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Welcome to the
1992 AS Town 8 Country, Caravan 8 voyager

Electronic Service Nanual
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FOR INSTRUCTIONS
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Page 1
03/30/99
Rev. 0
7DEOH2I&RQWHQWV
Section Page
1.0 Viewing A Manual In Windows98/95/NT. 2
2.0 Viewing A Manual In Windows 3.1 . 3
3.0 Using The CD-ROM
3.1 Welcome Page Of A Manual 4
3.2 Tab Page Of A Manual . 5
3.3 Returning To The Tab Page Of A Manual 6
3.4 Viewing The Contents Of A Group Within A Manual .. 7
3.5 Using Electronic Bookmarks To Navigate A Manual .. 8
4.0 Using The Acrobat Reader Toolbar
4.1 Acrobat Reader On-Line Help 9
4.2 Summary Of Acrobat Reader Toolbar Features . 10
2
1.0 Viewing A Manual In Windows98/95/NT
To view the contents of A CD-ROM, you will need to keep the CD-ROM in
the CD-ROM drive. The Acrobat Reader runs off the hard drive and
uses the CD-ROM drive to access the document content.
1. Click the START button, point to the Programs Group, then point to the
desired DaimlerChrysler manual group. Figure 1.0-1 shows the selection for
the 1995 Service Manual CD-ROM.
Figure 1.0-1
2. Proceed to Section 3.0 of this instruction booklet.
Page 3
03/30/99
Rev. 0
2.0 Viewing A Service Manual In Windows3.1
To view the contents of A CD-ROM, you will need to keep the CD-ROM in
the CD-ROM drive. The Acrobat Reader runs off the hard drive and
uses the CD-ROM drive to access the document content.
1. Double click on the Program Group icon for the DaimlerChrysler
Manual. Figure 3.0-1 shows the icon for the 1995 Service Manual.
Figure 2.01-1
2. Proceed to Section 4.0 of this instruction booklet.
4
3.0 Using The CD-ROM
3.1 Welcome Page Of A Manual
The Welcome Page is the first page that is displayed to a user after
launching the Acrobat Reader application. Refer to Sections 1.0, and 2.0 of this
CD-ROM Instruction Booklet. Double click on the logo to enter
the Electronic Manual. Figure 3.1-1 is a Welcome Page.
Figure 3.1-1
Page 5
03/30/99
Rev. 0
3.2 Tab Page Of A Manual
The tab page contains a listing of all the groups within a manual. Point the cursor
the desired group and click to display the content for a group.
Figure 4.2-1 is a sample tab page for a manual.
Figure 3.2-1
6
3.3 Returning To The Tab Page Of A Manual
On the Acrobat Reader Toolbar, select the menu option "File" and then
"xxx_tab.pdf" to return to the Tab Page in a manual. In Figure 3.3-1
the Tab Page is "ean_tab.pdf".
Figure 3.3-1
Page 7
03/30/99
Rev. 0
3.4 Viewing The Contents Of A Group Within A Manual
Point the cursor over a desired content section and click to
display the contents within a group. Figure 3.4-1 shows the
electronic outline within the left hand window and the document
with associated sections within the right hand window.
Figure 3.4-1
8
3.5 Using Electronic Bookmarks For Navigation Within A Manual.
Point the cursor over an item in the electronic outline window which is
located in the left window of the Acrobat Reader.
Click on an outline item to display the contents within a group.
Figure 3.5-1 is a sample document with electronic bookmarks in the
left hand window and the document in the right hand window.
Figure 3.5-1
Page 9
03/30/99
Rev. 0
4.0 Using The Acrobat Reader
4.1 Acrobat Reader On-Line Help
The complete user help file can be accessed by selecting the
Help Menu option and then Reader Online Guide option within
the Acrobat Reader application.
4.2 Summary Of Acrobat Reader Toolbar Features
Section 4.2 describes how to use the basic features of the Adobe Acrobat Reader to
navigate the CD-ROM manual. A Quick Summary of The basic Acrobat Reader
features is contained in Table 4.2-1
Description Icon Usage
Display The Previous
View
Click on the icon to use the previous view
function
Display The Next
View
Click on the icon to use the next view function
Set Image Size To
100%
Click on the icon to set the document view
image to 100%
Make The Current
Page Fit Inside The
Window
Click on the icon to scale a large page format
to fit within the viewing window.
Make The Visible
Width Of The Current
Page Fit The Viewing
Window
Click on the icon to make the width of a
document fit the viewing window.
Table 4.2-1
10
Description Icon Usage
Display The Previous
View
Click on the icon to use the previous view
function
Display The Next
View
Click on the icon to use the next view function
Set Image Size To
100%
Click on the icon to set the document view
image to 100%
Make The Current
Page Fit Inside The
Window
Click on the icon to scale a large page format
to fit within the viewing window.
Make The Visible
Width Of The Current
Page Fit The Viewing
Window
Click on the icon to make the width of a
document fit the viewing window.
Table 4.2-1
CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN
ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All t e s t and re pair proc e dure s on c ompone nt s or as s e mblie s in
non-aut omot ive applic at ions s hould be re paire d in ac c ordanc e wit h ins t ruc t ions
s upplie d by t he manufac t ure r of t he t ot al produc t .
Proper service and repair is important to the safe, reliable, operation of all motor
vehicles. The service procedures recommended and described in this publication were
developed for professional service personnel and are effective methods for performing
vehicle repair. Following these procedures will help assure efficient economical vehicle
performance and service reliability. Some of these service procedures require the use
of special tools designed for specific procedures. These special tools should be used
when recommended throughout this publication.
Spe c ial at t e nt ion s hould be e xe rc is e d whe n working wit h s pring or t e ns ion loade d
fas t e ne rs and de vic e s s uc h as E-Clips , Circ lips , Snap rings , e t c . , as c are le s s re moval
may c aus e pe rs onal injury. Always we ar s afe t y goggle s whe ne ve r working on ve hic le s
or ve hic le c ompone nt s .
It is important to note that this publication contains various Caut ions and Warnings .
These should be carefully read in order to minimize the risk of personal injury, or the
possibility that improper service methods may damage the vehicle or render it unsafe.
It is important to note that these Caut ions and Warnings cover only the situations
and procedures DaimlerChrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation could not possibly know, evaluate, and advise the
service trade of all conceivable ways that service may be performed, or of the possible
hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken any
such broad service review. Accordingly, anyone who uses a service procedure, or tool,
that is not recommended in this publication must assure oneself thoroughly that
neither personal safety, nor vehicle safety, be jeopardized by the service methods they
select.
SERVICE AND OWNER MANUALS
Available f or Chrysler, Plymout h, Dodge,
Dodge Truck, and Jeep
vehicles.
Telephoneorders may beplaced at thenumber below.
Credit cards are accepted (no CODs). Please have your
order information available at time of call.
CALL: (800) 890-4038 OR FAX: (440) 572-0815
FOR A FREE CATALOG OR TO PLACE AN ORDER.
NEXT PAGE
llllllllllll
UNITED STATES
The special service tools referred to herein are required for certain service operations. These special service tools
or their equivalent, if not obtainable through a local source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
OTC Division, SPX Corporat ion
Telephone 1-800-801-5420 FAX 1-800-578-7375
CANADA
C & D Riley Enterprises Ltd., P.O. Box 243, Amherstburg, Ontario N9V 2Z4
Telephone (519) 736-4600 FAX (519) 736-8433
INTERNATIONAL
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
OTC Division, SPX Corporat ion
Telephone 1-800-801-5420 FAX 1-800-578-7375
NEXT PAGE
WIRING DIAGRAMS
CONTENTS
page page
COMPONENT IDENTIFICATION . . . . . . . . . . . . . 11
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . 33
WIRING DIAGRAMS AS-BODY H-K . . . . . . . . . . 47
GENERAL I NFORMATI ON
INDEX
page page
Component Identification . . . . . . . . . . . . . . . . . . . . 3
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Distributor Secondary Wiring . . . . . . . . . . . . . . . . . 1
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Locating a System . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Circuit Identification . . . . . . . . . . . . . . . . . . . . 2
Splice Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols, Fuses and Abbreviations . . . . . . . . . . . . . 6
Troubleshooting Wiring Problems . . . . . . . . . . . . . . 4
Wire Code Identification . . . . . . . . . . . . . . . . . . . . . 2
Wiring Diagram Sheets and Indexes . . . . . . . . . . . . 1
The wi ri ng di agrams contai n the l atest i nformati on
at the ti me of publ i cati on.
Throughout thi s group references may be made to a
parti cul ar vehi cl e by l etter or number desi gnati on. A
chart showi ng the breakdown of these desi gnati ons i s
i ncl uded i n the I ntroducti on Secti on at the front of thi s
servi ce manual .
DISTRIBUTOR SECONDARY WIRING
Di stri butor secondary wi ri ng i s shown i n Fi gures 1,
2, 3, and 4. For addi ti onal i nformati on on i gni ti on
systems or di stri butor operati on refer to Group 8D
I gni ti on Systems, i n thi s manual .
WIRING DIAGRAM SHEETS AND INDEXES
The wi ri ng di agram sheets are organi zed i n
such a manner that systems rel ati ng to the basi c
vehi cl e and al l of i ts opti ons are shown, add-on or
non-factory opti ons are not covered. Di agram
pages are i denti fi ed by a sheet number whi ch i s
l ocated at the l ower ri ght or l eft hand corner of
each sheet, page numbers at the top of each
page do not apply to diagramsheets.
Di agram sheets show al l i nformati on rel ati ng to the
system. Thi s i ncl udes feeds, grounds, swi tch i nternal ci rcu-
i ty, connectors, spl i ces, and pi n i denti fi cati on for control l ers
and modul es.
I n certai n i nstances a wi re may be referenced to
another sheet. When thi s happens, the wi re wi l l be
Fig. 1 Distributor Secondary Wiring 2.5L Engine
Fig. 2 Distributor Cap 3.0L V6 Engine
WIRING DIAGRAMS 8W - 1
i denti fi ed as to what i t i s i e: feed, ground, etc, and
where i ts goi ng (Fi g. 5). Thi s has been done to ai d i n
the di agnosi s of wi ri ng and component probl ems.
The i ndex used for the di agrams i s l ocated at the
begi nni ng of the di agrams and covers al l systems
shown i n the di agrams. The i ndex i s i n al phabeti cal
order and i denti fi es the mai n system and al l rel ated
components.
WIRE CODE IDENTIFICATION
Each wi re shown i n the di agrams contai ns a code
(Fi g. 6) whi ch i denti fi es the mai n ci rcui t, part of the
mai n ci rcui t, gauge of wi re, and col or. The col or i s
shown as a two l etter code whi ch can be i denti fi ed by
referri ng to the Wi re Col or Code Chart (Fi g. 7). I f the
wi re has a tracer and i t i s a standard col or an asteri sk
wi l l fol l ow the mai n wi re col or. I f the tracer i s non-
standard the mai n wi re col or wi l l have a sl ash (/) after
i t fol l owed by the tracer col or.
MAIN CIRCUIT IDENTIFICATION
To i denti fy whi ch mai n ci rcui t code appl i es to a
system, refer to the Mai n Ci rcui t I denti fi cati on Code
Chart. Thi s chart shows the mai n feed ci rcui ts onl y and
does not show the secondary codes that may appl y to
some vehi cl es.
LOCATING A SYSTEM
To l ocate a system or component i n the di agrams,
refer to the al phabeti cal i ndex at the front of the
di agrams. Determi ne the di agram sheet number. Sheet
numbers are l ocated at the l ower ri ght or l eft hand
corner of each sheet. Pagenumbersat thetopof the
page do not apply to diagramsheets.
Fig. 3 Distributor Secondary Wiring 3.0L V6 En-
gine
Fig. 4 Ignition System Secondary Wiring 3.3L V6
Engine
Fig. 5 Wiring Diagram Page Sample
Fig. 6 Wire Color Code Identification
8W - 2 WIRING DIAGRAMS
The di agram i ndex i denti fi es the mai n system and al l
components that rel ate to that system. There are al so
secti ons of the i ndex that i denti fy speci fi c components
onl y (for exampl e modul es, l amps, etc.). Refer to a
components name i n the i ndex i f you are uncl ear as to
what a system may be cal l ed.
Di agram pages are arranged starti ng wi th the bat-
tery and fuses. Then worki ng i nto chargi ng, starti ng,
and i gni ti on systems. After thi s they start at the front
of the vehi cl e and work to rear of the vehi cl e. The
di agrams end wi th connector i denti fi cati on pages.
COMPONENT IDENTIFICATION
When l ooki ng for a components actual l ocati on
on the vehi cl e refer to the wi ri ng and components
secti on i ndex. Thi s secti on shows the wi re harness
routi ng and the components l ocati on i n the ve-
hi cl e. When usi ng thi s secti on refer to the wi ri ng
di agrams for the general l ocati on of the compo-
nent. Then use the component i denti fi cati on i ndex
to l ocate the proper fi gure number.
SPLICE LOCATIONS
Spl i ce l ocati ons are i ndi cated i n the di agrams by
a di amond wi th a spl i ce ci rcui t code wi thi n i t (Fi g.
8 exampl e 1). I f there i s more than one spl i ce per
ci rcui t a smal l box wi l l be connected to i t wi th the
spl i ce number i n i t (Fi g. 8 exampl e 2).
To l ocate a spl i ce i n the wi ri ng harness deter-
mi ne the spl i ce number from the wi ri ng di agrams
then refer to the spl i ce l ocati on i ndex. Thi s secti on
shows the general l ocati on of the spl i ce i n the
harness.
The wi ri ng di agrams al so i ndi cate what harness the
spl i ce i s l ocated i n. To i denti fy the harness an abbre-
vi ated cal l out i s pl aced next to the mai n spl i ce (Fi g. 5).
Fig. 7 Wire Color Code Chart
Fig. 8 Wiring Splice Examples
CONNECTORS
The connectors shown i n the di agram sheets are
vi ewed from the termi nal end unl ess otherwi se speci -
fi ed. For vi ewi ng bul khead, engi ne control l er, and
transmi ssi on control l er connectors refer to the rear of
the wi ri ng di agrams. Thi s area shows major connectors
and i denti fi es pi n and cavi ty i nformati on.
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are si x
steps whi ch can ai d i n the procedure. The steps are
l i sted and expl ai ned bel ow.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by perform-
i ng operati onal checks on components that are i n the
same ci rcui t as the probl em area. Refer to the wi ri ng
di agrams fuse appl i cati on chart for more i nformati on.
(3) Anal yze the symptoms. Use the wi ri ng di agrams
to determi ne what the ci rcui t i s doi ng, where the
probl em most l i kel y i s occurri ng and where the di ag-
nosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em.
(6) Veri fy proper operati on. For thi s step check for
proper operati on of al l i tems on the ci rcui t repai red.
Refer to the wi ri ng di agram fuse appl i cati on chart.
FUSIBLE LINKS
Vehi cl e wi ri ng harnesses are equi pped wi th fus-
i bl e l i nks to protect agai nst harness damage i n
the event of a short i n the system. Fusi bl e l i nks
are col or coded to i ndi cate wi re gauge and si ze.
Refer to the fusi bl e l i nk chart for col or and gauge
i denti fi cati on (Fi g. 9).
HARNESS REPAIR
FUSI BLE LI NK REPLACEMENT
CAUTION: Do not replace blown fusible links with a
standard wire. Only use fusible type wire with hypa-
lon insulation or damage to the electrical system
could occur. Also make sure correct gauge of wiring
is used. Refer to the wiring diagrams for proper
gauge and color.
When a fusi bl e l i nk bl ows i t i s i mportant to fi nd out
what the probl em i s. They are pl aced i n the el ectri cal
system for protecti on agai nst shorts to ground whi ch
can be caused by a component fai l ure or vari ous wi ri ng
fai l ures. Do not just replace the fusible link to
correct the problem.
When di agnosi ng a faul ty fusi bl e l i nk i t i s i mportant
to check the wi re careful l y. I n some i nstances the l i nk
may be bl own and i t wi l l not show through the i nsul a-
ti on, the wi re shoul d be checked over i ts enti re l ength
for i nternal breaks.
(1) Di sconnect battery negati ve cabl e.
(2) Cut out the bl own porti on of the fusi bl e l i nk.
(3) Stri p 1 i nch of i nsul ati on from each end of the
exi sti ng fusi bl e l i nk.
(4) Pl ace a pi ece of heat shri nk tubi ng over one of
si de of the fusi bl e l i nk. Make sure the tubi ng wi l l be
l ong enough to cover and seal the enti re repai r area.
(5) Cut a repl acement pi ece of fusi bl e l i nk approxi -
matel y two i nches l onger than the pi ece removed.
(6) Remove one i nch of i nsul ati on from each end of
the repl acement fusi bl e l i nk.
(7) Spread the strands of wi re apart on each of the
exposed wi res (Fi g. 10 exampl e 1).
(8) Push the two ends of the wi re together unti l the
strands of wi re are cl ose to the i nsul ati on (Fi g. 10
exampl e 2).
(9) Twi st the wi res together (Fi g. 10 exampl e 3).
(10) Sol der the wi res together usi ng rosi n core type
sol der onl y. Do not use acid core type solder.
(11) Center the heat shri nk tubi ng over the joi nt and
heat usi ng a heat gun. Heat the joi nt unti l the tubi ng
i s ti ghtl y seal ed and seal ant comes out of both ends of
the tubi ng.
Fig. 9 Fusible Link Chart
Fig. 10 Wire Repair
(12) Secure the fusi bl e l i nk to the exi sti ng ones to
prevent chafi ng or damage to the i nsul ati on.
(13) Connect battery and test al l affected systems.
WI RI NG REPAI R
When repl aci ng or repai ri ng a wi re, i t i s i mportant
that the correct gauge be used as shown i n the wi ri ng
di agrams. The wi res must al so be hel d securel y i n
pl ace to prevent damage to the i nsul ati on.
(2) Remove 1 i nch of i nsul ati on from each end the
wi re.
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(4) Spread the strands of the wi re apart on each part
of the exposed wi res (Fi g. 10 exampl e 1).
(5) Push the two ends of wi re together unti l the
exampl e 2).
(7) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
the tubi ng.
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on.
CONNECTOR REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector that i s to be repai red
from i ts mati ng hal f.
(3) Remove connector l ocki ng wedge (Fi g. 11).
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal whi l e pul l i ng on the wi re to remove the
termi nal from the connector (Fi g. 12).
(5) Reset the termi nal l ocki ng tang, i f i t has one.
(6) I nsert the removed wi re i n the same cavi ty on the
repai r connector.
(7) Repeat steps four thru si x for each wi re i n the
connector, bei ng sure that al l wi res are i nserted i nto
the proper cavi ti es. For addi ti onal connector pi n out
i denti fi cati on refer to the wi ri ng di agrams.
(8) I nsert the connector l ocki ng wedge i nto the re-
pai red connector.
(9) Connect connector to i ts mati ng hal f.
CONNECTOR AND TERMI NAL ASSEMBLY RE-
PLACEMENT
(1) Di sconnect Battery.
(2) Di sconnect the connector bei ng repai red from i ts
mati ng hal f.
(3) Cut off the exi sti ng wi re connector di rectl y be-
hi nd the i nsul ator and remove si x i nches of tape from
the harness.
(4) Stagger cut al l wi res on the harness si de about
1/2 i nch apart (Fi g. 13).
Fig. 11 Connector Locking Wedge Tab
Fig. 12 Connector Locking Finger and Locking
Wedge
Fig. 13 Stagger Cutting Wires
(5) Remove 1 i nch of i nsul ati on from each wi re on
the harness si de.
(6) Stagger cut the matchi ng wi res on the repai r
connector assembl y i n the opposi te order as was done
on the harness si de of the repai r (al l ow extra l ength for
sol dered connecti ons). Check that the overal l l ength i s
the same as the ori gi nal (Fi g. 13).
(7) Remove 1 i nch of i nsul ati on from each wi re.
(9) Spread the strands of the wi re apart on each part
of the exposed wi res (Fi g. 10 exampl e 1).
exampl e 2).
the tubi ng.
(14) Repeat steps 8 thru 13 for each wi re.
(15) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(16) Reconnect the repai red connector.
TERMI NAL REPLACEMENT
(2) Di sconnect the connector bei ng repai red form i ts
mati ng hal f.
(3) Remove connector l ocki ng wedge (Fi g. 11).
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal whi l e pul l i ng on the wi re to remove the
termi nal from the connector (Fi g. 12).
(5) Cut the wi re 6 i nches from the back of the
connector.
(6) Remove 1 i nch of i nsul ati on from the wi re on the
harness si de.
(7) Sel ect a wi re from the termi nal repai r assembl y
that best matches the col or wi re bei ng repai red.
(8) Cut the repai r wi re to the proper l ength and
remove 1 i nch of i nsul ati on.
(10) Spread the strands of the wi re apart on each
part of the exposed wi res (Fi g. 10 exampl e 1).
exampl e 2).
the tubi ng.
(15) I nsert the repai red wi re i nto the connector.
(16) I nstal l the connector l ocki ng wedge and recon-
nect the connector to i ts mati ng hal f.
(17) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
SYMBOLS, FUSES AND ABBREVIATIONS
Vari ous symbol s are used throughout the wi ri ng
di agrams. These symbol s can be i denti fi ed by referri ng
to the symbol i denti fi cati on chart (Fi g. 14).
Certai n abbrevi ati ons are al so used i n the di agrams.
These have been devel oped i n such a way that there
meani ng shoul d be cl ear. Refer to the abbrevi ati ons
chart for an expl anati on of the terms used (Fi g. 15).
For fuse and rel ay bank i nformati on refer to
(Fi g 16).
CAUTION: When replacing a blown fuse it
is important to replace it with a fuse having
the correct amperage rating. The use of a
fuse with a rating other than indicated may
result in an electrical overload. If a proper
rated fuse continues to blow, it indicates a
problem that should be corrected.
Fig. 14 Symbol Identification
Fig. 15 Abbreviation Chart
F
i
g
.
1
6
F
u
s
e
B
l
o
c
k
a
n
d
R
e
l
a
y
B
a
n
k
A
S
COMPONENT I DENTI FI CATI ON
Caption Fig.
Body Wiring Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Body Wiring Right Side . . . . . . . . . . . . . . . . . . . . . . . .6, 7
Door Wiring (Body) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Door Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Compartment Wiring 2.5L . . . . . . . . . . . . . . . . . . .19
Engine Compartment Wiring 3.0L . . . . . . . . . . . . . . . . . . .20
Engine Compartment Wiring 3.3L . . . . . . . . . . . . . . . .21, 22
Engine Wiring 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Engine Wiring 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Engine Wiring 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Front End Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fuel Tank/AWD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .14
Ground Strap Locations . . . . . . . . . . . . . . . . . . . . . . . . .18
Caption Fig.
Instrument Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . .12
Instrument Panel Wiring (Connections) . . . . . . . . . . . . . . .13
Liftgate Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Overhead Console Wiring . . . . . . . . . . . . . . . . . . . . . . . .4
Power Seat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Rear A/C Heater Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .5
Roof Wiring Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Roof Wiring Right Side . . . . . . . . . . . . . . . . . . . . . . . . . .3
Steering Column Wiring . . . . . . . . . . . . . . . . . . . . . . . . .11
Transmission Wiring 2.5L . . . . . . . . . . . . . . . . . . . . . . .23
Underhood Lamp Wiring . . . . . . . . . . . . . . . . . . . . . . . .17
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Fig. 2 Roof Wiring Left Side
Fig. 3 Roof Wiring Right Side
Fig. 4 Overhead Console Wiring
Fig. 5 Rear A/C Heater Wiring
Fig. 6 Body Wiring Right Side
Fig. 7 Body Wiring Right Side
Fig. 8 Power Seat Wiring
Fig. 9 Door Wiring (Body Side)
Fig. 10 Door Wiring
Fig. 11 Steering Column Wiring
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Fig. 15 Liftgate Wiring
Fig. 16 Front End Wiring
Fig. 17 Underhood Lamp Wiring
Fig. 18 Ground Strap Locations
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L
SPLI CE LOCATI ON
INDEX
Splice Number Fig.
A0 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A0 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A1 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
A1-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A1-2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A1-3 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
A2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A2 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A4-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A4-2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A4-2 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A11 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A11 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A14 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A14 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A14-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A16 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A16-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A16-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A21 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A21 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
A21-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A21-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
A21-2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A21-2 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
A21-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
A22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
A31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A141 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A142 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
A142-3 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
B47 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
C7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
C15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
C20 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
C23 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
D1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
D2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
E2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
F21-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
F21-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
F21-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
F35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
F62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Splice Number Fig.
G5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
G7 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
G7 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
G9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
G9-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
G19 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
K4 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
K4 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
K4 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
K4-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
K4-2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
K4-2 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
K4-3 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
K4-3 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
K4-4 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
K6 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
K6 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
K6-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
K7 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
K22 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
K22 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
K24 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
L2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
L3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
L7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
L7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
L39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
L44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
L44-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
L50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
L60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
L61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
L94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
M1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
M1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
M2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
M2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
M11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
M11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
P33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
P33-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
P34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
P34-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
T13 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
T13 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Splice Number Fig.
T16 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
T41 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
V3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
V23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
V23-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
V23-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
X2 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
X13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
X15-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
X53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X53-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
X54-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
X55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
X56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Z0 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Z0-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Z1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Splice Number Fig.
Z1 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Z1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Z1 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Z1-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Z1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Z1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Z1-3 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Z1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Z1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Z1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Z1-7 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Z1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 5
Z1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Z1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Z1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Z1-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z11 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Z11-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Z12 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Z12 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Z13 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Z13-1 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Z14 3.0L, 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fig. 2 Rear End Splices
Fig. 1 Liftgate Splices
Fig. 3 Roof Splices (Left Side)
Fig. 4 Floor Pan Splices
Fig. 5 Body Left Side Splices
Fig. 6 Rear Heater A/C Splices
Fig. 7 Roof Rail Splices
Fig. 8 Cowl Panel Splices
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Fig. 11 Instrument Panel Splices
Fig. 12 Engine Compartment Splices 2.5L
Fig. 13 Engine Compartment Splices 2.5L
Fig. 14 Engine Compartment Splices 3.0L, 3.3L
Fig. 17 Engine Compartment Splices
Fig. 18 Engine Splices 2.5L
Fig. 22 Front End Splices
WI RI NG DI AGRAMS AS-BODY H-K
ALPHABETICAL INDEX
Wiring Diagram Name Sheet Number
ABS Module Connector . . . . . . . . . . . . . . . . . . . . . . . .178
ABS Pump Motor Relay . . . . . . . . . . . . . . . . . . . . . . . .132
ABS Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . . .132,133
Airbag Diagnostic Module Connector . . . . . . . . . . . . . . . .177
Airbag System . . . . . . . . . . . . . . . . . . . . . . . . . . .135,136
Airbag System Diagnostic Module . . . . . . . . . . . . . . . .135
Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Left Airbag Sensor . . . . . . . . . . . . . . . . . . . . . . . . .136
Right Airbag Sensor . . . . . . . . . . . . . . . . . . . . . . . . .136
Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Air Conditioning System (2.5L Engine) . . . . . . . . .97,98,99,100
A/C and Heater Vacuum Switch . . . . . . . . . . . . . . . . .100
A/C Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
A/C Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
A/C Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
A/C High Pressure Clutch Cut-Out Switch . . . . . . . . . .97,99
A/C Low Pressure Cut-Out Switch . . . . . . . . . . . . . . . . .97
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . .96,100
Blower Slide Switch . . . . . . . . . . . . . . . . . . . . . . . . .100
Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Electronic A/C Cycling Switch . . . . . . . . . . . . . . . . . . .97
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . .99
Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . .98
Air Conditioning System (3.0L Engine) . . . .101, 102, 103, 104,
105, 106, 107, 108
A/C Ambient Temperature Sensor . . . . . . . . . . . . .101,105
A/C and Heater Vacuum Switch . . . . . . . . . . . . . . .104,108
A/C Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . .102,106
A/C Fan Cut-Out Switch . . . . . . . . . . . . . . . . . . . .103,107
A/C Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . .102,106
A/C Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . .101,105
A/C High Pressure Clutch Cut-Out Switch . . . . . .101,103,105
A/C Low Pressure Cut-Out Switch . . . . . . . . . . . . .101,105
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . .104,108
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . .104
Blower Slide Switch . . . . . . . . . . . . . . . . . . . . . .104,108
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . .103,107
Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . .104,108
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . .103,107
Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . .102,106
Air Conditioning System (3.3L Engine) . . . . . .109,110,111,112
A/C Ambient Temperature Sensor . . . . . . . . . . . . . . . .109
A/C and Heater Vacuum Switch . . . . . . . . . . . . . . . . .112
A/C Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .110
A/C Fan Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . .109
A/C Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
A/C Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
A/C High Pressure Clutch Cut-Out Switch . . . . . . . . . . .109
A/C Low Pressure Cut-Out Switch . . . . . . . . . . . . . . . .109
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . .112
Blower Slide Switch . . . . . . . . . . . . . . . . . . . . . . . . .112
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . .111
Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . .110
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6,9,12
Ambient Switch - Overhead Console . . . . . . . . . . . . . . . . .66
Anti-Lock Brake System . . . . . . . . . . . . . . . . . .132,133,134
ABS Electronic Module . . . . . . . . . . . . . . . . .132,133,134
ABS Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . .132,133
ABS Pump Hydraulic Modulator . . . . . . . . . . . . . .132,133
ABS Pump Motor Relay . . . . . . . . . . . . . . . . . . . . . .132
Left Front Wheel Speed Sensor . . . . . . . . . . . . . . . . .133
Left Rear Wheel Speed Sensor . . . . . . . . . . . . . . . . . .134
Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Right Front Wheel Speed Sensor . . . . . . . . . . . . . . . . .133
Right Rear Wheel Speed Sensor . . . . . . . . . . . . . . . . .134
Automatic Idle Speed 2.5L Engine . . . . . . . . . . . . . . . . . .20
Automatic Idle Speed 3.0L Engine . . . . . . . . . . . . . . . .30,39
Automatic Idle Speed 3.3L Engine . . . . . . . . . . . . . . . . . .45
Automatic Shutdown Relay 2.5L Engine . . . . . . . . . . . . . . .23
Automatic Shutdown Relay 3.0L Engine . . . . . . . . . . . . .29,36
Automatic Shutdown Relay 3.3L Engine . . . . . . . . . . . . . . .41
Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . .16,18
Battery . . . . . . . . . . . . . . . . . . . . . . . . . .1,5,8,11,28,35,40
Body Computer . . . . . . . . . . . . . . . . . . . . . . . . . .137,138
Body Computer Connector . . . . .43, 47, 48, 54, 56, 57, 60, 61,
62, 63, 64, 66, 67, 70, 71, 72,
73, 74, 76, 85, 88, 91, 94, 113,
119, 125, 130, 136, 139, 153, 154
Brake Pedal Support Bracket . . . . . . . . . . . . . . . . . . . . . .14
Brake Warning Lamp Switch . . . . . . . . . . . . . . . . . . . . . .14
Bulkhead Disconnect Connector (50 Way)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .144,145,146,147,148
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Cam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Center High Mounted Stop Lamp . . . . . . . . . . . . . . . . . .140
Charging System (2.5L TBI Engine) . . . . . . . . . . . . . . . .5,6,7
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Charging System (3.0L Engine) . . . . . . . . . . . . . . . . .8,9,10
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Charging System (3.3L Engine) . . . . . . . . . . . . . . . .11,12,13
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chime - Key-In,Seatbelt Warning, Headlamp On . . . . . . . . . .71
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Circuit Breaker
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . .3,58,62,123
Power Door Locks . . . . . . . . . . . . . . . . . . . . . .3,123,126
Power Windows . . . . . . . . . . . . . . . . . . . . . .2,14,65,121
Clock - with Radio . . . . . . . . . . . . . . . . . . . . . . . . . .85,91
Cluster Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Clutch Interlock J umper . . . . . . . . . . . . . . . . . . . . . . . . .14
Clutch Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . .14
Combo Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Console Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Coolant Sensor 2.5L Engine . . . . . . . . . . . . . . . . . . . . . .24
Coolant Sensor 3.0L Engine . . . . . . . . . . . . . . . . . . . .31,37
Coolant Sensor 3.3L Engine . . . . . . . . . . . . . . . . . . . . . .43
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . . .67,68,69
Crank Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Cycling Switch-A/C Electronic . . . . . . . . . . . . . . . . . . . . .97
Daytime Running Light Module . . . . . . . . . . . . . . . . . . . .57
Daytime Running Light Module Connector . . . . . . . . . . . .172
Daytime Running Light Module Wiring . . . . . . . . . . . . . . .57
Defogger, Heater Rear Window . . . . . . . . . . . . . . . . . . .118
Dimmer Switch - Headlamp . . . . . . . . . . . . . . . . . . . .61,62
Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Distance Sensor 2.5L Engine . . . . . . . . . . . . . . . . . . . . .24
Distance Sensor 3.0L Engine . . . . . . . . . . . . . . . . . . .32,38
Distance Sensor 3.3L Engine . . . . . . . . . . . . . . . . . . . . .42
Dome and Body Courtesy Lamps . . . . . . . . . . . . . . .67,68,69
Dome and Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . .72
Door Lock System . . . . . . . . . . . . . . . . . . . . . . . .125,126
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Left Front Door Lock Motor . . . . . . . . . . . . . . . . . . . .125
Left Front Door Lock Switch . . . . . . . . . . . . . . . . . . .125
Lock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Right Front Door Lock Motor . . . . . . . . . . . . . . . . . . .125
Right Front Door Lock Relay . . . . . . . . . . . . . . . . . . .125
Sliding Side Door Lock Motor . . . . . . . . . . . . . . . . . .126
Unlock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Electronically Tuned Radios . . . . . . . . . . . . . . . . . .85,86,87
Electronic Automatic Transaxle Control
Module Connector . . . . . . . . . . . . . . . . . . . . . . . .59,176
Electronic Fuel Injection Ignition System
(2.5L Engine) . . . . . . . . . . . . . . .20, 21, 22, 23, 24, 25
Automatic Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . .20
Automatic Shutdown Relay . . . . . . . . . . . . . . . . . . . . .23
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . .23,25
Distance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Engine Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . . .24
Engine Controller-60 Way Connector . . . . .20,21,22,23,24,25
Exhaust Gas Recirculation Solenoid . . . . . . . . . . . . . . . .21
Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . .20
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . .20
Electronic Fuel Injection Ignition System w/o Elect
Transaxle (3.0L Engine) . . . . . . . . . .26,27,28,29,30,31,32
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . .29
Distance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Engine Controller-60 Way Connector . . .26,27,28,29,30,31,32
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Electronic Fuel Injection Ignition System w/ Elect Transaxle
(3.0L Engine) . . . . . . . . . . . . . . . . . .33,34,35,36,37,38,39
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Distance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .34,39
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . .34,39
Electronic Fuel Injection Ignition System
(3.3L Engine) . . . . . . . . . . . . .40, 41, 42, 43, 44, 45, 46
Cam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Crank Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Direct Ignition System Coil Pack . . . . . . . . . . . . . . . . . .43
Distance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43,44
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Temperature Sending Unit . . . . . . . . . . . . . . . . . . . . . .43
Electronic Transaxle System . . . . . . . . . . . . . . . .79,80,81,82
Back-Up Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . .59
Control Module . . . . . . . . . . . . . . . . . . . .59,79,80,81,82
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . .81
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . .82
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
PRNDL Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Safety Shutdown Mini Relay . . . . . . . . . . . . . . . . . . . .80
Transaxle Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . .79
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .82
Electronic Vehicle Information Center w/ Electronic
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
w/o Electronic Transaxle . . . . . . . . . . . . . . . . . . . . . . .60
Engine Controller 60 Way Connector . . . .20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 31, 32, 33,
34, 35, 36, 37, 38, 39, 40, 41,
42, 43, 44, 45, 46, 49, 59, 60,
149, 150, 151, 152,
4 Speaker Stereo Radio . . . . . . . . . . . . . . . . . . . . .88,89,90
Flasher - Combo . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . .53,54,55,56
Front Door Ajar Switches . . . . . . . . . . . . . . . . . . . . . . . .74
Front Door Courtesy Lamps . . . . . . . . . . . . . . . . . . . .67,68
Front End Lighting . . . . . . . . . . . . . . . . . . . . . . . . . .53,54
Front End Lighting w/Daytime Running Lights . . . . . . . . .55,56
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Fuel Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Fuel Tank Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . .70
Fuse Application Chart . . . . . . . . . . . . . . . . . . . . . . .1,2,3,4
Fuse Block Module . . . . . . . . . . . . . . . . . . . . . . . .141,142
Fuses
Fuse 1 . . . . . . . . . . . . . . . . . . . . . .1,5,8,11,15,17,19,61
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,118,128
Fuse 3 . . . . . . . . . . . . . . . . . . .1,64,85,88,91,117,119,125
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,14,76
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,85,88,91
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,61
Fuse 8 . . . . . . . . . .2,14,16,18,97,101,105,109,114,117,135
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . .4,85,88,91,138
Fuse 13 . . . . . . . . . . . . . . . . . . . . .2,5,8,11,14,21,95,131
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . .2,5,8,11,14,21,50
Fuse 15 . . . . . . . . . . . . . . . . . . . . .2,5,8,11,14,21,73,135
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . .3,54,56,62,138
Fuse 18 . . . . . . . . . . . . . . . . . . . . . .3,54,56,57,113,138
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3,49,123
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . .3,113,115,123
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,113
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4,62
Fuse 23 . . . . . . . . . . . . . . . . . .4,5,8,11,25,59,60,71,85,91
Fuse 26 . . . . . . . . . . . . . . . . . . .2,14,96,100,104,108,112
Fusible Links . . . . . . . . . . . . . . . . . . . .1,2,3,4,5,7,10,11,13
Glove Box Lamp and Switch . . . . . . . . . . . . . . . . . . . . . .64
Ground Straps . . . . . . . . . . . . . . . . . . . . . . . . . . .85,88,91
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Headlamp Dimmer Switch (Optical Horn) . . . . . . . . . . . . . .62
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .61,62
Headlamp Switch Connector . . . . . . . . . . . . .61,169,170,171
Heated Oxygen Sensor 2.5L Engine . . . . . . . . . . . . . . . . .20
Heated Oxygen Sensor 3.0L Engine . . . . . . . . . . . . . . .27,34
Heated Oxygen Sensor 3.3L Engine . . . . . . . . . . . . . . . . .46
Heated Rear Window Defogger System . . . . . . . . . . .117,118
Heater System 2.5L,3.0L and 3.3L Engine . . . . . . . . . . . . .96
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Blower Slide Control . . . . . . . . . . . . . . . . . . . . . . . . .96
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . .96
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
High Beam Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . .73
Horn System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Horn (Hi Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Horn (Lo Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Ignition Coil 2.5L Engine . . . . . . . . . . . . . . . . . . . . . . . .22
Ignition Coil 3.0L Engine . . . . . . . . . . . . . . . . . . . . . .29,36
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Illuminated Entry System . . . . . . . . . . . . . . . . . . . . . . .139
Instrument Panel Illumination Lamps . . . . . . . . . . . . . . . .85
Instrument Panel to Body Wiring . . . .155, 156, 157, 158, 159,
160, 163, 164, 165, 166
Intermittent Wiper System . . . . . . . . . . . . . . . . . . . . .75,76
Intermittent Windshield Wiper Motor . . . . . . . . . . . . . . .76
Intermittent Wiper Switch . . . . . . . . . . . . . . . . . . . . . .75
Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Windshield Washer Low Fluid Level Sensor . . . . . . . . . . .75
Windshield Washer Pump Motor . . . . . . . . . . . . . . . . .75
I.O.D. Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . .51,52
Key-In, Seatbelt Warning, Headlamp On Chime
w/Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Lamps
Airbag Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . .73
Anti-lock (Yellow) Warning Lamp . . . . . . . . . . . . . . . . .73
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .63
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . . .129,130
Brake Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . .73
Center High Mounted Stop Lamp . . . . . . . . . . . . . . . .140
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .63
Front Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Front Door Courtesy Lamps . . . . . . . . . . . . . . . . . . .67,68
Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
High Beam Indicator Lamp . . . . . . . . . . . . . . . . . . . . .73
Instrument Panel Illumination Lamps . . . . . . . . . . . . . . .84
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .54,56
Left Header Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . .54,56
Left Liftgate Courtesy Lamp . . . . . . . . . . . . . . . . . . . .69
Left Park and Turn Signal Lamp . . . . . . . . . . . . . . . .54,56
Left Tail, Stop, Turn & Side Marker Lamp . . . . . . . . . . .129
Left Turn Signal Indicator Lamp . . . . . . . . . . . . . . . . . .73
License Lamps . . . . . . . . . . . . . . . . . . . . . . . . .129,130
Maintenance Required Lamp . . . . . . . . . . . . . . . . . . . .73
Rear Dome and Cargo Lamp . . . . . . . . . . . . . . . . . . . .68
Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .53,55
Right Front Door Courtesy Lamp . . . . . . . . . . . . . . . . .68
Right Header Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .68
Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . .53,55
Right Liftgate Courtesy Lamp . . . . . . . . . . . . . . . . . . . .69
Right Park and Turn Signal Lamp . . . . . . . . . . . . . . .53,55
Right Pod Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Right Tail, Stop, Turn & Side Marker Lamp . . . . . . . . . .129
Right Turn Signal Indicator Lamp . . . . . . . . . . . . . . . . .73
Seat Belt (Timed On) . . . . . . . . . . . . . . . . . . . . . . . . .73
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . .51,52
Underseat Storage Lamp . . . . . . . . . . . . . . . . . . . . . .69
Vanity Mirror Lamps . . . . . . . . . . . . . . . . . . . . . . .67,69
Left Sill to Body Wiring . . . . . . . . . . . . . . . . . . . . . . . .161
Liftgate Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . .69
Liftgate Latch Switch . . . . . . . . . . . . . . . . . . . . . . . . . .69
Liftgate Release Solenoid . . . . . . . . . . . . . . . . . . . . . . .119
Liftgate Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Liftgate Wiper and Washer System . . . . . . . . . . . . . . . .77,78
Integral Wiper Park Switch . . . . . . . . . . . . . . . . . . . . .78
Liftgate Washer Motor . . . . . . . . . . . . . . . . . . . . . . . .78
Liftgate Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . .78
Rear Wash-Wiper Module . . . . . . . . . . . . . . . . . . . . . .77
Rear Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . .77
Right Pod Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Lo Beam Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Map Sensor 2.5L Engine . . . . . . . . . . . . . . . . . . . . . . . .21
Map Sensor 3.0L Engine . . . . . . . . . . . . . . . . . . . . . .30,30
Map Sensor 3.3L Engine . . . . . . . . . . . . . . . . . . . . . . . .46
Mechanical Cluster Printed Circuit Board . . . . . . . . . . . . . .84
Modules
Airbag System Diagnostic Module . . . . . . . . . . . . . . . .135
ABS Electronic Module . . . . . . . . . . . . . . . . .132,133,134
Daytime Running Light Module . . . . . . . . . . . . . . . . . .57
Electronic Automatic Transaxle Control Module . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59,79,80,81,82
Fog Lamp Switch Module . . . . . . . . . . . . . . . . . . . . .113
Fuse Block Module . . . . . . . . . . . . . . . . . . . . . . .141,142
Rear Wash-Wiper Module . . . . . . . . . . . . . . . . . . . . . .77
Motors
A/C Blower Motor . . . . . . . . . . . . . . .100,104,108,112,114
A/C Fan Motor . . . . . . . . . . . . . . . . . . . . .98,102,106,110
ABS Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . .132
Fuel Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Heater Blower Motor . . . . . . . . . . . . . . . . . . .96,100,114
Intermittent Windshield Wiper Motor . . . . . . . . . . . . . . .76
Left Front Door Lock Motor . . . . . . . . . . . . . . . . . . . .125
Left Power Vent Motor . . . . . . . . . . . . . . . . . . . . . . .120
Liftgate Washer Motor . . . . . . . . . . . . . . . . . . . . . . . .78
Liftgate Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . .78
Mode Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . .114
Power Seat Motor . . . . . . . . . . . . . . . . . . . . . . . . . .124
Power Window Motors . . . . . . . . . . . . . . . . . . . .121,122
Radiator Fan Motor . . . . . . . . . . . . . . . .95,99,103,107,111
Right Front Door Lock Motor . . . . . . . . . . . . . . . . . . .125
Right Power Vent Motor . . . . . . . . . . . . . . . . . . . . . .120
Sliding Side Door Lock Motor . . . . . . . . . . . . . . . . . .126
Starter (2.5L Engine) Motor . . . . . . . . . . . . . . . . . . . . .15
Starter (3.0L Engine) Motor . . . . . . . . . . . . . . . . . . . . .17
Starter (3.0 & 3.3L Engine) Motor . . . . . . . . . . . . . . . .19
Windshield Washer Pump Motor . . . . . . . . . . . . . . . . .75
Multi-Function Switch Connector . . . . . . . . . . . . . . . . . .167
Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . . . . .85
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . .81
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . .16,18
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . .47,48
Oil Pressure and Temp System w/Electronic Transaxle
(3.0L & 3.3L Eng) . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Oil Pressure and Temp System w/o Electronic Transaxle
(2.5L & 3.0L Eng) . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Optical Horn (Headlamp Dimmer) Switch . . . . . . . . . . . . . .62
Overhead Console Lamp . . . . . . . . . . . . . . . . . . . . . .65,66
Overhead Console Connector . . . . . . . . . . . . . . . .65,120,179
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Park Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Part Throttle Unlock . . . . . . . . . . . . . . . . . . . . . . . . .16,18
Power Rear Quarter Window . . . . . . . . . . . . . . . . . . . . .120
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Power Remote Mirrors . . . . . . . . . . . . . . . . . . . . . .127,128
Left Heated Mirror . . . . . . . . . . . . . . . . . . . . . . . . . .127
Left Power Mirror . . . . . . . . . . . . . . . . . . . . . . . . . .127
Mirror Control Switch . . . . . . . . . . . . . . . . . . . . . . . .127
Right Heated Mirror . . . . . . . . . . . . . . . . . . . . . . . . .128
Right Power Mirror . . . . . . . . . . . . . . . . . . . . . . . . .128
Power Seat System . . . . . . . . . . . . . . . . . . . . . . . .123,124
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Front Vertical Motor . . . . . . . . . . . . . . . . . . . . . . . . .124
Horizontal Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Rear Vertical Motor . . . . . . . . . . . . . . . . . . . . . . . . .124
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Power Window Lift System . . . . . . . . . . . . . . . . . . .121,122
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Left Door Master Window Lift Switch . . . . . . . . . . . . . .121
Left Front Door Window Lift Motor . . . . . . . . . . . . . . .121
Left Front Door Window Lift Switch . . . . . . . . . . . . . . .121
Right Door Window Lift Switch . . . . . . . . . . . . . . . . .122
Right Front Door Window Lift Motor . . . . . . . . . . . . . .122
Printed Circuit Board Connector . . . . . . . . . . . . . . . . . . . .83
Purge Solenoid 2.5L Engine . . . . . . . . . . . . . . . . . . . . . .21
Purge Solenoid 3.0L Engine . . . . . . . . . . . . . . . . . . . .27,34
Purge Solenoid 3.3L Engine . . . . . . . . . . . . . . . . . . . . . .40
Radiator Fan Motor . . . . . . . . . . . . . . . . . . .95,103,107,111
Radiator Fan Relay . . . . . . . . . . . . . . . . .95,98,102,106,110
Radiator Fan System w/Heater . . . . . . . . . . . . . . . . . . . .95
Radio - Electronically Tuned . . . . . . . . . . . . . . . . . .85,86,87
Left Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .86
Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . . . .85
Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Right Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .86
Right Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .86
Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Radio - 4 Speaker Stereo (w/o NBS) . . . . . . . . . . . . .88,89,90
Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Radio - 6 Speaker Stereo . . . . . . . . . . . . . . . . . . . .91,92,93
Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . . . .91
Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Right Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .92
Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Radio with Clock . . . . . . . . . . . . . . . . . . . . . . . . . . .85,91
Rear Heater and A/C System . . . . . . . . . . . . . . . . . .113,114
A/C or Fog Lamp Relay . . . . . . . . . . . . . . . . . . . .113,115
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . .114,116
Front Control Switch . . . . . . . . . . . . . . . . . . . . .113,115
Heater A/C Assembly . . . . . . . . . . . . . . . . . . . . . . . .114
Lamp-Switch Illumination Front . . . . . . . . . . . . . . . . .114
Lamp-Switch Illumination Rear . . . . . . . . . . . . . . . . . .114
Microtemp Sensor . . . . . . . . . . . . . . . . . . . . . . .114,116
Mode Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . .114
Mode Slide Switch . . . . . . . . . . . . . . . . . . . . . . . . .114
Rear Blower Slide Switch . . . . . . . . . . . . . . . . . . .114,116
Rear Heater-ONLY . . . . . . . . . . . . . . . . . . . . . . . . .115,116
Rear Lighting and Trailer Tow . . . . . . . . . . . . . . . . .129,130
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . . .129
Left License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .129
Left Tail, Stop, Turn & Side Marker Lamp . . . . . . . . . . .129
Right Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . .130
Right License Lamp . . . . . . . . . . . . . . . . . . . . . . . . .130
Right Tail, Stop, Turn & Side Marker Lamp . . . . . . . . . .130
Rear Window Defogger . . . . . . . . . . . . . . . . . . . . .117,118
Heater Rear Window Switch . . . . . . . . . . . . . . . . . . . .117
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Rear Wiper Switch Connector . . . . . . . . . . . . . . . . . . . .168
Relays
ABS Pump Motor Relay . . . . . . . . . . . . . . . . . . . . . .132
ABS Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . .132,133
A/C Clutch Relay . . . . . . . . . . . . . . . . . . .98,102,106,110
A/C Fan Relay . . . . . . . . . . . . . . . . . . . . .97,101,105,109
Automatic Shutdown Relay . . . . . . . . . . . . . . .23,29,36,41
Back-Up Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . .59
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Low Beam Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . .85,91
Park Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Power Door Lock Relay . . . . . . . . . . . . . . . . . . . . . .126
Power Door Unlock Relay . . . . . . . . . . . . . . . . . . . . .126
Radiator Fan Relay . . . . . . . . . . . . . . . .95,98,102,106,111
Rear A/C and Fog Lights Relay . . . . . . . . . . . . . . .113,115
Safety Shutdown Mini-Relay . . . . . . . . . . . . . . . . . . . .80
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . .15,17,19
Van Conversion Relay . . . . . . . . . . . . . . . . . . . . . . . .131
Relay Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Seat Belt Warning System . . . . . . . . . . . . . . . . . . . . . . .71
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Sensors
A/C Ambient Temperature Sensor . . . . . . . . . . .101,105,109
Cam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Crank Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Distance Sensor (2.5L Eng) . . . . . . . . . . . . . . . . . . . . .24
Distance Sensor (3.0L Eng) . . . . . . . . . . . . . . . . . . .32,38
Distance Sensor (3.3L Eng) . . . . . . . . . . . . . . . . . . . . .42
Engine Coolant Sensor (2.5L Eng) . . . . . . . . . . . . . . . .24
Engine Coolant Sensor (3.0L Eng) . . . . . . . . . . . . . . .31,37
Engine Coolant Sensor (3.3L Eng) . . . . . . . . . . . . . . . .43
Heated Oxygen Sensor (2.5L Eng) . . . . . . . . . . . . . . . .20
Heated Oxygen Sensor (3.0L Eng) . . . . . . . . . . . . . . .27,34
Heated Oxygen Sensor (3.3L Eng) . . . . . . . . . . . . . . . .46
Left Airbag Sensor . . . . . . . . . . . . . . . . . . . . . . . . .136
Left Front Wheel Speed Sensor . . . . . . . . . . . . . . . . .133
Left Rear Wheel Speed Sensor . . . . . . . . . . . . . . . . . .134
Low Windshield Washer Fluid Level Sensor . . . . . . . . . . .75
MAP Sensor (2.5L Eng) . . . . . . . . . . . . . . . . . . . . . . .21
MAP Sensor (3.0L Eng) . . . . . . . . . . . . . . . . . . . . .30,39
MAP Sensor (3.3L Eng) . . . . . . . . . . . . . . . . . . . . . . .46
Micro Temp Sensor . . . . . . . . . . . . . . . . . . . . . .114,116
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . .82
Right Airbag Sensor . . . . . . . . . . . . . . . . . . . . . . . . .136
Right Front Wheel Speed Sensor . . . . . . . . . . . . . . . . .133
Right Rear Wheel Speed Sensor . . . . . . . . . . . . . . . . .134
Throttle Position Sensor (2.5L Eng) . . . . . . . . . . . . . . . .20
Throttle Position Sensor (3.0L Eng) . . . . . . . . . . . . . .30,39
Throttle Position Sensor (3.3L Eng) . . . . . . . . . . . . . . . .45
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .82
Solenoids
Exhaust Gas Recirculation 2.5L Engine . . . . . . . . . . . . . .21
Liftgate Release Solenoid . . . . . . . . . . . . . . . . . . . . .119
Part Throttle Unlock Solenoid . . . . . . . . . . . . . . . . .16,18
Purge Solenoid (2.5L Eng) . . . . . . . . . . . . . . . . . . . . .21
Purge Solenoid (3.0L Eng) . . . . . . . . . . . . . . . . . . .27,34
Purge Solenoid (3.3L Eng) . . . . . . . . . . . . . . . . . . . . .40
Vacuum Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . .79
Speed Control and Stop Lamp Switch . . . . . . . . . . . . . .49,50
Speed Control Servo . . . . . . . . . . . . . . . . . . . . . . . . .50
Speed Control Switch . . . . . . . . . . . . . . . . . . . . . . . .50
Splices
Splice A0 . . . . . . . . . . . . . . . . . . . . . . . .1,2,3,4,7,10,13
Splice A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Splice A1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . .26,33,43
Splice A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58,123
Splice A3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117,119
Splice A4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51,52
Splice A4-2 . . . . . . . . . . . . . . . . . . . . . . . .7,10,13,51,52
Splice A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5,8,11
Splice A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,13
Splice A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A14 . . . . . . . . . . . . . . . . . . . . . . . . .23,29,36,41
Splice A14-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A15 . . . . . . . . . . . . . . . . . . . . . . .5,8,11,15,17,19
Splice A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,10,13
Splice A16-1 . . . . . . . . . . . . . . . . . . . .95,98,102,106,110
Splice A18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Splice A20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,13
Splice A21 . . . . . . . . . . . . . . . . . . . . . . .21,28,35,40,81
Splice A21-1 . . . . . . . . . . . . . . . .5,11,21,28,35,40,95,132
Splice A21-2 . . . . . . . . . . . . . . . . . . . . . .21,29,36,40,95
Splice A21-3 . . . . . . . . . . . . . . . . . .5,8,11,14,21,40,73,95
Splice A22 . . . . . . . . . . . . . . . .14,16,97,101,105,109,117
Splice A31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Splice A141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25,70
Splice B47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Splice C7 . . . . . . . . . . . . . . . . . . . . .96,100,104,108,112
Splice C15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Splice C20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Splice C23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Splice D1 . . . . . . . . . . . . . . . . . . . . . . . . . .25,59,60,66
Splice D1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Splice D2 . . . . . . . . . . . . . . . . . . . . . . . . . .25,59,60,66
Splice D2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Splice E2 . . . . . . . . . . . . . . . . . . . . . . . .63,85,88,91,117
Splice E2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Splice F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16,97
Splice F20-1 . . . . . . . . . .16,18,97,101,105,109,113,117,135
Splice F21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Splice F21-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .65,121
Splice F21-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Splice F35 . . . . . . . . . . . . . . . . . . . . . . . . . . . .123,126
Splice F62 . . . . . . . . . . . . . . . . . . . . . .25,59,60,71,85,91
Splice G5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73,135
Splice G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47,48
Splice G7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .24,31,37
Splice G9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Splice G9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Splice G19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Splice K4 . . . . . . . . . . . . . . . . . . . . . . . . . .24,27,34,45
Splice K4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Splice K4-2 . . . . . . . . . . . . . . . . . . . . . . . . .24,31,37,42
Splice K4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . .32,38,42
Splice K4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Splice K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .30,39,45
Splice K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Splice K6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Splice K22 . . . . . . . . . . . . . . . . . . . . . . . . . . .39,45,82
Splice K24 . . . . . . . . . . . . . . . . . . . . . . . . . . .37,42,81
Splice L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Splice L1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Splice L2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Splice L3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .53,55,57
Splice L7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85,88
Splice L7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Splice L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Splice L39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54,56
Splice L44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55,57
Splice L44-1 . . . . . . . . . . . . . . . . . . . . . . .53,55,57,113
Splice L50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Splice L60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Splice L61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Splice L94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Splice M1 . . . . . . . . . . . . . . . . . . . . . . .64,85,88,91,125
Splice M1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .125,128
Splice M1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65,68
Splice M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67,72
Splice M2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65,67
Splice M2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Splice M2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Splice M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Splice M11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Splice M11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Splice P33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Splice P33-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Splice P34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Splice P34-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Splice T13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Splice T16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Splice T41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Splice V3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Splice V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Splice V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Splice V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Splice V23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Splice V23-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Splice V23-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Splice X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Splice X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86,92
Splice X13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .86,92
Splice X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86,92
Splice X15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .86,92
Splice X53-1 . . . . . . . . . . . . . . . . . . . . . . . . . .86,89,92
Splice X54-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .86,92
Splice X55 . . . . . . . . . . . . . . . . . . . . . . . . . . .86,89,92
Splice X56 . . . . . . . . . . . . . . . . . . . . . . . . . . .86,89,92
Splice Z0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Splice Z1 . . . . . . . . . . . . . . . . . . . .5,9,12,95,99,103,107
Splice Z1-1 . . . . . . . . . . . . . . . . . . . . . . .58,113,115,126
Splice Z1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .128,139
Splice Z1-3 . . . . . . . . . . . . . . . . . . . . . .53,55,57,58,111
Splice Z1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54,56
Splice Z1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58,71
Splice Z1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54,56
Splice Z1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . .130,132
Splice Z1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Splice Z1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Splice Z1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Splice Z1-11 . . . . . . . . . . . . . . . . . . . . . . .65,72,122,123
Splice Z1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . .129,140
Splice Z1-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Splice Z1-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Splice Z2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Splice Z3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64,77
Splice Z11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Splice Z11-1 . . . . . . . . . . . . . . . . . . . . . . . . . .28,35,40
Splice Z12 . . . . . . . . . . . . . . . . . . . . . . . .22,28,36,41,80
Splice Z13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Splice Z13-1 . . . . . . . . . . . . . . . . . . . . . . . . . .28,40,80
Splice Z14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Squib (Airbag Igniter) . . . . . . . . . . . . . . . . . . . . . . . . .135
Starter System (2.5L TBI Engine) . . . . . . . . . . . . . . . . .15,16
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Neutral Start/Back-Up Lamp Switch . . . . . . . . . . . . . . . .16
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Starter System (3.0L Engine) . . . . . . . . . . . . . . . . . . .17,18
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Neutral Start/Back-Up Lamp Switch . . . . . . . . . . . . . . . .18
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Starter System (3.0L & 3.3L Eng w/Elect Trans) . . . . . . . . .19
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Stop Lamp/Speed Control Switch . . . . . . . . . . . . . . . . . . .49
Stop/Turn and Hazard Flasher Systems . . . . . . . . . . . . . . .94
Switches
A/C and Heater Vacuum Switch . . . . . . . . .100,104,108,112
A/C Cycling Clutch . . . . . . . . . . . . . . . . . . . . . . . . . .91
A/C Fan Cut-Out Switch . . . . . . . . .97,101,103,105,107,109
A/C/Heater Front Control Switch . . . . . . . . . . . . . .113,115
A/C High Pressure Clutch Cut-Out Switch
(2.5L Engine) . . . . . . . . . . . . . . . . . . . . . . . . .97,99
(3.0L Engine) . . . . . . . . . . . . . . . . . . . . .101, 103, 105
(3.3L Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . .109
A/C Low Pressure Cut-Out Switch . . . . . . . .97,101,105,109
A/C Mode Slide Switch . . . . . . . . . . . . . . . . . . . . . . .114
Ambient-Overhead Console . . . . . . . . . . . . . . . . . . . . .66
Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . . . . .16,18
Blower Slide Control Switch . . . . . . . . .96,100,104,108,112
Brake Warning Lamp Switch . . . . . . . . . . . . . . . . . . . .14
Clutch Interlock Switch . . . . . . . . . . . . . . . . . . . . . . .14
Dimmer Slider Switch . . . . . . . . . . . . . . . . . . . . . . . .61
Defrost Switch . . . . . . . . . . . . . . . . . . . .100,104,108,112
EBL Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Fog Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . .113
Front Left Door Ajar Switch . . . . . . . . . . . . . . . . . . . . .74
Front Right Door Ajar Switch . . . . . . . . . . . . . . . . . . . .74
Glove Box Lamp Switch . . . . . . . . . . . . . . . . . . . . . . .64
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Headlamp Dimmer Switch . . . . . . . . . . . . . . . . . . . . . .62
Heated Rear Window Defogger Switch . . . . . . . . . . . . .117
Heater Blower Control Switch . . . . . . . . . . . . . . . . . . .96
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Intermittent Wiper Switch . . . . . . . . . . . . . . . . . . . . . .75
Left Door Master Window Lift Switch . . . . . . . . . . . . . .121
Left Front Door Lock Switch . . . . . . . . . . . . . . . . . . .125
Left Front Door Illuminated Entry Switch . . . . . . . . . . . .139
Left Front Door J am Switch . . . . . . . . . . . . . . . . . . .67,72
Left Header Lamp Switch . . . . . . . . . . . . . . . . . . . . . .68
Left Vent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Liftgate Latch Switch . . . . . . . . . . . . . . . . . . . . . . . . .69
Liftgate Release Switch . . . . . . . . . . . . . . . . . . . . . . .119
Lo Beam Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Low Fuel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Master Window Lift Switch . . . . . . . . . . . . . . . . . . . .121
Mirror Control Switch . . . . . . . . . . . . . . . . . . . . . . . .127
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . .81
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . .16,18
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . .47,48
Optical Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . .62
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Park Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Power Seat Switches . . . . . . . . . . . . . . . . . . . . . . . .124
PRNDL Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Rear Blower Slide Switch . . . . . . . . . . . . . . . . . . .114,116
Rear Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . .77
Right Door Window Lift Switch . . . . . . . . . . . . . . . . .122
Right Front Door Lock Switch . . . . . . . . . . . . . . . . . .125
Right Front Door Illuminated Entry Switch . . . . . . . . . . .139
Right Front Door J am Switch . . . . . . . . . . . . . . . . . . . .72
Right Header Lamp Switch . . . . . . . . . . . . . . . . . . . . .68
Right Vent Switch . . . . . . . . . . . . . . . . . . . . . . . . . .120
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Sliding Door Ajar Switch . . . . . . . . . . . . . . . . . . . . . . .74
Sliding Side Door Switch . . . . . . . . . . . . . . . . . . . . . .67
Speed Control Switch . . . . . . . . . . . . . . . . . . . . . . . .50
Stop Lamp/Speed Control Switch . . . . . . . . . . . . . . . . .49
Transaxle Solenoids & Pressure Switch . . . . . . . . . . . . .79
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . .94
Underseat Storage Lamp Switch . . . . . . . . . . . . . . . . . .69
Vanity Mirror Lamp On Switch . . . . . . . . . . . . . . . . . . .69
Windshield Wiper-Intermittent Switch . . . . . . . . . . . . . .75
Wiper Park Switch . . . . . . . . . . . . . . . . . . . . . . . .76,78
Temperature Sending Unit . . . . . . . . . . . . . . . . . . .43,47,48
Throttle Position Sensor (2.5L Eng) . . . . . . . . . . . . . . . . .20
Throttle Position Sensor (3.0L Eng) . . . . . . . . . . . . . . .30,39
Throttle Position Sensor (3.3L Eng) . . . . . . . . . . . . . . . . .45
Transaxle Solenoid Connector . . . . . . . . . . . . . . . . . . . .175
Transaxle Solenoids & Pressure Switch . . . . . . . . . . . . . . .79
Underhood Lamp w/Electronic Transaxle . . . . . . . . . . . . . .51
Underhood Lamp w/o Electronic Transaxle . . . . . . . . . . . . .52
Vacuum Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Van Conversion Relay . . . . . . . . . . . . . . . . . . . . . . . . .131
Van Conversion Wiring . . . . . . . . . . . . . . . . . . . . . . . .131
Warning Lamp Center . . . . . . . . . . . . . . . . . . . . . . . . . .73
Warning Lamp Center Connector . . . . . .14, 21, 28, 35, 41, 57,
62, 64, 94, 132, 136, 174
Warning Lamp System . . . . . . . . . . . . . . . . . . . . . . . . .74
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . . . .133,134
Wiper - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . .75,76
Low Washer Fluid Level Sensor . . . . . . . . . . . . . . . . . .75
Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . .75
Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
1992 Van/Wagon FWD/AWD
Pulication No. 81-370-2105
TSB 08-16-93 April 16, 1993
Publication No. 81-270-2105
TSB 08-18-92 August 24, 1992
TSB 08-06-92 April 6, 1992
TSB 08-16-93 April 16, 1993
TSB 08-23-92 November 2, 1992
TSB 08-06-92 April 6, 1992
TSB 08-23-92 November 2, 1992
COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1
BATTERY/STARTER/ALTERNATOR SERVICE. . . . . . . . . . 8B-1
ALTERNATOR SERVICE PROCEDURES . . . . . . . . . . . 8B-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8B-10
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
BATTERY/STARTING/CHARGING SYSTEMS
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ALTERNATOR TEST PROCEDURES ON VEHICLE. . . . . 8-15
BATTERY TEST PROCEDURES ON-VEHICLE . . . . . . . . 8-2
FAULT CODESON BOARD DIAGNOSTICS . . . . . . . . 8-18
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . 8-1
IGNITION OFF DRAW (IOD) . . . . . . . . . . . . . . . . . . . 8-7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
STARTER TEST PROCEDURES ON VEHICLE . . . . . . . . 8-9
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
BODY COMPONENT SERVICE . . . . . . . . . . . . . . . . 23-20
BODY DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . 23-2
GENERAL SERVICE INFORMATION . . . . . . . . . . . . . 23-1
PAINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
SEAT COMPONENT SERVICE . . . . . . . . . . . . . . . . . 23-7
WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ANTI-LOCK BRAKE SYSTEM (BENDIX ANTI-LOCK
10 AS BODY FWD/AWD). . . . . . . . . . . . . . . . . . . 5-56
BRAKE DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . 5-15
BRAKE DISC (ROTOR). . . . . . . . . . . . . . . . . . . . . . 5-42
DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
HYDRAULIC SYSTEM CONTROL VALVES . . . . . . . . . 5-28
KELSEY HAYES DOUBLE PIN FAMILY CALIPER . . . . . 5-35
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 5-49
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5-46
POWER BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
SERVICE ADJ USTMENTS. . . . . . . . . . . . . . . . . . . . . 5-3
SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . 5-31
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . 5-54
WHEEL CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . 5-26
CHIME WARNING/REMINDER SYSTEM . . . . . . . . . . . . . 8-1
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ACCESSORY DRIVE BELTS. . . . . . . . . . . . . . . . . . . 7-23
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . . . 7-27
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
GROUP INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . 25-1
EVAPORATIVE EMISSION CONTROLS . . . . . . . . . . . 25-2
EXHAUST EMISSION CONTROLS . . . . . . . . . . . . . . 25-8
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
2.5L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
3.3L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
STANDARD SERVICE PROCEDURES . . . . . . . . . . . . . 9-1
EXHAUST SYSTEM AND INTAKE MANIFOLD. . . . . . . . . 11-1
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 11-1
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . 11-17
FRAME AND BUMPERS. . . . . . . . . . . . . . . . . . . . . . . 13-1
FRONT SUSPENSION AND DRIVE SHAFTS . . . . . . . . . . . 2-1
DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 2-2
FRONT SUSPENSION SERVICE PROCEDURES. . . . . . . 2-6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
2.5L SINGLE POINT FUEL INJ ECTIONGENERAL
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
2.5L SINGLE POINT FUEL INJ ECTIONSERVICE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 14-45
2.5L SINGLE POINT FUEL INJ ECTIONSYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
3.0L MULTI-POINT FUEL INJ ECTIONGENERAL
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 14-64
3.0L MULTI-POINT FUEL INJ ECTIONSERVICE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 14-75
3.0L MULTI-POINT FUEL INJ ECTIONSYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-52
3.3L MULTI-POINT FUEL INJ ECTIONGENERAL
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 14-93
3.3L MULTI-POINT FUEL INJ ECTIONSERVICE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 14-105
3.3L MULTI-POINT FUEL INJ ECTIONSYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-81
ACCELERATOR PEDAL AND THROTTLE CABLE . . . . 14-20
FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . . . . 14-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 14-113
HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . 24-1
AUXILIARY REAR HEATING OR
HEATING-AIR/CONDITIONING. . . . . . . . . . . . . . . 24-50
COMPONENT DIAGNOSIS. . . . . . . . . . . . . . . . . . . 24-38
COMPONENT SERVICE PROCEDURES . . . . . . . . . . 24-41
FIXED DISPLACEMENT COMPRESSOR AND COMPONENTS
DIAGNOSTIC PROCEDURES. . . . . . . . . . . . . . . . 24-13
HEATER AND A/C PERFORMANCE TESTS . . . . . . . . 24-19
REFRIGERANT SERVICE PROCEDURES . . . . . . . . . 24-22
VACUUM CONTROL SYSTEM DIAGNOSIS . . . . . . . . 24-18
VARIABLE COMPRESSOR AND COMPONENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 24-4
VARIABLE DISPLACEMENT COMPRESSOR SERVICE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 24-27
HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-1
IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 8D-1
2.5L AND 3.0L IGNITION SYSTEMSDIAGNOSTIC
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 8D-10
2.5L AND 3.0L IGNITION SYSTEMSSERVICE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 8D-13
2.5L AND 3.0L IGNITION SYSTEMSSYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-1
3.3L IGNITION SYSTEMDIAGNOSTIC
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 8D-32
3.3L IGNITION SYSTEMSYSTEM OPERATION. . . . 8D-25
3.3L IGNITION SYSTEMSSERVICE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 8D-35
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 8D-40
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8D-42
INSTRUMENT PANEL AND GAUGES. . . . . . . . . . . . . . . 8E-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1
LAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-1
BULB APPLICATION TABLE. . . . . . . . . . . . . . . . . . 8L-11
EXTERIOR LAMPS, SWITCHES AND SYSTEMS . . . . . 8L-2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . 8L-1
ILLUMINATED ENTRY SYSTEM. . . . . . . . . . . . . . . . 8L-9
LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . 0-1
CHASSIS AND BODY. . . . . . . . . . . . . . . . . . . . . . . 0-19
DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
MANUAL TRANSAXLE CLUTCH. . . . . . . . . . . . . . . . . . . 6-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . 8C-1
POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-1
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . . . 8S-1
REAR SUSPENSION AND DRIVELINE. . . . . . . . . . . . . . . 3-1
ALL WHEEL DRIVE REAR SUSPENSION. . . . . . . . . . . 3-5
REAR DRIVE LINE MODULE ASSEMBLY
(ALL WHEEL DRIVE) . . . . . . . . . . . . . . . . . . . . . . 3-9
REAR DRIVE LINE MODULE ASSEMBLY SERVICE
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
REAR DRIVE LINE MODULE VACUUM ACTUATION
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
TWO WHEEL DRIVE REAR SUSPENSION . . . . . . . . . . 3-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . . . . . . . . . 8N-1
RESTRAINT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8M-1
SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-1
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
ACUSTAR STANDARD AND TILT STEERING
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-28
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . . 19-20
POWER STEERING PUMPS . . . . . . . . . . . . . . . . . . 19-2
SPECIFICATIONS AND TIGHTENING REFERENCE . . . 19-35
TRANSAXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-141
4 SPEED ELECTRONIC TRANSAXLE HYDRAULIC
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 21-184
4-SPEED ELECTRONIC AUTOMATIC TRANSAXLE . . . 21-82
4-SPEED ELECTRONIC TRANSAXLE ON-BOARD
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 21-157
A-523 MANUAL TRANSAXLE . . . . . . . . . . . . . . . . . 21-1
ALL WHEEL DRIVE POWER TRANSFER UNIT
(P.T.U.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-141
THREE SPEED TRANSAXLE HYDRAULIC
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 21-197
THREE SPEED TORQUEFLITE AUTOMATIC
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
TURN SIGNALS AND HAZARD WARNING FLASHER . . . . 8J -1
WHEELS TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TIRE SERVICE PROCEDURES . . . . . . . . . . . . . . . . . 22-1
WHEEL SERVICE PROCEDURES . . . . . . . . . . . . . . . 22-6
WINDSHIELD WIPER AND WASHER SYSTEMS . . . . . . . 8K-1
INTERMITTENT WINDSHIELD WIPER MOTOR AND
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-7
REAR WINDOW WIPER/WASHER SYSTEM . . . . . . . 8K-10
WINDSHIELD WASHERS . . . . . . . . . . . . . . . . . . . . 8K-9
WINDSHIELD WIPER BLADE AND ARM . . . . . . . . . . 8K-1
WINDSHIELD WIPER MOTOR AND LINKAGE. . . . . . . 8K-4
WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
COMPONENT IDENTIFICATION. . . . . . . . . . . . . . . 8W-11
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 8W-1
SPLICE LOCATION. . . . . . . . . . . . . . . . . . . . . . . 8W-33
WIRING DIAGRAMS AS-BODY H-K. . . . . . . . . . . . 8W-47
INTRODUCTION
CONTENTS
page page
BODY CODE PLATE LOCATION AND DECODING
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 3
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 5
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6
METRIC THREAD AND GRADE
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . . 4
VEHICLE FAMILY IDENTIFICATION . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . 1
VEHICLE FAMILY IDENTIFICATION
Throughout thi s servi ce manual references are made
to Vehi cl e Fami l y, Body Codes. The l etters AS i s a body
code that i s assi gned to a i ndi vi dual vehi cl e fami l y (Fi g.
1). Al so di gi t boxes 16 and 17 on the Body Code Pl ate
i ndi cate the Vehi cl e fami l y.
VEHICLE IDENTIFICATION NUMBER
The Vehi cl e I denti fi cati on Number (VI N) i s l ocated
on the upper l eft corner of the i nstrument panel , near
the l eft wi ndshi el d pi l l ar. The VI N consi sts of 17
characters i n a combi nati on of l etters and numbers
that provi de speci fi c i nformati on about the vehi cl e
(Fi g. 2). Refer to Vehi cl e I denti fi cati on Number Decod-
i ng Chart.
VEHICLE SAFETY CERTIFICATION LABEL
A vehi cl e safety certi fi cati on l abel (Fi g. 3) i s attached
to the rear faci ng of the dri vers door. Thi s l abel
i ndi cates date of manufacture (month and year), Gross
Vehi cl e Wei ght Rati ng (GVWR), Gross Axl e Wei ght
Rati ng (GAWR) front, Gross Axl e Wei ght Rati ng
(GAWR) rear and the Vehi cl e I denti fi cati on Number
(VI N). The Month, Day and Hour of manufacture i s
al so i ncl uded.
Al l communi cati ons or i nqui ri es regardi ng the ve-
hi cl e shoul d i ncl ude the Month-Day-Hour and Vehi cl e
I denti fi cati on Number.
Fig. 1 Vehicle Family Identification
Fig. 2 Vehicle Identification Number (VIN Plate)
INTRODUCTION 1
Fig. 3 Vehicle Safety Certification Label
VEHI CLE I DENTI FI CATI ON NUMBER DECODI NG CHART
2 INTRODUCTION
BODY CODE PLATE LOCATION AND DECODING
INFORMATION
The Body Code Pl ate i s attached to the top of the
radi ator cl osure panel i n the engi ne compartment.
There are seven l i nes of i nformati on on the body code
pl ate. Li nes 4, 5, 6, and 7 are not used to defi ne servi ce
i nformati on. I nformati on reads from l eft to ri ght, start-
i ng wi th l i ne 3 i n the center of the pl ate to l i ne 1 at the
bottom of the pl ate.
BODY CODE PLATE LI NE 3
DIGIT BOXES 1 THROUGH 12Vehicle Order Number
DIGIT BOXES 13, 14, AND 15Vinyl Roof Code
DIGIT BOXES 16, 17, AND 18Vehicle Shell Car Line
ASY = Town & Country
ASK = 2x4-Caravan CV, Caravan, Caravan SE,
Grand Caravan SE,
Caravan LE, Grand Caravan LE
ASD = 4x4-Caravan CV, Caravan SE, Grand Cara-
van SE,
Caravan LE, Grand Caravan LE
ASH = 2x4-Voyager, Voyager SE, Grand Voyager SE,
Voyager LE, Grand Voyager LE
ASP = 4x4-Voyager SE, Grand Voyager SE, Voyager
LE, Grand Voyager LE
DIGIT BOX 19Price Class
E = Economy
H = Hi gh Li ne
L = Low Li ne
M = Maxi mum
P = Premi um
S = Speci al /Sport
X = Performance I mage
DIGIT BOXES 20 AND 21Body Type
12 = Van/Short Wheel Base
13 = Van/Long Wheel Base
52 = Wagon/Short Wheel Base
53 = Wagon/Long Wheel Base
DIGIT BOXES 22, 23, AND 24Paint Procedure
DIGIT BOXES 25 THROUGH 28Primary Paint
See Group 23, Body for col or codes
DIGIT BOXES 29 THROUGH 32Secondary Paint
DIGIT BOXES 33 THROUGH 36Interior Trim Code
DIGIT BOXES 37, 38, AND 39Engine Code
EDM = 2.5 L, 4 cyl i nder EFI GasAutomati c or
Manual Transaxl e
EFA = 3.0 L, V6 Gas (EFI )Automati c or Manual
Transaxl e
EGA = 3.3 L, V6 Gas (EFI )Automati c Transaxl e
DIGIT BOXES 40, 41, AND 42Transaxle Codes
DGM = A670 3-speed Automati c Transaxl e
DGC = A413 3-speed Automati c Transaxl e
DGB =A604 4-speed Std. Duty Automati c Transaxl e
DGL =A604 4-speed El ectroni c Automati c Transaxl e
BODY CODE PLATE
INTRODUCTION 3
DIGIT BOX 43Market Code
U = Uni ted States
C = Canada
B = I nternati onal
M = Mexi co
DIGIT BOXES 44 THROUGH 60Vehicle Identification
Number (VIN)
Refer to Vehi cl e I denti fi cati on Number (VI N) para-
graph for proper breakdown of VI N code.
I F TWO BODY CODE PLATES ARE REQUI RED
The l ast code shown on ei ther pl ate wi l l be fol l owed
by END. When two pl ates are requi red, the l ast code
space on the fi rst pl ate wi l l show CTD (for conti nued).
When a second pl ate i s requi red, the fi rst four spaces
of each l i ne wi l l not be used due to overl ap of the pl ates.
TORQUE REFERENCES
I ndi vi dual Torque Charts appear at the end of many
Groups. Refer to the Standard Torque Speci fi cati ons
and Bol t I denti fi cati on Chart i n thi s Group for torques
not l i sted i n the i ndi vi dual torque charts (Fi g. 4).
Torque speci fi cati ons on the Bol t Torque chart are
based on the use of cl ean and dry threads. Reduce the
torque by 10% when the threads are l ubri cated wi th
engi ne oi l and by 20% i f new pl ated bol ts are used.
Varioussizesof Torx headfastenersareusedto
securenumerouscomponentstoassemblies. Due
to ever changing usage of fasteners, Torx head
fasteners may not be identified in art or text.
STANDARD BODY DI MENSI ONS
Fig. 4 Grade 5 and 8 Standard Torque Specifica-
tions
4 INTRODUCTION
METRIC THREAD AND GRADE IDENTIFICATION
Metri c and SAE thread notati ons di ffer sl i ghtl y. The
di fference i s i l l ustrated i n Fi gure 5.
Common metri c fastener strength cl asses are 9.8 and
12.9 wi th the cl ass i denti fi cati on embossed on the head
of each bol t (Fi g. 6). Some metri c nuts wi l l be marked
wi th a si ngl e di gi t strength number on the nut face.
SAE strength cl asses range from grade 2 to 8 wi th
l i ne i denti fi cati on embossed on each bol t head. Mark-
i ngs correspondi ng to two l i nes l ess than the actual
grade (Fi g. 7). For Exampl e: Grade 7 bol t wi l l have 5
embossed l i nes on the bol t head.
INTERNATIONAL SYMBOLS
Some I nternati onal Symbol s are used to i denti fy
control s and di spl ays i n thi s vehi cl e. These symbol s are
appl i cabl e to those control s whi ch are di spl ayed on the
i nstrument panel or i n the i mmedi ate vi ci ni ty of the
dri ver (Fi g. 8).
Fig. 7 SAE Bolt Identification
Fig. 5 Thread Notation (Metric and SAE)
Fig. 6 Metric Bolt Identification
INTRODUCTION 5
METRIC SYSTEM
Fi gure art, speci fi cati ons, and ti ghteni ng references
i n thi s Servi ce Manual are i denti fi ed i n the metri c
system and i n the SAE system.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage metri c fasteners (nuts, bol ts, etc.)
for reassembl y. I f the fastener i s not sal vageabl e, a
fastener of equi val ent speci fi cati on shoul d be used.
WARNING: USE OF AN INCORRECT FASTENER MAY
RESULT IN COMPONENT DAMAGE OR PERSONAL
INJURY.
The metri c system i s based on quanti ti es of one, ten,
one hundred, one thousand, and one mi l l i on (Fi g. 9).
The fol l owi ng Tabl es wi l l assi st you i n conversi on
procedures.
Fig. 8 International Symbols
Fig. 9 Metric Prefixes
6 INTRODUCTION
CONVERSI ON TABLES
INTRODUCTION 7
CONVERSI ON TABLES
8 INTRODUCTION
CHRYSLER
CORPORATION
SERVICE MANUAL
1992 FRONT WHEEL DRIVE
ALL WHEEL DRIVE
VAN/WAGON
To order the speci al servi ce tool s used and
i l l ustrated, pl ease refer to the i nstructi ons on
i nsi de back cover.
NO PART OF THI S PUBLI CATI ON MAY BE
REPRODUCED, STORED I N A RETRI EVAL
SYSTEM, OR TRANSMI TTED, I N ANY FORM
OR BY ANY MEANS, ELECTRONI C, ME-
CHANI CAL, PHOTOCOPYI NG, RECORDI NG,
OR OTHERWI SE, WI THOUT THE PRI OR
WRI TTEN PERMI SSI ON OF CHRYSLER
CORPORATI ON.
Chrysler Corporation reserves the right to make changes in design or to make
additions to or improvements in its products without imposing any obligations
upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1991 Chrysler Corporation 20M0791
NEXT PAGE
FOREWORD
The i nformati on contai ned i n thi s servi ce manual has been prepared for the professi onal automoti ve techni ci an
i nvol ved i n dai l y repai r operati ons. Thi s manual does not cover theory of operati on, whi ch i s addressed i n servi ce
trai ni ng materi al .
Ti ghteni ng torques are provi ded as a speci fi c val ue throughout thi s manual . Thi s val ue represents the
mi dpoi nt of the acceptabl e engi neeri ng torque range for a gi ven fastener appl i cati on. These torque val ues are
i ntended for use i n servi ce assembl y and i nstal l ati on procedures usi ng the correct OEM fasteners. When repl aci ng
fasteners, al ways use the same type (part number) fastener as removed.
I nformati on i n thi s manual i s di vi ded i nto groups. These groups contai n general i nformati on, di agnosi s,
testi ng, adjustments, removal , i nstal l ati on, di sassembl y, and assembl y procedures for the components.
The Component and System I ndex i n the back of thi s manual i denti fi es the correct group for the component
or system to be servi ced.
To assi st i n l ocati ng a group ti tl e page, use the Group Tab Locator on the fol l owi ng page. The sol i d bar after
the group ti tl e i s al i gned to a sol i d tab on the fi rst page of each group. The fi rst page of the group has a contents
secti on that l i sts major topi cs wi thi n the group.
Chrysl er Corporati on reserves the ri ght to change testi ng procedures, speci fi cati ons, di agnosi s, repai r
methods, or vehi cl e wi ri ng at any ti me wi thout pri or noti ce or i ncurri ng obl i gati on.
I nformati on descri bi ng the operati on and use of standard and opti onal equi pment i s i ncl uded i n the Owners
Manual provi ded wi th the vehi cl e.
NEXT PAGE
GROUP TAB LOCATOR
Introduction
0
Lubrication and Maintenance
2
Front Suspension and Drive Shafts
3
Rear Suspension and Driveline
5
Brakes
6
Manual Transaxle Clutch
7
Cooling System
8
Electrical
9
Engine
11
Exhaust System and Intake Manifold
13
Frame and Bumpers
14
Fuel System
19
Steering
21
Transaxle
22
Wheels/Tires
23
Body
24
Heating and Air Conditioning
25
Emission Control Systems
Component Index
ENGINE
CONTENTS
page page
2. 5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3. 3L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
STANDARD SERVICE PROCEDURES . . . . . . . . . 1
STANDARD SERVI CE PROCEDURES
INDEX
page page
Crankshaft Sprocket Bolt Access Plug . . . . . . . . . . 2
Engine Performance . . . . . . . . . . . . . . . . . . . . . . . 2
Form-In-Place Gaskets . . . . . . . . . . . . . . . . . . . . . 1
Honing Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Locked Engine . . . . . . . . . . . . . . . . . . . 5
Lash Adjuster (Tappet) Noise Diagnosis . . . . . . . . . 4
Measuring Main Bearing Clearance and Connecting
Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . 3
Repair of Damaged or Worn Threads . . . . . . . . . . . 4
FORM-IN-PLACE GASKETS
There are numerous pl aces where form-i n-pl ace gas-
kets are used on the engi ne. Care must be taken when
appl yi ng form-i n-pl ace gaskets. Do not use form-in-
place gasket material unless specifically called
for. Bead si ze, conti nui ty, and l ocati on are of great
i mportance. Too thi n a bead can resul t i n l eakage whi l e
too much can resul t i n spi l l -over, a conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free joi nt.
Two types of form-i n-pl ace gasket materi al s are used
i n the engi ne area. MOPAR Si l i cone Rubber Adhesi ve
Seal ant and MOPAR Gasket Maker, each have di ffer-
ent properti es and cannot be used i nterchangeabl y.
MOPAR SI LI CONE RUBBER ADHESI VE SEAL-
ANT
MOPAR Si l i cone Rubber Adhesi ve Seal ant or equi va-
l ent, normal l y bl ack i n col or, i s avai l abl e i n three ounce
tubes. Moi sture i n the ai r causes the MOPAR Si l i cone
Rubber Adhesi ve Seal ant materi al to cure. Thi s mate-
ri al i s normal l y used on fl exi bl e metal fl anges. I t has a
shel f l i fe of one year and wi l l not properl y cure i f over
age. Al ways i nspect the package for the expi rati on date
before use.
MOPAR GASKET MAKER
MOPAR Gasket Maker i s an anaerobi c type gasket
materi al normal l y red i n col or. The materi al cures i n
the absence of ai r when squeezed between two metal l i c
surfaces. I t wi l l not cure i f l eft i n the uncovered tube. I t
i s normal l y red i n col or. The anaerobi c materi al i s for
use between two machi ned surfaces. Do not used on
fl exi bl e metal fl anges.
GASKET DI SASSEMBLY
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some i n-
stances, i t may be necessary to l i ghtl y tap the part wi th
a mal l et or other sui tabl e tool to break the seal be-
tween the mati ng surfaces. A fl at gasket scraper may
al so be l i ghtl y tapped i nto the joi nt but care must be
taken not to damage the mati ng surfaces.
SURFACE PREPARATI ON
Scrape cl ean or wi re brush al l gasket surfaces to
remove al l l oose materi al . I nspect stamped parts to
ensure gasket rai l s are fl at. Fl atten rai l s wi th a ham-
mer on a fl at pl ate i f requi red. Gasket surfaces must be
free of oi l and di rt. Make sure ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
FORM-I N-PLACE GASKET APPLI CATI ON
Assembl i ng parts usi ng a form-i n-pl ace gasket re-
qui res care but i ts easi er then usi ng precut gaskets.
MOPAR Gasket Maker materi al shoul d be appl i ed
spari ngl y 1mm(0.040 i nch.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can easi l y
be wi ped off. Components shoul d be torqued i n pl ace
wi thi n 15 mi nutes. The use of a l ocati ng dowel i s
recommended duri ng assembl y to prevent smeari ng
the materi al off l ocati on.
ENGINE 9 - 1
The MOPAR Si l i cone Rubber Adhesi ve Seal ant gas-
ket materi al or equi val ent shoul d be appl i ed i n a
conti nuous bead approxi matel y 3mm (0.120 i nch) i n
di ameter. Al l mounti ng hol es must be ci rcl ed. For
corner seal i ng, a 3.17 or 6.35 mm (1/8 or 1/4 i nch.) drop
i s pl aced i n the center of the gasket contact area.
Uncured seal ant may be removed wi th a shop towel s.
Components shoul d be torqued i n pl ace whi l e the
seal ant i s sti l l wet to the touch (wi thi n 10 mi nutes).
The usage of a l ocati ng dowel i s recommended duri ng
assembl y to prevent smeari ng of materi al off l ocati on.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access pl ug i s l ocated i n the ri ght i nner fender
shi el d. Remove the pl ug and i nsert proper si ze socket,
extensi on and rachet, when crankshaft rotati on i s
necessary.
ENGINE PERFORMANCE
I f a l oss of performance i s noti ced, i gni ti on ti mi ng
shoul d be checked. I f i gni ti on ti mi ng i s retarded by 9,
18 or 27 i ndi cati ng 1, 2 or 3 (ti mi ng bel t) teeth may
have ski pped, then, camshaft and accessory shaft ti m-
i ng wi th the crankshaft shoul d be checked. Refer to
Engi ne Ti mi ng Sprockets and Oi l Seal s of the Engi ne
Secti on.
To provi de best vehi cl e performance and l owest ve-
hi cl e emi ssi ons, i t i s most i mportant that the tune-up
be done accuratel y. Use the speci fi cati ons l i sted on the
Vehi cl e Emi ssi on Control I nformati on l abel found i n
the engi ne compartment.
(1) Test cranki ng amperage draw. See Starti ng Mo-
tor Cranki ng Amperage Draw El ectri cal Secti on of thi s
manual .
(2) Ti ghten the i ntake mani fol d bol ts to speci fi ca-
ti ons.
(3) Perform cyl i nder compressi on test.
(a) Check engi ne oi l l evel and add oi l i f necessary.
(b) Dri ve the vehi cl e unti l engi ne reaches normal
operati ng temperature.
(c) Sel ect a route free from traffi c and other forms
of congesti on, observe al l traffi c l aws, and accel erate
through the gears several ti mes bri skl y.
CAUTION: Do not overspeed the engine. The higher
engine speed may help clean out valve seat deposits
which can prevent accurate compression readings.
(d) Remove al l spark pl ugs from engi ne. As spark
pl ugs are bei ng removed, check el ectrodes for abnor-
mal fi ri ng i ndi cators foul ed, hot, oi l y, etc. Record
cyl i nder number of spark pl ug for future reference.
(e) Di sconnect coi l wi re from di stri butor and se-
cure to good ground to prevent a spark from starti ng
a fi re (Conventi onal I gni ti on System). For Di rect
I gni ti on System DI S di sconnect the coi l connector.
(f) Be sure throttl e bl ade i s ful l y open duri ng the
compressi on check.
(g) I nsert compressi on gage adaptor i nto the #1
spark pl ug hol e i n cyl i nder head. Crank engi ne unti l
maxi mum pressure i s reached on gage. Record thi s
pressure as #1 cyl i nder pressure.
(h) Repeat Step G for al l remai ni ng cyl i nders.
(i ) Compressi on shoul d not be l ess than (689kPa)
100 psi and not vary more than 25 percent from
cyl i nder to cyl i nder.
(j) I f one or more cyl i nders have abnormal l y l ow
compressi on pressures, repeat steps 4b through 4h.
(k) I f the same cyl i nder or cyl i nders repeat an
abnormal l y l ow readi ng on the second compressi on
test, i t coul d i ndi cate the exi stence of a probl em i n
the cyl i nder i n questi on.
The recommended compression pressures
are to be used only as a guide to diagnosing
engine problems. An engine should not be dis-
assembled to determine the cause of low com-
pression unless some malfunction is present.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8. Ti ghten to
speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
I gni ti on System Secondary Ci rcui t I nspecti on El ectri -
cal Secti on Group 8.
(6) I nspect the pri mary wi re. Test coi l output vol t-
age, pri mary and secondary resi stance. Repl ace parts
as necessary. Refer to I gni ti on System and make nec-
essary adjustment.
(7) I gni ti on ti mi ng shoul d be set to speci fi cati ons.
(See Speci fi cati on Label i n engi ne compartment).
(8) Test fuel pump for pressure and vacuum. Refer to
Fuel System Group 14, Speci fi cati ons.
(9) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(10) I nspect crankcase venti l ati on system as out
l i ned i n Lubri cati on and Mai ntenance, Group 0. For
emi ssi on control s see Emi ssi on Control s Group 25 for
servi ce procedures.
(11) I nspect and adjust accessory bel t dri ves refer-
ri ng to Accessory Bel t Dri ve i n Cool i ng System, Group
7 for proper adjustments.
(12) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores, over the crankshaft to keep abrasi ve
materi al s from enteri ng crankcase area.
(1) Used careful l y, the cyl i nder bore resi zi ng hone
C-823 equi pped wi th 220 gri t stones, i s the best tool for
thi s job. I n addi ti on to degl azi ng, i t wi l l reduce taper
and out-of-round as wel l as removi ng l i ght
9 - 2 ENGINE
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i mi ts.
(2) Degl azi ng of the cyl i nder wal l s may be done
usi ng a cyl i nder surfaci ng hone, Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810) i f the cyl i nder bore
i s strai ght and round. 20-60 strokes dependi ng on the
bore condi ti on wi l l be suffi ci ent to provi de a sati sfac-
tory surface. I nspect cyl i nder wal l s after each 20
strokes. Usi ng a l i ght honi ng oi l avai l abl e from major
oi l di stri butors. Do not useengineor transmission
oil, mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the
cross hatch angl e i s most sati sfactory for proper seat-
i ng of ri ngs (Fi g. 1).
(4) A control l ed hone motor speed between 200-300
RPM i s necessary to obtai n the proper cross-hatch
angl e. The number of up and down strokes per mi nute
can be regul ated to get the desi red 50-60 degree angl e.
Faster up and down strokes i ncrease the cross-hatch
angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned agai n to remove al l traces of abrasi ve.
CAUTION: Be sure all abrasive are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a brush
and the parts then thoroughly dried. The bore can be
considered clean when it can be wiped clean with a
white cloth and cloth remains clean. Oil the bores
after cleaning to prevent rusting.
MEASURING MAIN BEARING CLEARANCE AND
CONNECTING ROD BEARING CLEARANCE
PLASTI GAGE METHOD
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage or equi val ent. The fol l owi ng
i s the recommended procedure for the use of Pl asti -
gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) The total cl earance of the main bearings can
onl y be determi ned by removi ng the wei ght of the
crankshaft. Thi s can be accompl i shed by ei ther of two
methods:
PREFERRED METHOD Shi mmi ng the bear-
i ngs adjacent to the beari ng to be checked i n order to
remove the cl earance between upper beari ng shel l and
the crankshaft. Thi s can be accompl i shed by pl aci ng a
mi ni mum of 0.254mm (.010 i nch) shi m (e. g. cardboard,
matchbook cover, etc.) between the beari ng shel l and
the beari ng cap on the adjacent beari ngs and snuggi ng
bol ts to 14-20 Nm (10-15 ft.l b.)
When checki ng #1 mai n brg shi m #2 mai n brg
When checki ng #2 mai n brg shi m #1 & 3 mai n brg
When checki ng #5 mai n brg shi m #4 mai n brg
Fig. 1 Cylinder Bore Cross-Hatch Pattern
Fig. 2 Plastigage Placed in Lower Shell
Fig. 3 Clearance Measurement
ENGINE 9 - 3
REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD Wi th the wei ght of
the crankshaft bei ng supported by a jack under the
counterwei ght adjacent to the beari ng bei ng checked.
(3) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng shel l i n the cap approxi matel y
6.35mm (1/4 i nch) off center and away from the oi l
hol es (Fi g. 2). (I n addi ti on, suspect areas can be
checked by pl aci ng the Pl asti gage i n the suspect area).
Torque the beari ng cap bol ts of the beari ng bei ng
checked to the proper speci fi cati ons.
(4) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage (Fi g. 3) wi th the metri c scal e
provi ded on the package. Locate the band cl osest to the
same wi dth. Thi s band shows the amount of cl earance
i n thousandths of a mi l l i meter. Di fferences i n readi ngs
between the ends i ndi cate the amount of taper present.
Record al l readi ngs taken. Refer to Engi ne Speci fi ca-
ti ons. Plastigagegenerallyisaccompaniedbytwo
scales. One scale is in inches, the other is a
metric scale.
(5) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076mm (.001-.003 i nch) i s usual l y
the most appropri ate for checki ng engi ne beari ng
proper speci fi cati ons.
CONNECTI NG ROD BEARI NG CLEARANCE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage or equi val ent. The fol l owi ng
i s the recommended procedure for the use of Pl asti -
gage:
(1) Rotate the crankshaft unti l the connecti ng rod to
be checked i s at the bottom of i ts stroke.
(2) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(3) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng shel l i n the beari ng cap approxi -
matel y 6.35 mm (1/4 i nch.) off center and away from
the oi l hol e (Fi g. 2). I n addi ti on, suspect areas can be
checked by pl aci ng pl asti gage i n the suspect area.
(4) Before assembl i ng the rod cap wi th Pl asti gage i n
pl ace, the crankshaft must be rotated unti l the con-
necti ng bei ng checked starts movi ng toward the top of
the engi ne. Onl y then shoul d the cap be assembl ed and
torqued to speci fi cati ons. Do not rotate the crank-
shaft whileassemblingthecap or thePlastigage
may be smeared, giving inaccurate results.
(5) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage (Fi g. 3) wi th the metri c scal e
provi ded on the package. Locate the band cl osest to the
same wi dth. Thi s band shows the amount of cl earance
i n thousandths of a mi l l i meter. Di fferences i n readi ngs
between the ends i ndi cate the amount of taper present.
Record al l readi ngs taken. Refer to Engi ne Speci fi ca-
ti ons. Plastigagegenerallyisaccompaniedbytwo
scales. One scale is in inches, the other is a
metric scale.
(6) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076mm (.001-.003 i nch) i s usual l y
the most appropri ate for checki ng engi ne beari ng
proper speci fi cati ons.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause them
to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
Duri ng thi s ti me, turn engi ne off and l et set for a few
mi nutes before restarti ng. Repeat thi s several ti mes
after engi ne has reached normal operati ng tempera-
ture.
(3) Low oi l pressure.
(4) The oi l restri ctor pressed i nto the verti cal oi l
passage to the cyl i nder head Bal ance Shaft Engi nes
Onl y i s pl ugged wi th debri s.
(5) Ai r i ngested i nto oi l due to broken or cracked oi l
pump pi ck up.
(6) Worn val ve gui des.
(7) Rocker arm ears contacti ng val ve spri ng retai ner
(2.5L engi nes).
(8) Rocker arm l oose, adjuster stuck or at maxi mum
extensi on and sti l l l eaves l ash i n the system.
(9) Faul ty l ash adjuster.
(a) Check for spongi ness whi l e sti l l i nstal l ed i n
cyl i nder head. Depress part of rocker arm just over
adjuster. Normal adjusters shoul d feel very fi rm.
Spongy adjusters can be depressed to the bottomed
posi ti on easi l y.
(b) Remove suspected l ash adjusters, pry off re-
tai ner cap and di sassembl e Do not reuse retainer
caps. Do not i nterchange parts and make sure that
care and cl eanl i ness i s exerci sed i n the handl i ng of
parts.
(c) Cl ean out di rt and varni sh wi th sol vent.
(d) Reassembl e wi th engi ne oi l .
(e) Check for spongi ness.
(f) I f sti l l spongy, repl ace wi th new adjuster.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (i ncl udi ng al umi num head
spark pl ug threads) can be repai red. Essenti al l y, thi s
repai r consi sts of dri l l i ng out worn or damaged
threads, tappi ng the hol e wi th a speci al Hel i -Coi l (or
equi val ent) Tap, and i nstal l i ng an i nsert i nto the
tapped hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
CAUTION: Be sure that the tapped holes maintain the
original centerline.
9 - 4 ENGINE
Hel i -Coi l tool s and i nserts are readi l y avai l abl e from
automoti ve parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engi ne i s suspected to be hydrostati cl y
l ocked, regardl ess of what caused the probl em, these
steps shoul d be used.
CAUTION: Do Not Use Starter Motor To Rotate En-
gine, severe damage may occur.
(1) I nspect ai r cl eaner, i nducti on system and i ntake
mani fol d to i nsure system i s dry and cl ear of forei gn
materi al .
(2) Remove negati ve battery cabl e.
(3) Pl ace a shop towel around the spark pl ugs when
removi ng them from the engi ne. Thi s wi l l catch any
fl ui d that may possi bl y be i n the cyl i nder under pres-
sure.
(4) Wi th al l spark pl ugs removed, rotate engi ne
crankshaft usi ng a breaker bar and socket.
(5) I denti fy the fl ui d i n the cyl i nder(s) (i .e., cool ant,
fuel , oi l or other).
(6) Make sure al l fl ui d has been removed from the
cyl i nders. I nspect engi ne for damage (i .e., Connecti ng
Rods, Pi stons, Val ves etc.)
(7) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
CAUTION: Squirt approximately 1 teaspoon of oil into
cylinders, rotate engine to lubricate the cylinder walls
to prevent damage on restart.
(8) I nstal l new spark pl ugs.
(9) Drai n engi ne oi l and remove oi l fi l ter.
(10) Fi l l engi ne wi th speci fi ed amount of approved
oi l and i nstal l new oi l fi l ter.
(11) Connect negati ve battery cabl e.
(12) Start engi ne and check for any l eaks.
ENGINE 9 - 5
ENGI NE DI AGNOSI SPERFORMANCE
9 - 6 ENGINE
ENGI NE DI AGNOSI SMECHANI CAL
ENGINE 9 - 7
2.5L ENGI NE
INDEX
page page
Balance Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Camshaft, Crankshaft and Intermediate Shafts
Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . 17
Checking Engine Oil Pressure . . . . . . . . . . . . . . . 46
Crankshaft Oil Seals Service . . . . . . . . . . . . . . . . 34
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . 35
Crankshaft,Intermediate and Balance Shaft
Assemblies Service . . . . . . . . . . . . . . . . . . . . . . 33
Cylinder Block, Piston and Connecting Rod
Assembly Service . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cylinder Head and Valve Assembly Service . . . . . 18
Cylinder Head ComponentsIn-Vehicle Service . . 19
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Core Plugs . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine Lubrication System . . . . . . . . . . . . . . . . . . 41
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 47
General Information . . . . . . . . . . . . . . . . . . . . . . . . 8
Intermediate Shaft Service . . . . . . . . . . . . . . . . . . 39
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 43
Solid Mount Compressor Bracket Service . . . . . . . 13
Timing System and Seals Service . . . . . . . . . . . . . 14
Valve ServiceCylinder Head Removed . . . . . . . . 23
GENERAL INFORMATION
ENGI NE I DENTI FI CATI ON NUMBER OR CODE
The engi ne i denti fi cati on number i s l ocated on the
rear of the cyl i nder bl ock just bel ow the cyl i nder head
(Fi g. 1).
BLOCK: Al l four cyl i nder cast i ron bl ocks have
cast-i n recesses i n the bottom of each cyl i nder bore to
provi de connecti ng rod cl earance; especi al l y for 2.5L
engi nes. The bores are al so si amese to mi ni mi ze engi ne
l ength. A parti al open deck i s used for cool i ng and
wei ght reducti on wi th oi l fi l ter, water pump, and
di stri butor mounti ng bosses mol ded i nto the front
(radi ator si de) of the bl ock. Nomi nal wal l thi ckness i s
4.5 mm. Fi ve mai n beari ng bul kheads and a bl ock ski rt
extendi ng 3 mm bel ow the crankshaft center l i ne add
to the bl ocks hi gh ri gi di ty wi th l i ght wei ght.
CRANKSHAFT:A nodul ar cast i ron crankshaft
that i s used i n 2.5L engi ne. These engi nes have 5
mai n beari ngs, wi th number 3 fl anged to control
thrust. The 60 mm di ameter mai n and 50 mm
di ameter crank pi n journal s (al l ) have undercut
radi uses fi l l ets that are deep rol l ed for added
strength. To opti mi ze beari ng l oadi ng 4 counter-
wei ghts are used. Hydrodynami c seal s (i nstal l ed
i n di ecast al umi num retai ners) provi des end seal -
i ng, where the crankshaft exi ts the bl ock. Anaero-
bi c gasket materi al i s used for retai ner-to-bl ock
seal i ng. No vi brati on damper i s used. A si ntered
i ron ti mi ng bel t sprocket i s mounted
SPECI FI CATI ONS
9 - 8 2. 5L ENGINE
on the crankshaft nose. Thi s sprocket provi des moti ve
power; vi a ti mi ng bel t to the camshaft and i ntermedi -
ate shaft sprockets (al so si ntered i ron) provi di ng ti med
val ve, di stri butor, and oi l pump actuati on.
PISTONS: Some Chrysl er pi stons have cast-i n steel
struts at the pi n bosses for autothermi c control . Al l
2.5L pi stons have val ve cuts to provi de val ve cl earance.
Some pi stons are di shed to provi de vari ous compres-
si on rati os. Standard 2.5L engi nes are desi gned for
8.9:1 compressi on rati os respecti vel y. The standard
2.5L pi ston i s di shed and i s a new l i ghtwei ght desi gn to
further enhance engi ne smoothness. Al l standard 2.5L
engi nes use pressed-i n pi ston pi ns to attach forged
steel connecti ng rods.
CYLINDER HEAD: The cyl i nder head i s cast al u-
mi num wi th i n-l i ne val ves arranged wi th al ternati ng
exhaust and i ntake. The i ntake and exhaust ports are
l ocated i n the rearward, faci ng si de of the head. The
i ntake ports feed fast-burn desi gn combusti on cham-
bers wi th spark pl ugs l ocated cl ose to the center l i ne of
the combusti on chamber for opti mum effi ci ency. An
i ntegral oi l gal l ery wi thi n the cyl i nder head suppl i es oi l
to the hydraul i c l ash adjusters, camshaft, and val ve
mechani sms.
CAMSHAFT: The nodul ar i ron camshaft has fi ve
beari ng journal s. Fl anges at the rear journal control
camshaft end pl ay. A si ntered i ron ti mi ng bel t sprocket
i s mounted on the cam nose, and a hydrodynami c oi l
seal i s used for oi l control at the front of the camshaft.
ACCESSORY SHAFT: The i ron accessory shaft has
two beari ng journal s and i s housed i n the forward
faci ng si de of the bl ock. A hydrodynami c seal , i nstal l ed
i n an al umi num housi ng attached to the bl ock, pro-
vi des retenti on, shaft thrust, and oi l control . The
accessory shaft i s dri ven by the ti mi ng bel t through a
si ntered i ron sprocket mounted on the nose of the
accessory shaft. The accessory shaft i n turn dri ves the
oi l pump and di stri butor.
VALVES: The val ves are actuated by rol l er cam
fol l owers whi ch pi vot on stati onary hydraul i c l ash
adjusters.
The val ve trai n wi th 40.6 mm (1.60 i nch) di ameter
i ntake val ves and 35.4 mm (1.39 i nch) di ameter ex-
haust val ves empl oy vi ton rubber val ve stem seal s.
Val ve spri ngs, spri ng retai ners, and l ocks are conven-
ti onal .
BALANCE SHAFTS: 2.5L engi nes are equi pped
wi th two bal ance shafts i nstal l ed i n a carri er attached
to the l ower crankcase. The shafts i nterconnect
through gears to rotate i n opposi te di recti ons. These
gears are dri ven by a short chai n from the crankshaft,
to rotate at two ti mes crankshaft speed. Thi s counter-
bal ances certai n engi ne reci procati ng masses.
INTAKE MANIFOLDS: Al l i ntake mani fol ds are
al umi num casti ngs. N.A. engi nes use a four branch
desi gn. Thi s l ong branch fan desi gn enhances l ow and
mi dspeed torque and al so features an i ntegral l y cast
water crossover passage to warm i ncomi ng fuel /ai r
mi xture, pl us EGR mounti ng boss and PCV i nl et.
EXHAUST MANIFOLDS: Al l exhaust mani fol ds
are made of nodul ar cast i ron for strength and hi gh
temperatures. Al l natural l y aspi rated engi nes exi t ex-
haust gasses through a machi ned, arti cul ated joi nt
connecti on to the exhaust pi pe. Al l mani fol ds i nter-
mesh wi th the i ntake mani fol d at the cyl i nder head.
2.5L engi nes use a four branch desi gn wi th cyl i nders
one and four joi ned and cyl i nder two and three joi ned
to exi t at the outl et.
ENGINE LUBRICATION: System i s ful l fl ow fi l -
trati on, pressure feed type. The oi l pump i s mounted
wi thi n the crankcase and dri ven by the auxi l i ary shaft.
Pressuri zed oi l i s routed through the mai n oi l gal l ery,
to the mai n and rod beari ngs, then to the l ower bal ance
shaft assembl i es. Pi stons are l ubri cated from di rected
hol es i n connecti ng rod assembl i es. Camshaft and
val ve mechani sms are l ubri cated from a ful l -l ength
cyl i nder head oi l gal l ery suppl i ed from the crankcase
mai n oi l gal l ery.
ENGINE MOUNTS
REMOVAL AND I NSTALLATI ON
RI GHT SI DE MOUNT
(1) Remove the ri ght engi ne mount i nsul ator verti -
cal fasteners from frame rai l .
(2) Remove the l oad on the engi ne motor mounts by
careful l y supporti ng the engi ne and transmi ssi on as-
sembl y wi th a fl oor jack.
Fig. 1 Engine Identification
2. 5L ENGINE 9 - 9
(3) Remove the thru bol t from the i nsul ator assem-
bl y. Remove i nsul ator.
(4) Reverse removal procedure for i nstal l ati on. Refer
to (Fi g. 3) for bol t ti ghteni ng speci fi cati ons.
(5) Engi ne mount adjustment, Refer to Engi ne
Mount I nsul ator Adjustment of thi s secti on.
FRONT MOUNT
(1) Support the engi ne and transmi ssi on assembl y
wi th a fl oor jack so i t wi l l not rotate.
(2) Remove the thru bol t from the i nsul ator and
front crossmember mounti ng bracket.
(3) Remove the front engi ne mount bracket to front
crossmember screws and nuts. Remove the i nsul ator
assembl y.
LEFT SI DE MOUNT
(1) Rai se vehi cl e on hoi st and remove l eft front
wheel .
(2) Remove i nter spl ash shi el d.
(3) Support the transmi ssi on wi th a transmi ssi on
jack.
(4) Remove the i nsul ator thru bol t from the mount.
(5) Remove the transmi ssi on mount fasteners and
remove mount.
ENGI NE MOUNT RUBBER I NSULATORS
I nsul ator l ocati on on frame rai l (ri ght si de) and
transmi ssi on bracket (l eft si de) are adjustabl e to al l ow
ri ght/l eft dri ve trai n adjustment i n rel ati on to dri ve
shaft assembl y l ength.
Check and reposi ti on ri ght engi ne mount i nsul ator
(l eft engi ne mount i nsul ator i s fl oati ng type and wi l l
adjust automati cal l y (Fi g. 4). Adjust dri ve trai n posi -
ti on, i f requi red, for the fol l owi ng condi ti ons:
Dri ve shaft di stress: See Dri veshafts i n Suspensi on,
Group 2.
Any front end structural damage (after repai r).
I nsul ator repl acement.
ENGI NE MOUNT I NSULATOR ADJUSTMENT
(2) Loosen the ri ght engi ne mount i nsul ator verti cal
fasteners, and the front engi ne mount bracket to front
crossmember screws and nuts.
Fig. 2 Engine
9 - 10 2. 5L ENGINE
Left engine mount insulator is sleeved over
shaft and long support bolt to provide lateral
movement adjustment with engine weight re-
moved or not.
(3) Pry the engi ne ri ght or l eft as requi red to achi eve
the proper dri ve shaft assembl y l ength. See Dri ve
Shaft i n Suspensi on Group 2 for dri veshaft i denti fi ca-
ti on and rel ated assembl y l ength measuri ng.
(4) Ti ghten ri ght engi ne mount i nsul ator verti cal
bol ts to 37 Nm (27 ft. l bs.). Then ti ghten front engi ne
mount screws and nuts to 54 Nm (40 ft. l bs.) and
center l eft engi ne mount i nsul ator.
(5) Recheck dri ve shaft l ength.
ENGINE ASSEMBLY
REMOVAL
(2) Scri be hood hi nge outl i ne on hood and remove
hood.
(3) Drai n cool i ng system. Refer to Group 7 Cool i ng
System for procedure.
(4) Remove hoses from radi ator and engi ne.
(5) Remove radi ator and fan assembl y (Fi g. 5).
(6) Remove ai r cl eaner and hoses.
(7) Remove ai r condi ti oni ng compressor mounti ng
bol ts and set compressor asi de (i f so equi pped).
(8) Remove power steeri ng pump mounti ng bol ts
and set pump asi de.
(9) Remove oi l fi l ter.
(10) Di sconnect fuel l i ne, heater hose and accel era-
tor cabl e.
(11) Remove al ternator mounti ng bol ts and set al ter-
nator asi de.
(12) Di sconnect al l el ectri cal connecti ons from
throttl e body, and engi ne.
(13) Manual Transmission
(a) Di sconnect cl utch cabl e.
Fig. 3 Engine Mounting
Fig. 4 Left Insulator Movement
2. 5L ENGINE 9 - 11
(b) Remove transmi ssi on case l ower cover.
(c) Di sconnect exhaust pi pe at mani fol d.
(d) Di sconnect starter and l ay asi de.
(e) I nstal l transmi ssi on hol di ng fi xture.
(14) Automatic Transmission
(a) Di sconnect exhaust pi pe at mani fol d.
(b) Di sconnect starter and l ay asi de.
(c) Remove transmi ssi on case l ower cover.
(d) Mark fl ex pl ate to torque converter.
(e) Remove screws hol di ng torque converter to fl ex
pl ate.
(15) Attach C-cl amp on front bottom of torque con-
verter housi ng to prevent torque converter from com-
i ng out.
(16) I nstal l transmi ssi on hol di ng fi xture.
(17) Remove ri ght i nner spl ash shi el d (Fi g. 6).
(18) Remove ground strap.
(19) To lower engi ne, separate ri ght engi ne bracket
from yoke bracket To raise engi ne, remove l ong bol t
through yoke and i nsul ator. I F I NSULATOR TO RAI L
SCREWS ARE TO BE REMOVED, MARK I NSULA-
TOR POSI TI ON ON SI DE RAI L TO I NSURE EXACT
REI NSTALLATI ON (Fi g. 3).
(20) Remove transmi ssi on case to cyl i nder bl ock
mounti ng screws.
(21) Remove front engi ne mount screw and nut.
(22) Remove l eft i nsul ator through bol t (from i nsi de
wheel house) or i nsul ator bracket to transmi ssi on
screws.
(23) Remove engi ne from vehi cl e.
I NSTALLATI ON
(1) I nstal l hoi st to the engi ne and l ower engi ne i nto
SEE: ENGI NE MOUNT RUBBER I NSULATORS,
THI S GROUP.
(2) Al i gn engi ne mounts and i nstal l but do not
tighten unti l al l mounti ng bol ts have been i nstal l ed.
Ti ghten to 54 Nm (40 ft. l bs.).
(3) I nstal l transmi ssi on case to cyl i nder bl ock
mounti ng screws. Ti ghten to 95 Nm (70 ft. l bs.).
(4) Remove engi ne hoi st and transmi ssi on hol di ng
fi xture.
(5) Secure ground strap.
(6) I nstal l ri ght i nner spl ash shi el d.
(7) Connect starter. See El ectri cal Group 8 for i nstal -
l ati on.
(8) Connect exhaust system. See Exhaust Group 11
for i nstal l ati on.
(9) Manual Transmission I nstal l transmi ssi on
case l ower cover.
(10) Automatic Transmission Remove C cl amp
from torque converter housi ng. Al i gn fl expl ate to
torque converter and i nstal l mounti ng screws. Ti ghten
to 54 Nm (40 ft. l bs.).
(11) Manual Transmission Connect cl utch cabl e.
See Cl utch Group 6.
(12) I nstal l power steeri ng pump (i f equi pped). Refer
to Cool i ng System Group 7 for bel t tensi on adjustment.
(13) I nstal l al ternator. Refer to Cool i ng System
Group 7 for bel t i nstal l ati on.
(14) Connect fuel l i ne, heater hose, and accel erator
cabl e.
(15) Connect al l el ectri cal connecti ons at al ternator,
throttl e body and engi ne.
(16) I nstal l oi l fi l ter. Refi l l engi ne crankcase wi th
proper oi l to correct l evel .
Fig. 5 Radiator and Fan Assembly
Fig. 6 Right Inner Splash Shield
9 - 12 2. 5L ENGINE
(17) Rei nstal l ai r condi ti oni ng compressor (i f
equi pped). See Heater and Ai r Condi ti oni ng , Group 24
for i nstal l ati on.
(18) Rei nstal l ai r cl eaner and hoses.
(19) Rei nstal l radi ator and shroud assembl y. I nstal l
radi ator hoses. Fi l l cool i ng system. Refer to Cool i ng
System Group 7 for fi l l i ng procedure.
(20) I nstal l hood.
(21) Connect battery.
(22) Start engi ne and run unti l operati ng tempera-
ture i s reached.
(23) Adjust transmi ssi on l i nkage i f necessary.
SOLID MOUNT COMPRESSOR BRACKET SERVICE
When servi ce procedures requi re sol i d mount bracket
removal and i nstal l ati on for exampl e: cyl i nder head
removal , etc., i t i s i mportant that bracket fasteners
numbered 1 through 7 (Fi g. 7) be removed and i n-
stal l ed i n sequence, as i nstructed i n Removal and
I nstal l ati on.
ACCESSORI ES REMOVAL
(1) Remove (and i nstal l /adjust) bel ts, Refer to Acces-
sory Dri ve Bel ts i n Cool i ng System, Group 7.
(2) Remove ai r condi ti oni ng compressor (i n vehi cl e
wi th l i nes and set asi de) (Fi g. 7).
(3) Remove al ternator pi vot bol t and remove al ter-
nator (i n vehi cl e: turn wi ri ng si de up and di sconnect,
then rotate al ternator, pul l ey end towards engi ne and
remove).
(4) Remove ai r condi ti oner compressor bel t i dl er.
SOLI D MOUNT BRACKETREMOVAL (FI G. 7)
(1) Remove ri ght engi ne mount yoke screw. (Refer to
Engi ne Mounts (Fi g. 3) securi ng i sol ator support
bracket to engi ne mount bracket.
(2) Remove fi ve si de mounti ng bol ts #1, #4 , #5, #6,
and #7 (Fi g. 7).
(3) Remove front mounti ng nut, #2, and remove (or
l oosen) front bol t #3*.
*I n vehi cl e: ful l y l oosen bol t and remove wi th assem-
bl y.
(4) Rotate sol i d mount bracket away from engi ne
and sl i de on stud (#2 nut mounti ng stud) unti l free.
Front mounti ng bol t and spacer wi l l be removed wi th
bracket.
SOLI D MOUNT BRACKETI NSTALLATI ON
Front mounti ng bol t and spacer need to be i nstal l ed
si mul taneousl y wi th bracket.
(1) I nstal l bracket on front (#2 nut) mounti ng stud
and sl i de bracket over ti mi ng bel t cover i nto posi ti on.
(2) Loosen assembl y bracket to engi ne fasteners
(numbered #1 through #7 i n Fi g. 7).
CAUTION: Fasteners MUST BE TIGHTENED IN SE-
QUENCE and to specified torque as follows:
(3)
Fi rst Bol t #1 to 30 Nm (30 i n. l bs.)
Second Nut #2 and Bol t #3 to 54 Nm (40 ft. l bs.).
Thi rd Bol ts #1 (second ti ghteni ng) #4 and #5 to 54
Nm (40 ft. l bs.).
Fourth Bol ts #6 and #7 to 54 Nm (40 ft. l bs.).
(4) I nstal l al ternator and compressor. Ti ghten com-
pressor mounti ng bracket bol ts to 54 Nm (40 ft. l bs.).
Fig. 7 Solid Mount Compressor Bracket 2.5L Engines
2. 5L ENGINE 9 - 13
TIMING SYSTEM AND SEALS SERVICE
Refer to (Fi g. 1) for parts i denti fi cati on and torque
speci fi cati ons
TI MI NG BELT SERVI CE
(1) Remove Sol i d Mount Compressor Bracket. Refer
to procedure outl i ned i n thi s secti on.
(2) Rai se vehi cl e on a hoi st and remove ri ght i nner
spl ash shi el d (Fi g. 2).
(3) Remove screws retai ni ng water pump pul l ey and
bol ts retai ni ng crankshaft pul l ey (Fi g. 3) and l ay pul l ey
asi de.
(4) Remove nuts hol di ng cover to cyl i nder head.
Fig. 1 Timing System and Seals
Fig. 2 Right Inner Splash Shield
Fig. 3 Crankshaft and Water Pump Pulley
9 - 14 2. 5L ENGINE
(5) Remove screws hol di ng cover to cyl i nder bl ock.
(6) Remove both hal ves of ti mi ng bel t cover and l ay
asi de (Fi g. 4)
(7) Pl ace a jack under engi ne.
(8) Separate ri ght engi ne mount (Fi g. 5) and rai se
engi ne sl i ghtl y.
(9) Loosen ti mi ng bel t tensi oner screw (Fi g. 6) and
remove ti mi ng bel t.
SERVI CI NG FRONT OI L
SEALSREPLACEMENT
(1) Wi th ti mi ng bel t removed, remove crankshaft
sprocket bol t.
(2) Remove crankshaft sprocket usi ng Speci al Tool
C-4685, I nsert and 5.9 i nch l ong screw (Fi g. 7).
(3) I nstal l crankshaft sprocket usi ng pl ate L-4524,
Thrust Beari ng/washer and 5.9 i nch l ong screw (Fi g.
7).
Fig. 4 Timing Belt Cover
Fig. 5 Right Engine Mount
Fig. 7 Crankshaft Sprocket
Fig. 6 Remove Timing Belt
2. 5L ENGINE 9 - 15
(4) Hol d engi ne sprocket wi th Speci al Tool C-4687
(wi th adaptor Tool C-4687-1) whi l e removi ng/i nstal l i ng
screw (Fi g. 8). The 2.5L Engi ne camshaft/i ntermedi ate
shaft sprockets have an off-set hub and are i denti fi ed
wi th a si x-hol e pattern .
(5) Remove crankshaft seal usi ng Speci al Tool 6341.
Remove i ntermedi ate and camshaft seal s usi ng Speci al
Tool C-4679 (Fi g. 10).
CAUTION: Do not nick shaft seal surface or seal bore.
(6) Shaft seal l i p surface must be free of varni sh, di rt
or ni cks. Pol i sh wi th 400 gri t paper i f necessary.
(7) I nstal l engi ne crankshaft seal i nto retai ner usi ng
Speci al Tool 6342 and 6343. I nstal l I ntermedi ate
and Camshaft seal s usi ng Speci al Tool C-4680. I nstal l
seal s unti l fl ush (Fi g. 10).
Fig. 8 Removing/Installing Camshaft or Intermediate
Shaft Sprocket Screw
Fig. 9 Removing Crankshaft, Intermediate Shaft and
Camshaft Oil Seal
Fig. 10 Installing Crankshaft,Intermediate Shaft, and
Camshaft Seal
9 - 16 2. 5L ENGINE
CAMSHAFT, CRANKSHAFT AND INTERMEDIATE
SHAFTS TIMING PROCEDURE
(1) Remove al l spark pl ugs. Turn crankshaft and
i ntermedi ate shaft unti l marki ngs on sprockets are i n
l i ne, see arrows (Fi g. 11 ).
(2) Turn camshaft unti l arrows on hub are i nl i ne
wi th No. 1 camshaft cap to cyl i nder headl i ne. Smal l
hol e (arrow Fi g. 12) must be i n verti cal center l i ne.
(3) I nstal l ti mi ng bel t.
(4) Rotate crankshaft two ful l revol uti ons and re-
check ti mi ng.
CAUTION: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
(5) Rotate crankshaft ti l l number 1 cyl i nder i s at the
TDC posi ti on.
(6) Put bel t tensi on Speci al Tool C-4703 hori zontal l y
on l arge hex of ti mi ng bel t tensi oner pul l ey and l oosen
tensi oner l ock nut.
(7) Reset bel t tensi on Speci al Tool C-4703 i ndex i f
necessary to have axi s wi thi n 15 of hori zontal .(Fi g. 13)
(8) Turn engi ne cl ockwi se from TDC two crank revo-
l uti ons to TDC. Do not reverse rotate crankshaft
or attempt to rotate engine using cam or acces-
sory shaft attaching screw.
(9) Hol d wei ghted wrench i n posi ti on whi l e ti ghten-
i ng bol t on tensi oner to 61 Nm (45 ft. l bs.) torque.
(10) Lower engi ne onto engi ne mount i nstal l mount-
i ng bol ts and ti ghten to speci fi cati ons refer to (Fi g. 3).
(11) Remove jack from under engi ne.
(12) Posi ti on both hal ves of ti mi ng bel t cover to-
gether (Fi g. 4).
(13) I nstal l fasteners hol di ng cover to cyl i nder head
and bl ock. Ti ghten fasteners to 4 Nm (40 i n. l bs.)
torque.
(14) Val ve Ti mi ng Check; (ti mi ng bel t cover i n-
stal l ed). Wi th number one cyl i nder at TDC, smal l hol e
i n sprocket must be centered i n ti mi ng bel t cover hol e
(Fi g. 12). I f hol e i s not al i gned correctl y perform
procedure agai n.
(15) I nstal l spark pl ugs.
Fig. 11 Crankshaft and Intermediate Shaft Timing
Fig. 12 Camshaft Timing
Fig. 13 Adjusting Drive Belt Tension
2. 5L ENGINE 9 - 17
CYLINDER HEAD AND VALVE ASSEMBLY SERVICE
Fig. 1 Cylinder Head and Valve Assembly
9 - 18 2. 5L ENGINE
CYLI NDER HEAD COVER AND CURTAI N
A curtai n ai di ng ai r/oi l separati on i s i nstal l ed on the
cyl i nder head bel ow the cyl i nder head cover (Fi gs. 1
and 2).
REMOVAL
(1) Remove the cyl i nder head cover bol ts (Fi g. 2).
(2) Remove cyl i nder head cover and curtai n from
cyl i nder head. Do not mi spl ace the rubber bumpers on
curtai n.
CLEANI NG
Before i nstal l ati on, cl ean cyl i nder head and cover
mati ng surfaces. Make certai n the rai l s are fl at.
CURTAI N I NSTALLATI ON
I nstal l curtai n mani fol d si de fi rst wi th cutouts over
cam towers and contacti ng cyl i nder head fl oor, then
press opposi te di stri butor si de i nto posi ti on bel ow
cyl i nder head rai l .
Curtai n i s retai ned i n posi ti on wi th rubber bumpers
(Fi g. 1).
COVER SEALI NG AND I NSTALLATI ON
Before i nstal l ati on, cl ean cyl i nder head and cover
mati ng surfaces. Make certai n rai l s are fl at.
(1) I nstal l new end seal s on val ve cover.
(2) Appl y form-i n-pl ace Mopar Si l i cone Rubber Ad-
hesi ve Seal ant or equi val ent gasket materi al to cyl i n-
der head cover rai l (Fi g. 3). Refer to procedure detai l ed
i n form-i n-pl ace gasket secti on of Standard Servi ce
Procedures, i n thi s Group.
Caution: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
(3) I nstal l curtai n, cover and end seal assembl y to
head and ti ghten to 12 Nm (105 i n.l bs.) torque.
CYLINDER HEAD COMPONENTS IN-VEHICLE
SERVICE
Removal and i nstal l ati on of cyl i nder head or cam-
shaft requi re separati on of camshaft ti mi ng sprocket
from camshaft. To mai ntai n camshaft, i ntermedi ate
shaft, and crankshaft ti mi ng duri ng servi ce proce-
dures, the ti mi ng bel t i s l eft i ndexed on the sprocket
whi l e the assembl y i s suspended under l i ght tensi on
(Fi g. 4).
CAUTION: Failure to maintain adequate tension on
camshaft, intermediate, and crankshaft sprocket belt
can result in lost engine timing. If timing is lost, refer
to Timing System and Seals and (Fig. 4).
When removi ng the sprocket from the camshaft, you
must mai ntai n adequate tensi on on the sprocket
Fig. 2 Cylinder Head Cover and Curtain
Fig. 3 Cylinder Head Valve Cover Rail Sealing
Fig. 4 Suspending Camshaft Sprocket
2. 5L ENGINE 9 - 19
and bel t assembl y to prevent the bel t from di sengagi ng
wi th the i ntermedi ate or crankshaft ti mi ng sprockets.
Refer to Ti mi ng System and Seal s for removal and
i nstal l ati on of camshaft sprocket procedure and to
Camshaft Servi ce for removal and i nstal l ati on of cam-
shaft procedures.
CAMSHAFT SERVI CE
Refer to TI MI NG SYSTEM AND SEALS for cam-
shaft ti mi ng bel t and sprocket removal and i nstal l a-
ti on, and CYLI NDER HEAD I n Vehi cl e Servi ce.
REMOVAL
(1) Remove the cyl i nder head cover and curtai n.
(2) Mark rocker arms for rei nstal l ati on i n the same
posi ti on (Fi g. 6).
(3) Loosen camshaft beari ng cap screws several
revol uti ons (Fi g. 7).
(4) Jar camshaft at rear of cam to l oosen (break free)
the beari ng caps. Use a soft faced mallet.
CAUTION: Care should be exercised not to cock the
camshaft during removal. Cocking of the camshaft
could cause damage to the cam or bearing thrust
surfaces.
(5) Remove screws and caps such that cam does not
cock.
I NSPECTI ON
Check beari ng cap and oi l feed hol es for bl ockage.
I nspect beari ng cap and cyl i nder head journal s for
wear and/or oversi ze, Refer to CYLI NDER HEAD,
Inspect and Speci fi cati ons.
Camshaft beari ng journal s and l obe wear. Lobe wear
shoul d not exceed .25mm (.010 i nch). To measure cam
l obe wear (Fi g. 8), measure l obe di ameter i n two pl aces
at the l argest di ameter (over the nose). Take fi rst
readi ng wi th mi crometer i n unworn area
Fig. 5 Engine Sprocket Timing
Fig. 6 Rocker Arm and Lash Adjuster
Fig. 7 Camshaft Cap Removal Sequence
Fig. 8 Camshaft
9 - 20 2. 5L ENGINE
at the edge of the l obe. Take second readi ng i n the worn
area where rocker arm contacts the l obe. Subtract
second readi ng from the fi rst. The di fference i s the cam
l obe wear.
CAMSHAFT END PLAY
(1) Oi l camshaft journal s and i nstal l camshaft wi th-
out cam fol l owers. Ti ghten screws to speci fi ed torque.
(2) Usi ng a sui tabl e tool , move camshaft as far
rearward as i t wi l l go.
(3) Zero di al i ndi cator (Fi g. 9).
(4) Move camshaft as far forward as i t wi l l go.
(5) End pl ay travel : 0.13 - 0.33mm (0.005 - 0.013
i nch).
(6) Remove beari ng caps and camshaft.
I NSTALLATI ON
(1) I nstal l cam fol l owers i n correct order as removed.
(2) Al i gn camshaft beari ng caps i n proper sequence
wi th Cap No. 1 at ti mi ng bel t end and Cap No. 5 at
transmi ssi on end. Arrows on Caps No. 1, 2, 3, 4 must
poi nt toward ti mi ng bel t to prevent cap breakage (Fi g.
10).
(3) Appl y Mopar Gasket Maker to No.1 and No.5
beari ng cap (Fi g. 11).
(4) Caps must be i nstal l ed before camshaft seal s are
i nstal l ed.
LASH ADJUSTER (TAPPET) NOI SE
A tappet-l i ke noi se may be produced from several
i tems. Refer to Lash Adjuster and Tappet Noi se -
Di agnosi s i n Standard Servi ce Procedures, thi s Group.
VALVE COMPONENTS REPLACECYLI NDER
HEAD NOT REMOVED
ROCKER ARM AND HYDRAULI C LASH AD-
JUSTER
REMOVAL
(1) Remove val ve cover.
(2) For each rocker arm, rotate cam unti l base ci rcl e
i s i n contact wi th rocker arm. Depress val ve spri ng
usi ng Speci al Tool C-4682 (Fi g. 12) and sl i de rocker
arm out. Keep rocker arms i n order for reassembl y.
(3) Remove hydraul i c l ash adjuster.
I NSTALLATI ON
(1) I nstal l hydraul i c l ash adjusters maki ng sure that
adjusters are at l east parti al l y ful l of oi l . Thi s i s
i ndi cated by l i ttl e or no pl unger travel when the l ash
adjuster i s depressed.
(2) Rotate cam unti l base ci rcl e i s i n contact posi ti on
wi th rocker arm. Depress val ve spri ng wi th Speci al
Tool C-4682 (Fi g. 12) and sl i de rocker arm i n pl ace.
Keep rockers i n order. I t i s possi bl e for the val ve spri ng
retai ner l ocks to become di sl ocated when depressi ng
the val ve spri ng. Check and make sure the locks
are in their proper location.
Fig. 9 Camshaft End Play
Fig. 10 Camshaft Bearing Caps Installation
Fig. 11 Cam Tower Cap Sealing
2. 5L ENGINE 9 - 21
(3) I nstal l val ve cover as previ ousl y outl i ned i n thi s
secti on.
VALVE SPRI NGS AND VALVE STEM SEALS
REMOVAL
(1) Remove rocker arms as previ ousl y outl i ned i n
thi s secti on.
(2) Rotate crankshaft unti l pi ston i s at TDC on
compressi on.
(3) Wi th ai r hose attached to adapter tool i nstal l ed
i n spark pl ug hol e, appl y 90-120 psi ai r pressure.
(4) Usi ng Speci al Tool C-4682 (Fi g. 12) compress
val ve spri ngs and remove val ve l ocks.
(5) Remove val ve spri ng.
(6) Remove val ve stem seal by gentl y pryi ng si de-to-
si de wi th a screwdri ver bl ade. Once di sl odged from
gui de post, seal may be easi l y removed.
I NSTALLATI ON
(1) I nstal l val ve seal s (Fi g. 13) as outl i ned i n step (2)
of ValveGear Reassembly - After ValveServicei n
thi s secti on.
(2) Usi ng Speci al Tool C-4682 compress val ve
spri ngs onl y enough to i nstal l l ocks. Correct al i gnment
of tool i s necessary to avoi d ni cki ng val ve stems (ai r
pressure requi red), pi ston at TDC.
(3) I nstal l rocker arms as previ ousl y outl i ned i n thi s
secti on.
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure rel ease procedure
before attempting any repairs. Refer to Fuel Sys-
tem Group 14.
(2) Di sconnect negati ve battery cabl e. Drai n cool i ng
system. Refer to Cool i ng System, Group 7.
(3) Remove ai r cl eaner and di sconnect al l vacuum
l i nes, el ectri cal wi ri ng and fuel l i nes from throttl e body.
(4) Remove throttl e l i nkage.
(5) Loosen power steeri ng pump and remove bel t.
(6) Remove power brake vacuum hose from i ntake
mani fol d.
(7) Remove water hoses from water crossover.
(8) Rai se vehi cl e and remove exhaust pi pe from
mani fol d.
(9) Remove power steeri ng pump assembl y and set
asi de.
(10) Di sconnect coi l wi ri ng connector and coi l wi re
from coi l .
(11) Di sconnect di psti ck tube from thermostat hous-
i ng and ROTATE bracket from stud. DO NOT bend
the bracket.
(12) Refer to Sol i d Mount Compressor Bracket re-
moval i n, thi s Group.
(13) Remove cyl i nder head cover and curtai n from
head.
(14) Remove cyl i nder head bol ts.
I NSPECT HEAD AND CAMSHAFT BEARI NG
JOURNALS
(1) Cyl i nder head must be fl at wi thi n 0.1mm (.004
i nch)(Fi g. 14).
(2) I nspect camshaft journal s for scori ng and journal
caps for oversi ze marki ngs. When servi ci ng cyl -
Fig. 12 Removing and Installing Valve Spring
Fig. 13 Valve Stem Seals
Fig. 14 Checking Cylinder Head Flatness
9 - 22 2. 5L ENGINE
i nder head or camshaft, i t i s necessary to be certai n
that oversi zed camshafts are used onl y i n oversi zed
heads. Identify oversize components follows:
Cyl i nder Head: Top of beari ng caps pai nted green
and O/SJ stamped rearward of oi l gal l ery pl ug on end
of head.
Camshaft: Barrel of camshaft pai nted green and
O/SJ stamped on end of shaft.
CLEANI NG
Remove al l gasket materi al from cyl i nder head and
bl ock. Becareful not gouge or scratch al umi num head
seal i ng surface.
I NSTALLATI ON
CAUTION: Head bolt diameter is 11mm. These bolts
are identified with 11 on the head of the bolt. 10mm
bolts will thread into the 11mm hole but will strip the
cylinder block bolt hole.
Since the Cylinder head bolts are torqued us-
ing a new procedure they should be examined
BEFORE reuse. If the threads are necked down
the bolts should be replaced (Fi g. 15).
Necki ng can be checked by hol di ng a scal e or strai ght
edge agai nst the threads. I f al l the threads do not
contact the scal e the bol t shoul d be repl aced.
(1) Posi ti on new head gasket on the cyl i nder bl ock.
(2) Ti ghten the cyl i nder head bol ts i n the sequence
shown i n (Fi g. 16). Usi ng the 4 step torque turn
method, ti ghten accordi ng to the fol l owi ng val ues:
Fi rst Al l to 61 Nm (45 ft. l bs.)
Second Al l to 88 Nm (65 ft. l bs.)
Thi rd Al l (agai n) to 88 Nm (65 ft. l bs.)
Fourth + 1/4 Turn Do use a not torque wrench
for this step.
Bolt torque after 1/4 turn should be over 90 ft.
lbs. If not, replace the bolt.
(3) Rotate di psti ck tube on bracket.
(4) Ti ghten bracket retai ni ng nut to 23 Nm (200 i n.
l bs.).
(5) I nstal l cyl i nder head cover and curtai n. Refer to
cover seal i ng of thi s group for procedure.
VALVE SERVICE CYLINDER HEAD REMOVED
VALVES AND VALVE SPRI NGS
REMOVAL
(1) Wi th cyl i nder head removed, compress val ve
spri ngs usi ng Tool C-3422-B.
(2) Remove val ve retai ni ng l ocks, val ve spri ng re-
tai ners, val ve stem seal s and val ve spri ngs.
(3) Before removi ng val ves, remove any burrs
fromvalvestemlock grooves to prevent damage
to the valve guides. I denti fy val ves to i nsure i nstal -
l ati on i n ori gi nal l ocati on.
VALVE I NSPECTI ON
(1) Cl ean val ves thoroughl y and di scard burned,
warped and cracked val ves.
(2) Measure val ve stems for wear.
(3) I f val ve stems are worn more than 0.05 mm (.002
i nch.) repl ace val ve.
VALVE GUI DES
(1) Remove carbon and varni sh deposi ts from i nsi de
of val ve gui des wi th a rel i abl e gui de cl eaner.
(2) Checki ng Val ve Gui de Wear:
I nsert val ve wi th val ve head posi ti oned 10 mm (.400
i nch) above cyl i nder head gasket surface.
Move val ve to and from the i ndi cator (Fi g. 17). The
total di al i ndi cator readi ng shoul d not exceed the
amount speci fi ed i n (Fi g. 18). Readi ngs shoul d be taken
for l engthwi se and crosswi se (wi th respect to cyl i nder
head) movement for each val ve. Ream the gui des for
val ves wi th oversi ze stems i f di al i ndi cator readi ng i s
excessi ve or i f the stems are scuffed or scored.
(3) Servi ce val ves wi th oversi ze stems and oversi ze
seal s are avai l abl e i n 0.15mm, (.005 i nch) 0.40mm,
(.015 i nch) and 0.80mm(.031 i nch) oversi ze.
Oversize seals must be used with oversize
valves.
Reamers si zes to accommodate the oversi ze val ve
stem are shown i n (Fi g. 18).
(4) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Do not at-
tempt to ream the valve guides from standard
Fig. 15 Checking Bolts for Stretching (Necking)
Fig. 16 Cylinder Head Tightening Sequence
2. 5L ENGINE 9 - 23
directly to 0.80mm (.030 inch). Use step proce-
dure of 0.15mm (.005 inch), 0.40mm (.015 inch)
and 0.80mm (.030 inch) so the valve guides may
bereamedtruein relation tothevalveseat.After
reaming guides, the seat runout should be mea-
sured and resurfaced if necessary. See Refacing
Valves and Valve Seats.
Replace cylinder head if guide does not clean
upwith 0.80mm(.030inch) oversizereamer, or if
guide is loose in cylinder head.
TESTI NG VALVE SPRI NGS
(1) Whenever val ves have been removed for i nspec-
ti on, recondi ti oni ng or repl acement, val ve spri ngs
shoul d be tested. As an exampl e, the compressi on
l ength of the spri ng to be tested i s 33.34mm (1-5/16
i nches). Turn tabl e of Tool C-647 unti l surface i s i n l i ne
wi th the 33.34mm (1-5/16 i nch) mark on the threaded
stud and the zero mark on the front. Pl ace spri ng over
stud on the tabl e and l i ft compressi ng l ever to set tone
devi ce (Fi g. 19). Pul l on torque wrench unti l pi ng i s
heard. Take readi ng on torque wrench at thi s i nstant.
Mul ti pl y thi s readi ng by two. Thi s wi l l gi ve the spri ng
l oad at test l ength. Fracti onal measurements are i ndi -
cated on the tabl e for fi ner adjustments. Refer to
speci fi cati ons to obtai n speci fi ed hei ght and al l owabl e
tensi ons. Di scard the spri ngs that do not meet speci fi -
cati ons.
(2) I nspect each val ve spri ng for squareness wi th a
steel square and surface pl ate, test spri ngs from both
ends. I f the spri ng i s more than 1.5mm (1/16 i nch) out
of square, i nstal l a new spri ng.
Fig. 17 Checking Wear on Valve GuideTypical
Fig. 18 Valve Guide Specification
Fig. 19 Testing Valve Spring with Special Tool C-647
Fig. 20 Intake and Exhaust Valves
Fig. 21 Valve Dimensions
9 - 24 2. 5L ENGINE
REFACI NG VALVES AND VALVE SEATS
(1) The i ntake and exhaust val ve seats and val ve
face have a 45 degree angl e.
(2) I nspect the remai ni ng margi n after the val ves
are refaced (Fi g. 22). Exhaust val ves wi th l ess than
1.191mm (3/64 i nch) margi n and i ntake val ves wi th
l ess than .794mm (1/32 i nch) margi n shoul d be di s-
carded.
(3) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseati ng
stones. A true and compl ete surface must be obtai ned.
(4) Measure the concentri ci ty of val ve seat usi ng a
val ve seat di al i ndi cator. Total runout shoul d not ex-
ceed. 051mm (.002 i nch) (total i ndi cator readi ng).
(5) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do thi s,
coat val ve seat LIGHTLY wi th Prussi an bl ue then set
val ve i n pl ace. Rotate the val ve wi th l i ght pressure. I f
the bl ue i s transferred to the center of val ve face,
contact i s sati sfactory. I f the bl ue i s transferred to top
edge of the val ve face, l ower val ve seat wi th a 15
degrees stone. I f the bl ue i s transferred to the bottom
edge of val ve face rai se val ve seat wi th a 65 degrees
stone.
I ntake val ve seat di ameter 40.45mm (1.593 i nch)
Exhaust val ve seat di ameter 34.84mm (1.371 i nch)
Val ve seats whi ch are worn or burned can be re-
worked, provi ded that correct angl e and seat wi dth are
mai ntai ned. Otherwi se cyl i nder head must be re-
pl aced.
(6) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.75 to 2.25mm (0.69 to .088
i nch) The wi dth of the exhaust seats shoul d be 1.50 to
2.00mm (.059 to .078 i nch) (Fi g. 23 Di mensi on 1).
(7) Check val ve ti p to val ve spri ng seat di mensi ons
after gri ndi ng to seats or faces. Gri nd val ve ti p to gi ve
49.76 to 51.04mm (1.960 to 2.009 i nch) over val ve
spri ng seat when i nstal l ed i n the head (Fi g. 24). The
val ve ti p di ameter shoul d be no l ess than 7.0mm (0.275
i nch), i f necessary, the ti p chamfer shoul d be reground
to prevent seal damage when the val ve i s i nstal l ed.
(8) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat (Fi g. 25).
CAUTION: If more than .5mm (.020 inch) must be
ground from the valve tip, check the clearance be-
tween the rocker arm and the valve spring retainer if
below 1.25mm (.050 inch), grind the rocker arm ears
according to the procedure described in Refacing
CLEANI NG
Cl ean al l val ve gui des, val ves and val ve spri ng
assembl i es thoroughl y sui tabl e cl eani ng sol uti on be-
fore reassembl i ng.
VALVE GEAR REASSEMBLY AFTER VALVE
SERVI CE
(1) Coat val ve stems wi th l ubri cati on oi l and i nsert
i n cyl i nder head.
(2) I nstal l new val ve stem seal s on al l val ves. The
val ve stem seal s shoul d be pushed fi rml y and squarel y
over val ve gui de. The l ower edge of the seal shoul d be
resti ng on the val ve gui de boss.
Fig. 22 Refacing Intake and Exhaust Valves
Fig. 23 Refacing Valve Seats
Fig. 24 Valve Tip to Valve Spring Seat Dimensions
2. 5L ENGINE 9 - 25
CAUTION: When oversize valves are used, the corre-
sponding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals are
not used with oversize valves.
(3) I nstal l val ve spri ng seats and spri ngs and retai n-
ers. Compress val ve spri ngs onl y enough to i nstal l
l ocks, taki ng care not to mi sal i gn the di recti on of
compressi on. Ni cked val ve stems may resul t from
mi sal i gnment of the val ve spri ng compressor.
CAUTION: When depressing the valve spring retain-
ers with Special Tool C-3422-B the locks can become
dislocated. Check to make sure both locks are in their
correct location after removing tool.
(4) Check i nstal l ed hei ght of spri ngs. Measurement
i s to be taken from the l ower edge of the val ve spri ng to
i ts upper edge. Do not i ncl ude the spri ng seat or
retai ner fl ange. Correct hei ght i s 41.2mm to 42.7mm
(1.62 to 1.68 i nches). I f seats have been reground an
addi ti onal spri ng seat may be requi red to mai ntai n
correct i nstal l ed spri ng hei ght.
(5) I nstal l adjusters, rocker arms i n order, and cam-
shaft as previ ousl y descri bed, see Camshaft-I nstal l .
Check for cl earance between the projecti ng ears (ei ther
si de of val ve ti p) of the rocker arms and the val ve
spri ng retai ners. At l east 1.25 mm (.050 i nch) cl earance
must be present, i f necessary, the rocker arm ears may
be ground to obtai n thi s cl earance (Fi g. 25).
(6) Checki ng dry l ash. Dry l ash i s the amount of
cl earance that exi sts between the base ci rcl e of an
i nstal l ed cam and the rocker arm rol l er when the
adjuster i s drai ned of oi l and compl etel y col l apsed.
Speci fi ed dry l ash i s 0.62 to 1.52 mm (.024 to .060 i nch).
To compl etel y col l apse adjuster for dry l ash measure-
ment, pry off retai ner cap, di sassembl e, drai n the
adjuster of oi l , reassembl e, and i nstal l . After perform-
i ng dry l ash check, refi l l adjuster wi th oi l (do not reuse
retai ner cap/s) and al l ow 10 mi nutes for adjuster/s to
bl eed down before rotati ng cam.
Fig. 25 Checking Spring Installed Height and Spring
Retainer Clearance
9 - 26 2. 5L ENGINE
CYLINDER BLOCK, PISTON AND CONNECTING
ROD ASSEMBLY SERVICE
PI STON AND CONNECTI NG RODREMOVAL
(1) Remove top ri dge of cyl i nder bores wi th a rel i abl e
ri dge reamer before removi ng pi stons from cyl i nder
bl ock.Be sure to keep tops of pistons covered
during this operation. Mark pi ston wi th matchi ng
cyl i nder number (Fi g. 2).
(2) Remove oi l pan. I nspect connecti ng rods and
connecti ng rod caps for cyl i nder i denti fi cati on. I denti fy
them i f necessary. (Fi g. 3)
(3) Val ve rel i ef toward mani fol d si de of engi ne.
(4) Squi rt hol e on connecti ng rod must face ti mi ng bel t
end of engi ne.
(5) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. Rotate crankshaft so that
each connecti ng rod i s centered i n cyl i nder bore.
(6) Remove connecti ng rod cap. I nstal l connecti ng
rod bol t protectors on connecti ng rod bol ts (Fi g. 4).
Push each pi ston and rod assembl y out of cyl i nder bore.
Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mati ng
rod.
Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly
Fig. 2 Piston Marking
Fig. 3 Identify Connecting Rod to Cylinder
2. 5L ENGINE 9 - 27
CYLI NDER BLOCK CLEANI NG AND I NSPEC-
TI ON
(1) Cl ean cyl i nder bl ock thoroughl y and check al l
core hol e pl ugs for evi dence of l eaki ng.
(2) I f new core pl ugs are i nstal l ed, Refer to Engi ne
Core Oi l and Cam Pl ugs.
(3) Exami ne bl ock and cyl i nder bores for cracks or
fractures.
CYLI NDER BORE I NSPECTI ON
The cyl i nder wal l s shoul d be checked for out- of-
round and taper wi th Tool C-119 (Fi g. 5). I f the cyl i nder
wal l s are badl y scuffed or scored, the cyl i nder bl ock
shoul d be rebored and honed, and new pi stons and
ri ngs fi tted. Whatever type of bori ng equi pment i s
used, bori ng and honi ng operati on shoul d be cl osel y
coordi nated wi th the fi tti ng of pi stons and ri ngs i n
order that speci fi ed cl earances may be mai ntai ned.
Refer to Honing Cylinder Bores outlined in the
Standard Service Procedures for specification
and procedures.
Measure the cyl i nder bore at three l evel s i n di rec-
ti ons A and B (Fi g. 5). Top measurement shoul d be
10mm ( 3/8 i nch) down and bottom measurement
shoul d be 10mm ( 3/8 i nch.) up from bottom of bore.
Refer to (Fi g. 6) for speci fi cati ons.
SI ZI NG PI STONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Pi ston di ameter shoul d be measured 90 degrees to
pi ston pi n at si ze l ocati on shown i n (Fi g. 7). Cyl i nder
bores shoul d be measured hal fway down the cyl i nder
Fig. 4 Connecting Rod Protectors
Fig. 5 Checking Cylinder Bore Size
Fig. 6 Piston Size Location and Clearance Chart
Fig. 7 Piston Installation and Sizing Information
9 - 28 2. 5L ENGINE
bore and transverse to the engi ne crankshaft center
l i ne shown i n (Fi g. 5). Refer to (Fi g. 6) for speci fi ca-
ti ons.
Pistonsandcylinder boresshouldbemeasured
at normal roomtemperature, 70F. (21C).
PI STON RI NGREMOVAL
(1) I D mark on face of upper and i ntermedi ate pi ston
ri ngs must poi nt toward pi ston crown.
(2) Usi ng a sui tabl e ri ng expander, remove upper
and i ntermedi ate pi ston ri ngs (Fi g. 8).
(3) Remove the upper oi l ri ng si de rai l , l ower oi l ri ng
si de rai l and then oi l ri ng expander from pi ston.
(4) Cl ean ri ng grooves of any carbon deposi ts.
FI TTI NG RI NGS
(1) Wi pe cyl i nder bore cl ean. I nsert ri ng and push
down wi th pi ston to ensure i t i s square i n bore. The
ri ng gap measurement must be made wi th the ri ng
posi ti oni ng at l east 12mm (.50 i nch) from bottom of
cyl i nder bore. Check gap wi th feel er gauge (Fi g. 9).
Refer to speci fi cati ons (Fi g. 12).
(2) Check pi ston ri ng to groove cl earance: (Fi g. 10).
Refer to speci fi cati on (Fi g. 12).
PI STON RI NGSI NSTALLATI ON
(1) The No. 1 and No. 2 pi ston ri ngs have a di fferent
cross secti on. I nstal l ri ngs wi th manufacturers I .D.
mark faci ng up, to the top of the pi ston (Fi g. 11).
Fig. 8 Piston RingsRemoving and Installing
Fig. 9 Piston Ring Gap
Fig. 10 Measuring Piston Ring Groove Clearance
Fig. 11 Piston Ring End Gap Position
Fig. 12 Piston Ring Specifications
2. 5L ENGINE 9 - 29
CAUTION: Install piston rings in the following order:
(a) Oi l ri ng expander.
(b) Upper oi l ri ng si de rai l .
(c) Lower oi l ri ng si de rai l .
(d) No. 2 I ntermedi ate pi ston ri ng.
(e) No. 1 Upper pi ston ri ng.
(2) I nstal l the si de rai l by pl aci ng one end between
the pi ston ri ng groove and the expander. Hol d end
fi rml y and press down the porti on to be i nstal l ed unti l
si de rai l i s i n posi ti on. Do not use a piston ring
expander (Fi g. 13).
(3) I nstal l upper si de rai l fi rst and then the l ower
si de rai l .
(4) I nstal l No. 2 pi ston ri ng and then No. 1 pi ston
ri ng (Fi g. 8).
(5) Posi ti on pi ston ri ng end gaps as shown i n (Fi g.
14).
(6) Posi ti on oi l ri ng expander gap at l east 45 from
the si de rai l gaps but not on the pi ston pi n center or on
the thrust di recti on. Staggeri ng ri ng gap i s i mportant
for oi l control .
PI STON AND CONNECTI NG ROD ASSEMBLY
I NSTALLATI ON
(1) Before i nstal l i ng pi stons, and connecti ng rod
assembl i es i nto the bore, besure that compressi on ri ng
gaps are staggered so that nei ther i s i n l i ne wi th oi l
ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make sure
the oi l ri ng expander ends are butted and the rai l gaps
l ocated as shown i n (Fi g. 14).
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l , sl i de the ri ng compressor, over the pi ston
and ti ghten wi th the speci al wrench. Besureposition
of rings does not change during this operation .
(4) The val ve cut shoul d be toward the mani fol d si de
of the engi ne (Fi g. 16).
(5) I nstal l connecti ng rod bol t protectors on rod bol ts
(Fi g. 4).
Fig. 13 Installing Side Rail
Fig. 15 Installing Piston
Fig. 16 Piston Markings
9 - 30 2. 5L ENGINE
(6) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. I nsert rod
and pi ston i nto cyl i nder bore and gui de rod over the
crankshaft journal .
(7) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on connecti ng rod journal .
(8) I nstal l rod caps. I nstal l nuts on cl eaned and oi l ed
rod bol ts and ti ghten nuts to 54 Nm (40 ft. l b.) Pl us 1/4
turn.
CONNECTI NG RODS
(1) Fol l ow procedure speci fi ed i n the Standard Ser-
vi ce Procedures Secti on for Measuri ng Mai n Beari ng
Cl earance and Connecti ng Rod Beari ng Cl earance
(Fi g. 17). Refer to speci fi cati ons (Fi g. 20).
CAUTION: Do not rotate crankshaft or the Plastic-
Gage may be smeared.
The rod bearing bolts should be examined be-
fore reuse. If the threads are necked down the
bolts should be replaced (Fig. 18).
(2) Before i nstal l i ng the nuts the threads shoul d be
oi l ed wi th engi ne oi l .
(3) I nstal l nuts on each bol t fi nger ti ght than al ter-
natel y torque each nut to assembl e the cap properl y.
(4) Ti ghten the nuts to 54 Nm PLUS 1/4 turn (40 ft.
l bs. PLUS 1/4 turn). Donot useatorquewrenchfor
last step.
(5) Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 19). Refer to connecti ng rod speci fi ca-
ti ons (Fi g. 20).
ENGINE CORE PLUGS
REMOVAL
Usi ng a bl unt tool such as a dri ft or a screwdri ver
and a hammer, stri ke the bottom edge of the cup
Fig. 17 Checking Connecting Rod Bearing Clear-
ance
Fig. 18 Checking Bolts for Stretching (Necked)
Fig. 19 Checking Connecting Rod Side Clearance
Fig 20 Connecting Rod Specifications
2. 5L ENGINE 9 - 31
pl ug (Fi g. 21). Wi th the cup pl ug rotated, grasp fi rml y
wi th pl i ers or other sui tabl e tool and remove pl ug (Fi g.
21).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en-
gine problems.
I NSTALLATI ON
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i nder
bl ock or head. Be sure to remove ol d seal er. Li ghtl y coat
i nsi de of cup pl ug hol e wi th seal er. Make certai n the
new pl ug i s cl eaned of al l oi l or grease. Usi ng proper
dri ve pl ug, dri ve pl ug i nto hol e so that the sharp edge
of the pl ug i s at l east 0.5mm (.020 i nch) i nsi de the
l ead-i n chamfer (Fi g. 21).
I t i s i n not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
Fig. 21 Core Hole Plug Removal
9 - 32 2. 5L ENGINE
CRANKSHAFT, INTERMEDIATE AND BALANCE
SHAFT ASSEMBLIES SERVICE
Fig. 1 Crankshaft Intermediate and Balance Shaft Assemblies and Oil Seals
2. 5L ENGINE 9 - 33
CRANKSHAFT OIL SEALS SERVICE
(1) Pry out rear seal wi th screwdri ver. Be careful not
to ni ck or damage crankshaft fl ange seal surface or
retai ner bore (Fi g. 2).
(2) Pl ace Speci al Tool C-4681 on crankshaft (Fi g. 3).
(3) Li ghtl y coat seal O.D. wi th Locti te Stud N Bear-
i ng Mount or equi val ent.
(4) Pl ace seal over Tool C-4681 and tap i n pl ace wi th
a pl asti c hammer.
REAR CRANKSHAFT SEAL RETAI NER AND
OI L SEAL
When retai ner removal i s requi red, use Mopar Gas-
ket Maker appl i ed as shown i n (Fi g 4.) to provi de
retai ner to bl ock seal i ng duri ng re-i nstal l ati on.
FRONT CRANKSHAFT SEAL RETAI NER
See Ti mi ng System and Seal s Secti on for ti mi ng bel t
covers, bel t, crankshaft sprocket and oi l seal s removal
and i nstal l ati on.
(1) Remove retai ner screws (Fi g. 5).
For reassembl y Mopar Gasket Maker i s appl i ed to
the retai ner as shown i n (Fi g. 6). Thi s materi al cures i n
the absence of ai r provi di ng retai ner to bl ock seal i ng.
(2) I nstal l retai ner and ti ghten screws to 12 Nm
(105 i n. l bs.).
Fig. 2 Removing Rear Crankshaft Oil Seal
Fig. 3 Installing Rear Crankshaft Oil Seal
Fig. 4 Rear Crankshaft Seal Retainer Sealing
Fig. 5 Front Crankshaft Oil Seal Retainer
Fig. 6 Front Crankshaft Seal Retainer Sealing
9 - 34 2. 5L ENGINE
CRANKSHAFT SERVICE
CRANKSHAFT MAI N BEARI NGS
Beari ng caps are not i nterchangeabl e and shoul d be
marked at removal to i nsure correct assembl y. Upper
and l ower beari ng hal ves are NOT i nterchangeabl e.
Lower mai n beari ng hal ves of 1, 2, 4 and 5 are
i nterchangeabl e. Upper mai n beari ng hal ves of 1, 2, 4
and 5 are i nterchangeabl e.
CRANKSHAFT MAI N JOURNALS
The crankshaft journal s shoul d be checked for exces-
si ve wear, taper and scori ng. (Fi g. 7) Li mi ts of taper or
out-of-round on any crankshaft journal s shoul d be hel d
to .025mm (.001 i nch). Journal gri ndi ng shoul d not
exceed .305mm (.012 i nch) under the standard journal
di ameter. Do NOTgri nd thrust faces of Number 3 mai n
beari ng. Do NOTni ck crank pi n or beari ng fi l l ets. After
gri ndi ng, remove rough edges from crankshaft oi l hol es
and cl ean out al l passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth polish
after any journal regrind be in the same direction as
normal rotation in the engine.
Upper and l ower Number 3 beari ng hal ves are
fl anged to carry the crankshaft thrust l oads and are
NOTi nterchangeabl e wi th any other beari ng hal ves i n
the engi ne (Fi g. 7). Al l beari ng cap bol ts removed
duri ng servi ce procedures are to be cl eaned and oi l ed
before i nstal l ati on. Beari ng shel l s are avai l abl e i n
standard and the fol l owi ng undersi zed: 0.025mm (.001
i nch), .051mm (.002 i nch), .076mm (.003 i nch), .254mm
(.010 i nch), and .305mm (.012 i nch). Never i nstal l an
undersi ze beari ng that wi l l reduce cl earance bel ow
speci fi cati ons.
MAI N BEARI NG SERVI CECRANKSHAFT NOT
REMOVED
REMOVAL
(1) Remove oi l pan and i denti fy beari ng caps before
removal .
(2) Remove beari ng caps one at a ti me. Remove
upper hal f of beari ng by i nserti ng Speci al Mai n Bear-
i ng Tool C-3059 (Fi g. 8) i nto the oi l hol e of crankshaft.
(3) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Only one main bearing should be selectively
fittedwhileall other mainbearingcapsareprop-
erly tightened.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Mai n Beari ng
Tool C-3059 i nto oi l hol e of crankshaft (Fi g. 8).
(2) Sl owl y rotate crankshaft counter-cl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Speci al Mai n
Beari ng Tool C-3059.
CHECKI NG CRANKSHAFT END PLAY
(1) Mount a di al i ndi cator to front of engi ne, l ocati ng
probe on nose of crankshaft (Fi g. 9).
(2) Move crankshaft al l the way to the rear of i ts
travel .
(3) Zero the di al i ndi cator.
(4) Move crankshaft al l the way to the front and read
the di al i ndi cator. Refer to (Fi g. 10) for speci fi cati ons.
OPTI ONAL CRANKSHAFT END PLAY CHECK
travel usi ng the appropri ate tool i nserted between a
Fig. 7 Main Bearing Identification
Fig. 8 Removing and Installing Upper Main Bearing
With Special Tool C-3059
2. 5L ENGINE 9 - 35
mai n beari ng cap and a crankshaft cheek, usi ng care
not to damage any beari ng surface. Do not l oosen mai n
beari ng cap.
(2) Use a feel er gauge between number three thrust
beari ng and machi ned crankshaft surface to determi ne
end pl ay.
CRANKSHAFT BEARI NG CLEARANCE
(1) Refer to Measuri ng Mai n, Connecti ng Rod Bear-
i ng Cl earance i n Standard Servi ce Procedures. Refer to
(Fi g. 10) for speci fi cati ons.
CAUTION: Do not rotate crankshaft or the
Plastigage maybe smeared.
(2) I nstal l the mai n beari ng shel l s wi th the l ubri ca-
ti on groove i n the cyl i nder bl ock (Fi g. 12). The 1, 2, 4
and 5 main bearings are full groove to provide
full time oiling to the connecting rod. Only the
number 3 is half-groove.
(3) Make certai n oi l hol es i n bl ock l i ne up wi th oi l
hol e i n beari ngs and beari ng tabs seat i n the bl ock tab
sl ots.
(4) Oi l the beari ngs and journal s and i nstal l crank-
shaft.
(5) I nstal l mai n beari ng cap No.1 on ti mi ng bel t end.
(6) I nstal l mai n beari ng cap No.5 on transmi ssi on
end.
Sincethemain bearingboltsaretorqued using
a new procedure they should be examined BE-
FORE reuse. If the threads are necked down the
edge agai nst the threads or by runni ng a M11 x 1.50
nut the full length of the thread. If all
Fig. 9 Checking Crankshaft End Play
Fig. 10 Crankshaft Specifications
Fig. 11 Checking Crankshaft Oil Clearance with
Plastigage
Fig. 12 Installing Main Bearing Upper Shell
9 - 36 2. 5L ENGINE
thethreads do not contact thescaleor if thenut
does not run down smoothly the bolt should be
replaced.
(7) Before i nstal l i ng the bol ts the threads shoul d be
(8) I nstal l both bol ts i n each cap fi nger ti ght, then
al ternatel y torque each bol t to assembl e the cap prop-
erl y.
(9) Ti ghten the bol ts to 41 Nm pl us 1/4 turn (30 ft.
l bs. pl us 1/4 turn). (Fi g. 14)
BALANCE SHAFTS
2.5L engi nes are equi pped wi th two bal ance shafts
i nstal l ed i n a carri er attached to the l ower crankcase
(Fi g. 1).
The shafts are i nterconnected through gears to ro-
tate i n opposi te di recti ons. These gears are dri ven by a
short chai n from the crankshaft, to rotate at two ti mes
crankshaft speed. Thi s counterbal ances certai n engi ne
reci procati ng masses.
REMOVAL
Refer to Engi ne Lubri cati on, Ti mi ng System and
Seal s Servi ce of thi s group for removal procedure of
necessary components to repai r bal ance shafts.
(1) Remove chai n cover, gui de and tensi oner (Fi g.
16). Al so see Carri er Assembl y Removal for servi ce
procedures requi ri ng onl y temporary rel ocati on of as-
sembl y.
(2) Remove bal ance shaft gear and chai n sprocket
retai ni ng screws and crankshaft chai n sprocket torx
screws. Remove chai n and sprocket assembl y. (Fi g. 17)
(3) Remove gear cover retai ni ng stud (doubl e ended
to al so retai n chai n gui de). Remove cover and bal ance
shaft gears (Fi g. 18).
(4) Remove carri er rear cover and bal ance shafts.
(Fi g. 18).
(5) Remove si x carri er to crankcase attachi ng bol ts
to separate carri er (Fi g. 1).
Fig. 13 Main Bearing Caps
Fig. 14 Installing Main Bearing Caps
Fig. 15 Checking Bolts For Stretching
(Necked down)
Fig. 16 Chain Cover, Guide and Tensioner
2. 5L ENGINE 9 - 37
BALANCE SHAFTS CARRI ER ASSEMBLY
REMOVAL
The fol l owi ng components wi l l remai n i ntact duri ng
carri er removal . Gear cover, gears, bal ance shafts and
the rear cover.
(1) Remove chai n cover and dri ven bal ance shaft
chai n sprocket screw.
(2) Loosen tensi oner pi vot and adjusti ng screws,
move dri ven bal ance shaft i nboard through dri ven
chai n sprocket. Sprocket wi l l hang i n l ower chai n l oop.
(3) Remove carri er to crankcase attachi ng bol ts to
remove carri er.
INSTALLATION
Bal ance shaft and carri er assembl y i nstal l ati on i s
the reverse of the removal procedure.During instal-
lationcrankshaft tobalanceshaft timingmust be
established.
TIMING
(1) Wi th bal ance shafts i nstal l ed i n carri er (Fi g. 18)
posi ti on carri er on crankcase and i nstal l si x attachi ng
bol ts and ti ghten to 54 Nm (40 ft. l bs.).
(2) Turn bal ance shafts unti l both shaft key ways are
up Paral l el to verti cal centerl i ne of engi ne. I nstal l
short hub dri ve gear on sprocket dri ven shaft and l ong
hub gear on gear dri ven shaft. After i nstal l ati on gear
and bal ance shaft keyways must be up wi th gear
ti mi ng marks meshed as shown i n (Fi g. 20).
(3) I nstal l gear cover and ti ghten doubl e ended
stud/washer fastener to 12 Nm (105 i n. l bs.).
(4) I nstal l crankshaft sprocket and ti ghten socket
head torx screws to 13 Nm (130 i n. l bs.).
Fig. 20 Gear Timing
Fig. 17 Drive Chain and Sprockets
Fig. 18 Gear Cover and Gears
Fig. 19 Balance Shaft(s) Remove/Install
9 - 38 2. 5L ENGINE
(5) Turn crankshaft unti l number one cyl i nder i s at
Top Dead Center (TDC). The ti mi ng marks on the
chai n sprocket shoul d l i ne up wi th the parti ng l i ne on
the l eft si de of number one mai n beari ng cap. (Fi g. 21).
(6) Pl ace chai n over crankshaft sprocket so that the
ni ckel pl ated l i nk of the chai n i s over the ti mi ng mark
on the crankshaft sprocket (Fi g. 21).
(7) Pl ace bal ance shaft sprocket i nto the ti mi ng
chai n (Fi g. 17) so that the ti mi ng mark on the sprocket
(yel l ow dot) mates wi th the (l ower) ni ckel pl ated l i nk
on the chai n
(8) Wi th bal ance shaft keyways poi nti ng up 12
ocl ock) sl i de the bal ance shaft sprocket onto the nose of
the bal ance shaft. The bal ance shaft may have to be
pushed i n sl i ghtl y to al l ow for cl earance.
THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE AR-
ROW ON THE SIDE OF THE GEAR COVER
SHOULD LINE UP WHEN THE BALANCE
SHAFTS ARE TIMED CORRECTLY.
(9) I f the sprockets are ti med correctl y i nstal l the
bal ance shaft bol ts and ti ghten to 28 Nm (250 i n. l bs.).
A wood bl ock pl aced between crankcase and crankshaft
counterbal ance wi l l prevent crankshaft and gear rota-
ti on.
CHAI N TENSI ONI NG
(1) I nstal l chai n tensi oner l oosel y assembl ed.
(2) Posi ti on gui de on doubl e ended stud maki ng sure
tab on the gui de fi ts i nto sl ot on the gear cover. I nstal l
and ti ghten nut/washer assembl y to 12 Nm (105 i n.
l bs.).
(3) Pl ace a shi m 1mm (.039 i nch) thi ck x 70mm (2.75
i nch) l ong or between tensi oner and chai n. Push ten-
si oner and shi m up agai nst the chai n.Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the ad-
justment slot to takeup all slack (chai n must have
shoe radi us contact as shown i n Fi g. 22).
(4) Wi th the l oad appl i ed, ti ghten top tensi oner bol t
fi rst, then bottom pi vot bol t. Ti ghten bol ts to 12 Nm
(105 i n. l bs.), Remove shi m.
(5) I nstal l carri er covers and ti ghten screws to 12
Nm (105 i n. l bs.).
INTERMEDIATE SHAFT SERVICE
REMOVAL
CAUTION: The oil pump and distributor must be
removed before attempting to remove intermediate
shaft.
(1) Hol d sprocket wi th Tool C-4687 and adaptor Tool
C-4687-1 when removi ng or i nstal l i ng screw (Fi g. 23).
(2) See Ti mi ng System and Seal s for i ntermedi ate
seal removal and repl acement.
(3) Remove retai ner screws (Fi g. 24).
(4) Remove retai ner and l ay asi de.
(5) Remove i ntermedi ate shaft.
Fig. 21 Balance Shaft Timing
Fig. 22 Chain Tension Adjustment
2. 5L ENGINE 9 - 39
I NSTALLATI ON
(1) Lubri cate di stri butor dri ve gear when i nstal l i ng.
(2) Appl y Mopar Gasket Maker as shown i n (Fi g. 25)
and i nstal l i ntermedi ate shaft retai ner.
(3) I nstal l retai ni ng screws and torque to 12 Nm
(105 i n. l bs.).
I NTERMEDI ATE SHAFT BUSHI NG SERVI CE
(1) Remove front bushi ng usi ng Speci al Tool
C-4697-2 wi th Speci al Tool Handl e C-4171 (Fi g. 26).
(2) I nstal l front bushi ng usi ng Speci al Tool C-4697-1
and Speci al Tool Handl e C-4171 unti l tool i s fl ush wi th
bl ock.
(3) Remove rear bushi ng usi ng Speci al Tool
C-4686-2 and Speci al Tool Handl e C-4171 (Fi g. 27).
(4) I nstal l rear bushi ng usi ng Speci al Tool C-4686-1
and Speci al Tool Handl e C-4171 unti l tool i s fl ush wi th
bl ock.
Fig. 25 Intermediate Shaft Retainer Sealing
Fig. 26 Intermediate Shaft Bushing, Front
Fig. 27 Intermediate Shaft BushingRear
Fig. 28 Intermediate Shaft Journal Specifications
Fig. 23 Removing/Installing Intermediate
Shaft Sprocket
Fig. 24 Intermediate Shaft Retainer
9 - 40 2. 5L ENGINE
ENGINE LUBRICATION SYSTEM
Fig. 1 Engine Lubrication System
2. 5L ENGINE 9 - 41
Fig. 2 Engine Lubrication Components
9 - 42 2. 5L ENGINE
OI L PAN
A formed steel oi l pan provi des l ower engi ne protec-
ti on as wel l as servi ng as the engi ne oi l reservoi r (Fi g.
2). Pan si de fl anges to bl ock are seal ed wi th gaskets.
The 2.5L engi ne pi ckup i s unsupported and the l ower
end has a box type strai ner (Fi g. 4).
PRESSURE LUBRI CATI ON
Oi l drawn up through the pi ckup tube i s pressuri zed
by the pump and routed through the ful l fl ow fi l ter to
the mai n oi l gal l ery runni ng the l ength of the cyl i nder
bl ock (Fi g. 1). Modi fi ed oi l pi ckup, pump and check
val ve provi de i ncreased oi l fl ow to the mai n oi l gal l ery.
MAI N/ROD BEARI NGS
A di agonal hol e i n each bul khead feeds oi l to each
mai n beari ng. Dri l l ed passages wi thi n the crankshaft
route oi l from mai n beari ng journal s to crankpi n jour-
nal s (Fi g. 1).
ACCESSORY SHAFT
Two separate hol es suppl y oi l to the accessory shaft.
BALANCE SHAFTS
For 2.5L engi ne bal ance shafts l ubri cati on an addi -
ti onal hol e i nterconnects wi th a passage i n one l eg of
the bal ance shaft carri er to route oi l down to the carri er
oi l gal l ery. Thi s gal l ery di rectl y suppl i es the bal ance
shafts front beari ngs and i nternal machi ned passages
i n the shafts routes oi l from front to rear shaft beari ng
journal s.
CAMSHAFT/HYDRAULI C LI FTERS
A verti cal hol e at the number fi ve bul khead routes
(through a restri ctor) pressuri zed oi l up past a cyl i nder
head bol t to an oi l gal l ery runni ng the l ength of the
cyl i nder head. Hydraul i c adjusters are suppl i ed di -
rectl y from thi s gal l ery whi l e di agonal hol es suppl y oi l
to the camshaft journal s. The camshaft journal s are
parti al l y sl otted to al l ow a predetermi ned amount of
pressuri zed oi l to pass i nto the beari ng cap cavi ti es
wi th smal l hol es di rected to spray l ubri cate the cam-
shaft l obes.
SPLASH LUBRI CATI ON
Oi l returni ng to the pan from pressuri zed compo-
nents suppl i es l ubri cati on to the val ve stems. Cyl i nder
bores and wri st pi ns are spl ash l ubri cated from di -
rected hol es i n the connecti ng rods.
OIL PAN
REMOVAL
(1) Drai n engi ne oi l and remove oi l pan.
(2) Cl ean oi l pan and al l gasket surfaces.
OI L PAN RAI L TO BLOCK SEALI NG
2.5L engi nes use si de gaskets for rai l seal i ng (Fi g. 2).
I NSTALLATI ON
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
or equi val ent at the front seal retai ner parti ng l i ne
(Fi g. 3).
(2) I nstal l the oi l pan si de gaskets to the bl ock. Use
heavy grease or Mopar Si l i cone Rubber Adhesi ve Seal -
ant or equi val ent to hol d i n pl ace.
or equi val ent to ends of new oi l pan end seal s at
juncti on of cyl i nder bl ock pan rai l gasket (Fi g. 3).
(4) I nstal l pan and ti ghten screws to 23 Nm (200 i n.
l bs.).
OIL PUMP SERVICE
OI L PI CKUP
(1) Remove screw on pump cover hol di ng oi l pi ck-up
tube to oi l pump (Fi g. 4).
(2) Remove oi l pi ck-up tube. When reinstalling
make sure to use a new O-Ring on pickup tube.
Fig. 3 Sealing, Front and Rear End Seals
Fig. 4 Oil Pick-Up
2. 5L ENGINE 9 - 43
REMOVAL
(1) Remove two (2) screws hol di ng oi l pump to cyl i n-
der bl ock assembl y (Fi g. 5).
I NSTALLATI ON
(1) Appl y Mopar Gasket Maker to pump body-to-
bl ock i nterface (machi ned surface).
(2) Lubri cate oi l pump rotor & shaft and dri ve gear.
(3) Turn crankshaft and i ntermedi ate shaft unti l
marki ngs on sprockets are i n l i ne (arrows Fi g. 6).
(4) Sl ot i n oi l pump shaft must be paral l el to center
l i ne of crankshaft when i ntermedi ate shaft and crank-
shaft are properl y ti med (Fi g. 7).
(5) I nstal l pump ful l depth and rotate back and forth
sl i ghtl y to ensure proper posi ti oni ng and al i gnment
through ful l surface contact of pump and bl ock ma-
chi ned i nterface surfaces (Fi g. 5).
CAUTION: Pump must be held in fully seated position
(described above) while installing screws.
(6) Ti ghten screws to 23 Nm (200 i n. l bs.).
I NSPECTI ON
(1) Check rotor end cl earance wi th feel er gauge as
shown i n (Fi g. 8).
(2) Li mi ts:
0.03mm (.001 i nch) mi n
0.09mm (.0035 i nch) max.
(3) Thi ckness: 23.96mm (.9435 i nch) mi n. Outer Di -
ameter: 62.7mm (2.469 i nch) mi n (Fi g. 9).
(4) I nstal l wi th l arge chamfered edge i n pump body
(Fi g. 9).
Cl earance: 0.20mm (.008 i nch) max. (Fi g. 10)
Oi l pressure rel i ef val ve spri ng: Free l ength: 49.5mm
(1.95 i nch). Load: 89 N at 34mm. Load: (20 l bs. at 1.34
i nch) (Fi g. 13).
Thi ckness: 23.96mm (.9435 i nch) Mi ni mum (Fi g. 14).
Fig. 5 Oil Pump Assembly
Fig. 6 Crankshaft and Intermediate Shaft Timing
Fig. 7 Oil Pump Shaft Alignment
9 - 44 2. 5L ENGINE
Fig. 8 Checking Rotor End Clearance
Fig. 9 Measuring Outer Rotor
Fig. 10 Clearance Between Rotors
Fig. 11 Outer Rotor Clearance
Fig. 12 Oil Pump Cover
2. 5L ENGINE 9 - 45
CHECKING ENGINE OIL PRESSURE
(1) Remove pressure sendi ng uni t and i nstal l Spe-
ci al Tool S-94 wi th gauge assembl y C-3292 (Fi g. 15).
(2) Warm engi ne at hi gh i dl e unti l thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM
(3) Oi l Pressure: CurbIdle25 kPa (4 psi ) mi ni mum
3000 RPM 170-550 kPa (25-80 psi ).
OIL FILTER
ANTI -DRAI N BACK VALVE
I nstal l ati on: Appl y l i qui d (Tefl on Type) seal ant to
val ve-to-bl ock threads (Fi g. 16). Ti ghten assembl y to
55 Nm (40 ft. l bs.).
FI LTER
CAUTION: When servicing the oil filter (Fig. 16) avoid
deforming the filter can by installing the
remove/install tool band strap against the can-to-
base lockseam. The lockseam joining the can to the
base is reinforced by the base plate.
(1) Turn counter cl ockwi se to remove.
(2) To i nstal l , l ubri cate new fi l ter gasket. Check
fi l ter mounti ng surface. The surface must be smooth,
fl at and free of debri s or ol d pi eces of rubber. Screw
fi l ter on unti l gasket contacts base. Ti ghten to 1 turn.
Fig. 13 Oil Pressure Relief Valve
Fig. 14 Measuring Inner Rotor Thickness
Fig. 15 Checking Oil Pump PressureTypical
Fig. 16 Engine Oil Filter and Antidrain Back Valve
9 - 46 2. 5L ENGINE
ENGINE SPECIFICATIONS
2. 5L ENGINE 9 - 47
ENGINE SPECIFICATIONS (CONT. )
9 - 48 2. 5L ENGINE
TORQUE
2. 5L ENGINE 9 - 49
3.0L ENGI NE
INDEX
page page
Accessory Drive Belt Service . . . . . . . . . . . . . . . . 54
Auto Lash Adjuster . . . . . . . . . . . . . . . . . . . . . . . . 59
Camshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking Engine Oil Pressure . . . . . . . . . . . . . . . 77
Crankshaft and Cylinder Block,Assembly Service . 70
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cylinder Head and Camshaft Service . . . . . . . . . . 59
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Lubrication System . . . . . . . . . . . . . . . . . . 75
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 79
General Information . . . . . . . . . . . . . . . . . . . . . . . 50
Oil Filter and Bracket . . . . . . . . . . . . . . . . . . . . . . 78
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 76
Piston and Connecting Rod Assembly Service . . . 66
Timing Belt InspectionIn Vehicle . . . . . . . . . . . . 55
Timing Belt Service . . . . . . . . . . . . . . . . . . . . . . . 56
Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
GENERAL INFORMATION
(Fi g. 1).
BLOCK: The cyl i nder bl ock i s a l i ght wei ght desi gn
created by reduci ng thi ckness i n many parts and a
short 10 mm (3/8 i nch) bl ock ski rt. Hi gh ri gi di ty i s
provi ded wi th ri bs cast i n the outer wal l , a ful l l ength
water jacket, and a monobl ock or beam type, mai n
beari ng cap. Thi s si ngl e uni t four beari ng cap i s de-
si gned to control vi brati on of the cyl i nder bl ock parti -
ti on wal l s.
CRANKSHAFT:A si x throw, fi ve wei ght crankshaft
i s supported by four mai n beari ngs wi th number three
bei ng the thrust beari ng. The si x separate connecti ng
rod throws pi ns reduce torque fl uctuati ons whi l e a
torsi onal vi brati on damper i s used to control torsi on
caused vi brati on of the crankshaft. Rubber l i pped seal s
are used at front and rear. The front seal i s retai ned i n
the oi l pump case and the rear i s retai ned i n a
bl ock-mounted housi ng.
3.0L ENGI NE
9 - 50 3. 0L ENGINE
PISTONS: Are al umi num al l oy wi th a steel strut,
short hei ght, and thi n wal l so as to be autothermi c and
l i ght wei ght. The pi ston head wi th val ve recesses, i n
combi nati on wi th the cyl i nder head, forms a compact
spheri cal head wi th cl earance for total val ve l i ft wi th
pi stons at top dead center. The pi ston ski rt, top and
second ri ng l ands are fi ni shed wi th curvi l i near tapered
roughness for oi l retenti on and hi gh resi stance to
scuffi ng. Pi ston pi ns, press-fi tted i nto pl ace, joi n the
pi stons to the connecti ng rods.
CYLINDER HEAD: The al l oy cyl i nder heads fea-
ture cross-fl ow type i ntake and exhaust ports. Val ve
gui des and i nserts are hardened cast i ron. Val ves of
heat resi stance steel are arranged i n a V wi th each
camshaft on center. To i mprove combusti on speed the
chambers are a compact spheri cal desi gn wi th a squi sh
area of approxi matel y 30 percent of the pi ston top area.
The cyl i nder heads are common to ei ther cyl i nder bank
by reversi ng the di recti on of i nstal l ati on.
CAMSHAFTS: Two overhead camshafts provi de
val ve actuati on, one front (radi ator si de of cyl i nder
bank) and one rear. The front camshaft i s provi ded
wi th a di stri butor dri ve and i s l onger. Both camshafts
are supported by four beari ng journal s, thrust for the
front camshaft i s taken at journal two and the rear at
journal three. Front and rear camshaft dri vi ng sprock-
ets are i nterchangeabl e. The sprockets and the engi ne
water pump are dri ven by a si ngl e notched ti mi ng bel t.
ROCKER ARM SHAFTS: The shafts are retai ned
by the camshaft beari ng journal caps. Four shafts are
used, one for each i ntake and exhaust rocker arm
assembl y on each cyl i nder head. The hol l ow shafts
provi de a duct for l ubri cati ng oi l fl ow from the cyl i nder
head to the val ve mechani sms.
ROCKER ARMS: Are of l i ght wei ght di e-cast wi th
rol l er type fol l ower operati ng agai nst the cam shaft.
The val ve actuati ng end of the rocker arms are ma-
chi ned to retai n hydraul i c l ash adjusters, el i mi nati ng
val ve l ash adjustment.
VALVES: Are made of heat resi stant steel and are
further treated to resi st heat.
VALVE SPRINGS: Are especi al l y desi gned to be
short. The val ve spri ng wi re cross-secti on i s oval
SPECI FI CATI ONS
3. 0L ENGINE 9 - 51
shaped and provi des the same spri ng tensi on as l onger
spri ngs. Val ve spri ng retai ners, l ocks and seal s are
conventi onal .
INTAKE MANIFOLD: The al umi num al l oy mani -
fol d i s a cross type wi th l ong runners to i mprove
i nerti a. The runners, attachi ng bel ow at the cyl i nder
head, al so attach above and support an ai r pl enum.
The ai r pl enum chamber absorbs ai r pul sati ons created
duri ng the sucti on phase of each cyl i nder.
EXHAUST MANIFOLDS: Both mani fol ds are a l og
styl e made of ducti l e cast i ron. Exhaust gasses, col -
l ected from the front cyl i nder bank, l eave the front
mani fol d through an end outl et and are fed through an
upper crossover tube to the rear mani fol d. The col -
l ected exhaust from both mani fol ds are combi ned, and
exi t to the exhaust pi pe through an arti cul ated joi nt.
ENGINE LUBRICATION: System i s a ful l fl ow
fi l trati on, pressure feed type. The oi l pump i s mounted
i n the chai ncase cover. The pump i nner rotor i s dri ven
by the crankshaft. The engi ne oi l pan contai ns a baffl e
pl ate to control oi l l evel fl uctuati on duri ng engi ne
operati on.
ENGINE MOUNTS
RI GHT SI DE MOUNT
FRONT MOUNT
assembl y.
Fig. 2 Engine Mounting
9 - 52 3. 0L ENGINE
LEFT SI DE MOUNT
wheel .
jack.
remove mount.
Group 2.
moved or not.
ENGINE ASSEMBLY
REMOVAL
(2) Mark hood posi ti on at hi nges and remove hood.
(3) Drai n cool i ng system. Refer to Cool i ng System
Group 7 for drai ni ng procedure.
(4) Di sconnect al l el ectri cal connecti ons.
(5) Remove cool ant hoses from radi ator and engi ne.
(6) Remove radi ator and fan assembl y.
(7) See Fuel System Group 14, For procedures to
rel ease fuel pressure, di sconnect fuel l i nes and accel -
erator cabl e.
(8) Remove ai r cl eaner assembl y.
(9) Hoi st vehi cl e and drai n engi ne oi l .
bol ts and set compressor asi de.
(11) Di sconnect exhaust pi pe at mani fol d.
(12) Remove transmi ssi on i nspecti on cover and
mark fl ex pl ate to torque converter posi ti on.
(13) Remove screws hol di ng torque converter to fl ex
pl ate and attach C-cl amp on bottom of converter hous-
i ng to prevent torque converter from comi ng out.
(15) Remove two l ower transmi ssi on to bl ock screws.
(16) Remove starter.
(17) Lower vehi cl es and di sconnect vacuum l i nes
and ground strap.
(19) Attach engi ne l i fti ng hoi st and support engi ne.
(20) Remove upper transmi ssi on case to bl ock bol ts.
(21) See Engi ne Mounti ng i n (Fi g. 2) and separate
mount/i nsul ators as fol l ows:
(a) Mark RI GHT i nsul ator on ri ght rai l s supports.
Remove i nsul ator to rai l s screws.
(b) Remove FRONT engi ne mount through bol t
and nut.
(c) Remove LEFT i nsul ator through bol t from i n-
si de wheel house or i nsul ator bracket to transmi ssi on
screws.
(22) Remove engi ne.
3. 0L ENGINE 9 - 53
I NSTALLATI ON
(1) Attach hoi st and l ower engi ne i nto engi ne com-
partment.
Ti ghten bol ts to torque speci fi ed i n (Fi g. 2).
(3) I nstal l transmi ssi on case to cyl i nder bl ock,
ti ghten bol ts to 102 Nm (75 ft. l bs.) torque.
fi xture.
(5) Remove C cl amp from torque converter housi ng.
Al i gn fl ex pl ate to torque converter and i nstal l mount-
i ng screws. Ti ghten to 75 Nm (55 ft. l bs.)
(6) I nstal l transmi ssi on i nspecti on cover.
(7) Connect exhaust system at mani fol d.
(8) I nstal l starter.
(9) I nstal l power steeri ng pump and ai r condi ti oni ng
compressor. For bel t i nstal l ati on Refer to Accessory
Bel t Dri ve i n Cool i ng System Group 7.
(10) Lower vehi cl e and connect al l vacuum l i nes.
(11) Connect al l el ectri cal connecti ons i ncl udi ng
ground strap.
(12) Connect fuel l i nes and accel erator cabl e.
(13) I nstal l radi ator and fan assembl y. Connect fan
motor el ectri cal l ead. I nstal l radi ator hoses. Fi l l cool i ng
system. Refer to Cool i ng System Group 7 for fi l l i ng
procedure.
(14) Fi l l engi ne crankcase wi th proper oi l to correct
l evel .
ture i s reached.
(18) Adjust transmi ssi on or l i nkage i f necessary.
ACCESSORY DRIVE BELT SERVICE
REMOVAL
(1) Loosen adjusti ng l ock nut (Fi g. 6).
(2) Turn adjusti ng jack screw countercl ockwi se to
reduce bel t tensi on. Remove bel t.
Fig. 4 Accessories Mounting Brackets
Fig. 5 Drive Belt Inspection
9 - 54 3. 0L ENGINE
(3) I nspect dri ve bel t for wear and damage (Fi g. 5).
(4) I nstal l ati on: Adjust bel t tensi on to 5/16 defl ecti on
between pul l eys (Fi g. 6).
(5) I nstal l breaker bar i nto 1/2 square openi ng i n
tensi oner.
(6) Rotate tensi oner countercl ockwi se to remove and
i nstal l bel t (Fi g. 7).
ENGI NE MOUNT BRACKET
REMOVAL
(1) Remove ai r condi ti oni ng compressor to mounti ng
bracket screws and l ay compressor asi de (Fi g. 4).
(2) Remove screws attachi ng ai r condi ti oni ng com-
pressor mounti ng bracket and adjustabl e dri ve bel t
tensi oner from bl ock and engi ne mounti ng bracket.
Remove both assembl i es.
(3) Remove steeri ng pump/al ternator bel t tensi oner
mounti ng bol t and remove automati c bel t tensi oner.
(4) Remove two steeri ng pump to engi ne mounti ng
bracket screws and one rear support l ock nut.
(5) Lay power steeri ng pump asi de.
(6) Rai se vehi cl e and remove ri ght i nner spl ash
shi el d (Fi g. 8).
(7) Remove crankshaft dri ve pul l eys and torsi onal
damper (Fi g. 9).
(8) Lower vehi cl e and pl ace a jack under engi ne.
(9) Separate engi ne mount i nsul ator from engi ne
mount bracket (Fi g. 10). Rai se engi ne sl i ghtl y.
(10) Remove engi ne mount bracket (Fi g. 10).
(11) Remove ti mi ng bel t covers (Fi g. 11).
TIMING BELT INSPECTION IN VEHICLE
(1) Remove the upper front outer ti mi ng bel t cover
by l ooseni ng the three attachi ng bol ts. (Fi g. 11).
(2) I nspect both si des of the ti mi ng bel t dri ve & back.
Repl ace bel t i f any of the fol l owi ng condi ti ons exi st.
Hardeni ng of back rubber back si de i s gl ossy wi th-
out resi l i ence and l eaves no i ndent when pressed wi th
fi ngernai l .
Fig. 6 Air Conditioning Belt
Fig. 7 Alternator/Power Steering Belt
Fig. 8 Right Inner Splash ShieldTypical
Fig. 9 Crankshaft Drive Pulleys
3. 0L ENGINE 9 - 55
Cracks on rubber back.
Cracks or peel i ng of canvas.
Cracks on ri b root.
Cracks on bel t si des.
Mi ssi ng teeth.
Abnormal wear of bel t si des. The si des are normal i f
they are sharp as i f cut by a kni fe (Fi g. 12).
(3) I f none of the above condi ti ons are seen on the
bel t, the bel t cover can be rei nstal l ed.
TIMING BELT SERVICE
REMOVAL
(1) Mark bel t runni ng di recti on for i nstal l ati on (Fi g.
14).
(2) Loosen ti mi ng bel t tensi oner bol t (Fi g. 16) and
remove ti mi ng bel t.
(3) Remove crankshaft sprocket fl ange shi el d (Fi g.
9).
CAMSHAFT SPROCKETS
REMOVAL
(1) Hol d camshaft sprocket wi th Spanner Tool
MB990775 l oosen and remove bol t and washer (Fi g.
15).
(2) Remove camshaft sprocket from camshaft.
I NSTALLATI ON
(1) Pl ace camshaft sprocket on camshaft.
(2) I nstal l bol t and washer to camshaft. Usi ng Span-
ner Tool MB990775 hol d camshaft sprocket and torque
bol t to 95 Nm (70 ft. l bs.) (Fi g. 15).
TI MI NG BELT TENSI ONER
(1) I nstal l ti mi ng bel t tensi oner and tensi oner
spri ng.
(2) Hook spri ng upper end to water pump pi n and
l ower end to tensi oner bracket wi th hook out (Fi g. 16).
(3) Turn ti mi ng bel t tensi oner counter-cl ockwi se ful l
travel i n adjustment sl ot and ti ghten bol t to tempo-
rari l y hol d thi s posi ti on (Fi g. 17).
Fig. 10 Right Engine Mount and
Engine Mount Bracket
Fig. 11 Timing Belt Covers
Fig. 12 Timing Belt Inspection
9 - 56 3. 0L ENGINE
Fig. 13 Timing Belt System
Fig. 14 Timing Belt EFngine Sprocket Timing
3. 0L ENGINE 9 - 57
I NSTALLATI ONTI MI NG BELT
(1) I nstal l ti mi ng bel t on crankshaft sprocket fi rst
and whi l e keepi ng bel t ti ght on tensi on si de (Fi g. 14)
i nstal l bel t on the front (radi ator si de) camshaft
sprocket.
(2) Then, i nstal l on the water pump pul l ey and on
the rear camshaft sprocket and fi nal l y on the ti mi ng
bel t tensi oner.
(3) Appl y rotati ng force to the front camshaft
sprocket i n opposi te di recti on to tensi on the bel t ten-
si on si de and check that al l ti mi ng marks are l i ned up
(Fi g. 14).
(4) I nstal l crankshaft sprocket fl ange (Fi g. 13).
(5) Loosen tensi oner bol t and al l ow spri ng to tensi on
ti mi ng bel t.
(6) Turn crankshaft two ful l turns i n cl ockwi se di -
recti on. Turn smoothly andin clockwisedirection
ONLY.
(7) Agai n l i ne up the ti mi ng marks on the sprockets
and ti ghten the ti mi ng bel t tensi oner l ocki ng bol t to 25
Nm (250 i n. l bs.) torque.
(8) Reassembl y bel t covers, engi ne Bracket, I nsul a-
tor, crankshaft pul l eys, accessori es and accessory dri ve
bel ts i n reverse order.
Fig. 15 Camshaft Sprockets
Fig. 16 Timing Belt Tensioner
Fig. 17 Positioning Belt Tensioner
9 - 58 3. 0L ENGINE
CYLINDER HEAD AND CAMSHAFT SERVICE
CYLI NDER HEAD COVER
REMOVAL
(2) Di sconnect battery and rel ocate spark pl ug
wi res.
(3) Remove vacuum connecti ons.
(4) Remove rocker cover screws and remove cover
(Fi g. 2).
I NSTALLATI ON
(1) Cl ean cyl i nder head and cover mati ng surfaces.
I nstal l new gasket.
(2) See (Fi g. 2) and appl y seal ant such as Mopar
Si l i cone Rubber Adhesi ve Seal ant to cover ends.
(3) I nstal l cover and ti ghten cover bol t washer and
gasket assembl y to 10 Nm (88 i n. l bs.).
AUTO LASH ADJUSTER
The automati c l ash adjusters are preci si on uni ts
i nstal l ed i n machi ned openi ngs i n the val ve actuati ng
ends of the rocker arms. Do not di sassembl e the auto
l ash adjuster.
FUNCTI ON CHECK
Check auto adjusters for free pl ay by i nserti ng a
smal l wi re through the ai r bl eed hol e i n the rocker arm
and VERY LIGHTLY push the auto adjuster bal l
check down (Fi g. 3). Whi l e l i ghtl y hol di ng the check
bal l down move the rocker up and down to check for
free pl ay. I f there i s no pl ay repl ace the adjuster.
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
3. 0L ENGINE 9 - 59
CAMSHAFT SERVICE
SEE AUTO LASH ADJUSTER FUNCTI ON
CHECK BEFORE DI SASSEMBLY
REMOVAL
(1) I nstal l auto l ash adjuster retai ners. (Fi g. 4).
(2) Remove di stri butor extensi on (Fi g. 1).
(3) When removi ng camshaft beari ng caps do not
remove the bol ts from the beari ng caps. Remove the
rocker arm, rocker shafts and beari ng cap as an
assembl y.
CAMSHAFT I NSPECTI ON
(1) I nspect camshaft beari ng journal s for damage
and bi ndi ng (Fi g. 5). I f journal s are bi ndi ng,al so check
the cyl i nder head for damage (Fi g. 1). Al so check
cyl i nder head oi l hol es for cl oggi ng.
(2) Front cyl i nder head camshaft check the tooth
surface of the di stri butor dri ve gear teeth of the cam-
shaft and repl ace i f abnormal wear i s evi dent (Fi g. 5).
(3) Check the cam surface for abnormal wear and
damage and repl ace i f defecti ve. Al so measure the cam
hei ght (Fi g. 5) and repl ace i f out of l i mi t, standard
val ue i s 41.25 mm (1.624 i nch), wear limit i s 40.75 mm
(1.604 i nch).
CAMSHAFT I NSTALL
Lubri cate camshaft journal s and cams wi th engi ne
oi l and i nstal l camshaft on cyl i nder head.
ROCKER ARMS
(1) Check rocker arms for wear or damage (Fi g. 6).
Repl ace as necessary. Al so see Auto Lash Adjuster.
ROCKER ARM SHAFTS
The rocker arm shaft i s hol l ow and i s used as a
l ubri cati on oi l duct. The rocker arm shaft on the inlet
Fig. 3 Auto Lash Adjuster Check
Fig. 4 Auto Lash Adjuster Retainers
Fig. 5 Check Camshafts
Fig. 6 Inspect Rocker Arms
9 - 60 3. 0L ENGINE
si de has a 3mm di ameter oi l passage hol e from the
cyl i nder head. The exhaust si de doesnot have thi s oi l
passage (Fi g. 7).
(1) Check the rocker arm mounti ng porti on of the
shafts for wear or damage. Repl ace i f heavi l y damaged
or worn.
(2) Check oi l hol es for cl oggi ng wi th smal l wi re,
cl ean as requi red (Fi g. 7).
REASSEMBLE
(1) Al i gn the camshaft beari ng caps wi th arrows
(dependi ng on cyl i nder bank) di rected as shown i n (Fi g.
8) and i n numeri cal order.
I denti fy number one beari ng cap number one and
number four caps are si mi l ar (Fi g. 9).
(2) I nstal l rocker shafts i nto beari ng cap number one
wi th end notches posi ti oned as shown i n (Fi g. 9) that
the machi ned porti on of the rocker shaft i s faci ng
down.
(3) I nsert attachi ng bol ts to retai n assembl y.
ASSEMBLE ROCKER ASSEMBLY
I nstal l the rocker arms, beari ng caps and spri ngs.
Springs are the same and can be used at all
locations on the rocker arm shafts (Fi gs. 8 and 10).
I nsert bol ts i n number four beari ng cap to retai n
assembl y.
I NSTALL ROCKER ARM SHAFT ASSEMBLY
at beari ng cap ends as shown i n (Fi g. 8).
(2) I nstal l the rocker arm shaft assembl y maki ng
sure that the arrow mark on the beari ng cap and the
arrow mark on the cyl i nder head are i n the same
di recti on (Fi g. 8).
The direction of arrow marks on the front and
rear assemblies are opposite to each other.
(3) Ti ghten beari ng cap bol ts i n the fol l owi ng order
to 10 Nm (85 i n. l bs.). Fi rst #3, then #2, #1 and #4.
(4) Repeat step 3 i ncreasi ng the torque to 20 Nm
(180 i n.l bs.).
(5) I nstal l di stri butor dri ve adaptor assembl y (Fi g.
11).
CAMSHAFT OI L SEAL ENGI NE OUT OF VE-
HI CLE
(1) Appl y l i ght coat of engi ne oi l to the camshaft oi l
seal l i p.
(2) I nstal l the oi l seal usi ng camshaft oi l seal i n-
stal l er tool MD998713 (Fi g. 12).
CAMSHAFT END SEAL (PLUG) ENGI NE I N
VEHI CLE
(1) Remove ai r cl eaner assembl y from engi ne.
(2) Use a smal l punch and a hammer, careful l y
remove cam pl ug from cyl i nder head.
(3) Cl ean the area of the cyl i nder head where the
new cam pl ug wi l l be i nstal l ed.
(4) Appl y a l i ght coati ng of Mopar Si l i cone Rubber
Adhesi ve Seal ant to the outer di ameter of the NEW
cam pl ug.
(5) Usi ng a sui tabl e i nstal l i ng tool and a hammer,
Fig. 7 Rocker Arm Shaft Identification
Fig. 8 Camshaft Bearing Caps Position
Fig. 9 Number One Camshaft Bearing Cap
3. 0L ENGINE 9 - 61
i nstal l the new cam pl ug to a depth of 0.5mm (0.020
i nch) bel ow the surface of the cyl i nder head.
(6) Repl ace ai r cl eaner assembl y.
CAMSHAFT END SEAL (PLUG) ENGI NE OUT
OF VEHI CLE
I nstal l end seal pl ug wi th Speci al Tool MD998306.
(Fi g. 13).
CYLINDER HEAD
REMOVAL
(1) See Ti mi ng System thi s group for di sassembl y
and remove camshaft sprockets.
Fig. 10 Assemble Rocker Arm and Shafts
Fig. 11 Distributor Drive
Fig. 12 Install Camshaft Oil Seal
9 - 62 3. 0L ENGINE
(2) See Camshaft Rocker Arms Removal .
(3) Remove upper i ntake mani fol d assembl y. Refer
to I ntake and Exhaust Mani fol ds, Group 11.
(4) Remove di stri butor.
(5) Remove exhaust mani fol ds and cross over Refer
(6) Remove cyl i nder head bol ts i n sequence shown
i n (Fi g. 14) and remove cyl i nder head.
I NSPECTI ON
(1) Before cl eani ng, check for l eaks, damage and
cracks.
(2) Cl ean cyl i nder head and oi l passages.
(3) Check cyl i nder head for fl atness (Fi g. 15).
(4) Cyl i nder head must be fl at wi thi n;
Standard di mensi on = l ess than 0.05mm (.002
i nch)
Servi ce Li mi t = 0.2mm (.008 i nch)
Gri ndi ng Li mi t = Maxi mum of 0.2 mm (.008 i nch)
i s permi tted.
CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.
I NSTALLATI ON
(1) Cl ean surfaces of head and bl ock, i nstal l head
gasket over l ocati ng dowel s.
(2) I nstal l head on l ocati ng dowel s.
(3) I nstal l 10mm Al l en Hex head bol ts wi th wash-
ers.
Fig. 13 Install Camshaft End SealPlug
Fig. 14 Cylinder Head Bolt Removal Sequence
Fig. 15 Check Cylinder Head
Fig. 16 Cylinder Head Bolt Tightening Sequence
3. 0L ENGINE 9 - 63
(4) Ti ghten bol ts i n the order shown i n (Fi g. 16).
When ti ghteni ng the cyl i nder head bol ts, ti ghten
gradual l y, worki ng i n two or three steps and fi nal l y
ti ghten to speci fi ed torque of 108 Nm (80 ft. l bs.).
VALVE SERVICE
VALVE AND VALVE SPRI NGS
(1) Wi th sui tabl e val ve spri ng compressor, remove
spri ng retai ner l ocks, retai ner, val ve spri ng, spri ng
seat and val ve (Fi g. 17).
(2) Remove val ve stem seal s wi th sui tabl e tool (Fi g.
18). Do not reuse val ve stem seal s.
VALVES
(1) Check val ve stem ti p for pi tti ng or depressi on at
poi nt A (Fi g. 19).
(2) Check for wear and ri dge wear at Poi nt B.
(3) Check for even contact (at face center) wi th val ve
seat, Poi nt C.
(4) Check margi n. Repl ace val ve i f margi n i s out of
speci fi cati on (Fi g. 20).
(5) Measure val ve stem to gui de cl earance.
(6) Measure Val ve spri ng free l ength and squareness
(Fi g. 21). Refer to (Fi g. 20) for speci fi cati ons.
VALVE SEAT I NSPECTI ON
I nspect the val ve seat wi th Prussi an bl ue to deter-
mi ne where the val ve contacts the seat. To do thi s,
Fig. 17 Remove Valves
Fig. 18 Remove Valve Stem Seals
Fig. 19 Valve Inspection
Fig. 20 Valve Specification
Fig. 21 Valve Spring
9 - 64 3. 0L ENGINE
edge of the val ve face, l ower val ve seat wi th a 15
degrees stone. I f the bl ue i s transferred to the bottom
edge of val ve face rai se val ve seat wi th a 65 degree
stone.
(1) I nstal l val ve spri ng seat.
(2) Usi ng sui tabl e tool i nstal l seal by tappi ng l i ghtl y
unti l seal i s i n pl ace. (Fi g. 23).
(3) I nstal l val ve spri ng wi th the enamel l ed ends
faci ng the rocker arms (Fi g. 24).
CAUTION: During reassembly, compressing the valve
spring more than necessary to install valve spring
retainer locks can cause the retainer to be forced
against the stem seal and damaging it.
Fig. 24 Installed Valve Spring Position
Fig. 22 Valve Seat Reconditioning
Fig. 23 Install Valve Stem Seals
3. 0L ENGINE 9 - 65
PISTON AND CONNECTING ROD ASSEMBLY SER-
VICE
(1) Mark I denti fy Pi stons.The pistons are not in-
terchangeable frombank to bank (Fi g. 2).
(2) Mark connecti ng rod and cap wi th cyl i nder num-
ber (Fi g. 3).
(3) Remove pi ston ri ngs (Fi g. 4).
(1) Measure the cyl i nder bore at three l evel s i n
di recti ons A and B (Fi g. 5). Top measurement shoul d be
12mm (.50 i nch) down and bottom measurement
shoul d be 10mm (.38 i nch) up.
(2) Standard bore di mensi on: 91.1mm (3.587 i nch)
(3) Maxi mum out-of-round or taper: 0.02mm (.0008
i nch)
FI TTI NG PI STONS
Measure approxi matel y 2mm (.080 i nch) above the
bottom of the pi ston ski rt and across the thrust face.
(Fi g. 6), See Bori ng Cyl i nder i n Cyl i nder Bl ock.
FI TTI NG PI STON RI NGS
posi ti oni ng at l east 16mm (0.63 i nch) from bottom of
Refer to (Fi g. 8) for speci fi cati on.
(2) Check pi ston ri ng to groove cl earance; Refer to
Pi ston Ri ng Speci fi cati on Chart (Fi g. 8).
Fig. 1 Pistons, Connecting Rods
Fig. 2 Mark Pistons
Fig. 3 Mark Matching Parts
9 - 66 3. 0L ENGINE
cross secti on. I nstal l ri ngs wi th manufacturers mark
and si ze mark faci ng up, to the top of the pi ston (Fi g.
10).
Fig. 4 Remove Piston Rings
Fig. 6 Piston Clearance and Wear
Fig. 7 Check Gap on Piston Rings
Fig. 8 Piston Ring Specification Chart
Fig. 9 Piston Ring Clearance
3. 0L ENGINE 9 - 67
si de rai l i s i n posi ti on. Do Not use a piston ring
expander (Fi g. 11).
si de rai l .
ri ng (Fi g. 12).
13).
the thrust di recti on.
(7) Connecti ng rod front mark 72 must al ways face
forward, toward ti mi ng bel t end. (Fi g. 14)
(8) I nstal l the pi ston and connecti ng rod assembl y
i nto there respecti ve bore from the cyl i nder bl ock top.
CAUTION: Piston assemblies are not to be inter-
changed from bank to bank.
(9) Check al i gnment marks made duri ng di sassem-
bl y and that beari ng posi ti on notches new or used are
on the same si de as shown i n (Fi g. 15).
CONNECTI NG ROD CLEARANCE
(1) Fol l owi ng procedures speci fi ed i n the Standard
Servi ce Procedures Secti on for Measuri ng Mai n Bear-
i ng Cl earance and Connecti ng Rod Beari ng Cl earance.
(Fi g. 16). Refer to (Fi g. 18) for speci fi cati ons.
(2) Ti ghten nuts to 52 Nm (38 ft. l bs.).
(3) Remove connecti ng rod cap and measure Pl asti -
gage (Fi g. 16).
Fig. 10 Piston Ring Installation
Fig. 12 Installing Upper and Intermediate Rings
9 - 68 3. 0L ENGINE
CAUTION: Do not rotate crankshaft or the Plastigage
may be smeared.
CONNECTI NG ROD SI DE CLEARANCE
Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 17). Refer to (Fi g. 18) for speci fi cati on.
Fig. 14 Identify Piston/Rod Assembly
for Cylinder Installation
Fig. 15 Connecting Rod and Cap
Fig. 16 Connecting Rod Checking
Bearing Clearance
Fig. 18 Connecting Rod Clearance Specifications
3. 0L ENGINE 9 - 69
CRANKSHAFT AND CYLINDER BLOCK, ASSEMBLY
SERVICE
CRANKSHAFT SERVI CE
The crankshaft i s supported i n four mai n beari ngs.
Al l upper beari ng shel l s i n the crankcase have oi l
grooves. Al l l ower beari ng shel l s i n stal l ed i n the
monobl ock mai n beari ng cap are pl ai n. Crankshaft end
pl ay i s control l ed by thrust washers on the number
three mai n beari ng journal .
CRANKSHAFTREMOVAL
(1) Remove front mounted oi l pump assembl y and
gasket (Fi gs. 1 and 2).
(2) Remove rear oi l seal retai ner and seal as assem-
bl y (Fi g. 3).
(3) Rel ease monobl ock mai n beari ng cap bol ts
evenl y. Remove l ower beari ng shel l s and i denti fy for
reassembl y.
(4) Li ft out crankshaft and remove upper thrust
washers from each si de of number three mai n beari ng
i n the crankcase (Fi g. 1).
I NSPECTI ON
Vi sual l y check the mai n and connecti ng rod beari ng
journal s for wear, scuffs or scori ng and repl ace i f
necessary.
CRANKSHAFT OI L CLEARANCE
MECHANI CAL MEASUREMENT
Measure the journal outsi de di ameter and the mai n
beari ng i nsi de di ameter (Fi gs. 4 and 5). I f the cl earance
exceeds the speci fi cati ons l i mi t (Fi g. 6). Repl ace the
mai n beari ng(s) and i f necessary repl ace the crank-
shaft.
Fig. 1 Crankshaft and Cylinder Block
9 - 70 3. 0L ENGINE
PLASTI GAGE MEASUREMENT
(1) Remove oi l from journal and beari ng shel l .
(2) I nstal l crankshaft.
(3) Cut pl asti gage to same l ength as wi dth of the
beari ng and pl ace i t i n paral l el wi th the journal axi s.
(Fi g. 7).
(4) I nstal l the mai n beari ng cap careful l y and
ti ghten the bol ts to speci fi ed torque.
CAUTION: Do not rotate crankshaft or the plastigage
will be smeared.
(5) Careful l y remove the beari ng cap and measure
the wi dth of the pl asti gage at the wi dest part usi ng the
scal e on the pl asti gage package (Fi g. 8). Refer to
speci fi cati on (Fi g. 6) for proper cl earances. Al so see
Measuri ng Mai n and Connecti ng Rod Beari ng Cl ear-
ance i n Standard Servi ce Procedures.
CRANKSHAFT BEARI NGS
I NSTALLATI ON
(1) I nstal l upper mai n beari ng shel l s maki ng certai n
oi l hol es are i n al i gnment, and beari ng tabs seat i n
bl ock tabs. Al l upper beari ngs have oi l grooves (Fi g. 9).
THRUST BEARINGS. Crankshaft thrust beari ngs
(washers) are i nstal l ed at journal #3 separatel y from
the radi al beari ngs. Thrust beari ngs shown i n (Fi g. 9)
are di fferent, one has end posi ti oni ng tabs,
Fig. 3 Rear Seal Assembly
Fig. 4 Measure Crankshaft Journal O.D.
Fig. 5 Measure Main Bearing I.D.
Fig. 6 Crankshaft Clearance Specification
Fig. 7 Measure Oil Clearance with Plastigage
3. 0L ENGINE 9 - 71
whi l e the other i s pl ai n. One pair of each thrust
washers are i nstal l ed i nto the bl ock and one pair i nto
the mai n beari ng cap (Fi g. 9).
(2) Appl y a thi n fi l m of grease to pl ai n si de of thrust
washers and posi ti on them on each si de of number
three mai n beari ng. Grooved surface towards crank-
shaft.
(3) Oi l the beari ngs and journal s and i nstal l crank-
shaft.
(4) I nstal l l ower mai n beari ng shel l s wi thout oi l
grooves i n monobl ock cap.
(5) I nstal l one pai r of thrust washers i n cap. Refer to
Thrust Beari ngs (Fi g. 9).
(6) Careful l y i nstal l beari ng cap wi th arrows (Fi g.
10) toward ti mi ng bel t end.
(7) Oi l the beari ng cap bol t threads, i nstal l and
ti ghten bol ts progressi vel y i n sequence shown i n (Fi g.
9) to 80 Nm (60 ft. l bs.) torque.
travel . (3) Zero the di al i ndi cator.
the di al i ndi cator. Refer to (Fi g. 6) for speci fi cati on.
CRANKSHAFT OI L SEALS SERVI CE
REAR CRANKSHAFT SEAL RETAI NER
(1) I nstal l rear crankshaft oi l seal i n housi ng wi th
Speci al Tool MD998718 (Fi g. 12).
(2) Appl y (Mopar Si l i cone Rubber Adhesi ve Seal ant
or equi val ent) to oi l seal housi ng (Fi g. 13) per proce-
dure detai l ed i n form-i n-pl ace gasket secti on i n Stan-
dard Servi ce Procedures.
(3) Appl y l i ght coati ng of engi ne oi l to the enti re
ci rcumference of oi l seal l i p.
Fig. 9 Install Main Bearings
Fig. 8 Measuring Clearance
9 - 72 3. 0L ENGINE
(4) I nstal l seal assembl y on cyl i nder bl ock and
ti ghten bol ts to 12 Nm (104 i n. l bs.).
FRONT CRANKSHAFT OI L PUMP AND OI L
SEAL
(1) I nstal l oi l pump gasket and oi l pump case (Fi gs.
1 and 14).
CAUTION: Install bolts, depending on length in loca-
tions shown in (Fig. 14).
(2) Usi ng front crankshaft oi l seal i nstal l er Speci al
Tool MB998306 i nstal l oi l seal i n oi l pump (Fi g. 15).
CYLINDER BLOCK
I nspect cyl i nder bl ock for scratches, cracks and rust
or corrosi on, and repai r or repl ace as requi red.
(1) Cl ean cyl i nder bl ock and check top surface for
di storti on wi th a strai ght edge and thi ckness gauge
(Fi g. 16).
(2) Top surface must be fl at wi thi n:
Standard Val ue: 0.05 mm (.002 i nch)
Fig. 10 Crankshaft Main Bearing Cap
Fig. 12 Install Crankshaft Rear Oil Seal
3. 0L ENGINE 9 - 73
Servi ce Li mi t 0.1 mm (.003 i nch)
CAUTION: Maximum of 0.2mm (.008 inch) is permit-
ted. This is a combined total dimension of stock
removal from cylinder head (if any) and block top
surface.
BORI NG CYLI NDER
Exami ne cyl i nder wal l s for scuffs, scori ng and mea-
sure cyl i nder bore for out-of-round or taper. I f defec-
ti ve, bore cyl i nder to oversi ze. Measure at poi nts shown
i n (Fi g. 17).
Four oversi ze pi stons are avai l abl e (0.25mm (.010
i nch) 0.50mm (.020 i nch) 0.75mm (.030 i nch) and
1.0mm (.039 i nch). Determi ne oversi ze pi ston on basi s
of l argest cyl i nder bore.
(1) Bore to speci fi ed cl earance between the pi ston
O.D. and cyl i nder. The measuri ng poi nt of the pi ston
O.D. i s shown i n (Fi g. 18).
(2) Based on measured pi ston O.D., cal cul ate bori ng
fi ni sh di mensi on. Bori ng fi ni sh di mensi on equal s pi s-
ton O.D. pl us 0.03 to 0.05 mm (.0012 to .002 i nch)
(cl earance between pi ston O.D. and cyl i nder) mi nus
0.02 mm whi ch i s the bori ng margi n.
Fig. 13 Apply Sealant to Oil Seal Housing
Fig. 14 Oil Pump
Fig. 15 Crankshaft Front Oil Seal
Fig. 16 Distortion Check
Fig. 17 Measure Cylinder Bore
9 - 74 3. 0L ENGINE
(3) Bore al l cyl i nders to cal cul ated bori ng fi ni sh
di mensi on. Then bore the fi nal fi ni sh di mensi on (pi s-
ton O.D. pl us cyl i nder cl earance).
(4) Check cl earance between pi ston and cyl i nder,
cl earance shoul d be 0.03 to 0.05 mm (.0012 to .002
i nch).
The l ubri cati on system i s a ful l fl ow fi l trati on pres-
sure feed type. Oi l , stored i n the oi l pan, i s taken i n and
di scharged by a i nternal gear type oi l pump di rectl y
coupl ed to the crankshaft and i ts pressure i s regul ated
by a rel i ef val ve. The oi l i s fed through an oi l fi l ter and
to the crankshaft journal s from the oi l gal l ery i n the
cyl i nder bl ock. Thi s gal l ery al so feeds oi l under pres-
sure to the cyl i nder heads. I t then
fl ows from a camshaft beari ng cap one each cyl i nder
head through passages i n the rocker shafts and i s fed
to the rocker arm pi vots, auto l ash adjusters, and
camshaft journal s (Fi g. 1).
Fig. 18 Measure Piston
Fig. 1 Engine Oiling
3. 0L ENGINE 9 - 75
OIL PAN
The oi l pan i s made of sheet metal and i s provi ded
wi th a baffl e-pl ate to prevent fl uctuati ons i n the oi l
l evel whi l e the vehi cl e i s runni ng (Fi g. 2).
OI L PAN SEALI NG AND I NSTALLATI ON
Oi l pan to crankcase seal i ng i s provi ded wi th Mopar
Si l i cone Rubber Adhesi ve Seal ant or equi val ent gasket
materi al . See Form-I n-Pl ace Gaskets i n Standard Ser-
vi ce Procedures.
(1) Appl y seal ant as shown i n (Fi g. 3).
(2) I nstal l pan and ti ghten screws to 6 Nm (50 i n.
l bs.) i n sequence shown i n (Fi g. 4).
OIL PUMP SERVICE
The oi l pump assembl y i s mounted on the ti mi ng bel t
end of the cyl i nder bl ock wi th the i nner pump rotor
i ndexed and i nstal l ed on the crankshaft nose. (Fi g. 5).
The oi l pump case al so retai ns the crankshaft front
oi l seal and provi des oi l pan front end cl osure.
REMOVAL
Remove accessory dri ve system. Refer to Accessory
Dri ve Servi ce i n thi s group.
Remove 5 bol ts that attach oi l pump to bl ock (Fi g. 6).
I NSPECTI ON OI L PUMP
(1) Check oi l pump case for damage and remove rear
cover.
(2) Remove pump rotors and i nspect case for exces-
si ve wear.
(3) Measure cl earance between case and i nner rotor
(Fi g. 8).
(4) I nsert the rotor i nto the oi l pump case (Fi gs. 9
and 10) and measure cl earance wi th a feel er gauge as
i ndi cated.
(5) Repl ace i f out of l i mi ts.
Fig. 2 Oil Pan
Fig. 3 Oil Pan Sealing
Fig. 4 Oil Pan Screw Tightening Sequence
Fig. 5 Oil Pump-Installed
9 - 76 3. 0L ENGINE
OI L RELI EF PLUNGER
(1) Check that the oi l rel i ef pl unger sl i des smoothl y.
(2) Check for broken rel i ef spri ng.
I NSTALLATI ON
(1) Cl ean bl ock and pump surfaces.
(2) I nstal l new gasket (Fi g. 7) make sure correct
l ength bol ts are used (Fi g. 6).
(3) Torque bol ts to 13 Nm (120 i n. l bs.).
Check oi l pressure usi ng gauge at oi l pressure swi tch
l ocati on. Oi l pressure shoul d be 41 kPa ( 6 psi .) at i dl e
or 241 to 517 kPa (35 to 75 psi .) at 3000 RPM.
(1) Remove pressure sendi ng uni t and i nstal l oi l
pressure gauge. (Fi g. 11)
engine at 3000 RPM.
Fig. 7 Oil Pump Components
Fig. 8 Inner Rotor to Case
Fig. 9 Checking Clearance-Between Outer Rotor and
Case
Fig. 10 Checking Rotor End Clearance
Fig. 11 Checking Oil Pump Pressure
3. 0L ENGINE 9 - 77
OIL FILTER AND BRACKET
BRACKET
I NSPECTI ON
(1) Check the oi l fi l ter mounti ng surface. The sur-
face must be smooth, fl at and free of debri s or ol d
pi eces of rubber (Fi g. 12).
(2) Check bracket for cracks and oi l l eaks.
OI L FI LTER
(1) Turn counter cl ockwi se to remove.
(2) To i nstal l , l ubri cate new fi l ter gasket. Screw
fi l ter on unti l gasket contacts base. Ti ghten 1 turn.
Fig. 12 Oil Filter and Bracket
9 - 78 3. 0L ENGINE
3. 0L ENGINE 9 - 79
9 - 80 3. 0L ENGINE
TORQUE
3. 0L ENGINE 9 - 81
3.3L ENGI NE
INDEX
page page
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Camshaft BearingsEngine Removed From
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Checking Engine Oil Pressure . . . . . . . . . . . . . . 110
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . 103
Crankshaft Oil Seals Service . . . . . . . . . . . . . . . 106
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . 103
Cylinder Block, Piston and Connecting Rod
Assembly Service . . . . . . . . . . . . . . . . . . . . . . . 99
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 85
Engine Core Oil and Cam Plugs . . . . . . . . . . . . . . 98
Engine Lubrication System . . . . . . . . . . . . . . . . . 107
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Engine Specifications . . . . . . . . . . . . . . . . . . . . . 111
Hydraulic Tappets . . . . . . . . . . . . . . . . . . . . . . . . 92
Installing Piston and Connecting Rod Assembly . 102
Intake Manifold Sealing . . . . . . . . . . . . . . . . . . . . 88
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Oil Pan Service . . . . . . . . . . . . . . . . . . . . . . . . . 107
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 108
Rocker Arms and Shaft Assembly . . . . . . . . . . . . . 86
Timing Chain Cover, Oil Seal and Chain . . . . . . . . 94
Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
GENERAL INFORMATION
(Fi g. 2).
ENGINE: The 3.3L (201 Cubi c. I nches.) di spl ace-
ment engi nes are 60 V type si x cyl i nder power pl ant
wi th cast i ron cyl i nder bl ock and al umi num cyl i nder
heads (Fi g. 1). Fi ri ng order for these engi nes i s 1-2-3-
4-5-6. Hi gh turbul ence cyl i nder heads al l ow a 8.9-1
compressi on rati o.
CRANKSHAFT: The nodul ar i ron crankshaft i s
supported by four mai n beari ngs, wi th number two
bei ng the thrust beari ng. Crankshaft end seal i ng i s
provi ded by front and rear rubber seal .
PISTONS: The pi stons are cast al umi num al l oy.
Three ri ngs are used. Pi ston pi ns, press fi tted i nto
pl ace, joi n the pi stons to forged steel connecti ng rods.
CAMSHAFTS:The cast i ron camshaft i s mounted i n
four steel backed babbi tt beari ngs. A thrust pl ate
l ocated i n front of the fi rst beari ng, and bol ted to the
bl ock, control s end pl ay. Si l ent ti mi ng chai n dri ves the
camshaft. Thi s chai n i s encl osed by a cast al umi num
cover whi ch al so carri es a front crankshaft seal , pro-
vi des front oi l pan cl osure, water pump mounti ng.
CYLINDER HEADS: Cyl i nder heads i ncorporate
val ve shroudi ng to create turbul ence-produci ng com-
busti on chambers, descri bed as fast burn. Si ntered
SPECI FI CATI ONS
9 - 82 3. 3L ENGINE
val ve seat i nserts are used. A steel fl anged composi ti on
type gasket i s used between head and bl ock.
VALVE COVERS: The covers are seal ed wi th steel
rei nforced si l i con rubber gaskets.
INTAKE MANIFOLD: The i ntake mani fol d i s a
tuned two-pi ece semi -permanent mol d al umi num cast-
i ng wi th i ndi vi dual pri mary runners l eadi ng from a
pl enum to the cyl i nders. The mani fol d i s desi gned to
boost torque i n the 3600 rpm range and contri butes to
the engi nes broad, fl at torque curve, whi ch was de-
si red for excel l ent engi ne tractabi l i ty, response and
usabl e power output.
The i ntake mani fol d i s al so cored wi th upper l evel
EGR passages for bal anced cyl i nder to cyl i nder EGR
di stri buti on.
VALVE TRAIN: Val ve trai n desi gn i ncorporates the
use of hydraul i c rol l er tappets. Rocker arms are i n-
stal l ed on a rocker arm shaft attached to the cyl i nder
head wi th four bol ts and retai ners. Vi ton val ve stem
seal s provi de val ve seal i ng. Uni que beehi ve styl e val ve
spri ng are used wi th l i ghtwei ght retai ners for i m-
proved hi gh RPM performance.
EXHAUST MANIFOLDS: Exhaust mani fol ds are
l og type wi th a crossover and i s attached di rectl y to the
cyl i nder heads.
ENGINE MOUNTS
RI GHT SI DE MOUNT
Fig. 1 3.3L Engine
3. 3L ENGINE 9 - 83
F
i
g
.
3
E
n
g
i
n
e
M
o
u
n
t
i
n
g
9 - 84 3. 3L ENGINE
FRONT MOUNT
assembl y.
LEFT SI DE MOUNT
wheel .
jack.
remove mount.
Group 2.
moved or not.
ENGINE ASSEMBLY
REMOVAL
(2) Mark hood posi ti on at hi nges and remove hood.
(3) Drai n cool i ng system. Refer to Cool i ng System,
Group 7 for procedure.
(4) Di sconnect al l el ectri cal connecti ons.
(5) Remove cool ant hoses from radi ator and engi ne.
(6) Remove radi ator and fan assembl y.
(7) See Fuel System, Group 14, to rel ease fuel pres-
sure. Di sconnect fuel l i nes and accel erator cabl e.
(9) Hoi st vehi cl e and drai n engi ne oi l .
bol ts and set compressor asi de.
(11) Di sconnect exhaust pi pe at mani fol d.
(12) Remove transmi ssi on i nspecti on cover and
mark fl ex pl ate to torque converter posi ti on. For di sas-
sembl y procedure for the al l wheel dri ve vehi cl e refer to
Group 21 Transaxl e.
(13) Remove screws hol di ng torque converter to fl ex
pl ate and attach C-cl amp on bottom of converter hous-
i ng to prevent torque converter from counti ng out.
(15) Remove two l ower transmi ssi on to bl ock screws.
(16) Remove starter.
(17) Lower vehi cl es and di sconnect vacuum l i nes
and ground strap.
3. 3L ENGINE 9 - 85
(19) Attach engi ne l i fti ng hoi st and support engi ne.
(20) Remove upper transmi ssi on case to bl ock bol ts.
(21) See Engi ne Mounti ng i n (Fi g. 3) and separate
mount/i nsul ators as fol l ows:
(a) Mark RI GHT i nsul ator on ri ght rai l s supports.
Remove i nsul ator to rai l s screws.
(b) Remove FRONT engi ne mount through bol t
and nut.
(c) Remove LEFT i nsul ator through bol t from i n-
si de wheel house or i nsul ator bracket to transmi ssi on
screws.
(22) Remove engi ne.
I NSTALLATI ON
(1) Attach hoi st and l ower engi ne i nto engi ne com-
partment.
Ti ghten bol ts to torque speci fi ed i n (Fi g. 3).
(3) I nstal l transmi ssi on case to cyl i nder bl ock,
ti ghten bol ts to 102 Nm (75 ft. l bs.) torque.
fi xture.
(5) Remove C-cl amp from torque converter housi ng.
Al i gn fl ex pl ate to torque converter and i nstal l mount-
i ng screws. Ti ghten to 75 Nm (55 ft. l bs.) torque. Refer
to Group 21 transaxl e for the al l wheel dri ve i nstal l a-
ti on procedure.
(6) I nstal l transmi ssi on i nspecti on cover.
(7) Connect exhaust system at mani fol d.
(8) I nstal l starter.
(9) I nstal l power steeri ng pump and ai r condi ti oni ng
compressor. For bel t i nstal l ati on see Accessory Bel t
Dri ve i n Cool i ng System Group 7.
(10) Lower vehi cl e and connect al l vacuum l i nes.
(11) Connect al l el ectri cal connecti ons i ncl udi ng
ground strap.
(12) Connect fuel l i nes and accel erator cabl e.
(13) I nstal l radi ator and fan assembl y. Reconnect
fan motor el ectri cal l ead. Rei nstal l radi ator hoses. Fi l l
cool i ng system. See Cool i ng System Group 7 for fi l l i ng
procedure.
(14) Fi l l engi ne crankcase wi th proper oi l to correct
l evel .
ture i s reached.
(18) Adjust transmi ssi on or l i nkage i f necessary.
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Remove upper i ntake mani fol d assembl y. Refer
(2) Di sconnect spark pl ug wi res by pul l i ng on the
boot strai ght out i n l i ne wi th pl ug.
(3) Di sconnect cl osed venti l ati on system and evapo-
rati on control system from cyl i nder head cover.
(4) Remove cyl i nder head cover and gasket.
(5) Remove four rocker shaft bol ts and retai ners.
(6) Remove rocker arms and shaft assembl y.
(7) I f rocker arm assembl i es are di sassembl ed for
cl eani ng or repl acement. Assembl e rocker arms i n
there ori gi nal posi ti on refer to (Fi g. 5) for rocker arm
for posi ti oni ng on the shaft.
I NSTALLATI ON
(1) I nstal l rocker arm and shaft assembl i es wi th the
stamped steel retai ners i n the four posi ti ons, ti ghten to
28 Nm (250 i n. l bs.) (Fi g. 5).
WARNING: THE ROCKER ARM SHAFT
SHOULDBE TORQUEDDOWNSLOWLY, START-
ING WITH THE CENTERMOST BOLTS. ALLOW
20 MINUTES TAPPET BLEED DOWN TIME AF-
TER INSTALLATION OF THE ROCKER SHAFTS
BEFORE ENGINE OPERATION.
(2) Cl ean cyl i nder head cover gasket surface. I nspect
cover for di storti on and strai ghten i f necessary.
(3) Cl ean head rai l i f necessary. I nstal l a new gasket
and ti ghten cyl i nder head cover fasteners to 12 Nm
(105 i n. l bs.).
(4) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
(5) I nstal l spark pl ug wi res.
(6) I nstal l upper i ntake mani fol d assembl y. Refer to
Exhaust Systems and I ntake Mani fol ds Group 11.
CYLINDER HEADS
The al l oy al umi num cyl i nder heads shown i n (Fi g. 6)
are hel d i n pl ace by 9 bol ts. The spark pl ugs are l ocated
i n peak of the wedge between the val ves.
Fig. 5 Rocker Arm Location Left Blank
9 - 86 3. 3L ENGINE
REMOVAL
(1) Drai n cool i ng system refer to Cool i ng System
Group 7 for procedure and di sconnect negati ve battery
cabl e.
Remove i ntake mani fol d, and throttl e body. Refer to
Group 11 Exhaust System and I ntake Mani fol d.
(2) Di sconnect coi l wi res, sendi ng uni t wi re, heater
hoses and by-pass hose.
(3) Remove cl osed venti l ati on system, evaporati on
control system and cyl i nder head covers.
(4) Remove exhaust mani fol ds.
(5) Remove rocker arm and shaft assembl i es. Re-
move push rods and identify to insure installation
in original locations.
(6) Remove the 9 head bol ts from each cyl i nder head
and remove cyl i nder heads (Fi g. 7).
I NSPECTI ON
(1) Before cl eani ng, check for l eaks, damage and
cracks.
(2) Cl ean cyl i nder head and oi l passages.
(3) Check cyl i nder head for fl atness (Fi g. 8).
(4) I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out of fl atness exceeds
.019mm (.00075 i nch). ti mes the span l ength i n i nches
i n any di recti on, ei ther repl ace head or l i ghtl y machi ne
the head surface. As an exampl e, i f a 12 i nch span i s
1mm (.004 i nch) out of fl at, al l owabl e i s 12 x .019mm
(.00075 i nch) equal s .22mm (.009 i n.) Thi s amount of
out of fl at i s acceptabl e.
*Maxi mum of 0.2 mm (.008 i nch) for gri ndi ng i s
permi tted.
CAUTION: This is a combined total dimension of
stock removal from cylinder head and block top
surface.
I NSTALLATI ON
(1) Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
(2) I nstal l new gaskets on cyl i nder bl ock (Fi g. 9).
The Cylinder head bolts are torqued using the
torque yield method, they should be examined
BEFORE reuse. If the threads are necked down,
the bolts should be replaced (Fi g. 10).
Fig. 6 Cylinder Head Assembly
Fig. 7 Cylinder Head Bolts Location
Fig. 8 Check Cylinder Head
Fig. 9 Head Gasket Installation
3. 3L ENGINE 9 - 87
(3) Ti ghten the cyl i nder head bol ts 1 thru 8 i n the
sequence shown i n (Fi g. 11). Usi ng the 4 step torque
turn method, ti ghten accordi ng to the fol l owi ng val ues:
Fi rst-Al l to 61 Nm (45 ft. l bs.)
Second-Al l to 88 Nm (65 ft. l bs.)
Thi rd-Al l (agai n) to 88 Nm (65 ft. l bs.)
Fourth + 1/4 Turn Do not use a torque wrench
for this step
(4) Bolt torqueafter 1/4turn shouldbeover 122
Nm(90 ft. lbs.). If not, replace the bolt.
(5) Ti ghten head bol t number 9 (Fi g. 11) to 33 Nm
(25 ft. l bs.) after head bol ts 1 thru 8 have been ti ghten
to speci fi cati ons.
(6) I nspect push rods and repl ace worn or bent rods.
