sensor Screw Coolant Temp. Sensor 18.6 Ignition Coil to Cyl. Head 11.8 Knock Sensor Bolt 2.0/2.4L Spark Plugs *...
Page 403: Ignition Coils
IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) IGNITION COILS Primary Resistance at Secondary Resistance at 21°C-27°C Engines Coil Manufacture 21°C-27°C (70°F-80°F) (70°F-80°F) Toyodenso/ 2.4L 0.45 TO 0.65 Ohms 11,500 to 14,700 Ohms Diamond SPARK PLUGS SPARK PLUG CABLE RESISTANCE 1.6L CABLE RESISTANCE...
Page 404: Operation
8I - 4 IGNITION CONTROL AUTO SHUT DOWN RELAY (Continued) When energized, the ASD relay on SBEC vehicles supplies battery voltage to the fuel injectors, ignition coils and the heating element in each oxygen sensor. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR...
Page 405: Removal Removal - 2.0/2.4L
IGNITION CONTROL 8I - 5 CAMSHAFT POSITION SENSOR (Continued) Fig. 5 Target Magnet Polarity - NGC 1 - TARGET MAGNET Fig. 3 Target Magnet - Typical (3) Disconnect electrical connector from camshaft 1 - CAM MAGNET/TARGET position sensor. 2 - CAMSHAFT POSITION SENSOR (4) Remove camshaft position sensor mounting screws.
Page 406: Removal - 1.6L
8I - 6 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) REMOVAL - 1.6L torque. Over torquing could cause cracks in magnet. If magnet cracks replace it. (1) Disconnect the negative battery cable. (2) Install camshaft position sensor. Tighten sensor (2) Relocate the power steering return hose. mounting screws to 9 N·m (80 ±15 in.
Page 407: Removal Removal - 1.6L
IGNITION CONTROL 8I - 7 IGNITION COIL (Continued) Fig. 10 IGNITION COIL LOCATION - 2.4L TURBO Fig. 11 INLET AIR TEMP. SENSOR High tension leads route to each cylinder from the (3) Disconnect the electrical connector at the throt- coil. The coil fires two spark plugs every power tle body.
Page 408: Removal - 2.0/2.4L
8I - 8 IGNITION CONTROL IGNITION COIL (Continued) (6) Remove the 2 bolts to the upper manifold to struts (Fig. 13) and (Fig. 14). Fig. 15 IGNITION COIL (9) Remove the spark plug cables from the ignition Fig. 13 FRONT STRUT BOLTS UPPER INTAKE coil.
Page 409: Removal - 2.4L Turbo
IGNITION CONTROL 8I - 9 IGNITION COIL (Continued) REMOVAL - 2.4L TURBO (1) Disconnect the negative battery cable. (2) Remove the throttle control shield (Fig. 17). Fig. 19 THROTTLE CABLE BRACKET (5) Remove the spark plug cables from the ignition coil.
Page 410: Installation - 1.6L
8I - 10 IGNITION CONTROL IGNITION COIL (Continued) (8) Pull coil up (Fig. 21) and out by the throttle body side of the intake manifold (Fig. 22). Fig. 23 RUBBER INSULATORS AND COIL 1 - Rubber Insulators 2 - Coil Fig.
Page 411: Installation - 2.4L Turbo
IGNITION CONTROL 8I - 11 IGNITION COIL (Continued) Fig. 25 UPPER INTAKE GASKET INPLACE Fig. 26 COIL CAPACITOR - 2.4L TURBO INSTALLATION - 2.4L TURBO (2) Transfer spark plug cables to new coil pack. The coil pack towers are numbered with the cylinder (1) Install coil capacitor and mounting bolt and identification.
Page 412: Removal Removal - 1.6L
8I - 12 IGNITION CONTROL KNOCK SENSOR (Continued) Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maxi- mum authority that long term memory has over tim- ing retard can be calibrated.
Page 413: Spark Plug Removal Removal - 1.6L
IGNITION CONTROL 8I - 13 REMOVAL - 2.0/2.4L SPARK PLUG Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the REMOVAL spark plugs or short circuit the cables to ground. REMOVAL - 1.6L NOTE: REMOVE cables from coil first before remov- ing spark plug insulator.
Page 414: Installation - 2.0/2.4L
8I - 14 IGNITION CONTROL SPARK PLUG (Continued) Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. (1) To avoid cross threading, start the spark plug into the cylinder head by hand.
Page 415: Removal Removal - 1.6L
IGNITION CONTROL 8I - 15 SPARK PLUG CABLE (Continued) plugs. Spark plug cables with insulators that are Always remove the spark plug cable by grasping cracked or torn must be replaced. the top of the spark plug insulator, turning the boot Clean Spark Plug cables with a cloth moistened 1/2 turn and pulling straight up in a steady motion.
Page 417 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER STANDARD PROCEDURE - SELF- DESCRIPTION ......1 DIAGNOSTICS .
Page 418 8J - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER - EXPORT NOTE: If any of the gauge pointers are stuck on the wrong side of the pointer stop, perform one of the following: • Pull the M1 fuse in the fuseblock (refer to Wir- ing Diagrams for fuse locations) and key on.
Page 419 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) instrument cluster operates in the same manner as 26-WAY CLUSTER HARNESS CONNECTOR PIN non-export clusters. Refer to the appropriate Body CALL-OUT Diagnostic Procedures manual for complete diagnosis CAV. FUNCTION and testing of the instrument cluster. POWER GROUND LOGIC GROUND DIAGNOSIS AND TESTING...
Page 420 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) STANDARD PROCEDURE - SELF-DIAGNOSTICS (1) Open hood. (2) Disconnect and isolate the battery negative To put the instrument cluster in Self-Diagnostic cable. Mode, press the trip reset button down and then turn (3) Remove the instrument cluster bezel.
Page 421 INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) INSTALLATION CAUTION: DO NOT turn cluster upside down for longer than 30 minutes (preferably NEVER). This can result in dampening fluid within the gauge pointer assembly to leak causing permanent dam- age to the instrument cluster gauges. DO NOT expose the instrument cluster to direct sunlight for extended periods of time.
Page 423 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....28 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 424: Lamps/Lighting - Exterior
8L - 2 LAMPS/LIGHTING - EXTERIOR OPERATION ......18 REAR FOG LAMP SWITCH - EXPORT LICENSE PLATE LAMP DESCRIPTION .
Page 425: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 3 BACK-UP LAMP (Continued) Fig. 1 BACK-UP LAMP 1 - REAR FASCIA 4 - BULB 2 - BACK-UP LAMP ASSEMBLY 5 - CONNECTOR 3 - LICENSE PLATE LAMP BACK-UP LAMP UNIT REMOVAL (1) Remove screws attaching the back-up lamp assembly to the fascia (Fig.
Page 426: Operation
8L - 4 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) OPERATION (3) Gently push the plunger on the brake lamp switch in until it stops. When the brake pedal is pressed, the plunger on (4) With the switch in this depressed position the outside of the brake lamp switch extends out- (plunger pushed in), use an ohmmeter to test each of ward.
Page 427: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 5 BRAKE LAMP SWITCH (Continued) INSTALLATION (9) Road test the vehicle to ensure proper opera- tion of the brakes (including ABS) and speed control (if equipped). CAUTION: Do not reuse the original brake lamp switch. The switch can only be adjusted once. That is during initial installation of the switch.
Page 428: Installation
8L - 6 LAMPS/LIGHTING - EXTERIOR CENTER HIGH MOUNTED STOP LAMP UNIT (Continued) (4) Remove screws attaching the CHMSL unit (Fig. 7). Fig. 8 COMBINATION FLASHER 1 - COMBINATION FLASHER 2 - MULTI-FUNCTION SWITCH warning switch. An inoperative bulb or incomplete turn signal circuit will cause the flasher rate to dou- Fig.
Page 429: Daytime Running Lamp Module Description
LAMPS/LIGHTING - EXTERIOR 8L - 7 COMBINATION FLASHER (Continued) (4) Close hood. cluster, then back out to the front turn signal switch (5) Verify vehicle and system operation. lamps. OPERATION DAYTIME RUNNING LAMP The Canadian cluster provides steady illumination MODULE of the front turn signal when the ignition switch is in the ON position.
Page 430: Removal
8L - 8 LAMPS/LIGHTING - EXTERIOR FOG LAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS DO NOT 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Wiring Diagnosis. ILLUMINATE 2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to Wiring Diagnosis.
Page 431: Front Position Lamp - Export Description
LAMPS/LIGHTING - EXTERIOR 8L - 9 FOG LAMP UNIT (Continued) Fig. 10 FOG LAMP UNIT ALIGNMENT SCREEN 1 - CENTER LINE OF FOG LAMPS 5 - FOG LAMP HOT SPOT 2 - CENTER LINE OF VEHICLE 6 - FRONT OF FOG LAMP 3 - FLOOR TO CENTER OF FOG LAMP 7 - 7.62 METERS (25 FT.) 4 - 10cm (4 IN.)
Page 432: Removal
8L - 10 LAMPS/LIGHTING - EXTERIOR FRONT POSITION LAMP - EXPORT (Continued) REMOVAL (1) Working in the appropriate wheel well, open the lamp bulb access door located in the front portion of the front wheel well splash shield. (2) Grasp the front position lamp socket extension and pull straight out of headlamp unit.
Page 433: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 11 HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE 1. Charging system output too 1. Test and repair charging system. Refer to Charging DIM WITH ENGINE low. Systems. RUNNING EVEN 2. Poor lighting circuit Z1 - 2.
Page 434: Headlamp Unit Standard Procedure Standard Procedure - Headlamp Unit Alignment
8L - 12 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) HEADLAMP UNIT STANDARD PROCEDURE STANDARD PROCEDURE - HEADLAMP UNIT ALIGNMENT ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicu- lar to a flat wall 7.62 meters (25 ft.) away from front of headlamp lens.
Page 435: Standard Procedure - Headlamp Unit Alignment - Export
LAMPS/LIGHTING - EXTERIOR 8L - 13 HEADLAMP UNIT (Continued) (6) A small dot is molded into each headlamp lens (6) Jounce front suspension three times by pushing signifying the center of the low-beam headlamp. downward on front bumper and releasing. Measure the distance from the center of the head- (7) Measure the distance from the center of head- lamp to the floor.
Page 436 8L - 14 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) Fig. 14 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT 1 - CENTER OF HEADLAMPS 2 - FRONT OF HEADLAMP Fig. 15 FASCIA CENTER ATTACHING POINT 1 - ATTACHING POINTS 2 - FRONT FASCIA Fig.
Page 437: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP UNIT (Continued) Fig. 17 HEADLAMP UNIT HOUSING 1 - ATTACHING STUDS 2 - ATTACHING STUDS 3 - FRONT SIDE MARKER/TURN SIGNAL/PARK LAMP BULB Fig. 19 HEADLAMP UNIT REMOVAL 4 - LOW BEAM LAMP 5 - HIGH BEAM LAMP 1 - MOUNTING HOLES 2 - FRONT SIDE MARKER/PARK/TURN SIGNAL LAMP...
Page 438: Operation
8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING MOTOR - EXPORT (Continued) est, 3 being the highest headlight beam vertical set- accessed by opening the lamp access panel, found in ting. the appropriate front wheel well splash shield. When performing a headlamp beam pattern align- ment on a vehicle equipped with headlamp leveling, be certain the headlamp leveling switch is in the “0”...
Page 439: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP LEVELING MOTOR - EXPORT (Continued) (4) Pull leveling motor straight from headlamp unit. Significant force will be required to unsnap motor control arm from lens reflector. NOTE: The headlamp leveling motor control arm is snapped into the lens reflector mechanism very securely.
Page 440: Installation
8L - 18 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING SWITCH - EXPORT (Continued) INSTALLATION (1) Connect the headlamp leveling switch electrical connector. (2) Install the headlamp leveling switch in the accessory switch bezel. (3) Position and install the accessory switch bezel retaining screws (Fig.
Page 441: License Plate Lamp Unit Removal
LAMPS/LIGHTING - EXTERIOR 8L - 19 LICENSE PLATE LAMP (Continued) (3) Disconnect wire connector and bulb. INSTALLATION (1) Connect wire connector and bulb (Fig. 25). (2) Place lamp in position. (3) Install screws attaching license plate lamp to rear bumper. MULTI-FUNCTION SWITCH DESCRIPTION MULTI-FUNCTION SWITCH...
Page 442: Operation
8L - 20 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) HAZARD WARNING SYSTEM left or right intermediate detent position. In this position the signal lamps flash as described above, The hazard warning system is actuated by a push but the switch returns to the OFF position as soon as button located in the multi-function switch (Fig.
Page 443 LAMPS/LIGHTING - EXTERIOR 8L - 21 MULTI-FUNCTION SWITCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION HAZARD WARNING (1) FAULTY FUSE. (1) REPLACE FUSE. SYSTEM DOES NOT (2) FAULTY FLASHER. (2) REPLACE FLASHER. FLASH. (3) OPEN CIRCUIT IN FEED (3) REPAIR WIRING HARNESS, CHECK WIRE TO SWITCH.
Page 444 8L - 22 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) SWITCH DIAGNOSIS (1) Disconnect and isolate the battery negative cable (Fig. 27). (2) Remove the upper and lower steering column shrouds. (3) Disconnect the switch connector. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the MULTI- FUNCTION SWITCH CONTINUITY TEST table for diagnosis.
Page 445 LAMPS/LIGHTING - EXTERIOR 8L - 23 MULTI-FUNCTION SWITCH (Continued) SWITCH POSITION MODE CONTINUITY BETWEEN TURN SIGNAL IN NEUTRAL, HAZARD A-2 AND B-2 WARNING SWITCH ON A-2 AND B-4 A-2 AND B-5 A-2 AND B-6 A-3 AND A-5 A-3 AND B-7 NEUTRAL B-2 AND B-4 B-2 AND B-5...
Page 446: Removal
8L - 24 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) Fig. 28 COMBINATION FLASHER CONNECTOR (A) Fig. 31 MULTI-FUNCTION SWITCH REMOVE/ INSTALL 1 - MULTI-FUNCTION SWITCH CONNECTOR 2 - HAZARD/WARNING SWITCH 3 - WINDSHIELD WIPER/WASHER SWITCH CONNECTOR 4 - MOUNTING SCREWS 5 - COMBINATION FLASHER (5) Remove multi-function switch mounting screws (Fig.
Page 447: Park/Turn Signal Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 25 INSTALLATION PARK/TURN SIGNAL LAMP (1) Connect wire connector to the back of front side REMOVAL marker/park/turn signal lamp. (2) Install bulb into headlamp unit (Fig. 32) (1) Remove headlamp access cover in splash shield (3) Rotate socket clockwise one quarter turn.
Page 448: Side Repeater Lamp - Export Diagnosis And Testing - Side Repeater Lamp
8L - 26 LAMPS/LIGHTING - EXTERIOR (3) Rotate and pull bulb from socket. SIDE REPEATER LAMP - EXPORT INSTALLATION (1) Push and twist bulb into socket. DIAGNOSIS AND TESTING - SIDE REPEATER (2) Push side repeater lamp socket into side LAMP repeater lamp unit.
Page 449: Tail Lamp Unit Removal
LAMPS/LIGHTING - EXTERIOR 8L - 27 TAIL LAMP (Continued) TAIL LAMP UNIT REMOVAL (1) Remove screw attaching tail lamp assembly to the aperture panel (Fig. 35). (2) Slide the lamp assembly downward in the sheet metal opening. (3) Remove the lamp assembly from the vehicle. (4) Remove the bulb sockets from the lamp assem- bly by rotating the sockets counter-clockwise until free of the assembly.
Page 450 8L - 28 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR INSTALLATION ......30 SPECIFICATIONS DOME LAMP UNIT WITH INTRUSION SENSOR - INTERIOR LAMPS...
Page 451: Center Console Flood Lamp Removal
LAMPS/LIGHTING - INTERIOR 8L - 29 LAMPS/LIGHTING - INTERIOR (Continued) CANDLE BULB LAMP POWER MALFUNCTION INDICATOR LIGHT MAP/READING T1037 LAMP REAR CARGO T904 LAMP SEAT BELT INDICATOR SECURITY ALARM INDICATOR TRAC OFF INDICATOR TURN SIGNAL INDICATOR VISOR VANITY 6501966 VOLTAGE INDICATOR All the interior bulbs utilize a brass or glass wedge base.
Page 452: Courtesy/Reading Lamp Removal
8L - 30 LAMPS/LIGHTING - INTERIOR CENTER CONSOLE FLOOD LAMP HOUSING (Continued) (3) Remove the dome lamp unit from vehicle. INSTALLATION (1) Place lamp into position. (2) Connect electrical connector. (3) Install dome lamp unit into headliner by firmly pushing upward. DOME LAMP WITH INTRUSION SENSOR - EXPORT REMOVAL...
Page 453: Installation
LAMPS/LIGHTING - INTERIOR 8L - 31 DOME LAMP UNIT WITH INTRUSION SENSOR - EXPORT (Continued) Fig. 5 DOME LAMP UNIT WITH INTRUSION SENSOR ORIENTATION TO HEADLINER Fig. 4 DOME LAMP UNIT WITH INTRUSION SENSOR REMOVAL (3) Pull straight down on dome lamp unit with intrusion sensor.
Page 454: Installation
8L - 32 LAMPS/LIGHTING - INTERIOR CLUSTER ILLUMINATION LAMPS (Continued) other indicators are burned out, the entire cluster must be replaced. The cluster illumination bulbs are serviceable and may be replaced once the instrument cluster is removed (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - REMOVAL).
Page 455: Trans Range Indicator Illumination Removal
LAMPS/LIGHTING - INTERIOR 8L - 33 REAR CARGO LAMP UNIT (Continued) (3) Place cargo lamp unit into opening and apply INSTALLATION hand pressure to seat lamp unit into rear quarter (1) Push bulb into socket (Fig. 10). panel. (2) Snap socket into position. (4) Install jack and tool bag in the storage area.
Page 457 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE INSTALLATION ......5 DESCRIPTION .
Page 458 8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) • Compass/Temperature displayed in Celsius graphic north is great enough to cause the compass To put the compass/temperature in the F° display, to give false readings. For proper compass function, press the STEP button once. To put the compass/tem- the correct variance zone must be set.
Page 459 MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) bridges; or, near overhead or underground power NOTE: If the wrong direction is still indicated in the lines. compass display, the area selected for calibration (1) Start the engine. If the compass/temperature may be too close to a strong magnetic field.
Page 460 8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) (3) Depress the Step push button and hold down until the compass mini-trip computer enters the vari- ation adjustment mode and “VAR” along with the current variance zone will appear in the display. (4) Momentarily depress and release the Step push button to step through the zone numbers, until the zone number for your geographic location appears in...
Page 461 MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) (2) Grasp the front of the overhead console and OPERATION pull downward to disconnect the front retaining clips. The ambient temperature sensor is a variable (3) Slide the overhead console forward to disen- resistor that operates on a five-volt reference signal.
Page 462 8M - 6 MESSAGE SYSTEMS AMBIENT TEMP SENSOR (Continued) the sensor resistance should be between 9-11 Kilo- REMOVAL hms (9000-11000 ohms). The sensor resistance should (1) Open hood. read between these two values. If OK, refer to Sensor (2) Working through the hole in the top center of Circuit Testing below.
Page 463 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEAT SYSTEM.
Page 464: Power Locks
8N - 2 POWER LOCKS POWER LOCKS (Continued) For proper diagnosis of these electronic modules or of inder to the UNLOCK position (toward the front of the the PCI data bus network, the use of a DRBIII scan vehicle) will mechanically unlock the door whose key tool and the appropriate diagnostic information are cylinder is being turned.
Page 465: Standard Procedure
POWER LOCKS 8N - 3 POWER LOCKS (Continued) DIAGNOSIS AND TESTING - POWER LOCKS STANDARD PROCEDURE - ROLLING DOOR The most reliable, efficient, and accurate means to LOCKS diagnose the power lock system requires the use of a The toggling of the rolling door lock feature DRBIII scan tool and the proper Diagnostic Proce- (between enabled and disabled) can be performed dures manual.
Page 466: Removal
8N - 4 POWER LOCKS DOOR LOCK SWITCH (Continued) DOOR LOCK SWITCH TEST direction. Reversing the current will cause the motor to move in the opposite direction. SWITCH PINS RESISTANCE DIAGNOSIS AND TESTING - DOOR LOCK POSITION VALUE MOTOR LOCK 2 AND 3 1K OHM ±10 % The most reliable, efficient, and accurate means to...
Page 467: Liftgate Lock Motor Removal
POWER LOCKS 8N - 5 REMOVAL LIFTGATE LOCK MOTOR (1) Disconnect and isolate the battery negative REMOVAL cable. (2) Remove the instrument panel top cover. (1) Disconnect and isolate the battery negative (3) Remove the two screws holding the RKE mod- cable.
Page 468: Remote Keyless Entry Transmitter Description
8N - 6 POWER LOCKS Press any transmitter button, then test each button REMOTE KEYLESS ENTRY individually. The tool will beep if a radio signal TRANSMITTER strength that lights five or more LED’s is detected. Repeat this test three times. If transmitter fails any DESCRIPTION of the test refer to the Diagnostic Procedures man- ual.
Page 469: Standard Procedure - Transmitter Programing
POWER LOCKS 8N - 7 REMOTE KEYLESS ENTRY TRANSMITTER (Continued) STANDARD PROCEDURE - TRANSMITTER four possible). After each transmitter is successfully programmed, a chime will be heard to verify that PROGRAMING successful programming of the transmitter has The Remote Keyless Entry transmitters can be occurred.
Page 470 8N - 8 POWER MIRRORS POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......9 DESCRIPTION .
Page 471 POWER MIRRORS 8N - 9 POWER MIRRORS (Continued) • Refer to the Mirror Motor Test Chart for proper MIRROR SWITCH TEST TABLE wire connections at the switch connector (Fig. 1). Fig. 1 Mirror Switch Harness Connector - LHD MIRROR MOTOR TEST CHART 12 VOLTS GROUND MIRROR REACTION...
Page 472 8N - 10 POWER MIRRORS POWER MIRROR SWITCH - LHD (Continued) Fig. 2 Power Mirror Switch Remove/Install (6) Roll bezel upward and snap into place. (7) Connect the battery negative cable. Fig. 3 Power Fold-Away Mirror Switch POWER FOLDAWAY MIRROR WOBBLE LEFT MIRROR RIGHT...
Page 473 POWER MIRRORS 8N - 11 POWER FOLDAWAY MIRROR SWITCH - RHD (Continued) RETRACTED MIRROR SWITCH CIRCUIT TEST NOTE: MIRROR POSITION SWITCH MUST BE IN THE “RETRACTED” POSITION TO USE CHART BELOW. WOBBLE LEFT MIRROR RIGHT PLATE SELECTED MIRROR POSITION SELECTED CONTINUITY CONTINUITY BETWEEN...
Page 474 8N - 12 POWER SEAT SYSTEM POWER SEAT SYSTEM TABLE OF CONTENTS page page POWER SEAT SYSTEM POWER SEAT TRACK DESCRIPTION ......12 DESCRIPTION .
Page 475: Description
POWER SEAT SYSTEM 8N - 13 POWER SEAT SYSTEM (Continued) DIAGNOSIS AND TESTING - POWER SEAT The power seat switch should not be held applied in either direction after the adjuster has reached its SYSTEM travel limit. The power seat adjuster motor contains Before any testing of the power seat system is a self-resetting circuit breaker to protect it from over- attempted, the battery should be fully-charged and...
