GROU P TAB LOCAT OR

Introduction

0 Lubrication & Maintenance

2 Suspension

3 Driveline

5 Brakes

7 Cooling

8A Audio

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9 Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transaxle

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Service Manual Comment Forms (Rear of Manual)

WJ INTRODUCTION 1

INTRODUCTION
TABLE OF CON T EN T S

page page

BODY CODE PLATE TORQUE REFERENCES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...7
FASTENER IDENTIFICATION VEHICLE EMISSION CONTROL INFORMATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....1 (VECI)
FASTENER USAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8
DESCRIPTION - FASTENER USAGE . . . . . ....4 VEHICLE IDENTIFICATION NUMBER
THREADED HOLE REPAIR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8
DESCRIPTION - THREADED HOLE REPAIR ....4 VEHICLE SAFETY CERTIFICATION LABEL
INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...9
DESCRIPTION - INTERNATIONAL SYMBOLS ...4
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....5

BODY CODE PLAT E FAST EN ER I DEN T I FI CAT I ON

DESCRIPTION
A m et a l Body Code pla t e is loca t ed in t h e en gin e
com pa r t m en t a n d a t t a ch ed t o t h e t op of t h e r igh t
fr a m e r a il. Th e in for m a t ion list ed on t h e pla t e (F ig.
1) is u sed for m a n u fa ct u r in g a n d ser vice pu r poses.
DESCRIPTION
Th e SAE bolt st r en gt h gr a des r a n ge fr om gr a de 2
t o gr a de 8. Th e h igh er t h e gr a de n u m ber, t h e gr ea t er
t h e bolt st r en gt h . Iden t ifica t ion is det er m in ed by t h e
lin e m a r ks on t h e t op of ea ch bolt h ea d. Th e a ct u a l
bolt st r en gt h gr a de cor r espon ds t o t h e n u m ber of lin e
m a r ks plu s 2. Th e m ost com m on ly u sed m et r ic bolt
st r en gt h cla sses a r e 9.8 a n d 10.9. Th e m et r ic
st r en gt h cla ss iden t ifica t ion n u m ber is im pr in t ed on
t h e h ea d of t h e bolt . Th e h igh er t h e cla ss n u m ber,
t h e gr ea t er t h e bolt st r en gt h . Som e m et r ic n u t s a r e
im pr in t ed wit h a sin gle-digit st r en gt h cla ss on t h e
n u t fa ce. Refer t o t h e F a st en er Iden t ifica t ion a n d
F a st en er St r en gt h Ch a r t s (F ig. 2) a n d (F ig. 3).

Fig. 1 Body Code Plate

2 INTRODUCTION WJ
FAST EN ER I DEN T I FI CAT I ON (Cont inue d)

Fig. 2 FASTENER IDENTIFICATION

WJ INTRODUCTION 3
FAST EN ER I DEN T I FI CAT I ON (Cont inue d)

Fig. 3 FASTENER STRENGTH

4 INTRODUCTION WJ

FAST EN ER U SAGE T H READED H OLE REPAI R

DESCRIPTION - FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR
Most st r ipped t h r ea ded h oles ca n be r epa ir ed u sin g
WARNING: USE OF AN INCORRECT FASTENER a H elicoil!. F ollow t h e veh icle or H elicoil! r ecom m en -
MAY RESULT IN COMPONENT DAMAGE OR PER- da t ion s for a pplica t ion a n d r epa ir pr ocedu r es.
SONAL INJURY.

F a st en er s a n d t or qu e specifica t ion s r efer en ces in I N T ERN AT I ON AL SY M BOLS

t h is Ser vice Ma n u a l a r e iden t ified in m et r ic a n d SAE
for m a t .
Du r in g a n y m a in t en a n ce or r epa ir pr ocedu r es, it is
im por t a n t t o sa lva ge a ll fa st en er s (n u t s, bolt s, et c.)
for r ea ssem bly. If t h e fa st en er is n ot sa lva gea ble, a
fa st en er of equ iva len t specifica t ion m u st be u sed.
DESCRIPTION - INTERNATIONAL SYMBOLS
Th e gr a ph ic sym bols illu st r a t ed in t h e followin g
In t er n a t ion a l Con t r ol a n d Displa y Sym bols Ch a r t a r e
u sed t o iden t ify va r iou s in st r u m en t con t r ols. Th e
sym bols cor r espon d t o t h e con t r ols a n d displa ys t h a t
a r e loca t ed on t h e in st r u m en t pa n el.

INTERNATIONAL SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
WJ INTRODUCTION 5

M ET RI C SY ST EM Th e followin g ch a r t will a ssist in con ver t in g m et r ic

u n it s t o equ iva len t E n glish a n d SAE u n it s, or vise
ver sa .
DESCRIPTION
Th e m et r ic syst em is ba sed on qu a n t it ies of on e,
t en , on e h u n dr ed, on e t h ou sa n d a n d on e m illion .

CON V ERSI ON FORM U LAS AN D EQU I VALEN T VALU ES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters N·m x 8.851 = in-lbs
(N·m)
ft-lbs x 1.3558 = Newton Meters N·m x 0.7376 = ft-lbs
(N·m)
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. Km/h x 0.6214 = mph
(Km/h)
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

COM M ON M ET RI C EQU I VALEN T S

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer t o t h e Met r ic Con ver sion Ch a r t t o con ver t

t or qu e va lu es list ed in m et r ic Newt on - m et er s (N·m ).
Also, u se t h e ch a r t t o con ver t bet ween m illim et er s
(m m ) a n d in ch es (in .) (F ig. 4).
6 INTRODUCTION WJ
M ET RI C SY ST EM (Cont inue d)

Fig. 4 METRIC CONVERSION CHART

WJ INTRODUCTION 7

T ORQU E REFEREN CES t ion s Ch a r t for t or qu e r efer en ces n ot list ed in t h e

in dividu a l t or qu e ch a r t s (F ig. 5).
DESCRIPTION
In dividu a l Tor qu e Ch a r t s a ppea r wit h in m a n y or
t h e Gr ou ps. Refer t o t h e St a n da r d Tor qu e Specifica -

Fig. 5 TORQUE SPECIFICATIONS

8 INTRODUCTION WJ

V EH I CLE EM I SSI ON CON T ROL

I N FORM AT I ON (V ECI )
DESCRIPTION
All veh icles a r e equ ipped wit h a com bin ed veh icle
em ission con t r ol in for m a t ion (VE CI) la bel(s). Th e
la bel is loca t ed in t h e en gin e com pa r t m en t on t h e
veh icle h ood (F ig. 6). Two la bels a r e u sed for veh icles
bu ilt for sa le in t h e cou n t r y of Ca n a da .
Th e VE CI la bel(s) con t a in t h e followin g:
• E n gin e fa m ily a n d displa cem en t
• E va por a t ive fa m ily
• E m ission con t r ol syst em sch em a t ic
• Cer t ifica t ion a pplica t ion
• Spa r k plu g a n d ga p
Th e la bel a lso con t a in s a n en gin e va cu u m sch e-
m a t ic. Th er e a r e u n iqu e la bels for veh icles bu ilt for
sa le in t h e st a t e of Ca lifor n ia a n d t h e cou n t r y of
Ca n a da . Ca n a dia n la bels a r e wr it t en in bot h t h e
E n glish a n d F r en ch la n gu a ges. Th ese la bels a r e per-
m a n en t ly a t t a ch ed a n d ca n n ot be r em oved wit h ou t Fig. 6 VECI Label Location
defa cin g in for m a t ion a n d dest r oyin g la bel. 1 - VECI LABEL (CANADIAN)
2 - VECI LABEL
3 - HOOD
V EH I CLE I DEN T I FI CAT I ON
N U M BER Th e VIN con t a in s 17 ch a r a ct er s t h a t pr ovide da t a
con cer n in g t h e veh icle. Refer t o t h e decodin g ch a r t t o
DESCRIPTION det er m in e t h e iden t ifica t ion of a veh icle.
Th e Veh icle Iden t ifica t ion Nu m ber (VIN) pla t e is
a t t a ch ed t o t h e t op left side of t h e in st r u m en t pa n el.

V EH I CLE I DEN T I FI CAT I ON N U M BER DECODI N G CH ART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line X = Grand Cherokee 4X2 (LHD)
W = Grand Cherokee 4X4 (LHD)
6 Series 3 = Sport
4 = Laredo
5 = Limited
6 = Overland
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0 Liter Gasoline
N = 4.7 Liter Gasoline
9 Check Digit 0 through 9 or X
10 Model Year 2=2002
11 Assembly Plant C = Jefferson Assembly
12 thru 17 Vehicle Build Sequence
WJ INTRODUCTION 9

V EH I CLE SAFET Y Th e la bel is loca t ed on t h e dr iver-side door

sh u t -fa ce.
CERT I FI CAT I ON LABEL
DESCRIPTION
A veh icle sa fet y cer t ifica t ion la bel (F ig. 7) is
a t t a ch ed t o ever y Da im ler Ch r ysler Cor por a t ion veh i-
cle. Th e la bel cer t ifies t h a t t h e veh icle con for m s t o a ll
a pplica ble F eder a l Mot or Veh icle Sa fet y St a n da r ds.
Th e la bel a lso list s:
• Mon t h a n d yea r of veh icle m a n u fa ct u r e.
• Gr oss Veh icle Weigh t Ra t in g (GVWR). Th e gr oss
fr on t a n d r ea r a xle weigh t r a t in gs (GAWR’s) a r e
ba sed on a m in im u m r im size a n d m a xim u m cold t ir e
in fla t ion pr essu r e.
• Veh icle Iden t ifica t ion Nu m ber (VIN).
• Type of veh icle.
• Type of r ea r wh eels.
• Ba r code.
• Mon t h , Da y a n d H ou r (MDH ) of fin a l a ssem bly. Fig. 7 VEHICLE SAFETY CERTIFICATION LABEL -
• P a in t a n d Tr im codes. TYPICAL
• Cou n t r y of or igin .
WJ LUBRICATION & MAINTENANCE 0-1

LUBRICATION & MAINTENANCE

TABLE OF CON T EN T S

page page

LUBRICATION & MAINTENANCE OPERATION - AUTOMATIC TRANSMISSION

SPECIFICATIONS - FLUID CAPACITIES . . . . ...1 FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
INTERNATIONAL SYMBOLS FLUID FILL/CHECK LOCATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...2 INSPECTION - FLUID FILL/CHECK
PARTS & LUBRICANT RECOMMENDATION LOCATIONS ....................... ...6
STANDARD PROCEDURE - PARTS & MAINTENANCE SCHEDULES
LUBRICANT RECOMMENDATIONS . . . . . . ...2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...6
FLUID TYPES LIFT POINTS
DESCRIPTION STANDARD PROCEDURE - HOISTING AND
DESCRIPTION - ENGINE COOLANT . . . . . . . .2 JACKING RECOMMENDATIONS . . . . . . . . ...6
DESCRIPTION - ENGINE COOLANT . . . . . . . .3 JUMP STARTING
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . .4 STANDARD PROCEDURE - JUMP STARTING ..7
DESCRIPTION - ENGINE OIL . . . . . . . . . . . . .4 EMERGENCY TOW HOOKS
DESCRIPTION ..................... . . .5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8
DESCRIPTION - TRANSFER CASE - NV242 . .5 TOWING
DESCRIPTION - TRANSFER CASE - NV247 . .5 STANDARD PROCEDURE - TOWING
DESCRIPTION - AUTOMATIC RECOMMENDATIONS . . . . . . . . . . . . . . . . ...8
TRANSMISSION FLUID . . . . . . . . . . . . . . . ...5
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . ...6

LU BRI CAT I ON & DESCRIPTION SPECIFICATION

M AI N T EN AN CE
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION
FUEL TANK
Engine Oil - with Filter -
2.7L Diesel
Engine Oil - with Filter -
4.0L
Engine Oil - with Filter -
4.7L
Cooling System - 2.7L
Diesel
Cooling System - 4.0L
Cooling System - 4.7L
AUTOMATIC TRANSMISSION
Service Fill - 42RE
Service Fill - 545RFE
O-haul Fill - 42RE
O-haul Fill - 545RFE 13.33 L (28.0 pts.)
Dry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or use
of an auxiliary cooler, these figures may vary. (Refer to
SPECIFICATION appropriate 21 - TRANSMISSION/TRANSAXLE/
20 U.S. Gallons (76 AUTOMATIC/FLUID - STANDARD PROCEDURE).
Liters)**** TRANSFER CASE
6.5L (6.9 qts.) NV242 1.35L (2.85 pts.)
NV247 1.6L (3.4 pts.)
5.7 L (6.0 qts.) FRONT AXLE ± 0.3 L (1 oz.)
186 FBI (Model 30) 1.18 L (2.5 pts.)*
5.7 L (6.0 qts.)
* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier.
14.2L (15 qts.)*** REAR AXLE ± 0.3 L (1 oz.)
198 RBI (Model 35) 1.66 L (3.5 pts.)*
14.1 L (15 qts.)*** 226 RBA (Model 44) 2.24 L (4.75 pts.)**
13.7 L (14.5 qts.)*** * With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier.
** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of
3.8 L (4.0 qts.) Friction Modifier.
2WD - 5.2 L (11 pts.) *** Includes 0.9L (1.0 qts.) for coolant reservoir.
4WD - 6.2 L (13 pts.) ****Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
9.1-9.5 L (19-20 pts.) manufacturing tolerance and refill procedure.
0-2 LUBRICATION & MAINTENANCE WJ

I N T ERN AT I ON AL SY M BOLS FLU I D T Y PES

DESCRIPTION
Da im ler Ch r ysler Cor por a t ion u ses in t er n a t ion a l DESCRI PT I ON
sym bols t o iden t ify en gin e com pa r t m en t lu br ica n t
a n d flu id in spect ion a n d fill loca t ion s (F ig. 1). DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.

Th e r equ ir ed et h ylen e-glycol (a n t ifr eeze) a n d wa t er

Fig. 1 INTERNATIONAL SYMBOLS
PART S & LU BRI CAN T
RECOM M EN DAT I ON
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS
Lu br ica t in g gr ea se is r a t ed for qu a lit y a n d u sa ge
by t h e NLGI. All a ppr oved pr odu ct s h a ve t h e NLGI
sym bol (F ig. 2) on t h e la bel. At t h e bot t om NLGI
sym bol is t h e u sa ge a n d qu a lit y iden t ifica t ion let t er s.
Wh eel bea r in g lu br ica n t is iden t ified by t h e let t er
“G”. Ch a ssis lu br ica n t is iden t ified by t h e la t t er “L”.
Th e let t er followin g t h e u sa ge let t er in dica t es t h e
qu a lit y of t h e lu br ica n t . Th e followin g sym bols in di-
ca t e t h e h igh est qu a lit y.
m ixt u r e depen ds u pon t h e clim a t e a n d veh icle oper-
a t in g con dit ion s. Th e r ecom m en ded m ixt u r e of 50/50
et h ylen e-glycol a n d wa t er will pr ovide pr ot ect ion
a ga in st fr eezin g t o -37 deg. C (-35 deg. F ). Th e a n t i-
fr eeze con cen t r a t ion m u s t a lw a y s be a m in im u m of
44 per cen t , yea r-r ou n d in a ll clim a t es. If p e rc e n ta g e
is lo w e r th a n 44 p e rc e n t, e n g in e p a rts m a y be
e ro d e d by c a v ita tio n , a n d c o o lin g s y s te m c o m -
p o n e n ts m a y be s e v e re ly d a m a g e d by c o rro s io n .
Ma xim u m pr ot ect ion a ga in st fr eezin g is pr ovided
wit h a 68 per cen t a n t ifr eeze con cen t r a t ion , wh ich
pr even t s fr eezin g down t o -67.7 deg. C (-90 deg. F ). A
h igh er per cen t a ge will fr eeze a t a wa r m er t em per a -
t u r e. Also, a h igh er per cen t a ge of a n t ifr eeze ca n
ca u se t h e en gin e t o over h ea t beca u se t h e specific
h ea t of a n t ifr eeze is lower t h a n t h a t of wa t er.
Use of 100 per cen t et h ylen e-glycol will ca u se for-
m a t ion of a ddit ive deposit s in t h e syst em , a s t h e cor-
r osion in h ibit ive a ddit ives in et h ylen e-glycol r equ ir e
t h e pr esen ce of wa t er t o dissolve. Th e deposit s a ct a s
in su la t ion , ca u sin g t em per a t u r es t o r ise t o a s h igh a s
149 deg. C (300) deg. F ). Th is t em per a t u r e is h ot
en ou gh t o m elt pla st ic a n d soft en solder. Th e
in cr ea sed t em per a t u r e ca n r esu lt in en gin e det on a -
t ion . In a ddit ion , 100 per cen t et h ylen e-glycol fr eezes
a t 22 deg. C (-8 deg. F ).

PROPYLENE-GLYCOL MIXTURES
It ’s over a ll effect ive t em per a t u r e r a n ge is sm a ller
t h a n t h a t of et h ylen e-glycol. Th e fr eeze poin t of 50/50
pr opylen e-glycol a n d wa t er is -32 deg. C (-26 deg. F ).
Fig. 2 NLGI Symbol 5 deg. C h igh er t h a n et h ylen e-glycol’s fr eeze poin t .
1 - WHEEL BEARINGS Th e boilin g poin t (pr ot ect ion a ga in st su m m er boil-
2 - CHASSIS LUBRICATION over ) of pr opylen e-glycol is 125 deg. C (257 deg. F )
3 - CHASSIS AND WHEEL BEARINGS a t 96.5 kP a (14 psi), com pa r ed t o 128 deg. C (263
deg. F ) for et h ylen e-glycol. Use of pr opylen e-glycol
Wh en ser vice is r equ ir ed, Da im ler Ch r ysler Cor po- ca n r esu lt in boil-over or fr eeze-u p on a coolin g sys-
r a t ion r ecom m en ds t h a t on ly Mopa r ! br a n d pa r t s, t em design ed for et h ylen e-glycol. P r opylen e glycol
lu br ica n t s a n d ch em ica ls be u sed. Mopa r pr ovides a lso h a s poor er h ea t t r a n sfer ch a r a ct er ist ics t h a n
the best en gin eer ed pr odu ct s for ser vicin g et h ylen e glycol. Th is ca n in cr ea se cylin der h ea d t em -
Da im ler Ch r ysler Cor por a t ion veh icles. per a t u r es u n der cer t a in con dit ion s.
WJ
FLU I D T Y PES (Cont inue d)
P r opylen e-glycol/et h ylen e-glycol Mixt u r es ca n
ca u se t h e dest a biliza t ion of va r iou s cor r osion in h ibi-
t or s, ca u sin g da m a ge t o t h e va r iou s coolin g syst em
com pon en t s. Also, on ce et h ylen e-glycol a n d pr opy-
len e-glycol ba sed coola n t s a r e m ixed in t h e veh icle,
con ven t ion a l m et h ods of det er m in in g fr eeze poin t will
n ot be a ccu r a t e. Bot h t h e r efr a ct ive in dex a n d spe-
cific gr a vit y differ bet ween et h ylen e glycol a n d pr opy-
len e glycol.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL 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 IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
Th e coolin g syst em is design ed a r ou n d t h e coola n t .
Th e coola n t m u st a ccept h ea t fr om en gin e m et a l, in
t h e cylin der h ea d a r ea n ea r t h e exh a u st va lves a n d
en gin e block. Th en coola n t ca r r ies t h e h ea t t o t h e
r a dia t or wh er e t h e t u be/fin r a dia t or ca n t r a n sfer t h e
h ea t t o t h e a ir.
Th e u se of a lu m in u m cylin der blocks, cylin der
h ea ds, a n d wa t er pu m ps r equ ir es specia l cor r osion
pr ot ect ion . Mopa r ! An t ifr eeze/Coola n t ,
Yea r /100,000 Mile F or m u la (MS-9769), or t h e equ iva -
len t et h ylen e glycol ba se coola n t wit h or ga n ic cor r o-
sion in h ibit or s (ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en
m ixed wit h 50% E t h ylen e Glycol a n d 50% dist illed
wa t er t o obt a in a fr eeze poin t of -37°C (-35°F ). If it
loses color or becom es con t a m in a t ed, dr a in , flu sh ,
a n d r epla ce wit h fr esh pr oper ly m ixed coola n t solu -
t ion .
LUBRICATION & MAINTENANCE 0-3
CAUTION: Mopar" Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
Th e r equ ir ed et h ylen e-glycol (a n t ifr eeze) a n d wa t er
m ixt u r e depen ds u pon clim a t e a n d veh icle oper a t in g
con dit ion s. Th e coola n t per for m a n ce of va r iou s m ix-
t u r es follows:
P u re Wa te r-Wa t er ca n a bsor b m or e h ea t t h a n a
m ixt u r e of wa t er a n d et h ylen e-glycol. Th is is for pu r-
pose of h ea t t r a n sfer on ly. Wa t er a lso fr eezes a t a
h igh er t em per a t u r e a n d a llows cor r osion .
100 p e rc e n t Eth y le n e -Gly c o l-Th e cor r osion
in h ibit in g a ddit ives in et h ylen e-glycol n eed t h e pr es-
en ce of wa t er t o dissolve. Wit h ou t wa t er, a ddit ives
for m deposit s in syst em . Th ese a ct a s in su la t ion
ca u sin g t em per a t u r e t o r ise t o a s h igh a s 149°C
(300°F ). Th is t em per a t u r e is h ot en ou gh t o m elt pla s-
t ic a n d soft en solder. Th e in cr ea sed t em per a t u r e ca n
r esu lt in en gin e det on a t ion . In a ddit ion , 100 per cen t
et h ylen e-glycol fr eezes a t -22°C (-8°F ).
50/50 Eth y le n e -Gly c o l a n d Wa te r-Is t h e r ecom -
m en ded m ixt u r e, it pr ovides pr ot ect ion a ga in st fr eez-
in g t o -37°C (-34°F ). Th e a n t ifr eeze con cen t r a t ion
m u s t a lw a y s be a m in im u m of 44 per cen t , yea r-
r ou n d in a ll clim a t es. If per cen t a ge is lower, en gin e
pa r t s m a y be er oded by ca vit a t ion . Ma xim u m pr ot ec-
t ion a ga in st fr eezin g is pr ovided wit h a 68 per cen t
a n t ifr eeze con cen t r a t ion , wh ich pr even t s fr eezin g
down t o -67.7°C (-90°F ). A h igh er per cen t a ge will
fr eeze a t a wa r m er t em per a t u r e. Also, a h igh er per-
cen t a ge of a n t ifr eeze ca n ca u se t h e en gin e t o over-
h ea t beca u se specific h ea t of a n t ifr eeze is lower t h a n
t h a t of wa t er.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
5
COOLANT SELECTION AND ADDITIVES
Th e u se of a lu m in u m cylin der blocks, cylin der
h ea ds a n d wa t er pu m ps r equ ir es specia l cor r osion
pr ot ect ion . On ly Mopa r ! An t ifr eeze/Coola n t , 5
Yea r /100,000 Mile F or m u la (glycol ba se coola n t wit h
cor r osion in h ibit or s ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en
m ixed wit h 50% dist illed wa t er t o obt a in t o obt a in a
fr eeze poin t of -37°C (-35°F ). If it loses color or
0-4 LUBRICATION & MAINTENANCE
FLU I D T Y PES (Cont inue d)
becom es con t a m in a t ed, dr a in , flu sh , a n d r epla ce wit h
fr esh pr oper ly m ixed coola n t solu t ion .
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL 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 PROBLEMS 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.
API SERVICE GRADE CERTIFIED
Use a n en gin e oil t h a t is AP I Ser vice Gr a de Cer t i-
fied. MOPAR! pr ovides en gin e oils t h a t con for m t o
t h is ser vice gr a de.
SAE VISCOSITY
An SAE viscosit y gr a de is u sed t o specify t h e vis-
cosit y of en gin e oil. Use on ly en gin e oils wit h m u lt i-
ple viscosit ies su ch a s 5W-30 or 10W-30. Th ese a r e
specified wit h a du a l SAE viscosit y gr a de wh ich in di-
ca t es t h e cold-t o-h ot t em per a t u r e viscosit y r a n ge.
Select a n en gin e oil t h a t is best su it ed t o you r pa r-
t icu la r t em per a t u r e r a n ge a n d va r ia t ion (F ig. 3).
Fig. 3 Temperature/Engine Oil Viscosity - 4.7L
WJ
ENERGY CONSERVING OIL
An E n er gy Con ser vin g t ype oil is r ecom m en ded for
ga solin e en gin es. Th e design a t ion of E NE RGY CON-
SE RVING is loca t ed on t h e la bel of a n en gin e oil con -
t a in er.
CONTAINER IDENTIFICATION
St a n da r d en gin e oil iden t ifica t ion n ot a t ion s h a ve
been a dopt ed t o a id in t h e pr oper select ion of en gin e
oil. Th e iden t ifyin g n ot a t ion s a r e loca t ed on t h e la bel
of en gin e oil pla st ic bot t les a n d t h e t op of en gin e oil
ca n s (F ig. 4).
Fig. 4 API SYMBOL
DESCRIPTION - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL 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 PROBLEMS 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.
API SERVICE GRADE CERTIFIED
Use a n en gin e oil t h a t is AP I Ser vice Gr a de Cer t i-
fied. MOPAR! pr ovides en gin e oils t h a t con for m t o
t h is ser vice gr a de.
SAE VISCOSITY
An SAE viscosit y gr a de is u sed t o specify t h e vis-
cosit y of en gin e oil. Use on ly en gin e oils wit h m u lt i-
ple viscosit ies su ch a s 5W-30 or 10W-30. Th ese oils
a r e specified wit h a du a l SAE viscosit y gr a de wh ich
in dica t es t h e cold-t o-h ot t em per a t u r e viscosit y r a n ge.
Select a n en gin e oil t h a t is best su it ed t o you r pa r-
t icu la r t em per a t u r e r a n ge a n d va r ia t ion (F ig. 5).
WJ
FLU I D T Y PES (Cont inue d)
Fig. 5 Temperature/Engine Oil Viscosity - 4.0L
ENERGY CONSERVING OIL
An E n er gy Con ser vin g t ype oil is r ecom m en ded for
ga solin e en gin es. Th e design a t ion of E NE RGY CON-
SE RVING is loca t ed on t h e la bel of a n en gin e oil con -
t a in er.
CONTAINER IDENTIFICATION
St a n da r d en gin e oil iden t ifica t ion n ot a t ion s h a ve
been a dopt ed t o a id in t h e pr oper select ion of en gin e
oil. Th e iden t ifyin g n ot a t ion s a r e loca t ed on t h e la bel
of en gin e oil pla st ic bot t les a n d t h e t op of en gin e oil
ca n s (F ig. 6).
Fig. 6 API Symbol
DESCRIPTION
A m u lt i-pu r pose, h ypoid gea r lu br ica n t wh ich con -
for m s t o MIL-L-2105C a n d AP I GL 5 qu a lit y specifi-
ca t ion s sh ou ld be u sed. Mopa r H ypoid Gea r
Lu br ica n t con for m s t o t h ese specifica t ion s.
FRONT AXLE
• Lu br ica n t is SAE 75W-140 SYNTH E TIC.
REAR AXLE
• Lu br ica n t is a t h er m a lly st a ble SAE 80W-90
gea r lu br ica n t .
• Lu br ica n t for h ea vy-du t y or t r a iler t ow u se is
SAE 75W-140 SYNTH E TIC.
NOTE: Trac-lok" and Vari-lok" equipped axles
require a friction modifier be added to the lubricant.
LUBRICATION & MAINTENANCE 0-5
DESCRIPTION - TRANSFER CASE - NV242
Recom m en ded lu br ica n t for t h e NV242 t r a n sfer
ca se is Mopa r ! ATF +4, t ype 9602 Au t om a t ic Tr a n s-
m ission F lu id.
DESCRIPTION - TRANSFER CASE - NV247
Mopa r ! Tr a n sfer Ca se Lu br ica n t (P /N 05016796) is
t h e on ly lu br ica n t r ecom m en ded for t h e NV247
t r a n sfer ca se.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopa r ! ATF +4, t ype 9602, Au t om a t ic Tr a n sm is-
sion F lu id is the r ecom m en ded flu id for
Da im ler Ch r ysler a u t om a t ic t r a n sm ission s.
D e x ro n II flu id IS N OT re c o m m e n d e d . Clu tc h
c h a tte r c a n re s u lt fro m th e u s e o f im p ro p e r
flu id .
Mopa r ! ATF +4, t ype 9602, Au t om a t ic Tr a n sm is-
sion F lu id wh en n ew is r ed in color. Th e ATF is dyed
r ed so it ca n be iden t ified fr om ot h er flu ids u sed in
t h e veh icle su ch a s en gin e oil or a n t ifr eeze. Th e r ed
color is n ot per m a n en t a n d is n ot a n in dica t or of flu id
con dit ion . As t h e veh icle is dr iven , t h e ATF will begin
t o look da r ker in color a n d m a y even t u a lly becom e
br own . Th is is n o rm a l. ATF +4 a lso h a s a u n iqu e
odor t h a t m a y ch a n ge wit h a ge. Con sequ en t ly, odor
a n d color ca n n ot be u sed t o in dica t e t h e flu id con di-
t ion or t h e n eed for a flu id ch a n ge.
FLUID ADDITIVES
Da im ler Ch r ysler st r on gly r ecom m en ds a ga in st t h e
a ddit ion of a n y flu ids t o t h e t r a n sm ission , ot h er t h a n
t h ose a u t om a t ic t r a n sm ission flu ids list ed a bove.
E xcept ion s t o t h is policy a r e t h e u se of specia l dyes
t o a id in det ect in g flu id lea ks.
Va r iou s “specia l” a ddit ives a n d su pplem en t s exist
t h a t cla im t o im pr ove sh ift feel a n d/or qu a lit y. Th ese
a ddit ives a n d ot h er s a lso cla im t o im pr ove con ver t er
clu t ch oper a t ion a n d in h ibit over h ea t in g, oxida t ion ,
va r n ish , a n d slu dge. Th ese cla im s h a ve n ot been su p-
por t ed t o t h e sa t isfa ct ion of Da im ler Ch r ysler a n d
t h ese a ddit ives m u s t n o t be u s e d . Th e u se of t r a n s-
m ission “sea ler s” sh ou ld a lso be a voided, sin ce t h ey
m a y a dver sely a ffect t h e in t egr it y of t r a n sm ission
sea ls.
0-6 LUBRICATION & MAINTENANCE WJ
FLU I D T Y PES (Cont inue d)

DESCRIPTION - ENGINE OIL - DIESEL M AI N T EN AN CE SCH EDU LES

ENGINES
Use on ly Diesel E n gin e Oil m eet in g st a n da r d MIL- DESCRIPTION
2104C or AP I Cla ssifica t ion CD o r h ig h e r or CCML #Ma in t en a n ce Sch edu le In for m a t ion n ot in clu ded in
D 4, D 5. t h is sect ion , is loca t ed in t h e a ppr opr ia t e Own er ’s
Ma n u a l.#
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper LI FT POI N T S
API quality or the CCMC G5 designation.
STANDARD PROCEDURE - HOISTING AND
To a ssu r e of pr oper ly for m u la t ed en gin e oils, it is
r ecom m en ded t h a t SAE Gr a de 10W-40 en gin e oils
JACKING RECOMMENDATIONS
t h a t m eet Ch r ysler m a t er ia l st a n da r d MS-6395, be
u sed. E u r opea n Gr a de 10W-40 oils a r e a lso a ccept -
FLOOR JACK
Wh en pr oper ly posit ion ed, a floor ja ck ca n be u sed
a ble.
t o lift a WJ veh icle (F ig. 7). Su ppor t t h e veh icle in
Oils of t h e SAE 5W-40 or 8W-80 gr a de n u m ber a r e
t h e r a ised posit ion wit h ja ck st a n ds a t t h e fr on t a n d
pr efer r ed wh en m in im u m t em per a t u r es con sist en t ly
r ea r en ds of t h e fr a m e r a ils.
fa ll below -12°C.
CAUTION: Do not attempt to lift a vehicle with a
OPERATION - AUTOMATIC TRANSMISSION floor jack positioned under:
FLUID • An axle tube.
Th e a u t om a t ic t r a n sm ission flu id is select ed ba sed • Aluminum differential.
u pon sever a l qu a lit ies. Th e flu id m u st pr ovide a h igh • A body side sill.
level of pr ot ect ion for t h e in t er n a l com pon en t s by • A steering linkage component.
pr ovidin g a lu br ica t in g film bet ween a dja cen t m et a l • A drive shaft.
com pon en t s. Th e flu id m u st a lso be t h er m a lly st a ble • The engine or transmission oil pan.
so t h a t it ca n m a in t a in a con sist en t viscosit y t h r ou gh • The fuel tank.
a la r ge t em per a t u r e r a n ge. If t h e viscosit y st a ys con - • A front suspension arm.
st a n t t h r ou gh t h e t em per a t u r e r a n ge of oper a t ion ,
t r a n sm ission oper a t ion a n d sh ift feel will r em a in con -
sist en t . Tr a n sm ission flu id m u st a lso be a good con - HOIST
du ct or of h ea t . Th e flu id m u st a bsor b h ea t fr om t h e A veh icle ca n be lift ed wit h :
in t er n a l t r a n sm ission com pon en t s a n d t r a n sfer t h a t • A sin gle-post , fr a m e-con t a ct h oist .
h ea t t o t h e t r a n sm ission ca se. • A t win -post , ch a ssis h oist .
• A r a m p-t ype, dr ive-on h oist .

FLU I D FI LL/CH ECK NOTE: When a frame-contact type hoist is used,

LOCAT I ON S
INSPECTION - FLUID FILL/CHECK LOCATIONS
Th e flu id fill/ch eck loca t ion s a n d lu br ica t ion poin t s
a r e loca t ed in ea ch a pplica ble gr ou p.
verify that the lifting pads are positioned properly
(Fig. 7).
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT 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.
WJ
LI FT POI N T S (Cont inue d)
Fig. 7 Correct Vehicle Lifting Locations
J U M P START I N G
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
LUBRICATION & MAINTENANCE 0-7
TO JUMP START A DISABLED VEHICLE:
(1) Ra ise h ood on disa bled veh icle a n d visu a lly
in spect en gin e com pa r t m en t for :
• Ba t t er y ca ble cla m p con dit ion , clea n if n ecessa r y.
• F r ozen ba t t er y.
• Yellow or br igh t color t est in dica t or, if equ ipped.
• Low ba t t er y flu id level.
• Gen er a t or dr ive belt con dit ion a n d t en sion .
• F u el fu m es or lea ka ge, cor r ect if n ecessa r y.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) Wh en u sin g a n ot h er veh icle a s a boost er
sou r ce, pa r k t h e boost er veh icle wit h in ca ble r ea ch .
Tu r n off a ll a ccessor ies, set t h e pa r kin g br a ke, pla ce
t h e a u t om a t ic t r a n sm ission in PARK or t h e m a n u a l
t r a n sm ission in NE UTRAL a n d t u r n t h e ign it ion
OF F.
(3) On disa bled veh icle, pla ce gea r select or in pa r k
or n eu t r a l a n d set pa r k br a ke. Tu r n off a ll a ccesso-
r ies.
(4) Con n ect ju m per ca bles t o boost er ba t t er y. RE D
cla m p t o posit ive t er m in a l (+). BLACK cla m p t o n eg-
a t ive t er m in a l (-). DO NOT a llow cla m ps a t opposit e
en d of ca bles t o t ou ch , elect r ica l a r c will r esu lt .
Review a ll wa r n in gs in t h is pr ocedu r e.
(5) On disa bled veh icle, con n ect RE D ju m per ca ble
cla m p t o posit ive (+) t er m in a l. Con n ect BLACK
ju m per ca ble cla m p t o en gin e gr ou n d a s close t o t h e
gr ou n d ca ble a t t a ch in g poin t a s possible (F ig. 8).
(6) St a r t t h e en gin e in t h e veh icle wh ich h a s t h e
boost er ba t t er y, let t h e en gin e idle a few m in u t es,
t h en st a r t t h e en gin e in t h e veh icle wit h t h e dis-
ch a r ged ba t t er y.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow ba t t er y in disa bled veh icle t o ch a r ge t o
a t lea st 12.4 volt s (75% ch a r ge) befor e a t t em pt in g t o
st a r t en gin e. If en gin e does n ot st a r t wit h in 15 sec-
on ds, st op cr a n kin g en gin e a n d a llow st a r t er t o cool
(15 m in .), befor e cr a n kin g a ga in .
0-8 LUBRICATION & MAINTENANCE WJ
J U M P START I N G (Cont inue d)

Fig. 8 Jumper Cable Clamp Connections Fig. 9 Emergency Tow Hooks

1 - ENGINE GROUND 1 - TOW HOOK
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE
4 - POSITIVE JUMPER CABLE
T OWI N G
5 - BATTERY POSITIVE CABLE
6 - BATTERY STANDARD PROCEDURE - TOWING
7 - TEST INDICATOR RECOMMENDATIONS
A veh icle equ ipped wit h SAE a ppr oved wh eel lift -
DISCONNECT CABLE CLAMPS AS FOLLOWS: t ype t owin g equ ipm en t ca n be u sed t o t ow WJ veh i-
• Discon n ect BLACK ca ble cla m p fr om en gin e cles. Wh en t owin g a 4WD veh icle u sin g a wh eel-lift
gr ou n d on disa bled veh icle. t owin g device, u se t ow dollies u n der t h e opposit e en d
• Wh en u sin g a Boost er veh icle, discon n ect of t h e veh icle. A veh icle wit h fla t bed device ca n a lso
BLACK ca ble cla m p fr om ba t t er y n ega t ive t er m in a l. be u sed t o t r a n spor t a disa bled veh icle (F ig. 10).
Discon n ect RE D ca ble cla m p fr om ba t t er y posit ive
t er m in a l.
• Discon n ect RE D ca ble cla m p fr om ba t t er y posi-
t ive t er m in a l on disa bled veh icle.

EM ERGEN CY T OW H OOK S
DESCRIPTION
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.

Som e J eep veh icles a r e equ ipped wit h fr on t em er-

gen cy t ow h ooks (F ig. 9). Th e t ow h ooks sh ou ld be
u sed for EMERGEN CYpu r poses on ly.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
Fig. 10 Tow Vehicles With Approved Equipment
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:

• Secu r e loose a n d pr ot r u din g pa r t s.