(7) I nstal l push rods, rocker arm and shaft assem-
bl i es wi th the stamped steel retai ners i n the four
posi ti ons, ti ghten to 28 Nm (250 i n. l bs.) (Fi g. 12).
(8) Pl ace new cyl i nder head cover gaskets i n posi ti on
and i nstal l cyl i nder head covers. Ti ghten to 12 Nm
(105 i n. l bs.).
INTAKE MANIFOLD SEALING
The i ntake mani fol d gasket i s a one-pi ece stamped
steel gasket wi th a seal er appl i ed from the manufac-
turer. Thi s gasket has end seal s i ncorporated wi th i t.
WARNING: INTAKE MANIFOLD GASKET IS
MADE OF VERY THIN METAL AND MAY CAUSE
PERSONAL INJ URY, HANDLE WITH CARE.
heads.
(2) Pl ace a drop ( about 1/4 i n. di ameter) of Mopar
Si l i cone Rubber Adhesi ve Seal ant or equi val ent, onto
each of the four mani fol d to cyl i nder head gasket
corners (Fi g. 13).
(3) Careful l y i nstal l the i ntake mani fol d gasket (Fi g.
14). Torque end seal retai ner screws to 12 Nm (105 i n.
l bs.).
(4) I nstal l i ntake mani fol d and (8) bol ts and torque
to 1 Nm (10 i n. l bs.). Then retorque bol ts to 22 Nm
(200 i n. l bs.) i n sequence shown i n (Fi g. 15). Then
retorque agai n to 22 Nm (200 i n. l bs.). After i ntake
mani fol d i s i n pl ace, inspect to makesureseals are
in place. Refer to Group 11 Exhaust System and
I ntake Mani fol d to compl ete I ntake Mani fol d Assem-
bl y.
(5) I nstal l exhaust mani fol ds and ti ghten bol ts to 27
Nm (20 ft. l b.) and nuts to 20 Nm (15 ft. l bs.).
(6) Adjust spark pl ugs to speci fi cati on i n El ectri cal
Secti on, Group 8, and i nstal l the pl ugs.
Fig. 10 Checking Bolts for Stretching (Necking)
Fig. 11 Cylinder Head Tightening Sequence
Fig. 12 Rocker Arm Shaft Retainers
Fig. 13 Intake Manifold Gasket Sealing
9 - 88 3. 3L ENGINE
VALVE SERVICE
VALVES AND VALVE SPRI NGS
The val ves are arranged i n l i ne i n the cyl i nder heads
and i ncl i ned 18 degrees. The rocker shaft support and
the val ve gui des are cast i ntegral wi th the heads.
REMOVAL
(1) Wi th cyl i nder head removed, compress val ve
spri ngs usi ng Val ve Spri ng Compressor Tool C-3422-B
wi th adapter 6412 as shown i n (Fi g. 16).
(2) Remove val ve retai ni ng l ocks, val ve spri ng re-
tai ners, val ve stem cup seal s and val ve spri ngs.
(3) Before removi ng val ves,remove any burrs
fromvalvestemlock grooves to prevent damage
to the valve guides. I denti fy val ves to i nsure i nstal -
l ati on i n ori gi nal l ocati on.
VALVE I NSPECTI ON
(1) Cl ean val ves thoroughl y and di scard burned,
warped and cracked val ves.
(2) Measure val ve stems for wear. Refer to speci fi ca-
ti ons (Fi g. 19).
Valve stems are chrome plated and should not
be polished.
(3) Remove carbon and varni sh deposi ts from i nsi de
of val ve gui des wi th a rel i abl e gui de cl eaner.
(4) Measure val ve stem gui de cl earance as fol l ows:
(a) I nstal l val ve i nto cyl i nder head so i t i s 14mm
(.551 i nch) off the val ve seat. A smal l pi ece of hose
may be used to hol d val ve i n pl ace.
(b) Attach di al i ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl e of val ve stem bei ng
measured (Fi g. 17).
(c) Move val ve to and from the i ndi cator. Refer to
speci fi cati ons (Fi g. 19).
Ream the gui des for val ves wi th oversi zed stems i f
di al i ndi cator readi ng i s excessi ve or i f the stems are
scuffed or scored.
(5) Servi ce val ves wi th oversi ze stems and over si ze
seal s are avai l abl e i n 0.15mm (.005 i nch), 0.40mm,
(.015 i nch) and 0.80mm (.030 i nch) oversi ze.
Fig. 14 Intake Manifold Gasket Retainers
Fig. 15 Intake Manifold Removal and Installation
Fig. 16 Compress Valve Springs with Special Tool
C-3422B with adapter 6412
Fig. 17 Measuring Valve Guide Wear
3. 3L ENGINE 9 - 89
Oversize seals must be used with oversize
valves.
Reamers to accommodate the oversi ze val ve stem are
as fol l ows:
(6) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Do not at-
tempt to ream the valve guides from standard
directlyto0.80mm(.030inch) Usestepprocedure
of 0.15mm (.005 inch), 0.40mm (.015 inch) and
0.80mm (.030 inch) so the valve guides may be
reamed true in relation to the valve seat. After
reaming guides, the seat runout should be mea-
sured and resurfaced if necessary. See Refacing
VALVE GUI DES
Replace cylinder head if guide does not clean
up with 0.80mm(.030inch) oversizereamer, or if
guide is loose in cylinder head.
REFACI NG VALVES AND VALVE SEATS
The i ntake and exhaust val ves have a 44-1/2 to 45
degree face angl e. The val ve seats have a 45 to 45-1/2
degree face angl e. The val ve face and val ve seat angl es
are shown i n (Fi g. 21).
VALVES
(1) I nspect the remai ni ng margi n after the val ves
are refaced Refer to speci fi cati ons (Fi g. 20).
VALVE SEATS
CAUTION: Do not un-shroud valves during valve seat
refacing (Fig. 22).
(1) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseati ng
stones. A true and compl ete surface must be obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng di al
i ndi cator. Total runout shoul d not exceed .051mm (.002
i nch) total i ndi cator readi ng.
(3) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do thi s,
edge of val ve face,l ower val ve seat wi th
Fig. 18 Intake and Exhaust Valves
Fig. 19 Valve Guide Specifications
Fig. 20 Valve Dimensions
Fig. 21 Valve Seats
9 - 90 3. 3L ENGINE
a 15 degree stone. I f the bl ue i s transferred to the
bottom edge of val ve face rai se val ve seat wi th a 65
degrees stone.
Valve seats which are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head
must be replaced.
(4) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.75 to 2.25mm (0.69 to .088
i nch) The wi dth of the exhaust seats shoul d be 1.50 to
2.00mm (.059 to .078 i nch) (Fi g. 21)
(5) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat (Fi g. 24).
TESTI NG VALVE SPRI NGS
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d be
tested (Fi g. 23). As an example; the compressi on
l ength of the spri ng to be tested i s 33.34mm (1-5/16
i nches). Turn tabl e of Tool C-647 unti l surface i s i n l i ne
wi th the 33.34mm (1-5/16 i nch) mark on the threaded
stud and the zero mark on the front. Pl ace spri ng over
stud on the tabl e and l i ft compressi ng l ever to set tone
devi ce. Pul l on torque wrench unti l pi ng i s heard. Take
readi ng on torque wrench at thi s i nstant. Mul ti pl y thi s
readi ng by two. Thi s wi l l gi ve the spri ng l oad at test
l ength. Fracti onal measurements are i ndi cated on the
tabl e for fi ner adjustments. Refer to speci fi cati ons to
obtai n speci fi ed hei ght and al l owabl e tensi ons. Di scard
the spri ngs that do not meet speci fi cati ons.
VALVE I NSTALLATI ON
(1) Coat val ve stems wi th cl ean engi ne oi l and i nsert
them i n cyl i nder head.
(2) I f val ves or seats are reground, check i nstal l ed
val ve spri ng hei ght (Fi g. 24).
(3) I nstal l new cup seal s on al l val ve stems and over
val ve gui des (Fi g. 24). I nstal l val ve spri ngs and val ve
retai ners.
(4) Compress val ve spri ngs wi th Val ve Spri ng Com-
pressor Tool C-3422-B, wi th adapter 6412 i nstal l l ocks
and rel ease tool . If valves and/or seats are re-
ground, measure the installed height of springs,
make sure measurements is taken from top of
spring seat to the bottom surface of spring re-
tainer. If height is greater than 1-19/32 inches,
(40.6mm), install a 1/32 inch (.794mm) spacer in
head counterbore to bringspringheight back to
normal 1-17/32 to 1-19/32 inch (39.1 to 40.6mm).
Fig. 22 Refacing Valve Seats
Fig. 23 Testing Valve Spring with Special Tool C-647
Fig. 24 Checking Valve Installed Height
Fig. 25 Installing Valve, Cup Seal, Spring and Re-
tainer
3. 3L ENGINE 9 - 91
REPLACE VALVE STEM SEALS OR VALVE
SPRI NGS, CYLI NDER HEAD NOT REMOVED
before attempting any repairs
(2) Di sconnect negati ve battery cabl e.
(3) Remove Ai r Cl eaner Cover and hose assembl y.
(4) Remove I ntake Mani fol d; Refer to
I ntake/Exhaust Mani fol d 3.3L Engi ne Group 11 Ex-
haust System and I ntake Mani fol ds of thi s manual for
removal procedure.
(5) Remove cyl i nder head covers and spark pl ugs.
(6) Remove connector wi re from i gni ti on coi l s.
(7) Usi ng sui tabl e socket and fl ex handl e at crank-
shaft pul l ey retai ni ng screw, turn engi ne so the num-
ber 1 pi ston i s at Top Dead Center on the compressi on
stroke.
(8) Remove rocker arms wi th rocker shaft and i n-
stal l a shaft. The rocker arms shoul d not be di sturbed
and l eft on shaft.
(9) Wi th ai r hose attached to spark pl ug adapter
i nstal l ed i n number 1 spark pl ug hol e, appl y 90 to 100
psi ai r pressure (620.5 to 689 kPa). Thi s i s to hol d
val ves i nto pl ace whi l e servi ci ng components.
(10) Usi ng Tool C-4682 or Equi val ent compress
val ve spri ng and remove retai ner val ve l ocks and val ve
spri ng.
(11) I nstal l cup shi el ds on the exhaust val ve stem
and posi ti on down agai nst val ve gui des.
(12) The i ntake val ve stem seal s shoul d be pushed
fi rml y and squarel y over the val ve gui de usi ng the
val ve stem as gui de. Do Not Forceseal agai nst top of
gui de. When i nstal l i ng the val ve retai ner l ocks, com-
press the spri ng only enough to i nstal l the l ocks.
CAUTION:Do not pinch seal between retainer and top
of valve guide.
(13) Fol l ow the same procedure on the remai ni ng 5
cyl i nders usi ng the fi ri ng sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(14) Remove spark pl ug adapter tool .
(15) Remove shaft and i nstal l rocker shaft assembl y
and ti ghten screws to 28 Nm (250 i n. l bs.).
(16) I nstal l rocker arm covers ti ghten screws to 14
Nm (120 i n. l bs.) and connector to i gni ti on coi l s.
(17) I nstal l I ntake Mani fol d; Refer to I ntake Mani -
fol d I nstal l ati on 3.3L Engi ne, Group 11 Exhaust Sys-
tem and I ntake Mani fol d.
HYDRAULIC TAPPETS
The val ve trai n i ncl udes rol l er tappet assembl i es,
al i gni ng yokes and yoke retai ner.
Rol l er tappet al i gnment i s mai ntai ned by machi ned
fl ats on tappet body bei ng fi tted i n pai rs i nto si x
al i gni ng yokes. The yokes are secured by an al i gnment
yoke retai ner (Fi g. 26).
PRELI MI NARY STEP TO CHECKI NG THE HY-
DRAULI C TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, read the oi l pressure at the gauge.
I nstal l a rel i abl e gauge at pressure sendi ng uni t i f
vehi cl e has no oi l pressure gauge and check the oi l l evel
i n the oi l pan. The pressure shoul d be between 30 and
80 psi (206.8 to 551.6 kPa) at 2000 rpm.
The oi l l evel i n the pan shoul d never be above the
MAX mark on di psti ck, or bel ow the MI N mark. Ei ther
of these two condi ti ons coul d be responsi bl e for noi sy
tappets. Oil Level Check: stop engineafter reach-
ing normal operating temperature. Al l ow 5 mi n-
utes to stabi l i ze oi l l evel , check di psti ck.
OI L LEVEL TOO HI GH
I f oi l l evel i s above the MAX mark on di p sti ck, i t i s
possi bl e for the connecti ng rods to di p i nto the oi l whi l e
engi ne i s runni ng and create foam. Foam i n oi l pan
woul d be fed to the hydraul i c tappets by the oi l pump
causi ng them to l ose l ength and al l ow val ves to seat
noi si l y.
OI L LEVEL TOO LOW
Low oi l l evel may al l ow pump to take i n ai r whi ch
when fed to the tappets,causes them to l ose l ength and
al l ows val ves to seat noi si l y. Any l eaks on i ntake si de of
pump through whi ch ai r can be drawn wi l l create the
same tappet acti on. Check the l ubri cati on system from
the i ntake strai ner to the pump cover, i ncl udi ng the
rel i ef val ve retai ner cap. When tappet noi se i s due to
aerati on, i t may be i ntermi ttent or constant, and
usual l y more than one tappet wi l l be noi sy. When oi l
l evel and l eaks have been corrected,engi ne shoul d be
operated at fast i dl e for suffi ci ent ti me to al l ow al l of
the ai r i nsi de of the tappets to be bl ed out.
TAPPET NOI SE DI AGNOSI S
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
Fig. 26 Roller Tappets Aligning Yoke and Retainer
9 - 92 3. 3L ENGINE
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
Worn valveguides or cocked springs aresome-
times mistaken for noisy tappets. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not appre-
ciably reduced, it can be assumed the noise is in
the tappet. Inspect the rocker arm push rod
sockets and push rod ends for wear.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by excessi ve
l eakdown around the uni t pl unger whi ch wi l l necessi -
tate repl aci ng the tappet, or by the pl unger parti al l y
sti cki ng i n the tappet body cyl i nder. A heavy cl i ck i s
caused ei ther by a tappet check val ve not seati ng, or by
forei gn parti cl es becomi ng wedged between the
pl unger and the tappet body, causi ng the pl unger to
sti ck i n the down posi ti on. Thi s heavy cl i ck wi l l be
accompani ed by excessi ve cl earance between the val ve
stem and rocker arm as val ve cl oses. I n ei ther case,
tappet assembl y shoul d be removed for i nspecti on and
cl eani ng.
TAPPET REMOVAL
(1) Refer to Cyl i nder Head Removal of thi s secti on to
remove i ntake mani fol d and cyl i nder heads for access
to tappets for servi ce.
(2) Remove yoke retai ner and al i gni ng yokes.
(3) Use Tool C-4129 to remove tappets from thei r
bores. I f al l tappets are to be removed, i denti fy tappets
to i nsure i nstal l ati on i n ori gi nal l ocati on.
If thetappet or boreincylinder block isscored,
scuffed, or showssignsof sticking, reamthebore
to next oversize and replace with oversize tap-
pet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must always
be fitted to the original body. It is advisable to work on
one tappet at a time to avoid mixing of parts. Mixed
parts are not compatible. Do not disassemble a tap-
pet on a dirty work bench.
DI SASSEMBLY (FI G. 27)
(1) Pry out pl unger retai ner spri ng cl i p.
(2) Cl ean varni sh deposi ts from i nsi de of tappet body
above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, fl at or bal l check val ve, check val ve spri ng,
check val ve retai ner and pl unger spri ng. Check val ve
coul d be fl at or bal l .
CLEANI NG AND ASSEMBLY
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further servi ce
wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear and
val ve i s pi tted, or i f val ve seat on end of pl unger
i ndi cates any condi ti on that woul d prevent val ve from
seati ng, i nstal l a new tappet assembl y.
(4) Assembl e tappets (Fi g. 27).
I NSTALLATI ON
(1) Lubri cate tappets.
(2) I nstal l tappets i n thei r ori gi nal posi ti ons.
(3) Wi th rol l er tappets, i nstal l al i gni ng yokes wi th
(Fi g. 25).
(4) I nstal l yoke retai ner and torque screws to 12
Nm (105 i n. l bs.) (Fi g. 25).
(5) I nstal l cyl i nder heads. Refer to cyl i nder head
i nstal l ati on of thi s secti on for procedure.
(6) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have be-
come quiet.
VALVE TIMING
(1) Remove front val ve cover and al l 6 spark pl ugs.
(2) Rotate engi ne unti l the #2 pi ston i s at TDC of the
compressi on stroke.
(3) I nstal l a degree wheel on the crankshaft pul l ey.
(4) Wi th proper adaptor, i nstal l a di al i nto #2 spark
pl ug hol e. Usi ng the i ndi cator fi nd TDC on the com-
pressi on stroke.
(5) Posi ti on the degree wheel to zero.
(6) Remove di al i ndi cator from spark pl ug hol e.
(7) Pl ace a 5.08mm (.200 i nch) spacer between the
val ve stem ti p of #2 i ntake val ve and rocker arm pad.
Al l ow tappet to bl eed down to gi ve a sol i d tappet effect.
(8) I nstal l a di al i ndi cator so pl unger contacts the #2
i ntake val ve spri ng retai ner as nearl y perpendi cul ar as
possi bl e. Zero the i ndi cator.
(9) Rotate the engi ne cl ockwi se unti l the i n take
val ve has l i fted .254mm (0.010 i nch).
Fig. 27 Hydraulic Roller Tappet Assembly
3. 3L ENGINE 9 - 93
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel shoul d read 3 degrees BTDC to 4
degrees ATDC.
TIMING CHAIN COVER, OIL SEAL AND CHAIN
COVER
REMOVAL
(2) Drai n cool i ng system. Refer to Cool i ng System
(3) Support engi ne and remove ri ght engi ne mount.
(4) Rai se vehi cl e on hoi st. Drai n engi ne oi l .
(5) Remove oi l pan and oi l pump pi ck-up. I t may
necessary to remove transmi ssi on i nspecti on cover.
(6) Remove ri ght wheel and i nner spl ash shi el d.
(7) Remove dri ve bel t. Refer to Cool i ng System
(8) Remove A/C compressor and set asi de.
(9) Remove A/C compressor mounti ng bracket.
(10) Remove crankshaft pul l ey. (Fi g. 1)
(11) Remove i dl er pul l ey from engi ne bracket.
(12) Remove engi ne bracket. (Fi g. 2)
(13) Remove cam sensor from chai n case cover. (Fi g.
3)
(14) Remove chai n case cover (Fi g. 3)
MEASURI NG TI MI NG CHAI N FOR STRETCH
(1) Pl ace a scal e next to ti mi ng chai n so that any
movement of chai n may be measured.
(2) Pl ace a torque wrench and socket on camshaft
sprocket attachi ng bol t and appl y torque i n di recti on of
crankshaft rotati on to take up sl ack; 41 Nm (30 ft. l b.)
wi th cyl i nder head i nstal l ed or 20 Nm (15 ft. l b.) wi th
cyl i nder heads removed. With a torque applied to
the camshaft sprocket bolt, crankshaft should
not bepermitted to move. It may benecessary to
block crankshaft to prevent rotation.
(3) Hol di ng a scal e even, wi th di mensi on readi ng as
shown (Fi g. 4 ), al ong edge of chai n l i nks. Appl y torque
i n the reverse di recti on to 41 Nm (30 ft. l bs.) wi th
cyl i nder heads i nstal l ed, or 20 Nm (15 ft. l bs.) wi th
cyl i nder heads removed. Check amount of chai n move-
ment (Fi g. 4).
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175mm (1/8 i nch) (Fi g. 4).
(5) I f chai n i s not sati sfactory, remove camshaft
sprocket attachi ng bol t, and remove ti mi ng chai n wi th
camshaft sprocket.
(6) Usi ng a sui tabl e pul l er remove the crankshaft
pul l ey. Be careful not to damage the crankshaft sur-
face.
(7) Posi ti on a new crankshaft sprocket on the shaft,
i nstal l sprocket wi th sui tabl e tool and mal l et. Be sure
sprocket i s seated i nto posi ti on.
(8) Rotate crankshaft sprocket so the ti mi ng mark i s
to the 12 ocl ock posi ti on.
Fig. 1 Removing Crankshaft Pulley
Fig. 2 Engine Bracket
Fig. 3 Timing Chain Case Cover
9 - 94 3. 3L ENGINE
(9) Pl ace ti mi ng chai n around camshaft sprocket
and pl ace the ti mi ng mark to the 6 ocl ock posi ti on.
(10) Pl ace ti mi ng chai n around crankshaft sprocket
and i nstal l camshaft sprocket i nto posi ti on.
(11) Usi ng strai ght edge to check al i gnment of ti m-
i ng marks (Fi g. 5).
(12) I nstal l camshaft bol t and washer. Ti ghten to 47
Nm (35 ft. l bs.).
(13) Rotate crankshaft 2 revol uti ons. Ti mi ng marks
shoul d l i ne up. I f ti mi ng marks do not l i ne up remove
cam sprocket and real i gn.
(14) Check camshaft endpl ay. Wi th new thrust pl ate
speci fi cati on i s .0127 to .304 mm (.005 to .012 i nches.).
Ol d thrust pl ate speci fi cati on i s .31 mm (.012 i nch.)
maxi mum. I f not wi thi n these l i mi ts i nstal l new thrust
pl ate.
(15) I nstal l ti mi ng chai n snubber. Ti ghten retai ni ng
screws to 12 Nm (105 i n. l bs.). These bolts are
20mm long for this model year, they should not
be interchanged with previous year engines.
INSTALLATION
(1) Be sure mati ng surfaces of chai n case cover and
cyl i nder bl ock are cl ean and free from burrs. Crank-
shaft oi l seal must be removed to i nsure correct oi l
pump engagement.
(2) Use a new cover gasket, O-ri ngs. (Fi g. 6).
(3) Rotate crankshaft so that the oi l pump dri ve fl ats
are verti cal .
(4) Posi ti on oi l pump i nner rotor so the mati ng fl ats
are i n the same posi ti on as the crankshaft dri ve fl ats
(Fi g. 6).
(5) I nstal l cover onto crankshaft. Make sure the oi l
pump i s engaged on the crankshaft correctl y or severe
damage may resul t.
(6) I nstal l chai n case cover screws and torque to 27
Nm (20 ft. l bs.).
(7) I nstal l crankshaft oi l seal (Fi g. 7).
(8) I nstal l crankshaft pul l ey (Fi g. 8).
(9) I nstal l engi ne bracket (Fi g. 2) torque screws to 54
Nm (40 ft. l bs.).
(10) I nstal l i dl er pul l ey on engi ne bracket.
(11) I nstal l cam sensor Refer to I gni ti on System
Group 8D for i nstal l ati on procedure.
(12) I nstal l A/C compressor mounti ng bracket.
(13) I nstal l A/C compressor.
(14) I nstal l dri ve bel t Refer to Cool i ng System Group
7 for i nstal l ati on procedure.
(15) I nstal l i nner spl ash shi el d and wheel .
(16) I nstal l oi l pump pi ck-up and oi l pan and trans-
mi ssi on i nspecti on cover i f removed.
(17) I nstal l engi ne mount.
(18) Fi l l crankcase wi th oi l to proper l evel .
Fig. 4 Measuring Timing Chain Wear and Stretch
Fig. 5 Alignment of Timing Marks
Fig. 6 Timing Chain Case Cover Gaskets and
O-Rings
3. 3L ENGINE 9 - 95
(19) Fi l l cool i ng system Refer to Cool i ng System
TI MI NG CHAI N COVER EXTERNAL OI L SEAL
REMOVAL
(1) Rai se vehi cl e on hoi st. Remove ri ght wheel and
i nner spl ash shi el d.
(2) Remove dri ve bel t. (Refer to Cool i ng System
Group 7) for procedure.
(3) Remove crankshaft pul l ey (Fi g. 1).
(4) Usi ng Tool C-4991 to remove oi l seal (Fi g. 9). Be
careful not to damage that crankshaft seal surface of
cover.
INSTALLATION
(1) I nstal l new seal by usi ng Tool C-4992 (Fi g. 7).
(2) Pl ace seal i nto openi ng wi th seal spri ng towards
the i nsi de of engi ne. I nstal l seal unti l fl ush wi th cover.
(3) I nstal l crankshaft pul l ey usi ng pl ate L-4524.
Thrust Beari ng/washer and 5.9 i nch screw (Fi g. 8).
(4) I nstal l dri ve bel t (Refer to Cool i ng System Group
7) for i nstal l ati on procedure.
(5) I nstal l i nner spl ash shi el d and wheel .
CAMSHAFT
REMOVALENGI NE REMOVED FROM VE-
HI CLE
Remove i ntake mani fol d, cyl i nder head covers, cyl i n-
der heads, ti mi ng chai n case cover and ti mi ng chai n.
(1) Remove rocker arm and shaft assembl i es.
(2) Remove push rods and tappets; i denti fy so each
part wi l l be repl aced i n i ts ori gi nal l ocati on.
(3) Remove camshaft thrust pl ate (Fi g. 10).
(4) I nstal l a l ong bol t i nto front of camshaft to
faci l i tate removal of the camshaft; remove camshaft,
bei ng careful not to damage cam beari ng wi th the cam
l obes.
I NSTALLATI ON
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 2 i nches of
i ts fi nal posi ti on i n cyl i nder bl ock.
Whenever an engine has been rebuilt and/or a
new camshaft and/or new tappets have been
installed, add one pint of Chrysler Crankcase
Conditioner or equivalent to engine oil to aid in
break in. Theoil mixtureshould beleft in engine
for a minimumof 805km(500miles) and drained
at the next normal oil change.
(2) I nstal l camshaft thrust pl ate wi th two screws as
shown i n (Fi g. 10). Ti ghten to 12 Nm (105 i n. l bs.)
torque.
(3) Pl ace both camshaft sprocket and crankshaft
Fig. 7 Install Crankshaft Oil Seal
Fig. 8 Installing Crankshaft Pulley
Fig. 9 Removing Crankshaft Oil Seal
9 - 96 3. 3L ENGINE
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(4) Pl ace ti mi ng chai n around both sprockets.
(5) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(6) Li ft sprockets and chai n keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed.
(7) Sl i de both sprockets evenl y over thei r respecti ve
shafts use a strai ghtedge to check al i gnment of ti mi ng
marks (Fi g. 12).
(8) I nstal l the camshaft bol t. Ti ghten bol t to 54 Nm
(40 ft. l bs.).
(9) Rotate crankshaft 2 revol uti ons. Ti mi ng marks
shoul d l i ne up. I f ti mi ng marks do not l i ne up, remove
cam sprocket and real i gn.
(10) Measure camshaft end pl ay. End Pl ay shoul d
measure .0127 to .304 mm (.005 to .012 i nches.) .310
mm (.012 i nch. Max.). I f not wi thi n l i mi ts i nstal l a new
thrust pl ate.
(11) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS ENGINE REMOVED FROM
VEHICLE
REMOVAL
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horse shoe wash-
ers part of Tool C-3132-A at back of each beari ng shel l
to be removed and dri ve out beari ng shel l s (Fi g. 13).
I NSTALLATI ON
(1) I nstal l new camshaft beari ngs wi th Tool
C-3132-A by sl i di ng the new camshaft beari ng shel l
over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same manner.
Beari ngs must be careful l y al i gned to bri ng oi l hol es
i nto ful l regi ster wi th oi l passages from the mai n
beari ng. Number two beari ng must i ndex wi th the oi l
passage to the l eft cyl i nder head and Number three
beari ng must i ndex wi th the oi l passage to the ri ght
cyl i nder head. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and rei nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
Fig. 10 Camshaft Thrust Plate
Fig. 11 Camshaft and Sprocket Assembly
Fig. 12 Alignment of Timing Marks
3. 3L ENGINE 9 - 97
ENGINE CORE OIL AND CAM PLUGS
REMOVAL
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui tabl e
tool and remove pl ug (Fi g. 14).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en-
gine problems.
I NSTALLATI ON
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i nder
bl ock or head. Be sure to remove ol d seal er. Li ghtl y coat
i nsi de of cup pl ug hol e wi th Locti te Stud N Beari ng
Mount or equi val ent. Make certai n the new pl ug i s
cl eaned of al l oi l or grease. Usi ng proper dri ve pl ug,
dri ve pl ug i nto hol e so that the sharp edge of the pl ug
i s at l east 0.5mm (.020 i nch) i nsi de the l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
Fig. 14 Core Hole Plug Removal
Fig. 13 Removed Installation of Camshaft Bearings
with Tool C-3132ATypical
9 - 98 3. 3L ENGINE
CYLINDER BLOCK, PISTON AND CONNECTING
ROD ASSEMBLY SERVICE
CYLI NDER BLOCK
PI STONREMOVAL
(1) Remove top ri dge of cyl i nder bores wi th a rel i abl e
ri dge reamer before removi ng pi stons from cyl i nder
bl ock. Be sure to keep tops of pistons covered
during this operation. Pistons and connecting
rodsmust beremovedfromtopof cylinder block.
When removing piston and connecting rod as-
semblies from the engine, rotate crankshaft so
that each connecting rod is centered in cylinder
bore.
(2) I nspect connecti ng rods and connecti ng rod caps
for cyl i nder i denti fi cati on. I denti fy them i f necessary.
(Fi g. 2)
(3) Remove connecti ng rod cap. I nstal l connecti ng
rod bol t protectors on connecti ng rod bol ts (Fi g. 3).
Push each pi ston and rod assembl y out of cyl i nder bore.
Be careful not to nick crankshaft journals.
(4) After removal , i nstal l beari ng cap on the mati ng
rod.
CLEANI NG AND I NSPECTI ON
(1) Cl ean cyl i nder bl ock thoroughl y and check al l
core hol e pl ugs for evi dence of l eaki ng.
(2) I f new core pl ugs are i nstal l ed, see Engi ne Core
Oi l and Cam Pl ugs.
(3) Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out- of-
round and taper wi th Tool C-119 (Fi g. 4). I f the cyl i nder
wal l s are badl y scuffed or scored, the cyl i nder bl ock
shoul d be rebored and honed, and new pi stons
Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly
Fig. 2 Identify Connecting Rod to Cylinder
Fig. 3 Connecting Rod Protectors
3. 3L ENGINE 9 - 99
and ri ngs fi tted. Whatever type of bori ng equi pment i s
used, bori ng and honi ng operati on shoul d be cl osel y
coordi nated wi th the fi tti ng of pi stons and ri ngs i n
order that speci fi ed cl earances may be mai ntai ned.
Refer toHoningCylinder Bores outlined in the
Standard Service Procedures for specification
and procedures.
Measure the cyl i nder bore at three l evel s i n di rec-
ti ons A and B (Fi g. 4). Top measurement shoul d be
12mm (.50 i nch) down and bottom measurement
shoul d be 12mm (.50 i nch.) up from bottom of bore.
Refer to (Fi g. 5) for speci fi cati ons.
FI NI SHED PI STONS
Al l pi stons are machi ned to the same wei ght i n
grams, regardl ess of oversi ze, to mai ntai n pi ston bal -
ance.
FI TTI NG PI STONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Pi ston di ameter shoul d be measured 90 degrees to
pi ston pi n at si ze l ocati on shown i n (Fi g. 6). Cyl i nder
bores shoul d be measured hal fway down the cyl i nder
bore and transverse to the engi ne crankshaft center
l i ne shown i n (Fi g. 4). Refer to (Fi g. 5) for speci fi ca-
ti ons.
Pistonsandcylinder boresshouldbemeasured
at normal roomtemperature, 70F. (21C).
PI STON PI NS
The pi ston pi n rotates i n the pi ston onl y, and i s
retai ned by the press i nterference fi t of the pi ston pi n
i n the connecti ng rod. The piston pin is not to be
removed damage to the piston may result.
FI TTI NG RI NGS
posi ti oni ng at l east 12mm (.50 i nch) from bottom of
Refer to speci fi cati ons (Fi g. 8).
(2) Check pi ston ri ng to groove cl earance: (Fi g. 9).
Refer to speci fi cati on (Fi g. 8).
cross secti on. I nstal l ri ngs wi th manufacturers I .D.
mark faci ng up, to the top of the pi ston (Fi g. 10).
Fig. 5 Cylinder Bore and Piston Specifications
Fig. 6 Piston Measurements
Fig. 7 Check Gap on Piston Rings
9 - 100 3. 3L ENGINE
si de rai l i s i n posi ti on. Do not use a piston ring
expander. (Fi g. 11).
si de rai l .
ri ng (Fi g. 12).
13).
the thrust di recti on. Staggeri ng ri ng gap i s i mportant
for oi l control .
Fig. 8 Piston Ring Specifications
Fig. 9 Measuring Piston Ring Side Clearance
Fig. 10 Piston Ring Installation
Fig. 12 Installing Upper and Intermediate Rings
3. 3L ENGINE 9 - 101
INSTALLING PISTON AND CONNECTING ROD AS-
SEMBLY
(1) Before i nstal l i ng pi stons, and connecti ng rod
assembl i es i nto the bore, besure that compressi on ri ng
gaps are staggered so that nei ther i s i n l i ne wi th oi l
ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make sure
the oi l ri ng expander ends are butted and the rai l gaps
l ocated as shown i n (Fi g. 14).
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l , sl i de the ri ng compressor, over the pi ston
and ti ghten wi th the speci al wrench. Besureposition
of rings does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts. (Fi g. 3)
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. I nsert rod
and pi ston i nto cyl i nder bore and gui de rod over the
crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on connecti ng rod journal .
(7) The notch or groove on top of pi ston must be
poi nti ng toward front of engi ne (Fi g. 15).
(8) I nstal l rod caps. I nstal l nuts on cl eaned and oi l ed
rod bol ts and ti ghten nuts to 54 Nm (40 ft. l b.) Pl us 1/4
turn.
Fig. 14 Installing Piston
Fig. 15 Piston I.D. Notches
Fig. 16 Checking Connecting Rod Bearing Clear-
ance
9 - 102 3. 3L ENGINE
CONNECTING RODS
I NSTALLATI ON OF CONNECTI NG ROD BEAR-
I NGS
Fi t al l rods on one bank unti l compl ete.
The beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to i nsure correct assembl y.
The beari ng shel l s must be i nstal l ed wi th the tangs
i nserted i nto the machi ned grooves i n the rods and
caps. I nstal l cap wi th the tangs on the same si de as the
rod.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to .025mm (.001 i nch). Bear-
i ngs are avai l abl e i n .025mm (.001 i nch),.051mm (.002
i nch),.076mm (.003 i nch),.254mm (.010 i nch) and
.305mm (.012 i nch) undersi ze. Install the bearings
in pairs. Do not use a new bearing half with an
old bearing half. Do not file the rods or bearing
caps.
(1) Fol l ow procedure speci fi ed i n the Standard Ser-
vi ce Procedure Secti on for Measuri ng Mai n Beari ng
Cl earance and Connecti ng Rod Beari ng Cl earance
(Fi g. 16).
The rod bearing bolts should be examined be-
fore reuse. If the threads are necked down the
(2) Before i nstal l i ng the nuts the threads shoul d be
(3) I nstal l nuts on each bol t fi nger ti ght then al ter-
natel y torque each nut to assembl e the cap properl y.
(4) Ti ghten the nuts to 54 Nm PLUS 1/4 turn (40 ft.
l bs. PLUS 1/4 turn).
(5) Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 17). Refer to (Fi g. 18) for speci fi cati ons.
CRANKSHAFT SERVICE
CRANKSHAFT MAI N BEARI NGS
Beari ng caps are not i nterchangeabl e and shoul d be
marked at removal to i nsure correct assembl y. (Fi g. 1)
Upper and l ower beari ng hal ves are NOT i nterchange-
abl e. Lower mai n beari ng hal ves of 1, 3 and 4 are
i nterchangeabl e. Upper mai n beari ng hal ves of 1, 3
and 4 are i nterchangeabl e.
CRANKSHAFT MAI N JOURNALS
The crankshaft journal s shoul d be checked for exces-
si ve wear, taper and scori ng. (Fi g. 6) Li mi ts of taper or
out-of-round on any crankshaft journal s shoul d be hel d
to .025mm (.001 i nch). Journal gri ndi ng shoul d not
exceed .305mm (.012 i nch) under the standard journal
di ameter. Do NOTgri nd thrust faces of Number 2 mai n
beari ng. Do NOTni ck crank pi n or beari ng fi l l ets. After
gri ndi ng, remove rough edges from crankshaft oi l hol es
and cl ean out al l passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth polish
after any journal regrind be in the same direction as
normal rotation in the engine.
Upper and l ower Number 2 beari ng hal ves are
fl anged to carry the crankshaft thrust l oads and are
NOTi nterchangeabl e wi th any other beari ng hal ves i n
the engi ne (Fi g. 2). Al l beari ng cap bol ts removed
duri ng servi ce procedures are to be cl eaned and oi l ed
before i nstal l ati on. Beari ng shel l s are avai l abl e i n
Fig. 18 Connecting Rod Specifications
Fig. 19 Check for Stretched Rod Bolts
3. 3L ENGINE 9 - 103
standard and the fol l owi ng undersi zes: 0.025mm (.001
i nch), .051mm (.002 i nch), .076mm (.003 i nch), .254mm
(.010 i nch), and .305mm (.012 i nch). Never i nstal l an
undersi ze beari ng that wi l l reduce cl earance bel ow
speci fi cati ons.
REMOVAL
(1) Remove oi l pan and i denti fy beari ng caps before
removal .
(2) Remove beari ng caps one at a ti me. Remove
upper hal f of beari ng by i nserti ng Speci al Mai n Bear-
i ng Tool C-3059. (Fi g. 3) i nto the oi l hol e of crankshaft.
(3) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Only one main bearing should be selectively
fittedwhileall other mainbearingcapsareprop-
erly tightened.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Mai n Beari ng
Tool C-3059 i nto oi l hol e of crankshaft (Fi g. 3).
(2) Sl owl y rotate crankshaft counter-cl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Speci al Mai n
Beari ng Tool C-3059.
(3) I nstal l each mai n cap and ti ghten bol ts fi nger
ti ght.
(4) Ti ghten number 1, 3 and 4 mai n cap bol ts to 41
Nm + 1/4 Turn (30 ft. l bs.+ 1/4 Turn).
(5) Rotate the crankshaft unti l number 6 pi ston i s at
TDC.
(6) To ensure correct thrust beari ng al i gnment the
fol l owi ng procedure must be done:
(a) Move crankshaft al l the way to the rear of i ts
travel .
(b) Then, move crankshaft al l the way to the front
of i ts travel .
(c) Wedge a appropri ate tool between the rear of
the cyl i nder bl ock and rear crankshaft counter-
wei ght. Thi s wi l l hol d the crankshaft i n i ts most
forward posi ti on.
(d) Ti ghten the #2 Thrust Beari ng cap bol ts to 41
Nm + 1/4 Turn (30 ft. l bs.+ 1/4 Turn). Remove the
hol di ng tool .
travel .
(3) Zero the di al i ndi cator.
the di al i ndi cator. Refer to (Fi g. 5) for speci fi cati on.
CRANKSHAFT END PLAY CHECKOPTI ONAL
travel usi ng a screwdri ver or other l ever i nserted
between a mai n beari ng cap and a crankshaft cheek us-
Fig. 1 Main Bearing Cap Identification
Fig. 2 Main Bearing Identification
Fig. 3 Removing and Installing Upper Main Bearing
With Special Tool C-3059
9 - 104 3. 3L ENGINE
i ng care not to damage any beari ng surface.Do not-
l oosen mai n beari ng cap.
(2) Use a feel er gauge between number 2 thrust
beari ng and machi ned crankshaft surface to determi ne
end pl ay. Refer to (Fi g. 5) for speci fi cati on.
CRANKSHAFT OI L CLEARANCE
(1) Measure the journal outsi de di ameter as shown
i n (Fi g. 6). Refer to speci fi cati on (Fi g. 5).
PLASTI GAGE (OI L CLEARANCE) MEASURE-
MENT
(1) Remove oi l from journal and beari ng shel l .
(2) I nstal l crankshaft.
(3) Cut pl asti gage to same l ength as wi dth of the
beari ng and pl ace i t i n paral l el wi th the journal axi s
(Fi g. 7).
(4) I nstal l the mai n beari ng cap careful l y and
ti ghten the bol ts to speci fi ed torque.
CAUTION: Do not rotate crankshaft or the plastigage
will be smeared.
(5) Careful l y remove the beari ng cap and measure
the wi dth of the pl asti gage at the wi dest part usi ng the
scal e on the pl asti gage package (Fi g. 7). Refer to
speci fi cati on (Fi g. 5) for proper cl earances. I f the cl ear-
ance exceeds the speci fi ed l i mi ts. Repl ace the mai n
beari ng(s) and i f necessary have the crankshaft ma-
chi ned to next undersi ze. Al so see Measuri ng Mai n and
Connecti ng Rod Beari ng Cl earance i n Standard Ser-
vi ce Procedures.
CAUTION: Do not rotate crankshaft or the Plastigage
may be smeared.
Fig. 5 Crankshaft specification
Fig. 6 Measure Crankshaft Journal O.D.
Fig. 7 Measuring Bearing Clearance with Plastigage
3. 3L ENGINE 9 - 105
CRANKSHAFT OIL SEALS SERVICE
REMOVAL
Pry out rear seal wi th screwdri ver. Be careful not to
ni ck or damage crankshaft fl ange seal surface or re-
tai ner bore (Fi g. 8).
I NSTALLATI ON
(1) Pl ace Speci al Seal Pi l ot Tool C-4681 on crank-
shaft (Fi g. 9).
(2) Li ghtl y coat seal O.D. wi th Locti te Stud N Bear-
i ng Mount or equi val ent.
(3) Pl ace seal over Speci al Seal Pi l ot Tool C-4681 and
tap i n pl ace wi th a pl asti c hammer.
REAR CRANKSHAFT SEAL RETAI NER
When retai ner removal i s requi red, remove retai ner
cl ean engi ne bl ock and retai ner of ol d gasket. Make
sure surfaces are cl ean and free of oi l . I nstal l new
gasket and ti ghten screws to 12 Nm (105 i n. l bs.).
Fig. 9 Installing Rear Crankshaft Oil Seal
Fig. 8 Removing Rear Crankshaft Oil Seal
9 - 106 3. 3L ENGINE
The l ubri cati on system i s a ful l fl ow fi l trati on pres-
sure feed type. Oi l stored i n the oi l pan i s taken i n and
di scharged by a i nternal gear type oi l pump di rectl y
coupl ed to the crankshaft. I ts pressure i s regul ated by
a rel i ef val ve l ocated i n the Chai n Case Cover. The oi l
i s pumped through an oi l fi l ter and feeds a mai n oi l
gal l ey.Thi s oi l gal l ery feeds oi l under pressure to the
mai n and rod beari ngs, camshaft beari ngs. Passages i n
the cyl i nder bl ock feed oi l to the hydraul i c l i fters and
rocker shaft brackets whi ch feeds the rocker arm pi vots
(Fi g. 1).
OIL PAN SERVICE
REMOVAL
(1) Di sconnect negati ve battery cabl e, remove en-
gi ne oi l di psti ck.
(2) Rai se vehi cl e. Drai n engi ne oi l .
(3) Remove oi l pan screws and remove oi l pan.
(1) Cl ean oi l pan i n sol vent and wi pe dry wi th a
cl ean cl oth. Cl ean al l gasket materi al from mounti ng
surfaces of pan and bl ock.
(2) I nspect oi l drai n pl ug and pl ug hol e for stri pped
or damaged threads and repai r as necessary. I nstal l a
new drai n pl ug gasket. Ti ghten to 27 Nm (20 ft. l b.).
(3) I nspect oi l pan mounti ng fl ange for bends or
di storti on. Strai ghten fl ange i f necessary.
(4) Cl ean oi l screen and pi pe i n cl ean sol vent. I n-
spect condi ti on of screen.
I NSTALLATI ON
(1) I nstal l oi l pi ck-up tube i nto Chai n Case Cover
ti ghten screw to 28 Nm (250 i n. l bs.) (Fi g. 2).
(2) Appl y a 1/8 i nch bead of Mopar Si l i cone Rubber
Adhesi ve Seal ant or equi val ent, at the parti ng l i ne of
the Chai n Case Cover and the Rear Seal Retai ner (Fi g.
3).
(3) Use a new pan gasket (Fi g. 4).
(4) I nstal l pan and ti ghten screws to 23 Nm (200 i n
l b.).
(5) Lower vehi cl e and i nstal l oi l di psti ck.
(7) Fi l l crankcase wi th oi l to proper l evel .
Fig. 1 Engine Oiling System
Fig. 2 Oil Pump Pick-up Tube Service
3. 3L ENGINE 9 - 107
OIL PUMP SERVICE
I t i s necessary to remove the oi l pan, oi l pi ckup and
chai n case cover (CCC) to servi ce the oi l pump rotors.
The oi l pump pressure rel i ef val ve can be servi ced by
removi ng the oi l pan and oi l pi ckup tube. Refer to
Ti mi ng Chai n Cover Removal and I nstal l ati on of thi s
secti on for procedures.
DI SASSEMBLY
(1) To remove the rel i ef val ve, proceed as fol l ows:
(a) Dri l l a 3.175mm (1/8 i nch) hol e i nto the rel i ef
val ve retai ner cap and i nsert a sel f-threadi ng sheet
metal screw i nto cap.
(b) Cl amp screw i nto a vi se and whi l e supporti ng
chai n case cover (CCC), remove cap by tappi ng CCC
usi ng a soft hammer. Di scard retai ner cap and re-
move spri ng and rel i ef val ve (Fi g. 5).
(2) Remove oi l pump cover screws, and l i ft off cover.
(3) Remove pump rotors.
(4) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear (Fi g. 6).
I NSPECTI ON AND REPAI R
(1) Cl ean al l parts thoroughl y. Mati ng surface of the
chai n case cover (CCC) shoul d be smooth. Repl ace
pump cover i f scratched or grooved.
(2) Lay a strai ghtedge across the pump cover surface
(Fi g. 7). I f a .076mm (.003 i nch) feel er gauge can be
i nserted between cover and strai ght edge, cover shoul d
be repl aced.
(3) Measure thi ckness and di ameter of outer rotor. I f
outer rotor thi ckness measures 7.36mm (.3005 i nch) or
l ess (Fi g. 8), or i f the di ameter i s 79.78mm (3.141
i nches) or l ess, repl ace outer rotor.
(4) I f i nner rotor measures 7.64mm (.301 i nch) or
l ess repl ace i nner rotor and shaft assembl y (Fi g. 9).
(5) Sl i de outer rotor i nto CCC, press to one si de wi th
fi ngers and measure cl earance between rotor and CCC
(Fi g. 10). I f measurement i s 56mm (.022 i nch) or more,
repl ace CCC onl y i f outer rotor i s i n spec.
(6) I nstal l i nner rotor i nto CCC. I f cl earance be-
tween i nner and outer rotors (Fi g. 11) i s .203mm (.008
i nch) or more,repl ace both rotors.
Fig. 3 Oil Pan Sealing
Fig. 4 Oil Pan Gasket Installation
Fig. 5 Oil Pressure Relief Valve
Fig. 6 Oil Pump
9 - 108 3. 3L ENGINE
(7) Pl ace a strai ghtedge across the face of the CCC,
between bol t hol es. I f a feel er gauge of .102mm (.004
i nch) or more can be i nserted between rotors and the
strai ghtedge, repl ace pump assembl y (Fi g.12). ONLY i f
rotors are i n specs.
(8) I nspect oi l pressure rel i ef val ve pl unger for scor-
i ng and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
(9) The rel i ef val ve spri ng has a free l ength of
approxi matel y 49.5mm (1.95 i nch) and shoul d test
between 19.5 and 20.5 pounds when compressed to
34mm (1-11/32 i nches). Repl ace spri ng that fai l s to
meet speci fi cati ons (Fi g. 5).
(10) I f oi l pressure i s l ow and pump i s wi thi n speci -
fi cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
OI L PUMP ASSEMBLY AND I NSTALLATI ON
(1) Assembl e pump, usi ng new parts as requi red.
(2) Ti ghten cover screws to 12 Nm (105 i n. l bs.).
(3) Pri me oi l pump before i nstal l ati on by fi l l i ng rotor
cavi ty wi th engi ne oi l .
(4) I nstal l chai n case cover sl owl y refer to Ti mi ng
Chai n Cover I nstal l ati on of thi s secti on.
Fig. 7 Checking Oil Pump Cover Flatness
Fig. 8 Measuring Outer Rotor Thickness
Fig. 9 Measuring Inner Rotor Thickness
Fig. 10 Measuring Outer Rotor Clearance in Hous-
ing
Fig. 11 Measuring Clearance Between Rotors
3. 3L ENGINE 9 - 109
Check oi l pressure usi ng gauge at oi l pressure swi tch
l ocati on. Oi l pressure shoul d be 34.47 kPa ( 5 psi .) at
i dl e or 205 to 551 kPa (30 to 80 psi .) at 3000 RPM.
(1) Remove pressure sendi ng uni t and i nstal l oi l
pressure gauge (Fi g. 13).
engine at 3000 RPM.
OIL FILTER
When servicing oil filter avoid deforming the
filter can by installing the remove/install tool
bandstrapagainst thecan tobaselockseam. The
lockseamjoiningthecantothebaseisreinforced
by the base plate.
(1) Usi ng Tool C-4065, unscrew fi l ter from base and
di scard (Fi g. 14).
(2) Wi pe base cl ean, then i nspect gasket contact
surface.
(3) Lubri cate gasket of new fi l ter wi th cl ean engi ne
oi l .
(4) I nstal l and ti ghten fi l ter to 20 Nm (15 ft. l bs.)
torque after gasket contacts base. Use fi l ter wrench i f
necessary.
(5) Start engi ne and check for l eaks.
Fig. 12 Measuring Clearance Over Rotors
Fig. 13 Checking Oil Pump Pressure
Fig. 14 Oil Filter
9 - 110 3. 3L ENGINE
3. 3L ENGINE 9 - 111
9 - 112 3. 3L ENGINE
3. 3L ENGINE 9 - 113
9 - 114 3. 3L ENGINE
TORQUE
3. 3L ENGINE 9 - 115
CHIME WARNING/REMINDER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AN AIR
BAG, REFER TO THE AIR BAG PORTION OF THIS
SECTION FOR STEERING WHEEL OR SWITCH RE-
MOVAL AND INSTALLATION PROCEDURES.
The chi me warni ng/remi nder system i ncl udes si g-
nal s for fasten seat bel ts, turn si gnal warni ng, exteri or
l amps l eft on and key l eft i n i gni ti on.
When usi ng the DRB I I refer to the Body Chassi s
Di agnosti c Manual for the procedure.
FASTEN SEAT BELTS
A warni ng l amp on the i nstrument panel , and an
audi bl e chi me tone are used as the fasten seat bel t
warni ng/remi nder.
TURN SIGNAL WARNING
An audi bl e chi me tone shows that the turn si gnal has
been on for .8 km (.6 mi .) at a speed above 24 km/h (15
mph).
EXTERI OR LAMPS LEFT ON
An audi bl e chi me tone i ndi cates the exteri or l amps
were l eft on.
KEY LEFT I N I GNI TI ON
An audi bl e chi me tone i ndi cates the key was l eft i n
i gni ti on.
FASTEN SEAT BELTS
To test the i gni ti on swi tch must be i n the off posi ti on
for several mi nutes before testi ng the fasten seat bel ts.
Turn the i gni ti on swi tch to the ON posi ti on wi th the
dri vers seat bel t unbuckl ed. The seat bel t warni ng
l amp shoul d l i ght for 4 to 8 seconds and the tone shoul d
sound 4 to 8 seconds.
TURN SIGNAL WARNING
To test turn si gnal warni ng system i t must have:
The i nput from ei ther the ri ght or l eft turn si gnal
l amps creates a vol tage change between 0 and battery
vol tage.
The di stance sensor message from the engi ne con-
trol l er, must exceed 24 km/h (15 mph) for .8 km (.6 mi .).
When the two condi ti ons above are met, the chi me
wi l l sound. The chi me wi l l stop when no further vol tage
change or a drop i n speed i s detected.
I f hazard warni ng si gnal s are pul si ng, then no chi me
shal l sound.
I f turn si gnal l amps are not worki ng properl y, the
chi me wi l l not sound.
When usi ng DRB I I refer to the Body Chassi s
Di agnosti c Manual for the procedure.
EXTERIOR LAMPS LEFT ON
To test the headl amps l eft on functi on, turn i gni ti on
off, turn exteri or l amps on wi th dri vers door open.
Chi me shoul d sound unti l headl amps are turned off or
dri vers door i s cl osed.
KEY LEFT IN IGNITION
To test the key l eft i n i gni ti on functi on, i nsert key
i nto the i gni ti on and open dri vers door. Chi me shoul d
sound unti l key i s removed from i gni ti on or dri vers
door i s cl osed.
CHIME SYSTEM DIAGNOSIS
CONDI TI ON: NO TONE WHEN I GNI TI ON
SWI TCH I S TURNED ON AND DRI VERS SEAT
BELT I S UNBUCKLED
REPAIR
(1) Check dri vers seat bel t buckl e swi tch for a
ground when unbuckl ed.
(2) Check for battery feed at termi nal B-16 and
i gni ti on feed at termi nal B-12 of body control l er (Fi g. 1
and 2).
(3) Check for tone i n any other functi on.
(4) Repai r as necessary.
CONDI TI ON: NO FASTEN SEAT BELT LAMP
WHEN I GNI TI ON SWI TCH I S TURNED ON
REPAIR
(1) Check for burned out bul b.
(2) Check for battery feed at termi nal B-16 and l amp
output at termi nal B-21 of body control l er.
(3) Check for i gni ti on feed at termi nal B-12 of body
control l er.
CONDI TI ON: FASTEN SEAT BELT LAMP OR
TONE CONTI NUE FOR MORE THAN 10 SEC-
ONDS AFTER SEAT BELTS ARE FASTENED
AND DRI VERS DOOR I S CLOSED
REPAIR
(1) Check l eft door jamb swi tch.
(2) I nspect body control l er connectors and wi res for
proper connecti on.
CONDI TI ON: NO TONE WHEN HEADLAMPS
ARE ON AND DRI VERS DOOR I S OPEN
REPAIR
(1) Check l eft door jamb swi tch for good ground
when dri vers door i s open.
CHIME WARNING/REMINDER SYSTEM 8U - 1
proper connecti on.
(3) Check for battery feed at termi nal B-16 of body
control l er.
(4) Check headl amp swi tch.
CONDI TI ON: NO TONE WHEN KEY I S LEFT I N
I GNI TI ON AND DRI VERS DOOR I S OPEN
REPAIR
(1) Check l eft door jamb swi tch for good ground
when dri vers door i s open.
proper connecti on.
(3) Check for battery feed at termi nal B-16 of body
control l er (Fi g. 1).
(4) Check key-i n swi tch.
CONDI TI ON: CHI MES CONTI NUE WHEN
HEADLAMPS ARE TURNED OFF AND/OR KEY
I S REMOVED FROM I GNI TI ON
REPAIR
(1) Check wi ri ng for a grounded condi ti on between
headl amp swi tch, key-i n swi tch and chi me modul e.
proper connecti on.
HEADLAMP SWITCH REPLACEMENT
Refer to Group 8E, I nstrument Panel and Gauges.
SEAT BELT BUCKLE REPLACEMENT
Refer to Group 23, Body for servi ce procedures.
KEY-IN SWITCH
The Key-i n swi tch i s bui l t i nto the i gni ti on swi tch
assembl y. I f the Key-i n swi tch requi re servi ce, the
i gni ti on swi tch assembl y must be repl aced. Refer to
Group 8D, I gni ti on System for servi ce procedures.
Fig. 1 Chime Warning/Reminder Wiring
Fig. 2 Body Controller 25-Way Connectors
8U - 2 CHIME WARNING/REMINDER SYSTEM
POWER MIRRORS
CONTENTS
page page
HEATED MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 1
MIRROR ASSEMBLY REPLACEMENT . . . . . . . . . 2
MIRROR MOTOR TEST . . . . . . . . . . . . . . . . . . . . 1
MIRROR SWITCH REPLACEMENT . . . . . . . . . . . 2
MIRROR SWITCH TEST . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
El ectri cal l y-operated remote control mi rrors are
avai l abl e as an opti on on AS-body vehi cl es. The mi rrors
are control l ed by a swi tch assembl y l ocated on the
dri vers door armrest bezel .
The vehi cl e use a rocker swi tch for ri ght or l eft si de
mi rror sel ecti on and four buttons for mi rror UP,
DOWN, RI GHT, or LEFT movement.
The motors whi ch operate the mi rrors are part of the
mi rror assembl y and cannot be servi ced separatel y.
MIRROR MOTOR TEST
(1) Remove door tri m panel . Refer to Group 23, Body.
(2) Di sconnect wi ri ng harness connector to the
Power Mi rror.
(3) Usi ng two jumper wi res:
Connect one to a 12-vol t source
Connect the other to a good body ground
Refer to the Mi rror Test Chart for wi re hookups at
the swi tch connector (Fi g. 1).
(4) I f resul ts shown i n chart are not obtai ned, check
for broken or shorted ci rcui t, or repl ace mi rror assem-
bl y as necessary.
MIRROR SWITCH TEST
(1) Remove power mi rror swi tch from mounti ng po-
si ti on.
(2) Di sconnect wi ri ng harness at swi tch connector.
(3) Usi ng a ohmmeter, test for conti nui ty between
the termi nal s of the swi tch as shown i n the Mi rror
Swi tch Conti nui ty Chart (Fi g. 2).
I f resul ts shown i n the chart are not obtai ned,
repl ace the swi tch.
HEATED MIRROR
Heated mi rrors are avai l abl e wi th Power Mi rrors
and Rear Wi ndow Defogger onl y. The heated mi rror i s
control l ed by the rear wi ndow defogger swi tch. The
heated mi rror i s on when the rear wi ndow defogger i s
on.
Fig. 1 Power Mirror Test
Fig. 2 Mirror Switch Test
POWER MIRRORS 8T - 1
TEST PROCEDURES
(1) The mi rror shoul d be warm to the touch.
(a) I f not check fuses.
(b) Test vol tage at rear wi ndow defogger swi tch.
I f no vol tage repai r wi re.
Appl y vol tage to one wi re and ground the other, refer
to Fi g. 1 for pi n numbers. Mi rror shoul d become warm
to the touch.
I f not remove mi rror gl ass and test the wi res for
conti nui ty. I f no conti nui ty repai r wi res.
I f wi res are OK, repl ace mi rror gl ass.
To test defogger swi tch refer to Group 8N, Rear
Wi ndow Defogger.
MIRROR SWITCH REPLACEMENT
(1) Remove dri vers door mi rror swi tch bezel from
armrest (Fi g.3).
(2) Di sconnect wi ri ng connector.
(3) Remove swi tch from bezel .
(4) For i nstal l ati on, reverse above procedures.
MIRROR ASSEMBLY REPLACEMENT
(1) Remove door tri m panel and weather shi el d.
Refer to Group 23, Body.
(2) Reach i nsi de door and di sconnect mi rror wi ri ng
at connector.
(3) Remove two mi rror tri m bezel retai ni ng screws,
and pul l bezel away from door (Fi g. 4).
(4) Remove three mi rror retai ni ng nuts.
(5) Pul l mi rror l oose from door, and feed wi ri ng
harness out through hol e i n outer door panel .
Fig. 4 Power Mirror
Fig. 3 Power Mirror/Window switch Bezel
8T - 2 POWER MIRRORS
POWER WINDOWS
CONTENTS
page page
MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . 2
POWER VENT WINDOWS . . . . . . . . . . . . . . . . . . 3
POWER WINDOW CABLE HOUSING/MOTOR
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 2
SWITCH CONTINUITY TEST . . . . . . . . . . . . . . . . 1
SWITCH VOLTAGE TEST . . . . . . . . . . . . . . . . . . . 1
VENT CABLE AND CRANK MECHANISM . . . . . . 4
VENT WINDOW MOTOR REPLACEMENT . . . . . . 5
VENT WINDOW MOTOR TEST . . . . . . . . . . . . . . 3
VENT WINDOW SWITCH TEST . . . . . . . . . . . . . . 3
WINDOW MOTOR TEST . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
Wi ndow l i ft motors are of the permanent magnet
type. A posi ti ve and negati ve battery connecti on to
ei ther of the two motor termi nal s wi l l cause the motor
to rotate i n one di recti on. Reversi ng current through
these same two connecti ons wi l l cause the motor to
rotate i n the opposi te di recti on.
Each i ndi vi dual motor i s grounded through the mas-
ter swi tch by a bl ack wi re attached to the l eft cowl
panel .
I t i s necessary that the wi ndow be free to sl i de up
and down i n the gl ass channel s or tubes and tracks. I f
the wi ndow i s not free to move up and down, the
wi ndow l i ft motor wi l l not be abl e to move the gl ass.
To determi ne i f the gl ass i s free i s to di sconnect the
el ectri c wi ndow regul ator l i ft pl ate from the gl ass (Fi g.
1). Then sl i de the wi ndow up and down by hand.
SWITCH VOLTAGE TEST
The fol l owi ng wi ri ng test sequence determi nes
whether or not vol tage i s conti nuous through the body
harness to swi tch (Fi g. 2).
(1) After removi ng swi tch from tri m panel for testi ng
purposes, careful l y separate mul ti pl e termi nal bl ock
on wi ri ng harness from swi tch body.
(2) Connect one l ead of test l i ght to bl ack wi re
termi nal and touch other test l i ght l ead to tan wi re
termi nal .
(3) I f the test l i ght comes on, the wi ri ng ci rcui t
between the battery and swi tch i s functi onal .
(3) I f l i ght does not come on, check 30 amp ci rcui t
breaker or for a broken wi re.
SWITCH CONTINUITY TEST
To check the swi tch, remove the swi tch from i ts
mounti ng posi ti on. Usi ng an ohmmeter, and referri ng
to the Swi tch Conti nui ty (Fi gs. 3 and 4), determi ne i f
conti nui ty i s correct. I f there i s no conti nui ty at any one
of the swi tch posi ti ons, repl ace the swi tch.
Fig. 1 Power Window Regulator
Fig. 2 Mirror/Window Switch
POWER WINDOWS 8S - 1
WINDOW MOTOR TEST
(1) Connect posi ti ve (+) l ead from a test battery to
ei ther of the two motor termi nal s.
(2) Connect negati ve (-) l ead from test battery to
remai ni ng motor termi nal .
(3) The motor shoul d now rotate i n one di recti on to
ei ther move wi ndow up or down.
(a) I f wi ndow happens to be al ready i n ful l UP
posi ti on and motor i s connected so to rotate i n UP
di recti on no movement wi l l be observed.
(b) Al so, the motor connected to DOWN di recti on
rotati on, no movement wi l l be observed i f wi ndow i s
al ready i n ful l down posi ti on.
(4) Reverse battery l eads (steps 1 and 2) and wi ndow
shoul d now move. I f wi ndow does not move, remove
motor. See bel ow for motor removal from vehi cl e.
(5) I f wi ndow moved compl etel y up or down, motor
shoul d be reversed one more ti me (step 4) to compl ete
a ful l wi ndow travel i nspecti on.
POWER WINDOW CABLE HOUSING/MOTOR RE-
PLACEMENT
(1) Remove front door tri m panel . Refer to group 23,
Body.
(2) Di sconnect wi ndow l i ft pl ate from gl ass (Fi g. 5).
(3) Di sconnect wi ndow track from door.
(4) Di sconnect wi ndow l i ft motor and dri ve cabl es.
(5) Di sconnect el ectri cal connecti ons.
(6) Careful l y remove wi ndow track, cabl es and l i ft
motor assembl y from door.
(7) For i nstal l ati on reverse above procedures.
MOTOR REPLACEMENT
REMOVAL
(1) Refer to Front Door Wi ndow Regul ator for re-
moval .
(2) The door gl ass must be i n the ful l up posi ti on.
(3) Tape gl ass to door frame to hol d gl ass i n the up
posi ti on.
(4) I f the wi ndow i s not i n the ful l up posi ti on,
remove onl y the motor from the door.
(5) Remove nuts from motor and cabl e housi ng (Fi g.
6).
(6) Make sure motor i s faci ng you before separati ng
motor from housi ng.
(7) Usi ng a fl at tool sl owl y separate motor from
housi ng, maki ng sure the cabl e drum under the motor
stays i n cabl e housi ng. When motor i s ful l y separated
the assi st spri ng wi l l be compl etel y unwound (Fi g. 7).
(8) Remove assi st spri ng by rel easi ng the tabs on the
opposi te si des of the spri ng, do not remove spri ng from
i ts case (Fi g. 8).
I NSTALLATI ON
(1) I nstal l motor i nto housi ng wi th one stud and i n
center of housi ng to secure motor to housi ng.
Fig. 3 Master Switch Continuity
Fig. 4 Front Door Window or Rear Vent Window
Switch Continuity
Fig. 5 Cable and Housing/Motor
8S - 2 POWER WINDOWS
(2) Before i nstal l i ng new spri ng, power the motor
i nto the ful l -up posi ti on.
(3) Repl ace assi st spri ng on cabl e housi ng. Wi nd
spri ng cl ockwi se 3 1/2 turns on the l eft door. The ri ght
door, wi nd spri ng counter cl ockwi se 3 1/2 turns (Fi g. 9).
(4) I nstal l the other two studs and nuts and ti ghten
to 4 to 5 Mm (35 to 45 i n. l bs.).
(5) I nspect that cabl es are not twi sted pri or to i n-
stal l i ng motor and housi ng i nto door.
POWER VENT WINDOWS
AS-body vehi cl es have, as an opti on, power rear vent
wi ndows. The wi ndows are operated by swi tches
mounted i n the overhead consol e. A separate swi tch i s
used for each wi ndow.
The vent wi ndow motors are of the permanent mag-
net type. A posi ti ve and negati ve battery connecti on to
ei ther of the two motor termi nal s wi l l cause the motor
to rotate i n one di recti on. Reversi ng current through
these same two connecti ons wi l l cause the motor to
rotate i n the opposi te di recti on.
VENT WINDOW SWITCH TEST
For power vent wi ndow swi tch testi ng, see power
wi ndows Swi tch Test.
VENT WINDOW MOTOR TEST
(1) Connect posi ti ve (+)l ead from a test battery to
ei ther of the two motor termi nal s.
(2) Connect negati ve (-) l ead from test battery to
remai ni ng motor termi nal .
(3) The motor shoul d now rotate i n one di recti on to
ei ther move the wi ndow OPEN or CLOSED.
(a) I f wi ndow happens to be al ready i n the ful l
CLOSED posi ti on and motor i s connected to rotate
toward the CLOSED posi ti on no movement wi l l be
observed.
(b) Al so, the motor connected to rotate OPEN, no
movement wi l l be observed i f the wi ndow i s al ready
i n ful l OPEN posi ti on.
(4) Reverse battery l eads (opposi te steps 1 and 2)
and wi ndow shoul d now move, or move i n the opposi te
di recti on. I f wi ndow does not move, remove motor and
cabl e assembl y.
Fig. 6 Separating Motor from Housing
Fig. 7 Cable/Drum and Motor
Fig. 8 Assist Spring Cover
Fig. 9 Wind Assist Spring Cover
(5) I f wi ndow moved compl etel y OPEN and
CLOSED, motor shoul d be reversed one more ti me
(reverse l eads from step 4) to compl ete a ful l wi ndow
movement i nspecti on.
VENT CABLE AND CRANK MECHANISM
REMOVAL
(1) Remove wi ndshi el d si de garni sh mol di ng.
(2) Remove rear seat(s).
(3) Remove front door and l i ftgate scuff pl ates.
(4) I f servi ci ng ri ght si de cabl e, remove si de door
scuff pl ate and upper track cover.
(5) Remove B-pi l l ar garni sh mol di ng and seat bel t.
(6) Remove upper and l ower tri m panel s for the l eft
si de or one pi ece tri m panel for the ri ght si de.
(7) Remove two bol ts attachi ng crank mechani sm to
quarter panel (Fi g. 10).
(8) Remove three screws attachi ng cabl e to motor.
(9) Di sengage pi vot from quarter gl ass.
(10) Remove cabl e retai ni ng cl i p and remove cabl e
assembl y.
I NSTALLATI ON
(1) Posi ti on cabl e to motor maki ng sure cabl e pul l ey
engages wi th motor and i nstal l three screws (Fi g. 11).
(2) Engage pi vot to quarter gl ass.
(3) I nstal l crank mechani sm bol ts and pul l mecha-
ni sm rearward whi l e ti ghteni ng (Proper al i gnment i s
requi red for smooth non-bi ndi ng operati on).
(4) I nstal l cabl e retai ni ng cl i p.
(5) I nstal l upper and l ower tri m panel s for the l eft
si de or one pi ece tri m panel ri ght si de.
(6) I nstal l B pi l l ar garni sh mol di ng and seat bel t.
(7) I nstal l si de door scuff pl ate and upper track
cover.
(8) I nstal l front door scuff pl ate, l i ftgate scuff pl ate,
rear seat(s) and wi ndshi el d si de garni sh mol di ng.
Fig. 10 Motor and Cable Assemblies
Fig. 11 Cable Attaching Screws
8S - 4 POWER WINDOWS
VENT WINDOW MOTOR REPLACEMENT
The fol l owi ng procedure descri bes repl acement of a
defecti ve motor wi thout removi ng the cabl e assembl y
from the vehi cl e.
REMOVAL
(1) Remove rear quarter tri m panel .
(2) Di sconnect wi ri ng connector.
(3) Remove three screws attachi ng motor to cabl e
(Fi g. 11).
(4) Remove two bol ts attachi ng motor bracket to
quarter panel .
(5) Remove motor.
I NSTALLATI ON
(1) Posi ti on motor to cabl e assembl y maki ng sure
cabl e pul l ey engages wi th motor and i nstal l three
screws.
(2) I nstal l motor bracket to quarter panel bol ts.
(3) Connect wi ri ng connector.
(4) I nstal l rear quarter tri m panel .
POWER SEATS
CONTENTS
page page
ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CIRCUIT BREAKER TEST . . . . . . . . . . . . . . . . . . 1
HARNESS VOLTAGE TEST . . . . . . . . . . . . . . . . . 1
HORIZONTAL AND VERTICAL
TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . 3
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MOTOR CABLE AND HOUSING . . . . . . . . . . . . . 2
MOTOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 2
SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
Dri vers power seat can be adjusted i n si x di fferent
di recti ons up, down, forward, back, ti l t forward, or ti l t
rearward.
A three armature permanent magnet reversi bl e mo-
tor i s coupl ed through cabl es to worm gear box assem-
bl i es l ocated i n the seat tracks, provi di ng the vari ous
seat movements.
The el ectri cal ci rcui t i s protected by a 30 amp ci rcui t
breaker l ocated on the fuse bl ock.
TEST PROCEDURES
Before any testi ng i s attempted the battery shoul d be
careful l y charged and al l connecti ons and termi nal s
cl eaned and ti ghtened to i nsure proper conti nui ty and
grounds.
Wi th dome l amp on, appl y swi tch i n di recti on of
fai l ure. I f dome l amp di ms the seat moti on i s tryi ng to
work i ndi cati ng mechani cal jammi ng. I f dome l amp
does not di m, then proceed wi th the fol l owi ng el ectri cal
tests.
CIRCUIT BREAKER TEST
Fi nd correct ci rcui t breaker on fuse bl ock. Pul l out
sl i ghtl y but be sure that ci rcui t breaker termi nal s sti l l
contact termi nal s i n fuse bl ock. Connect ground wi re of
vol tmeter to a good ground. Wi th probe of vol tmeter
posi ti ve wi re, check both termi nal s of ci rcui t breaker
for battery vol tage. I f onl y one termi nal checks at
battery vol tage, ci rcui t breaker i s defecti ve and must
be repl aced. I f nei ther termi nal shows battery vol tage,
check for open or shorted ci rcui t to ci rcui t breaker.
HARNESS VOLTAGE TEST
The fol l owi ng test wi l l determi ne whether or not
vol tage i s conti nuous through the body harness to the
swi tch.
(1) Remove power seat swi tch from mounti ng posi -
ti on and di sconnect swi tch from wi ri ng harness.
(2) Connect one l ead of test l i ght to ground termi nal ,
bl ack wi re (BK) of center secti on, and touch other test
l i ght l ead to red wi re (RD) termi nal .
(3) I f test l i ght comes on, harness to swi tch i s good.
I f test l i ght does not come on, perform ci rcui t breaker
test.
MOTOR TESTS
(1) Remove swi tch from mounti ng posi ti on and di s-
connect from harness (Fi g. 1).
(2) To check the front motor, connect a covered
jumper wi re between cavi ty number 2 and cavi ty
number 9. Connect a second jumper wi re between
cavi ty number 6 and cavi ty number 5. I f the motor does
not operate, reverse the jumpers (2 to 5 and 6 to 9). I f
motor sti l l does not operate check wi ri ng between
swi tch connector and motor assembl y. I f wi ri ng checks
good repl ace motor assembl y.
(3) To check the center motor, connect a covered
jumper wi re between cavi ty number 2 and cavi ty
number 8. Connect a second jumper wi re between
cavi ty 6 and cavi ty number 7. I f the motor does not
Fig. 1 Power Seat Switch Connector
POWER SEATS 8R - 1
operate, reverse the jumpers (2 to 7 and 6 to 8). I f motor
sti l l does not operate check wi ri ng between swi tch
connector and motor assembl y. I f wi ri ng checks good
repl ace motor assembl y.
(4) To check the rear motor, connect a covered
jumper between cavi ty number 2 and cavi ty number
10. Connect a second jumper wi re between cavi ty
number 6 and cavi ty number 3. I f the motor does not
operate, reverse the jumpers (2 to 3 and 6 to 10). I f
motor sti l l does not operate, check wi ri ng between
swi tch connector and motor assembl y. I f wi ri ng checks
good repl ace motor assembl y.
(5) To check the seatback recl i ner motor (i f
equi pped), connect a covered jumper wi re be tween
cavi ty number 2 and cavi ty number 1. Connect a
second jumper wi re between cavi ty number 6 and
cavi ty number 11. I f the motor does not operate,
reverse the jumpers (2 to 11 and 6 to 1). I f motor sti l l
does not operate check wi ri ng be tween swi tch connec-
tor and motor assembl y. I f wi ri ng checks good repl ace
motor assembl y.
(6) I f al l motors and the seat operate properl y, per-
form Swi tch Test.
SWITCH TEST
To check the swi tch, remove the swi tch from i ts
mounti ng posi ti on. Usi ng an ohmmeter, and referri ng
to the Swi tch Conti nui ty, determi ne i f conti nui ty i s
correct. I f there i s no conti nui ty at any one of the
swi tch posi ti ons, repl ace the swi tch.
SEAT ASSEMBLY
REMOVAL
(1) Remove adjuster attachi ng bol ts and nuts from
fl oor pan. Move adjuster as requi red for access.
(2) Di sconnect battery ground cabl e.
(3) Di sconnect wi ri ng harness power l ead at carpet.
(4) Remove assembl y from vehi cl e.
I NSTALLATI ON
(1) Posi ti on seat assembl y i n vehi cl e.
(2) Connect wi ri ng harness.
(3) I nstal l and ti ghten mounti ng bol ts and nuts.
(4) Connect battery ground cabl e and check seat
operati on.
MOTOR CABLE AND HOUSING
REMOVAL
I t i s recommended that anyti me a cabl e i s to be
repl aced that the motor assembl y be removed al so for
ease of repl acement.
(1) After motor has been di sconnected, remove
corbi n cl amp from cabl e housi ng.
(2) Remove cabl es from motor by removi ng two
screws from bracket, then sl i de cabl es out of motor.
I NSTALLATI ON
(1) I nsert cabl e and housi ng i nto bracket and i nstal l
corbi n cl amp.
(2) Synchroni ze l eft and ri ght hand adjuster posi -
ti ons.
(3) Posi ti on cabl es i n motor wi th bracket i n posi ti on,
then secure wi th two screws.
Fig. 2 Switch Continuity
8R - 2 POWER SEATS
(4) I nstal l motor assembl y.
HORIZONTAL AND VERTICAL TRANSMISSIONS
Transmi ssi ons are not removabl e and no mai nte-
nance i s requi red. I f transmi ssi on fai l s repl ace enti re
seat adjuster assembl y.
ADJUSTER
REMOVAL
(1) Remove seat assembl y from vehi cl e fol l owi ng
procedure outl i ned under Seat Assembl y Removal .
(2) Lay seat on i ts back on a cl ean surface.
(3) Remove bol ts attachi ng adjuster to seat assem-
bl y.
(4) Di sconnect wi ri ng harness at swi tch i f seat
mounted swi tch i s used.
I NSTALLATI ON
(2) Posi ti on adjuster to seat assembl y and i nstal l
attachi ng bol ts.
(3) Connect wi ri ng harness at swi tch.
(4) I nstal l seat assembl y fol l owi ng procedure out-
l i ned under Seat Assembl y I nstal l ati on.
MOTOR
REMOVAL
Anyti me the motor, cabl e and housi ng assembl i es, or
verti cal and hori zontal transmi ssi on assembl i es re-
qui re mai ntenance, the assembl i es must be synchro-
ni zed to i nsure easy and proper operati on.
(1) Remove seat assembl y from vehi cl e fol l owi ng
procedure outl i ned under Seat Assembl y Removal .
(3) Remove motor mounti ng screws.
(4) Careful l y di sconnect housi ng and cabl es from
motor assembl y.
I NSTALLATI ON
(1) Pl ace motor assembl y i nto posi ti on.
(2) Careful l y connect cabl es and housi ngs to motor
assembl y.
(3) I nstal l mounti ng screws.
(4) I nstal l bol t hol di ng motor assembl y to adjuster.
(5) I nstal l seat assembl y fol l owi ng procedure out-
l i ned under Seat Assembl y I nstal l ati on.
POWER SEATS 8R - 3
POWER LOCKS
CONTENTS
page page
CIRCUIT BREAKER TEST . . . . . . . . . . . . . . . . . . 2
CIRCUIT TEST SLIDING DOOR . . . . . . . . . . . . . . 2
DOOR LATCH WITH INTEGRAL LOCKFRONT
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DOOR LOCK INHIBIT . . . . . . . . . . . . . . . . . . . . . 1
DOOR LOCK SYSTEM TEST . . . . . . . . . . . . . . . . 1
ELECTRIC MOTOR TEST . . . . . . . . . . . . . . . . . . . 2
LIFT GATE OPERATION . . . . . . . . . . . . . . . . . . . 3
LOCK MOTOR REPLACEMENT LIFTGATE
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOCK MOTOR REPLACEMENT SLIDING DOOR . 3
POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . . 1
SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SWITCH VOLTAGE TEST . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
Both front doors and sl i di ng si de door, when el ectri -
cal l y equi pped, can be l ocked or unl ocked el ectri cal l y
by operati ng the swi tch on a front door panel .
Al l doors can be l ocked or unl ocked mechani cal l y
wi th the l ocki ng knob.
Both front doors and sl i di ng door can be l ocked or
unl ocked mechani cal l y from the outsi de wi th the key or
el ectri cal l y as descri bed above. The both front doors
can al so be unl ocked by actuati on of thei r respecti ve
i nsi de remote door handl e.
The l i ft gate rel ease consi sts of a l atch wi th i nternal
sol enoi d and push button swi tch. The sol enoi d i s ener-
gi zed onl y when the push button i s depressed.
DOOR LOCK INHIBIT
When the key i s i n the i gni ti on swi tch i n the ON or
OFF posi ti on wi th the dri vers door open, the Body
Control l er wi l l i gnore the command to l ock the power
door l ocks. Once the key i s removed, or the dri vers
door i s cl osed, the Body Control l er wi l l al l ow the power
door l ocks to l ock.
POWER DOOR LOCKS
When vehi cl e i s equi pped wi th power door l ocks, the
system i ncl udes an automati c door l ocki ng feature.
Whi ch i s actuated through the vehi cl es body control -
l er.
The vehicle is built with the systemdisabled.
When the system i s di sabl ed the door l ocks wi l l work
by use of the door l ock swi tches onl y. When thi s system
i s enabl ed the automati c door l ocks wi l l work automati -
cal l y.
The body control l er control s the power l ocks when
the door l ock swi tch i s acti vated. I f the door l ock swi tch
i s pressed for l onger than ei ght consecuti ve seconds,
the body control l er wi l l de-energi ze the door l ock rel ay.
Al so, the body control l er wi l l automati cal l y l ock al l
doors when al l of the condi ti ons bel ow are met:
Al l doors are cl osed
The vehi cl e speed exceeds 15 1 MPH
The throttl e posi ti on sensor ti p-i n i s greater than 10
2 degrees.
The DRB I I must be used to enabl e/di sabl e the
automati c door l ock system. Refer to the Body Di ag-
nosti c Procedures Manual for the procedure.
The body control l er wi l l automati cal l y re-l ock al l
doors i f the above condi ti ons are met and i f any of the
doors become ajar. The body control l er does not control
the door unl ock functi on. The swi tch i s wi red di rectl y
to the l ock rel ay.
The power l ock motors are al so equi pped wi th a
thermal protecti on system whi ch prevents the motors
from burni ng out. The motors may chatter i f they are
conti nousl y acti vated.
The sl i di ng door can be l ocked or unl ocked el ectri -
cal l y when the door i s cl osed. The sl i di ng door can al so
be l ocked el ectri cal l y when the door i s open as fol l ows:
By acti vati ng the power l ock swi tch to the l ock posi ti on
whi l e door i s open, and the key i s not i n the i gni ti on
swi tch. The front doors wi l l l ock and send a si gnal to
the body control l er to l ock the sl i di ng door upon cl os-
i ng.
DOOR LOCK SYSTEM TEST
For compl ete testi ng of the automati c door l ock
systems, refer to the Body Di agnosti c Procedures
Manual .
SWITCH VOLTAGE TEST
The fol l owi ng wi ri ng test sequence determi nes
whether or not vol tage i s conti nuous through the body
harness to swi tch.
(1) After removi ng swi tch from tri m panel for testi ng
purposes, careful l y separate mul ti pl e termi nal bl ock
on wi ri ng harness from swi tch body. Connect one l ead
of test l i ght to bl ack wi re termi nal and touch other test
l i ght l ead to red wi re termi nal . I f the test l i ght comes
on, the wi ri ng ci rcui t between
POWER LOCKS 8P - 1
the battery and swi tch i s functi onal . I f l i ght does not
come on, check 30 amp ci rcui t breaker or for a open
ci rcui t.
CIRCUIT BREAKER TEST
Fi nd correct ci rcui t breaker on fuse bl ock. Pul l out
sl i ghtl y but be sure that ci rcui t breaker termi nal s sti l l
contact termi nal s i n fuse bl ock. Connect ground wi re of
vol tmeter to a good ground. Wi th probe of vol tmeter
posi ti ve wi re, check both termi nal s of ci rcui t breaker
for 12 vol ts. I f onl y one termi nal checks at 12 vol ts,
ci rcui t breaker i s defecti ve and must be repl aced. I f
nei ther termi nal shows 12 vol ts, check for open or
shorted ci rcui t to ci rcui t breaker.
SWITCH TEST
For swi tch testi ng, remove the swi tch from i ts
mounti ng l ocati on. Usi ng an ohmmeter, refer to (Fi g. 1)
to determi ne i f conti nui ty i s correct i n the Lock and
Unl ock swi tch posi ti ons. I f these resul ts are not ob-
tai ned, repl ace the swi tch.
CIRCUIT TEST SLIDING DOOR
Connect one l ead of a test l i ght to the upper contact
on the B pi l l ar and the other l ead to the l ower
contact. I f the test l i ght comes on when the l ock swi tch
i s depressed, the wi ri ng ci rcui t to the contacts i s good.
I f the test l i ght does not come on, perform the ci rcui t
breaker test, check connectors at the ri ght si de cowl , or
check for a broken wi re.
Wi th the sl i di ng door parti al l y open, connect jumper
wi res from contacts on door to contacts on Bpi l l ar.
Connecti ng these contacts shoul d l ock or unl ock door
when swi tch i s depressed.
I f l ock and unl ock occurs, the faul t i s at the door and
pi l l ar swi tch contacts. Check for proper shi m at door
contact pl ate. I f l ock and unl ock does not occur, remove
door tri m panel and check for vol tage at motor connec-
tor.
ELECTRIC MOTOR TEST
Make certai n battery i s i n normal condi ti on before
ci rcui ts are tested.
To determi ne whi ch motor i s faul ty, check each
i ndi vi dual door for el ectri cal l ock and unl ock or di scon-
nect the motor connectors one at a ti me, whi l e operat-
i ng the door l ock swi tch. I n the event that none of the
motors work, the probl em maybe caused by a shorted
motor, or a bad swi tch. Di sconnecti ng the defecti ve
motor wi l l al l ow the others to work.
To test an i ndi vi dual door l ock motor, di sconnect the
el ectri cal connector from the motor. To l ock the
Fig. 1 Door Lock Switch Continuity
Fig. 2 Sliding Door lock Motor
Fig. 3 Front Door Lock Motor
8P - 2 POWER LOCKS
door, connect a 12 vol t power source to the posi ti ve pi n
of the l ock motor and a ground wi re to the other pi n
(Fi g. 2, and 3). To unl ock the door reverse the wi re
connecti ons at the motor pi n termi nal s. I f these resul ts
are NOT obtai ned, repl ace the motor.
LIFT GATE OPERATION
TEST
(1) Confi rm sol enoi d l ead wi re i s connected and 10
vol ts or more are avai l abl e at sol enoi d (Fi g. 4).
(2) Provi de proper ground through l atch mounti ng
screws.
(3) Remove l atch and exami ne pl unger, to i nsure i t i s
undamaged and properl y attached, the pl unger shoul d
spri ng back when pressed.
(4) I nsure that sol enoi d pl unger travel i s adequate
approxi matel y 16 mm (5/8 i n.).
ADJUSTMENT
Adjust l i ft gate l atch and stri ker so that l i ftgate
l atches wi th a moderate sl am. Shoul d l atch fai l to l ock,
repl ace l atch assembl y.
Wi th i gni ti on swi tch i n ON or ACCESSORY posi ti on,
push l i ft gate swi tch to a ensure proper operati on.
DOOR LATCH WITH INTEGRAL LOCKFRONT
DOOR
REMOVAL
(1) Remove i nsi de door rel ease handl e, wi ndow regu-
l ator handl e and door tri m panel .
(2) Rol l door watershi el d away from l ower rear cor-
ner of door to reveal i nsi de panel access openi ng.
(3) Di sconnect l atch l i nks and remove door l atch
wi th i ntegral l ock motor (Fi g. 5).
(4) Di sconnect motor from wi ri ng harness.
(5) Remove motor mounti ng bracket screws and re-
move motor assembl y from mounti ng.
I NSTALLATI ON
(1) Connect motor l i nk at l atch and connect wi res.
(2) Attach motor to door i nsi de panel and i nstal l
screws.
(3) Reset watershi el d at l ower rear corner of door.
(4) I nstal l wi ndow regul ator handl e, door i nsi de re-
l ease handl e bezel and door tri m panel .
LOCK MOTOR REPLACEMENT SLIDING DOOR
REMOVAL
(1) Remove two i nsi de handl e bezel screws.
(2) Remove compl ete door tri m panel .
(3) Remove motor l i nk at l ocki ng l ever.
(4) Di sconnect motor power connector.
(5) Remove motor mounti ng screws and motor from
door.
I NSTALLATI ON
(1) Attach motor to control assembl y pl ate and i n-
stal l pop ri vets.
(2) Connect motor l i nk to l ocki ng l ever and connect
motor power connector.
(3) I nstal l door tri m panel and i nsi de handl e bezel .
LOCK MOTOR REPLACEMENT LIFTGATE DOOR
REMOVAL
(1) Remove l i ftgate tri m panel
(2) Remove motor l i nk at l ocki ng l ever.
(3) Di sconnect motor power connector.
(4) Remove motor mounti ng screws and motor from
door.
Fig. 4 Lift Gate Release Assembly
Fig. 5 Front Door Assembly
POWER LOCKS 8P - 3
I NSTALLATI ON
(1) I nstal l motor, ti ghten screws to 3 Nm (25 i n.
l bs.) torque.
(2) Connect motor l i nk to l ocki ng l ever and connect
motor power connector.
(3) I nstal l door tri m panel .
Fig. 6 Sliding Side Door Wiring and Component
Identification
8P - 4 POWER LOCKS
REAR WINDOW DEFOGGER
CONTENTS
page page
ACCESSORY SWITCH CARRIER TEST . . . . . . . . 2
ACCESSORY SWITCH CARRIER . . . . . . . . . . . . . 1
REAR WINDOW GRID LINES TEST . . . . . . . . . . 2
REPAIR GRID LINES, TERMINALS
AND PIGTAILS . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
The el ectri cal l y heated rear wi ndow defogger (Fi g. 1)
i s avai l abl e on si ngl e rear door wagons and vans.
The system consi sts of two verti cal bus bars and a
seri es of el ectri cal l y connected gri d l i nes on the i nsi de
surface of the rear wi ndow.
When the swi tch i s turned to the ON posi ti on,
current i s di rected to the rear wi ndow gri d l i nes. The
heated gri d l i nes i n turn heat the rear wi ndow to cl ear
the outsi de surface of the gl ass.
CAUTION: Since grid lines can be damaged or
scraped off with sharp instruments, care should be
taken in cleaning the glass or removing foreign ma-
terials, decals or stickers. Normal glass cleaning
solvents or hot water used with rags or toweling is
recommended.
ACCESSORY SWITCH CARRIER
The accessory swi tch carri er i s i ntegrated i nto a the
accessory swi tch carri er assembl y. An i ndi cator l amp
i l l umi nates when the swi tch i s acti vated. Actuati ng the
swi tch energi zes the el ectroni c ti mi ng ci rcui t whi ch
al l ows current to fl ow through the gri d system for
approxi matel y 10 mi nutes, or unti l ei ther the control
swi tch or i gni ti on i s turned off. I f the l i ftgate rel ease
swi tch i s actuated, the power to control swi tch i s
momentari l y opened unti l l i ftgate swi tch i s rel eased,
but the i ndi cator l amp wi l l stay i l l umi nated.
SYSTEM TEST
El ectri cal l y heated rear wi ndow defogger operati on
can be checked on the vehi cl e i n the fol l owi ng manner:
(1) Turn the i gni ti on ON.
(2) Turn rear wi ndow defogger control swi tch ON.
(3) Usi ng a ammeter on the battery, turn the Defog-
ger control swi tch to the ON posi ti on, a di sti nct i n-
crease i n amperage draw shoul d be noted.
(4) The rear wi ndow defogger operati on can be
checked by feel i ng the gl ass. A di sti nct di fference i n
temperature between the gri d l i nes and adjacent cl ear
gl ass can be detected i n 3 to 4 mi nutes of operati on.
(5) Usi ng a DC vol tmeter (Fi g. 2) contact termi nal B
wi th the negati ve l ead, and termi nal A wi th the posi -
ti ve l ead. The vol tmeter shoul d read 10-14 vol ts.
(6) Onl y steps (3) and (4) or (5) above wi l l confi rm
system operati on. I ndi cator l i ght i l l umi nati on means
that there i s power avai l abl e at the output of the rel ay
onl y, and does not necessari l y veri fy system operati on.
(7) I f turni ng the swi tch ON produced no di sti nct
current draw on the ammeter the probl em shoul d be
i sol ated i n the fol l owi ng manner:
(a) Confi rm that i gni ti on swi tch i s ON.
(b) Ensure that the heated rear wi ndow feed pi g-
tai l i s connected to the wi ri ng harness and that the
ground pi gtai l i s i n fact grounded.
(c) Ensure that the fusi bl e l i nk or ci rcui t breaker
i s operati onal .
Fig. 1 Rear Window Defogger Wiring
REAR WINDOW DEFOGGER 8N - 1
(8) When the above steps have been compl eted and
the system i s sti l l i noperati ve, one or more of the
fol l owi ng i s defecti ve:
(a) Accessory Swi tch Carri er
(b) Check for l oose connector or a wi re pushed out
of connector.
(c) Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken, or one of the feed pi gtai l s not
connected to the bus bar, for no ammeter defl ecti on).
(9) I f turni ng the swi tch ON produces severe vol tme-
ter defl ecti on, the ci rcui t shoul d be cl osel y checked for
a shorti ng condi ti on.
(10) I f the system operati on has been veri fi ed but
i ndi cator LED does not l i ght, repl ace swi tch.
(11) For detai l ed wi ri ng i nformati on, refer to Group
8W, Wi ri ng Di agrams.
REAR WINDOW GRID LINES TEST
The hori zontal gri d l i nes and verti cal bus bar l i nes
pri nted and baked on i nsi de surface of rear wi ndow
gl ass makes up an el ectri cal paral l el ci rcui t. The el ec-
tri cal l y conducti ve l i nes are composed of a si l ver ce-
rami c materi al whi ch when baked on gl ass becomes
bonded to the gl ass and i s hi ghl y resi stant to abrasi on.
I t i s possi bl e, however, that a break may exi st or occur
i n an i ndi vi dual gri d l i ne resul ti ng i n no current fl ow
through the l i ne. To detect breaks i n gri d l i nes, the
fol l owi ng procedure i s requi red:
(1) Turn i gni ti on and rear wi ndow defogger control
swi tch ON. The i ndi cator l i ght shoul d come on.
(2) Usi ng a DC vol tmeter wi th 0-15 vol t range,
contact verti cal bus bar connecti ng gri d l i nes on pas-
senger si de of vehi cl e at termi nal A (Fi g. 2) wi th
negati ve l ead of vol tmeter. Wi th posi ti ve l ead of vol t-
meter, contact verti cal bus bar on dri ver si de of vehi cl e
at termi nal B (Fi g. 2). The vol tmeter shoul d read 10-14
vol ts.
(3) Wi th negati ve l ead of vol tmeter, contact a good
body ground poi nt. The vol tage readi ng shoul d not
change. A di fferent readi ng i ndi cates a poor ground
connecti on.
(4) Connect negati ve l ead of vol tmeter to termi nal A
on passenger si de bus bar and touch each gri d l i ne at
Mi d-Poi nt wi th posi ti ve l ead. A readi ng of approxi -
matel y 6 vol ts i ndi cates a l i ne i s good. A readi ng of 0
vol ts i ndi cates a break i n l i ne between Mi d-Poi nt C and
termi nal B. A readi ng of 10-14 vol ts i ndi cates a break
between Mi d-Poi nt C and ground termi nal A. Move
toward break and vol tage wi l l change as soon as break
i s crossed.
ACCESSORY SWITCH CARRIER TEST
Accessory swi tch carri er may be tested i n-vehi cl e or
bench tested. I n vehi cl e testi ng i s accompl i shed i n the
fol l owi ng manner:
(1) Remove the accessory swi tch carri er assembl y
from the i nstrument panel or consol e, see Group 8E,
I nstrument Panel and l eave the swi tch connector
pl ugged i n (Fi g. 3).
(2) Turn i gni ti on ON.
(3) Usi ng a DC vol tmeter, wi th 0-15 range, check
vol tage at termi nal s B, D and A. (Fi gs. 3 and 4).Termi -
nal s B and D shoul d confi rm a vol tage of 10 to 14 vol ts
to ground. Termi nal A shoul d confi rm vol tage to
ground. When termi nal s B and D show no vol tage,
trace ci rcui t upstream of accessory swi tch carri er for
probl em, exampl e; wi ri ng cut, fusi bl e l i nk or ci rcui t
breaker i noperati ve, bul khead connector not operati ve,
etc.. I f termi nal A i ndi cates vol tage, pl ace swi tch i n Off
posi ti on. I f vol tage at termi nal A i s sti l l i ndi cated or
i ndi cator l amp remai ns on, the accessory swi tch carri er
shoul d be repl aced.
(4) I f the rel ay checks out to thi s poi nt, momen-
tari l y operate swi tch to ON posi ti on. The i ndi cator
l amp shoul d come on and remai n on for approxi -
matel y 10 mi nutes. Termi nal A shoul d confi rm vol t-
Fig. 2 Grid Line Test
Fig. 3 Accessory Switch Carrier
8N - 2 REAR WINDOW DEFOGGER
age. I f the i ndi cator l amp fai l s to l i ght or vol tage at
termi nal A i s not confi rmed repl ace accessory swi tch
carri er.
Bench checki ng of the rel ay may be accompl i shed i n
the fol l owi ng manner. By fol l owi ng the i n-vehi cl e pro-
cedure except Step 2: Wi th a DC power suppl y, appl y 12
vol ts to termi nal B and 4 and ground termi nal E.
REPAIR GRID LINES, TERMINALS AND PIGTAILS
The repai r of gri d l i nes and repl acement of the
termi nal i s possi bl e usi ng the Mopar Repai r Package or
equi val ent.
(1) Cl ean area surroundi ng gri d l i ne or termi nal by
gentl y rubbi ng area wi th steel wool .
(2) Wi pe area wi th cl ean cl oth soaked i n al cohol or
si mi l ar sol vent. I t i s necessary that al l contami nants
be removed from repai r area.
(3) Remove package separator cl amp and mi x pl asti c
conducti ve epoxy thoroughl y.
(4) For gri d l i ne, mark off area to be repai red wi th
maski ng tape (Fi g.5).
(5) Appl y conducti ve epoxy through sl i t i n maski ng
tape. Overl ap both ends of the break.
(6) For a termi nal repl acement, appl y a thi n l ayer of
epoxy to area where termi nal was fastened.
(7) Appl y a thi n l ayer of epoxy on termi nal and pl ace
termi nal on desi red l ocati on. To prevent termi nal from
fal l i ng off use a wooden wedge to secure i t.
(8) Careful l y remove maski ng tape from gri d l i ne.
CAUTION: Do not allow the glass surface to exceed
204C (400F), glass may fracture.
(9) Al l ow epoxy to cure 24 hours at room tempera-
ture or use heat gun wi th a 260-371C (500-700F)
range for 15 mi nutes. Hol d gun approxi matel y 254mm
(10 i nches) from repai red area.
(10) After epoxy i s properl y cured remove wedge
from termi nal and check the operati on of the rear
wi ndow defogger.
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, HARMFUL IF SWALLOWED.
AVOID CONTACT WITH SKIN AND EYES. FOR SKIN,
WASH AFFECTED AREAS WITH SOAP AND WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY,
INDUCE VOMITING; CALL A PHYSICIAN IMMEDI-
ATELY. IF IN CONTACT WITH EYES, FLUSH WITH
PLENTY OF WATER. USE WITHADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TENTS CONTAINS 3
FLAMMABLE SOLVENTS.
WARNING: KEEP OUT OF REACH OF CHILDREN.
Fig. 4 Rear Window Defogger CircuitTypical
Fig. 5 Grid Line RepairTypical
REAR WINDOW DEFOGGER 8N - 3
RESTRAINT SYSTEMS
CONTENTS
page page
AIR BAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 3
AIR BAG SERVICE AND TEST PROCEDURES . . 1
AIR BAG SYSTEM CHECK . . . . . . . . . . . . . . . . . 3
AIR BAG SYSTEM DIAGNOSTIC
MODULE (ASDM) . . . . . . . . . . . . . . . . . . . . . . 5
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLOCKSPRING CENTERING PROCEDURE . . . . . 6
LEFT FRONT IMPACT SENSOR . . . . . . . . . . . . . 4
RIGHT FRONT IMPACT SENSOR . . . . . . . . . . . . 4
STEERING COLUMN SWITCHES . . . . . . . . . . . . 7
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . 7
AIR BAG SERVICE AND TEST PROCEDURES
WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX
ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPT-
ING TO DIAGNOSE, REMOVE OR INSTALL THE AIR
BAG SYSTEM COMPONENTS, YOU MUST FIRST DIS-
CONNECT AND ISOLATE THE NEGATIVE (GROUND)
BATTERY CABLE. FAILURE TO DO SO COULD RE-
SULT INACCIDENTAL DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WHEN AN UNDEPLOYEDAI R BAG ASSEMBLY I S
TO BE REMOVED FROM THE STEERI NG WHEEL,
DI SCONNECT BATTERY GROUND CABLE AND
I SOLATE. ALLOW SYSTEM CAPACI TOR TO DI S-
CHARGE FOR TWO MI NUTES THEN BEGI N AI R
BAG SYSTEM COMPONENT REMOVAL.
Vehi cl es equi pped wi th a Mi ni van Dri ver Ai r Bag
System must be i nspected every 3 years or 30,000
mi l es / 48,000 Km. To i nspect system use Passi ve
Restrai nt System Di agnosti c Procedures Manual .
I f the Ai r Bag Modul e Assembl y i s defecti ve and
non-depl oyed, refer to Chrysl er Motors current return
l i st for proper handl i ng procedures.
WARNING: REPLACE AIR BAG SYSTEM COMPO-
NENTS WITH CHRYSLER MOPAR SPECIFIED RE-
PLACEMENT PARTS. SUBSTITUTE PARTS MAY VI-
SUALLY APPEAR INTERCHANGEABLE, BUT
INTERNAL DIFFERENCES MAY RESULT IN INFERIOR
OCCUPANT PROTECTION.
THE FASTENERS, SCREWS, AND BOLTS, ORI GI -
NALLY USED FOR THE AI R BAG COMPONENTS,
HAVE SPECI AL COATI NGS AND ARE SPECI FI -
CALLY DESI GNED FOR THE AI R BAG SYSTEM.
THEY MUST NEVER BE REPLACED WI TH ANY
SUBSTI TUTES. ANYTI ME A NEW FASTENER I S
NEEDED, REPLACE WI TH THE CORRECT FAS-
TENERS PROVI DED I N THE SERVI CE PACKAGE
OR FASTENERS LI STED I N THE PARTS BOOKS.
GENERAL INFORMATION
AI R BAG MODULE
The ai r bag modul e i s the most vi si bl e part of the
system (Fi g 1). I t contai ns the ai r bag cushi on and i ts
supporti ng components. The ai r bag modul e contai ns a
housi ng to whi ch the cushi on and i nfl ator are attached
and seal ed.
The i nfl ator assembl y i s mounted to the back of the
modul e housi ng. When suppl i ed wi th the proper el ec-
tri cal si gnal the i nfl ator assembl y wi l l produce a gas
and di scharges i t di rectl y i nto the cushi on. A protecti ve
cover i s fi tted to the front of the ai r bag modul e and
forms a decorati ve cover i n the center of the steeri ng
wheel . The ai r bag modul e i s mounted di rectl y to the
steeri ng wheel .
FRONT I MPACT SENSORS
The dri ver ai r bag system i s a safety devi ce desi gned
to deduce the ri sk of fatal i ty or seri ous i njury, caused
by a frontal i mpact of the vehi cl e.
The i mpact sensors provi de veri fi cati on of the
di recti on and severi ty of the i mpact. Three i mpact
sensors are used. One i s cal l ed a safi ng sensor. I t
i s l ocated i nsi de the di agnosti c modul e whi ch i s
Fig. 1 Minivan Driver Air Bag System
RESTRAINT SYSTEMS 8M - 1
mounted on the fl oor pan, just forward of the center
consol e. The other two sensors are mounted on the
upper crossmember of the radi ator cl osure panel on the
l eft and ri ght si de of the vehi cl e under the hood.
The i mpact sensors are threshol d sensi ti ve swi tches
that compl ete an el ectri cal ci rcui t when an i mpact
provi des a suffi ci ent G force to cl ose the swi tch. The
sensors are cal i brated for the speci fi c vehi cl e and react
to the severi ty and di recti on of the i mpact.
CLOCKSPRI NG
The cl ockspri ng i s mounted on the steeri ng col umn
behi nd the steeri ng wheel , and i s used to mai ntai n a
conti nuous el ectri cal ci rcui t between the wi ri ng har-
ness and the dri vers ai r bag modul e. Thi s assembl y
consi sts of a fl at ri bbon-l i ke el ectri cal l y conducti ve
tape whi ch wi nds and unwi nds wi th the steeri ng wheel
rotati on.
DI AGNOSTI C MODULE
The Ai r Bag System Di agnosti c Modul e (ASDM)
contai ns the safi ng sensor and energy reserve capaci -
tor. The ASDM moni tors the system to determi ne the
system readi ness. The ASDM wi l l stored suffi ci ent
energy to depl oy the ai r bag for onl y two mi nutes after
the battery i s di sconnected. Unl ess both front i mpact
sensors are open the ai r bag coul d be depl oyed up to 9.5
mi nutes after the battery i s di sconnected. The ASDM
contai ns on-board di agnosti cs, and wi l l i l l umi nate the
AI R BAG warni ng l amp i n the cl uster when a faul t
occurs.
STORAGE
The ai r bag modul e must be stored i n i ts ori gi nal
speci al contai ner unti l used for servi ce. Al so, i t must be
stored i n a cl ean, dry envi ronment, away from sources
of extreme heat, sparks, and sources of hi gh el ectri cal
energy. Al ways pl ace or store the modul e on a surface
wi th the tri m cover faci ng up to mi ni mi ze movement i n
case of acci dental depl oyment.
HANDLI NG LI VE MODULE
At no ti me shoul d any source of el ectri ci ty be permi t-
ted near the i nfl ator on the back of the modul e. When
carryi ng a l i ve modul e, the tri m cover shoul d be
poi nted away from the body to mi ni mi ze i njury i n the
event of acci dental depl oyment. I n addi ti on, i f the
modul e i s pl aced on a bench or other surface, the
pl asti c tri m cover shoul d be face up to mi ni mi ze move-
ment i n case of acci dental depl oyment.
When handl i ng a steeri ng col umn wi th an ai r bag
modul e attached, never pl ace the col umn on the fl oor or
other surface wi th the steeri ng wheel or modul e face
down.
DEPLOYED MODULE
The vehi cl e i nteri or may contai n a very smal l
amount of sodi um hydroxi de powder, a byproduct of ai r
bag depl oyment. Si nce thi s powder can i rri tate the
ski n, eyes, nose or throat, be sure to wear safety
gl asses, rubber gl oves and l ong sl eeves duri ng cl eanup
(Fi g. 2).
I f you fi nd that the cl eanup i s i rri tati ng your ski n,
run cool water over the affected area. Al so, i f you
experi ence nasal or throat i rri tati on, exi t the vehi cl e
for fresh ai r unti l the i rri tati on ceases. I f i rri tati on
conti nues, see a physi ci an.
CLEANUP PROCEDURE
Begi n the cl eanup by putti ng tape over the two ai r
bag exhaust vents (Fi g. 3) so that no addi ti onal powder
wi l l fi nd i ts way i nto the vehi cl e i nteri or. Then remove
the ai r bag and ai r bag modul e from the vehi cl e.
Use a vacuum cl eaner to remove any resi dual powder
from the vehi cl e i nteri or. Work from the outsi de i n so
that you avoi d kneel i ng or si tti ng i n a uncl eaned area.
Be sure to vacuum the heater and A/C outl ets as wel l
(Fi g. 4). I n fact i ts a good i dea to run the bl ower
Fig. 2 Wear Safety Glasses and Rubber Gloves
Fig. 3 Seal the Air Bag Exhaust Vents
8M - 2 RESTRAINT SYSTEMS
on l ow and to vacuum up any powder expel l ed from the
pl enum. You may need to vacuum the i nteri or of the car
a second ti me to recover al l of the powder.
Pl ace the depl oyed bag and modul e i n your automo-
ti ve scrap.
SERVI CE OF DEPLOYED AI R BAG MODULE
After an ai r bag has been depl oyed, the ai r bag
modul e and cl ockspri ng must be repl aced because they
cannot be reused. Other ai r bag system components are
repl aced i f damaged.
AIR BAG SYSTEM CHECK
WARNING: BEFORE BEGINNING ANY AIR BAG SYS-
TEM CHECK PROCEDURES, REMOVE AND ISOLATE
THE BATTERY NEGATIVE (-) CABLE (GROUND)
FROM THE VEHICLE BATTERY. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIR BAG SYSTEM.
FAILURE TO DO THIS COULD RESULT IN ACCIDEN-
TAL AIR BAG DEPLOYMENT AND POSSIBLE PER-
SONAL INJURY.
CHARGE FOR TWO MI NUTES, THEN BEGI N AI R
BAG REMOVAL.
(1) Di sconnect the battery negati ve cabl e and i so-
l ate.
(2) Remove forward consol e or cover as necessary.
(3) Connect DRB I I to ASDM di agnosti c 6-way con-
nector, l ocated at ri ght si de of modul e.
(4) Turn the i gni ti on key to ON posi ti on. Exi t vehi cl e
wi th DRB I I . Use the l atest versi on of the proper
cartri dge.
(5) After checki ng that no one i s i nsi de the vehi cl e,
connect the negati ve battery cabl e.
(6) Usi ng the DRB I I , read and record acti ve faul t
data.
(7) Read and record any stored faul ts.
(8) Refer to the Passi ve Restrai nt Di agnosti c Test
Manual i f any faul ts are found i n steps 6 and 7.
(9) Erase stored faul ts i f there are no acti ve faul t
codes. I f probl ems remai n, faul t codes wi l l not erase.
(10) Wi th the i gni ti on key i n the ON posi ti on, make
sure no one i s i n the vehi cl e.
(11) From the passenger si de of vehi cl e, turn the
i gni ti on key to OFF then ON and observe the i nstru-
ment cl uster ai r bag l amp. I t shoul d go on for si x to
ei ght seconds, then go out; i ndi cati ng system i s func-
ti oni ng normal l y.
If air bag warning lamp either fails to light, or
goes on and stays on, there is a systemmalfunc-
tion. Refer to the Passive Restraint Diagnostic
Test Manual to diagnose the problem.
AIR BAG MODULE
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE (-)
CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RESULT
IN ACCIDENTAL AIR BAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
UNDEPLOYED AI R BAG REMOVAL FROM THE
STEERI NG WHEEL: DI SCONNECT BATTERY
GROUND CABLE AND I SOLATE. ALLOW SYSTEM
CAPACI TOR TO DI SCHARGE FOR TWO MI NUTES.
BEGI N AI R BAG REMOVAL.
REMOVAL
When removi ng a depl oyed modul e, rubber gl oves,
eye protecti on and l ong sl eeve shi rt shoul d be worn, as
there may be deposi ts on the surface whi ch coul d
i rri tate the ski n and eyes.
(1) Di sconnect battery negati ve cabl e and i sol ate.
(2) Wai t two mi nutes for the reserve capaci tor to
di scharge before removi ng undepl oyed modul e.
(3) Remove four nuts attachi ng ai r bag modul e to
steeri ng wheel (Fi g. 5).
(4) Li ft modul e, and di sconnect el ectri cal connector
from rear of modul e.
(5) Remove modul e.
(6) When repl aci ng a depl oyed modul e, the cl ock-
spri ng must al so be repl aced. Refer to Cl ockspri ng
Removal and I nstal l ati on for proper procedure.
I NSTALLATI ON
(1) Connect cl ockspri ng squi b connector to the mod-
ul e, by pressi ng strai ght i n on the connector.
(2) I nstal l four nuts and ti ghten to 9 to 11 Nm (80
to 100 i n. l bs.) torque.
Fig. 4 Vacuum Heater and A/C Outlets
(3) Do not connect battery negati ve cabl e. Refer to
Ai r Bag System Check for proper procedure.
LEFT FRONT IMPACT SENSOR
REMOVAL
(2) Remove three nuts hol di ng sensor to upper cross-
member of radi ator cl osure panel and remove sensor
(Fi g. 6).
(3) Di sconnect i mpact sensor el ectri cal connector.
I NSTALLATI ON
(1) Connect sensor wi ri ng l ead from harness to con-
nector on body of sensor.
(2) I nstal l l eft sensor wi th arrow poi nti ng forward
(Fi g. 6) and ti ghten nuts to 4.5 to 7 Nm ( 40 to 60 i n.
l bs.) torque usi ng nuts provi ded wi th the new sensor.
Ai r Bag Systems Check for proper procedure.
RIGHT FRONT IMPACT SENSOR
REMOVAL
(2) Remove three nuts hol di ng sensor to upper cross-
member of radi ator cl osure panel . Remove ri ght sensor.
(3) Di sconnect i mpact sensor el ectri cal connector
(Fi g. 7).
I NSTALLATI ON
(1) Connect sensor wi ri ng l ead from harness to con-
nector on body of sensor.
Fig. 5 Air Bag Module
Fig. 6 Left Impact Sensor
Fig. 7 Right Impact Sensor
(2) I nstal l ri ght sensor wi th arrow poi nti ng forward
(Fi g. 6) and ti ghten nuts to 4.5 to 7 Nm ( 40 to 60 i n.
l bs.) torque usi ng nuts provi ded wi th the new sensor.
AIR BAG SYSTEM DIAGNOSTIC MODULE (ASDM)
WARNING: THE ASDM CONTAINS ONE OF THE IM-
PACT SENSORS WHICH ENABLE THE SYSTEM TO
DEPLOY THE AIR BAG. TO AVOID ACCIDENTAL DE-
PLOYMENT, NEVER CONNECT ASDM ELECTRI-
CALLY TO THE SYSTEM WHILE VEHICLE BATTERY
IS CONNECTED. BEFORE BEGINNING ANY AIR BAG
SYSTEM REMOVAL OR INSTALLATION PROCE-
DURES, REMOVE AND ISOLATE THE BATTERY
NEGATIVE (-) CABLE (GROUND) FROMTHE VEHICLE
BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE
THE AIR BAG SYSTEM. FAILURE TO DO THIS COULD
RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT,
AND POSSIBLE PERSONAL INJURY.
REMOVAL
(1) Di sconnect battery negati ve cabl e, and i sol ate
cabl e.
(2) Remove forward consol e or cover as necessary
(Fi g. 8 and 9).
(3) Remove fi ve modul e and bracket mounti ng
screws, and l i ft modul e careful l y up and rearward.
(4) Di sconnect wi ri ng at ASDM and remove modul e.
I NSTALLATI ON
(1) Posi ti on modul e and bracket faci ng forward.
Connect wi ri ng connectors and ensure they are l ocked
i nto posi ti on.
(2) Pl ace the modul e and bracket on the l ower
mounti ng bracket, usi ng l ocati ng tab to posi ti on mod-
ul e.
(3) Attach modul e and bracket wi th screws and
ti ghten to 4 Nn (35 i n. l bs.) torque.
CAUTION:USE SUPPLIED SCREWS
(4) I nstal l forward consol e.
CLOCKSPRING
BAG SYSTEM. FAILURE TO DO SO COULD RESULT
IN ACCIDENTAL AIR BAG DEPLOYMENT, AND POS-
SIBLE INJURY.
CHARGE FOR 2 MI NUTES, THEN BEGI N AI R BAG
REMOVAL.
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on before starti ng the repai r.
Fig. 8 Air Bag System Diagnostic Module
Fig. 9 Air Bag System Diagnostic Module with Cen-
ter Console
(4) Remove the ai r bag modul e.
(5) Remove Speed Control swi tch and connector i f so
equi pped or cover.
(6) Di sconnect horn termi nal s.
(7) Remove the steeri ng wheel .
(8) Remove upper and l ower steeri ng col umn
shrouds to gai n access to cl ockspri ng wi ri ng.
(9) Di sconnect the 2-way connector between the
cl ockspri ng and the i nstrument panel wi ri ng harness
on top of the fuse bl ock.
(10) To remove, pul l cl ockspri ng assembl y from the
steeri ng col umn by l i fti ng l ocati ng fi ngers as necessary.
The cl ockspri ng cannot be repai red, and must be re-
pl aced i f faul ty.
I NSTALLATI ON
(1) Snap cl ockspri ng onto the steeri ng col umn. I f the
cl ockspri ng i s not properl y posi ti oned, fol l ow the cl ock-
spri ng centeri ng procedure before i nstal l i ng steeri ng
wheel .
(2) Connect the cl ockspri ng to the i nstrument panel
harness, ensure wi ri ng l ocator cl i ps are properl y
seated on wi ri ng trough. Ensure harness l ocki ng tabs
are properl y engaged.
(3) I nstal l steeri ng col umn shrouds. Be sure ai r bag
wi re i s i nsi de of shrouds.
(4) Front wheel s shoul d sti l l be i n the strai ght-ahead
posi ti on. I nstal l steeri ng wheel , ensure the fl ats on hub
al i gn wi th cl ockspri ng. Pul l the horn l ead through the
smal l er upper hol e. Pul l the ai r bag and speed control
l eads through the l arger bottom hol e. Ensure l eads are
not pi nched under the steeri ng wheel .
(5) Connect the horn l ead wi re, then the ai r bag l ead
wi re to the ai r bag modul e.
(6) I nstal l the ai r bag modul e and ti ghten nuts to 9
to 11 Nm (80 to 100 i n. l b.) torque.
(7) I nstal l speed control swi tch and connector or
cover.
CLOCKSPRING CENTERING PROCEDURE
I f the rotati ng tape wi thi n the cl ockspri ng i s not
posi ti oned properl y wi th the steeri ng wheel and the
front wheel s, the cl ockspri ng may fai l duri ng use. The
fol l owi ng procedure MUST BE USED to center the
cl ockspri ng i f i t i s not known to be properl y posi ti oned,
or i f the front wheel s were moved from the strai ght
ahead posi ti on.
SIBLE INJURY.
CHARGE FOR TWO MI NUTES, THEN BEGI N AI R
BAG REMOVAL.
(1) Pl ace front wheel s i n the strai ght ahead posi ti on.
(3) Refer to Steeri ng Wheel procedures for removal
of ai r bag modul e and steeri ng wheel .
(4) Depress the two pl asti c l ocki ng pi ns to di sengage
l ocki ng mechani sm (Fi g. 10).
(5) Keepi ng l ocki ng mechani sm di sengaged, rotate
the cl ockspri ng rotor i n the CLOCKWI SE DI RECTI ON
to the end of travel . Do not appl y excessi ve torque.
(6) From the end of travel , rotate the rotor two ful l
turns and a hal f i n the countercl ockwi se di recti on. The
horn wi re shoul d end up at the top and the squi b wi re
at the bottom. Engage cl ockspri ng l ocki ng mechani sm.
(7) Refer to Steeri ng Wheel procedures for i nstal l a-
ti on of steeri ng wheel and ai r bag modul e.
Fig. 10 Clockspring (Auto-Locking)
STEERING WHEEL
WHEN AN UNDEPLOYED AI R BAG ASSEMBLY I S TO
BE REMOVED FROM THE STEERI NG WHEEL, DI SCON-
NECT BATTERY GROUND CABLE AND I SOLATE. AL-
LOW SYSTEM CAPACI TOR TO DI SCHARGE FOR TWO
MI NUTES. BEGI N AI R BAG REMOVAL.
REMOVAL
(1) Make sure front wheel s are strai ght, and steer-
i ng col umn i s l ocked i n pl ace.
(4) Remove four nuts attachi ng ai r bag modul e from
the back si de of steeri ng wheel .
(5) Li ft modul e, and di sconnect connector from rear
of modul e.
(6) Remove speed control swi tch and connector i f so
equi pped or cover.
(7) Remove steeri ng wheel retai ni ng nut.
(8) Remove steeri ng wheel wi th steeri ng wheel
pul l er Tool C-3428B.
I NSTALLATI ON
(1) I f the cl ockspri ng i s not properl y posi ti oned or i f
front wheel s were moved, fol l ow the cl ockspri ng cen-
teri ng procedure before i nstal l i ng steeri ng wheel . Wi th
the front wheel s i n the strai ght ahead posi ti on. Posi -
ti on the steeri ng wheel on the steeri ng col umn. Maki ng
sure to fi t the fl ats on the hub of the steeri ng wheel
wi th the formati ons on the i nsi de of the cl ockspri ng.
Pul l the ai r bag and speed control wi res through the
l ower, l arger hol e i n the steeri ng wheel and the horn
wi re through smal l er hol e at the top. Make sure not to
pi nch wi res (Fi g. 11).
(2) I nstal l retai ni ng nut, and ti ghten i t to 61 Nm
(45 ft. l bs.) torque.
(3) Connect horn wi ri ng l ead.
(4) Connect 4-way connector to speed control swi tch
and attach swi tch to steeri ng wheel .
(5) Connect ai r bag l ead wi re to ai r bag modul e, and
secure modul e to steeri ng wheel .
(6) Do not connect negati ve battery cabl e. Refer to
STEERING COLUMN SWITCHES
Thi s procedure covers the removal and i nstal l ati on of
the steeri ng wheel and cl ockspri ng. Once the steeri ng
wheel and cl ockspri ng have been removed, refer to the
appropri ate secti on of thi s servi ce manual for swi tch
repl acement.
SIBLE INJURY.
WHEN AN UNDEPLOYED AI R BAG ASSEMBLY I S TO
BE REMOVED FROM THE STEERI NG WHEEL, DI SCON-
NECT BATTERY GROUND CABLE AND I SOLATE. AL-
LOW SYSTEM CAPACI TOR TO DI SCHARGE FOR TWO
MI NUTES. BEGI N AI R BAG REMOVAL.
REMOVAL
(1) Di sconnect battery negati ve cabl e, and i sol ate.
(3) Remove four nuts attachi ng ai r bag modul e from
the back si de of steeri ng wheel .
(4) Li ft modul e, and di sconnect connector from rear
of modul e.
(5) Remove speed control swi tch and connector i f so
equi pped or cover.
(6) Remove steeri ng wheel .
(7) Unsnap cl ockspri ng, and remove i t.
(8) Refer to the appropri ate secti on for swi tch re-
pl acement.
I NSTALLATI ON
(1) Snap cl ockspri ng on to steeri ng col umn. Assure
the 4-way connector i s sti l l seated.
(2) I nstal l steeri ng wheel .
(3) I nstal l speed control swi tch and connector or
cover.
Fig. 11 Steering Wheel Wiring
(4) Connect cl ockspri ng wi ri ng connector to the mod-
ul e.
(5) I nstal l four nuts to modul e, and ti ghten to 9 to 11
Nm (80 to 100 i n. l bs.) torque.
(6) Do not connect negati ve battery cabl e. Refer to
LAMPS
CONTENTS
page page
BULB APPLICATION TABLE . . . . . . . . . . . . . . . 11
EXTERIOR LAMPS, SWITCHES AND
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ILLUMINATED ENTRY SYSTEM . . . . . . . . . . . . . 9
Each vehi cl e i s equi pped wi th l amps used for i l l umi -
nati ng and i ndi cati ng purposes. A ci rcui t must have a
good ground to be compl ete. Ci rcui t ground occurs
when the l amp socket makes contact wi th the metal
body. On vehi cl es wi th pl asti c l amps, a wi re between
the socket and the body makes the grounds.
When changi ng l amp bul bs, check the socket for
corrosi on. I f corrosi on i s present, cl ean contacts wi th a
wi re brush and coat the i nsi de of the socket wi th
Mopar Mul ti -purpose Grease or equi val ent.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or any possibly oily surface, reduced
bulb life will result.
DIAGNOSTIC PROCEDURES
Begi n el ectri cal system fai l ure di agnosi s by testi ng
al l rel ated fuses and ci rcui t breakers i n the fuse bl ock
and engi ne compartment. Al so refer to Group 8W,
Wi ri ng Di agrams for component l ocati on and ci rcui t
i nformati on.
HEADLAMP DI AGNOSI S
LAMPS 8L - 1
EXTERI OR LAMPS, SWI TCHES AND SYSTEMS
INDEX
page page
Aero Headlamp Bulb . . . . . . . . . . . . . . . . . . . . . . . 3
Aero Headlamp Lens/Housing . . . . . . . . . . . . . . . . 4
Center High-Mounted Stop Lamp (CHMSL) . . . . . . 7
Daytime Running LampsCanada Only . . . . . . . . . 8
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Headlamp Adjustment Using Alignment Screen . . . . 2
Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . 2
Headlamp Alignment Preparation . . . . . . . . . . . . . . 2
Headlamp Dimmer Switch . . . . . . . . . . . . . . . . . . . 2
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Headlamp Time Delay System . . . . . . . . . . . . . . . . 8
License Plate Lamp/Bulb . . . . . . . . . . . . . . . . . . . . 7
Park/Turn Signal and Side Marker Lamp . . . . . . . . . 6
Park/Turn Signal and Side Marker Lamp
Aero Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tail Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEADLAMP SWITCH
Servi ce procedures for the headl amp swi tch can be
found i n Group 8E, I nstrument Panel and Gauges.
More i nformati on can be found i n Group 8W, Wi ri ng
Di agrams.
HEADLAMP DIMMER SWITCH
The headl amp di mmer swi tch i s i ncorporated i nto
the turn si gnal swi tch. Proper procedures can be found
i n Group 8J, Turn Si gnal and Fl ashers. More i nforma-
ti on can be found i n Group 8W, Wi ri ng Di agrams.
HEADLAMP ALIGNMENT
Headl amps can be al i gned usi ng the screen method
provi ded i n thi s secti on. Al i gnment Tool C4466-A or
equi val ent can al so be used. Refer to i nstructi ons
provi ded wi th the tool for proper procedures. The
preferredheadlampalignment settingis0for the
left/right adjustment and 0 for the up/down ad-
justment.
HEADLAMP ALIGNMENT PREPARATION
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) I nspect and correct damaged or defecti ve compo-
nents that coul d i nterfere wi th proper headl amp al i gn-
ment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5 l bs.)
of wei ght over the fuel tank for each esti mated gal l on of
mi ssi ng fuel .
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALI GNMENT SCREEN PREPARATI ON (FI G. 1)
(1) Posi ti on vehi cl e on a l evel surface perpendi cul ar
to a fl at wal l 7.62 meters (25 ft) away from front of
headl amp l ens.
(2) I f necessary, tape a l i ne on the fl oor 7.62 meters
(25 ft) away from and paral l el to the wal l .
(3) From the fl oor up 1.27 meters (5 ft), tape a l i ne on
the wal l at the centerl i ne of the vehi cl e. Si ght al ong the
centerl i ne of the vehi cl e (from rear of vehi cl e forward)
to veri fy accuracy of the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for up/down
adjustment reference.
(7) Measure di stance from the centerl i ne of the ve-
hi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/ri ght
adjustment reference.
HEADLAMP ADJUSTMENT (FI G. 2 OR 3)
A properl y ai med l ow beam headl amp wi l l project the
top edge of hi gh i ntensi ty pattern on the al i gnment
screen from 50 mm (2 i n.) above to 50 mm (2 i n.) bel ow
the headl amp centerl i ne. The si de-to-si de outboard
edge of hi gh i ntensi ty pattern shoul d be from 50 mm (2
i n.) l eft to 50mm (2 i n.) ri ght of headl amp centerl i ne
(Fi g. 1). The preferred headlamp alignment is 0
for the up/down adjustment and 0 for the
left/right adjustment. The hi gh beams on a vehi cl e
wi th aero headl amps cannot be al i gned. The hi gh beam
pattern shoul d be correct when the l ow beams are
al i gned properl y.
To adjust headl amp ai m, rotate al i gnment screws to
achi eve the speci fi ed hi gh i ntensi ty pattern (Fi g. 2 or
3).
FOG LAMP ALI GNMENT (FI G. 4)
Prepare a al i gnment screen. Refer to Al i gnment
Screen Preparati on paragraph i n thi s secti on. A prop-
erl y al i gned fog l amp wi l l project a pattern on the
al i gnment screen 100 mm (4 i n.) bel ow the fog l amp
centerl i ne and strai ght ahead.
8L - 2 LAMPS
AERO HEADLAMP BULB
REMOVAL (FI G. 5)
(1) Open hood.
(2) Di sconnect wi re connector from behi nd head-
l amp i n the engi ne compartment.
CAUTION: Do not touch the bulb with fingers or any
possibly oily surface, reduced bulb life will result.
(3) Rotate the bul b retai ni ng ri ng countercl ockwi se
one quarter turn and remove the retai ni ng ri ng
(4) Pul l bul b from back of l amp.
I NSTALLATI ON
(1) Al i gn the gui de notches on the bul b base wi th the
gui des i n l amp recei ver hol e.
(2) Push the socket i nto the l amp unti l i t seats.
(3) I nstal l retai ni ng ri ng.
Fig. 1 Headlamp Alignment Screen
Fig. 2 Aero Headlamp Alignment ScrewsAS/D-K
Vehicle
Fig. 3 Aero Headlamp Alignment ScrewsAS/H-P-Y
Vehicle
LAMPS 8L - 3
(4) Connect wi re connector to back of l amp and test
operati on.
AERO HEADLAMP LENS/HOUSING
REMOVAL
(1) Open hood.
(2) Remove gri l l , refer to Group 23, Body.
(3) Remove screws hol di ng gri l l e extensi on mol di ng
to headl amp housi ng, on AS/H-Y vehi cl es.
(4) Separate gri l l e extensi on mol di ng from vehi cl e.
(5) Di sconnect wi re connector from back of head-
l amp.
(6) Remove Park/Turn Si gnal Lamp.
(7) Turn headl amp retai ner bl ocks one quarter turn
i n ei ther di recti on to al i gn the retai ner to the hol e i n
the headl amp housi ng. There i s one retai ner on top of
headl amp and two on the bottom (Fi g. 6).
(8) Separate l amp from vehi cl e.
I NSTALLATI ON
Reverse the precedi ng operati on.
Fig. 4 Fog Lamp Alignment
Fig. 5 Aero Headlamp Bulb
Fig. 6 Aero Headlamp/Lens Retaining Blocks
8L - 4 LAMPS
PARK/TURN SIGNAL AND SIDE MARKER
LAMP AERO HEADLAMPS
LAMP OR BULB REMOVAL
(1) Open hood and support on prop rod.
(2) Remove screw hol di ng gri l l e l ower corner and
l amp mounti ng to rei nforcement bracket (Fi g. 7).
(3) Remove screw hol di ng park/turn si gnal l amp to
headl amp housi ng (Fi g. 8).
(4) Remove verti cal screw hol di ng park/turn l amp to
cl osure panel (Fi g. 9).
(5) Separate park/turn l amp from headl amp housi ng
(Fi g. 10).
(6) Twi st sockets countercl ockwi se and separate
sockets from l amp (Fi g. 11).
(7) Pul l bul b strai ght out of socket.
LAMP OR BULB I NSTALLATI ON
Fig. 7 Grille/Lamp Mounting Screw
Fig. 8 Outer Mounting Screw
Fig. 9 Vertical Mounting Screw
Fig. 10 Park/Turn Signal and Side Marker
LampAero Headlamp Lamp
Fig. 11 Park/Turn Signal and Side Marker Lamp
Sockets
LAMPS 8L - 5
PARK/TURN SIGNAL AND SIDE MARKER LAMP
LAMP OR BULB REMOVAL
(1) Open hood and support on prop rod.
(2) Remove screw hol di ng park/turn si gnal l amp to
headl amp housi ng (Fi g. 12).
(3) Di sengage cl i p at outboard edge of l amp and
separate l amp from vehi cl e (Fi g. 13).
sockets from l amp.
(5) Pul l bul b strai ght out of socket.
LAMP OR BULB I NSTALLATI ON
FOG LAMP
BULB REMOVAL
(1) Remove screws hol di ng fog l amp to mounti ng
fi xture (Fi g. 14).
(2) Separate fog l amp from mounti ng fi xture.
(3) Di sconnect wi re connector.
CAUTION: Do not touch the bulb with fingers or any
possibly oily surface, reduced bulb life will result.
(4) Pi nch together and hi nge spri ng retai ner to one
si de (Fi g. 15) to rel ease bul b from l amp assembl y.
BULB I NSTALLATI ON
TAIL LAMP
The tai l l amp i ncl udes back-up, si de marker, stop
and turn si gnal l amps.
BULB REPLACEMENT (FI G. 16)
(1) Rai se l i ft gate to the open posi ti on.
(2) Remove screws hol di ng top of tai l l amp to quar-
ter panel openi ng.
(3) Ti l t top of tai l l amp away from quarter panel
enough to gai n access to bul b sockets.
(4) Twi st socket countercl ockwi se and separate
socket from l amp.
(5) Pul l bul b from socket.
To i nstal l , reverse the precedi ng operati on.
REMOVAL (FI G. 16)
(2) Remove screws hol di ng top of tai l l amp to quar-
ter panel openi ng.
(3) Ti l t top of tai l l amp away from quarter panel
enough to gai n access to bul b sockets.
Fig. 12 Lamp ScrewLow Line
Fig. 13 LampLow Line
Fig. 14 Fog Lamp Mounting Screws
8L - 6 LAMPS
sockets from l amp.
(5) Di sengage tai l l amp from l ower mounti ng
bracket.
I NSTALLATI ON
LICENSE PLATE LAMP/BULB
REMOVAL (FI G. 17)
(1) Remove screws hol di ng l i cense pl ate l amp to l i ft
gate.
(2) Separate l i cense pl ate l amp l ens from socket
base.
(3) Pul l bul b from socket base.
I NSTALLATI ON
CENTER HIGH-MOUNTED STOP LAMP (CHMSL)
BULB OR LAMP REMOVAL (FI G. 18)
To repl ace bul b i n CHMSL, remove socket from l amp
and pul l bul b from socket.
(2) Remove pl ugs and screws hol di ng CHMSL access
cover to l i ft gate tri m panel .
(3) Separate access cover from l i ft gate.
sockets from l amp.
(5) Remove screws hol di ng CHMSL to l i ft gate and
separate l amp from vehi cl e.
BULB OR LAMP I NSTALLATI ON
Fig. 15 Fog Lamp Bulb
Fig. 16 Tail lamp
Fig. 17 License Plate Lamp
Fig. 18 Center High-Mounted Stop Lamp
LAMPS 8L - 7
DAYTIME RUNNING LAMPS CANADA ONLY
The dayti me runni ng l amps are control l ed by the
Dayti me Runni ng Lamp Rel ay (DRLR). The DRLR i s
l ocated i n the engi ne compartment near the ri ght strut
tower attached to the dash panel (Fi g. 19). The DRLR
al l ows the hi gh beam headl amps to i l l umi nate at 50%
of the swi tched ON bri ghtness when the engi ne i s
runni ng wi th the headl amp swi tch OFF. The Dayti me
runni ng l amps wi l l go out when the headl amp swi tch i s
pul l ed out. The passi ng l i ght feature wi l l fl ash bri ght
hi gh beams whi l e the dayti me runni ng l amps are
acti vated.
DI AGNOSTI CS
The dayti me runni ng l amp system shears fuse 24, i n
the fuse panel , wi th the back-up l amp ci rcui t. The
DRLR i s control l ed by i nputs recei ved from the Speed
Sensor, Headl amp Swi tch and the Engi ne Control l er
(SBEC). Refer to Group 8W, Wi ri ng Di agrams for
component l ocati on and ci rcui t i nformati on.
RELAY REMOVAL (FI G. 19)
(1) Rai se hood to open posi ti on and support hood on
prop-rod.
(2) Di sconnect wi re connector from DRLR.
(3) Remove screw hol di ng DRLR to engi ne compart-
ment dash panel .
(4) Separate DRLR from dash panel .
RELAY I NSTALLATI ON
HEADLAMP TIME DELAY SYSTEM
The opti onal Headl amp Ti me Del ay system i s con-
trol l ed by the Body Control l er (BC). The BC i s l ocated
behi nd the i nstrument panel on the l eft si de of the
center consol e. The headl amp ti me del ay system can be
acti vated by turni ng ON the headl amps when the
engi ne i s runni ng, turn OFF the i gni ti on swi tch, then
turn OFF the headl amp swi tch. The BC wi l l al l ow the
headl amps to remai n ON for 60 seconds before they
automati cal l y turn off. Refer to Owners Manual for
more i nformati on.
DI AGNOSTI CS
Refer to Group 8W, Wi ri ng Di agrams for component
l ocati on and ci rcui t i nformati on. Refer to the Body
Systems Di agnosti c Procedures Manual for more i nfor-
mati on.
Fig. 19 Daytime Running Lamp Relay (DRLR)
8L - 8 LAMPS
I LLUMI NATED ENTRY SYSTEM
GENERAL INFORMATION
The opti onal I l l umi nated Entry System turns ON the
courtesy l amps (except i gni ti on swi tch l amp) when the
exteri or front door handl es are l i fted. Front door
handl e swi tches (Fi g. 20) and the Body Control l er (Fi g.
21) are used to control the system. Courtesy l amps wi l l
turn on for 30 seconds ( 1 second) and turn OFF. The
courtesy l amps wi l l stay ON for 6 seconds after the
engi ne has started then the Body Control l er wi l l turn
the courtesy l amps OFF. After the engi ne has started,
the courtesy l amps wi l l go OFF as soon as:
The parki ng l amps are turned ON.
The vehi cl e i s i n moti on.
The transaxl e i s shi fted out of PARK on vehi cl es
wi th Ul tradri ve Transaxl e.
The I l l umi nated Entry System cannot be acti vated
unl i t 30 seconds after the system has ti med out or the
i gni ti on swi tch has been turned OFF.
When testi ng the system, al l doors must be cl osed to
prevent courtesy l amps from l i ghti ng. The I l l umi nated
Entry Di agnosi s Chart provi des a step by step proce-
dure. The instrument cluster lamp dimmer
switch must be ON for the Illuminated Entry
System to operate. If switch is OFF it will not
operate.
Refer to Group 8W, Wi ri ng Di agrams for component
l ocati on and ci rcui t i nformati on. Refer to Body Systems
Di agnosti c Procedures Manual for more i nformati on.
BODY CONTROLLER
BODY CONTROLLER REMOVAL (FI G. 21)
The Body Control l er i s l ocated behi nd the i nstru-
ment panel , l eft of center consol e. Refer to Group 8E,
I nstrument Panel and Gauges for proper procedures.
ILLUMINATED ENTRY SWITCH
REMOVAL (FI G. 20)
(1) Di sconnect Fusi bl e Li nk connector l ocated rear-
ward of the battery i n the engi ne compartment.
(2) Remove door tri m panel and weather shi el d,
refer to Group 23, Body.
(3) Di sconnect i l l umi nated entry actuator swi tch
wi re connector.
(4) Di sengage push-i n fasteners hol di ng swi tch to
outsi de door handl e.
(5) Separate swi tch from door.
I NSTALLATI ON
INSTRUMENT PANEL LAMPS AND SWITCHES
For repl acement of i nstrument panel l amps and
swi tches, refer to Group 8E, I nstrument Panel and
Gauges.
Fig. 21 Body Controller
Fig. 20 Door Latch Switches
LAMPS 8L - 9
I LLUMI NATED ENTRY DI AGNOSI S
8L - 10 LAMPS
BULB APPLI CATI ON TABLE
GENERAL INFORMATION
The fol l owi ng Bul b Appl i cati on Tabl e l i sts the l amp
ti tl e on the l eft si de of the col umn and trade number or
part number on the ri ght.
CAUTION: Do not use bulbs that have a higher candle
power than the bulb listed in the Bulb Application
Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
EXTERIOR LAMPS
Back-up ...................................................................921
Center Hi gh Mounted Stop ...................................921
Fog............................................................................H3
Front Si de Marker .................................................168
Headl amp/Aero.....................................................9004
Headl amp/Seal ed Beam ..............HP4666 or HP6545
Li cense Pl ate ..........................................................168
Park/Turn Si gnal W/O Si de Marker ...................3157
Park/Turn Si gnal Wi th Si de Marker ..................2057
Tai l /Stop/Turn Si gnal ...........................................3157
INTERIOR LAMPS
DI MMER CONTROLLED LAMPS
Servi ce procedures for most of the l amps i n the
i nstrument panel , I nstrument cl uster and swi tches are
l ocated i n Group 8E, I nstrument Panel and Gauges.
Some components have l amps that can onl y be servi ced
by a Authori zed Servi ce Center (ASC) after the compo-
nent i s removed from the vehi cl e. Contact l ocal deal er
for l ocati on of nearest ASC.
A/C Heater Control ..................................................37
Ash Recei ver .............................................................37
Auxi l i ary Heater Control .........................................37
Fog Lamp Swi tch Symbol ..............................4685005
Gear Shi ft Sel ector ...................................................73
Headl amp Swi tch ...........................................4685003
Heater Control ........................................................158
I nstrument Cl uster ...........................................PC194
Radi o......................................................................ASC
Rear Defogger Swi tch ....................................4685005
Rear Wi per Swi tch .........................................4685004
I NDI CATOR LAMPS
i nstrument panel , i nstrument cl uster and swi tches are
l ocated i n Group 8E, I nstrument Panel and Gauges.
Anti -l ock Brake .................................................PC194
Brake Warni ng ..................................................PC194
Check Engi ne.....................................................PC194
Check Gauges ....................................................PC194
Door Open ..........................................................PC194
Engi ne Oi l Pressure ..........................................PC194
Hazard Fl asher .......................................................194
Hi gh Beam.........................................................PC194
Li ft Gate Open...................................................PC194
Low Fuel ............................................................PC194
Low Washer Fl ui d .............................................PC194
Mai ntenance Requi red......................................PC194
Seat Bel t ............................................................PC194
Turn Si gnal ........................................................PC194
NON-DI MMI NG LAMPS
fol l owi ng l i st can be found i n Group 23, Body. Some
components have l amps that can onl y be servi ced by a
Authori zed Servi ce Center (ASC) after the component
i s removed from the vehi cl e. Contact l ocal deal er for
l ocati on of nearest ASC.
Door Courtesy .........................................................562
Dome ....................................................................212-2
Engi ne Compartment.............................................105
Gl ove Compartment .............................................1891
I gni ti on Lock .........................................................ASC
Overhead Consol e ...............................................212-2
Readi ng Lamp ........................................................906
Under Seat Storage Bi n.........................................194
Vi sor Vani ty ....................................................6501966
LAMPS 8L - 11
RWINDSHIELD WIPER AND WASHER SYSTEMS
CONTENTS
page page
INTERMITTENT WINDSHIELD WIPER MOTOR
AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR WINDOW WIPER/WASHER SYSTEM . . . 10
WINDSHIELD WASHERS . . . . . . . . . . . . . . . . . . 9
WINDSHIELD WIPER BLADE AND ARM . . . . . . 1
WINDSHIELD WIPER MOTOR AND LINKAGE . . 4
WI NDSHI ELD WI PER BLADE AND ARM
INDEX
page page
Wiper Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . 3
Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . 1
Wiper Blade Element Change Replacement . . . . . . 1
Wiper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG,
SEE GROUP 8M, RESTRAINT SYSTEMS FOR STEER-
ING WHEEL OR COLUMN REMOVAL PROCEDURES.
The wi ndshi el d wi pers can be operated wi th the
wi ndshi el d wi per swi tch onl y when the i gni ti on swi tch
i s i n the ACCESSORY or I GNI TI ON posi ti on. A fuse
l ocated i n the fuse bl ock protects the ci rcui try of the
wi per system and the vehi cl e.
The wi per motor has permanent magneti c fi el ds. The
speeds are determi ned by current fl ow to the appropri -
ate set of brushes.
The i ntermi ttent wi pe system has a l ow and hi gh
speed wi th a del ay mode. The del ay mode has a range
of 2 to 15 seconds. Thi s i s done by a vari abl e resi stor i n
wi per swi tch and i s control l ed el ectri cal l y by a rel ay.
The wi per system compl etes the wi pe cycl e when the
swi tch i s turned OFF. The bl ades park i n the l owest
porti on of the wi pe pattern (Fi g. 1).
WIPER BLADES
Wi per bl ades exposed to the weather for a l ong peri od
of ti me tend to l ose thei r wi pi ng effecti veness. Peri odi c
cl eani ng of the wi per bl ade i s suggested to remove the
accumul ati on of sal t and road fi l m. The wi per bl ades,
arms and wi ndshi el d shoul d be cl eaned wi th a sponge
or cl oth and a mi l d detergent or nonabrasi ve cl eaner. I f
the bl ades conti nue to streak or smear, they shoul d be
repl aced.
WIPER BLADE ELEMENT CHANGE REPLACEMENT
(1) Turn wi per swi tch ON, posi ti on bl ades to a con-
veni ent pl ace by turni ng the i gni ti on swi tch ON and
OFF.
(2) Li ft wi per arm to rai se bl ade off gl ass.
(3) Remove bl ade assembl y from arm by i nserti ng a
smal l screwdri ver bl ade i nto rel ease sl ot of wi per bl ade
and depressi ng sl i ghtl y (Fi g. 2), or push rel ease button
(Fi g. 3).
(4) To remove wi pi ng el ement from bl ade assembl y:
Fi rst type: pi nch l ock on end of bl ade assembl y and
pul l wi pi ng el ement (bl ade) out of end bri dge cl aws
(Fi g. 2).
Second type: l i ft tab on one end of l i nks and squeeze
the l i nk to remove from center bri dge. Sl i de end l i nk off
the el ement from cl aws of other l i nk (Fi g. 3).
Thi rd type: grasp rubber el ement where channel i s
rubber and pul l rubber el ement and verti bra out for
repl acement (Fi g. 4).
(6) Check each rel ease poi nt for posi ti ve l ocki ng
when i nstal l i ng bl ade el ement and bl ade assembl y on
vehi cl e.
WIPER ARM REPLACEMENT
(1) Li ft the arm to permi t the l atch (Fi g. 5) to be
pul l ed out to the hol di ng posi ti on then rel ease the arm.
The arm wi l l remai n off the gl ass i n thi s posi ti on.
(2) Remove the arm from the pi vot by usi ng a
rocki ng moti on.
WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 1
Fig. 1 Wiper Blade and Element
8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS
(3) Set arm on pi vot and push down.
(4) Li ft arm and push l atch i n to rel ease arm to
wi ndshi el d.
(5) For proper al i gnment of wi per arm, refer to
Wi per Arm Adjustment.
WIPER ARM ADJUSTMENT
(1) Cycl e the wi per motor i nto the PARK posi ti on.
(2) Check the ti ps of the bl ades i n bl ackout area.
From the bottom edge of the wi ndshi el d to the bl ade
shoul d be no cl oser than 25 mm (1 i nch) (Fi g. 6).
(3) Operate the wi pers i f the requi rements are not
met, check l i nkage and pi vot assembl y for worn parts.
Fig. 5 Removing Wiper Arm
Fig. 6 Windshield Wiper Arm Adjustment
WI NDSHI ELD WI PER MOTOR AND LI NKAGE
INDEX
page page
Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . 7
SEE GROUP 8M, RESTRAINT SYSTEMS FOR STEER-
ING WHEEL OR COLUMN REMOVAL PROCEDURES.
The fol l owi ng i s a l i st of general wi per motor system
probl ems. The tests are to be performed to l ocate the
faul ty part and the correcti ve acti on to be taken. These
tests wi l l cover both two speed and i ntermi ttent wi pe
functi ons, refer to Wi ndshi el d Wi per Motor Di agnosi s
(Fi g. 7).
MOTOR TESTS
CONDI TI ON: MOTOR WI LL NOT RUN I N ANY
SWI TCH POSI TI ON
REPAIR
(1) Check for a bl own fuse i n the fuse bl ock.
(a) I f fuse i s good, go to step 2.
(b) I f fuse i s defecti ve, repl ace and check motor
operati on i n al l swi tch posi ti ons.
(c) I f motor i s sti l l i noperati ve and the fuse does
not bl ow, go to step 2.
(d) I f repl acement fuse bl ows, go to step 5.
(2) Pl ace swi tch i n LOW speed posi ti on.
(3) Li sten to motor. I f you cannot hear i t runni ng, go
to Step No. 4. I f you hear i t runni ng, check motor
output shaft. I f output shaft i s not turni ng, repl ace
motor assembl y. I f i t i s turni ng, dri ve l i nk to output
shaft or l i nkage i s not properl y connected. Repl ace
worn parts and/or properl y connect dri ve l i nk to the
motor output shaft.
(4) Connect a vol tmeter between motor termi nal 3
and ground strap (Fi g. 8). I f there i s no vol tage or very
l i ttl e vol tage (l ess than one vol t) present, move nega-
ti ve test l ead from the ground strap to negati ve battery
termi nal .
(a) I f an i ncrease i n vol tage i s noti ced, the probl em
i s a bad ground ci rcui t. Make sure the motor mount-
i ng i s free of pai nt and that nuts or bol ts are ti ght.
(b) I f there i s sti l l no i ndi cati on of vol tage, the
probl em i s an open ci rcui t i n the wi ri ng harness or
wi per swi tch.
(c) I f no noti ceabl e i ncrease greater than 3 vol ts i s
observed, the probl em i s a faul ty motor assembl y.
(5) Di sconnect motor wi ri ng connector and repl ace
fuse.
(a) I f fuse does not bl ow, motor i s defecti ve.
(b) I f fuse bl ows, swi tch or wi ri ng i s at faul t.
CONDI TI ON: MOTOR RUNS SLOWLY AT ALL
SPEEDS
REPAIR
(1) Di sconnect wi ri ng harness connector at motor.
Remove wi per arms and bl ades. Connect an ammeter
between battery (B+) and termi nal 3 on motor (Fi g. 9).
(a) I f motor runs and average ammeter readi ng i s
more than 6 amps, go to step 2.
(b) I f motor runs and average ammeter readi ng i s
l ess than 6 amps, go to step 3.
(2) Check to see i f wi per l i nkage or pi vots are bi nd-
i ng or caught. Di sconnect dri ve l i nk from motor.
(a) I f motor now runs and draws l ess than 3 amps,
repai r l i nkage system.
(b) I f motor conti nues to draw more than 3 amps,
(3) Check motor wi ri ng harness for shorti ng be-
tween hi gh and l ow speed wi res as fol l ows:
(a) Connect a vol tmeter or test l amp to motor
ground strap.
(b) Set wi per swi tch to LOW posi ti on.
(c) Connect other l ead of vol tmeter to termi nal 4 of
the wi ri ng harness.
(d) I f vol tage i s present, there i s a short i n the
wi ri ng or wi per swi tch.
(e) I f no vol tage i s present set wi per swi tch to
HI GH posi ti on.
(f) Move vol tmeter l ead from termi nal 4 to termi -
nal 3 of the wi ri ng harness.
(g) I f vol tage i s present, there i s a short i n the
wi ri ng or wi per swi tch.
CONDI TI ON: MOTOR WI LL RUN AT HI GH
SPEED, BUT NOT AT LOW SPEED OR
MOTOR WI LL RUN ATLOW SPEED, BUTNOTAT
HI GH SPEED.
REPAIR
(1) I f motor wi l l not run on hi gh speed, put swi tch i n
HI GH posi ti on and connect a test l amp between motor
Termi nal 4 and ground (Fi g. 10).
Fig. 7 Windshield Wiper Motor Diagnosis
(2) I f motor wi l l not run on l ow speed, put swi tch i n
LOW posi ti on and connect a test l amp between motor
Termi nal 3 and ground.
(3) I f test l amp does not l i ght at motor termi nal ,
there i s an open i n wi ri ng or swi tch. I f test l amp l i ghts
at motor termi nal , repl ace motor assembl y.
CONDI TI ON: MOTOR KEEP RUNNI NG WI TH
SWI TCH I N OFF POSI TI ON
REPAIR
Remove wi ri ng harness. Connect jumper from Termi -
nal 1 to Termi nal 3 of wi per motor (Fi g. 11). Connect
second jumper from Termi nal 2 to battery (B+). I f
motor runs to PARK posi ti on and stops, wi per swi tch i s
faul ty. I f motor keeps runni ng and does not park,
CONDI TI ON: MOTOR WI LL STOP, WHEN
SWI TCH I S SET I N OFF POSI TI ON. WI PERS DO
NOT CONTI NUE RUNNI NG TO PARK POSI -
TI ON.
REPAIR
(1) Remove motor wi ri ng connector and cl ean termi -
nal s. Reconnect connector and test motor. I f probl em
persi sts, go to Step 2.
(2) Set wi per swi tch to OFF posi ti on. Di sconnect
motor wi ri ng connector. Connect a vol tmeter or test
l amp to the motor ground strap. Connect the other l ead
to termi nal 2 of wi ri ng connector.
(a) I f vol tage i s not present, check for an open
ci rcui t i n the wi ri ng harness or wi per control swi tch.
(b) I f vol tage i s present, go to step 3.
(3) Connect an ohmmeter or conti nui ty tester be-
tween termi nal s 3 and 1 (Fi g. 12).
(a) I f there i s conti nui ty between these termi nal s,
the probl em i s a defecti ve motor.
Fig. 8 Voltmeter Between Terminal 3 and Ground
Fig. 9 Ammeter Between Terminal 3 and Battery
Fig. 10 Test Lamp Between Terminal 4 and Ground
Fig. 11 One Jumper Wire Between Terminal 1 and 3.
One Jumper Wire Between Terminal 2 and Battery
Positive
(b) I f there i s no conti nui ty, the probl em i s an open
ci rcui t i n the wi per control swi tch or wi ri ng harness.
WIPER MOTOR REPLACEMENT
(1) Remove wi ndshi el d wi per arms (Fi g. 5).
(2) Open hood assembl y.
(3) Remove cowl top pl enum gri l l e.
(4) Remove hoses from hose connectors.
(5) Remove cowl pl enum chamber pl asti c screen.
(6) Remove wi per pi vot retai ni ng screws.
(7) Push pi vots down i nto pl enum chamber.
(8) Remove nut from wi per motor output shaft and
remove l i nkage assembl y.
(9) Di sconnect wi per motor wi ri ng harness.
(10) Remove mounti ng screw and nuts from wi per
motor.
(11) Remove wi per motor.
(12) Perform di sassembl y and servi ce on pi eces as
necessary.
(13) For i nstal l ati on reverse above procedures. Ex-
cept the fol l owi ng torque speci fi cati ons:
(a) Ti ghten motor mounti ng screw and nuts 7 to 8
Nm (60 to 70 i n. l bs.) torque.
(b) Ti ghten pi vot screws 7 to 8 Nm (60 to 70 i n.
l bs.) torque.
(c) Posi ti on wi per motor dri ve crank on motor
shaft and ti ghten retai ni ng nut 10 to 11 Nm (90 to
100 i n.l bs.) torque.
(d) Refer to Wi per Arm Adjustment for proper
al i gnment.
I NTERMI TTENT WI NDSHI ELD WI PER MOTOR AND SWI TCH
INDEX
page page
Intermittent Function Tests . . . . . . . . . . . . . . . . . . . 8
Intermittent Windshield Wiper Switch . . . . . . . . . . . 8
Intermittent Wiper Motor Test . . . . . . . . . . . . . . . . . 7
INTERMITTENT WIPER MOTOR TEST
I ntermi ttent Wi per Motor Servi ce Procedures for
di agnosi s of probl ems whi ch, do not i nvol ve the del ay
functi on, refer to the Motor Tests. The two-speed func-
ti ons of al l wi per motors are i denti cal .
I f a probl em occurs, onl y i n the DELAY mode, the
fol l owi ng tests are to be performed.
CONDI TI ON: EXCESSI VE DELAY OF MORE
THAN 30 SECONDS OR I NADEQUATE VARI A-
TI ON I N DELAY
REPAIR
Vari ati ons i n del ay shoul d be as fol l ows:
(1) Mi ni mum del ay control to extreme countercl ock-
wi se posi ti on before fi rst detent of one hal f to two
seconds.
(2) Maxi mum del ay control to extreme cl ockwi se
posi ti on before off detent of ten to thi rty seconds.
(3) I f there i s excessi ve del ay or no vari ati ons i n
del ay go to i ntermi ttent wi pe swi tch test.
CONDI TI ON: I N DELAY MODE WI PERS RUN
CONTI NUALLY WHEN WASH I S OPERATED
BUT DO NOT PROVI DE AN EXTRA WI PE
WHEN THE WASH CONTROL I S RELEASED
REPAIR
Repl ace the body control l er.
CONDITION: WIPERS START ERRATICALLY DURING DELAY
MODE
REPAIR
(1) Veri fy that the ground connecti on at the i nstru-
ment panel i s maki ng good connecti on, free from pai nt
and i s ti ght.
(2) Veri fy that the motor ground strap i s maki ng
good contact and that the motor mounti ng bol ts are
ti ght.
(3) Veri fy that the wi ri ng ground connecti ons for the
i ntermi ttent wi pe control uni t and the wi per swi tch are
ti ght.
(4) I f condi ti on i s not corrected, repl ace body control -
l er.
Fig. 12 Ohmmeter Between Terminals 3 and 1
INTERMITTENT WINDSHIELD WIPER SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
STEERING WHEEL OR COLUMN REMOVAL PROCE-
DURES.
The i ntermi ttent wi pe functi on i s control l ed by the
body control l er, l ocated at the l ower ri ght si de of
steeri ng col umn. I f the body control l er i s determi ned to
be the probl em, refer to Group 8E, I nstrument Panel s
and Gauges, for repl acement procedures.
To test the i ntermi ttent wi pe functi ons a DRB I I wi l l
be needed, and the Body Di agnosti c Procedures
Manual .
The DRB I I i s used to moni tor the i ntermi ttent wi pe
i nput, washer i nput and the dwel l swi tch i nput.
To test the swi tch, fi rst di sconnect the swi tch wi res
from the body wi ri ng i n the steeri ng col umn. Usi ng an
ohmmeter, test for conti nui ty between the termi nal s of
the swi tch, as i ndi cated i n the fol l owi ng conti nui ty
chart. The i denti ty of each termi nal i s shown i n Fi g. 13.
For test purposes, the fi rst posi ti on i s the OFF
posi ti on, next i s the sl i de for the DELAY wi pe. LOW i s
the next detent posi ti on and HI GH i s the ful l counter-
cl ockwi se detent posi ti on.
I n any wi per mode, i f the knob i s pushed al l the way
i n, the washer ci rcui t wi l l be compl eted.
The wi per swi tch i s part of the mul ti -functi on swi tch
assembl y. I f the wi per swi tch fai l s, the mul ti -functi on
swi tch must be repl aced. Refer to Group 8J, Turn
Si gnal s and Hazard Warni ng Fl asher for mul ti -
functi on swi tch servi ce procedure.
INTERMITTENT FUNCTION TESTS
CONDI TI ON: EXCESSI VE DELAY, MORE THAN
30 SECONDS OR I NADEQUATE VARI ATI ON I N
DELAY
REPAIR
Vari ati ons i n del ay shoul d be as fol l ows:
(1) Mi ni mum del ay control to extreme countercl ock-
wi se posi ti on before fi rst detent of one hal f to two
seconds.
(2) Maxi mum del ay control to extreme cl ockwi se
posi ti on before off detent of ten to thi rty seconds.
(3) I f there i s excessi ve del ay or no vari ati ons i n
del ay go to i ntermi ttent wi pe swi tch test.
(4) I f not wi thi n speci fi cati ons, repl ace body control -
l er.
CONDI TI ON: I N DELAY MODE WI PERS RUN
CONTI NUALLY WHEN WASH I S OPERATED
BUT DO NOT PROVI DE AN EXTRA WI PE
WHEN THE WASH CONTROL I S RELEASED
REPAIR
Repl ace the body control l er.
CONDI TI ON: WI PERS START ERRATI CALLY
DURI NG DELAY MODE
REPAIR
(1) Veri fy that the ground connecti on at the i nstru-
ment panel i s maki ng good connecti on, free from pai nt
and i s ti ght.
(2) Veri fy that the motor ground strap i s maki ng
good contact and that the motor mounti ng bol ts are
ti ght.
(3) Veri fy that the wi ri ng ground connecti ons for the
i ntermi ttent wi pe control uni t and the wi per swi tch are
ti ght.
(4) I f condi ti on i s not correct, repl ace body control l er.
Fig. 13 Multi-Function Switch Connector and Inter-
mittent Wipe Continuity
WI NDSHI ELD WASHERS
INDEX
page page
Washer Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Washer Reservoir Pump Replacement . . . . . . . . . . 9
Washer Reservoir Removal . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
Al l model s are equi pped wi th el ectri c operated wi nd-
shi el d washer pumps.
The wash functi on can be accessed i n the OFF
posi ti on of the wi per control swi tch. Hol di ng the wash
button depressed when the swi tch i s i n the OFF
posi ti on wi l l operate the wi pers and washer motor
pump conti nuousl y unti l the washer button i s rel eased.
Rel easi ng the button wi l l stop the washer pump. The
wi pers wi l l compl ete the current wi pe cycl e fol l owed by
an average of two more wi pe cycl es (1) before the
wi pers park and the modul e turns off.
Whenever a wi ndshi el d washer mal functi on occurs,
veri fy that the wi ndshi el d washer wi re harness i s
properl y connected before starti ng normal di agnosi s
and repai r procedures. Refer to Wi ndshi el d Washer
Di agnosi s Chart (Fi g. 14).
WASHER RESERVOIR REMOVAL
(1) Unl ock and open the hood.
(2) Remove screws attachi ng the reservoi r i n pl e-
num.
(3) Di sconnect the wi ri ng harness from the reservoi r
pump and sensor, i f equi pped.
(4) Di sconnect the washer hose and bl ock the l i qui d
outl et to prevent the l i qui d from runni ng out whi l e
removi ng the reservoi r from engi ne compartment.
Ti ghten attachi ng screws to 3 Nm (26 i n. l bs.) torque.
WASHER RESERVOIR PUMP REPLACEMENT
(1) Remove washer reservoi r and pump assembl y,
refer to Reservoi r Removal .
(2) Noti ce posi ti on of pump, then usi ng a 19mm (3/4
i n.) socket through the l i qui d fi l l er openi ng, l oosen the
pump fi l ter and nut.
(3) Di sconnect the outsi de porti on of the pump.
Fig. 14 Windshield Washer Diagnosis
(4) Remove i nner and outer porti ons of the pump.
(a) I nstal l rubber grommet i nto pl ace i n bottom of
reservoi r.
(b) Refer to Washer Reservoi r Removal for i nstal -
l ati on of reservoi r.
WASHER NOZZLE
These model s are equi pped wi th two washer nozzl es
attached to the wi per arms. Each arm emi ts fi ve
streams across the wi per pattern. No adjustment i s
requi red. I f nozzl e performance i s unsati sfactory they
shoul d be repl aced. The ri ght and l eft nozzl es are
i denti cal .
To repl ace unsnap nozzl e from wi per arm and di scon-
nect hose. When i nstal l i ng make sure that both the
nozzl e and the hose guard are securel y snapped i nto
posi ti on.
REAR WI NDOW WI PER/WASHER SYSTEM
INDEX
page page
Liftgate Motor Replacement . . . . . . . . . . . . . . . . . 12
Liftgate Washer Reservoir Pump Replacement . . . 13
Liftgate Washer Reservoir Removal . . . . . . . . . . . 12
Liftgate Wiper Motor Test . . . . . . . . . . . . . . . . . . . 11
Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rear Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . 10
Rear Window Intermittent Wipe Module Location . . 10
Rear Wiper/Washer Control Pod Switch . . . . . . . . 11
Rear Wiper/Washer Control Pod Switch
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Washer Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . 13
For wi per bl ade servi ce, refer to wi ndshi el d Wi per
Bl ades.
REAR ARM ADJUSTMENT
(1) Wi th the motor i n park posi ti on, mount the arm
on the motor shaft. Choose a serrati on engagement
that properl y l ocates ti p of the bl ade about 90 mm (3
1/2 i nch) paral l el , wi th l ower edge of l i ftgate gl ass (Fi g.
15).
(2) Operate the wi per on dry gl ass wi th the engi ne
off. The ti p of the wi per bl ade shoul d be wi thi n 60 mm
(2 3/8 i nch) to 120 mm (4 3/4 i nch) above l ower edge of
l i ftgate gl ass.
REAR WINDOW INTERMITTENT WIPE MODULE
LOCATION
The i ntermi ttent wi pe modul e i s l ocated i nsi de the
l i ft gate on the ri ght van si de (Fi g. 16).
Fig. 15 Installing Liftgate Wiper Arm
Fig. 16 Intermittent Wipe Module Location
MODULE TEST
(1) Remove l i ftgate tri m panel . Refer to Group 23,
Body.
(2) Usi ng a vol t/ohmmeter test each pi n and repai r
as necessary.
(a) Pi n 1, test for modul e output battery vol tage to
wi per motor, wi th the i gni ti on swi tch i n the ON
posi ti on and the rear wi per swi tch ON (Fi g. 17).
(b) Pi n 2, test for battery vol tage from i gni ti on
swi tch, wi th the i gni ti on i n the ON posi ti on.
(c) Pi n 3, test for conti nui ty to ground.
(d) Pi n 4, i gni ti on swi tch ON and the rear wi ndow
washer swi tch ON, test for battery vol tage.
(e) Pi n 5, i gni ti on swi tch ON and wi per swi tch ON,
test for conti nui ty to ground. The i ntermi ttent mode
wi l l have an ei ght second del ay between wi pes.
(f) Pi n 6, i gni ti on swi tch ON and washer swi tch
pushed i n, test conti nui ty to ground.
REAR WIPER/WASHER CONTROL POD SWITCH
(1) The Rear Wi per swi tch porti on of thi s assembl y
i s a push ON, push OFF l atchi ng acti on and provi des:
Rear wi per operates wi th a fi xed i ntermi ttent cycl e.
A ground si gnal to the rear wash/wi pe modul e to
turn the rear wi per system ON (fi xed i ntermi ttent)
when rear wi per button i s l atched down.
There shal l be conti nui ty between termi nal s B5 and
B2 when the rear wi per button i s depressed and
l atched down.
When the rear wi per button i s l atched, the ON
i ndi cator l amp wi l l l i ght onl y when headl amps are on.
I f not repl ace rear wi per/washer control POD swi tch.
(2) The Rear Washer swi tch porti on of thi s assembl y
i s a push ON, momentary acti on and provi des:
A ground si gnal to the rear wash/wi pe modul e to
turn the rear washer system ON when the rear wash
button i s depressed.
There shal l conti nui ty between termi nal s B4 and B3
onl y when the front washer button i s depressed.
I f not repl ace rear wi per/washer control POD swi tch.
(3) Servi ceabl e: l amp control the i l l umi nati on of the
swi tch assembl y. The l amp i s feed by termi nal s B6
(power) and B5 (ground).
REPLACEMENT
(1) Remove warni ng i ndi cator gri l l e by pryi ng up
wi th a fl at bl ade tool .
(2) Remove three mounti ng screws from the warni ng
i ndi cator modul e assembl y.
(3) Remove ei ght screws mounti ng the cl uster bezel
to the i nstrument panel .
(4) Ti l t col umn down i f possi bl e for ease.
(5) Gentl y pul l cl uster bezel out, to gai n access to the
swi tch assembl ys snap fi ngers and push swi tch out
through mounti ng hol e for POD swi tch assembl y (Fi g.
18).
(6) Remove wi ri ng connectors for POD swi tch as-
sembl y.
(7) Remove l amp.
(8) For i nstal l ati on reverse above procedures. Veri fy
the functi ons of the front and rear wi pe/wash system.
LIFTGATE WIPER MOTOR TEST
The fol l owi ng test i s used to l ocate and then repai r
l i ftgate wi per motor defects. Refer to Group 8W, Wi ri ng
Di agrams for l i ftgate wi per motor wi ri ng schemati c.
(1) Di sconnect feed wi re connector from wi per motor
(Fi g. 19).
(2) Wi th i gni ti on swi tch i n ON posi ti on, check for
battery vol tage at bl ue wi re.
Fig. 17 Intermittent Wipe Module
Fig. 18 Rear Wiper/Washer Control POD Switch
(3) Wi th i gni ti on swi tch i n ON posi ti on and wi per
swi tch ON, check for battery vol tage at bl ue and brown
wi re. I f battery vol tage i s not present i n steps 2 and 3,
check fuse, l i ftgate wi per swi tch and wi ri ng.
(4) Wi th i gni ti on swi tch i n ON posi ti on, and wi per
swi tch i n OFF posi ti on, check for battery vol tage
between bl ue and brown wi res. I f battery vol tage i s not
present check ground wi re to l i ftgate swi tch.
(5) I f battery vol tage i s present i n steps 2 and 3,
repl ace motor.
LIFTGATE MOTOR REPLACEMENT
(1) Remove l i ftgate wi per arm assembl y, refer to
Wi per Arm Repl acement.
(2) Unl ock and open the l i ftgate.
(3) Remove l i ftgate tri m panel , refer to Group 23,
Li ftgate Tri m Panel Removal .
(4) Remove fi ve l i ftgate motor mounti ng screws (Fi g.
19).
(5) Di sconnect wi ri ng harness from l i ftgate motor
connector.
(6) Remove motor assembl y from l i ftgate.
(a) I nstal l fi ve l i ftgate motor mounti ng screws.
Ti ghten screws 3 to 5 Nm (25 to 45 i n. l bs.) of torque.
(b) I nstal l wi per arm assembl y, refer to Wi per Arm
Adjustment.
LIFTGATE WASHER RESERVOIR REMOVAL
(1) Unl ock and open the l i ftgate.
(2) Remove two si de aperture panel and reservoi r
mounti ng screws (Fi g. 20).
(3) Di sconnect the wi ri ng harness from the washer
pump.
(5) Di sconnect the washer hose from reservoi r sys-
tem, bl ock the l i qui d outl et to prevent the l i qui d from
runni ng out whi l e removi ng the reservoi r.
(6) Remove one upper reservoi r screw.
Fig. 19 Liftgate Wiper Motor and Bracket Assembly
Fig. 20 Liftgate Washer System
(7) Remove reservoi r and pump assembl y through
the si de aperture panel access hol e. Work fi l l er tube off
reservoi r. Empty the reservoi r outsi de of vehi cl e.
(a) Fi l l reservoi r and test system.
LIFTGATE WASHER RESERVOIR PUMP REPLACE-
MENT
(1) Remove washer reservoi r and pump assembl y,
refer to Washer Reservoi r Removal .
(2) Wi th mechani cal fi ngers, l oosen pump fi l ter and
nut through l i qui d fi l l er openi ng.
(3) Di sconnect the outsi de porti on of the pump.
(4) Remove i nner and outer porti ons of the pump,
and remove pump.
WASHER NOZZLE
To repl ace unsnap nozzl e from wi per arm and di scon-
nect hose. When i nstal l i ng make sure that both the
nozzl e and the hose guard are securel y snapped i nto
posi ti on.
TURN SIGNALS AND HAZARD WARNING FLASHER
CONTENTS
page page
CHIME FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
ELECTRONIC COMBINATION FLASHER . . . . . . . 1
FLASHER SYSTEM DIAGNOSIS . . . . . . . . . . . . . 3
HAZARD WARNING SWITCH . . . . . . . . . . . . . . . 1
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
SEE GROUP 8M, RESTRAINT SYSTEMS FORAIRBAG
REMOVAL PROCEDURES.
The turn si gnal s are apart of the mul ti -functi on
swi tch. The swi tch contai ns the turn si gnal , headl amp
beam sel ect, headl amp opti cal horn, wi ndshi el d wi per,
pul se wi pe and wi ndshi el d washer control s. The i nte-
grated swi tch i s mounted on the l eft si de of the steeri ng
col umn. The dri ver moves the l ever upward for the
ri ght si gnal and downward for the l eft si gnal to fl ash.
After compl eti on of a turn the system i s cancel ed
automati cal l y.
I f onl y momentary si gnal i ng such as i ndi cati on of a
l ane change i s desi red, the swi tch i s actuated to a l eft
or ri ght i ntermedi ate detent posi ti on. I n thi s posi ti on
the si gnal l amps fl ash as descri bed above, but the
swi tch returns to the OFF posi ti on as the l ever i s
rel eased.
Acti vate the system and the i ndi cator l amps wi l l
fl ash i n uni son wi th the turn si gnal l amps. Thi s shows
that the system i s operati ng.
HAZARD WARNING SWITCH
Refer to Group 8E, I nstrument Panel , Headl amp
Swi tch.
CHIME FUNCTION
The chi me wi l l sound after the vehi cl e has travel ed a
di stance of 0.6 mi l es at a speed above 15 mi l es per
hour.
MULTI-FUNCTION SWITCH
The mul ti -functi on swi tch contai ns:
El ectri cal ci rcui try for turn si gnal
Headl amp beam sel ect
Headl amp opti cal horn
Wi ndshi el d wi per
Pul se wi pe
Wi ndshi el d washer swi tchi ng
Thi s i ntegrated swi tch assembl y i s mounted to the
l eft hand si de of the steeri ng col umn. I f any functi on of
the swi tch fai l s, the enti re swi tch assembl y must be
repl aced. Refer to Fi g. 1 for di agnosi s.
SWI TCH TEST
(1) Di sconnect the negati ve battery cabl e.
(2) Remove the upper and l ower col umn covers to
gai n access to the swi tch connector.
(3) Remove swi tch connector.
(4) Usi ng an ohmmeter, test for conti nui ty between
the termi nal s of the swi tch as shown i n the fol l owi ng
conti nui ty charts (Fi g 2 and 3).
(5) I f readi ng are i ncorrect, repl ace swi tch.
REMOVAL
(2) Ti l t col umn onl y remove ti l t l ever.
(3) Remove both upper and l ower steeri ng col umn
covers.
(4) Remove mul ti -functi on swi tch tamper proof
mounti ng screws (Fi g.4).
(5) Gentl y pul l swi tch away from col umn and l oosen
connector screw. The screw wi l l remai n i n the connec-
tor.
(6) Remove wi ri ng connector from mul ti -functi on
swi tch.
I NSTALLATI ON
(1) I nstal l wi ri ng connector to swi tch and ti ghten
connector retai ni ng screw to 2 Nm (17 i n. l bs.) torque.
(2) Mount mul ti -functi on swi tch to col umn and
ti ghten retai ni ng screws to 2 Nm (17 i n. l bs.) torque.
(3) I nstal l steeri ng col umn covers. Ti ghten retai ni ng
screws to 2 Nm (17 i n. l bs.) torque.
(4) Ti l t col umn onl y, i nstal l the ti l t l ever.
(5) Connect battery negati ve cabl e.
(6) Check the swi tch functi ons for proper operati on.
ELECTRONIC COMBINATION FLASHER
The modul e provi des both turn si gnal and hazard
fl asher operati on. The fl asher pl ugs i nto the l ower l eft
corner of rel ay bank to the l eft of the fuse bl ock. To gai n
access to the fl asher, remove the l ower steeri ng col umn
cover. The fl ash rate for the turn si gnal and hazard
warni ng fl asher i s constant for any number of l amps.
Dependi ng on exact current draw of l amps, there
shoul d be between 60 and 120 fl ashes per mi nute. I f a
l amp or ci rcui t to a l amp i s open, the
TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1
Fig. 1 Turn Signal and Hazard Warning Flasher Diagnosis
8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER
fl ash rate for that si de of the vehi cl e may doubl e. The
turn si gnal and hazard warni ng functi ons are each
fused separatel y but from the same fuse l i nk (Fi g. 5).
FLASHER SYSTEM DIAGNOSIS
(1) Hazard warni ng and turn si gnal fl asher are not
worki ng (Fi g. 6):
Check el ectroni c combi nati on fl asher
Check both fuses
Check fuse l i nk
Check wi ri ng
Repai r as necessary
Confi rm proper operati on
(2) Actuate hazard warni ng fl asher swi tch, l ocated
i n headl amp POD swi tch.
Observe l amps for proper operati on
I denti fy any non-fl ashi ng l amp
Check and repl ace any defecti ve l amp
Hazard warni ng fl asher i s not operati ng at al l , check
fuse or wi ri ng. Repai r as necessary.
Confi rm proper operati on. I f OK, go to step 3.
(3) The hazard warni ng fl asher system i s operati ng
properl y:
Turn OFF hazard warni ng fl asher swi tch
Turn i gni ti on swi tch ON
Actuate the turn si gnal l ever to both ri ght and l eft
si des to confi rm proper operati on of l amps for each
si de.
Check and repl ace any defecti ve l amp
Confi rm proper operati on. I f not go to step 4.
(4) I f hazard warni ng fl asher system i s OK and the
turn si gnal i s not operati ng properl y:
Fig. 4 Multi-Function Switch
Fig. 2 Turn Signal and Hazard Switch Continuity
Fig. 3 Beam Select Switch Continuity
Fig. 5 Relay Bank
TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3
Turn si gnal appears to be defecti ve on one si de,
probl em maybe i n the turn si gnal swi tch or wi ri ng?
Turn si gnal i s not operati ng at al l , check fuse or
wi ri ng. Repai r as necessary.
Confi rm proper operati on
Fig. 6 Combination Flasher Schematic Diagram
8J - 4 TURN SIGNALS AND HAZARD WARNING FLASHER
SPEED CONTROL SYSTEM
CONTENTS
page page
CHECKING FOR FAULT CODE . . . . . . . . . . . . . . . 2
DIAGNOSIS PROCEDURES . . . . . . . . . . . . . . . . . 2
ELECTRICAL TEST: . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE CONTROLLER ELECTRICAL TEST . . . . . 6
INOPERATIVE SYSTEM . . . . . . . . . . . . . . . . . . . . 2
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVO ELECTRICAL TESTS . . . . . . . . . . . . . . . . 5
SERVO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVO VACUUM TEST . . . . . . . . . . . . . . . . . . . . 8
SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . . 8
SPEED CONTROL SWITCH TEST . . . . . . . . . . . . 7
STOP LAMP SPEED CONTROL SWITCH TEST . 7
VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
The speed control system i s el ectroni cal l y control l ed
and vacuum operated. The el ectroni c control i s i nte-
grated i nto the engi ne control l er, l ocated next to bat-
tery. The control s are l ocated on the steeri ng wheel and
consi st of the ON/OFF, RESUME/ACCEL and
SET/DECEL buttons (Fi g.1). For i denti fi cati on and
l ocati on of the major components (Fi g. 2 through 4).
The system i s desi gned to operate at speeds above 35
mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIPPERY.
TO ACTIVATE:
the ON/OFF button to the depressed l atched posi -
ti on, ON, the speed control functi on i s now ready for
use.
TO DEACTIVATE:
A soft tap of the brake pedal , normal brake appl i ca-
ti on or depressi ng the cl utch pedal whi l e the system i s
engaged wi l l di sengage speed control wi thout erasi ng
memory. A sudden i ncrease i n engi ne rpm may be
experi enced i f the cl utch pedal i s depressed whi l e the
speed control system i s engaged. Pushi ng the ON/OFF
button to the unl atched posi ti on or turni ng off the
i gni ti on erases the memory.
TO SET SPEED:
When the vehi cl e has reached the desi red speed push
the SET/DECEL button to engage system whi ch, wi l l
then automati cal l y mai ntai n the desi red speed.
TO DECELERATE:
When speed control i s engaged, hol di ng the
SET/DECEL button depressed al l ows the vehi cl e to
coast to a l ower speed setti ng.
Fig. 1 Speed Control Switch
Fig. 2 Speed Control System2.2L and 2.5L
SPEED CONTROL SYSTEM 8H - 1
TO RESUME:
After di sengagi ng the speed control system by tap-
pi ng the brake pedal or cl utch pedal , push the
RESUME/ACCEL button to return vehi cl e to the pre-
vi ousl y set speed.
TO ACCELERATE:
Whi l e speed control i s engaged, hol d the
RESUME/ACCEL button depressed and rel ease at a
new desi red speed. Thi s wi l l al l ow the vehi cl e to
accel erate and set at a hi gher speed setti ng.
TAP-UP:
When the speed control system i s engaged, tappi ng
the RESUME/ACCEL button wi l l i ncrease the speed
setti ng by 2 mph (3 km/h). The system wi l l respond to
mul ti pl e tap-ups.
TO ACCELERATE for PASSING:
Depress the accel erator as you woul d normal l y.
When the pedal i s rel eased the vehi cl e wi l l return to
the speed setti ng i n memory.
DIAGNOSIS PROCEDURES
Whenever a speed control mal functi on occurs, fi rst
veri fy that the speed control wi re harness i s properl y
connected to al l connectors before starti ng normal
di agnosi s and repai r procedures. Refer to El ectroni c
Speed Control System Di agnosi s Chart or Speed Con-
trol Ci rcui t (Fi g. 5).
A poor connecti on can cause a compl ete or i ntermi t-
tent mal functi on and i s al so the onl y connecti on i n the
ci rcui t, that cannot be tested. For thi s reason, a l oose
connecti on may be mi sdi agnosed as a component mal -
functi on.
Al so, check al l vacuum connecti ons for ti ghtness and
cracked hoses.
ROAD TEST
Road test vehi cl e to veri fy reports of speed control
system mal functi on. The road test shoul d i ncl ude at-
tenti on to the speedometer. Speedometer operati on
shoul d be smooth and wi thout fl utter at al l speeds.
Fl utter i n the speedometer shows a probl em whi ch,
mi ght cause surgi ng i n the speed control system. The
cause of any speedometer defi ci enci es shoul d be cor-
rected before proceedi ng.
INOPERATIVE SYSTEM
I f road test veri fi es an i noperati ve system wi th a
correct speedometer operati on:
I nspect fuse
Check for l oose el ectri cal and vacuum connecti ons at
the servo
Check for correct posi ti on of the vacuum check val ve
i n the hose from servo to vacuum source. The word
VAC on the val ve must poi nt toward the vacuum
source.
Corrosi on shoul d be removed from el ectri cal termi -
nal s and a l i ght coati ng of Mopar Mul ti -Purpose
Grease, or equi val ent, appl i ed.
I nspecti on al so shoul d be made to veri fy that both
ends of the speed control cabl e are securel y attached. I f
ei ther end i s l oose, the speed control system wi l l be
i noperati ve.
CHECKING FOR FAULT CODE
(1) When tryi ng to veri fy a speed control system
el ectroni c mal functi on:
(a) Connect a DRB I I i f avai l abl e.
Fig. 3 Speed Control System3.0L
Fig. 4 Speed Control System3.3L
8H - 2 SPEED CONTROL SYSTEM
SYSTEM DI AGNOSI S
SYSTEM DI AGNOSI SCONTI NUED
(b) Pl ug DRB I I i nto the di agnosti c connector i n
(c) Check that ei ther a Faul t Code 34 or Faul t
Code 15 i s shown.
(d) An i noperati ve speed control may sti l l occur
wi thout ei ther faul t code bei ng shown.
(e) Wi th key i nserted i n i gni ti on swi tch, cycl e
swi tch to ON posi ti on three ti mes. On thi rd cycl e,
l eave swi tch i n ON posi ti on.
(f) After swi tch has been cycl ed three ti mes, ob-
serve CHECK ENGI NE i ndi cator on i nstrument
cl uster. I f a Faul t Code i s present, the i ndi cator wi l l
fl ash (bl i nk) i n a seri es and wi l l show whi ch Faul t
Code i s the probl em. EXAMPLE: A seri es of three
fl ashes i n rapi d successi on, a sl i ght pause, then four
fl ashes i n rapi d successi on woul d show a Faul t Code
34.
(2) I f no Faul t Code appears, or Faul t Code 34 i s
observed, refer to:
The Servo El ectri cal Test.
The Engi ne Control l er El ectri cal Test.
(3) I f a faul t code 15 i s observed, test di stance sensor.
For testi ng di stance sensor and rel ated components
refer to the Powertrai n Di agnosti cs Test Procedure
Manual .
(4) Correct any probl ems found when performi ng
these tests and recheck for Faul t Code i f changes were
made.
(5) I f no probl ems were found above, repl ace engi ne
control l er.
ELECTRICAL TEST:
El ectroni c speed control systems may be tested usi ng
two di fferent methods. One i nvol ves use of a DRB I I . I f
thi s test method i s desi red, pl ease refer to the Power-
trai n Di agnosti c Test Procedures for chargi ng and
speed control system manual .
The other test method uses a vol t/ohm meter and i s
descri bed i n the fol l owi ng tests.
I f any i nformati on i s needed concerni ng wi ri ng, refer
to Group 8W, Wi ri ng Di agrams.
CAUTION: When test probing for voltage or continu-
ity at electrical connectors, care must be taken not to
damage connector, terminals, or seals. If these com-
ponents are damaged, intermittent or complete sys-
tem failure may occur.
SERVO ELECTRICAL TESTS
SEE GROUP 8M, RESTRAINT SYSTEMS FOR AIR-
BAG, STEERING WHEEL OR COLUMN REMOVAL
PROCEDURES.
(1) Turn i gni ti on swi tch to the ON posi ti on. Wi th the
speed control swi tch i n the ON posi ti on, set up a
vol tmeter to read battery vol tage and connect the
negati ve l ead to a good chassi s ground.
(2) Di sconnect the four-way connector goi ng to the
servo (Fi g. 6). Test pi n 2 of the mai n harness four-way
connector for battery vol tage. I f not OK go to step 3. I f
vol tage i s OK go to step 4.
(3) Perform the fol l owi ng tests.
(a) Di sconnect the si x-way connector at the stop
l amp swi tch and test pi n 1 of the mai n harness for
battery vol tage. I f vol tage i s OK perform the stop
l amp swi tch test.
(b) I f the stop l amp swi tch tests OK; repai r wi re
between the servo and the stop l amp swi tch.
(c) I f no vol tage at pi n 1 at the 6-way stop l amp
connector, remove the speed control swi tch and di s-
Fig. 5 Speed Control Circuit
Fig. 6 Servo Harness Connector
connect the four-way connector. Test pi n 1 of mai n
harness for battery vol tage.
(d) I f vol tage i s OK perform the speed control
swi tch test.
(e) I f speed control swi tch i s OK, test conti nui ty
across the cl ockspri ng.
(f) I f cl ockspri ng OK, repai r as requi red, wi re be-
tween stop l amp swi tch and cl ockspri ng.
(g) I f no vol tage at pi n 1 of the 4-way speed con-
trol swi tch connector.
Test for battery vol tage between the i gni ti on and
the fuse
I f vol tage OK, check fuse
I f fuse OK, repai r wi re between fuse and cl ock-
spri ng
(4) Connect a jumper wi re between pi n 2 of the
four-way servo connector of the mai n harness and
pi n 2 of the speed control servo (Fi g. 6). The other
three pi ns from the servo shoul d show battery vol t-
age. I f not, repl ace the servo.
(5) Usi ng an ohmmeter, connect one l ead to a good
body ground. Wi th the other l ead touch pi n 1 i n the
four-way servo connector of the mai n harness.The
meter shoul d show conti nui ty. I f not, repai r the
ground ci rcui t as necessary.
ENGINE CONTROLLER ELECTRICAL TEST
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
AIRBAG, STEERING WHEEL OR COLUMN RE-
MOVAL PROCEDURES.
(1) Unpl ug 60-way connector from the engi ne con-
trol l er, l ocated next to the battery (Fi g. 7).
(2) Remove speed control swi tch. Refer to Speed
Control Swi tch Removal . Di sconnect the 4-way con-
nector.
(3) Usi ng an ohmmeter test conti nui ty between pi n
23 of engi ne control l er and pi n 4 of the speed control
swi tch harness. Refer to Fi g. 8 for control l er termi nal
l ocati ons.
(a) I f no conti nui ty, repai r wi re ci rcui t as neces-
sary.
(b) Conti nui ty OK, refer to Speed Control Swi tch
Test.
(4) Connect the 4-way connector to speed control
swi tch.
(5) Connect negati ve l ead of vol tmeter to a good
body ground near the engi ne control l er.
(6) Turn i gni ti on swi tch ON.
(7) Pl ace speed control swi tch i n the OFF posi ti on.
Touch the posi ti ve l ead of the vol tmeter to pi n 53,
the vol tmeter shoul d read 0 vol ts.
(8) Pl ace speed control swi tch i n the ON posi ti on.
the vol tmeter shoul d read battery vol tage.
(9) I f no vol tage, repai r the wi re between pi n 53
and pi n 3 of the speed control servo (Fi g. 6). I f vol t-
age i s OK go to step 8.
(10) Pl ace speed control swi tch i n the OFF posi -
ti on. Touch the posi ti ve l ead of the vol tmeter to pi n
33, vol tmeter shoul d read 0 vol ts.
(11) Pl ace speed control swi tch i n the ON posi ti on.
the vol tmeter shoul d read battery vol tage.
(12) I f no vol tage, repai r the wi re between pi n 33
and pi n 4 of the speed control servo (Fi g. 6). I f vol t-
age i s OK go to step 11.
(13) Usi ng an ohmmeter, connect one l ead to a
good body ground and touch the other l ead to pi n 29.
Wi th the brake pedal rel eased, the meter shoul d
show conti nui ty. When the pedal i s depressed, the
meter shoul d show no conti nui ty. I f no conti nui ty
perform the fol l owi ng test:
(a) Usi ng an ohmmeter test conti nui ty between
pi n 29 of engi ne control l er and pi n 3 of the stop
l amp swi tch connector.
(b) I f no conti nui ty, repai r as necessary.
Fig. 7 Engine Controller and Connector Location
Fig. 8 Engine Controller 60-Way Connector Shown
from Terminal End
(c) I f conti nui ty, refer to Stop Lamp Swi tch Test.
(d) I f stop l amp swi tch test OK, Test conti nui ty
between pi n 6 of stop l amp swi tch and ground.
(14) Usi ng an ohmmeter, touch one l ead to a good
body ground and touch the other l ead to pi n 30. The
meter shoul d show no conti nui ty when transmi ssi on i s
i n DRI VE and conti nui ty when i n PARK or NEUTRAL.
I f not test Neutral Start and Back-Up swi tch usi ng
DRB I I .
SPEED CONTROL SWITCH TEST
WARNING: IF REMOVAL OF AIR BAG MODULE IS
NECESSARY, REFER TO GROUP 8M, RESTRAINT
SYSTEMS.
(1) Remove the swi tch and di sconnect 4-way connec-
tor.
(2) Usi ng an ohmmeter, test conti nui ty at the four
pi ns of the speed control swi tch. Refer to Speed Control
Swi tch Conti nui ty (Fi g. 9).
(3) I f there i s no conti nui ty or i ncorrect conti nui ty at
any one of the swi tch posi ti ons, repl ace the swi tch.
STOP LAMP SPEED CONTROL SWITCH TEST
(1) Di sconnect the si x way connector at the stop
l amp swi tch (Fi g. 10). Usi ng an ohmmeter, conti nui ty
may be checked at the swi tch si de of the connector as
fol l ows:
(a) Wi th brake pedal rel eased, there shoul d be
conti nui ty:
Between pi n 1 and pi n 4.
No conti nui ty between pi n 2 and pi n 5.
(b) Wi th brake pedal depressed, there shoul d be no
conti nui ty:
Conti nui ty between pi n 2 and pi n 5.
(2) I f the above resul ts are not obtai ned, the stop
l amp swi tch i s defecti ve or out of adjustment.
(3) Stop l amp swi tch adjustment i s detai l ed i n
Group 5, Brakes.
VACUUM SUPPLY TEST
(1) Di sconnect vacuum hose at the servo and i nstal l
a vacuum gauge i n the hose (Fi g. 11).
(2) Start engi ne and observe gauge at i dl e. Vacuum
gauge shoul d read at l east ten i nches of mercury. Shut
off engi ne, the vacuum shoul d conti nue to hol d 10
i nches of mercury.
Fig. 9 Speed Control Switch Continuity
Fig. 10 Stop Lamp and Speed Control Switch Wiring
Fig. 11 Vacuum Gauge Test
(3) I f vacuum does not meet thi s requi rement, check
and correct the fol l owi ng vacuum l eaks:
Vacuum l i nes
Check val ve
Vacuum reservoi r
Servo Vacuum, refer to Servo Vacuum Test
Poor engi ne performance.
SERVO VACUUM TEST
(1) Remove the speed control cabl e at the throttl e
body end.
(2) Di sconnect the 4-way el ectri cal connector and
the vacuum harness at the servo (Refer to Fi g. 6).
(3) Connect battery vol tage to pi n 2 of the servo.
(4) Ground the remai ni ng three servo pi ns 1, 3 and
4.
(5) Connect a hand hel d vacuum pump to the servo
vacuum ni ppl e and appl y 10 to 15 i nches of vacuum.
(6) The cabl e shoul d pul l i n and hol d for as l ong as
vacuum i s appl i ed.
SERVO UNIT
REMOVAL
(1) Remove two nuts attachi ng speed control cabl e
and mounti ng bracket to servo.
(2) Remove screws attachi ng servo mounti ng
bracket.
(3) Remove servo mounti ng bracket.
(4) Di sconnect el ectri cal connectors and vacuum
hose.
(5) Pul l cabl e away from servo to expose retai ni ng
cl i p and remove cl i p attachi ng cabl e to servo.
I NSTALLATI ON
(1) Wi th throttl e i n ful l open posi ti on al i gn hol e i n
speed control cabl e sl eeve wi th hol e i n servo pi n and
i nstal l retai ni ng cl i p.
(2) Connect vacuum hose to servo.
(3) Connect el ectri cal connector.
(4) Posi ti on mounti ng bracket and i nstal l screws
attachi ng bracket. Ti ghten screws to 12 Nm (105 i n.
l bs.), i f mounted to shock tower 5 Nm (45 i n. l bs.).
(5) I nsert servo studs through hol es i n speed control
cabl e and mounti ng bracket.
(6) I nstal l nuts, ti ghten to 7 Nm (60 i n. l bs.).
SPEED CONTROL SWITCH
The speed control swi tch i s mounted i n the steeri ng
wheel and wi red through the cl ock spri ng devi ce under
the steeri ng wheel hub (Fi g.1).
WARNING: IF REMOVAL OF AIR BAG MODULE IS
NECESSARY, REFER TO GROUP 8M, RESTRAINT
SYSTEMS.
REMOVAL
(1) Turn off i gni ti on.
(2) Remove two (2) screws from back si de of steeri ng
wheel .
(3) Rock swi tch away from ai r bag or horn pad whi l e
l i fti ng swi tch out of steeri ng wheel .
(4) Di sconnect 4-way el ectri cal connector.
I NSTALLATI ON
(1) Turn off i gni ti on.
(2) Connect 4-way el ectri cal connector from cl ock
spri ng to swi tch.
(3) Pl ace swi tch i n steeri ng wheel , sl i di ng the for-
ward edge of swi tch under ai r bag or horn pad. Li ne up
l ocati ng pi ns on swi tch wi th hol es i n steeri ng wheel
frame.
(4) Attach swi tch to wheel wi th two screws starti ng
wi th the screw at the l eft end of the swi tch.
HORNS
CONTENTS
page page
DIAGNOSIS TESTING . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH REPLACEMENT . . . . . . . . . . . . . 2
HORNS SOUND CONTINUOUSLY . . . . . . . . . . . . 2
HORNS WILL NOT SOUND . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
The horn ci rcui t consi sts of a horn swi tch, horn rel ay,
and horns. On al l model s the rel ay pl ugs i nto the rel ay
bank. The horn ci rcui t feed i s from the fuse box to the
number 1 termi nal on the horn rel ay. When the horn
swi tch i s depressed, thi s compl etes the ground. A set of
contacts i n the horn rel ay cl ose, whi ch al l ows current
to fl ow to the horn(s).
HORNS WILL NOT SOUND
I f the horns do not sound, check for a bl own horn fuse
i n the fuse bl ock. I f the fuse i s bl own, repl ace i t wi th
the same type fuse. The fuse bl ows when depressi ng
the swi tch, a short ci rcui t i n the horn or wi ri ng
between the fuse termi nal and the horn i s responsi bl e.
I f the fuse i s OK, di sconnect wi re connector from
horn and connect test l amp wi re and l ead to a good
body ground (Fi g. 2). Depress the horn swi tch, the test
l amp shoul d i l l umi nate. I f not connect the test l amp
wi re to a good ground and depress the horn swi tch. I f
test l amp l i ghts i nspect ground wi re ci rcui t and repai r
as needed.
I f the test l amp fai l s to i l l umi nate, check for a
defecti ve horn rel ay. Substi tuti ng a known good horn
rel ay i n the ci rcui t. I f the test l amp i l l umi nates when
depressi ng the horn swi tch, the ori gi nal rel ay i s defec-
ti ve. I f the l amp fai l s to i l l umi nate wi th a known good
rel ay, unpl ug that rel ay. Connect a jumper wi re from
the battery termi nal to the horn termi nal on the rel ay
termi nal board (Fi g. 3). I f a l amp connected i n pl ace of
the horns and fai l s to i l l umi nate, an open ci rcui t i n the
wi ri ng between the rel ay termi nal and the horn swi tch
i s at faul t.
Fig. 1 Horn System
Fig. 2 Horn and Connector
Fig. 3 Testing for an Open Circuit
HORNS 8G - 1
I f the l amp i l l umi nates, horn swi tch i s defecti ve or an
open ci rcui t i n the wi ri ng between the rel ay termi nal
and the horn swi tch i s at faul t.
HORNS SOUND CONTINUOUSLY
CAUTION: Continuous sounding of horns may cause
relay to fail.
I f the horns sound conti nuousl y, unpl ug the horn
rel ay from the termi nal board i nsi de the passenger
compartment. Pl ug i n a known, good rel ay. I f the horns
stop bl owi ng, rel ay i s defecti ve and must be repl aced.
Shoul d the horns sti l l sound, proceed as fol l ows:
(1) Connect one vol tmeter l ead to battery termi nal
on rel ay board and the other l ead to swi tch termi nal
(Fi g. 4).
(2) Vol tmeter wi l l regi ster battery vol tage when the
wi re to the horn swi tch i s shorted to ground or the horn
swi tch i s defecti ve.
Remove steeri ng wheel horn pad and di sconnect wi re
from horn swi tch. Repeat the above test and i f the test
l amp sti l l i l l umi nates, wi re i s shorted and shoul d be
repai red. I f test l amp does not i l l umi nate, horn swi tch
i s defecti ve and must be repl aced.
DIAGNOSIS TESTING
Horn does not sound, horn sounds i ntermi ttentl y, or
horn sounds conti nuousl y go to Horn Di agnosi s Chart
(Fi g. 5).
HORN SWITCH REPLACEMENT
(1) Di sconnect i sol ate negati ve battery cabl e i n en-
gi ne compartment.
(2) On l uxury and sport steeri ng wheel s (Fi g. 6 and
7):
(a) Remove four retai ni ng nuts from back of steer-
i ng wheel and Remove pad assembl y.
(b) Pry out two tri m cover buttons on back of
steeri ng wheel to access retai ni ng screws for the horn
swi tch.
(c) Remove two screws and di sconnect horn wi res
l ocated i n the l ower porti on of steeri ng wheel . Feed
wi res through the access ports and remove horn
swi tch.
(3) On standard steeri ng wheel s (Fi g. 8), remove two
retai ni ng screws from back of wheel i ng wheel and
remove horn pad.
(4) For i nstal l ati on reverse the above procedures.
Use cauti on not to pi nch wi res.
Fig. 4 Testing for Short to Ground
8G - 2 HORNS
Fig. 5 Horn Diagnosis
HORNS 8G - 3
Fig. 8 Standard Steering Wheel
Fig. 6 High Line Steering Wheel
Fig. 7 Low Line Steering Wheel
8G - 4 HORNS
AUDIO SYSTEM
CONTENTS
page page
MANUAL ANTENNAS . . . . . . . . . . . . . . . . . . . . . 1
RADIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RELAY/CHOKEINFINITY SPEAKERS . . . . . . . . 4
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RADIOS
CAUTION: Do not operate the radio with speaker
leads detached since damage to the transistors may
result.
For operati on of the factory i nstal l ed standard and
opti onal radi os, refer to the Operati ng I nstructi ons
Manual suppl i ed wi th the vehi cl e.
Al l vehi cl es are equi pped wi th an I gni ti on-Off Draw
Connector whi ch, i s used when the vehi cl es are ori gi -
nal l y shi pped from the factory. Thi s connector, whi ch i s
l ocated near the battery, hel ps to prevent battery
di scharge duri ng storage. For speci fi c connector type
and l ocati on, refer to Wi ri ng Di agrams.
Thi s connector i s part of the radi o memory ci rcui try
and shoul d be checked i f the memory of ti me or radi o
stati on programmi ng i s i noperati ve.
I NTERFERENCE ELI MI NATI ON
Some components on the vehi cl e are equi pped wi th a
radi o capactor, to suppress radi o frequency i nterfer-
ence (stati c).
Capaci tors are mounted i n vari ous l ocati ons, on the
al ternator (ei ther i nternal or external ), i nternal to the
i nstrument cl uster, and i nternal to the wi ndshi el d
wi per motor.
Ground straps are mounted from radi o chassi s to
cowl , engi ne to cowl , across engi ne mount on ri ght
hand si de. On vehi cl es wi th ai r condi ti oni ng there i s a
strap from evaporator val ve to cowl . These ground
straps shoul d be securel y ti ghtened to assure good
metal to metal contact. Ground straps conduct very
smal l hi gh frequency el ectri cal si gnal s to ground and
requi re cl ean l arge surface area contact.
Radi o resi stance type spark pl ug cabl es i n the hi gh
tensi on ci rcui t of the i gni ti on system compl ete the
i nterference suppressi on (Fi g. 1).
I f radi o noi ses are evi dent, be sure the capaci tor l ead
wi res are maki ng good contact on thei r respecti ve
termi nal s and are securel y mounted. Faul ty or deteri o-
rated spark pl ug wi res shoul d be repl aced.
TEST
Whenever a radi o mal functi on occurs, fi rst veri fy
that the radi o wi re harness i s properl y connected to al l
connectors before starti ng normal di agnosi s and repai r
procedures. Refer to Radi o Di agnosi s Chart (Fi g. 2),
and/or Radi o Connector Ci rcui t Chart (Fi g. 3).
REPLACEMENT
(1) Remove bezel by openi ng gl ove box and pryi ng
behi nd the bezel (Fi g. 4).
(2) Remove two screws that attach the radi o to the
panel .
(3) Remove the ground strap screw.
(4) Remove the antenna pl ug.
(5) Remove the two wi ri ng connectors.
MANUAL ANTENNAS
TESTI NG
Antenna performance may be tested by substi tuti ng
a known good antenna. I t i s al so possi bl e to check short
or open ci rcui ts wi th an ohmmeter or conti nui ty l i ght
once the antenna cabl e i s di sconnected from the radi o
as fol l ows:
(1) Conti nui ty shoul d be present between the an-
tenna mast and radi o end pi n of antenna cabl e pl ug
(Fi g. 5).
(2) No conti nui ty shoul d be observed between the
ground shel l of the connector and radi o end pi n.
(3) Conti nui ty shoul d be observed between the
ground shel l of the connector and the mounti ng hard-
ware on the vehi cl e fender.
REMOVAL
(1) Remove si de cowl cover and di sconnect antenna
cabl e by pul l i ng apart.
Fig. 1 Resistance Type Spark Plug Cables
AUDIO SYSTEM 8F - 1
(2) Remove antenna mast by unscrewi ng mast from
antenna body (Fi g. 6).
(3) Remove cap nut wi th Antenna Nut Wrench
C-4816 (Fi g. 7).
(4) Remove antenna adapter (Fi g. 7).
(5) From under fender remove antenna l ead and
body assembl y (Fi g. 5).
I NSTALLATI ON
(1) I nstal l antenna body and cabl e from underneath
fender (Fi g. 5).
(2) I nstal l adapter and cap nut. Ti ghten cap nut to
14 Nm (125 i n. l bs.) wi th Antenna Nut Wench C-4816.
(3) I nstal l antenna mast i nto antenna body unti l
sl eeve bottoms on antenna body.
(4) Route cabl e through body hol e, make sure the
grommet i s seated to the body pl ug i n cabl e to connec-
tor.
BENCH TEST FOR ANTENNA MALFUNCTI ON
I t i s al so possi bl e to check short or open ci rcui ts wi th
an ohmmeter or conti nui ty l i ght once the antenna has
been removed from the vehi cl e.
(1) Conti nui ty shoul d be present between the ti p of
the mast and radi o end pi n (Fi g. 8).
(2) No conti nui ty shoul d be observed between the
ground shel l of the connector and radi o end pi n.
(3) Conti nui ty shoul d be observed between the
ground shel l of the connector and the mounti ng hard-
ware.
Wiggle cable over its entire length to reveal
intermittent short or open circuits during steps
(1), (2) and (3).
SPEAKERS
CAUTION: Do not operate the radio with speaker
leads detached since damage to the transistors may
result.
FRONT SPEAKER REPLACEMENT
(1) Remove speaker gri l l e by pushi ng forward unti l
the back edge i s cl ear of the pad (Fi g.9).
(2) Remove two screws that retai n the speaker.
(3) Remove the speaker and di sconnect the wi ri ng
connector.
FRONT DOOR SPEAKERS REPLACEMENT
(1) Remove speaker gri l l e by pryi ng at top wi th a fl at
tool .
(2) Remove four speaker mounti ng screws. Pul l
speaker forward and remove speaker wi ri ng connector.
Fig. 2 Radio Diagnosis
8F - 2 AUDIO SYSTEM
Fig. 3 Radio Connector Circuit
AUDIO SYSTEM 8F - 3
REAR SPEAKERS REPLACEMENT
(1) Remove the speaker gri l l e by pryi ng from the
undersi de (Fi g. 10).
(2) Remove four screws attachi ng speaker to door.
(3) Di sconnect speaker wi ri ng connector.
RELAY/CHOKEINFINITY SPEAKERS
No Bass, test across the connector for conti nui ty. I f
no conti nui ty Repl ace Rel ay/Choke Assembl y (Fi g. 11).
The Rel ay/Choke i s l ocated under the l eft si de of the
I nstrument Panel on the Di mmer Modul e bracket.
Fig. 5 Radio Antenna Cable
Fig. 4 Radio and Bezel
Fig. 6 Antenna Mast Removal & Installation
8F - 4 AUDIO SYSTEM
Fig. 7 Removing or Tightening Antenna Cap Nut
Fig. 8 Antenna Bench Test Points
Fig. 9 Front Speaker System
Fig. 10 Rear Speaker System
Fig. 11 Relay/ChokeInfinity Speaker[001a]
AUDIO SYSTEM 8F - 5
INSTRUMENT PANEL AND GAUGES
CONTENTS
page page
ACCESSORY SWITCH CARRIER . . . . . . . . . . . . 12
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 14
ACCESSORY SWITCH CARRIER TEST . . . . . . . 14
CLUSTER AND GAUGE SERVICE . . . . . . . . . . . . 2
GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTRUMENT PANEL REPLACEMENT . . . . . . . 17
LOWER RIGHT INSTRUMENT PANEL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 16
REAR WIPER/WASHER CONTROL POD
SWITCH REPLACEMENT . . . . . . . . . . . . . . . . 12
SWITCH AND PANEL COMPONENT SERVICE . . 12
WARNING LAMP SYSTEM TESTS . . . . . . . . . . 10
GENERAL INFORMATION
I NSTRUMENT CLUSTERS
The mechani cal cl uster i s an el ectroni c cl uster wi th
anal og di spl ays. The body computer sends the me-
chani cal cl uster the gauge readi ngs and warni ng mes-
sages over the CCD Bus.
The el ectroni c cl uster recei ves most i nformati on di s-
pl ayed from the body and engi ne control l er vi a the
Chrysl er Col l i si on Detecti on (CCD) Seri al Data Bus.
The odometer memory i s no l onger retai ned i n the
cl uster i t i s retai ned i n the body control l er.
The mechani cal cl uster wi thout tachometer (Fi g. 1)
i ncl udes a 160 km/h (100 mph) speedometer, tri p
odometer, fuel , temperature gauges and warni ng i ndi -
cators. The warni ng l amps i ncl ude: l ow fuel , check
gauges, door ajar, l ow washer fl ui d, check engi ne, gate
ajar, vol t and l ow oi l pressure.
The mechani cal cl uster wi th tachometer (Fi g. 2) wi l l
i ncl ude a 160 km/h (100 mph) speedometer, tri p odom-
eter, gauges for fuel l evel , cool ant temperature, oi l
pressure, and chargi ng system vol tage. Al so, i ncl uded
i s a 7,000 rpm tachometer. The warni ng l amps may
i ncl ude: l ow fuel , check gauges, door ajar, l ow washer
fl ui d, check engi ne and gate ajar.
The el ectroni c cl uster (Fi g. 3) contai ns:
Di gi tal speedometer and odometer
Anal og bar type gauges for, oi l pressure, tempera-
ture, vol tage, tachometer and fuel
Vehi cl e graphi c showi ng door ajar, l i ft gate ajar and
l ow washer fl ui d
MAGNETI C GAUGES
Al l the gauges on i nstrument cl usters are the mag-
neti c type gauges. When the i gni ti on swi tch i s i n the
OFF posi ti on each gauge shoul d rest at or bel ow the
l ow graduati on.
ELECTRONI C DI GI TAL CLOCK
The el ectroni c di gi tal cl ock i s i n the radi o. The cl ock
and radi o each use the di spl ay panel bui l t i nto the
radi o. A di gi tal readout shows the ti me i n hours and
mi nutes whenever the i gni ti on swi tch i s i n the ON or
ACC posi ti on.
When the i gni ti on swi tch i s i n the OFF posi ti on, or
when the radi o frequency i s bei ng di spl ayed, ti me
keepi ng i s accuratel y mai ntai ned.
Fig. 1 Mechanical Cluster Without Tachometer
Fig. 2 Mechanical Cluster With Tachometer
Fig. 3 Electronic Cluster
INSTRUMENT PANEL AND GAUGES 8E - 1
The procedure for setti ng the cl ock vari es sl i ghtl y
wi th each radi o. The correct procedure i s descri bed
under the i ndi vi dual radi o operati ng i nstructi ons re-
ferred to i n the owners manual suppl i ed wi th the
vehi cl e.
MAI NTENANCE REQUI RED REMI NDER
Thi s system i s desi gned to act as a remi nder that
schedul ed vehi cl e emi ssi ons mai ntenance shoul d be
performed. The l amp i s l ocated i n the Message Center.
I t i s not i ntended to show a warni ng or that a state of
emergency exi sts whi ch or must be corrected to i nsure
safe vehi cl e operati on. The components covered by the
system i ncl ude the EGR system, PCV val ve, and Oxy-
gen sensor.
For further i nformati on, refer to Group 25, Emi ssi ons.
SEAT BELT WARNI NG SYSTEM
For testi ng of thi s system refer to Group 8U, Chi me
Warni ng/Remi nder system.
SEAT BELT WARNI NG LAMP
The seat bel t warni ng l amp i s l ocated i n the warni ng
i ndi cator modul e assembl y. Refer to Warni ng I ndi cator
Modul e Assembl y Lamp Repl acement for l amp repl ace-
ment.
CLUSTER AND GAUGE SERVICE
CAUTION: Disconnect battery cable, before servicing
instrument panel. When power is required for test
purposes, reconnect battery cable for test only.
Di sconnect battery cabl e after test and before con-
ti nui ng servi ce procedures.
Refer to Fi g. 4 for cl uster connector wi re cal l out.
MECHANI CAL CLUSTER SERVI CE
To test the gauges and mechani cal cl uster a DBR I I
wi l l be needed, and the Body Di agnosti c Procedures
Manual .
ELECTRONI C CLUSTER SERVI CE
Refer to Body Di agnosti c Procedures Manual when
usi ng DRB I I .
SELF DI AGNOSTI C SYSTEM
The el ectroni c cl uster has an i nternal di agnosti c
routi ng to i sol ate probl ems wi thi n the cl uster.
Perform cl uster Sel f-Di agnosti c Test to deci de whether
probl em i s wi thi n cl uster or outsi de of cl uster. Start test by
depressi ng and hol di ng Tri p and Tri p Reset buttons whi l e
turni ng the i gni ti on swi tch ON, CHEC wi l l appear i n the
odometer. Depressi ng the US/M swi tch wi l l perform the next
test. Refer to Fi g. 5 and 6.
Successful compl eti on of the SELF-DI AGNOSTI C
TEST shows that the probl em i s i n the wi ri ng, connec-
tors or sensors out si de of the cl uster.
CONDI TI ON: MECHANI CAL CLUSTER I S NOT
FUNCTI ONAL WI TH ENGI NE RUNNI NG
The cl uster i s i ndi cati ng that i t i s not recei vi ng any
CCD Bus messages i f:
Check gauge l amp i s ON.
Tachometer, speedometer and gauges are at l ow
scal e.
Check Bus wi ri ng goi ng to the cl uster and body
computer.
WARNI NG I NDI CATOR MODULE REPLACE-
MENT OR LAMP REPLACEMENT
wi th a fl at bl ade tool (Fi g. 7).
(3) Repl ace one pi ece l amp and socket. The l amp
cannot be separated from the socket.
I NSTRUMENT PANEL CLUSTER BEZEL RE-
PLACEMENT
i ndi cator modul e assembl y and di sconnect wi re con-
nector.
(3) Remove steeri ng col umn cover (Fi g. 8). Set park-
i ng brake and shi ft gear sector i nto l ow.
(4) Remove i nstrument cl uster bezel fi ve screws and
remove bezel . Di sconnect POD swi tch wi re connectors
(Fi g. 9).
(5) Remove POD swi tches by unsnappi ng from the
back si de of the cl uster bezel .
(6) For i nstal l ati on reverse above procedures. Fig. 4 Cluster Connector
8E - 2 INSTRUMENT PANEL AND GAUGES
Fig. 5 Electronic Cluster Self-Diagnostic Test
Fig. 6 Electronic Cluster Self-Diagnostic TestContinued
I NSTRUMENT PANEL CLUSTER LENS RE-
PLACEMENT
wi th a fl at bl ade tool . (2) Remove three mounti ng
screws from the warni ng i ndi cator modul e assembl y
and di sconnect wi re connector.
i ng brake and shi ft gear sel ector i nto l ow.
(4) Remove cl uster bezel and di sconnect wi re con-
nectors.
(5) Remove si x screws securi ng l ens to cl uster hous-
i ng (Fi g. 10).
(6) Remove l ens.
I NSTRUMENT PANEL CLUSTER REPLACE-
MENT
nector.
Fig. 7 Warning Indicator Module
Fig. 8 Instrument Panel Steering Column Cover
Fig. 9 Instrument Cluster Bezel
nectors.
(5) Remove four screws securi ng cl uster. Careful l y
rotate cl uster and di sconnect connector, to access
PRNDL attachi ng screws. Remove two screws attach-
i ng PRNDL to cl uster (Fi g. 11).
(6) For el ectroni c i nstrument cl uster i f equi pped:
(a) Remove four screws securi ng cl uster.
(b) Remove four screws attachi ng mask to hous-
i ng.
(c) Rotate mask down then di sconnect buttons and
PRNDL.
(d) Remove two screws attachi ng PRNDL to mask
on el ectroni c i nstrument cl uster onl y.
(7) Remove cl uster.
When i nstal l i ng cl uster, do not ki nk or bi nd PRNDL
gui de tube and posi ti on gui de tube i n ori gi nal l ocati on.
Move shi ft l ever to Neutral (N) and note poi nter
l ocati on. Move shi ft l ever to D, L and P note poi nter
l ocati on. Adjust, i f necessary to center poi nter on N.
Refer to Fi g. 12 for adjusti ng procedure.
CLUSTER PRI NTED CI RCUI T BOARD RE-
PLACEMENT
nector.
(4) Remove cl uster bezel and di sconnect POD swi tch
wi re connectors.
(7) Remove si x screws and attach cover (Fi g. 13).
(8) Di sconnect odometer connector and remove
screw attachi ng pri nted ci rcui t board and housi ng.
Fig. 10 Cluster Lens
Fig. 11 Removal of PRNDL
Fig. 12 Adjusting PRNDL
CLUSTER LAMPS BULB REPLACEMENT
MECHANI AL CLUSTER ONLY
nector.
wi re connectors.
(5) Careful l y rol l cl uster out of i nstrument panel
wi thout di sconnecti ng PRNDL.
(6) Remove one pi ece i ntegral bul b and socket from
rear of cl uster (Fi g. 14).
GAUGES
To test the gauges and mechani cal cl uster a DRB I I
wi l l be needed and Body Di agnosti c Procedures
Manual .
It is not necessary to remove instrument clus-
ter fromvehicle for gauge replacement.
Whenremovinggaugefromcluster, gaugemust
be pulled straight out, without twisting or dam-
age to gauge pins may result.
FUEL GAUGE REPLACEMENT
i ndi cator modul e.
wi re connectors.
(5) Remove cl uster l ens.
(6) Remove si x screws attachi ng gauge to cl uster
(Fi g. 15 and 16).
(7) Remove fuel gauge.
VOLTMETER REPLACEMENT
Fig. 13 Printed Circuit Board
Fig. 14 Mechanical Cluster Bulb Location
Fig. 15 Gauge Assembly Without Tachometer
Fig. 16 Gauge Assembly With Tachometer
wi re connectors.
(Fi g. 15 or 16).
(7) Remove vol tmeter gauge.
TEMPERATURE GAUGE REPLACEMENT
wi re connectors.
(Fi g. 15 or 16).
(7) Remove temperature gauge.
OI L PRESSURE GAUGE REPLACEMENT
wi re connectors.
(Fi g. 15 or 16).
(7) Remove oi l pressure gauge.
TACHOMETER REPLACEMENT
wi re connectors.
(Fi g. 15 or 16).
(7) Remove tachometer gauge.
SPEEDOMETER ASSEMBLY REPLACEMENT
wi re connectors.
(Fi g. 15 or 16).
(7) Remove speedometer gauge.
ODOMETER ASSEMBLY REPLACEMENT
wi re connectors.
(7) Remove si x screws that attach cover (Fi g. 13).
(8) Di sconnect odometer motor connector on rear of
cl uster (Fi g. 17).
CAUTION: Do Not disconnect pancake connector on
back side of motor (Fig. 18).
(9) Remove l ens.
(10) Remove screws attachi ng gauge to cl uster.
(11) Remove three screws and odometer.
Fig. 17 Odometer
DI STANCE SENSOR REPLACEMENT
(1) Remove harness connector from sensor and
make sure the weather seal i s on harness connector
(Fi gs. 19 and 20).
(2) Remove sensor retai ni ng bol t.
(3) Pul l sensor and pi ni on gear assembl y out of
transaxl e. I f necessary, careful l y pry l oose wi th a fl at
bl ade screwdri ver.
(4) Remove pi ni on gear from sensor.
(5) For i nstal l ati on reverse above procedures. Seat
sensor assembl y by hand to i nsure proper gear en-
gagement. Ti ghten retai ni ng bol t to 7 Nm (60 i n.
l bs.).
DI STANCE SENSOR TEST
For testi ng of the di stance sensor and rel ated com-
ponents, use DRB I I and Body Di agnosti c Procedures
Manual .
SENDI NG UNI T TEST
When a probl em occurs wi th a cl uster gauge, be-
fore di sassembl i ng the cl uster to check the gauge,
check for a defecti ve sendi ng uni t or wi ri ng.
(1) Sendi ng uni ts and wi ri ng can be checked by
groundi ng the connector l eads, at the sendi ng uni t,
i n the vehi cl e.
(2) Wi th the i gni ti on i n the ON posi ti on, a
grounded i nput wi l l cause the fuel or temperature
gauge to read at or above maxi mum.
FUEL TANK SENDI NG UNI T TEST
(1) Di sconnect wi ri ng from fuel tank sendi ng uni t.
(2) Connect wi ri ng to a known good sendi ng uni t
(Fi g. 21).
(3) Check fuel gauge as descri bed i n the fol l owi ng
steps. Al l ow at l east two mi nutes at each test poi nt
for gauge to settl e.
(a) Move fl oat arm of sendi ng uni t to i ts empty
stop and turn i gni ti on key to ON posi ti on. The
gauge shoul d read Empty or bel ow.
(b) Move sendi ng uni t fl oat arm to ful l stop. The
gauge shoul d read Ful l or above.
CONDI TI ON
(1) I f fuel gauge does not meet speci fi cati ons, check
fol l owi ng i tems as possi bl e causes:
(a) Wi ri ng and connecti ons between gauge send-
i ng uni t and body computer.
Fig. 18 Odometer Motor and Connector
Fig. 19 Distance Sensor and Connector
Fig. 20 Distance Sensor and Speedometer Pinion
(b) Check for l oose gauge adaptor nuts on the
i nstrument cl uster pri nted ci rcui t board. Ti ghten
gauge adapter nuts as necessary.
(c) I f the body computer and pri nted ci rcui t board
check okay the fuel gauge i s defecti ve.
(2) I f fuel gauge meets speci fi cati ons check fuel tank
and ori gi nal fuel l evel assembl y as fol l ows:
(a) Careful l y remove fuel l evel uni t from tank.
(b) Refer to sendi ng uni t removal Group 14, Fuel .
(c) Connect sendi ng uni t wi re as descri bed i n the
test procedure.
(3) I f fuel gauge now checks wi thi n speci fi cati ons,
ori gi nal sendi ng uni t i s el ectri cal l y okay, check fol l ow-
i ng as possi bl e cause:
(a) Ground wi re from sendi ng uni t to l eft si de cowl
for conti nui ty.
(b) fuel l evel assembl y i s deformed. Make sure
sendi ng uni t fl oat arm moves freel y.
(c) Fuel l evel assembl y i mproperl y i nstal l ed, i n-
stal l properl y.
(d) Mounti ng fl ange on fuel tank for fuel pump
l evel assembl y i s deformed.
(e) Fuel tank bottom deformed causi ng i mproper
posi ti oni ng of fuel l evel assembl y. Repl ace or repai r
tank and recheck sendi ng uni t.
WARNING LAMP SYSTEM TESTS
Al l warni ng l amps come on when the i gni ti on swi tch
i s fi rst turn to the ON posi ti on. They wi l l stay on for a
few seconds to see i f l amps are worki ng.
BRAKE SYSTEM WARNI NG LAMP TEST
The brake warni ng l amp i l l umi nates when parki ng
brake i s appl i ed wi th i gni ti on key turned ON. The
same l i ght wi l l al so i l l umi nate shoul d one of the two
servi ce brake systems fai l when brake pedal i s appl i ed.
To test system turn i gni ti on key ON and appl y parki ng
brake. I f l amp fai l s to l i ght, i nspect for a burned out
bul b, di sconnected socket, a broken or di sconnected
wi re at swi tch. The l amp al so l i ghts when the i gni ti on
swi tch i s turned to start.
To test servi ce brake warni ng system, rai se vehi cl e
on a hoi st and open a wheel cyl i nder bl eeder whi l e a
hel per depresses brake pedal and observes warni ng
l amp. I f l amp fai l s to l i ght, i nspect for a burned out
bul b, di sconnected socket, a broken or di sconnected
wi re at swi tch (Fi g. 22 and 23).
I f l amp i s not burned out and wi re conti nui ty i s
proven, repl ace brake warni ng swi tch. The swi tch i s
l ocated i n brake l i ne Tee fi tti ng mounted on frame rai l
i n engi ne compartment bel ow master cyl i nder (Fi g. 23).
CAUTION: If wheel cylinder bleeder was opened
check master cylinder fluid level.
TEMPERATURE WARNI NG LAMP TEST
To test the temperature warni ng l amp, turn the
i gni ti on swi tch to the ON posi ti on. Di sconnect the wi re
from the temperature swi tch on the engi ne and mo-
mentari l y touch the wi re to ground. When the wi re i s
grounded the bul b of the i ndi cator shoul d i l l umi nate. I f
the bul b fai l s to i l l umi nate, i ndi cati ons are of a faul ty
ci rcui t i n the system, body computer i s mal functi oni ng
or possi bl y the i ndi cator bul b i s faul ty. Repai r or
repl ace as necessary.
LOW OI L PRESSURE WARNI NG LAMP TEST
The l ow oi l pressure warni ng l amp wi l l i l l umi nate
when the i gni ti on key i s turned to the ON posi ti on. The
l amp al so i l l umi nates when the engi ne oi l pressure
drops bel ow a safe oi l pressure l evel .
To test the system, turn the i gni ti on key to the ON
posi ti on. I f the l amp fai l s to l i ght, i nspect for broken or
di sconnected wi res at the oi l pressure combi nati on uni t
l ocated at the front of the engi ne (Fi gs. 24 and 25).
I f the wi re at the connector checks good, pul l connec-
tor l oose from the uni t. Wi th a jumper wi re ground
swi tch termi nal i n the connector to the engi ne. Wi th
the i gni ti on key turned to the ON posi ti on, check the
warni ng l amp. I f l amp sti l l fai l s to l i ght, i nspect for a
burned out bul b or di sconnected socket i n the cl uster.
COMBI NATI ON OI L SENDI NG UNI T TESTS
The combi nati on oi l uni t has two functi ons (Fi gs. 24
and 25):
(1) The normal l y cl osed ci rcui t keeps the oi l pressure
warni ng l amp on unti l there i s oi l pressure.
(2) The sendi ng uni t provi des a resi stance that var-
i es wi th oi l pressure.
(3) To test the normal l y cl osed oi l l amp ci rcui t,
di sconnect the l ocki ng connector and measure the
resi s-
Fig. 21 Fuel Pump Assembly (Typical)
tance between the swi tch termi nal and the metal
housi ng (Fi g. 26). The ohmmeter shoul d read zero
ohms.
(4) Start the engi ne. I f there i s oi l pressure, the
ohmmeter shoul d read an open ci rcui t.
(5) To test the sendi ng uni t, measure the resi stance
between the sendi ng uni t termi nal and the metal
housi ng. The ohmmeter shoul d read open.
(6) Start the engi ne. The ohmmeter shoul d read
between 30 and 55 ohms, dependi ng on engi ne speed,
oi l temperature, and oi l vi scosi ty.
(7) I f the above resul ts are not obtai ned, repl ace the
swi tch.
Fig. 22 Brake System Warning Lamp Diagnosis
Fig. 23 Brake Warning Lamp Switch
Fig. 24 Combination Oil Sending Unit
SWITCH AND PANEL COMPONENT SERVICE
HEADLAMP SWI TCH
The headl amp, parki ng l amp and hazard swi tches
operate wi th a push-on, push-off acti on. The i nteri or
l amp/di mmi ng control swi tch has a hori zontal sl i di ng
acti on wi th fi ve cl earl y defi ned detent posi ti ons. The
parki ng/headl amp l amp swi tches l atch ON and use a
cross cancel l i ng mechani sm to ensure the two systems
are not ON at once (Fi g. 27).
SWI TCH TEST
(1) Remove headl amp swi tch, refer to Swi tch/Lamp
Repl acement.
(2) Usi ng ohmmeter test conti nui ty between termi -
nal s, refer to Fi g. 28. I f no conti nui ty or not wi thi n
l i mi ts, repl ace headl amp swi tch.
SWI TCH/LAMP REPLACEMENT
wi th a fl at bl ade tool (Fi g. 9).
27).
sembl y.
the functi ons of the headl amp swi tch.
REPLACEMENT
29).
sembl y.
the functi ons of the front and rear wi pe/wash system.
The accessory swi tch carri er consi st of one or more of
the fol l owi ng swi tches (Fi g. 30).
Li ftgate rel ease swi tch
Rear wi ndow defogger swi tch
Fog l amps
Rear A/C heater bl ower
Fig. 25 Combination Oil Sending Unit3.0L Engine
Fig. 26 Combination Oil Sending Unit Terminals
Fig. 27 Headlamp POD Switch
(1) Li ftgate rel ease swi tch operates wi th a push-on
momentary acti on. The swi tch operates a rel ay to
provi de power to the l i ftgate sol enoi d. Vehi cl e must be
i n Park or Neutral and not movi ng for l i ftgate rel ease
swi tch to operate.
(2) The rear wi ndow defogger operates wi th a
push-on and push-off momentary acti on. The swi tch
porti on of the carri er consi sts of a ti mer ci rcui t, rel ay
and a power management ci rcui t. An amber i ndi cator
on the button shows when the swi tch i s ON. Once the
rear wi ndow defogger i s ON, the system shal l remai n
on unti l one of the fol l owi ng occurs:
The swi tch i s actuated agai n by push-off acti on.
Ten mi nutes 2 mi nutes has el apsed si nce the
swi tch has been actuated
The l i ftgate rel ease swi tch i s actuated. Under thi s
condi ti on, the rear wi ndow defogger rel ay contact i s
temporary opened unti l the l i ftgate swi tch i s rel eased.
Thi s power management ci rcui t prevents the pri nted
ci rcui t board of the accessory swi tch carri er from bei ng
damage by too much current fl ow.
(3) Fog l amp swi tch operates wi th a push-on and
push-off momentary acti on. The swi tch porti on of the
carri er has a rel ay and an el ectroni c l atchi ng ci rcui t
and the fol l owi ng:
A green i ndi cator on the button shows when the
swi tch i n ON.
Fog l amps can be turned on onl y when the head-
l amps are on l ow beams.
(4) Power to the rear passenger compartment i s
control l ed by the rear A/C header bl ower swi tch. The
swi tch operates by a hori zontal sl i di ng acti on. The
swi tch has four cl earl y defi ned detent posi ti ons:
Fig. 30 Accessory Switch Carrier
Fig. 28 Headlamp POD Switch Continuity Test
Fig. 29 Rear Wiper/Washer Control POD Switch
(a) The l eft most detent i s OFF posi ti on.
(b) The second detent from the l eft i s the ON
posi ti on. The ON posi ti on suppl i es power to the
swi tch i n the rear passenger compartment. When the
swi tch i s i n any other posi ti on than ON, the rear
passenger compartment swi tch i s over ri dden.
(c) The thi rd detent from the l eft i s the Low
posi ti on.
(d) The fourth detent at the ful l ri ght i s the Hi gh
posi ti on.
ACCESSORY SWITCH CARRIER TEST
(1) Remove swi tch, refer to swi tch repl acement.
(2) Usi ng a vol t/ohm meter, refer to Fi g. 31 for
testi ng of wi re end of connector whi l e connected to
swi tch.
(3) Refer to Fi g. 32 to test A/C heater swi tch. I f
conti nui ty i s not correct repl ace A/C heater swi tch.
ACCESSORY SWITCH CARRIER REPLACEMENT
(1) Remove center bezel usi ng a tri m sti ck from
i nstrument panel (Fi g. 33).
(2) Remove ash recei ver l amp socket from bezel .
(3) Remove accessory swi tch carri er from the panel
(Fi g. 30).
(4) Di sconnect wi re connectors and l amp.
A/C AND HEATER CONTROL/BLOWER SWI TCH
REPLACEMENT
(3) Remove ci gar l i ghter el ement.
(4) Remove accessory swi tch carri er.
(5) Remove two screws and pul l control assembl y
rearward. Reach behi nd control and di sconnect the
wi ri ng harnesses, vacuum l i nes and temperature con-
trol cabl e (Fi g. 34).
A/C AND HEATER CONTROL LAMP REPLACE-
MENT
(5) Remove two screws and pul l control assembl y
rearward. Reach behi nd control and di sconnect l amp
(Fi g. 34).
Fig. 31 Accessory Switch Carrier Test
Fig. 32 A/C Heater Switch Test
REAR A/C-HEATER SWI TCH REPLACEMENT
For the bl ower swi tch on the i nstrument panel , refer
to Accessory Swi tch Carri er Repl acement (Fi g. 30).
The rear A/C-heater swi tch assembl y i n the l eft rear
quarter tri m panel (Fi g. 34).
(1) Usi ng a tri m sti ck pry swi tch from l eft quarter
tri m panel .
(2) Di sconnect wi re connectors.
CI GAR LI GHTER REPLACEMENT
(1) Di sconnect battery
(3) Remove center tri m bezel . Remove ash recei ver
l amp and socket i f a equi pped.
(4) Remove accessory swi tch carri er attachi ng
screws.
(5) Remove A/C heater control attachi ng screws. Pul l
out and di sconnect the wi re connector and control
cabl e(s).
(6) Di sconnect wi re connectors and l amp/socket from
rear of ci gar l i ghter cl amp.
(7) Hol d outer cl amp, whi l e turni ng shel l . Do not
l ose ci gar l i ghter shi el d (Fi g. 36).
FORWARD CONSOLE REMOVAL
(3) Remove fi l l er pl ate (Fi g. 37).
(4) Remove ash recei ver/cup hol di ng assembl y from
consol e. Refer to Ash Recei ver Assembl y for removal .
(5) Remove screws attachi ng consol e to i nstrument
panel :
Two upper corners
Two behi nd ash recei ver
Fig. 33 Center Bezel
Fig. 34 A/C Heater Control
Fig. 35 Rear A/C Heater Control Switch
Two at the l ower bracket
(6) Pul l consol e rearward and di sconnect wi re con-
nector and bul b.
(7) Remove consol e.
CENTER STORAGE MODULE REMOVAL
(3) Remove ash recei ver/cup hol di ng assembl y from
consol e. Refer to Ash Recei ver Assembl y for removal .
(4) Open the storage bi n door and remove the check
strap pi ns so that door swi ngs ful l y open.
(5) Remove four mounti ng screws and storage mod-
ul e.
ASH RECEI VER ASSEMBLY
Depress the ash recei ver/cuphol der assembl y stops
and remove by sl i di ng rearward.
BODY CONTROLLER REPLACEMENT
(1) Remove steeri ng col umn cover to gai n access to
the body control l er (Fi g. 38).
(2) Di sconnect the two 25-way connectors from body
control l er.
(3) Remove mounti ng screws from body control l er.
(4) Pul l to the l eft to rel ease body control l er of S-cl i ps
and remove uni t.
(5) For i nstal l ati on reverse above procedures. En-
sure body control l er i s l ocked i nto the S-cl i ps.
LOWER RIGHT INSTRUMENT PANEL REPLACE-
MENT
(1) Remove center consol e bezel usi ng a tri m sti ck
from i nstrument panel (Fi g. 33).
(3) Remove heater control (Fi g. 34).
(4) Di sconnect ci gar l i ghter.
(5) Remove center or forward consol e, refer to re-
moval procedures (Fi g. 36).
(6) Remove attachi ng screws and ri ght l ower panel
(Fi g. 39).
Fig. 36 Cigar Lighter
Fig. 37 Forward and Center Console
Fig. 38 Instrument Panel Steering Column Cover
INSTRUMENT PANEL REPLACEMENT
WARNING: CHOCK WHEELS WHEN LOWER PANEL
IS TO BE ROLLED DOWN. THE STEERING COLUMN
IS REMOVED AND TRANSMISSION MAY BE OUT OF
PARK. RELEASE THE PARK BRAKE BEFORE THE
RELEASE CABLE IS DISCONNECTED. DISCONNECT-
ING PARK BRAKE CABLE WHILE PARK BRAKE IS
ENGAGED MAY CAUSE PERSONAL INJURY.
(1) Remove steeri ng col umn cover (Fi g. 38). Set
parki ng brake and shi ft gear sel ector i nto l ow.
(2) Remove l ower l eft i nstrument panel si l encer.
(3) Di sconnect PRNDL at col umn.
(a) Unhook PRNDL cabl e eyel et from col umn ac-
tuati ng arm (Fi g. 40).
(b) Rel ease col umn i nsert l ock tab.
(c) Squeeze l egs together and l i ft i nsert from steer-
i ng col umn, l eave i nsert free.
(d) Pl ace cabl e on i nstrument panel to avoi d
PRNDL cabl e damage duri ng removal .
(4) Remove steeri ng col umn, refer to Group 19,
Steeri ng.
(5) Remove l ower ri ght i nstrument panel si l encer
(Fi g. 41).
(6) Remove forward consol e i f necessary.
(7) Remove i nstrument panel speaker gri l l s.
(8) Remove A-pi l l ar i ntermedi ate and si l l scuff gar-
ni sh mol di ngs.
(9) Unfasten the hood rel ease mechani sm from the
si de cowl .
(10) Unfasten the pack brake handl e bracket.
(11) Di sconnect the brake l i ght swi tch, parki ng
brake swi tch and bul k head wi ri ng connectors.
(12) Under the hood di sconnect the ABS connector
and resi stor bl ock. Unseat the grommet at the dash
panel and feed wi ri ng back i nto passenger compart-
ment.
(13) Remove the two nuts securi ng the i nstrument
panel , at the steeri ng col umn support brace.
(14) Loosen the i nstrument panel rol l up bol ts.
(15) Remove screw securi ng i nstrument panel at the
l eft cowl si de ramp bracket.
(16) Remove the si x screws securi ng the i nstrument
panel at the fence l i ne.
(17) Li ft upward on i nstrument panel to cl ear rol l up
ramp. Rol l the i nstrument panel back and hang i t from
the short posi ti on of the rol l up hook.
(18) Wi th i nstrument panel hangi ng i n the short
posi ti on di sconnect the l eft si de body wi ri ng connec-
ti ons.
(19) Rol l the i nstrument panel to the l ong posi ti on
on the rol l up hook and perform the fol l owi ng opera-
ti ons:
(a) Di sconnect the antenna cabl e.
(b) Di sconnect the bl ower motor l ead connecti on.
