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Chrysler Dodge Caravan 2002, Manual

Get your hands on the Chrysler Dodge Caravan 2002 Manual for free download at 88.208.23.73:8080. This user manual provides essential information for owners of this reliable and spacious minivan. Easily access valuable maintenance and troubleshooting tips to keep your vehicle running smoothly for years to come.

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Component

Page

Headlamp Washer Pump Motor . . . . . . . 8W-10-26, 52
Headlamp Washer Relay . . . . . . . . . 8W-10-26, 52, 63
High Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-36
Horn Relay . . . . . . . . . . . . . . . . . . . 8W-10-17, 36, 59
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42
Ignition Switch . . 8W-10-18, 25, 37, 45, 46, 48, 53, 54,

60

Instrument Cluster . . . . . . . . . . . . . . . . 8W-10-25, 51
Integrated Power Module . . . 8W-10-3, 4, 5, 13, 15, 16,

17, 18, 19, 20, 21, 22, 23,
24, 25, 26, 27, 28, 29, 30,
31, 32, 33, 36, 37, 38, 39,
40, 41, 42, 43, 44, 45, 46,
47, 48, 49, 51, 52, 53, 54,
55, 56, 57, 58, 59, 60, 61,

62, 63, 64, 65, 66, 68

Leak Detection Pump . . . . . . . . . . . . . . . . . 8W-10-46
Left B-Pillar Switch . . . . . . . . . . . . . . . . . . 8W-10-33
Left Combination Relay . . . . . . . . . . . . . . . 8W-10-67
Left Fog Lamp . . . . . . . . . . . . . . . . . . . 8W-10-15, 27
Left Front Park/Turn Signal

Lamp . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 56, 65

Left Headlamp . . . . . . . . . . . . . . . . . . . . . . 8W-10-57
Left Headlamp Leveling Motor . . . . . 8W-10-29, 62, 65
Left High Beam Lamp . . . . . . . . . . . . . . . . 8W-10-58
Left Low Beam Lamp . . . . . . . . . . . . . . . . . 8W-10-58
Left Park Lamp . . . . . . . . . . . . . . . . . . . 8W-10-29, 65
Left Power Mirror . . . . . . . . . . . . . . . . . . . . 8W-10-39
Left Rear Lamp Assembly . . . 8W-10-28, 29, 65, 66, 67
Left Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-10-51
Left Side Impact Airbag Control Module . . . 8W-10-62
Left Sliding Door Control Module . . . . . . . . 8W-10-52
Left Stop/Turn Signal Relay . . . . . . . . . . . . 8W-10-67
Left Turn Signal Lamp . . . . . . . . . . . . . . . . 8W-10-56
License Lamp . . . . . . . . . . . . . . . . . 8W-10-28, 29, 65
Lift Pump Motor . . . . . . . . . . . . . . . . . . 8W-10-23, 43
Lift Pump Relay . . . . . . . . . . . . . . . . . . 8W-10-23, 43
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
Mass Air Flow Sensor . . . . . . . . . . . . . . . . . 8W-10-44
Memory Seat/Mirror Module . . . . . . . . . . . . 8W-10-49
Message Center . . . . . . . . . . . . . . . . . . . . . 8W-10-51
Name Brand Speaker Relay . . . . . . . 8W-10-20, 39, 59
Overhead Console . . . . . . . . . . . . . . . . . . . . 8W-10-40
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-10-42
Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-10-42
Park Lamp Relay . . . . . . . . . . . . 8W-10-15, 28, 29, 59
Park/Neutral Position Switch . . . . . . . . . . . 8W-10-65
Passenger Door Lock Switch . . . . . . . . . 8W-10-31, 33
Passenger Folding Mirror Relay . 8W-10-22, 24, 45, 47
Passenger Heated Seat Module . . . . . . . . . . 8W-10-50
Passenger Power Seat Switch . . . . . . . . . . . 8W-10-50
Passenger Power Window Switch . . . . . . . . 8W-10-31
Power Liftgate Module . . . . . . . . . . . . . 8W-10-26, 52
Power Mirror Switch . . . . . . . . . 8W-10-22, 24, 46, 47
Power Outlet . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36

Component

Page

Power Seat Circuit Breaker . . . . . . . . . . 8W-10-25, 49
Power Window Circuit Breaker . . . . . . . 8W-10-16, 31
Power Window Switch . . . . . . . . . . . . . . . . . 8W-10-34
Powertrain Control

Module . . . . 8W-10-18, 21, 22, 37, 41, 42, 45, 46, 55

PTC 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39
PTC 7 . . . . . . . . . . . . . . . . . . . . 8W-10-16, 17, 18, 36
Radiator Fan Relay . . . . . . . . . . . . . 8W-10-26, 51, 55
Radiator Fan Relay No. 1 . . . . . . . . . . . 8W-10-13, 44
Radiator Fan Relay No. 2 . . . . . . . . . 8W-10-26, 44, 51
Radiator Fan Relay No. 3 . . . . . . . . . . . . . . 8W-10-44
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, 40
Radio Choke . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39
Rear A/C-Heater Unit . . . . . . . . . . . . . . 8W-10-19, 38
Rear Blower Motor Power Module . . . . . 8W-10-19, 38
Rear Blower Motor Relay . . . . . . 8W-10-19, 20, 38, 63
Rear Power Outlet . . . . . . . . . . . . . . 8W-10-16, 31, 32
Rear Washer Pump Motor . . . . . . . . 8W-10-16, 31, 68
Rear Window Defogger Grid . . . . . . . . . 8W-10-20, 39
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . 8W-10-33
Remote Keyless Entry Module . . . . . . . . . . . 8W-10-40
Right B-Pillar Switch . . . . . . . . . . . . . . . . . 8W-10-33
Right Combination Relay . . . . . . . . . . . . . . 8W-10-67
Right Fog Lamp . . . . . . . . . . . . . . . . . . 8W-10-15, 27
Right Front Park/Turn Signal

Lamp . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 56, 60

Right Headlamp . . . . . . . . . . . . . . . . . . . . . 8W-10-57
Right Headlamp Leveling Motor . . . . 8W-10-29, 60, 62
Right High Beam Lamp . . . . . . . . . . . . . . . 8W-10-58
Right Low Beam Lamp . . . . . . . . . . . . . . . . 8W-10-58
Right Park Lamp . . . . . . . . . . . . . . . . . 8W-10-29, 60
Right Power Mirror . . . . . . . . . . . . . . . . . . . 8W-10-39
Right Rear Lamp Assembly . . . . 8W-10-15, 28, 29, 66
Right Repeater Lamp . . . . . . . . . . . . . . . . . 8W-10-51
Right Side Impact Airbag Control Module . . 8W-10-62
Right Sliding Door Control Module . . . . . . . 8W-10-52
Right Stop/Turn Signal Relay . . . . . . . . . . . 8W-10-67
Right Turn Signal Lamp . . . . . . . . . . . . . . . 8W-10-56
Sentry Key Immobilizer

Module . . . . . . . . . . . . . . . 8W-10-40, 46, 48, 53, 54

Solenoid/Pressure Switch Assy . . . . . . . . . . 8W-10-41
Starter Motor . . . . . . . . . . . . . . . 8W-10-13, 14, 18, 37
Starter Motor Relay . . . . . . . . . . 8W-10-18, 37, 53, 54
Thatcham Alarm Module . . . . . . 8W-10-46, 48, 54, 68
Torque Converter Clutch Solenoid . . . . . . . . 8W-10-46
Trailer Tow Connector . . . . . . . . . . . . . . 8W-10-28, 65
Transmission Control

Module . . . . . . . . . . . . 8W-10-18, 21, 37, 41, 61, 62

Transmission Control Relay . . . . . . . . . . 8W-10-21, 41
Transmission Range Sensor . . . . . . . . . . . . . 8W-10-65
TXV Solenoid . . . . . . . . . . . . . . . . . . . . . . . 8W-10-38
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . 8W-10-43
Washer Fluid Level Switch . . . . . . . . . . . . . 8W-10-60
Wiper Module . . . . . . . . . . . . . . . . . 8W-10-16, 30, 59

8W - 10 - 2

8W-10 POWER DISTRIBUTION

RS

Summary of Contents for Dodge Caravan 2002

Page 1: ...s 8H Horn 8I Ignition Control 8Ia 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 Wiri...

Page 2: ...ate Fig 1 is located in the engine compartment on the radiator closure panel crossmember There are seven lines of information on the body code plate Lines 4 5 6 and 7 are not used to define service in...

Page 3: ...OUGH 23 Vehicle Identification Number Refer to Vehicle Identification Number VIN paragraph for proper breakdown of VIN code IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate wil...

Page 4: ...Fig 2 FASTENER IDENTIFICATION RS INTRODUCTION 3 FASTENER IDENTIFICATION Continued...

Page 5: ...Fig 3 FASTENER STRENGTH 4 INTRODUCTION RS FASTENER IDENTIFICATION Continued...

Page 6: ...procedures INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart Fig 4 are used to identify various instrument con trols Th...

Page 7: ...x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0 9144 Meters M x 1 0936 Yards mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M...

Page 8: ...Fig 5 METRIC CONVERSION CHART RS INTRODUCTION 7 METRIC SYSTEM Continued...

Page 9: ...N Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 6 Fig 6 TORQUE SPECI...

Page 10: ...o use the check digit is not released to the general public VIN CODE BREAKDOWN CHART POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 Built in the United States by DaimlerChrysler 2 Buil...

Page 11: ...hort Wheelbase with CYX Less AS8 7 Comercial Van Short Wheelbase with AS8 8 Comercial Van Long Wheelbase Highline with CYX 9 Comercial Van Long Wheelbase Premium Line with CYX CYX No Rear Seat Package...

Page 12: ...Regulation Number Regulation Amendment Number Approval Number VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor mation VECI Label Chrysler permanently attaches the label in the e...

Page 13: ......

Page 14: ...CAPACITIES DESCRIPTION SPECIFICATION Fuel Tank Gas 75 L 20 gal Fuel Tank Diesel 75 L 20 gal Engine Oil 2 4 L 4 7 L 5 0 qts Engine Oil 3 3 3 8 L 4 0 L 4 5 qts Engine Oil 2 5 L Diesel 6 0 L 6 3 qts Coo...

Page 15: ...m Institute API National Lubricating Grease Institute NLGI API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified MOPARt provides engine oils that meet or exceed this requirement SAE VISC...

Page 16: ...t from engine metal in the cylinder head area near the exhaust valves and engine block Then coolant carries the heat to the radiator where the tube fin radiator can transfer the heat to the air The us...

Page 17: ...peration DESCRIPTION AUTOMATIC TRANSMISSION FLUID NOTE Refer to the maintenance schedules for the recommended maintenance fluid filter change intervals for this transaxle NOTE All transaxles have a co...

Page 18: ...r not his her gasoline contains MMT It is even more important to look for gasoline with out MMT in Canada because MMT can be used at levels higher than allowed in the United States MMT is prohibited i...

Page 19: ...ld starting and warm up perfor mance DESCRIPTION ENGINE OIL DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL 2104C or API Classification CD or higher or CCML D4 D5 SAE VISCOSITY GRADE CA...

Page 20: ...URE WARNING DO NOT JUMP START A FROZEN BAT TERY PERSONAL INJURY CAN RESULT WARNING DO NOT JUMP START WHEN MAINTE NANCE FREE BATTERY INDICATOR DOT IS BRIGHT COLOR WARNING DO NOT ALLOW JUMPER CABLE CLAM...

Page 21: ...D cable clamp from battery posi tive terminal on disabled vehicle TOWING STANDARD PROCEDURE TOWING WARNINGS AND CAUTIONS WARNING DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINE...

Page 22: ...omponents or engine mounts damage to vehicle can result The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails behind the front wheels The tw...

Page 23: ......

Page 24: ...TESTING LOWER BALL JOINT 10 LOWER BALL JOINT SEAL BOOT DESCRIPTION EXPORT 10 REMOVAL REMOVAL BALL JOINT SEAL BOOT 11 REMOVAL EXPORT 11 INSTALLATION INSTALLATION BALL JOINT SEAL BOOT 11 INSTALLATION E...

Page 25: ...the lower ball joint turn as an assembly STANDARD PROCEDURE LUBRICATION There are no serviceable lubrication points on the front suspension The ball joints are sealed for life and require no maintenan...

Page 26: ...ts 65 45 Hub And Bearing Axle Hub Nut 244 180 Lower Control Arm Pivot Bolt 183 135 Stabilizer Bar Bushing Retainer Bolts 68 50 Stabilizer Bar Link Nuts 88 65 Strut Body Tower Mounting Nuts 28 21 250 S...

Page 27: ...all the two nuts and tighten to 68 N m 50 ft lbs torque 5 Reattach emission leak detection pump to cra dle crossmember reinforcement with two mounting bolts 6 Lower the vehicle HUB BEARING DESCRIPTION...

Page 28: ...ring knuckle The steering knuckle will require removal from the vehi cle to allow the hub bearing assembly to be pressed out of the steering knuckle Refer to 2 SUSPENSION FRONT KNUCKLE REMOVAL 1 Raise...

Page 29: ...tud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 7 Lower vehicle to the ground 8 Che...

Page 30: ...end stud while loosening and removing nut with a wrench Fig 11 7 Remove tie rod end from steering knuckle using Remover Special Tool C 3894 A Fig 12 8 If equipped with antilock brakes remove the front...

Page 31: ...le faces outward 14 Remove the nut from the top of the ball joint stud 15 Remove the steering knuckle from the vehicle 16 If the hub and bearing needs to be trans ferred remove the four bolts attachin...

Page 32: ...teering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation Install nuts while holding bolts stationary in the steering knuckle CAUTION If the vehicle bei...

Page 33: ...lower control arm of this vehicle is a sealed for life ball joint and requires no maintenance lubrication The ball joint has been lubricated for life during the manufacturing process A special fittin...

Page 34: ...at the socket 2 Install a NEW seal boot by hand as far as pos sible on the ball joint Installation of the seal boot is to be with the shield positioned as shown Fig 18 CAUTION Do not use an arbor pre...

Page 35: ...rossmember Fig 1 The lower control arm is an iron casting with two rubber bushings and a ball joint The lower control arm front bushing is the spool type and is pressed into the lower control arm The...

Page 36: ...ithout using excessive clamping force 3 Using a sharp knife such as a razor slit the bushing lengthwise Fig 23 to allow its removal from the lower control arm Fig 23 4 Remove the bushing from the lowe...

Page 37: ...ntrol arm bushing 1 Apply Mopar Silicone Spray Lube or an equiv alent to the hole in lower control arm rear bushing This will aid in the installation of the bushing on the lower control arm 2 With the...

Page 38: ...f the bushing 4 Begin to tighten forcing screw As bushing nears lower control arm flange place Spacer Plate Special Tool 8460 4 between flange and bushing inner sleeve straddling the stem as shown Fig...

Page 39: ...3 N m 135 ft lbs 10 Install the wheel and tire assembly Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening...

Page 40: ...d of the stabilizer bar link do not allow the stud to rotate in it s socket Hold the stud from rotating by placing an open end wrench on the flat machined into the stud Fig 33 5 Remove the stabilizer...

Page 41: ...ers onto crossmember aligning raised bead on retainer with cutouts in bushings Fig 36 Do not tighten Stabilizer bar bushing retainers bolts at this time 3 Check position of the stabilizer bar in the f...

Page 42: ...s going through the strut clevis bracket and steering knuckle The top of the strut mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies upper mount The st...

Page 43: ...leakage will be a stream of fluid running down the side and dripping off lower end of unit A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect perf...

Page 44: ...turned during removal Remove nuts while holding bolts stationary in the steering knuckles 6 Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts Fig 42 Fig 39 Strut Assembly...

Page 45: ...the coil spring so the strut is held in place once the strut shaft nut is removed 3 Compress the coil spring until all coil spring tension is removed from the upper mount 4 Install Strut Nut Socket S...

Page 46: ...top to bottom Left and right springs must not be interchanged NOTE If the coil spring has been removed from the spring compressor proceed with the next step oth erwise proceed with step 5 1 Place the...

Page 47: ...ing Fig 49 If necessary reposition the strut or coil spring in the compressor so both of these line up straight outward away from the compressor to the 6 o clock position Install the clamp to hold the...

Page 48: ...mbly with steering knuckle Position arm of steering knuckle into strut assembly clevis bracket Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes Install t...

Page 49: ...ALLATION 43 SPRING MOUNTS REAR REMOVAL 43 INSTALLATION 44 STABILIZER BAR DESCRIPTION 44 OPERATION 44 REMOVAL REMOVAL AWD 44 REMOVAL FWD 44 INSTALLATION INSTALLATION AWD 44 INSTALLATION FWD 45 TRACK BA...

Page 50: ...spension A hub and bearing assembly is used Fig 1 Front Wheel Drive Rear Suspension 1 SHACKLE 7 LEAF SPRING MONO LEAF 2 REAR MOUNT HANGER 8 ISOLATOR 3 TRACK BAR 9 FWD REAR AXLE 4 SPRING PLATE 10 STABI...

Page 51: ...Mount To Body Bolts 61 45 Leaf Spring Shackle Plate Nuts 61 45 Shock Absorber Mounting Bolts 88 65 Stabilizer Bar Bushing Retainer Bolts 61 45 Stabilizer Bar Link Nuts 61 45 Stabilizer Bar Link Frame...

Page 52: ...e a wooden block between the spring and vehicle to hold forward end of the spring in place 6 Remove leaf spring forward pivot bolt then remove mounting bracket 7 Straighten the retainer tabs on the bu...

Page 53: ...nder vehicle 11 Tighten the spring front pivot bolt to 156 N m 115 ft lbs torque 12 Tighten the lower shock absorber mounting bolt to 88 N m 65 ft lbs torque HUB BEARING DESCRIPTION The rear wheel bea...

Page 54: ...is some times noticeable at lower speeds and at other times is more noticeable at speeds above 105 km h 65 mph REMOVAL FRONT WHEEL DRIVE VEHICLES 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOIST...

Page 55: ...18 from the stub shaft of the outer C V joint 5 Remove the spring washer Fig 17 from the stub shaft of the outer C V joint 6 Remove the hub nut and washer Fig 16 from the stub shaft of the outer C V j...

Page 56: ...4 bolts in a crisscross pat tern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle Tighten the 4 mounting bolts to a torque of 129 N m 95 ft lbs N...

Page 57: ...cross thread the cal iper guide pin bolts 6 Install the disc brake caliper guide pin bolts Fig 15 Tighten the guide pin bolts to a torque of 35 N m 26 ft lbs Fig 12 Hub Bearing Removal And Installatio...

Page 58: ...the outer C V joint 15 Install the wheel speed sensor on the hub bearing and adapter Install the wheel speed sensor attaching bolt Fig 19 Tighten the wheel speed sen sor attaching bolt to a torque of...

Page 59: ...bolt attaching the jounce bumper to frame rail Fig 21 2 Remove the jounce bumper from the frame rail INSTALLATION INSTALLATION AWD AND HEAVY DUTY 1 Install jounce bumper through bumper support plate...

Page 60: ...wer mounting bolt deflects upward during removal raise axle by adjusting the support jack If the lower shock absorber bolt deflects downward during removal lower the axle by adjusting the support jack...

Page 61: ...wer mounting bolt securing the lower end of the shock absorber to the axle 3 Remove the support jack 4 Lower the vehicle to the ground so the full curb weight of the vehicle is supported by the suspen...

Page 62: ...r of the spring hanger and the spring 9 Remove the rear leaf spring from the outer half of the spring shackle 10 Remove the leaf spring from the vehicle 11 Loosen and remove the pivot bolt from the fr...

Page 63: ...ting bolt to 102 N m 75 ft lbs torque SPRING FWD DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono leaf or multi leaf design depending on model and options...

Page 64: ...remove the hanger plate from the hanger and remove the spring from the spring hanger Fig 35 10 Remove the leaf spring from the vehicle 11 Loosen and remove the pivot bolt from the front mount of the r...

Page 65: ...ue 13 Tighten rear spring shackle pin nuts to 61 N m 45 ft lbs torque 14 Tighten rear spring shackle inner to outer half retaining bolts to 61 N m 45 ft lbs torque 15 Tighten the lower shock absorber...

Page 66: ...as a guide When the four mounting bolt holes line up with their threads in the body Install the mounting bolts Fig 37 Tighten the four mounting bolts to 61 N m 45 ft lbs torque 4 Raise or lower the ja...

Page 67: ...rear frame rails is through rubber isolated bushings The 2 rubber isolated links are connected to the rear frame rails by brackets These brackets are bolted to the bottom of the frame rails OPERATION...

Page 68: ...e rear axle The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle REMOVAL 1 Remove the nut and bolt mounting the track bar to t...

Page 69: ...tion s wheel alignment spec ifications differ On this vehicle the suspension angles that can be adjusted are as follows Front Camber with camber bolt package and standard procedure Front Toe Check the...

Page 70: ...ar a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster CROSS CASTER Cross caster is the difference between left and right caster TO...

Page 71: ...t necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehi cle h...

Page 72: ...e wheel bearing 2 Incorrect wheel alignment 2 Check and reset wheel alignment 3 Worn tires 3 Replace tires Front End Growl Or Grinding On Turns 1 Defective wheel bearing 1 Replace wheel bearing 2 Engi...

Page 73: ...t 1 Replace engine mount 2 Worn or defective transaxle gears or bearings 2 Replace transaxle gears or bearings 3 Loose lug nuts 3 Verify wheel lug nut torque 4 Worn or broken C V joint 4 Replace C V j...

Page 74: ...ght will affect the curb height of the vehicle and the alignment angles 2 The passenger and luggage compartments of the vehicle should be free of any load that is not fac tory equipment 3 Check the ti...

Page 75: ...nd 4 nuts This package services both sides of the vehicle Use the package to attach the strut clevis bracket to the steering knuckle after the strut clevis bracket has been modified To install and adj...

Page 76: ...t the front camber to the preferred set ting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket Fig 11 When camber is set tighten the upper strut cle vis b...

Page 77: ...e same size as stan dard equipment Vehicle height is checked with the fuel tank full of fuel and no passenger or luggage compartment load Vehicle height is not adjustable If the measure ment is not wi...

Page 78: ...measure ment is not within specifications inspect the vehicle for bent or weak suspension components Compare the parts tag on the suspect coil spring s to the parts book and the vehicle sales code ch...

Page 79: ...e to side difference 0 0 1 00 TOTAL TOE 0 10 20 10 to 0 30 Maximum side to side difference 0 0 0 06 REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER 0 0 0 25 to 0 25 TOTAL TOE 0 0 20 20...

Page 80: ...pen sion On vehicles equipped with ABS brakes the outer CV joint is equipped with a tone wheel used to deter mine vehicle speed for ABS brake operation The inner tripod joint of both half shafts is sp...

Page 81: ...ce tires or wheels Refer to 22 TIRES WHEELS STANDARD PROCEDURE Improper tire and or wheel runout Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING REMOVAL 1 Raise vehicle 2 Remove the cotter pin and nut...

Page 82: ...rake rotor from the hub and bear ing assembly 10 Remove the steering knuckle to strut attach ment bolts Fig 6 from the steering knuckle 11 Pull the steering knuckle from the strut clevis bracket NOTE...

Page 83: ...til snap ring is engaged with trans axle side gear Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand If snap ring is fully engaged with si...

Page 84: ...f shaft and securely tighten nut 12 Install front wheel and tire assembly Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specificat...

Page 85: ...g which retains spider assem bly to interconnecting shaft Fig 13 Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft 7 Remove the spider assembly fr...

Page 86: ...arings in an attempt to install spider assem bly on interconnecting shaft Fig 14 Spider Assembly Removal from Interconnecting Shaft 1 SPIDER ASSEMBLY 2 DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN REMOVIN...

Page 87: ...clamp evenly on sealing boot 7 Place crimping tool C 4975 A over bridge of clamp Fig 20 8 Tighten nut on crimping tool C 4975 A until jaws on tool are closed completely together face to face Fig 21 Fi...

Page 88: ...re trim stick is held flat and firmly against the tripod housing If this is not done damage to the sealing boot can occur 12 With trim stick inserted between sealing boot insert and the CV joint housi...

Page 89: ...joint to interconnecting shaft retaining ring 6 Spread ears apart on CV joint assembly to interconnecting shaft retaining ring Fig 28 7 Slide outer CV joint assembly off end of inter connecting shaft...

Page 90: ...oint sealing boot onto interconnecting shaft Outer CV joint seal boot MUST be posi tioned on interconnecting shaft so that only the thinnest sight groove on interconnecting shaft is visible Fig 30 5 P...

Page 91: ...A until jaws on tool are closed completely together face to face Fig 34 11 Install the half shaft requiring boot replace ment back on the vehicle Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLA...

Page 92: ...flush against the face of the outer CV joint interference with steering knuckle will occur when driveshaft is installed 3 Using a hammer drive the bearing shield on the outer CV joint until it is flu...

Page 93: ...VIBRATION IN TURNS A clicking noise and or a vibration in turns could be caused by one of the following conditions Damaged outer CV or inner tripod joint seal boot or seal boot clamps This will result...

Page 94: ...l downward to clear rear differential output flange Then pull half shaft assembly outward to remove Fig 3 INSTALLATION 1 Install the outer CV joint stub shaft through the hub bearing Fig 4 2 The half...

Page 95: ...6 Install rear wheel Torque the lug nuts to 135 N m 100 ft lbs SPECIFICATIONS HALF SHAFT FRONT TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Nut Hub 244 180 Nuts Rear Wheel Lug 135 100 Bolt Half...

Page 96: ...lamps holding the CV boot to the CV joint and the interconnecting shaft Fig 8 4 Pull the boot back from the CV joint Fig 9 5 Remove the CV housing from the interconnect ing shaft and tripod assembly F...

Page 97: ...idual grease and dirt 2 Slide the new small diameter retaining clamp onto the interconnecting shaft 3 Install the CV boot onto the interconnecting shaft Fig 14 Fig 12 Slide Tripod Off The Shaft 1 TRIP...

Page 98: ...tripod housing Put the remaining amount into the sealing boot 8 Install the CV housing onto the interconnecting shaft and tripod assembly Fig 17 9 Clamp the half shaft into a suitable vise with prote...

Page 99: ...sure in boot and shape it by hand 14 Position CV boot into the CV housing retain ing groove Install the boot large diameter retaining clamp evenly onto the boot 15 Clamp the CV joint boot to the CV jo...

Page 100: ...wer band of clamp Fig 24 16 Install the half shaft into the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION Fig 21 Crimping Tool Installed on Sealing Boot Clamp Typical 1 CLAMP 2 TRI...

Page 101: ...Center support bearing Rubber coupler at driveline module flange The front shaft segment utilizes a CV joint at the power transfer unit connection and a plunging CV joint at the center bearing locati...

Page 102: ...t shaft with two hands 5 Lower propeller shaft assembly to ground using care not to damage fore and aft flanges Fig 1 INSTALLATION CAUTION Propeller shaft installation is a two man operation Never all...

Page 103: ...es Mopart ATF 4 Automatic Transmission Fluid Type 9602 or equiv alent The differential assembly requires Driveline module service is limited to the following components Differential Assembly serviced...

Page 104: ...E MODULE NOISE Different sources can be the cause of noise that the rear driveline module assembly is suspected of mak ing Refer to the following causes for noise diagnosis DRIVELINE MODULE ASSEMBLY N...

Page 105: ...of insufficient or incorrect lubricant in the carrier housing Abnormal gear noise can be easily recognized It produces a cycling tone that will be very pronounced within a given speed range The noise...

Page 106: ...wer transfer unit components as necessary Vibration at all speeds continuous torque transfer 1 Mis matched tires worn tires on front axle 1 Replace worn or incorrect mis matched tires with same make a...

Page 107: ...Tool 6958 and a breaker bar Fig 5 3 Remove input flange Fig 6 4 Remove input flange seal from overrunning clutch housing using suitable screwdriver Fig 7 Fig 4 Torque Arm Fasteners 1 TORQUE ARM ASSEMB...

Page 108: ...rom vis cous coupler Fig 9 10 Remove viscous coupler from differential pin ion shaft Fig 10 11 Remove shim select from differential pinion gear Fig 11 Fig 8 Overrunning Clutch Housing Bolts 1 OVERRUNN...

Page 109: ...stall output flange seals using tools C4171 and 8493 Fig 15 2 Install large overrunning clutch housing o ring to differential assembly Fig 14 3 Install shim to differential pinion shaft Fig 16 Fig 12...

Page 110: ...NG 3 INPUT FLANGE SHIELD 8 O RING 13 SHIM SELECT 4 SEAL INPUT FLANGE 9 WASHER 14 DIFFERENTIAL ASSEMBLY 5 OVERRUNNING CLUTCH HOUSING BOLT 10 BI DIRECTIONAL OVERRUNNING CLUTCH Fig 16 Shim Select 1 SHIM...

Page 111: ...clock position Fig 19 9 Install overrunning clutch housing into posi tion making sure ground tab engages with notch in housing Fig 20 Fig 17 Viscous Coupler 1 VISCOUS COUPLER 2 DIFFERENTIAL PINION Fi...

Page 112: ...23 13 Install input flange washer and nut Using tool 6958 Fig 24 torque nut to 135 N m 100 ft lbs Fig 21 Overrunning Clutch Housing Bolts 1 OVERRUNNING CLUTCH HOUSING 2 BOLT FOUR Fig 22 Input Flange S...

Page 113: ...all and torque torque arm mount to body bolts to 54 N m 40 ft lbs 5 Install halfshafts to differential output flanges and torque bolts Fig 27 to 61 N m 45 ft lbs 6 Install propeller shaft Refer to 3 D...

Page 114: ...ch Housing to Differential 60 44 Bolt Torque Arm to Differential Assembly 60 44 Bolt Torque Arm Mount to Body 54 40 Nut Input Flange 135 100 Plug Differential Drain Fill 35 26 Plug Overrunning Clutch...

Page 115: ...ential instabilities on a slippery surface The BOC de couples the rear driv eline as soon the rear wheels begin to spin faster than the front wheels front wheels locked in order to provide increased b...

Page 116: ...oupler 1 POWERFLOW BOC OVERUNNING 6 VISCOUS COUPLER 2 POWERFLOW BOC LOCKED 7 BOC ROLLER CAGE 3 BOC GROUND TAB 8 BOC INPUT SHAFT 4 FRICTION BRAKE SHOES 9 INPUT FLANGE 5 BOC ROLLERS RS REAR DRIVELINE MO...

Page 117: ...running under these conditions at low vehicle speeds the drag shoes and the cage keep the rollers up on the left side forward side of the inner shaft flats This is what is known as overrunning mode N...

Page 118: ...ion ground due to centrifugal forces at higher rotational speeds To keep the rollers in the overrunning position and avoid undesired 9high speed lockup9 a high speed latch Fig 33 positions the cage be...

Page 119: ...the high speed latch is activated propeller shaft speed reaches X amount the cage is partially fixed and cannot lock on the wrong side of the flat as shown Fig 34 The high speed latch is a one way de...

Page 120: ...d are free to rotate on the shaft The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts OPERATION In operation power flow occurs as follows...

Page 121: ...in the bottom of the differential assem bly case toward the rear of the unit The fill plug Fig 41 for the differential assembly is located on the rear of the assembly case The correct fill level is to...

Page 122: ...ft lbs 5 Re position the drain pan under the overrun ning clutch housing fill plug 6 Remove fill plug Fig 44 7 Using a suction gun Fig 45 add 0 58 L 1 22 pts of Mopart ATF 4 Automatic Transmission Flu...

Page 123: ...les in them In the shear mode normal operation the plates are evenly spaced and the torque is created by the shearing of the plates through the fluid and 90 100 of the torque is applied to the rear ax...

Page 124: ...cous Coupler Powerflow 1 POWERFLOW BOC OVERUNNING 6 VISCOUS COUPLER 2 POWERFLOW BOC LOCKED 7 BOC ROLLER CAGE 3 BOC GROUND TAB 8 BOC INPUT SHAFT 4 FRICTION BRAKE SHOES 9 INPUT FLANGE 5 BOC ROLLERS RS R...

Page 125: ...2 Install rear driveline module assembly Refer to 3 DIFFERENTIAL DRIVELINE REAR DRIV ELINE MODULE INSTALLATION 3 Lower vehicle INPUT FLANGE SEAL REMOVAL 1 Raise vehicle on hoist 2 Remove propeller sh...

Page 126: ...Using tool 6958 torque flange nut to 135 N m 100 ft lbs Fig 53 4 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 5 Lower vehicle Fig 50 Input Flange Seal Remov...

Page 127: ...ential housing casting pry output flange out of differential Fig 55 4 Use suitable screwdriver to remove output flange seal Fig 56 Fig 54 Inner Half Shaft Bolts 1 SHAFT 2 FLANGE Fig 55 Output Flange R...

Page 128: ...Install rear halfshaft inner joint to output flange 4 Install and torque bolts to 61 N m 45 ft lbs Fig 58 5 Check differential assembly fluid level and adjust as required Refer to 3 DIFFERENTIAL DRIVE...

Page 129: ......

Page 130: ...REAR 15 DESCRIPTION DISC BRAKES EXPORT 15 DESCRIPTION DRUM BRAKES REAR 16 OPERATION OPERATION DISC BRAKES FRONT 16 OPERATION DISC BRAKES REAR 16 DIAGNOSIS AND TESTING DRUM BRAKE AUTOMATIC ADJUSTER 16...

Page 131: ...SPECIFICATIONS BRAKE FLUID 35 JUNCTION BLOCK DESCRIPTION NON ABS JUNCTION BLOCK 36 OPERATION NON ABS JUNCTION BLOCK 36 REMOVAL NON ABS JUNCTION BLOCK 36 INSTALLATION NON ABS JUNCTION BLOCK 36 MASTER C...

Page 132: ...lamp switch Brake fluid level switch Parking brakes Front disc brakes control the braking of the front wheels rear braking is controlled by rear drum brakes or rear disc brakes depending on options Th...

Page 133: ...or nicking of brake lining on the brake shoes CAUTION At no time when servicing a vehicle can a sheet metal screw bolt or other metal fastener be installed in the shock tower to take the place of an o...

Page 134: ...HIRP 1 Excessive brake rotor runout 1 Follow brake rotor diagnosis and testing Correct as necessary 2 Lack of lubricant on brake caliper slides 2 Lubricate brake caliper slides 3 Caliper shoes not ful...

Page 135: ...oze up 1 Check cable routing Replace cables as necessary 2 Parking brake cable return spring not returning shoes 2 Replace cables as necessary 3 Service brakes not adjusted properly rear drum brakes o...

Page 136: ...of adjustment 1 Replace brake lamp switch 2 Brake pedal binding 2 Inspect and replace as necessary 3 Obstruction in pedal linkage 3 Remove obstruction 4 Power Brake Booster not allowing pedal to retu...

Page 137: ...amount of fluid to expel all the trapped air from the brake system Be sure to monitor the fluid level in the master cylinder so it stays at a proper level so air will not enter the brake system throu...

Page 138: ...e Pedal Position Sensor Mounting Screws 7 5 66 Adjustable Pedal Module Mounting Screws 2 0 15 DESCRIPTION N m Ft Lbs In Lbs Brake Tube Nuts 17 145 Brake Hose Intermediate Bracket Bolt 12 105 Brake Hos...

Page 139: ...he Full mark with DOT 3 brake fluid If the brake fluid level has dropped below the add line in the master cylinder fluid reservoir the entire brake hydraulic system should be checked for evidence of a...

Page 140: ...Disconnect parking brake release link at release handle 5 Compress tabs on sides of data link diagnostic connector and remove it from knee blocker reinforce ment plate 6 Remove screws securing knee b...

Page 141: ...ble to negative post of bat tery 11 Connect scan tool DRBIIIt to data link diag nostic connector located below steering column 12 Turn ignition key to ON position 13 Using scan tool check for and clea...

Page 142: ...or against mounting bracket and into brake pedal Fig 12 Move carriage as necessary to align slot with pin Install two mounting screws Tighten screws to 7 5 N m 66 in lbs torque 3 Align the bulkhead co...

Page 143: ...ning a single piston 66 mm diam eter bore Fig 13 with a phenolic piston The caliper mounts to a caliper adapter using two guide pin bolts that thread into the caliper adapter and slide on bushings mou...

Page 144: ...to the caliper adapter and uses the interior of the rear disc brake rotor as a drum hat section of drum in hat style brake rotor The outboard rear disc brake shoes pads are side oriented The shoes ar...

Page 145: ...ATION DISC BRAKES REAR The rear disc brakes operate similarly to front disc brakes however there are some features that require different service procedures DIAGNOSIS AND TESTING DRUM BRAKE AUTOMATIC...

Page 146: ...of the hose can take place with possible burst failure Faulty installation can cause twisting resulting in wheel tire or chassis interference The brake tubing should be inspected periodically for evid...

Page 147: ...PRACTICES PRESCRIBED BY THE OCCUPA TIONAL SAFETY AND HEALTH ADMINISTRATION OSHA AND THE ENVIRONMENTAL PROTECTION AGENCY EPA FOR THE HANDLING PROCESSING AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN...

Page 148: ...w caliper hold down spring anti rattle clip on the outboard side of the caliper Start the spring into the holes on the caliper then stretch the clip legs past the abutments on the caliper adapter 11 R...

Page 149: ...e outboard brake shoe from the cali per Brake shoe is removed by pushing the shoe toward the piston disengaging the two metal protru sions on the shoe back then sliding the brake shoe off the caliper...

Page 150: ...ould be replaced For rear disc brake shoes when a set of brake shoes are worn to a thickness of approximately 7 0 mm 9 32 inch they should be replaced Typically if front shoes are worn out both fronts...

Page 151: ...INTENANCE HOISTING STANDARD PROCE DURE 2 Remove the rear wheel and tire assemblies from the vehicle 3 Remove rear brake drum to hub retaining clips if equipped then remove rear brake drums Refer to 5...

Page 152: ...AUTOMATIC ADJUSTER LEVER Fig 30 Remove Install Brake Shoe Lower Return Spring 1 ANCHOR PLATE 2 LOWER BRAKE SHOE RETURN SPRING 3 REAR BRAKE SHOE 4 FRONT BRAKE SHOE 5 BRAKE SUPPORT PLATE Fig 31 Brake S...

Page 153: ...36 from the brake shoe Remove the leading brake shoe from the brake support plate Fig 33 Brake Shoe Upper Return Spring 1 BRAKE SHOE RETURN SPRING 2 LEADING BRAKE SHOE 3 TRAILING BRAKE SHOE Fig 34 Tra...

Page 154: ...g the required special Mopart Brake Lubricant or equiva lent 2 Install leading brake shoe on brake support plate Install the leading brake shoe hold down spring and pin Fig 36 on the brake shoe 3 Inst...

Page 155: ...fore raising the vehicle verify the parking brake lever is fully released 1 Raise the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove rubber plug from rear brake adjusti...

Page 156: ...the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehi cle so brake fluid cannot get on these components Remove the brake shoes and place a small piece of wood betwe...

Page 157: ...oot Damaged dry or brittle guide pin dust boots If caliper fails inspection disassemble and recondi tion caliper replacing the seals and dust boots ASSEMBLY ASSEMBLY CALIPER GUIDE PIN BUSHINGS DISC DI...

Page 158: ...and increased stopping distance can occur 1 Completely retract the caliper piston back into piston bore of the caliper Use a C clamp to retract the piston if necessary Place a wood block over the pis...

Page 159: ...rake caliper adapter 3 Align the caliper guide pin bolt holes with the guide pins Install the caliper guide pin bolts and tighten them to a torque of 35 N m 26 ft lbs Fig 40 4 Install the banjo bolt c...

Page 160: ...nect the brake fluid flex hose from the caliper assembly and remove it from the vehicle CAUTION Do not use excessive force when clamp ing caliper in vise Excessive vise pressure will cause bore distor...

Page 161: ...any fluid containing mineral oil to clean the caliper These flu ids will damage rubber cups and seals INSPECTION CALIPER Inspect the disc brake caliper for the following Brake fluid leaks in and aroun...

Page 162: ...Tighten the guide pin bolts to a torque of 35 N m 26 ft lbs CAUTION When connecting the brake hose to the caliper install new brake hose to caliper special washers 5 Install the brake hose on the cal...

Page 163: ...adjust brake fluid level as neces sary DISC BRAKE CALIPER GUIDE PINS REMOVAL DISC BRAKE CALIPER GUIDE PINS DISC DRUM BRAKES 1 Raise the vehicle Refer to HOISTING in LUBRICATION AND MAINTENANCE 2 Remo...

Page 164: ...tions of fluid contamination are swollen or deteriorated rubber parts Swollen rubber parts indicate the presence of petroleum in the brake fluid To test for contamination put a small amount of drained...

Page 165: ...ake pedal to a position past its first 1 inch of travel This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the junction block 2 Disconnect the...

Page 166: ...with CAUTION Master cylinders are not interchangeable between systems Performance and stopping dis tance issues will result if the incorrect master cyl inder is installed on the vehicle For informatio...

Page 167: ...r Master cylinder outlet ports vary in size and type depending on whether master cylin der is for a vehicle equipped with traction control or not Traction control equipped master cylinders require the...

Page 168: ...not running pump brake pedal until a firm pedal is achieved 4 5 strokes 2 Disconnect negative battery terminal 3 Disconnect positive battery terminal 4 Remove battery shield 5 Remove nut and clamp se...

Page 169: ...brake vacuum booster the master cylinder and vacuum booster must be thoroughly cleaned This must be done to prevent dirt particles from falling into the power brake vacuum booster 9 Clean area where m...

Page 170: ...ster cylinders are used on this vehicle depending on brake options If a new master cylinder is being installed be sure it is the correct master cylinder for the type of brake system the vehicle is equ...

Page 171: ...ensure proper operation of brakes PEDAL ADJUSTABLE DESCRIPTION The Adjustable Pedals System APS is designed to enable the fore and aft repositioning of the brake and accelerator pedals This results in...

Page 172: ...ic connector and remove it from knee blocker reinforce ment plate 6 Remove screws securing knee blocker reinforce ment plate in place then remove reinforcement plate Fig 62 7 Remove screws securing in...

Page 173: ...ove the pinch bolt securing column cou pling to intermediate shaft Fig 67 Fig 64 Steering Column Shrouds 1 FIXED SHROUD 2 UPPER SHROUD 3 CLOCKSPRING 4 LOWER SHROUD 5 STEERING COLUMN Fig 65 Pedal Switc...

Page 174: ...d off pedal pin 29 Remove the four nuts attaching power brake booster to dash panel Fig 71 30 Remove two brake pedal upper mounting bolts at instrument panel dash bracket Fig 71 31 Disconnect accelera...

Page 175: ...ct column wiring harness connectors to SKIM if equipped BTSI solenoid ignition switch halo lamp multi function switch and clockspring 16 Install the upper shroud Refer to 19 STEERING COLUMN LOWER SHRO...

Page 176: ...icle to ensure proper opera tion of the steering and brake systems PEDAL TORQUE SHAFT RHD REMOVAL 1 Remove the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 2 Re...

Page 177: ...rly or has been removed for some service a new switch must be installed and adjusted 10 Remove and replace the brake lamp switch with a NEW switch Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE L...

Page 178: ...pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system DIAGNOSIS AND TESTING POWER BRAKE BOOSTER BASIC TEST 1 With engine off depress and release the brake...

Page 179: ...ve battery cable terminal from battery 4 Remove battery thermal guard shield 5 Remove battery clamp nut and battery from the battery tray 6 Remove screw securing engine coolant filler tube to battery...

Page 180: ...pedal pin retaining clip Fig 79 19 Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin Then pull retaining clip off brake pedal pin Discard retaining cli...

Page 181: ...h in master cylinder fluid res ervoir Fig 82 CAUTION Before removing the master cylinder from the power brake vacuum booster the master cylinder and vacuum booster must be thoroughly cleaned This must...

Page 182: ...he power brake vacuum booster It is serviced ONLY as a complete assembly INSTALLATION INSTALLATION LHD 1 Position power brake booster on dash panel using the reverse procedure of its removal Fig 81 It...

Page 183: ...ower brake booster CAUTION The master cylinder and its rear seal is used to create the seal for holding vacuum in the vacuum booster The vacuum seal on the master cylinder MUST be replaced with a NEW...

Page 184: ...the mounting nuts to a torque of 29 N m 250 in lbs 3 Using lubriplate or equivalent coat the sur face of the brake pedal torque shaft pin where it con tacts the booster input rod CAUTION When installi...

Page 185: ...of the brakes PROPORTIONING VALVE DESCRIPTION PROPORTIONING VALVE HEIGHT SENSING NOTE Only vehicles without antilock brakes ABS have a proportioning valve Vehicles with ABS uti lize electronic brake d...

Page 186: ...ings on this vehicle will cause the height sens ing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes This inap propriate reduction in hydraulic pressure potentia...

Page 187: ...VALVE SPECIFICATIONS WHEEL BASE DRIVE TRAIN SALES CODE BRAKE SYSTEM SPLIT POINT SLOPE INLET PRESSURE PSI OUTLET PRESSURE PSI SWB FWD BRB BGF 159 DISC DRUM W O ANTILOCK VAR 59 1000 PSI 675 875 PSI REM...

Page 188: ...rake shoes are installed improper wear of the shoes will result If a vehicle has not been driven for a period of time the rotor s braking surface will rust in the areas not covered by the brake shoes...

Page 189: ...e a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken This way the original mounting spot of the rotor on the hub is indexed Fig 96 Remove...

Page 190: ...maintain the rotor within service tolerances to ensure proper brake action If the rotor surface is deeply scored or warped or there is a complaint of brake roughness or brake pedal pulsation the rotor...

Page 191: ...g the disc brake caliper adapter with brake caliper to the steering knuckle Fig 102 4 Remove the disc brake caliper and adapter as an assembly from the steering knuckle Fig 102 Hang the assembly out o...

Page 192: ...0 0003 in 0 035 mm 0 0014 in Rear Rotor 12 4 12 6 mm 0 488 0 496 in 11 25 mm 0 443 in 0 013 mm 0 0005 in 0 14 mm 0 0055 in TIR Total Indicator Reading Measured On Vehicle BRAKE ROTOR EXPORT NOTE Use...

Page 193: ...hub and bearing to axle mounting bolts into the mounting holes in the flange of the rear axle 2 Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle F...

Page 194: ...ly cleaned inspected and new parts installed If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid the brake shoes must be replaced INSTALLATION 1 Apply sealant su...

Page 195: ...lizer bracket is used at the rear end of the front parking brake cable to distribute tension equally to each parking brake cable STANDARD PROCEDURE STANDARD PROCEDURE PARKING BRAKE AUTOMATIC ADJUSTER...

Page 196: ...a hoist Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Manually release the automatic self adjusting mechanism tension of the parking brake lever pedal assembly Refer to 5 BRAKES STAND...

Page 197: ...e cable connector attaching it to the right rear parking brake cable Fig 112 Remove the lock ing nut securing the intermediate cable housing to the side bracket on the frame rail Fig 112 6 If the vehi...

Page 198: ...racket slide a 14 mm box end wrench over the end of cable retainer to compress the retaining fingers Fig 115 The alternate method using an aircraft type hose clamp will not work on the right side of t...

Page 199: ...king brake cable equalizer Fig 118 6 To remove parking brake cable housing from the body bracket slide a 14 mm box end wrench over retainer end compressing the three fingers Fig 119 Alternate method i...

Page 200: ...ually reset the automatic self adjusting mechanism tension of the parking brake lever pedal assembly Refer to 5 BRAKES STANDARD PRO CEDURE 10 Assemble the park brake cables onto the park brake cable e...

Page 201: ...le housing retainer fingers lock the housing firmly into place 5 Connect rear parking brake cable to the equal izer bracket Fig 118 6 Install brake drum and wheel and tire assem bly 7 Remove the locki...

Page 202: ...mechanism Tap end housing for front park brake cable out of park brake pedal mech anism INSTALLATION 1 Install park brake cable end housing into park brake pedal mechanism 2 Install cable retainer on...

Page 203: ...king brake cable just rear ward of the second body outrigger bracket Fig 123 3 Remove the left rear and intermediate parking brake cables from the parking brake cable equalizer Fig 124 4 Remove the eq...

Page 204: ...bracket Press the cable housing into the outrigger hole until all three retaining fin gers lock the cable in place 10 Grasp the exposed section of the front parking brake cable and pull rearward on it...

Page 205: ...sc brake caliper to adapter guide pin bolts Fig 129 10 Remove rear caliper from adapter using the following procedure First rotate front of caliper up from the adapter Then pull the rear of the calipe...

Page 206: ...press the locking tabs on the park brake cable retainer Fig 130 Removing Installing Caliper 1 LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST 2 DISC BRAKE CALIPER 3 ADAPTER ABUTMENT 4 OUTBOARD BRAKE...

Page 207: ...ull back on wheel speed sensor head removing it from hub and bearing c Remove wheel speed sensor from hub bear ing 18 Remove the hub bearing to axle mounting bolts Fig 136 19 Remove the hub bearing Fi...

Page 208: ...Remover Special Tool 8214 1 on the cast housing of hub bearing Fig 138 Do not position the special tool on the inner race of hub bearing Lightly strike the Remover with a hammer to remove the hub bea...

Page 209: ...e removed from the brake shoe anchor Then remove the upper return springs Fig 143 from the leading brake shoe Fig 140 Lower Return Spring 1 ADAPTER 2 LEADING PARK BRAKE SHOE 3 RETURN SPRING 4 TRAILING...

Page 210: ...e at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter 6 Install the adjuster Fig 142 between the leading and trailing park brake shoe NOTE When the h...

Page 211: ...m in hat brake shoes Refer to 5 BRAKES PARKING BRAKE SHOES ADJUSTMENTS 20 Install the rotor on the hub bearing 21 Carefully lower caliper and brake shoes over rotor and onto the adapter using the reve...

Page 212: ...the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum 5 Using Brake Shoe Gauge Special Tool C 3919 or equivalent accurately meas...

Page 213: ...rake shoes are dragging remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum Continue with the previous step until brake shoes are not dragging on brake...

Page 214: ...3 ASSEMBLY ICU 103 INSTALLATION INSTALLATION LHD 104 INSTALLATION RHD 105 BRAKES ABS DESCRIPTION DESCRIPTION ANTILOCK BRAKE SYSTEM This section covers the physical and operational descriptions and the...

Page 215: ...lectrical signal Wheel lockup may be perceived at the very end of an ABS stop and is considered nor mal During an ABS stop the brakes hydraulic system is still diagonally split However the brake syste...

Page 216: ...alve is switched off and the inlet valve is pulsed This increases the pressure to the rear brakes This back and forth pro cess will continue until the required slip difference is obtained At the end o...

Page 217: ...with approved removal and installation procedures in this manual should be serviced CAUTION If welding work is to be performed on the vehicle using an electric arc welder the CAB con nector should be...

Page 218: ...system 7 Fill the master cylinder reservoir to the full level 8 Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy SPECIFICATIONS ABS F...

Page 219: ...e metal clip to rear of axle Remove metal clip from cable if necessary CAUTION If speed sensor head has seized due to corrosion do not use pliers on speed sensor head in an attempt to remove it Use a...

Page 220: ...moval or installation of the speed sensor cable 3 Carefully remove speed sensor cable from press in routing clips Fig 3 4 Remove bolt securing metal routing clip to rear of axle and remove sensor cabl...

Page 221: ...replacement the drive shaft must be replaced No attempt should be made to replace just the tone wheel Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL If a rear tone wheel is found to need replace...

Page 222: ...g operation NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram Fig 6 shows the vehicle in the normal braking mode of the base brake hydraulic system The diagram shows n...

Page 223: ...hat the brake fluid from the low pressure accumulators is returned to the master cylinder circuits The brake fluid is routed to either the master cylinder or the wheel brake depending on the posi tion...

Page 224: ...om the low pressure accumulators is returned to the master cylinder circuits The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the norma...

Page 225: ...age the brakes and stop the vehicle the hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump motor Fig 9 ABS With Traction Control Norm...

Page 226: ...he pump motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits The brake fluid is routed to either the master cylinder or the wheel...

Page 227: ...inder at a fixed pressure setting The normally open and normally closed valves modulate build decay the brake pressure as required to the spinning wheel Fig 11 Traction Control Hydraulic Circuit 1 OUT...

Page 228: ...at the HCU pump motor is sending to the front driving wheels when traction control is being applied The rear brakes need to be isolated from the master cylinder when traction control is being applied...

Page 229: ...nents of the ICU are the HCU and the CAB No attempt should be made to service any individual components of the HCU or CAB For information on the CAB Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES C...

Page 230: ...es 4 from the outlet ports on the HCU Fig 14 13 Remove the primary and secondary brake tubes from the inlet ports on the HCU Fig 14 14 Center and prop the steering wheel 15 Remove the silencer panel u...

Page 231: ...ll raise and unlock the 24 way connector from the socket on the CAB CAUTION Before removing the brake tubes from the HCU the HCU must be thoroughly cleaned This must be done to prevent dirt particles...

Page 232: ...ll the CAB Fig 24 on the HCU 2 Install the 4 bolts mounting the CAB Fig 23 to the HCU Tighten the CAB mounting bolts to a torque of 2 N m 17 in lbs 3 Plug the pump motor wiring harness into the CAB 4...

Page 233: ...ct each other or other vehicle components when installed Also after the brake tubes are installed on the HCU ensure all spacer clips are reinstalled on the brake tubes 8 Install the primary and second...

Page 234: ...ICU bracket to the front suspen sion crossmember 2 Install the ICU and its mounting bracket as an assembly on the front suspension crossmember Install the 3 bolts attaching the ICU bracket to the cro...

Page 235: ...tive cable back on negative post of the battery 9 Bleed the base and ABS hydraulic systems Refer to 5 BRAKES STANDARD PROCEDURE 10 Road test vehicle to ensure proper operation of the base and antilock...

Page 236: ...OVAL 13 INSTALLATION 13 CLUTCH DESCRIPTION CLUTCH COMPONENTS Models equipped with a 2 4L Gas engine utilize a modular clutch assembly Fig 1 The modular clutch consists of a single dry type clutch disc...

Page 237: ...er bore displacing fluid through the master cylinder plumbing This fluid displace ment forces the slave cylinder piston to travel forc ing the clutch release bearing into the clutch diaphragm spring v...

Page 238: ...rear main or transaxle input shaft seal Correct leak and replace modular clutch assembly 2 4L Gas or clutch cover and disc 2 5L TD Too much grease applied to splines of disc and input shaft Apply ligh...

Page 239: ...leaking seals Replace modular clutch assembly 2 4L Gas or clutch cover and disc 2 5L TD Excessive amount of grease applied to input shaft splines Apply less grease to input shaft Replace modular clut...

Page 240: ...ic circuit Allow system to self bleed or replace hydraulic components Leak in clutch hydraulic circuit Replace worn damaged leaking hydraulic components Clutch pedal requires excessive force high rele...

Page 241: ...see if the release bearing is sticky or binding Replace bearing if needed c Check linkage for excessive wear on the pivot stud and fork fingers Replace all worn parts d Check clutch assembly for cont...

Page 242: ...Install clutch release bearing to lever Apply grease to interface points Make sure release bearing retainers engage lever pocket as shown in Fig 10 3 Apply grease to pivot ball and on release lever a...