Page 476: Description
8N - 14 POWER SEAT SYSTEM DRIVER SEAT SWITCH (Continued) REMOVAL (1) Open hood. (2) Disconnect and isolate the battery negative cable. (3) Remove two screws to left cushion side shield. (4) Disconnect wiring from switch. (5) Remove attaching screws and switch from bezel.
Page 477: Removal
POWER SEAT SYSTEM 8N - 15 POWER SEAT TRACK (Continued) cavity of the power seat wire harness connector for the power seat switch. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit between the power seat switch and the JB as required.
Page 478: Lumbar Description
8N - 16 POWER SEAT SYSTEM OPERATION LUMBAR The lumbar adjuster lever, located on the inboard DESCRIPTION side of each front seat attaches to a cable located inside the seat back. This cable/lever operates the Some vehicles are equipped with a mechanical lumbar adjuster mechanism.
Page 479 POWER WINDOWS 8N - 17 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS REMOVAL ......19 DESCRIPTION .
Page 480: Power Window Switch
8N - 18 POWER WINDOWS POWER WINDOWS (Continued) will grunt and the inner door panel will flex when POWER WINDOW SWITCH CONTINUITY actuated in that one direction. TABLE (6) Reverse jumper probes at the motor connector terminals and window should now move in opposite SWITCH POSITION CONTINUITY BETWEEN direction.
Page 481 POWER WINDOWS 8N - 19 POWER WINDOW SWITCH (Continued) REMOVAL FRONT (1) Disconnect and isolate the battery negative cable. (2) Using a trim stick (special tool #C-4755) or equivalent, gently pry at the top of the switch (Fig. Fig. 5 REAR WINDOW SWITCH INSTALLATION FRONT (1) Connect electrical harness connector to switch.
Page 483 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS INSTALLATION ......12 DESCRIPTION ......1 OCCUPANT RESTRAINT CONTROLLER OPERATION .
Page 484: Operation
8O - 2 RESTRAINTS RESTRAINTS (Continued) Fig. 1 FRONT AIRBAG SYSTEM COMPONENT LOCATION 1 - DRIVER AIRBAG Fig. 2 SEAT BELT TENSIONER LOCATION - 2 - CLOCK SPRING TYPICAL 3 - PASSENGER AIRBAG 4 - OCCUPANT RESTRAINT CONTROLLER (ORC) 1 - SEAT BELT TENSIONER •...
Page 485 RESTRAINTS 8O - 3 RESTRAINTS (Continued) BELT TENSIONER SYSTEM REPLACE AIRBAG SYSTEM COMPONENTS WITH MOPAR REPLACEMENT PARTS ONLY. SUBSTI- At the onset of an impact event, each tensioner TUTE PARTS MAY APPEAR INTERCHANGEABLE, uses a pyrotechnic device which is triggered simulta- BUT INTERNAL DIFFERENCES MAY RESULT IN neously with the airbags to rapidly retract the seat INFERIOR OCCUPANT PROTECTION.
Page 486: Diagnosis And Testing - Airbag System
8O - 4 RESTRAINTS RESTRAINTS (Continued) SIDE IMPACT AIRBAG SYSTEM DIAGNOSIS AND TESTING - AIRBAG SYSTEM (1) With the battery negative remote cable discon- WARNING: THE SIDE IMPACT AIRBAG SYSTEM nected, connect the DRB III scan tool to the Data CONTAINS SENSITIVE, COMPLEX ELECTRONIC Link connector.
Page 487: Standard Procedure - Service After An Airbag Deployment
RESTRAINTS 8O - 5 RESTRAINTS (Continued) STANDARD PROCEDURE - SERVICE AFTER AN mode at time of airbag deployment, operate blower motor on low speed and vacuum powder residue AIRBAG DEPLOYMENT expelled from the heater and A/C outlets. Multiple vacuum cleaning may be necessary to decontaminate DRIVER AIRBAG the interior of the vehicle.
Page 488: Operation
8O - 6 RESTRAINTS CLOCK SPRING (Continued) The clock spring is mounted to the steering column WARNING: DO NOT CONNECT BATTERY NEGATIVE behind the steering wheel (Fig. 4). This assembly CABLE YET (Refer to 8 - ELECTRICAL/RESTRAINTS consists of a flat, ribbon like, electrically conductive - DIAGNOSIS AND TESTING - AIRBAG SYSTEM).
Page 489: Installation
RESTRAINTS 8O - 7 CLOCK SPRING (Continued) (11) Lock the clock spring rotor in the center posi- DRIVER AIRBAG tion as follows: Insert a paper clip wire through the hole in the rotor at the 10 o’clock position and bend DESCRIPTION to prevent it from falling out.
Page 490: Operation
8O - 8 RESTRAINTS DRIVER AIRBAG (Continued) The driver airbag protective trim cover is the most (5) Using a pair of 90° internal snap ring pliers or visible part of the driver airbag system (Fig. 6). The equivalent, pry open the retaining clip (Fig. 8) on the driver airbag is mounted directly to the steering back of the steering wheel to release the retaining wheel.
Page 491: Installation
RESTRAINTS 8O - 9 DRIVER AIRBAG (Continued) Fig. 10 SECOND DRIVER AIRBAG RETAINING PIN - REMOVAL Fig. 12 DRIVER AIRBAG HORN CONNECTOR 1 - WIRE FROM CLOCK SPRING 2 - WIRE TO HORN SWITCH 3 - DRIVER AIRBAG IGNITER 4 - SMALL SCREWDRIVER (1) Connect the squib wire to the driver airbag.
Page 492: Installation
8O - 10 RESTRAINTS DRIVER AIRBAG COVER (Continued) (4) Remove the driver airbag (Refer to 8 - ELEC- TRICAL/RESTRAINTS/DRIVER AIRBAG - REMOV- AL). (5) With driver airbag removed, pick a corner and push down on the inflator or latch hook mounting plate until the latch hooks push out of the driver air- bag cover (Fig.
Page 493: Front Seat Belt & Retractor Removal
RESTRAINTS 8O - 11 (6) Align locating pins on backside of trim panel to FRONT SEAT BELT & mating holes in B-pillar. RETRACTOR (7) Push clips on trim panel into slots in B-pillar. (8) Install access cover to B-pillar trim. REMOVAL (9) Install bolt attaching lower seat belt anchor to floor pan kick-up.
Page 494: Front Seat Belt Height Adjuster Removal
8O - 12 RESTRAINTS FRONT SEAT BELT HEIGHT OCCUPANT RESTRAINT ADJUSTER CONTROLLER REMOVAL DESCRIPTION WARNING: FRONT SEAT BELT ASSEMBLIES MUST BE REPLACED AFTER A COLLISION. (1) Remove B-pillar trim (Refer to 23 - BODY/IN- TERIOR/B-PILLAR TRIM - REMOVAL). (2) Remove the two bolts attaching front seat belt height adjuster to B-pillar (Fig.
Page 495: Removal
RESTRAINTS 8O - 13 OCCUPANT RESTRAINT CONTROLLER (Continued) The microprocessor in the ORC monitors internal INSTALLATION components and the airbag system electrical circuits (1) Connect ORC connector and ensure that the to determine the system readiness. If the ORC connector and all locking tabs are engaged. detects a monitored system fault, it sends messages to the instrument cluster over the PCI data bus to CAUTION: USE SUPPLIED NUTS ONLY...
Page 496: Operation
8O - 14 RESTRAINTS PASSENGER AIRBAG (Continued) The passenger airbag is located behind the passen- ger airbag cover, between the glove box and instru- ment panel top cover (Fig. 19). The passenger airbag includes a stamped steel housing within which the cushion and inflator are mounted and sealed.
Page 497: Installation
RESTRAINTS 8O - 15 PASSENGER AIRBAG (Continued) (3) Install two passenger airbag cover screws along the top edge of the airbag cover. Torque trim screws to 2 N·m (20 in. lbs.). (4) Install four passenger airbag cover screws along the bottom end of the airbag cover. Torque trim screws to 2 N·m (20 in.
Page 498: Rear Center Seat Belt & Retractor Removal
8O - 16 RESTRAINTS PASSENGER AIRBAG COVER (Continued) (2) Install the passenger airbag (Refer to 8 - (6) Feed seat belt and hardware through trim ELECTRICAL/RESTRAINTS/PASSENGER AIRBAG openings. - INSTALLATION). (7) Unbolt and remove the retractor and belt assembly. WARNING: DO NOT CONNECT BATTERY NEGATIVE CABLE YET (Refer to 8 - ELECTRICAL/RESTRAINTS INSTALLATION - DIAGNOSIS AND TESTING - AIRBAG SYSTEM).
Page 499 RESTRAINTS 8O - 17 SEAT AIRBAG (Continued) The left and right seat airbags (Fig. 23) are located in the outboard end of the front seat backs. The air- bag contains a bag, an inflator (small canister of highly compressed gas), and a mounting bracket. The seat airbag cannot be repaired and must be replaced, with the entire seat back assembly, if deployed or in any way damaged.
Page 500: Installation
8O - 18 RESTRAINTS SEAT AIRBAG (Continued) (2) Pull seat airbag and nylon sleeve assembly up to line up mounting studs with holes provided in seat back frame mounting bracket (Fig. 27). Install the seat airbag retaining nuts. Torque to 10.7 N·m (94.7 in.
Page 501: Side Impact Airbag Control Module Description
RESTRAINTS 8O - 19 same time as the DTC is set, the ORC sends a PCI SIDE IMPACT AIRBAG data bus message to the cluster requesting the air- CONTROL MODULE bag warning lamp to be turned ON. Observe all ORC WARNING and CAUTION statements (Refer to 8 - DESCRIPTION ELECTRICAL/RESTRAINTS - WARNING) when ser-...
Page 502: Installation
8O - 20 RESTRAINTS SIDE IMPACT AIRBAG CONTROL MODULE (Continued) (6) Remove the seat belt retractor (Refer to 8 - NOTE: Place the ground eyelet over the TOP REAR ELECTRICAL/RESTRAINTS/FRONT SEAT BELT & (towards the rear of the vehicle) weld stud when RETRACTOR - REMOVAL).
Page 503 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL SERVO DESCRIPTION ......1 DESCRIPTION .
Page 504: Speed Control
8P - 2 SPEED CONTROL SPEED CONTROL (Continued) • The speed signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) • The speed signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) •...
Page 505: Operation - Checking For Diagnostic Codes
SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) train) and can maintain the set speed at a reduced cles) (PCM on NGC vehicles) waits until the speed throttle position, the transmission will upshift, as control system opens the throttle at least 6 degrees appropriate, until the set speed can be maintained in before upshifting to OVERDRIVE again.
Page 506: Description
8P - 4 SPEED CONTROL SPEED CONTROL (Continued) • Secure attachment at both ends of the speed control servo cable. • Smooth operation of throttle linkage and throttle body air valve. • Conduct electrical test at PCM. • Failed speed control servo. Do the servo vacuum test.
Page 507: Removal - 2.4L Turbo
SPEED CONTROL 8P - 5 CABLE (Continued) Fig. 5 Retaining Tabs Fig. 7 THROTTLE CONTROL SHIELD Fig. 8 Retaining Tabs (7) Push and pull up the speed control servo from the mounting bracket. Fig. 6 Speed Control System (8) Unlock and disconnect the electrical connector REMOVAL - 2.4L TURBO from the speed control servo (Fig.
Page 508: Installation - 2.4L Turbo
8P - 6 SPEED CONTROL CABLE (Continued) Fig. 11 Cable Clip Fig. 9 VACUUM AND ELECTRICAL CONNECTION 1 - HAIRPIN CLIP 1 - Electrical Connector 2 - Vacuum Line and Nipple (10) Install the air cleaner lid, makeup air hose. INSTALLATION - 2.4L TURBO (1) Install the cable.
Page 509: Operation
SPEED CONTROL 8P - 7 SERVO (Continued) OPERATION The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is ser- viced only as a complete assembly.
Page 510: Installation
8P - 8 SPEED CONTROL SERVO (Continued) WARNING: IF REMOVAL OF AIRBAG MODULE IS INSTALLATION NECESSARY, REFER TO THE RESTRAINT SYS- TEMS. INSTALLATION (1) Install hairpin clip to servo and cable (Fig. 13). (1) Remove the air cleaner lid, disconnect the inlet (2) Install servo studs through cable bell and then air temperature sensor and makeup air hose.
Page 511: Switch Removal
SPEED CONTROL 8P - 9 SWITCH (Continued) OPERATION The reservoir stores engine vacuum. Manifold vac- uum is supplied from the brake booster check valve. The speed control vacuum supply hose has a check valve at the source (brake booster) to maintain the highest available vacuum level in the servo, reservoir and vacuum hoses.
Page 512: Installation
8P - 10 SPEED CONTROL VACUUM RESERVOIR (Continued) (6) Remove the 2 screws from vacuum reservoir (Fig. 19). Fig. 20 Vacuum Reservoir 1 - VACUUM RESERVOIR Fig. 19 Reservoir Mounting Screws (2) Install reservoir and tighten screws to 5 N·m (7) Disconnect vacuum hose from reservoir (Fig.
Page 513 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY REMOVAL ......5 DESCRIPTION .
Page 514: Vehicle Theft Security
8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) OPERATION In the event the Standard VTSS is triggered, the VTSS will sound the vehicle horn and flash the head- lamp and park lamps in a alternating fashion. VEHICLE THEFT SECURITY SYSTEM The VTSS and RKE system receives signals from The system is armed when the vehicle is locked the hand-held key fob or transmitter.
Page 515: Standard Procedure
Check for battery voltage at the fused ignition switch assigned to it’s original SKIM from the vehicle output (run/start) circuit cavity of the SKIM wire owner, the vehicle’s invoice or from Chrysler’s Cus- harness connector. If OK, use a DRB lll scan tool tomer Center.
Page 516: Door Cylinder Lock Switch Removal
8Q - 4 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) enter secured access mode. Once secured access (5) Remove the switch from the inside of the door mode is active, the SKIM will remain in that mode by pulling the switch and attached wires out of the for 60 seconds.
Page 517: Hood Ajar Switch - Export Removal
VEHICLE THEFT SECURITY 8Q - 5 HOOD AJAR SWITCH - EXPORT REMOVAL (1) Open hood. (2) Disconnect and isolate the battery negative cable (Fig. 1). (3) Disconnect wire harness connector from hood ajar switch. (4) Firmly press tangs on the bottom side of the switch together and push up through bracket (Fig.
Page 518: Installation
8Q - 6 VEHICLE THEFT SECURITY INTRUSION SENSOR - EXPORT (Continued) (3) Push the dome lamp unit with intrusion sensor straight up. (4) Rotate the dome lamp unit with intrusion sen- sor clockwise. (5) Connect the battery negative cable. LIFTGATE CYLINDER LOCK SWITCH REMOVAL (1) Open hood.
Page 519: Skis Indicator Lamp Description
VEHICLE THEFT SECURITY 8Q - 7 LIFTGATE CYLINDER LOCK SWITCH (Continued) (4) Install the liftgate trim panel (Refer to 23 - SIREN - EXPORT BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/ TRIM PANEL - INSTALLATION). DESCRIPTION (5) Connect the battery negative cable (Fig. 1). (6) Close hood. (7) Verify vehicle and system operation.
Page 520: Installation
8Q - 8 VEHICLE THEFT SECURITY SIREN - EXPORT (Continued) Fig. 10 SENTRY KEY IMMOBILIZER TRANSPONDER 1 - MOLDED CAP Fig. 9 SIREN LOCATION 2 - TRANSPONDER 3 - MOLDED CAP REMOVED 1 - SIREN 4 - SENTRY KEY 2 - LEFT FRONT FENDER 3 - LEFT DOOR MIRROR these codes is stored within the transponder and in INSTALLATION...
Page 521 VEHICLE THEFT SECURITY 8Q - 9 TRANSPONDER KEY (Continued) Sentry Keys. When programming a blank Sentry Key (2) Insert one of the two valid Sentry Keys into the transponder, the key must first be cut to match the ignition switch and turn the ignition switch to the ignition lock cylinder of the vehicle for which it will ON position.
Page 523 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS FRONT WIPER MOTOR - RHD DESCRIPTION ......1 REMOVAL .
Page 524: Wipers/Washers
8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) Fig. 1 FRONT WINDSHIELD WIPER/WASHER SWITCH LOCATION 1 - TURN SIGNAL CONTROL STALK 5 - CANCELLING CAM 2 - HAZARD WARNING SWITCH 6 - PANEL DIMMER/INTERIOR LIGHT SWITCH 3 - WINDSHIELD WIPER/WASHER CONTROL 7 - EXTERIOR LIGHTING CONTROL/FOG LAMP 4 - WINDSHIELD WIPER/WASHER SWITCH RETAINING SCREWS FRONT WINDSHIELD WASHER SYSTEM The rear wiper system includes the following com-...
Page 525: Operation
WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) OPERATION Fluid, gravity fed from the reservoir, is forced by the pump through rubber hoses to the hood mounted nozzles which direct the fluid streams to the wind- FRONT WINDSHIELD WIPER SYSTEM shield. Move the control lever up to select the desired wiper speed.
Page 526 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) (b) If fuse is defective, replace and check motor (5) Check terminal 2 of wiper switch connector for operation in all switch positions. continuity to ground. If OK, go to Step 6. If not OK, (c) If motor is still inoperative and the fuse does repair the ground circuit as necessary.
Page 527: Diagnosis And Testing - Rear Wiper System
WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) WIPERS WILL OPERATE CONTINUOUSLY WITH (3) Check the fused ignition switch output (run/ac- cessory) fuse in the fuse block. If OK, go to Step 4. If THE SWITCH IN THE INTERMITTENT POSITION - not OK, repair the shorted circuit or component as WHEN WIPER SWITCH IS TURNED OFF, WIPERS required and replace the faulty fuse.
Page 528: Front Washer Nozzle Removal
8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) WASHER SYSTEM TEST CONDITION POSSIBLE CAUSES CORRECTION PUMP RUNS NO FLUID 1. NO FLUID IN THE 1. FILL RESERVOIR. FLOWING. RESERVOIR. 2. NOZZLE PLUGGED 2. THAW AND CHECK FLOW IF BLOCKED OR FROZEN. 3. BROKEN, LOOSE OR 3.
Page 529: Installation
WIPERS/WASHERS 8R - 7 FRONT WIPER ARMS (Continued) Fig. 7 FRONT WIPER ARM - REMOVE/INSTALL INSTALLATION Fig. 8 WIPER BLADE/ARM PARK LINES Before installation activate wiper system to ensure the wiper module is in the PARK position. Position 1 - PARK LINES 2 - BLACK OUT AREA wiper arms so that the tip of the driver’s blade and the middle of the passenger’s blade is on the park...
Page 530: Cleaning - Front Wiper Blades
8R - 8 WIPERS/WASHERS FRONT WIPER BLADES (Continued) slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the wind- shield.
Page 531: Front Wiper Module Removal
WIPERS/WASHERS 8R - 9 FRONT WIPER BLADE ELEMENTS (Continued) (1) Install wiping element into blade assembly. (8) Remove three front wiper module mounting Push pocket of the rubber element in the end claw bolts and remove module from vehicle (Fig. 13). together with vertebra (metal rails) (Fig.
Page 532: Front Wiper Module - Rhd Removal
8R - 10 WIPERS/WASHERS FRONT WIPER MODULE (Continued) (5) Install the wiper arm retaining nut (Fig. 7) and torque to 21 N·m (190 in. lbs.). (6) Install the wiper arm nut cap (Fig. 7). (7) Connect the battery negative cable (Fig. 12). (8) Close hood.
Page 533 WIPERS/WASHERS 8R - 11 FRONT WIPER MOTOR (Continued) WIPER MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION WIPER BLADES DO NOT (1) WIPER ARMS (1) REMOVE WIPER ARMS AND REPARK. PARK PROPERLY. IMPROPERLY PARKED. REFER TO ELECTRICAL, WIPERS/WASHERS, WIPER ARM, REMOVAL. (2) WIPER ARMS ARE LOOSE (2) REMOVE WIPER ARM AND REPARK.
Page 534: Installation
8R - 12 WIPERS/WASHERS FRONT WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION WIPER MOTOR WILL NOT (1) BLOWN FUSE. (1) REPLACE FUSE, AND RUN SYSTEM. RUN. (2) NEW FUSE BLOWS. (2) CHECK FOR SHORT IN WIRING OR SWITCH. (3) NEW FUSE BLOWS. (3) REPLACE FUSE, REMOVE MOTOR CONNECTOR, TURN SWITCH ON, FUSE DOES NOT BLOW, REPLACE MOTOR.
Page 535: Installation
WIPERS/WASHERS 8R - 13 FRONT WIPER MOTOR - RHD (Continued) (6) Remove the cowl cover. The right side cover FRONT WIPER SWITCH overlaps the left side cover, so they both must be removed. DIAGNOSIS AND TESTING - FRONT (a) Remove the rear engine compartment seal at WIPER/WASHER SWITCH the cowl.
Page 536: Rear Washer Nozzle Removal
8R - 14 WIPERS/WASHERS FRONT WIPER SWITCH (Continued) REAR WASHER NOZZLE REMOVAL (1) Open liftgate. (2) Remove liftgate CHMSL access panel (Refer to BODY/DECKLID/HATCH/LIFTGATE/TAIL- GATE/CHMSL COVER PANEL - REMOVAL). (3) Disconnect the rear washer hose at nozzle. (4) Remove the nut retaining the rear washer noz- zle and remove the nozzle from rear window glass and vehicle.
Page 537: Installation
WIPERS/WASHERS 8R - 15 REAR WIPER ARMS (Continued) Fig. 20 REAR WIPER BLADE/ARM TICK MARK Fig. 19 REAR WIPER ARM - REMOVE/INSTALL 1 - EBL GRID LINES INSTALLATION 2 - TICK MARK Before installation activate wiper system to ensure the wiper module is in the PARK position. Position wiper arm so that the tip of the blade is on the park line on the windshield.
Page 538: Installation
8R - 16 WIPERS/WASHERS REAR WIPER MOTOR (Continued) REAR WIPER SWITCH DIAGNOSIS AND TESTING - REAR WIPER SWITCH The rear windshield wiper/washer switch may be tested in the vehicle or out of the vehicle, on the bench. IN-VEHICLE TESTING (1) Remove the switch from the instrument panel but leave the switch connected, refer to Instrument Panel Systems, Accessory Switch Bezel Removal and Installation.
Page 539: Removal
WIPERS/WASHERS 8R - 17 REAR WIPER SWITCH (Continued) to (Fig. 25) hose routing. Refer also to Body, Interior component Removal and Installation. INSTALLATION Depending on how much of the vehicle has been de-trimmed, either splice in a small piece of hose or replace the entire length of affected hose.
Page 540: Installation
8R - 18 WIPERS/WASHERS WASHER PUMP MOTOR (Continued) (11) Remove plastic strap from around pump. (4) Remove wiper arm retaining nut (Fig. 7). (12) Gently pry pump away from reservoir and out (5) Remove the arm from the pivot using a rocking of grommet.
Page 541: Washer Reservoir Removal
WIPERS/WASHERS 8R - 19 WASHER PUMP MOTOR - RHD (Continued) (9) Install the wiper arm retaining nut (Fig. 7) and INSTALLATION torque to 21 N·m (190 in. lbs.). (1) Insert pump into pump grommet. (10) Install the wiper arm nut cap (Fig. 7). (2) Place plastic strap over pump assembly and (11) Connect the battery negative cable (Fig.