(c) Di sconnect the temperature control cabl e from
the A/C or heater uni t.
(d) Di sconnect the vacuum l i nes from the cl i mate
control assembl y.
(e) Di sconnect the ri ght si de body wi ri ng connec-
tors.
(20) Remove i nstrument panel from vehi cl e.
Fig. 40 PRNDL Release
Fig. 39 Lower Right Instrument Panel
DOOR COURTESY LAMP/REFLECTOR RE-
PLACEMENT
(1) Detach door tri m panel and al l wi ri ng.
(2) Remove three screws to remove l amp or refl ector.
DOOR COURTESY LAMP BULB REPLACE-
MENT
(1) Use a fl at edge tool to pry l ens off the l amp
assembl y. Start at top and bottom forward porti on of
l amp l ens and move rearward.
(2) Repl ace bul b.
(3) To i nstal l l ens press unti l snap attachments
engage.
DOME LAMP
(1) Pry the l ens from bezel .
(2) Repl ace bul b.
(3) To i nstal l l ens press unti l snap attachments
engage.
LI FTGATE LAMP BULBS REPLACEMENT
To servi ce l i ftgate l amp bul b: The l ens i s part of
speaker gri l l e and cannot be removed separatel y.
(1) Remove the speaker gri l l e/l amp assembl y from
the tri m panel by pryi ng wi th a screw dri ver. There are
two sl ots provi ded at the l ower corners of the speaker
gri l l e.
(3) There i s an i nsul ator assembl y on the back si de
of gri l l e. Use a screw dri ver i n sl ot provi ded to pry the
i nsul ator from the gri l l e.
(4) Repl ace bul b.
GLOVEBOX LI GHT SWI TCH REPLACEMENT
(1) Pry gl ovebox l i ght swi tch from the gl ovebox (re-
pl ace l amp i f necessary).
PRNDL REPLACEMENT
Fig. 41 Instrument Panel
nector.
(3) Remove steeri ng col umn cover (Fi g. 38). Set
parki ng brake and shi ft gear sel ector i nto l ow.
nectors
(5) Remove four screws securi ng cl uster. Rotate cl us-
ter and di sconnect connector, to access PRNDL attach-
i ng screws. Remove two screws attachi ng PRNDL to
cl uster (Fi g. 11).
(6) For el ectroni c i nstrument cl uster i f equi pped:
(a) Remove four screws securi ng cl uster.
(b) Remove four screws attachi ng mask to hous-
i ng.
(c) Rotate mask down then di sconnect buttons and
PRNDL.
(d) Remove two screws attachi ng PRNDL to mask.
(8) Unhook PRNDL cabl e eyel et from col umn actu-
ati ng arm (Fi g. 40).
(9) Rel ease col umn i nsert l ock tab, squeeze l egs
together and l i ft i nsert from steeri ng col umn, l eave
i nsert free.
(10) Remove PRNDL assembl y.
IGNITION SYSTEMS
CONTENTS
page page
2. 5L AND 3. 0L IGNITION SYSTEMS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . 10
SERVICE PROCEDURES . . . . . . . . . . . . . . . . 13
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . 1
3. 3L IGNITION SYSTEMDIAGNOSTIC
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 32
3. 3L IGNITION SYSTEMSYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3. 3L IGNITION SYSTEMSSERVICE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 35
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . 40
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 42
2.5L AND 3.0L I GNI TI ON SYSTEMSSYSTEM OPERATI ON
INDEX
page page
Auto Shutdown (ASD) Relay and Fuel Pump Relay . 8
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . 7
Distributor Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Distributor Pick-Up3.0L Engine . . . . . . . . . . . . . . 7
Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hall Effect Pick-Up2.5L Engines . . . . . . . . . . . . . 6
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manifold Absolute Pressure (MAP) Sensor . . . . . . . 7
Rotor2.5L and 3.0L Engines . . . . . . . . . . . . . . . . 2
Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . . 2
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
Thi s secti on descri bes the i gni ti on systems of the
2.5L and 3.0L engi nes.
On Board Di agnosti cs i s descri bed i n the Fuel I njec-
ti on Secti ons of Group 14.
Group 0, Lubri cati on and Mai ntenance, contai ns
general mai ntenance i nformati on for i gni ti on rel ated
i tems. The Owners Manual al so contai ns mai ntenance
i nformati on.
DISTRIBUTOR CAP
Remove the di stri butor cap and i nspect the i nsi de for
fl ashover, cracki ng of carbon button, l ack of spri ng
tensi on on carbon button, cracki ng of cap, and burned,
worn termi nal s (Fi g. 1). Al so check for broken di stri bu-
tor cap towers. I f any of these condi ti ons are present
the di stri butor cap and/or cabl es shoul d be repl aced.
When repl aci ng the di stri butor cap, transfer spark
pl ug wi res from the ori gi nal cap to the new cap one at
a ti me. Ensure that each wi re i s i nstal l ed i nto the
tower of the new cap that corresponds to i ts tower
posi ti on i n the ori gi nal cap. Ful l y seat the wi res i nto
the towers. I f necessary, refer to the appropri ate engi ne
fi ri ng order di agram (Fi g. 2 or Fi g. 3).
Li ght scal i ng of the termi nal s can be cl eaned wi th a
sharp kni fe. I f the termi nal s are heavl y scal ed, repl ace
the di stri butor cap.
A cap that i s greasy, di rty or has a powder-l i ke
substance on the i nsi de shoul d be cl eaned wi th a
sol uti on of warm water and a mi l d detergent. Scrub the
cap wi th a soft brush. Thoroughl y ri nse the cap and dry
i t wi th a cl ean soft cl oth.
Fig. 1 Distributor Cap Inspection
IGNITION SYSTEMS 8D - 1
ROTOR2. 5L AND 3. 0L ENGINES
Repl ace the rotor i f i t i s cracked, the ti p i s excessi vel y
burned or heavi l y scal ed (Fi g. 4). I f the spri ng termi nal
does not have adequate tensi on, repl ace the rotor.
SPARK PLUG CABLES
Spark Pl ug cabl es are someti mes referred to as
secondary i gni ti on wi res. They transfer el ectri cal cur-
rent from the di stri butor to i ndi vi dual spark pl ugs at
each cyl i nder. 2.5L and 3.0L engi nes use resi stance
type cabl es. The cabl es suppress radi o frequency emi s-
si ons from the i gni ti on system.
Check the spark pl ug cabl e connecti ons for good
contact at the coi l and di stri butor cap towers and at the
spark pl ugs. Termi nal s shoul d be ful l y seated. The
ni ppl es and spark pl ug covers shoul d be i n good condi -
ti on. Ni ppl es shoul d fi t ti ghtl y on the coi l and di stri bu-
tor cap towers and spark pl ug cover shoul d fi t ti ght
around spark pl ug i nsul ators. Cabl e connecti ons that
are l oose wi l l corrode and i ncrease the resi stance and
permi t water to enter the towers causi ng i gni ti on
mal functi on. To maintain proper sealing at the
terminal connections, the connections should
not bebroken unlesstestingindicateshigh resis-
tance, an open circuit or other damage.
CAUTION: Do not pull spark plug cables from dis-
tributor cap of four cylinder engines. The cables must
be released from inside the distributor cap (Fig. 5).
Cl ean hi gh tensi on cabl es wi th a cl oth moi stened
wi th a non-fl ammabl e sol vent and wi pe dry. Check for
bri ttl e or cracked i nsul ati on.
When testi ng secondary cabl es for punctures and
cracks wi th an osci l l oscope, fol l ow the equi pment
manufacturers i nstructi ons.
I f an osci l l oscope i s not avai l abl e, secondary cabl es
can be tested as fol l ows:
Fig. 2 Engine Firing Order2.5L Engine
Fig. 3 engine firing order3.0l engine
Fig. 4 Rotor InspectionTypical
Fig. 5 Spark Plug Cable Removal/Installation2.5L
Engines
8D - 2 IGNITION SYSTEMS
CAUTION: Do not leave any one spark plug cable
disconnected any longer than necessary during test-
ing. Excessive heat could damage the catalytic con-
verter. Total test time must not exceed ten minutes.
(a) Wi th the engi ne not runni ng, connect one end
of a test probe (i .e. a pi ece of wi re wi th i nsul ated
al l i gator cl i ps on each end) to a good ground, other
end free for probi ng.
(b) Wi th engi ne runni ng, move test probe al ong
enti re l ength of al l cabl es (approxi matel y 0 to 1/8
i nch gap). I f punctures or cracks are present there
wi l l be a noti ceabl e spark jump from the faul ty area
to the probe. Check the coi l cabl e the same way.
Repl ace cracked, l eaki ng or faul ty cabl es.
When replacingthecables, install thenewhigh
tension cable and nipple assembly over cap or
coil tower. When entering the terminal into the
tower, push lightly, then pinch the large diam-
eter of nippleto releaseair trapped between the
nippleand tower. Continuepushingon thecable
andnippleuntil cablesareproperlyseatedinthe
cap towers. Snap should be heard as terminal
goes into place.
Use the same procedure to i nstal l cabl e i n coi l tower.
Wi pe the spark pl ug i nsul ator cl ean before rei nstal l i ng
cabl e and cover.
Use the fol l owi ng procedure when removi ng the hi gh
tensi on cabl e from the spark pl ug. Fi rst, remove the
cabl e from the retai ni ng bracket. Then grasp the ter-
mi nal as cl ose as possi bl e to the spark pl ug. Rotate the
cover and pul l the cabl e strai ght back. Pullingon the
cableitself will damagetheconductor andtermi-
nal connection. Do not usepliers and do not pull
the cable at an angle. Doing so will damage the
insulation, cable terminal or the spark plug in-
sulator. Wipe spark plug insulator clean before
reinstalling cable and cover.
Resi stance type cabl e i s i denti fi ed by the words
Electronic Suppression pri nted on the cabl e jacket.
Use an ohmmeter to check resi stance type cabl e for
open ci rcui ts, l oose termi nal s or hi gh resi stance as
fol l ows:
(a) Remove cabl e from spark pl ug.
(b) Li ft di stri butor cap from di stri butor wi th
cabl es i ntact. Donot removecablesfromcap. The
cabl es must be removed from the spark pl ugs.
(c) Connect the ohmmeter between spark pl ug end
termi nal and the correspondi ng el ectrode i nsi de the
cap, make sure ohmmeter probes are i n good contact.
Resi stance shoul d be wi thi n tol erance shown i n the
cabl e resi stance chart. I f resi stance i s not wi thi n
tol erance, remove cabl e at cap tower and check the
cabl e. I f resi stance i s sti l l not wi thi n tol erance,
repl ace cabl e assembl y. Test al l spark pl ug cabl es i n
same manner.
To test coi l to di stri butor cap hi gh tensi on cabl e,
remove di stri butor cap wi th the cabl e i ntact. Do not
remove cable fromthe cap. Connect the ohmmeter
between center contact i n the cap and remove the cabl e
at coi l tower and check cabl e resi stance. I f resi stance i s
not wi thi n tol erance, repl ace the cabl e. Al so, check for
a l oose connecti on at the tower or for a faul ty coi l .
I nspect coi l tower for cracks or carbon tracki ng.
SPARK PLUGS
Resi stor spark pl ugs are used i n al l engi nes and have
resi stance val ues of 6,000 to 20,000 ohms when
checked wi th at l east a 1000 vol t tester.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken porce-
l ai n i nsul ators. Keep pl ugs arranged i n the order i n
whi ch they were removed from the engi ne. An i sol ated
pl ug di spl ayi ng an abnormal condi ti on i ndi cates that a
probl em exi sts i n the correspondi ng cyl i nder. Repl ace
spark pl ugs at the i nterval s recommended i n Group O.
Undamaged l ow mi l eage spark pl ugs can be cl eaned
and reused. Refer to the Spark Pl ug Condi ti on secti on
of thi s group. After cl eani ng, fi l e the center el ectrode
fl at wi th a smal l poi nt fi l e or jewel ers fi l e. Adjust the
gap between the el ectrodes (Fi g. 6) to the di mensi ons
speci fi ed i n the chart at the end of thi s secti on.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap. Ti ghten 2.5L and 3.0L
engi ne spark pl ugs to 28 Nm (20 ft. l bs.) torque.
SPARK PLUG CONDI TI ON
NORMAL OPERATING CONDITIONS
The few deposi ts present wi l l be probabl y l i ght tan or
sl i ghtl y gray i n col or wi th most grades of commerci al
gasol i ne (Fi g. 7). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than ap-
proxi matel y 0.025 mm (.001 i n) per 1600 km (1000
mi l es) of operati on. Spark pl ugs that have normal wear
can usual l y be cl eaned, have the el ectrodes fi l ed and
regapped, and then rei nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
coats the enti re ti p of the spark pl ug wi th a
CABLE RESI STANCE CHART
rust col or deposi t. The rust col or deposi ts coul d be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. MMT deposi ts do not affect spark
pl ug performance.
COLD FOULING (CARBON FOULING)
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 7). A dry, bl ack deposi t on one or two
pl ugs i n a set may be caused by sti cki ng val ves or
defecti ve spark pl ug cabl es. Col d (carbon) foul i ng of the
enti re set may be caused by a cl ogged ai r cl eaner.
Col d foul i ng i s normal after short operati ng peri ods.
The spark pl ugs do not reach a hi gh enough operati ng
temperature duri ng short operati ng peri ods.
WET FOULING
A spark pl ug that i s coated wi th excessi ve wet fuel or
oi l i s wet foul ed. I n ol der engi nes, wet foul i ng can be
caused by worn ri ngs or excessi ve cyl i nder wear.
Break-in fouling of new engines may occur be-
fore normal oil control is achieved. In new or
recently overhauled engines, wet fouled spark
plugs can be usually be cleaned and reinstalled.
OIL OR ASH ENCRUSTED
I f one or more pl ugs are oi l or oi l ash encrusted, the
engi ne shoul d be eval uated for the cause of oi l entry
i nto the combusti on chamber (Fi g. 8).
HIGH SPEED MISS
When repl aci ng spark pl ugs because of a hi gh speed
mi ss condi ti on; wide open throttle operation
should be avoided for approximately 80 km (50
miles) after installation of new plugs. Thi s wi l l
al l ow deposi t shi fti ng i n the combusti on chamber to
take pl ace gradual l y and avoi d pl ug destroyi ng spl ash
foul i ng shortl y after the pl ug change.
ELECTRODE GAP BRIDGING
Loose deposi ts i n the combusti on chamber can cause
el ectrode gap bri dgi ng. The deposi ts accumul ate on the
spark pl ugs duri ng conti nuous stop-and-go dri vi ng.
When the engi ne i s suddenl y subjected to a hi gh torque
l oad, the deposi ts parti al l y l i quefy and bri dge the gap
between the el ectrodes (Fi g. 9). Thi s short ci rcui ts the
el ectrodes. Spark pl ugs wi th el ectrode gap bri dgi ng can
be cl eaned usi ng standard procedures.
Fig. 6 Setting Spark Plug Electrode GapTypical
Fig. 7 Normal Operation and Cold (Carbon) Fouling
Fig. 8 Oil or Ash Encrusted
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or
yel l ow (Fi g. 10). They may appear to be harmful , but
are a normal condi ti on caused by chemi cal addi ti ves i n
certai n fuel s. These addi ti ves are desi gned to change
the chemi cal nature of deposi ts and decrease spark
pl ug mi sfi re tendenci es. Noti ce that accumul ati on on
the ground el ectrode and shel l area may be heavy but
the deposi ts are easi l y removed. Spark pl ugs wi th
scavenger deposi ts can be consi dered normal i n condi -
ti on and cl eaned usi ng standard procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the spark
pl ug el ectrode gap. Under certai n condi ti ons, severe
detonati on al so can separate the i nsul ator from the
center el ectrode (Fi g. 11). Repl ace spark pl ugs wi th
chi pped el ectrode i nsul ators.
PREIGNITION DAMAGE
Excessi ve combusti on chamber temperature can
cause prei gni ti on damage. The center el ectrode di s-
sol ves fi rst and the ground el ectrode di ssol ves some-
what l ater (Fi g. 12). I nsul ators appear rel ati vel y de-
posi t free. Determi ne i f the spark pl ug has the correct
heat range rati ng for the engi ne, i f i gni ti on ti mi ng i s
over advanced or i f other operati ng condi ti ons are
causi ng engi ne overheati ng. (The heat range rati ng
refers to the operati ng temperature of a parti cul ar type
spark pl ug. Spark pl ugs are desi gned to operate wi thi n
speci fi c temperature ranges dependi ng upon the thi ck-
ness and l ength of the center el ectrode and porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
13). The i ncrease i n el ectrode gap wi l l be consi derabl y
i n excess of 0.001 i n per 1000 mi l es of operati on. Thi s
suggests that a pl ug wi th a cool er heat range rati ng
shoul d be used. Over advanced i gni ti on ti m-
Fig. 10 Scavenger Deposits Fig. 12 Preignition Damage
Fig. 9 Electrode Gap Bridging Fig. 11 Chipped Electrode Insulator
i ng, detonati on and cool i ng system mal functi ons al so
can cause spark pl ug overheati ng.
SPARK PLUG SERVI CE
When repl aci ng the spark pl ug and coi l cabl es, route
the cabl es correctl y and secure them i n the appropri ate
retai ners. Fai l ure to route the cabl es properl y can
cause the radi o to reproduce i gni ti on noi se, cross i gni -
ti on of the spark pl ugs or short ci rcui t the cabl es to
ground.
SPARK PLUG REMOVAL
Al ways remove the spark pl ug cabl e by graspi ng at
the spark pl ug boot, turni ng the boot 1/2 turn and
pul l i ng strai ght back i n a steady moti on.
(1) Pri or to removi ng the spark pl ug spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug.
(2) Remove the spark pl ug usi ng a qual i ty socket
wi th a rubber or foam i nsert.
(3) I nspect the spark pl ug condi ti on. Refer to Spark
Pl ug Condi ti on i n thi s secti on.
SPARK PLUG GAP ADJUSTMENT
(1) Check the spark pl ug gap wi th a gap gauge. I f the
gap i s not correct, adjust i t by bendi ng the ground
el ectrode (Fi g. 6).
SPARK PLUG INSTALLATION
(1) To avoi d cross threadi ng, start the spark pl ug
i nto the cyl i nder head by hand.
(2) Ti ghten spark pl ugs to 28 Nm (20 ft. l bs.)
torque.
(3) I nstal l spark pl ug cabl es over spark pl ugs.
ENGINE CONTROLLER
The i gni ti on system i s regul ated by the Si ngl e board
Engi ne Control l er I I (SBEC I I ), referred to in this
manual as the Engine Controller (Fig. 14). The
control l er suppl i es battery vol tage to the i gni ti on coi l
through the Auto Shutdown (ASD) Rel ay. The control -
l er al so control s the ground ci rcui t for the i gni ti on coi l .
By swi tchi ng the ground path for the coi l on and off, the
engi ne control l er adjusts i gni ti on ti mi ng to meet
changi ng engi ne operati ng condi ti ons.
Duri ng the crank-start peri od the control l er ad-
vances i gni ti on ti mi ng a set amount. Duri ng engi ne
operati on, the amount of spark advance provi ded by
the engi ne control l er i s determi ned by three i nput
factors:
cool ant temperature
engi ne RPM
avai l abl e mani fol d vacuum
The engi ne control l er al so regul ates the fuel i njecti on
system. Refer to the Fuel I njecti on secti ons of Group
14.
HALL EFFECT PICK-UP2. 5L ENGINES
The hal l effect pi ck-up (Fi g. 15) i s l ocated i n the
di stri butor assembl y. I t suppl i es engi ne rpm and i gni -
ti on ti mi ng data to the engi ne control l er. Thi s al l ows
the engi ne control l er to advance or retard the i gni ti on
spark as requi red by di fferent operati ng condi ti ons.
Fig. 13 Spark Plug Overheating
Fig. 14 Engine Controller
Fig. 15 Hall Effect Distributor2.5L Engines
DISTRIBUTOR PICK-UP3. 0L ENGINE
The di stri butor pi ck-up provi des two i nputs to the
engi ne control l er. From one i nput the engi ne control l er
determi nes RPM (engi ne speed). From the other i nput
i t deri ves crankshaft posi ti on. The engi ne control l er
regul ates i njector synchroni zati on and adjusts i gni ti on
ti mi ng and engi ne speed based on these i nputs.
The di stri butor pi ck-up contai ns two si gnal genera-
tors. The pi ck-up uni t consi sts of 2 l i ght emi tti ng
di odes (LED), 2 photo di odes, and a separate ti mi ng
di sk. The ti mi ng di sk contai ns two sets of sl ots. Each
set of sl ots rotates between a l i ght emi tti ng di ode and
a photo di ode (Fi g. 16). The i nner set contai ns 6 l arge
sl ots, one for each cyl i nder. The outer set contai ns
several smal l er sl ots.
The outer set of sl ots on the rotati ng di sk represents
2 degrees of crankshaft rotati on. Up to 1200 engi ne
RPM, the control l er uses the i nput from the outer set of
sl ots to i ncrease i gni ti on ti mi ng accuracy.
The outer set of sl ots contai ns a 10 degree fl at spot.
Thi s area i s not sl otted (Fi g. 17). The fl at spot tel l s the
engi ne control l er that the next pi ston at TDC wi l l be
number 6. Each pi stons posi ti on i s referenced by one of
the si x i nner sl ots (Fi g. 17).
As each sl ot on the ti mi ng di sk passes between the
di odes, they i nterrupt the beam from the l i ght emi tti ng
di ode. Thi s creates an al ternati ng vol tage i n each photo
di ode whi ch i s converted i nto on-off pul ses. The pul ses
are the i nput to the engi ne control l er.
Duri ng cranki ng, the engi ne control l er cannot deter-
mi ne whi ch cyl i nder wi l l be at TDC unti l the 10 degree
fl at spot on the outer set of sl ots rotates through the
opti cal uni t. Once the fl at spot i s detected, the control -
l er knows pi ston i n cyl i nder number 6 wi l l be the next
pi ston at TDC.
Si nce the di sk rotates at hal f crankshaft speed, i t
may take up to 2 engi ne revol uti ons duri ng cranki ng
before the engi ne control l er determi nes the posi ti on of
pi ston number 6. For thi s reason the engi ne control l er
energi zes al l si x i njectors at the same ti me unti l i t
senses the posi ti on of pi ston number 6.
COOLANT TEMPERATURE SENSOR
On 2.5L engi nes, the cool ant temperature sensor i s
i nstal l ed behi nd the thermostat housi ng and i gni ti on
coi l i n the hot box (Fi g. 18). On 3.0L engi nes the sensor
i s l ocated next to the thermostat housi ng (Fi g. 19). The
sensor provi des an i nput vol tage to the engi ne control -
l er. The sensor i s a vari abl e resi stance (thermi stor)
wi th a range of -40F to 265F. As cool ant temperature
vari es, the sensors resi stance changes, resul ti ng i n a
di fferent i nput vol tage to the engi ne control l er.
The engi ne control l er contai ns di fferent spark ad-
vance schedul es for col d and warm engi ne operati on.
The schedul es reduce engi ne emi ssi ons and i mprove
dri veabi l i ty. Because spark advance changes at di ffer-
ent engi ne operati ng temperatures duri ng warm-up,
al l spark advance testi ng shoul d be done wi th the
engi ne ful l y warmed.
When the engi ne i s col d, the engi ne control l er de-
mands sl i ghtl y ri cher ai r-fuel mi xtures and hi gher i dl e
speeds unti l normal operati ng temperatures are
reached.
The cool ant sensor i nput i s al so used for cool i ng fan
control .
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d and provi des an i nput vol tage to the
engi ne control l er. As engi ne l oad changes, mani fol d
pressure vari es. The changes i n engi ne l oad causes the
MAP sensors resi stance to change. The change i n MAP
sensor resi stance resul ts i n a di fferent i nput vol tage to
the engi ne control l er.
Fig. 16 Distributor Pick-up3.0L Engine
Fig. 17 Inner and Outer Slots of Rotating Disk3.0L
Engine
The i nput vol tage l evel suppl i es the engi ne control l er
wi th i nformati on rel ati ng to ambi ent barometri c pres-
sure duri ng engi ne start-up (cranki ng) and engi ne l oad
whi l e i ts operati ng. The engi ne control l er uses thi s
i nput al ong wi th i nputs from other sensors to adjust
ai r-fuel mi xture.
On 2.5L engi nes, the MAP sensor i s mounted to the
dash panel (Fi g. 20). On 3.0L engi nes, the sensor i s
mounted to a bracket across from the di stri butor (Fi g.
21). The sensor i s connected to the throttl e body wi th a
vacuum hose and to the engi ne control l er el ectri cal l y.
AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP
RELAY
The engi ne control l er operates the auto shutdown
(ASD) rel ay and fuel pump rel ay through one ground
path. The control l er operates the rel ays by swi tchi ng
the ground path on and off. Both rel ays turn on and off
at the same ti me.
The ASD rel ay connects battery vol tage to the fuel
i njector and i gni ti on coi l . The fuel pump rel ay connects
battery vol tage to the fuel pump and oxygen sensor
heati ng el ement.
The engi ne control l er turns the ground path off when
the i gni ti on swi tch i s i n the Off posi ti on. Both rel ays
are off. When the i gni ti on swi tch i s i n the On or Crank
posi ti on, the engi ne control l er moni tors the di stri butor
pi ck-up si gnal to determi ne engi ne speed and i gni ti on
ti mi ng (coi l dwel l ). I f the engi ne control l er does not
reci eve a di stri butor si gnal when the i gni ti on swi tch i s
i n the Run posti on, i t wi l l de-energi ze both rel ays.
When the rel ays are de-energi zed, battery vol tage i s
not suppl i ed to the fuel i njector, i gni ti on coi l , fuel pump
and oxygen sensor heati ng el ement.
The ASD rel ay and fuel pump rel ay are mounted on
the dri vers si de fender wel l , near to the engi ne control -
l er (Fi g. 22).
Fig. 18 Coolant Temperature Sensor2.5L Engines
Fig. 19 Coolant Temperature Sensor3.0L Engines
Fig. 20 MAP Sensor2.5L TBI Engines
Fig. 21 MAP Sensor3.0L Engine
IGNITION COIL
The 2.5L and 3.0L engi nes use an epoxy type coi l .
The coi l s are not oi l fi l l ed. The wi ndi ngs are embedded
i n a heat and vi brati on resi stant epoxy compound.
The engi ne control l er operates the i gni ti on coi l
through the auto shutdown (ASD) rel ay. When the
rel ay i s energi zed by the engi ne control l er, battery
vol tage i s connected to the i gni ti on coi l posi ti ve termi -
nal . The engi ne control l er wi l l de-energi ze the ASD
rel ay i f i t does not recei ve an i nput from the di stri butor
pi ck-up. Refer to Auto Shutdown (ASD) Rel ay and Fuel
Pump Rel ay i n thi s secti on.
On 2.5L engi nes the i gni ti on coi l i s mounted to the
thermostat housi ng (Fi g. 23). On 3.0L engi nes the coi l
i s mounted on the rear of the i ntake mani fol d next to
the ai r cl eaner (Fi g. 24).
Fig. 22 Auto Shutdown Relay and Fuel Pump Relay
Fig. 23 Ignition Coil2.5L Engine
2.5L AND 3.0L I GNI TI ON SYSTEMSDI AGNOSTI C PROCEDURES
INDEX
page page
Coolant Temperature Sensor Test . . . . . . . . . . . . . 12
Failure to Start Test2.5L TBI and 3.0L Engines . . 11
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Manifold Absolute Pressure (MAP) Sensor Test . . . 12
Poor Performance Test . . . . . . . . . . . . . . . . . . . . . 12
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing for Spark at Coil . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
For addi ti onal i nformati on, refer to On Board Di ag-
nosti cs i n the Fuel I njecti on General Di agnosi s sec-
ti ons of Group 14.
SPARK PLUGS
Faul ty or foul ed spark pl ugs may perform wel l at i dl e
speed, but frequentl y fai l at hi gher engi ne speeds.
Faul ty pl ugs can be i denti fi ed i n a number of ways:
poor fuel economy, power l oss, decrease i n engi ne
speed, hard starti ng and, i n general , poor engi ne
performance.
Spark pl ugs al so mal functi on because of carbon foul -
i ng, excessi ve el ectrode ai r gap, or a broken i nsul ator.
Refer to the General I nformati on Secti on of thi s group
for spark pl ug di agnosi s.
IGNITION COIL
The i gni ti on coi l i s desi gned to operate wi thout an
external bal l ast resi stor.
I nspect the coi l for arci ng. Test the coi l accordi ng to
coi l tester manufacturers i nstructi ons. Test coi l pri -
mary and secondary resi stance. Repl ace any coi l that
does not meet speci fi cati ons. Refer to the Coi l Resi s-
tance chart.
I f the i gni ti on coi l i s repl aced due to a burned tower,
carbon tracki ng, arci ng at the tower, or damage to the
termi nal or boot on the coi l end of the secondary cabl e,
the cabl e must be repl aced. Arci ng at the tower wi l l
carboni ze the ni ppl e whi ch, i f i t i s connected to a new
coi l , wi l l cause the coi l to fai l .
I f a secondary cabl e shows any si gns of damage, the
cabl e shoul d be repl aced wi th a new cabl e and new
termi nal . Carbon tracki ng on the ol d cabl e can cause
arci ng and the fai l ure of a new coi l .
TESTING FOR SPARK AT COIL
WARNING: APPLY PARKING BRAKE AND/OR BLOCK
THE WHEELS BEFORE PERFORMING ANY TEST
WITH THE ENGINE RUNNING.
CAUTION: Spark plug cables may be damaged if this
test is performed with more than 1/4 inch clearance
between the cable and engine ground.
Remove the coi l secondary cabl e from the di stri butor
cap. Hol d the end of cabl e about 6 mm (1/4-i nch) away
from a good engi ne ground (Fi g. 1). Crank the engi ne
and i nspect for spark at the coi l secondary cabl e.
There must be a constant spark at the coi l secondary
cabl e. I f the spark i s constant, have a hel per conti nue
to crank engi ne and, whi l e sl owl y movi ng coi l second-
ary cabl e away from ground, l ook for arci ng at the coi l
tower. I f arci ng occurs at the tower, repl ace the coi l . I f
spark i s not constant or there i s no spark, proceed to
the fai l ure to start test.
I f a constant spark i s present and no arci ng occurs at
the coi l tower, the i gni ti on system i s produci ng the
necessary hi gh secondary vol tage. However, make sure
that the spark pl ugs are fi ri ng. I nspect the di stri butor
rotor, cap, spark pl ug cabl es, and spark pl ugs. I f they
are i n proper worki ng order, the
COI L RESI STANCE
i gni ti on system i s not the reason why the engi ne wi l l
not start. I nspect the fuel system and engi ne for proper
operati on.
FAILURE TO START TEST2. 5L TBI AND 3. 0L
ENGINES
Before proceeding with this test make sure
Testing For Spark At Coil has been performed.
Failure to do this may lead to unnecessary diag-
nostic time and wrong test results.
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY TEST WITH THE ENGINE RUNNING.
(1) Battery vol tage must be at l east 12.4 vol ts to
perform test.
(2) Crank the engi ne for 5 seconds whi l e moni tori ng
the vol tage at the coi l posi ti ve (+) termi nal (Fi g. 2 or
Fi g. 3). I f the vol tage remai ns near zero duri ng the
enti re peri od of cranki ng, refer to Group 14 for On-
Board Di agnosti c checks. These checks wi l l hel p di ag-
nose probl ems wi th the engi ne control l er and auto
shutdown rel ay.
(3) I f vol tage i s at near-battery vol tage and drops to
zero after 1-2 seconds of cranki ng, see Group 14 for
On-Board Di agnosti c check for the di stri butor refer-
ence pi ckup ci rcui t to the engi ne control l er.
(4) I f vol tage remai ns at near battery vol tage duri ng
the enti re 5 seconds, with the key off, remove the
engi ne control l er 60-way connector. Check the 60-way
connector for any termi nal s that are pushed out or
l oose.
(5) Remove the connector to coi l (+) and connect a
jumper wi re between battery (+) and coi l (+).
(6) Usi ng the speci al jumper (Fi g. 4), momentari l y
ground termi nal #19 of the 60-way connector (Fi g. 5). A
spark shoul d be generated when the ground i s re-
moved.
Fig. 1 Checking for Spark
Fig. 2 Coil Terminals2.5L Engines
Fig. 3 Coil Terminals3.0L Engine
Fig. 4 Special Jumper to Ground Coil Negative
Fig. 5 60-Way Electrical Connector, Engine Control-
ler
(7) I f spark i s generated, repl ace the engi ne control -
l er.
(8) I f no spark i s seen, use the speci al jumper to
ground the coi l (-) termi nal di rectl y.
(9) I f spark i s produced, i nspect wi ri ng harness for
an open condi ti on.
(10) I f no spark i s produced, repl ace the i gni ti on coi l .
POOR PERFORMANCE TEST
To prevent unnecessary diagnostic time and
possible incorrect results, the TestingFor Spark
At Coil procedure should be performed before
this test.
THE WHEELS BEFORE PERFORMING ANY ENGINE
RUNNING TESTS.
Check and adjust basi c ti mi ng (refer to the speci fi ca-
ti on secti on of thi s group and see servi ce procedures).
Refer to Group 14, General Di agnosi s On Board
Di agnosti cs.
COOLANT TEMPERATURE SENSOR TEST
(1) Wi th key off, di sconnect wi re connector from
cool ant temperature sensor (Fi g. 6).
(2) Connect one l ead of ohmmeter to one termi nal of
cool ant temperature sensor.
(3) Connect the other l ead of ohmmeter to remai ni ng
connector of cool ant temperature sensor. The ohmme-
ter shoul d read as fol l ows;
Engi ne/Sensor at normal operati ng temperature
around 200F shoul d read approxi matel y 700 to 1,000
ohms.
Engi ne/Sensor at room temperature around 70F,
ohmmeter shoul d read approxi matel y 7,000 to 13,000
ohms.
See On Board Diagnostics in the General
Diagnosis section of Group 14, or refer to the
appropriate diagnostic manual for further test
procedures.
TEST
Refer to Board Di agnosti cs i n the Fuel I njecti on
General Di agnosi s secti ons of Group 14, or the appro-
pri ate Powertrai n Di agnosti c Procedures manual for
further test procedures.
Fig. 6 Coolant Temperature Sensor Test
2.5L AND 3.0L I GNI TI ON SYSTEMSSERVI CE PROCEDURES
INDEX
page page
Coolant Temperature Sensor . . . . . . . . . . . . . . . . 13
Distributor Pick-Up2.5L Engine . . . . . . . . . . . . . 19
Distributor Service3.0L Engine . . . . . . . . . . . . . 19
Distributor2.5L Engine . . . . . . . . . . . . . . . . . . . . 18
Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . 13
Idle RPM Test2.5L and 3.0L Engines . . . . . . . . . 15
Ignition Coil2.5L TBI Engines . . . . . . . . . . . . . . 14
Ignition Coil3.0L Engines . . . . . . . . . . . . . . . . . . 14
Ignition Timing Procedure2.5L TBI and
3.0L Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold Absolute Pressure (MAP) Sensor
Service2.5L TBI and 3.0L Engines . . . . . . . . . 24
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE CONTROLLER
The engi ne control l er i s l ocated next to the battery
(Fi g. 1).
REMOVAL
(1) Remove ai r cl eaner duct or ai r cl eaner assembl y.
(2) Remove battery.
(3) Remove engi ne control l er mounti ng screws.
(4) Remove 60-way wi ri ng connector from the engi ne
control l er.
(5) Remove control l er.
I NSTALLATI ON
(1) Connect 60-Way el ectri cal connector to Engi ne
Control l er (Fi g. 1).
(2) I nstal l engi ne control l er. Ti ghten mounti ng
screws.
(3) I nstal l battery.
(4) I nstal l ai r cl eaner duct or ai r cl eaner assembl y.
On 2.5L engi nes the cool ant temperature sensor i s
l ocated behi nd the i gni ti on coi l (Fi g. 2). On 3.0L en-
gi nes the sensor i s l ocated next to the thermostat
housi ng (Fi g. 3).
REMOVAL
(1) Drai n cool i ng system unti l cool ant l evel i s bel ow
cool ant sensor. Refer to Group 7, Cool i ng System.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from engi ne.
I NSTALLATI ON
(1) I nstal l cool ant sensor. Ti ghten 2.5L engi ne cool -
ant sensor to 28 Nm (20 ft. l bs.) torque. Ti ghten the
3.0L engi ne cool ant sensor to 7 Nm (60 i n. l bs.) torque.
(2) Connect el ectri cal connector to sensor.
(3) Fi l l cool i ng system. Refer to Group 7, Cool i ng
System.
Fig. 2 Coolant Temperature Sensor2.5L TBI En-
gines
IGNITION COIL2. 5L TBI ENGINES
The i gni ti on coi l mounts to the thermostat housi ng
(Fi g. 4).
REMOVAL
(1) Di sconnect the coi l to di stri butor i gni ti on cabl e
(Fi g. 4).
(2) Di sconnect the wi ri ng harness connector from
the coi l .
(3) Remove i gni ti on coi l mounti ng screws.
I NSTALLATI ON
(1) I nstal l i gni ti on coi l onto the bracket. Ti ghten the
screws to 9.5 Nm (85 i n. l bs.) torque.
(2) Connect the wi ri ng harness connector.
(3) Connect the coi l to di stri butor i gni ti on cabl e.
IGNITION COIL3. 0L ENGINES
The i gni ti on coi l i s l ocated at the back of the i ntake
mani fol d (Fi g. 5).
REMOVAL
(2) Di sconnect i gni ti on cabl e from coi l .
(3) Di sconnect wi ri ng harness connector from coi l .
(4) Remove coi l mounti ng screws.
I NSTALLATI ON
(1) Loosel y i nstal l i gni ti on coi l on i ntake mani fol d.
Ti ghten the i ntake mani fol d fastener to 13 Nm (115
i n.l bs.) torque. Ti ghten i gni ti on coi l bracket fasteners
to 10 Nm (96 i n. l bs.) torque.
(2) Connect the wi ri ng harness connector.
(3) Connect the coi l to di stri butor i gni ti on cabl e.
(4) I nstal l the ai r cl eaner assembl y. Ti ghten the ai r
cl eaner fasteners to 25 Nm (225 i n. l bs.) torque.
SPARK PLUG SERVICE
When repl aci ng the spark pl ug and coi l cabl es, route
the cabl es correctl y and secure them i n the appropri ate
cause the radi o to reproduce i gni ti on noi se, cause cross
i gni ti on of the spark pl ugs or short ci rcui t the cabl es to
ground.
SPARK PLUG REMOVAL
Fig. 3 Coolant Temperature Sensor3.0L Engine
Fig. 4 Ignition Coil2.5L Engines
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
torque.
IDLE RPM TEST2. 5L AND 3. 0L ENGINES
WHEELS BEFORE PERFORMING IDLE CHECK OR
ADJUSTMENT, OR ANY TESTS WITH A RUNNING
ENGINE.
Engi ne i dl e set rpmshoul d be testedandrecorded
when the vehicle is first brought into shop for
testing. Thi s wi l l assi st i n di agnosi ng compl ai nts of
engi ne stal l i ng, creepi ng and hard shi fti ng on vehi cl es
equi pped wi th automati c transmi ssi ons.
Proceed to the Throttl e Body Mi ni mum Ai rfl ow pro-
cedures.
THROTTLE BODY MI NI MUM AI R FLOW CHECK
PROCEDURE2.5L ENGI NE
(1) Connect Di agnosti c Readout Box I I (DRBI I ).
(2) Remove ai r cl eaner assembl y. Pl ug the heated ai r
door vacuum hose.
(3) Warm engi ne i n Park or Neutral unti l the cool i ng
fan has cycl ed on and off at l east once.
(4) Hook-up ti mi ng check devi ce and tachometer.
(5) Di sconnect the cool ant temperature sensor and
set basi c ti mi ng to 12BTDC 2BTDC.
(6) Shut off engi ne. Reconnect cool ant temperature
sensor.
(7) Di sconnect the PCV val ve hose from the i ntake
mani fol d ni ppl e.
(8) Attach Ai r Meteri ng Fi tti ng #6457 (Fi g. 7) to the
i ntake mani fol d PCV ni ppl e.
(9) Restart the engi ne, al l ow engi ne to i dl e for at
l east one mi nute.
(10) Usi ng the DRBI I , Access Mi n Ai rfl ow I dl e Spd
i n the sensor read test mode.
(11) The fol l owi ng wi l l then occur:
AI S motor wi l l ful l y cl ose.
I dl e spark advance wi l l become fi xed.
I dl e fuel wi l l be provi ded at a set val ue.
Engi ne RPM wi l l be di spl ayed on Di agnosti c Read-
out Box I I (DRBI I ).
(12) Check i dl e RPM wi th tachometer. I f i dl e RPM i s
wi thi n the speci fi cati ons l i sted bel ow, then the throttl e
body mi ni mum ai r fl ow i s set correctl y.
I f i dl e RPM i s not wi thi n speci fi cati on repl ace
throttl e body.
Fig. 6 Setting Spark Plug GapTypical
Fig. 7 Air Metering Fitting
I DLE SPECI FI CATI ONS
(13) Shut off engi ne.
(14) Remove Speci al Tool number 6457 from i ntake
mani fol d PCV ni ppl e. Rei nstal l the PCV val ve hose.
(15) Remove DRBI I .
(16) Rei nstal l ai r cl eaner assembl y. Rei nstal l heated
ai r door vacuum hose.
(17) Di sconnect ti mi ng check devi ce and tachometer.
PROCEDURE3.0L ENGI NE
(2) Ensure that al l accessori es are off.
(3) Hook-up the ti mi ng check devi ce and tachometer.
set basi c ti mi ng to 12 BTDC 2 BTDC.
sensor wi re.
(6) Di sconnect the PCV val ve hose from the PCV
val ve (Fi g. 8).
(7) Pl ug the PCV val ve ni ppl e.
(8) Di sconnect the i dl e purge hose from the engi ne
vacuum harness tee (Fi g. 9).
(9) I nstal l ai r meteri ng fi tti ng, speci al tool number
6457 (0.125 i nch ori fi ce) i n the i ntake mani fol d
mounted i dl e purge hose (Fi g. 7).
(10) Connect Di agnosti c Readout Box I I (DRB I I ).
l east one mi nute.
(12) Usi ng the DRBI I , access Mi n. Ai rfl ow I dl e
Speed.
out Box I I (DRB I I )
(14) Check i dl e RPM wi th tachometer, i f i dl e RPM i s
wi thi n the bel ow speci fi cati on then the throttl e body
mi ni mum ai r fl ow i s set correctl y.
(15) I f i dl e RPM i s not wi thi n speci fi cati ons, shut off
the engi ne and cl ean the throttl e body as fol l ows:
(a) Remove the throttl e body from engi ne.
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OF BUTYL
GLOVES. DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
(b) Whi l e hol di ng the throttl e open, spray the
enti re throttl e body bore and the mani fol d si de of the
throttl e pl ate wi th Mopar Parts Cl eaner. Only use
Mopar PartsCleaner toclean thethrottlebody.
(c) Usi ng a soft scuff pad, cl ean the top and bottom
of throttl e body bore and the edges and mani fol d si de
of the throttl e bl ade. The edges of the throttle
bladeand portions of thethrottleborethat are
closest to the throttle blade when is closed,
must be free of deposits.
(d) Use compressed ai r to dry the throttl e body.
(e) I nspect throttl e body for forei gn materi al .
Fig. 8 3.0L PCV Valve
Fig. 9 3.0L Idle Purge Hose
I DLE SPECI FI CATI ONS3.0L ENGI NE
(f) I nstal l throttl e body on mani fol d.
(g) Repeat steps 1 through 14. I f the mi ni mum ai r
fl ow i s sti l l not wi thi n speci fi cati ons, the probl em i s
not caused by the throttl e body.
(17) Remove Ai r Meteri ng Fi tti ng #6457 from the
i ntake mani fol d i dl e purge hose. Reconnect the hose to
the engi ne vacuum harness tee.
(18) Remove the pl ug from the PCV val ve. Reconnect
the PCV val ve hose to the PCV val ve.
(19) Di sconnect the DRB I I .
IGNITION TIMING PROCEDURE2. 5L TBI AND
3. 0L ENGINES
SETTING IGNITION TIMING OR PERFORMING ANY
TEST ON AN OPERATING ENGINE.
Proper i gni ti on ti mi ng i s requi red to obtai n opti mum
engi ne performance. The di stri butor must be correctl y
i ndexed to provi de correct i ni ti al i gni ti on ti mi ng.
(1) Set the gearshi ft sel ector i n park or neutral and
appl y the parki ng brake. Al l l i ghts and accessori es
must be off.
(2) I f usi ng a magneti c ti mi ng l i ght, i nsert the
pi ckup probe i nto the open receptacl e next to the
ti mi ng scal e wi ndow. I f a magneti c ti mi ng uni t i s not
avai l abl e, use a conventi onal ti mi ng l i ght connected to
the number one cyl i nder spark pl ug cabl e.
Do not puncture cables, boots or nipples with
test probes. Always use proper adapters. Punc-
turing the spark plug cables with a probe will
damage the cables. The probe can separate the
conductor andcausehigh resistance. In addition
breaking the rubber insulation may permit sec-
ondary current to arc to ground.
(3) Turn sel ector swi tch to the appropri ate cyl i nder
posi ti on.
ture i s obtai ned.
(5) Wi th the engi ne at normal operati ng tempera-
ture, connect the DRB I I to the di agnosti c connector.
Access the State Di spl ay screen. Refer to the appropri -
ate Powertrai n Di agnosti cs Procedures Manual . If not
using the DRB II tester, disconnect the coolant
temperature sensor electrical connector. The
el ectri c radi ator fan wi l l operate and the Check Engi ne
l i ght wi l l turn on after di sconnecti ng the cool ant sensor
or starti ng the DRB I I procedure.
(6) Ai m Ti mi ng Li ght at ti mi ng scal e (Fi g. 10 or Fi g.
11) or read magneti c ti mi ng uni t. I f fl ash occurs when
ti mi ng mark i s before speci fi ed degree mark, ti mi ng i s
advanced. To adjust, turn di stri butor housi ng i n di rec-
ti on of rotor rotati on.
I f fl ash occurs when ti mi ng mark i s after speci fi ed
degree mark, ti mi ng i s retarded. To adjust, turn di s-
tri butor housi ng agai nst di recti on of rotor rotati on.
Refer to Vehi cl e Emi ssi on Control I nformati on l abel for
correct ti mi ng speci fi cati on. I f ti mi ng i s wi thi n 2 of
val ue speci fi ed on the l abel , proceed to step (8). I f
outsi de speci fi ed tol erance, proceed to next step.
(7) Loosen di stri butor hol d-down arm screw enough
to rotate the di stri butor housi ng (Fi g. 12 or Fi g. 13).
Turn di stri butor housi ng to adjust ti mi ng. Ti ghten the
hol d-down arm screw and recheck ti mi ng.
Fig. 10 Timing Scale2.5L Engine
Fig. 11 Timing Scale3.0L Engine
Fig. 12 Distributor Holddown2.5L Engine
(8) Turn the engi ne off. Remove ti mi ng l i ght or
magneti c ti mi ng uni t and tachometer. I f the cool ant
temperature sensor was di sconnected, connect the sen-
sor and erase fault codes using the Erase Fault
CodeModeontheDRBII. Refer to Group 14 General
Di agnosi s, On Board Di agnosti cs.
DISTRIBUTOR2. 5L ENGINE
REMOVAL
(1) Di sconnect di stri butor pi ck-up connector from
wi ri ng harness connector (Fi g. 14).
(2) Remove spl ash shi el d retai ni ng screws (Fi g. 15).
(3) Remove spl ash shi el d (Fi g. 15).
(4) Loosen di stri butor cap retai ni ng screws (Fi g. 16).
(5) Li ft cap off of di stri butor (Fi g. 17).
(6) Rotate engi ne crankshaft unti l the di stri butor
rotor i s poi nti ng toward the cyl i nder bl ock. Use thi s as
reference when rei nstal l i ng di stri butor.
(7) Remove di stri butor hol d-down screw (Fi g. 12).
(8) Careful l y l i ft the di stri butor from the engi ne.
I NSTALLATI ON
(1) Posi ti on di stri butor i n engi ne. Make certai n that
the O-ri ng i s properl y seated on di stri butor. I f O-ri ng i s
cracked or ni cked, repl ace i t wi th new one.
(2) Careful l y engage di stri butor dri ve wi th auxi l i ary
shaft dri ve. When di stri butor i s i nstal l ed properl y,
rotor wi l l be poi nti ng toward cyl i nder bl ock. If engine
hasbeencrankedwhiledistributor isremoved, it
will be necessary to establish proper relation-
shipbetween thedistributor shaft andNumber 1
piston position as follows:
Fig. 13 Distributor Holddown3.0L Engine
Fig. 14 Distributor Pickup Connector2.5L Engine
Fig. 15 Splash Shield2.5L Engine
Fig. 16 Distributor Cap Retaining Screws2.5L En-
gine
(a) Rotate the crankshaft unti l number one pi ston
i s at top of compressi on stroke. Poi nter on cl utch
housi ng shoul d be i n l i ne wi th the O (TDC) mark on
fl ywheel .
(b) Rotate rotor to a posi ti on just ahead of the
number one di stri butor cap termi nal .
(c) Lower the di stri butor i nto the openi ng, engag-
i ng di stri butor dri ve wi th dri ve on auxi l i ary shaft.
Wi th di stri butor ful l y seated on engi ne, rotor shoul d
be under the cap number 1 tower.
(3) I nstal l the di stri butor cap. Ensure al l hi gh ten-
si on wi res snap fi rml y i n the cap towers.
(4) I nstal l hol d-down arm screw and fi nger ti ghten.
(5) I nstal l spl ash shi el d.
(6) Connect di stri butor pi ck-up connector l ead wi re
at wi ri ng harness connector.
(7) Set i gni ti on ti mi ng to speci fi cati on. Refer to I g-
ni ti on Ti mi ng.
DISTRIBUTOR PICK-UP2. 5L ENGINE
REMOVAL
(1) Remove spl ash shi el d and cap. Refer to Di stri bu-
tor Removal .
(2) Remove rotor from shaft (Fi g. 18).
(3) Remove Hall effect pick-up assembly (Fi g.
19).
I NSTALLATI ON
(1) Pl ace pi ck-up assembl y i nto di stri butor housi ng
(Fi g. 19).
Thedistributor pick-up wires may bedamaged
if not properly reinstalled.
(2) I nstal l rotor (Fi g. 18).
(3) I nstal l cap and spl ash shi el d. Refer to Di stri bu-
tor I nstal l ati on.
DISTRIBUTOR SERVICE3. 0L ENGINE
REMOVAL
(1) Di sconnect di stri butor connector from wi ri ng
harness connector (Fi g. 20).
(2) Loosen di stri butor cap retai ni ng screws.
(3) Li ft cap of off di stri butor (Fi g. 21).
Fig. 17 Distributor Cap2.5L Engine Fig. 18 Ignition Rotor2.5L Engine
Fig. 19 Hall Effect Pickup Assembly2.5L Engine
(4) Rotate engi ne crankshaft unti l the di stri butor
rotor poi nts the i ntake mani fol d pl enum. Scri be a mark
on the pl enum i n l i ne wi th the rotor. The scri be l i ne
i ndi cates where to posi ti on the rotor when rei nstal l i ng
the di stri butor.
(5) Remove di stri butor hol d down nut (Fi g. 22).
(6) Careful l y l i ft the di stri butor from the engi ne.
I NSTALLATI ON
(1) Posi ti on di stri butor i n engi ne. Make certai n that
the O-ri ng i s properl y seated on di stri butor. I f O-ri ng i s
cracked or ni cked repl ace wi th new one.
(2) Careful l y engage di stri butor dri ve wi th gear on
camshaft. When the di stri butor i s i nstal l ed properl y,
the rotor wi l l be i n l i ne wi th previ ousl y scri be l i ne on
ai r i ntake pl enum. If engine was cranked while
distributor was removed, it will be necessary to
establish proper relationship between the dis-
tributor shaft and Number 1 piston position as
follows:
(a) Rotate the crankshaft unti l number one pi ston
i s at top of compressi on stroke.
(b) Rotate rotor to number one rotor termi nal (Fi g.
23).
(c) Lower the di stri butor i nto the openi ng, engag-
i ng di stri butor dri ve wi th dri ve on camshaft. Wi th
di stri butor ful l y seated on engi ne, rotor shoul d be
under the number 1 termi nal (Fi g. 23).
(3) I nstal l the di stri butor cap (Fi g. 21). Ensure sure
al l hi gh tensi on wi res are fi rml y i n the cap towers.
(4) I nstal l hol d-down nut and fi nger ti ghten (Fi g.
22).
(5) Connect di stri butor el ectri cal connector to wi ri ng
harness connector (Fi g. 20).
(6) Set i gni ti on ti mi ng to speci fi cati on. Refer to I g-
ni ti on Ti mi ng i n thi s secti on.
DI SASSEMBLY
(1) Remove di stri butor cap mounti ng screws (Fi g.
21).
Fig. 20 Distributor Electrical Connector3.0L En-
gine
Fig. 21 Distributor Cap3.0L Engine
Fig. 22 Distributor Hold-Down3.0L Engine
Fig. 23 3.0L Engine Distributor Cap Terminal
RoutingView from Top of Cap
(2) Remove di stri butor cap and i nspect for fl ashover,
cracked carbon button, cracked cap, or burned termi -
nal s. I f any of these condi ti ons exi st, repl ace cap.
(3) Remove rotor screw (Fi g. 24). I nspect rotor for
cracks or burned el ectrode. I f any of these condi ti ons
exi st, repl ace rotor.
(4) Remove protecti ve cover from di stri butor hous-
i ng (Fi g. 25).
(5) Remove l ead wi re cl amp screw and remove l ead
wi re (Fi g. 26).
(6) Remove di sk assembl y screw (Fi g. 27).
(7) Remove di sk spacers and di sk (Fi g. 28). Di sk and
spacers are keyed. Check di sk for warpage, cracks or
damaged sl ots (Fi g. 29).
(8) Remove bushi ng and photo opti c sensi ng uni t
fasteners. Remove uni t from di stri butor housi ng (Fi g.
30).
(9) Remove beari ng retai ner screws (Fi g. 31).
(10) Make reassembl y al i gnment marks on gear and
shaft (Fi gs. 32 and 33).
(11) Wi th a pi n punch dri ve out di stri butor dri ve
gear rol l pi n (Fi g. 34).
(12) Remove di stri butor dri ve gear (Fi g. 35).
(13) Remove di stri butor shaft and beari ng assembl y
(Fi g. 36).
(14) To reassembl e, reverse precedi ng procedure. Re-
fer to Fi g. 37.
Fig. 24 Rotor Screw
Fig. 25 Protective Cover
Fig. 26 Lead Wire Clamp
Fig. 27 Disk Assembly Screw
Fig. 28 Disk and Spacers Installed
Fig. 29 Disk and Spacers
Fig. 30 Photo Optic Sensing Unit Assembly and
Bushing
Fig. 31 Bearing Retainer Screws
Fig. 32 Marking Drive Gear and Shaft
Fig. 33 Marks on Drive Gear and Shaft
Fig. 34 Drive Gear Roll Pin
Fig. 35 Drive Gear Fig. 36 Distributor Shaft
Fig. 37 Distributor3.0L Engine
SERVICE2. 5L TBI AND 3. 0L ENGINES
(1) Remove vacuum hose and remove mounti ng
screws from sensor (Fi g. 38 and Fi g. 39).
(2) Remove wi ri ng harness and remove sensor.
(3) Reverse the above procedure for i nstal l ati on.
Check that vacuum hose i s attached to vacuum source.
Fig. 38 Manifold Absolute Pressure (MAP)
Sensor2.5L TBI Engines
Fig. 39 Manifold Absolute Pressure (MAP)
Sensor3.0L Engine
3.3L I GNI TI ON SYSTEMSYSTEM OPERATI ON
INDEX
page page
Auto Shutdown (ASD) RelayEngine Controller
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Camshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 28
Coolant Temperature SensorEngine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Crankshaft Timing Sensor . . . . . . . . . . . . . . . . . . 29
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Manifold Absolute Pressure (MAP) Sensor . . . . . . 31
Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . 26
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION
Thi s secti on descri bes the i gni ti on systems for the
3.3L engi ne.
On Board Di agnosti cs i s descri bed i n the Fuel I njec-
ti on Secti ons of Group 14.
Group 0, Lubri cati on and Mai ntenance, contai ns
general mai ntenance i nformati on for i gni ti on rel ated
i tems. The Owners Manual al so contai ns mai ntenance
i nformati on.
The 3.3L engine uses a fixed ignition timing
system. Basic ignition timing is not adjustable.
All spark advance is determined by the engine
controller.
The 3.3L engi ne uses a di stri butorl ess i gni ti on sys-
tem, refereed to as the Di rect I gni ti on System. The
systems three mai n components are the coi l pack,
crankshaft ti mi ng sensor, and camshaft reference sen-
sor. The crankshaft and camshaft sensors are hal l
effect devi ces.
The camshaft and crankshaft sensors generate
pul ses that are the i nputs sent to the engi ne control l er.
The engi ne control l er i nterprets crankshaft posi ti on
from these sensors. The engi ne control l er uses crank-
shaft posi ti on reference to determi ne i njector sequence
and i gni ti on ti mi ng.
The camshaft sensor senses when a sl ot i n the
camshaft gear passes beneath i t (Fi g. 1). The crank-
shaft sensor senses when a wi ndow i n the dri ve pl ate
passes under i t (Fi g. 2). When a sl ot or wi ndow i s
sensed, the i nput vol tage from the sensor to the engi ne
control l er swi tches from l ow (l ess than .3 vol ts) to hi gh
(5 vol ts). As the sl ot or wi ndow passes, the i nput
vol tage i s swi tched back to l ow (l ess than .3 vol ts).
FI RI NG ORDER
The fi ri ng order of the 3.3L engi ne di rect i gni ti on
system i s 1-2-3-4-5-6 (Fi g. 3).
ENGINE CONTROLLER
The i gni ti on system i s regul ated by the Si ngl e board
manual as the Engine Controller (Fig. 4). The
control l er suppl i es battery vol tage to the i gni ti on coi l
through the Auto Shutdown (ASD) Rel ay. The control -
l er al so control s ground ci rcui t for the i gni ti on coi l . By
swi tchi ng the ground path for the coi l on and off, the
engi ne control l er adjusts i gni ti on ti mi ng to meet
changi ng engi ne operati ng condi ti ons.
Fig. 1 Camshaft Sprocket
Fig. 2 Driveplate
Duri ng the crank-start peri od the control l er ad-
vances i gni ti on ti mi ng a set amount. Duri ng engi ne
operati on, the amount of spark advance provi ded by
the engi ne control l er i s determi ned by three i nput
factors:
engi ne RPM
avai l abl e mani fol d vacuum
The engi ne control l er al so regul ates the fuel i njecti on
system. Refer to the Fuel I njecti on secti ons of Group
14.
SPARK PLUG CABLES
Spark Pl ug cabl es are someti mes referred to as
secondary i gni ti on wi res. The wi res transfer el ectri cal
current from the di stri butor to i ndi vi dual spark pl ugs
at each cyl i nder. The spark pl ug cabl es are of nonme-
tal l i c constructi on and have a bui l t i n resi stance. The
cabl es provi de suppressi on of radi o frequency emi s-
si ons from the i gni ti on system.
Check the spark pl ug cabl e connecti ons for good
contact at the coi l and di stri butor cap towers and at the
spark pl ugs. Termi nal s shoul d be ful l y seated. The
ni ppl es and spark pl ug covers shoul d be i n good condi -
ti on. Ni ppl es shoul d fi t ti ghtl y on the coi l and di stri bu-
tor cap towers and spark pl ug cover shoul d fi t ti ght
around spark pl ug i nsul ators. Cabl e connecti ons that
are l oose wi l l corrode and i ncrease the resi stance and
permi t water to enter the towers causi ng i gni ti on
mal functi on.
SPARK PLUGS
The 3.3L engi ne uses resi stor spark pl ugs. They have
resi stance val ues of 6,000 to 20,000 ohms when
checked wi th at l east a 1000 vol t tester.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken porce-
l ai n i nsul ators. Keep pl ugs arranged i n the order i n
whi ch they were removed from the engi ne. An i sol ated
pl ug di spl ayi ng an abnormal condi ti on i ndi cates that a
probl em exi sts i n the correspondi ng cyl i nder. Repl ace
spark pl ugs at the i nterval s recommended i n Group O.
Spark pl ugs that have l ow mi l age may be cl eaned
and reused i f not otherwi se defecti ve. Refer to the
Spark Pl ug Condi ti on secti on of thi s group. After
cl eani ng, fi l e the center el ectrode fl at wi th a smal l
poi nt fi l e or jewel ers fi l e. Adjust the gap between the
el ectrodes (Fi g. 5) to the di mensi ons speci fi ed i n the
chart at the end of thi s secti on.
Fig. 3 Spark Plug Wire Routing3.3L Engine
Fig. 4 Single Board Engine Controller
Fig. 5 Setting Spark Plug Electrode GapTypical
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap. Ti ghten 3.3L engi ne
spark pl ugs to 28 Nm (20 ft. l bs.) torque.
SPARK PLUG CONDI TI ON
NORMAL OPERATING CONDITIONS
The few deposi ts present wi l l be probabl y l i ght tan or
sl i ghtl y gray i n col or wi th most grades of commerci al
gasol i ne (Fi g. 6). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than ap-
proxi matel y 0.025 mm (.001 i n) per 1600 km (1000
mi l es) of operati on. Spark pl ugs that have normal wear
can usual l y be cl eaned, have the el ectrodes fi l ed and
regapped, and then rei nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
may coat the enti re ti p of the spark pl ug wi th a rust
col ored deposi t. The rust col or deposi ts can be mi sdi -
agnosed as bei ng caused by cool ant i n the combusti on
chamber. Spark pl ug performance i s not affected by
MMT deposi ts.
COLD FOULING (CARBON FOULING)
Col d foul i ng i s someti mes referred to as carbon
foul i ng because the deposi ts that cause col d foul i ng are
basi cal l y carbon (Fi g. 6). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves or
defecti ve spark pl ug cabl es. Col d (carbon) foul i ng of the
enti re set may be caused by a cl ogged ai r cl eaner.
Col d foul i ng i s normal after short operati ng peri ods.
The spark pl ugs do not reach a hi gh enough operati ng
temperature duri ng short operati ng peri ods.
WET FOULING
A spark pl ug that i s coated wi th excessi ve wet fuel or
oi l i s wet foul ed. I n ol der engi nes, wet foul i ng can be
caused by worn ri ngs or excessi ve cyl i nder wear.
Break-in fouling of new engines may occur be-
fore normal oil control is achieved. In new or
recently overhauled engines, wet fouled spark
plugs can be usually be cleaned and reinstalled.
OIL OR ASH ENCRUSTED
I f one or more pl ugs are oi l or oi l ash encrusted, the
engi ne shoul d be eval uated for the cause of oi l entry
i nto the combusti on chamber (Fi g. 7).
HIGH SPEED MISS
When repl aci ng spark pl ugs because of a hi gh speed
mi ss condi ti on; wide open throttle operation
should be avoided for approximately 80 km (50
miles) after installation of new plugs. Thi s wi l l
al l ow deposi t shi fti ng i n the combusti on chamber to
take pl ace gradual l y and avoi d pl ug destroyi ng spl ash
foul i ng shortl y after the pl ug change.
ELECTRODE GAP BRIDGING
Loose deposi ts i n the combusti on chamber can cause
el ectrode gap bri dgi ng. The deposi ts accumul ate on the
spark pl ugs duri ng conti nuous stop-and-go dri vi ng.
When the engi ne i s suddenl y subjected to a hi gh torque
l oad, the deposi ts parti al l y l i quefy and bri dge the gap
between the el ectrodes (Fi g. 8). Thi s short ci rcui ts the
el ectrodes. Spark pl ugs wi th el ectrode gap bri dgi ng can
be cl eaned usi ng standard procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or
yel l ow (Fi g. 9). They may appear to be harmful , but are
a normal condi ti on caused by chemi cal addi ti ves i n
Fig. 6 Normal Operation and Cold (Carbon) Fouling
Fig. 7 Oil or Ash Encrusted
certai n fuel s. These addi ti ves are desi gned to change
the chemi cal nature of deposi ts and decrease spark
pl ug mi sfi re tendenci es. Noti ce that accumul ati on on
the ground el ectrode and shel l area may be heavy but
the deposi ts are easi l y removed. Spark pl ugs wi th
scavenger deposi ts can be consi dered normal i n condi -
ti on and be cl eaned usi ng standard procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the spark
pl ug el ectrode gap. Under certai n condi ti ons, severe
detonati on al so can separate the i nsul ator from the
center el ectrode (Fi g. 10). Spark pl ugs wi th chi pped
el ectrode i nsul ators must be repl aced.
PREIGNITION DAMAGE
Excessi ve combusti on chamber temperature can
cause prei gni ti on damage. Fi rst, the center el ectrode
di ssol ves and the ground el ectrode di ssol ves somewhat
l ater (Fi g. 11). I nsul ators appear rel ati vel y deposi t
free. Determi ne i f the spark pl ug has the correct heat
range rati ng for the engi ne, i f i gni ti on ti mi ng i s over
advanced or i f other operati ng condi ti ons are causi ng
engi ne overheati ng. (The heat range rati ng refers to
the operati ng temperature of a parti cul ar type spark
pl ug. Spark pl ugs are desi gned to operate wi thi n
speci fi c temperature ranges dependi ng upon the thi ck-
ness and l ength of the center el ectrode and porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
12). The i ncrease i n el ectrode gap wi l l be consi derabl y
i n excess of 0.001 i n per 1000 mi l es of operati on. Thi s
suggests that a pl ug wi th a cool er heat range rati ng
shoul d be used. Over advanced i gni ti on ti mi ng, deto-
nati on and cool i ng system mal functi ons al os can cause
spark pl ug overheati ng.
CAMSHAFT SENSOR
The camshaft sensor provi des fuel i njecti on synchro-
ni zati on and cyl i nder i denti fi cati on i nformati on (Fi g.
13). The sensor generates pul ses that are the
Fig. 9 Scavenger Deposits
Fig. 11 Preignition Damage
Fig. 8 Electrode Gap Bridging Fig. 10 Chipped Electrode Insulator
i nput sent to the engi ne control l er. The engi ne control -
l er i nterprets the camshaft sensor i nput (al ong wi th
the crankshaft sensor i nput) to determi ne crankshaft
posi ti on. The engi ne control l er uses crankshaft posi -
ti on reference to determi ne i njector sequence and i gni -
ti on ti mi ng.
The camshaft sensor determi nes when a sl ot i n the
camshaft gear passes beneath i t (Fi g. 14). When a sl ot
i s sensed, the i nput vol tage from the sensor to the
engi ne control l er swi tches from l ow (l ess than 0.3 vol ts)
to hi gh (5 vol ts). As the sl ot or wi ndow passes, the i nput
vol tage i s swi tched back to l ow (l ess than 0.3 vol ts).
The camshaft sensor i s mounted to the top of the
ti mi ng case cover (Fi g. 15). The bottom of the sensor i s
posi ti oned above the camshaft sprocket. Thedistance
between the bottom of sensor and the camshaft
sprocket is critical to the operation of the sys-
tem. Whenservicingthecamshaft sensor, refer to
the 3.3L Ignition SystemService Procedures
section in this Group.
CRANKSHAFT TIMING SENSOR
The crankshaft sensor (Fi g. 16) senses sl ots cut i nto
the transmi ssi on dri vepl ate extensi on. There are a 3
sets of sl ots. Each set contai ns 4 sl ots, for a total of 12
sl ots (Fi g. 17). Basi c ti mi ng i s set by the posi ti on of the
l ast sl ot i n each group. Once the engi ne control l er
senses the l ast sl ot, i t determi nes crankshaft posi ti on
(whi ch pi ston wi l l next be at TDC) from the camshaft
sensor i nput. I t may take the control l er up to two
thi rds of an engi ne revol uti on to determi ne crankshaft
posi ti on.
The engi ne control l er uses crankshaft posi ti on refer-
ence to determi ne i njector sequence and i gni ti on ti m-
i ng. Once crankshaft posi ti on has been determi ned, the
engi ne control l er begi ns energi zi ng the i njectors i n
sequence.
The crankshaft sensor i s l ocated i n the transmi ssi on
housi ng, above the vehi cl e di stance sensor (Fi g. 18).
The bottom of the sensor i s posi ti oned next to the dri ve
pl ate. Thedistancebetween thebottomof sensor
and the drive plate is critical to the op-
Fig. 12 Spark Plug Overheating
Fig. 13 Camshaft Sensor
Fig. 14 Camshaft Gear
Fig. 15 Camshaft Sensor Location
eration of thesystem. When servicingthecrank-
shaft sensor, refer to the 3.3L Ignition System
Service Procedures section in this Group.
IGNITION COIL
WARNING: THE 3.3L ENGINES DIRECT IGNITION
SYSTEM GENERATES APPROXIMATELY 40,000
VOLTS. PERSONAL INJURY COULD RESULT FROM
CONTACT WITH THIS SYSTEM.
The coi l assembl y consi sts of 3 coi l s mol ded together
(Fi g. 19). The coi l assembl y i s mounted on the i ntake
mani fol d. Hi gh tensi on l eads route to each cyl i nder
from the coi l . The coi l fi res two spark pl ugs every
power stroke. One pl ug i s the cyl i nder under compres-
si on, the other cyl i nder fi res on the exhaust stroke. The
engi ne control l er determi nes whi ch of the coi l s to
charge and fi re at the correct ti me.
Coi l s one fi res cyl i nders 1 and 4, coi l two fi res
cyl i nders 2 and 5, coi l three fi res cyl i nders three and
si x.
The coi l s l ow pri mary resi stance (0.5-0.7 ohm) al l ows
the engi ne control l er to ful l y charge the coi l for each
fi ri ng.
COOLANT TEMPERATURE SENSORENGINE CON-
TROLLER INPUT
The cool ant temperature sensor i s l ocated next to the
thermostat housi ng (Fi g. 20). The sensor provi des an
i nput vol tage to the engi ne control l er. The sensor i s a
vari abl e resi stance (thermi stor) wi th a range of -40F
to 265F. As cool ant temperature vari es, the sensors
resi stance changes, resul ti ng i n a di fferent i nput vol t-
age to the engi ne control l er.
Fig. 16 Crankshaft Sensor
Fig. 17 Timing Slots in Transmission Driveplate
Fig. 18 Crankshaft Sensor Location
Fig. 19 Coil Pack3.3L Engine
Fig. 20 Coolant Temperature Sensor
The engi ne control l er contai ns di fferent spark ad-
vance schedul es for col d and warm engi ne operati on.
The schedul es reduce engi ne emi ssi on and i mprove
dri veabi l i ty.
When the engi ne i s col d, the engi ne control l er wi l l
demand sl i ghtl y ri cher ai r-fuel mi xtures and hi gher
i dl e speeds unti l normal operati ng temperatures are
reached.
The cool ant sensor i nput i s al so used for cool i ng fan
control .
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d and provi des an i nput vol tage to the
engi ne control l er. As engi ne l oad changes, mani fol d
pressure vari es. The changes i n engi ne l oad cause the
MAP sensors resi stance to change. The change i n MAP
sensor resi stance resul ts i n a di fferent i nput vol tage to
The i nput vol tage l evel suppl i es the engi ne control l er
wi th i nformati on rel ati ng to ambi ent barometri c pres-
sure duri ng engi ne start-up (cranki ng) and engi ne l oad
whi l e i ts operati ng. The engi ne control l er uses thi s
i nput al ong wi th i nputs from other sensors to adjust
ai r-fuel mi xture.
The MAP sensor (Fi g. 21) i s mounted to the si de of
the i ntake mani fol d, bel ow the posi ti ve crankcase ven-
ti l ati on (PCV) val ve. The sensor i s connected to the
engi ne control l er el ectri cal l y.
AUTO SHUTDOWN (ASD) RELAYENGINE CON-
TROLLER OUTPUT
The Auto Shutdown Rel ay (ASD) connects battery
vol tage to the fuel i njectors and i gni ti on coi l . The
ground ci rcui t for the ASD rel ay i s control l ed by the
engi ne control l er. The engi ne control l er operates the
rel ay by swi tchi ng the ground ci rcui t on and off.
I f the engi ne control l er does not recei ve an i gni ti on
si gnal i nput when the i gni ti on key i n the RUN posi -
ti on, i t de-energi zes the ASD rel ay. When the rel ay i s
de-energi zed the battery vol tage i s removed from fuel
i njectors and i gni ti on coi l .
The ASD rel ay i s l ocated on the dri vers si de fender
wel l , near to the engi ne control l er (Fi g. 22).
Fig. 21 Map Sensor
Fig. 22 Auto Shutdown Relay
3.3L I GNI TI ON SYSTEMDI AGNOSTI C PROCEDURES
INDEX
page page
Check Coil Test3.3L Engine . . . . . . . . . . . . . . . 32
Coolant Temperature Sensor Test . . . . . . . . . . . . . 33
Crankshaft Sensor and Camshaft Sensor Tests . . . 34
Failure to Start Test . . . . . . . . . . . . . . . . . . . . . . . 33
Manifold Absolute Pressure (MAP) Sensor Test . . . 34
Testing for Spark at Coil . . . . . . . . . . . . . . . . . . . . 32
TESTING FOR SPARK AT COIL
WARNING: THE 3.3L ENGINE DIRECT IGNITION SYS-
TEM GENERATES APPROXIMATELY 40,000 VOLTS.
PERSONAL INJURY COULD RESULT FROM CON-
TACT WITH THIS SYSTEM.
The coi l pack contai ns 3 i ndependent coi l s. Each coi l
must be checked i ndi vi dual l y.
CAUTION: Spark plug wire damage may occur if the
spark plug is moved more than 1/4 inch away fromthe
engine ground.
Remove the cabl e from number 2 spark pl ug. I nsert a
cl ean spark pl ug i nto the spark pl ug boot, and ground
pl ug to the engi ne (Fi g. 1).
Crank the engi ne and l ook for spark across the
el ectrodes of the spark pl ug. Repeat the above test for
the fi ve remai ni ng cyl i nders. I f there i s no spark
duri ng al l cyl i nder tests, proceed to the fai l ure to start
test.
I f one or more tests i ndi cate i rregul ar, weak, or no
spark, proceed to Check Coi l Test.
CHECK COIL TEST3. 3L ENGINE
Coils one fires cylinders 1 and 4, coil two fires
cylinders 2and 5, coil threefires cylinders three
and six.
Each coi l tower i s l abel ed wi th the number of the
correspondi ng cyl i nder.
(1) Remove the i gni ti on cabl es and measure the
resi stance of the cabl es. Resi stance must be between
3,000 to 12,000 ohms per foot of cabl e. Repl ace any
cabl e not wi thi n tol erance.
(2) Di sconnect the el ectri cal connector from the coi l
pack (Fi g. 2).
(3) Measure the pri mary resi stance of each coi l . At
the coi l , connect an ohmmeter between the B+ pi n and
the pi n correspondi ng to the cyl i nders i n questi on (Fi g.
3). Resi stance on the pri mary si de of each coi l shoul d be
0.5-0.7 ohm. Repl ace the coi l i f resi stance i s not wi thi n
tol erance.
(4) Remove i gni ti on cabl es from the secondary tow-
ers of the coi l . Measure the secondary resi stance of
Fig. 1 Testing For Spark
Fig. 2 Ignition Coil Electrical Connection
Fig. 3 Ignition Coil Terminal Identification
the coi l between the towers of each i ndi vi dual coi l (Fi g.
4). Secondary resi stance shoul d be 7,000 to 15,800
ohms. Repl ace the coi l i f resi stance i s not wi thi n
tol erance.
FAILURE TO START TEST
Thi s no-start test checks the camshaft sensor and
crankshaft sensor.
The engi ne control l er suppl i es 9 vol ts to the camshaft
sensor and crankshaft sensor through one ci rcui t. I f
the 9-vol t suppl y ci rcui t i s shorted to ground, nei ther
sensor wi l l produce a si gnal (output vol tage to the
engi ne control l er).
When the i gni ti on key i s turned and l eft i n the On
posi ti on, the engi ne control l er automati cal l y energi zes
the auto shutdown (ASD) rel ay. However, the control l er
de-energi zes the rel ay wi thi n one second because i t has
not recei ved a crankshaft si gnal i ndi cati ng engi ne
rotati on.
Duri ng cranki ng, the ASD rel ay wi l l not energi ze
unti l the engi ne control l er recei ves a crankshaft si gnal .
Secondl y, the ASD rel ay remai ns energi zed onl y i f the
control l er senses a camshaft sensor si gnal i mmedi atel y
after detecti ng the crankshaft sensor si gnal .
(1) Check battery vol tage. Vol tage shoul d approxi -
matel y 12.66 vol ts or hi gher to perform fai l ure to start
test.
(2) Di sconnect the harness connector from the coi l
pack (Fi g. 2).
(3) Connect a test l i ght to the B+ (battery vol tage)
termi nal of the coi l el ectri cal connector and ground.
The wi re for the B+ termi nal i s dark green wi th a bl ack
tracer.
(4) Turn the i gni ti on key to the ON position. The
test l i ght shoul d fl ash On and then Off. Do not turn
theKeytooff position, leaveit intheOnposition.
(a) I f the test l i ght fl ashes momentari l y, the engi ne
control l er grounded the auto shutdown (ASD) rel ay.
Proceed to step 5.
(b) I f the test l i ght di d not fl ash, the ASD rel ay di d
not energi ze. The cause i s ei ther the rel ay or one of
the rel ay ci rcui ts. Use the DRB I I to test the ASD
rel ay and ci rcui ts. Refer to the appropri ate Power-
trai n Di agnosti cs Procedure Manual . Refer to the
wi ri ng di agrams secti on for ci rcui t i nformati on.
(5) Crank the engi ne. (I f the key was pl aced i n the
off posi ti on after step 4, pl ace the key i n the On
posi ti on before cranki ng. Wai t for the test l i ght to fl ash
once, then crank the engi ne.)
(a) I f the test l i ght momentari l y fl ashes duri ng
cranki ng, the engi ne control l er i s not recei vi ng a
camshaft sensor si gnal . Use the DRB I I to test the
camshaft sensor and sensor ci rcui ts. Refer to the
appropri ate Powertrai n Di agnosti cs Procedure
Manual . Refer to the wi ri ng di agrams secti on for
ci rcui t i nformati on.
(b) I f the test l i ght di d not fl ash duri ng cranki ng,
unpl ug the camshaft sensor connector. Turn the
i gni ti on key to the off posi ti on. Turn the key to the
On posi ti on, wai t for the test l i ght to momentari l y
fl ash once, then crank the engi ne. I f the test l i ght
momentari l y fl ashes, the camshaft sensor i s shorted
and must be repl aced. I f the l i ght di d not fl ash, the
cause of the no-start i s i n ei ther the crankshaft
sensor/camshaft sensor 9-vol t suppl y ci rcui t, or the
crankshaft sensor 5-vol t output or ground ci rcui ts.
Use the DRB I I to test the crankshaft sensor and the
sensor ci rcui ts. Refer to the appropri ate Powertrai n
Di agnosti cs Procedure Manual . Refer to the wi ri ng
di agrams secti on for ci rcui t i nformati on.
COOLANT TEMPERATURE SENSOR TEST
(1) Wi th key off, di sconnect wi re connector from
cool ant temperature sensor (Fi g. 5).
(2) Connect one l ead of ohmmeter to one termi nal of
cool ant temperature sensor.
Fig. 4 Checking Ignition Coil Secondary Resistance
Fig. 5 Coolant Temperature Sensor Test
(3) Connect the other l ead of ohmmeter to remai ni ng
connector of cool ant temperature sensor. The ohmme-
ter shoul d read as fol l ows;
Engi ne/Sensor hot at normal operati ng temperature
around 200F shoul d read approxi matel y 700 to 1,000
ohms.
Engi ne/Sensor at room temperature around 70F,
ohmmeter shoul d read approxi matel y 7,000 to 13,000
ohms.
SeeOn Board Diagnostics in theGeneral Diag-
nosis section of Group 14, or refer to the appro-
priate diagnostic manual for further test proce-
dures.
TEST
Refer to the appropri ate Powertrai n Di agnosti c Pro-
cedure manual .
CRANKSHAFT SENSOR AND CAMSHAFT SENSOR
TESTS
Refer to the appropri ate Powertrai n Di agnosi tc Pro-
cedure manual .
3.3L I GNI TI ON SYSTEMSSERVI CE PROCEDURES
INDEX
page page
Camshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 38
Coolant Temperature Sensor . . . . . . . . . . . . . . . . 35
Idle Rpm Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ignition Timing Procedure . . . . . . . . . . . . . . . . . . . 38
Spark Plug Cable Service . . . . . . . . . . . . . . . . . . . 36
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE CONTROLLER
REMOVAL
(1) Remove ai r cl eaner duct or ai r cl eaner assembl y.
(2) Remove battery.
(3) Remove engi ne control l er mounti ng screws (Fi g.
1).
(4) Remove 60-way connector from engi ne control l er.
Remove control l er.
I NSTALLATI ON
(1) Connect 60-Way connector to engi ne control l er
(Fi g. 1).
(2) I nstal l Engi ne Control l er on i nsi de l eft front
fender (Fi g. 1). I nstal l and ti ghten mounti ng screws.
(3) I nstal l the battery.
(4) I nstal l ai r cl eaner duct or ai r cl eaner assembl y.
The cool ant temperature sensor i s l ocated bel ow the
i gni ti on coi l (Fi g. 2).
REMOVAL
(1) Drai n cool i ng system unti l cool ant l evel i s bel ow
cool ant sensor. Refer to Group 7, Cool i ng System.
(2) Remove el ectri cal connector from coi l (Fi g. 3).
Fig. 1 Removing the Engine Controller
Fig. 3 Ignition Coil Removal
(3) Remove coi l mounti ng screws.
(4) Rotate coi l away from cool ant temperature sen-
sor.
(5) Di sconnect el ectri cal connector from cool ant tem-
perature sensor.
(6) Remove sensor from engi ne.
I NSTALLATI ON
(1) Ti ghten the cool ant sensor to 7 Nm (60 i n. l bs.)
torque.
(2) Connect el ectri cal connector to sensor.
(3) Fi l l cool i ng system. Refer to Group 7, Cool i ng
System.
(4) I nstal l coi l . Ti ghten coi l mounti ng screws to 12
(5) Connect el ectri cal connector to coi l .
SPARK PLUG CABLE SERVICE
Cl ean hi gh tensi on cabl es wi th a cl oth moi stened
wi th a non-fl ammabl e sol vent. Wi pe the cabl es dry.
Check for bri ttl e or cracked i nsul ati on.
When testi ng cabl es for punctures and cracks wi th
an osci l l oscope, fol l ow the i nstructi ons of the equi p-
ment manufacturers.
CAUTION: Do not leave any one spark plug cable
disconnected any longer than necessary during test
or possible heat damage to catalytic converter will
occur. Total test time must not exceed ten minutes.
I f an osci l l oscope i s not avai l abl e, cabl es can be tested
as fol l ows:
(1) Wi th the engi ne not runni ng, connect one end of
a test probe (i .e. a pi ece of wi re wi th i nsul ated al l i gator
cl i ps on each end) to a good ground, other end free for
probi ng.
WARNING: THE 3.3L ENGINE DIRECT IGNITION SYS-
TEM GENERATES APPROXIMATELY 40,000 VOLTS.
PERSONAL INJURY COULD RESULT FROM CON-
TACT WITH THIS SYSTEM.
(2) Wi th engi ne runni ng, move test probe al ong
enti re l ength of al l cabl es (approxi matel y 0 to 1/8 i nch
gap). I f punctures or cracks are present there wi l l be a
noti ceabl e spark jump from the faul ty area to the
probe. Cracked, l eaki ng or faul ty cabl es shoul d be
repl aced.
Use the fol l owi ng procedure when removi ng the hi gh
tensi on cabl e from the spark pl ug. Fi rst, remove the
cabl e from the retai ni ng bracket. Then grasp the ter-
mi nal as cl ose as possi bl e to the spark pl ug. Rotate the
cover (boot) sl i ghtl y and pul l strai ght back. Donot use
pliersanddonot pull thecableat an angle. Doi ng
so wi l l damage the i nsul ati on, cabl e termi nal or the
spark pl ug i nsul ator. Wipe spark plug insulator
clean before reinstalling cable and cover.
Resi stance cabl es are i denti fi ed by the words Elec-
tronic Suppression.
Use an ohmmeter to check cabl es for opens, l oose
termi nal s or hi gh resi stance.
(a) Remove cabl e from spark pl ug.
(b) Remove cabl e from the coi l tower.
(c) Connect the ohmmeter between spark pl ug end
termi nal and the coi l end termi nal . Resi stance
shoul d be wi thi n tol erance shown i n the cabl e resi s-
tance chart. I f resi stance i s not wi thi n tol erance,
repl ace cabl e assembl y. Test al l spark pl ug cabl es i n
same manner.
SPARK PLUG SERVICE
When repl aci ng the spark pl ug cabl es, route the
cabl es correctl y and secure them i n the appropri ate
cause the radi o to reproduce i gni ti on noi se, cross i gni -
ti on of the spark pl ugs or short ci rcui t the cabl es to
ground.
SPARK PLUG REMOVAL
(1) To avoi d cross threadi ng, start the spark pl ug
i nto the cyl i nder head by hand.
torque.
IDLE RPM TEST
ANY ENGINE RUNNING TESTS.
CABLE RESI STANCE CHART
Engi ne i dl e set rpmshoul d be testedandrecorded
asit iswhenthevehicleisfirst brought intoshop
for testing. Thi s wi l l assi st i n di agnosi ng compl ai nts
of engi ne stal l i ng, creepi ng and hard shi fti ng on ve-
hi cl es equi pped wi th automati c transmi ssi ons.
Proceed to the Throttl e Body Mi ni mum Ai rfl ow pro-
cedures.
PROCEDURE
(5) Attach Ai r Meteri ng Fi tti ng #6457 (0.125 i n.
ori fi ce) to the i ntake mani fol d PCV ni ppl e (Fi g. 5).
(6) Di sconnect the 3/16 i nch i dl e purge l i ne from the
throttl e body ni ppl e (Fi g. 6). Cap the 3/16 i nch ni ppl e.
(8) Restart the engi ne. Al l ow engi ne to i dl e for at
l east one mi nute.
(9) Usi ng the DRBI I , access Mi n. Ai rfl ow I dl e Spd.
Engi ne RPM wi l l be di spl ayed on DRB I I .
(11) I f i dl e RPM i s wi thi n the range shown i n the
I dl e Speci fi cati on chart, throttl e body mi ni mum ai r-
fl ow i s set correctl y.
GLOVES, DO NOT LET MOPAR PARTS CLEANER
i ntake mani fol d PCV ni ppl e. Rei nstal l the PCV val ve
hose.
Fig. 4 Setting Spark Plug GapTypical
Fig. 5 Air Metering Fitting #6457
(15) Uncap the throttl e body i dl e purge ni ppl e and
connect the i dl e purge l i ne.
(16) Remove DRB I I .
IGNITION TIMING PROCEDURE
The 3.3L engi ne uses a fi xed i gni ti on system. Basi c
i gni ti on ti mi ng i s not adjustabl e. The engi ne control l er
regul ates i gni ti on ti mi ng.
REMOVAL
(1) Di sconnect crankshaft ti mi ng sensor el ectri cal
connector from the wi ri ng harness connector (Fi g. 6).
(2) Remove crankshaft ti mi ng sensor retai ni ng bol t.
(3) Pul l crankshaft ti mi ng sensor strai ght up out of
the transaxl e housi ng.
I NSTALLATI ON
If theremovedsensor istobereinstalled, clean
off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face
before installation. If the sensor is being re-
placed, confirmthat thepaper spacer isattached
to the face of the new sensor (Fig. 7).
(1) I nstal l sensor i n transaxl e and push sensor down
unti l contact i s made wi th the dri ve pl ate. Whi l e
hol di ng the sensor i n thi s posi ti on, i nstal l and ti ghten
the retai ni ng bol t to 11.9 Nm (105 i n. l bs.) torque.
(2) Connect crankshaft ti mi ng sensor el ectri cal con-
nector to the wi ri ng harness connector.
CAMSHAFT SENSOR
REMOVAL
(1) Di sconnect camshaft reference sensor el ectri cal
(2) Loosen camshaft ti mi ng sensor retai ni ng bol t
enough to al l ow sl ot i n sensor to sl i de past the bol t.
(3) Pul l sensor up out of the chai n case cover. Donot
pull on the sensor lead. There i s an O-ri ng on the
sensor case. The O-ri ng may make removal di ffi cul t. A
l i ght tap to top of sensor pri or to removal may reduce
force needed for removal .
I NSTALLATI ON
If the removed sensor is reinstalled, clean off
theoldspacer onthesensor face.ANEWSPACER
must be attached to the face before installation.
I nspect O-ri ng for damage, repl ace i f necessary. I f the
sensor i s bei ng repl aced, confi rm that the paper spacer
i s attached to the face and O-ri ng i s posi ti oned i n
groove of the new sensor (Fi g. 9).
Fig. 6 Crankshaft Timing Sensor
Fig. 7 Crankshaft Sensor and Spacer
(1) Appl y a coupl e drops of cl ean engi ne oi l to the
O-ri ng pri or to i nstal l ati on. I nstal l sensor i n the chai n
case cover and push sensor down unti l contact i s made
wi th the cam ti mi ng gear. Whi l e hol di ng the sensor i n
thi s posi ti on, i nstal l and ti ghten the retai ni ng bol t 11.9
(2) Connect camshaft reference sensor el ectri cal con-
nector to harness connector. Posi ti on connector away
from the accessory bel t.
IGNITION COIL
(1) Remove spark pl ug cabl es from coi l (Fi g. 10).
(2) Remove i gni ti on coi l el ectri cal connector.
(3) Remove i gni ti on coi l mounti ng screws.
(4) Remove i gni ti on coi l .
Reverse the above procedure for i nstal l ati on. Ti ghten
mounti ng screws to 12 Nm (105 i n. l bs.) torque.
(1) Di sconnect el ectri cal connector from MAP sensor.
(2) Remove sensor by unscrewi ng from the i ntake
Fig. 11 Manifold Absolute Pressure Sensor
Fig. 10 Ignition Coil Removal and Installation
I GNI TI ON SWI TCH
IGNITION SWITCH AND KEY CYLINDER SERVICE
The i gni ti on swi tch i s l ocated on the steeri ng col umn.
The Key I n Swi tch i s l ocated i n the i gni ti on swi tch
modul e. For di agnosi s of the Key I n Swi tch, refer to
Secti on 8M.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) I f the vehi cl e has a ti l t col umn, remove the ti l t
l ever by turni ng i t countercl ockwi se.
(3) Remove upper and l ower covers from steeri ng
col umn.
(4) Remove i gni ti on swi tch mounti ng screws. Use
tamper proof torx bi t Snap-on TTXR15A2, TTXR20A2
or equi val ent to remove the screws (Fi g. 1).
(5) Gentl y pul l swi tch away from the col umn. Re-
l ease connector l ocks on the 7 termi nal wi ri ng connec-
tor, then remove the connector from the i gni ti on
swi tch.
(6) Rel ease connector l ock on the 4 termi nal connec-
tor, then remove the connector from the i gni ti on
swi tch.
(7) To remove the key cyl i nder from the i gni ti on
swi tch:
(a) I nsert key i n the i gni ti on swi tch. Turn the key
to the LOCK posi ti on. Usi ng a smal l screwdri ver,
depress the key cyl i nder retai ni ng pi n unti l i t i s fl ush
wi th the key cyl i nder surface (Fi g. 2).
(b) Rotate the key cl ockwi se to the OFF posi ti on.
The key cyl i nder wi l l unseat from the i gni ti on swi tch
(Fi g. 3). When the key cyl i nder i s unseated, i t wi l l be
approxi matel y 1/8 i nch away from the i gni ti on swi tch
hal o l i ght ri ng. Donot attempt toremovethekey
cylinder at this time.
(c) Wi th the key cyl i nder i n the unseated posi ti on,
rotate the key countercl ockwi se to the l ock posi ti on
and remove the key.
(d) Remove key cyl i nder from i gni ti on swi tch (Fi g.
4).
Fig. 1 Ignition Switch Screw Removal
Fig. 2 Key Cylinder Retaining Pin
I GNI TI ON SWI TCH DESI GNATI ONS
I NSTALLATI ON
(1) Connect el ectri cal connectors to the i gni ti on
swi tch. Make sure that the swi tch l ocki ng tabs are ful l y
seated i n the wi ri ng connectors.
(2) Before attachi ng the i gni ti on swi tch to a ti l t
steeri ng col umn, the transmi ssi on shi fter must be i n
Park posi ti on. Al so the park l ock dowel pi n and the
col umn l ock fl ag must be properl y i ndexed before
i nstal l i ng the swi tch (Fi g. 5).
(a) Pl ace the transmi ssi on shi fter i n the PARK
posi ti on.
(b) Pl ace the i gni ti on swi tch i n the l ock posi ti on.
The swi tch i s i n the l ock posi ti on when the col umn
l ock fl ag i s paral l el to the i gni ti on swi tch termi nal s
(Fi g. 5).
(c) Posi ti on i gni ti on swi tch park l ock dowel pi n so
i t wi l l engage the steeri ng col umn park l ock sl i der
l i nkage (Fi g. 6).
(d) Appl y a l i ght coati ng of grease to the col umn
l ock fl ag and the park l ock dowel pi n.
(3) Pl ace the i gni ti on swi tch agai nst the l ock hous-
i ng openi ng on the steeri ng col umn. Ensure that i gni -
ti on swi tch park l ock dowel pi n enters the sl ot i n the
park l ock sl i der l i nkage i n the steeri ng col umn.
(4) I nstal l i gni ti on swi tch mounti ng screws. Ti ghten
screws to 2 Nm (17 i n. l bs.) torque.
(5) I nstal l steeri ng col umn covers. Ti ghten screws to
2 Nm (17 i n. l bs.) torque.
(6) I f the vehi cl e i s equi pped wi th a ti l t steeri ng
col umn, i nstal l the ti l t l ever.
(7) To i nstal l the i gni ti on key i n the l ock cyl i nder:
(a) Wi th the key cyl i nder and the i gni ti on swi tch
i n the Lock posi ti on, i nsert the key cyl i nder i nto the
i gni ti on swi tch unti l i t bottoms.
(b) I nsert i gni ti on key i nto l ock cyl i nder. Whi l e
gentl y pushi ng the key cyl i nder i n toward the i gni -
ti on swi tch, rotate the i gni ti on key unti l to the end of
travel .
Fig. 3 Unseated Key Cylinder
Fig. 4 Key Cylinder Removal
Fig. 5 Ignition Switch View From Column
Fig. 6 Ignition Switch Mounting Pad
(c) Connect negati ve cabl e to battery.
(8) Check for proper operati on of the hal o l i ght, shi ft
l ock (i f appl i cabl e), and col umn l ock. Al so check for
proper operati on of the i gni ti on swi tch accessory, l ock,
off, run, and start posi ti ons.
SPECI FI CATI ONS
GENERAL INFORMATION
The fol l owi ng speci fi cati ons are publ i shed from the
l atest i nformati on avai l abl e at the ti me of publ i cati on.
I f anythi ng di ffers from the speci fi cati ons on the Ve-
hi cl e Emi ssi on Control I nformati on Label , use the
speci fi cati ons on the l abel .
SPARK PLUG WI RE ROUTI NG2.5L ENGI NES
SPARK PLUG WI RE ROUTI NG3.0L ENGI NE
SPARK PLUG WI RE ROUTI NG3.3L ENGI NES
3.3L ENGI NE DI RECT I GNI TI ON SYSTEM
DI STRI BUTORS
I GNI TI ON COI LS
SPARK PLUGS
TORQUE
OVERHEAD CONSOLE
CONTENTS
page page
COMPASS MINI-TRIP COMPUTER (CMTC) . . . . 2
COMPASS MODULE REPLACEMENT . . . . . . . . . 4
FRONT HEADER READING LAMP . . . . . . . . . . . 4
FRONT HEADER READING LAMP
REPLACEMENT/LAMP REPLACEMENT . . . . . . 4
MAP/READING LAMPS . . . . . . . . . . . . . . . . . . . . 1
OVERHEAD CONSOLE REPLACEMENT . . . . . . . . 4
REAR VENT WINDOWS SWITCHES . . . . . . . . . . 1
The overhead consol e i ncl udes:
Four map readi ng l amps
Storage compartments for sungl asses and garage
door opener transmi tter
Rear vent wi ndows swi tches
Di gi tal el ectroni c di spl ay
The Compass Mi ni Tri p Computer (CMTC) el ectroni c
di spl ay shows 6 condi ti ons:
Compass/Temperature.
Tri p odometer (ODO).
Average mi l es per gal l on (ECO).
I nstant mi l es per gal l on (ECO).
Di stance to empty (DTE).
El apsed ti me (ET).
As the dri ver pushes the STEP button they wi l l
di spl ay i ndi vi dual l y.
The US/M button changes the di spl ay from US to
metri c uni ts. For compl ete operati ng i nstructi ons, refer
to owners manual provi ded wi th vehi cl e.
MAP/READING LAMPS
The four map readi ng l amps are turned on and off by
pressi ng the l ens cover i ndent. The rear l amps operate
as courtesy l amps when the doors are open or cl osed.
The l amps al so operated when the headl amp POD
swi tch i s sl i d to the ful l ri ght posi ti on. The front
readi ng l amps do not come ON wi th the doors open or
headl amp di mmer swi tch i n courtesy mode (Fi g. 1).
LAMP HOUSI NG REPLACEMENT
(1) I nsert a l ong fl at bl ade tool at ei ther si de between
the l amp housi ng and mounti ng bracket. Ensure the
tool i s between the l amp and bracket. Careful l y pry the
l amp from the bracket unti l i t cl ears one of the four
retai ni ng cl i ps. Locate other cl i p on the same si de and
pry a l ong si de cl i p. Do the same to other two cl i ps unti l
i t free.
LENS/LAMP REPLACEMENT
(1) I nsert a l ong fl at bl ade tool at i nsi de edge of the
l ens. Careful l y pry the l ens from the housi ng and pi vot
the l ens out. May need to move the tool al ong the edge
to free l ens.
(2) Remove bul b by pul l i ng strai ght down.
(3) I nstal l new bul b by pushi ng fi rml y i nto socket.
(4) Begi n at outboard edge pi vot l ens i nto posi ti on
and snap i n. Test by pressi ng l ens from proper opera-
ti on and l i ghti ng.
LAMP TEST
(1) Cl ose vehi cl e doors.
(2) Press each l amp l ens. Ri ght hand l ens shoul d
l i ght passenger l amp and l eft hand l ens shoul d l i ght
dri vers l amp.
(3) I f ei ther of the rear l amps fai l to i l l umi nate, open
vehi cl e doors.
(a) I f rear l amp does not i l l umi nate check for a
burned out bul b.
(b) I f front l amp i l l umi nates when doors are open
check swi tch and wi ri ng (Fi g. 2).
REAR VENT WINDOWS SWITCHES
The swi tch on the ri ght si de operates the ri ght rear
vent wi ndow and swi tch on the l eft operates the l eft
rear wi ndow.
SWI TCH VOLTAGE TEST
(1) Remove the overhead consol e and di sconnect
wi re connectors.
(2) I gni ti on swi tch i n the run posi ti on.
(3) Connect vol tmeter to termi nal 4 and 5. Test for
battery vol tage.
(4) I f no vol tage, test 30 amp ci rcui t breaker or wi re.
(5) I f OK, go to Swi tch Modul e Test.
Fig. 1 Overhead Console
OVERHEAD CONSOLE 8C - 1
SWI TCH MODULE TEST
wi re connectors.
(2) I gni ti on swi tch i n the run posi ti on.
(3) Usi ng an Ohmmeter refer to Fi g. 3 to test
swi tches.
(4) I f no conti nui ty, at any of the posi ti ons, repl ace
swi tch modul e.
SWI TCH REMOVAL
wi re connectors.
(2) Remove swi tch from overhead consol e by movi ng
the four retai ni ng tabs. Two are l ocated on the si des
and two at the rear of the modul e. Take care i n
pressi ng tabs and pi vot modul e out of consol e.
COMPASS MINI-TRIP COMPUTER (CMTC)
CMTC i s a modul e that combi nes Travel er and Com-
pass / Temperature features. Actuati ng the STEP
swi tch wi l l cause the CMTC to change mode of opera-
ti on when i gni ti on i s ON. Exampl e:
Compass/Temperature
Tri p odometer (ODO)
Average mi l es per gal l on (ECO)
I nstant mi l es per gal l on (ECO)
Di stance to empty (DTE)
El apsed ti me (ET)
THERMOMETER AND COMPASS
Engi ne temperature can i ncrease the di spl ayed tem-
perature. The CMTC i s desi gned to dampen tempera-
ture readi ngs when the vehi cl e i s movi ng at a rate
sl ower than 18 mi l es per hour.
The outsi de temperature i s measured from a sensor
mounted i n the front of the vehi cl e. I f the temperature
i s more than 55C (131F) or the temperature sendi ng
l i ne i s shorted to ground, the temperature di spl ay
shoul d read SC. I f the temperature i s l ess than -40C
(-40F), or the sendi ng l i ne i s an open ci rcui t, the
di spl ay shoul d read OC.
I f the cal i brati on data stored i n the Body Control l er
i s not recei ved, the compass wi l l read onl y NE North-
East. The CMTC i s sel f cal i brati ng and requi res no
adjusti ng. The word CAL i s di spl ayed to show that the
compass i s i n cal i brati on mode. CAL wi l l turn off after
the vehi cl e has gone through three compl ete ci rcl es
wi thout stoppi ng, i n an area free of magneti c di stur-
bance. I f modul e di spl ays temperature whi l e the com-
pass i s bl ank, turn off i gni ti on and run sel f di agnosti cs
then demagneti ze the vehi cl e. After demagneti zi ng,
check compass cal i brati on number, refer to Sel f Di ag-
nosti c Test. I f greater than 15, demagneti ze agai n unti l
readi ng i s l ess than 15. I f compass sti l l goes bl ank after
demagneti zi ng then check i nternal di agnosti cs and
demagneti ze.
Fig. 2 Map Lamp Diagnosis
8C - 2 OVERHEAD CONSOLE
VARI ANCE PROCEDURE
Vari ance i s the di fference between magneti c North
and geographi c North refer to Fi g. 4 for vari ance
number. To adjust the compass vari ance set the CMTC
to Compass/Temperature mode and depress both the
US/M and STEP buttons for 5 seconds. The word VAR
and the l ast vari ance zone wi l l be di spl ayed. Depress
the US/M button to sel ect the desi red zone. Depress the
STEP button to set the new vari ance zone and resume
normal operati on. I f both buttons are hel d for 10
seconds i nstead of 5 seconds the CMTC wi l l set vari -
ance to 8 and enter the fast cal i brati on mode.
TRAVELER MESSAGES
Travel er data i s obtai ned from the Body Control l er
on the CCD l i nes. I f the bri ghtness l evel i s i mproper or
the data di spl ayed i s wrong then check CCD commu-
ni cati on by the fol l owi ng test. STEP the CMTC to the
el apsed ti me ET mode and si mul taneousl y press both
the US/M and STEP buttons to reset the modul e. I f the
el apsed ti me cl ock does not reset or fai l s to up-date
then check the CCD l i nes and Body Control l er. Run sel f
di agnosti cs before repl aci ng CMTC. The DRB I I i s
recommended for checki ng out the CCD l i nes and Body
Control l er.
DEMAGNETI ZI NG PROCEDURE
Every vehi cl e has i ts own magneti c fi el d. Thi s mag-
neti c fi el d i s created by the vari ous processes a steel
roof goes through when the vehi cl e i s bui l t. A magneti c
fi el d can al so be created i f the roof i s subjected to a
magnet. Exampl e:
Magneti c C.B. antenna
Magneti c ti pped screwdri ver
etc.
I f the roof becomes magneti zed use a demagneti zer
tool 6029 to demagneti ze the roof.
Fig. 3 Power Vent Window Continuity Test
Fig. 4 Variance Settings
I n thi s demagneti zi ng procedure you wi l l use the
demagneti zi ng tool to demagneti ze the roof and mount-
i ng screws i n the overhead consol e. I t i s i mportant that
you fol l ow the i nstructi ons bel ow exactl y. The mount-
i ng screws and the mounti ng brackets around the
compass area are steel , and therefore ai d i n the demag-
neti zi ng of the roof panel .
(1) Be sure the i gni ti on swi tch i s i n the OFF posi ti on
before you begi n the demagneti ze procedure.
(2) Pl ug the demagneti zi ng tool i nto a standard
110/115 vol t AC outl et, keepi ng the demagneti zi ng tool
at l east 12 i nches away from the compass area when
pl uggi ng i t i n.
(3) Sl owl y approach and contact the consol e mount-
i ng screw wi th the pl asti c coated ti p of the tool for at
l east two seconds.
(4) Wi th the demagneti zi ng tool sti l l energi zed,
sl owl y back i t away from the screw unti l the ti p i s at
l east 12 i nches from the screw head.
(5) After you have pul l ed at l east 12 i nches from the
l ast screw, remove the demagneti zi ng tool from i nsi de
vehi cl e and di sconnect i t from the el ectri cal outl et.
(6) Pl ace an 8-1/2 X 11 i nch pi ece of paper l engthwi se
on the roof of vehi cl e di rectl y above compass. The
purpose of the paper i s to protect the roof panel from
scratches and defi ne the area to be demagneti zed.
(7) Pl ug i n the demagneti zi ng tool , keepi ng i t at
l east two feet away from the compass uni t.
(8) Sl owl y approach the center of the roof panel at
the wi ndshi el d wi th the demagneti zi ng tool pl ugged i n.
(9) Contact the roof panel wi th the ti p of the tool .
Usi ng sl ow sweepi ng moti ons of 1/2 i nch between
sweeps. Move the tool approxi matel y four i nches ei ther
si de of the centerl i ne and at l east 11 i nch back from the
wi ndshi el d.
(10) Wi th the demagneti zi ng tool sti l l energi zed,
sl owl y back away from the roof panel unti l the ti p i s at
l east two feet from the roof before unpl uggi ng the tool .
(11) Recal i brate compass.
SELF-DI AGNOSTI C TEST
(1) The i gni ti on swi tch i n the OFF posi ti on, press
both the STEP button and the US/M button.
(2) Turn i gni ti on swi tch ON.
(3) Di spl ay showi ng do, rel ease buttons:
STEP button advances test to next procedure
US/M button repeats l ast procedure
(4) Pressi ng US/M button whi l e do i s di spl ayed
causes CMTC to exi t di agnosti cs and di spl ay current
headi ng as a number between 0 and 359 i n tempera-
ture of the di spl ay.
(5) Pressi ng STEP button, symbol s and numbers
correspondi ng to North/South and East/West cal i bra-
ti on are di spl ayed.
(6) Wi th d1 di spl ayed, press STEP button to show
the i nternal di agnosti cs:
(a) F1: I nternal fai l ure - repl ace modul e.
(b) F2: CCD bus fai l ure:
Check wi ri ng
Check any other body computer CCD functi on, i f
CCD functi ons are OK, and wi ri ng i s OK, then repl ace
modul e
(7) Wi th d2 di spl ayed, press STEP button and test
al l segment. I f any segment fai l s to l i ght, repl ace
modul e.
(8) Wi th d3di spl ayed, press STEP button and EXI T
di agnosti cs and resume normal operati on.
OVERHEAD CONSOLE REPLACEMENT
(1) Unscrew the mounti ng screws (Fi g. 5).
(2) Sl i de consol e forward toward wi ndshi el d unti l
the consol e unhooks from roof bracket.
(3) Di sconnect wi re harness from consol e.
COMPASS MODULE REPLACEMENT
(1) Remove overhead consol e and di sconnect wi ri ng.
(2) Remove two forward screws and pry rear of
compass modul e al ong the si des from the consol e
housi ng so 1 of the 2 compass pi ns cl ear the consol e.
Rotate modul e out of the consol e.
The front header readi ng l amps are turned ON and
OFF by pressi ng on thei r i ndi vi dual l ens cover i ndents.
REPLACEMENT/LAMP REPLACEMENT
(1) Pul l the l amp assembl y down, al ong the si des
from the bracket. Four metal cl i ps hol d the l amp i n the
bracket (Fi g. 6).
Fig. 5 Overhead Console Mounting
8C - 4 OVERHEAD CONSOLE
(2) Di sconnect the wi re harness connector from the
l amp assembl y.
(3) After the l amp assembl y i s free of the vehi cl e,
pul l the metal center refl ector to gai n access to the
l amp.
Fig. 6 Header Reading Lamp
BATTERY/STARTER/ALTERNATOR SERVICE
CONTENTS
page page
ALTERNATOR SERVICE PROCEDURES . . . . . . . 8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 10
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BATTERY
GENERAL INFORMATION
Thi s fi rst secti on wi l l cover Battery repl acement and
servi ce procedures onl y. For Battery di agnosti c proce-
dures, refer to Group 8A, Battery/Starti ng/Chargi ng
Systems Di agnosti cs.
Factory i nstal l ed batteri es (Fi g. 1) do not have re-
movabl e battery cel l caps. Water cannot be added to
factory i nstal l ed battery. Battery i s seal ed, except for
smal l vent hol es i n the top. Chemi cal composi ti on
i nsi de the battery produces an extremel y smal l amount
of gases at normal chargi ng vol tages. The factory
i nstal l ed battery i s equi pped wi th a test i ndi cator (Fi g.
1) that di spl ays a col ored bal l to show battery state-of-
charge.
Green I ndi cator = Ful l charge
Bl ack I ndi cator = Di scharged
Yel l ow I ndi cator = Battery repl acement requi red.
BATTERY VISUAL INSPECTION AND SERVICE
(1) Make sure i gni ti on swi tch i s i n OFF posi ti on and
al l accessori es are OFF.
(2) Di sconnect and remove the battery termi nal s
from the battery posts. Remove NEGATI VE cabl e fi rst
(Fi g. 2).
WARNING: TO PROTECT THE HANDS FROM BAT-
TERY ACID, A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES, NOT THE HOUSEHOLD TYPE,
SHOULD BE WORN WHEN REMOVING OR SERVIC-
ING A BATTERY. SAFETY GLASSES ALSO SHOULD
BE WORN.
(3) Remove battery hol d down cl amp (Fi g. 3) and
remove battery from vehi cl e.
CAUTION: Do not allow baking soda solution to enter
vent holes, as damage to battery can result.
(4) Cl ean top of battery wi th a sol uti on of warm
water and baki ng soda. Appl y sol uti on wi th a bri stl e
brush and al l ow to soak unti l aci d deposi ts l oosen (Fi g.
4). Ri nse wi th cl ear water and bl ot dry wi th paper
towel i ng. Di spose of towel i ng i n a safe manner. Refer to
the WARNI NGS on top of battery.
(5) I nspect battery case and cover for cracks or
l eakage. I f l eakage i s present battery must be repl aced.
(6) I nspect battery tray (Fi g. 3) for damage caused
by aci d from battery. I f aci d damage i s present, i t wi l l
be necessary to cl ean area wi th same sol uti on de-
scri bed i n Step (4).
Fig. 1 Maintenance Free BatteryTypical
Fig. 2 Remove Battery Cables
BATTERY/STARTER/ALTERNATOR SERVICE 8B - 1
(7) Cl ean battery posts wi th a sui tabl e battery post
cl eani ng tool (Fi g. 5).
(8) Cl ean i nsi de surfaces of battery termi nal cl amps
wi th a sui tabl e battery termi nal cl eani ng tool (Fi g. 6).
Repl ace damaged or frayed cabl es and broken termi nal
cl amps.
(9) I nspect battery for proper or damaged hol d down
l edge.
(10) I nstal l battery i n vehi cl e maki ng sure that
battery i s properl y posi ti oned on battery tray (Fi g. 3).
(11) I nstal l battery hol d down cl amp, maki ng sure
that i t i s properl y posi ti oned on battery.
(12) Pl ace fel t grease washer onto Posi ti ve (+) bat-
tery post.
(13) Connect battery cabl e cl amps to battery posts
maki ng sure top of cl amp i s fl ush wi th top of post (Fi g.
7). I nstal l POSI TI VE cabl e fi rst.
(14) Ti ghten cl amp nuts securel y.
Fig. 3 Battery Hold-Down/Tray
Fig. 4 Cleaning Battery
Fig. 5 Cleaning Battery Posts
Fig. 6 Cleaning Battery Cable Terminal
8B - 2 BATTERY/STARTER/ALTERNATOR SERVICE
STARTER
INDEX
page page
Neutral Starting and Back-up Switch . . . . . . . . . . . . 7
Starter Component Replacement . . . . . . . . . . . . . . 5
Starter Motor Replacement . . . . . . . . . . . . . . . . . . . 3
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supply Circuit and Control Circuit . . . . . . . . . . . . . . 3
GENERAL INFORMATION
Thi s secti on wi l l cover STARTER repl acement and
servi ce procedures onl y. For starter di agnosti c proce-
dures, refer to Group 8A, Battery/Starti ng/Chargi ng
Systems Di agnosti cs.
STARTING SYSTEM
The starti ng system has:
I gni ti on swi tch
Starter rel ay
Neutral starti ng and back-up swi tch
Wi ri ng harness
Battery
Starter motor wi th an i ntegral sol enoi d
BOSCH STARTERS
A Bosch permanent magnet starter motor i s avai l -
abl e on
2.5L and 3.0L engi nes on al l vehi cl es. A pl anetary
gear trai n transmi ts power between starter motor and
pi ni on shaft. The fi el ds have si x permanent magnets.
NI PPONDENSO STARTERS
A Ni ppondenso reducti on gear-fi el d coi l starter mo-
tor i s avai l abl e on 3.0L, and 3.3L engi nes.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
Both starter systems consi sts of two separate ci r-
cui ts:
A hi gh amperage suppl y to feed the starter motor.
A l ow amperage ci rcui t to control the starter sol e-
noi d.
For addi ti onal i nformati on on starter motor suppl y
and control ci rcui ts, refer to Group 8A,
Battery/Starti ng/Chargi ng Systems Di agnosti cs.
STARTER MOTOR REPLACEMENT
BOSCH STARTER 2.5L ENGI NE
(1) Di sconnect battery NEGATI VE cabl e (Fi g. 1).
(2) Rai se vehi cl e.
(3) Remove heat shi el d cl i p from the starter and
heat shi el d (Fi g. 2).
(4) Remove two bol ts and one nut attachi ng starter
to engi ne (Fi g. 3).
(5) Remove starter/starter sol enoi d assembl y from
engi ne. Posi ti on the starter to gai n access to the wi ri ng
connectors.
(6) Di sconnect the posi ti ve battery cabl e and wi ri ng
at the starter.
(7) Remove the starter from vehi cl e.
Fig. 7 Battery Cables Disconnected
Fig. 1 Remove or Install Battery Cable
(8) For i nstal l ati on, reverse above procedures. Cl ean
corrosi on/di rt from the cabl e and wi re termi nal s before
i nstal l i ng wi ri ng to the sol enoi d.
BOSCH OR NI PPONDENSO STARTER3.0L OR
3.3L ENGI NE
(1) Di sconnect NEGATI VE battery cabl e (Fi g. 1).
(3) Remove three starter attachi ng bol ts from
engi ne/transaxl e (Fi g. 4).
(3) Remove two wi re connector termi nal nuts and
remove connector (Bosch, Fi g. 5) (Ni ppondenso, Fi g. 6
or 7).
(4) Remove starter from vehi cl e (Bosch, Fi g. 8) (Ni p-
pondenso, Fi g. 9).
(5) For i nstal l ati on, reverse above procedures. Cl ean
corrosi on/di rt from the cabl e and wi re termi nal s before
i nstal l i ng wi ri ng to the sol enoi d.
Fig. 2 Starter Heat Shield4 Cylinder Engines
For easier servicing, do not remove the wiring
from starter at this time.
Fig. 3 Bosch Starter2.5L Engine
Fig. 4 Remove or Install Attaching Bolts
Fig. 5 Wire Terminal ConnectionsBosch Starter
Fig. 6 Wire Terminal Connections3.0L
EngineNippondenso Starter
STARTER COMPONENT REPLACEMENT
Caution: When servicing the starter assembly off the
vehicle, do not clamp the starter to a vice. Internal
damage may result.
NI PPONDENSO STARTER GEAR AND CLUTCH
(1) Remove the two gear housi ng attachi ng screws
and separate the gear housi ng from the sol enoi d hous-
i ng (Fi g. 10). The pi ni on gear, pi ni on gear beari ng, and
dri ve gear wi l l be l oose between the sol enoi d housi ng
and gear housi ng (Fi g. 11). When rei nstal l i ng pi ni on
gear and beari ng, wi pe wi th a cl ean rag and coat wi th
l i ghtwei ght hi gh temperature wheel beari ng grease.
Pl ace the l ubri cated beari ng and gear over beari ng
shaft i n the gear housi ng (Fi g. 12).
(2) Remove the starter gear and cl utch assembl y
from the sol enoi d housi ng (Fi g. 13).
Fig. 9 Remove/Install
StarterNippondensoTypical
Fig. 7 Wire Terminal Connections3.3L
EngineNippondenso Starter
Fig. 8 Remove/Install StarterBoschTypical
Fig. 10 Remove or Install Gear Housing
Fig. 11 Remove or Install Drive and Pinion Gears
BOSCH STARTER SOLENOI D REPLACEMENT
(1) Remove fi el d termi nal nut (Fi g. 14).
(2) Remove fi el d termi nal (Fi g. 15).
(3) Remove fi el d washer (Fi g. 16).
(4) Remove three sol enoi d mounti ng screws (Fi g.
17).
(5) Remove the sol enoi d from the starter assembl y.
Fig. 12 Lubricate and Install Pinion Gear Bearing
Fig. 13 Gear and Clutch Assembly
Fig. 14 Field Terminal Nut
Fig. 15 Field Coil Terminal
Fig. 16 Field Terminal Washer
Fig. 17 Solenoid Mounting Screws
BOSCH STARTER GEAR AND CLUTCH RE-
PLACEMENT
(1) Remove sol enoi d assembl y (Fi g. 18).
(2) Remove the two through-bol ts securi ng the
starter dri ve end housi ng to the motor housi ng (Fi g. 19)
and separate housi ngs.
(3) Remove rubber seal (Fi g. 20).
(4) Pul l the gear and cl utch assembl y from the dri ve
end housi ng (Fi g. 21).
NEUTRAL STARTING AND BACK-UP SWITCH
For el ectri cal di agnosti cs, when checki ng the starter
ci rcui ts, refer to the STARTER RELAY TESTS chart i n
Group 8A, Battery/Starti ng/Chargi ng Systems Di ag-
nosti cs.
For removal and i nstal l ati on of neutral swi tch, refer
to Neutral Swi tch Repl acement i n Group 21, Tran-
saxl e.
Fig. 18 Solenoid
Fig. 19 Through-Bolt
Fig. 20 Rubber Seal
Fig. 21 Starter Drive Gear Train
ALTERNATOR SERVI CE PROCEDURES
INDEX
page page
Alternator Replacement2.5L Engine . . . . . . . . . . . 8
Alternator Replacement3.0L Engine . . . . . . . . . . . 9
Alternator Replacement3.3L Engine . . . . . . . . . . 10
GENERAL INFORMATION
Thi s secti on wi l l cover al ternator repl acement onl y.
I nformati on coveri ng al ternator on-vehi cl e testi ng and
di agnosi s can be found i n Group 8A,
Battery/Starti ng/Chargi ng Systems Di agnosti cs. To
i denti fy the al ternator, refer to the Al ternator Speci fi -
cati on chart at the rear of thi s secti on.
Thesealternators arenot intended to bedisas-
sembled for service. It must be replaced as an
assembly.
ALTERNATOR REPLACEMENT2. 5L ENGINE
Removal and reposi ti oni ng of A/C Compressor wi th-
out di sconnecti ng refri gerant l i nes i s necessary on
some model s to gai n access to al ternator.
(1) Di sconnect battery negati ve cabl e (Fi g. 1).
(2) I f Equi pped Wi th ai r condi ti oni ng:
(a) Remove the A/C dri ve bel t. Refer to Group 7,
Cool i ng System.
(b) Remove the four bol ts retai ni ng the A/C com-
pressor to the mounti ng bracket (Fi g. 2).
(c) Do not di sconnecti ng the A/C refri gerant l i nes,
posi ti on the A/C compressor to al l ow al ternator re-
moval .
WARNING: THE A/C REFRIGERANT SYSTEM IS UN-
DER PRESSURE EVEN WHEN THE ENGINE IS OFF.
REFER TO THE SAFETY PRECAUTIONS AND WARN-
INGS SECTION IN HEATING AND A/C, GROUP 24,
BEFORE PERFORMING ANY SERVICE OPERATION.
(3) Remove the al ternator dri ve bel t. Refer to Group
7, Cool i ng System.
(4) Remove the two al ternator mounti ng bol ts (Fi g.
3) and posi ti on the al ternator to gai n access to al l the
wi re connectors. I f equi pped wi th a :
BOSCH ALTERNATOR. Remove B+ termi nal nut,
fi el d termi nal nuts, and ground harness hol d down
nuts (Fi g. 4). Remove wi re connector assembl y.
NI PPONDENSOALTERNATOR. Remove nuts from
fi el d termi nal s, ground termi nal , wi re harness
Fig. 3 Remove or Install Mounting Bolts
Fig. 1 Remove Battery Negative (-) Cable
Fig. 2 A/C Compressor Removal and
Installation2.5 L Engine
and B+ termi nal (Fi g. 5). B+ termi nal nut must be
removed l ast to prevent damage to termi nal i nsul ator.
(5) Remove the al ternator from the vehi cl e.
Torque al l fasteners. Refer to the TORQUE SPECI FI -
CATI ONS chart at the rear of thi s group.
(1) Di sconnect battery negati ve cabl e (Fi g. 1).
(2) Remove al ternator dri ve bel t. Refer to Group 7,
Cool i ng System.
(3) Remove the al ternator mounti ng bol ts and sepa-
rate the al ternator from the mounti ng bracket (Fi g. 6).
(4) Remove the B+ termi nal nut, fi el d termi nal nuts,
and ground/wi re harness hol d-down nuts. Remove wi re
connectors.
(5) Remove the al ternator from the vehi cl e.
Torque al l fasteners. Refer to the Torque Speci fi cati ons
chart at the back of thi s group.
Fig. 4 Remove or Install Wire Connector
AssemblyBosch Alternator
Fig. 5 Remove or Install Wire Connector
AssemblyNippondenso Alternator
Fig. 6 Remove or Install Alternator Mounting
Bolts3.0L Engine
Fig. 7 Support Bracket for Alternator Tensioner
Power Steering Bracket
(1) Di sconnect battery NEGATI VE cabl e (Fi g. 1).
(2) Remove al ternator dri ve bel t. Refer to Group 7,
Cool i ng System.
(3) Loosen, but do not remove the nut on the support
bracket at exhaust mani fol d (Fi g. 7).
(4) Remove the al ternator tensi oner power steeri ng
bracket bol t.
(5) Remove the tensi oner stud nut and the tensi oner
(Fi g. 8).
(6) Remove the al ternator mounti ng bol ts.
(7) Remove and posi ti on the power steeri ng reser-
voi r from the al ternator mounti ng bracket. Do not
remove the hoses from the reservoi r.
(8) Remove the three al ternator support bracket
bol ts (Fi g. 7).
(9) Remove i ntake pl enum-to-al ternator mounti ng
bracket bol t.
(10) Remove al ternator support bracket (Fi g. 8).
(11) Posi ti on al ternator and remove al ternator wi r-
i ng.
(12) Remove al ternator.
Torque al l fasteners. Refer to the Torque Speci fi cati ons
chart at the back of thi s group.
SPECI FI CATI ONS
Fig. 8 Alternator/Support Bracket3.3L Engine
STARTER/BATTERY
ALTERNATOR AMPERAGE/I DENTI FI CATI ON NUMBERS
TORQUE SPECI FI CATI ONSALTERNATOR/STARTER
ELECTRICAL
GROUP I NDEX
Page Page
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 8F
BATTERY/STARTER/ALTERNATOR SERVICE . . . 8B
BATTERY/STARTING/CHARGING SYSTEMS
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 8A
CHIME/BUZZER WARNING SYSTEM . . . . . . . . . 8U
HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8D
INSTRUMENT PANEL AND GAUGES . . . . . . . . . 8E
LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . 8C
POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . 8P
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . 8T
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . 8R
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . 8S
REAR WINDOW DEFOGGER . . . . . . . . . . . . . . . 8N
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . 8M
SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8H
TURN SIGNAL AND FLASHERS . . . . . . . . . . . . . 8J
WINDSHIELD WIPERS AND WASHERS . . . . . . 8K
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 8W
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page page
ALTERNATOR TEST PROCEDURES ON
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY TEST PROCEDURES ON-VEHICLE . . . 2
FAULT CODES ON BOARD DIAGNOSTICS . . . 18
IGNITION OFF DRAW (IOD) . . . . . . . . . . . . . . . . 7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 23
STARTER TEST PROCEDURES ON VEHICLE . . . 9
For Battery, Starter or Al ternator Repl acement,
refer to Group 8B, Battery/Starter/Al ternator Servi ce.
Group 8A, Battery/Starti ng/Chargi ng Systems Di ag-
nosti cs wi l l cover di agnosti cs onl y.
The Battery, Starti ng, and Chargi ng Systems oper-
ate i n conjuncti on wi th one another, and must be
thoroughl y tested as a compl ete system. To enabl e the
vehi cl e to start and charge properl y, i t must have a
battery that wi l l perform to speci fi cati ons. The starter
motor, al ternator, wi ri ng, and el ectroni cs al so must
perform wi thi n speci fi cati ons. Group 8A wi l l cover
Starti ng (Fi g. 1) and Chargi ng System (Fi g. 2) di agnos-
ti c procedures. These wi l l be covered from the most
basi c conventi onal methods to On Board Di agnosti cs
(OBD) bui l t i nto the vehi cl es el ectroni cs. The need for
conventi onal testi ng equi pment has not been el i mi -
nated by the i ntroducti on of OBD. Frequent use of an
ammeter, vol t/ohmmeter, battery charger, carbon pi l e
rheostat (l oad tester), and 12 vol t (l ow wattage) test
l i ght wi l l be requi red.
Al l front wheel dri ve vehi cl es are equi pped wi th OBD
and al l OBD sensi ng systems are moni tored by
Fig. 1 Starting System Components
ELECTRICAL 8A - 1
the Engi ne Control computer. The Engi ne Control
computer wi l l store i n el ectroni c memory, any detect-
abl e fai l ure wi thi n the moni tored ci rcui ts. I t wi l l retai n
thi s i nformati on for a peri od of 50 engi ne starts, then
erase the memory i f the fai l ure does not reoccur duri ng
that peri od. Thi s al so wi l l transl ate a moni tored fai l ure
i n the form of a FAULT CODE when a readout com-
mand i s gi ven. A readout command can be made by
turni ng the i gni ti on swi tch to ON-OFF-ON-OFF-ON
wi thout starti ng the engi ne. The CHECK ENGI NE
LAMP on the i nstrument cl uster wi l l fl ash i n predeter-
mi ned sequences to show Faul t Codes. However, the
Check Engi ne Lamp cannot express faul t codes for al l
fai l ures. Faul t codes are easi er to obtai n and more
compl ete wi th the use of Di agnosti c Tool (DRB I I ). Thi s
tool i s pl ugged i nto the di agnosti c connector l ocated i n
the engi ne compartment (Fi g. 2). Refer to the i nstruc-
ti ons provi ded wi th the (DRB I I ) tool bei ng used.
For numbered Faul t Codes pertai ni ng to components
wi thi n thi s parti cul ar Group, refer to Fai l ure CodesOn
Board Di agnosti cs i n Group 8A. For other numbered Faul t
Codes not pertai ni ng to thi s Group (8A), refer to On Board
Di agnosti cs i n the General Di agnosi s secti on of Group 14,
Fuel System for more i nformati on.
BATTERY TEST PROCEDURES ON-VEHI CLE
INDEX
page page
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery Open Circuit Voltage Test . . . . . . . . . . . . . . 4
Causes of Battery Discharging . . . . . . . . . . . . . . . . 3
State of Charge Tests . . . . . . . . . . . . . . . . . . . . . . 3
Test Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
The battery stores, stabi l i zes, and produces el ectri cal
current to operate vari ous el ectri cal systems i n the vehi cl e.
The determi nati on of whether a battery i s good or bad i s
made by i ts abi l i ty to accept a charge. I t al so must produce
hi gh-amperage current output over an extended peri od to
be abl e to start the vehi cl e. The capabi l i ty of the battery to
store el ectri cal current comes from a chemi cal reacti on. Thi s
reacti on takes pl ace between the sul furi c aci d sol uti on
el ectrol yte and the l ead +/- pl ates i n each cel l of the battery.
As the battery di scharges, the pl ates react wi th the aci d
from the el ectrol yte. When the chargi ng system charges the
battery, the water i s converted to sul furi c aci d i n the
battery. The amount of aci d, speci fi c gravi ty i n the el ectro-
l yte can be measured wi th a hydrometer. The factory
i nstal l ed battery i s equi pped wi th a bui l t-i n hydrometer, as
a test i ndi cator (Fi gs. 3, 4 and 5) to assi st i n deci de i ts state
of charge. The factory i nstal l ed battery i s al so seal ed. Water
cannot and shoul d not be added.
The battery i s vented to rel ease gases that are
created when the battery i s bei ng charged and di s-
charged. The battery top, posts, and termi nal s shoul d
be cl eaned when other under hood mai ntenance i s
performed (Fi g. 3).
WARNING: DO NOT ASSIST BOOST, CHARGE, ADD
WATER, OR LOAD TEST BATTERY WHEN ELECTRO-
LYTE LEVEL IS BELOW THE TOP OF THE PLATES.
PERSONAL INJURY MAY OCCUR.
Fig. 2 Charging System Components
8A - 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
When the el ectrol yte l evel i s bel ow the top of the
pl ates a yel l ow or bri ght col or i ndi cator i n si ght gl ass
(Fi gs. 4 and 5), the battery must be repl aced. Refer to
Test I ndi cator. The battery must be compl etel y charged
wi th a green col or i n si ght gl ass. The top, posts, and
termi nal s shoul d be properl y cl eaned before di agnosti c
procedures are performed. Al so refer to Group 8B,
Battery/Starter/Al ternator Servi ce for addi ti onal i nfor-
mati on.
TEST INDICATOR
A test i ndi cator a hydrometer vi ewed through a si ght
gl ass, i s bui l t i nto the top of battery case (Fi gs. 3, 4 and
5). Thi s provi des vi sual i nformati on for battery testi ng.
The test i ndi cator si ght gl ass i s to be used wi th
di agnosti c procedures descri bed i n thi s Group.
I t i s i mportant when usi ng the Test I ndi cator that
the battery be l evel and have a cl ean top to see the
correct i ndi cati ons. A l i ght may be requi red to vi ew the
I ndi cator.
WARNING: DO NOT USE OPEN FLAME NEAR BAT-
TERY. EXPLOSIVE GASES FORM ABOVE BATTERY.
STATE OF CHARGE TESTS
USI NG TEST I NDI CATOR
The bui l t-i n test hydrometer (Fi gs. 3, 4 and 5) mea-
sures the speci fi c gravi ty of the el ectrol yte. Speci fi c
Gravi ty (SG) of the el ectrol yte wi l l show state-of-
charge (vol tage). The test i ndi cator WI LL NOT show
cranki ng capaci ty of the battery. Refer to Battery Load
Test for more i nformati on. Look i nto the si ght gl ass
(Fi gs. 4 and 5) and note the col or of the i ndi cator (Fi g.
5). Refer to the fol l owi ng descri pti on as col or show:
GREEN = 75 to 100
state-of-charge
The battery i s adequatel y charged for further testi ng
and may be returned to use. I f the vehi cl e wi l l not
crank for a maxi mum 15 seconds, refer to BATTERY
LOAD TEST i n thi s Group for more i nformati on.
BLACK OR DARK = 0 to 75
state-of-charge
The battery i s I NADEQUATELY charged and must
be charged unti l green dot i s vi si bl e, (12.4 vol ts or
greater) before the battery i s tested or returned to use.
Refer to Causes of Battery Di schargi ng i n thi s Group
for more i nformati on.
YELLOW OR BRI GHT COLOR = Battery must be
repl aced.
WARNING: DO NOT CHARGE, ASSIST BOOST, LOAD
TEST, OR ADD WATER TO THE BATTERY WHEN
YELLOW OR BRIGHT COLOR DOT IS VISIBLE. PER-
SONAL INJURY MAY OCCUR.
A yel l ow or bri ght col or dot shows el ectrol yte l evel i n
battery i s bel ow the test i ndi cator (Fi g. 5). Water
cannot be added to a mai ntenance free battery. The
battery must be repl aced. A l ow el ectrol yte l evel may be
caused by an over chargi ng condi ti on. Refer to Al ter-
nator Test Procedures on Vehi cl e.
CAUSES OF BATTERY DISCHARGING
I t i s normal to have a smal l 5 to 30 mi l l i amperes
conti nuous el ectri cal draw from the battery. Thi s
draw wi l l take pl ace wi th the i gni ti on i n the OFF
posi ti on, and the courtesy, dome, storage compart-
Fig. 3 Battery Construction and Test Indicator
Fig. 4 Built in Test Indicator
Fig. 5 Test Indicator Sight Glass
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3
ments, and engi ne compartment l i ghts OFF. The
conti nuous draw i s due to vari ous el ectroni c features or
accessori es that requi re el ectri cal current wi th the
i gni ti on OFF to functi on properl y. When a vehi cl e i s not
used over an extended peri od of approxi matel y 20 days
the Mai n Fusi bl e Li nk Connector (Fi g. 6) shoul d be
di sconnected. Thi s i s l ocated near the battery on the
engi ne wi ri ng harness. Di sconnecti on of thi s connector
wi l l hel p prevent battery di schargi ng.
ABNORMAL BATTERY DI SCHARGI NG
(1) Corroded battery posts, cabl es or termi nal s.
(2) Loose or worn al ternator dri ve bel t.
(3) El ectri cal l oads that exceed the output of the
chargi ng system due to equi pment or accessori es i n-
stal l ed after del i very.
(4) Sl ow dri vi ng speeds i n heavy traffi c condi ti ons or
prol onged i dl i ng wi th hi gh-amperage el ectri cal sys-
tems i n use.
(5) Defecti ve el ectri cal ci rcui t or component causi ng
excess I gni ti on Off Draw (I OD). Refer to I gni ti on Off
Draw (I OD).
(6) Defecti ve chargi ng system.
(7) Defecti ve battery.
BATTERY OPEN CIRCUIT VOLTAGE TEST
An open ci rcui t vol tage no l oad test shows the state of
charge of a battery. Al so, i f i t wi l l pass a l oad test of 50
percent of the battery col d crank rati ng. Refer to
Battery Load Test. I f a battery has an open ci rcui t
vol tage readi ng of 12.4 vol ts or greater, and wi l l not
endure a l oad test, i t i s defecti ve and repl acement
woul d be requi red. To test open ci rcui t vol tage, perform
the fol l owi ng operati on:
(1) Remove both battery cabl es, negati ve fi rst. I f the
battery has been boosted, charged, or l oaded just pri or
to thi s operati on, al l ow the battery a few mi nutes to
stabi l i ze.
(2) Usi ng a vol tmeter connected to the battery posts
and measure the open ci rcui t vol tage (Fi g. 7).
Thi s vol tage readi ng wi l l show the state of charge of
the battery. I t wi l l not reveal battery cranki ng capaci ty
(Fi g. 8).
BATTERY LOAD TEST
A ful l y charged battery must have reserve cranki ng
capaci ty. Thi s wi l l enabl e the starter motor and i gni -
ti on system enough power to start the engi ne over a
broad range of ambi ent temperatures. A battery l oad
test wi l l veri fy the actual cranki ng performance based
on the col d crank rati ng of the battery.
Fig. 6 Main Fusible Link Connector
Fig. 7 Testing Open Circuit Voltage
Fig. 8 BATTERY OPEN CIRCUIT VOLTAGE
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY RE-
SULT.
(1) Remove both battery cabl es, NEGATI VE fi rst.
Battery top, cabl es and posts shoul d be cl ean. I f green
dot i s not vi si bl e i n i ndi cator, charge the battery. Refer
to Battery Chargi ng Procedures.
(2) Use a sui tabl e Vol t/Ammeter/Load tester (Fi g. 9)
connected to the battery posts (Fi g. 10). Check the open
ci rcui t vol tage of the battery. Vol tage shoul d be equal to
or greater than 12.4 vol ts wi th the green dot vi si bl e i n
test i ndi cator.
(3) Rotate the l oad control knob of the Carbon pi l e
rheostat to appl y a 300 amp l oad. Appl y thi s l oad for 15
seconds to remove the surface charge from the battery,
and return the control knob to off (Fi g. 11).
(4) Al l ow the battery to stabi l i ze for 15 seconds, and
then veri fy open ci rcui t vol tage.
(5) Rotate the l oad control knob on the tester to
mai ntai n 50% of the battery col d crank rati ng for a
mi ni mum 15 seconds (Fi g. 12).
After 15 seconds, record the l oaded vol tage readi ng
and return the l oad control to off.
(6) Vol tage drop wi l l vary accordi ng to battery tem-
perature at the ti me of the l oad test. Battery tempera-
ture can be esti mated by the temperature of exposure
over the precedi ng several hours. I f the battery has
been charged, boosted, or l oaded a few mi nutes pri or to
the test, the battery woul d be sl i ghtl y warmer. Refer to
Fi g. 13 for proper l oaded vol tage readi ng.
Fig. 9 Volt-Ammeter-Load Tester
Fig. 10 Volt-Ammeter-Load Tester Connections
Fig. 11 Remove Surface Charge from Battery
Fig. 12 Load 50% Cold Crank Rating
Fig. 13 LOAD TEST TEMPERATURE
(7) I f battery passes l oad test, i t i s i n good condi ti on
and further tests are not necessary. I f i t fai l s l oad test,
i t shoul d be repl aced.
BATTERY CHARGING
A battery i s consi dered ful l y charged when i t wi l l
meet al l the fol l owi ng requi rements:
I t has an open ci rcui t vol tage charge of at l east 12.4
vol ts (Fi g. 8).
I t passes the 15 second l oad test (Fi g. 13).
The bui l t i n test i ndi cator dot i s GREEN (Fi g. 5).
The battery cannot be refi l l ed wi th water, i t must be repl aced.
WARNING: DO NOT CHARGE A BATTERY THAT HAS
EXCESSIVELY LOW ELECTROLYTE LEVEL. BAT-
TERY MAY SPARK INTERNALLY AND EXPLODE.
EXPLOSIVE GASES FORM OVER THE BATTERY.
DO NOT SMOKE, USE FLAME, OR CREATE SPARKS
NEAR BATTERY.
DO NOT ASSIST BOOST OR CHARGE A FROZEN
BATTERY. BATTERY CASING MAY FRACTURE.
BATTERY ACID IS POISON, AND MAY CAUSE SE-
VERE BURNS. BATTERIES CONTAIN SULFURIC
ACID. AVOID CONTACT WITH SKIN, EYES, OR
CLOTHING. IN THE EVENT OF CONTACT, FLUSH
WITH WATER AND CALL PHYSICIAN IMMEDIATELY.
KEEP OUT OF REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable
first (Fig. 14) before charging battery to avoid damage
to electrical systems. Do not exceed 16.0 volts while
charging battery. Refer to the instructions supplied
with charging equipment
Battery el ectrol yte wi l l bubbl e i nsi de of battery case
whi l e bei ng charged properl y. I f the el ectrol yte boi l s
vi ol entl y, or i s di scharged from the vent hol es whi l e
chargi ng, i mmedi atel y reduce chargi ng rate or turn off
charger. Eval uate battery condi ti on. Battery damage
may occur i f chargi ng i s excessi ve.
Some battery chargers are equi pped wi th pol ari ty sensi ng
devi ces to protect the charger or battery from bei ng damaged
i f i mproperl y connected. I f the battery state of charge i s too
l ow for the pol ari ty sensor to detect, the sensor must be
bypassed for charger to operate. Refer to operati ng i nstruc-
ti ons provi ded wi th battery charger bei ng used.
CAUTION: Charge battery until test indicator appears
green. Do not overcharge.
I t may be necessary to ji ggl e the battery or vehi cl e to
bri ng the green dot i n the test i ndi cator i nto vi ew.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne cranki ng
capaci ty. Refer to BATTERY LOAD TEST i n thi s
Group. I f the battery wi l l endure a l oad test, return the
battery to use. I f battery wi l l not endure a l oad test, i t
must be repl aced. Properl y cl ean and i nspect battery
hol d downs, tray, termi nal s, cabl es, posts, and top
before compl eti ng servi ce. Al so refer to Group 8B,
Battery/Starter/Al ternator Servi ce.
CHARGI NG TI ME REQUI RED
The ti me requi red to charge a battery wi l l vary
dependi ng upon the fol l owi ng factors:
SI ZE OF BATTERY
A compl etel y di scharged of a l arge heavy-duty bat-
tery requi res more than twi ce the rechargi ng ti me as a
compl etel y di scharged smal l capaci ty battery (Fi g. 15).
TEMPERATURE
A l onger ti me wi l l be needed to charge a battery at
-18C (0F) than at 27C (80F). When a fast charger i s
connected to a col d battery, current accepted by battery
wi l l be very l ow at fi rst. I n ti me, the battery wi l l accept
a hi gher rate as battery warms.
CHARGER CAPACI TY
A charger whi ch can suppl y onl y fi ve amperes wi l l
requi re a much l onger peri od of chargi ng than a
charger that can suppl y 30 amperes or more.
STATE-OF-CHARGE
A compl etel y di scharged battery requi res more
chargi ng ti me than a parti al l y charged battery. El ec-
trol yte i s nearl y pure water i n a compl etel y di scharged
battery. At fi rst, the chargi ng current amperage wi l l be
l ow. As water i s converted to sul furi c aci d i nsi de the
battery, the current amp rate wi l l ri se. Al so, the speci fi c
gravi ty of the el ectrol yte wi l l ri se, bri ngi ng the green
dot (Fi g. 5).
Fig. 14 Disconnect Negative Battery Cable
Fig. 15 BATTERY CHARGING TIME
WARNING: NEVER EXCEED 20 AMPS WHEN CHARG-
ING A COLD -1C (30F) BATTERY. PERSONAL IN-
JURY MAY RESULT.
CHARGI NG COMPLETELY DI SCHARGED BAT-
TERY
The fol l owi ng procedure shoul d be used to recharge a
compl etel y di scharged battery. Unl ess procedure i s
properl y fol l owed, a good battery may be needl essl y
repl aced (Fi g. 16).
(1) Measure the vol tage at battery posts wi th a
vol tmeter accurate to 1/10 vol t (Fi g. 17). I f bel ow 10
vol ts, charge current wi l l be l ow, and i t coul d take some
ti me before i t accepts a current i n excess of a few
mi l l i amperes. Such l ow current may not be detectabl e
on amp meters bui l t i nto many chargers.
(2) Connect charger l eads. Some chargers feature
pol ari ty protecti on ci rcui try that prevents operati on
unl ess charger i s connected to battery posts correctl y. A
compl etel y di scharged battery may not have enough
vol tage to acti vate thi s ci rcui try. Thi s may happen
though the l eads are connected properl y.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. For the ti me requi red for the
battery to accept measurabl e charger current at vari -
ous vol tages, refer to Fi g. 16. I f charge current i s sti l l
not measurabl e after chargi ng ti mes, the battery
shoul d be repl aced. I f charge current i s measurabl e
duri ng chargi ng ti me, the battery may be good, and
chargi ng shoul d be compl eted i n the normal manner.
I GNI TI ON OFF DRAW (I OD)
GENERAL INFORMATION
A normal el ectri cal system wi l l draw from 5 to 30
mi l l i amperes from the battery. Thi s i s wi th the i gni ti on
i n the OFF posi ti on, and al l non-i gni ti on control l ed
ci rcui ts i n proper worki ng order. The amount of I OD
wi l l depend on body model and el ectri cal components. A
vehi cl e that has not been operated for an extended
peri od approxi matel y 20 days may di scharge the bat-
tery to an i nadequate l evel . I n thi s case, the MAI N
Fusi bl e Li nk Connector shoul d be di sconnected. The
Mai n Fusi bl e Li nk connector i s l ocated rearward of the
battery on the engi ne wi ri ng harness (Fi g. 18).
I f the I OD i s over 30 mi l l i amperes, the defect must be
found and corrected before repl aci ng the battery. Usu-
al l y, the battery can be charged and returned to servi ce
(Fi g. 15).
Fig. 16 CHARGE RATE
Fig. 17 Voltmeter Accurate to 1/10 Volt (Connected)
Fig. 18 IOD Test
I GNI TI ON OFF DRAW (I OD) TESTS
VEHICLES WITHOUT ELECTRONIC AUTOMATIC TRANSMIS-
SION
Testi ng for HI GHER AMPERAGE I OD must be per-
formed fi rst to prevent damage to most mi l l i amp
meters.
A standard 12 vol t test l i ght and a mi l l i amp meter
that i s equi pped wi th two l eads must be used for the
fol l owi ng tests. The mi l l i amp meter shoul d be abl e to
handl e up to two amps.
(1) Veri fy that al l el ectri cal accessori es are OFF.
Turn off al l l i ghts, cl ose trunk l i d, cl ose gl ove box door,
turn off sun vi sor vani ty l i ghts, cl ose al l doors and
remove i gni ti on key. Al l ow the I l l umi nated Entry Sys-
tem i f equi pped to ti me out i n approxi matel y 30 sec-
onds.
(2) Veri fy the engi ne compartment l amp i s worki ng
by
openi ng/cl osi ng hood. Remove the l amp.
(3) Di sconnect negati ve battery cabl e (Fi g. 14).
(4) Connect a typi cal 12-vol t test l i ght l ow wattage
l amp between the negati ve cabl e cl amp and the nega-
ti ve battery post (Fi g. 18). The test l i ght may be
bri ghtl y l i t for up to three mi nutes or may not be l i t at
al l dependi ng on the body model or el ectroni c compo-
nents on the vehi cl e.
(a) The term bri ghtl y used throughout the fol l ow-
i ng tests. Thi s i mpl i es the bri ghtness of the test l i ght
wi l l be the same as i f i t were connected across the
battery posts. Thi s woul d be wi th a ful l y charged
battery.
(b) The test l i ght or the mi l l i amp meter MUST be
posi ti vel y connected to the battery post and the
battery cabl e duri ng al l I OD testi ng.
(c) Do not al l ow the test l i ght or the mi l l i amp
meter to become di sconnected duri ng any of the I OD
tests. I f thi s happens, the el ectroni c ti mer functi ons
wi l l be acti vated and al l I OD tests must be repeated
from the begi nni ng. Cl amp the test l i ght at both ends
to prevent acci dental di sconnecti on.
(d) After three mi nutes ti me has el apsed, the test
l i ght shoul d turn off or be di ml y l i t dependi ng on the
el ectroni c components on the vehi cl e. I f the test l i ght
remai ns bri ghtl y l i t, do not di sconnect test l i ght.
Di sconnect each fuse or ci rcui t breaker (refer to
Group 8W, Wi ri ng Di agrams) unti l test l i ght i s ei ther
off or di ml y l i t. Thi s wi l l el i mi nate hi gher amperage
I OD. I t i s now safe to i nstal l mi l l i amp meter to check
for l ow amperage I OD.
(e) Possi bl e sources of hi gh I OD are usual l y ve-
hi cl e trunk l amp, gl ove compartment, l uggage com-
partment and etc..
(f) I f test l i ght i s sti l l BRI GHTLY l i t after di scon-
necti ng each fuse and ci rcui t breaker, di sconnect the
wi ri ng harness from the al ternator. Refer to Al terna-
tor Testi ng. Do not di sconnect test l i ght.
CAUTION: The last test has higher amperage IOD
must be performed before proceeding with low am-
perage IOD tests. The higher amperage IOD must be
eliminated before hooking up milliamp meter to
check for low amperage IOD. If higher amperage IOD
has not been eliminated, milliamp meter may be
damaged. Most milliamp meters will not handle over
one or two amps. Do not hook up meter if test light is
glowing brightly. Refer to maximum amperage speci-
fications and instructions supplied with milliamp
meter.
After hi gher amperage I OD has been corrected, l ow
amperage I OD may be checked. The MAXI MUM I OD =
30 MI LLI AMPERES.
(5) Wi th test l i ght sti l l connected, connect mi l l i amp
meter between battery negati ve post and negati ve
battery cabl e (Fi g. 19). Do not open any doors or turn
on any el ectri cal accessori es wi th the test l i ght di scon-
nected and the mi l l i amp meter connected. Meter may
be damaged.
(6) Di sconnect test l i ght. Mi l l i amp meter readi ng
shoul d be l ess than 30 mi l l i amperes. I f l ow amperage
I OD i s not wi thi n speci fi cati ons, di sconnect:
(a) The 60 way connector at the Engi ne Control l er
computer l ocated outboard of the battery. Refer to
Group 8D, I gni ti on, for more i nformati on.
(b) The 25 way connectors on the Body Control l er
computer, i f equi pped.
(c) The ci rcui ts to the cl ock and radi o.
(d) The wi ri ng harness from the al ternator. Refer
to Al ternator Testi ng i n thi s Group.
Check each component unti l excessi ve I OD i s found.
Fig. 19 Low Amperage IOD Test
Each ti me the test l i ght or mi l l i amp meter i s di scon-
nected and connected, al l el ectroni c ti mer functi ons
wi l l be acti vated. Tests must be repeated from the
begi nni ng.
Test l i ght or meter MUST remai n connected for al l
tests.
VEHICLES WITH ELECTRONIC AUTOMATIC TRANSMISSION
Thi s vehi cl e wi l l have temporary hi gh I OD of 5 amps
or more for up to 25 mi nutes. Thi s hi gher I OD can often
mask another probl em and shoul d be consi dered when
performi ng I OD testi ng.
I f hi gh or l ow I OD i s suspected, al l ow an addi ti onal
25 mi nutes (mi ni mum) of el ectroni c shut off ti me.
To defeat the ti mer, di sconnect the 60-way connector
on the Transmi ssi on Control l er. Thi s computer i s l o-
cated behi nd the ri ght front strut tower.
STARTER TEST PROCEDURES ON VEHI CLE
INDEX
page page
Diagnostic Preparation . . . . . . . . . . . . . . . . . . . . . . 9
Starter Control Circuit Tests . . . . . . . . . . . . . . . . . 12
Starter Feed Circuit Resistance Test . . . . . . . . . . . 11
Starter Feed Circuit Tests . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
The starti ng system (Fi g. 1) has:
I gni ti on swi tch
Starter rel ay (Fi g. 2)
Neutral starti ng and back-up swi tch wi th automati c
transmi ssi ons onl y
Wi ri ng harness
Battery
Starter motor wi th an i ntegral sol enoi d
These components form two separate ci rcui ts. A hi gh
amperage ci rcui t that feeds the starter motor up to
300+ amps, and a control ci rcui t that operates on l ess
than 20 amps.
DIAGNOSTIC PREPARATION
Before proceedi ng wi th starti ng system di agnosti cs,
veri fy:
(1) The battery top, posts, and termi nal s are cl ean.
(2) The al ternator dri ve bel t tensi on and condi ti on i s
correct.
(3) The battery state-of-charge i s correct.
(4) The battery wi l l endure l oad test.
(5) The battery cabl e (+/-) connecti ons at the starter
and engi ne bl ock are cl ean and free from corrosi on.
(6) The wi ri ng harness connectors and termi nal s are
cl ean and free from corrosi on.
(7) Proper ci rcui t groundi ng.
(8) Refer to Starter System Di agnosti cs (Fi g. 3).
STARTER FEED CIRCUIT TESTS
The fol l owi ng procedure wi l l requi re a sui tabl e vol t-
ampere tester (Fi g. 4).
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
Fig. 1 Starting SystemTypical Components/Wiring
(1) Connect a vol t-ampere tester (Fi g. 4) to the
battery termi nal s (Fi g. 5). Refer to the operati ng i n-
structi ons provi ded wi th the tester bei ng used.
(2) Di sabl e i gni ti on system as fol l ows:
VEHI CLES WI TH CONVENTI ONAL DI STRI BU-
TORS: Di sconnect the i gni ti on coi l cabl e from the
di stri butor cap. Connect a sui tabl e jumper wi re be-
tween the coi l cabl e end-termi nal and a good body
ground (Fi g. 6).
VEHI CLES WI TH DI RECT I GNI TI ON SYSTEM:
Di sconnect the i gni ti on coi l s el ectri cal connector (Fi g.
7).
(3) Veri fy that al l l i ghts and accessori es are OFF,
and the transmi ssi on shi ft sel ector i s i n the PARK. Set
parki ng brake.
(4) Rotate and hol d the i gni ti on swi tch i n the START
posi ti on. Observe the vol t-ampere tester (Fi g. 8).
Fig. 3 STARTER SYSTEM DIAGNOSTICS
Fig. 4 Volt Ampere Tester
Fig. 2 Starter Relay
I f vol tage reads above 9.6 vol ts, and amperage draw
reads above 250 amps, go to the starter feed ci rcui t
resi stance test.
I f vol tage reads 12.4 vol ts or greater and amperage
reads 0 to 10 amps, go to starter control ci rcui t test.
CAUTION: Do not overheat the starter motor or draw
the battery voltage below 9.6 volts during cranking
operations.
(5) After the starti ng system probl ems have been
corrected, veri fy the battery state-of-charge and charge
battery i f necessary. Di sconnect al l testi ng equi pment
and connect i gni ti on coi l cabl e or i gni ti on coi l connec-
tor. Start the vehi cl e several ti mes to assure the
probl em has been corrected.
STARTER FEED CIRCUIT RESISTANCE TEST
Before proceedi ng wi th thi s operati on, revi ew Di ag-
nosti c Preparati on and Starter Feed Ci rcui t Tests i n
thi s Group. The fol l owi ng operati on wi l l requi re a
vol tmeter, accurate to 1/10 of a vol t.
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) Di sabl e i gni ti on system as fol l ows:
VEHI CLES WI TH CONVENTI ONAL DI STRI BU-
TORS
Di sconnect the i gni ti on coi l cabl e from the di stri butor
cap. Connect a sui tabl e jumper wi re between the coi l
cabl e end-termi nal and a good body ground (Fi g. 6).
VEHI CLES WI TH DI RECT I GNI TI ON SYSTEM:
Di sconnect the i gni ti on coi l s el ectri cal connector (Fi g.
7).
(2) Wi th al l wi ri ng harnesses and components prop-
erl y connected, perform the fol l owi ng:
(a) Connect the negati ve l ead of the vol tmeter to
the negati ve battery post, and posi ti ve l ead to the
negati ve battery cabl e cl amp (Fi g. 9). Rotate and
hol d the i gni ti on swi tch key i n the START posi ti on.
Observe the vol tmeter. I f vol tage i s detected, correct
poor contact between cabl e cl amp and post.
Fig. 5 Volt-Ampere Tester Connections
Fig. 6 Ground Ignition Coil Cable
Fig. 7 Ignition Coils Electrical Connection
Fig. 8 Starter Draw Tests
(b) Connect posi ti ve l ead of the vol tmeter to the
posi ti ve battery post, and negati ve l ead to the posi -
ti ve battery cabl e cl amp. Rotate and hol d the i gni ti on
swi tch key i n the START posi ti on. Observe the vol t-
meter. I f vol tage i s detected, correct poor contact
between the cabl e cl amp and post.
(c) Connect negati ve l ead of vol tmeter to negati ve
battery termi nal , and posi ti ve l ead to engi ne bl ock
near the battery cabl e attachi ng poi nt (Fi g. 10).
Rotate and hol d the i gni ti on swi tch i n the START
posi ti on. I f vol tage reads above 0.2 vol t, correct poor
contact at ground cabl e attachi ng poi nt. I f vol tage
readi ng i s sti l l above 0.2 vol t after correcti ng poor
contacts, repl ace ground cabl e.
(3) Remove starter heat shi el d. Refer to Group 8B,
Starter Repl acement to gai n access to the starter motor
and sol enoi d connecti ons. Perform the fol l owi ng steps:
(a) Connect posi ti ve vol tmeter l ead to the starter
motor housi ng and the negati ve l ead to the negati ve
battery termi nal (Fi g. 11). Hol d the i gni ti on swi tch
key i n the STARTposi ti on. I f vol tage reads above 0.2
vol t, correct poor starter to engi ne ground.
(b) Connect the posi ti ve vol tmeter l ead to the
posi ti ve battery termi nal , and negati ve l ead to bat-
tery cabl e termi nal on starter sol enoi d (Fi g. 12).
Rotate and hol d the i gni ti on swi tch i n the START
posi ti on. I f vol tage reads above 0.2 vol t, correct poor
contact at battery cabl e to sol enoi d connecti on. I f
readi ng i s sti l l above 0.2 vol t after correcti ng poor
contacts, repl ace posi ti ve battery cabl e.
I f resi stance tests do not detect feed ci rcui t fai l ures,
remove the starter motor and go to Bench Testi ng
Starter Sol enoi d i n thi s Group.
STARTER CONTROL CIRCUIT TESTS
The starter control ci rcui t has:
Starter sol enoi d
Starter rel ay (Fi g. 2)
Neutral starti ng and back-up swi tch wi th automati c
transmi ssi ons onl y
I gni ti on swi tch
Battery
Al l rel ated wi ri ng and connecti ons
Fig. 9 Test Battery Connection Resistance (Negative
or Positive Posts)
Fig. 10 Test Ground Circuit Resistance
Fig. 11 Test Starter Motor GroundTypical
Fig. 12 Test Positive Battery Cable Resistance
CAUTION: Before performing any starter tests, the
ignition system must be disabled.
VEHI CLES EQUI PPED WI TH A CONVENTI ONAL
DI STRI BUTOR: Di sconnect coi l wi re from di stri butor
cap center tower. Secure wi re to a good ground to
prevent engi ne from starti ng (Fi g. 6).
VEHI CLES EQUI PPED WI TH DI RECTI GNI TI ON
SYSTEM: Unpl ug the coi l s el ectri cal connector (Fi g. 7).
STARTER SOLENOI D TEST
WARNING: CHECK TO ENSURE THAT THE
TRANSMISSION IS IN THE PARK POSITION
WITH THE PARKING BRAKE APPLIED
(1) Veri fy battery condi ti on. Battery must be i n good
condi ti on wi th a ful l charge before performi ng any
starter tests. Refer to Battery Tests.
(2) Perform thi s starter sol enoi d test BEFORE per-
formi ng the starter rel ay test.
(3) Rai se the vehi cl e.
(4) Perform a vi sual i nspecti on of the starter/starter
sol enoi d for corrosi on, l oose connecti ons or faul ty wi r-
i ng.
(5) Lower the vehi cl e.
(6) Locate the starter rel ay (Fi g. 13).
(7) Remove the starter rel ay from the connector.
(8) Connect a remote starter swi tch or a jumper wi re
between the battery posi ti ve post and termi nal 87 on
the starter rel ay connector. To determi ne the starter
rel ay termi nal numbers, refer to Fi g. 14.
I f engi ne cranks, starter/starter sol enoi d i s good. Go
to the Starter Rel ay Test.
I f engi ne does not or sol enoi d chatters, check wi ri ng
and connectors from starter rel ay to starter sol enoi d
for l oose or corroded connecti ons. Parti cul arl y at
starter termi nal s.
Repeat test. I f engi ne sti l l fai l s to crank properl y,
troubl e i s wi thi n starter or starter mounted sol enoi d,
and i t must be removed for repai rs. Refer to Group 8B,
Battery/Starter/Al ternator Servi ce, Starter Repl ace-
ment.
STARTER RELAY TEST
WARNING: CHECK TO ENSURE THAT THE
TRANSMISSION IS IN THE PARK POSITION
WITH THE PARKING BRAKE APPLIED
(1) Veri fy battery condi ti on. Battery must be i n good
condi ti on wi th a ful l charge before performi ng any
starter tests. Refer to Battery Tests.
(2) Perform the precedi ng starter sol enoi d tests BE-
FORE performi ng starter rel ay tests. Refer to Starter
Sol enoi d Test.
(3) Locate and remove the starter rel ay (Fi g. 13).
(4) After the starter rel ay has been l ocated and
removed, refer to Starter Rel ay Tests (Fi g. 14).
NEUTRAL STARTI NG AND BACK-UP SWI TCH
AUTOMATIC TRANSMISSION ONLY
For el ectri cal di agnosti cs, when checki ng starter
ci rcui ts, refer to Starter Rel ay Tests (Fi g. 14).
For removal and i nstal l ati on of neutral swi tch, refer
to Neutral Starti ng and Back-up Swi tch i n Group 21,
Transaxl e.
I GNI TI ON SWI TCH TEST
After testi ng starter sol enoi d and rel ay, test i gni ti on
swi tch and wi ri ng. Refer to Group 8D, I gni ti on Sys-
tems or Group 8W, Wi ri ng Di agrams. Check al l wi ri ng
for opens or shorts, and al l connectors for bei ng l oose or
corroded.
BENCH TESTI NG STARTER SOLENOI D
(1) Di sconnect fi el d coi l wi re from fi el d coi l termi nal
(Fi g. 15 or 16).
(2) Check for conti nui ty between sol enoi d termi nal
and fi el d coi l termi nal wi th a conti nui ty tester. Conti -
nui ty shoul d be detected (Fi g. 17 or 18).
(3) Check for conti nui ty between sol enoi d termi nal
and sol enoi d housi ng (Fi g. 19 or 20). Conti nui ty shoul d
be detected. I f conti nui ty i s detected, sol enoi d i s good.
(4) I f conti nui ty i s not detected i n ei ther test, sol e-
noi d has an open ci rcui t and i s defecti ve.
Fig. 13 Starter Relay Location
Fig. 14 STARTER RELAY TESTS
BOSCH STARTERS: Repl ace the sol enoi d
NI PPONDENSO STARTERS: Repl ace the starter
assembl y
ALTERNATOR TEST PROCEDURES ON VEHI CLE
INDEX
page page
Current Output Test . . . . . . . . . . . . . . . . . . . . . . 17 Output Wire Resistance Test . . . . . . . . . . . . . . . . 15
OUTPUT WIRE RESISTANCE TEST
The al ternator output wi re resi stance test shows the
amount of vol tage drop across the al ternator output
wi re between the al ternator B+ termi nal and the
posi ti ve battery post.
PREPARATI ON
Before starti ng test, make sure the vehi cl e has a ful l y
charged battery. Tests and procedures to check for a
ful l y charged battery are shown i n the Battery secti on
of thi s Group.
(1) Turn the i gni ti on swi tch OFF.
(3) Di sconnect the al ternator B+ output wi re from
the al ternator output battery termi nal (Fi g. 1).
(4) Connect a 0-150 ampere scal e (DC) ammeter i n
seri es between B+ termi nal and output wi re (Fi g. 1 and
2). Connect posi ti ve l ead to B+ termi nal , and negati ve
l ead to output wi re.
(5) Usi ng 0-18 vol t scal e vol tmeter, connect the posi -
ti ve l ead to the di sconnected (B+) output wi re. Connect
the negati ve l ead to posi ti ve battery cabl e at posi ti ve
post.
(6) Remove fresh ai r hose between Engi ne Control -
l er and ai r cl eaner i f necessary.
Fig. 15 Field Coil Wire TerminalBosch
Fig. 16 Field Coil Wire TerminalNippondenso
Fig. 17 Continuity Test Between Solenoid Terminal
and Field Coil TerminalBosch
and Field Coil TerminalNippondenso
and Solenoid Case Bosch
and Solenoid Case Nippondenso
(7) Connect jumper wi re between a good ground, and
K20 ci rcui t termi nal at the back of the al ternator.
CAUTION: Do not connect the A142 circuit terminal
(Fig. 1) to ground the Fusible link will burn.
(8) Connect an engi ne tachometer and connect bat-
tery negati ve cabl e.
(9) Connect a vol t/amp tester equi pped wi th a vari -
abl e carbon pi l e rheostat between battery termi nal s
(Fi g. 3).
Caution: Be sure the carbon pile is in OFF position
before connecting leads.
TEST
(1) Start engi ne. I mmedi atel y after starti ng, reduce
engi ne speed to i dl e.
Fig. 2 Alternator Output Wire Resistance Test
Fig. 3 Volt/Amp Tester Connections
Fig. 1 Alternator Wiring Connections
(2) Adjust engi ne speed and carbon pi l e to mai ntai n
20 amperes fl owi ng i n the ci rcui t. Observe vol tmeter
readi ng. Vol tmeter readi ng shoul d not exceed 0.5 vol ts.
RESULTS
I f a hi gher vol tage drop i s shown, i nspect, cl ean and
ti ghten al l connecti ons between al ternator B+ termi nal
and battery posi ti ve post. A vol tage drop test may be
performed at each connecti on to l ocate a connecti on
wi th excessi ve resi stance. I f resi stance tests are sati s-
factory, reduce engi ne speed, turn off carbon pi l e, and
turn off i gni ti on swi tch.
(2) Remove test ammeter, vol tmeter, carbon pi l e,
and tachometer.
(3) Remove jumper wi re.
(4) Connect output wi re to B+ termi nal .
(5) Connect battery negati ve cabl e.
(6) Connect fresh ai r hose between Engi ne Control -
l er and ai r cl eaner i f removed.
CURRENT OUTPUT TEST
The current output test determi nes whether or not
the al ternator i s capabl e of del i veri ng i ts rated current
output. For al ternator i denti fi cati on and output am-
perage speci fi cati ons, refer to Al ternator Speci fi ca-
ti ons.
For al ternator maxi mum vol tage at i ndi vi dual tem-
peratures, refer to Al ternator Output Vol tage Speci fi -
cati ons.
PREPARATI ON
Before starti ng any tests, make sure the vehi cl e has
a ful l y charged battery. Tests and procedures to check
for a ful l y charged battery are shown i n Battery
secti on.
(2) Di sconnect output wi re at the B+ termi nal (Fi gs.
1 and 4).
(3) Connect a 0-150 ampere scal e (DC) ammeter i n
seri es between the B+ termi nal and output wi re. Con-
nect Posi ti ve l ead to B+ termi nal and negati ve l ead to
output wi re.
(4) Usi ng 0-18 vol tmeter, connect the posi ti ve l ead to
B+ termi nal (Fi gs. 2 and 4). Connect negati ve l ead to a
good ground.
(5) Connect an engi ne tachometer and connect bat-
tery negati ve cabl e.
(6) Connect a vol t/amp tester equi pped wi th a vari -
abl e carbon pi l e rheostat between battery termi nal s
(Fi g. 5). Be sure carbon pi l e i s i n OFF posi ti on before
connecti ng l eads.
(8) Remove fresh ai r hose between Engi ne Control -
l er and ai r cl eaner i f necessary.
Fig. 4 Alternator Current Output Test
(9) Ful l fi el d the al ternator. Connect a jumper wi re
between a good ground and to the K20 ci rcui t termi nal
at the back of the al ternator (Fi gs. 1 and 4).
CAUTION: Do not connect the A142 circuit terminal
(Fig. 1) to ground the Fusible link will burn.
TEST
(1) Start the engi ne. I mmedi atel y after starti ng,
reduce engi ne speed to i dl e.
(2) Adjust the carbon pi l e and engi ne speed i n steps
unti l an engi ne speed of 1250 rpm, and a vol tmeter
readi ng of 15 vol ts i s obtai ned.
CAUTION: Do not allow the battery voltage to exceed
16 volts.
(3) The al ternator amperage must meet the output
requi rements for the parti cul ar al ternator bei ng
tested. Refer to Al ternator Speci fi cati ons for al ternator
i denti fi cati on and amperage outputs.
RESULTS
(1) I f amperage readi ng i s l ess than speci fi ed, and
al ternator output wi re resi stance i s not excessi ve
(found from the previ ous tests), al ternator shoul d be
repl aced. Refer to Al ternator repl acement i n Group 8B,
Battery/Starter/Al ternator Servi ce. These al ternators
are not i ntended to be di sassembl ed for servi ce. I t must
be repl aced as an assembl y.
(2) After current output test i s compl eted, reduce
engi ne speed, turn off carbon pi l e, and turn off i gni ti on
swi tch.
(4) Remove test ammeter, vol tmeter, tachometer and
carbon pi l e.
(5) Remove jumper wi re between K20 ci rcui t termi -
nal and ground.
(6) Connect output wi re to B+ termi nal .
(8) Connect fresh ai r hose between Engi ne Control -
l er and ai r cl eaner i f removed.
FAULT CODESON BOARD DI AGNOSTI CS
INDEX
page page
Diagnostic Testing Using Fault Codes . . . . . . . . . . 19
Drb II Diagnostic Tester . . . . . . . . . . . . . . . . . . . . 22
General Description/Information . . . . . . . . . . . . . . 18
GENERAL DESCRIPTION/INFORMATION
Another way of di agnosi ng chargi ng system prob-
l ems can be accompl i shed usi ng the On-Board Di ag-
nosti c System Faul t Codes.
A Faul t Code shows a potenti al probl em i n a moni -
tored ci rcui t,
or a condi ti on caused by a faul ty component. A Faul t
Code can be retri eved by turni ng the i gni ti on swi tch
ON-OFF-ON-OFF-ON wi thout starti ng the engi ne,
and counti ng the possi bl e number of fl ashes of the
CHECK ENGI NE LAMP i n the i nstrument cl uster.
EXAMPLES:
I f the Check Engi ne Lamp fl ashes four ti mes,
pauses, and fl ashes one more ti me, a Code 41 i s shown.
The fi rst set of four fl ashes i ndi cates the number four.
The second set of one fl ash i ndi cates one.
pauses, and fl ashes si x more ti mes, a Code 46 i s shown.
The fi rst set of four fl ashes i ndi cates the number four.
The second set of si x fl ashes i ndi cates si x.
pauses, and fl ashes seven more ti mes, a Code 47 i s
Fig. 5 Volt/Amp Tester Connections
i ndi cated. The fi rst set of four fl ashes i ndi cates the
number four. The second set of seven fl ashes i ndi cates
seven.
ENGINE CONTROLLER
The Engi ne Control l er i s equi pped wi th On-Board
Di agnosti c features and moni tors al l engi ne control
ci rcui ts duri ng a run/dri ve peri od. I f a ci rcui t or system
does not perform properl y, the Engi ne Control l er wi l l
fi l e i n memory a predetermi ned Faul t Code. Thi s can
be used to hel p i n di agnosi ng a probl em. After 50 to 100
i gni ti on swi tch ON/RUN cycl es, the memory wi l l be
erased i f the faul t does not reoccur.
The Engi ne Control l er i s l ocated i n the engi ne com-
partment outboard of the battery (Fi g. 6).
16 Refer to Fi g. 7 Al ternator Faul t Code chart for
rel ati onshi ps of al ternator/chargi ng system Faul t Code
numbers.
DIAGNOSTIC TESTING USING FAULT CODES
For di agnosti c testi ng when usi ng the faul t codes,
refer to Fi g. 8 through 12.
Fig. 6 Engine Controller and Diagnostic Connector
Fig. 7 ALTERNATOR FAULT CODES
Fig. 8 CHECK FOR INADEQUATE/LOW CHARGINGUSING ON BOARD DIAGNOSTIC FAULT CODES
Fig. 9 CHECK FOR OVERCHARGINGUSING ON BOARD DIAGNOSTIC FAULT CODES
DRB II DIAGNOSTIC TESTER
TESTI NG FAULT CODES
A more accurate devi ce to retri eve faul t codes i s
Di agnosti c Tool (DRB I I ). Thi s di agnosti c tool , pl ugged
i nto the di agnosti c connector (Fi g. 6) l ocated near the
battery, wi l l di spl ay faul t descri pti ons. The DRB I I can
al so test vari ous ci rcui ts and component functi ons.
Refer to the i nstructi ons provi ded wi th the (DRB I I )
tool bei ng used. Descri pti ons of Faul t Codes for other
vehi cl e systems can be found i n the General Di agnosi s
secti on of Group 14, Fuel System.
Fig. 10 Alternator Wiring Connections
Fig. 11 Engine Controller Connector
Fig. 12 Electrical Resistance Test
SPECI FI CATI ONS
SPECI FI CATI ONSSTARTER/BATTERY
SPECI FI CATI ONSALTERNATOR AMPERAGE/I DENTI FI CATI ON NUMBERS
TORQUE SPECI FI CATI ONS SPECI FI CATI ONSALTERNATOR OUTPUT
VOLTAGE
COOLING SYSTEM
CONTENTS
page page
ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 23
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 27
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 29
COOLING SYSTEM
Throughout thi s group, references may be made to a
servi ce manual .
The cool i ng system has a radi ator, cool ant, el ectri c
fan motor, shroud, pressure cap, thermostat, cool ant
reserve system, transmi ssi on oi l cool er, a water pump
to ci rcul ate the cool ant, hoses, and cl amps to compl ete
the ci rcui t.
When Engi ne i s col d: Thermostat i s cl osed, cool i ng
system has no fl ow through the radi ator. The cool ant
bypass fl ows through the engi ne onl y.
When Engi ne i s warm: Thermostat i s open, cool i ng
system has bypass fl ow and cool ant fl ow through
radi ator.
I ts pri mary purpose i s to mai ntai n engi ne tempera-
ture i n a range that wi l l provi de sati sfactory engi ne
performance and emi ssi on l evel s under al l expected
dri vi ng condi ti ons. I t al so provi des hot water (cool ant)
for heater performance and cool i ng for automati c
transmi ssi on oi l . I t does thi s by transferri ng heat from
engi ne metal to cool ant, movi ng thi s heated cool ant to
the radi ator, and then transferri ng thi s heat to the
ambi ent ai r.
Cool ant fl ow ci rcui ts for 2.5L engi ne equi pped ve-
hi cl es i s shown i n Fi gure 1. Fi gure 2 shows 3.0L engi ne
cool ant routi ng. Fi gure 4 shows 3.3L Engi ne Cool ant
routi ng.
Excl udi ng heated i ntake mani fol d hose routi ng (hose
i s routed from waterbox di rectl y to heater), al l other
system functi ons are essenti al l y the same as shown for
standard engi nes.
Fig. 1 Cooling System Operation 2.5L Engines
COOLING SYSTEM 7 - 1
3.0L WATER PI PES
The 3.0L engi nes use metal pi pi ng beyond the l ower
radi ator hose to route (sucti on) cool ant to the water
pump, whi ch i s i n the V of the cyl i nder banks. (Fi g. 3)
These pi pes are provi ded wi th i nl et ni ppl es for ther-
mostat bypass and heater return cool ant hoses, and
brackets for ri gi d engi ne attachment. The pi pes empl oy
O-ri ngs for seal i ng at thei r i nterconnecti on and to the
water pump (Fi g. 3).
Fig. 2 Cooling System Operation 3.0 Engine
Fig. 3 Engine Inlet Coolant Pipes
7 - 2 COOLING SYSTEM
Fig. 4 Cooling System Operation 3.3L Engine
COOLI NG SYSTEM DI AGNOSI S
SERVI CE PROCEDURES
WATER PUMPS
A qui ck test to tel l whether the pump i s worki ng i s to
see i f the heater warms properl y. A defecti ve pump can
not ci rcul ate heated cool ant through the l ong heater
hose.
Thewater pump on all models can bereplaced
without dischargingtheair conditioningsystem.
WATER PUMP 2.5L ENGI NE
The 2.5L engi ne water pump has a di ecast al umi num
body and housi ng wi th a stamped steel i mpel l er. The
2.5L pump uses an O-ri ng gasket between body and
housi ng. The assembl y bol ts di rectl y to the bl ock.
Cyl i nder bl ock to water pump seal i ng uses a rubber
O-ri ng.
REMOVAL
(1) Drai n cool i ng system. Refer to Drai ni ng Cool i ng
System i n thi s group.
(2) I f equi pped wi th ai r condi ti oni ng, see Sol i d
Mount Accessory Bracket i n (Standard Servi ce Proce-
dures) Group 9, Engi ne:
(a) Remove ai r condi ti oni ng compressor and al ter-
nator from sol i d mount bracket and set asi de. I t i s
not necessary to di scharge the a/c system.
(b) Remove sol i d mount bracket.
(3) I f the vehi cl e i s not equi pped wi th ai r condi ti on-
i ng, remove al ternator and mounti ng bracket.
(4) Di sconnect l ower radi ator and heater hoses from
pump.
(5) Remove water pump attachi ng screws to engi ne
(Fi g. 1).
DISASSEMBLY
(1) Remove three screws hol di ng pul l ey to water
pump.
(2) Remove ni ne screws hol di ng water pump body to
housi ng. Remove the pump body from housi ng. (Fi g. 2)
(3) Cl ean gasket surfaces on water pump housi ng
and engi ne bl ock.
(4) Remove and di scard O-ri ng gaskets and cl ean
O-ri ng grooves.
INSPECTION
Repl ace water pump body assembl y i f i t has any of
these defects:
(1) Cracks or damage on the body.
(2) Water l eaks from the shaft seal , evi dent by
cool ant traces bel ow the vent hol e.
(3) Loose or rough turni ng beari ng.
(4) I mpel l er rubs ei ther the pump body or the hous-
i ng.
ASSEMBLY
Body assembl y and housi ng are servi ced as separate
components.
(1) I nstal l new O-ri ng gasket i n body O-ri ng groove.
(2) Assembl e pump body to housi ng and ti ghten ni ne
screws to 12 Nm (105 i n. l bs.) (Fi g. 2).
(3) Rotate pump by hand to check for freedom of
movement.
(4) Posi ti on water pump pul l ey to water pump. I n-
stal l three screws and ti ghten to 30 Nm (250 i n. l bs.).
(5) Posi ti on new O-ri ng i n housi ng to bl ock O-ri ng
groove.
Fig. 1 Water Pump 2.5L Engines
Fig. 2 2.5L Water Pump Components
INSTALLATION
(1) I nstal l water pump on engi ne. Ti ghten top three
screws (Fi g. 1) to 30 Nm (250 i n. l bs.). I nstal l l ower
screw and ti ghten to 68 Nm (50 ft. l bs.).
(2) Rei nstal l bypass/heater hose and l ower radi ator
hose.
(3) Rei nstal l al ternator and ai r condi ti oni ng com-
pressor bracket(s). For sol i d mount bracket see stan-
dard servi ce procedures i n Group 9 Engi ne.
(4) Rei nstal l al ternator and ai r condi ti oni ng com-
pressor.
(5) Refi l l cool i ng system. See Refilling Cooling
System.
(6) I nstal l dri ve bel t, See Accessory Dri ve Bel ts, thi s
Group.
The 3.0L pump bol ts di rectl y to the engi ne bl ock,
usi ng a gasket for pump to bl ock seal i ng (Fi g. 3). The
pump i s servi ced as a uni t.
The water pump i s dri ven by the ti mi ng bel t. See
Ti mi ng System i n Group 9, Engi ne for component
removal provi di ng access to water pump.
REMOVAL
(2) Remove mounti ng bol ts.
(3) Separate pump from water i nl et pi pe (Fi gs. 3 and
4) and remove.
INSPECTION
Repl ace the water pump i f i t has any of the fol l owi ng
defects.
(1) Damage or cracks on the pump body.
(2) Cool ant l eaks, i f the shaft seal i s l eaki ng, evi dent
by traces of cool ant l eaks from vent hol e A i n (Fi g. 4).
(3) I mpel l er rubs the i nsi de of pump.
INSTALLATION
(1) Cl ean al l gasket and O-ri ng surfaces on pump
and water pi pe i nl et tube.
(2) I nstal l new O-ri ng on water i nl et pi pe (Fi g. 5).
Wet the O-ri ng (wi th water) to ease assembl y.
CAUTION: Keep the O-ring free of oil or grease.
(3) I nstal l new gasket on water pump and i nstal l
pump i nl et openi ng over water pi pe, press assembl y to
cause water pi pe i nserti on i nto pump housi ng.
(4) I nstal l pump to bl ock mounti ng bol ts and ti ghten
to 27 Nm (20 ft. l bs.).
(5) See Ti mi ng System i n Engi ne, Group 9 and
i nstal l ti mi ng bel t. Reassembl e engi ne.
(6) Fi l l cool i ng system. See Refi l l i ng Cool i ng System.
The 3.3L pump has a di e cast al umi num body and a
stamped steel i mpel l er. I t bol ts di rectl y to the chai n
case cover, usi ng an O-ri ng for seal i ng. I t i s dri ven by
the back surface of the Pol y-V Dri ve Bel t.
Fig. 3 Water Pump 3.0L Engine
Fig. 4 Water Pump Inspection
Fig. 5 Water Pipe O-Ring
REMOVAL
(1) Drai n Cool i ng System. Refer to Drai ni ng Cool i ng
(2) Remove Pol y V Dri ve Bel t.
(3) Remove ri ght front l ower fender shi el d.
(4) Remove pump pul l ey bol ts and remove pul l ey.
(5) Remove pump mounti ng screws (Fi g. 6). Remove
pump.
(6) Remove and di scard O-ri ng seal .
(7) Cl ean O-ri ng groove and O-ri ng surfaces on
pump and chai n case cover. Take care not to scratch or
gouge seal i ng surface.
INSPECTION
Repl ace the water pump i f i t has any of the fol l owi ng
defects.
(1) Damage or cracks on the pump body.
(2) Cool ant l eaks; i f the seal i s l eaki ng, evi dent by
traces of cool ant l eaks from vent hol e.
(4) I mpel l er rubs ei ther the pump body or chai n case
cover.
INSTALLATION
(1) I nstal l new O-ri ng i n O-ri ng groove (Fi g. 7).
(2) I nstal l pump to chai n case cover. Torque screws
to 12 Nm (105 i n. l bs.)
(3) Rotate pump by hand to check for freedom of
movement.
(4) Posi ti on pul l ey on pump. I nstal l screws and
torque to 30 Nm (250 i n. l bs.).
(5) I nstal l dri ve bel t. See Accessory Dri ve Bel ts thi s
group.
(6) I nstal l ri ght front l ower fender shi el d.
(7) Refi l l Cool i ng System. See Refi l l i ng Cool i ng Sys-
tem.
ENGINE THERMOSTAT
The 2.5L engi ne thermostat i s l ocated on the front of
the engi ne (radi ator si de) i n the waterbox that i s part
of the cyl i nder head constructi on (Fi g. 8).
These thermostats do not have an ai r bl eed notch.
The 3.0L engi ne thermostat i s i n a water box, formed
i n the ti mi ng bel t end of the i ntake mani fol d. Thi s
thermostat has an ai r bl eed val ve, l ocated i n the
thermostat fl ange (Fi g. 9).
The 3.3L engi ne thermostat i s i n a water box, formed
i n the dri ve bel t si de of the i ntake mani fol d (Fi g. 11).
DESCRI PTI ON AND OPERATI ON
The engi ne cool i ng thermostats are wax pel l et
dri ven, reverse poppet choke type. They are desi gned
to provi de the fastest warm up possi bl e by preventi ng
l eakage through them and to guarantee a mi ni mum
engi ne operati ng temperature of 88 to 93C (192 to
199F). They al so automati cal l y reach wi de open so
they do not restri ct fl ow to the radi ator as temperature
of the cool ant ri ses i n hot weather to around 104C
(220F). Above thi s temperature the cool ant tempera-
ture i s control l ed by the radi ator, fan, and ambi ent
temperature, not the thermostat.
OPERATI ON AND TESTI NG
The thermostat operateds by a wax fi l l ed contai ner
(pel l et) that i s seal ed so that when heated to a prede-
termi ned temperature. The wax expands enough to
overcome the cl osi ng spri ng and water pump pressure,
whi ch forces the val ve to open. Cool ant l eakage i nto the
pel l et wi l l cause a thermostat to fai l open. Do not
attempt to free up a thermostat wi th a screwdri ver.
The open too soon type fai l ure mode i s i ncl uded i n
the on-board di agnosi s. The check engi ne l i ght wi l l not
be l i t by an open too soon condi ti on. Onl y i f the
thermostat has fai l ed open, a code 17 wi l l be set. Do not
change a thermostat for l ack of heat by gauge or heater
performance, unl ess code 17 i s present, see di agnosi s
for other probabl e causes. Fai l i ng shut i s the normal
l ong term mode of fai l ure, and normal l y, onl y
Fig. 6 Water Pump 3.3L Engine
Fig. 7 Water Pump Body
on hi gh mi l eage vehi cl es. The temperature gauge wi l l
show thi s, Refer to di agnosi s i n thi s secti on.
REMOVAL
(1) Drai n cool i ng system down bel ow the thermostat
l evel . Refer to Drai ni ng Cool i ng System i n thi s group.
(2) Remove thermostat housi ng bol ts and housi ng
(Fi gs. 8, 9 and 10).
(3) Remove thermostat, di scard gasket and cl ean
both gasket seal i ng surfaces.
I NSTALLATI ON2.5L ENGI NE
Pl ace a new gasket (di pped i n cl ean water) on water
box surface, center thermostat i n water box on gasket.
Pl ace housi ng over gasket and thermostat, maki ng
sure thermostat i s i n the thermostat housi ng. Bol t
housi ng to water box (Fi g. 8 ). Ti ghten bol ts to 28 Nm
(250 i n. l bs.). Refi l l cool i ng system (see Refilling
System).
I NSTALLATI ON3.0L ENGI NE
Center thermostat i n water box pocket. Check that
the fl ange i s seated correctl y i n the countersunk por-
ti on of the i ntake mani fol d water box (Fi gs. 9 and 10).
I nstal l new gasket on water box. I nstal l housi ng over
gasket and thermostat and ti ghten bol ts to 12 Nm
(133 i n. l bs.).
I NSTALLATI ON3.3L
Pl ace a new gasket (di pped i n water) on the water
box surface, center thermostat i nto openi ng i n the i n-
Fig. 8 Thermostat, Housing, and Water Box2.5L
Engine
Fig. 9 Thermostat, Housing, and Water Box3.0L
Engine
Fig. 10 Thermostat Installed3.0L Engine
Fig. 11 Thermostat, Housing and Waterbox3.3L
Engine
take mani fol d. Pl ace housi ng over gasket and thermo-
stat, maki ng sure thermostat i s i n recess provi ded (Fi g.
11). Bol t housi ng to i ntake mani fol d, ti ghten bol ts to 28
Nm (250 i n. l bs.). Refi l l cool i ng system (see Refilling
System).
COOLANT
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n the
cyl i nder head area near the exhaust val ves. Then carry
thi s heat to the radi ator where the tube/fi n assembl i es
of these components can gi ve i t up to the ai r.
PERFORMANCE
Performance i s measurabl e. For heat transfer pure
water excel s (Formul a = 1 btu per mi nute for each
degree of temperature ri se for each pound of water).
Thi s formul a i s al tered when necessary addi ti ves to
control boi l i ng, freezi ng, and corrosi on are added as
fol l ows:
Pure Water (1 btu) boi l s at 100C (212F) and
freezes at 0C (32F).
100 percent Gl ycol (.7 btu) can cause a hot engi ne
and detonati on and wi l l l ower the freeze poi nt to -22C
(-8F).
50/50 Gl ycol and Water (.82 btu) i s the recommended
combi nati on that provi des a freeze poi nt of -37C(-
35F). The radi ator, water pump, engi ne water jacket,
radi ator pressure cap, thermostat, temperature gauge,
sendi ng uni t and heater are al l desi gned for 50/50
gl ycol .
Where requi red, a 56 percent gl ycol and 44 percent
water mi xture wi l l provi de a freeze poi nt of-59C
(-50F).
CAUTION: Richer mixtures cannot be measured with
field equipment that can lead to problems associated
with 100 percent glycol.
SELECTI ON AND ADDI TI VES
The use of al umi num cyl i nder heads, i ntake mani -
fol ds, and water pumps requi res speci al corrosi on pro-
tecti on. Mopar Anti freeze, Prestone I I , Peak or anti -
freeze contai ni ng Al ugard 340-2, or thei r equi val ent i s
recommended for best engi ne cool i ng wi thout corro-
si on. When mi xed onl y to a freeze poi nt of-37C (-35F)
to -59C (-50F). I f i t l ooses col or or becomes contami -
nated, drai n, fl ush, and repl ace wi th fresh properl y
mi xed sol uti on.
SERVI CE
Cool ant shoul d be changed at 52,500 mi l es or three
years, whi chever occurs fi rst, then every two years or
30,000 mi l es.
ROUTI NE LEVEL CHECK
Donot removeradiator cap for routinecoolant
level inspections.
The cool ant reserve system provi des a qui ck vi sual
method for determi ni ng the cool ant l evel wi thout re-
movi ng the radi ator cap. Si mpl y observe, wi th the
engi ne i dl i ng and warmed up to normal operati ng
temperature, that the l evel of the cool ant i n the reserve
tank (Fi g. 15) i s between the mi ni mum and maxi mum
marks.
ADDING ADDITIONAL COOLANT
The radiator cap should not be removed. When
addi ti onal cool ant i s needed to mai ntai n thi s l evel , i t
shoul d be added to the cool ant reserve tank. Use onl y
50/50 mi x of ethyl ene gl ycol type anti freeze and water.
SERVI CE COOLANT LEVEL
The cool i ng system i s cl osed and desi gned to mai n-
tai n cool ant l evel to the top of the radi ator.
When servi ci ng requi res a cool ant l evel check i n the
radi ator, the engi ne must be off and not under pres-
sure. Drai n several ounces of cool ant from the radi ator
drai n cock whi l e observi ng the Cool ant Recovery Sys-
tem (CRS) Tank. Cool ant l evel i n the CRS tank shoul d
drop sl i ghtl y. Then remove the radi ator cap. The radi a-
tor shoul d be ful l to the top. I f not, and the cool ant l evel
i n the CRS tank i s at the MI N mark there i s an ai r l eak
i n the CRS system. Check hose or hose connecti ons to
the CRS tank, radi ator fi l l er neck or the pressure cap
seal to the radi ator fi l l er neck for l eaks.
LOW COOLANT LEVEL AERATI ON
Low cool ant l evel i n a cross fl ow radi ator wi l l equal -
i ze i n both tanks wi th engi ne off. Wi th engi ne at
runni ng operati ng temperature the hi gh pressure i nl et
tank runs ful l and the l ow pressure outl et tank drops.
I f thi s l evel drops bel ow the top of the transmi ssi on oi l
cool er, ai r wi l l be sucked i nto the water pump:
Transmi ssi on oi l wi l l become hotter.
Hi gh readi ng shown on the temperature gauge.
Ai r i n the cool ant can cause l oss of fl ow through the
heater.
Exhaust gas l eaks i nto the cool ant al so can cause the
same probl ems?
DEAERATI ON
Ai r can onl y be removed from the system by gather-
i ng under the pressure cap. On the next heat up i t wi l l
be pushed past the pressure cap i nto the CRS tank by
thermal expansi on of the cool ant. I t then escapes to the
atmosphere i n the CRS tank and i s repl aced wi th sol i d
cool ant on cool down.
COOLING SYSTEM DRAIN, CLEAN FLUSH AND
REFILL
Drai n, fl ush, and fi l l the cool i ng system at the
mi l eage or ti me i nterval s speci fi ed i n the Mai ntenance
Schedul e i n thi s Group. I f the sol uti on i s di rty or rusty
or contai ns a consi derabl e amount of sedi ment, cl ean
and fl ush wi th a rel i abl e cool i ng system cl eaner. Care
shoul d be taken i n di sposi ng of the used engi ne cool ant
from your vehi cl e. Check governmental regul ati ons for
di sposal of used engi ne cool ant.
DRAI NI NG COOLI NG SYSTEM
To drai n cool i ng system move temperature sel ector
for heater to ful l heat wi th engi ne runni ng (to provi de
vacuum for actuati on). Without removing radiator
pressure cap and with system not under pres-
sure, Shut engi ne off and open drai ncock. The cool ant
reserve tank (Fi g. 15) shoul d empty fi rst, then remove
radi ator pressure cap. (i f not, see Testi ng Cool i ng
System for l eaks). To vent 2.5L engi ne remove the pl ug
above thermostat housi ng (Fi g. 12). To vent 3.3L en-
gi ne remove the engi ne temperature sendi ng uni t (Fi g.
13).
Removal of a pl ug or other component i s requi red
because these thermostats do not have an ai r vent and
prevents ai r fl ow through i t. Thi s al l ows the cool ant to
drai n from the engi ne bl ock.
CLEANI NG
Drai n cool i ng system (see: Draining Cooling Sys-
tem) and refi l l wi th cl ean water (see Refilling Cool-
ing System). Run engi ne wi th radi ator cap i nstal l ed
unti l upper radi ator hose i s hot. Stop engi ne and drai n
water from system. I f water i s di rty, fi l l , run and drai n
system agai n unti l water runs cl ear.
REVERSE FLUSHI NG
Reverse fl ushi ng of the cool i ng system, i s the forci ng
of water through the cool i ng system, usi ng ai r pressure
i n a di recti on opposi te to that of the normal fl ow of
water. Thi s i s usual l y onl y necessary wi th very di rty
systems wi th some evi dence of parti al pl uggi ng.
RADIATOR
Drai n cool i ng system and remove radi ator hoses from
engi ne. I nstal l sui tabl e fl ushi ng gun i n radi ator l ower
hose. Fi l l radi ator wi th cl ean water and turn on ai r i n
short bl asts.
CAUTION: Internal radiator pressure must not exceed
138 kPa (20 psi) as damage to radiator may result.
Continue this procedure until water runs clear.
ENGINE
Drai n radi ator (see: Draining Cooling System)
and remove hoses from radi ator. Remove engi ne ther-
mostat and rei nstal l thermostat housi ng. I nstal l sui t-
abl e fl ushi ng gun to thermostat housi ng hose. Turn on
water, and when engi ne i s fi l l ed, turn on ai r, but no
hi gher than 138 kPa (20 psi ) i n short bl asts. Al l ow
engi ne to fi l l between bl asts of ai r. Conti nue thi s
procedure unti l water runs cl ean. Rei nstal l thermostat
usi ng a new housi ng gasket. Fi l l cool i ng system (See
Refilling).
CHEMI CAL CLEANI NG
One type of corrosi on encountered wi th al umi num
cyl i nder heads i s al umi num hydroxi de deposi ts. Corro-
si on products are carri ed to the radi ator and deposi ted
when cool ed off. They appear as dark grey when wet
and whi te when dry. Thi s corrosi on can be removed
wi th a two part cl eaner (oxal i c aci d and neutral i zer)
avai l abl e i n auto parts outl ets. Fol l ow manufacturers
di recti ons for use.
Fig. 12 Thermostat Housing Drain/Fill Plug2.5L
Engine
Fig. 13 Engine Temperature Sending Unit 3.3L
Drain/Fill
REFI LLI NG
Fi rst cl ean system to remove ol d gl ycol , see Cool i ng
System Cl eani ng.
Fi l l system, usi ng anti freeze descri bed i n Cool ant.
Fi l l 50 of capaci ty wi th 100 gl ycol . Then compl ete
fi l l i ng system wi th water. The 2.5L engi ne requi res
venti ng by removal of the pl ug on top of the water box
(Fi g. 12). The 3.3L Engi ne requi res removal of the
Engi ne Temperature Sendi ng Uni t on the front of the
cyl i nder head (Fi g. 13). When cool ant reaches thi s hol e;
I nstal l vent pl ug and ti ghten to 20 Nm (15 ft. l bs.)
for 2.5L Engi nes.
I nstal l Engi ne Temperature Sendi ng Uni t and
ti ghten to 7 Nm (60 i n. l bs.) for 3.3L Engi nes.
Conti nue fi l l i ng system unti l ful l , thi s provi des bet-
ter heater performance. Becareful not to spill cool-
ant on drive belts or the alternator.
Fi l l cool ant reserve system to at l east the MAX mark
wi th 50/50 sol uti on. I t may be necessary to add cool ant
to the reserve tank after three or four warm up, cool
down cycl es to mai ntai n cool ant l evel between the
MAX and MI N mark. Thi s wi l l al l ow trapped ai r to be
removed from the system.
TESTING SYSTEM FOR LEAKS
Wi th engi ne not runni ng, wi pe the radi ator fi l l er
neck seal i ng seat cl ean. The radi ator shoul d be ful l .
Attach the Tester Radi ator Pressure Tool to the
radi ator, as shown i n (Fi g. 14) and appl y 104 kPa (15
psi ) pressure. I f the pressure drops more than 2 psi i n
2 mi nutes i nspect al l poi nts for external l eaks.
Al l hoses, radi ator and heater, shoul d be shaken
whi l e at 104 kPa (15 psi ) si nce some l eaks occur onl y
whi l e dri vi ng due to engi ne rock, etc.
I f there are no external l eaks, after the gauge di al
shows a drop i n pressure, detach the tester. Start
engi ne and run the engi ne up to normal operati ng
temperature to open the thermostat and al l ow the
cool ant to expand. Reattach the tester. I f the needl e on
the di al fl uctuates i t i ndi cates a combusti on l eak,
usual l y a head gasket l eak.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL
BUILDS UP FAST. EXCESSIVE PRESSURE BUILT UP,
BY CONTINUOUS ENGINE OPERATION, MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 PSI).
I f the needl e on the di al does not fl uctuate, race the
engi ne a few ti mes. I f an abnormal amount of cool ant
or steam emi ts from the tai l pi pe, i t may i ndi cate a
cool ant l eak caused by a faul ty head gasket, cracked
engi ne bl ock, or cracked cyl i nder head.
There may be i nternal l eaks that can be determi ned
by removi ng the oi l di p-sti ck. I f water gl obul es appear
i ntermi xed wi th the oi l i t wi l l i ndi cate an i nternal l eak
i n the engi ne. I f there i s an i nternal l eak, the engi ne
must be di sassembl ed for repai r.
COOLANT RECOVERY SYSTEM (CRS)
Thi s system works wi th the radi ator pressure cap to
use thermal expansi on and contracti on of the cool ant to
keep the cool ant free of trapped ai r. Provi des a conve-
ni ent and safe method for checki ng cool ant l evel and
adjusti ng l evel at atmospheri c pressure wi thout re-
movi ng the radi ator pressure cap. I t al so provi des some
reserve cool ant to cover mi nor l eaks and evaporati on or
boi l i ng l osses. Al l vehi cl es are equi pped wi th thi s
system and take vari ous shapes and forms. (Fi g. 15)
shows a typi cal system i n the typi cal l ocati on.
Fig. 14 Pressure Testing Cooling System
Fig. 15 Typical Coolant Recovery System
See Cool ant Level Check Servi ce and Deaerati on,
and Pressure Cap secti ons for operati on and servi ce.
Vehi cl es equi pped wi th the el ectri c moni tor system
have a l evel sensor i n the CRS tank, see Group 8,
El ectri cal , for servi ce.
RADIATOR PRESSURE CAP
Radi ators are equi pped wi th a pressure cap that
rel eases pressure at some poi nt wi thi n a range of
97-124 kPa (14-18 psi ).
The system wi l l operate at hi gher than atmospheri c
pressure that rai ses the cool ant boi l i ng poi nt al l owi ng
i ncreased radi ator cool i ng capaci ty.
There i s al so a vent val ve i n the center of the cap.
Thi s val ve al so opens when cool ant i s cool i ng and
contracti ng al l owi ng cool ant to return to radi ator from
cool ant reserve system tank by vacuum through con-
necti ng hose. If valve is stuck shut, the radiator
hoses will be collapsed on cool down. Clean the
vent valve (Fig. 16) to ensure proper sealing
when boiling point is reached.
The gasket i n the cap seal s the fi l l er neck, so that
vacuum can be mai ntai ned, al l owi ng cool ant to be
drawn back i nto the radi ator from the reserve tank.
RADI ATOR CAP TO FI LLER NECK SEAL PRES-
SURE RELI EF CHECK
The pressure cap upper gasket (seal ) pressure rel i ef
can be checked by removi ng the overfl ow hose at the
radi ator fi l l er neck ni ppl e (Fi g. 16). Attach the Radi a-
tor Pressure Tool to the fi l l er neck ni ppl e and pump ai r
i nto the radi ator. Pressure cap upper gasket shoul d
rel i eve at 69-124 kPa (10-18 psi ) and hol d pressure at
55 kPa (8 psi ) mi ni mum.
WARNING: THE WARNING WORDS DO NOT OPEN
HOT ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM IS
HOT OR UNDER PRESSURE.
There i s no need to remove the radi ator cap at any
ti me except for the fol l owi ng purposes:
(1) Check and adjust anti freeze freeze poi nt.
(2) Refi l l system wi th new anti -freeze.
(3) Conducti ng servi ce procedures.
(4) Checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTER-
CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS
TO ESCAPE THROUGH THE OVERFLOW 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 PRESSURE) BE-
FORE AND AFTER TURNING TO THE FIRST STOP IS
RECOMMENDED.
PRESSURE TESTING RADIATOR CAP
Di p the pressure cap i n water, cl ean any deposi ts off
the vent val ve or i ts seat and appl y cap to end of
Radi ator Pressure Tool . Worki ng the pl unger, bri ng the
pressure to 104 kPa (15 psi ) on the gauge. I f the
pressure cap fai l s to hol d pressure of at l east 97 kPa
(14 psi ) repl ace cap. See CAUTION.
I f the pressure cap tests properl y whi l e posi ti oned on
Radi ator Pressure Tool (Fi g. 17), but wi l l not hol d
pressure or vacuum when posi ti oned on the radi ator.
I nspect the radi ator fi l l er neck and cap top gasket for
i rregul ari ti es that may prevent the cap from seal i ng
properl y.
CAUTION: Radiator Pressure Tool is very sensitive to
small air leaks that will not cause cooling system
problems. A pressure cap that does not have a
history of coolant loss should not be replaced just
because it leaks slowly when tested with this tool.
Add water to the tool. Turn tool upside down and
recheck pressure cap to confirm that cap is bad.
I NSPECTI ON
Hol d the cap i n hand, right side up (Fi g. 16). The
vent val ve at the bottom of the cap shoul d open. I f the
rubber gasket has swol l en and prevents the val ve from
openi ng, repl ace the cap.
Hol d the cl eaned cap i n hand upside down. I f any
l i ght shows between vent val ve and rubber gasket,
repl ace cap. Donot useareplacement capthat has
a spring to hold the vent shut.
Repl acement cap must be of the type desi gned for
cool ant reserve system wi th a compl etel y seal ed di a-
phragm spri ng, and rubber gasket to seal to fi l l er neck
top surface. Thi s desi gn assures cool ant return to
radi ator.
Fig. 16 Radiator Pressure Cap Filler Neck
RADIATORS
The radi ators are downfl ow types (verti cal tubes)
wi th desi gn features that provi de greater strength al so
suffi ci ent heat transfer capabi l i ti es to keep the engi ne
sati sfactori l y cool ed.
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.
I f the pl asti c tank i s damage, pl asti c tank and
O-ri ngs are avai l abl e for servi ce repai r. Tank repl ace-
ment shoul d be done by qual i fi ed personnel wi th
proper equi pment.
RADI ATOR DRAI NCOCK SERVI CE
REMOVAL
(1) Turn the drai n cock stem countercl ockwi se to
unscrew the stem. When the stem i s unscrewed to the
end of the threads, pul l the stem (Fi g. 1) from the
radi ator tank and drai ncock body.
(2) Remove the drai ncock body from the radi ator
tank by squeezi ng the si des together wi th a pai r of
needl e nose pl i ers (Fi g. 2). Then, pul l the body from the
i nl et tank.
INSTALLATION
(1) Check the drai ncock to be sure the body i s
i nstal l ed l oosel y on the stem (Fi g. 3). I f the stem i s
screwed i nto the body, the drai ncock cannot be i n-
stal l ed i nto the tank openi ng.
(2) Push the l oosel y assembl ed drai ncock assembl y
body i nto the tank openi ng unti l i t snaps i nto pl ace.
(3) Ti ghten the drai ncock stem by turni ng cl ockwi se
to 2.0-2.7 Nm (18-25 i n. l bs.).
Fig. 17 Pressure Testing Radiator Cap
Fig. 1 Driancock Disassembled (Typical)
Fig. 2 Removing Draincock Body (Typical)
Fig. 3 Draincock Assembled for Installation (Typical)
RADI ATOR COOLANT FLOW CHECK
To determi ne whether cool ant i s fl owi ng through the
cool i ng system, use the fol l owi ng procedure:
(1) I f engi ne i s col d, i dl e engi ne unti l normal operat-
i ng temperature i s reached. Then feel the upper radi a-
tor hose. I f i t i s hot, cool ant i s ci rcul ati ng.
WARNING: DO NOT REMOVE RADIATOR PRESSURE
CAP WITH THE SYSTEM HOT AND UNDER PRES-
SURE BECAUSE SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(2) Remove radi ator pressure cap when engi ne i s
col d, I dl e engi ne unti l thermostat opens, you shoul d
observe cool ant fl ow whi l e l ooki ng down the fi l l er neck.
Once fl ow i s detected i nstal l radi ator pressure cap.
REMOVAL
(1) Di sconnect negati ve battery cabl e from battery.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK
OR THE RADIATOR DRAINCOCK WITH THE SYSTEM
HOT AND UNDER PRESSURE BECAUSE SERIOUS
BURNS FROM COOLANT CAN OCCUR.
System of thi s secti on.
(3) Remove hose cl amps and hoses from the radi ator
(Fi g. 4).
Remove cool ant reserve system tank to fi l l er neck
tube.
(4) Remove automati c transmi ssi on hoses, i f
equi pped.
(5) Remove fan and fan support assembl y by di scon-
necti ng fan motor el ectri cal connector. Remove upper
shroud attachi ng nuts, and l i ft shroud up and out of
bottom shroud attachment cl i ps separati ng shroud
from radi ator. Fan damage shoul d al ways be avoi ded.
(6) Remove upper radi ator mounti ng screws. Di scon-
nect the engi ne bl ock heater wi re i f equi pped.
(7) Radi ator can now be l i fted free from engi ne
compartment. Careshouldbetaken not todamage
radiator cooling fins or water tubes during re-
moval.
INSTALLATION
(1) Sl i de radi ator down i nto posi ti on behi nd radi ator
support (yoke). Seat the radi ator wi th the rubber
i sol ators i nto the mount hol es provi ded, wi th a 10 l bs.
force .
(2) I nstal l the upper i sol ator panel . Ti ghten radi ator
mounti ng bol ts to 11.9 Nm (105 i n. l bs.) (Fi g. 4).
(3) Connect automati c transmi ssi on hoses (i f
equi pped).
(4) Sl i de fan shroud, fan and motor down i nto cl i ps
on l ower radi ator tank. Attach upper shroud screws.
(5) I nstal l upper, l ower radi ator hoses (i ncl udi ng
cool ant reserve hose) (Fi g. 4) and fan motor el ectri cal
connecti on. See Refilling Cooling Systems.
RADIATOR HOSES
The 2.5L engi ne l ower radi ator hose MUST be
cl i pped to front engi ne mounti ng bracket to protect
hose from fan and road damage. (Fi g. 4)
A hardened, cracked, swol l en or restri cted hose
shoul d be repl aced. Do not damage radi ator i nl et and
outl et when l ooseni ng hoses.
Radi ator hoses shoul d be routed wi thout any ki nks
and i ndexed as desi gned. The use of mol ded hoses i s
recommended.
Spri ng type cl amps are used on al l appl i cati ons. I f
repl acement i s necessary repl ace wi th the ori gi nal
styl e spri ng type cl amp.
FANS
Al l model s use el ectri c motor dri ven cool i ng system
fans. The fan modul es i ncl ude a motor support whi ch
may (dependi ng on model ) i ncl ude a shroud. The mod-
ul e i s fastened to the radi ator by screws, see (Fi g. 4).
Al l fan motors are one speed. Attempts to reduce
hi gh temperature gauge readi ng by i ncreasi ng engi ne
speed, at the same vehi cl e speed, can i ncrease hi gh
temperature.
FAN SERVICE
There are no repai rs to be made to the fan. I f the fan
i s warped, cracked, or otherwi se damaged, i t must be
repl aced wi th onlythe recommended part for adequate
strength, performance and safety.
REMOVAL
Di sconnect el ectri c motor l ead. Remove fan, motor
and shroud or support as an assembl y from radi ator
support.
To remove fan from motor shaft, bench support the
motor and motor shaft, whi l e removi ng the fan retai n-
i ng cl i p, so that the shaft and motor wi l l not be
damaged by excessi ve force. Surface or burr re-
moval may berequiredtoremovefanfrommotor
shaft. (Fi g. 5). Do not permi t the fan bl ades to touch
the bench.
I NSTALLATI ON
Sl i de the fan on motor shaft. Support motor and
shaft as above, whi l e i nstal l i ng fan retai ni ng cl i p.
I nstal l assembl y i nto pocket on l ower radi ator tank.
Attach support nuts and washers. Connect fan motor
l ead. For wiring diagrams of fan motor systems
see Electrical Group 8.
RADI ATOR FAN CONTROL
Fan control i s done two ways. The fan i s turned on by
the temperature of the cool ant that i s sensed by the
cool ant temperature sensor whi ch sends the message
to the on-board computer. The computer turns on the
fan through the fan rel ay. See Group 8W for ci rcui ty
and di agnosti cs provi ded.
Swi tchi ng through the on-board computer provi des
fan control for the fol l owi ng condi ti ons;
The fan wi l l not run duri ng cranki ng unti l the
engi ne starts no matter what the cool ant temperature
i s.
The fan wi l l run i f cool ant temperature reaches 99C
(210F). I t wi l l turn off when the temperature drops to
93C (200F).
Thi s i s to hel p prevent steami ng. The fan wi l l
run onl y bel ow 16C (60F) ambi ent. Between 38C
(100F) to 97C (195F) cool ant temperature, at i dl e
and then onl y for three mi nutes.
TEMPERATURE GAUGE I NDI CATI ON
At i dl e wi th Ai r Condi ti oni ng off the temperature
gauge wi l l ri se sl owl y to about 5/8 gauge travel , the fan
wi l l come on and the gauge wi l l qui ckl y drop to about
1/2 gauge travel thi s i s normal .
ELECTRIC FAN MOTOR
To check out the el ectri c fan motor, di sconnect the fan
motor wi re connector and connect i t wi th #14 gauge
wi res to a good 12-vol t battery observi ng correct pol ar-
i ty per (Fi g. 6). I f the fan runs normal l y, the motor i s
functi oni ng properl y. I f not, repl ace motor usi ng the
removal and i nstal l ati on i nstructi ons
Fig. 4 Radiator, ALL
Fig. 5 Radiator Fan Retaining Clip (Typical)
contai ned i n the Fan Secti on. I f the motor i s noti ceabl y
overheated(i .e., wi re i nsul ati on mel ted, motor charred)
the system vol tage may be too hi gh. Check chargi ng
system, see Group 8A, Battery/Starti ng/Chargi ng Sys-
tem Di agnosti cs.
ELECTRIC FAN MOTOR TEST
EQUI PMENT REQUI RED
Di agnosti c Tool DRB I I or equi val ent
Vol t/Ohm Meter
Wi ri ng Di agrams Manual
TEST PROCEDURE
(1) Run the engi ne to normal operati ng temperature
(2) Check wi ri ng connector i n C25, C9, and C26 for
proper engagement, see Wi ri ng Di agrams.
(3) Usi ng a di agnosti c tool , pl ug i t i nto the di agnosti c
connector rearward of the battery. Check the On-Board
Di agnosti cs (OBD) i n the Si ngl e Board Engi ne Control
(Engi ne Control l er) for faul t codes, Refer to Group 14,
Fuel I njecti on for i nstructi ons.
(4) I f faul t code 88-12-35-55 i s detected, go to Step 5.
(5) Wi th the i gni ti on swi tch i n the run posi ti on, test
for battery vol tage at si ngl e pi n connector at the fan
rel ay. Vol tage readi ng OK, go to Step 6. Vol tage at 0-1
vol t, go to Step 7.
(6) Wi th the i gni ti on off, di sconnect the 60-way con-
nector from the Engi ne Control l er (outboard of battery)
and return the i gni ti on to the run posi ti on. Test for
battery vol tage at cavi ty 31 of the 60-way connector
(Fi g. 7). Vol tage readi ng OK and femal e termi nal i s not
damaged, repl ace the Engi ne Control l er. Vol tage read-
i ng 0, repai r open or short i n C27 ci rcui t.
(7) Wi th the i gni ti on off, di sconnect the 60-way con-
nector from the Engi ne Control l er (outboard of bat-
tery)and return the i gni ti on to the run posi ti on. Test
for battery vol tage at the si ngl e pi n connector at the
fan rel ay. Vol tage readi ng OK, repl ace the Engi ne
Control l er. Vol tage readi ng 0-1 vol t, go to Step 7.
(8) Wi th i gni ti on i n the run posi ti on, test for battery
vol tage at the bl ue wi re (C27) i n the 3-way connector of
the fan rel ay. Vol tage readi ng OK, repl ace the fan rel ay.
Vol tage readi ng 0, repai r open or short, i n C27 ci rcui t.
(9) Turn i gni ti on off, connect the 60-way connector
at the Engi ne Control l er, and test the system.
FAN SHROUD
These fan shrouds may cover l ess than ful l radi ator
frontal area to prevent the shroud from restri cti ng
ai rfl ow at hi gh speeds.
The shroud supports the el ectri c fan motor and fan.
Al l other non A/C vehi cl es have a fan motor support
assembl y i nstead of a shroud. For removal and i nstal -
l ati on Refer to Radi ator Removal Secti on.
AUTOMATIC TRANSMISSION OIL COOLERS
Oi l cool ers are of two types, i nternal oi l to cool ant
type, mounted i n the radi ator l ower tank (Fi g. 8) or
external oi l -to-ai r type mounted ahead of the radi ator,
(Fi g. 8).
Rubber oi l l i nes feed the oi l cool er and the automati c
transmi ssi on. Use onl y approved transmi ssi on oi l
cool er hose. Si nce these are mol ded to fi t space avai l -
abl e, mol ded hoses are recommended.
Fig. 6 Electric Fan Motor (Typical)
Fig. 7 Engine Controller 60-Way Connector from
Terminal End
Fig. 8 Transmission Oil Coolers
ACCESSORY DRI VE BELTS
INDEX
page page
2.5L Engine Belts Remove/Install-Adjust . . . . . . . . 23
3.0L Engine Belts Remove/Install-Adjust . . . . . . . . 24
3.3L Engine Accessory Drive Belt Remove/Install . 25
GENERAL INFORMATION
PROPER BELT TENSI ON
Sati sfactory performance of the bel t dri ven accesso-
ri es depends on proper bel t tensi on. Bel t tensi oni ng
shoul d be performed wi th the ai d of a Burroughs gauge
Speci al Tool C-4162. Because of space l i mi tati ons i n the
engi ne compartment of front wheel dri ve vehi cl es, the
gauge may be restri cted to use after the vehi cl e has
been rai sed on a hoi st and the spl ash shi el d has been
removed.
Bel t tensi oni ng methods are gi ven i n order of prefer-
ence:
Bel t tensi on gauge method.
Torque equi val ent method.
BELT TENSI ON GAUGE METHOD
Use bel t tensi oni ng Speci al Tool Ki t C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V belt is
not to be used on the V-belt. These gauges are not
interchangeable.
For conventi onal V-bel ts affi x the Burroughs gauge
(Speci al Tool C-4162) to the bel t. Adjust the bel t ten-
si on for New or Used bel t as prescri bed i n the Bel t
Tensi on Chart. For a Pol y-V bel t affi x the Pol y-V
Burroughs gauge to the bel t and then appl y speci fi ed
tensi on to the bel t as prescri bed i n the Bel t Tensi on
Chart.
Adjust the bel t tensi on for a New or Used bel t as
prescri bed i n the Bel t Tensi on Chart.
TORQUE EQUI VALENT METHOD
Adjustabl e accessory brackets provi ded wi th a 13mm
(1/2 i n.) square hol e for a torque wrench can use an
equi val ent torque val ue for bel t adjustment.
Equi val ent torque val ues for adjusti ng these acces-
sory dri ve bel ts are speci fi ed on the Bel t Tensi on Chart.
2. 5L ENGINE BELTS REMOVE/INSTALL-ADJUST
AI R CONDI TI ONI NG COMPRESSOR
(1) Loosen the i dl er bracket pi vot screw A and l ock-
i ng screws B (Fi g. 2) to remove and i nstal l bel t or
adjust bel t tensi on.
ACCESSORY DRI VE BELTS DI AGNOSI S
(2) Adjust bel t tensi on by appl yi ng torque to square
hol e C on i dl er bracket. Adjust tensi on to speci fi cati on
gi ven i n Bel t Tensi on Chart.
(3) Ti ghten i n order, fi rst, l ocki ng screws B then
pi vot screw A to 54 Nm (40 ft. l bs.).
POWER STEERI NG PUMPS TYPE
(1) From on top of the vehi cl e l oosen l ocki ng screw G.
(2) From under the vehi cl e l oosen the pi vot screw
and pi vot nut H.
(3) After i nstal l i ng a new bel t adjust bel t tensi on
wi th 1/2 i n. breaker bar i nstal l ed i n adjusti ng bracket.
See tensi on speci fi cati on i n Bel t Tensi on Chart.
(4) Ti ghten l ocki ng screw G to 54 Nm (40 ft. l bs.).
(5) Ti ghten pi vot screw H and the pi vot nut to 54
Nm (40 ft. l bs.)
ALTERNATOR BELT
(1) Loosen al ternator pi vot nut D.
(2) Loosen T-Bol t l ocki ng nut E and adjusti ng screw
F to remove and i nstal l Pol y V bel t or adjust bel t
tensi on.
(3) Ti ghten pi vot nut D TO 54 Nm (40 ft. l bs.).
(4) Ti ghten adjusti ng screw F to adjust bel t tensi on
to speci fi cati on shown i n Bel t Tensi on Chart.
(5) Ti ghten T-Bol t l ocki ng nut E to 54 Nm (40 ft.
l bs.)
3. 0L ENGINE BELTS REMOVE/INSTALL-ADJUST
AI R CONDI TI ONI NG BELT
To remove and i nstal l the ai r condi ti oni ng compres-
sor dri ve bel t, fi rst l oosen the i dl er pul l ey l ock nut, then
turn the adjusti ng screw to rai se or l ower the i dl er
pul l ey (Fi gs. 3 and 4).
To adjust theair conditioningdrivebelt, l oosen
the i dl er pul l ey nut (Fi g. 3) and adjust bel t tensi on by
ti ghteni ng adjusti ng screw (Fi gs. 3 and 4). Ti ghten
pul l ey nut to 54 Nm (40 ft. l bs.) after adjustment.
Fig. 1 Drive Belt Inspection
Fig. 2 Accessory Drive Belts 2.5L Engine
ALTERNATOR/POWER STEERI NG PUMP BELT
The Pol y-V al ternator/power steeri ng pump bel t i s
provi ded wi th a dynami c tensi oner (Fi g. 5) to mai ntai n
proper bel t tensi on. To remove or i nstal l thi s bel t, appl y
force i n a cl ockwi se di recti on to the tensi oner pul l ey
bol t (Fi g. 5).
3. 3L ENGINE ACCESSORY DRIVE BELT
REMOVE/INSTALL
ALTERNATOR, POWER STEERI NG PUMP, AI R
CONDI TI ONI NG COMPRESSOR AND WATER
PUMP DRI VE BELT
The Pol y-V Dri ve bel t i s provi ded wi th a dynami c
tensi oner (Fi g. 6) to mai ntai n proper bel t tensi on. To
remove or i nstal l thi s bel t.
(1) Rai se vehi cl e on hoi st.
(2) Remove ri ght front spl ash shi el d.
(3) Rel ease tensi on by rotati ng the tensi oner cl ock-
wi se (Fi g. 6).
(4) Reverse above procedure to i nstal l .
Fig. 3 Accessory Drive Belts3.0L Engine
Fig. 4 Air Conditioning Belt Idler
Fig. 5 Release Belt Tensioner
BELT TENSI ON CHART
Fig. 6 Accessory Drive Belt3.3L Engine
ENGI NE BLOCK HEATER
DESCRIPTION AND OPERATION
On al l model s an engi ne bl ock heater i s avai l abl e as
an opti onal accessory. The heater i s operated by ordi -
nary house current (110 Vol t A.C.) through a power
cord l ocated behi nd the radi ator gri l l e. Thi s provi des
easi er engi ne starti ng and faster warm-up when ve-
hi cl e i s operated i n areas havi ng extremel y l ow tem-
peratures. The heater i s mounted i n a core hol e (i n
pl ace of a core hol e pl ug) i n the engi ne bl ock, wi th the
heati ng el ement i mmersed i n cool ant (Fi g. 7).
Thepower cord must besecured in its retainer
clips, and not positioned soit could contact link-
ages or exhaust manifolds and becomedamaged.
I f uni t does not operate, troubl e can be i n ei ther the
power cord or the heater el ement. Test power cord for
conti nui ty wi th a 110-vol t vol tmeter or 110-vol t test
l i ght; test heater el ement conti nui ty wi th an ohmmeter
or 12-vol t test l i ght.
REMOVAL
(1) Drai n cool ant from radi ator and cyl i nder bl ock.
Refer to Cool i ng System Drai n, Cl ean, Fl ush and Refi l l
of thi s secti on for procedure.
(2) Detach power cord pl ug from heater.
(3) Loosen screw i n center of heater. Remove heater
assembl y.
I NSTALLATI ON
(1) Thoroughl y cl ean core hol e and heater seat.
(2) I nsert heater assembl y wi th el ement l oop posi -
ti oned upward.
(3) Wi th heater seated, ti ghten center screw securel y
to assure a posi ti ve seal .
(4) Fi l l cool i ng system wi th cool ant to the proper
l evel , vent ai r, and i nspect for l eaks. Pressuri ze system
wi th Radi ator Pressure Tool before l ooki ng for l eaks.
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SPECI FI CATI ONS
TORQUE
COOLI NG SYSTEM CAPACI TY
MANUAL TRANSAXLE CLUTCH
CONTENTS
page page
CLEANING PRECAUTIONS . . . . . . . . . . . . . . . . . 9
CLUTCH DISC REPLACEMENT . . . . . . . . . . . . . . 8
CLUTCH CABLE REPLACEMENT . . . . . . . . . . . . 5
CLUTCH CABLE MECHANISM . . . . . . . . . . . . . . 1
CLUTCH CHATTER COMPLAINTS . . . . . . . . . . . . 1
CLUTCH/STARTER INTERLOCK SWITCH . . . . . . 7
EXCESSIVE CLUTCH SPIN TIME/CLASH
INTO REVERSE COMPLAINTS . . . . . . . . . . . . . 1
RELEASE BEARING AND FORK . . . . . . . . . . . . . 9
GENERAL INFORMATION
servi ce manual .
The cl utch used i n al l model s i s a si ngl e, dry di sc type
wi th automati c adjustment for wear bei ng provi ded i n
the cl utch pedal .
The cl utch pedal i s connected to the torque shaft
through a cabl e and l ever.
The upper end of the cl utch pedal pi vots i n the pedal
bracket on two nyl on bushi ngs. These bushi ngs do not
requi re peri odi c l ubri cati on.
CLUTCH CHATTER COMPLAINTS
For al l cl utch chatter compl ai nts, do the fol l owi ng:
(1) Check for l oose, mi sal i gned, or broken engi ne
and transmi ssi on mounts. I f present, they shoul d be
corrected at thi s ti me. Test vehi cl e for chatter. I f
chatter i s gone, there i s no need to go any further. I f
chatter persi sts:
(2) Check to see i f cl utch cabl e routi ng i s correct and
operates smoothl y.
(3) Check for l oose connecti ons i n dri ve trai n. Cor-
rect any probl ems and determi ne i f cl utch chatter
compl ai nt has been sati sfi ed. I f not,
(4) Remove transaxl e. See Group 21, Manual Tran-
saxl e, for procedure.
(5) Check to see i f the rel ease beari ng i s sti cky or
bi ndi ng. Repl ace beari ng, i f needed.
(6) Check l i nkage for excessi ve wear on bushi ngs.
Repl ace al l worn parts.
(7) Check fl ywheel and cl utch pressure pl ate for
contami nati on (di rt, oi l ) or scored. Repl ace fl ywheel
and/or pressure pl ate, i f requi red.
(8) Check to see i f the cl utch di sc hub spl i nes are
damaged. Repl ace wi th new di sc.
(9) Check i nput shaft on the transaxl e for damaged
spl i nes. Repl ace i f necessary.
(10) Check for uneven wear on cl utch fi ngers.
EXCESSIVE CLUTCH SPIN TIME/CLASH INTO RE-
VERSE COMPLAINTS
For al l excessi ve cl utch spi n ti me/cl ash i nto reverse
compl ai nts, do the fol l owi ng:
(1) Depress cl utch pedal to fl oor and hol d. After
three seconds, shi ft to reverse. I f cl ash i s present,
cl utch has excessi ve spi n ti me.
(3) Check the i nput shaft spl i ne, cl utch di sc spl i ne
and rel ease beari ng for dry rust. I f dry rust i s present,
cl ean rust off. Appl y a l i ght coat of beari ng grease to
the i nput shaft spl i ne, where the cl utch di sc sl i des.
(4) Check to see i f the cl utch di sc hub spl i nes are
damaged. I f damaged repl ace wi th new di sc.
(5) Check i nput shaft spl i ne of the transaxl e for
damage. Repl ace i nput shaft i f requi red.
(6) I nstal l cl utch assembl y and transaxl e.
CLUTCH CABLE MECHANISM
The manual transaxl e cl utch rel ease system has a
uni que sel f-adjusti ng mechani sm to compensate for
cl utch di sc wear. Thi s adjuster mechani sm i s l ocated
wi thi n the cl utch pedal . The prel oad spri ng mai ntai ns
tensi on on the cabl e. Thi s tensi on keeps the cl utch
rel ease beari ng conti nuousl y l oaded agai nst the fi ngers
of the cl utch cover assembl y.
When the pedal i s depressed, teeth on the adjuster
and the posi ti oner engage and pul l the rel ease cabl e. A
spri ng l ocated behi nd the adjuster ensures proper
tooth engagement.
When the pedal i s rel eased, the adjuster contacts the
bumper. Thi s separates the adjuster and posi ti oner
teeth, al l owi ng the prel oad spri ng to functi on.
MANUAL TRANSAXLE CLUTCH 6 - 1
SERVI CE DI AGNOSI SCLUTCH SLI PS
6 - 2 MANUAL TRANSAXLE CLUTCH
SERVI CE DI AGNOSI SI MPROPER CLUTCH RELEASE
SERVI CE DI AGNOSI SCLUTCH NOI SE
CLUTCH CABLE REPLACEMENT
(1) Remove retai ner from cl utch rel ease l ever at
transaxl e by pul l i ng on the tai l of the bal l stud (Fi g. 1).
(2) Pry out bal l end of cabl e from posi ti oner adjuster
and remove cabl e, passi ng i t through the hoop i n the
shock tower mounti ng bracket.
(3) I nspect cabl e for wear and contami nati on. The
i nner cabl e strand shoul d move smoothl y i nsi de the
cabl e housi ng. I f cabl e i s worn or damaged, repl ace the
cabl e. Do not lubricate.
(4) I nspect the cl utch pedal and adjuster mechani sm
for wear. Appl y a mul ti purpose l ubri cant on parts
i ndi cated (Fi g. 1).
SERVI CE DI AGNOSI SCLUTCH GRAB/CHATTER
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(5) To i nstal l , reverse procedure of steps (3) through
(1).
(6) After i nstal l ati on, push and l i ft the cl utch pedal 2
or 3 ti mes to al l ow adjuster mechani sm to functi on.
(7) Check cl utch pedal starter i nterl ock swi tch op-
erati on.
CLUTCH/STARTER INTERLOCK SWITCH
The cl utch/starter i nterl ock swi tch functi ons as a
safety i nterl ock devi ce. I t prevents possi bl e engi ne
cranki ng wi th the manual transmi ssi on i n gear.
The cl utch swi tch i s wi red i n seri es between the
starter rel ay coi l and the i gni ti on swi tch.
The cl utch/starter i nterl ock swi tch i s mounted to a
bracket l ocated next to the cl utch pedal . The swi tch i s
hel d i n pl ace by two pl asti c wi ng tabs.
The cl utch/starter i nterl ock swi tch has an adjustabl e
stri ker pl ate. The stri ker pl ate i s l ocated on the l eft
si de of the cl utch pedal (Fi g. 2).
DI AGNOSI S
Di sconnect cl utch/starter i nterl ock swi tch harness
from i nstrument panel wi ri ng harness. Usi ng a ohm
meter, check for conti nui ty between the two termi nal s
i n the connector on the swi tch harness. There shoul d
be no conti nui ty between the termi nal s when the
swi tch i s i n i ts neutral (ful l y extended) posi ti on. When
the swi tch i s depressed more than 1 mm (0.040) the
ohm meter shoul d show conti nui ty at the swi tch har-
ness.
I f al l ohm meter readi ngs are correct and the swi tch
does not operate correctl y, adjustment i s requi red.
Refer to Swi tch Adjustment Procedure to adjust
swi tch.
REMOVAL
(1) Di sconnect el ectri cal harness to swi tch connec-
tor.
(2) Push swi tch out of mounti ng bracket and sl i de
wi res through sl ot i n bracket.
I NSTALLATI ON
(1) Sl i de swi tch wi res through sl ot i n swi tch bracket.
(2) Li ne up swi tch tab wi th sl ot i n swi tch bracket
and push swi tch i nto posi ti on. Do not pul l on the swi tch
wi res to seat swi tch i nto bracket, swi tch damage may
occur.
(3) After i nstal l ati on, the swi tch must be adjusted
and checked for proper operati on. Refer to Swi tch
Adjustment Procedure.
ADJUSTMENT PROCEDURE
When performi ng swi tch adjustment, the fl oor mat
shoul d be removed before begi nni ng adjustment proce-
dures.
(1) Set the park brake.
(2) Di sconnect cl utch cabl e at the transaxl e end of
the cabl e.
(3) Depress cl utch pedal , l oosen adjusti ng nut and
sl i de the stri ker pl ate forward to ful l y compress the
i nterl ock swi tch pl unger.
(4) Ti ghten adjusti ng nut to 12 Nm (105 i n. l bs.).
(5) Reconnect cl utch cabl e.
The interlock switch is now adjusted. A final
check is required to insure that the switch is
made below the clutch release point.
(1) Wi th the park brake set and the vehi cl e IN
NEUTRAL turn the key to the start posi ti on. The
vehi cl e shoul d not crank. If the vehicle cranks do
not continuewith this test. Recheck the swi tch and
swi tch adjustment to determi ne the cause. I f the ve-
hi cl e does not crank proceed to step 2.
(2) Wi th the park brake set and the vehi cl e IN
GEAR turn the key to the start posi ti on.
WARNING:BEFORE PERFORMING STEP THREE BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VE-
HICLE MAY MOVE WHEN PERFORMING THIS TEST.
(3) Sl owl y depress the cl utch pedal and feel for any
vehi cl e moti on when the starter i s energi zed. I f there i s
no moti on the swi tch i s properl y adjusted. I f moti on i s
fel t, repeat the adjustment procedure.
Fig. 2 Clutch Interlock Switch and Components
CLUTCH DISC REPLACEMENT
REMOVAL
(2) Mark cl utch cover and fl ywheel , to mai ntai n
thei r same rel ati ve posi ti ons when i nstal l i ng cl utch
assembl y (Fi g. 3).
(3) I nsert Cl utch Di sc Al i gni ng Tool C-4676 through
the cl utch di sc hub to prevent the cl utch di sc from
fal l i ng and damagi ng the faci ngs (Fi g. 4).
(4) Loosen cl utch cover attachi ng bol ts, one or two
turns at a ti me, i n a cri sscross pattern, to rel ease
spri ng pressure evenl y and avoi d cover damage.
(5) Remove the cl utch pressure pl ate and cover as-
sembl y and di sc from fl ywheel . Handl e careful l y to
avoi d contami nati ng the fri cti on surfaces.
CAUTION: Avoid touching disc face with oily hands.
Clutch chatter may result.
I NSPECTI ON
(1) I nspect for oi l l eakage through engi ne rear mai n
beari ng oi l seal and transaxl e dri ve pi ni on seal . I f
l eakage i s noted, i t shoul d be corrected at thi s ti me.
(2) The fri cti on faces of the fl ywheel and pressure
pl ate shoul d not have excessi ve di scol orati on, burned
areas, smal l cracks, deep grooves, or ri dges. Repl ace
parts as requi red.
(3) Cl ean the fl ywheel face wi th crocus cl oth or fi ne
sandpaper (400-600 grade), then wi pe the surface wi th
mi neral spi ri ts. I f the surface i s severel y scored, heat
checked, or warped, repl ace the fl ywheel .
CAUTION: Do not flat-machine the flywheel face. The
surface profile is tapered.
(4) The heavy si de of the fl ywheel i s i ndi cated by a
daub of whi te pai nt near the outsi de di ameter. To
Fig. 3 Manual Transaxle Clutch
Fig. 4 Clutch Disc Aligning Tool
minimize the effects of fl ywheel unbal ance, perform
the fol l owi ng i nstal l ati on procedure:
(a) Loose assembl e the fl ywheel to the crankshaft.
Use new fl ywheel attachi ng bol ts whi ch have seal ant
on the threads. I f new bol ts are not avai l abl e, appl y
Locti te seal ant to the threads of the ori gi nal bol ts.
Thi s seal ant i s requi red to prevent engi ne oi l l eak-
age.
(b) Rotate the fl ywheel and crankshaft unti l the
daub of whi te pai nt (heavy si de) i s at the 12 ocl ock
posi ti on.
(c) Torque fl ywheel attachi ng bol ts to 95 Nm(70
ft. l bs.) usi ng a cri sscross pattern.
(5) The di sc assembl y shoul d be handl ed wi thout
touchi ng the faci ngs. Repl ace di sc i f the faci ngs show
evi dence of grease or oi l soakage, or wear to wi thi n l ess
than .38 mm (.015 i nch) of the ri vet heads. The spl i nes
on the di sc hub and transaxl e i nput shaft shoul d be a
snug fi t wi thout si gns of excessi ve wear. Metal l i c
porti ons of di sc assembl y shoul d be dry and cl ean, and
not been di scol ored from excessi ve heat. Each of the
arched spri ngs between the faci ngs shoul d not be
broken and al l ri vets shoul d be ti ght.
(6) Wi pe the fri cti on surface of the pressure pl ate
wi th mi neral spi ri ts.
(7) Usi ng a strai ght edge, check pressure pl ate for
fl atness. The pressure pl ate fri cti on area shoul d be fl at
wi thi n .010 i nch and free from di scol orati on, burned
areas, cracks, grooves, or ri dges.
(8) Usi ng a surface pl ate, test cover for fl atness. Al l
secti ons around attachi ng bol t hol es shoul d be i n
contact wi th surface pl ate wi thi n .015 i nch.
(9) The cover shoul d be a snug fi t on fl ywheel dow-
el s. I f the cl utch assembl y does not meet these requi re-
ments, i t shoul d be repl aced.
I NSTALLATI ON
(1) Mount cl utch assembl y on fl ywheel , bei ng careful
to properl y al i gn dowel s and the al i gnment marks
made before removal . I f new cl utch or fl ywheel i s
i nstal l ed, al i gn cover bal ance spot as cl ose as possi bl e
to fl ywheel bal ance orange spot. Appl y pressure to the
al i gnment tool . Center the ti p of the tool i nto the
crankshaft and the sl i di ng cone i nto the cl utch fi ngers.
Ti ghten the cl utch attachi ng bol ts suffi ci entl y to hol d
the di sc i n posi ti on.