Page 243: ...UMBING REFRIGERANT STANDARD PROCEDURE 7 Remove suction discharge line from evaporator junction block 8 Using tool 6638A disconnect clutch hydraulic quick connect fitting Fig 12 9 Remove clutch master...

Page 244: ...iesel models Install wiper module assembly Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE INSTALLATION 9 Install battery and tray 10 Connect battery negative cable 11 Charge Air Conditioning system...

Page 245: ...t to bend or kink plumbing Note plumbing routing to aid in installa tion INSTALLATION 1 Install master cylinder into position while routing plumbing as originally installed 2 Insert master cylinder pu...

Page 246: ...ls Remove underbody splash shield 2 Using Tool 6638A disconnect hydraulic clutch circuit quick connect fitting 3 Remove clutch slave cylinder Fig 20 by lifting nylon tab with a small screwdriver and t...

Page 247: ...place as necessary Refer to 6 CLUTCH CLUTCH RELEASE BEARING REMOVAL INSTALLATION 1 Install clutch release bearing and lever if removed Refer to 6 CLUTCH CLUTCH RELEASE BEARING INSTALLATION 2 Install c...

Page 248: ...STALLATION 1 Install NEW flywheel to crankshaft bolts by hand 2 Torque bolts in a criss cross sequence to 25 N m 18 ft lbs Fig 22 3 Torque bolts in a criss cross sequence an addi tional 60 4 Install c...

Page 249: ......

Page 250: ...ITY 6 ACCESSORY DRIVE BELT TENSION 6 TORQUE 6 SPECIAL TOOLS COOLING SYSTEM 7 ACCESSORY DRIVE 8 ENGINE 14 TRANSMISSION 38 COOLING DESCRIPTION DESCRIPTION COOLING SYSTEM The cooling system components co...

Page 251: ...nt flow circuits for the 2 4L and 3 3 3 8L engines are shown in Fig 2 OPERATION HOSE CLAMPS The spring type hose clamp applies constant ten sion on a hose connection To remove a spring type hose clamp...

Page 252: ...mal amount of coolant or steam emits from the tailpipe it may indicate a coolant leak caused by a faulty head gas ket cracked engine block or cracked cylinder head There may be internal leaks that can...

Page 253: ...OM THE COOLANT CAN OCCUR 1 Without removing radiator pressure cap and with system not under pressure open the draincock The draincock is located on the lower left side of radiator Fig 5 2 After the co...

Page 254: ...removing the radiator cap With the engine cold and not running simply observe the level of the coolant in the recovery reserve container Fig 7 The coolant level should be between the MIN and MAX mark...

Page 255: ...me 3 3 3 8L ENGINES Air Conditioning Compressor Dynamic Tensioner Generator Water Pump Power Steering TORQUE DESCRIPTION N m Ft Lbs In Lbs Accessory Drive Belt Tensioner Assembly 3 3 3 8L Bolt 28 250...

Page 256: ...Pliers 6094 Hose Clamp Pliers 8495A Cooling System Tester 7700 Coolant Refractometer 8286 DRB IIIT with PEP Module OT CH6010A Belt Tension Gauge Adapter 8371 Belt Tension Gauge 7198A Cooler Flusher 6...

Page 257: ...LTS REMOVAL 4 Remove the belt tensioner Fig 1 INSTALLATION 1 Install belt tensioner and bolt Fig 1 Tighten bolt to 54 N m 40 ft lbs 2 Install generator A C compressor drive belt Refer to 7 COOLING ACC...

Page 258: ...ed belts b Adjust power steering belt tension 4 cyl engine 2 Belt excessively glazed or worn 2 Replace and tighten as specified BELT SQUEAL WHEN ACCELERATING ENGINE 1 Belts too loose 1 a Replace belt...

Page 259: ...le tool The frequency of the belt in hertz Hz will display on DRBIIIt screen 4 Adjust belt to obtain proper frequency ten sion Refer to ACCESSORY DRIVE BELT TENSION CHART for belt tension specificatio...

Page 260: ...are not Fig 6 NOTE Do not use any type of belt dressing or restorer on Poly V Belts INSTALLATION GENERATOR AND AIR CONDITIONING BELT 1 Install belt onto all pulleys except for the crankshaft Fig 7 2 R...

Page 261: ...ehicle on a hoist and the remove the splash shield to gain access to the drive belts if nec essary Adjust belt tension for either a New or Used belt For specifications Refer to 7 COOLING AC CESSORY DR...

Page 262: ...t use any type of belt dressing or restorer on Poly V Belts INSTALLATION 1 Route and position the drive belt onto all pul leys except for the crankshaft Fig 11 2 Rotate belt tensioner counterclockwise...

Page 263: ...T THERMOSTAT 2 4L REMOVAL 23 INSTALLATION 23 ENGINE COOLANT THERMOSTAT 3 3 3 8L REMOVAL 24 INSTALLATION 24 RADIATOR DESCRIPTION 25 OPERATION 25 REMOVAL 25 INSTALLATION 26 RADIATOR DRAINCOCK REMOVAL 27...

Page 264: ...ed hoses Loose damaged hose clamps Damaged incorrect engine thermostat Damaged cooling fan motor fan blade and fan shroud Damaged head gasket Damaged water pump Damaged radiator Damaged coolant recove...

Page 265: ...necessary d Reserve overflow container is internally blocked Clean and repair as necessary INADEQUATE AIR CONDITIONER PERFORMANCE COOLING SYSTEM SUSPECTED 1 Radiator and or A C condenser is restricted...

Page 266: ...Repair as necessary 4 Undercoating been applied to an unnecessary component 4 Clean undercoating as necessary 5 Engine may be running rich causing the catalytic converter to overheat 5 Refer to Appro...

Page 267: ...UATES CYCLES OR IS ERRATIC 1 Normal reaction to fan and or thermostat cycle Fig 1 Examples B and C During cold weather operation with the heater blower in the high position the gauge reading may drop...

Page 268: ...erio ration and leaks Inspect radiator and heater core for leaks COOLANT DIAGNOSIS AND TESTING COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was add...

Page 269: ...ing losses DIAGNOSIS AND TESTING COOLANT RECOVERY SYSTEM The cooling system is closed and designed to main tain coolant level to the top of the radiator 1 With the engine off and cooling system not un...

Page 270: ...adiator and cylinder block Refer to 7 COOLING STANDARD PROCEDURE 2 Disconnect the power cord plug from heater 3 Loosen screw in center of heater Remove the heater assembly INSTALLATION 1 Clean block c...

Page 271: ...racket Fig 5 4 Disconnect coolant sensor electrical connector Fig 6 5 Remove coolant sensor Fig 6 INSTALLATION 1 Install engine coolant temperature sensor Fig 6 Tighten sensor to 7 N m 60 in lbs 2 Con...

Page 272: ...open Do not attempt to free up a thermo stat with a screwdriver Thermostat diagnostics is included in powertrain control module s PCM programing for on board diagnosis The malfunction indicator light...

Page 273: ...ement ther mostat carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place Fig 11 It is not ne...

Page 274: ...ow across the exterior of the radiator tubes This heat is then transferred from the coolant and into the passing air REMOVAL 1 Disconnect negative cable from battery 2 Remove radiator upper crossmembe...

Page 275: ...nditioning condenser onto the radiator lower mounts and install upper screws Fig 15 Tighten fasteners to 5 N m 45 in lbs 3 Install the radiator upper and lower hoses Fig 13 or Fig 14 4 Connect the coo...

Page 276: ...Pa 14 18 psi The cooling system will operate at higher than atmospheric pressure The higher pressure raises the coolant boiling point thus allowing increased radia tor cooling capacity There is also a...

Page 277: ...ach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator Pressure cap upper gas ket should relieve at 69 124 kPa 10 18 psi and hold pressure at 55 kPa 8 psi minimum WARN...

Page 278: ...n consist of the fan blade electric motor and a support shroud which are all serviced as an assembly OPERATION RADIATOR FAN OPERATION CHART COOLANT TEMPERATURE A C PRESSURE TRANSAXLE OIL TEMPERATURE F...

Page 279: ...or wiring defective 1 Refer to Appropriate Diagnostic Information Repair as necessary 2 Check for low coolant level 2 Add coolant as necessary 3 Defective A C pressure transducer 3 Refer to Appropria...

Page 280: ...n noise A C performance better engine cooling and additional vehicle power To control operation of the relay the PCM looks at inputs from Engine coolant temperature A C pressure transducer Ambient tem...

Page 281: ...VAL 12 Remove the generator and bracket Fig 24 13 Remove water pump to engine attaching screws Fig 25 CLEANING Clean gasket mating surfaces as necessary INSPECTION Replace water pump body assembly if...

Page 282: ...UNT 5 BOLT 2 BOLT 6 TENSIONER DRIVE BELT 3 GENERATOR 7 BOLT 4 BOLT 8 BOLT Fig 25 Water Pump 2 4L 1 CYLINDER BLOCK 2 WATER PUMP Fig 26 Water Pump Body 1 IMPELLER 2 WATER PUMP BODY 3 O RING LOCATING GRO...

Page 283: ...head heater core and radiator REMOVAL 1 Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 2 Remove the accessory drive belt shield 3 Remove the accessory drive belt Refer to 7 COOLING AC...

Page 284: ...ns unchanged do not replace the water pump for this condition Replace the water pump if a steady flow of engine coolant is evident from the weep hole reservoir slot Fig 30 shaft seal failure Be sure t...

Page 285: ...tall inlet tube into the cylinder block opening Fig 32 3 Install the two inlet tube fasteners and tighten to 12 N m 105 in lbs 4 Connect the radiator lower hose Fig 7 and heater hose to inlet tube Fig...

Page 286: ...r vehicle 7 Fill the cooling system Refer to 7 COOLING STANDARD PROCEDURE Fig 34 RAD HOSES TO ENGINE 3 3 3 8L 1 UPPER HOSE 2 LOWER HOSE Fig 35 Engine Oil Cooler Hoses Engine Oil Cooler Equipped 1 OIL...

Page 287: ...Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nect red alligator clip to positive battery post Connect black alligator clip to a good ground NOTE When flushing trans...

Page 288: ...or Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 4 Start engine Check and adjust the fluid level as necessary TRANSMISSION OIL COOLER LINES REMOVAL 1 Using appropriate hose clamp pliers release tens...

Page 289: ...Connect hoses to cooler and transaxle fittings Fig 3 or Fig 4 2 Using appropriate pliers position clamps over fittings and release tension 3 Start engine and check transaxle fluid level Adjust fluid l...

Page 290: ...coolant tank A pressure vent cap on the coolant tank Fan shroud Thermostat Coolant Low coolant warning lamp Coolant temperature gauge Water pump Hoses and hose clamps DIAGNOSIS AND TESTING DIAGNOSIS...

Page 291: ...ry Refer to Heating and Air Conditioning for procedures TEMPERATURE GAUGE READS HIGH COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbe...

Page 292: ...heck thermostat and replace if necessary 14 Cylinder head gasket leaking 14 Check cylinder head gasket for leaks 15 Heater core leaking 15 Check heater cor for leaks Repair as necessary TEMPERATURE GA...

Page 293: ...ND OR COOLANT TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL BUT NOT HIGH COOLANT LEVEL MAY BE HIGH IN COOLANT TANK 1 Pressure relief valve in pressure vent cap is defective 1 Check condition of pressu...

Page 294: ...evel low 2 Pressure test cooling system Repair leaks as necessary 3 Obstruction in heater hose fitting at engine 3 Remove heater hoses and check for obstructions Repair as necessary 4 Heater hose kink...

Page 295: ...M TO PREVENT SCALDING OR INJURY THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE With engine not running remove pressure vent cap from the coolant recovery pressure con...

Page 296: ...nlet tank runs full and the low pressure outlet tank drops resulting in cooling system aera tion Aeration will draw air into the water pump resulting in the following High reading shown on the tempera...

Page 297: ...27 5 21 Accessory Drive Belt Tensioner Bolt 47 1 35 Accessory Drive Belt Idler Bolt 53 39 SPECIFICATIONS COOLING SYSTEM CAPACITY SPECIFICATIONS DESCRIPTION SPECIFICATION Cooling System With Auxiliary...

Page 298: ...LT TENSIONER REMOVAL WARNING BECAUSE OF HIGH SPRING TENSION DO NOT ATTEMPT TO DISASSEMBLE THE AUTO MATIC BELT TENSIONER THE TENSIONER IS SER VICED AS AN ASSEMBLY 1 Remove the power steering belt Refer...

Page 299: ...r belt tension DESCRIPTION POWER STEERING BELT The power steering belt is a serpentine type belt Fig 3 Satisfactory performance of this belt depends on condition of the belt OPERATION OPERATION ACCESS...

Page 300: ...s 5 Non uniform groove or eccentric pulley 5 Replace pulley BELT ROLLED OVER IN GROOVE OR BELT JUMPS OFF 1 Broken cord in belt 1 Replace belt 2 Belt too loose or too tight 2 Replace belt 3 Misaligned...

Page 301: ...LEY 6 WRENCH Fig 5 LOCKING LOCKING BELT TENSIONER Fig 6 POWER STEERING BELT REMOVAL TOOL 1 VIBRATION DAMPER 2 POWER STEERING PULLEY 3 POWER STEERING BELT 4 POWER STEERING BELT REMOVER Fig 7 POWER STEE...

Page 302: ...shaft clockwise until belt is fully installed on crankshaft Fig 10 3 Remove installation tool from crankshaft 4 Install right front fender inner splash shield 5 Lower vehicle from hoist Fig 8 ACCESSOR...

Page 303: ...OVAL 22 INSTALLATION 22 WATER PUMP DESCRIPTION 23 OPERATION 23 REMOVAL REMOVAL WATER PUMP 23 REMOVAL WATER PUMP HOUSING 23 CLEANING 23 INSTALLATION INSTALLATION WATER PUMP 23 INSTALLATION WATER PUMP H...

Page 304: ...er boil over of propylene glycol is 125 deg C 257 deg F at 96 5 kPa 14 psi compared to 128 deg C 263 deg F for ethylene gly col Use of propylene glycol can result in boil over or freeze up in Chrysler...

Page 305: ...YPES DESCRIPTION STANDARD PROCEDURE COOLANT LEVEL CHECK NOTE Do not remove pressure vent cap for routine coolant level inspections The coolant reserve system provides a quick visual method for determi...

Page 306: ...iner is empty then remove coolant pressure vent cap COOLANT RECOVERY PRESS CONTAINER DESCRIPTION The coolant recovery pressure container is mounted in the engine compartment next to the bat tery The c...

Page 307: ...tall in mounting bracket 2 Connect coolant recovery pressure container retaining clip Fig 5 3 Connect coolant bypass and overflow hoses to coolant recovery pressure container 4 Refill cooling system R...

Page 308: ...S HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR 1 Drain the cooling system Refer to 7 COOL ING ENGINE COOLANT STANDARD PROCE DURE 2 Disconnect coolant temperature sensor elec...

Page 309: ...t be replaced as an assembly 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove front wiper unit to gain access to ther mostat hou...

Page 310: ...NING DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 3 Drain the cooling system Refer to 7 COOL ING...

Page 311: ...er to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 8 Connect negative cable to battery RADIATOR DRAINCOCK REMOVAL CAUTION Use of pliers on draincock is not recom mended Damage may occur to radiator or...

Page 312: ...le 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove both outer and inner timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 4 Disco...

Page 313: ...ter pump housing to thermostat housing bypass hose Fig 16 6 Install both inner and outer timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 7 Refill cooling syste...

Page 314: ...lting is loss of coolant and eventual overheating due to low coolant level in radiator and engine DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING COOLING SYSTEM PRESSURE CAP Dip the pressure cap in water...

Page 315: ...W TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COM PLETELY SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL TO CHECK PR...

Page 316: ...repair as necessary 3 Air obstructions at radiator or A C condenser 3 Remove obstructions and or clean debris 4 Electric fan motor defective 4 Replace fan assembly Refer to 7 COOLING ENGINE RADIATOR...

Page 317: ...oved Tighten to 8 N m 70 in lbs 6 Install the radiator upper hose to the support clip 2 4L engine HOSE CLAMPS DESCRIPTION HOSE CLAMPS The cooling system uses spring type hose clamps If a spring type c...

Page 318: ...CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE 1 Remove engine cover Refer to 9 ENGINE REMOVAL 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remov...

Page 319: ...pass hose Fig 26 INSTALLATION INSTALLATION UPPER RADIATOR HOSE 1 Install upper radiator hose Fig 26 2 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Install engine cover...

Page 320: ...FM Cassette with single Compact Disc Player and Compact Disc changer controls AM FM Cassette with Compact Disc changer controls AM FM Cassette with Compact Disc player rear seat audio system and Compa...

Page 321: ...KERS FAULTY 6 SEE SPEAKER DIAGNOSIS IN THIS GROUP NO DISPLAY 1 FUSE FAULTY 1 CHECK RADIO FUSES IN FUSE BLOCK MODULE REPLACE FUSES IF REQUIRED 2 RADIO CONNECTOR FAULTY 2 CHECK FOR LOOSE OR CORRODED RAD...

Page 322: ...ION 1 FAULTY CD 1 INSERT KNOWN GOOD CD AND TEST OPERATION 2 FOREIGN MATERIAL ON CD 2 CLEAN CD AND TEST OPERATION 3 CONDENSATION ON CD OR OPTICS 3 ALLOW TEMPERATURE OF VEHICLE INTERIOR TO STABILIZE AND...

Page 323: ...na coaxial cable from the radio chassis and isolate Remove the antenna mast 2 Connect an ohmmeter test lead to the inside center of the antenna base Connect the other test lead to a metallic portion o...

Page 324: ...a base to front fender Fig 4 12 Remove antenna base from under front fender INSTALLATION 1 Install antenna base to underside of front fender 2 Install cap nut holding antenna base to front fender 3 In...

Page 325: ...io signals supplied by the side window integral radio antenna system and selectively amplifies them The amplified signal is then sent through the body length coax cable to the radio input DIAGNOSIS AN...

Page 326: ...anger with the exception of the CD load and eject functions which are controlled by buttons located on the front of the CD changer All features you would expect such as Disc Up Down Track Up Down Rand...

Page 327: ...tenna element is bonded to the right rear quarter glass and is replaced with the glass assembly only Fig 7 OPERATION The integral antenna receives RF Radio Frequen cies and sends them to the antenna m...

Page 328: ...e Integrated Power Module IPM If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the faulty fuse s 2 Check for battery voltage at the fuse in the IPM If OK go...

Page 329: ...s and other on board electrical com ponents such as generators wiper motors blower motors and fuel pumps that have been found to be potential sources of RFI or EMI OPERATION There are two common strat...

Page 330: ...OTE SWITCHES WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE T...

Page 331: ...efore further service 2 Remove the driver side airbag module from the vehicle Refer to ELECTRICAL RESTRAINTS DRIVER AIR BAG 3 Remove the steering wheel from the steering column Refer to STEERING COLUM...

Page 332: ...s connector for con tinuity to ground There should be no continuity If OK go to Step 5 If not OK repair the shorted speaker feed and or return circuits s to the speaker as required 5 Disconnect wire h...

Page 333: ...nstall jack cover left side 8 Connect battery negative cable FRONT DOOR SPEAKER 1 Connect the wire harness connector and install speaker to door 2 Install the speaker mounting screws 3 Install the fro...

Page 334: ...mph OPERATION The Chime Buzzer Warning System is diagnosed using a DRB lllt scan tool Refer to the proper Body Diagnostic Procedures Manual HIGH SPEED WARNING EXPORT When the vehicle speed sensor see...

Page 335: ...ver s door OPEN door ajar switch is closed to ground and Dome lamps are ON dome lamp switch is closed to ground The chime will sound continuously until the driv ers door is closed dome lamps turned OF...

Page 336: ...1 minute before starting the test Turn the ignition switch to the on position with the driver s seat belt not buck led The seat belt warning lamp should light and the chime should sound 4 to 8 seconds...

Page 337: ...airbag door ajar or gate ajar lamps are first illuminated the chime will sound one tone The door liftgate ajar warning lamp announcement chime sounds only if the vehicle speed is above 4 m p h Two sec...

Page 338: ...TION 11 POWERTRAIN CONTROL MODULE DESCRIPTION DESCRIPTION 11 DIAGNOSTIC TROUBLE CODE 13 OPERATION SENSOR RETURN PCM INPUT 25 OPERATION SCI RECEIVE PCM INPUT 25 OPERATION IGNITION SENSE PCM INPUT 25 OP...

Page 339: ...get to the Select System menu and select ENGINE MISCELLANEOUS and SRI MEMORY CHECK 8 The DRB III will ask Is odometer reading between XX and XX Select the YES or NO button on the DRB III If NO is sel...

Page 340: ...ts the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmis sion of el...

Page 341: ...NT FOG LAMPS POWER SLIDING DOOR PCI IFR RECEIVED FROM MODULE THE BCM HAS FOUR SWITCH INPUTS FOR THE POWER SLIDING DOOR FEATURE LOCATED IN THE OVERHEAD CONSOLE ARE THE LEFT AND RIGHT SIDE SLIDING DOOR...

Page 342: ...stall the BCM to the mounting bracket 2 Install the screws holding the BCM to the bulkhead 3 Connect the five wire connectors to the bottom of the Body Control Module BCM 4 Install the knee blocker an...

Page 343: ...ll be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3 500 miles CAB INPUTS Wheel speed sensors four Brake lamp switch Ignition switch System and...

Page 344: ...POWER MODULE DESCRIPTION OPERATION As messages are sent over the Programmable Com munications Interface PCI data bus the Front Con trol Module FCM reads these messages and controls power to some of th...

Page 345: ...lly charged and all wire harness and ground connections inspected around the affected areas on the vehicle REMOVAL 1 Disconnect the positive and negative battery cables from the battery 2 Remove the b...

Page 346: ...the heated seat sensor inputs from the seat cushions of each front seat In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and controls the g...

Page 347: ...ess connec tors INSTALLATION 1 Connect the module wire harness connectors 2 Snap the module on the seat cushion pan 3 Install the appropriate front seat in the vehicle Refer to 23 BODY SEATS SEAT INST...

Page 348: ...NTROL MODULE DESCRIPTION DESCRIPTION The Powertrain Control Module PCM is a digital computer containing a microprocessor Fig 11 The PCM receives input signals from various switches and sensors referre...

Page 349: ...ake Switch Engine Coolant Temperature Engine Speed crankshaft position sensor Park Neutral transmission gear selection Transaxle Gear Engagement Throttle Position Vehicle Speed from Transmission Contr...

Page 350: ...ndition detected in the oxygen sensor heater element control feedback sense circuit P0044 O2 sensor 1 3 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback s...

Page 351: ...h MAP TPS signal does not correlate to MAP sensor signal P0122 M Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable voltage range P0123 M Throttle Position Sensor...

Page 352: ...tained above normal operating range P0153 M 2 1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency P0154 M 2 1 O2 Sensor Stays at Center Neither rich or le...

Page 353: ...l P0208 Injector 8 Control Circuit Injector 8 output driver stage does not respond properly to the control signal P0209 Injector 9 Control Circuit Injector 9 output driver stage does not respond prope...

Page 354: ...current not achieved with maximum dwell time High Impedance P0355 M Ignition Coil Primary 5 Circuit Peak primary circuit current not achieved with maximum dwell time High Impedance P0356 M Ignition Co...

Page 355: ...rad fan relay control circuit P0481 High Speed Fan Relay Control Circuit An open or shorted condition detected in the high speed rad fan relay control circuit P0498 NVLD Canister Vent Valve Solenoid C...

Page 356: ...circuit P0586 Speed Control Vent Solenoid Circuit An open or shorted condition detected in speed control vent solenoid control circuit P0594 Speed Control Servo Power Circuit An open or shorted condit...

Page 357: ...0 Low Output SPD Sensor RPM Above 15 MPH The relationship between the Output Shaft Speed Sensor and vehicle speed is not within acceptable limits P0740 M Torque Con Clu No RPM Drop at Lockup Relations...

Page 358: ...or Volts Too Low Radiator coolant temperature sensor input below the minimum acceptable voltage P1281 Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures dur...

Page 359: ...f secondary air injection detected during aspirator test was P0411 P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during aspirator test was P0411 P1478 M Battery Temp...

Page 360: ...tected in the control circuit of the 3 high speed radiator fan control relay P1594 G Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation...

Page 361: ...transmission control module EATX or the Aisin transmission controller P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission 2 3 gear lock out solenoid control cir...

Page 362: ...e as many as three different ground pins There are power grounds and sensor grounds The power grounds are used to control the ground side of any relay solenoid ignition coil or injector The signal gro...

Page 363: ...efer to the Battery section for more information 3 Remove the 2 upper PCM bracket bolts Fig 12 4 Remove the 2 PCM connectors 5 Remove the headlamp refer to the Lamps sec tion for more information 6 Re...

Page 364: ...ds an 9invalid key9 message to the PCM The PCM will enable or disable engine operation based upon the status of the SKIM messages It is important to note that the default condition in the PCM is 9inva...

Page 365: ...ed 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 Engine Coolant Temperature...

Page 366: ...hanges as clutches are applied and released By monitoring the length of time it takes for the gear ratio to change following a shift request the TCM can determine the volume of fluid used to apply or...

Page 367: ...stdown shift approximately 30 mph Early 3 2 coastdown shift approximately 17 mph High speed 4 2 3 2 2 1 kickdown shifts are prevented No EMCC Warm Oil temperature at start up above 36 F and below 80 d...

Page 368: ...nt Solenoid Pressure Switch Assembly Replacement Clutch Plate and or Seal Replacement Valve Body Replacement or Recondition To perform the Quick Learn Procedure the follow ing conditions must be met T...

Page 369: ...splash shield into position with fasten ers 4 Install left front wheel tire assembly 5 Lower vehicle 6 Connect battery negative cable 7 If TCM was replaced reset Pinion Factor and Quick Learn Refer t...

Page 370: ...Look for broken bent pushed out or corroded terminals If any of the above conditions are present repair as necessary If not use a DRB IIIt scan tool and the proper Diagnostic Procedures Manual to tes...

Page 371: ...ops any problems the control module will store and recall Diagnostic Trouble Codes DTC The use of a diagnostic scan tool such as the DRB IIIt is required to read and troubleshoot these trouble codes R...

Page 372: ...hat are programmed into it for that device If the input voltage is not within the specifications and other trouble code criteria are met a DTC will be stored in the ECM memory ECM OPERATING MODES As i...

Page 373: ...at is not current every time the ECM SKIM checks the circuit or function is an intermit tent code Most intermittent DTCs are caused by wiring or connector problems Problems that come and go like this...

Page 374: ...sories are turned off Also monitor the battery state and connect a battery charger if necessary 6 Press ENTER to transfer the secret key the SKIM will send the secret key to the PCM 7 Press Page Back...

Page 375: ...emove ECM upper mounting bolts Fig 3 5 Lift ECM from radiator support 6 Disconnect ECM electrical connectors 7 Separate ECM from mounting bracket INSTALLATION 1 Install ECM on mounting bracket 2 Conne...

Page 376: ...5 REMOVAL 15 INSTALLATION 16 BATTERY CABLES DESCRIPTION 16 OPERATION 16 DIAGNOSIS AND TESTING BATTERY CABLE 16 REMOVAL 18 INSTALLATION 18 BATTERY TRAY DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATI...

Page 377: ...lectrical components or circuits in the vehicle DIAGNOSIS AND TESTING BATTERY SYSTEM The battery starting and charging systems in the vehicle operate with one another and must be tested as a complete...

Page 378: ...nal connections are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The batte...

Page 379: ...g procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause exce...

Page 380: ...lacement battery is the correct size and has the correct ratings for the vehicle 4 Clean the battery thermowrap with a sodium bicarbonate baking soda and warm water cleaning solution using a soft bris...

Page 381: ...nk ing Amperage CCA rating specifies how much cur rent in amperes the battery can deliver for thirty seconds at 18 C 0 F Terminal voltage must not fall below 7 2 volts during or after the thirty secon...

Page 382: ...water within the electrolyte eliminating the need to add distilled water Therefore these batteries have non removable battery vent caps Fig 4 Water can not be added to this battery The acid inside an...

Page 383: ...ls that are connected in series Each cell contains positively charged plate groups that are connected with lead straps to the positive terminal post and negatively charged plate groups that are connec...

Page 384: ...to produce high amperage cur rent over an extended period A battery must also be able to accept a charge so that its voltage potential may be restored The battery is vented to release excess hydrogen...

Page 385: ...ery hold downs tray terminals posts and top before completing battery service Refer to Battery System Cleaning for the proper battery system cleaning procedures and Bat tery System Inspection for the...

Page 386: ...battery to its full potential failure to use the spiral plate battery charging procedure could result in damage to the battery or personal injury Battery charging is the means by which the bat tery ca...

Page 387: ...l not accept charging cur rent See the instructions provided by the manufac turer of the battery charger for details on how to bypass the polarity sensing circuitry 3 Battery chargers vary in the amou...

Page 388: ...IOD identifies a nor mal condition where power is being drained from the battery with the ignition switch in the Off position A normal vehicle electrical system will draw from five to thirty five mil...

Page 389: ...ch the multi meter to progressively lower amperage scales and if necessary repeat the fuse and circuit breaker remove and replace process to identify and correct all sources of excessive IOD It is now...

Page 390: ...ed to the proper specifications Improper hold down fastener tightness whether too loose or too tight can result in damage to the battery the vehicle or both Refer to Battery Hold Downs in this section...

Page 391: ...e potential of the battery The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts The ter...

Page 392: ...he ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor con nection between the battery negative cable terminal clamp and the battery negative terminal p...

Page 393: ...ect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle 6 Feed the battery cable out of the vehicle INSTALLATION 1 Position the battery cable in th...

Page 394: ...1 Disconnect and isolate the negative battery cable 2 Remove the battery from the vehicle Refer to the procedure in this section 3 Remove the battery tray retaining fasteners Fig 18 4 Pull battery tra...

Page 395: ...helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment REMOVAL 1 Disconnect and isolate the negative battery cable 2 Disconnect the positi...

Page 396: ...lay is energized when the PCM grounds the ASD control circuit This voltage is connected through the PCM or IPM intelligent power module if equipped and supplied to one of the generator field terminals...

Page 397: ...stand what caused a DTC to be set ERASING DIAGNOSTIC TROUBLE CODES The DRBIIIt Scan Tool must be used to erase a DTC The following procedures may be used to diagnose the charging system if the check g...

Page 398: ...ENERATOR Type Engine Minimun Test Amperage Denso 2 4 L 125 Amp Denso 3 3 3 8L 135 Amp or 145 Amp Test Specification 1 Engine RPM 2500 RPM 20 RPM 2 Voltage Output 14 0 V 0 5 V 3 Field Current 5 amps 0...

Page 399: ...current it also provides the current needed to energize the rotor The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification From the d...

Page 400: ...l nut to hold B wire terminal to back of generator 7 Connect the push in field wire connector into back of generator 8 Raise vehicle and support 9 Install the lower mounting bolt and tighten 10 Instal...

Page 401: ...Raise vehicle and support 4 Remove the right front lower splash shield 5 Remove accessory drive belt refer to the Cool ing System section for proper procedures Fig 5 6 Lower vehicle 7 Remove the Air...

Page 402: ...ng the ground path to control the strength of the rotor magnetic field The EVR circuitry monitors system line voltage B and calculated battery temperature or inlet air tempera ture sensor refer to Inl...

Page 403: ...ARTING SYSTEM TEST For circuit descriptions and diagrams refer to the Wiring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO THE PASSIVE RESTRAINT SYS TEMS BEFORE ATTEMPTING STEERING WHEE...

Page 404: ...r corroded wire harness connections at main engine ground and remote jump post Power Distribution Center PDC Visually inspect the B connections at the PDC for physical damage and loose or corroded har...

Page 405: ...SSEMBLY IF NECESSARY 8 STARTER ASSEMBLY FAULTY 8 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 9 FAULTY TEETH ON RING GEAR 9 ROTATE FLYWHEEL 360 AND INSPECT TE...

Page 406: ...the Power Distribution Center PDC Refer to the PDC cover for the proper relay location STARTER SOLENOID WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE AP...

Page 407: ...to Step 4 If not OK repair the open circuit to the starter solenoid as required 4 The coil battery terminal 86 is connected to the electromagnet in the relay It is energized when the ignition switch i...

Page 408: ...ct positive lead of the voltmeter to the battery positive post and negative lead to the bat tery positive cable clamp Rotate and hold the igni tion switch key in the START position Observe the voltmet...

Page 409: ...e below 9 6 volts and amperage draw above 300 amps the problem is the starter Replace the starter refer to starter removal 6 After the starting system problems have been corrected verify the battery s...

Page 410: ...solenoid wire connector from termi nal Fig 5 4 Remove nut holding B wire to terminal 5 Disconnect solenoid and B wires from starter terminals 6 Remove the lower bolt 7 Remove the upper bolt and groun...

Page 411: ...ion on starter terminals Fig 5 5 Install nut to hold B wire to terminal 6 Connect solenoid wire connector onto terminal 7 Connect battery negative cable 8 Verify starter operation INSTALLATION 3 3 3 8...

Page 412: ...5 REMOVAL 16 INSTALLATION 16 BATTERY CABLES DESCRIPTION 16 OPERATION 16 DIAGNOSIS AND TESTING BATTERY CABLE 16 REMOVAL 18 INSTALLATION 18 BATTERY TRAY DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATI...

Page 413: ...ectrical components or circuits in the vehicle DIAGNOSIS AND TESTING BATTERY SYSTEM The battery starting and charging systems in the vehicle operate with one another and must be tested as a complete s...

Page 414: ...nal connections are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The batte...

Page 415: ...st procedures Replace the faulty battery as required 5 The starting system is faulty 5 Determine if the starting system is performing to specifications Refer to Starting System for the proper starting...

Page 416: ...rocedures be per formed any time the battery or related components must be removed for vehicle service 1 Clean the battery cable terminal clamps of all corrosion Remove any corrosion using a wire brus...

Page 417: ...SPECIFICATIONS The battery Group Size number the Cold Cranking Amperage CCA rating and the Reserve Capacity RC rating or Ampere Hours AH rating can be found on the original equipment battery label Be...

Page 418: ...di tional batteries lead and sulfuric acid to the next level By tightly winding layers of spiral grids and acid permeated vitreous separators into cells the manufacturer has developed a battery with m...

Page 419: ...larger in diameter than the nega tive terminal post for easy identification The letters POS and NEG are also molded into the top of the battery case adjacent to their respective positive and negative...

Page 420: ...rough the load device attached to the battery ter minals As the plate materials become more similar chem ically and the electrolyte becomes less acid the volt age potential of each cell is reduced How...

Page 421: ...he touch If the battery feels hot to the touch turn off the charger and let the battery cool before continu ing the charging operation Damage to the battery may result After the battery has been charg...

Page 422: ...pecific gravity of the electrolyte will gradually rise The Battery Charging Time Table gives an indica tion of the time required to charge a typical battery at room temperature based upon the battery...

Page 423: ...e dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at the battery posts with a voltmeter accurate to 1 10 0 10 volt Fig 8 If the reading is below ten volts the...

Page 424: ...attery voltage to stabilize 2 Disconnect and isolate both battery cables neg ative cable first 3 Using a voltmeter connected to the battery posts see the instructions provided by the manufac turer of...

Page 425: ...iate wiring information in this service manual for complete Inte grated Power Module fuse circuit breaker and cir cuit identification This will isolate each circuit and identify the circuit that is th...

Page 426: ...ositive cable first Torque terminal fasteners to 8 5 N m 75 in lbs BATTERY HOLDDOWN DESCRIPTION The battery hold down hardware consists of a molded plastic lip that is integral to the outboard edge of...

Page 427: ...ts for the generator and other components on some models Refer to Wiring Diagrams in the index of this service manual for the location of more information on the various wiring circuits included in th...

Page 428: ...voltmeter to the battery negative cable terminal clamp Fig 13 Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor con nection betwe...

Page 429: ...le is free from the vehicle 6 Feed the battery cable out of the vehicle INSTALLATION 1 Position the battery cable in the vehicle 2 One at a time trace and install the battery cable retaining fasteners...

Page 430: ...attery tray retaining fasteners Fig 18 4 Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted vacuum reservoir 5 Remove the battery tray from the...

Page 431: ...is on when the engine is running and the ASD relay is energized The ASD relay is energized when the PCM grounds the ASD control circuit This voltage is connected through the PCM or IPM intelligent pow...

Page 432: ...n be the reason for another DTC to be set Therefore it is important that the test pro cedures be followed in sequence to understand what caused a DTC to be set ERASING DIAGNOSTIC TROUBLE CODES The DRB...

Page 433: ...t engine if equipped They should all be clean and tight Repair as required SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage Denso 2 4 L 125 Amp Denso 3 3 3 8L 135 Amp or 145 Amp Test Specifi...

Page 434: ...rator assembly subcompo nents generator and decoupler pulley must be inspected for individual failure and replaced accord ingly OPERATION As the energized rotor begins to rotate within the generator t...

Page 435: ...ne cover Fig 2 3 Raise vehicle and support 4 Turn wheels to the right Remove the right front splash shield Fig 3 5 Remove the generator drive belt Fig 4 Fig 1 BATTERY CONNECTION Fig 2 ENGINE COVER Fig...

Page 436: ...sconnect the push in field wire connector from back of generator 4 Remove nut holding B wire terminal to back of generator 5 Separate B terminal from generator 6 Raise vehicle and support 7 Remove the...

Page 437: ...the generator from vehicle Fig 10 REMOVAL 3 5L 1 Disconnect the negative battery cable 2 Turn wheels to the right 3 Raise and support the vehicle 4 Remove the right front tire 5 Remove the front axle...

Page 438: ...e the axle from vehicle oil will leak from transmission 15 Remove the 3 mounting bolts for generator 16 Remove generator from vehicle Fig 16 INSTALLATION INSTALLATION 2 4L 1 Install the generator 2 In...

Page 439: ...cedures 12 Install the right front lower splash shield 13 Lower vehicle 14 Install wiring harness to the oil dip stick tube 15 Connect battery negative cable 16 Verify generator output rate INSTALLATI...

Page 440: ...ght front lower splash shield 5 Remove accessory drive belt refer to the Cool ing System section for proper procedures Fig 18 6 Lower vehicle 7 Remove the Air Box refer to the Engine section for more...

Page 441: ...This circuitry is connected in series with the generators second rotor field terminal and its ground Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field...

Page 442: ...ring harness Battery Starter motor with an integral solenoid Powertrain Control Module PCM OPERATION These components form two separate circuits A high amperage circuit that feeds the starter motor up...

Page 443: ...rroded wire harness connections Starter Visually inspect the starter for indica tions of physical damage and loose or corroded wire harness connections Starter Solenoid Visually inspect the starter so...

Page 444: ...SSEMBLY IF NECESSARY 8 STARTER ASSEMBLY FAULTY 8 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 9 FAULTY TEETH ON RING GEAR 9 ROTATE FLYWHEEL 360 AND INSPECT TE...

Page 445: ...he Power Distribution Center PDC Refer to the PDC cover for the proper relay location STARTER SOLENOID WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APP...

Page 446: ...o Step 4 If not OK repair the open circuit to the starter solenoid as required 4 The coil battery terminal 86 is connected to the electromagnet in the relay It is energized when the ignition switch is...

Page 447: ...ct positive lead of the voltmeter to the battery positive post and negative lead to the bat tery positive cable clamp Rotate and hold the igni tion switch key in the START position Observe the voltmet...

Page 448: ...below 9 6 volts and amperage draw above 300 amps the problem is the starter Replace the starter refer to starter removal 6 After the starting system problems have been corrected verify the battery st...

Page 449: ...solenoid wire connector from termi nal Fig 5 4 Remove nut holding B wire to terminal 5 Disconnect solenoid and B wires from starter terminals 6 Remove the lower bolt 7 Remove the upper bolt and groun...

Page 450: ...Remove starter from bellhousing Fig 9 8 Separate starter spacer from transaxle bell housing REMOVAL 3 5L 1 Disconnect the negative battery cable 2 Raise vehicle and support 3 Disconnect the battery p...

Page 451: ...g bolt 8 Remove the middle mounting bolts Fig 12 9 Remove the lower mounting bolt Fig 13 10 Remove starter REMOVAL 2 5L 1 Disconnect the negative battery cable 2 Raise vehicle and support 3 Remove the...

Page 452: ...starter 5 Install nut to hold B terminal to starter sole noid 6 Lower vehicle 7 Connect battery negative cable 8 Verify starter operation INSTALLATION 3 5L 1 Install starter 2 Install the middle Fig 1...

Page 453: ......

Page 454: ...GER GRID STANDARD PROCEDURE GRID LINE REPAIR REAR 2 REAR WINDOW DEFOGGER SWITCH DESCRIPTION 2 OPERATION 2 WINDSHIELD GRID DIAGNOSIS AND TESTING SYSTEM TEST 3 STANDARD PROCEDURE GRID LINE AND TERMINAL...

Page 455: ...tay ON until the another mode is selected For circuit information and component location refer to appropriate section for Wiring Diagrams CAUTION Since grid lines can be damaged or scraped off with sh...

Page 456: ...IPM Rear window defogger relay control circuity in the FCM portion of the IPM Check for loose connector or a wire pushed out of connector Rear window or the windshield grid lines all grid lines would...

Page 457: ...ermi nal from falling off use a wooden wedge to secure it 8 Carefully remove masking tape from grid line CAUTION Do not allow the laminated windshield glass surface to exceed 82 C 180 F or the glass m...

Page 458: ...rear window defog ger switch The heated mirror is ON when the rear window defogger is ON 1 The mirror glass should be warm to the touch 2 If not check the 20 amp fuse 11 in the Power Distribution Cen...

Page 459: ...iew mirrors The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off HEATED MIRROR GRID STANDARD PROCEDURE HEATED MIRROR Replacement of the mirr...

Page 460: ...mental elec trical seat heating HI LO or no seat heating to suit their individual comfort requirements The heated seat system for this vehicle includes the following major components which are describ...

Page 461: ...the ignition switch is turned to any position except On or Acces sory Also the heated seat system will not operate when the surface temperature of the seat cushion cover at either heated seat sensor i...

Page 462: ...t to the seat heater elements of the selected seat The Low heat position set point is about 36 C 97 F and the High heat position set point is about 41 C 105 F DIAGNOSIS AND TESTING DRIVER HEATED SEAT...

Page 463: ...SISTANCE OHMS Off Pin 4 5 OPEN Low Pin 4 5 3570 High Pin 4 5 1430 All resistance values are 1 4 Reconnect the instrument panel switch bank and test the heated seat system for proper operation If the s...

Page 464: ...onnect the seat electrical connectors just use care not to damage the attached wire harnesses while testing NOTE WHEN CHECKING HEATED SEAT ELE MENTS FOR CONTINUITY BE CERTAIN TO MOVE THE HEATING ELEME...

Page 465: ...securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover HEATED SEAT SENSOR DESCRIPTION Two heated seat sensors are used per vehicle one in each front seat cushi...

Page 466: ...to the seat heater elements of the selected seat The Low heat position set point is about 36 C 97 F and the High heat position set point is about 41 C 105 F DIAGNOSIS AND TESTING PASSENGER HEATED SEA...

Page 467: ...SWITCH TEST SWITCH POSITION RESISTANCE BETWEEN RESISTANCE OHMS Off Pin 3 4 OPEN Low Pin 3 4 3570 High Pin 3 4 1430 All resistance values are 1 4 Reconnect the instrument panel switch bank and test the...

Page 468: ...e heated seat switch to the back of the instrument panel center bezel Tighten the screws to 1 5 N m 13 in lbs Fig 8 3 Install the center bezel onto the instrument panel Refer to Instrument Panel Cente...

Page 469: ......

Page 470: ...more than 30 seconds Once the switch is OPEN a 20 30 second delay will occur before the horns are functional again DIAGNOSIS AND TESTING HORN SYSTEM WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER T...

Page 471: ...RONT CONTROL MODULE HORN SOUND INTERMITTENTLY AS THE STEERING WHEEL IS TURNED 1 HORN RELAY CONTROL CIRCUIT X3 IS SHORTED TO GROUND INSIDE STEERING COLUMN OR WHEEL 1 REMOVE DRIVER AIRBAG MODULE AND OR...

Page 472: ...nd wire for continu ity to ground 6 If no ground repair as necessary 7 If wires test OK and horn does not sound replace horn HORNS SOUND CONTINUOUSLY CAUTION Continuous sounding of horns may cause rel...

Page 473: ...nuity from the X3 cavity of the horn relay to ground a If continuity is detected proceed to Step 3 b If NO continuity proceed to Step 4 3 Using a suitable jumper wire jump across the fuse F62 cavity a...

Page 474: ...und b If NO voltage check fuse 8 of the intelligent power module c If incorrect voltage repair as necessary 5 Insert a jumper wire between terminal 30 and 87 of the intelligent power module a If horn...

Page 475: ......

Page 476: ...10 IGNITION CONTROL DESCRIPTION IGNITION SYSTEM NOTE All engines use a fixed ignition timing sys tem Basic ignition timing is not adjustable All spark advance is determined by the Powertrain Control...

Page 477: ...10 7 SPARK PLUG CABLE RESISTANCE 2 4L CABLE Maximum Resistance 1 2 3 4 10 8K ohms 3 3 3 8L CABLE Maximum Resistance 1 22 5K ohms 2 22 8K ohms 3 19 3K ohms 4 19 3K ohms 5 13 6K ohms 6 16 4K ohms SPARK...

Page 478: ...o the PCM for diagnostic purposes If the PCM does not receive 12 volts from this input after grounding the ASD relay it sets a Diagnostic Trouble Code DTC The PCM energizes the ASD any time there is a...

Page 479: ...tal to high notch then back to low The number of notches determine the amount of pulses If available an oscilloscope can display the square wave patterns of each timing event Top Dead Center TDC does...

Page 480: ...make removal difficult A light tap to top of sensor prior to removal may reduce force needed for removal Fig 3 EGR CAM SENSOR 2 4L Fig 4 Target Magnet Removal Installation 1 TARGET MAGNET 2 MOUNTING B...

Page 481: ...ft position sensor electrical connector to harness connector 5 Install the air box cover and inlet hose Fig 5 6 Connect the negative battery cable IGNITION COIL DESCRIPTION The ignition coil assembly...

Page 482: ...ering reservoir Fig 11 6 Remove the ignition cables from the ignition coil 7 Disconnect the electrical connector from the ignition coil 8 Remove 2 nuts from the ignition coil studs 9 Remove 2 bolts fr...

Page 483: ...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...

Page 484: ...r schedule A in this manual The spark plugs have a recommended service life of 75 000 miles for severe driving conditions per schedule B in this manual A thin platinum pad is welded to both or center...

Page 485: ...s with insulators that are cracked or torn must be replaced Clean Spark Plug cables with a cloth moistened with a non flammable solvent Wipe the cables dry Check for brittle or cracked insulation The...

Page 486: ...0 amps after the plugs are heated Electrical operation of the glow plugs is controlled by two glow plug relays Each glow plug relay con trols two glow plugs Refer to glow plug relays for more informat...

Page 487: ...MP sensor is mounted in the top of cylinder head cover intake manifold at the rear of the engine The CMP sensor is a hall effect device Fig 3 OPERATION The CMP sensor is a hall effect switch A tooth m...

Page 488: ...lt Door Ajar Coolant Temperature Anti Lock Brake Brake Airbag Traction Control Autostick The mechanical instrument cluster without a tachometer also has the following warning lamps Turns Signals High...

Page 489: ...ULT 100 4 FCM COMMUNICATION FAULT 100 5 ORC COMMUNICATION FAULT 100 6 SBEC DEC MCM COMMUNICATION FAULT 200 0 AIRBAG LED SHORT 200 1 AIRBAG LED OPEN 200 2 ABS LED SHORT 200 3 ABS LED OPEN 200 6 EL INVE...

Page 490: ...HARNESS CONNECTOR FOR SPREAD TERMINAL IF OK LOOK FOR ANOTHER POSSIBLE CAUSE FOR THE CLUSTER FAILURE IF NOT OK REPAIR CONNECTOR BCM IS NOT RECEIVING PROPER INPUT FROM THE IGNITION SWITCH 1 USE A DRB II...

Page 491: ...O THE INSTRUMENT PANEL 2 NO SPEED PCI BUS MESSAGE OR ZERO MPH PCI SPEED BUS MESSAGE 2 A CHECK THE PCM CODE 10 USING A DRB IIIT SCAN TOOL IF OK GO TO STEP 2 B IF NOT OK REFER TO THE PROPER POWERTRAIN D...

Page 492: ...HE FOLLOWING SOURCES A DISTANCE SENSOR FOR VEHICLES WITH 3 SPEED AUTOMATIC TRANSMISSION CHECK CONTINUITY FROM DISTANCE SENSOR TO PCM IF OK REPLACE DISTANCE SENSOR IF NOT OK REPAIR WIRING THE TCM FOR V...

Page 493: ...O SEE IF THE CORRECT TIRE SIZE HAS BEEN PROGRAMMED INTO THE TCM IF THE INCORRECT TIRE SIZE WAS SELECTED SELECT THE PROPER TIRE SIZE IF THE CORRECT TIRE SIZE WAS SELECTED CHECK SPEED SENSOR 3 BAD SPEED...

Page 494: ...E CLUSTER ASSEMBLY FUEL GAUGE DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO POINTER MOVEMENT 1 INTERNAL CLUSTER FAILURE 1 PERFORM CLUSTER SELF DIAGNOSTIC TEST IF FUEL GAUGE POINTER MOVES TO CALIBR...

Page 495: ...E TO THE CALIBRATION POINTS REPLACE CLUSTER ASSEMBLY 2 FUEL LEVEL SENDING UNIT IS OUT OF CALIBRATION 2 REFER TO THE FUEL SECTION OF THE SERVICE MANUAL FOR TESTING AND REPAIR PROCEDURE TEMPERATURE GAUG...

Page 496: ...TIC TEST IF POINTER IS ACCURATE TO THE CALIBRATION POINTS LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE IF POINTER IS INACCURATE TO THE CALIBRATION POINTS REPLACE CLUSTER ASSEMBLY 2 COOLANT SENSOR OUT OF...

Page 497: ...ESN T WORK IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC MODE AND TRIP ODOMETER WILL NOT RESET REPLACE CLUSTER ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO DISPLAY...

Page 498: ...LACE CLIP ON INDICATOR INDICATOR DOES NOT MAKE FULL TRAVEL P 1 1 CABLE DISLODGED FROM ITS PATH ON THE INDICATOR BASE 1 VERIFY CORRECT ATTACHMENT OF INDICATOR CABLE TO SHIFT LEVER PIN UNDER HOOP OF TRA...

Page 499: ...ent clus ter to instrument panel 5 Position cluster bezel into place 6 Install the four bezel attaching screws 7 Install the Over Steering Column Bezel by firmly snapping into place 8 Connect the clip...

Page 500: ...ck by the ignition switch every time the ignition switch is placed in the crank position OPERATION The red BRAKE warning indicator lamp is sup plied a 12 volt ignition feed anytime the ignition switch...

Page 501: ......

Page 502: ...LAMP UNIT ALIGNMENT EXPORT 10 REMOVAL 11 INSTALLATION 11 FRONT POSITION LAMP EXPORT REMOVAL 11 INSTALLATION 11 HEADLAMP DIAGNOSIS AND TESTING HEADLAMP 12 REMOVAL 14 INSTALLATION 14 HEADLAMP EXPORT RE...

Page 503: ...it ground Refer to the appropriate wiring information AUTOMATIC HEADLAMP SYSTEM The Automatic Headlamp system turns the instru mentation and exterior illumination lamps ON when the ambient light level...

Page 504: ...OFF and headlamp switch OFF The BCM will allow the headlamps to remain ON for 90 seconds config urable before they automatically turn off If the key is in the ignition during the headlamp time delay m...

Page 505: ...witches assume the opposite positions The switch for terminals 1 and 2 is now open while the other two switches are now closed completing their circuits A lever on the back of the switch is used to se...

Page 506: ...stall the switch replace it Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH INSTALLATION CAUTION The switch can only be adjusted once That is during initial installation of the switch...

Page 507: ...silencer panel below steering column knee blocker 3 Reconnect the battery negative terminal 4 Check the stop lamps to verify they are operat ing properly and not staying on when the pedal is in the r...

Page 508: ...not holding the com ponent in place FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF 1 Loose or corroded battery cables 1 Clean and s...

Page 509: ...erminals or splices in circuit 4 Inspect and repair all connectors and splices Refer to Electrical Wiring Information 5 Is relay engaging properly 5 Verify function of fog lamp relay in IPM 6 PCI Bus...

Page 510: ...MOVAL 1 Disconnect and isolate the battery negative cable 2 Remove access cover from under bumper fascia 3 Disengage spring clip from fog lamp Fig 8 4 Remove bulb from lamp 5 Disconnect wire harness c...

Page 511: ...ustment screw located through the lens on Dodge vehicles and by a knob on the back of the lamp STANDARD PROCEDURE FOG LAMP UNIT ALIGNMENT EXPORT Prepare an alignment screen Refer to 8 ELEC TRICAL LAMP...

Page 512: ...AMP EXPORT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the headlamp unit Fig 11 3 Remove the plastic cover from the back of the headlamp unit 4 Pull front position lamp socket...

Page 513: ...t in place HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF 1 Loose or corroded battery cables 1 Clean and secure battery cable clamp...

Page 514: ...mp switch HEADLAMPS DO NOT ILLUMINATE 1 No voltage to headlamps 1 Repair open headlamp circuit refer to Electrical Wiring Information 2 No Z343 Z344 ground at headlamps 2 Repair circuit ground refer t...

Page 515: ...REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the headlamp unit 3 Remove the cover high beam lamp or rubber boot low beam lamp to access bulbs Fig 13 4 Disconnect the wire harne...

Page 516: ...amp leveling switch operation 2 No voltage at leveling motors 2 Repair no voltage condition Refer to Wiring Diagrams 3 No ground at leveling motors 3 Repair no ground condition Refer to Wiring Diagram...

Page 517: ...amp leveling switch If the headlamp leveling switch is faulty the headlamp switch must be replaced HEADLAMP SWITCH DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HEADLAMP SWITCH Using a Digital Multi met...

Page 518: ...SWITCH POSITION 13 WAY CONNECTOR TERMINAL RESISTANCE 0 1 TO 7 3238 3456 V 1 TO 2 3181 3400 V 1 1 TO 7 1195 1225 V 2 1 TO 7 746 765 V REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remo...

Page 519: ...18 2 If necessary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 Rock vehicle side to side three times and allow suspension to stabilize 4 Jounce front suspension thre...

Page 520: ...e perpendicu lar to a flat wall 10 meters 32 8 ft away from front of headlamp lens Fig 20 2 If necessary tape a line on the floor 10 meters 32 8 ft away from and parallel to the wall 3 Rock vehicle si...

Page 521: ...ORT 1 CENTER OF VEHICLE 5 10 METERS 32 8 FT 2 CENTER OF HEADLAMPS 6 HORIZONTAL CUT OFF LINE 3 15 CUT OFF LINE 7 110 mm 4 3 in 4 FRONT OF HEADLAMP Fig 21 HEADLAMP UNIT ADJUSTMENT 1 HEADLAMP ADJUSTMENT...

Page 522: ...resistive MUX switch that feeds inputs to the BCM OPERATION TURN SIGNAL SYSTEM Lane change signaling is actuated by applying par tial turn signal stalk movement toward the direction desired until the...