Page 543 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 AUDIO SYSTEM ..... 8W-47-1 COMPONENT INDEX .
Page 545 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 546: Wiring Diagram Information
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 547 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 548 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 549: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 550: Description - Section Identification And Information
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 551: Description - Connector, Ground And Splice Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 552: Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 553: Standard Procedure - Testing Of Voltage Potential
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (2) Connect the other lead of the voltmeter to the selected test point.
Page 554: Voltage Drop
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS VOLTAGE DROP WIRING/TERMINAL (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). (2) Connect the other lead of the voltmeter to the other side of the switch, component or circuit.
Page 555: Connector Removal
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 INSTALLATION CONNECTOR (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 556 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 557 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 558: Diode Removal
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 559: Standard Procedure - Wire Splicing
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 561 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... . 8W-42 Fog Lamps ......8W-50, 51 A/C Compressor Clutch .
Page 562 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Output Speed Sensor ....8W-31 Side Markers ......8W-52 Overhead Console Module .
Page 563 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch Relay ..8W-10-10, 16, 21 Glow Plug No. 1 ..... 8W-10-32 A/C Compressor Clutch .
Page 595 8W-11 FUSE BLOCK 8W - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page A/C Compressor Clutch Relay ..8W-11-14 Heated Seat Module ....8W-11-10 Airbag Control Module .
Page 615 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page Left Rear Power Window Switch ... . 8W-15-27 A/C Compressor Clutch ....8W-15-10, 11 Left Rear Turn Signal Lamp .
Page 643 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Airbag Control Module ....8W-18-5 Power Distribution Center ..8W-18-2, 3, 4 Controller Antilock Brake .
Page 649 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auto Shut Down Relay ..8W-20-2, 3, 4, 6 G103 ......8W-20-3, 5 Battery .
Page 657 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2, 3, 4 Ignition Switch .
Page 661 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-8, 23, 24, 41 G102 ..8W-30-10, 11, 14, 28, 32, 37, 43, 50 A/C High Pressure Switch .
Page 711 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Autostick Switch ....8W-31-8 Ignition Switch .
Page 719 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-4, 5 Input Speed Sensor ....8W-33-6 Clockspring .
Page 727 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-35-2 G201 ......8W-35-3 Controller Antilock Brake .
Page 731 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Clockspring ......8W-39-12 Left Low Beam Headlamp .
Page 745 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page A/C-Heater Control Switch ... . 8W-40-13 Left Fog Lamp ....8W-40-16, 17 Airbag Control Module .
Page 763 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter ..... . . 8W-41-3 Horn Relay .
Page 767 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ..8W-42-3, 5, 7, 9 Fuse 12 ....8W-42-3, 4, 5, 6, 7 A/C Compressor Clutch Relay .
Page 777 8W-43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Component Page Component Page Airbag Control Module ..8W-43-2, 3, 4, 5, 6 Fuse Block ..... . . 8W-43-2, 3 Clockspring .
Page 783 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C-Heater Control Switch ... . . 8W-44-5 Instrument Cluster ....8W-44-2, 4, 5 Cargo Lamp .
Page 789 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Data Link Connector ....8W-47-2 Left Instrument Panel Speaker ..8W-47-4 Fuse 2 .
Page 793 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Fuse 6 ......8W-48-2 Instrument Cluster .
Page 795 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temperature Sensor ... 8W-49-2 G203 ......8W-49-3 Cargo Lamp .
Page 799 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Fuse 1 ......8W-50-2 Left City Lamp .
Page 809 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-2 Left Rear Fog Lamp ....8W-51-3 Brake Lamp Switch .
Page 819 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page G103 ......8W-52-3, 6 Left Turn Signal Indicator .
Page 825 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Front Washer Pump Motor ... 8W-53-2, 3 G201 ......8W-53-2, 3 Front Wiper Motor .
Page 829 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 2 (FB) ... 8W-60-2, 4 Left Front Power Window Motor ..8W-60-3 Front Power Window Switch .
Page 835 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Data Link Connector ....8W-61-7 Liftgate Ajar Switch ....8W-61-7 Driver Door Ajar Switch .
Page 845 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Fuse 2 ......8W-62-2 Left Power Mirror .
Page 853 8W-63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Driver Heated Seat Back ....8W-63-5 Heated Seat Module ....8W-63-5, 6 Driver Heated Seat Cushion .
Page 859 8W-64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 14 ......8W-64-2 Sunroof Motor .
Page 861 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-10-19, 20 S172 .
Page 865 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch (Diesel) ..8W-80-4 C112 (1.6L) ......8W-80-20 A/C Compressor Clutch (Gas) .
Page 866 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C303 ......8W-80-36 Fuel Injector No.
Page 867 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Left Turn Signal Indicator ... . 8W-80-65 Right Cylinder Lock Switch (Export) ..8W-80-82 Left Visor/Vanity Lamp (Light Package) . . 8W-80-65 Right Door Lock Switch .
Page 868 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS A/C COMPRESSOR CLUTCH (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND A/C COMPRESSOR CLUTCH (GAS) - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND...
Page 869 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C LOW PRESSURE SWITCH - DK. GREEN 2 WAY CIRCUIT FUNCTION C21 20DB/OR (EXCEPT 2.4L TURBO) A/C LOW PRESSURE SIGNAL C21 20DB/WT (2.4L TURBO) A/C LOW PRESSURE SIGNAL C20 20BR A/C REQUEST SIGNAL A/C PRESSURE TRANSDUCER (2.4L TURBO) - BLACK 4 WAY CIRCUIT FUNCTION...
Page 870 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS ACCELERATOR PEDAL POSITION SENSOR (1.6L/DIESEL) - BLACK 10 WAY CIRCUIT FUNCTION K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR NO. 1 GROUND F858 20LG/PK (DIESEL) ACCELERATOR PEDAL POSITION SENSOR NO. 1 5V SUPPLY F858 20DG/LG (1.6L) ACCELERATOR PEDAL POSITION SENSOR NO.
Page 871 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AIRBAG CONTROL MODULE C1 (ORC) (PREMIUM) - YELLOW 32 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R131 20LG/YL...
Page 872 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS AIRBAG CONTROL MODULE C2 (ORC) (PREMIUM) - YELLOW 32 WAY CIRCUIT FUNCTION R45 20DG/LB DRIVER SQUIB 1 LINE 2 R43 20BK/LB DRIVER SQUIB 1 LINE 1 R44 20DG/YL PASSENGER SQUIB 1 LINE 2 R42 20BK/YL PASSENGER SQUIB 1 LINE 1 D25 20VT/YL...
Page 873 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AMBIENT TEMPERATURE SENSOR (NGC) - GRAY 2 WAY CIRCUIT FUNCTION K145 20BR/OR AAT SIGNAL K167 20BR/YL SENSOR GROUND 2 AUTOSTICK SWITCH - WHITE 4 WAY CIRCUIT FUNCTION T44 20YL/LB AUTOSTICK DOWNSHIFT SWITCH SIGNAL T5 20LG/LB AUTOSTICK UPSHIFT SWITCH SIGNAL Z1 20BK...
Page 874 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BATTERY TEMPERATURE SENSOR (2.0L/2.4L) - BLACK 2 WAY CIRCUIT FUNCTION K118 20PK/YL BATTERY TEMP SIGNAL K167 20BR/YL SENSOR GROUND 2 BATTERY TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K118 20PK/YL BATTERY TEMPERATURE SENSOR SIGNAL K4 20BK/LB SENSOR GROUND...
Page 875 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 BOOST PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION K121 20BR/WT SENSOR GROUND K1 20BK/YL BOOST PRESSURE SENSOR SIGNAL K9 20RD/BK SENSOR REFERENCE VOLTAGE B BRAKE LAMP SWITCH (DIESEL) - BLACK 6 WAY CIRCUIT FUNCTION F32 18PK/DB...
Page 876 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER Z1 20BK GROUND C102 (2.0L/2.4L) - BLACK (ENGINE SIDE) CIRCUIT C3 20DB/BK G7 20WT/OR (MTX) G6 20GY A142 16DG/OR T40 14BR...
Page 877 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C103 (2.0L/2.4L EXCEPT TURBO) - DK. GRAY (ENGINE SIDE) CIRCUIT K4 20BK/LB K2 20TN/BK K11 18WT/DB K12 18TN K13 18YL/WT K14 18LB/BR A142 16DG/OR C103 (2.0L/2.4L EXCEPT TURBO) - DK. GRAY (INJECTOR HARNESS SIDE) CIRCUIT K4 20BK/LB K2 20TN/BK...
Page 878 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C103 (2.4L TURBO) - BLACK (INJECTOR HARNESS SIDE) CIRCUIT K1 20DG/RD K4 20BK/LB K11 18WT/DB K12 18TN K13 18YL/WT K14 18LB/BR A142 18DG/OR K17 16DB/TN K19 16BK/GY K20 18DG K41 20BK/DG K7 20OR K904 20DB/DG K99 18BR/OR Z1 18BK...
Page 879 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C105 - WHITE (HEADLAMP AND DASH SIDE) CIRCUIT B27 18RD/YL (TRACTION CONTROL) L1 20VT/BK (EXCEPT 2.0L RHD EATX) L1 18VT/BK (2.0L RHD EATX) A1 14RD C7 14BK/TN K4 20BK/LB (DIESEL) K167 20BR/YL (EXCEPT1.6L/DIESEL) A15 18PK/DG X5 20LB/RD (SIREN) L44 16VT/RD...
Page 880 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C106 - GRAY (HEADLAMP AND DASH SIDE) CIRCUIT L39 18LB (FOG LAMPS) V20 18BK/WT A3 12RD/WT L160 18TN/RD (EXCEPT EXPORT) C20 20BR L161 18LG/OR (EXCEPT EXPORT) X3 20BK/RD G4 20DB F11 20RD/WT (AUTOSTICK) F1 16DB/BK A35 14DB L50 18WT/TN...
Page 881 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C106 - GRAY (INSTRUMENT PANEL SIDE) CIRCUIT L39 18LB (FOG LAMPS) V20 18BK/WT A3 12RD/WT L160 18TN/RD (EXCEPT EXPORT) C20 20BR L161 18LG/OR (EXCEPT EXPORT) X3 20BK/RD G4 20DB F11 20RD/WT (AUTOSTICK) F1 16DB/BK A35 14DB (POWER SEATS) A35 14DB (HEATED SEATS)
Page 882 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C107 (EXPORT) - BLACK (HEADLAMP LEVELING SIDE) CIRCUIT L7 18BK Z1 18BR L13 18OR L43 18YL C108 (EXPORT) - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT L7 18BK/YL Z1 18BK L13 20BR/YL L43 18VT C108 (EXPORT) - BLACK (HEADLAMP LEVELING SIDE) CIRCUIT...
Page 883 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C110 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT G4 20DB Z2 20BK/LG A141 16DG/WT Z1 16BK K106 18WT/DG (LEAK DETECTION PUMP) K107 18OR/YL (LEAK DETECTION PUMP) C110 - BLACK (UNDERBODY SIDE) CIRCUIT G4 20DB Z2 20BK/LG A141 16DG/WT...
Page 884 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C111 (1.6L) - LT. GRAY (HEADLAMP AND DASH SIDE) CIRCUIT F12 20DB/WT C3 20DB/BK T40 14BR A142 16DG/OR K90 20TN C21 20DB/OR F20 20WT L1 20VT/BK L50 20WT/TN A14 16RD/WT C112 (1.6L) - BLACK (ENGINE SIDE) CIRCUIT V37 20RD/LG G9 20GY/BK...
Page 885 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C114 (1.6L) - DK. GRAY (ENGINE SIDE) CIRCUIT K80 20BK/LG F858 20DG/LG K167 20BR/YL K81 20DB/DG F859 20DG/PK K981 20BR/DG Z1 20BK C24 20YL/RD C114 (1.6L) - DK. GRAY (HEADLAMP AND DASH SIDE) CIRCUIT K80 20BK/LG...
Page 886 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C121 (DIESEL) - BLACK (HEADLAMP & DASH SIDE) CIRCUIT K31 20BR A14 16RD/WT K137 20DB/GY K47 20DB/YL K118 20PK/YL K90 20TN F12 20DB/WT K4 20BK/LB Z12 14BK/TN K981 20BR/DG Z12 20BK/TN A41 14YL C122 (DIESEL) - LT.
Page 887 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C124 (DIESEL) - DK. GRAY (ENGINE SIDE) CIRCUIT D21 20RD D25 20VT/YL K81 20LB/LG K167 20BR/YL F859 20LG/PK K80 20BK/LG F858 20LG/VT C27 20LB/BK C24 20LB/PK C41 20LG/LB C42 20GY/LB K152 20WT L50 18WT/LB K29 20WT/RD C124 (DIESEL) - DK.
Page 888 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C125 (DIESEL) - DK. GRAY (ENGINE SIDE) CIRCUIT K154 10BK/LG K154 10BK/RD C126 (DIESEL) - DK. GRAY (CABIN HEATER SIDE) CIRCUIT K132 12VT K232 10YL K232 10YL C126 (DIESEL) - DK. GRAY (HEADLAMP & DASH SIDE) CIRCUIT K132 12VT...
Page 889 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C128 (DIESEL) - BLACK (HEADLAMP & DASH SIDE) CIRCUIT A193 14RD/DB A54 10RD A222 10RD/LB C128 (DIESEL) - BLACK (JUNCTION POST SIDE) CIRCUIT A193 14RD A54 10RD A222 10RD/LB C200 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT E2 20OR (OVERHEAD CONSOLE) F10 18YL/RD (OVERHEAD CONSOLE)
Page 890 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C201 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT M1 18PK M2 20YL M2 20YL Z1 18BK Z2 20BK/LG (OVERHEAD CONSOLE) G120 20WT/LB (RKE EXPORT) X54 18VT X56 18DB/RD C201 - BLACK (LT/RT HEADLINER JUMPER SIDE) CIRCUIT M1 20PK...
Page 891 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C202 - WHITE (LEFT BODY SIDE) CIRCUIT G10 20LG/RD (LHD) G77 20TN/OR C15 12BK/WT L1 18VT/BK L50 18WT/TN X51 18BR/YL X57 18BR/LB R55 20LG/DG (BASE ORC) L38 18BR/WT (REAR FOG LAMP) L63 18DG/RD G78 20TN/BK A120 16RD/LG (LHD POWER SEAT) V13 18BR/LG...
Page 892 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C203 - DK. GREEN (RIGHT BODY SIDE) CIRCUIT Q1 14YL G76 20TN/YL A120 16RD/LG (RHD POWER SEAT) X52 18DB/WT X58 18DB/BK P35 18OR/BK (POWER LOCKS) P36 18PK/BK (POWER LOCKS) F98 18RD/WT (HEATED SEATS) R56 20LB/DG (BASE ORC) G10 20LG/RD (RHD) L62 18BR/RD...
Page 893 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C204 (EXCEPT EXPORT) - NATURAL (LEFT FRONT DOOR SIDE) CIRCUIT C16 20LB/YL (HEATED MIRRORS) Q11 14LB G75 20TN/DB P75 20DB/WT (POWER MIRRORS) L7 18BK/YL (POWER LOCKS) X53 18DG P73 20YL/PK (POWER MIRRORS) Z1 20BK Q21 14WT P34 18PK/BK (DRIVER POWER LOCKS)
Page 894 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C204 (EXPORT) - BLACK (LEFT FRONT DOOR SIDE) CIRCUIT C16 20LB/YL (HEATED MIRRORS) Q11 14LB G75 20TN/DB P75 20DB/WT (POWER MIRRORS) L7 18BK/YL (POWER LOCKS) P159 20DG/WT (POWER FOLDING MIRRORS) X53 18DG/VT P73 20YL/PK (LHD POWER MIRRORS) P76 20YL/PK (RHD POWER MIRRORS) Z1 20BK...
Page 895 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C205 (EXCEPT EXPORT) - NATURAL (RIGHT FRONT DOOR SIDE) CIRCUIT C16 20LB/YL (HEATED MIRRORS) Q12 14LB G74 20TN/DB P74 20DB/WT (POWER MIRRORS) L7 18BK/YL (POWER LOCKS) X54 18VT P70 20YL/PK (POWER MIRRORS) Z1 20BK Q22 14WT P36 18PK/BK (PASSENGER POWER...
Page 896 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C205 (EXPORT) - BLACK (RIGHT FRONT DOOR SIDE) CIRCUIT C16 20LB/YL (HEATED MIRRORS) Q12 14BR G74 20TN/RD P74 20DB (POWER MIRRORS) L7 18BK/YL (POWER LOCKS) P159 20DG/WT (POWER FOLDING MIRRORS) X54 18VT P70 20WT (LHD POWER MIRRORS) P76 20YL/PK (RHD POWER MIRRORS) Z1 20BK...
Page 897 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C207 - RED (DOME LAMP SIDE) CIRCUIT M1 20PK M2 20YL Z1 20BK (EXCEPT POWER SUNROOF) Z1 18BK (POWER SUNROOF) Z2 20BK/LG (OVERHEAD CONSOLE) G120 20WT/LB (RKE EXPORT) C207 - RED (LT/RT HEADLINER JUMPER SIDE) CIRCUIT M1 20PK M2 18YL...
Page 898 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C209 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT C1 14DG C7 14BK/TN C209 - BLACK (HEATER JUMPER SIDE) CIRCUIT C1 14DG C7 14BK/TN C210 (HEATED SEATS) - BLACK (HEATED SEAT SIDE) CIRCUIT Z122 18BK F98 18RD/WT C210 (HEATED SEATS) - BLACK (INSTRUMENT PANEL SIDE)
Page 899 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C211 - WHITE (POWER SUNROOF SIDE) CIRCUIT L1 20VT L2 20BR L3 20LB L4 20WT Z1 14BK/VT L5 14YL/RD C300 - BLACK (LEFT REAR DOOR SIDE) CIRCUIT P35 18OR/VT (POWER LOCKS) P36 18PK/VT (POWER LOCKS) Q13 14DB/GY (POWER LOCKS) Q13 14DB (EXCEPT POWER LOCKS) Q23 14RD/WT (EXCEPT POWER LOCKS)
Page 900 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C302 - WHITE (LEFT BODY SIDE) CIRCUIT P35 18OR/BK (POWER LOCKS) P36 18PK/BK (POWER LOCKS) G78 20TN/BK V13 18BR/LG V23 18BR/PK P96 20WT/LG (POWER LOCKS) L50 18WT/TN C15 12BK/WT Z1 12BK Z1 16BK C302 - WHITE (LIFTGATE SIDE) CIRCUIT P35 18OR/VT (POWER LOCKS)
Page 901 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C303 - DK. GRAY (REAR FASCIA SIDE) CIRCUIT L1 20VT/BK L38 18BR/WT (REAR FOG LAMP) L7 18BK/YL Z1 18BK C304 - BLACK (FUEL TANK SIDE) CIRCUIT Z1 16BK Z2 20BK/LG G4 20DB A141 16DG/WT K106 20WT/DG (LEAK DETECTION PUMP)
Page 902 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C305 (PASSENGER) - YELLOW (UNIBODY SIDE) CIRCUIT R32 18LB/OR R34 18LB/WT C306 (DRIVER) - YELLOW (AIRBAG SIDE) CIRCUIT R31 18OR R33 18WT C306 (DRIVER) - YELLOW (UNIBODY SIDE) CIRCUIT R31 18LG/OR R33 18LG/WT C307 (PASSENGER) - BLACK (SEAT SIDE) CIRCUIT Z122 18BK...
Page 903 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 C308 (DRIVER) - BLACK (SEAT SIDE) CIRCUIT A120 16RD/LG Z121 16BK P141 20TN/LB (HEATED SEAT) P139 20VT/WT (HEATED SEAT) P137 20VT/DG (HEATED SEAT) P7 20LB/BK (HEATED SEAT) F99 18RD/WT (HEATED SEAT) P143 20BK/DG (HEATED SEAT) P131 20RD/DG (HEATED SEAT) C308 (DRIVER) - BLACK (UNIBODY SIDE) CIRCUIT...
Page 904 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS CARGO LAMP - BLACK 3 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) M2 20YL COURTESY LAMPS DRIVER CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 18BK GROUND CENTER STACK LAMP - BLACK 2 WAY...
Page 905 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 CLUTCH PEDAL POSITION SWITCH (UP) (MTX) - BLACK 3 WAY CIRCUIT FUNCTION K119 20LG/BK (1.6L/DIESEL) CLUTCH UPSTOP SWITCH SIGNAL Z12 20BK/TN GROUND T141 18YL/RD (2.4L TURBO) CLUTCH INTERLOCK SWITCH SIGNAL T141 20YL/RD (EXCEPT 2.4L TURBO) CLUTCH INTERLOCK SWITCH SIGNAL CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY CIRCUIT...
Page 906 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K24 20YL CRANKSHAFT POSITION SENSOR SIGNAL NO. 2 K3 20BK CRANKSHAFT POSITION SENSOR SIGNAL NO. 1 CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY CIRCUIT FUNCTION K7 20OR (EXCEPT 1.6L)
Page 907 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 DOME LAMP - BLACK 3 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) M2 20YL COURTESY LAMPS DRIVER DOME LAMP/INTRUSION SENSOR (EXPORT) - WHITE 4 WAY CIRCUIT FUNCTION M2 20YL COURTESY LAMPS DRIVER M1 20PK FUSED B(+) Z2 20BK/LG...
Page 908 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS DRIVER DOOR POWER LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G75 20TN/DB (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE G74 20TN/DB (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE Z1 20BK GROUND P34 20PK/BK DRIVER DOOR UNLOCK RELAY OUTPUT...
Page 909 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 DRIVER SEAT BELT SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G10 20LG/RD SEAT BELT SWITCH SENSE Z1 20BK GROUND DRIVER SEAT BELT TENSIONER - YELLOW 2 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 DRIVER SIDE IMPACT SENSOR 1 - GRAY 2 WAY...
Page 910 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS ELECTRONIC THROTTLE CONTROL MODULE (1.6L) - BLACK 6 WAY CIRCUIT FUNCTION K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL NO. 1 K122 20DB/GY THROTTLE POSITION SENSOR SIGNAL NO. 2 F855 20OR/PK THROTTLE POSITION SENSOR 5V SUPPLY V50 20VT/OR ELECTRONIC THROTTLE CONTROL POSITIVE MOTOR CONTROL...
Page 911 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY CIRCUIT FUNCTION K2 20LG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K48 20LG/WT INLET AIR TEMPERATURE SENSOR SIGNAL Z31 20 GROUND (DRAIN) K24 20YL CRANKSHAFT POSITION SENSOR SIGNAL NO. 2 L50 18WT/LB PRIMARY BRAKE SWITCH SIGNAL K29 20WT/RD...
Page 912 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY CIRCUIT FUNCTION C22 20VT/YL A/C HIGH PRESSURE SIGNAL T141 20YL/RD CLUTCH INTERLOCK SWITCH SIGNAL G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER G6 20VT/LG ENGINE OIL PRESSURE SWITCH SIGNAL K119 20LG/BK CLUTCH UPSTOP SWITCH SIGNAL...
Page 913 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K2 20LG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K4 20BK/LB (1.6L) ENGINE COOLANT TEMPERATURE SENSOR GROUND...