(2) To avoi d di storti on of the cl utch cover, bol ts
shoul d be ti ghtened a few turns at a ti me, i n a
cri sscross pattern, unti l they are al l seated. Ti ghten
bol ts to 28 Nm (250 i n. l bs.) fol l owi ng a cri sscross
pattern sequence. Remove cl utch di sc al i gnment tool .
(3) I nstal l transaxl e. See Group 21, Manual Tran-
RELEASE BEARING AND FORK
Remove the transaxl e from the vehi cl e. See
Group 21 for removal and i nstal l ati on procedures.
(1) Remove cl utch rel ease shaft E-cl i p.
(2) Remove the cl utch rel ease shaft and then sl i de
the fork and beari ng assembl y off the beari ng pi l ot.
(3) Remove the fork from the beari ng thrust pl ate.
(4) Exami ne the condi ti on of the rel ease beari ng. It
is pre-lubricated and sealed and should not be
immersed in solvent.
(5) The beari ng shoul d turn smoothl y when hel d i n
the hand under a l i ght thrust l oad. A l i ght drag caused
by the l ubri cant fi l l i s normal . I f the beari ng i s noi sy,
rough, or dry, repl ace the compl ete beari ng assembl y
wi th a new beari ng.
(6) The beari ng has a pl asti c sl eeve pre-l ubri cated at
assembl y. Wi pe out the ol d grease. Refi l l the sl eeve
cavi ti es and coat the i nner surface wi th mul ti purpose
grease. I f the l i ner i s cracked or worn, repl ace the
beari ng assembl y.
(7) Check the condi ti on of the spri ng cl i ps. I f the
cl i ps are broken or di storted, repl ace the beari ng as-
sembl y.
(8) Before assembl i ng the fork, l ubri cate the
rounded thrust pads and the spri ng cl i p cavi ti es wi th
mul ti purpose grease.
(9) Assembl e the fork to the beari ng by sl i di ng the
thrust pads under the spri ng cl i ps. Be careful to avoi d
di storti ng the spri ng cl i ps. These clips prevent the
bearingthrust platefromrotatingwith thebear-
ing.
(10) Sl i de the beari ng and fork assembl y onto the
i nput shaft beari ng retai ner.
(11) Posi ti on the rel ease shaft bushi ngs i n the hous-
i ng and i nstal l the rel ease shaft. A smal l amount of
beari ng grease between the rel ease shaft bushi ng and
the shaft i s often benefi ci al but not requi red.
(12) I nstal l the retai ner cl i p i n the shaft groove near
the l arge bushi ng.
(13) I nstal l the rel ease l ever and retai ni ng cl i p on
the outer end of the rel ease shaft.
CLEANING PRECAUTIONS
Condensati on from steam vapors tend to accumul ate
on the i nternal cl utch mechani sm when the vehi cl e i s
steam cl eaned. The faci ng of the di sc wi l l absorb
moi sture. The force exerted by the pressure pl ate wi l l
bond the faci ngs to fl ywheel and/or, pressure pl ate, i f
vehi cl e i s al l owed to stand for some ti me before use. I f
thi s condi ti on occurs, i t wi l l requi re repl acement of di sc
assembl y, fl ywheel , and/or cl utch assembl y. After
cl eani ng, dri ve the vehi cl e to i ts normal cl utch operat-
i ng temperature. Thi s wi l l dry off di sc assembl y, pres-
sure pl ate, and fl ywheel .
BRAKES
CONTENTS
page page
ANTI-LOCK BRAKE SYSTEM (BENDIX
ANTI-LOCK 10 AS BODY FWD/AWD) . . . . . . 56
BRAKE DISC (ROTOR) . . . . . . . . . . . . . . . . . . . 42
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BRAKE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 15
DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SYSTEM CONTROL VALVES . . . . 28
KELSEY HAYES DOUBLE PIN FAMILY
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 49
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . 46
POWER BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 51
SERVICE ADJUSTMENTS . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . 31
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 90
WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . 54
WHEEL CYLINDERS . . . . . . . . . . . . . . . . . . . . . 26
servi ce manual .
Standard brake equi pment consi sts of:
Doubl e pi n fl oati ng cal i per di sc front brakes.
Rear automati c adjusti ng drum brakes.
Di fferenti al val ve wi th a brake warni ng swi tch.
Master cyl i nder.
Hei ght sensi ng proporti oni ng val ve.
Vacuum power booster.
Front brake shoes have semi metal l i c l i ni ngs. The
brake system (Fi g. 1 and 2) i s di agonal l y spl i t on both
the Non-ABS and ABS braki ng system. Wi th the l eft
front and ri ght rear brakes on one hydraul i c system
and the ri ght front and l eft rear on the other.
The master cyl i nder i s anodi zed, l i ghtwei ght al umi -
num. I t has a bore di ameter of 24.0 mm.
Fig. 1 Proper Nut Thread Size and Tube Routing (Non-ABS Equipped Vehicles)
BRAKES 5 - 1
Fig. 2 Proper Nut Thread Size and Tube Routing (ABS-Equipped Vehicles)
5 - 2 BRAKES
SERVI CE ADJUSTMENTS
INDEX
page page
Adjusting Rear Service Brakes . . . . . . . . . . . . . . . . 3
Bleeding Brake System . . . . . . . . . . . . . . . . . . . . . 5
Brake Hose and Tubing . . . . . . . . . . . . . . . . . . . . . 7
Master Cylinder Fluid Level . . . . . . . . . . . . . . . . . . 4
Stop Lamp Switch Adjustment . . . . . . . . . . . . . . . . 9
Test for Fluid Contamination . . . . . . . . . . . . . . . . . . 7
Testing Application Adjuster Operation . . . . . . . . . 10
Wheel Stud Nut Tightening . . . . . . . . . . . . . . . . . . . 7
ADJUSTING REAR SERVICE BRAKES
Normally, self adjusting drum brakes will not
require manual brake shoe adjustment. Al-
though in the event of a brake reline it is advis-
able to make the initial adjustment manually to
speed up the adjusting time.
FRONT WHEEL DRI VE
(1) Rai se the vehi cl e so al l wheel s are free to turn.
See Hoi sti ng Recommendati ons i n the Lubri cati on And
Mai ntenance Secti on, at the front of thi s servi ce
manual .
(2) Remove rear brake adjusti ng hol e rubber pl ug
(Fi g. 1), from the rear brake shoe support pl ate.
(3) Be sure parking brake lever is fully re-
leased. Thenback off parkingbrakecableadjust-
ment so there is slack in the cable.
(4) I nsert Brake Adjusti ng, Speci al Tool C-3784,
(Fi g. 2) or equi val ent through the adjusti ng hol e i n
support pl ate and agai nst star wheel of adjusti ng
screw. Move handl e of tool upward unti l a sl i ght drag i s
fel t when road wheel i s rotated.
(5) I nsert a thi n screwdri ver or pi ece of wel di ng rod
i nto brake adjusti ng hol e (Fi g. 2). Push adjusti ng l ever
out of engagement wi th star wheel . Care should be
taken soas not tobend adjustinglever or distort
lever spring. Whi l e hol di ng adjusti ng l ever out of
engagement, back off star wheel to ensure a free wheel
wi th no brake shoe drag.
(6) Repeat above adjustment at the other rear wheel .
I nstal l adjusti ng hol e rubber pl ugs (Fi g. 1) i n rear
brake supports.
(7) Adjust parki ng brake after wheel brake adjust-
ment.
It is important to followthe above sequence to
avoidthepossibility of theparkingbrakesystem
causingbrakedrag. Thiscould occur if thepark-
ing brakes are adjusted before the service
brakes.
ALL WHEEL DRI VE
(1) Rai se the vehi cl e so al l wheel s are free to turn.
See Hoi sti ng Recommendati ons i n the Lubri cati on And
Mai ntenance Secti on, at the front of thi s servi ce
manual .
(2) Be sure parking brake lever is fully re-
leased. Thenback off parkingbrakecableadjust-
ment so there is slack in the cable.
(3) Remove the rear ti re and wheel assembl y from
the vehi cl e to expose the front of the rear brake drum.
Fig. 1 Brake Adjusting Hole Plug
Fig. 2 Brake Drum Adjustment With Tool C-3784
BRAKES 5 - 3
(4) Rotate the rear brake drum so the adjusti ng
hol es i n the face of the brake drum are posi ti oned at
12:00 and 6:00 (Fi g. 3).
(5) I nsert Brake Adjusti ng, Speci al Tool C-3784 (Fi g.
4) or equi val ent through the adjusti ng hol e i n brake
drum and agai nst star wheel of adjusti ng screw. Move
adjusti ng tool i n a downward moti on unti l a sl i ght drag
i s fel t when brake drum i s rotated.
(6) Then i nsert a hooked pi ece of wel di ng rod
through the adjusti ng hol e i n brake drum. Hook rod
onto adjusti ng l ever and pul l l ever out of engagement
wi th star wheel . Whi l e pul l i ng adjustment l ever out of
engagement wi th star wheel , back off star wheel ad-
juster just unti l there i s no contact between brake
shoes and brake drum. Caremust betakensoasnot
to bend adjusting lever or distort lever spring.
(7) Repeat above adjustment procedure at the other
wheel .
(8) I nstal l the ti re and wheel assembl i es back on the
vehi cl e. I nstal l the wheel stud nuts and torque to 129
Nm (95 ft. l bs.).
(9) Adjust parki ng brake AFTER wheel brakes are
adjusted.
It is important to followthe above sequence to
avoidthepossibility of theparkingbrakesystem
causingbrakedrag. Thisconditioncouldoccur if
the parking brakes are adjusted before the ser-
vice brakes.
MASTER CYLINDER FLUID LEVEL
NON-ABS BRAKES
Check master cyl i nder reservoi r fl ui d l evel a mi ni -
mum of twi ce annual l y.
Master cyl i nder reservoi rs are marked wi th the
words fi l l to bottom of ri ngs i ndi cati ng proper fl ui d
l evel (Fi g. 5).
I f necessary, add fl ui d to bri ng the l evel to the bottom
of the pri mary reservoi r spl i t ri ng.
Use onl y Mopar brake fl ui d or an equi val ent from a
seal ed contai ner. Brake fl ui d must conform to DOT 3,
speci fi cati ons.
DO NOT use brake fl ui d wi th a l ower boi l i ng poi nt,
as brake fai l ure coul d resul t duri ng prol onged hard
braki ng.
Use onl y brake fl ui d that was stored i n a ti ghtl y-
seal ed contai ner.
Fig. 3 Rear Brake Drum Position For Parking Brake
Adjustment (AWD)
Fig. 4 Brake Shoe Adjustment
Fig. 5 Master Cylinder Fluid Level (Non-ABS)
5 - 4 BRAKES
DO NOT use petrol eum-based fl ui d because seal
damage wi l l resul t.
ABS BRAKES
The hydraul i c assembl y i s equi pped wi th a pl asti c
fl ui d reservoi r wi th a fi l ter/strai ner i n the fi l l er neck.
The Anti -Lock brake system requi res that the hy-
draul i c accumul ator be de-pressuri zed when checki ng
the fl ui d l evel . To check the brake fl ui d l evel , the
fol l owi ng procedure shoul d be used:
(1) Wi th the i gni ti on off, de-pressuri ze the hydraul i c
accumul ator by appl yi ng the brake pedal approxi -
matel y 40 ti mes, usi ng a pedal force of approxi matel y
220 N (50 l bs.). A noti ceabl e change i n pedal feel wi l l
occur when the accumul ator i s de-pressuri zed. Con-
ti nue to appl y the pedal several ti mes after thi s change
i n pedal feel occurs to i nsure that the brake system i s
ful l y de-pressuri zed.
(2) Thoroughl y cl ean both reservoi r caps and sur-
roundi ng area, (Fi g. 6) before removi ng caps. Thi s i s to
avoi d getti ng di rt i nto the reservoi r.
(3) I nspect the fl ui d l evel , see i nstructi ons on top of
reservoi r. (TO TOP OF WHI TE SCREEN ON FRONT
FI LTER/STRAI NER.)
(4) Fi l l wi th brake fl ui d to top of screen (Fi g. 7) on
the fi l ter/strai ner l ocated i n brake fl ui d reservoi r. Use
onl y brake fl ui d conformi ng to DOT 3 speci fi cati ons
such as Mopar or equi val ent.
(5) Repl ace reservoi r cap.
BLEEDING BRAKE SYSTEM
PRESSURE BLEEDI NG
Before removi ng the master cyl i nder cover, wi pe i t
cl ean to prevent di rt and other forei gn matter from
droppi ng i nto the master cyl i nder.
Fig. 6 Master Cylinder Fluid Level (W/ABS)
Fig. 7 ABS Reservoir Fill Level On Filter/Strainer
BRAKES 5 - 5
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool C-4578 to pressurize the
system for bleeding.
Fol l ow pressure bl eeder manufacturers i nstructi ons,
for use of pressure bl eedi ng equi pment.
When bl eedi ng the brake system. Some ai r may be
trapped i n the brake l i nes or val ves far upstream. As
much as ten feet from the bl eeder screw (Fi g. 8).
Therefore, i t i s essenti al to have a fast fl ow of a l arge
vol ume of brake fl ui d when bl eedi ng the brakes to
ensure al l the ai r gets out.
To bl eed the brake system. Attach a cl ear pl asti c hose
to the bl eeder screw at one wheel and feed the hose i nto
a cl ear jar contai ni ng fresh brake fl ui d (Fi g. 9).
Next, open the bl eeder screw at l east one full turn
or more to obtai n an adequate fl ow of brake fl ui d (Fi g.
10).
CAUTION: Just cracking the bleeder screw often
restricts fluid flow, and a slow, weak fluid discharge
will NOT get all the air out.
After 4 to 8 ounces of fl ui d has been bl ed through the
brake system. And an ai r-free fl ow i s mai ntai ned i n the
cl ear pl asti c hose and jar, thi s wi l l i ndi cate a good
bl eed.
Repeat the procedure at al l the other remai ni ng
bl eeder screws. Then check the pedal for travel . I f
pedal travel i s excessi ve or has not been i mproved.
Enough fl ui d has not passed through the system to
expel al l the trapped ai r. Be sure to moni tor the fl ui d
l evel i n the pressure bl eeder, so i t stays at a proper
l evel so ai r wi l l not enter the brake system through the
master cyl i nder.
BLEEDI NG WI THOUT A PRESSURE BLEEDER
I f a pressure bl eeder i s not avai l abl e. A good brake
fl ui d fl ow can be obtai ned by manual bl eedi ng of the
brake hydraul i c system, fol l owi ng these steps:
(1) Pump the brake pedal three or four ti mes and
hol d i t down before the bl eeder screw i s opened.
(2) Push the brake pedal toward the fl oor and hol d i t
down. Then open the bl eeder screw at l east 1 ful l turn.
When the bl eeder screw opens the brake pedal wi l l
drop al l the way to the fl oor.
(3) Rel ease the brake pedal onl y after the bl eeder
screw i s cl osed.
(4) Repeat steps 1 through 3, four or fi ve ti mes, at
each bl eeder screw. Thi s shoul d pass a suffi ci ent
amount of fl ui d to expel al l the trapped ai r from the
brake system. Be sure to moni tor the fl ui d l evel i n the
master cyl i nder, so i t stays at a proper l evel so ai r wi l l
not enter the brake system through the master cyl i n-
der.
Test dri ve vehi cl e to be sure brakes are operati ng
correctl y and that pedal i s sol i d.
Fig. 8 Trapped Air in Brake Line
Fig. 9 Proper Method for Purging Air From Brake
System (Typical)
Fig. 10 Open Bleeder Screw at Least One Full Turn
(Typical)
5 - 6 BRAKES
TEST FOR FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of petro-
l eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d separates
i nto l ayers, there i s mi neral oi l contami nati on.
I f brake fl ui d i s contami nated, drai n and thoroughl y
fl ush system. Repl ace master cyl i nder, proporti oni ng
val ve, cal i per seal s, wheel cyl i nder seal s and al l hoses.
WHEEL STUD NUT TIGHTENING
When ti ghteni ng wheel stud nuts, a cri ss-cross ti ght-
eni ng sequence shoul d be fol l owed (Fi g. 11).
Ti ghten al l stud nuts to one-hal f speci fi ed torque.
Repeat, ful l y ti ghteni ng to 129 Nm (95 ft. l bs.).
BRAKE HOSE AND TUBING
I NSPECTI ON OF BRAKE HOSE AND TUBI NG
Fl exi bl e rubber hose i s used at both front brakes and
at the rear axl e. I nspecti on of brake hoses shoul d be
performed whenever the brake system i s servi ced and
every 7,500 mi l es or 12 months, whi chever comes fi rst
(every engi ne oi l change). I nspect hydraul i c brake
hoses for severe surface cracki ng, scuffi ng, or worn
spots. I f the fabri c casi ng of the rubber hose becomes
exposed due to cracks or abrasi ons i n the rubber hose
cover, the hose shoul d be repl aced i mmedi atel y. Even-
tual deteri orati on of the hose can take pl ace wi th
possi bl e burst fai l ure. Faul ty i nstal l ati on can cause
twi sti ng, and wheel , ti re, or chassi s i nterference.
The steel brake tubi ng shoul d be i nspected peri odi -
cal l y for evi dence of physi cal damage or contact wi th
movi ng or hot components.
I NSTALLATI ON OF BRAKE HOSE
Al ways use factory recommended brake hose to en-
sure qual i ty, correct l ength and superi or fati gue l i fe.
Care shoul d be taken to make sure that the tube and
hose mati ng surfaces are cl ean and free from ni cks and
burrs. Right and left hoses are not interchange-
able.
Use new copper seal washers on al l Banjo bol ts and
ti ghten al l fi tti ngs to speci fi ed torque. Al l connecti ons
must be torqued to correct speci fi cati ons and properl y
made.
The fl exi bl e hydraul i c brake hose shoul d al ways be
i nstal l ed on the vehi cl e by fi rst attachi ng the Banjo
connector to the cal i per assembl y. Then bol t the i nter-
medi ate hose bracket to the strut assembl y al l owi ng
the bracket to posi ti on the hose to prevent twi sti ng.
Lastl y attach the hose to the body bracket and steel
brake tubi ng. Ti ghten al l fi tti ngs to speci fi ed torque.
The body bracket and hose end are keyed so that they
wi l l onl y fi t one way.
I nstal l rear brake hoses fi rst to the trai l i ng arm
crossmember tubes and then to the fl oor pan tubes.
Thi s procedure shoul d be fol l owed to mi ni mi ze hose
twi sti ng.
TYPES OF TUBI NG FLARES
Two di fferent tubi ng fl ares (Fi g. 12) are used on 92
M.Y. vehi cl es. On al l ABS brake systems the tubi ng
connecti ons made to the hydraul i c assembl y use an
I SO fl are. Al l other ABS brake system component,
tubi ng connecti ons are made usi ng a doubl e i nverted
fl are. On non-ABS brake systems al l component tubi ng
connecti ons use onl y the doubl e i nverted fl are. No I SO
fl ares are used.
Fig. 11 Wheel Stud Nut Tightening Sequence
Fig. 12 Hydraulic Brake Tubing Flares
BRAKES 5 - 7
REPAI R AND I NSTALLATI ON OF BRAKE TUB-
I NG
Onl y doubl e wal l 4.75mm (3/16 i n.) steel tubi ng
shoul d be used for repl acement. Care shoul d be taken
when repl aci ng brake tubi ng, to be sure the proper
bendi ng and fl ari ng tool s and procedures are used, to
avoi d ki nki ng. Do not route the tubes agai nst sharp
edges, movi ng components or i nto hot areas. Al l tubes
shoul d be properl y attached wi th recommended retai n-
i ng cl i ps.
TO REPAI R OR FLARE TUBI NG
CAUTION: ALWAYS USE THE PROPER FLARING
TOOL AND PROCEDURE, FOR THE TYPE OF BRAKE
SYSTEM THAT IS BEING SERVICED TO INSURE THE
INTEGRITY OF THE HYDRAULIC SYSTEM.
Usi ng Tubi ng Cutter, Speci al Tool C-3478-A or
equi val ent, cut off damaged seat or tubi ng (Fi g. 13).
Ream out any burrs or rough edges showi ng on i nsi de
of tubi ng (Fi g. 14). Thi s wi l l make the ends of tubi ng
square (Fi g. 14) and ensure better seati ng of fl ared end
tubi ng. PLACE TUBE NUT ON TUBING BEFORE
FLARING THE TUBING.
DOUBLE I NVERTED TUBI NG FLARES.
To make a doubl e i nverted tubi ng fl are (Fi g. 12 & 15).
Open handl es of Fl ari ng Tool , Speci al Tool C-4047 or
equi val ent. Then rotate jaws of tool unti l the mati ng
jaws of tubi ng si ze are centered between verti cal posts
on tool . Sl owl y cl ose handl es wi th tubi ng i nserted i n
jaws but do not appl y heavy pressure to handl e as thi s
wi l l l ock tubi ng i n pl ace.
Pl ace gauge (Form A) on edge over end of brake
tubi ng. Push tubi ng through jaws unti l end of tubi ng
contacts the recessed notch i n gauge matchi ng the
tubi ng si ze. Squeeze handl es of fl ari ng tool and l ock
tubi ng i n pl ace. Pl ace 3/16 i nch pl ug of gauge (A) down
i n end of tubi ng. Swi ng compressi on di sc over gauge
and center tapered fl ari ng screw i n recess of di sc.
Screw i n unti l pl ug gauge has seated on jaws of fl ari ng
tool . Thi s acti on has started to i nvert the ex-
Fig. 13 Cutting and Flaring of Brake Line Tubing
Fig. 14 Brake Tube Preparation For Flaring
Fig. 15 Double Flare And ISO-Flare Tubing Connec-
tions
5 - 8 BRAKES
tended end of the tubi ng. Remove gauge and conti nue
to screw down unti l tool i s fi rml y seated i n tubi ng.
Remove tubi ng from fl ari ng tool and i nspect seat. Refer
to routi ng di agrams (Fi gs. 18 to 21) for proper routi ng
and cl i p l ocati on. Repl ace any damaged tube routi ng
cl i ps.
I SO TUBI NG FLARES
CAUTION: All ISOstyle tubing flares (Fig. 12 & 15 ) are
of metric dimensions. When performing any service
procedures on vehicles using ISO style tubing flares,
metric size tubing of 4.75 mm MUST be used with
metric ISO tube flaring equipment.
To create a (metri c) I SO styl e tubi ng fl are, Use
Snap-On Fl ari ng Tool TFM-428, or equi val ent. See
(Fi g. 16) and proceed wi th the steps l i sted bel ow.Be
sure to place the tubing nut on the tube before
flaring the tubing.
(1) Careful l y prepare the end of the tubi ng to be
fl ared. Be sure the end of the tubi ng to be fl ared i s
square and al l burrs on the i nsi de of the tubi ng are
removed (Fi g. 14). This preparation is essential to
obtain the correct formof a (metric) ISO tubing
flare.
(2) Open the jaws of the Fl ari ng Tool . Al i gn the
mati ng si ze jaws of the fl ari ng tool around the si ze of
the tubi ng to be fl ared. Cl ose the jaws of the Fl ari ng
Tool around the tubi ng to keep i t from sl i di ng out of the
fl ari ng tool , but do not l ock the tubi ng i n pl ace. See
(Fi g. 16)
(3) Posi ti on the tubi ng i n the jaws of the Fl ari ng Tool
so that i t i s fl ush wi th the top surface of the fl ari ng tool
bar assembl y. (See Fi g. 16)
(4) I nstal l the correct si ze adaptor for the brake
tubi ng bei ng fl ared, on the feed screw of the yoke
assembl y. Center the yoke and adapter over the end of
the tubi ng. Appl y l ubri cant to the adapter area that
contacts brake tubi ng. Maki ng sure the adapter pi l ot i s
ful l y i nserted i n the end of the brake tubi ng. Screw i n
the feed screw of the yoke assembl y unti l the adaptor
has seated squarel y on the surface of the bar assembl y
(Fi g. 16). Thi s process has created the (metri c) I SO
tubi ng fl are.
STOP LAMP SWITCH ADJUSTMENT
The stop l amp swi tch i ncorporates a sel f adjusti ng
feature. I f adjustment or repl acement i s requi red,
proceed as fol l ows: I nstal l the swi tch i n the retai ni ng
bracket and push the swi tch forward as far as i t wi l l go.
The brake pedal wi l l move forward sl i ghtl y (Fi g. 17).
Gentl y pul l back on the brake pedal bri ngi ng the
stri ker back toward the swi tch unti l the brake pedal
wi l l go back no further. Thi s wi l l cause the swi tch to
ratchet backward to the correct posi ti on. Very l i ttl e
movement i s requi red, and no further adjustment i s
necessary.
Fig. 16 ISO Tubing Flare Process
Fig. 17 Stop Lamp Switch
BRAKES 5 - 9
TESTING APPLICATION ADJUSTER OPERATION
Pl ace the vehi cl e on a hoi st wi th a hel per i n the
dri vers seat to appl y the brakes. Remove the access
pl ug from the rear adjustment sl ot i n each brake
support pl ate (Fi g. 1) to provi de access to the adjuster
star wheel . Then, to el i mi nate the possi bi l i ty of maxi -
mum adjustment, where the adjuster does not operate
because the cl osest possi bl e adjustment has been
reached. Back the star wheel off approxi matel y 30
notches. I t wi l l be necessary to hol d the adjuster l ever
away from the star wheel to permi t thi s adjustment.
Spi n the wheel and brake drum i n the reverse
di recti on and wi th a greater than normal force appl y
the brakes suddenl y. Thi s sudden appl i cati on of force
wi l l cause the secondary brake shoe to l eave the
anchor. The wrap up effect wi l l move the secondary
shoe, and the cabl e wi l l pul l the adjuster l ever up.
Upon appl i cati on of the brake pedal , the l ever shoul d
move upward, turni ng the star wheel . Thus, a defi ni te
rotati on of the adjuster star wheel can be observed i f
the automati c adjuster i s worki ng properl y. I f one or
more adjusters do not functi on properl y, the respecti ve
drum must be removed for adjuster servi ci ng.
5 - 10 BRAKES
F
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.
1
8
C
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BRAKES 5 - 11
F
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5 - 12 BRAKES
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BRAKES 5 - 13
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5 - 14 BRAKES
BRAKE DI AGNOSI S
BASI C DI AGNOSI S GUI DE
BRAKES 5 - 15
BRAKE SYSTEM DI AGNOSTI CS
5 - 16 BRAKES
TSB 05-12-92 October 19, 1992
BRAKES 5 - 17
5 - 18 BRAKES
BRAKES 5 - 19
TSB 05-12-92 October 19, 1992
DRUM BRAKES
INDEX
page page
Brake Drum Installation . . . . . . . . . . . . . . . . . . . . 24
Drum Refacing Recommendations . . . . . . . . . . . . 23
Remove and Install Brake Support Plate . . . . . . . . 24
Service Procedures . . . . . . . . . . . . . . . . . . . . . . . 20
GENERAL INFORMATION
Rear wheel brakes (Fi g. 1 & 2) are two shoe, i nternal
expandi ng type wi th automati c appl i cati on adjusters.
The l ower ends of the brake shoes are connected by a
tubul ar star wheel adjusti ng screw (Fi gs.1 and 2).
WARNING: DUST AND DIRT ON BRAKE PARTS GENER-
ATED DURING THE NORMAL USE AND WEAR OF MOTOR
VEHICLE BRAKE SYSTEMS CAN CONTAIN ASBESTOS
FIBERS. BREATHING EXCESSIVE CONCENTRATIONS OF
ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM,
SUCH AS ASBESTOSIS AND CANCER. EXTREME CARE
SHOULD BE EXERCISED WHILE SERVICING BRAKE AS-
SEMBLIES OR COMPONENTS.
DO NOT CLEAN BRAKE ASSEMBLIES OR COMPO-
NENTS WITH COMPRESSEDAIR OR BY DRY BRUSH-
ING; USE A VACUUM CLEANER SPECIFICALLY REC-
OMMENDED FOR USE WITHASBESTOS FIBERS. IF A
SUITABLE VACUUM CLEANER IS NOT AVAILABLE,
CLEANING SHOULD BE DONE WET USING A WATER
DAMPENED CLOTH.
DO NOT CREATE DUST BY SANDING, GRINDING,
AND/OR SHAVING BRAKE LININGS OR PADS UN-
LESS SUCH OPERATION IS DONE WHILE USING
PROPERLY EXHAUST VENTILATED EQUIPMENT.
DISPOSE OF ALL DUST AND DIRT SUSPECTED TO
CONTAIN ANY ASBESTOS FIBERS IN SEALED BAGS
OR CONTAINERS TO MINIMIZE DUST EXPOSURE TO
YOURSELF AND OTHERS.
FOLLOW ALL RECOMMENDED PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION AND THE ENVIRONMEN-
TAL PROTECTION AGENCY. FOR THE HANDLING,
PROCESSING, AND DISPOSITION OF DUST OR DIRT
WHICH MAY CONTAIN ASBESTOS FIBERS.
SERVICE PROCEDURES
BRAKE DRUM REMOVAL
FRONT WHEEL DRIVE
(1) Remove the ti re and wheel assembl y from the
vehi cl e
(2) Remove the rear adjusti ng hol e cover pl ug, from
the rear brake adjusti ng access hol e i n brake support
pl ate.
(3) I nsert a thi n screwdri ver i nto brake adjusti ng
hol e and hol d adjusti ng l ever away from notches of
adjusti ng screw star wheel .
(4) I nsert Tool C-3784 i nto brake adjusti ng hol e and
engage notches of brake adjusti ng screw star wheel .
Rel ease brake by pryi ng down wi th adjusti ng tool .
(5) Remove the rear hub and drum assembl y from vehi cl e.
(6) I nspect brake l i ni ng for wear, shoe al i gnment, or
contami nati on from grease or brake fl ui d.
ALL WHEEL DRIVE
(1) Remove rear wheel and ti re assembl y from ve-
hi cl e. Access for the adjuster screw assembl y on ALL
WHEEL DRI VE APPLI CATI ONS i s through the access
hol e on the front of the brake drum.
(2) I nsert a thi n screwdri ver i nto brake shoe adjust-
i ng hol e. Hol d adjusti ng l ever away from notches of
adjusti ng screw star wheel .
(3) I nsert Tool C-3784 i nto brake adjusti ng hol e and
engage notches of brake adjusti ng screw star wheel .
Rel ease brake by pryi ng up wi th the adjusti ng tool .
(4) Remove rear brake drum from the hub assembl y.
Rear hub and beari ng DOES not come off wi th the
brake drum on al l wheel dri ve appl i cati ons.
(5) I nspect brake l i ni ng for wear, shoe al i gnment, or
contami nati on from grease or brake fl ui d.
For i l l ustrati ons of the above procedures, pertai ni ng
to adjuster screw assembl y adjustments see the Ser-
vi ce Adjustments secti on of thi s group.
BRAKE SHOE REMOVAL
BRAKE SHOE ASSEMBLIES
The procedure for rear brake shoe removal , i s the
same for both the Front Wheel Dri ve and Al l Wheel
Dri ve van appl i cati ons. Though some of the brake
components may be sl i ghtl y di fferent (Fi gs. 1 & 2).
Support pl ate and park brake assembl i es ARE NOT
SYMMETRI CALLY OPPOSI TE.
5 - 20 BRAKES
Right Side:Park brake cabl e enters support pl ate at
rear. Cabl e attaches to the i nternal park brake l ever
whi ch i s attached to the pri mary shoe.
Left Side: Park brake cabl e enters support pl ate at
front (tradi ti onal ) and attaches to the i nternal park
brake l ever whi ch i s attached to the secondary shoe.
(1) Remove rear wheel and ti re assembl y from ve-
hi cl e.
(2) Remove hub and drum assembl y on front wheel
dri ve appl i cati ons. On al l wheel dri ve appl i cati ons
remove onl y the brake drum, the hub assembl y (Fi g. 2)
wi l l remai n on the vehi cl e.
(3) Usi ng Remover Speci al Tool C-3785, remove
brake shoe return spri ngs (Fi g. 3). (Note how second-
ary shoe return spri ng overl aps pri mary shoe return
spri ng). (Fi gs. 1 and 2).
(4) Sl i de eye of automati c adjuster cabl e off anchor
pi n and then unhook from adjusti ng l ever (Fi g. 2)
Remove cabl e, overl oad spri ng, cabl e gui de and anchor
pi n pl ate.
(5) Di sengage adjusti ng l ever (Fi gs. 1 & 2) from
spri ng by sl i di ng i t forward to cl ear pi vot, then worki ng
i t out from under spri ng. Remove spri ng from pi vot.
Remove shoe to shoe spri ng from secondary shoe web
and di sengage from pri mary shoe web. Remove spri ng.
(6) Di sengage pri mary and secondary shoes from the
adjuster screw assembl y. Remove adjuster screw as-
sembl y.
(7) Remove brake shoe retai ners, spri ngs and nai l s
usi ng Remover Speci al Tool C-4070, (Fi g. 4), and re-
move from support.
Fig. 1 Rear Wheel Brake F.W.D. Applications
Fig. 2 Rear Wheel Brake A.W.D. Applications
Fig. 3 Removing or Installing Brake Shoe Return
Springs
BRAKES 5 - 21
(8) Remove parki ng brake l ever (Fi g. 1 & 2) from
secondary shoe, l eft si de or pri mary shoe, ri ght si de.
Remove shoes.
(9) Di sengage parki ng brake l ever from parki ng
brake cabl e.
Wi pe wi th a water dampened cl oth the metal por-
ti ons of the brake shoes. Exami ne the l i ni ng contact
pattern to determi ne i f the shoes are bent. The l i ni ng
shoul d show contact across the enti re wi dth, extendi ng
from heel to toe. Shoes showi ng contact onl y on one
si de shoul d be repl aced. Shoes havi ng suffi ci ent l i ni ng
but l ack of contact at toe and heel may be i mproperl y
ground.
Cl ean the brake support pl ate, usi ng a sui tabl e
sol vent. Then i nspect for rough or rusted shoe contact
areas. Cl ean and i nspect the adjusti ng screws for
damaged threads. Appl y a thi n fi l m of l ubri cant such as
Mopar Mul ti -Purpose Lubri cant or equi val ent to the
adjuster threads, socket and washer (Fi g. 8). Repl ace
adjuster screw assembl y i f corrosi on of any part i nhi b-
i ts very free operati on.
I nstal l new brake shoe return spri ngs and hol ddown
spri ngs where the ol d spri ngs have been subjected to
overheati ng or i f thei r strength i s questi onabl e. Spri ng
pai nt di scol orati on or di storted end coi l s i ndi cate a
spri ng that had been overheated.
BRAKE SHOE I NSTALLATI ON
Lubri cate the si x shoe tab contact pads on support
pl ate wi th a thi n fi l m of Mopar Mul ti -Purpose Lubri -
cant, or equi val ent (Fi g. 5).
(1) Sl i de pri mary shoe agai nst support pl ate, at the
same ti me engage shoe web wi th wheel cyl i nder pi ston
and agai nst anchor. Usi ng I nstal l er Speci al Tool
C-4070, i nstal l shoe retai ni ng nai l , retai ner, and spri ng
(Fi g. 4).
(2) I nstal l anchor pl ate over anchor, then i nstal l eye
of adjuster cabl e over anchor (Fi g. 2).
(3) Engage pri mary shoe return spri ng i n web of
shoe and i nstal l free end over anchor, usi ng Spri ng
I nstal l er, Speci al Tool C-3785 (Fi g. 3).
(4) Sl i de parki ng brake strut i nto sl ot i n parki ng
brake l ever. Sl i de anti -rattl e spri ng over free end of
strut (Fi g. 6).
(5) Engage parki ng brake l ever wi th cabl e. I nstal l
parki ng brake l ever i nto rectangul ar hol e of secondary
brake shoe (l eft si de) or pri mary shoe (ri ght si de) (Fi g.
7).
Fig. 4 Removing or Installing Shoe Retainers,
Springs, and Nails
Fig. 5 Shoe Contact Pads on Support
Fig. 6 Removing or Installing Parking Brake Strut
and Spring
5 - 22 BRAKES
(6) Sl i de secondary shoe i nto posi ti on and engage
wi th wheel cyl i nder pi ston and free end of strut. I nstal l
shoe retai ni ng nai l , retai ner, and spri ng usi ng I n-
stal l er, Speci al Tool C-4070 (Fi g. 4).
(7) I nsert protrudi ng hol e ri m of cabl e gui de (Fi g. 1
or 2) i nto hol e i n secondary shoe web. Hol di ng gui de i n
posi ti on, engage secondary shoe return spri ng through
both, hol e i n gui de, and hol e i n web. Usi ng I nstal l er,
Speci al Tool C-3785, i nstal l spri ng over anchor (Fi g. 3).
(Be sure cabl e gui de remai ns fl at agai nst shoe web and
that secondary spri ng overl aps pri mary (Fi g. 1 & 2).
Usi ng pl i ers, squeeze ends of spri ng l oops (around
anchor) unti l paral l el .
(8) I nstal l adjuster screw assembl y (Fi g. 8) between
pri mary and secondary shoes, wi th star wheel of ad-
juster screw assembl y next to secondary shoe (Fi g. 1 &
2). The l eft star wheel adjusti ng stud end i s stamped
(L) (i ndi cati ng i ts posi ti on on the vehi cl e) and the star
wheel i s cadmi um pl ated (Fi g. 8). The ri ght star wheel
i s bl ack and the adjusti ng stud end i s stamped (R).
I nstal l shoe to shoe spri ng between shoes (Fi g. 1).
(Engage pri mary shoe fi rst).
(9) I nstal l adjusti ng l ever spri ng (Fi g. 1 & 2) over
pi vot pi n on shoe web. I nstal l adjusti ng l ever under
spri ng and over pi vot pi n. Sl i de l ever sl i ghtl y rearward
to l ock i n posi ti on.
(10) Thread adjuster cabl e over gui de and hook end
of overl oad spri ng i n l ever (Fi g. 1 & 2). (Be sure eye of
cabl e i s pul l ed ti ght agai nst anchor and i n a strai ght
l i ne wi th gui de). Check operati on of automati c appl i -
cati on adjuster by pul l i ng adjuster cabl e rearward, star
wheel shoul d rotate upwards.
DRUM REFACING RECOMMENDATIONS
All drums will show markings of maximum
allowablediameter (Fig. 1). For example, a drum
will have a markingof MAX. DIA. 231.0mm(9.09
inch). Thismarkingincludes0.76mm(0.030inch)
for allowable drum wear beyond the recom-
mended 1.52 mm(0.060 inch) of drumrefacing.
Drum Refacing Measure the drum runout and
di ameter wi th an accurate gauge. There shoul d be no
vari ati on i n the drum di ameter greater than 0.090 mm
(0.004 i nch). Drum runout shoul d not exceed 0.15 mm
(0.006 i nch) out of round. I f the drum runout or
di ameter vari ati on exceed these val ues the drum
shoul d be refaced. For best resul ts i n el i mi nati ng the
i rregul ari ti es that cause brake roughness and surge,
the amount of materi al removed duri ng a si ngl e cut
shoul d be l i mi ted to 0.13 mm (0.005 i nch). When the
enti re braki ng surface has been cl eaned. A fi nal cut of
0.0254 mm (0.001 i nch) wi l l ensure a good drum
surface provi di ng the equi pment used i s capabl e of the
preci si on requi red for resurfaci ng brake drums. Deeper
cuts are permi ssi bl e for the sol e purpose of removi ng
deep score marks. Donot refacemorethan1.52mm
(0.60 inch) over the standard drumdiameter.
Fig. 7 Installing Parking Bake Cable
Fig. 8 Adjuster Screw Assembly
Fig. 1 Drum Maximum Diameter Identification
BRAKES 5 - 23
BRAKE DRUM INSTALLATION
FRONT WHEEL DRI VE
(1) I nstal l brake drum/hub assembl y on spi ndl e, be
sure i nner beari ng and grease seal i s i nstal l ed i n hub.
(2) I nstal l outer beari ng, thrust washer, and nut.
(3) Ti ghten wheel beari ng adjusti ng nut to 27 to 34
Nm (240 to 300 i n. l bs.) whi l e rotati ng hub. Thi s seats
the beari ngs.
(4) Back off adjusti ng nut 1/4 turn (90) then ti ghten
adjusti ng nut fi nger ti ght.
(5) Posi ti on l ock nut wi th one pai r of sl ots i n l i ne
wi th cotter pi n hol e. I nstal l cotter pi n.
(6) I nstal l grease cap and wheel and ti re assembl i es.
Ti ghten wheel stud nuts to 129 Nm (95 ft. l bs.) on al l
model s. I nstal l wheel covers (i f equi pped).
(7) Adjust brakes as descri bed under Servi ce Adjust-
ments at front of thi s secti on.
ALL WHEEL DRI VE
(1) I nstal l brake drum on hub.
(2) I nstal l wheel and ti re assembl i es. Ti ghten wheel
stud nuts to 129 Nm (95 ft. l bs.) on al l model s. I nstal l
wheel covers (i f equi pped).
(3) Adjust brakes as descri bed under Servi ce Adjust-
ments at front of thi s secti on.
BRAKE SUPPORT PLATE
FRONT WHEEL DRI VE
REMOVE
(1) Wi th wheel and brake drum removed. Remove
brake shoe assembl i es and di sconnect brake cabl e,
from parki ng brake l ever.
(2) Usi ng a sui tabl e tool such as an ai rcraft type
hose cl amp or a 14mm box wrench. Compress the
fl ared l egs of cabl e retai ner and pul l brake cabl e out of
brake support pl ate (Fi g. 1).
(3) Di sconnect hydraul i c brake tube from wheel cyl -
i nder (Fi g. 2).
(4) Remove wheel cyl i nder to brake support pl ate
attachi ng bol ts and washers (Fi g. 2).
(5) Remove support pl ate and spi ndl e mounti ng
bol ts (Fi g. 3).
(6) Remove support pl ate, spi ndl e and gasket from
rear axl e.
ALL WHEEL DRI VE
REMOVE
(1) Wi th wheel and brake drum removed, remove
brake shoe assembl i es and di sconnect parki ng brake
cabl e from parki ng brake l ever.
(2) Remove the rear axl e hal f shaft from the vehi cl e.
Refer to Group 3 Rear Axl e i n thi s servi ce manual for
speci fi c removal procedure.
(3) Usi ng a sui tabl e tool such as an ai rcraft type
hose cl amp or a 14 mm box wrench compress the fl ared
l egs on park brake cabl e retai ner. Then pul l the park-
i ng brake cabl e out of brake support pl ate (Fi g. 1).
(4) Di sconnect hydraul i c brake tube from wheel cyl -
i nder (Fi g. 2).
(5) Remove support pl ate to wheel cyl i nder attach-
i ng bol ts and washers (Fi g. 2).
(6) Remove support pl ate and rear beari ng hub uni t
mounti ng bol ts (Fi g. 4).
(7) Remove rear beari ng hub uni t, support pl ate and
gasket from the rear axl e.
Fig. 1 Removing Brake Cable from Support Plate
Fig. 2 Removal And Installation Brake Tube And
Wheel Cylinder
5 - 24 BRAKES
FRONT WHEEL DRI VE
INSTALL
(1) I nstal l gasket, support pl ate and spi ndl e and
onto the rear axl e.
(2) Appl y seal ant such as Mopar Gasket-I n-A-Tube
or equi val ent around wheel cyl i nder mounti ng surface
(Fi g. 5).
(3) I nstal l wheel cyl i nder onto brake support, and
ti ghten the wheel cyl i nder to brake support pl ate
attachi ng bol ts (Fi g. 2) to 8 Nm (75 i n. l bs.). Attach
hydraul i c brake tube to wheel cyl i nder, and ti ghten
tube to wheel cyl i nder fi tti ng to 17 Nm (145 i n. l bs.)
(4) I nsert parki ng brake cabl e i nto support pl ate and
attach cabl e to parki ng brake l ever.
(5) I nstal l brake shoes onto support pl ate.
(6) I nstal l rear brake drum onto rear hub. I nstal l
rear wheel and ti re assembl y, ti ghten wheel stud nuts
to 129 Nm (95 ft. l bs.).
(7) Adjust the rear brakes, (See Adjusti ng Servi ce
Brakes) i n Servi ce Adjustments secti on i n thi s group of
the servi ce manual .
(8) Bl eed the enti re brake system. See (Bl eedi ng
Brake System) i n Servi ce Adjustments secti on i n thi s
group of the servi ce manual .
ALL WHEEL DRI VE
INSTALL
(1) I nstal l gasket, support pl ate and rear beari ng
hub uni t onto the rear axl e (Fi g. 4). Ti ghten the rear
beari ng hub uni t/support pl ate to axl e attachi ng bol ts
to 108 Nm (80 ft. l bs.).
(2) Appl y seal ant such as Mopar Gasket-I n-A-Tube
or equi val ent around wheel cyl i nder mounti ng surface
(Fi g. 5).
attachi ng bol ts (Fi g. 2) to 8 Nm (75 i n. l bs.). Attach
hydraul i c brake tube to wheel cyl i nder, and ti ghten
tube to wheel cyl i nder fi tti ng to 17 Nm (145 i n. l bs.).
(4) I nstal l the rear axl e hal f shaft. Refer to Group 3
Rear Axl e i n thi s servi ce manual for procedure and
torque speci fi cati ons.
Fig. 3 Brake Support And Spindle Mounting Bolts
Fig. 4 Remove and Install Brake Support Plate and
Bearing Hub Bolts.
Fig. 5 Apply Sealant on Support Plate
BRAKES 5 - 25
(5) I nsert parki ng brake cabl e i nto support pl ate and
attach cabl e to parki ng brake l ever.
(6) I nstal l brake shoes on support pl ate.
to 129 Nm (95 ft. l bs.).
WHEEL CYLI NDERS
INDEX
page page
Installing Wheel Cylinders . . . . . . . . . . . . . . . . . . 27
GENERAL INFORMATION
The pi ston boots are of the push-on type and prevent
moi sture from enteri ng the wheel cyl i nder.
To perform servi ce operati ons or i nspecti ons of the
rear wheel brake cyl i nders. I t wi l l be necessary to
remove the cyl i nders from the support pl ate and di s-
assembl e on the bench.
CAUTION: Wheel cylinders with cup expanders must
have cup expanders after any service procedures
(reconditioning or replacement).
SERVICE PROCEDURES
REMOVI NG WHEEL CYLI NDERS FROM BRAKE
SUPPORT PLATES
Wi th brake drums removed, i nspect the wheel cyl i n-
der boots for evi dence of a brake fl ui d l eak. Then bl ock
the brake pedal i n the stroke posi ti on, and vi sual l y
check the boots for cuts, tears, or heat cracks. I f any of
these condi ti ons exi st, the wheel cyl i nders shoul d be
compl etel y cl eaned, i nspected and new parts i nstal l ed.
(A sl i ght amount of fl ui d on the boot may not be a l eak,
but maybe preservati ve fl ui d used at assembl y.)
(1) I n case of a l eak, remove brake shoes, (repl ace i f
soaked wi th grease or brake fl ui d.)
(2) Di sconnect brake tube from wheel cyl i nder (Fi g.
1).
(3) Remove the rear wheel cyl i nder attachi ng bol ts
(Fi g. 1). Then pul l wheel cyl i nder assembl y off the
DI SASSEMBLI NG WHEEL CYLI NDERS
To di sassembl e the wheel cyl i nders, (Fi g. 3) proceed
as fol l ows:
(1) Pry boots away from cyl i nders and remove.
(2) Press IN on one pi ston to force out opposi te
pi ston, cup and spri ng (wi th cup expanders). Then
usi ng
Fig. 1 Brake Tube Disconnected
Fig. 2 Remove or Install Wheel Cylinder
5 - 26 BRAKES
a soft tool such as a dowel rod, press out the cup and
pi ston that remai n i n the wheel cyl i nder.
(3) Wash wheel cyl i nder, pi stons, and spri ng i n cl ean
brake fl ui d or al cohol ; (DO NOT USE ANY PETRO-
LEUM BASE SOLVENTS) cl ean thoroughl y and
bl ow dry wi th compressed ai r. I nspect cyl i nder bore
and pi ston for scori ng and pi tti ng. (Do not use a rag as
l i nt from the rag wi l l sti ck to bore surfaces.)
Wheel cyl i nder bores and pi stons that are badl y
scored or pi tted shoul d be repl aced. Cyl i nder wal l s that
have l i ght scratches, or show si gns of corrosi on, can
usual l y be cl eaned wi th crocus cl oth, usi ng a ci rcul ar
moti on. Bl ack stai ns on the cyl i nder wal l s are caused
by pi ston cups and wi l l not i mpai r operati on of cyl i n-
der.
ASSEMBLI NG WHEEL CYLI NDERS
Before assembl i ng the pi stons and new cups i n the
wheel cyl i nders, di p them i n cl ean brake fl ui d. I f the
boots are deteri orated, cracked or do not fi t ti ghtl y on
the pi stons or the cyl i nder casti ng, i nstal l new boots.
(1) Coat cyl i nder bore wi th cl ean brake fl ui d.
(2) I nstal l expansi on spri ng wi th cup expanders i n
cyl i nder. I nstal l cups i n each end of cyl i nder wi th open
end of cups faci ng each other (Fi g. 3).
(3) I nstal l pi ston i n each end of cyl i nder havi ng the
fl at face of each pi ston contacti ng the fl at face of each
cup, al ready i nstal l ed (Fi g. 3).
(4) I nstal l a boot over each end of cyl i nder. Be
careful not to damage boot during installation.
INSTALLING WHEEL CYLINDERS
(1) Appl y Mopar Gasket I n-A-Tube or equi val ent
seal ant around wheel cyl i nder mounti ng surface
(Fi g. 4).
attachi ng bol ts to 8 Nm (75 i n. l bs.).
(3) Attach hydraul i c brake tube to wheel cyl i nder,
and ti ghten tube to wheel cyl i nder fi tti ng to 17 Nm
(145 i n. l bs.).
(4) I nstal l brake shoes on support pl ate.
to 129 Nm (95 ft. l bs.).
Fig. 3 Rear Wheel Cylinder
Fig. 4 Apply Sealant on Support Plate
BRAKES 5 - 27
HYDRAULI C SYSTEM CONTROL VALVES
INDEX
page page
ABS Brake Proportioning Valve Operation . . . . . . . 29 General Information . . . . . . . . . . . . . . . . . . . . . . . 28
GENERAL INFORMATION
Al l model s have a hydraul i c system pressure di ffer-
enti al warni ng l i ght swi tch and a hei ght sensi ng pro-
porti oni ng val ve, i n the brake system (Fi gs. 1 and 3).
The swi tch i s attached to the frame rai l bel ow the
master cyl i nder (Fi g. 2).
PRESSURE DI FFERENTI AL WARNI NG LI GHT
SWI TCH
The hydraul i c brake system on al l vehi cl es i s a
di agonal l y spl i t system. The l eft front and ri ght rear
brakes are part of one system. The ri ght front and l eft
rear are part of another. Both systems are routed
through, but hydraul i cal l y separated by the Pressure
Di fferenti al Swi tch (Fi g. 1). The functi on of the Pres-
sure Di fferenti al Swi tch i s to al ert the dri ver of a
mal functi on i n the brake system.
I f hydraul i c pressure i s l ost i n one system, the
warni ng l i ght swi tch (Fi g. 2) wi l l acti vate a red l i ght on
the i nstrument panel , when the brake pedal i s de-
pressed. At thi s poi nt the brakes requi re servi ce. How-
ever, si nce the brake systems are spl i t di agonal l y the
vehi cl e wi l l retai n 50% of i ts stoppi ng capabi l i ty i n the
event of a fai l ure i n ei ther hal f.
Thewarninglight switchisthelatchingtype. It
will automatically center itself after therepair is
made and the brake pedal is depressed.
The i nstrument panel bul b can be checked each ti me
the i gni ti on swi tch i s turned to the start posi ti on or the
parki ng brake i s set.
HEI GHT SENSI NG DUAL PROPORTI ONI NG
UNI T OPERATI ON
These vehi cl es use a hei ght sensi ng proporti oni ng
val ve (Fi g. 3) i n addi ti on to the pressure di fferenti al
swi tch. The hei ght sensi ng proporti oni ng val ve i s
mounted on the l eft rear frame rai l forward of the
spri ng assembl y (Fi g. 3). An actuator assembl y i s
connected between the val ve l ever and a pl asti c re-
tai ner i nserted i nto the actuator bracket.
The hei ght sensi ng proporti oni ng val ve modul ates
the pressure to the rear brakes, sensi ng vehi cl e l oad
condi ti on through movement of the actuator bracket.
Opti mum front to rear brake bal ance i s mai ntai ned
regardl ess of the vehi cl e l oad condi ti on. Under a l i ght
l oad condi ti on, l i ne pressure to the rear brakes i s
mi ni mi zed. As the l oad condi ti on i ncreases, so does the
pressure to the rear brakes.
Fig. 1 Pressure Differential Valve And Switch As-
sembly
Fig. 2 Brake Warning Switch Location
5 - 28 BRAKES
CAUTION: The use of after market load leveling or
capacity increasing devices are prohibited. Use of air
shock absorbers or helper springs will cause the
valve to inappropriately reduce the rear brake power
potentially resulting in increased stopping distance.
The proporti oni ng val ve secti on operates by trans-
mi tti ng ful l i nput pressure to the rear brakes up to a
certai n poi nt. Cal l ed the spl i t poi nt. Beyond that poi nt
i t reduces the amount of pressure i ncrease to the rear
brakes accordi ng to a certai n rati o.
Thus, on l i ght pedal appl i cati ons. Approxi matel y
equal brake pressure wi l l be transmi tted to the front
and rear brakes. Whi l e at hi gher pressures, the pres-
sure transmi tted to the rear brakes wi l l be l ower than
to the front brakes. Thi s wi l l prevent premature rear
wheel l ock-up and ski d.
The hei ght sensi ng proporti oni ng val ve changes the
spl i t poi nt of the val ve, based on vehi cl e rear suspen-
si on hei ght. When the rear hei ght i s l ow, the val ve
i nterprets thi s as extra l oad and rai ses the spl i t poi nt
to al l ow more rear braki ng. When the rear suspensi on
hei ght i s hi gh, the spl i t poi nt i s l owered and rear
braki ng reduced.
ABS BRAKE PROPORTIONING VALVE OPERATION
On vehi cl es usi ng the ABS braki ng system, screw i n
proporti oni ng val ves are used i n pl ace of the conven-
ti onal di fferenti al pressure/proporti oni ng val ve.
Each rear brake ci rcui t has i ts own screw-i n propor-
ti oni ng val ve whi ch i s attached to the rear brake outl et
ports of the hydraul i c assembl y. These val ves l i mi t
brake pressure to the rear brakes after a certai n
pressure i s reached. Thi s i mproves front to rear brake
bal ance duri ng normal braki ng.
Screw i n proporti oni ng val ves can be i denti fi ed by
the numbers stamped on the body of the val ve. The
fi rst di gi t represents the sl ope, the second di gi t repre-
sents the spl i t (cut-i n) poi nt, and the arrow represents
the fl ow di recti on of the val ve. Be sure that the
numbers listed on thereplacement valvearethe
as on thevalvethat is beingremoved. See (Fi g. 4)
for detai l of the val ve i denti fi cati on.
Fig. 3 Height Sensing Proportioning Valve Assembly
BRAKES 5 - 29
Fig. 4 ABS PROPORTIONING VALVE
IDENTIFICATION
PROPORTI ONI NG VALVE APPLI CATI ONS
5 - 30 BRAKES
SERVI CE PROCEDURES
INDEX
page page
Brake Warning System . . . . . . . . . . . . . . . . . . . . . . 1
Height Sensing Proportioning Valve . . . . . . . . . . . . 1
Testing ABS Proportioning Valves . . . . . . . . . . . . . 32
BRAKE WARNING SYSTEM
CHECKI NG THE BRAKE WARNI NG SWI TCH
UNI T
The brake warni ng l i ght wi l l come on when the
parki ng brake i s appl i ed wi th the i gni ti on key turned
ON. The same l i ght wi l l al so i l l umi nate shoul d one of
the two servi ce brake systems fai l .
To test the servi ce brakes warni ng system. Rai se the
vehi cl e on a hoi st and open a wheel cyl i nder bl eeder
whi l e a hel per depresses the brake pedal and observes
the warni ng l i ght. I f the l i ght fai l s to l i ght, i nspect for
a burned out bul b, di sconnected socket, or a broken or
di sconnected wi re at the swi tch. I f the bul b i s not
burned out and the wi re conti nui ty i s uni nterrupted.
Check the servi ce brake warni ng swi tch operati on wi th
a test l amp between the swi tch termi nal and a known
good vehi cl e ground. Be sure to fi l l master cyl i nder and
bl eed brake system after correcti on has been made, i f
necessary.
HEIGHT SENSING PROPORTIONING VALVE
TESTI NG THE HEI GHT SENSI NG VALVE UNI T
When a premature rear wheel ski d i s obtai ned on
brake appl i cati on i t coul d be an i ndi cati on that the
fl ui d pressure to the rear brakes i s above the desi red
output and that a mal functi on may have occurred
wi thi n the proporti oni ng val ve uni t and that the val ve
shoul d be tested.
Pri or to testi ng proporti oni ng val ve operati on, en-
sure the front and rear brake l i ni ngs are i n sati sfactory
condi ti on. I t i s al so necessary to veri fy brakes on
vehi cl e bei ng tested are ori gi nal equi pment manufac-
turers (OEM), ori gi nal or repl acement brake shoe
assembl i es. The vehi cl es brake system i s not bal anced
for after market brake shoe assembl y l i ni ng materi al .
I f brake shoe assembl y l i ni ng materi al i s of sati sfac-
tory condi ti on, proceed to veri fy that hei ght sensi ng
proporti oni ng val ve actuator i s properl y adjusted. See
I nstal l ati on and Adjustment paragraph steps 1
through 6. I f adjustment i s sati sfactory then proceed
wi th the proporti oni ng val ve test.
To test the proporti oni ng val ve, proceed as fol l ows:
(1) Loosen and remove the actuator assembl y ad-
justment nut (Fi g. 2 or 4). Di sconnect the assembl y
from the val ve l ever and remove.
(2) I nstal l one gauge and T of set C-4007-A i n the
l i ne from ei ther master cyl i nder port to the brake val ve
assembl y.
(3) I nstal l the second gauge of set C-4007-A to ei ther
rear brake outl et port between proporti oni ng val ve
assembl y and the rear brake l i ne. Bl eed both hydraul i c
ci rcui ts and the gauges.
(4) Have a hel per exert pressure on the brake pedal
(hol di ng pressure) to get a readi ng on the val ve i nl et
gauge and check the readi ng on the outl et gauge. The
i nl et pressure shoul d be 3445 kPa (500 psi ) and the
outl et pressure shoul d be 689 to 780 kPa (100-200 psi ).
I f not, repl ace the val ve and ti ghten mounti ng bol ts to
28 Nm (250 i n. l bs.) torque. I f the val ve tests OK
i nstal l actuator assembl y, adjust and road test ve-
hicle.
I NSTALLATI ON AND ADJUSTMENT (FI G. 4)
After i nstal l i ng a new hei ght sensi ng proporti oni ng
val ve, bl eed both hydraul i c ci rcui ts at the rear brakes.
The rubber stone/snow shi el d must be i nstal l ed
whenever the val ve i s servi ced. Thi s shi el d protects the
val ve and hydraul i c l i nes from stone i mpact and the
packi ng of snow and sl ush.
(1) Li ft vehi cl e wi th a frame contact hoi st or other
means so that the rear suspensi on i s hangi ng free wi th
the shock absorbers di sconnected from the axl e. Re-
move the ti res and wheel s from the rear axl e. Besure
that therear springs do not contact thehoist, or
an improper adjustment may result. Loosen both
front spri ng hanger pi vot bol ts.
(2) Loosen adjustment nut on the actuator assembl y
(Fi g. 4). Before adjustment, be sure that actuator
assembl y hook i s properl y seated on val ve l ever.
(3) Pul l actuator assembl y toward the spri ng hanger
unti l the val ve l ever bottoms on the val ve body, hol d i n
thi s posi ti on.
(4) Ti ghten the adjustment nut to 5 Nm (25 i n. l bs.)
torque. Adjustment i s now compl ete.
(5) I nstal l wheel and ti res and connect shock absorb-
ers.
(6) Lower vehicle to floor and with full weight
of vehicle on the wheels, ti ghten both front spri ng
hanger pi vot bol ts to 129 Nm (95 ft. l bs.) torque. Road
test vehi cl e.
BRAKES 5 - 31
1992 Van/Wagon RWD/AWD
TSB 05-12-92 October 19, 1992
TESTING ABS PROPORTIONING VALVES
Al l A.B.S. components use an ISO fl are. Use the
correct adapters when i nstal l i ng gauges.
(1) I nstal l one gauge and (T) between the hydraul i c
assembl y and the mal e end (I nl et) of the val ve.
(2) I nstal l the second gauge at the femal e end (Out-
l et) of the val ve (Fi g. 5).
(3) Have a hel per exert pressure on the brake pedal
(hol di ng pressure) to get a readi ng on the val ve i nl et
gauge.
(4) Check the readi ng on the outl et gauge. I f the
i nl et and outl et pressures do not agree wi th the fol l ow-
i ng chart, repl ace the val ve. See (Fi g. 4) i n Hydraul i c
Control Val ves Secti on for ABS proporti oni ng val ve
i denti fi cati on.
Fig. 4 Height Sensing Proportioning Valve Assembly
Fig. 5 Tube Connections for ABS
PROPORTI ONI NG VALVE PRESSURES ABS-
BRAKES
5 - 32 BRAKES
DI SC BRAKES
INDEX
page page
General Information . . . . . . . . . . . . . . . . . . . . . . . 33 Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 35
GENERAL INFORMATION
The si ngl e pi ston, fl oati ng cal i per di sc brake assem-
bl y (Fi g. 1 and 2) consi sts of:
The dri vi ng hub.
Braki ng di sc (rotor).
Cal i per assembl y.
Shoes and l i ni ngs.
Adapter for mounti ng the cal i per assembl y to the
steeri ng knuckl e.
The doubl e pi n Kel sey-Hayes fami l y cal i per, i s
mounted to the adapter usi ng bushi ngs and sl eeves and
2 through bol ts threaded i nto the adapter (Fi g. 3)
Two machi ned abutments on the adapter, posi ti on
and al i gn the cal i per fore and aft. The gui de pi ns and
bushi ngs control the si de to si de movement of the
cal i per. The pi ston seal , i s desi gned to assi st i n mai n-
tai ni ng proper brake shoe to braki ng di sc (rotor) cl ear-
ance.
The Kel sey-Hayes doubl e pi n fami l y cal i per has one
anti -rattl e cl i p attached to the top of the adapter (Fi g.
1).
Al l of the braki ng force i s taken di rectl y by the
adapter and the steeri ng knuckl e.
The cal i per i s a one pi ece casti ng wi th the i nboard
si de contai ni ng a si ngl e pi ston cyl i nder bore.
The phenol i c pi ston i s 60 mm (2.36 i nch) i n di ameter.
A square cut rubber pi ston seal i s l ocated i n a
machi ned groove i n the cyl i nder bore. I t provi des a
hydraul i c seal between the pi ston and the cyl i nder wal l
(Fi g. 4).
A mol ded rubber dust boot i nstal l ed i n a groove i n the
cyl i nder bore and pi ston, keeps contami nati on from the
cyl i nder wal l and pi ston.
The dust boot mounts i n a counter bore of the
cyl i nder bore openi ng and i n a groove whi ch i s ma-
chi ned i n the outer surface of the pi ston (Fi g. 4). Thi s
prevents contami nati on of the pi ston and the bore
area.
As l i ni ng wears, reservoi r l evel wi l l go down. I f fl ui d
has been added, reservoi r overfl ow may occur when the
pi ston i s pushed back i nto the new l i ni ng posi ti on.
Overfl owi ng can be avoi ded by removi ng a smal l
amount of fl ui d from the master cyl i nder reservoi r.
SHOE AND LI NI NG WEAR
I f a vi sual i nspecti on does not adequatel y determi ne
the condi ti on of the l i ni ng, a physi cal check
Fig. 1 Disk Brake Caliper Assembly (Family Caliper)
BRAKES 5 - 33
wi l l be necessary. To check the amount of l i ni ng
wear, remove the wheel and ti re assembl i es, and the
cal i pers.
Remove the shoe and l i ni ng assembl i es. (See Brake
Shoe Removal ).
Combi ned shoe and l i ni ng thi ckness shoul d be
measured at the thi nnest part of the brake shoe as-
sembl y.
When a shoe and l i ni ng assembl y i s worn to a
thi ckness of approxi matel y 7.95 mm (0.313 i nch) i t
shoul d be repl aced.
Repl ace both shoe assembl i es (i nboard and out-
board) on the front wheel s. I t i s al so necessary that
both front wheel brake shoe assembl y sets be re-
pl aced, whenever shoe assembl i es on ei ther si de of
the vehi cl e requi re repl acement.
I f a shoe assembl y does not requi re repl acement,
rei nstal l i t, maki ng sure each shoe assembl y i s re-
turned to i ts ori gi nal posi ti on. (See Brake Shoe I n-
stal l ati on).
Fig. 2 Front Disc Brake Assembly
Fig. 3 Disc Brake Caliper Mounting
Fig. 4 Caliper Piston Seal Function for Automatic
Adjustment
5 - 34 BRAKES
SERVICE PRECAUTIONS
WARNING: DUST AND DIRT ON BRAKE PARTS GEN-
ERATED DURING THE NORMAL USE AND WEAR OF
MOTOR VEHICLE BRAKE SYSTEMS CAN CONTAIN
ASBESTOS FIBERS. BREATHING EXCESSIVE CON-
CENTRATIONS OF ASBESTOS FIBERS CAN CAUSE
SERIOUS BODILY HARM, SUCH AS ASBESTOSIS
AND CANCER. EXTREME CARE SHOULD BE EXER-
CISED WHILE SERVICING BRAKE ASSEMBLIES OR
COMPONENTS.
DO NOT CLEAN BRAKE ASSEMBLIES OR COMPO-
NENTS WITH COMPRESSEDAIR OR BY DRY BRUSH-
ING; USE A VACUUM CLEANER SPECIFICALLY REC-
OMMENDED FOR USE WITHASBESTOS FIBERS. IF A
SUITABLE VACUUM CLEANER IS NOT AVAILABLE,
CLEANING SHOULD BE DONE WET USING A WATER
DAMPENED CLOTH.
DO NOT CREATE DUST BY SANDING, GRINDING,
AND/OR SHAVING BRAKE LININGS OR PADS UN-
LESS SUCH OPERATION IS DONE WHILE USING
PROPERLY EXHAUST VENTILATED EQUIPMENT.
DISPOSE OF DUST AND DIRT SUSPECTED TO
CONTAIN ANY ASBESTOS FIBERS IN SEALED BAGS
OR CONTAINERS TO MINIMIZE DUST EXPOSURE TO
YOURSELF AND OTHERS.
FOLLOW ALL RECOMMENDED PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION AND THE ENVIRONMEN-
TAL PROTECTION AGENCY. FOR THE HANDLING,
PROCESSING, AND DISPOSITION OF DUST OR DIRT
WHICH MAY CONTAIN ASBESTOS FIBERS.
Grease or any other forei gn materi al must be kept off
the cal i per assembl y, surfaces of the braki ng di sc and
external surfaces of the hub, duri ng servi ce proce-
dures.
Handl i ng of the braki ng di sc and cal i per shoul d be
done i n such a way as to avoi d deformati on of the di sc
and scratchi ng or ni cki ng the brake l i ni ngs (pads).
I f i nspecti on reveal s that the square secti oned cal i -
per pi ston fl ui d seal i s worn or damaged, i t shoul d be
repl aced i mmedi atel y.
Duri ng removal and i nstal l ati on of a wheel and ti re
assembl y, be careful not to stri ke the cal i per.
Beforevehicleismovedafter any brakeservice
work, be sure to obtain a firmbrake pedal.
KELSEY HAYES DOUBLE PI N FAMI LY CALI PER
INDEX
page page
Assembling Caliper . . . . . . . . . . . . . . . . . . . . . . . 40
Brake Shoe Installation . . . . . . . . . . . . . . . . . . . . 37
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . 39
Disassembling Caliper . . . . . . . . . . . . . . . . . . . . . 38
SERVICE PROCEDURES
BRAKE SHOE REMOVAL
(1) Rai se vehi cl e on jackstands or centered on a
hoi st. See Hoi sti ng i n the Lubri cati on and Mai nte-
nance secti on of thi s manual .
(2) Remove front wheel and ti re assembl i es.
(3) Remove cal i per gui de pi n bol ts (Fi g. 1).
Fig. 1 Removing or Installing Caliper Guide Pin
Bolts
BRAKES 5 - 35
(4) After removi ng the cal i per gui de pi n bol ts. Pry
the cal i per away from the braki ng di sc wi th a pry bar
or screwdri ver (Fi g. 2).
(5) Remove cal i per assembl y from braki ng di sc and
adapter by sl i di ng the assembl y out and away from the
braki ng di sc and adapter (Fi g. 3).
(6) Support cal i per fi rml y to prevent wei ght of cal i -
per from damagi ng the fl exi bl e brake hose (Fi g. 4).
Fig. 2 Loosening Family Caliper Assembly From
Adapter And Rotor
Fig. 3 Removing or Installing Caliper Assembly
Fig. 4 Storing Caliper
5 - 36 BRAKES
(7) Remove the outboard brake shoe assembl y from
the cal i per adapter (Fi g. 5).
(8) Remove the braki ng di sk (rotor) from the hub by
pul l i ng i t strai ght off the wheel mounti ng studs (Fi g.
6).
(9) Remove the i nboard brake shoe assembl y by
sl i di ng i t out al ong the bottom adapter abutment unti l
brake shoe assembl y l oosens from anti -rattl e cl i p (Fi g.
7).
(10) Remove the anti -rattl e cl i p from the top adapter
abutment (Fi g. 8).
BRAKE SHOE INSTALLATION
(1) Lubri cate both adapter abutments wi th a l i beral
amount of Mopar Mul ti purpose Lubri cant, or equi va-
l ent.
(2) I nstal l the anti -rattl e cl i p on the upper abutment
of the cal i per mounti ng adapter (Fi g. 8).
Fig. 5 Removing and Installing Outboard Shoe As-
sembly
Fig. 6 Removing or Installing Braking Disc
Fig. 7 Removing or Installing Inboard Shoe Assem-
bly
Fig. 8 Remove Or Replace Anti-Rattle Clip
BRAKES 5 - 37
(3) Remove the protecti ve paper from the noi se sup-
pressi on gasket on both the i nner and outer brake shoe
assembl i es (i f equi pped).
(4) I nstal l the new i nboard brake shoe assembl y on
the adapter by sl i di ng i t al ong the adapter abutments.
Be careful not to get any grease from the adapter
abutment on the surface of the brake l i ni ng materi al ,
(Fi g. 7). Be sure i nboard brake shoe assembl y i s cor-
rectl y posi ti oned agai nst anti -rattl e cl i p (Fi g. 6).
(5) Rei nstal l the Braki ng Di sk on the hub, by i nstal l -
i ng i t over the wheel studs unti l i t i s seated agai nst the
face of the hub (Fi g. 6).
(6) Sl i de the new outboard brake shoe assembl y on
the adapter abutment, (Fi g. 5).
(7) Careful l y l ower cal i per over the braki ng di sk and
brake shoe assembl i es (Fi g. 3). Make sure that the
cal i per gui de pi n bol t, bushi ngs and sl eeves are cl ear of
the adapter.
(8) I nstal l the cal i per gui de pi n bol ts and ti ghten to
34 to 37 Nm (25 to 35 ft. l bs.). Extreme caution
should be taken not to cross the threads of the
caliper guide pin bolts.
(9) I nstal l the wheel and ti re assembl y. Ti ghten the
wheel mounti ng stud nuts i n proper sequence (Fi g. 9)
unti l al l nuts are torqued to hal f speci fi cati on. Thi s i s
i mportant. Then repeat the ti ghteni ng sequence to the
ful l speci fi ed torque of 129 Nm (95 ft. l bs.).
(10) Remove jackstands or l ower hoi st. Beforemov-
ing vehicle, pump the brake pedal several times
to insure the vehicle has a firm brake pedal to
adequately stop vehicle..
Road test the vehi cl e and make several stops to wear
off any forei gn materi al on the brakes and to seat the
brake shoe l i ni ngs.
Check for pi ston fl ui d seal l eaks (brake fl ui d i n and
around boot area and i nboard l i ni ng) and for any
ruptures of pi ston dust boot. I f boot i s damaged, or fl ui d
l eak i s vi si bl e, di sassembl e cal i per assembl y and i n-
stal l a new seal and boot,(and pi ston i f scored). Refer to
procedures ti tl ed Di sassembl i ng Cal i per.
Check the cal i per dust boot and cal i per pi n bushi ngs
to determi ne i f they are i n good condi ti on. Repl ace i f
they are damaged, dry, or found to be bri ttl e. Refer to
Cal i per Servi ce.
DISASSEMBLING CALIPER
(1) Remove cal i per from braki ng di sc (See Brake
Shoe Removal ). Hang assembl y on a wi re hook away
from braki ng di sc, so hydraul i c fl ui d cannot get on
braki ng di sc (See Fi g. 4 i n Brake Shoe Removal ). Pl ace
a smal l pi ece of wood between the pi ston and cal i per
fi ngers.
(2) Carefully depress brake pedal to hydraul i cal l y
push pi ston out of bore. (Brake pedal wi l l fal l away
when pi ston has passed bore openi ng.) Then prop up
the brake pedal to any posi ti on bel ow the fi rst i nch of
pedal travel , thi s wi l l prevent l oss of brake fl ui d from
the master cyl i nder.
(3) I f both front cal i per pi stons are to be removed,
di sconnect fl exi bl e brake l i ne at frame bracket after
removi ng pi ston. Pl ug brake tube and remove pi ston
from opposi te cal i per. Usi ng the same process as above
for the fi rst pi ston removal .
WARNING: UNDER NO CONDITION SHOULD AIR
PRESSURE BE USED TO REMOVE PISTON FROM
CALIPER BORE. PERSONAL INJURY COULD RE-
SULT FROM SUCH A PRACTICE.
(4) Di sconnect brake fl exi bl e hose from the cal i per.
To di sassembl e, mount cal i per assembl y i n a vi se
equi pped wi th protecti ve jaws.
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
Support cal i per and remove dust boot and di scard
(Fi g. 1).
Usi ng a pl asti c tri m sti ck, work pi ston seal out of i ts
groove i n cal i per pi ston bore (Fi g. 2). Di scard ol d seal .
Do not use a screwdriver or other metal tool for
this operation, because of the possibility of
scratching piston bore or burring edges of seal
groove.
The doubl e pi n cal i per uses a seal ed for l i fe bushi ng
and sl eeve assembl y. I f requi red thi s assembl y can be
servi ced usi ng the fol l owi ng procedure.
(1) Push out and then pul l the i nner sl eeve from
i nsi de of the bushi ng usi ng your fi ngers as shown i n
(Fi g. 3)
(2) Usi ng your fi ngers col l apse one si de of the bush-
i ng. Then pul l on the opposi te si de to remove the
bushi ng from the cal i per assembl y (Fi g. 4).
Fig. 9 Tightening Wheel Nuts
5 - 38 BRAKES
CLEANING AND INSPECTION
Cl ean al l parts usi ng al cohol or a sui tabl e sol vent
and wi pe dry. Cl ean out al l dri l l ed passages and bores.
(Whenever a caliper has been disassembled, a
newboot andseal must beinstalledat assembly).
I nspect the pi ston bore for scori ng or pi tti ng. Bores
that show l i ght scratches or corrosi on, can usual l y be
cl eared wi th crocus cl oth.
Bores that have deep scratches or scori ng shoul d be
honed. Use Cal i per Hone, Speci al Tool C-4095, or
equi val ent provi di ng the di ameter of the bore i s not
i ncreased more than 0.0254 mm (0.001 i nch) (Fi g. 5).
I f the bore does not cl ean up wi thi n thi s speci fi cati on,
a new cal i per housi ng shoul d be i nstal l ed. I nstal l a new
pi ston i f the ol d one i s pi tted or scored.
When using Caliper Honing Tool, Special Tool
C-4095, coat thestonesandborewithbrakefluid.
After honing the bore, carefully clean the seal
and boot grooves with a stiff non-metallic rotary
brush.
Fig. 1 Removing Piston Dust Boot
Fig. 2 Removing Piston Seal
Fig. 3 Removing Inner Sleeve
Fig. 4 Removing Bushings From Caliper
BRAKES 5 - 39
Use extreme care in cleaning the caliper after
honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean,
lint free cloth and then clean a second time.
ASSEMBLING CALIPER
Cl amp cal i per i n vi se (wi th protecti ve caps on vi se
jaws).
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
Di p new pi ston seal i n cl ean brake fl ui d and i nstal l i n
the groove of the cal i per bore. Seal shoul d be posi ti oned
at one area i n groove and gentl y worked around the
groove (Fi g. 1), usi ng onl y your fi ngers unti l properl y
seated.
NEVER USE AN OLD PISTON SEAL. (Be sure
that fi ngers are cl ean and seal i s not twi sted or rol l ed)
(Fi g. 1).
Coat new pi ston boot wi th cl ean brake fl ui d l eavi ng a
generous amount i nsi de boot.
Posi ti on dust boot over pi ston after coati ng wi th
brake fl ui d.
I nstal l pi ston i nto cal i per bore pushi ng i t past the
pi ston seal unti l i t bottoms i n the cal i per bore (Fi g. 2).
CAUTION: Force must be applied to the piston uni-
formly to avoid cocking and binding of the piston in
the bore of the caliper.
Fig. 5 Honing Piston Bore
Fig. 1 Installing New Piston Seal
Fig. 3 Installing Dust Boot in Caliper Counterbore
Fig. 2 Pushing Piston into Bore
5 - 40 BRAKES
Posi ti on dust boot i n counterbore of the cal i per pi ston
bore.
Usi ng a hammer and I nstal l er Pi ston Cal i per Boot,
Speci al Tool C-4689 and Handl e, Speci al Tool C-4171,
dri ve boot i nto counterbore of the cal i per (Fi g. 3).
Use the fol l owi ng steps, to i nstal l the Gui de Pi n
Sl eeve Bushi ngs i nto the cal i per assembl y.
(1) Fol d the bushi ng i n hal f l engthwi se at the sol i d
mi ddl e secti on of the bushi ng (Fi g. 4).
(2) Usi ng your fi ngers i nsert the fol ded bushi ng i nto
the cal i per assembl y (Fi g. 5). Do not use a sharp
object toperformthisstepdotopossibledamage
to the bushing.
(3) Unfol d the bushi ng usi ng your fi ngers or a
wooden dowel unti l the bushi ng i s ful l y seated i nto the
cal i per assembl y. Fl anges shoul d be seated evenl y on
both si des of the bushi ng hol e i n the cal i per assembl y
(Fi g. 6).
I nstal l the Gui de Pi n Sl eeve i nto the gui de bushi ng
usi ng the fol l owi ng procedure.
(1) I nstal l the sl eeve i nto one end of the bushi ng
unti l the seal area of the bushi ng i s past the seal groove
i n the sl eeve (Fi g. 7).
(2) Hol di ng the convol uted end of the bushi ng wi th
one hand. Push the sl eeve through the bushi ng (Fi g.
Fig. 4 Folded Caliper Guide Pin Bushing
Fig. 5 Installing Caliper Guide Pin Sleeve Bushings
Fig. 6 Bushing Correctly Installed In Caliper
Fig. 7 Installing Caliper Sleeves
BRAKES 5 - 41
7) unti l the one end of the bushi ng i s ful l y seated i nto
the seal groove on the one end of the sl eeve.
(3) Hol di ng the sl eeve i n pl ace work the other end of
the bushi ng over the end of the sl eeve and i nto the seal
grove (Fi g. 8). Be sure the other end of the bushi ng di d
not come out of the seal grove i n the sl eeve.
(4) When the sl eeve i s seated properl y i nto the
bushi ng. The seal ed for l i fe bushi ng can be hel d be-
tween your fi ngers and easi l y sl i d back and forth
wi thout the bushi ng seal unseati ng from the sl eeve.
Before i nstal l i ng cal i per assembl y on vehi cl e, i nspect
braki ng di sc. I f any condi ti ons as descri bed i n Check-
i ng Braki ng Di sc for Runout and Thi ckness are present
the braki ng di sc, must be repl aced or refaced. I f the
braki ng di sc does not requi re any servi ci ng, i nstal l
cal i per assembl y.
I nstal l brake hose onto cal i per usi ng banjo bol t.
Torque the brake hose to cal i per assembl y banjo bol t to
33 Nm (24 ft. l bs.). New seal washers MUST al-
ways be used when installingbrake hose to cali-
per.
Bl eed the brake system (see Bl eedi ng Brake System).
BRAKE DI SC (ROTOR)
INDEX
page page
Braking Disc Removal . . . . . . . . . . . . . . . . . . . . . 44
Inspection Diagnosis . . . . . . . . . . . . . . . . . . . . . . 42
Installing Braking Disc . . . . . . . . . . . . . . . . . . . . . 44
Refinishing Braking Disc . . . . . . . . . . . . . . . . . . . . 44
GENERAL INFORMATION
Any servi ci ng of the braki ng di sc requi res extreme
care to mai ntai n the braki ng di sc wi thi n servi ce tol er-
ances to ensure proper brake acti on.
CAUTION: If the braking disk (rotor) needs to be
replaced with a new part. The protective coating on
the braking surfaces of the rotor MUST BE REMOVED
with an appropriate solvent, to avoid contamination
of the brake shoe linings.
When replacing a rotor with a new part do NOT
reface the new rotor. Rotor already has the required
micro finish when manufactured, only remove the
protective coating.
INSPECTION DIAGNOSIS
Before refi ni shi ng or refaci ng a braki ng di sc, the di sc
shoul d be checked and i nspected for the fol l owi ng
condi ti ons:
Braki ng surface scori ng, rust, i mpregnati on of l i ni ng
materi al and worn ri dges.
Excessi ve l ateral rotor runout or wobbl e.
Thi ckness vari ati on (Paral l el i sm).
Di shi ng or di storti on (Fl atness).
I f a vehi cl e has not been dri ven for a peri od of ti me.
The di scs wi l l rust i n the area not covered by the brake
l i ni ng and cause noi se and chatter when the brakes are
appl i ed.
Excessi ve wear and scori ng of the di sc can cause
temporary i mproper l i ni ng contact i f ri dges are not
removed before i nstal l ati on of new brake shoe assem-
bl i es.
Some di scol orati on or wear of the di sc surface i s
normal and does not requi re resurfaci ng when l i ni ngs
are repl aced.
Excessi ve runout or wobbl e i n a di sc can i ncrease
pedal travel due to pi ston knock back. Thi s wi l l i n-
crease gui de pi n bushi ng wear due to tendency of
cal i per to fol l ow di sc wobbl e.
Thi ckness vari ati on i n a di sc can al so resul t i n pedal
pul sati on, chatter and surge due to vari ati on i n brake
output. Thi s can al so be caused by excessi ve runout i n
braki ng di sc or hub.
Di shi ng or di storti on can be caused by extreme heat
and abuse of the brakes.
Fig. 8 Installed Caliper Bushing Sleeve
5 - 42 BRAKES
SERVICE PROCEDURES
CHECKI NG BRAKI NG DI SC FOR RUNOUT AND
THI CKNESS
On vehi cl e, braki ng di sc (rotor) runout i s the combi -
nati on of the i ndi vi dual runout of the hub face and the
runout of the di sc. (The hub and di sc are separabl e). To
measure runout on the vehi cl e, remove the wheel and
rei nstal l the l ug nuts ti ghteni ng the di sc to the hub.
Mount Di al I ndi cator, Speci al Tool C-3339 wi th Mount-
i ng Adaptor, Speci al Tool SP-1910 on steeri ng arm.
Di al i ndi cator pl unger shoul d contact di sc (braki ng
surface) approxi matel y one i nch from edge of di sc (See
Fi g. 1). Check l ateral runout (both si des of di sc) runout
shoul d not exceed 0.13 mm (0.005 i nch).
I f runout i s i n excess of the speci fi cati on, check the
l ateral runout of the hub face. Before removi ng di sc
from hub, make a chal k mark across both the di sc and
one wheel stud on the hi gh si de of runout. So youl l
know exactl y how the di sc and hub was ori gi nal l y
mounted (Fi g. 2). Remove di sc from hub.
I nstal l Di al I ndi cator, Speci al Tool C-3339 and
Mounti ng Adaptor, Speci al Tool SP-1910 on steeri ng
knuckl e. Posi ti on stem so i t contacts hub face near
outer di ameter. Care must be taken to posi ti on stem
outsi de the stud ci rcl e but i nsi de the chamfer on the
hub ri m. Clean hub surface before checking. (See
Fi g. 3)
Runout shoul d not exceed 0.08 mm (0.003 i nch). I f
runout exceeds thi s speci fi cati on, hub must be re-
pl aced. See Suspensi on Group 2. I f hub runout does not
exceed thi s speci fi cati on, i nstal l di sc on hub wi th chal k
marks two wheel studs apart (Fi g. 4). Ti ghten nuts i n
the proper sequence and torque to speci fi cati ons. Fi -
nal l y, check runout of di sc to see i f runout i s now wi thi n
speci fi cati ons.
I f runout i s not wi thi n speci fi cati ons. I nstal l a new
braki ng di sc or reface di sc, bei ng careful to remove as
l i ttl e as possi bl e from each si de of di sc. Remove equal
amounts from each si de of di sc. Do not reduce thi ck-
ness bel ow mi ni mum thi ckness cast i nto the un-
machi ned surface of the rotor.
Thi ckness vari ati on measurements of di sc shoul d be
made i n conjuncti on wi th runout. Measure thi ckness of
di sc at 12 equal poi nts wi th a mi crometer at a radi us
approxi matel y 25.4 mm (1 i nch) from edge
Fig. 1 Checking Braking Disc for Runout
Fig. 2 Marking Braking Disc and Wheel Stud
Fig. 3 Checking Hub for Runout
BRAKES 5 - 43
of di sc (Fi g. 5). I f thi ckness measurements vary by
more than 0.013 mm (0.0005 i nch) di sc shoul d be
removed and resurfaced (Fi gs. 6 and 7), or a new di sc
i nstal l ed. I f cracks or burned spots are evi dent i n the
di sc, di sc must be repl aced.
Li ght scori ng and/or wear i s acceptabl e. I f heavy
scori ng or warpi ng i s evi dent, the di sc must be refi n-
i shed or repl aced (See Refi ni shi ng/Refaci ng Braki ng
Di sc). I f cracks are evi dent i n the di sc, repl ace the di sc.
BRAKING DISC REMOVAL
(1) Rai se vehi cl e on hoi st or jackstands. Remove
wheel and ti re assembl y.
(2) Remove cal i per assembl y, as descri bed under
Brake Shoe Removal i n thi s Group, (but do not di scon-
nect brake l i ne). Suspend cal i per from wi re hook or
l oop to avoi d strai n on fl exi bl e hose.
(3) Remove braki ng di sc from the hub.
INSTALLING BRAKING DISC
(1) Sl i de braki ng di sc on hub. Cl ean both si des of
braki ng di sc wi th al cohol or sui tabl e sol vent.
(2) I nstal l cal i per assembl y, as descri bed i n Brake
Shoe I nstal l ati on paragraph.
REFINISHING BRAKING DISC
REFACI NG BRAKI NG DI SC
Refaci ng of the braki ng di sc i s not requi red each ti me
the shoe assembl i es are repl aced.
I f the braki ng di sc surface i s deepl y scored or warped
or there i s a compl ai nt of brake roughness or pul sati on
the rotor shoul d be resurfaced or refaced (Fi gs. 6 and
7).
When refaci ng a braki ng di sc the requi red 0.10 mm
(0.004 i nch) TI R (Total I ndi cator Readi ng) and 0.013
mm (0.0005 i nch) thi ckness vari ati on l i mi ts MUST BE
MAI NTAI NED. Extreme care i n the operati on of
braki ng di sc turni ng equi pment i s requi red.
The col l ets, shafts and adapters i n the l athe and the
beari ng cups i n the rotor MUSTbe cl ean and free from
any chi ps or contami nati on.
When mounti ng the di sc on the l athe, stri ct attenti on
to the l athe manufacturers i nstructi ons i s requi red.
Fig. 4 Index Braking Disc and Wheel Stud
Fig. 5 Checking Disc for Thickness
Fig. 6 Refacing Braking Disc
5 - 44 BRAKES
I f the di sc i s not mounted properl y the run-out wi l l be
worse after refaci ng than before refaci ng.
The use of a doubl e straddl e cutter (Fi g. 6) that
machi nes both si des of the di sc at the same ti me i s
hi ghl y recommended.
RESURFACI NG BRAKI NG DI SC
Thi s operati on can be used when the di sc surface i s
rusty or has l i ni ng deposi ts.
A sandi ng di sc attachment wi l l remove surface con-
tami nati on wi thout removi ng much braki ng di sc ma-
teri al .
I t wi l l general l y fol l ow vari ati ons i n thi ckness that
are i n the di sc.
The fol l owi ng chart shows the l ocati on of measure-
ments and speci fi cati ons when servi ci ng the braki ng
di sc.
All braking discs have markings for minimum
allowablethickness cast on an un-machined sur-
face (Fig. 8). This surface may be as shown in
(Fig. 8) or on an alternate surface.
Thi s marki ng i ncl udes 0.76 mm (0.030 i nch) al l ow-
abl e di sc wear beyond the recommended 0.76
mm(0.030 i nch) of di sc refaci ng.
Fig. 7 Resurfacing Braking Disc (Final Finish)
Fig. 8 Minimum Thickness Markings
BRAKI NG DI SC (ROTOR) REFI NI SHI NG LI MI TS
BRAKES 5 - 45
PARKI NG BRAKES
INDEX
page page
Front Parking Brake Cable . . . . . . . . . . . . . . . . . . 48
Parking Brake Pedal Assembly . . . . . . . . . . . . . . . 48
Rear Parking Brake Cable . . . . . . . . . . . . . . . . . . 49
GENERAL INFORMATION
The rear wheel servi ce brakes al so act as parki ng
brakes. The brake shoes are mechani cal l y operated by
an i nternal l ever and strut connected to a fl exi bl e steel
cabl e. The di fferent l ength rear cabl es are connected to
the front cabl e by an equal i zer/adjuster assembl y that
i s encl osed i n a covered anchor bracket. The front cabl e
extends to the parki ng brake pedal assembl y (Fi gs. 1
and 4).
The parki ng brake cabl es are constructed of speci al
materi al s and use uni que constructi on wi th i nternal
seal s. Thi s hel ps to provi de good corrosi on protecti on i n
severe envi ronments and resi stance to freezi ng i n col d
wet cl i mates. Ease of and more accurate parki ng brake
adjustment i s provi ded by usi ng the bent nai l adjuster.
Cabl e routi ng and brake shoe actuati on (for the
parki ng brake) i s as fol l ows. The ri ght rear cabl e enters
the support from the rear. The i nternal l ever i s at-
tached to the pri mary (front) shoe where i t pi vots to
push the strut i nto the secondary (rear) shoe. The l eft
brake i s tradi ti onal , the cabl e enters the support from
the front. The l ever i s attached to the secondary (rear)
shoe to push the strut i nto the pri mary (front) shoe.
The l eft and ri ght brake shoes l ook si mi l ar, BUT
THEY ARE NOT INTERCHANGEABLE. The back-
i ng pl ates and cabl es are col or coded; l eft i s bl ack, ri ght
i s grey.
5 - 46 BRAKES
F
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.
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P
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B
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a
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C
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BRAKES 5 - 47
SERVICE PROCEDURES
ADJUSTI NG PARKI NG BRAKE
The servi ce brakes must be properl y adjusted before
adjusti ng the parki ng brake.
Remove pl asti c cover by pressi ng i n the fi ngers of the
cover through hol es i n bracket (Fi g. 1).
Before l ooseni ng cabl e adjusti ng nut, cl ean threads
wi th brush and l ubri cate wi th grease. Do not use a
metal wi re brush because i t wi l l scratch off pl ati ng and
coati ng.
Rel ease the parki ng brake pedal then back off cabl e
adjusti ng nut so there i s sl ack i n the cabl e.
Push parki ng brake pedal al l the way to the fl oor.
Mark bent nai l adjuster approxi matel y 6 mm (1/4
i nch) from bracket (Fi g. 2).
Ti ghten adjusti ng nut unti l mark moves i nto al i gn-
ment wi th edge of bracket. Important: Repl ace bent
nai l wi th a new part i f nai l end hook has moved al l the
way to the bracket.
Repl ace pl asti c cover and tethered pl ug.
Appl y and rel ease the parki ng brake to see that the
rear wheel s rotate freel y wi thout draggi ng.
CAUTION: The threaded rod, washer and nut of the
adjuster are made of stainless steel. Do not use a
non-stainless steel washer or nut because an electro-
chemical reaction could occur. This could cause
highly accelerated corrosion leading to failure of the
washer or nut.
PARKING BRAKE PEDAL ASSEMBLY
REMOVE
Loosen cabl e adjusti ng nut and di sconnect front
cabl e from adjuster (Fi g. 2).
Remove si l l mol di ng/cowl si de scuff panel and steer-
i ng col umn cover. I ncrease access by removi ng fuse
box, i f requi red.
Di sconnect the el ectri cal connector for the brake
l i ght swi tch. Remove pedal assembl y to body attachi ng
bol ts (Fi g. 3).
Remove front cabl e strand button from cl evi s. Tap
cabl e housi ng end fi tti ng out of assembl y (Fi g. 3).
I NSTALL
I nstal l cabl e retai ner i nto pedal assembl y bracket
(Fi g. 3).
I nstal l cabl e i nto retai ner and strand button i nto
cl evi s (Fi g. 3).
Bol t pedal assembl y i nto pl ace. Ti ghten pedal assem-
bl y attachi ng bol ts to 28 Nm (250 i n. l bs.). I nstal l
el ectri cal connector for the brake l i ght swi tch.
I nstal l fuse box, steeri ng col umn cover and si l l
mol di ng/cowl si de scuff panel .
Connect front cabl e and adjust parki ng brake (Fi g.
2). See Adjusti ng Parki ng Brake i n thi s secti on of the
servi ce manual for the correct adjusti ng procedure.
FRONT PARKING BRAKE CABLE
REMOVE
Loosen cabl e adjusti ng nut and di sengage front cabl e
from adjuster. Remove cabl e housi ng retai ner from
anchor bracket, by sl i di ng a 14 mm box wrench over
cabl e retai ner and compressi ng the three fi ngers. Al -
ternate method i s to use an ai rcraft type hose cl amp
and screwdri ver. Thi s i s si mi l ar to the method shown
for removi ng the parki ng brake cabl e from the support
pl ate (Fi g. 4).
Remove cabl e gui de brackets from frame rai l and
l oosen cabl e housi ng at pedal assembl y.
Fig. 2 Equalizer/Bent Nail Adjuster Assembly
Fig. 3 Parking Brake Pedal Remove And Install
5 - 48 BRAKES
Li ft fl oor mat for access to fl oor pan and force seal out
of hol e (i nto vehi cl e).
Pul l cabl e end forward and di sconnect button from
cl evi s. Tap cabl e housi ng end fi tti ng out of pedal
assembl y bracket.
Pul l cabl e assembl y through hol e.
I NSTALL
Pass cabl e assembl y through hol e i n fl oor from i nsi de
vehi cl e (Fi g. 3).
I nstal l cabl e retai ner i nto brake pedal assembl y
bracket and then i nstal l cabl e housi ng end fi tti ng i nto
retai ner.
Engage cabl e strand button i nto cl evi s.
I nstal l fl oor pan seal and fl oor mat.
I nsert brake cabl e and housi ng i nto anchor bracket
maki ng certai n that housi ng retai ner fi ngers l ock the
housi ng fi rml y i nto pl ace.
I nstal l cabl e gui de brackets.
Assembl e adjuster to front cabl e.
Adjust parki ng brake.
REAR PARKING BRAKE CABLE
REMOVE
Wi th vehi cl e jacked up on sui tabl e hoi st remove
wheel and ti re.
Back off cabl e adjusti ng nut to provi de sl ack and
di sconnect rear cabl e from equal i zer bracket.
To remove cabl e from anchor bracket. Remove cabl e
housi ng retai ner from anchor bracket by sl i di ng a 14
mm box wrench over retai ner end compressi ng the
three fi ngers. Al ternate method i s to use an ai rcraft
type hose cl amp and screwdri ver. Thi s i s si mi l ar to the
method shown for removi ng the brake cabl e from the
Remove cabl e wrap-around cl i ps where appl i cabl e.
Di sconnect cabl e gui de wi res where appl i cabl e.
Remove brake drum and hub from spi ndl e.
Di sconnect cabl e from brake i nternal l ever.
Remove park brake cabl e housi ng retai ner from the
brake support pl ate. Use the same method for remov-
i ng cabl e retai ner from brake support pl ate as was
used above for the cabl e anchor bracket.
I NSTALL
I nsert park brake cabl e i nto hol e i n the brake sup-
port pl ate. Attach park brake cabl e to park brake
i nternal l ever attached to brake shoe.
I nsert cabl e housi ng retai ner i nto brake support
pl ate maki ng certai n that cabl e housi ng retai ner fi n-
gers l ock the housi ng and retai ner fi rml y i nto pl ace.
I nstal l brake drum, wheel and ti re.
I nsert cabl e housi ng retai ner i nto anchor bracket
maki ng certai n that cabl e housi ng retai ner fi ngers l ock
the housi ng fi rml y i nto pl ace.
Attach cabl e gui de wi res and wrap-around cl i ps
where appl i cabl e.
Connect equal i zer bracket.
Adjust servi ce brakes and then adjust parki ng brake.
MASTER CYLI NDER
INDEX
page page
Reservoir Replacement . . . . . . . . . . . . . . . . . . . . 50
GENERAL INFORMATION
The tandem master cyl i nder (Fi g. 1) has a gl ass
rei nforced nyl on reservoi r and an anodi zed al umi num
body.
CAUTION: Do not hone the bore of the cylinder, as
this will remove the anodized surface.
The master cyl i nder reservoi r i s i ndexed to prevent
i nstal l ati on i n the wrong di recti on. The cap di a-
phragms are sl i t to al l ow pressure to equal i ze.
The secondary outl et tube from the master cyl i nder
i s connected to the proporti oni ng val ve mounted under
the master cyl i nder. The front part of thi s val ve sup-
pl i es the ri ght rear and l eft front brakes.
Fig. 4 Removing Brake Cable from Brake Support
Plate
BRAKES 5 - 49
The pri mary outl et tube from the master cyl i nder i s
al so connected to the proporti oni ng val ve. The back
part of thi s val ve suppl i es the ri ght front and l eft rear
brakes.
RESERVOIR REPLACEMENT
See Master Cyl i nder Removal .
Cl ean master cyl i nder housi ng and fl ui d reservoi r.
Remove caps and empty brake fl ui d from reservoi r.
Posi ti on master cyl i nder i n vi se.
Rock fl ui d reservoi r from si de to si de and remove
from master cyl i nder housi ng (Fi g. 2).
Remove master cyl i nder housi ng-to-fl ui d reservoi r
grommets (Fi g. 3).
I nstal l new master cyl i nder housi ng-to-fl ui d reser-
voi r grommets i n master cyl i nder housi ng.
Lubri cate fl ui d reservoi r mounti ng areas wi th brake
fl ui d. Pl ace reservoi r i n posi ti on over grommets. Seat
fl ui d reservoi r onto master cyl i nder housi ng, by appl y-
i ng downward pressure whi l e usi ng a si de to si de
rocki ng moti on unti l reservoi r i s ful l y seated i n grom-
mets.
Be sure reservoi r i s posi ti oned properl y. Al l l etteri ng
shoul d be properl y read from the l eft si de of the master
cyl i nder.
Make sure bottom of reservoi r touches top of grom-
met.
SERVICE PROCEDURES
MASTER CYLI NDER
REMOVE
Di sconnect pri mary and secondary brake tubes from
master cyl i nder housi ng. I nstal l pl ugs at brake tube
outl ets.
Remove 2 nuts (Fi g. 4) attachi ng master cyl i nder
housi ng to power brake booster uni t.
Fig. 1 Aluminum Master Cylinder
Fig. 2 Removing Reservoir Do not pry fluid reser-
voir off master cylinder housing using a tool, dam-
age to the fluid reservoir may result.
Fig. 3 Removing Grommets
Fig. 4 Master Cylinder Mounting
5 - 50 BRAKES
Sl i de master cyl i nder strai ght out, and away from
power brake booster uni t.
BLEEDING MASTER CYLINDER
Cl amp master cyl i nder i n vi se and attach Bl eedi ng
Tubes, Speci al Tool C-4546 (Fi g. 5).
Use a resi dual val ve on outl et of each bl eeder tube, to
keep ai r from bei ng drawn back up tube and i nto
master cyl i nder.
Fi l l both reservoi rs to the appropri ate ful l mark, wi th
approved brake fl ui d.
Depress push rod sl owl y and then al l ow pi stons to
return. Repeat several ti mes unti l al l ai r bubbl es are
expel l ed (Fi g. 5).
Remove bl eedi ng tubes from master cyl i nder. Pl ug
outl et ports on master cyl i nder and i nstal l caps on fl ui d
reservoi r.
Remove master cyl i nder from vi se and i nstal l master
cyl i nder back on the power brake uni t.
It isnot necessary tobleedtheentirehydraulic
systemafter replacing the master cylinder. Pro-
viding that the master cylinder had been thor-
oughly bled of all air and filled with approved
brake fluid before installing it on the vehicle.
INSTALL
Posi ti on master cyl i nder over studs on power brake
uni t, al i gn push rod wi th master cyl i nder pi ston.
I nstal l master cyl i nder to power brake uni t attachi ng
nuts (Fi g. 4) and ti ghten to 28 Nm (250 i n. l bs.).
Connect brake tubes to master cyl i nder outl et ports.
Ti ghten the brake tube to master cyl i nder fi tti ngs to 17
Nm (145 i n. l bs.).
POWER BRAKES
INDEX
page page
General Information . . . . . . . . . . . . . . . . . . . . . . . 51 Service Procedures . . . . . . . . . . . . . . . . . . . . . . . 52
GENERAL INFORMATION
A 270 mm power brake booster assembl y i s used on
these vehi cl es (Fi g. 1 and 2).
The purpose of the power brake booster i s to reduce
the amount of force appl i ed to the brake pedal , to
obtai n the requi red hydraul i c pressure i n the brake
system to stop the vehi cl e.
The power brake booster can be i denti fi ed i f requi red,
by the tag attached to the body of the booster assembl y
(Fi g. 1). Thi s tag contai ns the fol l owi ng i nformati on.
The producti on part number of the power booster
assembl y, the date i t was bui l t and who manufactured
i t.
The power brake booster assembly is not a
repairable part and must be replaced as a com-
plete unit if it is found to be faulty in any way.
The power booster vacuum check valve is not
repairablebut canbereplaceableasanassembly.
The power brake booster i n vacuum operated. The
vacuum i s suppl i ed from the i ntake mani fol d through
the power brake booster check val ve (Fi g. 1).
As the brake pedal i s depressed, the power boosters
i nput rod moves forward. Thi s opens and cl oses val ves
i n the power booster, creati ng a vacuum on one si de of
a di aphragm and al l owi ng atmospheri c pressure to
enter on the other. Thi s di fference i n pressure forces
the output rod of the power booster out agai nst the
pri mary pi ston of the master cyl i nder. As the pi stons i n
the master cyl i nder move forward thi s creates the
hydraul i c pressure i n the brake system.
Di fferent systems and engi ne combi nati ons requi re
di fferent vacuum hose routi ngs. The hose i s needed to
suppl y the power brake uni t wi th a vacuum si gnal from
the engi nes i ntake mani fol d. Thi s vacuum si gnal i s
requi red for the proper operati on of the power brake
uni t. Bel ow i s l i sted the di fferent hose routi ng requi re-
ments and routi ng i l l ustrati ons.
Fig. 5 Bleeding Master
BRAKES 5 - 51
Vehi cl es equi pped wi th the Chrysl er 2.5L engi ne use
a charcoal fi l ter i n the hose between the booster and
the throttl e body (Fi g. 3).
Vehi cl es equi pped wi th the opti onal 3.0L and 3.3L
engi ne use a preformed vacuum hose connected di -
rectl y to the i ntake mani fol d (Fi g. 4 and 5).
SERVICE PROCEDURES
POWER BRAKE BOOSTER ASSEMBLY
REMOVE
(1) Remove the 2 nuts (Fi g. 6) attachi ng master
cyl i nder assembl y to power brake uni t.
(2) Careful l y sl i de master cyl i nder off mounti ng
studs wi th brake l i nes attached, and al l ow the assem-
bl y to rest agai nst fender shi el d.
Fig. 1 Power Brake Booster Identification
Fig. 2 Power Brake Booster Assembly
Fig. 3 Power Brake Unit/Vacuum Hose Connections
2.5L TBI and 2.5L Turbocharged Engines
Fig. 4 Power Brake Unit/Vacuum Hose Connections
3.0L Engine
5 - 52 BRAKES
(3) Di sconnect vacuum hose from power brake
booster check val ve (Fi g. 1). DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(4) From under i nstrument panel , posi ti on a smal l
screwdri ver between the center tang on the power
brake booster i nput rod to brake pedal pi n retai ni ng
cl i p.
(5) Rotate screwdri ver enough to al l ow retai ner cl i p
center tang to pass over end of brake pedal pi n and pul l
retai ner cl i p off pi n. Discard retainer clip it is not
to be reused, replace only with a new retainer
clip.
(6) Remove the four nuts that attach the power
brake booster to the vehi cl e dash panel . Nuts are
accessi bl e from under the dash panel i n the area of the
steeri ng col umn and pedal bracket (Fi g. 7).
(7) Unfasten brackets on steel heater water l i ne at
dash panel and l eft frame rai l . On Manual Transmis-
sion vehicles, unfasten cl utch cabl e bracket at shock
tower and move asi de.
(8) Sl i de the power brake uni t up and to the l eft
(mounti ng hol es are sl otted) on the dash panel , then
ti l t i nboard and up to remove.
CAUTION: Do not attempt to disassemble power
brake unit as this booster is serviced ONLY as a
complete assembly.
INSTALL
(1) Posi ti on power brake booster onto dash panel .
(2) I nstal l and ti ghten the 4 power brake booster to
dash panel mounti ng nuts (Fi g. 7) to 29 Nm (250 i n.
l bs.) torque.
(3) I nstal l steel heater water l i ne and cl utch cabl e
bracket, i f so equi pped.
Fig. 5 3.3L Engine Power Brake Unit/Vacuum Hose
Connections
Fig. 6 Master Cylinder Mounting
Fig. 7 Power Brake Booster Mounting
BRAKES 5 - 53
(4) Careful l y posi ti on master cyl i nder on power
brake uni t.
(5) I nstal l and ti ghten the 2 master cyl i nder to
power booster mounti ng nuts (Fi g. 6) to 29 Nm (250
i n. l bs.) torque.
(6) Connect vacuum hose onto the check val ve, l o-
cated on the power brake uni t.
(7) Usi ng l ubri pl ate, or equi val ent, coat the beari ng
surface of pedal pi n (Fi g. 7).
(8) Connect power brake booster i nput rod to brake
pedal pi n and i nstal l a NEW retai ner cl i p. Useonly a
new retainer clip DO NOT USE the old clip.
(9) Check stop l i ght operati on.
WHEEL BEARI NGS
FRONT WHEEL BEARINGS
Front wheel dri ve vehi cl es are equi pped wi th perma-
nentl y seal ed front wheel beari ngs. There i s no peri odi c
l ubri cati on or mai ntenance recommended for these
uni ts. However i f duri ng servi ci ng of the brake system,
servi ce to the front wheel beari ng i s requi red refer to
Group 2, Suspensi on i n thi s servi ce manual .
REAR WHEEL BEARINGS (FRONT WHEEL DRIVE)
NORMAL SERVI CE
The l ubri cant i n the rear wheel beari ngs shoul d be
i nspected whenever the hubs are removed to i nspect or
servi ce the brake system, or every 30,000 mi l es (48 000
km). The beari ng shoul d be cl eaned and repacked wi th
a Hi gh Temperature Mul ti purpose E.P. Grease when-
ever the brake drums are resurfaced.
I NSPECTI ON
Check l ubri cant to see that i t i s adequate i n quanti ty
and qual i ty. I f the grease i s l ow i n quanti ty, contai ns
di rt, appears dry or mi l ky i n appearance, the beari ngs
must be cl eaned and repacked. Do not add greaseto
a lubricated wheel bearing, it must be cleaned
and completely repacked. Mixing of different
types of greases in wheel bearings should be
avoided sinceit may result in excessivethinning
and leakage of the grease.
For the servi ci ng, removal and i nstal l ati on of the
rear wheel beari ngs fol l ow the procedure l i sted bel ow.
(1) Remove the rear ti re and wheel assembl y.
(2) Remove grease cap, cotter pi n, nut l ock, nut,
thrust washer and outer wheel beari ng.
(3) Careful l y sl i de hub or drum from spi ndl e. Donot
drag inner bearing or grease seal over stub axle
(thread, bearing, and oil seal may be damaged.)
Usi ng an appropri ate tool remove the grease seal and
i nner beari ng from the drum or hub. Di scard grease
seal , a new seal shoul d be used when rei nstal l i ng the
i nner beari ng. (See Fi g. 1)
(5) Thoroughl y cl ean al l ol d grease from the outer
and i nner beari ngs, beari ng cups and hub cavi ty (See
Fi g. 1). To clean bearings, soak themin an appro-
priatecleaningsolvent. Striketheflat surfaceof
thebearinginner raceagainst a hardwood block
several times, to loosen grease. Immerse the
bearings in solvent between blows to jar loose
and wash old particles of hardened grease from
bearings. Repeat this operation until bearings
are clean. Bearings can be dried using com-
pressed air but do not spin the bearings. After
cleaning, oil the bearings with engine oil. Insert
the bearinginto its appropriate cup, apply pres-
sureto thebearingwhilerotatingit to test them
for pitting and roughness. Replace all worn or
defective bearings. If bearing shows signs of
pitting or roughness they should be replaced.
Bearings must be replaced as a set, both the cup
and the bearing need to be replaced at the same
time. If bearings are suitable for further use,
removeengineoil frombearings usingappropri-
ate solvent and dry bearings. Repack the bear-
ings using a Multi-Purpose NLGI. Grade 2 EP
Grease such as Mopar or equivalent, and place
themin aclean coveredcontainer until ready for
installation. If a bearing packer is not available,
hand pack grease into all cavities between bear-
ing cage and rollers.
(6) I f beari ngs and cups are to be repl aced, remove
cups from the drum or hub usi ng a brass dri ft or
sui tabl e remover.
Fig. 1 Rear Wheel Bearings
5 - 54 BRAKES
(7) Repl ace beari ng cups wi th appropri ate i nstal l i ng
tool .
(8) I nstal l i nner beari ng i n grease coated hub and
beari ng cup, and i nstal l new grease seal s usi ng the
appropri ate seal i nstal l er.
(9) Coat outer hub cavi ty and cup wi th grease.
(10) Before i nstal l i ng hub or drum assembl y, i nspect
stub axl e and seal surface for burrs or roughness, and
smooth out al l rough surfaces.
(11) Coat the stub axl e wi th Mul ti -Purpose NLGI ,
Grade 2 EP grease such as Mopar or equi val ent.
(12) Careful l y sl i de the hub of drum assembl y onto
the stub axl e. Do not drag seal or inner bearing
over the threaded area of the stub axle.
(13) I nstal l outer beari ng, thrust washer and nut.
(14) Ti ghten the wheel beari ng adjusti ng nut to 27 to
34 Nm (240 to 300 i n. l bs.) whi l e rotati ng hub or drum
assembl y. Thi s seats the beari ngs.
(15) Back off adjusti ng nut 1/4 turn (90) then
ti ghten adjusti ng nut onl y fi nger ti ght.
(16) Posi ti on the nut l ock over the beari ng adjusti ng
nut wi th one pai r of sl ots i n l i ne wi th the cotter pi n hol e
i n the stub axl e. I nstal l cotter pi n.
(17) I nstal l the grease caps and the wheel and ti re
assembl i es. Ti ghten wheel stud nuts to 115 Nm (85 ft.
l bs.) on al l model s. Rei nstal l wheel covers i f so
equi pped.
BRAKES 5 - 55
ANTI -LOCK BRAKE SYSTEM (BENDI X ANTI -LOCK 10 AS BODY FWD/AWD)
INDEX
page page
ABS Braking System Diagnosis . . . . . . . . . . . . . . 71
ABS Controller Anti-Lock Brake (CAB) Service
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ABS Equipped Vehicle Performance . . . . . . . . . . . 58
ABS Hydraulic Circuits and Valve Operation . . . . . 69
ABS System Diagnostic Connector . . . . . . . . . . . . 65
ABS System Diagnostic Features . . . . . . . . . . . . . 75
ABS System General Service Precautions . . . . . . 72
ABS System Self-Diagnostics . . . . . . . . . . . . . . . . 59
Anti-Lock Brake System Components . . . . . . . . . . 60
Anti-Lock Brake System Definitions . . . . . . . . . . . 56
Anti-Lock Operation and Performance . . . . . . . . . . 58
Anti-Lock System Relays and Warning Lamps . . . 67
Controller Anti-Lock Brake (CAB) . . . . . . . . . . . . . 65
General Service Precautions . . . . . . . . . . . . . . . . 75
Major ABS Components . . . . . . . . . . . . . . . . . . . . 57
Mechanical Diagnostics and Service Procedures . . 73
On Car Electronic ABS Component Service . . . . . 85
On Car Hydraulic ABS Component Service . . . . . . 75
Warning Systems Operation . . . . . . . . . . . . . . . . . 59
GENERAL INFORMATION
The purpose of the Anti -Lock Brake System (ABS)
(Fi g. 1) i s to prevent wheel l ock-up under heavy brak-
i ng condi ti ons on al most any type of road surface.
Anti -Lock Braki ng i s desi rabl e because a vehi cl e that
i s stopped wi thout l ocki ng the wheel s wi l l retai n di rec-
ti onal stabi l i ty and some steeri ng capabi l i ty. Thi s al -
l ows the dri ver to retai n greater control of the vehi cl e
duri ng heavy braki ng.
ANTI-LOCK BRAKE SYSTEM DEFINITIONS
I n thi s secti on of the manual several abbrevi ati ons
are used for the components that are i n the Anti -Lock
Braki ng System They are l i sted bel ow for your refer-
ence.
CABControl l er Anti -Lock Brake
ABSAnti -Lock Brake System
PSI Pounds per Square I nch (pressure)
WSSWheel Speed Sensor
Fig. 1 Four-Wheel Anti-Lock Brake System
5 - 56 ANTI-LOCK BRAKES
MAJOR ABS COMPONENTS
The fol l owi ng i s a l i st of major system components.
Detai l s of al l components can be found l ater i n thi s
secti on.
HYDRAULI C ASSEMBLY
The Hydraul i c Assembl y (Fi g. 1) provi des the func-
ti on of an i ntegral master cyl i nder and hydraul i c
booster assembl y, and contai ns the wheel ci rcui t val ves
used for brake pressure modul ati on.
WHEEL SPEED SENSORS
A Wheel Speed Sensor (Fi g. 2) i s l ocated at each
wheel to transmi t wheel speed i nformati on to the
Control l er Anti -Lock Brake (CAB).
CONTROLLER-ANTI -LOCK BRAKE (CAB)
The CAB (Fi g. 3) i s a smal l control computer that
recei ves wheel speed i nformati on, control s Anti -Lock
operati on and moni tors system operati on.
Fig. 1 ABS Hydraulic Assembly
Fig. 2 Wheel Speed Sensor
Fig. 3 (CAB) Controller Anti-Lock Brake Module
ANTI-LOCK BRAKES 5 - 57
PUMP/MOTOR ASSEMBLY
The Pump/Motor Assembl y (Fi g. 4) i s an el ectri cal l y
dri ven pump. I t takes l ow pressure brake fl ui d from
the hydraul i c assembl y reservoi r and pressuri zes i t for
storage i n the accumul ators for power assi st and Anti
-Lock braki ng.
ANTI-LOCK OPERATION AND PERFORMANCE
NORMAL BRAKI NG SYSTEM FUNCTI ON
Under normal braki ng condi ti ons, the ABS System
functi ons much the same as a standard brake system
wi th a di agonal l y spl i t master cyl i nder. The pri mary
di fference i s that power assi st i s provi ded by hydraul i c
power assi st i nstead of the conventi onal vacuum assi st.
I f a wheel l ocki ng tendency i s noti ced duri ng a brake
appl i cati on, the system wi l l enter Anti -Lock mode.
Duri ng Anti -Lock braki ng, hydraul i c pressure i n the
four wheel ci rcui ts i s modul ated to prevent any wheel
from l ocki ng. Each wheel has a set of el ectri cal sol enoi d
val ves and a hydraul i c l i ne to provi de modul ati on,
al though for vehi cl e stabi l i ty, both rear wheel val ves
recei ve the same el ectri cal si gnal . The system can
bui l d, hol d or reduce pressure at each wheel . Depend-
i ng on the si gnal s generated by the wheel speed sen-
sors (WSS) at each wheel and recei ved at the
Control l er-Anti -Lock Brake (CAB).
The ABS system represents the current state-of-the-
art i n vehi cl e braki ng systems and offers the dri ver
i ncreased safety and control duri ng braki ng. Thi s i s
accompl i shed by a sophi sti cated system of el ectri cal
and hydraul i c components. That di ffer from conven-
ti onal vacuum boosted hydraul i c actuati on systems.
Because, there are several performance characteri sti cs
that may at fi rst seem di fferent but shoul d be consi d-
ered normal . These characteri sti cs are di scussed bel ow.
More techni cal detai l s are di scussed further i n thi s
secti on.
PEDAL FEEL
The ABS System uses hydraul i c power assi st for both
normal power assi sted braki ng and to provi de a source
of hi gh pressure hydraul i c fl ui d duri ng Anti -Lock
Braki ng. I n general , pedal feel wi l l be si mi l ar to that of
a conventi onal vacuum boosted brake system. I f duri ng
an Anti -Lock stop addi ti onal force i s appl i ed to the
brake pedal , or the brake pedal i s rel eased and reap-
pl i ed rapi dl y. The dri ver may noti ce a very hard pedal
feel . Thi s i s due to normal i sol ati on of the master
cyl i nder duri ng A.B.S. operati on as wheel brake pres-
sure i s fed from the hydraul i c booster.
ANTI -LOCK OPERATI ON
Duri ng Anti -Lock Braki ng, brake pressures are
modul ated by cycl i ng el ectri c val ves. The cycl i ng of
these val ves can be heard as a seri es of poppi ng or
ti cki ng noi ses. I n addi ti on, the cycl i ng may be fel t as a
pul sati on i n the brake pedal , al though no pedal move-
ment wi l l be noti ced. I f Anti -Lock operati on occurs
duri ng hard braki ng. Some pul sati on may be fel t i n the
vehi cl e body due to fore and aft movement of the
vehi cl es suspensi on as brake pressures are modul ated.
Al though ABS operati on i s avai l abl e at vi rtual l y al l
vehi cl e speeds. I t wi l l automati cal l y turn off at speeds
bel ow 3 to 5 mph. Therefore wheel l ock-up may be
percei ved at the very end of an Anti -Lock stop and
shoul d be consi dered normal .
TI RE NOI SE & MARKS
Al though the ABS system prevents compl ete wheel
l ock-up, some wheel sl i p i s desi red to achi eve opti mum
braki ng performance. Duri ng brake pressure modul a-
ti on, as brake pressure i s i ncreased, wheel sl i p i s
al l owed to reach up to 30%. Thi s means that the wheel
rol l i ng vel oci ty i s 30% l ess than that of a free rol l i ng
wheel at a gi ven vehi cl e speed. Thi s sl i p may resul t i n
some ti re chi rpi ng, dependi ng on the road surface. Thi s
sound shoul d not be i nterpreted as total wheel l ock-up.
Compl ete wheel l ock-up normal l y l eaves bl ack ti re
marks on dry payment. However, Anti -Lock Braki ng
wi l l not l eave dark bl ack ti re marks si nce the wheel
never reaches a l ocked condi ti on. Ti re marks may
however be noti ceabl e as l i ght patched marks.
ABS EQUIPPED VEHICLE PERFORMANCE
Anti -Lock Brakes provi de the dri ver wi th some steer-
i ng control duri ng hard braki ng. However there are
condi ti ons where the system does not provi de any
benefi t. I n parti cul ar, hydropl ani ng i s sti l l possi bl e
Fig. 4 ABS Pump/Motor Assembly
when the ti res ri de on a fi l m of water, resul ti ng i n the
ti re l eavi ng the road surface renderi ng the vehi cl e
al most uncontrol l abl e. I n addi ti on, extreme steeri ng
maneuvers at hi gh speed or hi gh speed corneri ng
beyond the l i mi ts of ti re adhesi on to the road surface
may cause vehi cl e ski ddi ng, i ndependent of vehi cl e
braki ng. So, the ABS system i s termed Anti -Lock
i nstead of Anti -Ski d.
One of the si gni fi cant benefi ts of the ABS system i s
that of mai ntai ni ng steeri ng control duri ng hard brak-
i ng or duri ng braki ng on sl i ppery surfaces. I t i s there-
fore possi bl e to steer the vehi cl e whi l e braki ng on
al most any road surface.
ABS SYSTEM SELF-DIAGNOSTICS
The ABS system has been desi gned wi th Sel f Di ag-
nosti c Capabi l i ty. There are two sel f checks the sys-
tems performs every ti me the vehi cl e i s started. Fi rst,
when the key i s turned on the system performs an
el ectri cal check cal l ed Start-Up Cycl e. Duri ng thi s
check, the Red Brake Warni ng Lamp and the Amber
Anti -Lock Warni ng Lamp are i l l umi nated. Then
turned off at the end of the test, after about 1 to 2
seconds. When the vehi cl e reaches a speed of about 3 to
4 mi l es per hour. The system performs a functi onal
check cal l ed Dri ve-Off. Duri ng Dri ve-Off. hydraul i c
val ves are acti vated bri efl y to test thei r functi on.
Dri ve-Off can be detected as a seri es of rapi d cl i cks
upon dri vi ng off the fi rst ti me the car i s started. I f the
brake pedal i s appl i ed duri ng Dri ve-Off, the test i s
by-passed. Both of these condi ti ons are a normal part
of the system sel f test. Most faul t condi ti ons wi l l set a
ABS Faul t Code i n the (CAB), whi ch can be retri eved to
ai d i n faul t di agnosi s. Detai l s can be found i n Di agno-
si s Secti on.
WARNING SYSTEMS OPERATION
The ABS system uses two methods for noti fyi ng the
dri ver of a system mal functi on. These i ncl ude the
standard Red Brake Warni ng Lamp and an Amber
Anti -Lock Warni ng Lamp, both l ocated i n the i nstru-
ment cl uster. The purpose of these two l amps are
di scussed i n detai l bel ow.
RED BRAKE WARNI NG LAMP
The Red Brake Warni ng Lamp, l ocated i n the i nstru-
ment cl uster, wi l l Turn On to warn the dri ver of brake
system condi ti ons that may resul t i n reduced braki ng
abi l i ty. The l amp i s al so turned on when the parki ng
brake i s not ful l y rel eased. Condi ti ons whi ch may
cause the Red Brake Warni ng Lamp to Turn On
i ncl ude:
Parki ng brake not ful l y rel eased. I f the parki ng
brake i s appl i ed or not ful l y rel eased. The swi tch on the
parki ng brake pedal assembl y wi l l ground the Red
Brake Warni ng Lamp ci rcui t and cause the l amp to
turn on. On vehi cl es equi pped wi th mechani cal i nstru-
ment cl usters, the Amber Anti -Lock Lamp wi l l turn on
i f the vehi cl e i s dri ven above 3 mi l es per hour wi th the
Parki ng Brake appl i ed.
Low brake fl ui d. The fl ui d l evel sensor i n the hy-
draul i c assembl y reservoi r wi l l ground the Red Brake
Warni ng Lamp ci rcui t i f l ow brake fl ui d l evel i s de-
tected. I n addi ti on, ABS wi l l be deacti vated above 3
mi l es per hour and the Amber Anti -Lock Warni ng
Lamp wi l l be i l l umi nated. I f the vehi cl e i s equi pped
wi th EVI C, a l ow fl ui d condi ti on wi l l al so cause the
Low Brake Fl ui d message to appear.
Low accumul ator pressure. I n the event of l ow
accumul ator pressure, the dual functi on pressure
swi tch i n the hydraul i c assembl y wi l l si gnal the (CAB)
to ground the Red Brake Warni ng Lamp ci rcui t. Thi s
wi l l cause the Red Brake Warni ng Lamp to turn on.
Low accumul ator pressure may resul t i n l oss of power
assi st.
Hydraul i c assembl y or (CAB) faul ts. The hydraul i c
assembl y or (CAB) may turn on the Red Brake Warn-
i ng Lamp. I f certai n faul ts are detected i n ei ther the
hydraul i c assembl y or the (CAB), or the normal brake
system.
Bul b check. As a bul b check, the Red Brake Warni ng
Lamp wi l l i l l umi nate whenever the i gni ti on swi tch i s
pl aced i n the crank posi ti on.
Illumination of the red Brake Warning Lamp
may indicate reduced braking ability. A vehicle
that hastheRedBrakeWarningLampONshould
not bedriven except tododiagnostic procedures
described in Section 2 of this manual. Most con-
ditions that turn on the Red Brake Warning
Lamp will also turn on the Amber Anti-Lock
WarningLamp, consequently disablingthe Anti-
Lock function.
ANTI -LOCK WARNI NG LAMP
The Anti -Lock Warni ng Lamp i s l ocated i n the i n-
strument cl uster and i s Amber i n col or. The Amber
Anti -Lock Warni ng Lamp i s i l l umi nated when the
(CAB) detects a condi ti on that resul ts i n a shutdown of
Anti -Lock functi on. The Amber Anti -Lock Warni ng
Lamp i s normal l y on unti l the (CAB) compl etes i ts sel f
tests and turns the l amp off. For exampl e, i f the (CAB)
i s di sconnected, the l amp i s on.
Display of theAmber Anti-Lock WarningLamp
without the Red Brake Warning Lamp indicates
only that Anti-Lock function has been disabled.
Power assisted normal braking is unaffected.
NORMAL OPERATI ON OF WARNI NG LAMPS
Wi th the i gni ti on i n the Crank posi ti on, the Red
Brake Warni ng Lamp wi l l turn on as a bul b check. The
Amber Anti -Lock Warni ng Lamp wi l l turn on for as
l i ttl e as 1 second to as l ong as 30 seconds.
I f the car has not been started for several hours, for
exampl e after si tti ng overni ght. The Red Brake Warn-
i ng Lamp and the Amber Anti -Lock Warni ng
Lamp may both be turned on for as l ong as 60 seconds
after turni ng the i gni ti on on. Thi s condi ti on i s caused
by the l oss of accumul ator charge when the vehi cl e i s
parked for extended peri ods, parti cul arl y i n col d
weather. When the key i s then turned on. The
Pump/Motor assembl y must recharge the hydraul i c
accumul ator to i ts normal operati ng pressure. As re-
chargi ng i s compl eted, both warni ng l amps wi l l remai n
on unti l accumul ator pressure reaches about (1,000
psi ). Both l amps shoul d remai n off at al l other ti mes,
i ndi cati ng normal operati on.
ANTI-LOCK BRAKE SYSTEM COMPONENTS
The fol l owi ng i s a detai l ed descri pti on of the Anti -
Lock Brake System components. For i nformati on on
servi ci ng the other Non-ABS rel ated components that
may be referred to i n thi s secti on. See the Standard
Brakes Secti on that refers to the speci fi c component.
HYDRAULI C ASSEMBLY
The ABS system uses an i ntegral Hydraul i c Assem-
bl y (Fi g. 1) whi ch i ncl udes a Booster/Master Cyl i nder,
Modul ator, Hydraul i c Bl adder Accumul ator and Fl ui d
Reservoi r. The Hydraul i c Assembl y i s l ocated on the
dash panel cowl on the dri vers si de of the vehi cl e. The
fol l owi ng i s a descri pti on of the components that make
up the Hydraul i c Assembl y.
HYDRAULI C ASSEMBLY BRAKE FLUI D RES-
ERVOI R
A one pi ece Fl ui d Reservoi r i s attached to the hy-
draul i c assembl y wi th rubber seal s. The Fl ui d Reser-
voi r (Fi g. 1) i s i nternal l y separated i nto three fl ui d
secti ons. Most of the brake fl ui d i s contai ned i n the
Fl ui d Reservoi r and hydraul i c bl adder accumul ator
(Fi g. 1)Addi ti onal fl ui d i s contai ned i n the pump/motor
assembl y accumul ator.
BOOSTER/MASTER CYLI NDER
The Booster/Master Cylinder portion of the
hydraulic assemblyisanintegral component and
should never be disassembled.
The Booster/Master Cyl i nder uses a di agonal l y spl i t
confi gurati on duri ng normal braki ng. The two ci rcui ts
are hydraul i cal l y i sol ated so a l eak or mal functi on i n
one ci rcui t wi l l al l ow conti nued braki ng abi l i ty i n the
other.
When force i s appl i ed to the brake pedal , the i nput
pushrod appl i es force to the boost control val ve. As the
boost control val ve i s moved, i t al l ows the pressuri zed
fl ui d from the accumul ator to fl ow i nto the master
cyl i nder booster chamber. The pressure generated i n
the booster i s di rectl y proporti oned to the brake pedal
force exerted by the dri ver. Thi s pressure i n the booster
servo i n turn appl i es pressure to the pri mary master
cyl i nder pi ston that i n turn ap-
Fig. 1 Hydraulic Assembly
pl i es pressure to the secondary master cyl i nder pi ston.
The pressure generated i n the pri mary and secondary
ci rcui ts are used to appl y the brakes duri ng normal
braki ng.
WARNING: THE HYDRAULIC ACCUMULATORS CON-
TAIN BRAKE FLUID AND NITROGEN GAS AT HIGH
PRESSURE. CERTAIN PORTIONS OF THE BRAKE
SYSTEM ALSO CONTAIN BRAKE FLUID AT HIGH
PRESSURE. REMOVAL OR DISASSEMBLY MAY RE-
SULT IN PERSONAL INJURY AND IMPROPER SYS-
TEM OPERATION. REFER TO THE APPROPRIATE
SERVICE MANUAL FOR PROPER SERVICE PROCE-
DURES.
HYDRAULI C BLADDER ACCUMULATOR
A Hydraul i c Bl adder Accumul ator (Fi g.2) i s used to
store brake fl ui d at hi gh pressure. The pressuri zed
fl ui d i s used for Anti -Lock operati on and for power
assi sted normal braki ng. The accumul ator uses an
el astomeri c bl adder confi gurati on wi th a ni trogen pre-
charge of about 6,895 kPa (1,000 psi .) Wi th no brake
fl ui d i n the system, the ni trogen gas pre-charge appl i es
approxi matel y 6,895 kPa (1,000 psi .) to one si de of the
di aphragm (Fi g. 2)
Under normal operati on, the Pump/Motor assembl y
charges the accumul ator to an operati ng pressure of
between 11,032 and 13,790 kPa (1600 psi to 2,000 psi .)
As pressuri zed brake fl ui d enters the accumul ator,
pushi ng agai nst the opposi te si de of the di aphragm,
(Fi g. 2) the ni trogen gas i s compressed and i ncreases i n
pressure.
DUAL FUNCTI ON PRESSURE SWI TCH
The Dual Functi on Pressure Swi tch i s l ocated on the
bottom of the hydraul i c assembl y (Fi g. 1) and moni tors
Accumul ator Pressure. The Dual Functi on Pressure
Swi tch, i f found to be functi oni ng i mproperl y usi ng the
ABS di agnosti cs, can be repl aced. See servi ce proce-
dure i n El ectroni c Components area of On Car ABS
Servi ce i n thi s secti on of the servi ce manual . The
pri mary functi on i s to control operati on of the
Pump/Motor assembl y and thus mai ntai n proper accu-
mul ator operati ng pressure. When accumul ator pres-
sure fal l s to or bel ow 11,032 kPa (1600 psi ,) the
Pump/Motor swi tch (i nternal to the dual functi on pres-
sure swi tch) wi l l cl ose. Thi s provi des a ground, through
Pi n 1 of the Transducer and Swi tch, 10 way el ectri cal
connector to the Pump/Motor rel ay coi l . The energi zed
coi l pul l s the rel ay contacts cl osed, provi di ng battery
vol tage to run the Pump/Motor. When Accumul ator
Pressure reaches 13,790 kPa (2,000 psi ,) the swi tch
opens, de-energi zi ng the Pump/Motor Rel ay that turns
off the Pump/Motor. NOTE: THE (CAB) DOES NOT
REGULATE OR CONTROL ACCUMULATOR
PRESSURE.
The second purpose of the Dual Functi on Pressure
Swi tch i s to provi de a si gnal to the (CAB) when the
Accumul ator Pressure fal l s bel ow 6,895 kPa (1,000
psi ). A Warni ng Pressure Swi tch, i nternal to the Dual
Functi on Pressure Swi tch, i s normal l y cl osed above
6,895 kPa (1,000 psi .) Thi s sends a ground si gnal to pi n
17 at the (CAB). At or bel ow 6,895 kPa (1,000 psi .) the
Warni ng Pressure Swi tch opens. I nternal l y, the (CAB)
(pi n 17) detects 12 vol ts and thus l ow pressure. At thi s
warni ng pressure, the (CAB) wi l l di sabl e the Anti -Lock
Braki ng functi ons, l i ght the Red Brake Warni ng Lamp
and the Amber Anti -Lock Warni ng Lamp. After two
mi nutes of conti nuous detecti on, a l ow accumul ator
faul t i s stored.
Groundi ng for the Dual Functi on Pressure Swi tch. I s
provi ded through Pi n 1 of the Transducer and Swi tch,
10 way el ectri cal connector and the Modul ator Assem-
bl y.
Fig. 2 Hydraulic Fluid Accumulator
PRESSURE TRANSDUCERS
Two Pressure Transducers are used for brake system
faul t detecti on. Both transducers generate a vol tage
si gnal (between 0.25 vol ts and 5.0 vol ts) that i s propor-
ti onal to pressure. These si gnal s are compared by the
(CAB) and used to detect brake system faul ts that
woul d requi re Anti -Lock Braki ng to be di sabl ed.
The Boost Pressure Transducer i s mounted on the
bottom of the hydraul i c assembl y, (Fi g. 1) and moni tors
booster servo pressure. The Pri mary Pressure Trans-
ducer i s mounted on the l eft si de of the hydraul i c
assembl y and moni tors pri mary master cyl i nder pres-
sure.
DI FFERENTI AL PRESSURE SWI TCH
A non-l atchi ng Di fferenti al Pressure Swi tch i s used
to detect a pressure di fference greater than 2,068 kPa
(300 psi .) between the pri mary and secondary master
cyl i nder hydraul i c ci rcui ts. I f detected, the Di fferenti al
Pressure Swi tch grounds the output of the pri mary
pressure transducer (ci rcui t B-218). Thi s resul ts i n a
0.0 vol t si gnal from the Pri mary Pressure Transducer
that i s sensed by the (CAB) as a di fferenti al pressure
faul t. The (CAB) wi l l then l i ght the Red Brake Warni ng
Lamp and the Amber Anti -Lock Warni ng Lamp and
di sabl e the Anti -Lock braki ng functi on. See Fi g. 1 for
l ocati on of the di fferenti al pressure swi tch.
PROPORTI ONI NG VALVES
The ABS system uses screw-i n Proporti oni ng Val ves
i n pl ace of the conventi onal Hei ght Sensi ng Proporti on-
i ng Val ve. Each rear brake ci rcui t has i ts own screw-i n
Proporti oni ng Val ve that i s attached to the rear brake
outl et ports of the hydraul i c assembl y (Fi g. 1). These
val ves l i mi t brake pressure to the rear brakes after a
certai n brake pressure i s reached. Thi s i mproves front
to rear wheel brake bal ance duri ng normal braki ng.
FI LTERS-SERVI CEABI LI TY
There i s a screen fi l ter i n each of the two master
cyl i nder fi l l ports. There i s al so a l ow pressure fi l ter for
the pump/motor. The fi l ter i s i ntegral to the
Pump/Motor l ow pressure hose.
FLUI D LEVEL SWI TCH
A Low Fl ui d Swi tch i s l ocated i n the hydraul i c
assembl y fl ui d reservoi r, (Fi g. 1). The swi tch consi sts of
a fl oat and magneti c reed swi tch that cl oses when l ow
fl ui d i s detected. The Low Fl ui d Swi tch i s used as an
i nput, to the Red Brake Warni ng Lamp, the (CAB), and
the EVI C (i f so equi pped). When a l ow
DUAL FUNCTI ON PRESSURE SWI TCH WI RI NG DI AGRAM
fl ui d condi ti on exi sts the swi tch wi l l cl ose, groundi ng
the l ow fl ui d ci rcui t and i l l umi nati ng the Red Brake
Warni ng Lamp. The (CAB) wi l l di sabl e the Anti -Lock
Functi on and l i ght the Amber Anti -Lock Warni ng
Lamp i f the vehi cl e i s i n moti on above 3 mph. I f the
vehi cl e i s not i n moti on, the Amber Anti -Lock Warni ng
Lamp wi l l NOT be l i t.
PUMP/MOTOR ASSEMBLY
The Pump/Motor Assembl y i s mounted to the tran-
saxl e bel ow the hydraul i c assembl y,(Fi g. 3). I ntegral to
the Pump/Motor Assembl y i s an accumul ator usi ng a
sl i di ng pi ston confi gurati on wi th a ni trogen pre-charge
of 3,172 kPa (460 psi .) The Pump/Motor i s an el ectri -
cal l y dri ven pump that takes l ow pressure brake fl ui d
from the hydraul i c assembl y fl ui d reservoi r and pres-
suri zes i t. The pressuri zed fl ui d i s then stored i n the
pi ston accumul ator and hydraul i c bl adder accumul ator
for power assi st and Anti -Lock Braki ng. Operati on of
the Pump/Motor i s control l ed by the Dual Functi on
Pressure Swi tch through the Pump/Motor Rel ay. The
(CAB) does NOT control the Pump/Motor activa-
tion. Rubber i sol ators are used to mount the pump to
i ts bracket for noi se i sol ati on. The Pump/Motor Assem-
bl y i s connected to the Hydraul i c Assembl y wi th a l ow
pressure return hose and a hi gh pressure hose. A fi l ter
i s l ocated i n the l ow pressure return l i ne.
WHEEL SPEED SENSORS
One Wheel Speed Sensor (WSS), i s l ocated at each
wheel (Fi g. 4, 5 and 6) and sends a smal l (AC) el ectri cal
si gnal to the control modul e (CAB). Thi s si gnal i s
generated by magneti c i nducti on. The magneti c i nduc-
ti on i s created when a toothed sensor ri ng (Tone Wheel )
passes by the stati onary magneti c (Wheel Speed Sen-
sor). The (CAB) converts the (AC) el ectri cal si gnal
generated at each wheel i nto a di gi tal si gnal . I f a wheel
l ocki ng tendency i s detected, the (CAB) wi l l then
modul ate hydraul i c pressure to prevent the wheel (s)
from l ocki ng.
The front Wheel Speed Sensor (Fi g. 4) i s mounted to
a boss on the steeri ng knuckl e, for both the Front
Wheel Dri ve and Al l Wheel Dri ve appl i cati ons. The
Tone Wheel i s part of the outboard constant vel oci ty
joi nt housi ng.
The Rear Wheel Speed Sensor, on Front Wheel Dri ve
appl i cati ons. I s mounted to the rear brake
PRESSURE SWI TCH AND PRESSURE TRANSDUCER WI RI NG
Fig. 3 Pump/Motor Assembly And Heat Shield
Backi ng Pl ate (Fi g. 5). And the rear Tone Wheel i s an
i ntegral part of the rear wheel brake drum (Fi g. 6).
The Al l Wheel Dri ve, rear wheel speed sensor i s
mounted to the rear carri er axl e (Fi g. 7). The Rear Tone
Wheel on thi s appl i cati on i s part of the outboard
constant vel oci ty joi nt housi ng.
The speed sensor, to tone wheel ai r gap al l appl i ca-
ti ons i s NOT adjustabl e.
Al l four, Wheel Speed Sensors are servi ced i ndi vi du-
al l y as repl aceabl e components. The Front Wheel Dri ve
and Al l Wheel Dri ve front Tone Wheel s are servi ced as
an assembl y wi th the front outboard constant vel oci ty
joi nt housi ng. The Front Wheel Dri ve rear Tone Wheel s
are servi ced as an assembl y wi th the rear brake drum
hub. The Al l Wheel Dri ve rear Tone Wheel s are ser-
vi ced as an assembl y wi th the rear outboard constant
vel oci ty joi nt housi ng.
Correct Anti -Lock System operati on i s dependent on
wheel speed si gnal s from the wheel speed sensors. The
vehi cl es wheel s and ti res must al l be the same si ze and
type to generate accurate si gnal s. I n addi ti on, the ti res
must be i nfl ated to the recommended
Fig. 4 Front Wheel Speed Sensor FWD/AWD
Fig. 5 Rear Wheel Speed Sensor FWD
Fig. 6 Rear Tone Wheel FWD
Fig. 7 Rear Wheel Speed Sensor AWD
pressures for opti mum system operati on. Vari ati ons i n
wheel and ti re si ze or si gni fi cant vari ati ons i n i nfl ati on
pressure can produce i naccurate wheel speed si gnal s.
CONTROLLER ANTI-LOCK BRAKE (CAB)
The Anti -Lock Brake Control l er i s a smal l mi cropro-
cessor based devi ce that moni tors the brake system
and control s the system whi l e i t functi ons i n Anti -Lock
Mode. The CAB i s l ocated under the battery tray (Fi g.
8) and uses a 60-way system connector. The power
source for the CAB i s through the i gni ti on swi tch to pi n
60 of the control l er. Wi th the i gni ti on i n the RUN or ON
posi ti on. THE FRONT WHEEL DRIVE CONTROL-
LER IS DIFFERENT FROM THE ALL WHEEL
DRIVE CONTROLLER. IF THE CONTROLLER
NEEDS TO BE REPLACED BE SURE THE COR-
RECT CONTROLLER IS USED. THE CONTROL-
LER ANTI-LOCK BRAKE (CAB) IS NOT ON THE
CCD BUS
The pri mary functi ons of the (CAB) are:
(1) Detect wheel l ocki ng tendenci es.
(2) Control fl ui d modul ati on to the brakes whi l e i n
Anti -Lock mode.
(3) Moni tor the system for proper operati on.
(4) Provi de communi cati on to the DRB I I whi l e i n
di agnosti c mode.
The (CAB) conti nuousl y moni tors the speed of each
wheel , through the si gnal s generated at the Wheel
Speed Sensors, to determi ne i f any wheel i s begi nni ng
to l ock. When a wheel l ocki ng tendency i s detected, the
(CAB) wi l l i sol ate the master cyl i nder from the wheel
brakes. Thi s i s done by acti vati ng the I sol ati on Val ves.
The (CAB) then commands the appropri ate Bui l d or
Decay val ves to modul ate brake fl ui d pressure i n some
or al l of the hydraul i c ci rcui ts. The fl ui d used for
modul ati on comes from the booster servo ci rcui t. The
(CAB) conti nues to control pressure i n i ndi vi dual hy-
draul i c ci rcui ts unti l a l ocki ng tendency i s no l onger
present.
The (ABS) system i s constantl y moni tored by the
(CAB) for proper operati on. I f the (CAB) detects a faul t,
i t can di sabl e the Anti -Lock braki ng functi on. Depend-
i ng on the faul t, the(CAB) wi l l l i ght one or both of the
brake warni ng l amps.
The (CAB) contai ns a System Di agnosti c Program
whi ch tri ggers the brake system warni ng l amps when
a system faul t i s detected. Faul ts are stored i n a
di agnosti c program memory. There are 19 faul t codes
that may be stored i n the (CAB) and di spl ayed through
the DRB I I . These faul t codes wi l l remai n i n the (CAB)
memory even after the i gni ti on has been turned off.
These faul t codes wi l l remai n i n memory unti l they are
cl eared wi th the DRB I I , or automati cal l y erased from
the memory after (50) i gni ti on swi tch on/off cycl es.
CONTROLLER ANTI -LOCK BRAKE (I NPUTS)
Four wheel speed sensors.
Boost pressure transducer.
Pri mary pressure transducer.
Low fl ui d l evel swi tch.
Di fferenti al pressure swi tch.
Parki ng brake swi tch.
Dual functi on pressure swi tch (warni ng pressure
onl y)
Stop l amp swi tch.
I gni ti on swi tch.
System rel ay vol tage.
Ground.
Low Accumul ator
CONTROLLER ANTI -LOCK BRAKE (OUTPUTS)
Ten modul ator val ves-3 decay, 3 bui l d and 4 i sol a-
ti on.
Red Brake warni ng l amp.
Amber Anti -Lock Warni ng Lamp.
System rel ay actuati on.
Di agnosti c communi cati on.
ABS SYSTEM DIAGNOSTIC CONNECTOR
The Bendi x Anti -Lock system di agnosti c connector i s
l ocated under the l ower dash panel or i n the area of the
fuse box. The fuse box i s l ocated behi nd the access
panel that i s on the bottom porti on of the dash panel ,
l eft of the steeri ng col umn. The di agnosti cs connector i s
a bl ue 6 way connector.
Fig. 8 Location Controller Anti-Lock Brake (CAB)
A
B
S
S
Y
S
T
E
M
W
I
R
I
N
G
S
C
H
E
M
A
T
I
C
ANTI-LOCK SYSTEM RELAYS AND WARNING
LAMPS
PUMP/MOTOR RELAY
Pump/Motor power i s suppl i ed by the Pump/Motor
Rel ay. The Pump/Motor rel ay i s l ocated i n front of the
l eft shock tower (Fi g. 9). The rel ay coi l i s energi zed by
a ground from the Dual Functi on Pressure Swi tch.
SYSTEM RELAY
The (ABS) Modul ator Val ves and Anti -Lock Warni ng
Lamp Rel ay are control l ed through a System Rel ay.
The System rel ay i s l ocated on the top l eft i nner fender
behi nd the headl i ght (Fi g. 9). The system rel ay pro-
vi des power to the (CAB) for modul ator val ve operati on
(pi ns 47 and 50) after the start-up cycl e when the
i gni ti on i s turned on.
ANTI -LOCK WARNI NG LAMP RELAY
The Anti -Lock Warni ng Lamp i s control l ed by the
Yel l ow Li ght Rel ay. See (Fi g. 9) for l ocati on behi nd the
l eft headl i ght. Wi th the rel ay de-energi zed, the l amp i s
l i t. When the system rel ay i s energi zed by the (CAB),
the Anti -Lock Warni ng Lamp rel ay i s energi zed, and
the l amp i s turned off. Thus, the l amp wi l l be l i t i f the
(CAB) i s di sconnected or i f a system faul t causes (ABS)
functi on to be turned off, or i f the system rel ay fai l s
open.
ANTI -LOCK WARNI NG LAMP OFF
SystemRelay (normally open) andYellowLight
Relay (normally closed) Energized.
From pi n 57 the (CAB) energi zes the system rel ay
coi l . The current fl ow i n the coi l cl oses the system rel ay.
Current i s then provi ded to pi ns 47 and 50 of the (CAB)
to provi de power to the modul ator val ves. Thi s current
al so energi zes the Yel l ow Li ght Rel ay coi l . The current
fl ow i n the yel l ow l i ght rel ay coi l opens the Anti -Lock
Warni ng Lamp Rel ay Swi tch. Thi s breaks the ground
path to the Anti -Lock Warni ng Lamp and the l amp i s
turned off.
The (CAB) by i tsel f, al so can turn on the Anti -Lock
Warni ng Lamp. The (CAB) can turn on the Anti -Lock
Warni ng Lamp by provi di ng a ground at pi n 15.
ANTI -LOCK WARNI NG LAMP ON
System Relay and Anti-Lock Warning Lamp
Relay De-Energized.
When the Amber Anti -Lock Warni ng Lamp i s on,
there i s no current fl ow from the (CAB) at pi n 57. The
system rel ay coi l i s NOTenergi zed. No current fl ows to
pi ns 47 and 50 (modul ator val ve power), or to the
Anti -Lock Warni ng Lamp rel ay coi l . Thus, the Anti -
Lock Warni ng Lamp Rel ay i s not energi zed. The Anti -
Lock Warni ng Lamp i s grounded through the Anti -
Lock Warni ng Lamp rel ay contacts. The Anti -Lock
Warni ng Lamp i s i l l umi nated.
Fig. 9 Pump/Motor and Anti-Lock System Relays
A
N
T
I
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L
O
C
K
S
Y
S
T
E
M
R
E
L
A
Y
W
I
R
I
N
G
S
C
H
E
M
A
T
I
C
ABS HYDRAULIC CIRCUITS AND VALVE OPERA-
TION
Through the fol l owi ng operati on descri pti ons and
di agrams. The functi on of the vari ous hydraul i c control
val ves i n the ABS system wi l l be descri bed. The fl ui d
control val ves menti oned bel ow, control the fl ow of
pressuri zed brake fl ui d to the wheel brakes duri ng the
di fferent modes of Anti -Lock Braki ng.
NORMAL BRAKI NG
ISOLATION VALVES
Open to pri mary and secondary master cyl i nder
brake fl ui d suppl y (Fi g. 10)
DECAY AND BUILD VALVES
Cl osed, not al l owi ng for the bui l d-up or rel ease of
brake fl ui d suppl y (Fi g. 10).
The brake pedal i s appl i ed. The travel of the brake
pedal cl oses pri mary, secondary and booster servo
ci rcui ts from fl ui d suppl y at the fl ui d reservoi r. Brake
fl ui d from the pri mary and secondary ci rcui ts fl ows
through the open i sol ati on val ves and appl i es the
wheel brakes. Fl ui d from the booster servo ci rcui t does
not fl ow to the wheel brakes. The fl ui d fl ow i s bl ocked
by the cl osed bui l d val ves and check val ves.
POWER ASSIST
The boost control val ve shuttl es between i ts three
posi ti ons to provi de power assi sted braki ng (Fi g. 10).
ABS BRAKI NG-BUI LD PRESSURE
ISOLATION VALVES
Cl osed, i sol ati ng wheel brakes from master cyl i nder
pri mary and secondary fl ui d suppl i es and open to
booster servo ci rcui t pressure through open bui l d
val ves (Fi g. 11)
DECAY VALVES
Cl osed, not al l owi ng the escape of pressuri zed fl ui d
suppl y from the hydraul i c system (Fi g. 11).
BUILD VALVES
Open, al l owi ng booster servo ci rcui t pressure to fl ow
to wheel brakes through the i sol ati on val ves (Fi g 11).
Fig. 10 Normal Braking - Hydraulic Control
POWER ASSIST
The boost control val ve shuttl es between i ts three
posi ti ons to provi de power assi sted braki ng (Fi g. 11).
ABS BRAKI NG-HOLD PRESSURE
For expl anati on purposes we wi l l assume al l speed
sensors are sendi ng the same wheel speed i nformati on,
requi ri ng the same modul ati on at the same rate.
ISOLATION VALVES
Cl osed, i sol ati ng the wheel brakes from the master
cyl i nder pri mary and secondary fl ui d suppl i es. Bui l d
and decay val ves are cl osed preventi ng any fl ui d from
reachi ng the open i sol ati on val ves (Fi g. 12).
DECAY AND BUILD VALVES
Cl osed, not al l owi ng fl ui d suppl y to reach the open
i sol ati on val ves (Fi g. 12).
ABS BRAKI NG-DECAY PRESSURE
ISOLATION VALVES
Cl osed, i sol ati ng the wheel brakes from the master
cyl i nder pri mary and secondary fl ui d suppl i es (Fi g. 13)
DECAY VALVES
Open, al l owi ng rel ease of fl ui d pressure through
decay val ve to the fl ui d reservoi r (Fi g. 13)
BUILD VALVE
Cl osed, bl ocki ng booster servo ci rcui t fl ui d to wheel
brakes (Fi g. 13).
Fig. 11 Build Pressure - Hydraulic Control
ABS BRAKING SYSTEM DIAGNOSIS
WARNING: SOME OPERATIONS IN THIS SECTION
REQUIRE THAT HYDRAULIC TUBES, HOSES AND
FITTINGS BE DISCONNECTED FOR INSPECTION OR
TESTING PURPOSES. THIS BRAKE SYSTEM USES A
HYDRAULIC ACCUMULATOR THAT, WHEN FULLY
CHARGED, CONTAINS BRAKE FLUIDAT HIGH PRES-
SURE. BEFORE DISCONNECTING ANY HYDRAULIC
TUBE, HOSE OR FITTING. BE SURE THAT THE AC-
CUMULATOR IS FULLY DE-PRESSURIZED AS DE-
SCRIBED IN THIS SECTION. FAILURE TO DE-
PRESSURIZE THE ACCUMULATOR MAY RESULT IN
PERSONAL INJURY AND/OR DAMAGE TO PAINTED
SURFACES.
CAUTION: Certain components of the Anti-Lock
Brake System (ABS) are not intended to be serviced
individually. Attempting to remove or disconnect cer-
tain system components, may result in personal
injury and/or improper system operation. Only those
components with approved removal, service and in-
stallation procedures described in this manual
should be serviced.
Thi s secti on contai ns i nformati on necessary for di ag-
nosi s of mechani cal condi ti ons that can affect the
operati on of the Bendi x Anti - Lock 10 Brake System.
Speci fi cal l y, thi s secti on shoul d be used to hel p di ag-
nose mechani cal condi ti ons that resul t i n any of the
fol l owi ng:
CAUTION: Review this entire section before perform-
ing any mechanical work on a vehicle equipped with
the Bendix Anti-Lock 10 brake system. For informa-
tion on precautions pertaining to potential compo-
nent damage, vehicle damage and personal injury.
(1) Anti -Lock warni ng l amp i l l umi nated
(2) BRAKE warni ng l amp on
(3) Lack of Power Assi st or Excessi ve Pedal Travel
(4) Brakes Lock on Hard Appl i cati on
Di agnosi s of condi ti ons that are obvi ousl y mechani -
cal i n nature. Such as brake noi se, brake pul sati on, or
vehi cl e vi brati on duri ng normal braki ng. Shoul d be
di rected to Group 5 Brakes i n the servi ce manual . Thi s
al so pertai ns to probl ems i nvol vi ng the parki ng brake
system.
Fig. 12 Hold Pressure - Hydraulic Control
I n order to effecti vel y di agnose an Anti -Lock Brake
System (ABS) condi ti on. I t i s i mportant to read Secti on
1 of thi s manual , Anti -Lock Brake System Descri pti on.
Thi s secti on wi l l gi ve you i nformati on on the functi on
of the ABS components. Then fol l ow the di agnosti c
procedures outl i ned i n thi s secti on.
Many condi ti ons that generate customer compl ai nts
may be normal operati ng condi ti ons, but are judged to
be a probl em due to unfami l i ari ty wi th the ABS sys-
tem. These condi ti ons can be recogni zed wi thout per-
formi ng extensi ve di agnosti c work. Gi ven adequate
understandi ng of the operati ng pri nci pl es and perfor-
mance characteri sti cs of the ABS system. See Secti on 1
of thi s manual to fami l i ari ze yoursel f wi th the operat-
i ng pri nci pl es of the ABS system.
DEFI NI TI ONS
Several abbrevi ati ons are used i n thi s manual . They
are presented here for reference.
CABControl l er Anti -Lock Brake
ABSAnti -Lock Brake System
PSI Pounds per Square I nch (pressure)
WSSWheel Speed Sensor
ABS CONTROLLER ANTI-LOCK BRAKE (CAB) SER-
VICE PRECAUTIONS
The ABS system uses an el ectroni c control modul e,
the (CAB). Thi s modul e i s desi gned to wi thstand nor-
mal current draws associ ated wi th vehi cl e operati on.
However care must be taken to avoi d overl oadi ng the
(CAB) ci rcui ts. I n testi ng for open or short ci rcui ts, do
not ground or appl y vol tage to any of the ci rcui ts unl ess
i nstructed to do so by the appropri ate di agnosti c pro-
cedure. These ci rcui ts shoul d onl y be tested usi ng a
hi gh i mpedance mul ti -meter, speci al tool s or the DRB
I I tester as descri bed i n thi s secti on. Power shoul d
never be removed or appl i ed to any control modul e wi th
the i gni ti on i n the ON posi ti on. Before removi ng or
connecti ng battery cabl es, fuses, or connectors, al ways
turn the i gni ti on to the OFF posi ti on.
ABS SYSTEM GENERAL SERVICE PRECAUTIONS
TEST DRI VI NG ABS COMPLAI NT VEHI CLES
Most ABS compl ai nts wi l l requi re a test dri ve as a
part of the di agnosti c procedure. The purpose of the
test dri ve i s to dupl i cate the condi ti on.
Before test driving a brake complaint vehicle,
especially if the Red Brake Warning Lamp is on,
test the brakes at low speed to be sure that the
car will stop normally. Remember that condi-
tionsthat result in illumination of theRedBrake
Warning Lamp may indicate reduced braking
ability. The following procedure should be used
to test drive an ABS complaint:
Fig. 13 Decay Pressure - Hydraulic Control
(1) I gni ti on on. Turn the i gni ti on to the ON posi ti on
wi thout starti ng the car and wai t unti l the Red Brake
Warni ng Lamp and Amber Anti -Lock Warni ng Lamp
turn off. Thi s wi l l al l ow the pump to charge the
accumul ator to operati ng pressure. I f the warni ng
l amp(s) do not turn off, go to step 3.
(2) I gni ti on off for 15 seconds.
(3) Start car. Wai t for di spl ays to return to normal
operati ng mode before proceedi ng.
(4) Wi th Shi ft l ever i n PARK, sl owl y depress brake
pedal and rel ease.
(5) Dri ve vehi cl e a short di stance. Duri ng thi s test
dri ve, be sure that the vehi cl e achi eves at l east 20 mph.
Then brake to at l east one compl ete stop and accel erate
sl owl y back up to at l east 20 mph.
(6) I f a functi onal probl em wi th the A.B.S. system i s
determi ned whi l e test dri vi ng a vehi cl e. Refer to the
Bendi x Anti -Lock 10 Di agnosti cs Manual for requi red
test procedures and proper use of the DRB I I tester.
CAUTION: The following are general precautions that
should be observed when servicing and diagnosing
the ABS systemand/or other vehicle systems. Failure
to observe these precautions may result in ABS
system damage.
(1) I f wel di ng work i s to be performed on the vehi cl e
usi ng an arc wel der, the (CAB) shoul d be di sconnected
before the wel di ng operati on begi ns.
(2) The (CAB) and hydraul i c assembl y 10 way con-
nectors shoul d never be connected or di sconnected wi th
the i gni ti on on.
(3) Some components of the ABS system are not
servi ced separatel y and must be servi ced as compl ete
assembl i es. Do not di sassembl e any component whi ch
i s desi gnated as non-servi ceabl e.
(4) Always de-pressurize the Hydraulic Accu-
mulator when performing any work that re-
quires disconnecting any hydraulic tube, flex
hose or fitting. TheABS systemuses brake fluid
at high pressure. Failure to de-pressurize the
accumulator may result in personal injury
and/or damage to painted surfaces.
Brake fl ui d wi l l damage pai nted surfaces. I f brake
fl ui d i s spi l l ed on any pai nted surfaces, wash off wi th
water i mmedi atel y.
DE-PRESSURI ZI NG HYDRAULI C ACCUMULA-
TOR
The ABS pump/motor assembl y keeps the hydraul i c
accumul ator charged between approxi matel y 11,032
and 13,790 kPa (1600 and 2000 psi ) anyti me the
i gni ti on i s i n the ON posi ti on. The pump/motor assem-
bl y cannot run i f the i gni ti on i s off or i f ei ther battery
cabl e i s di sconnected.
Unl ess otherwi se speci fi ed, the hydraul i c accumul a-
tor shoul d be de-pressuri zed before di sassembl i ng any
porti on of the hydraul i c system. The fol l owi ng proce-
dure shoul d be used to de-pressuri ze the hydraul i c
accumul ator:
(1) Wi th i gni ti on off, or ei ther battery cabl e di scon-
nected, pump the brake pedal a mi ni mum of 40 ti mes
usi ng approxi matel y 50 pounds of pedal force. A noti ce-
abl e change i n pedal feel wi l l occur when the accumu-
l ator becomes di scharged.
(2) When a defi ni te i ncrease i n pedal effort i s fel t,
pump the pedal a few addi ti onal ti mes. Thi s wi l l i nsure
removal of al l hydraul i c pressure from the brake sys-
tem.
WHEEL SPEED SENSOR CABLES
Proper i nstal l ati on of wheel speed sensor cabl es i s
cri ti cal to conti nued ABS system operati on. Be sure
that cabl es are i nstal l ed and routed properl y. Fai l ure to
i nstal l cabl es i n thei r retai ners, as shown i n Secti on 3
of thi s manual . May resul t i n contact wi th movi ng
parts or over extensi on of cabl es, resul ti ng i n an open
ci rcui t.
MECHANICAL DIAGNOSTICS AND SERVICE PRO-
CEDURES
SPECI AL SERVI CE TOOLS
Some di agnosti c procedures i n thi s secti on requi re
the use of speci al servi ce tool s. Each of these tool s i s
descri bed bel ow.
DRB II DIAGNOSTIC TESTER
Some of the di agnosti c procedures that are expl ai ned
i n thi s secti on requi re the use of the DRB I I DI AG-
NOSTI CS TESTER to i nsure that proper di agnosti cs
are performed. Refer to those secti ons for proper test-
i ng procedures and the DRB I I manual for i ts proper
operati onal i nformati on.
MST-6163 PRESSURE TESTER
Some di agnosti c procedures i n thi s manual requi re
the use of the MST-6163 pressure gauge and adaptor
(Fi g. 1) to measure accumul ator pressure duri ng cer-
tai n phases of operati on. The pressure gauge and
adaptor shoul d be i nstal l ed as fol l ows:
(1) De-pressuri ze the accumul ator by pumpi ng the
brake pedal a mi ni mum of 40 ti mes wi th the i gni ti on
off. The procedure i s ful l y expl ai ned under De-
Pressuri zi ng Hydraul i c Accumul ator whi ch i s de-
scri bed earl i er i n thi s System Di agnosi s Secti on.
WARNING: FAILURE TO DE-PRESSURIZE THE AC-
CUMULATOR PRIOR TO PERFORMING THIS OPERA-
TION MAY RESULT IN PERSONAL INJURY AND/OR
DAMAGE TO PAINTED SURFACES.
(2) Remove hydraul i c assembl y accumul ator port
pl ug,l ocated on ri ght hand si de of hydraul i c assembl y
(Fi g. 1).
(3) I nstal l pressure gauge to hydraul i c assembl y
adaptor (Fi g. 2) i nto accumul ator port of hydraul i c
assembl y, and ti ghten to 10 Nm (7.5 ft. l bs.) torque.
(4) I nstal l adaptor onto the pressure gauge hose
(Fi g. 2) and ti ghten the fi tti ng to 15 Nm (11 ft. l bs.)
torque.
(5) I nstal l pressure gauge and hose adaptor assem-
bl y onto the adaptor i nstal l ed i n the hydraul i c assem-
bl y accumul ator port. Then i nstal l the retai ni ng cl i p
i nto the grove on the accumul ator port adaptor (Fi g. 2).
MAKE SURE THAT THE RETAINING CLIP IS
INSTALLED ON THE ACCUMULATOR PORT
ADAPTOR BEFORE RE-PRESSURIZING THE
HYDRAULIC SYSTEM.
WARNING: BEFORE REMOVING PRESSURE GAUGE
AND ADAPTOR, BE SURE TO DE-PRESSURIZE THE
HYDRAULIC ASSEMBLY. THEN INSTALL AND
TIGHTEN ACCUMULATOR PORT PLUG TO 12 NM (9
FT. LBS.).
I t i s not necessary to bl eed the hydraul i c assembl y or
brake system after i nstal l ati on and removal of the
pressure gauge. Unl ess addi ti onal tubes, hoses, or
fi tti ngs were removed or l oosened.
I NTERMI TTENT FAULTS
As wi th al most any el ectroni c system, i ntermi ttent
faul ts i n the ABS system may be di ffi cul t to accuratel y
di agnose.
Most i ntermi ttent faul ts are caused by faul ty el ectri -
cal connecti ons or wi ri ng. When an i ntermi ttent faul t
i s encountered, check suspect ci rcui ts for:
(1) Poor mati ng of el ectri cal connector hal ves, or
el ectri cal termi nal s not ful l y seated i n the connector
body.
(2) I mproperl y formed or damaged el ectri cal termi -
nal s. Al l connector termi nal s i n a suspect ci rcui t shoul d
be careful l y reformed to i ncrease contact tensi on.
(3) Poor termi nal to wi re connecti on. Thi s requi res
removi ng the termi nal from the connector body and
i nspecti ng for proper termi nal to wi re connecti on.
I f a vi sual check does not fi nd the cause of the
probl em, operate the vehi cl e i n an attempt to dupl i cate
the condi ti on and record the Faul t Code.
Most fai l ures of the ABS system wi l l di sabl e the
Anti -Lock functi on for the enti re i gni ti on cycl e even i f
the faul t cl ears before i gni ti on key-off. There are some
fai l ure condi ti ons however, whi ch wi l l al l ow ABS op-
erati on to resume duri ng the i gni ti on cycl e i n whi ch a
fai l ure occurred. I f the fai l ure condi ti ons are no l onger
present.
The fol l owi ng condi ti ons may resul t i n i ntermi ttent
i l l umi nati on of the Red Brake Warni ng Lamp and/or
Amber Anti -Lock Warni ng Lamp. Al l other fai l ures wi l l
cause the l amp(s) to remai n on unti l the i gni ti on swi tch
i s turned off. Ci rcui ts and or components i nvol vi ng
these i nputs to the (CAB) shoul d be i nvesti gated i f a
compl ai nt of i ntermi ttent warni ng system operati on i s
encountered.
Fig. 1 Hydraulic Assembly Accumulator Port Plug
Location
Fig. 2 Pressure Gauge and Adapter Installed on Hy-
draulic Assembly
Low system vol tage. I f l ow system vol tage i s de-
tected by the (CAB), the (CAB) wi l l turn on the Amber
Anti -Lock Warni ng Lamp unti l normal system vol tage
i s achi eved. Once normal vol tage i s seen at the (CAB),
normal operati on resumes.
Low Brake Fl ui d. A l ow brake fl ui d condi ti on wi l l
cause the Red Brake Warni ng Lamp to i l l umi nate.
When the fl ui d sensor agai n i ndi cates an acceptabl e
fl ui d l evel , the Red Brake Warni ng Lamp wi l l go out.
Thi s condi ti on may exi st duri ng hard corneri ng or
whi l e the vehi cl e i s on a grade. I f the vehi cl e i s i n
moti on above 3 M.P.H. the Amber Anti -Lock Warni ng
Lamp wi l l al so be turned on.
Low Accumul ator Pressure. Low Accumul ator Pres-
sure wi l l cause both the Red Brake Warni ng and
Amber Anti -Lock Warni ng Lamps to i l l umi nate. Once
normal operati ng pressure i s achi eved, the l amps wi l l
exti ngui sh and the system wi l l return to normal opera-
ti on.
Addi ti onal l y, any condi ti on that resul ts i n i nterrup-
ti on of power to the (CAB) or hydraul i c assembl y may
cause the Red Brake Warni ng and Amber Anti -Lock
Warni ng Lamps to i l l umi nate i ntermi ttentl y.
Al l the condi ti ons (or faul ts) menti oned above, can
store a faul t code i n the (CAB) modul e.
ABS SYSTEM DIAGNOSTIC FEATURES
SYSTEM SELF DI AGNOSI S
The ABS system i s equi pped wi th a di agnosti c capa-
bi l i ty that may be used to assi st i n i sol ati on of ABS
faul ts. The features of the di agnosti cs system are
descri bed bel ow.
CONTROLLER ANTI -LOCK BRAKE (CAB)
Faul t codes are kept i n a Non-Vol ati l e memory unti l
ei ther erased by the techni ci an usi ng the DRB I I or
erased automati cal l y after 50 i gni ti on cycl es (key ON-
OFF cycl es). The onl y faul t that wi l l not be erased after
50 (KEY CYCLES) i s the (CAB) faul t. The (CAB) faul t
can onl y be erased by usi ng the DRB I I . More than one
faul t can be stored at a ti me. The number of key cycl es
si nce the most recent faul t was stored i s al so di spl ayed.
Most functi ons of the (CAB) and (ABS) system can be
accessed by the techni ci an for testi ng and di agnosti c
purposes by usi ng the DRB I I Di agnosti c Tester.
START-UP CYCLE
The START-UP CYCLE takes pl ace i mmedi atel y
after the i gni ti on swi tch i s turned on. I t i s an el ectri cal
check of basi c el ectri cal functi ons such as the System
Rel ay and Anti -Lock Warni ng Lamp Rel ay. Duri ng thi s
check, the Amber Anti -Lock Warni ng Lamp i s turned
on, then turned off at the end of the test. The test takes
approxi matel y 1 - 2 seconds to compl ete.
DRI VE-OFF CYCLE
The DRI VE-OFF CYCLE takes pl ace when the ve-
hi cl e reaches about 3 mi l es per hour the fi rst ti me after
an i gni ti on reset. Duri ng thi s test, the modul ator
sol enoi d val ves are acti vated bri efl y to test thei r func-
ti on. The DRI VE-OFF CYCLE wi l l be bypassed i f you
dri ve-off wi th the servi ce brake pedal depressed.
LATCHI NG VERSUS NON-LATCHI NG FAULTS
Some faul ts detected by the (CAB) are l atchi ng. The
faul t i s l atched and (ABS) functi on i s di sabl ed unti l the
i gni ti on swi tch i s reset (turned OFF/ON). Thus (ABS)
functi on i s di sabl ed even i f the ori gi nal faul t has
di sappeared duri ng the i gni ti on cycl e i n whi ch i t oc-
curred. Other faul ts are non-l atchi ng; any warni ng
l i ghts that are turned on are onl y on as l ong as the
faul t condi ti on exi sts. As soon as the condi ti on goes
away. The Amber Anti -Lock Warni ng Li ght i s turned
off. Al though a faul t code wi l l be set i n most cases.
(Exampl e: l ow accumul ator faul t wi l l not be stored for
a ti me of 2 mi nutes after the faul t i s detected).
BENDI X ABS SYSTEMS DI AGNOSTI CS
The Bendi x Anti -Lock 10 Brake System di agnosti cs.
Beyond the basi c mechani cal di agnosti cs, systems and
components covered earl i er i n thi s secti on, i s accom-
pl i shed by usi ng the DRB I I di agnosti c tester. See
testi ng procedures outl i ned i n the Bendi x Anti -Lock 10
Di agnosti cs Manual for the 1992 M.Y.
Pl ease reference the above menti oned manual . For
any further di agnosti c servi ce procedures that are
requi red on the Bendi x Anti -Lock 10 Brake System,
requi ri ng the use of the DRB I I di agnosti c tester.
ON CAR HYDRAULIC ABS COMPONENT SERVICE
WARNING: FAILURE TOFULLY DE-PRESSURIZE THE
HYDRAULIC ACCUMULATOR BEFORE PERFORM-
ING HYDRAULIC SYSTEM SERVICE OPERATIONS.
COULD RESULT IN INJURY TO SERVICE PERSON-
NEL AND OR DAMAGE TO PAINTED SURFACES. SEE
SECTION 2 FOR ADDITIONAL WARNINGS AND CAU-
TIONS.
GENERAL SERVICE PRECAUTIONS
The fol l owi ng are general precauti ons that shoul d be
observed when servi ci ng the Anti -Lock Brake System
and/or other vehi cl e systems. Fai l ure to observe these
precauti ons may resul t i n Anti -Lock brake system
damage.
I f wel di ng work i s to be performed on the vehi cl e,
usi ng an el ectri c arc wel der, the (CAB) connector
shoul d be di sconnected duri ng the wel di ng operati on.
The (CAB) or hydraul i c assembl y connector shoul d
never be connected or di sconnected wi th the i gni ti on
swi tch i n the ON posi ti on.
Many components of the Anti -Lock brake system are
not servi ceabl e and must be repl aced as an assembl y.
Do not attempt to disassemble any component
that is not designed to be a serviced component.
DE-PRESSURI ZI NG HYDRAULI C ACCUMULA-
TOR
The pump/motor assembl y wi l l keep the hydraul i c
accumul ator charged to approxi matel y 11,032 and
13,790 kPa (1600 and 2000 psi ) any ti me that the
i gni ti on i s i n the ON posi ti on. The pump/motor assem-
bl y cannot run i f the i gni ti on i s off or i f ei ther battery
cabl e i s di sconnected.
Unl ess otherwi se speci fi ed, the hydraul i c accumul a-
tor shoul d be de-pressuri zed before di sassembl i ng any
porti on of the hydraul i c system. The fol l owi ng proce-
dure shoul d be used to rel i eve the pressure i n the
hydraul i c accumul ator:
(1) Wi th i gni ti on off, or ei ther battery cabl e di scon-
nected, pump the brake pedal a mi ni mum of 40 ti mes,
usi ng approxi matel y 222 N (50 l bs.) pedal force. A
noti ceabl e change i n pedal feel wi l l occur, when the
accumul ator i s di scharged.
(2) When a defi ni te i ncrease i n pedal effort i s fel t,
pump pedal a few addi ti onal ti mes. Thi s wi l l i nsure
removal of al l hydraul i c pressure from the brake sys-
tem.
CHECKI NG BRAKE FLUI D LEVEL
CAUTION: Use only brake fluid conforming to DOT 3
specifications such as Mopar or Equivalent. Do not
use any fluid in the brake hydraulic system, which
contains a petroleum base. Do not use a container
which has been used for petroleum based fluids or a
container that is wet with water. Petroleum based
fluids will cause swelling and distortion of rubber
parts in the hydraulic brake systemand water will mix
with brake fluid, lowering the fluid boiling point. Keep
all brake fluid containers tightly capped to prevent
contamination.
The hydraul i c assembl y i s equi pped wi th a pl asti c
fl ui d reservoi r, wi th a fi l ter/strai ner l ocated i n the fi l l er
neck of each reservoi r secti on.
The Anti -Lock brake system requi res that the hy-
draul i c accumul ator be de-pressuri zed when checki ng
the fl ui d l evel . To check the brake fl ui d l evel , the
fol l owi ng procedure shoul d be used:
(1) Wi th the i gni ti on off, de-pressuri ze the hydraul i c
accumul ator by appl yi ng the brake pedal approxi -
matel y 40 ti mes, usi ng a pedal force of approxi matel y
220 N (50 l bs.). A noti ceabl e change i n pedal feel wi l l
occur when the accumul ator i s de-pressuri zed. When a
defi ni te i ncrease i n pedal effort i s fel t, pump pedal a
few addi ti onal ti mes. Thi s wi l l i nsure removal of al l
hydraul i c pressure from the brake system.
(2) Thoroughl y cl ean both reservoi r caps and sur-
roundi ng area of reservoi r before cap removal . Thi s wi l l
avoi d getti ng di rt i nto the reservoi r and brake fl ui d.
(3) I nspect the fl ui d l evel , see i nstructi ons on top of
reservoi r (Fi l l To Top Of The Whi te Screen I n Front
Fi l ter/Strai ner).
(4) Fi l l reservoi r to top of whi te screen on
fi l ter/strai ner (Fi g. 1) as requi red. Use onl y brake fl ui d
conformi ng to DOT 3 speci fi cati ons such as Mopar or
an Equi val ent.
(5) Repl ace reservoi r cap.
BLEEDI NG BRAKE SYSTEM
The Anti -Lock brake system must be bl ed anyti me
ai r i s permi tted to enter the brake hydraul i c system,
due to di sconnecti on of brake l i nes or hoses for servi ce.
I t i s i mportant to note that excessi ve ai r i n the brake
system may set a pri mary pressure/del ta P faul t i n the
(CAB). Refer to Di agnosi s, for further i nformati on.
Pressure bl eedi ng or manual bl eedi ng procedures
can be used when bl eedi ng the (ABS) hydraul i c system,
after brake l i nes or hoses have been di sconnected.
Bl eedi ng the (ABS) hydraul i c system i s al so necessary
after the repl acement of the hydraul i c assembl y or
wheel brakes.
Duri ng bl eedi ng operati ons, be sure that the brake
fl ui d l evel remai ns cl ose to the FULL l evel i n the
reservoi r. Check the fl ui d l evel peri odi cal l y duri ng
Fig. 1 ABS Fill Level On Filter/Strainer
the bl eedi ng procedure and add onl y DOT3 brake fl ui d
to the reservoi r as requi red.
PRESSURE BLEEDING (FIG. 2)
The brake l i nes may be pressure bl ed, usi ng a
standard di aphragm type pressure bl eeder. Onl y di a-
phragm type pressure bl eedi ng equi pment shoul d be
used to prevent ai r, moi sture, and other contami nants
from enteri ng the system. The fol l owi ng procedure
shoul d be used for pressure bl eedi ng of the master
cyl i nder and wheel ci rcui ts (Fi g. 2)
(1) I gni ti on shoul d be turned off and remai n off
throughout thi s procedure.
(2) De-pressuri ze the hydraul i c accumul ator by
pumpi ng the brake pedal a mi ni mum of 40 ti mes, as
ful l y descri bed i n thi s secti on under De-Pressuri zi ng
Hydraul i c Accumul ator.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(3) Remove both reservoi r caps (Fi g. 2).
(4) I nstal l pressure bl eeder adapter, on front reser-
voi r port and a cap on the rear port of the reservoi r
(Fi g. 2)
(5) Attach bl eedi ng equi pment to bl eeder adapter
(Fi g. 2). Charge pressure bl eeder to approxi matel y 138
kPa (20 psi ).
(6) Connect a transparent hose to the cal i per bl eed
screw (Fi g. 3). Submerge the free end of the hose i n a
cl ear gl ass contai ner, whi ch i s parti al l y fi l l ed wi th
cl ean, fresh brake fl ui d.
(7) Wi th the pressure bl eeder turned on, open the
cal i per bl eed screw 3/4 to one ful l turn al l owi ng brake
fl ui d to fl ow i nto the contai ner. Leave bl eed screw open
unti l a cl ear, bubbl e-free fl ow of brake fl ui d i s comi ng
from the hose i n the contai ner. I f the reservoi r has been
drai ned or the hydraul i c assembl y removed from the
car before the bl eedi ng operati on. Sl owl y pump the
brake pedal one or two ti mes whi l e the bl eed screw i s
open and fl ui d i s fl owi ng. Thi s wi l l hel p purge any
trapped ai r from the hydraul i c assembl y. Ti ghten
bl eeder screw to 10 Nm (7.5 ft. l bs.) torque.
(8) Step 7 above shoul d be done at al l wheel brakes,
fol l owi ng the order wheel by wheel as l i sted bel ow.
a) Left rear.
b) Ri ght rear.
c) Left front.
d) Ri ght front.
(9) After bl eedi ng i s compl eted at al l four wheel
brakes. Remove the pressure bl eedi ng equi pment and
bl eeder adapter by cl osi ng the pressure bl eeder val ve
and sl owl y unscrewi ng the bl eeder adapter from the
hydraul i c assembl y reservoi r. Failure to release
pressure in the reservoir will cause spillage of
brake fluid, and could result in personal injury
or damage to painted surfaces.
(10) Usi ng a syri nge or equi val ent method, remove
excess fl ui d from the reservoi r to bri ng the brake fl ui d
to the requi red fi l l l evel (Fi g. 1). I f brake fl ui d i s bel ow
the proper l evel add Mopar brake fl ui d or equi val ent
conformi ng to DOT 3, requi rements.
(11) I nstal l the reservoi r caps and turn on the i gni -
ti on to al l ow the (ABS) pump to charge the accumul a-
tor.
MANUAL BLEEDING
Brake l i nes can be bl ed, usi ng the manual bl eedi ng
method. Manual bl eedi ng i s a two person operati on,
one to pump the brake pedal and the other to bl eed
each wheel brake. The fol l owi ng procedure shoul d be
used:
De-pressuri zi ng the hydraul i c accumul ator i s done
by fol l owi ng the steps descri bed bel ow.
(1) Veri fy that the i gni ti on swi tch i s i n the off posi -
ti on.
pumpi ng the brake pedal a mi ni mum of 40 ti mes. Use
the procedure as descri bed i n De-Pressuri zi ng Hydrau-
l i c Accumul ator l i sted earl i er i n thi s secti on.
LIC ACCUMULATOR, PRIOR TO PERFORMING THIS
(3) Connect a transparent hose to the bl eed screw on
the wheel cyl i nder or brake cal i per that i s to be
Fig. 2 Pressure Bleeding Brake System
bl ed (Fi g. 3). Submerge the free end of the hose i n a
cl ear gl ass contai ner, whi ch i s parti al l y fi l l ed wi th
cl ean, fresh brake fl ui d.
(4) Sl owl y pump the brake pedal several ti mes,
usi ng ful l strokes of the pedal and al l owi ng approxi -
matel y fi ve seconds between pedal strokes. After two or
three strokes, conti nue to hol d pressure on the pedal ,
keepi ng i t at the bottom of i ts travel .
(5) Wi th pressure on the pedal , open the bl eed screw
3/4 to 1 ful l turn. Leave bl eed screw open unti l fl ui d no
l onger fl ows from the hose. Ti ghten the bl eed screw
and rel ease the pedal . Besurethat thebleed screw
it tightenedbeforebrakepedal isreleased, or air
may be drawn back into hydraulic system.
(6) Repeat Steps 3, 4 and 5 on each wheel brake,
unti l cl ear, bubbl e-free fl ui d fl ows from the hose.
(7) Repeat the above sequence at each wheel brake,
i n the fol l owi ng order:
a) Left rear.
b) Ri ght rear.
c) Left front.
d) Ri ght front.
(8) Fi l l the hydraul i c assembl y to the proper fi l l l evel
(Fi g. 1) usi ng Mopar or equi val ent brake fl ui d meet-
i ng DOT 3, requi rements.
(9) I nstal l both reservoi r caps on reservoi r.
(10) Turn the i gni ti on swi tch to the RUN posi ti on to
al l ow the Pump/Motor to turn on and recharge the
accumul ator.
PUMP/MOTOR SERVI CE (FI G. 4)
REMOVE
pumpi ng the brake pedal a mi ni mum of 40 ti mes.
Usi ng the procedure as descri bed i n De-Pressuri zi ng
Hydraul i c Accumul ator l i sted earl i er i n thi s secti on.
(2) Remove the fresh ai r i ntake ducts from the
engi ne i nducti on system.
(3) Loosen the l ow pressure hose cl amp (Fi g. 5) at
the hydraul i c assembl y.
(4) Di sconnect the hi gh pressure fl ui d l i ne routi ng
cl i p from the battery tray (Fi g. 5).
(5) Di sconnect el ectri cal connectors (i ncl udi ng the
pump/motor) that runs across the engi ne compart-
ment, i n the vi ci ni ty of the pump/motor assembl y hi gh
and l ow pressure hoses.
(6) Loosen the hi gh pressure hose tube nut at the
hydraul i c assembl y fi tti ng (Fi g. 5).
(7) Remove the hi gh and l ow pressure hose assembl y
(Fi g. 5) from the hydraul i c assembl y. Cap al l open ports
on reservoi r and hydraul i c assembl y to prevent brake
fl ui d from l eaki ng out.
(8) Di sconnect the pump/motor el ectri cal connector
(Fi g. 5) from the engi ne mount.
(9) Remove the pump/motor assembl y heat shi el d
bol t, from front of pump bracket.
(10) Remove front heat shi el d.
(11) Li ft pump/motor assembl y from bracket and
remove assembl y from the vehi cl e.
Fig. 3 Bleeding Brake System
Fig. 4 Pump/Motor Assembly Mounting
INSTALL
(1) I nstal l pump/motor assembl y i n reverse order of
removal .
(2) Ti ghten the pump/motor assembl y fl ui d l i nes to
the torque val ues shown bel ow.
Low pressure hose cl amp. 1 Nm (10 i n. l bs.)
Hi gh pressure hose fi tti ng to pump/motor assembl y.
16 Nm (145 i n. l bs.) Fi g. 5.
CAUTION:Be sure the high pressure hose routing
clip, is securely fastened to the battery tray and hose,
when hose is reinstalled (See Fig. 5).
BRAKE FLUI D PRESSURE AND RETURN
HOSES (FI G. 6)
REMOVE
(1) Remove the pump/motor assembl y from i ts
mounti ng bracket, see Pump/Motor Servi ce.
(2) Cut the 4 ti e straps that secure the hi gh and l ow
pressure hoses and pump/motor assembl y wi ri ng har-
ness together Fi g. 6.
(3) Remove the banjo bol t and spray shi el d from the
pump/motor assembl y Fi g. 6.
(4) Remove the hi gh and l ow pressure hose assembl y
from the pump/motor assembl y Fi g. 6.
I NSTALL
(1) The rubber O-Ri ngs used on the hi gh and l ow
pressure hose connecti ons to the pump/motor assem-
bl y. Shoul d be l ubri cated wi th cl ean brake fl ui d before
connecti ng hoses to pump/motor assembl y.
(2) Posi ti on hi gh and l ow pressure hoses and spray
shi el d on the pump/motor assembl y (Fi g. 6). Then
i nstal l the banjo bol t and torque to 14 Nm (120 i n.l bs.)
(3) Careful l y route wi ri ng harness al ong the si de of
the hi gh and l ow pressure hose assembl y Fi g. 6.
(4) I nstal l the 4 ti e straps around the hose assembl y
and wi ri ng harness per the sequence and l ocati ons
shown i n (Fi g. 6).
(5) I nstal l the pump/motor assembl y back on mount-
i ng bracket, See Pump/Motor Servi ce.
(6) Turn the i gni ti on swi tch to the RUN posi ti on.
Thi s wi l l turn on the pump/motor assembl y to charge
the hi gh pressure system.
Fig. 5 Brake Tube and Hose Routing
Fig. 6 Positioning Tie Straps
(7) Pump the brake system down as detai l ed i n
De-pressuri zi ng Hydraul i c Accumul ator i n thi s secti on
of the servi ce manual .
(8) Fi l l the hydraul i c assembl y to the proper l evel
wi th Mopar brake fl ui d or an equi val ent meeti ng DOT
3 speci fi cati ons. See Master Cyl i nder Fl ui d Level i n the
Servi ce Adjustments secti on of thi s group.
HYDRAULI C ASSEMBLY
REMOVE
(2) Remove fresh ai r i ntake duct and ai r cl eaner
from vehi cl e.
(3) Remove the wi ndshi el d washer fl ui d bottl e from
the vehi cl e.
(4) Di sconnect al l el ectri cal connectors from the hy-
draul i c assembl y.
(5) Remove as much fl ui d as possi bl e from the res-
ervoi r on the hydraul i c assembl y.
(6) Remove pump hi gh pressure hose fi tti ng (Fi g. 7)
from hydraul i c assembl y.
(7) Di sconnect pump return hose from steel tube.
Cap the end of the steel tube.
(8) Di sconnect the 4 brake tubes from the hydraul i c
assembl y (Fi g. 7).
(9) From under the i nstrument panel , posi ti on a
smal l screwdri ver between the center tang on the
retai ner cl i p and the pi n i n the brake pedal . Rotate the
screwdri ver enough to al l ow the retai ner cl i p center
tang to pass over the end of the brake pedal pi n.
Discard the old retainer clip, a new clip must be
used when hydraulic assembly is reinstalled
(Fig. 8).
(9) Remove the 4 hydraul i c assembl y to dash panel
mounti ng nuts from the hydraul i c assembl y mounti ng
studs, l ocated under i nstrument panel (Fi g. 8).
(10) Remove hydraul i c assembl y from vehi cl e.
INSTALL
(1) Posi ti on the hydraul i c assembl y i nto i ts mount-
i ng hol es on the dash panel of the vehi cl e.
(2) I nstal l and ti ghten the 4 hydraul i c assembl y to
dash panel mounti ng stud nuts (Fi g. 8) to 28 Nm (250
i n. l bs.) torque.
(3) Usi ng l ubri pl ate or equi val ent, coat the beari ng
surface of the brake pedal pi n.
(4) Connect push rod to pedal pi n and i nstal l a NEW
retai ner cl i p. HYDRAULIC ASSEMBLY PUSH ROD
MUST BE ASSEMBLED TO BRAKE PEDAL PIN
IN THE POSITION AS SHOWN IN (FIG. 8).
(5) I nstal l al l 4 brake tubes on the hydraul i c assem-
bl y (Fi g. 7) and torque tube fi tti ngs to thei r speci fi ed
val ues (See Torque Speci fi cati ons). I f proporti oni ng
val ves were removed from the hydraul i c assembl y,
i nstal l and ti ghten to 40 Nm (30 ft. l bs.) torque.
(6) I nstal l return hose on steel tube. Ti ghten the
return hose cl amp to 1 Nm (10 i n.l bs.)
(7) I nstal l hi gh pressure hose to hydraul i c assembl y
(Fi g. 7). Ti ghten the hose, to hydraul i c assembl y fi tti ng
to 16 Nm (145 i n. l bs)
(8) Fi l l hydraul i c assembl y brake fl ui d reservoi r to
top of screen on the reservoi r fi l ter/strai ner (Fi g. 9).
(9) Connect al l el ectri cal connectors to the hydraul i c
assembl y.
(10) Bl eed the enti re brake system, see Bl eedi ng
Brake System i n thi s secti on of the Servi ce Manual .
(11) Repl ace al l fresh ai r i ntake ducts, ai r cl eaner
and washer bottl e.
(12) Check that the brake fl ui d i n the hydraul i c
assembl y i s at the correct l evel before movi ng vehi cl e.
(See Checki ng Brake Fl ui d Level i n thi s secti on of the
servi ce manual ).
Fig. 7 Brake Tube and Hose Routing at Hydraulic
Unit
BRAKE FLUI D RESERVOI R
REMOVE
(2) Remove as much brake fl ui d as possi bl e from the
fl ui d reservoi r, usi ng a syri nge or equi val ent method.
(3) Usi ng Oi l Fi l ter Band Wrench, Speci al Tool
C-4065 or equi val ent l oosen bl adder accumul ator. Then
remove the bl adder accumul ator and brake fl ui d spray
shi el d from the hydraul i c assembl y (Fi g. 10). Remove
hi gh pressure banjo fi tti ng from hydraul i c assembl y.
(4) Usi ng needl e nose pl i ers, remove the three fl ui d
reservoi r retai ni ng pi ns from the hydraul i c assembl y
(Fi g. 11). Compress the barb on the opposi te si de of
retai ni ng pi n to prevent pi n from breaki ng.
(5) Remove reservoi r from hydraul i c assembl y by
CAREFULLY pryi ng between reservoi r and hydraul i c
assembl y wi th a bl unt pryi ng tool (Fi g. 12). Use a
rocki ng moti on to hel p di sengage reservoi r from grom-
mets whi l e pryi ng. BE EXTREMELY CAREFUL TO
AVOID DAMAGING OR PUNCTURING RESER-
VOIR DURING THIS PROCEDURE.
Fig. 8 Removing or Installing Hydraulic Assembly
Fig. 9 ABS Fill Level On Filter/Strainer
(6) Remove the brake fl ui d l evel sensor swi tch from
the reservoi r.
Remove swi tch by compressi ng the retai ni ng barbs
(Fi g. 13) on the end of the swi tch and then sl i de swi tch
out of the brake fl ui d reservoi r (Fi g. 14)
(7) Usi ng fi ngers, remove the 3 reservoi r grommets
(Fi g. 14) from the hydraul i c assembl y or reservoi r, and
di scard. Grommets must not to be reused when
reservoir is installed on hydraulic assembly.
INSTALL
(1) Thoroughl y l ubri cate the new reservoi r grom-
mets wi th cl ean brake fl ui d and i nstal l on reservoi r
outl et ports (Fi g. 14). The new reservoir grommets
supplied with reservoir, must ALWAYS be used.
(2) I nstal l brake fl ui d l evel swi tch i nto brake fl ui d
reservoi r (FI G. 14).
(3) Press reservoi r i nto hydraul i c assembl y BY
HAND, usi ng a rocki ng moti on to hel p seat reservoi r
i nto hydraul i c assembl y. Be sure that grommets are
ful l y seated i n the hydraul i c assembl y. DO NOT AT-
Fig. 10 Removing Bladder Accumulator
Fig. 11 Remove Reservoir Retaining Pins
Fig. 12 Remove Reservoir From Hydraulic Assembly
Fig. 13 Fluid Switch Retaining Barbs
TEMPT TO POUND RESERVOIR INTO HY-
DRAULIC ASSEMBLY, USING A HAMMER.
(4) Usi ng needl e nose pl i ers, i nstal l the 3 brake fl ui d
reservoi r to hydraul i c assembl y retai ni ng pi ns (Fi g.
11). Make sure that pi ns are ful l y i nstal l ed wi th barbs
extendi ng past reservoi r on opposi te si de.
(5) Rei nstal l the hi gh pressure hose, banjo fi tti ng
onto the hydraul i c assembl y and torque the fi tti ng to
13 Nm (10.0 ft.l bs).
(6) I nstal l the brake fl ui d spray shi el d and bl adder
accumul ator onto the hydraul i c assembl y. I nstal l the
bl adder accumul ator by hand to be sure i t does not bet
cross threaded. Be sure that the O-Ring on the
bladder accumulator is fully seated into the hy-
draulic assembly.
C-4065 or equi val ent, (Fi g. 10) torque the bl adder
accumul ator to 48 Nm (35 ft. l bs.)
(8) Fi l l the hydraul i c assembl y reservoi r to the top of
the screen on the fi l ter/strai ner (Fi g. 15). Usi ng fresh
cl ean brake fl ui d such as Mopar or equi val ent, con-
formi ng to DOT 3 requi rements.
HYDRAULI C BLADDER ACCUMULATOR
REMOVE
WARNING: FAILURE TO DE-PRESSURIZE THE HY-
DRAULIC ASSEMBLY/ACCUMULATOR BEFORE
PERFORMING THIS OPERATION, MAY RESULT IN
SURFACES OF THE VEHICLE.
C-4065 or equi val ent l oosen bl adder accumul ator. Then
remove the bl adder accumul ator and brake fl ui d shi el d
from the hydraul i c assembl y (Fi g. 16).
INSTALL
(1) I nstal l the brake fl ui d spray shi el d onto the
hydraul i c accumul ator (Fi g. 1).
(2) I nstal l the bl adder accumul ator onto the hy-
Fig. 14 Remove Brake Fluid Level Switch
Fig. 15 ABS Reservoir Fill Level On Filter/Strainer
Fig. 16 Remove And Install Bladder Accumulator
draul i c assembl y by hand. Be sure that the O-Ri ng on
the bl adder accumul ator i s ful l y seated i nto the hy-
draul i c assembl y.
C-4065 or equi val ent, (Fi g. 16) torque the bl adder
accumul ator to 48 Nm (35 ft. l bs.)
(4) Turn i gni ti on swi tch to the run posi ti on to ener-
gi ze the pump/motor assembl y and pressuri ze hydrau-
l i c system. Check for l eakage at the hydraul i c assembl y
to hydraul i c bl adder accumul ator fi tti ng.
(5) Agai n de-pressuri ze the accumul ator by pumpi ng
the brake pedal a mi ni mum of 40 ti mes as descri bed i n
De-Pressuri zi ng Hydraul i c Accumul ator i n thi s secti on
of the manual .
(6) Then check the brake fl ui d l evel i n the hydraul i c
assembl y reservoi r. I f brake fl ui d l evel i s l ow, fi l l
reservoi r to proper l evel (Fi g. 15) wi th Mopar brake
fl ui d or equi val ent conformi ng to DOT3 requi rements.
PROPORTI ONI NG VALVES (FI G. 17)
CAUTION: Proportioning valves should never be dis-
assembled or repaired in any way, repair is by re-
placement only.
REMOVE
DRAULIC ASSEMBLY/ACCUMULATOR PRIOR TO
(2) Remove fresh ai r i ntake ducts and ai r cl eaner.
(3) Remove pressure and return hose (Fi g. 5) from
hydraul i c uni t. (See Pressure and Return Hose Secti on
For Proper Removal Procedure).
(4) Remove brake tube from the proporti oni ng val ve
that requi res servi ci ng.
Fig. 17 ABS Proportioning Valve
Fig. 18 Hydraulic Assembly
(5) Remove proporti oni ng val ve requi ri ng servi ce
from the hydraul i c assembl y (Fi g. 18).
INSTALL
(1) I nstal l proporti oni ng val ve on hydraul i c assem-
bl y and ti ghten to 40 Nm (30 ft. l bs.) torque.
(2) I nstal l brake tube on proporti oni ng val ve.
Ti ghten tube nut to 16 Nm (145 i n. l bs.) torque.
(3) I nstal l hydraul i c pressure and return hoses.
Torque pressure hose to hydraul i c assembl y fi tti ng to
16 Nm (145 i n. l bs). Torque return hose to metal tube
hose cl amp to 1 Nm (10 i n. l bs.).
(4) I nstal l fresh ai r i ntake duct and ai r cl eaner.
(5) Bl eed the affected brake l i ne, see Bl eedi ng Brake
System i n thi s secti on.
ON CAR ELECTRONIC ABS COMPONENT SERVICE
CONTROLLER ANTI -LOCK BRAKE (FI G. 1)
REMOVE
(1) Turn vehi cl e i gni ti on off.
(2) Remove speed control servo from vehi cl e. (See
Secti on 8 i n the Servi ce Manual for speed control servo,
remove/i nstal l procedure.)
(3) Di sconnect the wi ri ng harness 60 way connector
(Fi g. 1) from the Control l er Anti -Lock Brake Modul e
(CAB). VERIFY THAT THE VEHICLE IGNITION
IS OFF, BEFORE REMOVING THE 60WAY CON-
NECTOR.
(4) Remove the 3 (CAB) modul e to fender shi el d
(5) Remove the (CAB) modul e from the vehi cl e.
INSTALL
(1) The Control l er Anti -Lock Brake (CAB) modul e
i nstal l ati on i s done i n the reverse order of removal .
Ti ghten the 60 way (CAB) el ectri cal connector re-
tai ni ng bol t to 5 Nm (40 i n. l bs.).
Ti ghten the (CAB) modul e to fender shi el d attachi ng
bol ts to 12 Nm (105 i n.l bs.).
SYSTEM RELAY, ANTI -LOCK WARNI NG LAMP
RELAY AND PUMP/MOTOR RELAYS (FI G. 2)
REMOVE/INSTALL
The service procedure for removing and in-
stalling both the SystemRelay, Yellow Light Re-
lay and Pump/Motor are the same. Though the
SystemRelay andYellowLight Relay areasingle
module, and thePump/Motor Relay is a separate
component.
(1) Di sconnect the wi ri ng harness el ectri cal connec-
tor from the rel ay housi ng (Fi g. 2).
(2) Remove the attachi ng screw hol di ng the rel ay
housi ng to the fender shi el d (Fi g. 2).
(3) I nstal l the new rel ay assembl y. By i nserti ng the
anti -rotati on tab on the assembl y i nto i ts hol e i n the
i nner fender. Then secure the rel ay assembl y to the
fender shi el d wi th i ts attachi ng screw.
(4) I nstal l the wi ri ng harness onto the rel ay assem-
bl y. Fi rml y pushi ng the connector onto the rel ay unti l
the l ocki ng tabs are ful l y engaged wi th the rel ay.
Fig. 1 Location Controller Anti-Lock Brake (CAB)
Fig. 2 Pump/Motor and Anti-Lock System Relays
DUAL FUNCTI ON PRESSURE SWI TCH
REMOVE
DRAULIC ASSEMBLY/ACCUMULATOR PRIOR TO
CAUTION: THROUGHLY CLEAN THE BOTTOM OF
THE HYDRAULIC ASSEMBLY IN THE AREA OF THE
DUAL FUNCTION PRESSURE SWITCH, BEFORE RE-
MOVING THE SWITCH FROM HYDRAULIC ASSEM-
BLY. USE MOPAR BRAKE PARTS CLEANER OR AN
EQUIVALENT. EXTREME CARE MUST BE USED SO
NO DIRT IS ALLOWED TO ENTER THE HYDRAULIC
ASSEMBLY THROUGH WHERE THE DUAL FUNC-
TION PRESSURE SWITCH IS MOUNTED. ANY DIRT
ENTERING HYDRAULIC ASSEMBLY MAY PLUG IN-
TERNAL PASSAGES CAUSING A HYDRAULIC AS-
SEMBLY FAILURE.
(2) Rai se vehi cl e See Hoi sti ng, Group 0.
(3) From under vehi cl e, di sconnect the wi ri ng har-
ness connectors from the dual functi on pressure swi tch
and boost pressure transducer (Fi g. 3) on the bottom of
the hydraul i c assembl y.
WARNING: WEAR EYE PROTECTION WHEN PER-
FORMING THE FOLLOWING PROCEDURE. SERIOUS
EYE INJURY CAN RESULT FROM BRAKE FLUID
CONTACTING THE EYES.
(4) Be sure that the hydraulic system is de-
pressurized. Remove the dual functi on pressure
swi tch from the hydraul i c assembl y usi ng Socket,
Speci al Tool 6607. Access to the swi tch i s from under
the vehi cl e usi ng a l ong extensi on.
INSTALL
CAUTION: Be sure that the dual function pressure
switch is thoroughly cleaned using Mopar Brake
Parts Cleaner or an equivalent before installing it into
the hydraulic assembly. Wet the O-ring seals on the
switch with fresh clean brake fluid before installing it
into the hydraulic assembly.
CAUTION: Do not insert dual function pressure
switch into hydraulic assembly using the socket and
ratchet. Cross threading of the switch may occur.
(1) I nstal l the dual functi on pressure swi tch i nto the
hydraul i c assembl y by hand unti l the O-ri ng seal s are
seated.
(2) Usi ng Socket, Speci al Tool 6607, torque the dual
functi on pressure swi tch i nto the hydral i c assembl y to
12 Nm (9 ft. l bs.).
(3) Connect the wi ri ng harness connectors (Fi g. 3)
onto the dual functi on pressure swi tch and the boost
pressure transducer. Be sure the l ocki ng tabs on the
connectors are ful l y engaged on the swi tches.
(4) Lower the vehi cl e.
(5) Turn the i gni ti on swi tch to the on posi ti on and l et
the system pressuri ze. Check for any l eaks at the dual
functi on pressure swi tch.
(6) Ful l y de-pressuri ze the hydraul i c assembl y a
second ti me to purge any ai r out that may have entered
hydraul i c assembl y when the swi tch was removed.
Turn the i gni ti on swi tch to the on posi ti on and l et the
system pressuri ze agai n.
(7) Road test vehi cl e to i nsure that the brake system
i s performi ng correctl y.
WHEEL SPEED SENSORS
I nspect tone wheel s (Fi g. 4) for any mi ssi ng or broken
teeth, thi s can cause errati c speed sensor si gnal s.
Tone wheel s shoul d show no evi dence of contact wi th
the wheel speed sensor. I f contact was made, determi ne
cause and correct.
Excessi ve runout of the tone wheel s can cause errati c
wheel speed sensor si gnal s. Repl ace assembl y i f runout
exceeds approxi matel y 0.25 mm (0.010 i nch).
Fig. 3 Dual Function Pressure Switch And Pressure
Transducer Wiring
FRONT WHEEL SPEED SENSOR (REMOVE)
(1) Rai se vehi cl e and remove front wheel and ti re
assembl y.
(2) Remove screw from cl i p (Fi g. 5) that hol ds sensor
assembl y grommet i nto fender shi el d.
(3) Careful l y, pul l sensor assembl y grommet from
fender shi el d. When removing grommet from
fender shield, do not pull on speed sensor cable.
(4) Unpl ug speed sensor cabl e connector, from ve-
hi cl e wi ri ng harness.
(5) Remove the 2 screws (Fi g. 5) that secure the
speed sensor cabl e, routi ng tube to the fender wel l .
(6) Remove the 2 sensor assembl y grommets from
the retai ner bracket, on the strut damper (Fi g. 5).
(7) Remove speed sensor assembl y to steeri ng
knuckl e attachi ng bol t (Fi g 6).
(8) Careful l y, remove sensor head from steeri ng
knuckl e. I f the sensor has sei zed, due to corrosi on, use
a hammer and punch to tap edge of sensor ear (Fi g. 6),
rocki ng the sensor si de to si de unti l free. DO NOT
USE PLIERS ON SENSOR HEAD.
INSTALL
(1) Connect the wheel speed sensor cabl e connector,
to the vehi cl e wi ri ng harness.
(2) Push sensor assembl y grommet i nto hol e i n
fender shi el d. I nstal l cl i p and screw (Fi g 6). Torque
screw to 4 Nm (35 i n. l bs.).
(3) I nstal l speed sensor cabl e grommets i n bracket
on strut damper (Fi g. 5).
(4) I nstal l speed sensor cabl e routi ng tube to fender
wel l (Fi g. 5). Torque both screws to 4 Nm (35 i n. l bs.).
(5) Coat the speed sensor wi th Hi gh Temperature
Mul ti -purpose E.P. Grease before i nstal l i ng i nto the
steeri ng knuckl e. I nstal l speed sensor attachi ng screw
and ti ghten to 7 Nm (60 i n. l bs.)
CAUTION: Proper installation of wheel speed sensor
cables is critical to continued system operation. Be
sure that cables are routed correctly and installed in
all retainers. Failure to properly route and install
cables in retainers, as shown in this section. May
result in contact with moving parts and/or over ex-
tension of cables, resulting in an open circuit.
Fig. 5 Front Wheel Speed Sensor And Cable Rout-
ing FWD/AWD
Fig. 4 Tone Wheel (Typical)
Fig. 6 Removing Speed Sensor (Typical)
REAR WHEEL SPEED SENSOR
REMOVAL FRONT WHEEL DRIVE
(1) Rai se vehi cl e and remove rear wheel and ti re
assembl y.
(2) Remove rear speed sensor wi ri ng grommet re-
tai ni ng bracket. Remove grommet from underbody and
pul l harness through hol e i n underbody. (Fi g. 7) When
removing grommet from underbody, do not pull
on speed sensor cable.
(4) Remove the 4 arrow head cl i ps whi ch route the
speed sensor wi ri ng al ong the underbody (Fi g. 7).
(5) Remove the wi ri ng to frame rai l attachi ng
bracket (Fi g. 7).
(6) Loosen and remove the rear axl e U-bol t nuts,
whi ch retai n the rear speed sensor cabl e assembl y
mounti ng bracket. Remove the bracket from the ve-
hi cl e.
(7) Remove speed sensor head to rear brake support
pl ate, attachi ng bol t (Fi g. 8).
(9) Careful l y, remove sensor head from rear brake
support pl ate assembl y. I f the sensor has sei zed, due to
corrosi on. Use a hammer and punch (Fi g. 6) to tap edge
of sensor ear, rocki ng the sensor si de to si de unti l free.
DO NOT USE PLIERS TO TRY TO REMOVE
SENSOR HEAD.
INSTALL FRONT WHEEL DRIVE.
(1) Posi ti on the rear speed sensor cabl e and bracket
assembl y on the rear axl e U-bol t (Fi g. 7). I nstal l the
rear axl e U-bol t nuts and ti ghten to 88 Nm (65 ft. l bs.)
torque.
(2) Coat the speed sensor head wi th Hi gh Tempera-
ture Mul ti -Purpose E.P. Grease. I nstal l the speed sen-
sor head i nto rear brake support pl ate. On the dri ver
si de the speed sensor wi re i s routed between the brake
tube and the wheel brake. Torque the speed sensor to
rear brake support pl ate attachi ng bol t (Fi g. 8) to 7
Nm (60 i n.l bs.)
(3) Bend the speed sensor cabl e assembl y, rubber
coated secti on toward the front of the vehi cl e. Posi ti on
the anti -rotati on tab of the sensor assembl y frame rai l
bracket i nto i ts respecti ve hol e. I nstal l the screw that
attaches the frame rai l bracket to the frame and torque
to 4 Nm (35 i n. l bs).
(4) Connect the speed sensor cabl e assembl y to the
vehi cl e rear wi ri ng harness. I nstal l the speed sensor
cabl e assembl y grommet (Fi g. 5) back i nto the under-
body wi ri ng access hol e.
(5) Posi ti on the rear sensor assembl y grommet re-
tai ni ng bracket back on the underbody, (Fi g. 7) maki ng
sure the bracket does not pi nch the sensor wi ri ng.
I nstal l the 2 bracket mounti ng screws and torque to 4
Nm (35 i n.l bs.).
(6) Route the speed sensor wi ri ng al ong the vehi cl e
frame rai l (Fi g. 7) and i nstal l the 4 arrow head cl i ps.
(7) I nstal l the rear wheel assembl y and torque the
wheel stud nuts to 129 Nm (95 ft.l bs.)
Fig. 7 Rear Wheel Speed Sensor Routing FWD
Fig. 8 Rear Speed Sensor F.W.D.
REMOVE ALL WHEEL DRIVE
(1) Rai se vehi cl e and remove rear wheel and ti re
assembl y.
(2) Remove rear speed sensor wi ri ng grommet, re-
tai ni ng bracket. Remove grommet from underbody and
pul l harness through hol e i n underbody. (Fi g. 9) When
removing grommet from underbody, do not pull
on speed sensor cable.
(4) Remove the 4 arrow head cl i ps whi ch route the
speed sensor cabl e al ong the underbody (Fi g. 9).
(5) Remove the speed sensor cabl e and i ts frame rai l
routi ng bracket as an assembl y. (Fi g. 9).
(6) Remove the 2 bol ts whi ch secure the speed sensor
cabl e assembl y mounti ng bracket to the rear axl e.
Remove the bracket assembl y from the vehi cl e by
rotati ng the bracket and removi ng i t from under the
brake tube.
(7) Remove the speed sensor assembl y attachi ng bol t
(Fi g. 10).
(9) Careful l y, remove sensor head from rear axl e
assembl y casti ng. I f the sensor has sei zed, due to
corrosi on. Use a hammer and punch (Fi g. 6) to tap edge
of sensor ear, rocki ng the sensor si de to si de unti l free.
DONOT USE PLIERSTOTRY TOREMOVE THE
SPEED SENSOR HEAD.
INSTALL ALL WHEEL DRIVE.
(1) Posi ti on the rear wheel speed sensor assembl y
bracket under the brake tube (Fi g. 9). Hand start the
outboard bracket attachi ng bol t. Al i gn the brake tube
cl i p and sensor assembl y bracket and secure wi th bol t.
Torque both bol ts to 17 Nm (145 i n. l bs.)
(2) Coat the wheel speed sensor head wi th Hi gh
Temperature Mul ti -Purpose E.P. Grease. I nstal l the
wheel speed sensor head i nto the rear axl e casti ng (Fi g.
10) and i nstal l bol t. Torque the speed sensor to rear
axl e attachi ng bol t to 7 N (60 i n.l bs.)
(3) Bend the speed sensor cabl e assembl y, rubber
coated secti on toward the rear of the vehi cl e. Posi ti on
the anti -rotati on tab of the sensor assembl y frame rai l
bracket, i nto i ts respecti ve hol e. I nstal l the screw that
attaches the frame rai l bracket to the frame and torque
to 4 Nm (35 i n. l bs).
(4) Connect the speed sensor cabl e assembl y to the
vehi cl e rear wi ri ng harness. I nstal l the speed sensor
cabl e assembl y wi ri ng grommet (Fi g. 9) back i nto the
underbody wi ri ng access hol e.
(5) Posi ti on the rear speed sensor cabl e assembl y
grommet retai ni ng bracket on the underbody, (Fi g. 9)
maki ng sure the bracket does not pi nch the sensor
wi ri ng. I nstal l the 2 bracket mounti ng screws and
torque to 4 Nm (35 i n.l bs.).
(6) Route the speed sensor wi ri ng al ong the vehi cl e
frame rai l (Fi g. 9) and i nstal l the 4 arrow head cl i ps.
(7) I nstal l the rear wheel assembl y and torque the
wheel stud nuts to 129 Nm (95 ft.l bs.)
Fig. 9 Rear Wheel Speed Sensor Routing A.W.D
Fig. 10 Rear Wheel Speed Sensor Mounting A.W.D
SPECI FI CATI ONS
BRAKE SYSTEM COMPONENTS
BRAKE ACTUATI ON SYSTEM
TI GHTENI NG REFERENCE
REAR SUSPENSION AND DRIVELINE
CONTENTS
page page
ALL WHEEL DRIVE REAR SUSPENSION . . . . . . 5
(ALL WHEEL DRIVE) . . . . . . . . . . . . . . . . . . . . 9
REAR DRIVE LINE MODULE ASSEMBLY SERVICE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 11
REAR DRIVE LINE MODULE VACUUM
ACTUATION DIAGNOSIS . . . . . . . . . . . . . . . . 37
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 42
TWO WHEEL DRIVE REAR SUSPENSION . . . . . 1
TWO WHEEL DRI VE REAR SUSPENSI ON
INDEX
page page
Rear Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . 2
Rear Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rear Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear Wheel AlignmentFront Wheel Drive
Van/Wagons Only . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
The rear suspensi on on these vehi cl es i ncl ude l eaf
spri ngs and a tubeandcastingaxle. I t i s desi gned to
handl e vari ous l oad requi rements.
The shackl e angl es provi de i ncreasi ng suspensi on
rates as the vehi cl e i s l oaded. Thi s provi des a comfort-
abl e unl oaded ri de and al so ampl e suspensi on travel
when the vehi cl e i s l oaded.
The rear shock absorbers are mounted at an angl e,
paral l el to the spri ngs and forward at the top. Thi s
desi gn provi des greater stabi l i ty i n addi ti on to control -
l i ng ri de moti on.
CAUTION: The installation of aftermarket load level-
ing devices is prohibited on these models. Adjustable
air shocks or helper springs will cause the rear brake
height sensing proportioning valve to sense a light
load condition. The loaded condition is being sup-
ported by add-on devices. See Brakes Group 5 of this
manual for detailed information on the rear brake height
sensing proportioning valve.
REAR SPRINGS
REMOVAL
(1) Rai se vehi cl e on frame contact hoi st to a comfort-
abl e worki ng posi ti on.
(2) Usi ng fl oor stands under the axl e assembl y, rai se
axl e assembl y to rel i eve wei ght on rear spri ngs.
(3) Di sconnect the actuator assembl y for hei ght
sensi ng proporti oni ng val ve (Fi g. 1). Di sconnect l ower
ends of rear shock absorbers at axl e brackets.
(4) Loosen and remove U bol t nuts and washers,
remove U bol ts.
(5) Lower rear axl e assembl y, permi tti ng rear
spri ngs to hang free.
(6) Loosen and remove four bol ts from front spri ng
hanger.
(7) Loosen and remove rear spri ng shackl e nuts and
pl ate, remove shackl e from spri ng.
(8) Loosen and remove front pi vot bol t from front
spri ng hanger.
I NSTALLATI ON
(1) Assembl e shackl e, bushi ngs and pl ate on rear of
spri ng and rear spri ng hanger, start shackl e bol t nuts.
Do not ti ghten.
(2) Assembl e front spri ng hanger to front of spri ng
eye and i nstal l pi vot bol t and nut. Do not ti ghten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(3) Rai se front of spri ng and i nstal l four hanger
bol ts, ti ghten to 61 Nm (45 ft. l bs.) torque. Connect
actuator assembl y for hei ght sensi ng proporti oni ng
val ve.
(4) Rai se axl e assembl y i nto correct posi ti on wi th
axl e centered under spri ng center bol t.
REAR SUSPENSION AND DRIVELINE 3 - 1
(5) I nstal l U bol ts, nuts and washers. Ti ghten U
bol t nuts to 81 Nm (60 ft. l bs.) torque.
(6) I nstal l shock absorbers and start bol ts.
(7) Lower vehi cl e to fl oor and wi th ful l wei ght of
vehi cl e on wheel s, ti ghten component fasteners as
fol l ows:
Front pi vot bol t 142 Nm (105 ft. l bs.)
Shackl e nuts 47 Nm (35 ft. l bs.)
Shock absorber bol ts:
Upper 115 Nm (85 ft. l bs.)
Lower 108 Nm (80 ft. l bs.)
(8) Rai se vehi cl e and connect rear brake proporti on-
i ng val ve spri ng and adjust. Refer to Adjusti ng Proce-
dure i n the Brake Secti on of thi s manual .
REAR SHOCK ABSORBERS
(1) Li ft vehi cl e on a frame contact hoi st.
(2) Support axl e wi th a jack stand.
(3) Remove l ower shock bol t.
(4) Whi l e hol di ng shock, remove upper shock bol t.
(5) To I nstal l , Reverse Removal Procedure.
REAR WHEEL ALIGNMENTFRONT WHEEL DRIVE
VAN/WAGONS ONLY
Al i gnment adjustment i f requi red, i s made by addi ng
0.010 shi ms between the spi ndl e mounti ng surface and
axl e casti ng. Each shi m equal s wheel change by .3, as
shown i n fi gures 3 through 6. These shi ms are to be
used on two wheel dri ve vehi cl es onl y.
I f rear wheel al i gnment i s requi red, pl ace vehi cl e on
al i gnment rack and check al i gnment speci fi cati ons.
When recordingrear toe-in (vehiclebacked onto
alignment rack) REMEMBER to reverse sign
convention; a total toe-in on direct reading
charts is actually toe-out while driving. Mai ntai n
rear al i gnment wi thi n Chrysl er Corporati on recom-
mendati ons found i n Speci fi cati ons.
I NSTALLATI ON OF REAR ALI GNMENT SHI MS
(1) Bl ock front ti res so vehi cl e wi l l not move.
(2) Rel ease parki ng brake.
(3) Hoi st vehi cl e so that rear suspensi on i s i n ful l
rebound and ti res are off the ground. See Hoi sti ng i n
Lubri cati on and Mai ntenance, Group 0.
(4) Remove wheel and ti re assembl y.
(5) Pry off grease cap.
(6) Remove cotter pi n and castl e l ock.
(7) Remove adjusti ng nut.
(8) Remove brake drum (Fi g. 2).
(9) Loosen four (4) brake assembl y and spi ndl e
mounti ng bol ts enough to al l ow cl earance for shi m
i nstal l ati on (Fi g. 3). Donot removemountingbolts.
Fig. 1 Rear Suspension
3 - 2 REAR SUSPENSION AND DRIVELINE
(10) I nstal l shi ms as shown i n Fi gs. 4, 5, 6 and 7 for
desi red wheel change. No more than two shi ms on each
spi ndl e shoul d be used to bri ng al i gnment wi thi n
acceptabl e range.
Wheel change by .3 per shim.
(11) Ti ghten four (4) brake assembl y and spi ndl e
mounti ng bol ts. Ti ghten to 108 Nm (80 ft. l bs.) torque.
(12) I nstal l brake drum.
Fig. 4 Shim Installation for Toe-Out (typical)
Fig. 2 Remove Brake Drum
Fig. 3 Loosen Mounting Bolts
Fig. 5 Shim Installation for Toe-In (typical)
Fig. 6 Shim Installation for Positive Camber (typical)
Fig. 7 Shim Installation for Negative Camber (typi-
cal)
(13) I nstal l washer and nut. Ti ghten adjusti ng nut
to 27-34 Nm (240-300 i n. l bs.) torque whi l e rotati ng
wheel . Back off adjusti ng nut wi th wrench to com-
pl etel y rel ease beari ng prel oad. Fi nger ti ghten adjust-
i ng nut.
(14) Posi ti on nut l ock wi th one pai r of sl ots i n-l i ne
wi th cotter pi n hol e. I nstal l cotter pi n. The end pl ay
shoul d be 0.025-0.076 mm (0.001-0.003 i nch). Cl ean
and i nstal l grease cap.
(15) I nstal l wheel and ti re assembl y. Ti ghten wheel
nut to 129 Nm (95 ft. l bs.) torque.
(16) Lower vehi cl e.
(17) Check al i gnment speci fi cati ons.
REAR SWAY BAR
The sway bar i nterconnects both si des of the rear
axl e and attaches to the rear frame rai l s usi ng 2 rubber
i sol ated l i nk arms.
Jounce and rebound movements affecti ng one wheel
are parti al l y transmi tted to the opposi te wheel to
reduce body rol l .
Attachment to the rear axl e tube, and rear frame
rai l s i s through rubber-i sol ated bushi ngs. Al l parts are
servi ceabl e, and the sway bar to axl e bushi ngs are spl i t
for easy removal and i nstal l ati on. The spl i t i n the
bushi ng shoul d be posi ti oned up when i nstal l ed on the
vehi cl e.
The 2 rubber i sol ated l i nk arms are connected to the
rear frame rai l s by brackets whi ch are bol ted to the
bottom of the frame rai l s (Fi g. 8).
REMOVAL
(1) Rai se and support the vehi cl e. See Hoi sti ng i n
(2) Remove the 2 l ower bol ts whi ch hol d the sway
bar to the l i nk arm on each si de of the vehi cl e (Fi g. 2).
(3) Loosen but do not ful l y remove the four bol ts that
attach the sway bar bushi ng retai ners to the rear axl e
tube brackets.
(4) Whi l e hol di ng the sway bar i n pl ace. Ful l y re-
move the 4 bol ts l oosened i n step 3.
(5) Remove sway bar from vehi cl e.
Fig. 8 Rear Sway Bar
Fig. 9 Rear Sway Bar Remove and Replace
(6) I f the l i nk arms need to be servi ced, remove the
upper l i nk arm to bracket bol t. Then remove l i nk arm
from frame rai l attachi ng bracket.
I NSPECTI ON
I nspect for broken or di storted cl amps, retai ners, and
bushi ngs. I f bushi ng repl acement i s requi red, the sway
bar to axl e bushi ng can be removed by openi ng the
spl i t.
(1) I nstal l the l i nk arms onto the frame rai l brack-
ets. DO NOT TI GHTEN.
(2) Posi ti on the axl e to sway bar bushi ng on the
sway bar wi th the sl i t i n the bushi ng faci ng up.
(3) Li ft the bar assembl y onto the rear axl e and
i nstal l the retai ners and four bol ts. DO NOT
TI GHTEN.
(4) I nstal l the two l ower l i nk arm bol ts to the sway
bar. DO NOT TI GHTEN.
(5) Lower the vehi cl e so the wei ght of the vehi cl e i s
on al l four ti res. Wi th the vehi cl e at i ts curb hei ght,
ti ghten al l attachi ng bol ts to the proper torque l i sted
bel ow.
Bushi ng to axl e bracket Bol ts 61 Nm (45 ft. l bs.)
Li nk arm to frame rai l bracket 61 Nm (45 ft. l bs.)
Sway Bar to Li nk Arm 61 Nm (45 ft. l bs.)
Frame Rai l Bracket to Frame Rai l 33 Nm (290 i n.
l bs.)
For the fastener l ocati ons referri ng to the torques
l i sted above see fi gures 1 and 2.
ALL WHEEL DRI VE REAR SUSPENSI ON
INDEX
page page
Jounce Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . 8
Rear Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
The rear suspensi on on these vehi cl es i ncl ude l eaf
spri ngs and a tubeandcastingaxle. I t i s desi gned to
handl e vari ous l oad requi rements.
The shackl e angl es provi de i ncreasi ng suspensi on
rates as the vehi cl e i s l oaded. Thi s provi des a comfort-
abl e unl oaded ri de and al so ampl e suspensi on travel
when the vehi cl e i s l oaded.
The rear shock absorbers are mounted at an angl e,
paral l el to the spri ngs and forward at the top. Thi s
desi gn provi des greater stabi l i ty i n addi ti on to control -
l i ng ri de moti on.
CAUTION: The installation of aftermarket load level-
ing devices is prohibited on these models. Adjustable
air shocks or helper springs will cause the rear brake
height sensing proportioning valve to sense a light
load condition. The loaded condition is being sup-
ported by add-on devices. See Brakes Group 5 of this
manual for detailed information on the rear brake height
sensing proportioning valve.
REAR WHEEL BEARINGS
The rear wheel beari ngs used i n the Al l Wheel Dri ve
system are si mi l ar to the beari ngs used i n the front
wheel s. The beari ngs are permanentl y seal ed and
requi re no mai ntenance. The beari ng and hub are
servi ced as an assembl y.
Defecti ve or damaged rear wheel beari ngs produce a
vi brati on or growl noi se. The noi se wi l l conti nue after
the transmi ssi on i s shi fted to NEUTRAL and the
vehi cl e i s coasti ng.
To tel l the di fference between rear wheel beari ng
noi se and di fferenti al gear noi se, road test the vehi cl e
on a smooth road. Wi th traffi c permi tti ng, swerve the
vehi cl e sharpl y ri ght-to-l eft. I f the noi se i s caused by a
rear wheel beari ng, i t wi l l usual l y i ncrease i n l oudness
when the vehi cl e i s swerved.
REMOVAL
(2) Remove wheel and ti re assembl y.
WARNING: DUST INSIDE OF BRAKE DRUM MAY
CONTAIN ASBESTOS FIBERS. BREATHING ASBES-
TOS FIBERS CAN CAUSE SERIOUS BODILY HARM,
SUCH AS ASBESTOSIS OR CANCER. EXTREME
CARE SHOULD BE TAKEN WHILE SERVICING
BRAKE ASSEMBLIES OR COMPONENTS.
(3) Remove brake drum (Fi g. 1).
(4) Remove cotter pi n, nut l ock, spri ng washer and
hub nut (Fi g. 2).
(5) Remove hal f shaft fl ange retai ni ng bol ts (Fi g. 3).
(6) The hal f shaft i s spri ng l oaded. Compress i nner
hal f shaft joi nt sl i ghtl y and pul l downward to cl ear rear
carri er output shaft. Then pul l hal f shaft assembl y
i nboard to remove (Fi g. 4).
CAUTION: The half shaft, when installed, acts as a
bolt and secures the hub/bearing assembly. If the
vehicle is to be supported or moved on its wheels,
install and torque a bolt through the hub. This will
insure that the hub/bearing assembly cannot loosen.
(7) Remove wheel beari ng mounti ng bol ts (Fi g 5).
(8) Remove wheel beari ng and hub assembl y (Fi g 6).
(9) Replacement of the grease seal is recom-
mended whenever this service is performed.
I NSTALLATI ON
(1) I nstal l new hub and beari ng assembl y and
ti ghten screws i n a cri s-cross pattern to 130 Nm (96 ft.
l bs.).
CAUTION: Knuckle and bearing mounting surfaces
must be smooth and completely free of foreign ma-
terial or nicks.
(2) Use speci al tool No. 6536-A to i nstal l seal i f seal
repl acement i s requi red.
CAUTION: During any service procedures where
knuckle and half shaft are separated, thoroughly
clean seal and wear sleeve and lubricate BOTH com-
ponents.
Fig. 1 Remove Rear Drum
Fig. 2 Hub Nut Assembly
Fig. 3 Half Shaft Flange Retaining Bolts
Fig. 4 Half Shaft Removal
(3) Lubri cate the FULL ci rcumference of the seal
(and wear sl eeve) wi th MOPAR Mul ti -Purpose Lubri -
cant, or equi val ent.
(4) I nstal l washer and hub nut after cl eani ng forei gn
matter from threads.
(5) Wi th brakes appl i ed, ti ghten nut to 244 Nm
(180 ft. l bs.).
(6) I nstal l spri ng washer, nut l ock and new cotter
pi n. Wrap cotter pi n prongs ti ghtl y around nut l ock.
nuts to 115 Nm (85 ft. l bs.).
REAR SPRINGS
REMOVAL
(1) Rai se vehi cl e on frame contact hoi st to a comfort-
abl e worki ng posi ti on.
(2) Usi ng fl oor stands under the axl e assembl y, rai se
axl e assembl y to rel i eve wei ght on rear spri ngs.
(3) Di sconnect the actuator assembl y for hei ght
sensi ng proporti oni ng val ve. Di sconnect l ower ends of
rear shock absorbers at axl e brackets.
(4) Loosen and remove U-bol t nuts and washers,
remove U-bol ts.
(5) Lower rear axl e assembl y, permi tti ng rear
spri ngs to hang free.
(6) Loosen and remove four bol ts from front spri ng
hanger.
(7) Loosen and remove rear spri ng shackl e nuts and
pl ate, remove shackl e from spri ng.
spri ng hanger.
(9) Separate the rear shackl e pl ate, from the shackl e
and pi n assembl y. Remove the shackl e and pi n assem-
bl y from the spri ng.
spri ng hanger (Fi g. 7).
I NSTALLATI ON
(1) Assembl e shackl e and pi n assembl y, bushi ngs
and shackl e pl ate on rear of spri ng and rear spri ng
hanger. Start shackl e bol t nuts. Do not ti ghten.
(2) Assembl e front spri ng hanger to front of spri ng
eye and i nstal l pi vot bol t and nut. Do not ti ghten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(3) Rai se front of spri ng and i nstal l four hanger
bol ts, ti ghten to 61 Nm (45 ft. l bs.) torque. Connect
actuator assembl y for hei ght sensi ng proporti oni ng
val ve.
(4) Rai se axl e assembl y i nto correct posi ti on wi th
axl e centered under spri ng center bol t.
(5) I nstal l U-bol ts, nuts and washers. Ti ghten U-bol t
nuts to 88 Nm (65 ft. l bs.) torque.
(6) I nstal l shock absorbers and start bol ts.
(7) Lower vehi cl e to fl oor and wi th ful l wei ght of
vehi cl e on wheel s, ti ghten component fasteners as
fol l ows:
CAUTION:The following sequence must be followed
when tightening the rear shackle pin assembly and
nut. First, the shackle and pin assembly through
bolts must be torqued to the specification listed
below. Second, torque the shackle and pin assembly
retaining bolts to torque listed below. This sequence
must be followed to properly seat the bushings into
the springs and avoid bending the shackle assembly.
Fig. 5 Wheel Bearing Mounting Bolts
Fig. 6 Pull Wheel Bearing Assembly from Housing
Front pi vot bol t 142 Nm (105 ft. l bs.)
Shackl e and pi n assembl y through bol t nuts 61
Nm (45 ft. l bs.)
Shock absorber bol ts:
Upper 115 Nm (85 ft. l bs.)
Lower 108 Nm (80 ft. l bs.)
(8) Rai se vehi cl e and connect rear brake proporti on-
i ng val ve spri ng and adjust (see Adjusti ng Procedure i n
Brake Secti on of thi s manual ).
JOUNCE BUMPER
I f the jounce bumper i s removed from the vehi cl e, i t
must be repl aced i n the correct l ocati on on the frame
rai l . Thi s l ocati on i s i mportant so that the bumper wi l l
contact the axl e correctl y and not i nterfere wi th the
rear dri ve shafts.
The frame rai l has 4 hol es i n the area where the
jounce bumper mounts. Two of the hol es are threaded
and two are not. Refer to fi gure 7 for the tab and screw
l ocati on of the jounce bumper to frame rai l .
REAR SHOCK ABSORBERS
(1) Li ft vehi cl e on a frame contact hoi st.
(2) Support axl e wi th a jack stand.
(3) Remove l ower shock bol t.
(4) Whi l e hol di ng shock, remove upper shock bol t.
Fig. 7 Rear Suspension All Wheel Drive
REAR DRI VE LI NE MODULE ASSEMBLY (ALL WHEEL DRI VE)
INDEX
page page
Fluid Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . . 10
Rear Drive Line Noise Diagnosis . . . . . . . . . . . . . . 9
GENERAL INFORMATION
The Al l Wheel Dri ve (AWD) system i s avai l abl e on al l
Caravan/Voyager model s equi pped wi th 3.3 Li ter V-6
engi ne and Ul tradri ve transaxl e.
The pri mary benefi t of Al l Wheel Dri ve i s:
Superi or strai ght l i ne accel erati on, and corneri ng on
al l surfaces
Better tracti on and handl i ng under adverse condi -
ti ons, resul ti ng i n i mproved hi l l cl i mbi ng abi l i ty and
safer dri vi ng.
The heart of the system i s an i nter-axl e vi scous
coupl i ng. The vehi cl e retai ns predomi nantl y front-
wheel dri ve characteri sti cs, but the Al l Wheel Dri ve
capabi l i ty takes effect when the front wheel s start to
sl i p. Under normal l evel road, strai ght l i ne dri vi ng,
90% of the torque i s al l ocated to the front wheel s. The
vi scous coupl i ng al l ows more torque to the rear wheel s
i n accordance wi th the amount of the sl i ppage at the
front wheel s. The vari abl e torque di stri buti on i s auto-
mati c wi th no dri ver i nputs requi red.
The rear dri ve l i ne modul e assembl y consi sts of fi ve
mai n parts: the rear carri er, torque tube, overrunni ng
cl utch assembl y, a vacuum operated dog cl utch, and a
vi scous coupl i ng.
The rear carri er contai ns a conventi onal open di ffer-
enti al wi th hypoi d ri ng gear and pi ni on gear set. The
hypoi d gears are l ubri cated by SAE 85W-90 gear l ubri -
cant.
The torque tube assembl y attaches to the overrun-
ni ng cl utch case. The front torque shaft beari ng i s
l ocated i n the torque tube. The front torque shaft
beari ng i s permanentl y seal ed and does not requi re
mai ntenance. The torque shaft i s l ocated wi thi n the
torque tube assembl y. The vacuum reservoi r and sol e-
noi d assembl y are attached to the top of the torque
tube.
The overrunni ng cl utch al l ows the rear wheel s to
overrun the front wheel s duri ng a rapi d front wheel
l ock braki ng maneuver. The overrunni ng acti on pre-
vents any feed-back of front wheel braki ng torque to
the rear wheel s. I t al so al l ows the braki ng system to
control the braki ng behavi or as a two wheel dri ve
(2WD) vehi cl e.
The overrunni ng cl utch has a separate oi l sump and
i s fi l l ed i ndependentl y from the di fferenti al . The fi l l
pl ug i s l ocated on the si de of the overrunni ng cl utch
case. When fi l l i ng the overrunni ng cl utch wi th l ubri -
cant use Mopar Type 7176 Automati c Transmi ssi on
fl ui d or equi val ent.
The dog-cl utch provi des Al l Wheel Dri ve i n reverse
by bri dgi ng and l ocki ng out the overrunni ng cl utch.
The dog-cl utch i s operated by a doubl e-acti ng servo
usi ng i ntake mani fol d vacuum as i ts power source. Two
vacuum sol enoi ds, control l ed by the back up l i ght
swi tch, engage and di sengage the dog-cl utch. A spri ng
i n the vacuum servo di sengages the dog cl utch i f
vacuum i s l ost.
Located i n front of the torque tube i s the vi scous
coupl i ng. The vi scous coupl i ng control s and di stri butes
torque/power to the rear wheel s. The coupl i ng i s si mi -
l ar to a mul ti -pl ate cl utch. I t consi sts of a seri es of
cl osel y spaced di scs, al ternatel y connected to the front
and rear dri ve uni ts, whi ch operate i n si l i cone fl ui d.
The uni t i s total l y seal ed and parti al l y fi l l ed wi th
si l i cone fl ui d. There i s no adjustment, mai ntenance or
fl ui d checks requi red duri ng the l i fe of the uni t.
REAR DRIVE LINE NOISE DIAGNOSIS
Di fferent sources can be the cause of noi se that the
rear dri ve l i ne modul e assembl y i s suspected of mak-
i ng. Refer to the fol l owi ng causes for noi se di agnosi s.