Page 523: ...ering column adapter collar 5 Remove the multi function switch INSTALLATION 1 Position the switch on to the steering column 2 Install the two retaining screws 3 Connect the wire harness connector 4 In...

Page 524: ...negative cable 2 Remove the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL 3 Squeeze the tabs on the bulb socket and remove from tail lamp unit Fig 28 4 Pull bulb...

Page 525: ...Disconnect wire harness connector from tail lamp unit by sliding the red lock then pressing release tab Fig 31 INSTALLATION 1 Reconnect wire harness connector to the tail lamp Slide lock into positio...

Page 526: ...LARM SET PC74 AUTOSTICK VFD BRAKE SYSTEM WARNING LED CONSOLE 194 CRUISE INDICATOR VFD DOME RAIL LAMPS 578 DOOR AJAR INDICATOR LED DOOR COURTESY LAMP 578 FRONT DOOR COURTESY 567 GLOVE BOX 194 HIGH BEAM...

Page 527: ...Installation COURTESY LAMP REMOVAL 1 Disconnect and isolate the battery negative cable 2 Using a trim stick pry lamp from door panel Fig 1 3 Disconnect wire harness from the lamp 4 Remove lens from t...

Page 528: ...y negative cable READING LAMP REMOVAL The front reading lamps are incorporated into the overhead console If the reading lamps require replacement the overhead console must be replaced Refer to 8 ELECT...

Page 529: ...y 1 Disconnect and isolate the battery negative cable 2 Using a pick or other suitable tool pry the lens from the lamp Fig 8 3 Remove bulb INSTALLATION 1 Install bulb 2 Snap lamp lens into position 3...

Page 530: ...ea tures The overhead console is mounted with one screw and two snap clips to a molded plastic retainer bracket located above the headliner DESCRIPTION COMPASS All the available overhead consoles on t...

Page 531: ...egrated power module as required 3 Check the fused ignition switch output run start fuse in the integrated power module If OK go to Step 4 If not OK repair the shorted circuit or component as required...

Page 532: ...pass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use If the compass read ings appear to be erratic or out of calibration per form the foll...

Page 533: ...degaussing tool connected 9 Contact the roof panel with the plastic coated tip of the degaussing tool Be sure that the template is in place to avoid scratching the roof panel Using a slow back and fo...

Page 534: ...e correct directions are now indicated by the compass REMOVAL OVERHEAD CONSOLE 1 Disconnect and isolate the remote negative bat tery cable 2 Remove the overhead console retaining screw located in the...

Page 535: ...f battery current so that some of its features remain operational at any time while others may only operate with the ignition switch in the On position When the ignition switch is turned to the On pos...

Page 536: ...able features appear in the selected language DISPLAY U S OR METRIC The options include U S and M The default is U S This feature toggles the trip computer temperature fuel economy and odometer displa...

Page 537: ...ption When Off is selected the headlamp delay feature is disabled HEADLAMPS ON WITH WIPERS This pro grammable feature only applies to vehicles equipped with the optional Auto Headlamps The options inc...

Page 538: ...TC and Com pass Temperature CT data is obtained from the Body Control Module BCM on the J1850 Data Bus circuit The CMTC and CT will display dashes for any of the screens it did not receive the bus mes...

Page 539: ...universal transmitter with a known good transmitter as instructed in the owner s manual and test the universal transmitter operation again If the unit is still inoperative replace the faulty universa...

Page 540: ...turn circuit and the ambient temperature sensor signal circuit cavities of the Front Control Module wire har ness connector There should be continuity If OK go to Step 4 If not OK repair the open sens...

Page 541: ......

Page 542: ...LATION 9 FULL OPEN SWITCH DESCRIPTION 10 OPERATION 10 REMOVAL 10 INSTALLATION 10 LIFTGATE MOTOR DESCRIPTION 10 OPERATION 11 REMOVAL 11 INSTALLATION 11 ENGAGE ACTUATOR DESCRIPTION 11 OPERATION 11 REMOV...

Page 543: ...part of the liftgate gear motor assembly The pawl and ratchet switches are part of the latch assembly The pinch sensor or sensors are located along the right and left sides of the power liftgate just...

Page 544: ...ol module BCM The BCM then sends a signal out on the J1850 PCI Data Bus circuit to the power liftgate module The power liftgate module then signals the power liftgate motor to start an open or close c...

Page 545: ...G NEVER STICK OBJECTS IN THE POWER LIFTGATE WHEN CINCHING CLOSED YOU COULD DAMAGE THE VEHICLE POWER LIFTGATE SYS TEM COMPONENTS AND OR CAUSE PERSONAL INJURY DIAGNOSIS AND TESTING POWER LIFTGATE SYSTEM...

Page 546: ...he necessary components Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Replace latch assembly if necessary Bind...

Page 547: ...nding and replace necessary components Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module function liftgate if no function exists check for loose wire c...

Page 548: ...t then reconnect battery to reset module function liftgate if no function exists check for loose wire connections see Body Diagnostic Manual for detailed procedures Failure of liftgate motor assembly...

Page 549: ...ilure of liftgate motor assembly Check wire connections Replace motor assembly if necessary Failure of liftgate prop rods Replace prop rods if necessary Binding or sticking of components Establish loc...

Page 550: ...ng a power close cycle OPERATION During a power liftgate close cycle if either of the two conductive rubber strips tapeswitch of the pinch sensor come in contact with an obstacle the pinch sensor circ...

Page 551: ...re ends and reinstall in the main lift gate motor electrical connector 2 Position and install the full open switch retain ing screw 3 Install the power liftgate lift gear and link rod assembly Refer t...

Page 552: ...bolts from the motor housing and the one bolt from the transverse mount bracket 5 Grab the liftgate motor assembly and lift upward and out to unhook the motor assembly from the D pillar 6 Remove the...

Page 553: ...ve battery cable 6 Using an appropriate scan tool check and erase any power liftgate control module diagnostic trouble codes 7 Verify power liftgate system and engage actua tor operation Cycle the pow...

Page 554: ...or assembly electrical con nector and engage retaining pushpin 6 Install the appropriate D pillar trim from the vehicle Refer to Body for the procedure LIFT GEAR LINK ROD DESCRIPTION Vehicles equipped...

Page 555: ...ease latch This latch performs the same features as a manual liftgate latch as well as the power cinch and or release capability A second type of power latch can also be found on some RS models this l...

Page 556: ...d close cycle this will allow the power liftgate control module to relearn its cycle with the new components 8 Verify power liftgate manual operation Using liftgate key rotate the lock cylinder to ver...

Page 557: ...unted can be used to perform a full power open cycle The exterior handle switch is a serviceable compo nent Consult your Mopar parts catalog for a spe cific part number OPERATION When the exterior han...

Page 558: ...tion provides an audible chime sound which is controlled by the power liftgate module The chime thermistor assembly is hardwired to the power liftgate module Second the thermistor provides a outside t...

Page 559: ...a right side power door or right and left side power doors This power sliding door system is a complex system consisting of many components Some of these components are the door motor latch assembly...

Page 560: ...liding door system through a 40 amp fuse located in the Intelligent Power Module IPM assembly Fig 3 The child lockout switch pre vents children from opening or actuating the power sliding door system...

Page 561: ...s made the module must re learn the effort required to open or close the door A learn cycle can be performed with a Diagnostic Scan Tool such as the DRB IIIt or with a complete cycle of the door using...

Page 562: ...ining many compo nents and modules In order to obtain conclusive testing the Programmable Communications Interface J1850 data bus network and all of the electronic modules that provide inputs to or re...

Page 563: ...ble connections at latch and handle assembly Check for binds or kinks in cable Check for foreign matter preventing the operation of handle assembly Replace the handle if necessary Failure of latch ass...

Page 564: ...nect then reconnect battery to reset module function door if no function exists check for loose wire connections see Body Diagnostic Manual for detailed procedures Failure of latch assembly Check wire...

Page 565: ...s check for loose wire connections see Body Diagnostic Manual for detailed procedures Door seal force too high Inspect seals for damage mis assembly foreign matter Refer to Door adjustment in the Body...

Page 566: ...Replace BCM if necessary Failure of key fob Replace key fob battery Replace key fob if necessary Failure of sliding door control module Disconnect then reconnect battery to reset module function door...

Page 567: ...ics Refer to wiring diagrams Door continues to open during power mode runaway motor Failure of sliding door control or body control module Disconnect then reconnect battery to reset module function do...

Page 568: ...at the system is performing properly and is able to be returned to ser vice To perform a power door learn cycle do the fol lowing 1 Obtain a DRB IIIt scan tool Connect the DRB IIIt to the vehicle and...

Page 569: ...ual door latch as well as power cinch release lock and unlock operations The power latch mounted actuator cinches the door closed and latches it in its primary latched position During a power close cy...

Page 570: ...DESCRIPTION Vehicles equipped with a power sliding door utilize a door motor assembly The door motor is located in the center of the side door Fig 7 and is comprised of three parts The three parts of...

Page 571: ...cedure FULL OPEN SWITCH DESCRIPTION Vehicles equipped with a power sliding door utilize a full open switch This switch is located in the hold open latch Fig 9 under the side door lower hinge When the...

Page 572: ...appropriate power side door The B pillar switches are replaceable Consult your Mopar parts catalog for a specific part number OPERATION When the Pillar switch is depressed a signal is sent to the Body...

Page 573: ...e flex drive collar straight on until the it snaps in place Fig 12 3 Install the lower drive unit retaining fasteners Fig 12 Torque the larger allen headed center stud to 9 N m 80 in lbs Torque the sm...

Page 574: ...le 2 Remove the side door sill plate from the lower of the door opening Refer to the Body section for the procedure 3 Remove the hold open striker Refer to Body for the procedure 4 Position a floor ja...

Page 575: ...ground and other various electrical connections to the side sliding door During sliding door movement the wir ing track folds and unfolds like the links in a chain REMOVAL 1 Disconnect and isolate th...

Page 576: ...the Body section for the procedure 10 Connect the negative battery cable FLEX DRIVE DESCRIPTION Vehicles equipped with a power sliding side door utilize a flex drive assembly The flex drive assembly i...

Page 577: ...traight off the lower drive unit 8 Remove the flex drive assembly from the vehi cle INSTALLATION 1 Position the flex drive assembly in the vehicle 2 Install the flex drive on the lower drive unit Push...

Page 578: ...uter for the power sliding side door system All power door functions are processed through the power door control module and or the vehicles body control module BCM At the start of a power open comman...

Page 579: ...odule from the vehicle INSTALLATION 1 Position the control module and install the retaining screw 2 Connect the control module electrical connec tors Slide the locking tab into the locked position 3 I...

Page 580: ...Rolling automatic lock ENABLE doors auto matically lock at approximately at 25 7 Km h 16 mph No rolling automatic lock DISABLE doors do not automatically lock when the vehicle is moving AUTOMATIC DOO...

Page 581: ...l power door lock function ing shall be disabled when activating either door lock switch Also if the Vehicle Theft Alarm VTA is armed the door lock switch UNLOCK feature will be disabled until the veh...

Page 582: ...r set ting 1 or 2 Two additional key fob transmitters can be added but they will not be able to operate the mem ory seat and mirror system Refer to 8 ELECTRI CAL POWER SEATS OPERATION and Refer to 8 E...

Page 583: ...t the motor connectors one at a time while operating the door lock switch In the event that none of the motors work the problem may be caused by a shorted motor or a bad switch Disconnecting the defec...

Page 584: ...or all transmitters STANDARD PROCEDURE BATTERY REPLACEMENT 1 With the transmitter buttons facing down use a coin a penny is suggested to pry the two halves of the transmitter apart Fig 3 Make sure not...

Page 585: ...LOCK button for a minimum five seconds maximum ten seconds 5 While still holding UNLOCK button and before ten seconds passes press the PANIC button and release both at the same time A single chime wil...

Page 586: ...nd pad as necessary 4 Remove latch lock control cover 5 Remove latch lock control 6 Remove screws holding door lock motor to latch lock control Fig 5 7 Remove lock motor from control INSTALLATION 1 Po...

Page 587: ...An optional driver side outside electrochromic mir ror is able to automatically change its reflectance level This mirror is controlled by the circuitry of the automatic day night inside rear view mirr...

Page 588: ...or is able to automat ically change its reflectance A thin layer of electro chromic material between two pieces of conductive glass make up the face of the mirror Two photocell sensors are used to mon...

Page 589: ...wire harness connector and a good ground There should be conti nuity If OK go to Step 5 If not OK repair the cir cuit to ground as required 5 Turn the ignition switch to the On position Set the parkin...

Page 590: ...onnect wire connector from power mirror switch 5 Disengage lock tabs above and below the mir ror switch 6 Remove power mirror switch from headlamp switch bezel INSTALLATION 1 Install power mirror swit...

Page 591: ...ting and retention connector pin out information and location views for the various wire harness connectors splices and grounds REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the...

Page 592: ...system option allows the driver and front seat passenger to electrically adjust their seating positions for optimum control and comfort using the power seat switches located on the out board seat cush...

Page 593: ...d or when the doors are unlocked using the corresponding Remote Keyless Entry RKE transmitter A customer programmable feature of the memory system allows the RKE recall of memory features to be disabl...

Page 594: ...ons are requested the priority for response will be as follows Seat Track Rearward or Forward Seat Front Down or Up Seat Rear Down or Up Recliner Rearward or Forward The inputs from these switches to...

Page 595: ...direction of the failure If the dome lamp dims the seat may be jamming Check under and behind the seat for binding or obstructions If the dome lamp does not dim proceed with testing of the individual...

Page 596: ...on the power seat switch functions and the seat adjusting procedures DIAGNOSIS AND TESTING DRIVER SEAT SWITCH 1 Remove the power seat switch refer to the Switch Removal and Installation procedures in...

Page 597: ...en the screws to 1 5 N m 14 in lbs 6 Install the switch knobs on the switch control levers if equipped 7 Reconnect the battery negative cable MEMORY SET SWITCH DESCRIPTION Vehicles equipped with the m...

Page 598: ...o screws that secure the memory switch to the back of the driver side front door trim panel switch bezel Tighten the screws to 2 2 N m 20 in lbs 2 Reconnect the memory switch wire harness connector to...

Page 599: ...TER SWITCH FORWARD PIN 5 3 PIN 1 10 CENTER SWITCH REARWARD PIN 5 10 PIN 3 1 REAR RISER UP PIN 5 8 PIN 1 7 REAR RISER DOWN PIN 5 7 PIN 1 8 RECLINER UP PIN 5 2 PIN 4 1 RECLINER DOWN PIN 5 4 PIN 2 1 REMO...

Page 600: ...re recommended The MSMM cannot be repaired and if faulty or damaged it must be replaced Refer to Memory System in the Power Seat or Power Mirror section of this manual for more information on the memo...

Page 601: ...ve unit in the selected direc tion until the switch is released or until the travel limit of the adjuster is reached When the switch is moved in the opposite direction the battery feed and ground path...

Page 602: ...e seat cushion pan 9 Remove the power seat track from the seat INSTALLATION 1 Position the seat cushion on the seat track 2 Install the four seat track retaining bolts in the seat cushion pan Torque t...

Page 603: ...n to be certain that the adjuster is not at its travel limit If the power seat track adjuster still fails to operate in only one direction refer to Diagnosis and Testing Power Seat Switch in this sect...

Page 604: ...Remove the power seat track from the seat INSTALLATION 1 Position the seat cushion on the seat track 2 Install the four seat track retaining bolts in the seat cushion pan Torque the bolts to 28 5 N m...

Page 605: ...hrough these same two connections will cause the motor to rotate in the opposite direction Refer to the appropriate wiring information The wir ing information includes wiring diagrams proper wire and...

Page 606: ...pillar trim panel necessary to gain access to power vent window motor wire connector Refer to 23 BODY INTERIOR LEFT D PILLAR TRIM PANEL REMOVAL or Refer to 23 BODY INTERIOR RIGHT D PILLAR TRIM PANEL...

Page 607: ...ITCH POSITION CONTINUITY BETWEEN OFF 13 and 1 13 and 2 13 and 3 13 and 4 13 and 5 13 and 6 13 and 7 13 and 8 UP DRIVER 11 and 8 DOWN DRIVER 11 and 6 X DOWN DRIVER 11and 6 UP PASSENGER 9 and 4 DOWN PAS...

Page 608: ...motor The AUTO feature can be cancelled by actuat ing the switch UP or DOWN while window is in motion If the electronic circuit in the switch fails to detect a stall current the auto down circuit wil...

Page 609: ......

Page 610: ...D SWB THREE DOOR REMOVAL 8 INSTALLATION 8 SEAT BELT FIRST ROW OUTBOARD SWB FOUR DOOR REMOVAL 9 INSTALLATION 9 SEAT BELT FIRST ROW OUTBOARD LWB FOUR DOOR REMOVAL 10 INSTALLATION 10 SEAT BELT SECOND RIG...

Page 611: ...IN PERSONAL INJURY WHEN CARRYING OR HANDLING AN UNDEPLOYED AIRBAG MODULE THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTING AWAY FROM THE BODY TO MINIMIZE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT O...

Page 612: ...travel rotate the rotor two turns counterclockwise until the wires end up at the top 7 Install steering wheel and airbag WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REFER TO ELECTRICAL RESTRAI...

Page 613: ...er airbag from steering wheel 4 Disconnect wire connectors from Airbag and Clock Spring 5 Adjust the steering wheel so that the tires are in a straight ahead position Remove steering wheel Refer to 19...

Page 614: ...us injury caused by a frontal impact of the vehicle The Occupant Restraint Controller ORC contains the impact sensor and energy reserve capacitor It is mounted on a bracket under the instrument panel...

Page 615: ...river Airbag Passenger Airbag Upper Instrument Panel with Pad CARE OF UNDEPLOYED AIRBAGS Airbags must be stored in their original special container until used for service At no time should a source of...

Page 616: ...l tear open and allow the side airbag to fully inflate and quickly deflate SEAT BELT OUTBOARD FRONT REMOVAL Inspect the condition of the shoulder belt and lap belt Replace any belt that is cut frayed...

Page 617: ...ve lower quarter trim panel 12 Route seat belt webbing and turning loop through access hole in lower quarter trim panel 13 Remove bolt attaching seat belt retractor to quarter panel 14 Lift retractor...

Page 618: ...lt from vehicle INSTALLATION 1 Install seat belt into position 2 Lower retractor into position to quarter panel 3 Install bolt attaching seat belt retractor to quarter panel Tighten seat belt anchor b...

Page 619: ...djuster 13 Install first and second row seats Refer to Owner s manual for proper procedures NOTE The tightening specification for all seat belt anchor bolts is 39 N m 29 ft lbs torque SEAT BELT SECOND...

Page 620: ...el Fig 8 d Remove screws attaching upper evaporator housing to lower evaporator housing e Remove coolant line retaining bracket hold down bolt 13 Remove bolts attaching seat belt guide loop to inner q...

Page 621: ...er anchor cover from over the anchor shoulder nut 3 Remove lower anchor shoulder nut 4 Remove lower anchor from wheelhouse Fig 9 5 Remove D pillar trim panel 6 Route seat belt webbing and turning loop...

Page 622: ...move side cover from seat 4 Remove bolts attaching recliner bracket to seat cushion 5 Remove recliner bracket from seat 6 Remove bolt attaching seat belt buckle to seat track Fig 10 7 Remove buckle fr...

Page 623: ...nt in their respective seat by retracting the seat belt up to four inches They are integral to the front seat belt buckles and cannot be serviced If found defective they must be replaced After an airb...

Page 624: ...2 Install screws attaching shoulder belt height adjuster to pillar Tighten seat belt anchor bolts to 39 N m 29 ft lbs torque 3 Install B or C pillar trim cover SHOULDER BELT HEIGHT ADJUSTER KNOB REMOV...

Page 625: ...require airbag protection the SIACM microprocessor sends a signal to deploy the side airbag that completes the electrical circuits to the right or left side airbag The sensor is cali brated for the sp...

Page 626: ...d on the right side of the airbag module Fig 1 The system is designed to operate at speeds above 30 mph 48 km h WARNING THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT PERMI...

Page 627: ...de the interactive speed con trol tries to maintain the set speed by increasing the throttle opening while inhibiting delaying down shifts OPERATION If opening the throttle alone cannot maintain the s...

Page 628: ...eter operation should be smooth and without flut ter at all speeds Flutter in the speedometer indicates a problem which might cause surging in the speed control sys tem The cause of any speedometer pr...

Page 629: ...enoids Vacuum Vent Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage OPERATION The PCM controls the solenoid valve body The solenoid valve body control...

Page 630: ...and are located on the steering wheel OPERATION The speed control system has five separate resis tive switches that provide a single multiplexed MUX voltage inputs to the PCM The switch names are ON...

Page 631: ...ment It is made of plastic 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 so...

Page 632: ...n with the molded integral antenna mounted on the ignition housing The indicator light is located in the message center OPERATION VEHICLE THEFT SECURITY SYSTEM Upon failure of proper SKIM communicatio...

Page 633: ...y locking the front doors with the doors closed and the ignition locked will begin the arming time out period If method A 16 second time out sequence was in process when method B was actuated the 16 s...

Page 634: ...use a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual to complete the diagnosis of the SKIS If not OK repair the open circuit to the fuse in the IPM as required DIAGNOSIS AND TEST...

Page 635: ...plete this task since you will need it to enter the Secured Access Mode in the SKIM The following steps must be completed using a DRB IIIt scan tool 1 Insert the blank key into the ignition and turn i...

Page 636: ...if It sees a non blank Sentry Key when it should see a blank If it has already programmed eight 8 valid Sentry Keys If the ignition switch is turned to the OFF posi tion for more than about fifty 50 s...

Page 637: ......

Page 638: ...AR WIPER MOTOR REMOVAL 16 INSTALLATION 16 REAR WIPER WASHER SWITCH DESCRIPTION 16 OPERATION 16 WASHER FLUID LEVEL SWITCH REMOVAL 16 INSTALLATION 17 WASHER HOSES REMOVAL 17 INSTALLATION 17 WASHER RESER...

Page 639: ...ery 7 seconds The intermit tent delay time is also adjusted based upon vehicle speed With the vehicle traveling greater than 50 mph the cycle changes to every 5 seconds DIAGNOSIS AND TESTING DIAGNOSIS...

Page 640: ...TO WIPER ARM REMOVAL AND INSTALLATION 3 MOTOR CRANK LOOSE AT OUTPUT SHAFT 3 REMOVE WIPER ARM RUN WIPER MOTOR TO PARK POSITION AND REMOVE THE MODULE WITHOUT ROTATING THE MOTOR OUTPUT SHAFT REMOVE THE...

Page 641: ...ACE WIPER MOTOR REFER TO WIPER MOTOR REMOVAL AND INSTALLATION WIPER MOTOR WILL NOT RUN 1 BLOWN FUSE 1 REPLACE FUSE AND RUN SYSTEM 2 NEW FUSE BLOWS 2 CHECK FOR SHORT IN WIRING OR SWITCH 3 NEW FUSE BLOW...

Page 642: ...E 2 PROPERLY INSTALL IPM FUSE 33 IN SOCKET BLOWN FUSE WHEN IGNITION SWITCH IS IN THE RUN OR ACCESSORY POSITION 1 SHORT IN IPM BETWEEN FUSE 33 AND PIN 11 OR PIN 1 1 REFER TO IPM DIAGNOSTIC PROCEDURES I...

Page 643: ...IRCUIT BETWEEN IPM BODY CONTROLLER PIN 22 AND WASHER SELECT SWITCH PIN 2 IF NOT OK REPAIR CIRCUIT 7 OPEN OR DEFECTIVE WASHER SELECT SWITCH 7 Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MULTI FUNCTIO...

Page 644: ...OUTPUT IS LOW 1 PARTIALLY PINCHED HOSE 1 ASSURE WASHER HOSE IS NOT PARTIALLY PINCHED IF NOT OK PROPERLY ROUTE HOSE 2 REVERSE POLARITY TO PUMP 2 CHECK FOR CROSSED CIRCUIT TO PUMP IF NOT OK REPAIR CIRCU...

Page 645: ...4 REFER TO IPM DIAGNOSTIC PROCEDURES IN WIRING DIAGRAMS 5 FLUID LEVEL SENSOR SWITCH OPEN OR DEFECTIVE 5 APPLY OHMMETER TO THE SWITCH TERMINALS TO CHECK FOR COMPLETE CIRCUIT CYCLE SWITCH FLOAT BACK AND...

Page 646: ...nst the reservoir and that pump connector is fac ing up in the fully seated position Assure the pump is aligned to and fully seated in the reservoir cavity 3 Push filler neck and front washer hose thr...

Page 647: ...EMOVAL 1 Remove the front wiper motor from vehicle Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE REMOVAL 2 Remove four backwall bolts and four brace nuts 3 Remove wiper linkage from wiper module 4...

Page 648: ...rs headlamps ON and windshield washer control depressed the headlamp washers will spray its two timed pulses every fourth request from the washer control DIAGNOSIS AND TESTING HEADLAMP WASHERS EXPORT...

Page 649: ...IPER WASHER SWITCH TERMINAL 1 AND 2 AND DEPRESS WASHER BUTTON AND CHECK FOR CONTINUITY IF NOT OK REFER TO WIPER WASHER SWITCH DIAGNOSTIC PROCEDURES 8 OPEN POWER CIRCUIT TO MOTOR 8 OPEN OR DEFECTIVE CI...

Page 650: ...firmly until snap is heard 8 Remove vehicle from hoist or jack stands 9 Connect the battery negative cable 10 Verify vehicle and system operation HEADLAMP WASHER HOSE EXPORT REMOVAL The headlamp washe...

Page 651: ...r hose by firmly pushing hose onto inlet until a snap is heard 8 Connect the left right front wheelhouse splash shield and move aside Refer to 23 BODY EXTERI OR WHEELHOUSE SPLASH SHIELD INSTALLA TION...

Page 652: ...evel sen sor Slide the red lock on the connector to the closed or locked position 6 Assure that washer hose is properly routed to prevent pinching and possible inoperative washers 7 Connect the left r...

Page 653: ...REAR WIPER WASHER SWITCH DESCRIPTION The rear window wiper washer switches are located on the center bezel with the hazard and heated seat switches Fig 7 They are not service able separately from the...

Page 654: ...sh filler neck and front washer hose through the opening in the front fender side shield Connect the reservoir to the body mount by lowering the res ervoir down 4 Install the two reservoir mounting sc...

Page 655: ...hat the reservoir filler neck and front washer hose pull through the opening in the front fender side shield INSTALLATION 1 Push filler neck and front washer hose through the opening in the front fend...

Page 656: ...iper unit 4 Remove cowl cover brackets from the wiper unit 5 Remove nuts holding linkage to the wiper unit 6 Remove the wiper linkage from the wiper unit 7 Disconnect the wire connectors from back of...

Page 657: ...nector to the wiper module Fig 11 7 Connect the positive lock on the wiper module wire connector Fig 10 CAUTION Do not allow wiper module to rest on brake master cylinder reservoir damage to brake sys...

Page 658: ...USTER 8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 BODY CONTROL MODULE 8W 45 1 MESSAGE CENTER 8W 46 1 AUDIO SYSTEM 8W...

Page 659: ......

Page 660: ...iring content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics Diagr...

Page 661: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION Continued...

Page 662: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 RS 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued...

Page 663: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION Continued...

Page 664: ...t Vehicles Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and c...

Page 665: ...r group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can howev...

Page 666: ...general warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER...

Page 667: ...for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify...

Page 668: ...r lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with...

Page 669: ...round has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 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 t...

Page 670: ...moved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pi...

Page 671: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION RS CONNECTOR Continued...

Page 672: ...APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPE...

Page 673: ...ected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire fr...

Page 674: ...of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION...

Page 675: ......

Page 676: ...trol Module 8W 30 Engine Coolant Temp Sensor 8W 30 Engine Oil Pressure Switch 8W 30 EVAP Purge Solenoid 8W 30 Evaporator Temperature Sensor 8W 42 Floor Console Lamp 8W 44 Component Page Fog Lamps 8W 5...

Page 677: ...W 42 Rear Blower Motor 8W 42 Rear Blower Rear Control Switch 8W 42 Rear Intrusion Sensor 8W 39 Component Page Rear Lamp Assemblies 8W 51 Rear Mode Motor 8W 42 Rear Power Outlet 8W 41 Rear Temperature...

Page 678: ...dule 8W 10 19 38 Front Blower Motor Relay 8W 10 18 19 38 63 Front Cigar Lighter 8W 10 16 32 Front Control Module 8W 10 15 16 17 18 19 20 22 24 26 27 28 29 30 31 36 37 38 39 45 47 52 53 54 57 58 59 60...

Page 679: ...ror Switch 8W 10 22 24 46 47 Power Outlet 8W 10 36 Component Page Power Seat Circuit Breaker 8W 10 25 49 Power Window Circuit Breaker 8W 10 16 31 Power Window Switch 8W 10 34 Powertrain Control Module...

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Page 746: ...Ajar Switch 8W 15 14 Left Sliding Door Motor 8W 15 14 Left Stop Turn Signal Relay 8W 15 24 Left Turn Signal Lamp 8W 15 18 Left Visor Vanity Lamp 8W 15 21 License Lamp 8W 15 23 26 Lift Pump Motor 8W 15...

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Page 772: ...8W 18 2 3 G101 8W 18 2 3 G300 8W 18 2 3 Instrument Cluster 8W 18 4 Component Page Integrated Power Module 8W 18 2 3 Integrated Power Module 8W 18 4 Left Side Impact Airbag Control Module 8W 18 5 Left...

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Page 778: ...sor 8W 20 3 ECM PCM Relay 8W 20 3 Engine Control Module 8W 20 3 Fuse 16 8W 20 2 3 Fuse 17 8W 20 2 Component Page Fuselink 8W 20 2 3 G100 8W 20 2 3 G101 8W 20 2 3 Generator 8W 20 2 3 Integrated Power M...

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Page 782: ...W 21 2 Engine Control Module 8W 21 3 Front Control Module 8W 21 2 Fuse 9 8W 21 2 3 Fuselink 8W 21 2 3 Component Page G101 8W 21 2 3 Generator 8W 21 2 3 Ignition Switch 8W 21 2 3 Integrated Power Modul...

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Page 786: ...id 8W 30 20 Fuel Pump Module 8W 30 4 19 Fuel Pump Relay 8W 30 4 Fuse 14 8W 30 17 Fuse 15 8W 30 22 29 Fuse 16 8W 30 2 5 7 8 12 13 18 20 24 26 28 Fuse 17 8W 30 2 4 19 29 Component Page Fuse 18 8W 30 18...

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Page 818: ...8W 31 5 Ignition Switch 8W 31 9 Component Page Input Speed Sensor 8W 31 5 Integrated Power Module 8W 31 2 4 5 6 7 8 9 Output Speed Sensor 8W 31 5 Park Neutral Position Switch 8W 31 9 Powertrain Contr...

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Page 828: ...33 4 Engine Control Module 8W 33 4 G103 8W 33 3 G300 8W 33 4 Component Page Left Speed Control Switch 8W 33 2 4 Powertrain Control Module 8W 33 2 3 Right Speed Control Switch 8W 33 2 4 Speed Control...

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Page 832: ...ol Module 8W 35 3 Fuse 9 8W 35 2 Fuse 21 8W 35 2 Fuse 26 8W 35 3 G100 8W 35 2 Component Page G200 8W 35 2 G300 8W 35 3 Integrated Power Module 8W 35 2 3 Left Front Wheel Speed Sensor 8W 35 4 Left Rear...

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Page 836: ...ontrol Module 8W 39 9 10 Component Page Left Sliding Door Latch Sensing Switch 8W 39 9 Left Sliding Door Lock Motor 8W 39 10 Left Sliding Door Lock Motor Ajar Switch 8W 39 11 Liftgate Ajar Switch 8W 3...

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Page 852: ...itch 8W 40 3 Left Sliding Door Control Module 8W 40 4 Left Sliding Door Latch Sensing Switch 8W 40 4 Component Page Left Sliding Door Lock Motor Ajar Switch 8W 40 4 Left Speed Control Switch 8W 40 9 L...

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Page 864: ...3 Front Control Module 8W 41 2 3 4 Fuse 5 8W 41 3 4 Fuse 6 8W 41 3 4 Fuse 8 8W 41 2 G102 8W 41 2 G200 8W 41 3 4 Component Page G302 8W 41 3 4 High Note Horn 8W 41 2 Horn Relay 8W 41 2 Horn Switch 8W...

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Page 868: ...7 Fuse 18 8W 42 14 16 Fuse 27 8W 42 15 18 Fuselink 8W 42 17 G102 8W 42 15 18 Component Page G103 8W 42 14 16 G200 8W 42 2 3 4 6 8 9 11 12 G300 8W 42 7 13 G302 8W 42 12 Integrated Power Module 8W 42 2...

Page 869: ...2002 RS Service Manual Publication No 81 370 02062 TSB 26 12 01 December 2001...

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Page 873: ...2002 RS Service Manual Publication No 81 370 02062 TSB 26 12 01 December 2001...

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Page 886: ...nsioner 8W 43 3 Front Control Module 8W 43 2 6 7 G200 8W 43 2 G201 8W 43 2 6 7 Component Page Instrument Cluster 8W 43 2 Integrated Power Module 8W 43 2 6 7 Left Seat Airbag 8W 43 6 Left Side Impact A...

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Page 894: ...alo Lamp 8W 44 2 Headlamp Switch 8W 44 3 5 6 7 8 Component Page Instrument Cluster 8W 44 7 Instrument Panel Switch Bank 8W 44 7 Integrated Power Module 8W 44 4 Left Liftgate Flood Lamp 8W 44 2 Left Mi...

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Page 902: ...r Lock Motor 8W 45 7 Left Sliding Door Lock Motor Ajar Switch 8W 45 7 8 Component Page Left Stop Turn Signal Relay 8W 45 5 Left Visor Vanity Lamp 8W 45 13 License Lamp 8W 45 8 Liftgate Ajar Switch 8W...

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Page 922: ...6 MESSAGE CENTER Component Page Body Control Module 8W 46 2 Fuse 24 8W 46 2 Instrument Cluster 8W 46 2 Component Page Integrated Power Module 8W 46 2 Message Center 8W 46 2 RS 8W 46 MESSAGE CENTER 8W...

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Page 924: ...tegrated Power Module 8W 47 2 5 6 Left Door Speaker 8W 47 3 8 9 Component Page Left Instrument Panel Speaker 8W 47 3 8 Left Rear Pillar Speaker 8W 47 10 Left Rear Speaker 8W 47 4 6 10 Left Remote Radi...

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Page 936: ...gger Relay 8W 48 2 Electric Wiper De Icer 8W 48 2 Front Control Module 8W 48 2 Fuse 11 8W 48 2 Fuse 13 8W 48 2 Component Page G200 8W 48 3 G400 8W 48 2 Integrated Power Module 8W 48 2 Left Power Mirro...

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Page 940: ...49 2 3 4 Diagnostic Junction Port 8W 49 4 Front Control Module 8W 49 2 Front Reading Lamps Switch 8W 49 4 Fuse 14 8W 49 2 Component Page G301 8W 49 4 Integrated Power Module 8W 49 2 Left Power Mirror...

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Page 944: ...7 8 9 10 11 Left Fog Lamp 8W 50 11 Left Front Park Turn Signal Lamp 8W 50 4 Component Page Left Headlamp 8W 50 3 Left Headlamp Leveling Motor 8W 50 6 10 Left High Beam Lamp 8W 50 6 7 Left Low Beam La...

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Page 956: ...se 2 8W 51 2 4 Fuse 3 8W 51 2 4 5 Fuse 26 8W 51 2 4 G101 8W 51 5 G103 8W 51 5 Component Page G302 8W 51 2 3 4 5 G400 8W 51 6 Integrated Power Module 8W 51 2 4 5 Left Rear Lamp Assembly 8W 51 2 3 4 5 L...

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Page 962: ...Park Turn Signal Lamp 8W 52 2 Left Rear Lamp Assembly 8W 52 4 Component Page Left Repeater Lamp 8W 52 6 Left Stop Turn Signal Relay 8W 52 4 5 Left Turn Signal Lamp 8W 52 3 Multi Function Switch 8W 52...

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Page 968: ...8W 53 2 Fuse 4 8W 53 2 Fuse 11 8W 53 3 Fuse 30 8W 53 4 Fuse 33 8W 53 3 G102 8W 53 4 Component Page G200 8W 53 6 G300 8W 53 2 G400 8W 53 3 Headlamp Washer Pump Motor 8W 53 4 Headlamp Washer Relay 8W 53...

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Page 974: ...W 54 2 G302 8W 54 2 Integrated Power Module 8W 54 2 Left Combination Relay 8W 54 3 Component Page Left Rear Lamp Assembly 8W 54 2 Left Stop Turn Signal Relay 8W 54 2 3 Park Lamp Relay 8W 54 2 Right Co...

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Page 978: ...l Module 8W 60 2 Fuse 28 8W 60 2 G300 8W 60 3 4 7 G301 8W 60 5 6 Component Page Integrated Power Module 8W 60 2 Left Rear Vent Motor 8W 60 3 6 Passenger Power Window Motor 8W 60 5 7 Passenger Power Wi...

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Page 986: ...61 7 9 Left Sliding Door Lock Motor 8W 61 13 Component Page Left Sliding Door Lock Motor Ajar Switch 8W 61 14 Left Sliding Door Motor 8W 61 8 License Lamp 8W 61 18 19 Liftgate Ajar Switch 8W 61 15 Li...

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Page 1006: ...W 62 2 3 4 5 10 Integrated Power Module 8W 62 2 3 4 5 9 10 Left Power Mirror 8W 62 2 4 7 8 9 10 Component Page Memory Seat Mirror Module 8W 62 3 6 7 8 Memory Set Switch 8W 62 3 Passenger Folding Mirro...

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Page 1016: ...ecliner Motor 8W 63 2 7 Driver Power Seat Recliner Position Sensor 8W 63 8 Component Page Driver Power Seat Switch 8W 63 2 6 Fuse 22 8W 63 2 4 G200 8W 63 2 4 6 9 G301 8W 63 3 10 Instrument Panel Switc...

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Page 1026: ...05 8W 42 7 S206 8W 10 50 S207 8W 42 5 S208 8W 45 10 S209 8W 18 5 S210 8W 10 45 47 S211 8W 47 7 Component Page S212 8W 47 7 S302 8W 18 5 S303 8W 10 35 S304 8W 10 65 S305 8W 63 8 S306 8W 45 5 6 S307 8W...

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Page 1032: ...W 80 17 C102 3 3L 3 8L 8W 80 17 C102 3 3L 3 8L 8W 80 18 C103 Diesel 8W 80 18 C103 Diesel 8W 80 18 C106 Built Up Export 8W 80 18 C106 Built Up Export 8W 80 19 C107 Built Up Export 8W 80 19 C107 Built U...

Page 1033: ...W 80 50 Driver Power Seat Horizontal Motor 8W 80 50 Driver Power Seat Horizontal Position Sensor 8W 80 51 Driver Power Seat Rear Riser Motor 8W 80 51 Driver Power Seat Rear Riser Position Sensor 8W 80...

Page 1034: ...uilt Up Export 8W 80 74 Component Page Left Instrument Panel Speaker 8W 80 75 Left Liftgate Flood Lamp 8W 80 75 Left Low Beam Lamp Built Up Export 8W 80 75 Left Mid Reading Lamp Premium Luxury 8W 80 7...

Page 1035: ...Fan Relay Gas 8W 80 96 Radiator Fan Relay No 1 Diesel 8W 80 97 Radiator Fan Relay No 2 Diesel 8W 80 97 Radiator Fan Relay No 3 Diesel 8W 80 97 Radio C1 8W 80 98 Radio C2 8W 80 98 Radio Choke 8W 80 99...

Page 1036: ...tor Power Sliding Door 8W 80 110 Right Speed Control Switch 8W 80 110 Right Stop Turn Signal Relay Trailer Tow 8W 80 110 Component Page Right Turn Signal Lamp Built Up Export 8W 80 111 Right Visor Van...

Page 1037: ...ENSOR GROUND 3 C22 20LB WT 3 ZONE HVAC REAR TEMPERATURE FEEDBACK SIGNAL 4 5 F850 20LB PK 3 ZONE HVAC 5 VOLT SUPPLY 6 C900 18LB VT WIPER DE ICER DRIVER 7 C32 20DB TN RECIRCULATION DOOR DRIVER A 8 C54 2...

Page 1038: ...2 20OR DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL 8 K167 20BR YL ACCELERATOR PEDAL POSITION SENSOR GROUND 9 10 F852 20VT PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY ADJUSTABLE PEDALS MODULE EX...

Page 1039: ...18LG OR DRIVER SQUIB 1 LINE 2 13 14 F201 18PK OR FCM OUTPUT ORC RUN START DRIVER 15 F100 18PK VT FCM OUTPUT ORC RUN ONLY DRIVER 16 Z12 18BK OR GROUND 17 R59 18LG TN DRIVER SEAT BELT SWITCH LINE 1 18 R...

Page 1040: ...R GY PANEL LAMPS DRIVER 4 A114 20GY RD FUSED B I O D 5 F504 20GY PK FUSED IGNITION SWITCH OUTPUT RUN 6 D25 20WT VT PCI BUS 7 C56 20DB LB BLOWER MOTOR CONTROL 8 C59 20DB LB REAR BLOWER MOTOR CONTROL 9...

Page 1041: ...TN BATTERY TEMPERATURE SENSOR SIGNAL 2 K900 20DB DG SENSOR GROUND BLOWER MOTOR RESISTOR C1 MTC BLACK 6 WAY CAV CIRCUIT FUNCTION 1 C75 12DB GY BLOWER MOTOR HIGH DRIVER 2 C74 12DB WT BLOWER MOTOR M3 DRI...

Page 1042: ...DRIVER 13 14 15 Z15 18BK TN GROUND 16 G920 20VT YL MEMORY MEMORY SELECT SWITCH RETURN 17 G153 20VT YL POWER LIFTGATE LIFTGATE MODULE WAKE UP SIGNAL 18 P32 20TN VT LEFT SLIDING DOOR LOCK DRIVER 19 Z10...

Page 1043: ...G165 20VT GY LIFTGATE CYLINDER LOCK SWITCH MUX 14 G163 20VT LB LEFT CYLINDER LOCK SWITCH MUX 15 G162 20VT WT EXCEPT BUILT UP EXPORT RIGHT CYLINDER LOCK SWITCH MUX 15 G162 20VT TN BUILT UP EXPORT RIGH...

Page 1044: ...IVER 10 F504 20GY PK FUSED IGNITION SWITCH OUTPUT RUN 11 E14 20OR TN PANEL LAMPS DRIVER RADIO 12 E13 20OR YL PANEL LAMPS DRIVER INSTRUMENT CLUSTER 13 X920 20GY OR RADIO CONTROL MUX RETURN 14 G900 20VT...

Page 1045: ...ASHER SWITCH MUX 28 W26 20BR DB REAR WIPER SWITCH MUX 29 W52 20BR YL FRONT WIPER SWITCH MUX 30 E2 20OR BR PANEL LAMPS DIMMER SIGNAL 31 L305 20WT LB TURN SIGNAL SWITCH MUX 32 33 34 L39 20WT OR HIGH LIN...

Page 1046: ...TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL 2 F2 18PK YL FCM OUTPUT UNLOCK RUN START C100 BLACK BODY SIDE CAV CIRCUIT 1 D21 20WT DG BUILT UP EXPORT 1 D21 20WT BR EXCEPT BUILT UP EXPORT 2 D16 20WT O...

Page 1047: ...BRAKES 14 B2 18DG LB ANTILOCK BRAKES C101 LT GRAY BODY SIDE CAV CIRCUIT 1 L50 18WT TN 2 3 F853 20LG PK DIESEL 4 K900 18DB DG DIESEL 5 B4 18DG GY ANTILOCK BRAKES 6 B3 18DG YL ANTILOCK BRAKES 7 F500 18D...

Page 1048: ...K POWERTRAIN SIDE CAV CIRCUIT 1 K11 16BR YL 2 K12 16BR DB 3 K13 16BR LB 4 K14 16BR TN 5 K342 16BR WT 6 K900 18DB DG 7 K2 18VT OR 8 K1 18VT BR 9 10 F855 18PK YL C102 3 3L 3 8L BLACK FUEL RAIL SIDE CAV...

Page 1049: ...CIRCUIT 1 K342 16BR WT 2 K342 16BR WT 3 N122 20DB YL 4 N210 20DB DG 5 A201 12RD LG 6 C103 DIESEL BLACK FRONT END LIGHTING SIDE CAV CIRCUIT 1 K342 16BR WT 2 K342 16BR WT 3 N122 20DB YL 4 N210 18DB DG 5...

Page 1050: ...BLACK FRONT END LIGHTING SIDE CAV CIRCUIT 1 L44 16WT TN 2 L34 16WT GY 3 L78 18WT OR 4 L60 16WT TN 5 Z344 16BK TN 6 L13 20WT YL 7 Z203 20BK YL 8 Z378 18BK TN DIESEL 8 Z378 18BK LB GAS C107 BUILT UP EX...

Page 1051: ...PORT AUTOMATIC TEMPERATURE CONTROL 12 C153 12DB BR 3 ZONE HVAC 13 Z849 12BK OR 14 A105 16DB RD BUILT UP EXPORT 14 A105 18DB RD EXCEPT BUILT UP EXPORT 15 A114 16GY RD 16 F306 16DB PK 17 C154 20LB OR 3...

Page 1052: ...EPT BUILT UP EXPORT POWER MIRRORS TOWN COUNTRY 47 D23 20WT BR RHD 48 P114 20TN WT EXCEPT BUILT UP EXPORT POWER MIRRORS 48 B25 20DG WT BUILT UP EXPORT 49 C154 20LB OR AUTOMATIC TEMPERATURE CONTROL 3 ZO...

Page 1053: ...PERATURE CONTROL 13 Z849 12BK OR 14 A105 16DB RD 15 A114 16GY RD 16 F306 16DB PK 17 C169 20DB OR AUTOMATIC TEMPERATURE CONTROL 17 C154 20LB OR 3 ZONE HVAC 18 C121 20DB DG 3 ZONE HVAC 18 D22 20WT TN EX...

Page 1054: ...LB PREMIUM 8 SPEAKER 52 X154 20GY YL PREMIUM 8 SPEAKER 53 R57 18LG GY 54 R58 18LB GY 55 R59 18LG TN 56 R60 18DB LB 57 T55 20YL VT AUTOSTICK 57 P162 20LG DG BUILT UP EXPORT 58 T751 20YL 59 X15 16GY DG...

Page 1055: ...RE CONTROL 12 C21 20DB LG 13 C121 20DB DG C202 GRAY COMPONENT SIDE CAV CIRCUIT 1 Z134 12BK OR AUTOMATIC TEMPERATURE CONTROL 2 C34 20DB LB MANUAL TEMPERATURE CONTROL 2 C56 20DB LB AUTOMATIC TEMPERATURE...

Page 1056: ...16WT PK EXCEPT POWER WINDOWS 9 10 11 Q13 16OR DB POWER WINDOWS 12 Q23 16OR LB POWER WINDOWS 13 Q14 16OR GY POWER WINDOWS 14 Q24 16OR DG POWER WINDOWS C300 LHD BLACK BODY SIDE CAV CIRCUIT 1 G75 20VT 2...

Page 1057: ...8 F304 12WT PK 9 10 C301 LT GRAY LEFT DOOR SIDE CAV CIRCUIT 1 M21 20YL BR 2 X13 16DG GY 3 X15 16GY DG 4 X153 20DG YL 5 X155 20DG LB 6 G163 20VT LB POWER LOCKS 7 G200 20VT BR MEMORY 8 G920 20VT YL MEMO...

Page 1058: ...GY YL 5 X156 20GY LB 6 G162 20VT TN POWER LOCKS BUILT UP EXPORT 6 G162 20VT WT POWER LOCKS EXCEPT BUILT UP EXPORT 7 G200 20VT BR RHD MEMORY 8 G920 20VT YL RHD MEMORY 9 Q16 12OR TN 10 Q26 12OR GY C303...

Page 1059: ...AV CIRCUIT 1 G74 20VT WT 2 Z821 12BK BR 3 X54 20GY 4 X56 20GY BR 5 G160 20VT LG 6 P2 20TN GY 7 P4 20TN BR 8 F304 12WT PK 9 10 11 Q13 16OR DB 12 Q23 16OR LB 13 Q14 16OR GY 14 Q24 16OR DG C303 RHD BLACK...

Page 1060: ...4 R33 18LG WT C305 GRAY BODY SIDE CAV CIRCUIT 1 Z849 12BK OR 2 R57 18LG GY 3 R59 18LG TN 4 P7 20LG DG 5 A210 14OR RD 6 F503 20WT PK 7 A110 12OR RD 8 9 10 11 12 13 C305 GRAY SEAT SIDE CAV CIRCUIT 1 Z84...

Page 1061: ...DG RHD 2 R56 18LB DG LHD 3 R32 18LB OR 4 R34 18LB WT C307 GRAY BODY SIDE CAV CIRCUIT 1 Z848 12BK OR 2 R58 18LB GY 3 R60 18LB TN 4 P8 20LG WT 5 A210 14OR RD 6 F503 20WT PK 7 8 9 10 11 12 C307 GRAY SEAT...

Page 1062: ...L SLIDING DOOR 1 Z825 14BK WT BUILT UP EXPORT MANUAL SLIDING DOOR POWER SLIDING DOOR 2 P32 20TN VT 3 G77 20VT GY 4 P5 20TN OR 5 6 7 G151 20VT BR POWER SLIDING DOOR 8 D25 20WT VT POWER SLIDING DOOR 9 1...

Page 1063: ...8DB RD C310 FRONT CONSOLE BLACK FRONT CONSOLE SIDE CAV CIRCUIT 1 Z746 16BK 1 Z746 16BK 2 M27 18OR 3 A105 16RD C311 GRAY REAR A C JUMPER SIDE CAV CIRCUIT 1 C153 12 DB BR 3 ZONE HVAC 2 F850 20LB PK 3 ZO...

Page 1064: ...20BK OR 3 ZONE HVAC 9 Z27 18BK DG AUTOMATIC TEMPERATURE CONTROL 10 C50 12DB OR 3 ZONE HVAC C312 GRAY HEADLINER SIDE CAV CIRCUIT 1 M27 20YL LB 2 M22 20YL OR 3 G23 20VT DB EXCEPT BASE 4 G25 20VT TN EXCE...

Page 1065: ...OR EXCEPT BUILT UP EXPORT POWER MIRRORS TOWN COUNTRY 10 P114 20TN WT EXCPET BUILT UP EXPORT POWER MIRRORS 11 M24 20YL WT 12 Z837 20BK WT 13 Z13 20BK WT 14 Z113 20BK WT 15 16 17 18 19 20 C313 REAR CON...

Page 1066: ...K C314 HIGH LINE BLACK LIFTGATE SIDE CAV CIRCUIT 1 G32 20VT LB POWER LIFTGATE 2 L77 18WT BR 3 L50 18WT TN 4 P30 20TN DG 5 P31 20TN YL POWER RELEASE 6 Q60 20OR YL POWER LIFTGATE 7 Q84 18TN GY POWER LIF...

Page 1067: ...IDE CAV CIRCUIT 1 P5 20BK DB 2 P32 20BK TN 3 G77 20BK DG 4 Z825 14BK 5 6 7 G151 20BK GY 8 D25 20BK VT 9 10 A113 14BK RD C316 POWER SLIDING DOOR BLACK LEFT SLIDING DOOR SIDE CAV CIRCUIT 1 P5 20TN OR 2...

Page 1068: ...18WT LG 5 Z363 18BK DG 6 L50 18WT TN C318 TRAILER TOW BLACK HARNESS SIDE CAV CIRCUIT 1 L63 18WT DG 1 L63 18WT DG 2 L62 18WT BR 3 L77 18WT BR 3 L77 18WT BR 4 L1 18WT LG 5 Z363 18BK DG 5 Z1 18BK DG 6 L5...

Page 1069: ...20YL VT 8 W13 18BR LG 9 F302 18GY PK 10 Z800 12BK C320 DK GRAY SEAT SIDE CAV CIRCUIT 1 Z849 14BK OR 2 A210 14OR RD C320 DK GRAY POWER SEAT SIDE CAV CIRCUIT 1 Z849 14BK OR 2 A210 14OR RD C321 DK GRAY S...

Page 1070: ...UP EXPORT 10 P71 18TN DG EXCEPT BUILT UP EXPORT 10 P71 18TN GY BUILT UP EXPORT 11 P70 18TN LB 12 P74 18TN DB 13 P72 18TN GY 14 C322 MEMORY BLACK POWER SEAT SIDE CAV CIRCUIT 1 P69 20TN WT 2 P67 20OR 3...

Page 1071: ...AL SLIDING DOOR BLACK RIGHT MANUAL SLIDING DOOR SIDE CAV CIRCUIT 1 P38 20BK DB 2 P34 20BK TN 3 G76 20BK DG 4 Z76 20BK C326 YELLOW SEAT SIDE CAV CIRCUIT 1 2 3 R33 18LG WT 4 R31 18LG OR C326 YELLOW SAFE...

Page 1072: ...Z201 18BK OR 3 N1 16DB OR 4 Z201 18BK OR 5 F853 20LG PK 6 K900 18DB DG C329 DIESEL BLACK LIFT PUMP SIDE CAV CIRCUIT 1 N2 18OR 2 Z201 18OR 3 N1 16RD 4 Z201 18RD 5 F853 20RD 6 K900 18RD C330 DIESEL LT...

Page 1073: ...20LB 2 C169 20DB OR 3 C51 12LB BR 4 C59 20DB LB 5 6 Z135 12BK LB 7 C54 20LB YL 8 C154 20LB OR 9 10 C200 20LB DG C332 ATC BLACK COMPONENT SIDE CAV CIRCUIT 1 C53 18LB 2 C169 18LB TN 3 C51 12DB BR 4 C59...

Page 1074: ...SUPPLY 2 K900 18DB DG SENSOR GROUND 3 K44 18DB GY CAMSHAFT POSITION SENSOR SIGNAL CD CHANGER 8 WAY CAV CIRCUIT FUNCTION 1 X40 24GY WT AUDIO OUT RIGHT 2 E14 18OR TN PANEL LAMPS DRIVER 3 D25 20WT VT EX...

Page 1075: ...SQUIB 2 LINE 2 3 R43 18LG BR DRIVER SQUIB 1 LINE 1 4 R45 18LG OR DRIVER SQUIB 1 LINE 2 CLOCKSPRING C3 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z23 20BK VT RIGHT SPEED CONTROL SWITCH GROUND 2 Z23 20BK VT L...

Page 1076: ...CAV CIRCUIT FUNCTION 1 T141 20YL OR IGNITION SWITCH OUTPUT START 2 T751 20YL IGNITION SWITCH OUTPUT START CLUTCH PEDAL INTERLOCK SWITCH JUMPER ATX BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T141 20YL OR IGNI...

Page 1077: ...DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 20 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 21 22 B8 18DG TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL 23 B9 18DG WT 3 3L 3 8L LEFT FRONT WHEEL SPEED...