• Alwa ys u se a sa fet y ch a in syst em t h a t is in de-
pen den t of t h e lift in g a n d t owin g equ ipm en t .
WJ
T OWI N G (Cont inue d)
• Do n ot a llow t owin g equ ipm en t t o con t a ct t h e
disa bled veh icle’s fu el t a n k.
• Do n ot a llow a n yon e u n der t h e disa bled veh icle
wh ile it is lift ed by t h e t owin g device.
• Do n ot a llow pa ssen ger s t o r ide in a veh icle
bein g t owed.
• Alwa ys obser ve st a t e a n d loca l la ws r ega r din g
t owin g r egu la t ion s.
• Do n ot t ow a veh icle in a m a n n er t h a t cou ld
jeopa r dize t h e sa fet y of t h e oper a t or, pedest r ia n s or
ot h er m ot or ist s.
• Do n ot a t t a ch t ow ch a in s, T-h ooks, or J -h ooks t o
a bu m per, st eer in g lin ka ge, dr ive sh a ft s or a n on -r e-
in for ced fr a m e h ole.
• Do n ot t ow a h ea vily loa ded veh icle. Use a fla t -
bed device t o t r a n spor t a loa ded veh icle.
TWO-WHEEL-DRIVE VEHICLE TOWING
Da im ler Ch r ysler Cor por a t ion r ecom m en ds t h a t a
veh icle be t owed wit h t h e r ea r en d lift ed, wh en ever
possible.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD veh icles ca n be t owed wit h t h e fr on t wh eels
on t h e su r fa ce for ext en ded dist a n ces a t speeds n ot
exceedin g 48 km /h (30 m ph ).
(1) At t a ch wh eel lift device t o r ea r wh eels.
(2) P la ce t h e t r a n sm ission in n eu t r a l.
(3) Ra ise veh icle t o t owin g posit ion .
(4) At t a ch sa fet y ch a in s. Rou t e ch a in s so n ot t o
in t er fer e wit h t a il pipe wh en veh icle is lift ed.
(5) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion t o
u n lock t h e st eer in g wh eel.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Secu r e st eer in g wh eel in st r a igh t a h ea d posi-
t ion wit h a cla m p device design ed for t owin g.
(7) P la ce t r a n sm ission in pa r k.
LUBRICATION & MAINTENANCE 0-9
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
(1) At t a ch wh eel lift device t o r ea r wh eels.
(2) P la ce t h e t r a n sm ission in n eu t r a l.
(3) Ra ise t h e r ea r of t h e veh icle off t h e gr ou n d a n d
in st a ll t ow dollies u n der r ea r wh eels.
(4) At t a ch wh eel lift device t o fr on t wh eels a n d
r a ise veh icle t o t owin g posit ion .
(5) At t a ch t h e sa fet y ch a in s.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion t o
u n lock t h e st eer in g wh eel.
(7) Secu r e st eer in g wh eel in st r a igh t a h ea d posi-
t ion wit h a cla m p device design ed for t owin g.
(8) P la ce t r a n sm ission in pa r k.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Da im ler Ch r ysler Cor por a t ion r ecom m en ds t h a t a
4WD veh icle be t r a n spor t ed on a fla t -bed device. A
Wh eel-lift device ca n be u sed pr ovided th e tra ilin g
w h e e ls a re o ff th e g ro u n d a n d p o s itio n e d in
to w d o llie s .
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
FOUR WHEEL DRIVE TOWING—REAR END LIFTED
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
(1) At t a ch wh eel lift device t o fr on t wh eels.
(2) P la ce t h e t r a n sm ission in n eu t r a l.
(3) Ra ise t h e fr on t of t h e veh icle off t h e gr ou n d
a n d in st a ll t ow dollies u n der fr on t wh eels.
(4) At t a ch wh eel lift device t o r ea r wh eels a n d
r a ise veh icle t o t owin g posit ion .
(5) At t a ch sa fet y ch a in s. Rou t e ch a in s so n ot t o
in t er fer e wit h t a il pipe wh en veh icle is lift ed.
0 - 10 LUBRICATION & MAINTENANCE
T OWI N G (Cont inue d)
(6) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion t o
u n lock t h e st eer in g wh eel.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(7) Secu r e st eer in g wh eel in st r a igh t a h ea d posi-
t ion wit h a cla m p device design ed for t owin g.
(8) P la ce t r a n sm ission in pa r k.
FOUR WHEEL DRIVE TOWING—FRONT END
LIFTED
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
(1) At t a ch wh eel lift device t o r ea r wh eels.
WJ
(2) P la ce t h e t r a n sm ission in n eu t r a l.
(3) Ra ise t h e r ea r of t h e veh icle off t h e gr ou n d a n d
in st a ll t ow dollies u n der r ea r wh eels.
(4) At t a ch wh eel lift device t o fr on t wh eels a n d
r a ise veh icle t o t owin g posit ion .
(5) At t a ch t h e sa fet y ch a in s.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion t o
u n lock t h e st eer in g wh eel.
(7) Secu r e st eer in g wh eel in st r a igh t a h ea d posi-
t ion wit h a cla m p device design ed for t owin g.
(8) P la ce t r a n sm ission in pa r k.
WJ
SUSPENSION
TABLE OF CON T EN T S
page
SUSPENSION WHEEL ALIGNMENT
DIAGNOSIS AND TESTING - SUSPENSION FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1 REAR
SU SPEN SI ON
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM
CONDITION POSSIBLE CAUSES
FRONT END NOISE 1. Loose or worn wheel bearings.
2. Loose or worn steering or
suspension components.
EXCESSIVE PLAY IN 1. Loose or worn wheel bearings.
STEERING
2. Loose or worn steering or
suspension components.
3. Loose or worn steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings.
2. Loose or worn steering or
suspension components.
3. Tires worn or out of balance.
4. Alignment.
5. Leaking steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings.
2. Loose or worn steering or
suspension components.
3. Tire pressure.
4. Alignment.
EXCESSIVE STEERING 1. Loose or worn steering gear.
EFFORT 2. Power steering fluid low.
3. Column coupler binding.
4. Tire pressure.
5. Alignment.
SUSPENSION 2-1
page
......................3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CORRECTION
1. Adjust or replace wheel bearings.
2. Tighten or replace components as
necessary.
1. Adjust or replace wheel bearings.
2. Tighten or replace components as
necessary.
3. Adjust or replace steering gear.
1. Adjust or replace wheel bearings.
2. Tighten or replace components as
necessary.
3. Replace or balance tires.
4. Align vehicle to specifications.
5. Replace steering dampener.
1. Adjust or replace wheel bearings.
2. Tighten or replace components as
necessary.
3. Adjust tire pressure.
4. Align vehicle to specifications.
1. Adjust or replace steering gear.
2. Add fluid and repair leak.
3. Replace coupler.
4. Adjust tire pressure.
5. Align vehicle to specifications.
2-2 SUSPENSION
SU SPEN SI ON (Cont inue d)
CONDITION POSSIBLE CAUSES
VEHICLE PULLS TO ONE 1. Uneven tire pressure.
SIDE DURING BRAKING
2. Worn brake components.
3. Air in brake line.
VEHICLE LEADS OR 1. Radial tire lead.
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON 2. Brakes dragging.
UNCROWNED ROAD 3. Weak or broken spring.
4. Uneven tire pressure.
5. Wheel Alignment.
6. Loose or worn steering or
suspension components.
7. Cross caster out of spec.
KNOCKING, RATTLING 1. Worn shock bushings.
OR SQUEAKING
2. Loose, worn or bent steering/
suspension components.
3. Shock valve.
IMPROPER TRACKING 1. Loose, worn or bent track bar.
2. Loose, worn or bent steering/
suspension components.
WJ
CORRECTION
1. Adjust tire pressure.
2. Repair brakes as necessary.
3. Repair as necessary.
1. Cross front tires.
2. Repair brake as necessary.
3. Replace spring.
4. Adjust tire pressure.
5. Align vehicle.
6. Repair as necessary.
7. Align vehicle.
1. Replace shock.
2. Inspect, tighten or replace components
as necessary.
3. Replace shock.
1. Inspect, tighten or replace component as
necessary.
2. Inspect, tighten or replace components
as necessary.
WJ
WH EEL ALI GN M EN T
TABLE OF CONTENTS
page
WHEEL ALIGNMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER . . . . . . . 3
WH EEL ALI GN M EN T
DESCRIPTION
Wh eel a lign m en t in volves t h e cor r ect posit ion in g of
t h e wh eels in r ela t ion t o t h e veh icle. Th e posit ion in g
is a ccom plish ed t h r ou gh su spen sion a n d st eer in g
lin ka ge a dju st m en t s. An a lign m en t is con sider ed
essen t ia l for efficien t st eer in g, good dir ect ion a l st a bil-
it y a n d t o m in im ize t ir e wea r. Th e m ost im por t a n t
m ea su r em en t s of a n a lign m en t a r e ca st er, ca m ber
a n d t oe posit ion (F ig. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated, Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
• CAS TER is t h e for wa r d or r ea r wa r d t ilt of t h e
st eer in g kn u ckle fr om ver t ica l. Tilt in g t h e t op of t h e
kn u ckle r ea r wa r d pr ovides posit ive ca st er. Tilt in g t h e
t op of t h e kn u ckle for wa r d pr ovides n ega t ive ca st er.
Ca st er is a dir ect ion a l st a bilit y a n gle. Th is a n gle
en a bles t h e fr on t wh eels t o r et u r n t o a st r a igh t
a h ea d posit ion a ft er t u r n s (F ig. 1).
• CAMB ER is t h e in wa r d or ou t wa r d t ilt of t h e
wh eel r ela t ive t o t h e cen t er of t h e veh icle. Tilt in g t h e
t op of t h e wh eel in wa r d pr ovides n ega t ive ca m ber.
Tilt in g t h e t op of t h e wh eel ou t wa r d pr ovides posit ive
ca m ber. In cor r ect ca m ber will ca u se wea r on t h e
WHEEL ALIGNMENT 2-3
page
STANDARD PROCEDURE - CASTER . . . . . . . 4
STANDARD PROCEDURE - TOE POSITION . . 4
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5
in side or ou t side edge of t h e t ir e. Th e a n gle is n ot
a dju st a ble, da m a ged com pon en t (s) m u st be r epla ced
t o cor r ect t h e ca m ber a n gle (F ig. 1).
• WHEEL TOE P OS ITION is t h e differ en ce
bet ween t h e lea din g in side edges a n d t r a ilin g in side
edges of t h e fr on t t ir es. In cor r ect wh eel t oe posit ion
is t h e m ost com m on ca u se of u n st a ble st eer in g a n d
u n even t ir e wea r. Th e wh eel t oe posit ion is t h e fin a l
fr on t wh eel a lign m en t a dju st m en t (F ig. 1).
• S TEERIN G AXIS IN CLIN ATION AN GLE is
m ea su r ed in degr ees a n d is t h e a n gle t h a t t h e st eer-
in g kn u ckles a r e t ilt ed. Th e in clin a t ion a n gle h a s a
fixed r ela t ion sh ip wit h t h e ca m ber a n gle. It will n ot
ch a n ge except wh en a spin dle or ba ll st u d is da m -
a ged or ben t . Th e a n gle is n ot a dju st a ble, da m a ged
com pon en t (s) m u st be r epla ced t o cor r ect t h e st eer in g
a xis in clin a t ion a n gle.
• THRU S T AN GLE is t h e a n gle of t h e r ea r a xle
r ela t ive t o t h e cen t er lin e of t h e veh icle. In cor r ect
t h r u st a n gle ca n ca u se off-cen t er st eer in g a n d exces-
sive t ir e wea r. Th is a n gle is n ot a dju st a ble, da m a ged
com pon en t (s) m u st be r epla ced t o cor r ect t h e t h r u st
a n gle (F ig. 1).
STAN DARD PROCEDU RE
STANDARD PROCEDURE - CAMBER
Befor e ea ch a lign m en t r ea din g t h e veh icle sh ou ld
be jou n ced (r ea r fir st , t h en fr on t ). Gr a sp ea ch
bu m per a t t h e cen t er a n d jou n ce t h e veh icle u p a n d
down t h r ee t im es. Alwa ys r elea se t h e bu m per in t h e
down posit ion .
To obt a in a n a ccu r a t e a lign m en t , a 4 wh eel a lign -
m en t m a ch in e m u st be u sed a n d t h e equ ipm en t ca li-
br a t ion ver ified.
Th e wh eel ca m ber a n gle is pr eset . Th is a n gle is n ot
a dju st a ble a n d ca n n ot be a lt er ed.
2-4 WHEEL ALIGNMENT WJ
WH EEL ALI GN M EN T (Cont inue d)

Fig. 1 Wheel Alignment Measurements

1 - WHEEL CENTERLINE 6 - KING PIN
2 - NEGATIVE CAMBER ANGLE 7 - VERTICAL
3 - PIVOT CENTERLINE 8 - POSITIVE CASTER
4 - SCRUB RADIUS
5 - TRUE VERTICAL

STANDARD PROCEDURE - CASTER To obt a in a n a ccu r a t e a lign m en t , a 4 wh eel a lign -

Befor e ea ch a lign m en t r ea din g t h e veh icle sh ou ld
be jou n ced (r ea r fir st , t h en fr on t ). Gr a sp ea ch
bu m per a t t h e cen t er a n d jou n ce t h e veh icle u p a n d
down t h r ee t im es. Alwa ys r elea se t h e bu m per in t h e
down posit ion .
To obt a in a n a ccu r a t e a lign m en t , a 4 wh eel a lign -
m en t m a ch in e m u st be u sed a n d t h e equ ipm en t ca li-
br a t ion ver ified.
Th e wh eel ca st er a n gle is pr eset . Th is a n gle is n ot
a dju st a ble a n d ca n n ot be a lt er ed.
STANDARD PROCEDURE - TOE POSITION
Befor e ea ch a lign m en t r ea din g t h e veh icle sh ou ld
be jou n ced (r ea r fir st , t h en fr on t ). Gr a sp ea ch
bu m per a t t h e cen t er a n d jou n ce t h e veh icle u p a n d
down t h r ee t im es. Alwa ys r elea se t h e bu m per in t h e
down posit ion .
m en t m a ch in e m u st be u sed a n d t h e equ ipm en t ca li-
br a t ion ver ified.
NOTE: For an accurate wheel toe position adjust-
ment the engine must be engine running.
(1) Apply pa r kin g br a kes.
(2) St a r t t h e en gin e a n d t u r n wh eels bot h wa ys
befor e st r a igh t en in g t h e st eer in g wh eel. Cen t er a n d
secu r e t h e st eer in g wh eel.
(3) Loosen t h e t ie r od a dju st m en t sleeve cla m p
bolt s (F ig. 2).
(4) Tu r n t h e sleeve t o obt a in t h e pr efer r ed posit ive
TOE -IN specifica t ion . P osit ion t h e cla m p bolt s a s
sh own (F ig. 2) for pr oper clea r a n ce.
(5) Tigh t en t h e cla m p bolt s t o 68 N·m (50 ft . lbs.).
WJ WHEEL ALIGNMENT 2-5
WH EEL ALI GN M EN T (Cont inue d)
NOTE: Make sure the toe setting does not change SPECI FI CAT I ON S
during clamp tightening.
ALIGNMENT
(6) Ver ify a lign m en t specifica t ion s, t h en t u r n t h e
en gin e off. NOTE: Specifications are in degrees.

FRONT WHEELS - STANDARD SUSPENSION

SPECI FI CAT I ON S
DESCRIPTION SPECIFICATION
PREFERRED CASTER CAMBER TOTAL
+ 6.75° ! 0.37° TOE-IN
+ 0.20°
RANGE + 6.0° to ! 0.75° + .14° to
+ 7.5° to + 0.5° + .26°
MAX RT/LT 0.5° 0.5° 0.5°
DIFFERENCE

FRONT WHEELS - UP-COUNTRY SUSPENSION

Fig. 2 Steering Linkage
1 - DRAG LINK ADJUSTMENT SLEEVE SPECI FI CAT I ON S
2 - TIE ROD ADJUSTMENT SLEEVE
DESCRIPTION SPECIFICATION
STEERING WHEEL CENTERING PREFERRED CASTER CAMBER TOTAL
+ 6.5° ! 0.37° TOE-IN
NOTE: The steering wheel can be centered without + 0.20°
affecting the toe position. RANGE + 5.7° to ! 0.75° + 0.0° to
+ 7.2° to + 0° + .36°
(1) Loosen t h e dr a g lin k a dju st m en t sleeve cla m p
bolt s. MAX RT/LT 0.5° 0.5° 0.06°
(2) Tu r n t h e a dju st m en t sleeve t o cen t er t h e DIFFERENCE
wh eel.
(3) P osit ion t h e cla m p bolt s a s sh own (F ig. 2)for REAR AXLE
pr oper clea r a n ce.
(4) Tigh t en t h e cla m p bolt s t o 68 N·m (50 ft . lbs.). SPECI FI CAT I ON S
(5) Roa d t est t h e veh icle t o ver ify t h e wh eel is cen - DESCRIPTION SPECIFICATION
t er ed.
PREFERRED CAMBER THRUST TOTAL
–.37° ANGLE TOE-IN
0° +.37°
RANGE 0° to ± 0.25° 0° to
–.75° +.70°
2-6 FRONT WJ

FRON T

TABLE OF CONTENTS
page page

FRONT SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - SERVICE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
TORQUE CHART ......................7 SPRING
SPECIAL TOOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STABILIZER BAR
HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRACK BAR
KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL - STEERING KNUCKLE . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 UPPER BALL JOINT
LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 UPPER CONTROL ARM
LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11

FRON T CAUTION: Suspension components with rubber

bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
DESCRIPTION
supporting the weight of the vehicle when the fas-
Th e fr on t su spen sion (F ig. 1) is a lin k/coil design
teners are torqued. If springs are not at their normal
com pr ised of :
ride position, vehicle ride comfort will be affected
• Dr ive a xle
and cause premature bushing wear.
• Sh ock a bsor ber s
• Coil spr in gs
• Upper a n d lower su spen sion a r m s STANDARD PROCEDURE - SERVICE
• St a bilizer ba r
• Tr a ck ba r WARNINGS AND CAUTIONS
• J ou n ce bu m per s
CAUTION: Suspension components with rubber
CAUTION: Components attached with a nut and cot- bushings must be tightened with the vehicle at nor-
ter pin must be torqued to specification. Then if the mal ride height. It is important to have the springs
slot in the nut does not line up with the cotter pin supporting the weight of the vehicle when the fas-
hole, tighten nut until it is aligned. Never loosen the teners are torqued. If springs are not at their normal
nut to align the cotter pin hole. ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
WJ FRONT 2-7
FRON T (Cont inue d)

Fig. 1 Front
1 - SHOCK
2 - COIL SPRING
3 - UPPER SUSPENSION ARM
4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
6 - TRACK BAR

SPECI FI CAT I ON S
TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber Upper Nut 35 26 —
Shock Absorber Lower Nut 28 — 250
Suspension Arm Upper Axle Bracket Nut 61 45 —
Suspension Arm Upper Frame Bracket Bolt 61 45 —
Suspension Arm Lower Axle Bracket Nut 163 120 —
Suspension Arm Lower Frame Bracket Bolt 156 115 —
Stabilizer Bar Retainer Bolts 92 68 —
Stabilizer Bar Link Upper Nut 106 78 —
Stabilizer Bar Link Lower Nut 106 78 —
Track Bar Frame Bracket Nut 108 80 —
Track Bar Axle Bracket Bolt 100 74 —
Hub Bearing Knuckle Bolts 102 75 —
2-8 FRONT WJ
FRON T (Cont inue d)

SPECI AL T OOLS
FRONT SUSPENSION

Remover C-4150A

Remover/Installer Suspension Bushing 7932

Remover/Installer 6289

Spacer 8279

Reciever 6761

Nut, Long 7603

Installer 6752

Bolt, Special 7604

WJ
BU SH I N GS
REMOVAL
(1) Rem ove t h e u pper su spen sion a r m fr om a xle.
(2) P osit ion Spa cer 8279 over t h e a xle bu sh in g on
a 4x2 veh icle a n d r igh t side on a 4x4 veh icle.
(3) P la ce Receiver 7932-1 over fla n ged en d of t h e
bu sh in g. (F ig. 2).
(4) P la ce sm a ll en d of Rem over /In st a ll 7932-2
a ga in st ot h er side of t h e bu sh in g.
(5) In st a ll bolt 7604 t h r ou gh r em over, bu sh in g a n d
r eceiver.
(6) In st a ll Lon g Nu t 7603 a n d t igh t en n u t t oo pu ll
bu sh in g ou t of t h e a xle br a cket .
Fig. 2 Bushing Removal
1 - RECEIVER
2 - AXLE BRACKET
3 - BOLT
4 - REMOVER/INSTALLER
5 - LONG NUT
(7) Rem ove n u t , bolt , r eceiver, r em over a n d bu sh -
in g.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 8279 in position for bushing installa-
tion.
INSTALLATION
(1) P la ce Receiver 7932-1on t h e ot h er side of t h e
a xle br a cket .
(2) P osit ion n ew bu sh in g u p t o t h e a xle br a cket .,
a n d la r ge en d of Rem over /In st a ll 7932-2 a ga in st t h e
bu sh in g (F ig. 3).
(3) In st a ll bolt 7604 t h r ou gh r eceiver, bu sh in g a n d
in st a ller.
(4) In st a ll Lon g Nu t 7603 a n d t igh t en n u t t o dr a w
t h e bu sh in g in t o t h e a xle br a cket .
FRONT 2-9
Fig. 3 Bushing Installation
1 - REMOVER/INSTALLER
2 - AXLE BRACKET
3 - BOLT
4 - RECEIVER
5 - LONG NUT
(5) Rem ove t ools a n d in st a ll t h e u pper su spen sion
arm.
H U B / BEARI N G
DESCRIPTION
Th e bea r in g u sed on t h e fr on t h u b of t h is veh icle is
t h e com bin ed h u b a n d bea r in g u n it t ype a ssem bly.
Th is u n it a ssem bly com bin es t h e fr on t wh eel m ou n t -
in g h u b (fla n ge) a n d t h e fr on t wh eel bea r in g in t o a
on e piece u n it . Th e wh eel m ou n t in g st u ds a r e t h e
on ly r epla cea ble com pon en t of t h e h u b/bea r in g
a ssem bly.
OPERATION
Th e h u b/bea r in g a ssem bly is m ou n t ed t o t h e st eer-
in g kn u ckle a n d is r et a in ed by t h r ee m ou n t in g bolt s
a ccessible fr om t h e ba ck of t h e st eer in g kn u ckle. Th e
h u b/bea r in g u n it is n ot ser vicea ble a n d m u st be
r epla ced a s a n a ssem bly if t h e bea r in g or t h e h u b is
det er m in ed t o be defect ive.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e wh eel a n d t ir e a ssem bly.
(3) Rem ove t h e br a ke ca liper, ca liper a n ch or, r ot or
a n d ABS wh eel speed sen sor,(Refer t o 5 - BRAKE S/
E LE CTRICAL/F RONT WH E E L SP E E D SE NSOR -
RE MOVAL).
(4) Rem ove t h e cot t er pin , n u t r et a in er a n d a xle
hub nut.
(5) Rem ove t h e h u b bea r in g m ou n t in g bolt s fr om
t h e ba ck of t h e st eer in g kn u ckle. Rem ove h u b bea r-
2 - 10 FRONT WJ
H U B / BEARI N G (Cont inue d)
in g (F ig. 4) fr om t h e st eer in g kn u ckle a n d off t h e in st a lla t ion of u pper a n d lower ba ll st u ds r equ ir e t h e
a xle sh a ft . u se of Tool Kit 6289.
(1) Rem ove h u b bea r in g a n d a xle sh a ft .
(2) Discon n ect t h e t ie-r od or dr a g lin k fr om t h e
st eer in g kn u ckle a r m ,(Refer t o 19 - STE E RING/
LINKAGE /TIE ROD E ND - RE MOVAL) .
(3) Rem ove t h e cot t er pin s fr om t h e u pper a n d
lower ba ll st u ds.
(4) Rem ove t h e u pper a n d lower ba ll st u d n u t s.
(5) St r ike t h e st eer in g kn u ckle wit h a br a ss h a m -
m er t o loosen kn u ckle fr om t h e ba ll st u ds. Rem ove
kn u ckle fr om ba ll st u ds (F ig. 5).

Fig. 4 Hub Bearing & Knuckle

1 - HUB BEARING
2 - KNUCKLE

INSTALLATION
(1) In st a ll t h e h u b bea r in g t o t h e kn u ckle.
(2) In st a ll t h e h u b bea r in g t o kn u ckle bolt s a n d
t igh t en t o 102 N·m (75 ft . lbs.).
(3) In st a ll t h e h u b wa sh er a n d n u t . Tigh t en t h e
h u b n u t t o 237 N·m (175 ft . lbs.). In st a ll t h e n u t
r et a in er a n d a n ew cot t er pin .
(4) In st a ll t h e br a ke r ot or, ca liper a n ch or, ca liper
a n d ABS wh eel speed sen sor,(Refer t o 5 - BRAKE S/
E LE CTRICAL/F RONT WH E E L SP E E D SE NSOR -
INSTALLATION).
(5) In st a ll t h e wh eel a n d t ir e a ssem bly (Refer t o 22 Fig. 5 Steering Knuckle Removal/Installation
- TIRE S/WH E E LS - STANDARD P ROCE DURE ). 1 - AXLE YOKE
(6) Rem ove t h e su ppor t a n d lower t h e veh icle. 2 - UPPER BALL STUD
3 - LOWER BALL STUD
4 - STEERING KNUCKLE
K N U CK LE
DESCRIPTION INSTALLATION
Th e kn u ckle is a sin gle ca st in g wit h legs m a ch in ed (1) P osit ion t h e st eer in g kn u ckle on t h e ba ll st u ds.
for t h e u pper a n d lower ba ll join t s. Th e kn u ckle a lso (2) In st a ll a n d t igh t en t h e bot t om r et a in in g n u t t o
h a s m a ch in ed m ou n t in g loca t ion s for t h e fr on t br a ke 109 N·m (80 ft . lbs.) t or qu e. In st a ll n ew cot t er pin .
ca liper s a n d h u b bea r in g. (3) In st a ll a n d t igh t en t h e t op r et a in in g n u t t o 101
N·m (75 ft . lbs.) t or qu e. In st a ll n ew cot t er pin .
OPERATION (4) In st a ll t h e h u b bea r in g a n d a xle sh a ft .
(5) Con n ect t h e t ie-r od or dr a g lin k en d t o t h e
Th e st eer in g kn u ckle pivot bet ween t h e u pper a n d
st eer in g kn u ckle a r m .,(Refer t o 19 - STE E RING/
lower ba ll join t . St eer in g lin ka ge a t t a ch ed t o t h e
LINKAGE /TIE ROD E ND - INSTALLATION) .
kn u ckle a llows t h e veh icle t o be st eer ed.

REMOVAL - STEERING KNUCKLE

Ba ll st u d ser vice pr ocedu r es below r equ ir e r em ova l
of t h e h u b bea r in g a n d a xle sh a ft . Rem ova l a n d
WJ FRONT 2 - 11

LOWER BALL J OI N T REMOVAL

REMOVAL
Ba ll st u d ser vice pr ocedu r es below r equ ir e r em ova l
of t h e h u b bea r in g a n d a xle sh a ft . Rem ova l a n d
in st a lla t ion of u pper a n d lower ba ll st u ds r equ ir e t h e
u se of Tool Kit 6289.
(1) P osit ion t ools a s sh own t o r em ove a n d in st a ll
ba ll st u d (F ig. 6).
LOWER CON T ROL ARM
DESCRIPTION
Th e lower su spen sion a r m s a r e h ydr ofor m ed st eel
a n d u se voided ova l bu sh in gs a t on e en d of t h e a r m .
OPERATION
Th e bu sh in gs pr ovide isola t ion fr om t h e a xle. Th e
a r m s m ou n t t o t h e u n ibody fr a m e r a il br a cket a n d
t h e a xle br a cket s. Th e a r m a n d bu sh in gs pr ovide
loca t ion a n d r ea ct t o loa ds fr om t h e a xle.
(1) Ra ise t h e veh icle a n d su ppor t t h e fr on t a xle.
(2) Rem ove t h e lower su spen sion a r m n u t a n d bolt
fr om t h e a xle br a cket (F ig. 7).
(3) Rem ove t h e n u t a n d bolt fr om t h e fr a m e r a il
br a cket a n d r em ove t h e lower su spen sion a r m (F ig.
7).
INSTALLATION
(1) P osit ion t h e lower su spen sion a r m in t h e a xle
br a cket a n d fr a m e r a il br a cket .
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) In st a ll t h e a xle br a cket bolt a n d n u t fin ger
t igh t .
(3) In st a ll t h e fr a m e r a il br a cket bolt a n d n u t fin -
ger t igh t .
(4) Rem ove su ppor t a n d lower t h e veh icle.
(5) Wit h t h e veh icle on t h e gr ou n d t igh t en t h e
fr a m e br a cket bolt t o 156 N·m (115 ft . lbs.). Tigh t en
t h e a xle br a cket n u t t o 163 N·m (120 ft . lbs.).
(6) Ch eck t h e a lign m en t if n ew pa r t s wer e
in st a lled.

Fig. 6 Lower
1 - SPECIAL TOOL 6289–12 5 - SPECIAL TOOL 6289–1
2 - SPECIAL TOOL 6289–4 6 - SPECIAL TOOL 6289–3
3 - SPECIAL TOOL 4212F
4 - SPECIAL TOOL 4212F
2 - 12 FRONT WJ
LOWER CON T ROL ARM (Cont inue d)

Fig. 7 Lower Suspension Arm Fig. 8 Upper Shock Mounting

1 - LOWER SUSPENSION ARM 1 - RETAINER
2 - FRAME RAIL BRACKET 2 - STUD
3 - AXLE BRACKET 3 - NUT
4 - GROMMET

SH OCK
DESCRIPTION
Th e t op of t h e sh ock a bsor ber s a r e bolt ed t o t h e
body. Th e bot t om of t h e sh ocks a r e bolt ed t o t h e a xle
br a cket s. Th e st a n da r d sh ocks h a ve con ven t ion a l
t win t u be con st r u ct ion a n d a r e low pr essu r e ga s
ch a r ged. Ga s ch a r gin g pr even t s ca vit a t ion du r in g
r ou gh r oa d oper a t ion . Up-Cou n t r y sh ocks a r e m on o
t u be design a n d a r e h igh pr essu r e ga s ch a r ged.

OPERATION
Th e sh ock a bsor ber s da m pen jou n ce a n d r ebou n d
m ot ion of t h e veh icle over va r iou s r oa d con dit ion s
a n d lim it su spen sion r ebou n d t r a vel.
REMOVAL
(1) Rem ove t h e n u t , r et a in er a n d gr om m et fr om
t h e sh ock st u d in t h e en gin e com pa r t m en t (F ig. 8).
(2) Ra ise a n d su ppor t t h e fr on t a xle.
(3) Rem ove t h e lower m ou n t in g n u t s fr om t h e a xle
br a cket (F ig. 9). Rem ove t h e sh ock a bsor ber.
INSTALLATION
(1) P osit ion t h e lower r et a in er a n d gr om m et on t h e
sh ock st u d. In ser t t h e sh ock a bsor ber t h r ou gh t h e
sh ock t ower h ole.
(2) In st a ll t h e lower sh ock st u ds in t o t h e a xle
br a cket .
(3) In st a ll t h e m ou n t in g n u t s a n d t igh t en t o 28
N·m (250 in . lbs.).
(4) Rem ove su ppor t a n d lower t h e veh icle.
Fig. 9 Lower Shock Mounting
1 - SHOCK ABSORBER
2 - MOUNTING NUTS
(5) In st a ll t h e u pper gr om m et , r et a in er a n d n u t on
t h e st u d in t h e en gin e com pa r t m en t . H old t h e sh ock
st u d wit h a 8 m m wr en ch a n d t igh t en t h e n u t t o 35
N·m (26 ft . lbs.).
SPRI N G
DESCRIPTION
Th e coil spr in gs m ou n t u p in t h e wh eelh ou se wh ich
is pa r t of t h e u n it ized body br a cket . A r u bber dou gh -
n u t isola t or is loca t ed bet ween t h e t op of t h e spr in g
a n d t h e body. Th e bot t om of t h e spr in g sea t s on a
a xle isola t or m a de of r u bber wit h a st eel in ser t .
WJ FRONT 2 - 13
SPRI N G (Cont inue d)

OPERATION
Th e coil spr in gs con t r ol r ide qu a lit y a n d m a in t a in
pr oper r ide h eigh t . Th e isola t or s pr ovide r oa d n oise
isola t ion .

REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e wh eel a n d t ir e a ssem blies.
(3) P osit ion a h ydr a u lic ja ck u n der t h e a xle t o su p-
por t it .
(4) Rem ove sh ock a bsor ber s lower m ou n t in g n u t s
fr om t h e a xle br a cket s.
(5) Rem ove t h e t r a ck ba r m ou n t in g bolt fr om t h e
a xle br a cket .

NOTE: Make sure the lower part of the shock does

not hold tension on the brake lines at the axle tube
housing located at the lower shock mounting area.

(6) Lower t h e a xle u n t il t h e spr in g is fr ee fr om t h e Fig. 11 Lower Isolator

u pper m ou n t a n d isola t or (F ig. 10). 1 - LOCATING NUB
2 - LOWER ISOLATOR
3 - AXLE SPRING PAD
4 - LOCATING HOLE

CAUTION: Ensure the spring is positioned on the

lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 12).

Fig. 10 Front Coil Spring

1 - UPPER ISOLATOR
2 - COIL SPRING
3 - LOWER ISOLATOR
4 - STABILIZER LINK
Fig. 12 Isolator Spring Locator
(7) Rem ove t h e spr in g fr om t h e veh icle. 1 - COIL SPRING
(8) Rem ove a n d in spect t h e u pper a n d lower 2 - SPRING LOCATOR
spr in g isola t or s. 3 - LOWER ISOLATOR

INSTALLATION (4) Ra ise t h e a xle a n d gu ide t h e spr in gs on t o t h e

(1) In st a ll t h e u pper isola t or. spr in g u pper m ou n t s a n d lower sh ock st u ds in t o t h e
(2) In st a ll t h e lower isola t or wit h t h e isola t or loca - a xle br a cket s.
t or n u b in t h e a xle pa d h ole (F ig. 11). (5) In st a ll t h e sh ock a bsor ber s lower m ou n t in g
(3) P osit ion t h e coil spr in g on t h e a xle spr in g pa d. n u t s.
2 - 14 FRONT
SPRI N G (Cont inue d)
(6) In st a ll t h e t r a ck ba r t o t h e a xle br a cket a n d
in st a ll t h e m ou n t in g bolt .
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar bolt.
(7) Rem ove t h e h ydr a u lic ja ck fr om u n der t h e
veh icle.
(8) Tigh t en a ll su spen sion com pon en t s t o pr oper
t or qu e.
(9) In st a ll t h e wh eel a n d t ir e a ssem blies.
(10) Rem ove su ppor t a n d lower veh icle.
WJ
INSTALLATION
(1) P osit ion t h e st a bilizer ba r on t h e fr a m e r a il
a n d in st a ll t h e r et a in er s a n d bolt s. E n su r e t h e ba r is
cen t er ed wit h equ a l spa cin g on bot h sides. Tigh t en
t h e bolt s t o 92 N·m (68 ft . lbs.).
(2) In st a ll t h e lin ks on t o t h e st a bilizer ba r a n d
a xle br a cket s a n d in st a ll t h e bolt s a n d n u t s fin ger
t igh t .
(3) Rem ove t h e su ppor t s a n d lower t h e veh icle.
(4) Wit h t h e veh icle on t h e gr ou n d t igh t en t h e st a -
bilizer ba r lin k n u t s t o 106 N·m (78 ft . lbs.).

STABI LI Z ER BAR T RACK BAR

DESCRIPTION DESCRIPTION
Th e ba r is a t t a ch ed t o a fr a m e r a il br a cket a n d
Th e ba r ext en ds a cr oss t h e fr on t u n der side of t h e
ch a ssis a n d is m ou n t ed t o t h e fr a m e r a ils. Lin ks a r e a xle br a cket . Th e ba r is for ged a n d h a s n on r epla ce-
a ble isola t or bu sh in gs a t bot h en ds.
con n ect ed fr om t h e ba r t o t h e a xle br a cket s. Th e st a -
bilizer ba r a n d lin ks a r e isola t ed by r u bber bu sh in gs.
OPERATION
OPERATION Th e t r a ck ba r is u sed t o con t r ol fr on t a xle la t er a l
Th e st a bilizer ba r is u sed t o con t r ol veh icle body m ovem en t a n d pr ovides cr oss ca r loca t ion of t h e a xle
r oll du r in g t u r n s. Th e spr in g st eel ba r h elps t o con - a ssem bly.
t r ol t h e veh icle body in r ela t ion sh ip t o t h e su spen -
sion . REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
REMOVAL (2) Rem ove t h e n u t a n d bolt fr om t h e fr a m e r a il
(1) Ra ise a n d su ppor t t h e veh icle. br a cket (F ig. 14).
(2) Rem ove lin k n u t s a n d bolt s (F ig. 13) a n d
r em ove t h e lin ks.
(3) Rem ove t h e st a bilizer ba r r et a in er bolt s (F ig.
13)fr om t h e fr a m e r a ils a n d r em ove t h e st a bilizer
ba r.

Fig. 14 Track Bar Frame Rail Bracket

1 - FRAME RAIL
2 - TRACK BAR

(3) Rem ove t h e bolt fr om t h e a xle sh a ft t u be

Fig. 13 Stabilizer Bar br a cket (F ig. 15). Rem ove t h e t r a ck ba r.
1 - LINK
2 - STABILIZER BAR INSTALLATION
3 - BUSHING (1) In st a ll t h e t r a ck ba r t o t h e a xle t u be br a cket .
4 - RETAINER In st a ll t h e r et a in in g bolt fin ger t igh t .
WJ FRONT 2 - 15
T RACK BAR (Cont inue d)
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar to the frame rail
bracket.

(3) Rem ove t h e su ppor t s a n d lower t h e veh icle.

(4) Wit h t h e veh icle on t h e gr ou n d t igh t en t h e n u t
a t t h e fr a m e r a il br a cket a n d t o t h e bolt a t t h e a xle
br a cket t o 100 N·m (74 ft . lbs.).
(5) Ch eck a lign m en t specifica t ion s if a n ew t r a ck
ba r wa s in st a lled.

U PPER BALL J OI N T
REMOVAL
Fig. 15 Track Bar Axle Bracket Ba ll st u d ser vice pr ocedu r es below r equ ir e r em ova l
1 - AXLE BRACKET of t h e h u b bea r in g a n d a xle sh a ft . Rem ova l a n d
2 - TRACK BAR in st a lla t ion of u pper a n d lower ba ll st u ds r equ ir e t h e
u se of Tool Kit 6289.
(2) In st a ll t r a ck ba r t o t h e fr a m e r a il br a cket . (1) P osit ion t ools a s sh own t o r em ove a n d in st a ll
In st a ll t h e bolt a n d n u t fin ger t igh t . ba ll st u d (F ig. 16).

Fig. 16 Upper
2 - 16 FRONT WJ

U PPER CON T ROL ARM (3) Rem ove t h e n u t a n d bolt (F ig. 17) a t t h e fr a m e
r a il a n d r em ove t h e u pper su spen sion a r m .
DESCRIPTION
Th e u pper su spen sion a r m s a r e h ydr ofor m ed st eel
INSTALLATION
(1) P osit ion t h e u pper su spen sion a r m a t t h e a xle
a n d u se r u bber bu sh in gs a t ea ch en d of t h e a r m .
a n d fr a m e r a il.
(2) In st a ll t h e bolt s a n d fin ger t igh t en t h e n u t s.
OPERATION
(3) Rem ove t h e su ppor t s a n d lower t h e veh icle.
Th e a r m s m ou n t t o t h e u n ibody fr a m e r a il br a cket
(4) Wit h t h e veh icle on t h e gr ou n d t igh t en t h e a xle
a n d t h e a xle br a cket s. Th e a r m a n d bu sh in gs pr ovide
br a cket n u t a n d t h e fr a m e br a cket bolt t o 61 N·m (45
loca t ion a n d r ea ct t o loa ds fr om t h e a xle. Th e bu sh -
ft . lbs.).
in gs pr ovide isola t ion fr om t h e a xle.
(5) Ch eck t h e a lign m en t if n ew pa r t s wer e
in st a lled.
REMOVAL
(1) Ra ise veh icle a n d su ppor t t h e a xle.
(2) Rem ove t h e u pper su spen sion a r m m ou n t in g
n u t a n d bolt (F ig. 17) fr om t h e a xle br a cket .

Fig. 17 Upper Suspension Arm

1 - UPPER SUSPENSION ARM
2 - FRAME BOLT
3 - AXLE BOLT
WJ REAR 2 - 17

REAR

TABLE OF CONTENTS
page page

REAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - REAR STABILIZER BAR
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . 18 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 19 UPPER BALL JOINT
LOWER CONTROL ARM DESCRIPTION - UPPER SUSPENSION ARM,
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19 BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 OPERATION - UPPER SUSPENSION ARM,
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SHOCK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19 UPPER CONTROL ARM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPRING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20

REAR
DESCRIPTION
Th e r ea r su spen sion (F ig. 1) is com pr ised of :
• Dr ive a xle
• Sh ock a bsor ber s
• Coil spr in gs
• Lower su spen sion a r m s
• Upper su spen sion a r m
• St a bilizer ba r

CAUTION: Suspension components with rubber/ure-

thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle Fig. 1 Rear Suspension
ride comfort and prevent premature bushing wear.
1 - SHOCK
2 - UPPER SUSPENSION ARM
3 - COIL SPRING
WARNING 4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs ride position, vehicle ride comfort will be affected
supporting the weight of the vehicle when the fas- and cause premature bushing wear.
teners are torqued. If springs are not at their normal
2 - 18 REAR WJ
REAR (Cont inue d)

DIAGNOSIS AND TESTING - REAR

SUSPENSION

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose, worn or bent suspension 2. Inspect, tighten or replace components

components. as necessary.
3. Tire pressure. 3. Adjust tire pressure.

VEHICLE PULLS TO ONE 1. Weak or broken spring. 1. Replace spring.

SIDE
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension 5. Inspect, tighten or replace components
components. as necessary.

IMPROPER TRACKING 1. Loose, worn or bent suspension 1. Inspect, tighten or replace components
components. as necessary.
2. Bent axle. 2.Replace axle.

SPECI FI CAT I ON S
TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber Upper Nut 108 80 —
Shock Absorber Lower Nut 115 85 —
Suspension Arm Upper Ball Joint Nut 142 105 —
Suspension Arm Upper Frame Bolts 100 74 —
Ball Joint Plate Bolts 136 100 —
Suspension Arms Lower Axle Bracket Nut 163 120 —
Suspension Arms Lower Frame Bracket Nut 156 115 —
Stabilizer Bar Retainer Bolts 54 40 —
Stabilizer Bar Bar Link Nut 54 40 —
Stabilizer Bar Bracket Link Nut 92 68 —
WJ REAR 2 - 19
REAR (Cont inue d)

SPECI AL T OOLS INSTALLATION

(1) P osit ion t h e lower su spen sion a r m in t h e a xle
REAR SUSPENSION br a cket a n d fr a m e r a il br a cket .

NOTE: The end of the arm with the oval bushing

attaches to the axle bracket.

(2) In st a ll t h e a xle br a cket bolt a n d n u t fin ger

Remover 8278
LOWER CON T ROL ARM
DESCRIPTION
Th e lower su spen sion a r m s a r e h ydr ofor m ed st eel
a n d u se voided ova l bu sh in gs a t ea ch en d of t h e a r m .
OPERATION
Th e bu sh in gs pr ovide isola t ion fr om t h e a xle. Th e
a r m s m ou n t t o t h e u n ibody fr a m e r a il br a cket a n d
t h e a xle br a cket s. Th e a r m a n d bu sh in gs pr ovide
loca t ion a n d r ea ct t o loa ds.
REMOVAL
(1) Ra ise t h e veh icle a n d su ppor t t h e r ea r a xle.
(2) Rem ove t h e lower su spen sion a r m n u t a n d bolt
fr om t h e a xle br a cket (F ig. 2).
(3) Rem ove t h e n u t a n d bolt (F ig. 2) fr om t h e
fr a m e r a il a n d r em ove t h e lower su spen sion a r m .
t igh t .
(3) In st a ll t h e fr a m e r a il br a cket bolt a n d n u t fin -
ger t igh t .
(4) Rem ove t h e su ppor t s a n d lower t h e veh icle.
(5) Wit h t h e veh icle on t h e gr ou n d t igh t en t h e n u t
a t t h e fr a m e t o 156 N·m (115 ft . lbs.). Tigh t en t h e
n u t a t t h e a xle br a cket t o 163 N·m (120 ft . lbs.).
SH OCK
DESCRIPTION
Th e t op of t h e sh ock a bsor ber s a r e bolt ed t o t h e
body. Th e bot t om of t h e sh ocks a r e bolt ed t o t h e a xle
br a cket s. Th e st a n da r d sh ocks h a ve con ven t ion a l
t win t u be con st r u ct ion a n d a r e low pr essu r e ga s
ch a r ged. Ga s ch a r gin g pr even t s ca vit a t ion du r in g
r ou gh r oa d oper a t ion . Up-Cou n t r y sh ocks a r e m on o
t u be design a n d a r e h igh pr essu r e ga s ch a r ged.
OPERATION
Th e sh ock a bsor ber s da m pen jou n ce a n d r ebou n d
m ot ion of t h e veh icle over va r iou s r oa d con dit ion s
a n d lim it su spen sion r ebou n d t r a vel.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle. P osit ion a
h ydr a u lic ja ck u n der t h e a xle t o su ppor t t h e a xle.