REAR CARRI ER ASSEMBLY NOI SE
The most i mportant part of rear carri er servi ce i s
correctl y i denti fyi ng the cause of fai l ures and noi se
compl ai nts. The cause of most rear carri er fai l ures i s
rel ati vel y easy to i denti fy, but the cause of rear carri er
noi se i s more di ffi cul t to i denti fy.
I f vehi cl e noi se becomes objecti onabl e, an effort
shoul d be made to i sol ate the noi se to one parti cul ar
area of the vehi cl e. Many noi ses that are reported as
comi ng from the rear carri er may actual l y ori gi nate at
other sources. For exampl e ti res, road surfaces, wheel
beari ngs, engi ne, transmi ssi on, exhaust, propel l er
shaft (vi brati on), or vehi cl e body (drummi ng). Rear
carri er noi ses are normal l y di vi ded i nto two categori es:
gear noi se or beari ng noi se. A thorough and careful
i nspecti on shoul d be compl eted to determi ne the actual
source of the noi se before repl aci ng the rear carri er.
The rear carri er assembl y rubber mounti ng bushi ngs
hel p to dampen-out rear carri er noi se when correctl y
i nstal l ed. I nspect to confi rm that no metal contact
exi sts between the rear carri er case and the
body. Metal -to-metal contact can resul t i n a noi se that
woul d not normal l y be objecti onabl e i f the components
were correctl y i nstal l ed and ti ghtened. The compl ete
i sol ati on of noi se to any one area requi res consi derabl e
experti se and experi ence. I denti fyi ng certai n types of
vehi cl e noi se baffl es even the most experi enced techni -
ci ans. Often such practi ces as:
i ncrease ti re i nfl ati on pressure to el i mi nate ti re
noi se.
l i sten for noi se at varyi ng speeds wi th di fferent
dri vel i ne l oad condi ti ons (e.g., dri ve, fl oat and coast)
swervi ng the vehi cl e from l eft to ri ght to detect
wheel beari ng noi se.
Al l rear carri er assembl i es produce noi se to a certai n
extent. Sl i ght carri er noi se that i s noti ceabl e onl y at
certai n speeds or i sol ated si tuati ons shoul d be consi d-
ered normal . Carri er noi se tends to peak at a vari ety of
vehi cl e speeds and noi se i s NOT ALWAYS an i ndi ca-
ti on of a probl em wi thi n the carri er.
TI RE NOI SE
Ti re noi se i s often mi staken for rear carri er noi se.
Ti res that are unbal anced, worn unevenl y or are worn
i n a saw-tooth manner are usual l y noi sy. They often
produce a noi se that appears to ori gi nate i n the rear
carri er.
Ti re noi se changes wi th di fferent road surfaces, but
rear carri er noi se does not. I nfl ate al l four ti res wi th
approxi matel y 20 psi (138 kPa) more than the recom-
mended i nfl ati on pressure (for test purposes onl y).
Thi s wi l l al ter noi se caused by ti res, but wi l l not affect
noi se caused by the di fferenti al . Rear axl e noi se usu-
al l y ceases when coasti ng at speeds l ess than 30 mph
(48 km/h); however, ti re noi se conti nues, but at a l ower
frequency, as the speed i s reduced.
After test has been compl eted l ower ti re pressure
back to recommended pressure.
GEAR NOI SE (DRI VE PI NI ON AND RI NG GEAR)
Abnormal gear noi se i s rare and i s usual l y caused by
scori ng on the ri ng gear and dri ve pi ni on. Scori ng i s the
resul t of i nsuffi ci ent or i ncorrect l ubri cant i n the car-
ri er housi ng.
Abnormal gear noi se can be easi l y recogni zed. I t
produces a cycl i ng tone that wi l l be very pronounced
wi thi n a gi ven speed range. The noi se can occur duri ng
one or more of the fol l owi ng dri ve condi ti ons:
Dri ve
Road l oad
Fl oat
Coast
Abnormal gear noi se usual l y tends to peak wi thi n a
narrow vehi cl e speed range or ranges. I t i s usual l y
more pronounced between 30 to 40 mph (48 to 64 km/h)
and 50 to 60 mph (80 to 96 km/h). When objecti onabl e
gear noi se occurs, note the dri vi ng condi ti ons and the
speed range.
BEARI NG NOI SE (DRI VE PI NI ON AND DI FFER-
ENTI AL)
Defecti ve or damaged beari ngs wi l l normal l y produce
a rough growl that i s constant i n pi tch and vari es wi th
the speed of the vehi cl e. Bei ng aware of thi s wi l l enabl e
a techni ci an to separate beari ng noi se from gear noi se.
Dri ve pi ni on beari ng noi se that resul ts from defec-
ti ve or damaged beari ngs can usual l y be i denti fi ed by
i ts constant, rough sound. Dri ve pi ni on front beari ng i s
usual l y more pronounced duri ng a coast condi ti on.
Dri ve pi ni on rear beari ng noi se i s more pronounced
duri ng a dri ve condi ti on. The dri ve pi ni on beari ngs are
rotati ng at a hi gher rate of speed than ei ther the
di fferenti al si de beari ngs or the axl e shaft beari ng.
Di fferenti al si de beari ng noi se wi l l usual l y produce a
constant, rough sound that i s much l ower i n frequency
than the noi se caused by dri ve pi ni on beari ngs.
Beari ng noi se can best be detected by road testi ng
the vehi cl e on a smooth road (bl ack top). However, i t i s
easy to mi stake ti re noi se for beari ng noi se. I f a doubt
exi sts, the ti re treads shoul d be exami ned for i rregu-
l ari ti es that often causes a noi se that resembl es bear-
i ng noi se.
ENGI NE AND TRANSMI SSI ON NOI SE
Occasi onal l y noi se that appears to ori gi nate i n the
rear carri er assembl y i s actual l y caused by the engi ne
or the transmi ssi on. To i denti fy the true source of the
noi se, note the approxi mate vehi cl e speed and/or RPM
when the noi se i s most noti ceabl e. Stop the vehi cl e next
to a fl at bri ck or cement wal l (thi s wi l l hel p refl ect the
sound). Pl ace the transaxl e i n NEUTRAL. Accel erate
the engi ne sl owl y up through the engi ne speed that
approxi matel y corresponds to the vehi cl e speed or
RPM noted when the noi se occurred. I f a si mi l ar noi se
i s produced by thi s method, i t usual l y i ndi cates that
the noi se i s bei ng caused by the engi ne or the tran-
saxl e, not the di fferenti al assembl y.
FLUID LEAK DIAGNOSIS
When di agnosi ng fl ui d l eaks on the rear dri ve l i ne
modul e assembl y two weep hol es are provi ded to di ag-
nose certai n seal l eaks. These hol es are l ocated on the
bottom si de of the assembl y (Fi g. 1).
I f fl ui d l eak i s detected from ei ther weep hol e, seal
repl acement i s necessary. Do not attempt to repair
the leak by sealing weep holes, they must be kept
cl ear of seal ants for proper seal operati on.
I f fl ui d i s l eaki ng from weep hol e A (Fi g. 1) and i t i s
i denti fi ed to be Automati c Transmi ssi on Fl ui d, the
front overrunni ng cl utch seal i s l eaki ng. For repl ace-
ment of thi s seal refer to Rear Dri ve Li ne Assembl y
Servi ce Procedures.
I f fl ui d i s l eaki ng from weep hol e B (Fi g. 1) the type
of fl ui d l eaki ng wi l l determi ne whi ch seal i s l eaki ng. I f
the fl ui d l eaki ng i s red i n col or (transmi ssi on fl ui d) thi s
i ndi cates that the rear overrunni ng cl utch seal shoul d
be repl aced. I f the fl ui d l eaki ng i s l i ght brown (hypoi d
gear l ube) thi s i ndi cates that the i nput pi ni on seal
shoul d be repl aced. For repl acement of these seal s
refer to Rear Dri ve Li ne Assembl y Servi ce Procedures.
REAR DRI VE LI NE MODULE ASSEMBLY SERVI CE PROCEDURES
INDEX
page page
Case Cover Service . . . . . . . . . . . . . . . . . . . . . . . 23
Drive Pinion Bearing Shim Selection . . . . . . . . . . . 22
Drive Pinion Seal And/Or Rear Overrunning
Clutch Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front Overrunning Clutch Seal . . . . . . . . . . . . . . . 15
Half Shaft Service . . . . . . . . . . . . . . . . . . . . . . . . 34
Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . 28
Propeller Shaft Service . . . . . . . . . . . . . . . . . . . . . 33
Rear Carrier Output Shaft Seals . . . . . . . . . . . . . . 13
Rear Carrier Unit . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Drive Line Module Assembly . . . . . . . . . . . . 11
Rear Driveline Module Differential Side Gears . . . . 22
Torque Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
(2) Remove ri ght and l eft i nner hal f shaft joi nt
(3) Support i nner si de of hal f shaft wi th mechani cs
wi re or equi val ent (Fi g. 2). Do not al l ow hal f shafts to
hang freel y.
(4) Remove mounti ng bol ts from the rear si de of
propel l er shaft (Fi g. 3).
Fig. 1 Remove Mounting Bolts
Fig. 2 Support Half Shafts
Fig. 1 Weep Hole Locations
CAUTION: Do not allow propeller shaft to hang freely
(5) Support propel l er shaft wi th mechani cs wi re
and/or jack stand
(6) Di sconnect mai n vacuum l i ne for rear dri ve l i ne
modul e assembl y. Al so di sconnect el ectri cal connec-
ti ons at the front of the modul e.
(7) Support rear dri ve l i ne modul e assembl y wi th
transmi ssi on jack or equi val ent.
WARNING: BE SURE TO CHAIN REAR DRIVE LINE
MODULE ASSEMBLY SECURELY TO THE JACK TO
PREVENT IT FROM FALLING.
(8) Remove rear dri ve l i ne modul e assembl y rear
(9) Remove rear dri ve l i ne modul e assembl y front
(10) Parti al l y l ower rear dri ve l i ne modul e assembl y
and di sconnect remote sol enoi d vent and remote car-
ri er vent.
(11) Remove rear dri ve l i ne modul e assembl y.
(12) To I nstal l , Reverse Removal Procedure. Refer to
TORQUE SPECIFICATION i n the rear of thi s sec-
ti on for ti ghteni ng speci fi cati ons.
REAR CARRIER UNIT
(1) Remove rear dri ve l i ne modul e assembl y from
vehi cl e.
(2) Drai n oi l from overrunni ng cl utch case.
Fig. 3 Remove Mounting Bolts
Fig. 4 Rear Drive Line Module Assembly Rear
Mounting Bolts
Fig. 5 Rear Drive Line Module Front Mounting Bolts
Fig. 6 Overrunning Clutch Case to Rear Carrier
Case Bolts
(3) Remove overrunni ng cl utch case to rear carri er
case bol ts (Fi g. 6).
(4) Separate rear carri er case from overrunni ng
cl utch case (Fi g. 7).
(5) For I nstal l ati on, Reverse Removal Procedure.
REAR CARRIER OUTPUT SHAFT SEALS
The rear dri ve l i ne modul e assembl y does not have to
be removed from vehi cl e to servi ce the carri er output
shaft seal s.
The output fl ange seal s are l ocated on the rear
carri er uni t (Fi g. 1).
REMOVAL
(1) Remove i nner hal f shaft retai ni ng bol ts (Fi g. 2).
CAUTION: Do not allow half shafts to hang freely
(2) Support i nner si de of hal f shaft wi th mechani cs
wi re or equi val ent (Fi g. 3).
(3) Usi ng two pry bars and wooden support bl ocks,
pop out output shaft (Fi g. 4).
Fig. 7 Separate Rear Carrier Case from Overrunning
Clutch Case
Fig. 1 Rear Drive Line Module Oil Seal Location
(4) Usi ng a pry bar, pry out oi l seal (Fi g. 5), bei ng
careful not to damage race.
I NSTALLATI ON
(1) Cl ean and i nspect shaft and seal area.
(2) I nstal l oi l seal wi th speci al tool MD998334 (Fi g.
6).
(3) I nstal l output shaft (Fi g. 7). Li ghtl y tap shaft to
seat retai ner ri ng i nto di fferenti al si de gear.
Fig. 2 Inner Half Shaft Bolts
Fig. 3 Support Half Shafts
Fig. 4 Output Flange Removal
Fig. 5 Seal Removal
Fig. 6 Installing Oil Seal
(4) Check di fferenti al fl ui d l evel , fi l l as requi red.
FRONT OVERRUNNING CLUTCH SEAL
The rear dri ve l i ne modul e must be removed to
servi ce thi s seal .
The front overrunni ng cl utch seal i s l ocated i n the
overrunni ng cl utch case (Fi g. 1).
REMOVAL
vehi cl e.
(2) Remove vi scous coupl i ng uni t.
(3) Remove overrunni ng cl utch cover assembl y.
(4) Drai n fl ui d from overrunni ng cl utch case.
bol ts (Fi g. 8).
(6) Separate overrunni ng cl utch case from rear car-
ri er case (Fi g. 9).
(7) Remove overrunni ng cl utch i nner race snap ri ng
(Fi g. 10).
(8) Sl i de overrunni ng cl utch i nner race off of shaft
(Fi g. 11).
Fig. 7 Installing Output Shaft
Bolts
Fig. 9 Separate Housings
Fig. 10 Inner Race Snap Ring Removal
(9) Remove shaft snap ri ng and sl i de dog cl utch off of
the shaft (Fi g. 12).
(10) Remove torque shaft snap ri ng (Fi g. 13) and
torque tube beari ng shi el d.
(11) Remove torque tube retai ni ng bol ts (Fi g. 14).
(12) Remove i nner torque shaft beari ng snap ri ng.
(13) Separate overrunni ng cl utch case from torque
tube.
(14) Remove rear torque shaft beari ng retai ni ng
outer snap ri ng i n overrunni ng cl utch case (Fi g. 15).
(15) Remove rear torque shaft beari ng.
Fig. 11 Remove Overrunning Clutch Inner Race
Fig. 12 Remove Snap Ring
Fig. 13 Remove Torque Shaft Snap Ring and Torque
Tube Bearing Shield
Fig. 14 Torque Tube Bolts
Fig. 15 Torque Shaft Rear Bearing Snap Ring
(16) Dri ve out seal wi th speci al tool C-4967 (Fi g. 16)
I NSTALLATI ON
(1) Cl ean and i nspect shaft seal i ng surface and case
for ni cks or grooves. Repl ace as requi red.
(2) I nstal l new seal wi th speci al tool MD998334.
Seal shoul d be fl ush wi th outsi de edge of case (Fi g. 17).
(3) I nstal l rear torque shaft beari ng and outer snap
ri ng.
(4) I nstal l overrunni ng cl utch case onto torque tube.
Ti ghten bol ts to 28 Nm (250 i n. l bs.).
(5) I nstal l torque shaft i nner snap ri ng.
(6) Sl i de dog cl utch onto shaft and i nstal l snap ri ng.
(7) Sl i de overrunni ng cl utch i nner race onto shaft
and i nstal l retai ni ng snap ri ng (tapered end of i nner
race must face outward).
(8) Cl ean al l seal i ng surfaces. Then appl y a bead of
Mopar Gasket Maker, Locti te Gasket El i mi nator or
equi val ent and rei nstal l the overrunni ng cl utch hous-
i ng to the rear carri er case. I nstal l retai ni ng bol ts and
ti ghten to 28 Nm (250 i n. l bs.).
(9) Appl y Mopar Gasket Maker, Locti te Gasket
El i mi nator or equi val ent and rei nstal l overrunni ng
cl utch cover. When i nstal l i ng cover be sure that the
overrunni ng cl utch fork engages i nto the overrunni ng
cl utch dog.
(10) I nstal l rear dri ve l i ne modul e assembl y i nto
vehi cl e.
(11) Check and fi l l fl ui d l evel s as requi red.
DRIVE PINION SEAL AND/OR REAR OVERRUN-
NING CLUTCH SEAL
servi ce these seal s. The dri ve pi ni on seal i s l ocated i n
the front carri er cover, behi nd the overrunni ng cl utch
rear seal (Fi g. 1). The overrunni ng cl utch seal must be
removed to gai n access to the i nput pi ni on seal . Do not
reuse overrunni ng cl utch seal .
Fig. 16 Seal Removal Fig. 17 Installing New Seal
R
E
A
R
C
A
R
R
I
E
R
C
O
M
P
O
N
E
N
T
I
D
E
N
T
I
F
I
C
A
T
I
O
N
REMOVAL
(1) Remove rear dri ve l i ne modul e from vehi cl e.
bol ts (Fi g. 1).
(3) Separate overrunni ng cl utch case from di fferen-
ti al carri er case (Fi g. 2).
(4) Remove overrunni ng cl utch outer race snap ri ng
(Fi g. 3).
(5) Sl i de overrunni ng cl utch outer race off of shaft
(Fi g. 4).
(6) Usi ng Spl i ne Socket Tool 6534 and a wrench,
remove pi ni on nut (Fi g. 5).
Bolts
Fig. 2 Separate Cases
Fig. 3 Overrunning Clutch Snap Ring Removal
Fig. 4 Overrunning Clutch Outer Race Removal
Fig. 5 Remove Pinion Nut
(7) Remove front carri er cover retai ni ng screws (Fi g.
6)
(8) Remove front carri er cover from carri er case (Fi g.
7).
(9) Pl ace a bl ock of wood under the end of the pi ni on
shaft. Tap end of pi ni on agai nst the wood to dri ve the
pi ni on spacer off of the pi ni on shaft (Fi g. 8).
CAUTION: Shim should be installed with front carrier
cover. This will eliminate the potential of cutting the
O-Ring with the shim.
(10) Rei nstal l front carri er cover i nto carri er case
(Fi g. 9). I nstal l carri er retai ni ng bol ts and ti ghten to 12
Nm (105 i n. l bs.).
(11) Use seal pul l er 7794-A (Fi g. 10) to remove the
overrunni ng cl utch seal and dri ve pi ni on seal . The
overrunni ng cl utch seal must be removed fi rst to gai n
access to the dri ve pi ni on seal . The overrunni ng cl utch
seal must be repl aced after the dri ve pi ni on seal i s
i nstal l ed, do not reuse ol d seal .
Fig. 6 Front Carrier Cover Retaining Screws
Fig. 7 Front Carrier Cover
Fig. 8 Removing Drive Pinion Spacer
Fig. 9 Reinstalling Front Carrier Cover
I NSTALLATI ON
(1) Cl ean and i nspect seal area.
(2) Appl y a l i ght coat of oi l onto the dri ve pi ni on seal
and i nstal l wi th Seal I nstal l er 6507. Seal must be
i nstal l ed wi th the spri ng si de i n towards the rear
carri er case (Fi g 11).
CAUTION: If the drive pinion spacer is grooved or
damaged it must be replaced. A new drive pinion
bearing shim may be required. Refer to Drive Pinion
Bearing Shim Selection in this section before con-
tinuing with this procedure.
(3) Appl y a l i ght coat of oi l onto the dri ve pi ni on
spacer and sl i de onto the pi ni on shaft wi th the tapered
si de faci ng outward (Fi g. 12).
(4) Appl y a l i ght coat of oi l onto the overrunni ng
cl utch seal and i nstal l wi th Seal I nstal l er 6508 . Seal
must be i nstal l ed wi th the spri ng si de away from the
rear carri er case (Fi g. 13).
(5) Cl ean pi ni on nut and pi ni on shaft threads wi th
Mopar Brake and Parts Cl eaner, Locti te Cl eani ng
Pri mer or equi val ent.
(6) Appl y Mopar Lock and Seal Adhesi ve to both
the pi ni on nut and pi ni on shaft threads.
(7) I nstal l pi ni on and ti ghten nut to 340 Nm (250 ft.
l bs.) torque.
(8) Wi pe off al l excess adhesi ve.
(9) I nstal l overrunni ng cl utch outer race and snap
ri ng.
(10) Appl y Locti te seal er to overrunni ng cl utch seal -
i ng surface and rei nstal l the overrunni ng cl utch case to
rear carri er case.
(11) Rei nstal l rear dri ve l i ne modul e assembl y i nto
the vehi cl e.
(12) Check and fi l l al l fl ui ds as requi red.
Fig. 10 Removing Seals
Fig. 11 Input Seal Installation
Fig. 12 Installing Drive Pinion Spacer onto Pinion
Fig. 13 Overrunning Clutch Seal Installation
DRIVE PINION BEARING SHIM SELECTION
Thi s procedure must be performed when ever the
dri ve pi ni on spacer has been repl aced.
(1) Usi ng a one i nch mi crometer, measure the thi ck-
ness of the original spacer (Fi g. 14).
(2) Measure the thi ckness of the new spacer the
same way that the ori gi nal spacer was measured.
The di fference i n the measurements of the ol d spacer
and the new spacer wi l l determi ne whi ch shi m to use.
I f the new dri ve pi ni on spacer i s the samethickness
as the ori gi nal dri ve pi ni on spacer use the ori gi nal
shi m.
I f the new dri ve pi ni on spacer i s thinner than the
ori gi nal dri ve pi ni on spacer, a thi cker shi m wi l l must
be used. Thi s wi l l compensate for the di fference i n si ze.
(a) Determi ne the di fference i n si ze between the
new spacer and the ori gi nal spacer. Record thi s
di mensi on.
(b) Measure the thi ckness of the ori gi nal shi m.
Record thi s di mensi on.
(c) Add together the two di mensi ons recorded i n
steps (a) and (b). Use a new shi m that i s equal to thi s
si ze.
For Exampl e: The new spacer i s 0.010 thi nner than
the ori gi nal spacer. The ori gi nal shi m measures 0.205 .
Addi ng 0.205 and 0.010 equal s a new shi m thi ckness of
0.215 .
(3) I f the new dri ve pi ni on spacer i s thicker than the
ori gi nal dri ve pi ni on spacer, a thi nner shi m wi l l must
be used. Thi s wi l l compensate for the di fference i n si ze.
(a) Determi ne the di fference i n si ze between the
new spacer and the ori gi nal spacer. Record thi s
di mensi on.
(b) Measure the thi ckness of the ori gi nal shi m.
Record thi s di mensi on.
(c) Subtract the di mensi ons recorded i n steps (a)
from the di mensi on recorded i n step (b). Use a new
shi m that i s equal to thi s si ze.
For Exampl e: The new spacer i s 0.010 thi cker than
the ori gi nal spacer. The ori gi nal shi m measures 0.205 .
Subtracti ng 0.010 from 0.205 equal s a new shi m thi ck-
ness of 0.195 .
REAR DRIVELINE MODULE DIFFERENTIAL SIDE
GEARS
(1) Di sconnect both hal f shafts from rear dri vel i ne
modul e.
(2) Usi ng two pry bars, pop out output shaft.
(3) Remove output shaft.
(4) Remove end cover retai ni ng bol ts.
(5) Remove di fferenti al end cover.
(6) Remove di fferenti al assembl y from rear dri vel i ne
case.
(7) Remove ri ng gear bol ts and separate di fferenti al
case from di fferenti al body.
(8) Usi ng a punch and hammer remove the di fferen-
ti al pi ni on shaft pi n.
(9) Sl i de di fferenti al pi ni on shaft out of di fferenti al
case.
(10) I nspect and repl ace pi ni on gears, pi ni on shaft or
pi ni on washers as requi red.
(11) Reverse steps 7 through 10 to assembl e di ffer-
enti al . Torque the ri ng gear bol ts to 95 Nm (70 ft. l bs.).
(12) I nstal l di fferenti al assembl y i nto dri vel i ne mod-
ul e case.
(13) Cl ean and i nspect seal er surfaces.
El i mi nator or equi val ent and i nstal l end cover. Ti ghten
to 28 Nm (250 i n. l bs.).
(15) Ti ghten bol ts i n the sequence shown i n Fi g. 15.
Reti ghten fi rst bol t after al l others are ti ght.
(16) I nstal l output shafts
(17) Reconnect both hal f shafts.
(18) Fi l l di fferenti al wi th l ubri cant.
Fig. 14 Measuring Drive Pinion Spacer Thickness
CASE COVER SERVICE
DI FFERENTI AL CARRI ER END COVER (RE-
SEAL)
(1) Remove l eft hal f shaft.
(2) Usi ng two pry bars, pop out output shaft (Fi g. 1).
(3) Remove output shaft.
(4) Remove end cover retai ni ng bol ts (Fi g. 2).
(5) Remove di fferenti al end cover.
El i mi nator or equi val ent and i nstal l end cover. Ti ghten
to 28 Nm (250 i n. l bs.).
(8) Ti ghten bol ts i n the sequence shown i n Fi g. 3.
Reti ghten fi rst bol t after al l others are ti ght.
(9) Fi l l di fferenti al wi th l ubri cant.
Fig. 15 Bolt Tightening Sequence.
Fig. 1 Output Flange Removal
Fig. 2 Remove End Cover Bolts
Fig. 3 Bolt Tightening Sequence.
OVERRUNNI NG CLUTCH COVER (RESEAL)
vehi cl e.
(2) Remove overrunni ng cl utch cover assembl y
(3) Li ft overrunni ng cl utch cover off of overrunni ng
cl utch housi ng.
(4) Cl ean and i nspect seal i ng surfaces.
El i mi nator or equi val ent and rei nstal l cover and
vacuum hose cl i p. When i nstal l i ng cover be sure that
the overrunni ng cl utch fork engages i nto the overrun-
ni ng cl utch dog.
(6) I nstal l overrunni ng cl utch cover mounti ng bol ts
and ti ghten bol ts to 28 Nm (250 i n. l bs.).
(7) Rei nstal l rear dri ve l i ne modul e assembl y i nto
vehi cl e.
(8) Check and fi l l fl ui d l evel s as requi red. Use onl y
MOPAR TYPE 7176 Automati c Transmi ssi on Fl ui d or
equi val ent i n the overrunni ng cl utch case.
OVERRUNNI NG CLUTCH CASE TO REAR CAR-
RI ER CASE (RESEAL)
vehi cl e.
bol ts (Fi g. 5).
(4) Separate overrunni ng cl utch case from rear car-
ri er uni t (Fi g. 6).
(5) Cl ean and i nspect seal i ng surfaces.
(6) Appl y a bead of Mopar Gasket Maker, Locti te
Gasket El i mi nator or equi val ent to seal i ng surfaces
and reassembl e.
(7) Rei nstal l rear dri ve l i ne modul e assembl y.
(8) Check and fi l l fl ui d l evel s as requi red. Use onl y
MOPAR TYPE 7176 Automati c Transmi ssi on Fl ui d or
equi val ent i n the overrunni ng cl utch housi ng.
Fig. 4 Mounting Bolts
Bolts
Clutch Case
T
O
R
Q
U
E
T
U
B
E
A
N
D
O
V
E
R
R
U
N
N
I
N
G
C
L
U
T
C
H
C
O
M
P
O
N
E
N
T
S
TORQUE TUBE
vehi cl e.
(2) Remove vi scous coupl i ng.
(3) Remove snap ri ng and torque tube beari ng shi el d
(Fi g. 1).
(4) Remove torque tube to overrunni ng cl utch case
bol ts (Fi g 2).
(5) Sl i de torque tube off of torque shaft.
FRONT BEARI NG
REMOVAL AND INSTALLATION
servi ce thi s beari ng.
vehi cl e.
(2) Remove vi scous coupl i ng.
ti al carri er case (Fi g. 4).
(Fi g. 5).
(8) Sl i de overrunni ng cl utch i nner race off of shaft
(Fi g. 6).
the shaft.
(10) Remove torque shaft rear beari ng snap ri ng.
(11) Remove overrunni ng case to torque tube bol ts
(Fi g. 7).
(12) Separate torque tube from overrunni ng cl utch
housi ng.
(13) Remove front snap ri ng and torque tube beari ng
shi el d (Fi g. 8).
(14) Sl i de shaft out of torque tube.
(15) Dri ve beari ng out of housi ng.
(16) To I nstal l Beari ng, Reverse Removal Procedure.
Fig. 1 Remove Torque Shaft Snap Ring and Torque
Tube Shield
Fig. 3 Overrunning Clutch Housing to Rear carrier
Bolts
REAR BEARI NG
REMOVAL AND INSTALLATION
The rear dri ve l i ne modul e assembl y must be re-
moved to servi ce thi s beari ng.
vehi cl e.
(2) Remove vi scous coupl i ng uni t.
(5) Remove overrunni ng cl utch case to di fferenti al
carri er bol ts.
ti al carri er case.
(7) Remove overrunni ng cl utch i nner race snap ri ng.
(8) Sl i de overrunni ng cl utch i nner race off of shaft.
the shaft.
(10) Remove torque shaft rear beari ng i nner snap
ri ng.
(11) Remove torque tube retai ni ng bol ts.
tube.
(13) Remove rear beari ng retai ni ng snap ri ng i n
Fig. 4 Separate Rear Carrier case from overrunning
clutch case
Fig. 6 Remove Overrunning Clutch Race
OVERRUNNING CLUTCH
VACUUM MOTOR
REMOVAL
vehi cl e.
(2) Cut cl amps and di sconnect vacuum hose to
vacuum motor.
(3) Remove overrunni ng cl utch cover assembl y
(4) Li ft overrunni ng cl utch cover assembl y off of
overrunni ng cl utch case.
(5) Cl amp assembl y i n soft jawed vi se (Fi g. 2).
(6) Remove two E-cl i ps from vacuum motor shaft
(Fi g. 3).
(7) Hol di ng the overrunni ng cl utch shi ft fork, sl i de
shi ft motor out of housi ng (Fi g. 4).
CAUTION: Shift fork can be installed backwards. Note
its position before removing.
(8) Cl ean and i nspect al l parts and seal i ng surfaces.
Repl ace worn or damaged parts.
INSTALLATION
(1) Sl i de vacuum shi ft motor i nto housi ng and
through shi ft fork. Shi ft fork off set must be angl e away
from vacuum motor (Fi g. 5).
(2) I nstal l two E-cl i ps. One onto vacuum shi ft motor
shaft and one on the vacuum motor bushi ng.
El i mi nator or equi val ent and rei nstal l cover. When
Fig. 8 Remove Torque Shaft Snap Ring and Shield
Fig. 1 Mounting Bolts
Fig. 2 Clamp Housing in Vise
i nstal l i ng cover be sure that the overrunni ng cl utch
fork engages i nto the overrunni ng cl utch dog.
(4) I nstal l overrunni ng cl utch cover assembl y
mounti ng bol ts and ti ghten bol ts to 28 Nm (250 i n.
l bs.).
(5) Rei nstal l rear dri ve l i ne assembl y i nto vehi cl e.
REMOVAL
case bol ts (Fi g 6).
Fig. 3 Remove Two E-Clips
Fig. 4 Shift Fork Removal
Fig. 5 Shift Fork Position
Bolts
(5) Separate the overrunni ng cl utch case from the
rear carri er case (Fi g. 7).
(6) Remove overrunni ng cl utch snap ri ng (Fi g. 8).
(7) Remove spacers and overrunni ng cl utch. Over-
runni ng cl utch can be i nstal l ed backwards. Keep the
spacers and overrunni ng cl utch i n order when taki ng
the uni t apart (Fi g. 9).
(8) Remove overrunni ng cl utch outer race snap ri ng
(Fi g. 10).
(9) Sl i de overrunni ng cl utch outer race off of shaft
(Fi g. 11).
(10) Remove overrunni ng cl utch i nner race snap
ri ng (Fi g. 12).
(11) Sl i de overrunni ng cl utch i nner race off of the
shaft (Fi g. 13).
(12) Remove dog-cl utch snap ri ng (Fi g. 14).
(13) Sl i de dog-cl utch off of the shaft (Fi g. 15).
(14) Cl ean and i nspect al l parts. Repl ace worn or
damaged parts.
Clutch Case
Fig. 8 Overrunning Clutch Snap Ring
Fig. 9 Overrunning Clutch Removal
Fig. 10 Overrunning Clutch Snap Ring Removal
Fig. 11 Overrunning Clutch Outer Race Removal
I NSTALLATI ON
(1) I nstal l outer overrunni ng cl utch race and retai n-
i ng snap ri ng.
(2) I nstal l overrunni ng cl utch spacers and snap ri ng.
CAUTION: The overrunning clutch can be installed
backwards.
(3) To check for proper i nstal l ati on of the overrun-
ni ng cl utch, temporal l y i nstal l the i nner race i nto the
overrunni ng cl utch wi th the tapered end goi ng i n fi rst
(Fi g. 16). The i nner race shoul d spi n when turned
countercl ockwi se (Fi g. 17) and grab when turned cl ock-
wi se (Fi g. 18).
(4) I nstal l dog cl utch onto shaft and rei nstal l snap
ri ng.
(5) I nstal l overrunni ng cl utch on the shaft wi th the
tapered end faci ng outward and i nstal l snap ri ng.
(6) Cl ean al l seal i ng surfaces. Appl y a bead of Mo-
par Gasket Maker, Locti te Gasket El i mi nator or
equi val ent. Then rei nstal l the overrunni ng cl utch case
to the rear carri er case. I nstal l retai ni ng bol ts and
El i mi nator or equi val ent and rei nstal l cover. When
i nstal l i ng cover be sure that the overrunni ng cl utch
fork engages i nto the overrunni ng cl utch dog.
Fig. 13 Remove Overrunning Clutch Race
Fig. 14 Dog Clutch Snap Ring
Fig. 15 Dog Clutch Removal
Fig. 16 Temporally Install Inner Race
(8) I nstal l rear dri ve l i ne modul e assembl y i nto the
vehi cl e.
OVERRUNNI NG CLUTCH CASE
REMOVAL
(5) Separate the overrunni ng cl utch housi ng from
the rear carri er housi ng.
(Fi g. 20).
(7) Sl i de overrunni ng cl utch i nner race off of the
shaft.
(8) Remove dog-cl utch snap ri ng and sl i de dog-cl utch
off of the shaft.
(9) Remove torque shaft rear beari ng snap ri ng.
(10) Remove torque tube retai ni ng bol ts (Fi g. 21).
tube.
(12) Remove rear beari ng retai ni ng snap ri ng i n
(14) Dri ve out front overrunni ng cl utch seal wi th
speci al tool C-4967 (Fi g. 23).
INSTALLATION
(1) I nstal l new seal wi th speci al tool MD998334.
Seal shoul d be fl ush wi th outsi de edge of housi ng (Fi g.
24).
(2) I nstal l rear torque shaft beari ng and snap ri ng.
(3) I nstal l overrunni ng cl utch case onto torque tube.
Ti ghten bol ts to 28 Nm (250 i n. l bs.).
(4) I nstal l torque shaft snap ri ng.
Fig. 17 Turn Inner Race Counterclockwise
Fig. 18 Turn Inner Race Clockwise
Bolts
Fig. 20 Inner Race Snap Ring
(5) Sl i de dog cl utch onto shaft and i nstal l snap ri ng.
(6) Sl i de overrunni ng cl utch i nner race onto shaft
and i nstal l retai ni ng snap ri ng.
(7) Cl ean al l seal i ng surfaces. Then appl y a bead of
Mopar Gasket Maker, Locti te Gasket El i mi nator or
equi val ent. Then rei nstal l the overrunni ng cl utch case
to the rear carri er case. I nstal l retai ni ng bol ts and
El i mi nator or equi val ent and rei nstal l vacuum shi ft
cover. When i nstal l i ng cover be sure that the overrun-
ni ng cl utch fork engages i nto the overrunni ng cl utch
dog.
(9) I nstal l rear dri ve l i ne modul e i nto vehi cl e.
(10) Check and fi l l al l fl ui d l evel s as requi red.
PROPELLER SHAFT SERVICE
The propel l er shaft i s a hol l ow shaft wi th a pl ungi ng
tri pod joi nt on the front of the shaft and a fi xed tri pod
joi nt on the rear of the shaft. There are no servi ceabl e
parts. The shaft i s servi ced as an assembl y. The fl ange
patterns are di fferent at each end to prevent i nstal l i ng
the shaft backwards.
(1) Pl ace vehi cl e i n neutral and l i ft vehi cl e on hoi st.
CAUTION:Do not allow end of propeller shaft to hang
free.
(2) Remove propel l er shaft rear mounti ng bol ts and
support end of propel l er shaft (Fi g. 1).
(3) Remove propel l er shaft front mounti ng bol ts and
remove propel l er shaft assembl y (Fi g. 2)
CAUTION: Do not allow the propeller shaft to hang
freely while installing.
Fig. 23 Seal Removal
(4) To I nstal l , Reverse Removal Procedure. Be sure
fl ange mati ng faces are cl ean.
HALF SHAFT SERVICE
The hal f shaft assembl i es are three pi ece uni ts. Each
hal f shaft has one tri pod joi nt at each end and a sol i d
i nterconnecti ng shaft. The procedure to recondi ti on the
i nner or outer joi nt i s i denti cal .
Note that l ubri cant requi rements and quanti ti es
coul d be di fferent than other axl e shaft joi nts l ocated
on the vehi cl e. Onl y use the correct l ubri cant and
amount suppl i ed wi th the boot package or joi nt. Do not
use standard wheel beari ng grease or other l ubri cants,
joi nt fai l ure wi l l resul t.
(1) Li ft vehi cl e on hoi st so that the wheel s hang
freel y.
(2) Remove rear wheel .
(3) Remove cotter pi n, nut l ock and spri ng washer
(Fi g. 3).
(4) Remove hub nut and washer.
CAUTION: The half shaft outer C.V. joint, when in-
stalled, acts as a bolt and secures the hub/bearing
assembly. If the vehicle is to be supported or moved
on its wheels, install and torque a bolt through the
hub. This will insure that the hub/bearing assembly
cannot loosen.
(5) Remove i nner hal f shaft retai ni ng bol ts (Fi g. 4).
Fig. 24 Installing New Seal
Fig. 1 Propeller Shaft Mounting Bolts (Rear)
Fig. 2 Propeller Shaft Bolts (Front)
Fig. 3 Cotter Pin, Nut Lock, and Spring Washer
(6) The hal f shaft i s spri ng l oaded. Compress i nner
hal f shaft joi nt sl i ghtl y and pul l downward to cl ear rear
di fferenti al . Then pul l hal f shaft assembl y outward to
remove (Fi g. 5).
REAR HALF SHAFT JOI NT/BOOT REPLACE-
MENT
(1) Remove hal f shaft from vehi cl e. Refer to Hal f
Shaft Servi ce i n thi s secti on for removal procedure.
Cl ean and i nspect al l parts for wear or damage,
repl ace any worn or damaged parts.
To I nstal l , Reverse Removal Procedure.
Fig. 1 Clamp Shaft in Soft Jawed Vice
Fig. 2 Remove Boot Clamps
Fig. 3 Pull Back Boot
Fig. 4 Inner Half Shaft Bolts
Fig. 5 Half Shaft Removal
Fig. 4 Remove Housing
Fig. 5 Remove Snap Ring
Fig. 6 Slide Tripod Off the Shaft
Fig. 7 Remove Boot
REAR DRI VE LI NE MODULE VACUUM ACTUATI ON DI AGNOSI S
REAR WHEELS NOT OVERRUNNI NG
NO ALL WHEEL DRI VE, I N FORWARD; PROPELLER SHAFT TURNI NG
NO ALL WHEEL DRI VE FORWARD OR REVERSE
XNO ALL WHEEL DRI VE, REVERSE ONLY; PROPELLER SHAFT TURNI NG
NO ALL WHEEL DRI VE, REVERSE ONLY; PROPELLER SHAFT TURNI NG (CONT.)
VACUUM ACTUATI ON SCHEMATI C (SOLENOI DS ENERGI ZED)
VACUUM ACTUATI ON SCHEMATI C (SOLENOI DS DE-ENERGI ZED)
SPECI FI CATI ONS
FASTENER TORQUE SPECI FI CATI ONS
REAR WHEEL BEARI NG TORQUE SPECI FI CATI ONS
REAR CARRI ER ASSEMBLY TORQUE SPECI FI CATI ONS
OVERRUNNI NG CLUTCH AND TORQUE TUBE ASSEMBLY TORQUE SPECI FI CATI ONS
BOLT APPLI CATI ONS AND TORQUE SPECI FI CATI ONS
EMISSION CONTROL SYSTEMS
CONTENTS
page page
EVAPORATIVE EMISSION CONTROLS . . . . . . . . 2 EXHAUST EMISSION CONTROLS . . . . . . . . . . . . 8
GENERAL INFORMATION
parti cul ar vehi cl e by l etter or number desi gnati on. The
I ntroducti on Secti on at the front of thi s manual con-
tai ns a chart showi ng the breakdown of the desi gna-
ti ons.
EMISSION MAINTENANCE REMINDER (EMR) SYS-
TEM
Some systems and components requi re peri odi c
mai ntenance. For exampl e, the PCV val ve, EGR sys-
tem, the heated oxygen sensor, and some vacuum
operated components requi re peri odi c servi ce.
The engi ne control l er operates the Emi ssi ons Mai n-
tenance Remi nder (EMR) system. Every 8 mi l es, the
engi ne control l er records vehi cl e mi l eage and stores i t
i nto memory. When stori ng the mi l age i nto memory,
the engi ne control l er checks for the 96,000 km (60,000
mi l e), 132,000 km (82,500 mi l e) and 192,000 km
(120,000 mi l e) i nterval s. When the current mi l eage
matches a speci fi ed i nterval , the control l er turns the
EMR l i ght on.
Repl ace the fol l owi ng parts at the i ndi cated mi l eage,
or when the EMR l i ght remai ns on conti nuousl y wi th
the key i n the on posi ti on, whi chever occurs fi rst.
96,000 km (60,000 mi l es):
(a) Repl ace EGR Val ve.
(b) Repl ace EGR Tube (i f equi pped).
(c) Cl ean EGR passage.
(d) Repl ace PCV Val ve.
132,000 km (82,500 mi l es):
(a) Repl ace Oxygen Sensor.
192,000 km (120,000 mi l es):
(a) Repl ace EGR Val ve.
(b) Repl ace EGR Tube (i f equi pped).
(c) Cl ean EGR passage.
(d) Repl ace PCV Val ve.
After performi ng the requi red mai ntenance, the
EMR system must be reset to turn off the l i ght.
Fai l ure to perform the requi red mai ntenance and
onl y reset the EMR l i ght may be a vi ol ati on of federal
l aw. Reset the EMR l i ght onl y after performi ng the
requi red mai ntenance.
RESETTI NG EMR LAMP
(1) Connect DRB I I tool to the di agnosti c connector.
(2) Turn the i gni ti on swi tch to the run posi ti on,
access Select Systems on the DRB I I .
(3) Sel ect the appl i cabl e engi ne.
(4) Sel ect wi th or wi thout ai r condi ti oni ng.
(5) Sel ect Fuel and Ignition.
(6) Sel ect Adjustments
(7) Sel ect Reset EMR Light.
(8) Reset the EMR Li ght.
EMISSION CONTROL SYSTEMS 25 - 1
EVAPORATI VE EMI SSI ON CONTROLS
INDEX
page page
Canister Purge Solenoid . . . . . . . . . . . . . . . . . . . . 5
Evaporation Control System . . . . . . . . . . . . . . . . . . 5
Vacuum Schematics . . . . . . . . . . . . . . . . . . . . . . . . 3
Vehicle Emission Control Information Label . . . . . . . 2
VEHICLE EMISSION CONTROL INFORMATION LA-
BEL
Al l model s have a Vehi cl e Control I nformati on
(VECI ) Label . Chrysl er permanentl y attaches the l abel
to the mi ddl e of the hood (Fi g. 1). I t cannot be removed
wi thout defaci ng i nformati on and destroyi ng the l abel .
The l abel contai ns the vehi cl es emi ssi on speci fi ca-
ti ons and vacuum hose routi ngs. Al l hoses must be
connected and routed accordi ng to the l abel .
I f any di fference exi sts between the l abel and the
Servi ce Manual , refer to the l abel . Thelabels shown
are examples.
Fig. 1 Underhood Label Location
FEDERAL EMI SSI ON CONTROL
I NFORMATI ON LABELTYPI CAL
25 - 2 EMISSION CONTROL SYSTEMS
VACUUM SCHEMATICS
I f any di fference exi sts between the l abel and the
schemati cs i n the Servi ce Manual , refer to the l abel .
CALI FORNI A VEHI CLE CONTROL
CANADA VEHI CLE EMI SSI ON CONTROL
ENGI NE VACUUM SCHEMATI C2.5L ENGI NE
EVAPORATION CONTROL SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When fuel
evaporates i n the fuel tank, the vapors pass through
vent hoses or tubes to a charcoal cani ster. The cani ster
temporari l y hol ds the vapors. The engi ne control l er
al l ows i ntake mani fol d vacuum to draw vapors i nto the
combusti on chambers duri ng certai n operati ng condi -
ti ons. The control l er uses the cani ster purge sol enoi d to
regul ate vapor fl ow.
Mani fol d vacuum purges the vapors at i dl e as wel l as
off i dl e. The system i s a bi -l evel purge system. The
system uses 2 sources of vacuum remove fuel vapors
from the cani ster.
The evaporative system uses specially manu-
factured hoses. If they need replacement, only
use fuel resistant hose.
PRESSURE RELI EF/ROLLOVER VALVE
Al l vehi cl es have a combi nati on pressure rel i ef and
rol l over val ve. The dual functi on val ve rel i eves fuel
tank pressure. The val ve al so prevents fuel fl ow
through the fuel tank vent val ve hoses shoul d the
vehi cl e rol l over. Al l vehi cl es pass a 360 rol l over wi th-
out fuel l eakage.
The pressure rel i ef val ve opens at a certai n pressure.
When fuel tank pressure i ncreases above the cal i -
brated pressure, the val ve opens to rel ease fuel tank
vapors pressure. The evaporati ve (charcoal ) cani ster
stores the vapors. For pressure rel i ef/rol l over val ve
servi ce, refer to the Fuel Tank secti on of
Group 14.
EVAPORATI VE CANI STER
Al l vehi cl es use a seal ed, mai ntenance free, evapora-
ti ve (charcoal ) cani ster. The cani ster mounts to the
i nner wheel wel l area of the engi ne compartment (Fi g.
2).
Fuel tank pressure vents i nto the cani ster. The
cani ster temporari l y hol ds the fuel vapors unti l i ntake
mani fol d vacuum draws them i nto the combusti on
chamber. The cani ster purge sol enoi d al l ows the can-
i ster to be purged at predetermi ned i nterval s and
engi ne condi ti ons.
CANISTER PURGE SOLENOID
The engi ne control l er operates the cani ster purge
sol enoi d (Fi g. 3). Duri ng warm-up and for a speci fi ed
peri od after hot starts, the engi ne control l er grounds
the purge sol enoi d causi ng i t to energi ze. When the
control l er grounds the sol enoi d, vacuum does not reach
the charcoal cani ster val ve.
When the engi ne reaches a speci fi ed operati ng tem-
perature and the ti me del ay i nterval has occurred, the
control l er de-energi zes the sol enoi d by turni ng off the
ground. When the engi ne control l er de-energi zes
the sol enoi d, vacuum fl ows to the cani ster purge val ve.
I ntake mani fol d vacuum purges fuel vapors through
the throttl e body. The engi ne control l er al so energi zes
the purge sol enoi d duri ng certai n i dl e condi ti ons to
update the fuel del i very cal i brati on. Refer to On
Board Diagnostics in the General Diagnosis sec-
tion of Group 14 for test procedures.
PRESSURE-VACUUM FI LLER CAP
CAUTION: Remove the fuel filler cap to relieve fuel
tank pressure. The cap must be removed prior to
disconnecting any fuel system component or servic-
ing the fuel tank.
A pressure-vacuum rel i ef cap seal s the fuel tank (Fi g.
4). Ti ghteni ng the cap on the fuel fi l l er tube forms a
seal between them. The rel i ef val ves i n the cap are a
safety feature. They prevent possi bl e excessi ve pres-
sure or vacuum i n the tank. Excessi ve fuel tank pres-
sure coul d be caused by a mal functi on i n the system or
damage to the vent l i nes.
The seal between the cap and fi l l er tube breaks when
the cap i s removed. Removi ng the cap breaks the seal
and rel i eves fuel tank pressure.
I f the fi l l er cap needs repl acement, onl y use a si mi l ar
uni t.
POSI TI VE CRANKCASE VENTI LATI ON (PCV)
SYSTEMS
I ntake mani fol d vacuum removes crankcase vapors
and pi ston bl ow-by from the engi ne. The emi ssi ons
pass through the PCV val ve i nto the i ntake mani fol d
where they become part of the cal i brated ai r-fuel
mi xture. They are burned and expel l ed wi th the ex-
haust gases. The ai r cl eaner suppl i es make up ai r
when the engi ne does not have enough vapor or
bl ow-by gases. I n thi s system, fresh ai r does not enter
the crankcase (Fi gs. 5, 6, 7, 8, 9).
PCV VALVE TEST
WHEELS BEFORE PERFORMING ANY TEST OR AD-
JUSTMENT WITH THE ENGINE OPERATING.
Wi th the engi ne i dl i ng, remove the PCV val ve from
i ts attachi ng poi nt. I f the val ve i s operati ng properl y, a
hi ssi ng noi se wi l l be heard and a strong vacuum fel t
when pl aci ng a fi nger over the val ve i nl et (Fi g. 10).
Wi th the engi ne off, the shake the val ve. The val ve
shoul d rattl e when shaken. Repl ace
Fig. 4 Pressure Vacuum Filler Cap
Fig. 2 Evaporative Canister
Fig. 3 Canister Purge Solenoid
Fig. 5 PCV Valve 2.5L Engine
the val ve i f i t does not operate properl y. Do not
attempt to clean the PCV valve.
CRANKCASE VENT FI LTER
Al l engi nes have a crankcase vent fi l ter. The fi l ter
cl eans outsi de ai r before i t enters the PCV system. On
2.5L engi nes, the fi l ter mounts to the upper shel l
assembl y of the ai r cl eaner. On 3.0L engi nes, i t at-
taches to the i nsi de of the fi l ter el ement box under the
fi l ter el ement. On the 3.3L engi nes, the mounts to the
bottom of the fi l ter el ement box. (Refer to Group 0 for
mi l eage i nterval s and servi ce procedures.)
Fig. 7 Fresh Air Hose3.0L Engine PCV System
Fig. 9 Fresh Air Hose3.3L Engine PCV System
Fig. 10 Typical PCV Test
EXHAUST EMI SSI ON CONTROLS
INDEX
page page
EGR System Service . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust Gas Recirculation (EGR) System . . . . . . . 10
Heated Inlet Air System . . . . . . . . . . . . . . . . . . . . . 8
Heated Oxygen Sensor (O
2
Sensor) . . . . . . . . . . . . 9
HEATED INLET AIR SYSTEM
The 3.0L and 3.3L engi nes do not have a heated i nl et
ai r system.
The 2.5L engi ne ai r cl eaner has a heated ai r assem-
bl y (Fi g. 1). When ambi ent temperatures are l ow, the
assembl y warms the ai r before i t enters the throttl e
body. The heated ai r assembl y reduces hydrocarbon
emi ssi ons, i mproves engi ne warm-up characteri sti cs
and mi ni mi zes i ci ng.
The heated ai r assembl y contai ns a vacuum operated
bl end door. The bl end door opens to ei ther heated ai r
from a stove on the exhaust mani fol d or ambi ent ai r
(outsi de ai r). A vacuum di aphragm operates the door. A
spri ng opposes the vacuum di aphragm. A temperature
sensor control s the vacuum di aphragm (Fi g. 2). Adjust-
ment of i nl et ai r temperature occurs onl y at road l oad
throttl e posi ti ons or when the i ntake mani fol d vacuum
exceeds the vacuum di aphragm spri ng rate.
Ai r fl ows through the outsi de ai r i nl et when ambi ent
ai r temperature i s 8C (15F) or more above the ai r
temperature sensor control temperature.
When ambi ent ai r temperature fal l s bel ow the con-
trol temperature, ai r fl ows through both the ambi ent
and heated ci rcui ts. Thi s occurs after the engi ne has
been started and the exhaust mani fol d starts to gi ve off
heat. Col der ambi ent ai r cause greater ai r fl ow through
the heat stove on the exhaust mani fol d. Warmer am-
bi ent ai r resul ts i n greater ambi ent ai r fl ow through
the ai r cl eaner snorkel .
HEATED I NLET AI R SYSTEM SERVI CE
Heated ai r i nl et system mal functi ons may affect
dri veabi l i ty and vehi cl e exhaust emi ssi ons.
Use the fol l owi ng procedure to determi ne i f the
system functi ons properl y.
(1) I nspect the condi ti on of the heat stove to ai r
cl eaner fl exi bl e connector and al l vacuum hoses. I n-
spect them for proper attachment. Repl ace as neces-
sary.
(2) Wi th a col d engi ne and ambi ent temperature l ess
than 46C (115F.), the heat control door (val ve pl ate)
shoul d be i n the up or heat on position.
(3) Wi th the engi ne warmed up and runni ng, check
the ai r temperature enteri ng the snorkel or at the
sensor. When the ai r temperature enteri ng the outer
end of snorkel i s 60C (140F.) or hi gher, the door
shoul d be i n the down posi ti on (heat off).
(4) Remove the ai r cl eaner from the engi ne and
al l ow i t to cool down to 46C (115F). Wi th 20 i nches of
vacuum appl i ed to the sensor, the door shoul d be i n the
up or (heat on position). I f the door does not ri se to
the heat on posi ti on, check the vacuum di aphragm for
proper operati on.
Fig. 2 Heated Air Temperature Sensor
Fig. 1 Heated Air Inlet System
(5) To test the di aphragm, appl y 20 i nches of vacuum
to the di aphragm wi th vacuum pump tool number
C-4207 or equi val ent (Fi g. 3). The di aphragm shoul d
not bl eed down more than 10 i nches of vacuum i n 5
mi nutes. The door shoul d not l i ft off the bottom of the
snorkel at l ess than 2 i nches of vacuum. The door
shoul d be i n the ful l up posi ti on wi th no more than 4
i nches of vacuum.
(6) I f the vacuum di aphragm does not perform ad-
equatel y, repl ace the heated ai r assembl y.
(7) I f the vacuum di aphragm performs adequatel y
but proper temperature i s not mai ntai ned, repl ace the
sensor and repeat the temperature checks i n steps 2
and 3.
HEATED AI R TEMPERATURE SENSOR SER-
VI CE
REMOVAL
Wi th ai r cl eaner housi ng removed from vehi cl e:
(1) Di sconnect vacuum hoses from sensor, remove
retai ner cl i ps (Fi g. 4), and di scard (new cl i ps are
suppl i ed wi th a new sensor).
(2) Remove sensor wi th gasket and di scard.
INSTALLATION
(1) Posi ti on gasket on the sensor. I nstal l sensor (Fi g.
5).
(2) Whi l e supporti ng the sensor on outer di ameter,
i nstal l new retai ner cl i ps securel y. Ensure the gasket
compresses to form an ai r seal . Do not attempt to
adjust the sensor.
HEATED OXYGEN SENSOR (O
2
SENSOR)
The O
2
sensor threads i nto the exhaust mani fol d. I t
provi des an i nput vol tage to the engi ne control l er. The
i nput tel l s the engi ne control l er the oxygen content of
the exhaust gas (Fi g. 6, 7 or 8). The engi ne control l er
uses thi s i nformati on to fi ne tune the ai r-fuel rati o by
adjusti ng i njector pul se wi dth.
The O
2
sensor produces vol tages from 0 to 1 vol t,
dependi ng upon the oxygen content of the exhaust gas
i n the exhaust mani fol d. When a l arge amount of
Fig. 6 Oxygen Sensor2.5L Engine
Fig. 3 Testing Vacuum Diaphragm on Heated Air In-
let Systems
Fig. 4 Removing Sensor Clips
Fig. 5 Installing Gasket and Sensor
oxygen i s present (caused by a l ean ai r-fuel mi xture),
the sensor produces a l ow vol tage. When there i s a
l esser amount present (ri ch ai r-fuel mi xture) the sen-
sor produces a hi gher vol tage. By moni tori ng the
oxygen content and converti ng i t to el ectri cal vol tage,
the sensor acts as a ri ch-l ean swi tch.
The oxygen sensor contai ns a heati ng el ement that
keeps i t at proper operati ng temperature duri ng al l
operati ng modes. Mai ntai ni ng correct sensor tempera-
ture at al l ti mes al l ows the system to enter i nto cl osed
l oop operati on sooner and to remai n i n cl osed l oop
operati on duri ng peri ods of extended i dl e.
I n Cl osed Loop operati on the engi ne control l er
moni tors the O
2
sensor i nput (al ong wi th other i nputs)
and adjusts the i njector pul se wi dth accordi ngl y. Dur-
i ng Open Loop operati on the engi ne control l er i g-
nores the O
2
sensor i nput. The control l er adjusts
i njector pul se wi dth based on preprogrammed (fi xed)
oxygen sensor i nput val ues and the current i nputs
from other sensors.
REMOVAL
CAUTION: Do not pull on the oxygen sensor wire
when disconnecting the electrical connector.
WARNING: THE EXHAUST MANIFOLD MAY BE EX-
TREMELY HOT. USE CARE WHEN SERVICING THE
OXYGEN SENSOR.
(1) Di sconnect oxygen sensor el ectri cal connector.
(2) Remove sensor usi ng Tool C-4907 (Fi g. 9).
After removi ng the sensor, the exhaust mani fol d
threads must be cl eaned wi th an 18 mm X 1.5 + 6E tap.
I f reusi ng the ori gi nal sensor, coat the sensor threads
wi th an anti -sei ze compound such as Locti te 771-64 or
equi val ent. New sensors have compound on the
threads and do not requi re an addi ti onal coati ng.
Ti ghten the sensor to 27 Nm (20 ft. l bs.) torque.
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Exhaust Gas Reci rcul ati on (EGR) systems may be
used on certai n Cal i forni a vehi cl es equi pped wi th a
3.0L engi ne and an automati c transmi ssi on.
The EGR system reduces oxi des of ni trogen (NOx) i n
engi ne exhaust and hel ps prevent spark knock. The
system al l ows a predetermi ned amount of hot exhaust
gas to reci rcul ate and di l ute the i ncomi ng ai r/fuel
mi xture. The di l uted ai r/fuel mi xture reduces peak
fl ame temperature duri ng combusti on.
The EGR system (Fi g. 10) consi sts of:
EGR tube (connects a passage i n the i ntake mani -
fol d to the exhaust mani fol d)
EGR val ve
El ectroni c EGR Transducer (EET)
Connecti ng hoses
The el ectroni c EGR transducer (EET) contai ns an
el ectri cal l y operated sol enoi d and a back-pressure
transducer (Fi g. 11). The engi ne control l er operates the
sol enoi d. The control l er determi nes when to energi ze
the sol enoi d. Exhaust system back-pressure control s
the transducer.
Fig. 9 Oxygen Sensor Socket
When the control l er energi zes the sol enoi d, vacuum
does not reach the transducer. Vacuum fl ows to the
transducer when the control l er de-energi zes the sol e-
noi d.
When exhaust system back-pressure becomes hi gh
enough, i t ful l y cl oses a bl eed val ve i n the transducer.
When the control l er de-energi zes the sol enoi d and
back-pressure cl oses the transducer bl eed val ve,
vacuum fl ows through the transducer to operate the
EGR val ve.
De-energi zi ng the sol enoi d, but not ful l y cl osi ng the
transducer bl eed hol e (because of by l ow back-
pressure), vari es the strength of vacuum appl i ed to the
EGR val ve. Varyi ng the strength of the vacuum
changes the amount of EGR suppl i ed to the engi ne.
Thi s provi des the correct amount of exhaust gas reci r-
cul ati on for di fferent operati ng condi ti ons.
Thi s system does not al l ow EGR at i dl e. The EGR
systems can operate at al l temperatures above 60F.
EGR SYSTEM ON-BOARD DI AGNOSTI CS
(CALI FORNI A VEHI CLES)
The engi ne control l er performs an on-board di agnos-
ti c check of the EGR system on al l Cal i forni a vehi cl es
wi th EGR systems. The di agnosti c system uses the
El ectri c EGR Transducer (EET) for the system tests.
The di agnosti c check acti vates onl y duri ng sel ected
engi ne/dri vi ng condi ti ons. When the condi ti ons are
met, the engi ne control l er energi zes the transducer
sol enoi d to di sabl e the EGR. The control l er checks for a
change i n the oxygen sensor si gnal . I f the ai r-fuel
mi xture goes l ean, the engi ne control l er wi l l attempt to
enri chen the mi xture. The engi ne control l er regi sters a
faul t i f the EGR system has fai l ed or degraded. After
regi steri ng a faul t, the engi ne control l er turns the
CHECK ENGINE l i ght on. The CHECK ENGINE
l i ght i ndi cates the need for i mmedi ate servi ce.
I f a mal functi on i s i ndi cated by the CHECK EN-
GINE l i ght and a faul t code for the EGR system, check
for proper operati on of the EGR system. Use the
System Test, EGR Gas Fl ow Test and EGR Di agnosi s
Chart. I f the EGR system tests properl y, check the
system usi ng the DRB I I tester. Refer to On-Board
Di agnosi s i n the General Di agnosi s secti ons of Group
14. Al so, refer to the DRB I I and the appropri ate
Powertrai n Di agnosti cs Procedure manual .
EXHAUST GAS RECI RCULATI ON (EGR) SYS-
TEM TEST
WHEELS BEFORE PERFORMING EGR SYSTEM
TEST.
A fai l ed or mal functi oni ng EGR system can cause
engi ne spark knock, sags or hesi tati on, rough i dl e,
and/or engi ne stal l i ng. To ensure proper operati on of
the EGR system, al l passages and movi ng parts must
be free of deposi ts that coul d cause pl uggi ng or sti ck-
i ng. Ensure that the system hoses does not l eak.
Repl ace l eaki ng components.
I nspect hose connecti ons between throttl e body, i n-
take mani fol d, EGR sol enoi d and transducer, and the
EGR val ve. Repl ace hardened, cracked, or mel ted
hoses. Repai r or repl ace faul ty connectors.
Check the EGR control system and EGR val ve wi th
the engi ne ful l y warmed up and runni ng (engi ne cool -
ant temperature over 150F). Wi th the transmi ssi on i n
neutral and the throttl e cl osed, al l ow the engi ne to i dl e
for 70 seconds. Abruptl y accel erate the engi ne to ap-
proxi matel y 2000 rpm, but not over 3000 rpm. The
EGR val ve stem shoul d move when accel erati ng the
engi ne (the rel ati ve posi ti on of the groove on the EGR
val ve stem shoul d change). Repeat the test several
ti mes to confi rm movement. I f the EGR val ve stem
moves, the control system i s operati ng normal l y. I f the
control system i s not operati ng normal l y, refer to the
EGR Di agnosi s Chart to determi ne the cause.
Fig. 10 EGR System3.0L Engine
Fig. 11 Electric EGR Transducer (EET) Assembly
EGR DI AGNOSI S CHART
EGR GAS FLOW TEST
The fol l owi ng procedure shoul d be used to determi ne
i f exhaust gas i s fl owi ng through the EGR system:
Connect a hand vacuum pump to the EGR val ve
vacuum motor. Wi th engi ne runni ng at i dl e speed,
sl owl y appl y vacuum. Engi ne speed shoul d begi n to
drop when appl i ed vacuum reaches 2.0 to 3.5 i nches.
Engi ne speed may drop qui ckl y or engi ne may even
stal l . Thi s i ndi cates that EGR gas i s fl owi ng through
the system.
I f both the EGR Gas Fl ow Check, System Check and
Di agnosi s Chart are compl eted sati sfactori l y, then the
EGR system functi ons normal l y.
I f engi ne speed does not drop off when performi ng
the test, remove both the EGR val ve and EGR tube and
check for pl ugged passages. Al so, check the i ntake
mani fol d i nl et passage. Cl ean or repl ace these compo-
nents for restorati on of proper fl ow.
EGR SYSTEM SERVICE
The EGR val ve and El ectri cal EGR Transducer
(EET) are servi ced as an assembl y.
EGR VALVE REMOVAL
(1) Di sconnect vacuum l i ne between the throttl e
body and the el ectri c EGR transducer (EET). I nspect
for damage.
(2) Remove EGR val ve mounti ng bol ts.
(3) Remove EGR val ve.
(4) Cl ean gasket surfaces. Di scard the ol d gasket.
Check for any si gns of l eakage or cracked surfaces.
I NSTALLATI ON
(1) Pl ace EGR val ve and new gasket on mani fol d.
(2) Ti ghten EGR bol ts to 22 Nm (200 i n. l bs.)
torque.
(3) Reconnect vacuum l i ne between the throttl e body
and el ectri c EGR transducer (EET).
EGR TUBE REMOVAL
(1) Remove EGR tube attachi ng bol ts (4) from i ntake
and exhaust mani fol ds (Fi g. 10)
(2) Remove EGR tube.
(3) Cl ean i ntake and exhaust mani fol d gasket sur-
faces and EGR tube fl ange gasket surfaces. Di scard ol d
gaskets.
(4) Check for si gns of l eakage or cracked surfaces on
the mani fol ds and tube. Repai r or repl ace as necessary.
I NSTALLATI ON
(1) Loosel y connect the EGR tube and new gaskets
wi th the mounti ng bol ts.
(2) Ti ghten mounti ng bol ts to 22 Nm (200 i n.l bs.)
torque.
HEATING AND AIR CONDITIONING
CONTENTS
page page
AUXILIARY REAR HEATING OR HEATING-AIR/
CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 50
COMPONENT DIAGNOSIS PROCEDURES . . . . 38
COMPONENT SERVICE PROCEDURES . . . . . . . 41
FIXED DISPLACEMENT COMPRESSOR AND
COMPONENTS DIAGNOSTIC PROCEDURES . 13
FIXED DISPLACEMENT COMPRESSOR SERVICE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 32
HEATER AND A/C PERFORMANCE TESTS . . . . 19
REFRIGERANT SERVICE PROCEDURES . . . . . . 22
VACUUM CONTROL SYSTEM DIAGNOSIS . . . . 18
VARIABLE COMPRESSOR AND COMPONENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 4
VARIABLE DISPLACEMENT COMPRESSOR SER-
VICE PROCEDURES . . . . . . . . . . . . . . . . . . . . 27
INDEX
page page
A/C System Identification . . . . . . . . . . . . . . . . . . . . 1
Cooling System Precautions . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . 1
Engine Cooling System Requirements . . . . . . . . . . 2
Handling Tubing and Fittings . . . . . . . . . . . . . . . . . 3
Safety Precautions and Warnings . . . . . . . . . . . . . . 2
Side Window Demisters . . . . . . . . . . . . . . . . . . . . . 2
System Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A/C SYSTEM IDENTIFICATION
The terms Fi xed Di spl acement Compressor and Vari -
abl e Di spl acement Compressor are used to descri be the
two types of A/C systems used throughout thi s Group.
Refer to (Fi gs. 1 and 2).
The Vari abl e Di spl acement Compressor can be i den-
ti fi ed by the l ocati on of the hi gh pressure l i ne. I t i s
mounted to the end of the compressor case (Fi g. 2).
DESCRIPTION AND OPERATION
Both the heater and the heater/ai r condi ti oni ng sys-
tems share many of the same components. Thi s Group
wi l l deal wi th both systems together when component
functi on i s common, and separatel y when they are not.
For proper operati on of the i nstrument panel con-
trol s, refer to the Owners Manual provi ded wi th the
vehi cl e.
Al l vehi cl es are equi pped wi th a common A/C-heater
uni t housi ng assembl y. When the vehi cl e has onl y a
heater system, the evaporator and reci rcul ati ng ai r
door are omi tted from the heater uni t housi ng assem-
bl y (Fi g. 3).
SYSTEM AIRFLOW
The system pul l s outsi de (ambi ent) ai r through the
cowl openi ng at the base of the wi ndshi el d. Then i t goes
i nto the pl enum chamber above the A/C-heater uni t
housi ng. On ai r-condi ti oned vehi cl es, the ai r passes
through the evaporator. At thi s poi nt the ai r
Fig. 1 Fixed Displacement CompressorModel
10PA17
HEATING AND AIR CONDITIONING 24 - 1
fl ow can be di rected ei ther through or around the
heater core. Thi s i s done by adjusti ng the bl end-ai r
door wi th the TEMP control on the i nstrument panel .
The ai r fl ow can then be di rected from the PANEL,
BI -LEVEL (panel and fl oor), and FLOOR-DEFROST
outl ets. Ai r fl ow vel oci ty can be adjusted wi th the
bl ower speed sel ector swi tch on the i nstrument panel
(Fi g. 4).
On ai r-condi ti oned vehi cl es, ambi ent ai r i ntake can
be shut off by cl osi ng the reci rcul ati ng ai r door to
reci rcul ate the ai r that i s al ready i nsi de the vehi cl e.
Thi s i s done by movi ng the TEMP control i nto the
RECI RC posi ti on. Depressi ng the DEFROST or A/C
button wi l l engage the compressor. Thi s wi l l send
refri gerant through the evaporator, and wi l l remove
heat and humi di ty from the ai r before i t i s di rected
through or around the heater core.
SIDE WINDOW DEMISTERS
The si de wi ndow demi sters di rect ai r from the heater
assembl y. The outl ets are l ocated on the top outboard
corners of the i nstrument panel . The Demi sters oper-
ate when the A/C control mode sel ector i s on FLOOR,
DEFROST or BI -LEVEL setti ng.
ENGINE COOLING SYSTEM REQUIREMENTS
To mai ntai n adequate temperature l evel s from the
heati ng/ai r-condi ti oni ng system, the engi ne cool i ng
system must be i n proper worki ng order. Refer to
Group 0, Lubri cati on and Mai ntenance, or Group 7,
Cool i ng System of thi s manual .
The use of a bug screen i s not recommended. Any
obstructi ons forward of the radi ator or condenser can
reduce the effecti veness of the ai r-condi ti oni ng or en-
gi ne cool i ng system.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SERVIC-
ING THE AIR-CONDITIONING REFRIGERANT SYS-
TEM. SERIOUS EYE INJURY CAN RESULT FROMEYE
CONTACT WITH REFRIGERANT. IF EYE CONTACT IS
MADE, SEEK MEDICAL ATTENTION IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN FLAME.
POISONOUS GAS IS CREATED WHEN REFRIGER-
ANT IS BURNED. AN ELECTRONIC TYPE LEAK DE-
TECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF (R-12) REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT WILL
FREEZE. ALWAYS PROTECT SKIN OR DELICATE
OBJECTS FROM DIRECT CONTACT WITH REFRIG-
ERANT.
Fig. 2 Variable Displacement CompressorModel
6C17
Fig. 3 Common Blend-Air Heater A/C System
Fig. 4 Heater only or HeaterA/C Controls
24 - 2 HEATING AND AIR CONDITIONING
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions and pre-
cautions supplied with equipment being used when
servicing refrigerant system.
COOLING SYSTEM PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWALLOWED
OR INHALED. IF SWALLOWED, DRINK TWO
GLASSES OF WATER AND INDUCE VOMITING. IF
INHALED, MOVE TO FRESH AIR AREA. SEEK MEDI-
CAL ATTENTION IMMEDIATELY.
DO NOT STORE IN OPEN OR UNMARKED CON-
TAINERS.
WASH SKINAND CLOTHING THOROUGHLYAFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE ISAT RUNNING TEMPERATURE. PERSONAL
INJURY CAN RESULT.
The engi ne cool i ng system i s desi gned to devel op
i nternal pressure of 97 to 123 kPa (14 to 18 psi ) under
normal operati ng condi ti ons. Al l ow the vehi cl e approxi -
matel y 15 mi nutes (or unti l a safe temperature and
pressure are attai ned) before openi ng the cool i ng sys-
tem. Refer to Group 7, Cool i ng System.
HANDLING TUBING AND FITTINGS
Ki nks i n the refri gerant tubi ng or sharp bends i n the
refri gerant hose l i nes wi l l greatl y reduce the capaci ty
of the enti re system. Hi gh pressures are produced i n
the system when i t i s operati ng. Extreme care must be
exerci sed to make sure that al l connecti ons are pres-
sure ti ght. Di rt and moi sture can enter the system
when i t i s opened for repai r or repl acement of l i nes or
components. The refri gerant oi l wi l l absorb moi sture
readi l y out of the ai r. Thi s moi sture wi l l convert i nto
aci ds wi thi n a cl osed system.
The fol l owi ng precauti ons must be observed:
The system must be compl etel y di scharged before
openi ng any fi tti ng or connecti on i n the refri gerati on
system. Open fi tti ngs wi th cauti on even after the
system has been di scharged. I f any pressure i s noti ced
as a fi tti ng i s l oosened, al l ow trapped pressure to bl eed
off very sl owl y.
A good rul e for the fl exi bl e hose l i nes i s to keep the
radi us of al l bends at l east 10 ti mes the di ameter of the
hose. Sharper bends wi l l reduce the fl ow of refri gerant.
The fl exi bl e hose l i nes shoul d be routed so they are at
l east 3 i nches (80 mm) from the exhaust mani fol d.
I nspect al l fl exi bl e hose l i nes to make sure they are i n
good condi ti on and properl y routed.
Uni fi ed pl umbi ng connecti ons wi th al umi num gas-
kets cannot be servi ced wi th O-ri ngs. These gaskets
are not reusabl e and do not requi re l ubri cati on before
i nstal l i ng.
The use of correct wrenches when maki ng connec-
ti ons i s very i mportant. I mproper wrenches or i m-
proper use of wrenches can damage the fi tti ngs.
The i nternal parts of the refri gerati on system wi l l
remai n i n a state of chemi cal stabi l i ty as l ong as
pure-moi sture-free Refri gerant 12 and refri gerant oi l i s
used. Abnormal amounts of di rt, moi sture or ai r can
upset the chemi cal stabi l i ty. Thi s may cause opera-
ti onal troubl es or even seri ous damage i f present i n
more than very smal l quanti ti es.
When openi ng a refri gerati on system, have every-
thi ng you wi l l need to repai r the system ready. Thi s
wi l l mi ni mi ze the amount of ti me the system must be
opened. Cap or pl ug al l l i nes and fi tti ngs as soon as
they are opened. Thi s wi l l hel p prevent the entrance or
di rt and moi sture. Al l new l i nes and components
shoul d be capped or seal ed unti l they are ready to be
used.
Al l tool s, i ncl udi ng the refri gerant di spensi ng mani -
fol d, the mani fol d gauge set, and test hoses shoul d be
kept cl ean and dry.
VARI ABLE COMPRESSOR AND COMPONENTS DI AGNOSTI C PROCEDURES
INDEX
page page
Ambient Switch Diagnosis . . . . . . . . . . . . . . . . . . . 8
Clutch Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor Clutch Inoperative . . . . . . . . . . . . . . . . 4
Compressor Identification . . . . . . . . . . . . . . . . . . . . 4
Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . . 4
Condenser Fan Control Switch Diagnosis . . . . . . . . 8
Differential Pressure Cut-Out Switch Diagnosis . . . . 8
Expansion Valve Tests . . . . . . . . . . . . . . . . . . . . . 11
High Pressure Cut-Out Switch Diagnosis . . . . . . . 10
High Pressure Relief Valve (HPR) Diagnosis . . . . . 11
Variable Displacement Compressor Diagnosis . . . . . 4
GENERAL INFORMATION
The Vari abl e Di spl acement Compressor (VDC) pro-
vi des maxi mum ai r-condi ti oni ng performance i n most
ambi ent condi ti ons. I t i s desi gned to operate conti nu-
ousl y wi thout any cycl i ng of the compressor cl utch. The
basi c compressor mechani sm i s a vari abl e angl e
wobbl e pl ate wi th si x axi al l y ori ented cyl i nders.
The compressor wi l l change di spl acement to match
the vehi cl e ai r condi ti oni ng demand. The pumpi ng
stroke i s governed by the pressure di fferenti al of the
sucti on and the crankcase pressures. When the sucti on
pressure i s hi gher than the crankcase pressure, the
wobbl e pl ate angl e i n the compressor wi l l i ncrease.
When the sucti on pressure i s l ower than the crankcase
pressure, the wobbl e pl ate angl e wi l l decrease and so
wi l l the compressor pumpi ng stroke. When the heat
l oad at the evaporator decreases or when compressor
RPM i ncreases, the sucti on pressure decreases. Thi s
causes the mai n control val ve to open and al l ow hi gh
pressure di scharge gas to bl eed i nto the crankcase to
i ncrease the crankcase pressure. The el evated crank-
case pressure wi l l reduce the wobbl e pl ate angl e or
reduce the pumpi ng stroke. When qui ck cool i ng i s
needed at the system starti ng up, the sub-control val ve
i s opened for qui cker rel ease of crankcase pressure to
the sucti on si de. Under hi gh heat l oad condi ti ons, the
mai n control i s compl etel y cl osed.
COMPRESSOR IDENTIFICATION
The Vari abl e Di spl acement Compressor can be i den-
ti fi ed by the l ocati on of the hi gh pressure l i ne. I t i s
mounted to the end of the compressor case (Fi g. 1).
VARIABLE DISPLACEMENT COMPRESSOR DIAG-
NOSIS
(1) Veri fy that refri gerant system i s at ful l charge.
(2) Perform A/C Performance Test.
(3) I f performance i s not acceptabl e, perform expan-
si on val ve tests.
(4) I f expansi on val ve test i s correct, refer to the
Vari abl e Di spl acement Compressor test charts.
COMPRESSOR NOISE
Excessi ve noi se that occurs when the ai r-
condi ti oni ng i s bei ng used, can be caused by:
Loose bol ts
Mounti ng brackets
Loose cl utch
Excessi ve hi gh refri gerant system operati ng pres-
sure
Veri fy compressor dri ve bel t condi ti on, proper refri g-
erant charge and head pressure before compressor
repai r i s performed.
For noi se di agnosti c procedures, refer to the Com-
pressor Noi se and Compressor Cl utch Di agnosi s chart
i n thi s secti on.
COMPRESSOR CLUTCH INOPERATIVE
The ai r-condi ti oni ng compressor cl utch el ectri cal ci r-
cui t i s control l ed by the engi ne control l er computer. I t
i s l ocated i n the engi ne compartment outboard of the
battery.
6C17
VARI ABLE DI SPLACEMENT COMPRESSOR DI AGNOSI S
REFRI GERANT SYSTEM DI AGNOSI SVARI ABLE DI SPLACEMENT COMPRESSOR
COMPRESSOR NOI SE AND COMPRESSOR CLUTCH DI AGNOSI S

I f the compressor cl utch does not engage:
Veri fy refri gerant charge.
I f the compressor cl utch sti l l does not engage:
Check for battery vol tage at the di fferenti al pressure
cut-off swi tch l ocated on the expansi on val ve. I f vol tage
i s not detected, refer to:
(1) Group 8W, Wi ri ng Di agrams.
(2) The appropri ate Powertrai n Di agnosti c Proce-
dures manual for di agnosti c i nformati on.
(3) The Compressor Cl utch Di agnosi sVari abl e
Di spl acement Compressor chart i n thi s secti on.
I f vol tage i s detected at the cut-off swi tch, connect
swi tch and check for battery vol tage between the
compressor cl utch connector termi nal s.
I f vol tage i s detected, perform A/C Cl utch Coi l Tests.
CLUTCH COIL TESTS
(1) Veri fy battery state of charge. (Test i ndi cator i n
battery shoul d be green).
(2) Connect an ammeter (0-10 ampere scal e) i n se-
ri es wi th the cl utch coi l termi nal . Use a vol t meter
(0-20 vol t scal e) wi th cl i p l eads measuri ng vol tage
across the battery and A/C cl utch.
(3) Wi th A/C control i n A/C mode and bl ower at l ow
speed, start the engi ne and run at normal i dl e.
(4) The A/C cl utch shoul d engage i mmedi atel y and
the cl utch vol tage shoul d be wi thi n two vol ts of the
battery vol tage. I f the A/C cl utch does not engage, test
the fusi bl e l i nk.
(5) The A/C cl utch coi l i s acceptabl e i f the current
draw i s 2.0 to 3.7 amperes at 11.5-12.5 vol ts at cl utch
coi l . Thi s i s wi th the work area temperature at 21C
(70F). I f vol tage i s more than 12.5 vol ts, add el ectri cal
l oads by turni ng on el ectri cal accessori es unti l vol tage
reads bel ow 12.5 vol ts.
I f coi l current reads zero, the coi l i s open and shoul d
be repl aced. I f the ammeter readi ng i s 4 amperes or
more, the coi l i s shorted and shoul d be repl aced. I f the
coi l vol tage i s not wi thi n two vol ts of the battery
vol tage, test cl utch coi l feed ci rcui t for excessi ve vol t-
age drop.
DIFFERENTIAL PRESSURE CUT-OUT SWITCH DI-
AGNOSIS
The Di fferenti al Pressure Cut-Out (DPCO) Swi tch
(Fi g. 2) moni tors the l i qui d refri gerant pressure on the
l i qui d si de of the system. The DPCO i s l ocated on the
expansi on val ve. The expansi on val ve i s bl ack i n col or
when a vari abl e di spl acement compressor i s used. The
DPCO turns off vol tage to the compressor cl utch coi l
when l i qui d refri gerant pressure drops to l evel s that
coul d damage the compressor. The DPCO i s a seal ed
factory cal i brated uni t. I t must be repl aced i f defecti ve.
DPCO SWI TCH TEST
The work area temperature must not be bel ow 10C
(50F) to test the compressor cl utch ci rcui t.
(1) Wi th gear sel ector i n park or neutral , and park
brake set, start engi ne and al l ow to i dl e.
(2) Rai se hood and di sconnect DPCO swi tch connec-
tor boot.
(3) Usi ng a sui tabl e jumper wi re, jump across the
termi nal s i nsi de wi re connector boot.
(4) I f cl utch does not engage, the wi ri ng, fuse, rel ay,
ambi ent swi tch, or hi gh pressure cut-off swi tch can be
defecti ve. Refer to Group 8W, Wi ri ng Di agrams.
(5) I f cl utch engages, connect a sui tabl e mani fol d
gauge set. Read l ow pressure gauge. At pressure 283
kPa (41 psi ) and above, DPCO swi tch wi l l compl ete the
cl utch ci rcui t. I f the l ow pressure gauge reads bel ow
317 kPa (46 psi ), the system i s l ow on refri gerant
charge or empty due to a l eak.
(6) I nstal l connector boot on swi tch and repeat step
number 3. I f the cl utch does not engage, repl ace the
DPCO swi tch.
AMBIENT SWITCH DIAGNOSIS
The ambi ent swi tch i s a temperature sensor l ocated
i n front of the condenser behi nd the gri l l e. The ambi ent
swi tch prevents the compressor from engagi ng i n col d
temperatures. The ambi ent swi tch i s a seal ed factory
cal i brated uni t. I t must be repl aced i f defecti ve.
AMBI ENT SWI TCH TEST
(1) Di sconnect ambi ent swi tch wi re connector.
(2) Usi ng a sui tabl e ohm meter or conti nui ty tester,
test for conti nui ty across the ambi ent swi tch termi -
nal s.
(a) At temperature above 10C (50F), the swi tch
ci rcui t shoul d be compl ete.
(b) Chi l l the swi tch wi th i ce to bel ow 10C (50F)
and test for conti nui ty. The swi tch ci rcui t shoul d be
open, wi th conti nui ty not detected.
Repl ace ambi ent swi tch i f defecti ve.
CONDENSER FAN CONTROL SWITCH DIAGNOSIS
The Fan Control Swi tch i s l ocated on the pl umbi ng
di scharge l i ne at the A/C compressor (Fi g. 3). The fan
control swi tch cycl es the radi ator/condenser fan on and
off by moni tori ng the compressor di scharge pressure.
The radi ator top tank temperature sensor can over ri de
the functi on of the fan control swi tch. I t wi l l cycl e the
radi ator/condenser fan on and off dependi ng on the
engi ne cool ant temperature.
FAN CONTROL SWI TCH TEST
Revi ew Safety Precauti ons and Warni ngs i n the
General I nformati on secti on of thi s Group before pro-
ceedi ng wi th thi s operati on. Connect a sui tabl e man-
COMPRESSOR CLUTCH DI AGNOSI SVARI ABLE DI SPLACEMENT COMPRESSORMODEL 6C17
i fol d gauge set to the refri gerant system servi ce ports.
Work area temperature can not be bel ow 21C (70F).
WARNING: AVOID RADIATOR/CONDENSER FAN
BLADES WHEN WORKING IN THE RADIATOR AREA.
FAN IS CONTROLLED BY TEMPERATURE AND CAN
START ANY TIME IGNITION IS ON. PERSONAL IN-
JURY CAN RESULT.
(1) Di sconnect fan control swi tch wi re connector.
(2) Usi ng a sui tabl e jumper wi re, jump across termi -
nal s i n wi re connector.
(3) Connect a sui tabl e conti nui ty tester across fan
control swi tch termi nal s.
(4) Start engi ne and set i dl e at 1300 rpm. The
radi ator fan shoul d run constantl y.
(5) Set the A/C control s to A/C and hi gh bl ower.
(6) I f the hi gh pressure gauge reads bel ow 1102 kPa
(160 psi ) there shoul d be no conti nui ty across the
swi tch termi nal s.
CAUTION: Do not allow engine to overheat when
radiator air flow is blocked.
(7) Bl ock radi ator ai r fl ow wi th a sui tabl e cover to
i ncrease the hi gh si de pressure to at l east 1585 kPa
(230 psi ). El ectri cal conti nui ty shoul d be detected
across the fan control swi tch termi nal s.
(8) Remove cover from front of vehi cl e to al l ow hi gh
si de pressure to decrease. When pressure drops bel ow
1102 kPa (160 psi ), conti nui ty shoul d cease.
I f fan control swi tch i s defecti ve, repl ace i t.
HIGH PRESSURE CUT-OUT SWITCH DIAGNOSIS
The Hi gh Pressure Cut Out (HPCO) swi tch i s l ocated
on the rear cover of the Vari abl e Di spl acement Com-
pressor (Fi g. 4). The functi on of the swi tch i s to
di sengage the compressor cl utch by moni tori ng the
compressor di scharge (hi gh) pressure. The HPCO
Swi tch i s i n the same ci rcui t as the Di fferenti al Pres-
sure Cut Out (DPCO) swi tch and Ambi ent Swi tch.
HPCO SWI TCH TESTS
General I nformati on secti on before proceedi ng wi th
thi s operati on.
Connect a sui tabl e mani fol d gauge set to the refri g-
erant system servi ce ports. Work area temperature can
not be bel ow 21C (70F).
(1) Rai se hood of vehi cl e.
(2) Wi th gear sel ector i n park or neutral , and park
brake set, start engi ne and al l ow to i dl e at 1300 rpm.
(3) Set the A/C control s to A/C and Hi gh bl ower.
Fig. 2 Differential Pressure Cut-Out Switch
Fig. 3 Condenser Fan Control Switch
6C17
(4) I f the hi gh pressure gauge reads bel ow 2963 kPa
(430 psi ) 138 kPa (20 psi ) the compressor cl utch
shoul d be engaged.
CAUTION: Do not allow engine to overheat when
radiator air flow is blocked.
(5) Bl ock radi ator ai r fl ow wi th a sui tabl e cover to
i ncrease the hi gh si de pressure to at l east 3100 kPa
(450 psi ). Compressor cl utch shoul d di sengage.
(6) Remove cover from front of vehi cl e to al l ow hi gh
si de pressure to decrease. When pressure drops bel ow
1826 kPa (265 psi ), compressor cl utch shoul d engage.
I f Hi gh Pressure Cut-Out Swi tch i s defecti ve, repl ace
i t.
BLACK EXPANSION VALVE TEST
General I nformati on secti on of thi s Group. The work
area temperature must be 21C to 27C (70F to 85F)
when testi ng expansi on val ve. To test the expansi on
val ve:
(1) Connect a chargi ng stati on or mani fol d gauge set
to the refri gerant system servi ce ports. Veri fy the
refri gerant charge l evel usi ng the si ght gl ass method.
(2) Di sconnect and pl ug the vacuum l i ne at the
water control val ve.
(3) Di sconnect the wi re connector at the di fferenti al
pressure cut-off swi tch. Usi ng a jumper wi re, jump
across the termi nal s i nsi de the connector boot (Fi g. 5).
(4) Cl ose al l doors, wi ndows and vents to the passen-
ger compartment.
(5) Set heater-A/C control to A/C, ful l heat, FLOOR,
and hi gh bl ower. System shoul d be i n a reci rcul ati on
mode wi th reheat. Thi s i s not possi bl e wi th control .
(6) Remove l ower ri ght si de of panel and swi tch the
two vacuum l i nes to al l ow reheat wi th reci rcul ati on.
(7) Start the engi ne and al l ow to i dl e (1000 R.P.M.).
After the engi ne has reached runni ng temperature,
al l ow the passenger compartment to heat up to create
the need for maxi mum refri gerant fl ow i nto the evapo-
rator.
(8) Di scharge (hi gh pressure) gauge shoul d read 965
to 1655 kPa (140 to 240 psi ) when the refri gerant
charge i s suffi ci ent. I f system cannot achi eve proper
pressure, repl ace the expansi on val ve. I f pressure i s
correct, record readi ng and proceed wi th test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO
2
PERSONAL INJURY CAN RESULT.
(9) I f di scharge pressure i s wi thi n speci fi ed range,
freeze the expansi on val ve control head for 30 seconds.
Use a super col d substance (l i qui d CO
2
).Donot spray
R-12Refrigerant on the expansion valve for this
test. I f compressor di scharge (hi gh) pressure does not
drop by 15% or more of the pressure recorded i n step 8,
repl ace the expansi on val ve. Al l ow the expansi on val ve
to thaw. The di scharge pressure shoul d stabi l i ze to the
pressure recorded i n step 8. I f the pressure does not
stabi l i ze, repl ace the expansi on val ve.
(10) Correct water val ve vacuum l i ne and reci rc.
actuator l i nes. I nstal l l ower ri ght panel .
HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS
The HPR val ve prevents damage to the ai r-
condi ti oni ng system i f excessi ve pressure devel ops.
Excessi ve pressure can caused by condenser ai r fl ow
bl ockage, refri gerant overcharge, or ai r and moi sture
i n the system.
HPR VALVE LOCATI ON
The HPR Val ve i s l ocated on the compressor end
pl ate. (Fi g. 6).
The hi gh pressure rel i ef val ve vents onl y a smal l
amount of refri gerant necessary to reduce system pres-
sure and then reseats i tsel f. The majori ty of the refri g-
erant i s conserved i n the system. The val ve i s cal i -
brated to vent at a pressure of 3100 to 4140 Kpa (450 to
600 psi ). I f a val ve has vented a smal l amount of
refri gerant, i t does not necessari l y mean the val ve i s
defecti ve.
For (HPR) val ve repl acement, refer to Vari abl e Di s-
pl acement Compressor Servi ce Procedures.
Fig. 5 Differential Pressure Cut-Out Switch
Fig. 6 High Pressure Relief ValveVariable Dis-
placement Compressor
FI XED DI SPLACEMENT COMPRESSOR AND COMPONENTS DI AGNOSTI C PROCE-
DURES
INDEX
page page
Clutch Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressor Clutch Inoperative . . . . . . . . . . . . . . . 13
Compressor Identification . . . . . . . . . . . . . . . . . . . 13
Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 13
Electronic Cycling Clutch Switch . . . . . . . . . . . . . . 15
Expansion Valve Tests (Silver Colored Expansion Valve)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fixed Displacement Compressor Refrigerant
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High Pressure Relief Valve (HPR) Diagnosis . . . . . 17
Low-Pressure Cut-Off Switch Diagnosis . . . . . . . . 13
GENERAL INFORMATION
COMPRESSOR IDENTIFICATION
COMPRESSOR NOISE
Excessi ve noi se that occurs when the ai r-
condi ti oni ng i s bei ng used, can be caused by l oose bol ts,
mounti ng brackets, l oose cl utch, or excessi ve hi gh
refri gerant system operati ng pressure. Veri fy compres-
sor dri ve bel t condi ti on, proper refri gerant charge and
head pressure before compressor repai r i s performed.
For noi se di agnosti c procedures, refer to the Com-
pressor Noi se and Compressor Cl utch Di agnosi s chart
i n thi s secti on.
COMPRESSOR CLUTCH INOPERATIVE
The ai r-condi ti oni ng compressor cl utch el ectri cal ci r-
cui t i s control l ed by the engi ne control l er computer. I t
i s l ocated i n the engi ne compartment outboard of the
battery.
I f the compressor cl utch does not engage:
Veri fy refri gerant charge.
I f the compressor cl utch sti l l does not engage check
for battery vol tage at the l ow pressure or di fferenti al
pressure cut-off swi tch l ocated on the expansi on val ve.
I f vol tage i s not detected, refer to:
Group 8W, Wi ri ng di agrams.
The appropri ate Powertrai n Di agnosti c Procedures
manual for di agnosti c i nformati on.
I f vol tage i s detected at the cut-off swi tch, connect
swi tch and check for battery vol tage between the
compressor cl utch connector termi nal s.
I f vol tage i s detected, perform A/C Cl utch Coi l Tests.
CLUTCH COIL TESTS
(1) Veri fy battery state of charge. (Test i ndi cator i n
battery shoul d be green).
(2) Connect an ammeter (0-10 ampere scal e) i n se-
ri es wi th the cl utch coi l termi nal . Use a vol t meter
(0-20 vol t scal e) wi th cl i p l eads measuri ng vol tage
across the battery and A/C cl utch.
(3) Wi th A/C control i n A/C mode and bl ower at l ow
speed, start the engi ne and run at normal i dl e.
(4) The A/C cl utch shoul d engage i mmedi atel y and
the cl utch vol tage shoul d be wi thi n two vol ts of the
battery vol tage. I f the A/C cl utch does not engage, test
the fusi bl e l i nk.
(5) The A/C cl utch coi l i s acceptabl e i f the current
draw i s 2.0 to 3.7 amperes at 11.5-12.5 vol ts at cl utch
coi l . Thi s i s wi th the work area temperature at 21C
(70F). I f vol tage i s more than 12.5 vol ts, add el ectri cal
l oads by turni ng on el ectri cal accessori es unti l vol tage
reads bel ow 12.5 vol ts.
I f coi l current reads zero, the coi l i s open and shoul d
be repl aced. I f the ammeter readi ng i s 4 amperes or
more, the coi l i s shorted and shoul d be repl aced. I f the
coi l vol tage i s not wi thi n two vol ts of the battery
vol tage, test cl utch coi l feed ci rcui t for excessi ve vol t-
age drop.
LOW-PRESSURE CUT-OFF SWITCH DIAGNOSIS
The Low Pressure Cut-Off (LPCO) Swi tch (Fi g. 2)
moni tors the refri gerant gas pressure on the sucti on
si de of the system. The LPCO i s l ocated on the ex
Fig. 1 Fixed Displacement CompressorModel

10PA17
COMPRESSOR NOI SE AND COMPRESSOR CLUTCH DI AGNOSI S
pansi on val ve, and the expansi on val ve i s si l ver i n col or
when a fi xed di spl acement compressor i s used. The
LPCO turns off vol tage to the compressor cl utch coi l
when refri gerant gas pressure drops to l evel s that
coul d damage the compressor. The LPCO i s a seal ed
factory cal i brated uni t. I t must be repl aced i f defecti ve.
LPCO SWI TCH TEST
The work area temperature must not be bel ow 10C
(50F) to test the compressor cl utch ci rcui t.
(1) Wi th gear sel ector i n park or neutral and park
brake set, start engi ne and al l ow to i dl e.
(2) Rai se hood and di sconnect LPCO swi tch connec-
tor boot.
(3) Usi ng a sui tabl e jumper wi re, jump across the
termi nal s i nsi de wi re connector boot.
(4) I f the compressor cl utch does not engage, the
cycl i ng cl utch swi tch, wi ri ng, rel ay, or fuse can be
defecti ve. Refer to Group 8W, Wi ri ng Di agrams.
(5) I f cl utch engages, connect mani fol d gauge set.
Read l ow pressure gauge. At pressure above 97 kPa (14
psi ) and above, LPCO swi tch wi l l compl ete the cl utch
ci rcui t. I f the l ow pressure gauge reads bel ow 172 kPa
(25 psi ), the system i s l ow on refri gerant charge or
empty due to a l eak.
(6) I nstal l connector boot on swi tch and repeat step
number 3. I f the cl utch does not engage, repl ace the
LPCO swi tch.
ELECTRONIC CYCLING CLUTCH SWITCH
The El ectroni c Cycl i ng Cl utch Swi tch (ECCS) i s
l ocated on the A/C refri gerant l i ne at the expansi on
val ve (Fi g. 3). The ECCS prevents evaporator freeze-up
by si gnal i ng the Engi ne Control l er Computer to cycl e
the compressor ON and OFF by moni tori ng the tem-
perature of the sucti on l i ne.
The ECCS uses a thermi stor probe i n a capi l l ary
tube. Thi s i s i nserted i nto a capi l l ary tube wel l on the
sucti on l i ne. The wel l must be fi l l ed wi th conducti ve
grease to prevent corrosi on and al l ow thermal transfer
to the probe. The ECCS i s a seal ed uni t and cannot be
adjusted or repai red. I t must be repl aced i f found
defecti ve.
TEST PROCEDURE
Wi th the ambi ent temperature i n the test area
around 21C (70F), suppl y 12 (1) vol ts to pi n 2 and
ground pi n 4 (Fi g. 4). Test for conti nui ty from pi n 1 to
pi n 3. I f the test shows conti nui ty, refer to Compressor
Cl utch I noperati ve tests i n thi s Group. I f conti nui ty i s
detected, repl ace the ECCS.
FIXED DISPLACEMENT COMPRESSOR REFRIGER-
ANT SYSTEM
Refer to the Refri gerant System Di agnosi s chart i n
thi s secti on.
SILVER EXPANSION VALVE TESTS
Expansion valve tests should be performed af-
ter compressor tests.
General I nformati on secti on of thi s Group. The work
area and vehi cl e temperature must be 21C to 27C
(70F to 85F) when testi ng expansi on val ve. To test
the expansi on val ve:
(1) Connect a chargi ng stati on or mani fol d gauge set
to the refri gerant system servi ce ports. Veri fy the
refri gerant charge l evel usi ng the si ght gl ass method.
Fig. 2 Low Pressure Cut-Off Switch
Fig. 3 Electronic Cycling Clutch Switch
Fig. 4 ECCS Connector
REFRI GERANT SYSTEM DI AGNOSI S
(2) Di sconnect and pl ug the vacuum l i ne at the
water control val ve.
(3) Di sconnect wi re connector at l ow pressure cut-off
swi tch (Fi g. 5). Usi ng a jumper wi re, jump termi nal s
i nsi de wi re connector boot.
(4) Cl ose al l doors, wi ndows and vents to the passen-
ger compartment.
(5) Set heater-A/C control to A/C, ful l heat, FLOOR,
and hi gh bl ower.
(6) Start the engi ne and al l ow to i dl e (1000 rpm).
After the engi ne has reached runni ng temperature,
al l ow the passenger compartment to heat up to create
the need for maxi mum refri gerant fl ow i nto the evapo-
rator.
(7) I f the refri gerant charge i s suffi ci ent, di scharge
(hi gh pressure) gauge shoul d read 965 to 1655 kPa (140
to 240 psi ). Sucti on (l ow pressure) gauge shoul d read
140 kPa to 207 kpa (20 psi to 30 psi ). I f system cannot
achi eve proper pressure readi ngs, repl ace the expan-
si on val ve. I f pressure i s correct, proceed wi th test.
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO
2
(8) I f sucti on si de l ow pressure i s wi thi n speci fi ed
range, freeze the expansi on val ve control head (Fi g. 6)
for 30 seconds. Use a super col d substance (l i qui d
CO
2
).Donot spray R-12Refrigerant on theexpan-
sion valve for this test. Sucti on si de l ow pressure
shoul d drop to -50 kPa (-15 i n. Hg) I f not, repl ace
expansi on val ve.
(9) Al l ow expansi on val ve to thaw. The l ow pressure
gauge readi ng shoul d stabi l i ze at 140 kPa to 240 kPa
(20 psi to 30 psi ). I f not, repl ace expansi on val ve.
When expansi on val ve test i s compl ete, test A/C
overal l performance. Remove al l test equi pment before
returni ng vehi cl e to use.
HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS
The HPR val ve prevents damage to the ai r-
condi ti oni ng system i f excessi ve pressure devel ops.
Excessi ve pressure can be caused by condenser ai r fl ow
bl ockage, refri gerant overcharge, or ai r and moi sture
i n the system.
HPR VALVE LOCATI ON
The HPR Val ve i s l ocated on the di scharge l i ne at the
A/C compressor (Fi g. 7).
The hi gh pressure rel i ef val ve vents onl y a smal l
amount of refri gerant necessary to reduce system pres-
sure and then reseats i tsel f. The majori ty of the refri g-
erant i s conserved i n the system. The val ve i s cal i -
brated to vent at a pressure of 3100 to 4140 Kpa (450 to
600 psi ). I f a val ve has vented a smal l amount of
refri gerant, i t does not necessari l y mean the val ve i s
defecti ve.
For (HPR) val ve repl acement, refer to Fi xed Di s-
pl acement Compressor Servi ce procedures secti on.
Fig. 6 Expansion Valve
Fig. 5 Low Pressure Cut-Off Switch
Fig. 7 High Pressure Relief Valve Typical
VACUUM CONTROL SYSTEM DI AGNOSI S
INDEX
page page
Locating Vacuum Leaks . . . . . . . . . . . . . . . . . . . . 18
Vacuum Testing the Heater-A/C Controls . . . . . . . 18
Vacuum Testing the One-Way Check Valve . . . . . . 18
GENERAL INFORMATION
Use an adjustabl e Vacuum Test Gauge (C-3707) and
a sui tabl e vacuum pump to test heater A/C control
vacuum. Wi th a fi nger pl aced over the end of test hose
(Fi g. 1), cal i brate vacuum control val ve on the test
gauge to obtai n -27 kPa (8 i n. Hg.). Rel ease and bl ock
the end of the test hose several ti mes to veri fy vacuum
setti ng.
VACUUM TESTING THE ONE-WAY CHECK VALVE
(1) I n the engi ne compartment, di sconnect the
Heater-A/C vacuum suppl y (bl ack) hose. Thi s hose
passes through an openi ng i n the dash panel used for
the ai r condi ti oni ng expansi on val ve.
(2) Remove the vacuum check val ve. Thi s val ve i s
l ocated on the (bl ack) vacuum suppl y hose at the brake
power booster.
(3) Connect test vacuum suppl y hose to the HEATER
si de of the val ve. I n thi s di recti on the gauge shoul d
return to cal i brated setti ng. I f val ve l eaks vacuum i n thi s
di recti on, val ve repl acement i s necessary.
(4) Connect test vacuum suppl y hose to the ENGI NE
VACUUM si de of the val ve. Vacuum shoul d fl ow
through val ve.
VACUUM TESTING THE HEATER-A/C CONTROLS
(1) Connect the test vacuum prod to the vehi cl es (bl ack)
vacuum suppl y hose. Posi ti on vacuum test gauge so i t can
be vi ewed from the passenger compartment.
(2) Posi ti on the heater A/C control mode sel ector to
DEFROST, FLOOR, BI -LEVEL, PANEL, and RECI RC
(wi th A/C). Pause after each sel ecti on. The test gauge
shoul d return to the cal i brated setti ng of -27 kPa (8 i n.
Hg.) after each sel ecti on i s made. I f the gauge cannot
achi eve the cal i brated setti ng, a vacuum ci rcui t or
component has a l eak.
LOCATING VACUUM LEAKS
To l ocate a vacuum l eak, di sconnect 7-way vacuum
connector behi nd the i nstrument panel at the heater
A/C control . For removal and i nstal l ati on of heater A/C
control panel , refer to the Swi tch and Panel Component
Servi ce secti on of Group 8E, I nstrument Panel . Connect
the cal i brated vacuum hose prod (Fi g. 4) to each port i n
the vacuum harness connector (Fi g. 2). The brown,
bi -l evel , vacuum ci rcui t has a metal fi ber restri cti ve
devi ce l ocated i n the l i ne. More reacti on ti me i s requi red
for the test gauge to return to cal i brated setti ng. After
each connecti on i s made, the test gauge shoul d return to
cal i brated setti ng. I f al l ci rcui ts functi on properl y, re-
pl ace control mode vacuum swi tch. I f not, determi ne the
col or of the vacuum ci rcui t that i s l eaki ng. To determi ne
vacuum l i ne col ors, refer to the Vacuum Ci rcui ts-Heater
or Heater A/C Control chart i n thi s secti on. Di sconnect
the vacuum actuator at the other end of the ci rcui t.
(I nstrument panel removal may be necessary to gai n
access to some components). Bl ock the end of the di s-
connected vacuum l i ne. The test gauge shoul d return to
cal i brated setti ng. I f not, that ci rcui t has a l eak and
must be repai red or repl aced. I f test gauge returns to
cal i brated setti ng, the vacuum actuator must be re-
pl aced.
Fig. 1 Adjust Vacuum Test Bleed Valve
Fig. 2 Vacuum Circuit Test
HEATER AND A/C PERFORMANCE TESTS
VACUUM CI RCUI TSHEATER OR HEATER A/C CONTROL
HEATER OUTPUT TEST
PRE-DI AGNOSTI C PREPARATI ONS
General I nformati on secti on of thi s Group before per-
formi ng the fol l owi ng procedures.
Check the radi ator cool ant l evel , dri ve bel t tensi on,
engi ne vacuum l i ne connecti ons, radi ator ai r fl ow and
radi ator fan operati on. Start engi ne and al l ow to warm
up to normal runni ng temperature.
WARNING: DO NOT REMOVE RADIATOR CAP WHEN
ENGINE IS HOT, PERSONAL INJURY CAN RESULT.
I f vehi cl e has been run recentl y, wai t 15 mi nutes
before removi ng cap. Pl ace a rag over the cap and turn
i t to the fi rst safety stop. Al l ow pressure to escape
through the overfl ow tube. When the system stabi l i zes,
remove the cap compl etel y.
MAXI MUM HEATER OUTPUT:TEST AND AC-
TI ON
Engi ne cool ant i s provi ded to the heater system by
two 16 mm (5/8 i nch i nsi de di ameter) heater hoses.
Wi th engi ne i dl i ng at normal runni ng temperature, set
the control to maxi mum heat, fl oor, and hi gh bl ower
setti ng. Usi ng a test thermometer, check the ai r tem-
perature comi ng from the fl oor outl ets, refer to Tem-
perature Reference chart.
I f the fl oor outl et ai r temperature i s i nsuffi ci ent,
refer to Group 7, Cool i ng Systems for normal engi ne
cool ant temperature speci fi cati ons. Both heater hoses
shoul d be HOTto the touch (cool ant return hose shoul d
be sl i ghtl y cool er than the suppl y hose). I f cool ant
return hose i s much cool er than the suppl y hose, l ocate
and repai r engi ne cool ant fl ow obstructi on i n heater
system.
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOL-
ANT FLOW
(a) Pi nched or ki nked heater hoses.
(b) I mproper heater hose routi ng.
(c) Pl ugged heater hoses or suppl y and return
ports at cool i ng system connecti ons, refer to Group 7,
Cool i ng System.
(d) Pl ugged heater core.
(e) Water val ve sti cki ng or i noperati ve.
I f proper engi ne cool ant fl ow through heater system
i s veri fi ed and fl oor outl et ai r temperature i s sti l l
i nsuffi ci ent, a mechani cal probl em can exi st i n the
heater system.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
(a) Obstructed cowl ai r i ntake.
(b) Obstructed heater system outl ets.
(c) Bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f temperature cannot be adjusted wi th the TEMP
l ever on the control panel , or TEMP l ever i s di ffi cul t to
move, the fol l owi ng coul d requi re servi ce:
(a) Bl end-ai r door bi ndi ng.
(b) Control cabl es mi ss-routed, pi nched, ki nked, or
di sconnected.
(c) I mproper engi ne cool ant temperature.
A/C PERFORMANCE TEST
The ai r-condi ti oni ng system i s desi gned to remove
heat and humi di ty from the ai r enteri ng the passenger
compartment. The evaporator, l ocated i n the heater
A/C uni t behi nd the i nstrument panel , i s cool ed to
temperatures near the freezi ng poi nt. As warm damp
ai r passes over the fi ns i n the evaporator, moi sture i n
the ai r condenses to water, dehumi di fyi ng the ai r.
Condensati on on the evaporator fi ns reduces the
evaporators abi l i ty to absorb heat. Duri ng peri ods of
hi gh heat and humi di ty, an ai r-condi ti oni ng system
wi l l be l ess effecti ve than duri ng peri ods of hi gh heat
and l ow humi di ty. Wi th the i nstrument control set to
RECI RC, onl y ai r from the passenger compartment
passes through the evaporator. As the passenger com-
partment ai r dehumi di fi es, A/C performance l evel s
ri se.
PERFORMANCE TEST PROCEDURE
General I nformati on secti on of thi s Group before pro-
ceedi ng wi th thi s procedure. Ai r temperature i n test
room and on vehi cl e must be 70F (21C) mi ni mum for
thi s test.
(1) Connect a tachometer and mani fol d gauge set.
(2) Set control to A/C, RECI RC, PANEL, or MAX
A/C, temperature l ever on ful l cool and bl ower on hi gh.
(3) Start engi ne and hol d at 1000 rpm wi th A/C
cl utch engaged.
(4) Engi ne shoul d be warmed up wi th doors and
wi ndows cl osed.
TEMPERATURE REFERENCE CHART
(5) I nsert a thermometer i n the l eft center A/C outl et
and operate the engi ne for fi ve mi nutes. The A/C cl utch
may cycl e dependi ng on ambi ent condi ti ons.
(6) Wi th the A/C cl utch engaged, compare the di s-
charge ai r temperature to the A/C Performance Tem-
peratures chart.
(7) I f the di scharge ai r temperature fai l s to meet the
speci fi cati ons i n the performance temperature chart.
Refer to the Di agnosti c Anal ysi s charts i n thi s Group
for further test i nformati on.
A/C PERFORMANCE TEMPERATURES
REFRI GERANT SERVI CE PROCEDURES
INDEX
page page
Adding Partial Refrigerant Charge . . . . . . . . . . . . . 24
Charging Refrigerant SystemEmpty System . . . . 26
Discharging Refrigerant System . . . . . . . . . . . . . . 25
Evacuating Refrigerant System . . . . . . . . . . . . . . . 25
Manifold Gauge Set Connections . . . . . . . . . . . . . 23
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Refrigerant (R-12) Equipment . . . . . . . . . . . . . . . . 22
Refrigerant Recycling . . . . . . . . . . . . . . . . . . . . . . 23
Sight Glass Refrigerant Level Inspection . . . . . . . . 22
Testing for Refrigerant Leaks . . . . . . . . . . . . . . . . 24
SIGHT GLASS REFRIGERANT LEVEL INSPECTION
The fi l ter-dri er i s equi pped wi th a si ght gl ass (Fi g. 1)
that i s used as a refri gerant l evel i ndi cator onl y. This
sight glass is not to be used for A/C performance
testing. To check the refri gerant l evel , remove the
vehi cl e jack and cl ean the si ght gl ass. Then start and
warm up engi ne, and hol d i dl e at 1100 rpm. Pl ace the
ai r-condi ti oni ng control on A/C, RECI RC and hi gh
bl ower. The work area temperature shoul d be at l east
21C (70F). I f a Fi xed Di spl acement type compressor
does not engage, the refri gerant l evel i s probabl y too
l ow for the Low Pressure Cut-Off swi tch to detect. Or,
wi th a Vari abl e Di spl acement compressor, for the Di f-
ferenti al Pressure Cut-off to detect. I f compressor
cl utch does not engage, refer to Testi ng Refri gerant
System for Leaks i n thi s Group. I f compressor cl utch
engages, al l ow approxi matel y one mi nute for refri ger-
ant to stabi l i ze. Vi ew refri gerant through si ght gl ass.
The sucti on l i ne shoul d be col d to the touch and the
si ght gl ass shoul d be cl ear.
I f foam or bubbl es are vi si bl e i n si ght gl ass, the
refri gerant l evel i s probabl y l ow. Occasi onal foam or
bubbl es are normal when the work area temperature i s
above 43C (110F) or bel ow 21C (70F). I f sucti on l i ne
i s col d and occasi onal bubbl es are vi si bl e i n the si ght
gl ass, bl ock the condenser ai r fl ow. Thi s wi l l i ncrease
the compressor di scharge pressure (Do not al l ow en-
gi ne to over heat). Bubbl es shoul d di ssi pate. I f not, the
refri gerant l evel i s l ow.
WARNING: R-12 REFRIGERANT IS DETRIMENTAL TO
THE ENVIRONMENT WHEN RELEASED TO THE AT-
MOSPHERE. DO NOT RECHARGE AN A/C SYSTEM
BY ADDING R-12 REFRIGERANT TOA SYSTEM THAT
HAS A KNOWN LEAK.
The refri gerant system wi l l not be l ow on R-12 unl ess
there i s a l eak. Fi nd and repai r the l eak before charg-
i ng.
R-12 REFRIGERANT EQUIPMENT
WARNING: EYE PROTECTION MUST BE USED WHEN
SERVICING AN AIR-CONDITIONING REFRIGERANT
SYSTEM.
TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON
THE EQUIPMENT BEING USED BEFORE PROCEED-
ING WITH THIS OPERATION. PERSONNEL INJURY
CAN RESULT.
When servi ci ng an ai r-condi ti oni ng system, i t i s
recommended that a sui tabl e ai r-condi ti oni ng chargi ng
stati on (Fi g. 2) be used. An (R-12) refri gerant
recovery/recycl i ng devi ce (Fi g. 3) shoul d al so be used.
Thi s devi ce shoul d meet SAE standard J1991. Contact
an automoti ve servi ce equi pment suppl i er for refri ger-
ant recycl i ng/recoveri ng equi pment. Refer to the oper-
ati ng i nstructi ons provi ded wi th the equi pment for
proper operati on.
A mani fol d gauge set (Fi g. 4) must al so be used i n
conjuncti on wi th the chargi ng and/or
recovery/recycl i ng devi ce. The servi ce hoses on the
gauge set shoul d have manual (turn wheel ) or auto-
mati c back fl ow val ves at the servi ce port connector
ends. Thi s wi l l prevent refri gerant (R-12) from bei ng
rel ease i nto the atmosphere.
Fig. 1 Filter Drier and Sight Glass
REFRIGERANT RECYCLING
(R-12) refri gerant i s a chl orofl uorocarbon (CFC) that
can contri bute to the depl eti on of the ozone l ayer i n the
upper atmosphere. Ozone fi l ters out harmful radi ati on
from sunl i ght. To assi st i n protecti ng the ozone l ayer,
an (R-12) refri gerant recycl i ng devi ce that meets SAE
standard J1991 shoul d be used. Contact an automoti ve
servi ce equi pment suppl i er for refri gerant recycl i ng
equi pment. Refer to the operati ng i nstructi ons pro-
vi ded wi th the recycl i ng equi pment for proper opera-
ti on.
MANIFOLD GAUGE SET CONNECTIONS
The hi gh pressure (di scharge) (RED) hose shoul d be
attached to the 1/4 i n. di scharge servi ce port. Thi s port
wi l l be l ocated on the di scharge l i ne between the ai r
condi ti oni ng compressor and the condenser, or on the
hi gh pressure (l i qui d) l i ne.
The l ow pressure (sucti on) (BLUE) hose shoul d be
attached to the 3/8 i n. sucti on servi ce port. Thi s port i s
l ocated on ei ther the ai r condi ti oni ng compressor, or
the sucti on l i ne between the expansi on val ve and the
compressor.
SUCTION (LOW PRESSURE) GAUGE CONNECTION
(1) Remove the servi ce port cap from 3/8 i n. sucti on
servi ce port.
(2) Check al l val ves on the equi pment bei ng used to
veri fy they are cl osed.
(3) I nspect the hose gasket i n the servi ce port con-
nector at the end of the (BLUE) hose. I f the gasket i s
fl awed, repl ace i t.
(4) Thread the hose connector onto the servi ce port
unti l the val ve core depressor i n the hose end makes
contact wi th the val ve core i n the servi ce port. Qui ckl y
secure hose connector to the servi ce port to avoi d
l oosi ng refri gerant.
To di sconnect sucti on gauge (BLUE) hose:
(a) Wrap the end of hose wi th a shop towel .
(b) Loosen the hose connector.
Fig. 2 Refrigerant Charging StationTypical
Fig. 3 Refrigerant Recovery/Recycling
StationTypical
Fig. 4 Manifold Gauge SetTypical
(c) Push and hol d the end of hose toward the
servi ce port to keep the gasket i n contact wi th servi ce
port.
(d) Qui ckl y rotate the connector countercl ockwi se.
When the hose connector i s compl etel y backed off,
i mmedi atel y poi nt the end of hose toward fl oor, as
possi bl y trapped refri gerant i n the hose wi l l be
rel eased.
(e) I nstal l servi ce port cap.
DISCHARGE (HIGH PRESSURE) GAUGE CONNECTION
(1) Remove the servi ce port cap from the 1/4 i n.
servi ce port.
(2) Check al l val ves on the equi pment bei ng used to
veri fy they are cl osed.
(3) I nspect the hose gasket i n the servi ce port con-
nector at the end of the (RED) hose. I f the gasket i s
fl awed, repl ace i t.
(4) Use a sui tabl e (3/8 i n. mal e to 1/4 i n. femal e)
adapter (Fi g. 5), threaded securel y i nto the end of the
(RED) hose connector.
(5) Start threadi ng the 1/4 i n. hose adapter connec-
tor onto the servi ce port. Thread unti l the val ve core
depressor i n the adapter makes contact wi th the val ve
core i n the servi ce port. Qui ckl y secure adapter connec-
tor to servi ce port to avoi d l oosi ng refri gerant.
To di sconnect the di scharge gauge (RED) hose:
(a) Wrap the end of hose wi th a shop towel .
(b) Loosen the hose connector.
(c) Push and hol d the end of hose toward the
servi ce port to keep the gasket i n contact wi th servi ce
port.
(d) Qui ckl y rotate the connector countercl ockwi se.
When the hose connector i s compl etel y backed off,
i mmedi atel y poi nt the end of hose toward fl oor, as
possi bl y trapped refri gerant i n the hose wi l l be
rel eased.
(e) I nstal l servi ce port cap.
EVACUATION/RECOVERY/RECYCLING/CHARGING LINE CON-
NECTION
The center mani fol d (YELLOW) or (WHI TE) hose i s
used to di scharge, recycl e, recover, evacuate, and
charge the refri gerant system. When the di scharge or
sucti on val ves on the mani fol d gauge set are opened,
the refri gerant i n the system wi l l escape through thi s
hose.
It isrecommendedthat thishosebeattachedto
a refrigerant (R-12) Recovery/Recycling device.
Refer to the operators manual for procedures.
For di sconnecti on of thi s hose, refer to Di sconnecti ng
the Di scharge Gauge (RED) hose i n the precedi ng
paragraphs.
TESTING FOR REFRIGERANT LEAKS
I f the A/C system i s not cool i ng the passenger com-
partment, determi ne i f the refri gerant system i s ful l y
charged. I f the refri gerant system i s empty or l ow i n
refri gerant charge, a l eak at any l i ne fi tti ng or compo-
nent seal i s l i kel y. To detect a l eak i n the refri gerant
system, perform one of the fol l owi ng procedures as
i ndi cated by the symptoms.
EMPTY REFRI GERANT SYSTEM LEAK TEST
CAUTION: Review Safety Precautions and Warnings
in General Information section of this Group.
(1) Evacuate the refri gerant system to the l owest
degree of vacuum possi bl e.
(2) Prepare a 10 oz. refri gerant (R-12) charge to be
i njected i nto the system.
(3) Connect and di spense 10 ozs. of refri gerant i nto
the evacuated refri gerant system.
(4) Proceed to step two of Low Refri gerant Level
Leak Test.
LOW REFRI GERANT LEVEL LEAK TEST
Caution: Review Safety Precautions and Warnings in
the General Information section of this group.
(1) Usi ng the refri gerant l evel si ght gl ass, determi ne
i f there i s any (R-12) refri gerant i n the system.
(2) Posi ti on the vehi cl e i n a wi nd free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(3) Bri ng the refri gerant system up to operati ng
temperature and pressure by al l owi ng the engi ne to
run for approxi matel y fi ve mi nutes.
(4) Wi th the engi ne not runni ng, use an El ectroni c
Leak Detector (or equi val ent) and search for l eaks.
Fi tti ngs, l i nes, or components that appear to be oi l y
usual l y wi l l i ndi cate a refri gerant l eak. To i nspect the
evaporator core for l eaks, i t i s possi bl e to i nsert the
l eak detector probe i nto the reci rcul ati ng ai r door
openi ng (Fi g. 6).
ADDING PARTIAL REFRIGERANT CHARGE
I f i t was not necessary to compl etel y di scharge the
refri gerant system, a parti al refri gerant charge can be
added to the system.
Fig. 5 Discharge Hose Adapter
CAUTION: Review all Safety Precautions and Warn-
ings in the General Information Section before adding
refrigerant to the system. Do not add refrigerant to a
system that is known to have a leak.
(1) Attach mani fol d gauge set.
(2) Open the wi ndows of the passenger compartment
and set the ai r-condi ti oni ng control s to A/C, RECI RC,
and Low bl ower speed.
(3) Start the engi ne and al l ow i t to warm up to
normal runni ng temperature.
(4) I f the ai r-condi ti oni ng compressor does not en-
gage, di sconnect the l ow pressure cut-off swi tch. Pl ace
a jumper wi re across the termi nal s i n the connector
boot. I f the compressor sti l l does not engage, a probl em
exi sts i n the compressor cl utch feed ci rcui t.
(5) Hol d the engi ne speed at 1400 rpm.
(6) Whi l e fol l owi ng the i nstructi ons provi ded wi th
the chargi ng equi pment bei ng used, charge through
the sucti on si de of the system. Add enough refri gerant
to cl ear the si ght gl ass i n the fi l ter dri er.
(7) At the poi nt when the si ght gl ass cl ears, note the
wei ght of the refri gerant suppl y drum or the l evel i n
the chargi ng cyl i nder. Add an addi ti onal 340 g (12 oz) of
refri gerant to the system. Remove the jumper wi re
from the l ow pressure cut-off swi tch connector and
connect the cut-off swi tch.
(8) Test the over al l performance of the ai r-
condi ti oner. Cl ose al l val ves on the chargi ng equi pment
and di sconnect the hoses from the servi ce ports. I nstal l
the servi ce port caps.
DISCHARGING REFRIGERANT SYSTEM
(R-12) refri gerant i s a chl orofl uorocarbon (CFC) that
can contri bute to the depl eti on of the ozone l ayer i n the
upper atmosphere. Ozone fi l ters out harmful radi ati on
from sunl i ght. To assi st i n protecti ng the ozone l ayer,
Chrysl er Corporati on recommends that an (R-12) re-
fri gerant recycl i ng devi ce that meets SAE standard
J1991 be used. Use thi s devi ce when i t i s necessary to
di scharge the refri gerant system. Contact an automo-
ti ve servi ce equi pment suppl i er for refri gerant recy-
cl i ng equi pment. Refer to the operati ng i nstructi ons
provi ded wi th the recycl i ng equi pment for proper op-
erati on.
EVACUATING REFRIGERANT SYSTEM
I f the ai r-condi ti oni ng refri gerant system has been
open to the atmosphere, i t must be evacuated before
the system can be charged wi th refri gerant. Moi sture
and ai r mi xed wi th the refri gerant wi l l rai se the
compressor head pressure above acceptabl e operati ng
l evel s. Thi s wi l l reduce the performance of the ai r-
condi ti oner and damage the compressor. Moi sture wi l l
boi l at near room temperature when exposed to
vacuum. To evacuate the refri gerant system:
(1) Connect a sui tabl e chargi ng stati on, refri gerant
recovery machi ne, and a mani fol d gauge set wi th
vacuum pump.
(2) Open the sucti on and di scharge val ves and start
the vacuum pump. When the sucti on gauge reads -88
kPa (-26 i n. Hg) vacuum or greater, cl ose al l val ves and
turn off vacuum pump. I f the system fai l s to reach
speci fi ed vacuum, the refri gerant system l i kel y has a
l eak that must be corrected. I f the refri gerant system
mai ntai ns speci fi ed vacuum for at l east 30 mi nutes,
start the vacuum pump, open the sucti on and di s-
charge val ves. Then al l ow the system to evacuate an
addi ti onal 10 mi nutes.
(3) Cl ose al l val ves. Turn off and di sconnect the
vacuum pump.
The refri gerant system i s prepared to be charged
wi th refri gerant.
Fig. 6 Testing for A/C LeaksTypical Front/Rear A/C
System
CHARGING REFRIGERANT SYSTEMEMPTY SYS-
TEM
CAUTION: Do not over charge refrigerant system, as
excessive compressor head pressure can cause
noise and system failure.
WARNING: REVIEW SAFETY PRECAUTIONS AND
WARNINGS IN GENERAL INFORMATION SECTION
OF THIS GROUP BEFORE CHARGING THE REFRIG-
ERANT SYSTEM.
After the refri gerant system has been tested for l eaks
and evacuated, a refri gerant (R-12) charge can be
i njected i nto the refri gerant system.
(1) Connect mani fol d gauge set.
(2) Measure refri gerant (refer to capaci ti es) and
heat to 52C (125F) wi th the chargi ng stati on. Refer to
the i nstructi ons provi ded wi th the equi pment bei ng
used.
REFRI GERANT CAPACI TI ES:
Wi thout Rear A/C = 964 g (34 oz.)
Wi th Rear A/C = 1276 g (45 oz.)
(3) Open the sucti on and di scharge val ves. Open the
charge val ve to al l ow the heated refri gerant to fl ow i nto
the system. When the transfer of refri gerant has
stopped, cl ose the sucti on and di scharge val ve.
(4) I f al l of the refri gerant charge di d not transfer
from the di spensi ng devi ce, start the engi ne and run
engi ne at a hi gh i dl e (1400 rpm). Set the A/C control to
A/C, l ow bl ower speed, and open wi ndows. I f the A/C
compressor does not engage, test the compressor cl utch
control ci rcui t and correct any fai l ure. Refer to Group
8W, Wi ri ng Di agrams.
(5) Open the sucti on val ve to al l ow the remai ni ng
refri gerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Cl ose al l val ves and test the A/C system perfor-
mance.
(7) Di sconnect the chargi ng stati on or mani fol d
gauge set. I nstal l the servi ce port caps.
OIL LEVEL
I t i s i mportant to have the correct amount of oi l i n
the A/C system to ensure proper l ubri cati on of the
compressor. Too l i ttl e oi l wi l l resul t i n damage to the
compressor. Too much oi l wi l l reduce the cool i ng capac-
i ty of the system and consequentl y resul t i n hi gher
di scharge ai r temperatures.
The oi l used i n the compressor i s a 500 SUS vi scosi ty,
wax-free refri gerant oi l . Onl y refri gerant oi l of the
same type shoul d be used to servi ce the system. Do not
use any other oi l . The oi l contai ner shoul d be kept
ti ghtl y capped unti l i t i s ready for use, and then ti ghtl y
capped after use to prevent contami nati on from di rt
and moi sture. Refri gerant oi l wi l l qui ckl y absorb any
moi sture i t comes i n contact wi th.
I t wi l l not be necessary to check oi l l evel i n the
compressor or to add oi l unl ess there has been an oi l
l oss. Thi s may be due to a ruptured l i ne, shaft seal
l eakage, l eakage from the evaporator, condenser l eak,
fi l ter dri er or l oss of refri gerant due to a col l i si on. Oi l
l oss at a the l eak poi nt wi l l be evi dent by the presence
of a wet, shi ny surface around the l eak.
REFRI GERANT OI L LEVEL CHECK
When an ai r-condi ti oni ng system i s fi rst assembl ed
at the factory, al l of the components (except the com-
pressor) are refri gerant oi l free. After the system has
been charged wi th (R12) refri gerant and operated, the
oi l i n the compressor i s di spersed through the l i nes and
components. The evaporator, condenser, and fi l ter-
dri er wi l l retai n a si gni fi cant amount of oi l . (Refer to
the Refri gerant Oi l Capaci ti es chart). When a compo-
nent i s repl aced, the speci fi ed amount of refri gerant oi l
must be added. When the compressor i s repl aced, the
amount of oi l that i s retai ned i n the rest of the system
must be drai ned from the repl acement compressor.
When a refri gerant l i ne or component has ruptured
and has rel eased an unknown amount of oi l , the
compressor shoul d be removed and drai ned through
the sucti on port. The fi l ter-dri er must be repl aced
al ong wi th the ruptured part. The oi l capaci ty of the
system, mi nus the amount of oi l sti l l i n the remai ni ng
components, can be measured and poured i nto the
sucti on port of the compressor.
Exampl e:The evaporator retai ns 60 ml (2 oz). The
condenser retai ns 30 ml (1 oz) of oi l , and system
capaci ty may be 214 ml (7.25 oz) of oi l .
214 ml mi nus 90 ml = 124 ml (4.25 oz).
VERI FY REFRI GERANT OI L LEVEL
(1) Sl owl y di scharge refri gerant system.
(2) Remove refri gerant l i nes from A/C compressor.
(3) Remove compressor from vehi cl e.
(4) From sucti on port on top of compressor, drai n
refri gerant oi l from compressor.
REFRI GERANT OI L CAPACI TI ES
(5) Add system capaci ty mi nus the capaci ty of com-
ponents that have not been repl aced (refer to the
Refri gerant Oi l Capaci ty Chart), through sucti on port
on compressor.
(6) I nstal l compressor, connect refri gerant l i nes,
evacuate, and charge refri gerant system.
VARI ABLE DI SPLACEMENT COMPRESSOR SERVI CE PROCEDURES
INDEX
page page
Compressor Clutch/Coil Assembly . . . . . . . . . . . . 27
Compressor Front Shaft Seal . . . . . . . . . . . . . . . . 28
Compressor High Pressure Cut-Out Switch . . . . . . 30
Compressor High Pressure Relief Valve . . . . . . . . 31
Compressor Main or Sub Control Valves . . . . . . . . 31
Compressor Removal and Installation . . . . . . . . . . 27
COMPRESSOR REMOVAL AND INSTALLATION
The A/C compressor may be removed and posi ti oned
wi thout di schargi ng the refri gerant system. Di scharg-
i ng i s not necessary i f removi ng the A/C compressor
cl utch/coi l assembl y, engi ne, cyl i nder head, or al terna-
tor.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE TURNED
OFF. BEFORE REMOVING A FULLY CHARGED COM-
PRESSOR, REVIEW THE SAFETY PRECAUTIONS
AND WARNINGS SECTION IN THIS GROUP. DO NOT
TWIST OR KINK THE REFRIGERANT LINES WHEN
REMOVING A FULLY CHARGED COMPRESSOR.
SAFETY GLASSES MUST BE WORN.
I f the A/C compressor refri gerant l i nes must be
removed i n order to remove compressor. Refer to Di s-
chargi ng Refri gerant System i n the Refri gerant Ser-
vi ce Procedures secti on before proceedi ng wi th the
fol l owi ng steps.
(1) Di sconnect NEGATI VE battery cabl e.
(2) Loosen and remove dri ve bel ts (Refer to Group 7,
Cool i ng System) and di sconnect compressor cl utch
wi re l ead.
(3) Remove refri gerant l i nes from compressor (i f
necessary).
(4) Remove compressor attachi ng nuts and bol ts
(Fi g. 1 and 2).
(5) Remove compressor. I f refri gerant l i nes were not
removed, l i ft compressor/cl utch assembl y and ti e i t to a
sui tabl e component.
To i nstal l , Reverse the precedi ng operati on.
COMPRESSOR CLUTCH/COIL ASSEMBLY
Compressor assembl y must be removed from mount-
i ng. Al though, refri gerant di scharge i s not necessary.
Installation3.3L Engines
Installation3.0 L Engine
3. 0 L ENGINE
Remove the front l ower spl ash shi el d and front
engi ne mount through-bol t. Al l ow the engi ne to swi ng
down to provi de access to the front of the compressor.
3. 3 L ENGINE
Remove the cool ant recovery bottl e to provi de access
the front of the compressor.
(1) Remove cl utch retai ni ng center nut by usi ng
CLUTCH PLATE HOLDER (6355) (Fi g. 3).
(2) Usi ng a Cl utch Pl ate Remover (6354), remove the
cl utch front pl ate from the compressor (Fi g. 4). When
i nstal l i ng the front pl ate, sel ect the proper shi ms to
achi eve .5 to .9 mm (.020 to .035 i nch) ai r gap to the
pul l ey surface (Fi g. 5). To i nstal l front pl ate, al i gn shaft
key to groove i n front pl ate hub. Push on unti l i t seats,
and measure the ai r gap (Fi g. 6).
(3) Remove cl utch pul l ey retai ni ng snap ri ng (Fi g. 7)
and pul l the pul l ey from the assembl y (Fi g. 8).
(4) Remove the cl utch coi l wi re l ead strap screw.
(5) Remove cl utch coi l retai ni ng snap ri ng (Fi g. 9)
and pul l the coi l from the assembl y (Fi g. 10). When
i nstal l i ng the cl utch coi l , al i gn the pi n on the front of
the compressor to the mi ddl e hol e i n the hub of the coi l .
Posi ti on the pi n i n the snap ri ng gap.
COMPRESSOR FRONT SHAFT SEAL
REMOVAL
(1) Di scharge the refri gerant system.
(2) Remove A/C compressor.
Fig. 3 Remove or Install Front Plate Retaining Nut
Fig. 4 Remove Front Plate
Fig. 5 Install Front Plate and Shims
Fig. 6 Measure Front Plate Air Gap
Fig. 7 Remove or Install Pulley Snap Ring
(3) Remove the compressor cl utch assembl y and
shaft key.
(4) Remove the fel t contami nant absorber and re-
tai ner (Fi g. 11).
(5) Usi ng a mi neral spi ri ts based sol vent, thoroughl y
cl ean and dry the seal end of the compressor. Thi s wi l l
hel p to avoi d refri gerant system contami nati on.
(6) Remove the snap ri ng shaft seal retai ner (Fi g.
12). Do not use the ol d snap ri ng to assembl e.
(7) Usi ng Seal Remover/I nstal l er (6429), remove the
shaft seal (Fi g. 13).
Fig. 12 Shaft Seal Snap Ring
Fig. 13 Remove Shaft Seal
Fig. 8 Remove or Install Pulley
Fig. 9 Remove or Install Clutch Coil Snap Ring
Fig. 10 Remove or Install Clutch Coil
Fig. 11 Felt Contaminant Absorber
I NSTALLATI ON
(1) Lubri cate the new shaft seal wi th refri gerant oi l .
(2) Pl ace Seal Protector (6231) over the end of com-
pressor shaft (Fi g. 14). Use the l arger fl at end of the
remover/i nstal l er and push the seal i n unti l i t seats
and the snap ri ng groove i s vi si bl e above the seal (Fi g.
15).
(3) I nstal l cl utch/coi l assembl y.
(4) I nstal l compressor.
(5) Evacuate and charge the refri gerant system. I f
oi l l oss of 3 ml (1 oz) or greater i s suspected, refer to Oi l
Level i n the Refri gerant Servi ce Procedures secti on.
COMPRESSOR HIGH PRESSURE CUT-OUT SWITCH
(2) Di sconnect wi re connector from the hi gh pres-
sure cut-out swi tch (Fi g. 16).
(3) Remove snap ri ng securi ng the swi tch i n the
compressor end cover (Fi g. 17).
(4) Pul l swi tch strai ght out from end cover. Remove
and di scard used O-ri ng seal (Fi g. 18).
CAUTION: The High Pressure Cut-Out switch service
kit has two snap rings. One snap ring is black and the
other is silver. Use the one that is the same color as
the original snap ring.
Fig. 14 Shaft Seal Protector
Fig. 15 Install Shaft Seal
Fig. 16 High Pressure Cut-out Switch
Fig. 17 Remove or Install Snap Ring
Fig. 18 Remove or Install High Pressure Cut-out
Switch
To i nstal l , reverse the precedi ng operati on usi ng a
new O-ri ng seal . Evacuate and charge the refri gerant
system.
COMPRESSOR HIGH PRESSURE RELIEF VALVE
(2) Rotate the hi gh pressure rel i ef val ve counter-
cl ockwi se and separate rel i ef val ve from the vehi cl e
(Fi g. 19).
To i nstal l , reverse the precedi ng operati on usi ng a
system.
COMPRESSOR MAIN OR SUB CONTROL VALVES
I f the mai n or sub control val ve i s l eaki ng refri gerant
to the atmosphere, repl ace the mai n or sub control
val ve. I f a functi onal probl em i s suspected wi th the
mai n or sub control val ve, the compressor shoul d be
repl aced.
(2) Remove the compressor assembl y. Posi ti on i t to
gai n access to the control val ves. I t i s not necessary to
di sconnect the sucti on or di scharge l i nes from the
compressor.
(3) Remove the snap ri ng retai ni ng ei ther the mai n
or sub control val ve to the compressor (Fi g. 20).
(4) Pul l the mai n or sub control val ve from the
compressor end cover (Fi g. 21).
To i nstal l , reverse the precedi ng operati on usi ng new
O-ri ng seal s. Evacuate and charge the refri gerant
system.
Fig. 19 High Pressure Relief Valve Removal
Fig. 20 Main or Sub Control Valve Snap Ring
Fig. 21 Remove or Install Main or Sub Control Valve
FI XED DI SPLACEMENT COMPRESSOR SERVI CE PROCEDURES
INDEX
page page
Compressor Clutch/Coil Assembly
Model 10PA17 . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compressor Front Shaft SealModel 10PA17 . . . 34
Compressor High-Pressure Relief Valve . . . . . . . . 36
Compressor Removal and Installation . . . . . . . . . . 32
COMPRESSOR REMOVAL AND INSTALLATION
The A/C compressor may be removed and posi ti oned
wi thout di schargi ng the refri gerant system. Di scharg-
i ng i s not necessary i f removi ng the A/C compressor
cl utch/coi l assembl y, engi ne, cyl i nder head or al terna-
tor.
WARNING: Refrigerant pressures remain high even
though the engine may be turned off. Before remov-
ing a fully charged compressor, review the Safety
Precautions and Warnings section in this Group. Do
not twist or kink the refrigerant lines when removing
a fully charged compressor. Safety glasses must be
worn.
I f the A/C compressor refri gerant l i nes wi l l be re-
moved for compressor removal . Refer to Di schargi ng
Refri gerant System i n the Refri gerant Servi ce Proce-
dures secti on before proceedi ng wi th the fol l owi ng
steps.
(2) Loosen and remove dri ve bel ts (refer to Group 7,
Cool i ng System) and di sconnect compressor cl utch
wi re l ead.
(3) Remove refri gerant l i nes from compressor (i f
necessary).
(4) Remove compressor attachi ng nuts and bol ts
(Fi g. 1).
(5) Remove compressor. I f refri gerant l i nes were not
removed, l i ft compressor/cl utch assembl y and ti e i t to a
sui tabl e component.
COMPRESSOR CLUTCH/COILMODEL 10PA17
REMOVAL
Compressor assembl y must be removed from mount-
i ng. Al though, refri gerant di scharge i s not necessary.
(1) Remove the compressor shaft bol t (Fi g. 2). A band
type oi l fi l ter removal tool can be pl aced around the
cl utch pl ate to ai d i n bol t removal .
(2) Tap the cl utch pl ate wi th a pl asti c hammer and
remove cl utch pl ate and shi m (Fi g. 3).
CAUTION: Do not use screwdrivers between the
clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
(3) Remove pul l ey retai ni ng snap ri ng wi th snap
ri ng pl i ers (C-4574), and sl i de pul l ey assembl y off of
compressor (Fi g. 4).
Installation2.5 L Engines
Fig. 2 Compressor Shaft Bolt and Clutch Plate
(4) Remove coi l wi re cl i p screw and wi re harness.
(5) Remove snap ri ng retai ni ng fi el d coi l onto com-
pressor housi ng (Fi g. 5). Sl i de fi el d coi l off of compres-
sor housi ng.
(6) Exami ne fri cti onal faces of the cl utch pul l ey and
front pl ate for wear. The pul l ey and front pl ate shoul d
be repl aced i f there i s excessi ve wear or scori ng. I f the
fri cti on surfaces are oi l y, i nspect the shaft nose area of
the compressor for oi l and remove the fel t from the
front cover. I f the compressor fel t i s saturated wi th oi l ,
the shaft seal i s l eaki ng and wi l l have to be repl aced.
(7) Check beari ng for roughness, excessi ve l eakage
or grease. I f grease from beari ng has contami nated the
faces of the pul l ey or front pl ate, or i f the beari ng i s
rough, the cl utch pul l ey and front pl ate shoul d be
repl aced.
CAUTION: The clutch pulley and the front plate were
mated at the factory by a burnishing operation. No
attempt should be made to separately replace either
part. This will result in clutch slippage due to insuf-
ficient contact area.
I NSTALLATI ON
(1) Al i gn pi n i n back of fi el d coi l wi th hol e i n com-
pressor end housi ng, and posi ti on fi el d coi l i nto pl ace.
Make sure that l ead wi res are properl y routed, and
fasten wi th the wi re cl i p retai ni ng screw.
(2) I nstal l fi el d coi l retai ni ng snap ri ng (bevel si de
outward and both eyel ets to the ri ght or l eft of the pi n
on the compressor) wi th SNAP RI NG PLI ERS. Press
snap ri ng to make sure i t i s properl y seated i n the
groove.
CAUTION: If snap ring is not fully seated it will vibrate
out, resulting in a clutch failure and severe damage to
the front face of the compressor.
(3) I nstal l pul l ey assembl y to compressor. I f neces-
sary, tap gentl y wi th a bl ock of wood on the fri cti on
surface (Fi g. 6).
CAUTION: Do not mar the pulley frictional surface.
(4) I nstal l pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th snap ri ng pl i ers. Press the
snap ri ng to make sure i t i s properl y seated i n the
groove.
Fig. 3 Clutch Plate and Shim(s)
Fig. 4 Removing Pulley Snap Ring
Fig. 5 Clutch Coil Snap Ring
(5) I f the ori gi nal front pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be used.
I f not, pl ace a tri al stack of shi ms, 2.54 mm (0.10 i n.)
thi ck, on the shaft agai nst the shoul der.
(6) I nstal l front pl ate assembl y onto shaft.
(7) Wi th the front pl ate assembl y ti ght agai nst the
shi m(s), measure the ai r gap between front pl ate and
pul l ey face wi th feel er gauges. The ai r gap shoul d be
between 0.5 and 0.9 mm (.020 and .035 i nch) I f proper
ai r gap i s not obtai ned, add or subtract shi ms unti l
desi red ai r gap i s obtai ned.
(8) I nstal l compressor shaft bol t. Ti ghten to 17.52
Nm (15520 i n. l bs.).
Shimsmaycompressafter tighteningshaft nut.
Check air gap in four or more places to verify if
air gapisstill correct. Spinpulleyfor final check.
CLUTCH BREAK-I N
After a new cl utch has been i nstal l ed, check the
vol tage and amperage to the cl utch (determi ne i t to be
sati sfactory). Then cycl e the A/C cl utch approxi matel y
20 ti mes (5 sec. on and 5 sec. off). For thi s procedure,
set the system to the A/C mode, usi ng hi gh bl ower, and
engi ne rpm at 1500-2000. Thi s procedure (burni shi ng)
wi l l seat the opposi ng fri cti on surfaces and provi de a
hi gher cl utch torque capabi l i ty.
COMPRESSOR FRONT SHAFT SEALMODEL
10PA17
REMOVAL
(2) Remove A/C compressor.
(3) Remove compressor cl utch/coi l assembl y.
(4) Remove compressor through-bol ts (Fi g. 7).
(5) Remove front cover by tappi ng on the outsi de
di ameter of the cover wi th a pl asti c hammer (Fi g. 8).
(6) Remove and di scard steel val ve pl ate gasket and
O-ri ng seal (Fi g. 9 and 10).
Never reuse cover O-rings or the steel valve
plate gaskets.
(7) Pry out the fel t retai ner and remove fel t from
front cover (Fi g. 11).
(8) Remove seal snap ri ng (Fi g. 12).
Fig. 6 Installing Pulley Assembly
Fig. 7 Compressor Through-Bolts
Fig. 8 Removing Front Cover
(9) Pl ace compressor front cover on a fl at surface
wi th neck of cover faci ng up. Usi ng a brass dri ft, press
out seal assembl y (Fi g. 13).
(10) Remove dowel pi ns, val ve pl ates, and steel val ve
pl ate gasket. Di scard steel gasket (Fi g. 14).
I NSTALLATI ON
(1) I nstal l dowel pi ns i n front compressor body.
(2) I nstal l cl eaned val ve pl ates.
(3) I nstal l steel gasket.
(4) Cl ean crankshaft and coat l i ghtl y wi th refri ger-
ant oi l .
(5) Lubri cate crankshaft seal seat cavi ty of front
housi ng wi th refri gerati on oi l .
(6) Lubri cate crankshaft l i p seal and seal O-ri ng
wi th refri gerati on oi l . Then i nstal l l i p seal i n front
cover usi ng a socket that contacts the outer di ameter of
the l i p seal (Fi gs. 15 and 16).
(7) I nstal l seal snap ri ng (Fi g. 17).
(8) Lubri cate front cover O-ri ng wi th refri gerati on
oi l and careful l y pl ace i t i n seal groove.
(9) I nstal l l i p seal protector on shaft (Fi g. 18).
(10) I nstal l front cover to front compressor body.
(11) I nstal l compressor through-bol ts and fi nger
ti ghten onl y. After bol ts have been fi nger ti ghtened,
torque to 29Nm (260 i n. l bs.).
(12) I nstal l fel t shaft seal and retai ner (Fi g. 19) i nto
front housi ng.
CAUTION: Refer to Oil Level in the Refrigerant Ser-
vice Procedures section for further details.
Fig. 9 Removing Steel Valve Plate Gasket
Fig. 10 Removing O-Ring
Fig. 11 Removing Felt Retainer and Felt
Fig. 12 Seal Snap Ring
(13) I nstal l refri gerati on oi l (500 SUS) i nto the com-
pressor through the sucti on port.
(14) Check compressor operati on for smoothness by
rotati ng crankshaft at l east fi ve ful l revol uti ons.
(15) Check front housi ng cl utch coi l al i gnment pi n
for proper i nstal l ati on.
(16) I nstal l cl utch assembl y.
(17) I nstal l compressor.
(18) Evacuate and charge refri gerant system.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
(2) Rotate the hi gh pressure rel i ef val ve counter-
cl ockwi se and separate rel i ef val ve from the vehi cl e
(Fi g. 20).
To i nstal l , Reverse the precedi ng operati on usi ng a
system.
Fig. 14 Disassembling Compressor Front End
Fig. 13 Removing Seal
Fig. 15 Match Socket to Outer Seal Diameter
Fig. 16 Installing Seal Seat
Fig. 17 Seal Snap Ring
Fig. 18 Installing Lip Seal Protector
Fig. 19 Felt Retainer and Felt
Fig. 20 High Pressure Relief ValveTypical
COMPONENT DI AGNOSI S
CONDENSATE WATER DRAINAGE
Condensati on that accumul ates on the bottom of the
evaporator housi ng i s drai ned from a rubber tube
through the dash panel and on to the ground. Thi s tube
must be kept open to prevent condensate water from
col l ecti ng i n the bottom of the heater A/C uni t housi ng
(Fi g. 1).
The tapered end of the drai n tube i s desi gned to keep
contami nants from enteri ng the heater A/C uni t hous-
i ng. I f the tube i s pi nched or bl ocked, condensate
cannot drai n, causi ng water to back up and spi l l i nto
the passenger compartment. I t i s normal to see con-
densate drai nage bel ow the vehi cl e. I f the tube i s
damaged, i t shoul d be repl aced.
BLOWER MOTOR VIBRATION AND/OR NOISE DI-
AGNOSIS
The bl ower speed swi tch, i n conjuncti on wi th the
resi stor bl ock (Fi g. 2), suppl i es the bl ower motor wi th
vari ed vol tage.
CAUTION: Stay clear of the blower motor and resistor
block (Hot). Do not operate the blower motor with the
resistor block removed from the heater-A/C housing.
Refer to the Bl ower Motor Vi brati on/Noi se chart i n
thi s secti on for di agnosi s.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
Refer to the Bl ower Motor El ectri cal System Di agno-
si s chart i n thi s secti on. Al so refer to Group 8W, Wi ri ng
Di agrams for more i nformati on.
Fig. 1 Condensate Water Drain TubeTypical
Fig. 2 Blower Motor Resistor BlockTypical
BLOWER MOTOR NOI SE/VI BRATI ON DI AGNOSI S
BLOWER MOTOR ELECTRI CAL SYSTEM DI AGNOSI S
COMPONENT SERVI CE PROCEDURES
INDEX
page page
Air Distribution Duct . . . . . . . . . . . . . . . . . . . . . . . 42
Ambient Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Blower Motor and Wheel Assembly . . . . . . . . . . . . 46
Blower Motor Wheel . . . . . . . . . . . . . . . . . . . . . . . 47
Blower Resistor Block . . . . . . . . . . . . . . . . . . . . . 41
Condensate Drain Tube . . . . . . . . . . . . . . . . . . . . 49
Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . 46
Condenser Fan Control SwitchVariable
Displacement Compressor System . . . . . . . . . . 44
Defroster Ducts/Demister Ducts and Hoses . . . . . . 43
Electronic Cycling Clutch Switch (ECCS) . . . . . . . 44
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . 45
Filter-Drier Assembly . . . . . . . . . . . . . . . . . . . . . . 46
Heater A/C Unit Recondition . . . . . . . . . . . . . . . . . 47
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Heater-A/C Unit Housing . . . . . . . . . . . . . . . . . . . 47
Low or Differential Pressure Cut-Off Switch . . . . . . 45
Temperature Control Cable . . . . . . . . . . . . . . . . . . 41
Vacuum ActuatorFresh/Recirc Door . . . . . . . . . . 42
Vacuum ActuatorsMode Doors . . . . . . . . . . . . . 42
Water Control Valve . . . . . . . . . . . . . . . . . . . . . . . 44
TEMPERATURE CONTROL CABLE
(1) Remove heater-A/C control panel . Refer to
Swi tch and Panel Component Servi ce i n Group 8E,
I nstrument Panel . Di sconnect the attachi ng fl ag on the
control cabl e from the heater-A/C control panel .
(2) Remove consol e assembl y. Refer to Group 8E,
I nstrument Panel .
(3) Remove i nstrument panel l ower steeri ng col umn
cover. Refer to Group 8E, I nstrument Panel .
(4) Remove the ri ght l ower i nstrument panel /gl ove
box door assembl y. Thi s assembl y i s cl i pped to the
upper i nstrument panel at the ri ght upper si de.
(5) A/C equi pped vehi cl es: From under the hood,
di sconnect the A/C sucti on l i ne mounti ng bracket from
the dash panel (above the expansi on val ve).
(6) From under the hood, l oosen (do not remove) the
four heater-A/C assembl y to dash panel mounti ng nuts.
(7) From i nsi de the vehi cl e: Remove the verti cal
(heater-A/C housi ng) support bracket (bel ow the gl ove
box).
(8) Ti l t the enti re heater-A/C housi ng assembl y
downward to gai n access to the temperature cabl e.
(9) Locate and di sconnect the attachi ng fl ag on the
control cabl e at the heater-A/C housi ng (Fi g. 1).
(10) Sl i p the cabl e sel f-adjusti ng cl i p from the bl end-
ai r door crank.
(11) Remove the cabl e from the vehi cl e.
(12) To remove the sel f-adjusti ng cl i p from cabl e
(Fi g. 1):
(a) I nsert a 3/16 i nch (4 mm) di ameter tool (dri l l
bi t or phi l l i ps screw dri ver shank) i nto the door crank
access hol e. Then rotate the cl i p from the cabl e.
To adjust temperature cabl e: Posi ti on the TEMP
l ever on the control to the cool si de of i ts travel .
Al l owi ng the sel f-adjusti ng cl i p to sl i de on the cabl e,
rotate the bl end-ai r door crank countercl ockwi se by
hand unti l i t stops.
BLOWER RESISTOR BLOCK
(1) Open hood.
(2) Locate and remove the wi re connector from the
bl ower resi stor bl ock. Bl ock i s l ocated at the back of the
engi ne compartment on the passenger si de of the
vehi cl e (Fi g. 2).
Fig. 1 Temperature Control CableTypical
Fig. 2 Resistor Block Removal or Installation
COWL
PANEL
(3) Remove resi stor bl ock attachi ng screws and pul l
the resi stor bl ock from the vehi cl e.
CAUTION: The resistor block may be hot and could
cause burns.
To i nstal l , reverse the precedi ng operati on. The coi l s
on the Resi stor Bl ock shoul d not be contacti ng one
another. Before i nstal l ati on, gentl y separate the coi l s
(wi th fi ngers onl y) i f one coi l i s contacti ng another.
VACUUM ACTUATORFRESH/RECIRC DOOR
The Vacuum Actuator for the Fresh/Reci rc Door i s
l ocated on the passenger si de of the heater-A/C hous-
i ng.
(1) Remove heater-A/C control panel . Refer to
Swi tch and Panel Component Servi ce i n Group 8E,
I nstrument Panel .
(2) Remove consol e assembl y. Refer to Group 8E,
I nstrument Panel .
(3) Remove i nstrument panel l ower steeri ng col umn
cover. Refer to Group 8E, I nstrument Panel .
(4) Remove the ri ght l ower i nstrument panel /gl ove
box door assembl y. Thi s assembl y i s cl i pped to the
upper i nstrument panel at the ri ght upper si de.
(5) Remove vacuum l i nes from actuator.
(6) Loosen (do not remove) the two actuator attach-
i ng nuts (Fi g. 3).
(7) Di sengage actuator l i nkage at mode door.
(8) Remove actuator from vehi cl e.
To I nstal l , Reverse the precedi ng operati on.
VACUUM ACTUATORSMODE DOORS
The Vacuum Actuators for the Mode Doors are l o-
cated on the dri vers si de of heater/AC housi ng above
the accel erator pedal .
REMOVAL
(1) Remove the i nstrument panel cover under the
steeri ng col umn. Refer to Group 8E, I nstrument Panel
and Gauges.
Heat/Defrost Actuator:
Remove two screws from bracket. Li ft actuator up-
ward and pul l out (Fi g. 4).
Mode Door Actuator:
Remove two screws from bracket (Fi g. 5). Rotate
actuator counter-cl ockwi se to unhook from door and
pul l to remove.
I NSTALLATI ON
Heat/Defrost Actuator:
I nstal l actuator l i nk through housi ng and i nsert i n
heat defrost door sl ot. Push down to hook l i nk to door.
Locate the bracket to the housi ng and i nstal l two
screws.
Mode Door Actuator:
I nsert the actuator shaft through the hol e i n the
housi ng and heat/defrost door. Attach through mount-
i ng hol e i n the mode door. I nstal l two screws i n bracket.
I nstal l the i nstrument panel cover under the steeri ng
col umn.
AIR DISTRIBUTION DUCT
(1) I nstrument panel assembl y must be removed.
Refer to Group 8E, I nstrument Panel and Gauges.
Fig. 3 Removing or Installing Fresh/Recirc Vacuum
Actuator
Fig. 4 Removing or Installing Heat/Defrost Vacuum
Actuator Assembly
(2) After i nstrument panel has been removed, sepa-
rate the defroster/demi ster ducts from the ai r di stri bu-
ti on duct.
(3) Remove the ai r di stri buti on duct-to-i nstrument
panel mounti ng screws (Fi g. 6).
DEFROSTER DUCTS/DEMISTER DUCTS AND
HOSES
(1) I nstrument panel assembl y must be removed.
Refer to group 8e, I nstrument Panel and Gauges.
(2) After i nstrument panel has been removed, sepa-
rate the defroster/demi ster ducts from the ai r di stri bu-
ti on duct.
(3) Remove the demi ster tubes and hoses (Fi g. 7).
HEATER HOSES
Review Safety Precautions and Warnings the
in General Information section before proceed-
ing with this operation.
(1) Drai n engi ne cool i ng system. Refer to Group 7,
Cool i ng System.
(2) Loosen cl amps at each end of hose to be removed
(Fi gs. 8 or 9).
(3) Careful l y rotate hose back and forth whi l e tug-
gi ng sl i ghtl y away from connector ni ppl e.
CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant into heater A/C unit.
Fig. 5 Mode Door Vacuum Actuators
Fig. 6 Air Distribution Duct
Fig. 7 Defroster Ducts/Demister Ducts and Hoses
Fig. 8 Heater Hose Routing V6 Engine
WATER CONTROL VALVE
Cool i ng System.
(2) Locate and l oosen cl amps at water control val ve
(Fi g. 10).
(3) Di sconnect the vacuum l i ne and heater hoses
from water control val ve (mark the heater hoses to
assure correct val ve i nstal l ati on).
AMBIENT SWITCH
The ambi ent swi tch i s l ocated i n front of the con-
denser.
(1) Di sconnect the wi ri ng connector.
(2) Remove the mounti ng screw and the ambi ent
temperature swi tch.
To i nstal l , reverse removal procedure.
ELECTRONIC CYCLING CLUTCH SWITCH (ECCS)
(1) Di sconnect the 4 pi n connector at the ECCS.
(2) Remove the ti e strap securi ng the capi l l ary tube
spl i ce to the sucti on l i ne (Fi g. 11).
(3) Remove two attachi ng screws securi ng the
swi tch to the refri gerant l i ne mani fol d pl ate at the
expansi on val ve.
(4) Separate the swi tch from the mani fol d pl ate and
sl i p the capi l l ary tube from the wel l on the sucti on
l i ne.The capillary-tube-well is filled with a spe-
cial temperature conductive grease. Save this
special grease and re-use it when installing the
switch.
CONDENSER FAN CONTROL SWITCHVARIABLE
DISPLACEMENT COMPRESSOR SYSTEM
The Fan Control Swi tch i s l ocated on the pl umbi ng
di scharge l i ne at the A/C compressor (Fi g. 12).
CAUTION: Refrigerant discharge is not necessary
when removing the Condenser Fan Control Switch.
However, a small amount of refrigerant will vent from
the switch port.
Fig. 9 Heater Hose Routing 2.5L Engine
Fig. 10 Water Control Valve
Fig. 11 Remove or Install Electronic Cycling Clutch
Switch
Fig. 12 Condenser Fan Control Switch
(1) Di sconnect wi re connector from condenser fan
control swi tch.
(2) Loosen and qui ckl y rotate the swi tch counter-
cl ockwi se and separate from the hi gh pressure l i ne
swi tch port.
LOW OR DIFFERENTIAL PRESSURE CUT-OFF
SWITCH
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Di sconnect the boot l i ke wi re connector at the
cut-off swi tch.
(2) Usi ng a sender uni t type socket, remove the
swi tch from the expansi on val ve (Fi g. 13 or 14).
To i nstal l , assure an adequate seal by usi ng a smal l
amount of thread seal i ng tape on the repl acement
swi tch and reverse the precedi ng steps.
Evacuate and charge the system.
EXPANSION VALVE
REMOVAL
(1) Remove the boot-type wi re connector from the
pressure
cut-off swi tch.
(2) Remove the attachi ng bol t i n center of refri ger-
ant l i ne-pl umbi ng seal i ng pl ate (Fi g. 15).
(3) Careful l y pul l the refri gerant l i ne-seal i ng pl ate
assembl y from the expansi on val ve towards front of
vehi cl e. Do not scratch the expansi on val ve seal i ng
surfaces wi th pi l ot tubes.
(4) Cover the openi ngs on refri gerati on l i ne-seal i ng
pl ate assembl y to prevent di rt or moi sture contami na-
ti on.
(5) Remove two screws securi ng the expansi on val ve
to the evaporator seal i ng pl ate.
(6) Careful l y remove val ve.
I NSTALLATI ON
(1) Remove and repl ace the al umi num gasket on the
evaporator seal i ng pl ate.
(2) Careful l y hol d the expansi on val ve to the evapo-
rator seal i ng pl ate (do not scratch seal i ng surface).
I nstal l two attachi ng screws and ti ghten to 11 3 Nm
(100 30 i nch l bs.).
(3) Remove and repl ace the al umi num gasket on the
refri gerant l i ne-seal i ng pl ate assembl y.
(4) Careful l y hol d the refri gerant l i ne-seal i ng pl ate
assembl y
Fig. 13 Low Pressure Cut-Off Switch and Expansion
ValveTypical
Fig. 14 Differential Pressure Cut-Off Switch and Ex-
pansion ValveTypical
Fig. 15 Expansion Valve
to the expansi on val ve, i nstal l bol t and ti ghten to 23
3 Nm
(200 30 i nch l bs.).
(5) Connect wi res to l ow pressure cut-off swi tch.
(6) Evacuate and recharge system.
(7) After expansi on val ve i s i nstal l ed, system i s
charged, and l eaks have been checked, repeat A/C
performance check.
FILTER-DRIER ASSEMBLY
(1) Remove the vehi cl e jack.
(2) Remove the two hi gh pressure refri gerant l i nes
from the si des of the fi l ter-dri er assembl y (Fi g. 16).
Then careful l y separate l i nes from fi l ter-dri er. Di scard
the ol d gaskets.
(3) Cover the open ends of the refri gerant l i nes to
mi ni mi ze refri gerant system contami nati on.
(4) Remove two mounti ng strap bol ts and l i ft the
fi l ter-dri er from vehi cl e. I f repl aci ng the fi l ter-dri er
assembl y, transfer the mounti ng strap to repl acement
part.
To i nstal l , repl ace both refri gerant l i ne-to-fi l ter-dri er
gaskets. Then reverse the precedi ng operati on.
Evacuate and recharge system.
CONDENSER ASSEMBLY
(1) Remove gri l l assembl y. Refer to Group 23, Body.
(2) Remove refri gerant l i ne attachi ng nut (Fi g. 17)
and separate refri gerant l i ne assembl y from condenser
seal i ng pl ate.
(3) Cover the open ends of the refri gerant l i nes and
condenser to mi ni mi ze refri gerati on system contami -
nati on.
(4) Remove bol ts securi ng the condenser assembl y to
the radi ator core support. Then l i ft the condenser
assembl y from vehi cl e.
To i nstal l , repl ace al l O-ri ngs and gaskets, coat al l
seal i ng surfaces wi th approved wax-free refri gerant
oi l . Then reverse the precedi ng operati on.
Evacuate and recharge system.
BLOWER MOTOR AND WHEEL ASSEMBLY
(1) To remove the bl ower motor, the l ower ri ght
i nstrument panel assembl y must be removed. Refer to
Group 8E, I nstrument Panel and Gauges.
(2) Remove bl ower assembl y-to-heater housi ng
mounti ng screws.
(3) Al l ow the bl ower assembl y to drop down, and
remove assembl y from vehi cl e.
Fig. 16 Filter-DrierTypical
Fig. 17 A/C Condenser Removal and
InstallationTypical
BLOWER MOTOR WHEEL
Bl ower motor must be removed from vehi cl e before
performi ng thi s operati on.
(1) Remove the spri ng type retai ni ng ri ng from the
center of the bl ower wheel (Fi g. 18). Note the l ocati on
of the bl ower wheel on the bl ower motor shaft.
(2) Remove bl ower wheel from bl ower motor shaft.
To i nstal l , reverse the precedi ng operati on. To pre-
vent noi se or vi brati on, rotate the bl ower wheel by
hand to check for rubbi ng.
HEATER CORE
Refer to Heater A/C Uni t Recondi ti on i n thi s Group.
EVAPORATOR COIL
Refer to Heater A/C Uni t Recondi ti on i n thi s Group.
HEATER-A/C UNIT HOUSING
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY DISCHARGED BEFORE PROCEEDING
(1) Set parki ng brake.
(3) Di scharge refri gerant system.
(4) Di sconnect al l engi ne compartment l i nes and
vacuum hoses.
(5) Drai n engi ne cool ant. Pl ug cool ant l i nes.
(6) Remove the steeri ng col umn cover.
(7) Remove the l eft under panel si l encer.
(8) Remove the ri ght under panel si l encer.
(9) Remove the center bezel (cl i ps to i nstrument
panel ).
(10) Remove the accessory swi tch carri er.
(11) Remove Heat-A/C control s.
(12) Remove standard storage modul e.
(13) Remove the ri ght l ower i nstrument panel .
(14) Remove the ri ght 40-way wi ri ng bracket.
(15) Remove the l ower ri ght rei nforcement, body
computer bracket, and mi d-to-l ower rei nforcement as
one assembl y.
(16) Di sconnect al l necessary i nstrument panel wi r-
i ng and temporari l y route wi ri ng out of the way.
(17) Di sconnect the A/C uni t hanger strap from the
uni t and temporari l y re-posi ti on.
(18) Remove the rubber condensate drai n tube (i n
engi ne compartment).
(19) Remove the four nuts (i n the engi ne compart-
ment) securi ng the uni t to the dash panel .
(20) Pul l the enti re uni t rearward unti l the studs on
the uni t cl ear the dash panel . Drop the uni t down and
pul l i t rearward to remove i t from vehi cl e.
To i nstal l the assembl y, reverse the precedi ng opera-
ti on.
HEATER A/C UNIT RECONDITION
Heater-A/C Housi ng must be removed from vehi cl e
before performi ng thi s operati on. Refer to Heater-A/C
Uni t Housi ngRemoval and I nstal l ati on.
DI SASSEMBLY
(1) Pl ace heater/A/C uni t assembl y (Fi g. 19) on
workbench.
(2) Remove one screw retai ni ng the vacuum har-
ness. Feed harness through hol e i n cover.
(3) Remove thi rteen screws from top cover and re-
move cover. Temperature control door wi l l come out
wi th the cover. Remove the nut and l ever from the door
shaft to remove the temperature door from the cover.
(4) Remove screw from heater core tube retai ni ng
bracket and l i ft heater core out of uni t (Fi g. 20).
(5) Remove A/C evaporator coi l out of uni t (Fi g. 21).
Fig. 18 Blower Wheel Retaining Ring Removal and
Installation
Fig. 19 Heater/A/C Assembly
(6) Di sconnect actuator l i nkage from
fresh/reci rcul ati on door and vacuum l i nes from actua-
tor. Loosen two nuts attachi ng actuator to housi ng and
remove actuator (Fi g. 22).
(7) Remove four screws attachi ng fresh/reci rcul ati on
cover to uni t and l i ft off cover (Fi g. 23).
(8) Fresh/reci rcul ati ng door may now be removed
from i ts housi ng.
(9) To remove heat defrost door, remove retai ni ng
cl i p from shaft i nsi de the housi ng. Pul l shaft from
housi ng and remove door.
(10) To remove mode door, remove retai ni ng cl i p
from shaft i nsi de the housi ng. Pul l the shaft from the
housi ng and remove door.
ASSEMBLY
(1) Pl ace evaporator coi l i nto uni t.
(2) Pl ace heater core i nto uni t and fasten wi th
screws.
(3) Rei nstal l bl ower wheel onto bl ower motor shaft
and secure wi th retai ni ng cl amp.
(4) Feed bl ower motor wi res through hol e i n hous-
i ng. Lower bl ower assembl y (rubber seal i n pl ace) i nto
housi ng. Pul l wi ri ng grommet i nto pl ace and i nstal l
three mounti ng screws.
(5) I nstal l bl ower motor assembl y (fi ve screws) to
housi ng.
(6) I nstal l fresh/reci rcul ati ng door i nto housi ng. I n-
stal l fresh/reci rcul ati ng cover (four screws). Rotate
actuator shaft i nto door and sl i de actuator i nto bracket
and ti ghten two nuts.
Fig. 20 Removing or Installing Heater Core Assem-
bly
Fig. 21 Removing or Installing A/C Evaporator Coil
Fig. 22 Removing or Installing Fresh/Recirc Vacuum
Actuator and Linkage
Fig. 23 Evaporator Heater Assembly
(7) To i nstal l mode door to housi ng, i nsert door shaft
through housi ng and door pi vot. Push on shaft retai ner
(Fi g. 24).
(8) To i nstal l demi ster door, connect wi re rod to mode
door. I nsert pi vot end of door i nto hol e i n housi ng.
Posi ti on opposi te i nto sl ot.
(9) To i nstal l heat/defrost door, i nsert door shaft
through housi ng and door pi vot. Push on shaft re-
tai ner.
(10) I nstal l heat di stri buti on duct to bottom of hous-
i ng wi th three screws.
(11) To i nstal l temperature control door, i nstal l door
shaft i nto l ower pi vot i n the case housi ng. Pl ace uni t
cover over housi ng whi l e feedi ng temperature door
shaft through cover. I f the temperature control door i s
attached to the cover, feed the door i nto the housi ng
wi th the cover. Di rect the bottom pi vot of the door wi th
your hand through the mode door openi ng.
(12) To i nstal l housi ng cover, l i ne up cover to housi ng
usi ng pi l ot pi ns, the temperature door, and screw hol es
for al i gnment. I nstal l thi rteen screws.
(13) Route vacuum harness through hol es i n cover.
I nstal l screw to retai n vacuum harness. Make al l
vacuum hose attachments to vacuum actuators.
CONDENSATE DRAIN TUBE
(2) Locate rubber Drai n Tube on ri ght si de of dash
panel (Fi g. 25).
(3) Squeeze cl amp and remove drai n tube.
To i nstal l , reverse the precedi ng operati on. Check the
drai n tube ni ppl e on the heater-A/C housi ng for any
obstructi ons.
Fig. 24 Removing or Installing Mode Door Shaft
Fig. 25 Condensate Water Drain TubeTypical
AUXI LI ARY REAR HEATI NG OR HEATI NG-AI R/CONDI TI ONI NG
INDEX
page page
Air Distribution Duct . . . . . . . . . . . . . . . . . . . . . . . 51
Auxiliary Under Body Heater Plumbing . . . . . . . . . 52
Auxiliary Under Body Refrigerant Plumbing . . . . . . 52
Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . 50
Evaporator and Expansion Valve . . . . . . . . . . . . . 51
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Rear Blower Resistor Block . . . . . . . . . . . . . . . . . 51
Rear Heater A/C Air Outlets . . . . . . . . . . . . . . . . . 50
Rear Heater A/C Blower Motor . . . . . . . . . . . . . . . 51
Rear Heater A/C Control . . . . . . . . . . . . . . . . . . . 50
Rear Heater A/C Control Illumination Bulb . . . . . . . 50
Rear Heater-A/C Unit . . . . . . . . . . . . . . . . . . . . . . 51
GENERAL INFORMATION
For proper operati on of the rear heati ng-
ai r/condi ti oni ng system, refer to the Owners Manual
suppl i ed wi th the vehi cl e.
The auxi l i ary rear heater functi ons the same as the
heater-A/C system. The rear heater uti l i zes the same
components as the rear heater-A/C system. Onl y the
refri gerant components have been omi tted.
The auxi l i ary rear heati ng-ai r/condi ti oni ng system i s
l ocated i n the l eft rear quarter panel . I t i s a manual l y
operated devi ce, control l ed by the rear-seat occupant.
The rear heater A/C control operates i n conjuncti on
wi th the front heater A/C control . A four posi ti on
bl ower (overri de) swi tch i s l ocated on the i nstrument
panel (Fi g. 1). The vehi cl e operator can use the rear
heater-A/C bl ower i nstrument panel swi tch to operate
the bl ower at HI or LO speed, regardl ess of the setti ng
of the rear control . I n the OFF posi ti on, the rear control
wi l l not functi on. I n the ON posi ti on, the rear control
wi l l functi on normal l y.
Ai r from i nsi de the vehi cl e i s drawn i nto the ai r
i ntake gri l l e i n the l eft rear quarter tri m panel . The ai r
enters the bl ower and i s pushed through the heater
core and A/C evaporator coi l (i f equi pped). When the
HEATmode i s sel ected, the ai rfl ow i s di rected from the
heat outl ets at the fl oor. When the FAN or A/C mode i s
sel ected, the ai rfl ow i s di rected from the upper ai r
outl ets.
When di agnosi ng el ectri cal probl ems i n the auxi l i ary
rear heater or rear A/C system, refer to Group 8W,
Wi ri ng Di agrams.
When di agnosi ng mechani cal probl ems i n the auxi l -
i ary rear heater or rear A/C systems, refer to the
Di agnosti c and Test procedures secti ons for (front)
heater-A/C.
REAR HEATER A/C CONTROL
REMOVE AND I NSTALL
(1) Pry outward on the outsi de upper and l ower
corners of the control .
(2) Separate the control from the tri m panel and
di sconnect the wi re connectors.
To i nstal l , push the control i nto the openi ng unti l i t
l ocks i nto pl ace.
REAR HEATER A/C CONTROL ILLUMINATION BULB
REMOVE AND I NSTALL
(1) Remove rear heater A/C control from tri m panel .
(2) On the back of control opposi te from the wi re
connectors, l ocate the bul b socket l ug.
(3) Rotate the socket countercl ockwi se and pul l the
socket from the control .
To i nstal l , reverse the precedi ng operati on. Refer to
the back of Group 8L, Lamps, for bul b usage.
REAR HEATER A/C AIR OUTLETS
REMOVAL AND I NSTALL
(1) Pry outward on the outsi de upper and l ower
corners of the outl ets.
(2) Separate the ai r outl et from the tri m panel .
To i nstal l , push the outl et fi rml y i nto the openi ng
unti l i t l ocks i nto pl ace.
Fig. 1 Rear Heater, Rear Heater-A/C Controls
REAR BLOWER RESISTOR BLOCK
REMOVE AND I NSTALL
(1) Remove the l eft l ower quarter tri m panel . Refer
to Group 23, Body.
(2) Di sconnect wi re connectors from resi stor bl ock.
(3) Remove two attachi ng screws from resi stor bl ock
and separate from the heater-A/C uni t.
REAR HEATER A/C BLOWER MOTOR
REMOVE AND I NSTALL
(1) Remove the l eft l ower quarter tri m panel . Refer
to Group 23, Body.
(2) Remove one bl ower cover to fl oor attachi ng screw
and seven bl ower cover to uni t attachi ng screws.
(3) Rotate bl ower cover from under heater-A/C uni t
cover.
(4) Compress the cl amp at the center of the bl ower
wheel and pul l the wheel from the bl ower shaft.
(5) Remove three bl ower motor attachi ng screws.
(6) Separate the bl ower motor from the housi ng uni t.
REAR HEATER-A/C UNIT
REMOVE AND I NSTALL
WARNING: ON VEHICLES EQUIPPED WITH REAR
A/C, THE REFRIGERANT SYSTEM MUST BE DIS-
CHARGED BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM MUST
ALSO BE RELIEVED OF ALL PRESSURE.
Cool i ng System. Di sconnect heater hoses at rear
heater-A/C uni t.
(2) Di scharge refri gerant system. Di sconnect A/C
pl umbi ng from rear heater-A/C uni t.
(3) Remove l eft l ower quarter tri m panel . Refer to
Group 23, Body.
(4) Remove the attachi ng screws securi ng the ai r
di stri buti on duct to the rear wheel housi ng.
(5) Remove the attachi ng screws securi ng the heater
uni t to the fl oor pan.
(6) Remove attachi ng screw securi ng the uni t to the
quarter panel support.
(7) Li ft the uni t enough to cl ear the fl oor pan and
remove the uni t from the vehi cl e.
To I nstal l , Reverse the precedi ng operati on. I nstal l
new gaskets at refri gerant l i nes and expansi on val ve.
Evacuate and charge the refri gerant system. Refi l l the
cool i ng system. Test for l eaks and overal l performance.
AIR DISTRIBUTION DUCT
REMOVE AND I NSTALL
(1) Remove l eft quarter tri m panel . Refer to Group
23, Body.
(2) Remove the screws securi ng the A/C duct to the
heater-A/C uni t and the body.
(3) Pul l the di stri buti on duct strai ght up to remove.
HEATER CORE
REMOVE AND I NSTALL
(1) Drai n the engi ne cool ant system.
(2) Di sconnect heater tubi ng from the under body
heater l i nes to the rear uni t.
(3) Remove the l ower l eft quarter tri m panel . Refer
to Group 23, BODY.
(4) Remove FAN-A/C di stri buti on duct.
(5) Remove heater-uni t cover.
(6) Careful l y pul l the heater core and heater tubes
strai ght out of the uni t.
(7) Rai se the heater core to drai n resi dual cool ant
from the core.
(8) Di sconnect two heater hose cl amps that attach
pl umbi ng to the heater core tube.
(9) To i nstal l , reverse the precedi ng operati on.
EVAPORATOR AND EXPANSION VALVE
REMOVE
WARNING: THE REFRIGERANT SYSTEM MUST BE
DISCHARGED BEFORE PERFORMINGTHE FOLLOW-
ING OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
(1) Remove l eft quarter tri m panel . Refer to Group
23, Body.
(2) Remove FAN-A/C di stri buti on duct.
(3) Remove rear A/C uni t.
(4) Remove uni t cover.
(5) Remove the bol t that mounts the uni fi ed refri g-
erant pl umbi ng bl ock to the expansi on val ve.
(6) Careful l y pul l the evaporator and expansi on
val ve strai ght out of uni t. Do not scratch the seal i ng
surfaces wi th the pl umbi ng extensi on tube pi l ots.
(7) Remove and di scard the al umi num gasket be-
tween the pl umbi ng extensi on and the expansi on
val ve.
(8) Cover the pl umbi ng extensi on seal i ng surface to
prevent contami nati on.
(9) Bri ng evaporator and expansi on val ve to a cl ean
work space.
(10) Remove two 1/4-20 Torx Head screws.
(11) Remove expansi on val ve.
(12) Measure and record the amount of resi dual oi l
from the removed evaporator.
I NSTALL
(1) Repl ace the al umi num gaskets (one on evapora-
tor pl ate and one on pl umbi ng pl ate).
(2) Hol d expansi on val ve agai nst evaporator seal i ng
pl ate (do not scratch the seal i ng surface). I nstal l two
screws and ti ghten to 100 30 i nch pounds (11 3
Nm).
(3) Careful l y i nstal l the evaporator and expansi on
val ve strai ght i nto the uni t. Do not scratch the seal i ng
surfaces wi th the pl umbi ng extensi on tube pi l ots.
(4) Determi ne the amount of ol d refri gerant oi l
drai ned from the evaporator. Add thi s amount (of cl ean
refri gerant oi l ) back i nto the system.
(5) Careful l y al i gn the expansi on val ve onto the pi l ot
tube of the pl umbi ng seal i ng pl ate (do not scratch the
seal i ng surface). I nstal l the bol t through the pl umbi ng
pl ate i nto the uni t seal i ng pl ate and ti ghten to 200
30 i nch pounds (23 3 Nm).
(6) I nstal l uni t cover and ai r di stri buti on duct.
(7) I nstal l quarter tri m panel , evacuate/charge sys-
tem, and test performance.
AUXILIARY UNDER BODY HEATER PLUMBING
WARNING: THE ENGINE COOLING SYSTEM MUST
BE RELIEVED OF ALL PRESSURE.
(1) Drai n the engi ne cool i ng system. Refer to Group
7, Cool i ng System.
(2) I n the engi ne compartment, and di sconnect two
auxi l i ary rear heater hoses from the (front) heater hose
tee fi tti ngs.
(3) Hoi st the vehi cl e. Di sconnect two push-together
coupl i ngs from the auxi l i ary rear heater core tubes
protrudi ng through the fl oor pan.
(4) Remove four bol ts and one pal nut hol di ng the
pl umbi ng to the fl oor pan and l ower the pl umbi ng from
the vehi cl e (Fi g. 2).
AUXILIARY UNDER BODY REFRIGERANT PLUMB-
ING
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE
DISCHARGED BEFORE PERFORMINGTHE FOLLOW-
ING OPERATION.
(1) Hoi st the vehi cl e. Di sconnect two tube-fi tti ngs
from the engi ne compartment pl umbi ng.
(2) Remove the bol t from the uni fi ed pl umbi ng bl ock
(l eft si de of car, outboard of rai l , forward of fuel tank).
(3) Careful l y pul l refri gerant l i ne assembl y down
(take care NOT to scratch the seal i ng surface wi th the
tube pi l ots). Remove and di scard the al umi num gasket
and cover uni t seal i ng surface to prevent contami na-
ti on.
(4) Remove two screws hol di ng pl umbi ng to the fuel
tank support and l eft-si de support rai l (near muffl er
support bracket).
(5) Remove two screws hol di ng the pl umbi ng to the
fl oor pan.
(6) Di sconnect the parki ng brake system at hook
above muffl er and the cabl e connecti on near the sup-
port rai l s.
(7) Fi sh the nyl on tubi ng and uni fi ed pl umbi ng bl ock
above the muffl er support member.
(8) Lower the pl umbi ng from the vehi cl e.
(9) Measure the resi dual oi l i n the under body
pl umbi ng out of each end of the pl umbi ng. The l ow-si de
(l arger di ameter l i ne) has a check val ve that can
restri ct oi l fl ow from the tube-fi tti ng to the uni fi ed
pl umbi ng end of the hose. Measure cl ean 500 SUS
vi scosi ty wax-free refri gerant oi l to be returned to the
refri gerant system.
I NSTALL
(1) Protect the pl umbi ng ends from scratches. I f
pl umbi ng i s new, do not remove the shi ppi ng caps unti l
joi ni ng together.
(2) Reverse the precedi ng steps from the REMOVAL
procedure.
(3) New gaskets and O-ri ngs are requi red for i nstal -
l ati on. The O-ri ngs must be covered wi th cl ean refri g-
erant oi l pri or to i nstal l ati on.
(4) Connect the tube-fi tti ngs to the engi ne compart-
ment under body pl umbi ng. Avoi d mi sal i gnment of the
threads (cross threadi ng) and ti ghten to 200 i n-l bs.
(5) Remove the shi ppi ng cap from the pl umbi ng si de
seal i ng surface and veri fy that the al umi num gasket i s
present.
Fig. 2 Rear Heater Under body Plumbing
(6) Careful l y al i gn the pi l ot tubes of the pl umbi ng
l i ne bl ock i nto the uni t (take care not to scratch the
seal i ng surface).
(7) I nstal l the bol t through the pl umbi ng pl ate i nto
the uni t seal i ng pl ate and ti ghten to 200 30 i nch
pounds (23 3 Nm) (Fi g. 3).
Fig. 3 Rear A/C Under body Plumbing
BODY
CONTENTS
page page
BODY COMPONENT SERVICE . . . . . . . . . . . . . 20
BODY DIAGNOSTIC PROCEDURES . . . . . . . . . . 2
GENERAL SERVICE INFORMATION . . . . . . . . . . 1
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SEAT COMPONENT SERVICE . . . . . . . . . . . . . . . 7
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL SERVI CE I NFORMATI ON
VEHICLE IDENTIFICATION
Throughout thi s group, references to the Chrysl er
Corporati on vehi cl e fami l y i denti fi cati on code are used
when descri bi ng a procedure that i s uni que to that
vehi cl e. Refer to I ntroducti on Group of thi s manual for
detai l ed i nformati on on vehi cl e i denti fi cati on. I f a
procedure i s common to al l vehi cl es covered i n thi s
manual , no reference wi l l be made to a vehi cl e fami l y
code.
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
USE A BREATHING FILTER WHEN SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL BASED CLEANING SOLVENTS.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL 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 components.
Damage to vehicle can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to finish
or color can result.
Do not hammer or pound on plastic trimpanel when
servicing interior trim, plastic panel can break.
Chrysl er Corporati on uses many di fferent types of
push-i n fasteners to secure the i nteri or and exteri or
tri m to the body. Most of these fasteners can be reused
to assembl e the tri m duri ng vari ous repai r procedures.
At ti mes a push-i n fastener cannot be removed wi thout
damagi ng the fastener or the component i t i s hol di ng.
I f i t i s not possi bl e to remove a fastener wi thout
damagi ng a component or body, cut or brake the
fastener and use a new one when i nstal l i ng the com-
ponent. Never pry or pound on a pl asti c or press-board
tri m component. Usi ng a sui tabl e fork-type pryi ng
devi ce, pry the fastener from the retai ni ng hol e behi nd
the component bei ng removed. When i nstal l i ng, veri fy
fastener al i gnment wi th the retai ni ng hol e, by hand,
push di rectl y on or over the fastener unti l i t seats.
Appl y a l ow force pul l to the panel to veri fy that i t i s
secure.
When i t i s necessary to remove components to servi ce
another, i t shoul d not be necessary to appl y excessi ve
force or bend a component to remove i t. Before damag-
i ng a tri m component, veri fy hi dden fasteners or cap-
tured edges hol di ng the component i n pl ace.
BODY 23 - 1
BODY DI AGNOSTI C PROCEDURES
WATER LEAKS
Water l eaks can be caused by poor seal i ng, i mproper
body component al i gnment, body seam porosi ty, mi ss-
i ng pl ugs, or bl ocked drai n hol es. Centri fugal and
gravi tati onal force can cause water to dri p from a
l ocati on away from the actual l eak poi nt, maki ng l eak
detecti on di ffi cul t. Al l body seal i ng poi nts shoul d be
water ti ght i n normal wet dri vi ng condi ti ons. Water
fl owi ng downward from the front of the vehi cl e shoul d
not enter the passenger or l uggage compartment. Mov-
i ng seal i ng surfaces wi l l not al ways seal water ti ght
under al l condi ti ons. At ti mes, si de gl ass or door seal s
wi l l al l ow water to enter the passenger compartment
duri ng hi gh pressure washi ng or hard dri vi ng rai n
(severe) condi ti ons. Over compensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons, can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng a
repai r, water test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VI SUAL I NSPECTI ON BEFORE WATER LEAK
TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear and body components are properl y
al i gned and seal ed. I f component al i gnment or seal i ng
i s necessary, refer to the appropri ate secti on of thi s
group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA, PERSONAL IN-
JURY CAN RESULT.
When the condi ti ons causi ng a water l eak has been
determi ned, si mul ate the condi ti ons as cl osel y as pos-
si bl e.
I f a l eak occurs wi th the vehi cl e parked i n a steady
l i ght rai n, fl ood the l eak area wi th an open ended
garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds i n a
steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the spray
i n the di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mul ate
thi s condi ti on. Thi s method can be used when the l eak
occurs when the vehi cl e accel erates, stops or turns. I f
the l eak occurs on accel erati on, hoi st the front of the
vehi cl e. I f the l eak occurs when braki ng, hoi st the back
of the vehi cl e. I f the l eak occurs on l eft turns, hoi st the
l eft si de of the vehi cl e. I f the l eak occurs on ri ght turns,
hoi st the ri ght si de of the vehi cl e. For hoi sti ng recom-
mendati ons refer to Group 0, Lubri cati on and Mai nte-
nance, General I nformati on secti on.
WATER LEAK DETECTI ON
To detect a water l eak poi nt of entry, do a water test
and watch for water tracks or dropl ets formi ng on the
i nsi de of the vehi cl e. I f necessary, remove i nteri or tri m
covers or panel s to gai n vi sual access to the l eak area.
I f the hose cannot be posi ti oned wi thout bei ng hel d,
have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak ap-
pears, fi nd the hi ghest poi nt of the water track or drop.
The hi ghest poi nt usual l y wi l l show the poi nt of entry.
After l eak poi nt has been found, repai r the l eak and
water test to veri fy that l eak has stopped.
Locati ng the entry poi nt of water that i s l eaki ng i nto
a cavi ty between panel s can be di ffi cul t. The trapped
water spl ashes or runs from the cavi ty i t i s dammed up
i n, often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on a i ncl i ne.
MI RROR I NSPECTI ON METHOD
When a l eak poi nt area i s vi sual l y obstructed, use a
sui tabl e mi rror to gai n vi sual access. A mi rror can al so
be used to defl ect l i ght to a l i mi ted access area to assi st
i n l ocati ng a l eak poi nt.
BRI GHT LI GHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can be
detected wi thout water testi ng. Posi ti on the vehi cl e i n
a bri ghtl y l i ght area. From i nsi de the darkened l ug-
gage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the openi ng.
PRESSURI ZED LEAK TEST METHOD
When a water l eak i nto the passenger compartment
can not be detected by water testi ng, pressuri ze the
passenger compartment and soap test exteri or of the
vehi cl e. To pressuri ze the passenger compartment,
cl ose al l doors and wi ndows, start engi ne, and set
heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to assure adequate vol tage to the bl ower. Wi th
i nteri or pressuri zed, appl y di sh detergent sol uti on to
suspected l eak area on the exteri or of the vehi cl e.
Appl y detergent sol uti on wi th spray devi ce or
23 - 2 BODY
soft bri stl e brush. I f soap bubbl es occur at a body seam,
joi nt, seal or gasket the l eak entry poi nt coul d be at
that l ocati on.
WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai r ti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai r ti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross-wi nds. Over compensati ng on door or gl ass ad-
justments to stop wi nd noi se that occurs under severe
condi ti ons, can cause premature seal wear and exces-
si ve cl osi ng or l atchi ng effort. After a repai r procedure
has been performed, test vehi cl e to veri fy noi se has
stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose mol d-
i ngs can fl utter, creati ng a buzzi ng or chatteri ng noi se.
An open cavi ty or protrudi ng edge can create whi stl i ng
or howl i ng noi se. I nspect the exteri or of the vehi cl e to
veri fy that these condi ti ons do not exi st.
VI SUAL I NSPECTI ON BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and body
components are al i gned and seal ed. I f component
al i gnment or seal i ng i s necessary, refer to the appro-
pri ate secti on of thi s group for proper procedures.
ROAD TESTI NG WI ND NOI SE
(1) Dri ve the vehi cl e to veri fy the general l ocati on of
the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm (6
i n.) l engths al ong weatherstri ps, wel d seams or mol d-
i ngs. After each l ength i s appl i ed dri ve vehi cl e. I f noi se
goes away after a pi ece of tape i s appl i ed, remove tape,
l ocate and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
BODY 23 - 3
PAI NT
INTRODUCTION
A pai nt code i s provi ded on the body code pl ate
l ocated i n the engi ne compartment. Refer to the I ntro-
ducti on secti on at the front of thi s manual for body code
pl ate descri pti on.
BASE COAT/CLEAR COAT FINISH
On most vehi cl es a two part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul tra vi ol et l i ght and provi des a durabl e
hi gh gl oss fi ni sh.
WET SANDING, BUFFING AND POLISHING
Mi nor aci d etchi ng, orange peel or smudgi ng i n cl ear
coat can be reduced wi th l i ght wet sandi ng, hand buffi ng
and pol i shi ng. I f the fi ni sh has been wet sanded i n the
past, i t can not be repeated. Wet sandi ng operati on shoul d
be performed by a trai ned automoti ve pai nter.
CAUTION: Do not remove clear coat finish, if equipped.
Base coat paint must retain clear coat to shine.
PAINTED SURFACE TOUCH-UP
When a pai nted metal surface has been scratched or
chi pped, i t shoul d be touched-up as soon as possi bl e to
avoi d corrosi on. For best resul ts, use Mopar Scratch
Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top Coat.
Refer to I ntroducti on group of thi s manual for Body
Code Pl ate i nformati on.
TOUCH-UP PROCEDURE
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat of
fi l l er/pri mer. Do not overl ap pri mer onto good surface
fi ni sh. The appl i cator brush shoul d be wet enough to
puddl e fi l l the defect wi thout runni ng. Do not stroke
brush appl i cator on body surface. Al l ow the fi l l er/
pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up pai nt. Do
not overl ap touch-up col or onto the ori gi nal col or coat around
the scratch or chi p. Butt the new col or to the ori gi nal col or i f
possi bl e. Do not stroke appl i cator brush on body surface.
Al l ow touch-up pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up col or
can be l i ghtl y (600 gri t) wet sanded and pol i shed wi th
rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, Appl y cl ear top coat
to touch-up pai nt wi th the same techni que as descri bed
i n step 4. Al l ow cl ear top coat to dry hard. I f desi red,
step 5 can be performed on cl ear top coat.
PAI NT AND TRI M CODE DESCRI PTI ONS
23 - 4 BODY
WI NDSHI ELD
WARNING: DO NOT USE URETHANE ADHESIVE OR
PRIMER IN CLOSED WORK AREA, PERSONAL IN-
JURY CAN RESULT.
PROTECT SKIN FROM COMING IN CONTACT WITH
URETHANE, PERSONAL INJURY CAN RESULT.
WEAR EYE AND HAND PROTECTION WHEN
WORKING WITH GLASS, PERSONAL INJURY CAN
RESULT.
CAUTION: Protect all painted or trimmed surfaces
from coming in contact with urethane or primers,
damage will result.
Do not damage painted surfaces when removing
moldings or cutting urethane around windshield.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the struc-
tural support for the roof. The urethane bondi ng used
to secure the wi ndshi el d to the fence i s di ffi cul t to cut
or cl ean from any surface. I f the mol di ngs are set i n
urethane, i t woul d al so be unl i kel y they coul d be
sal vaged. Before removi ng the wi ndshi el d, check the
avai l abi l i ty of the wi ndshi el d and mol di ngs from the
parts suppl i er.
WINDSHIELD REPLACEMENT
REMOVAL
(1) Remove i nsi de rear vi ew mi rror.
(2) Remove cowl cover. Refer to Cowl Cover Removal
paragraph i n thi s group.
(3) Remove wi ndshi el d mol di ngs (Fi g. 1). Pul l out-
ward on mol di ng at the bottom of A-pi l l ars usi ng pl i ers.
(4) Cut urethane bondi ng from around wi ndshi el d
usi ng a sui tabl e sharp col d kni fe. A pneumati c cutti ng
devi ce can be used i f avai l abl e (Fi g. 2).
(5) Separate wi ndshi el d from vehi cl e.
I NSTALLATI ON
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment if a door or the trunk lid is
slammed before urethane bonding is cured. Water
leaks can result.
Al l ow the urethane at l east 4 hours to cure before
returni ng the vehi cl e to use.
The wi ndshi el d fence shoul d be cl eaned of ol d ure-
thane bondi ng materi al . Support spacers shoul d be
cl eaned and properl y i nstal l ed on wel d studs or repai r
screws at bottom of wi ndshi el d openi ng.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng and posi ti on gl ass i n the center of the openi ng
agai nst the support spacers. Mark the gl ass at the
support spacers wi th a grease penci l or pi eces of
maski ng tape and i nk pen to use as a reference for
i nstal l ati on. Remove repl acement wi ndshi el d from
wi ndshi el d openi ng (Fi g. 3).
(2) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm by
50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced paral l el 75
cm (2.5 ft.) apart (Fi g. 4).
(3) Cl ean i nsi de of wi ndshi el d wi th Mopar Gl ass
Cl eaner and l i nt-free cl oth.
(4) Appl y cl ear gl ass pri mer 25 mm (1 i n.) wi de
around peri meter of wi ndshi el d and wi pe wi th
cl ean/dry l i nt-free cl oth.
(5) Appl y bl ack-out pri mer 15 mm (.75 i n.) wi de on
top and si des of wi ndshi el d and 25 mm (1 i n.) on
bottom of wi ndshi el d. Al l ow at l east three mi nutes
dryi ng ti me.
(6) Posi ti on wi ndshi el d bondi ng compressi on spac-
ers on l ower fence above the support spacers at the
edge of the wi ndshi el d openi ng (Fi g. 5).
(7) Appl y a 10 mm (0.4 i n.) bead of urethane around
peri meter of wi ndshi el d al ong the i nsi de of the mol d-
i ngs.
Fig. 1 Windshield Moldings
Fig. 2 Cut Urethane Around Windshield
BODY 23 - 5
(8) Wi th the ai d of a hel per, posi ti on the wi ndshi el d
over the wi ndshi el d openi ng. Al i gn the reference marks
at the bottom of the wi ndshi el d to the support spacers.
(9) Sl owl y l ower wi ndshi el d gl ass to wi ndshi el d
openi ng fence. Gui de the top mol di ng i nto proper
posi ti on i f necessary. Push wi ndshi el d i nward to fence
spacers at bottom and unti l top mol di ng i s fl ush to roof
l i ne (Fi g. 6).
(10) Cl ean access urethane from exteri or wi th Mo-
par, Super Cl ean or equi val ent.
(11) I nstal l wi ndshi el d mol di ng. Appl y 150 mm (6
i n.) l engths of 50 mm (2 i n.) maski ng tape spaced 250
mm (10 i n.) apart to hol d mol di ng i n pl ace unti l
urethane cures.
(12) I nstal l cowl cover and wi pers.
(13) I nstal l i nsi de rear vi ew mi rror.
(14) After urethane has cured, remove tape stri ps
and water test wi ndshi el d to veri fy repai r.
Fig. 3 Center Windshield and Mark at Support Spac-
ers
Fig. 4 Work Surface Set up and Molding Installation
Fig. 5 Position Urethane Compression Spacers
Fig. 6 Lower Windshield Into Position
23 - 6 BODY
SEAT COMPONENT SERVI CE
INDEX
page page
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bucket Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket Seat Cushion Frame . . . . . . . . . . . . . . . . . 11
Bucket Seat Cushion Pad . . . . . . . . . . . . . . . . . . . 11
Bucket Seat Cushion Side Cover . . . . . . . . . . . . . 11
Bucket Seat Riser . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket Seat Riser Trim Cover . . . . . . . . . . . . . . . . 11
Child Restraint Seat . . . . . . . . . . . . . . . . . . . . . . . 14
Child Seat Back Cover and Pads . . . . . . . . . . . . . 16
Child Seat Cushion Cover and Pad . . . . . . . . . . . 16
Child Seat Module . . . . . . . . . . . . . . . . . . . . . . . . 14
Child Seat Module Cushion Cover and Pad . . . . . 15
Child Seat Module Head Restraint . . . . . . . . . . . . 15
Child Seat Module Head Restraint Cover and
Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Converta-Bed Forward Rail and Pivot . . . . . . . . . . 17
Converta-Bed Latch Handle and Link Bar . . . . . . . 18
Converta-Bed Seat Back Frame . . . . . . . . . . . . . . 18
Converta-Bed Seat Back Hinge . . . . . . . . . . . . . . 18
Converta-Bed Seat Cushion Frame . . . . . . . . . . . 19
Converta-Bed Seat Hinge Covers. . . . . . . . . . . . . 17
Converta-Bed Seat Riser . . . . . . . . . . . . . . . . . . . 17
Converta-Bed Seats . . . . . . . . . . . . . . . . . . . . . . . 17
Head Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lumbar Support Handle . . . . . . . . . . . . . . . . . . . . . 9
Recliner Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Seat Back Assist Strap . . . . . . . . . . . . . . . . . . . . . . 9
Seat Back Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Seat Back Recliner . . . . . . . . . . . . . . . . . . . . . . . . 9
Second Rear Seat Back . . . . . . . . . . . . . . . . . . . . 12
Second Rear Seat Back Hinge . . . . . . . . . . . . . . . 13
Second Rear Seat Back Hinge Cover . . . . . . . . . . 12
Second Rear Seat Back Pad . . . . . . . . . . . . . . . . 14
Second Rear Seat Back Panel . . . . . . . . . . . . . . . 12
Second Rear Seat Cushion Pad . . . . . . . . . . . . . . 14
Second Rear Seat Riser . . . . . . . . . . . . . . . . . . . . 13
Second Rear Seat Track . . . . . . . . . . . . . . . . . . . 13
GENERAL INFORMATION
On some tri m styl es, the cushi on and back pads are
mol ded i nto the covers. Mol ded i n pl ace tri m covers are
not servi ced separatel y from the base pad. Mol ded i n
pl ace tri m cover and pad can be i denti fi ed by the l ack
of sewi ng sti tches i n areas the appear to be sewn
together.
HEAD RESTRAINT
REMOVAL (FI G. 1)
The head restrai nt i s retai ned wi th a l eaf spri ng cl i p
at the bottom of the sl eeve attached to the seat back
frame.
(1) Fabri cate a tool from 25 mm (1 i n.) steel shi ppi ng
band stock 6 cm (24 i n.) l ong.
(2) Li ft head restrai nt to the hi ghest posi ti on.
(3) I nsert end of tool between the bar and sl eeve at
the front of the head restrai nt. Push tool i n unti l i t
comes to a sol i d stop.
(4) Push downward on head restrai nt al l owi ng the
tool to travel wi th the bar.
(5) Hol d tool downward and pul l upward on head
restrai nt. I f head restrai nt stops, the tool was not
i nserted far enough.
(6) Separate head restrai nt from seat back.
(7) Pul l sl eeve from seat back.
I NSTALLATI ON (FI G. 2)
(1) I nstal l sl eeve through hol e i n tri m cover at top of
seat back, open si de forward.
(2) I nsert bar i nto sl eeve and push head restrai nt
downward.
ARMREST
REMOVAL (FI G. 3)
(1) Remove tri m pl ug coveri ng screw on si de of
armrest.
(2) Remove screw hol di ng armrest to mounti ng.
(3) Rotate armrest upward to al i gn armrest stop to
gate i n mount.
(4) Pul l outward to separate armrest from mount.
(5) Remove screws hol di ng mount to seat back.
Fig. 1 Remove Head Restraint
BODY 23 - 7
(6) Separate mount from seat back.
I NSTALLATI ON
BUCKET SEAT BACK
REMOVAL (FI G. 4 AND 5)
(1) Posi ti on seat back recl i ner i n the ful l upri ght
posi ti on.
(2) Remove seat and posi ti on seat on a cl ean soft
work surface. Refer to Body Component Servi ce secti on
of thi s group. For fi rst rear seat, refer to Owners
Manual for i nstructi ons.
(3) Remove seat base ri ser.
(4) Di sengage cl i p hol di ng i nboard seat bel t buckl e
tether to si de cover.
(5) Remove recl i ner handl e.
(6) Remove si de covers.
(7) Di sengage J-stri p retai ner hol di ng seat cushi on
cover to rear frame rai l .
(8) Remove nut and wave washer hol di ng seat back
frame to recl i ner shaft.
(9) Separate recl i ner shaft from stud on seat back.
(10) Remove shoul der bol ts hol di ng cushi on frame to
seat back frame.
(11) Separate seat back from cushi on.
I NSTALLATI ON
RECLINER HANDLE
REMOVAL (FI G. 6)
(1) Remove screw hol di ng handl e to recl i ner spl i ne
shaft.
(2) Pul l outward and separate handl e from seat.
Fig. 2 Install Head Restraint
Fig. 3 Arm Rest
Fig. 4 Recliner Shaft Nut and Wave Washer
Fig. 5 Seat Back Pivot Bolts
23 - 8 BODY
RECLI NER HANDLE I NSTALLATI ON
Reverse the precedi ng operati on
SEAT BACK RECLINER
REMOVAL (FI G. 7)
(1) Remove Seat From vehi cl e.
(2) Remove seat cushi on si de cover.
(4) Remove bol ts hol di ng recl i ner to cushi on frame.
(5) Separate recl i ner from cushi on.
I NSTALLATI ON
LUMBAR SUPPORT HANDLE
REMOVAL (FI G. 8)
(1) Remove screw hol di ng l umbar support handl e to
spl i ne shaft on seat back.
(2) Pul l and separate handl e from seat.
LUMBAR SUPPORT HANDLE I NSTALLATI ON
SEAT BACK ASSIST STRAP
REMOVAL (FI G. 9)
(1) Remove screws hol di ng assi st strap to seat back.
(2) Separate assi st strap from seat back.
I NSTALLATI ON
SEAT BACK FRAME
REMOVAL (FI G. 10 AND 11)
(1) Remove seat from vehi cl e.
(2) Remove head restrai nt.
(3) Remove arm rest and mount.
(4) Remove assi st strap.
(5) Remove l umbar adjuster handl e.
Fig. 6 Recliner Handle
Fig. 7 Seat Back Recliner
Fig. 8 Lumbar Support Handle
Fig. 9 Seat Back Assist Strap
BODY 23 - 9
(7) Remove hog-ri ngs cl osi ng tri m cover at bottom of
seat back.
(8) Pul l cover i nsi de out and upward to the fi rst pul l
down l i sti ng.
(9) Separate hook/l oop fastener stri ps hol di ng cover
to pad.
(10) Remove hog-ri ngs hol di ng l i sti ng wi res to pul l
down wi res mol ded i nto pad.
(11) Pul l cover from top of pad.
(12) Remove hog-ri ngs hol di ng pad apron to back of
frame.
(13) Separate seat back frame from pad.
SEAT BACK FRAME I NSTALLATI ON (FI G. 12,
13 AND 14)
(1) I nsert frame i nto pad.
(2) Hog-ri ng pad apron to rear of seat back.
(3) Sl i p tri m cover over top of seat to the pul l down
wi re groove i n the pad.
(4) Wi th l i sti ng centered i n the pul l down groove,
hog-ri ng l i sti ng wi re to pul l down wi re mol ded i nto pad.
(5) Rol l tri m cover down to bottom of seat back.
(6) Engage hook/l op fasteners to hol d cover to pad.
(7) Hog-ri ng bottom cl osure wi res together.
(8) Reverse steps 6 through 1 of the removal opera-
ti on.
Fig. 10 Seat Back Cover Listing and Hook/Loop
Fasteners
Fig. 11 Seat Back Frame and Pad
Fig. 12 Hog-ring Apron to Seat Back
Fig. 13 Hog-ring Listing to Pull DownTypical
Fig. 14 Hog-ring Cover Closure TogetherTypical
23 - 10 BODY
BUCKET SEAT RISER TRIM COVER
REMOVAL (FI G. 15)
(1) Remove screw hol di ng ri ser tri m cover to seat
ri ser crossmember.
(2) Separate tri m cover from seat ri ser.
I NSTALLATI ON
BUCKET SEAT RISER
REMOVAL (FI G. 16)
(1) Remove seat from vehi cl e. Refer Body Compo-
nent Servi ce secti on for front seat procedures. Refer to
Owners Manual for rear seat procedures.
(2) Remove storage drawer, i f equi pped.
(3) Remove nuts hol di ng ri ser to bottom of seat.
(4) Separate ri ser from seat.
I NSTALLATI ON
BUCKET SEAT CUSHION SIDE COVER
REMOVAL (FI G. 17)
(1) Remove recl i ner handl e, i f equi pped.
(2) Di sengage seat bel t buckl e tether from si de cover,
i f equi pped.
(3) Remove screws hol di ng si de cover to seat cushi on
frame.
(4) Separate si de cover from seat.
I NSTALLATI ON
BUCKET SEAT CUSHION FRAME
REMOVAL (FI G. 18)
(2) Remove ri ser.
(4) Di sengage J-stri p retai ners from cushi on frame.
(5) Separate frame from pad.
I NSTALLATI ON
BUCKET SEAT CUSHION PAD
REMOVAL (FI G. 19)
(4) Di sengage J-stri p retai ners from cushi on frame.
Fig. 15 Bucket Seat Riser Trim Cover
Fig. 16 Bucket Seat Riser
Fig. 17 Bucket Seat Cushion Side Cover
BODY 23 - 11
(5) Di sengage hook/l oop fasteners hol di ng cover to
pad.
(6) Remove hog-ri ngs hol di ng l i sti ng wi re to hol d
down wi re i n pad.
(7) Separate cover from pad.
BUCKET SEAT CUSHI ON PAD I NSTALLATI ON
(FI G. 20)
(1) Center l i sti ng wi re i n pul l down groove.
(2) Hog-ri ng l i sti ng wi re to pul l down wi re i n pad.
(3) Reverse steps 5 through 1 of precedi ng operati on.
SECOND REAR SEAT BACK PANEL
REMOVAL (FI G. 21)
(1) Remove screws hol di ng rear panel to seat back.
(2) Li ft upward on base of panel and pul l rearward
to di sengage hooks hol di ng top of panel to seat back.
(3) Separate panel from seat back.
I NSTALLATI ON
SECOND REAR SEAT BACK HINGE COVER
REMOVAL (FI G. 22)
(1) Remove screw hol di ng hi nge cover to seat back
hi nge.
(2) Separate cover from seat back hi nge.
I NSTALLATI ON
SECOND REAR SEAT BACK
REMOVAL (FI G. 23)
(1) Remove seat back hi nge covers.
(2) Remove bol ts hol di ng bottom of seat back hi nges
to cushi on frame.
Fig. 19 Seat Cushion Cover Listing and Hook/Loop
Fasteners
Fig. 18 Bucket Seat Cushion Frame
Fig. 20 Hog-ring Cover Listing to Pull Down
Fig. 21 Second Rear Seat Back Panel
23 - 12 BODY
SECOND REAR SEAT BACK I NSTALLATI ON
SECOND REAR SEAT BACK HINGE
REMOVAL (FI G. 24)
(1) Remove seat back hi nge cover.
(2) Remove bol ts hol di ng seat back hi nge to cushi on
frame.
(3) Remove nuts hol di ng hi nge to seat back.
(4) Separate seat back hi nge from seat.
I NSTALLATI ON
SECOND REAR SEAT TRACK
REMOVAL (FI G. 25)
(1) Remove second rear seat from vehi cl e.
(2) Posi ti on seat upsi de down on a cl ean work sur-
face.
(3) Di sconnect track adjuster l i nk wi re from l atch
arm.
(4) Remove nuts hol di ng track to ri ser.
(5) Separate track from ri ser.
I NSTALLATI ON
SECOND REAR SEAT RISER
REMOVAL (FI G. 26)
(1) Remove seat track, i f equi pped.
(2) Remove bol ts hol di ng ri ser to bottom of seat
frame.
I NSTALLATI ON
Fig. 22 Second Rear Seat Back Hinge Cover
Fig. 23 Second Rear Seat Back
Fig. 24 Second Rear Seat Back Hinge
Fig. 25 Second Rear Seat Track
BODY 23 - 13
SECOND REAR SEAT CUSHION PAD
REMOVAL
(2) Posi ti on seat on a cl ean work surface.
(3) Separate seat back hi nges from cushi on frame.
(4) Remove seat ri sers.
(5) Remove seat bel ts from rear rai l of seat cushi on
frame.
(6) Di sengage J-stri p retai ners hol di ng tri m cover to
bottom cushi on frame.
(7) Separate frame from cushi on pad and cover.
(8) Turn cushi on pad upri ght on work surface.
(9) Rol l cover i nsi de out to top of cushi on pad.
(10) Remove hog-ri ngs hol di ng cover l i sti ng wi re to
hol d down wi re i n cushi on pad. Refer to Bucket Seat
Cushi on Pad paragraph for typi cal i l l ustrati ons.
(11) Separate cover from pad.
I NSTALLATI ON
SECOND REAR SEAT BACK PAD
REMOVAL
(1) Remove seat back hi nge covers.
(2) Remove bol ts hol di ng hi nges to cushi on frame.
(4) Posi ti on seat back on a cl ean work surface.
(5) Remove seat back tri m panel .
(6) Remove hog-ri ngs hol di ng cover to seat back
frame.
(7) Separate frame from back pad and cover.
(8) Turn back pad upri ght on work surface.
(9) Rol l cover i nsi de out to top of back pad.
(10) Remove hog-ri ngs hol di ng cover l i sti ng wi res to
hol d down wi res i n pad. Refer to Bucket Seat Back Pad
paragraph for typi cal i l l ustrati ons.
(11) Separate cover from back pad.
I NSTALLATI ON
CHILD RESTRAINT SEAT
The chi l d restrai nt, two passenger seat, l ocated i n
the fi rst rear posi ti on can be removed from the vehi cl e
usi ng i nstructi ons provi ded i n the Owners manual .
CHILD SEAT MODULE
REMOVAL
(1) Remove tri m panel from rear of seat back.
(2) Open chi l d seat and separate hook and l oop
fasteners hol di ng vi nyl i nsert to modul e.
(3) Di sengage J-stri p retai ner hol di ng head re-
strai nt tri m cover to seat back frame.
(4) Remove hog-ri ngs hol di ng seat back tri m cover to
upper seat back frame (Fi g. 27).
(5) Di sengage push-i n fasteners hol di ng seat back
tri m cover to modul e under head restrai nt.
(6) Pul l seat back tri m cover from under head re-
strai nt.
(7) Remove screws hol di ng top of modul e to seat
back frame (Fi g. 28).
(8) Cl ose chi l d restrai nt seat.
(9) Defl ect pad at base of modul e upward to gai n
access to hi dden screws under modul e.
(10) Remove screws hol di ng bottom of modul e to
seat back frame (Fi g. 28).
(11) Rotate top of modul e forward whi l e pul l i ng
upward and separate modul e from seat back.
I NSTALLATI ON
Fig. 26 Second Rear Seat RiserTypical
Fig. 27 Seat Back Cover Hog-ring
23 - 14 BODY
CHILD SEAT MODULE HEAD RESTRAINT
REMOVAL (FI G. 29)
(1) Remove chi l d restrai nt seat modul e from seat
back.
(2) Remove screws hol di ng head restrai nt hi nge to
modul e.
(3) Separate head restrai nt from modul e.
I NSTALLATI ON
CHILD SEAT MODULE HEAD RESTRAINT COVER
AND PAD
REMOVAL
(1) Remove tri m panel from rear of seat back.
(2) Di sengage J-stri p retai ner hol di ng head re-
strai nt tri m cover to seat back frame.
(3) Open head restrai nt to the hi ghest posi ti on.
(4) Di sengage hook and l oop cl osure at bottom of
head restrai nt.
(5) Turn head restrai nt cover i nsi de-out from bottom
of cover up.
(6) Separate cover from head restrai nt armature
and pad.
(7) Separate pad from armature.
I NSTALLATI ON
CHILD SEAT MODULE CUSHION COVER AND PAD
REMOVAL
(1) Remove chi l d seat modul e.
(2) Remove bol ts hol di ng chi l d seat cushi on and
restrai nt bel ts to modul e pi vots (Fi g. 30).
(3) Di sengage push-i n fasteners hol di ng tri m cover
to cushi on pan (Fi g. 31).
(4) Separate tri m cover from cushi on pad and pan.
(5) Separate pad from pan.
I NSTALLATI ON
Fig. 28 Child Seat Module
Fig. 29 Child Restraint Head Restraint
Fig. 30 Child Seat Cushion Pivot Bolts
BODY 23 - 15
CHILD SEAT BACK COVER AND PADS
REMOVAL
(2) Remove ri sers from bottom of seat.
(3) Remove chi l d seat modul es.
(4) Remove outboard arm rest and pi vot bracket.
(5) Remove hog-ri ngs hol di ng l ower rear corners of
seat back cover to cushi on frame (Fi g. 32).
(6) Di sengage J-stri ps hol di ng seat back cover to
bottom of cushi on frame (Fi g. 33).
seat back frame retai ni ng wi res.
(8) Remove hog-ri ngs hol di ng cover to outboard seat
back frame retai ni ng wi res.
(9) Separate cover from pads and frame (Fi g. 34).
(10) Remove hog-ri ngs hol di ng pads to seat back
frame.
(11) Separate pads from frame.
(12) Remove screws hol di ng upper i nsul ator cap to
seat back frame.
(13) Separate i nsul ator cap from frame.
I NSTALLATI ON
CHILD SEAT CUSHION COVER AND PAD
REMOVAL
(2) Remove ri sers from bottom of seat.
(3) Remove bol ts hol di ng seat bel t buckl es to cushi on
frame.
(4) Separate seat bel ts from cushi on.
bottom of cushi on frame.
(6) Remove hog-ri ngs hol di ng l ower rear corners of
seat back cover to cushi on frame.
(7) Di sengage J-stri ps hol di ng cushi on cover and
pad to seat frame.
(8) Separate cover and pad from seat frame.
Fig. 31 Child Seat Cushion Cover
Fig. 32 Seat Back Cover Hog-rings
Fig. 33 Seat Back Cover J-strip
Fig. 34 Seat Back Cover and Pads
23 - 16 BODY
CHI LD SEAT CUSHI ON COVER AND PAD I N-
STALLATI ON
CONVERTA-BED SEATS
The opti onal Converta-bed seats are removed from
the vehi cl e usi ng the same procedure as the two and
three passenger bench seats. Refer to the Owners
Manual provi ded wi th the vehi cl e for proper removal
procedure.
CONVERTA-BED SEAT RISER
REMOVAL (FI G. 35)
(3) Remove bol ts hol di ng seat track to rear frame
rai l .
(4) Remove bol ts hol di ng seat track to forward pi vot
bracket and rai l .
I NSTALLATI ON
CONVERTA-BED FORWARD RAIL AND PIVOT
REMOVAL (FI G. 36)
(3) Remove bol ts hol di ng seat track to rear frame
rai l .
(4) Remove bol ts hol di ng seat track to forward pi vot
bracket and rai l .
(6) Separate forward rai l from pi vot bracket.
(7) Remove shoul der bol t hol di ng pi vot bracket from
cushi on frame.
(8) Separate pi vot bracket from seat.
I NSTALLATI ON
CONVERTA-BED SEAT HINGE COVERS.
REMOVAL
(1) I f necessary, Remove seat from vehi cl e.
(2) Remove screw hol di ng upper hi nge cover to seat
back hi nge.
(3) Separate upper hi nge cover from seat (Fi g. 37).
(4) Remove screw hol di ng l ower hi nge cover to seat
back hi nge.
(5) Separate l ower hi nge cover from seat (Fi g. 38).
I NSTALLATI ON
Fig. 35 Converta-bed Riser
Fig. 36 Forward Rail and Pivot
Fig. 37 Upper Hinge Cover
BODY 23 - 17
CONVERTA-BED LATCH HANDLE AND LINK BAR
REMOVAL
(2) Remove upper and l ower seat back hi nge covers.
(3) Remove ri sers from seat cushi on frame.
(4) Remove push-nut hol di ng l atch handl e to ri ght
seat back hi nge (Fi g. 39).
(5) Di sengage seat back l atch return spri ng from
ri ght hi nge (Fi g. 39).
(6) Loosen bol ts hol di ng ri ght seat back hi nge to
cushi on frame (Fi g. 40).
(7) Separate l atch handl e and l i nk bar from cushi on
frame.
I NSTALLATI ON
CONVERTA-BED SEAT BACK HINGE
REMOVAL
(3) I f removi ng ri ght hi nge, remove push-nut hol d-
i ng l atch handl e to ri ght seat back hi nge. Di sengage
seat back l atch return spri ng from ri ght hi nge (Fi g. 39).
(4) Di sengage i nterl ocki ng J-stri ps hol di ng carpet
cover together bel ow rear rai l (Fi g. 41).
(5) Remove bol ts hol di ng seat back hi nge and spacer
to rear rai l (Fi g. 42).
(6) Remove nuts hol di ng seat back hi nge to back
frame.
(7) Remove bol ts hol di ng seat back hi nge to cushi on
frame.
(8) Separate seat back hi nge from seat.
I NSTALLATI ON
CONVERTA-BED SEAT BACK FRAME
REMOVAL
(3) On three passenger seat, di sengage hook and
channel retai ner hol di ng seat back l ower apron to the
rear rai l cover (Fi g. 43).
(4) Di sengage i nterl ocki ng J-stri ps hol di ng carpet
cover together bel ow rear rai l .
(5) Remove bol ts hol di ng l eft seat back hi nge and
spacer to rear rai l .
(6) Remove nuts hol di ng seat back hi nges to seat
back frame.
Fig. 38 Lower Hinge Cover
Fig. 39 Push-nut and Return Spring
Fig. 40 Latch Handle, Link Bar and Return Spring
23 - 18 BODY
(7) Remove bol ts hol di ng l eft seat back hi nge to
cushi on frame.
(8) Separate l eft seat back hi nge from seat.
(10) On three passenger seat, remove seat back rear
tri m panel .
(11) For two passenger seat refer to procedure A. For
three passenger seat refer to procedure B.
a) Di sengage i nterl ocki ng J-stri p hol di ng bottom of
seat back cover together.
b) Di sengage J-stri ps hol di ng seat back cover and
pad to frame.
(12) Separate cover and pad from seat back frame.
CONVERTA-BED SEAT BACK FRAME I NSTAL-
LATI ON
CONVERTA-BED SEAT CUSHION FRAME
REMOVAL
(3) Remove l eft seat back hi nge and l atch handl e
from cushi on frame.
(4) Di sengage J-stri ps hol di ng cover and pad to
cushi on frame.
(5) Separate cover and pad from cushi on frame.
I NSTALLATI ON
Fig. 41 Interlocking J-strips
Fig. 42 Seat Back Hinge
Fig. 43 Hook and Channel Retainer
BODY 23 - 19
BODY COMPONENT SERVI CE
INDEX
page page
A-Pillar and Roof Rail Moldings . . . . . . . . . . . . . . 36
Body Side Applique (Fig. 35) . . . . . . . . . . . . . . . . 33
Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cowl Trim and Scuff Plates . . . . . . . . . . . . . . . . . 35
Door Opening Weatherstrips . . . . . . . . . . . . . . . . . 32
Exterior Moldings (Fig. 34) . . . . . . . . . . . . . . . . . . 33
Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Center Console . . . . . . . . . . . . . . . . . . . . . . 40
Front Door and Hinge . . . . . . . . . . . . . . . . . . . . . 24
Front Door Belt Molding and WeatherstripVan . . 26
Front Door Belt Molding and Weatherstrip
Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Front Door Frame Rear MoldingVan . . . . . . . . . 26
Front Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front Door Glass Channel and Run Weatherstrip . 27
Front Door Glass Lower Channel . . . . . . . . . . . . . 27
Front Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . 25
Front Door Side View Mirror . . . . . . . . . . . . . . . . . 26
Front Door Trim Panel . . . . . . . . . . . . . . . . . . . . . 24
Front Door Window RegulatorManual . . . . . . . . 27
Front Door Window RegulatorPower . . . . . . . . . 28
Front End Splash Shields . . . . . . . . . . . . . . . . . . . 23
Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Front Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Fill Door Release Cable . . . . . . . . . . . . . . . . 42
Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Head Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hood and Hinges . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hood Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hood Ornament . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hood Release Cable . . . . . . . . . . . . . . . . . . . . . . 22
Hood Safety Catch . . . . . . . . . . . . . . . . . . . . . . . . 21
Left Quarter Trim Panel . . . . . . . . . . . . . . . . . . . . 37
Left Quarter Trim PanelWith Rear A/C . . . . . . . . 38
Liftgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Liftgate Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Liftgate Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . 41
Outside Front Door Latch Release Handle . . . . . . 25
Overhead Console . . . . . . . . . . . . . . . . . . . . . . . . 40
Rear Engine Compartment Splash Shield . . . . . . . 23
Rear Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Rear Window Glass . . . . . . . . . . . . . . . . . . . . . . . 43
Right B-Pillar Trim Cover . . . . . . . . . . . . . . . . . . . 36
Right Quarter Trim Panel . . . . . . . . . . . . . . . . . . . 37
Right Side Grab Handle . . . . . . . . . . . . . . . . . . . . 35
Roof Top Luggage Rack . . . . . . . . . . . . . . . . . . . . 42
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sight Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Sliding Door Center Hinge . . . . . . . . . . . . . . . . . . 29
Sliding Door Center Hinge Track Cover . . . . . . . . . 29
Sliding Door Frame Upper Molding . . . . . . . . . . . . 28
Sliding Door Inside Latch/Lock Control . . . . . . . . . 30
Sliding Door Latch/Lock Linkage . . . . . . . . . . . . . . 30
Sliding Door Lower Hinge . . . . . . . . . . . . . . . . . . . 30
Sliding Door Outside Latch Release Handle . . . . . 31
Sliding Door Power Lock Actuator . . . . . . . . . . . . . 31
Sliding Door Pull Handle . . . . . . . . . . . . . . . . . . . 28
Sliding Door Rear Latch . . . . . . . . . . . . . . . . . . . . 31
Sliding Door Trim Panel . . . . . . . . . . . . . . . . . . . . 28
Sliding Door Upper Hinge . . . . . . . . . . . . . . . . . . . 29
Stick-On Body Side Molding . . . . . . . . . . . . . . . . . 32
Transaxle Splash Shield . . . . . . . . . . . . . . . . . . . . 23
Upper Track Cover . . . . . . . . . . . . . . . . . . . . . . . . 36
Vent Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Vent Window Weatherstrip . . . . . . . . . . . . . . . . . . 32
Wood Grain Overlay . . . . . . . . . . . . . . . . . . . . . . . 35
GRILLE
REMOVAL (FI G. 1 OR 2)
(1) Remove bol t hol di ng gri l l e to bracket i n front of
radi ator.
(2) Remove headl amp bezel and park/turn si gnal
l amp on l ow l i ne model s. Refer to Group 8L, Lamps for
proper procedures.
(3) Remove screws hol di ng gri l l e to front headl amp
assembl i es.
(4) Separate gri l l e from vehi cl e.
I NSTALLATI ON
HOOD ORNAMENT
REMOVAL (FI G. 3)
(1) Rai se hood to the ful l up posi ti on.
(2) Remove nut hol di ng hood ornament to hood.
(3) Separate ornament from hood.
I NSTALLATI ON
Fig. 1 GrilleLow Line
23 - 20 BODY
HOOD AND HINGES
HOOD REMOVAL (FI G. 4)
(1) Rai se hood to ful l up posi ti on.
(2) Remove cowl cover as necessary to gai n access to
under hood l amp connector. Di sconnect under hood
l amp wi re connector.
(3) Mark al l bol t and hi nge attachment l ocati ons
wi th a grease penci l or other sui tabl e devi ce to provi de
reference marks for i nstal l ati on. When i nstal l i ng hood,
al i gn al l marks and secure bol ts. The hood shoul d be
al i gned to 4 mm (0.160 i n.) gap to the front fenders and
fl ush across the top surfaces al ong fenders.
(4) Remove the top hood to hi nge attachi ng bol ts and
l oosen the bottom bol ts unti l they can be removed by
hand.
(5) Wi th assi stance of a hel per at the opposi te si de of
the vehi cl e to support the hood, remove the bottom
hood to hi nge attachi ng bol ts. Separate the hood from
the vehi cl e.
HOOD I NSTALLATI ON
HOOD HI NGE REMOVAL (FI G. 4)
(1) Support hood on the si de that requi res hi nge
repl acement.
(2) Mark al l bol t and hi nge attachment l ocati ons
wi th a grease penci l or other sui tabl e devi ce to provi de
reference marks for i nstal l ati on. When i nstal l i ng hood
hi nge, al i gn al l marks and secure bol ts. The hood
shoul d be al i gned to 4 mm (0.160 i n.) gap to the front
fenders and fl ush across the top surfaces al ong fenders.
Shi ms can be added or removed between the hood and
hi nge to achi eve proper hood hei ght.
(3) Remove cowl cover as necessary to gai n access to
hood hi nge pi n.
(4) Remove hood to hi nge attachi ng bol ts.
(5) Remove push-on retai ner hol di ng hood hi nge
arm to hi nge pi n through access hol e i n cowl .
HOOD HI NGE I NSTALLATI ON
Reverse the precedi ng operati on. I f necessary, pai nt
new hi nge before i nstal l ati on.
HOOD SAFETY CATCH
REMOVAL (FI G. 5)
(1) Rai se hood and support wi th prop rod.
(2) Remove bol ts hol di ng safety catch to hood.
(3) Separate safety catch from hood.
I NSTALLATI ON
HOOD LATCH
REMOVAL (FI G. 6)
(1) Rai se hood and remove gri l l e and radi ator cl o-
sure panel si ght shi el d.
(2) Remove bol ts hol di ng l atch to radi ator cl osure
panel .
(3) Separate l atch from cl osure panel . Pry l atch ca-
Fig. 2 GrilleHigh Line
Fig. 3 Hood Ornament
Fig. 4 Hood and Hinge Assembly
BODY 23 - 21
bl e casi ng from sl ot retai ner on l atch.
(4) Di sengage cabl e end from l atch rel ease arm.
HOOD LATCH I NSTALLATI ON
HOOD RELEASE CABLE
REMOVAL (FI G. 7)
(2) Remove gri l l e and radi ator cl osure si ght shi el d.
(3) Di sconnect hood rel ease cabl e casi ng and cabl e
end from hood l atch assembl y.
(4) Remove hood l atch rel ease cabl e handl e attach-
i ng bol ts from under l eft l ower edge of i nstrument
panel .
(5) Di sengage rel ease cabl e rubber grommet from
engi ne compartment dash panel behi nd i nstrument
panel .
(6) Rout cabl e assembl y through engi ne compart-
ment around battery, under fender l i p, around rel ay
bank, and under wi ri ng harnesses, toward dash panel .
Push cabl e through access hol e i n dash panel under the
brake master cyl i nder, i nto passenger compartment.
I NSTALLATI ON
SIGHT SHIELD
REMOVAL (FI G. 8)
(2) Remove gri l l e as necessary to gai n cl earance for
si ght shi el d removal .
(3) Remove push-i n fasteners hol di ng si ght shi el d to
radi ator cl osure panel .
(4) Separate si ght shi el d from vehi cl e.
I NSTALLATI ON
COWL COVER
REMOVAL (FI G. 9)
Fig. 5 Hood Safety Catch
Fig. 6 Hood Latch
Fig. 7 Hood Release Cable
Fig. 8 Sight Shield
23 - 22 BODY
(2) Remove wi ndshi el d wi per arms. Refer to Group
8K, El ectri cal /Wi ndshi el d Wi pers and Washers for
proper procedures.
(3) Remove screws hol di ng cowl cover to cowl panel
bel ow wi ndshi el d.
(4) Separate cowl cover from vehi cl e.
COWL COVER I NSTALLATI ON
FRONT END SPLASH SHIELDS
FRONT WHEELHOUSE SPLASH SHI ELD RE-
MOVAL (FI G. 10)
(1) Remove rear engi ne compartment spl ash shi el d.
(2) Remove bol ts hol di ng wheel house spl ash shi el d
to front frame member.
(3) Remove push-i n fasteners hol di ng wheel house
spl ash shi el d to front fender wheel l i p and upper
suspensi on tower.
(4) Separate wheel house spl ash shi el d from vehi cl e.
FRONT WHEELHOUSE SPLASH SHI ELD I N-
STALLATI ON
ENGI NE DRI VE BELT SPLASH SHI ELD RE-
MOVAL (FI G. 10)
(1) Remove wheel house spl ash shi el d as necessary
to gai n access to engi ne dri ve bel t spl ash shi el d.
(2) Remove screws hol di ng engi ne dri ve bel t spl ash
shi el d to front frame member.
(3) Separate spl ash shi el d from vehi cl e.
ENGI NE DRI VE BELT SPLASH SHI ELD I NSTAL-
LATI ON
REAR ENGINE COMPARTMENT SPLASH SHIELD
REAR ENGI NE COMPARTMENT SPLASH
SHI ELD REMOVAL (FI G. 10)
(1) Remove bol t hol di ng rear engi ne compartment
spl ash shi el d to frame si de member.
(2) Remove push-i n fastener hol di ng rear engi ne
compartment spl ash shi el d to wheel house spl ash
shi el d.
REAR ENGI NE COMPARTMENT SPLASH
SHI ELD I NSTALLATI ON
TRANSAXLE SPLASH SHIELD
REMOVAL (FI G. 11)
(1) Remove front wheel house spl ash shi el d as neces-
sary to gai n access to transaxl e spl ash shi el d.
(2) Remove screws hol di ng transaxl e spl ash shi el d
to front frame member.
I NSTALLATI ON
FRONT FENDER
REMOVAL (FI G. 12)
(1) Remove gri l l e and headl amp assembl y.
(2) Remove wheel house spl ash shi el d.
(3) Remove bol ts hol di ng jack hoi sti ng pad to under
body and separate pad from vehi cl e.
(4) Remove bol ts hol di ng fender to hi nge pi l l ar from
i nsi de wheel openi ng.
Fig. 9 Cowl Cover and Seal
Fig. 10 Front End Splash Shields
BODY 23 - 23
(5) Remove bol t hol di ng fender to rocker panel .
(6) Remove bol ts hol di ng fender to l ower radi ator
cl osure panel .
(7) Remove bol ts hol di ng fender to cowl si de panel .
(8) Cut adhesi ve hol di ng support brace to fender
near upper door hi nge, i f equi pped.
(9) Separate fender from vehi cl e.
FRONT FENDER I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn front fender
to 6 mm (0.240 i n.) to forward edge of door and 4 mm
(0.160) to edge of hood. Al l surfaces across gaps shoul d
be fl ush.
FRONT DOOR TRIM PANEL
REMOVAL (FI G. 13)
(1) Lower door gl ass.
(2) Di sconnect battery negati ve cabl e i f equi pped
wi th power wi ndows.
(3) Remove screw hol di ng door l atch handl e bezel to
door tri m panel . Separate bezel from door.
(4) Remove screw hol di ng upper door tri m to si de
vi ew mi rror frame.
(5) Remove pl ugs and screws hol di ng tri m to door
from above map pocket.
(6) Remove pl ug and screw hol di ng bottom rearward
edge of tri m to door.
(7) Remove pl ugs and screws hol di ng arm rest to
door panel .
(8) Remove screw hol di ng wi ndow crank to regul ator
and separate crank from door, i f equi pped.
(9) Di sengage tri m cl i ps hol di ng tri m panel to peri m-
eter door i nner panel .
(10) Li ft tri m panel upward to di sengage barb cl i ps
at top of tri m panel .
(11) Di sconnect courtesy l amp, power l ock swi tch
and power wi ndow swi tch wi re connectors, i f equi pped.
(12) Separate tri m panel from door.
FRONT DOOR TRI M PANEL I NSTALLATI ON
FRONT DOOR AND HINGE
The front door hi nge i s wel ded to the door and bol ted
to the hi nge pi l l ar. The door hal f of the hi nge pi vots on
a removabl e hi nge pi n. The hi nge pi n i s dri ven i n from
the bottom on the top hi nge and from the top on the
bottom hi nge. Al l adjustments to the hi nge are per-
formed on the hi nge pi l l ar hal f of the hi nge. I f the
wel ded hal f of the hi nge must be bent to al i gn door,
consul t an authori zed body repai r faci l i ty.
FRONT DOOR REMOVAL (FI G. 14)
(1) Remove door tri m panel , si l encer pad, and water
shi el d.
(2) Di sconnect al l wi re connectors and wi re harness
hol d downs i nsi de door and push wi re harness through
access hol e i n front of door i nto hi nge pi l l ar openi ng.
(3) Open door and support door on a sui tabl e l i fti ng
devi ce.
Fig. 11 Transaxle Splash Shield
Fig. 12 Front Fender
Fig. 13 Front Door Trim Panel
23 - 24 BODY
(4) Dri ve bottom hi nge pi n upward and remove pi n
from hi nge.
(5) Dri ve top hi nge pi n downward and remove pi n
from hi nge.
(6) Separate door from vehi cl e.
FRONT DOOR I NSTALLATI ON
Reverse the precedi ng operati on. The door shoul d not
requi re re-al i gnment. I f door does need al i gnment,
refer to Front Door Hi nge I nstal l ati on paragraph i n
thi s secti on.
FRONT DOOR HI NGE REMOVAL (FI G. 14)
(1) Remove front fender wheel house spl ash shi el d.
Refer to Front Wheel house Spl ash Shi el d Removal
paragraph i n thi s secti on.
(2) Support door on a sui tabl e l i fti ng devi ce.
(3) Dri ve out hi nge pi n on the effected hi nge.
(4) Remove bol ts hol di ng hi nge to hi nge pi l l ar and
separate hi nge form vehi cl e.
FRONT DOOR HI NGE I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn door to
achi eve 6 mm (0.240 i n.) gap to al l surroundi ng panel s
and fl ush across gaps.
OUTSIDE FRONT DOOR LATCH RELEASE HANDLE
REMOVAL (FI G. 15)
(1) Remove door tri m panel and water shi el d as
necessary to gai n access to outsi de door handl e.
(2) Di sconnect l ock cyl i nder l i nkage from door l atch.
(3) Di sconnect l atch rel ease l i nkage from door l atch.
(4) Di sconnect i l l umi nated entry swi tch wi re connec-
tor.
(5) Remove nut hol di ng outsi de handl e retai ni ng
bracket to door panel and separate bracket from door.
(6) Li ft l ock cyl i nder l i nkage upward to paral l el back
of outsi de handl e.
(7) Separate outsi de handl e from door.
I NSTALLATI ON
FRONT DOOR LATCH
REMOVAL (FI G. 16)
necessary to gai n access to door l atch.
(2) Di sconnect al l l i nkage rods from l atch.
(3) Di sconnect power door l ock actuator wi re connec-
tor.
(4) Remove screws hol di ng l atch to door end frame.
(5) Separate door l atch from door.