Page 914 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS FRONT POWER WINDOW SWITCH - BLACK 14 WAY CIRCUIT FUNCTION Q18 14GY/BK MASTER RIGHT REAR WINDOW DRIVER (UP) Q28 14DG/WT MASTER RIGHT REAR WINDOW DRIVER (DOWN) Q22 14VT/WT RIGHT FRONT WINDOW DRIVER (DOWN) Z1 14BK GROUND Q1 14YL...
Page 915 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 FRONT WIPER/WASHER SWITCH - GRAY 7 WAY CIRCUIT FUNCTION V5 18DG WIPER SWITCH MODE SENSE Z1 18BK GROUND V10 18BR WASHER SWITCH SENSE F88 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC) V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT V3 16BR/WT WIPER SWITCH LOW SPEED OUTPUT...
Page 916 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K12 12BK/VT FUEL INJECTOR NO. 2 CONTROL K63 12LB COMMON INJECTOR DRIVER FUEL INJECTOR NO. 2 (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN (1.6L)
Page 917 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K14 12BK/YL FUEL INJECTOR NO. 4 CONTROL K63 12BK COMMON INJECTOR DRIVER FUEL INJECTOR NO. 4 (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K14 18LB/BR (1.6L)
Page 918 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS FUEL PUMP MODULE - LT. GRAY 4 WAY CIRCUIT FUNCTION Z1 16BK GROUND Z2 20BK/LG GROUND G4 20DB FUEL LEVEL SENSOR SIGNAL A141 16DG/WT FUEL PUMP RELAY OUTPUT GENERATOR (2.4L TURBO) - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK...
Page 919 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 HEADLAMP LEVELING SWITCH (EXPORT) - BLACK 4 WAY CIRCUIT FUNCTION L13 20BR/YL HEADLAMP ADJUST SIGNAL L43 18VT FUSED LEFT LOW BEAM OUTPUT Z1 20BK GROUND E2 20OR PANEL LAMPS DRIVER HEATED SEAT MODULE - GREEN 14 WAY CIRCUIT FUNCTION P7 20LB/BK...
Page 920 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS IDLE AIR CONTROL MOTOR (2.0L/2.4L) - BLACK 2 WAY CIRCUIT FUNCTION K610 18VT/GY IAC MOTOR CONTROL K961 18BR/VT IAC RETURN IGNITION COIL (GAS) - BLACK 3 WAY CIRCUIT FUNCTION K17 18DB/TN (1.6L) IGNITION COIL NO.
Page 921 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 INLET AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K21 20BK/RD (1.6L) INLET AIR TEMPERATURE SENSOR SIGNAL K21 20BK/RD (EXCEPT 1.6L) IAT SIGNAL K921 20RD (1.6L) INLET AIR TEMPERATURE SENSOR GROUND K4 20BK/LB (EXCEPT 1.6L) SENSOR GROUND 1 INPUT SPEED SENSOR - LT.
Page 922 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS INSTRUMENT CLUSTER C2 - BLACK 10 WAY CIRCUIT FUNCTION L39 18LB (FOG LAMPS) FOG LAMP SWITCH OUTPUT G69 20BK/OR (RKE) VTSS INDICATOR DRIVER L38 18BR/WT (REAR FOG LAMPS) REAR FOG LAMP SWITCH OUTPUT E19 20RD PANEL LAMPS DIMMER SIGNAL L1 20VT/BK (MTX)
Page 923 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 LEFT CITY LAMP (EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BR GROUND L7 18BK HEADLAMP SWITCH OUTPUT LEFT CYLINDER LOCK SWITCH - BLACK 2 WAY CIRCUIT FUNCTION P97 20LG LEFT DOOR SWITCH MUX Z1 20BK GROUND LEFT DOOR LOCK SWITCH - BLACK 3 WAY...
Page 924 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL HEADLAMP SWITCH OUTPUT L161 18LG/OR LEFT TURN SIGNAL (OUT) LEFT FRONT POWER WINDOW MOTOR - BLACK 2 WAY CIRCUIT FUNCTION Q21 14WT...
Page 925 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 LEFT FRONT WHEEL SPEED SENSOR - (SENSOR SIDE) 2 WAY CIRCUIT FUNCTION LEFT FRONT WHEEL SPEED SENSOR 12V SUPPLY RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION B9 18RD...
Page 926 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X55 18RD/BR LEFT FRONT SPEAKER (-) X53 18DG LEFT FRONT SPEAKER (+) LEFT LICENSE LAMP (EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK...
Page 927 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 LEFT REAR DOOR POWER LOCK MOTOR - BLACK 3 WAY CIRCUIT FUNCTION P35 18OR/VT DOOR LOCK RELAY OUTPUT P36 18PK/VT DOOR UNLOCK RELAY OUTPUT LEFT REAR FOG LAMP (LHD EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION L38 18BR/WT...
Page 928 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS LEFT REAR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X57 18BR/LB LEFT REAR SPEAKER (-) X51 18BR/YL LEFT REAR SPEAKER (+) LEFT REAR TURN SIGNAL LAMP - GRAY 2 WAY CIRCUIT FUNCTION L63 18DG/RD LEFT REAR TURN SIGNAL Z1 18BK...
Page 929 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 LEFT TURN SIGNAL INDICATOR - BLACK 2 WAY CIRCUIT FUNCTION L61 20LG LEFT TURN SIGNAL (IN) Z1 20BK GROUND LEFT VISOR/VANITY LAMP (LIGHT PACKAGE) - BLACK 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND...
Page 930 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS LIFTGATE POWER LOCK MOTOR - BLACK 4 WAY CIRCUIT FUNCTION P35 18OR/VT DOOR LOCK RELAY OUTPUT P36 18PK/VT DOOR UNLOCK RELAY OUTPUT LOW NOTE HORN - BLACK 2 WAY CIRCUIT FUNCTION X2 20DG/RD HORN RELAY OUTPUT Z1 20BK GROUND...
Page 931 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 MASS AIR FLOW SENSOR (DIESEL) - BLACK 5 WAY CIRCUIT FUNCTION K21 20YL/LG AMBIENT AIR TEMPERATURE SENSOR SIGNAL A142 20RD/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K957 20BR MASS AIR FLOW SENSOR GROUND F859 20LG/PK SENSOR REFERENCE VOLTAGE A K155 20YL/WT...
Page 932 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS NATURAL VACUUM LEAK DETECTION ASSEMBLY (EXCEPT EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION Z1 20BK GROUND K107 20OR/YL NVLD SWITCH SIGNAL K106 20WT/DG NVLD SOL CONTROL OUTPUT SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION T13 20DB/BK...
Page 933 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) - BLACK 4 WAY CIRCUIT FUNCTION Z1 18BK (EXCEPT 1.6L) GROUND K199 18BR/VT (1.6L) OXYGEN SENSOR 1/2 CONTROL K199 18BR/VT (EXCEPT 1.6L) O2 1/2 HEATER CONTROL A142 18DG/OR (1.6L) AUTOMATIC SHUT DOWN RELAY OUTPUT K904 20DB/DG (1.6L) OXYGEN SENSOR 1/2 GROUND...
Page 934 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS PASSENGER HEATED SEAT CUSHION - 4 WAY CIRCUIT FUNCTION Z122 18BK GROUND P130 18RD/TN PASSENGER SEAT HEATER CUSHION DRIVER P141 20TN/DB SEAT TEMPERATURE SENSOR 5V SUPPLY P144 20BK/LG PASSENGER SEAT TEMPERATURE SENSOR RETURN PASSENGER HEATED SEAT SWITCH - 6 WAY CIRCUIT FUNCTION...
Page 935 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 PCV HEATER (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION A141 18DG/WT FUEL PUMP RELAY OUTPUT Z1 18BK GROUND POWER MIRROR SWITCH (LHD) - BLACK 10 WAY CIRCUIT FUNCTION P73 20YL/PK LEFT MIRROR RIGHT/DOWN MOVEMENT P74 20DB/WT RIGHT MIRROR LEFT MOVEMENT Z1 20BK...
Page 936 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS POWER OUTLET - RED 3 WAY CIRCUIT FUNCTION F1 16DB/BK FUSED B(+) Z1 16BK GROUND POWER SEAT MOTOR - GRAY 2 WAY CIRCUIT FUNCTION P121 16RD/LG (RHD) SEAT DOWN DRIVER P120 16LG/YL (LHD) SEAT UP DRIVER P120 16LG/YL (RHD) SEAT UP DRIVER...
Page 937 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 POWER SUNROOF MODULE C2 - BLACK 4 WAY CIRCUIT FUNCTION L5 14YL/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L7 14DB MOTOR TILT DOWN FEED L6 14DG MOTOR TILT UP FEED Z1 14BK/VT GROUND POWERTRAIN CONTROL MODULE (1.6L) - BLACK 90 WAY CIRCUIT FUNCTION...
Page 938 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE (1.6L) - BLACK 90 WAY CIRCUIT FUNCTION G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER D20 20LG SCI RECEIVE (PCM) K944 20BR/GY CAMSHAFT POSITION SENSOR GROUND F854 20GY/PK CAMSHAFT POSITION SENSOR 5V SUPPLY K7 20OR CRANKSHAFT POSITION SENSOR 5V SUPPLY F857 20OR/PK...
Page 939 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK 38 WAY CIRCUIT FUNCTION Z12 16BK/TN GROUND F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F11 20RD/WT (AUTOSTICK) FUSED IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F12 20DB/WT (EXCEPT AUTOSTICK) FUSED IGNITION SWITCH OUTPUT (RUN-START) G7 20WT/OR (MTX) VEHICLE SPEED SIGNAL...
Page 940 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C2 (NGC) - BLACK 38 WAY CIRCUIT FUNCTION K17 18DB/TN COIL CONTROL NO. 2 K19 18BK/GY COIL CONTROL NO. 1 K14 18LB/BR INJECTOR CONTROL NO. 4 K13 18YL/WT INJECTOR CONTROL NO. 3 K12 18TN INJECTOR CONTROL NO.
Page 941 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 POWERTRAIN CONTROL MODULE C3 (NGC) - BLACK 38 WAY CIRCUIT FUNCTION K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL C27 20DB/PK (EXCEPT 2.4L TURBO) HIGH SPEED RAD FAN RELAY CONTROL V35 20LG/RD (SPEED CONTROL) S/C VENT CONTROL C24 20DB/PK (2.0L RHD MTX) LOW SPEED RAD FAN RELAY CONTROL...
Page 942 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C4 (NGC) (EATX) - DK. GREEN 38 WAY CIRCUIT FUNCTION T60 18BR OVERDRIVE SOLENOID CONTROL T59 18PK (2.0L/2.4L EXCEPT TURBO) UNDERDRIVE SOLENOID CONTROL T59 18PK/BK (2.4L TURBO) UNDERDRIVE SOLENOID CONTROL T19 18WT 2-4 SOLENOID CONTROL T20 18LB...
Page 943 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 RADIATOR FAN MOTOR (2.4L TURBO) - BLACK 4 WAY CIRCUIT FUNCTION Z1 10BK GROUND A110 10VT/RD FUSED B(+) A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT N23 20DB/DG RADIATOR FAN MOTOR CONTROL RADIATOR FAN MOTOR (EXCEPT 2.4L TURBO) - BLACK 3 WAY CIRCUIT FUNCTION C23 12DG...
Page 944 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS REAR POWER OUTLET - RED 3 WAY CIRCUIT FUNCTION F30 16RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z1 16BK GROUND REAR WINDOW DEFOGGER SWITCH - BLACK 5 WAY CIRCUIT FUNCTION A4 12BK/PK FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) Z1 20BK...
Page 945 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 REMOTE KEYLESS ENTRY MODULE - BLACK 26 WAY CIRCUIT FUNCTION L4 16VT/WT (EXCEPT HEADLAMP DIMMER SWITCH LOW BEAM OUTPUT LEVELING) L63 18DG/RD (HEADLAMP LEVELING) LEFT REAR TURN SIGNAL L7 18BK/YL (EXCEPT HEADLAMP HEADLAMP SWITCH OUTPUT LEVELING) L62 18BR/RD (HEADLAMP LEVELING)
Page 946 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS RIGHT CITY LAMP (EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BR GROUND L7 18BK HEADLAMP SWITCH OUTPUT RIGHT CYLINDER LOCK SWITCH (EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION P96 20LG RIGHT DOOR SWITCH MUX Z1 20BK GROUND RIGHT DOOR LOCK SWITCH - BLACK 3 WAY...
Page 947 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 RIGHT FRONT DOOR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X56 18DB/RD RIGHT FRONT SPEAKER (-) X54 18VT RIGHT FRONT SPEAKER (+) RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK...
Page 948 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS RIGHT FRONT WHEEL SPEED SENSOR - (SENSOR SIDE) 2 WAY CIRCUIT FUNCTION RIGHT FRONT WHEEL SPEED SENSOR 12V SUPPLY WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION B7 18WT...
Page 949 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 RIGHT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X56 18DB/RD RIGHT FRONT SPEAKER (-) X54 18VT RIGHT FRONT SPEAKER (+) RIGHT LICENSE LAMP (EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z1 18BK...
Page 950 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS RIGHT REAR DOOR POWER LOCK MOTOR - BLACK 3 WAY CIRCUIT FUNCTION P35 18OR/VT DOOR LOCK RELAY OUTPUT P36 18PK/VT DOOR UNLOCK RELAY OUTPUT RIGHT REAR FOG LAMP (RHD EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION L38 18BR/WT...
Page 951 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 RIGHT REAR SPEAKER - BLACK 2 WAY CIRCUIT FUNCTION X58 18DB/BK RIGHT REAR SPEAKER (-) X52 18DB/WT RIGHT REAR SPEAKER (+) RIGHT REAR TURN SIGNAL LAMP - GRAY 2 WAY CIRCUIT FUNCTION L62 18BR/RD RIGHT REAR TURN SIGNAL Z1 18BK...
Page 952 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS RIGHT TURN SIGNAL INDICATOR - BLACK 2 WAY CIRCUIT FUNCTION L60 20TN RIGHT TURN SIGNAL (IN) Z1 20BK GROUND RIGHT VISOR/VANITY LAMP (LIGHT PACKAGE) - BLACK 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND...
Page 953 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 SPEED CONTROL SWITCH - YELLOW 3 WAY CIRCUIT FUNCTION V131 20BK/LG SPEED CONTROL SWITCH SIGNAL Z123 20RD/TN GROUND SUNROOF MOTOR - NATURAL 2 WAY CIRCUIT FUNCTION L6 14DG MOTOR TILT UP FEED L7 14DB MOTOR TILT DOWN FEED SURGE SOLENOID (2.4L TURBO) - BLACK 2 WAY...
Page 954 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS THROTTLE INLET PRESSURE SOLENOID (2.4L TURBO) - BLACK 2 WAY CIRCUIT FUNCTION K55 18LB TIP SOL CONTROL F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) THROTTLE POSITION SENSOR (2.0L/2.4L) - NATURAL 3 WAY CIRCUIT FUNCTION K7 20OR...
Page 955 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 TRANSMISSION RANGE INDICATOR ILLUMINATION (PRNDL) (EXCEPT AUTOSTICK) - BLACK 2 WAY CIRCUIT FUNCTION E2 20OR PANEL LAMPS DRIVER Z1 20BK GROUND TRANSMISSION RANGE SENSOR (2.0L/2.4L) - DK. GRAY 10 WAY CIRCUIT FUNCTION F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) T13 20DB/BK...
Page 956 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS VEHICLE SPEED SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION K9 20RD/BK SENSOR REFERENCE VOLTAGE B N907 20BK/VT VEHICLE SPEED SENSOR GROUND G7 20GY/WT VEHICLE SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR (GAS MTX) - BLACK 3 WAY CIRCUIT FUNCTION K7 20OR (EXCEPT 1.6L)
Page 957 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 958 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Barometric Read Solenoid Right Rear Engine Compartment (2.4L Turbo) Battery Jump Post Left Rear Engine Compartment Battery Temperature Sensor Lower Passenger B-Pillar (Diesel) Battery Temperature Sensor Left Front Engine Compartment (Gas)
Page 959 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER C201 Right Side of Instrument Panel 29, 33 C202 Left Kick Panel 28, 32, 44 C203 Lower Right Kick Panel 29, 33, 41 C204 Left Side of Instrument Panel 28, 32, 38, 39, 44...
Page 960 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Driver Heated Seat Cushion Driver Seat Driver Heated Seat Switch Driver Seat Driver Seat Airbag Driver Seat Driver Seat Belt Switch (LHD) Lower Left B-Pillar Driver Seat Belt Switch (RHD) Lower Right B-Pillar Driver Seat Belt Tensioner...
Page 961 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Fuse Block Left Bottom of Instrument Panel 27, 28, 33 Fusible Link (2.0L/2.4L) Front of Engine Compartment on Engine Generator Right Front of Engine Compartment 18, 20, 22, 26 on Engine Glow Plug No.
Page 962 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Left Front Power Window Motor Left Front Door 38, 39 Left Front Side Marker Lamp Left Front Wheel Opening 3, 15 (Export) Left Front Turn Signal Lamp Left Front of Vehicle Left Front Wheel Speed Sensor Left Front Wheel Opening...
Page 963 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Output Speed Sensor Front of Engine Compartment on 21, 23 Transmission Overhead Console Module Front Center of Headliner Oxygen Sensor 1/1 Upstream Left Side Engine Compartment 22, 2425 Oxygen Sensor 1/2 Left Side Engine Compartment...
Page 964 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Radiator Fan Motor Front Center Engine Compartment 1, 2, 19 Radio Center of Instrument Panel Radio Antenna (LHD) Right Rear Instrument Panel Radio Antenna (RHD) Left Rear Instrument Panel Radio Antenna Cable Center Instrument Panel...
Page 965 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/ COLOR LOCATION FIG. NUMBER Right Rear Power Window Rear of Front Center Console Switch Right Rear Speaker Right Side Shelf Panel Right Rear Turn Signal Lamp In Rear Lamp Assembly Right Rear Wheel Speed Right Rear Wheel Opening Sensor...
Page 966 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS GROUND LOCATION FIG. G100 (Gas) Left Front Engine Compartment 2, 5, 6 G100 (Diesel) Below Passenger Seat 7, 48 G101 At Battery Tray 5, 6, 7, 18 G102 Left Fender Area 1, 14, 16 G103...
Page 967 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. S121 Right Side Engine Compartment 9, 10, 17 S122 In T/O for Data Link Connector S123 (IN PDC) Inside of Power Distribution Center (PDC) 5, 6, 7, 12, 15 S124 (IN PDC) Inside of Power Distribution Center (PDC) 5, 6, 12, 15...
Page 968 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. S164 (Diesel) Near T/O for C128 S165 (Diesel) Near Fusible Link S166 (Diesel) Near Fusible Link S167 (Diesel) Near T/O for C128 S168 (Diesel) Near T/O for C128 S169 (Diesel) Near T/O for C128 S170 (1.6L)
Page 969 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. S228 Near T/O for Power Mirror Switch S229 Near T/O for Grounds G200 and G203 S232 (LHD) In T/O for C203 S233 Near T/O for Turn Signal Indicators 29, 31, 32 S235 (RHD) In T/O for Inline C202...
Page 970 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 971 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 2 LEFT FRONT ENGINE COMPARTMENT (1.6L) Fig. 3 LEFT SIDE OF ENGINE COMPARTMENT (1.6L)
Page 972 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 973 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 5 LEFT FRONT ENGINE COMPARTMENT (1.6L) Fig. 6 LEFT FRONT ENGINE COMPARTMENT (2.0L/2.4L)
Page 974 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 7 LEFT FRONT ENGINE COMPARTMENT (2.4L TURBO) Fig. 8 RIGHT FRONT ENGINE COMPARTMENT (1.6L)
Page 975 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 9 RIGHT SIDE ENGINE COMPARTMENT (DIESEL RHD) Fig. 10 RIGHT REAR ENGINE COMPARTMENT (2.0L/2.4L)
Page 976 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 11 RIGHT REAR ENGINE COMPARTMENT (1.6L)
Page 977 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 978 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 979 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 980 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 981 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 982 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 983 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 984 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 985 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 986 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 987 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 988 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 989 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 990 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 991 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 992 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 993 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 28 LEFT REAR INSTRUMENT PANEL (LHD)
Page 994 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 995 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 996 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 997 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 998 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 999 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1000 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1001 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1002 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1003 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1004 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1005 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 49 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1006 8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1007 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 51 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1008 8W - 91 - 52 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1009 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 53 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 44 LEFT FRONT BODY Fig. 45 LEFT SIDE BODY...
Page 1010 8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 46 LEFT REAR QUARTER Fig. 47 LEFT REAR SPEAKER...
Page 1011 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 55 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1012 8W - 91 - 56 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1013 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 57 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 50 LOWER LIFTGATE Fig. 51 HEATED REAR WINDOW...
Page 1014 8W - 91 - 58 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 52 CENTER HIGH MOUNTED STOP LAMP Fig. 53 BACK-UP LAMPS...
Page 1015 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION IOD FUSE DESCRIPTION ......1 DESCRIPTION .
Page 1016 8W - 97 - 2 8W-97 POWER DISTRIBUTION CIGAR LIGHTER/POWER OUTLET (Continued) repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model.
Page 1017 8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER/POWER OUTLET (Continued) When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element caus- ing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heat- ing element to pop back outward to their relaxed position.
Page 1018: Description
8W - 97 - 4 8W-97 POWER DISTRIBUTION PANEL COMPONENT DIAGNOSIS OR SERVICE. FAIL- FUSE BLOCK URE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND DESCRIPTION POSSIBLE PERSONAL INJURY. The Fuse Block is serviced with the instrument panel wire harness.
Page 1019: Description
8W-97 POWER DISTRIBUTION 8W - 97 - 5 IOD FUSE (Continued) as various other accessories that require battery cur- POWER DISTRIBUTION rent when the ignition switch is in the Off position, CENTER including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehi- DESCRIPTION cle electrical system during new vehicle transporta-...
Page 1020: Removal
8W - 97 - 6 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) The fusible link, fuses and relays are available for nents. Refer Wiring Diagrams more service replacement. The PDC unit cannot be information on the harness routing and retainer loca- repaired and is only serviced as a unit with the tions.
Page 1021 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 1.6L SOHC ......1 ENGINE 2.4L DOHC ..... . 149 ENGINE 2.0L DOHC .
Page 1022 9 - 2 ENGINE 1.6L SOHC VALVE SPRINGS AND SEALS (CYLINDER RIGHT MOUNT HEAD REMOVED) REMOVAL ......55 STANDARD PROCEDURE - VALVE SPRINGS INSTALLATION .
Page 1023: Engine 1.6L Sohc
ENGINE 1.6L SOHC 9 - 3 ENGINE 1.6L SOHC DESCRIPTION The 1.6 Liter (97.6 cu. in.) in-line four cylinder engine is a single over head camshaft with four valves per cylinder design. The engine does not have provisions for a free wheeling valve train. The cylinders are numbered from front of the engine to the rear.
Page 1024 9 - 4 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) DIAGNOSIS AND TESTING - ENGINE PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1025 ENGINE 1.6L SOHC 9 - 5 ENGINE 1.6L SOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 1026: Diagnosis And Testing - Engine Mechanical
9 - 6 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) DIAGNOSIS AND TESTING - ENGINE MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1027 ENGINE 1.6L SOHC 9 - 7 ENGINE 1.6L SOHC (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 1028: Diagnosis And Testing - Cylinder Compression Pressure Test
9 - 8 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1029: Diagnosis And Testing - Cylinder Combustion Pressure Leakage Test
ENGINE 1.6L SOHC 9 - 9 ENGINE 1.6L SOHC (Continued) • Loss of coolant DIAGNOSIS AND TESTING - CYLINDER • Excessive steam (white smoke) emitting from COMBUSTION PRESSURE LEAKAGE TEST exhaust The combustion pressure leakage test provides an • Coolant foaming accurate means for determining engine condition.