Page 1078: ...EXPORT SCI TRANSMIT 8 9 D23 20WT BR FLASH PROGRAM ENABLE 10 11 12 13 14 D16 20WT OR GAS SCI RECEIVE 15 16 A105 20DB RD FUSED B DIAGNOSTIC JUNCTION PORT BLACK 16 WAY CAV CIRCUIT FUNCTION 1 D25 20WT VT...

Page 1079: ...18OR LB DRIVER SQUIB 2 LINE 1 2 R63 18TN LB DRIVER SQUIB 2 LINE 2 DRIVER BLEND DOOR ACTUATOR ATC GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C61 20DB LG DRIVER BLEND DOOR DRIVER A 2 C161 20LB WT DRIVER BLEND DO...

Page 1080: ...SEAT BACK GREEN 2 WAY CAV CIRCUIT FUNCTION 1 S2 18BK RHD DRIVER SEAT BACK HEATER GROUND 1 S2 18DG LHD DRIVER SEAT BACK HEATER GROUND 2 S1 18RD RHD DRIVER SEAT BACK HEATER B DRIVER 2 S1 18DB LHD DRIVER...

Page 1081: ...RIVER 1 P19 14LG LB DRIVER FRONT UP SWITCH SENSE 2 P121 14LG DB MEMORY SEAT FRONT DOWN DRIVER 2 P21 14LG TN DRIVER FRONT DOWN SWITCH SENSE DRIVER POWER SEAT FRONT RISER POSITION SENSOR BLACK 3 WAY CAV...

Page 1082: ...RISER POSITION SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20LG BR SEAT POSITION SENSOR GROUND B P27 20LG LB REAR RISER POSITION SIGNAL C P29 20LG WT SEAT SENSOR 5 VOLT SUPPLY DRIVER POWER SEAT REC...

Page 1083: ...P13 20LG OR MEMORY SEAT REAR DOWN SWITCH SENSE 9 P13 14LG OR DRIVER SEAT REAR DOWN SWITCH SENSE 10 P21 14LG TN DRIVER FRONT DOWN SWITCH SENSE 10 P21 20LG TN MEMORY SEAT FRONT DOWN SWITCH SENSE DRIVER...

Page 1084: ...R GY MASTER WINDOW SWITCH PASSENGER DOWN 5 Q13 16OR DB DRIVER SIDE REAR WINDOW CLOSE 6 Q16 12OR TN MASTER WINDOW SWITCH PASSENGER UP 7 Q24 16OR DG PASSENGER SIDE REAR WINDOW OPEN 8 F304 16WT PK FUSED...

Page 1085: ...AY CAV CIRCUIT FUNCTION 1 K35 18DB VT EGR SOLENOID CONTROL 2 F202 18PK GY FUSED IGNITION SWITCH OUTPUT RUN START ELECTRIC WIPER DE ICER C1 WHITE 2 WAY CAV CIRCUIT FUNCTION 1 F302 18GY PK FUSED ACCESSO...

Page 1086: ...4 K3 20BR OR CRANKSHAFT POSITION SENSOR SIGNAL NO 1 25 26 27 28 29 30 G6 20VT GY ENGINE OIL PRESSURE SENSOR SIGNAL 31 F853 20LG PK WATER IN FUEL SENSOR SIGNAL 32 K25 20BR TN BATTERY TEMPERATURE SENSOR...

Page 1087: ...20WT LOW IDLE POSITION SWITCH SENSE 65 66 K936 20BR YL ENGINE OIL PRESSURE SENSOR GROUND 67 68 69 C13 20LB OR A C COMPRESSOR CLUTCH RELAY CONTROL 70 N210 20DB DG LOW SPEED RADIATOR FAN RELAY CONTROL 7...

Page 1088: ...09 110 111 112 K119 20DB LG CLUTCH PEDAL UPSTOP SWITCH SENSE 113 114 115 K14 14LB BR FUEL INJECTOR NO 4 CONTROL 116 K111 14DB LB COMMON INJECTOR DRIVER 117 118 K11 14WT DB FUEL INJECTOR NO 1 CONTROL 1...

Page 1089: ...936 20BR YL ENGINE OIL PRESSURE SENSOR GROUND ENGINE OIL PRESSURE SWITCH GAS LT GREEN 2 WAY CAV CIRCUIT FUNCTION 1 G6 16VT GY ENGINE OIL PRESSURE SWITCH SENSE 2 ENGINE OIL TEMPERATURE SENSOR DIESEL BL...

Page 1090: ...RD REAR CONSOLE ACCESSORY RELAY POSITION FUSED ACCESSORY RELAY OUTPUT 1 F307 16RD REAR CONSOLE BATTERY POSITION FUSED B 1 A105 16RD FRONT CONSOLE FUSED B 2 3 Z747 16BK REAR CONSOLE GROUND 3 Z746 16BK...

Page 1091: ...20BK LB GROUND 3 4 M27 20YL LB READING LAMPS DRIVER 5 M24 20YL WT COURTESY LAMPS DRIVER 6 FRONT WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 2 F300 18...

Page 1092: ...R NO 2 DRIVER FUEL INJECTOR NO 2 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K111 14DB LB COMMON INJECTOR DRIVER 2 K12 14TN FUEL INJECTOR NO 2 CONTROL FUEL INJECTOR NO 3 2 4L 3 3L 3 8L BLACK 2 WAY CAV C...

Page 1093: ...O 5 3 3L 3 8L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K38 16BR OR FUEL INJECTOR NO 5 DRIVER FUEL INJECTOR NO 6 3 3L 3 8L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K...

Page 1094: ...1 K342 16BR WT DIESEL ECM PCM RELAY OUTPUT 1 K342 16BR WT GAS AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K20 14BR GY DIESEL GENERATOR FIELD CONTROL 2 K20 18BR GY GAS GENERATOR FIELD CONTROL GLOVE BOX LAMP BLU...

Page 1095: ...MUX 12 E2 20OR BR PANEL LAMPS DIMMER SIGNAL 13 HEADLAMP WASHER PUMP MOTOR BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 V53 12BR OR HEADLAMP WASHER RELAY OUTPUT 2 Z243 12BK OR GROUND HIGH NOTE HO...

Page 1096: ...DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K19 16DB DG IGNITION COIL NO 1 DRIVER 4 K17 16DB TN IGNITION COIL NO 2 DRIVER IGNITION SWITCH BLACK 5 WAY CAV CIRCUIT FUNCTION 1 G900 20VT OR...

Page 1097: ...8DG WT LHD BUILT UP EXPORT PARK BRAKE SWITCH SENSE 10 B25 20DG WT RHD PARK BRAKE SWITCH SENSE 10 B25 16DG WT LHD EXCEPT BUILT UP EXPORT PARK BRAKE SWITCH SENSE 11 G26 20VT OR CHIME DRIVER 12 G150 20VT...

Page 1098: ...LEFT 17 18 G931 18VT BR EXCEPT BASE AMBIENT TEMPERATURE SENSOR RETURN 19 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 20 W10 18BR FRONT WASHER PUMP MOTOR CONTROL INTEGRATED POWER MODULE C2 GREEN BLUE 1...

Page 1099: ...UTPUT 20 INTEGRATED POWER MODULE C3 GAS NATURAL RED 20 WAY CAV CIRCUIT FUNCTION 1 Z115 20BK OR EATX 3 3L 3 8L GROUND 1 Z115 18BK OR EATX 2 4L GROUND 2 F1 18PK WT EATX FCM OUTPUT UNLOCK RUN START 3 T75...

Page 1100: ...D ANTILOCK BRAKES FUSED B 9 A710 14RD BR DIESEL B HAZARD FEED 9 A701 14BR RD GAS B HAZARD FEED 10 INTEGRATED POWER MODULE C5 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A1 4RD B 2 3 4 INTEGRATED POWER MODULE C...

Page 1101: ...18PK WT GAS FCM OUTPUT UNLOCK RUN START 14 15 A114 16GY RD FUSED B I O D 16 D23 20WT BR FLASH PROGRAM ENABLE 17 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 18 X1 16DG BR PREMIUM 8 SPEAKER NAME BRAND SPEAKER...

Page 1102: ...9 A115 12YL RD POWER LIFTGATE FUSED B 10 F302 18GY PK FUSED ACCESSORY RELAY OUTPUT KNOCK SENSOR 2 4L GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K42 18DB YL KNOCK SENSOR SIGNAL 2 K900 18DB DG SENSOR GROUND KNO...

Page 1103: ...FUNCTION 1 L63 18WT DG LEFT REAR TURN SIGNAL DRIVER 2 Z1 18BK DG GROUND 2 Z1 18BK DG GROUND 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 4 L615 18OR LEFT COMBINATION S...

Page 1104: ...20VT LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z75 20BK VT GROUND LEFT FRONT DOOR LOCK MOTOR AJAR SWITCH EXCEPT BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z75 20BK...

Page 1105: ...EN SWITCH SENSE 2 Z77 20BK GY GROUND LEFT HEADLAMP EXCEPT BUILT UP EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L43 18WT DB LEFT LOW BEAM DRIVER 2 Z343 18BK LG GROUND 3 L33 18WT LG LEFT HIGH BEAM DRIVER...

Page 1106: ...SY LAMPS DRIVER LEFT LOW BEAM LAMP BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z343 16BR GROUND 2 L43 16WT LEFT LOW BEAM DRIVER LEFT MID READING LAMP PREMIUM LUXURY GRAY 3 WAY CAV CIRCUIT FUNCT...

Page 1107: ...AY CAV CIRCUIT FUNCTION 1 L63 18WT DG EXCEPT BUILT UP EXPORT LEFT REAR TURN SIGNAL DRIVER 1 Z363 18BK DG BUILT UP EXPORT GROUND 2 L62 18WT BR EXCEPT BUILT UP EXPORT RIGHT REAR TURN SIGNAL DRIVER 2 L63...

Page 1108: ...1 Q13 16OR DB LHD DRIVER SIDE REAR WINDOW CLOSE 2 Q24 16OR DG RHD PASSENGER SIDE REAR WINDOW OPEN 2 Q23 16OR LB LHD DRIVER SIDE REAR WINDOW OPEN 3 LEFT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT...

Page 1109: ...OR OPEN DRIVER 3 Q69 16TN OR LEFT SLIDING DOOR CLOSE DRIVER 4 5 A113 14WT RD FUSED B 6 7 8 Z123 14BK WT GROUND LEFT SLIDING DOOR CONTROL MODULE C2 POWER SLIDING DOOR BLACK RED 20 WAY CAV CIRCUIT FUNCT...

Page 1110: ...OR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P5 20BK DB LEFT SLIDING DOOR UNLOCK DRIVER 2 P32 20BK TN LEFT SLIDING DOOR LOCK DRIVER 3 G77 20BK DG LEFT SLIDING DOOR AJAR SWITCH SENSE 4 Z77 20BK GROUND LEFT SL...

Page 1111: ...FT FRONT TURN SIGNAL DRIVER LEFT VISOR VANITY LAMP PREMIUM LUXURY BLACK 2 WAY CAV CIRCUIT FUNCTION A Z327 20BK OR GROUND B M27 20YL LB READING LAMP DRIVER LICENSE LAMP MANUAL RELEASE DK GRAY 2 WAY CAV...

Page 1112: ...G78 20VT OR LIFTGATE AJAR SWITCH SENSE LIFTGATE AJAR SWITCH POWER RELEASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK OR GROUND 2 G78 20VT OR LIFTGATE AJAR SWITCH SENSE 3 P31 20TN YL LIFTGATE RELEASE...

Page 1113: ...SENSOR POWER LIFTGATE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q77 20OR DB RIGHT PINCH SENSOR SIGNAL 2 Z78 20BK OR GROUND LOW NOTE HORN BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z298 18BK DB GROUND 2 X2 18DG OR HO...

Page 1114: ...MIRROR VERTICAL POSITION SIGNAL 8 P21 20LG TN SEAT FRONT DOWN SWITCH SENSE 9 P13 20LG OR SEAT REAR DOWN SWITCH SENSE 10 P15 20LG WT SEAT HORIZONTAL FORWARD SWITCH SENSE 11 P43 14LG VT RECLINER UP SWI...

Page 1115: ...V CIRCUIT FUNCTION 1 P111 14LG YL SEAT REAR UP DRIVER 2 P115 14LG SEAT HORIZONTAL FORWARD DRIVER 3 P119 14LG DG SEAT FRONT UP DRIVER 4 P113 14LG WT SEAT REAR DOWN DRIVER 5 P121 14LG DB SEAT FRONT DOWN...

Page 1116: ...DRIVER 11 G69 20VT WT RHD VTSS INDICATOR DRIVER 12 L134 20WT GY LHD HIGH BEAM INDICATOR DRIVER 13 G3 20VT LB RHD MALFUNCTION INDICATOR LAMP DRIVER 14 L161 20WT LG RHD LEFT TURN INDICATOR DRIVER MODE...

Page 1117: ...P FEED 9 10 11 L24 20BK GY EXCEPT BUILT UP EXPORT PREMIUM LUXURY AUTOMATIC HEADLAMP SWITCH SENSOR 12 L1 20BK WT PREMIUM LUXURY BACK UP LAMP FEED RADIATOR FAN RELAY NO 1 DIESEL BLUE 9 WAY CAV CIRCUIT F...

Page 1118: ...4 WAY CAV CIRCUIT FUNCTION 1 R42 18LB BR PASSENGER SQUIB 1 LINE 2 2 R44 18LB OR PASSENGER SQUIB 1 LINE 1 3 R62 18LB PK PASSENGER SQUIB 2 LINE 2 4 R64 18LB WT PASSENGER SQUIB 2 LINE 1 PASSENGER BLEND D...

Page 1119: ...IT FUNCTION 1 2 3 4 A108 18LG RD FUSED B 5 P164 18LG DB PASSENGER FOLDING MIRROR RELAY INPUT 6 P162 18LG DG PASSENGER FOLDING MIRROR RELAY CONTROL 7 8 P160 18TN LG PASSENGER FOLDING MIRROR RELAY OUTPU...

Page 1120: ...UND 2 S1 18WT PASSENGER SEAT BACK HEATER B DRIVER PASSENGER HEATED SEAT MODULE C3 GREEN 4 WAY CAV CIRCUIT FUNCTION 1 P87 16LG OR PASSENGER SEAT CUSHION HEATER GROUND 2 P89 20LG BR SEAT SENSOR 5 VOLT S...

Page 1121: ...SWITCH SENSE PASSENGER POWER SEAT SWITCH GREEN 10 WAY CAV CIRCUIT FUNCTION 1 Z848 14BK OR GROUND 2 P44 14LG VT PASSENGER RECLINER UP SWITCH SENSE 3 P16 14LG WT PASSENGER HORIZONTAL REARWARD SWITCH SEN...

Page 1122: ...NDOW CIRCUIT BREAKER OUTPUT 7 Z422 20BK BR GROUND 8 Q12 14OR BR PASSENGER WINDOW DRIVER UP PASSENGER SEAT BELT SWITCH 2 WAY CAV CIRCUIT FUNCTION 1 R60 18LB TN PASSENGER SEAT BELT SWITCH LINE 1 2 R58 1...

Page 1123: ...AJAR SWITCH SENSE 13 Q60 20OR YL LIFTGATE PAWL SWITCH SENSE 14 Q51 20OR LIFTGATE FULL OPEN SWITCH SENSE 15 16 G32 20VT LB LIFTGATE TEMPERATURE SENSOR SIGNAL 17 Q91 20TN LG LIFTGATE HALL EFFECT SIGNAL...

Page 1124: ...RIVER 9 A108 18LG RD FUSED B 10 11 Z408 18BK LG GROUND 12 P71 20TN DG LEFT MIRROR UP DRIVER 12 P71 18TN DG MEMORY LEFT MIRROR UP DRIVER 13 P72 18TN GY MEMORY RIGHT MIRROR UP DRIVER 13 P72 20TN GY RIGH...

Page 1125: ...IL PRESSURE SWITCH SENSE 13 K11 16BR YL FUEL INJECTOR NO 1 DRIVER 14 K58 16BR VT 3 3L 3 8L FUEL INJECTOR NO 6 DRIVER 15 K38 16BR OR 3 3L 3 8L FUEL INJECTOR NO 5 DRIVER 16 K14 16BR TN FUEL INJECTOR NO...

Page 1126: ...WT SECONDARY BRAKE SWITCH SIGNAL 63 T10 18DG LG EATX TORQUE MANAGEMENT REQUEST SENSE 64 C13 18LB OR A C COMPRESSOR CLUTCH RELAY CONTROL 65 D21 18WT BR SCI TRANSMIT 66 N7 18DB OR VEHICLE SPEED SENSOR...

Page 1127: ...R FAN NO 2 DIESEL GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z823 12BK GROUND 2 N112 12DB OR RADIATOR FAN RELAY NO 2 AND NO 3 COMMON OUTPUT RADIATOR FAN NO 2 GAS BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N23 12DB DG...

Page 1128: ...2DB OR RADIATOR FAN RELAY NO 2 AND NO 3 COMMON OUTPUT 3 4 K342 16BR WT ECM PCM RELAY OUTPUT 5 6 N122 18DB YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL 7 8 A112 12OR RD FUSED B 9 RADIATOR FAN RELAY NO...

Page 1129: ...BUILT UP EXPORT GROUND 11 Z333 16BK PK EXCEPT BUILT UP EXPORT GROUND 12 A114 16GY RD EXCEPT BUILT UP EXPORT FUSED B I O D 13 X60 20GY YL BUILT UP EXPORT RADIO 12 VOLT OUTPUT 14 D25 18WT VT EXCEPT BUIL...

Page 1130: ...B YL REAR BLEND DOOR DRIVER 8 C154 20LB OR REAR COMMON DOOR DRIVER 9 10 C200 20LB DG TXV SOLENOID FEED REAR AUTO TEMP CONTROL SWITCH ATC BLACK 13 WAY CAV CIRCUIT FUNCTION 1 F504 20GY PK FUSED IGNITION...

Page 1131: ...WAY CAV CIRCUIT FUNCTION 1 C153 12DB BR REAR BLOWER MOTOR HIGH 2 C152 16LB LG REAR BLOWER MOTOR MED 3 C151 18LB DG REAR BLOWER MOTOR LOW 4 C50 12DB OR REAR BLOWER FRONT CONTROL FEED REAR BLOWER REAR...

Page 1132: ...7 16BK LB GROUND REAR TEMPERATURE MOTOR ATC GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C54 18LB YL REAR BLEND DOOR DRIVER A 2 C169 18LB TN REAR BLEND DOOR DRIVER B REAR WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUI...

Page 1133: ...TRY ANTENNA 2 D10 18WT LB REMOTE KEYLESS ENTRY ANTENNA REMOTE KEYLESS ENTRY MODULE BLACK RED 6 WAY CAV CIRCUIT FUNCTION 1 G96 20VT DG REMOTE KEYLESS ENTRY INTERFACE 2 D9 20WT GY RKE MODULE PROGRAM ENA...

Page 1134: ...PUT 4 L605 18DG RIGHT COMBINATION SIGNAL 5 RIGHT CYLINDER LOCK SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z462 20BK WT GROUND 2 G162 20VT WT RIGHT CYLINDER LOCK SWITCH MUX RIGHT DOOR SPEAKER BLACK RED...

Page 1135: ...VT WT RIGHT FRONT DOOR AJAR SWITCH SENSE 2 Z74 20BK WT GROUND 3 P4 20TN BR RIGHT FRONT DOOR UNLOCK DRIVER 4 P2 20TN GY RIGHT FRONT DOOR LOCK DRIVER RIGHT FRONT PARK TURN SIGNAL LAMP EXCEPT BUILT UP EX...

Page 1136: ...RIGHT HEADLAMP LEVELING MOTOR BUILT UP EXPORT WHITE 3 WAY CAV CIRCUIT FUNCTION 1 Z203 16BR GROUND 2 L78 16BK FUSED PARK LAMP RELAY OUTPUT RIGHT 3 L13 16RD HEADLAMP ADJUST SIGNAL RIGHT HIGH BEAM LAMP...

Page 1137: ...RK LAMP RELAY OUTPUT RIGHT RIGHT POWER MIRROR BLACK 12 WAY CAV CIRCUIT FUNCTION 1 P174 20TN LB BUILT UP EXPORT RIGHT FOLDING MIRROR UNFOLD DRIVER 2 3 4 P68 20TN YL MEMORY RIGHT MIRROR HORIZONTAL POSIT...

Page 1138: ...R SPEAKER 2 X152 20GY WT RIGHT REAR PILLAR SPEAKER RIGHT REAR READING LAMP LUXURY GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL OR COURTESY LAMPS DRIVER 2 Z327 20BK OR GROUND 3 M27 20YL LB READING LAMPS...

Page 1139: ...0WT VT RIGHT SIDE REPEATER LAMP FEED RIGHT SEAT AIRBAG YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R32 18LB OR EXCEPT BUILT UP EXPORT RIGHT SEAT SQUIB LINE 1 1 R34 18WT BK BUILT UP EXPORT RIGHT SEAT SQUIB LIN...

Page 1140: ...CH DRIVER 9 Q48 18TN WT RIGHT CINCH RELEASE MOTOR UNLATCH DRIVER 10 11 D25 20WT VT PCI BUS 12 G76 20TN OR RIGHT SLIDING DOOR AJAR SWITCH SENSE 13 Q58 20OR YL RIGHT PAWL SWITCH SENSE 14 Q52 20OR RIGHT...

Page 1141: ...SUPPLY 3 Q68 16TN BR RIGHT SLIDING DOOR OPEN DRIVER 4 Z164 18BK TN GROUND 5 Q64 18OR TN RIGHT DOOR MOTOR CLUTCH DRIVER 6 Q70 16TN OR RIGHT SLIDING DOOR CLOSE DRIVER 7 Z34 20BK TN GROUND 8 Q74 20TN YL...

Page 1142: ...ED B I O D SIREN UNITED KINGDOM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 D97 18WT OR SIREN SIGNAL OUTPUT 2 D96 18WT LB SIREN SIGNAL CONTROL 3 A600 18RD LB SIREN SUPPLY 4 G944 18LB BR SIREN SIGNAL RETURN SOL...

Page 1143: ...L CONTROL 7 F20 20PK WT FUSED IGNITION SWITCH OUTPUT RUN START 8 G944 20LB BR SIREN SIGNAL RETURN 9 10 11 G922 20GY VTSS INDICATOR DRIVER 12 13 D25 20WT VT PCI BUS 14 15 L91 20WT DB HAZARD SWITCH SENS...

Page 1144: ...OID CONTROL TRACTION CONTROL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B27 20DG WT TRACTION CONTROL SWITCH SENSE 2 Z427 20BK WT GROUND TRAILER TOW CONNECTOR EXCEPT BUILT UP EXPORT 4 WAY CAV CIRCUIT FU...

Page 1145: ...R TRANSMISSION CONTROL RELAY CONTROL 16 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPUT 17 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPUT 18 19 T19 18YL DB 2 4 SOLENOID CONTROL 20 T20 18DG WT LOW REVERSE...

Page 1146: ...T1 SENSE 8 T3 18DG DB TRS T3 SENSE 9 T42 18DG YL TRS T42 SENSE 10 T41 18YL DB PARK NEUTRAL POSITION SWITCH SENSE TRS T41 TXV SOLENOID ATC 2 WAY CAV CIRCUIT FUNCTION 1 C200 18LB DG TXV SOLENOID FEED 2...

Page 1147: ...GNAL 2 K900 18RD SENSOR GROUND WIPER MODULE DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 W3 12BR WT FRONT WIPER HIGH LOW RELAY LOW SPEED OUTPUT 2 W7 20BR GY FRONT WIPER PARK SWITCH SENSE 3 W4 12BR OR FRONT WI...

Page 1148: ...Position Sensor Diesel BK At Accelerator Pedal 36 Airbag Control Module YL RD Right Side of Instrument Panel 15 19 20 Ambient Temperature Sensor BK On Radiator Closure Panel 1 ATC Remote Sensor Above...

Page 1149: ...er N S C300 RHD BK Right Front Door Lower C301 LTGY Left Front Door Upper N S C302 LTGY Right Front Door Upper 8 33 37 C303 LHD BK Right Front Door Lower 8 37 C303 RHD BK Left Front Door Lower 33 37 C...

Page 1150: ...At Switch Driver Side 36 Clutch Pedal Upstop Switch Diesel BK At Switch Driver Side 36 Controller Anti Lock Brake BK Right Side of Engine Compartment 9 10 12 13 14 Crank Case Ventilation Heater Diesel...

Page 1151: ...l BK Right Side of Engine 11 Engine Coolant Temperature Sensor Gas BK On Cylinder Block N S Engine Coolant Temperature Sensor Diesel BL On Cylinder Block 11 Engine Oil Pressure Sensor Diesel BK Rear o...

Page 1152: ...ngine 14 Ignition Switch BK Rear of Switch at Steering Column 15 16 17 18 26 Inlet Air Temperature Sensor BK Top Left of Engine N S Instrument Cluster BK Rear of Cluster 15 16 23 Instrument Panel Swit...

Page 1153: ...Rear Speaker BK At Speaker 40 Left Rear Vent Motor NAT At Motor 39 40 Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 40 Left Remote Radio Switch Steering Wheel N S Left Repeater Lamp GY Lef...

Page 1154: ...ear Vertical Motor RD Under Seat N S Memory Seat Rear Vertical Position Sensor BK Under Seat N S Memory Seat Recliner Motor GN Under Seat N S Memory Seat Recliner Position Sensor BK Under Seat N S Mem...

Page 1155: ...r of Switch 25 Power Outlet NAT Instrument Panel 15 18 20 Power Seat Circuit Breaker GY Under Seat N S Powertrain Control Module C1 GY BK LT Fender Side Shield N S Powertrain Control Module C2 GY LT F...

Page 1156: ...Front Door Lock Motor Ajar Switch BK Right Front Door 37 Right Front Park Turn Signal Lamp BK At Lamp 1 3 Right Front Wheel Speed Sensor GY Right Fender Side Shield 9 12 13 Right Full Open Switch BK R...

Page 1157: ...Siren United Kingdom BK Left Front Body N S Solenoid Pressure Switch Assembly EATX BK Side of Transmission N S Speed Control Servo BK Near Controller Antilock Brake 14 Thatcham Alarm Module C1 BK Top...

Page 1158: ...or 11 S106 3 3L 3 8L Near T O for G103 14 S107 2 4L In T O for EGR Solenoid 10 S107 2 5L Between T O for Engine Starter Motor and T O for Engine Control Module C1 12 S107 3 3L 3 8L In T O for EGR Sole...

Page 1159: ...O for Intelligent Power Module C3 N S S134 Near T O for Controller Antilock Brake N S S135 2 5L Near T O for Glow Plug No 2 11 S136 2 5L Between T O for Radiator Fan No 2 and T O for G102 N S S137 2 5...

Page 1160: ...g Column Wiring Assembly N S S302 In Floor Pan Track Wiring 31 S303 In T O to Data Link Connector 31 S304 Near T O for C307 32 S305 Near T O for Memory Seat Mirror Module C2 N S S306 In Floor Pan Trac...

Page 1161: ...S346 Near T O for Driver Power Window Switch 37 S347 Near T O for Right Sliding Door Lock Motor 39 S348 Near T O for Left Sliding Door Lock Motor 39 S349 In T O to Left Sliding Door Control Module C2...

Page 1162: ...Fig 1 HEADLAMP CONNECTORS RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1163: ...Fig 2 LEFT FRONT ENGINE COMPARTMENT Fig 3 WASHER PUMP CONNECTORS 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1164: ...Fig 4 LEFT REPEATER LAMP Fig 5 LEFT FENDER SHIELD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1165: ...Fig 6 LEFT SIDE ENGINE COMPARTMENT 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1166: ...Fig 7 INTEGRATED POWER MODULE RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1167: ...Fig 8 RIGHT FRONT WHEEL HOUSING 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1168: ...Fig 9 2 4 LITER ENGINE CONNECTORS REAR RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1169: ...Fig 10 2 4 LITER ENGINE FRONT 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1170: ...Fig 11 2 5 LITER DIESEL ENGINE FRONT RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1171: ...Fig 12 2 5 LITER DIESEL ENGINE REAR 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1172: ...Fig 13 3 3 3 8 LITER ENGINE REAR RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1173: ...Fig 14 3 3 3 8 LITER ENGINE FRONT 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1174: ...Fig 15 INSTRUMENT PANEL HARNESS LHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1175: ...Fig 16 LEFT SIDE INSTRUMENT PANEL LHD 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1176: ...Fig 17 STEERING COLUMN RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1177: ...Fig 18 CENTER INSTRUMENT PANEL 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1178: ...Fig 19 RIGHT SIDE INSTRUMENT PANEL RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1179: ...Fig 20 CENTER INSTRUMENT PANEL RHD 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1180: ...Fig 21 INSTRUMENT PANEL RHD Fig 22 LEFT SIDE INSTRUMENT PANEL UPPER RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1181: ...Fig 23 RIGHT SIDE INSTRUMENT PANEL UPPER RHD Fig 24 LEFT SIDE INSTRUMENT PANEL LOWER RHD 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1182: ...Fig 25 RIGHT SIDE INSTRUMENT PANEL LOWER RHD Fig 26 STEERING COLUMN CONNECTORS RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1183: ...Fig 27 LEFT SIDE BODY LHD 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1184: ...Fig 28 RIGHT SIDE BODY RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1185: ...Fig 29 BODY HARNESS SPLICES 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1186: ...Fig 30 BODY HARNESS SPLICES Fig 31 LEFT FRONT BODY SPLICES RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1187: ...Fig 32 REAR BODY SPLICES 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1188: ...Fig 33 RIGHT B PILLAR Fig 34 LEFT B PILLAR RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1189: ...Fig 35 LEFT SIDE KICK PANEL LHD 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1190: ...Fig 36 RIGHT SIDE KICK PANEL RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1191: ...Fig 37 PASSENGER DOOR Fig 38 RIGHT SLIDING DOOR 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1192: ...Fig 39 LIFTGATE AND SLIDING DOOR MODULES RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 45 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1193: ...Fig 40 LEFT REAR BODY 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1194: ...Fig 41 RIGHT QUARTER RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 47 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1195: ...Fig 42 LIFTGATE 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1196: ...esetting circuit breakers Blade type fuses Bus bars Cartridge fuses Circuit splice blocks Flashers Fusible links Relays Following are general descriptions of the major components in the power distribu...

Page 1197: ...n the Inte grated Power Module IPM in the engine compart ment For complete circuit diagrams refer to Wiring Diagrams 1 Remove the accessory relay from the IPM Refer to Accessory Relay in the Removal a...

Page 1198: ...relays while the front control module contains the electronics con trolling the IPM and other functions This IPM con nects directly to the battery positive via a four pin connector The ground connecti...

Page 1199: ...e until secured in mounting bracket An audible click may be heard 3 Install the battery in the vehicle Refer to the Battery section for the procedure 4 Install the battery thermal guard in the vehi cl...

Page 1200: ...damaged Refer to Battery System for additional service information REMOVAL 1 Turn the ignition switch to the Off position 2 Unlatch and open the cover of the intelligent power module 3 Remove the IOD...

Page 1201: ...battery voltage at the fused B circuit cavity of the power outlet wire harness connector If OK replace the faulty power outlet receptacle If not OK repair the open fused B circuit to the IPM fuse as r...

Page 1202: ...CE GASKETS AND SEALERS 11 STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION 11 STANDARD PROCEDURE MEASURING BEARING CLEARANCE USING PLASTIGAGE 12 REMOVAL ENGINE ASSEMBLY 12 INSTALLATION ENGINE ASSE...

Page 1203: ...ALLATION 44 PISTON CONNECTING ROD DESCRIPTION 45 OPERATION 45 REMOVAL 45 INSTALLATION 46 PISTON RINGS STANDARD PROCEDURE PISTON RING FITTING 47 VIBRATION DAMPER REMOVAL 48 INSTALLATION 48 STRUCTURAL C...

Page 1204: ...g 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAGNOSIS INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance The...

Page 1205: ...ation 5 Incorrect spark plug gap 5 Set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS 6 Contamination in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump 7 Test fuel pu...

Page 1206: ...essary 9 Faulty ignition coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Clean spark plugs...

Page 1207: ...adjusters 7 Replace hydraulic lifters lash adjusters 8 Worn valve guides 8 Replace cylinder head assembly 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves CONNECTING RO...

Page 1208: ...vel 1 Check engine oil level 2 Faulty oil pressure sensor switch 2 Replace oil pressure sensor switch 3 Low oil pressure 3 Check oil pressure sensor switch and main bearing oil clearance 4 Clogged oil...

Page 1209: ...ect the fresh air hose make up air at the cylinder head cover and plug or cap the nipple on the cover Remove the PCV valve hose from the cylinder head cover Cap or plug the PCV valve nipple on the cov...

Page 1210: ...riskly 3 Remove all spark plugs from engine As spark plugs are being removed check electrodes for abnor mal firing indicators fouled hot oily etc Record cyl inder number of spark plug for future refer...

Page 1211: ...e vehicle placed in service immediately STANDARD PROCEDURE REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads excluding spark plug and camshaft bearing cap attaching threads can be repaired Ess...

Page 1212: ...a unique green in color anaerobic type gasket material that is specially made to seal the area between the bed plate and cylinder block without disturbing the bear ing clearance or alignment of these...

Page 1213: ...stigage with the metric scale provided on the package Locate the band clos est to the same width This band shows the amount of clearance in thousandths of a millimeter Differ ences in readings between...

Page 1214: ...ctors 11 Disconnect throttle body linkage 12 Disconnect engine wiring harness 13 Disconnect heater hoses from heater Fig 5 14 Discharge air conditioning system Refer to 24 HEATING AIR CONDITIONING PLU...

Page 1215: ...be installed under vehicle Fig 8 32 Loosen cradle posts to allow movement for proper positioning Locate two rear posts right side of engine into the holes on the engine bedplate Locate the two front...

Page 1216: ...ne Cradle Support Post Mounts 1 SPECIAL TOOL POSTS 6848 4 SPECIAL TOOL 6710 CRADLE 2 SPECIAL TOOL 6135 DOLLY 5 SPECIAL TOOL 6848 POST CONTACT ON PAN RAIL 3 SPECIAL TOOL POSTS 6848 RS ENGINE 2 4L 9 15...

Page 1217: ...OLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 16 Install axle shafts Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLA TION 17 Install accessory drive belt splash shield 18 Install front wheels...

Page 1218: ...n Length 66 25 mm 2 608 in DESCRIPTION SPECIFICATION Piston Ring Groove Depth No 1 4 640 4 784 mm 0 182 0 188 in Piston Ring Groove Depth No 2 4 575 4 719 mm 0 180 0 185 in Piston Ring Groove Depth No...

Page 1219: ...Camshaft Journal Diameter No 1 6 25 951 25 970 mm 1 021 1 022 in Bearing Clearance Diametrical 0 069 0 071 mm 0 0027 0 003 in End Play 0 05 0 17 mm 0 0019 0 0066 in DESCRIPTION SPECIFICATION Lift Zer...

Page 1220: ...25 mm 0 010 in Exhaust 0 0736 0 094 mm 0 0029 0 0037 in Max Allowable 0 101 mm 0 004 in DESCRIPTION SPECIFICATION Service Limit 0 25 mm 0 010 in Valve Springs Free Length Approx 48 4 mm 1 905 in Nomi...

Page 1221: ...Engine Mount Bracket Right Bolts 61 45 Engine Mounting Bolts Refer to 9 ENGINE ENGINE MOUNTING DESCRIPTION N m Ft Lbs In Lbs Exhaust Manifold to Cylinder Head Bolts 19 170 Exhaust Manifold Heat Shiel...

Page 1222: ...er Removal Insert 6827A Dolly 6135 Cradle 6710A Post Kit Engine Cradle 6848 Camshaft Sprocket Holder 6847 Camshaft Seal Remover C 4679A Camshaft Seal Installer MD 998306 Crankshaft Damper Sprocket Ins...

Page 1223: ...or MD998772A Valve Spring Compressor Adapter 6779 Indicator Cylinder Bore C 119 Connecting Rod Guides 8189 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C 4685 C2 Front Crankshaf...

Page 1224: ...Rear Crankshaft Oil Seal Installer 6926 Driver Handle C 4171 Balance Shaft Sprocket Installer 6052 Combustion Leak Tester C 3685 A Pressure Transducer CH7059 Cylinder Compression Pressure Adaptor 811...

Page 1225: ...DESCRIPTION The cross flow designed aluminum cylinder head contains dual over head camshafts with four valves per cylinder Fig 13 The valves are arranged in two in line banks The intake valves face to...

Page 1226: ...XCEED 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 cylin...

Page 1227: ...r scratch the alumi num head sealing surface Clean all engine oil passages INSPECTION 1 Cylinder head must be flat within 0 1 mm 0 004 in Fig 14 2 Inspect camshaft bearing journals for scoring 3 Remov...

Page 1228: ...tion coil wiring connector 12 Install power steering pump reservoir and line support bracket to cylinder head 13 Raise vehicle and install the exhaust pipe to the manifold 14 Install accessory drive b...

Page 1229: ...TALLATION 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 h...

Page 1230: ...d camshaft for wear replace as necessary REMOVAL 1 Remove cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER REMOVAL 2 Remove camshaft position sensor and camshaft target magnet R...

Page 1231: ...ft lobes 2 Install all rocker arms in original positions if reused 3 Position camshafts on cylinder head bearing journals Install right and left camshaft bearing caps No 2 5 and right No 6 Tighten M6...

Page 1232: ...ON Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping 3 Apply Mopart Engine RTV GEN II at the camshaft cap corners and at the top edges...

Page 1233: ...HEAD COVER S REMOVAL 2 Remove camshafts Refer to 9 ENGINE CYL INDER HEAD CAMSHAFT S REMOVAL 3 Rotate crankshaft until piston is at TDC on compression 4 With air hose attached to adapter tool installe...

Page 1234: ...998772 A with adapter 6779 to compress valve springs only enough to install locks Fig 33 Correct alignment of tool is necessary to avoid nick ing valve stems 3 Remove air hose and install spark plugs...

Page 1235: ...d still leaves lash in the system 10 Faulty lash adjuster a Check lash adjusters for sponginess while installed in cylinder head Depress part of rocker arm over adjuster Normal adjusters should feel v...

Page 1236: ...TION 1 Lubricate rocker arm with clean engine oil 2 Using Special Tools 8215A and 8436 slowly depress valve assembly until rocker arm can be installed on the hydraulic lifter and valve stem Fig 38 3 R...

Page 1237: ...re and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone recommended tool C 3501 or equivalent equipped with 280 grit stones if the cylinder b...

Page 1238: ...lls should be checked for out of round and taper with Tool C119 or equivalent Fig 44 Refer to 9 ENGINE SPECIFICATIONS If the cylinder walls are badly scuffed or scored the cylinder block should be rep...

Page 1239: ...cating probe perpendicular on nose of crankshaft Fig 47 2 Move crankshaft all the way to the rear of its travel 3 Zero the dial indicator 4 Move crankshaft all the way to the front and read the dial i...

Page 1240: ...block dowel pins to prevent damage to the dowel pins and thrust bearing 17 Lift out crankshaft from cylinder block Do not damage the main bearings or journals when removing the crankshaft INSPECTION...

Page 1241: ...furthest forward position Step 5 Install and tighten bolts 1 10 in sequence shown in Fig 52 to 41 N m 30 ft lbs Step 6 Remove wedge tool used to hold crank shaft 9 Tighten bolts 1 10 again to 41 N m...

Page 1242: ...g service procedures are to be cleaned and oiled before installation Bearing shells are available in standard and the following undersized 0 025 mm 0 001 in and 0 250 mm 0 010 in Never install an unde...

Page 1243: ...o 41 N m 30 ft lbs in sequence shown in Fig 56 CAUTION Do Not use a torque wrench for the fol lowing step 11 Turn bolts 1 10 an additional 1 4 turn in sequence shown in Fig 56 12 Install main bearing...

Page 1244: ...R REMOVAL 1 Remove transaxle Refer to TRANSMISSION TRANSAXLE REMOVAL for procedure 2 Remove flex plate 3 Insert a 3 16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft...

Page 1245: ...en into the block past flush this may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 63 until the tool bot toms out against the block Fig 64 Fig 61 R...

Page 1246: ...er block Be sure to keep tops of pistons covered during this operation 2 Pistons have a directional stamping in the front half of the piston facing towards the front of engine Fig 65 3 Remove oil pan...

Page 1247: ...guide rod over the crankshaft journal 6 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal NOTE The connecting ro...

Page 1248: ...the piston Fig 72 CAUTION Install piston rings in the following order Oil ring expander Upper oil ring side rail Lower oil ring side rail No 2 Intermediate piston ring No 1 Upper piston ring 2 Instal...

Page 1249: ...27 A Fig 75 INSTALLATION 1 Install crankshaft vibration damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Fig 76 2 Install crankshaft vibration damper bolt and t...

Page 1250: ...40 ft lbs 2 Install engine front mount bracket and insula tor Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT INSTALLATION 3 Lower vehicle ENGINE MOUNTING DESCRIPTION The engine mounting system consist...

Page 1251: ...bolts 8 Remove the horizontal bolts from the mount to the transaxle Fig 81 or Fig 82 NOTE To remove mount additional lowering of transaxle may be required 9 Remove left mount INSTALLATION 1 Install l...

Page 1252: ...ching bracket to transaxle Fig 85 7 Remove rear mount bracket INSTALLATION 1 Install rear mount bracket if removed Fig 85 2 Install the rear mount and bolts Fig 84 Tighten bolts to 54 N m 40 ft lbs 3...

Page 1253: ...e bolts attaching the engine mount to the engine bracket Fig 86 9 Remove the right engine mount Fig 86 INSTALLATION 1 Position right engine mount and install frame rail to mount vertical bolts Fig 86...

Page 1254: ...lubrication to the valve stems Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 1 Discon...

Page 1255: ...plug threads for stretching or other damage Replace drain plug and gasket if damaged 6 Remove oil filter Refer to 9 ENGINE LUBRI CATION OIL FILTER REMOVAL 7 Install and tighten drain plug in crankcas...

Page 1256: ...vehicle and fill engine crankcase with proper oil to correct level OIL PRESSURE SWITCH REMOVAL 1 Raise vehicle 2 Position oil collecting container under pressure switch location 3 Disconnect oil pres...

Page 1257: ...95 3 Remove pump rotors Fig 95 4 Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 91 Crankshaft Sprocket Removal 1 SPECIAL TOOL 6793 2 SPECIAL TOOL C 4685 C2 3 CRANKSH...

Page 1258: ...ss and diameter of outer rotor If outer rotor thickness measures 9 40 mm 0 370 in or less Fig 98 or if the diameter is 79 95 mm 3 148 in or less replace outer rotor 4 If inner rotor measures 9 40 mm 0...

Page 1259: ...g 93 CAUTION To align the front crankshaft seal MUST be out of pump or damage may result 5 Install new front crankshaft seal using Special Tool 6780 Fig 101 6 Install crankshaft key Fig 92 CAUTION The...

Page 1260: ...one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN...

Page 1261: ...voir if equipped at upper intake manifold fittings 9 Disconnect throttle speed control if equipped and transaxle control 31TH equipped only cables from throttle lever and bracket Refer to 14 FUEL SYST...

Page 1262: ...e tube to throttle body 13 Connect inlet air temperature sensor connec tor Fig 104 14 Connect negative cable to battery INTAKE MANIFOLD LOWER REMOVAL 1 Perform fuel system pressure release proce dure...

Page 1263: ...and high tempera tures The manifold attaches to the cylinder head OPERATION The exhaust manifold collects the exhaust gasses exiting the combustion chambers Then it channels the exhaust gasses to the...

Page 1264: ...ne Fig 115 INSTALLATION REAR COVER 1 Install timing belt rear cover and bolts Fig 115 CAUTION Do not use an impact wrench for tighten ing camshaft sprocket bolt Damage to the timing locating pin can o...

Page 1265: ...oist 4 Remove right front wheel 5 Remove right inner splash shield 6 Remove accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE BELT TENSION ERS REMOVAL Fig 113 ENGINE FRONT MOUNT BRACKET 1 ENGIN...

Page 1266: ...marks before removing timing belt 14 Before the removal of the timing belt rotate crankshaft until the TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket trailing edge of spr...

Page 1267: ...a pre determined depth from the factory for correct tim ing belt tracking If removed use of Special Tool 6792 is required to set the sprocket to original installation depth An incorrectly installed s...

Page 1268: ...CAUTION Ensure that the arrows on both camshaft sprockets are facing up 3 Install timing belt Starting at the crankshaft go around the water pump sprocket idler pulley camshaft sprockets and then aro...

Page 1269: ...all crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 12 Install accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 13 Install dri...

Page 1270: ...5 4 Install timing belt idler pulley and torque mounting bolt to 61 N m 45 ft lbs 5 Install camshaft sprockets Use Special Tool 6847 to hold sprockets Fig 124 torque bolts to 101 N m 75 ft lbs 6 Insta...

Page 1271: ...move chain and sprocket 6 Using two wide pry bars work the crankshaft sprocket back and forth until it is off the crankshaft shaft 7 Remove gear cover retaining stud double ended to also retain chain...

Page 1272: ...Turn balance shafts until both shaft key ways are up parallel to vertical centerline of engine Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft After insta...

Page 1273: ...chain is over the number 1 cyl inder timing mark on the balance shaft crankshaft sprocket Fig 135 8 Place balance shaft sprocket into the timing chain Fig 135 and align the timing mark on the sprocke...

Page 1274: ...c Place a shim 1 mm 0 039 in thick x 70 mm 2 75 in long or between tensioner and chain Push tensioner and shim up against the chain Apply firm pressure 2 5 3 Kg 5 5 6 6 lbs directly behind the adjust...

Page 1275: ...9 AIR CLEANER HOUSING REMOVAL 99 INSTALLATION 100 CYLINDER HEAD DESCRIPTION 100 OPERATION 100 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 100 REMOVAL CYLINDER HEAD 100 CLEANING 101 INSPECTION 101 INSTA...

Page 1276: ...G ROD DESCRIPTION 126 OPERATION 126 STANDARD PROCEDURE STANDARD PROCEDURE FITTING CONNECTING RODS 127 STANDARD PROCEDURE FITTING PISTONS 127 REMOVAL 127 INSTALLATION 128 PISTON RINGS STANDARD PROCEDUR...

Page 1277: ...URE STANDARD PROCEDURE VALVE TIMING VERIFICATION 155 STANDARD PROCEDURE MEASURING TIMING CHAIN WEAR 155 TIMING CHAIN COVER REMOVAL 155 INSTALLATION 156 TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL TIMIN...

Page 1278: ...r to 9 ENGINE DIAGNOSIS AND TESTING PERFORMANCE For fuel system diagnosis Refer to 14 FUEL SYSTEM FUEL DELIVERY DIAGNOSIS AND TESTING Additional tests and diagnostic procedures may be necessary for sp...

Page 1279: ...n 5 Incorrect spark plug gap 5 Set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS 6 Contamination in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump 7 Test fuel pump a...

Page 1280: ...y 9 Faulty ignition coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Clean spark plugs and s...

Page 1281: ...sters 7 Replace hydraulic lifters lash adjusters 8 Worn valve guides 8 Replace cylinder head assembly 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves CONNECTING ROD NOI...

Page 1282: ...Check engine oil level 2 Faulty oil pressure sensor switch 2 Replace oil pressure sensor switch 3 Low oil pressure 3 Check oil pressure sensor switch and main bearing oil clearance 4 Clogged oil filt...

Page 1283: ...the fresh air hose make up air at the cylinder head cover and plug or cap the nipple on the cover Remove the PCV valve hose from the cylinder head cover Cap or plug the PCV valve nipple on the cover A...

Page 1284: ...y 3 Remove all spark plugs from engine As spark plugs are being removed check electrodes for abnor mal firing indicators fouled hot oily etc Record cyl inder number of spark plug for future reference...

Page 1285: ...inches the other is a metric scale NOTE Plastigage is available in a variety of clear ance ranges Use the most appropriate range for the specifications you are checking 4 Install the proper crankshaft...

Page 1286: ...All mounting holes must be circled For corner sealing a 3 17 or 6 35 mm 1 8 or 1 4 in drop is placed in the center of the gasket contact area Uncured sealant may be removed with a shop towel Component...

Page 1287: ...R WORN THREADS Damaged or worn threads excluding spark plug and camshaft bearing cap attaching threads can be repaired Essentially this repair consists of drilling out worn or damaged threads tapping...

Page 1288: ...ure ECT sensor and ignition coil electrical connectors 20 Disconnect the fuel injector electrical harness connector and disengage clip from support bracket 21 Disconnect camshaft and crankshaft positi...

Page 1289: ...sconnect the engine block heater electrical connector if equipped 43 Remove the accessory belt splash shield 44 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 45 Di...

Page 1290: ...st mounts until the engine is resting on posts Tighten all cradle post mounts to cradle frame This will keep mounts from moving when removing or installing engine and transmission 56 Lower vehicle so...

Page 1291: ...nerator and wiring harness Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 9 Raise vehicle 10 Attach wiring harness support clip to the engine oil dipstick tube 11 Connect oil pressure switch el...

Page 1292: ...e harness clip to engine right side mount 41 Connect the brake booster and speed control vacuum hoses 42 Connect the vacuum hoses to the throttle body 43 Connect the EGR transducer electrical connec t...

Page 1293: ...Taper Service Limits 0 051 mm 0 002 in Lifter Bore Diameter 22 980 23 010 mm 0 905 0 906 in Deck Surface Flatness Max 0 1 mm 0 004 in Pistons Piston Diameter 3 3L Measured 39 8 mm 1 567 in from pisto...

Page 1294: ...Steel Rails 3 3L 0 435 0 490 mm 0 017 0 019 in 3 8L 0 435 0 510 mm DESCRIPTION SPECIFICATION 0 017 0 020 in Connecting Rod Bearing Clearance 0 019 0 065 mm 0 0008 0 0026 in Wear Limit 0 074 mm 0 003...

Page 1295: ...Gasket Thickness Compressed 0 65 0 75 mm 0 025 0 029 in DESCRIPTION SPECIFICATION Valve Seat Angle 44 5 45 Valve Seat Runout Service Limits 0 0762 mm 0 003 in Valve Seat Width Intake Exhaust 1 50 2 00...

Page 1296: ...SPECIFICATION 3 148 in Tip Clearance Between Rotors Max 0 20 mm 0 008 in Oil Pressure At Curb Idle Speed Minimum with engine at operating temerature 34 47 kPa 5 psi At 3000 rpm 205 551 kPa 30 80 psi O...

Page 1297: ...Filter Adapter Bolts 28 250 Oil Gallery Plug 27 20 Oil Pan Bolts 12 105 Oil Pan Drain Plug 27 20 Oil Pressure Switch 23 200 Oil Pump Cover Plate Screws 12 105 Oil Pump Pick up Tube Bolt 28 250 Oil Dip...

Page 1298: ...ft 8450 Crankshaft Damper Sprocket Installer 8452 Indicator Cylinder Bore C 119 Tester Valve Spring C 647 Compressor Valve Spring In vehicle 8453 Valve Spring Compressor Off vehicle C 3422 D RS ENGINE...

Page 1299: ...Front Seal 6341A Installer Crankshaft Front Seal C 4992 Remover and Installer Crankshaft Main Bearing C 3059 Rear Crankshaft Oil Seal Installer 6926 Oil Pressure Gauge C 3292 Adapter 8406 Cooling Sys...

Page 1300: ...clips AIR CLEANER HOUSING REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the inlet air temperature sensor Fig 16 3 Remove the inlet hose to throttle body 4 Remove the bolt for air box a...

Page 1301: ...LINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the proce dures in Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TE...

Page 1302: ...omponents and multi layer steel cylinder head gaskets NOTE Multi Layer Steel MLS head gaskets require a scratch free sealing surface Remove all gasket material from cylinder head and block Refer to 9...

Page 1303: ...ethod they should be exam ined BEFORE reuse If the threads are necked down the bolts must be replaced Fig 21 4 Necking can be checked by holding a scale or straight edge against the threads If all the...

Page 1304: ...ocation Fig 23 NOTE Due to the tight packaging near the cylinder head covers which makes spill clean up difficult a spill during an engine oil change may be misinter preted as an oil leak When investi...

Page 1305: ...er head cover Fig 24 8 Connect spark plug wires to spark plugs 9 Install wiper module Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER MODULE INSTALLATION 10 Connect negative cable to battery Fig 24 P S Su...

Page 1306: ...with four bead lock grooves The valve stem seals are made of Viton rubber OPERATION The two valves per cylinder are opened using hydraulic lifters push rods and rocker arms STANDARD PROCEDURE REFACIN...

Page 1307: ...efacing the valve and seat Fig 32 If valves and or seats are reground measure the installed height of springs Fig 32 make sure measurements are taken from top of spring seat to the bottom surface of s...

Page 1308: ...cylinder head 2 Install valve spring seat on head Fig 36 3 Install new seals on all valve stems and over valve guides Fig 36 Install valve springs and valve retainers Fig 36 4 Install the valve sprin...

Page 1309: ...e engine until the piston in the cylinder bore requiring spring removal is at TDC 6 Install Special Tool 8453 to the cylinder head Fig 38 Tighten the attaching bolts to 23 N m 200 in lbs 7 Install a s...

Page 1310: ...INSTALLATION INSTALLATION CYLINDER HEAD OFF 1 If removed install a new valve stem seal Refer to 9 ENGINE CYLINDER HEAD VALVE STEM SEALS INSTALLATION 2 Position valve spring and retainer on spring seat...

Page 1311: ...and up motions on the valve stem on the opposing end OPERATION PUSHRODS The pushrod is a solid link between the hydraulic lifter and the rocker arm Also the pushrod supplies engine oil from the hydrau...

Page 1312: ...the rocker arm and shaft assemblies on the pedestal mounts CAUTION Ensure all pushrods are properly located on the lifter and the rocker arm socket 2 Align each rocker arm socket with each push rod en...

Page 1313: ...ER LENGTH 5 ROCKER ARM EXHAUST 2 SHAFT RETAINER SPACER 21 5 mm 0 84 in 6 WASHER 3 SHAFT RETAINER SPACER 37 5 mm 1 47 in 7 ROCKER ARM INTAKE LARGER OFFSET 4 SHAFT RETAINER SPACER 40 9 mm 1 61 in 8 ROCK...

Page 1314: ...down fast enough to get a cross hatch pattern When hone marks intersect at 40 60 degrees the cross hatch angle is most satisfactory for proper seat ing of rings Fig 45 4 A controlled hone motor speed...

Page 1315: ...earing journal and rear lobe Fig 48 The 3 3L engine application is as cast only The 3 8L engine applica tion the cast ring is machined off OPERATION The camshaft is driven by the crankshaft through a...

Page 1316: ...hain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install the cylinder heads Refer to 9 ENGINE CYLINDER HEAD INSTALLATION 10 Install the cylinder head covers Refer to...

Page 1317: ...of taper present Record all readings taken Refer to Engine Specifications Refer to 9 ENGINE SPECIFICA TIONS Plastigage generally is accompanied by two scales One scale is in inches the other is a metr...

Page 1318: ...nt engine on an engine stand 4 Remove the oil filter 5 Remove the oil pan and oil pick up tube Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 6 Remove the timing chain cover Refer to 9 ENGINE VALVE TIM...