I NSTALLATI ON
Fig. 14 Front DoorTypical
Fig. 15 Outside Door Latch Release Handle
Fig. 16 Front Door Latch
BODY 23 - 25
FRONT DOOR SIDE VIEW MIRROR
REMOVAL (FI G. 17)
necessary to gai n access to si de vi ew mi rror.
(2) Di sconnect power si de vi ew mi rror wi re connec-
tor, i f equi pped.
(3) Remove nuts hol di ng si de vi ew mi rror to door
frame.
(4) Separate mi rror from door.
I NSTALLATI ON
FRONT DOOR GLASS
REMOVAL (FI G. 18)
(1) Remove front door tri m panel and water shi el d.
(2) Rai se gl ass to al i gn attachi ng nuts to access hol es
i n i nner door panel .
(3) Remove nuts hol di ng door gl ass to wi ndow regu-
l ator l i ft pl ate.
(4) Separate gl ass from l i ft pl ate.
(5) Li ft gl ass upward through openi ng at top of door.
I NSTALLATI ON
Reverse the precedi ng operati on. To al i gn gl ass,
i nstal l attachi ng nuts hand ti ght al l owi ng gl ass to sl i de
on l i ft pl ate. Rai se gl ass to ful l up posi ti on. Secure
gl ass attachi ng nuts.
FRONT DOOR BELT MOLDING AND
WEATHERSTRIPVAN
REMOVAL (FI G. 19)
(1) Remove door gl ass.
(2) Remove si de vi ew mi rror.
(3) Remove screws hol di ng bel t mol di ng and weath-
erstri p to door panel .
(4) Separate bel t mol di ng and weatherstri p from
door.
I NSTALLATI ON
FRONT DOOR FRAME REAR MOLDINGVAN
REMOVAL (FI G. 19)
(1) Remove bel t mol di ng and weatherstri p as neces-
sary to cl ear door frame mol di ng removal path.
(2) Remove gl ass run weatherstri p to gai n access to
mol di ng cl i ps.
(3) Di sengage cl i ps hol di ng door frame mol di ng to
door frame.
(4) Separate mol di ng from door.
I NSTALLATI ON
Fig. 17 Side View Mirror
Fig. 18 Front Door Glass
Fig. 19 Belt Molding and WeatherstripVan Only
23 - 26 BODY
FRONT DOOR BELT MOLDING AND
WEATHERSTRIPWAGON
REMOVAL (FI G. 20)
(1) Remove door gl ass.
(2) Remove si de vi ew mi rror.
(3) Remove door gl ass run weatherstri p.
(4) Di sengage cl i ps hol di ng door frame mol di ng to
door frame.
(5) Remove screws hol di ng bel t mol di ng and weath-
erstri p to door panel .
(6) Separate bel t mol di ng and weatherstri p from
door.
I NSTALLATI ON
FRONT DOOR GLASS CHANNEL AND RUN WEATH-
ERSTRIP
REMOVAL (FI G. 21)
(1) Lower door gl ass to down posi ti on.
(2) Remove si de vi ew mi rror as necessary to gai n
cl earance for weatherstri p removal .
(3) Pul l gl ass run weatherstri p from door frame
channel .
I NSTALLATI ON
FRONT DOOR GLASS LOWER CHANNEL
REMOVAL (FI G. 22)
(1) Remove door tri m panel and water shi el d.
(2) Rai se gl ass to up posi ti on.
(3) Remove bol ts hol di ng channel to i nner door
panel .
(4) Separate channel from door.
I NSTALLATI ON
FRONT DOOR WINDOW REGULATORMANUAL
REMOVAL (FI G. 22)
(2) Remove bol ts hol di ng door gl ass to wi ndow l i ft
pl ate.
(3) Al l ow gl ass to rest on bottom of door.
(4) Remove bol ts hol di ng regul ator to door i nner
panel .
(5) Di sengage push-i n fastener hol di ng regul ator
cabl es to i nner door panel .
Fig. 20 Belt Molding and WeatherstripWagon Only
Fig. 21 Glass Channel and Run Weatherstrip
Fig. 22 Front Lower Channel and Window Regulator
BODY 23 - 27
(6) Separate regul ator from door.
MANUAL WI NDOW REGULATOR I NSTALLA-
TI ON
FRONT DOOR WINDOW REGULATORPOWER
REMOVAL (FI G. 22)
(2) Remove bol ts hol di ng door gl ass to wi ndow l i ft
pl ate.
(4) Al l ow gl ass to rest on bottom of door.
(5) Di sconnect power wi ndow regul ator motor wi re
connector. Di sengage push-i n fastener hol di ng wi re
harness to i nner door panel .
(6) Remove bol ts hol di ng regul ator to door i nner
panel .
(7) Di sengage push-i n fastener hol di ng regul ator
cabl es to i nner door panel .
(8) Separate regul ator from door.
I NSTALLATI ON
SLIDING DOOR TRIM PANEL
REMOVAL (FI G. 23)
(1) Cl ose sl i di ng door. From i nsi de vehi cl e perform
the fol l owi ng.
(2) Remove screw pl ug at rearward center of door
tri m and remove screw.
(3) Remove hi dden screw from upper rearward cor-
ner of carpet i nsert.
(4) Remove screws hol di ng tri m to door from al ong
bottom of tri m panel .
(5) Di sengage tri m cl i ps hol di ng tri m to door from
around peri meter of tri m panel .
(6) Li ft tri m panel upward to di sengage barbed re-
tai ners hol di ng top of tri m to door fl ange.
(7) Separate tri m panel from sl i di ng door.
I NSTALLATI ON
SLIDING DOOR FRAME UPPER MOLDING
REMOVAL (FI G. 23)
(1) Remove sl i di ng door tri m panel .
(2) Remove screw pl ugs from upper door frame
mol di ng.
(3) Remove screws hol di ng upper mol di ng to door
frame.
(4) Separate mol di ng from door frame.
I NSTALLATI ON
SLIDING DOOR PULL HANDLE
REMOVAL (FI G. 23)
(2) Remove upper door frame mol di ng.
(3) Remove screw hol di ng top of pul l handl e to door
frame.
(4) Remove bol ts hol di ng pul l handl e to i nner door
panel .
(5) Separate pul l handl e from door.
I NSTALLATI ON
SLIDING DOOR
REMOVAL
When removi ng the sl i di ng door as an assembl y i t i s
not necessary to l oosen bol ts that woul d al ter the
al i gnment.
(1) Remove sl i di ng door upper track cover.
(2) Remove upper track over travel stop.
(3) Remove sl i di ng door si l l pl ate.
(4) Remove l ower track over travel stop.
(5) Remove sl i di ng door center track cover.
(6) Remove center track over travel stop.
(7) Wi th assi stance, rol l the door rearward and di s-
engage hi nge rol l ers from tracks.
(8) Separate sl i di ng door from vehi cl e.
Fig. 23 Sliding Door Trim and Pull Handle
23 - 28 BODY
SLI DI NG DOOR I NSTALLATI ON
SLIDING DOOR CENTER HINGE TRACK COVER
REMOVAL (FI G. 24)
(1) Open l i ftgate.
(2) Remove screws hol di ng center track cover to
quarter panel from above ri ght tai l l amp.
(3) Open sl i di ng door.
(4) Remove screws hol di ng center track cover to
quarter panel from above sl i di ng door rear l atch
stri ker.
(5) Di sengage cl i ps hol di ng track cover to quarter
panel .
(6) Separate track cover from vehi cl e.
I NSTALLATI ON
SLIDING DOOR CENTER HINGE
REMOVAL (FI G. 25)
(1) Remove sl i di ng door center hi nge track cover.
(2) Remove screw hol di ng over travel stop to center
hi nge track (Fi g. 24).
(4) Mark hi nge l ocati on on sl i di ng door for reference
poi nts when i nstal l i ng.
(5) Support Sl i di ng door on a sui tabl e l i fti ng devi ce.
(6) Remove bol ts hol di ng center hi nge to sl i di ng
door.
(7) Separate hi nge from door.
(8) Sl i de hi nge rol l ers from open end of channel at
rear of quarter panel .
I NSTALLATI ON
Reverse the precedi ng operati on. Cl ean center track
wi th sui tabl e sol vent and wi pe or bl ow dry wi th com-
pressed ai r. Lubri cate track and rol l ers wi th Mopar
Mul ti -purpose Grease. Al i gn sl i di ng door to 6 mm
(0.240 i n.) gap to edge of quarter panel and B-pi l l ar, 7
mm (0.280 i n.) gap to rocker and fl ush across gaps.
SLIDING DOOR UPPER HINGE
REMOVAL (FI G. 26)
(1) Remove sl i di ng door upper frame mol di ng and
pul l handl e.
(3) Remove upper track over travel stop.
(5) Support Sl i di ng door on a sui tabl e l i fti ng devi ce.
(6) Remove bol ts hol di ng hi nge to sl i di ng door.
(7) Separate hi nge from sl i di ng door.
(8) Sl i de hi nge from open end of track at rear of door
openi ng.
Fig. 24 Sliding Door Center Track Cover and Over
Travel Stop
Fig. 25 Sliding Door Center Hinge
BODY 23 - 29
SLI DI NG DOOR UPPER HI NGE I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn sl i di ng door
to 6 mm (0.240 i n.) gap to edge of quarter panel and
B-pi l l ar, 7 mm (0.280 i n.) gap to rocker and fl ush across
gaps.
SLIDING DOOR LOWER HINGE
REMOVAL (FI G. 27)
(2) Remove sl i di ng door l ower hi nge cover.
(3) Remove sl i di ng door si l l pl ate.
(4) Remove l ower track over travel stop.
(6) Support sl i di ng door on a sui tabl e l i fti ng devi ce.
Do not al l ow door to contact quarter panel .
(7) Remove bol ts hol di ng hi nge to mounti ng bracket.
I f mounti ng bracket must be repl aced, remove bol ts
hol di ng mounti ng bracket to sl i di ng door.
(8) Separate hi nge from sl i di ng door.
(9) Sl i de hi nge from open end of track at rear of door
openi ng.
I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn sl i di ng door
to 6 mm (0.240 i n.) gap to edge of quarter panel and
B-pi l l ar, 7 mm (0.280 i n.) gap to rocker and fl ush across
gaps.
SLIDING DOOR INSIDE LATCH/LOCK CONTROL
REMOVAL (FI G. 28)
(1) Remove sl i di ng door tri m panel and water shi el d.
(2) Remove screws hol di ng i nsi de door handl e bezel
to l atch/l ock control assembl y.
(3) Separate bezel from control .
(4) Remove bol ts hol di ng l atch/l ock control to i nner
door panel .
(5) Pul l control away from i nner door panel and
di sconnect l i nkage rods and power door l ock wi re
connector, i f equi pped.
(6) Separate control from door.
I NSTALLATI ON
SLIDING DOOR LATCH/LOCK LINKAGE
REMOVAL (FI G. 29)
(2) Remove l atch/l ock control .
Fig. 26 Sliding Door Upper Hinge and Guide Wedge
Fig. 27 Sliding Door Lower Hinge
Fig. 28 Inside Latch/Lock Control
23 - 30 BODY
(3) Di sconnect ends of l i nkage rod to be repl aced.
(4) Separate l i nkage rod from door.
SLI DI NG DOOR LATCH/LOCK LI NKAGE I N-
STALLATI ON
SLIDING DOOR POWER LOCK ACTUATOR
REMOVAL (FI G. 29)
(1) Remove sl i di ng door l atch/l ock control assembl y.
(2) Di sconnect l i nkage rod from power door l ock
actuator.
(3) Remove screws hol di ng actuator to control .
(4) Separate actuator from control .
I NSTALLATI ON
SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE
REMOVAL (FI G. 30)
(2) Remove screws hol di ng i nsi de l atch/l ock control
assembl y to door i nner panel .
(3) Di sconnect l i nkage rods and wi re connectors as
necessary to gai n access to outsi de handl e mounti ng.
(4) Di sconnect l ock rod from l ock cyl i nder arm.
(5) Remove nuts hol di ng mounti ng pl ate to i nner
door panel and separate pl ate from door.
(6) Separate outsi de handl e from door.
I NSTALLATI ON
SLIDING DOOR REAR LATCH
REMOVAL (FI G. 31)
(1) Remove sl i di ng door tri m panel and water shi el d
as necessary.
(2) Unl atch door and al l ow to swi ng outward, do not
open.
(3) Di sconnect l i nkage rods from rear l atch.
(4) Remove screws hol di ng l atch to door end frame.
(5) Separate l atch from door end frame and remove
through access hol e i n i nner door panel .
I NSTALLATI ON
Fig. 29 Sliding Door Latch/Lock Linkage
Fig. 30 Sliding Door Outside Release Handle
Fig. 31 Sliding Door Rear Latch
BODY 23 - 31
VENT WINDOW
REMOVAL (FI G. 32)
The sl i di ng door, body si de and quarter gl ass vent
wi ndows are servi ced usi ng same procedure.
(1) Remove upper tri m mol di ng from around gl ass.
(2) Remove screw hol di ng l atch to gl ass.
(3) Separate gl ass from l atch.
(4) Remove nut covers and nuts hol di ng gl ass hi nge
to wi ndow openi ng fl ange.
(5) Separate gl ass from vehi cl e.
I NSTALLATI ON
VENT WINDOW WEATHERSTRIP
REMOVAL (FI G. 33)
(1) Remove i nteri or tri m as necessary to gai n cl ear-
ance for weatherstri p removal .
(2) Remove screw hol di ng l atch to gl ass.
(3) Hi nge vent gl ass away from weatherstri p.
(4) Pul l vent gl ass weatherstri p from pi nch fl ange.
I NSTALLATI ON
DOOR OPENING WEATHERSTRIPS
REMOVAL
(1) Remove i nteri or tri m as necessary to gai n cl ear-
ance for weatherstri p removal .
(2) Pul l weatherstri p from pi nch fl ange around door
openi ng.
I NSTALLATI ON
(1) Locate the mi ddl e to the weatherstri p at the
center of the upper pi nch fl ange. Push weatherstri p
onto pi nch fl ange at the top corner.
(2) When the weatherstri p has been i nstal l ed down
the door openi ng to the si l l pi nch fl ange, mate the ends
of the weatherstri p together and fi ni sh i nstal l i ng.
STICK-ON BODY SIDE MOLDING
(1) Warm the effected sti ck-on mol di ng and body
metal to approxi matel y 38C (100F) usi ng a sui tabl e
heat l amp or heat gun.
(2) Pul l sti ck-on mol di ng from pai nted surface.
(3) Remove adhesi ve tape resi due from pai nted sur-
face of vehi cl e.
(4) I f mol di ng i s to be reused, Remove tape resi due
from mol di ng. Cl ean back of mol di ng wi th Mopar,
Super Kl een sol vent or equi val ent. Wi pe mol di ng dry
wi th l i nt free cl oth. Appl y new body si de mol di ng (two
si ded adhesi ve) tape to back of mol di ng.
(5) Cl ean body surface wi th Super Kl een sol vent or
equi val ent. Wi pe surface dry wi th l i nt free cl oth.
(6) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the mol di ng to use as a gui de,
i f necessary.
(7) Remove protecti ve cover from tape on back of
mol di ng. Appl y mol di ng to body bel ow the maski ng
tape gui de.
(8) Remove maski ng tape gui de and heat body and
mol di ng, see step one. Fi rml y press mol di ng to body
surface to assure adhesi on.
Fig. 32 Vent WindowSliding Door, Body Side or
Quarter
Fig. 33 Vent Window Weatherstrip
23 - 32 BODY
EXTERIOR MOLDINGS (FIG. 34)
UPPER MOLDI NGS
LIFTGATE
(1) Open l i ftgate and remove nuts hol di ng upper
mol di ng to l i ftgate.
(2) Di sengage cl i ps hol di ng upper mol di ng to l i ft-
gate.
(3) Separate mol di ng from l i ftgate.
SLIDING DOOR TRACK COVER
(1) Di sengage barrel cl i p fastener hol di ng rear end of
upper mol di ng to sl i di ng door center track cover.
(2) Di sengage cl i ps hol di ng upper mol di ng to center
track cover.
(3) Separate mol di ng from track cover.
DOORS
(1) Di sengage cl i ps hol di ng upper mol di ng to door.
(2) Separate upper mol di ng from door.
FENDERS
(1) Remove headl amp bezel as necessary to gai n
access to mol di ng fastener.
(2) Remove screw hol di ng upper mol di ng to fender at
front of mol di ng.
(3) Di sengage cl i ps hol di ng upper mol di ng to fender.
(4) Separate mol di ng from fender.
LEFT QUARTER PANEL
(1) Di sengage cl i ps hol di ng upper mol di ng to quarter
panel .
(2) Separate mol di ng from quarter panel .
LOWER MOLDI NGS
DOORS
(1) Di sengage cl i ps hol di ng l ower mol di ng to door.
(2) Separate l ower mol di ng from door.
LEFT QUARTER PANEL
(1) Di sengage cl i ps hol di ng l ower mol di ng to l eft
quarter panel .
(2) Separate l ower mol di ng from quarter panel .
WHEEL LI P MOLDI NGS
(1) Remove screws hol di ng wheel l i p mol di ngs to
wheel openi ng fl ange.
(2) Separate wheel l i p mol di ng from vehi cl e.
SI LL MOLDI NGS
RIGHT QUARTER
(1) Remove screws hol di ng ri ght quarter panel si l l
mol di ng to wheel openi ng fl ange.
(2) Di sengage cl i ps hol di ng si l l mol di ng to si l l panel .
LEFT QUARTER
(1) Di sengage cl i ps hol di ng si l l mol di ng to si l l .
(2) Separate si l l mol di ng from vehi cl e.
DOORS
(1) Di sengage cl i ps hol di ng si l l mol di ng to door.
(2) Separate si l l mol di ng from door.
FENDERS
(1) Remove screws hol di ng si l l mol di ng to wheel
openi ng fl ange.
(2) Di sengage cl i ps hol di ng si l l mol di ng to fender.
(3) Separate si l l mol di ng from front fender.
BODY SIDE APPLIQUE (FIG. 35)
DOOR APPLI QUE
(1) Remove screws hol di ng appl i que to bottom edge
of door.
(2) Li ft appl i que upward to di sengage from retai ni ng
channel .
(3) Separate appl i que from door.
FRONT SI LL APPLI QUE
(1) Remove screws hol di ng front si l l appl i que to
front wheel openi ng fl ange.
(2) Remove screws hol di ng appl i que to under si de of
rocker panel .
channel .
(4) Separate appl i que from si l l .
RI GHT REAR SI LL APPLI QUE
(1) Remove screws hol di ng rear si l l appl i que to rear
wheel openi ng fl ange.
rocker panel .
channel .
(4) Separate appl i que from si l l .
BODY 23 - 33
LEFT QUARTER APPLI QUE
(1) Remove screws hol di ng l eft quarter appl i que to
rear wheel openi ng fl ange.
Fig. 34 Exterior Moldings
Fig. 35 Body Side Applique
23 - 34 BODY
rocker panel .
channel .
(4) Separate appl i que from quarter panel .
WOOD GRAIN OVERLAY
REMOVAL
(1) Remove exteri or tri m as necessary to cl ear cap-
tured edges of wood grai n overl ay for removal .
(2) Remove wood grai n overl ay usi ng a sui tabl e heat
gun or sun l amp to soften the adhesi ve backi ng. Start
removal i n most accessi bl e corner of panel to be ser-
vi ced.
(3) Cl ean adhesi ve resi due from body fi ni sh usi ng a
sui tabl e adhesi ve remover.
I NSTALLATI ON
INSTALLATION EQUIPMENT
Pai l fi l l ed wi th mi l d di sh soap sol uti on.
Li nt free appl i cator cl oth or sponge.
Body putty appl i cator squeegee.
Heat gun or sun l amp.
Razor kni fe.
The pai nted surface of the body panel to be covered
by a wood grai n overl ay must be smooth and com-
pl etel y cured before overl ay can be appl i ed. I f pai nted
surface i s not smooth, wet sand wi th 600 gri t wet/dry
sand paper unti l surface i s smooth.
Ri ppl es and feather edgi ng wi l l read through overl ay
i f surface i s not properl y prepared.
(1) Wi th backi ng sti l l i n pl ace, posi ti on overl ay
across panel to recei ve overl ay. Appl y maski ng at top of
overl ay to hol d i t i n posi ti on.
(2) Mark outsi de edge of panel on overl ay wi th a
grease penci l .
(3) Tri m overl ay to wi thi n 17 mm (0.750 i n.) of
outl i ne marks.
(4) Spread overl ay across a smooth fl at work surface,
wood grai n si de down.
(5) Peel paper backi ng away from overl ay exposi ng
adhesi ve back of overl ay.
(6) Appl y soap sol uti on l i beral l y to adhesi ve back of
overl ay.
(7) Appl y soap sol uti on l i beral l y to body panel sur-
face.
(8) Pl ace overl ay i nto posi ti on on body panel . Smooth
out wri nkl es by pul l i ng l i ghtl y on edges of overl ay unti l
i t l ays fl at on pai nted surface.
(9) Push ai r pockets from under overl ay to the pe-
ri meter of the panel from the center of the overl ay out.
(10) Squeegee soap sol uti on and ai r bubbl es from
behi nd overl ay from the center of the panel out usi ng a
body putty appl i cator squeegee.
CAUTION: Do not cut into painted surface of body
panel when trimming overlay to size.
(11) Tri m overl ay to si ze usi ng a razor kni fe. Leave
at l east 13 mm (0.5 i n.) for edges of doors and openi ngs.
CAUTION: Do not overheat overlay when performing
step 12.
(12) Appl y heat to overl ay to evaporate resi dual
moi sture from edges of overl ay and to al l ow overl ay to
be stretched i nto concave surfaces.
(13) Edge turn overl ay around doors or fenders.
(14) I nstal l exteri or tri m i f necessary.
Smal l ai r or water bubbl es under overl ay can be
pi erced wi th a pi n and smoothed out.
RIGHT SIDE GRAB HANDLE
REMOVAL (FI G. 36)
(1) Remove screw covers from grab handl e.
(2) Remove screws hol di ng grab handl e to roof rai l
above ri ght front door.
(3) Separate grab handl e from roof rai l .
(4) Remove A-pi l l ar/roof rai l mol di ng.
(5) Remove bol ts hol di ng grab handl e rei nforcement
to roof rai l .
(6) Separate rei nforcement from roof rai l .
I NSTALLATI ON
COWL TRIM AND SCUFF PLATES
REMOVAL (FI G. 37)
(1) Remove pl ug and screw hol di ng wi ndshi el d si de
garni sh mol di ng to cowl tri m cover.
(2) Remove screws hol di ng scuff pl ate to door si l l .
(3) Separate cowl tri m/scuff pl ate from vehi cl e.
Fig. 36 Grab Handle
BODY 23 - 35
COWL TRI M AND SCUFF PLATE I NSTALLA-
TI ON
SLI DI NG DOOR SCUFF PLATE REMOVAL
(FI G. 37)
(1) Remove screws hol di ng sl i di ng door scuff pl ate to
si l l .
(2) Separate scuff pl ate from vehi cl e.
SLI DI NG DOOR SCUFF PLATE I NSTALLATI ON
A-PILLAR AND ROOF RAIL MOLDINGS
REMOVAL (FI G. 37)
(1) Remove grab handl e, i f equi pped.
(2) Remove wi ndshi el d si de garni sh mol di ng.
(3) Remove pl ug and screw hol di ng A-pi l l ar tri m to
roof rai l .
(4) Di sengage fasteners hol di ng A-pi l l ar tri m to
A-pi l l ar.
(5) Separate A-pi l l ar tri m from vehi cl e.
I NSTALLATI ON
RIGHT B-PILLAR TRIM COVER
REMOVAL (FI G. 37)
(1) Remove cover and bol t hol di ng shoul der harness
turni ng l oop to B-pi l l ar.
(2) Remove bol t hol di ng outboard seat bel t anchor to
fl oor.
(3) Remove A-pi l l ar tri m as necessary to gai n cl ear-
ance for removal of B-pi l l ar tri m.
(4) Remove door si l l scuff pl ates to gai n cl earance for
removal of B-pi l l ar tri m.
(5) Remove screws hol di ng B-pi l l ar tri m to B-pi l l ar.
(6) Separate B-pi l l ar tri m from vehi cl e
I NSTALLATI ON
UPPER TRACK COVER
REMOVAL (FI G. 37)
(1) Remove pl ugs and screws hol di ng upper track
cover to sl i di ng door track.
(2) Separate track cover from vehi cl e.
I NSTALLATI ON
Fig. 37 Interior Trim
23 - 36 BODY
RIGHT QUARTER TRIM PANEL
REMOVAL (FI G. 37)
(1) Remove l i ftgate and sl i di ng door si l l scuff pl ate.
(3) Pul l outward at bottom of quarter tri m i nsert to
di sengage fasteners hol di ng i nsert to tri m panel .
(4) Li ft upward on quarter tri m i nsert and separate
i nsert from quarter tri m panel .
(5) Remove screw hol di ng coat hook to roof rai l and
separate hook from vehi cl e.
(6) Remove covers and bol ts hol di ng shoul der har-
ness turni ng l ops to roof rai l and separate bel ts from
tri m panel .
(7) Remove bol ts hol di ng outboard seat bel t to fl oor
and separate bel t from fl oor.
(8) Remove pl ugs and screws hol di ng quarter tri m to
i nner quarter panel .
(9) Separate quarter tri m panel from vehi cl e.
I NSTALLATI ON
LEFT QUARTER TRIM PANEL
REMOVAL (FI G. 38)
(1) Remove ash tray.
(2) Remove screw hol di ng quarter tri m i nsert to
quarter tri m from i nsi de ash tray openi ng.
(3) Pul l outward at bottom of tri m i nsert to di sen-
gage cl i ps hol di ng i nsert to quarter tri m.
(4) Li ft i nsert upward and separate quarter tri m
i nsert from vehi cl e.
(5) Remove screws hol di ng l ower quarter tri m panel
to i nner quarter panel .
(6) Separate l ower quarter tri m from vehi cl e.
ness turni ng l oops to upper quarter panel .
(8) Remove bol ts hol di ng outboard seat bel t anchor
to fl oor.
(9) Remove seat bel t retractor covers.
(10) Remove screw hol di ng coat hook to quarter
panel .
(11) Remove screws hol di ng upper quarter tri m
panel to i nner quarter panel .
(12) Separate upper quarter tri m panel from vehi cl e.
I NSTALLATI ON
Fig. 38 Quarter Trim Panel
BODY 23 - 37
LEFT QUARTER TRIM PANELWITH REAR A/C
REMOVAL (FI G. 39)
(1) Remove ash tray.
(2) Remove screw hol di ng quarter tri m i nsert to
quarter tri m from i nsi de ash tray openi ng.
(3) Pul l outward at bottom of tri m i nsert to di sen-
gage cl i ps hol di ng i nsert to quarter tri m.
(4) Li ft i nsert upward and separate quarter tri m
i nsert from vehi cl e.
(5) Remove screws hol di ng l ower quarter tri m panel
to i nner quarter panel .
(6) Separate l ower quarter tri m from vehi cl e.
ness turni ng l oops to upper quarter panel .
(8) Remove bol ts hol di ng outboard seat bel t anchor
to fl oor.
(9) Remove seat bel t retractor covers.
(10) Remove screws hol di ng coat hook to quarter
panel .
(11) Remove screws hol di ng upper quarter tri m
panel to i nner quarter panel .
(12) Separate upper quarter tri m panel from vehi cl e.
I NSTALLATI ON
FRONT SEAT BELTS
OUTBOARD SHOULDER HARNESS/LAP BELT
(1) Remove shoul der harness turni ng l oop.
(2) Remove B-pi l l ar or quarter tri m panel s as neces-
sary to gai n access to bel t retractor.
(3) Remove bol t hol di ng retractor and l ower l ap bel t
anchor to B-pi l l ar.
(4) Separate bel t from vehi cl e.
I NSTALLATI ON
I NBOARD BUCKLE REMOVAL (FI G. 42)
(1) Remove bol t hol di ng seat bel t buckl e t o seat
ri ser.
(2) separate buckl e from seat ri ser.
(3) Di sconnect seat bel t sensor wi re connector, i f
equi pped.
I NBOARD BUCKLE I NSTALLATI ON
Fig. 39 Quarter Trim PanelWith Rear A/C
23 - 38 BODY
REAR SEAT BELTS
(1) Remove i nteri or tri m as necessary to gai n access
to bel t retractor.
(2) Remove bol t hol di ng l ower l ap bel t anchor to fl oor
bracket.
(3) Remove bol t hol di ng bel t retractor to i nner quar-
ter panel .
(4) Separate bel t from vehi cl e.
I NSTALLATI ON
SEATS
Refer to Owners Manual for rear seat removal pro-
cedures.
FRONT SEAT REMOVAL (FI G. 45)
(1) Remove fuel fi l l door rel ease handl e and di scon-
nect seat bel t sensor wi re connector i f l eft seat i s bei ng
servi ced.
(2) Remove nuts hol di ng seat ri ser to fl oor.
(3) Separate seat and ri ser from vehi cl e.
FRONT SEAT I NSTALLATI ON
Fig. 40 Front Outboard Seat BeltLeft Side
Fig. 41 Front Outboard Seat BeltRight Side
Fig. 42 Front Inboard Seat Belt Buckle
Fig. 43 Rear Shoulder/lap BeltsLeft Side
BODY 23 - 39
FRONT CENTER CONSOLE
REMOVAL (FI G. 46)
(1) Remove center i nstrument panel bezel . Refer to
Group 8E, I nstrument Panel for proper procedure.
(2) Remove screws hol di ng top of consol e to i nstru-
ment panel .
(3) Remove ash tray or open sun gl ass bi n. Remove
screws hol di ng consol e to i nstrument panel .
(4) Separate upper consol e modul e from i nstrument
panel , i f equi pped.
(5) Di sconnect ash tray l amp wi re connector.
(6) Remove screws hol di ng bottom of ful l forward
consol e to fl oor bracket.
(7) separate froward consol e from vehi cl e.
I NSTALLATI ON
FLOOR CARPET
REMOVAL (FI G. 47)
(1) Remove ful l forward consol e, i f equi pped.
(2) Remove Seats.
(3) Remove door si l l scuff pl ates.
(4) Remove rear seat anchor wel l bezel s, i f equi pped.
(5) Fol d carpet to center of vehi cl e and remove
through sl i di ng door.
I NSTALLATI ON
OVERHEAD CONSOLE
REMOVAL (FI G. 48)
(1) Di sengage sun vi sor ends from overhead consol e
(2) Remove screws hol di ng overhead consol e to roof
at front of consol e.
(3) Sl i de overhead consol e forward to di sengage
Fig. 44 Rear Shoulder/lap BeltsRight Side
4h x 3.5w Fig. 45 Front Seat and RiserTypical
Fig. 46 Forward Console
23 - 40 BODY
cl i ps hol di ng rear of consol e to roof.
(4) Di sconnect wi re connectors from back of consol e.
(5) Separate overhead consol e from vehi cl e.
OVERHEAD CONSOLE I NSTALLATI ON
HEAD LINING
REMOVAL (FI G. 49)
(1) Remove overhead consol e, i f equi pped.
(2) Remove i nboard sun vi sor cl i ps, i f equi pped.
(3) Remove roof rai l mol di ngs as necessary to gai n
cl earance for head l i ni ng removal .
(5) Remove ri ght quarter tri m panel .
(6) Remove dome l amp, i f equi pped.
(7) Separate head l i ni ng from vehi cl e.
I NSTALLATI ON
LIFTGATE
REMOVAL (FI G. 50)
(1) Rai se and support l i ftgate i n open posi ti on.
(2) Mark hi nge to l i ftgate attachi ng l ocati ons to
assi st i nstal l ati on.
(2) Di sconnect l i ft prop rods from l i ftgate.
(3) Remove bol ts hol di ng body hal f of hi nge cl osed.
Li ftgate wi l l rotate away from roof panel .
(4) Wi th assi stance of a hel per at the opposi te si de of
the vehi cl e to support the l i ftgate, remove the hi nge to
l i ftgate attachi ng bol ts.
(5) Separate the l i ftgate from the vehi cl e.
I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn l i ftgate to 7
mm (0.280 i n.) gap to roof panel and 6 mm (0.240 i n.)
gap to quarter panel s. Surfaces shoul d be fl ush across
gaps.
LIFTGATE TRIM PANEL
REMOVAL (FI G. 51)
(1) Rai se l i ftgate and remove courtesy l amp l enses.
(2) Remove courtesy l amp assembl i es. I nsert cour-
tesy l amps through openi ngs i n the tri m panel i nto
l i ftgate, i f equi pped.
(3) Remove speaker gri l l es, i f equi pped.
(4) Remove pl ugs at the ends of the assi st handl e,
and remove screws. Separate handl e from tri m panel ,
i f equi pped.
(5) Remove push-i n fasteners from above the rear
wi ndow.
(6) Remove two tri m pl ugs at l ower corners of tri m
panel and remove screws.
(7) Di sengage frog-l eg fasteners around peri meter of
tri m panel . Separate tri m panel from l i ftgate.
I NSTALLATI ON
(1) Posi ti on tri m panel under l i ftgate between the
prop-rod cyl i nders. I nsert courtesy l amp assembl i es
through tri m cover openi ngs.
Fig. 47 Floor Carpet and Silencers
Fig. 48 Overhead Console
Fig. 49 Head Lining
BODY 23 - 41
(2) Posi ti on frog-l eg fasteners bel ow hol es i n l i ftgate,
one at a ti me, push (do not pound) fasteners i nto l ocked
posi ti on.
(3) I nstal l assi st handl e, courtesy l amps, outer cor-
ner attachi ng screws, speaker gri l l es and push-i n fas-
teners above rear wi ndow.
LIFTGATE LATCH
REMOVAL (FI G. 52)
(1) Rai se l i ftgate to open posi ti on.
(2) Remove l i ftgate tri m panel .
(3) Di sconnect l i nkage rods from l atch.
(4) Remove screws hol di ng l atch to l i ftgate.
(5) Separate l atch from l i ftgate.
I NSTALLATI ON
ROOF TOP LUGGAGE RACK
REMOVAL (FI G. 53)
The l uggage rack ski d stri ps are attached to the roof
panel wi th adhesi ve stri ps usi ng the same methods as
sti ck-on body si de mol di ngs. Refer to Sti ck-on Body
Mol di ngs paragraph for procedures.
(1) Sl i de si de rai l end covers from ends of si de rai l s.
(2) Remove screws hol di ng rai l s to roof panel .
(3) Separate l uggage rack from vehi cl e.
I NSTALLATI ON
FUEL FILL DOOR RELEASE CABLE
REMOVAL (FI G. 54)
(1) Remove i nteri or tri m as necessary to gai n access
to cabl e.
Fig. 50 LiftGate
Fig. 51 LiftGate Trim Panel
Fig. 52 LiftGate Latch
23 - 42 BODY
(2) Remove screw hol di ng hood rel ease handl e to
mechani sm. Separate handl e from mechani sm.
(3) Remove screws hol di ng rel ease mechani sm to
seat ri ser. Separate mechani sm from ri ser.
(4) Di sengage cabl e casi ng from sl ot on mechani sm.
(5) Remove nut hol di ng cabl e end to fuel fi l l openi ng.
(6) Remove cabl e from vehi cl e.
FUEL FI LL DOOR CABLE I NSTALLATI ON
REAR WINDOW GLASS
The rear wi ndow gl ass i s servi ced usi ng the same
method as servi ci ng the wi ndshi el d. Refer to Wi nd-
shi el d secti on of thi s group for proper servi ce proce-
dures.
Fig. 53 Roof Top Luggage Rack
Fig. 54 Fuel Fill Door Release Cable
BODY 23 - 43
WHEELS TIRES
CONTENTS
page page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8
TIRE SERVICE PROCEDURES . . . . . . . . . . . . . . . 1
WHEEL SERVICE PROCEDURES . . . . . . . . . . . . 6
TI RE SERVI CE PROCEDURES
INDEX
page page
Cleaning of Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Radial-Ply Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Repairing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement Tires . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire Inflation Pressures . . . . . . . . . . . . . . . . . . . . . 2
Tire Noise or Vibration . . . . . . . . . . . . . . . . . . . . . . 3
Tire Wear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tread Wear Indicators . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
Throughout thi s group, references are made to par-
ti cul ar vehi cl e by l etter or number desi gnati on. A chart
showi ng the breakdown of these desi gnati ons i s i n-
cl uded i n the I ntroducti on Secti on.
Ti res, as defi ned bel ow and descri bed i n Fi gure 1, are
desi gned for the vehi cl e. They provi de the best overal l
performance for normal operati on. The ri de and han-
dl i ng characteri sti cs match the vehi cl es requi rements.
Wi th proper care they wi l l gi ve excel l ent rel i abi l i ty
tracti on, ski d resi stance, and tread l i fe. These ti res
have l oad carryi ng capaci ty, to operate sati sfactori l y at
al l l oads up to and i ncl udi ng the speci fi ed Maxi mum
Vehi cl e Capaci ty.
Ti res used at l ow speeds, i n cool cl i mates, and wi th
l i ght l oads wi l l have l onger l i fe. Ti res used for hi gh-
speed dri vi ng i n hot cl i mates wi th heavy l oads wi l l
have shorter l i fe. Abrasi ve road surfaces wi l l accel erate
ti re wear.
Dri vi ng habi ts have more effect on ti re l i fe than any
other factor. Careful dri vers wi l l obtai n, i n most cases,
much greater mi l eage than severe or carel ess dri vers. A
few of the dri vi ng habi ts whi ch wi l l shorten the l i fe of
any ti re are:
Rapi d accel erati on and decel erati on
Severe appl i cati on of brakes
Hi gh-speed dri vi ng
Taki ng turns at excessi ve speeds
Stri ki ng curbs and other obstacl es
Longer weari ng ti res are more suscepti bl e to i rregu-
l ar tread wear. I t i s i mportant to fol l ow the ti re rotati on
i nterval shown i n the secti on on Ti re Rotati on. Thi s
wi l l hel p to achi eve a greater tread-l i fe potenti al .
RADIAL-PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe, ri de
qual i ty and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of four
and under no ci rcumstances shoul d they be used on the
front onl y. They may be mi xed wi th temporary spare
ti res when necessary. Reduced speeds are recom-
mended whi l e temporary spare i s i n use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
SPARE TI RE (COMPACT)
The compact spare ti re i s desi gned for emergency use
onl y. The ori gi nal ti re shoul d be repai red and rei n-
stal l ed at the fi rst opportuni ty. Refer to Owners
Manual for compl ete detai l s.
TI RE CHAI NS
Ti re snow chai ns may be used on certai n model s.
Refer to Owners Manual for more i nformati on.
CLEANING OF TIRES
Remove protecti ve coati ng on ti res before del i very of
vehi cl e. The coati ng coul d cause deteri orati on of ti res.
Remove protecti ve coati ng by:
(a) Appl yi ng warm water
(b) Letti ng i t soak one mi nute
WHEELS TIRES 22 - 1
(c) Scrubbi ng the coati ng away wi th a soft bri stl e
brush.
Steam cl eani ng may al so be used for cl eani ng.
DO NOT use gasol i ne or wi re brush for cl eani ng.
DO NOT use mi neral oi l or an oi l -based sol vent.
PRESSURE GAUGES
A hi gh-qual i ty ai r-pressure gauge i s recommended to
check ti re pressure. After checki ng wi th the gauge,
repl ace val ve caps and ti ghten fi nger ti ght.
TIRE INFLATION PRESSURES
Under i nfl ati on (Fi g. 1) causes rapi d shoul der wear
and ti re fl exi ng and can resul t i n ti re fai l ure.
Over i nfl ati on (Fi g. 2) causes rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks.
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
The vehi cl e to dri ft.
Proper ti re pressure can be found on the Vehi cl es
Certi fi cati on Label (See Owners Manual ).
Ti re pressures have been careful l y sel ected to pro-
vi de for safe vehi cl e operati on, vehi cl e stabi l i ty, and a
comfortabl e ri de. Ti re pressure shoul d be checked
col d once per month. Check ti re pressure more fre-
quentl y when the weather temperature vari es wi del y.
Ti re pressure wi l l decreases when the outdoor tem-
perature drops.
I nfl ati on pressures speci fi ed on the pl acards are
al ways col d i nfl ati on pressure. Col d i nfl ati on pres-
sure i s obtai ned after the vehi cl e has not been operated
for at l east 3 hours. Or the vehi cl e i s dri ven l ess than
one mi l e after bei ng i noperati ve for 3 hours. Ti re
i nfl ati on pressures may i ncrease from 2 to 6 pounds
per square i nch (psi ) duri ng operati on. Do not reduce
thi s normal pressure bui l d-up.
Col d i nfl ati on pressures must not exceed 240kPa (35
psi ) for P-Seri es standard l oad ti res.
TI RE PRESSURE FOR HI GHSPEED OPERA-
TI ON
Chrysl er Corporati on advocates dri vi ng at safe
speeds wi thi n posted speed l i mi ts. Where speed l i mi ts
al l ow the vehi cl e to be dri ven at hi gh speeds, correct
ti re i nfl ati on pressure i s very i mportant. For speeds up
to and i ncl udi ng 75 mph (120 km/h), ti res must be
i nfl ated to the pressures shown on the ti re pl acard. For
speeds i n excess of 75 mph (120 km/h), ti res must be
i nfl ated to the maxi mum pressure speci fi ed on the ti re
si dewal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d not
be dri ven at conti nuous speeds above 75 mph (120
km/h).
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL
SUDDENLY, RESULTING IN LOSS OF VEHICLE CON-
TROL.
For pol i ce or emergency vehi cl es that are dri ven at
conti nuous speeds over 90 mph (144 km/h), speci al
hi gh-speed ti res must be used. Consul t ti re manufac-
turer for correct ti re and i nfl ati on pressure recommen-
dati ons.
REPLACEMENT TIRES
The ori gi nal equi pment ti res on the vehi cl e have
been engi neered to provi de a proper bal ance of many
characteri sti cs such as:
ri de
noi se
handl i ng
durabi l i ty
tread l i fe
tracti on
rol l i ng resi stance
speed capabi l i ty
Fig. 1 Under inflation Wear
Fig. 2 Over inflation Wear
22 - 2 WHEELS TIRES
I t i s recommend that ti res equi val ent to the ori gi nal
equi pment ti res be used when repl acement i s needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi cl e.
The use of oversi ze ti res not l i sted i n the speci fi cati on
charts may cause i nterference wi th vehi cl e compo-
nents. Under extremes of suspensi on and steeri ng
travel i nterference wi th vehi cl e components may cause
ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY CAN
RESULT IN SUDDEN TIRE FAILURE AND LOSS OF
VEHICLE CONTROL.
ROTATION
Ti res on the front and rear axl es of vehi cl es operate
at di fferent l oads and perform di fferent steeri ng, dri v-
i ng, and braki ng functi ons. For these reasons, they
wear at unequal rates, and tend to devel op i rregul ar
wear patterns. These effects can be reduced by ti mel y
rotati on of ti res. The benefi ts of rotati on are especi al l y
worthwhi l e. Rotati on wi l l i ncrease tread l i fe, hel p to
mai ntai n mud, snow, and wet tracti on l evel s, and
contri bute to a smooth, qui et ri de.
The suggested rotati on method i s the forward-cross
ti re rotati on method. Thi s method takes advantage of
current ti re i ndustry practi ce whi ch al l ows rotati on of
radi al -pl y ti res. Other rotati on methods may be used,
but may not have al l the benefi ts of the recommended
method.
For proper ti re rotati on, refer to the Owners Manual .
TREAD WEAR INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom of
the tread grooves. When tread i s 1.6 mm (1/16 i n.), the
tread wear i ndi cators wi l l appear as a 13 mm (1/2 i n.)
band.
Ti re repl acement i s necessary when i ndi cators ap-
pear i n two or more grooves or i f l ocal i zed bal di ng
occurs (Fi g. 3).
REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area. The ti re shoul d
be repl aced i f the puncture i s l ocated i n the si dewal l .
Defl ate ti re compl etel y before di smounti ng ti re from
the wheel . Use l ubri cati on such as a mi l d soap sol uti on
when di smounti ng or mounti ng ti re. Use tool s free of
burrs or sharp edges whi ch coul d damage the ti re or
wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
scal e i s removed from the ri m and repai nt i f necessary.
I nstal l wheel s on vehi cl e, progressi vel y ti ghteni ng
wheel nuts to 129 Nm (95 ft. l bs.) torque (See
Wheel s).
TIRE NOISE OR VIBRATION
Radi al -pl y ti re are more sensi ti ve to force i mpul ses
caused by i mproper mounti ng, wheel i rregul ari ti es, or
i mbal ance than the bi as-pl y ti re.
To determi ne i f the ti res are causi ng the noi se or
vi brati on, dri ve the vehi cl e over a smooth road at
di fferent speeds. Note the effect of accel erati on and
decel erati on on noi se l evel . Di fferenti al and exhaust
noi ses wi l l change i n i ntensi ty as speed vari es, whi l e
ti re noi se wi l l usual l y remai n constant.
TIRE WEAR PATTERNS
Under i nfl ati on resul ts i n faster wear on shoul ders of
ti re. Over i nfl ati on causes faster wear at center of
tread.
Excessi ve camber causes the ti re to run at an angl e
to the road. One si de of tread i s worn more than the
other.
Excessi ve toe-i n or toe-out causes wear on the tread
edges of the ti re, from draggi ng of ti re. There i s a
feathered effect across the tread (Fi g. 4).
Fig. 3 Tread Wear Indicators
WHEELS TIRES 22 - 3
Fig. 4 Tire Wear Patterns
22 - 4 WHEELS TIRES
LEAD CORRECTI ON CHART
WHEELS TIRES 22 - 5
WHEEL SERVI CE PROCEDURES
GENERAL INFORMATION
Ori gi nal equi pment wheel s are desi gned for sati sfac-
tory operati on at al l l oads up to the speci fi ed maxi mum
vehi cl e capaci ty.
Al l model s use steel or cast al umi num drop center
wheel s. The safety ri m wheel (Fi g. 1) has rai sed sec-
ti ons between the ri m fl anges and ri m wel l A.
I ni ti al i nfl ati on of the ti res forces the bead over these
rai sed secti ons. I n case of ti re fai l ure, the rai sed
secti ons help hol d the ti re i n posi ti on on the wheel .
Cast al umi num wheel s requi re speci al bal ance
wei ghts and al i gnment equi pment.
WHEEL INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons and must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l essor qual i ty or
a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts wi th an enl arged nose.
Thi s enl arged nose i s necessary to ensure proper re-
tenti on of the al umi num wheel s.
Before i nstal l i ng the wheel , remove any bui l d up of
corrosi on on the wheel mounti ng surfaces. I nstal l i ng
wheel s wi thout good metal -to-metal contact coul d
cause l ater l ooseni ng of wheel nuts. Thi s coul d ad-
versel y affect the safety and handl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on the
mounti ng surface usi ng the hub pi l ot as a gui de. Al l
wheel nuts shoul d then be ti ghtened just snug. Then
progressi vel y ti ghten them i n the proper sequence (Fi g.
3). Ti ghten wheel nuts to 129 Nm (95 ft. l bs.). Never
use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheel s must be repl aced i f they:
have excessi ve run out
are bent or dented
l eak ai r through wel ds
have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment repl acement wheel s are avai l -
abl e through your deal er. When obtai ni ng repl acement
wheel s, they shoul d be equi val ent i n l oad carryi ng
capaci ty. The physi cal di mensi ons (di ameter, wi dth,
offset, and mounti ng confi gurati on) of the ri m shoul d
be the same as the ori gi nal wheel . Fai l ure to use
equi val ent repl acement wheel s may adversel y affect
the safety and handl i ng of the vehi cl e. Replacement
with used wheels is not recommended. The
service history of the rim may have included
severe treatment or very high mileage. The rim
could fail without warning.
TIRE AND WHEEL BALANCE
Bal anci ng need i s i ndi cated by vi brati on of seats,
fl oor pan, or steeri ng wheel . The vi brati on wi l l noti ced
mostl y when dri vi ng over 64 km/h (40 mph) on a
smooth road.
I t i s recommended that a two pl ane dynami c ti re
bal ance machi ne be used. Stati c bal anci ng shoul d be
used onl y when a two pl ane ti re bal ance machi ne i s not
avai l abl e.
For stati c i mbal ance, fi nd l ocati on of heavy spot
causi ng i mbal ance and counter bal ance wheel di rectl y
opposi te the heavy spot. Determi ne wei ght requi red to
counterbal ance the area of i mbal ance. Pl ace hal f of thi s
wei ght on the inner ri m fl ange. Then pl ace the other
hal f on the outer ri m fl ange (Fi g. 2).
Off-vehi cl e bal anci ng i s preferred.
Fig. 1 Safety Rim
Fig. 2 Counterbalancing
22 - 6 WHEELS TIRES
TIRE AND WHEEL RUN OUT
Radi al run out i s the di fference between the hi gh and
l ow poi nts on the ti re or wheel peri phery.
Lateral run out i s the wobbl e of the ti re or wheel .
Radi al run out of more than 0.7 mm (.030 i nch)
measured at the center l i ne of the tread may cause the
vehi cl e to shake.
Lateral run out of more than 0.7 mm (.030 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al run out can be reduced by rel ocat-
i ng the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce run out to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounti ng surface; ad-
just wheel beari ngs.
Dri ve vehi cl e a short di stance to el i mi nate ti re fl at
spotti ng from a parked posi ti on.
Make sure al l wheel nuts are properl y torqued (Fi g.
3).
Use run out gauge D-128-TR to determi ne run out
(Fi g. 4).
Rel ocate wheel on the mounti ng, two studs over from
the ori gi nal posi ti on.
Reti ghten wheel nuts (Fi g. 3) unti l al l are properl y
torqued. Thi s wi l l prevent brake di storti on.
Check radi al run out. I f sti l l excessi ve, mark ti re
si dewal l , wheel , and stud at poi nt of maxi mum run out
and proceed to Method 2.
METHOD 2 (RELOCATE TI RE ON WHEEL)
Rotati ng ti re on wheel i s parti cul arl y effecti ve when
there i s run out i n both ti re and wheel .
Remove ti re from wheel and mount wheel on dy-
nami c wheel bal ancer.
Check wheel radi al run out at each bead seat (Fi g. 5).
I t shoul d be no more than 0.7 mm (0.30 i nch).
Lateral run out on each ri m shoul d be no more than
0.7 mm (0.30 i nch) (Fi g. 5).
I f poi nt of greatest wheel radi al run out i s near
ori gi nal chal k mark, remount ti re 45 degrees from i ts
ori gi nal posi ti on. Recheck run out.
Fig. 4 Run out Gauge
Fig. 3 Tightening Wheel Nuts
Fig. 5 Checking Wheel Run out
WHEELS TIRES 22 - 7
1992 Van/Wagon RWD/AWD
TSB 22-06-94 October 7, 1994
SPECI FI CATI ONS
TORQUE
22 - 8 WHEELS TIRES
TRANSAXLE
CONTENTS
page page
A-523 MANUAL TRANSAXLE . . . . . . . . . . . . . . . 1
ALL WHEEL DRIVE POWER TRANSFER UNIT
(P. T. U. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4-SPEED ELECTRONIC TRANSAXLE HYDRAULIC
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 184
4-SPEED ELECTRONIC TRANSAXLE ON-BOARD
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 157
4-SPEED ELECTRONIC AUTOMATIC
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 197
THREE SPEED TORQUEFLITE AUTOMATIC
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 32
THREE SPEED TRANSAXLE HYDRAULIC
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 176
A-523 MANUAL TRANSAXLE
INDEX
page page
Bearing Adjustment Procedure . . . . . . . . . . . . . . . 29
Differential Bearing Preload Adjustment . . . . . . . . 30
Gearshift Linkage Adjustment (Cable Operated) . . . 2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
In-Car Transaxle Disassemble/Assemble . . . . . . . . 4
Out of Car TransaxleDisassemble and Assemble . 5
Subassembly-Recondition . . . . . . . . . . . . . . . . . . 15
Transaxle Removal and Installation . . . . . . . . . . . . 4
GENERAL INFORMATION
Safety goggles should be worn at all times
when working on these transaxles. Al l manual
transaxl es use SAE 5W-30 engi ne oi l , meeti ng SG
and/or SG-CC qual i fi cati ons, as the l ubri cant to reduce
wear.
The Chrysl er 5-speed manual transaxl es combi ne
gear reducti on, rati o sel ecti on, and di fferenti al func-
ti ons i n one uni t. I t i s housed i n a di e-cast al umi num
case (Fi g. 1).
Al l shi ft forks are cast i ron. Donot interchange1-2
or 5th shift fork padswith the3-4shift fork pads.
Al l synchroni zers use a winged strut desi gn that
prevents the struts from poppi ng out of posi ti on.
If anysynchronizer istobedisassembled, mark
all parts so that they will be reassembled in the
same position.
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly, or with previous model years tran-
saxles; they will NOT function correctly.
To reduce wear, the manual transaxl e uses SAE
5W-30 engi ne oi l as the l ubri cant.
Gear rati os for the A-523 are as fol l ows:1st-3.31,
2nd-2.06, 3rd-1.36, 4th-0.97, 5th-0.71, Reverse-3.14.
Fi nal dri ve rati o i s 3.77.
IDENTIFICATION
The transaxl e model , assembl y number, bui l d date,
and fi nal -dri ve rati o are stamped on a tag that i s
attached to the top of the transaxl e (Fi g. 2).
Certain transaxleassembliesusehigh-strength
Steel in various gears toprovideadequatelifein
heavy-duty applications. Therefore, it is impera-
tive that the correct transaxle assembly number
is used when orderingservice parts. Al so, be sure
Fig. 1 External Transaxle Components
TRANSAXLE 21 - 1
to rei nstal l thi s tag whenever i t i s removed, so the
i nformati on i s avai l abl e for future servi ce.
CAUTION:All gears and shafts must not be inter-
changed with previous model years; they will not
function correctly.
The l ast ei ght di gi ts of the Vehi cl e I denti fi cati on
Number (V.I .N.) are stamped on a rai sed boss on top of
the cl utch housi ng area.
GEARSHIFT LINKAGE ADJUSTMENT (CABLE OPER-
ATED)
Before repl aci ng the gearshi ft sel ector cabl e or cross-
over cabl e for a hard-shifting compl ai nt, di sconnect
both cabl es at the transaxl e (Fi g. 3). Then, from the
dri vers seat, manual l y operate the gearshi ft l ever
through al l gear ranges. I f the gearshi ft l ever moves
smoothl y, the cabl e(s) shoul d NOT be repl aced.
(1) Worki ng over the l eft front fender, remove the
l ock pi n from the transaxl e gearshi ft (sel ector shaft)
housi ng (Fi g. 4).
(2) Reverse the l ock pi n (so l ong end i s down) and
i nsert l ock pi n i nto same threaded hol e. A hol e i n the
sel ector shaft wi l l al i gn wi th the l ock pi n, al l owi ng the
l ock pi n to be screwed i nto the housi ng. Thi s operati on
l ocks the sel ector shaft i n the 3-4 neutral posi ti on.
(3) Remove or i nstal l gearshi ft knob (Fi g. 5 or 6).
(4) Remove or i nstal l boot (Fi g. 7).
(5) Remove or i nstal l sel ector and crossover cabl es
(Fi g. 8 or 9).
Cable attachment clips must be installed from
the side. Install cable fittings to shifter pins by
pushing with thumb.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw (Fig. 10).
Fig. 2 A-523 Transaxle Identification
Fig. 3 Gearshift Mechanism
21 - 2 TRANSAXLE
CAUTION: Proper torque to the crossover cable ad-
justing screw is very important (Fig. 10).
(6) Remove l ock pi n from gearshi ft housi ng and
rei nstal l l ock pi n (so l ong end i s up) i n gear shi ft
housi ng (Fi g. 4). Ti ghten l ock pi n to 8 Nm (70 i n. l bs.).
(7) Check for shi ft i nto fi rst and reverse. Check for
bl ockout i nto reverse.
(8) Gearshi ft mechani sm and cabl es are now func-
ti oni ng properl y.
Fig. 4 Manual Transaxle Pinned in the Neutral Posi-
tion to Adjust Gearshift
Fig. 5 Remove Gearshift Knob
Fig. 6 Install Gearshift Knob
Fig. 7 Remove or Install Boot
Fig. 8 Remove Cables
TRANSAXLE 21 - 3
IN-CAR TRANSAXLE DISASSEMBLE/ASSEMBLE
The fol l owi ng i tems can be servi ced wi thout remov-
i ng the transaxl e:
Gear shi ft housi ng
Synchroni zers
I ntermedi ate shaft speed gears
I nput shaft
Reverse i dl er gear and shaft
Shi ft forks and pads
Shi ft rai l s
Rol l er detents
Speedometer pi ni on
Al l external covers
Observe fol l owi ng procedure:
(2) Remove both shi ft cabl es from shi ft cover l evers.
(3) Remove l eft front wheel and ti re assembl y and
l eft spl ash shi el d.
(4) Pl ace drai n pan under transaxl e and remove
transaxl e rear end cover.
(5) Push out the fi fth fork rol l pi n and sl i de the fi fth
fork and synchroni zer sl eeve off the rai l /hub.
(6) Remove the fi fth hub snap ri ng, hub assembl y
and speed gear.
(7) Remove fi fth gear nut and fi fth i nput gear.
(8) Remove the beari ng retai ner pl ate, i nterl ock
pl ate and shuttl es.
CAUTION: Before removing the gearshift housing
assembly, reverse the lock pin (so the long end is
down) and insert lock pin into the same threaded
hole. This procedure will save time when the gear
shift housing assembly is reinstalled.
(9) Remove sel ector shaft housi ng bol ts (note the two
pi l ot bol ts) and remove housi ng.
(10) Remove rol l er detents and spri ngs, noti ng that
the rol l ers al i gn wi th the shi ft rai l s.
(11) Push out the 1-2 and 3-4 l ug rol l pi ns, remove
the reverse pi vot l ever and fi fth rai l C-Cl i p. If a roll
pin or C-Clip falls, be sure to remove it fromthe
bottomof the case.
(12) Pul l out the fi fth shi ft rai l and remove the fi fth
shi ft l ug and i nterl ock pi n.If thepin falls, besureto
remove it fromthe bottomof the case.
(13) Remove the i ntermedi ate shaft bal l beari ng
snap ri ng and the beari ng support pl ate.
(14) Remove reverse shi ft rai l and l ug assembl y.
(15) Remove the reverse i dl er shaft and gear assembl y.
(16) Rotate the 1-2 shi ft l ug and rai l , and 3-4 shi ft
l ug toward the front of the vehi cl e.
(17) Fi rml y grasp both the i nput and i ntermedi ate
shaft assembl i es and pul l them out of the transmi ssi on
wi th the 1-2 and 3-4 shi ft rai l s, l ugs and forks.
The differential assembly can only be serviced
by removing the complete transaxle from the
vehicle because bearing preload must be reset.
The components l i sted i n the fi rst paragraph can now be servi ced.
Refer to the appropri ate subassembly recondition secti on.
To reassembl e the transaxl e i n the vehi cl e, reverse
the above procedure usi ng the proper seal ants. Fi l l the
transaxl e wi th SAE 5W-30 engi ne oi l to the bottom of
the fi l l hol e i n the end cover.
TRANSAXLE REMOVAL AND INSTALLATION
Transaxle removal does not require engine removal.
After i nstal l i ng transaxl e, fi l l transaxl e to bottom of
fi l l pl ug hol e wi th SAE 5W-30 engi ne oi l before l ower-
i ng vehi cl e to fl oor.
(1) Di sconnect or connect negative battery cabl e.
(2) I nstal l a liftingeyeon battery ground strap bol t
on l eft si de of engi ne and i nstal l the engi ne support
fi xture as shown i n Fi gure 11.
(3) Di sconnect or connect gearshi ft cabl es at tran-
saxl e. Di sconnect speedometer. Di sconnect or connect
gearshi ft cabl es bracket at transaxl e.
(4) Remove or i nstal l both front wheel and ti re assembl i es.
(5) Remove or i nstal l l eft front spl ash shi el d.
(6) Remove or i nstal l engi ne l eft mount from transaxl e.
Fig. 9 Install Cables
Fig. 10 Adjusting Crossover Cable
21 - 4 TRANSAXLE
CAUTION: Bolts used for position number 1 and
number 3 are the same length. The bolt in the number
2 position is longer. If bolt number 2 is used in
position number 3 it can damage the selector shaft
housing when the bolt is seated (Fig. 12).
(7) Remove or i nstal l anti -rotati onal l i nk (or anti -
hop damper) from crossmember bracket. Do not re-
move bracket fromtransaxle.
(8) Refer to Group 2 Suspension, to remove or
i nstal l both dri ve shafts.
When removing or installing the transaxle, it
may be helpful to use two locating pins in place
of the top two transaxle to engine block bolts
(Fig. 13).
Make the l ocati ng pi ns from two stock (transaxl e
case to engi ne bl ock) bol ts as fol l ows: Usi ng a hacksaw,
remove bol t heads, cut sl ot i n end of bol ts for a screw
dri ver, and remove burrs wi th a gri ndi ng wheel . I nstal l
the l ocati ng pi ns i nto the engi ne bl ock and proceed
wi th transaxl e i nstal l ati on. After transaxl e i s i n pl ace,
i nstal l bol ts and remove l ocati ng pi ns before removi ng
transmi ssi on jack.
OUT OF CAR TRANSAXLE DISASSEMBLE AND
ASSEMBLE
DI FFERENTI AL
Fig. 11 Engine Support Fixture
Fig. 12 Left Engine Mount Bolt Location
Fig. 13 Remove or Install Bolts
Fig. 1 Remove or Install 2 Extension Outer Bolts
Fig. 2 Remove or Install 3 Differential Bearing Re-
tainer Outer Bolts
TRANSAXLE 21 - 5
Fig. 3 Remove or Install Differential Cover Bolts
Fig. 4 Remove Differential Cover
Fig. 5 Differential Cover Removed
Fig. 6 Remove or Install 2 Extension Bolts
Fig. 7 Remove or Install Extension
Fig. 8 Remove or Install 3 Differential Bearing Re-
tainer Bolts
21 - 6 TRANSAXLE
GEAR SET
Fig. 9 Remove or Install Differential Bearing Re-
tainer
Fig. 10 Differential Assembly Removed
Fig. 1 Rear End Cover Bolts
Fig. 2 Rear End Cover Removed
Fig. 3 Remove 5th Fork Roll Pin
Fig. 4 Install 5th Fork Roll Pin
TRANSAXLE 21 - 7
CAUTION: Tool 6252 must be used to remove or
install this nut. Always install a NEW nut and tighten
to 258 Nm (190 ft. lbs.).
Fig. 5 5th Fork and Sleeve
Fig. 6 Snap Ring
Fig. 7 Remove 5th Synchronizer Hub
Fig. 8 Install 5th Synchronizer Hub
Fig. 9 Remove or Install 5th Gear Nut
21 - 8 TRANSAXLE
Fig. 12 A-523 Shift Forks and Shift Rail Components
Fig. 10 Bearing Retainer Plate Bolts Fig. 11 Bearing Retainer Plate
TRANSAXLE 21 - 9
CAUTION: Before removing the gearshift housing,
reverse the lock pin (so the long end is down) and
insert lock pin into the same threaded hole. This
procedure will save time when the gearshift housing
assembly is reinstalled.
To install gearshift housing, be sure to reverse
the lock pin in the housing to lock the selector
shaft in the 3-4 neutral position.
CAUTION: Install roller detents so roller and slots are
parallel with shift rails.
Remove or i nstal l 3-4 l ug rol l pi n, 3-4 fork rol l pi n,
and reverse l ug rol l pi n usi ng the above procedure.
Fig. 13 Interlock Shuttles
Fig. 14 Interlock Plate
Fig. 15 Gearshift Housing Bolts
Fig. 16 Gearshift Housing Removed
Fig. 17 Remove Roller Detents
21 - 10 TRANSAXLE
CAUTION: If any roll pin falls out, retrieve roll pin from
bottom of case.
Fig. 18 Remove 1-2 shift Lug Roll Pin
Fig. 19 Install 1-2 Shift Lug Roll Pin
Fig. 20 Remove 1-2 Shift Fork Roll Pin
Fig. 21 Reverse Pivot Lever
Fig. 22 5th Shift Rail C-Clip
Fig. 23 5th Shift Rail and Shift Lug
TRANSAXLE 21 - 11
Fig. 24 5th Shift Lug with Interlock Pin
Fig. 25 5th Shift Lug Properly Installed
Fig. 26 Reverse Shift Rail and Shift Lug
Fig. 27 3-4 Shift Rail and Shift Lug
Fig. 28 1-2 Shift Rail and Shift Lug
Fig. 29 Remove or Install Large Snap Ring
21 - 12 TRANSAXLE
CAUTION: Pry only at slot as shown (Fig. 30).
Fig. 30 Pry Bearing Retainer Plate to Remove
Fig. 31 Bearing Support Plate
Fig. 32 Remove or Install Reverse Idler Gear
Fig. 33 Reverse Idler Gear Assembly
Fig. 34 Remove or Install Gear Set
Fig. 35 Gear Set
TRANSAXLE 21 - 13
CLUTCH RELEASE BEARI NG I NPUT SHAFT OI L SEAL
Fig. 1 Remove Retaining E-Clip
Fig. 2 Remove or Install Clutch Release Shaft
Fig. 3 Clutch Release Shaft Components
Fig. 4 Remove or Install Input Shaft Seal Retainer
Fig. 5 Input Shaft Seal Retainer
Fig. 6 Install New Input Shaft Seal
21 - 14 TRANSAXLE
REVERSE SHI FT LEVER
SUBASSEMBLY-RECONDITION
TRANSAXLE CASE
Use Tool C-4660-2A Screw. The screw has a l arger
hol e i n the l ower end to fi t over the l arger oi l feeder
ni ppl e (Fi g. 5).
Fig. 8 Reverse Shift Lever Components
Fig. 7 Remove or Install Reverse Shift Lever E-Clip
Fig. 1 Remove Input Shaft Front Bearing Cup
Fig. 2 Install Input Shaft Front Bearing Cup
Fig. 3 Remove or Install Bearing Retaining Strap
Fig. 4 Remove Intermediate Shaft Front Bearing
TRANSAXLE 21 - 15
I NTERMEDI ATE SHAFT ASSEMBLY
When assembling intermediate shaft, make
sure all speed gears turn freely.
Fig. 5 Oil Feeder
Fig. 6 Install Intermediate Shaft Front Bearing
Fig. 1 Intermediate Shaft Bearing Snap Ring
Fig. 2 Remove Intermediate Shaft Rear Bearing
Fig. 3 Install Intermediate Shaft Rear Bearing
Fig. 4 3-4 Synchronizer Hub Snap Ring
21 - 16 TRANSAXLE
CAUTION: Index snap ring 90 degrees to the split in
the thrust washer, as shown above.
1-2 SYNCHRONI ZER (DUAL-CONE)
Fig. 5 Remove 3-4 Synchronizer Hub and 3rd Speed
Gear
Fig. 6 Install 3-4 Synchronizer Hub and 3rd Speed
Gear
Fig. 7 Snap Ring and Split Thrust Washer
Fig. 1 2nd Speed Gear
Fig. 2 1-2 Synchronizer Hub Snap Ring
Fig. 3 1st Speed Gear and 1-2 Synchronizer Assem-
bly
TRANSAXLE 21 - 17
Fig. 4 Split Thrust Washer
Fig. 5 Intermediate Shaft Assembly
21 - 18 TRANSAXLE
SYNCHRONI ZERS
Fig. 6 1-2 and 3-4 Synchronizer Sleeves and Hubs
Fig. 7 5th Speed Synchronizer
TRANSAXLE 21 - 19
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly, or with previous model years tran-
saxles; they will NOT function correctly.
Fig. 8 Synchronizer Identification
Fig. 9 Synchronizers
21 - 20 TRANSAXLE
GEARSHI FT HOUSI NG
Roll pin must be flush with top of lever.
Fig. 1 Gearshift Housing Disassembled
Fig. 2 Remove or Install Roll Pin and Lever Fig. 3 Dust Boot
TRANSAXLE 21 - 21
The C-Clip groves in the selector shaft will
damage the oil seal. Install oil seal after selector
shaft is installed. Always usea newoil seal when
selector shaft is removed.
Proper torque to the 5-R blocker attaching
bolts is very important (Fig. 8).
Fig. 4 Remove Oil Seal
Fig. 5 Install Oil Seal
Fig. 6 Remove Vent Cap
Fig. 7 Crossover Shaft Roll Pin
Fig. 8 5-R Blocker Attaching Bolts
Fig. 9 5-R Blocker Assembly
21 - 22 TRANSAXLE
For Disassembly: Drive roll pin out far enough
toclear theselector shaft, but pinmust remainin
the selector so not to break the housing.
Fig. 10 Crossover Shaft
Fig. 11 Selector Shaft C-Clip
Fig. 12 Selector Shaft C-Clip
Fig. 13 Selector Assembly Roll Pin
Fig. 14 Remove or Install Selector Shaft
Fig. 15 Disassembled View
TRANSAXLE 21 - 23
DI FFERENTI AL BEARI NG RETAI NER
Fig. 1 Remove Differential Bearing Retainer Seal
Fig. 2 Install Differential Bearing Retainer Seal
Fig. 3 Remove Differential Bearing Retainer Cup
Fig. 4 Differential Bearing Retainer
Fig. 5 Install Oil Baffle
Fig. 6 Insert (Select) Shim and Differential Bearing
Retainer Cup
21 - 24 TRANSAXLE
EXTENSI ON HOUSI NG
Fig. 1 Remove Extension Seal
Fig. 2 Install New Seal into Extension
Fig. 3 Remove Extension Bearing Cup
Fig. 4 Extension
Fig. 5 Install Extension Oil Baffle
Fig. 6 Install Extension Bearing Cup
TRANSAXLE 21 - 25
I NPUT SHAFT
Shi m thi ckness need onl y be determi ned i f any of the
fol l owi ng parts are repl aced:
Transaxl e case
I nput shaft seal retai ner
Beari ng retai ner pl ate
Rear end cover
I nput shaft
I nput shaft beari ngs
Refer to BearingAdjustment Procedurei n rear of
thi s secti on to determi ne proper shi m thi ckness for
correct beari ng end pl ay and proper turni ng torque.
Fig. 1 Remove Input Shaft Rear Bearing Cone
Fig. 2 Install Input Shaft Rear Bearing Cone
Fig. 3 Remove Input Shaft Front Bearing Cone
Fig. 4 Install Input Shaft Front Bearing Cone
Fig. 5 Remove Input Shaft Rear Bearing Cup
21 - 26 TRANSAXLE
CAUTION: Bolt on bearing support plate before in-
stalling input shaft rear bearing cup.
A-523 DI FFERENTI AL
Transaxl e case
Di fferenti al beari ng retai ner
Extensi on housi ng
Di fferenti al case
Di fferenti al beari ngs
Refer to BearingAdjustment Procedurei n rear of
correct beari ng prel oad and proper beari ng turni ng
torque.
Fig. 6 Install Input Shaft Rear Bearing Cup
Fig. 1 Remove Differential Bearing Cone
Fig. 2 Install Differential Bearing Cone
TRANSAXLE 21 - 27
CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued (See Tightening Refer-
ence).
CAUTION: Side gear end play must be within .001 to
.013 inch. Four select thrust washers are available:
.032, .037, .042, and .047 inch.
After assembl i ng the di fferenti al si de gears, pi ni on
gears and pi ni on gears with the pi ni on gear washers
but without the si de gear thrust washers. Rotate the
assembl y two ful l revol uti ons both cl ockwi se and coun-
tercl ockwi se.
Set up di al i ndi cator as shown and record end pl ay.
Rotate si de gear 90 degrees and record another end
pl ay. Agai n, rotate si de gear 90 degrees and record a
fi nal end pl ay.
Usi ng the smal l est end pl ay recorded, shi m that si de
gear to wi thi n .001 to .013 i nch. The other si de gear
shoul d be checked usi ng the same procedure.
Fig. 5 Remove or Install Ring Gear Bolts and Ring
Gear
Fig. 6 Remove Pinion Shaft Roll Pin
Fig. 7 Remove or Install Pinion Shaft
Fig. 8 Remove or Install Pinion Gears, Side Gears,
and Thrust Washers by Rotating Side Gears to
Opening in Case
Fig. 9 Differential Gears
21 - 28 TRANSAXLE
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVI CI NG BEARI NGS
(1) Take extreme care when removi ng and i nstal l i ng
beari ng cups and cones. Use onl y an arbor press for
i nstal l ati on, as a hammer may not properl y al i gn the
beari ng cup or cone. Burrs or ni cks on the beari ng seat
wi l l gi ve a fal se end pl ay readi ng whi l e gaugi ng for
proper shi ms. I mproperl y seated beari ng cups and
cones are subject to l ow mi l eage fai l ure.
(2) Beari ng cups and cones shoul d be repl aced i f they
show si gns of pi tti ng or heat di stress. I f di stress i s seen
on ei ther the cup or beari ng rol l ers, both cup and cone
must be repl aced.
(3) Beari ng prel oad and drag torque speci fi cati ons
must be maintained to avoi d premature beari ng
fai l ures. Used (ori gi nal ) beari ng may l ose up to 50% of
the ori gi nal drag torque after break-i n. All bearing
adjustments must bemadewith no other compo-
nent interference or gear intermesh.
(4) Repl ace beari ngs as a pai r. For exampl e, i f one
di fferenti al beari ng i s defecti ve, repl ace both di fferen-
ti al beari ngs. I f one i nput shaft beari ng i s defecti ve,
repl ace both i nput shaft beari ngs.
(5) Beari ng cones must not be reused i f removed.
(6) Turni ng torque readi ngs shoul d be obtai ned
whi l e smoothl y rotati ng i n ei ther di recti on (break-
away readi ng i s not i ndi cati ve of the true turni ng
torque).
(7) Repl ace oi l baffl e, i f damaged.
I NPUT SHAFT BEARI NG END PLAY ADJUST-
MENT
(1) Usi ng Tool C-4656 wi th Handl e C-4171, press
i nput shaft front beari ng cup sl i ghtl y forward i n case.
Then, usi ng Tool C-4655 wi th Handl e C-4171, press
beari ng cup back i nto case from the front. Properl y
posi ti on beari ng cup, before checki ng i nput shaft end
pl ay (see i nput shaft front beari ng cup repl ace i n
Subassembly Recondition secti on). This step is
not necessary if Tool C-4655was previously used
to install input shaft front bearing cup in the
case. Also no input shaft shimhas been installed
since pressing cup into case.
(2) Sel ect a gaugi ng shi m whi ch wi l l gi ve 0.025 to
0.254mm (.001 to .010 inch) end pl ay. SUGGES-
TION: Measure original shim from input shaft
seal retainer and select a shim 0.254mm (.010
inch) thinner than original for thegaugingshim.
(3) I nstal l gaugi ng shi m on beari ng cup and i nstal l
i nput shaft seal retai ner.
CAUTION: The input shaft seal retainer is used to
draw the input shaft front bearing cup the proper
distance into the case bore during this step. Alter-
nately tighten input shaft seal retainer bolts until
input shaft seal retainer is bottomed against case.
Tighten bolts to 28 Nm (21 ft. lbs.).
(4) Oi l i nput shaft beari ngs wi th SAE 5W-30 engi ne
oi l and i nstal l i nput shaft i n case. I nstal l beari ng
retai ner pl ate wi th i nput shaft rear beari ng cup
pressed i n and beari ng support pl ate i nstal l ed. Ti ghten
al l bol ts and nuts to 28 Nm (21 ft. l bs.).
(5) Posi ti on di al i ndi cator to check i nput shaft end
pl ay. Appl y moderate l oad, by hand, to i nput shaft
spl i nes (Fi g. 1). Push toward rear whi l e rotati ng i nput
shaft back and forth a number of ti mes to settl e out
beari ngs. Zero di al i ndi cator. Pul l i nput shaft toward
the front whi l e rotati ng i nput shaft back and forth a
number of ti mes to settl e out beari ngs. Record end pl ay.
(6) The shimrequi red for proper beari ng end pl ay i s
the total of the gauging shim thickness, plus end
play, minus (constant) end play of 0.051mm(.002
inch). Combi ne shi ms, i f necessary, to obtai n a shi m
wi thi n .04mm (.0016 i nch) of the requi red shi m (see
Shi m Chart for proper shi m).
(7) Remove i nput shaft seal retai ner and gaugi ng
shi m. I nstal l shi m(s) sel ected i n step (6) and rei nstal l
Fig. 10 Checking Side Gear End Play
TRANSAXLE 21 - 29
i nput shaft seal retai ner wi th a 1/16 i nch bead of
MOPAR Gasket Maker, Locti te 518, or equi val ent for
a gasket. Record end pl ay. Observe the CAUTION i n
step (3). Ti ghten i nput shaft seal retai ner bol ts to 28
Nm (21 ft. l bs.).
(8) To veri fy that a prel oad condi ti on does not exi st,
use Speci al Tool L-4508 and an i nch-pound torque
wrench to check i nput shaft turni ng torque (Fi g. 2).
The turning torque should be less than 5 in. lbs.
CAUTION: Step (1) MUST be repeated every time a
thinner shim is installed. This will assure that the
input shaft bearing cup is pressed the proper dis-
tance into the case. If the turning torque is too high,
install a .04mm (.0016 inch) thinner shim.
(9) Recheck i nput shaft turni ng torque. Repeat step
(8) unti l the proper beari ng turni ng torque i s obtai ned.
Observe CAUTION i n step (8).
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
(1) Remove beari ng cup and exi sti ng shi m from
di fferenti al beari ng retai ner. (See Di fferenti al Beari ng
Retai ner i n Subassembly Recondition secti on).
(2) Sel ect a gaugi ng shi m whi ch wi l l gi ve 0.025 to
0.254mm (.001 to .010 i nch) end pl ay. SUGGESTION:
Measure original shimfromdifferential bearing
retainer and select a shim 0.381mm (.015 inch-
)thinner than original for the gauging shim. I n-
stal l gaugi ng shi m i n di fferenti al beari ng retai ner and
press i n beari ng cup. Installation of oil baffleisnot
necessary when checking differential assembly
end play.
(3) Oi l di fferenti al beari ngs wi th SAE 5W-30 engi ne
oi l and i nstal l di fferenti al assembl y i n transaxl e case.
Check extensi on housi ng O-ri ng for damage (repl ace i f
necessary). Add a 1/16 i nch bead of MOPAR Gasket
Maker, Locti te 518, or equi val ent to extensi on fl ange.
I nstal l extensi on housi ng and di fferenti al beari ng re-
tai ner. Torque bol ts (see Ti ghteni ng Reference).
(4) Posi ti on transaxl e wi th bel l housi ng faci ng down
on workbench wi th C-cl amps. Posi ti on di al i ndi cator.
(5) Appl y a medi um l oad to di fferenti al wi th Tool
C-4995 and a T-Handl e, i n the downward di recti on.
Rol l di fferenti al assembl y back and forth a number
Fig. 1 Checking Input Shaft Bearing End Play to De-
termine Shim Thickness
Fig. 2 Checking Input Shaft Bearing Turning Torque
I NPUT SHAFT SHI M CHART
21 - 30 TRANSAXLE
of ti mes. Thi s wi l l settl e the beari ngs. Zero di al i ndi -
cator. To obtai n end pl ay readi ngs, appl y a medi um
l oad i n the upward di recti on whi l e rol l i ng di fferenti al
assembl y back and forth a number of ti mes to settl e out
the beari ngs (Fi g. 3). Record end pl ay.
(6) The Shimrequi red for proper beari ng prel oad i s
the total of the gaugingshimthickness, plus end
play, plus (constant) preload of 0.254mm (.010
inch). Combi ne shi ms, i f necessary, to obtai n a shi m
wi thi n .05mm (.002 i nch) of the requi red shi m (see
Shi m Chart for proper shi ms).
(7) Remove di fferenti al beari ng retai ner. Remove
beari ng cup and gaugi ng shi m. Properl y i nstal l oi l
baffl e. Be sure oil baffle is not damaged. I nstal l
shi m(s) sel ected i n step (6) and press i n the beari ng cup
i nto di fferenti al beari ng retai ner.
(8) Usi ng a 1/16 i nch bead of MOPAR Gasket
Maker, Locti te 518, or equi val ent for gasket, i nstal l
di fferenti al beari ng retai ner. Torque al l bol ts (See
Ti ghteni ng Reference).
(9) Usi ng Speci al Tool C-4995 and an i nch-pound
torque wrench, check turni ng torque of the di fferenti al
assembl y i n cl ockwi se and countercl ockwi se di recti ons
(Fi g. 4). The turning torque should be 9 to 14 in.
lbs. for new bearings or a minimum of 6 in. lbs.
for used bearings. If the turning torque is too
high, install a .05mm(.002 inch) thinner shim. If
the turning torque is too low, install a .05mm
(.002 inch) thicker shim.
(10) Recheck turni ng torque. Repeat Step (9) unti l
the proper turni ng torque i s obtai ned.
Fig. 4 Checking Differential Bearing Turning Torque
DI FFERENTI AL BEARI NG SHI M CHART
Fig. 3 Checking Differential Bearing End Play to De-
termine Shim Thickness
TRANSAXLE 21 - 31
THREE SPEED TORQUEFLI TE AUTOMATI C TRANSAXLE
INDEX
page page
Accumulator-Recondition . . . . . . . . . . . . . . . . . . . 64
Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 45
Band Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 44
Bearing Adjustment Procedures . . . . . . . . . . . . . . 79
Clutch and Servo Air Pressure Tests . . . . . . . . . . . 40
Differential Repair . . . . . . . . . . . . . . . . . . . . . . . . 73
Distance Sensor Pinion Gear . . . . . . . . . . . . . . . . 44
Fluid and Filter Change . . . . . . . . . . . . . . . . . . . . 37
Fluid Drain and Refill . . . . . . . . . . . . . . . . . . . . . . 37
Fluid Leakage-Transaxle Torque Converter Housing
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fluid Level and Condition . . . . . . . . . . . . . . . . . . . 36
Front Clutch-Recondition . . . . . . . . . . . . . . . . . . . 59
Front Planetary & Annulus Gear-Recondition . . . . . 62
Gearshift Linkage Adjustment . . . . . . . . . . . . . . . . 43
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic Control Pressure Adjustments . . . . . . . . 44
Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 38
Kickdown Servo (Controlled Load)-Recondition . . . 64
Lockup Solenoid Wiring Connector . . . . . . . . . . . . 37
Low/Reverse (Rear) Servo-Recondition . . . . . . . . . 63
Neutral Starting and Back-Up Lamp Switch . . . . . . 44
Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . . 45
Oil Coolers and Tubes Reverse Flushing . . . . . . . 45
Oil Pump-Recondition . . . . . . . . . . . . . . . . . . . . . 59
Output Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . 70
Parking Pawl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Pump Oil Seal-Replacement . . . . . . . . . . . . . . . . . 58
Rear Clutch-Recondition . . . . . . . . . . . . . . . . . . . . 61
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Selection of Lubricant . . . . . . . . . . . . . . . . . . . . . . 37
Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . 37
Throttle Pressure Linkage Adjustment . . . . . . . . . . 43
Torqueflite Diagnosis and Tests . . . . . . . . . . . . . . 33
Transaxle and Torque Converter Removal . . . . . . . 46
Transaxle Assembly (Subassembly Installation) . . . 54
Transaxle Disassembly (Subassembly Removal) . . 48
Transfer Shaft Repair . . . . . . . . . . . . . . . . . . . . . . 65
Valve Body Recondition . . . . . . . . . . . . . . . . . . . . 54
GENERAL INFORMATION
when working on these transaxles.
Thi s transaxl e combi nes a torque converter, ful l y
automati c three speed transmi ssi on, fi nal dri ve gear-
i ng, and di fferenti al i nto a compact front-wheel -dri ve
system. The uni t i s basi cal l y a Metri c desi gn. The
i denti fi cati on marki ngs and usage of the transaxl e are
charted i n Di agnosi s and Tests.
Transaxle operation requirements are differ-
ent for each vehicleand enginecombination and
some internal parts will be different to provide
for this. Therefore, whenreplacingparts, refer to
the seven digit part number stamped on rear of
the transaxle oil pan flange.
Wi thi n thi s transaxl e, there are three pri mary areas:
(1) Mai n center l i ne pl us val ve body.
(2) Transfer shaft center l i ne (i ncl udes governor and
parki ng sprag).
(3) Di fferenti al center l i ne. Center di stances be-
tween the mai n rotati ng parts i n these 3 areas are hel d
preci sel y to mai ntai n a l ow noi se l evel through smooth
accurate mesh of the gears connecti ng the center l i nes.
The torque converter, transaxl e area, and di fferenti al
are housed i n an i ntegral al umi num di e casti ng. The
differential oil sumpiscommon with thetran-
saxlesump.Separatefillingof thedifferential is
NOT necessary.
The torque converter i s attached to the crankshaft
through a fl exi bl e dri vi ng pl ate. Cool i ng of the con-
verter i s accompl i shed by ci rcul ati ng the transaxl e
fl ui d through an oi l -to-water type cool er l ocated i n the
radi ator si de tank and/or an oi l -to ai r heat exchanger.
The torque converter assembl y i s a seal ed uni t that
cannot be di sassembl ed.
The transaxl e fl ui d i s fi l tered by an i nternal fi l ter
attached to the l ower si de of the val ve body assembl y.
Engi ne torque i s transmi tted to the torque converter
then, through the i nput shaft to mul ti pl e-di sc cl utches
i n the transaxl e. The power fl ow depends on the
appl i cati on of the cl utches and bands. Refer to El e-
ments i n Use Chart i n Di agnosi s and Tests secti on.
The transaxl e consi sts of two mul ti pl e-di sc cl utches, an
overrunni ng cl utch, two servos, a hydraul i c accumul a-
tor, two bands, and two pl anetary gear sets. Thi s
provi des three forward rati os and a reverse rati o. The
common sun gear of the pl anetary gear sets i s con-
nected to the front cl utch by a dri vi ng shel l . The dri ve
shel l i s spl i ned to the sun gear and to the front cl utch
retai ner. The hydraul i c system consi sts of an oi l pump,
and a si ngl e val ve body whi ch contai ns al l of the val ves
except the governor val ves. The transaxl e sump and
di fferenti al sump are both vented through the di p-
sti ck. Output torque from the mai n center l i ne i s
del i vered through hel i cal gears to the transfer shaft.
Thi s gear set i s a factor of the fi nal dri ve (axl e) rati o.
The shaft al so carri es the governor and parki ng sprag.
An i ntegral hel i cal gear on the transfer shaft dri ves the
di fferenti al ri ng gear. The fi nal dri ve geari ng i s com-
pl eted wi th one of three gear sets produci ng overal l top
gear rati os of 2.78, 3.02, or 3.22 dependi ng on model
and appl i cati on.
21 - 32 TRANSAXLE
LOCKUP TORQUE CONVERTER
The l ockup torque converter i s standard on al l ve-
hi cl es. The l ockup mode i s acti vated onl y i n di rect dri ve
and i s control l ed by the engi ne el ectroni cs. A l ockup
sol enoi d on the val ve body, i s powered by the engi ne
control l er to acti vate torque converter l ockup.
HYDRAULI C CONTROL SYSTEM
The hydraul i c control ci rcui ts show the posi ti on of
the vari ous val ves wi th col or coded passages to i ndi cate
those under hydraul i c pressure for al l operati ons of the
transaxl e.
The hydraul i c control system makes the transaxl e
ful l y automati c, and has four i mportant functi ons to
perform. I n a general way, the components of any
automati c control system may be grouped i nto the
fol l owi ng basi c groups:
The pressure suppl y system, the pressure regul ati ng
val ves, the fl ow control val ves, the cl utches, and band
servos.
Taki ng each of these basi c groups or systems i n turn,
the control system may be descri bed as fol l ows:
PRESSURE SUPPLY SYSTEM
The pressure suppl y system consi sts of an oi l pump
dri ven by the engi ne through the torque converter. The
si ngl e pump furni shes pressure for al l the hydraul i c
and l ubri cati on requi rements. Oil pump housing
assemblies are available with preselected pump
gears.
PRESSURE REGULATI NG VALVES
The pressure regul ati ng val ve control s l i ne pressure
dependent on throttl e openi ng. The governor val ve
transmi ts regul ated pressure to the val ve body (i n
conjuncti on wi th vehi cl e speed) to control upshi ft and
downshi ft.
The throttl e val ve transmi ts regul ated pressure to
the transaxl e (dependent on throttl e posi ti on) to con-
trol upshi ft and downshi ft.
FLOW CONTROL VALVES
The manual val ve provi des the di fferent transaxl e
dri ve ranges as sel ected by the vehi cl e operator.
The 1-2 shi ft val ve automati cal l y shi fts the transaxl e
from fi rst to second or from second to fi rst, dependi ng
on the vehi cl e operati on.
The 2-3 shi ft val ve automati cal l y shi fts the transaxl e
from second to thi rd or from thi rd to second dependi ng
on the vehi cl e operati on.
The ki ckdown val ve makes possi bl e a forced down-
shi ft from thi rd to second, second to fi rst, or thi rd to
fi rst (dependi ng on vehi cl e speed). Thi s can be done by
depressi ng the accel erator pedal past the detent feel
near wi de open throttl e.
The shuttl e val ve has two separate functi ons and
performs each i ndependentl y of the other. The fi rst i s
that of provi di ng fast rel ease of the ki ckdown band,
and smooth front cl utch engagement when the dri ver
makes a l i ft-foot upshi ft from second to thi rd. The
second functi on of the shuttl e val ve i s to regul ate the
appl i cati on of the ki ckdown servo and band when
maki ng thi rd to second ki ckdown.
The by-pass val ve provi des for smooth appl i cati on of
the ki ckdown band on 1-2 upshi fts.
The l ockup sol enoi d al l ows for the el ectroni c control
of the l ockup cl utch i nsi de the torque converter. I t al so
unl ocks the torque converter at cl osed throttl e, duri ng
engi ne warm-up, and duri ng part-throttl e accel erati on.
The swi tch val ve di rects oi l to appl y the l ockup cl utch
i n one posi ti on and rel eases the l ockup cl utch i n the
other posi ti on.
CLUTCHES, BAND SERVOS, AND ACCUMULA-
TOR
The front and rear cl utch pi stons, and both servo
pi stons are moved hydraul i cal l y to engage the cl utches
and appl y the bands. The pi stons are rel eased by
spri ng tensi on when hydraul i c pressure i s rel eased. On
the 2-3 upshi ft, the ki ckdown servo pi ston i s rel eased
by spri ng tensi on and hydraul i c pressure.
The accumul ator control s the hydraul i c pressure on
the appl y si de of the ki ckdown servo duri ng the 1-2
upshi ft; thereby, cushi oni ng the ki ckdown band appl i -
cati on at any throttl e posi ti on.
GEARSHI FT AND PARKI NG LOCK CONTROLS
The transaxl e i s control l ed by a l ever type gearshi ft
i ncorporated wi thi n the steeri ng col umn. The control
has si x sel ector l ever posi ti ons: P (park), R (reverse), N
(neutral ), and D (dri ve), 2 (second), and 1 (fi rst). The
parki ng l ock i s appl i ed by movi ng the sel ector l ever
past a gate to the P posi ti on. Do not apply the
parking lock until the vehicle has stopped; oth-
erwise, a severe ratchet noise will occur.
TORQUEFLITE DIAGNOSIS AND TESTS
Automati c transaxl e mal functi ons may be caused by
four general condi ti ons:
(1) Poor engi ne performance
(2) I mproper adjustments
(3) Hydraul i c mal functi ons
(4) Mechani cal mal functi ons
Di agnosi s of these probl ems shoul d al ways begi n by
checki ng the easi l y accessi bl e vari abl es: fl ui d l evel and
condi ti on, gearshi ft cabl e adjustment, and throttl e
pressure cabl e adjustment. Then perform a road test to
determi ne i f the probl em has been corrected or that
more di agnosi s i s necessary. I f the probl em exi sts after
the prel i mi nary tests and correcti ons are compl eted,
hydraul i c pressure tests shoul d be performed.
TRANSAXLE 21 - 33
21 - 34 TRANSAXLE
TRANSAXLE 21 - 35
FLUID LEVEL AND CONDITION
Thetransmission and differential sump havea
commonoil sumpwithacommunicatingopening
between the two.
Before removi ng the di psti ck, wi pe al l di rt off of the
protecti ve di sc and the di psti ck handl e.
The torque converter fi l l s i n both the P Park and
N Neutral posi ti ons. Pl ace the sel ector l ever i n P
Park to be sure that the fl ui d l evel check i s accurate.
Theengineshouldberunningat idlespeedfor at
least one minute, with the vehicle on level
ground. This will assurecompleteoil level stabi-
lization between differential and transmission.
The fl ui d shoul d be at normal operati ng temperature
(approxi matel y 82 C. or 180 F.). The fl ui d l evel i s
correct i f i t i s i n the HOT regi on (cross-hatched area)
on the di psti ck.
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th the
fl ui d. As i n any hydraul i c system,ai r bubbl es make the
fl ui d spongy, therefore, pressures wi l l be l ow and bui l d
up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transaxl e has too much fl ui d, the gears
churn up foam and cause the same condi ti ons whi ch
occur wi th a l ow fl ui d l evel .
I n ei ther case, the ai r bubbl es can cause overheati ng,
fl ui d oxi dati on, and varni shi ng, whi ch can i nterfere
wi th normal val ve, cl utch, and servo operati on. Foam-
i ng can al so resul t i n fl ui d escapi ng from the transaxl e
vent (di psti ck handl e) where i t may be mi staken for a
l eak.
Al ong wi th fl ui d l evel , i t i s i mportant to check the
condi ti on of the fl ui d. When the fl ui d smel l s burned,
and i s contami nated wi th metal or fri cti on materi al
parti cl es, a compl ete transaxl e overhaul i s needed.
DI AGNOSI S GUI DEABNORMAL NOI SE
21 - 36 TRANSAXLE
Be sure to exami ne the fl ui d on the di psti ck cl osel y. I f
there i s any doubt about i ts condi ti on, drai n out a
sampl e for a doubl e check.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
SELECTION OF LUBRICANT
I t i s i mportant that the proper l ubri cant be used i n
these transmi ssi ons. MOPAR ATF PLUS (Automati c
Transmi ssi on Fl ui d-Type 7176) shoul d be used to ai d i n
assuri ng opti mum transmi ssi on performance. Fl ui ds of
the type l abel ed DEXRON I I Automati c Transmi ssi on
Fl ui d shoul d be used onl y i f the recommended fl ui d i s
not avai l abl e. I f more than a smal l amount of Dexron
fl ui d i s used, shudder or shi ft qual i ty probl ems may be
encountered. I t i s i mportant that the transmi ssi on
fl ui d be mai ntai ned at the prescri bed l evel usi ng the
recommended fl ui ds.
SPECIAL ADDITIVES
Chrysl er Corporati on does not recommend the addi -
ti on of any fl ui ds to the transmi ssi on, other than the
automati c transmi ssi on fl ui d l i sted above. An excep-
ti on to thi s pol i cy i s the use of speci al dyes to ai d i n
detecti ng fl ui d l eaks. The use of transmi ssi on seal ers
shoul d be avoi ded, si nce they may adversel y affect
seal s.
FLUID AND FILTER CHANGE
When the factory fill fluid is changed, only
fluids of the type labeled MOPAR ATF PLUS
(Automatic Transmission fluid) Type7176should
be used. A band adjustment and filter change
shouldbemadeat thetimeof theoil change. The
magnet (insideof oil pan) shouldbecleanedwith
a clean, dry cloth.
If thetransaxleisdisassembled for any reason,
the fluid and filter should be changed, and the
band(s) adjusted.
FLUID DRAIN AND REFILL
(1) Rai se vehi cl e on a hoi st (See Lubri cati on,Group
0). Pl ace a drai n contai ner wi th a l arge openi ng, under
transaxl e oi l pan.
(2) Loosen pan bol ts and tap the pan at one corner to
break i t l oose al l owi ng fl ui d to drai n, then remove the
oi l pan.
(3) I nstal l a new fi l ter and gasket on bottom of the
val ve body and ti ghten retai ni ng screws to 5 Nm (40
i nch-pounds).
(4) Cl ean the oi l pan and magnet. Rei nstal l pan
usi ng new seal ant. Ti ghten oi l pan bol ts to 19 Nm
(165 i n. l bs.).
(5) Pour four quarts of MOPAR ATF PLUS (Auto-
mati c Transmi ssi on Fl ui d) Type 7176 through the
di psti ck openi ng.
(6) Start engi ne and al l ow to i dl e for at l east one
mi nute. Then, wi th parki ng and servi ce brakes ap-
pl i ed, move sel ector l ever momentari l y to each posi -
ti on, endi ng i n the park or neutral posi ti on.
(7) Add suffi ci ent fl ui d to bri ng l evel to 1/8 i nch
bel ow the ADD mark.
Recheck fl ui d l evel after transaxl e i s at normal
operati ng temperature. The l evel shoul d be i n the HOT
regi on (Fi g. 1).
To prevent di rt from enteri ng transaxl e, make cer-
tai n that di psti ck i s ful l seated i nto the di psti ck open-
i ng.
LOCKUP SOLENOID WIRING CONNECTOR
I f wi ri ng connector i s unpl ugged, the torque con-
verter wi l l not l ock-up (Fi g. 2).
ROAD TEST
Pri or to performi ng a road test, be certai n that the
fl ui d l evel and condi ti on, and control cabl e adjustments
have been checked and approved.
Duri ng the road test, the transaxl e shoul d be oper-
ated i n each posi ti on to check for sl i ppi ng and any
vari ati on i n shi fti ng.
I f vehi cl e operates properl y at hi ghway speeds, but
has poor through-gear accel erati on, the torque con-
verter stator overrunni ng cl utch may be sl i ppi ng. I f
through-gear accel erati on i s normal , but abnormal l y
hi gh throttl e openi ng i s requi red to mai ntai n hi ghway
speeds, the torque converter stator cl utch may
Fig. 1 Dipstick and Transaxle Vent
Fig. 2 Lockup Solenoid Wiring Connector
TRANSAXLE 21 - 37
have sei zed. Both of these stator defects requi re re-
pl acement of the torque converter.
Observe cl osel y for sl i ppi ng or engi ne speed fl are-up.
Sl i ppi ng or fl are-up i n any gear usual l y i ndi cates
cl utch, band, or overrunni ng cl utch probl ems. I f the
condi ti on i s far advanced, an overhaul wi l l probabl y be
necessary to restore normal operati on.
I n most cases, the cl utch or band that i s sl i ppi ng can
be determi ned by noti ng the transaxl e operati on i n al l
sel ector posi ti ons. Then compari ng whi ch i nternal
uni ts are appl i ed i n those posi ti ons. The El ements i n
Use Chart provi des a basi s for road test anal ysi s.
The rear cl utch i s appl i ed i n both the D fi rst gear
and 1fi rst gear posi ti ons. Al so the overrunni ng cl utch
i s appl i ed i n D fi rst gear and the l ow/reverse band i s
appl i ed i n 1 fi rst gear posi ti on. I f the transaxl e sl i ps
i n D range fi rst gear, but does not sl i p i n 1 fi rst gear,
the overrunni ng cl utch i s sl i ppi ng. Si mi l arl y, i f the
transaxl e sl i ps i n any two forward gears, the rear
cl utch i s sl i ppi ng.
Usi ng the same procedure, the rear cl utch and front
cl utch are appl i ed i n D thi rd gear. I f the transaxl e
sl i ps i n thi rd gear, ei ther the front cl utch or the rear
cl utch i s sl i ppi ng. By sel ecti ng another gear whi ch does
not use one of those uni ts, the uni t whi ch i s sl i ppi ng
can be determi ned. I f the transaxl e al so sl i ps i n re-
verse, the front cl utch i s sl i ppi ng. I f the transaxl e does
not sl i p i n reverse, the rear cl utch i s sl i ppi ng.
The process of el i mi nati ng can be used to detect any
uni t whi ch sl i ps and to confi rm proper operati on of
good uni ts. However, al though road test anal ysi s can
usual l y di agnose sl i ppi ng uni ts, the actual cause of the
mal functi on usual l y cannot be deci ded. Practi cal l y any
condi ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Therefore, unl ess the condi ti on i s obvi ous, l i ke no
dri ve i n D range fi rst gear onl y, the transaxl e shoul d
never be di sassembl ed unti l hydraul i c pressure tests
have been performed.
HYDRAULIC PRESSURE TESTS
Pressure testi ng i s a very i mportant step i n the
di agnosti c procedure. These tests usual l y reveal the
cause of most transaxl e probl ems.
Before performi ng pressure tests, be certai n that
fl ui d l evel and condi ti on, and control cabl e adjustments
have been checked and approved. Fl ui d must be at
operati ng temperature (150 to 200 degrees F.).
I nstal l an engi ne tachometer, rai se vehi cl e on hoi st
whi ch al l ows front wheel s to turn, and posi ti on ta-
chometer so i t can be read.
Di sconnect throttl e cabl e and shi ft cabl e from tran-
saxl e l evers so they can be control l ed from outsi de the
vehi cl e.
Attach 150 psi gauges to ports requi red for test bei ng
conducted. A 300 psi gauge (C-3293) i s requi red for
reverse pressure test at rear servo.
Test port l ocati ons are shown i n (Fi g. 3).
TEST ONE (SELECTOR I N 1)
(1) Attach gauges to l i ne and l ow-reverse ports
(Fi g. 3).
(2) Operate engi ne at 1000 rpm for test.
(3) Move sel ector l ever on transaxl e al l the way
rearward (1 posi ti on).
(4) Read pressures on both gauges as throttl e l ever
on transaxl e i s moved from ful l cl ockwi se posi ti on to
ful l countercl ockwi se posi ti on.
(5) Li ne pressure shoul d read 52 to 58 psi wi th
throttl e l ever cl ockwi se and gradual l y i ncrease, as
l ever i s moved countercl ockwi se, to 80 to 88 psi .
(6) Low-reverse pressure shoul d read the same as
l i ne pressure wi thi n 3 psi .
(7) Thi s tests pump output, pressure regul ati on, and
condi ti on of rear cl utch and rear servo hydraul i c ci r-
cui ts.
ELEMENTS I N USE AT EACH POSI TI ON OF THE SELECTOR LEVER
21 - 38 TRANSAXLE
TEST TWO (SELECTOR I N 2)
(1) Attach one gauge to l i ne pressure port and tee
another gauge i nto l ower cool er l i ne fi tti ng to read
l ubri cati on pressure (Fi g 3).
(3) Move sel ector l ever on transaxl e one detent
forward from ful l rearward posi ti on. Thi s i s sel ector 2
posi ti on.
l ever i s moved countercl ockwi se, to 80 to 88 psi .
(6) Lubri cati on pressure shoul d be 10 to 25 psi wi th
l ever cl ockwi se and 10 to 35 psi wi th l ever ful l coun-
tercl ockwi se.
condi ti on of rear cl utch and l ubri cati on hydraul i c ci r-
cui ts.
TEST THREE (SELECTOR I N D)
(1) Attach gauges to l i ne and ki ckdown rel ease
ports (Fi g. 3).
(3) Move sel ector l ever on transaxl e two detents
forward from ful l rearward posi ti on. Thi s i s sel ector
D posi ti on.
l ever i s moved countercl ockwi se to 80 to 88 psi .
(6) Ki ckdown rel ease i s pressuri zed onl y i n di rect
dri ve and shoul d be same as l i ne pressure wi thi n 3 psi ,
up to ki ckdown poi nt.
condi ti on of rear cl utch, front cl utch, and hydraul i c
ci rcui ts.
TEST FOUR (SELECTOR I N REVERSE)
(1) Attach 300 psi gauge to l ow-reverse port (Fi g.
3).
(3) Move sel ector l ever on transaxl e four detents
forward from ful l rearward posi ti on. Thi s i s sel ector R
posi ti on.
Fig. 3 Transaxle (Left Side)
TRANSAXLE 21 - 39
(4) Low-reverse pressure shoul d read 180 to 220 psi
wi th throttl e l ever cl ockwi se and gradual l y i ncrease, as
l ever i s moved countercl ockwi se to 260 to 300 psi .
condi ti on of front cl utch and rear servo hydraul i c
ci rcui ts.
(6) Move sel ector l ever on transaxl e to Dposi ti on to
check that l ow-reverse pressure drops to zero.
(7) Thi s tests for l eakage i nto rear servo, due to case
porosi ty, whi ch can cause reverse band burn out.
TEST RESULT I NDI CATI ONS
(1) I f proper l i ne pressure, mi ni mum to maxi mum, i s
found i n any one test, the pump and pressure regul ator
are worki ng properl y.
(2) Low pressure i n D, 1, and 2but correct pressure
i n R i ndi cates rear cl utch ci rcui t l eakage.
(3) Low pressure i n D and Rbut correct pressure i n
1 i ndi cates front cl utch ci rcui t l eakage.
(4) Low pressure i n R and 1 but correct pressure i n
2 i ndi cates rear servo ci rcui t l eakage.
(5) Low l i ne pressure i n al l posi ti ons i ndi cates a
defecti ve pump, a cl ogged fi l ter, or a stuck pressure
regul ator val ve.
GOVERNOR PRESSURE
Test onl y i f transaxl e shi fts at wrong vehi cl e speeds
when throttl e cabl e i s correctl y adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off poi nt, l ocated at l ower ri ght si de of
case, bel ow di fferenti al cover (Fi g. 3).
(2) Operate transaxl e i n thi rd gear to read pres-
sures. The governor pressure shoul d respond smoothl y
to changes i n mph and shoul d return to 0 to 3 psi when
vehi cl e i s stopped. Hi gh pressure at standsti l l (above 3
psi ) wi l l prevent the transaxl e from downshi fti ng.
THROTTLE PRESSURE
No gauge port i s provi ded for throttl e pressure.
I ncorrect throttl e pressure shoul d onl y be suspected i f
part throttl e upshi ft speeds are ei ther del ayed or occur
too earl y i n rel ati on to vehi cl e speeds, wi th correctl y
adjusted throttl e cabl e. Engi ne runaway on ei ther
upshi fts or downshi fts can al so be an i ndi cator of
i ncorrect (l ow) throttl e pressure setti ng, or mi sad-
justed throttl e cabl e.
I n no case shoul d throttl e pressure be adjusted unti l
the transaxl e throttl e cabl e adjustment has been veri -
fi ed to be correct.
CLUTCH AND SERVO AIR PRESSURE TESTS
A no dri ve condi ti on mi ght exi st even wi th correct
fl ui d pressure, because of i noperati ve cl utches or
bands. The i noperati ve uni ts, cl utches, bands, and
servos can be l ocated through a seri es of tests by
substi tuti ng ai r pressure for fl ui d pressure (Fi g. 4).
The front and rear cl utches, ki ckdown servo, and
l ow-reverse servo may be tested by appl yi ng ai r pres-
sure to thei r respecti ve passages after the val ve body
assembl y has been removed. To make ai r pressure
tests, proceed as fol l ows:
Compressed air supply must be free of all dirt
or moisture. Use a pressure of 30 psi.
Remove oi l pan and val ve body See Di sassembl y-
Subassembl y Removal .
FRONT CLUTCH
Appl y ai r pressure to front cl utch appl y passage
and l i sten for a dul l thud whi ch i ndi cates that front
cl utch i s operati ng. Hol d ai r pressure on for a few
seconds and i nspect system for excessi ve oi l l eaks.
REAR CLUTCH
Appl y ai r pressure to rear cl utch appl y passage and
l i sten for a dul l thud whi ch i ndi cates that rear cl utch
i s operati ng. Al so i nspect for excessi ve oi l l eaks. I f a
dul l thudcannot be heard i n the cl utches, pl ace fi nger
ti ps on cl utch housi ng and agai n appl y ai r pressure.
Movement of pi ston can be fel t as the cl utch i s appl i ed.
KI CKDOWN SERVO (FRONT)
Di rect ai r pressure i nto KI CKDOWN SERVO ON
passage. Operati on of servo i s i ndi cated by a ti ghteni ng
of front band. Spri ng tensi on on servo pi ston shoul d
rel ease the band.
LOW AND REVERSE SERVO (REAR)
Di rect ai r pressure i nto LOW-REVERSE SERVO
APPLY passage. Operati on of servo i s i ndi cated by a
ti ghteni ng of rear band. Spri ng tensi on on servo pi ston
shoul d rel ease the band.
I f cl utches and servos operate properl y, no upshi ft
or errati c shi ft condi ti ons i ndi cate that mal functi ons
exi st i n the val ve body.
FLUID LEAKAGE-TRANSAXLE TORQUE CON-
VERTER HOUSING AREA
(1) Check for Source of Leakage.
Si nce fl ui d l eakage at or around the torque converter
area may ori gi nate from an engi ne oi l l eak, the area
shoul d be exami ned cl osel y. Factory fi l l fl ui d i s dyed
red and, therefore, can be di sti ngui shed from engi ne
oi l .
(2) Pri or to removi ng the transaxl e, perform the
fol l owi ng checks:
When l eakage i s determi ned to ori gi nate from the
transaxl e, check fl ui d l evel pri or to removal of the
transaxl e and torque converter.
21 - 40 TRANSAXLE
Hi gh oi l l evel can resul t i n oi l l eakage out the vent i n
the di psti ck. I f the fl ui d l evel i s hi gh, adjust to proper
l evel .
After performi ng thi s operati on, i nspect for l eakage.
I f a l eak persi sts, perform the fol l owi ng operati on on
the vehi cl e to determi ne i f i t i s the torque converter or
transaxl e that i s l eaki ng.
LEAKAGE TEST PROBE
(1) Remove torque converter housi ng dust shi el d.
(2) Cl ean the i nsi de of torque converter housi ng
(l ower area) as dry as possi bl e. A sol vent spray fol l owed
by compressed ai r dryi ng i s preferabl e.
(3) Fabri cate and fasten test probe (Fi g. 5) securel y
to conveni ent dust shi el d bol t hol e. Make certai n
torque converter i s cl eared by test probe. Tool must be
cl ean and dry.
(4) Run engi ne at approxi matel y 2,500 rpm wi th
transaxl e i n neutral , for about 2 mi nutes. Transaxl e
must be at operati ng temperature.
(5) Stop engi ne and careful l y remove tool .
(6) I f upper surface of test probe i s dry, there i s no
torque converter l eak. A path of fl ui d across probe
i ndi cates a torque converter l eak. Oi l l eaki ng under the
probe i s comi ng from the transaxl e pump area.
(7) Remove transaxl e and torque converter assembl y
from vehi cl e for further i nvesti gati on.The fl ui d shoul d
be drai ned from the transaxl e. Rei nstal l oi l pan (wi th
Mopar Si l i cone Rubber Adhesi ve Seal ant or equi va-
l ent) at speci fi ed torque.
Possi bl e sources of transaxl e torque converter area
fl ui d l eakage are:
(1) Torque converter hub seal .
Seal l i p cut, check torque converter hub fi ni sh.
Bushi ng moved and/or worn.
Oi l return hol e i n pump housi ng pl ugged or omi tted.
Seal worn out (hi gh-mi l eage vehi cl es).
Fig. 4 Air Pressure Tests
Fig. 5 Leak Locating Test Probe Tool
TRANSAXLE 21 - 41
(2) Fl ui d l eakage at the outsi de di ameter from pump
housi ng O-ri ng.
(3) Fl ui d l eakage at the pump to case bol ts. Check
condi ti on of washers on bol ts and use new bol ts i f
necessary.
(4) Fl ui d l eakage due to case or pump housi ng po-
rosi ty.
TORQUE CONVERTER LEAKAGE
Possi bl e sources of torque converter l eakage are:
Torque converter wel d l eaks at the outsi de di ameter
(peri pheral ) wel d.
Torque converter hub wel d.
Torque converter i mpel l er shel l cracked adjacent to
hub.
At dri ve l ug wel ds.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
AI R PRESSURE TEST OF TRANSAXLE
Fabri cate equi pment needed for test as shown i n
fi gures 6 and 7.
The transaxl e shoul d be prepared for pressure test as
fol l ows after removal of the torque converter:
(1) I nstal l a di psti ck bore pl ug and pl ug oi l cool er
l i ne fi tti ng (l ower fi tti ng).
(2) Wi th rotary moti on, i nstal l converter hub seal
cup over i nput shaft, and through the converter hub
seal unti l the cup bottoms agai nst the pump gear l ugs.
Before use, i nspect hub seal cup (Fi g. 6) for ni cks or
burrs that coul d damage seal . Secure wi th cup retai ner
strap (Fi g. 7) usi ng starter upper hol e and opposi te
bracket hol e.
(3) Attach and cl amp hose from nozzl e of Tool C-4080
to the upper cool er l i ne fi tti ng posi ti on i n case.
CAUTION: Do not, under any circumstances, pressur-
ize a transaxle to more than 10 psi.
(4) Pressuri ze the transaxl e usi ng Tool C-4080 unti l
the pressure gauge reads 8 psi . Posi ti on transaxl e so
that pump housi ng and case front may be covered wi th
soapy sol uti on or water. Leaks are someti mes caused
by porosi ty i n the case or pump housi ng.
I f a l eak source i s l ocated, that part and al l associ -
ated seal s, O-ri ngs, and gaskets shoul d be repl aced
wi th new parts.
Fig. 6 Torque Converter Hub Seal Cup
Fig. 7 Hub Seal Cup Retaining Strap
21 - 42 TRANSAXLE
GEARSHIFT LINKAGE ADJUSTMENT
Normal operati on of the neutral safety swi tch pro-
vi des a qui ck check to confi rm proper manual l i nkage
adjustment.
Move the sel ector l evel sl owl y upward unti l i t cl i cks
i nto the P Park notch i n the sel ector gate. I f the
starter wi l l operate, the P posi ti on i s correct.
After checki ng P posi ti on, move the sel ector sl owl y
toward N Neutral posi ti on unti l l ever drops at the
end of the N stop. I f the starter wi l l al so operate at
thi s poi nt the gearshi ft l i nkage i s properl y adjusted. I f
the starter fai l s to operate i n ei ther posi ti on, l i nkage
adjustment i s requi red.
CAUTION: When it is necessary to disassemble link-
age cable from levers, which use plastic grommets as
retainers, the grommets should be replaced with new
grommets. Use a prying tool to force rod from grom-
met in lever, then cut away old grommet. Use pliers to
snap new grommet into lever and rod into grommet.
(2) Pl ace gearshi ft l ever i n P (PARK) posi ti on.
(3) Loosen cl amp bol t on gearshi ft cabl e bracket.
(4) Col umn shi ft: I nsure that prel oad adjustment
spri ng engages fork on transaxl e bracket.
(5) Pul l the shi ft l ever by hand al l the way to the
front detent posi ti on (PARK) and ti ghten l ock. Ti ghten
screw to 11 Nm (100 i n. l bs.). Gearshi ft l i nkage shoul d
now be properl y adjusted.
(6) Check adjustment as fol l ows:
(a) Detent posi ti on for neutral and dri ve shoul d be
wi thi n l i mi ts of hand l ever gate stops.
(b) Key start must occur onl y when shi ft l ever i s i n
park or neutral posi ti ons.
(7) I f consol e removal i s requi red, di sconnect battery
ground cabl e. To remove button assembl y, i nsert a 1/16
i nch di ameter wi re i n hol e i n bottom of knob and push
up on wi re. To remove knob retai ner cl i p, i nsert l ong-
nose pl i er ti ps i n cl i p hol es, push downward l i ghtl y and
turn countercl ockwi se (acti on si mi l ar to a l i ght bul b
socket). Pul l knob strai ght up to remove from gearshi ft
l ever. Proceed as outl i ned i n consol e removal ,Group
23.
After consol e i s back i n pl ace, i nstal l shi ft knob and
button by reversi ng the above procedure.
(8) To remove button assembl y, compl etel y remove
knob attachi ng fasteners. Pul l knob up sharpl y. Pro-
ceed as outl i ned i n consol e removal , Group 23.
After consol e i s back i n pl ace, i nstal l knob and button
by reversi ng the above procedure.
THROTTLE PRESSURE LINKAGE ADJUSTMENT
The throttl e pressure cabl e adjustment i s very i m-
portant to proper transaxl e operati on. Thi s adjustment
posi ti ons a val ve whi ch control s shi ft speed, shi ft
qual i ty, and part throttl e downshi ft sensi ti vi ty. I f the
setti ng i s too l ong, earl y shi fts and sl i ppage between
shi fts may occur. I f the setti ng i s too short, shi fts may
be del ayed and part throttl e downshi fts may be very
sensi ti ve.
Wi th engi ne at operati ng temperature, adjust i dl e
speed of engi ne usi ng a tachometer. Refer to Fuel
System Group 14 for i dl e speed Speci fi cati ons and
adjustment.
CABLE ADJUSTMENT PROCEDURE (4-CYL.)
(1) Perform transaxl e throttl e pressure cabl e adjust-
ment whi l e engi ne i s at normal operati ng temperature.
(2) Loosen cabl e mounti ng bracket l ock screw.
(3) Bracket shoul d be posi ti oned wi th both bracket
al i gnment tabs touchi ng the transaxl e cast surface.
Ti ghten l ock screw to 12 Nm (105i n. l bs.) see Fi gure 8.
(4) Rel ease cross-l ock on the cabl e assembl y (pul l
cross-l ock upward) see Fi gure 8.
(5) To i nsure proper adjustment, the cabl e must be
free to sl i de al l the way toward the engi ne, agai nst i ts
stop, after the cross-l ock i s rel eased.
(6) Move transaxl e throttl e control l ever ful l y cl ock-
wi se, agai nst i ts i nternal stop, and press cross-l ock
downward i nto l ocked posi ti on.
(7) The adjustment i s compl ete and transaxl e
throttl e cabl e backl ash was automati cal l y removed.
(8) Test cabl e freedom of operati on by movi ng the
transaxl e throttl e l ever forward (countercl ockwi se) and
sl owl y rel ease i t to confi rm i t wi l l return ful l y rearward
(cl ockwi se).
(9) No l ubri cati on i s requi red for any component of
the throttl e cabl e system.
ROD ADJUSTMENT PROCEDURE (6-CYL.)
(1) Perform transaxl e throttl e pressure cabl e adjust-
ment whi l e engi ne i s at normal operati ng temperature.
(2) Loosen adjustment swi vel l ock screw.
(3) To i nsure proper adjustment, swi vel must be free
to sl i de al ong fl at end of throttl e rod so that pre-
Fig. 8 Throttle Pressure Cable (Typical)
TRANSAXLE 21 - 43
l oad spri ng acti on i s not restri cted. Di sassembl e and
cl ean or repai r parts to assure free acti on, i f necessary.
(4) Hol d transaxl e throttl e l ever fi rml y toward en-
gi ne, agai nst i ts i nternal stop and ti ghten swi vel l ock
screw to 11 Nm (100 i n. l bs.)
(5) The adjustment i s fi ni shed and l i nkage back l ash
was automati cal l y removed by the prel oad spri ng.
(6) I f l ubri cati on i s requi red see Lubri cati on, Group
0.
BAND ADJUSTMENT
KI CKDOWN BAND (FRONT)
The ki ckdown band adjusti ng screw i s l ocated on l eft
si de (top front) of the transaxl e case.
(1) Loosen l ocknut and back off nut approxi matel y
fi ve turns. Test adjusti ng screw for free turni ng i n the
transaxl e case.
(2) Usi ng wrench, Tool C-3880-A wi th adapter Tool
C-3705, ti ghten band adjusti ng screw to 5 Nm (47 to
50 i n. l bs.). I f adapter C-3705 i s not used, ti ghten
adjusti ng screw to 8 Nm (72 i n. l bs.) whi ch i s the true
torque.
(3) Back off adjusti ng screw the number of turns
l i sted i n Speci fi cati ons. Hol d adjusti ng screw i n thi s
posi ti on and ti ghten l ocknut to 47 Nm (35ft. l bs.)
LOW/REVERSE BAND (REAR)
To adjust l ow-reverse band, proceed as fol l ows:
(1) Loosen and back off l ocknut approxi matel y 5
turns.
(2) Usi ng an i nch-pound torque wrench, ti ghten ad-
justi ng screw to 5 Nm (41 i n. l bs.) true torque.
(3) Back off adjusti ng screw the number of turns
l i sted under Speci fi cati ons i n the rear of the Tran-
saxl e Secti on i n thi s servi ce manual .
(4) Ti ghten l ocknut to 14 Nm (10 ft. l bs.).
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LI NE PRESSURE
An i ncorrect throttl e pressure setti ng wi l l cause
i ncorrect l i ne pressure readi ngs even though l i ne pres-
sure adjustment i s correct. Al ways i nspect and correct
throttl e pressure adjustment before adjusti ng the l i ne
pressure.
The approxi mate adjustment for l i ne pressure i s
1-5/16 i nches, measured from val ve body to i nner edge
of adjusti ng nut. However, due to manufacturi ng tol er-
ances, the adjustment can be vari ed to obtai n speci fi ed
l i ne pressure.
The adjusti ng screw may be turned wi th an Al l en
wrench. One compl ete turn of adjusti ng screw changes
cl osed throttl e l i ne pressure approxi matel y 1-2/3 psi .
Turni ng adjusti ng screw countercl ockwi se i ncreases
pressure, and cl ockwi se decreases pressure.
THROTTLE PRESSURE
Throttl e pressures cannot be tested accuratel y;
therefore, the adjustment shoul d be measured i f a
mal functi on i s evi dent.
(1) I nsert gauge pi n of Tool C-3763 between the
throttl e l ever cam and ki ckdown val ve.
(2) By pushi ng i n on tool , compress ki ckdown val ve
agai nst i ts spri ng so throttl e val ve i s compl etel y bot-
tomed i nsi de the val ve body.
(3) Whi l e compressi ng spri ng, turn throttl e l ever
stop screw wi th adapter C-4553. Turn unti l head of
screw touches throttl e l ever tang, wi th throttl e l ever
cam touchi ng tool and throttl e val ve bottomed. Be sure
adjustment i s made wi th spri ng ful l y compressed and
val ve bottomed i n the val ve body.
DISTANCE SENSOR PINION GEAR
When the di stance sensor i s removed for any reason,
a NEW O-ri ng must be i nstal l ed on i ts outsi de di am-
eter.
(1) Remove speedometer cabl e (i f so equi pped).
(2) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(3) Remove bol t securi ng the di stance sensor i n the
extensi on housi ng.
(4) Careful l y pul l sensor and pi ni on gear assembl y
out of extensi on housi ng.
(6) To i nstal l , reverse the above procedure. Make
sure extensi on housi ng and sensor fl ange are cl ean
pri or to i nstal l ati on. Al ways use a NEW sensor O-ri ng.
(7) Ti ghten securi ng bol t to 7 Nm (60 i n. l bs.).
Ti ghten speedometer cabl e to 4 Nm (35 i n. l bs.).
NEUTRAL STARTING AND BACK-UP LAMP SWITCH
REPLACEMENT AND TEST
The neutral starti ng swi tch i s the center termi nal of
the 3 termi nal swi tch. I t provi des ground for the
starter sol enoi d ci rcui t through the sel ector l ever i n
onl y Park and Neutral posi ti ons.
(1) To test swi tch, remove wi ri ng connector from
swi tch and test for conti nui ty between center pi n of
swi tch and transaxl e case. Conti nui ty shoul d exi st onl y
when transaxl e i s i n Park or Neutral .
(2) Check gearshi ft cabl e adjustment before repl ac-
i ng a swi tch whi ch tests bad.
(3) Unscrew swi tch from transaxl e case al l owi ng
fl ui d to drai n i nto a contai ner. Move sel ector l ever to
Park and then to Neutral posi ti ons, and i nspect to see
that the swi tch operati ng l ever fi ngers are centered i n
swi tch openi ng i n the case.
21 - 44 TRANSAXLE
(4) Screw the swi tch wi th a new seal i nto transaxl e
case and ti ghten to 33 Nm (24 ft. l bs.). Retest swi tch
wi th the test l amp.
(5) Add fl ui d to transaxl e to bri ng up to proper l evel .
(6) The back-up l amp swi tch ci rcui t i s through the
two outsi de termi nal s of the 3 termi nal swi tch.
(7) To test swi tch, remove wi ri ng connector from
swi tch and test for conti nui ty between the two outsi de
pi ns.
(8) Conti nui ty shoul d exi st onl y wi th transaxl e i n
Reverse posi ti on.
(9) No conti nui ty shoul d exi st from ei ther pi n to the
case.
GOVERNOR
To servi ce the governor assembl y i n the vehi cl e, i t i s
not necessary to remove the transfer gear cover, trans-
fer gear, and governor support. The governor may be
servi ced by removi ng the transaxl e oi l pan and val ve
body assembl y. Wi th the oi l pan and val ve body re-
moved, the governor may be unbol ted from the gover-
nor support and removed from the transaxl e for recon-
di ti oni ng or repl acement.
When cl eani ng or assembl i ng the governor, make
sure the governor val ves move freel y i n the bores of the
governor body.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num tran-
saxl e case and val ve body can be repai red by the use of
Hel i -Coi l s, or equi val ent. Thi s repai r consi sts of dri l l -
i ng out the worn-out damaged threads. Then tappi ng
the hol e wi th a Hel i -Coi l tap, or equi val ent, and i nstal l -
i ng a Hel i -Coi l i nsert, or equi val ent, i nto the hol e. Thi s
bri ngs the hol e back to i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are readi l y
avai l abl e from most automoti ve parts suppl i ers.
OIL COOLERS AND TUBES REVERSE FLUSHING
When a transaxl e fai l ure has contami nated the fl ui d,
the oi l cool er(s) must be fl ushed and the cool er bypass
val ve i n the transaxl e must be repl aced. The torque
converter must al so be repl aced wi th an exchange uni t.
Thi s wi l l i nsure that metal parti cl es or sl udged oi l are
not transferred back i nto the recondi ti oned (or re-
pl aced) transaxl e.
CAUTION: If vehicle is equipped with two oil coolers
(one in the radiator tank, one in front of the radiator)
they must be flushed separately. Do not attempt to
flush both coolers at one time.
(1) Di sconnect the cool er l i nes at the transmi ssi on.
(2) Usi ng a hand sucti on gun fi l l ed wi th mi neral
spi ri ts, reverse fl ush the cool er by forci ng mi neral
spi ri ts i nto the FromCooler l i ne of the cool er (Fi g. 1).
Catch the exi ti ng spi ri ts from the To Cooler l i ne.
Observe for the presence of debri s i n the exi ti ng fl ui d.
Conti nue unti l fl ui d exi ti ng i s cl ear and free from
debri s.
(3) Usi ng compressed ai r i n i ntermi ttent spurts,
bl ow any remai ni ng mi neral spi ri ts from the cool er,
agai n i n the reverse di recti on.
(4) To remove any remai ni ng mi neral spi ri ts from
the cool er, one (1) quart of automati c transmi ssi on fl ui d
shoul d be pumped through the cool er before reconnect-
i ng.
(5) I f at any stage of the cl eani ng process, the cool er
does not freel y pass fl ui d, the cool er must be repl aced.
OIL COOLER FLOW CHECK
After the new or repai red transmi ssi on has been
i nstal l ed and fi l l ed to the proper l evel wi th automati c
transmi ssi on fl ui d, the fl ow shoul d be checked usi ng
the fol l owi ng procedure:
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f the fl ui d fl ow i s i ntermi ttent or i t takes more
than 20 seconds to col l ect one quart of automati c
transmi ssi on fl ui d, the cool er shoul d be repl aced.
CAUTION: With the fluid set at the proper level, fluid
collection should not exceed (1) quart or internal
damage to the transmission may occur.
(4) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
reconnect the cool er l i ne and fi l l transmi ssi on to the
proper l evel , usi ng the approved type of automati c
transmi ssi on fl ui d.
Fig. 1 Cooler Line Identification
TRANSAXLE 21 - 45
TRANSAXLE AND TORQUE CONVERTER REMOVAL
Transaxle removal does NOT require engine
removal.
(1) The transaxl e and torque converter must be
removed as an assembl y; otherwi se, the torque con-
verter dri ve pl ate, pump bushi ng, or oi l seal may be
damaged. The dri ve pl ate wi l l not support a l oad;
therefore, none of the wei ght of the transaxl e shoul d be
al l owed to rest on the pl ate duri ng removal .
(2) Di sconnect or connect negative battery cabl e.
(3) Di sconnect or connect throttl e l i nkage and shi ft
l i nkage from transaxl e.
If soequipped, unpluglockuptorqueconverter
plug, located near the dipstick.
CAUTION: Raise vehicle. Remove front wheels. Refer
to Suspension, Group 2 to remove or install wheel
hub nut and both drive shafts.
Remove torque converter dust cover. Mark
torque converter and drive plate with chalk, for
reassembly. Remove torque converter mounting
bolts.
Fig. 1 Remove Upper and Lower Oil Cooler Hoses
Fig. 2 Engine Support Fixture (Typical)
Fig. 3 Remove Bell Housing Upper Bolts
Fig. 4 Remove or Install Left Splash Shield
Fig. 5 Remove or Install Access Plug in Right
Splash Shield to Rotate Engine Crankshaft
21 - 46 TRANSAXLE
Remove or i nstal l starter. Remove or i nstal l l ower
bel l housi ng bol ts.
Fig. 6 Remove or Install Wire to Neutral/Park Safety
Switch
Fig. 7 Remove or Install Engine Mount Bracket from
Front Crossmember
Fig. 8 Remove or Install Front Mount Insulator
Through-Bolt and Bell Housing Bolts
Fig. 9 Positioning Transmission Jack
Fig. 10 Remove or Install Left Engine Mount
Fig. 11 Remove or Install Left Engine Mount from
Engine
TRANSAXLE 21 - 47
Careful l y work transaxl e and torque converter as-
sembl y rearward off engi ne bl ock dowel s and
di sengage converter hub from end of crankshaft. At-
tach a small C clamp to edge of bell housing.
This will hold torque converter in place during
transaxle removal. Lower transaxl e and remove as-
sembl y from under the vehi cl e.
When i nstal l i ng transaxl e, reverse the above procedure.
To remove torque converter assembl y, remove C
cl amp from edge of bel l housi ng and sl i de converter out
of transaxl e.
I f torque converter was removed from transaxl e be
sure to al i gn pump i nner gear pi l ot fl ats wi th torque
converter i mpel l er hub fl ats.
Adjust gearshi ft and throttl e cabl es.
Refi l l transaxl e wi th MOPAR ATF PLUS (Auto-
mati c Transmi ssi on Fl ui d) Type 7176.
TRANSAXLE DISASSEMBLY (SUBASSEMBLY RE-
MOVAL)
Pri or to removi ng any transaxl e subassembl i es, pl ug
al l openi ngs and thoroughl y cl ean exteri or of the uni t,
preferabl y by steam. Cl eanl i ness through enti re di sas-
sembl y and assembl y cannot be overemphasi zed. When
di sassembl i ng, each part shoul d be washed i n a sui t-
abl e sol vent, then dri ed by compressed ai r. Do not wi pe
parts wi th shop towel s. Al l mati ng surfaces i n the
transaxl es are accuratel y machi ned; therefore, careful
handl i ng of al l parts must be exerci sed to avoi d ni cks or
burrs.
Remove al l ol d seal ant before appl yi ng new seal ant.
Use onl y Mopar Si l i cone Rubber Seal ant or equi va-
l ent when i nstal l i ng oi l pan.
Put seal ant on the oi l pan fl ange (Fi g. 2) and on al l oi l
pan bol ts (undersi de of bol t head).
Remove or i nstal l neutral starti ng and back-up l amp
swi tch.
Measuri ng i nput shaft end pl ay before di sassembl y
wi l l usual l y i ndi cate when a thrust washer change i s
requi red, (except when major parts are repl aced). The
thrust washer i s l ocated between i nput and output
shafts.
Attach a di al i ndi cator to transaxl e bel l housi ng wi th
i ts pl unger seated agai nst end of i nput shaft (Fi g. 9).
Fig. 12 Raise or Lower Transaxle
Fig. 13 Pry Engine for Clearance
Fig. 1 Transaxle Oil Pan Bolts
Fig. 2 Transaxle Oil Pan
21 - 48 TRANSAXLE
Fig. 3 Oil Filter Screws
Fig. 4 Oil Filter
Fig. 5 Remove or Install Parking Rod E-Clip
Fig. 6 Parking Rod
Fig. 7 Valve Body Attaching Bolts
Fig. 8 Valve Body and Governor Tubes
TRANSAXLE 21 - 49
Move i nput shaft i n and out to obtai n end pl ay
readi ng. End pl ay speci fi cati ons are 0.19 to 1.50 mm
(.008 to .060 i nch).
Record i ndi cator readi ng for reference when reas-
sembl i ng the transaxl e.
Fig. 9 Measure Input Shaft End Play
Fig. 10 Loosen Lock Nut and Tighten Kickdown
Band Adjusting Screw
Fig. 11 Pump Attaching Bolts
Fig. 12 Install Tool C-3752 with Adapters L-4437
Fig. 13 Oil Pump with No. 1 Thrust Washer
Fig. 14 Oil Pump Gasket
21 - 50 TRANSAXLE
CAUTION: The input shaft for non-lockup torque
converter has 2 seal rings. The lockup input shaft has
three seal rings.
Fig. 15 Loosen Kickdown Band Adjusting Screw
Fig. 16 Kickdown Band and Strut
Fig. 17 Front Clutch Assembly
Fig. 18 No. 2 Thrust Washer and Rear Clutch
Fig. 19 No. 3 Thrust Washer
Fig. 20 Front Planetary Gear Snap Ring
TRANSAXLE 21 - 51
Fig. 21 Front Planetary Gear Assembly
Fig. 23 Sun Gear Driving Shell
Fig. 24 Sun Gear Driving Shell Components
Fig. 26 Rear Planetary Gear Assembly
21 - 52 TRANSAXLE
Fig. 28 Overrunning Clutch Cam Assembly
Fig. 29 Overrunning Clutch Rollers and Springs
Fig. 30 Loosen or Adjust Low-Reverse Band
Fig. 31 Low-Reverse Band and Strut
TRANSAXLE 21 - 53
TRANSAXLE ASSEMBLY (SUBASSEMBLY INSTAL-
LATION)
When rebui l di ng, reverse the above procedure.
VALVE BODY RECONDITION
Tighten all valve body screws to 5 Nm (40 in.
lbs.)
Do not cl amp any porti on of val ve body or transfer
pl ate i n a vi se. Any sl i ght di storti on of the al umi num
body or transfer pl ate wi l l resul t i n sti cki ng val ves,
excessi ve l eakage or both. When removing or in-
stalling valves or plugs, slide them in or out
carefully. Do not use force.
TAG ALL SPRINGS AS THEY ARE REMOVED
FOR REASSEMBLY IDENTIFICATION.
Al l ow al l parts to soak a few mi nutes i n a sui tabl e
cl ean sol vent. Wash thoroughl y and bl ow dry wi th
compressed ai r. Make sure al l passages are cl ean and
free from obstructi ons.
I nspect manual and throttl e val ve operati ng l evers
and shafts for bei ng bent, worn or l oose. I f a l ever i s
l oose on i ts shaft, i t shoul d be repl aced. Do not attempt
to strai ghten bent l evers.
I nspect al l mati ng surfaces for burrs, ni cks and
scratches. Mi nor bl emi shes may be removed wi th cro-
cus cl oth, usi ng onl y a very l i ght pressure. Usi ng a
strai ghtedge, i nspect al l mati ng surfaces for warpage
or di storti on. Sl i ght di storti on may be corrected, usi ng
a surface pl ate. Make sure al l meteri ng hol es i n steel
pl ate are open. Usi ng a pen l i ght, i nspect bores i n val ve
body for scores, scratches, pi ts and i rregul ari ti es.
I nspect al l val ve spri ngs for di storti on and col l apsed
coi l s. I nspect al l val ves and pl ugs for burrs, ni cks, and
scores. Smal l ni cks and scores may be removed wi th
crocus cl oth, provi di ng extreme care i s taken not to
round off sharp edges. The sharpness of these edges i s
vi tal l y i mportant because i t prevents forei gn matter
from l odgi ng between val ve and val ve body, thus reduc-
i ng possi bi l i ty of sti cki ng. I nspect al l val ves and pl ugs
for freedom of operati on i n val ve body bores.
When bores, val ves, and pl ugs are cl ean and dry, the
val ves and pl ugs shoul d fal l freel y i n the bores. The
val ve body bores do not change i ts di mensi ons wi th
use. Therefore, a val ve body that was functi oni ng
properl y when vehi cl e was new, wi l l operate correctl y i f
i t i s properl y and thoroughl y cl eaned. There i s no need
to repl ace val ve body unl ess i t i s damaged i n handl i ng.
Fig. 33 Install Overrunning Clutch Rollers and
Springs
Fig. 1 Detent Spring Attaching Screw and Spring
Fig. 2 Using Tool L-4553 on Valve Body Screws
21 - 54 TRANSAXLE
Fig. 3 Remove or Install Valve Body Screws
Fig. 4 Transfer Plate and Separator Plate
Fig. 5 Steel Ball Locations
Fig. 6 Remove or Install Throttle Shaft E-Clip
Fig. 7 Throttle Shaft E-Clip, Washer, and Seal
Fig. 8 Manual Valve Lever Assembly
TRANSAXLE 21 - 55
Fig. 9 Throttle Valve Lever Assembly
Fig. 10 Manual Valve
Fig. 11 Pressure Regulator and Adjusting Screw
Bracket
Fig. 12 Pressure Regulators and Manual Controls
21 - 56 TRANSAXLE
Fig. 13 Governor Plugs
Fig. 14 Pressure Regulator Valve Plugs
TRANSAXLE 21 - 57
PUMP OIL SEAL-REPLACEMENT
The pump oi l seal can be repl aced wi thout removi ng
the pump and reacti on shaft support assembl y from
the transaxl e case.
(1) Screw seal remover Tool C-3981 i nto seal (Fi g. 1),
then ti ghten screw porti on of tool to wi thdraw the seal .
(2) To i nstal l a new seal , pl ace seal i n openi ng of the
pump housi ng (l i p si de faci ng i nward). Usi ng Tool
C-4193 and Handl e Tool C-4, dri ve new seal i nto
housi ng unti l tool bottoms (Fi g. 2).
Fig. 15 Shift Valves and Shuttle Valve
Fig. 1 Remove Pump Oil Seal
Fig. 2 Install Pump Oil Seal
21 - 58 TRANSAXLE
OIL PUMP-RECONDITION
FRONT CLUTCH-RECONDITION
I NSPECTI ON
I nspect pl ates and di scs for fl atness. They must not
be warped or cone shaped.
I nspect faci ng materi al on al l dri vi ng di scs. Repl ace
di scs that are charred, gl azed or heavi l y pi tted. Di scs
shoul d al so be repl aced i f they show evi dence of mate-
ri al fl aki ng off or i f faci ng materi al can be scraped off
easi l y. I nspect dri vi ng di sc spl i nes for wear or other
damage. I nspect steel pl ate surfaces for burni ng, scor-
i ng, or damaged dri vi ng l ugs. Repl ace i f necessary.
Also, check gear side clearance with a straight
edge and a feeler gauge (See Specifications).
I nspect steel pl ate l ug grooves i n cl utch retai ner for
smooth surfaces, pl ates must travel freel y i n grooves.
I nspect band contacti ng surface on cl utch retai ner for
scores, the contact surface shoul d be protected from
damage duri ng di sassembl y and handl i ng. Note bal l
check i n cl utch retai ner, make sure bal l moves freel y.
I nspect pi ston seal surfaces i n cl utch retai ner for ni cks
or deep scratches, l i ght scratches wi l l not i nterfere
wi th seal i ng of seal s. I nspect cl utch retai ner i nner bore
surface for wear from reacti on shaft support seal ri ngs.
I nspect cl utch retai ner bushi ng for wear or scores.
I nspect i nsi de bore of pi ston for score marks, i f l i ght,
remove wi th crocus cl oth. I nspect seal grooves for ni cks
and burrs. I nspect seal s for deteri orati on, wear, and
hardness. I nspect pi ston spri ng, retai ner and snap ri ng
for di storti on.
Fig. 3 Reaction Shaft Support Bolts
Fig. 4 Reaction Shaft Support
Fig. 5 Inner and Outer Pump Gears
Fig. 6 Measuring Pump Clearance (Gear to Pocket)
TRANSAXLE 21 - 59
DI SASSEMBLE/ASSEMBLE
MEASURI NG PLATE CLEARANCE
To reassembl e, reverse the above procedure.
Fig. 1 Front Clutch Waved Snap Ring
Fig. 2 Thick Steel Plate and Waved Snap Ring
Fig. 3 Front Clutch (3-Disc Shown)
Fig. 4 Front Clutch Return Spring Snap Ring
Fig. 5 Front Clutch Return Spring and Piston
Fig. 6 Measuring Front Clutch Plate Clearance
21 - 60 TRANSAXLE
REAR CLUTCH-RECONDITION
I NSPECTI ON
I nspect faci ng materi al on al l dri vi ng di scs. Repl ace
di scs that are charred, gl azed or heavi l y pi tted. Di scs
shoul d al so be repl aced i f they show evi dence of mate-
ri al fl aki ng off or i f faci ng materi al can be scraped off
easi l y. I nspect dri vi ng di sc spl i nes for wear or other
damage. I nspect steel pl ate and pressure pl ate surface
for burni ng, scori ng or damaged dri vi ng l ugs. Re pl ace
i f necessary. I nspect pl ates and di scs for fl atness, they
must not be warped or cone-shaped.
I nspect steel pl ate l ug grooves i n cl utch retai ner for
smooth surfaces, pl ates must travel freel y i n the
grooves. Note bal l check i n pi ston; make sure bal l
moves freel y. I nspect seal ri ngs surfaces i n cl utch
retai ner for ni cks or deep scratches; l i ght scratches wi l l
not i nterfere wi th seal i ng of the seal s. I nspect neo-
prene seal ri ngs for deteri orati on, wear and hardness.
I nspect pi ston spri ng and waved snap ri ng for di stor-
ti on or breakage.
I nspect tefl on and/or cast i ron seal ri ngs on i nput
shaft for wear. Do not remove ri ngs unl ess condi ti ons
warrant. I nspect rear cl utch to front cl utch No. 2
thrust washer for wear. Washer thi ckness shoul d be
.061 to .063 i nch, repl ace i f necessary.
DI SASSEMBLE/ASSEMBLE
Fig. 1 Rear Clutch Outer Snap Ring
Fig. 2 Rear Clutch (3-Disc Shown)
Fig. 3 Piston Spring Waved Snap Ring
Fig. 4 Rear Clutch Piston and Piston Spring
TRANSAXLE 21 - 61
Press out i nput shaft, i f requi red.
To reassembl e, reverse the above procedure.
MEASURI NG PLATE CLEARANCE
FRONT PLANETARY & ANNULUS
GEAR-RECONDITION
Fig. 5 Remove or Install Input Shaft Snap Ring
Fig. 6 Input Shaft Snap Ring
Fig. 1 Front Planetary Gear Snap Ring and No. 4
Thrust Washer (Always Install a New Snap Ring)
Fig. 2 Front Planetary Gear
Fig. 3 Annulus Gear Support Front Snap Ring
Fig. 7 Measuring Rear Clutch Plate Clearance
21 - 62 TRANSAXLE
LOW/REVERSE (REAR) SERVO-RECONDITION
To assembl e, reverse the above procedure.
Fig. 4 Front Annulus Gear Support and Snap Ring
Fig. 5 Front Annulus Gear Support Snap Ring
Fig. 2 Snap Ring and Retainer
Fig. 3 Low/Reverse Servo Return Spring
Fig. 4 Low/Reverse Servo Assembly
Fig. 1 Low/Reverse Servo Snap Ring
TRANSAXLE 21 - 63
ACCUMULATOR-RECONDITION
KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION
Fig. 5 Accumulator Snap Ring
Fig. 6 Accumulator Plate and Snap Ring
Fig. 7 Accumulator Spring and Piston
Fig. 8 Kickdown Servo Snap Ring
Fig. 9 Kickdown Servo Rod Guide and Snap Ring
Fig. 10 Kickdown Piston Return Spring and Piston
21 - 64 TRANSAXLE
TRANSFER SHAFT REPAIR
Remove old sealant before applying new seal-
ant. Use Mopar Silicone Rubber Adhesive Seal-
ant when installing cover.
Fig. 11 Controlled Load Kickdown Servo
Fig. 1 Rear Cover Bolts
Fig. 2 Remove or Install Rear Cover
Fig. 3 Remove Transfer Shaft Gear Retaining Nut
Fig. 4 Transfer Shaft Gear Nut and Washer
Fig. 5 Remove Transfer Shaft Gear
TRANSAXLE 21 - 65
Fig. 6 Transfer Shaft Gear and (Select) Shim
Fig. 7 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
Fig. 8 Install Transfer Shaft Gear Bearing Cone
Fig. 9 Governor Support Retainer
Fig. 10 Remove Governor Support Retainer Bearing
Cup
Fig. 11 Install Governor Support Retainer Bearing
Cup
21 - 66 TRANSAXLE
Remove or install both governor valves and
governor body.
To i nstal l transfer shaft, reverse the above proce-
dure.
Fig. 12 Low-Reverse Band Anchor Pin
Fig. 13 Governor Assembly
Fig. 14 Transfer Shaft Bearing Snap Ring
Fig. 15 Remove Transfer Shaft and Bearing Retainer
Assembly
Fig. 16 Remove or Install Transfer Shaft and Bear-
ing Retainer Assembly Using Tool L-4512
Fig. 17 Transfer Shaft and Bearing Retainer
TRANSAXLE 21 - 67
Fig. 18 Remove Transfer Shaft Bearing Cone
Fig. 19 Install Transfer Shaft Bearing Cone
Fig. 20 Remove Transfer Shaft Bearing Cup
Fig. 21 Install Transfer Shaft Bearing Cup
21 - 68 TRANSAXLE
DETERMI NI NG SHI M THI CKNESS
fol l owi ng parts are repl aced: (a) transaxl e case, (b)
transfer shaft, (c) transfer shaft gear, (d) transfer shaft
beari ngs, (e) governor support retai ner, (f) transfer
shaft beari ng retai ner, (g) retai ner snap ri ng, or (h)
governor support. Refer to Beari ng Adjustment Proce-
dure i n rear of thi s secti on to determi ne proper shi m
thi ckness for correct end pl ay.
PARKING PAWL
To i nstal l , reverse the above procedure.
Fig. 22 Tighten Transfer Shaft Gear Retaining Nut to
271 Nm (200 ft. lbs.)
Fig. 23 Checking Transfer Shaft End Play
Fig. 24 Parking Sprag Rod Support Bolts
Fig. 25 Support and Bolts
Fig. 26 Parking Pawl, Return Spring, and Pivot Shaft
TRANSAXLE 21 - 69
OUTPUT SHAFT REPAIR
Transfer shaft should be removed for repair of
output shaft. Planetary gear sets must be re-
moved to accurately check output shaft bearing
turning torque.
Fig. 1 Remove Output Shaft Retaining Nut and
Washer
Fig. 2 Remove Output Shaft Gear
Fig. 3 Output Shaft Gear and (Select) Shim
Fig. 4 Remove Output Shaft Gear Bearing Cone
Fig. 5 Install Output Shaft Gear Bearing Cone
21 - 70 TRANSAXLE
Fig. 6 Remove Output Shaft and Rear Annulus Gear
Assembly
Fig. 7 Remove Output Shaft
Fig. 8 Remove Rear Planetary Annulus Gear
Bearing Cone
Fig. 9 Install Rear Planetary Annulus Gear Bearing
Cone
Fig. 10 Install Output Shaft into Rear Planetary
Annulus Gear
Fig. 11 Remove Output Shaft Gear Bearing Cup
TRANSAXLE 21 - 71
Transaxl e case
Output shaft
Rear pl anetary annul us gear
Output shaft gear
Rear annul us and output shaft gear beari ng cones
Overrunni ng cl utch race cups
Refer to Beari ng Adjustment Procedure at the rear
of thi s secti on, to determi ne proper shi m thi ckness for
correct beari ng prel oad and turni ng torque. Check
output shaft bearings turning torque, using an
inch-pound torquewrench. If turningtorqueis3
to 8 inch-pounds, the proper shim has been in-
stalled.
Fig. 12 Remove Rear Planetary Annulus Gear Bear-
ing Cup
Fig. 13 Install Output Shaft Gear Bearing Cup
Fig. 14 Install Rear Planetary Annulus Gear Bearing
Cup
Fig. 15 Install Output Shaft Assembly
Fig. 16 Output Shaft and (Select) Shims in Position
21 - 72 TRANSAXLE
DIFFERENTIAL REPAIR
The transfer shaft should be removed for dif-
ferential repair and bearing turning torque
checking.
Fig. 17 Start Output Shaft Gear onto Output Shaft
Fig. 18 Holding Output Shaft Gear
Fig. 19 Tighten Output Shaft Retaining Nut to 271
Nm (200 ft. lbs.)
Fig. 20 Checking Output Shaft End Play
Fig. 21 Checking Bearings Turning Torque
TRANSAXLE 21 - 73
Use Mopar Silicone Rubber Adhesive Sealant
or equivalent when installing differential cover.
Use Mopar Silicone Rubber Adhesive Sealant
or equivalent when installing differential bear-
ing retainer.
Fig. 2 Install New Seal into Extension
Fig. 3 Differential Cover Bolts
Fig. 4 Remove or Install Differential Cover
Fig. 5 Differential Bearing Retainer Bolts
Fig. 6 Remove or Install Bearing Retainer
Fig. 7 Differential Bearing Retainer (Typical)
21 - 74 TRANSAXLE
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Use Mopar Si l i cone Rubber Adhesi ve Seal ant or
equi val ent when i nstal l i ng extensi on housi ng.
Fig. 8 Extension Bolts
Fig. 9 Remove or Install Extension Housing
Fig. 10 Differential and Extension
TRANSAXLE 21 - 75
CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued.
Fig. 15 Remove or Install Ring Gear Bolts and Ring
Gear
and Tabbed Thrust Washers, by Rotating Pinion
Gears to Opening in Differential Case
21 - 76 TRANSAXLE
.013 inch.
Four select thrust washers are available: .032,
.037, .042, and .047 inch.
Transaxl e case
Di fferenti al carri er
Extensi on housi ng
Di fferenti al beari ng cups and cones
Refer to Beari ng Adjustment Procedure i n rear of
torque.
Fig. 23 Install New Oil Seal
TRANSAXLE 21 - 77
Remove old before applying new sealant. Use
Mopar Silicone Rubber Adhesive Sealant or
equivalent on retainer to seal retainer to case.
Fig. 24 Remove Bearing Cup
Fig. 26 Install Bearing Cup
Fig. 27 Checking Differential End Play
Fig. 28 Tool L-4436 and Torque Wrench
Fig. 29 Checking Differential Bearings Turning
Torque
21 - 78 TRANSAXLE
BEARING ADJUSTMENT PROCEDURES
(1) Take extreme care when removi ng and i n stal l i ng
beari ng cups and cones. Useonly an arbor pressfor
installation, as a hammer may not properl y al i gn the
wi l l gi ve a fal se end pl ay readi ng, whi l e gaugi ng for
proper shi ms. I mproperl y seated beari ng cup and cones
are subject to l ow-mi l eage fai l ure.
show si gns of pi tti ng or heat di stress.
I f di stress i s seen on ei ther the cup or beari ng rol l ers,
both cup and cone must be repl aced.
Bearing end play and drag torque specifica-
tions must be maintained to avoid premature
bearing failures.
Used (ori gi nal ) beari ng may l ose up to 50
of the ori gi nal drag torque after break-i n.
All bearingadjustments must be made with no
other component interference or gear inter-
mesh, except the transfer gear bearing.
OUTPUT SHAFT BEARI NG
Wi th output shaft gear removed.
(1) I nstal l a 13.65 mm (.537 i nch) and a 1.34 mm
(.053 i nch) gaugi ng shi ms on the pl anetary rear annu-
l us gear hub usi ng grease to hol d the shi ms i n pl ace.
The 13.65 mm shi m has a l arger i nsi de di ameter and
must be i nstal l ed over the output shaft fi rst. The 1.34
mm shi m pi l ots on the output shaft.
(2) I nstal l output shaft gear and beari ng assembl y,
torque to 271 Nm (200 ft. l bs.).
(3) To measure beari ng end pl ay:
(a) Attach Tool L-4432 to the output shaft gear.
(b) Mount a steel bal l wi th grease i nto the end of
the output shaft.
(c) Push and pul l the gear whi l e rotati ng back and
forth to i nsure seati ng of the beari ng rol l ers.
(d) Usi ng a di al i ndi cator, mounted to the tran-
saxl e case, measure output shaft end pl ay.
(4) Once beari ng end pl ay has been determi ned,
refer to the output shaft beari ng shi m chart for the
requi red shi m combi nati on to obtai n proper beari ng
setti ng.
(a) The 12.65 mm (.498 i nch), 13.15 mm (.518 i nch)
or 13.65 mm (.537 i nch) shi ms are al ways i nstal l ed
fi rst. These shims have lubrication slots which
are necessary for proper bearing lubrication.
(b) Shi ms thi nner than 12.65 mm l i sted i n the
chart are common to both the transfer shaft and
output shaft beari ngs.
(5) Use Tool L-4434 to remove the retai ni ng nut and
washer. To remove the output shaft gear use Tool
L-4407.
(6) Remove the two gaugi ng shi ms and i nstal l the
proper shi m combi nati on, maki ng sure to i nstal l the
12.65, 13.15, or 13.65 mm shi m fi rst. Use grease to hol d
the shi ms i n pl ace. I nstal l the output shaft gear and
beari ng assembl y.
(7) I nstal l the retai ni ng nut and washer and torque
to 271 Nm (200 ft. l bs.).
(8) Usi ng an i nch-pound torque wrench, check the
turni ng torque. The torque should be between 3
and 8 inch-pounds.
I f the turni ng torque i s too hi gh, i nstal l a .05mm
(.002 i nch) thi cker shi m. I f the turni ng torque i s too
l ow, i nstal l a .05 mm (.002 i nch) thi nner shi m. Repeat
unti l the proper turni ng torque i s 3 to 8 i nch pounds.
DI FFERENTI AL BEARI NG
(1) Remove the beari ng cup from the di fferenti al
beari ng retai ner usi ng Tool L-4518, and remove the
exi sti ng shi m from under the cup.
(2) I nstal l a .50 mm (.020 i nch) gaugi ng shi m and
rei nstal l the beari ng cup i nto the retai ner. Use an
arbor press to i nstal l the cup.
Oil Baffle is not required when making shim
selection.
OUTPUT SHAFT BEARI NG SHI M CHART
TRANSAXLE 21 - 79
(3) I nstal l the beari ng retai ner i nto the case and
torque bol ts to 28 Nm (250 i n. l bs.).
(4) Posi ti on the transaxl e assembl y verti cal l y on the
support stand and i nstal l Tool L-4436 i nto the exten-
si on.
(5) Rotate the di fferenti al at l east one ful l revol uti on
to ensure the tapered rol l er beari ngs are ful l y seated.
(6) Attach a di al i ndi cator to the case and zero the
di al i ndi cator. Pl ace the i ndi cator ti p on the end of Tool
L-4436.
(7) Pl ace a l arge screwdri ver to each si de of the ri ng
gear and l i ft. Check the di al i ndi cator for the amount of
end pl ay.
CAUTION: Do not damage the transaxle case and/or
differential cover sealing surface.
(8) When the end pl ay has been determi ned, refer to
the Di fferenti al Beari ng Shi m Chart for the correct
shi m combi nati on to obtai n the proper beari ng setti ng.
(9) Remove the di fferenti al beari ng retai ner. Re-
move the beari ng cup and the .50 mm (.020 i nch)
gaugi ng shi m.
(10) I nstal l the proper shi m combi nati on under the
beari ng cup. Make sure the oi l baffl e i s i nstal l ed
properl y i n the beari ng retai ner, bel ow the beari ng
shi m and cup.
(11) I nstal l the di fferenti al beari ng retai ner. Seal
the retai ner to the housi ng wi th Mopar Si l i cone
Rubber Adhesi ve Seal ant or equi val ent and torque
bol ts to 28 Nm (250 i n. l bs.).
(12) Usi ng speci al Tool L-4436 and an i nch-pound
torque wrench, check the turni ng torque of the di ffer-
enti al . The turning torque should be between 5
and 18 inch-pounds.
If the turning torque is too high, install a .05
mm (.002 inch) thinner shim. If the turning
torque is too low, install a .05 mm (.002 inch)
thicker shim. Repeat until 5 to 18 inch-pounds
turning torque is obtained.
TRANSFER SHAFT BEARI NG
washer. Remove the transfer shaft gear usi ng Tool
L-4407.
(2) I nstal l a 2.29 mm (.090 i nch) and a 1.39 mm (.055
i nch) gaugi ng shi ms on the transfer shaft behi nd the
governor support.
(3) I nstal l transfer shaft gear and beari ng assembl y
and torque the nut to 271 Nm (200 ft. l bs.).
(a) Attach Tool L-4432 to the transfer gear.
the transfer shaft.
(d) Usi ng a di al i ndi cator, measure transfer shaft
end pl ay.
(5) Refer to the Transfer Beari ng Shi m Chart for the
requi red shi m combi nati on to obtai n the proper bear-
i ng setti ng.
L-4407.
(7) Remove the two gaugi ng shi ms and i nstal l the
correct shi m combi nati on. I nstal l the transfer gear and
beari ng assembl y.
to 271 Nm (200 ft. l bs.). Measure transfer shaft end
pl ay, end pl ay shoul d be .05 to .25 mm (.002 to .010
i nch).
(9) Measure beari ng end pl ay as outl i ned i n Step (4).
End pl ay shoul d be between .05 mm and .25 mm (.002
to .010 i nch).
21 - 80 TRANSAXLE
If end play is too high, install a .05 mm (.002
inch) thinner shim combination. If end play is
too low, install a .05mm(.002inch) thicker shim
combination. Repeat until .05 to .25 mm (.002 to
.010 inch) end play is obtained.
TRANSFER BEARI NG SHI M CHART
BEARI NG SHI M CHART
TRANSAXLE 21 - 81
4-SPEED ELECTRONI C AUTOMATI C TRANSAXLE
INDEX
page page
Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . 95
Bearing Adjustment Procedures . . . . . . . . . . . . . 137
Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . . 92
Determining No. 4 Thrust Plate Thickness
(Input Shaft End Play) . . . . . . . . . . . . . . . . . . . 115
Differential Repair . . . . . . . . . . . . . . . . . . . . . . . 132
Distance Sensor Gear . . . . . . . . . . . . . . . . . . . . . 95
Fluid and Filter Change . . . . . . . . . . . . . . . . . . . . 89
Fluid Drain and Refill . . . . . . . . . . . . . . . . . . . . . . 89
Fluid Leakage-Transaxle Torque Converter Housing
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Fluid Level and Condition . . . . . . . . . . . . . . . . . . . 89
Gearshift Linkage Adjustment . . . . . . . . . . . . . . . . 94
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 85
Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . 91
Input Clutches-Recondition . . . . . . . . . . . . . . . . . 116
Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . . 99
Oil Cooler Flow Check . . . . . . . . . . . . . . . . . . . . . 95
Oil Coolers and Tubes Reverse Flushing . . . . . . . 95
Oil Pump Seal-Replace . . . . . . . . . . . . . . . . . . . 132
PRNDL Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Selection of Lubricant . . . . . . . . . . . . . . . . . . . . . . 89
Solenoid Assembly-Replace . . . . . . . . . . . . . . . . . 98
Special Additives . . . . . . . . . . . . . . . . . . . . . . . . . 89
Speed Sensor-Input . . . . . . . . . . . . . . . . . . . . . . . 99
Speed Sensor-Output . . . . . . . . . . . . . . . . . . . . . . 99
Transaxle Removal and Installation . . . . . . . . . . . . 96
Transaxle-Recondition . . . . . . . . . . . . . . . . . . . . 100
Valve Body-Recondition . . . . . . . . . . . . . . . . . . . 128
GENERAL INFORMATION
Thi s el ectroni c four-speed FWD transaxl e i s the fi rst
use of ful l y-adapti ve control s i n a producti on automo-
ti ve transaxl e. Adapti ve control s are those whi ch per-
form thei r functi ons based on real -ti me feedback sen-
sor i nformati on, just as i s done by el ectroni c anti -l ock
brake control s. The transaxl e i s conventi onal i n that i t
uses hydraul i cal l y-appl i ed cl utches to shi ft a pl anetary
gear trai n, i ts uses el ectroni cs to control vi rtual l y al l
functi ons.
TRANSAXLE I DENTI FI CATI ON
The transaxl e i denti fi cati on code i s pri nted on a
l abel . The l abel i s l ocated on the transaxl e case next to
the sol enoi d assembl y (Fi g. 1).
Refer to Fi gure 2 for an i nternal vi ew of the transaxl e
assembl y.
OPERATI ON
The transaxl e provi des forward rati os of 2.84, 1.57,
1.00, and 0.69 wi th torque converter l ockup avai l abl e
i n 2nd, di rect, or overdri ve gear; the Reverse rati o i s
2.21. The shi ft l ever i s conventi onal wi th si x posi ti ons:
P, R, N, OD, 3, and L. When OD i s sel ected the
transaxl e shi fts normal l y through al l four speeds wi th
l ockup i n overdri ve; thi s posi ti on i s recommended for
most dri vi ng. The 3 posi ti on i s tai l ored for use i n hi l l y
or mountai nous dri vi ng. When 3 i s sel ected, the trans-
mi ssi on uses onl y 1st, 2nd, and di rect gears wi th
2nd-di rect shi ft del ayed to 40 mph or greater. When
operati ng i n 3 or L posi ti ons torque converter l ockup
occurs i n di rect gear for i mproved transmi ssi on cool i ng
when towi ng trai l ers and on steep grades. I f hi gh
engi ne cool ant temperature occurs, the torque con-
verter wi l l al so l ock up i n 2nd gear. The L posi ti on
provi des maxi mum engi ne braki ng for descendi ng
steep grades. Unl i ke most current transaxl es, upshi fts
are provi ded to 2nd or di rect gear at peak engi ne
speeds i f the accel erator i s depressed. Thi s provi des
engi ne over-speed protecti on and maxi mum perfor-
mance.
Fig. 1 Identification Tag Location
21 - 82 TRANSAXLE
F
i
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2
I
n
t
e
r
n
a
l
V
i
e
w
o
f
T
r
a
n
s
a
x
l
e
TRANSAXLE 21 - 83
CLUTCH AND GEAR
The 4-speed el ectroni c transaxl e consi sts of:
Three mul ti pl e-di sc i nput cl utches
Two mul ti pl e di sc grounded cl utches
Four hydraul i c accumul ators
Two pl anetary gear sets
Thi s provi des four forward rati os and a reverse rati o.
The cl utch-appl y pi stons were desi gned wi th centri fu-
gal l y bal anced oi l cavi ti es so that qui ck response and
good control can be achi eved at any speed. A push/pul l
pi ston i s i ncorporated for two of the three i nput
cl utches.
CAUTION: Some clutch packs appear similar, but
they are not the same. Do not interchange clutch
components as they might fail.
HYDRAULI CS
The hydraul i cs of the new transaxl e provi de the
manual shi ft l ever sel ect functi on, mai n l i ne pressure
regul ati on, and torque converter and cool er fl ow con-
trol . Oi l fl ow to the fri cti on el ements i s control l ed
di rectl y by four sol enoi d val ves. The hydraul i cs al so
i ncl ude a uni que l ogi c-control l ed sol enoi d l ock-up con-
trol val ve. Thi s val ve l ocks out the 1st gear reacti on
el ement wi th the appl i cati on of 2nd, di rect, or over-
dri ve gear el ements. I t al so redi rects the 1st gear
sol enoi d output so that i t can control torque converter
l ockup operati on. To regai n access to 1st gear, a speci al
sequence of sol enoi d commands must be used to unl ock
and move the sol enoi d l ock-up control val ve. Thi s
precl udes any appl i cati on of the 1st gear reacti on
el ement wi th other el ements appl i ed, unl ess speci fi -
cal l y commanded the control l er. I t al so al l ows one
sol enoi d to control two fri cti on el ements.
Smal l , hi gh-rate accumul ators are provi ded i n each
control l ed fri cti on el ement ci rcui t. These serve to ab-
sorb the pressure responses, and al l ow the control s to
read and respond to changes that are occurri ng.
SOLENOI DS
Si nce the sol enoi d val ves perform vi rtual l y al l con-
trol functi ons, these val ves must be extremel y durabl e
and tol erant of normal di rt parti cl es. For that reason
hardened-steel poppet and bal l val ves are used. These
are free from any cl ose operati ng cl earances, and the
sol enoi ds operate the val ves di rectl y wi thout any i nter-
medi ate el ement. Di rect operati on means that these
uni ts must have very hi gh output so that they can cl ose
agai nst the si zeabl e fl ow areas and hi gh l i ne pressures.
Fast response i s al so requi red to meet the control
requi rements.
Two of the sol enoi ds are normal l y-venti ng and two
are normal l y-appl yi ng; thi s was done to provi de a
defaul t mode of operati on. Wi th no el ectri cal power, the
transmi ssi on provi des 2nd gear i n OD,3,or Lshi ft
l ever posi ti ons. Al l other shi ft l ever posi ti ons wi l l
functi on normal l y. The choi ce of 2nd gear was made to
provi de adequate performance whi l e sti l l accommodat-
i ng hi ghway speeds.
SENSORS
There are three pressure swi tches to i denti fy sol e-
noi d appl i cati on and two speed sensors to read i nput
(torque converter turbi ne) and output (parki ng sprag)
speeds. There i s al so a posi ti on swi tch to i ndi cate the
manual shi ft l ever posi ti on. The pressure swi tches are
i ncorporated i n an assembl y wi th the sol enoi ds. Engi ne
speed, throttl e posi ti on, temperature, etc., are al so
observed. Some of these si gnal s are read di rectl y from
the engi ne control sensors; others are read from a
mul ti pl ex ci rcui t wi th the engi ne control l er.
ELECTRONI CS
The el ectroni c control uni t i s l ocated underhood i n a
potted, di e cast al umi num housi ng wi th a seal ed,
60-way connector.
ADAPTI VE CONTROLS
These control s functi on by readi ng the i nput and
output speeds over 140 ti mes a second and respondi ng
to each new readi ng. Thi s provi des the preci se and
sophi sti cated fri cti on el ement control needed to make
smooth cl utch-to-cl utch shi fts for al l gear changes. As
wi th most automati c transaxl es, al l shi fts i nvol ve re-
l easi ng one el ement and appl yi ng a di fferent el ement.
I n si mpl i fi ed terms, the upshi ft l ogi c al l ows the rel eas-
i ng el ement to sl i p back wards sl i ghtl y to ensure that i t
does not have excess capaci ty; the appl y el ement i s
fi l l ed unti l i t begi ns to make the speed change to the
hi gher gear; i ts appl y pressure i s then control l ed to
mai ntai n the desi red rate of speed change unti l the
shi ft i s compl ete. The key to provi di ng excel l ent shi ft
qual i ty i s preci si on; for exampl e, as menti oned, the
rel ease el ement for upshi fts i s al l owed to sl i p back-
wards sl i ghtl y; the amount of that sl i p i s typi cal l y l ess
than a total of 20 degrees. To achi eve that preci si on,
the controller learns the characteristics of the
particular transaxle that it is controlling. It
learns the release rate of the releasing element
and the apply time of the applying element. It
also learns the rate at which the apply element
builds pressure sufficient to begin making the
speed change. Thi s method achi eves more preci si on
than woul d be possi bl e wi th exacti ng tol erances. I t can
al so adapt to any changes that occur wi th age or
envi ronment, for exampl e, al ti tude, temperature, en-
gi ne output, etc.
For ki ckdown shi fts, the control l ogi c al l ows the
rel easi ng el ement to sl i p and then control s the rate at
whi ch the i nput (and engi ne) accel erate; when the
l ower gear speed i s achi eved, the rel easi ng el ement
21 - 84 TRANSAXLE
reappl i es to mai ntai n that speed unti l the appl y el e-
ment i s fi l l ed. Thi s provi des qui ck response si nce the
engi ne begi ns to accel erate i mmedi atel y and a smooth
torque exchange si nce the rel ease el ement can control
the rate of torque i ncrease. Thi s control can make any
power trai n feel more responsi ve wi thout i n creasi ng
harshness.
Adapti ve control s respond to i nput speed changes.
They compensate for changes i n engi ne or fri cti on
el ement torque and provi de good, consi stent shi ft qual -
i ty for the l i fe of the transaxl e.
ON-BOARD DI AGNOSTI CS
These control s al so provi de comprehensi ve, on-board
transaxl e di agnosti cs. The i nformati on avai l abl e can
ai d i n transaxl e di agnosi s. For exampl e, appl y el ement
bui l dup rate i ndi cates sol enoi d performance. Al so i n-
cl uded are sel f-di agnosti c functi ons whi ch al l ow the
techni ci an to test the i ntegri ty of the el ectroni c control s
wi thout requi ri ng a road test. The control l er conti nu-
ousl y moni tors i ts cri ti cal functi ons, records any mal -
functi ons, and the number of engi ne starts si nce the
l ast mal functi on. The techni ci an can use thi s i nforma-
ti on i n the event of a customer compl ai nt.
GENERAL DIAGNOSIS
CAUTION: Before attempting any repair on a Elec-
tronic Automatic Transaxle, check for fault codes
with the DRBII. Always use the Powertrain Diagnos-
tic Test Procedure Manual.
El ectroni c automati c transaxl e mal functi ons may be
caused by these general condi ti ons:
Poor engi ne performance
I mproper adjustments
Hydraul i c mal functi ons
Mechani cal mal functi ons
El ectroni c mal functi ons
Di agnosi s of these probl ems shoul d al ways begi n by
checki ng the easi l y accessi bl e vari abl es: fl ui d l evel and
condi ti on, gearshi ft cabl e adjustment. Then perform a
road test to determi ne i f the probl em has been cor-
rected or that more di agnosi s i s necessary. I f the
probl em exi sts after the prel i mi nary tests and correc-
ti ons are compl eted, hydraul i c pressure checks shoul d
be performed.
DI AGNOSI S GUI DE-VEHI CLE WI LL NOT MOVE
TRANSAXLE 21 - 85
FAULT CODE CHART A
21 - 86 TRANSAXLE
DI AGNOSI S CHART B
TRANSAXLE 21 - 87
DI AGNOSI S GUI DE-ABNORMAL NOI SE
DI AGNOSI S GUI DE-FLUI D LEAKS
21 - 88 TRANSAXLE
FLUID LEVEL AND CONDITION
Thetransmission and differential sump havea
commonoil sumpwithacommunicatingopening
between the two.
The torque converter fi l l s i n both the P Park and
N Neutral posi ti ons. Pl ace the sel ector l ever i n P
Park to be sure that the fl ui d l evel check i s accurate.
Theengineshouldberunningat idlespeedfor at
least one minute, with the vehicle on level
ground. This will assurecompleteoil level stabi-
lization between differential and transmission.
The fl ui d shoul d be at normal operati ng temperature
(approxi matel y 82 C. or 180 F.). The fl ui d l evel i s
correct i f i t i s i n the HOT regi on (cross-hatched area)
on the oi l l evel i ndi cator.
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th the
fl ui d. As i n any hydraul i c system, ai r bubbl es make the
fl ui d spongy, therefore, pressures wi l l be l ow and bui l d
up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transaxl e has too much fl ui d, the gears
churn up foam and cause the same condi ti ons whi ch
occur wi th a l ow fl ui d l evel .
I n ei ther case, the ai r bubbl es can cause over heat-
i ng, fl ui d oxi dati on, and varni shi ng, whi ch can i nter-
fere wi th normal val ve, cl utch, and accumul ator opera-
ti on. Foami ng can al so resul t i n fl ui d escapi ng from the
transaxl e vent where i t may be mi staken for a l eak.
Al ong wi th fl ui d l evel , i t i s i mportant to check the
condi ti on of the fl ui d. When the fl ui d smel l s burned,
and i s contami nated wi th metal or fri cti on materi al
parti cl es, a compl ete transaxl e overhaul i s needed. Be
sure to exami ne the fl ui d on the di psti ck cl osel y. I f
there i s any doubt about i ts condi ti on, drai n out a
sampl e for a doubl e check.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
SELECTION OF LUBRICANT
I t i s i mportant that the proper l ubri cant be used i n
these transmi ssi ons. MOPAR ATF PLUS (Automati c
Transmi ssi on Fl ui d-Type 7176) shoul d be used to ai d i n
assuri ng opti mum transmi ssi on performance. Fl ui ds of
the type l abel ed DEXRON I I Automati c Transmi ssi on
Fl ui d i s not recommended. DEXRON I I can be used
onl y i f the recommended fl ui d i s not avai l abl e. I f more
than a smal l amount of Dexron fl ui d i s used, shutter or
shi ft qual i ty probl ems may be encountered. I t i s i mpor-
tant that the transmi ssi on fl ui d be mai ntai ned at the
prescri bed l evel usi ng the recommended fl ui ds.
SPECIAL ADDITIVES
Chrysl er Corporati on does not recommend the addi -
ti on of any fl ui ds to the transmi ssi on, other than the
automati c transmi ssi on fl ui d l i sted above. An excep-
ti on to thi s pol i cy i s the use of speci al dyes to ai d i n
detecti ng fl ui d l eaks. The use of transmi ssi on seal ers
shoul d be avoi ded, si nce they may adversel y affect
seal s.
FLUID AND FILTER CHANGE
When the factory fi l l fl ui d i s changed, onl y fl ui ds of
the type l abel ed MOPAR ATF PLUS (Automati c
Transmi ssi on fl ui d) Type 7176 shoul d be used. A fi l ter
change shoul d be made at the ti me of the oi l change.
Al so the magnet (on the i nsi de of the oi l pan) shoul d be
cl eaned wi th a cl ean, dry cl oth.
I f the transaxl e i s di sassembl ed for any reason, the
fl ui d and fi l ter shoul d be changed.
FLUID DRAIN AND REFILL
(1) Rai se vehi cl e on a hoi st (See Lubri cati on, Group
0). Pl ace a drai n contai ner wi th a l arge openi ng, under
transaxl e oi l pan.
(2) Loosen pan bol ts and tap the pan at one corner to
break i t l oose al l owi ng fl ui d to drai n, then remove the
oi l pan.
(3) I nstal l a new fi l ter and O-ri ng on bottom of the
val ve body.
(4) Cl ean the oi l pan and magnet. Rei nstal l pan
usi ng Mopar Si l i cone Rubber Adhesi ve Seal ant or
equi val ent. Ti ghten oi l pan bol ts to 19 Nm (165 i n.
l bs.).
(5) Pour four quarts of MOPAR ATF PLUS (Auto-
mati c Transmi ssi on Fl ui d) Type 7176 through the fi l l
tube.
(6) Start engi ne and al l ow to i dl e for at l east one
mi nute. Then, wi th parki ng and servi ce brakes ap-
pl i ed, move sel ector l ever momentari l y to each posi -
ti on, endi ng i n the park or neutral posi ti on.
(7) Add suffi ci ent fl ui d to bri ng l evel to 1/8 i nch
bel ow the ADD mark (Fi g. 3).
Recheck fl ui d l evel after transaxl e i s at normal
operati ng temperature. The l evel shoul d be i n the HOT
regi on (Fi g. 3).
To prevent di rt from enteri ng transaxl e, make cer-
tai n that di psti ck i s seated i nto the di psti ck fi l l tube
(Fi g. 4).
Fig. 3 Oil Level Indicator
TRANSAXLE 21 - 89
ROAD TEST
Pri or to performi ng a road test, be certai n that the
fl ui d l evel and condi ti on, and control cabl e adjustment
have been checked and approved.
Duri ng the road test, the transaxl e shoul d be oper-
ated i n each posi ti on to check for sl i ppi ng and any
vari ati on i n shi fti ng.
I f vehi cl e operates properl y at hi ghway speeds, but
has poor through-gear accel erati on, the torque con-
verter stator overrunni ng cl utch may be sl i ppi ng. I f
through-gear accel erati on i s normal , but abnormal l y
hi gh throttl e openi ng i s requi red to mai ntai n hi ghway
speeds, the torque converter stator cl utch may have
sei zed. Both of these stator defects requi re repl acement
of the torque converter.
I n most cases, the cl utch that i s sl i ppi ng can be
determi ned by noti ng the transaxl e operati on i n al l
sel ector posi ti ons. Then compari ng whi ch i nternal
uni ts are appl i ed i n those posi ti ons. The El ements i n
Use Chart provi des a basi s for road test anal ysi s.
The process of el i mi nati ng can be used to detect any
uni t whi ch sl i ps and to confi rm proper operati on of
good uni ts. However, al though road test anal ysi s can
usual l y di agnose sl i ppi ng uni ts, the actual cause of the
mal functi on usual l y can not be deci ded. Practi cal l y any
condi ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Fig. 4 Oil Level Indicator Location
ELEMENTS I N USE AT EACH POSI TI ON OF THE SELECTOR LEVER
21 - 90 TRANSAXLE
HYDRAULIC PRESSURE TESTS
Pressure testi ng i s a very i mportant step i n the
di agnosti c procedure. These tests usual l y reveal the
cause of most transaxl e probl ems.
Before performi ng pressure tests, be certai n that
fl ui d l evel and condi ti on, and shi ft cabl e adjustments
have been checked and approved. Fl ui d must be at
operati ng temperature 66 to 93 degrees C. (150 to 200
degrees F.).
I nstal l an engi ne tachometer, rai se vehi cl e on hoi st
whi ch al l ows front wheel s to turn, and posi ti on ta-
chometer so i t can be read.
Attach 150 psi gauges to ports requi red for test bei ng
conducted. A 300 psi gauge (C-3293) i s requi red for
reverse pressure test.
Test port l ocati ons are shown i n (Fi gure 1).
TEST ONE (SELECTOR I N L 1ST GEAR)
(1) Attach pressure gauge to the l ow/reverse cl utch
tap.
(2) Move sel ector l ever to the L posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
to 20 mph.
(4) Low/reverse cl utch pressure shoul d read 115 to
145 psi .
(5) Thi s test checks pump output, pressure regul a-
ti on and condi ti on of the l ow/reverse cl utch hydraul i c
ci rcui t and shi ft schedul e.
TEST TWO (SELECTOR I N 3 2ND GEAR)
(1) Attach gauge to the underdri ve cl utch tap.
(2) Move sel ector l ever to the 3 posi ti on.
of 30 mph.
(4) Underdri ve cl utch pressure shoul d read 110 to
145 psi .
(5) Thi s test checks the underdri ve cl utch hydraul i c
ci rcui t as wel l as the shi ft schedul e.
TEST THREE (OVERDRI VE CLUTCH CHECK)
(1) Attach gauge to the overdri ve cl utch tap.
(2) Move sel ector l ever to the ci rcl e D posi ti on.
of 20 mph.
(4) Overdri ve cl utch pressure shoul d read 74 to 95
psi .
(5) Move sel ector l ever to the 3 posi ti on and i n-
crease i ndi cated vehi cl e speed to 30 mph.
(6) The vehi cl e shoul d be i n second gear and over-
dri ve cl utch pressure shoul d be l ess than 5 psi .
(7) Thi s test checks the overdri ve cl utch hydraul i c
ci rcui t as wel l as the shi ft schedul e.
TEST FOUR (SELECTOR I N CI RCLE D OVER-
DRI VE GEAR)
(1) Attach gauge to the 2/4 cl utch tap.
(3) Al l ow vehi cl e front wheel s to turn and i ncrease
of 30 mph.
(4) The 2/4 cl utch pressure shoul d read 75 to 95 psi .
(5) Thi s test checks the 2/4 cl utch hydraul i c ci rcui t.
TEST FI VE (SELECTOR I N CI RCLE D OVER-
DRI VE LOCKUP)
(1) Attach gauge to the l ockup off pressure tap.
of 50 mph.
CAUTION: Both wheels must turn at the same speed.
(4) Lockup off pressure shoul d be l ess than 5 psi .
(5) Thi s test checks the l ockup cl utch hydraul i c
ci rcui t.
TEST SI X (SELECTOR I N REVERSE)
(1) Attach gauge to the reverse cl utch tap.
(2) Move sel ector l ever to the reverse posi ti on.
(3) Read reverse cl utch pressure wi th output sta-
ti onary (foot on brake) and throttl e opened to achi eve
1500 rpm.
(4) Reverse cl utch pressure shoul d read 165 to 235
psi .
(5) Thi s test checks the reverse cl utch hydraul i c
ci rcui t.
Fig. 1 Pressure Taps
TRANSAXLE 21 - 91
TEST RESULT I NDI CATI ONS
(1) I f proper l i ne pressure i s found i n any one test,
the pump and pressure regul ator are worki ng properl y.
(2) Low pressure i n al l posi ti ons i ndi cates a defec-
ti ve pump, a cl ogged fi l ter, or a stuck pressure regul a-
tor val ve.
(3) Cl utch ci rcui t l eaks are i ndi cated i f pressures do
not fal l wi thi n the speci fi ed pressure range.
(4) I f the overdri ve cl utch pressure i s greater than 5
psi i n step (6) of Test Three, a worn reacti on shaft seal
ri ng i s i ndi cated.
CLUTCH AIR PRESSURE TESTS
I noperati ve cl utches can be l ocated usi ng a seri es of
tests by substi tuti ng ai r pressure for fl ui d pressure
(Fi gs. 2 and 3). The cl utches may be tested by appl yi ng
ai r pressure to thei r respecti ve passages after the val ve
body has been removed and Tool 6056 has been i n-
stal l ed. To make ai r pressure tests, proceed as fol l ows:
The compressed air supply must be free of all
dirt and moisture. Use a pressure of 30 psi.
Remove oi l pan and val ve body (See Val ve body-
Recondi ti on).
OVERDRI VE CLUTCH
Appl y ai r pressure to the overdri ve cl utch appl y
passage and watch for the push/pul l pi ston to move
forward. The pi ston shoul d return to i ts starti ng posi -
ti on when the ai r pressure i s removed.
REVERSE CLUTCH
Appl y ai r pressure to the reverse cl utch appl y pas-
sage and watch for the push/pul l pi ston to move rear-
ward. The pi ston shoul d return to i ts starti ng posi ti on
when the ai r pressure i s removed.
PRESSURE CHECK SPECI FI CATI ONS
Fig. 2 Air Pressure Test Plate
21 - 92 TRANSAXLE
2/4 CLUTCH
Appl y ai r pressure to the feed hol e l ocated on the 2/4
cl utch retai ner. Look i n the area where the 2/4 pi ston
contacts the fi rst separator pl ate and watch careful l y
for the 2/4 pi ston to move rearward. The pi ston shoul d
return to i ts ori gi nal posi ti on after the ai r pressure i s
removed.
LOW/REVERSE CLUTCH
Appl y ai r pressure to the l ow/reverse cl utch feed hol e
(rear of case, between 2 bol t hol es). Then, l ook i n the
area where the l ow/reverse pi ston contacts the fi rst
separator pl ate and watch careful l y for the pi ston to
move forward. The pi ston shoul d return to i ts ori gi nal
posi ti on after the ai r pressure i s removed.
UNDERDRI VE CLUTCH
Because thi s cl utch pi ston cannot be seen, i ts opera-
ti on i s checked by functi on. Ai r pressure i s appl i ed to
the l ow/reverse and the 2/4 cl utches. Thi s l ocks the
output shaft. Use a pi ece of rubber hose wrapped
around the i nput shaft and a pai r of cl amp-on pl i ers to
turn the i nput shaft. Next appl y ai r pressure to the
underdri ve cl utch. The i nput shaft shoul d not rotate
wi th hand torque. Rel ease the ai r pressure and confi rm
that the i nput shaft wi l l rotate.
FLUID LEAKAGE-TRANSAXLE TORQUE CON-
VERTER HOUSING AREA
(1) Check for source of l eakage.
Si nce fl ui d l eakage at or around the torque converter
area may ori gi nate from an engi ne oi l l eak, the area
shoul d be exami ned cl osel y. Factory fi l l fl ui d i s dyed
red and, therefore, can be di sti ngui shed from engi ne
oi l .
(2) Pri or to removi ng the transaxl e, perform the
When l eakage i s determi ned to ori gi nate from the
transaxl e, check fl ui d l evel pri or to removal of the
transaxl e and torque converter.
Hi gh oi l l evel can resul t i n oi l l eakage out the vent i n
the manual shaft. I f the fl ui d l evel i s hi gh, adjust to
proper l evel .
After performi ng thi s operati on, i nspect for l eakage.
I f a l eak persi sts, perform the fol l owi ng operati on on
the vehi cl e to determi ne i f i t i s the torque converter or
transaxl e that i s l eaki ng.
Possi bl e sources of transaxl e torque converter area
fl ui d l eakage are:
(1) Torque converter hub seal .
Seal l i p cut, check torque converter hub fi ni sh.
Bushi ng moved and/or worn.
Oi l return hol e i n pump housi ng pl ugged or omi tted.
Seal worn out (hi gh-mi l eage vehi cl es).
(2) Fl ui d l eakage at the outsi de di ameter from pump
housi ng O-ri ng.
(3) Fl ui d l eakage at the front pump to case bol ts.
Check condi ti on of washers on bol ts and use new bol ts,
i f necessary.
(4) Fl ui d l eakage due to case or front pump housi ng
porosi ty.
TORQUE CONVERTER LEAKAGE
Possi bl e sources of torque converter l eakage are:
Torque converter wel d l eaks at the out si de (peri ph-
eral ) wel d.
Torque converter hub wel d.
Hub weld is inside and not visible. Do not
attempt to repair. Replace torque converter.
LEAKAGE TEST PROBE
(1) Remove torque converter housi ng dust shi el d.
(2) Cl ean the i nsi de of torque converter housi ng
(l ower area) as dry as possi bl e. A sol vent spray fol l owed
by compressed ai r dryi ng i s preferabl e.
(3) Fabri cate and fasten test probe (Fi g. 4) securel y
to conveni ent dust shi el d bol t hol e. Make certai n
torque converter i s cl eared by test probe. Tool must be
cl ean and dry.
Fig. 3 Testing Reverse Clutch
Fig. 4 Leak Locating Test Probe Tool
TRANSAXLE 21 - 93
(4) Run engi ne at approxi matel y 2,500 rpm wi th
transaxl e i n neutral , for about 2 mi nutes. Transaxl e
must be at operati ng temperature.
(5) Stop engi ne and careful l y remove tool .
(6) I f upper surface of test probe i s dry, there i s no
torque converter l eak. A path of fl ui d across probe
i ndi cates a torque converter l eak. Oi l l eaki ng under the
probe i s comi ng from the transaxl e torque converter
area.
(7) Remove transaxl e and torque converter assembl y
from vehi cl e for further i nvesti gati on. The fl ui d shoul d
be drai ned from the transaxl e. Rei nstal l oi l pan (wi th
Mopar Si l i cone Rubber Adhesi ve Seal ant or equi va-
l ent) at speci fi ed torque.
AI R PRESSURE TEST OF TRANSAXLE
Fabri cate equi pment needed for test as shown i n
Fi gures 5 and 6.
The transaxl e shoul d be prepared for pressure test as
fol l ows after removal of the torque converter:
(1) Pl ug di psti ck tube and pl ug oi l cool er l i ne fi tti ng.
Remove vent from manual shaft and i n stal l a 1/8 i nch
pi pe pl ug.
CAUTION: Prevent manual shaft rotation during in-
stallation and removal.
(2) Wi th rotary moti on, i nstal l converter hub seal
cup over i nput shaft, and through the converter hub
seal unti l the cup bottoms agai nst the pump gear l ugs.
Secure wi th cup retai ner strap (Fi g. 6) usi ng starter
upper hol e and opposi te bracket hol e.
(3) Attach and cl amp hose from nozzl e of Tool C-4080
to the upper cool er l i ne fi tti ng posi ti on i n case.
CAUTION: Do not, under any circumstances, pressur-
ize a transaxle to more than 10 psi.
(4) Pressuri ze the transaxl e usi ng Tool C-4080 unti l
the pressure gauge reads 8 psi . Posi ti on transaxl e so
that pump housi ng and case front may be covered wi th
soapy sol uti on of water. Leaks are someti mes caused
by porosi ty i n the case or pump housi ng.
I f a l eak source i s l ocated, that part and al l associ -
ated seal s, O-ri ngs, and gaskets shoul d be repl aced
wi th new parts.
GEARSHIFT LINKAGE ADJUSTMENT
Normal operati on of the PRNDL and neutral safety
swi tch provi des a qui ck check to confi rm proper
manual l i nkage adjustment.
Move the sel ector l evel sl owl y upward unti l i t cl i cks
i nto the P Park notch i n the sel ector gate. I f the
starter wi l l operate the P posi ti on i s correct.
After checki ng P posi ti on, move the sel ector sl owl y
toward N Neutral posi ti on unti l l ever drops at the
end of the N stop. I f the starter wi l l al so operate at
thi s poi nt the gearshi ft l i nkage i s properl y adjusted. I f
adjustment i s requi red, refer to gearshi ft l i nkage ad-
justment i n Mai ntenance and Adjustments and refer to
DRBI I i n the Di agnosti c Test Procedure Manual .
CAUTION: When it is necessary to disassemble link-
age cable from levers, which use plastic grommets as
retainers, the grommets should be replaced with new
grommets. Use a prying tool to force rod from grom-
met in lever, then cut away old grommet. Use pliers to
snap new grommet into lever and rod into grommet.
(2) Pl ace gearshi ft l ever i n P (PARK) posi ti on.
(3) Loosen cl amp bol t on gearshi ft cabl e bracket.
(4) Col umn shi ft: I nsure that prel oad adjustment
spri ng engages fork on transaxl e bracket.
(5) Pul l the shi ft l ever by hand al l the way to the
front detent posi ti on (PARK) and ti ghten l ock screw to
11 Nm (100 i n. l bs.). Gearshi ft l i nkage shoul d now be
properl y adjusted.
Fig. 5 Torque Converter Hub Seal Cup
Fig. 6 Hub Seal Cup Retaining Strap
21 - 94 TRANSAXLE
(6) Check adjustment as fol l ows:
(a) Detent posi ti on for neutral and dri ve shoul d be
wi thi n l i mi ts of hand l ever gate stops.
(b) Key start must occur onl y when shi ft l ever i s i n
park or neutral posi ti ons.
(7) To remove button assembl y, compl etel y remove
knob attachi ng fasteners. Pul l knob up sharpl y. Pro-
ceed as outl i ned i n consol e removal , Group 23.
After consol e i s back i n pl ace, i nstal l knob and button
by reversi ng the above procedure.
DISTANCE SENSOR GEAR
When the di stance sensor i s removed for any reason,
a NEW O-ri ng must be i nstal l ed on i ts outsi de di am-
eter.
REMOVAL AND I NSTALL
(1) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(2) Remove bol t securi ng the di stance sensor i n the
extensi on housi ng.
(3) Careful l y pul l sensor and pi ni on gear assembl y
out of extensi on housi ng.
(5) To i nstal l , reverse the above procedure. Make
sure extensi on housi ng and sensor fl ange are cl ean
pri or to i nstal l ati on. Al ways use a NEW sensor O-ri ng.
(6) Ti ghten securi ng bol t to 7 Nm (60 i n. l bs.).
Ti ghten speedometer cabl e to 4 Nm (35 i n. l bs.).
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num tran-
saxl e case and val ve body can be repai red by the use of
Hel i -Coi l s, or equi val ent. Thi s repai r consi sts of dri l l -
i ng out the worn-out damaged threads. Then tappi ng
the hol e wi th a speci al Hel i -Coi l tap, or equi val ent, and
i nstal l i ng a Hel i - Coi l i nsert, or equi val ent, i nto the
hol e. Thi s bri ngs the hol e back to i ts ori gi nal thread
si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are readi l y
avai l abl e from most automoti ve parts suppl i ers.
OIL COOLERS AND TUBES REVERSE FLUSHING
When a transaxl e fai l ure has contami nated the fl ui d,
the oi l cool er(s) must be fl ushed and the cool er bypass
val ve i n the transaxl e must be repl aced. The torque
converter must al so be repl aced wi th an exchange uni t.
Thi s wi l l i nsure that metal parti cl es or sl udged oi l are
not l ater transferred back i nto the recondi ti oned (or
repl aced) transaxl e.
CAUTION:If the vehicle is equipped with two oil
coolers (one in the radiator tank, one in front of the
radiator) they must be flushed separately. Do not
attempt to flush both coolers at one time.
(1) Di sconnect the cool er l i nes at the transmi ssi on.
(2) Usi ng a hand sucti on gun fi l l ed wi th mi neral
spi ri ts, reverse fl ush the cool er by forci ng mi neral
spi ri ts i nto the FromCooler l i ne of the cool er (Fi g. 1).
Catch the exi ti ng spi ri ts from the To Cooler l i ne.
Observe for the presence of debri s i n the exi ti ng fl ui d.
Conti nue unti l fl ui d exi ti ng i s cl ear and free from
debri s.
(3) Usi ng compressed ai r i n i ntermi ttent spurts,
bl ow any remai ni ng mi neral spi ri ts from the cool er,
agai n i n the reverse di recti on.
(4) To remove any remai ni ng mi neral spi ri ts from
the cool er, one (1) quart of automati c transmi ssi on fl ui d
shoul d be pumped through the cool er before reconnect-
i ng.
(5) I f at any stage of the cl eani ng process, the cool er
does not freel y pass fl ui d, the cool er must be repl aced.
OIL COOLER FLOW CHECK
After the new or repai red transmi ssi on has been
i nstal l ed and fi l l ed to the proper l evel wi th automati c
transmi ssi on fl ui d, the fl ow shoul d be checked usi ng
the fol l owi ng procedure:
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f the fl ui d fl ow i s i ntermi ttent or i t takes more
than 20 seconds to col l ect one quart of automati c
transmi ssi on fl ui d, the cool er shoul d be repl aced.
CAUTION: WITH THE FLUID SET AT THE PROPER
LEVEL, FLUID COLLECTION SHOULD NOT EXCEED
(1) QUART OR INTERNAL DAMAGE TO THE TRANS-
MISSION MAY OCCUR.
Fig. 1 Cooler Line Location
TRANSAXLE 21 - 95
(4) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
reconnect the cool er l i ne and fi l l transmi ssi on to the
proper l evel , usi ng the approved type of automati c
transmi ssi on fl ui d.
TRANSAXLE REMOVAL AND INSTALLATION
Transaxl e removal does NOT requi re engi ne re-
moval .
See Group 7-Cool i ng, to drai n engi ne cool i ng system
and remove cool ant return extensi on (3.0 l i ter engi ne
onl y).
On vehi cl es equi pped wi th Al l Wheel Dri ve, the
power transfer uni t (P.T.U.) must be removed before
removi ng the transaxl e. Refer to P.T.U Removal and
I nstal l ati on i n thi s secti on for procedures.
(1) The transaxl e and torque converter must be
removed as an assembl y; otherwi se, the torque con-
verter dri ve pl ate, pump bushi ng or oi l seal may be
damaged. The dri ve pl ate wi l l not support a l oad;
therefore, none of the wei ght of the transaxl e shoul d be
al l owed to rest on the dri ve pl ate duri ng removal .
(3) Di sconnect transaxl e shi ft l i nkage.
(4) I nstal l engi ne support fi xture and support engi ne
(Fi g.1).
(5) Remove bel l housi ng upper bol ts.
(6) Rai se vehi cl e. Remove front wheel s. Refer to
Suspensi on, Group 2 to remove wheel hub nut and
both dri ve shafts.
(7) Remove l eft pl asti c spl ash to gai n access to the
transaxl e (Fi g. 2).
(8) Remove torque converter dust shi el d to gai n
access to torque converter bol ts (Fi g. 3).
Fig. 1 Engine Support Fixture (Typical)
Fig. 2 Remove Left Splash Shield
Fig. 3 Remove Torque Converter Dust Shield
21 - 96 TRANSAXLE
(9) Mark torque converter and dri ve pl ate wi th
chal k, for reassembl y. Remove torque converter mount-
i ng bol ts.
(10) Di sconnect el ectri cal connectors at PRNDL
swi tch and neutral safety swi tch (Fi g. 4).
(11) Remove front engi ne mount i nsul ator and
bracket.
(12) On vehi cl es equi pped wi th D.I .S.i gni ti on sys-
tem, remove crankshaft posi ti on sensor from bel l hous-
i ng (Fi g. 6). For i nstal l ati on procedure refer to secti on
8D of thi s servi ce manual .
CAUTION: Failure to remove the crankshaft position
sensor from the bell housing could cause damage to
the sensor or the torque converter drive plate during
transmission removal or installation.
(13) Di sconnect and remove vehi cl e di stance sensor
(Fi g. 7).
(14) Remove starter bol ts and set starter asi de. Do
not al l ow the starter to hang from battery cabl e (Fi g.
8).
(15) Posi ti on transmi ssi on jack securel y under tran-
saxl e (Fi g. 9).
(16) Wi th transmi ssi on jack i n posi ti on, remove the
l eft transmi ssi on mount (Fi g. 10).
(17) Careful l y l ower the transaxl e assembl y from
vehi cl e.
When i nstal l i ng transaxl e, reverse the above proce-
dure.
Check and/or adjust gear shi ft cabl e.
Refi l l transaxl e wi th MOPAR ATF PLUS (Auto-
mati c Transmi ssi on Fl ui d) Type 7176 or equi val ent.
Fig. 4 Disconnect PRNDL Switch and Neutral Safety
Switch
Fig. 5 Remove Front Engine Mount
Fig. 6 Remove Crank Position Sensor (D.I.S. Ignition
Only)
Fig. 7 Remove Distance Sensor
TRANSAXLE 21 - 97
SOLENOID ASSEMBLY-REPLACE
Fig. 8 Remove Starter Assembly
Fig. 9 Position Transmission Jack
Fig. 10 Remove Left Transmission Mount
Fig. 11 Lower Transaxle Assembly
Fig. 1 Input Speed Sensor
Fig. 2 Input Speed Sensor Removed
21 - 98 TRANSAXLE
PRNDL SWITCH
CAUTION: Switch seal washer must be seated prop-
erly before tightening switch. Failure to do so may
result in leakage of transmission fluid.
NEUTRAL SAFETY SWITCH
CAUTION: Switch seal washer must be seated prop-
erly before tightening switch. Failure to do so may
result in leakage of transmission fluid.
SPEED SENSOR-INPUT
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall off
or remain in old sensor.
The i nput speed sensor i s l ocated to the ri ght of the
manual shi ft l ever.
SPEED SENSOR-OUTPUT
The output speed sensor i s l ocated to the l eft of the
manual shi ft l ever (Fi g. 8).
CAUTION: When disconnecting speed sensor con-
nector, be sure that the weather seal does not fall off
or remain in old sensor.
Fig. 3 Sound Cover
Fig. 4 Attaching Screws
Fig. 5 Solenoid Assembly
Fig. 6 PRNDL Switch
Fig. 7 Neutral Safety Switch
TRANSAXLE 21 - 99
TRANSAXLE-RECONDITION
abl e sol vent, then dri ed by compressed ai r. Do not
wipepartswith shop towels. Al l mati ng surfaces i n
the transaxl es are accuratel y machi ned; therefore,
careful handl i ng of al l parts must be exerci sed to avoi d
ni cks or burrs.
Fig. 8 Output Speed Sensor
Fig. 1 Oil Pan Bolts
Fig. 2 Oil Pan
Fig. 3 Oil Filter
21 - 100 TRANSAXLE
Fig. 5 Push Park Rod Rollers from Guide Bracket
Fig. 6 Remove or Install Valve Body
Fig. 7 Valve Body Removed
Fig. 8 Accumulators
Fig. 9 Accumulator
Fig. 10 Low/Reverse Accumulator Snap Ring
TRANSAXLE 21 - 101
Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
Measuri ng i nput shaft end pl ay before di sassembl y
wi l l usual l y i ndi cate when a #4 thrust pl ate change i s
requi red, (except when major parts are repl aced). The
#4 thrust pl ate i s l ocated behi nd the overdri ve cl utch
hub.
Attach a di al i ndi cator to transaxl e bel l housi ng wi th
i ts pl unger seated agai nst end of i nput shaft (Fi g. 14).
Move i nput shaft i n and out to obtai n end pl ay
readi ng. End pl ay speci fi cati ons are .13 to .64 mm (.005
to .025 i nch).
Record i ndi cator readi ng for reference when reas-
sembl i ng the transaxl e.
CAUTION: Be sure input speed sensor is removed
before removing oil pump.
Fig. 11 Low/Reverse Accumulator Plug (Cover)
Fig. 12 Low/Reverse Accumulator Piston
Fig. 13 Low/Reverse Accumulator
Fig. 15 Pump Attaching Bolts
21 - 102 TRANSAXLE
CAUTION: The cooler bypass valve must be replaced
if a transaxle failure has occurred. Do not reuse old
valve or attempt to clean old valve. When installing
bypass valve, insert with O-ring end towards rear of
case.
Fig. 16 Install Tool C-3752
Fig. 17 Remove Oil Pump
Fig. 18 Oil Pump Removed
Fig. 19 Oil Pump Gasket
Fig. 20 Remove Cooler Bypass Valve
Fig. 21 No. 1 Caged Needle Bearing
TRANSAXLE 21 - 103
Fig. 22 Input Clutches Assembly
Fig. 23 Front Sun Gear Assembly
Fig. 24 Front Carrier and Rear Annulus Assembly
Fig. 25 Rear Sun Gear
Fig. 26 2/4 Clutch Retainer Snap Ring
Fig. 27 Remove 2/4 Clutch Retainer
21 - 104 TRANSAXLE
Tag 2/4 clutch pack for reassembly identifica-
tion.
Fig. 28 2/4 Clutch Retainer
Fig. 29 2/4 Clutch Return Spring
Fig. 30 2/4 Retainer and Spring Indexed
Fig. 31 2/4 Clutch Pack
Fig. 32 Tapered Snap Ring
TRANSAXLE 21 - 105
Fig. 33 Tapered Snap Ring Instructions
Fig. 34 Snap Ring Installed
Fig. 35 Low/Reverse Reaction Plate
Fig. 36 Remove One Disc
Fig. 37 Low/Reverse Reaction Plate Snap Ring
21 - 106 TRANSAXLE
Tag low/reverse clutch pack for reassembly
identification.
Fig. 38 Low/Reverse Clutch Pack
Fig. 40 Rear Cover
Fig. 41 Remove Transfer Shaft Gear Nut
Fig. 42 Transfer Shaft Gear Nut and Washer
Fig. 43 Remove Transfer Shaft Gear
TRANSAXLE 21 - 107
Fig. 44 Install Transfer Shaft Gear
Fig. 45 Tighten Nut to 271 Nm (200 Ft. Lbs.)
Fig. 46 Transfer Shaft Gear and (Select) Shim
Fig. 47 Bearing Cup Retainer
Fig. 49 Install Transfer Shaft Bearing Cone
21 - 108 TRANSAXLE
Fig. 50 Remove Transfer Shaft Bearing Cup
Fig. 51 Install New Bearing Cup
Fig. 52 Transfer Shaft Bearing Snap Ring
Fig. 53 Transfer Shaft
Fig. 55 Install Bearing Cone
TRANSAXLE 21 - 109
Fig. 56 Bearing Cup Removed
Fig. 57 Remove Output Gear Bolt
Fig. 58 Output Gear Bolt and Washer
Fig. 59 Remove Output Gear
Fig. 60 Install Output Gear
Fig. 61 Tighten Output Gear to 271 Nm (200 Ft.
Lbs.)
21 - 110 TRANSAXLE
Fig. 62 Output Gear and (Select) Shim
Fig. 63 Remove Bearing Cone
Fig. 64 Install New Bearing Cone
Fig. 65 Rear Carrier Assembly
Fig. 66 Remove Rear Carrier Bearing Cone
Fig. 67 Install Rear Carrier Bearing Cone
TRANSAXLE 21 - 111
Fig. 68 Low/Reverse Spring Compressor Tool
Fig. 69 Compressor Tool in Use
Fig. 70 Remove or Install Snap Ring
Fig. 71 Low/Reverse Piston Return Spring
Fig. 72 Drive Out Anchor Shaft
Fig. 73 Anchor Shaft and Plug
21 - 112 TRANSAXLE
CAUTION: When installing, be sure guide bracket and
split sleeve touch the rear of the transaxle case.
Fig. 74 Guide Bracket Pivot Shaft
Fig. 75 Pivot Shaft and Guide Bracket
Fig. 76 Guide Bracket Assembled
Fig. 77 Guide Bracket Disassembled
Fig. 78 Low/Reverse Clutch Piston
Fig. 79 Piston Retainer Attaching Screws
TRANSAXLE 21 - 113
CAUTION: Drift bearing cup all the way around.
To assembl e, reverse the above procedure. Be sure to
check both grounded cl utch cl earances (Fi gs. 87 and
88). Before i nstal l i ng the i nput cl utches retai ner, fol l ow
the i nstructi ons i n Determi ni ng No. 4 Thrust Pl ate
Thi ckness (Fi gs. 89, 90, 91, 92).
Fig. 80 Piston Retainer
Fig. 81 Piston Retainer Gasket
Fig. 82 Remove Output Bearing Inner Cup
Fig. 83 Remove Output Bearing Outer Cup
Fig. 84 Install Both Output Bearing Cups
Fig. 85 Checking Output Gear Bearings End Play
21 - 114 TRANSAXLE
Press down cl utch pack wi th fi nger and zero di al
i ndi cator. Low/Reverse clutch pack clearance is
1.04 to 1.65mm(.042 to .065 inch).
Sel ect the proper l ow/reverse reacti on pl ate to
achi eve speci fi cati ons:
Press down cl utch pack wi th fi nger and zero di al
i ndi cator. The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch). I f not wi thi n speci fi ca-
ti ons, the cl utch i s not assembl ed properl y. There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE THICKNESS
(Input Shaft End Play)
To determi ne the proper thi ckness of the No. 4 thrust
pl ate, sel ect the thi nnest No. 4 thrust pl ate. Usi ng
petrol atum to hol d thrust pl ate i n posi ti on, i nstal l
i nput cl utches assembl y. Be sure the i nput cl utches
assembl y i s compl etel y seated.
Fig. 86 Checking Output Gear Bearings Turning
Torque
Fig. 87 Check Low/Reverse Clutch Clearance
LOW/REVERSE REACTI ON PLATE CHART
Fig. 88 Check 2/4 Clutch Clearance
Fig. 89 Select Thinnest No. 4 Thrust Plate
TRANSAXLE 21 - 115
CAUTION: If view through input speed sensor hole is
not as shown above, the input clutches assembly is
not seated properly.
CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.
By removi ng the oi l pump O-ri ng, you wi l l be abl e to
i nstal l and remove the oi l pump and gasket very easi l y
to sel ect the proper No. 4 thrust pl ate.
Input shaft end play must be .005 to .025 inch.
For exampl e, i f end pl ay readi ng i s .055 i nch, sel ect
No. 4 Thrust Pl ate whi ch i s .071 to .074 thi ck. Thi s
shoul d provi de an i nput shaft end pl ay readi ng of .020
i nch whi ch i s wi thi n speci fi cati ons.
See chart to sel ect the proper No. 4 thrust pl ate.
INPUT CLUTCHES-RECONDITION
DI SASSEMBLY
Tag reverse clutch pack for reassembly identi-
fication.
Fig. 90 View Through Input Speed Sensor Hole
Fig. 91 Remove Oil Pump O-Ring
NO. 4 THRUST PLATE CHART
Fig. 1 Tapping Reaction Plate
21 - 116 TRANSAXLE
Fig. 2 Reverse Clutch Snap Ring
Fig. 3 Pry Reverse Clutch Reaction Plate
Fig. 4 Reverse Clutch Reaction Plate
Fig. 5 Reverse Clutch Pack
Fig. 6 OD/Reverse Pressure Plate Snap Ring 192195
Fig. 7 OD/Reverse Pressure Plate
TRANSAXLE 21 - 117
Tagoverdriveclutch pack for reassembly iden-
tification.
Fig. 8 Waved Snap Ring
Fig. 9 Remove OD Clutch Pack
Fig. 10 Overdrive Clutch Pack
Fig. 11 Overdrive Shaft Assembly
Fig. 12 Underdrive Shaft Assembly
Fig. 13 No. 2 Needle Bearing
21 - 118 TRANSAXLE
Tag underdrive clutch pack for reassembly
identification.
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 14 OD/UD Reaction Plate Tapered Snap Ring
Fig. 15 OD/UD Reaction Plate
Fig. 16 Remove One UD Clutch Disc
Fig. 17 UD Clutch Flat Snap Ring
Fig. 18 Underdrive Clutch Pack
Fig. 19 UD Spring Retainer Snap Ring
TRANSAXLE 21 - 119
Fig. 20 UD Return Spring and Retainer
Fig. 21 Underdrive Clutch Piston
Fig. 22 Input Hub Tapered Snap Ring
Fig. 23 Tap on Input Hub
Fig. 24 Input Hub Removed
Fig. 25 Pull Retainer from Piston
21 - 120 TRANSAXLE
ASSEMBLY
Use petrol atum on al l seal s to ease assembl y of
components.
Fig. 26 Install Snap Ring
Fig. 27 Snap Ring and Return Spring
Fig. 28 Remove Input Shaft Snap Ring
Fig. 29 Remove Input Shaft
Fig. 1 Install Input Shaft
Fig. 2 Install Input Shaft Snap Ring
TRANSAXLE 21 - 121
Fig. 3 Return Spring and Snap Ring
Fig. 4 Install Snap Ring
Fig. 5 Install OD/Reverse Piston
Fig. 6 Install Input Shaft Hub Assembly
Fig. 7 Input Hub Tapered Snap Ring
Fig. 8 Underdrive Clutch Piston
21 - 122 TRANSAXLE
CAUTION: Compress return spring just enough to
remove or install snap ring.
Fig. 9 Seal Compressor Tool 5067
Fig. 10 UD Return Spring and Retainer
Fig. 11 Install UD Spring Retainer and Snap Ring
Fig. 12 Underdrive Clutch Pack
Fig. 13 UD Clutch Flat Snap Ring
Fig. 14 Install Last UD Clutch Disc
TRANSAXLE 21 - 123
Snap ring ends must be located within one
finger of theinput clutch hub. Besurethat snap
ringisfully seated, by pushingwith screwdriver,
into snap ring groove all the way around.
Fig. 15 OD/UD Reaction Plate
Fig. 16 Tapered Snap Ring
Fig. 17 Seating Tapered Snap Ring
Fig. 18 Set Up Dial Indicator for Clutch Clearance
Fig. 19 Use Hook Tool to Raise One Clutch Disc
21 - 124 TRANSAXLE
Underdriveclutch pack clearancemust be0.91
to 1.47mm (.036 to .058 inch). Sel ect the proper
reacti on pl ate to achi eve speci fi cati ons:
UNDERDRI VE REACTI ON PLATE CHART
Fig. 20 Install OD Clutch Pack
Fig. 21 Install Waved Snap Ring
Fig. 22 OD/Reverse Pressure Plate
Fig. 23 Pressure Plate Installed
Fig. 24 Install Flat Snap Ring
TRANSAXLE 21 - 125
The overdrive (OD) clutch pack clearance is
.965 to 2.26 mm (.038 to .089 inch). I f not wi thi n
speci fi cati ons, the cl utch i s not assembl ed properl y.
There i s no adjustment for the OD cl utch cl earance.
Fig. 25 Check OD Clutch Pack Clearance
Fig. 26 Install Reverse Clutch Pack
Fig. 27 Install Reaction Plate
Fig. 28 Install Reverse Clutch Snap Ring
Fig. 29 Seating Snap Ring to Determine Reverse
Clutch Clearance
Fig. 30 Check Reverse Clutch Pack Clearance
21 - 126 TRANSAXLE
The reverse clutch pack clearance is 0.76 to
1.24mm(.030to.049inch). Sel ect the proper reverse
cl utch snap ri ng to achi eve speci fi cati ons:
Al l cl utch cl earances i n the i nput cl utches retai ner
have now been checked and approved.
To compl ete the assembl y of the i nput cl utches re-
tai ner, the reverse cl utch and the overdri ve cl utch
must be removed from the retai ner.
CAUTION: Do not intermix clutch parts. Keep in exact
same order.
Now proceed wi th the next phase of the assembl y:
Now that both shaft assembl i es and thrust washers
are properl y i nstal l ed, rei nstal l overdri ve cl utch and
reverse cl utch as shown i n Fi gures 20 through 28.
Recheckingtheseclutch clearances is not neces-
sary, as they were set and approved previously.
REVERSE CLUTCH SNAP RI NG CHART
Fig. 31 Install No. 2 Needle Bearing
Fig. 32 Install Underdrive Shaft Assembly
Fig. 33 Install No. 3 Thrust Washer
Fig. 34 Install No. 3 Thrust Plate
TRANSAXLE 21 - 127
VALVE BODY-RECONDITION
abl e sol vent, then dri ed by compressed ai r. Do not
wipepartswith shop towels. Al l mati ng surfaces i n
the transaxl es are accuratel y machi ned; therefore,
careful handl i ng of al l parts must be exerci sed to avoi d
ni cks or burrs.
Tag all springs, as they are removed, for reas-
sembly identification.
Fig. 35 Install Overdrive Shaft Assembly
Fig. 36 Input Clutches Assembly
Fig. 1 Oil Pan Bolts
Fig. 2 Oil Pan
Fig. 3 Oil Filter
21 - 128 TRANSAXLE
Fig. 5 Push Park Rod Rollers from Guide Bracket
Fig. 6 Remove or Install Valve Body
Fig. 7 Valve Body Removed
Fig. 8 Manual Shaft Screw
Fig. 9 Retaining Plate Screw
TRANSAXLE 21 - 129
Fig. 10 Transfer Plate and Separator Plate
Fig. 11 Transfer Plate
Fig. 12 Ball Check and Retainer Locations
21 - 130 TRANSAXLE
Fig. 13 Springs and Valves Identification
Fig. 14 Remove or Install Dual Retainer Plate Fig. 15 Remove or Install Retainer Plate
TRANSAXLE 21 - 131
When i nstal l i ng val ve body assembl y onto transaxl e,
observe Fi gure 5. Gui de park rod rol l ers i nto gui de
bracket, whi l e shi fti ng manual l ever assembl y out of
the i nstal l ati on posi ti on.
OIL PUMP SEAL-REPLACE
DIFFERENTIAL REPAIR
The transfer shaft shoul d be removed for di fferenti al
repai r and beari ng turni ng torque checki ng.
Fig. 16 Remove Oil Pump Seal
Fig. 17 Install Oil Pump Seal
Fig. 2 Install New Seal Into Extension
Fig. 3 Differential Cover Bolts
21 - 132 TRANSAXLE
CAUTION:Vehicles equipped with All Wheel Drive
have a retainer plate instead of an extension housing.
Remove retainer plate bolts to remove retainer plate.
Disregard Fig. 8, 9 and 10 on vehicles equipped with
All Wheel Drive.
Fig. 4 Remove or Install Differential Cover
Fig. 5 Differential Retainer Bolts
Fig. 6 Remove or Install Bearing Retainer
Fig. 8 Extension Bolts (Front Wheel Drive Vehicles)
Fig. 9 Remove or Install Extension (Front Wheel
Drive vehicles)
TRANSAXLE 21 - 133
CAUTION:Vehicles equipped with All Wheel Drive use
a larger differential bearing on the retainer plate side
of the differential assembly. Be sure to use the cor-
rect special tools when removing or installing the
differential bearing.
Fig. 10 Differential and Extension (Front Wheel
Drive Vehicles)
Fig. 11 Remove Differential Bearing Cone (Front
Wheel Drive)
Fig. 12 Remove Differential Bearing Cone (All Wheel
Drive)
Fig. 14 Remove Differential Bearing Cone (All)
Fig. 15 Install Differential Bearing Cone (All)
21 - 134 TRANSAXLE
CAUTION: Always install NEW ring gear bolts. Bolts
must be properly torqued.
.013 inch.
Fig. 16 Torque New Ring Gear Bolts to 95 Nm (70
Ft. Lbs.)
and Tabbed Thrust Washers, by Rotating Pinion
Gears to Opening in Differential Case
TRANSAXLE 21 - 135
Four sel ect thrust washers are avai l abl e: .032, .037,
.042, and .047 i nch.
.013 inch.
Four sel ect thrust washers are avai l abl e: .032, .037,
.042, and .047 i nch.
Transaxl e case
Di fferenti al carri er
Extensi on housi ng
Di fferenti al beari ng cups and cones
Refer to Beari ng Adjustment Procedure i n rear of
torque.
Fig. 24 Install New Oil Seal
Fig. 25 Remove Bearing Cup
21 - 136 TRANSAXLE
Remove old sealant before applying new Mo-
par Silicone Rubber Adhesive Sealant. Use Mo-
par Silicone Rubber Adhesive Sealant on re-
tainer to seal retainer to case.
BEARING ADJUSTMENT PROCEDURES
(1) Take extreme care when removi ng and i n stal l i ng
beari ng cups and cones. Useonly an arbor pressfor
installation, as a hammer may not properl y al i gn the
wi l l gi ve a fal se end pl ay readi ng, whi l e gaugi ng for
proper shi ms. I mproperl y seated beari ng cup and cones
are subject to l ow-mi l eage fai l ure.
show si gns of pi tti ng or heat di stress.
I f di stress i s seen on ei ther the cup or beari ng rol l ers,
both cup and cone must be repl aced.
Bearing end play and drag torque specifica-
tions must be maintained to avoid premature
bearing failures.
Used (ori gi nal ) beari ng may l ose up to 50% of the
ori gi nal drag torque after break-i n.
All bearingadjustments must be made with no
other component interference or gear inter-
mesh, except the transfer gear bearing.
Oi l al l beari ngs before checki ng turni ng torque.
OUTPUT GEAR BEARI NG
Wi th output gear removed:
Fig. 27 Install Bearing Cup
Fig. 28 Checking Differential End Play
Fig. 29 Tool L-4436 and Torque Wrench
Fig. 30 Checking Differential Bearings Turning
Torque
TRANSAXLE 21 - 137
(1) I nstal l a 4.50 mm (0.177 i nch) gaugi ng shi m on
the rear carri er assembl y hub, usi ng grease to hol d the
shi m i n pl ace.
(2) I nstal l output gear and beari ng assembl y. Torque
to 271 Nm (200 ft. l bs.).
(a) Attach Tool L-4432 to the gear.
(b) Push and pul l the gear whi l e rotati ng back and
(c) Usi ng a di al i ndi cator, mounted to the tran-
saxl e case, measure output gear end pl ay.
(4) Once beari ng end pl ay has been determi ned,
refer to the output gear beari ng shi m chart for the
requi red shi m to obtai n proper beari ng setti ng.
(5) Use Tool 6259 to remove the retai ni ng nut and
washer. To remove the output gear, use Tool L-4407.
(6) Remove the gaugi ng shi m and i nstal l the proper
shi m. Use grease to hol d the shi m i n pl ace. I nstal l the
output gear and beari ng assembl y.
to 271 Nm (200 ft. l bs.).
(8) Usi ng an i nch-pound torque wrench, check the
turni ng torque. The torque should be between 3
and 8 inch-pounds.
I f the turni ng torque i s too hi gh, i nstal l a .04 mm
(.0016 i nch) thi cker shi m. I f the turni ng torque i s too
l ow, i nstal l a .04 mm (.0016 i nch) thi nner shi m. Repeat
unti l the proper turni ng torque i s 3 to 8 i nch pounds.
DI FFERENTI AL BEARI NG
(1) Remove the beari ng cup from the di fferenti al
beari ng retai ner usi ng Tool L-4518, and remove the
exi sti ng shi m from under the cup.
(2) I nstal l a .50 mm (.020 i nch) gaugi ng shi m and
rei nstal l the beari ng cup i nto the retai ner. Use an
arbor press to i nstal l the cup.
Oil Baffle is not required when making shim
selection.
(3) I nstal l the beari ng retai ner i nto the case and
torque bol ts to 28 Nm (250 i n. l bs.).
(4) Posi ti on the transaxl e assembl y verti cal l y on the
support stand and i nstal l Tool C-4995 i nto si de gear.
(5) Rotate the di fferenti al at l east one ful l revol uti on
to ensure the tapered rol l er beari ngs are ful l y seated.
(6) Attach a di al i ndi cator to the case and zero the
di al i ndi cator. Pl ace the i ndi cator ti p on the end of Tool
L-4436.
(7) Pl ace a l arge screwdri ver to each si de of the ri ng
gear and l i ft. Check the di al i ndi cator for the amount of
end pl ay.
CAUTION: Do not damage the transaxle case and/or
differential cover sealing surface.
OUTPUT GEAR BEARI NG SHI M CHART
21 - 138 TRANSAXLE
(8) When the end pl ay has been determi ned, refer to
the Di fferenti al Beari ng Shi m Chart for the correct
shi m combi nati on to obtai n the proper beari ng setti ng.
(9) Remove the di fferenti al beari ng retai ner. Re-
move the beari ng cup and the .50 mm (.020 i nch)
gaugi ng shi m.
(10) I nstal l the proper shi m combi nati on under the
beari ng cup. Make sure the oi l baffl e i s i nstal l ed
properl y i n the beari ng retai ner, bel ow the beari ng
shi m and cup.
(11) I nstal l the di fferenti al beari ng retai ner. Seal
the retai ner to the housi ng wi th Mopar Si l i cone
Rubber Adhesi ve Seal ant and torque bol ts to 28 Nm
(250 i n. l bs.).
(12) Usi ng Tool C-4995 and an i nch-pound torque
wrench, check the turni ng torque of the di fferenti al .
The turning torque should be between 5 and 18
inch-pounds.
If the turning torque is too high, install a .05
mm (.002 inch) thinner shim. If the turning
torque is too low, install a .05 mm (.002 inch)
thicker shim. Repeat until 5 to 18 inch-pounds
turning torque is obtained.
TRANSFER SHAFT BEARI NG
L-4407.
(2) I nstal l a 4.66 mm (.184 i nch) gaugi ng shi m on the
transfer shaft.
(3) I nstal l transfer shaft gear and beari ng assembl y
and torque the nut to 271 Nm (200 ft. l bs.).
(a) Attach Tool L-4432 to the transfer gear.
the transfer shaft.
(d) Usi ng a di al i ndi cator, measure transfer shaft
end pl ay.
(5) Refer to the Transfer Beari ng Shi m Chart for the
requi red shi m combi nati on to obtai n the proper bear-
i ng setti ng.
L-4407.
(7) Remove the gaugi ng shi m and i nstal l the correct
shi m. I nstal l the transfer gear and beari ng assembl y.
to 271 Nm (200 ft. l bs.). Measure transfer shaft
endplay, endplay shouldbe.05to.10mm(.002to
.004 inch).
(9) Measure beari ng end pl ay as outl i ned i n Step (4).
End pl ay shoul d be between .05 mm and .10 mm (.002
to .004 i nch).
If end play is too high, install a .04 mm (.0016
inch) thinner shim. If end play is too low, install
a .04 mm(.0016 inch) thicker shimcombination.
Repeat until .05to .10mm(.002to .004inch) end
play is obtained.
TRANSFER BEARI NG SHI M CHART
TRANSAXLE 21 - 139
BEARI NG SHI M CHART
21 - 140 TRANSAXLE
ALL WHEEL DRI VE POWER TRANSFER UNI T (P.T.U.)
INDEX
page page
Fluid Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . 141
General Information . . . . . . . . . . . . . . . . . . . . . . 141
Output Flange Shim Selection . . . . . . . . . . . . . . 150
Power Transfer Unit (P.T.U.) . . . . . . . . . . . . . . . . 142
Power Transfer Unit End Cover Ball Bearing . . . . 155
Power Transfer Unit End CoverReseal . . . . . . . 145
Power Transfer Unit Half Shaft Inner Seal . . . . . . 152
Power Transfer Unit Input Shaft Cover Seal . . . . 150
Power Transfer Unit Input Shaft End Seal . . . . . . 153
Power Transfer Unit Input Shaft Seal . . . . . . . . . 146
Power Transfer Unit Outer Half Shaft Seal . . . . . 155
Power Transfer Unit Output Seal . . . . . . . . . . . . . 148
Power Transfer Unit Rear Cover O-Ring . . . . . . . 148
Seal Identification . . . . . . . . . . . . . . . . . . . . . . . . 141
Transaxle Differential Carrier Seal . . . . . . . . . . . . 147
GENERAL INFORMATION
The Power Transfer Uni t (P.T.U.) i s attached to a
modi fi ed automati c transaxl e case where the ri ght hal f
shaft extensi on housi ng woul d normal l y be l ocated.
The Transfer Uni t provi des the power to the rear
wheel s through a hypoi d ri ng gear and pi ni on set.
The Power Transfer Uni t i s seal ed from the transaxl e
and has i ts own oi l sump. The Uni t uses SAE 85W-90
gear l ubri cant and hol ds 1.15 l i ters (1.22 quarts).
The Power Transfer Uni t fi l l pl ug i s l ocated on the
end cover (Fi g. 1). Donot mistaketheblack plastic
inspection pluglocated on theP.T.U. casefor the
fill plug.
Servi ce of the Power Transfer Uni t i s l i mi ted to the
seal s, gaskets and one bal l beari ng. I f the ri ng gear and
pi ni on, any tapered rol l er beari ngs, case, covers, or
pi ni on carri er fai l the enti re uni t must be repl aced.
SEAL IDENTIFICATION
For accurate seal di agnosi s and repai r seal name and
l ocati on i s cri ti cal . Refer to fi gures 1, 2, 3 and 4 for
appropri ate seal name and l ocati on.
FLUID LEAK DIAGNOSIS
When di agnosi ng fl ui d l eaks on the Power Transfer
Uni t assembl y two weep hol es are provi ded to di agnose
certai n seal l eaks. These hol es are l ocated on the
bottom si de of the assembl y (Fi g. 5).
I f fl ui d l eak i s detected from ei ther weep hol e, seal
repl acement i s necessary. Do not attempt to repair
Fig. 1 Fill Plug Location
Fig. 1 Seal Location
TRANSAXLE 21 - 141
the leak by sealing weep holes, they must be kept
cl ear of seal ants for proper seal operati on.
I f fl ui d i s l eaki ng from weep hol e A (Fi g. 5) the type
of fl ui d l eaki ng wi l l determi ne whi ch seal needs to be
repl aced. I f the fl ui d l eaki ng i s red i n col or (transmi s-
si on fl ui d) thi s i ndi cates that the Transmi ssi on di ffer-
enti al carri er seal shoul d be repl aced. I f the fl ui d
l eaki ng i s l i ght brown (gear l ube) thi s i ndi cates that
the Power Transfer Uni t i nput seal shoul d be repl aced.
For repl acement of these seal s refer to Power Transfer
Uni t Servi ce Procedures.
I f fl ui d i s l eaki ng from weep hol e B (Fi g. 5) the type
of fl ui d l eaki ng wi l l determi ne whi ch seal i s l eaki ng. I f
the fl ui d l eaki ng i s red i n col or (transmi ssi on fl ui d) thi s
i ndi cates that the i nput shaft end seal shoul d be
repl aced. I f the fl ui d l eaki ng i s l i ght brown (gear l ube)
thi s i ndi cates that the hal f shaft i nner seal and P.T.U.
i nput shaft cover seal shoul d be repl aced. For repl ace-
ment of these seal s refer to Power Transfer Uni t
Servi ce Procedures.
Before condemni ng any seal or gasket be sure that
the rear rocker arm cover on the engi ne i s not the cause
of the oi l l eak. Oi l l eaki ng from the rocker arm cover i s
easi l y mi staken for a l eaki ng Power Transfer Uni t.
POWER TRANSFER UNIT (P. T. U. )
(1) Rai se vehi cl e and remove front wheel s.
(2) Remove propel l er shaft assembl y.
Fig. 5 Weep Hole Locations
Fig. 1 Remove Cross Member Bridge Bolts
21 - 142 TRANSAXLE
Fig. 2 Remove Power Steering Hose Bracket
Fig. 3 Secure Rack and Pinion to Frame Rail
Fig. 4 Remove Ball Joint Bolt (Right and Left Side)
Fig. 5 Remove Lower Bobble Strut Bolt
TRANSAXLE 21 - 143
CAUTION: A certain amount of oil will drain out of the
transaxle when the drive shaft is removed.
Remove right front drive shaft. Refer to Sus-
pension, Group 2toremoveor install wheel hub
nut and right drive shaft.
Fig. 6 Support Crossmember with Transmission
Jack
Fig. 7 Remove Front Suspension Crossmember
Fasteners
Fig. 8 Lower Crossmember Assembly and Remove
Fig. 9 Remove P.T.U Support Bracket and Bobble
Strut Assembly
Fig. 10 Remove Rear P.T.U Brace Bolts
21 - 144 TRANSAXLE
Remove P.T.U. remote vent from left engine
mount.
Remove P.T.U. assembly fromvehicle.
To Install, Reverse Removal Procedure.
POWER TRANSFER UNIT END COVER RESEAL
The Power Transfer Uni t must be removed from the
vehi cl e to perform thi s operati on. Refer to Power
Transfer Uni t Removal i n thi s secti on for procedures.
(1) Remove P.T.U. end cover bol ts (Fi g. 13).
(2) Gentl y tap on end cover ears wi th a hammer to
separate end cover from the case (Fi g. 14).
El i mi nator No.518 or equi val ent to seal i ng surfaces.
(5) Rei nstal l cover and ti ghten bol ts to 28 Nm (250
i n. l bs.) i n the sequence shown i n fi gure 15. Reti ghten
fi rst bol t after al l others are ti ght.
CAUTION: When end cover is installed be careful not
to damage the P.T.U. Input Shaft Cover Seal.
(6) Rei nstal l P.T.U. i nto vehi cl e.
(7) Check and fi l l fl ui ds as requi red.
Fig. 11 Remove Distance Sensor from P.T.U.
Fig. 12 Remove P.T.U. Mounting Bolts (4)
Fig. 13 P.T.U. End Cover Bolts
Fig. 14 End Cover Removal
TRANSAXLE 21 - 145
POWER TRANSFER UNIT INPUT SHAFT SEAL
vehi cl e to servi ce thi s seal . Refer to Power Transfer
Uni t Removal i n thi s secti on for procedures.
REMOVAL
(2) Gentl y tap on end cover ears to separate cover
from case (Fi g. 2).
(3) Remove ri ng gear oi l sl i nger (Fi g. 3).
(4) Remove i nput shaft and ri ng gear from case (Fi g.
4).
(5) Use Speci al Tool No. 7794-A (seal pul l er) to
remove seal (Fi g. 5).
I NSTALLATI ON
(2) Lay housi ng on bench and i nstal l new seal wi th
seal dri ver C-4657 and handl e C-4171 (Fi g. 6). The seal
must be i nstal l ed wi th the spri ng si de faci ng to-
Fig. 15 Bolt Tightening Sequence
Fig. 3 Oil Trough
21 - 146 TRANSAXLE
wards the ri ng gear. Dri ve the seal i n unti l i t bottoms
agai nst the case shoul der.
(3) I nstal l i nput shaft.
(4) I nstal l oi l trough.
El i mi nator No. 518 or equi val ent to seal i ng surfaces of
end cover and rei nstal l . Ti ghten bol ts to 28 Nm (250
i n. l bs.)
(6) Rei nstal l P.T.U. assembl y i nto vehi cl e.
TRANSAXLE DIFFERENTIAL CARRIER SEAL
vehi cl e to repl ace thi s seal .
REMOVAL
(1) Remove P.T.U. from vehi cl e.
(2) Use a pry bar to remove seal from retai ner pl ate
(Fi g. 7). Be careful not to damage seal journal when
removi ng seal .
I NSTALLATI ON
(1) Usi ng a l arge socket, careful l y i nstal l new seal .
The spri ng si de of the seal must face the transaxl e
di fferenti al .
(2) Rei nstal l the P.T.U. i nto the vehi cl e.
Fig. 7 Transaxle Differential Carrier Seal
Fig. 4 Input Shaft and Ring Gear Removal
Fig. 5 Seal Removal
Fig. 6 Seal Installation
TRANSAXLE 21 - 147
POWER TRANSFER UNIT REAR COVER O-RING
REMOVAL
(2) Remove rear cover retai ni ng bol ts (Fi g. 1).
(3) I ndex rear cover to the case for l ater reassembl y
(Fi g. 2).
(4) Pul l rear cover out of the P.T.U. case (Fi g. 3).
(5) Remove rear cover O-Ri ng (Fi g. 4).
POWER TRANSFER UNIT OUTPUT SEAL
The power transfer uni t must be removed from the
vehi cl e to repl ace thi s seal .
REMOVAL
(2) Remove propel l er shaft.
(3) Remove rear cover retai ni ng bol ts (Fi g. 5).
(4) I ndex rear cover to the case for l ater reassembl y
(Fi g. 6).
(5) Pul l rear cover out of the P.T.U. case (Fi g. 7).
(6) Remove output fl ange nut (Fi g. 8).
(7) I ndex the pi ni on to the fl ange (Fi g. 9).
(8) Usi ng a hydraul i c press, press off output fl ange
from pi ni on.
Fig. 2 Mark Rear Cover
Fig. 3 Rear Cover Removal
Fig. 4 O-Ring Removal
21 - 148 TRANSAXLE
(9) Use a hammer and chi sel to remove output seal
(Fi g. 10).
CAUTION: If the output flange requires replacement,
a new shim may be required. Refer to Output Flange
Shim Selection procedure in this section to deter-
mine correct shim requirements.
I NSTALLATI ON
(1) I nstal l new seal wi th Seal I nstal l er 5049 (Fi g.
11).
(2) I f the ori gi nal fl ange i s used, al i gn i ndex marks
and press fl ange onto pi ni on. I f a new fl ange i s used
di sregard the al i gnment marks on the pi ni on and press
fl ange onto the pi ni on.
(3) I nstal l fl ange nut and ti ghten to 163 Nm (120 ft.
l bs.).
(4) I nstal l rear cover. Use care not to cut rear cover
O-Ri ng when i nstal l i ng rear cover i nto P.T.U. housi ng.
Fig. 6 Mark Rear Cover
Fig. 7 Rear Cover Removal
Fig. 8 Output Flange Nut
Fig. 9 Mark Flange and shaft
Fig. 10 Seal Removal
TRANSAXLE 21 - 149
(5) I nstal l rear cover retai ni ng bol ts and ti ghten to
28 Nm (250 i n. l bs.).
(6) I nstal l propel l er shaft.
OUTPUT FLANGE SHIM SELECTION
Thi s procedure i s used when the output fl ange i s
repl aced. Repl acement of the output fl ange requi res
i nstal l ati on of the correct si ze shi m to mai ntai n bear-
i ng prel oad. Theshimmust protrudefromthenew
output flangethesamedistancethat theoriginal
shimprotruded fromthe original flange.
(1) Stand the ori gi nal output fl ange on end wi th
shi m si de poi nti ng up.
(2) Pl ace ori gi nal shi m i nto groove i n top of fl ange.
(3) Pl ace a strai ght edge across the shi m.
(4) Usi ng feel er gauge, measure the di stance be-
tween the strai ght edge and the top of the fl ange (Fi g.
12). Record thi s measurement.
(5) Repeat steps 1 through 4 usi ng the new flange
and the original shim. Record thi s measurement.
(6) I f measurements are not equal , use a new shi m
that wi l l protrude from new output fl ange the same
amount that ori gi nal shi m protruded from ori gi nal
output fl ange.
For Exampl e: The ori gi nal shi m protrudes 0.075 i nch
from the ori gi nal output fl ange. Pl ace the original
shimi nto the new output fl ange. The protrusi on of the
shi m i n the new fl ange i s 0.085 i nch. Thi s i ndi cates
that a 0.010 i nch thi nner shi m i s requi red to mai ntai n
the ori gi nal protrusi on.
(7) I nstal l output fl ange and torque fl ange nut to 163
Nm (120 ft. l bs.).