Page 1030: Diagnosis And Testing - Engine Oil Leak Inspection
9 - 10 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) • Attach an air hose with pressure gauge and reg- (2) Insufficient running time after rebuilding cylin- der head. Low speed running up to 1 hour may be ulator to the dipstick tube. required.
Page 1031: Damaged Or Worn Threads
ENGINE 1.6L SOHC 9 - 11 ENGINE 1.6L SOHC (Continued) CAUTION: Do not exceed 20.6 kPa (3 psi). any fluid that may possibly be in the cylinder under pressure. (5) If the leak is not detected, very slowly turn the (4) With all spark plugs removed, rotate engine crankshaft and watch for leakage.
Page 1032: Standard Procedure - Engine Gasket Surface Preparation
9 - 12 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) tubes and has a shelf life of one year. After one year STANDARD PROCEDURE - ENGINE GASKET this material will not properly cure. Always inspect SURFACE PREPARATION the package for the expiration date before use. To ensure engine gasket sealing, proper surface MOPAR GASKET MAKER is an anaerobic type preparation must be performed, especially with the...
Page 1033: Standard Procedure - Measuring Bearing Clearance Using Plastigage
ENGINE 1.6L SOHC 9 - 13 ENGINE 1.6L SOHC (Continued) STANDARD PROCEDURE - MEASURING STANDARD PROCEDURE - ENGINE CORE AND BEARING CLEARANCE USING PLASTIGAGE OIL GALLERY PLUGS Engine crankshaft bearing clearances can be deter- Using a blunt tool such as a drift and a hammer, mined by use of Plastigage or equivalent.
Page 1034 9 - 14 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) body. Remove bolts attaching PDC and set aside (Fig. Fig. 6 Battery—Removal/Installation 1 - BATTERY Fig. 8 PDC Bracket Attaching Bolts 1 - PDC 2 - PDC BRACKET BOLTS 3 - BATTERY TRAY BOLT (9) Disconnect coolant recovery container hose from radiator neck.
Page 1035: Installation - Engine Assembly
ENGINE 1.6L SOHC 9 - 15 ENGINE 1.6L SOHC (Continued) bracket. Disconnect reservoir hose from power steer- ing pump. Reposition reservoir out of way. (22) Raise vehicle on hoist. (23) Drain engine oil. (24) Remove both front wheels. (25) Remove accessory drive belt splash shield. (26) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE...
Page 1036 9 - 16 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) Fig. 11 Engine Mounting - Right Side 1 - BOLTS 7 - ENGINE MOUNT BRACKET 2 - RIGHT FENDER 8 - BOLT 3 - UPPER TORQUE STRUT BRACKET 9 - LOWER TORQUE STRUT 4 - NUTS 10 - BOLT 5 - BOLT...
Page 1037: Specifications
ENGINE 1.6L SOHC 9 - 17 ENGINE 1.6L SOHC (Continued) (22) Connect A/C lines at junction near upper torque strut. (23) Connect upper A/C line to A/C condenser. (24) Connect upper and lower radiator hoses. (25) Install upper radiator crossmember (Refer to 23 - BODY/EXTERIOR/RADIATOR CROSSMEMBER - INSTALLATION).
Page 1038 9 - 18 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Firing Order 1-3-4-2 Length 56.50–57.00 mm Compression Pressure 1172–1551 kPa (2.224–2.2244 in.) (170–225 psi) Piston Rings Max. Variation Between Ring Gap—Top 0.20–0.36 mm Cylinders Compression Ring (0.007–0.014 in.) Engine Block Wear Limit...
Page 1039 ENGINE 1.6L SOHC 9 - 19 ENGINE 1.6L SOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Crankshaft Camshaft Connecting Rod Journal 43.992–44.008 mm Journal Diameter 25.290–25.309 mm Diameter (1.731–1.732 in.) (0.9957–0.9964 in.) Main Bearing Journal 47.922–48.008 mm Bearing Clearance— 0.050–0.090 mm Diameter Diametrical (1.731–1.890 in.) (0.0027–0.003 in.)
Page 1040 9 - 20 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valve Guide Valve Stem to Guide Clearance Inside Diameter 5.975–6.000 mm Intake 0.023–0.066 mm (0.235–0.236 in.) (0.0009–0.0026 in.) Guide Height (spring seat 13.25–13.75 mm Max. Allowable 0.076 mm to guide tip) (0.521–0.541 in.)
Page 1041: Torque
ENGINE 1.6L SOHC 9 - 21 ENGINE 1.6L SOHC (Continued) TORQUE SPECIAL TOOLS 1.6L SOHC ENGINE DESCRIPTION N·m Lbs. Lbs. Camshaft Position Sensor — Crankshaft Position Sensor — Camshaft Sprocket—Bolt — Rocker Shaft/Camshaft — Bearing Cap Timing Chain Cover — Timing Chain Guide —...
Page 1042 9 - 22 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) Puller Adaptor 8539 Spark Plug Tube Installer 8447 Spark Plug Tube Seal Installer MD-998306 Crankshaft Sprocket Installer 8386 Puller, Slide Hammer C-3752 Protective Sleeve 8448 Valve Spring Compressor C-3422-D Spark Plug Tube Remover 8819...
Page 1043 ENGINE 1.6L SOHC 9 - 23 ENGINE 1.6L SOHC (Continued) Spring Compressor Adapter 6526A Camshaft Sprocket Holding Wrench 8435 Valve Spring Compressor MD998772A Camshaft Sprocket Holder 8446 Adapter Studs/Spacers 8813 Connecting Rod Installation Guides 8388 Spring Compressor Adapter 6779 Front Crankshaft Seal Installer 6780...
Page 1044 9 - 24 ENGINE 1.6L SOHC ENGINE 1.6L SOHC (Continued) Post Kit Engine Cradle 6848 Driver Handle C-4171 Dial Indicator C-3339 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Cylinder Bore Indicator C-119 Dolly 6135 Valve Spring Tester C-647 Cradle 6710A Pressure Gauge C-3292...
Page 1045: Air Cleaner Element Removal
ENGINE 1.6L SOHC 9 - 25 ENGINE 1.6L SOHC (Continued) AIR CLEANER ELEMENT REMOVAL (1) Unsnap the 2 clips holding the air cleaner Adapter 8406 housing cover. (2) Lift the air cleaner housing cover up. (3) Remove the air cleaner element (Fig. 14). DRB III with PEP Module –...
Page 1046: Installation
9 - 26 ENGINE 1.6L SOHC AIR CLEANER HOUSING (Continued) (9) Remove fastener securing heater return tube to thermostat housing. (10) Disconnect upper radiator hose. (11) Raise vehicle on hoist. (12) Remove right front wheel. (13) Remove accessory drive belt splash shield. (14) Remove lower torque strut.
Page 1047: Cleaning
ENGINE 1.6L SOHC 9 - 27 CYLINDER HEAD (Continued) (28) Using Special Tool 8435 to hold camshaft (30) Remove camshaft sprocket from camshaft. sprocket, remove camshaft sprocket bolt (Fig. 17). Partially lower camshaft sprocket to allow timing chain to be removed from camshaft sprocket. Allow timing chain to fall into crankcase.
Page 1048: Installation - Cylinder Head
9 - 28 ENGINE 1.6L SOHC CYLINDER HEAD (Continued) (4) Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bot- tom (Fig. 22). (Refer to 9 - ENGINE - SPECIFICA- TIONS). Replace cylinder head if they are not within specification.
Page 1049 ENGINE 1.6L SOHC 9 - 29 CYLINDER HEAD (Continued) CAUTION: Avoid damaging spark plug tubes when installing/torquing cylinder head bolts. (4) Before installing cylinder head bolts, the threads should be oiled with engine oil. (5) Tighten the cylinder head bolts in the sequence shown in (Fig.
Page 1050 9 - 30 ENGINE 1.6L SOHC CYLINDER HEAD (Continued) (16) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (17) Install camshaft position sensor. Torque fas- tener to 10 N·m (85 in. lbs.). Reconnect connector. (18) Install right engine mount bracket (Refer to 9 - ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - INSTALLATION).
Page 1051: Cylinder Head Cover Removal
ENGINE 1.6L SOHC 9 - 31 CYLINDER HEAD COVER REMOVAL (1) Disconnect the negative battery cable. (2) Remove upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL). (3) Disconnect make-up air hose and PCV hoses (Fig. 28) from cylinder head cover. Fig.
Page 1052: Spark Plug Tube Seal Description
9 - 32 ENGINE 1.6L SOHC CYLINDER HEAD COVER (Continued) SPARK PLUG TUBE SEAL DESCRIPTION The spark plug tube seals are located in the cylin- der head cover (Fig. 33). These seals are pressed into the cylinder head cover to seal the outside perimeter of the spark plug tubes.
Page 1053: Spark Plug Tube
ENGINE 1.6L SOHC 9 - 33 SPARK PLUG TUBE SEAL (Continued) Fig. 35 Spark Plug Tube - Removal 1 - SPECIAL TOOL C-3752 2 - SPECIAL TOOL 8819 Fig. 34 Spark Plug Tube Seal Installation 3 - SET SCREWS 1 - SPECIAL TOOL MD-998306 (2) Apply Mopar Stud and Bearing Mount or 2 - SPARK PLUG TUBE SEAL...
Page 1054: Rocker Arm Shaft / Rocker Arm / Lash Adjuster Description
9 - 34 ENGINE 1.6L SOHC SPARK PLUG TUBE (Continued) (5) Install sealer end of tube into the cylinder head. Carefully install the tube using Special Tool 8447–2 Installer and mallet until Special Tool 8447–2 bottoms against 8447–1 (Fig. 37). Fig.
Page 1055: Installation
ENGINE 1.6L SOHC 9 - 35 ROCKER ARM SHAFT / ROCKER ARM / LASH ADJUSTER (Continued) (3) Loosen the rocker shaft/camshaft bearing cap bolts starting with the center bolt and working toward the ends. (4) Remove the rocker shafts/roller rocker arm assemblies (Fig.
Page 1056: Inspection
9 - 36 ENGINE 1.6L SOHC CAMSHAFT (Continued) (6) Install Special Tool 8446 as shown in (Fig. 42). Hold tool against camshaft and tighten tool mounting bolts. (7) Slide camshaft sprocket onto Special Tool 8446 (Fig. 42). Fig. 43 Rocker Arm Shafts/Lash Adjusters/Camshaft 1 - EXHAUST VALVE ROCKER ARM 2 - INTAKE VALVE ROCKER ARM SPACER 3 - INTAKE VALVE ROCKER SHAFT...
Page 1057: Valve Springs And Seals (On Vehicle Service)
ENGINE 1.6L SOHC 9 - 37 CAMSHAFT (Continued) (8) Slide camshaft sprocket off Special Tool 8446 and into it’s mounting position. Remove Special Tool 8446 from cylinder head (Fig. 42). CAUTION: Do Not use an impact wrench for tight- ening the camshaft sprocket bolt. Damage to the camshaft timing pin can result.
Page 1058 9 - 38 ENGINE 1.6L SOHC VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE) (Continued) Fig. 46 Valve Spring/Seal - On Vehicle Service 1 - SPECIAL TOOL MD998772A 3 - SPECIAL TOOL 8813 ADAPTER STUDS/SPACERS 2 - SPECIAL TOOL 6779 ADAPTER 4 - AIR HOSE Fig.
Page 1059: Valve Springs And Seals (Cylinder Head Removed)
ENGINE 1.6L SOHC 9 - 39 VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE) (Continued) (16) Repeat above procedures on remaining cylin- (8) Install valve locks. ders. (9) Release Spring compressor. (17) Remove Special Tools MD998772A, 6779, (10) Repeat procedure for remaining valve springs 8813.
Page 1060 9 - 40 ENGINE 1.6L SOHC VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED) (Continued) ENGINE - SPECIFICATIONS). Replace springs that (4) Reface valve seats using a suitable valve seat do not meet specifications. machine (5) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- ing stones or cutter.
Page 1061: Engine Block Description
ENGINE 1.6L SOHC 9 - 41 INTAKE/EXHAUST VALVES & SEATS (Continued) STANDARD PROCEDURE - CYLINDER BORE HONING (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 1062 9 - 42 ENGINE 1.6L SOHC ENGINE BLOCK (Continued) Fig. 55 Engine Block/Bedplate/Crankshaft 1 - MAIN BEARING CAP BOLTS 5 - CRANKSHAFT 2 - BEDPLATE BOLTS 6 - UPPER CRANKSHAFT MAIN BEARINGS 3 - BEDPLATE 7 - ENGINE BLOCK 4 - LOWER CRANKSHAFT MAIN BEARINGS A controlled hone motor speed between degree angle.
Page 1063: Cleaning
ENGINE 1.6L SOHC 9 - 43 ENGINE BLOCK (Continued) (4) Check block deck surfaces for flatness. Deck surface must be within service limit of 0.1 mm (0.004 in.). CYLINDER BORE NOTE: The cylinder bores should be measured at normal room temperature, 21°C (70°F). The cylinder walls should be checked for out-of- round and taper with Tool C119 or equivalent (Fig.
Page 1064: Description
9 - 44 ENGINE 1.6L SOHC CRANKSHAFT MAIN BEARINGS DESCRIPTION NOTE: The upper and lower main bearing shells are NOT interchangeable. The crankshaft is supported by five main bearings. All upper bearing shells in the crankcase have oil grooves/oil feed holes. All lower bearing shells installed in the (bedplate) main bearing cap are plain.
Page 1065: Inspection
ENGINE 1.6L SOHC 9 - 45 CRANKSHAFT (Continued) (8) Remove the timing chain (Refer to 9 - CAUTION: Do not pry up on one side of the bed- ENGINE/VALVE TIMING/TIMING BELT/CHAIN plate. Damage may occur to cylinder block and bed- AND SPROCKETS - REMOVAL).
Page 1066 9 - 46 ENGINE 1.6L SOHC CRANKSHAFT (Continued) seated into the bedplate slots. Install the main bear- ing/bedplate onto engine block. (6) Before installing the main bearing cap/bedplate bolts, oil threads with clean engine oil, wipe off any excess oil. (7) Install and finger tighten the main bearing cap bolts.
Page 1067: Crankshaft Oil Seal - Front Removal
ENGINE 1.6L SOHC 9 - 47 CRANKSHAFT (Continued) (19) Install the timing chain (Refer to 9 - CAUTION: Do not permit the screwdriver blade to ENGINE/VALVE TIMING/TIMING BELT/CHAIN contact crankshaft seal surface. Contact of the AND SPROCKETS - INSTALLATION). screwdriver blade against crankshaft edge (cham- (20) Install the right engine mount bracket (Refer fer) is permitted.
Page 1068: Piston & Connecting Rod
9 - 48 ENGINE 1.6L SOHC CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 68 Connecting Rod Bearing NOTE: The rod bearing bolts should not be reused. (2) Before installing NEW bolts, lubricate the threads with clean engine oil. (3) Install each bolt finger tight than alternately Fig.
Page 1069: Removal
ENGINE 1.6L SOHC 9 - 49 PISTON & CONNECTING ROD (Continued) piston to bore clearance must be established in order (2) Using a permanent ink marker or scribe tool to assure quiet and economical operation. mark the cylinder number on the side of the rod and cap (Fig.
Page 1070: Installation
9 - 50 ENGINE 1.6L SOHC PISTON & CONNECTING ROD (Continued) INSTALLATION (1) Install piston rings on piston (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS INSTALLATION). (2) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubri- cate connecting rod journal with clean engine oil.
Page 1071: Removal
ENGINE 1.6L SOHC 9 - 51 PISTON RINGS (Continued) Fig. 76 Piston Ring Side Clearance 1 - FEELER GAUGE Fig. 78 Piston Ring Installation 1 - NO. 1 PISTON RING REMOVAL 2 - NO. 2 PISTON RING (1) Using a suitable ring expander, remove upper 3 - SIDE RAIL 4 - OIL RING and intermediate piston rings (Fig.
Page 1072: Vibration Damper
9 - 52 ENGINE 1.6L SOHC PISTON RINGS (Continued) (5) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is impor- tant for oil control.
Page 1073: Removal
ENGINE 1.6L SOHC 9 - 53 ENGINE MOUNTING (Continued) right side load-carrying mount. The upper torque strut connects to the suspension strut tower and the lower torque strut connects to the suspension cross- member. TORQUE STRUTS REMOVAL UPPER TORQUE STRUT (1) Remove bolts attaching strut to shock tower bracket and engine mount bracket (Fig.
Page 1074: Installation
9 - 54 ENGINE 1.6L SOHC TORQUE STRUTS (Continued) INSTALLATION UPPER TORQUE STRUT (1) Position the upper torque strut into mounting locations (Fig. 83). (2) Install the mounting bolts. (3) Perform torque strut adjustment procedure (Refer ENGINE/ENGINE MOUNTING/ TORQUE STRUT - ADJUSTMENTS). LOWER TORQUE STRUT (1) Position lower torque strut into mounting loca- tions (Fig.
Page 1075: Installation
ENGINE 1.6L SOHC 9 - 55 RIGHT ENGINE MOUNT BRACKET (Continued) (7) Remove lower torque strut (Refer to 9 - (13) Install upper torque strut (Refer to 9 - ENGINE/ENGINE MOUNTING/TORQUE STRUT - ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL). INSTALLATION). (8) Remove lower right engine mount bracket bolt. (9) Lower vehicle.
Page 1076: Left Mount
9 - 56 ENGINE 1.6L SOHC RIGHT MOUNT (Continued) (2) Perform the following procedure if mount posi- tion was not previously marked or the frame rail was replaced: • Insert the new mount loosely in frame rail. • Align the four holes in the mount with the mat- ing holes in the rail such that the holes are concen- tric (frame rail holes centered in the mount holes).
Page 1077: Lubrication Description
ENGINE 1.6L SOHC 9 - 57 OPERATION LUBRICATION Engine oil is drawn up through the pickup tube DESCRIPTION and is pressurized by the oil pump and routed through the oil filter to the main oil gallery running The lubrication system is a full-flow filtration, the length of the cylinder block.
Page 1078 9 - 58 ENGINE 1.6L SOHC LUBRICATION (Continued) Fig. 92 Oil Lubrication System...
Page 1079: Oil Filter Cartridge
ENGINE 1.6L SOHC 9 - 59 LUBRICATION (Continued) Fig. 93 Oil Filter Cartridge Housing 1 - OIL FILTER CAP 2 - OIL FILTER CARTRIDGE HOUSING 3 - OIL PRESSURE SWITCH Fig. 94 Oil Filter Cartridge 4 - SEAL 1 - GROMMET 2 - OIL FILTER CARTRIDGE OIL FILTER CARTRIDGE 3 - CENTER TUBE...
Page 1080: Oil Filter Cartridge Housing
9 - 60 ENGINE 1.6L SOHC INSTALLATION OIL FILTER CARTRIDGE (1) Inspect and clean oil filter cartridge housing HOUSING sealing surfaces. (2) Replace oil filter cartridge housing seal (Fig. DESCRIPTION The oil filter cartridge housing is attached to the (3) Install oil filter cartridge housing mounting right side of the engine utilizing a seal between the fasteners.
Page 1081: Installation
ENGINE 1.6L SOHC 9 - 61 OIL PAN (Continued) INSTALLATION (1) Clean oil pan and all sealing surfaces. (2) Position new oil pan gasket onto pan. (3) Install oil pan (Fig. 100). Fig. 97 Air Conditioning Compressor Lower Bracket Fig. 100 Oil Pan and Gasket Fig.
Page 1082: Oil Pump
9 - 62 ENGINE 1.6L SOHC OIL PAN (Continued) OIL PUMP PICK-UP REMOVAL (1) Remove oil pan (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL). (2) Remove fasteners securing oil pump pick-up to engine block (Fig. 102). (3) Remove oil pump pick-up. Fig.
Page 1083: Intake Manifold
ENGINE 1.6L SOHC 9 - 63 (4) Disconnect fuel line from fuel rail. INTAKE MANIFOLD (5) Disconnect fuel injector electrical connectors. (6) Remove fuel rail. REMOVAL (7) Remove lower intake manifold mounting bolts. (8) Remove lower intake manifold (Fig. 104). REMOVAL - UPPER INTAKE MANIFOLD (1) Disconnect negative battery cable.
Page 1084: Cleaning
9 - 64 ENGINE 1.6L SOHC INTAKE MANIFOLD (Continued) (4) Install lower intake manifold mounting bolts. CLEANING Tighten bolts to 26 N·m (230 in. lbs.). (Fig. 104). (1) Discard gasket (if equipped) and clean all sur- (5) Apply a light coating of clean engine oil to the faces of manifold and cylinder head.
Page 1085: Description
ENGINE 1.6L SOHC 9 - 65 EXHAUST MANIFOLD (Continued) (9) Install ignition coil and spark plug cables (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - INSTALLATION). (10) Connect ignition coil and capacitor electrical connector. (11) Connect negative battery cable. VALVE TIMING DESCRIPTION The timing drive system consists of the following...
Page 1086: Installation
9 - 66 ENGINE 1.6L SOHC TIMING CHAIN COVER (Continued) (11) Remove the accessory drive belt idler pulley (Refer to 7 - COOLING/ACCESSORY DRIVE/IDLER PULLEY - REMOVAL). (12) Remove conditioning compressor mounting bolts and position compressor out of the way. Do Not disconnect lines from air conditioning compressor.
Page 1087 ENGINE 1.6L SOHC 9 - 67 TIMING CHAIN COVER (Continued) Fig. 111 Timing Chain Cover Seals Fig. 113 Timing Chain Cover Tightening Sequence 1 - TIMING CHAIN COVER SEALS (10) Install the crankshaft vibration damper (Refer 2 - OIL PUMP ENGINE/ENGINE BLOCK/VIBRATION 3 - PRESSURE RELIEF VALVE...
Page 1088 9 - 68 ENGINE 1.6L SOHC TIMING CHAIN/GUIDES/SPROCKETS (Continued) (4) Remove timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL). (5) Rotate crankshaft until number one cylinder is at TDC on compression stroke. (6) Using Special Tool 8435 to hold camshaft sprocket, remove camshaft sprocket bolt (Fig.
Page 1089: Installation - Crankshaft Sprocket
ENGINE 1.6L SOHC 9 - 69 TIMING CHAIN/GUIDES/SPROCKETS (Continued) Fig. 117 Identify Timing Chain Link for Reassembly Purposes 1 - PAINT THE LINK THAT ALIGNS WITH TIMING MARK 2 - CAMSHAFT SPROCKET TIMING MARK REMOVAL - CRANKSHAFT SPROCKET Fig. 118 Crankshaft Sprocket Removal (1) Remove timing chain (Refer to 9 - ENGINE/ VALVE TIMING/TIMING CHAIN - REMOVAL).
Page 1090: Guides
9 - 70 ENGINE 1.6L SOHC TIMING CHAIN/GUIDES/SPROCKETS (Continued) (3) Install camshaft sprocket bolt. While holding the camshaft sprocket with Special Tool 8435, torque bolt to 115 N·m (85 ft. lbs.) (Fig. 114). (4) Reset the timing chain tensioner using the fol- lowing method: (a) Remove oil reservoir cap from timing chain tensioner (Fig.