CAUTION: Do not allow the axle to hang from the

upper suspension arm ball joint.

(2) Rem ove t h e u pper n u t a n d bolt fr om t h e fr a m e

br a cket (F ig. 3).
(3) Rem ove t h e lower n u t a n d bolt fr om t h e a xle
br a cket . Rem ove t h e sh ock a bsor ber.

INSTALLATION
(1) In st a ll t h e sh ock a bsor ber in t h e fr a m e br a cket
a n d in st a ll t h e bolt a n d n u t .
(2) In st a ll t h e sh ock a bsor ber in t h e a xle br a cket
a n d in st a ll t h e bolt a n d n u t .
(3) Tigh t en t h e u pper m ou n t in g n u t s t o 108 N·m
Fig. 2 Lower Suspension Arm (80 ft . lbs.). Tigh t en t h e lower m ou n t in g n u t s t o 115
1 - LOWER SUSPENSION ARM N·m (85 ft . lbs.).
2 - AXLE BRACKET (4) Rem ove t h e su ppor t s a n d lower t h e veh icle.
3 - FRAME BRACKET
2 - 20 REAR WJ
SH OCK (Cont inue d)

Fig. 3 Shock Absorber

Fig. 4 Coil Spring
1 - SHOCK
1 - COIL SPRING
2 - ISOLATOR
3 - STABILIZER LINK
SPRI N G 4 - ISOLATOR

DESCRIPTION
Th e coil spr in gs m ou n t u p in t h e wh eelh ou se wh ich
is pa r t of t h e u n it ized body br a cket . A r u bber dou gh -
n u t isola t or is loca t ed bet ween t h e t op of t h e spr in g
a n d t h e body. Th e bot t om of t h e spr in g sea t s on a
a xle isola t or m a de of r u bber wit h a st eel in ser t . Th e
isola t or s pr ovide r oa d n oise isola t ion

OPERATION
Th e coil spr in gs con t r ol r ide qu a lit y a n d m a in t a in
pr oper r ide h eigh t .

REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle. P osit ion a
h ydr a u lic ja ck u n der t h e a xle t o su ppor t t h e a xle.
(2) Rem ove t h e wh eel a n d t ir e a ssem blies.
(3) Rem ove t h e st a bilizer ba r lin k fr om t h e st a bi-
lizer ba r (F ig. 4).
(4) Rem ove t h e sh ock a bsor ber lower bolt fr om t h e
a xle br a cket .
(5) Lower t h e h ydr a u lic ja ck a n d t ilt t h e a xle a n d
r em ove t h e coil spr in g (F ig. 4).
(6) Rem ove a n d in spect t h e u pper a n d lower
spr in g isola t or s (F ig. 4).
INSTALLATION
(1) In st a ll t h e u pper isola t or.
(2) In st a ll t h e lower isola t or wit h t h e isola t or loca -
t or n u b in t h e a xle pa d h ole (F ig. 5).
(3) P u ll down on t h e a xle a n d posit ion t h e coil
spr in g in t h e lower isola t or.
Fig. 5 Isolator Locator Nub
1 - LOWER ISOLATOR
2 - LOCATOR NUB
3 - AXLE SPRING PAD
CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 6).
(4) Ra ise t h e a xle wit h t h e h ydr a u lic ja ck.
(5) In st a ll t h e sh ock a bsor ber t o t h e a xle br a cket
a n d t igh t en t o specifica t ion .
(6) In st a ll t h e st a bilizer ba r lin k t o t h e st a bilizer
ba r.
(7) In st a ll t h e wh eel a n d t ir e a ssem blies.
(8) Rem ove t h e su ppor t s a n d lower t h e veh icle.
(9) Tigh t en t h e st a bilizer ba r lin ks t o specifica t ion .
WJ REAR 2 - 21
SPRI N G (Cont inue d)

Fig. 7 Rear Stabilizer Bar

Fig. 6 Isolator Spring Locator - Typical
1 - LINK
1 - LOWER ISOLATOR 2 - RETAINER
2 - SPRING LOCATOR 3 - BUSHING
3 - COIL SPRING 4 - STABILIZER BAR

STABI LI Z ER BAR U PPER BALL J OI N T

DESCRIPTION
Th e st a bilizer ba r ext en ds a cr oss t h e ba ck side of
t h e r ea r a xle. Lin ks a r e con n ect ed bet ween t h e ba r
a n d fr a m e r a il br a cket s. Th e st a bilizer ba r a n d lin ks
a r e isola t ed by r u bber bu sh in gs.
OPERATION
Th e st a bilizer ba r is u sed t o con t r ol veh icle body
r oll, du r in g t u r n s. Th e ba r h elps con t r ol t h e veh icle
body in r ela t ion sh ip t o t h e su spen sion .
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e st a bilizer ba r lin ks fr om st a bilizer
ba r a n d fr a m e m ou n t . (F ig. 7).
(3) Rem ove t h e st a bilizer ba r r et a in er bolt s.
(4) Rem ove t h e st a bilizer ba r.
INSTALLATION
(1) P osit ion t h e st a bilizer ba r on t h e a xle a n d
in st a ll t h e r et a in er s a n d bolt s. E n su r e t h e ba r is cen -
t er ed wit h equ a l spa cin g on bot h sides. Tigh t en t h e
bolt s t o 54 N·m (40 ft . lbs.).
(2) In st a ll t h e lin ks t o t h e st a bilizer ba r a n d fr a m e
br a cket s.
(3) Tigh t en t h e n u t s a t t h e st a bilizer ba r t o 54
N·m (40 ft . lbs.).
(4) Tigh t en t h e n u t s a t t h e fr a m e br a cket s t o 92
N·m (68 ft . lbs.).
(5) Rem ove su ppor t a n d lower t h e veh icle.
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
Th e su spen sion a r m u ses ver t ica l spool bu sh in gs t o
isola t e r oa d n oise. Th e su spen sion a r m is bolt ed
t h r ou gh bu sh in gs t o ca ge n u t s in t h e body a n d a ba ll
join t pla t e t o t h e t op of t h e differ en t ia l h ou sin g.
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
Th e u pper su spen sion a r m pr ovides for e/a ft a n d
la t er a l loca t ion of t h e r ea r a xle. Th e su spen sion a r m
t r a vel is lim it ed t h r ou gh t h e u se of jou n ce bu m per s
in com pr ession a n d sh ock a bsor ber s in r ebou n d.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Su ppor t t h e r ea r a xle wit h a h ydr a u lic ja ck.
(3) Rem ove t h e ba ll join t n u t fr om t h e t op of t h e
u pper su spen sion a r m (F ig. 8).
(4) Sepa r a t e ba ll join t fr om t h e a r m wit h Rem over
8278 (F ig. 9).
NOTE: It may be necessary to strike the upper con-
trol arm with a hammer to separate the ball joint
from the arm.
(5) Rem ove t h e ba ll join t m ou n t in g bolt s (F ig.
10)fr om t h e differ en t ia l h ou sin g.
(6) Rem ove t h e ba ll join t fr om t h e differ en t ia l
h ou sin g.
2 - 22 REAR WJ
U PPER BALL J OI N T (Cont inue d)

Fig. 8 Ball Joint Nut

1 - BALL JOINT NUT
2 - UPPER SUSPENSION ARM

Fig. 10 Ball Joint Mounting Bolts

1 - BALL JOINT
2 - MOUNTING BOLTS

(4) P u ll t h e a r m down on t h e ba ll join t st u d a n d

in st a ll a n e w n u t . Tigh t en t h e n u t t o 142 N·m (105
ft . lbs.).
(5) Rem ove t h e su ppor t s a n d lower t h e veh icle.

U PPER CON T ROL ARM

DESCRIPTION
Th e su spen sion a r m u ses ver t ica l spool bu sh in gs t o
isola t e r oa d n oise. Th e su spen sion a r m is bolt ed
t h r ou gh bu sh in gs t o ca ge n u t s in t h e body a n d a ba ll
join t pla t e t o t h e t op of t h e differ en t ia l h ou sin g.

OPERATION
Th e u pper su spen sion a r m pr ovides for e/a ft a n d
la t er a l loca t ion of t h e r ea r a xle. Th e su spen sion a r m
t r a vel is lim it ed t h r ou gh t h e u se of jou n ce bu m per s
Fig. 9 Separate Ball Joint in com pr ession a n d sh ock a bsor ber s in r ebou n d.
1 - REMOVER
2 - UPPER SUSPENSION ARM REMOVAL
3 - BALL JOINT STUD
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Su ppor t t h e r ea r a xle wit h a h ydr a u lic ja ck.
INSTALLATION (3) Rem ove t h e pa r k br a ke ca bles a n d br a ke h ose
(1) In st a ll t h e ba ll join t on t h e differ en t ia l h ou s- fr om t h e a r m (F ig. 11).
in g. (4) Rem ove t h e ba ll join t n u t fr om t h e t op of t h e
(2) In st a ll t h e ba ll join t m ou n t in g bolt s a n d u pper su spen sion a r m (F ig. 12).
t igh t en t o 136 N·m (100 ft . lbs.). (5) Sepa r a t e ba ll join t fr om t h e a r m wit h Rem over
(3) Ra ise t h e r ea r a xle wit h a h ydr a u lic ja ck t o 8278 (F ig. 13).
a lign t h e u pper a r m wit h t h e ba ll join t .
WJ REAR 2 - 23
U PPER CON T ROL ARM (Cont inue d)

Fig. 11 Park Brake Cables And Brake Hose

1 - UPPER SUSPENSION ARM
2 - REAR BRAKE HOSE
3 - PARK BRAKE CABLES

Fig. 13 Separate Ball Joint

1 - REMOVER
2 - UPPER SUSPENSION ARM
3 - BALL JOINT STUD

Fig. 12 Ball Joint Nut

1 - BALL JOINT NUT
2 - UPPER SUSPENSION ARM

NOTE: It may be necessary to strike the upper con-

trol arm with a hammer to separate the ball joint Fig. 14 Upper Suspension Arm Mounting Bolt
from the arm. 1 - UPPER SUSPENSION ARM
2 - MOUNTING BOLT
(6) Rem ove t h e u pper su spen sion a r m m ou n t in g
bolt s a n d r em ove t h e a r m (F ig. 14).
(4) In st a ll t h e pa r k br a ke ca bles a n d br a ke h ose t o
INSTALLATION the arm.
(1) P osit ion t h e u pper su spen sion a r m in t h e (5) Rem ove t h e su ppor t s a n d lower t h e veh icle.
fr a m e r a il br a cket s.
(2) In st a ll t h e m ou n t in g bolt s a n d t igh t en t o 100
N·m (74 ft . lbs.).
(3) P u ll t h e a r m down on t h e ba ll join t st u d a n d
in st a ll a n e w n u t . Tigh t en t h e n u t t o 142 N·m (105
ft . lbs.).
WJ DIFFERENTIAL & DRIVELINE 3-1

DIFFERENTIAL & DRIVELINE

TABLE OF CON T EN T S

page page

PROPELLER SHAFT ......................1 REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 50

FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 14 REAR AXLE - 226RBA . . . . . . . . . . . . . . . . . . . . 90
FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 15

PROPELLER SH AFT

TABLE OF CONTENTS
page page

PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSIS AND TESTING ... . . . . . . . . . . . . .1 PROPELLER SHAFT - REAR
STANDARD PROCEDURES . . . . . . . . . . . . . . . .3 REMOVAL .............................7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS ........... . . . . . . . . . . . . .5 SINGLE CARDAN UNIVERSAL JOINTS
PROPELLER SHAFT - FRONT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL ................ .............6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . .............6 DOUBLE CARDAN UNIVERSAL JOINTS
PROPELLER SHAFT - FRONT 4.7L DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL ................ .............6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PROPELLER SH AFT Dr ivelin e vibr a t ion ca n a lso r esu lt fr om loose or

da m a ged en gin e m ou n t s.
P r opeller sh a ft vibr a t ion in cr ea ses a s t h e veh icle
DIAGNOSIS AND TESTING
speed is in cr ea sed. A vibr a t ion t h a t occu r s wit h in a
specific speed r a n ge is n ot u su a lly ca u sed by a pr o-
VIBRATION
peller sh a ft bein g u n ba la n ced. Defect ive u n iver sa l
Tir es t h a t a r e ou t -of-r ou n d, or wh eels t h a t a r e
join t s, or a n in cor r ect pr opeller sh a ft a n gle, a r e u su -
u n ba la n ced, will ca u se a low fr equ en cy vibr a t ion .
a lly t h e ca u se of su ch a vibr a t ion .
(Refer t o 22 - TIRE S/WH E E LS - DIAGNOSIS AND
TE STING)
Br a ke r ot or s t h a t a r e u n ba la n ced will ca u se a
h a r sh , low fr equ en cy vibr a t ion . (Refer t o 5 - BRAKE S
- DIAGNOSIS AND TE STING)
3-2 PROPELLER SHAFT WJ
PROPELLER SH AFT (Cont inue d)
DRI V ELI N E V I BRAT I ON

Drive Condition Possible Cause Correction

Propeller Shaft Noise
1) Undercoating or other foreign material
on shaft.
2) Loose U-joint clamp screws.
3) Loose or bent U-joint yoke or
excessive runout.
4) Incorrect driveline angularity.
5) Rear spring center bolt not in seat.
6) Worn U-joint bearings.
7) Propeller shaft damaged or out of
balance.
8) Broken rear spring.
9) Excessive runout or unbalanced
condition.
10) Excessive drive pinion gear shaft
runout.
11) Excessive axle yoke deflection.
12) Excessive transfer case runout.
1) Clean exterior of shaft and wash with
solvent.
2) Install new clamps and screws and
tighten to proper torque.
3) Install new yoke.
4) Measure and correct driveline angles.
5) Loosen spring u-bolts and seat center
bolt.
6) Install new U-joint.
7) Installl new propeller shaft.
8) Install new rear spring.
9) Re-index propeller shaft, test, and
evaluate.
10) Re-index propeller shaft and evaluate.
11) Inspect and replace yoke if necessary.
12) Inspect and repair as necessary.

Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace U-joints as necessary.

BALANCE (9) In st a ll a scr ew cla m p a t posit ion 1 (F ig. 1).

NOTE: Removing and re-indexing the propeller

shaft 180° relative to the yoke may eliminate some
vibrations.

If pr opeller sh a ft is su spect ed of bein g u n ba la n ced,

it ca n be ver ified wit h t h e followin g pr ocedu r e:
(1) Ra ise t h e veh icle.
(2) Clea n a ll t h e for eign m a t er ia l fr om t h e pr opel-
ler sh a ft a n d t h e u n iver sa l join t s.
(3) In spect t h e pr opeller sh a ft for m issin g ba la n ce
weigh t s, br oken welds, a n d ben t a r ea s. If th e p ro -
p e lle r s h a ft is be n t, it m u s t be re p la c e d .
(4) In spect t h e u n iver sa l join t s t o en su r e t h a t t h ey
a r e n ot wor n , a r e pr oper ly in st a lled, a n d a r e cor-
r ect ly a lign ed wit h t h e sh a ft .
(5) Ch eck t h e u n iver sa l join t cla m p scr ews t or qu e.
(6) Rem ove t h e wh eels a n d t ir es. In st a ll t h e wh eel Fig. 1 CLAMP SCREW - POSITION 1
lu g n u t s t o r et a in t h e br a ke dr u m s or r ot or s. 1 - CLAMP
(7) Ma r k a n d n u m ber t h e sh a ft six in ch es fr om t h e 2 - SCREWDRIVER
yoke en d a t fou r posit ion s 90° a pa r t .
(8) Ru n a n d a cceler a t e t h e veh icle u n t il vibr a t ion
occu r s. Not e t h e in t en sit y a n d speed t h e vibr a t ion
occu r r ed. St op t h e en gin e.
WJ
PROPELLER SH AFT (Cont inue d)
(10) St a r t t h e en gin e a n d r e-ch eck for vibr a t ion . If
t h er e is lit t le or n o ch a n ge in vibr a t ion , m ove t h e
cla m p t o on e of t h e ot h er t h r ee posit ion s. Repea t t h e
vibr a t ion t est .
(11) If t h er e is n o differ en ce in vibr a t ion a t t h e
ot h er posit ion s, t h e sou r ce of t h e vibr a t ion m a y n ot
be pr opeller sh a ft .
(12) If t h e vibr a t ion decr ea sed, in st a ll a secon d
cla m p (F ig. 2) a n d r epea t t h e t est .
Fig. 2 TWO CLAMP SCREWS
(13) If t h e a ddit ion a l cla m p ca u ses a n a ddit ion a l
vibr a t ion , sepa r a t e t h e cla m ps (1/4 in ch a bove a n d
below t h e m a r k). Repea t t h e vibr a t ion t est (F ig. 3).
Fig. 3 CLAMP SCREWS SEPARATED
1 - ½ INCH
(14) In cr ea se dist a n ce bet ween t h e cla m p scr ews
a n d r epea t t h e t est u n t il t h e a m ou n t of vibr a t ion is
a t t h e lowest level. Ben d t h e sla ck en d of t h e cla m ps
so t h e scr ews will n ot loosen .
(15) If t h e vibr a t ion r em a in s u n a ccept a ble, a pply
t h e sa m e st eps t o t h e fr on t en d of t h e pr opeller sh a ft .
(16) In st a ll t h e wh eel a n d t ir es. Lower t h e veh icle.
PROPELLER SHAFT 3-3
RUNOUT
(1) Rem ove dir t , r u st , pa in t , a n d u n der coa t in g
fr om t h e pr opeller sh a ft su r fa ce wh er e t h e dia l in di-
ca t or will con t a ct t h e sh a ft .
(2) Th e dia l in dica t or m u st be in st a lled per pen dic-
u la r t o t h e sh a ft su r fa ce.
(3) Mea su r e r u n ou t a t t h e cen t er a n d en ds of t h e
sh a ft su fficien t ly fa r a wa y fr om weld a r ea s t o en su r e
t h a t t h e effect s of t h e weld pr ocess will n ot en t er in t o
t h e m ea su r em en t s.
(4) Refer t o Ru n ou t Specifica t ion s ch a r t .
(5) If t h e pr opeller sh a ft r u n ou t is ou t of specifica -
t ion , r em ove t h e pr opeller sh a ft , in dex t h e sh a ft 180°,
a n d r e-in st a ll t h e pr opeller sh a ft . Mea su r e sh a ft
r u n ou t a ga in .
(6) If t h e pr opeller sh a ft r u n ou t is n ow wit h in
specifica t ion s, m a r k t h e sh a ft a n d yokes for pr oper
or ien t a t ion .
(7) If t h e pr opeller sh a ft r u n ou t is n ot wit h in spec-
ifica t ion s, ver ify t h a t t h e r u n ou t of t h e t r a n sm ission /
t r a n sfer ca se a n d a xle a r e wit h in specifica t ion s.
Cor r ect a s n ecessa r y a n d r e-m ea su r e pr opeller sh a ft
r u n ou t .
(8) Repla ce t h e pr opeller sh a ft if t h e r u n ou t st ill
exceeds t h e lim it s.
RU N OU T SPECI FI CAT I ON S
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES
Th is pr ocedu r e a pplies t o bot h t h e fr on t pr opeller
sh a ft s a n d t h e r ea r pr opeller sh a ft . To obt a in t h e
fr on t (ou t pu t ) a n gle on t h e C/V fr on t pr opeller sh a ft ,
t h e in clin om et er is pla ced on t h e m a ch in ed r in g of
t h e pin ion fla n ge. To obt a in t h e pr opeller sh a ft a n gle
m ea su r em en t on t h e C/V fr on t pr opeller sh a ft , t h e
in clin om et er is pla ced on t h e pr opeller sh a ft t u be.
PROPELLER SHAFT ANGLE
(1) Ra ise a n d su ppor t t h e veh icle a t t h e a xles a s
level a s possible. Allow t h e wh eels a n d pr opeller
sh a ft t o t u r n .
(2) Rem ove a n y ext er n a l bea r in g sn a p r in gs fr om
u n iver sa l join t if equ ipped, so t h e in clin om et er ba se
will sit s fla t .
3-4 PROPELLER SHAFT WJ
PROPELLER SH AFT (Cont inue d)
(3) Rot a t e t h e sh a ft u n t il t r a n sm ission /t r a n sfer
ca se ou t pu t yoke bea r in g ca p is fa cin g down wa r d, if
n ecessa r y.

NOTE: Always make measurements from front to rear.

(4) P la ce In clin om et er on yoke bea r in g ca p, or t h e

pin ion fla n ge r in g, (A) pa r a llel t o t h e sh a ft (F ig. 4). Cen -
t er bu bble in sigh t gla ss a n d r ecor d m ea su r em en t .

NOTE: This measurement will give you the trans-

mission or Output Yoke Angle (A).

Fig. 5 PROPELLER SHAFT ANGLE (C)

1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER

Fig. 4 OUTPUT YOKE ANGLE (A)

1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER

(5) Rot a t e pr opeller sh a ft 90 degr ees a n d pla ce

In clin om et er on yoke bea r in g ca p, or pr opeller sh a ft
t u be on C/V pr opeller sh a ft , pa r a llel t o t h e sh a ft (F ig.
5). Cen t er bu bble in sigh t gla ss a n d r ecor d m ea su r e-
m en t . Th is m ea su r em en t ca n a lso be t a ken a t t h e
r ea r en d of t h e sh a ft .

NOTE: This measurement will give you the propeller Fig. 6 INPUT YOKE ANGLE (B)
shaft angle (C). 1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
(6) Su bt r a ct sm a ller figu r e fr om la r ger (C m in u s
A) t o obt a in t r a n sm ission ou t pu t oper a t in g a n gle.
(7) Rot a t e pr opeller sh a ft 90 degr ees a n d pla ce Refer t o r u les given below a n d t h e exa m ple in (F ig.
In clin om et er on pin ion yoke bea r in g ca p pa r a llel t o 7) for a ddit ion a l in for m a t ion .
t h e sh a ft (F ig. 6). Cen t er bu bble in sigh t gla ss a n d • Good ca n cella t ion of U-join t oper a t in g a n gles
r ecor d m ea su r em en t . (wit h in 1°).
• Oper a t in g a n gles less t h a n 3°.
NOTE: This measurement will give you the pinion • Oper a t in g a n gles less t h a n 10° for dou ble ca r da n
shaft or input yoke angle (B). U-join t .
• At lea st 1/2 of on e degr ee con t in u ou s oper a t in g
(8) Su bt r a ct sm a ller figu r e fr om la r ger (C m in u s (pr opeller sh a ft ) a n gle.
B) t o obt a in a xle In pu t Oper a t in g An gle.
WJ PROPELLER SHAFT 3-5
PROPELLER SH AFT (Cont inue d)

Fig. 7 U-JOINT ANGLE EXAMPLE

1 - 4.9° Angle (C) 4 - 3.0° Angle (A)
2 - 3.2° Angle (B) 5 - Output Yoke
3 - Input Yoke

SPECIFICATIONS
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shaft - Companion Flange Bolts 32 24 -
4.7L Front Shaft - Axle Yoke Nuts 19 14 -
4.7L Front Shaft - Transfer Case Bolts 27 20 -
Rear Shaft - Yoke Nuts 19 14 -

SPECIAL TOOLS

Inclinometer 7663
3-6 PROPELLER SHAFT
PROPELLER SH AFT - FRON T
REMOVAL
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
(1) P la ce veh icle on floor or dr ive-on h oist wit h fu ll
weigh t of veh icle on su spen sion .
(2) Sh ift t h e t r a n sm ission a n d t r a n sfer ca se, if n ec-
essa r y, in t o t h e Neu t r a l posit ion .
(3) Mea su r e t h e dist a n ce fr om t h e fa ce of t h e C/V
join t cu p t o t h e en d of t h e C/V join t boot (F ig. 8).
Fig. 8 MEASUREMENT
1 - C/V JOINT CUP
2 - C/V BOOT END
3 - MEASUREMENT
(4) Th e cor r ect len gt h is 142.7 m m (5.61 in .).
NOTE: If the measurement is not correct, the wrong
shaft may have been installed or a mating compo-
nent (front axle or transfer case) may be installed
incorrectly. Investigate and correct as necessary.
(5) Ma r k a lin e a cr oss t h e com pa n ion fla n ge a t t h e
t r a n sfer ca se a n d C/V join t a t t h e r ea r of t h e fr on t
pr opeller sh a ft for in st a lla t ion r efer en ce.
(6) Ma r k a lin e a cr oss t h e C/V join t s a n d t h e pin -
ion com pa n ion fla n ges for in st a lla t ion r efer en ce.
(7) Rem ove bolt s fr om t h e fr on t C/V join t t o t h e
pin ion com pa n ion fla n ge.
(8) Rem ove bolt s fr om t h e r ea r C/V join t t o t h e
t r a n sfer ca se com pa n ion fla n ge.
(9) P u sh t h e pr opeller sh a ft for wa r d t o clea r t r a n s-
fer ca se com pa n ion fla n ge a n d r em ove t h e sh a ft .
WJ
INSTALLATION
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
(1) In st a ll t h e sh a ft bet ween com pa n ion fla n ges.
(2) Th e sh a ft sh ou ld r ot a t e fr eely in t h e pin ion
fla n ge.
(3) Align m a r ks on t h e com pa n ion fla n ges wit h t h e
m a r ks on t h e C/V join t s.
(4) In st a ll bolt s t o t h e fr on t C/V join t a n d t igh t en
bolt s t o 32 N·m (24 ft . lbs.).
(5) In st a ll t h e bolt s t o t h e r ea r C/V join t a n d
t igh t en bolt s t o 32 N·m (24 ft . lbs.).
(6) Ver ify pr opeller sh a ft len gt h .
(7) Lower veh icle.
PROPELLER SH AFT - FRON T
4 .7 L
REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove cr ossm em ber /skid pla t e a s n ecessa r y t o
ga in a ccess t o t h e pr opeller sh a ft .
(3) Sh ift t r a n sm ission a n d t r a n sfer ca se, if n eces-
sa r y in t o Neu t r a l.
(4) Ma r k a lin e a cr oss t h e yoke a t t h e t r a n sfer
ca se, lin k yoke a n d pr opeller sh a ft yoke a t t h e r ea r of
t h e fr on t pr opeller sh a ft for in st a lla t ion r efer en ce
(F ig. 9).
(5) Ma r k a lin e a cr oss t h e pr opeller sh a ft yoke a n d
pin ion sh a ft yoke for in st a lla t ion r efer en ce.
Fig. 9 REFERENCE MARKS ON YOKES
1 - REFERENCE MARKS
WJ PROPELLER SHAFT 3-7
PROPELLER SH AFT - FRON T 4 .7 L (Cont inue d)
(6) Rem ove t h e U-join t st r a p bolt s a t t h e pin ion PROPELLER SH AFT - REAR
sh a ft yoke (F ig. 10).
(7) Rem ove bolt s h oldin g r ea r u n iver sa l join t t o
REMOVAL
t h e t r a n sfer ca se yoke.
(1) Ra ise a n d su ppor t veh icle on sa fet y st a n ds.
(8) Sepa r a t e t h e r ea r u n iver sa l join t fr om t h e
(2) Sh ift t h e t r a n sm ission a n d t r a n sfer ca se if n ec-
t r a n sfer ca se yoke.
essa r y, t o t h eir n eu t r a l posit ion s.
(9) P u sh r ea r of pr opeller sh a ft u pwa r d t o clea r
(3) Ma r k a lin e a cr oss t h e a xle pin ion yoke a n d t h e
t r a n sfer ca se yoke.
pr opeller sh a ft yoke for in st a lla t ion r efer en ce.
(10) Sepa r a t e fr on t u n iver sa l join t fr om fr on t a xle.
(4) Rem ove t h e bolt s h oldin g t h e u n iver sa l join t
(11) Sepa r a t e pr opeller sh a ft fr om veh icle.
cla m ps t o t h e pin ion yoke.
(5) Slide t h e slip yoke off of t h e t r a n sm ission , or
t r a n sfer ca se, ou t pu t sh a ft a n d r em ove t h e pr opeller
sh a ft (F ig. 11).

Fig. 10 FRONT PROPELLER SHAFT - 4.7L

1 - FRONT AXLE
2 - BOOT
3 - PROPELLER SHAFT
4 - DOUBLE CARDAN U-JOINT
5 - TRANSFER CASE
6 - BOOT
7 - SLINGER
8 - CLAMP
9 - YOKE

Fig. 11 REAR PROPELLER SHAFT

INSTALLATION
1 - SLIDING YOKE
(1) P osit ion fr on t pr opeller sh a ft u n der veh icle
2 - PROPELLER SHAFT
wit h r ea r u n iver sa l join t over t h e t r a n sfer ca se yoke.
3 - PINION YOKE
(2) P la ce fr on t u n iver sa l join t in t o t h e a xle pin ion 4 - CLAMP/STRAP
yoke. 5 - BOLT
(3) Align m a r k on t h e r ea r lin k yoke a n d u n iver sa l 6 - OUTPUT SHAFT
join t t o t h e m a r k on t h e t r a n sfer ca se yoke.
(4) Loosely in st a ll bolt s t o h old u n iver sa l join t t o
t r a n sfer ca se yoke. INSTALLATION
(5) Align m a r k on fr on t u n iver sa l join t t o t h e m a r k (1) Slide t h e slip yoke on t h e t r a n sm ission , or
on t h e a xle pin ion yoke. t r a n sfer ca se, ou t pu t sh a ft .
(6) Tigh t en t h e U-join t st r a p/cla m p bolt s a t t h e (2) Align t h e in st a lla t ion r efer en ce m a r ks m a de on
a xle yoke t o 19 N·m (14 ft . lbs.). t h e pr opeller sh a ft a n d pin ion yoke.
(7) Tigh t en t h e u n iver sa l join t t o t r a n sfer ca se (3) P osit ion u n iver sa l join t in t o pin ion yoke.
bolt s t o 27 N·m (20 ft . lbs.). (4) In st a ll t h e u n iver sa l join t cla m p a n d cla m p
(8) Lower t h e veh icle. bolt s t o t h e pin ion yoke. Tigh t en bolt s t o 19 N·m (14
ft . lbs.).
(5) Lower t h e veh icle.
3-8 PROPELLER SHAFT WJ

SI N GLE CARDAN U N I V ERSAL

J OI N T S
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable. If worn or leaking, they
must be replaced as an assembly.

(1) Rem ove t h e pr opeller sh a ft .

(2) Ta p t h e ou t side of t h e bea r in g ca p a ssem bly
wit h a dr ift t o loosen sn a p r in g.
(3) Rem ove sn a p r in gs fr om bot h sides of yoke
(F ig. 12).

Fig. 13 PRESS OUT BEARING

1 - PRESS
2 - SOCKET

score the walls of the yoke bore and damage can

occur.

Fig. 12 REMOVE SNAP RING

1 - SNAP RING

(4) Set t h e yoke in a n a r bor pr ess or vise wit h a

socket wh ose in side dia m et er is la r ge en ou gh t o
r eceive t h e bea r in g ca p posit ion ed ben ea t h t h e yoke.
(5) P osit ion t h e yoke wit h t h e gr ea se fit t in g, if
equ ipped, poin t in g u p.
(6) P la ce a socket wit h a n ou t side dia m et er
sm a ller t h a n t h e u pper bea r in g ca p on t h e u pper
bea r in g ca p a n d pr ess t h e ca p t h r ou gh t h e yoke t o
r elea se t h e lower bea r in g ca p (F ig. 13).
(7) If t h e bea r in g ca p will n ot pu ll ou t of t h e yoke
by h a n d a ft er pr essin g, t a p t h e yoke ea r n ea r t h e
bea r in g ca p t o dislodge t h e ca p.
(8) To r em ove t h e opposit e bea r in g ca p, t u r n t h e
yoke over a n d st r a igh t en t h e cr oss in t h e open h ole.
Th en , ca r efu lly pr ess t h e en d of t h e cr oss u n t il t h e Fig. 14 PRESS OUT REMAINING BEARING
r em a in in g bea r in g ca p ca n be r em oved (F ig. 14). 1 - CROSS
2 - BEARING CAP
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
WJ PROPELLER SHAFT 3-9
SI N GLE CARDAN U N I V ERSAL J OI N T S (Cont inue d)

ASSEMBLY
(1) Apply ext r em e pr essu r e (E P ) N.L.G.I. Gr a de 1
or 2 gr ea se t o in side of yoke bor es.
(2) P osit ion t h e cr oss in t h e yoke wit h it s lu be fit -
t in g, if equ ipped, poin t in g u p (F ig. 15).

Fig. 16 INSTALL BEARING ON TRUNNION

1 - BEARING CAP
2 - TRUNNION

(1) Rem ove t h e pr opeller sh a ft .

(2) Ma r k t h e pr opeller sh a ft yoke a n d lin k yoke for
Fig. 15 CROSS IN YOKE a ssem bly r efer en ce.
1 - CROSS (3) Ta p t h e ou t side of t h e bea r in g ca p a ssem bly
2 - YOKE wit h dr ift t o loosen sn a p r in gs.
(4) Rem ove a ll t h e bea r in g ca p sn a p r in gs (F ig.
(3) P la ce a bea r in g ca p over t h e t r u n n ion a n d 17).
a lign t h e ca p wit h t h e yoke bor e (F ig. 16). Keep t h e
n eedle bea r in gs u pr igh t in t h e bea r in g ca p.
(4) P r ess t h e bea r in g ca p in t o t h e yoke bor e
en ou gh t o clea r sn a p r in g gr oove.
(5) In st a ll a sn a p r in g.
(6) Repea t St ep 3 a n d St ep 4 t o in st a ll t h e oppo-
sit e bea r in g ca p.

NOTE: If the joint is stiff or binding, strike the yoke

with a soft hammer to seat the needle bearings.

(7) Add gr ea se t o lu be fit t in g, if equ ipped.

(8) In st a ll t h e pr opeller sh a ft .

DOU BLE CARDAN U N I V ERSAL

J OI N T S
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable they must be replaced as Fig. 17 SNAP RINGS
an assembly.
3 - 10 PROPELLER SHAFT WJ
DOU BLE CARDAN U N I V ERSAL J OI N T S (Cont inue d)
(5) Rem ove a n y gr ea se fit t in gs if equ ipped. (10) F lip a ssem bly a n d r epea t St ep 6, St ep 7, St ep
(6) P osit ion a socket on t h e pr ess wit h a n in side 8 a n d St ep 9 t o r em ove t h e opposit e bea r in g ca p.
dia m et er la r ge en ou gh t o r eceive t h e bea r in g ca p (11) Rem ove t h e cr oss cen t er in g kit a ssem bly a n d
u n der t h e lin k yoke. spr in g (F ig. 20).
(7) P la ce a n ot h er socket wit h a n ou t side dia m et er
sm a ller t h a n t h e bea r in g ca p on t h e u pper bea r in g ca p.
(8) P r ess on e bea r in g ca p fr om t h e ou t boa r d side of
t h e lin k yoke en ou gh t o gr a sp t h e ca p wit h vise ja ws
(F ig. 18).

Fig. 20 REMOVE CENTERING KIT

(12) P r ess t h e r em a in in g bea r in g ca ps ou t t h e
ot h er en d of t h e lin k yoke a s descr ibed a bove t o com -
plet e t h e disa ssem bly.

ASSEMBLY
Fig. 18 PRESS OUT BEARING
(9) Gr a sp pr ot r u din g bea r in g ca p wit h vise ja ws CAUTION: All alignment marks on the link yoke and
a n d t a p lin k yoke wit h a m a llet a n d dr ift t o r em ove propeller shaft yoke must be aligned during assem-
bea r in g ca p (F ig. 19). bled.

(1) Apply ext r em e pr essu r e (E P ) N.L.G.I. Gr a de 1

or 2 gr ea se t o in side of yoke bor es.
(2) F it a cr oss in t o t h e pr opeller sh a ft yoke (F ig. 21).

Fig. 19 REMOVE BEARING FROM YOKE Fig. 21 INSTALL CROSS IN YOKE

WJ PROPELLER SHAFT 3 - 11
DOU BLE CARDAN U N I V ERSAL J OI N T S (Cont inue d)
(3) P la ce a bea r in g ca p over t h e t r u n n ion a n d (6) F lip pr opeller sh a ft yoke a n d in st a ll ot h er bea r-
a lign t h e ca p wit h t h e yoke bor e (F ig. 22). Keep n ee- in g ca p on t o t h e opposit e t r u n n ion a n d in st a ll a sn a p
dle bea r in gs u pr igh t in t h e bea r in g ca p. r in g (F ig. 24).

Fig. 22 INSTALL BEARING CAP

(4) P r ess bea r in g ca p in t o t h e yoke bor e en ou gh t o Fig. 24 PRESS BEARING CAP
clea r sn a p r in g gr oove (F ig. 23). (7) F it t h e lin k yoke on t o t h e r em a in in g t r u n n ion s
(5) In st a ll a sn a p r in g. a n d pr ess bot h bea r in g ca ps in t o pla ce a n d in st a ll
sn a p r in gs (F ig. 25).

Fig. 25 INSTALL LINK YOKE

Fig. 23 PRESS BEARING CAP
3 - 12 PROPELLER SHAFT WJ
DOU BLE CARDAN U N I V ERSAL J OI N T S (Cont inue d)
(8) In st a ll cen t er in g kit a ssem bly in side t h e lin k (10) P r ess t h e r em a in in g t wo bea r in g ca ps in t o
yoke (F ig. 26). pla ce a n d in st a ll sn a p r in gs (F ig. 28).

NOTE: Making sure the spring is properly posi-

tioned.

Fig. 28 PRESS BEARING CAP

(11) Ta p t h e sn a p r in gs t o sea t t h em in t o t h e
Fig. 26 CENTERING KIT gr ooves (F ig. 29).
(9) P la ce t wo bea r in g ca ps on opposit e t r u n n ion s of
t h e r em a in in g cr oss. F it t h e open t r u n n ion s in t o t h e
lin k yoke bor es a n d t h e bea r in g ca ps in t o t h e cen t er-
in g kit (F ig. 27).

Fig. 29 SEAT SNAP RINGS

Fig. 27 REMAINING CROSS
WJ PROPELLER SHAFT 3 - 13
DOU BLE CARDAN U N I V ERSAL J OI N T S (Cont inue d)
(12) Ver ify for pr oper a ssem bly. F lexin g t h e join t
beyon d cen t er, t h e join t sh ou ld sn a p over-cen t er in
bot h dir ect ion s if cor r ect ly a ssem bled (F ig. 30).
(13) In st a ll t h e pr opeller sh a ft .