Page 1319: ...CK CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE 4 Inspect main cap bolts for stretching Fig 55 Replace bolts that are stretched NOTE The main cap bolts should be examined before reuse Bolt stretch can...

Page 1320: ...Upper main bearing halves of 1 3 and 4 are interchangeable Fig 56 CRANKSHAFT AND BLOCK 3 3L 1 MAIN BEARING CAP No 4 2 MAIN BEARING CAP No 3 3 MAIN BEARING CAP No 2 4 MAIN BEARING CAP BOLT QTY 2 PER CA...

Page 1321: ...earing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 N m 10 15 ft lbs When checking 1 main bearing shim 2 main bearing When checking 2 main bearing shim 1 3 main bea...

Page 1322: ...RANKSHAFT MAIN BEARINGS 1 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 2 Identify main bearing caps before removal 3 Remove bearing caps one at a time Remove upper half of bearing...

Page 1323: ...the holding tool 9 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 10 Fill engine crankcase with proper oil to cor rect level CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Disconnect negati...

Page 1324: ...f the seal Pry out seal CAUTION Do not permit the pry tool blade to con tact crankshaft seal surface Contact of the pry tool blade against crankshaft edge chamfer is permit ted INSTALLATION CAUTION If...

Page 1325: ...BRI CATION OIL PAN INSTALLATION 3 Install oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION FLEX PLATE REMOVAL 1 Remove the transaxle Refer to 21 TRANS MISSION TRANSAXLE AU...

Page 1326: ...ters it causes them to become soft and allows valves to seat noisily Any leaks on intake side of pump through which air can be drawn will create the same lifter noise Check the lubrication system from...

Page 1327: ...nal positions if reused 3 Install lifter aligning yokes Fig 73 4 Install yoke retainer and torque screws to 12 N m 105 in lbs Fig 73 5 Install the cylinder heads Refer to 9 ENGINE CYLINDER HEAD INSTAL...

Page 1328: ...n and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to pis ton pin at size location shown in Fig 76 Cylinder bores should be measured halfway down the cylinder bore...

Page 1329: ...s are butted and the rail gaps located as shown in Fig 80 3 Lubricate the piston and rings with clean engine oil Position a ring compressor over the piston and rings and tighten the compressor Fig 81...

Page 1330: ...me time guide connecting rod into position on connecting rod journal 9 Install lower bearing shell and connecting rod cap Fig 81 Install nuts on cleaned and oiled rod bolts and tighten to 54 N m 40 ft...

Page 1331: ...lean Insert the ring and push down with piston to ensure squareness in bore to approximately 12 mm 0 50 in from top of cylin der bore Check ring gap with a feeler gauge Fig 83 For clearance specificat...

Page 1332: ...r b Upper oil ring side rail c Lower oil ring side rail d No 2 Intermediate piston ring e No 1 Upper piston ring 2 Install the side rail by placing one end between the piston ring groove and the expan...

Page 1333: ...ing screw until damper releases from crankshaft 8 Remove the crankshaft vibration damper INSTALLATION 1 Install crankshaft vibration damper using the forcing screw nut and thrust bearing washer from S...

Page 1334: ...insulator and front crossmember mounting bracket Fig 92 3 Remove six screws from air dam to allow access to the front mount screws 4 Remove the front engine mount screws and remove the insulator asse...

Page 1335: ...NOTE To remove mount additional lowering of transaxle may be required 9 Remove left mount INSTALLATION 1 Install left mount on transaxle Fig 94 or Fig 95 2 Raise transaxle with jack until left mount i...

Page 1336: ...LEFT MOUNT TO BRACKET 1 BOLT BRACKET TO FRAME RAIL 68 N m 50 ft lbs 2 BOLT MOUNT TO RAIL THRU 75 N m 55 ft lbs 3 BOLT LEFT MOUNT TO TRANSAXLE 54 N m 40 ft lbs 4 TRANSAXLE 5 MOUNT LEFT 6 BRACKET LEFT...

Page 1337: ...ig 97 Tighten through bolt to 54 N m 40 ft lbs 4 Install the rear mount heat shield Fig 96 5 Lower vehicle on hoist Fig 97 REAR MOUNT 1 BOLT 54 N m 40 ft lbs 2 REAR MOUNT BRACKET 3 THRU BOLT 54 N m 40...

Page 1338: ...an air tube to throttle body LUBRICATION DESCRIPTION The lubrication system is a full flow filtration pres sure feed type The oil pump is mounted in the tim ing chain cover and is driven by the cranks...

Page 1339: ...ne off 2 Open hood remove oil fill cap 3 Hoist and support vehicle on safety stands Refer to Hoisting and Jacking Recommendations Refer to LUBRICATION MAINTENANCE HOIST ING STANDARD PROCEDURE 4 Place...

Page 1340: ...ECK The best time to check engine oil level is after it 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 Checking th...

Page 1341: ...r 4 Connect oil cooler inlet and outlet hoses Fig 103 5 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM FILLING OIL FILTER REMOVAL CAUTION When servicing the oil filter avoid...

Page 1342: ...move engine oil dipstick 2 Raise vehicle on hoist and drain engine oil 3 Remove drive belt splash shield 4 Remove strut to transaxle attaching bolt Fig 106 Loosen strut to engine block attaching bolts...

Page 1343: ...m 105 in lbs Fig 107 4 Install cover to transaxle case Fig 106 5 Install the strut bolt to transaxle housing Fig 106 Tighten all bending brace bolts 6 Install the drive belt splash shield 7 Lower vehi...

Page 1344: ...nd diagnostic information Refer to Appropriate Wiring Diagnostic Information REMOVAL 1 Raise vehicle on hoist 2 Disconnect electrical connector from switch 3 Remove oil pressure switch Fig 110 INSTALL...

Page 1345: ...place outer rotor 4 If inner rotor thickness measures 7 64 mm 0 301 in or less replace inner rotor Fig 114 5 Install outer rotor into chain case cover Press rotor to one side with fingers and measure...

Page 1346: ...proximately 49 5 mm 1 95 inches it should test between 19 5 and 20 5 pounds when compressed to 34 mm 1 11 32 inches Replace spring that fails to meet specifications Fig 113 Measuring Outer Rotor Thick...

Page 1347: ...ak the composite manifold can be salvaged The vacuum ports are designed to break at the shoulder if overloaded Additional material in the shoulder area provides sufficient stock to repair For more inf...

Page 1348: ...ming this procedure avoid get ting the manifold material residue into the plenum chamber 1 File or sand the remaining port back until a flat surface is obtained plane normal to nipple port axis 2 Dril...

Page 1349: ...ts and remove the manifold Fig 123 13 Cover the lower intake manifold with a suit able cover while the upper manifold is removed 14 Clean and inspect the upper intake manifold Refer to 9 ENGINE MANIFO...

Page 1350: ...ig 123 Install and tighten bolts to 12 N m 105 in lbs following torque sequence in Fig 124 5 Connect the MAP sensor electrical connector 6 Connect the brake booster and LDP vacuum hose to intake manif...

Page 1351: ...MANIFOLD INSPECTION Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD CLEANING CLEANING 1 Discard gasket s 2 Clean all sealing surfaces INSPECTION Check for Damage and cracks of each section Clogged water p...

Page 1352: ...DS INTAKE MANIFOLD INSTALLATION 10 Connect negative battery cable 11 Fill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE Fig 126 ECT SENSOR HEATER SUPPLY 1 ENGINE COOLANT TEMPERATURE SENSOR...

Page 1353: ...the heat shield attaching screws Fig 133 7 Remove the upper heat shield Fig 133 8 Raise vehicle on hoist and remove drive belt shield 9 Loosen the power steering pump support strut lower bolt Fig 131...

Page 1354: ...taching bolts Tighten all bolts to 23 N m 200 in lbs 4 Position the power steering pump support strut and install upper bolt Fig 131 5 Install heat shield and attaching screws Fig 133 6 Install and co...

Page 1355: ...er head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge Fig 137 Manifold surface flatness limits should not exceed 1 0 mm 0 039 in INSTALLATION 1 Positi...

Page 1356: ...to 9 ENGINE VALVE TIMING TIMING CHAIN COVER REMOVAL 1 Position a scale next to timing chain so that any movement of chain may be measured Fig 138 2 Position a torque wrench and socket on the camshaft...

Page 1357: ...aces of chain case cover and cylinder block are clean and free from burrs Crankshaft oil seal must be removed to insure cor rect oil pump engagement NOTE DO NOT USE SEALER ON COVER GASKET 2 Position n...

Page 1358: ...N m 21 ft lb lbs 11 Install idler pulley on engine mount bracket Fig 142 12 Install right side engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 13 Install camshaft position sens...

Page 1359: ...sh shield and right front wheel 21 Fill crankcase with engine oil to proper level 22 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 23 Connect negative cable to battery Fig 145 TIMING CHAIN...

Page 1360: ...Position the sprocket on the crankshaft timing mark out with the timing slot aligned with the tim ing pin 2 Install sprocket using Special Tool 8452 Fig 148 Install sprocket until it is fully seats on...

Page 1361: ...lbs 6 Rotate crankshaft 2 revolutions and check tim ing mark alignment Fig 146 If timing marks do not line up remove camshaft sprocket and realign 7 Install the timing chain cover Refer to 9 ENGINE VA...

Page 1362: ...OVAL 27 INSTALLATION 27 ROCKER ARMS DESCRIPTION 27 OPERATION 27 REMOVAL 27 INSTALLATION 28 HYDRAULIC LIFTERS DESCRIPTION 29 REMOVAL 29 INSPECTION 30 INSTALLATION 30 ENGINE BLOCK DESCRIPTION 30 CRANKSH...

Page 1363: ...TION 61 ENGINE 2 5L TURBO DIESEL DESCRIPTION DESCRIPTION 2 5L COMMON RAIL DIESEL ENGINE This 2 5 Liter 2500cc four cylinder common rail direct injection engine is an in line overhead valve diesel engi...

Page 1364: ...ke tube assembly Fig 3 4 Remove coolant pressure tank pressure cap 5 Raise vehicle on hoist 6 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 7 Remove lower splash shield 8 R...

Page 1365: ...7 COOLING ENGINE COOLANT STANDARD PROCEDURE 16 Remove coolant pressure tank Fig 5 Fig 4 RESERVOIR AND HOSES 2 5L DIESEL 1 POWER STEERING FLUID RESERVOIR 2 RESERVOIR BRACKET 3 SUPPLY HOSE BRACKET 4 RE...

Page 1366: ...r to 13 FRAME BUMPERS FRAME ENGINE CRADLE CROSSMEMBER REMOVAL 35 Remove both axle shaft assemblies Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 36 Disconnect the clutch slave cylinder quick di...

Page 1367: ...ngine cover retaining bolts 2 Remove engine cover from engine Fig 10 Fig 8 ENGINE COMPONENT LOCATIONS 1 FUEL INJECTOR RETURN LINE 2 FUEL INJECTOR SUPPLY LINE 3 OIL SEPARATOR 4 FUEL INJECTOR 5 CAMSHAFT...

Page 1368: ...connectors Fig 8 23 Connect egr solenoid vacuum supply line to brake boost vacuum supply line 24 Connect brake booster vacuum supply line 25 Connect heater core return hose to coolant pipe 26 Connect...

Page 1369: ...Clearance Between Journal and Bearing 0 045 0 080 mm Connecting Rod Journal Nominal 53 940 53 955 mm DESCRIPTION SPECIFICATION 0 25 53 690 53 705 mm Connecting Rod Bearing Nominal 53 977 54 016 mm 0 2...

Page 1370: ...ameter 11 994 0 006 mm VALVES Intake Valve Opens 16 B T D C Closes 58 A B D C Exhaust Valve DESCRIPTION SPECIFICATION Opens 65 B B D C Closes 29 A T D C Face Angle Intake 45 25 55 35 Exhaust 45 25 45...

Page 1371: ...ump Housing Nuts 24 4 18 212 Connecting Rod Bolts Refer to the Service Procedure Balance Shaft Bolts 32 4 24 Oil Jet Bolts 10 8 8 96 Oil Pan Bolts 11 8 8 96 Crankshaft Hub Bolt 304 225 Front Engine Co...

Page 1372: ...Pump Nut 88 3 65 Engine Lift Hook Bolts 32 4 24 Thermostat Housing Bolts 27 5 21 Turbocharger Oil Feed Line Fitting 24 5 18 217 Exhaust Manifold Nuts 32 4 24 Exhaust Manifold Heatshield Bolts 27 5 21...

Page 1373: ...AL TOOLS VM 1001 CYLINDER LINER PULLER VM 1005 TORQUE ANGLE GAUGE VM 1010 CYLINDER LINER PROTRUSION TOOL VM 1013 DIAL INDICATOR VM 1016 CYLINDER RETAINER 9a 12 ENGINE RG ENGINE 2 5L TURBO DIESEL Conti...

Page 1374: ...LIGNMENT PIN VM 1052 INTAKE CAMSHAFT ALIGNMENT PIN VM 1053 EXHAUST CAMSHAFT ALIGNMENT PIN VM 1054 RELIEF VALVE REMOVER CENTRAL CARRIER PIN REMOVER INSTALLER VM 1055 CAMSHAFT INJECTION PUMP GEAR HOLDER...

Page 1375: ...N VM 1059 OIL PRESSURE RELIEF VALVE INSTALLER VM 1060 OIL JET REMOVER INSTALLER VM 1061 FRONT OIL SEAL INSTALLER VM 1062 POWER STEERING PUMP INSTALLER VM 1063 FUEL INJECTOR REMOVER 9a 14 ENGINE RG ENG...

Page 1376: ...ER VM 1065 PISTON RING COMPRESSOR VM 1066 CYLINDER HEAD COVER ALIGNMENT PINS VM 1068 90 DEGREES AFTER TDC ALIGNMENT PIN VM 1069 CRANKSHAFT REM INSTALL SLEEVE VM 1070 FLYWHEEL LOCKING TOOL RG ENGINE 9a...

Page 1377: ...M 1073 CRANKSHAFT FRONT BEARING REMOVER INSTALLER VM 1074 TIMING BELT RETAINER VM 1075 FLYWHEEL ALIGNMENT PINS VM 1077 POWER STEERING BELT REMOVER VM 1078 POWER STEERING BELT INSTALLER 9a 16 ENGINE RG...

Page 1378: ...angle 2 After refacing a margin of at least 4 52 4 49 mm 178 177 inch must remain Fig 12 If the margin is less than 4 49 mm 177 inch the valve must be replaced VALVE SEAT REFACING 1 Install a pilot o...

Page 1379: ...ring the piston of cylinder no 1 exactly to top dead center 3 Zero the dial indicator on the cylinder block mating surface 4 Setup the dial indicator on the piston crown above the center of the piston...

Page 1380: ...ne and remove right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT REMOVAL CAUTION Before removing the cylinder head cover intake manifold or timing belt the engine must put at 90 after TD...

Page 1381: ...nifold studs Fig 17 22 Remove cylinder head bolts Fig 16 TURBOCHARGER AND COOLANT PIPES 1 TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 TURBOCHARGER OUTLET PIPE 3 ADAPTER HOSE 4 HEAT SHIELD 5 HOSE CLAMPS...

Page 1382: ...t was removed can be used 1 Clean and inspect gasket mating surfaces 2 Position correct head gasket on engine block 3 Place cylinder head on engine block Fig 18 CAUTION New cylinder head bolts must be...

Page 1383: ...ALLATION 20 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 21 Install power steering belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 22 Insta...

Page 1384: ...ial indicator The end play should be between 10 mm 30 mm NOTE If the camshaft endplay is not within speci fication measure thickness of the camshaft spacer Camshaft spacer thickness should be 2 8 02mm...

Page 1385: ...BELTS REMOVAL 8 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 9 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL 10 Support engine and remove righ...

Page 1386: ...ter assemblies from cylinder head Fig 25 27 Remove cylinder head cover intake manifold gasket from cylinder head INSTALLATION 1 Clean and inspect sealing surfaces 2 Install new gasket on cylinder head...

Page 1387: ...tube retaining bolt at intake manifold Torque bolt to 27 5 N m 11 Connect oil separator outlet hose at separator 12 Install oil dipstick tube retaining bolt at intake manifold inlet Torque bolt to 10...

Page 1388: ...and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 5 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Using VM 1055 rem...

Page 1389: ...r equivlalent 4 Connect rocker arm s to lifter and reposition on valve s Fig 30 5 Install cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 6 Inst...

Page 1390: ...ilure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 6 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND...

Page 1391: ...ngine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 7 Install engine cover Refer to 9 ENGINE INSTALLATION 8 Install front wiper unit Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER MODU...

Page 1392: ...MING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 7 Remove cylinder head cover intake manifold Refer to 9 E...

Page 1393: ...de special tool VM 1069 on crankshaft Fig 38 20 Using special tool VM 1054 remove crank shaft support retainers Fig 39 21 Slide crankshaft out rear of engine block INSTALLATION NOTE Before installing...

Page 1394: ...fold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 16 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 17 Install timing belt...

Page 1395: ...eck with a dial indicator mounted on a special tool VM 1010 A All the measurements must be taken on high pressure pump side of engine block Zero dial gauge on block deck 3 Move dial gauge to cylinder...

Page 1396: ...GINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL NOTE Crankshaft hub has LHD thread 10 Remove crankshaft hub 11 Remove front engine cover Refer to 9 ENGINE ENGINE BLOCK ENGINE COVER REMOVAL 12 Remo...

Page 1397: ...t 12 mm 0 50 in from bottom of cylinder bore Fig 49 Check gap with feeler gauge Top compression ring gap 30 to 45mm 0118 to 0177 in Second compression ring gap 30 to 45mm 0118 to 0177 in Oil control r...

Page 1398: ...ting rod is centered in cylinder bore NOTE Be careful not to nick or scratch crankshaft journals 9 After removal install bearing cap on the mat ing rod and mark pistons with matching cylinder number w...

Page 1399: ...loosening connecting rod bolts tighten all bolts to 88N m 4 Check and record internal diameter of crank end of connecting rod NOTE When changing connecting rods all four must have the same weight and...

Page 1400: ...ton The third is an oil control ring Ring gaps must be positioned before inserting piston into the liners as follows 3 Top ring gap must be positioned at the 3 posi tion looking at the piston crown fr...

Page 1401: ...aces towards front of engine NOTE Be careful not to nick crankshaft journals 4 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Insert rod and piston into cyl...

Page 1402: ...TIMING BELT CHAIN AND SPROCKETS REMOVAL 9 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL NOTE Crankshaft hub retaining bolt has LHD thread 10 Remove c...

Page 1403: ...13 Install right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 14 Install air cleaner housing 15 Connect negative battery cable VIBRATION DAMPER REMOVAL 1 Remove power steer...

Page 1404: ...S REMOVAL NOTE Crankshaft hub has LHD thread 10 Remove crankshaft hub 11 Remove front engine cover Fig 63 INSTALLATION 1 Clean engine block and front engine cover seal ing surfaces 2 Apply a continous...

Page 1405: ...ft and remove bearing halves from supports Fig 64 CRANKSHAFT FRONT MAIN BEARING 1 Using special tool VM 1073 push front main bearing out of front of engine block Fig 65 Fig 64 CRANKSHAFT ASSEMBLY 1 CR...

Page 1406: ...oil hole in bearing lines up with oil gal lery in engine block Fig 68 3 Reassemble engine and install in vehicle Fig 66 CRANKSHAFT ASSEMBLY 1 CRANKSHAFT SUPPORT HALVE 2 MAIN BEARING HALVE 3 CRANKSHAFT...

Page 1407: ...N 1 Clean oil pan and sealing surfaces Inspect oil pan and engine block 2 Install oil pan gasket and retaining bolts Fig 70 3 Be sure power steering line brackets are in proper location Fig 70 4 Torqu...

Page 1408: ...OVAL 8 Remove crankshaft sprocket Fig 71 9 Remove oil pump retaining bolts and remove pump from engine block Fig 71 REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoist 3 Remove oil pa...

Page 1409: ...N The oil pressure switch is located on the right side of the engine block The switch screws into the engines main oil gallery Fig 73 REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoi...

Page 1410: ...ATION 1 Thoroughly clean all components and relief valve pocket in cylinder block 2 Lubricate all oil pressure relief valve compo nents with engine oil 3 Install oil pressure relief valve plunger spri...

Page 1411: ...6 Remove oil cooler retaining bolt at engine block Fig 79 7 Remove oil cooler retaining stud and remove oil cooler from engine block Fig 79 INSTALLATION 1 Clean oil cooler and engine block sealing sur...

Page 1412: ...style filter Fig 80 REMOVAL 1 Raise vehicle on hoist 2 Remove oil filter cap drain plug and drain oil from oil filter housing Fig 81 3 Remove oil filter cap with suitable oil filter wrench Fig 81 4 R...

Page 1413: ...il jets Damage to oil jet nozzle could cause severe engine damage 1 Lubricate o ring on oil jet 2 Using special tool VM 1060 install oil jet in engine block Fig 83 3 Install oil jet retaining bolt Tor...

Page 1414: ...7 Remove plug in cylinder head cover intake manifold and insert VM 1053 to lock exhaust cam shaft in position Fig 86 8 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL Fig 84 CRANKSH...

Page 1415: ...LATION 18 Connect negative battery cable BALANCE SHAFT DESCRIPTION The 2 5L Common Rail Diesel engine is equipped with two nodular cast iron balance shafts in a cast aluminum carrier The balance shaft...

Page 1416: ...assembly can be installed 2 With balance shaft assembly on work bench Insert special tool VM 1056 into balance shaft assem bly Fig 91 This will ensure proper balance shaft and crankshaft timing after...

Page 1417: ...fer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 7 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRA...

Page 1418: ...M FUEL DELIVERY FUEL INJEC TION PUMP INSTALLATION 5 Install camshaft sprockets Fig 93 Torque bolts to 108N m 6 Install timing belt idler pulleys Refer to 9 ENGINE VALVE TIMING TIMING BELT IDLER PULLEY...

Page 1419: ...lt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL NOTE Idler pulley retaining bolts are LHD thread 10 Remove timing belt idler pulleys Fig 95 INSTALLATION 1 Install timing belt...

Page 1420: ...r Refer to 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER PULLEY ADJUSTMENTS 3 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 4 Install vibratio...

Page 1421: ...embly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE REMOVAL 3 Remove air cleaner housing assembly 4 Support engine and r...

Page 1422: ...MING BELT CHAIN COVER S INSTALLATION 7 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 8 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE B...

Page 1423: ......

Page 1424: ...t system consists of a catalytic converter muffler and a resonator with connecting pipes in be tween Fig 1 The system is serviced in two sections the catalytic converter and pipe and the muffler and r...

Page 1425: ...en clamps at leaking joints 2 Burned or rusted out muffler assembly or exhaust pipe 2 Replace muffler resonator tailpipe assembly or exhaust pipe with catalytic converter assembly 3 Burned or rusted o...

Page 1426: ...for cracked joints broken welds and corrosion damage that would result in a leaking exhaust system Inspect the clamps support brackets and insulators for cracks and corrosion damage NOTE Slip joint b...

Page 1427: ...ultaneously converts three exhaust emissions into harmless gases Specifically HC and CO emissions are con verted into water H2O and carbon dioxide CO2 Oxides of Nitrogen NOx are converted into elemen...

Page 1428: ...to avoid ruining the catalyst core Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes This condition may result in excessive exhaust system floor pan temperat...

Page 1429: ...INSTALLA TION CROSS OVER PIPE 3 3 3 8L REMOVAL 1 Disconnect negative cable from battery 2 Remove the fasteners attaching the left bank manifold connection to cross over pipe Fig 6 3 Raise vehicle and...

Page 1430: ...in lbs Fig 7 Fig 8 or Fig 9 3 Lower vehicle MUFFLER REMOVAL 1 Raise vehicle on a body contact type hoist NOTE To provide removal clearance between muf fler resonator pipe and rear axle parts the rear...

Page 1431: ...ptable exhaust noise levels Provide proper exhaust system back pressure for maintaining emission and performance levels INSTALLATION 1 Install the muffler resonator assembly by guid ing resonator betw...

Page 1432: ...l spot weld breaks Clean remaining spot weld from the pipe using a file or grinder until surface is smooth NOTE Maintain proper clamp orientation when replacing with new clamp 5 Tighten the band clamp...

Page 1433: ......

Page 1434: ...cked or loose joints stripped screw or bolt threads corrosion damage and worn cracked or broken hangers Replace all components that are badly corroded or damaged DO NOT attempt to repair When replacem...

Page 1435: ...ession the air must pass through a charge air cooler to cool the incoming air and maintain power and efficiency Increasing air flow to the engine provides Improved engine performance Lower exhaust smo...

Page 1436: ...as a guide in determining the amount of engine idle time required to sufficiently cool down the turbo charger before shut down depending upon the type of driving and the amount of cargo TURBOCHARGER...

Page 1437: ...NT PIPES 1 TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 TURBOCHARGER OUTLET PIPE 3 ADAPTER HOSE 4 HEAT SHIELD 5 HOSE CLAMPS 6 TURBOCHARGER INLET PIPE RETAINING BOLT 7 TURBOCHARGER INLET PIPE 8 ADAPTER HO...

Page 1438: ...ield Fig 6 Torque bolts to 27 5N m 6 Install engine lift hook Fig 6 Torque bolts to 32 4N m 7 Install thermostat to upper radiator hose tube and turbocharger outlet tube Fig 5 8 Install engine in vehi...

Page 1439: ...N 6 Install front wiper unit Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER MODULE INSTALLATION Fig 8 EXHAUST MANIFOLD AND TURBOCHARGER 1 TURBOCHARGER OIL SUPPLY BANJO BOLT 2 COPPER WASHER 3 EXHAUST MANI...

Page 1440: ...m of fas cia air dam to radiator closure panel 5 Remove front wheels 6 Remove front wheelhouse splash shields fasten ers as necessary to gain access to bolts attaching front fascia to fender Refer to...

Page 1441: ...t from vehi cle INSTALLATION NOTE Check position of the arrows molded into the foam for correct orientation 1 Support front bumper reinforcement using a suitable lifting device and lift into position...

Page 1442: ...een liftgate and fascia 5 Install the six screws attaching rear fascia to rear fascia brackets 6 Install the four plastic push pins attaching bot tom of rear fascia to fascia support 7 Lower vehicle 8...

Page 1443: ...ick pry up the rear edge of the scuff pad to release tabs from the rear bumper fascia and pull scuff pad to release the forward tabs Fig 5 INSTALLATION 1 Verify that there are fifteen slots in the fas...

Page 1444: ...Fig 6 CROSSMEMBER DIMENSIONS RS FRAME BUMPERS 13 5 FRAME Continued...

Page 1445: ...Fig 7 ENGINE BOX TOP VIEW 13 6 FRAME BUMPERS RS FRAME Continued...

Page 1446: ...Fig 8 ENGINE COMPARTMENT AND FRAME RAIL SIDE VIEW RS FRAME BUMPERS 13 7 FRAME Continued...

Page 1447: ...Fig 9 FULL VEHICLE BOTTOM VIEW 13 8 FRAME BUMPERS RS FRAME Continued...

Page 1448: ...cedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure These thread inserts have been specifically devel oped for this application and use of other...

Page 1449: ...hose coupling 9 Using a hose pinch off pliers C 4390 pinch power steering oil return hose off between the cross member coupling and the pump 10 Loosen hose clamp at the cradle crossmember coupling 11...

Page 1450: ...REAR MOUNT Fig 13 CRADLE CROSSMEMBER MOUNT 1 CROSSMEMBER MOUNT 2 BRAKE HOSE MOUNT 3 STEERING TIE ROD 4 FRONT CROSSMEMBER 5 FRAME RAIL Fig 14 CRADLE CROSSMEMBER 1 ENGINE OIL PAN 2 TRANSAXLE 3 LOWER CO...

Page 1451: ...shaft 18 Install steering column cover backing plate Refer to 23 BODY INSTRUMENT PANEL STEER ING COLUMN COVER BACKING PLATE INSTALLATION 19 Install steering column lower cover from instrument panel Re...

Page 1452: ...EL SENDING UNIT SENSOR DESCRIPTION 4 OPERATION 4 REMOVAL 4 INSTALLATION 6 FUEL LINES DESCRIPTION FUEL LINES HOSES AND CLAMPS 6 STANDARD PROCEDURE HOSES AND CLAMP 6 FUEL PRESSURE REGULATOR OPERATION 7...

Page 1453: ...the fuel pump relay The PCM requires only three inputs and a good ground to operate the fuel pump relay The three inputs are Ignition voltage Crankshaft Position CKP sensor Camshaft Position CMP sens...

Page 1454: ...el Rail 3 3 3 8L 11 8 105 Fuel Tank Strap 54 40 Fuel Tank T Strap 28 2 250 Fuel Filter Bolt 4 5 40 SPECIAL TOOLS FUEL Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 68...

Page 1455: ...ehicle 8 Connect the negative battery cable 9 Pressurize the fuel system with the DRBIIIt and check for leaks FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION The fuel gauge level sending unit is attached t...

Page 1456: ...n slightly 6 Slide level sensor wires through opening fuel pump module Fig 6 7 Slide level sensor out of installation channel in module Fig 3 Wire Terminal Locking Finger 1 LOCKING FINGER 2 WIRE TERMI...

Page 1457: ...are of a special rolled edge construction This construction is used to prevent the edge of the clamp from cutting into the hose Only these rolled edge type clamps may be used in this system All other...

Page 1458: ...3 Ensure both upper and lower O rings were removed with regulator INSTALLATION The fuel pressure regulator is part of the fuel pump module Remove the fuel pump module from the fuel tank to access the...

Page 1459: ...y 400 34 kPa 58 5 psi FUEL PUMP ELECTRICAL CONTROL Voltage to operate the electric pump is supplied through the fuel pump relay For an electrical opera tional description of the fuel pump refer to fue...

Page 1460: ...g from the chassis tube Refer to Fuel Hoses Clamps and Quick Connect Fittings in this Section Place a shop towel under the connections to absorb any fuel spilled from the fitting WARNING WRAP A SHOP T...

Page 1461: ...The fuel tank is constructed of a plastic material Its main functions are for fuel storage and for place ment of the fuel pump module The tank is made from High density Polyethylene HDPE material If e...

Page 1462: ...al connector has a retainer that locks it in place 11 Slide fuel pump module electrical connector lock to unlock Fig 17 12 Push down on connector retainer Fig 18 and pull connector off module 13 Lower...

Page 1463: ...ctor to make sure of connection 9 Fill fuel tank replace cap and connect battery negative cable 10 Use the DRBIIIt scan tool to pressurize the fuel system Check for leaks FUEL TANK FILLER TUBE REMOVAL...

Page 1464: ...NG STANDARD PROCEDURE QUICK CONNECT FITTINGS REMOVAL When disconnecting a quick connect fitting the retainer will remain on the fuel tube nipple WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTI...

Page 1465: ...S UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSES FITTINGS OR LINES THE FUEL SYSTEM PRES SURE MUST BE RELEASED REFER TO THE FUEL PRESSURE RELEASE PROCEDURE I...

Page 1466: ...on 2 Disconnect negative battery cable from battery or auxiliary jumper terminal 3 Clean fitting of any foreign material before dis assembly 4 To release fuel system component from quick connect fitti...

Page 1467: ...AY DESCRIPTION 27 OPERATION 27 IDLE AIR CONTROL MOTOR DESCRIPTION 27 OPERATION 27 REMOVAL 28 INSTALLATION 28 INLET AIR TEMPERATURE SENSOR DESCRIPTION 28 OPERATION 28 MAP SENSOR DESCRIPTION 29 OPERATIO...

Page 1468: ...ored dur ing OPEN LOOP modes except for heated oxygen sensor diagnostics they are checked for shorted con ditions at all times During CLOSED LOOP modes the PCM monitors the inputs from the upstream an...

Page 1469: ...E WARM UP MODE This is an OPEN LOOP mode The following inputs are received by the PCM Manifold Absolute Pressure MAP Crankshaft position engine speed Engine coolant temperature Inlet Intake air temper...

Page 1470: ...PCM senses a wide open throttle condi tion through the Throttle Position Sensor TPS it de energizes the A C compressor clutch relay This disables the air conditioning system and disables EGR if equipp...

Page 1471: ...blem that would drive long term to 25 and short term to another 25 for a total change of 50 away from base pulse width calculation TYPICAL ADAPTIVE MEMORY FUEL CELLS Open Throttle Open Throttle Open T...

Page 1472: ...R ALUMINUM MANIFOLD 11 9 105 THROTTLE CABLE BRACKET PLASTIC MANIFOLD 5 7 50 THROTTLE CABLE BRACKET ALUMINUM MANIFOLD 11 9 105 EGR TUBE PLASTIC MANIFOLD 5 7 50 EGR TUBE ALUMINUM MANIFOLD 11 9 105 THROT...

Page 1473: ...al retainer and throttle cable from the upper end of the pedal lever Fig 2 3 Remove nuts from accelerator pedal attaching studs Remove assembly from vehicle Fig 3 Pressure Gauge Assembly C 4799 B Fuel...

Page 1474: ...in the wide open position and install the throttle cable Fig 1 CRANKSHAFT POSITION SENSOR DESCRIPTION The 2 4L crankshaft sensor is located on the rear of the engine near the accessory drive belt Fig...

Page 1475: ...haft position it begins energizing the injectors in sequence REMOVAL 1 Disconnect the negative battery cable 2 Raise vehicle and support 3 Disconnect the electrical connector Fig 8 4 Remove crankshaft...

Page 1476: ...voltage to each injector through the ASD relay Injector operation is con trolled by a ground path provided for each injector by the PCM Injector on time pulse width is variable and is determined by th...

Page 1477: ...the top slot of the injector The edge of the receiver cup will slide into the side slots of clip 3 Install injector top end into fuel rail receiver cap Be careful not to damage O ring during installa...

Page 1478: ...dle speed through the idle air control motor to compensate for engine load coolant temperature or barometric pressure changes The throttle body has an air bypass passage that provides air for the engi...

Page 1479: ...screws to 2 N m 17 in lbs torque 4 Connect electrical connector to idle air control motor 5 Connect negative cable to battery INLET AIR TEMPERATURE SENSOR DESCRIPTION The IAT Sensor is a Negative Temp...

Page 1480: ...t above sea level because the air density changes with altitude It will also help to correct for varying weather conditions If a hurricane was coming through the pressure would be very very low or the...

Page 1481: ...onding barometric pressure is for your area REMOVAL REMOVAL 2 4L 1 Disconnect the negative battery cable 2 Disconnect electrical connector and vacuum hose from MAP sensor Fig 18 3 Remove two screws ho...

Page 1482: ...width accordingly During Open Loop operation the PCM ignores the O2 sensor input The PCM adjusts injector pulse width based on pre programmed fixed values and inputs from other sensors The Automatic S...

Page 1483: ...ed the threads must be cleaned with an 18 mm X 1 5 6E tap If using the original sensor coat the threads with Loctite 771 64 anti seize compound or equivalent REMOVAL DOWNSTREAM 1 2 2 4 3 3 3 8L 1 Disc...

Page 1484: ...ize compound to the threads of a new oxygen sensor 1 Install sensor and tighten to 27 N m 20 ft lbs 2 Connect the electrical connector 3 Lower vehicle 4 Install the negative battery cable THROTTLE BOD...

Page 1485: ...e cable retainer and throttle cable from the upper end of the pedal shaft 4 Remove retainer clip from throttle cable and grommet at dash panel 5 From the engine compartment pull the throttle cable and...

Page 1486: ...emove the electrical connector from the Inlet Air Temperature sensor 3 Remove the air cleaner box lid Remove hose from throttle body 4 Disconnect the electrical connector at TPS 5 Disconnect the elect...

Page 1487: ......

Page 1488: ...Water draining WARNING HIGH FUEL SYSTEM PRESSURE WARNING THE INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE LINES FUEL UNDER THIS AMOUNT OF PRESSURE CAN P...

Page 1489: ...just behind the alternator Fig 1 3 Attach a hose of about 1 or 2 meters to this fit ting using an appropriate connector 4 Direct the end of the hose into an appropriate fuel container 5 Turn the igni...

Page 1490: ...t 10 8 8 96 Boost Pressure Intake Air Temperature Sensor Bolts 5 4 48 Fuel Pump Nuts 27 5 21 Fuel Line Fittings at Pump 27 5 21 Fuel Pump Sprocket Nut 88 3 65 Fuel Injector Retaining Bolts 32 4 24 Hig...

Page 1491: ...The fuel rail is common to all cylinders hence it s name common rail Even when large quantities of fuel are extracted the fuel rail maintains a constant inner pressure This ensures that the injection...

Page 1492: ...e fuel heater and Water In Fuel WIF sensor OPERATION The fuel filter water separator protects the fuel injection pump by removing water and contaminants from the fuel The construction of the filter se...

Page 1493: ...placement of high pressure fuel line is necessary High pressure fuel lines deliver fuel under extremely high pressure from the injection pump to the fuel injectors The lines expand and contract from t...

Page 1494: ...nsfer pump is controlled by the Engine Control Module ECM The ECM turns the fuel transfer pump on for 30 seconds when the ignition ket is turned ON With the ignition ON and fuel tranfer pump run ning...

Page 1495: ...ket as shown Fig 8 10 Install inner flange of special tool VM 1067 on injection pump sprocket as shown Fig 9 Secure flange to feet in injection pump sprocket with allen bolts supplied with tool 11 Scr...

Page 1496: ...the accessory bracket into the injection pump sprocket 2 Install injection pump retaining nuts Fig 11 Torque nuts to 27 5N m 3 Unscrew injection pump holding plate part of VM 1067 from inner timing be...

Page 1497: ...le WATER IN FUEL SENSOR DESCRIPTION The WIF sensor is located in the bowl assembly of the fuel filter water separator OPERATION The sensor sends an input to the Engine Control Module ECM when it sense...

Page 1498: ...injectors for all four cyl inders These fuel injectors are used to spray fuel into the combustion chamber Fig 1 OPERATION The injector operation can be subdivided into four operating states with the...

Page 1499: ...and the fuel is injected into the combustion chamber at a pressure almost equal to that in the fuel rail Fig 2 Injector closes end of injection As soon as the solenoid valve is no longer trig gered th...

Page 1500: ...or pedal As the accelerator pedal is depressed and released the sensor provides a variable voltage sig nal to the engine control module This voltage signal is directly proportional to accelerator peda...

Page 1501: ...o monitor air pressure within the intake manifold This sensor is also used to monitor the intake air temperature Fig 5 OPERATION When the intake manifold pressure is low high vacuum sensor voltage out...

Page 1502: ...or retain ing screws and sensor Fig 6 INSTALLATION 1 Install intake air temperature sensor and retaining bolts Fig 6 Torque to 5 4 N m 2 Connect intake air temperature sensor 3 Install engine cover an...

Page 1503: ...ure The change in resistance varies the signal voltage output to the ECM The diesel power relay supplies battery power the to MAF sensor Ground is provided by the ECM The MAF sensor signal is provided...

Page 1504: ...f the helical pinion teeth with the rack teeth within the steering gear The lateral travel pushes and pulls the tie rods to change the direction of the vehicle s front wheels Power assist steering is...

Page 1505: ...r steering system on the vehi cle 1 Check belt tension and adjust as necessary 2 Disconnect the power steering fluid pressure hose from the power steering pump Fig 3 Fig 4 3 Connect Adapter Fitting Sp...

Page 1506: ...xtreme left until the stop in the steering gear is met Hold it there for 2 4 seconds then release it Now turn the steering wheel to the right until the right stop is met Hold it there for 2 4 seconds...

Page 1507: ...er tie rod 2 Loose inner tie rod 2 Replace power steering gear CHIRP OR SQUEAL POWER STEERING PUMP 1 Loose power steering pump drive belt 1 Check and adjust power steering pump drive belt to specifica...

Page 1508: ...nd the steer ing wheel is at the end of its travel Hiss is a very high frequency noise similar to that experienced while slowly closing a water tap The noise is present in every valve and results when...

Page 1509: ...id reservoir to specified level and check for leaks 2 Tires not inflated to specified pressure 2 Inflate tires to the specified pressure 3 Lack of lubrication in front lower control arm ball joints 3...

Page 1510: ...assembly 8 Binding shaft bearing in steering column 8 Replace the steering column 9 Excessive friction in steering column coupling 9 Replace steering column coupling 10 Excessive friction in power ste...

Page 1511: ...sed low speed or stationary steer ing effort can be expected if the steering fluid is at a high temperature High fluid temperature usually results from high engine rpm due to trailer towing ascending...

Page 1512: ...Size M14 183 N m 135 ft lbs Mounting Bolts Size M12 95 N m 70 ft lbs Tie Rod Steering Knuckle Nut 75 N m 55 ft lbs Tie Rod Jam Nut 75 N m 55 ft lbs Coupling Pinch Bolt 28 N m 250 in lbs Power Steerin...

Page 1513: ...They are the key cylinder ignition switch lock cylinder housing multi function switch clockspring halo lamp speed control switches driver airbag trim shrouds steering wheel and steering column interm...

Page 1514: ...Fig 2 Steering Column And Components Typical RS COLUMN 19 11 COLUMN Continued...

Page 1515: ...Disconnect negative ground cable from the battery and isolate cable from battery terminal 3 Remove the lower shroud Refer to 19 STEERING COLUMN LOWER SHROUD REMOV AL 4 Remove the traction off switch...

Page 1516: ...ING COLUMN KEY LOCK CYLINDER REMOVAL 25 Remove the BTSI INSTALLATION To service the steering wheel components or the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL Follow all WARN INGS...

Page 1517: ...G WHEEL INSTALLATION 15 Install the vibration damper weight 16 Install the steering wheel retaining nut Tighten the nut to 61 N m 45 ft lbs 17 Install the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVE...

Page 1518: ...re har ness connectors splices and grounds 1 Disconnect negative cable from battery 2 Remove steering column cover retaining screws Fig 8 3 Remove parking brake release cable from han dle Fig 9 4 Remo...

Page 1519: ...ing on the end opposite the lock cylinder Fig 7 For ignition switch terminal and circuit identifica tion refer to the Wiring Diagrams section 1 Ensure the ignition switch is in the RUN posi tion and t...

Page 1520: ...the key to the lock position unless the shifter is in the park posi tion On vehicles equipped with floor shift refer to the Transaxle for Automatic Transmission Shifter Ignition Interlock REMOVAL 1 D...

Page 1521: ...el is mounted to the instrument panel using 2 screws one on each side of the column and retaining clips 7 Remove the 2 screws securing the steering col umn fixed shroud to the steering column Fig 21 t...

Page 1522: ...cylinder straight out of the lock cyl inder housing 11 Remove the vehicle wiring harness connector from the key cylinder halo lamp Fig 25 12 Remove the key cylinder halo lamp from the lock cylinder ho...

Page 1523: ...g holes 2 Install the self tapping lock cylinder housing mounting screws through the top of the column into the housing Fig 29 Tighten the two mounting screws to a torque of 11 N m 100 in lbs 3 Connec...

Page 1524: ...ll the lower steering column shroud on the steering column Install and securely tighten the center screw attaching the lower shroud to the tilt head on the column Fig 20 16 Install the upper steering...

Page 1525: ...EMOVAL 3 Remove the upper and lower shrouds Refer to 19 STEERING COLUMN LOWER SHROUD REMOVAL 4 Remove the cluster trim bezel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL REMOVAL 5 Remove the fixed...

Page 1526: ...etaining screws Tighten the screws to 11 N m 100 in lbs Fig 35 STEERING WHEEL REMOVAL NOTE Before proceeding Refer to 19 STEERING COLUMN WARNING 1 Rotate key cylinder to the lock position and remove k...

Page 1527: ...than a half inch If bolts are threaded into the steering wheel more than a half inch they will contact and damage the clock spring 6 Remove the steering wheel from steering col umn shaft using a stee...

Page 1528: ...damper on the steer ing wheel When damper is installed it must be posi tioned on the steering wheel as shown in Fig 39 3 Install the steering wheel retaining nut Tighten the steering wheel retaining...

Page 1529: ...by an open center rotary type control valve which directs oil from the pump to either side of the integral rack piston upon demand Road feel is controlled by the diameter of a torsion bar which initia...

Page 1530: ...tire assemblies 7 Remove front emissions vapor canister Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS VAPOR CANISTER REMOVAL 8 Remove a single hose at power steering cooler and allow fluid to dr...

Page 1531: ...ion of the various sizes 14 Remove the bolts attaching the cradle cross member reinforcement to the front suspension cradle crossmember Fig 6 Remove the 2 bolts fastening the reinforcement and rear of...

Page 1532: ...ehicle on the ground disconnect the steering column shaft coupler from the steering gear intermediate coupler Fig 2 6 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 7 Remo...

Page 1533: ...steering gear 19 Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin Fig 9 Install Remover Installer Special Tool 6831A through the center of the rol...

Page 1534: ...N CRADLE 4 REMOVER SPECIAL TOOL 6831A 5 STEERING GEAR 6 NUT 7 ROLL PIN 8 THREADED ROD Fig 10 RHD Gear Heat Shield And Hose Fittings 1 HEAT SHIELD 2 CRADLE CROSSMEMBER 3 RETURN HOSE FITTING 4 PRESSURE...

Page 1535: ...n the cradle reinforce ment to suspension cradle mounting bolts is very important 7 Install the reinforcement on the front suspen sion cradle crossmember and install the bolts attach ing the reinforce...

Page 1536: ...radle mounting bolt to a torque of 95 N m 70 ft lbs CAUTION Proper torque on the steering gear to suspension cradle mounting bolts is very impor tant 5 Install the heat shield on the steering gear Fig...

Page 1537: ...t wheel toe Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE SPECIAL TOOLS POWER STEERING GEAR OUTER TIE ROD REMOVAL 1 Loosen inner tie rod to outer tie rod jam nut Fig 14 2 Remove nut attac...

Page 1538: ...ghten tie rod jam nut Fig 14 to 75 N m 55 ft lbs torque CAUTION During this procedure do not allow the steering gear boot to become twisted 5 Adjust the front toe setting on the vehicle Refer to 2 SUS...

Page 1539: ...ON 3 3L 3 8L ENGINE 50 HOSE POWER STEERING SUPPLY REMOVAL REMOVAL 2 4L ENGINE 51 REMOVAL 3 3L 3 8L ENGINE 51 INSTALLATION INSTALLATION 2 4L ENGINE 51 INSTALLATION 3 3L 3 8L ENGINE 51 RESERVOIR POWER S...

Page 1540: ...D WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS CAUTION CAUTION When the system is open cap all open ends of the hoses power steering pump fittings or power steering gear ports to p...

Page 1541: ...sensor wiring harness from the vehicle wiring harness at the rear engine mount bracket NOTE The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pu...

Page 1542: ...oses 2 4L 1 POWER STEERING PUMP 2 RETURN HOSE HEAT SLEEVE COVERED 3 ROUTING CLAMPS 4 PRESSURE HOSE TUBE NUT 5 RETURN HOSE TUBE NUT 6 CRADLE CROSSMEMBER 7 POWER STEERING GEAR 8 PRESSURE HOSE Fig 6 Powe...

Page 1543: ...iper module unit Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MOD ULE REMOVAL 3 Raise the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 4 Remove the drive belt splash shield 5 Re...

Page 1544: ...ose from the pump Fig 12 9 Remove the bolt fastening the stamped bracket on the rear of the pump to the cast bracket Fig 13 10 Remove the three front mounting bolts through the pulley 11 Remove the pu...

Page 1545: ...p once the pump is removed from the vehicle 1 Install the pulley with Installer C 4063 Fig 15 Do not use the tool adapters 2 Ensure that the tool and the pulley remain aligned with the pump shaft Prev...

Page 1546: ...ve battery post 15 Perform the POWER STEERING PUMP INI TIAL OPERATION procedure to properly fill and bleed the power steering system Refer to 19 STEERING PUMP STANDARD PROCEDURE 16 Inspect for leaks I...

Page 1547: ...POWER STEERING PUMP FLUID STANDARD PROCEDURE POWER STEERING FLUID LEVEL CHECKING WARNING FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS AND TO ENSURE ACCU RATE...

Page 1548: ...luid reservoir 2 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 3 Remove the hose clamps at the cooler and remove the hoses from the cooler inlet and outlet tubes 4 Remove...

Page 1549: ...luid 7 Disconnect pressure hose at power steering gear Fig 20 8 Remove pressure hose routing bracket bolt at engine Fig 21 Bolt can be accessed through hole in cradle crossmember Fig 22 9 Disconnect p...

Page 1550: ...D PROCEDURE 12 Inspect system for leaks INSTALLATION 3 3L 3 8L ENGINE 1 Remove any used O rings from ends of power steering hose 2 Using a lint free towel wipe clean hose ends power steering pump pres...

Page 1551: ...lbs torque 8 Route hose behind cradle crossmember and start hose end into gear port Do not tighten hose tube nut at this time 9 Attach hose to suspension cradle crossmember and steel reinforcement usi...

Page 1552: ...crossmember reinforcement Fig 23 9 Remove bolts attaching routing clamps to front suspension cradle crossmember Fig 19 Remove return hose from clamps 10 Back out return hose tube nut at power steer i...

Page 1553: ...SSIONS VAPOR CANISTER INSTALLATION 12 Lower vehicle 13 Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure Refer to 19 STEERING PUMP STAN DARD PROCEDURE...

Page 1554: ...Fig 21 INSTALLATION INSTALLATION 2 4L ENGINE 1 Install and correctly route power steering fluid supply hose from remote fluid reservoir to power steering pump 2 Install fluid supply hose onto power st...

Page 1555: ...ble from power steering fluid reservoir 3 Open retainer on side of reservoir and remove cables from retainer 4 Remove clamp attaching supply hose to power steering fluid reservoir Disconnect hose from...

Page 1556: ...se clamp in installed past bead on fluid reservoir fitting 4 Install return hose onto reservoir Fig 21 Slide the hose clamp into position on fluid reservoir and attach it Be sure hose clamp in install...

Page 1557: ......

Page 1558: ...FT INNER SEAL REMOVAL 12 INSTALLATION 13 INPUT SHAFT COVER SEAL REMOVAL 13 INSTALLATION 14 INPUT SHAFT END SEAL REMOVAL 16 INSTALLATION 16 INPUT SHAFT SEAL REMOVAL 17 INSTALLATION 18 OUTER HALF SHAFT...

Page 1559: ...Power Transfer Unit Components 21 2 POWER TRANSFER UNIT RS POWER TRANSFER UNIT Continued...

Page 1560: ...T DIFFERENTIAL PINION 8 TAPERED ROLLER BEARING 25 LOCK NUT HEX FLANGE 42 PIN 9 SEAL RING 26 O RING 43 CASE DIFFERENTIAL 10 SEAL RING 27 RETAINER PLATE 44 TAPERED ROLLER BEARING CONE 11 HEX HEAD SCREW...

Page 1561: ...vice Procedures If fluid is leaking from weep hole B Fig 5 the type of fluid leaking will determine which seal is leaking If the fluid leaking is red in color transmis sion fluid this indicates that t...

Page 1562: ...URE PTU FLUID CHANGE NOTE PTU Fluid should be changed upon servic ing the unit or at the unit s regular scheduled inter val Refer to LUBRICATION MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION 1 Raise v...

Page 1563: ...peller shaft front flange CAUTION Do not let propeller shaft to hang freely Damage to the shaft will occur 4 Remove propeller shaft assembly Fig 10 Refer to 3 DIFFERENTIAL DRIVELINE PRO PELLER SHAFT R...

Page 1564: ...Fig 15 Record this measurement 5 Repeat steps Step 1 through Step 4using the new flange and the original shim Record this measurement 6 If measurements are not equal use a new shim that protrudes from...

Page 1565: ...N m 180 in lbs Rear Cover 28 N m 250 in lbs Ring Gear 94 N m 70 ft lbs SPECIAL TOOLS SDP POWER TRANSFER UNIT 5049 a Seal Puller 5065 Bearing Installer 6514 Bearing Remover 6522 Bearing Remover 7794 a...

Page 1566: ...he vehicle 3 Check and fill fluids as required END COVER BALL BEARING REMOVAL The end cover ball bearing can be removed and installed without removing the Power Transfer Unit from the vehicle When rep...

Page 1567: ...all bearing Fig 20 into the housing 2 Install bearing retaining snap ring CAUTION When installing bearing retaining snap ring be sure to index the snap ring so that the snap ring does not cover bearin...

Page 1568: ...STALLATION 1 Reinstall cover and tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 24 Retighten first bolt after all others are tight CAUTION When end cover is installed be careful not t...

Page 1569: ...emove end cover bolts Fig 25 3 Tap on end cover ears to separate cover from case Fig 26 4 Drive seal out with a hammer and small chisel Fig 27 Fig 26 End Cover Removal 1 END COVER EARS 2 HAMMER 3 POWE...

Page 1570: ...cover onto P T U case and install bolts Tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 29 Retighten first bolt after all other bolts are tight 5 Reinstall P T U assembly 6 Check and f...

Page 1571: ...cover The differential bearing cup must be removed to service this seal 1 Clean and inspect seal area 2 Use special tool No MD998803 and install seal Fig 34 When installing seal the spring side of the...

Page 1572: ...stall bolts Tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 37 Retighten first bolt after all others are tight CAUTION When end cover is installed be careful not to damage the P T U In...

Page 1573: ...2 Remove input shaft from housing and stand on soft block of wood Install input shaft end seal with seal installer 5065 and handle C 4171 3 Lubricate seal lip after installing seal into input shaft 4...

Page 1574: ...le to service this seal Refer to Power Trans fer Unit Removal in this section for procedures 1 Remove P T U end cover bolts Fig 42 2 Gently tap on end cover ears to separate cover from case Fig 43 3 R...

Page 1575: ...led with the spring side facing towards the ring gear Drive the seal in until it bot toms against the case shoulder 3 Install input shaft 4 Install oil trough Fig 44 Oil Trough 1 OIL TROUGH 2 POWER TR...

Page 1576: ...vehicle 3 Remove seal with a chisel and hammer Fig 48 INSTALLATION The outer half shaft seal is located on the outside of the end cover The P T U does not have to be removed to replace this seal 1 Cle...

Page 1577: ...r O Ring Fig 53 INSTALLATION 1 To install reverse removal procedure Fig 52 Rear Cover Removal 1 POWER TRANSFER UNIT ASSEMBLY 2 REAR COVER 3 O RING Fig 51 Mark Rear Cover 1 REAR COVER 2 OUTPUT SHAFT 3...

Page 1578: ...82 OPERATION 82 DISASSEMBLY 82 ASSEMBLY 84 CLUTCH REAR DESCRIPTION 86 OPERATION 86 DISASSEMBLY 87 ASSEMBLY 89 FINAL DRIVE DISASSEMBLY 91 ASSEMBLY 94 ADJUSTMENTS ADJUSTMENT DIFFERENTIAL BEARING 97 FLUI...

Page 1579: ...al oil sump is common with the transaxle sump Separate filling of the differen tial is NOT necessary The torque converter is attached to the crankshaft through a flexible driving plate Cooling of the...

Page 1580: ...NVERTER CLUTCH 2 TORQUE CONVERTER 3 OIL PUMP 4 FRONT CLUTCH 5 REAR CLUTCH 6 OVER RUNNING CLUTCH 7 PLANETARY GEARS 8 TRANSFER GEARS 9 SHAFT 10 GOVERNOR 11 DIFFERENTIAL RS 31TH AUTOMATIC TRANSAXLE 21 23...