Page 1091 ENGINE 1.6L SOHC 9 - 71 TIMING CHAIN/GUIDES/SPROCKETS (Continued) Fig. 122 Timing Chain Tensioner/Oil Reservoir Cap/Plug 1 - CHECK BALL 2 - PLUG WITH SEAL RING 3 - OIL RESERVOIR CAP 4 - TIMING CHAIN TENSIONER Fig. 121 Timing Drive System 1 - CAMSHAFT TIMING MARK ALIGNS WITH SINGLE PLATED/ DIMPLED LINK 2 - CAMSHAFT SPROCKET...
Page 1092 9 - 72 ENGINE 1.6L SOHC TIMING CHAIN/GUIDES/SPROCKETS (Continued) Fig. 124 Timing Chain Tensioner Activation (16) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (17) Connect negative battery cable.
Page 1093 ENGINE 2.0L DOHC 9 - 73 ENGINE 2.0L DOHC TABLE OF CONTENTS page page ENGINE 2.0L DOHC INSTALLATION ......99 DESCRIPTION .
Page 1094 9 - 74 ENGINE 2.0L DOHC CRANKSHAFT OIL SEAL - FRONT INSTALLATION ......129 REMOVAL ......114 OIL FILTER ADAPTER INSTALLATION .
Page 1095: Engine 2.0L Dohc
ENGINE 2.0L DOHC 9 - 75 ENGINE 2.0L DOHC DESCRIPTION The 2.0 Liter (122 cu. in.) in-line four cylinder engine is a dual over-head camshaft with hydraulic lash adjusters and four valves per cylinder design (Fig. 1). The engine does not have provisions for a free wheeling valvetrain.
Page 1096: Diagnosis And Testing
9 - 76 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) For fuel system diagnosis, (Refer to 14 - FUEL DIAGNOSIS AND TESTING SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). DIAGNOSIS AND TESTING - ENGINE Additional tests and diagnostic procedures may be DIAGNOSIS - INTRODUCTION necessary for specific engine malfunctions that can- Engine diagnosis is helpful in determining the...
Page 1097 ENGINE 2.0L DOHC 9 - 77 ENGINE 2.0L DOHC (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 1098 9 - 78 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (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 1099 ENGINE 2.0L DOHC 9 - 79 ENGINE 2.0L DOHC (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 1100: Diagnosis And Testing - Cylinder Combustion Pressure Leakage
9 - 80 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1101 ENGINE 2.0L DOHC 9 - 81 ENGINE 2.0L DOHC (Continued) transducer (Special Tool CH7059) with cable adap- CAUTION: Do not subject the engine assembly to tors to the DRBIII . For Special Tool identification, more than 20.6 kpa (3 PSI) of test pressure. (Refer to 9 - ENGINE - SPECIAL TOOLS).
Page 1102: Standard Procedure - Hydrostatic
9 - 82 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) (5) If the leak is not detected, very slowly turn the (4) With all spark plugs removed, rotate engine crankshaft and watch for leakage. If a leak is crankshaft using a breaker bar and socket. detected between the crankshaft and seal while (5) Identify the fluid in the cylinder(s) (i.e., cool- slowly turning the crankshaft, it is possible the...
Page 1103 ENGINE 2.0L DOHC 9 - 83 ENGINE 2.0L DOHC (Continued) this material will not properly cure. Always inspect STANDARD PROCEDURE - ENGINE GASKET the package for the expiration date before use. SURFACE PREPARATION MOPAR GASKET MAKER is an anaerobic type To ensure engine gasket sealing, proper surface gasket material.
Page 1104: Standard Procedure - Measuring
9 - 84 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) STANDARD PROCEDURE - ENGINE CORE AND holes (Fig. 5). (In addition, suspected areas can be checked by placing the Plastigage in the suspected OIL GALLERY PLUGS area). Torque the bearing cap bolts of the bearing Using a blunt tool such as a drift and a hammer, being checked to the proper specifications.
Page 1105 ENGINE 2.0L DOHC 9 - 85 ENGINE 2.0L DOHC (Continued) (6) Discharge air conditioning system, if equipped (Refer to 24 - HEATING & AIR CONDITIONING - STANDARD PROCEDURE). (7) Disconnect throttle and speed control cables from throttle body. (8) Disconnect engine wiring harness at Power- train Control Module (PCM).
Page 1106 9 - 86 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) Fig. 8 Clutch Slave Cylinder Connection 1 - SLAVE CYLINDER 2 - HYDRAULIC TUBE Fig. 10 Converter to Exhaust Manifold Connection - 2.0L 1 - FLAG NUT 2 - GASKET 3 - BOLT 4 - NUT 5 - CATALYTIC CONVERTER...
Page 1107 ENGINE 2.0L DOHC 9 - 87 ENGINE 2.0L DOHC (Continued) (37) Remove lower engine torque strut (Refer to 9 - ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL). (38) Lower vehicle and remove A/C compressor. (39) Disconnect power steering lines from power steering pump. (40) Remove power steering pump.
Page 1108 9 - 88 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) Fig. 14 Positioning Engine Cradle Support Post 1 - POST LOCATING HOLES IN BLOCK 5 - FLOOR JACK 2 - POST POSITIONED UNDER BRACKET 6 - SPECIAL TOOL 6848 3 - POST LOCATING HOLE IN STRUT 7 - SPECIAL TOOL 6135 4 - SAFETY STRAPS 8 - SPECIAL TOOL 6710...
Page 1109: Specifications
ENGINE 2.0L DOHC 9 - 89 ENGINE 2.0L DOHC (Continued) (39) Install oil filter. Fill engine crankcase with DESCRIPTION SPECIFICATION proper oil to correct level. Clearance @ 17.5 mm 0.018–0.050 mm (40) Fill power steering system. (11/16 in.) from bottom of (41) Fill cooling system (Refer to 7 - COOLING/ (0.0007–0.0020 in.) skirt...
Page 1110 9 - 90 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Ring Side Clearance—Oil 0.004–0.178 mm Cylinder Head Camshaft Bearing Bore Diameter Ring Pack (0.0002–0.0070 in.) Journals No.1–6 26.020–26.041 mm Ring Width— 1.17–1.19 mm (1.024–1.025 in.) Compression Rings (0.046–0.047 in.) Camshaft Ring Width—Oil Ring...
Page 1111 ENGINE 2.0L DOHC 9 - 91 ENGINE 2.0L DOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Service Limit—Intake 2.0 mm Exhaust 47.99 mm (0.079 in.) (1.889 in.) Service Limit—Exhaust 2.5 mm Valve Stem to Guide Clearance (0.098 in.) Intake 0.048–0.066 mm Valve Guide (0.0018–0.0025 in.) Diameter I.D.
Page 1112 9 - 92 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION N·m Lbs. Lbs. Tip Clearance Between 0.20 mm Rotors (Max.) Spark Plugs — (0.008 in.) Timing Belt Covers Oil Pressure —Front Cover Bolts — At Curb Idle Speed* 25 kPa —Rear Cover Bolts —...
Page 1113 ENGINE 2.0L DOHC 9 - 93 ENGINE 2.0L DOHC (Continued) Camshaft Seal Remover C-4679A Dolly 6135 Camshaft Seal Installer MD-998306 Cradle 6710 Valve Spring Compressor 8215-A Post Kit Engine Cradle 6848 Camshaft Sprocket Remover/Installer C-4687 Adaptor 8436 Camshaft Sprocket Remover/Installer Adapter C-4687-1...
Page 1114 9 - 94 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) Cylinder Bore Gage C-119 Valve Spring Compressor MD-998772-A Connecting Rod Guides 8189 Valve Spring Compressor Adapter 6779 Crankshaft Sprocket Remover 6793 Valve Spring Compressor C-3422-D Crankshaft Sprocket Remover Insert C-4685-C2 Spring Compressor Adaptor 6526 Crankshaft Seal Remover 6771 Valve Spring Tester C-647...
Page 1115 ENGINE 2.0L DOHC 9 - 95 ENGINE 2.0L DOHC (Continued) Combustion Leak Tester C-3685-A Oil Pressure Gage C-3292 Adaptor 8406 DRB III with PEP Module OT-CH6010A Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Pressure Transducer CH7059 Front Crankshaft Oil Seal Installer 6780 Cylinder Compression Pressure Adaptor 8116 Cooling System Tester 7700...
Page 1116 9 - 96 ENGINE 2.0L DOHC AIR CLEANER ELEMENT REMOVAL (1) Unfasten clasps on sides of air cleaner housing cover. Lift cover off air cleaner housing (Fig. 15) . Fig. 16 Air Inlet System CYLINDER HEAD DESCRIPTION The cross flow designed, aluminum cylinder head Fig.
Page 1117 ENGINE 2.0L DOHC 9 - 97 CYLINDER HEAD (Continued) SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi). Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
Page 1118 9 - 98 ENGINE 2.0L DOHC CYLINDER HEAD (Continued) (8) Disconnect the fuel supply line quick-connect at (21) Remove rocker arms. the fuel rail assembly (Refer to 14 - FUEL SYSTEM/ (22) Remove cylinder head bolts in the reverse FUEL DELIVERY/QUICK CONNECT FITTING - sequence of tightening (Fig.
Page 1119 ENGINE 2.0L DOHC 9 - 99 CYLINDER HEAD (Continued) TIONS) Replace guides if they are not within specification. (5) Check valve guide height (Fig. 22). Fig. 23 Checking Bolts for Stretching (Necking) 1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE Fig.
Page 1120 9 - 100 ENGINE 2.0L DOHC CYLINDER HEAD (Continued) CAMSHAFT OIL SEAL(S) REMOVAL (1) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL). (2) Hold each camshaft sprocket with Special Tool 6847 while removing center bolt (Fig. 26). (3) Remove camshaft sprockets.
Page 1121 ENGINE 2.0L DOHC 9 - 101 CAMSHAFT OIL SEAL(S) (Continued) CAUTION: Do not nick shaft seal surface or seal bore. INSTALLATION (1) Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. (2) Install camshaft seals into cylinder head using Special Tool MD-998306 until flush with head (Fig.
Page 1122 9 - 102 ENGINE 2.0L DOHC CAMSHAFT(S) (Continued) Fig. 30 Camshaft End Play - Typical Fig. 32 Camshaft Bearing Cap - Removal (4) Remove camshaft sprockets and timing belt 1 - REMOVE OUTSIDE BEARING CAPS FIRST rear cover (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT COVER(S) - REMOVAL).
Page 1123 ENGINE 2.0L DOHC 9 - 103 CAMSHAFT(S) (Continued) (1) Lubricate all camshaft bearing journals, rocker (8) Install timing belt rear cover and camshaft arms and camshaft lobes. sprockets (Refer to 9 - ENGINE/VALVE TIMING/ (2) Install all rocker arms in original positions, if TIMING BELT COVER(S) - INSTALLATION).
Page 1124 9 - 104 ENGINE 2.0L DOHC CYLINDER HEAD COVER (Continued) (1) Install new cylinder head cover gaskets (Fig. 37) and spark plug well seals (Fig. 38). (2) Replace cylinder head cover bolt seals (Fig. 39). Fig. 37 Cylinder Head Cover Gasket and Spark Plug Well Seals Fig.
Page 1125 ENGINE 2.0L DOHC 9 - 105 CYLINDER HEAD COVER (Continued) ter locations of cover. Tighten bolts in sequence (5) The oil restrictor (integral to the cylinder head shown in (Fig. 41). Using a 3 step torque method as gasket) in the vertical oil passage to the cylinder follows: head is plugged with debris.
Page 1126: Rocker Arms
9 - 106 ENGINE 2.0L DOHC HYDRAULIC LASH ADJUSTERS (Continued) (2) Install rocker arm (Refer to 9 - ENGINE/CYL- INDER HEAD/ROCKER ARMS - INSTALLATION). (3) Repeat installation procedure for each hydrau- lic lifter. (4) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD...
Page 1127 ENGINE 2.0L DOHC 9 - 107 ROCKER ARMS (Continued) (5) Install cylinder head cover (Refer to 9 - (3) Before removing valves, remove any burrs ENGINE/CYLINDER HEAD/CYLINDER HEAD from valve stem lock grooves to prevent dam- COVER(S) - INSTALLATION). age to the valve guides. Identify valves, locks and (6) Connect negative battery cable.
Page 1128 9 - 108 ENGINE 2.0L DOHC VALVE SPRINGS AND SEALS (Continued) bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification. Fig.
Page 1129 ENGINE 2.0L DOHC 9 - 109 ENGINE BLOCK (Continued) scuffing, scoring or scratches. Usually a few strokes CLEANING will clean up a bore and maintain the required lim- Clean cylinder block thoroughly using a suitable its. cleaning solvent. (2) Deglazing of the cylinder walls may be done using a cylinder surfacing hone, recommended tool INSPECTION C-3501 or equivalent, equipped with 280 grit stones,...
Page 1130 9 - 110 ENGINE 2.0L DOHC ENGINE BLOCK (Continued) should be 10 mm (3/8 in.) up from bottom of bore. (9) Remove the timing belt tensioner and pulley (Refer to 9 - ENGINE - SPECIFICATIONS). bracket (Refer to 9 - ENGINE/VALVE TIMING/TIM- ING BELT TENSIONER &...
Page 1131 ENGINE 2.0L DOHC 9 - 111 CRANKSHAFT (Continued) Fig. 53 Engine Block and Components 1 - OIL PASSAGE O-RING 9 - BEDPLATE 2 - FRONT CRANKSHAFT SEAL 10 - CRANKSHAFT POSITION SENSOR 3 - UPPER BEARING (GROOVED) 11 - CONNECTING ROD BEARINGS 4 - THRUST BEARINGS 12 - PISTON AND CONNECTING ROD ASSEMBLY 5 - BOLT...
Page 1132 9 - 112 ENGINE 2.0L DOHC CRANKSHAFT (Continued) INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 56). Limits of taper or out of round on any crankshaft journals should be held to 0.025 mm (0.001 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter.
Page 1133 ENGINE 2.0L DOHC 9 - 113 CRANKSHAFT (Continued) • Step 1: Rotate crankshaft until number 4 piston CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the is at TDC. • Step 2: Move crankshaft rearward to limits of engine.
Page 1134 9 - 114 ENGINE 2.0L DOHC CRANKSHAFT (Continued) (22) Install rear timing belt cover and camshaft sprockets (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT COVER(S) - INSTALLATION). (23) Install front crankshaft oil seal and crank- shaft sprocket (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION).
Page 1135 ENGINE 2.0L DOHC 9 - 115 CRANKSHAFT OIL SEAL - FRONT (Continued) Fig. 63 Front Crankshaft Oil Seal—Removal Fig. 65 Crankshaft Sprocket - Installation 1 - SPECIAL TOOL 6771 1 - SPECIAL TOOL 6792 (5) Install crankshaft vibration damper. (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) (6) Install accessory drive belts.
Page 1136 9 - 116 ENGINE 2.0L DOHC CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 67 Rear Crankshaft Seal and Special Tool Fig. 66 Rear Crankshaft Oil Seal - Removal 6926-1 1 - REAR CRANKSHAFT SEAL 1 - SPECIAL TOOL 6926–1 PILOT 2 - ENGINE BLOCK 2 - SEAL 3 - ENGINE BLOCK...
Page 1137 ENGINE 2.0L DOHC 9 - 117 CRANKSHAFT OIL SEAL - REAR (Continued) STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 70°F (21°C). Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin about 14 mm (9/16 inch.) from the bottom of the skirt as shown in (Fig.
Page 1138 9 - 118 ENGINE 2.0L DOHC PISTON & CONNECTING ROD (Continued) REMOVAL tion assemblies. The weight designation stamps should face toward the timing belt side of the engine. (1) Remove the cylinder head (Refer to 9 - (6) Pistons and connecting rods must be removed ENGINE/CYLINDER HEAD - REMOVAL).
Page 1139 ENGINE 2.0L DOHC 9 - 119 PISTON & CONNECTING ROD (Continued) gaps are staggered, and neither is in line with the oil (13) Install each bolt finger tight then alternately ring rail gap (Fig. 82). torque each bolt to assemble the cap properly. (3) Before installing the ring compressor, ensure (14) Tighten the connecting rod bolts using the 2 the oil ring expander ends are butted and the rail...
Page 1140 9 - 120 ENGINE 2.0L DOHC CONNECTING ROD BEARINGS (Continued) Fig. 76 Connecting Rod Side Clearance PISTON RINGS Fig. 78 Piston Ring Side Clearance 1 - FEELER GAUGE STANDARD PROCEDURE - PISTON RING - FITTING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
Page 1141 ENGINE 2.0L DOHC 9 - 121 PISTON RINGS (Continued) (4) Position piston ring end gaps as shown in (Fig. 82). (5) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction.
Page 1142 9 - 122 ENGINE 2.0L DOHC STRUCTURAL COLLAR (Continued) INSTALLATION (1) Install crankshaft damper using Special Tool 6792 (M12 1.75 x 150 mm bolt, washer, thrust bear- ing and nut). NOTE: Lubricate the threads of the M12 1.75 x 150 mm bolt using Mopar Nickel Anti-seize Compound or equivalent, before beginning to press the damper (2) Install crankshaft damper bolt and tighten to...
Page 1143 ENGINE 2.0L DOHC 9 - 123 ENGINE MOUNTING (Continued) and left mounts dampen and isolate vertical motion and vibration. The two struts absorbs torque reaction forces and torsional vibrations. LEFT MOUNT REMOVAL (1) Remove air cleaner assembly. (2) Disconnect negative cable from battery. (3) Remove bolts attaching the power distribution center (PDC) bracket to left mount and battery tray (Fig.
Page 1144 9 - 124 ENGINE 2.0L DOHC RIGHT MOUNT (Continued) (b) Align the four holes in the mount with the mat- ing holes in the rail such that the holes are concentric (frame rail holes centered in the mount holes). (c) Using a permanent ink marker or equivalent, mark the position of engine mount to the body frame rail while maintaining mounting hole con- centricity.
Page 1145 ENGINE 2.0L DOHC 9 - 125 TORQUE STRUT (Continued) REMOVAL - LOWER (4) Remove bolts attaching lower torque strut to crossmember and strut bracket (Fig. 89). (1) Raise vehicle on hoist. (5) Remove lower torque strut. (2) Remove accessory drive belt splash shield (Fig. 90).
Page 1146 9 - 126 ENGINE 2.0L DOHC TORQUE STRUT (Continued) the shock tower bracket and crossmember. Reinstall (7) With the engine held at the proper position, the torque strut bolt(s), but do not tighten. tighten both the upper and lower torque strut bolts to 115 N·m (85 ft.
Page 1147 ENGINE 2.0L DOHC 9 - 127 LUBRICATION (Continued) Fig. 94 Engine Lubrication Components 1 - O-RING 7 - O-RING 2 - OIL FILTER ADAPTER 8 - OIL PUMP BODY 3 - OIL PAN GASKET 9 - FILTER 4 - OIL PAN 10 - O-RING 5 - OIL PICK-UP TUBE 11 - NIPPLE...
Page 1148 9 - 128 ENGINE 2.0L DOHC STANDARD PROCEDURE ENGINE OIL LEVEL CHECK The best time to check engine oil level is after the vehicle has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level.
Page 1149: Oil Filter
ENGINE 2.0L DOHC 9 - 129 OIL (Continued) STANDARD PROCEDURE - ENGINE OIL AND USED ENGINE OIL DISPOSAL Care should be exercised when disposing used FILTER CHANGE engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN.
Page 1150 9 - 130 ENGINE 2.0L DOHC OIL FILTER ADAPTER REMOVAL (1) Remove the oil filter (Refer to 9 - ENGINE/LU- BRICATION/OIL FILTER - REMOVAL). (2) Remove assembly by unscrewing adaptor fit- ting (Fig. 99). (3) Remove O-ring seal. Fig. 99 Engine Oil Filter Adapter to Engine Block 1 - O-RING Fig.
Page 1151: Oil Pump
ENGINE 2.0L DOHC 9 - 131 OIL PRESSURE SENSOR/ OIL PUMP SWITCH REMOVAL (1) Disconnect negative cable from battery. REMOVAL (2) Remove crankshaft vibration damper (Refer to (1) Raise vehicle. ENGINE/ENGINE BLOCK/VIBRATION (2) Position oil collecting container under pressure DAMPER - REMOVAL). switch location.
Page 1152 9 - 132 ENGINE 2.0L DOHC OIL PUMP (Continued) Fig. 104 Oil Pump and Tube 1 - O-RING 7 - O-RING 2 - OIL FILTER ADAPTER 8 - OIL PUMP BODY 3 - OIL PAN GASKET 9 - FILTER 4 - OIL PAN 10 - O-RING 5 - OIL PICK-UP TUBE 11 - NIPPLE...
Page 1153 ENGINE 2.0L DOHC 9 - 133 OIL PUMP (Continued) Fig. 106 Oil Pump Fig. 108 Measuring Outer Rotor Thickness 1 - OIL PUMP BODY 2 - OIL PUMP COVER 3 - OUTER ROTOR 4 - INNER ROTOR (2) Lay a straightedge across the pump cover sur- face (Fig.
Page 1154 9 - 134 ENGINE 2.0L DOHC OIL PUMP (Continued) tube screen, clogged oil filter and stuck open pres- sure relief valve or other reasons for oil pressure loss. ASSEMBLY (1) Install oil pump rotors (Fig. 106). (2) Install oil pump cover and screws (Fig. 106). Tighten screws to 12 N·m (105 in.
Page 1155: Special Tools
ENGINE 2.0L DOHC 9 - 135 OIL PUMP (Continued) (11) Install the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION). (12) Install the front timing belt cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION).
Page 1156 9 - 136 ENGINE 2.0L DOHC INTAKE MANIFOLD (Continued) Fig. 116 Clean Air Hose 1 - AIR CLEANER HOUSING 2 - INLET AIR TEMPERATURE SENSOR Fig. 118 MAP Sensor 3 - MAKE-UP AIR HOSE 1 - MAP SENSOR Fig. 117 Engine Cover 1 - BALL STUDS Fig.
Page 1157 ENGINE 2.0L DOHC 9 - 137 INTAKE MANIFOLD (Continued) (7) Disconnect proportional purge hoses (Fig. 120). (10) Remove throttle body support bracket bolt at (8) Disconnect brake booster hose (Fig. 121). the throttle body (Fig. 122). Fig. 122 Throttle Body Support Bracket and PCV Hose Fig.
Page 1158 9 - 138 ENGINE 2.0L DOHC INTAKE MANIFOLD (Continued) REMOVAL - LOWER INTAKE MANIFOLD WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING SYSTEM COMPONENTS. SER- VICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. (1) Perform fuel system pressure release procedure before attempting any repairs (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD...
Page 1159 ENGINE 2.0L DOHC 9 - 139 INTAKE MANIFOLD (Continued) (9) Connect Idle Air Control (IAC) motor and (4) If removed, install the fuel rail assembly to Throttle Position Sensor (TPS) wiring connectors intake manifold. Tighten screws to 23 N·m (200 in. (Fig.
Page 1160 9 - 140 ENGINE 2.0L DOHC EXHAUST MANIFOLD REMOVAL (1) Remove clean air hose and air cleaner housing. (2) Disconnect negative cable from battery. (3) Disconnect throttle and speed control cables from the throttle lever and bracket. (4) Disconnect MAP sensor electrical connector. (5) Remove fasteners securing power steering fluid reservoir to cylinder head.