Fig. 30 VERIFY ASSEMBLY

3 - 14 FRONT TUBE AXLE WJ

FRON T T U BE AX LE

TABLE OF CONTENTS
page page

FRONT TUBE AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

FRON T T U BE AX LE mal ride position, ride height and handling could be

affected.
(1) In st a ll spr in gs a n d r et a in er clips a n d t igh t en
REMOVAL
r et a in er bolt s t o 21 N·m (16 ft . lbs.).
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Lift a n d posit ion a xle u n der t h e veh icle a n d
(2) P osit ion a lift in g device u n der t h e a xle a n d
a lign it wit h t h e spr in g pa ds.
secu r e a xle t o lift .
(3) P osit ion u pper a n d lower su spen sion a r m s in
(3) Rem ove t h e wh eels a n d t ir es.
t h e a xle br a cket s a n d loosely in st a ll bolt s a n d n u t s.
(4) Rem ove t h e br a ke r ot or s (Refer t o 5 - BRAKE S/
(4) In st a ll t r a ck ba r t o t h e a xle br a cket a n d loosely
H YDRAULIC/ME CH ANICAL/ROTORS - RE MOVAL)
in st a ll bolt .
a n d ca liper s.
(5) In st a ll sh ock a bsor ber s a n d t igh t en bolt s t o 23
(5) Discon n ect wh eel sen sor wir in g h a r n ess fr om
N·m (17 ft . lbs.).
t h e veh icle wir in g h a r n ess.
(6) In st a ll st a bilizer ba r lin ks t o t h e a xle br a cket s
(6) Rem ove st a bilizer ba r lin ks a t t h e a xle.
a n d t igh t en n u t s t o 95 N·m (70 ft . lbs.).
(7) Rem ove sh ock a bsor ber s fr om a xle br a cket s.
(7) In st a ll dr a g lin k a n d t ie r od t o t h e st eer in g
(8) Rem ovet t r a ck ba r.
kn u ckles.
(9) Rem ove t ie r od a n d dr a g lin k fr om t h e st eer in g
(8) In st a ll st eer in g da m per t o t h e a xle br a cket a n d
kn u ckle.
t igh t en n u t t o 75 N·m (55 ft . lbs.).
(10) Rem ove st eer in g da m per fr om t h e a xle
(9) In st a ll t h e br a ke r ot or s a n d ca liper s.
br a cket .
(10) Con n ect wh eel speed sen sor wir in g h a r n ess, if
(11) Rem ove u pper a n d lower su spen sion a r m s
equ ipped.
fr om t h e a xle br a cket s.
(11) In st a ll t h e wh eel a n d t ir e a ssem blies.
(12) Lower t h e lift en ou gh t o r em ove t h e a xle. Th e
(12) Rem ove lift fr om t h e a xle a n d lower t h e veh i-
coil spr in gs will dr op wit h t h e a xle.
cle.
(13) Rem ove t h e coil spr in gs fr om t h e a xle.
(13) Tigh t en u pper su spen sion a r m n u t s t o 75 N·m
(55 ft . lbs.). Tigh t en lower su spen sion a r m n u t s t o
INSTALLATION 115 N·m (85 ft . lbs.).
CAUTION: The weight of the vehicle must be sup- (14) Tigh t en t r a ck ba r bolt a t t h e a xle br a cket t o
100 N·m (74 ft . lbs.).
ported by the springs before suspension arms and
(15) Ch eck t h e fr on t wh eel a lign m en t .
track bar fasteners are tightened. If not at their nor-
WJ FRONT AXLE - 186FBI 3 - 15

FRON T AX LE - 1 8 6 FBI

TABLE OF CONTENTS
page page

FRONT AXLE - 186FBI INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37

DESCRIPTION . . . . . . . . ... . . . . . . . . . . . . . . 15 PINION SEAL
OPERATION . . . . . . . . . . ... . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING .. . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . ... . . . . . . . . . . . . . . 20 COLLAPSIBLE SPACER
INSTALLATION . . . . . . . . ... . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ADJUSTMENTS . . . . . . . ... . . . . . . . . . . . . . . 21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS . . . . . . ... . . . . . . . . . . . . . . 30 DIFFERENTIAL
SPECIAL TOOLS ...... ... . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
AXLE SHAFTS DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
AXLE SHAFT SEALS DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
AXLE - C/V JOINT PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
AXLE - U-JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FRON T AX LE - 1 8 6 FBI t h e differ en t ia l t h r ou gh t h e gea r m esh wit h t h e r in g

gea r bolt ed t o t h e differ en t ia l ca se. Th e en gin e power
is t r a n sm it t ed t o t h e a xle sh a ft s t h r ou gh t h e pin ion
DESCRIPTION
m a t e a n d side gea r s. Th e side gea r s a r e splin ed t o
Th e F r on t Bea m -design Ir on (F BI) a xle con sist s of
t h e a xle sh a ft s.
a ca st ir on differ en t ia l h ou sin g wit h a xle sh a ft t u bes
ext en din g fr om eit h er side. Th e t u bes a r e pr essed
STANDARD DIFFERENTIAL
in t o t h e differ en t ia l h ou sin g a n d welded. Th e a xles
Du r in g st r a igh t -a h ea d dr ivin g, t h e differ en t ia l pin ion
a r e sem i-floa t in g a xle sh a ft s, m ea n in g t h e loa ds a r e
gea r s do n ot r ot a t e on t h e pin ion m a t e sh a ft . Th is
su ppor t ed by t h e h u b bea r in gs. Th e a xle sh a ft s a r e
occu r s beca u se in pu t t or qu e a pplied t o t h e gea r s is
r et a in ed by n u t s a t t h e h u b bea r in gs.
divided a n d dist r ibu t ed equ a lly bet ween t h e t wo side
Th e differ en t ia l ca se is a on e-piece design . Differ-
gea r s. As a r esu lt , t h e pin ion gea r s r evolve wit h t h e pin -
en t ia l bea r in g pr eloa d a n d r in g gea r ba ckla sh is
ion m a t e sh a ft bu t do n ot r ot a t e a r ou n d it (F ig. 1).
a dju st ed by t h e u se of sh im s loca t ed bet ween t h e dif-
Wh en t u r n in g cor n er s, t h e ou t side wh eel m u st
fer en t ia l bea r in g cu ps a n d h ou sin g. P in ion bea r in g
t r a vel a gr ea t er dist a n ce t h a n t h e in side wh eel t o
pr eloa d is set a n d m a in t a in ed by t h e u se of a colla ps-
com plet e a t u r n . Th e differ en ce m u st be com pen sa t ed
ible spa cer. A differ en t ia l cover pr ovides a m ea n s for
for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin g
in spect ion a n d ser vicin g.
t h r ou gh t u r n s. To a ccom plish t h is, t h e differ en t ia l
An opt ion a l Va r i-Lok! differ en t ia l h a s a on e-piece
a llows t h e a xle sh a ft s t o t u r n a t u n equ a l speeds (F ig.
differ en t ia l ca se wh ich con t a in s t h e ger ot or pu m p
2). In t h is in st a n ce, t h e in pu t t or qu e a pplied t o t h e
a ssem bly a n d t h e clu t ch m ech in ism . Th is u n it is ser-
pin ion gea r s is n ot divided equ a lly. Th e pin ion gea r s
viced a s a n a ssem bly.
n ow r ot a t e a r ou n d t h e pin ion m a t e sh a ft in opposit e
dir ect ion s. Th is a llows t h e side gea r a n d a xle sh a ft
OPERATION a t t a ch ed t o t h e ou t side wh eel t o r ot a t e a t a fa st er
Th e a xle r eceives power fr om t h e t r a n sfer ca se
speed.
t h r ou gh t h e fr on t pr opeller sh a ft . Th e fr on t pr opeller
sh a ft is con n ect ed t o t h e pin ion gea r wh ich r ot a t es
3 - 16 FRONT AXLE - 186FBI
FRON T AX LE - 1 8 6 FBI (Cont inue d)
Fig. 1 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
VARI-LOK" DIFFERENTIAL
In a st a n da r d differ en t ia l if on e wh eel spin s, t h e
opposit e wh eel will gen er a t e on ly a s m u ch t or qu e a s
t h e spin n in g wh eel.
A ger ot or pu m p a n d clu t ch pa ck a r e u sed t o pr o-
vide t h e t or qu e t r a n sfer ca pa bilit y. On e a xle sh a ft is
splin ed t o t h e ger ot or pu m p a n d on e of t h e differ en -
t ia l side gea r s, wh ich pr ovides t h e in pu t t o t h e pu m p.
As a wh eel begin s t o lose t r a ct ion , t h e speed differ-
en t ia l is t r a n sm it t ed fr om on e side of t h e differ en t ia l
t o t h e ot h er t h r ou gh t h e side gea r s. Th e m ot ion of
on e side gea r r ela t ive t o t h e ot h er t u r n s t h e in n er
r ot or of t h e pu m p. Sin ce t h e ou t er r ot or of t h e pu m p
is gr ou n ded t o t h e differ en t ia l ca se, t h e in n er a n d
ou t er r ot or s a r e n ow m ovin g r ela t ive t o ea ch ot h er
a n d t h er efor e cr ea t es pr essu r e in t h e pu m p. Th e t u n -
WJ
in g of t h e fr on t a n d r ea r a xle or ifices a n d va lves
in side t h e ger ot or pu m p is u n iqu e a n d ea ch syst em
in clu des a t or qu e-lim it in g pr essu r e r elief va lve t o
pr ot ect t h e clu t ch pa ck, wh ich a lso fa cilit a t es veh icle
con t r ol u n der ext r em e side-t o-side t r a ct ion va r ia -
t ion s. Th e r esu lt in g pr essu r e is a pplied t o t h e clu t ch
pa ck a n d t h e t r a n sfer of t or qu e is com plet ed.
Un der con dit ion s in wh ich opposit e wh eels a r e on
su r fa ces wit h widely differ en t fr ict ion ch a r a ct er ist ics,
Va r i-lok! deliver s fa r m or e t or qu e t o t h e wh eel on
t h e h igh er t r a ct ion su r fa ce t h a n do con ven t ion a l
Tr a c-lok! syst em s. Beca u se con ven t ion a l Tr a c-lok!
differ en t ia ls a r e in it ia lly pr e-loa ded t o a ssu r e t or qu e
t r a n sfer, n or m a l dr ivin g (wh er e in n er a n d ou t er
wh eel speeds differ du r in g cor n er in g, et c.) pr odu ces
t or qu e t r a n sfer du r in g even sligh t side-t o-side speed
va r ia t ion s. Sin ce t h ese devices r ely on fr ict ion fr om
t h is pr eloa d t o t r a n sfer t or qu e, n or m a l u se t en ds t o
ca u se wea r t h a t r edu ces t h e a bilit y of t h e differ en t ia l
t o t r a n sfer t or qu e over t im e. By design , t h e Va r i-lok!
syst em is less su bject t o wea r, r em a in in g m or e con -
sist en t over t im e in it s a bilit y t o t r a n sfer t or qu e. Th e
cou plin g a ssem bly is ser viced a s a u n it . F r om a ser-
vice st a n dpoin t t h e cou plin g a lso ben efit s fr om u sin g
t h e sa m e lu br ica n t su pply a s t h e r in g a n d pin ion
gea r s.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gea r n oise ca n be ca u sed by in su fficien t lu br i-
ca n t , in cor r ect ba ckla sh , t oot h con t a ct , wor n /da m a ged
gea r s or t h e ca r r ier h ou sin g n ot h a vin g t h e pr oper
offset a n d squ a r en ess.
Gea r n oise u su a lly h a ppen s a t a specific speed
r a n ge. Th e n oise ca n a lso occu r du r in g a specific t ype
of dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a -
t ion , deceler a t ion , coa st or con st a n t loa d.
Wh en r oa d t est in g, fir st wa r m -u p t h e a xle flu id by
dr ivin g t h e veh icle a t lea st 5 m iles a n d t h en a cceler-
a t e t h e veh icle t o t h e speed r a n ge wh er e t h e n oise is
t h e gr ea t est . Sh ift ou t -of-gea r a n d coa st t h r ou gh t h e
pea k-n oise r a n ge. If t h e n oise st ops or ch a n ges
gr ea t ly:
• Ch eck for in su fficien t lu br ica n t .
• In cor r ect r in g gea r ba ckla sh .
• Gea r da m a ge.
Differ en t ia l side gea r s a n d pin ion s ca n be ch ecked
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se
n oise du r in g st r a igh t -a h ea d dr ivin g wh en t h e gea r s
a r e u n loa ded. Th e side gea r s a r e loa ded du r in g veh i-
cle t u r n s. A wor n pin ion m a t e sh a ft ca n a lso ca u se a
sn a ppin g or a kn ockin g n oise.
WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)
BEARING NOISE
Th e a xle sh a ft , differ en t ia l a n d pin ion bea r in gs ca n
a ll pr odu ce n oise wh en wor n or da m a ged. Bea r in g
n oise ca n be eit h er a wh in in g or a gr owlin g sou n d.
P in ion bea r in gs h a ve a con st a n t -pit ch n oise. Th is
n oise ch a n ges on ly wit h veh icle speed. P in ion bea r in g
n oise will be h igh er pit ch ed beca u se it r ot a t es a t a
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en -
t ia l. If bea r in g n oise occu r s, t h e r ea r pin ion bea r in g
is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is
h ea r d du r in g a coa st , t h e fr on t pin ion bea r in g is t h e
sou r ce.
Wor n or da m a ged differ en t ia l bea r in gs u su a lly pr o-
du ce a low pit ch n oise. Differ en t ia l bea r in g n oise is
sim ila r t o pin ion bea r in g n oise. Th e pit ch of differ en -
t ia l bea r in g n oise is a lso con st a n t a n d va r ies on ly
wit h veh icle speed.
Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion
wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges
wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle.
Tu r n t h e veh icle sh a r ply t o t h e left a n d t o t h e r igh t .
Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise
level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise
is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph .
LOW SPEED KNOCK
Low speed kn ock is gen er a lly ca u sed by a wor n
U-join t or by wor n side-gea r t h r u st wa sh er s. A wor n
pin ion sh a ft bor e will a lso ca u se low speed kn ock.
VIBRATION
Vibr a t ion a t t h e r ea r of t h e veh icle is u su a lly
ca u sed by a :
• Da m a ged dr ive sh a ft .
• Missin g dr ive sh a ft ba la n ce weigh t (s).
FRONT AXLE - 186FBI 3 - 17
• Wor n or ou t -of-ba la n ce wh eels.
• Loose wh eel lu g n u t s.
• Wor n U-join t (s).
• Loose/br oken spr in gs.
• Da m a ged a xle sh a ft bea r in g(s).
• Loose pin ion gea r n u t .
• E xcessive pin ion yoke r u n ou t .
• Ben t a xle sh a ft (s).
Ch eck for loose or da m a ged fr on t –en d com pon en t s
or en gin e/t r a n sm ission m ou n t s. Th ese com pon en t s
ca n con t r ibu t e t o wh a t a ppea r s t o be a r ea r-en d
vibr a t ion . Do n ot over look en gin e a ccessor ies, br a ck-
et s a n d dr ive belt s.
All dr ivelin e com pon en t s sh ou ld be exa m in ed
befor e st a r t in g a n y r epa ir.
(Refer t o 22 - TIRE S/WH E E LS - DIAGNOSIS AND
TE STING)
DRIVELINE SNAP
A sn a p or clu n k n oise wh en t h e veh icle is sh ift ed
in t o gea r (or t h e clu t ch en ga ged), ca n be ca u sed by:
• H igh en gin e idle speed.
• Tr a n sm ission sh ift oper a t ion .
• Loose en gin e/t r a n sm ission /t r a n sfer ca se m ou n t s.
• Wor n U-join t s.
• Loose spr in g m ou n t s.
• Loose pin ion gea r n u t a n d yoke.
• E xcessive r in g gea r ba ckla sh .
• E xcessive side gea r t o ca se clea r a n ce.
Th e sou r ce of a sn a p or a clu n k n oise ca n be det er-
m in ed wit h t h e a ssist a n ce of a h elper. Ra ise t h e veh i-
cle on a h oist wit h t h e wh eels fr ee t o r ot a t e. In st r u ct
t h e h elper t o sh ift t h e t r a n sm ission in t o gea r. List en
for t h e n oise, a m ech a n ics st et h oscope is h elpfu l in
isola t in g t h e sou r ce of a n oise.
3 - 18 FRONT AXLE - 186FBI
FRON T AX LE - 1 8 6 FBI (Cont inue d)
Condition
Wheel Noise
Axle Shaft Noise
Axle Shaft Broke
Differential Cracked
DI AGN OST I C CH ART
Possible Causes
1. Wheel loose.
2. Faulty, brinelled wheel bearing.
1. Misaligned axle tube.
2. Bent or sprung axle shaft.
3. End-play in pinion bearings.
4. Excessive gear backlash
between the ring gear and pinion.
5. Improper adjustment of pinion
gear bearings.
6. Loose pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
1. Misaligned axle tube.
2 Vehicle overloaded.
3. Erratic clutch operation.
4. Grabbing clutch.
1. Improper adjustment of the
differential bearings.
2. Excessive ring gear backlash.
3. Vehicle overloaded.
4. Erratic clutch operation.
WJ
Correction
1. Tighten loose nuts.
2. Replace bearing.
1. Inspect axle tube alignment.
Correct as necessary.
2. Inspect and correct as necessary.
3. Refer to pinion pre-load
information and correct as
necessary.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Adjust the pinion bearings
pre-load.
6. Tighten the pinion yoke nut.
7. Inspect and replace as
necessary.
1. Replace the broken shaft after
correcting tube mis-alignment.
2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Replace broken shaft and inspect
and repair clutch as necessary.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)
Condition
Differential Gears Scored
Loss Of Lubricant
Axle Overheating
Gear Teeth Broke
Possible Causes
1. Insufficient lubrication.
2. Improper grade of lubricant.
3. Excessive spinning of one
wheel/tire.
1. Lubricant level too high.
2. Worn axle shaft seals.
3. Cracked differential housing.
4. Worn pinion seal.
5. Worn/scored yoke.
6. Axle cover not properly sealed.
1. Lubricant level low.
2. Improper grade of lubricant.
3. Bearing pre-loads too high.
4. Insufficient ring gear backlash.
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavement.
4. Improper adjustments.
FRONT AXLE - 186FBI 3 - 19
Correction
1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
1. Drain lubricant to the correct
level.
2. Replace seals.
3. Repair as necessary.
4. Replace seal.
5. Replace yoke and seal.
6. Remove, clean, and re-seal
cover.
1. Fill differential to correct level.
2. Fill differential with the correct
fluid type and quantity.
3. Re-adjust bearing pre-loads.
4. Re-adjust ring gear backlash.
1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Replace gears and examine
remaining parts for damage.
4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
3 - 20 FRONT AXLE - 186FBI WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)

Condition Possible Causes Correction

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct

2. Improper ring gear and pinion
adjustment.
3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
5. Loose pinion bearings.
6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap
bolts.
9. Housing not machined properly.
fluid type and quantity.
2. Check ring gear and pinion
contact pattern.
3. Replace gears with a matched
ring gear and pinion.
4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load.
6. Adjust differential bearing
pre-load.
7. Measure ring gear run-out.
Replace components as necessary.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Replace housing.

VARI-LOK"
(1) P a r k t h e veh icle on a level su r fa ce or r a ise
veh icle on h oist so t h a t t h e veh icle is level.
(2) Rem ove t h e a xle fill plu g.
(3) Ver ify t h a t t h e a xle flu id level is cor r ect . Th e
flu id level is cor r ect if t h e flu id is level wit h t h e bot -
t om of t h e fill h ole.
(4) Sh ift t h e t r a n sfer ca se in t o t h e 4WD fu ll-t im e
posit ion .
(5) Dr ive t h e veh icle in a t igh t cir cle for 2 m in u t es
a t 5m ph t o fu lly pr im e t h e pu m p.
(6) Block t h e t ir es opposit e t h e a xle t o be t est ed t o
pr even t t h e veh icle fr om m ovin g.
(7) Sh ift t h e t r a n sfer ca se in t o t h e 4WD Low posi-
t ion a n d t h e t r a n sm ission in t o t h e P a r k posit ion .
(8) Ra ise bot h t h e wh eels of t h e a xle t o be t est ed
off of t h e gr ou n d.
(9) Rot a t e t h e left wh eel by h a n d a t a m in im u m of
on e r evolu t ion per secon d wh ile a n a ssist a n t r ot a t es
t h e r igh t wh eel in t h e opposit e dir ect ion .
(10) Th e left wh eel sh ou ld spin fr eely a t fir st a n d
t h en in cr ea se in r esist a n ce wit h in 5 r evolu t ion s u n t il
t h e wh eels ca n n ot be con t in u ou sly r ot a t ed in opposit e
dir ect ion s.
(11) Th e Va r i-lok! differ en t ia l h a s en ga ged pr op-
er ly if t h e wh eels ca n n ot be r ot a t ed in opposit e dir ec-
t ion s for a m om en t . Aft er t h e wh eels st op r ot a t in g for
a m om en t , t h e flu id pr essu r e will dr op in t h e differ-
en t ia l a n d t h e wh eels begin t o r ot a t e on ce a ga in .
(12) If t h e syst em does n ot oper a t e pr oper ly,
r epla ce t h e Va r i-lok! differ en t ia l.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) P osit ion a su it a ble lift in g device u n der t h e
a xle.
(3) Secu r e a xle t o lift .
(4) Rem ove t h e wh eels a n d t ir es.
(5) Rem ove t h e br a ke ca liper s a n d r ot or s (Refer t o
5 - BRAKE S/H YDRAULIC/ME CH ANICAL/ROTORS
- RE MOVAL) fr om t h e a xle.
(6) Discon n ect t h e wh eel sen sor wir in g h a r n ess
fr om t h e veh icle wir in g h a r n ess.
(7) Discon n ect t h e ven t h ose fr om t h e a xle sh a ft
t u be.
(8) Ma r k pr opeller sh a ft a n d yoke/pin ion fla n ge for
in st a lla t ion a lign m en t r efer en ce.
(9) Rem ove pr opeller sh a ft .
(10) Discon n ect st a bilizer ba r lin ks a t t h e a xle.
(11) Discon n ect sh ock a bsor ber s fr om a xle br a ck-
et s.
(12) Discon n ect t r a ck ba r.
(13) Discon n ect t h e t ie r od a n d dr a g lin k fr om t h e
st eer in g kn u ckle.
(14) Discon n ect t h e st eer in g da m per fr om t h e a xle
br a cket .
(15) Discon n ect t h e u pper a n d lower su spen sion
a r m s fr om t h e a xle br a cket s.
(16) Lower t h e lift in g device en ou gh t o r em ove t h e
a xle. Th e coil spr in gs will dr op wit h t h e a xle.
(17) Rem ove t h e coil spr in gs fr om t h e a xle.
WJ FRONT AXLE - 186FBI 3 - 21
FRON T AX LE - 1 8 6 FBI (Cont inue d)

INSTALLATION a m ou n t (in t h ou sa n dt h s of a n in ch ) t h e dept h va r ies

fr om t h e st a n da r d dept h set t in g of a pin ion et ch ed
CAUTION: The weight of the vehicle must be sup- wit h a (0). Th e st a n da r d set t in g fr om t h e cen t er lin e
ported by the springs before suspension arms and of t h e r in g gea r t o t h e ba ck fa ce of t h e pin ion is 92.1
track bar fasteners can be tightened. If springs are m m (3.625 in .). Th e st a n da r d dept h pr ovides t h e best
not at their normal ride position, ride height and gea r t oot h con t a ct pa t t er n . Refer t o Ba ckla sh a n d
handling could be affected. Con t a ct P a t t er n An a lysis pa r a gr a ph in t h is sect ion
for a ddit ion a l in for m a t ion .
(1) In st a ll t h e spr in gs a n d r et a in er clips. Tigh t en
t h e r et a in er bolt s t o 21 N·m (16 ft . lbs.).
(2) Su ppor t t h e a xle on a lift in g device a n d posi-
t ion a xle u n der t h e veh icle.
(3) Ra ise t h e a xle a n d a lign it wit h t h e spr in g
pa ds.
(4) P osit ion t h e u pper a n d lower su spen sion a r m s
in t h e a xle br a cket s. Loosely in st a ll bolt s a n d n u t s t o
h old su spen sion a r m s t o t h e a xle br a cket s.
(5) In st a ll ven t h ose t o t h e a xle sh a ft t u be.
(6) In st a ll t r a ck ba r in t h e a xle br a cket a n d in st a ll
t h e bolt loosely.
(7) In st a ll sh ock a bsor ber s a n d t igh t en t h e bolt s t o
23 N·m (17 ft . lbs.).
(8) In st a ll st a bilizer ba r lin ks t o t h e a xle br a cket s
a n d t igh t en t h e n u t s t o 95 N·m (70 ft . lbs.).
(9) In st a ll dr a g lin k a n d t ie r od t o t h e st eer in g Fig. 3 PINION GEAR ID NUMBERS
kn u ckles. 1 - PRODUCTION NUMBERS
(10) In st a ll st eer in g da m per t o t h e a xle br a cket 2 - DRIVE PINION GEAR DEPTH VARIANCE
a n d t igh t en t h e n u t t o 75 N·m (55 ft . lbs.). 3 - GEAR MATCHING NUMBER
(11) In st a ll t h e br a ke r ot or s (Refer t o 5 - BRAKE S/
H YDRAULIC/ME CH ANICAL/ROTORS - INSTALLA- Com pen sa t ion for pin ion dept h va r ia n ce is
TION) a n d ca liper s. a ch ieved wit h a select sh im /oil slin ger. Th e sh im s a r e
(12) Con n ect t h e wh eel speed sen sor wir in g h a r- pla ced bet ween t h e r ea r pin ion bea r in g a n d t h e pin -
n ess t o t h e veh icle wir in g h a r n ess. ion gea r h ea d (F ig. 4).
(13) Align t h e pr eviou sly m a de m a r ks on t h e pr o-
peller sh a ft a n d t h e yoke/pin ion fla n ge.
(14) In st a ll pr opeller sh a ft t o pin ion fla n ge bolt s ,
if equ ipped.
(15) In st a ll pr opeller sh a ft t o yoke st r a ps a n d
bolt s, if equ ipped.
(16) Ch eck a n d fill a xle lu br ica n t .
(17) In st a ll t h e wh eel a n d t ir e a ssem blies.
(18) Rem ove t h e lift in g device fr om t h e a xle a n d
lower t h e veh icle.
(19) Tigh t en t h e u pper su spen sion a r m n u t s t o 75
N·m (55 ft . lbs.). Tigh t en t h e lower su spen sion a r m
n u t s t o 115 N·m (85 ft . lbs.).
(20) Tigh t en t h e t r a ck ba r bolt a t t h e a xle br a cket
t o 100 N·m (74 ft . lbs.).
(21) Ch eck t h e fr on t wh eel a lign m en t .
Fig. 4 ADJUSTMENT SHIM LOCATIONS
ADJUSTMENTS 1 - PINION DEPTH SHIM/OIL SLINGER
Rin g a n d pin ion gea r s a r e su pplied a s m a t ch ed 2 - DIFFERENTIAL BEARING SHIM
set s on ly. Th e iden t ifyin g n u m ber s for t h e r in g a n d 3 - RING GEAR
pin ion gea r a r e et ch ed on t o ea ch gea r (F ig. 3). A plu s 4 - DIFFERENTIAL BEARING SHIM
(+) n u m ber, m in u s (–) n u m ber or zer o (0) is et ch ed 5 - COLLAPSIBLE SPACER
in t o t h e fa ce of t h e pin ion gea r. Th is n u m ber is t h e
3 - 22 FRONT AXLE - 186FBI
FRON T AX LE - 1 8 6 FBI (Cont inue d)
If a n ew gea r set is bein g in st a lled, n ot e t h e dept h
va r ia n ce et ch ed in t o bot h t h e or igin a l a n d r epla ce-
m en t pin ion . Add or su bt r a ct t h is n u m ber fr om t h e
t h ickn ess of t h e or igin a l dept h sh im /oil slin ger t o
com pen sa t e for t h e differ en ce in t h e dept h va r ia n ces.
Refer t o t h e P in ion Gea r Dept h Va r ia n ce ch a r t .
Not e wh er e Old a n d New P in ion Ma r kin g colu m n s
in t er sect . In t er sect in g figu r e r epr esen t s plu s or
m in u s t h e a m ou n t n eeded.
WJ
Not e t h e et ch ed n u m ber on t h e fa ce of t h e pin ion
gea r h ea d (–1, –2, 0, +1, +2, et c.). Th e n u m ber s r ep-
r esen t t h ou sa n ds of a n in ch devia t ion fr om t h e st a n -
da r d. If t h e n u m ber is n ega t ive, a dd t h a t va lu e t o t h e
r equ ir ed t h ickn ess of t h e dept h sh im s. If t h e n u m ber
is posit ive, su bt r a ct t h a t va lu e fr om t h e t h ickn ess of
t h e dept h sh im . If t h e n u m ber is 0 n o ch a n ge is n ec-
essa r y.

PI N I ON GEAR DEPT H VARI AN CE

Original Pinion
Gear Depth Replacement Pinion Gear Depth Variance
Variance
!4 !3 !2 !1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003
0 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004
!1 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005
!2 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006
!3 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006 !0.007
!4 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006 !0.007 !0.008

PINION DEPTH MEASUREMENT
Mea su r em en t s a r e t a ken wit h pin ion bea r in g cu ps
a n d pin ion bea r in gs in st a lled in t h e h ou sin g. Ta ke
m ea su r em en t s wit h P in ion Ga u ge Set a n d Dia l In di-
ca t or C-3339 (F ig. 5).
(1) Assem ble P in ion H eigh t Block 6739, P in ion
Block 8804 a n d r ea r pin ion bea r in g on t o Scr ew 6741
(F ig. 5).
(2) In ser t a ssem bled h eigh t ga u ge com pon en t s,
r ea r bea r in g a n d scr ew in t o t h e h ou sin g t h r ou gh pin -
ion bea r in g cu ps (F ig. 6).
(3) In st a ll fr on t pin ion bea r in g a n d Con e-n u t 6740
h a n d t igh t (F ig. 5).
(4) P la ce Ar bor Disc 6732 on Ar bor D-115-3 in posi-
t ion , in t h e h ou sin g side bea r in g cr a dles (F ig. 7).
In st a ll differ en t ia l bea r in g ca ps on Ar bor Discs a n d
t igh t en ca p bolt s t o 41 N·m (30 ft . lbs.).
(5) Assem ble Dia l In dica t or C-3339 in t o Scoot er
Block D-115-2 a n d secu r e set scr ew.
(6) P ost t ion Scoot er Block/Dia l In dica t or so dia l
pr obe a n d scoot er block a r e flu sh on t h e su r fa ce of
t h e pin ion h eigh t block (F ig. 5). H old scoot er block
a n d zer o t h e dia l in dica t or.
(7) H old scoot er block a ga in st t h e pin ion h eigh t
block a n d slowly slide a cr oss t h e pin ion h eigh t block
t o t h e a r bor (F ig. 8). Move t h e scoot er block t ill t h e
dia l pr obe cr est s t h e a r bor s a n d r ecor d t h e h igh est
r ea din g.
(8) Select a sh im /oil slin ger equ a l t o t h e dia l in di-
ca t or r ea din g plu s t h e pin ion dept h va r ia n ce n u m ber
et ch ed in t h e fa ce of t h e pin ion (F ig. 3). F or exa m ple,
if t h e dept h va r ia n ce is –2, a dd +0.002 in . t o t h e dia l
in dica t or r ea din g.

NOTE: Arbor Discs 6732 has different step diame-

ters to fit other axles. Choose proper step for axle
being serviced.
WJ FRONT AXLE - 186FBI 3 - 23
FRON T AX LE - 1 8 6 FBI (Cont inue d)

Fig. 7 GAUGE TOOLS IN HOUSING

1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK

Fig. 5 PINION GEAR DEPTH TOOLS

1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC

Fig. 8 PINION GEAR DEPTH MEASUREMENT

1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR

Fig. 6 PINION HEIGHT BLOCK

1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 24 FRONT AXLE - 186FBI
FRON T AX LE - 1 8 6 FBI (Cont inue d)
DIFFERENTIAL
Differ en t ia l side bea r in g pr eloa d a n d gea r ba ckla sh
is a ch ieved by select ive sh im s posit ion ed beh in d t h e
differ en t ia l side bea r in g con es. Th e pr oper sh im
t h ickn ess ca n be det er m in ed u sin g slip-fit Du m m y
Bea r in gs D-348 in pla ce of t h e differ en t ia l side bea r-
in gs a n d a Dia l In dica t or C-3339. Befor e pr oceedin g
wit h t h e differ en t ia l bea r in g pr eloa d a n d gea r ba ck-
la sh m ea su r em en t s, m ea su r e t h e pin ion gea r dept h
a n d pr epa r e t h e pin ion for in st a lla t ion . E st a blish in g
pr oper pin ion gea r dept h is essen t ia l t o est a blish in g
gea r ba ckla sh a n d t oot h con t a ct pa t t er n s. Aft er t h e
over a ll sh im t h ickn ess t o t a ke u p differ en t ia l side
pla y is m ea su r ed, t h e pin ion is in st a lled, a n d t h e
gea r ba ckla sh sh im t h ickn ess is m ea su r ed. Th e over-
a ll sh im t h ickn ess is t h e t ot a l of t h e dia l in dica t or
r ea din g a n d t h e pr eloa d specifica t ion a dded t oget h er.
Th e gea r ba ckla sh m ea su r em en t det er m in es t h e
t h ickn ess of t h e sh im u sed on t h e r in g gea r side of
t h e differ en t ia l ca se. Su bt r a ct t h e gea r ba ckla sh sh im
t h ickn ess fr om t h e t ot a l over a ll sh im t h ickn ess a n d
select t h a t a m ou n t for t h e pin ion gea r side of t h e dif-
fer en t ia l (F ig. 9). Differ en t ia l sh im m ea su r em en t s
a r e per for m ed wit h spr ea der W-129-B r em oved.
WJ
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Rem ove differ en t ia l side bea r in gs fr om differ-
en t ia l ca se.
(2) In st a ll r in g gea r on differ en t ia l ca se a n d
t igh t en bolt s t o specifica t ion .
(3) In st a ll du m m y side bea r in gs D-348 on differ en -
t ia l ca se.
(4) In st a ll differ en t ia l ca se in t h e h ou sin g.
CAUTION: When installing a Vari-Lok" differential,
the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.
(5) Recor d t h e t h ickn ess of Du m m y Sh im s 8107.
In ser t t h e sh im s bet ween t h e du m m y bea r in gs a n d
t h e differ en t ia l h ou sin g (F ig. 10).

Fig. 9 ADJUSTMENT SHIM LOCATIONS

1 - PINION DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER Fig. 10 DUMMY SHIM LOCATION
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
WJ FRONT AXLE - 186FBI 3 - 25
FRON T AX LE - 1 8 6 FBI (Cont inue d)
(6) In st a ll t h e bea r in g ca ps in t h eir cor r ect posi-
t ion s a n d sn u g t h e bolt s (F ig. 11).

Fig. 13 SEAT DUMMY BEARING RING GEAR SIDE

1 - DIFFERENTIAL HOUSING
2 - HAMMER
Fig. 11 BEARING CAP BOLTS
3 - DIFFERENTIAL CASE
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE (8) Th r ea d P ilot St u d C-3288-B in t o r ea r cover bolt
h ole below r in g gea r (F ig. 14).
(9) At t a ch a dia l in dica t or C-3339 t o P ilot St u d.
(7) Wit h a dea d-blow h a m m er, sea t t h e differ en t ia l
P osit ion t h e dia l in dica t or plu n ger on a fla t su r fa ce
du m m y bea r in gs t o ea ch side of t h e h ou sin g (F ig. 12)
bet ween t h e r in g gea r bolt h ea ds (F ig. 14).
a n d (F ig. 13).

Fig. 12 SEAT DUMMY BEARING PINION SIDE

1 - HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE

Fig. 14 DIFFERENTIAL SIDE PLAY MEASUREMET

1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
3 - 26 FRONT AXLE - 186FBI WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)
(10) P u sh a n d h old differ en t ia l ca se t o pin ion gea r (12) Add 0.152 m m (0.006 in .) t o t h e zer o en d pla y
side of t h e h ou sin g a n d zer o dia l in dica t or (F ig. 15). t ot a l. Th is n ew t ot a l r epr esen t s t h e t h ickn ess of
sh im s t o com pr ess or pr eloa d t h e n ew bea r in gs wh en
t h e differ en t ia l is in st a lled.
(13) Rot a t e dia l in dica t or ou t of t h e wa y on t h e
pilot st u d.
(14) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om t h e h ou sin g.
(15) In st a ll t h e pin ion gea r in t h e h ou sin g. In st a ll
t h e pin ion yoke a n d est a blish t h e cor r ect pin ion
r ot a t in g t or qu e.
(16) In st a ll differ en t ia l ca se a n d Du m m y Bea r in gs
D-348 in t h e h ou sin g.
(17) In st a ll a sin gle du m m y sh im in t h e r in g gea r
side. In st a ll bea r in g ca ps a n d t igh t en bolt s sn u g.
(18) Sea t r in g gea r side du m m y bea r in g (F ig. 13).
(19) P osit ion t h e dia l in dica t or plu n ger on a fla t
su r fa ce bet ween t h e r in g gea r bolt h ea ds (F ig. 14).
Fig. 15 ZERO DIAL INDICATOR (20) P u sh a n d h old differ en t ia l ca se t owa r d pin ion
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
gea r a n d zer o dia l in dica t or (F ig. 17).
2 - PILOT STUD
3 - INDICATOR EXTENSION
4 - DIAL INDICATOR FACE

(11) P u sh a n d h old differ en t ia l ca se t o r in g gea r

side of t h e h ou sin g a n d r ecor d dia l in dica t or r ea din g
(F ig. 16).

Fig. 17 ZERO DIAL INDICATOR

1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE

Fig. 16 RECORED DIAL INDICATOR READING

1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)
(21) P u sh a n d h old differ en t ia l ca se t o r in g gea r
side of t h e h ou sin g a n d r ecor d dia l in dica t or r ea din g
(F ig. 18). Add du m m y sh im t h ickn ess t o t h is r ea din g.
Th is will be t h e t ot a l sh im t h ickn ess t o a ch ieve zer o
ba ckla sh .
FRONT AXLE - 186FBI 3 - 27
(25) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om t h e h ou sin g.
(26) In st a ll side bea r in gs a n d cu ps on differ en t ia l
ca se.
(27) In st a ll spr ea der W-129-B wit h Ada pt er Set
6987 on t h e h ou sin g a n d spr ea d a xle open in g en ou gh
t o r eceive differ en t ia l ca se.
(28) P la ce t h e bea r in g pr eloa d sh im s in t h e a xle
h ou sin g, a ga in st t h e a xle t u bes.
(29) In st a ll differ en t ia l ca se in t o t h e h ou sin g.

CAUTION: When installing a Vari-Lok" differential,

the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.

(30) Rem ove spr ea der fr om t h e h ou sin g.

(31) Rot a t e t h e differ en t ia l ca se sever a l t im es t o
sea t t h e side bea r in gs.
(32) P osit ion t h e in dica t or plu n ger a ga in st a r in g
gea r t oot h (F ig. 19).
Fig. 18 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE

(22) Su bt r a ct 0.076 m m (0.003 in .) fr om t h e dia l

in dica t or r ea din g t o com pen sa t e for ba ckla sh bet ween
r in g a n d pin ion gea r s. Th is t ot a l is t h e t h ickn ess
sh im r equ ir ed t o a ch ieve pr oper ba ckla sh .
(23) Su bt r a ct t h e ba ckla sh sh im t h ickn ess fr om
t h e t ot a l pr eloa d sh im t h ickn ess. Th e r em a in der is
t h e sh im t h ickn ess r equ ir ed on t h e pin ion side of t h e
a xle h ou sin g.
(24) Rot a t e dia l in dica t or ou t of t h e wa y on pilot
st u d.
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
3 - 28 FRONT AXLE - 186FBI WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)
(33) P u sh a n d h old r in g gea r u pwa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e.
(34) Zer o dia l in dica t or fa ce t o poin t er.
(35) P u sh a n d h old r in g gea r down wa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e. Dia l in dica t or
r ea din g sh ou ld be bet ween 0.12 m m (0.005 in .) a n d
0.20 m m (0.008 in .). If ba ckla sh is n ot wit h in specifi-
ca t ion s t r a n sfer t h e n ecessa r y a m ou n t of sh im t h ick-
n ess fr om on e side of t h e h ou sin g t o t h e ot h er (F ig.
20).
(36) Ver ify differ en t ia l ca se a n d r in g gea r r u n ou t
by m ea su r in g r in g t o pin ion gea r ba ckla sh a t eigh t
loca t ion s a r ou n d t h e r in g gea r. Rea din gs sh ou ld n ot
va r y m or e t h a n 0.05 m m (0.002 in .). If r ea din gs va r y
m or e t h a n specified, t h e r in g gea r or t h e differ en t ia l
ca se is defect ive.
Aft er t h e pr oper ba ckla sh is a ch ieved, per for m
Gea r Con t a ct P a t t er n An a lysis pr ocedu r e.

GEAR CONTACT PATTERN

Th e r in g gea r a n d pin ion t eet h con t a ct pa t t er n s
will sh ow if t h e pin ion dept h is cor r ect in t h e h ou s-
in g. It will a lso sh ow if t h e r in g gea r ba ckla sh h a s
been a dju st ed cor r ect ly. Th e ba ckla sh ca n be a dju st ed
wit h in specifica t ion s t o a ch ieve desir ed t oot h con t a ct
pa t t er n s.
(1) Apply a t h in coa t of h ydr a t ed fer r ic oxide or
equ iva len t t o t h e dr ive a n d coa st side of t h e r in g gea r
t eet h .
(2) Wr a p, t wist a n d h old a sh op t owel a r ou n d t h e
pin ion yoke t o in cr ea se t h e t u r n in g r esist a n ce of t h e
pin ion . Th is will pr ovide a m or e dist in ct con t a ct pa t -
t er n .
(3) Wit h a boxed en d wr en ch on a r in g gea r bolt ,
r ot a t e t h e differ en t ia l ca se on e com plet e r evolu t ion in
Fig. 20 BACKLASH SHIM ADJUSTMENT
bot h dir ect ion s wh ile a loa d is bein g a pplied fr om
sh op t owel.
Th e a r ea s on t h e r in g gea r t eet h wit h t h e gr ea t est
degr ee of con t a ct a ga in st t h e pin ion t eet h will squ ee-
gee t h e com pou n d t o t h e a r ea s wit h t h e lea st a m ou n t
of con t a ct . Not e a n d com pa r e pa t t er n s on t h e r in g
gea r t eet h t o Gea r Toot h Con t a ct P a t t er n s ch a r t (F ig.
21)a n d a dju st pin ion dept h a n d gea r ba ckla sh a s n ec-
essa r y.
WJ FRONT AXLE - 186FBI 3 - 29
FRON T AX LE - 1 8 6 FBI (Cont inue d)

Fig. 21 GEAR TOOTH CONTACT PATTERNS

3 - 30 FRONT AXLE - 186FBI WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)
DIFFERENTIAL BEARING PRELOAD CHECK Tor qu e t o r ot a t e t h e differ en t ia l a n d pin ion sh ou ld
Th e fin a l ch eck on t h e differ en t ia l a ssem bly befor e be t h e t or qu e t o r ot a t e t h e pin ion plu s 0.79-1.24 N·m
in st a llin g t h e a xles is t or qu e t o r ot a t e pin ion a n d dif- (7-11 in . lbs.).
fer en t ia l com bin ed. Th is will ver ify t h e cor r ect differ-
en t ia l bea r in g pr eloa d.