Page 1581: ...saxle problems should always begin with checking the easily accessible variables Fluid level and condition Gearshift cable adjustment Throttle valve cable adjustment After verifying or adjusting these...

Page 1582: ...REVERSE 1 Fluid Level Low 1 Correct level and check for leaks 2 Filter Clogged 2 Change filter 3 Gearshift Linkage Misadjusted 3 Adjust linkage and repair linkage if worn or damaged 4 Rear Band Misad...

Page 1583: ...se Misadjusted 2 Inspect adjust and reassemble linkage as needed Replace worn damaged parts 3 Filter Plugged 3 Remove and disassemble transmission Repair or replace failed components as needed Replace...

Page 1584: ...gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Misadjusted Damaged 1 Repair or replace linkage parts as needed 2 Rear Band Misadjusted Worn 2 Adjust band repl...

Page 1585: ...ressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 5 Valve Body Malfunction 5 Sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shi...

Page 1586: ...Air pressure check clutch servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks...

Page 1587: ...required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan WHINE NOISE RELATED TO ENG...

Page 1588: ...hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent d...

Page 1589: ...he actual cause of the problem may not be detected Practically any condition can be caused by leaking hydraulic circuits or sticking valves Therefore unless the condition is obvious the transaxle shou...

Page 1590: ...n pressure readings to be taken 2 Operate engine at 1000 rpm for test 3 Move selector lever on transaxle one detent for ward from full rearward position This is selector 2 position Fig 1 Test Port Loc...

Page 1591: ...ise 5 This tests pump output pressure regulation and condition of front clutch and rear servo hydraulic circuits 6 Move selector lever on transaxle to D position to check that low reverse pressure dro...

Page 1592: ...wn the inside of the converter hous ing Fig 3 TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are Torque converter weld leaks at the outside diam eter weld Fig 4 Torque converter...

Page 1593: ...E SERVO REAR Direct air pressure into LOW REVERSE SERVO APPLY passage Operation of servo is indicated by a tightening of rear band Spring tension on servo pis ton should release the band If clutches a...

Page 1594: ...el indicator tube bolt and tube indicator assembly Fig 6 Plug opening to prevent debris intrusion 3 Disconnect torque converter clutch solenoid TCC connector 4 Disconnect kickdown cable from lever and...

Page 1595: ...Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT REMOVAL 11 Remove starter motor assembly Fig 10 Fig 9 Rear Mount Bracket 1 BOLT VERTICAL 2 BRACKET REAR MOUNT 3 BOLT HORIZONTAL Fig 10 Starter Motor Remov...

Page 1596: ...mount thru bolt 18 Support engine with screw jack and wood block 19 Remove torque converter to drive plate bolts 20 Remove left wheel splash shield Fig 11 Front Mount and Bracket 1 BRACKET FRONT MOUNT...

Page 1597: ...1 TRANSMISSION TRANSAXLE AUTOMATIC 31TH FINAL DRIVE DISASSEMBLY 1 Measure input shaft end play before disassembly using Tool 8266 and dial indicator C 3339 Fig 15 a Set up tools as shown in Fig 15 b M...

Page 1598: ...itch 7 Remove park rod retainer e clip Fig 20 Fig 17 Transaxle Oil Pan 1 TRANSAXLE OIL PAN 2 OIL FILTER Fig 18 Oil Filter Screws 1 SCREWDRIVER HANDLE 2 SPECIAL TOOL L 4553 3 OIL FILTER SCREWS 2 4 OIL...

Page 1599: ...and location of governor tubes Fig 21 Parking Rod 1 VALVE BODY 2 PARKING ROD Fig 22 Cooler Bypass Valve and Seal 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL Fig 23 Valve Body Attaching Bolts 1 VALVE BODY...

Page 1600: ...Fig 28 Fig 25 Loosen Low Reverse Band 1 LOW REVERSE BAND LEVER 2 ADJUSTING SCREW 3 STRUT 4 LOW REVERSE BAND 5 LOCK NUT 6 LEVER SHORT Fig 26 Low Reverse Servo Snap Ring 1 SNAP RING PLIERS Fig 27 Remove...

Page 1601: ...e strut removal Fig 29 Accumulator Plate and Snap Ring 1 SNAP RING 2 ACCUMULATOR PLATE 3 88O RING Fig 30 Accumulator Spring and Piston 1 ACCUMULATOR SPRING 2 ACCUMULATOR PISTON 3 SEAL RINGS Fig 31 Kic...

Page 1602: ...WN PISTON ROD GUIDE Fig 34 Kickdown Servo Rod Guide and Snap Ring 1 SNAP RING 2 ACCUMULATOR PLATE 3 RETURN SPRING 4 O RING 5 PISTON ROD GUIDE Fig 35 Kickdown Piston Return Spring and Piston 1 RETURN S...

Page 1603: ...ot shaft Fig 39 26 Remove oil pump to transaxle case bolts Fig 40 Fig 37 Parking Sprag Rod Support 1 PARKING SPRAG ROD SUPPORT 2 BOLT 2 3 OUTPUT SHAFT GEAR Fig 38 Support and Bolts 1 BOLT 2 2 PARKING...

Page 1604: ...2 with Adapters L 4437 1 PUMP 2 PULLERS TOOL C 3752 3 ADAPTERS TOOL L 4437 Fig 42 Oil Pump Removal 1 FRONT CLUTCH 2 OIL PUMP ASSEMBLY Fig 43 Oil Pump Gasket 1 SPLIT IN GASKET DIFFERENTIAL OIL FEED 2 P...

Page 1605: ...embly 1 REAR CLUTCH ASSEMBLY 2 FRONT CLUTCH ASSEMBLY Fig 46 No 2 Thrust Washer and Rear Clutch 1 REAR CLUTCH ASSEMBLY 2 2 THRUST WASHER Fig 47 No 3 Thrust Washer 1 OUTPUT SHAFT 2 SUN GEAR DRIVING SHEL...

Page 1606: ...t Planetary Gear Assembly 1 SUN GEAR 2 FRONT PLANETARY GEAR ASSEMBLY 3 6 THRUST WASHER Fig 50 Sun Gear Driving Shell 1 SUN GEAR DRIVING SHELL 2 REAR PLANETARY GEAR Fig 51 Sun Gear Driving Shell Compon...

Page 1607: ...tary Gear Assembly 1 REAR PLANETARY GEAR ASSEMBLY Fig 54 No 10 Thrust Washer 1 OVERRUNNING CLUTCH CAM ASSEMBLY 2 10 THRUST WASHER Fig 55 Overrunning Clutch Cam Assembly 1 OUTPUT SHAFT 2 OVERRUNNING CL...

Page 1608: ...NAL DRIVE ASSEMBLY NOTE This procedure does not include assembly of transfer system transfer shaft and output shaft components Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 31TH TRANSFER SYSTEM INSTAL...

Page 1609: ...ar planetary gear assembly Fig 63 8 Install 9 thrust washer Fig 64 Use petrola tum to secure Fig 61 Install Overrunning Clutch Rollers and Springs 1 TOOL L 4440 2 ROLLER 8 3 OVERRUNNING CLUTCH CAM ASS...

Page 1610: ...ment is necessary Fig 65 Sun Gear Driving Shell 1 SUN GEAR DRIVING SHELL 2 REAR PLANETARY GEAR Fig 66 Front Planetary Gear Assembly 1 SUN GEAR 2 FRONT PLANETARY GEAR ASSEMBLY 3 6 THRUST WASHER Fig 67...

Page 1611: ...nd Fig 71 Do not install strut or adjust at this time 17 Install oil pump gasket Fig 72 Fig 69 No 2 Thrust Washer and Rear Clutch 1 REAR CLUTCH ASSEMBLY 2 2 THRUST WASHER Fig 70 Front Clutch Assembly...

Page 1612: ...Fig 75 22 Install rod support and bolts Fig 76 Torque bolts to 28 N m 250 in lbs Fig 77 Fig 73 Oil Pump Attaching Bolts 1 SEAL 2 PUMP ATTACHING BOLTS 7 3 PUMP HOUSING Fig 74 Measure Input Shaft End P...

Page 1613: ...HAFT GEAR Fig 78 Controlled Load Kickdown Servo 1 KICKDOWN PISTON 2 O RING 3 SNAP RING 4 PISTON ROD GUIDE 5 SNAP RING 6 O RING 7 PISTON RETURN SPRING 8 PISTON ROD 9 SEAL RINGS Fig 79 Kickdown Piston R...

Page 1614: ...84 and place snap ring into position for installation Fig 81 Kickdown Servo Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE 4 KICKDOWN LEVER 5 KICKDOWN PISTON ROD GUIDE Fig 82 Adjust Kic...

Page 1615: ...ting nut 31 2 turns Torque lock nut to 14 N m 125 in lbs Fig 85 Accumulator Snap Ring 1 ACCUMULATOR PLATE SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE Fig 86 Install Retainer Spring and Servo 1 SE...

Page 1616: ...to 5 N m 40 in lbs 39 Install park rod into position and retain with e clip Fig 92 Fig 89 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES Fig 90 Valve Body Attaching Bolts 1 VALVE...

Page 1617: ...case and immediately install and torque oil pan to case bolts Fig 96 to 19 N m 165 in lbs torque Fig 93 Oil Filter and Gasket 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 94 Oil Filter Screws 1 SCREWDRIVER...

Page 1618: ...ld 5 Install torque converter to drive plate bolts and torque to 88 N m 65 ft lbs 6 Install rear mount bracket to transaxle Fig 98 Install bolts by hand but do not tighten at this time 7 Align rear mo...

Page 1619: ...nt and bracket Fig 101 Fig 99 Structural Collar 1 BOLT COLLAR TO OIL PAN 2 BOLT COLLAR TO TRANSAXLE 3 STRUCTURAL COLLAR 4 OIL PAN Fig 100 Starter Motor Removal Installation 1 STARTER MOTOR 2 BOLT 3 BO...

Page 1620: ...cle on hoist 22 Torque rear mount bracket to transaxle case horizontal bolt Fig 98 to 102 N m 75 ft lbs 23 Torque rear mount thru bolt to 54 N m 40 ft lbs 24 Lower vehicle 25 Connect battery negative...

Page 1621: ...SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATICS Drive First Half Throttle 21 64 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Page 1622: ...Drive Second Half Throttle RS 31TH AUTOMATIC TRANSAXLE 21 65 31TH AUTOMATIC TRANSAXLE Continued...

Page 1623: ...Drive Third Not Locked Up 21 66 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Page 1624: ...Drive Third Lock Up RS 31TH AUTOMATIC TRANSAXLE 21 67 31TH AUTOMATIC TRANSAXLE Continued...

Page 1625: ...Drive Kickdown Part Throttle 21 68 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Page 1626: ...Second Manual Closed Throttle RS 31TH AUTOMATIC TRANSAXLE 21 69 31TH AUTOMATIC TRANSAXLE Continued...

Page 1627: ...Low Manual Closed Throttle 21 70 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Page 1628: ...Reverse RS 31TH AUTOMATIC TRANSAXLE 21 71 31TH AUTOMATIC TRANSAXLE Continued...

Page 1629: ...Standard Differential Assembly 0 7 1 4 N m 6 12 in lbs Output Shaft 0 0 3 N m 0 3 in lbs Transfer Shaft 0 051 0 254 mm 0 002 0 010 in end play Overall Drag At Output Hub 0 03 1 8 N m 3 16 in lbs CLUT...

Page 1630: ...53 1 62 mm 0 060 0 064 in Output Shaft No 3 Select 1 96 2 03 mm 0 077 0 080 in Output Shaft No 3 Select 2 15 2 22 mm 0 085 0 087 in Output Shaft No 3 Select 2 34 2 41 mm 0 092 0 095 in Front Annulus...

Page 1631: ...tor to Transaxle 54 40 Bolt Transaxle Case to Engine Block 95 70 Bolt Transfer Gear Cover to Case 19 165 Bolt Transfer Gear Strap 23 17 Bolt Valve Body to Case 12 105 Fitting Transaxle Oil Cooler to C...

Page 1632: ...293 52 Puller Press C 293 PA Pressure Gauge High C 3293SP Dial Indicator C 3339 Spring Compressor C 3575 A Band Adjusting Adapter C 3705 Oil Pump Puller C 3752 Throttle Setting Gauge C 3763 Seal Pull...

Page 1633: ...ller C 4193A Bearing Installer C 4637 Adapter C 4658 Torque Tool C 4995 Adapter C 4996 Remover Kit L 4406 Bearing Remover Cup L 4406 1 Bearing Remover Jaws L 4406 2 21 76 31TH AUTOMATIC TRANSAXLE RS 3...

Page 1634: ...6 Bearing Installer L 4408 Bearing Installer L 4410 Bearing Installer L 4411 Installer Adapter L 4429 3 Gear Checking Plate L 4432 Gear Removing Plate L 4434 Bearing Puller L 4435 RS 31TH AUTOMATIC T...

Page 1635: ...L 4437 Starter Nut L 4439 Transfer Shaft Remover Installer L 4512 Bearing Cup Remover L 4517 Special Jaw Set L 4518 Installer L 4520 End Play Socket Set 8266 Bearing Splitter P 334 21 78 31TH AUTOMATI...

Page 1636: ...e kickdown servo As the line pressure reaches the accumulator the combination of spring pressure and line pressure forces the piston away from the accu mulator plate This causes a balanced pressure si...

Page 1637: ...design the band does not completely encompass wrap the drum that it holds OPERATION The rear band holds the rear planet carrier sta tionary by being mounted around and applied to the low reverse drum...

Page 1638: ...alant to the oil pan and install to case imme diately 8 Install oil pan to case bolts and torque to 19 N m 165 in lbs 9 Lower vehicle and refill transmission with Mopart ATF Plus 4 Type 9602 fluid Fig...

Page 1639: ...into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack In some transmissions the snap ring is select...

Page 1640: ...sc Shown 1 FRONT CLUTCH RETAINER 2 CLUTCH PLATES 3 DRIVING DISCS Fig 117 Front Clutch Return Spring Snap Ring 1 COMPRESSOR TOOL C 3575 A 2 FRONT CLUTCH RETAINER 3 SNAP RING 4 SNAP RING PLIERS Fig 118...

Page 1641: ...retainer Fig 119 Fig 120 Fig 119 Front Clutch Assembly 1 SNAP RING WAVE 5 SEAL 9 SPRING 2 REACTION PLATE 6 CLUTCH RETAINER 10 SNAP RING 3 CLUTCH DISC 7 SEAL 11 SPRING RETAINER 4 CLUTCH PLATE 8 PISTON...

Page 1642: ...N SPRING RETAINER 4 SNAP RING 5 PISTON RETURN SPRING 6 FRONT CLUTCH RETAINER Fig 121 Front Clutch Return Spring Snap Ring 1 COMPRESSOR TOOL C 3575 A 2 FRONT CLUTCH RETAINER 3 SNAP RING 4 SNAP RING PLI...

Page 1643: ...e applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the i...

Page 1644: ...p Ring 1 SCREWDRIVER 2 SNAP RING 3 REAR CLUTCH ASSEMBLY Fig 127 Rear Clutch 4 Disc Shown 1 REAR CLUTCH RETAINER 2 CLUTCH PLATES 3 THICK STEEL PLATE 4 SNAP RING SELECTIVE 5 DRIVING DISCS 6 PRESSURE PLA...

Page 1645: ...ig 129 Rear Clutch Piston and Piston Spring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PISTON SPRING 4 WAVED SNAP RING 5 PISTON 6 PISTON SEALS Fig 130 Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RET...

Page 1646: ...4 Fig 132 Fig 132 Rear Clutch Assembly 1 SNAP RING SELECT 6 CLUTCH RETAINER 11 SNAP RING WAVE 2 REACTION PLATE 7 INPUT SHAFT 12 SEAL 3 CLUTCH DISC 8 SNAP RING 13 SEAL 4 CLUTCH PLATE 9 PISTON 5 REACTIO...

Page 1647: ...AP RING PLIERS 4 SNAP RING Fig 134 Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 SNAP RING Fig 135 Rear Clutch Piston and Piston Spring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PISTON SPR...

Page 1648: ...fferential bearing turning torque Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC 31TH BEARINGS ADJUSTMENTS 3 Remove adapter plate seal 4 Remove differential cover to transaxle case bolts Fig 140 Fig 13...

Page 1649: ...plate out of assembly Clean surfaces of old adhesive prior to reassembly 11 Measure and record differential side gear end play using dial indicator C 3339 and Tool C 4995 as shown in Fig 144 and Fig 1...

Page 1650: ...OTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY Fig 146 Remove Differential Bearing Cone Extension Housing Side 1 SPECIAL TOOL C 293 2 SPECIAL TOOL C 293 36 3 SPECIAL TOOL C 293 3 Fig 147 Di...

Page 1651: ...ool 5052 and driver handle C 4171 Fig 152 Install bearing cup into extension housing using Tool 6536 and driver handle C 4171 Fig 149 Remove Differential Bearing Cone 1 SPECIAL TOOL 5048 2 RING GEAR F...

Page 1652: ...ng Cone Onto Differential 1 DIFFERENTIAL ASSEMBLY 2 DIFFERENTIAL BEARING Fig 154 Install Differential Bearing Cone 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 6536 3 DIFFERENTIAL ASSEMBLY Fig 155 Checking Si...

Page 1653: ...8 9 Install and torque bearing retainer bolts to 34 N m 25 ft lbs torque Fig 159 10 Install bearing retainer axle seal using Tool L 4520 inverted and driver handle C 4171 Fig 160 Fig 157 Differential...

Page 1654: ...or differential teardown assembly or if any of the following parts are replaced Transaxle case Differential carrier Differential bearing retainer Extension housing Differential bearing cups and cones...

Page 1655: ...tial Bearing Shim Chart Oil Baffle is not required when making shim selection e Install the proper shim under the bearing cup Make sure the oil baffle is installed properly in the bearing retainer bel...

Page 1656: ...d so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehicle is driven the...

Page 1657: ...ransaxle oil pan This will ensure complete evacuation of the fluid in the pan 4 Follow the manufacturers recommended proce dure and evacuate the fluid from the transaxle 5 Remove the suction line from...

Page 1658: ...el lower silencer Fig 170 5 Remove knee bolster Fig 171 6 Disconnect PRNDL cable from gear shift lever Fig 172 Fig 169 Gearshift Cable at Transaxle 1 MANUAL VALVE LEVER 2 GEAR SHIFT CABLE 3 UPPER MOUN...

Page 1659: ...and secure grommet Fig 175 2 Install gear shift cable through column bracket Fig 176 until audible click is heard 3 Connect gear shift cable to gear shift lever Fig 176 Fig 173 Gearshift Cable at Colu...

Page 1660: ...le end to transaxle man ual valve lever Fig 180 9 Adjust gearshift cable Refer to 21 TRANS MISSION TRANSAXLE AUTOMATIC 31TH GEAR SHIFT CABLE ADJUSTMENTS Fig 177 PRNDL Cable 1 PRNDL CABLE 2 GEAR SHIFT...

Page 1661: ...selector in a forward driving range line pressure flows from the manual valve and down to the governor valve When the output shaft starts to rotate with vehicle motion the governor weight assembly wi...

Page 1662: ...l pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body STANDARD PROCEDURE OIL PUMP VOLUME CHECK Measuring t...

Page 1663: ...o not need to be replaced unless cracked broken or severely worn 2 Visually inspect the pump and support compo nents Replace the pump assembly if the seal ring grooves or machined surfaces are worn sc...

Page 1664: ...TCH The park neutral starting switch is the center ter minal of the 3 terminal switch It provides ground for the starter solenoid circuit through the selector lever in only Park P and Neutral N positi...

Page 1665: ...Thrust Washer 1 SNAP RING 2 4 THRUST WASHER 3 SNAP RING 4 FRONT PLANETARY GEAR ASSEMBLY Fig 186 Annulus Gear Support Front Snap Ring 1 ANNULUS GEAR SUPPORT 2 FRONT SNAP RING 3 SCREWDRIVER 4 FRONT PLAN...

Page 1666: ...ring Fig 192 Fig 189 Front Planetary Gear 1 FRONT PLANETARY GEAR ASSEMBLY Fig 190 Front Planetary Gear 1 FRONT PLANETARY GEAR ASSEMBLY Fig 191 Front Annulus Gear Support Snap Ring 1 FRONT ANNULUS GEA...

Page 1667: ...aft support assembly from the transaxle case 1 To install a new seal place seal in opening of the pump housing lip side facing inward Using Tool C 4193 and Handle Tool C 4171 drive new seal into housi...

Page 1668: ...by bleeding oil through a small orifice in the larger piston The release timing of the kickdown servo is very important to obtain a smooth but firm shift The release has to be very quick just as the...

Page 1669: ...er visible Replace any servo component if doubt exists about condition Do not reuse suspect parts Fig 199 Kickdown Piston Return Spring and Piston 1 RETURN SPRING 2 KICKDOWN LEVER 3 PISTON ROD 4 KICKD...

Page 1670: ...erse band OPERATION While in the de energized state no pressure applied the piston is held up in its bore by the pis ton spring The plug is held down in its bore in the piston by the plug spring When...

Page 1671: ...spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use new ones at assembly Fig 204 Low Reverse Lever 1 LOW REVERSE LEVER Fig...

Page 1672: ...solenoid is hardwired to and controlled by the Intelligent Power Module IPM Battery voltage is applied to one side of the solenoid with the ignition key is in either the OFF ON RUN or START positions...

Page 1673: ...ion 1 Shifter CAN be shifted out of park with brake pedal applied 2 Turn key to the 9ON RUN9 position 2 Shifter CANNOT be shifted out of park 3 Turn key to the 9ON RUN9 position and depress the brake...

Page 1674: ...ARK9 and try to remove the key 5 Key can be removed after returning to 9LOCK9 position 6 With the key removed try to shift out of 9PARK9 6 Shifter cannot be shifted out of 9PARK9 NOTE Any failure to m...

Page 1675: ...gearshift lever is in PARK P and con nect solenoid connector Fig 219 3 Install steering column lower shroud 4 Install knee bolster Fig 220 Fig 217 Solenoid Retaining Screw 1 SOLENOID RETAINING SCREW...

Page 1676: ...pplication of the torque converter clutch It is controlled by the Powertrain Control Module PCM which determines when conditions are acceptable for torque converter lock up REMOVAL 1 Remove valve body...

Page 1677: ...cable 2 Disconnect cable core from throttle lever pin Fig 224 3 Disconnect cable retainer from throttle body bracket Fig 224 Fig 223 Torque Converter Clutch Solenoid and Regulator Control Valves 1 CO...

Page 1678: ...dy bracket Fig 227 4 Connect cable core clip to throttle lever Fig 227 5 Adjust throttle valve cable Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 31TH THROTTLE VALVE CABLE ADJUST MENTS 6 Connect batte...

Page 1679: ...ue converter Fig 229 is a hydraulic device that couples the engine crankshaft to the transmission The torque converter consists of an outer shell with an internal turbine a stator an overrunning clutc...

Page 1680: ...f the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system Fig 230 Impeller 1 ENGINE FLEXPLATE 4 E...

Page 1681: ...d through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 231 Tur...

Page 1682: ...is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mec...

Page 1683: ...s transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a clockwise direction following the impeller As the fluid is leav ing the trailing edge...

Page 1684: ...e clutch will engage at approximately 56 km h 35 mph with light throttle after the shift to third gear REMOVAL 1 Remove transmission and torque converter from vehicle Refer to 21 TRANSMISSION TRANS AX...

Page 1685: ...E AUTO MATIC 31TH TRANSFER SYSTEM REMOVAL NOTE Transaxle geartrain must be removed to gain access to and service output shaft Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 31TH DISASSEMBLY 1 Using a su...

Page 1686: ...ear and select shim Fig 244 Fig 240 Remove Strap From Stirrup and Gear 1 OUTPUT GEAR 2 STRAP Fig 241 Remove Stirrup From Gear 1 OUTPUT GEAR 2 STIRRUP Fig 242 Remove Output Shaft Retaining Nut and Wash...

Page 1687: ...CONE 4 OUTPUT SHAFT GEAR 5 OUTPUT SHAFT Fig 245 Remove Output Shaft and Rear Annulus Gear Assembly 1 BEARING CUP 2 REAR ANNULUS GEAR 3 OUTPUT SHAFT Fig 246 Remove Output Shaft Gear Bearing Cone 1 SPEC...

Page 1688: ...ress Fig 251 Fig 248 Remove Rear Planetary Annulus Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 2 REAR PLANETARY ANNULUS GEAR Fig 249 Remove Output Shaft Gear Bearing Cup 1 OUTPUT...

Page 1689: ...e cups To determine proper shim thickness Refer to Output Shaft Bearing Adjustment Check output shaft bearing turning torque using an inch pound torque wrench If turning torque is 3 8 in lbs the prope...

Page 1690: ...GREASE TO HOLD SHIMS IN POSITION 3 BEARING CONE 4 LUBRICATION HOLE 5 SELECT SHIMS Fig 257 Output Shaft and Select Shims in Position 1 BEARING CUP 2 SELECT SHIM 3 OUTPUT SHAFT ASSEMBLY Fig 258 Start O...

Page 1691: ...ts of the output gear retaining nut 13 Rotate stirrup clockwise against flats of gear retaining nut Fig 263 Fig 260 Tighten Output Shaft Retaining Nut 1 OUTPUT SHAFT GEAR 2 SPECIAL TOOL L 4434 AND C 4...

Page 1692: ...rans axle case measure output shaft end play 8 Once bearing end play has been determined refer to the output shaft bearing shim chart 9 The 12 65 mm 0 498 inch 13 15 mm 0 518 inch or 13 65 mm 0 537 in...

Page 1693: ...34 14 49 570 50 020 13 15 1 29 14 44 568 55 022 13 15 1 24 14 39 566 60 024 13 15 1 19 14 34 564 65 026 13 15 1 14 14 29 562 70 028 13 15 1 09 14 24 560 75 030 13 15 1 04 14 19 558 80 032 13 15 99 14...

Page 1694: ...Remove stirrup and retaining strap 6 Using Tool L 4434 Fig 267 remove transfer shaft gear retaining nut and washer Fig 268 Fig 265 Rear Cover Bolts 1 REAR COVER 2 REAR COVER BOLTS 10 Fig 266 Remove Re...

Page 1695: ...er Shaft Gear using L 4407A 1 TRANSFER GEAR 2 TOOL L 4407A Fig 270 Remove Transfer Shaft Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 2 TRANSFER SHAFT GEAR Fig 271 Governor Support Retainer 1 TRANSFER SH...

Page 1696: ...BAND ANCHOR PIN 2 OUTPUT SHAFT GEAR Fig 274 Governor Assembly 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 GOVERNOR ASSEMBLY Fig 275 Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS 2 SNAP RING 3 OUTPUT...

Page 1697: ...ainer Assembly 1 OUTPUT SHAFT GEAR 2 O RING 3 SPECIAL TOOL L 4512 4 BEARING RETAINER ASSEMBLY 5 TRANSFER SHAFT Fig 278 Transfer Shaft and Bearing Retainer 1 O RING 2 TRANSFER SHAFT 3 BEARING CONE 4 TR...

Page 1698: ...ft Bearing Cone 1 PRESS 2 SPECIAL TOOL L 4411 3 BEARING CONE 4 TRANSFER SHAFT Fig 281 Install Transfer Shaft Bearing Cup 1 PRESS 2 HANDLE C 4171 3 SPECIAL TOOL L 4520 4 TRANSFER SHAFT BEARING RETAINER...

Page 1699: ...p Ring 1 SNAP RING PLIERS 2 SNAP RING 3 OUTPUT SHAFT GEAR 4 TRANSFER SHAFT Fig 286 Governor Assembly 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 GOVERNOR ASSEMBLY Fig 287 Low Reverse Band Anchor Pin 1 LOW...

Page 1700: ...g Governor support 12 Install transfer shaft gear and select shim Fig 291 13 Install transfer shaft gear nut and washer Fig 292 Fig 289 Governor Support Retainer 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3...

Page 1701: ...Rubber Adhesive Sealant to transfer gear cover Fig 295 Immediately install to transaxle case 22 Install and torque transfer gear cover to case bolts Fig 296 to 19 N m 165 in lbs Fig 293 Tighten Trans...

Page 1702: ...lined in Step 4 End play should be between 0 05 mm and 0 25 mm 0 002 to 0 010 inch NOTE If end play is too high install a 0 05 mm 0 002 inch thinner shim combination If end play is too low install a 0...

Page 1703: ...Fig 297 7 Separate oil pan from case and drain fluid into suitable container Fig 298 8 Remove oil filter to valve body screws Fig 299 9 Remove oil filter and gasket Fig 300 Fig 297 Transaxle Oil Pan...

Page 1704: ...se bolts Fig 304 Fig 301 Cooler Bypass Valve and Seal 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL Fig 302 Parking Rod E Clip 1 VALVE BODY 2 SCREWDRIVER 3 E CLIP 4 PARKING ROD Fig 303 Parking Rod 1 VALVE BO...

Page 1705: ...IDENTIFICATION 1 Remove detent spring to valve body screws and remove spring Fig 306 2 Remove valve body to separator plate screws Fig 307 Fig 308 Fig 305 Valve Body and Governor Tubes 1 VALVE BODY AS...

Page 1706: ...parator Plate from Valve Body 1 SEPARATOR PLATE 2 TRANSFER PLATE 3 OIL SCREEN 4 VALVE BODY Fig 310 Steel Ball Locations 1 MANUAL VALVE 2 STEEL BALLS 8 3 STEEL BALLS Fig 311 Remove Throttle Shaft E Cli...

Page 1707: ...alve Lever 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE LEVER ASSEMBLY 3 VALVE BODY Fig 314 Throttle Valve Lever Assembly 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE 3 VALVE BODY Fig 315 Manual V...

Page 1708: ...ig 317 Pressure Regulators and Manual Controls 1 VALVE BODY 7 SPRING 2 LINE PRESSURE VALVE 8 KICKDOWN VALVE 3 SPRING 9 SPRING 4 ADJUSTING SCREW 10 MANUAL VALVE 5 SCREW 11 THROTTLE VALVE 6 GUIDE RS 31T...

Page 1709: ...g 318 Fig 318 Governor Plugs 1 SHUTTLE VALVE SECONDARY SPRING 5 SCREW 4 2 SHUTTLE VALVE 6 END COVER 3 1 2 SHIFT VALVE GOVERNOR PLUG 7 2 3 SHIFT VALVE GOVERNOR PLUG 4 END COVER 8 E CLIP 21 152 31TH AUT...

Page 1710: ...319 Torque Converter Clutch Solenoid and Regulator Control Valves 1 CONVERTER PRESSURE CONTROL VALVE 3 SCREW 3 5 REGULATOR VALVE THROTTLE PRESSURE PLUG 2 END COVER 4 REGULATOR VALVE THROTTLE PRESSURE...

Page 1711: ...replaced CAUTION Many of the valve body valves and plugs are made of coated aluminum Aluminum compo nents can be identified by the dark color of the spe cial coating applied to the surface or by testi...

Page 1712: ...ings The springs must be free of distortion warpage or broken coils Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely i...

Page 1713: ...roper location of check balls Fig 326 Fig 323 Install Throttle Valve Lever Assembly 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE 3 VALVE BODY Fig 324 Install Manual Valve Lever 1 THROTTLE VALVE LEVE...

Page 1714: ...327 Install Transfer Plate and Separator Plate to Valve Body 1 SEPARATOR PLATE 2 TRANSFER PLATE 3 OIL SCREEN 4 VALVE BODY Fig 328 Using Tool L 4553 on Valve Body Screw 1 SCREWDRIVER HANDLE 2 VALVE BO...

Page 1715: ...stall park rod to valve body and install e clip Fig 334 Fig 335 Fig 331 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES Fig 332 Valve Body Attaching Bolts 1 VALVE BODY 2 VALVE BOD...

Page 1716: ...l pan Fig 338 and immediately install to case Fig 335 Parking Rod 1 VALVE BODY 2 PARKING ROD Fig 336 Oil Filter and Gasket 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 337 Oil Filter Screws 1 SCREWDRIVER HA...

Page 1717: ...Insert gauge pin of Tool C 3763 between the throttle lever cam and kickdown valve 2 By pushing in on tool compress kickdown valve against its spring so throttle valve is com pletely bottomed inside t...

Page 1718: ...NDITION CHECK 249 STANDARD PROCEDURE FLUID AND FILTER SERVICE 250 GEAR SHIFT CABLE REMOVAL 251 INSTALLATION 253 ADJUSTMENTS GEARSHIFT CABLE ADJUSTMENT 254 HOLDING CLUTCHES DESCRIPTION 255 OPERATION 25...

Page 1719: ...ut clutches Two multiple disc holding clutches Four hydraulic accumulators Two planetary gear sets Hydraulic oil pump Valve body Solenoid Pressure switch assembly Integral differential assembly Contro...

Page 1720: ...SPEED SENSOR 14 OIL PUMP 3 UNDERDRIVE CLUTCH 9 PLANETARY GEAR SET 15 TORQUE CONVERTER 4 OVERDRIVE CLUTCH 10 OUTPUT SHAFT GEAR 16 TORQUE CONVERTER CLUTCH 5 REVERSE CLUTCH 11 TRANSFER SHAFT 6 2 4 CLUTC...

Page 1721: ...ive 0 69 1 Reverse 2 21 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING 41TE TRANSAXLE GENERAL DIAGNOSIS NOTE Before attempting any repair on a 41TE four speed automatic transaxle check for diagnostic t...

Page 1722: ...ver A slipping clutch may also set a DTC and can be determined by operating the transaxle in all selector positions ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER Shift Lever Position INPUT CLUTCH...

Page 1723: ...n either the solenoid assembly or TCM is at fault TEST THREE OVERDRIVE CLUTCH CHECK 3rd and 2nd Gear 1 Attach gauge to the overdrive clutch tap 2 Move selector lever to the OD position 3 Allow vehicle...

Page 1724: ...a worn reaction shaft seal ring or a defective solenoid assembly is indi cated 5 If the underdrive clutch pressure is greater than 5 psi in Step 4 of Test Two A a defective sole noid assembly or TCM i...

Page 1725: ...ston contacts the first separator plate Watch carefully for the piston to move forward The piston should return to its origi nal position after the air pressure is removed UNDERDRIVE CLUTCH Because th...

Page 1726: ...d leaks at the outside diam eter weld Fig 8 Torque converter hub weld Fig 8 REMOVAL NOTE If transaxle assembly is being replaced or overhauled clutch and or seal replacement it is necessary to perform...

Page 1727: ...lhousing 11 Reposition leak detection pump harness and hoses 12 Remove rear mount bracket to transaxle case bolts Fig 13 13 Remove transaxle upper bellhousing to block bolts 14 Raise vehicle on hoist...

Page 1728: ...g 14 30 Remove remaining transaxle bellhousing to engine bolts 31 Remove transaxle assembly from vehicle DISASSEMBLY CAUTION If transaxle failure has occurred it is necessary to flush the transaxle oi...

Page 1729: ...ROUGH 3 BOLT LEFT MOUNT TO TRANSAXLE 4 TRANSAXLE 5 MOUNT LEFT 6 BRACKET LEFT MOUNT Fig 15 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 GASKET Fig 16 Remove Oil Pa...

Page 1730: ...ne application some accumulators will have two springs and others will have one spring The springs are color coded according to application and year When disassem bling mark accumulator spring locatio...

Page 1731: ...CLUTCH ACCUMULATOR 3 SEAL RING 2 4 OVERDRIVE CLUTCH ACCUMULATOR Fig 23 Accumulator Underdrive 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 24 Accumulator Overdrive 1 AC...

Page 1732: ...If outside of this range a 4 thrust plate change is required Record indicator reading for reference upon reassembly Fig 26 Remove Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 27...

Page 1733: ...g 31 18 Remove oil pump assembly Fig 32 Fig 33 Fig 33 Oil Pump Removed 1 OIL PUMP 2 GASKET Fig 30 Remove Pump Attaching Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 31 Install Tool C 3752 1 PULLERS...

Page 1734: ...1 Remove 1 needle bearing Fig 36 22 Remove input clutch assembly Fig 37 Fig 34 Remove Oil Pump Gasket 1 PUMP GASKET Fig 35 Remove Bypass Valve 1 COOLER BYPASS VALVE Fig 36 Remove Caged Needle Bearing...

Page 1735: ...the rear sun gear Fig 42 A small amount of petrolatum can be used to hold the bearing to the rear sun gear Fig 38 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETRO...

Page 1736: ...locking pliers and bolts to center the tool properly 28 Remove 2 4 clutch retainer Fig 44 29 Remove 2 4 clutch return spring Fig 45 Fig 42 Number 7 Bearing 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 43 Re...

Page 1737: ...ve 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 Fig 47 Remove Tapered Snap Ring 1 LOW REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN FACE 5 L...

Page 1738: ...late Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 51 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 52 Remove Rear Cover...

Page 1739: ...Nut 1 TRANSFER SHAFT GEAR 2 OUTPUT GEAR 3 SPECIAL TOOL 6259 Fig 55 Transfer Shaft Gear Nut and Coned Washer 1 TRANSFER SHAFT 2 LOCK WASHER 3 NUT Fig 56 Remove Transfer Shaft Gear 1 SPECIAL TOOL L4407...

Page 1740: ...ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 59 Remove Transfer Gear Bearing Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR Fig 60 Remove Tra...

Page 1741: ...emove output shaft stirrup strap bolts Fig 65 Fig 62 Remove Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR Fig 63 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT...

Page 1742: ...ig 69 Fig 66 Remove Stirrup Strap 1 OUTPUT GEARBOLT 2 RETAINING STRAP 3 STIRRUP Fig 67 Remove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 Fig 68 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED...

Page 1743: ...73 Fig 70 Output Gear and Select Shim 1 REAR CARRIER ASSEMBLY 2 SHIM SELECT 3 OUTPUT GEAR Fig 71 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR Fig 72 Re...

Page 1744: ...ing Compressor Tool 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 75 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 76 Rem...

Page 1745: ...ig 81 Fig 78 Remove Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 79 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL F...

Page 1746: ...Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 83 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 84 Remove Piston...

Page 1747: ...eing overhauled clutch and or seal replacement the TCM Quick Learn pro cedure must be performed Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Insta...

Page 1748: ...tainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 90 Install Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 91 Install Low Reverse Clu...

Page 1749: ...g 96 Fig 93 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL Fig 94 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 95 In...

Page 1750: ...l in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 98 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNA...

Page 1751: ...ure output gear end play as shown in Fig 102 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retaining b...

Page 1752: ...4412813AB 0 25mm 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14m...

Page 1753: ...a 0 04 mm 0 0016 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 104 Install Output Gear...

Page 1754: ...ue stirrup strap bolts to 23 N m 200 in lbs Fig 111 Fig 108 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 109 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 1...

Page 1755: ...n Strap Up Against Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 113 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 1...

Page 1756: ...ERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 117 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RE...

Page 1757: ...4505588AB 0 76mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm...

Page 1758: ...in 4412806AB 0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 1...

Page 1759: ...epeat until 0 05 0 10 mm 0 002 0 004 in end play is obtained 36 Install a bead of Mopart ATF RTV MS GF41 to transfer gear cover Fig 123 37 Install transfer gear cover to case bolts and torque to 20 N...

Page 1760: ...h flat side up Fig 128 Fig 125 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 126 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT S...

Page 1761: ...fications LOW REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in...

Page 1762: ...2 4 Clutch Plate Pads 1 PILOT PADS 2 LUGS Fig 134 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 135 2 4 Clutch Retainer 1 2 4 CLUTCH R...

Page 1763: ...gear and 7 needle bearing Fig 139 NOTE The number seven needle bearing has three anti reversal tabs and is common with the number five and number two position The orientation should allow the bearing...

Page 1764: ...speed sensor hole is not as shown in Fig 143 the input clutch assembly is not seated prop erly Fig 142 Select Thinnest No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF...

Page 1765: ...thrust plate chart to select the proper No 4 thrust plate NO 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431665AB 1 60mm 0 063 in 3836237AB 1 73mm 0 068 in 4431666AB 1 80mm 0 071 in 3836238AB 1 96mm...

Page 1766: ...g end towards rear of case Fig 148 56 Install oil pump gasket Fig 149 57 Install oil pump assembly Fig 150 Fig 147 Install Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 148...

Page 1767: ...ing Fig 154 Fig 151 Install Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 152 Install Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 153 Ins...

Page 1768: ...tion Make sure park rod rollers are posi tioned within park guide bracket Fig 155 Accumulator Underdrive 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 156 Accumulator Ov...

Page 1769: ...165 in lbs 68 Install solenoid pressure switch assembly and gasket to case Fig 162 Fig 159 Install Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 160 Install Oil Filter 1 OI...

Page 1770: ...le and torque bolts to 54 N m 40 ft lbs Fig 164 3 Raise engine transaxle assembly into position Install and torque upper mount to bracket thru bolt to 75 N m 55 ft lbs Fig 164 4 Remove transmission ja...

Page 1771: ...r mount bracket to tran saxle vertical bolts Fig 165 to 102 N m 75 ft lbs 17 Install transaxle upper bellhousing to block bolts and torque to 95 N m 70 ft lbs 18 Install and connect crank position sen...

Page 1772: ...eld 27 Connect battery cables 28 Fill transaxle with suitable amount of ATF 4 Automatic Transmission Fluid Type 9602 Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE FLUID STANDARD PROCEDURE Fig 167...

Page 1773: ...SCHEMATICS AND DIAGRAMS 41TE TRANSAXLE HYDRAULIC SCHEMATICS Park Neutral Speed Under 8 MPH 21 216 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1774: ...Neutral Speed Over 8 MPH RS 41TE AUTOMATIC TRANSAXLE 21 217 41TE AUTOMATIC TRANSAXLE Continued...

Page 1775: ...Reverse 21 218 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1776: ...Reverse Block Shift to Reverse W Speed Over 8 mph RS 41TE AUTOMATIC TRANSAXLE 21 219 41TE AUTOMATIC TRANSAXLE Continued...

Page 1777: ...First Gear 21 220 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1778: ...Second Gear RS 41TE AUTOMATIC TRANSAXLE 21 221 41TE AUTOMATIC TRANSAXLE Continued...

Page 1779: ...Second Gear EMCC 21 222 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1780: ...Direct Gear RS 41TE AUTOMATIC TRANSAXLE 21 223 41TE AUTOMATIC TRANSAXLE Continued...

Page 1781: ...Direct Gear CC On 21 224 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1782: ...Overdrive RS 41TE AUTOMATIC TRANSAXLE 21 225 41TE AUTOMATIC TRANSAXLE Continued...

Page 1783: ...Overdrive EMCC 21 226 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1784: ...Overdrive CC On RS 41TE AUTOMATIC TRANSAXLE 21 227 41TE AUTOMATIC TRANSAXLE Continued...

Page 1785: ...004 in Overall Drag At Output Hub 0 3 1 9 N m 3 16 in lbs CLUTCH CLEARANCES DESCRIPTION METRIC STANDARD Low Rev Clutch Select Reaction Plate 0 89 1 47 mm 0 035 0 058 in Two Four Clutch No Selection 0...

Page 1786: ...Gear Stirrup Strap 23 17 Bolt Oil Pump to Case 27 20 Bolt Reaction Support to Case 27 20 Bolt Solenoid Pressure Switch Assy to Case 12 110 Bolt Torque Converter to Driveplate 75 55 Bolt Transfer Gear...

Page 1787: ...Puller C 637 Pressure Gauge High C 3293SP Dial Indicator C 3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Adapter C 4996 21 230 41TE AUTOMATIC TRANSAXLE...

Page 1788: ...Puller L 4407A Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 Installer L 4520 RS 41TE AUTOMATIC TRANSAXLE 21 231 41TE AUTOM...

Page 1789: ...ton L 4539 2 Adapter L 4559 Adapter L 4559 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 21 232 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE...

Page 1790: ...Compressor 5058A Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 RS 41TE AUTOMATIC TRANSAXLE 21 233 41TE AUTOMATIC TRANSAXLE Continued...

Page 1791: ...Disk 6057 Installer 6061 Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 21 234 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Page 1792: ...mover Installer 6302 Installer 6536 A Cooler Flusher 6906A Puller 7794 A End Play Socket Set 8266 Input Clutch Pressure Fixture 8391 RS 41TE AUTOMATIC TRANSAXLE 21 235 41TE AUTOMATIC TRANSAXLE Continu...

Page 1793: ...nd retaining screws Fig 171 OPERATION The function of an accumulator is to cushion the application of a frictional clutch element When pres surized fluid is applied to a clutch circuit the appli catio...

Page 1794: ...erdrive OFF 9Lockout9 depressed 2 8V 3 8V All switches open 3 8V 4 8V Voltage values 3V and 4 8V are considered INVALID and will result in a DTC Moving the switch up causes an upshift and mov ing the...

Page 1795: ...applied the front sun gear assembly is driven FINAL DRIVE DISASSEMBLY NOTE The differential is serviced as an assembly Differential service is limited to bearing cups and cones Any other differential...

Page 1796: ...Fig 178 Position Button and Collets Onto Differential and Bearing Ring Gear Side 1 SPECIAL TOOL L 4539 2 2 SPECIAL TOOL 5048 3 SPECIAL TOOL 5048 4 Fig 179 Position Tool 5048 Over Button and Collets at...

Page 1797: ...retainers Fig 183 9 Separate ring gear from differential case Fig 184 Fig 181 Position Bearing Cup Remover Tool in Retainer 1 SPECIAL TOOL 6062A 2 DIFFERENTIAL BEARING RETAINER Fig 182 Remove Bearing...

Page 1798: ...ig 188 Fig 185 Separating Differential Support with Screwdrivers 1 DIFFERENTIAL SUPPORT 2 DIFFERENTIAL CASE 3 SCREWDRIVER 4 RELIEF 2 180 APART Fig 186 Differential Support Removal 1 DIFFERENTIAL SUPPO...

Page 1799: ...r Fig 192 18 Inspect all components for excessive wear Fig 189 Pinion Shaft Removal 1 PINION SHAFT Fig 190 Pinion Gear and Washer Removal 1 PINION GEAR 2 TABBED WASHER 3 LOCATING TAB 4 NOTCH Fig 191 S...

Page 1800: ...2 Install side gear to differential case Fig 194 3 Install both pinion gears and washers to case while orientating washer tabs to notch in case Fig 195 4 Install pinion shaft Fig 196 Fig 193 Thrust Wa...

Page 1801: ...199 8 Install differential ring gear to case Fig 200 Fig 197 Side Gear Installation 1 DIFFERENTIAL SIDE GEAR Fig 198 Side Gear Thrust Washer 1 SIDE GEAR THRUST WASHER Fig 199 Diff Support Installatio...

Page 1802: ...Use MoparT Silicone Rubber Adhesive Seal ant or equivalent on retainer and extension hous ing adapter plate to seal to case 14 Install differential assembly into transaxle case Install differential be...

Page 1803: ...orm all differential bearing preload mea surements with the transfer shaft and gear removed DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM 1 Position the transaxle assembly vertically on...

Page 1804: ...m 0 002 inch thicker shim Repeat until 5 18 inch pounds turning torque is obtained Oil Baffle is not required to be installed when making shim selection f Install the proper shim under the bearing cup...

Page 1805: ...bearings are fully seated 7 Attach a dial indicator to the case and zero the dial Place the tip on the end of Special Tool L 4436 A 8 Place a large screwdriver to each side of the ring gear and lift C...

Page 1806: ...t idle speed for at least one minute with the vehicle on level ground At normal operating temperature 82 C 180 F the fluid level is correct if it is in the HOT region on the oil level indicator Fig 21...

Page 1807: ...rmal ATF 4 also has a unique odor that may change with age Consequently odor and color cannot be used to indicate the fluid condition or the need for a fluid change After the fluid has been checked se...

Page 1808: ...e dipstick tube 6 Pour four quarts of Mopart ATF 4 Automatic Transmission Fluid Type 9602 through the dipstick opening 7 Start engine and allow to idle for at least one minute Then with parking and se...

Page 1809: ...11 Disengage grommet from dash panel Fig 218 and remove gear shift cable from inside vehicle Fig 215 Instrument Panel Lower Silencer 1 INSTRUMENT PANEL LOWER SILENCER Fig 216 Knee Bolster 1 KNEE BOLS...

Page 1810: ...cable to gear shift lever Fig 220 4 Install knee bolster Fig 221 5 Install instrument panel lower silencer Fig 222 Fig 219 Gearshift Cable Grommet at Dash Panel 1 CABLE GROMMET 2 DASH PANEL Fig 220 Ge...

Page 1811: ...gine starts in both neutral N or park P gearshift cable is adjusted properly No adjustment is required 6 If engine does not start in either park P or neutral N perform adjustment procedure ADJUSTMENT...

Page 1812: ...se LOW REVERSE CLUTCH The Low Reverse clutch is hydraulically applied in park reverse neutral and first gears by pressurized fluid against the Low Reverse clutch piston When the Low Reverse clutch is...

Page 1813: ...Fig 227 Reverse Clutch Snap Ring 1 REACTION PLATE 2 SCREWDRIVER 3 REVERSE CLUTCH SNAP RING SELECT Fig 228 Pry Reverse Clutch Reaction Plate 1 REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 SCREWDRIVER...

Page 1814: ...ure Plate Snap Ring 1 OD REVERSE PRESSURE PLATE 2 SCREWDRIVER 3 OD REVERSE PRESSURE PLATE SNAP RING Fig 232 OD Reverse Pressure Plate 1 OD REVERSE PRESSURE PLATE STEP SIDE DOWN 2 STEP SIDE DOWN Fig 23...

Page 1815: ...VE CLUTCH PLATE 2 OVERDRIVE SHAFT ASSEMBLY 3 OVERDRIVE CLUTCH DISC Fig 236 3 4 Thrust Washers 1 3 THRUST PLATE 3 TABS 2 OD SHAFT ASSEMBLY 3 4 THRUST PLATE 3 SLOTS Fig 237 Underdrive Shaft Assembly 1 3...

Page 1816: ...lutch flat snap ring Fig 242 Fig 239 OD UD Reaction Plate Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER DO NOT SCRATCH REACTION PLATE Fig 240 OD UD R...

Page 1817: ...245 19 Remove spring retainer Fig 245 20 Remove UD clutch piston Fig 246 Fig 243 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 244 UD Spring Retainer Snap Ring 1 SNAP RI...

Page 1818: ...d Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS Fig 248 Tap on Input Hub 1 INPUT SHAFT AND HUB ASSEMBLY 2 PLASTIC HAMMER Fig 249 Input Hub Remove...

Page 1819: ...RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING Fig 252 Snap Ring and Return Spring 1 OD REVERS...

Page 1820: ...T 2 ARBOR PRESS RAM 3 INPUT SHAFT HUB ASSEMBLY Fig 256 Install Input Shaft Snap Ring 1 INPUT SHAFT 2 SCREWDRIVER DO NOT SCRATCH BEARING SURFACE 3 SNAP RING 4 O RINGS 5 SEALS Fig 257 Return Spring and...

Page 1821: ...nstall OD Reverse Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 260 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO AL...

Page 1822: ...installed Fig 266 Fig 263 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 264 UD Return Spring and Retainer 1 UNDERDRIVE SPRIN...

Page 1823: ...tapered step side up Fig 267 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 268 Install Last UD Clutch Disc 1 ONE UNDERDRIVE CLUTCH DISC Fig 269 OD UD Re...

Page 1824: ...cator Fig 274 When releasing pressure on clutch pack indica tor reading should advance 0 005 0 010 CAUTION Do not apply more than 30 psi 206 kPa to the underdrive clutch pack 18 Apply 30 psi 206 kPa t...

Page 1825: ...tall the OD clutch pack four frictions three steels Fig 275 22 Install OD pressure plate waved snap ring Fig 276 23 Install the OD Reverse pressure plate with large step down towards OD clutch pack Fi...

Page 1826: ...25 mm 0 042 0 128 in If not within specifications the clutch is not assembled properly There is no adjustment for the OD clutch clearance 28 Install reverse clutch pack two frictions one steel Fig 28...

Page 1827: ...r Fig 285 When releasing pressure indicator should advance 0 005 0 010 as clutch pack relaxes Fig 282 Install Reverse Clutch Snap Ring 1 REVERSE CLUTCH SNAP RING SELECT 2 SCREWDRIVER 3 REVERSE CLUTCH...

Page 1828: ...rive clutch must be removed 37 Install the 2 needle bearing Fig 286 38 Install the underdrive shaft assembly Fig 287 39 Install the 3 thrust washer to the underdrive shaft assembly Be sure five tabs a...

Page 1829: ...tlet and to the valve body STANDARD PROCEDURE OIL PUMP VOLUME CHECK Measuring oil pump output volume will determine if sufficient flow to the transmission oil cooler exists and whether or not an inter...

Page 1830: ...he transaxle it is necessary to inspect the oil pump for wear and damage 1 Remove the reaction shaft support bolts 2 Remove reaction shaft support from pump housing Fig 293 3 Remove the pump gears Fig...

Page 1831: ...20 ft lbs torque PLANETARY GEARTRAIN DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case The planetary geartrain consists of two sun gea...

Page 1832: ...etic solenoid mounted to the steering column Fig 300 The solenoid s plunger consists of an integrated hook which operates the shift lever pawl part of shift lever assembly and a plunger return spring...

Page 1833: ...de ener gizing the solenoid When the brake pedal is released the ground circuit is closed energizing the solenoid When the ignition key is in either the OFF ON RUN or START positions the BTSI solenoid...

Page 1834: ...GNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID For intended BTSI system operation refer to the following chart ACTION EXPECTED RESPONSE 1 Turn key to the 9OFF9 position 1 Shifter CAN b...

Page 1835: ...r engages gearshift lever pawl pin Install and tighten screws Fig 309 2 Verify gearshift lever is in PARK P and con nect solenoid connector Fig 310 Fig 307 BTSI Solenoid Connector 1 BTSI SOLENOID 2 SO...

Page 1836: ...o the LR CC 2 4 OD and UD friction elements The reverse clutch is controlled by line pressure from the manual valve in the valve body The solenoids are contained within the Solenoid Pressure Switch As...

Page 1837: ...g point For example a switch may close at 18 psi and open at 17 psi The switches are continuously monitored by the TCM for the cor rect states open or closed in each gear as shown in the following cha...

Page 1838: ...olenoid pressure switch 8 way connec tor and torque to 4 N m 35 in lbs 6 Install air cleaner assembly 7 Connect battery negative cable 8 If solenoid pressure switch assembly was replaced perform TCM Q...

Page 1839: ...l and the engine speed signal to determine the following Torque converter clutch slippage Torque converter element speed ratio REMOVAL 1 Disconnect battery negative cable 2 If necessary disconnect and...

Page 1840: ...ol Module TCM OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating As the rear planetary carrier park pawl lugs pass by the sensor coil Fig 324 an AC voltage...

Page 1841: ...icle on hoist 3 Disconnect output speed sensor connector 4 Unscrew and remove output speed sensor Fig 325 5 Inspect speed sensor o ring Fig 326 and replace if necessary INSTALLATION 1 Verify o ring is...

Page 1842: ...so provides reduced transmission fluid temperatures The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump The torque converter is a sealed welded...

Page 1843: ...f the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system Fig 328 Impeller 1 ENGINE FLEXPLATE 4 E...

Page 1844: ...d through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 329 Tur...

Page 1845: ...is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mec...

Page 1846: ...tor blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum tor...