(8) Check the turni ng torque of the pi ni on before
i nstal l i ng the rear cover i nto the P.T.U. The turni ng
torque shoul d be between 2.6 Nm and 3.0 Nm (23 i n.
l bs. and 27 i n. l bs.).
POWER TRANSFER UNIT INPUT SHAFT COVER
SEAL
The power transfer uni t i nput shaft cover seal i s the
l arger of the two seal s l ocated on the i nsi de of the end
cover. The di fferenti al beari ng cup must be removed to
servi ce thi s seal .
The Power Transfer Uni t must be removed from
vehi cl e to perform thi s operati on.
REMOVAL
(2) Gentl y tap on end cover ears to separate cover
from case (Fi g. 2).
(3) Use speci al tool No. 6514 and remove the di ffer-
enti al beari ng race l ocated i n the end cover (Fi g. 3).
The race must be removed to gai n access to the seal .
(4) Use speci al tool No. 7794-A to remove seal (Fi g.
4).
I NSTALLATI ON
Fig. 12 Output Flange Shim Measurement
21 - 150 TRANSAXLE
(2) Use speci al tool No. MD998803 and i nstal l seal
(Fi g 5). When i nstal l i ng seal the spri ng si de of the seal
must face toward the speci al tool .
(3) Rei nstal l the ori gi nal beari ng race and shi m
usi ng speci al tool No. 6522 (Fi g. 6 and 7).
CAUTION:The original shim must be installed behind
the bearing cup to maintain proper bearing preload.
El i mi nator No. 518 or equi val ent to seal i ng surfaces of
end cover.
(5) Pl ace end cover onto P.T.U. case and i nstal l bol ts.
Ti ghten bol ts to 28 Nm (250 i n. l bs.) i n the se-
Fig. 3 Bearing Race Removal
Fig. 4 Seal Removal
TRANSAXLE 21 - 151
quence shown i n fi gure 8. Reti ghten fi rst bol t after al l
others are ti ght.
(6) Rei nstal l P.T.U. assembl y i nto vehi cl e.
POWER TRANSFER UNIT HALF SHAFT INNER
SEAL
The power transfer uni t hal f shaft i nner seal i s the
smal l er of the two seal s l ocated on the i nsi de of the end
cover.
REMOVAL
(1) Remove power transfer uni t from the vehi cl e.
(2) Remove end cover bol ts (Fi g. 1).
(3) Tap on end cover ears to separate cover from case
(Fi g. 2).
(4) Dri ve seal out wi th a hammer and smal l chi sel
(Fi g. 3).
I NSTALLATI ON
(2) I nstal l seal wi th a 1 1/16 i nch socket (Fi g. 4). The
seal must be i nstal l ed wi th the spri ng si de of the seal
faci ng end cover bal l beari ng. The seal wi l l bottom
agai nst a machi ned shoul der i n the cover.
(3) Cl ean seal i ng surfaces of the end cover and P.T.U.
case. Appl y a bead of Mopar Gasket Maker, Locti te
Gasket El i mi nator No. 518 or equi val ent.
Fig. 6 Bearing Shim and Race
Fig. 7 Installing Bearing Race
Fig. 1 End Cover Bolts
21 - 152 TRANSAXLE
Ti ghten bol ts to 28 Nm (250 i n. l bs.) i n the sequence
shown i n fi gure 5. Reti ghten fi rst bol t after al l other
bol ts are ti ght.
(5) Rei nstal l P.T.U. assembl y.
POWER TRANSFER UNIT INPUT SHAFT END SEAL
The i nput shaft end seal i s l ocated on the end of the
i nput shaft.
REMOVAL
(1) Remove power transfer uni t from the vehi cl e.
(2) Remove end cover bol ts (Fi g. 6).
Fig. 3 Seal Removal
TRANSAXLE 21 - 153
(3) Tap on end cover ears to separate end cover from
case (Fi g. 7).
(4) Pry out seal wi th a pry bar (Fi g. 8).
I NSTALLATI ON
(2) Remove i nput shaft from housi ng and stand on
soft bl ock of wood. I nstal l i nput shaft end seal wi th seal
i nstal l er 5065 and handl e C-4171.
(3) Lubri cate seal l i p after i nstal l i ng seal i nto i nput
shaft.
(4) Cl ean seal i ng surfaces of the end cover and P.T.U.
case. Appl y a bead of Mopar Gasket Maker, Locti te
Gasket El i mi nator No. 518 or equi val ent.
Ti ghten bol ts to 28 Nm (250 i n. l bs.) i n the sequence
shown i n fi gure 9. Reti ghten fi rst bol t after al l others
are ti ght.
(6) Rei nstal l P.T.U. assembl y.
Fig. 6 End Cover Bolts
Fig. 8 Seal Removal
21 - 154 TRANSAXLE
POWER TRANSFER UNIT OUTER HALF SHAFT
SEAL
The outer hal f shaft seal i s l ocated on the outsi de of
the end cover. The P.T.U. does not have to be removed
to repl ace thi s seal .
REMOVAL
(1) Li ft vehi cl e on hoi st.
(2) Remove ri ght front hal f shaft from vehi cl e.
(3) Remove seal wi th a chi sel and hammer (Fi g. 1).
I NSTALLATI ON
(2) I nstal l new seal wi th seal i nstal l er MD998334
(Fi g. 2).
(3) Rei nstal l ri ght front hal f shaft.
POWER TRANSFER UNIT END COVER BALL BEAR-
ING
The end cover bal l beari ng can be removed and
i nstal l ed wi thout removi ng the Power Transfer Uni t
from the vehi cl e. When repl aci ng the beari ng the
output seal must be removed to gai n access to the
beari ng.
REMOVAL
(2) Remove ri ght front hal f shaft from vehi cl e.
(3) Remove output seal wi th a hammer and chi sel
(Fi g. 3).
(4) Remove beari ng retai ni ng snap ri ng (Fi g. 4).
Fig. 1 Seal Removal
Fig. 3 Output Seal Removal
Fig. 4 Bearing Snap Ring
TRANSAXLE 21 - 155
(5) Use beari ng pul l er MD998346 to remove beari ng
(Fi g.5).
I NSTALLATI ON
(1) Use beari ng dri ver L-4530 and handl e C-4171-2
to i nstal l beari ng.
(2) I nstal l beari ng retai ni ng snap ri ng.
CAUTION:When installing bearing retaining snap
ring, be sure to index the snap ring so that the snap
ring does not cover bearing oil passage.
(3) I nstal l new output seal usi ng MD998334 seal
i nstal l er (Fi g. 7). Do not reuse the old seal.
(4) Rei nstal l ri ght front hal f shaft.
Fig. 5 Bearing Removal
Fig. 6 Bearing Installation
Fig. 7 Installing New Seal
21 - 156 TRANSAXLE
4-SPEED ELECTRONI C TRANSAXLE ON-BOARD DI AGNOSTI CS
INDEX
page page
Ccd Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
DRBII (Diagnostic Read-Out Box) . . . . . . . . . . . . 158
Fault Code Charts . . . . . . . . . . . . . . . . . . . . . . . 158
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Limp-In Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
On-Board Diagnostics Information . . . . . . . . . . . . 157
System Fault Messages/Codes . . . . . . . . . . . . . . 157
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 174
GENERAL INFORMATION
The i nformati on i n thi s manual i s desi gned to hel p
the techni ci an understand and repai r the el ectroni c
transaxl e wi th the ai d of the bui l t i n on-board di agnos-
ti cs.
Chrysler Corporation has developed a com-
plete set of diagnostic manuals which cover di-
agnosis. They have been designed to make tran-
saxle diagnosis accurate and simple. Use these
manualswith theDRBII andthelatest cartridge,
when diagnosing transaxle problems.
ON-BOARD DIAGNOSTICS INFORMATION
The 4-Speed El ectroni c Transaxl e i s control l ed and
moni tored by the EATX control l er. The control l er moni -
tors cri ti cal i nput and output ci rcui ts wi thi n the El ec-
troni c Transaxl e system.
Some ci rcui ts are tested conti nuousl y; others are checked
onl y under certai n condi ti ons. Each ci rcui t moni tored by the
control l er has a correspondi ng faul t message assi gned to i t
that can be read wi th the DRBI I .
I f the on-board di agnosti c system senses that one of
the ci rcui ts i s mal functi oni ng, the correspondi ng faul t
message i s stored i n memory. I f the mal functi on goes
away after the faul t code i s stored, the control l er wi l l
erase the faul t after 75 key cycl es.
CCD BUS
I n order to di agnose the EATX, faul t codes i n the
EATX control l ers memory shoul d be read usi ng the
Di agnosti c Readout Box (DRBI I ). I f more than one
faul t code exi sts, di agnosti c pri ori ty shoul d be gi ven to
the most recent code. Wi th CCD bus bi as and commu-
ni cati on probl ems, however, the DRBI I di spl ays an
appropri ate message and faul t codes mi ght not be
accessi bl e unti l the bus probl em i s fi xed. The fol l owi ng
i s a l i st of probabl e causes for a bus probl em:
Open or short to ground/battery i n ei ther or both
CCD bus wi res (pi ns 4 and 43).
Open or short to ground/battery i n ei ther or both
EATX bi as wi res (pi n 5 and 44) on vehi cl es requi ri ng
EATX to bi as the bus.
Open or short to ground/battery i n the di agnosti c
connector bus wi re.
I nternal fai l ure of any control l er connected to the
bus.
The CCD bus shoul d have 2.5 vol ts (+2.5 vol ts on
CCD+ and -2.5 vol ts on CCD-).
The bus error message di spl ayed by the DRBI I
shoul d be hel pful i n di agnosi ng the CCD bus.
For more detai l ed i nformati on on di agnosi ng CCD bus
probl ems, refer to the 1992 di agnosti c procedures Manual for
non-communi cati on wi th the CCD bus probl ems. Al l other
probl ems refer to the 1992 Body Vehi cl e Communi cati ons
Di agnosti c Procedures Manual .
SYSTEM FAULT MESSAGES/CODES
Faul t codes are two-di gi t numbers that i denti fy
whi ch ci rcui t i s mal functi oni ng. A faul t code can be set
for hydraul i c and mechani cal reasons as wel l as for
el ectri cal probl ems. I n most cases, faul t codes do not
pi npoi nt whi ch speci fi c component i s defecti ve.
Fault codecan only beread with theuseof the
DRBII Read-out Box or equivalent.
HARD FAULTS
Any faul t code that comes back wi thi n 3 engi ne
starts (reset count 3 or l ess) i s a Hard Faul t. Thi s
means that the defect i s there every ti me the control l er
checks that ci rcui t.
SOFT FAULTS
A Soft Faul t i s one that occurs i ntermi ttentl y. I t i s
not there every ti me the control l er checks the ci rcui t.
Most soft faul ts are caused by wi ri ng or connector
probl ems. I ntermi ttent defects must be l ooked for
under the speci fi c condi ti ons that caused them.
LIMP-IN MODE
The control l er conti nuousl y checks for el ectri cal and
i nternal transaxl e probl ems. When a probl em i s
sensed, the control l er stores a faul t code. Al l but twel ve
of these codes cause the transaxl e to go i nto the
Li mp-i n mode. Whi l e i n thi s mode, el ectri cal power i s
taken away from the transaxl e. When thi s happens,
the onl y transaxl e ranges that wi l l functi on are:
Park
Neutral
Reverse
Second Gear
TRANSAXLE 21 - 157
No upshi fts or downshi fts are al l owed whi l e i n the
Li mp-i n mode. The posi ti on of the manual val ve al one
al l ows the three ranges that are avai l abl e.
Al though engi ne performance wi l l be reduced whi l e
i n thi s mode, the vehi cl e can be dri ven i n for servi ce.
DRBII (DIAGNOSTIC READ-OUT BOX)
The DRBI I i s a di agnosti c read-out box desi gned by
Chrysl er to gai n access to the on-board di agnosti cs that
are found on al l Chrysl er-bui l t cars and trucks.
The DRBI I has a few di agnosti c capabi l i ti es by i tsel f.
To perform most di agnosti c tests, a program cartri dge
must be i nserted. I t contai ns the di agnosti c test pro-
grams.
There are di agnosti c read-out boxes avai l abl e from
other manufactures that can be used on Chrysl er
vehi cl es. However, the di agnosti c test procedures i n
thi s manual have been desi gned for use wi th the
Chrysl ers DRBI I di agnosti c readout box.
The DRBI I operates by communi cati ng wi th the
control l er of the vehi cl e system bei ng tested. To com-
muni cate wi th the control l er, the DRBI I must be con-
nected to the bl ue CCD bus connector l ocated under the
i nstrument panel . Refer to theUsi ng the DRBI I
manual or the Di agnosti c Procedures Manual for com-
pl ete i nformati on on how to hook up and use the
DRBI I .
FAULT CODE CHARTS
Bel ow i s a bri ef descri pti on of what each secti on of
the faul t code charts are addressi ng.
FAULT CODE-Tel l s the code number and name (as
shown on the DRBI I ).
BACKGROUND-A bri ef descri pti on of the ci rcui t
that the control l er i s moni tori ng.
WHEN CHECKED-The poi nt of ti me or condi ti on
when the control l er makes i ts system check.
ARMING CONDITIONS-The parameters that
must be met before a code can be set.
FAULT CONDITION-What the control l er saw that
i s determi ned to be a probl em. (i e. vol tage to hi gh or
l ow, swi tch/sol enoi d probl ems)
FAULT SET TIME-Refers to the amount of ti me (i n
seconds) a fai l ure must occur before a faul t code i s set
i n memory.
EFFECT-Refers to how the faul t effects transaxl e
operati ons.
POSSIBLE CAUSE-Refers to the systems or ci r-
cui ts whi ch coul d cause the faul t to be recorded.
FAULT CODE 11
21 - 158 TRANSAXLE
FAULT CODE 12
FAULT CODE 13
TRANSAXLE 21 - 159
FAULT CODE 14
FAULT CODE 15
21 - 160 TRANSAXLE
FAULT CODE 16
FAULT CODE 17
TRANSAXLE 21 - 161
FAULT CODE 18
FAULT CODE 19
21 - 162 TRANSAXLE
FAULT CODE 20
TRANSAXLE 21 - 163
FAULT CODE 21-27
21 - 164 TRANSAXLE
FAULT CODE 28
TRANSAXLE 21 - 165
FAULT CODE 29
FAULT CODE 31-32
21 - 166 TRANSAXLE
FAULT CODE 36
FAULT CODE 37
TRANSAXLE 21 - 167
FAULT CODE 38
21 - 168 TRANSAXLE
FAULT CODE 41-44
TRANSAXLE 21 - 169
FAULT CODE 45
FAULT CODE 46
21 - 170 TRANSAXLE
FAULT CODE 47
TRANSAXLE 21 - 171
FAULT CODE 50-58
21 - 172 TRANSAXLE
FAULT CODE 60-63
TRANSAXLE 21 - 173
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ON BOARD DI AGNOSTI CS GLOSSARY
TRANSAXLE 21 - 175
THREE SPEED TRANSAXLE HYDRAULI C SCHEMATI CS
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TRANSAXLE 21 - 183
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21 - 184 TRANSAXLE
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TRANSAXLE 21 - 185
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TRANSAXLE 21 - 187
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TRANSAXLE 21 - 195
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21 - 196 TRANSAXLE
3-SPEED AUTOMATI C TRANSAXLE
TRANSAXLE 21 - 197
4-SPEED ELECTRONI C AUTOMATI C TRANSAXLE
21 - 198 TRANSAXLE
SPECI FI CATI ONS
THREE SPEED TRANSAXLE TI GHTENI NG REFERENCE
Three Speed Automatic Transaxle:
TRANSAXLE 21 - 199
4 SPEED ELECTRONI C TRANSAXLE TI GHTENI NG REFERENCE
POWER TRANSFER UNI T TI GHTENI NG REFERENCE
21 - 200 TRANSAXLE
<CONVERSI ON CHART
TRANSAXLE 21 - 201
_FRONT SUSPENSION AND DRIVE SHAFTS
CONTENTS
page page
DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . 26
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 2
FRONT SUSPENSION SERVICE PROCEDURES . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 46
i ncl uded i n the I ntroducti on secti on at the front of thi s
Servi ce Manual .
An i ndependent MacPherson Type front suspensi on
i s used on these vehi cl es. Verti cal shock absorbi ng
struts attach to the upper fender rei nforcement and
the steeri ng knuckl e to provi de upper steeri ng knuckl e
posi ti on. Lower control arms are attached i nboard to a
crossmember and outboard to the steeri ng knuckl e
through a bal l joi nt to provi de l ower steeri ng knuckl e
posi ti on. Duri ng steeri ng maneuvers, the strut
(through a pi vot beari ng i n the upper retai ner) and the
steeri ng knuckl e turn as an assembl y (Fi g. 1).
Fig. 1 Front Suspension (Typical)
FRONT SUSPENSION AND DRIVE SHAFTS 2 - 1
FRONT SUSPENSI ON
FRONT SUSPENSION MAJOR COMPONENTS (Fig.
1, 2 and 3)
STRUT SUPPORT
The system i s supported by coi l spri ngs posi ti oned
offset around the struts. The spri ngs are contai ned
between an upper seat, l ocated just bel ow the top strut
mount assembl y (Fi g. 2) and a l ower spri ng seat on the
strut l ower housi ng.
The top of each strut assembl y i s bol ted to the upper
fender rei nforcement (shock tower) through a rubber
i sol ated mount.
The bottom attaches to the top of the steeri ng
knuckl e wi th two through bol ts. On some vehi cl es, one
bol t has an eccentri c cam l ocated bel ow the head of the
bol t for camber adjustment. On the other vehi cl es the
camber adjustment i s done by manual l y movi ng the
steeri ng knuckl e wi thi n the strut assembl y. Caster i s a
fi xed setti ng on al l vehi cl es and i s not adjustabl e.
STEERI NG KNUCKLE
The steeri ng knuckl e i s a si ngl e casti ng wi th l egs
machi ned for attachment to the strut damper, steeri ng
l i nkage, brake adaptor, and l ower control arm bal l
joi nt. The knuckl e al so hol ds the front dri ve hub
beari ng. The hub i s posi ti oned through the beari ng and
knuckl e, wi th the constant vel oci ty stub shaft spl i ned
through the hub.
LOWER CONTROL ARM
The l ower control arm i s a steel casti ng wi th 2 l arge
spool type rubber pi vot bushi ngs. The l ower control
arm i s bol ted to the crossmember wi th pi vot bol ts
through the center of the rubber pi vot bushi ngs.
The bal l joi nt i s pressed i nto the control arm and has
a non-tapered stud wi th a notch for cl amp bol t cl ear-
ance. The stud i s cl amped and l ocked i nto the steeri ng
knuckl e l eg wi th a cl amp bol t.
The l ower control arms are i nter-connected through
a rubber i sol ated sway bar (Fi g. 2).
DRI VESHAFTS
A l eft and ri ght dri veshaft i s attached i nboard to the
transaxl e di fferenti al si de gears, and outboard to the
dri ven wheel hub.
To del i ver dri vi ng force from the transaxl e to the
front wheel s duri ng turni ng maneuvers and suspen-
si on movement. Both shafts are constructed wi th con-
stant vel oci ty uni versal joi nts at both ends.
Both shafts have a Tri pod (sl i di ng) joi nt at the
transaxl e end and Rzeppa joi nts (wi th spl i ned stub
shafts) on the hub ends. Due to the transaxl e l ocati on
the connecti ng shafts between the C/V joi nts are of
di fferent l ength and constructi on. The ri ght shaft i s
l onger and of tubul ar constructi on. The l eft shaft i s
sol i d.
2 - 2 FRONT SUSPENSION AND DRIVE SHAFTS
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SUSPENSI ON/STEERI NG/DRI VE DI AGNOSI S/FRONT WHEEL DRI VE
FRONT SUSPENSI ON SERVI CE PROCEDURES
INDEX
page page
Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hub and Bearing Assembly . . . . . . . . . . . . . . . . . 20
Knuckle (Front Suspension) . . . . . . . . . . . . . . . . . 16
Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . . . 10
Lower Control Arm Pivot Bushings . . . . . . . . . . . . 11
Shock Absorbers (Strut Damper) . . . . . . . . . . . . . 10
Strut Damper Assembly . . . . . . . . . . . . . . . . . . . . . 8
Suspension Coil Springs . . . . . . . . . . . . . . . . . . . 10
Sway Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WHEEL ALIGNMENT
Front wheel al i gnment i s the proper adjustment of
al l the i nterrel ated suspensi on angl es affecti ng the
runni ng and steeri ng of the front wheel s of the vehi cl e.
The method of checki ng front al i gnment wi l l vary
dependi ng on the type of equi pment bei ng used. The
i nstructi ons furni shed by the manufacturer of the
equi pment shoul d al ways be fol l owed. Wi th the excep-
ti on that the wheel al i gnment speci fi cati ons recom-
mended by Chrysl er Corporati on shoul d al ways be
used. The Chrysl er Corporati on recommended speci fi -
cati ons, are l i sted i n Speci fi cati ons at the back of thi s
servi ce manual secti on.
There are si x basi c factors whi ch are the foundati on
to front wheel al i gnment. These are vehi cl e hei ght,
caster, camber, toe-i n, steeri ng axi s i ncl i nati on and
toe-out on turns. Of the si x basi c factors onl y camber
and toe are mechani cal l y adjustabl e (Fi g. 1).
Do not attempt to modify any suspension or
steering components by heating or bending.
Adjustments and checks shoul d be made i n the
fol l owi ng sequence.
(a) Camber
(b) Toe
Camber i s the number of degrees the top of the
wheel and ti re assembl y i s ti l ted i nboard or outboard
from a true verti cal l i ne. I nboard ti l t i s negati ve
camber. Outboard ti l t i s posi ti ve camber (Fi g. 1).
Excessi ve camber i s a ti re wear factor: negati ve
camber causes wear on the i nsi de of the ti re, whi l e
posi ti ve camber causes wear to the outsi de.
Toe i s measured i n degrees or i nches and i s the
di stance the front edges of the ti res are cl oser (or
farther apart) than the rear edges. See Front Wheel
Dri ve Speci fi cati ons for Toe. setti ngs.
PRE-ALI GNMENT
Before any attempt i s made to change or correct the
wheel al i gnment factors. The fol l owi ng part i nspecti on
and the necessary correcti ons shoul d be made to those
parts whi ch i nfl uence the steeri ng of the vehi cl e.
(1) Check and i nfl ate al l ti res to recommended pres-
sure. Al l ti res shoul d be the same si ze and i n good
condi ti on and have approxi matel y the same wear. Note
the type of tread wear whi ch wi l l ai d i n di agnosi ng, see
Wheel s and Ti res, Group 22.
(2) Check front wheel and ti re assembl y for radi al
runout.
(3) I nspect l ower bal l joi nts and al l steeri ng l i nkage
for l ooseness.
(4) Check for broken or sagged front and rear
spri ngs.
Front suspensi on MUST onl y be checked after the
vehi cl e has the fol l owi ng areas i nspected and or ad-
justed. Recommended ti re pressures, ful l tank of fuel ,
no passenger or l uggage compartment l oad and i s on a
l evel fl oor or al i gnment rack.
Just pri or to each al i gnment readi ng. Vehi cl e shoul d
be bounced (rear fi rst, then front) by graspi ng bumper
at center and jounci ng each end an equal number of
ti mes. Al ways rel ease bumpers at bottom of down cycl e.
CAMBER ADJUSTMENT
(1) Prepare vehi cl e as descri bed i n Pre-Al i gnment.
(2) Loosen cam and through bol ts on each si de (See
Fi g. 1).
(3) Rotate cam bol t to move top of wheel i n or out to
speci fi ed camber.
(4) Whi l e hol di ng cam bol t wi th wrench to keep i t
from rotati ng. Ti ghten cam bol t nuts to 100 Nm (75 ft.
l bs.) torque plus 1/4 turn beyond speci fi ed torque.
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TOE ADJUSTMENT
(1) Prepare vehi cl e as descri bed i n Pre-Al i gnment.
(2) Center steeri ng wheel and hol d wi th steeri ng
wheel cl amp.
(3) Loosen ti e rod l ocknuts (Fi g. 2). Rotate i nner ti e
rods to al i gn front wheel toe to speci fi cati ons.
CAUTION: Do not twist inner tie rod to steering gear
rubber boots during adjustment.
(4) Ti ghten ti e rod l ocknuts to 75 Nm (55 ft. l bs.)
torque.
(5) Adjust steeri ng gear to ti e rod boots at ti e rod.
(6) Remove steeri ng wheel cl amp.
STRUT DAMPER ASSEMBLY
REMOVAL
(1) Loosen front wheel attachi ng l ug nuts.
(2) Rai se vehi cl e, see Hoi sti ng i n Lubri cati on and
Mai ntenance, Group O.
(3) Remove front wheel and ti re assembl y.
Wheretheserviceprocedureincludesreassem-
bly of original strut (shock absorber) to original
knuckle. Mark camadjusting bolt (Fig. 1).
(4) Remove cam bol t, knuckl e bol t and brake hose to
damper bracket retai ni ng bol t (Fi g. 1).
(5) Remove strut damper upper mount assembl y to
shock tower mounti ng nut and washer assembl i es (Fi g.
1)
SHOCK ABSORBER I NSPECT
I nspect for evi dence of fl ui d l eaki ng from around the
strut assembl y shaft seal at the upper end of the
reservoi r. (Actual l eakage wi l l be a stream of fl ui d
runni ng down the si de and dri ppi ng off l ower end of
uni t. (Aslight amount of seepagearoundthestrut
rod is not unusual and does not affect perfor-
mance).
I NSTALLATI ON
(1) I nstal l strut assembl y i nto shock tower. I nstal l
the 3 strut assembl y to shock tower attachi ng nut and
washer assembl i es. Ti ghten nuts to 27 Nm (20 ft. l bs.)
torque.
(2) Posi ti on neck of steeri ng knuckl e i nto strut as-
sembl y. I nstal l cam and knuckl e bol ts through strut
assembl y and steeri ng knuckl e. I nstal l washer pl ate
and nuts (Fi g. 1) do not ti ghten nuts.
(3) Attach brake hose retai ner to damper, ti ghten
screw to 13 Nm (10 ft. l bs.) torque.
(4) I ndex cam bol t to ori gi nal mark (Fi g. 2).
(5) Pl ace a 4 i nch (or l arger) C cl amp on the strut
and knuckl e (Fi g. 2). Ti ghten the cl amp just enough to
el i mi nate any l ooseness between the knuckl e and the
strut, then check al i gnment of the i ndex marks (Fi g. 2).
Hol di ng the cam and knuckl e bol t so they
Fig. 2 Front Wheel Toe Adjustment
Fig. 1 Strut Damper Removal
Fig. 2 Strut Assembly Installation
cannot rotate, ti ghten the nuts to 100 Nm (75 ft.
l bs.) torque plus 1/4 turn. Remove C cl amp.
nuts to 129 Nm (95 ft. l bs.) torque.
DI SASSEMBLY (STRUT DAMPER)
(1) Compress front coi l spri ng wi th Spri ng Com-
pressor, Speci al Tool C-4838 (Fi g. 3).
(2) Hol d end of strut shaft from rotati ng wi th
wrench, whi l e l ooseni ng strut shaft nut. Remove nut
from shaft (Fi g. 4).
(3) Remove the upper strut mount from the strut
assembl y.
(4) Remove coi l spri ng from the strut assembl y.
Mark spring for installation back on the same
side of the vehicle (Fig. 8).
CAUTION: see Suspension Coil Springs before re-
leasing coil from Tool C-4838.
(5) I nspect strut damper, mount assembl y (Fi g. 5)
for:
(a) Severe deteri orati on of rubber i sol ator; re-
tai ners for cracks and di storti on and bond fai l ure of
retai ners and rubber i sol ators.
(b) Beari ngs for bi ndi ng.
(c) Shock Absorber for fl at spots over ful l stroke
al so see, Shock Absorbers, (strut damper).
ASSEMBLE (STRUT DAMPER)
(1) Mount the strut assembl y i n a verti cal posi ti on.
(2) Pl ace the compressed spri ng onto the strut as-
sembl y, so the end of the coi l i s seated i n the seat re-
cess i n l ower spri ng mount (Fi g. 6).
(3) I nstal l the dust shi el d, i sol ator (i f so equi pped)
jounce bumper, spacer (as requi red), and spri ng seat
onto the top of the strut shaft (Fi g. 5).
(4) Posi ti on top spri ng seat al i gnment tab correctl y
wi th respect to bottom bracket (Fi g. 6).
(5) I nstal l the rebound retai ner and shaft nut
(Fi g. 5).
(6) Ti ghten the strut shaft nut usi ng, Strut Rod
Socket And Hol der, Speci al Tool L-4558. Torque strut
shaft nut to 75 Nm (55 ft. l bs.) pl us 1/4 turn (Fi g. 7).
Fig. 3 Compressing Coil Spring
Fig. 4 Loosening Strut Assembly Shaft Nut
Fig. 5 Mount Assembly
Fig. 6 Spring Seat Alignment Notch Position to
Bracket
WARNING: THIS STEP MUST BE DONE BEFORE
SPRING COMPRESSOR, SPECIAL TOOL C-4838 IS
RELEASED FROM THE COIL SPRING.
(7) Veri fy coi l spri ng i s al i gned correctl y wi th respect
to bottom bracket (Fi g. 6).
(8) Rel ease Spri ng Compressor Tool C-4838.
SUSPENSION COIL SPRINGS
Spri ngs are rated separatel y for each si de of vehi cl e
dependi ng on opti onal equi pment and type of servi ce.
Duri ng servi ce procedures where both spri ngs are
removed, mark spri ngs (Chal k, Tape, etc.) (Fi g. 8) to
ensure i nstal l ati on i n ori gi nal posi ti on. I f the coi l s
spri ngs requi re repl acement. Be sure that the
springs needing replacement, are replaced with
springs meeting the correct load rating for the
vehicle and its specific options.
During service procedures requiring the re-
moval or installation of a coil springwith Spring
Compressor, Special Tool C-4838. It is required
that fivecoils becaptured within thejaws of the
tool (Fig. 8).
SPRI NG RETAI NER UPPER
Ensure that upper spri ng retai ner i s posi ti oned prop-
erl y, see; step (4), Assembl e (Strut Damper).
SPRI NG SEAT LOWER
Duri ng assembl y of spri ng to strut damper, ensure
that l ower coi l end i s seated i n strut damper spri ng
seat recess refer to (Fi g. 6) i n assembl e (Strut Damper)
secti on.
SHOCK ABSORBERS (Strut Damper)
I NSPECTI ON
I nspect for evi dence of fl ui d l eaki ng from around the
strut assembl y shaft seal at the upper end of the
reservoi r. (Actual l eakage wi l l be a stream of fl ui d
runni ng down the si de and dri ppi ng off l ower end of
uni t. A sl i ght amount of seepage around the strut rod i s
not unusual and does not affect performance.
LOWER CONTROL ARM
The l ower control arm i f damaged, i s servi ced onl y as
a compl ete component. Do not attempt to repai r or
strai ghten a broken or bent l ower control arm.
The servi ceabl e components of the l ower control arm
are, the bal l joi nt assembl y, and both pi vot bushi ngs.
The servi ce procedure to repl ace these components i s
detai l ed i n the speci fi c component secti ons of thi s
group.
REMOVAL (ASSEMBLY)
(1) Rai se vehi cl e. See Hoi sti ng i n Lubri cati on, Group
0 of thi s servi ce manual .
(2) Remove the bal l joi nt stud to steeri ng knuckl e
cl amp nut and bol t (Fi g. 1).
(3) Remove the sway bar to l ower control arm re-
tai ner on both si des of the vehi cl e (Fi g. 2). Then rotate
the sway bar down away from the l ower control arms.
(4) Separate the steeri ng knuckl e from the bal l joi nt
stud (Fi g. 1).
(5) Remove the front and rear control arm pi vot
bushi ng to crossmember attachi ng nuts and bol ts (Fi g.
2). Then remove the l ower control arm from the cross-
member.
Fig. 7 Tighten Strut Rod Nut with Tool
Fig. 8 Identifying Coil Springs
Fig. 1 Control Arm To Steering Knuckle Attachment
CAUTION: Pulling steering knuckle out from vehicle
after releasing from ball joint can separate inner C/V
joint. See Driveshafts.
I nspect l ower control arm for di storti on. Check bush-
i ngs for severe deteri orati on.
I NSTALLATI ON (ASSEMBLY)
(1) Posi ti on the l ower control arm i nto the cross-
member and i nstal l front and rear pi vot bushi ng to
crossmember attachi ng bol ts and l oosel y assembl e
nuts to bol ts (Fi g. 2).
(2) I nstal l bal l joi nt stud i nto steeri ng knuckl e and
i nstal l cl amp bol t (Fi g. 1). Ti ghten cl amp bol t to 136
Nm (100 ft. l bs.).
(3) Posi ti on sway bar and bushi ngs agai nst the
l ower control arms. I nstal l sway bar to control arm
retai ners. I nstal l retai ner bol ts and ti ghten nuts to 70
Nm (50 ft. l bs.).
(4) Lower vehi cl e so the suspensi on i s supporti ng
vehi cl es wei ght (control arm at desi gn hei ght). Ti ghten
the l ower control arm to crossmember attachi ng bol ts
to 169 Nm (125 ft. l bs.) torque.
LOWER CONTROL ARM PIVOT BUSHINGS
When performi ng the repl acement procedure on the
l ower control arm pi vot bushi ngs, the fol l owi ng se-
quence must be fol l owed. When removi ng the pi vot
bushi ngs from the l ower control arm, the l arge bushi ng
must be removed fi rst then the smal l bushi ng. When
i nstal l i ng the pi vot bushi ngs i nto the l ower control
arm, the smal l bushi ng must be i nstal l ed fi rst then the
l arge bushi ng. Thi s sequence must be used when
removal and repl acement of bushi ngs i s done usi ng
Bushi ng Remover/I nstal l er, Speci al Tool 6602.
LARGE BUSHI NG
REMOVE
(1) Posi ti on and cl amp l ower control arm i n a vi se.
(2) Assembl e the washer, thrust beari ng and l arge
bushi ng di sk, Speci al tool 6602-5 onto the threaded rod
from Bushi ng Remover/I nstal l er, Speci al Tool 6602
(Fi g. 3).
(3) I nstal l the tool s assembl ed i n step 2 above i nto
the l arge bushi ng of the l ower control arm (Fi g. 4).
Then assembl e the remai ni ng Speci al Tool s, Cup
6602-2, thrust beari ng, washer and nut onto the
threaded rod (Fi g. 4) from Bushi ng Remover/I nstal l er,
Speci al Tool 6602.
(4) Hol d the l ong nut stati onary. Usi ng a deep socket
turn the l ong threaded rod unti l the l arge pi vot bush-
i ng i s pushed out of the l ower control arm.
Fig. 2 Lower Control Arm Typical
Fig. 3 Bushing Removal Tools
SMALL BUSHI NG
REMOVE
(1) Remove the speci al tool s from the l ower control arm
that were used for the removal of the l arge pi vot bushi ng.
(2) Remove the l arge Bushi ng Di sc, Speci al Tool
6602-2 from the threaded rod. Leave the thrust beari ng
and washer on the threaded rod. I nstal l the smal l
Bushi ng Di sc, Speci al Tool 6602-3 on the threaded rod
and agai nst thrust beari ng (Fi g. 5).
(3) I nstal l the tool s assembl ed i n step 2 above
through smal l l ower control arm bushi ng and hol e i n
l ower control arm where l arge bushi ng was removed
from (Fi g. 6). Assembl e the Cup, Speci al Tool 6602-2
thrust beari ng, washer and l ong nut onto the threaded
rod of Speci al Tool 6602. (Fi g. 6). Cup, Speci al Tool
6602-2 i s to be i nstal l ed on threaded rod wi th cup
faci ng out and undercut i n l arge bushi ng hol e of l ower
control arm (Fi g. 6).
(4) Hol d the threaded rod stati onary and turn the
l ong nut unti l the smal l pi vot bushi ng i s pul l ed out of
the l ower control arm.
SMALL BUSHI NG
INSTALL
(1) Remove the speci al tool s from the l ower control
arm that were used for the removal of the smal l pi vot
bushi ng.
(2) On the threaded rod from Remover/I nstal l er,
Speci al Tool 6602 assembl e the fol l owi ng pi eces.
Washer, thrust beari ng, smal l bushi ng di sc Speci al Tool
6602-3, smal l l ower control arm pi vot bushi ng and
smal l bushi ng si zer, Speci al Tool 6602 (Fi g. 7).
(3) I nstal l the pi eces assembl ed i n step 2 through
the smal l and l arge pi vot bushi ng hol es i n the l ower
control arm. At the l arge pi vot bushi ng hol e i n the
l ower control arm, assembl e Cup, Speci al Tool 6602-2,
thrust beari ng, washer and nut (Fi g. 8). Lubri cate the
i nstal l er cone and new bushi ng usi ng Mopar, Si l i cone
Sray Lube or equi val ent.
l ong nut unti l the smal l pi vot bushi ng i s ful l y i nstal l ed
i nto the l ower control arm. Be sure that the fl anges of
the bushi ng are ful l y expanded around the control arm
bushi ng hol es (Fi g. 13).
Fig. 4 Tool Assembled For Bushing Removal
Fig. 5 Bushing Removal Tools
Fig. 6 Tool Assembled For Bushing Removal
Fig. 7 Bushing Installing Tools Assembled
LARGE BUSHI NG
INSTALL
(1) Remove the speci al tool s from the l ower control
arm that were used for i nstal l i ng the smal l pi vot
bushi ng.
(2) On the threaded rod from Remover/I nstal l er, Speci al
Tool 6602 assembl e the fol l owi ng pi eces. Washer, thrust
beari ng, Cup Speci al Tool 6602-2 (Fi g. 9).
(3) I nstal l the pi eces assembl ed i n step 2 through
the hol e i n the smal l pi vot bushi ng and the l arge pi vot
bushi ng hol e i n the l ower control arm. At the l arge
pi vot bushi ng hol e i n the l ower control arm assembl e
the fol l owi ng speci al tool pi eces. Large Bushi ng Si zer,
Speci al Tool 6602-4, l arge l ower control arm pi vot
bushi ng, l arge bushi ng di sc Speci al Tool 6602-5, thrust
beari ng, washer and nut (Fi g. 10). Lubri cate the i n-
stal l er cone and new bushi ng usi ng Mopar Si l i cone
Spray Lube or equi val ent.
l ong nut unti l the bushi ng i s ful l y i nstal l ed i nto the
control arm. Be sure that the fl anges of the bushi ng are
ful l y expanded around the control arm bushi ng hol es.
(5) I f the posi ti on of the l arge l ower control arm pi vot
bushi ng (Fi g. 11) moved duri ng bushi ng i nstal l ati on.
I nstal l a nut and bol t through the bushi ng sl eeve and
ti ghten i t down (Fi g. 11). Usi ng a wrench rotate the
bol t unti l the bushi ng i s i n the correct posi ti on (Fi g. 10)
BALL JOINTS
The l ower front suspensi on bal l joi nts operate wi th
no free pl ay. See I nspecti on Bal l Joi nt Wear to deter-
mi ne i f the bal l joi nt i s worn and requi res repl acement.
The bal l joi nts are repl aceabl e as an assembl y, do not
attempt any type of repai r on the bal l joi nt assembl y.
The repl acement procedure for the bal l joi nt assembl y
i s detai l ed i n thi s secti on.
The bal l joi nt housi ng i s a pressed fi t i nto the l ower
control arm wi th the joi nt stud retai ned i n the steeri ng
knuckl e by a (cl amp) bol t.
I NSPECTI ON BALL JOI NT WEAR
Wi th the wei ght of the vehi cl e resti ng on the road
wheel s. Grasp the grease fi tti ng as shown i n (Fi g. 1)
and wi th no mechani cal assi stance or added force
attempt to move the grease fi tti ng.
Fig. 8 Bushing And Tool Position For Installation In
Control Arm
Fig. 9 Bushing Installer Tools
Fig. 10 Bushing And Tool Position For Installation
In Control Arm
Fig. 11 Positioning Control Arm Bushing
I f the bal l joi nt i s worn the grease fi tti ng wi l l move
easi l y. I f movement i s noted, repl acement of the bal l
joi nt i s recommended.
BALL JOI NT REMOVAL
(1) Pry off seal .
(2) osi ti on Recei vi ng Cup Tool C-4699-2 to support l ower
control arm whi l e recei vi ng bal l joi nt assembl y (Fi g. 2).
(3) I nstal l Remover/I nstal l er Speci al Tool C-4699-2
(Fi g. 2) over bal l joi nt stud and agai nst the bal l joi nt
upper housi ng.
(4) Press down agai nst the bal l joi nt upper housi ng,
to remove bal l joi nt assembl y from l ower control arm.
BALL JOI NT I NSTALLATI ON
(1) By hand, posi ti on bal l joi nt assembl y i nto the bal l
joi nt bore of the l ower control arm. Be sure the bal l
joi nt assembl y i s not cocked i n the bore of the control
arm, thi s wi l l cause bi ndi ng of the bal l assembl y.
(2) Posi ti on assembl y i n press wi th I nstal l er Tool
C-4699-2 supporti ng control arm (Fi g. 3).
(3) I nstal l the Remover/I nstal l er, Speci al Tool
C-4699-1 over the bal l joi nt stud and down on the l ower
control arm assembl y (Fi g. 3).
(4) Careful l y al i gn al l pi eces. Usi ng an arbor press
appl y pressure agai nst the bal l joi nt assembl y, unti l
bal l joi nt i s ful l y seated agai nst bottom surface of
control arm. Do not appl y excessi ve pressure agai nst
the control arm.
BALL JOI NT SEAL I NSTALLATI ON
(1) Support bal l joi nt housi ng wi th I nstal l er, Speci al
Tool C-4699-1 (Fi g. 4). Posi ti on new seal over bal l joi nt
stud and agai nst bal l joi nt housi ng.
(2) Wi th 1-1/2 i nch socket, press seal onto bal l joi nt
housi ng unti l i t i s squarel y seated agai nst top surface
of control arm as shown i n (Fi g. 4).
Fig. 1 Checking Ball Joint Wear
Fig. 2 Removing Ball Joint
Fig. 4 Installing Ball Joint Seal
Fig. 3 Installing Ball Joint
SWAY BAR
The sway bar i nterconnects the front l ower control
arms of the vehi cl e and attaches to the crossmember
(Fi g. 1).
Jounce and rebound movements affecti ng one wheel
are parti al l y transmi tted to the opposi te wheel to
stabi l i ze body rol l .
Attachment to the crossmember, and front l ower
control arms i s through rubber-i sol ated bushi ngs. Al l
parts are servi ceabl e, and the sway bar to crossmember
bushi ngs are spl i t for easy removal and i nstal l ati on.
The spl i t i n the sway bar to crossmember bushi ng
shoul d be posi ti oned toward the front of the vehi cl e.
REMOVAL
(2) Remove the nuts, bol ts, and sway bar retai ners
at the front l ower control arms (Fi g. 1).
(3) Remove the bol ts at sway bar crossmember
cl amps, and remove cl amps and sway bar from vehi cl e
(Fi g. 1).
I NSPECTI ON
I nspect for broken or di storted cl amps, retai ners, and
bushi ngs. I f bushi ng repl acement i s requi red, the i nner
bushi ng can be removed by openi ng the spl i t. The outer
bushi ng must be cut or hammered off the bar. I f
repl aced, the outer bushi ngs shoul d be forced on so
that approxi matel y 1/2 i nch of the bar protrudes. The
sway bar to crossmember bushi ngs, shoul d be posi -
ti oned when i nstal l ed, so the voi d on the bushi ng i s
posi ti oned toward the rear of the vehi cl e (Fi g. 2). Note
that the control arm retai ners are symmetri c and bend
sl i ghtl y upon i nstal l ati on.
I NSTALLATI ON
(1) I f i nspecti on of the sway bar assembl y, deter-
mi ned that sway bar to l ower control arm bushi ngs
requi re repl acement. I nstal l the new bushi ngs, by
forci ng them onto sway bar usi ng a rotati ng moti on.
Bushi ngs shoul d be i nstal l ed on sway bar so that sway
bar extends 1/2 i nch out past the end of the bushi ng.
(2) I f requi red posi ti on sway bar to crossmember
bushi ngs on sway bar wi th external ri b up and voi d i n
the bushi ng faci ng the rear of vehi cl e (Fi g. 2). Li ft the
bar assembl y i nto the crossmember, and i nstal l the
l ower cl amps and bol ts. The center offset i n the sway
bar shoul d be ori ented toward the front of the vehi cl e
(Fi g. 1)
Fig. 1 Front Sway Bar
Fig. 2 Sway Bar To Crossmember Bushing Position
(3) Posi ti on bushi ng retai ners on l ower control arms,
i nsert bol ts, and i nstal l nuts. The bol ts shoul d be
i nstal l ed so that the threaded porti on of the bol t i s up,
wi th the nut i s agai nst the l ower control arm not the
bushi ng retai ner (Fi g. 1).
(4) Wi th l ower control arms rai sed to desi gn hei ght,
ti ghten al l retai ner attachi ng bol ts to 70 Nm (50 ft.
l bs.) torque.
KNUCKLE (FRONT SUSPENSION)
The front suspensi on knuckl e (Fi g. 1) provi des for
steeri ng control of the vehi cl e. Supports the brake
cal i per and absorbs the l oads exerted duri ng vehi cl e
braki ng. I t al so supports the front (dri vi ng) hub and
beari ng and stub axl e assembl y.
The front suspensi on knuckl e al so provi des the abi l -
i ty to al i gn the front wheel s of the vehi cl e. Thi s i s done
by al l owi ng for front wheel camber adjustment and the
abi l i ty for front ti re Toe adjustments
The front suspensi on knuckl e i s not a servi ceabl e
component. Do not attempt to strai ghten or repai r the
front suspensi on knuckl e i n any way.
Servi ce repai r or repl acement of the front (dri ve) hub
and beari ng, can be done wi th the front suspensi on
knuckl e remai ni ng on the vehi cl e.
REMOVAL
(1) Remove the cotter pi n, hub nut l ock and spri ng
washer from the front axl e (Fi g. 2).
(2) Loosen hub nut whi l e the vehi cl e i s on the fl oor
wi th the brakes appl i ed (Fi g. 3). Thehub and drive-
shaft are splined together through the knuckle
(bearing) and retained by the hub nut.
(4) Remove the wheel l ug nuts, front ti re and wheel
assembl y and hub nut and washer.
(5) Remove the brake cal i per adapter to steeri ng
knuckl e attachi ng bol ts and washers (Fi g. 1). Remove
the brake cal i per and adapter from the steeri ng
knuckl e and braki ng di sc. Support brake
cal i per/adapter assembl y usi ng a wi re hook and not by
hydraul i c hose (Fi g. 4).
Fig. 3 Loosen Hub Nut
Fig. 1 Front Knuckle Assembly (Typical)
Fig. 2 Remove Cotter Pin, Hub Nut Lock, & Spring
Washer
(6) Remove the braki ng di sc from the front
hub/beari ng assembl y (Fi g. 5).
(7) Remove the cotter pi n and nut from the ti e rod
end. Remove the ti e rod end from the steeri ng knuckl e
arm usi ng Pul l er, Speci al Tool C-3894-A (Fi g. 6).
(8) Remove the cl amp nut and bol t (Fi g. 7) securi ng
the bal l joi nt stud i nto the steeri ng knuckl e.
Fig. 4 Supporting Brake Caliper
Fig. 5 Remove or Install Braking Disc
Fig. 6 Disconnect Tie Rod End
Fig. 7 Remove or Install Steering Knuckle Clamp
Bolt
(9) Separate bal l joi nt stud from knuckl e assembl y
by pryi ng down on l ower control arm. Pul l knuckl e
assembl y out and away from dri veshaft (Fi g. 8).
Care must be taken not to separate the inner
C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft
must be supported.
(10) Remove the steeri ng knuckl e to strut damper
attachi ng bol t and cam bol t (Fi g. 9). Notethelocation
of the cambolt, it must be installed in the same
location when steeringknuckleis installed back
on strut damper.
(11) Mount the steeri ng knuckl e i n a vi se and re-
move the 4 bol ts on back of steeri ng knuckl e, attachi ng
the hub and beari ng assembl y. Remove the hub and
beari ng assembl y from the steeri ng knuckl e (Fi g. 10).
Remove outer C/V joi nt seal from the steeri ng
knuckl e.
I NSTALL
CAUTION: Knuckle and bearing mounting surfaces
must be smooth and completely free of foreign ma-
terial or nicks.
(1) I nstal l the hub and beari ng assembl y i nto the
steeri ng knuckl e (Fi g. 10). I nstal l the 4 hub and
beari ng assembl y to steeri ng knuckl e attachi ng bol ts
and torque i n a cri ss-cross pattern to 65 Nm (45 ft.
l bs.)
(2) Posi ti on new seal i n recess on back of the steer-
i ng knuckl e. Assembl e I nstal l er, Speci al Tool C-4698
and i nstal l seal i nto steeri ng knuckl e unti l i t i s ful l y
seated i nto recess (Fi g. 11). I nspect the wear sl eeve on
the C/V joi nt housi ng and repl ace i f requi red.
(3) I nstal l the steeri ng knuckl e back on the strut
damper (Fi g. 9). I nstal l the strut damper to steeri ng
knuckl e attachi ng bol t, cam bol t, washer pl ate and
nuts. Torque bol ts to 100 Nm (75 ft.l bs.) pl us 1/4
turn.Be sure the cam bolt is installed in same
location it was removed from.
Fig. 8 Separate Ball Joint Stud from Knuckle As-
sembly
Fig. 9 Remove Or Install Steering Knuckle
Fig. 10 Remove Or Install Hub and Bearing Assem-
bly
(4) Lubri cate the FULL ci rcumference of the seal
(and wear sl eeve) wi th Mopar Mul ti -Purpose Lubri -
cant, or equi val ent (Fi g. 12).
(5) Sl i de the dri ve shaft back i nto the hub and
beari ng assembl y and i nstal l the steeri ng knuckl e onto
the bal l joi nt stud (Fi g. 13).
(6) I nstal l the ori gi nal (or equi val ent) steeri ng
knuckl e to bal l joi nt stud, cl amp bol t and nut (Fi g. 14).
Torque the cl amp bol t to 136 Nm (100 ft. l bs.).
Fig. 11 Seal Installation In Steering Knuckle
Fig. 12 Seal and Wear Sleeve Lubrication
Fig. 13 Installing Knuckle Assembly
Fig. 14 Tighten Steering Knuckle Clamp Bolt
(7) I nstal l the ti e rod end i nto the arm of the steeri ng
knuckl e. I nstal l the ti e rod end to steeri ng knuckl e
attachi ng nut, and torque to 47 Nm (35 ft. l bs.).
I nstal l a new cotter pi n i nto the ti e rod end (Fi g. 15).
(8) I nstal l the braki ng di sk back on the hub and
beari ng assembl y (Fi g. 5).
(9) I nstal l the front brake cal i per and adapter back
over the braki ng di sc and al i gn wi th the adapter
mounti ng hol es on steeri ng knuckl e (Fi g. 1). I nstal l the
cal i per adapter to steeri ng knuckl e attachi ng bol ts and
torque to 217 Nm (160 ft. l bs.).
(10) Cl ean al l forei gn matter from the threads of the
stub axl e (Fi g. 16). I nstal l the washer and hub nut onto
the threads of the stub axl e and ti ghten nut.
(11) Wi th the vehi cl es brakes appl i ed to keep front
braki ng di sc and hub from turni ng. Ti ghten the hub
nut to a torque of 244 Nm (180 ft. l bs.) (Fi g. 17).
(12) I nstal l the spri ng washer, hub nut l ock, and new
cotter pi n. Wrap the cotter pi n prongs ti ghtl y around
the hub nut l ock (Fi g. 18).
(13) I nstal l the front wheel and ti re assembl y. I nstal l
the front wheel l ug nuts and torque to 129 Nm (95
ft.l bs.).
(15) Al i gn the front wheel s of the vehi cl e. Use the
procedure l i sted under Wheel Al i gnment, i n the Front
Suspensi on Servi ce Procedures secti on of thi s servi ce
manual .
HUB AND BEARING ASSEMBLY
The Uni t I I I Front Hub and Beari ng (Fi g. 1) i s used
on al l Caravan, Voyager and Mi ni Ram Vans.
Al l hub and beari ng assembl i es mount to the steer-
i ng knuckl e the same way, but very by the wheel si ze
on the vehi cl e. Vehi cl es equi pped wi th 14 i nch wheel s
have a 4 i nch wheel mounti ng stud pattern. Vehi cl es
equi pped wi th 15 i nch wheel s have a 4 1/2 i nch wheel
mounti ng stud pattern. I f a hub and beari ng assembl y
needs to be repl aced, be sure that the repl acement
assembl y has the same si ze wheel mounti ng stud
pattern as the ori gi nal part.
Fig. 15 Install Tie Rod End
Fig. 16 Install Washer and Hub Nut
Fig. 17 Tighten Hub Nut
Fig. 18 Install Spring Washer, Nut Lock, & Cotter
Pin
Thi s uni t i s servi ced onl y as a compl ete assembl y
(Fi g. 1). I t i s mounted to the steeri ng knuckl e by four
mounti ng bol ts that are removed from the rear of the
steeri ng knuckl e (Fi g. 2).
REMOVAL
Repl acement of the front (dri ve) hub and beari ng
assembl y can be done wi thout havi ng to remove the
steeri ng knuckl e from the vehi cl e.
(1) Remove cotter pi n, hub nut l ock, and spri ng
washer (Fi g. 3).
(2) Loosen hub nut whi l e the vehi cl e i s on the fl oor
wi th the brakes appl i ed (Fi g. 4). Thehub and drive-
shaft are splined together through the knuckle
(bearingassembly) and retained by the hub nut.
(3) Rai se vehi cl e, see Hoi sti ng Recommendati ons i n
Group 0 of thi s servi ce manual .
(4) Remove the hub nut and the washer from the
stub axl e (Fi g. 3).
(5) Remove the wheel l ug nuts, and ti re and wheel
assembl y from the vehi cl e.
Fig. 1 Unit III Front Hub And Bearing Assembly
Fig. 2 Front Hub And Bearing Assembly Mounting
Fig. 3 Remove Cotter Pin, Nut Lock, & Spring
Washer
Fig. 4 Loosen Hub Nut
(6) Di sconnect ti e rod end from steeri ng arm wi th
Pul l er Speci al , Tool C-3894-A (Fi g. 5).
(7) Remove cl amp bol t securi ng the bal l joi nt stud
i nto the steeri ng knuckl e (Fi g. 6).
(8) Remove cal i per gui de pi n bol ts (Fi g. 6) and sepa-
rate cal i per assembl y from braki ng di sc. Support
caliper with wire hook and not by hydraulic
hose. (Fi g. 7) Remove braki ng di sc from hub and
beari ng assembl y (Fi g. 8).
(9) Separate the steeri ng knuckl e assembl y from the
bal l joi nt stud. Pul l knuckl e assembl y out and away
from dri veshaft (Fi g. 9).
Care must be taken not to separate the inner
C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft
must be supported.
(10) Remove the four hub and beari ng assembl y
mounti ng bol ts from rear of steeri ng knuckl e (Fi g. 9).
Fig. 5 Disconnect Tie Rod End
Fig. 6 Remove Clamp Bolt and Caliper Guide Pins
Fig. 7 Supporting Brake Caliper
Fig. 8 Remove or Install Braking Disc
(11) Remove the hub and beari ng assembl y from the
steeri ng knuckl e (Fi g. 10). Replacement of the
grease seal is recommended whenever this ser-
vice is performed.
I NSTALLATI ON
CAUTION: All steering knuckle and bearing mounting
surfaces must be smooth and completely free of
foreign material or nicks.
(1) I nstal l new front hub and beari ng assembl y i nto
the steeri ng knuckl e. Ti ghten the hub and beari ng
assembl y to steeri ng knuckl e attachi ng bol ts (Fi g. 9), i n
a cri ss-cross pattern to 65 Nm (45 ft. l bs.) torque.
(2) Posi ti on new hub and beari ng assembl y seal i n
recess of the steeri ng knuckl e (Fi g. 11). Assembl e
I nstal l er, Speci al Tool C-4698. Tool i s provi ded wi th a
handl e and dual purpose dri ve head for i nstal l i ng seal
i nto knuckl e and (head reversed) for i nstal l i ng wear
sl eeve onto C/V joi nt housi ng.
(3) Usi ng Speci al Tool C-4698 (Fi g. 11) i nstal l the
hub and beari ng seal , unti l ful l y seated i nto the steer-
i ng knuckl e recess.
knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and lubricate BOTH com-
ponents.
Fig. 9 Separate Ball Joint Stud from Steering
Knuckle
Fig. 10 Separate Hub and Bearing Assembly from
Knuckle
Fig. 11 Bearing Seal Installation
(4) Lubri cate the FULL ci rcumference of the beari ng seal
(and wear sl eeve) as shown i n (Fi g. 12). Wi th Mopar
Mul ti -Purpose Lubri cant, or equi val ent.
(5) I nsert dri veshaft through hub and beari ng as-
sembl y, whi l e i nstal l i ng steeri ng knuckl e assembl y on
l ower control arm bal l joi nt stud (Fi g. 13).
(6) I nstal l ori gi nal (or equi val ent) bal l joi nt to
knuckl e cl amp bol t (Fi g. 14) i nto steeri ng knuckl e.
Ti ghten cl amp bol t to 136 Nm (100 ft. l bs.) torque.
(7) I nstal l ti e rod end i nto steeri ng knuckl e arm (Fi g.
15). Ti ghten ti e rod to steeri ng knuckl e arm attachi ng
nut to 47 Nm (35 ft. l bs.) torque and i nstal l cotter pi n.
(8) I nstal l braki ng di sc (Fi g. 8).
(9) Careful l y l ower brake cal i per assembl y over
braki ng di sc (Fi g. 16).
(10) I nstal l brake cal i per assembl y gui de pi n bol ts.
Ti ghten gui de pi n bol ts to 25-35 Nm (18-26 ft. l bs.)
torque. When installing guide pins, use extreme
caution not to cross the threads.
Fig. 12 Seal and Wear Sleeve Lubrication
Fig. 13 Installing Knuckle Assembly
Fig. 14 Tighten Clamp Bolt
Fig. 15 Install Tie Rod End
(11) Cl ean al l forei gn matter from the threads of the
stub axl e (Fi g. 17). I nstal l the washer and hub nut (Fi g.
17) onto the threads of the stub axl e and ti ghten nut.
(12) Wi th brakes appl i ed, ti ghten front hub nut to
(244 Nm) 180 ft. l bs. torque (Fi g. 18).
(13) I nstal l spri ng washer, nut l ock, and new cotter
pi n. Wrap cotter pi n prongs ti ghtl y around nut l ock
(Fi g. 19).
I nstal l wheel and ti re assembl y. Ti ghten wheel nuts
to 129 Nm (95 ft. l bs.) torque.
Fig. 16 Installing Family Caliper
Fig. 19 Install Spring Washer, Nut Lock, & Cotter
Pin
DRI VESHAFTS
INDEX
page page
C/V Joint Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Damper Weights . . . . . . . . . . . . . . . . . . . . . . . . . 45
Driveshaft Identification . . . . . . . . . . . . . . . . . . . . 26
Driveshaft Positioning Specifications . . . . . . . . . . . 45
Driveshaft Reconditioning . . . . . . . . . . . . . . . . . . . 31
Driveshaft Service Procedures . . . . . . . . . . . . . . . 26
Inner C/V Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outer C/V Joint . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GENERAL INFORMATION
Al l Chrysl er front wheel dri ve vans and wagons use
onl y the unequal l ength dri veshaft system.
The unequal l ength system has a short sol i d i nter-
connecti ng shaft on the l eft si de of the vehi cl e for al l
engi ne transmi ssi on appl i cati ons. On the ri ght si de of
the vehi cl e the i nterconnecti ng shafts very dependi ng
on the transmi ssi on used i n the vehi cl e. The manual
transmi ssi on equi pped vehi cl es use a tubul ar shaft and
the automati c appl i cati ons use a sol i d shaft (Fi g. 1).
The dri veshaft assembl i es are three pi ece uni ts.
Each dri veshaft has a tri pod joi nt, an i nterconnecti ng
shaft and a Rzeppa joi nt. The Tri pod joi nt i s spl i ned
i nto the transaxl e si de gear and the Rzeppa joi nt has a
stub shaft that i s spl i ned i nto the wheel hub.
DRIVESHAFT IDENTIFICATION
Dri veshafts used i n front wheel van/wagon appl i ca-
ti ons are i denti fi ed by the dri veshaft manufacturer.
Vehi cl es can be equi pped wi th any of these dri veshaft
assembl i es. Each assembl y can be i denti fi ed as shown
i n (Fi g. 2).
DRIVESHAFT SERVICE PROCEDURES
Procedures for the removal and i nstal l ati on of the
dri veshafts are essenti al l y the same for al l front wheel
dri ve vehi cl es. Each dri veshaft has a spri ng wi thi n the
i nboard tri pod C/V joi nt that mai ntai ns constant en-
gagement wi th the transaxl e. Thi s al l ows transaxl e to
be removed wi thout di smantl i ng part of the transaxl e.
CAUTION: Boot sealing is vital to retain special lubri-
cants and to prevent foreign contaminants from en-
tering the C/V joint. Mishandling, such as allowing the
assemblies to dangle unsupported, pulling or push-
ing the ends can cut boots or damage C/V joints.
During removal and installation procedures always
support both ends of the driveshaft to prevent dam-
age.
Fig. 1 Front-Wheel-Drive - Driveshaft System
HUB NUT AND HUB ASSEMBLY REMOVAL
Hub nut removal and i nstal l ati on i s the same for al l
front wheel dri ve vehi cl es. For removal and i nstal l a-
ti on procedures see HUB NUT ASSEMBLIES IN-
STALL.
(1) Remove front stub axl e cotter pi n, nut l ock and
spri ng washer (Fi g. 1).
(2) Loosen front hub nut and wheel nuts whi l e
vehi cl es i s on fl oor and brakes appl i ed (Fi g. 2).
Fig. 2 Driveshaft Identification
Fig. 1 Remove Cotter Pin, Nut Lock, & Spring
Washer
Fig. 2 Loosen Hub Retaining Nut & Wheel Nuts
(3) Rai se vehi cl e, see Hoi sti ng i n Lubri cati on and
Mai ntenance, Group 0.
(4) Remove front hub nut and washer (Fi g. 3).
(5) Remove the front wheel and ti re assembl y from
the vehi cl e.
DRI VESHAFT ASSEMBLI ES
REMOVE
I nboard C/V joi nts have stub shafts spl i ned i nto the
di fferenti al si de gears. Dri veshafts are retai ned i n the
si de gears by a constant force provi ded by a spri ng
contai ned wi thi n the i nboard C/V joi nts.
(1) Before performi ng removal of the vehi cl es ri ght
si de dri veshaft assembl y. The speedometer pi ni on
must be removed from the transaxl e assembl y (Fi g. 4).
(2) Remove cl amp bol t securi ng bal l joi nt stud i nto
steeri ng knuckl e (Fi g. 5).
(3) Separate bal l joi nt stud from steeri ng knuckl e by
pryi ng agai nst knuckl e l eg and control arm (Fi g. 6).
CAUTION: Do not damage ball joint or C/V joint boots
(Fig. 6).
(4) Separate outer C/V joi nt spl i ned shaft from hub
by hol di ng C/V housi ng whi l e movi ng knuckl e (hub)
assembl y away (Fi g. 7).
CAUTION: Do not pry on or otherwise damage wear
sleeve on outer C/V joint.
(5) Support assembl y at C/V joi nt housi ngs. Remove
by pul l i ng outward on the i nner joi nt housi ng. DO
NOT PULL ON SHAFT (Fi g. 8).
The driveshaft, when installed, acts as a bolt
and secures the hub/bearing assembly. If the
vehicleistobesupportedor movedonitswheels.
Fig. 3 Remove Hub Nut & Washer
Fig. 5 Remove Ball Joint to Steering Knuckle Clamp
Bolt
Fig. 6 Separate Ball Joint from Knuckle
Fig. 4 Remove Speedometer Pinion (for Right Drive-
shaft)
I nstal l a bol t through the hub to ensure that the hub
beari ng assembl y cannot l oosen.
INSTALL
(1) Hol d i nner joi nt assembl y at housi ng (Fi gs. 8 and
9) whi l e al i gni ng and gui di ng the i nner joi nt spl i ne i nto
the transaxl e or i ntermedi ate shaft assembl y.
CAUTION: Follow this Seal/Wear sleeve lubrication
during any service procedures where knuckle and
driveshaft are separated. Thoroughly clean seal and
wear sleeve with suitable solvent (solvent must not
touch boot) and lubricate both components prior to
installing driveshaft. Lubricate wear sleeve and seal
with Mopar Multi-Purpose Lubricant, or equivalent.
Appl y on the ful l ci rcumference of the Wear Sl eeve a bead
of l ubri cant that i s 6 mm (1/4 i n.) wi de to seal contact area
(Fi g. 10). Fi l l l i p to housi ng cavi ty on Seal , compl ete ci rcum-
ference, and wet seal l i p wi th l ubri cant (Fi g. 10).
(2) Push knuckl e (hub) assembl y out and i nstal l
spl i ned outer C/V joi nt shaft i n hub (Fi g. 11).
Fig. 7 Separate Outer C/V Joint Shaft from Hub
Fig. 8 Removing Driveshaft Assembly Unequal
Length
Fig. 9 Installing Inner Shaft into Transaxle
Fig. 10 Seal & Wear Sleeve Lubrication
Fig. 11 Install Outer Shaft into Hub
(3) I nstal l steeri ng knuckl e assembl y on bal l joi nt
stud (Fi g. 12).
CAUTION: Steering knuckle clamp bolt shown in
Figs. 12 and 13 is prevailing torque type, original or
equivalent bolt must be installed during assembly.
(4) I nstal l and ti ghten cl amp bol t to 136 Nm (100 ft.
l bs.) torque (Fi g. 13).
(5) I nstal l speedometer pi ni on (Fi g. 14).
(6) Fi l l di fferenti al wi th proper l ubri cant (see Lubri -
cati on and Mai ntenance Group 0).
(7) I nstal l front hub nut assembl y.
(8) I f after i nstal l i ng the dri veshaft assembl y, the
inboard boot appears col l apsed or deformed. Vent the
i nner boot by i nserti ng, a round ti pped smal l di ameter
rod between the boot and shaft. I f necessary, massage
the boot to remove al l puckers bei ng careful not to
al l ow di rt to enter or grease to l eave the boot cavi ty. I f
the boot i s cl amped to the shaft wi th a rubber garter
cl amp, i t need not be removed to perform thi s venti ng
operati on. I f the boot i s cl amped to the shaft usi ng a
metal cl amp, the cl amp must be removed and di s-
carded before the rod can be i nserted. After venti ng,
i nstal l a new Servi ce Cl amp, or equi val ent usi ng
speci al Tool C-4653 (see Boots I nstal l secti on at the end
of thi s group for detai l s).
HUB NUT ASSEMBLI ES I NSTALL
The front wheel hub nuts use a l ock nut and cotter
pi n to mai ntai n proper wheel beari ng prel oad and
prevent the nut from backi ng off. I nstal l the assembl y
as fol l ows.
(1) I nstal l washer and hub nut after cl eani ng any
forei gn matter from stub axl e threads (Fi g. 15).
Fig. 12 Install Knuckle Assembly on Ball Joint Stud
Fig. 13 Tighten Clamp Bolt
Fig. 14 Install Speedometer Pinion
(2) Wi th brakes appl i ed, ti ghten hub nut to 245 Nm
(180 ft. l bs.) torque (Fi g. 16).
(3) I nstal l nut l ock, spri ng washer and NEWcotter
pi n. Wrap cotter pi n prongs ti ghtl y around nut l ock
(Fi g. 17).
nuts to 129 Nm (95 ft. l bs.) torque (Fi g. 18).
DRIVESHAFT RECONDITIONING
Dri veshaft recondi ti oni ng and/or boot repl acement
for al l front wheel dri ve vehi cl es i s essenti al l y the same
per C/V joint.
Note that lubricant requirements and quanti-
ties are different for inner joints than for outer
joints, and type being serviced. Use only the
recommended lubricants.
Compl ete dri veshaft components are shown i n (Fi g.
1).
Driveshaft requirements aredifferent for vari-
ous vehicle models, engines, and transaxles, and
often change fromone model year to the next.
Driveshaft parts will be different to accommo-
date this. Therefore, when replacing parts, be
sure to use only those specified in the service
parts catalog for the exact model year, model,
engine, transaxle, and type being serviced.
INNER C/V JOINT
DI SASSEMBLE
Wi th the dri veshaft removed from the vehi cl e, i den-
ti fy the uni t type (See Fi g. 2 under Dri veshafts I den-
ti fi cati on).
(1) Remove the boot cl amps and pul l back the boot to
gai n access to the tri pod retenti on system, whi ch
prevents acci dental separati on from the C/V joi nt hous-
i ng.
CAUTION: When removing the housing from the
tripod, hold the rollers in place on the trunnion studs
to prevent the rollers and needle bearings from falling
away. After the tripod is out of the housing secure the
rollers in place with tape (Fig. 4).
(2) Dependi ng on the type of C/V joi nt assembl y,
separate the C/V joi nt housi ng from the tri pod as
fol l ows:
Fig. 17 Install Spring Washer, Nut Lock, and New
Cotter Pin
Fig. 18 Install Wheel & Tire Assembly
S.S.G. Uti l i zes a wi re ri ng tri pod retai ner whi ch
expands i nto a groove around the top of the housi ng.
Use a fl athead screwdri ver to pry the wi re ri ng out of
the groove and sl i de the tri pod from the housi ng (Fi g.
2). Do not mangle or destroy retainer during
disassembly.
G.K.N. Theretentionsystemonthisassembly is
a integral part of the plastic collar on the inside
of the C/V joint housing. Clamp the stub shaft of
the C/V joint housing in a vise, use protective
caps on jaws of vise to prevent damage to stub
shaft. Hol d the i nterconnecti ng shaft on an angl e,
whi l e gentl y pul l i ng on the shaft unti l one of the tri pod
beari ngs i s free of the retai ni ng col l ar. Conti nue hol d-
i ng the i nterconnecti ng shaft on an angl e and gentl y
pul l on the shaft unti l al l rol l ers are free of the
retai ni ng col l ar. See (Fi g. 3).
TRI POD ASSEMBLY REMOVAL FROM I NTER-
CONNECTI NG SHAFT
S. S. G. AND G. K. N. WITH SINGLE RING TRIPOD RETEN-
TION.
Remove the tri pod assembl y to i nterconnecti ng shaft
retai ni ng snap ri ng from the i nterconnecti ng shaft end
groove (Fi g. 4). Remove the tri pod assembl y from the
i nterconnecti ng shaft by hand or by tappi ng the body of
the tri pod assembl y wi th a brass punch (Fi g. 5).
Fig. 1 Driveshaft Components
Fig. 2 Separate Tripod From Housing S.S.G.
G. K. N. WITH DOUBLE RING TRIPOD RETENTION.
(1) Expand and remove the outer tri pod assembl y to
i nterconnecti ng shaft, retai ni ng snap ri ng (Fi g. 6).
(2) Remove the tri pod assembl y from the i ntercon-
necti ng shaft. Tri pod can be removed ei ther by hand or
by tappi ng the tri pod body wi th a brass dri ft (Fi g. 5).
Do not hi t the outer tri pod beari ngs i n an attempt to
remove tri pod assembl y from i nterconnecti ng shaft.
(3) Remove the i nner tri pod assembl y to i ntercon-
necti ng shaft, retai ni ng snap ri ng from the of i ntercon-
necti ng shaft (Fi g. 7).
Fig. 3 Separate Tripod From Housing G.K.N.
Fig. 4 Outer Tripod Retaining Snap Ring Removal
Fig. 5 Tripod Assembly Removal From Interconnect-
ing Shaft
Fig. 6 Removing Outer Tripod Retaining Snap Ring
(G.K.N.)
Fig. 7 Removing Inner Tripod Retaining Snap Ring
(G.K.N.)
I NSPECT TRI POD AND HOUSI NG
Remove as much grease as possi bl e from assembl y
and i nspect joi nt housi ng bal l raceway and tri pod
components for EXCESSI VE wear and repl ace i f nec-
essary.
I nspect the spri ng, spri ng cup, and the spheri cal end
of the connecti ng shaft for EXCESSI VE wear or dam-
age and repl ace, i f necessary.
ASSEMBLE C/V JOI NT
TRIPOD ASSEMBLY INSTALLATION S. S. G. & G. K. N. WITH
SINGLE RING RETENTION
(1) Fasten the (new) boot to the i nterconnecti ng
shaft. See Boots I nstal l .
(2) I nstal l the tri pod assembl y onto the i ntercon-
necti ng shaft unti l i t i s past the snap ri ng groove on the
shaft (Fi g. 8). I f requi red the tri pod assembl y can be
tapped onto the i nterconnecti ng shaft usi ng a brass
dri ft, on the body of the tri pod assembl y (Fi g. 5). Do not
hi t the outer tri pod assembl y beari ngs i n an attempt to
i nstal l tri pod on i nterconnecti ng shaft.
(3) I nstal l a NEWouter tri pod assembl y to i ntercon-
necti ng shaft retai ni ng snap ri ng, i nto the i ntercon-
necti ng shaft snap ri ng groove (Fi g. 9). Be sure that the
snap ri ng i s ful l y seated i nto the snap ri ng groove
around the enti re i nterconnecti ng shaft.
TRIPOD ASSEMBLY INSTALLATION G. K. N. WITH DOUBLE
RING RETENTION
(1) Fasten the (new) boot to the i nterconnecti ng
shaft. See Boots I nstal l .
(2) I nstal l the i nner tri pod assembl y retai ni ng snap
ri ng i nto the retai ni ng groove on the i nterconnecti ng
shaft (Fi g. 10).
(3) I nstal l the tri pod assembl y onto the i ntercon-
necti ng shaft unti l i t i s past the outer snap ri ng groove
on the shaft (Fi g. 10). I f requi red the tri pod assembl y
can be tapped onto the i nterconnecti ng shaft usi ng a
brass dri ft, on the body of the tri pod assembl y (Fi g. 5).
Do not hi t the outer tri pod assembl y beari ngs i n an
attempt to i nstal l tri pod on i nterconnecti ng shaft.
(4) I nstal l the outer tri pod assembl y to i ntermedi ate
shaft retai ni ng snap ri ng i nto the snap ri ng groove on
the i ntermedi ate shaft (Fi g. 11).
Fig. 8 Interconnecting Shaft Snap Ring Groove
Fig. 9 Outer Tripod Retaining Snap Ring Installation
Fig. 10 Inner Snap Ring Installation
Fig. 11 Outer Snap Ring Installation
I NNER C/V JOI NT HOUSI NG I NSTALLATI ON
G. K. N. Assembly
(1) Di stri bute 1/2 the amount of the grease provi ded
i nto the housi ng and the remai ni ng amount i nto the
boot.
(2) Posi ti on the spri ng i n the housi ng spri ng pocket
wi th the spri ng cup attached to the exposed end of the
spri ng (Fi g. 12). Pl ace a smal l amount of grease on the
concave surface of the spri ng cup.
CAUTION: Care must be taken to ensure proper
spring positioning. The spring must remain centered
in the housing spring pocket when the tripod is
installed and seated in the spring cup (Fig. 12).
(3) Cl amp the stub shaft of the housi ng i n a vi se.
Use protective caps on jaws of vise so stub shaft
does not get damaged by the vise. Posi ti on the
i nterconnecti ng shaft and tri pod assembl y on top of the
pl asti c retai ni ng col l ar. Careful l y i nsert each of the
tri pod rol l ers i nto the retai ni ng col l ar, one at a ti me.
Hol d the i nterconnecti ng shaft on an angl e and care-
ful l y push down on the shaft unti l the rol l ers are l ocked
i nto the retai ni ng col l ar on the housi ng.
(4) Posi ti on the boot over the boot retai ni ng groove
i n the housi ng and cl amp i n pl ace. See Boots I nstal l .
S. S. G. Assembly
(1) Di stri bute 1/2 the amount of the grease provi ded
i nto the housi ng and the remai ni ng amount i nto the
boot.
(2) Posi ti on the spri ng i n the housi ng spri ng pocket
wi th the spri ng cup attached to the exposed end of the
spri ng (Fi g. 12). Pl ace a smal l amount of grease on the
concave surface of the spri ng cup.
CAUTION: Care must be taken to ensure proper
spring positioning. The spring must remain centered
in the housing spring pocket when the tripod is
installed and seated in the spring cup (Fig. 12).
(3) Sl i p tri pod i nto housi ng and i nstal l the tri pod
wi re retai ni ng ri ng i nto posi ti on. Check for the abi l i ty
of the retai ni ng ri ng to hol d the tri pod i n the housi ng.
(4) Posi ti on the boot over the boot retai ni ng groove
i n the housi ng and cl amp i n pl ace. See Boots I nstal l .
OUTER C/V JOINT
DI SASSEMBLE
(1) Remove boot cl amps on boot and di scard (Fi g. 1).
(2) Wi pe away grease to expose joi nt.
(3) G.K.N. Remove outer C/V Joi nt from shaft by
supporti ng the i nterconnecti ng shaft i n a vi se. Use
protectivecapson thejawsof thevisetoprevent
damagetotheinterconnectingshaft. Gi ve a sharp
tap to the top of housi ng to di sl odge joi nt from
Fig. 12 Spring and Cup Installation
Fig. 1 Outer C/V Joint Components
i nternal ci rcl i p i nstal l ed i n a groove at the outer end of
the shaft (Fi g. 2).
S.S.G. A si ngl e ci rcl i p l ocated i n a groove on the cross,
i s used to retai n the cross to the shaft (Fi g. 3). Loosen
the damper wei ght bol ts and sl i de i t and the boot
towards the i nner joi nt. Expand the ci rcl i p wi th snap
ri ng pl i ers and sl i de joi nt from shaft. I nstal l damper
wei ght, see Damper Wei ghts.
WEAR SLEEVE
A wear sl eeve i nstal l ed on the outer C/V joi nt hous-
i ng (Fi g. 1) provi des a wi pe surface for the hub beari ng
seal (i nstal l ed i n the steeri ng knuckl e).
(4) I f bent or damaged, careful l y pry wear sl eeve
from C/V joi nt machi ned l edge.
(5) Remove ci rcl i p from shaft groove and di scard
(Fi g. 4). A repl acement boot package wi l l i ncl ude thi s
ci rcl i p.
(6) Unl ess the shaft i s damaged and needs repl aci ng,
do not remove the heavy spacer ri ng from the shaft,
G.K.N. onl y (Fi g. 4).
(7) Wi th joi nt separated from the i nterconnecti ng
shaft proceed as fol l ows:
I f outer C/V joi nt was operati ng sati sfactori l y and
grease does not appear to be contami nated, just repl ace
boot. Bypass the fol l owi ng di sassembl y procedure for
the C/V joi nt assembl y, See Boots I nstal l .
I f outer joi nt i s noi sy or badly worn. Bypass the
fol l owi ng di sassembl y and repl ace enti re uni t. I t i s al so
recommended that the boot be repl aced. The Boot
Package i ncl udes the boot, cl amps, retai ni ng ri ng (ci r-
cl i p), and l ubri cant. See boots i nstal l .
(8) Hol d joi nt verti cal l y i n vi se by cl ampi ng on
spl i ned shaft, usi ng soft jaws to prevent damage.
(9) Wi pe off surpl us grease and mark rel ati ve posi -
ti on of i nner cross, cage and housi ng wi th a dab of pai nt
(Fi g. 5).
(10) Press down on one si de of i nner race to ti l t cage
and remove bal l from opposi te si de (Fi gs. 5 and 6). I f
joi nt i s ti ght, use a hammer and brass dri ft to tap i nner
race. Donot hit thecage. Repeat thi s step unti l all 6
bal l s are removed. A screwdri ver may be used to pry
bal l s l oose.
Fig. 2 Remove Joint from Shaft .
Fig. 3 Circlip Retainer in Cross S.S.G.
Fig. 4 Remove Circlip
Fig. 5 Rotate Cage & Cross to Remove Balls
(11) Ti l t the cage and i nner race assembl y verti cal l y
and posi ti on two opposi ng cage wi ndows i n area be-
tween the bal l grooves. Remove the cage and i nner race
assembl y by pul l i ng upward away from the housi ng
(Fi g. 7).
(12) Turn i nner cross (dri ver) 90 to cage and al i gn
one of the race spheri cal l ands wi th cage wi ndow. Rai se
l and i nto cage wi ndow and remove i nner race by
swi ngi ng out (Fi g. 8).
I NSPECT
Check grease for contami nati on and al l parts for
defects as fol l ows:
(1) Wash al l parts i n sui tabl e sol vent and dry, pref-
erabl y wi th compressed ai r.
(2) I nspect housi ng bal l races for excessi ve wear and
scouri ng.
(3) Check spl i ned shaft and nut threads for damage.
(4) I nspect al l 6 bal l s for pi tti ng, cracks, scouri ng
and wear. Dul l i ng of surface i s normal .
(5) I nspect cage for excessi ve wear on i nsi de and
outsi de spheri cal surfaces, surface ri ppl es on cage
wi ndow, cracks, and chi ppi ng.
(6) I nspect i nner race (cross) for excessive wear or
scouri ng of bal l races.
Anyof theabovedefectswill warrant replacing
the C/V assembly as a unit.
Pol i shed areas i n races (cross and housi ng) and on
cage spheres are normal and do not i ndi cate need for
joi nt repl acement, unl ess they are suspected of causi ng
noi se and vi brati on.
Fig. 6 Ball Released
Fig. 7 Removing Cage & Cross Assembly from
Housing
Fig. 8 Removing Cross from Cage
ASSEMBLE
If outer joint was not disassembled nor the
wear sleeve damaged go to step 11.
(1) Posi ti on new wear sl eeve on joi nt housi ng ma-
chi ned l edge (Fi g. 1). Assembl e I nstal l er, Speci al Tool
C-4698 (Tool i s provi ded wi th handl e and dual purpose
dri ve head for i nstal l i ng wear sl eeve onto C/V joi nt
housi ng and (head reversed) seal i nto knuckl e). See
KNUCKLE BEARI NG SEAL.
(2) See (Fi g. 1). Assembl e tool and i nstal l wear
sl eeve.
(3) Li ghtl y oi l al l components before assembl i ng
outer joi nt.
(4) Al i gn parts accordi ng to pai nt marki ngs.
(5) I nsert one of the i nner race (cross) l ands i nto cage
wi ndow (Fi g. 2) and feed race i nto cage. Pi vot cross 90
to compl ete cage assembl y (Fi g. 3).
(6) Al i gn opposi ng cage wi ndows wi th housi ng l and
and feed cage assembl y i nto housi ng (Fi g. 4). Pi vot cage
90 to compl ete i nstal l ati on.
When properl y assembl ed the l arge counterbore i n
the cross shoul d be faci ng outward from the joi nt on
G.K.N. uni ts (Fi gs. 3 and 6). On the S.S.G. joi nt the
i nternal ci rcl i p i n the cross wi l l be faci ng outward from
the housi ng (Fi g. 5).
Fig. 1 Tool Set-Up for Wear Sleeve Installation
Fig. 2 Installing Cross into Cage
Fig. 3 Cage & Cross Assembled G.K.N.
Fig. 4 Installing Cage & Cross into Housing
(7) Appl y l ubri cant to bal l races from packet pro-
vi ded i n boot ki t and di stri bute equal l y between al l
si des of bal l grooves. One packet i s suffi ci ent to l ubri -
cate the joi nt.
(8) I nsert bal l s i nto raceway by ti l ti ng cage and
i nner race assembl y (Fi g. 7).
(9) Fasten boot to shaft. See Boots Install.
(10) On G.K.N. uni ts i nsert the new ci rcl i p, provi ded
wi th ki t i n shaft groove. Donot over expandor twist
ci rcl i p duri ng assembl y (Fi g. 8). The S.S.G. uni t has a
reusabl e ci rcl i p retai ner that i s an i ntegral part of
dri ver assembl y.
Fig. 5 Cage & Cross Assembled S.S.G.
Fig. 6 Cage & Cross Installed in Housing G.K.N.
Fig. 7 Inserting Balls into Raceway
Fig. 8 Installing New Circlip
(11) Posi ti on outer joi nt on spl i ned end wi th hub nut
on stub shaft. Engage spl i nes, and tap sharpl y wi th
mal l et (Fi g. 9).
(12) Check that ci rcl i p i s properl y seated by attempt-
i ng to pul l joi nt from the shaft.
(13) Locate l arge end of boot over joi nt housi ng
checki ng that boot i s not twi sted.
(14) Fasten boot to housi ng. See Boots Install.
C/V JOINT BOOTS
HANDLI NG AND CLEANI NG
I t i s vi tal l y i mportant duri ng any servi ce procedures
requi ri ng boot handl i ng. That care be taken not to
puncture or tear the boot by over ti ghteni ng cl amps,
mi suse of tool (s) or pi nchi ng the boot. Pi nchi ng can
occur by rotati ng the C/V joi nts (especi al l y the tri pod)
beyond normal worki ng angl es.
The dri veshaft boots are not compati bl e wi th oi l ,
gasol i ne, or cl eani ng sol vents. Care must be taken that
boots never come i n contact wi th any of these l i qui ds.
The only acceptable cleaning agent for drive-
shaft bootsissoapandwater.After washing, boot
must be thoroughly rinsed and dried before re-
using.
B00TS I NSPECT
Noti ceabl e amounts of grease on areas adjacent to
and on the exteri or of the C/V joi nt boot. I s the fi rst
i ndi cati on that a boot i s punctured, torn or that a
cl amp has l oosened. When a C/V joi nt i s removed for
servi ce. The boot shoul d be properl y cl eaned and i n-
spected for cracks, tears and scuffed areas on i nteri or
surfaces. I f any of these condi ti ons exi st, boot repl ace-
ment i s recommended.
BOOTS I NSTALL
THE HARD PLASTI C BOOTS REQUI RE APPROXI -
MATELY 100 TI MES THE CLAMPI NG FORCE OF
THE RUBBER BOOT. THE CLAMPS USED ON THE
RUBBER BOOTS DO NOT HAVE THE TYPE OF
LOAD CAPACI TY REQUI RED. TO SEAL THE HARD
PLASTI C BOOTS AND SHOULD NOTBE USED FOR
THI S PURPOSE.
Rubber boots appear onl y on the i nner joi nts of
certai n dri veshafts.
Rubber boots must be servi ced wi th the strap and
buckl e cl amp. Use the Cl amp I nstal l er, Speci al Tool
C-4653. Proceed wi th the boot i nstal l ati on as fol l ows:
(1) Sl i de the smal l end of the boot over the shaft.
Posi ti on the boot to the edge of the l ocati ng mark or
groove, whi chever i s appropri ate (Fi g. 1).
(2) I nstal l the C/V joi nt. See I nner or Outer C/V
Joi nt Assembl e.
(3) Sl i de the l arge di ameter of the boot i nto the
l ocati ng groove on the C/V Joi nt Housi ng.
(4) Wrap bi ndi ng strap around boot twice, PLUS 63
mm (2-1/2 i nches) (Fi g. 2).
Fig. 9 Position Joint onto Shaft Splines
Fig. 1 C/V Joint Boot Positioning G.K.N.
Fig. 2 Measure & Cut Binding Strap
(5) Pass the strap through the buckl e and fol d i t
back about 29 mm (1-1/8 i nches) on the i nsi de of the
buckl e (Fi g. 3).
(6) Put the strap around the boot wi th the eye of the
buckl e toward you (Fi g. 4). Wrap the stri p around the
boot once and pass i t through the buckl e, then wrap i t
around a second ti me al so passi ng i t through the
buckl e.
(7) Fol d the stri p back sl i ghtl y to prevent i t from
sl i ppi ng backwards (Fi g. 5).
(8) Open the tool al l the way and pl ace stri p i n
narrow sl ot approxi matel y 13 mm (1/2 i nch) from
buckl e (Fi g. 6).
(9) Hol d the bi ndi ng stri p wi th the l eft hand and push the
Tool forward and sl i ghtl y upward. Then fi t the hook of the
Tool i nto the eye of the buckl e (Fi g. 7).
Fig. 3 Install Buckle on Strap
Fig. 4 Wrap Strap (through Buckle Eye) Twice
Fig. 5 Fold Strap Lightly to Keep Position
Fig. 6 Open Tool, Position Strap in Narrow Slot 1/2
Inch from Buckle
Fig. 7 Push Tool Forward & Fit into Buckle Eye
(10) Ti ghten the stri p by cl osi ng the tool handl es
(Fi g. 8). Then rotate the tool (handl es) downward whi l e
sl owl y rel easi ng the pressure on the tool handl es. Al l ow
the tool (handl es) to open progressi vel y. Then open the
tool enti rel y and remove them si deways.
(11) I f the strap i s not ti ght enough, engage the tool
a second or even a thi rd ti me, al ways about 13 mm (1/2
i nch) from the buckl e (Fi g. 9). When ti ghteni ng al ways
be careful to see that the strap sl i des i n a strai ght l i ne
and wi thout resi stance i n the buckl e, that i s wi thout
maki ng a fol d. An effecti ve gri p wi l l be obtai ned onl y by
fol l owi ng the above i nstructi ons.
(12) Fi g. 10 shows WHATNOTTO DO, NEVER fol d
the strap back or bri ng the tool down whi l e ti ghteni ng,
thi s acti on wi l l break the strap.
(13) Fi g. 11 shows how to pul l the tool down whi l e
rel easi ng the pressure on the tool handl e. (14) I f the stri p i s ti ght enough. Remove the tool
si deways and cut off the strap 3 mm (1/8 i nch), so that
i t does not overl ap the edge of the buckl e. Compl ete job
by fol di ng the stri p back neatl y (Fi g. 12).
Fig. 8 Tighten Strap
Fig. 9 Tighten Strap (if Required)
Fig. 10 What Not to Do
Fig. 11 Correct Tightening Procedure
Fig. 12 Cut Strap 1/8 Inch from Buckle
(15) Fi g. 13 shows the fi ni shed bi ndi ng strap type
cl amp i n posi ti on, correctl y fi tted and unabl e to come
l oose.
(16) After attachi ng the boot to the shaft. I nstal l the
i nner or outer C/V joi nt fol l owi ng procedures under
I nner C/V Joi nt Assembl e or Outer C/V Joi nt Assembl e.
(17) Sl i p the l arge end of the boot on the housi ng and
al i gn i t i n the boot groove.
(18) Repeat steps 2 - 13 for boot cl ampi ng.
S.S.G. C/V joi nts use two di fferent type boots, one i s
made of pl asti c and the other of rubber. The pl asti c
boot requi res a heavy duty cl amp and I nstal l er, Speci al
Tool C-4975. The soft boot requi res a cl amp wi th round
edges that prevents the cl amp from cutti ng the boot.
Proceed wi th boot i nstal l ati on as fol l ows.
The hard pl asti c boots used on the G.K.N. C/V Joi nts.
Al so use thi s procedure for i nstal l ati on of the boot
cl amp to C/V Joi nt.
LEFT I NNER, LEFT AND RI GHT OUTER C/V
JOI NT WI TH PLASTI C BOOTS
(1) Sl i de smal l cl amp onto shaft.
(2) Posi ti on smal l end of boot over i nterconnecti ng
shaft wi th l i p of boot i n thi rd groove, towards center of
i nterconnecti ng shaft (Fi g. 14).
(3) Posi ti on boot cl amp evenl y over boot. Pl ace cl amp
i nstal l er Tool C-4975 over bri dge of cl amp and ti ghten
the nut unti l the jaws of the tool are cl osed compl etel y,
face to face (Fi g. 15).
(4) After attachi ng the boot to the shaft. I nstal l the
C/V joi nt fol l owi ng the procedure outl i ned under Inner
C/V J oint Assemble or Outer C/V J oint Assemble.
(5) Posi ti on the l arge end of boot on housi ng and
i nstal l cl amp, cri mp bri dge of cl amp wi th Cri mper,
Speci al Tool C-4975.
CAUTION: Use only the clamps provided in the boot
package for this application, otherwise damage to the
boot or C/V joint may occur.
RI GHT I NNER C/V JOI NT WI TH RUBBER BOOT
(1) Sl i de smal l end boot cl amp onto i nterconnecti ng
shaft.
Fig. 13 Correctly Installed Clamp
Fig. 14 Boot and Clamp Positioning S.S.G.
Fig. 15 Closing Clamp Bridge
(2) I nstal l boot onto i nterconnecti ng shaft, posi ti on
boot on the fl at between the l ocati ng shoul ders (Fi g.
16).
(3) Posi ti on cl amp on boot and cri mp bri dge of cl amp
wi th Cri mper Speci al Tool C-4124.
(4) I nstal l the C/V Joi nt fol l owi ng the procedure
outl i ned under Inner C/V J oint Assemble.
(5) Posi ti on the l arge end of boot on housi ng and
i nstal l cl amp, cri mp bri dge of cl amp wi th Cri mper,
Speci al Tool C-4124.
knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve with suitable solvent and
lubricate BOTH components at assembly. Do not
allow solvent to contact boot.
Lubri cate wear sl eeve (and seal ) wi th Mopar Mul ti -
Purpose Lubri cant, or equi val ent, as fol l ows:
Wear Sleeve: Appl y a ful l ci rcumference 6 mm (1/4
i nch) bead of l ubri cant to seal contact area. See (Fi g.
11), Dri veshaft Assembl i es I nstal l .
Seal: Fi l l l i p to housi ng cavi ty (ful l ci rcumference)
and wet seal l i p wi th l ubri cant.
S.S.G I NNER C/V JOI NT LARGE CLAMP
(MANUAL TRANS ONLY)
(1) I nstal l smal l cl amp and i nner C/V joi nt housi ng
accordi ng to the procedures outl i ned i n thi s manual .
(2) Posi ti on the boot over the outer C/V joi nt.
(3) Sl i de the l arge band cl amp over the boot and
posi ti on i t evenl y i n the groove on the i nner C/V joi nt
boot. (Fi g. 1).
(4) Use Cl amp Locki ng Tool Snap-On YA3050 or
equi val ent shown i n (Fi g. 2) to i nstal l the cl amp on the
boot.
(5) Pl ace the prongs of the cl amp l ocki ng tool i n the
hol es on the cl amp and squeeze together unti l the two
ends meet (Fi g. 2).
Fig. 16 Right Inner C/V Joint S.S.G.
Fig. 1 Boot Clamp Installed
Fig. 2 Locking Boot Clamp
DAMPER WEIGHTS
Damper wei ghts are used on the l eft dri veshaft
assembl i es of al l front wheel dri ve vehi cl es (Fi g. 1).
These wei ghts are attached to the i nterconnecti ng
shaft and are avai l abl e as a separate servi ce part. They
shoul d be removed from the dri veshaft assembl y dur-
i ng dri veshaft posi ti oni ng speci fi cati on procedures.
When the wei ghts are attached between the l ocati ng
shoul ders, ti ghten the fasteners to 28 Nm (21 ft. l bs.)
torque.
DRIVESHAFT POSITIONING SPECIFICATIONS
Front wheel dri ve vehi cl es have engi ne mounts wi th
sl otted hol es al l owi ng for si de to si de posi ti oni ng of the
engi ne. I f the verti cal bol ts on the ri ght or l eft upper
engi ne mount have been l oosened (e.g., engi ne removal
and i nstal l ati on) for any reason, or i f the vehi cl e has
experi enced front structural damage, dri veshaft
l engths must be checked and corrected, i f requi red. A
shorter than requi red dri veshaft l ength can resul t i n
objecti onabl e noi se. A l onger than requi red dri veshaft
l ength may resul t i n potenti al damage.
Use of the fol l owi ng procedure wi l l ensure sati sfac-
tory dri veshaft engagement under al l normal vehi cl e
operati ng condi ti ons.
(1) The vehi cl e must be compl etel y assembl ed. Front
wheel s must be properl y al i gned and i n the strai ght
ahead posi ti on. The vehi cl e must be i n a posi ti on so
that the ful l wei ght of the body i s di stri buted to al l four
ti res. A pl atform hoi st, or front end al i gnment rack, i s
recommended.
(2) Usi ng a tape measure or other sui tabl e measur-
i ng devi ce. Measure the di rect di stance from the i nner
edge of the outboard boot to the i nner edge of the
i nboard boot on both dri veshafts. Thi s measurement
must be taken at the bottom (si x ocl ock posi ti on) of the
dri veshafts (Fi g. 1).
Note that the requi red di mensi ons vary wi th dri ve-
shaft manufacturer.
(3) I f the l engths of both shafts are wi thi n the range
speci fi ed, on the chart bel ow, no further acti on i s
requi red.
I f ei ther the l eft or ri ght dri ve shaft l ength i s not
wi thi n the speci fi ed range. Refer to Engi ne, Group 09,
Engi ne Removal and I nstal l ati on to properl y posi ti on
the engi ne accordi ng to the dri veshaft l engths speci -
fi ed.
(4) I f proper dri veshaft l engths cannot be achi eved
wi thi n the travel l i mi ts avai l abl e i n the sl otted engi ne
mounts. Check for any condi ti on that coul d effect the
si de to si de posi ti on of the measurement l ocati ons (e.g.,
engi ne support brackets, si derai l al i gnment, etc.).
(5) After ensuri ng proper dri veshaft l engths the
transmi ssi on shi ft l i nkage must be adjusted to ensure
proper operati on. Refer to Transaxl e, Group 21.
Fig. 1 Left Driveshaft with Damper Weight
Fig. 1 Driveshaft Positioning
SPECI FI CATI ONS
DRI VESHAFT DI MENSI ONS I NSTALLED
TORQUE SPECI FI CATI ONS
ALI GNMENT SPECI FI CATI ONS AT CURB HEI GHT
STEERING
CONTENTS
page page
ACUSTAR STANDARD AND TILT STEERING
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 20
POWER STEERING PUMPS . . . . . . . . . . . . . . . . 2
SPECIFICATIONS AND TIGHTENING
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . 35
when working on any steering gear or pump.
servi ce manual .
The power steeri ng system consi sts of these four
major components. Power Steeri ng Pump, Power
Steeri ng Gear, Pressure Hose, and Return Li ne. Turn-
i ng of the steeri ng wheel i s converted i nto l i near travel
through the meshi ng of the hel i cal pi ni on teeth wi th
the rack teeth. Power assi st steeri ng i s provi ded by an
open center, rotary type control val ve. I t i s used to
di rect oi l from the pump to ei ther si de of the i ntegral
steeri ng rack pi ston.
Road feel i s control l ed by the di ameter of a torsi on
bar whi ch i ni ti al l y steers the vehi cl e. As requi red
steeri ng effort i ncreases, as i n a turn. The torsi on bar
twi sts, causi ng rel ati ve rotary moti on between the
rotary val ve body and the val ve spool . Thi s movement
di rects oi l behi nd the i ntegral rack pi ston, whi ch, i n
turn, bui l ds up hydraul i c pressure and assi sts i n the
turni ng effort.
STEERING 19 - 1
POWER STEERI NG PUMPS
INDEX
page page
Checking Power Steering Fluid Level . . . . . . . . . . 10
Power Steering Hoses . . . . . . . . . . . . . . . . . . . . . 10
Power Steering Pump Fluid Reservoir . . . . . . . . . . 19
Power Steering Pump Pressure Test . . . . . . . . . . . 10
Power Steering Pump Pulley . . . . . . . . . . . . . . . . 18
Power Steering Pump Removal . . . . . . . . . . . . . . 12
Power Steering Pump Service . . . . . . . . . . . . . . . . 9
Power Steering PumpInitial Operation . . . . . . . . 19
Steering Components Service Diagnosis . . . . . . . . . 3
GENERAL INFORMATION
Hydraul i c pressure for the operati on of the power
steeri ng gear i s provi ded by a bel t dri ven power steer-
i ng pump. The power steeri ng pump i s a constant fl ow
rate and di spl acement vane type pump. Di fferent
styl es of Sagi naw power steeri ng pumps are used
dependi ng on the engi ne appl i cati on of the vehi cl e. On
al l four cyl i nder appl i cati ons and 3.0-l i ter V-6 the Vane
Submerged i ntegral reservoi r (Fi g. 1) power steeri ng
pump i s used. On the 3.3-l i ter V-6 appl i cati ons the
Vane-Submerged remote reservoi r (Fi g. 2) power steer-
i ng pump i s used.
On the i ntegral reservoi r type pump (Fi g. 1) the
pump housi ng and i nternal components are combi ned
wi th the reservoi r to form a one-pi ece mechani sm.
The remote reservoi r type pump (Fi g. 2) has the
pump housi ng and i nternal components combi ned wi th
the fl ui d housi ng. But i t has a remote reservoi r for the
power steeri ng fl ui d suppl y.
Dri ve tangs on the power steeri ng pump pi ni on, mate
l oosel y wi th the stub shaft of the pump. Thi s i s to al l ow
manual steeri ng control to be mai ntai ned, i f the dri ve
bel t on the power steeri ng pump shoul d break. How-
ever, under these condi ti ons, steeri ng effort wi l l si gni fi -
cantl y i ncrease.
Fig. 1 Vane Submerged Power Steering Pump (Ham
Can)
Fig. 2 Vane Submerged Remote Reservoir Power
Steering Pump
19 - 2 STEERING
STEERING COMPONENTS SERVICE DIAGNOSIS
POWER STEERI NG SERVI CE DI AGNOSI S
STEERING 19 - 3
19 - 4 STEERING
STEERING 19 - 5
19 - 6 STEERING
STEERING 19 - 7
19 - 8 STEERING
POWER STEERING PUMP SERVICE
The servi ce procedures for the Sagi naw power steer-
i ng pump are l i mi ted to the areas and components
l i sted bel ow. No repair procedures are to be done
on the internal components of Saginaw power
steering pumps.
Repai r of power steeri ng fl ui d l eaks from areas of
the power steeri ng pump seal ed by O-ri ngs i s al l owed
(See Pump Leak Di agnosi s). However power steeri ng
pump shaft seal l eakage wi l l requi re repl acement of
the pump.
Power steeri ng fl ui d reservoi rs, rel ated components
and attachi ng hardware.
Power steeri ng fl ui d reservoi r fi l l er cap/di psti ck as-
sembl i es.
Because of uni que shaft beari ngs, fl ow control l evel s
or pump di spl acements, power steeri ng pumps may be
used onl y on speci fi c vehi cl e appl i cati ons. Be sure that
the pump i s onl y repl aced wi th a pump that i s the
correct repl acement for that speci fi c appl i cati on.
Hydraul i c pressure i s provi ded for operati on of the
power steeri ng gear by the bel t dri ven power steeri ng
pumps (Fi g. 1 & 2). I t i s a constant di spl acement, vane
type pump. The power steeri ng pump i s connected to
the steeri ng gear by a power steeri ng fl ui d pressure
hose and return l i ne.
Rectangul ar pumpi ng vanes carri ed by a shaft dri ven
rotor move the fl ui d from the i ntake to the cam ri ng
pressure cavi ti es. As the rotor begi ns to turn, centri fu-
gal force throws the vanes agai nst the i nsi de surface of
the cam ri ng to pi ckup resi dual oi l . Thi s oi l i s then
forced i nto the hi gh pressure area. As more oi l i s pi cked
up by the vanes. That addi ti onal oi l i s forced i nto the
cavi ti es of the thrust pl ate through two crossover hol es
i n the cam ri ng and pressure pl ate. The crossover hol es
empty i nto the hi gh pressure area between the pres-
sure pl ate and the housi ng end cover.
When the hi gh pressure area i s fi l l ed. Oi l fl ows under
the vanes i n the rotor sl ots, forci ng the vanes to fol l ow
the i nsi de oval surface of the cam ri ng. As the vanes
reach the restri cted area of the cam ri ng, oi l i s forced
out from between the vanes. When excess oi l fl ow i s
generated duri ng hi gh-speed operati on. A regul ated
amount of oi l returns to the pump i ntake si de through
a fl ow control val ve. The fl ow control val ve reduces the
power requi red to dri ve the pump and hol ds down
temperature bui l d-up.
When steeri ng condi ti ons exceed maxi mum pressure
requi rements, such as turni ng the wheel s agai nst the
stops. The pressure bui l t up i n the steeri ng gear al so
exerts pressure on the spri ng end of the fl ow control
val ve. Thi s end of the val ve houses the
PUMP LEAKAGE DI AGNOSI S
STEERING 19 - 9
pressure rel i ef val ve. Hi gh pressure l i fts the rel i ef
val ve bal l from i ts seat and al l ows oi l to fl ow through a
tri gger ori fi ce l ocated i n the outl et fi tti ng. Thi s reduces
pressure on the spri ng end of the fl ow control val ve
whi ch then opens and al l ows the oi l to return to the
i ntake si de of the pump. Thi s acti on l i mi ts maxi mum
pressure output of the pump to a safe l evel .
Under normal operati ng condi ti ons, the pressure
requi rements of the pump are bel ow maxi mum, caus-
i ng the pressure rel i ef val ve to remai n cl osed.
CHECKING POWER STEERING FLUID LEVEL
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TOPREVENT INJURY FROMMOV-
ING PARTS. DO NOT USE AUTOMATIC TRANSMIS-
SION FLUID IN THE POWER STEERING SYSTEM. DO
NOT OVERFILL THE POWER STEERING SYSTEM.
Wi pe reservoi r fi l l er cap free of di rt. Then check fl ui d
l evel . The di psti ck shoul d i ndi cate FULL COLD when
fl ui d i s at normal ambi ent temperature, approxi matel y
21C to 27C (70F to 80F). I n al l pumps add fl ui d as
necessary, use onl y Mopar Power Steering Fluid,
or equivalent. DO NOT USE ANY TYPE OF AU-
TOMATIC TRANSMISSION FLUID.
POWER STEERING PUMP PRESSURE TEST
The fol l owi ng procedure can be used to test the
operati on of the power steeri ng system on the vehi cl e.
(1) Check bel t tensi on and adjust as necessary.
(2) Di sconnect hi gh pressure hose at gear or pump.
Use a contai ner for dri ppi ng fl ui d.
(3) Connect Gauge C-3309-E (Fi g. 1) to both hoses
usi ng adapter fi tti ngs. Connect spare pressure hose to
gear or pump.
(4) Open the test val ve compl etel y.
(5) Start engi ne and l et i dl e.
(6) Check fl ui d l evel , add fl ui d as necessary.
(7) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure shoul d be i n the range
of 345-552 kPa (50-80 psi ).
CAUTION: The following test procedure involves test-
ing maximum pump pressure output and flow control
valve operation. Do not leave valve closed for more
than five seconds as the pump could be damaged.
(8) Cl ose val ve ful l y three ti mes and record hi ghest
pressure i ndi cated each ti me. All three readings
must beabovespecifications and within 345kPa
(50 psi) of each other.
Power steeringpumpmaximumrelief pressure
is 8275 to 8975 kPa (1200 to 1300 psi.).
Pressures above speci fi cati ons but not wi thi n 345
kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other but
bel ow speci fi cati ons, repl ace pump.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time
because, pump damage will result.
(9) Open the test val ve, turn steeri ng wheel extreme
l eft and ri ght posi ti ons agai nst the stops. Record the
hi ghest i ndi cated pressure at each posi ti on. Compare
readi ngs to speci fi cati ons. I f hi ghest output pressures
are not the same agai nst ei ther stop, the steeri ng gear
i s l eaki ng i nternal l y and must be repl aced.
POWER STEERING HOSES
Servi ce al l power steeri ng hoses wi th vehi cl e rai sed
on hoi st. Cap al l open ends of hoses, power steeri ng
pump fi tti ngs and steeri ng gear ports to prevent entry
of forei gn materi al i nto the components.
WARNING: POWER STEERING OIL, ENGINE PARTS
AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF ENGINE HAS BEEN RUNNING. DO NOT
START ENGINE WITH ANY LOOSE OR DISCON-
NECTED HOSES. DO NOT ALLOWHOSES TO TOUCH
HOT EXHAUST MANIFOLD OR CATALYST.
For part reference and part l ocati on for the vehi cl e
that i s bei ng servi ced, refer to Fi gs. 1 to 4. These show
the hose bracket l ocati ons, hose routi ngs and fi tti ng
l ocati ons by the engi ne appl i cati on of the vehi cl e. Use
these fi gure numbers when referri ng to the removal or
i nstal l ati on procedures for the power steeri ng hoses
l i sted bel ow.
Fig. 1 Pressure Test Gauge
19 - 10 STEERING
REMOVAL
(1) Remove bol ts from power steeri ng hose routi ng
bracket to crossmember attachment poi nts.
(2) Di sconnect power steeri ng hose at openi ng near-
est power steeri ng gear assembl y. Drai n the power
steeri ng fl ui d from power steeri ng pump and hose
through open end of hose.
(3) Di sconnect opposi te end of hose and remove
power steeri ng hose assembl y from vehi cl e.
(4) Di scard O-ri ng at end of tube and/or the washer
seal .
I NSTALLATI ON
(1) Usi ng a l i nt free towel , wi pe cl ean the open power
steeri ng hose ends, power steeri ng pump and steeri ng
gear ports.
(2) I nstal l new O-ri ngs and/or washer seal s on the
ends of the power steeri ng hoses. Lubri cate O-ri ngs or
washer seal s usi ng cl ean power steeri ng fl ui d.
(3) Attach power steeri ng hose to the proper connec-
ti ons at the power steeri ng pump and steeri ng gear.
Route hoses smoothl y i n thei r correct posi ti on avoi di ng
ti ght bends or ki nki ng. I nstal l the power steeri ng hose
to crossmember routi ng bracket. Hoses must remai n
away from the exhaust system. Do not bend tube ends.
(4) Ti ghten al l fasteners shown for speci fi c appl i ca-
ti ons shown i n (Fi g. 1 to 4) to thei r correct torques
l i sted bel ow:
Fig. 1 Power Steering Hose Routing 2.5L
Fig. 4 Power Steering Hose Routing 3.3L A.W.D.
STEERING 19 - 11
Pump End Banjo Bol t 34 Nm (25 ft. l bs.)
Pump End Tube Nut 34 Nm (25 ft. l bs.)
Gear End Tube Nuts (2) 34 Nm (25 ft. l bs.)
Crossmember Bracket Bol t 23 Nm (17 ft. l bs.)
Pump Bracket Nut 40 Nm (30 ft. l bs.)
Gear Bracket Bol t 68 Nm (50 ft. l bs.)
(5) When used, protecti ve sponge sl eeves must be
properl y posi ti oned on power steeri ng hoses. Thi s i s to
prevent hose contact wi th other components.
(6) After hose i s i nstal l ed, check for l eaks. (See
Pump I nstal l ati on).
POWER STEERING PUMP REMOVAL
WARNING: POWER STEERING OIL, ENGINE COMPO-
NENTS AND THE EXHAUST SYSTEM MAY BE EX-
TREMELY HOT IF ENGINE HAS BEEN RUNNING. DO
NOT START ENGINE WITH ANY LOOSE OR DISCON-
NECTED HOSES. DO NOT ALLOWHOSES TO TOUCH
HOT EXHAUST MANIFOLD OR CATALYST.
2.5 LI TER
REMOVE
(1) REMOVE THE (-) NEGATI VE BATTERY
CABLE FROM THE BATTERY AND I SOLATE
CABLE.
(2) Loosen power steeri ng pump adjustment bol t
and rotate the pump forward i n bracket. Remove the
power steeri ng pump dri ve bel t from pump (Fi g. 1). I t
i s not necessary to remove the power steeri ng pump
dri ve bel t from engi ne.
(3) Rai se vehi cl e See Hoi sti ng, Group 0. Put oi l drai n
pan under vehi cl e to catch power steeri ng fl ui d. Re-
move hose cl amp and l ow pressure fl ui d hose from
power steeri ng pump (Fi g. 2).
(4) Remove the power steeri ng, fl ui d pressure l i ne
(Fi g. 2) from the power steeri ng pump. Drai n excess
power steeri ng fl ui d from l i ne.
(5) Loosen but do not remove, nut hol di ng the back
of the power steeri ng pump to i ts mounti ng bracket
(Fi g. 3). Then remove bol t attachi ng the pul l ey si de of
the power steeri ng pump to the mounti ng bracket (Fi g.
3).
Fig. 3 Power Steering Pump Remove And Install
Fig. 1 Power Steering Pump Drive Belt Removal
Fig. 2 Power Steering Fluid Hoses
19 - 12 STEERING
(6) Lower Vehi cl e. Remove bol t retai ni ng the power
steeri ng pump i n adjusti ng sl ot of the power steeri ng
pump mounti ng bracket (Fi g. 3).
(7) Remove power steeri ng pump from vehi cl e.
Pump i s removabl e from the top of the vehi cl e. Li ft
power steeri ng pump out of mounti ng bracket, rotate
and l i ft i t out between the engi ne dash panel .
(8) Transfer the requi red parts from the removed
power steeri ng pump, to the repl acement power steer-
i ng pump.
INSTALL
(1) I nstal l power steeri ng pump back i n vehi cl e i n
the reverse order of removal .
(2) I nstal l power steeri ng pump back on mounti ng
bracket. Be sure stud on back of power steeri ng pump
i s i n sl otted hol e i n bracket. I nstal l bol t attachi ng
power steeri ng pump to adjusti ng sl ot i n bracket (Fi g.
3). Do not ti ghten nut or bol t.
(4) I nstal l the bol t attachi ng the pul l ey si de of the
power steeri ng pump to the mounti ng bracket (Fi g. 3).
Do not fully tighten the bolts.
(5) I nstal l the power steeri ng fl ui d pressure l i ne
onto the output fi tti ng of the power steeri ng pump (Fi g.
2). Torque the pressure l i ne pump fi tti ng nut to 31 Nm
(275 i n. l bs.). Before connecting the pressure line
topower steeringpumpinspect theO-ringonthe
pressure line for damage.
(6) I nstal l the power steeri ng fl ui d, l ow pressure
return hose on the power steeri ng pump l ow pressure
fi tti ng (Fi g. 2). I nstal l hose cl amp on l ow pressure
return hose. Be sure the cl amp i s i nstal l ed on hose past
upset bead on power steeri ng pump tube.
(8) I nstal l the power steeri ng pump dri ve bel t on
pump pul l ey. Usi ng the power steeri ng pump adjusti ng
bracket (Fi g. 1), rotate pump i n bracket to obtai n
correct bel t tensi on. Ti ghten bol t at power steeri ng
pump mounti ng bracket adjusti ng sl ot (Fi g. 1) to 54
Nm (40 ft. l bs.). Torque the power steeri ng pump to
mounti ng bracket pi vot, nut and bol t (Fi g. 1) to 54 Nm
(40 ft. l bs.).
CAUTION: Do not use automatic transmission fluid in
power steering system. Only use Mopar, Power
Steering Fluid, or equivalent.
(9) Fi l l the power steeri ng pump reservoi r to correct
fl ui d l evel .
(10) Connect the negati ve battery cabl e back on the
negati ve battery post.
(11) Start engi ne and turn steeri ng wheel several
ti mes from stop to stop to bl eed ai r from fl ui d i n
system. Stop engi ne, check fl ui d l evel , and i nspect
system for l eaks. See Checki ng Fl ui d Level .
3.0 LI TER
REMOVE
(1) REMOVE THE (-) NEGATI VE BATTERY
CABLE FROM THE BATTERY AND I SOLATE
CABLE.
(2) Remove the serpenti ne accessory dri ve bel t from
engi ne (Fi g. 4). See Cool i ng, Group 7 for detai l ed
removal procedure.
(3) Remove the hose cl amp and bol t mounti ng the
power steeri ng pump fi l l er tube and di psti ck assembl y
(Fi g. 5) to power steeri ng pump and al ternator bracket.
Remove fi l l er tube and di psti ck assembl y from power
steeri ng pump.
Fig. 5 Power Steering Pump Filler Tube/Dipstick As-
sembly
Fig. 4 3.0l Serpentine Drive Belt Routing
STEERING 19 - 13
(5) Remove the 2 nut, bol t and spri ng assembl i es
attachi ng the exhaust pi pe to exhaust mani fol d. Re-
move exhaust pi pe from exhaust mani fol d and move to
l eft si de of vehi cl e. Thisisrequiredfor clearanceto
remove power steering pump fromvehicle.
(6) Put oi l drai n pan under vehi cl e to catch power
steeri ng fl ui d. Remove hose cl amp and l ow pressure
fl ui d hose, from power steeri ng gear fl ui d tube (Fi g. 6).
Al l ow excess power steeri ng fl ui d to drai n from power
steeri ng pump and hose.
(7) Loosen the hi gh pressure power steeri ng fl ui d
l i ne fi tti ng at the power steeri ng pump (Fi g. 6). Then
remove hi gh pressure power steeri ng fl ui d l i ne from
power steeri ng pump.
(8) Remove nut hol di ng the power steeri ng pump rear
support bracket to pump (Fi g. 7). Then remove the 2 bol ts
(Fi g. 7) mounti ng the power steeri ng pump support bracket
to engi ne and remove bracket from vehi cl e.
(9) Remove the 2 bol ts that mount the front of the
power steeri ng pump to the mounti ng pl ate (Fi g. 8).
Access to the mounti ng bol ts i s through the hol es i n
power steeri ng pump pul l ey usi ng a deep wel l socket.
(10) Remove the power steeri ng pump and pul l ey
assembl y from vehi cl e. Remove pump assembl y from
vehi cl e i n area between fl oor pan and front suspensi on
crossmember. Pump wi l l fi t through area of exhaust
pi pe tunnel i n fl oor pan.
(11) Transfer Requi red parts to the new power steer-
i ng pump assembl y before i nstal l i ng i n vehi cl e.
INSTALL
(1) I nstal l the power steeri ng pump assembl y back
i n vehi cl e i n reverse order of removal .
(2) Hol d power steeri ng pump agai nst mounti ng
pl ate. Al i gn power steeri ng pump mounti ng hol es wi th
mounti ng hol es i n pl ate and i nstal l bol ts (Fi g. 8).
Torque the 2 power steeri ng pump to mounti ng pl ate
bol ts to 54 Nm (40 ft. l bs.).
(3) I nstal l the rear power steeri ng pump to engi ne bl ock
support bracket, onto the stud on back of power steeri ng
pump (Fi g. 7). Then i nstal l the 2 bol ts mounti ng the support
bracket to the engi ne bl ock. Torque the 2 support bracket to
engi ne bl ock mounti ng bol ts to 54 Nm (40 ft. l bs.).
(4) I nstal l the nut on stud of power steeri ng pump
attachi ng pump to rear support bracket (Fi g. 7). Torque
nut to 54 Nm (40 ft. l bs.)
(5) I nstal l the hi gh pressure power steeri ng fl ui d
l i ne on the power steeri ng pump outl et fi tti ng (Fi g. 6).
Torque the hi gh pressure fl ui d l i ne to power steeri ng
pump fi tti ng to 31 Nm (275 i n. l bs.).
(6) I nstal l the l ow pressure power steeri ng fl ui d hose
onto the power steeri ng gear fl ui d tube (Fi g. 6). I nstal l
hose cl amp on hose. Besurehoseclampisinstalled
beyond upset bead on tube.
(7) I nstal l the exhaust pi pe back on the exhaust
mani fol d. I nstal l the nut, bol t and spri ng assembl i es
Fig. 6 Power Steering Hose Remove/Replace
Fig. 7 Power Steerinqg Support Bracket
Fig. 8 Power Steering Pump Mounting 3.0L
19 - 14 STEERING
and torque bol ts to 28 Nm (250 i n. l bs.).
(9) I nstal l the power steeri ng pump fi l l er tube and
di p sti ck assembl y on the neck of the power steeri ng
pump (Fi g. 5). I nstal l the bol t (Fi g. 5) attachi ng the
fi l l er tube/di p sti ck assembl y to the al ternator bracket.
Torque the bol t to 11 Nm (100 i n. l bs.).
(10) Posi ti on the hose cl amp on the fi l l er tube assem-
bl y rubber boot and adequatel y ti ghten hose cl amp.
(11) I nstal l the serpenti ne accessory dri ve bel t on
i nstal l ati on procedure.
(12) Fi l l power steeri ng pump reservoi r to correct
fl ui d l evel .
(13) Connect the negati ve battery cabl e back on the
negati ve battery post.
3.3 LI TER F.W.D. & A.W.D
REMOVE
(1) Remove the (-) negati ve battery cabl e from the
battery and i sol ate cabl e.
(2) Remove the serpenti ne accessory dri ve bel t from
removal procedure.
pan under vehi cl e to catch power steeri ng fl ui d. Re-
move hose cl amp and l ow pressure fl ui d hose from
power steeri ng pump (Fi g. 10 or 11).
Fig. 9 Serpentine Drive Belt Routing
Fig. 10 Power Steering Hose Routing 3.3L F.W.D.
Fig. 11 Power Steering Hose Routing 3.3L A.W.D.
STEERING 19 - 15
(4) Remove hose cl amp and hose to the power steer-
i ng pump, from the remote fl ui d reservoi r (Fi g 12).
Drai n off excess power steeri ng fl ui d from hoses.
(5) Remove the power steeri ng, fl ui d pressure l i ne
(Fi g. 10 or 11) from the power steeri ng pump. Drai n
excess power steeri ng fl ui d from tube.
(6) Remove ri ght front wheel and ti re from vehi cl e.
Thi s wi l l ai d i n access to the power steeri ng pump
mounti ng bol ts.
(7) Remove the 3 bol ts hol di ng the power steeri ng
pump to the al ternator, power steeri ng and bel t ten-
si oner mounti ng bracket (Fi g. 13).
(8) Remove nut and bol t hol di ng the engi ne bl ock, to
power steeri ng pump support strut. Remove strut from
engi ne and power steeri ng pump (Fi g. 13). Lay the
power steering pump assembly down on top of
the steering gear. It will be removed later from
the top.
(9) Remove nut whi ch hol ds serpenti ne dri ve bel t
tensi oner to i ts mounti ng bracket (Fi g. 14). Remove
tensi oner assembl y from bracket.
(10) Remove nut and bol t attachi ng the
al ternator/power steeri ng pump bracket, support strut
(Fi g. 15).
(12) Remove the 2 bol ts hol di ng the power steeri ng
fl ui d reservoi r to the al ternator bracket. Remove the
bol t attachi ng the tube/hose assembl y to the power
Fig. 12 Power Steering Remote Fluid Reservoir And
Tube
Fig. 13 Power Steering Pump Mounting 3.3L
Fig. 14 Serpentine Belt Tensioner
Fig. 15 Bracket Support Strut
19 - 16 STEERING
steeri ng pump bracket (Fi g. 16). Then remove the fl ui d
reservoi r and tube/hose as an assembl y from vehi cl e.
(13) Remove the engi ne wi ri ng harness routi ng cl i p
from the al ternator bracket.
(14) Loosen but DO NOT REMOVE the bol t (Fi g.
17) hol di ng the engi ne bracket assembl y to the engi ne
support assembl y.
(15) Remove upper al ternator to al ternator bracket
mounti ng bol t (Fi g. 18). Rotate the al ternator assembl y
back toward the dash panel .
(16) Remove the 4 bol ts hol di ng the al ternator
bracket to the engi ne and i ntake mani fol d (Fi g. 18).
Remove al ternator bracket from engi ne.
(17) Remove the al ternator assembl y, to l ower al ter-
nator bracket bol t (Fi g. 18). Wi th out removi ng wi ri ng
harness from al ternator, remove al ternator from
bracket and l ay al ternator on top of i ntake mani fol d.
(18) Remove the power steeri ng pump out through
the top, i n the area between engi ne and dash panel
where the al ternator was mounted.
(19) Transfer the requi red parts from the removed
power steeri ng pump, to the repl acement power steer-
i ng pump.
INSTALL
(1) I nstal l power steeri ng pump back i n vehi cl e,
l ayi ng i t on the steeri ng gear. Do not mount i t to the
power steeri ng pump bracket.
(2) I nstal l al ternator back on the l ower al ternator
bracket and i nstal l bol t and nut (Fi g. 18). Do not
ti ghten bol t at thi s ti me.
(3) I nstal l the al ternator bracket back on engi ne and
i ntake mani fol d. Loosel y i nstal l the 4 al ternator bracket to
engi ne attachi ng bol ts (Fi g. 18). BesuretheSPACER (Fig.
17) isinstalledbetween theenginemountingstrut and
the alternator bracket.
(4) Temporari l y i nstal l the serpenti ne bel t tensi oner
bol t through both al ternator brackets to al i gn al l
bracket mounti ng hol es (Fi g. 14). Then torque the 4
al ternator bracket to engi ne and i ntake mani fol d
mounti ng bol ts to 54 Nm (40 ft. l bs.). Then remove the
serpenti ne bel t tensi oner from bracket.
(5) Ti ghten the bol t hol di ng the engi ne bracket as-
sembl y to the engi ne support assembl y (Fi g. 17) to 150
Nm (110 ft. l bs.).
(6) Attach the engi ne wi ri ng harness routi ng cl i p to
the al ternator bracket.
(7) I nstal l the al ternator to al ternator bracket at-
tachi ng bol t (Fi g. 17). Torque bol t to 54 Nm (40 ft.
l bs.). Ti ghten the l ower al ternator pi vot bol t to 54 Nm
(40 ft. l bs.).
(8) I nstal l the power steeri ng pump fl ui d reservoi r
and tube/hose assembl y onto the power steeri ng
pump bracket and al ternator bracket (Fi g. 16).
Torque the 2 bol ts hol di ng the reservoi r to the al ter-
nator bracket to 5 Nm (45 i n. l bs.). Torque the 1 bol t
Fig. 16 Power Steering Fluid Reservoir Mounting
Fig. 17 Engine Bracket Support Assembly
Fig. 18 Alternator Mounting
STEERING 19 - 17
hol di ng the tube/hose assembl y to the power steeri ng
pump bracket to 12 Nm (105 i n. l bs.).
(10) I nstal l the strut assembl y power
steeri ng/al ternator bracket to engi ne (Fi g. 15). Torque
the nut and bol t hol di ng the strut assembl y to bracket
and the i ntake mani fol d stud to 54 Nm (40 ft. l bs).
(11) I nstal l the serpenti ne dri ve bel t tensi oner onto
the power steeri ng/al ternator bracket (Fi g. 14). I nstal l
the tensi oner to bracket retai ni ng nut and torque to 54
Nm (40 ft. l bs.).
(12) I nstal l the power steeri ng pump on bracket, by
al i gni ng the 3 mounti ng hol es i n pump wi th mounti ng
hol es i n bracket (Fi g. 13). I nstal l the 3 power steeri ng
pump to bracket mounti ng bol ts. Torque power steer-
i ng pump mounti ng bol ts to 54 Nm (40 ft. l bs.).
(13) I nstal l the support strut, engi ne bl ock to power
steeri ng pump on pump stud (Fi g. 13). I nstal l the nut
and bol t hol di ng the strut to the power steeri ng pump
and engi ne bl ock and torque to 54 Nm (40 ft. l bs.).
(14) I nstal l the power steeri ng fl ui d pressure l i ne
onto the output fi tti ng of the power steeri ng pump (Fi g.
10 or 11). Torque the pressure l i ne pump fi tti ng nut to
31 Nm (275 i n. l bs.). Before connecting the pres-
sure line to power steering pump inspect the
O-ring on the pressure line for damage.
(15) I nstal l the power steeri ng fl ui d, l ow pressure
return hose on the power steeri ng pump l ow pressure
fi tti ng (Fi g 10 or 11). Then i nstal l the hose from the
remote reservoi r onto the power steeri ng pump (Fi g.
12). Be sure al l hose cl amps are properl y rei nstal l ed.
(16) I nstal l ri ght front ti re and wheel on vehi cl e.
I nstal l the wheel stud nuts and torque to 129 Nm (95
ft. l bs.).
(18) I nstal l the serpenti ne dri ve bel t. Refer to (Fi g.
9) for correct serpenti ne bel t routi ng. See Cool i ng,
Group 7 for detai l ed i nstal l ati on procedure.
(19) Fi l l power steeri ng pump reservoi r to correct
fl ui d l evel .
(20) Connect the negati ve battery cabl e on the nega-
ti ve battery post.
POWER STEERING PUMP PULLEY
REMOVAL
(1) Remove the pul l ey wi th Pul l er C-4333 (C-4068)
(Fi g. 1).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump.
(2) Repl ace pul l ey i f bent, cracked, or l oose.
I NSTALLATI ON
(1) I nstal l the pul l ey wi th I nstal l er C-4063 (Fi g. 2).
Do not use the tool adapters.
(2) Ensure that the tool and the pul l ey remai n
al i gned wi th the pump shaft. Prevent the pul l ey from
bei ng cocked on the shaft.
Fig. 1 Pulley Removal (Typical)
Fig. 2 Pulley Installation (Typical)
19 - 18 STEERING
(3) Force pul l ey fl ush wi th the end of the shaft.
Wi th Serpenti ne Bel ts; Run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be care-
ful that pulley does not contact mounting bolts.
POWER STEERING PUMP FLUID RESERVOIR
REMOVE
Discard all O-ring seals during disassembly,
they are not re-usable.
(1) Remove the fi l l er cap and drai n the fl ui d from
reservoi r before removi ng parts.
(2) Remove mounti ng studs and pressure fi tti ng
(Fi g. 1). Rock reservoi r by hand or use a soft face mal l et
to remove.
(3) Remove O-ri ng seal s from housi ng and reservoi r
(Fi g. 1).
(4) Remove fl ow control val ve and spri ng from housi ng.
I NSTALL
Clean all parts before installation. Lubricate
new O-ring seals with Mopar Power Steering
Fluid or equivalent.
(1) I nstal l fl ow control val ve and spri ng (Fi g. 2).
(2) I nstal l new O-ri ng seal s i n housi ng (Fi g. 1).
I nstal l the pump housi ng assembl y i nto the fl ui d
reservoi r. Ti ghten mounti ng studs to 48 Nm (35 ft.
l bs.) torque.
(3) I nstal l fi tti ng i n fl ow control val ve bore. Ti ghten
the fi tti ng to 75 Nm (55 ft. l bs.) torque.
POWER STEERING PUMPINITIAL OPERATION
CAUTION: The fluid level should be checked with engine off
to prevent injury from moving components. Use only Mo-
par Power Steering Fluid. Do not use automatic transmis-
sion fluid. Do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
Fig. 1 Pump and Reservoir
Fig. 2 Flow Control Valve/Spring Installation
STEERING 19 - 19
The di psti ck shoul d i ndi cate FULL COLD when the
fl ui d i s at normal temperature of approxi matel y 21C
to 27C (70F to 80F).
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two (2) mi nutes.
(2) Start the engi ne and l et run for a few seconds.
Then turn the engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Start the engi ne. Sl owl y turn the steeri ng wheel
ri ght and l eft, l i ghtl y contacti ng the wheel stops.
(6) Add power steeri ng fl ui d i f necessary.
(7) Lower the vehi cl e and turn the steeri ng wheel
sl owl y from l ock to l ock.
(8) Stop the engi ne. Check the fl ui d l evel and refi l l
as requi red.
(9) I f the fl ui d i s extremel y foamy, al l ow the vehi cl e
to stand a few mi nutes and repeat the above procedure.
POWER STEERI NG GEAR
INDEX
page page
Outer Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering Gear Boot Seal . . . . . . . . . . . . . . . . . . . 27
Steering Gear Service (All Wheel Drive) . . . . . . . . 23
Steering Gear Service (Front Wheel Drive) . . . . . . 21
GENERAL INFORMATION
Thepower steeringgear (Fig. 1) shouldNOT be
serviced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced.
I f a steeri ng gear boot needs to be repl aced due to
damage, refer to the power steeri ng gear servi ce sec-
ti on i n thi s manual for proper procedure.
The power steeri ng system consi sts of these four
major components. Power Steeri ng Gear, Power Steer-
i ng Pump, Pressure Hose, and Return Li ne. Turni ng of
the steeri ng wheel i s converted i nto l i near travel
through the meshi ng of the hel i cal pi ni on teeth wi th
the rack teeth. Power assi st steeri ng i s provi ded by an
open center, rotary type control val ve whi ch di rects oi l
from the pump to ei ther si de of the i ntegral rack pi ston.
Road feel i s control l ed by the di ameter of a torsi on
bar whi ch i ni ti al l y steers the vehi cl e. As requi red
steeri ng effort i ncreases, as i n a turn. The torsi on bar
twi sts, causi ng rel ati ve rotary moti on between the
rotary val ve body and the val ve spool . Thi s movement
di rects oi l behi nd the i ntegral rack pi ston, whi ch, i n
turn, bui l ds up hydraul i c pressure and assi sts i n the
turni ng effort.
Fig. 1 Power Steering Gear Assembly
19 - 20 STEERING
The dri ve tangs on the pi ni on mate l oosel y wi th a
stub shaft to permi t manual steeri ng control to be
mai ntai ned i f the dri ve bel t on the power steeri ng
pump shoul d break. However, under these condi ti ons,
steeri ng effort wi l l be i ncreased.
STEERING GEAR SERVICE (FRONT WHEEL DRIVE)
The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
replaced.
REMOVAL
pan under vehi cl e to catch power steeri ng fl ui d.
(2) Remove front road wheel s.
(3) Remove both ti e rod ends from steeri ng knuckl es,
usi ng Pul l er Speci al Tool C-3894-A (Fi g. 1).
(4) Di sconnect engi ne damper strut from crossmem-
ber (i f so equi pped).
(5) Remove the 3 front suspensi on crossmember at-
tachi ng bol ts and the nut (Fi g. 2) from the l ocati ng
stud. Lower front suspensi on crossmember, usi ng
transmi ssi on jack, so that the steeri ng gear can be
di sconnected from the steeri ng col umn.
Fig. 2 Crossmember Remove/Replace
Fig. 1 Tie Rod End Removal
STEERING 19 - 21
(6) Remove fl ui d tubes (Fi g. 3) from the power
steeri ng pump to the steeri ng gear. See hose removal
procedure.
(7) Remove the 4 bol ts (Fi g. 3) attachi ng steeri ng
gear to front suspensi on crossmember.
(8) Remove steeri ng gear assembl y from crossmember.
I NSTALLATI ON
An assistant will be required in the vehicle, at
the time of steering gear replacement. To help
guide the steering column coupling onto the
steering gear assembly.
(1) I nstal l steeri ng gear assembl y on the front cross-
member. I nstal l the 4 steeri ng gear to front crossmem-
ber mounti ng bol ts (Fi g. 3).
(2) Usi ng a transmi ssi on jack rai se the front crossmember
and steeri ng gear agai nst the frame rai l s. I nstal l the 3 cross-
member to frame rai l attachi ng bol ts and nut on l ocati ng stud
(Fi g. 2). The right rear crossmember stud is a pilot that
correctly locates the crossmember. Tighten down this
bolt first, then torque all 4 crossmember fasteners to
122 Nm(90 ft. lbs.).
CAUTION: Proper torque on the crossmember to frame
rail mounting bolts is very important.
Fig. 3 Steering Gear And Crossmember
STEERI NG GEAR ALL WHEEL DRI VE
19 - 22 STEERING
(3) Torque the 4 bol ts (Fi g. 3) attachi ng the steeri ng
gear assembl y to front crossmember, to 68 Nm (50 ft.
l bs.). To ensure proper alignment of the steering
gear tighten left front bolt first.
(4) Attach the engi ne damper strut from the engi ne
to the crossmember (i f so equi pped).
(5) Attach the fl ui d tubes (Fi g. 3) from the power
steeri ng pump to the fi tti ngs on the steeri ng gear.
Torque the fl ui d pressure l i ne to steeri ng gear tube nut
to 31 Nm (275 i n. l bs.).
(6) Mount the outer ti e rod ends to the steeri ng
knuckl es. I nstal l the ti e rod end to steeri ng knuckl e
attachi ng nuts. Torque the ti e rod end to steeri ng
knuckl e nuts to 52 Nm (38 ft. l bs.). I nstal l cotter pi n
i n ti e rod end.
(7) I nstal l the front ti re and wheel assembl i es on
vehi cl e. I nstal l the wheel l ug nuts and torque to 129
Nm (95 ft. l bs.).
CAUTION: Do not use automatic transmission fluid.
system for l eaks. Fill pump reservoir to correct
level with Mopar, Power Steering Fluid, or
equivalent. See Checki ng Fl ui d Level .
(8) Adjust toe (Refer to Group 2 Suspensi on).
STEERING GEAR SERVICE (ALL WHEEL DRIVE)
The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
replaced.
REMOVAL
(1) Remove front ti re and wheel assembl i es from
vehi cl e.
(2) Remove the steeri ng col umn assembl y from the
vehi cl e. (STEERING COLUMN MUST BE RE-
MOVED FROM VEHICLE, TO ALLOW CLEAR-
ANCE FOR STEERING GEAR REMOVAL ON
THE ALL WHEEL DRIVE APPLICATIONS). (Refer
to Steeri ng Col umn Removal i n thi s secti on of the
manual )
(3) Remove both ti e rod ends from steeri ng knuckl es,
(4) Remove the 2 bol ts and the 2 nuts attachi ng the
bri dge to the front crossmember. The bol ts and nuts are
accessi bl e through hol e i n the top of the bri dge assem-
bl y (Fi g. 5).
Fig. 5 Bridge Assembly Remove/Replace
STEERING 19 - 23
(5) Remove the bracket hol di ng the power steeri ng
hoses to the crossmember (Fi g. 6).
(6) Remove the 3 front suspensi on crossmember to
frame rai l attachi ng bol ts and the nut (Fi g. 7) from the
l ocati ng stud.
(7) Usi ng a transmi ssi on jack, (Fi g. 8) l ower the
front suspensi on crossmember suspendi ng i t from the
l ower control arms (Fi g. 9). I t i s not necessary to
compl etel y remove crossmember from vehi cl e
(8) Remove the power steeri ng pump fl ui d pressure
and return l i nes (Fi g. 10) from the steeri ng gear. See
Power Steeri ng Hose Removal i n thi s secti on of the
servi ce manual for detai l ed procedure.
(9) Remove the 4 bol ts attachi ng the steeri ng gear to
the crossover
bri dge (Fi g. 11). Note the location of the bolts,
they are different for the left and right steering
gear mounting brackets.
(10) Remove the l ower steeri ng col umn coupl i ng
from the steeri ng gear. Dri ve the steeri ng coupl er rol l
pi n (Fi g. 12) from the coupl er usi ng a sui tabl e dri ft.
Then separate steeri ng coupl er from steeri ng gear
shaft. THIS IS REQUIRED TO HAVE ADEQUATE
CLEARANCE BEFORE TRYING TO REMOVE
THE STEERING GEAR FROM THE VEHICLE.
Fig. 6 Power Steering Hoses
Fig. 7 Crossmember Assembly Remove/Replace
Fig. 8 Lowering Front Crossmember
Fig. 9 Crossmember Assembly Lowered in Vehicle
19 - 24 STEERING
(11) Remove the steeri ng gear from the vehi cl e by
pul l i ng i t out the dri ver si de wheel wel l . Rotate the
gear as requi red to cl ear the frame rai l as you are
sl i di ng the gear out of the vehi cl e (Fi g. 13).
Fig. 10 Power Steering Fluid Lines
Fig. 11 Steering Gear Remove/Replace
Fig. 12 Steering Coupler Remove/Replace
Fig. 13 Steering Gear Removal From Vehicle
STEERING 19 - 25
I NSTALLATI ON
(1) I f the bri dge assembl y was removed from the
vehi cl e. Lay the bri dge assembl y on the output shaft of
the P.T.U. (Fi g. 14).
(2) I nstal l the steeri ng gear i nto the vehi cl e (Fi g. 13)
i n the reverse order of i ts removal , through l eft wheel
wel l .
(3) I nstal l the l ower steeri ng col umn coupl er onto
the steeri ng gear shaft (Fi g. 12). Be sure the rol l pi n i s
ful l y i nstal l ed through the coupl er housi ng. The roll
pin retains the steering coupler to the splined
shaft on the steering gear.
(4) I nstal l the 4 bol ts that mount the steeri ng gear to
the bri dge assembl y, (Fi g. 11) but do not torque them.
Thebolts holdingthesteeringgear to thebridge
assembly. Must be replaced in the same steering
gear mount location they wereremoved from. Be
sure the power steeri ng hose bracket i s rei nstal l ed
under the ri ght steeri ng gear bracket.
(5) I nstal l the power steeri ng pump fl ui d, pressure
and return l i nes (Fi g. 10) onto the correct steeri ng gear
fi tti ngs. Torque the fl ui d l i ne to steeri ng gear tube nuts
to 31 Nm (275 i n.l bs.).
(6) Usi ng a Transmi ssi on Jack, (Fi g. 8) rai se and
i nstal l the crossmember assembl y i n the vehi cl e.
Ti ghten the 4 crossmember to frame rai l fasteners (Fi g.
7) to the torque speci fi cati ons l i sted bel ow. The right
rear crossmember stud is a pilot that correctly
locates thecrossmember. Tighten down this bolt
first, then torque all 4crossmember fasteners to
122 Nm(90 ft. lbs.).
CAUTION: Proper torque on the crossmember to
frame rail mounting bolts is very important.
(7) I nstal l the bri dge assembl y onto the crossmem-
ber assembl y (Fi g. 5) and torque the 4 fasteners to 68
Nm (50 ft. l bs.).
(8) I nstal l the routi ng bracket for the power steeri ng
l i nes (Fi g. 6) onto the crossmember assembl y. Torque
screw to 8 Nm (70 i n. l bs.).
(9) I nstal l the outer ti e rod ends on the steeri ng
knuckl es. I nstal l the ti e rod end to steeri ng knuckl e
attachi ng nuts and torque to 52 Nm (38 ft. l bs.). The
cotter pin that retains the tie rod end nut must
be installed.
(10) Start up the vehi cl e and check al l power steer-
i ng fl ui d hose fi tti ngs for oi l l eaks.
(11) Check and or adjust toe setti ng on vehi cl e after
steeri ng gear i s i nstal l ed (Refer to Group 2 Suspen-
si on).
OUTER TIE ROD
REMOVAL
(1) Loosen i nner ti e rod to outer ti e rod jam nut (Fi g.
1).
(2) Remove outer ti e rod to steeri ng knuckl e cotter
pi n and attachi ng nut (Fi g. 1).
(4) Remove the ti e rod end from steeri ng knuckl es,
(5) Remove outer ti e rod from i nner ti e rod.
I NSTALLATI ON
(1) I nstal l outer ti e rod onto i nner ti e rod. Make
sure jamnut is on inner tie rod (Fig. 1).
Fig. 14 Bridge Assembly Installed
Fig. 1 Outer Tie Rod
19 - 26 STEERING
(2) Do not ti ghten jam nut.
(3) I nstal l outer ti e rod onto steeri ng knuckl e. I nstal l
ti e rod to steeri ng knuckl e attachi ng nut and torque to
52 Nm (38 ft.l bs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(4) Make toe adjustment by turni ng i nner ti e rod.
(5) Ti ghten the i nner to outer ti e rod jam nut to 75
Nm (55 ft. l bs.) torque. Lubri cate ti e rod boot groove
wi th si l i cone type l ubri cant before i nstal l i ng outer boot
cl amp, maki ng sure boot i s not twi sted.
STEERING GEAR BOOT SEAL
The removal and installation of the following
components must be performed with the rack
and pinion assembly removed fromthe vehicle.
REMOVAL
(1) Remove outer ti e rod from steeri ng knuckl e (Fi g.
1).
(2) Loosen the i nner to outer ti e rod jam nut (Fi g. 2).
Remove the outer ti e rod from the i nner ti e rod.
(3) Remove jam nut.
(4) Usi ng pl i ers expand outer boot, to ti e rod cl amp
(Fi g. 3) and remove from steeri ng gear boot.
(5) Use pl i ers to expand boot snorkel cl amp (Fi g. 3)
and sl i de cl amp off boot and l eave on breather tube.
(6) Remove i nner, boot to steeri ng gear cl amp (Fi g.
3).
After removinginner boot clamps, a very small
screwdriver should be used to lift boot from its
groove, then the boot can be removed from the
steering gear.
I NSTALLATI ON
(1) I nstal l boot seal on i nner ti e rod.
(2) Al i gn vent hol e i n boot seal (Fi g. 3) wi th steeri ng
gear breather tube.
(3) I nstal l boot seal over steeri ng gear housi ng l i p
and onto the end of the breather tube (Fi g. 3).
(4) I nstal l boot seal to breather tube snorkel cl amp
(Fi g. 3)
(5) I nstal l new i nner boot seal to steeri ng gear cl amp
(Fi g. 3)
(6) Lubri cate i nner ti e rod boot groove wi th si l i cone
type l ubri cant, then i nstal l outer boot seal to i nner ti e
rod cl amp (Fi g. 3).
(Cl amp wi l l have to be l oosened for toe adjustment.)
(7) I nstal l i nner to outer ti e rod jam nut (Fi g. 2) on
i nner ti e rod.
(8) I nstal l outer ti e rod on i nner ti e rod (Fi g. 2). Do
not ti ghten jam nut.
(9) I nstal l outer ti e rod onto steeri ng knuckl e. I nstal l
ti e rod to steeri ng knuckl e attachi ng nut and torque to
52 Nm (38 ft. l bs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(10) Make toe adjustment by turni ng i nner ti e rod.
(11) Ti ghten the i nner to outer ti e rod jam nut to 75
Nm (55 ft. l bs.) torque. Lubri cate ti e rod boot groove
wi th si l i cone type l ubri cant, before i nstal l i ng outer
boot cl amp, maki ng sure boot i s not twi sted.
Fig. 3 Boot Seal Remove Install
STEERING 19 - 27
ACUSTAR STANDARD AND TI LT STEERI NG COLUMN
INDEX
page page
Ignition Switch Service . . . . . . . . . . . . . . . . . . . . . 34
Steering Column Component Service . . . . . . . . . . 33
Steering Column Service Procedures . . . . . . . . . . . 1
GENERAL INFORMATION
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE AIR BAG SYSTEM. THEY MUST
NEVER BE REPLACED WITH ANY SUBSTITUTES.
ANYTIME A NEW FASTENER IS NEEDED, REPLACE
WITH THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN THE
PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITHANAIR BAG, REFER TOGROUP 8M,
ELECTRICAL FOR PROPER AND SAFE SERVICE
PROCEDURES.
when working on steering columns.
The Acustar ti l t and standard col umn (Fi g. 1) has
been desi gned to be servi ced as an assembl y; l ess
wi ri ng, swi tches, shrouds, steeri ng wheel , etc. Al so,
most steeri ng col umn components can be servi ced
wi thout removi ng the steeri ng col umn from the ve-
hi cl e.
CAUTION: Disconnect negative (ground) cable from
the battery, before servicing any column component.
CAUTION: Do not attempt to remove the pivot pins to
disassemble the tilting mechanism. Damage will oc-
cur.
STEERING COLUMN SERVICE PROCEDURES
To servi ce the steeri ng wheel and i ts components or
the ai r bag, refer to Group 8M, Restrai nt Systems.
Fol l ow al l WARNI NGS.
To servi ce the swi tches, refer to the appropri ate
secti on of Group 8, El ectri cal .
To repl ace the steeri ng col umn assembl y, refer to the
steeri ng col umn removal procedure. For l ocati on of
components referred to i n the procedure see (Fi g. 1).
TEM COMPONENT INSTALLATION OR REMOVAL
PROCEDURES. REMOVE AND ISOLATE THE NEGA-
TIVE (-) BATTERY CABLE (GROUND) FROM THE
VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG DE-
PLOYMENT AND POSSIBLE PERSONAL INJURY.
19 - 28 STEERING
F
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STEERING 19 - 29
STEERI NG COLUMN REMOVAL
(1) Make sure the front wheel s of the vehi cl e are i n
the straight ahead posi ti on.
(2) Di sconnect the negati ve (ground) cabl e from the
battery and i sol ate cabl e.
(3) For vehi cl es equi pped wi th a col umn shi ft. Di s-
connect the transmi ssi on shi ft cabl e from the steeri ng
col umn by pryi ng i t out of the grommet i n the shi ft
l ever (Fi g. 2).
(4) Remove the steeri ng wheel center pad and di s-
connect el ectri cal components such as horn l ead, ai r
bag l ead and speed control swi tch l ead (i f equi pped)
(Fi g. 3).
(5) Remove the steeri ng wheel retai ni ng nut from
the steeri ng col umn shaft. Remove steeri ng wheel from
shaft usi ng Pul l er, Speci al Tool C-3428-B (Fi g. 4). Do
not bumpor hammer on steeringcolumn shaft to
remove wheel.
(6) Remove the l ower steeri ng col umn cover (Fi g. 5).
(7) Remove the retai ni ng pi n i n the upper to l ower
steeri ng coupl er retai ni ng bol t (Fi g. 6).
(8) Remove the upper to l ower steeri ng coupl er re-
tai ni ng nut and pi nch bol t (Fi g. 6). Remove the upper
steeri ng coupl er from the l ower steeri ng coupl er shaft.
(9) Pl ace the gear shi ft l ever i n ei ther the neutral or
park posi ti on.
Fig. 5 Steering Column Cover Removed
Fig. 2 Shift Cable Removal From Grommet
Fig. 3 Horn Pad Removal (Typical)
Fig. 4 Removing Steering Wheel (Typical)
19 - 30 STEERING
(10) Remove the PRNDL i ndi cator actuati on cabl e
from the steeri ng col umn actuati ng arm (Fi g. 7).
(11) Rel ease the l ock bar on the col umn i nsert.
Squeeze the l egs of the col umn i nsert together and
remove i nsert from steeri ng col umn assembl y (Fi g. 7).
(12) Secure the i nsert and actuati on cabl e out of the
way.
(13) Remove ti l t l ever (i f equi pped) from steeri ng
col umn.
(14) Remove the upper and l ower l ock housi ng
shrouds (Fi g. 1) from the steeri ng col umn assembl y.
Remove the l ower fi xed shroud from the steeri ng
col umn assembl y. The shroud fasteners are Torx-head
screws.
(15) Remove the wi ri ng harness connector to the
turn si gnal /mul ti -functi on swi tch usi ng a 7mm socket
as shown i n (Fi g. 8).
(16) Remove the el ectri cal connecti ons from the
Key-i n Swi tch & Hal o Li ght, Mai n I gni ti on Swi tch,
Horn connecti on or Cl ock Spri ng (Speed Control
Equi pped) (Fi g. 9).
(17) Loosen the upper steeri ng col umn support
bracket nuts (Fi g. 10) to al l ow some sl ack. Thi s wi l l ai d
i n removal of the upper fi xed shroud.
(18) Remove the upper fi xed shroud (Fi g. 1) from the
steeri ng col umn assembl y. Remove the wi ri ng
Fig. 7 PRNDL Cable Removal
Fig. 6 Steering Column Coupler Remove and Install
Fig. 8 Multi-function Switch Wiring Harness Con-
nector
Fig. 9 Steering Column Wiring
STEERING 19 - 31
harness from the steeri ng col umn assembl y by pryi ng
out the pl asti c retai ner buttons (Fi g. 8).
(19) Remove the l ower dash panel and support
bracket standoff fasteners (Fi g. 1).
(20) Remove the steeri ng col umn assembl y out
through the passenger compartment. Use care to avoi d
damagi ng the pai nt or i nteri or tri m.
STEERI NG COLUMN I NSTALLATI ON
(1) For col umn shi ft vehi cl es, i nstal l a new cable
attaching grommet into the steering column
shift lever (Fig. 11). Install grommet from the
cable side of the lever. Use pl i ers and a back-up
washer to snap the grommet i nto pl ace (Fi g. 11). Use
Mopar Mul ti purpose Lubri cant, or equi val ent, to ai d
i nstal l ati on of the grommet. A replacement grom-
met should be used whenever the rod is discon-
nected fromthe lever.
(2) I nstal l the ground cl i p on the l eft capsul e sl ot
(Fi g. 12). The pl asti c capsul es shoul d be pre-assembl ed
i n the bracket sl ots. Remove the shipping lock pin
(Fig. 1) located on lower column jacket when
installing a new steering column. I nsert the col -
umn through the fl oor pan openi ng whi l e bei ng careful
to avoi d damagi ng the i nteri or pai nt and tri m.
(3) Posi ti on the steeri ng col umn assembl y i n the
vehi cl e. Al i gn the steeri ng col umn assembl y mounti ng
bracket sl ots on the brake pedal bracket attachi ng
studs (Fi g. 13). I nstal l , but loose assemble the two
upper col umn bracket, washers and nuts.
(4) Make sure the front wheel s are i n the strai ght-
ahead posi ti on. Al i gn and assembl e the upper steeri ng
coupl er to l ower steeri ng coupl er. I nstal l the upper to
l ower steeri ng coupl er retai ni ng bol t and nut. Torque
the retai ni ng bol t nut to 28 Nm (250 i n.
Fig. 11 Replacement Cable Grommet Installation
Fig. 12 Ground Clip & Spacer Installation
Fig. 13 Steering Column Mounting
Fig. 10 Steering Column Support Bracket
19 - 32 STEERING
l bs.). Besuretoinstall theupper tolower steering
coupler retaining bolt retention pin (Fig. 6).
(5) I nstal l the buttons whi ch retai n the mul ti func-
ti on swi tch wi ri ng harness to the steeri ng col umn.
Connect the mul ti -functi on swi tch wi ri ng harness con-
nector to the mul ti -functi on swi tch. Torque the connec-
tor retai ni ng bol t to 2 Nm (17 i n. l bs) usi ng a 7mm
socket (Fi g. 8).
(6) I nstal l the upper fi xed shroud onto the steeri ng
col umn assembl y.
(7) Be sure both breakaway capsul es are ful l y seated
i n the sl ots of the steeri ng col umn upper support
bracket. Torque the 2 upper steeri ng col umn assembl y
to support bracket nuts to 12 Nm (105 i n. l bs.). Torque
the 2 l ower steeri ng col umn assembl y to mounti ng
bracket nuts to 12 Nm (105 i n. l bs.).
(8) Compl ete the wi ri ng harness connecti ons to the
remai ni ng steeri ng col umn swi tches (Fi g. 9). I nstal l
the l ower fi xed shroud onto the steeri ng col umn.
(9) Route the PRNDL actuator assembl y under l eft
steeri ng col umn wi ng and al ong l eft si de of steeri ng
col umn. I nsert the fl ange of the PRNDL actuator
steeri ng col umn i nsert i nto the steeri ng col umn jacket
(Fi g. 7). Squeeze the l egs of the steeri ng col umn i nsert
together and i nstal l tabs under steeri ng col umn jacket.
Engage l ock bar to secure the actuator assembl y i nto
the steeri ng col umn jacket (Fi g. 7).
(10) Hook the PRNDL actuator cabl e eyel et to the
steeri ng col umn actuator arm (Fi g. 7). Move the shi ft
l ever to neutral , check poi nter l ocati on, shoul d i ndi cate
neutral . I f poi nter does not i ndi cate neutral adjust
actuator wi th tool (Fi g. 14) to center poi nter on N
(Neutral ) and then check poi nter l ocati on i n other
gears.
(11) I nstal l the l ock housi ng shrouds. The shroud
fasteners are Torx-head screws. I nstal l the ti l t l ever
(i f equi pped).
(12) I nstal l the l ower dash panel cover.
(13) For steeri ng wheel i nstal l ati on wi th speed con-
trol refer to Group 8 El ectri cal . For non-speed control ,
pl ace the steeri ng wheel on the steeri ng col umn shaft
wi th the master spl i nes al i gned. I nstal l the steeri ng
wheel to col umn shaft retai ni ng nut. Ti ghten retai ni ng
nut to 61 Nm (45 ft. l bs.) torque. Do not force the
steering wheel onto the column shaft by driving
it on with a heavy object. Pull steering wheel
down ontocolumn shaft usingONLY thesteering
wheel retaining nut.
(14) For vehi cl es equi pped wi th a col umn shi ft. Pass
the transmi ssi on shi ft cabl e through i ts mounti ng
bracket on the steeri ng col umn assembl y. Connect the
transmi ssi on shi ft cabl e to the shi ft l ever on the
steeri ng col umn assembl y. I nstal l the shi ft cabl e to
mounti ng bracket retai ni ng cl i p (Fi g. 2). The grom-
met must be installed in the shift lever (Fig. 11)
beforethecableisinsertedintothegrommet. Use
Mopar Mul ti purpose Lubri cant, or an equi val ent
product, to ai d i nstal l ati on of shi ft l i nk rod i nto grom-
met.
(15) Re-adjust the transmi ssi on shi ft l i nkage.
Whenever the steering column is loosened or
removed, theshift linkageMUST beadjustedand
tested. Refer to Group 21 Transmi ssi on for the shi ft
l i nkage adjustment procedure.
(16) Connect the battery ground (negati ve) cabl e.
Test the operati on of the l i ghts and horns. I f appl i cabl e,
reset the cl ock and radi o.
STEERING COLUMN COMPONENT SERVICE
The Acustar ti l t and standard steeri ng col umns (Fi g.
1) have been desi gned to be servi ced as an assembl y;
l ess wi ri ng, swi tches, shrouds, steeri ng wheel , etc. Al so
most steeri ng col umn components can be servi ced
wi thout removi ng the steeri ng col umn from the ve-
hi cl e. For addi ti onal i nformati on on el ectri cal compo-
nents refer to Group 8H Electrical.
GEAR SHI FT LEVER
The gear shi ft l ever (i f equi pped) i s a servi ceabl e
component of the Acustar steeri ng col umn assembl y.
Fig. 14 PRNDL Actuator Cable Adjustment
STEERING 19 - 33
REMOVE
(1) Support the steeri ng col umn assembl y as shown
i n (Fi g. 1) usi ng a sui tabl e si ze socket.
(2) Usi ng a dri ft of the appropri ate si ze dri ve the rol l
pi n out of the steeri ng col umn and gear shi ft l ever (Fi g.
1). Remove the gear shi ft l ever from the steeri ng
col umn assembl y.
INSTALL
(1) Support the steeri ng col umn assembl y as shown
i n (Fi g. 1) usi ng a sui tabl e si ze socket.
(2) I nstal l the gear shi ft l ever i nto the steeri ng
col umn assembl y. Al i gn the rol l pi n hol es i n the gear
shi ft l ever and the steeri ng col umn assembl y.
(3) Careful l y I nstal l the rol l pi n i nto the steeri ng
col umn assembl y and through the shi ft l ever. I f the rol l
pi n bi nds check the al i gnment on the hol es. Be sure rol l
pi n i s ful l y i nstal l ed i nto the steeri ng col umn assembl y.
IGNITION SWITCH SERVICE
TEST AND REPAI R
I f the i gni ti on swi tch effort seems to be excessi ve due
to bi ndi ng. Fol l ow the procedure outl i ned bel ow to
determi ne the cause.
When servi ce procedures are performed on the
Acustar steeri ng col umn there are certai n areas of the
col umn that can not be tampered wi th. I f a probl em
rel ated to these areas of the steeri ng col umn are
detected. The enti re steeri ng col umn (l ess the remov-
abl e components) shoul d be repl aced see (Fi g. 2 and 3).
(1) Remove the i gni ti on swi tch from the steeri ng
col umn. Refer to Group 8H Electrical.
(2) Usi ng a key cyl i nder, check the turni ng effort of
the swi tch.
I f the i gni ti on swi tch bi nds l ook for the fol l owi ng
condi ti ons.
(1) Look for rough areas or fl ash i n the casti ng and i f
found remove wi th a fi l e (Fi g. 3).
(2) Remove the l i nk and sl i der.
(3) Check the l i nk to see i f i t has been bent and i f so
repl ace wi th a new part.
Put the sl i der i n i ts sl ot i n the sl eeve and veri fy a
l oose fi t over the l ength of the sl ot. I f the sl i der bi nds i n
the sl ot at any poi nt l i ghtl y fi l e the sl i der unti l cl ear-
ance i s achi eved.
I f no bi ndi ng i s found.
Li ghtl y fi l e the ramp on the i gni ti on swi tch, (The
ramp fi ts i nto the casti ng) unti l bi ndi ng no l onger
occurs.
Fig. 1 Gear Shift Lever Removal
Fig. 2 Steering Column Non-Serviceable Compo-
nents
Fig. 3 Steering Column Flash Removal And Non-
Serviceable Components
19 - 34 STEERING
SPECI FI CATI ONS AND TI GHTENI NG REFERENCE
TORQUE SPECI FI CATI ONS
STEERING 19 - 35
FUEL SYSTEM
CONTENTS
page page
2. 5L SINGLE POINT FUEL INJECTION
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . 34
SERVICE PROCEDURES . . . . . . . . . . . . . . 45
SYSTEM OPERATION . . . . . . . . . . . . . . . . . 22
3. 0L MULTI-POINT FUEL INJECTION
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . 64
SERVICE PROCEDURES . . . . . . . . . . . . . . 75
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . 93
SERVICE PROCEDURES . . . . . . . . . . . . . 105
ACCELERATOR PEDAL AND THROTTLE
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 113
servi ce manual .
The Fuel System consi sts of the fuel tank, fuel pump,
fuel fi l ter, throttl e body, fuel i njectors, fuel l i nes and
vacuum l i nes.
The Fuel Del i very System consi sts of the fuel pump
modul e, fuel fi l ter, fuel l i nes and fuel hoses.
The Fuel Tank Assembl y consi sts of the fuel tank,
fuel pump modul e, fi l l er tube, and a pressure-vacuum
fi l l er cap.
The Evaporati on Control System, i s al so consi dered
part of the fuel system. The system reduces the emi s-
si on of fuel vapor i nto the atmosphere.
The descri pti on and functi on of the Evaporati on
Control System i s found i n Group 25 of thi s manual .
FUEL REQUIREMENTS
Your vehi cl e was desi gned to meet al l emi ssi on
regul ati ons and provi de excel l ent fuel economy when
usi ng hi gh qual i ty unl eaded gasol i ne. Only use un-
leadedgasolinewithaminimumpostedoctaneof
87.
Li ght spark knock (pi ng) at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
shoul d be reported to your deal er i mmedi atel y. Engi ne
damage resul ti ng from operati ng wi th a heavy spark
knock may not be covered by the new vehi cl e warranty.
I n addi ti on to usi ng unl eaded gasol i ne wi th the
proper octane rati ng, gasol i nes that contai n deter-
gents, corrosi on and stabi l i ty addi ti ves are recom-
mended. Usi ng gasol i nes that have these addi ti ves wi l l
hel p i mprove fuel economy, reduce emi ssi ons, and
mai ntai n vehi cl e performance. General l y, premi um un-
l eaded gasol i nes contai n more addi ti ve than regul ar
unl eaded.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng, and stumbl e. I f you experi ence
these probl ems, try another brand of gasol i ne before
consi deri ng servi ce for the vehi cl e.
GASOLI NE/OXYGENATE BLENDS
Some fuel suppl i ers bl end gasol i ne wi th materi al s
that contai n oxygen such as al cohol , MTBE (Methyl
Terti ary Butyl Ether) and ETBE (Ethyl Terti ary Butyl
Ether). The type and amount of oxygenate used i n the
bl end i s i mportant.
The fol l owi ng are general l y used i n gasol i ne bl ends:
Ethanol - (Ethyl or Grai n Al cohol ) properl y bl ended,
i s used as a mi xture of 10 percent ethanol and 90
percent gasol i ne. Gasol i ne bl ended wi th ethanol may
be used i n your vehi cl e.
Methanol - (Methyl or Wood Al cohol ) i s used i n a
vari ety of concentrati ons when bl ended wi th unl eaded
gasol i ne. You may fi nd fuel s contai ni ng 3 percent or
more methanol al ong wi th other al cohol s cal l ed cosol -
vents.
Do not use gasolines containing Methanol.
FUEL SYSTEM 14 - 1
Use of methanol /gasol i ne bl ends may resul t i n start-
i ng and dri veabi l i ty probl ems and damage cri ti cal fuel
system components.
Probl ems that are the resul t of usi ng
methanol /gasol i ne bl ends are not the responsi bi l i ty of
Chrysl er Motors and may not be covered by the new
vehi cl e warranty.
MTBE/ETBE - Gasol i ne and MTBE (Methyl Ter-
ti ary Butyl Ether) bl ends are a mi xture of unl eaded
gasol i ne bl ended and up to 15 percent MTBE. Gasol i ne
and ETBE (Ethyl Terti ary Butl y Ether) are bl ends of
gasol i ne and up to 17 percent ETBE. Gasol i ne bl ended
wi th MTBE or ETBE may be used i n your vehi cl e.
Clean Air Gasoline
Many gasol i nes are now bei ng bl ended that contri b-
ute to cl eaner ai r, especi al l y i n those areas of the
country where pol l uti on l evel s are hi gh. These new
bl ends provi de a cl eaner burni ng fuel and some are
referred to as reformul ated gasol i ne.
I n areas of the country where carbon monoxi de l evel s
are hi gh, gasol i nes are bei ng treated wi th oxygenated
materi al s such as ETBE, MTBE and ethanol . The use
of gasol i ne bl ended wi th these materi al s al so contri b-
utes to cl eaner ai r.
Chrysl er Motors supports these efforts toward
cl eaner ai r and recommends that you use these gaso-
l i nes as they become avai l abl e.
Materials Added to Fuel
I ndi scri mi nate use of fuel system cl eani ng agents
shoul d be avoi ded. Many of these materi al s i ntended
for gum and varni sh removal may contai n acti ve sol -
vents of si mi l ar i ngredi ents that can be harmful to fuel
system gasket and di aphragm materi al s.
14 - 2 FUEL SYSTEM
FUEL DELI VERY SYSTEM
INDEX
page page
Chassis Fuel Tubes . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel FilterAll Wheel Drive . . . . . . . . . . . . . . . . . 11
Fuel FilterFront Wheel Drive . . . . . . . . . . . . . . . 10
Fuel Hoses, Clamps, and Quick Connect Fittings . . 3
Fuel Pump Module InstallationAll Wheel Drive . . 10
Fuel Pump Module RemovalAll Wheel Drive . . . . 9
Fuel Pump Pressure Test2.5L and 3.0L Engines . 5
Fuel Pump Pressure Test3.3L Engine . . . . . . . . . 6
Fuel Pump/Level Sending Unit Assembly
RemovalFront Wheel Drive . . . . . . . . . . . . . . . 8
Fuel Pump/Level Unit Assembly . . . . . . . . . . . . . . . 5
Fuel Pump/Level Unit Assembly InstallationFront
Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel System Pressure Release Procedure . . . . . . . 3
GENERAL INFORMATION
The front wheel dri ve van and the al l wheel dri ve van have
di fferent fuel del i very systems. The front wheel dri ve van
uses a metal fuel tank mounted i n the rear of the vehi cl e. The
al l wheel dri ve van has a pl asti c fuel tank l ocated on the l eft
si de of the vehi cl e. The fuel pumps and the chassi s fuel tubes
used on front wheel dri ve vans are di fferent from those used
on al l wheel dri ve vans.
Both the front wheel dri ve and al l wheel dri ve fuel pump
modul es have an i nternal fuel reservoi r, a fuel l evel sendi ng
uni t, and a fuel strai ner mounted on the pump housi ng. Both
systems use qui ck connect fi tti ngs at the fuel tank and
engi ne. The fuel fi l ter l ocati on i s the same for both front
wheel dri ve and al l wheel dri ve vehi cl es.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
(1) Loosen fuel fi l l er cap to rel ease fuel tank pres-
sure.
(2) Di sconnect i njector wi ri ng harness from engi ne
or mai n harness.
(3) Connect a jumper wi re from termi nal Number 1
(ground) of the i njector harness (Fi g. 1) to engi ne
ground.
(4) Connect one end of a jumper wi re to termi nal
Number 2 (posi ti ve) of the i njector harness (Fi g. 1).
Connect the other end to the posi ti ve post of the
battery for no l onger than 5 seconds. Thi s rel eases
system pressure.
(5) Remove jumper wi res.
(6) Conti nue fuel system servi ce.
FUEL HOSES, CLAMPS, AND QUICK CONNECT
FITTINGS
HOSES AND CLAMPS
I nspect al l hose connecti ons (cl amps and qui ck con-
nect fi tti ngs) for compl eteness and l eaks. Repl ace
cracked, scuffed, or swel l ed hoses. Repl ace hoses that
rub agai nst other vehi cl e components or show si gn of
wear.
Fuel i njected vehi cl es use speci al l y constructed
hoses. When repl aci ng hoses, onl y use hoses marked
EFM/EFI .
When i nstal l i ng hoses, ensure that they are routed
away from contact wi th other vehi cl e components that
coul d rub agai nst them and cause fai l ure. Avoi d contact
wi th cl amps or other components that cause abrasi ons
or scuffi ng. Ensure that rubber hoses are properl y
routed and avoi d heat sources.
The hose cl amps have rol l ed edge to prevent the
cl amp from cutti ng i nto the hose. Onl y use cl amps that
are ori gi nal equi pment or equi val ent. Other types of
cl amps may cut i nto the hoses and cause hi gh pressure
fuel l eaks. Ti ghten hose cl amps to 1 Nm (10 i n. l bs.)
torque.
QUI CK CONNECT FI TTI NGS
Some fuel l i nes have qui ck connect fi tti ngs. The
fi tti ngs are desi gned to speed up the i nstal l ati on and
removal of the fuel l i nes (Fi g. 2).
Qui ck connect fi tti ngs consi st of a metal casi ng, a
Fig. 1 Injector Harness Connectors
FUEL SYSTEM 14 - 3
bl ack pl asti c rel ease ri ng, a metal l ocki ng retai ner, and
i nternal O-ri ngs.
TUBE/FI TTI NG DI SASSEMBLY
WARNING: FUEL SYSTEM PRESSURE MUST BE RE-
LEASED BEFORE DISCONNECTING ANY FUEL SYS-
TEM COMPONENT.
(1) Di sconnect the negati ve battery cabl e.
(2) Remove the fuel tank gas cap to rel ease fuel tank
pressure.
(3) Perform the Fuel System Pressure Rel ease Pro-
cedure.
(4) Remove any l oose di rt from qui ck connect fi t-
ti ngs.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) To remove the fuel tube ni ppl e from a qui ck
connect fi tti ng, pul l back on the fi tti ng whi l e pushi ng
i n on the pl asti c ri ng (Fi g. 2). To ai d i n di sassembl y, an
open end wrench may be used to push the pl asti c ri ng
i n.
(6) Cover the qui ck connector to prevent contami na-
ti on.
TUBE/FI TTI NG ASSEMBLY
(1) I nspect the qui ck connect fi tti ng to ensure the
bl ack pl asti c rel ease ri ng i s i n the OUT posi ti on. I f the
l ocki ng retai ner i s stuck i n the RELEASE posi ti on due
to mushroomi ng of the rel ease ri ng or di rt accumul a-
ti on, the fi tti ng shoul d be repl aced.
The fuel tube nipples must be lubricated with
clean 30 weight engine oil prior to reconnecting
the quick-connect fitting.
(2) Lubri cate the mal e end of the fuel tube wi th 30
wei ght engi ne oi l .
(3) I nsert fuel tube ni ppl e i nto qui ck connector fi t-
ti ng. When the fuel tube ni ppl e i s i nserted i nto the
qui ck-connect fi tti ng, the shoul der of the ni ppl e i s
l ocked i n pl ace by the l ocki ng retai ner and the i nternal
O-ri ngs seal the tube.
(4) Pul l back on the qui ck connect fi tti ng to veri fy
the connecti on i s secure. The tube shoul d be l ocked i n
pl ace. I f the connecti on i s not compl ete, make sure the
bl ack pl asti c rel ease i s not causi ng the l ocki ng retai ner
to jam i n the rel ease posi ti on.
CAUTION: When using the ASD Fuel System Test, the
ASD relay and fuel pump relay remain energized for 7
minutes or until the test is stopped, or until the
ignition switch is turned to the Off position.
(5) Use the DRB I I ASD Fuel System Test to pres-
suri ze the fuel system. Check for l eaks.
TUBE/FI TTI NG SERVI CE
I f a qui ck connect fi tti ng needs to be servi ced, the
fol l owi ng procedure must be fol l owed:
(1) Di sconnect the battery negati ve battery cabl e.
cedure.
WARNING: WRAP SHOP TOWELS AROUND HOSES
(3) Remove the qui ck connect fi tti ng from the fuel
tube by pushi ng i n on the pl asti c ri ng l ocated on the
end of the fi tti ng. Gentl y pul l the fi tti ng from the fuel
tube.
(4) Cut off the cri mped ferrul es at each end of the
hose, taki ng care not to damage the qui ck connect
fi tti ng or the fuel tube.
(5) Di scard the ferrul es, hose and damaged qui ck
connect fi tti ng.
(6) Repl ace the hose usi ng hose marked EFM/EFI .
(7) Repl ace the qui ck connect fi tti ngs (i f necessary)
wi th the correct si ze and type.
(8) Attach the repl acement hose to the qui ck connect
fi tti ng and fuel tube usi ng the correct hose cl amps. The
hose cl amps used are of a speci al rol l ed edge construc-
ti on to prevent the edge of the cl amp cutti ng i nto the
hose. Onl y ori gi nal equi pment cl amps or equi val ent
may be used i n thi s system. Other types of cl amps may
cut i nto the hoses and cause hi gh pressure fuel l eaks.
(9) Ti ghten hose cl amps to 1 Nm (10 i n. l bs.) torque.
(10) Use the DRB I I ASD Fuel System Test to
pressuri ze the fuel system. Check for l eaks.
Fig. 2 Quick Connect Fuel Fittings
14 - 4 FUEL SYSTEM
FUEL PUMP/LEVEL UNIT ASSEMBLY
The al l wheel dri ve and front wheel dri ve vehi cl es
use di fferent fuel pumps. The fuel pump/l evel uni t
assembl y used on front wheel dri ve systems consi sts of
the fuel pump, reservoi r body, and l evel uni t (Fi g. 3).
Al l wheel dri ve vehi cl es have a fuel pump modul e
(Fi g. 4). The modul e contai ns the fuel pump, l evel uni t
and reservoi r body. The modul e i s spri ng l oaded. The
modul e must be pushed down to i nstal l i t i n the fuel
tank.
On both systems, the reservoi r body repl aces an
i nternal fuel tank reservoi r. The purpose of the reser-
voi r i s to provi de fuel at the pump i ntake duri ng al l
dri vi ng condi ti ons, especi al l y those when l ow fuel l ev-
el s are present.
The fuel pump used i n both systems i s a posi ti ve
di spl acement, gerotor i mmersi bl e pump wi th a perma-
nent magnet el ectri c motor. The fuel i s drawn i n
through an i nl et strai ner and pushed through the
el ectri c motor to the outl et. The pump modul e contai ns
two check val ves. One val ve i s used to rel i eve i nternal
fuel pump pressure and regul ate maxi mum pump
output. The other check val ve i s l ocated i n the fuel
return l i ne. I t restri cts fuel movement i n reverse
di recti on when the pump i s not operati ng. Vol tage to
operate the pump i s suppl i ed through the fuel pump
rel ay.
The l evel uni t i s attached to the si de of the fuel pump
assembl y. The l evel uni t consi sts of a fl oat, an arm, and
a vari abl e resi stor. As the fuel l evel i ncreases, the fl oat
and arm move up. Thi s decreases the sendi ng uni t
resi stance, causi ng the fuel gauge on the i nstrument
panel to read ful l .
The maxi mum output pressure of both front wheel
dri ve and al l wheel dri ve fuel pumps i s approxi matel y
930 kPa (135 psi ).
The pressure regul ator adjusts system pressure. On
3.0L and 3.3L engi nes the pressure regul ator i s
mounted on the fuel rai l . On 2.5L engi nes the regul ator
i s mounted on the throttl e body. Fuel system pressures
are shown i n the Fuel System Pressure chart.
Fuel system pressure must be rel eased before servi c-
i ng any fuel system component. Perform the Fuel
System Pressure Rel ease procedure.
FUEL PUMP PRESSURE TEST 2. 5L and 3. 0L EN-
GINES
LEASED BEFORE A FUEL SYSTEM HOSE OR COM-
PONENT IS DISCONNECTED.
The speci fi cati ons l i sted i n the Fuel System Pressure
Chart are determi ned wi thout vacuum appl i ed to the
fuel pressure regul ator.
(1) Perform fuel system pressure rel ease.
(2) Remove fuel suppl y hose qui ck connector from
the chassi s l i nes (at the engi ne). Refer to Qui ck Con-
nect Fi tti ngs i n thi s secti on.
(3) Connect Fuel Pressure Gauge C-4799 to Fuel
Pressure Test Adapter 6539 (Fi g. 5). I nstal l the adapter
between fuel suppl y hose and chassi s fuel l i ne assem-
bl y.
Fig. 3 Fuel Pump/Level UnitFront Wheel Drive
Fig. 4 Fuel Pump ModuleAll Wheel Drive
FUEL SYSTEM PRESSUREWI THOUT
VACUUM APPLI ED TO PRESSURE REGULATOR
FUEL SYSTEM 14 - 5
(4) Pl ace the i gni ti on key i n the ON posi ti on. Usi ng
the DRB I I tester, access ASD Fuel System Test. The
ASD Fuel System Test wi l l acti vate the fuel pump and
pressuri ze the system.
I f the gauge reads the pressure shown i n the Fuel
System Pressure chart, further testi ng i s not requi red.
I f pressure i s not correct, record the pressure and
remove gauge.
I f pressure i s bel ow speci fi cati ons, proceed to Fuel
System Pressure Bel ow Speci fi cati ons. I f pressure i s
above speci fi cati ons, proceed to Fuel System Pressure
Above Speci fi cati ons.
Fuel SystemPressure Below Specifications
I f the fuel pressure readi ng i n step (4) was bel ow
speci fi cati ons, test the system accordi ng to the fol l ow-
i ng procedure.
(a) Perform Fuel Pressure Rel ease procedure.
(b) I nstal l Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 i n the fuel suppl y l i ne (Fi g. 6)
between the fuel tank and fuel fi l ter.
(c) Usi ng the DRB I I , wi th the i gni ti on key i n the
ON posi ti on, repeat the ASD Fuel System Test.
I f pressure i s at l east 5 psi hi gher than readi ng
recorded i n step (4), repl ace fuel fi l ter.
I f no change i s observed, gentl y squeeze return
hose. I f pressure i ncreases, repl ace pressure regul ator.
I f the gauge readi ng does not change when the return
hose i s squeezed, the probl em i s ei ther a pl ugged i nl et
strai ner or defecti ve fuel pump.
Fuel SystemPressureAbove Specifications
I f the fuel pressure readi ng i n step (4) was above
speci fi cati ons test the system accordi ng to the fol l ow-
i ng procedure.
(c) Remove the fuel return l i ne hose from the fuel
pump at fuel tank. Connect Fuel Pressure Test
Adapter 6541 to the return l i ne. Pl ace the other end
of adapter 6541 i nto an approved gasol i ne contai ner
(mi ni mum 2 gal l on si ze). Al l return fuel wi l l fl ow i nto
contai ner.
(d) Usi ng the DRB I I , wi th the i gni ti on key i n the
I f pressure i s now correct, repl ace fuel pump
assembl y.
I f pressure i s sti l l above speci fi cati ons, remove
fuel return hose from chassi s fuel tubes (at engi ne).
Attach Fuel Pressure Test Connect Adapter 6541 to the
fuel return hose and pl ace other end of hose i n cl ean
contai ner (Fi g. 7). Repeat test. I f pressure i s now
correct, check for restri cted fuel return l i ne. I f no
change i s observed, repl ace fuel pressure regul ator.
FUEL PUMP PRESSURE TEST 3. 3L ENGINE
The speci fi cati ons l i sted i n the Fuel System Pressure
Chart are determi ned wi thout vacuum appl i ed to the
(1) Fuel system pressure must be rel eased each ti me
a fuel hose i s to be di sconnected. Perform fuel system
pressure rel ease.
(2) Remove protecti ve cover from servi ce val ve on
the fuel rai l .
Fig. 5 Gauge and Adapter
Fig. 6 Fuel Pressure Adapter
14 - 6 FUEL SYSTEM
(3) Connect Fuel Pressure Gauge C-4799 to fuel rai l
servi ce val ve. (Fi g. 8)
(4) Pl ace the i gni ti on key i n the ON posi ti on. Usi ng
the DRB I I tester, access ASD Fuel System Test. The
ASD Fuel System Test wi l l acti vate the fuel pump and
pressuri ze the system.
I f the gauge readi ng the speci fi cati on l i sted i n the
Fuel System Pressure chart, further testi ng i s not
requi red. I f pressure i s not correct, record the pressure
and remove gauge. Use the DRB I I ASD Fuel System
Test to pressuri ze the system. Ensure fuel does not
l eak from the fuel rai l servi ce val ve. Rei nstal l protec-
ti ve cover onto fuel rai l servi ce val ve.
I f pressure i s bel ow speci fi cati ons, proceed to Fuel
System Pressure Bel ow Speci fi cati ons. I f pressure i s
above speci fi cati ons, proceed to Fuel System Pressure
Above Speci fi cati ons.
Fuel SystemPressure Below Specifications
I f the fuel pressure readi ng i n step (4) was bel ow
speci fi cati ons, test the system accordi ng to the fol l ow-
i ng procedure.
Pressure Adapter 6433 i n the fuel suppl y l i ne be-
tween the fuel tank and fuel fi l ter (Fi g. 6).
(c) Usi ng the DRB I I , wi th the i gni ti on key i n the
I f pressure i s at l east 5 psi hi gher than readi ng
recorded i n step (4), repl ace fuel fi l ter.
I f no change i s observed, gentl y squeeze return
hose. I f pressure i ncreases, repl ace pressure regul ator.
I f the gauge readi ng does not change when the return
hose i s squeezed, the probl em i s ei ther a pl ugged i nl et
strai ner or defecti ve fuel pump.
Fuel SystemPressureAbove Specifications
I f the fuel pressure readi ng i n step (4) was above
speci fi cati ons test the system accordi ng to the fol l ow-
i ng procedure.
(c) Remove the fuel return l i ne hose from the fuel
pump at fuel tank. Connect Fuel Pressure Test
Adapter 6541 to the return l i ne. Pl ace the other end
of adapter 6541 i nto an approved gasol i ne contai ner
(mi ni mum 2 gal l on si ze). Al l return fuel wi l l fl ow i nto
contai ner.
(d) Usi ng the DRB I I , wi th the i gni ti on key i n the
I f pressure i s now correct, repl ace fuel pump
assembl y.
I f pressure i s sti l l above speci fi cati ons, remove
fuel return hose from chassi s fuel tubes (at engi ne).
Attach Fuel Pressure Test Connect Adapter 6541 to the
fuel return hose and pl ace other end of hose i n cl ean
contai ner (Fi g. 7). Repeat test. I f pressure i s now
correct, check for restri cted fuel return l i ne. I f no
change i s observed, repl ace fuel pressure regul ator.
Fig. 7 Fuel Return Connection
Fig. 8 Pressure Test Gauge
FUEL SYSTEM 14 - 7
FUEL PUMP/LEVEL SENDING UNIT ASSEMBLY
REMOVAL FRONT WHEEL DRIVE
The fuel tank must be removed to servi ce the fuel
pump/l evel sendi ng uni t assembl y. Refer to Fuel Tank
Secti on for fuel tank removal .
(1) Usi ng a hammer and a brass dri ft, careful l y tap
the l ock ri ng countercl ockwi se to rel ease assembl y
(Fi g. 9).
(2) Remove fuel pump/l evel sender assembl y and
O-ri ng seal from tank. Di scard ol d seal .
(3) Prevent di rt from enteri ng the tank by coveri ng
the fuel tank openi ngs.
FUEL PUMP I NLET STRAI NER
REMOVALFRONT WHEEL DRI VE
(1) Gentl y bend l ocki ng tabs on fuel pump reservoi r
assembl y to cl ear l ocki ng tangs on the fuel pump fi l ter.
(Fi g. 10)
(2) Remove strai ner.
(3) Remove strai ner O-ri ng from the fuel pump res-
ervoi r body.
(4) I f the i nl et strai ner i s pl ugged or di rty, cl ean the
fuel tank.
I NSTALLATI ONFRONT WHEEL DRI VE
(1) Li ghtl y l ubri cate the strai ner O-ri ng wi th Mopar
Si l i cone Spray Lube.
(2) I nsert strai ner O-ri ng i nto outl et of strai ner. The
O-ri ng must si t evenl y on the step i nsi de the fi l ter
outl et.
(3) Push strai ner onto the i nl et of the fuel pump
reservoi r body. Ensure the l ocki ng tabs on the reservoi r
body l ock over the l ocki ng tangs on the fi l ter.
FUEL LEVEL SENDI NG UNI T DI AGNOSI S
Refer to Group 8El ectri cal
FUEL LEVEL SENDI NG UNI T
REMOVALFRONT WHEEL DRI VE
(1) Bend l ocki ng tab and remove el ectri cal connector
from the bottom of the fuel pump el ectri cal connector
(Fi g. 11).
(2) Remove termi nal l ocki ng cover (red). Remove
sendi ng uni t wi ri ng termi nal s from the el ectri cal con-
nector.
(3) Use a wi de bl ade screwdri ver to rel ease the
sendi ng uni t l ocki ng tab (Fi g. 12). Use another wi de
bl ade screwdri ver to push on the sendi ng uni t body.
(4) Sl i de the enti re fuel l evel sendi ng uni t off of the
fuel pump/reservoi r body.
(5) Careful l y pul l the wi res through the coverpl ate
and reservoi r body.
I NSTALLATI ONFRONT WHEEL DRI VE
(1) Careful l y bend the l evel uni t wi res and l ay i nto
the sl ot on the back of the l evel uni t.
(2) Sl i de the l evel uni t i nto the sl ots on the fuel
pump/reservoi r assembl y. Feed the wi res through the
tri angul ar hol e i n the fuel pump/reservoi r body. Make
sure that the tab on the l evel uni t l ocks i nto the detente
i n the fuel pump/reservoi r assembl y.
Fig. 9 Fuel Pump ServiceFront Wheel Drive
Fig. 10 Fuel Pump Inlet StrainerFront Wheel Drive
Fig. 11 Fuel Pump Electrical ConnectorFront
Wheel Drive
14 - 8 FUEL SYSTEM
(3) Sl i p wi res i nto tab on the fuel pump/reservoi r
assembl y.
(4) Careful l y i nstal l the l evel uni t wi ri ng termi nal s
i nto the el ectri cal connector. I nstal l termi nal l ocki ng
cover.
(5) I nstal l the el ectri cal connector i nto the bottom of
the fuel pump el ectri cal connector. Ensure that the
connector i s ful l y l ocked i nto posi ti on.
FUEL PUMP/LEVEL UNIT ASSEMBLY
INSTALLATION FRONT WHEEL DRIVE
(1) Wi pe seal area of tank cl ean and pl ace a new
O-ri ng seal i n posi ti on on pump.
(2) Posi ti on fuel pump i n tank wi th l ocki ng ri ng.
(3) Usi ng a hammer and brass dri ft, tap ri ng around
cl ockwi se to l ock pump i n pl ace.
CAUTION: Over tightening the pump lock ring may
result in a leak.
(4) I nstal l tank. Refer to the Fuel Tank Secti on i n
thi s Group.
FUEL PUMP MODULE REMOVAL ALL WHEEL
DRIVE
The fuel tank must be removed to servi ce the fuel
pump/l evel sendi ng uni t assembl y. Refer to Fuel Tank
Secti on of thi s Group for fuel tank removal .
(1) Uncl i p fuel vapor hose and fuel drai n hose from
fuel tank (Fi g. 13).
The fuel pump modul e i s spri ng l oaded. I t wi l l ri se up
sl i ghtl y when the band cl amp i s removed.
(2) Whi l e hol di ng down on the fuel pump modul e,
remove the band cl amp from top of modul e (Fi g. 14).
(3) Remove the fuel pump modul e from fuel tank.
Di scard fl at rubber seal .
FUEL PUMP I NLET STRAI NER REMOVALALL
WHEEL DRI VE
(1) Remove the fuel pump from the fuel tank. Refer
to Fuel Pump Modul e Removal i n thi s secti on.
(2) Bend l ocki ng tabs on the strai ner to cl ear l ocki ng
tangs on the fuel pump modul e (Fi g. 15).
(3) Remove strai ner.
(4) I f the strai ner i s pl ugged or di rty, cl ean the fuel
tank.
I NSTALLATI ONALL WHEEL DRI VE
(1) Al i gn the ori entati on tabs i n the strai ner wi th
the sl ot i n the bottom of the fuel pump modul e.
(2) Push strai ner onto the i nl et of the fuel pump
modul e. Make sure that the l ocki ng tabs on the fi l ter
snap over the tangs on the pump modul e.
(3) I nstal l the fuel pump modul e i nto the fuel tank.
Refer to Fuel Pump Modul e I nstal l ati on i n thi s secti on.
FUEL LEVEL SENDI NG UNI T DI AGNOSI S
Refer to Group 8El ectri cal
Fig. 12 Fuel Level Sending UnitFront Wheel Drive Fig. 13 Hose Tank ClipsAll Wheel Drive
Fig. 14 Band Clamp RemovalAll Wheel Drive
FUEL SYSTEM 14 - 9
FUEL LEVEL SENDI NG UNI T REMOVALALL
WHEEL DRI VE
(1) Remove the fuel pump from the fuel tank. Refer
to Fuel Pump Modul e Removal i n thi s secti on.
(2) Remove the two screws hol di ng fuel l evel sendi ng
uni t i n pl ace. (Fi g. 16)
(3) Di sconnect el ectri cal l eads.
I NSTALLATI ONALL WHEEL DRI VE
(1) Connect el ectri cal l eads to the fuel l evel sendi ng
uni t.
CAUTION: Do not press against the sending unit
during installation.
(2) I nstal l l evel sendi ng uni t and ti ghten screws.
(3) I nstal l the fuel pump modul e i nto the fuel tank.
Refer to Fuel Pump Modul e I nstal l ati on i n thi s secti on.
FUEL PUMP MODULE INSTALLATION ALL
WHEEL DRIVE
(1) Wi pe cl ean the seal area of tank. Pl ace a new seal
i n posi ti on on pump.
CAUTION: Fuel pump module must be properly
aligned during installation.
(2) Posi ti on fuel pump modul e so that the arrow on
the edge of the modul e i s between the two l i nes mol ded
i nto the fuel tank (Fi g. 17).
The fuel pump modul e i s spri ng l oaded. The modul e
must be hel d down when i nstal l i ng the band cl amp.
(3) Compress fuel pump modul e. I nstal l band cl amp
and ti ghten to 5.0 Nm (40 i n. l bs.) torque.
(4) I nstal l fuel tank. Refer to the Fuel Tank Secti on
i n thi s Group.
FUEL FILTER FRONT WHEEL DRIVE
REMOVAL
LEASED BEFORE THE FUEL FILTER IS REMOVED.
(2) Remove fi l ter retai ni ng screw and remove fi l ter
assembl y from rai l (Fi g. 18).
(3) Loosen outl et hose cl amp on fi l ter and i nl et hose
cl amp on rear fuel tube.
(4) Wrap a shop towel around hoses to absorb fuel .
Remove hoses at fi l ter and fuel tube. Di scard cl amps.
Fig. 16 Fuel Level Sending UnitAll Wheel Drive
Fig. 15 Fuel Strainer ServiceAll Wheel Drive
Fig. 17 Fuel Pump Module AlignmentAll Wheel
Drive
14 - 10 FUEL SYSTEM
I NSTALLATI ON
(1) I nstal l i nl et hose on fuel tube and ti ghten new
cl amp to 1 Nm (10 i n. l bs.) torque.
(2) I nstal l outl et hose on fi l ter outl et fi tti ng and
torque new cl amp to 1 Nm (10 i n. l bs.).
(3) Posi ti on fi l ter assembl y on rai l and ti ghten
mounti ng screw to 8 Nm (75 i n. l bs.) torque.
FUEL FILTER ALL WHEEL DRIVE
REMOVAL
LEASED BEFORE THE FUEL FILTER IS REMOVED.
(1) Perform Fuel System Pressure Rel ease proce-
dure.
(2) Remove converter support bracket (Fi g. 19).
(3) Remove exhaust pi pe heat shi el d.
(4) Loosen outl et and i nl et hose cl amps on fi l ter (Fi g.
20).
CAUTION: Wrap shop towels around hoses to catch
any gasoline spillage.
(5) Remove fi l ter retai ni ng screw and remove fi l ter
assembl y from rai l .
(6) Remove hoses from fuel fi l ter. Di scard cl amps.
I NSTALLATI ON
(1) Loose i nstal l i nl et and outl et fuel hoses to fuel
fi l ter.
(2) Posi ti on fi l ter assembl y on rai l and ti ghten
mounti ng screw to 8 Nm (75 i n.l bs.) torque.
(3) Ti ghten new fuel hose cl amps to 1 Nm (10 i n.
l bs.) torque.
(4) I nstal l exhaust pi pe heat shi el d.
(5) I nstal l exhaust pi pe support bracket.
CHASSIS FUEL TUBES
Fuel system component l ocati ons and chassi s fuel
tube routi ngs are shown i n Fi g. 21.
Fig. 18 Fuel FilterFront Wheel Drive
Fig. 20 Fuel FilterAll Wheel Drive
Fig. 19 Support BracketAll Wheel Drive
FUEL SYSTEM 14 - 11
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14 - 12 FUEL SYSTEM
FUEL TANK
INDEX
page page
Fuel Pump ModuleAll Wheel Drive . . . . . . . . . . 18
Fuel Pump/Level UnitFront Wheel Drive . . . . . . 18
Fuel System Pressure Release Procedure . . . . . . 13
Fuel Tank Pressure Relief/Rollover Valve
All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel Tank Pressure Relief/Rollover ValveFront Wheel
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel TankAll Wheel Drive . . . . . . . . . . . . . . . . . 16
Fuel TankFront Wheel Drive . . . . . . . . . . . . . . . 14
No-Lead Fuel Tank Filler Tube . . . . . . . . . . . . . . . 13
Pressure-Vacuum Filler CapFront Wheel Drive . . 13
GENERAL INFORMATION
The fuel tanks of al l Chrysl er Motors bui l t vehi cl es
are equi pped wi th fuel and vapor control s that al l ow
the vehi cl e to pass a ful l 360 rol l over wi thout fuel
l eakage.
Both front wheel dri ve and al l wheel dri ve fuel
del i very systems contai n a fuel tank pressure
rel i ef/rol l over val ve. The val ve i s mounted on the top of
the fuel tank on front wheel dri ve vehi cl es and on top of
the fuel pump modul e on al l wheel dri ve vehi cl es. The
val ve functi ons as a pressure rel i ef val ve whi l e the
vehi cl e i s upri ght, but contai ns a check val ve that
prevents fuel from escapi ng from the fuel tank when
the vehi cl e i s turned over.
The fuel fi l l er cap al so acts as a pressure/vacuum
val ve. When ai r pressure i nsi de the fuel tank gets too
hi gh or too l ow, the fuel fi l l er cap opens to rel i eve the
di fference i n pressure.
An evaporati on control system restri cts fuel evapo-
rati on i nto the atmosphere and reduces unburned
hydrocarbons. Vapors from the fuel tank are col l ected
i n a charcoal fi l l ed cani ster. The vapors are hel d i n the
cani ster unti l the engi ne i s operati ng. When the engi ne
i s runni ng, the vapors are drawn through the i ntake
mani fol d i nto the combusti on chambers.
NO-LEAD FUEL TANK FILLER TUBE
Al l catal yst equi pped vehi cl es have a speci al fuel
tank fi l l er tube. The fuel fi l l er openi ng i s smal l er i n
di ameter than those used for non-catal yst vehi cl es.
Gasol i ne stati on pumps for l eaded and unl eaded fuel
have di fferent si ze nozzl es. The unl eaded pump nozzl e
i s smal l er than the l eaded pump nozzl e. The fuel tank
fi l l er neck openi ng contai ns a defl ector that the smal l er
unl eaded nozzl e pushes back upon enteri ng the fi l l er
neck. The defl ector prevents the l arger di ameter
l eaded fuel nozzl es from enteri ng the fi l l er neck. I t al so
defl ects fuel away from the fi l l er neck i f fi l l i ng of the
tank wi th l eaded fuel i s attempted.
The fuel fi l l er tube on these model s i s equi pped wi th
a one way bal l check val ve. The val ve prevents fuel
spl ash back when fi l l i ng the tank.
As a remi nder, a l abel that reads UNLEADED
FUEL ONLY i s attached to the i nstrument panel
under the fuel gauge. A si mi l ar l abel i s l ocated near the
fuel tank fi l l er.
PRESSURE-VACUUM FILLER CAP FRONT WHEEL
DRIVE
The l oss of any fuel or vapor out of the fi l l er neck i s
prevented by the use of a safety fi l l er cap. The cap wi l l
rel ease pressure onl y under si gni fi cant pressure of 10.9
to 13.45 kPa (1.58 to 1.95 psi ). The vacuum rel ease for
al l gas caps i s between .97 and 2.0 kPa (.14 and .29 psi ).
The cap must be repl aced by a si mi l ar uni t i f repl ace-
ment i s necessary.
WARNING: REMOVE FILLER CAP TO RELIEVE TANK
PRESSURE BEFORE REMOVING OR REPAIRING
FUEL SYSTEM COMPONENTS.
The 2.5L engi ne fuel system i s under a constant
pressure of approxi matel y 270 kPa (39 psi ). The fuel
systems of 3.0L and 3.3L engi nes are under a constant
pressure of approxi matel y 330 kPa (48 psi ). Fuel sys-
tem pressure must be rel eased before servi ci ng any
fuel system component.
(1) Remove fuel fi l l er cap to rel ease fuel tank pres-
sure.
or mai n harness.
FUEL TANK CAPACI TI ES
FUEL SYSTEM 14 - 13
(3) Connect a jumper wi re from termi nal Number 1
(ground) of the i njector harness (Fi g. 1) to engi ne
ground.
(4) Connect one end of a jumper wi re to termi nal
Number 2 (posi ti ve) of the i njector harness (Fi g. 1).
Connect the other end to the posi ti ve post of the
battery for no l onger than 5 seconds. Thi s rel eases
system pressure.
FUEL TANK FRONT WHEEL DRIVE
DRAI NI NG FUEL TANK
(1) Remove fuel fi l l er cap and perform Fuel System
Pressure Rel ease procedure.
(4) Remove rubber cap from drai n tube. The tube i s
l ocated on rear of fuel tank. Connect a portabl e hol di ng
tank to the drai n tube (Fi g. 2).
(5) Drai n fuel tank dry i nto hol di ng tank or a prop-
erl y l abel ed gasoline safety contai ner.
FUEL TANK REMOVALFRONT WHEEL DRI VE
(2) Drai n fuel tank. Refer to Drai ni ng Fuel Tank.
(3) Remove fuel fi l l er cap before di sconnecti ng any
l i nes.
(4) Remove screws that hol d fi l l er tube to i nner and
outer quarter panel (Fi g. 3).
Fig. 1 Injector Harness Connectors
Fig. 2 Fuel Drain TubeFront Wheel Drive
14 - 14 FUEL SYSTEM
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FUEL SYSTEM 14 - 15
(5) Rai se vehi cl e. Di sconnect fuel pump/l evel uni t
el ectri cal connector.
(6) Di sconnect fuel l i ne qui ck connect fi tti ngs from
the tank. Refer to Tube/Fi tti ng Di sassembl y i n the Fuel
Del i very secti on of thi s Group.
(7) Use a transmi ssi on jack to support the fuel tank.
Remove the bol ts from the fuel tank straps.
(8) Lower tank sl i ghtl y. Careful l y remove fi l l er tube
from tank.
(9) Lower the fuel tank. Di sconnect pressure
rel i ef/rol l over val ve hose. Remove cl amp and remove
fuel fi l l er tube vent hose. Remove the fuel tank from
the vehi cl e.
FUEL TANK I NSTALLATI ONFRONT WHEEL
DRI VE
(1) Posi ti on fuel tank on transmi ssi on jack. Connect
pressure rel i ef/rol l over val ve hose. Connect fuel fi l l er
tube vent hose and repl ace cl amp.
(2) Rai se tank i nto posi ti on and careful l y work fi l l er
tube i nto tank. A l i ght coati ng of transmi ssi on fl ui d on
the tube end may be used to ai d assembl y.
(3) Ti ghten strap bol ts to 54.2 Nm (40 ft. l bs.)
torque. Remove transmi ssi on jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(4) Connect fuel pump/l evel uni t el ectri cal connector.
(5) Lubri cate the metal tubes on the fuel pump wi th
cl ean 30 wei ght engi ne oi l . I nstal l the qui ck connect
fuel fi tti ngs. Refer to Tube/Fi tti ng Assembl y i n the
Fuel Del i very secti on of thi s Group.
(6) Attach fi l l er tube to fi l l er neck openi ng i n quarter
panel . Ti ghten quarter panel screws to 1.9 Nm (17 i n.
l bs.) torque. On affected model s be sure to i nstal l the
gasket between the fi l l er tube and the i nner quarter
panel , before i nstal l i ng the mounti ng screws.
(7) Usi ng a new cl amp, i nstal l cap on fuel tank drai n
tube.
(8) Fi l l fuel tank, repl ace cap, and connect battery
ground cabl e.
(9) Use the DRB I I tester ASD Fuel System Test to
pressuri ze the fuel system. Check for l eaks.
FUEL TANK ALL WHEEL DRIVE
DRAI NI NG FUEL TANKALL WHEEL DRI VE
(1) Perform the Fuel System Pressure Rel ease pro-
cedure.
(4) Remove rubber cap from fuel tank drai n tube.
The cap i s l ocated above the rear di fferenti al torque
tube, on the i nboard si de of the fuel tank (Fi g. 4).
Connect a portabl e hol di ng tank to the drai n tube.
(5) Compl etel y drai n fuel tank i nto hol di ng tank or a
properl y l abel ed gasoline safety contai ner.
FUEL TANK REMOVALALL WHEEL DRI VE
cedure. Refer to Fuel System Pressure Rel ease i n thi s
secti on.
(4) Remove fuel fi l l er cap.
(3) Drai n fuel tank. Refer to Drai ni ng Fuel
TankAl l Wheel Dri ve i n thi s secti on.
(5) Remove screws that hol d fi l l er tube to openi ng i n
quarter panel .
(7) Remove fasteners hol di ng the park brake cabl e
support bracket assembl y i n pl ace (Fi g. 5).
Fig. 4 Fuel Tank Drain Cap
Fig. 5 Brake Cable Support BracketAll Wheel
Drive
14 - 16 FUEL SYSTEM
(8) Use a transmi ssi on jack to support the fuel tank.
Remove the bol ts from the fuel tank straps (Fi g. 6).
(9) Loosen fuel fi l l er tube vent hose cl amp and
remove hose from tube.
(10) Lower tank sl i ghtl y.
(11) Cl ean the qui ck connectors to remove any di rt.
(Use ai r pressure or an appropri ate cl eani ng agent).
Di sconnect fuel suppl y and return hoses from the
chassi s fuel tubes by pushi ng i n on the bl ack pl asti c
rel ease ri ng and pul l i ng on the connector. Refer to
Tube/Fi tti ng di sassembl y i n the Fuel Del i very Secti on
of thi s group.
(12) Di sconnect the fuel vent hose. Pl ug hoses to
prevent contami nati on.
(13) Remove el ectri cal connector from the fuel pump
modul e (Fi g. 7).
(14) Pul l fuel fi l l er vent hose through the frame rai l .
(15) Lower the fuel tank and remove the fuel fi l l er
tube from the fuel tank.
FUEL TANK I NSTALLATI ONALL WHEEL
DRI VE
(1) Posi ti on fuel tank on transmi ssi on jack. I nsert
fuel fi l l er tube i nto openi ng i n tank.
(2) Rai se fuel tank whi l e i nserti ng fuel fi l l er vent
hose through hol e i n frame rai l .
(3) Ensure that the bl ack rel ease ri ngs of the suppl y
and return fuel hose qui ck connect fi tti ngs are i n the
OUT posi ti on. The rel ease ri ng shoul d be l oose and free
fl oati ng.
(4) Lubri cate the ends of the chassi s fuel tubes
(suppl y and return onl y) wi th cl ean 30 wei ght engi ne
oi l .
CAUTION: When making connections with quick con-
nect fittings, always pull back on the fitting to ensure
complete engagement. If the fitting will not fully
connect, make sure the black release ring is not
jammed into the metal casing of the fitting. If the
fitting fails, replace it with a new one of the correct
size.
(5) Coupl e qui ck connect fi tti ngs of the fuel suppl y
and return hoses to the chassi s fuel tubes. Refer to
Tube/Fi tti ng Assembl y i n the Fuel Del i very Secti on of
thi s Group.
(6) Connect the fuel tank vent hose to the chassi s
fuel tube.
(7) Connect fuel pump el ectri cal connector to the
fuel pump modul e.
(8) I nstal l drai n tube cap.
(9) Rai se fuel tank i nto posi ti on. Careful l y twi st the
fi l l er tube and fuel fi l l er vent tube i nto posi ti on.
CAUTION: Be sure straps are not twisted or bent
before or after tightening strap nuts.
(10) I nstal l fuel tank support straps. Ti ghten fasten-
ers to 54.2 Nm (40 ft.l bs.) torque. Remove the trans-
mi ssi on jack.
(11) Connect fuel fi l l er vent hose and ti ghten hose
cl amp.
(12) I nstal l park brake cabl e support bracket.
Ti ghten the fasteners to 22.6 Nm (200 i n. l bs.) torque.
(14) Attach fi l l er tube to fi l l er neck openi ng i n quar-
ter panel . Ti ghten quarter panel screws to 1.9 Nm (17
i nch-pounds) torque. On affected model s, i nstal l gasket
between the fi l l er tube and the i nner quarter panel
before i nstal l i ng the mounti ng screws.
Fig. 6 All Wheel Drive Fuel Tank
Fig. 7 Fuel Pump ModuleAll Wheel Drive
FUEL SYSTEM 14 - 17
(15) Fi l l fuel tank, repl ace cap, connect battery
ground cabl e and check system operati on.
(16) Pressuri ze the system usi ng the DRB I I . Wi th
i gni ti on key i n the Run posi ti on, use ASD Fuel System
Test. Thi s wi l l acti vate the fuel pump and pressuri ze
the system. Check system for l eaks.
FUEL PUMP/LEVEL UNIT FRONT WHEEL DRIVE
Refer to the Fuel Del i very Secti on i n thi s Group for
fuel pump/l evel uni t servi ce.
FUEL PUMP MODULE ALL WHEEL DRIVE
Refer to the Fuel Del i very Secti on i n thi s Group for
fuel pump modul e servi ce.
FUEL TANK PRESSURE RELIEF/ROLLOVER
VALVE FRONT WHEEL DRIVE
REMOVAL
(1) Remove fuel tank. Refer to fuel tank removal .
(2) Wedge the bl ade of a screwdri ver between the
rubber grommet and the fuel tank where the support
ri b i s l ocated. Donot wedgebetween thevalveand
thegrommet, thiscoulddamagethevalveduring
removal.
(3) Use a second screwdri ver as a support to pry the
val ve and grommet assembl y from the tank (Fi g. 8).
(4) Pl ace the val ve upri ght on a fl at surface to
remove the grommet. Push down on the grommet and
peel i t off the val ve.
I NSTALLATI ON
(1) Posi ti on the rubber grommet i n the fuel tank by
rol l i ng i t around the curl ed l i p of the tank.
Only use power steering fluid to lubricate the
grommet.
(2) Lubri cate the grommet wi th power steeri ng fl ui d.
(3) Push the val ve downward i nto the grommet.
Twi st val ve unti l properl y posi ti oned (Fi g. 9).
(4) I nstal l fuel tank. Refer to fuel tank i nstal l ati on
i n thi s secti on.
Fig. 9 Installing Pressure Relief/Rollover Valve
Fig. 8 Removing Pressure Relief/Rollover
ValveFront Wheel Drive.
14 - 18 FUEL SYSTEM
FUEL TANK PRESSURE RELIEF/ROLLOVER
VALVE ALL WHEEL DRIVE
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal i n
thi s secti on.
(2) Wedge the bl ade of a screwdri ver between the
rubber grommet and the fuel pump modul e.
(3) Pry the val ve and grommet assembl y from the
pump (Fi g. 10).
(4) Pl ace the val ve upri ght on a fl at surface to
remove the grommet. Push down on the grommet and
peel i t off the val ve.
I NSTALLATI ON
(1) I nstal l the rubber grommet i n the fuel pump
modul e.
Only use power steering fluid to lubricate the
grommet.
(2) Lubri cate the grommet wi th power steeri ng fl ui d.
(3) Push the val ve downward i nto the grommet.
Twi st val ve unti l properl y posi ti oned.
(3) I nstal l fuel tank. Refer to Fuel Tank I nstal l ati on
i n thi s secti on.
Fig. 10 Removing Pressure Relief/Rollover Valve
FUEL SYSTEM 14 - 19
ACCELERATOR PEDAL AND THROTTLE CABLE
INDEX
page page
Accelerator Pedal Service . . . . . . . . . . . . . . . . . . 20 Throttle Cable Service . . . . . . . . . . . . . . . . . . . . . 20
ACCELERATOR PEDAL SERVICE
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not damage
or kink the core wire inside the cable sheathing.
REMOVAL
(1) Worki ng from the engi ne compartment, hol d the
throttl e body throttl e l ever i n the wi de open posi ti on.
Remove the throttl e cabl e from the throttl e body cam.
(2) From i nsi de the vehi cl e, hol d up the pedal and
remove the cabl e retai ner and throttl e cabl e from the
upper end of the pedal shaft (Fi g. 1 and Fi g. 2).
(3) Worki ng from the engi ne compartment, remove
nuts from accel erator pedal assembl y studs (Fi g. 1).
Remove assembl y from vehi cl e.
I NSTALLATI ON
(1) Posi ti on accel erator pedal assembl y on dash
panel . I nstal l retai ni ng nuts. Ti ghten retai ni ng nuts to
11.8 Nm (105 i n. l bs.) torque.
i nstal l the throttl e cabl e and cabl e retai ner i n the
upper end of the pedal shaft.
(3) From the engi ne compartment, hol d the throttl e
body l ever i n the wi de open posi ti on and i nstal l the
throttl e cabl e.
THROTTLE CABLE SERVICE
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not damage
or kink the core wire inside the cable sheathing.
REMOVAL
(1) Worki ng from the engi ne compartment, hol d the
throttl e body throttl e l ever i n the wi de open posi ti on.
remove the throttl e cabl e from the throttl e body cam
(Fi gs. 3, 4, and 5).
remove the cabl e retai ner and throttl e cabl e from the
upper end of the pedal shaft (Fi g. 1).
(3) Remove retai ner cl i p from throttl e cabl e and
grommet at dash panel (Fi g. 2).
(4) From the engi ne compartment, pul l the throttl e
cabl e out of the dash panel grommet. The grommet
shoul d remai n i n the dash panel .
(5) Remove the throttl e cabl e from throttl e bracket
by careful l y compressi ng both retai ni ng ears si mul ta-
neousl y. Then gentl y pul l the throttl e cabl e from
throttl e bracket.
I NSTALLATI ON
(1) From the engi ne compartment, push the housi ng
end fi tti ng i nto the dash panel grommet.
(2) I nstal l the cabl e housi ng (throttl e body end) i nto
the cabl e mounti ng bracket on the engi ne.
Fig. 1 Accelerator Pedal and Throttle CableFront
View
Fig. 2 Accelerator Pedal and Throttle CableRear
View
14 - 20 FUEL SYSTEM
i nstal l throttl e cabl e and cabl e retai ner i n the upper
end of the pedal shaft.
(4) At the dash panel , i nstal l the cabl e retai ner
cl i p between the end of the throttl e cabl e fi tti ng and
grommet (Fi g. 2).
(5) From the engi ne compartment, rotate the throt-
tl e l ever wi de open and i nstal l the throttl e cabl e.
Fig. 3 Throttle Cable to Throttle Body
Attachment2.5L Engines
Fig. 4 Throttle Cable Attachment to Throttle Body
Attachment 3.0L Engine
Fig. 5 Throttle Cable Attachment to Throttle Body
Attachment3.3L Engine
FUEL SYSTEM 14 - 21
2.5L SI NGLE POI NT FUEL I NJECTI ONSYSTEM OPERATI ON
INDEX
page page
Air Conditioning (A/C) Clutch RelayEngine
Controller Output . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air Conditioning Switch SenseEngine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Alternator FieldEngine Controller Output . . . . . . 27
Auto Shutdown (ASD) Relay and Fuel Pump
RelayEngine Controller Output . . . . . . . . . . . . 27
Automatic Idle Speed (AIS) MotorEngine
Controller Output . . . . . . . . . . . . . . . . . . . . . . . . 27
Battery VoltageEngine Controller Input . . . . . . . . 24
Brake SwitchEngine Controller Input . . . . . . . . . 24
Canister Purge SolenoidEngine Controller
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Ccd Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check Engine LampEngine Controller Output . . 28
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Diagnostic ConnectorEngine Controller Output . . 28
Distributor (Hall Effect) Pick-UpEngine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Emission Maintenance Reminder (EMR) Lamp
Engine Controller Output . . . . . . . . . . . . . . . . . . 28
Engine Controller Reprogramming (Flash) . . . . . . . 24
Fuel InjectorEngine Controller Output . . . . . . . . 29
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . 31
Ignition CoilEngine Controller Output . . . . . . . . . 29
Manifold Absolute Pressure (MAP) SensorEngine
Controller Input . . . . . . . . . . . . . . . . . . . . . . . . . 25
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . 30
Oxygen Sensor (O
2
Sensor)Engine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Part Throttle Unlock SolenoidEngine Controller
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Radiator Fan RelayEngine Controller Output . . . 29
Speed Control SolenoidsEngine Controller
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Speed ControlEngine Controller Input . . . . . . . . 26
TachometerEngine Controller Output . . . . . . . . . 29
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Throttle Position Sensor (TPS)Engine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Transmission Park/Neutral SwitchEngine
Vehicle Distance (Speed) SensorEngine
GENERAL INFORMATION
The El ectroni c Fuel I njecti on System (Fi g. 1) i s a
computer regul ated si ngl e poi nt fuel i njecti on system
that provi des preci se ai r/fuel rati o for al l dri vi ng con-
di ti ons. The fuel i njecti on system i s control l ed by the
Si ngl e Board Engi ne Control l er I I (SBEC I I ), referred
to in this manual as the engine controller.
The engi ne control l er i s a pre-programmed di gi tal
computer.
The engi ne control l er regul ates i gni ti on ti mi ng, ai r-
fuel rati o, emi ssi on control devi ces, cool i ng fan, charg-
i ng system, speed control , and i dl e speed. The engi ne
control l er can adapt i ts requi rement to meet changi ng
operati ng condi ti ons.
Vari ous sensors provi de the i nputs necessary for the
engi ne control l er to correctl y regul ate fuel fl ow at the
fuel i njector. These i ncl ude the mani fol d absol ute pres-
sure, throttl e posi ti on, oxygen sensor, cool ant tempera-
ture, and vehi cl e di stance sensors. I n addi ti on to the
sensors, vari ous swi tches and rel ays provi de i mportant
i nformati on and system control . These i ncl ude the
park/neutral swi tch, ai r condi ti oni ng cl utch swi tch,
auto shutdown rel ay and fuel pump rel ay.
Al l i nputs to the engi ne control l er are converted i nto
si gnal s. Based on these i nputs the engi ne control l er
adjusts ai r-fuel rati o, i gni ti on ti mi ng and other con-
trol l ed outputs. The engi ne control l er adjusts the ai r-
fuel rati o by changi ng the i njector pul se wi dth. I njector
pul se wi dth i s the peri od of ti me the i njector i s ener-
gi zed.
SYSTEM DI AGNOSI S
The engi ne control l er tests many of i ts own i nput and
output ci rcui ts. I f a faul t i s found i n a system, thi s
i nformati on i s stored i n memory. Faul t codes can
di spl ayed usi ng the Check Engi ne l amp. Al so, the
techni ci an can obtai n the faul t descri pti on by connect-
i ng the DRB I I to the vehi cl e. For faul t code i nforma-
ti on, refer to On Board Di agnosti cs i n the General
Di agnosi sSi ngl e Poi nt Fuel I njecti on secti on of thi s
group.
CCD BUS
Vari ous control l ers and modul es exchange i nforma-
ti on through a communi cati ons port cal l ed the CCD
Bus. The engi ne control l er transmi ts the check engi ne
l amp On/Off si gnal , engi ne RPM and vehi cl e l oad data
on the CCD Bus.
ENGINE CONTROLLER
The engi ne control l er i s a di gi tal computer contai n-
i ng a mi croprocessor (Fi g. 2). The control l er recei ves
i nput si gnal s from vari ous swi tches and sensors that
are referred to as Engi ne Control l er I nputs. Based on
these i nputs, the control l er adjusts vari ous engi ne and
vehi cl e operati ons through devi ces that are referred to
as Engi ne Control l er Outputs.
14 - 22 FUEL SYSTEM
Engine Controller Inputs:
Ai r Condi ti oni ng Control s
Battery Vol tage
Brake Swi tch
Cool ant Temperature Sensor
Di stri butor (Hal l Effect) Pi ck-up
Mani fol d Absol ute Pressure (MAP) Sensor
Oxygen Sensor
SCI Recei ve
Speed Control System Control s
Throttl e Posi ti on Sensor
Park/Neutral Swi tch (automati c transmi ssi on)
Vehi cl e Di stance (Speed) Sensor
Engine Controller Outputs:
Ai r Condi ti oni ng Cl utch Rel ay
Al ternator Fi el d
Automati c I dl e Speed (AI S) Motor
Auto Shutdown (ASD) Rel ay
Cani ster Purge Sol enoi d
Check Engi ne Lamp
Di agnosti c Connector
Emi ssi on Mai ntenance Remi nder (EMR) Lamp
Fuel I njectors
I gni ti on Coi l
Part Throttl e Unl ock Sol enoi d (Automati c Trans-
mi ssi on)
Radi ator Fan Rel ay
Speed Control Sol enoi ds
Tachometer Output
Based on i nputs i t recei ves, the engi ne control l er
adjusts fuel i njector pul se wi dth, i dl e speed, i gni ti on
spark advance, i gni ti on coi l dwel l and cani ster purge
operati on. The engi ne control l er regul ates operati on of
the EGR, cool i ng fan, A/C and speed control systems.
The control l er changes al ternator charge rate by ad-
justi ng the al ternator fi el d.
The engi ne control l er adjusts i njector pul se wi dth
(ai r-fuel rati o) based on the fol l owi ng i nputs.
battery vol tage
Fig. 1 Electronic Fuel Injection Components
FUEL SYSTEM 14 - 23
exhaust gas content
engi ne speed (di stri butor pi ck-up)
mani fol d absol ute pressure
throttl e posi ti on
The engi ne control l er adjusts i gni ti on ti mi ng based
on the fol l owi ng i nputs.
The Automati c Shut Down (ASD) and Fuel Pump
rel ays are mounted external l y, but turned on and off by
the engi ne control l er through the same ci rcui t.
The di stri butor pi ck-up si gnal i s sent to the engi ne
control l er. I f the engi ne control l er does not recei ve a
di stri butor si gnal wi thi n approxi matel y one second of
engi ne cranki ng, the ASD rel ay and fuel pump rel ay
are deacti vated. When these rel ays are deacti vated,
power i s shut off from the fuel i njector, fuel pump,
i gni ti on coi l , and oxygen sensor heater el ement.
The engi ne control l er contai ns a vol tage converter
that changes battery vol tage to a regul ated 9.0 vol ts to
power the di stri butor pi ck-up and vehi cl e speed sensor.
The control l er al so provi des a 5.0 vol ts suppl y for the
mani fol d absol ute pressure sensor and throttl e posi -
ti on sensor.
AIR CONDITIONING SWITCH SENSE ENGINE
CONTROLLER INPUT
When the ai r condi ti oni ng or defrost swi tch i s put i n
the ON posi ti on and the l ow pressure, A/C cycl i ng, and
hi gh pressure swi tches are cl osed, the engi ne control l er
recei ves an i nput for ai r condi ti oni ng. After recei vi ng
thi s i nput, the engi ne control l er acti vates the A/C
compressor cl utch by groundi ng the A/C cl utch rel ay.
The engi ne control l er al so adjusts i dl e speed to a
schedul ed RPM to compensate for i ncreased engi ne
l oad.
BATTERY VOLTAGE ENGINE CONTROLLER INPUT
The engi ne control l er moni tors the battery vol tage
i nput to determi ne fuel i njector pul se wi dth and al ter-
nator fi el d control .
I f battery vol tage i s l ow the engi ne control l er wi l l
i ncrease i njector pul se wi dth (peri od of ti me that the
i njector i s energi zed).
BRAKE SWITCH ENGINE CONTROLLER INPUT
When the brake swi tch i s acti vated, the engi ne
control l er recei ves an i nput i ndi cati ng that the brakes
are bei ng appl i ed. After recei vi ng the i nput, the con-
trol l er vents the speed control servo. Venti ng the servo
turns the speed control system off.
COOLANT TEMPERATURE SENSOR ENGINE CON-
TROLLER INPUT
The cool ant temperature sensor i s i nstal l ed behi nd
the thermostat housi ng and i gni ti on coi l i n the hot box.
The sensor provi des an i nput vol tage to the engi ne
control l er (Fi g. 3). As cool ant temperature vari es, the
sensor resi stance changes, resul ti ng i n a di fferent
i nput vol tage to the engi ne control l er.
reached.
Thi s sensor i s al so used for cool i ng fan control .
DISTRIBUTOR (HALL EFFECT) PICK-UP ENGINE
CONTROLLER INPUT
The engi ne speed i s suppl i ed to the engi ne control l er
by the di stri butor pi ck-up. The di stri butor pi ck-up i s a
Hal l Effect devi ce (Fi g. 4).
A shutter (someti mes referred to as an i nterrupter) i s
attached to the di stri butor shaft. The shutter contai ns
four bl ades, one per engi ne cyl i nder. A swi tch pl ate i s
mounted to the di stri butor housi ng above the shutter.
The swi tch pl ate contai ns the di stri butor pi ck-up (a
Hal l Effect devi ce and magnet) through whi ch the
shutter bl ades rotate. As the shutter bl ades pass
through the pi ck-up, they i nterrupt the magneti c fi el d.
The Hal l effect devi ce i n the pi ck-up senses the change
i n the magneti c fi el d and swi tches on and off, creati ng
pul ses. The pul ses are the i nput si gnal to the engi ne
control l er. The engi ne control l er cal cul ates engi ne
speed through the number of pul ses generated.
14 - 24 FUEL SYSTEM
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR ENGINE CONTROLLER INPUT
The engi ne control l er suppl i es 5 vol ts to the MAP
sensor. The MAP sensor converts i ntake mani fol d pres-
sure i nto vol tage. The engi ne control l er moni tors the
MAP sensor output vol tage. As vacuum i ncreases, MAP
sensor vol tage decreases proporti onatel y. Al so, as
vacuum decreases, MAP sensor vol tage i ncreases pro-
porti onatel y.
Duri ng cranki ng, before the engi ne starts runni ng,
the engi ne control l er determi nes atmospheri c ai r pres-
sure from the MAP sensor vol tage. Whi l e the engi ne
operates, the control l er determi nes i ntake mani fol d
pressure from the MAP sensor vol tage.
Based on MAP sensor vol tage and i nputs from other
sensors, the engi ne control l er adjusts spark advance
and the ai r/fuel mi xture.
The MAP sensor mounts on the dash panel (Fi g. 5). A
vacuum hose connects the sensor to the throttl e body.
OXYGEN SENSOR (O
2
SENSOR) ENGINE CON-
TROLLER INPUT
The O
2
sensor i s l ocated i n the exhaust mani fol d and
the exhaust gas (Fi g. 6). The engi ne control l er uses thi s
i nformati on to fi ne tune the ai r-fuel rati o by adjusti ng
i njector pul se wi dth.
The O
2
l esser amount present (ri ch ai r-fuel mi xture) i t pro-
duces a hi gher vol tage. By moni tori ng the oxygen
content and converti ng i t to el ectri cal vol tage, the
sensor acts as a ri ch-l ean swi tch.
The oxygen sensor i s equi pped wi th a heati ng el e-
ment that keeps the sensor at proper operati ng tem-
perature duri ng al l operati ng modes. Mai ntai ni ng cor-
rect sensor temperature at al l ti mes al l ows the system
to enter i nto cl osed l oop operati on sooner. Al so, i t
al l ows the system to remai n i n cl osed l oop operati on
duri ng peri ods of extended i dl e.
moni tors the O
2
nores the O
2
oxygen sensor i nput val ue (al ong wi th other sensor
i nputs).
Fig. 4 Distributor Pick-UpTypical
Fig. 5 Manifold Absolute Pressure (MAP) Sensor
Location
FUEL SYSTEM 14 - 25
SPEED CONTROL ENGINE CONTROLLER INPUT
The speed control system provi des four separate
vol tages (i nputs) to the engi ne control l er. The vol tages
correspond to the On/Off, Set, and Resume.
The speed control On vol tage i nforms the engi ne
control l er that the speed control system has been
acti vated. The speed control Set vol tage i nforms the
control l er that a fi xed vehi cl e speed has been sel ected.
The speed control Resume vol tage i ndi cates the previ -
ous fi xed speed i s requested. The speed control Off
vol tage tel l s the control l er that the speed control sys-
tem has deacti vated. Refer to Group 8H for further
speed control i nformati on.
TRANSMISSION PARK/NEUTRAL
SWITCH ENGINE CONTROLLER INPUT
The park/neutral swi tch i s l ocated on automati c
transmi ssi on housi ng (Fi g. 7). Manual transmi ssi on do
not use park neutral swi tches. The swi tch provi des an
i nput to the engi ne control l er that i ndi cates whether
the automati c transmi ssi on i s i n Park, Neutral , or a
dri ve gear sel ecti on. Thi s i nput i s used to determi ne
i dl e speed (varyi ng wi th gear sel ecti on), fuel i njector
pul se wi dth, and i gni ti on ti mi ng advance. The park
neutral swi tch i s someti mes referred to as the neutral
safety swi tch.
THROTTLE POSITION SENSOR (TPS) ENGINE
CONTROLLER INPUT
The Throttl e Posi ti on Sensor (TPS) i s mounted on
the throttl e body and connected to the throttl e bl ade
shaft (Fi g. 8). The TPS i s a vari abl e resi stor that
provi des the engi ne control l er wi th an i nput si gnal
(vol tage) that represents throttl e bl ade posi ti on. As the
posi ti on of the throttl e bl ade changes, the resi stance of
the TPS changes.
The engi ne control l er suppl i es approxi matel y 5 vol ts
to the TPS. The TPS output vol tage (i nput si gnal to the
engi ne control l er) represents the throttl e bl ade posi -
ti on. The TPS output vol tage to the control l er vari es
from approxi matel y 0.5 vol t at mi ni mum throttl e open-
i ng (i dl e) to 4 vol ts at wi de open throttl e. Al ong wi th
i nputs from other sensors, the engi ne control l er uses
the TPS i nput to determi ne current engi ne operati ng
condi ti ons and adjust fuel i njector pul se wi dth and
i gni ti on ti mi ng.
VEHICLE DISTANCE (SPEED) SENSOR ENGINE
CONTROLLER INPUT
The di stance sensor (Fi g. 9) i s l ocated i n the trans-
mi ssi on extensi on housi ng. The sensor i nput i s used by
the engi ne control l er to determi ne vehi cl e speed and
di stance travel ed.
The di stance sensor generates 8 pul ses per sensor
revol uti on. These si gnal s are i nterpreted al ong wi th a
cl osed throttl e si gnal from the throttl e posi ti on sensor
by the engi ne control l er. The i nputs are used to deter-
mi ne i f a cl osed throttl e decel erati on or a normal i dl e
(vehi cl e stopped) condi ti on exi sts. Under decel erati on
condi ti ons, the engi ne control l er adjusts the AI S motor
to mai ntai n a desi red MAP val ue. Under i dl e condi -
ti ons, the engi ne control l er adjusts the AI S motor to
mai ntai n a desi red engi ne speed.
AIR CONDITIONING (A/C) CLUTCH
RELAY ENGINE CONTROLLER OUTPUT
The engi ne control l er operates the ai r condi ti oni ng
cl utch rel ay ground ci rcui t (Fi g. 10). The ai r condi ti on-
i ng (A/C) fan rel ay suppl i es battery power to the
sol enoi d si de of the rel ay. The ai r condi ti oni ng cl utch
rel ay wi l l not energi ze unl ess the A/C fan rel ay en-
Fig. 7 Park Neutral Switch
Fig. 8 Throttle Position Sensor
Fig. 9 Vehicle Distance (Speed) Sensor
14 - 26 FUEL SYSTEM
ergi zes. The A/C fan rel ay energi zes when the ai r
condi ti oni ng or defrost swi tch i s put i n the ON posi ti on
and the l ow pressure, A/C cycl i ng, and hi gh pressure
swi tches cl ose.
Wi th the engi ne operati ng, the engi ne control l er
cycl es the ai r condi ti oni ng cl utch on and off when the
A/C swi tch cl oses wi th the bl ower motor swi tch i n the
on posi ti on. When the engi ne control l er senses l ow i dl e
speeds or wi de open throttl e through the throttl e
posi ti on sensor, i t de-energi zes the A/C cl utch rel ay.
The rel ay contacts open, preventi ng ai r condi ti oni ng
cl utch engagement.
ALTERNATOR FIELD ENGINE CONTROLLER OUT-
PUT
The engi ne control l er regul ates the chargi ng system
vol tage wi thi n a range of 12.9 to 15.0 vol ts. Refer to
Group 8A for chargi ng system i nformati on.
at the same ti me.
heati ng el ement.
recei ve a di stri butor si gnal when the i gni ti on swi tch i s
i n the Run posi ti on, i t wi l l de-energi ze both rel ays.
l er (Fi g. 11).
AUTOMATIC IDLE SPEED (AIS) MOTOR ENGINE
CONTROLLER OUTPUT
The i dl e speed stepper motor i s mounted on the
throttl e body and i s control l ed by the engi ne control l er
(Fi g. 12). The engi ne control l er adjusts engi ne i dl e
speed through the AI S to compensate for engi ne l oad or
ambi ent condi ti ons.
The throttl e body has an ai r bypass passage that
provi des ai r for the engi ne at i dl e (the throttl e bl ade
Fig. 10 Relay Identification
Fig. 12 Automatic Idle Speed Motor
FUEL SYSTEM 14 - 27
i s cl osed). The AI S motor pi ntl e protrudes i nto the
ai r bypass passage and regul ates ai r fl ow through i t.
The engi ne control l er adjusts engi ne i dl e speed by
movi ng the AI S motor pi ntl e i n and out of the bypass
passage. The adjustments are based on i nputs the
control l er recei ves. The i nputs are from the throttl e
posi ti on sensor, speed sensor (di stri butor pi ck-up
coi l ), cool ant temperature sensor, and vari ous swi tch
operati ons (brake, park/neutral , ai r condi ti oni ng).
Decel erati on di e out i s al so prevented by i ncreasi ng
ai rfl ow when the throttl e i s cl osed qui ckl y after a
dri vi ng (speed) condi ti on.
CANISTER PURGE SOLENOID ENGINE
CONTROLLER OUTPUT
Vacuum for the Evaporati ve Cani ster i s control l ed
by the Cani ster Purge Sol enoi d (Fi g. 13). The sol e-
noi d i s control l ed by the engi ne control l er.
The engi ne control l er operates the sol enoi d by
swi tchi ng the ground ci rcui t on and off based on en-
gi ne operati ng condi ti ons. When energi zed, the sol e-
noi d prevents vacuum from reachi ng the evaporati ve
cani ster. When not energi zed the sol enoi d al l ows vac-
uum to fl ow to the cani ster.
Duri ng warm-up and for a speci fi ed ti me peri od af-
ter hot starts the engi ne control l er grounds the purge
sol enoi d causi ng i t to energi ze. Vacuum does not op-
erate the evaporati ve cani ster val ve.
The engi ne control l er removes the ground to the
sol enoi d when the engi ne reaches a speci fi ed temper-
ature and the ti me del ay i nterval has occurred.
When the sol enoi d i s de-energi zed, vacuum fl ows to
the cani ster purge val ve. Vapors are purged from the
cani ster and fl ow to the throttl e body.
The purge sol enoi d i s al so energi zed duri ng certai n
i dl e condi ti ons to update the fuel del i very cal i bra-
ti on.
CHECK ENGINE LAMP ENGINE CONTROLLER
OUTPUT
The engi ne control l er suppl i es a check engi ne l amp
on/off si gnal to the i nstrument panel through the
CCD Bus. The CCD Bus i s a communi cati ons port.
Vari ous modul es use the CCD Bus to exchange i nfor-
mati on.
The Check Engi ne Lamp comes on each ti me the
i gni ti on key i s turned ON and stays on for 3 seconds
as a bul b test. The Check Engi ne Lamp warns the
operator that the engi ne control l er has entered a
Li mp-i n mode. Duri ng Li mp-i n-Mode, the control l er
attempts to keep the system operati onal . The check
engi ne l amp si gnal s the need for i mmedi ate servi ce.
I n l i mp-i n mode, the Engi ne control l er compensates
for the fai l ure of certai n components that send i ncor-
rect si gnal s. The control l er substi tutes for the i ncor-
rect si gnal s wi th i nputs from other sensors.
Signals that can trigger the Check Engine
Lamp.
Mani fol d Absol ute Pressure Sensor
Battery Vol tage I nput
An Emi ssi ons Rel ated System
Chargi ng system
The Check Engi ne Lamp can al so be used to di s-
pl ay faul t codes. Cycl e the i gni ti on swi tch on, off, on,
off, on, wi thi n fi ve seconds and any faul t codes stored
i n the Engi ne control l er wi l l be di spl ayed. Refer to
On Board Di agnosti cs i n the General
Di agnosi s2.5L TBI Engi nes secti on of thi s Group
for Faul t Code Descri pti ons.
DIAGNOSTIC CONNECTOR ENGINE CONTROLLER
OUTPUT
The di agnosti c connector provi des the techni ci an
wi th the means to connect the DRB I I tester to di ag-
nosi s the vehi cl e.
EMISSION MAINTENANCE REMINDER (EMR)
LAMP ENGINE CONTROLLER OUTPUT
The Emi ssi ons Mai ntenance Remi nder System
(EMR) i s i ncorporated i nto the engi ne control l er. The
engi ne control l er records the vehi cl e mi l eage and
stores i t i nto memory every 8 mi l es. At that ti me,
the engi ne control l er checks for the 60,000, 82,500,
and 120,000 mi l eage tri p poi nts. When the current
mi l eage matches one of the above menti oned tri p
poi nts, the EMR l amp on the i nstrument panel i s ac-
ti vated.
Certai n components must be repl aced at the i ndi -
cated mi l eage, or when the EMR l amp stays on wi th
the key i n the on posi ti on, whi chever occurs fi rst. Af-
ter performi ng the requi red mai ntenance, the EMR
l amp must be reset to turn the l amp off.
For more i nformati on, refer to Group 25 or the ap-
propri ate di agnosti c manual .
14 - 28 FUEL SYSTEM
FUEL INJECTOR ENGINE CONTROLLER OUTPUT
The Fuel I njector i s an el ectri c sol enoi d dri ven by the
engi ne control l er (Fi g 14).
Based on sensor i nputs, the engi ne control l er deter-
mi nes when and how l ong the fuel i njector shoul d
operate.
The amount of ti me the i njector operates i s referred
to as i njector pul se wi dth. The auto shutdown (ASD)
rel ay suppl i es battery vol tage to the i njector. The
engi ne control l er suppl i es the ground path. By swi tch-
i ng the ground path on and off, the engi ne control l er
adjusts i njector pul se wi dth. When the control l er sup-
pl i es a ground path, a spri ng l oaded needl e or arma-
ture l i fts from i ts seat. Fuel fl ows through the ori fi ce
and defl ects off the sharp edge of the i njector nozzl e.