SPECIFICATIONS
AX LE SPECI FI CAT I ON S

DESCRIPTION SPECIFICATION
Axle Ratio 3.31, 3.55, 3.73, 3.91
Differential Side Gear Clearance 0.13-0.20 mm (0.005-0.008 in.)
Differential Bearing Preload 0.152 mm (0.006 in.)
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Pinion Gear Std. Depth 92.08 mm (3.625 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1.7-3.4 N·m (15-30 in. lbs.)

T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Axle Nut 237 175 -
Hub Bearing Bolts 102 75 -
WJ FRONT AXLE - 186FBI 3 - 31
FRON T AX LE - 1 8 6 FBI (Cont inue d)

SPECIAL TOOLS

DIAL INDICATOR C-3339

PULLER C-293-PA

INSTALLER C-3716-A

PLUG SP-3289

ADAPTER C-293-42

HANDLE C-4171

PULLER C-452

INSTALLER C-4308

FLANGE WRENCH C-3281

REMOVER C-4307
3 - 32 FRONT AXLE - 186FBI WJ
FRON T AX LE - 1 8 6 FBI (Cont inue d)

DUMMY SHIMS 8107

INSTALLER W-162-D

PINION BLOCK 8804

CUP 8109

SEAL REMOVER 7794-A

SEAL INSTALLER 8110

CLAMP INSTALLER C-4975-A

TURNBUCKLE 6797

SPANNER WRENCH 6958

PINION DEPTH SET 6774

WJ FRONT AXLE - 186FBI 3 - 33
FRON T AX LE - 1 8 6 FBI (Cont inue d)

SPREADER W-129-B REMOVER D-158

ADAPTER KIT 6987B INSTALLER D-144

PILOT STUD C-3288-B

INSTALLER 6448
3 - 34 FRONT AXLE - 186FBI WJ

AX LE SH AFT S
REMOVAL
If t h e a xle sh a ft a n d h u b bea r in g a r e bein g
r em oved in or der t o ser vice a n ot h er com pon en t , t h e
a xle sh a ft a n d h u b bea r in g ca n be r em oved a s a n
a ssem bly.
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e wh eel a n d t ir e a ssem bly.
(3) Rem ove br a ke ca liper, r ot or a n d ABS wh eel
speed sen sor.
(4) Rem ove cot t er pin , n u t r et a in er a n d a xle n u t .
(5) Rem ove t h e h u b bea r in g bolt s (F ig. 22).

Fig. 23 HUB BEARING AND AXLE ASSEMBLY

1 - AXLE
2 - KNUCKLE
3 - HUB BEARING
4 - AXLE SHAFT

INSTALLATION
(1) Th or ou gh ly clea n t h e a xle sh a ft a n d a pply a
t h in film of Mopa r Wh eel Bea r in g Gr ea se or equ iva -
len t t o t h e sh a ft splin es, sea l con t a ct su r fa ce a n d h u b
bor e.
(2) In st a ll br a ke r ot or sh ield t o t h e kn u ckle.
(3) In st a ll h u b bea r in g a n d a xle sh a ft a ssem bly or
Fig. 22 HUB BEARING BOLTS a xle sh a ft in t o t h e h ou sin g a n d differ en t ia l side
1 - AXLE SHAFT
gea r s. Avoid da m a gin g t h e a xle sh a ft oil sea ls in t h e
2 - AXLE a xle h ou sin g.
3 - KNUCKLE (4) In st a ll t h e h u b bea r in g.
4 - HUB BEARING (5) In st a ll h u b bea r in g bolt s a n d t igh t en t o 102
N·m (75 ft . lbs.).
(6) In st a ll a xle h u b wa sh er a n d n u t a n d t igh t en
(6) Rem ove h u b bea r in g a n d a xle sh a ft a ssem bly
n u t t o 237 N·m (175 ft . lbs.). In st a ll t h e n u t r et a in er
(F ig. 23). Av o id d a m a g in g th e a x le s h a ft o il s e a ls
a n d a n ew cot t er pin .
in th e a x le h o u s in g .
(7) In st a ll ABS wh eel speed sen sor, br a ke r ot or
(7) Rem ove br a ke r ot or sh ield fr om t h e h u b bea r-
a n d ca liper.
in g or kn u ckle.
(8) In st a ll t h e wh eel a n d t ir e a ssem bly.
(9) Rem ove su ppor t a n d lower t h e veh icle.
WJ FRONT AXLE - 186FBI 3 - 35

AX LE SH AFT SEALS AX LE - C/V J OI N T

REMOVAL REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove a xle sh a ft s. NOTE: The only service procedure to be performed
(3) Rem ove differ en t ia l a ssem bly. on the axle C/V joint, is the replacement of the joint
(4) Rem ove in n er a xle sh a ft sea ls wit h a pr y ba y. seal boot. If any failure of internal axle shaft com-
ponents is diagnosed during a vehicle road test, the
INSTALLATION axle shaft must be replaced as an assembly.
(1) Rem ove a n y sea ler r em a in in g fr om or igin a l
sea ls. (1) Rem ove a xle sh a ft .
(2) In st a ll oil sea ls wit h Discs 8110 a n d Tu r n - (2) Rem ove la r ge a n d sm a ll C/V boot cla m ps (F ig.
bu ckle 6797 (F ig. 24). Tigh t en t ool u n t il disc bot t om s 25) a n d disca r d.
in h ou sin g. (3) Slid boot off t h e C/V join t h ou sin g a n d slide it
down t h e a xle sh a ft .

Fig. 25 OUTER C/V BOOT CLAMPS

1 - C/V JOINT HOUSING
2 - LARGE CLAMP
3 - AXLE SHAFT
4 - SMALL CLAMP
5 - SEALING BOOT
Fig. 24 AXLE SEAL TOOLS
1 - TURNBUCKLE (4) Rem ove C/V join t fr om a xle t h en slid boot off
2 - DISCS
t h e a xle.
(5) Th or ou gh ly clea n a n d in spect a xle C/V join t
(3) In st a ll differ en t ia l a n d a xle sh a ft s. a ssem bly a n d a xle sh a ft for a n y sign s of excessive
(4) F ill differ en t ia l wit h lu br ica n t . wea r.
(5) Rem ove su ppor t a n d lower veh icle.
INSTALLATION
(1) Slide n e w boot over a xle sh a ft .
(2) In st a ll C/V join t on t o t h e a xle sh a ft .
(3) Dist r ibu t e 1/2 t h e a m ou n t of gr ea se pr ovided in
sea l boot ser vice pa cka ge (D O N OT U S E AN Y
OTHER TYP E OF GREAS E) in t o a xle C/V join t
a ssem bly h ou sin g. P u t t h e r em a in in g a m ou n t in t o
t h e sea lin g boot .
(4) P osit ion boot on t h e a xle loca t in g gr ove a n d on
t h e C/V join t .
3 - 36 FRONT AXLE - 186FBI WJ
AX LE - C/V J OI N T (Cont inue d)
CAUTION: Boot must not be dimpled, stretched or
out of shape in any way. If not shaped correctly,
equalize pressure in boot and shape it by hand.

(5) In st a ll t h e t wo boot cla m ps.

(6) Cr im p t h e boot cla m ps wit h Cla m p In st a ller
C-4975A. P la ce cla m p t ool over br idge of cla m p (F ig.
26).

Fig. 28 LARGE BOOT CLAMP

1 - CLAMP TOOL
2 - SEALING BOOT
3 - OUTER C/V JOINT
4 - BOOT CLAMP

AX LE - U -J OI N T
Fig. 26 CRIMPING TOOL
1 - INSTALLER REMOVAL
2 - AXLE SHAFT
3 - CLAMP CAUTION: Clamp only the narrow forged portion of
4 - SEALING BOOT the yoke in the vise. Do not over tighten the vise
jaws, to avoid distorting the yoke.
(7) Tigh t en n u t on t h e t ool u n t il ja ws on t ool a r e
closed com plet ely t oget h er (F ig. 27) a n d (F ig. 28). (1) Rem ove a xle sh a ft .
(2) Rem ove t h e bea r in g ca p r et a in in g sn a p r in gs
(F ig. 29).

NOTE: Saturate the bearing caps with penetrating

oil prior to removal.

(3) Loca t e a socket wit h a n in side dia m et er is

la r ger t h a n t h e bea r in g ca p. P la ce t h e socket (r eceiv-
er ) a ga in st t h e yoke a n d a r ou n d t h e per im et er of t h e
bea r in g ca p t o be r em oved.
(4) Loca t e a socket wit h a n ou t side dia m et er is
sm a ller t h a n t h e bea r in g ca p. P la ce t h e socket (dr iv-
er ) a ga in st t h e opposit e bea r in g ca p.
(5) P osit ion t h e yoke wit h t h e socket s in a vise
(F ig. 30).
(6) Tigh t en t h e vise ja ws t o for ce t h e bea r in g ca p
Fig. 27 SMALL BOOT CLAMP in t o t h e la r ger socket (r eceiver ).
1 - CLAMP
(7) Relea se t h e vise ja ws. Rem ove t h e socket s a n d
2 - INSTALLER bea r in g ca p t h a t wa s pa r t ia lly for ced ou t of t h e yoke.
3 - AXLE SHAFT (8) Repea t t h e a bove pr ocedu r e for t h e r em a in in g
4 - SEALING BOOT bea r in g ca p a n d r em ove spider fr om t h e pr opeller
sh a ft yoke.
(8) In st a ll t h e a xle sh a ft .
WJ FRONT AXLE - 186FBI 3 - 37
AX LE - U -J OI N T (Cont inue d)

INSTALLATION
(1) P a ck t h e bea r in g ca ps 1/3 fu ll of wh eel bea r in g
lu br ica n t . Apply ext r em e pr essu r e (E P ), lit h iu m -ba se
lu br ica n t t o a id in in st a lla t ion .
(2) P osit ion t h e spider in t h e yoke. In ser t t h e sea ls
a n d bea r in gs, t h en t a p bea r in g ca ps in t o t h e yoke
bor es fa r en ou gh t o h old t h e spider in posit ion .
(3) P la ce t h e socket (dr iver ) a ga in st on e bea r in g
ca p. P osit ion t h e yoke wit h t h e socket in a vise.
(4) Tigh t en t h e vise t o for ce t h e bea r in g ca ps in t o
t h e yoke. F or ce t h e ca ps en ou gh t o in st a ll t h e r et a in -
in g clips.
(5) In st a ll t h e bea r in g ca p r et a in in g clips.
(6) In st a ll a xle sh a ft .

PI N I ON SEAL
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
Fig. 29 AXLE SHAFT OUTER U-JOINT (2) Rem ove wh eel a n d t ir e a ssem blies.
1 - SHAFT YOKE (3) Rem ove br a ke r ot or s a n d ca liper s, r efer t o 5
2 - BEARING CAP
Br a kes for pr ocedu r es.
3 - SNAP RINGS
(4) Ma r k pr opeller sh a ft a n d pin ion com pa n ion
4 - BEARING CAP
5 - SPINDLE YOKE
fla n ge for in st a lla t ion r efer en ce.
6 - BEARING (5) Rem ove t h e pr opeller sh a ft fr om t h e pin ion
7 - BEARING CAP com pa n ion fla n ge.
8 - SNAP RINGS (6) Rot a t e t h e pin ion gea r a m in im u m of t en t im es
9 - BEARING CAP a n d ver ify t h e pin ion r ot a t es sm oot h ly.
(7) Recor d t or qu e n ecessa r y t o r ot a t e t h e pin ion
gea r wit h a in ch pou n d t or qu e wr en ch .
(8) Usin g a sh or t piece of pipe a n d Spa n n er
Wr en ch 6958 t o h old t h e pin ion com pa n ion fla n ge
a n d r em ove t h e pin ion n u t a n d wa sh er.
(9) Rem ove pin ion com pa n ion fla n ge wit h Rem over
C-452 a n d F la n ge Wr en ch C-3281.
(10) Rem ove pin ion sea l wit h Rem over 7794-A a n d
a slide h a m m er (F ig. 31).

INSTALLATION
(1) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lip of pin ion sea l. In st a ll sea l wit h a n a ppr opr ia t e
in st a ller (F ig. 32).
(2) In st a ll pin ion com pa n ion fla n ge on t h e pin ion
gea r wit h In st a ller W-162-D, Cu p 8109 a n d Wr en ch
6958.

CAUTION: Never exceed the minimum tightening

Fig. 30 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET
2 - VISE
3 - SMALL-DIAMETER SOCKET
torque 298 N·m (220 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) In st a ll t h e pin ion wa sh er a n d a n e w n u t on
t h e pin ion gea r. Tig h te n th e n u t o n ly e n o u g h to
re m o v e th e s h a ft e n d p la y.
3 - 38 FRONT AXLE - 186FBI WJ
PI N I ON SEAL (Cont inue d)

Fig. 31 PINION SEAL

1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL

Fig. 33 PINION ROTATION TORQUE

1 - PINION YOKE/COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH

collapsible spacer may have been damaged.

Replace the collapsible spacer.

Fig. 32 PINION SEAL

1 - HANDLE
2 - INSTALLER

CAUTION: Never loosen pinion nut to decrease pin-

ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.

(4) Rot a t e pin ion a m in im u m of t en t im e a n d ver-

ify pin ion r ot a t es sm oot h ly. Rot a t e t h e pin ion sh a ft
wit h a n in ch pou n d t or qu e wr en ch . Rot a t in g t or qu e
sh ou ld be equ a l t o t h e r ea din g r ecor ded du r in g
r em ova l plu s 0.56 N·m (5 in . lbs.) (F ig. 33).
(5) If t h e r ot a t in g t or qu e is low, u se Spa n n er
Wr en ch 6958 t o h old t h e pin ion com pa n ion fla n ge
(F ig. 34), a n d t igh t en t h e pin ion sh a ft n u t in 6.8 N·m
Fig. 34 PINION SHAFT NUT
(5 ft . lbs.) in cr em en t s u n t il pr oper r ot a t in g t or qu e is
a ch ieved. 1 - PINION FLANGE
2 - FRONT AXLE
CAUTION: If maximum tightening torque is reached 3 - SPANNER WRENCH
prior to reaching the required rotating torque, the
WJ FRONT AXLE - 186FBI 3 - 39
PI N I ON SEAL (Cont inue d)
(6) In st a ll pr opeller sh a ft wit h in st a lla t ion r efer- NOTE: If bearing becomes bound on the pinion
en ce m a r ks a lign ed. shaft, lightly tap the end of the pinion gear with a
(7) F ill differ en t ia l wit h gea r lu br ica n t . rawhide/rubber mallet.
(8) In st a ll br a ke r ot or s a n d ca liper s.
(9) In st a ll wh eel a n d t ir e a ssem blies. (12) Rem ove t h e colla psible spa cer.
(10) Lower t h e veh icle.
INSTALLATION
(1) In st a ll a n e w colla psible pr eloa d spa cer on pin -
COLLAPSI BLE SPACER ion sh a ft .
(2) In st a ll pin ion fr on t bea r in g.
REMOVAL (3) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
(1) Ra ise a n d su ppor t t h e veh icle. lip of pin ion sea l. In st a ll sea l wit h a n a ppr opr ia t e
(2) Rem ove wh eel a n d t ir e a ssem blies. in st a ller (F ig. 36).
(3) Rem ove br a ke r ot or s a n d ca liper s. Refer t o 5
Br a kes for pr ocedu r es.
(4) Ma r k t h e pr opeller sh a ft a n d pin ion com pa n ion
fla n ge for in st a lla t ion r efer en ce.
(5) Rem ove pr opeller sh a ft fr om t h e pin ion com -
pa n ion fla n ge.
(6) Rot a t e pin ion gea r a m in im u m of t en t im es a n d
ver ify pin ion r ot a t es sm oot h ly.
(7) Recor d pin ion gea r r ot a t in g t or qu e wit h a
t or qu e wr en ch for in st a lla t ion r efer en ce.
(8) Rem ove pin ion n u t a n d wa sh er. Usin g a sh or t
piece of pipe a n d Spa n n er Wr en ch 6958 t o h old t h e
pin ion com pa n ion fla n ge.
(9) Rem ove pin ion com pa n ion fla n ge wit h Rem over Fig. 36 PINION SEAL INSTALLER
C-452 a n d F la n ge Wr en ch C-3281. 1 - HANDLE
(10) Rem ove pin ion sh a ft sea l wit h Rem over 2 - INSTALLER
7794-A a n d slide h a m m er (F ig. 35).
(4) In st a ll pin ion com pa n ion fla n ge wit h In st a ller
W-162-D, Cu p 8109 a n d F la n ge H older 6958.
(5) In st a ll pin ion wa sh er a n d a n e w n u t on t h e
pin ion gea r. Tigh t en t h e n u t t o 298 N·m (220 ft . lbs.)
m in im u m . D o n o t o v e rtig h te n . Ma xim u m t or qu e is
500 N·m (368 ft . lbs.).

CAUTION: Never loosen pinion nut to decrease pin-

ion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.

(6) Usin g Spa n n er Wr en ch 6958, a len gt h of 1 in .

pipe a n d a t or qu e wr en ch set a t 500 N·m (368 ft . lbs.)
cr u sh colla psible spa cer u n t il bea r in g en d pla y is
Fig. 35 PINION SEAL PULLER t a ken u p (F ig. 37).
(7) Slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.)
1 - REMOVER
2 - SLIDE HAMMER
in cr em en t s u n t il t h e r equ ir ed r ot a t in g t or qu e is
3 - PINION SEAL a ch ieved. Mea su r e t h e r ot a t in g t or qu e fr equ en t ly t o
a void over cr u sh in g t h e colla psible spa cer.
(8) Rot a t e pin ion gea r a m in im u m of t en t im es a n d
(11) Rem ove fr on t pin ion bea r in g u sin g a pa ir of ver ify pin ion r ot a t es sm oot h ly. Ch eck r ot a t in g t or qu e
pick t ools t o pu ll t h e bea r in g st r a igh t off pin ion wit h a n in ch pou n d t or qu e wr en ch . Th e r ot a t in g
sh a ft . t or qu e sh ou ld be t h e a m ou n t r ecor ded du r in g
r em ova l plu s:
• Or igin a l Bea r in gs: 0.56 N·m (5 in . lbs.).
3 - 40 FRONT AXLE - 186FBI WJ
COLLAPSI BLE SPACER (Cont inue d)

Fig. 38 BEARING CAP IDENTIFICATION

1 - REFERENCE LETTERS
2 - REFERENCE LETTERS

Fig. 37 PINION COMPANION FLANGE

1 - COMPANION FLNAGE
2 - DIFFERENTIAL HOUSING
3 - SPANNER WRENCH

• New Bea r in gs: 1.7 t o 3.4 N·m (15 t o 30 in . lbs.).

(9) In st a ll pr opeller sh a ft wit h r efer en ce m a r ks
a lign ed.
(10) In st a ll br a ke r ot or s a n d ca liper s.
(11) Add gea r lu br ica n t if n ecessa r y.
(12) In st a ll wh eel a n d t ir e a ssem blies.
(13) Lower veh icle.

DI FFEREN T I AL
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove lu br ica n t fill h ole plu g fr om t h e differ-
en t ia l h ou sin g cover.
(3) Rem ove differ en t ia l cover a n d dr a in lu br ica n t . Fig. 39 DIFFERENTIAL SPREADER LOCATION
(4) Clea n t h e h ou sin g ca vit y wit h a flu sh in g oil, 1 - DIFFERENTIAL HOUSING
ligh t en gin e oil or lin t fr ee clot h . N e v e r u s e w a te r, 2 - ADAPTER
s te a m , k e ro s e n e o r g a s o lin e fo r c le a n in g . 3 - HOLD DOWN CLAMPS
(5) Rem ove h u b bea r in gs a n d a xle sh a ft s. 4 - SPREADER
(6) Not e in st a lla t ion r efer en ce let t er s st a m ped on 5 - TURNBUCKLE
t h e bea r in g ca ps a n d h ou sin g m a ch in ed sea lin g su r-
fa ce (F ig. 38).
(7) Loosen t h e differ en t ia l bea r in g ca p bolt s.
(8) P osit ion Spr ea der W-129-B wit h Ada pt er Kit
6987B on differ en t ia l loca t in g h oles (F ig. 39). In st a ll
h old down cla m ps a n d t igh t en t h e t ool t u r n bu ckle
fin ger-t igh t .
WJ FRONT AXLE - 186FBI 3 - 41
DI FFEREN T I AL (Cont inue d)
(9) In st a ll a P ilot St u d C-3288-B a t t h e left side of
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o st u d. Loa d t h e lever a da pt er a ga in st t h e opposit e
side of t h e h ou sin g (F ig. 40) a n d zer o t h e in dica t or.

Fig. 40 DIAL INDICATOR LOCATION

1 - CLAMP Fig. 41 SPREAD DIFFERENTIAL HOUSING
2 - DIAL INDICATOR
1 - DIAL INDICATOR
3 - LEVER ADAPTER
2 - SPREADER
4 - SPREADER
5 - PILOT STUD

(10) Spr ea d h ou sin g en ou gh t o r em ove t h e differ-

en t ia l ca se fr om t h e h ou sin g. Mea su r e t h e dist a n ce
wit h t h e dia l in dica t or (F ig. 41).

CAUTION: Never spread the housing over 0.50 mm

(0.020 in). If housing is over-spread, it could dis-
torted and damaged the housing.

(11) Rem ove t h e dia l in dica t or.

(12) H old differ en t ia l ca se in posit ion a n d r em ove
differ en t ia l bea r in g ca p bolt s a n d ca ps.
(13) Rem ove differ en t ia l fr om t h e h ou sin g a n d t a g
differ en t ia l bea r in g cu ps t o en su r e loca t ion (F ig. 42).
(14) Rem ove differ en t ia l ca se pr eloa d sh im s fr om
t h e a xle h ou sin g.
(15) Rem ove spr ea der fr om h ou sin g. Ta g differ en -
Fig. 42 DIFFERENTIAL CASE REMOVAL
t ia l bea r in g pr eloa d sh im s t o en su r e cor r ect loca t ion .
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
3 - 42 FRONT AXLE - 186FBI WJ
DI FFEREN T I AL (Cont inue d)

DISASSEMBLY
(1) Rem ove t h e r in g gea r.
(2) Dr ive ou t t h e r oll pin h oldin g pin ion gea r m a t e
sh a ft wit h a h a m m er a n d pu n ch (F ig. 43).

Fig. 44 PINION MATE GEAR

1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR

Fig. 43 MATE SHAFT ROLL PIN

1 - PUNCH
2 - LOCKPIN
3 - MATE SHAFT

(3) Rem ove pin ion gea r m a t e sh a ft fr om t h e differ-

en t ia l ca se a n d t h e pin ion m a t e gea r s.
(4) Rot a t e differ en t ia l side gea r s a n d r em ove t h e
pin ion m a t e gea r s a n d t h r u st wa sh er s (F ig. 44).
(5) Rem ove differ en t ia l side gea r s a n d t h r u st
wa sh er s.

ASSEMBLY
(1) In st a ll differ en t ia l side gea r s a n d t h r u st wa sh -
er s.
(2) In st a ll pin ion m a t e gea r s a n d t h r u st wa sh er s.
(3) In st a ll pin ion gea r m a t e sh a ft . Align t h e r oll
pin h oles in sh a ft a n d t h e differ en t ia l ca se.
(4) In st a ll t h e r oll pin in t h e differ en t ia l ca se (F ig.
45).
(5) In st a ll t h e r in g gea r.
(6) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t . Fig. 45 MATE SHAFT ROLL PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
WJ FRONT AXLE - 186FBI 3 - 43
DI FFEREN T I AL (Cont inue d)

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.

(1) P osit ion Spr ea der W-129-B wit h Ada pt er Kit

6987B on differ en t ia l loca t in g h oles. In st a ll h old
down cla m ps a n d t igh t en t h e t ool t u r n bu ckle fin ger-
t igh t .
(2) In st a ll a P ilot St u d C-3288-B a t t h e left side of
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
opposit e side of t h e h ou sin g a n d zer o t h e in dica t or.
(3) Spr ea d t h e h ou sin g en ou gh t o in st a ll t h e ca se
in t h e h ou sin g. Mea su r e t h e dist a n ce wit h t h e dia l Fig. 46 DIFFERENTIAL CASE REMOVAL
in dica t or. 1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
CAUTION: Never spread the housing over 0.50 mm 3 - BEARING CUPS
(0.020 in). If housing is over-spread, it could dis-
torted and damaged the housing.

(4) Rem ove t h e dia l in dica t or.

(5) In st a ll differ en t ia l ca se in t h e h ou sin g (F ig.
46). Ma ke su r e t h e differ en t ia l bea r in g cu ps r em a in
on t h e bea r in gs a n d t h e pr eloa d sh im s r em a in
bet ween t h e fa ce of t h e bea r in g cu p a n d h ou sin g. Ta p
t h e differ en t ia l ca se t o en su r e t h e bea r in gs cu ps a n d
sh im s a r e fu lly sea t ed in t h e h ou sin g.

CAUTION: On a Vari-lok" differential the oil feed

tube must be pointed at the bottom of the housing.
If differential is installed with the oil feed tube
pointed at the top, the anti-rotation tabs will be
damaged.

(6) In st a ll t h e bea r in g ca ps a t t h eir or igin a l loca -

t ion s (F ig. 47). Fig. 47 Bearing Cap Reference
(7) Loosely in st a ll differ en t ia l bea r in g ca p bolt s. 1 - REFERENCE LETTERS
(8) Rem ove a xle h ou sin g spr ea der. 2 - REFERENCE LETTERS
(9) Tigh t en t h e bea r in g ca p bolt s t o 61 N·m (45 ft .
lbs.).
(10) In st a ll t h e h u b bea r in gs a n d a xle sh a ft s.
3 - 44 FRONT AXLE - 186FBI WJ
DI FFEREN T I AL (Cont inue d)
(11) Apply a bea d 6.35m m (1/4 in ch ) of r ed Mopa r
Silicon e Ru bber Sea la n t or equ iva len t t o t h e h ou sin g
cover (F ig. 48).

Fig. 48 DIFFERENTIAL COVER Fig. 49 DIFFERENTIAL CASE BEARING

1 - COVER
1 - ADAPTERS
2 - SEALANT
2 - BEARING
3 - SEALANT BEAD
3 - DIFFERENTIAL
4 - PLUG
CAUTION: If cover is not installed within 3 to 5 min- 5 - PULLER
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
INSTALLATION
(12) In st a ll differ en t ia l cover a n d t igh t en cover
NOTE: If replacement differential side bearings or
bolt s in a cr iss-cr oss pa t t er n t o 41 N·m (30 ft . lbs.).
differential case are being installed, differential side
(13) F ill differ en t ia l wit h gea r lu br ica n t t o bot t om
bearing shim requirements may change. Refer to
of t h e fill plu g h ole.
Adjustments (Differential Bearing Preload and Gear
(14) Tigh t en fill plu g t o 34 N·m (25 ft . lbs.).
Backlash) to determine the proper shim selection.
(15) Rem ove su ppor t a n d lower t h e veh icle.

CAUTION: Vari-lok" plenum must be fully seated

DI FFEREN T I AL CASE against the differential case prior to installing the
BEARI N GS ring gear side differential bearing.

REMOVAL (1) In st a ll differ en t ia l side bea r in gs wit h H a n dle

C-4171 a n d In st a ller C-3726-A (F ig. 50).
(1) Rem ove differ en t ia l ca se fr om h ou sin g.
(2) In st a ll differ en t ia l in h ou sin g.
(2) Rem ove bea r in gs fr om t h e differ en t ia l ca se
wit h P u ller C-293-PA, Ada pt er s 8352 a n d P lu g
SP -3289 (F ig. 49).
WJ FRONT AXLE - 186FBI 3 - 45
DI FFEREN T I AL CASE BEARI N GS (Cont inue d)

Fig. 51 RING GEAR

1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER

Fig. 50 DIFFERENTIAL CASE BEARING (8) Wit h Spa n n er Wr en ch 6958 a n d a sh or t len gt h

1 - INSTALLER of 1 in . pipe, h old pin ion com pa n ion fla n ge a n d
2 - HANDLE r em ove pin ion n u t a n d wa sh er (F ig. 52).
(9) Rem ove pin ion com pa n ion fla n ge fr om pin ion
sh a ft wit h Rem over C-452 a n d F la n ge Wr en ch
PI N I ON GEAR/RI N G GEAR C-3281.

REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Nevar replace one gear without replac-
ing the other matching gear.

(1) Ra ise a n d su ppor t veh icle

(2) Ma r k pin ion com pa n ion fla n ge a n d pr opeller
sh a ft for in st a lla t ion a lign m en t .
(3) Rem ove pr opeller sh a ft fr om pin ion com pa n ion
fla n ge a n d t ie pr opeller sh a ft t o u n der body.
(4) Rem ove differ en t ia l fr om a xle h ou sin g.
(5) P la ce differ en t ia l ca se in a vise wit h soft m et a l
ja w (F ig. 51).
(6) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l
ca se.

NOTE: On Veri-Lok" differential the side bearing

and oil feed plenum must be removed before
removing the ring gear bolts.

(7) Dr iver r in g gea r off t h e differ en t ia l ca se wit h a

r a wh ide h a m m er (F ig. 51). Fig. 52 Pinion Flange
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
3 - 46 FRONT AXLE - 186FBI WJ
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(10) Rem ove pin ion gea r a n d colla psible spa cer (12) Rem ove r ea r pin ion bea r in g cu p (F ig. 55) wit h
fr om h ou sin g (F ig. 53). Rem over C-4307 a n d H a n dle C-4171.

Fig. 55 REAR PINION BEARING CUP

Fig. 53 REMOVE PINION GEAR 1 - REMOVER
2 - HANDLE
1 - RAWHIDE HAMMER

(13) Rem ove colla psible pr eloa d spa cer fr om pin ion
(11) Rem ove fr on t pin ion bea r in g cu p, bea r in g, oil
gea r (F ig. 56).
slin ger a n d pin ion sea l wit h Rem over D-158 a n d
(14) Rem ove r ea r pin ion bea r in g fr om t h e pin ion
H a n dle C-4171 (F ig. 54).
wit h P u ller /P r ess C-293-PA a n d Ada pt er s C-293-42
(F ig. 57). Rem ove oil slin ger /pin ion dept h sh im fr om
t h e pin ion sh a ft a n d r ecor d t h ickn ess.

INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and the pinion head to
achieve proper ring and pinion gear mesh. If ring
and pinion gears are reused, the pinion oil slinger/
depth shim should not require replacement. Refer
to Adujstments (Pinion Gear Depth) to select the
proper thickness shim before installing pinion gear.

(1) Apply Mopa r Door E a se or equ iva len t lu br ica n t

t o ou t side su r fa ce of pin ion bea r in g cu ps.
(2) In st a ll r ea r bea r in g cu p wit h In st a ller C-4308
a n d H a n dle C-4171 a n d ver ify cu p is sea t ed (F ig. 58).
(3) In st a ll bea r in g cu p wit h In st a ller D-144 a n d
H a n dle C-4171 (F ig. 59) a n d ver ify cu p is sea t ed.
(4) In st a ll fr on t pin ion bea r in g, a n d oil slin ger if
equ ipped.

Fig. 54 FRONT PINION BEARING CUP

1 - REMOVER
2 - HANDLE
WJ FRONT AXLE - 186FBI 3 - 47
PI N I ON GEAR/RI N G GEAR (Cont inue d)

Fig. 56 COLLAPSIBLE SPACER Fig. 58 REAR PINION BEARING CUP

1 - COLLAPSIBLE SPACER 1 - INSTALLER
2 - SHOULDER 2 - HANDLE
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING

Fig. 59 FRONT PINION BEARING CUP

1 - INSTALLER
2 - HANDLE

Fig. 57 REAR PINION BEARING

1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
3 - 48 FRONT AXLE - 186FBI WJ
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(5) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lip of pin ion sea l a n d in st a ll sea l wit h a n a ppr opr ia t e
in st a ller (F ig. 60).

Fig. 60 PINION SEAL

1 - HANDLE
2 - INSTALLER

(6) In st a ll r ea r pin ion bea r in g a n d oil slin ger /dept h

sh im on t o t h e pin ion sh a ft wit h In st a ller 6448 a n d a
pr ess (F ig. 61). Fig. 62 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING

(9) In st a ll pin ion wa sh er a n d a n e w n u t on t o t h e

pin ion gea r a n d t igh t en t h e n u t t o 298 N·m (220 ft .
lbs.). D o n o t o v e r-tig h te n .

CAUTION: Never loosen pinion gear nut to decrease

pinion rotating torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.

(10) Use F la n ge Wr en ch 6958, a len gt h of 1 in .

pipe a n d a t or qu e wr en ch set a t 500 N·m (368 ft . lbs.)
a n d cr u sh colla psible spa cer u n t il bea r in g en d pla y is
t a ken u p (F ig. 63).
(11) Slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lb.)
in cr em en t s u n t il t h e r equ ir ed r ot a t in g t or qu e is
a ch ieved. Mea su r e t h e r ot a t in g t or qu e fr equ en t ly t o
a void over cr u sh in g t h e colla psible spa cer (F ig. 64).
Fig. 61 REAR PINION BEARING (12) Rot a t e t h e pin ion a m in im u m of t en t im es.
1 - INSTALLER Ver ify pin ion r ot a t es sm oot h ly a n d ch eck r ot a t in g
2 - OIL SLINGER t or qu e wit h a n in ch pou n d t or qu e wr en ch (F ig. 64).
3 - PINION GEAR P in ion gea r r ot a t in g t or qu e is:
4 - REAR PINION BEARING
• Or igin a l Bea r in gs: 1 t o 2.25 N·m (10 t o 20 in .
5 - PRESS
lbs.).
• New Bea r in gs: 1.7 t o 3.4 N·m (15 t o 30 in . lbs.).
(7) In st a ll a n e w colla psible spa cer on pin ion sh a ft (13) In ver t t h e differ en t ia l ca se a n d st a r t t wo r in g
a n d in st a ll t h e pin ion in t o t h e h ou sin g (F ig. 62). gea r bolt s. Th is will pr ovide ca se-t o-r in g gea r bolt
(8) In st a ll pin ion com pa n ion fla n ge, wit h In st a ller h ole a lign m en t .
W-162-B, Cu p 8109 a n d Spa n n er Wr en ch 6958.
WJ FRONT AXLE - 186FBI 3 - 49
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(14) In ver t t h e differ en t ia l ca se in t h e vise.
(15) In st a ll n ew r in g gea r bolt s a n d a lt er n a t ely
t igh t en t o 108 N·m (80 ft . lbs.) (F ig. 65).

CAUTION: Never reuse the ring gear bolts. The

bolts can fracture causing extensive damage.

NOTE: If equipped with Veri-Lok" differential install

oil feed plenum and side bearing.

Fig. 63 Pinion Nut

1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH

Fig. 65 RING GEAR BOLTS

1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE

(16) In st a ll differ en t ia l in h ou sin g a n d ver ify dif-

fer en t ia l bea r in g pr eloa d, gea r m esh a n d con t a ct pa t -
t er n . Refer t o Adju st m en t for pr ocedu r e.
(17) In st a ll differ en t ia l cover a n d fill wit h gea r
lu br ica n t .
(18) In st a ll pr opeller sh a ft wit h r efer en ce m a r ks
a lign ed.
(19) Rem ove su ppor t s a n d lower veh icle.