Page 1847: ...nverter hub and oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the...

Page 1848: ...pack pressure switches is checked After the relay is energized the TCM monitors the terminals to verify that the voltage is greater than 3 volts TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission...

Page 1849: ...when a transmission overheat condition exists If the thermistor circuit fails the TCM will revert to calculated oil temperature usage CALCULATED TEMPERATURE A failure in the temperature sensor or circ...

Page 1850: ...er clutch switch valve Converter clutch control valve Torque converter regulator valve Low Reverse switch valve In addition the valve body also contains the ther mal valve 2 3 4 check balls the 5 over...

Page 1851: ...clutch piston both the con verter clutch control valve and the converter control valve move allowing pressure to be applied to the back side of the clutch T C REGULATOR VALVE The torque converter reg...

Page 1852: ...345 Fig 346 CAUTION The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped Fig 343 Oil Filter 1 OIL FILTER 2 O RING Fig 344 Valve Body Attac...

Page 1853: ...ist 5 Remove oil pan bolts Fig 347 6 Remove oil pan Fig 348 7 Remove oil filter Fig 349 8 Remove the valve body to transaxle case bolts Fig 350 NOTE To ease removal of the valve body turn the manual v...

Page 1854: ...AL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Remove manual shaft seal Fig 353 2 Remove Transmission Range Sensor retaining screw Fig 354 Fig 351 Push Park Rod Rollers...

Page 1855: ...aft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 356 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 3...

Page 1856: ...5 check valve Fig 361 10 Remove separator plate Fig 362 Fig 359 Remove Transfer Plate 1 TRANSFER PLATE Fig 360 Remove Oil Screen 1 OIL SCREEN Fig 361 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE...

Page 1857: ...64 Fig 363 Remove Thermal Valve 1 THERMAL VALVE Fig 364 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VA...

Page 1858: ...s reconditioned the TCM Quick Learn Procedure must be performed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valves and springs as shown in...

Page 1859: ...VE 3 L R SWITCH VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 REGULATOR VALVE Fig 369 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 370 Install...

Page 1860: ...n Fig 372 If necessary secure them with petrolatum or transmission assembly gel for assembly ease Fig 372 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK...

Page 1861: ...rator plate Fig 375 9 Install oil screen to separator plate Fig 376 Fig 373 Install Thermal Valve 1 THERMAL VALVE Fig 374 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY Fig 375 Install Overdri...

Page 1862: ...in Fig 379 13 Torque 2 4 Accumulator retainer to 5 N m 45 in lbs Fig 380 Fig 377 Install Transfer Plate 1 TRANSFER PLATE Fig 378 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE...

Page 1863: ...LECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valve body assembly to transaxle Fig 384 Install and torque valve body to transaxle case bolts Fig 385 to...

Page 1864: ...ensor connector 6 Install manual valve lever to manual shaft 7 Install gearshift cable to manual valve lever 8 Connect battery negative cable 9 Fill transaxle with Mopart ATF 4 Transmis sion fluid Ref...

Page 1865: ...INSTALLATION 371 GEARSHIFT KNOB REMOVAL 374 INSTALLATION 374 GEARSHIFT MECHANISM REMOVAL 375 INSTALLATION 377 INPUT SHAFT DESCRIPTION 380 DISASSEMBLY 380 ASSEMBLY 383 INTERMEDIATE SHAFT DESCRIPTION 3...

Page 1866: ...SSEMBLY 4 4TH GEAR SPEED 12 5 R SHIFT FORK 20 EXTENSION HOUSING 5 5TH GEAR INPUT 13 5TH GEAR SPEED 21 INTERMEDIATE SHAFT BEARING CAGED ROLLER 6 REVERSE IDLER GEAR 14 3 4 CLUSTER GEAR 22 INTERMEDIATE S...

Page 1867: ...ICATION NOTE Since transaxles use unique gear ratios for each of the two engine applications it is imperative that the transaxle is properly identified and the cor rect transaxle assembly number is us...

Page 1868: ...and the input shaft turns Since no synchronizers are engaged on either the input or intermediate shafts power is not transmitted to the intermediate shaft and the differential does not turn Fig 3 Fig...

Page 1869: ...irst speed gear freewheels until first gear is selected As the gearshift lever is moved to the first gear position the 1 2 fork moves the 1 2 synchronizer sleeve towards first gear on the inter mediat...

Page 1870: ...cond speed gear freewheels until second gear is selected As the gearshift lever is moved to the second gear position the 1 2 fork moves the 1 2 synchronizer sleeve towards second gear on the intermedi...

Page 1871: ...ut shaft third speed gear freewheels until third gear is selected As the gearshift lever is moved to the third gear position the 3 4 fork moves the 3 4 synchronizer sleeve towards third gear on the in...

Page 1872: ...shaft fourth speed gear free wheels until fourth gear is selected As the gearshift lever is moved to the fourth gear position the 3 4 fork moves the 3 4 synchronizer sleeve towards fourth gear on the...

Page 1873: ...ft fifth speed gear freewheels until fifth gear is selected As the gearshift lever is moved to the fifth gear position the 5 R fork moves the 5 R synchronizer sleeve towards the intermediate shaft fif...

Page 1874: ...ar Because of this constant mesh the intermediate shaft reverse gear freewheels until reverse gear is selected As the gearshift lever is moved to the reverse gear position the 5 R fork moves the 5 R s...

Page 1875: ...o causes gear disengagement Check for missing snap rings LOW LUBRICANT LEVEL Insufficient transaxle lubricant is usually the result of leaks or inaccurate fluid level check or refill method Leakage is...

Page 1876: ...ctural collar 14 Remove modular clutch assembly to drive plate bolts 15 Position screw jack and wood block to engine oil pan 16 Remove transmission upper mount through bolt from left frame rail 17 Low...

Page 1877: ...assembly clutch release components and engine drive plate REMOVAL 2 5L TD 1 Raise hood 2 Disconnect both battery cables 3 Remove battery thermal shield Fig 15 4 Remove battery hold down bolt clamp an...

Page 1878: ...19 Remove cables and secure out of way 10 Remove three 3 right engine mount bracket to transaxle bolts Fig 20 Fig 17 Battery Tray 1 BATTERY TRAY Fig 18 Coolant Recovery Bottle Bracket 1 COOLANT RECOVE...

Page 1879: ...ith screwdriver Fig 21 17 Remove engine left mount bracket Fig 22 18 Remove starter motor Fig 23 19 Disconnect back up lamp switch connector 20 Position screw jack and wood block to engine oil pan 21...

Page 1880: ...nd flywheel DISASSEMBLY 1 Remove clutch release lever and bearing Fig 26 Inspect release lever pivot balls and replace if necessary Fig 27 Use slide hammer C 3752 and remover installer 6891 Fig 28 if...

Page 1881: ...hift cover assembly Fig 30 Fig 27 Pivot Ball Orientation 1 PIVOT BALL 1 Fig 28 Pivot Ball Removal Installation 1 C 3752 SLIDE HAMMER 2 REMOVER INSTALLER 6891 3 PIVOT BALL Fig 29 Input Bearing Retainer...

Page 1882: ...with bellhousing surface down 7 Remove backup lamp switch Fig 33 8 Remove end plate Fig 34 Fig 31 Extension Housing Seal 1 SCREWDRIVER 2 EXTENSION HOUSING 3 SEAL Fig 32 Extension Housing to Case Bolt...

Page 1883: ...ase bolts 12 Fig 36 14 Remove end cover from transaxle Fig 37 15 Remove 3 4 shift rail bushing from end cover using slide hammer C 3752 and remover 6786 Fig 38 Fig 35 Input Bearing Snap Ring 1 SNAP RI...

Page 1884: ...should be measured to ensure proper shim selection upon reassembly 22 Reinstall and torque extension housing and measure differential turning torque Refer to 21 TRANSMISSION TRANSAXLE MANUAL DIFFER E...

Page 1885: ...earing race with puller 8472 Fig 44 29 Remove shift rail bushing from case with remover 6786 and slide hammer C 3752 Fig 45 Fig 42 Differential Shim Slinger Orientation 1 SLINGER 2 BEARING RACE 3 DIFF...

Page 1886: ...ed with geartrain out of case 1 Install input shaft bearing using an arbor press and remover installer 8474 Fig 47 2 Install shift shaft bushing to case using installer 8475 Fig 48 Fig 46 Input Shaft...

Page 1887: ...all bearing before assembling transaxle Refer to 21 TRANSMISSION TRANSAXLE MANUAL INPUT SHAFT DISASSEMBLY 4 Install assembled input and intermediate shafts to fixture 8487 Fig 50 Fig 49 Install Interm...

Page 1888: ...artrain to case When installing geartrain to case use care not to damage bearing surfaces 7 Remove lifting bar 8489 from geartrain 8 Install shift 1 2 5 R rail as shown in Fig 52 9 Install reverse idl...

Page 1889: ...washer Fig 56 13 Install wave washer Fig 57 Fig 54 Install Reverse Idler Gear Bearing 1 NEEDLE BEARING 2 REVERSE IDLER SHAFT Fig 55 Install Reverse Idler Gear 1 REVERSE IDLER GEAR Fig 56 Install Flat...

Page 1890: ...ll to transaxle case Fig 61 While installing end cover be sure to guide oil trough into pocket Fig 62 Torque end cover to case bolts to 28 N m 250 in lbs Fig 63 Fig 58 Install Input Shaft Sealed Rolle...

Page 1891: ...emove lifting bar 8489 22 Install a bead of Mopart Gear Lube RTV to end plate and immediately install to case Install and torque bolts to 28 N m 250 in lbs Fig 65 Fig 62 Oil Trough Pocket 1 OIL TROUGH...

Page 1892: ...in bead of Mopart Gas ket Maker to differential cover and install to case Torque differential cover to case bolts to 54 N m 40 ft lbs 28 Install a 1 mm 0 04 in bead of Mopart Gas ket Maker to extensi...

Page 1893: ...8 N m 250 in lbs 31 Install input shaft bearing retainer Fig 73 Torque bolts to 12 N m 105 in lbs Fig 70 Axle Seal Installation Extension Housing Side 1 EXTENSION HOUSING 2 SEAL 3 INSTALLER 8476 4 DRI...

Page 1894: ...lever assembly into position by sliding bearing onto input bearing retainer and using moderate hand pressure to seat release lever to pivot ball Fig 77 A pop sound should be heard Verify proper engag...

Page 1895: ...olts to 102 N m 75 ft lbs Install and torque bracket to engine bolts to 68 N m 50 ft lbs Torque through bolt and nut to 68 N m 50 ft lbs 10 Install clutch slave cylinder into position not ing orientat...

Page 1896: ...mount bracket and secure with retaining clips 15 Connect battery cables 16 Check transaxle fluid and engine coolant lev els Adjust if necessary Refer to 21 TRANSMIS SION TRANSAXLE MANUAL FLUID STANDAR...

Page 1897: ...Install and torque four 4 mount to transaxle bolts to 54 N m 40 ft lbs 4 Raise transaxle engine assembly into position and install upper mount through bolt Torque through bolt to 75 N m 55 ft lbs 5 R...

Page 1898: ...e case cutout and hydraulic tube is vertical Connect quick connect connection until an audible click is heard Verify connection by pulling outward on connection 10 Install underbody splash panel 11 In...

Page 1899: ...e sensor and install battery tray Fig 89 18 Install battery hold down clamp and nut Fig 90 Fig 87 Gearshift Cables at Transaxle 1 SELECTOR CABLE 2 CABLE RETAINER 3 CABLE RETAINER 4 CROSSOVER CABLE 5 M...

Page 1900: ...nt mesh fully synchronized 5 speed with integral differential Lubrication Method Splash oil collected in case passage and oil trough and distributed to mainshafts via gravity Fluid Type ATF 4 Automati...

Page 1901: ...mm 0 004 0 030 in Reverse 0 066 0 805 mm 0 003 0 0317 in DIFFERENTIAL DESCRIPTION METRIC STANDARD Differential Turning Torque 2 3 3 4 N m 20 30 in lbs Side Gear End Play each side 0 025 0 152 mm 0 001...

Page 1902: ...850 TRANSAXLE Bearing Splitter P 334 Slide Hammer C 3752 Universal Handle C 4171 Torque Tool C 4995 Puller Set 5048 Disconnect Tool 6638A Remover 6786 RS T850 MANUAL TRANSAXLE 21 345 T850 MANUAL TRANS...

Page 1903: ...ler 6891 Alignment Pins 8470 Installer 8471 Race Remover 8472 Bearing Installer 8473 Remover Installer 8474 Installer 8475 Installer 8476 Wrench 8478 21 346 T850 MANUAL TRANSAXLE RS T850 MANUAL TRANSA...

Page 1904: ...Stake Tool 8479 Installer 8481 Bearing Installer 8482 Fixture 8483 Fixture 8487 Lifting Bar 8489 Thrust Buttons 8491 Wrench 8827 RS T850 MANUAL TRANSAXLE 21 347 T850 MANUAL TRANSAXLE Continued...

Page 1905: ...lfshaft assemblies Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION 3 Check transaxle fluid level and adjust if neces sary Refer to 21 TRANSMISSION TRANSAXLE MANUAL FLUID STANDARD PROCEDURE 4...

Page 1906: ...ntial case is supported in the transaxle by tapered roller bearings OPERATION The differential assembly is driven by the interme diate shaft via the ring gear The ring gear drives the differential cas...

Page 1907: ...ocedure tools work for both sides 2 Remove ring gear to case bolts Fig 100 and remove ring gear Fig 97 Tool 8491 1 TOOL 8491 Fig 98 Puller 5048 1 5048 1 FORCING SCREW 2 5048 4 COLLETS 3 5048 6 SLEEVE...

Page 1908: ...Fig 101 Separate Differential Case Halves 1 BOLT 3 2 DIFFERENTIAL CASE 3 DIFFERENTIAL SUPPORT Fig 102 Differential Support Plate 1 DIFFERENTIAL SUPPORT PLATE 2 DIFFERENTIAL CASE Fig 103 Side Gear Thr...

Page 1909: ...e four pinion gears and thrust washers Fig 108 Fig 105 Long Pinion Shaft 1 PINION SHAFT LONG Fig 106 Short Pinion Shaft 2 1 PINION SHAFT SHORT 2 Fig 107 Pinion Shaft Retaining Ring 1 RETAINING RING Fi...

Page 1910: ...Install differential side gear Fig 112 Fig 109 Differential Side Gear 1 DIFFERENTIAL SIDE GEAR Fig 110 Side Gear Thrust Washer 1 SIDE GEAR THRUST WASHER Fig 111 Side Gear Thrust Washer 1 SIDE GEAR TH...

Page 1911: ...Install one 1 long pinion shaft Fig 116 7 Install differential side gear Fig 113 Pinion Gear and Thrust Washer 1 THRUST WASHER 4 2 PINION GEAR 4 Fig 114 Pinion Shaft Retaining Ring 1 RETAINING RING Fi...

Page 1912: ...all remain ing ring gear to differential case bolts and torque to 95 N m 70 ft lbs Fig 121 13 Install tapered roller bearings using installer 8473 and an arbor press Fig 122 Insert button 8491 on oppo...

Page 1913: ...40 ft lbs 3 Install extension housing and torque extension housing to case bolts to 28 N m 250 in lbs 4 Place transaxle on work bench so axle center line is parallel to the ground 5 Install turning to...

Page 1914: ...354 4659256 0 94 0 0370 4659257 0 98 0 0386 4659258 1 02 0 0402 4659259 1 06 0 0418 4659260 1 10 0 0434 4659261 1 14 0 0449 4659262 1 18 0 0465 4659263 1 22 0 0481 4659264 1 26 0 0497 4659265 1 30 0 0...

Page 1915: ...CEDURE FLUID LEVEL CHECK NOTE For proper fluid level check intervals Refer to LUBRICATION MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION The fluid required in this transaxle is Mopart ATF 4 Automatic T...

Page 1916: ...tall drain plug and torque to 23 N m 17 ft lbs FLUID FILL 1 Remove transaxle fill plug Fig 128 2 Add 2 4 2 7L 2 5 2 9 qts of Mopart ATF 4 Automatic Transmission Fluid Type 9602 until fluid is within 1...

Page 1917: ...1 Disconnect battery negative cable 2 Remove gearshift knob by pushing down and rotating 1 4 turn clock wise Fig 131 3 Remove gearshift boot from center console by disengaging at three 3 retaining cli...

Page 1918: ...cable retainer clip Fig 136 Fig 133 Cup Holder Plugs 1 CUPHOLDER PLUG 2 Fig 134 Center Console Removal Installation LHD Shown RHD Typical 1 CENTER CONSOLE 2 SCREW 4 3 GEARSHIFT MECHANISM Fig 135 Cent...

Page 1919: ...battery Fig 139 12 Remove battery tray Fig 140 Disconnect battery temperature sensor Fig 137 Crossover Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 CROSSOVER CABLE Fig 138 Battery Thermal Shie...

Page 1920: ...r cable into passenger compartment through floor pan hole Install remainder of cable into posi tion in engine compartment 2 Lower vehicle 3 Install crossover cable to mount bracket and secure with ret...

Page 1921: ...tion Fig 145 8 Install battery hold down clamp and nut Fig 146 9 Install battery thermal shield Fig 147 Fig 144 Coolant Recovery Bottle Bracket 1 COOLANT RECOVERY BOTTLE BRACKET 2 NUT 3 MOUNT BRACKET...

Page 1922: ...console assembly Fig 151 Install and torque center console to gearshift mecha nism screws to 5 N m 45 in lbs Fig 148 Crossover Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 CROSSOVER CABLE Fig...

Page 1923: ...ry negative cable ADJUSTMENTS ADJUSTMENT 1 Disconnect battery negative cable 2 Remove gearshift knob by pushing down and rotating 1 4 turn clock wise Fig 155 Fig 152 Cup Holder Plugs 1 CUPHOLDER PLUG...

Page 1924: ...hift lever back and forth between 1 2 and 5 R planes Release lever allowing shifter spring to return lever to the neutral position in the 3 4 plane Place gearshift lever in the 3rd gear posi tion Fig...

Page 1925: ...knob 1 4 turn clockwise push down and rotate 1 4 turn counter clockwise and release Secure boot to knob 15 Connect battery negative cable GEARSHIFT CABLE SELECTOR REMOVAL 1 Disconnect battery negative...

Page 1926: ...hift mecha nism Fig 166 Fig 163 Center Console Removal Installation LHD Shown RHD Typical 1 CENTER CONSOLE 2 SCREW 4 3 GEARSHIFT MECHANISM Fig 164 Center Console Support Bracket 1 BRACKET 2 SCREW 3 GE...

Page 1927: ...ove coolant recovery bottle from bracket 14 Remove coolant recovery bottle mounting bracket Fig 170 Fig 167 Battery Thermal Shield 1 BATTERY THERMAL SHIELD Fig 168 Battery and Hold Down Clamp 1 BATTER...

Page 1928: ...in engine compartment 2 Lower vehicle 3 Install selector cable to mount bracket and secure with retainer clip Fig 172 4 Install cable to transaxle selector lever Fig 172 5 2 4L Gas models goto Step 10...

Page 1929: ...mal shield Fig 176 10 Install selector cable to gearshift mechanism Fig 177 Install retainer clip Fig 178 Fig 174 Battery Tray 1 BATTERY TRAY Fig 175 Battery and Hold Down Clamp 1 BATTERY 2 HOLD DOWN...

Page 1930: ...ism screws to 5 N m 45 in lbs 13 Install cupholder plugs Fig 181 Fig 178 Selector Cable Retainer Clip 1 RETAINER CLIP Fig 179 Center Console Support Bracket 1 BRACKET 2 SCREW 3 GEARSHIFT MECHANISM Fig...

Page 1931: ...nob 2 Remove gearshift knob by pushing down and rotating 1 4 turn clockwise Fig 184 INSTALLATION 1 Install gearshift knob pattern 1 4 turn clock wise press down and rotate 1 4 turn counter clock wise...

Page 1932: ...sole upon removal 5 Remove two 2 cupholder bottom plugs Fig 187 6 Remove four 4 center console to gearshift mechanism screws Remove console assembly Fig 188 Fig 185 Gearshift Knob Removal Installation...

Page 1933: ...le retainer clip Fig 192 Fig 189 Center Console Support Bracket 1 BRACKET 2 SCREW 3 GEARSHIFT MECHANISM Fig 190 Crossover Cable Retainer Clip 1 RETAINER CLIP 2 CROSSOVER CABLE Fig 191 Crossover Cable...

Page 1934: ...t mechanism Fig 196 Install retainer clip Fig 197 Fig 193 Selector Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 SELECTOR CABLE Fig 194 Gearshift Mechanism Removal Installation RHD Shown LHD Ty...

Page 1935: ...ift mechanism screws to 12 N m 108 in lbs Fig 197 Selector Cable Retainer Clip 1 RETAINER CLIP Fig 198 Crossover Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 CROSSOVER CABLE Fig 199 Crossover...

Page 1936: ...1 4 turn clockwise push down and rotate 1 4 turn counter clockwise and release Secure boot to knob 10 Connect battery negative cable Fig 201 Center Console Removal Installation LHD Shown RHD Typical...

Page 1937: ...ing at the rear of the transaxle DISASSEMBLY NOTE When servicing the input shaft assembly all snap rings which are removed MUST be replaced with new snap rings upon reassembly The 5th gear nut must be...

Page 1938: ...ear nut is staked to the shaft If neces sary grind stake area to ease removal but use care not to contact gear 5 Remove 5th gear nut with wrench 8478 Fig 208 Discard nut and use a new one upon assembl...

Page 1939: ...emove 3 4 synchronizer Fig 212 11 Remove 3rd gear blocker ring Fig 213 Fig 210 4th Gear Blocker Ring 1 4th GEAR BLOCKER RING Fig 211 3 4 Synchro Snap Ring 1 SNAP RING 2 3 4 SYNCHRONIZER Fig 212 3 4 Sy...

Page 1940: ...e replaced NOTE When installing 3 4 synchronizer hub to shaft make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub jour nal NOTE Refer to Fig 215 for input shaf...

Page 1941: ...hub to shaft make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal 6 Install NEW 3 4 synchronizer snap ring Fig 219 Fig 216 3rd Gear Removal Installation...

Page 1942: ...ut and torque to 200 N m 148 ft lbs using wrench 8478 Fig 223 Fig 220 4th Gear Blocker Ring 1 4th GEAR BLOCKER RING Fig 221 4th Gear Removal Installation 1 4th GEAR Fig 222 5th Gear Installation 1 ARB...

Page 1943: ...rews and thumb screws Remove tool and visually inspect stake Fig 226 NOTE The input shaft sealed roller bearing and snap ring do not get installed until transaxle assem bly to facilitate installation...

Page 1944: ...1 2 Synchronizer 5 R Synchronizer The intermediate shaft is supported by a caged roller bearing at the front of the transaxle and a sealed roller bearing at the rear of the transaxle Fig 227 Intermed...

Page 1945: ...arbor press ram press reverse gear and inter mediate roller bearing off of shaft while holding remaining assembly with hand Fig 228 3 Remove reverse gear blocker ring 4 Remove reverse gear needle bea...

Page 1946: ...ig 233 9 Remove 3 4 cluster gear snap ring Fig 234 Fig 231 5 R Synchronizer 1 5 R SYNCHRO ASSEMBLY Fig 232 5th Gear Blocker Ring 1 5th GEAR BLOCKER RING Fig 233 5th Gear 1 5th GEAR Fig 234 3 4 Cluster...

Page 1947: ...e shaft from fixture and remove 3 4 cluster gear from shaft Fig 238 Fig 235 Fixture 8483 1 FIXTURE 8483 2 COLLAR 8483 3 Fig 236 Loading Intermediate Shaft 1 FIXTURE 8483 1 3 4 CLUSTER GEAR 2 COLLAR 84...

Page 1948: ...ve 2nd Gear outer blocker ring Fig 242 Fig 239 2nd Gear Removal 1 2ND GEAR 2 INTERMEDIATE SHAFT Fig 240 2nd Gear Reactor Ring 1 2ND GEAR REACTOR RING Fig 241 2nd Gear Friction Cone 1 2ND GEAR FRICTION...

Page 1949: ...45 20 Remove 1st gear friction cone Fig 246 Fig 243 1 2 Synchro Snap Ring 1 SNAP RING 2 1 2 SYNCHRO HUB Fig 244 1 2 Synchronizer 1 1 2 SYNCHRONIZER Fig 245 1st Gear Blocker Ring 1 1ST GEAR BLOCKER RIN...

Page 1950: ...ve intermediate shaft roller bearing snap ring Fig 250 Fig 247 1st Gear Reactor Ring 1 1ST GEAR REACTOR RING Fig 248 1st Gear Removal 1 1ST GEAR Fig 249 1st Gear Needle Bearing 1 1ST GEAR NEEDLE BEARI...

Page 1951: ...ler bearing is not re usable once removed It is necessary to install a new roller bearing upon re assembly Fig 251 Intermediate Shaft Roller Bearing Removal 1 ARBOR PRESS RAM 2 INTERMEDIATE SHAFT 3 RO...

Page 1952: ...s intermediate shaft into NEW roller bear ing with arbor press Fig 253 Fig 252 Intermediate Shaft Assembly 1 INTERMEDIATE SHAFT 10 SNAP RING 2 ROLLER BEARING 11 SEALED ROLLER BEARING 3 SNAP RING 12 TH...

Page 1953: ...blocker ring friction cone and reactor ring as shown in Fig 257 Fig 254 Intermediate Shaft Roller Bearing Snap Ring 1 SNAP RING Fig 255 1st Gear Needle Bearing 1 1ST GEAR NEEDLE BEARING Fig 256 1st Ge...

Page 1954: ...ring tabs to gear slots Remove shaft assembly from fix ture 7 Install NEW 1 2 synchro snap ring Fig 259 8 Install 2nd gear blocker ring Fig 260 Fig 258 Install 1 2 Synchro to Intermediate Shaft 1 INTE...

Page 1955: ...o intermediate shaft using cup 8481 Fig 264 Fig 261 2nd Gear Friction Cone 1 2ND GEAR FRICTION CONE Fig 262 2nd Gear Reactor Ring 1 2ND GEAR REACTOR RING Fig 263 2nd Gear 1 2ND GEAR 2 INTERMEDIATE SHA...

Page 1956: ...onizer make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal Fig 265 3 4 Cluster Gear Snap Ring 1 SNAP RING Fig 266 5th Gear Installation 1 5th GEAR Fig...

Page 1957: ...d roller bear ing and thrust washer using installer 8482 Fig 272 Fig 269 5 R Synchro Snap Ring 1 SNAP RING Fig 270 Reverse Gear Blocker Ring 1 REVERSE BLOCKER RING 2 5 R SYNCHRONIZER Fig 271 Reverse G...

Page 1958: ...isms transaxle vent a main shift selector shaft and the 5 R blockout mechanism The shift cover is only ser viced as an assembly Fig 274 Shift Lever Identification 1 SHIFT COVER ASSEMBLY 2 VENT 3 CROSS...

Page 1959: ...one style is used for the 5th Reverse and 3rd 4th applications Fig 277 and a dual cone style for the 1st 2nd gear appli cation Fig 278 DISASSEMBLY Place synchronizer in a clean shop towel and wrap Pre...

Page 1960: ...ed sensor from transaxle CAUTION Carefully remove vehicle speed sensor so that sensor drive gear does not fall into trans axle Should sensor drive gear fall into the trans axle during sensor removal d...

Page 1961: ......

Page 1962: ...ND TESTING DIAGNOSIS AND TESTING TIRE NOISE 14 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD 14 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 14 DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 14 STANDARD PROCEDURE...

Page 1963: ...continue with this diagnosis and testing procedure TIRE AND WHEEL RUNOUT MATCH MOUNTING 1 System Radial Runout This on the vehicle system check will measure the radial runout includ ing the hub wheel...

Page 1964: ...rmed as follows a Dismount the tire from the wheel b Mount the wheel back on the wheel balancer c Measure radial runout of the wheel at the tire bead seat Fig 4 Runout should not exceed 0 254 mm 0 010...

Page 1965: ...5 miles following the format described in Road Test If vibration persists and all components tested are within specification the tires may have an exces sive radial force condition Radial force variat...

Page 1966: ...y spot causing imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counterbalance the area of imbalance Place half of this weight on the inner rim flange and...

Page 1967: ...TER LINE OF SPINDLE 5 TIRE OR WHEEL TRAMP OR WHEEL HOP 3 ADD BALANCE WEIGHTS HERE Fig 9 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 3 CORRECTIVE WEIGHT LOCATION 2 ADD BALANCE WEIGHTS HERE 4 HEA...

Page 1968: ...res are designed to improve traction on wet pave ment To obtain the full benefits of this design the tires must be installed so that they rotate in the cor rect direction This is indicated by arrows o...

Page 1969: ...Fig 13 Tighten wheel mounting nuts to 135 N m 100 ft lbs 3 Lower the vehicle INSTALLATION TIRE AND WHEEL ASSEMBLY STEEL WHEEL NOTE Never use oil or grease on studs or wheel mounting nuts 1 Position t...

Page 1970: ...r technology to monitor tire air pres sure levels Sensors mounted to each road wheel as part of the valve stem transmit tire pressure read ings to a receiver located in the overhead console These tran...

Page 1971: ...r core in a tire pressure sensor in place of the original equipment style sensor cap and core CAUTION Do not attempt to install a tire pressure sensor in a steel wheel or aftermarket wheel Use tire pr...

Page 1972: ...ure from entering the valve stem Retain this valve stem cap for reuse Do not substitute a regu lar valve stem cap in its place CAUTION The valve stem used on this vehicle is made of aluminum and the c...

Page 1973: ...cedure on both the upper and lower tire beads b Rotating Tool Tire Changers Position the wheel on the changer so that the sensor valve stem is approximately 210 from the head of the changer in a clock...

Page 1974: ...follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread life potential TIRE IDENTIFICATION Tire type size load index and speed rating are enc...

Page 1975: ...ence spare tire should be inflated to the pressure listed on its sidewall Do not exceed speeds of 80 km h 50 mph when the tempo rary spare tire is in use on the vehicle Refer to the Owner s Manual for...

Page 1976: ...VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART RS TIRES WHEELS 22 15 TIRES Continued...

Page 1977: ...quare inch psi 14 to 41 kPa during operation Do not reduce this normal pressure buildup Improper inflation can cause Uneven wear patterns Reduced tread life Reduced fuel economy Unsatisfactory ride Th...

Page 1978: ...ten the 5 wheel nuts to a torque of 135 N m 100 ft lbs CLEANING TIRES Before delivery of a vehicle remove the protective coating on the tires with white sidewalls or raised white letters To remove the...

Page 1979: ...THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREAT MENT OR VERY HIGH MILEAGE THE RIM COULD FAIL WITHOUT WARNING CLEANING ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels shou...

Page 1980: ...e edges in line with the remaining installed wheel nuts and pull straight outward from the wheel This will pop the wheel cover retaining tabs over the two remaining wheel nuts removing the wheel cover...

Page 1981: ...embly from the steering knuckle Fig 34 Hang the assembly out of the way using wire or a bungee cord Use care not to overextend the brake hose when doing this 5 Remove brake rotor from hub by pulling i...

Page 1982: ...ION If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs MUST NOT be hammered out of the hub flange If a stud is removed by hammering it out of the bearing flange d...

Page 1983: ...rum or disc brake rotor and caliper on the hub and bearing assembly 4 Install wheel and tire assembly on vehicle Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to h...

Page 1984: ...AL INJURY CAN RESULT CAUTION When holes must be drilled or punched in an inner body panel verify depth of space to the outer body panel electrical wiring or other compo nents Damage to vehicle can res...

Page 1985: ...of entry After leak point has been found repair the leak and water test to verify that the leak has stopped Locating the entry point of water that is leaking into a cavity between panels can be diffi...

Page 1986: ...which include SMC ABS and Polycarbonates Semi Rigid Plastics Examples of semi rigid plastic use Interior Panels Under Hood Panels and other Body Trim Panels Flexible Plastics Examples of flexible pla...

Page 1987: ...C POLYESTER RYNITE TRIM PBT PPO PBT PPO ALLOY GERMAX CLADDINGS PBTP POLYBUTYLENE THEREPTHALATE PBT PBTP POCAN VALOX WHEEL COVERS FENDERS GRILLES PBTP EEBC POLYBUTYLENE THEREPTHALATE EEBC ALLOY BEXLOY...

Page 1988: ...DYLON PRAVEX INNER FENDER SPOILERS KICK PANELS PP EPDM PP EPDM ALLOY PP EPDM SPOILERS GRILLES PUR POLYURETHANE COLONELS PUR PU FASCIAS BUMPERS PUR PC PUR PC ALLOY TEXIN BUMPERS PVC POLYVINYL CHLORIDE...

Page 1989: ...o dry before moving on with the repair PANEL REINFORCEMENT Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing Reinforcements can be made wit...

Page 1990: ...However a backer panel open fiberglass tape or matted material must be bonded from behind Fig 7 Fig 6 PANEL SURFACE PREPARATION If a body panel has been punctured cracked or crushed the damaged area...

Page 1991: ...e cutout hole in the panel 2 Trim 3 mm 0 125 in from edges of pattern so patch will have a gap between connecting surfaces 3 Using the pattern as a guide cut the patch to size 4 Cut scrap pieces of pa...

Page 1992: ...inder grind a 50 mm 2 in to 75 mm 3 in wide and 2 mm 0 080 in deep path across the gaps around the patch Fig 13 With compressed air blow dust from around patch 18 Apply adhesive backed nylon mesh dry...

Page 1993: ...gun with a flat tip melt the material securing the components together Do not over heat the affected area dam age to the exterior of the trim panel may occur b If the heat staked material is broken o...

Page 1994: ...pillar bolts 34 25 Front door hinge to door nuts and bolts 34 25 Front door latch striker bolts 28 21 Front quad seat cushion bolts 28 5 21 Front seat belt retractor bolts 38 28 Front seat riser to fl...

Page 1995: ...nd wear When performing other under hood services the hood latch release mechanism and safety catch should be inspected cleaned and lubri cated During the winter season external door lock cylinders sh...

Page 1996: ...ate Latch MOPART Multipurpose GREASE OR EQUIVALENT All Other Hood Mechanisms MOPART LOCK CYLINDER LUBRICANT OR EQUIVALENT Door Lock Cylinders Liftgate Lock Cylinder SPECIAL TOOLS BODY INDEX DESCRIPTIO...

Page 1997: ...door frame 4 Remove applique from vehicle Fig 1 INSTALLATION 1 Position applique on vehicle 2 Hook rear edge of applique over rear edge of door frame and seat applique bottom edge on sheet metal 3 En...

Page 1998: ...s attaching door check strap to A pillar Fig 4 7 Support door on suitable lifting device 8 Remove bolts attaching lower hinge to door end frame Fig 5 9 Steady door on lifting device and remove bolts a...

Page 1999: ...8 Connect clips attaching door harness wire con nector to inner fender brace 9 Install front wheelhouse splash shield 10 Verify door operation and alignment Adjust as necessary DOOR GLASS REMOVAL 1 Re...

Page 2000: ...THERSTRIP SEALS FRONT DOOR INNER BELT MOLDING INSTALLATION 10 Verify door glass operation and fit 11 Install watershield Refer to 23 BODY DOOR FRONT WATERSHIELD INSTALLATION FRAME CLOSEOUT MOLDING REM...

Page 2001: ...necessary LATCH REMOVAL 1 Roll door glass up 2 Remove front door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 3 Remove watershield as necessary to gain access to the outside door handle 4...

Page 2002: ...4 Retrieve any shims found between latch striker and B pillar INSTALLATION 1 Position latch striker and any shims retrieved on vehicle 2 Loosely install screws attaching latch striker to B pillar 3 Al...

Page 2003: ...Verify door latch operation 10 Install watershield and door trim panel TRIM PANEL REMOVAL 1 Remove the plug and remove screw attaching door pull cup to inner door panel 2 Remove switch bezel and disco...

Page 2004: ...l 16 If equipped install screws to attach door assist handle to inner door panel 17 Connect wire connector into courtesy lamp 18 Install lamp in door trim 19 Install switch bezel WATERSHIELD REMOVAL 1...

Page 2005: ...rough front access hole INSTALLATION 1 Insert front guide rail through front access hole 2 Insert rear guide rail through rear access hole 3 Place window regulator in position on inner door panel 4 Pl...

Page 2006: ...or handle to door outer panel 10 Remove outside door handle from vehicle INSTALLATION If outside door handle replacement is necessary transfer lock cylinder from the original handle to the new one 1 P...

Page 2007: ...LATION 35 UPPER HINGE REMOVAL 36 INSTALLATION 36 OUTSIDE HANDLE CABLE REMOVAL 36 INSTALLATION 37 INSIDE HANDLE CABLE REMOVAL 37 INSTALLATION 37 HOLD OPEN LATCH CABLE REMOVAL 38 INSTALLATION 38 CENTER...

Page 2008: ...r to door inner panel Fig 1 3 Tighten screws attaching rear of stop bumper to door inner panel 4 Install door stop bumper bezel HOLD OPEN LATCH REMOVAL 1 Open sliding door 2 Remove sliding door sill p...

Page 2009: ...nd perimeter of inner door panel CAUTION Replace the latch lock control if any of the metal clips on the latch lock control are bent or broken DO NOT attempt to repair the clips to retain the links 4...

Page 2010: ...Install sliding door trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL INSTAL LATION CENTER STRIKER REMOVAL 1 Remove sliding door trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL REMOVAL 2 Remo...

Page 2011: ...ocedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRI CAL section 1 Place roller arm into position Fig 7 2 Engage roller arm to lower channel 3 Install roller arm to sliding door 4 Install bolts...

Page 2012: ...ice with a padded upper surface The door must be moveable with lifting device in place CAUTION Do not allow the center hinge roller to contact the quarter glass Glass can break 12 Slide door rearward...

Page 2013: ...anism 2 On vehicles with left sliding doors check the fuel door blocker striker entry into latch Striker at this point must not affect alignment 3 Check C post and B post for door to aperture gaps and...

Page 2014: ...t to position the sliding door into the correct location e Tighten center hinge bolts f Verify alignmen adjust as necessary 3 If the sliding door is low at the B post a Remove access plug in the slidi...

Page 2015: ...arm on lower roller arm bracket to assist in making adjustments Fig 15 c Loosen bolts holding lower roller arm to lower roller arm bracket d Pivot lower roller arm toward center of vehi cle to decrea...

Page 2016: ...e INSTALLATION 1 Place sliding door trim panel in position on vehicle 2 Align locating pins on backside of trim panel to mating holes in the inner door panel 3 Engage push in fasteners to hold trim to...

Page 2017: ...N BELLCRANK REMOVAL 1 Remove stop bumper Refer to 23 BODY DOORS SLIDING STOP BUMPER REMOVAL 2 Remove sliding door trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL REMOVAL 3 Peel watershield away f...

Page 2018: ...de door handle to outer door panel 3 Engage clip attaching linkage to outside door handle 4 Engage rigging cam to latch lock control mech anism 5 Move clip on latch lock control to bottom of slot and...

Page 2019: ...TE For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRI CAL section 1 Disconnect and isolate the negative battery cable 2 Remove stop bumper Refer to 23 BODY DOORS SLIDI...

Page 2020: ...AL 3 Peel watershield away from adhesive around perimeter of inner door panel 4 Remove the inside handle assembly from the side door Refer to 23 BODY DOORS SLIDING INSIDE LATCH HANDLE REMOVAL 5 Discon...

Page 2021: ...3 BODY DOORS SLIDING HOLD OPEN LATCH REMOVAL 8 Disconnect the hold open latch cable from the hold open latch Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable en...

Page 2022: ...exterior handle electrical connector through the door and position handle 2 Install the two out screws and tighten to 20 N m 15 ft lbs 3 Install the two inner bolts and tighten to 40 N m 30 ft lbs 4 C...

Page 2023: ...ftgate latch 4 Verify liftgate fit and operation Adjust as nec essary 5 Install liftgate trim panel LATCH STRIKER REMOVAL 1 Open liftgate 2 Mark outline of striker on sill to aid installa tion 3 Remov...

Page 2024: ...ness into body wire harness 6 Install screws attaching wire connector to rear header 7 Connect rear window washer hose onto spray nozzle 8 Install liftgate upper frame molding 9 Verify liftgate alignm...

Page 2025: ...vot 4 Remove bolt attaching end pivot to D pillar Fig 6 5 Remove bolt attaching prop assembly to lift gate 6 Remove prop assembly from vehicle INSTALLATION Ensure that the cylinder end is attached to...

Page 2026: ...ate stop bumper REMOVAL LIFTGATE SIDE 1 Open liftgate 2 Remove liftgate stop bumper liftgate side attaching bolts Fig 10 3 Remove liftgate stop bumper INSTALLATION INSTALLATION 1 Place liftgate stop b...

Page 2027: ...FENDER AIR EXHAUSTER DESCRIPTION 57 REMOVAL 57 INSTALLATION 58 ROOF JOINT MOLDING REMOVAL 58 INSTALLATION 58 SIDE VIEW MIRROR REMOVAL 58 INSTALLATION 58 SIDE VIEW MIRROR GLASS REMOVAL 59 INSTALLATION...

Page 2028: ...ive tape to back of molding 2 Clean body surface with Mopart Super Kleen or equivalent Wipe surface dry with lint free cloth 3 Remove protective cover from tape on back of molding 4 Apply molding to b...

Page 2029: ...NE TYPICAL 1 QUARTER PANEL 2 FRONT FENDER 3 POP RIVET 4 FENDER MOLDING 5 FRONT DOOR MOLDING 6 SLIDING DOOR MOLDING 7 GUIDE PINS 8 QUARTER PANEL MOLDING 9 LIFTGATE MOLDING 10 POP RIVET 23 46 EXTERIOR R...

Page 2030: ...YPICAL 1 QUARTER PANEL 2 FRONT FENDER 3 POP RIVET 4 FENDER MOLDING 5 POP RIVET 6 FASCIA 7 FRONT DOOR MOLDING 8 SLIDING DOOR MOLDING 9 QUARTER PANEL MOLDING 10 FASCIA MOLDING 11 POP RIVET RS EXTERIOR 2...

Page 2031: ...YPICAL 1 QUARTER PANEL 2 FRONT FENDER 3 POP RIVET 4 FENDER MOLDING 5 POP RIVET 6 FASCIA 7 FRONT DOOR MOLDING 8 SLIDING DOOR MOLDING 9 QUARTER PANEL MOLDING 10 FASCIA MOLDING 11 POP RIVET 23 48 EXTERIO...

Page 2032: ...E MOLDINGS WITH APPLIQUE TYPICAL 1 FRONT ROCKER PANEL APPLIQUE 2 FRONT DOOR MOLDING 3 SLIDING DOOR MOLDING 4 REAR ROCKER PANEL APPLIQUE 5 LIFTGATE MOLDING 6 POP RIVET RS EXTERIOR 23 49 BODY SIDE MOLDI...

Page 2033: ...by raising over opposite wiper pivot shaft and removing away from vehicle 10 Remove cowl cover from vehicle INSTALLATION 1 Reverse removal procedure 2 When installing cowl cover over wiper module mak...

Page 2034: ...any reference points FRONT FENDER REMOVAL 1 Remove headlamp housing Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT REMOVAL 2 Remove mud guard 3 Remove inner splash shield 4 Remove fende...

Page 2035: ...eck in position 10 Install screws to hold fuel fill neck to fuel filler housing 11 Engage latch release link into clip on fuel fill blocker latch arm 12 Verify fuel fill blocker latch operation 13 Ins...

Page 2036: ...ield patch covering access hole in C pillar 3 Disengage fuel filler lockout link from clip on fuel fill blocker latch arm Fig 12 4 Open fuel fill door 5 Remove screws holding fuel filler housing to fu...

Page 2037: ...diator closure panel Fig 14 10 Lift crossmember upward and away from radiator closure panel 11 Remove crossmember from vehicle INSTALLATION 1 Place radiator closure panel crossmember in position on ve...

Page 2038: ...hing splash shield to frame rail forward of suspension 3 Install push pin fasteners attaching splash shield to frame rail rearward of suspension 4 Install screws attaching wheelhouse splash shield to...

Page 2039: ...o the unlock position Fig 18 Work from side to side sliding the crossbar assembly forward moving a little at a time to ensure it remains perpendicular to the side rails 3 Remove crossbar from vehicle...

Page 2040: ...of the body REMOVAL SHORT WHEELBASE 1 Remove the rear fascia from the body Refer to 13 FRAMES BUMPERS BUMPERS REAR FAS CIA REMOVAL 2 Using a trim stick or another suitable wide flat bladed tool caref...

Page 2041: ...F using a suit able heat lamp or heat gun 2 Pull stick on molding from painted surface 3 Remove adhesive tape residue from painted surface of vehicle Use a 3M Scotch Brite Molding Adhesive and Stripe...

Page 2042: ...he moisture drain hole on the mirror glass holder assembly is facing downward 2 Align the mirror glass holder s attaching fin gers to the mirror motor housing NOTE Ensure that the protective rubber co...

Page 2043: ...n lbs torque 4 Install pivot bolt to the body half of hood hinge Tighten bolts to 28 N m 21 ft lbs torque 5 Install Front Wiper Unit Refer to 8 ELEC TRICAL WIPERS WASHERS WIPER MODULE INSTALLATION for...

Page 2044: ...emove hood latch from vehicle INSTALLATION 1 Position hood latch on vehicle 2 Connect hood release cable from hood latch 3 Position hood latch on crossmember 4 Align hood latch by placing latch over n...

Page 2045: ...ommet cable insulator into hole in dash panel 6 Install hood release handle into instrument panel 7 Place cable in position on latch 8 Slide cable case end sideways into keyhole slot of hood latch 9 E...

Page 2046: ...70 INSTALLATION 70 STEERING COLUMN COVER BACKING PLATE REMOVAL 70 INSTALLATION 71 OVER STEERING COLUMN COVER REMOVAL 71 INSTALLATION 71 CLUSTER BEZEL REMOVAL 1 Disconnect and isolate the battery negat...

Page 2047: ...Open glove box 2 Push in on sides of glove box bin and lower door 3 Pivot glove box downward and disengage hinge hooks from instrument panel 4 Remove glove box INSTALLATION 1 Place glove box in posit...

Page 2048: ...19 Disconnect the steering column wiring There are seven connectors and then unclip the harness from the column 20 Disconnect the Occupant Restraint Controller ORC harness connector 21 Remove the fou...

Page 2049: ...K RIGHT LEFT REINFORCEMENT Fig 4 INSTRUMENT PANEL LEFT SILENCER 1 INSTRUMENT PANEL 2 INSTRUMENT PANEL LEFT SILENCER Fig 5 INSTRUMENT PANEL LOWER REINFORCEMENT 1 LOWER RIGHT REINFORCEMENT 2 STEERING WH...

Page 2050: ...right side wire connectors to the HVAC behind the glove box area and the two antenna connectors behind the glove box hinge 9 Install the bolts attaching the instrument panel frame to the dash panel b...

Page 2051: ...nsole to vehicle b Connect the auxiliary power outlet c Install the six retaining screws 33 Connect the battery negative cable INSTRUMENT PANEL CENTER BEZEL REMOVAL 1 Disconnect and isolate the batter...

Page 2052: ...trument panel 4 Pull top cover rearward 5 Install A pillar trim LOWER CONSOLE REMOVAL 1 Remove screws attaching the lower console to floor bracket and instrument panel Fig 11 2 Slide lower console rea...

Page 2053: ...nstall the cup holder and track 7 Install the lower console 8 Install the center bezel 9 Install the lower steering column cover 10 Install the right end cover LOWER STEERING COLUMN COVER REMOVAL 1 Re...

Page 2054: ...fer to 23 BODY INSTRUMENT PANEL STEERING COLUMN OPENING COVER INSTALLATION OVER STEERING COLUMN COVER REMOVAL 1 Taking a firm grasp of the over steering col umn cover front edge give a quick upward pu...

Page 2055: ...PILLAR TRIM PANEL REMOVAL 77 INSTALLATION 77 LIFTGATE SILL PLATE REMOVAL 77 INSTALLATION 77 QUARTER TRIM BOLSTER REMOVAL 77 INSTALLATION 77 RIGHT QUARTER TRIM PANEL REMOVAL 78 INSTALLATION 78 LEFT QU...

Page 2056: ...ps 5 Install the assist handle if equipped Refer to 23 BODY INTERIOR ASSIST HANDLE INSTAL LATION ASSIST HANDLE REMOVAL 1 Using a trim stick C 4755 remove screw access covers from grab handle 2 Remove...

Page 2057: ...elt through B pillar trim and web guide Fig 3 2 Place B pillar trim cover in position on vehicle 3 Engage hidden clips attaching trim cover to B pillar 4 Install shoulder belt bezel into trim cover 5...

Page 2058: ...ers 10 Install lower B pillar trim covers 11 Install rear door sill plate 12 Install sliding door sill plates Refer to 23 BODY INTERIOR SLIDING DOOR SILL PLATE INSTALLATION 13 Install front cowl panel...

Page 2059: ...dules 5 Remove A pillar trim covers 6 Remove B pillar upper trim covers 7 Remove C pillar upper trim covers 8 Remove D pillar trim covers 9 Remove liftgate opening header trim 10 If equipped remove ov...

Page 2060: ...stall bolt attaching second row seat belt lower anchor to quarter on short wheel base vehicle Tighten all seat belt bolts to 39 N m 29 ft lbs 7 Install second row seat belt turning loop on long wheel...

Page 2061: ...rea 9 Install second row seat belt anchor on long wheel base vehicle Tighten all seat belt bolts to 39 N m 29 ft lbs torque 10 Install first row seat belt anchor 11 Install D pillar trim panel 12 Inst...

Page 2062: ...engage hidden clips holding trim to rear header Fig 10 2 Separate rear header trim from vehicle INSTALLATION 1 Place rear header trim in position on vehicle 2 Align guide pins on trim to holes in head...

Page 2063: ...e 3 Connect speaker wire connector to speaker if equipped 4 Align locating pins on backside of trim panel to mating holes in D pillar 5 Engage hidden clips attaching trim to D pillar 6 Install screws...

Page 2064: ...he sun visor verify label availability and ensure the label is installed 1 Place sun visor in position on vehicle 2 Connect illuminated vanity mirror wire connec tor into body harness 3 Place sun viso...

Page 2065: ...Manual for proper procedures FLOOR CONSOLE TRAY BRACKET ASSEMBLY REMOVAL 1 Remove the floor carpet Refer to 23 BODY INTERIOR CARPETS AND FLOOR MATS REMOVAL 2 Disconnect the electrical connector 3 Rem...

Page 2066: ...RED TINTED PEARLCOAT WEL STERLING BLUE SATIN GLOW YB2 LIGHT ALMOND PEARL METALLIC CLEARCOAT ZKJ STONE WHITE CLEARCOAT SW1 INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER COLOR CODE INTERIOR COLOR DAIM...

Page 2067: ...od sur face finish The applicator brush should be wet enough to puddle fill the defect without running Do not stroke brush applicator on body surface Allow the filler primer to dry hard 4 Cover the fi...

Page 2068: ...ATION 94 FRONT SEAT TRACK POWER ADJUSTER REMOVAL 94 INSTALLATION 94 FRONT SEAT TRACK MANUAL ADJUSTER REMOVAL 94 INSTALLATION 95 FRONT SEAT TRACK FRONT COVER REMOVAL 95 INSTALLATION 95 FRONT SEAT TRACK...

Page 2069: ...Remove seat back cover 3 Remove screws attaching child restraint seat module hinges to seat back frame lower rail Fig 1 4 Return seat back to upright position 5 Disengage push in fasteners attaching u...

Page 2070: ...interlock feature that will not allow the seat back to fold forward with the child seat open If the seat back hinges do not release at the same time the synchronizing cable must be adjusted 1 Remove s...

Page 2071: ...estraint to top of travel 2 Depress lock button on side of sleeve at top of seat back Fig 9 3 Pull head restraint from top of seat back INSTALLATION 1 Place head restraint in position 2 Depress lock b...

Page 2072: ...LE REMOVAL 1 Remove screw holding recliner handle to recliner spline shaft Fig 12 2 Remove recliner handle from spline shaft INSTALLATION 1 Place recliner handle in position on spline shaft 2 Install...

Page 2073: ...retainer Refer to 23 BODY SEATS PLASTIC GRO CERY BAG RETAINER INSTALLATION FRONT SEAT REMOVAL 1 From under vehicle remove nuts attaching front seat risers to the floor 2 Remove seat and riser from flo...

Page 2074: ...taching the recliner to the seat back frame Tighten nut to 12 N m 105 in lbs torque 4 Install both seat cushion side covers Refer to 23 BODY SEATS FRONT SEAT CUSHION SIDE COVER INSTALLATION 5 Install...

Page 2075: ...ATION NOTE On vehicles equipped with seat side air bags the seat cover is NOT serviceable The seat back is serviced as an assembly only Refer to 23 BODY SEATS SEAT BACK INSTALLATION 1 Fit seat cover o...

Page 2076: ...TION and Refer to 23 BODY SEATS QUAD BUCKET SEAT SIDE SHIELD NO CUP HOLDER INSTALLATION 9 Install seat cushion side covers Refer to 23 BODY SEATS FRONT SEAT CUSHION SIDE COVER INSTALLATION FRONT SEAT...

Page 2077: ...ove nut attaching recliner to seat back frame 4 Remove bolts attaching seat back frame to seat track 5 Remove stud on seat back frame from recliner 6 Remove seat back 7 If power seat track is being re...

Page 2078: ...SEAT CUSHION INSTAL LATION 7 Install seat in vehicle Refer to 23 BODY SEATS FRONT SEAT INSTALLATION FRONT SEAT TRACK FRONT COVER REMOVAL 1 Remove screws attaching front cover to seat track Fig 23 2 R...

Page 2079: ...nd remove the hinge cover Fig 25 3 Remove the dump latch handle 4 Remove the three screws Fig 26 5 Depress the tab on the cup holder assembly Fig 27 6 Using a deep well socket or equivalent depress th...

Page 2080: ...AT SIDE SHIELD NO CUP HOLDER REMOVAL 4 Remove the five bolts two nuts strut bushing and remove the riser from the seat Fig 30 INSTALLATION 1 Install the riser the strut bushing into the hole the five...

Page 2081: ...hronizer cable if equipped Fig 31 5 Remove the seatback frame bolts and remove the seat back Fig 32 INSTALLATION 1 Install the seatback 2 Install the shoulder bolts attaching the seat back hinge to th...

Page 2082: ...rd row bench seats install grocery bag holder Refer to 23 BODY SEATS PLASTIC GRO CERY BAG RETAINER INSTALLATION SEAT CUSHION COVER QUAD BUCKET 50 50 SPLIT BENCH REMOVAL BENCH SEAT 50 50 SPLIT 1 Remove...

Page 2083: ...TION 6 Install seat into vehicle BENCH SEAT RISER 50 50 SPLIT REMOVAL 1 Remove the seat from the vehicle Refer to the Owners Manual for proper procedures 2 Unclip the seat cushion cover j strap Fig 35...

Page 2084: ...nge cover to seat back hinge Tighten screws to 2 3 N m 20 in lbs torque 3 Place lower cover in position on hinge 4 Install screws attaching lower cover to seat back hinge Fig 37 Tighten screws to 2 3...