The resul ti ng fuel sprays forms a 45 cone shaped
pattern before enteri ng the ai r stream i n the throttl e
body.
Fuel i s suppl i ed to the i njector constantl y at regu-
l ated 270 Kpa (39 psi ). Unused fuel returns to the fuel
tank.
IGNITION COIL ENGINE CONTROLLER OUTPUT
The engi ne control l er provi des a ground contact
(ci rcui t) for energi zi ng the i gni ti on coi l . When the
control l er breaks the contact, the energy i n the coi l
pri mary transfers to the secondary causi ng the spark.
The auto shutdown (ASD) rel ay provi des battery vol t-
age to the i gni ti on coi l posi ti ve termi nal . The engi ne
control l er wi l l de-energi ze the ASD rel ay i f i t does not
recei ve an i nput from the di stri butor pi ck-up. Refer to
Auto Shutdown (ASD) Rel ay/Fuel Pump
Rel ayEngi ne Control l er Output i n thi s secti on for
rel ay operati on.
The i gni ti on coi l i s mounted on the hot box next to
the thermostat housi ng (Fi g. 15).
PART THROTTLE UNLOCK SOLENOID ENGINE
CONTROLLER OUTPUT
Three-speed automati c transaxl es use a part throttl e
unl ock sol enoi d. The engi ne control l er control s the
l ock-up of the torque convertor through the part
throttl e unl ock sol enoi d. The transmi ssi on i s l ocked up
onl y i n di rect dri ve mode. Refer to Group 21 for
transmi ssi on i nformati on.
RADIATOR FAN RELAY ENGINE CONTROLLER
OUTPUT
The radi ator fan i s energi zed by the engi ne control l er
through the radi ator fan rel ay. The radi ator fan rel ay i s
l ocated on the dri vers si de fender wel l near to the
engi ne control l er (Fi g. 11). The engi ne control l er
grounds the radi ator fan rel ay when engi ne cool ant
reaches a predetermi ned temperature. For more i nfor-
mati on, refer to Group 7, Cool i ng Systems.
SPEED CONTROL SOLENOIDS ENGINE CONTROL-
LER OUTPUT
The speed control vacuum and vent sol enoi ds are
operated by the engi ne control l er. When the engi ne
control l er suppl i es a ground to the vacuum sol enoi d,
the speed control system opens the throttl e pl ate.
When the control l er suppl i es a ground to the vent
sol enoi d, the throttl e bl ade cl oses. The engi ne control -
l er bal ances the two sol enoi ds to mai ntai n the set
speed. Refer to Group 8H for speed control i nformati on.
TACHOMETER ENGINE CONTROLLER OUTPUT
The engi ne control l er suppl i es engi ne RPM to the
i nstrument panel tachometer through the CCD Bus.
Fig. 14 Fuel Injector
Fig. 15 Ignition Coil
FUEL SYSTEM 14 - 29
The CCD Bus i s a communi cati ons port. Vari ous mod-
ul es use the CCD Bus to exchange i nformati on. Refer
to Group 8E for more i nformati on.
MODES OF OPERATION
As i nput si gnal s to the engi ne control l er change, the
engi ne control l er adjusts i ts response to the output
devi ces. For exampl e, the engi ne control l er must cal -
cul ate a di fferent i njector pul se wi dth and i gni ti on
ti mi ng for i dl e than i t does for wi de open throttl e
(WOT). There are several di fferent modes of operati on
that determi ne how the engi ne control l er responds to
the vari ous i nput si gnal s.
There are two di fferent areas of operati on, OPEN
LOOP and CLOSED LOOP.
Duri ng OPEN LOOP modes, the engi ne control l er
recei ves i nput si gnal s and responds accordi ng to preset
engi ne control l er programmi ng. I nput from the oxygen
(O
2
) sensor i s not moni tored duri ng OPEN LOOP
modes.
Duri ng CLOSED LOOP modes, the engi ne control l er
does moni tor the oxygen (O
2
) sensor i nput. Thi s i nput
i ndi cates to the engi ne control l er whether or not the
cal cul ated i njector pul se wi dth resul ts i n the i deal
ai r-fuel rati o of 14.7 parts ai r to 1 part fuel . By
moni tori ng the exhaust oxygen content through the O
2
sensor, the engi ne control l er can fi ne tune the i njector
pul se wi dth. Fi ne tuni ng i njector pul se wi dth al l ows
the control l er to achi eve opti mum fuel economy com-
bi ned wi th l ow emi ssi ons.
The si ngl e poi nt fuel i njecti on system has the fol l ow-
i ng modes of operati on:
I gni ti on swi tch ON - Zero RPM
Engi ne start-up
Engi ne warm-up
Crui se (I dl e)
Accel erati on
Decel erati on
Wi de Open Throttl e
I gni ti on swi tch OFF
The engi ne start-up (crank), engi ne warm-up, and
wi de open throttl e modes are OPEN LOOP modes.
Under most operati ng condi ti ons, the accel erati on,
decel erati on, and crui se modes, with the engine at
operatingtemperature, are CLOSED LOOP modes.
IGNITION SWITCH ON (ZERO RPM) MODE
When the si ngl e poi nt fuel i njecti on system i s acti -
vated by the i gni ti on swi tch, the fol l owi ng acti ons
occur:
The engi ne control l er determi nes atmospheri c ai r
pressure from the MAP sensor i nput to determi ne basi c
fuel strategy.
The engi ne control l er moni tors the cool ant tempera-
ture sensor and throttl e posi ti on sensor i nputs. The
engi ne control l er modi fi es fuel strategy based on these
i nputs.
When the key i s i n the ON posi ti on and the engi ne i s
not runni ng or cranki ng (zero rpm), the auto shutdown
(ASD) rel ay and fuel pump rel ay are not energi zed.
Therefore battery vol tage i s not suppl i ed to the fuel
pump, i gni ti on coi l , fuel i njector or oxygen sensor
heati ng el ement.
ENGINE START-UP MODE
Thi s i s an OPEN LOOP mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
I f the engi ne control l er recei ves a di stri butor si gnal ,
i t energi zes the auto shutdown (ASD) rel ay and fuel
pump rel ay. These rel ays suppl y battery vol tage to the
fuel pump, fuel i njector, i gni ti on coi l and oxygen sensor
heati ng el ement. I f the engi ne control l er does not
recei ve a di stri butor i nput, the ASD and fuel pump
rel ays wi l l be de-energi zed after approxi matel y one
second.
When the engi ne i s i dl i ng wi thi n 64 RPM of the
target RPM, the control l er compares current MAP
val ue wi th the atmospheri c pressure val ue recei ved
duri ng the I gni ti on Swi tch On (Zero RPM) Mode. I f a
mi ni mum di fference between the two i s not detected, a
MAP sensor faul t i s set i nto memory.
Once the ASD rel ay and fuel pump rel ay have ener-
gi zed, the engi ne control l er:
Suppl i es a ground path to the i njector. The i njector
i s pul sed four ti mes per engi ne revol uti on i nstead of
the normal two pul ses per revol uti on.
Determi nes i njector pul se wi dth based on cool ant
temperature, MAP sensor i nput, throttl e posi ti on, and
the number of engi ne revol uti ons si nce cranki ng was
i ni ti ated.
Moni tors the cool ant temperature sensor, di stri bu-
tor pi ck-up, MAP sensor, and throttl e posi ti on sensor to
determi ne correct i gni ti on ti mi ng.
ENGINE WARM-UP MODE
Thi s i s a OPEN LOOP mode. The fol l owi ng i nputs
are recei ved by the engi ne control l er:
mani fol d absol ute pressure (MAP)
A/C swi tch
battery vol tage
The engi ne control l er provi des a ground path for the
i njector to preci sel y control i njector pul se wi dth (by
swi tchi ng the ground on and off). The control l er ener-
gi zes the i njector twi ce per engi ne revol uti on. The
engi ne control l er regul ates engi ne i dl e speed (by ad-
justi ng the automati c i dl e speed motor) and i gni ti on
ti mi ng.
14 - 30 FUEL SYSTEM
CRUISE OR IDLE MODE
When the engi ne i s at operati ng temperature thi s i s
a CLOSED LOOP mode. Duri ng crui si ng speed and at
i dl e the fol l owi ng i nputs are recei ved by the engi ne
control l er:
engi ne speed
exhaust gas oxygen content
A/C control posi ti ons
battery vol tage
The engi ne control l er provi des a ground path for the
i njector to preci sel y control i njector pul se wi dth. The
control l er energi zes the i njector twi ce per engi ne revo-
l uti on. The engi ne control l er control s engi ne i dl e speed
and i gni ti on ti mi ng. The engi ne control l er control s the
ai r/fuel rati o accordi ng to the oxygen content i n the
exhaust gas.
ACCELERATION MODE
Thi s i s a CLOSED LOOP mode. The engi ne control -
l er recogni zes an abrupt i ncrease i n throttl e posi ti on or
MAP pressure as a demand for i ncreased engi ne output
and vehi cl e accel erati on. The engi ne control l er i n-
creases i njector pul se wi dth i n response to i ncreased
fuel demand.
DECELERATION MODE
Thi s i s a CLOSED LOOP mode. Duri ng decel erati on
the fol l owi ng i nputs are recei ved by the engi ne control -
l er:
engi ne speed
battery vol tage
The engi ne control l er may recei ve a cl osed throttl e
i nput from the throttl e posi ti on sensor (TPS) when i t
senses an abrupt decrease i n mani fol d pressure. Thi s
i ndi cates a hard decel erati on. The engi ne control l er
may reduce i njector fi ri ng to once per engi ne revol u-
ti on. Thi s hel ps mai ntai n better control of the ai r-fuel
mi xture (as sensed through the O
2
sensor).
Duri ng a decel erati on condi ti on, the engi ne control -
l er grounds the exhaust gas reci rcul ati on (EGR) and
evaporati ve purge sol enoi ds. When these sol enoi ds are
grounded, the EGR and cani ster purge functi ons stop.
WIDE OPEN THROTTLE MODE
Thi s i s an OPEN LOOP mode. Duri ng wi de-open-
throttl e operati on, the fol l owi ng i nputs are recei ved by
the engi ne control l er:
engi ne speed
When the engi ne control l er senses a wi de open
throttl e condi ti on through the throttl e posi ti on sensor
(TPS) i t wi l l :
De-energi ze the ai r condi ti oni ng rel ay. Thi s di sabl es
the ai r condi ti oni ng system.
The exhaust gas oxygen content i nput i s not accepted
by the engi ne control l er duri ng wi de open throttl e
operati on. The engi ne control l er wi l l adjust i njector
pul se wi dth to suppl y a predetermi ned amount of
addi ti onal fuel .
IGNITION SWITCH OFF MODE
When the i gni ti on swi tch i s turned to the OFF
posi ti on, the fol l owi ng occurs:
Al l outputs are turned off.
No i nputs are moni tored.
The engi ne control l er shuts down.
FUEL PRESSURE REGULATOR
The pressure regul ator i s a mechani cal devi ce l o-
cated at the top of the throttl e body (Fi g. 16). I ts
functi on i s to mai ntai n a constant 270 kPa (39 PSI )
across the fuel i njector ti p.
The regul ator uses a spri ng l oaded rubber di a-
phragm to uncover a fuel return port. When the fuel
pump operates, fuel fl ows past the i njector i nto the
regul ator. The bl ocked return port restri cts fuel from
fl owi ng any further. When fuel pressure reaches 270
kPa (39 PSI ) i t pushes on the di aphragm, compressi ng
the spri ng, and uncovers the fuel return port. The
di aphragm and spri ng wi l l constantl y move from an
open to cl osed posi ti on to keep the fuel pressure con-
stant.
Fig. 16 Fuel Pressure Regulator
FUEL SYSTEM 14 - 31
THROTTLE BODY
The throttl e body assembl y (Fi g. 17) i s mounted on
top of the i ntake mani fol d. I t contai ns the fuel i njector,
pressure regul ator, throttl e posi ti on sensor and auto-
mati c i dl e speed motor. Ai r fl ow through the throttl e
body i s control l ed by a cabl e operated throttl e bl ade
l ocated i n the base of the throttl e body. The throttl e
body i tsel f provi des the chamber for meteri ng, atomi z-
i ng, and mi xi ng fuel wi th the ai r enteri ng the engi ne.
14 - 32 FUEL SYSTEM
F
i
g
.
1
7
T
h
r
o
t
t
l
e
B
o
d
y
FUEL SYSTEM 14 - 33
2.5L SI NGLE POI NT FUEL I NJECTI ONGENERAL DI AGNOSI S
INDEX
page page
60-Way Engine Controller Wiring Connector . . . . . 43
Circuit Actuation Test Mode . . . . . . . . . . . . . . . . . 42
Fault Code Description . . . . . . . . . . . . . . . . . . . . . 40
On Board Diagnostics . . . . . . . . . . . . . . . . . . . . . 38
State Display Test Mode . . . . . . . . . . . . . . . . . . . . 40
Systems Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Throttle Body Minimum Air Flow Check
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 34
GENERAL INFORMATION
The fuel i njecti on system i s managed by the engi ne
control l er. The control l er recei ves i nputs from vari ous
swi tches and sensors (Fi g. 1). Based on these i nputs
the engi ne control l er adjusts i gni ti on ti mi ng and i dl e
speed through output devi ces. Refer to the Si ngl e Poi nt
Fuel I njecti on secti on of thi s group for system and
component descri pti ons.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected, or mi s-
routed wi res and hoses shoul d be made before attempt-
i ng to di agnose or servi ce the fuel i njecti on system. A
vi sual check hel ps save unnecessary test and di agnos-
ti c ti me. A thorough vi sual i nspecti on wi l l i ncl ude the
(1) Check I gni ti on Coi l El ectri cal Connecti ons (Fi g. 2).
Fig. 1 Throttle Body Fuel Injection Components
14 - 34 FUEL SYSTEM
(2) Veri fy that the el ectri cal connector i s attached to
the Cani ster Purge Sol enoi d (Fi g. 3).
(3) Veri fy that vacuum connecti on at Cani ster Purge
Sol enoi d i s secure and not l eaki ng.
(4) Veri fy the harness connector i s attached to the
MAP sensor (Fi g. 4).
(5) Veri fy mani fol d absol ute pressure sensor vacuum
hose i s attached at MAP sensor (Fi g. 4).
(6) Veri fy that al ternator wi ri ng and bel t are cor-
rectl y i nstal l ed and ti ghtened.
(7) Veri fy that hoses are securel y attached to vapor
cani ster (Fi g. 5).
(8) Veri fy that the throttl e body wi ri ng harness i s
connected to mai n harness.
(9) Veri fy the harness connector i s attached to AI S
motor (Fi g. 6).
throttl e posi ti on sensor (Fi g. 6).
fuel i njector (Fi g. 6).
(12) Veri fy the hose from PCV val ve i s securel y
attached to the i ntake mani fol d vacuum port (Fi g. 7).
Location
Fig. 5 Vapor Canister
Fig. 6 Throttle Body Wiring Connections
Fig. 7 Vacuum Hose from Intake Manifold to PCV
Valve
FUEL SYSTEM 14 - 35
(13) Veri fy the vacuum connecti ons on the front and
rear of throttl e body are secure and not l eaki ng (Fi gs.
8, and 9).
(14) Veri fy the heated ai r door vacuum connecti on i s
connected and not l eaki ng.
(15) Veri fy power brake and speed control vacuum
connectors are ti ght (Fi g. 10).
(16) Veri fy al l i gni ti on cabl es are i n correct order and
seated i nto pl ace (Fi g. 11).
(17) Veri fy el ectri cal connector i s attached to cool ant
temperature sensor (Fi g. 12).
(18) Veri fy battery negati ve ground eyel et i s
mounted to the cyl i nder head (l eft si de) (Fi g. 12).
(19) Veri fy the harness connector i s attached to
di stri butor (Fi g. 13).
(20) Veri fy radi ator fan el ectri cal connecti on i s se-
cure.
(21) Veri fy oi l pressure swi tch el ectri cal connecti ons
are secure (Fi g. 13).
(22) On vehi cl es wi th an automati c transmi ssi on,
ensure the neutral safety swi tch el ectri cal connector i s
secure (Fi g. 14).
Fig. 8 Throttle Body Vacuum PortsFront
Fig. 9 Throttle Body Vacuum PortsRear
Fig. 10 Power Brake and Speed Control Vacuum
Connection
Fig. 11 Ignition Cable Routing and Connection
14 - 36 FUEL SYSTEM
G(23) On vehi cl es wi th an automati c transmi ssi on,
check torque convertor l ockup sol enoi d el ectri cal con-
necti on (Fi g. 14).
(24) Check the 60-way el ectri cal connecti on at the
engi ne control l er for damage or spread termi nal s.
Veri fy that the 60-way connector i s ful l y i nserted i nto
the socket on the Engi ne Control l er (Fi g. 15). Ensure
that wi res are not stretched or pul l ed out of the
connector.
(25) Veri fy al l el ectri cal connectors are ful l y i nserted
i nto rel ays (Fi g. 16 and Fi g. 17).
(26) Ensure battery connecti ons are cl ean and ti ght.
(27) Veri fy engi ne harness to mai n harness connec-
ti ons are ful l y i nserted.
Fig. 13 Distributor, Oil Pressure Switch, and Radia-
tor Fan Electrical Connections
Fig. 14 Automatic Transmission Electrical Connec-
tions
Fig. 15 Engine Controller Electrical Connector
Fig. 16 ASD, Fuel Pump, Radiator Fan and Starter
Relays
FUEL SYSTEM 14 - 37
(28) Check di stance sensor connector (Fi g. 18).
(29) Veri fy engi ne ground strap i s attached at the
engi ne and dash panel (Fi gs. 19 and 20).
heated oxygen sensor (Fi g. 21).
(31) Check Hose and Wi ri ng Connecti ons at Fuel
Pump. Check that wi ri ng connector i s maki ng contact
wi th termi nal s on pump.
ON BOARD DIAGNOSTICS
The engi ne control l er has been programmed to moni -
tor many di fferent ci rcui ts of the fuel i njecti on system.
I f a probl em i s sensed wi th a moni tored ci rcui t often
enough to i ndi cate an actual probl em, the control l er
stores a faul t. I f the probl em i s repai red or ceases to
exi st, the engi ne control l er cancel s the Faul t Code after
51 vehi cl e key on/off cycl es.
Certai n cri teri a must be met for a faul t code to be
entered i nto engi ne control l er memory. The cri teri a
may be a speci fi c range of engi ne RPM, engi ne tem-
perature, and/or i nput vol tage to the engi ne control l er.
I t i s possi bl e that a faul t code for a moni tored ci rcui t
may not be entered i nto memory even though a mal -
functi on has occurred. Thi s may happen because one of
the faul t code cri teri a for the ci rcui t has not been met.
For example, assume that one of the faul t code
cri teri a for the MAP sensor ci rcui t i s that the engi ne
must be operati ng between 750 and 2000 RPM to be
moni tored for a faul t code. I f the MAP sensor output
ci rcui t shorts to ground when engi ne
Fig. 17 A/C Clutch and A/C Fan Relays
Fig. 18 Distance Sensor Wiring Connection
Fig. 19 Engine Ground Strap at Intake Manifold
Fig. 20 Engine Ground Strap to Dash Panel
Fig. 21 Heated Oxygen Sensor Electrical Connec-
tion
14 - 38 FUEL SYSTEM
RPM i s above 2400 RPM (resul ti ng i n a 0 vol t i nput to
the engi ne control l er) a faul t code wi l l not be entered
i nto memory. Thi s i s because the condi ti on does not
occur wi thi n the speci fi ed RPM range.
There are several operati ng condi ti ons that the en-
gi ne control l er does not moni tor and set faul t codes for.
Refer to Moni tored Ci rcui ts and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Stored faul t codes can be di spl ayed ei ther by cycl i ng
the i gni ti on key On - Off - On - Off - On, or through use
of the Di agnosti c Readout Box I I (DRB I I ). The DRB I I
connects to the di agnosti c connector i n the vehi cl e (Fi g.
22).
MONI TORED CI RCUI TS
The engi ne control l er can detect certai n faul t condi -
ti ons i n the fuel i njecti on system.
Open or Shorted Circuit - The engi ne control l er
can determi ne i f the sensor output (i nput to control l er)
i s wi thi n proper range. Al so, the control l er can deter-
mi ne i f the ci rcui t i s open or shorted.
Output DeviceCurrent Flow- The engi ne control -
l er senses whether the output devi ces are hooked up. I f
there i s a probl em wi th the ci rcui t, the control l er
senses whether the ci rcui t i s open, shorted to ground,
or shorted hi gh.
Oxygen Sensor - The engi ne control l er can deter-
mi ne i f the oxygen sensor i s swi tchi ng between ri ch
and l ean once the system has entered cl osed l oop. Refer
to Modes of Operati on i n thi s secti on for an expl anati on
of cl osed l oop operati on.
NON-MONI TORED CI RCUI TS
The engi ne control l er does not moni tor the fol l owi ng
ci rcui ts, systems and condi ti ons that coul d have mal -
functi ons that resul t i n dri veabi l i ty probl ems. Faul t
codes may not be di spl ayed for these condi ti ons. How-
ever, probl ems wi th these systems may cause faul t
codes to be di spl ayed for other systems. For exampl e, a
fuel pressure probl em wi l l not regi ster a faul t di rectl y,
but coul d cause a ri ch or l ean condi ti on. Thi s coul d
cause an oxygen sensor faul t to be stored i n the engi ne
control l er.
Fuel Pressure - Fuel pressure i s control l ed by the
fuel pressure regul ator. The engi ne control l er cannot
detect a cl ogged fuel pump i nl et fi l ter, cl ogged i n-l i ne
fuel fi l ter, or a pi nched fuel suppl y or return l i ne.
However, these coul d resul t i n a ri ch or l ean condi ti on
causi ng an oxygen sensor faul t to be stored i n the
engi ne control l er.
Secondary Ignition Circuit - The engi ne control -
l er cannot detect an i noperati ve i gni ti on coi l , foul ed or
worn spark pl ugs, i gni ti on cross fi ri ng, or open spark
pl ug cabl es.
Engine Timing - The engi ne control l er cannot de-
tect an i ncorrectl y i ndexed ti mi ng chai n, camshaft
sprocket and crankshaft sprocket. The engi ne control -
l er al so cannot detect an i ncorrectl y i ndexed di stri bu-
tor. However, these coul d resul t i n a ri ch or l ean
condi ti on causi ng an oxygen sensor faul t to be stored i n
Cylinder Compression - The engi ne control l er
cannot detect uneven, l ow, or hi gh engi ne cyl i nder
compressi on.
Exhaust System - The engi ne control l er cannot
detect a pl ugged, restri cted or l eaki ng exhaust system.
Fuel Injector Malfunctions - The engi ne control -
l er cannot determi ne i f the fuel i njector i s cl ogged, the
pi ntl e i s sti cki ng or the wrong i njector i s i nstal l ed.
ExcessiveOil Consumption - Al though the engi ne
control l er moni tors exhaust stream oxygen content
when the system i s i n cl osed l oop, i t cannot determi ne
excessi ve oi l consumpti on.
Throttle Body Air Flow - The engi ne control l er
cannot detect a cl ogged or restri cted ai r cl eaner i nl et or
fi l ter el ement.
Evaporative System - The engi ne control l er wi l l
not detect a restri cted, pl ugged or l oaded evaporati ve
purge cani ster.
Vacuum Assist - Leaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces are not moni tored by the engi ne con-
trol l er. However, these coul d resul t i n a MAP sensor
faul t bei ng stored i n the engi ne control l er.
Fig. 22 Diagnostic Connector Location
FUEL SYSTEM 14 - 39
Engine Controller System Ground - The engi ne
control l er cannot determi ne a poor system ground.
However, a faul t code may be generated as a resul t of
thi s condi ti on.
EngineController Connector Engagement - The
engi ne control l er cannot determi ne spread or damaged
connector pi ns. However, a faul t code may be generated
as a resul t of thi s condi ti on.
HI GH AND LOW LI MI TS
The engi ne control l er compares i nput si gnal vol tages from
each i nput devi ce wi th establ i shed hi gh and l ow l i mi ts that
are programmed i nto i t for that devi ce. I f the i nput vol tage i s
not wi thi n speci fi cati ons and other faul t code cri teri a are
met, a faul t code wi l l be stored i n memory. (Other faul t code
cri teri a mi ght i ncl ude engi ne RPM l i mi ts or i nput vol tages
from other sensors or swi tches that must be present before a
faul t condi ti on can be veri fi ed).
FAULT CODE DESCRIPTION
When a faul t code appears, i t i ndi cates that the
Engi ne Control l er has recogni zed an abnormal condi -
ti on i n the system. Faul t codes can be obtai ned from
the Check Engi ne l amp on the I nstrument Panel or
from the Di agnosti c Readout Box I I (DRB I I ). Faul t
codes i ndi cate the resul ts of a fai l ure but do not
i denti fy the fai l ed component di rectl y.
SYSTEMS TEST
Be sure to apply parking brake and/or block
wheels before performing idle check or adjust-
ment, or any engine running tests.
OBTAI NI NG FAULT CODES
(1) ]Connect DRBI I to the di agnosti c connector l ocated i n
the engi ne compartment near the engi ne control l er.
(2) Start the engi ne i f possi bl e, cycl e the transmi ssi on
sel ector and the A/C swi tch i f appl i cabl e. Shut off the engi ne.
(3) Turn the i gni ti on swi tch on, access Read Faul t
Screen. Record al l the faul t messages shown on the
DRB I I . Observe the check engi ne l amp on the i nstru-
ment panel . The l amp shoul d l i ght for 3 seconds then
go out (bul b check).
STATE DISPLAY TEST MODE
The swi tch i nputs used by the engi ne control l er have
onl y two recogni zed states, HI GH and LOW. For thi s
reason, the engi ne control l er cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus an
open ci rcui t, a short ci rcui t, or a defecti ve swi tch. I f the
change i s di spl ayed, i t can be assumed that the enti re
swi tch ci rcui t to the engi ne control l er i s functi onal .
From the state di spl ay screen access ei ther State
Di spl ay I nputs and Outputs or State Di spl ay Sensors.
STATE DI SPLAY I NPUTS AND OUTPUTS
Connect the DRB I I tester to the vehi cl e and access the
State Di spl ay screen. Then access I nputs and Outputs. The
fol l owi ng i s a l i st of the engi ne control system functi ons
accessi bl e through the I nputs and Outputs screen:
Park/Neutral Swi tch (automati c transmi ssi on onl y)
Speed Control Resume
Brake Swi tch
Speed Control On/Off
Speed Control Set
A/C Swi tch Sense
Z2 Vol tage Sense
B1 Vol tage Sense
S/C (Speed Control ) Vent Sol enoi d
S/C (Speed Control ) Vacuum Sol enoi d
PTU Sol enoi d
A/C Cl utch Rel ay
EMR Lamp
Auto Shutdown Rel ay
Purge Sol enoi d
Check Engi ne Lamp
STATE DI SPLAY SENSORS
Connect the DRB I I tester to the vehi cl e and access the
State Di spl ay screen. Then access Sensor Di spl ay. The fol -
l owi ng i s a l i st of the engi ne control system functi ons acces-
si bl e through the Sensor Di spl ay screen:
Battery Temp Sensor
Oxygen Sensor Si gnal
Cool ant Temperature
Cool ant Temp Sensor
Throttl e Posi ti on
Mi ni mum Throttl e
Battery Vol tage
MAP Sensor Readi ng
AI S Motor Posi ti on
Added Adapti ve Fuel
Adapti ve Fuel Factor
Barometri c Pressure
Mi n Ai rfl ow I dl Spd
Engi ne Speed
Faul t #1 Key-On I nfo
Modul e Spark Advance
Speed Control Target
Speed Control Status
Speed Control Swi tch Vol tage
Chargi ng System Goal
Theft Al arm Status
Map Sensor Vol tage
Vehi cl e Speed
Oxygen Sensor State
MAP Gauge Readi ng
Throttl e Openi ng
Total Spark Advance
14 - 40 FUEL SYSTEM
FAULT CODE DESCRI PTI ON
FUEL SYSTEM 14 - 41
CIRCUIT ACTUATION TEST MODE
The ci rcui t actuati on test mode checks for proper
operati on of output ci rcui ts or devi ces whi ch the engi ne
control l er cannot i nternal l y recogni ze. The engi ne con-
trol l er can attempt to acti vate these outputs and al l ow
an observer to veri fy proper operati on. Most of the tests
provi de an audi bl e or vi sual i ndi cati on of devi ce opera-
ti on (cl i ck of rel ay contacts, spray fuel , etc.). Except for
i ntermi ttent condi ti ons, i f a devi ce functi ons properl y
duri ng testi ng, assume the devi ce, i ts associ ated wi r-
i ng, and dri ver ci rcui t worki ng correctl y.
OBTAI NI NG CI RCUI T ACTUATI ON TEST
Connect the DRB I I tester to the vehi cl e and access
the Actuators screen. The fol l owi ng i s a l i st of the
engi ne control system functi ons accessi bl e through
Actuators screens:
FAULT CODE DESCRI PTI ON (CONT)
14 - 42 FUEL SYSTEM
Stop Al l Tests
I gni ti on Coi l #1
Fuel I njector #1
AI S Motor Open/Cl ose
A/C Cl utch Rel ay
Purge Sol enoi d
S/C Servo Sol enoi ds
Al ternator Fi el d
Tachometer Output
PTU Sol enoi d (Automati c Onl y)
Al l Sol enoi ds/Rel ays
ASD Fuel System Test
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(2) Remove ai r cl eaner assembl y. Pl ug the heated ai r
door vacuum hose.
(4) Hook-up ti mi ng check devi ce and tachometer.
set basi c ti mi ng to 12BTDC 2BTDC.
sensor.
(8) Attach Ai r Meteri ng Fi tti ng #6457 (Fi g. 23) to the
i ntake mani fol d PCV ni ppl e.
l east one mi nute.
(10) Usi ng the DRBI I , Access Mi n Ai rfl ow I dl e Spd
i n the sensor read test mode.
I dl e fuel wi l l be provi ded at a set val ue.
out Box I I (DRBI I ).
(12) Check i dl e RPM wi th tachometer. I f i dl e RPM i s
wi thi n the speci fi cati ons l i sted bel ow, then the throttl e
body mi n. ai r fl ow i s set correctl y.
I f i dl e RPM i s not wi thi n speci fi cati on repl ace
throttl e body.
(14) Remove Speci al Tool number 6457 from i ntake
mani fol d PCV ni ppl e. Rei nstal l the PCV val ve hose.
(15) Remove DRBI I .
(16) Rei nstal l ai r cl eaner assembl y. Rei nstal l heated
ai r door vacuum hose.
(17) Di sconnect ti mi ng check devi ce and tachometer.
I GNI TI ON TI MI NG PROCEDURE
Refer to Group 8D I gni ti on System
60-WAY ENGINE CONTROLLER WIRING CONNEC-
TOR
Refer to the engi ne control l er wi ri ng connector di a-
grams (Fi g. 24) for i nformati on regardi ng wi re col ors
and cavi ty numbers. Fig. 23 Air Metering Fitting
FUEL SYSTEM 14 - 43
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14 - 44 FUEL SYSTEM
2.5L SI NGLE POI NT FUEL I NJECTI ONSERVI CE PROCEDURES
INDEX
page page
Automatic Idle Speed (AIS) Motor . . . . . . . . . . . . . 50
Canister Purge Solenoid . . . . . . . . . . . . . . . . . . . . 50
Fuel Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel Lines and Hoses . . . . . . . . . . . . . . . . . . . . . . 1
Fuel System Pressure Release Procedure . . . . . . . 1
Manifold Absolute Pressure Sensor . . . . . . . . . . . 50
Oxygen Sensor (O
2
Sensor) . . . . . . . . . . . . . . . . . 51
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . 49
FUEL LINES AND HOSES
Rel ease fuel system pressure before servi ci ng the
fuel system. Preform the Fuel System Pressure Rel i ef
Procedure.
Do not damage the hose or hose ni ppl e when remov-
i ng the fuel hoses. Al ways use new hose cl amps, of the
correct type, duri ng reassembl y. Ti ghten hose cl amps
to 1 Nm (10 i n. l bs.) torque. Do not use aviation
style clamps on this systemor hose damage may
result.
CAUTION: Before servicing the fuel pump, fuel lines,
fuel filter, throttle body, or fuel injector, the fuel
system pressure must be released.
sure.
(2) Di sconnect i njector wi ri ng harness connector
(Fi g. 1).
(3) Connect a jumper wi re between termi nal Num-
ber 1 of the i njector harness and engi ne ground.
(4) Connect a jumper wi re to the posi ti ve termi nal
Number 2 of the i njector harness and touch the battery
posi ti ve post for no longer than 5 seconds. Thi s
rel eases system pressure.
THROTTLE BODY
CAUTION: The fuel system is under a constant pres-
sure of 270 kPa (39 psi). Perform the Fuel Pressure
Release Procedure before servicing the throttle body.
Al ways reassembl e throttl e body components wi th
new O-ri ngs and seal s where appl i cabl e. Never use
si l i cone l ubri cants on O-ri ngs or seal s, damage may
resul t. Use care when removi ng fuel tubes to prevent
damage to qui ck connect fi tti ngs or tube ends. Refer to
Fuel Hoses, Cl amps, and Qui ck Connect Fi tti ngs i n the
Fuel Del i very Secti on of thi s Group.
REMOVAL
(1) Remove ai r cl eaner (Fi g. 2).
(4) Di sconnect vacuum hoses and el ectri cal connec-
tors (Fi g. 3).
Fig. 1 Injector Harness Connector
Fig. 2 Throttle Body and Air Cleaner Assembly
FUEL SYSTEM 14 - 45
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14 - 46 FUEL SYSTEM
(5) Remove throttl e cabl e. I f equi pped, remove the
speed control and transmi ssi on ki ckdown cabl es.
(6) Remove return spri ng.
(7) Loosen fuel tube cl amp on val ve cover (Fi g. 4).
(8) Wi pe qui ck connect fi tti ngs to remove any di rt.
Remove fuel i ntake and return tubes. Refer to Fuel
Hoses, ClampsandQuick Connect Fittingsin the
Fuel Delivery Section of this Group. Pl ace a shop
towel under the connecti ons to absorb any fuel spi l l ed.
(9) Remove throttl e body mounti ng screws and l i ft
throttl e body from vehi cl e. Remove throttl e body gas-
ket from i ntake mani fol d.
I NSTALLATI ON
(1) Usi ng a new gasket, i nstal l throttl e body and
ti ghten mounti ng screws to 20 Nm (175 i n. l bs.)
torque.
(2) Lubri cate the ends of the fuel suppl y and return
tubes wi th 30 wei ght oi l . Connect fuel l i nes to qui ck
connect fi tti ngs. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in theFuel Delivery Sec-
tion of thisGroup. After the fuel tubes are connected
to the fi tti ngs, pul l on the tubes to ensure that they are
ful l y i nserted and l ocked i nto posi ti on.
(3) Ti ghten the fuel tube cl amp on the val ve cover.
(4) I nstal l return spri ng.
(5) I nstal l throttl e cabl e. I f equi pped, i nstal l ki ck-
down and speed control cabl es.
(6) I nstal l wi ri ng connectors and vacuum hoses.
(7) I nstal l ai r cl eaner.
(8) Reconnect negati ve battery cabl e.
(9) Wi th the i gni ti on key i n ON posi ti on, access the
DRB I I ASD Fuel System Test to pressuri ze the fuel
system. Check for l eaks.
FUEL FITTING
REMOVAL
dure.
(4) Loosen fuel tube cl amp on val ve cover.
(5) Wi pe any di rt from around qui ck connect fi tti ngs.
(Fi g. 5) Pl ace a shop towel under the connecti ons to
catch any spi l l ed fuel . Remove fuel tubes from qui ck
connect fi tti ngs. Refer to Fuel Hoses, Clamps and
tion of this Group.
(6) Remove each fi tti ng from throttl e body and note
i nl et di ameter. Remove copper washers.
I NSTALLATI ON
(1) Repl ace copper washers wi th new washers.
(2) I nstal l fuel fi tti ngs i n proper ports and ti ghten to
(3) Lubri cate ends of the fuel tubes wi th 30 wei ght
oi l . I nsert the tubes i nto the qui ck connect fi tti ngs.
Refer to Fuel Hoses, Clamps and Quick Connect
Fittings in the Fuel Delivery Section of this
Group. After the fuel tubes are connected to the
fi tti ngs, pul l on the tubes to ensure that they are ful l y
i nserted and l ocked i nto posi ti on.
(4) Ti ghten fuel tube cl amp on val ve cover.
(5) Reconnect negati ve battery cabl e.
Fig. 4 Fuel Line Clamp
Fig. 5 Servicing Fuel Fitting
FUEL SYSTEM 14 - 47
(7) Rei nstal l ai r cl eaner assembl y.
The fuel pressure regul ator i s mounted on top of the
throttl e body (Fi g. 6).
REMOVAL
dure.
(4) Remove pressure regul ator mounti ng screws
(Fi g. 6).
WARNING: PLACE A SHOP TOWEL AROUND FUEL
INLET CHAMBER TO CONTAIN ANY FUEL REMAIN-
ING IN THE SYSTEM.
(5) Pul l pressure regul ator from the throttl e body.
(6) Careful l y remove O-ri ng from pressure regul ator
and remove gasket.
I NSTALLATI ON
(1) Pl ace new gasket on pressure regul ator. Care-
ful l y i nstal l new O-ri ng.
(2) Posi ti on pressure regul ator on throttl e body.
Press regul ator i nto pl ace and i nstal l mounti ng screws.
Ti ghten screws to 5 Nm (40 i n. l bs.) torque.
(3) Connect negati ve cabl e to battery.
(5) Rei nstal l ai r cl eaner assembl y.
FUEL INJECTOR
The fuel i njector i s i nstal l ed i n the top of the throttl e
body. The i njector i s covered by a cap.
REMOVAL
dure.
(4) Remove i njector cap hol ddown screw (Torx-head).
(5) Wi th two smal l screwdri vers, l i ft the top off the
i njector usi ng the sl ots provi ded (Fi g. 7).
(6) Usi ng a smal l screwdri ver pl aced i n the hol e i n
the front of the el ectri cal connector, gentl y pry the
i njector from the pod (Fi g. 8).
(7) Ensure the i njector l ower O-ri ng has been re-
moved from the pod (Fi g. 9).
Fig. 6 Servicing Fuel Pressure Regulator
Fig. 7 Removing Injector Cap
Fig. 8 Removing Fuel Injector
14 - 48 FUEL SYSTEM
I NSTALLATI ON
(1) Pl ace a new O-ri ng on the i njector cap. The
i njector wi l l have the upper and l ower O-ri ngs al ready
i nstal l ed (Fi g. 9).
(2) Appl y a l i ght coati ng of cl ean engi ne oi l on the
O-ri ngs.
(3) Pl ace assembl y i n the pod. Al i gn the i njector
wi ri ng termi nal s wi th the i njector cap fastener hol e
(Fi g. 10).
(4) I nstal l i njector cap wi th l ocati ng notch al i gned
wi th the l ocati ng l obe on the i njector (Fi g. 11).
(5) Push down on the cap to ensure a good seal .
(6) Rotate the cap and i njector to l i ne up the attach-
ment hol e (Fi g. 12).
(7) I nstal l i njector cap hol ddown screw (torx-head
screw). Ti ghten screw to 4-5 Nm (35-45 i n. l bs.)
torque.
(10) Rei nstal l the ai r cl eaner assembl y.
THROTTLE POSITION SENSOR
REMOVAL
(2) Remove ai r cl eaner.
(3) Di sconnect harness connector from throttl e posi -
ti on sensor (Fi g. 13).
(4) Remove throttl e posi ti on sensor mounti ng
screws.
(5) Remove throttl e posi ti on sensor from throttl e
shaft.
Fig. 9 Servicing Fuel Injector
Fig. 11 Installing Fuel Injector Cap
Fig. 12 Fuel Injector Installed
Fig. 10 Fuel Injector Installation
FUEL SYSTEM 14 - 49
I NSTALLATI ON
(1) I nstal l throttl e posi ti on sensor to throttl e body,
posi ti on toward the front of the vehi cl e. Ti ghten screws
to 2 Nm (20 i n. l bs.) torque.
(2) Connect harness connector to throttl e posi ti on
sensor.
(3) I nstal l ai r cl eaner.
AUTOMATIC IDLE SPEED (AIS) MOTOR
The automati c i dl e speed (AI S) motor i s mounted on
the throttl e body (Fi g. 14).
REMOVAL
(1) Remove ai r cl eaner.
(3) Di sconnect AI S motor connector.
(4) Remove AI S motor mounti ng screws (Torx head
screws, 25 mm l ong).
(5) Remove AI S from throttl e body housi ng. Ensure
O-ri ng i s wi th AI S (Fi g. 14).
I NSTALLATI ON
(1) Ensure that AI S motor pi ntl e i s i n the retracted
posi ti on. If pintle measures more than 1 inch (25
mm) as shown i n Fi g. 14, i t must be retracted. Use the
DRB I I Actuate Outputs Test, AI S MOTOR
OPEN/CLOSE (battery must be connected for thi s
operati on).
(2) I nstal l new O-ri ng on AI S.
(3) I nstal l AI S motor i nto housi ng, ensuri ng the
O-ri ng i s i n pl ace.
(4) Ti ghten mounti ng screws to 2 Nm (20 i n. l bs.)
torque.
(5) Connect harness el ectri cal connector to AI S mo-
tor.
MANIFOLD ABSOLUTE PRESSURE SENSOR
The MAP sensor i s mounted underhood on the dash
panel (Fi g. 15)
REMOVAL
(1) Remove vacuum hose and el ectri cal connector
from sensor (Fi g. 15).
(2) Remove sensor mounti ng screws. Remove sensor.
Check the vacuum hose and el ectri cal connecti ons to
the sensor.
CANISTER PURGE SOLENOID
from sol enoi d (Fi g. 16).
(2) Depress tab on top of sol enoi d and sl i de the
sol enoi d downward out of mounti ng bracket.
ENGINE CONTROLLER
The engi ne control l er i s mounted underhood on the
dri vers si de i nner fender panel .
(1) Remove ai r cl eaner duct from engi ne control l er.
(2) Remove battery.
Fig. 13 Servicing Throttle Position Sensor
Fig. 14 Servicing Automatic Idle Speed (AIS) Motor
14 - 50 FUEL SYSTEM
17).
(4) Remove el ectri cal connector from engi ne control -
l er. Remove engi ne control l er.
OXYGEN SENSOR (O
2
SENSOR)
The oxygen sensor i s i nstal l ed i n the exhaust mani -
fol d (Fi g. 18).
OXYGEN SENSOR.
(1) Di sconnect oxygen sensor el ectri cal connector
(Fi g. 19).
Fig. 18 Heated Oxygen Sensor
Fig. 19 Oxygen Sensor Electrical Connection
FUEL SYSTEM 14 - 51
When the sensor i s removed, the exhaust mani fol d
I f usi ng ori gi nal sensor, coat the threads wi th Locti te
771-64 anti -sei ze compound or equi val ent. New sen-
sors are packaged wi th compound on the threads and
no addi ti onal compound i s requi red. The sensor must
be ti ghtened to 27 Nm (20 ft. l bs.) torque.
3.0L MULTI -POI NT FUEL I NJECTI ONSYSTEM OPERATI ON
INDEX
page page
Controller Output . . . . . . . . . . . . . . . . . . . . . . . . . 57
Air Conditioning Switch SenseEngine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Ccd Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Distributor Pick-UpEngine Controller Input . . . . . 54
Electronic Automatic Transmission Controller
Emission Maintenance Reminder (EMR) Lamp
Fuel InjectorsEngine Controller Output . . . . . . . . 59
Fuel Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . 62
Manifold Absolute Pressure (MAP) Sensor
Engine Controller Input . . . . . . . . . . . . . . . . . . . 55
Oxygen Sensor (O
2
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Part Throttle Unlock SolenoidEngine Controller
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Throttle Position Sensor (TPS)Engine Controller
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
GENERAL INFORMATION
The 3.0L engi ne uses a sequenti al Mul ti -poi nt El ec-
troni c Fuel I njecti on system (Fi g. 1). The MPI system i s
computer regul ated and provi des preci se ai r/fuel rati os
for al l dri vi ng condi ti ons.
The MPI system i s operated by the Si ngl e Board
manual as the engine controller.
i ng system, i dl e speed and speed control . Vari ous
sensors provi de the i nputs necessary for the engi ne
control l er to correctl y operate these systems. I n addi -
ti on to the sensors, vari ous swi tches al so provi de
i nputs to the engi ne control l er.
si gnal s. The engi ne control l er can adapt i ts program-
mi ng to meet changi ng operati ng condi ti ons.
Fuel i s i njected i nto the i ntake port above the i ntake
val ve i n preci se metered amounts through el ectri cal l y
operated i njectors. The engi ne control l er fi res the i n-
jectors i n a speci fi c sequence. The control l er mai ntai ns
an ai r fuel rati o of 14.7 parts ai r to 1 part fuel by
constantl y adjusti ng i njector pul se wi dth. I njector
pul se wi dth i s the l ength of ti me the i njector i s open.
The engi ne control l er adjusts i njector pul se wi dth by
openi ng and cl osi ng the ground path to the i njector.
Engi ne RPM (speed) and mani fol d absol ute pressure
(ai r densi ty) are the pri mary i nputs that determi ne
SYSTEM DI AGNOSI S
output ci rcui ts. I f a faul t i s found i n a ci rcui t, the
i nformati on i s stored i n the memory. Faul t codes can
i ng the DRB I I to the vehi cl e.
CCD BUS
Bus. The engi ne control l er transmi ts the check en-
14 - 52 FUEL SYSTEM
gi ne l amp On/Off si gnal , engi ne RPM and vehi cl e l oad
data on the CCD Bus.
ENGINE CONTROLLER
Battery Vol tage
Brake Swi tch
Di stri butor Pi ck-up
Oxygen Sensor
SCI Recei ve
Park/Neutral Swi tch (automati c transmi ssi on)
Al ternator Fi el d
Auto Shutdown (ASD) and Fuel Pump Rel ays
Check Engi ne Lamp
El ectri c EGR Transducer (EET)
Fuel I njectors
I gni ti on Coi l
Part Throttl e Unl ock (PTU) Sol enoi d
Fig. 1 Multi-Point Fuel Injection Components
FUEL SYSTEM 14 - 53
Tachometer Output
operati on. The engi ne control l er regul ates the cool i ng
fan, ai r condi ti oni ng and speed control systems. The
control l er changes al ternator charge rate by adjusti ng
the al ternator fi el d.
battery vol tage
exhaust gas content
The Automati c Shut Down (ASD) and Fuel Pump
rel ays are mounted external l y, but turned on and off by
the engi ne control l er through the same ci rcui t.
The di stri butor pi ck-up si gnal i s sent to the engi ne
control l er. I f the engi ne control l er does not recei ve a
di stri butor si gnal wi thi n approxi matel y one second of
engi ne cranki ng, the ASD rel ay and fuel pump rel ay
are deacti vated. When these rel ays are deacti vated,
power i s shut off to the fuel i njector, i gni ti on coi l ,
oxygen sensor heati ng el ement and fuel pump.
power the di stri butor pi ck-up and vehi cl e speed sensor.
The control l er al so provi des a 5.0 vol ts suppl y for the
mani fol d absol ute pressure sensor and throttl e posi -
ti on sensor.
CONTROLLER INPUT
When the ai r condi ti oni ng or defrost swi tch i s i n the
ON posi ti on and the l ow pressure, hi gh pressure and
ambi ent temperature swi tches are cl osed, the control -
l er recei ves an i nput for ai r condi ti oni ng. After recei v-
i ng thi s i nput, the engi ne control l er acti vates the A/C
compressor cl utch by groundi ng the A/C cl utch rel ay.
The engi ne control l er al so adjusts i dl e speed to a
schedul ed RPM to compensate for i ncreased engi ne
l oad.
are bei ng appl i ed. After recei vi ng thi s i nput the engi ne
control l er mai ntai ns i dl e speed to a schedul ed RPM
through control of the Automati c I dl e Speed Motor. The
brake swi tch i s mounted on the brake pedal support
bracket.
TROLLER INPUT
The cool ant temperature sensor i s a vari abl e resi stor
wi th a range of -40F to 265F. The sensor i s i nstal l ed
next to the thermostat housi ng.
The cool ant temperature sensor provi des an i nput
vol tage to the engi ne control l er (Fi g. 3). As cool ant
temperature vari es the cool ant temperature sensors
resi stance changes resul ti ng i n a di fferent i nput vol t-
age to the engi ne control l er.
reached.
Thi s sensor i s al so used for cool i ng fan control .
DISTRIBUTOR PICK-UP ENGINE CONTROLLER
INPUT
The di stri butor pi ck-up provi des two i nputs to the
engi ne control l er. From one i nput the engi ne control l er
determi nes RPM (engi ne speed). From the other i nput
i t deri ves crankshaft posi ti on. The engi ne control l er
regul ates i njector synchroni zati on and adjusts i gni ti on
ti mi ng and engi ne speed based on these i nputs.
The di stri butor pi ck-up contai ns two si gnal genera-
tors. The pi ck-up uni t consi sts of 2 l i ght emi tti ng
di odes (LED), 2 photo di odes, and a separate ti mi ng
di sk. The ti mi ng di sk contai ns two sets of sl ots. Each
set of sl ots rotates between a l i ght emi tti ng di ode and
a photo di ode (Fi g. 4). The i nner set contai ns 6
14 - 54 FUEL SYSTEM
l arge sl ots, one for each cyl i nder. The outer set contai ns
several smal l er sl ots.
The outer set of sl ots on the rotati ng di sk represents
2 degrees of crankshaft rotati on. Up to 1200 engi ne
RPM, the control l er uses the i nput from the outer set of
sl ots to i ncrease i gni ti on ti mi ng accuracy.
The outer set of sl ots contai ns a 10 degree fl at spot.
Thi s area i s not sl otted (Fi g. 5). The fl at spot tel l s the
engi ne control l er that the next pi ston at TDC wi l l be
number 6. The posi ti on of each pi ston i s referenced by
one of the si x i nner sl ots (Fi g. 5).
As each sl ot on the ti mi ng di sk passes between the
di odes, the beam from the l i ght emi tti ng di ode i s
i nterrupted. Thi s creates an al ternati ng vol tage i n
each photo di ode whi ch i s converted i nto on-off pul ses.
The pul ses are the i nput to the engi ne control l er.
Duri ng cranki ng, the control l er cannot determi ne
crankshaft posi ti on unti l the 10 degree fl at spot on the
outer set of sl ots passes through the opti cal uni t. Once
the fl at spot i s detected, the control l er knows pi ston i n
cyl i nder number 6 wi l l be the next pi ston at TDC.
Si nce the di sk rotates at hal f crankshaft speed, i t
may take 2 engi ne revol uti ons duri ng cranki ng for the
control l er to determi ne the posi ti on of pi ston number 6.
For thi s reason the engi ne control l er wi l l energi ze al l
si x i njectors at the same ti me unti l i t senses the
posi ti on of pi ston number 6.
sensor. The Map sensor converts i ntake mani fol d pres-
porti onatel y.
The MAP sensor (Fi g. 6) mounts on a bracket at-
tached to the al ternator bracket. The sensor i s con-
nected to the throttl e body wi th a vacuum hose and to
the engi ne control l er el ectri cal l y.
Fig. 4 Distributor Pick-up
Fig. 5 Inner and Outer Slots of Rotating Disk3.0L
Engine
Fig. 6 Map Sensor
FUEL SYSTEM 14 - 55
OXYGEN SENSOR (O
2
SENSOR) ENGINE CON-
TROLLER INPUT
The O
2
the exhaust gas (Fi g. 7). The engi ne control l er uses thi s
i nformati on to fi ne tune the ai r-fuel rati o by adjusti ng
The O
2
to enter i nto cl osed l oop operati on sooner. Al so, i t al l ow
the system to remai n i n cl osed l oop operati on duri ng
peri ods of extended i dl e.
moni tors the O
2
nores the O
2
val ues and from i nputs of other sensors.
The park/neutral swi tch i s l ocated on the transmi s-
si on housi ng (Fi g. 8 or Fi g. 9). I t provi des an i nput to
the engi ne control l er i ndi cati ng whether the automati c
transmi ssi on i s i n Park, Neutral , or a dri ve gear
sel ecti on. Thi s i nput i s used to determi ne i dl e speed
(varyi ng wi th gear sel ecti on), fuel i njector pul se wi dth,
and i gni ti on ti mi ng advance. The park/neutral swi tch
i s someti mes referred to as the neutral safety swi tch.
CONTROLLER INPUT
Fig. 8 Park Neutral Switch3-Speed Automatic
Transaxle
Fig. 9 Park Neutral Switch4-Speed Electronic Au-
tomatic Transaxle
14 - 56 FUEL SYSTEM
(vol tage) representi ng throttl e bl ade posi ti on. As the
the TPS changes.
engi ne control l er) represents throttl e bl ade posi ti on.
The TPS output vol tage to the control l er vari es from
approxi matel y 0.5 vol t at mi ni mum throttl e openi ng
(i dl e) to 3.5 vol ts at wi de open throttl e. The wi de open
throttl e i nput i s approxi matel y 3 vol ts more than the
mi ni mum throttl e openi ng val ue.
Al ong wi th i nputs from other sensors, the engi ne
control l er uses the TPS i nput to determi ne current
engi ne operati ng condi ti ons. After determi ni ng the
current operati ng condi ti ons, the control l er adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
CONTROLLER INPUT
cl utch rel ay ground ci rcui t (Fi g. 12). The i gni ti on
swi tch suppl i es battery power to the sol enoi d si de of
the rel ay. The A/C fan rel ay i s operated i ndependentl y
of the engi ne control l er by the Fan Cutout swi tch.
When the A/C cl utch rel ay energi zes, battery vol tage
powers the A/C compressor cl utch.
Wi th the engi ne operati ng and the bl ower motor
swi tch i n the On posi ti on, the engi ne control l er cycl es
the ai r condi ti oni ng cl utch on and off when the A/C
swi tch cl oses. When the engi ne control l er senses l ow
i dl e speeds or wi de open throttl e through the throttl e
cl utch engagement.
PUT
FUEL SYSTEM 14 - 57
at the same ti me.
heati ng el ement.
recei ve a di stri butor si gnal when the i gni ti on swi tch i s
i n the Run posi ti on, i t wi l l de-energi ze both rel ays.
l er (Fi g. 13).
CONTROLLER OUTPUT
The i dl e speed stepper motor i s mounted on the
throttl e body and i s control l ed by the engi ne control l er
(Fi g. 10). The engi ne control l er adjusts engi ne i dl e
speed through the AI S to compensate for engi ne l oad or
ambi ent condi ti ons.
provi des ai r for the engi ne at i dl e (the throttl e bl ade i s
cl osed). The AI S motor pi ntl e protrudes i nto the ai r
bypass passage and regul ates ai r fl ow through i t.
posi ti on sensor, engi ne speed sensor (di stri butor
pi ck-up coi l ), cool ant temperature sensor, and vari ous
swi tch operati ons (brake, park/neutral , ai r condi ti on-
i ng). Decel erati on di e out i s al so prevented by i ncreas-
i ng ai rfl ow when the throttl e i s cl osed qui ckl y after a
dri vi ng (speed) condi ti on.
CANISTER PURGE SOLENOID ENGINE CONTROL-
LER OUTPUT
Vacuum for the evaporati ve cani ster i s control l ed by
the Cani ster Purge Sol enoi d (Fi g. 14). The sol enoi d i s
control l ed by the engi ne control l er.
swi tchi ng the ground ci rcui t on and off. The control l er
turns the ground path on and off based on engi ne
operati ng condi ti ons. When energi zed, the sol enoi d
prevents vacuum from reachi ng the evaporati ve cani s-
ter. When not energi zed the sol enoi d al l ows vacuum to
fl ow to the cani ster.
Duri ng warm-up and for a speci fi ed ti me peri od after
hot starts the engi ne control l er grounds the purge
sol enoi d causi ng i t to energi ze. Vacuum does not oper-
ate the evaporati ve cani ster val ve.
sol enoi d when the engi ne reaches a speci fi ed tempera-
ture and the ti me del ay i nterval has occurred. When
the sol enoi d i s de-energi zed, vacuum fl ows to the
cani ster purge val ve. Vapors are purged from the
The purge sol enoi d wi l l al so be energi zed duri ng
certai n i dl e condi ti ons, i n order to update the fuel
del i very cal i brati on.
14 - 58 FUEL SYSTEM
OUTPUT
on/off si gnal to the i nstrument panel through the CCD
Bus. The CCD Bus i s a communi cati ons port. Vari ous
modul es use the CCD Bus to exchange i nformati on.
The check engi ne l amp comes on each ti me the
i gni ti on key i s turned ON and stays on for 3 seconds as
a bul b test. The check engi ne l amp warns the operator
that the engi ne control l er has entered a Li mp-i n mode.
Duri ng Li mp-i n Mode, the control l er attempts to keep
the system operati onal . The check engi ne l amp si gnal s
the need for i mmedi ate servi ce. I n l i mp-i n mode, the
Engi ne control l er compensates for the fai l ure of certai n
components that send i ncorrect si gnal s. The control l er
substi tutes for the i ncorrect si gnal s wi th i nputs from
other sensors.
Lamp.
An Emi ssi on Rel ated System (Cal i forni a vehi cl es)
Chargi ng system
The Check Engi ne Lamp can al so be used to di spl ay
faul t codes. Cycl e the i gni ti on swi tch on, off, on, off, on,
wi thi n fi ve seconds and any faul t codes stored i n the
Engi ne control l er wi l l be di spl ayed. Refer to On Board
Di agnosti cs i n the General Di agnosi sMul ti -Poi nt
Fuel I njecti on, 3.0L Engi ne secti on of thi s Group for
Faul t Code Descri pti ons.
OUTPUT
ELECTRONIC AUTOMATIC TRANSMISSION
CONTROLLER ENGINE CONTROLLER OUTPUT
The El ectroni c Automati c Transmi ssi on Control l er
and the Engi ne Control l er suppl y i nformati on to each
other through the CCD Bus. The i nformati on i ncl udes
engi ne speed and vehi cl e l oad. The engi ne control l er
uses the i nformati on when adjusti ng the fuel and
i gni ti on strategy.
stores i t i nto memory every 8 mi l es. At that ti me, the
engi ne control l er checks for the 60,000, 82,500, and
120,000 mi l eage tri p poi nts. When the current mi l eage
matches one of the above menti oned tri p poi nts, the
EMR l amp on the i nstrument panel i s acti vated.
the key i n the on posi ti on, whi chever occurs fi rst. After
performi ng the requi red mai ntenance, the EMR l amp
must be reset to turn the l amp off.
For more i nformati on, refer to Group 25 or the
appropri ate di agnosti c manual .
FUEL INJECTORS ENGINE CONTROLLER OUTPUT
The fuel i njectors are el ectri cal sol enoi ds (Fi g. 15).
The i njector contai ns a pi ntl e that cl oses off an ori fi ce
at the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and pi ntl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out the
ori fi ce. Because the fuel i s under hi gh pressure, a fi ne
spray i s devel oped i n the shape of a hol l ow cone. The
sprayi ng acti on atomi zes the fuel , addi ng i t to the ai r
enteri ng the combusti on chamber.
Fig. 15 Fuel Injector3.0L Engine
FUEL SYSTEM 14 - 59
The i njectors are posi ti oned i n the i ntake mani fol d
wi th the nozzl e ends di rectl y above the i ntake val ve
port (Fi g. 16).
The fuel i njectors are operated by the engi ne control -
l er. They are energi zed i n a sequenti al order duri ng al l
engi ne operati ng condi ti ons except start up. The con-
trol l er i ni ti al l y energi zes al l i njectors at the same ti me.
Once the engi ne control l er determi nes crankshaft po-
si ti on, i t begi ns energi zi ng the i njectors i n sequence.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay. The engi ne control l er provi des the
ground path for the i njectors. By swi tchi ng the ground
path on and off, the control l er adjusts i njector pul se
wi dth. Pul se wi dth i s the amount of ti me the i njector i s
energi zed. The control l er adjusts i njector pul se wi dth
based on i nputs i t recei ves.
The auto shutdown (ASD) rel ay provi des battery
vol tage to the i gni ti on coi l . The engi ne control l er pro-
vi des a ground contact (ci rcui t) for energi zi ng coi l .
When the control l er breaks the contact, the energy i n
the coi l pri mary transfers to the secondary causi ng the
spark. The engi ne control l er wi l l de-energi ze the ASD
rel ay i f i t does not recei ve an i nput from the di stri butor
pi ck-up. Refer to Auto Shutdown (ASD) Rel ay/Fuel
Pump Rel ayEngi ne Control l er Output i n thi s secti on
for rel ay operati on.
The auto shutdown (ASD) rel ay suppl i es battery
vol tage to the posi ti ve termi nal of the i gni ti on coi l . The
engi ne control l er de-energi zes the ASD rel ay i f i t does
not recei ve an i nput from the di stri butor pi ck-up. Refer
to Auto Shutdown (ASD) Rel ayEngi ne Control l er
Output i n thi s secti on for rel ay operati on.
The i gni ti on coi l i s mounted on a bracket next to the
ai r cl eaner (Fi g. 17).
PART THROTTLE UNLOCK SOLENOID ENGINE
CONTROLLER OUTPUT
Three-speed automati c transaxl es use a part throttl e
unl ock sol enoi d. The engi ne control l er control s the
l ock-up of the torque convertor through the part
throttl e unl ock sol enoi d. The transmi ssi on i s l ocked up
onl y i n di rect dri ve mode. Refer to Group 21 for
transmi ssi on i nformati on.
OUTPUT
reaches a predetermi ned temperature or when the ai r
condi ti oni ng system i s turned on.
LER OUTPUT
MODES OF OPERATION
engi ne control l er adjusts i ts response to the out-
Fig. 16 Fuel Injector Location
14 - 60 FUEL SYSTEM
put devi ces. For exampl e, the engi ne control l er must
cal cul ate a di fferent i njector pul se wi dth and i gni ti on
ti mi ng for i dl e than for wi de open throttl e (WOT).
There are several di fferent modes of operati on that
determi ne how the engi ne control l er responds to the
vari ous i nput si gnal s.
Duri ng OPEN LOOP modes the engi ne control l er
(O
2
modes.
Duri ng CLOSED LOOP modes the engi ne control l er
2
2
the engi ne control l er to achi eve opti mum fuel economy
combi ned wi th l ow emi ssi ons.
The 3.0L sequenti al MPI system has the fol l owi ng
modes of operati on:
I gni ti on swi tch ONZero-RPM
Engi ne start-up
Engi ne warm-up
Crui se (I dl e)
Accel erati on
Decel erati on
wi de open throttl e modes are OPEN LOOP modes. The
accel erati on, decel erati on, and crui se modes, with the
engine at operating temperature are CLOSED
LOOP modes (under most operati ng condi ti ons).
When the mul ti -poi nt fuel i njecti on system i s acti -
occur:
fuel strategy.
ture sensor and throttl e posi ti on sensor i nput. The
engi ne control l er modi fi es fuel strategy based on these
i nputs.
not runni ng (zero rpm), the auto shutdown (ASD) rel ay
and fuel pump rel ay are not energi zed. Therefore
battery vol tage i s not suppl i ed to the fuel pump,
i gni ti on coi l , fuel i njectors or oxygen sensor heati ng
el ement.
I f the engi ne control l er recei ves a di stri butor si gnal ,
i t energi zes the auto shutdown (ASD) rel ay and fuel
pump rel ay. These rel ays suppl y battery vol tage to the
fuel pump, fuel i njectors, i gni ti on coi l , and oxygen
sensor heati ng el ement. I f the engi ne control l er does
not recei ve a di stri butor i nput, the ASD rel ay and fuel
pump rel ay wi l l be de-energi zed after approxi matel y
one second.
The engi ne control l er energi zes al l si x i njectors unti l
i t determi nes crankshaft posi ti on from the di stri butor
pi ck-up si gnal s. The control l er determi nes crankshaft
posi ti on wi thi n 2 engi ne revol uti ons.
Once crankshaft posi ti on i s determi ned, the control -
l er begi ns energi zi ng the i njectors i n sequence. The
control l er adjusts i njector pul se wi dth and control s
i njector synchroni zati on by turni ng the i ndi vi dual
ground paths to the i njectors On and Off.
When the engi ne i dl es wi thi n 64 RPM of i ts target
RPM, the control l er compares current MAP sensor
duri ng the I gni ti on Swi tch On (zero RPM) mode. I f the
control l er does not detect a mi ni mum di fference be-
tween the two val ues, i t sets a MAP faul t i nto memory.
Once the ASD and fuel pump rel ays have been
energi zed, the engi ne control l er:
determi nes i njector pul se wi dth based on cool ant
temperature, mani fol d absol ute pressure (MAP) and
i ni ti ated.
ENGINE WARM-UP MODE
crankshaft posi ti on (di stri butor pi ck-up)
A/C swi tch
battery vol tage
The control l er adjusts i njector pul se wi dth and con-
trol s i njector synchroni zati on by turni ng the i ndi vi dual
regul ati ng the automati c i dl e speed motor and i gni ti on
ti mi ng.
FUEL SYSTEM 14 - 61
CRUISE OR IDLE MODE
When the engi ne i s at operati ng temperature thi s
i s a CLOSED LOOP mode. Duri ng crui si ng speed the
fol l owi ng i nputs are recei ved by the engi ne control -
l er:
battery vol tage
trol s i njector synchroni zati on by turni ng the i ndi vi d-
ual ground paths to the i njectors On and Off.
The engi ne control l er adjusts engi ne i dl e speed and
i gni ti on ti mi ng. The engi ne control l er control s the
exhaust gas.
ACCELERATION MODE
Thi s i s a CLOSED LOOP mode. The engi ne con-
trol l er recogni zes an abrupt i ncrease i n throttl e posi -
ti on or MAP pressure as a demand for i ncreased
engi ne output and vehi cl e accel erati on. The engi ne
control l er i ncreases i njector pul se wi dth i n response
to i ncreased fuel demand.
DECELERATION MODE
Thi s i s a CLOSED LOOP mode. Duri ng decel era-
ti on the fol l owi ng i nputs are recei ved by the engi ne
control l er:
battery vol tage
ti on. Thi s hel ps mai ntai n better control of the ai r-
fuel mi xture (as sensed through the O
2
sensor).
l er grounds the exhaust gas reci rcul ati on (EGR) sol e-
noi d and the evaporati ve purge sol enoi d. When the
sol enoi ds are grounded, EGR and cani ster purge
functi ons stop.
throttl e operati on, the fol l owi ng i nputs are recei ved
by the engi ne control l er:
When the engi ne control l er senses wi de open throt-
tl e condi ti on through the throttl e posi ti on sensor
(TPS) i t wi l l :
Provi de a ground for the el ectri cal EGR transducer
(EET) sol enoi d (Cal i forni a vehi cl es onl y). When the
control l er grounds the sol enoi d, the EGR system
stops operati ng.
De-energi ze the ai r condi ti oni ng rel ay. Thi s di s-
abl es the ai r condi ti oni ng system.
The exhaust gas oxygen content i nput i s not ac-
cepted by the engi ne control l er duri ng wi de open
throttl e operati on. The engi ne control l er wi l l adjust
i njector pul se wi dth to suppl y a predetermi ned
amount of addi ti onal fuel .
When the i gni ti on swi tch i s turned to the OFF po-
si ti on, the fol l owi ng occurs:
THROTTLE BODY
The throttl e body assembl y (Fi g. 18) i s l ocated at
the l eft end of the ai r i ntake pl enum. The throttl e
body houses the throttl e posi ti on sensor and the au-
tomati c i dl e speed motor. Ai r fl ow through the throt-
tl e body i s control l ed by a cabl e operated throttl e
bl ade l ocated i n the base of the throttl e body.
FUEL SUPPLY CIRCUIT
Fuel i s suppl i ed to the fuel rai l by an el ectri c pump
mounted i n the fuel tank. The pump i nl et i s fi tted
wi th a fi l ter to prevent water and other contami -
nants from enteri ng the fuel suppl y ci rcui t.
Fuel pressure i s control l ed to a preset l evel above
i ntake mani fol d pressure by a pressure regul ator.
The pressure regul ator i s mounted on the fuel rai l .
The regul ator uses i ntake mani fol d pressure as a ref-
erence.
cated on the fuel rai l , downstream of the fuel i njec-
tors (Fi g. 19). The regul ator mai ntai ns a constant
328 kPa (47.6 psi ) across the fuel i njector ti p.
The regul ator contai ns a spri ng l oaded rubber di a-
phragm that covers the fuel return port. When the
fuel pump i s operati ng, fuel fl ows past the i njectors
14 - 62 FUEL SYSTEM
i nto the regul ator, and i s restri cted from fl owi ng any
further by the bl ocked return port. When fuel pressure
reaches 328 kPa (47.6 psi ) i t pushes on the di aphragm,
compresses the spri ng, and uncovers the fuel return
port. The di aphragm and spri ng constantl y move from
an open to cl osed posi ti on to keep the fuel pressure
constant.
Fig. 18 Throttle Body
FUEL SYSTEM 14 - 63
3.0L MULTI -POI NT FUEL I NJECTI ONGENERAL DI AGNOSI S
INDEX
page page
60-Way Engine Controller Wiring Connector . . . . . 73
Circuit Actuation Test Mode . . . . . . . . . . . . . . . . . 72
Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . 64
System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FUEL SYSTEM DIAGRAM
The 3.0L MPI system i s managed by the engi ne
control l er. The control l er recei ves i nputs from vari ous
swi tches and sensors (Fi g. 1). Based on these i nputs,
the engi ne control l er adjusts i gni ti on ti mi ng and i dl e
speed through vari ous output devi ces. Refer to the
Mul ti -Poi nt Fuel I njecti on3.0L Engi ne secti on of thi s
group for system and component descri pti ons.
VISUAL INSPECTION
(1) Check for correct spark pl ug cabl e routi ng. En-
sure that the cabl es are compl etel y connected to the
spark pl ugs and di stri butor.
(2) Check i gni ti on coi l el ectri cal connecti ons (Fi g. 2).
the Purge Sol enoi d (Fi g. 3).
(4) Veri fy that vacuum connecti on at Purge Sol enoi d
i s secure and not l eaki ng (Fi g. 3).
the MAP sensor (Fi g. 4).
(6) Check MAP sensor hose at MAP Sensor Assem-
bl y (Fi g. 4), and at Vacuum Connecti on at I ntake
Pl enum Fi tti ng.
14 - 64 FUEL SYSTEM
(7) Check al ternator wi ri ng connecti ons. Ensure the
accessory dri ve bel t i s properl y tensi oned.
(8) Veri fy that hoses are securel y attached to the
vapor cani ster (Fi g. 5).
(9) Veri fy the engi ne ground strap i s attached at the
engi ne and dash panel (Fi g. 6 and 7).
(10) Ensure the heated oxygen sensor connector i s
connected to the harness connector (Fi g. 7).
Fig. 2 Ignition Coil Electrical Connection
Fig. 3 Electrical Connector Canister Purge Solenoid
Fig. 4 Map Sensor Electrical and Vacuum Connec-
tions
Fig. 6 Engine Ground Strap
Fig. 7 Oxygen Sensor Connector
FUEL SYSTEM 14 - 65
(11) Veri fy the di stri butor connector i s connected to
the harness connector (Fi g. 8).
(12) Veri fy the cool ant temperature sensor connector
i s connected to the harness connector (Fi g. 9).
(13) Check vacuum hose connecti on at fuel pressure
regul ator and i ntake pl enum connector (Fi g. 9).
(14) Ensure the harness connector i s securel y at-
tached to each fuel i njector.
(15) Check the oi l pressure sendi ng uni t el ectri cal
connecti on (Fi g. 10).
(16) Check hose connecti ons at throttl e body (Fi g.
11).
(17) Check throttl e body el ectri cal connecti ons (Fi g.
11).
(18) Check PCV hose connecti ons (Fi g. 12).
(19) I f equi pped, check EGR system vacuum hose
connecti ons (Fi g. 13).
(20) I f equi pped, check EGR tube to i ntake pl enum
connecti ons (Fi g. 13).
(21) Check power brake booster and speed control
connecti ons (Fi gs. 14).
Fig. 8 Distributor Connector
Fig. 9 Coolant Temperature Sensor Electrical Con-
nections and Vacuum Hose Connections at the Air
Intake Plenum
Fig. 10 Oil Pressure Sending Unit Electrical Connec-
tion
Fig. 11 Throttle Body Electrical and Vacuum Hose
Connections
Fig. 12 Positive Crankcase Ventilation (PCV) System
14 - 66 FUEL SYSTEM
(22) Check engi ne harness to mai n harness el ectri -
cal connecti ons.
(23) Check al l automati c transmi ssi on el ectri cal con-
necti ons (Fi g. 15 or 16).
(24) Check the vehi cl e di stance sensor el ectri cal
(25) I nspect the engi ne control l er 60-way el ectri cal
connector for damage or spread termi nal s. Veri fy the
60-way connector i s ful l y i nserted i nto the socket of the
engi ne control l er (Fi g. 18). Ensure that wi res are not
stretched or pul l ed out of the connector.
(26) Veri fy that al l el ectri cal connectors are ful l y
i nserted i nto rel ays (Fi g. 19 and Fi g. 20).
(27) Check Battery Cabl e Connecti ons.
(28) Check hose and wi ri ng connecti ons at fuel
pump. Check that wi ri ng connector i s maki ng contact
entered i nto engi ne control l er memory. The cri teri a
Fig. 15 Electronic Automatic Transmission Electrical
Connections
Fig. 13 EGR System Vacuum Hose Connections
Fig. 14 Power Brake Booster and Speed Control
Vacuum Hose Connections
tions
Fig. 17 Distance Sensor Electrical Connector
FUEL SYSTEM 14 - 67
ci rcui t shorts to ground when engi ne RPM i s above
2400 RPM (resul ti ng i n a 0 vol t i nput to the engi ne
control l er) a faul t code wi l l not be entered i nto memory.
Thi s i s because the condi ti on does not occur wi thi n the
speci fi ed RPM range.
18).
or shorted hi gh.
codes to be di spl ayed for other systems.
Fig. 19 ASD, Fuel Pump, Radiator Fan and Starter
Relays
14 - 68 FUEL SYSTEM
For exampl e, a fuel pressure probl em wi l l not regi ster
a faul t di rectl y, but coul d cause a ri ch or l ean condi ti on.
Thi s coul d cause an oxygen sensor faul t to be stored i n
vacuum assi sted fuel pressure regul ator. The engi ne
control l er cannot detect a cl ogged fuel pump i nl et fi l ter,
cl ogged i n-l i ne fuel fi l ter, or a pi nched fuel suppl y or
return l i ne. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng an oxygen sensor faul t to be
stored i n the engi ne control l er.
pl ug cabl es.
sprocket and crankshaft sprocket. The engi ne control -
l er al so cannot detect an i ncorrectl y i ndexed di stri bu-
tor. However, these coul d resul t i n a ri ch or l ean
condi ti on causi ng an oxygen sensor faul t to be stored i n
compressi on.
l er cannot determi ne i f the fuel i njector i s cl ogged, the
pi ntl e i s sti cki ng or the wrong i njector i s i nstal l ed.
fi l ter el ement.
purge cani ster.
thi s condi ti on.
The engi ne control l er compares i nput si gnal vol tages
from each i nput devi ce wi th establ i shed hi gh and l ow
l i mi ts that are programmed i nto i t for that devi ce. I f
the i nput vol tage i s not wi thi n speci fi cati ons, and other
faul t code cri teri a are met, a faul t code wi l l be stored i n
memory. (Other faul t code cri teri a mi ght i ncl ude en-
gi ne RPM l i mi ts or i nput vol tages from other sensors or
swi tches that must be present before a faul t condi ti on
can be veri fi ed).
When a faul t code appears, i t i ndi cates that the
Engi ne Control l er has recogni zed an abnormal condi -
ti on i n the system. Faul t codes can be obtai ned from
the Check Engi ne l amp on the I nstrument Panel or
from the Di agnosti c Readout Box I I (DRBI I ). Faul t
codes i ndi cate the resul ts of a fai l ure but do not
i denti fy the fai l ed component di rectl y.
SYSTEM TESTS
Apply parking brake and/or block wheels be-
foreperformingidlecheck or adjustment, or any
engine running tests.
(1) Connect DRBI I to the di agnosti c connector l o-
cated i n the engi ne compartment near the engi ne
control l er.
(2) Start the engi ne i f possi bl e, cycl e the transmi s-
si on sel ector and the A/C swi tch i f appl i cabl e. Shut off
the engi ne.
DRBI I . Observe the check engi ne l amp on the i nstru-
Fault codeerasure;accesserasefault codedata
FUEL SYSTEM 14 - 69
14 - 70 FUEL SYSTEM
Connect the DRB I I tester to the vehi cl e. Access the
State Di spl ay screen. Then access I nputs and Outputs.
The fol l owi ng i s a l i st of the engi ne control system
functi ons accessi bl e through the I nputs and Outputs
screen.
FUEL SYSTEM 14 - 71
Park/Neutral Swi tch
Brake Swi tch
Speed Control Set
A/C Swi tch Sense
Z2 Vol tage Sense
S/C Vent Sol enoi d
S/C Vacuum Sol enoi d
A/C Cl utch Rel ay
EMR Lamp
EGR Sol enoi d
Purge Sol enoi d
PTU Sol enoi d
Check Engi ne Lamp
the State Di spl ay screen. Then access Sensor Di spl ay.
functi ons accessi bl e through the Sensor Di spl ay
screen:
Battery Temp Sensor
Cool ant Temperature
Mi ni mum Throttl e
Battery Vol tage
MAP Sensor Readi ng
Mi n Ai rfl ow I dl e Speed
Engi ne Speed
Faul t #2 Key-on I nfo
Theft Al arm Status
Map Sensor Vol tage
Vehi cl e Speed
Oxygen Sensor State
MAP Gauge Readi ng
Throttl e Openi ng
Total Spark Advance
Actuators screens:
Stop Al l Tests
Fuel I njector #1
Fuel I njector #2
Fuel I njector #3
Fuel I njector #4
Fuel I njector #5
Fuel I njector #6
A/C Cl utch Rel ay
Fuel Pump Rel ay
Purge Sol enoi d
S/C Serv Sol enoi ds
Al ternator Fi el d
PROCEDURE
(3) Hook-up the ti mi ng check devi ce and tachometer.
set basi c ti mi ng to 12 BTDC 2 BTDC.
sensor wi re.
(6) Di sconnect the PCV val ve hose from the PCV
val ve (Fi g. 21).
(7) Pl ug the PCV val ve ni ppl e.
(8) Di sconnect the i dl e purge hose from the engi ne
vacuum harness tee (Fi g. 22).
(9) I nstal l Ai r Meteri ng Fi tti ng #6457 (0.125 i nch
ori fi ce) i n the i ntake mani fol d mounted i dl e purge hose
(Fi g. 23).
l east one mi nute.
(12) Usi ng the DRBI I , access Mi n. Ai rfl ow I dl e
Speed.
14 - 72 FUEL SYSTEM
out Box I I (DRB I I )
(14) Check i dl e RPM wi th tachometer, i f i dl e RPM i s
wi thi n the bel ow speci fi cati on then the throttl e body
mi n. ai r fl ow i s set correctl y.
i ntake mani fol d i dl e purge hose. Reconnect the hose to
the engi ne vacuum harness tee.
(18) Remove the pl ug from the PCV val ve. Reconnect
the PCV val ve hose to the PCV val ve.
(19) Di sconnect the DRB I I .
I GNI TI ON TI MI NG PROCEDURE
Refer to Group 8D I gni ti on System.
TOR
gram (Fi g. 24) for i nformati on regardi ng wi re col ors
and cavi ty numbers.
Fig. 21 3.0L PCV Valve
Fig. 22 3.0L Idle Purge Hose
Fig. 23 Air Metering Fitting 6457
FUEL SYSTEM 14 - 73
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14 - 74 FUEL SYSTEM
3.0L MULTI -POI NT FUEL I NJECTI ONSERVI CE PROCEDURES
INDEX
page page
Automatic Idle Speed (AIS) Motor . . . . . . . . . . . . . 76
Canister Purge Solenoid Service . . . . . . . . . . . . . 80
Fuel Injector Rail Assembly . . . . . . . . . . . . . . . . . 77
Fuel Injector Rail Assembly . . . . . . . . . . . . . . . . . 78
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fuel Pressure Regulator Service . . . . . . . . . . . . . 78
Fuel System Pressure Release Procedure . . . . . . 76
2
Sensor) . . . . . . . . . . . 80
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Throttle Body Service . . . . . . . . . . . . . . . . . . . . . . 75
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . 76
THROTTLE BODY SERVICE
(2) Remove ai r cl eaner hose cl amp to throttl e body
and remove hose. (Fi g. 1)
(3) Remove throttl e cabl e and transaxl e l i nkage.
(4) Di sconnect automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) wi ri ng connectors.
(5) Di sconnect vacuum hoses from throttl e body.
(6) Remove throttl e body to i ntake mani fol d attach-
i ng nuts. Remove engi ne harness wi ri ng bracket.
(7) Remove throttl e body and gasket.
(8) Reverse the above procedures for i nstal l ati on.
Ti ghten throttl e body mounti ng nuts to 25.4 Nm (225
i n. l bs.) torque.
THROTTLE BODY
When servi ci ng body components, al ways assembl e
components wi th new O-ri ngs and seal s where appl i -
cabl e (Fi g. 2). Never use l ubri cants on O-ri ngs or seal s,
damage may resul t. I f assembl y of component i s di ffi -
cul t, use water to ai d assembl y. Use care when remov-
i ng hoses to prevent damage to hose or hose ni ppl e.
Fig. 1 Throttle Body Assembly
Fig. 2 Throttle Body 3.0L
FUEL SYSTEM 14 - 75
The 3.0L MPI fuel system is under a constant
pressure of approximately 330 kPa (48 psi). Be-
foreservicingthefuel pump, fuel lines, fuel filter,
throttle body or fuel injectors, the fuel system
pressure must be released.
sure.
harness (Fi g. 3).
ber 1 of one i njector harness and engi ne ground.
posi ti ve post for no l onger than 5 seconds. Thi s rel eases
system pressure.
REMOVAL
(2) Remove el ectri cal connector from throttl e posi -
ti on sensor.
(3) Remove throttl e posi ti on sensor mounti ng screws
(Fi g. 4).
(4) Li ft throttl e posi ti on sensor off throttl e shaft.
I NSTALLATI ON
(1) I nstal l throttl e posi ti on sensor on throttl e shaft.
I nstal l mounti ng screws. Ti ghten screw to 2 Nm (17
i n. l bs.) torque.
(2) Connect el ectri cal connector to throttl e posi ti on
sensor.
REMOVAL
(2) Remove el ectri cal connector from automati c i dl e
speed (AI S) motor.
(3) Remove AI S motor mounti ng screws (Fi g. 5).
(4) Remove AI S motor from throttl e body. Ensure the
O-ri ng i s removed wi th the AI S motor.
I NSTALLATI ON
(1) The new AI S motor has a new O-ri ng i nstal l ed on
i t. I f pi ntl e measures more than 1 i nch (25 mm) i t must
be retracted. Use the DRB I I AI S Motor Open/Cl ose
Test to retract the pi ntl e (battery must be connected.)
(2) Careful l y pl ace AI S motor i nto throttl e body.
(3) I nstal l mounti ng screws. Ti ghten screws to 2
(4) Connect el ectri cal connector to AI S motor.
Fig. 5 Servicing Automatic Idle Speed Motor
14 - 76 FUEL SYSTEM
FUEL INJECTOR RAIL ASSEMBLY
REMOVAL
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER A
CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE RELEASE
PROCEDURE BEFORE SERVICING THE FUEL RAIL
OR FUEL INJECTORS.
(1) Perform the Fuel Pressure Rel ease Procedure.
(3) Remove ai r cl eaner to throttl e body hose.
(4) Remove throttl e cabl e (Fi g. 6).
(5) Di sconnect el ectri cal connectors from the auto-
mati c i dl e speed (AI S) motor and throttl e posi ti on
sensor (TPS).
(6) Remove vacuum hose harness from throttl e body
(Fi g. 7).
(7) Remove el ectri cal connector from the cool ant
temperature sensor (Fi g. 8).
(8) Remove vacuum connecti ons from ai r i ntake pl e-
num vacuum connector (Fi g. 8).
(9) Remove fuel hoses from fuel rai l (Fi g. 8).
(10) Remove ai r i ntake pl enum to i ntake mani fol d
mounti ng fasteners (Fi g. 9).
(11) Remove i gni ti on coi l .
(12) Remove ai r i ntake pl enum (Fi g. 10).
Fig. 6 Throttle Cable Attachment
Fig. 7 Electrical and Vacuum Connection to Throttle
Body
nections
Fig. 9 Air Intake Plenum to Intake Manifold Attach-
ing Fasteners
Fig. 10 Removing Air Intake Plenum
FUEL SYSTEM 14 - 77
(13) Cover i ntake mani fol d whi l e servi ci ng i njector
fuel rai l (Fi g. 11).
(14) Remove vacuum hoses from fuel rai l (Fi g. 11).
(15) Di sconnect fuel i njector wi ri ng harness from
engi ne wi ri ng harness (Fi g. 12).
CAUTION: Do not damage the injector O-Rings when
removing the injectors and fuel rail assembly.
(16) Remove fuel rai l mounti ng bol ts. Li ft fuel rai l
assembl y off of i ntake mani fol d.
I NSTALLATI ON
(1) Ensure i njectors are seated i nto the recei ver cup
of fuel rai l wi th l ock ri ng i n pl ace.
(2) Make sure the i njector hol es i n the mani fol d are
cl ean.
(3) To ease i nstal l ati on, l ubri cate i njector O-ri ng
wi th a drop of cl ean engi ne oi l .
(4) Put the ti p of each i njector i nto thei r ports. Push
the assembl y i nto pl ace unti l the i njectors are seated i n
the ports.
(5) I nstal l fuel rai l attachi ng bol ts. Ti ghten bol ts to
(6) I nstal l fuel suppl y and return tube hol ddown bol t
and the vacuum crossover tube hol ddown bol t. Ti ghten
bol ts to 10 Nm (95 i n. l bs.) torque.
(7) Connect fuel i njector wi ri ng harness to engi ne
wi ri ng harness.
(8) Connect vacuum harness to fuel rai l assembl y.
(9) Remove coveri ng from l ower i ntake mani fol d and
cl ean surface.
(10) Pl ace i ntake mani fol d gaskets with beaded
sealer up on l ower mani fol d. Put ai r i ntake i n pl ace.
I nstal l i gni ti on coi l . I nstal l attachi ng fasteners and
ti ghten to 13 Nm (115 i n. l bs.) torque.
(11) Connect fuel l i nes to fuel rai l . Ti ghten hose
cl amps to 1 Nm (10 i n. l bs.) torque.
(12) Connect vacuum harness to ai r i ntake pl enum
and fuel pressure regul ator.
(13) Connect cool ant temperature sensor el ectri cal
connector to sensor.
(14) Connect PCV and brake booster suppl y hose to
i ntake pl enum.
(15) Connect automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) el ectri cal connectors.
(16) Connect vacuum vapor harness to throttl e body.
(17) I nstal l throttl e cabl e.
(18) I nstal l ai r i nl et hose assembl y.
FUEL PRESSURE REGULATOR SERVICE
REMOVAL
PROCEDURE BEFORE SERVICING THE FUEL PRES-
SURE REGULATOR.
(3) Loosen fuel return hose cl amp and remove fuel
return hose from ni ppl e.
(4) Remove vacuum hose from fuel pressure regul a-
tor. (Fi g. 13)
(5) Remove screw hol di ng fuel return tube to the
i ntake mani fol d.
(6) Remove fuel pressure regul ator screws. Remove
fuel pressure regul ator from engi ne.
Fig. 11 Vacuum Connections at the Fuel Rail
Fig. 12 Fuel Injector Wiring Harness
14 - 78 FUEL SYSTEM
I NSTALLATI ON
(1) Lubri cate O-ri ng on fuel pressure regul ator wi th
cl ean 30 wei ght engi ne oi l .
(2) I nstal l fuel pressure regul ator i nto fuel rai l .
Ti ghten screws to 10 Nm (90 i n. l bs.) torque.
(3) I nstal l screw hol di ng fuel return tube cl amp i n
pl ace. Ti ghten screw to 10 Nm (95 i n. l bs.) torque.
(4) Connect vacuum hose to fuel pressure regul ator.
(5) Connect fuel return hose to fuel return tube.
Ti ghten hose cl amp to 1 Nm ( 10 i n. l bs.) torque.
FUEL INJECTORS
PROCEDURE BEFORE SERVICING THE FUEL INJEC-
TORS.
REMOVAL
The fuel rai l must be removed fi rst to servi ce the
i njectors. Refer to Fuel I njector Rai l Assembl y Removal
i n thi s secti on.
(3) Label each i njector connector wi th i ts cyl i nder
number. Di sconnect el ectri cal connector from i njector.
(4) Posi ti on fuel rai l assembl y so that the fuel i njec-
tors are easi l y accessi bl e.
(5) Remove i njector cl i p from fuel rai l and i njector
(Fi g. 14).
(6) Pul l i njector strai ght out of fuel rai l recei ver cup
(Fi g. 15).
(7) Check i njector O-ri ng for damage. I f O-ri ng i s
damaged, i t must be repl aced. I f i njector i s to be
reused, a protecti ve cap must be i nstal l ed on the
i njector ti p to prevent damage.
(8) Repeat procedure for remai ni ng i njectors.
I NSTALLATI ON
(1) Before i nstal l i ng an i njector, the rubber O-ri ng
must be l ubri cated wi th a drop of cl ean engi ne oi l to ai d
i n i nstal l ati on.
Fig. 14 Fuel Injector and Rail
Fig. 15 Servicing Fuel Injector
FUEL SYSTEM 14 - 79
(2) Bei ng careful not to damage O-ri ng, i nstal l i njec-
tor nozzl e end i nto fuel rai l recei ver cap (Fi g. 15).
(3) I nstal l i njector cl i p by sl i di ng open end i nto top
slot of the i njector. The edge of the recei ver cup wi l l
sl i de i nto the si de sl ots of cl i p (Fi g. 15).
(4) Repeat steps for remai ni ng i njectors.
(5) I nstal l fuel rai l assembl y. Refer to Fuel Rai l
Assembl y I nstal l ati on i n thi s secti on.
(6) Connect el ectri cal connectors to i njectors i n cor-
rect order.
(1) Remove vacuum hose and mounti ng screws from
mani fol d absol ute pressure (MAP) sensor (Fi g. 16).
(2) Di sconnect el ectri cal connector from sensor. Re-
move sensor.
CANISTER PURGE SOLENOID SERVICE
(3) Reverse above procedure to i nstal l .
ENGINE CONTROLLER
(2) Di sconnect negati ve cabl e from battery. Di scon-
nect posi ti ve cabl e from battery.
(3) Remove battery hol ddown. Remove battery.
18).
(5) Remove the el ectri cal connector from engi ne con-
trol l er. Remove engi ne control l er.
2
SENSOR)
fol d (Fi g. 19).
CAUTION: Do not pull on the oxygen sensor wires
14 - 80 FUEL SYSTEM
OXYGEN SENSOR.
(1) Di sconnect oxygen sensor el ectri cal connector.
I f usi ng ori gi nal sensor, coat the threads wi th Locti te
771-64 anti -sei ze compound or equi val ent. New sen-
sors are packaged wi th compound on the threads and
no addi ti onal compound i s requi red. The sensor must
be ti ghtened to 27 Nm (20 ft. l bs.) torque.
3.3L MULTI -POI NT FUEL I NJECTI ONSYSTEM OPERATI ON
INDEX
page page
Controller Output . . . . . . . . . . . . . . . . . . . . . . . 87
Air Conditioning Switch SenseEngine
Camshaft SensorEngine Controller Input . . . . . . 84
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Ccd Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Coolant Temperature SensorEngine
Crankshaft SensorEngine Controller Input . . . . . 84
Electronic Automatic Transaxle ControllerEngine Con-
troller Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Emission Maintenance Reminder (EMR)
LampEngine Controller Output . . . . . . . . . . . . 89
Fuel Injectors and Fuel Rail Assembly . . . . . . . . . 92
Fuel InjectorsEngine Controller Output . . . . . . . . 89
Fuel Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . 92
Manifold Absolute Pressure (MAP) SensorEngine
Oxygen Sensor (O
2
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Throttle Position Sensor (TPS)Engine
GENERAL INFORMATION
The 3.3L engi ne uses a sequenti al Mul ti -poi nt El ec-
troni c Fuel I njecti on system (Fi g. 1). The MPI system i s
computer regul ated and provi des preci se ai r/fuel rati os
for al l dri vi ng condi ti ons.
The MPI system i s operated by the Si ngl e Board
manual as the engine controller.
i ng system, i dl e speed and speed control .
Fig. 19 Heated Oxygen Sensor
FUEL SYSTEM 14 - 81
Vari ous sensors provi de the i nputs necessary for the
engi ne control l er to correctl y operate these systems. I n
addi ti on to the sensors, vari ous swi tches al so provi de
i nputs to the engi ne control l er.
si gnal s. The engi ne control l er can adapt i ts program-
mi ng to meet changi ng operati ng condi ti ons.
Fuel i s i njected i nto the i ntake port above the i ntake
val ve i n preci se metered amounts through el ectri cal l y
operated i njectors. The engi ne control l er fi res the i n-
jectors i n a speci fi c sequence. The control l er mai ntai ns
an ai r fuel rati o of 14.7 parts ai r to 1 part fuel by
constantl y adjusti ng i njector pul se wi dth. I njector
pul se wi dth i s the l ength of ti me the i njector i s open.
The engi ne control l er adjusts i njector pul se wi dth by
openi ng and cl osi ng the ground path to the i njector.
Engi ne RPM (speed) and mani fol d absol ute pressure
(ai r densi ty) are the pri mary i nputs that determi ne
SYSTEM DI AGNOSI S
output ci rcui ts. I f a faul t i s found i n a ci rcui t, the
i nformati on i s stored i n the memory. Faul t codes can
i ng the DRB I I to the vehi cl e.
CCD BUS
Bus. The engi ne control l er transmi ts the check engi ne
l amp On/Off si gnal , engi ne RPM and vehi cl e l oad
i nformati on on the CCD Bus.
ENGINE CONTROLLER
Battery Vol tage
Brake Swi tch
Camshaft Sensor
Crankshaft Sensor
Oxygen Sensor
SCI Recei ve
14 - 82 FUEL SYSTEM
Transmi ssi on Park/Neutral Swi tch (automati c
transmi ssi on)
Al ternator Fi el d
Auto Shutdown (ASD) and Fuel Pump Rel ays
Check Engi ne Lamp
Fuel I njectors
I gni ti on Coi l
Tachometer Output
operati on. The engi ne control l er regul ates the cool i ng
fan, ai r condi ti oni ng and speed control systems. The
control l er changes al ternator charge rate by adjusti ng
the al ternator fi el d.
battery vol tage
exhaust gas content (oxygen sensor)
engi ne speed (crankshaft sensor)
transmi ssi on gear sel ecti on (park/neutral swi tch)
The engi ne control l er al so adjusts engi ne i dl e speed
through the automati c i dl e speed (AI S) motor based on
the fol l owi ng i nputs.
ai r condi ti oni ng sel ect swi tch
brake swi tch
transmi ssi on gear sel ecti on (park/neutral swi tch)
vehi cl e di stance (speed)
The auto shutdown (ASD) and fuel pump rel ays are
mounted external l y, but turned on and off by the
engi ne control l er through the same ci rcui t.
The i gni ti on pi ck-up si gnal s, (camshaft and crank-
shaft) are sent to the engi ne control l er. I f the engi ne
control l er does not recei ve both si gnal s wi thi n approxi -
matel y one second of engi ne cranki ng, i t deacti vates
the ASD rel ay and fuel pump rel ay. When these rel ays
are deacti vated, power i s shut off to the fuel i njector,
i gni ti on coi l , oxygen sensor heati ng el ement and fuel
pump.
power the camshaft sensor, crankshaft sensor and
vehi cl e speed sensor. The control l er al so provi des a 5.0
vol ts suppl y for the mani fol d absol ute pressure sensor
and throttl e posi ti on sensor.
Beginning in this model year, the 3.3L engine
uses sequential fuel injection. The engine con-
troller for this model year differs fromprevious
model years. Do not use a previous model year
engine controller to test the system.
CONTROLLER INPUT
When the ai r condi ti oni ng or defrost swi tch i s put i n
the ON posi ti on and the l ow pressure and hi gh pres-
sure swi tches are cl osed, the engi ne control l er recei ves
an i nput for ai r condi ti oni ng. After recei vi ng thi s i nput,
the engi ne control l er acti vates the A/C compressor
cl utch by groundi ng the A/C cl utch rel ay. The engi ne
control l er al so adjusts i dl e speed to a schedul ed RPM to
compensate for i ncreased engi ne l oad.
are bei ng appl i ed. After recei vi ng thi s i nput
FUEL SYSTEM 14 - 83
the engi ne control l er mai ntai ns i dl e speed to a sched-
ul ed RPM through control of the Automati c I dl e Speed
Motor. The brake swi tch i s mounted on the brake pedal
support bracket.
CAMSHAFT SENSOR ENGINE CONTROLLER IN-
PUT
Fuel i njecti on synchroni zati on and cyl i nder i denti fi -
cati on i s provi ded through the camshaft reference
sensor (Fi g. 3). The sensor generates pul ses that are
the i nput sent to the engi ne control l er. The engi ne
control l er i nterprets the camshaft sensor i nput al ong
wi th the crankshaft sensor i nput to determi ne crank-
shaft posi ti on. The engi ne control l er uses crankshaft
posi ti on reference to determi ne i njector sequence and
The camshaft sensor senses when a sl ot i n the
camshaft gear passes beneath i t (Fi g. 4). When a sl ot i s
sensed, the i nput vol tage from the sensor to the engi ne
control l er swi tches from hi gh (5 vol ts) to l ow (l ess than
.3 vol ts). As the sl ot or wi ndow passes, the i nput
vol tage i s swi tched back to hi gh (5 vol ts).
The camshaft sensor i s mounted to the top of the
ti mi ng case cover (Fi g. 5). The bottom of the sensor i s
posi ti oned above the camshaft sprocket. Thedistance
between the bottom of sensor and the camshaft
sprocket is critical to the operation of the sys-
tem. Whenservicingthecamshaft sensor, refer to
the Multi-Point Fuel Injection Service
Procedures3.3L Engine section in this Group.
TROLLER INPUT
The cool ant temperature sensor i s a vari abl e resi stor
wi th a range of -40F to 265F. The sensor i s i nstal l ed
next to the thermostat housi ng (Fi g. 6).
The cool ant temperature sensor provi des an i nput
vol tage to the engi ne control l er. As cool ant tempera-
ture vari es, the sensor resi stance changes resul ti ng i n
a di fferent i nput vol tage to the engi ne control l er.
reached.
The cool ant sensor i s al so used for cool i ng fan control .
CRANKSHAFT SENSOR ENGINE CONTROLLER
INPUT
The crankshaft sensor (Fi g. 7) senses sl ots cut i nto
the transmi ssi on dri vepl ate extensi on. There are a 3
sets of sl ots. Each set contai ns 4 sl ots, for a total of 12
sl ots (Fi g. 8). Basi c ti mi ng i s set by the posi ti on of the
l ast sl ot i n each group. Once the engi ne control l er
senses the l ast sl ot, i t determi nes crankshaft posi ti on
(whi ch pi ston wi l l next be at TDC) from the camshaft
sensor i nput. I t may take the control l er one engi ne
revol uti on to determi ne crankshaft posi ti on.
The engi ne control l er uses crankshaft posi ti on refer-
ence to determi ne i njector sequence and i gni ti on
Fig. 4 Camshaft Gear
Fig. 5 Camshaft Sensor Location
14 - 84 FUEL SYSTEM
ti mi ng. Once crankshaft posi ti on has been determi ned,
the engi ne control l er begi ns energi zi ng the i njectors i n
sequence.
The crankshaft sensor i s l ocated i n the transmi ssi on
housi ng, above the vehi cl e di stance sensor (Fi g. 9). The
bottom of the sensor i s posi ti oned next to the dri ve
pl ate. Thedistancebetween thebottomof sensor
and thedriveplateis critical to theoperation of
the system. When servicing the crankshaft sen-
sor, refer to the Multi-Point Fuel Injection Ser-
vice Procedures3.3L Engine section in this
Group.
sensor. The Map sensor converts i ntake mani fol d pres-
porti onatel y.
Fig. 7 Crankshaft Sensor
Fig. 8 Timing Slots
Fig. 9 Crankshaft Sensor Location
FUEL SYSTEM 14 - 85
The MAP sensor (Fi g. 10) mounts to the si de of the
i ntake mani fol d, bel ow the posi ti ve crankcase venti l a-
ti on (PCV) val ve. The sensor connects el ectri cal l y to
OXYGEN SENSOR (O
2
SENSOR) ENGINE CON-
TROLLER INPUT
The O
2
the exhaust gas (Fi g. 11). The engi ne control l er uses
thi s i nformati on to fi ne tune the ai r-fuel rati o by
adjusti ng i njector pul se wi dth.
The O
2
to enter i nto cl osed l oop operati on sooner. Al so, i t
al l ows the system to remai n i n cl osed l oop operati on
duri ng peri ods of extended i dl e.
moni tors the O
2
nores the O
2
val ues and i nputs from other sensors.
The park/neutral swi tch i s l ocated on the transmi s-
si on housi ng (Fi g. 12). I t provi des an i nput to the
engi ne control l er i ndi cati ng whether the automati c
transmi ssi on i s i n Park, Neutral , or a dri ve gear
sel ecti on. Thi s i nput i s used to determi ne i dl e speed
(varyi ng wi th gear sel ecti on), fuel i njector pul se wi dth,
and i gni ti on ti mi ng advance. The park neutral swi tch
i s someti mes referred to as the neutral safety swi tch.
CONTROLLER INPUT
(vol tage) representi ng throttl e bl ade posi ti on. As the
the TPS changes.
Fig. 10 Map Sensor
14 - 86 FUEL SYSTEM
engi ne control l er) represents the throttl e bl ade posi -
ti on. The TPS output vol tage to the control l er vari es
from approxi matel y 0.5 vol t at mi ni mum throttl e open-
i ng (i dl e) to 4 vol ts at wi de open throttl e. Al ong wi th
i nputs from other sensors, the engi ne control l er uses
the TPS i nput to determi ne current engi ne operati ng
condi ti ons and adjust fuel i njector pul se wi dth and
CONTROLLER INPUT
cl utch rel ay ground ci rcui t (Fi g. 15). The i gni ti on
swi tch suppl i es battery vol tage to the sol enoi d si de of
the rel ay. The A/C fan rel ay i s operated i ndependentl y
of the engi ne control l er by the Fan Cutout swi tch.
When the A/C cl utch rel ay energi zes, battery vol tage
powers the A/C compressor cl utch.
Wi th the engi ne operati ng and the bl ower motor
swi tch i n the On posi ti on, the engi ne control l er cycl es
the ai r condi ti oni ng cl utch on and off when the A/C
swi tch cl oses. When the engi ne control l er senses l ow
i dl e speeds or wi de open throttl e through the throttl e
cl utch engagement.
PUT
Fig. 12 Park Neutral Switch4-Speed Electronic Au-
tomatic Transaxle
FUEL SYSTEM 14 - 87
at the same ti me.
heati ng el ement.
posi ti on, the engi ne control l er moni tors the crankshaft
and camshaft sensor si gnal s to determi ne engi ne speed
and i gni ti on ti mi ng (coi l dwel l ). I f the engi ne control l er
does not recei ve the crankshaft and camshaft si gnal s
when the i gni ti on swi tch i s i n the Run posi ti on, i t wi l l
de-energi ze both rel ays. When the rel ays are de-
energi zed, battery vol tage i s not suppl i ed to the fuel
i njector, i gni ti on coi l , fuel pump and oxygen sensor
heati ng el ement.
l er (Fi g. 16).
CONTROLLER OUTPUT
The i dl e speed stepper (AI S) motor i s mounted on the
throttl e body. The engi ne control l er operates the AI S
motor (Fi g. 13). The engi ne control l er adjusts engi ne
i dl e speed through the AI S to compensate for engi ne
l oad or ambi ent condi ti ons.
provi des ai r for the engi ne at i dl e (the throttl e bl ade i s
cl osed). The AI S motor pi ntl e protrudes i nto the ai r
bypass passage and regul ates ai r fl ow through i t.
posi ti on sensor, speed sensor (di stri butor pi ck-up coi l ),
cool ant temperature sensor, and vari ous swi tch opera-
ti ons (brake, park/neutral , ai r condi ti oni ng). Decel era-
ti on di e out i s al so prevented by i ncreasi ng ai rfl ow
when the throttl e i s cl osed qui ckl y after a dri vi ng
(speed) condi ti on.
CANISTER PURGE SOLENOID ENGINE CONTROL-
LER OUTPUT
Vacuum for the Evaporati ve Cani ster i s control l ed by
the Cani ster Purge Sol enoi d (Fi g. 17). The sol enoi d i s
control l ed by the engi ne control l er.
swi tchi ng the ground ci rcui t on and off based on en-
Fig. 16 Auto Shutdown Relay and Fuel Pump Relay
14 - 88 FUEL SYSTEM
gi ne operati ng condi ti ons. When energi zed, the sol e-
noi d prevents vacuum from reachi ng the evaporati ve
cani ster. When not energi zed the sol enoi d al l ows
vacuum to fl ow to the cani ster.
Duri ng warm-up and for a speci fi ed ti me peri od after
hot starts, the engi ne control l er grounds the purge
sol enoi d. When grounded, the sol enoi d i s energi zed and
vacuum does not operate the evaporati ve cani ster
val ve.
sol enoi d when the engi ne reaches a speci fi ed tempera-
ture and the ti me del ay i nterval has occurred. When
the sol enoi d i s de-energi zed, vacuum fl ows to the
cani ster purge val ve. Vapors are purged from the
The purge sol enoi d wi l l al so be energi zed duri ng
certai n i dl e condi ti ons, i n order to update the fuel
del i very cal i brati on.
OUTPUT
on/off si gnal to the i nstrument panel through the CCD
Bus. The CCD Bus i s a communi cati ons port. Vari ous
modul es use the CCD Bus to exchange i nformati on.
The Check Engi ne Lamp comes on each ti me the
i gni ti on key i s turned ON and stays on for 3 seconds as
a bul b test. The Check Engi ne Lamp warns the opera-
tor that the engi ne control l er has entered a Li mp-i n
mode. Duri ng Li mp-i n Mode, the control l er attempts to
keep the system operati onal . The check engi ne l amp
si gnal s the need for i mmedi ate servi ce. I n l i mp-i n
mode, the Engi ne control l er compensates for the fai l -
ure of certai n components that send i ncorrect si gnal s.
The control l er substi tutes for the i ncorrect si gnal s wi th
i nputs from other sensors.
Lamp.
An Emi ssi on Rel ated System (Cal i forni a vehi cl es)
Chargi ng system
The Check Engi ne Lamp can al so di spl ay faul t codes.
Cycl e the i gni ti on swi tch on, off, on, off, on, wi thi n fi ve
seconds and any faul t codes stored i n the Engi ne
control l er wi l l be di spl ayed. Refer to On Board Di ag-
nosti cs i n the General Di agnosi sMul ti -Poi nt Fuel
I njecti on, 3.3L Engi ne secti on of thi s Group for Faul t
Code Descri pti ons.
OUTPUT
ELECTRONIC AUTOMATIC TRANSAXLE
CONTROLLER ENGINE CONTROLLER OUTPUT
The el ectroni c automati c transaxl e control l er and the
Engi ne Control l er suppl y i nformati on to each other
through the CCD Bus. The i nformati on i ncl udes engi ne
speed and vehi cl e l oad. The engi ne control l er uses the
i nformati on when adjusti ng the fuel and i gni ti on strat-
egy.
stores i t i nto memory every 8 mi l es. At that ti me, the
engi ne control l er checks for the 60,000, 82,500, and
120,000 mi l eage tri p poi nts. When the current mi l eage
matches one of the above menti oned tri p poi nts, the
EMR l amp on the i nstrument panel i s acti vated.
the key i n the on posi ti on, whi chever occurs fi rst. After
performi ng the requi red mai ntenance, the EMR l amp
must be reset to turn the l amp off.
For more i nformati on, refer to Group 25 or the
appropri ate di agnosti c manual .
FUEL INJECTORS ENGINE CONTROLLER OUTPUT
The fuel i njectors are el ectri cal sol enoi ds (Fi g. 18).
The i njector contai ns a pi ntl e that cl oses off an ori fi ce
at the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out the
ori fi ce. Because the fuel i s under hi gh pressure, a fi ne
spray i s devel oped i n the shape of a hol l ow cone. The
sprayi ng acti on atomi zes the fuel , addi ng i t to the ai r
enteri ng the combusti on chamber. The i njectors are
posi ti oned i n the i ntake mani fol d.
Fig. 18 Fuel Injector3.3L Engine
FUEL SYSTEM 14 - 89
The fuel i njectors are operated by the engi ne control -
l er. They are energi zed i n a sequenti al order duri ng al l
engi ne operati ng condi ti ons except start up. The en-
gi ne control l er i ni ti al l y energi zes al l i njectors at the
same ti me. Once engi ne control l er determi nes crank-
shaft posi ti on, i t begi ns energi zi ng the i njectors i n
sequence.
vol tage to the i njectors. The engi ne control l er provi des
the ground path for the i njectors. By swi tchi ng the
ground path on and off, the control l er adjusts i njector
pul se wi dth. Pul se wi dth i s the amount of ti me the
i njector i s energi zed. The control l er adjusts i njector
pul se wi dth based on i nputs i t recei ves.
The coi l assembl y consi sts of 3 mol ded coi l s together
(Fi g. 19). The coi l assembl y i s mounted on the i ntake
mani fol d. Hi gh tensi on l eads route to each cyl i nder
from the coi l . The coi l fi res two spark pl ugs every
power stroke. One pl ug i s the cyl i nder under compres-
si on, the other cyl i nder fi res on the exhaust stroke. The
engi ne control l er determi nes whi ch of the coi l s to
charge and fi re at the correct ti me.
The auto shutdown (ASD) rel ay provi des battery
vol tage to the i gni ti on coi l . The engi ne control l er pro-
vi des a ground contact (ci rcui t) for energi zi ng the coi l .
When the control l er breaks the contact, the energy i n
the coi l pri mary transfers to the secondary causi ng the
spark. The engi ne control l er wi l l de-energi ze the ASD
rel ay i f i t does not recei ve the crankshaft sensor and
camshaft sensor i nputs. Refer to Auto Shutdown (ASD)
Rel ay/Fuel Pump Rel ayEngi ne Control l er Output i n
thi s secti on for rel ay operati on.
vol tage to the posi ti ve termi nal of the i gni ti on coi l . The
engi ne control l er de-energi zes the ASD rel ay i f i t does
not recei ve an i nput from the di stri butor pi ck-up. Refer
to Auto Shutdown (ASD) Rel ayEngi ne Control l er
Output i n thi s secti on for rel ay operati on.
OUTPUT
reaches a predetermi ned temperature or when the ai r
condi ti oni ng system i s turned on.
LER OUTPUT
MODES OF OPERATION
engi ne control l er adjusts i ts response to output de-
vi ces. For exampl e, the engi ne control l er must cal cu-
l ate a di fferent i njector pul se wi dth and i gni ti on ti mi ng
for i dl e than i t does for wi de open throttl e (WOT).
There are several di fferent modes of operati on that
determi ne how the engi ne control l er responds to the
vari ous i nput si gnal s.
Duri ng OPEN LOOP modes the engi ne control l er
(O
2
modes.
Duri ng CLOSED LOOP modes the engi ne control l er
2
2
the engi ne control l er to achi eve opti mum fuel economy
combi ned wi th l ow emi ssi ons.
The 3.3L mul ti -poi nt fuel i njecti on system has the
fol l owi ng modes of operati on:
I gni ti on swi tch ON (Zero RPM)
Fig. 19 Coil Pack3.3L Engine
14 - 90 FUEL SYSTEM
Engi ne start-up
Engi ne warm-up
Crui se (I dl e)
Accel erati on
Decel erati on
wi de open throttl e modes are OPEN LOOP modes.
Under most operati ng condi ti ons, the accel erati on,
decel erati on, and crui se modes, with the engine at
operating temperature are CLOSED LOOP modes.
When the mul ti -poi nt fuel i njecti on system i s acti -
occur:
fuel strategy.
ture sensor and throttl e posi ti on sensor i nput. The
engi ne control l er modi fi es fuel strategy based on thi s
i nput.
not runni ng (zero rpm), the auto shutdown (ASD) rel ay
and fuel pump rel ay are not energi zed. Therefore
battery vol tage i s not suppl i ed to the fuel pump,
i gni ti on coi l , fuel i njectors or oxygen sensor heati ng
el ement.
I f the engi ne control l er recei ves the camshaft and
crankshaft si gnal s, i t energi zes the auto shutdown
(ASD) rel ay and fuel pump rel ay. These rel ays suppl y
battery vol tage to the fuel pump, fuel i njectors, i gni ti on
coi l , and oxygen sensor heati ng el ement. I f the engi ne
control l er does not recei ve the camshaft and crank-
shaft si gnal s wi thi n approxi matel y one second, i t de-
energi zes the ASD rel ay and fuel pump rel ay.
The engi ne control l er energi zes al l si x i njectors unti l
i t determi nes crankshaft posi ti on from the camshaft
and crankshaft si gnal s. The control l er determi nes
crankshaft posi ti on wi thi n 1 engi ne revol uti on.
After determi ni ng crankshaft posi ti on, the control l er
begi ns energi zi ng the i njectors i n sequence. The con-
trol l er adjusts i njector pul se wi dth and control s i njec-
tor synchroni zati on by turni ng the i ndi vi dual ground
paths to the i njectors On and Off.
When the engi ne i dl es wi thi n 64 RPM of i ts target
RPM, the control l er compares current MAP sensor
duri ng the I gni ti on Swi tch On (zero RPM) mode. I f the
control l er does not detect a mi ni mum di fference be-
tween the two val ues, i t sets a MAP faul t i nto memory.
Once the ASD and fuel pump rel ays have been
energi zed, the engi ne control l er:
Determi nes i njector pul se wi dth based on cool ant
temperature, mani fol d absol ute pressure (MAP) and
i ni ti ated.
ENGINE WARM-UP MODE
engi ne speed (crankshaft posi ti on sensor)
A/C swi tch
battery vol tage
The engi ne control l er adjusts i gni ti on ti mi ng and
engi ne i dl e speed. Engi ne i dl e speed i s adjusted
through the automati c i dl e speed motor.
CRUISE OR IDLE MODE
When the engi ne i s at operati ng temperature thi s i s
a CLOSED LOOP mode. Duri ng crui si ng speed the
fol l owi ng i nputs are recei ved by the engi ne control l er:
engi ne speed (crankshaft posi ti on sensor)
battery vol tage
The engi ne control l er adjusts engi ne i dl e speed and
i gni ti on ti mi ng. The engi ne control l er adjusts the
exhaust gas.
ACCELERATION MODE
Thi s i s a CLOSED LOOP mode. The engi ne control -
l er recogni zes an abrupt i ncrease i n throttl e posi ti on or
MAP pressure as a demand for i ncreased engi ne output
and vehi cl e accel erati on. The engi ne control l er i n-
creases i njector pul se wi dth i n response to i ncreased
fuel demand.
FUEL SYSTEM 14 - 91
DECELERATION MODE
Thi s i s a CLOSED LOOP mode. Duri ng decel erati on
the fol l owi ng i nputs are recei ved by the engi ne control -
l er:
engi ne speed
battery vol tage
ti on. Thi s hel ps mai ntai n better control of the ai r-fuel
mi xture (as sensed through the O
2
sensor).
l er grounds the evaporati ve purge sol enoi d. When the
sol enoi d i s grounded, the cani ster purge functi on stops.
throttl e operati on, the fol l owi ng i nputs are recei ved by
the engi ne control l er:
engi ne speed
When the engi ne control l er senses wi de open throttl e
condi ti on through the throttl e posi ti on sensor (TPS) i t
wi l l :
De-energi ze the ai r condi ti oni ng rel ay. Thi s di sabl es
the ai r condi ti oni ng system.
The exhaust gas oxygen content i nput i s not accepted
by the engi ne control l er duri ng wi de open throttl e
operati on. The engi ne control l er wi l l adjust i njector
pul se wi dth to suppl y a predetermi ned amount of
addi ti onal fuel .
When the i gni ti on swi tch i s turned to the OFF
posi ti on, the fol l owi ng occurs:
THROTTLE BODY
The throttl e body assembl y i s l ocated on the l eft si de
of the i ntake mani fol d pl enum (Fi g. 20). The throttl e
body houses the throttl e posi ti on sensor and the auto-
mati c i dl e speed motor. Ai r fl ow through the throttl e
body i s control l ed by a cabl e operated throttl e bl ade
l ocated i n the base of the throttl e body.
FUEL SUPPLY CIRCUIT
Fuel i s pumped to the fuel rai l by an el ectri cal pump
i n the fuel tank. The pump i nl et i s fi tted wi th a fi l ter to
prevent water and other contami nants from enteri ng
the fuel suppl y ci rcui t.
Fuel pressure i s control l ed to a preset l evel above
i ntake mani fol d pressure by a pressure regul ator. The
regul ator i s mounted on the fuel rai l . The regul ator
uses i ntake mani fol d pressure as a reference.
FUEL INJECTORS AND FUEL RAIL ASSEMBLY
Si x fuel i njectors are retai ned i n the fuel rai l by
14 - 92 FUEL SYSTEM
l ock ri ngs (Fi g. 21). The rai l and i njector assembl y i s
i nstal l ed i n posi ti on wi th the i njectors i nserted i n
recessed hol es i n the i ntake mani fol d.
cated on the fuel rai l , downstream of the fuel i njectors
(Fi g. 22). The regul ator mai ntai ns a constant 330 kPa
(48 psi ) across the fuel i njector ti p.
The regul ator contai ns a spri ng l oaded rubber di aphragm
that covers the fuel return port. When the fuel pump i s
operati ng, fuel fl ows past the i njectors i nto the regul ator, and
i s restri cted from fl owi ng any further by the bl ocked return
port. When fuel pressure reaches 330 kPa (48 psi ) i t pushes
on the di aphragm, compresses the spri ng, and uncovers the
fuel return port. The di aphragm and spri ng constantl y move
from an open to cl osed posi ti on to keep the fuel pressure
constant.
3.3L MULTI -POI NT FUEL I NJECTI ONGENERAL DI AGNOSI S
INDEX
page page
60-Way Engine Controller Wiring Connector . . . . 103
Circuit Actuation Test Mode . . . . . . . . . . . . . . . . 102
Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . 93
System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FUEL SYSTEM DIAGRAM
Refer to the Component I denti fi cati on porti on of thi s
secti on for a more compl ete descri pti on of the compo-
nents shown i n Fi g. 1.
VISUAL INSPECTION
(1) Check i gni ti on cabl e routi ng from the coi l pack to
the spark pl ugs. Veri fy the cabl e are routed i n the
correct order and are ful l y seated to the coi l and spark
pl ug.
(2) Check di rect i gni ti on system (DI S) coi l el ectri cal
connecti on for damage and a compl ete connecti on to
the coi l (Fi g. 2).
(3) Veri fy the camshaft sensor el ectri cal connector i s
connected to the harness and not damaged (Fi g. 3).
(4) Ensure the engi ne temperature sensor el ectri cal
connector i s connected to the sensor and not damaged
(Fi g. 3).
(5) Ensure the cool ant temperature sensor el ectri cal con-
nector i s connected to the sensor and not damaged (Fi g. 4).
(6) Veri fy the qui ck connect fuel fi tti ngs are ful l y
i nserted on the fuel suppl y and return tubes.
(7) Check the vacuum hose connecti on at the fuel
pressure regul ator for damage or l eakage (Fi g. 5).
Fig. 21 Fuel Rail Assembly
FUEL SYSTEM 14 - 93
(8) Check the oi l pressure sendi ng uni t el ectri cal
(9) Veri fy the el ectri cal connector i s attached to the
Purge Sol enoi d (Fi g. 7) and not damaged.
(10) Veri fy the vacuum connecti on at the purge so-
l enoi d i s secure and not l eaki ng (Fi g. 7).
(11) Veri fy the hoses are securel y attached to the
vapor cani ster (Fi g. 8).
(12) Ensure the harness connectors for the fuel i n-
jector are attached to the correct i njector and not
damaged.
(13) Veri fy the fuel i njector harness and engi ne
wi ri ng harness connectors are ful l y i nserted i nto the
mai n wi ri ng harness.
Fig. 2 Ignition Coils Electrical Connection
14 - 94 FUEL SYSTEM
(14) Check the vacuum connecti ons at the throttl e
body (Fi g. 9).
(15) Ensure the AI S motor and TPS el ectri cal con-
nectors are ful l y seated and not damaged (Fi g. 9).
(16) I nspect the park/neutral swi tch wi ri ng connec-
ti on for damage. Ensure the automati c transmi ssi on
el ectri cal connecti ons are not damaged (Fi g. 10).
Fig. 5 Fuel Pressure Regulator Vacuum Connection
Fig. 6 Oil Pressure Sending Unit Electrical Connec-
tion
Fig. 7 Canister Purge Solenoid Electrical Connector
Fig. 9 Throttle Body Electrical and Vacuum Connec-
tions
FUEL SYSTEM 14 - 95
(17) Check the Vacuum Hose Harness connecti ons at
the I ntake Pl enum (Fi g. 11).
(18) I nspect the PCV system connecti ons for damage
(Fi g. 12).
(19) I nspect the crankshaft posi ti on sensor el ectri cal
connector for damage (Fi g. 13).
(20) Ensure the di stance sensor el ectri cal connector
i s attached to the sensor and not damaged (Fi g. 13).
(21) Veri fy the mani fol d absol ute pressure (map)
sensor el ectri cal connector i s attached to the sensor
and not damaged (Fi g. 14).
(22) Veri fy the engi ne ground strap i s attached at
the engi ne and dash panel (Fi g. 14). I nspect the strap
for corrosi on or damage.
(23) Check the heated oxygen sensor el ectri cal con-
nector for damage (Fi g. 14).
tions
Fig. 11 Vacuum Hose Connections
Fig. 12 PCV System
Fig. 13 Crankshaft Sensor and Vehicle Distance
Sensor Electrical Connections
Fig. 14 MAP Sensor, Heated Oxygen Sensor, and
Ground Strap
14 - 96 FUEL SYSTEM
(24) I nspect the al ternator wi ri ng connecti ons for
damage.
(25) Check the accessory dri ve bel t tensi on.
(26) Check the 60-way el ectri cal connecti on at the
Engi ne Control l er (Fi g. 15) for damage or spread
termi nal s. Veri fy that the 60-way connector i s ful l y
i nserted i nto the engi ne control l er socket. Ensure the
wi res are not stretched or pul l ed out of the connector.
(27) Ensure the rel ays are connected to the harness
connectors (Fi g. 16 and Fi g. 17) I nspect the connecti ons
for damage.
(28) I nspect battery cabl e connecti ons for corrosi on.
(29) Check the power brake booster hose connecti on
(wi thout anti -l ock brake systems) (Fi g. 18).
(30) I nspect the speed control vacuum connecti on
(Fi g. 19).
(31) I nspect hose and wi ri ng connecti ons at fuel
pump. Check that wi ri ng connector i s maki ng contact
entered i nto the engi ne control l er memory. The cri teri a
ci rcui t shorts to ground when engi ne RPM i s above
2400 RPM (resul ti ng i n a 0 vol t i nput to the engi ne
control l er) a faul t code wi l l not be entered i nto memory.
Thi s i s because the condi ti on does not occur wi thi n the
speci fi ed RPM range.
FUEL SYSTEM 14 - 97
15).
or shorted hi gh.
codes to be di spl ayed for other systems. For exampl e, a
fuel pressure probl em wi l l not regi ster a faul t di rectl y,
but coul d cause a ri ch or l ean condi ti on. Thi s coul d
cause an oxygen sensor faul t to be stored i n the engi ne
control l er.
vacuum assi sted fuel pressure regul ator. The engi ne
control l er cannot detect a cl ogged fuel pump i nl et fi l ter,
cl ogged i n-l i ne fuel fi l ter, or a pi nched fuel suppl y or
return l i ne. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng an oxygen sensor faul t to be
stored i n the engi ne control l er.
pl ug cabl es.
sprocket and crankshaft sprocket. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng an
oxygen sensor faul t to be stored i n the engi ne control -
l er.
compressi on.
l er cannot determi ne i f a fuel i njector i s cl ogged, the
needl e i s sti cki ng or the wrong i njector i s i nstal l ed.
Fig. 18 Power Brake Booster Hose
Fig. 19 Speed Control Vacuum
14 - 98 FUEL SYSTEM
fi l ter el ement.
purge cani ster.
thi s condi ti on.
The engi ne control l er compares i nput si gnal vol tages
from each i nput devi ce wi th establ i shed hi gh and l ow
l i mi ts that are programmed i nto i t for that devi ce. I f
the i nput vol tage i s not wi thi n speci fi cati ons and other
faul t code cri teri a are met, a faul t code wi l l be stored i n
memory. Other faul t code cri teri a mi ght i ncl ude engi ne
RPM l i mi ts or i nput vol tages from other sensors or
swi tches that must be present before a faul t condi ti on
can be veri fi ed.
A faul t code i ndi cates that the engi ne control l er has
recogni zed an abnormal condi ti on i n the system. Faul t
codes can be obtai ned from the Check Engi ne l amp on
the I nstrument Panel or from the Di agnosti c Readout
Box I I (DRBI I ). Faul t codes i ndi cate the resul ts of a
fai l ure but do not i denti fy the fai l ed component di -
rectl y.
SYSTEM TESTS
Be sure to apply parking brake and/or block
wheels before performing idle check or adjust-
ment, or any engine running tests.
(1) Connect DRBI I to the di agnosti c connector l o-
cated i n the engi ne compartment near the dri ver si de
strut tower (Fi g. 15).
(2) Start the engi ne i f possi bl e, cycl e the transmi s-
si on sel ector and the A/C swi tch i f appl i cabl e. Shut off
the engi ne.
DRBI I . Observe the check engi ne l amp on the i nstru-
Fault codeerasure;accesserasefault codedata
the State Di spl ay screen. Then access I nputs and
Outputs. The fol l owi ng i s a l i st of the engi ne control
system functi ons accessi bl e through the I nputs and
Outputs screen:
Park/Neutral Swi tch
Brake Swi tch
Speed Control Set
A/C Swi tch Sense
Z2 Vol tage Sense
S/C Vent Sol enoi d
S/C Vacuum Sol enoi d
A/C Cl utch Rel ay
EMR Lamp
Fuel Pump Rel ay
Purge Sol enoi d
Check Engi ne Lamp
FUEL SYSTEM 14 - 99
14 - 100 FUEL SYSTEM
FUEL SYSTEM 14 - 101
the State Di spl ay screen. Then access Sensor Di spl ay.
functi ons accessi bl e through the Sensor Di spl ay
screen:
Battery Temp Sensor
Mi ni mum Throttl e
Battery Vol tage
MAP Sensor Readi ng
Mi n Ai rfl ow I dl Spd
Engi ne Speed
DI S Sensor Status
Overal l Knock Retard
Theft Al arm Status
Map Sensor Vol tage
Vehi cl e Speed
Oxygen Sensor State
MAP Gauge Readi ng
Throttl e Openi ng
Total Spark Advance
Actuators screens:
Stop Al l Tests
Fuel I njector #1
Fuel I njector #2
Fuel I njector #3
Fuel I njector #4
Fuel I njector #5
Fuel I njector #6
A/C Cl utch Rel ay
Purge Sol enoi d
S/C Serv Sol enoi ds
Al ternator Fi el d
PROCEDURE
(5) Attach Ai r Meteri ng Fi tti ng #6457 (0.125 i n.
ori fi ce) to the i ntake mani fol d PCV ni ppl e (Fi g. 20).
(6) Di sconnect the 3/16 i nch i dl e purge l i ne from the
throttl e body ni ppl e. Cap the 3/16 i nch ni ppl e.
(8) Restart the engi ne. Al l ow engi ne to i dl e for at
l east one mi nute.
(9) Usi ng the DRBI I , access Mi n. Ai rfl ow I dl e Spd.
Engi ne RPM wi l l be di spl ayed on DRB I I .
(11) I f i dl e RPM i s wi thi n the range shown i n the
I dl e Speci fi cati on chart, throttl e body mi ni mum ai r-
fl ow i s set correctl y.
Fig. 20 Air Metering Fitting #6457
i ntake mani fol d PCV ni ppl e. Rei nstal l the PCV val ve
hose.
(15) Uncap the throttl e body i dl e purge ni ppl e and
connect the i dl e purge l i ne.
(16) Remove DRB I I .
TOR
gram (Fi g. 21) for wi re col ors and cavi ty numbers.
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3.3L MULTI -POI NT FUEL I NJECTI ONSERVI CE PROCEDURES
INDEX
page page
Automatic Idle Speed (AIS) Motor . . . . . . . . . . . . 106
Camshaft Sensor Service . . . . . . . . . . . . . . . . . . 112
Canister Purge Solenoid Service . . . . . . . . . . . . . 111
Engine Controller Service . . . . . . . . . . . . . . . . . . 111
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Injector Rail Assembly . . . . . . . . . . . . . . . . 106
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . 109
Fuel System Pressure Release Procedure . . . . . 106
2
Sensor) Service . . . . 112
Manifold Absolute Pressure (MAP) Sensor . . . . . 110
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Throttle Body Removal . . . . . . . . . . . . . . . . . . . . 105
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . 106
THROTTLE BODY REMOVAL
(2) Remove the ai r cl eaner to throttl e body hose
cl amp and the nut hol di ng the ai r cl eaner assembl y to
the ai r cl eaner bracket. Remove the ai r cl eaner (Fi g. 1).
(3) Remove throttl e and the speed control cabl es.
(4) Di sconnect el ectri cal connectors from the auto-
mati c i dl e speed (AI S) motor and throttl e posi ti on
sensor (TPS).
(5) Di sconnect vacuum hoses from throttl e body.
(6) Remove throttl e body to i ntake mani fol d attach-
i ng nuts.
(7) Remove throttl e body and gasket.
THROTTLE BODY
When servi ci ng throttl e body components, al ways
reassembl e components wi th new O-ri ngs and seal s
where appl i cabl e (Fi g. 2). Never use l ubri cants on
O-ri ngs or seal s, damage may resul t. I f assembl y of
component i s di ffi cul t, use water to ai d assembl y. Use
care when removi ng hoses to prevent damage to hose
or hose ni ppl e.
Fig. 1 Throttle Body Assembly
The 3.3L MPI fuel system is under a constant
pressure of approximately 330 kPa (48 psi). Be-
foreservicingthefuel pump, fuel lines, fuel filter,
throttle body or fuel injectors, the fuel system
sure.
harness (Fi g. 3).
ber 1 of one i njector harness and engi ne ground.
posi ti ve post for no l onger than 5 seconds. Thi s rel eases
system pressure.
REMOVAL
(2) Remove el ectri cal connector from throttl e posi -
ti on sensor.
(3) Remove throttl e posi ti on sensor mounti ng screws
(Fi g. 4).
(4) Li ft throttl e posi ti on sensor off throttl e shaft.
I NSTALLATI ON
(1) I nstal l throttl e posi ti on sensor on throttl e shaft.
I nstal l mounti ng screws. Ti ghten screw to 2 Nm (17
i n. l bs.) torque.
(2) Connect el ectri cal connector to throttl e posi ti on
sensor.
REMOVAL
(2) Remove el ectri cal connector from automati c i dl e
speed (AI S) motor.
(3) Remove AI S motor mounti ng screws (Fi g. 5).
(4) Remove AI S motor from throttl e body. Ensure the
O-ri ng i s removed wi th the AI S motor.
I NSTALLATI ON
(1) The new AI S motor has a new O-ri ng i nstal l ed on
i t. I f pi ntl e measures more than 1 i nch (25 mm) i t must
be retracted. Use the DRB I I AI S Motor Open/Cl ose
Test to retract the pi ntl e (battery must be connected.)
(2) Careful l y pl ace AI S motor i nto throttl e body.
(3) I nstal l mounti ng screws. Ti ghten screws to 2
(4) Connect el ectri cal connector to AI S motor.
REMOVAL
before servicing or starting repairs. Refer to Fuel
System Pressure Rel ease Procedure i n thi s secti on.
(3) Remove ai r cl eaner and hose assembl y (Fi g. 1).
Fig. 5 Servicing Automatic Idle Speed Motor
(4) Remove throttl e cabl e (Fi g. 6). Remove wi ri ng
harness from throttl e cabl e bracket and i ntake mani -
fol d water tube.
(5) Di sconnect automati c i dl es speed (AI S) motor
and throttl e posi ti on sensor (TPS) el ectri cal connectors
(Fi g. 7). Refer to Automati c I dl e Speed motor and
Throttl e Posi ti on Sensor i n thi s secti on.
(Fi g. 7).
(7) Remove PCV and brake booster vacuum hoses
from ai r i ntake pl enum.
(8) Remove vacuum harness connectors from i ntake
pl enum (Fi g. 8).
(9) Remove cyl i nder head to i ntake pl enum strut
(Fi g. 8).
(10) Di sconnect el ectri cal connectors from the MAP
sensor and heated oxygen sensor el ectri cal connecti on.
Remove the engi ne mounted ground strap (Fi g. 9).
(11) Remove the fuel hose qui ck connect fi tti ngs
from the chassi s tubes. Refer toFuel Hoses, Clamps
and Quick Connect Fittings in the Fuel Delivery
Section of this Group. Pl ace a shop towel under the
connecti ons to absorb any fuel spi l l ed. fi tti ngs.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
Body
Fig. 8 Electrical and Vacuum Connections To Intake
Manifold
Fig. 9 MAP Sensor Electrical Connector
(12) Remove di rect i gni ti on system (DI S) coi l s and
al ternator bracket to i ntake mani fol d bol t (Fi g. 10).
(13) Remove i ntake mounti ng mani fol d bol ts and
rotate mani fol d back over rear val ve cover (Fi g. 11).
(14) Cover i ntake mani fol d wi th sui tabl e cover when
servi ci ng (Fi g. 12).
(15) Remove vacuum harness connector from Fuel
Pressure Regul ator.
(16) Remove fuel tube retai ner bracket screw and
fuel rai l attachi ng bol ts (Fi g. 12). Spread the retai ner
bracket to al l ow fuel tube removal cl earance.
(17) Remove fuel rai l i njector wi ri ng cl i p from the
al ternator bracket (Fi g. 13).
(18) Di sconnect cam sensor, cool ant temperature
sensor, and engi ne temperature sensors (Fi g. 13).
(19) Remove fuel rai l . Be careful not to damage the
i njector O-ri ngs upon removal from thei r ports (Fi g.
14).
I NSTALLATI ON
(1) Ensure i njector hol es are cl ean. Repl ace O-ri ngs
i f damaged.
(2) Lube i njector O-ri ngs wi th a drop of cl ean engi ne
oi l to ease i nstal l ati on.
the ports (Fi g. 14).
(4) I nstal l the fuel rai l mounti ng bol ts. Ti ghten bol ts
to 22 Nm (200 i n. l bs.) torque (Fi g. 12).
(5) I nstal l fuel tube retai ni ng bracket screw. Ti ghten
screw to 4 Nm (35 i n. l bs.) torque.
Fig. 10 Ignition Coils
Fig. 11 Intake Manifold Bolts
Fig. 12 Fuel Rail Attaching Bolts
Fig. 13 Fuel Injector Wiring Clip
(6) Connect el ectri cal connectors to cam sensor, cool -
ant temperature sensor and engi ne temperature sen-
sors.
(7) I nstal l fuel i njector harness wi ri ng cl i ps on the
al ternator bracket and i ntake mani fol d water tube
(Fi g. 13).
(8) Connect vacuum l i ne to fuel pressure regul ator.
(9) Remove coveri ng on l ower i ntake mani fol d and
cl ean surface.
(10) Pl ace i ntake mani fol d gasket on l ower mani fol d.
Put upper mani fol d i nto pl ace and i nstal l bol ts fi nger
ti ght.
(11) I nstal l the al ternator bracket to i ntake mani fol d
bol t and the cyl i nder head to i ntake mani fol d strut
bol ts. (Do not ti ghten.)
(12) Fol l owi ng the ti ghteni ng sequence i n Fi gure 11,
ti ghten i ntake mani fol d bol ts to 28 Nm (250 i n. l bs.)
torque.
(13) Ti ghten al ternator bracket to i ntake mani fol d
bol t to 54 Nm (40 ft. l bs.) torque.
(14) Ti ghten the cyl i nder head to i ntake mani fol d
strut bol ts to 54 Nm (40 ft. l bs.) torque (Fi g. 8).
(15) Connect ground strap, MAP and heated oxygen
sensor el ectri cal connectors.
(16) Connect vacuum harness to i ntake pl enum.
Connect PCV system hoses.
(17) Cl i p wi ri ng harness i nto the hol e i n the throttl e
cabl e bracket.
(18) Connect el ectri cal connectors to the throttl e
posi ti on sensor (TPS) and Automati c I dl e Speed (AI S)
motor.
(19) Connect vacuum harness to throttl e body.
(20) I nstal l the di rect i gni ti on system (DI S) coi l s.
Ti ghten fasteners to 12 Nm (105 i n. l bs.) torque.
(21) I nstal l fuel hose qui ck connectors fi tti ngs to
chassi s tubes. Refer to Fuel Hoses, Clamps and
tion of this Group. Push the fi tti ngs onto the chassi s
tubes unti l they cl i ck i nto pl ace. Pul l on the fi tti ngs to
ensure compl ete i nserti on. Fuel suppl y fi tti ng i s 5/16
i nch and fuel return fi tti ng i s 1/4 i nch.
(22) I nstal l throttl e cabl e.
(23) I nstal l ai r cl eaner and hose assembl y.
REMOVAL
before attempti ng any repai rs. Refer to Fuel Pressure
Regul ator Procedure i n thi s secti on.
(2) Remove fuel pressure regul ator vacuum connec-
tor. (Fi g. 15).
(3) Remove regul ator retai ner screw (Fi g. 15).
(4) Remove the fuel pressure regul ator retai ner (Fi g.
15).
WARNING: PLACE A SHOP TOWEL UNDER FUEL
PRESSURE REGULATOR TO ABSORB ANY FUEL
SPILLAGE.
(5) Remove fuel pressure regul ator and O-ri ngs (Fi g.
16).
Fig. 14 Fuel Rail Removal
I NSTALLATI ON
(1) Ensure fuel pressure regul ator has two pl asti c
spacers (Fi g. 16). Pl ace O-ri ngs i n the fuel pressure
regul ator cavi ty (Fi g. 17). Do not i nstal l O-ri ngs on the
(2) I nsert fuel pressure regul ator i nto the fuel rai l .
(3) I nstal l fuel pressure regul ator retai ner (Fi g. 15).
(4) I nstal l retai ner screw. Ti ghten to 7 Nm (60 i n.
l bs.) torque.
(5) Connect vacuum l i ne to the fuel pressure regul a-
tor.
FUEL INJECTOR
The fuel rai l must be removed fi rst. Refer to Fuel
I njector Rai l Assembl y Removal i n thi s secti on.
REMOVAL
(1) Di sconnect i njector wi ri ng connector from i njec-
tor.
(2) Posi ti on fuel rai l assembl y so that the fuel i njec-
tors are easi l y accessi bl e (Fi g. 18).
(3) Rotate i njector and pul l i njector out of fuel rai l .
The cl i p wi l l stay on the i njector.
(4) Check i njector O-ri ng for damage. I f O-ri ng i s
damaged, i t must be repl aced. I f i njector i s reused, a
protecti ve cap must be i nstal l ed on the i njector ti p to
prevent damage. Repl ace the i njector cl i p i f i t i s dam-
aged.
(5) Repeat for remai ni ng i njectors.
I NSTALLATI ON
(1) Before i nstal l i ng an i njector the rubber O-ri ng
must be l ubri cated wi th a drop of cl ean engi ne oi l to ai d
i n i nstal l ati on.
(2) I nstal l i njector cl i p by sl i di ng open end i nto top
slot of the i njector. The edge of the recei ver cup wi l l
sl i de i nto the si de sl ots of cl i p (Fi g. 19).
(3) I nstal l i njector top end i nto fuel rai l recei ver cap.
Be careful not to damage O-ri ng duri ng i nstal l ati on
(Fi g. 19).
(4) Repeat steps for remai ni ng i njectors.
(5) Connect fuel i njector wi ri ng.
(1) Di sconnect el ectri cal connector from MAP sensor.
Removal/Installation
Fig. 17 Fuel Pressure Regulator O-Rings
Fig. 18 Fuel Injector and RailTypical
(2) Remove sensor by unscrewi ng from the i ntake
CANISTER PURGE SOLENOID SERVICE
(3) Reverse above procedure for i nstal l ati on.
ENGINE CONTROLLER SERVICE
(2) Remove battery.
22).
(4) Remove 60-way el ectri cal connector from engi ne
control l er.
REMOVAL
(1) Di sconnect crankshaft ti mi ng sensor el ectri cal
(2) Remove crankshaft ti mi ng sensor retai ni ng bol t.
(3) Pul l crankshaft ti mi ng sensor strai ght up out of
the transaxl e housi ng.
I NSTALLATI ON
If theremovedsensor istobereinstalled, clean
off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face
before installation. If the sensor is being re-
placed, confirmthat thepaper spacer isattached
to the face of the new sensor (Fig. 24).
(1) I nstal l sensor i n transaxl e and push sensor down
unti l contact i s made wi th the dri ve pl ate.
Fig. 19 Servicing Fuel InjectorTypical
Fig. 22 Engine Controller Removal
Whi l e hol di ng the sensor i n thi s posi ti on, i nstal l and
ti ghten the retai ni ng bol t to 11.9 Nm (105 i n. l bs.)
torque.
(2) Connect crankshaft ti mi ng sensor el ectri cal con-
nector to the wi ri ng harness connector.
CAMSHAFT SENSOR SERVICE
REMOVAL
(1) Di sconnect camshaft reference sensor el ectri cal
(2) Loosen camshaft ti mi ng sensor retai ni ng bol t
enough to al l ow sl ot i n sensor to sl i de past the bol t.
(3) Pul l sensor up out of the chai n case cover. Donot
pull on the sensor lead. There i s an O-ri ng on the
sensor case. The O-ri ng may make removal di ffi cul t. A
l i ght tap to top of sensor pri or to removal may reduce
force needed for removal .
I NSTALLATI ON
If the removed sensor is reinstalled, clean off
theoldspacer onthesensor face.ANEWSPACER
must be attached to the face before installation.
Inspect O-ring for damage, replace if necessary.
If the sensor is being replaced, confirmthat the
paper spacer isattachedtothefaceandO-ringis
positioned in groove of the new sensor (Fig. 26).
(1) Appl y a coupl e drops of cl ean engi ne oi l to the
O-ri ng pri or to i nstal l ati on. I nstal l sensor i n the chai n
case cover and push sensor down unti l contact i s made
wi th the cam ti mi ng gear. Whi l e hol di ng the sensor i n
thi s posi ti on, i nstal l and ti ghten the retai ni ng bol t 11.9
(2) Connect camshaft reference sensor el ectri cal con-
nector to harness connector. Posi ti on connector away
from the accessory bel t.
2
SENSOR) SERVICE
fol d (Fi g. 27).
OXYGEN SENSOR.
(1) Di sconnect oxygen sensor el ectri cal connector
(Fi g. 28).
threads must be cl eaned wi th an 18 mm X 1.5 + 6E
Fig. 23 Crankshaft Timing Sensor
Fig. 24 Crankshaft Sensor and Spacer
tap. I f usi ng ori gi nal sensor, coat the threads wi th
Locti te 771-64 anti -sei ze compound or equi val ent. New
sensors are packaged wi th compound on the threads
and no addi ti onal compound i s requi red. The sensor
must be ti ghtened to 27 Nm (20 ft. l bs.) torque.
SPECI FI CATI ONS
Fig. 27 Oxygen Sensor3.3L Engine Fig. 28 Oxygen Sensor Connector
TEMPERATURE SENSOR SPECI FI CATI ONS
TORQUE
FRAME AND BUMPERS
CONTENTS
page page
ALL WHEEL DRIVE VAN/WAGON
CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . 4
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 4
FRONT BUMPER SUPPORT BRACKET . . . . . . . . 2
FRONT WHEEL DRIVE VAN/WAGON
CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . 3
HIGH LINE FRONT BUMPER AND FASCIA . . . . 2
HIGH LINE REAR BUMPER AND FASCIA . . . . . . 3
LOW LINE FRONT BUMPER . . . . . . . . . . . . . . . . 1
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
I n thi s secti on, references are made to Vehi cl e Fami l y
(Body) codes. To determi ne the vehi cl e fami l y i denti fi -
cati on code, refer to the I ntroducti on Group at the front
of thi s manual .
LOW LINE FRONT BUMPER
REMOVAL (FI G. 1)
(1) Remove nut hol di ng front bumper end caps to
front fenders.
bumper support.
(3) Remove push-i n fastener hol di ng front bumper
end caps to bumper.
(4) Support front bumper on a sui tabl e l i fti ng devi ce.
(5) Remove nuts hol di ng front bumper to support
bracket.
I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn front bumper
to 15 mm (0.6 i n.) from bottom of gri l l e. To move
bumper up or down, l oosen nuts hol di ng support
bracket to radi ator cl osure panel .
Fig. 1 Low Line Front Bumper
FRAME AND BUMPERS 13 - 1
HIGH LINE FRONT BUMPER AND FASCIA
REMOVAL (FI G. 2)
(1) Remove retai ners hol di ng front bumper fasci a to
bottom of radi ator cl osure panel .
(2) Remove retai ners hol di ng fasci a to forward edge
of front wheel openi ngs.
(3) Remove nuts hol di ng fasci a to front fenders.
(4) Di sconnect fog l amp wi re connector, i f equi pped.
(6) Remove bol ts hol di ng front bumper rei nforce-
ment to bumper support bracket.
(7) Separate bumper assembl y from vehi cl e.
I NSTALLATI ON
Reverse the precedi ng operati on. Al i gn front bumper
to 15 mm (0.6 i n.) from bottom of gri l l e. To move
bumper up or down, l oosen nuts hol di ng support
bracket to radi ator cl osure panel .
OVERHAUL (FI G. 3)
(1) Remove hi gh l i ne front bumper and fasci a assem-
bl y.
(2) Posi ti on front bumper and fasci a on a sui tabl e
padded work surface to protect pai nted fi ni sh.
(3) Remove fog l amp assembl i es.
(4) Remove push-i n fasteners hol di ng fasci a to
bumper rei nforcement.
(5) Separate rei nforcement from fasci a.
HI GH LI NE FRONT BUMPER ASSEMBLY
FRONT BUMPER SUPPORT BRACKET
REMOVAL
(1) Remove front bumper as necessary to cl ear re-
moval path of support bracket.
(2) Remove nuts hol di ng bumper support bracket to
radi ator cl osure panel .
(3) Separate bumper support bracket from vehi cl e.
I NSTALLATI ON
Fig. 2 High Line Front Bumper
Fig. 3 High line Front Bumper Overhaul
13 - 2 FRAME AND BUMPERS
REAR BUMPER
REMOVAL (FI G. 4)
(1) Remove nuts hol di ng front bumper end caps to
quarter panel s.
bumper support.
(3) Remove push-i n fastener hol di ng front bumper
end caps to bumper.
(5) Remove nuts hol di ng front bumper to support
bracket.
I NSTALLATI ON
HIGH LINE REAR BUMPER AND FASCIA
REMOVAL (FI G. 5)
(1) Remove push-i n fasteners hol di ng fasci a to wheel
openi ngs.
(2) Remove nuts hol di ng fasci a to quarter panel s.
(4) Remove bol ts hol di ng bumper rei nforcement to
bumper support brackets.
(5) Separate bumper assembl y from vehi cl e.
I NSTALLATI ON
FRONT WHEEL DRIVE VAN/WAGON CROSSMEM-
BER
REMOVAL (FI G. 6)
(1) Hoi st vehi cl e and support on safety stands. Refer
to Group 0, Lubri cati on and Mai ntenance for proper
procedures.
(2) Remove front wheel s.
(3) Di sconnect l ower bal l joi nts from the knuckl e
assembl y. Refer to Group 2, Suspensi on for proper
procedures.
(4) Di sconnect power steeri ng hose ti e-down from
rear upper edge of crossmember, i f equi pped.
(5) Remove bol ts hol di ng steeri ng gear to crossmem-
ber. Refer to Group 19, Steeri ng for proper procedures.
(6) Support crossmember on a sui tabl e l i fti ng devi ce.
(7) Remove nuts hol di ng rear of crossmember to the
frame.
(8) Remove bol ts hol di ng crossmember to frame from
above l ower control arms.
(9) Separate the crossmember from the vehi cl e.
(10) Transfer l ower control arms and sway el i mi na-
tor shaft to new crossmember, i f crossmember i s bei ng
repl aced. Refer to Group 2, Suspensi on for proper
procedure.
Fig. 4 Rear Bumper
Fig. 5 High Line Rear Bumper and Fascia
I NSTALLATI ON
ALL WHEEL DRIVE VAN/WAGON CROSSMEMBER
REMOVAL (FI G. 7)
(1) Hoi st vehi cl e and support on safety stands. Refer
to Group 0, Lubri cati on and Mai ntenance for proper
procedures.
(2) Remove front wheel s.
(3) Di sconnect l ower bal l joi nts from the knuckl e
assembl y. Refer to Group 2, Suspensi on for proper
procedures.
(4) Di sconnect power steeri ng hose ti e-down from
rear upper edge of crossmember, i f equi pped.
(5) Remove bol ts hol di ng steeri ng gear support
bri dge to crossmember.
(6) Remove bol t hol di ng engi ne bobbl e strut to cross-
member.
(7) Support crossmember on a sui tabl e l i fti ng devi ce.
(8) Remove nuts hol di ng rear of crossmember to the
frame.
(9) Remove bol ts hol di ng crossmember to frame from
above l ower control arms.
(10) Separate the crossmember from the vehi cl e.
(11) Transfer l ower control arms and sway el i mi na-
tor shaft to new crossmember, i f crossmember i s bei ng
repl aced. Refer to Group 2, Suspensi on for proper
procedure.
I NSTALLATI ON
FRAME DIMENSIONS
Frame di mensi ons are l i sted i n metri c scal e then
converted to i nch scal e l i sted i n parenthesi s. Al l di men-
si ons are from center to center of Pri nci pal Locati ng
Poi nt (PLP), or from center to center of PLP and
fastener l ocati on.
VEHI CLE PREPARATI ON
Posi ti on the vehi cl e on a l evel work surface. Usi ng
screw or bottl e jacks, adjust the vehi cl e PLP hei ghts to
the speci fi ed di mensi on above a l evel work surface.
Verti cal di mensi ons can be taken from the work sur-
face to the l ocati ons i ndi cated (Fi g. 8, 9, 10 or 11).
Fig. 6 Front Wheel Drive Van/Wagon Crossmember
Fig. 7 All Wheel Drive Van/Wagon Crossmember
Fig. 8 Dimensions Rear of CrossmemberShort Wheel Base Van/Wagon
Fig. 9 Dimensions Rear of CrossmemberLong Wheel Base Van/Wagon
Fig. 10 Dimensions Forward of Gage Hole Rear of Crossmember All Van/Wagons
Fig. 11 Engine Compartment DimensionsAll Van/Wagons
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 17
servi ce manual .
EXHAUST SYSTEMS
The exhaust systems are produced i n several con-
fi gurati ons, dependi ng on engi ne and vehi cl e (Fi g. 1).
Al l wheel dri ve vehi cl es have underfl oor catal yti c con-
verters, front wheel dri ve vehi cl es requi re front
mounted catal yti c converters. Tai l pi pes, muffl ers, and
resonators are si zed and tuned to each
vehi cl e/powertrai n combi nati on (Fi g. 1).
CATALYTI C CONVERTERS
There i s no regul arl y schedul ed mai ntenance on any
Chrysl er catal yti c converter. I f damaged, the converter
must be repl aced.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies, ex-
treme care should be taken with replacement parts.
There are internal converter differences required in
some parts of the country (particularly California
vehicles).
Fig. 1 Exhaust SystemAll Vehicles
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
SPECI AL EXHAUST BALL-JOI NT COUPLI NG
A speci al exhaust bal l -joi nt coupl i ng (Fi g. 2) i s used
to secure the exhaust pi pe to the engi ne mani fol d. Thi s
l i vi ng joi nt actual l y moves back and forth as the engi ne
moves, preventi ng breakage that coul d occur from the
back-and-forth moti on of a transverse mounted engi ne.
The exhaust bal l joi nt has two bol ts, two spri ngs, and
a bal l joi nt seal ri ng that i s a separate part from the
exhaust pi pe.
EXHAUST GAS RECI RCULATI ON (EGR)
To assi st i n the control of oxi des of ni trogen (NOx) i n
engi ne exhaust, al l engi nes are equi pped wi th an
exhaust gas reci rcul ati on system. The use of exhaust
gas to di l ute i ncomi ng ai r/fuel mi xtures l owers peak
fl ame temperatures duri ng combusti on, thus l i mi ti ng
the formati on of NOx.
Exhaust gases are taken from openi ng i n the exhaust
mani fol d passage to the i ntake mani fol d.
REFER TO SECTI ON 25 FOR A COMPLETE
DESCRI PTI ON, DI AGNOSI S AND SERVI CE
PROCEDURES ON THE EXHAUST GAS RECI RCU-
LATI ON SYSTEM AND COMPONENTS.
HEAT SHI ELDS
Heat shi el ds (Fi g. 3) are needed to protect both the
vehi cl e and the envi ronment from the hi gh tempera-
tures devel oped near the catal yti c converters.
See Body and Sheet Metal , Group 23 for servi ce
procedures.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and ob-
jectionable fumes.
Fig. 2 Ball-Joint Connection
Fig. 3 Heat Shields
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD
The combusti on reacti on caused by the catal yst re-
l eases addi ti onal heat i n the exhaust system. Causi ng
temperature i ncreases i n the area of the reactor under
severe operati ng condi ti ons. Such condi ti ons can exi st
when the engi ne mi sfi res or otherwi se does not operate
at peak effi ci ency. Do not remove spark pl ug wi res
from pl ugs or by any other means short out cyl i nders i f
exhaust system i s equi pped wi th catal yti c converter.
Fai l ure of the catal yti c converter can occur due to
temperature i ncreases caused by unburned fuel pass-
i ng through the converter.
The use of the catal ysts al so i nvol ves some non-
automoti ve probl ems. Unl eaded gasol i ne must be used
to avoi d poi soni ng the catal yst core. Do not al l ow
engi ne to operate at fast i dl e for extended peri ods (over
5 mi nutes). Thi s condi ti on may resul t i n excessi ve
exhaust system and fl oor pan temperatures.
EXHAUST SYSTEM DI AGNOSI S
SERVI CE
PROCEDURES
EXHAUST PIPES, MUFFLERS AND TAILPIPES
REMOVAL
(1) Rai se vehi cl e on hoi st and appl y penetrati ng oi l
to cl amp bol ts and nuts of component bei ng removed.
(2) Remove cl amps and supports (Fi gs. 4, 5, and 6)
from exhaust system to permi t al i gnment of parts
duri ng assembl y.
(3) When removi ng tai l pi pe, rai se rear of vehi cl e to
rel i eve body wei ght from rear spri ngs to provi de cl ear-
ance between pi pe and rear axl e parts.
(4) Cl ean ends of pi pes or muffl er to assure mati ng of
al l parts. Di scard broken or worn i nsul ators, rusted
cl amps, supports and attachi ng parts.
When replacement is required on any compo-
nent of the exhaust system. It is important that
original equipment parts(or their equivalent) be
used;
To i nsure proper al i gnment wi th other parts i n the
system.
Provi de acceptabl e exhaust noi se l evel s and does not
change exhaust system back pressure that coul d effect
emi ssi ons and performance.
I NSTALLATI ON
(1) Assembl e pi pes, muffl er supports and cl amps
l oosel y to permi t al i gnment of al l parts.
(2) Begi nni ng at front of system, al i gn and cl amp
each component to mai ntai n posi ti on and proper cl ear-
ance wi th underbody parts.
(3) Ti ghten al l cl amps and supports to the proper
torques and cl earances.
INTAKE AND EXHAUST MANIFOLDSTBI ENGINE
I NTAKE MANI FOLDS:
Naturally Aspirated Di e-cast al umi num l ong-
branch fan desi gn wi th remote pl enum. The throttl e
body i s i nstal l ed on the upper pl enum of the mani fol d.
EXHAUST MANI FOLDS:
Al l hi gh strength i ron casti ng that i ntermesh wi th
the i ntake mani fol d. For standard engi nes a four
branch desi gn col l ects and di rects exhaust gases to the
coni cal (arti cul ated joi nt connecti on) outl et.
THROTTLE BODY AI R HEATER
The throttl e body ai r heater (Fi g. 7) i s attached to the
exhaust mani fol d and i s removabl e.
I nspect ai r heater connector tube; repl ace i f dam-
aged. Refer to Emi ssi on Control Systems, Group 25, for
di agnosti c and servi ce procedures on the ai r control
val ve and temperature sensor l ocated i n the ai r
cl eaner.
Fig. 4 Exhaust (Converter/Resonator) Pipe to Muffler
Fig. 5 Muffler to Tail Pipe
Fig. 6 Rear Tail Pipe Bracket and Insulator
|INTAKE AND EXHAUST MANIFOLDS
SERVICETBI ENGINE
I ntake and exhaust mani fol ds use a one pi ece gasket.
Servi ce procedures requi ri ng removal and i nstal l ati on
(of ei ther) must i ncl ude both mani fol ds.
FUEL SYSTEM PRESSURE RELEASE PROCE-
DURE
The Fuel System is under a constant pressure
of at least 265 kPa (39 psi). Before servicing the
fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released.
(a) Loosen fuel fi l l er cap to rel ease fuel tank pres-
sure.
(b) Di sconnect i njector wi ri ng harness from engi ne
harness.
(c) Connect a jumper wi re to ground termi nal
Number 1 of the i njector harness (Fi g. 8) to engi ne
ground.
(d) Connect a jumper wi re to the posi ti ve termi nal
Number 2 of the i njector harness (Fi g. 8) and touch
the battery posi ti ve post for no l onger than 5 seconds.
Thi s rel eases system pressure.
(e) Remove jumper wi res.
(f) Conti nue fuel system servi ce.
REMOVAL
before attempting any repairs.
system. Refer to Cool i ng System, Group 7 for proce-
dure.
(3) Remove ai r cl eaner and di sconnect al l vacuum
l i nes, el ectri cal wi ri ng and fuel l i nes from throttl e body.
(4) Remove throttl e l i nkage.
(5) Loosen power steeri ng pump and remove bel t.
(6) Remove power brake vacuum hose from i ntake
mani fol d.
(7) Di sconnect EGR tube from i ntake mani fol d and
remove water hoses from water crossover.
(8) Rai se vehi cl e and remove exhaust pi pe from
mani fol d.
(9) Remove power steeri ng pump assembl y and set
asi de.
(10) Remove i ntake mani fol d retai ni ng screws (Fi g.
9).
(11) Lower vehi cl e and remove i ntake mani fol d.
(12) Remove exhaust mani fol d retai ni ng nuts (Fi g.
9).
(13) Remove exhaust mani fol d.
Fig. 7 Air Heater TBI Engines
Fig. 9 Intake and Exhaust Manifold Attaching
Points2.5L Engines
(1) Di scard gaskets and cl ean al l gasket surfaces on
both mani fol ds and on cyl i nder head.
(2) Test gasket surfaces of mani fol ds for fl atness
wi th a strai ght edge. Surfaces must be fl at wi thi n
0.15mm per 300mm (.006 i n. per foot) of mani fol d
l ength.
(3) I nspect mani fol ds for cracks and di storti on.
I NSTALLATI ON
(1) I nstal l a new i ntake and exhaust mani fol d gas-
ket. Coat steel gasket l i ghtl y wi th Gasket Seal er on
mani fol d si de. Do not coat composi ti on gasket wi th
(any) seal er.
(2) Set exhaust mani fol d i n pl ace. Ti ghten retai ni ng
nuts starti ng at center and progressi ng outward i n
both di recti ons to 23 Nm (200 i n. l bs.) (Fi g. 9). Repeat
thi s procedure unti l al l nuts are at speci fi ed torque.
(3) Set i ntake mani fol d i n pl ace.
(4) Rai se vehi cl e and ti ghten retai ni ng screws start-
i ng at center and progressi ng outward i n both di rec-
ti ons to 23 Nm (200 i n. l bs.) (Fi g. 9). Repeat thi s
procedure unti l al l screws are at speci fi ed torque.
(5) Reverse removal procedures 1-9 for i nstal l ati on.
(6) Wi th the DRB I I use ASD Fuel System Test to
pressuri ze system to check for l eaks.
CAUTION: When using the ASD Fuel System Test,
The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE AND EXHAUST MANIFOLDS3. 0L ENGINE
The i ntake system has a l arge ai r i ntake pl enum of
al umi num al l oy and a cross type i ntake mani fol d (Fi g.
2).
The exhaust mani fol ds are made of ducti l e cast i ron
wi th the front bank and rear bank i ndependent of each
other. The exhaust from the front bank exhaust mani -
fol d i s l ed through on exhaust crossover pi pe to be
combi ned wi th the rear bank exhaust at the exhaust
outl et to the exhaust pi pe (Fi g. 2).
I NTAKE PLENUM/MANI FOLD
REMOVAL
(before attempting any repairs).
system. See Cool i ng System, Group 7.
(3) Remove ai r cl eaner to throttl e body hose (Fi g. 3).
DURE
The MPI fuel systemis under a constant pres-
sure of approximately 330 kPa (48 psi). Before
servicing the fuel pump, fuel lines, fuel filter,
throttle body or fuel injector, the fuel system
sure.
harness.
ground.
(4) Remove throttl e cabl e and transaxl e ki ckdown
(5) Remove automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) wi ri ng connectors from
(Fi g. 5).
(7) Remove PCV and Brake booster hoses from Ai r
I ntake Pl enum.
(8) Remove I gni ti on Coi l from I ntake Pl enum (Fi g.
6).
(9) Remove wi ri ng connectors from cool ant tempera-
ture sensor (Fi g. 7).
(10) Remove vacuum connecti ons from Ai r I ntake
Pl enum vacuum connector.
(11) Remove fuel hoses from fuel rai l (Fi g. 7).
WARNING: WRAP SHOP TOWELS AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
(12) Remove (8) Fasteners from Ai r I ntake Pl enum
to I ntake Mani fol d (Fi g. 8).
(13) Remove Ai r I ntake Pl enum (Fi g. 9).
servi ci ng.
(15) Remove vacuum hoses from fuel rai l and fuel
pressure regul ator (Fi g. 10).
(16) Di sconnect Fuel I njector wi ri ng harness from
engi ne wi ri ng harness (Fi g. 11).
(17) Remove fuel pressure regul ator attachi ng bol ts
and remove regul ator from rai l (Fi g. 12). Be careful
not to damage the rubber injector O-rings upon
removal fromthe ports.
(18) Remove fuel rai l attachi ng bol ts and l i ft fuel rai l
assembl y from i ntake mani fol d.
(19) Separate radi ator hose from thermostat hous-
i ng and heater hose from heater pi pe.
(20) Remove (8) nut and washer assembl i es and
remove i ntake mani fol d (Fi g. 2).
I NSPECTI ON
Check for:
Damage and cracks of each secti on (Fi g. 13).
Cl ogged water passages i n end cross overs.
Check for di storti on of the cyl i nder head mounti ng
surface usi ng a strai ghtedge and thi ckness gauge (Fi g.
14). Refer to (Fi g. 15) for Speci fi cati ons.
Fig. 2 Intake and Exhaust Manifolds3.0L Engine
Fig. 3 Throttle Body Assembly3.0L
I NSTALLATI ON
(1) Posi ti on new i ntake mani fol d gaskets on cyl i nder
head and i nstal l i ntake (cross) mani fol d.
(2) I nstal l (8) nuts and washers and ti ghten i n
several steps i n order shown i n (Fi g. 16) to 20 Nm
(174 i n. l bs.).
(3) Make sure the i njector hol es are cl ean and al l
pl ugs have been removed.
(4) Lube i njector O-ri ng wi th a drop of cl ean engi ne
the ports.
(6) I nstal l the (3) fuel rai l attachi ng bol ts and torque
to 13 Nm (115 i n. l bs.).
(7) I nstal l fuel pressure regul ator onto fuel rai l .
I nstal l attachi ng bol ts to i ntake mani fol d. Torque regu-
l ator nuts and bracket bol ts to 10 Nm (95 i n. l bs.) (Fi g.
12).
(8) I nstal l fuel suppl y and return tube hol d-down
bol t and the vacuum crossover tube hol d-down bol t and
torque to 10 Nm (95 i n. l bs.).
(9) Connect fuel i njector wi ri ng harness to engi ne
wi ri ng harness (Fi g. 11).
(10) Connect vacuum harness to fuel pressure regu-
l ator and fuel rai l assembl y (Fi g. 10).
(11) Remove coveri ng from l ower i ntake mani fol d
and cl ean surface.
(12) Pl ace i ntake mani fol d gaskets with beaded
sealant side up on l ower mani fol d. Put ai r i ntake i n
pl ace. I nstal l attachi ng fasteners (8) and ti ghten i n
several steps i n sequence shown (Fi g. 17) to 13 Nm
(115 i n. l bs.).
(13) Connect fuel l i ne to fuel rai l (Fi g. 7). Torque
hose cl amps to 1 Nm (10 i n. l bs.).
(14) Connect vacuum harness to ai r i ntake pl enum.
Fig. 5 Electrical and Vacuum Connections to
Throttle Body
Fig. 6 Ignition Coil Removal
nections
(15) Connect and cool ant temperature sensor el ectri -
cal connector to sensor (Fi g. 7).
(16) Connect PCV and brake booster suppl y hose to
i ntake pl enum.
(17) Connect automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) el ectri cal connectors
(Fi g. 5).
(18) Connect vacuum vapor harness to throttl e body
(Fi g. 5).
(19) I nstal l throttl e cabl e and transaxl e ki ckdown
(20) I nstal l ai r i nl et hose assembl y (Fi g. 3).
(21) I nstal l radi ator to thermostat housi ng hose and
heater hose to heater pi pe ni ppl e.
(22) Fi l l cool i ng system, see Refi l l i ng System i n
Cool i ng, Group 7.
lected.
Fig. 8 Air Intake Plenum to Intake Manifold Attach-
ing Bolts
Fig. 9 Removing Air Intake Plenum
Fig. 10 Vacuum Connections for Fuel Rail and Fuel
Pressure Regulator
Fig. 11 Fuel Injector Wiring Harness
Fig. 12 Fuel Pressure Regulator to Fuel Rail Assem-
bly
Fig. 13 Check Intake (Cross) Manifold Mounting
Surface
Fig. 14 Check Intake Plenum Mounting Surfaces
Fig. 15 Intake Plenum and Cylinder Head Mounting
Surface Specifications
Fig. 16 Nut Tightening Sequence for Intake (Cross)
Manifold
Fig. 17 Intake Plenum Tightening Sequence
EXHAUST MANI FOLDS
REMOVAL
(1) Rai se vehi cl e and di sconnect exhaust pi pe from
rear (cowl si de) exhaust mani fol d at arti cul ated joi nt.
(2) Di sconnect Oxygen Sensor l ead wi re at the rear
exhaust mani fol d (Fi g. 18).
(3) Remove bol ts attachi ng cross-over pi pe to mani -
fol d (Fi gs. 2 and 19).
(4) Remove nuts attachi ng rear mani fol d to cyl i nder
head and remove mani fol d.
(5) Lower vehi cl e and remove screws attachi ng front
heat shi el d to front mani fol d (Fi g. 2).
(6) Remove bol ts fasteni ng crossover pi pe to front
exhaust mani fol d and nuts fasteni ng mani fol d to cyl -
i nder head. Remove assembl i es.
INSPECTION
I nspect exhaust mani fol ds for damage or cracks and
check di storti on of the cyl i nder head mounti ng surface
and exhaust crossover mounti ng surface wi th a
strai ghtedge and thi ckness gauge (Fi g. 20).
INSTALLATION
I nstal l the gaskets wi th the numbers 1-3-5 embossed
on the top on the rear bank and those wi th numbers
2-4-6 on the front (Radi ator si de) bank (Fi g. 21).
(1) I nstal l rear exhaust mani fol d and ti ghten attach-
i ng nuts to 20 Nm (175 i n. l bs.).
(2) Attach exhaust pi pe to exhaust mani fol d and
ti ghten shoul der bol t to 28 Nm (250 i n. l bs.).
(3) Attach crossover pi pe to exhaust mani fol d and
ti ghten bol t to 69 Nm (51 ft. l bs.).
(4) Connect heated oxygen sensor l ead (Fi g. 18).
(5) I nstal l front exhaust mani fol d and attach ex-
haust crossover.
(6) I nstal l front mani fol d heat shi el d and ti ghten
attachi ng screws to 15 Nm (130 i n. l bs.) (Fi g. 2).
Fig. 18 Separate Articulated Joint, Disconnect Oxy-
gen Sensor Wire
Fig. 19 Crossover Pipe
Fig. 20 Check Exhaust Manifold Mounting Surface
Fig. 21 Identify Exhaust Manifold Gaskets
INTAKE/EXHAUST MANIFOLD 3. 3L ENGINE
REMOVAL
(before attempting any repairs).
system. See Cool i ng System, Group 7.
DURE
The MPI fuel systemis under a constant pres-
sure of approximately 330 kPa (48 psi). Before
servicing the fuel pump, fuel lines, fuel filter,
throttle body or fuel injector, the fuel system
sure.
harness.
ground.
(3) Remove ai r cl eaner to throttl e body hose assem-
bl y (Fi g. 2).
(4) Remove throttl e cabl e (Fi g. 3). Remove wi ri ng
harness from throttl e cabl e bracket.
(5) Remove automati c i dl e speed (AI S) motor and
throttl e posi ti on sensor (TPS) wi ri ng connectors from
(Fi g. 4).
(7) Remove PCV and brake booster hoses from ai r
i ntake pl enum (Fi g. 5).
(8) Remove EGR tube fl ange from i ntake pl enum
(Fi g. 5).
(9) Di sconnect Charge Temperature Sensor el ectri -
cal connector. Remove vacuum harness connectors
from I ntake Pl enum (Fi g. 5).
(10) Remove cyl i nder head to i ntake pl enum strut
(Fi g. 5).
(11) Di sconnect MAP Sensor and heated Oxygen
Sensor el ectri cal connecti on. Remove the engi ne
mounted ground strap (Fi g. 6).
Fig. 2 Throttle Body Assembly 3.3L
(12) Remove the fuel hose qui ck connect fi tti ngs
from the fuel rai l by usi ng an open end wrench pushi ng
i n on the pl asti c ri ng l ocated on the end of the fi tti ngs.
Gentl y pul l the fi tti ngs from the fuel rai l (Fi g. 7).
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE DURING RE-
MOVAL.
(13) Remove di rect i gni ti on system (DI S) coi l s and
al ternator bracket to i ntake mani fol d bol t (Fi g. 8).
(14) Remove i ntake mani fol d bol ts and rotate mani -
fol d back over rear val ve cover (Fi g. 9).
servi ci ng (Fi g. 10).
(16) Remove vacuum harness connector from Fuel
Pressure Regul ator.
Body
Fig. 5 Electrical and Vacuum Connections To Intake
Manifold
Fig. 6 MAP Sensor Electrical Connector
Fig. 7 Quick Connect Fuel Fittings to Fuel Rail
(17) Remove fuel tube retai ner bracket screw and
fuel rai l attachi ng bol ts (Fi g. 10). Spread the retai ner
bracket to al l ow fuel tube removal cl earance.
(18) Remove fuel rai l i njector wi ri ng cl i p from the
al ternator bracket (Fi g. 11).
(19) Di sconnect cam sensor, cool ant temperature
sensor, and engi ne temperature sensors (Fi g. 11).
(20) Remove fuel i njector wi ri ng cl i p from i ntake
mani fol d water tube.
(21) Remove fuel rai l . Be careful not to damage the
rubber i njector O-ri ngs upon removal from thei r ports
(Fi g. 12).
(22) Remove upper radi ator hose, bypass hose and
rear i ntake mani fol d hose (Fi g. 13).
(23) Remove i ntake mani fol d bol ts. Remove i ntake
mani fol d.
(24) Remove i ntake mani fol d seal retai ners screws
(Fi g. 14). Remove i ntake mani fol d gasket.
I NSPECTI ON
Check for:
Damage and cracks of each secti on.
Cl ogged water passages i n end crossovers.
INSTALLATION
heads.
(2) Pl ace a drop (approxi matel y 1/4 i n. di ameter) of
Mopar Si l i cone Rubber Adhesi ve Seal ant or equi val ent,
onto each of the four mani fol d to cyl i nder head gasket
corners (Fi g. 15).
Fig. 8 Ignition Coils
Fig. 9 Intake Manifold Bolts
Fig. 10 Fuel Rail Attaching Bolts
Fig. 11 Fuel Injector Wiring Clip
WARNING: INTAKE MANIFOLD GASKET IS MADE OF
VERY THIN METAL AND MAY CAUSE PERSONAL
INJURY, HANDLE WITH CARE.
(3) Careful l y i nstal l the i ntake mani fol d gasket (Fi g.
14). Torque end seal retai ner screws to 12 Nm (105 i n.
l bs.).
(4) I nstal l i ntake mani fol d and (8) bol ts and torque
to 1 Nm (10 i n. l bs.). Then retorque bol ts to 22 Nm
(200 i n. l bs.) i n sequence shown i n (Fi g. 13). Then
retorque agai n to 22 Nm (200 i n. l bs.). After i ntake
mani fol d i s i n pl ace, inspect to makesureseals are
in place.
(5) Make sure the i njector hol es are cl ean and al l
pl ugs have been removed.
(6) Lube i njector O-ri ng wi th a drop of cl ean engi ne
the ports (Fi g. 12).
(8) I nstal l the (4) fuel rai l attachi ng bol ts and torque
to 22 Nm (200 i n. l bs.) (Fi g. 10).
(9) I nstal l fuel tube retai ni ng bracket screw and
torque to 4 Nm (35 i n. l bs.) (Fi g. 10).
(10) Reconnect cam sensor, cool ant temperature sen-
sor and engi ne temperature sensors (Fi g. 11).
(11) I nstal l fuel i njector harness wi ri ng cl i ps on the
al ternator bracket and i ntake mani fol d water tube
(Fi g. 11).
(12) Connect fuel pressure regul ator vacuum l i ne.
(13) Remove coveri ng on l ower i ntake mani fol d and
cl ean surface.
(14) Pl ace i ntake mani fol d gasket on l ower mani fol d.
Put upper mani fol d i nto pl ace and i nstal l bol ts fi nger
ti ght.
(15) I nstal l the al ternator bracket to i ntake mani -
fol d bol t and the cyl i nder head to i ntake mani fol d strut
bol ts. (Do not torque.)
Fig. 12 Fuel Rail Removal
Fig. 13 Intake Manifold Removal and Installation
Fig. 14 Intake Manifold Gasket
Fig. 15 Intake Manifold Gasket Sealing
(16) Torque i ntake mani fol d bol ts to 28 Nm (250 i n.
l bs.) fol l owi ng torque sequence i n (Fi g. 9).
(17) Torque al ternator bracket to i ntake mani fol d
bol t to 54 Nm (40 ft. l bs.) (Fi g. 8).
(18) Torque the cyl i nder head to i ntake mani fol d
strut bol ts to 54 Nm (40 ft. l bs.) (Fi g. 5).
(19) Connect ground strap, MAP and heated oxygen
sensor el ectri cal connectors (Fi g. 6).
(20) Connect charge temperature sensor el ectri cal
connector (Fi g. 5).
(21) Connect vacuum harness to i ntake pl enum (Fi g.
5).
(22) Usi ng a new gasket, connect the EGR tube
fl ange to the i ntake mani fol d and torque to 22 Nm
(200 i n. l bs.).
(23) Cl i p wi ri ng harness i nto the hol e i n the throttl e
cabl e bracket.
(24) Connect the wi ri ng connectors to the throttl e
posi ti on sensor (TPS) and Automati c I dl e Speed (AI S)
motor (Fi g. 4).
(25) Connect vacuum harness to throttl e body (Fi g.
4).
(26) I nstal l the di rect i gni ti on system (DI S) coi l s.
Torque fasteners to 12 Nm (105 i n. l bs.) (Fi g. 8).
(27) Lubri cate the ends of the chassi s fuel tubes wi th
30 wt. oi l . Connect fuel suppl y and return hoses to
chassi s fuel tube assembl y. Pul l back on the qui ck
connect fi tti ng to ensure compl ete i nserti on (Fi g. 7).
(Refer to Fuel Hoses, Cl amps and Qui ck Connect
Fi tti ngs i n Group 14 Fuel Systems).
(28) I nstal l throttl e cabl e (Fi g. 3).
(29) Connect fuel i njector wi ri ng harness.
(30) I nstal l ai r cl eaner and hose assembl y (Fi g. 2).
(31) Connect negati ve battery cabl e. Fi l l Cool i ng
System. See Cool i ng System, Group 7.
lected.
EXHAUST MANI FOLDS
REMOVAL
(1) Rai se vehi cl e and di sconnect exhaust pi pe from
rear (cowl si de) exhaust mani fol d at arti cul ated joi nt.
(2) Separate EGR tube from rear mani fol d and di s-
connect Heated Oxygen Sensor l ead wi re (Fi g. 16).
(3) Remove Al ternator/Power Steeri ng Support
Strut (Fi g. 16).
(4) Remove bol ts attachi ng cross-over pi pe to mani -
fol d (Fi g. 16).
(5) Remove bol ts attachi ng rear mani fol d to cyl i nder
head and remove mani fol d.
(6) Lower vehi cl e and remove screws attachi ng front
heat shi el d to front mani fol d (Fi g. 17).
(7) Remove bol ts fasteni ng crossover pi pe to front
exhaust mani fol d and nuts fasteni ng mani fol d to cyl -
i nder head. Remove assembl i es (Fi g. 18).
INSPECTION
I nspect exhaust mani fol ds for damage or cracks and
check di storti on of the cyl i nder head mounti ng surface
and exhaust crossover mounti ng surface wi th a
strai ghtedge and thi ckness gauge (Fi g. 19).
INSTALLATION
(1) I nstal l rear exhaust mani fol d and ti ghten attach-
i ng bol ts to 23 Nm (200 i n. l bs.).
(2) Attach exhaust pi pe to exhaust mani fol d and
ti ghten shoul der bol t to 28 Nm (250 i n. l bs.).
(3) Attach crossover pi pe to exhaust mani fol d and
ti ghten bol t to 33 Nm (25 ft. l bs.) and connect oxygen
sensor l ead (Fi g. 16).
Fig. 16 EGR Tube, Heated Oxygen Sensor and
Alternator/Power Steering Strut
Fig. 17 Heat Shield
(4) Rei nstal l EGR Tube and Al ternator/Power Steer-
i ng Strut (Fi g. 16).
(5) I nstal l front exhaust mani fol d and attach ex-
haust crossover (Fi g. 18).
(6) I nstal l front mani fol d heat shi el d and ti ghten
attachi ng screws to 23 Nm (200 i n. l bs.) (Fi g. 17).
TORQUE SPECI FI CATI ON
Fig. 18 Crossover Pipe
Fig. 19 Check Exhaust Manifold Mounting Surface
LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY . . . . . . . . . . . . . . . . . . . . 19
DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INDEX
page page
Classification of Lubricants . . . . . . . . . . . . . . . . . . . 1
Fuel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hoisting Recommendations . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Jump Starting Procedure . . . . . . . . . . . . . . . . . . . . 2
Parts and Lubricant Recommendations . . . . . . . . . . 1
Parts Requiring No Lubrication . . . . . . . . . . . . . . . . 2
Severe Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Towing Recommendations . . . . . . . . . . . . . . . . . . . 6
INTRODUCTION
Chrysl er Corporati on has compi l ed recommended
l ubri cati on and mai ntenance schedul es and procedures
to hel p reduce premature wear or fai l ure over a broad
range of operati ng condi ti ons. When sel ecti ng the
proper mai ntenance schedul e, the cl i mate and operat-
i ng condi ti ons must be consi dered. A vehi cl e subjected
to severe usage requi res servi ce more frequentl y than a
vehi cl e used for general transportati on.
PARTS AND LUBRICANT RECOMMENDATIONS
When servi ce i s requi red, Chrysl er Corporati on rec-
ommends that onl y Mopar brand parts, l ubri cants
and chemi cal s be used. Mopar provi des the best
engi neered products for servi ci ng Chrysl er Corpora-
ti on vehi cl es.
SEVERE SERVICE
I f a vehi cl e i s operated under any of the fol l owi ng
condi ti ons, i t i s consi dered severe servi ce.
Extremel y dusty areas.
50% or more of vehi cl e operati on i n 32C (90F) or
hi gher temperatures.
Prol onged i dl i ng (such as, vehi cl e operati on i n stop
and go traffi c).
Frequent short runni ng peri ods. Not al l owi ng en-
gi ne to warm to operati ng temperatures.
Pol i ce or taxi usage.
FUEL USAGE
Al l Chrysl er Corporati on engi nes requi re the use of
unl eaded fuel to reduce exhaust emi ssi ons. See Engi ne
secti on of thi s group for Fuel Recommendati ons.
CLASSIFICATION OF LUBRICANTS
Onl y l ubri cants that are endorsed by the fol l owi ng
organi zati on shoul d be used to servi ce a Chrysl er
Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API )
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
ENGI NE OI L
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
SAE 30 = si ngl e grade engi ne oi l .
SAE 5W-30 = mul ti pl e grade engi ne oi l .
API QUALITY CLASSIFICATION.
SG servi ce engi ne oi l i s a hi gh qual i ty crankcase
l ubri cant desi gned for use i n al l natural l y aspi rated
engi nes.
SG/CD servi ce engi ne oi l i s a hi gh qual i ty crankcase
l ubri cant desi gned for use i n most natural l y aspi rated
and turbocharged gasol i ne or di esel engi nes.
GEAR LUBRI CANTS
SAE rati ngs al so appl y to mul ti pl e grade gear l ubri -
cants. I n addi ti on, API cl assi fi cati on defi nes the l ubri -
cants usage.
LUBRICATION AND MAINTENANCE 0 - 1
LUBRI CANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage by
the NLGI . Al l approved products have the NLGI sym-
bol on the l abel .
At the bottom NLGI symbol i s the usage and qual i ty
i denti fi cati on l etters. Wheel beari ng l ubri cant i s i den-
ti fi ed by the l etter G. Chassi s l ubri cant i s i denti fi ed
by the l atter L. The l etter fol l owi ng the usage l etter
i ndi cates the qual i ty of the l ubri cant. The fol l owi ng
symbol s i ndi cate the hi ghest qual i ty.
PARTS REQUIRING NO LUBRICATION
Many components on a Chrysl er Corporati on vehi cl e
requi re no peri odi c mai ntenance. Some components
are seal ed and permanentl y l ubri cated. Rubber bush-
i ngs can deteri orate or l i mi t dampi ng abi l i ty i f l ubri -
cated. The fol l owi ng l i st of components requi re no
l ubri cati on:
Ai r Pump
Al ternator Bushi ngs
Dri ve Bel ts
Dri ve Bel t I dl er/Tensi oner Pul l ey
Front Wheel Beari ngs
Rubber Bushi ngs
Starter Beari ngs/Bushi ngs
Suspensi on Strut Beari ngs
Throttl e Control Cabl e
Throttl e Li nkage
Water Pump Beari ngs
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A,
BATTERY/STARTING/CHARGING SYSTEMS DIAG-
NOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PER-
DO NOT JUMP START WHEN BATTERY INDICATOR
DOT IS YELLOW OR BRIGHT COLOR.
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCHING OF BATTERY CURRENT.
WARNING: WHEN USING A HIGH OUTPUT BOOST-
ING DEVICE, DO NOT ALLOW DISABLED VEHICLES
BATTERY TOEXCEED 16 VOLTS. PERSONAL INJURY
OR DAMAGE TO ELECTRICAL SYSTEM CAN RE-
SULT.
CAUTION: When using another vehicle as a booster,
do not allowvehicles to touch. Electrical systems can
be damaged on either vehicle.
TO JUMP START A DI SABLED VEHI CLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y i n-
spect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Al ternator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster source,
turn off al l accessori es, pl ace gear sel ector i n park or
neutral , set park brake or equi val ent and operate
engi ne at 1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park or
neutral and set park brake or equi val ent. Turn OFF al l
accessori es (Keyl ess Entry and Ul tral i ght systems
must be turned OFF manual l y).
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to nega-
ti ve termi nal (-). DO NOTal l ow cl amps at opposi te end
of cabl es to touch, el ectri cal arc wi l l resul t (Fi g. 1).
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK jumper
cabl e cl amp to engi ne ground as cl ose to the ground
cabl e attachi ng poi nt as possi bl e (Fi g. 1).
NLGI SYMBOL
0 - 2 LUBRICATION AND MAINTENANCE
LUBRI CATI ON AND MAI NTENANCE SCHEDULES
GENERAL MAI NTENANCE SCHEDULES
SEVERE SERVI CE SCHEDULES
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Al l ow battery i n di sabl ed vehi cl e to charge to at
l east 12.4 vol ts (75% charge) before attempti ng to start
engi ne. I f engi ne does not start wi thi n 15 seconds, stop
cranki ng engi ne and al l ow starter to cool (15 mi n.),
before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne ground
on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect BLACK
cabl e cl amp from battery negati ve termi nal . Di scon-
nect RED cabl e cl amp from battery posi ti ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal on di sabl ed vehi cl e.
HOISTING RECOMMENDATIONS
Refer to Owners Manual provi ded wi th vehi cl e for
proper emergency jacki ng procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VE-
HICLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
FLUI D CAPACI TI ES
Fig. 1 Jumper Cable Clamp Connections
TO HOI ST OR JACK VEHI CLE SEE FI G. 2
TOWING RECOMMENDATIONS
RECOMMENDED TOWI NG EQUI PMENT
To avoi d damage to bumper fasci a and ai r dams use
of a wheel l i ft or fl at bed towi ng devi ce (Fi g. 3) i s
recommended. When usi ng a wheel l i ft towi ng devi ce,
be sure the unl i fted end of di sabl ed vehi cl e has at l east
100 mm (4 i n.) ground cl earance. I f mi ni mum ground
cl earance cannot be reached, use a towi ng dol l y. I f a fl at
bed devi ce i s used, the approach angl e shoul d not
exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be sure
there i s adequate ground cl earance at the opposi te end
of the vehi cl e, especi al l y when towi ng over rough
terrai n or steep ri ses i n the road. I f necessary, remove
the wheel s from the l i fted end of the vehi cl e and l ower
the vehi cl e cl oser to the ground, to i ncrease the ground
cl earance at the opposi te end of the vehi cl e. I nstal l l ug
nuts on wheel attachi ng studs to retai n brake drums or
rotors.
LOCKED VEHI CLE TOWI NG
When a l ocked vehi cl e must be towed wi th the front
wheel s on the ground, use a towi ng dol l y or fl at bed
haul er.
FLAT TOWI NG WI TH TOW BAR
Manual transaxl e vehi cl es can be fl at towed at any
l egal hi ghway speed wi th no di stance restri cti ons. The
steeri ng col umn must be unl ocked and gear sel ector i n
neutral .
4-speed automati c transaxl e vehi cl es can be fl at
towed at speeds not to exceed 72 km/h (44 mph) for not
more than 160 km (100 mi l es). The steeri ng col umn
must be unl ocked and gear sel ector i n neutral .
3-speed automati c transaxl e vehi cl es can be fl at
towed at speeds not to exceed 40 km/h (25 mph) for not
more than 25 km (15 mi l es). The steeri ng col umn must
be unl ocked and gear sel ector i n neutral .
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT VENTURE UNDER A LIFTED VEHICLE IF
NOT SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other under
vehicle components when attaching towing device to
vehicle.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Fig. 2 Hoisting and Jacking Points
Fig. 3 Recommended Towing Devices
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
TOWI NGFRONT WHEEL LI FT
Chrysl er Corporati on recommends that a vehi cl e be
towed wi th the front end l i fted, whenever possi bl e.
TOWI NGREAR WHEEL LI FT
I f a front wheel dri ve vehi cl e cannot be towed wi th
the front wheel s l i fted, the rear wheel s can be l i fted
provi ded the fol l owi ng gui de l i nes are observed.
CAUTION: Do not use steering column lock to secure
steering wheel during towing operation.
Unl ock steeri ng col umn and secure steeri ng wheel
i n strai ght ahead posi ti on wi th a cl amp devi ce de-
si gned for towi ng.
Veri fy that front dri ve l i ne and steeri ng components
are i n good condi ti on.
4-speed automati c transaxl e vehi cl es can be towed
at speeds not to exceed 72 km/h (44 mph) for not more
than 160 km (100 mi l es). The gear sel ector must be i n
neutral posi ti on.
3-speed automati c transaxl e vehi cl es can be towed
at speeds not to exceed 40 km/h (25 mph) for not more
than 25 km (15 mi l es). The gear sel ector must be i n
neutral posi ti on.
ENGI NE
INDEX
page page
Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankcase Ventilation System . . . . . . . . . . . . . . . 12
Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emission Control System . . . . . . . . . . . . . . . . . . . 14
Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Cooling System . . . . . . . . . . . . . . . . . . . . 10
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Frequency of Engine Oil and Filter Changes . . . . . . 8
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . 13
Ignition Cables, Distributor Cap, and Rotor . . . . . . 14
Rubber and Plastic Component Inspection . . . . . . 14
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FREQUENCY OF ENGINE OIL AND FILTER
CHANGES
ENGI NE OI L
Road condi ti ons as wel l as your ki nd of dri vi ng affect
the i nterval at whi ch your oi l shoul d be changed. Check
the fol l owi ng to determi ne i f any appl y to you:
Frequent short tri p dri vi ng l ess than 8 ki l ometers (5
mi l es)
Frequent dri vi ng i n dusty condi ti ons
Frequent trai l er towi ng
Extensi ve i dl i ng (such as vehi cl e operati on i n stop
and go traffi c)
More than 50% of your dri vi ng i s at sustai ned hi gh
speeds duri ng hot weather, above 32C (90F)
I f any of these appl y to you then change your engi ne
oi l every 4 800 ki l ometers (3,000 mi l es) or 3 months,
whi chever comes fi rst.
I f none of these appl y to you then change your oi l
every 12 000 ki l ometers (7,500 mi l es) or 6 months,
whi chever comes fi rst.
I f none of these appl y and the vehi cl e i s i n commer-
ci al type servi ce such as, Pol i ce, Taxi or Li mousi ne
used for hi ghway dri vi ng of 40 ki l ometers (25 mi l es) or
more between stati ons, the engi ne oi l shoul d be
changed every 8 000 ki l ometers (5,000 mi l es) or 6
months.
OI L FI LTER
The engi ne oi l fi l ter shoul d be repl aced wi th a new
fi l ter at every second oi l change.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL. CON-
TAMINANTS IN USED ENGINE OIL, CAUSED BY IN-
TERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA..
BREAK-I N PERI OD
CAUTION: Wide open throttle operation in low gears,
before engine break-in period is complete, can dam-
age engine.
On a Chrysl er Corporati on vehi cl e an extended
break-i n peri od i s not requi red. Dri vi ng speeds of not
over 80-90 km/h (50-55 mph) for the fi rst 100 km (60
mi l es) i s recommended. Hard accel erati on and hi gh
engi ne rpm i n l ower gears shoul d be avoi ded.
SELECTI NG ENGI NE OI L
CAUTION: Do not use non-detergent or straight min-
eral oil when adding or changing crankcase lubricant.
Engine or Turbocharger failure can result.
The factory fi l l engi ne oi l i s a hi gh qual i ty, energy
conservi ng, crankcase l ubri cant. The Recommended
SAE Vi scosi ty Grades chart defi nes the vi scosi ty
grades that must be used based on temperature i n the
regi on where vehi cl e i s operated (Fi g. 1) and opti onal
equi pment.
Chrysl er Corporati on recommends that Mopar mo-
tor oi l , or equi val ent, be used when addi ng or changi ng
crankcase l ubri cant. The API symbol (Fi g. 2) on the
contai ner i ndi cates the vi scosi ty grade, qual i ty and fuel
economy rati ngs of the l ubri cant i t contai ns. Use EN-
ERGY CONSERVI NG I I motor oi l wi th API SERVI CE
SG or SG/CD cl assi fi cati on.
SG servi ce engi ne oi l i s a hi gh qual i ty crankcase
l ubri cant desi gned for use i n al l natural l y aspi rated
engi nes.
SG/CD servi ce engi ne oi l i s a hi gh qual i ty crankcase
l ubri cant desi gned for use i n most natural l y aspi rated
and turbocharged gasol i ne or di esel engi nes.
SAE 5W-30 engi ne oi l i s recommended for use i n
3.0L and 3.3L engi nes i n temperatures bel ow 38C
(100F) to reduce l ow temperature cranki ng effort.
SAE 5W-30 engi ne oi l i s not recommended for use i n
2.5L engi ne i n temperatures above 0C (32F).
SAE 10W-30 engi ne oi l i s recommended for use i n
2.5L engi ne i n temperatures above -18C (0F).
ENGI NE OI L ADDI TI VES
Chrysl er Corporati on recommends that Mopar En-
gi ne Oi l Suppl ement or equi val ent be used when fri c-
ti on and corrosi on reduci ng materi al s added to the
crankcase l ubri cant i s desi red.
CRANKCASE OI L LEVEL I NSPECTI ON
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Posi ti on vehi cl e on l evel sur-
face. Wi th engi ne OFF, al l ow enough ti me for oi l to
settl e to bottom of crankcase, remove engi ne oi l l evel
i ndi cator (di psti ck) and wi pe cl ean. I nstal l di psti ck and
veri fy i t i s seated i n the tube. Remove di psti ck, wi th
handl e above ti p, take oi l l evel readi ng (Fi g. 3). Add oi l
onl y i f l evel i s bel ow MI N or ADD mark on di psti ck.
ENGI NE OI L CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Lubri cati on and Mai ntenance Schedul es.
TO CHANGE ENGINE OIL:
(1) Posi ti on the vehi cl e on a l evel surface.
(2) Hoi st and support vehi cl e on safety stands. Refer
to Hoi sti ng and Jacki ng Recommendati ons i n thi s
group.
(3) Pl ace a sui tabl e 3.8 l i ter (4 qt.) drai n pan under
crankcase drai n.
(4) Remove drai n pl ug from crankcase and al l ow oi l
to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug and
gasket i f damaged.
(5) I nstal l drai n pl ug i n crankcase.
(6) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s secti on.
(7) Start engi ne and i nspect for l eaks.
(8) Stop engi ne and i nspect oi l l evel .
RECOMMENDED VI SCOSI TY GRADES
Fig. 1 Shaded Areas Cover Regions Where
Minimum Temperatures Can Be Consistently
Below -12C (10F) During Winter Seasons.
Fig. 2 API Symbol
Fig. 3 Oil Level Indicator DipstickTypical
ENGINE OIL FILTER
SELECTI NG OI L FI LTER
Chrysl er Corporati on recommends a Mopar or
equi val ent oi l fi l ter be used when repl acement i s re-
qui red. A repl acement fi l ter must be desi gned to wi th-
stand 1756 kPa (256 psi ) of i nternal pressure.
OI L FI LTER REMOVAL:
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench (Fi g. 4) l oosen
fi l ter.
(3) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l ter
from vehi cl e.
(4) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 5) of oi l and gri me. Wi pe off oi l resi due
from bel ow oi l fi l ter adapter.
OI L FI LTER I NSTALLATI ON:
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne oi l
or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, ti ghten fi l ter one
ful l turn. I f necessary use a fi l ter wrench, do not over
ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start en-
gi ne. I nspect for oi l l eaks.
ENGINE COOLING SYSTEM
WARNI NGS AND PRECAUTI ONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWALLOWED
OR INHALED. IF SWALLOWED, DRINK TWO
GLASSES OF WATER AND INDUCE VOMITING. IF
INHALED, MOVE TO FRESH AIR AREA. SEEK MEDI-
CAL ATTENTION IMMEDIATELY. DO NOT STORE IN
OPEN OR UNMARKED CONTAINERS. WASH SKIN
AND CLOTHING THOROUGHLY AFTER COMING IN
CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF
REACH OF CHILDREN.
DISPOSE OF GLYCOL BASE COOLANT PROPERLY,
CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CENTER
IN YOUR AREA.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE ISAT RUNNING TEMPERATURE, PERSONAL
INJURY CAN RESULT.
AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PER-
FORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Do not use straight antifreeze as engine
coolant, inadequate engine running temperatures
can result.
Do not operate vehicle without proper concentra-
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engi ne cool i ng system wi l l devel op i nternal pres-
sure of 97 to 123 kPa (14 to 18 psi ) at normal operati ng
temperature. Al l ow the vehi cl e approxi matel y one hal f
hour to cool off before openi ng the cool i ng system. As an
i ndi cator of pressure, squeeze the upper radi ator hose
between i ndex fi nger and thumb. I f i t col l apses wi th
l i ttl e effort the system woul d have l ow i nternal pres-
sure and shoul d be safe to open to the fi rst safety notch
of the radi ator cap. Refer to Group 7, Cool i ng System.
COOLI NG SYSTEM I NSPECTI ON
Cool ant l evel (Fi g. 6) shoul d be i nspected when other
engi ne compartment servi ce i s performed or when
cool ant l eak i s suspected. Cool ant recovery tank l evel
shoul d read between the MI N and MAX marks, l ocated
on the si de of recovery tank, when the engi ne i s at
normal operati ng temperature. Normal cool ant l evel
mai ntenance does not requi re the removal of radi ator
cap. Cool i ng system freeze protecti on shoul d be tested
at the onset of the wi nter season or every 12 months.
Servi ce i s requi red i f cool ant i s l ow, contami nated,
rusty or freeze protec-
Fig. 4 Remove Oil Filter
Fig. 5 Install Oil Filter
Mti on i s i nadequate. To properl y test cool i ng system,
see Group 7, Cool i ng System.
The cool i ng system factory fi l l i s a mi xture of 50%
Gl ycol based anti freeze and 50% water. Usi ng a sui t-
abl e hydrometer, measure anti freeze concentrati on i n
the radi ator when the engi ne i s cool . I f the cool i ng
system has recentl y been servi ced, al l ow cool ant to
ci rcul ate for at l east 20 mi nutes before taki ng hydrom-
eter readi ng. Properl y mi xed cool ant wi l l protect the
cool i ng system to -37C (-35F). I f the freeze protecti on
i s above -28C (-20F), drai n enough cool ant from the
cool i ng system to al l ow room to add anti freeze to
achi eve adequate protecti on. A mi x tabl e on the cool ant
contai ner i ndi cates the amount of anti freeze requi red
to wi nteri ze the cool i ng system based on the capaci ty,
see Capaci ty Chart i n General I nformati on secti on of
thi s group.
SELECTI NG ANTI FREEZE
Chrysl er Corporati on recommends Mopar
Anti freeze/Summer Cool ant, or equi val ent be used to
wi nteri ze and protect cool i ng system.
RADI ATOR CAP
The radi ator cap must be secure to provi de proper
pressure rel ease and cool ant recovery. I nspect and test
radi ator cap when cool i ng system servi ce i s performed
or when probl em i s suspected.
COOLI NG SYSTEM SERVI CE
The cool i ng system shoul d be drai ned, fl ushed and
fi l l ed wi th the proper cool ant mi xture at the i nterval s
descri bed i n the Lubri cati on and Mai ntenance Sched-
ul es. Refer to General I nformati on secti on of thi s
group. For proper servi ce i nstructi ons see Group 7,
Cool i ng System.
ENGINE AIR CLEANER
The engi ne ai r cl eaner shoul d be servi ced at the
i nterval s descri bed i n the Lubri cati on and Mai nte-
nance Schedul es. Refer to General I nformati on secti on
of thi s group. Addi ti onal i nformati on can be found i n
Group 14, Fuel System and Group 25, Emi ssi on Sys-
tem. I nspect al l ai r cl eaner hoses or tubes for damage
or l eaks when other engi ne compartment servi ce i s
performed. Repl ace faul ty components.
AI R CLEANER SERVI CE
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine control-
ler to function correctly.
Do not immerse paper air filter element or tempera-
ture sensor in cleaning solvents, damage can result.
TO SERVICE AIR CLEANER ASSEMBLY:
(1) Rai se hood of vehi cl e and i nspect al l ai r cl eaner
components for damage or i mproper attachment.
(2) Remove ai r cl eaner cover (Fi gs. 7, 8 or 9).
(3) Remove paper ai r fi l ter el ement from ai r cl eaner
body. Hol d a shop l i ght on throttl e body si de of el ement.
I nspect ai r i ntake si de of el ement. I f l i ght i s vi si bl e
through el ement, bl ow dust from el ement
Fig. 6 Coolant Recovery TankTypical
Fig. 7 Air Cleaner Assembly3.0L Engine
Fig. 8 Air Cleaner Assembly2.5L EFI Engine
(Fi g. 10) and reuse. I f el ement i s saturated wi th oi l or
l i ght i s not vi si bl e, repl ace fi l ter. I f el ement i s satu-
rated wi th oi l , perform crankcase venti l ati on system
tests.
(4) Remove fi ber crankcase fi l ter (Fi gs. 7, 8 or 9) and
cl ean wi th sol vent, squeeze fi l ter dry and appl y smal l
amount of engi ne oi l . I f a metal l i c mesh i s used to
retai n fi ber fi l ter, cl ean mesh wi th sol vent and reuse.
(5) Cl ean i nsi de of ai r cl eaner cover and body wi th
vacuum or compressed ai r. I f oi l y, wash wi th sol vent.
To I nstal l , reverse the precedi ng operati on.
CRANKCASE VENTILATION SYSTEM
Engi ne crankcase pressure and emi ssi ons are vented
i nto combusti on chambers through the posi ti ve crank-
case venti l ati on (PCV) system. The PCV system con-
si sts of a crankcase fi l ter (Fi gs. 7, 8 or 9), PCV val ve
(Fi gs. 11, 12 or 13) and hoses to compl ete a vacuum
ci rcui t. The PCV system shoul d have enough vol ume to
overcome crankcase pressure created by pi ston back-
wash. I f a PCV system becomes pl ugged, the crankcase
pressure wi l l i ncrease and force engi ne oi l past the
pi ston ri ngs creati ng oi l consumpti on. Bl ockage of PCV
system can occur at the vacuum source coupl i ng, PCV
val ve, crankcase fi l ter or a col l apsed hose.
Chrysl er Corporati on recommends that a PCV val ve
not be cl eaned. A new Mopar or equi val ent PCV val ve
shoul d be i nstal l ed when servi ci ng i s requi red. Over a
peri od of ti me, dependi ng on the envi ronment where
vehi cl e i s used, deposi ts bui l d up i n the PCV vacuum
ci rcui t. PCV system shoul d be i nspected at every oi l
change. Servi ce PCV system i f engi ne oi l i s di scharged
i nto ai r cl eaner.
PCV SYSTEM TEST
(1) Veri fy that fi ber crankcase fi l ter i s cl ean and
properl y i nstal l ed i n the ai r cl eaner assembl y.
(2) Wi th the engi ne runni ng at i dl e, remove crank-
case i nl et hose from the i nl et fi l ter ni ppl e. Posi ti on a
Fig. 9 Air Cleaner Assembly3.3L Engine
Fig. 10 Cleaning Air Filter Element
50 mm (2 i n.) square paper card over end of i nl et hose.
The card shoul d be drawn to the end of the i nl et hose
wi thi n 15 seconds. I f not, a l eak or restri cti on exi sts i n
the PCV vacuum ci rcui t.
(3) I f card does not hol d to end of i nl et hose, di scon-
nect PCV val ve from cyl i nder head cover or adapter.
Vacuum hi ssi ng sound shoul d be heard and engi ne
shoul d run steady. Pl ace a fi nger over end of PCV val ve
(Fi g. 14). The check val ve i n the PCV val ve shoul d cl i ck
and rattl e when PCV val ve i s shaken.
(4) Remove PCV val ve from vacuum source hose.
The engi ne shoul d run very errati cal l y or stal l . I f not, a
vacuum restri cti on or bl ockage exi sts at the vacuum
source.
FUEL RECOMMENDATIONS
Chrysl er Corporati on recommends that onl y fuel
purchased from a reputabl e retai l er be used. Use hi gh
qual i ty, unl eaded gasol i ne to provi de sati sfactory
dri veabi l i ty and hi ghest fuel economy. Gasol i ne con-
tai ni ng detergent and corrosi on control addi ti ves are
desi reabl e. I f the engi ne devel ops spark knock (audi bl e
pi ng), poor performance, hard starti ng or stal l i ng,
purchase fuel from another source. Engi ne perfor-
mance can vary when usi ng di fferent brands of gaso-
l i ne wi th the same octane rati ng. Occasi onal l i ght
engi ne spark knock under heavy accel erati on, at l ow
speed or when vehi cl e i s heavi l y l oaded i s not harmful .
Extended peri ods of spark knock under moderate ac-
cel erati on or at crui si ng speed can damage the engi ne.
The cause of excessi ve spark knock condi ti on must be
di agnosed and corrected. For di agnosti c procedures
refer to Group 14, Fuel System and Powertrai n Di ag-
nosti c Procedures manual .
SELECTI NG GASOLI NE
CAUTION:Do not use fuel containing METHANOL
(methyl or wood alcohol), damage to fuel system will
result.
Do not use leaded gasoline, damage to catalytic
converter will result and vehicle will not conform to
emission control standards.
Fig. 11 PCV System3.0L Engine
Fig. 12 PCV System3.3L Engine
Fig. 13 PCV System2.5L EFI Engine
Fig. 14 PCV Valve Test
NON-BLENDED GASOLINE
Use regul ar unl eaded gasol i ne havi ng a mi ni mum
octane rati ng of 87 (R+M)/2. Hi gher octane premi um
unl eaded gasol i ne can be used i f desi red.
ETHANOL, MTBE OR ETBE BLENDS
Al l Chrysl er Corporati on vehi cl es are desi gned to use
unl eaded gasol i ne ONLY. Gasohol bl ends, contai ni ng
10% Ethanol (ethyl or grai n al cohol ) 90% unl eaded
gasol i ne can be used provi ded i t has adequate octane
rati ng. Fuel bl ends contai ni ng up to 15% MTBE (Me-
thyl Terti ary Butyl Ether) and 85% unl eaded gasol i ne
can be used. Fuel bl ends contai ni ng up to 17% ETBE
(Ethyl Terti ary Butyl Ether) and 83% unl eaded gaso-
l i ne can al so be used.
Fuel bl ended wi th ethanol , MTBE or ETBE are al so
referred to as reformul ated or cl ean ai r gasol i ne. These
fuel s contri bute l ess emi ssi ons to the atmosphere.
Chrysl er Corporati on recommends that bl ended fuel s
be used when avai l abl e
METHANOL BLENDS
Usi ng gasol i ne bl ended wi th methanol can resul t i n
starti ng and dri veabi l i ty probl ems. Deteri orati on of
fuel system components wi l l resul t. Methanol i nduced
probl ems are not the responsi bi l i ty of Chrysl er Corpo-
rati on and may not be covered by the vehi cl e warranty.
FUEL FILTER
The fuel fi l ter requi res servi ce onl y when a fuel
contami nati on probl em i s suspected. For proper di ag-
nosti c and servi ce procedures refer to Group 14, Fuel
System,
IGNITION CABLES, DISTRIBUTOR CAP, AND RO-
TOR
I nspect and test i gni ti on cabl es, di stri butor cap and
rotor when the spark pl ugs are repl aced. Oi l and gri me
shoul d be cl eaned from the i gni ti on cabl es and di s-
tri butor cap to avoi d possi bl e spark pl ug foul i ng. Mo-
par, Foamy Engi ne Degreaser, or equi val ent i s recom-
mended for cl eani ng the engi ne compartment. For
proper servi ce and di agnosti c procedures refer to
Group 8D, I gni ti on System.
SPARK PLUGS
I gni ti on spark pl ugs shoul d be repl aced at the mi l e-
age i nterval descri bed i n the Lubri cati on and Mai nte-
nance Schedul es. Refer to the General I nformati on
secti on of thi s group. For proper servi ce procedures
refer to Group 8D, I gni ti on Systems.
DRIVE BELTS
I nspect and adjust dri ve bel ts at the i nterval de-
scri bed i n the Lubri cati on and Mai ntenance Schedul es.
Refer to General I nformati on secti on of thi s group. For
proper i nspecti on and adjustment procedures, see
Group 7, Cool i ng System.
EMISSION CONTROL SYSTEM
I nspect al l emi ssi on control components and hoses
when other under hood servi ce i s performed. Refer to
emi ssi on system Vacuum Hose Label l ocated on the
i nsi de of the hood i n the engi ne compartment and
Group 25, Emi ssi on Control Systems for proper servi ce
procedures.
BATTERY
I nspect battery tray, hol d down and termi nal connec-
ti ons when other under hood servi ce i s performed. For
proper di agnosti c procedures refer to Group 8A,
Battery/Starti ng/Chargi ng System Di agnosti cs. For
servi ce and cl eani ng procedures refer to Group 8B,
Battery/Starter Servi ce.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
Position plastic or rubber components away from
moving parts in engine compartment or under ve-
hicle, or damage will result.
Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause of
oil contamination and clean area.
Al l rubber and pl asti c components shoul d be i n-
spected when engi ne compartment or under vehi cl e
servi ce i s performed. When evi dence of deteri orati on
exi sts, repl acement i s requi red. To reduce deteri orati on
of rubber components, Chrysl er Corporati on recom-
mends Mopar Foamy Engi ne Degreaser or equi val ent
be used to cl ean engi ne compartment of oi l and road
gri me.
EXHAUST SYSTEM I SOLATOR AND HANGER
The exhaust system shoul d be i nspected when under
vehi cl e servi ce i s performed. The exhaust system
shoul d not make contact wi th under body, brake cabl es,
brake/fuel l i nes, fuel tank or suspensi on components.
Sl i ght cracki ng i n rubber i sol ator or hanger i s accept-
abl e. Severel y cracked or broken rubber components
must be repl aced. For proper servi ce procedures see
Group 11, Exhaust System and I ntake Mani fol d.
DRI VETRAI N
INDEX
page page
Automatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . 15
Automatic Transaxle Shift Mechanism . . . . . . . . . . 15
Drive Line Module . . . . . . . . . . . . . . . . . . . . . . . . 17
Drive Shaft CV and Tripod Joint Boots . . . . . . . . . 17
Front Wheel Bearings (Rear Wheel Bearings on
All Wheel Drive Models) . . . . . . . . . . . . . . . . . . 17
Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . 16
Power Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . 16
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CLUTCH AND GEARSHIFT LINKAGE
I f the cl utch or gearshi ft begi ns to operate wi th
di ffi cul ty, squeak or grunt, the cabl es and l i nkage
shoul d be l ubri cated before servi ce repl acement i s
performed. For proper l ubri cati on and servi ce proce-
dures refer to Group 6, Cl utch, or Group 21, Manual
Transaxl e.
MANUAL TRANSAXLE
The manual transaxl e shoul d be i nspected for oi l
l eaks and proper oi l l evel when other under vehi cl e
servi ce i s performed. To i nspect the transaxl e oi l l evel ,
posi ti on the vehi cl e on a l evel surface. Remove fi l l pl ug
(Fi g. 1) from the transaxl e si de cover. The oi l l evel
shoul d not be bel ow 4 mm (3/16 i n) from bottom of oi l
fi l l openi ng.
The manul transaxl e does not requi re peri odi c mai n-
tenance. The oi l shoul d be changed onl y when water
contami nati on i s suspected. I f oi l has a foamy or mi l ky
appearance i t probabl y i s contami ned. A ci rcul ar mag-
net l ocated behi nd the di fferenti al cover col l ects metal -
l i c parti cl es ci rcul ati ng i n the oi l . For proper di agnosti c
and servi ce procedures, refer to Group 21, Manual
Transaxl e.
SELECTI NG MANUAL TRANSAXLE OI L
Chrysl er Corporati on recommends Mopar Engi ne
Oi l , SG or SG/CD SAE 5W-30, or equi val ent, be used to
fi l l a 5-speed transaxl e.
AUTOMATIC TRANSAXLE SHIFT MECHANISM
I f the automati c transaxl e shi ft mechani sm becomes
di ffi cul t to operate or starts to make objecti onabl e
noi se, the mechani sm shoul d be l ubri cated before other
servi ce repai r i s performed. Appl y a fi l m of Mopar
Mul ti purpose Grease or equi val ent, to sl i de surfaces
and pawl spri ng. For addi ti onal i nformati on, refer to
Group 21, Transaxl e.
AUTOMATIC TRANSAXLE
The automati c transaxl e shoul d be i nspected for fl ui d
l eaks and proper fl ui d l evel when other under hood
servi ce i s performed.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill hole or tube after fluid
level reading is taken.
TO INSPECT THE TRANSAXLE FLUID LEVEL:
(1) Posi ti on the vehi cl e on a l evel surface.
(2) Start engi ne and al l ow to i dl e i n PARK for at
l east 60 seconds. The warmer the transaxl e fl ui d, the
more accurate the readi ng.
(3) Whi l e si tti ng i n dri ver seat, appl y brakes and
pl ace gear sel ector i n each posi ti on. Return gear sel ec-
tor to park.
(4) Rai se hood and remove transaxl e fl ui d l evel i ndi -
cator (di psti ck) and wi pe cl ean wi th a sui tabl e cl oth.
(5) I nstal l di psti ck and veri fy i t i s seated i n fi l l hol e
or tube (Fi g. 2 or 3).
CAUTION: Do not overfill automatic transaxle, leak-
age or damage can result.
(6) Remove di psti ck, wi th handl e above ti p, take
fl ui d l evel readi ng (Fi g. 4). I f the vehi cl e has been
dri ven for at l east 15 mi nutes before i nspecti ng fl ui d
l evel , transaxl e can be consi dered hot and readi ng
shoul d be above the WARM mark. I f vehi cl e has run for
l ess than 15 mi nutes and more than 60 seconds
Fig. 1 Manual Transaxle Fill Plug
transaxl e can be consi dered warm and readi ng shoul d
be above ADD mark. Add fl ui d onl y i f l evel i s bel ow
ADD mark on di psti ck when transaxl e i s warm.
The automati c transaxl e does not requi re peri odi c
mai ntenance when used for general transportati on. I f
the vehi cl e i s subjected to severe servi ce condi ti ons, the
automati c transaxl e wi l l requi re fl ui d/fi l ter change and
band adjustments every 24 000 km (15,000 mi l es). For
addi ti onal i nformati on, refer to Severe Servi ce para-
graph and Lubri cati on and Mai ntenance Schedul es i n
General I nformati on secti on of thi s group. The fl ui d
and fi l ter shoul d be changed when water contami na-
ti on i s suspected. I f fl ui d has foamy or mi l ky appear-
ance, i t i s probabl y contami nated. I f the fl ui d appears
brown or dark and a foul odor i s apparent, the fl ui d i s
burned, transaxl e requi res mai ntenance or servi ce. A
ci rcul ar magnet l ocated i n the transaxl e pan, col l ects
metal l i c parti cl es ci rcul ati ng i n the oi l . For proper
di agnosti c and servi ce procedures, refer to Group 21,
Automati c Transaxl e.
SELECTI NG AUTOMATI C TRANSAXLE FLUI D
Chrysl er Corporati on recommends Mopar ATF Pl us
(automati c transmi ssi on fl ui d type 7176) be used to
add to or repl ace automati c transaxl e fl ui d. I f ATF Pl us
i s not avai l abl e use Mopar Dexron I I Automati c
Transmi ssi on Fl ui d or equi val ent.
POWER TRANSFER UNIT
The Al l Wheel Dri ve (AWD) power transfer uni t
shoul d be i nspected for oi l l eaks and proper oi l l evel
when other under vehi cl e servi ce i s performed. To
i nspect the power transfer uni t oi l l evel , posi ti on the
vehi cl e on a l evel surface and remove the fi l l pl ug (Fi g.
5) from the uni t. The oi l l evel shoul d be at the bottom
edge of oi l fi l l openi ng.
The power transfer uni t does not requi re peri odi c
mai ntenance when subjected to normal dri vi ng condi -
ti ons. The oi l shoul d be changed when water contami -
nati on i s suspected. I f oi l has foamy or mi l ky appear-
ance i t probabl y i s contami nated. I f the vehi cl e i s
subjected to severe dri vi ng condi ti ons, the power trans-
fer uni t woul d requi re peri odi c mai ntenance every 29
000 km (12,000 mi l es). Refer to Severe Servi ce para-
graph i n General I nformati on of thi s group for defi ni -
ti on of severe servi ce. A magnet l ocated i n the uni t to
col l ect metal l i c parti cl es ci rcul ati ng i n the oi l . For
proper di agnosti c and servi ce procedures, refer to
Group 21, Transaxl e/Power Transfer Uni t.
SELECTI NG LUBRI CANT
Chrysl er Corporati on recommends Mopar Gear
Lube, SAE 85W-90, or equi val ent, be used to fi l l the
power transfer uni t.
OVERRUNNING CLUTCH
The Al l Wheel Dri ve (AWD) overrunni ng cl utch
shoul d be i nspected for oi l l eaks and proper oi l l evel
when other under vehi cl e servi ce i s performed. To
i nspect the overrunni ng cl utch oi l l evel , posi ti on the
vehi cl e on a l evel surface and remove the fi l l pl ug (Fi g.
6) from the uni t. The oi l l evel shoul d be at the bottom
edge of oi l fi l l openi ng.
The overrunni ng cl utch does not requi re peri odi c
ance i t probabl y i s contami nated. I f the vehi -
Fig. 2 Automatic Transaxle Fill hole
Fig. 3 Automatic Transaxle Fill tube
Fig. 4 Automatic Transaxle DipstickTypical
cl e i s subjected to severe dri vi ng condi ti ons the over-
runni ng cl utch woul d requi re peri odi c mai ntenance
every 36 000 km (22,500 mi l es). Refer to Severe Servi ce
paragraph i n General I nformati on of thi s group for
defi ni ti on of severe servi ce. For proper di agnosti c and
servi ce procedures, refer to Group 3, Rear Suspensi on
and Dri vel i ne.
Chrysl er Corporati on recommends Mopar ATF Pl us
(automati c transmi ssi on fl ui d type 7176) or equi val ent,
be used to add to or repl ace overrunni ng cl utch fl ui d.
DRIVE LINE MODULE
The dri ve l i ne modul e shoul d be i nspected for oi l
l eaks and proper oi l l evel when other under vehi cl e
servi ce i s performed. To i nspect the power transfer uni t
oi l l evel , posi ti on the vehi cl e on a l evel surface and
remove fi l l pl ug (Fi g. 7) from the modul e. The oi l l evel
shoul d be at the bottom edge of oi l fi l l openi ng.
The dri ve l i ne modul e does not requi re peri odi c
ance i t probabl y i s contami nated. I f the vehi cl e i s
subjected to severe dri vi ng condi ti ons, the dri ve l i ne
modul e woul d requi re peri odi c mai ntenance every 36
000 km (22,500 mi l es). Refer to Severe Servi ce para-
graph i n General I nformati on of thi s group for defi ni -
ti on of severe servi ce. For proper di agnosti c and servi ce
procedures, refer to Group 3, Rear Suspensi on and
Dri vel i ne.
Chrysl er Corporati on recommends Mopar Gear
Lube, SAE 85W-90, or equi val ent, be used to fi l l the
dri ve l i ne modul e.
DRIVE SHAFT CV AND TRIPOD JOINT BOOTS
The front dri ve shaft constant vel oci ty and tri pod
joi nt boots (Fi g. 8) shoul d be i nspected when other
under vehi cl e servi ce i s performed. I nspect boots for
cracki ng, tears, l eaks or other defects. I f servi ce repai r
i s requi red, refer to Group 2, Suspensi on.
FRONT WHEEL BEARINGS (REAR WHEEL BEAR-
INGS ON ALL WHEEL DRIVE MODELS)
The front wheel beari ngs are permanentl y seal ed,
requi ri ng no l ubri cati on. For proper di agnosti c and
servi ce procedures refer to Group 2, Suspensi on.
Fig. 5 Power Transfer Unit Fill Plug
Fig. 6 Overrunning Clutch Fill Plug
Fig. 7 Drive Line Module Fill Plug
Fig. 8 Drive Shaft Boots
TIRES
The ti res shoul d be i nspected at every engi ne oi l
change for proper i nfl ati on and condi ti on. The ti res
shoul d be rotated at the di stance i nterval s descri bed i n
the Lubri cati on and Mai ntenance Schedul es of the
General I nformati on secti on i n thi s group. For ti re
i nfl ati on speci fi cati ons refer to the Owners Manual . A
Ti re I nfl ati on sti cker i s l ocated i n the dri ver door
openi ng. For proper di agnosti c procedures, see Group
22, Wheel s and Ti res.
TI RE ROTATI ON
The Forward Cross rotati on method i s recommended
for use on Chrysl er Corporati on vehi cl es (Fi g. 9). Other
rotati on methods can be used, but may not have the
benefi ts of the recommended method. Onl y the four ti re
rotati on method can be used i f the vehi cl e i s equi pped
wi th a space saver spare ti re.
Fig. 9 Tire Rotation
CHASSI S AND BODY
INDEX
page page
Body Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Driver Supplemental Airbag System . . . . . . . . . . . 22
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lower Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear Wheel Bearings (Front Wheel Drive Only) . . . 21
Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 19
STEERING LINKAGE
I NSPECTI ON
The steeri ng l i nkage and steeri ng gear shoul d be
i nspected for wear, l eaks or damage when other under
vehi cl e servi ce i s performed. The rack and pi ni on
steeri ng gear end boots shoul d not have excess oi l or
grease resi due on the outsi de surfaces or surroundi ng
areas (Fi g.1). I f boot i s l eaki ng, i t shoul d be repai red.
For proper servi ce procedures, see Group 19, Steeri ng.
The ti e rod end seal shoul d fi t securel y between the
steeri ng knuckl e and ti e rod end (Fi g.2). The steeri ng
l i nkage shoul d be l ubri cated at the ti me and di stance
i nterval s descri bed i n the Lubri cati on and Mai nte-
nance Schedul es. Refer to General I nformati on secti on
of thi s group.
TI E ROD END LUBRI CATI ON
Lubri cate the steeri ng l i nkage wi th Mopar, Mul ti -
mi l eage Lube or equi val ent. Usi ng a wi pi ng cl oth, cl ean
grease and di rt from around grease fi tti ng and joi nt
seal . Usi ng a grease gun, fi l l ti e rod end unti l l ubri cant
l eaks from around the ti e rod end si de of the seal
(Fi g.2). When l ube operati on i s compl ete, wi pe off
excess grease.
LOWER BALL JOINTS
I NSPECTI ON
The front suspensi on l ower bal l joi nts shoul d be
i nspected for wear, l eaks or damage when other under
vehi cl e servi ce i s performed. The bal l joi nt seal shoul d
fi t securel y between the steeri ng knuckl e and l ower
control arm (Fi g. 3). The bal l joi nts shoul d be l ubri -
cated at the ti me and di stance i nterval s descri bed i n
the Lubri cati on and Mai ntenance Schedul es. Refer to
the General I nformati on secti on of thi s group.
BALL JOI NT LUBRI CATI ON
CAUTION: Do not over fill ball joint with grease,
damage to seal can result.
Lubri cate the bal l joi nts wi th Mopar, Mul ti -mi l eage
Lube or equi val ent. Usi ng a wi pi ng cl oth, cl ean grease
and di rt from around grease fi tti ng and joi nt seal .
Usi ng a grease gun, fi l l bal l joi nt unti l seal starts to
swel l (Fi g. 3). When l ube operati on i s compl ete, wi pe
off excess grease.
POWER STEERING
The power steeri ng fl ui d l evel shoul d be
i nspected when other under hood servi ce i s
performed. I f the fl ui d l evel i s l ow and system
i s not l eaki ng, use Mopar, Power Steeri ng
Fl ui d or equi val ent. The power steeri ng sys-
tem shoul d be i nspected for l eaks when
Fig. 1 Inspect Steering Linkage
Fig. 2 Tie Rod End Lubrication
other under vehi cl e servi ce i s performed. For proper
servi ce procedures, refer to Group 19, Steeri ng.
The power steeri ng pump dri ve bel t shoul d be i n-
spected at the ti me and di stance i nterval descri bed i n
the Lubri cati on and Mai ntenance Schedul es. Refer to
the General I nformati on secti on of thi s group.
POWER STEERI NG FLUI D I NSPECTI ON
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL, PER-
CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can
result.
TO INSPECT FLUID LEVEL:
(1) Posi ti on vehi cl e on a l evel surface wi th engi ne at
normal runni ng temperature.
(2) Turn OFF engi ne and remove i gni ti on key.
(3) Usi ng a wi pi ng cl oth, cl ean oi l and di rt resi due
from around power steeri ng reservoi r cap.
(4) Remove reservoi r cap or di psti ck and wi pe off
fl ui d.
(5) I nstal l cap or di psti ck.
(6) Remove cap or di psti ck. Hol di ng handl e or cap
above ti p of di psti ck, read fl ui d l evel (Fi g. 4, 5, or 6).
Add fl ui d i f readi ng i s bel ow col d l evel mark on
di psti ck.
Fig. 3 Ball Joint Lubrication
Fig. 4 Power Steering Reservoir Dipstick2.5L En-
gine
gine
gine
REAR WHEEL BEARINGS (FRONT WHEEL DRIVE
ONLY)
I NSPECTI ON
The rear wheel beari ngs shoul d be packed wi th new
l ubri cant at the di stance i nterval descri bed i n the
Lubri cati on and Mai ntenance Schedul es. Refer to the
General I nformati on secti on of thi s group. The bear-
i ngs shoul d be i nspected for contami nati on and wear
before they are cl eaned. Sl i ght di scol orati on of beari ng
rol l ers and race cup i s normal . I f metal fl akes are
vi si bl e i n the used l ubri cant or the beari ng rol l ers and
race cup i s di scol ored, the beari ng and race cup shoul d
be repl aced. For proper servi ce procedures, see Group
5, Brakes. Repl ace the i nner seal whenever the wheel
beari ngs are servi ced.
REAR WHEEL BEARI NG LUBRI CATI ON
CAUTION: Combining two types of lubricant can
cause bearing failure. Wash used or new bearings
with a suitable solvent and blot dry with a lint free
cloth before packing with new lubricant.
WARNING: DO NOT ALLOW BEARING TO SPIN AT
HIGH RPM WHEN USING COMPRESSED AIR TO
BLOW CLEANING SOLVENT FROM BEARING. BEAR-
ING CAGE CAN EXPLODE, CAUSING PERSONAL
INJURY.
TO LUBRICATE REAR WHEEL BEARINGS:
(1) Hoi st rear wheel s off the ground and support
vehi cl e on safety stands. Refer to Hoi sti ng Recommen-
dati ons i n the General I nformati on secti on of thi s
group.
(2) Remove rear wheel s.
(3) Remove brake cal i per on vehi cl es wi th rear di sc
brakes. For proper procedure, see Group 5, Brakes.
(4) Remove rear wheel hub (drum) assembl y and
remove i nner grease seal (Fi g. 7). For proper servi ce
procedure, see Group 5, Brakes.
(5) I nspect beari ngs, refer to I nspecti on paragraph
of thi s procedure. Wash used l ubri cant from beari ngs
wi th sol vent and bl ot or bl ow dry.
(6) Usi ng a beari ng packi ng devi ce, l ubri cate the
beari ngs wi th Mopar, Wheel Beari ng Grease or
equi val ent.
(7) Wi th a wi pi ng cl oth, cl ean used l ubri cant form
wheel hub assembl y and axl e spi ndl e.
(8) I nstal l i nner wheel beari ng i n the hub assembl y,
smal l end of beari ng toward hub. Wi th a fi nger, smooth
out grease around the outsi de of beari ng.
(9) Usi ng a seal dri ver, i nstal l new i nner hub seal .
(10) I nstal l wheel hub (drum) assembl y on axl e
spi ndl e.
(11) I nstal l outer wheel beari ng over the spi ndl e
end, smal l end of beari ng toward hub. Wi th a fi nger,
smooth out grease around the outsi de of beari ng.
(12) I nstal l washer and spi ndl e nut. Whi l e rotati ng
hub, ti ghten spi ndl e nut to 27 to 34 Nm (240 to 300 i n.
l bs.) torque. Loosen spi ndl e nut one quarter turn. Hand
ti ghten spi ndl e nut.
(13) I nstal l spi ndl e nut l ock cover, cotter pi n and
grease cap.
(14) I nstal l di sc brake cal i per on vehi cl es wi th di sc
brakes.
CAUTION: Pump brake pedal several times before
driving vehicle to verify brake operation.
(15) I nstal l wheel and l ower vehi cl e.
BRAKES
BRAKE PAD AND LI NI NG I NSPECTI ON
The brake pads and l i ni ngs shoul d be i nspected at
di stance i nterval s descri bed i n the Lubri cati on and
Mai ntenance Schedul es. Refer to the General I nforma-
ti on secti on of thi s group. I f brake pads or l i ni ngs
appear excessi vel y worn, the brakes woul d requi re
servi ce. For proper servi ce procedures, refer to Group
5, Brakes.
BRAKE HOSE I NSPECTI ON
WARNING: IF FRONT WHEEL, REAR AXLE, OR ANTI-
LOCK UNIT BRAKE HOSE OUTER COVER IS
CRACKED, CHAFED, OR BULGED, REPLACE HOSE
IMMEDIATELY. BRAKE FAILURE CAN RESULT.
The front wheel , rear axl e and anti -l ock uni t (i f
equi pped) brake hoses shoul d be i nspected at ti me
Fig. 7 Rear Wheel Bearings
and di stance i nterval s descri bed i n the Lubri cati on and
Mai ntenance Schedul es. Refer to the General I nforma-
ti on secti on of thi s group. A hose must be repl aced i f i t
has si gns of cracki ng, chafi ng, fati gue or bul gi ng. For
proper servi ce procedures, refer to Group 5, Brakes.
BRAKE LI NE I NSPECTI ON
The metal brake l i nes shoul d be i nspected when
other under vehi cl e servi ce i s preformed. I f a l i ne i s
pi nched, ki nked, or corroded, i t shoul d be repai red. For
proper servi ce procedures, refer to Group 5, Brakes.
BRAKE RESERVOI R LEVEL I NSPECTI ON
WARNING: DO NOT ALLOW PETROLEUM OR WATER
BASE LIQUIDS TO CONTAMINATE BRAKE FLUID,
SEAL DAMAGE AND BRAKE FAILURE CAN RESULT.
RELIEVE PRESSURE IN ANTI-LOCK BRAKE SYS-
TEM BEFORE ADDING BRAKE FLUID TO RESER-
VOIR. IF NOT, BRAKE FLUID COULD DISCHARGED
FROM THE RESERVOIR POSSIBLY CAUSING PER-
SONAL INJURY.
The brake reservoi r l evel shoul d be i nspected when
other under hood servi ce i s performed. I t i s normal for
the reservoi r l evel to drop as di sc brake pads wear.
When fl ui d must be added, use Mopar, Brake Fl ui d or
equi val ent. Use onl y brake fl ui d conformi ng to DOT 3,
Federal , Department of Transportati on speci fi cati on.
To avoi d brake fl ui d contami nati on, use fl ui d from a
properl y seal ed contai ner.
On vehi cl es wi th anti -l ock brakes, depressuri ze the
system before i nspecti ng fl ui d l evel . Turn OFF the
i gni ti on and remove the key. Pump the brake pedal at
l east 50 ti mes to rel i eve the pressure i n the system.
On al l vehi cl es, i f fl ui d shoul d become l ow after
several thousand ki l ometers (mi l es), fi l l the reservoi r
to l evel marks on the si de of the reservoi r (Fi g. 8 or 9).
HEADLAMPS
The headl amps shoul d be i nspected for i ntensi ty and
ai m whenever a probl em i s suspected. When l uggage
compartment i s heavi l y l oaded, the headl amp ai m
shoul d be adjusted to compensate for vehi cl e hei ght
change. For proper servi ce procedures, refer to Group
8L, Lamps.
DRIVER SUPPLEMENTAL AIRBAG SYSTEM
WARNING: FAILURE TO HAVE THE AIRBAG SYSTEM
PROMPTLY SERVICED BYANAUTHORIZED DEALER
SHOULD ONE OF THE FOLLOWING CONDITIONS
EXIST CAN LEAD TO POSSIBLE INJURY IN THE
EVENT OF AN ACCIDENT.
I f the AI RBAG i ndi cator l amp does not l i ght at al l ,
stays l i t or l i ghts momentari l y or conti nuousl y whi l e
dri vi ng, a mal functi on may have occurred. Prompt
servi ce i s requi red. Refer to Group 8M, Restrai nt
Systems for proper di agnosti c procedures.
The ai rbag system and components shoul d be i n-
spected and tested for el ectroni c di agnosti c faul t codes
at the i nterval s descri bed i n the Lubri cati on and Mai n-
tenance Schedul es i n the I ntroducti on secti on of thi s
group.
BODY LUBRICATION
Body mechani sms and l i nkages shoul d be i nspected,
cl eaned and l ubri cated as requi red to mai ntai n ease of
operati on and to prevent corrosi on and wear.
Before a component i s l ubri cated, oi l , grease and di rt
shoul d be wi ped off. I f necessary, use sol vent to cl ean
component to be l ubri cated. After l ubri cati on i s
Fig. 8 Anti-lock Brake Reservoir
Fig. 9 Master Cylinder Brake ReservoirExcept
Anti-lock
compl ete, wi pe off excess grease or oi l .
Duri ng wi nter season, external l ock cyl i nders shoul d
be l ubri cated wi th Mopar, Lock Lubri cant or equi va-
l ent to assure proper operati on when exposed to water
and i ce.
To assure proper hood l atchi ng component operati on,
use engi ne oi l to l ubri cate the l atch, safety catch and
hood hi nges when other under hood servi ce i s per-
formed. Mopar, Mul ti -purpose Grease or equi val ent
shoul d be appl i ed spari ngl y to al l pi vot and sl i de
contact areas.
USE ENGINE OIL ON
Door hi ngesHi nge pi n and pi vot poi nts.
Hood hi ngesPi vot poi nts.
Li ftgate hi ngesPi vot poi nts.
Sl i di ng door center hi nge pi vot.
USE MOPAR LUBRIPLATE OR EQUIVALENT ON
Door check straps.
Li ftgate l atches.
Li ftgate prop rod pi vots.
Ash tray sl i des.
Fuel Fi l l Door l atch mechani sm.
Park brake mechani sm.
Front seat tracks.
Sl i di ng door rear l atch stri ker.
sl i di ng door cl osure wedges
USE MOPAR MULTI-PURPOSE GREASE OR EQUIVALENT ON
Sl i di ng door center track.
Sl i di ng door upper track.
Sl i di ng door open posi ti on stri ker spri ng.

561

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Welcome to the

1992 AS Town 8 Country, Caravan 8 voyager

COMPRESSOR NOI SE AND COMPRESSOR CLUTCH DI AGNOSI S

Fig. 1 Fixed Displacement CompressorModel

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