Fig. 64 PINION ROTATING TORQUE

1 - TORQUE WRENCH
2 - PINION YOKE/FLANGE
3 - 50 REAR AXLE - 198RBI WJ

REAR AX LE - 1 9 8 RBI

TABLE OF CONTENTS
page page

REAR AXLE - 198RBI INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73

DESCRIPTION . . . . . . . . ... . . . . . . . . . . . . . . 50 DIFFERENTIAL
OPERATION . . . . . . . . . . ... . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DIAGNOSIS AND TESTING .. . . . . . . . . . . . . . . 51 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 77
REMOVAL . . . . . . . . . . . . ... . . . . . . . . . . . . . . 55 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . ... . . . . . . . . . . . . . . 56 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
ADJUSTMENTS . . . . . . . ... . . . . . . . . . . . . . . 56 DIFFERENTIAL-TRAC-LOC
SPECIFICATIONS . . . . . . ... . . . . . . . . . . . . . . 65 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 79
SPECIAL TOOLS ...... ... . . . . . . . . . . . . . . 66 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 79
AXLE SHAFTS CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 INSPECTION ............. . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
AXLE BEARINGS/SEALS DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
PINION SEAL PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

REAR AX LE - 1 9 8 RBI r ea r pr opeller sh a ft is con n ect ed t o t h e pin ion gea r

wh ich r ot a t es t h e differ en t ia l t h r ou gh t h e gea r m esh
wit h t h e r in g gea r bolt ed t o t h e differ en t ia l ca se. Th e
DESCRIPTION
en gin e power is t r a n sm it t ed t o t h e a xle sh a ft s
Th e Rea r Bea m -design Ir on (RBI) a xle h ou sin g h a s
t h r ou gh t h e pin ion m a t e a n d side gea r s. Th e side
a n ir on cen t er ca st in g wit h a xle sh a ft t u bes ext en d-
gea r s a r e splin ed t o t h e a xle sh a ft s.
in g fr om eit h er side. Th e t u bes a r e pr essed in t o a n d
welded t o t h e differ en t ia l h ou sin g t o for m a on e-piece
STANDARD DIFFERENTIAL
a xle h ou sin g. Th e a xles h a s sem i-floa t in g a xle sh a ft s,
Du r in g st r a igh t -a h ea d dr ivin g, t h e differ en t ia l pin -
m ea n in g t h a t loa ds a r e su ppor t ed by t h e a xle sh a ft
ion gea r s do n ot r ot a t e on t h e pin ion m a t e sh a ft . Th is
a n d bea r in gs. Th e a xle sh a ft s a r e r et a in ed by bea r in g
occu r s beca u se in pu t t or qu e a pplied t o t h e gea r s is
r et a in er pla t es on t h e a xles wh ich a r e bolt ed t o
divided a n d dist r ibu t ed equ a lly bet ween t h e t wo side
fla n ges a t t h e ou t boa r d en d of t h e a xle t u bes.
gea r s. As a r esu lt , t h e pin ion gea r s r evolve wit h t h e
Th e differ en t ia l ca se is a on e-piece design . Differ-
pin ion m a t e sh a ft bu t do n ot r ot a t e a r ou n d it (F ig. 1).
en t ia l bea r in g pr eloa d a n d r in g gea r ba ckla sh is
Wh en t u r n in g cor n er s, t h e ou t side wh eel m u st
a dju st ed by t h e u se of select ive spa cer sh im s. P in ion
t r a vel a gr ea t er dist a n ce t h a n t h e in side wh eel t o
bea r in g pr eloa d is set a n d m a in t a in ed by t h e u se of a
com plet e a t u r n . Th e differ en ce m u st be com pen sa t ed
colla psible spa cer. A differ en t ia l cover pr ovides a
for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin g
m ea n s for in spect ion a n d ser vice.
t h r ou gh t u r n s. To a ccom plish t h is, t h e differ en t ia l
Axles wit h opt ion a l Tr a c-Lok! differ en t ia l h a ve a
a llows t h e a xle sh a ft s t o t u r n a t u n equ a l speeds (F ig.
on e-piece differ en t ia l ca se, a n d t h e sa m e in t er n a l
2). In t h is in st a n ce, t h e in pu t t or qu e a pplied t o t h e
com pon en t s a s a st a n da r d differ en t ia l, plu s t wo
pin ion gea r s is n ot divided equ a lly. Th e pin ion gea r s
clu t ch disc pa cks.
n ow r ot a t e a r ou n d t h e pin ion m a t e sh a ft in opposit e
dir ect ion s. Th is a llows t h e side gea r a n d a xle sh a ft
OPERATION a t t a ch ed t o t h e ou t side wh eel t o r ot a t e a t a fa st er
Th e a xle r eceives power fr om t h e t r a n sm ission /
speed.
t r a n sfer ca se t h r ou gh t h e r ea r pr opeller sh a ft . Th e
WJ REAR AXLE - 198RBI 3 - 51
REAR AX LE - 1 9 8 RBI (Cont inue d)

Fig. 1 STRAIGHT AHEAD DRIVING

1 - WHEELS ROTATE AT CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE

Fig. 3 TRAC-LOK LIMITED SLIP DIFFERENTIAL

1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
Fig. 2 DIFFERENTIAL ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
ext r em e ca ses of differ en ces of t r a ct ion , t h e wh eel
wit h t h e lea st t r a ct ion m a y spin .
TRAC-LOK" DIFFERENTIAL
Th is differ en t ia ls clu t ch es a r e en ga ged by t wo con - DIAGNOSIS AND TESTING
cu r r en t for ces. Th e fir st bein g t h e pr eloa d for ce
exer t ed t h r ou gh Belleville spr in g wa sh er s wit h in t h e GEAR NOISE
clu t ch pa cks. Th e secon d is t h e sepa r a t in g for ces gen - Axle gea r n oise ca n be ca u sed by in su fficien t lu br i-
er a t ed by t h e side gea r s a s t or qu e is a pplied t h r ou gh ca n t , in cor r ect ba ckla sh , t oot h con t a ct , wor n /da m a ged
t h e r in g gea r (F ig. 3). gea r s, or t h e ca r r ier h ou sin g n ot h a vin g t h e pr oper
Th is design pr ovides t h e differ en t ia l a ct ion n eeded offset a n d squ a r en ess.
for t u r n in g cor n er s a n d for dr ivin g st r a igh t a h ea d Gea r n oise u su a lly h a ppen s a t a specific speed
du r in g per iods of u n equ a l t r a ct ion . Wh en on e wh eel r a n ge. Th e n oise ca n a lso occu r du r in g a specific t ype
looses t r a ct ion , t h e clu t ch pa cks t r a n sfer a ddit ion a l of dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a -
t or qu e t o t h e wh eel h a vin g t h e m ost t r a ct ion . Th is t ion , deceler a t ion , coa st , or con st a n t loa d.
differ en t ia l r esist wh eel spin on bu m py r oa ds a n d Wh en r oa d t est in g, fir st wa r m -u p t h e a xle flu id by
pr ovide m or e pu llin g power wh en on e wh eel looses dr ivin g t h e veh icle a t lea st 5 m iles a n d t h en a cceler-
t r a ct ion . P u llin g power is pr ovided con t in u ou sly u n t il a t e t h e veh icle t o t h e speed r a n ge wh er e t h e n oise is
bot h wh eels loose t r a ct ion . If bot h wh eels slip du e t o t h e gr ea t est . Sh ift ou t -of-gea r a n d coa st t h r ou gh t h e
u n equ a l t r a ct ion , Tr a c-lok™ oper a t ion is n or m a l. In
3 - 52 REAR AXLE - 198RBI
REAR AX LE - 1 9 8 RBI (Cont inue d)
pea k-n oise r a n ge. If t h e n oise st ops or ch a n ges
gr ea t ly:
• Ch eck for in su fficien t lu br ica n t .
• In cor r ect r in g gea r ba ckla sh .
• Gea r da m a ge.
Differ en t ia l side gea r s a n d pin ion s ca n be ch ecked
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se
n oise du r in g st r a igh t -a h ea d dr ivin g wh en t h e gea r s
a r e u n loa ded. Th e side gea r s a r e loa ded du r in g veh i-
cle t u r n s. A wor n pin ion m a t e sh a ft ca n a lso ca u se a
sn a ppin g or a kn ockin g n oise.
BEARING NOISE
Th e a xle sh a ft , differ en t ia l a n d pin ion bea r in gs ca n
a ll pr odu ce n oise wh en wor n or da m a ged. Bea r in g
n oise ca n be eit h er a wh in in g, or a gr owlin g sou n d.
P in ion bea r in gs h a ve a con st a n t -pit ch n oise. Th is
n oise ch a n ges on ly wit h veh icle speed. P in ion bea r in g
n oise will be h igh er pit ch ed beca u se it r ot a t es a t a
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en -
t ia l. If bea r in g n oise occu r s, t h e r ea r pin ion bea r in g
is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is
h ea r d du r in g a coa st , t h e fr on t pin ion bea r in g is t h e
sou r ce.
Wor n or da m a ged differ en t ia l bea r in gs u su a lly pr o-
du ce a low pit ch n oise. Differ en t ia l bea r in g n oise is
sim ila r t o pin ion bea r in g n oise. Th e pit ch of differ en -
t ia l bea r in g n oise is a lso con st a n t a n d va r ies on ly
wit h veh icle speed.
Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion
wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges
wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle.
Tu r n t h e veh icle sh a r ply t o t h e left a n d t o t h e r igh t .
Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise
level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise
is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph .
LOW SPEED KNOCK
Low speed kn ock is gen er a lly ca u sed by a wor n
U-join t or by wor n side–gea r t h r u st wa sh er s. A wor n
pin ion sh a ft bor e will a lso ca u se low speed kn ock.
WJ
VIBRATION
Vibr a t ion a t t h e r ea r of t h e veh icle is u su a lly
ca u sed by a :
• Da m a ged dr ive sh a ft .
• Missin g dr ive sh a ft ba la n ce weigh t (s).
• Wor n or ou t -of-ba la n ce wh eels.
• Loose wh eel lu g n u t s.
• Wor n U-join t (s).
• Loose/br oken spr in gs.
• Da m a ged a xle sh a ft bea r in g(s).
• Loose pin ion gea r n u t .
• E xcessive pin ion yoke r u n ou t .
• Ben t a xle sh a ft (s).
Ch eck for loose or da m a ged fr on t -en d com pon en t s
or en gin e/t r a n sm ission m ou n t s. Th ese com pon en t s
ca n con t r ibu t e t o wh a t a ppea r s t o be a r ea r en d vibr a -
t ion . Do n ot over look en gin e a ccessor ies, br a cket s
a n d dr ive belt s.
All dr ivelin e com pon en t s sh ou ld be exa m in ed
befor e st a r t in g a n y r epa ir.
(Refer t o 22 - TIRE S/WH E E LS - DIAGNOSIS AND
TE STING)
DRIVELINE SNAP
A sn a p or clu n k n oise wh en t h e veh icle is sh ift ed
in t o gea r (or t h e clu t ch en ga ged), ca n be ca u sed by:
• H igh en gin e idle speed.
• Tr a n sm ission sh ift oper a t ion .
• Loose en gin e/t r a n sm ission /t r a n sfer ca se m ou n t s.
• Wor n U-join t s.
• Loose spr in g m ou n t s.
• Loose pin ion gea r n u t a n d yoke.
• E xcessive r in g gea r ba ckla sh .
• E xcessive side gea r t o ca se clea r a n ce.
Th e sou r ce of a sn a p or a clu n k n oise ca n be det er-
m in ed wit h t h e a ssist a n ce of a h elper. Ra ise t h e veh i-
cle on a h oist wit h t h e wh eels fr ee t o r ot a t e. In st r u ct
t h e h elper t o sh ift t h e t r a n sm ission in t o gea r. List en
for t h e n oise, a m ech a n ics st et h oscope is h elpfu l in
isola t in g t h e sou r ce of a n oise.
WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)
DI AGN OST I C CH ART
Condition Possible Causes
Wheel Noise 1. Wheel loose.
2. Faulty, brinelled wheel bearing.
Axle Shaft Noise 1. Misaligned axle tube.
2. Bent or sprung axle shaft.
3. End-play in pinion bearings.
4. Excessive gear backlash
between the ring gear and pinion.
5. Improper adjustment of pinion
gear bearings.
6. Loose pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
Axle Shaft Broke 1. Misaligned axle tube.
2 Vehicle overloaded.
3. Erratic clutch operation.
4. Grabbing clutch.
Differential Cracked 1. Improper adjustment of the
differential bearings.
2. Excessive ring gear backlash.
3. Vehicle overloaded.
4. Erratic clutch operation.
REAR AXLE - 198RBI 3 - 53
Correction
1. Tighten loose nuts.
2. Replace bearing.
1. Inspect axle tube alignment.
Correct as necessary.
2. Inspect and correct as necessary.
3. Refer to pinion pre-load
information and correct as
necessary.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Adjust the pinion bearings
pre-load.
6. Tighten the pinion yoke nut.
7. Inspect and replace as
necessary.
1. Replace the broken shaft after
correcting tube mis-alignment.
2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Replace broken shaft and inspect
and repair clutch as necessary.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
3 - 54 REAR AXLE - 198RBI
REAR AX LE - 1 9 8 RBI (Cont inue d)
Condition
Differential Gears Scored
Loss Of Lubricant
Axle Overheating
Gear Teeth Broke
Possible Causes
1. Insufficient lubrication.
2. Improper grade of lubricant.
3. Excessive spinning of one
wheel/tire.
1. Lubricant level too high.
2. Worn axle shaft seals.
3. Cracked differential housing.
4. Worn pinion seal.
5. Worn/scored yoke.
6. Axle cover not properly sealed.
1. Lubricant level low.
2. Improper grade of lubricant.
3. Bearing pre-loads too high.
4. Insufficient ring gear backlash.
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavement.
4. Improper adjustments.
WJ
Correction
1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
1. Drain lubricant to the correct
level.
2. Replace seals.
3. Repair as necessary.
4. Replace seal.
5. Replace yoke and seal.
6. Remove, clean, and re-seal
cover.
1. Fill differential to correct level.
2. Fill differential with the correct
fluid type and quantity.
3. Re-adjust bearing pre-loads.
4. Re-adjust ring gear backlash.
1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Replace gears and examine
remaining parts for damage.
4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
WJ REAR AXLE - 198RBI 3 - 55
REAR AX LE - 1 9 8 RBI (Cont inue d)

Condition Possible Causes Correction

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct

2. Improper ring gear and pinion
adjustment.
3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
5. Loose pinion bearings.
6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap
bolts.
9. Housing not machined properly.
fluid type and quantity.
2. Check ring gear and pinion
contact pattern.
3. Replace gears with a matched
ring gear and pinion.
4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load.
6. Adjust differential bearing
pre-load.
7. Measure ring gear run-out.
Replace components as necessary.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Replace housing.

VARI-LOK" t ion s for a m om en t . Aft er t h e wh eels st op r ot a t in g for

(1) P a r k t h e veh icle on a level su r fa ce or r a ise
veh icle on h oist so t h a t t h e veh icle is level.
(2) Rem ove t h e a xle fill plu g.
(3) Ver ify t h a t t h e a xle flu id level is cor r ect . Th e
flu id level is cor r ect if t h e flu id is level wit h t h e bot -
t om of t h e fill h ole.
(4) Sh ift t h e t r a n sfer ca se in t o t h e 4WD fu ll-t im e
posit ion .
(5) Dr ive t h e veh icle in a t igh t cir cle for 2 m in u t es
a t 5m ph t o fu lly pr im e t h e pu m p.
(6) Block t h e t ir es opposit e t h e a xle t o be t est ed t o
pr even t t h e veh icle fr om m ovin g.
(7) Sh ift t h e t r a n sfer ca se in t o t h e 4WD Low posi-
t ion a n d t h e t r a n sm ission in t o t h e P a r k posit ion .
(8) Ra ise bot h t h e wh eels of t h e a xle t o be t est ed
off of t h e gr ou n d.
(9) Rot a t e t h e left wh eel by h a n d a t a m in im u m of
on e r evolu t ion per secon d wh ile a n a ssist a n t r ot a t es
t h e r igh t wh eel in t h e opposit e dir ect ion .
(10) Th e left wh eel sh ou ld spin fr eely a t fir st a n d
t h en in cr ea se in r esist a n ce wit h in 5 r evolu t ion s u n t il
t h e wh eels ca n n ot be con t in u ou sly r ot a t ed in opposit e
dir ect ion s.
(11) Th e Va r i-lok! differ en t ia l h a s en ga ged pr op-
er ly if t h e wh eels ca n n ot be r ot a t ed in opposit e dir ec-
a m om en t , t h e flu id pr essu r e will dr op in t h e differ-
en t ia l a n d t h e wh eels begin t o r ot a t e on ce a ga in .
(12) If t h e syst em does n ot oper a t e pr oper ly,
r epla ce t h e Va r i-lok! differ en t ia l.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) P osit ion a lift in g device u n der t h e a xle a n d
secu r e a xle.
(3) Rem ove t h e wh eels a n d t ir es.
(4) Rem ove br a ke ca liper s a n d r ot or s.
(5) Discon n ect pa r kin g br a ke ca bles fr om br a cket s
a n d lever.
(6) Rem ove wh eel speed sen sor s.
(7) Rem ove br a ke h ose a t t h e a xle ju n ct ion block.
Do n ot discon n ect t h e br a ke h ydr a u lic lin es a t t h e
ca liper s.
(8) Discon n ect t h e ven t h ose fr om t h e a xle sh a ft
t u be.
(9) Ma r k pr opeller sh a ft a n d yokes for in st a lla t ion
r efer en ce.
(10) Rem ove pr opeller sh a ft .
(11) Discon n ect st a bilizer ba r lin ks.
(12) Rem ove u pper su spen sion a r m r ea r a xle ba ll
join t n u t .
3 - 56 REAR AXLE - 198RBI
REAR AX LE - 1 9 8 RBI (Cont inue d)
(13) Sepa r a t e r ea r a xle ba ll join t fr om t h e u pper
su spen sion a r m wit h Rem over 8278 (F ig. 4).
Fig. 4 REAR BALL JOINT
1 - REMOVER
2 - UPPER SUSPENSION ARM
3 - BALL JOINT STUD
(14) Discon n ect sh ock a bsor ber s fr om a xle.
(15) Discon n ect t r a ck ba r.
(16) Discon n ect lower su spen sion a r m s fr om t h e
a xle br a cket s.
(17) Sepa r a t e t h e a xle fr om t h e veh icle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners are tightened. If springs are not
at their normal ride position, vehicle ride height and
handling could be affected.
(1) Ra ise a xle wit h lift a n d a lign coil spr in gs.
(2) In st a ll lower su spen sion a r m s in a xle br a cket s.
In st a ll n u t s a n d bolt s, do n ot t igh t en bolt s a t t h is
t im e.
(3) In st a ll u pper su spen sion a r m on r ea r a xle ba ll
join t .
(4) In st a ll r ea r a xle ba ll join t n u t a n d t igh t en t o
122 N·m (90 ft .lbs.) (F ig. 5).
(5) In st a ll t r a ck ba r a n d a t t a ch m en t bolt s, do n ot
t igh t en bolt s a t t h is t im e.
(6) In st a ll sh ock a bsor ber s a n d t igh t en n u t s t o 60
N·m (44 ft . lbs.).
WJ
Fig. 5 REAR BALL JOINT NUT
1 - UPPER SUSPENSION ARM
2 - REAR AXLE BALL JOINT
3 - REAR AXLE
(7) In st a ll st a bilizer ba r lin ks a n d t igh t en n u t s t o
36 N·m (27 ft . lbs.).
(8) In st a ll wh eel speed sen sor s.
(9) Con n ect pa r kin g br a ke ca ble t o br a cket s a n d
lever.
(10) In st a ll br a ke r ot or s a n d ca liper s.
(11) In st a ll t h e br a ke h ose t o t h e a xle ju n ct ion
block.
(12) In st a ll a xle ven t h ose.
(13) Align pr opeller sh a ft a n d pin ion yoke r efer-
en ce m a r ks. In st a ll U-join t st r a ps a n d n u t s t igh t en t o
19 N·m (14 ft . lbs.).
(14) In st a ll t h e wh eels a n d t ir es.
(15) Add gea r lu br ica n t , if n ecessa r y.
(16) Rem ove su ppor t a n d lower t h e veh icle.
(17) Tigh t en lower su spen sion a r m bolt s t o 177
N·m (130 ft . lbs.).
(18) Tigh t en t r a ck ba r bolt s t o 100 N·m (74 ft .
lbs.).
ADJUSTMENTS
Rin g a n d pin ion gea r s a r e su pplied a s m a t ch ed
set s on ly. Th e iden t ifyin g n u m ber s for t h e r in g a n d
pin ion gea r a r e et ch ed in t o t h e fa ce of ea ch gea r (F ig.
6). A plu s (+) n u m ber, m in u s (–) n u m ber or zer o (0) is
et ch ed in t o t h e fa ce of t h e pin ion gea r. Th is n u m ber
is t h e a m ou n t (in t h ou sa n dt h s of a n in ch ) t h e dept h
va r ies fr om t h e st a n da r d dept h set t in g of a pin ion
et ch ed wit h a (0). Th e st a n da r d set t in g fr om t h e cen -
t er lin e of t h e r in g gea r t o t h e ba ck fa ce of t h e pin ion
is 96.850 m m (3.813 in .). Th e st a n da r d dept h pr o-
vides t h e best gea r t oot h con t a ct pa t t er n . Refer t o
Ba ckla sh a n d Con t a ct P a t t er n An a lysis pa r a gr a ph in
t h is sect ion for a ddit ion a l in for m a t ion .
WJ REAR AXLE - 198RBI 3 - 57
REAR AX LE - 1 9 8 RBI (Cont inue d)

Fig. 6 PINION GEAR ID NUMBERS Fig. 7 SHIM LOCATIONS

1 - PRODUCTION NUMBERS 1 - PINION GEAR DEPTH SHIM
2 - PINION GEAR DEPTH VARIANCE 2 - DIFFERENTIAL BEARING SHIM
3 - GEAR MATCHING NUMBER 3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
Com pen sa t ion for pin ion dept h va r ia n ce is
a ch ieved wit h a select sh im . Th e sh im s a r e pla ced
bet ween t h e r ea r pin ion bea r in g a n d t h e pin ion gea r Not e t h e et ch ed n u m ber on t h e fa ce of t h e pin ion
h ea d (F ig. 7). gea r h ea d (–1, –2, 0, +1, +2, et c.). Th e n u m ber s r ep-
If a n ew gea r set is bein g in st a lled, n ot e t h e dept h r esen t t h ou sa n ds of a n in ch devia t ion fr om t h e st a n -
va r ia n ce et ch ed in t o bot h t h e or igin a l a n d r epla ce- da r d. If t h e n u m ber is n ega t ive, a dd t h a t va lu e t o t h e
m en t pin ion . Add or su bt r a ct t h is n u m ber fr om t h e r equ ir ed t h ickn ess of t h e dept h sh im s. If t h e n u m ber
t h ickn ess of t h e or igin a l dept h sh im /oil slin ger t o is posit ive, su bt r a ct t h a t va lu e fr om t h e t h ickn ess of
com pen sa t e for t h e differ en ce in t h e dept h va r ia n ces. t h e dept h sh im . If t h e n u m ber is 0 n o ch a n ge is n ec-
Refer t o t h e P in ion Gea r Dept h Va r ia n ce ch a r t . essa r y.
Not e wh er e Old a n d New P in ion Ma r kin g colu m n s
in t er sect . In t er sect in g figu r e r epr esen t s plu s or
m in u s t h e a m ou n t n eeded.

PI N I ON GEAR DEPT H VARI AN CE

Original Pinion
Gear Depth Replacement Pinion Gear Depth Variance
Variance
!4 !3 !2 !1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003
0 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004
!1 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005
!2 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006
!3 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006 !0.007
!4 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006 !0.007 !0.008
3 - 58 REAR AXLE - 198RBI WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)
PINION DEPTH MEASUREMENT
Mea su r em en t s a r e t a ken wit h pin ion bea r in g cu ps
a n d pin ion bea r in gs in st a lled in t h e h ou sin g. Ta ke
m ea su r em en t s wit h P in ion Ga u ge Set a n d Dia l In di-
ca t or C-3339 (F ig. 8).

Fig. 9 PINION HEIGHT BLOCK

1 - PINION BLOCK
2 - PINION HEIGHT BLOCK

Fig. 8 PINION GEAR DEPTH GAUGE TOOLS

1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC

(1) Assem ble P in ion H eigh t Block 6739, P in ion
Block 6735 a n d r ea r pin ion bea r in g on t o Scr ew 6741
(F ig. 8).
(2) In ser t a ssem bled h eigh t ga u ge com pon en t s,
r ea r bea r in g a n d scr ew in t o t h e h ou sin g t h r ou gh pin -
ion bea r in g cu ps (F ig. 9).
(3) In st a ll fr on t pin ion bea r in g a n d Con e-n u t 6740
h a n d t igh t (F ig. 8).
(4) P la ce Ar bor Disc 6732 on Ar bor D-115-3 in posi-
t ion in t h e h ou sin g side bea r in g cr a dles (F ig. 10).
In st a ll differ en t ia l bea r in g ca ps on Ar bor Discs a n d
t igh t en ca p bolt s t o 41 N·m (30 ft . lbs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
Fig. 10 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
(6) P la ce Scoot er Block/Dia l In dica t or in posit ion
in t h e h ou sin g so dia l pr obe a n d scoot er block a r e
flu sh a ga in st t h e r ea r wa r d su r fa ce of t h e pin ion
h eigh t block (F ig. 8). H old scoot er block in pla ce a n d
zer o t h e dia l in dica t or fa ce t o t h e poin t er. Tigh t en
dia l in dica t or fa ce lock scr ew.
(7) Wit h scoot er block st ill in posit ion a ga in st t h e
pin ion h eigh t block, slowly slide t h e dia l in dica t or
pr obe over t h e edge of t h e pin ion h eigh t block.

(5) Assem ble Dia l In dica t or C-3339 in t o Scoot er

Block D-115-2 a n d secu r e set scr ew.
WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)
(8) Slide t h e dia l in dica t or pr obe a cr oss t h e ga p
bet ween t h e pin ion h eigh t block a n d t h e a r bor ba r
wit h t h e scoot er block a ga in st t h e pin ion h eigh t block
(F ig. 11). Wh en t h e dia l pr obe con t a ct s t h e a r bor ba r,
t h e dia l poin t er will t u r n clockwise. Br in g dia l
poin t er ba ck t o zer o a ga in st t h e a r bor ba r, do n ot
t u r n dia l fa ce. Con t in u e m ovin g t h e dia l pr obe t o t h e
cr est of t h e a r bor ba r a n d r ecor d t h e h igh est r ea din g.
If t h e dia l in dica t or ca n n ot a ch ieve t h e zer o r ea din g,
t h e r ea r bea r in g cu p or t h e pin ion dept h ga u ge set is
n ot in st a lled cor r ect ly.
(9) Select a sh im equ a l t o t h e dia l in dica t or r ea d-
in g plu s t h e pin ion dept h va r ia n ce n u m ber et ch ed in
t h e fa ce of t h e pin ion (F ig. 6). F or exa m ple, if t h e
dept h va r ia n ce is –2, a dd +0.002 in . t o t h e dia l in di-
ca t or r ea din g.
Fig. 11 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
DIFFERENTIAL
Differ en t ia l side bea r in g pr eloa d a n d gea r ba ckla sh
is a ch ieved by select ive sh im s posit ion ed beh in d t h e
differ en t ia l ca s bea r in g cu ps. Th e pr oper sh im t h ick-
n ess ca n be det er m in ed u sin g slip-fit Du m m y Bea r-
in gs D-348 in pla ce of t h e differ en t ia l side bea r in gs
a n d a Dia l In dica t or C-3339. Befor e pr oceedin g wit h
t h e differ en t ia l bea r in g pr eloa d a n d gea r ba ckla sh
m ea su r em en t s, m ea su r e t h e pin ion gea r dept h a n d
pr epa r e t h e pin ion for in st a lla t ion . E st a blish in g
REAR AXLE - 198RBI 3 - 59
pr oper pin ion gea r dept h is essen t ia l t o est a blish in g
gea r ba ckla sh a n d t oot h con t a ct pa t t er n s. Aft er t h e
over a ll sh im t h ickn ess t o t a ke u p differ en t ia l side
pla y is m ea su r ed, t h e pin ion is in st a lled, a n d t h e
gea r ba ckla sh sh im t h ickn ess is m ea su r ed. Th e over-
a ll sh im t h ickn ess is t h e t ot a l of t h e dia l in dica t or
r ea din g a n d t h e pr eloa d specifica t ion a dded t oget h er.
Th e gea r ba ckla sh m ea su r em en t det er m in es t h e
t h ickn ess of t h e sh im u sed on t h e r in g gea r side of
t h e differ en t ia l ca se. Su bt r a ct t h e gea r ba ckla sh sh im
t h ickn ess fr om t h e t ot a l over a ll sh im t h ickn ess a n d
select t h a t a m ou n t for t h e pin ion gea r side of t h e dif-
fer en t ia l (F ig. 12). Differ en t ia l sh im m ea su r em en t s
a r e per for m ed wit h t h e spr ea der W-129-B r em oved.
Fig. 12 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Rem ove differ en t ia l side bea r in gs fr om differ-
en t ia l ca se.
(2) In st a ll r in g gea r on differ en t ia l ca se a n d
t igh t en bolt s t o specifica t ion .
(3) In st a ll Du m m y Bea r in gs D-348 on differ en t ia l
ca se.
(4) In st a ll differ en t ia l ca se in t h e h ou sin g.
3 - 60 REAR AXLE - 198RBI
REAR AX LE - 1 9 8 RBI (Cont inue d)
(5) Recor d t h e t h ickn ess of Du m m y Sh im s 8107.
In ser t t h e sh im s bet ween t h e du m m y bea r in gs a n d
t h e differ en t ia l h ou sin g (F ig. 13).
WJ
(7) Usin g a dea d-blow t ype h a m m er sea t t h e differ-
en t ia l du m m y bea r in gs t o ea ch side of t h e h ou sin g
(F ig. 15) a n d (F ig. 16).

Fig. 15 SEAT PINION SIDE BEARING

1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE

Fig. 13 SHIM POINT

1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS

(6) In st a ll t h e m a r ked bea r in g ca ps in t h eir cor r ect

posit ion s. In st a ll a n d sn u g t h e bolt s (F ig. 14).

Fig. 16 SEAT RING GEAR SIDE BEARING

1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE

Fig. 14 BEARING CAP BOLTS

1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
WJ REAR AXLE - 198RBI 3 - 61
REAR AX LE - 1 9 8 RBI (Cont inue d)
(8) Th r ea d P ilot St u d C-3288-B in t o r ea r cover bolt
h ole below r in g gea r (F ig. 17).
(9) At t a ch a Dia l In dica t or C-3339 t o pilot st u d.
P osit ion t h e dia l in dica t or plu n ger on a fla t su r fa ce
bet ween t h e r in g gea r bolt h ea ds (F ig. 17).

Fig. 18 ZERO DIAL INDICATOR

1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
4 - ZERO DIAL INDICATOR FACE

Fig. 17 DIFFERENTIAL SIDE PLAY

1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR

(10) P u sh a n d h old differ en t ia l ca se t o pin ion gea r

side of t h e h ou sin g a n d zer o dia l in dica t or (F ig. 18).
(11) P u sh a n d h old differ en t ia l ca se t o r in g gea r
side of t h e h ou sin g a n d r ecor d dia l in dica t or r ea din g
(F ig. 19).
(12) Add 0.152 m m (0.006 in .) t o t h e zer o en d pla y
t ot a l. Th is n ew t ot a l r epr esen t s t h e t h ickn ess of
sh im s t o com pr ess, or pr eloa d t h e n ew bea r in gs wh en
t h e differ en t ia l is in st a lled.
(13) Rot a t e dia l in dica t or ou t of t h e wa y on t h e
pilot st u d.
(14) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om t h e h ou sin g.
(15) In st a ll t h e pin ion gea r in a xle h ou sin g. In st a ll
t h e pin ion yoke a n d est a blish t h e cor r ect pin ion
r ot a t in g t or qu e.
(16) In st a ll differ en t ia l ca se a n d Du m m y Bea r in gs
D-348 in t h e h ou sin g.
(17) In st a ll a sin gle du m m y sh im in t h e r in g gea r
side. In st a ll bea r in g ca ps a n d t igh t en bolt s sn u g.
(18) Sea t r in g gea r side du m m y bea r in g (F ig. 16).
(19) P osit ion t h e dia l in dica t or plu n ger on a fla t
su r fa ce bet ween t h e r in g gea r bolt h ea ds. (F ig. 17).
Fig. 19 DIFFERENTIAL TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
(20) P u sh a n d h old differ en t ia l ca se t owa r d pin ion
gea r a n d zer o dia l in dica t or (F ig. 20).
(21) P u sh a n d h old differ en t ia l ca se t o r in g gea r
side of t h e h ou sin g a n d r ecor d dia l in dica t or r ea din g
(F ig. 21). Add du m m y sh im t h ickn ess t o t h is r ea din g.
Th is will be t h e t ot a l sh im t h ickn ess t o a ch ieve zer o
ba ckla sh .
(22) Su bt r a ct 0.076 m m (0.003 in .) fr om t h e dia l
in dica t or r ea din g t o com pen sa t e for ba ckla sh bet ween
r in g a n d pin ion gea r s. Th is t ot a l is t h e t h ickn ess
sh im r equ ir ed t o a ch ieve pr oper ba ckla sh .
(23) Su bt r a ct t h e ba ckla sh sh im t h ickn ess fr om
t h e t ot a l pr eloa d sh im t h ickn ess. Th e r em a in der is
3 - 62 REAR AXLE - 198RBI WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)
(27) In st a ll spr ea der W-129-B u t ilizin g som e it em s
fr om Ada pt er Set 6987, on t h e h ou sin g a n d spr ea d
a xle open in g en ou gh t o r eceive differ en t ia l ca se.

CAUTION: Never spread over 0.38 mm (0.015 in.). If

housing is over-spread, it could be distorted or
damaged.

(28) P la ce t h e bea r in g pr eloa d sh im s in t h e h ou s-

in g, a ga in st t h e a xle t u bes.
(29) In st a ll differ en t ia l ca se in t o t h e h ou sin g.
(30) Rem ove spr ea der fr om t h e h ou sin g.
(31) In st a ll differ en t ia l bea r in g ca ps in t h eir or igi-
n a l loca t ion s.
(32) In st a ll bea r in g ca p bolt s a n d t igh t en t o 77
N·m (57 ft . lbs.).
Fig. 20 ZERO DIAL INDICATOR (33) Rot a t e t h e differ en t ia l ca se sever a l t im es t o
1 - DIAL INDICATOR FACE
sea t t h e side bea r in gs.
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE (34) P osit ion t h e in dica t or plu n ger a ga in st a r in g
3 - PINION GEAR gea r t oot h (F ig. 22).
4 - DIFFERENTIAL HOUSING (35) P u sh a n d h old r in g gea r u pwa r d wh ile n ot
5 - DIFFERENTIAL CASE a llowin g t h e pin ion gea r t o r ot a t e.
(36) Zer o dia l in dica t or fa ce t o poin t er.
(37) P u sh a n d h old r in g gea r down wa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e. Dia l in dica t or
r ea din g sh ou ld be bet ween 0.12-0.20 m m (0.005-0.008
in .). If ba ckla sh is n ot wit h in specifica t ion s t r a n sfer
t h e n ecessa r y a m ou n t of sh im t h ickn ess fr om on e
side of t h e a xle h ou sin g t o t h e ot h er (F ig. 23).
(38) Ver ify differ en t ia l ca se a n d r in g gea r r u n ou t
by m ea su r in g r in g t o pin ion gea r ba ckla sh a t eigh t
loca t ion s a r ou n d t h e r in g gea r. Rea din gs sh ou ld n ot
va r y m or e t h a n 0.05 m m (0.002 in .). If r ea din gs va r y
m or e t h a n specified, t h e r in g gea r or t h e differ en t ia l
ca se is defect ive.
Aft er t h e pr oper ba ckla sh is a ch ieved, per for m
Gea r Con t a ct P a t t er n An a lysis pr ocedu r e.

Fig. 21 DIFFERENTIAL TO RING GEAR SIDE

1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE

t h e sh im t h ickn ess r equ ir ed on t h e pin ion side of t h e

h ou sin g.
(24) Rot a t e dia l in dica t or ou t of t h e wa y on pilot
st u d.
(25) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om t h e h ou sin g.
(26) In st a ll side bea r in gs a n d cu ps on differ en t ia l
ca se. Fig. 22 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)
Fig. 23 BACKLASH SHIM
REAR AXLE - 198RBI 3 - 63
GEAR CONTACT PATTERN
Th e r in g gea r a n d pin ion t eet h con t a ct pa t t er n s
will sh ow if t h e pin ion dept h is cor r ect in t h e h ou s-
in g. It will a lso sh ow if t h e r in g gea r ba ckla sh h a s
been a dju st ed cor r ect ly. Th e ba ckla sh ca n be a dju st ed
wit h in specifica t ion s t o a ch ieve desir ed t oot h con t a ct
pa t t er n s.
(1) Apply a t h in coa t of h ydr a t ed fer r ic oxide or
equ iva len t t o t h e dr ive a n d coa st side of t h e r in g gea r
t eet h .
(2) Wr a p, t wist a n d h old a sh op t owel a r ou n d t h e
pin ion yoke t o in cr ea se t h e t u r n in g r esist a n ce of t h e
pin ion . Th is will pr ovide a m or e dist in ct con t a ct pa t -
t er n .
(3) Wit h a boxed en d wr en ch on a r in g gea r bolt ,
r ot a t e t h e differ en t ia l ca se on e com plet e r evolu t ion in
bot h dir ect ion s wh ile a loa d is bein g a pplied fr om
sh op t owel.
Th e a r ea s on t h e r in g gea r t eet h wit h t h e gr ea t est
degr ee of con t a ct a ga in st t h e pin ion t eet h will squ ee-
gee t h e com pou n d t o t h e a r ea s wit h t h e lea st a m ou n t
of con t a ct . Not e a n d com pa r e pa t t er n s on t h e r in g
gea r t eet h t o Gea r Toot h Con t a ct P a t t er n s ch a r t (F ig.
24) a n d a dju st pin ion dept h a n d gea r ba ckla sh a s
n ecessa r y.
3 - 64 REAR AXLE - 198RBI WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)

Fig. 24 GEAR TOOTH CONTACT PATTERNS

WJ REAR AXLE - 198RBI 3 - 65
REAR AX LE - 1 9 8 RBI (Cont inue d)
DIFFERENTIAL BEARING PRELOAD CHECK Tor qu e t o r ot a t e t h e differ en t ia l a n d pin ion sh ou ld
Th e fin a l ch eck on t h e differ en t ia l a ssem bly befor e be t h e t or qu e t o r ot a t e t h e pin ion plu s 0.79-1.24 N·m
in st a llin g t h e a xles is t or qu e t o r ot a t e pin ion a n d dif- (7-11 in . lbs.).
fer en t ia l com bin ed. Th is will ver ify t h e cor r ect differ-
en t ia l bea r in g pr eloa d.

SPECIFICATIONS
AX LE SPECI FI CAT I ON S

DESCRIPTION SPECIFICATION
Axle Ratio 3.07, 3.31, 3.55, 3.73, 4.11
Differential Bearing Preload 0.1 mm (0.004 in.)
Ring Gear Diameter 198 mm (7.795 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Std. Depth 96.85 mm (3.813 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1.7-3.9 N·m (15-35 in. lbs.)

T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Differential Cover Bolts 41 30 -
Bearing Cap Bolts 77 57 -
Ring Gear Bolts 129-142 95-105 -
Pinion Nut Minimum 272 200 -
Pinion Mate Shaft Screw 16.25 12 -
Axle Bearing Retainer Plate
61 45 -
Nuts
3 - 66 REAR AXLE - 198RBI WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)

SPECIAL TOOLS

Wrench C-3281
PULLER C-293-PA

ADAPTER 8352 Spanner Wrench 6958

ADAPTER C-293-40
INSTALLER 8112

CUP 8109
PLUG SP-3289

Puller C-452
WJ REAR AXLE - 198RBI 3 - 67
REAR AX LE - 1 9 8 RBI (Cont inue d)

REMOVER D-149

HANDLE C-4171

INSTALLER W-262

INSTALLER C-3716-A

PINION DEPTH 6774

INSTALLER D-130

INSTALLER D-146
TRAC-LOK TOOLS 6960

REMOVER C-4345 FIXTURE 6965

3 - 68 REAR AXLE - 198RBI WJ
REAR AX LE - 1 9 8 RBI (Cont inue d)

SHIMS DUMMY 8107 DIAL INDICATOR C-3339

SPREADER W-129-B SPLITTER BEARING 1130

ADAPTER KIT 6987 INSTALLER 7913-A

PILOT STUDS C-3288-B

PULLER 6790
WJ REAR AXLE - 198RBI 3 - 69

AX LE SH AFT S
REMOVAL
(1) P la ce t r a n sm ission in n eu t r a l.
(2) Ra ise a n d su ppor t veh icle.
(3) Rem ove wh eel a n d t ir e a ssem bly.
(4) Rem ove br a ke ca liper a n d r ot or.
(5) Rem ove n u t s h oldin g a xle r et a in er pla t e t o a xle
t u be fr om t h e r ea r of t h e a xle fla n ge.
(6) P u ll a xle sh a ft fr om t h e a xle wit h Slide H a m -
m er 7420 a n d Ada pt er 6790. Mou n t t h e a da pt er t o
t h e a xle wit h lu g n u t s.

NOTE: The axle bearing race is normally loose in

the axle tube.

INSTALLATION
(1) In sa ll a xle in t o t h e a xle t u be wit h t h e fla t a r ea
of t h e r et a in er pla t e u pwa r d.
(2) In ser t r et a in in g pla t e st u ds in t o t h e br a ke
ba ckin g pla t e a n d a xle t u be fla n ge.
(3) In st a ll r et a in er n u t s a n d t igh t en n u t s t o 61
N·m (45 ft . lbs.).
(4) In st a ll t h e br a ke r ot or a n d ca liper.
(5) In st a ll wh eel a n d t ir e.
(6) Ch eck a n d fill t h e differ en t ia l wit h gea r lu br i-
ca n t .
(7) Lower veh icle. Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
AX LE BEARI N GS/SEALS 3 - RETAINING PLATE
4 - RETAINING RING
REMOVAL
(1) Rem ove a xle sh a ft fr om veh icle.

NOTE: The axle bearing race is normally loose in

the axle tube.

(2) Dr ill a sh a llow h ole in t o soft st eel a xle bea r in g

r et a in in g r in g wit h a 3/8 in . dr ill bit (F ig. 25). Use a
dr ill dept h st op t o a void m a r kin g t h e a xle.
(3) Wit h a cold ch isel cu t t h e r et a in in g r in g a cr oss
dr illed h ole. (F ig. 26)
(4) Slide r et a in in g r in g fr om a xle sh a ft .

Fig. 26 RETAINING RING

1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
3 - 70 REAR AXLE - 198RBI WJ
AX LE BEARI N GS/SEALS (Cont inue d)
(5) Rem ove a xle bea r in g fr om t h e sh a ft wit h , a
pr ess a n d Split t er 1130 pla ced bet ween t h e sea l a n d
bea r in g (F ig. 27).

Fig. 28 AXLE BEARING AND SEAL COMPONENTS

1 - RETAINING RING
2 - SEAL
3 - AXLE
Fig. 27 AXLE BEARING AND SEAL 4 - RETAINING PLATE
1 - SPLITTER 5 - AXLE BEARING
2 - AXLE
3 - BLOCKS
4 - PRESS PLATES

(6) Rem ove sea l fr om a xle.

(7) Rem ove r et a in in g pla t e fr om a xle sh a ft .

INSTALLATION
(1) Ver ify a xle sh a ft r et a in in g pla t e is fla t wit h a
st r a igh t edge.

NOTE: If the plate is warped or the studs are loose

in the plate replace the retaining plate.

(2) In st a ll r et a in in g pla t e on t h e a xle sh a ft (F ig.

28).
(3) Apply a coa t of m u lt i-pu r pose gr ea se on sea lin g
su r fa ce of a xle sea l.
(4) In st a ll sea l on t h e a xle sh a ft wit h ca vit y a wa y
fr om r et a in in g pla t e (F ig. 28).
(5) Lu br ica t e bea r in g wit h Mopa r Wh eel Bea r in g
Gr ea se or equ iva len t . Wipe excess gr ea se fr om t h e
bea r in g.
(6) In st a ll bea r in g on t h e a xle sh a ft wit h In st a ller
Fig. 29 PRESS BEARING ON AXLE
7913 a n d a pr ess (F ig. 29).
1 - PRESS RAM
2 - INSTALLER
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
WJ REAR AXLE - 198RBI 3 - 71
AX LE BEARI N GS/SEALS (Cont inue d)
(7) P r ess m et a l r et a in in g r in g on t o a xle sh a ft wit h
In st a ller 7913 a n d a pr ess (F ig. 30).
(8) In st a ll a xle in veh icle.

Fig. 31 PINION YOKE HOLDER

1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM

Fig. 30 BEARING RETAINING RING

1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - METAL RETAINING RING

PI N I ON SEAL
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove wh eel a n d t ir e a ssem blies.
(3) Rem ove br a ke ca liper s a n d r ot or s.
(4) Ma r k pr opeller sh a ft a n d pin ion yoke for
in st a lla t ion r efer en ce.
(5) Rem ove pr opeller sh a ft fr om t h e yoke.
(6) Rot a t e pin ion gea r a m in im u m of t en t im es a n d
ver ify pin ion r ot a t es sm oot h ly.
(7) Recor d r ot a t in g t or qu e of t h e pin ion gea r wit h
a n in ch pou n d dia l-t ype t or qu e wr en ch , for in st a lla -
t ion r efer en ce.
(8) H old t h e pin ion yoke wit h Spa n n er Wr en ch
6958 a n d r em ove t h e pin ion n u t a n d wa sh er (F ig.
31).
(9) Rem ove pin ion yoke wit h Rem over C-452 a n d
Wr en ch C-3281 (F ig. 32).
(10) Rem ove pin ion gea r sea l wit h Rem over
7794-A a n d slide h a m m er (F ig. 33).
Fig. 32 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - YOKE PULLER
INSTALLATION
(1) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lip of pin ion sea l a n d in st a ll sea l wit h a n a ppr opr ia t e
in st a ller (F ig. 34).
(2) In st a ll yoke on pin ion gea r wit h Scr ew 8112,
Cu p 8109 a n d Spa n n er Wr en ch 6958 (F ig. 35).
CAUTION: Do not exceed the minimum tightening
torque 271 N·m (200 ft. lbs.) when installing the pin-
ion yoke at this point. Damage to the collapsible
spacer or bearings may result.
(3) In st a ll yoke wa sh er a n d a n e w n u t on t h e pin -
ion gea r a n d t igh t en t h e n u t u n t il t h er e is zer o bea r-
in g en d-pla y.
3 - 72 REAR AXLE - 198RBI WJ
PI N I ON SEAL (Cont inue d)

Fig. 33 PINION SEAL

Fig. 35 PINION YOKE
1 - REMOVER
2 - SLIDE HAMMER 1 - PINION YOKE
3 - PINION SEAL 2 - DIFFERENTIAL HOUSING

Fig. 34 PINION SEAL

1 - HANDLE
2 - INSTALLER

(4) Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).