Page 1161 ENGINE 2.0L DOHC 9 - 141 EXHAUST MANIFOLD (Continued) (2) Position exhaust manifold in place. Tighten fas- teners, starting at center and progressing outward in both directions to 23 N·m (200 in. lbs.) (Fig. 133). Raise and lower vehicle for fastener access as neces- sary.
Page 1162 9 - 142 ENGINE 2.0L DOHC (10) Discharge A/C system and disconnect A/C VALVE TIMING lines at coupling block (Refer to 24 - HEATING & AIR CONDITIONING - STANDARD PROCEDURE). STANDARD PROCEDURE - VALVE TIMING (11) Remove upper torque strut (Refer to 9 - VERIFICATION ENGINE/ENGINE MOUNTING/TORQUE STRUT - (1) Remove number one spark plug.
Page 1163 ENGINE 2.0L DOHC 9 - 143 TIMING BELT COVER(S) (Continued) (2) Remove timing belt(Refer to 9 - ENGINE/ (3) Lower engine into mounting position and VALVE TIMING/TIMING BELT AND SPROCKETS - install right engine mount through bolt. Tighten bolt REMOVAL). to 118 N·m (87 ft.
Page 1164 9 - 144 ENGINE 2.0L DOHC TIMING BELT AND SPROCKETS (Continued) Fig. 137 Timing Belt System - 2.0L DOHC 1 - FRONT TIMING BELT COVER 7 - CRANKSHAFT SPROCKET 2 - CAMSHAFT SPROCKETS 8 - TIMING BELT 3 - REAR TIMING BELT COVER 9 - CRANKSHAFT DAMPER 4 - IDLER PULLEY 10 - ACCESS PLUG...
Page 1165 ENGINE 2.0L DOHC 9 - 145 TIMING BELT AND SPROCKETS (Continued) Fig. 138 Camshaft Timing Marks 1 - ALIGN CAMSHAFT SPROCKET TIMING MARKS TOGETHER 2 - CENTERLINE Fig. 140 Timing Belt Removal 1 - LOCK NUT 2 - TOP PLATE Fig.
Page 1166 9 - 146 ENGINE 2.0L DOHC TIMING BELT AND SPROCKETS (Continued) CLEANING INSTALLATION - TIMING BELT Do Not attempt to clean a timing belt. If contami- (1) Set crankshaft sprocket to TDC by aligning the nation from oil, grease, or coolants have occurred, the sprocket with the arrow on the oil pump housing, timing belt should be replaced.
Page 1167 ENGINE 2.0L DOHC 9 - 147 TIMING BELT AND SPROCKETS (Continued) Fig. 146 Adjusting Crankshaft Sprocket for Timing Belt 1 - TDC REFERENCE MARK Fig. 147 Timing Belt Tension Adjustment 2 - 1/2 NOTCH LOCATION 3 - TDC MARK 1 - ALIGN SETTING NOTCH WITH SPRING TANG 2 - TOP PLATE pulley.
Page 1168 9 - 148 ENGINE 2.0L DOHC INSTALLATION TIMING BELT TENSIONER & (1) Position timing belt tensioner assembly to the PULLEY engine. To ensure proper alignment of tensioner to engine block, temporarily install the engine mount REMOVAL bracket bolts into the upper holes of the timing belt (1) Remove the timing belt (Refer to 9 - ENGINE/ tensioner.
Page 1169 ENGINE 2.4L DOHC 9 - 149 ENGINE 2.4L DOHC TABLE OF CONTENTS page page ENGINE 2.4L DOHC INSTALLATION - CYLINDER HEAD ..177 DESCRIPTION ......151 CAMSHAFT OIL SEAL(S) DIAGNOSIS AND TESTING REMOVAL...
Page 1170 9 - 150 ENGINE 2.4L DOHC CRANKSHAFT OIL SEAL - FRONT OIL FILTER ADAPTER REMOVAL ......192 REMOVAL .
Page 1171: Engine 2.4L Dohc
ENGINE 2.4L DOHC 9 - 151 INSTALLATION - TIMING BELT ..229 OPERATION ......232 TIMING BELT TENSIONER &...
Page 1172: Diagnosis And Testing - Engine Diagnosis - Performance
9 - 152 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1173 ENGINE 2.4L DOHC 9 - 153 ENGINE 2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 1174: Diagnosis And Testing - Engine Diagnosis - Mechanical
9 - 154 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (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 1175 ENGINE 2.4L DOHC 9 - 155 ENGINE 2.4L DOHC (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 1176: Diagnosis And Testing - Cylinder Combustion Pressure Leakage Test
9 - 156 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1177: Diagnosis And Testing - Engine Oil Leak Inspection
ENGINE 2.4L DOHC 9 - 157 ENGINE 2.4L DOHC (Continued) transducer (Special Tool CH7059) with cable adap- CAUTION: Do not subject the engine assembly to tors to the DRBIII . For Special Tool identification, more than 20.6 kpa (3 PSI) of test pressure. (Refer to 9 - ENGINE - SPECIAL TOOLS).
Page 1178: Standard Procedure
9 - 158 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) (5) If the leak is not detected, very slowly turn the (4) With all spark plugs removed, rotate engine crankshaft and watch for leakage. If a leak is crankshaft using a breaker bar and socket. detected between the crankshaft and seal while (5) Identify the fluid in the cylinder(s) (i.e., cool- slowly turning the crankshaft, it is possible the...
Page 1179: Standard Procedure - Engine Gasket Surface Preparation
ENGINE 2.4L DOHC 9 - 159 ENGINE 2.4L DOHC (Continued) this material will not properly cure. Always inspect STANDARD PROCEDURE - ENGINE GASKET the package for the expiration date before use. SURFACE PREPARATION MOPAR GASKET MAKER is an anaerobic type To ensure engine gasket sealing, proper surface gasket material.
Page 1180: Standard Procedure - Engine Core And Oil Gallery Plugs
9 - 160 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) STANDARD PROCEDURE - ENGINE CORE AND holes (Fig. 4). (In addition, suspected areas can be checked by placing the Plastigage in the suspected OIL GALLERY PLUGS area). Torque the bearing cap bolts of the bearing Using a blunt tool such as a drift and a hammer, being checked to the proper specifications.
Page 1181 ENGINE 2.4L DOHC 9 - 161 ENGINE 2.4L DOHC (Continued) (6) Discharge air conditioning system, if equipped (Refer to 24 - HEATING & AIR CONDITIONING - STANDARD PROCEDURE). (7) Disconnect throttle and speed control cables from throttle body. (8) Disconnect engine wiring harness at Power- train Control Module (PCM).
Page 1182 9 - 162 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) Fig. 7 Clutch Hydraulic Line to Slave Cylinder— (Manual Transaxle Equipped) 1 - SLAVE CYLINDER 2 - HYDRAULIC TUBE Fig. 9 Charge Air Cooler Hoses 1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY 2 - CHARGE AIR COOLER 3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER Fig.
Page 1183 ENGINE 2.4L DOHC 9 - 163 ENGINE 2.4L DOHC (Continued) Fig. 13 Hoses At Power Steering Gear - 2.4L Turbo 1 - POWER STEERING GEAR 2 - ROUTING CLIP 3 - PRESSURE HOSE TUBE NUT Fig. 11 Converter to Exhaust Manifold Connection - 4 - RETURN HOSE CLAMP 2.4L Turbo 5 - PRESSURE/RETURN HOSE ASSEMBLY...
Page 1184: Installation - Engine Assembly
9 - 164 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) (40) Manual Transmission equipped vehicles: (a) Remove drive plate to clutch module bolts. (41) Remove lower engine torque strut (Refer to 9 - ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL). (42) Lower vehicle and remove A/C compressor. (43) Disconnect power steering lines from power steering pump.
Page 1185 ENGINE 2.4L DOHC 9 - 165 ENGINE 2.4L DOHC (Continued) Fig. 17 Positioning Engine Cradle Support Post 1 - POST LOCATING HOLES IN BLOCK 5 - FLOOR JACK 2 - POST POSITIONED UNDER BRACKET 6 - SPECIAL TOOL 6848 3 - POST LOCATING HOLE IN STRUT 7 - SPECIAL TOOL 6135 4 - SAFETY STRAPS 8 - SPECIAL TOOL 6710...
Page 1186: Specifications
9 - 166 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) (38) Connect engine wiring harness at Powertrain DESCRIPTION SPECIFICATION Control Module (PCM). (39) Connect throttle and speed control cables. Cylinder Block (40) Install battery tray and battery (Refer to 8 - Cylinder Bore Diameter 87.4924–87.5076 mm ELECTRICAL/BATTERY...
Page 1187 ENGINE 2.4L DOHC 9 - 167 ENGINE 2.4L DOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Piston Rings Crankshaft Ring Gap—Top 0.25–0.51 mm Connecting Rod Journal 49.984–50.000 mm Compression Ring Diameter (0.0098–0.020 in.) (1.968–1.9685 in.) Wear Limit 0.8 mm Main Bearing Journal 59.992–60.008 mm Diameter (0.031 in.)
Page 1188 9 - 168 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Opens (BBDC) 40° Valve Stem Diameter Duration 221° —Intake 5.934–5.952 mm Valve Overlap 5.4° (0.2337–0.2344 in.) *All readings in crankshaft degrees, at 0.5 mm (0.019 —Exhaust 5.906–5.924 mm in.) of valve lift.
Page 1189: Torque
ENGINE 2.4L DOHC 9 - 169 ENGINE 2.4L DOHC (Continued) DESCRIPTION SPECIFICATION DESCRIPTION N·m Lbs. Lbs. Number of Coils 7.82 Balance Shaft Chain — Wire Diameter 3.86 mm Tensioner—Bolts (1.496 in.) Balance Shaft Carrier — Oil Pump Cover—Bolts Clearance Over Rotors 0.10 mm Camshaft Sprocket—Bolt —...
Page 1190: Special Tools
9 - 170 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) DESCRIPTION N·m Lbs. Lbs. Timing Belt Cover - Front — Upper and Lower—Bolts Timing Belt Cover - Rear —M6 Bolts — —M8 Bolts — Timing Belt Idler Pulley — Cradle 6710 Timing Belt Tensioner —...
Page 1191 ENGINE 2.4L DOHC 9 - 171 ENGINE 2.4L DOHC (Continued) Camshaft Seal Installer MD-998306 Valve Spring Compressor MD-998772-A Crankshaft Damper/Sprocket Installer 6792 Valve Spring Compressor Adapter 6779 Valve Spring Compressor 8215-A Cylinder Bore Gage C-119 Connecting Rod Guides 8189 Adaptor 8436 Crankshaft Sprocket Remover 6793...
Page 1192 9 - 172 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Crankshaft Sprocket Remover Insert C-4685-C2 Crankshaft Front Seal Remover 6771 Balance Shaft Sprocket Installer 6052 Post Adapter 8130 Oil Pressure Gage C-3292 Adaptor 8406 Front Crankshaft Oil Seal Installer 6780 Combustion Leak Tester C-3685-A...
Page 1193: Air Cleaner Element Removal
ENGINE 2.4L DOHC 9 - 173 ENGINE 2.4L DOHC (Continued) AIR CLEANER ELEMENT REMOVAL (1) Unfasten clasps on sides of air cleaner housing cover. Lift cover off air cleaner housing (Fig. 18) . Cooling System Tester 7700 Pressure Transducer CH7059 Fig.
Page 1194: Diagnosis And Testing-Cylinder Head Gasket
9 - 174 ENGINE 2.4L DOHC AIR CLEANER HOUSING (Continued) (4) Connect the throttle body air inlet hose/clean air hose to the air cleaner housing (Fig. 19) or (Fig. 20) and (Fig. 21). Fig. 19 Air Inlet System Fig. 21 Clean Air Hose - 2.4L Turbo 1 - CLEAN AIR HOSE 2 - TURBOCHARGER CYLINDER HEAD...
Page 1195: Camshaft Oil Seal(S)
ENGINE 2.4L DOHC 9 - 175 CYLINDER HEAD (Continued) COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- SIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi).
Page 1196 9 - 176 ENGINE 2.4L DOHC CYLINDER HEAD (Continued) Fig. 23 Dipstick Tube Fig. 25 Turbocharger Brackets and Heat Shields 1 - DIPSTICK TUBE 1 - UPPER/LOWER HEAT SHIELDS 2 - SCREW 2 - TURBOCHARGER SUPPORT BRACKET 3 - ELBOW 4 - ELBOW SUPPORT BRACKET (15) Turbocharger equipped vehicles: (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-...
Page 1197: Cleaning
ENGINE 2.4L DOHC 9 - 177 CYLINDER HEAD (Continued) Fig. 27 Checking Cylinder Head Flatness 1 - FEELER GAUGE 2 - STRAIGHT EDGE (3) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. (4) Using a small hole gauge and a micrometer, Fig.
Page 1198 9 - 178 ENGINE 2.4L DOHC CYLINDER HEAD (Continued) (2) Position cylinder head onto engine block. (3) Before installing the bolts, the threads should be lightly coated with engine oil. (4) Tighten the cylinder head bolts in the sequence shown in (Fig. 32). Using the 4 step torque-turn method, tighten according to the following values: •...
Page 1199: Camshaft Oil Seal(S) Removal
ENGINE 2.4L DOHC 9 - 179 CYLINDER HEAD (Continued) • Install elbow • Install turbocharger support bracket • Install elbow support bracket • Install turbocharger heat shields (14) Install exhaust pipe to manifold. Tighten fas- teners to 28 N·m (20 ft. lbs.). (15) Install accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
Page 1200: Operation
9 - 180 ENGINE 2.4L DOHC CAMSHAFT OIL SEAL(S) (Continued) Fig. 35 Camshaft Seal - Installation 1 - SPECIAL TOOL MD-998306 ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION). Fig. 36 Camshafts CAMSHAFT(S) 1 - CAMSHAFT BEARING CAPS 2 - PLUG 3 - CAMSHAFT DESCRIPTION 4 - CYLINDER HEAD 5 - CAMSHAFT OIL SEAL...
Page 1201: Inspection
ENGINE 2.4L DOHC 9 - 181 CAMSHAFT(S) (Continued) (4) Remove camshaft sprockets and timing belt INSPECTION rear cover (Refer to 9 - ENGINE/VALVE TIMING/ (1) Inspect camshaft bearing journals for damage TIMING BELT COVER(S) - REMOVAL). and binding (Fig. 40). If journals are binding, check (5) Bearing caps identified...
Page 1202: Cylinder Head Cover Removal
9 - 182 ENGINE 2.4L DOHC CAMSHAFT(S) (Continued) (3) Disconnect PCV and make-up air hoses from cylinder head cover (Fig. 43). (4) Remove cylinder head cover bolts. CAUTION: When removing cylinder head cover bolts, be careful not to interchange the two (2) cen- ter bolts with the seven (7) perimeter bolts.
Page 1203 ENGINE 2.4L DOHC 9 - 183 CYLINDER HEAD COVER (Continued) Fig. 44 Cylinder Head Cover Gasket and Spark Plug Well Seals 1 - SPARK PLUG WELL SEALS 2 - GASKET Fig. 46 Cylinder Head Cover Bolt Assembly Fig. 45 Spark Plug Well Seals CAUTION: When installing cylinder head cover bolts, be careful not to interchange the two (2) cen- ter bolts with the seven (7) perimeter bolts.
Page 1204: Hydraulic Lash Adjusters Diagnosis And Testing Hydraulic Lash Adjuster Noise Diagnosis
9 - 184 ENGINE 2.4L DOHC CYLINDER HEAD COVER (Continued) • Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. •...
Page 1205: Description
ENGINE 2.4L DOHC 9 - 185 INTAKE/EXHAUST VALVES & SEATS DESCRIPTION The valves are made of heat resistant steel. They have chrome plated stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. The valves have three-bead lock keepers to retain springs and to promote valve rotation.
Page 1206: Removal - Cylinder Head On
9 - 186 ENGINE 2.4L DOHC INSPECTION VALVE SPRINGS & SEALS (1) Whenever valves have been removed for inspec- tion, reconditioning or replacement, valve springs REMOVAL should be tested for correct tension. Discard the springs that do not meet specifications. The following REMOVAL - CYLINDER HEAD ON specifications apply to both intake and exhaust (1) Remove cylinder head cover (Refer to 9 -...
Page 1207: Installation - Cylinder Head Off
ENGINE 2.4L DOHC 9 - 187 VALVE SPRINGS & SEALS (Continued) INSTALLATION - CYLINDER HEAD OFF Coat valve stems with clean engine oil and insert in cylinder head. Install new valve stem seals on all valves using a valve stem seal tool (Fig. 54). The valve stem seals should be pushed firmly and squarely over valve guide.
Page 1208: Inspection
9 - 188 ENGINE 2.4L DOHC 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 1209: Removal - Crankshaft
ENGINE 2.4L DOHC 9 - 189 ENGINE BLOCK (Continued) should be 10 mm (3/8 in.) up from bottom of bore. (10) Remove the timing belt (Refer to 9 - ENGINE/ (Refer to 9 - ENGINE - SPECIFICATIONS). VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL).
Page 1210: Inspection
9 - 190 ENGINE 2.4L DOHC CRANKSHAFT (Continued) CAUTION: Use extreme care when handling crank- INSTALLATION - CRANKSHAFT shaft. Tone wheel damage can occur if crankshaft is mis-handled. CRANKSHAFT MAIN BEARING LOCATION (21) Lift out crankshaft from cylinder block. Do Non-Turbo not damage the main bearings or journals when The crankshaft is supported in five main bearings.
Page 1211 ENGINE 2.4L DOHC 9 - 191 CRANKSHAFT (Continued) Fig. 64 Main Bearing Identification - Turbo Fig. 66 Bedplate Sealing 1 - OIL GROOVE 2 - MAIN BEARINGS 3 - OIL HOLE 4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR GROOVE) Fig.
Page 1212: Crankshaft Oil Seal - Front Removal
9 - 192 ENGINE 2.4L DOHC CRANKSHAFT (Continued) (11) Tighten bolts (1–10) to 75 N·m (55 ft. lbs.) in (33) Install the engine assembly (Refer to 9 - sequence shown in (Fig. 67). ENGINE - INSTALLATION). (12) Tighten bolts (11–20) again to 28 N·m (250 in. lbs.) in sequence shown in (Fig.
Page 1213: Crankshaft Oil Seal - Rear Removal
ENGINE 2.4L DOHC 9 - 193 CRANKSHAFT OIL SEAL - FRONT (Continued) Fig. 69 Front Crankshaft Oil Seal - Removal Fig. 71 Crankshaft Sprocket - Installation 1 - SPECIAL TOOL 6771 1 - SPECIAL TOOL 6792 2 - REAR TIMING BELT COVER 2 - TIGHTEN NUT TO INSTALL CRANKSHAFT OIL SEAL - REAR...
Page 1214 9 - 194 ENGINE 2.4L DOHC CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 73 Rear Crankshaft Seal and Special Tool Fig. 72 Rear Crankshaft Oil Seal - Removal 6926-1 1 - REAR CRANKSHAFT SEAL 1 - SPECIAL TOOL 6926–1 PILOT 2 - ENGINE BLOCK 2 - SEAL 3 - ENGINE BLOCK...
Page 1215: Piston & Connecting Rod Description
ENGINE 2.4L DOHC 9 - 195 CRANKSHAFT OIL SEAL - REAR (Continued) cylinder wall lubrication. The pistons and connecting rods are serviced as an assembly. STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 21°C (70°F).
Page 1216 9 - 196 ENGINE 2.4L DOHC PISTON & CONNECTING ROD (Continued) Fig. 77 Piston Measurement - Turbo Fig. 79 Piston Markings 1 - PISTON DIAMETER 2 - 22 mm ( 0.866 in.) 1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA Fig.
Page 1217: Installation
ENGINE 2.4L DOHC 9 - 197 PISTON & CONNECTING ROD (Continued) (11) Repeat procedure for each piston and connect- ring gaps are staggered so that neither is in line with ing rod assembly. oil ring rail gap (Fig. 83). (12) Remove piston rings (Refer to 9 - ENGINE/ (3) Before installing the ring compressor, make ENGINE BLOCK/PISTON RINGS - REMOVAL).
Page 1218: Connecting Rod - Fitting
9 - 198 ENGINE 2.4L DOHC PISTON & CONNECTING ROD (Continued) 1. Tighten the bolts to 27 N·m (20 ft. lbs.). 2. Tighten the connecting rod bolts an additional 1/4 TURN. (5) Using a feeler gauge, check connecting rod side clearance (Fig.
Page 1219: Removal
ENGINE 2.4L DOHC 9 - 199 PISTON RINGS (Continued) (2) Check piston ring to groove side clearance (Fig. INSTALLATION 87). Refer to Engine Specifications. NOTE: The identification mark on face of upper and intermediate piston rings must point toward top of piston.
Page 1220: Structural Collar Removal
9 - 200 ENGINE 2.4L DOHC PISTON RINGS (Continued) Fig. 90 Installing Side Rail Fig. 92 Structural Collar and Bending Strut— 1 - SIDE RAIL END (Automatic Transaxle Equipped) (5) Position oil ring expander gap at least 45° from 1–8 – BOLT TIGHTENING SEQUENCE the side rail gaps but not on the piston pin center or 9 –...
Page 1221: Vibration Damper Removal
ENGINE 2.4L DOHC 9 - 201 STRUCTURAL COLLAR (Continued) • Step 6: Position power steering hose support bracket (Fig. 94) and install the remaining collar to oil pan bolt (5), hand tight only. • Step 7: Final torque collar to transaxle bolts (1–3), to 101 N·m (75 ft.
Page 1222: Operation
9 - 202 ENGINE 2.4L DOHC VIBRATION DAMPER (Continued) ENGINE MOUNTING DESCRIPTION The engine mounting system (Fig. 98) and (Fig. 100) consists of a four-point system utilizing two load-carrying mounts and two torque struts. The load-carrying mounts are located on each frame rail. The right mount is a hydro-elastic mount and left mount is a conventional elastomeric isolator.
Page 1223: Left Mount
ENGINE 2.4L DOHC 9 - 203 LEFT MOUNT (Continued) RIGHT MOUNT REMOVAL (1) Remove the engine assembly for the required clearance to access the engine mount (Refer to 9 - ENGINE - REMOVAL). NOTE: The right engine mount attaching holes are slightly oversize to compensate for manufacturing tolerances.
Page 1224: Removal - Upper
9 - 204 ENGINE 2.4L DOHC RIGHT MOUNT (Continued) concentric (frame rail holes centered in the mount (3) Remove the upper torque strut. holes). REMOVAL - LOWER (c) Using a permanent ink marker or equivalent, mark the position of engine mount to the body (1) Raise vehicle on hoist.
Page 1225: Installation - Lower
ENGINE 2.4L DOHC 9 - 205 TORQUE STRUT (Continued) INSTALLATION - LOWER (1) Position lower torque strut into mounting loca- tions. (2) Install mounting bolts and perform torque strut adjustment procedure (Refer to 9 - ENGINE/ ENGINE MOUNTING/TORQUE STRUT - ADJUST- MENTS).
Page 1226: Operation
9 - 206 ENGINE 2.4L DOHC TORQUE STRUT (Continued) OPERATION Engine oil drawn up through the pickup tube and is pressurized by the oil pump and routed through the full-flow filter to the main oil gallery running the length of the cylinder block. A diagonal hole in each bulkhead feeds oil to each main bearing.