Page 2085: ...m the recline mechanism by pulling the cable end toward the front of the seat Fig 39 3 Pull U shaped locking tab on self adjusting mehcanism to disengage auto adjust feature 4 Reattach self adjusting...

Page 2086: ...e the bench seat back Refer to 23 BODY SEATS BENCH SEAT BACK REMOVAL 2 Remove the bench seatback panel Refer to 23 BODY SEATS BENCH SEATBACK PANEL REMOVAL 3 Disconnect the cover J straps 4 Remove the...

Page 2087: ...ALLATION 3 PASS BENCH SEAT 1 Place retainer in position 2 Install the five attaching screws and tighten 2 N m 17 in lbs torque 50 50 SPLIT BENCH SEAT 1 Engage bottom hooks of the retainer and place in...

Page 2088: ...bin track guide to seat riser Fig 45 Tighten screws to 81 N m 32 in lbs torque 3 Install under seat storage bin Refer to 23 BODY SEATS UNDER SEAT STORAGE BIN INSTALLATION UNDER SEAT STORAGE BIN LOCK...

Page 2089: ...assembly 4 Remove frame and replace INSTALLATION 1 Trim the seat back frame 2 Install seat back assembly to cushion 3 Install attaching screw to lumbar handle The handle is to be installed between tw...

Page 2090: ...BY THE ADHESIVE MANUFACTURER IF NOT STRUCTURAL INTEGRITY COULD BE COMPROMISED DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNI CAL DATA S...

Page 2091: ...nt windshield The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening 1 Place replacement windshield into windshield opening and pos...

Page 2092: ...LATION The temperature of the vehicle should be at least 21 C 70 F before removing the stationary quarter sliding door glass Butyl sealer becomes more pliable at high temperatures The stationary glass...

Page 2093: ...d if available Fig 1 5 Remove rear window from vehicle REAR WINDOW REMOVAL INTERIOR METHOD 1 Remove rear window wiper arm if equipped 2 Remove screws attaching moldings to liftgate at the sides of the...

Page 2094: ...m 1 in wide around perimeter of rear window Allow at least three min utes drying time 10 Apply Pinch weld Primer 19 mm 0 75 in wide around the rear window fence Allow at least three minutes drying tim...

Page 2095: ...ped 7 Remove watershed as necessary to gain access to screw attaching front lower corner of glass run weatherstrip to inner door panel 8 Remove screw attaching glass run weatherstrip to inner door pan...

Page 2096: ...Open front door 2 Using fork tool C 4829 remove push pin fas teners attaching front door weatherstrip to end frames and bottom of door Fig 2 3 Pull weatherstrip from retaining channel around window f...

Page 2097: ...and check alignment FRONT DOOR INNER BELT MOLDING REMOVAL 1 Remove door trim panel 2 Peel upper corner seals away form inner belt molding to clear removal path 3 Pull inner belt molding upward to dis...

Page 2098: ...OPENING DIMENSIONS 118 SEALER LOCATIONS SPECIFICATIONS BODY SEALING LOCATIONS 121 STUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS 147 WELD LOCATIONS SPECIFICATIONS WELD LOCA...

Page 2099: ...Fig 1 GAP FLUSH MEASUREMENTS 23 116 BODY STRUCTURE RS GAP AND FLUSH Continued...

Page 2100: ...ING DOOR GLASS 5 0 2 0 PARALLEL WITHIN 2 0 1 0 UNDER FLUSH 2 0 CONSISTENT WITHIN 3 0 I FRONT DOOR TO SLIDING DOOR 5 0 2 0 PARALLEL WITHIN 2 0 2 0 CONSISTENT WITHIN 2 0 J SLIDING DOOR TO REAR APERTURE...

Page 2101: ...OPENING DIMENSIONS SPECIFICATIONS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 2 LIFTGATE OPENING 3 BODY SIDE OPENINGS 4 Fig 2 WINDSHIELD OPENING 23 118 BODY STRUCTURE RS...

Page 2102: ...Fig 3 LIFTGATE OPENING RS BODY STRUCTURE 23 119 OPENING DIMENSIONS Continued...

Page 2103: ...Fig 4 BODY SIDE OPENINGS 23 120 BODY STRUCTURE RS OPENING DIMENSIONS Continued...

Page 2104: ...LEFT AND RIGHT SIDES 19 REAR WHEEL HOUSE FLOOR PAN LEFT AND RIGHT SIDES 20 REAR WHEELHOUSE TO FLOOR PAN LEFT AND RIGHT SIDES 21 UPPER SLIDING DOOR FLANGE LEFT AND RIGHT SIDES 22 UPPER LIFTGATE HINGE A...

Page 2105: ...JOINT LEFT AND RIGHT SIDES 42 ROOF RAP JOINT LEFT AND RIGHT SIDES 43 DRAIN HOLE PATCHES 44 WHEELHOUSE VENT HOLE LEFT SIDE SHOWN RIGHT SIDE TYPICAL 45 FLOOR PAN HOLES LEFT AND RIDE SIDES 46 HOOD FRONT...

Page 2106: ...Fig 5 METHODS OF APPLYING AUTO BODY SEALANT RS BODY STRUCTURE 23 123 SEALER LOCATIONS Continued...

Page 2107: ...Fig 6 LOWER WINDSHIELD OPENING RIGHT AND LEFT SIDES Fig 7 COWL SIDE LEFT AND RIGHT SIDES 23 124 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2108: ...Fig 8 SIDE QUARTER WINDSHIELD OPENING LEFT AND RIGHT SIDES Fig 9 UPPER WINDSHIELD A PILLAR LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 125 SEALER LOCATIONS Continued...

Page 2109: ...Fig 10 ROOF TRACK C PILLAR LEFT AND RIGHT SIDES Fig 11 SLIDING DOOR UPPER FLANGE SEAMS LEFT AND RIGHT SIDES 23 126 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2110: ...Fig 12 QUARTER PANEL EXTERIOR AREA LEFT AND RIGHT SIDES Fig 13 LOWER REAR EXTERIOR CORNER PANELS LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 127 SEALER LOCATIONS Continued...

Page 2111: ...Fig 14 LOWER SILL LIFTGATE OPENING LEFT AND RIGHT SIDES Fig 15 C PILLAR CAN LEFT AND RIGHT SIDES 23 128 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2112: ...Fig 16 SHOCK TOWER AREA LEFT AND RIGHT SIDES Fig 17 OUTER SHOCK TOWER AREA LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 129 SEALER LOCATIONS Continued...

Page 2113: ...Fig 18 CROSS MEMBER SUPPORT LEFT AND RIGHT SIDES Fig 19 A B PILLAR FLOOR PAN RISERS LEFT AND RIGHT SIDES 23 130 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2114: ...Fig 20 REAR WHEEL HOUSE FLOOR PAN LEFT AND RIGHT SIDES Fig 21 REAR WHEELHOUSE TO FLOOR PAN LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 131 SEALER LOCATIONS Continued...

Page 2115: ...Fig 22 UPPER SLIDING DOOR FLANGE LEFT AND RIGHT SIDES Fig 23 UPPER LIFTGATE HINGE AREA LEFT AND RIGHT SIDES 23 132 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2116: ...Fig 24 REAR BRACKET SUPPORT REAR HANGER LEFT AND RIGHT SIDES Fig 25 LIFTGATE PANEL OPENING UNDERSIDE RS BODY STRUCTURE 23 133 SEALER LOCATIONS Continued...

Page 2117: ...Fig 26 D PILLAR INSIDE SEAM LEFT AND RIGHT SIDES Fig 27 REAR TAIL LAMP AREA SEAMS LEFT AND RIGHT SIDES 23 134 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2118: ...Fig 28 UPPER LIFTGATE PANEL SILL LEFT AND RIGHT SIDES Fig 29 FRONT WHEELHOUSE SHOCK TOWER LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 135 SEALER LOCATIONS Continued...

Page 2119: ...Fig 30 REAR QUARTER WHEELHOUSE LIP SEAT ANCHOR BOLT LEFT AND RIGHT SIDES Fig 31 TAILLAMP CAN LEFT AND RIGHT SIDES 23 136 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2120: ...Fig 32 B PILLAR AND SILL AREAS LEFT AND RIGHT SIDES Fig 33 FRONT FLOOR PAN RISER RS BODY STRUCTURE 23 137 SEALER LOCATIONS Continued...

Page 2121: ...Fig 34 FLOOR PAN SEAMS LEFT AND RIGHT SIDES Fig 35 FLOOR PAN REAR WHEELHOUSE AREA LEFT AND RIGHT SIDES 23 138 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2122: ...Fig 36 FLOOR PAN SILL D PILLAR SEAMS LEFT AND RIGHT SIDES Fig 37 LEFT SIDE SEAT ANCHOR REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 139 SEALER LOCATIONS Continued...

Page 2123: ...Fig 38 UNDERBODY LEFT AND RIGHT SIDES Fig 39 ROOF TOP JOINT UPPER FRONT SLIDING DOOR LEFT AND RIGHT SIDES 23 140 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2124: ...Fig 40 ROOF TOP JOINT UPPER REAR SLIDING DOOR LEFT AND RIGHT SIDES Fig 41 ROOF TOP JOINT WINDSHIELD OPENING LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 141 SEALER LOCATIONS Continued...

Page 2125: ...Fig 42 LIFT GATE ROOF COACH JOINT LEFT AND RIGHT SIDES Fig 43 ROOF RAP JOINT LEFT AND RIGHT SIDES 23 142 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2126: ...Fig 44 DRAIN HOLE PATCHES Fig 45 WHEELHOUSE VENT HOLE LEFT SIDE SHOWN RIGHT SIDE TYPICAL RS BODY STRUCTURE 23 143 SEALER LOCATIONS Continued...

Page 2127: ...Fig 46 FLOOR PAN HOLES LEFT AND RIDE SIDES Fig 47 HOOD FRONT HEM FLANGE SIDES 23 144 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2128: ...Fig 48 FRONT DOOR LOWER FLANGE Fig 49 LIFTGATE HEM FLANGE AND LATCH COVER SEAMS RS BODY STRUCTURE 23 145 SEALER LOCATIONS Continued...

Page 2129: ...Fig 50 FRONT DOOR BELT DOOR BELT SEAMS FRONT Fig 51 FRONT DOOR BELT DOOR BELT SEAMS REAR 23 146 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Page 2130: ...WHEEL BASE ONLY 54 SUSPENSION HANGER REINFORCEMENTS LONG WHEEL BASE ONLY 55 FRONT HINGE PILLAR REINFORCEMENTS LONG WHEEL BASE ONLY 56 ROOF AND REAR QUARTER PANELS SHORT WHEEL BASE ONLY 57 FLOOR PAN S...

Page 2131: ...Fig 52 UPPER COWL PLENUM UPPER AND LOWER DASH PANEL 23 148 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2132: ...Fig 53 ROOF AND REAR QUARTER PANELS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 149 STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2133: ...Fig 54 FLOOR PAN LONG WHEEL BASE ONLY 23 150 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2134: ...Fig 55 SUSPENSION HANGER REINFORCEMENTS LONG WHEEL BASE ONLY Fig 56 FRONT HINGE PILLAR REINFORCEMENTS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 151 STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2135: ...Fig 57 ROOF AND REAR QUARTER PANELS SHORT WHEEL BASE ONLY 23 152 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2136: ...Fig 58 FLOOR PAN SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 153 STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2137: ...Fig 59 FRONT SIDE RAILS OUTER CROSS MEMBER BRACKETS Fig 60 OUTER ROOF PANEL UPPER WINDSHIELD FRAME 23 154 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2138: ...Fig 61 COWL SIDE PANEL BODY SIDE APERTURE B PILLAR SLIDING DOOR TRACK SUPPORT RS BODY STRUCTURE 23 155 STUCTURAL ADHESIVE LOCATIONS Continued...

Page 2139: ...MENTS 77 FLOOR PAN CROSS MEMBER REINFORCEMENTS 78 FRONT SEAT CROSS MEMBER 79 SEAT REINFORCEMENT CROSS MEMBERS SHORT WHEEL BASE 80 CENTER CONSOLE REINFORCEMENT SHORT WHEEL BASE 81 REAR SUSPENSION HANGE...

Page 2140: ...114 INNER BODY SIDE SILL TO LOWER DASH PANEL 115 FRONT HINGE TAPPING PLATE 116 FRONT HINGE PILLAR 117 INNER WINDSHIELD FRAME 118 WINDSHIELD FRAME 119 FENDER BRACKET 120 INNER B PILLAR 121 STRIKER LATC...

Page 2141: ...WHEEL BASE ONLY 156 UPPER WINDSHIELD FRAME ROOF PANEL LONG WHEEL BASE ONLY 157 ROOF BOWS INNER ROOF SIDE RAILS 158 OUTER ROOF PANEL LONG WHEEL BASE ONLY 159 INNER SIDE SILL SHORT WHEEL BASE ONLY 160...

Page 2142: ...Fig 62 FRONT FENDER SHIELD RIGHT Fig 63 FRONT FENDER SHIELD LEFT RS BODY STRUCTURE 23 159 WELD LOCATIONS Continued...

Page 2143: ...Fig 64 STRUT TOWER AND REINFORCEMENTS RIGHT 23 160 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2144: ...Fig 65 SUSPENSION RETAINERS AND REINFORCEMENTS RIGHT RS BODY STRUCTURE 23 161 WELD LOCATIONS Continued...

Page 2145: ...Fig 66 STRUT TOWER AND REINFORCEMENTS LEFT 23 162 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2146: ...Fig 67 SUSPENSION RETAINERS AND REINFORCEMENTS LEFT RS BODY STRUCTURE 23 163 WELD LOCATIONS Continued...

Page 2147: ...Fig 68 FLOOR PAN REINFORCEMENTS SIDE RAILS 23 164 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2148: ...Fig 69 REAR SUSPENSION BRACKETS RS BODY STRUCTURE 23 165 WELD LOCATIONS Continued...

Page 2149: ...Fig 70 FLOOR PAN CROSS MEMBERS 23 166 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2150: ...Fig 71 SEAT REINFORCEMENTS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 167 WELD LOCATIONS Continued...

Page 2151: ...Fig 72 STRIKER REINFORCEMENTS LONG WHEEL BASE ONLY 23 168 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2152: ...Fig 73 FUEL TANK MOUNTING REAR SEAT AND SUSPENSION RS BODY STRUCTURE 23 169 WELD LOCATIONS Continued...

Page 2153: ...Fig 74 REAR SUSPENSION HANGER BRACKETS LONG WHEEL BASE 23 170 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2154: ...Fig 75 FRONT SEAT CROSS MEMBER RS BODY STRUCTURE 23 171 WELD LOCATIONS Continued...

Page 2155: ...Fig 76 FLOOR PAN SIDE RAIL REINFORCEMENT 23 172 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2156: ...Fig 77 SILL BULKHEAD REINFORCEMENTS RS BODY STRUCTURE 23 173 WELD LOCATIONS Continued...

Page 2157: ...Fig 78 FLOOR PAN CROSS MEMBER REINFORCEMENTS 23 174 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2158: ...Fig 79 FRONT SEAT CROSS MEMBER RS BODY STRUCTURE 23 175 WELD LOCATIONS Continued...

Page 2159: ...Fig 80 SEAT REINFORCEMENT CROSS MEMBERS SHORT WHEEL BASE 23 176 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2160: ...Fig 81 CENTER CONSOLE REINFORCEMENT SHORT WHEEL BASE RS BODY STRUCTURE 23 177 WELD LOCATIONS Continued...

Page 2161: ...Fig 82 REAR SUSPENSION HANGER BRACKETS SHORT WHEEL BASE 23 178 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2162: ...Fig 83 LOWER LIFTGATE PANEL LATCH REINFORCEMENT RS BODY STRUCTURE 23 179 WELD LOCATIONS Continued...

Page 2163: ...Fig 84 ENGINE MOUNTING PLATE AND TOW BRACKET 23 180 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2164: ...Fig 85 HEADLAMP MOUNTING PLATE RS BODY STRUCTURE 23 181 WELD LOCATIONS Continued...

Page 2165: ...Fig 86 LOWER RADIATOR CROSS MEMBER BRACKETS 23 182 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2166: ...Fig 87 CROSS MEMBER EXTENSIONS RS BODY STRUCTURE 23 183 WELD LOCATIONS Continued...

Page 2167: ...Fig 88 JACK MOUNTING BRACKET LONG WHEEL BASE SHOWN SHORT SIMILAR 23 184 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2168: ...Fig 89 FRONT SEAT CROSS MEMBER LONG WHEELBASE ONLY Fig 90 FRONT SEAT CROSS MEMBER ALL WHEEL DRIVE ONLY RS BODY STRUCTURE 23 185 WELD LOCATIONS Continued...

Page 2169: ...Fig 91 FUEL TANK SUPPORT CROSS MEMBERS LONG WHEEL BASE ONLY 23 186 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2170: ...Fig 92 REAR SUPPORT AND TIRE STOWAGE CROSS MEMBERS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 187 WELD LOCATIONS Continued...

Page 2171: ...Fig 93 INNER SIDE SILLS LONG WHEEL BASE ONLY Fig 94 WHEELHOUSES SIDE SILLS SUSPENSION BRACKETS LONG WHEEL BASE ONLY 23 188 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2172: ...Fig 95 REAR SEAT REINFORCEMENTS SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 189 WELD LOCATIONS Continued...

Page 2173: ...Fig 96 FUEL TANK SUPPORT AND TIRE STOWAGE SHORT WHEEL BASE ONLY 23 190 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2174: ...Fig 97 INNER SIDE SILLS SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 191 WELD LOCATIONS Continued...

Page 2175: ...Fig 98 REAR SEAT REINFORCEMENTS SHORT WHEEL BASE ONLY 23 192 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2176: ...Fig 99 CENTER CONSOLE REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 193 WELD LOCATIONS Continued...

Page 2177: ...Fig 100 WHEELHOUSES SHORT WHEEL BASE ONLY Fig 101 FRONT SEAT CROSS MEMBER SHORT WHEELBASE ALL WHEEL DRIVE ONLY 23 194 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2178: ...Fig 102 FLOOR PAN SIDE RAIL LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 195 WELD LOCATIONS Continued...

Page 2179: ...Fig 103 INNER BODY SIDE SILL REINFORCEMENTS Fig 104 TOE BOARD CROSS MEMBER 23 196 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2180: ...Fig 105 FRONT SIDE RAIL SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 197 WELD LOCATIONS Continued...

Page 2181: ...Fig 106 DASH PANEL REINFORCEMENT 23 198 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2182: ...Fig 107 LOWER COWL PLENUM RS BODY STRUCTURE 23 199 WELD LOCATIONS Continued...

Page 2183: ...Fig 108 UPPER COWL PLENUM SUPPORT 23 200 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2184: ...Fig 109 UPPER DASH PANEL RS BODY STRUCTURE 23 201 WELD LOCATIONS Continued...

Page 2185: ...Fig 110 COWL SIDE PANELS Fig 111 INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 23 202 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2186: ...Fig 112 INSTRUMENT PANEL DASH PANEL ACM MODULE AND ACCELERATOR PEDAL Fig 113 STRUT TOWER BRACKET AND COWL PLENUM RS BODY STRUCTURE 23 203 WELD LOCATIONS Continued...

Page 2187: ...Fig 114 FRONT SIDE RAILS TO LOWER DASH PANEL 23 204 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2188: ...Fig 115 INNER BODY SIDE SILL TO LOWER DASH PANEL RS BODY STRUCTURE 23 205 WELD LOCATIONS Continued...

Page 2189: ...Fig 116 FRONT HINGE TAPPING PLATE 23 206 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2190: ...Fig 117 FRONT HINGE PILLAR RS BODY STRUCTURE 23 207 WELD LOCATIONS Continued...

Page 2191: ...Fig 118 INNER WINDSHIELD FRAME 23 208 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2192: ...Fig 119 WINDSHIELD FRAME RS BODY STRUCTURE 23 209 WELD LOCATIONS Continued...

Page 2193: ...Fig 120 FENDER BRACKET 23 210 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2194: ...Fig 121 INNER B PILLAR RS BODY STRUCTURE 23 211 WELD LOCATIONS Continued...

Page 2195: ...Fig 122 STRIKER LATCH AND TAPPING PLATES Fig 123 RIGHT REAR INNER QUARTER PANEL LONG WHEEL BASE ONLY 23 212 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2196: ...Fig 124 RIGHT REAR INNER QUARTER PANEL OUTER WHEELHOUSE LONG WHEEL BASE ONLY Fig 125 RIGHT REAR BODY SIDE APERTURE LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 213 WELD LOCATIONS Continued...

Page 2197: ...Fig 126 STRIKER LATCH REINFORCEMENT LONG WHEEL BASE ONLY 23 214 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2198: ...Fig 127 BELT TAPPING PLATE LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 215 WELD LOCATIONS Continued...

Page 2199: ...Fig 128 C PILLAR REINFORCEMENT LONG WHEEL BASE ONLY 23 216 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2200: ...Fig 129 OUTER WHEELHOUSE LONG WHEEL BASE ONLY Fig 130 C AND D PILLAR INNER REINFORCEMENTS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 217 WELD LOCATIONS Continued...

Page 2201: ...Fig 131 LEFT REAR INNER QUARTER PANEL LONG WHEEL BASE ONLY 23 218 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2202: ...Fig 132 OUTER WHEELHOUSE EXTENSION LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 219 WELD LOCATIONS Continued...

Page 2203: ...Fig 133 TAIL LAMP LONG WHEEL BASE ONLY Fig 134 SLIDING DOOR LATCH LONG WHEEL BASE ONLY 23 220 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2204: ...Fig 135 ROOF BOW EXTENSION LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 221 WELD LOCATIONS Continued...

Page 2205: ...Fig 136 RIGHT REAR INNER QUARTER PANEL SHORT WHEEL BASE ONLY 23 222 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2206: ...Fig 137 LATCH REINFORCEMENT AND OUTER WHEELHOUSE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 223 WELD LOCATIONS Continued...

Page 2207: ...Fig 138 D PILLAR REINFORCEMENT SHORT WHEEL BASE ONLY 23 224 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2208: ...Fig 139 OUTER WHEELHOUSE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 225 WELD LOCATIONS Continued...

Page 2209: ...Fig 140 LEFT REAR INNER QUARTER PANEL SHORT WHEEL BASE ONLY 23 226 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2210: ...Fig 141 LATCH REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 227 WELD LOCATIONS Continued...

Page 2211: ...Fig 142 D PILLAR REINFORCEMENT SHORT WHEEL BASE ONLY 23 228 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2212: ...Fig 143 OUTER WHEELHOUSE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 229 WELD LOCATIONS Continued...

Page 2213: ...Fig 144 BODY SIDE APERTURE RIGHT SIDE LONG WHEEL BASE ONLY 23 230 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2214: ...Fig 145 BODY SIDE APERTURE LEFT SIDE LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 231 WELD LOCATIONS Continued...

Page 2215: ...Fig 146 BODY SIDE APERTURE RIGHT SIDE SHORT WHEEL BASE ONLY 23 232 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2216: ...Fig 147 BODY SIDE APERTURE LEFT SIDE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 233 WELD LOCATIONS Continued...

Page 2217: ...Fig 148 LOWER SLIDING DOOR TRACK 23 234 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2218: ...Fig 149 LIFTGATE UPPER FRAME Fig 150 UPPER WINDSHIELD FRAME RS BODY STRUCTURE 23 235 WELD LOCATIONS Continued...

Page 2219: ...Fig 151 FRONT FENDER SHIELD BEAM 23 236 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2220: ...Fig 152 FRONT FENDER SHIELD BEAM COWL SIDE PANEL RS BODY STRUCTURE 23 237 WELD LOCATIONS Continued...

Page 2221: ...Fig 153 HINGE PILLAR REINFORCEMENT 23 238 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2222: ...Fig 154 INNER SIDE SILL LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 239 WELD LOCATIONS Continued...

Page 2223: ...Fig 155 INNER SIDE SILL OUTER SIDE SILL LONG WHEEL BASE ONLY 23 240 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2224: ...Fig 156 LOWER SLIDING DOOR TRACK REINFORCEMENT LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 241 WELD LOCATIONS Continued...

Page 2225: ...Fig 157 UPPER WINDSHIELD FRAME ROOF PANEL LONG WHEEL BASE ONLY Fig 158 ROOF BOWS INNER ROOF SIDE RAILS 23 242 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2226: ...Fig 159 OUTER ROOF PANEL LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 243 WELD LOCATIONS Continued...

Page 2227: ...Fig 160 INNER SIDE SILL SHORT WHEEL BASE ONLY 23 244 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2228: ...Fig 161 INNER SIDE OUTER SIDE SILLS SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 245 WELD LOCATIONS Continued...

Page 2229: ...Fig 162 LOWER SLIDING DOOR TRACK SHORT WHEEL BASE ONLY 23 246 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2230: ...Fig 163 UPPER WINDSHIELD FRAME OUTER ROOF PANEL SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 247 WELD LOCATIONS Continued...

Page 2231: ...Fig 164 REAR SUSPENSION HANGERS LONG WHEEL BASE SHOWN SHORT WHEEL BASE TYPICAL 23 248 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2232: ...Fig 165 FRONT LOWER LIFTGATE OPENING Fig 166 REAR JACKING REINFORCEMENT LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 249 WELD LOCATIONS Continued...

Page 2233: ...Fig 167 INNER WHEELHOUSE LONG WHEEL BASE ONLY 23 250 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2234: ...Fig 168 SUSPENSION HANGER REINFORCEMENT LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 251 WELD LOCATIONS Continued...

Page 2235: ...Fig 169 LOWER LIFTGATE OPENING PANEL LONG WHEEL BASE ONLY 23 252 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2236: ...Fig 170 ROOF BOWS UPPER LIFTGATE FRAME LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 253 WELD LOCATIONS Continued...

Page 2237: ...Fig 171 BODY SIDE APERTURE INNER QUARTER PANEL LONG WHEEL BASE ONLY 23 254 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2238: ...Fig 172 REAR JACKING REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 255 WELD LOCATIONS Continued...

Page 2239: ...Fig 173 INNER WHEELHOUSE INNER QUARTER PANEL SHORT WHEEL BASE ONLY 23 256 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2240: ...Fig 174 SUSPENSION HANGER REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 257 WELD LOCATIONS Continued...

Page 2241: ...Fig 175 LOWER LIFTGATE OPENING SHORT WHEEL BASE ONLY 23 258 BODY STRUCTURE RS WELD LOCATIONS Continued...

Page 2242: ...Fig 176 ROOF PANEL ROOF RAIL SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 259 WELD LOCATIONS Continued...

Page 2243: ......

Page 2244: ...box provides easy access to the filter element The control panel and integral computer is located in the instrument panel The instrument panel mounted control and inte gral computer contains a power b...

Page 2245: ...fold Absolute Pressure information from the PCM Coolant Temperature ATC computer moni tors Coolant temperature received from the PCM and converts it to degrees Fahrenheit Ambient Temperature ATC compu...

Page 2246: ...des a vacuum flourescent digital dis play a rocker control for temperature and rotary con trols for adjustment of mode and fan speed control of the rear unit by intermediate seat passengers OPERATION...

Page 2247: ...which controls the Rear Window Defogger and side view mirror if equipped circuitry The defogger function will be active for 10 minutes and can be turned off by a switch press The defogger will functio...

Page 2248: ...lake icon and the DELAY text stop blinking before two minutes then the cool down test has been completed successfully If the two minutes expire without the evaporator tem perature reaching 20 F less t...

Page 2249: ...FER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING Check the coolant le...

Page 2250: ...trol liquid line mounted input to Powertrain Control Module PCM PCM opens compressor clutch relay 29 4 psi High PSI Control pressure transducer liquid line mounted input to PCM PCM opens compressor cl...

Page 2251: ...IS AND TESTING COMPRESSOR CLUTCH RELAY 22 REMOVAL 22 INSTALLATION 22 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 22 OPERATION 23 REMOVAL 23 INSTALLATION 23 INFRARED TEMPERATURE SENSOR DESCRIPTION 24 OPE...

Page 2252: ...precautions to protect the center bezel from cosmetic damage 4 If the vehicle is equipped with the optional Automatic Temperature Control ATC system dis connect the infrared sensor jumper harness conn...

Page 2253: ...air condition ing compressor clutch from engaging when ambient temperatures are below about 10 C 50 F due to the pressure temperature relationship of the refriger ant The Schrader type valve in the l...

Page 2254: ...r the mode door and the recirculation air door Each actua tor is contained within an identical black molded plastic housing with an integral wire connector receptacle Two integral mounting tabs allow...

Page 2255: ...formations of the heater air conditioner hous ing near the dash panel 5 Remove the heater core shield from the distri bution housing 6 Disconnect the HVAC wire harness connector for the blend door ac...

Page 2256: ...er module ATC control The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized an electromagnetic field is prod...

Page 2257: ...rform further diagnosis of the relay circuits Refer to the appropriate diagnostic information If not OK replace the faulty relay REMOVAL 1 Disconnect and isolate the battery negative cable 2 Unlatch a...

Page 2258: ...r motor ground path through fewer of the resistor wires increasing the blower motor speed When the blower motor switch is in the high est speed position the blower motor resistor wires are bypassed an...

Page 2259: ...m the resistor connector receptacle 6 Remove the two screws that secure the blower motor resistor to the evaporator housing 7 Remove the blower motor resistor from the evaporator housing INSTALLATION...

Page 2260: ...IN CONTROL MODULE DESCRIPTION PCM OPERATION STANDARD PROCEDURE STANDARD PROCEDURE COMPRESSOR CLUTCH AIR GAP If a new clutch plate and or clutch pulley are being used the air gap between the clutch pla...

Page 2261: ...filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt removal 9 Tap the clutch plate lightly with a plastic ham mer and remove the clutch plate and shim s from the compr...

Page 2262: ...at the clutch coil pigtail wires are properly ori ented and routed so that they are not pinched between the compressor front cover and the clutch coil NOTE A new snap ring must be used to secure the c...

Page 2263: ...r The lower screw at the rear of the compressor The lower screw at the front of the compressor The upper nut at the front of the compressor 12 On models with the 3 3L and 3 8L engines only engage the...

Page 2264: ...dule IPM which is in the engine compartment near the battery See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location Th...

Page 2265: ...OPEN 87A NORMALLY CLOSED REMOVAL 1 Disconnect and isolate the battery negative cable 2 Unlatch and remove the cover from the Intelli gent Power Module IPM 3 See the fuse and relay layout map molded i...

Page 2266: ...to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE REMOVAL 4 Remove the temperature sensor attaching screw from the expansion valve 5 Pull the evaporator temperature sensor away from the expansion valve far...

Page 2267: ...e ATC system logic responds to the infrared sensor inputs by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the individ ually selected comf...

Page 2268: ...UMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAG...

Page 2269: ...system through a dedicated take out and connector of the instrument panel wire harness A second connector receptacle receives the pigtail wire connector from the blower motor The blower power module a...

Page 2270: ...e heater A C housing unit on the bottom of the lower intake air housing The recirculation door actuator is mechanically con nected to the recirculation air door The recirculation door actuator is inte...

Page 2271: ...air housing 5 Remove the recirculation door actuator from the lower intake air housing INSTALLATION WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING...

Page 2272: ...h to access the headliner wire harness connector on the back of the control 4 Disconnect the headliner wire harness connec tor for the rear heater A C control from the control connector receptacle 5 R...

Page 2273: ...blend door actuator is interchangeable with the actuator for the mode door Each actuator is contained within an identical black molded plastic housing with an inte gral wire connector receptacle Two...

Page 2274: ...f the rear heater A C unit housing away from the right quarter inner panel far enough to reach between the rear heater A C unit housing and the quarter inner panel to access the blend door actuator Fi...

Page 2275: ...pade type terminals extend from the bottom of the base to connect the relay to the vehicle electrical sys tem and the ISO designation for each terminal is molded into the base adjacent to each termina...

Page 2276: ...tion views for the various wire har ness connectors splices and grounds DIAGNOSIS AND TESTING BLOWER MOTOR RELAY The rear blower motor relay Fig 6 is located in the Intelligent Power Module IPM which...

Page 2277: ...e is secured with two screws to the rear heater A C unit housing and is accessed for service by removing the right quarter and D pillar trim panels The blower motor resistor wires will get hot when in...

Page 2278: ...to take this precaution can result in vehicle damage 1 Disconnect and isolate the battery negative cable 2 Remove the right quarter trim panel and right D pillar trim panel from the quarter inner pane...

Page 2279: ...nfrared sensor cir cuit and will store a Diagnostic Trouble Code DTC for any problem it detects This DTC information can be retrieved and the infrared temperature sensor diagnosed using a DRBIIIt scan...

Page 2280: ...ATER A C CONTROL CALIBRATION POWER MODULE DESCRIPTION A blower power module is used on this model when it is equipped with the optional Automatic Tempera ture Control ATC Fig 11 Models equipped with t...

Page 2281: ...nector receptacle 5 Remove the two screws that secure the blower power module to the rear heater A C unit housing 6 Remove the blower power module from the rear heater A C unit housing INSTALLATION 1...

Page 2282: ...ON CENTER BEZEL OUTLETS 43 INSTALLATION DEMISTER OUTLET 43 INSTALLATION FRONT DOOR REAR OUTLET 43 INSTALLATION INSTRUMENT PANEL OUTLET 43 BLOWER MOTOR DESCRIPTION 43 OPERATION 43 DIAGNOSIS AND TESTING...

Page 2283: ...s the center of the vehicle 2 With the air filter Airflow arrow properly ori ented carefully slide the filter fully upward into the evaporator housing through the air filter opening 3 With the latch s...

Page 2284: ...r the front floor carpet from an outlet nozzle on the bottom of the front heater A C unit distribution housing REMOVAL REMOVAL CENTER BEZEL OUTLETS The three outlets located near the top of the instru...

Page 2285: ...flat bladed tool gently pry the outer perimeter of the instrument panel outlet away from the instrument panel top pad until the snap features on the outlet are released Fig 6 2 Remove the instrument...

Page 2286: ...INSTALLATION 4 Reconnect the battery negative cable INSTALLATION INSTRUMENT PANEL OUTLET 1 Position the instrument panel outlet into the panel duct opening in the instrument panel top pad 2 Using han...

Page 2287: ...C If OK go to Step 4 If not OK repair the open fused front blower motor relay output circuit to the IPM as required 4 Turn the ignition switch to the Off position Disconnect and isolate the battery ne...

Page 2288: ...Fig 8 Blower Motor Noise Vibration Diagnosis RS DISTRIBUTION FRONT 24 45 BLOWER MOTOR Continued...

Page 2289: ...AUTION A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Gently flex the recirculation air door far enough to position the blower motor and blower wheel i...

Page 2290: ...negative cable 2 Remove the instrument panel from the vehicle Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY REMOVAL 3 Place the instrument panel face down on a suitable work surface Be...

Page 2291: ...the battery negative cable FLOOR DISTRIBUTION DUCTS REMOVAL 1 Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle Refer to 23 BODY INTERIOR CARPETS A...

Page 2292: ...the engine cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM DRAIN 3 Disconnect and isolate the battery negative cable 4 Disconnect the liquid line and suction line from the expansi...

Page 2293: ...er to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM EVACUATE 11 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIG...

Page 2294: ...side and two left side fully adjustable outlets along the roof rails distribute air from the rear A C distribution duct and the headliner ducts to the intermediate and rear seat occupants The headline...

Page 2295: ...top of the rear heater A C unit housing 4 Reinstall the trim onto the right quarter inner panel and the right D pillar Refer to 23 BODY IN TERIOR RIGHT QUARTER TRIM PANEL INSTALLATION BLOWER MOTOR DE...

Page 2296: ...wer is turned on Check for battery voltage at the fused rear blower motor relay output circuit cavity of the rear HVAC wire harness connector for the rear blower motor resistor MTC or the rear blower...

Page 2297: ...Fig 4 Blower Motor Noise Vibration Diagnosis 24 54 DISTRIBUTION REAR RS BLOWER MOTOR Continued...

Page 2298: ...er to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Recover the refrigerant from the refrigerant sy...

Page 2299: ...ear heater A C unit housing to the right quarter inner panel 22 Lift the rear heater A C unit housing up far enough for the lower mounting studs and the evapo rator extension lines to clear the mounti...

Page 2300: ...all and tighten the three nuts that secure the rear heater A C unit mounting studs to the rear floor panel behind the right rear wheel housing Tighten the nuts to 9 N m 80 in lbs 15 Remove the tape or...

Page 2301: ...rear heater distribution duct forward far enough to disengage it from the outlet on the front of the rear heater air conditioner unit housing 4 Remove the rear heater distribution duct from the vehic...

Page 2302: ...INSTALLATION HEATER CORE EXTENSION TUBES 76 INSTALLATION HEATER CORE 77 HEATER HOSE REMOVAL 78 INSTALLATION 79 HEATER HOSES DIESEL SUPPLEMENTAL HEATER BUX REMOVAL 80 INSTALLATION 80 HEATER PIPES DIESE...

Page 2303: ...E OF ETHYLENE GLYCOL BASED COOLANT PROPERLY CONTACT YOUR DEALER OR A LOCAL GOVERNMENT AGENCY FOR THE LOCATION OF AN APPROVED ETHYLENE GLY COL COLLECTION AND OR RECYCLING CENTER IN YOUR AREA WARNING A...

Page 2304: ...phere any longer than necessary CAUTION Before connecting an open refrigerant fitting always install a new seal or gasket All fit tings with O rings need to be coated with refriger ant oil before inst...

Page 2305: ...and closes when a minimum discharge pressure of 2756 kPa 400 psi is reached DIAGNOSIS AND TESTING COMPRESSOR NOISE DIAGNOSIS Excessive noise while the air conditioning compres sor is operating can be...

Page 2306: ...port 9 Remove the seal from the discharge line fitting and discard 10 Install plugs in or tape over the opened dis charge line fitting and the compressor discharge port 11 Raise and support the vehic...

Page 2307: ...e compressor The upper nut at the front of the compressor 4 On models with the 3 3L and 3 8L engines only engage the retainer on the engine wire harness com pressor clutch coil take out with the brack...

Page 2308: ...als or shrouds must be properly reinstalled following radiator or condenser service REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERA...

Page 2309: ...t system Use only refrigerant oil of the type recommended for the compressor in the vehi cle NOTE Be certain that each of the radiator and con denser air seals are reinstalled in their proper loca tio...

Page 2310: ...refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM CHARGE DISCHARGE LINE REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND C...

Page 2311: ...shield to the radiator closure panel crossmember Tighten the screws to 6 N m 53 in lbs 13 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROC...

Page 2312: ...harness from the routing clips molded into the outside of the HVAC housing components 7 Remove the three screws from the dash panel side of the unit that secure the top of the distribution housing to...

Page 2313: ...of the evaporator housing as a unit Be certain that the clam shell type rubber seal is fitted to the evaporator inlet and outlet tubes where they exit the evaporator housing 2 Position the upper half...

Page 2314: ...18 Run the HVAC Control Actuator Calibration procedure Refer to 24 HEATING AIR CONDI TIONING DIAGNOSIS AND TESTING Refer to 24 HEATING AIR CONDITIONING DIAGNOSIS AND TESTING EXPANSION VALVE DESCRIPTI...

Page 2315: ...emove all test equipment before returning the vehi cle to service REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 H...

Page 2316: ...erant oil and install it on the liquid line fitting 12 Reconnect the liquid line fitting to the filter drier outlet port on the top of the filter drier 13 Install and tighten the screw that secures th...

Page 2317: ...that secure the heater core shield to the left end of the HVAC distribution housing Fig 15 6 Pull the heater core shield rearward far enough to disengage the two location tabs that position the front...

Page 2318: ...r boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside 4 Remove the brake lamp switch from its mount ing bracket Refer to 8 ELECTRICAL...

Page 2319: ...OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURT...

Page 2320: ...celerator pedal upward far enough for clearance slide the heater core into the distribution housing 2 Install and tighten the two screws that secure the heater core mounting plate to the distribution...

Page 2321: ...MING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Drain the engine cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM DRAIN 2...

Page 2322: ...itioner All models use a combination of formed steel tubing and rubber hoses In most cases the rubber hose is secured to the steel tubing with a spring tension clamp WARNING REFER TO THE APPLICABLE WA...

Page 2323: ...UX REMOVAL CAUTION Allow cooling system to cool completely before removing radiator cap or draining cooling system Injury could result is system is opened while system coolant is hot and under pressur...

Page 2324: ...ATER CORE RETURN PIPE 3 A C LINES 4 A C EXPANSION VALVE 5 A C EXPANSION VALVE GROUND WIRE 6 CABIN HEATER RETURN PIPE 7 CABIN HEATER INTAKE PIPE 8 CABIN HEATER PIPES RETAINING NUT RS PLUMBING FRONT 24...

Page 2325: ...h the optional rear air conditioner the rear section of the front air condi tioner liquid line also includes a liquid line hose and tube extension that connects the front liquid line to the liquid lin...

Page 2326: ...he refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDI TIONING PLUMBING FRONT REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY 2 Disconnect and isolate the battery negative cable...

Page 2327: ...line to the liquid line for the rear air condi tioner FRONT SECTION 1 Position the front section of the front liquid line into the engine compartment 2 Remove the tape or plugs from the liquid line f...

Page 2328: ...o Step 23 17 Raise and support the vehicle 18 Remove the tape or plugs from the liquid line rear section extension fitting and the underbody liq uid line fitting 19 Lubricate a new rubber O ring seal...

Page 2329: ...the filter drier mounting bracket to the studs Tighten the nuts to 10 N m 89 in lbs 3 Remove the tape or plugs from the liquid line rear section fitting for the filter drier and the filter drier outle...

Page 2330: ...r refrigerant charge low include poor air conditioner performance fog emitted from the air conditioner outlets a hissing sound from the expansion valve evaporator area There are two different methods...

Page 2331: ...hart reclaim 0 057 kilo gram 0 125 pound or 2 ounces of refrigerant from the system 6 Recheck the system charge level following each refrigerant adjustment Continue this process until the system readi...

Page 2332: ...G PLUMBING FRONT CAUTION A C PLUMBING NOTE The proper amount of R 134a refrigerant for the refrigerant system in this model is Single or Dual Zone Front Unit Only 2 5L Die sel 0 91 kilograms 2 00 poun...

Page 2333: ...5 Observe the liquid line discharge pressure and liquid line temperature Using the Charge Deter mination Chart Fig 34 determine whether the refrigerant system is operating within the Proper Charge Ra...

Page 2334: ...valves on the manifold gauge set are opened the refrigerant in the system will escape through this hose STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE WARNING REFER TO THE APPLICABLE WARN INGS AND CAUT...

Page 2335: ...NG OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING If the refrigerant system has been op...

Page 2336: ...G THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING When an air conditioning...

Page 2337: ...line fitting from the compressor suction port 7 Remove the seal from the suction line fitting and discard 8 Install plugs in or tape over the opened suc tion line fitting and the compressor suction p...

Page 2338: ...stall and tighten the nut that secures the suction line fitting to the compressor Tighten the nut to 23 N m 17 ft lbs 11 Reconnect the drain tube to the wiper module drain on the right side of the eng...

Page 2339: ...vice port CAUTION A valve core that is not fully seated in the A C service port can result in damage to the valve during refrigerant system evacuation and charge Such damage may result in a loss of sy...

Page 2340: ...nt through the evaporator tubes The rear heater A C unit housing must be removed from the vehicle to access the evaporator for service The evaporator cannot be adjusted or repaired and if faulty or da...

Page 2341: ...UMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Remove the rear heater A C unit housing from the vehicle Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION RE...

Page 2342: ...ING AIR CONDI TIONING DISTRIBUTION REAR REAR HEATER A C HOUSING INSTALLATION INSTALLATION EVAPORATOR LINE EXTENSION 1 Remove the tape or plugs from the evaporator line extension fittings and both expa...

Page 2343: ...d read 965 to 1655 kPa 140 to 240 psi The suction low pressure gauge should read 140 kPa to 207 kPa 20 psi to 30 psi If OK go to Step 6 If not OK replace the faulty expansion valve WARNING PROTECT THE...

Page 2344: ...er output air temperature by controlling how much of the air flowing through the rear heater A C unit housing is directed through the heater core STANDARD PROCEDURE HEATER CORE FILLING In its final in...

Page 2345: ...C 70 F 1 Start the engine and allow it to idle until it warms up to normal operating temperature 2 Adjust the heater A C controls so that the front heater is turned Off the rear heater is set for ful...

Page 2346: ...R HOSE REMOVAL REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PER FORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMB ING FRONT WARNING HEATER PLUMBING 1 P...

Page 2347: ...to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING 1 Recover the refrigerant from the refrigerant system R...

Page 2348: ...clean refrigerant oil and install them on the suction line and liquid line fittings 4 Reconnect the liquid line and suction line fit tings to the expansion valve 5 Install and tighten the nut that se...

Page 2349: ...nd straight heater hoses used on the rear heater A C unit can be ser viced in the vehicle Refer to Group 7 Cooling Sys tem for the heater hose service procedures OPERATION The rear heater and A C line...

Page 2350: ...two rear retaining clamps behind rear wheel 5 Remove both compression fittings at front of A C lines Fig 9 6 Remove 1 bolt securing A C lines to block located at A C housing behind rear wheel and sepa...

Page 2351: ...ant oil 2 Install A C line into rear block with nylon wedge 3 Install A C lines into five underbody brackets 4 Connect forward compression fittings 5 Install bolt at sealing block to rear A C hous ing...

Page 2352: ...mounts of fuel to provide additional heat to the coolant Coolant is routed from the engine to the supplemental heater and then to the front heater core This provides additional heat to the passenger c...

Page 2353: ...be inspected and components should be replaced as required Loss of fuel dripping Check heater system integration in vehicles fuel system Check fuel line connection for leakage If OK there is an intern...

Page 2354: ...el line to pre vent fuel leakage while servicing dosing pump NOTE Utilize an approved fuel storage container to catch any residual fuel 3 Disconnect the electrical connector to the fuel pump by depres...

Page 2355: ...laced 5 Install the cabin heater line Refer to 24 HEATING AIR CONDITIONING CABIN HEAT ER FUEL LINE INSTALLATION 6 Verify function of the heater REMOVAL 1 Elevate vehicle on a lift taking note of the h...

Page 2356: ...eater activation during the first attempt to start the heater This will also set a Diagnostic Trouble Code DCT in the DCHA Control s memory do not per form the Dosing Pump Priming procedure if an atte...

Page 2357: ...exhaust tube Removal of the rail tube assembly may aid in this service operation Refer to 24 HEATING AIR CONDITIONING CABIN HEATER EXHAUST TUBE REMOVAL 11 Remove seat hex nut at the heater mounting f...

Page 2358: ...underside of the vehicle and install the two wiring harness retaining connectors 4 Plug the two connectors from the cabin heater harness to the cabin heater controller 5 Plug the connector to the cabi...

Page 2359: ...air intake muffler and install and tighten the retaining clamp 4 Install the heater tubes to the lower heater connection and the lower EGR cooler connection and tighten the retaining clamps 5 Lower t...

Page 2360: ...cles 80 warm up cycles for the Fuel System Monitor and the Misfire Monitor A warm up cycle can best be described by the following The engine must be running A rise of 40 F in engine temperature must o...

Page 2361: ...d was carried out by monitoring specific input signals for expected changes For example when the PCM com mands the Idle Air Control IAC Motor to a specific position under certain operating conditions...

Page 2362: ...e running or the MIL is illuminated for any of the following Misfire Monitor Front Oxygen Sensor and Heater Monitor MAP Sensor Vehicle Speed Sensor Engine Coolant Temperature Sensor Throttle Position...

Page 2363: ...culated The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter The PCM calculates the A F mixture from the output of the O2S A low vol...

Page 2364: ...Ethanel content learn is takeng place and the ethenal used once flag is set Suspend The Task Manager does not mature a catalyst fault if any of the following are present Oxygen Sensor Monitor Priorit...

Page 2365: ...a DRBIIIt scan tool The following is a list of the system monitors EGR Monitor if equipped Misfire Monitor Fuel System Monitor Oxygen Sensor Monitor Oxygen Sensor Heater Monitor Catalyst Monitor Evap...

Page 2366: ...ankshaft will vary more than normal FUEL SYSTEM MONITOR To comply with clean air regulations vehicles are equipped with catalytic converters These converters reduce the emission of hydrocarbons oxides...

Page 2367: ...the pump is set so that the system will achieve an equalized pressure of about 7 5 water The cycle rate of pump strokes is quite rapid as the system begins to pump up to this pressure As the pressure...

Page 2368: ...ld sooner than if the tank had to decay from a built up pressure The device itself has 3 wires Switch sense sole noid driver and ground It also includes a resistor to protect the switch from a short t...

Page 2369: ...ontrol Mod ule PCM have two recognized states HIGH and LOW For this reason the PCM cannot recognize the difference between a selected switch position versus an open circuit a short circuit or a defect...

Page 2370: ...rol system prevents the emis sion of fuel tank vapors into the atmosphere When fuel evaporates in the fuel tank the vapors pass through vent hoses or tubes to an activated carbon filled evaporative ca...

Page 2371: ...3 55 Fig 1 ORVR System Schematic 1 FUEL CAP 2 RECIRCULATION TUBE 3 LIQUID SEPARATOR 4 PURGE SOLENOID 5 W LDP 6 BREATHER ELEMENT 7 W O LDP 8 CANISTER 9 ROLLOVER VALVE 10 FUEL TANK 11 CHECK VALVE 12 CON...

Page 2372: ...rom solenoid 3 Remove solenoid from bracket INSTALLATION The solenoid attaches to a bracket near the radia tor on the passenger side of vehicle The solenoid will not operate unless it is installed cor...

Page 2373: ...through the control valve to the vapor canister Vapor is absorbed in the canister until vapor flow in the lines stops either following shut off or by having the fuel level in the tank rise high enough...

Page 2374: ...c 1 FUEL CAP 2 RECIRCULATION TUBE 3 LIQUID SEPARATOR 4 PURGE SOLENOID 5 W LDP 6 BREATHER ELEMENT 7 W O LDP 8 CANISTER 9 ROLLOVER VALVE 10 FUEL TANK 11 CHECK VALVE 12 CONTROL VALVE RS EVAPORATIVE EMISS...

Page 2375: ...lure requires double failure plugged to LDP and atmosphere Leak detection pump failed closed Leak detection pump filter plugged On Board diagnostics evaporative system leak test just conducted Caniste...

Page 2376: ...the top of the valve Fig 10 In this position there is minimal vapor flow through the valve During periods of moderate intake manifold vac uum the plunger is only pulled part way back from the inlet T...

Page 2377: ...bes connect to the top of the canister It is a charcoal canister Fig 12 or Fig 13 OPERATION All vehicles use a maintenance free evaporative EVAP canister Fuel tank vapors vent into the can ister The c...

Page 2378: ...remove canister INSTALLATION INSTALLATION 1 Install canister arrow heads into the rubber gromments Fig 14 2 Install bolt and tighten 3 Install hoses 4 Lower vehicle INSTALLATION REAR EVAP CANISTER 1 I...

Page 2379: ...E DESCRIPTION N m Ft Lbs In Lbs EGR valve to cyl head 2 4L 22 200 25 EGR tube to EGR valve 2 4L 11 9 105 20 EGR tube to intake manifold 2 4L 11 9 105 20 EGR valve to adaptor 3 3 3 8L 22 200 25 EGR tub...

Page 2380: ...ir box cover 9 Install the hose clamp at throttle body 10 Install the air box bolt 11 Connect the fresh air makeup hose on rear valve cover 12 Connect the negative battery cable INSTALLATION REAR TUBE...

Page 2381: ...cause of low back pressure varies the strength of vacuum applied to the EGR valve Varying the strength of the vacuum changes the amount of EGR supplied to the engine This pro vides the correct amount...

Page 2382: ...ing bolts 12 Remove the EGR valve INSTALLATION INSTALLATION 2 4L The EGR valve and Electrical EGR Transducer are serviced as an assembly Fig 1 1 Assemble EGR valve with new gasket onto the cylinder he...

Page 2383: ...f the MIL is illuminated and a fault is stored from another monitor In these situations the Task Manager postpones monitors pending resolu tion of the original fault The Task Manager does not run the...

Page 2384: ...trips the MIL is extinguished and the Task Manager automatically switches the trip counter to a warm up cycle counter DTCs are auto matically erased following 40 warm up cycles if the component does n...

Page 2385: ...different Similar conditions Windows Fuel System and Misfire FUEL SYSTEM Fuel System Similar Conditions Window An indicator that Absolute MAP When Fuel Sys Fail and RPM When Fuel Sys Failed are all in...

Page 2386: ...in accessing the Similar Conditions Window Adaptive Memory Factor The PCM utilizes both Short Term Compensation and Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correctio...

Page 2387: ......

Page 2388: ...onent resistance Output Device Current Flow The ECM senses whether the output devices are electrically connected If there is a problem with the circuit the ECM senses whether the circuit is open short...

Page 2389: ...ORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs EGR Cooler to EGR Bolts 32 4 24 EGR Cooler to Exhaust Manifold 27 5 21 EGR Valve Nuts 32 4 24 25a 2 EMISSIONS CONTROL 2 5L TURBO DIESEL RG EMISSIONS...

Page 2390: ...he power brake boosterb and the heating and air conditioning system The pump is located internally in the front of the engine block and is driven by the crankshaft gear Vacuum lines and hoses connect...

Page 2391: ...iper unit Refer to 8 ELEC TRICAL WIPERS WASHERS WIPER MODULE REMOVAL 3 Disconnect EGR valve vacuum line 4 Remove EGR cooler to EGR valve retaining bolts Fig 1 5 Remove EGR valve retaining nuts Fig 1 a...

Page 2392: ...er and new gasket to EGR valve Fig 2 Torque bolts to 32 4N m 3 Install EGR valve cooler to exhaust manifold attaching bolt Fig 2 Torque bolt to 32 4N m 4 Connect EGR cooler coolant supply and return h...

Page 2393: ...ut most likely will not identify the failed component directly Refer to the appropriate diagnos tic manual for more information on diagnosis of trou ble codes ACCESSING DIAGNOSTIC TROUBLE CODES A stor...

Page 2394: ...ure Sensor Circuit MALF Signal Voltage Too Low P0195 Oil Temperature Sensor Circuit MALF Signal Voltage Too High Oil Temperature Sensor Circuit MALF Signal Voltage Too Low P0201 Cylinder 1 Injector Ci...

Page 2395: ...P0500 Vehicle Speed Sensor Frequency Too High Vehicle Speed Sensor Frequency High Level Duration Vehicle Speed Sensor Plausibility Vehicle Speed Sensor Signal Voltage Too High P0514 Battery Temperatur...

Page 2396: ...Off Too Late P0703 Brake Switch Signal Circuits Incorrect Can Message Brake Switch Signal Circuits Plausibility With Redundant Contact P1130 Fuel Rail Pressure Malfunction Small Leakage Detected Fuel...

Page 2397: ...Access To EEPROM Failure P1696 EEPROM Communication Error EEPROM Communication Not Verified EEPROM Quanity Stop EEPROM Recovery Occured EEPROM Redundant Overrun Monitoring P1703 Brake Switch Signal CK...

Page 2398: ..._____________________________________________ ______________________________________________________________________________________ ___________________________________________________________________...

Page 2399: ...DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 8...

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