CAUTION: Never loosen pinion gear nut to decrease

pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be Fig. 36 PINION ROTATING TORQUE
installed. 1 - TORQUE WRENCH
2 - PINION YOKE
(5) Rot a t e t h e pin ion gea r a m in im u m of t en t im es
a n d ver ify pin ion r ot a t es sm oot h ly. Rot a t e pin ion
sh a ft a n in ch pou n d t or qu e wr en ch . Rot a t in g t or qu e
sh ou ld be equ a l t o r ecor ded r ea din g plu s a n a ddi-
t ion a l 0.56 N·m (5 in . lbs.) (F ig. 36).
WJ REAR AXLE - 198RBI 3 - 73
PI N I ON SEAL (Cont inue d)
(6) If t h e r ot a t in g t or qu e is low, u se Spa n n er
Wr en ch 6958 t o h old t h e pin ion yoke (F ig. 37), a n d
t igh t en t h e pin ion n u t in 6.8 N·m (5 ft . lbs.) in cr e-
m en t s u n t il t h e pr oper r ot a t in g t or qu e is a ch ieved.

Fig. 38 PINION YOKE HOLDER

1 - 1 in. PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM

Fig. 37 PINION SHAFT NUT

1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH

CAUTION: If maximum tightening torque is reached

prior to reaching required rotating torque, the col-
lapsible spacer may have been damaged. Replace
the collapsible spacer.

(7) In st a ll t h e pr opeller sh a ft wit h r efer en ce m a r ks

a lign ed.
(8) Add gea r lu br ica n t t o t h e differ en t ia l if n eces-
sa r y.
(9) In st a ll br a ke r ot or s a n d ca liper s.
(10) In st a ll wh eel a n d t ir e a ssem blies. Fig. 39 PINION YOKE PULLER
(11) Lower t h e veh icle. 1 - WRENCH
2 - PINION YOKE
3 - PULLER
COLLAPSI BLE SPACER
(9) Rem ove pin ion sh a ft sea l wit h Rem over 7794-A
REMOVAL
a n d slide h a m m er (F ig. 40).
(1) Ra ise a n d su ppor t t h e veh icle.
(10) Rem ove fr on t pin ion bea r in g u sin g a pa ir of
(2) Rem ove wh eel a n d t ir e a ssem blies.
pick t ools t o pu ll t h e bea r in g off t h e pin ion gea r
(3) Rem ove r ea r br a ke ca liper s a n d r ot or s.
sh a ft .
(4) Ma r k pr opeller sh a ft a n d pin ion yoke for
in st a lla t ion r efer en ce a n d r em ove pr opeller sh a ft . NOTE: If the pinion bearing becomes bound on the
(5) Rot a t e pin ion gea r a m in im u m of t en t im es a n d pinion shaft, lightly tap the end of the shaft with a
ver ify pin ion r ot a t es sm oot h ly. rawhide/rubber mallet.
(6) Recor d r ot a t e t or qu e of t h e pin ion gea r, wit h a n
in ch pou n d t or qu e wr en ch . (11) Rem ove t h e colla psible spa cer.
(7) H old pin ion yoke wit h Spa n n er Wr en ch 6958
a n d r em ove pin ion n u t a n d wa sh er (F ig. 38). INSTALLATION
(8) Rem ove pin ion yoke wit h Rem over C-452 a n d (1) In st a ll a n e w colla psible spa cer on pin ion
Wr en ch C-3281 (F ig. 39). sh a ft .
(2) In st a ll pin ion fr on t bea r in g on t h e pin ion sh a ft .
3 - 74 REAR AXLE - 198RBI WJ
COLLAPSI BLE SPACER (Cont inue d)

Fig. 40 PINION SEAL REMOVER

1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL

(3) Apply a ligh t coa t in g of gea r lu br ica n t on t h e

lip of pin ion sea l a n d in st a ll sea l wit h a n a ppr opr ia t e
in st a ller (F ig. 41). Fig. 42 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH

t h e r ot a t in g t or qu e fr equ en t ly t o a void over cr u sh in g

t h e colla psible spa cer (F ig. 44).

NOTE: If more than 474 N·m (350 ft. lbs.) torque is

required to crush the collapsible spacer, the spacer
is defective and must be replaced.

Fig. 41 PINION SEAL INSTALLER

1 - HANDLE
2 - INSTALLER

(4) In st a ll yoke wit h Scr ew 8112, Cu p 8109 a n d

Spa n n er Wr en ch 6958 (F ig. 42).
(5) In st a ll yoke wa sh er a n d n e w n u t on t h e pin ion
gea r. Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).

CAUTION: Never loosen pinion gear nut to decrease

pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed. Fig. 43 PINION NUT
1 - SPANNER WRENCH
(6) Usin g yoke wit h Spa n n er Wr en ch 6958 a n d a 2 - PIPE
t or qu e wr en ch set a t 474 N·m (350 ft . lbs.), (F ig. 43) 3 - TORQUE WRENCH
slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.) in cr e-
m en t s u n t il t h e r ot a t in g t or qu e is a ch ieved. Mea su r e
WJ REAR AXLE - 198RBI 3 - 75
COLLAPSI BLE SPACER (Cont inue d)
(7) Ch eck r ot a t in g t or qu e wit h a n in ch pou n d (6) Not e t h e r efer en ce let t er s st a m ped on t h e bea r in g
t or qu e wr en ch (F ig. 44). Th e r ot a t in g t or qu e of t h e ca ps a n d h ou sin g m a ch in ed sea lin g su r fa ce (F ig. 45).
pin ion gea r sh ou ld be, t h e r ea din g r ecor ded du r in g
r em ova l plu s a n a ddit ion a l 0.56 N·m (5 in . lbs.).

Fig. 45 BEARING CAP REFERENCE

1 - REFERENCE LETTERS
2 - REFERENCE LETTERS

(7) Loosen t h e differ en t ia l bea r in g ca p bolt s.

(8) P osit ion Spr ea der W-129-B wit h Ada pt er Kit
6987B on differ en t ia l loca t in g h oles (F ig. 46). In st a ll
h olddown cla m ps a n d t igh t en t h e t u r n bu ckle fin ger-
Fig. 44 PINION ROTATING TORQUE t igh t .
1 - TORQUE WRENCH
2 - PINION YOKE

(8) In st a ll pr opeller sh a ft wit h r efer en ce m a r ks

a lign .
(9) In st a ll r ea r br a ke ca liper s a n d r ot or s (Refer t o
5 - BRAKE S/H YDRAULIC/ME CH ANICAL/ROTORS
- INSTALLATION).
(10) Add gea r lu br ica n t , if n ecessa r y.
(11) In st a ll wh eel a n d t ir e a ssem blies.
(12) Rem ove su ppor t s a n d lower veh icle.

DI FFEREN T I AL
REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove fill h ole plu g fr om t h e differ en t ia l
h ou sin g cover.
(3) Rem ove differ en t ia l h ou sin g cover a n d dr a in
flu id.
(4) Clea n t h e h ou sin g ca vit y wit h flu sh in g oil, ligh t
Fig. 46 SPREADER LOCATION
en gin e oil or lin t fr ee clot h .
1 - DIFFERENTIAL HOUSING
NOTE: Do not use water, steam, kerosene or gaso- 2 - DOWEL
3 - SAFETY HOLD DOWN
line for cleaning.
4 - SPREADER
5 - TURNBUCKLE
(5) Rem ove a xle sh a ft s.
3 - 76 REAR AXLE - 198RBI WJ
DI FFEREN T I AL (Cont inue d)
(9) In st a ll a P ilot St u d C-3288-B a t t h e left side of
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
opposit e side of t h e h ou sin g (F ig. 47) a n d zer o t h e
in dica t or.

CAUTION: Never spread the housing over 0.38 mm

(0.015 in). If housing is over-spread, it could dis-
torted and damaged the housing.

Fig. 48 SPREAD DIFFERENTIAL HOUSING

1 - DIAL INDICATOR
2 - SPREADER

Fig. 47 DIAL INDICATOR LOCATION

1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD

(10) Spr ea d h ou sin g en ou gh t o r em ove t h e differ-

en t ia l ca se fr om t h e h ou sin g. Mea su r e t h e dist a n ce
wit h t h e dia l in dica t or (F ig. 48).
(11) Rem ove t h e dia l in dica t or.
(12) Wh ile h oldin g t h e differ en t ia l ca se in posit ion ,
r em ove t h e differ en t ia l bea r in g ca p bolt s a n d ca ps.
(13) Rem ove differ en t ia l fr om t h e h ou sin g a n d t a g
differ en t ia l bea r in g cu ps t o in dica t e loca t ion (F ig. 49).
(14) Rem ove spr ea der fr om h ou sin g.

Fig. 49 DIFFERENTIAL CASE REMOVAL

1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
WJ REAR AXLE - 198RBI 3 - 77
DI FFEREN T I AL (Cont inue d)

DISASSEMBLY ASSEMBLY
(1) Rem ove pin ion sh a ft lock scr ew (F ig. 50). (1) In st a ll differ en t ia l side gea r s a n d t h r u st wa sh -
er s.
(2) In st a ll differ en t ia l pin ion gea r s a n d t h r u st
wa sh er s.
(3) In st a ll t h e pin ion m a t e sh a ft .
(4) Align h ole in t h e pin ion m a t e sh a ft wit h t h e
h ole in t h e differ en t ia l ca se a n d in st a ll t h e pin ion
m a t e sh a ft lock scr ew.
(5) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t .

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Fig. 50 SHAFT LOCK SCREW Backlash) to determine the proper shim selection.
1 - LOCK SCREW
2 - PINION SHAFT (1) P osit ion Spr ea der W-129-B wit h Ada pt er set
6987 on differ en t ia l h ou sin g loca t in g h oles. In st a ll
t h e h olddown cla m ps a n d t igh t en t h e t ool t u r n bu ckle
(2) Rem ove pin ion sh a ft .
fin ger-t igh t .
(3) Rot a t e differ en t ia l side gea r s a n d r em ove dif-
(2) In st a ll a P ilot St u d C-3288-B a t t h e left side of
fer en t ia l pin ion s a n d t h r u st wa sh er s (F ig. 51).
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
opposit e side of t h e h ou sin g a n d zer o t h e in dica t or.

CAUTION: Never spread the housing over 0.38 mm

(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.

(3) Spr ea d h ou sin g en ou gh t o in st a ll t h e ca se in

t h e h ou sin g.
(4) Rem ove t h e dia l in dica t or.
(5) In st a ll differ en t ia l ca se in h ou sin g (F ig. 52).
Ver ify differ en t ia l bea r in g cu ps r em a in in posit ion on
t h e bea r in gs a n d pr eloa d sh im s a r e bet ween t h e fa ce
of t h e bea r in g cu p a n d t h e h ou sin g. Ta p t h e differ en -
t ia l ca se t o en su r e bea r in gs cu ps a n d sh im s a r e
sea t ed in t h e h ou sin g.

CAUTION: On a Vari-lok" differential the oil feed

tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
Fig. 51 DIFFERENTIAL GEARS
(6) In st a ll bea r in g ca ps in t h eir or igin a l loca t ion s
1 - THRUST WASHER
2 - SIDE GEAR
(F ig. 54).
3 - DIFFERENTIAL PINION (7) Loosely in st a ll differ en t ia l bea r in g ca p bolt s.
(8) Rem ove a xle h ou sin g spr ea der.
(9) Tigh t en bea r in g ca p bolt s in a cr iss-cr oss pa t -
(4) Rem ove differ en t ia l side gea r s a n d t h r u st t er n t o 77 N·m (57 ft . lbs.).
wa sh er s. (10) In st a ll t h e a xle sh a ft s.
3 - 78 REAR AXLE - 198RBI WJ
DI FFEREN T I AL (Cont inue d)

Fig. 54 BEARING CAP REFERENCE

1 - REFERENCE LETTERS
2 - REFERENCE LETTERS

(11) Apply a 6.35m m (1/4 in .) bea d of r ed Mopa r

Silicon e Ru bber Sea la n t or equ iva len t t o t h e h ou sin g
Fig. 52 SPREADER LOCATION
cover (F ig. 55).
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE

Fig. 55 DIFFERENTIAL COVER - TYPICAL

1 - COVER
2 - SEALANT
3 - SEALANT BEAD

Fig. 53 VARI-LOK CAUTION: If cover is not installed within 3 to 5 min-

1 - ANTI-ROTATION TAB utes, the cover must be cleaned and new RTV
2 - OIL FEED TUBE applied or adhesion quality will be compromised.
WJ REAR AXLE - 198RBI 3 - 79
DI FFEREN T I AL (Cont inue d)
(12) In st a ll cover a n d t igh t en bolt s in a cr iss-cr oss
pa t t er n t o 41 N·m (30 ft . lbs.).
(13) Refill t h e differ en t ia l wit h Mopa r H ypoid
Gea r Lu br ica n t or equ iva len t t o bot t om of t h e fill
plu g h ole.
(14) In st a ll fill h ole plu g.
(15) Rem ove su ppor t a n d lower t h e veh icle.

DI FFEREN T I AL-T RAC-LOC

DIAGNOSIS AND TESTING
Th e m ost com m on pr oblem is a ch a t t er n oise wh en
t u r n in g cor n er s. Befor e r em ovin g t h e u n it for r epa ir,
dr a in , flu sh a n d r efill t h e a xle wit h t h e specified
lu br ica n t . A con t a in er of Mopa r Tr a c-lok! Lu br ica n t
(fr ict ion m odifier ) sh ou ld be a dded a ft er r epa ir ser- Fig. 56 ROTATING TORQUE TEST
vice or du r in g a lu br ica n t ch a n ge. 1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
Aft er ch a n gin g t h e lu br ica n t , dr ive t h e veh icle a n d 2 - TORQUE WRENCH
m a ke 10 t o 12 slow, figu r e-eigh t t u r n s. Th is m a n eu -
ver will pu m p lu br ica n t t h r ou gh t h e clu t ch es. Th is
will cor r ect t h e con dit ion in m ost in st a n ces. If t h e
ch a t t er per sist s, clu t ch da m a ge cou ld h a ve occu r r ed.

DIFFERENTIAL TEST
Th e differ en t ia l ca n be t est ed wit h ou t r em ovin g t h e
differ en t ia l ca se by m ea su r in g r ot a t in g t or qu e. Ma ke
su r e br a kes a r e n ot dr a ggin g du r in g t h is m ea su r e-
m en t .
(1) P la ce blocks in fr on t a n d r ea r of bot h fr on t
wh eels.
(2) Ra ise on e r ea r wh eel u n t il it is com plet ely off
t h e gr ou n d.
(3) E n gin e off, t r a n sm ission in n eu t r a l, a n d pa r k-
in g br a ke off.
(4) Rem ove wh eel a n d bolt Specia l Tool 6790 or
equ iva len t t ool t o st u ds.
(5) Use t or qu e wr en ch on specia l t ool t o r ot a t e
wh eel a n d r ea d r ot a t in g t or qu e (F ig. 56).
(6) If r ot a t in g t or qu e is less t h a n 41 N·m (56 ft .
lbs.) or m or e t h a n 271 N·m (200 ft . lbs.) on eit h er
wh eel t h e u n it sh ou ld be ser viced.
Fig. 57 DIFFERENTIAL CASE FIXTURE
DISASSEMBLY 1 - HOLDING FIXTURE
(1) Cla m p side gea r H oldin g F ixt u r e 6965 in a vise 2 - VISE
a n d posit ion t h e differ en t ia l ca se on t h e H oldin g F ix- 3 - DIFFERENTIAL
t u r e (F ig. 57).
3 - 80 REAR AXLE - 198RBI WJ
DI FFEREN T I AL-T RAC-LOC (Cont inue d)
(2) Rem ove r in g gea r if t h e r in g gea r is t o be (5) In st a ll a n d lu br ica t e St ep P la t e C-6960-3 (F ig.
r epla ced. Th e Tr a c-lok! differ en t ia l ca n be ser viced 60).
wit h t h e r in g gea r in st a lled.
(3) Rem ove t h e pin ion gea r m a t e sh a ft lock scr ew
(F ig. 58).

Fig. 58 MATE SHAFT LOCK SCREW

1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT

(4) Rem ove pin ion gea r m a t e sh a ft wit h a dr ift a n d

h a m m er (F ig. 59).
Fig. 60 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE

(6) Assem ble Th r ea ded Ada pt er C-6960-1 in t o t op

side gea r. Th r ea d F or cin g Scr ew C-6960-4 in t o
a da pt er u n t il it becom es cen t er ed in a da pt er pla t e.
(7) P osit ion a sm a ll scr ew dr iver in slot of
Th r ea ded Ada pt er Disc C-6960-1 (F ig. 61) t o pr even t
a da pt er fr om t u r n in g.
(8) In st a ll F or cin g Scr ew C-6960-4 a n d t igh t en
scr ew t o 122 N·m (90 ft . lbs.) m a xim u m t o com pr ess
Belleville spr in gs in clu t ch pa cks (F ig. 62).
Fig. 59 PINION MATE SHAFT (9) Wit h a feeler ga u ge r em ove t h r u st wa sh er s
1 - PINION MATE SHAFT fr om beh in d t h e pin ion gea r s (F ig. 63).
2 - SIDE GEAR (10) In ser t Tu r n in g Ba r C-6960-2 in t o t h e pin ion
3 - DRIFT m a t e sh a ft h ole in t h e ca se (F ig. 64).
4 - PINION MATE GEAR (11) Loosen t h e F or cin g Scr ew in sm a ll in cr em en t s
u n t il t h e clu t ch pa ck t en sion is r elieved a n d t h e dif-
fer en t ia l ca se ca n be t u r n ed u sin g Tu r n in g Ba r.
(12) Rot a t e differ en t ia l ca se u n t il t h e pin ion gea r s
ca n be r em oved.
(13) Rem ove pin ion gea r s fr om differ en t ia l ca se.
(14) Rem ove F or cin g Scr ew, St ep P la t e a n d
Th r ea ded Ada pt er.
WJ REAR AXLE - 198RBI 3 - 81
DI FFEREN T I AL-T RAC-LOC (Cont inue d)

Fig. 63 PINION GEAR THRUST WASHER

1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 61 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - FORCING SCREW
6 - THREAD ADAPTER DISC

Fig. 64 PINION GEARS

1 - PINION GEARS
2 - TURNING BAR

Fig. 62 COMPRESS BELLEVILLE SPRING

1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
3 - 82 REAR AXLE - 198RBI WJ
DI FFEREN T I AL-T RAC-LOC (Cont inue d)
(15) Rem ove t op side gea r, clu t ch pa ck r et a in er NOTE: Dished plate is position with the convex side
a n d clu t ch pa ck. Keep pla t es in cor r ect or der du r in g against the side gear.
r em ova l (F ig. 65).

Fig. 66 CLUTCH PACK

1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
Fig. 65 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE (3) P osit ion a ssem bled clu t ch disc pa cks on t h e
2 - RETAINER side gea r h u bs.
3 - SIDE GEAR AND CLUTCH DISC PACK
(4) In st a ll clu t ch pa ck a n d side gea r in t h e r in g
gea r side of t h e differ en t ia l ca se (F ig. 67).Ve rify
(16) Rem ove differ en t ia l ca se fr om t h e H oldin g F ix- c lu tc h p a c k re ta in in g c lip s a re in p o s itio n a n d
t u r e. Rem ove side gea r, clu t ch pa ck r et a in er a n d clu t ch s e a te d in th e c a s e p o c k e ts .
pa ck. Keep pla t es in cor r ect or der du r in g r em ova l.

CLEANING
Clea n a ll com pon en t s in clea n in g solven t a n d dr y
com pon en t s wit h com pr essed a ir.

INSPECTION
In spect clu t ch pa ck pla t es for wea r, scor in g or da m -
a ge. Repla ce bot h clu t ch pa cks if a n y on e com pon en t
in eit h er pa ck is da m a ged. In spect side a n d pin ion
gea r s for cr a cks ch ips or da m a ge a n d r epla ce a s n ec-
essa r y. In spect differ en t ia l ca se a n d pin ion sh a ft a n d
r epla ce if wor n or da m a ged.

ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
Fig. 67 CLUTCH PACK AND LOWER SIDE GEAR
(1) Lu br ica t e com pon en t s wit h gea r lu br ica n t .
1 - DIFFERENTIAL CASE
(2) Assem ble clu t ch discs in t o pa cks a n d secu r e
2 - SIDE GEAR AND CLUTCH PACK
disc pa cks wit h r et a in in g clips (F ig. 66).
WJ REAR AXLE - 198RBI 3 - 83
DI FFEREN T I AL-T RAC-LOC (Cont inue d)
(5) P osit ion t h e differ en t ia l ca se on t h e H oldin g (15) In st a ll pin ion gea r m a t e sh a ft a n d a lign h oles
F ixt u r e 6965. in sh a ft a n d ca se.
(6) In st a ll lu br ica t ed St ep P la t e C-6960-3 in lower (16) In st a ll pin ion m a t e sh a ft lock scr ew fin ger
side gea r (F ig. 68). t igh t t o h old sh a ft du r in g differ en t ia l in st a lla t ion .
(17) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t .

DI FFEREN T I AL CASE
BEARI N GS
REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove differ en t ia l ca se fr om a xle h ou sin g.
(3) Rem ove bea r in gs fr om t h e differ en t ia l ca se
wit h P u ller /P r ess C-293-PA, Ada pt er 8352 a n d P lu g
SP -3289 (F ig. 69).

Fig. 68 CLUTCH PACK AND UPPER SIDE GEAR

1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE

(7) In st a ll t h e u pper side gea r a n d clu t ch disc pa ck

(F ig. 68).
(8) H old a ssem bly in posit ion . In ser t Th r ea ded
Ada pt er C-6960-1 in t o t op side gea r.
(9) In st a ll F or cin g Scr ew C-6960-4 a n d t igh t en
scr ew t o sligh t ly com pr ess clu t ch disc.
(10) P la ce pin ion gea r s in posit ion in side gea r s
a n d ver ify t h a t t h e pin ion m a t e sh a ft h ole is a lign ed.
(11) Rot a t e ca se wit h Tu r n in g Ba r C-6960-2 u n t il
t h e pin ion m a t e sh a ft h oles in pin ion gea r s a lign Fig. 69 Differential Bearing
wit h h oles in ca se. It m a y be n ecessa r y t o sligh t ly 1 - ADAPTERS
t igh t en t h e for cin g scr ew in or der t o in st a ll t h e pin - 2 - BEARING
ion gea r s. 3 - DIFFERENTIAL
(12) Tigh t en for cin g scr ew t o 122 N·m (90 ft . lbs.) 4 - PLUG
5 - PULLER
m a xim u m t o com pr ess t h e Belleville spr in gs.
(13) Lu br ica t e a n d in st a ll t h r u st wa sh er s beh in d
pin ion gea r s a n d a lign wa sh er s wit h a sm a ll scr ew
dr iver. In ser t m a t e sh a ft in t o ea ch pin ion gea r t o ver-
ify a lign m en t .
(14) Rem ove F or cin g Scr ew, St ep P la t e a n d
Th r ea ded Ada pt er.
3 - 84 REAR AXLE - 198RBI WJ
DI FFEREN T I AL CASE BEARI N GS (Cont inue d)

INSTALLATION (6) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l

ca se.
NOTE: If differential side bearings or differential (7) Dr ive r in g gea r fr om differ en t ia l ca se wit h a
case are replaced, differential side bearing shim r a wh ide h a m m er (F ig. 71).
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.

(1) In st a ll differ en t ia l side bea r in gs wit h In st a ller

C-3716-A a n d H a n dle C-4171 (F ig. 70).

Fig. 71 RING GEAR

1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER

(8) H old t h e pin ion yoke wit h Spa n n er Wr en ch

6958 a n d r em ove t h e pin ion yoke n u t a n d wa sh er
(F ig. 72).

Fig. 70 Differential Side Bearing

1 - INSTALLER
2 - HANDLE

(2) In st a ll differ en t ia l in a xle h ou sin g.

(3) Rem ove su ppor t a n d lower veh icle.

PI N I ON GEAR/RI N G GEAR
REMOVAL Fig. 72 PINION YOKE HOLDER
1 - 1 in. PIPE
NOTE: The ring and pinion gears are serviced as a
2 - PINION YOKE
matched set. Never replace one gear without the
3 - HOLDER
other gear. 4 - LOWER CONTROL ARM

(1) Ra ise a n d su ppor t veh icle.

(2) Ma r k pin ion yoke a n d pr opeller sh a ft for
in st a lla t ion r efer en ce.
(3) Discon n ect pr opeller sh a ft fr om pin ion yoke
a n d t ie sh a ft t o u n der body.
(4) Rem ove differ en t ia l fr om t h e h ou sin g.
(5) P la ce differ en t ia l ca se in a vise wit h soft m et a l
ja w.
WJ REAR AXLE - 198RBI 3 - 85
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(9) Rem ove pin ion yoke fr om pin ion sh a ft wit h (11) Rem ove pin ion sea l wit h Rem over 7794-A a n d
Rem over C-452 a n d F la n ge Wr en ch C-3281 (F ig. 73). a slide h a m m er (F ig. 75).

Fig. 75 PINION SEAL

Fig. 73 PINION YOKE REMOVER 1 - REMOVER
1 - FLANGE WRENCH 2 - SLIDE HAMMER
2 - YOKE 3 - PINION SEAL
3 - REMOVER
(12) Rem ove oil slin ger, if equ ipped, a n d fr on t pin -
(10) Rem ove pin ion gea r fr om h ou sin g (F ig. 74). ion bea r in g.
(13) Rem ove fr on t pin ion bea r in g cu p wit h
Rem over C-4345 a n d H a n dle C-4171 (F ig. 76).

Fig. 74 PINION GEAR REMOVAL

1 - RAWHIDE HAMMER

Fig. 76 FRONT PINION BEARING CUP

1 - REMOVER
2 - HANDLE
3 - 86 REAR AXLE - 198RBI WJ
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(14) Rem ove r ea r bea r in g cu p (F ig. 77) wit h
Rem over D-149 a n d H a n dle C-4171.

Fig. 77 REAR PINION BEARING CUP Fig. 78 COLLAPSIBLE SPACER

1 - REMOVER 1 - COLLAPSIBLE SPACER
2 - HANDLE 2 - SHOULDER
3 - PINION GEAR
4 - SHIM
(15) Rem ove colla psible pr eloa d spa cer (F ig. 78). 5 - REAR BEARING
(16) Rem ove r ea r bea r in g fr om t h e pin ion wit h
P u ller /P r ess C-293-PA a n d Ada pt er s C-293-40 (F ig.
79).
(17) Rem ove dept h sh im s fr om t h e pin ion gea r
sh a ft a n d r ecor d sh im t h ickn ess.

INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.

Fig. 79 REAR PINION BEARING

1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
WJ REAR AXLE - 198RBI 3 - 87
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(1) Apply Mopa r Door E a se or equ iva len t lu br ica n t (4) In st a ll pin ion fr on t bea r in g a n d oil slin ger, if
t o ou t side su r fa ce of t h e pin ion bea r in g cu ps. equ ipped.
(2) In st a ll pin ion r ea r bea r in g cu p wit h In st a ller (5) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
D-146 a n d Dr iver H a n dle C-4171 (F ig. 80) a n d ver ify lip of pin ion sea l. In st a ll sea l wit h a n a ppr opr ia t e
cu p is sea t ed. in st a ller (F ig. 82).

Fig. 82 PINION SEAL INSTALLER

1 - HANDLE
2 - INSTALLER

(6) In st a ll dept h sh im on t h e pin ion gea r.

(7) In st a ll r ea r bea r in g a n d slin ger if equ ipped, on
t h e pin ion gea r wit h In st a ller W-262 a n d a pr ess
(F ig. 83).

Fig. 80 REAR PINION BEARING CUP

1 - INSTALLER
2 - HANDLE

(3) In st a ll pin ion fr on t bea r in g cu p wit h In st a ller

D-130 a n d H a n dle C-4171 (F ig. 81) a n d ver ify cu p is
sea t ed.

Fig. 83 REAR PINION BEARING

1 - PRESS
2 - INSTALLER
Fig. 81 FRONT PINION BEARING CUP 3 - PINION GEAR
4 - PINION BEARING
1 - INSTALLER
2 - HANDLE
3 - 88 REAR AXLE - 198RBI WJ
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(8) In st a ll a n e w colla psible pr eloa d spa cer on pin -
ion sh a ft a n d in st a ll pin ion gea r in t h e h ou sin g (F ig.
84).

Fig. 85 PINION YOKE INSTALLER

1 - INSTALLER
2 - PINION YOKE

Fig. 84 COLLAPSIBLE SPACER

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING

(9) In st a ll yoke wit h In st a ller C-3718 a n d Spa n n er

Wr en ch 6958 (F ig. 85).
(10) In st a ll t h e yoke wa sh er a n d a n ew n u t on t h e
pin ion gea r a n d t igh t en t h e pin ion n u t u n t il t h er e is
zer o bea r in g en d-pla y.
(11) Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).

CAUTION: Never loosen pinion gear nut to decrease

pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be Fig. 86 PINION NUT
installed. 1 - SPANNER WRENCH
2 - PIPE
(12) Usin g Spa n n er Wr en ch 6958 a n d a t or qu e 3 - TORQUE WRENCH
wr en ch set a t 474 N·m (350 ft . lbs.), (F ig. 86) slowly
t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s
(13) Ch eck bea r in g r ot a t in g t or qu e wit h a in ch
u n t il t h e r ot a t in g t or qu e is a ch ieved. Mea su r e t h e
pou n d t or qu e wr en ch (F ig. 87). Th e pin ion gea r r ot a t -
r ot a t in g t or qu e fr equ en t ly t o a void over cr u sh in g t h e
in g t or qu e sh ou ld be:
colla psible spa cer (F ig. 87).
• Or igin a l Bea r in gs: 1 t o 2.25 N·m (10 t o 20 in .
NOTE: If more than 474 N·m (350 ft. lbs.) torque is lbs.).
required to crush the collapsible spacer, the spacer • New Bea r in gs: 1.7 t o 3.9 N·m (15 t o 35 in . lbs.).
is defective and must be replaced. (14) In ver t t h e differ en t ia l ca se a n d st a r t t wo r in g
gea r bolt s. Th is will pr ovide ca se-t o-r in g gea r bolt
h ole a lign m en t .
WJ REAR AXLE - 198RBI 3 - 89
PI N I ON GEAR/RI N G GEAR (Cont inue d)

Fig. 87 PINION ROTATING TORQUE Fig. 88 RING GEAR

1 - PINION YOKE/COMPANION FLANGE 1 - TORQUE WRENCH
2 - INCH POUND TORQUE WRENCH 2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
(15) In ver t t h e differ en t ia l ca se in t h e vise.
(16) In st a ll n e w r in g gea r bolt s a n d a lt er n a t ely
t igh t en t o 136 N·m (100 ft . lbs.) (F ig. 88).

CAUTION: Never reuse the ring gear bolts. The

bolts can fracture causing extensive damage.

(17) In st a ll differ en t ia l in h ou sin g a n d ver ify dif-

fer en t ia l bea r in g pr eloa d, gea r m esh a n d con t a ct pa t -
t er n . Refer t o Aju st m en t s for pr ocedu r e.

CAUTION: When installing a Vari-lok" differential

(Fig. 89), the oil feed tube must point to the bottom
of the housing. If differential is installed with the oil
feed tube pointed toward the top, the anti-rotation
tabs will be damaged.

(18) In st a ll differ en t ia l cover a n d fill wit h gea r

lu br ica n t .
(19) In st a ll t h e pr opeller sh a ft wit h t h e r efer en ce
m a r ks a lign ed.
(20) Rem ove su ppor t s a n d lower veh icle.

Fig. 89 VARI-LOK
1 - ANTI-ROTATION TAB
2 - OIL FEED TUBE
3 - 90 REAR AXLE - 226RBA
REAR AX LE - 2 2 6 RBA
TABLE OF CONTENTS
page
REAR AXLE - 226RBA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 92
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 97
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 105
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 106
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
AXLE BEARINGS/SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
REAR AX LE - 2 2 6 RBA
DESCRIPTION
Th e Rea r Bea m -design Alu m in u m (RBA) a xle h ou s-
in g h a s a n a lu m in u m cen t er ca st in g (differ en t ia l
h ou sin g) wit h a xle sh a ft t u bes ext en din g fr om eit h er
side. Th e t u bes a r e pr essed in t o t h e differ en t ia l h ou s-
in g t o for m a on e-piece a xle h ou sin g. Th e a xle h a s
sem i-floa t in g a xle sh a ft s, m ea n in g t h a t veh icle loa d
is su ppor t ed by t h e a xle sh a ft a n d bea r in gs.
Th e differ en t ia l ca se is a on e-piece design . Differ en -
t ia l bea r in g pr eloa d a n d r in g gea r ba ckla sh is a dju st ed
wit h select ive sh im s. P in ion bea r in g pr eloa d is set a n d
m a in t a in ed by t h e u se of a colla psible spa cer. Th e cover
pr ovides a m ea n s for in spect ion a n d ser vice.
Opt ion a l Tr a c-Lok! differ en t ia l differ en t ia l h a s a
on e-piece differ en t ia l ca se, a n d t h e sa m e in t er n a l
com pon en t s a s a st a n da r d differ en t ia l, plu s t wo
clu t ch disc pa cks.
Opt ion a l Va r i-Lok! differ en t ia l h a s a on e-piece dif-
fer en t ia l ca se wh ich con t a in s t h e ger ot or pu m p
a ssem bly a n d t h e clu t ch m ech in ism . Th e u n it is ser-
viced on ly a s a n a ssem bly.
OPERATION
Th e a xle r eceives power fr om t h e t r a n sfer ca se
t h r ou gh t h e fr on t pr opeller sh a ft . Th e fr on t pr opeller
WJ
page
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 117
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 119
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 119
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 121
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
sh a ft is con n ect ed t o t h e pin ion gea r wh ich r ot a t es
t h e differ en t ia l t h r ou gh t h e gea r m esh wit h t h e r in g
gea r bolt ed t o t h e differ en t ia l ca se. Th e en gin e power
is t r a n sm it t ed t o t h e a xle sh a ft s t h r ou gh t h e pin ion
m a t e a n d side gea r s. Th e side gea r s a r e splin ed t o
t h e a xle sh a ft s.
STANDARD DIFFERENTIAL
Du r in g st r a igh t -a h ea d dr ivin g t h e differ en t ia l pin -
ion gea r s do n ot r ot a t e on t h e pin ion m a t e sh a ft . Th is
occu r s beca u se in pu t t or qu e a pplied t o t h e gea r s is
divided a n d dist r ibu t ed equ a lly bet ween t h e t wo side
gea r s. As a r esu lt , t h e pin ion gea r s r evolve wit h t h e
pin ion m a t e sh a ft bu t do n ot r ot a t e a r ou n d it (F ig. 1).
Wh en t u r n in g cor n er s, t h e ou t side wh eel m u st t r a vel
a gr ea t er dist a n ce t h a n t h e in side wh eel t o com plet e a
t u r n . Th e differ en ce m u st be com pen sa t ed for t o pr even t
t h e t ir es fr om scu ffin g a n d skiddin g t h r ou gh t u r n s. To
a ccom plish t h is, t h e differ en t ia l a llows t h e a xle sh a ft s
t o t u r n a t u n equ a l speeds (F ig. 2). In t h is in st a n ce, t h e
in pu t t or qu e a pplied t o t h e pin ion gea r s is n ot divided
equ a lly. Th e pin ion gea r s n ow r ot a t e a r ou n d t h e pin ion
m a t e sh a ft in opposit e dir ect ion s. Th is a llows t h e side
gea r a n d a xle sh a ft a t t a ch ed t o t h e ou t side wh eel t o
r ot a t e a t a fa st er speed.
WJ REAR AXLE - 226RBA 3 - 91
REAR AX LE - 2 2 6 RBA (Cont inue d)

Fig. 1 OPERATION-STRAIGHT AHEAD DRIVING

1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE

Fig. 3 TRAC-LOK LIMITED SLIP DIFFERENTIAL

1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK

Fig. 2 OPERATION-ON TURNS

1 - PINION GEARS ROTATE ON PINION SHAFT
TRAC-LOK" DIFFERENTIAL
Th e differ en t ia l clu t ch es a r e en ga ged by t wo con -
cu r r en t for ces. Th e fir st bein g t h e pr eloa d for ce
exer t ed t h r ou gh Belleville spr in g wa sh er s wit h in t h e
clu t ch pa cks. Th e secon d is t h e sepa r a t in g for ces gen -
er a t ed by t h e side gea r s a s t or qu e is a pplied t h r ou gh
t h e r in g gea r (F ig. 3).
Th is design pr ovides t h e differ en t ia l a ct ion n eeded
for t u r n in g cor n er s a n d for dr ivin g st r a igh t a h ea d
du r in g per iods of u n equ a l t r a ct ion . Wh en on e wh eel
looses t r a ct ion , t h e clu t ch pa cks t r a n sfer a ddit ion a l
t or qu e t o t h e wh eel h a vin g t h e m ost t r a ct ion . Th e
differ en t ia l r esist wh eel spin on bu m py r oa ds a n d
pr ovide m or e pu llin g power wh en on e wh eel looses
t r a ct ion . P u llin g power is pr ovided con t in u ou sly u n t il
bot h wh eels loose t r a ct ion . If bot h wh eels slip du e t o
u n equ a l t r a ct ion , t h e oper a t ion is n or m a l. In ext r em e
ca ses of differ en ces of t r a ct ion , t h e wh eel wit h t h e
lea st t r a ct ion m a y spin .
VARI-LOK" DIFFERENTIAL
In a st a n da r d differ en t ia l, if on e wh eel spin s, t h e
opposit e wh eel will gen er a t e on ly a s m u ch t or qu e a s
t h e spin n in g wh eel.
A ger ot or pu m p a n d clu t ch pa ck a r e u sed t o pr o-
vide t h e t or qu e t r a n sfer ca pa bilit y. On e a xle sh a ft is
splin ed t o t h e ger ot or pu m p a n d on e of t h e differ en -
t ia l side gea r s, wh ich pr ovides t h e in pu t t o t h e pu m p.
As a wh eel begin s t o lose t r a ct ion , t h e speed differ-
en t ia l is t r a n sm it t ed fr om on e side of t h e differ en t ia l
t o t h e ot h er t h r ou gh t h e side gea r s. Th e m ot ion of
on e side gea r r ela t ive t o t h e ot h er t u r n s t h e in n er
r ot or of t h e pu m p. Sin ce t h e ou t er r ot or of t h e pu m p
is gr ou n ded t o t h e differ en t ia l ca se, t h e in n er a n d
ou t er r ot or s a r e n ow m ovin g r ela t ive t o ea ch ot h er
3 - 92 REAR AXLE - 226RBA
REAR AX LE - 2 2 6 RBA (Cont inue d)
a n d t h er efor e cr ea t es pr essu r e in t h e pu m p. Th e t u n -
in g of t h e fr on t a n d r ea r a xle or ifices a n d va lves
in side t h e ger ot or pu m p is u n iqu e a n d ea ch syst em
in clu des a t or qu e-lim it in g pr essu r e r elief va lve t o
pr ot ect t h e clu t ch pa ck, wh ich a lso fa cilit a t es veh icle
con t r ol u n der ext r em e side-t o-side t r a ct ion va r ia -
t ion s. Th e r esu lt in g pr essu r e is a pplied t o t h e clu t ch
pa ck a n d t h e t r a n sfer of t or qu e is com plet ed.
Un der con dit ion s in wh ich opposit e wh eels a r e on
su r fa ces wit h widely differ en t fr ict ion ch a r a ct er ist ics,
Va r i-lok! deliver s fa r m or e t or qu e t o t h e wh eel on
t h e h igh er t r a ct ion su r fa ce t h a n do con ven t ion a l
Tr a c-lok! syst em s. Beca u se con ven t ion a l Tr a c-lok!
differ en t ia ls a r e in it ia lly pr e-loa ded t o a ssu r e t or qu e
t r a n sfer, n or m a l dr ivin g (wh er e in n er a n d ou t er
wh eel speeds differ du r in g cor n er in g, et c.) pr odu ces
t or qu e t r a n sfer du r in g even sligh t side-t o-side speed
va r ia t ion s. Sin ce t h ese devices r ely on fr ict ion fr om
t h is pr eloa d t o t r a n sfer t or qu e, n or m a l u se t en ds t o
ca u se wea r t h a t r edu ces t h e a bilit y of t h e differ en t ia l
t o t r a n sfer t or qu e over t im e. By design , t h e Va r i-lok!
syst em is less su bject t o wea r, r em a in in g m or e con -
sist en t over t im e in it s a bilit y t o t r a n sfer t or qu e. Th e
cou plin g a ssem bly is ser viced a s a u n it . F r om a ser-
vice st a n dpoin t t h e cou plin g a lso ben efit s fr om u sin g
t h e sa m e lu br ica n t su pply a s t h e r in g a n d pin ion
gea r s.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gea r n oise ca n be ca u sed by in su fficien t lu br i-
ca n t , in cor r ect ba ckla sh , t oot h con t a ct , wor n /da m a ged
gea r s, or t h e ca r r ier h ou sin g n ot h a vin g t h e pr oper
offset a n d squ a r en ess.
Gea r n oise u su a lly h a ppen s a t a specific speed
r a n ge. Th e n oise ca n a lso occu r du r in g a specific t ype
of dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a -
t ion , deceler a t ion , coa st , or con st a n t loa d.
Wh en r oa d t est in g, fir st wa r m -u p t h e a xle flu id by
dr ivin g t h e veh icle a t lea st 5 m iles a n d t h en a cceler-
a t e t h e veh icle t o t h e speed r a n ge wh er e t h e n oise is
t h e gr ea t est . Sh ift ou t -of-gea r a n d coa st t h r ou gh t h e
pea k-n oise r a n ge. If t h e n oise st ops or ch a n ges
gr ea t ly:
• Ch eck for in su fficien t lu br ica n t .
• In cor r ect r in g gea r ba ckla sh .
• Gea r da m a ge.
Differ en t ia l side gea r s a n d pin ion s ca n be ch ecked
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se
n oise du r in g st r a igh t -a h ea d dr ivin g wh en t h e gea r s
a r e u n loa ded. Th e side gea r s a r e loa ded du r in g veh i-
cle t u r n s. A wor n pin ion m a t e sh a ft ca n a lso ca u se a
sn a ppin g or a kn ockin g n oise.
WJ
BEARING NOISE
Th e a xle sh a ft , differ en t ia l a n d pin ion bea r in gs ca n
a ll pr odu ce n oise wh en wor n or da m a ged. Bea r in g
n oise ca n be eit h er a wh in in g, or a gr owlin g sou n d.
P in ion bea r in gs h a ve a con st a n t -pit ch n oise. Th is
n oise ch a n ges on ly wit h veh icle speed. P in ion bea r in g
n oise will be h igh er pit ch ed beca u se it r ot a t es a t a
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en -
t ia l. If bea r in g n oise occu r s, t h e r ea r pin ion bea r in g
is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is
h ea r d du r in g a coa st , t h e fr on t pin ion bea r in g is t h e
sou r ce.
Wor n or da m a ged differ en t ia l bea r in gs u su a lly pr o-
du ce a low pit ch n oise. Differ en t ia l bea r in g n oise is
sim ila r t o pin ion bea r in g n oise. Th e pit ch of differ en -
t ia l bea r in g n oise is a lso con st a n t a n d va r ies on ly
wit h veh icle speed.
Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion
wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges
wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle.
Tu r n t h e veh icle sh a r ply t o t h e left a n d t o t h e r igh t .
Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise
level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise
is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph .
LOW SPEED KNOCK
Low speed kn ock is gen er a lly ca u sed by a wor n
U-join t or by wor n side–gea r t h r u st wa sh er s. A wor n
pin ion sh a ft bor e will a lso ca u se low speed kn ock.
VIBRATION
Vibr a t ion a t t h e r ea r of t h e veh icle is u su a lly
ca u sed by a :
• Da m a ged dr ive sh a ft .
• Missin g dr ive sh a ft ba la n ce weigh t (s).
• Wor n or ou t -of-ba la n ce wh eels.
• Loose wh eel lu g n u t s.
• Wor n U-join t (s).
• Loose/br oken spr in gs.
• Da m a ged a xle sh a ft bea r in g(s).
• Loose pin ion gea r n u t .
• E xcessive pin ion yoke r u n ou t .
• Ben t a xle sh a ft (s).
Ch eck for loose or da m a ged fr on t -en d com pon en t s
or en gin e/t r a n sm ission m ou n t s. Th ese com pon en t s
ca n con t r ibu t e t o wh a t a ppea r s t o be a r ea r en d vibr a -
t ion . Do n ot over look en gin e a ccessor ies, br a cket s
a n d dr ive belt s.
All dr ivelin e com pon en t s sh ou ld be exa m in ed
befor e st a r t in g a n y r epa ir.
(Refer t o 22 - TIRE S/WH E E LS - DIAGNOSIS AND
TE STING)
WJ REAR AXLE - 226RBA 3 - 93
REAR AX LE - 2 2 6 RBA (Cont inue d)
DRIVELINE SNAP • E xcessive r in g gea r ba ckla sh .
A sn a p or clu n k n oise wh en t h e veh icle is sh ift ed • E xcessive side gea r t o ca se clea r a n ce.
in t o gea r (or t h e clu t ch en ga ged), ca n be ca u sed by: Th e sou r ce of a sn a p or a clu n k n oise ca n be det er-
• H igh en gin e idle speed. m in ed wit h t h e a ssist a n ce of a h elper. Ra ise t h e veh i-
• Tr a n sm ission sh ift oper a t ion . cle on a h oist wit h t h e wh eels fr ee t o r ot a t e. In st r u ct
• Loose en gin e/t r a n sm ission /t r a n sfer ca se m ou n t s. t h e h elper t o sh ift t h e t r a n sm ission in t o gea r. List en
• Wor n U-join t s. for t h e n oise, a m ech a n ics st et h oscope is h elpfu l in
• Loose spr in g m ou n t s. isola t in g t h e sou r ce of a n oise.
• Loose pin ion gea r n u t a n d yoke.