Page 1227: Engine Oil Level Check
ENGINE 2.4L DOHC 9 - 207 STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE STANDARD PROCEDURE WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR ENGINE OIL LEVEL CHECK REPEATED SKIN CONTACT WITH ENGINE OIL. The best time to check engine oil level is after the CONTAMINANTS IN USED ENGINE OIL, CAUSED BY vehicle has sat overnight, or if the engine has been...
Page 1228 9 - 208 ENGINE 2.4L DOHC OIL (Continued) Fig. 106 Engine Oil Dipstick and Fill Locations - 2.4L Turbo 1 - ENGINE OIL FILL 3 - ENGINE OIL DIPSTICK 2 - COOLANT RECOVERY CONTAINER 4 - COOLANT PRESSURE CAP Fig. 107 Engine Oil Dipstick (5) Place a suitable oil collecting container under oil pan drain plug.
Page 1229: Oil Filter Removal
ENGINE 2.4L DOHC 9 - 209 OIL (Continued) (3) Screw oil filter (Fig. 108) or (Fig. 109) on until the gasket contacts base. Tighten to 21 N·m (15 ft. lbs.). OIL FILTER ADAPTER REMOVAL (1) Raise vehicle on hoist. (2) Place a suitable oil collecting container under oil filter.
Page 1230: Oil Pan Removal
9 - 210 ENGINE 2.4L DOHC OIL PAN REMOVAL (1) Raise vehicle on hoist. (2) Drain engine oil and remove oil filter. (3) Remove accessory drive belt splash shield. (4) Turbocharger Equipped Vehicles: Remove turbocharger to charge air cooler hose assembly (Refer EXHAUST SYSTEM/TURBO-...
Page 1231: Disassembly
ENGINE 2.4L DOHC 9 - 211 OIL PRESSURE SENSOR/SWITCH (Continued) OPERATION (6) Remove crankshaft key (Fig. 115). The oil pressure switch is normally “Closed.” The switch changes from a Closed circuit to an Open circuit, on increasing pressure of 7 psig. The oil pres- sure switch changes from an Open circuit to a Closed circuit, on decreasing pressure, between 2 psig and 4 psig.
Page 1232: Inspection
9 - 212 ENGINE 2.4L DOHC OIL PUMP (Continued) can be inserted between cover and straight edge, cover should be replaced. (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 10.699 mm (0.421 in.) or less (Fig. 119), or if the diameter is 85.924 mm (3.383 in.) or less, replace outer rotor.
Page 1233: Installation
ENGINE 2.4L DOHC 9 - 213 OIL PUMP (Continued) Fig. 120 Measuring Inner Rotor Thickness INSTALLATION (1) Make sure all surfaces are clean and free of oil and dirt. (2) Apply Mopar Gasket Maker to oil pump as shown in (Fig. 121). Install O-ring into oil pump body discharge passage.
Page 1234: Oil Jet - 2.4L Turbo Description
9 - 214 ENGINE 2.4L DOHC OIL PUMP (Continued) (8) Install oil pump pick-up tube. (9) Install oil pan (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - INSTALLATION). (10) Install timing belt rear cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION).
Page 1235: Oil Cooler & Lines - 2.4L Turbo Description
ENGINE 2.4L DOHC 9 - 215 OIL COOLER & LINES - 2.4L TURBO DESCRIPTION An engine oil cooler is used on the 2.4L Turbo- charged engine. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter (Fig.
Page 1236: Manifold Leaks
9 - 216 ENGINE 2.4L DOHC OIL COOLER & LINES - 2.4L TURBO (Continued) REMOVAL REMOVAL - UPPER INTAKE MANIFOLD Non-Turbo (1) Disconnect inlet air temperature sensor and make-up air hose from clean air hose (Fig. 131). (2) Remove air cleaner housing and clean air hose assembly.
Page 1237 ENGINE 2.4L DOHC 9 - 217 INTAKE MANIFOLD (Continued) (6) Disconnect manifold absolute pressure (MAP) (7) Disconnect proportional purge hoses (Fig. 135). sensor (Fig. 133), idle air control (IAC) motor and (8) Disconnect brake booster hose (Fig. 136). throttle position sensor (TPS) wiring connectors (Fig. 134).
Page 1238 9 - 218 ENGINE 2.4L DOHC INTAKE MANIFOLD (Continued) (10) Remove throttle body support bracket bolt at (3) Disconnect the throttle inlet pressure (TIP) the throttle body (Fig. 137). hose (Fig. 139). Fig. 137 Throttle Body Support Bracket and PCV Hose 1 - PCV HOSE 2 - BOLT...
Page 1239 ENGINE 2.4L DOHC 9 - 219 INTAKE MANIFOLD (Continued) (5) Disconnect idle air control (IAC) motor and throttle position sensor connectors. (6) Disconnect the MAP sensor connector (Fig. 141). Fig. 143 Throttle Cables - 2.4L Turbo Fig. 141 MAP Sensor - 2.4L Turbo 1 - MAP SENSOR (7) Remove the throttle control shield (Fig.
Page 1240: Removal - Lower Intake Manifold
9 - 220 ENGINE 2.4L DOHC INTAKE MANIFOLD (Continued) FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE). (2) Disconnect negative battery cable. (3) Remove upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD UPPER - REMOVAL). (4) Partially drain cooling system below thermo- stat level (Refer to 7 - COOLING/ENGINE - STAN- DARD PROCEDURE).
Page 1241: Cleaning
ENGINE 2.4L DOHC 9 - 221 INTAKE MANIFOLD (Continued) Fig. 149 Intake Manifold Tightening Sequence (6) Connect PCV hose to intake manifold (Fig. 137). (7) Connect manifold absolute pressure (MAP) electrical connector (Fig. 133). (8) Connect proportional purge hoses (Fig. 135). Fig.
Page 1242: Manifold
9 - 222 ENGINE 2.4L DOHC INTAKE MANIFOLD (Continued) Fig. 151 Lower Intake Manifold Seals - Naturally Aspirated Engine 1 - SEALS Fig. 150 Intake Manifold Tightening Sequence - 2.4L Turbo Fig. 152 Lower Intake Manifold Tightening (9) Install the throttle cable to the throttle body Sequence lever (Fig.
Page 1243: Exhaust Manifold Removal
ENGINE 2.4L DOHC 9 - 223 EXHAUST MANIFOLD REMOVAL NOTE: The exhaust manifold on Turbocharged equipped vehicles is serviced as an assembly with the Turbocharger. (Refer to 11 - EXHAUST SYSTEM/ TURBOCHARGER SYSTEM/TURBOCHARGER REMOVAL). (1) Remove clean air hose and air cleaner housing. (2) Disconnect negative cable from battery.
Page 1244: Cleaning
9 - 224 ENGINE 2.4L DOHC EXHAUST MANIFOLD (Continued) INSPECTION (1) Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. (2) Inspect manifolds for cracks or distortion. Replace manifold as necessary.
Page 1245: Timing Belt Cover(S) Removal
ENGINE 2.4L DOHC 9 - 225 EXHAUST MANIFOLD (Continued) (9) Install fasteners securing power steering fluid (2) Raise vehicle on hoist. Remove right front reservoir to cylinder head. wheel. (10) Connect MAP sensor electrical connector. (3) Remove the right splash shield. (11) Connect throttle and speed control cables to (4) Remove accessory drive belts (Refer to 7 - the throttle lever and bracket.
Page 1246 9 - 226 ENGINE 2.4L DOHC TIMING BELT COVER(S) (Continued) Fig. 162 Camshaft Sprocket—Removal/Installation 1 - SPECIAL TOOL 6847 Fig. 160 Engine Support Bracket 1 - ENGINE SUPPORT BRACKET 2 - BOLTS - 61 N·m (45 ft. lbs.) Fig. 163 Rear Timing Belt Cover Fasteners Fig.
Page 1247: Timing Belt And Sprockets
ENGINE 2.4L DOHC 9 - 227 TIMING BELT COVER(S) (Continued) (4) Perform torque strut adjustment procedure (4) Install timing belt (Refer to 9 - ENGINE/ (Refer ENGINE/ENGINE MOUNTING/ VALVE TIMING/TIMING BELT AND SPROCKETS - TORQUE STRUT - ADJUSTMENTS). INSTALLATION). (5) Install front timing belt covers. Refer to above FRONT COVER—LOWER procedures.
Page 1248: Removal - Crankshaft Sprocket
9 - 228 ENGINE 2.4L DOHC TIMING BELT AND SPROCKETS (Continued) (3) Use Special Tool 6847 to hold camshaft sprock- ets while removing the sprocket bolt(s) (Fig. 166). Remove camshaft sprocket(s). Fig. 166 Camshaft Sprocket—Removal/Installation 1 - SPECIAL TOOL 6847 REMOVAL - CRANKSHAFT SPROCKET Fig.
Page 1249: Installation - Camshaft Sprockets
ENGINE 2.4L DOHC 9 - 229 TIMING BELT AND SPROCKETS (Continued) (2) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT - INSTALLATION). (3) Install upper and lower front timing belt covers (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION).
Page 1250 9 - 230 ENGINE 2.4L DOHC TIMING BELT AND SPROCKETS (Continued) (5) Insert a 6 mm Allen wrench into the hexagon (7) Rotate the crankshaft CLOCKWISE two com- opening located on the top plate of the belt tensioner plete revolutions manually for seating of the belt, pulley.
Page 1251: Timing Belt Tensioner & Pulley Removal
ENGINE 2.4L DOHC 9 - 231 TIMING BELT AND SPROCKETS (Continued) Fig. 174 Camshaft Sprockets 1 - SPECIAL TOOL 6847 Fig. 173 Timing Belt Tension Verification 1 - SPRING TANG 2 - TOLERANCE WINDOW TIMING BELT TENSIONER & PULLEY REMOVAL (1) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL).
Page 1252 9 - 232 ENGINE 2.4L DOHC TIMING BELT TENSIONER & PULLEY (Continued) BALANCE SHAFTS AND CARRIER ASSEMBLY DESCRIPTION The 2.4L engine is equipped with two nodular cast iron balance shafts installed in a cast aluminum car- rier attached to the lower cylinder block (Fig. 177). OPERATION The balance shafts are driven by the crankshaft via a roller chain and sprockets.
Page 1253 ENGINE 2.4L DOHC 9 - 233 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 177 Balance Shafts and Carrier Assembly 1 - SPROCKET 7 - GEARS 2 - TENSIONER 8 - GEAR COVER 3 - PLUG 9 - CHAIN COVER 4 - CARRIER 10 - SPROCKET 5 - REAR COVER 11 - GUIDE...
Page 1254 9 - 234 ENGINE 2.4L DOHC BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 180 Gear Cover and Gears 1 - STUD (DOUBLE ENDED) 2 - DRIVE GEAR 3 - DRIVEN GEAR 4 - CARRIER DOWEL 5 - GEAR(S) 6 - GEAR COVER Fig.
Page 1255 ENGINE 2.4L DOHC 9 - 235 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 182 Gear Timing 1 - KEY WAYS UP 2 - GEAR ALIGNMENT DOTS Fig. 184 Balance Shaft Drive 1 - SPROCKET 2 - SPECIAL TOOL 6052 Fig. 183 Balance Shaft Sprocket Alignment to Crankshaft 1 - ALIGN FLATS sprocket (dot) with the (lower) plated link on the...
Page 1256 9 - 236 ENGINE 2.4L DOHC BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) (10) If the sprockets are timed correctly, install the balance shaft bolts and tighten to 28 N·m (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation.
Page 1257: Installation
EXHAUST SYSTEM AND TURBOCHARGER 11 - 1 EXHAUST SYSTEM AND TURBOCHARGER TABLE OF CONTENTS page page EXHAUST SYSTEM AND TURBOCHARGER INSTALLATION ......11 DESCRIPTION - EXHAUST SYSTEM .
Page 1258 11 - 2 EXHAUST SYSTEM AND TURBOCHARGER EXHAUST SYSTEM AND TURBOCHARGER DESCRIPTION - EXHAUST SYSTEM The exhaust system components consist of a cata- lytic converter, intermediate pipe, muffler, clamps and support isolators (Fig. 1). Fig. 1 Exhaust System 1 - CATALYTIC CONVERTER 4 - INTERMEDIATE PIPE 2 - BAND CLAMP 5 - BAND CLAMP...
Page 1259 EXHAUST SYSTEM AND TURBOCHARGER 11 - 3 EXHAUST SYSTEM AND TURBOCHARGER (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE EXHAUST 1. Leaks at pipe joints. 1. Tighten or replace clamps at leaking NOISE joints. 2. Burned, blown, or rusted out 2. Replace muffler or exhaust pipes. exhaust pipe or muffler.
Page 1260 11 - 4 EXHAUST SYSTEM AND TURBOCHARGER EXHAUST SYSTEM AND TURBOCHARGER (Continued) SPECIFICATIONS EXHAUST SYSTEM CLEARANCE...
Page 1261 EXHAUST SYSTEM AND TURBOCHARGER 11 - 5 EXHAUST SYSTEM AND TURBOCHARGER (Continued) 1 - TUNNEL HEAT SHIELD 11 - TAIL PIPE 2 - INTERMEDIATE PIPE 12 - HEAT SHIELD 3 - BAND CLAMP 13 - OXYGEN SENSOR 4 - FUEL TANK STRAP 14 - CATALYTIC CONVERTER 5 - FLOOR PAN 15 - TUNNEL HEAT SHIELD...
Page 1262 11 - 6 EXHAUST SYSTEM AND TURBOCHARGER INSTALLATION MUFFLER When assembling exhaust system do not tighten REMOVAL clamps until components are aligned and clearances are checked. (1) Install the muffler to intermediate pipe and the WARNING: THE NORMAL OPERATING TEMPERA- isolator supports to the underbody.
Page 1263 EXHAUST SYSTEM AND TURBOCHARGER 11 - 7 MUFFLER (Continued) Fig. 3 Muffler 1 - CLAMP 5 - HANGER 2 - INTERMEDIATE PIPE 6 - MUFFLER 3 - ISOLATOR 7 - HANGER 4 - CLAMP 8 - ISOLATOR INTERMEDIATE PIPE REMOVAL WARNING: THE NORMAL OPERATING TEMPERA- TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
Page 1264 11 - 8 EXHAUST SYSTEM AND TURBOCHARGER INTERMEDIATE PIPE (Continued) (3) Loosen band clamp and remove support isola- tor. Remove intermediate pipe from catalytic con- verter pipe (Fig. 5). (4) Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts.
Page 1265: Catalytic Converter
EXHAUST SYSTEM AND TURBOCHARGER 11 - 9 diagnosis of a catalyst related Diagnostic Trouble CATALYTIC CONVERTER Code (DTC). The combustion reaction caused by the catalyst DESCRIPTION releases additional heat in the exhaust system, caus- An under-floor catalytic converter inlet is attached ing temperature increases in the area of the reactor to the exhaust manifold using fasteners and a gasket under severe operating conditions.
Page 1266 11 - 10 EXHAUST SYSTEM AND TURBOCHARGER CATALYTIC CONVERTER (Continued) and (Refer to 11 - EXHAUST SYSTEM/INTERMEDI- ATE PIPE - REMOVAL). (2) Disconnect downstream oxygen sensor electri- cal connector (Fig. 8). Fig. 9 Converter to Exhaust Manifold Connection - 1.6L Fig.
Page 1267 EXHAUST SYSTEM AND TURBOCHARGER 11 - 11 CATALYTIC CONVERTER (Continued) Fig. 10 Converter to Exhaust Manifold Connection - Fig. 12 Converter to Exhaust Manifold Connection - 2.0L 2.4L Turbo 1 - FLAG NUT 1 - FLAG NUT 2 - GASKET 2 - GASKET 3 - BOLT 3 - NUT...
Page 1268 11 - 12 EXHAUST SYSTEM AND TURBOCHARGER SUPPORT BRACKETS AND ISOLATORS (Continued) Fig. 13 Exhaust System Isolator and Bracket (2) Connect isolator to exhaust system component. HEAT SHIELDS Fig. 15 Heat Shield - Catalytic Converter 1 - HEAT SHIELD DESCRIPTION 2 - NUT Heat shields (Fig.
Page 1269: Turbocharger System
EXHAUST SYSTEM AND TURBOCHARGER 11 - 13 HEAT SHIELDS (Continued) Fig. 17 Heat Shield - Muffler 1 - HEAT SHIELD 2 - FASTENER TURBOCHARGER SYSTEM DIAGNOSIS AND TESTING - TURBOCHARGER Check for Diagnostic Trouble Codes (DTC’S) stored in PCM memory. If any DTC’S are present, refer to the appropriate Powertrain Diagnostic Information.
Page 1270 11 - 14 EXHAUST SYSTEM AND TURBOCHARGER TURBOCHARGER SYSTEM (Continued) CONDITION POSSIBLE CAUSES Blue smoke from exhaust Oil return line blocked Engine breather clogged Turbocharger shaft seals damaged TURBOCHARGER DESCRIPTION CAUTION: The turbocharger is a performance part and must not be tampered with. Tampering with the wastegate components can reduce durability by increasing cylinder pressure and thermal loading due to incorrect inlet and exhaust manifold pres-...
Page 1271 EXHAUST SYSTEM AND TURBOCHARGER 11 - 15 TURBOCHARGER (Continued) Fig. 20 Turbocharger Oil Supply and Drain 1 - BEARINGS 2 - OIL SUPPLY (FROM ENGINE BLOCK) 3 - OIL RETURN (TO OIL PAN) REMOVAL - TURBOCHARGER CAUTION: IF TURBOCHARGER IS REPLACED DUE TO A BEARING FAILURE, REPLACEMENT OF THE OIL PRESSURE FEED LINE IS REQUIRED.
Page 1272 11 - 16 EXHAUST SYSTEM AND TURBOCHARGER TURBOCHARGER (Continued) (8) Disconnect vacuum hoses at throttle body and upper intake manifold. (9) Remove upper intake manifold support bracket (Fig. 23). Fig. 21 Clean Air Hose - 2.4L Turbo 1 - CLEAN AIR HOSE Fig.
Page 1273 EXHAUST SYSTEM AND TURBOCHARGER 11 - 17 TURBOCHARGER (Continued) Fig. 24 Turbocharger Lines and Hoses Fig. 26 Charge Air Cooler Hoses 1 - OIL SUPPLY LINE 1 - CHARGE AIR COOLER 2 - COOLANT RETURN LINE 2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER 3 - COOLANT SUPPLY LINE 3 - NUT 4 - OIL RETURN TUBE...
Page 1274 11 - 18 EXHAUST SYSTEM AND TURBOCHARGER TURBOCHARGER (Continued) cle for fastener access as necessary. Repeat tighten- ing procedure until all fasteners are at specified torque. Fig. 28 Exhaust Manifold Tightening Sequence (4) Install turbocharger elbow. Torque fasteners to 28 N·m (250 in. lbs.) (Fig. 27). (5) Install turbocharger lower heat shield.
Page 1275 EXHAUST SYSTEM AND TURBOCHARGER 11 - 19 TURBOCHARGER (Continued) (9) Install turbocharger elbow support bracket CHARGE AIR COOLER AND (Fig. 27). HOSES (10) Install turbocharger to charge air cooler hose assembly (Fig. 26). (11) Install catalytic converter and intermediate REMOVAL pipe as an assembly.
Page 1276 11 - 20 EXHAUST SYSTEM AND TURBOCHARGER CHARGE AIR COOLER AND HOSES (Continued) Fig. 31 IAT Sensor - 2.4L Turbo 1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY 2 - IAT SENSOR 3 - TIP HOSE Fig. 32 Charge Air Cooler Hoses HOSE - TURBOCHARGER TO CHARGE AIR COOLER 1 - CHARGE AIR COOLER 2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER...
Page 1277 EXHAUST SYSTEM AND TURBOCHARGER 11 - 21 CHARGE AIR COOLER AND HOSES (Continued) (13) Remove radiator (Refer to 7 - COOLING/EN- (2) Temporarily install nuts securing charge air GINE/RADIATOR - REMOVAL). cooler hose to structural collar (Fig. 32). (14) Remove charge air cooler. (3) Connect hose to turbocharger (Fig.
Page 1278 11 - 22 EXHAUST SYSTEM AND TURBOCHARGER CHARGE AIR COOLER AND HOSES (Continued) (10) Install battery tray and battery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY INSTALLATION). (11) Connect positive battery cable. (12) Connect negative battery cable. (13) Install air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR...
Page 1279 EXHAUST SYSTEM AND TURBOCHARGER 11 - 23 LINES AND HOSES (Continued) (4) Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose (Fig. 31). (5) Loosen hose clamp at throttle body. (6) Disconnect charge air cooler hose from throttle body.
Page 1280 11 - 24 EXHAUST SYSTEM AND TURBOCHARGER LINES AND HOSES (Continued) (6) Connect charge air cooler hose to throttle body. (7) Tighten hose clamp to 1.7 N·m (15 in. lbs.). (8) Connect Throttle Inlet Pressure (TIP) hose to charge air cooler hose (Fig. 31). (9) Connect Inlet Air Temperature (IAT) sensor connector (Fig.
Page 1281 EXHAUST SYSTEM AND TURBOCHARGER 11 - 25 LINES AND HOSES (Continued) (4) Install the two fasteners securing the oil return line to the turbocharger. Torque fasteners to 12 N·m (105 in. lbs.). (5) Install hose clamp for oil return line hose. (6) Lower vehicle.
Page 1282 11 - 26 EXHAUST SYSTEM AND TURBOCHARGER SOLENOIDS AND VACUUM HARNESS (Continued) (4) Push on solenoid lock tab and slide solenoid off bracket (Fig. 47). Fig. 47 Solenoid Lock Tab 1 - LOCK TAB Fig. 46 Solenoid Mounting Bracket (3) Connect solenoid electrical connector. 1 - NUTS (4) Install nuts...
Page 1283 FRAMES & BUMPERS 13 - 1 FRAMES & BUMPERS TABLE OF CONTENTS page page FRONT BUMPER REINFORCEMENT SPECIFICATIONS - TORQUE ... . . 8 REMOVAL ......1 FRONT CROSSMEMBER INSTALLATION .
Page 1284 13 - 2 FRAMES & BUMPERS FRONT BUMPER FASCIA REMOVAL (1) Remove Grille Attaching screws. (2) Remove Grille. (3) Remove nuts attaching front bumper fascia to bottom of fender flange (Fig. 2). (4) Remove fasteners attaching fascia to fender flange (Fig. 3). (5) Remove air dam fasteners from crossmember.
Page 1285 FRAMES & BUMPERS 13 - 3 (7) Lower vehicle. REAR BUMPER FASCIA (8) Install nuts attaching fascia to lower floor clo- sure. REMOVAL (9) Install the rubber body plugs or install new (1) Open liftgate. mastic tape patches, if equipped. (2) Remove the rubber body plugs or mastic tape (10) Close liftgate.
Page 1286 13 - 4 FRAMES & BUMPERS VEHICLE PREPARATION FRAME Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights SPECIFICATIONS to the specified dimension above a level work surface. Vertical dimensions can be taken from the work sur- SPECIFICATIONS - FRAME DIMENSIONS face to the locations indicated were applicable.
Page 1287 FRAMES & BUMPERS 13 - 5 FRAME (Continued) Fig. 7 ENGINE COMPARTMENT SIDE AND BOTTOM VIEW...
Page 1288 13 - 6 FRAMES & BUMPERS FRAME (Continued) Fig. 8 REAR FRAME SECTION SIDE AND BOTTOM VIEW...

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