DI AGN OST I C CH ART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

3. End-play in pinion bearings.
4. Excessive gear backlash
between the ring gear and pinion.
5. Improper adjustment of pinion
gear bearings.
6. Loose pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
3. Refer to pinion pre-load
information and correct as
necessary.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Adjust the pinion bearings
pre-load.
6. Tighten the pinion yoke nut.
7. Inspect and replace as
necessary.

Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
3 - 94 REAR AXLE - 226RBA
REAR AX LE - 2 2 6 RBA (Cont inue d)
Condition
Differential Cracked
Differential Gears Scored
Loss Of Lubricant
Axle Overheating
Possible Causes
1. Improper adjustment of the
differential bearings.
2. Excessive ring gear backlash.
3. Vehicle overloaded.
4. Erratic clutch operation.
1. Insufficient lubrication.
2. Improper grade of lubricant.
3. Excessive spinning of one
wheel/tire.
1. Lubricant level too high.
2. Worn axle shaft seals.
3. Cracked differential housing.
4. Worn pinion seal.
5. Worn/scored yoke.
6. Axle cover not properly sealed.
1. Lubricant level low.
2. Improper grade of lubricant.
3. Bearing pre-loads too high.
4. Insufficient ring gear backlash.
WJ
Correction
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
1. Drain lubricant to the correct
level.
2. Replace seals.
3. Repair as necessary.
4. Replace seal.
5. Replace yoke and seal.
6. Remove, clean, and re-seal
cover.
1. Fill differential to correct level.
2. Fill differential with the correct
fluid type and quantity.
3. Re-adjust bearing pre-loads.
4. Re-adjust ring gear backlash.
WJ REAR AXLE - 226RBA 3 - 95
REAR AX LE - 2 2 6 RBA (Cont inue d)

Condition Possible Causes Correction

Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other

gears and bearings for possible
damage.

2. Erratic clutch operation. 2. Replace gears and examine the

3. Ice-spotted pavement.
4. Improper adjustments.
remaining parts for damage. Avoid
erratic clutch operation.
3. Replace gears and examine
remaining parts for damage.
4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct

2. Improper ring gear and pinion
adjustment.
3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
5. Loose pinion bearings.
6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap
bolts.
9. Housing not machined properly.
fluid type and quantity.
2. Check ring gear and pinion
contact pattern.
3. Replace gears with a matched
ring gear and pinion.
4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load.
6. Adjust differential bearing
pre-load.
7. Measure ring gear run-out.
Replace components as necessary.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Replace housing.

VARI-LOK" (9) Rot a t e t h e left wh eel by h a n d a t a m in im u m of

(1) P a r k t h e veh icle on a level su r fa ce or r a ise
veh icle on h oist so t h a t t h e veh icle is level.
(2) Rem ove t h e a xle fill plu g.
(3) Ver ify t h a t t h e a xle flu id level is cor r ect . Th e
flu id level is cor r ect if t h e flu id is level wit h t h e bot -
t om of t h e fill h ole.
(4) Sh ift t h e t r a n sfer ca se in t o t h e 4WD fu ll-t im e
posit ion .
(5) Dr ive t h e veh icle in a t igh t cir cle for 2 m in u t es
a t 5m ph t o fu lly pr im e t h e pu m p.
(6) Block t h e t ir es opposit e t h e a xle t o be t est ed t o
pr even t t h e veh icle fr om m ovin g.
(7) Sh ift t h e t r a n sfer ca se in t o t h e 4WD Low posi-
t ion a n d t h e t r a n sm ission in t o t h e P a r k posit ion .
(8) Ra ise bot h t h e wh eels of t h e a xle t o be t est ed
off of t h e gr ou n d.
on e r evolu t ion per secon d wh ile a n a ssist a n t r ot a t es
t h e r igh t wh eel in t h e opposit e dir ect ion .
(10) Th e left wh eel sh ou ld spin fr eely a t fir st a n d
t h en in cr ea se in r esist a n ce wit h in 5 r evolu t ion s u n t il
t h e wh eels ca n n ot be con t in u ou sly r ot a t ed in opposit e
dir ect ion s.
(11) Th e Va r i-lok! differ en t ia l h a s en ga ged pr op-
er ly if t h e wh eels ca n n ot be r ot a t ed in opposit e dir ec-
t ion s for a m om en t . Aft er t h e wh eels st op r ot a t in g for
a m om en t , t h e flu id pr essu r e will dr op in t h e differ-
en t ia l a n d t h e wh eels begin t o r ot a t e on ce a ga in .
(12) If t h e syst em does n ot oper a t e pr oper ly,
r epla ce t h e Va r i-lok! differ en t ia l.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) P osit ion a lift in g device u n der t h e a xle a n d
secu r e a xle.
3 - 96 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)
(3) Rem ove t h e wh eels a n d t ir es. at their normal ride position, vehicle ride height and
(4) Rem ove br a ke ca liper s a n d r ot or s. handling could be affected.
(5) Discon n ect pa r kin g br a ke ca bles fr om br a cket s (1) Ra ise a xle wit h lift a n d a lign coil spr in gs.
a n d lever. (2) In st a ll lower su spen sion a r m s in a xle br a cket s.
(6) Rem ove wh eel speed sen sor s. In st a ll n u t s a n d bolt s, do n ot t igh t en bolt s a t t h is
(7) Rem ove br a ke h ose a t t h e a xle ju n ct ion block. t im e.
Do n ot discon n ect t h e br a ke h ydr a u lic lin es a t t h e (3) In st a ll u pper su spen sion a r m on r ea r a xle ba ll
ca liper s. join t .
(8) Discon n ect t h e ven t h ose fr om t h e a xle sh a ft (4) In st a ll r ea r a xle ba ll join t n u t a n d t igh t en t o
t u be. 122 N·m (90 ft .lbs.) (F ig. 5).
(9) Ma r k pr opeller sh a ft a n d yokes for in st a lla t ion
r efer en ce.
(10) Rem ove pr opeller sh a ft .
(11) Discon n ect st a bilizer ba r lin ks.
(12) Rem ove u pper su spen sion a r m r ea r a xle ba ll
join t n u t .
(13) Sepa r a t e r ea r a xle ba ll join t fr om t h e u pper
su spen sion a r m wit h Rem over 8278 (F ig. 4).

Fig. 5 REAR BALL JOINT NUT

1 - UPPER SUSPENSION ARM
2 - REAR AXLE BALL JOINT
3 - REAR AXLE

(5) In st a ll t r a ck ba r a n d a t t a ch m en t bolt s, do n ot
t igh t en bolt s a t t h is t im e.
(6) In st a ll sh ock a bsor ber s a n d t igh t en n u t s t o 60
N·m (44 ft . lbs.).
(7) In st a ll st a bilizer ba r lin ks a n d t igh t en n u t s t o
36 N·m (27 ft . lbs.).
(8) In st a ll wh eel speed sen sor s.
(9) Con n ect pa r kin g br a ke ca ble t o br a cket s a n d
lever.
Fig. 4 REAR BALL JOINT (10) In st a ll br a ke r ot or s a n d ca liper s.
1 - REMOVER (11) In st a ll t h e br a ke h ose t o t h e a xle ju n ct ion
2 - UPPER SUSPENSION ARM block.
3 - BALL JOINT STUD
(12) In st a ll a xle ven t h ose.
(13) Align pr opeller sh a ft a n d pin ion yoke r efer-
(14) Discon n ect sh ock a bsor ber s fr om a xle. en ce m a r ks. In st a ll U-join t st r a ps a n d n u t s t igh t en t o
(15) Discon n ect t r a ck ba r. 19 N·m (14 ft . lbs.).
(16) Discon n ect lower su spen sion a r m s fr om t h e (14) In st a ll t h e wh eels a n d t ir es.
a xle br a cket s. (15) Add gea r lu br ica n t , if n ecessa r y.
(17) Sepa r a t e t h e a xle fr om t h e veh icle. (16) Rem ove su ppor t a n d lower t h e veh icle.
(17) Tigh t en lower su spen sion a r m bolt s t o 177
INSTALLATION N·m (130 ft . lbs.).
(18) Tigh t en t r a ck ba r bolt s t o 100 N·m (74 ft .
CAUTION: The weight of the vehicle must be sup- lbs.).
ported by the springs before suspension arms and
track bar fasteners are tightened. If springs are not
WJ REAR AXLE - 226RBA 3 - 97
REAR AX LE - 2 2 6 RBA (Cont inue d)

ADJUSTMENTS pla ced bet ween t h e r ea r pin ion bea r in g a n d t h e pin -

Rin g a n d pin ion gea r s a r e su pplied a s m a t ch ed ion gea r h ea d (F ig. 7).
set s on ly. Th e iden t ifyin g n u m ber s for t h e r in g a n d
pin ion gea r a r e et ch ed in t o t h e fa ce of ea ch gea r (F ig.
6). A plu s (+) n u m ber, m in u s (–) n u m ber or zer o (0) is
et ch ed in t o t h e fa ce of t h e pin ion gea r. Th is n u m ber
is t h e a m ou n t (in t h ou sa n dt h s of a n in ch ) t h e dept h
va r ies fr om t h e st a n da r d dept h set t in g of a pin ion
et ch ed wit h a (0). Th e st a n da r d set t in g fr om t h e cen -
t er lin e of t h e r in g gea r t o t h e ba ck fa ce of t h e pin ion
is 109.52 m m (4.312 in .). Th e st a n da r d dept h pr o-
vides t h e best gea r t oot h con t a ct pa t t er n . Refer t o
Ba ckla sh a n d Con t a ct P a t t er n in t h is sect ion for
a ddit ion a l in for m a t ion .

Fig. 7 ADJUSTMENT SHIM LOCATIONS

1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER

If a n ew gea r set is bein g in st a lled, n ot e t h e dept h

va r ia n ce et ch ed in t o bot h t h e or igin a l a n d r epla ce-
m en t pin ion . Add or su bt r a ct t h is n u m ber fr om t h e
t h ickn ess of t h e or igin a l dept h sh im /oil slin ger t o
com pen sa t e for t h e differ en ce in t h e dept h va r ia n ces.
Fig. 6 PINION GEAR ID NUMBERS Refer t o t h e P in ion Gea r Dept h Va r ia n ce ch a r t .
1 - PRODUCTION NUMBERS Not e wh er e Old a n d New P in ion Ma r kin g colu m n s
2 - DRIVE PINION GEAR DEPTH VARIANCE in t er sect . In t er sect in g figu r e r epr esen t s plu s or
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR m in u s t h e a m ou n t n eeded.
NUMBER) Not e t h e et ch ed n u m ber on t h e fa ce of t h e pin ion
gea r h ea d (–1, –2, 0, +1, +2, et c.). Th e n u m ber s r ep-
Com pen sa t ion for pin ion dept h va r ia n ce is r esen t t h ou sa n ds of a n in ch devia t ion fr om t h e st a n -
a ch ieved wit h a select sh im /oil ba ffle. Th e sh im s a r e da r d. If t h e n u m ber is n ega t ive, a dd t h a t va lu e t o t h e
r equ ir ed t h ickn ess of t h e dept h sh im s. If t h e n u m ber
is posit ive, su bt r a ct t h a t va lu e fr om t h e t h ickn ess of
t h e dept h sh im . If t h e n u m ber is 0 n o ch a n ge is n ec-
essa r y.
3 - 98 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)
PI N I ON GEAR DEPT H VARI AN CE

Original Pinion
Gear Depth Replacement Pinion Gear Depth Variance
Variance
!4 !3 !2 !1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003
0 +0.004 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004
!1 +0.003 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005
!2 +0.002 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006
!3 +0.001 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006 !0.007
!4 0 !0.001 !0.002 !0.003 !0.004 !0.005 !0.006 !0.007 !0.008

PINION DEPTH MEASUREMENT
Mea su r em en t s a r e t a ken wit h pin ion bea r in g cu ps
a n d pin ion bea r in gs in st a lled in t h e h ou sin g. Ta ke
m ea su r em en t s wit h P in ion Ga u ge Set 6775 a n d Dia l
In dica t or C-3339 (F ig. 8).
(1) Assem ble P in ion H eigh t Block 6739, P in ion
Block 8144 a n d r ea r pin ion bea r in g on t o Scr ew 6741
(F ig. 8).
(2) In ser t a ssem bled h eigh t ga u ge com pon en t s,
r ea r bea r in g a n d scr ew in t o t h e h ou sin g t h r ou gh pin -
ion bea r in g cu ps (F ig. 9).
(3) In st a ll fr on t pin ion bea r in g a n d Con e-n u t 6740
h a n d t igh t (F ig. 8).

Fig. 9 PINION HEIGHT BLOCK

1 - PINION BLOCK
Fig. 8 PINION GEAR DEPTH GAUGE 2 - PINION HEIGHT BLOCK

1 - DIAL INDICATOR
2 - ARBOR (4) P la ce Ar bor Disc 6927A on Ar bor D-115-3 in
3 - PINION HEIGHT BLOCK posit ion in t h e h ou sin g side bea r in g cr a dles (F ig. 10).
4 - CONE In st a ll differ en t ia l bea r in g ca ps in t h eir or igin a l posi-
5 - SCREW t ion s on a r bor discs a n d t igh t en ca p bolt s t o 85 N·m
6 - PINION BLOCK
(63 ft . lbs.).
7 - SCOOTER BLOCK
8 - ARBOR DISC
WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)
NOTE: Arbor Discs 6927A has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
Fig. 10 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
(5) Assem ble Dia l In dica t or C-3339 in t o Scoot er
Block D-115-2 a n d secu r e set scr ew.
(6) P la ce Scoot er Block/Dia l In dica t or in posit ion
in a xle h ou sin g so dia l pr obe a n d scoot er block a r e
flu sh a ga in st t h e r ea r wa r d su r fa ce of t h e pin ion
h eigh t block (F ig. 8). H old scoot er block in pla ce a n d
zer o t h e dia l in dica t or fa ce t o t h e poin t er. Tigh t en
dia l in dica t or fa ce lock scr ew.
(7) Wit h scoot er block st ill in posit ion a ga in st t h e
pin ion h eigh t block, slowly slide t h e dia l in dica t or
pr obe over t h e edge of t h e pin ion h eigh t block.
(8) Slide t h e dia l in dica t or pr obe a cr oss t h e ga p
bet ween t h e pin ion h eigh t block a n d t h e a r bor ba r
wit h t h e scoot er block a ga in st t h e pin ion h eigh t block
(F ig. 11). Wh en t h e dia l pr obe con t a ct s t h e a r bor ba r,
t h e dia l poin t er will t u r n clockwise. Br in g dia l
poin t er ba ck t o zer o a ga in st t h e a r bor ba r, do n ot
t u r n dia l fa ce. Con t in u e m ovin g t h e dia l pr obe t o t h e
cr est of t h e a r bor ba r a n d r ecor d t h e h igh est r ea din g.
If t h e dia l in dica t or ca n n ot a ch ieve t h e zer o r ea din g,
t h e r ea r bea r in g cu p or t h e pin ion dept h ga u ge set is
n ot in st a lled cor r ect ly.
(9) Select a dept h sh im equ a l t o t h e dia l in dica t or
r ea din g plu s t h e pin ion dept h va r ia n ce n u m ber
et ch ed in t h e fa ce of t h e pin ion (F ig. 6). F or exa m ple,
if t h e dept h va r ia n ce is –2, a dd +0.002 in . t o t h e dia l
in dica t or r ea din g.
REAR AXLE - 226RBA 3 - 99
Fig. 11 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
DIFFERENTIAL BEARING PRELOAD & GEAR
BACKLASH
Differ en t ia l side bea r in g pr eloa d a n d gea r ba ckla sh
is a ch ieved by select ive sh im s posit ion ed beh in d t h e
differ en t ia l side bea r in g con es. Th e pr oper sh im
t h ickn ess ca n be det er m in ed u sin g slip-fit Du m m y
Bea r in gs 6929-A in pla ce of t h e differ en t ia l side bea r-
in gs a n d a Dia l In dica t or C-3339. Befor e pr oceedin g
wit h t h e differ en t ia l bea r in g pr eloa d a n d gea r ba ck-
la sh m ea su r em en t s, m ea su r e t h e pin ion gea r dept h
a n d pr epa r e t h e pin ion for in st a lla t ion . E st a blish in g
pr oper pin ion gea r dept h is essen t ia l t o est a blish in g
gea r ba ckla sh a n d t oot h con t a ct pa t t er n s. Aft er t h e
over a ll sh im t h ickn ess t o t a ke u p differ en t ia l side
pla y is m ea su r ed, t h e pin ion is in st a lled, a n d t h e
gea r ba ckla sh sh im t h ickn ess is m ea su r ed. Th e over-
a ll sh im t h ickn ess is t h e t ot a l of t h e dia l in dica t or
r ea din g a n d t h e pr eloa d specifica t ion a dded t oget h er.
Th e gea r ba ckla sh m ea su r em en t det er m in es t h e
t h ickn ess of t h e sh im u sed on t h e r in g gea r side of
t h e differ en t ia l ca se. Su bt r a ct t h e gea r ba ckla sh sh im
t h ickn ess fr om t h e t ot a l over a ll sh im t h ickn ess a n d
select t h a t a m ou n t for t h e pin ion gea r side of t h e dif-
fer en t ia l (F ig. 12). Differ en t ia l sh im m ea su r em en t s
a r e per for m ed wit h t h e spr ea der W-129-B r em oved.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Rem ove differ en t ia l side bea r in gs fr om differ-
en t ia l ca se.
3 - 100 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)
(6) In st a ll t h e bea r in g ca ps in t h eir or igin a l posi-
t ion s a n d sn u g t h e bolt s (F ig. 14).

Fig. 12 ADJUSTMENT SHIM LOCATIONS

1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR Fig. 14 TIGHTEN BEARING CAP BOLTS
4 - DIFFERENTIAL BEARING SHIM 1 - BEARING CAPS
5 - COLLAPSIBLE SPACER 2 - HOUSING
3 - DIFFERENTIAL CASE
(2) In st a ll r in g gea r on differ en t ia l ca se a n d
t igh t en bolt s t o specifica t ion . (7) Wit h a dea d-blow h a m m er, sea t t h e differ en t ia l
(3) Insta ll Dummy Bea rings 6929-A on differentia l ca se. du m m y bea r in gs t o ea ch side of t h e h ou sin g (F ig. 15)
(4) In st a ll differ en t ia l ca se in t h e h ou sin g. a n d (F ig. 16).
(5) Recor d t h e t h ickn ess of Du m m y Sh im s 8107,
t h en in ser t t h e sh im s bet ween t h e du m m y bea r in gs
a n d t h e differ en t ia l h ou sin g (F ig. 13).

Fig. 15 SEAT DUMMY BEARING

1 - HAMMER
2 - HOUSING
3 - DIFFERENTIAL CASE

Fig. 13 DUMMY SHIM POINT

1 - DUMMY SHIMS
2 - HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
WJ REAR AXLE - 226RBA 3 - 101
REAR AX LE - 2 2 6 RBA (Cont inue d)
(10) P u sh a n d h old differ en t ia l ca se t o pin ion gea r
side of t h e h ou sin g a n d zer o dia l in dica t or (F ig. 18).

Fig. 16 SEAT DUMMY BEARING

1 - HOUSING
2 - HAMMER Fig. 18 DIFFERENTIAL CASE PINION GEAR SIDE
3 - DIFFERENTIAL CASE 1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
(8) Th r ea d P ilot St u d C-3288-B in t o r ea r cover bolt
4 - DIAL INDICATOR FACE
h ole below r in g gea r (F ig. 17).
(9) At t a ch t h e Dia l In dica t or C-3339 t o pilot st u d
a n d posit ion t h e in dica t or plu n ger on t h e fla t su r fa ce (11) P u sh a n d h old differ en t ia l ca se t o r in g gea r
bet ween t h e r in g gea r bolt s (F ig. 17). side of t h e h ou sin g a n d r ecor d dia l in dica t or r ea din g
(F ig. 19).

Fig. 19 DIFFERENTIAL CASE RING GEAR SIDE

1 - READ DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING

Fig. 17 DIFFERENTIAL SIDE PLAY MEASUREMENT (12) Add 0.0254 m m (0.001 in .) t o t h e zer o en d
1 - DIFFERENTIAL CASE pla y t ot a l. Th is n ew t ot a l r epr esen t s t h e t h ickn ess of
2 - HOUSING sh im s t o com pr ess, or pr eloa d t h e n ew bea r in gs wh en
3 - PILOT STUD t h e differ en t ia l is in st a lled.
4 - DIAL INDICATOR (13) Rot a t e dia l in dica t or ou t of t h e wa y on t h e
pilot st u d.
3 - 102 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)
(14) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om t h e h ou sin g.
(15) In st a ll t h e pin ion gea r in t h e h ou sin g. In st a ll
t h e pin ion yoke a n d est a blish t h e cor r ect pin ion
r ot a t in g t or qu e.
(16) In st a ll differ en t ia l ca se a n d Du m m y Bea r in gs
6929-A in t h e h ou sin g.
(17) In st a ll a sin gle du m m y sh im in t h e r in g gea r
side. In st a ll bea r in g ca ps a n d t igh t en bolt s sn u g.
(18) Sea t r in g gea r side du m m y bea r in g (F ig. 16).
(19) P osit ion t h e dia l in dica t or plu n ger on a fla t
su r fa ce bet ween t h e r in g gea r bolt h ea ds. (F ig. 17).
(20) P u sh a n d h old differ en t ia l ca se t owa r d pin ion
gea r a n d zer o dia l in dica t or (F ig. 20).

Fig. 21 DIFFERENTIAL CASE RING GEAR SIDE

1 - READ DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE

(23) Su bt r a ct ba ckla sh sh im t h ickn ess fr om t h e

t ot a l pr eloa d sh im t h ickn ess. Th e r em a in der is t h e
sh im t h ickn ess r equ ir ed on t h e pin ion side of t h e
h ou sin g.
(24) Rot a t e dia l in dica t or ou t of t h e wa y on pilot
st u d.
(25) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
Fig. 20 ZERO DIAL INDICATOR fr om t h e h ou sin g.
1 - DIAL INDICATOR FACE (26) In st a ll side bea r in gs a n d cu ps on differ en t ia l
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE ca se.
3 - PINION GEAR (27) In st a ll spr ea der W-129-B, u t ilizin g som e it em s
4 - HOUSING fr om Ada pt er Set 6987, on t h e h ou sin g a n d spr ea d
5 - DIFFERENTIAL CASE a xle open in g en ou gh t o r eceive differ en t ia l ca se.
(28) P la ce t h e bea r in g pr eloa d sh im s in t h e h ou s-
(21) P u sh a n d h old differ en t ia l ca se t o r in g gea r in g a ga in st t h e a xle t u bes.
side of t h e h ou sin g a n d r ecor d dia l in dica t or r ea din g (29) In st a ll differ en t ia l ca se in t o t h e h ou sin g.
(F ig. 21). Add Du m m y Sh im t h ickn ess t o t h is r ea d- (30) Rem ove spr ea der fr om h ou sin g.
in g. Th is will be t h e t ot a l sh im t h ickn ess t o a ch ieve (31) Rot a t e t h e differ en t ia l ca se sever a l t im es t o
zer o ba ckla sh . sea t t h e side bea r in gs.
(22) Su bt r a ct 0.152 m m (0.006 in .) fr om t h e dia l
in dica t or r ea din g t o com pen sa t e for ba ckla sh bet ween
r in g a n d pin ion gea r s. Th is t ot a l is t h e t h ickn ess
sh im r equ ir ed t o a ch ieve pr oper ba ckla sh .
WJ REAR AXLE - 226RBA 3 - 103
REAR AX LE - 2 2 6 RBA (Cont inue d)
(32) P osit ion t h e in dica t or plu n ger a ga in st a r in g
gea r t oot h (F ig. 22).
(33) P u sh a n d h old r in g gea r u pwa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e.
(34) Zer o dia l in dica t or fa ce t o poin t er.
(35) P u sh a n d h old r in g gea r down wa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e. Dia l in dica t or
r ea din g sh ou ld be bet ween 0.076 m m (0.003 in .) a n d
0.15 m m (0.006 in .). If ba ckla sh is n ot wit h in specifi-
ca t ion s t r a n sfer t h e n ecessa r y a m ou n t of sh im t h ick-
n ess fr om on e side of t h e h ou sin g t o t h e ot h er (F ig.
23).
(36) Ver ify differ en t ia l ca se a n d r in g gea r r u n ou t
by m ea su r in g r in g t o pin ion gea r ba ckla sh a t eigh t
loca t ion s a r ou n d t h e r in g gea r. Rea din gs sh ou ld n ot
va r y m or e t h a n 0.05 m m (0.002 in .). If r ea din gs va r y
m or e t h a n specified, t h e r in g gea r or t h e differ en t ia l
ca se is defect ive.
Aft er t h e pr oper ba ckla sh is a ch ieved, per for m
Gea r Con t a ct P a t t er n pr ocedu r e.

Fig. 23 BACKLASH SHIM

Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
GEAR CONTACT PATTERN
Th e r in g gea r a n d pin ion t eet h con t a ct pa t t er n s
will sh ow if t h e pin ion dept h is cor r ect in t h e a xle
h ou sin g. It will a lso sh ow if t h e r in g gea r ba ckla sh
h a s been a dju st ed cor r ect ly. Th e ba ckla sh ca n be
a dju st ed wit h in specifica t ion s t o a ch ieve desir ed
t oot h con t a ct pa t t er n s.
(1) Apply a t h in coa t of h ydr a t ed fer r ic oxide or
equ iva len t t o t h e dr ive a n d coa st side of t h e r in g gea r
t eet h .
(2) Wr a p, t wist a n d h old a sh op t owel a r ou n d t h e
pin ion yoke t o in cr ea se t h e t u r n in g r esist a n ce of t h e
pin ion . Th is will pr ovide a m or e dist in ct con t a ct pa t -
t er n .
(3) Wit h a boxed en d wr en ch on a r in g gea r bolt ,
r ot a t e t h e differ en t ia l ca se on e com plet e r evolu t ion in
bot h dir ect ion s wh ile a loa d is bein g a pplied fr om
sh op t owel.
Th e a r ea s on t h e r in g gea r t eet h wit h t h e gr ea t est
degr ee of con t a ct a ga in st t h e pin ion t eet h will squ ee-
gee t h e com pou n d t o t h e a r ea s wit h t h e lea st a m ou n t
of con t a ct . Not e a n d com pa r e pa t t er n s on t h e r in g
gea r t eet h t o Gea r Toot h Con t a ct P a t t er n s ch a r t (F ig.
24) a n d a dju st pin ion dept h a n d gea r ba ckla sh a s
n ecessa r y.
3 - 104 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)

Fig. 24 Gear Contact Patterns

WJ REAR AXLE - 226RBA 3 - 105
REAR AX LE - 2 2 6 RBA (Cont inue d)
DIFFERENTIAL BEARING PRELOAD CHECK Tor qu e t o r ot a t e t h e differ en t ia l a n d pin ion sh ou ld
Th e fin a l ch eck on t h e differ en t ia l a ssem bly befor e be t h e t or qu e t o r ot a t e t h e pin ion plu s 0.79-1.24 N·m
in st a llin g t h e a xles is t or qu e t o r ot a t e pin ion a n d dif- (7-11 in . lbs.).
fer en t ia l com bin ed. Th is will ver ify t h e cor r ect differ-
en t ia l bea r in g pr eloa d.

SPECIFICATIONS
AX LE SPECI FI CAT I ON S

DESCRIPTION SPECIFICATION
Axle Ratio 3.31, 3.55, 3.73, 3.91
Differential Bearing Preload 0.025 mm (0.001 in.)
Ring Gear Diameter 226 mm (8.9 in.)
Ring Gear Backlash 0.076.-0.15 mm (0.003-0.006 in.)
Pinion Gear Std. Depth 109.52 mm (4.312 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 2.8-4 N·m (25-35 in. lbs.)

T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Differential Cover Bolts 41 30 -
Bearing Cap Bolts 85 63 -
Ring Gear Bolts 136 100 -
Pinion Nut 298-380 220-280 -
Pinion Mate Shaft Screw 17.6 13 -
Axle Bearing Retainer Plate
61 45 -
Nuts
3 - 106 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)

SPECIAL TOOLS

Wrench Flange C-3281

Puller Set C-293-PA

Adapter 8353 Installer C-3718

Adapter 8353

Handle C-4171

Adapter Plug C-293-3

Remover C-4307

Remover C-452
WJ REAR AXLE - 226RBA 3 - 107
REAR AX LE - 2 2 6 RBA (Cont inue d)

Installer C-4308 Installer C-3972-A

Installer D-129
Installer C-4340

Pilot Studs C-3288-B

Remover D-103

Dial Indicator C-3339

Spreader

Trac-lok Tool C-4487

Installer 6448
3 - 108 REAR AXLE - 226RBA WJ
REAR AX LE - 2 2 6 RBA (Cont inue d)

Adapter 6790
Wrench Spanner 6958

Pinion Depth Set 6955 Fixture Holding 6963-A

Remover 7794-A
Bearing Dummy Set 6956

Splitter Bearing 1130

Gauge Block 8144

Shims Dummy 8107

Installer Gear/Bearing 7913-A
WJ REAR AXLE - 226RBA 3 - 109

AX LE SH AFT S
REMOVAL
(1) P la ce t r a n sm ission in n eu t r a l.
(2) Ra ise a n d su ppor t veh icle.
(3) Rem ove wh eel a n d t ir e a ssem bly.
(4) Rem ove br a ke ca liper a n d r ot or.
(5) Rem ove n u t s h oldin g a xle r et a in er pla t e t o a xle
t u be fr om t h e r ea r of t h e a xle fla n ge.
(6) P u ll a xle sh a ft fr om t h e a xle wit h Slide H a m -
m er 7420 a n d Ada pt er 6790. Mou n t t h e a da pt er t o
t h e a xle wit h lu g n u t s.

NOTE: The axle bearing race is normally loose in

the axle tube.

INSTALLATION
(1) In sa ll a xle in t o t h e a xle t u be wit h t h e fla t a r ea
of t h e r et a in er pla t e u pwa r d.
(2) In ser t r et a in in g pla t e st u ds in t o t h e br a ke
ba ckin g pla t e a n d a xle t u be fla n ge.
(3) In st a ll r et a in er n u t s a n d t igh t en n u t s t o 61
N·m (45 ft . lbs.).
(4) In st a ll t h e br a ke r ot or a n d ca liper.
(5) In st a ll wh eel a n d t ir e.
(6) Ch eck a n d fill t h e differ en t ia l wit h gea r lu br i-
ca n t .
(7) Lower veh icle. Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
AX LE BEARI N GS/SEALS 3 - RETAINING PLATE
4 - RETAINING RING
REMOVAL
(1) Rem ove a xle sh a ft fr om veh icle.

NOTE: The axle bearing race is normally loose in

the axle tube.

(2) Dr ill a sh a llow h ole in t o soft st eel a xle bea r in g

r et a in in g r in g wit h a 3/8 in . dr ill bit (F ig. 25). Use a
dr ill dept h st op t o a void m a r kin g t h e a xle.
(3) Wit h a cold ch isel cu t t h e r et a in in g r in g a cr oss
dr illed h ole. (F ig. 26)
(4) Slide r et a in in g r in g fr om a xle sh a ft .

Fig. 26 RETAINING RING

1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
3 - 110 REAR AXLE - 226RBA WJ
AX LE BEARI N GS/SEALS (Cont inue d)
(5) Rem ove a xle bea r in g fr om t h e sh a ft wit h , a
pr ess a n d Split t er 1130 pla ced bet ween t h e sea l a n d
bea r in g (F ig. 27).

Fig. 28 AXLE BEARING AND SEAL COMPONENTS

1 - RETAINING RING
2 - SEAL
3 - AXLE
Fig. 27 AXLE BEARING AND SEAL 4 - RETAINING PLATE
1 - SPLITTER 5 - AXLE BEARING
2 - AXLE
3 - BLOCKS
4 - PRESS PLATES

(6) Rem ove sea l fr om a xle.

(7) Rem ove r et a in in g pla t e fr om a xle sh a ft .

INSTALLATION
(1) Ver ify a xle sh a ft r et a in in g pla t e is fla t wit h a
st r a igh t edge.

NOTE: If the plate is warped or the studs are loose

in the plate replace the retaining plate.

(2) In st a ll r et a in in g pla t e on t h e a xle sh a ft (F ig.

28).
(3) Apply a coa t of m u lt i-pu r pose gr ea se on sea lin g
su r fa ce of a xle sea l.
(4) In st a ll sea l on t h e a xle sh a ft wit h ca vit y a wa y
fr om r et a in in g pla t e (F ig. 28).
(5) Lu br ica t e bea r in g wit h Mopa r Wh eel Bea r in g
Gr ea se or equ iva len t . Wipe excess gr ea se fr om t h e
bea r in g.
(6) In st a ll bea r in g on t h e a xle sh a ft wit h In st a ller
Fig. 29 PRESS BEARING ON AXLE
7913 a n d a pr ess (F ig. 29).
1 - PRESS RAM
2 - INSTALLER
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
WJ REAR AXLE - 226RBA 3 - 111
AX LE BEARI N GS/SEALS (Cont inue d)
(7) P r ess m et a l r et a in in g r in g on t o a xle sh a ft wit h
In st a ller 7913 a n d a pr ess (F ig. 30).
(8) In st a ll a xle in veh icle.

Fig. 31 Pinion Yoke Holder

1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM

Fig. 30 BEARING RETAINING RING

1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - METAL RETAINING RING

PI N I ON SEAL
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle. Fig. 32 Pinion Yoke Remover
(2) Rem ove wh eel a n d t ir e a ssem blies. 1 - FLANGE WRENCH
(3) Rem ove r ea r br a ke ca liper s a n d r ot or s. 2 - YOKE
3 - YOKE PULLER
(4) Ma r k pr opeller sh a ft a n d pin ion yoke for
in st a lla t ion r efer en ce.
(5) Rem ove t h e pr opeller sh a ft fr om t h e yoke.
(6) Rot a t e pin ion gea r t h r ee or fou r t im es a n d ver-
ify t h a t pin ion r ot a t es sm oot h ly.
(7) Recor d t or qu e n ecessa r y t o r ot a t e t h e pin ion
gea r wit h a in ch pou n d dia l-t ype t or qu e wr en ch .
(8) Usin g a sh or t piece of pipe a n d Spa n n er
Wr en ch 6958 t o h old t h e pin ion yoke a n d r em ove pin -
ion n u t a n d wa sh er (F ig. 31).
(9) Rem ove pin ion com pa n ion fla n ge wit h Rem over
C-452 a n d F la n ge Wr en ch C-3281. (F ig. 32)
3 - 112 REAR AXLE - 226RBA WJ
PI N I ON SEAL (Cont inue d)
(10) Rem ove pin ion sea l wit h Rem over 7794-A a n d
a slide h a m m er (F ig. 33).

Fig. 35 PINION YOKE INSTALLER

1 - INSTALLER
Fig. 33 Pinion Seal Remover
2 - PINION YOKE
1 - REMOVER 3 - DIFFERENTIAL HOUSING
2 - SLIDE HAMMER 4 - SPANNER WRENCH
3 - PINION SEAL

(4) Rot a t e t h e pin ion a m in im u m of t en t im es a n d

INSTALLATION ver ify pin ion r ot a t es sm oot h ly. Rot a t e t h e pin ion
(1) Apply a ligh t coa t in g of gea r lu br ica n t on t h e sh a ft u sin g a n in ch pou n d t or qu e wr en ch . Rot a t in g
lip of pin ion sea l. In st a ll sea l wit h a n a ppr opr ia t e in t or qu e sh ou ld be equ a l t o t h e r ea din g r ecor ded du r-
in st a ller (F ig. 34). in g r em ova l, plu s 0.56 N·m (5 in . lbs.) (F ig. 36).

Fig. 34 PINION SEAL INSTALLER

1 - HANDLE
2 - INSTALLER

(2) In st a ll yoke on t h e pin ion gea r wit h In st a ller

C-3718 a n d Spa n n er Wr en ch 6958 (F ig. 35).
(3) In st a ll a n e w n u t on t h e pin ion gea r. Tig h te n
th e n u t o n ly e n o u g h to re m o v e th e s h a ft e n d
p la y.
Fig. 36 PINION ROTATING TORQUE
CAUTION: Do not exceed the minimum tightening 1 - TORQUE WRENCH
torque 298 N·m (220 ft. lbs.) when installing the pin- 2 - PINION YOKE
ion yoke retaining nut at this point. Damage to col-
lapsible spacer or bearings may result.
WJ REAR AXLE - 226RBA 3 - 113
PI N I ON SEAL (Cont inue d)
(5) If r ot a t in g t or qu e is low, u se Wr en ch 6958 t o
h old t h e pin ion yoke (F ig. 37) a n d t igh t en t h e pin ion
sh a ft n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s u n t il
r ot a t in g t or qu e is a ch ieved.

CAUTION: If the maximum tightening torque is

reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.

Fig. 38 PINION YOKE HOLDER

1 - 1 in. PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM

Fig. 37 PINION SHAFT NUT

1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH

(6) In st a ll pr opeller sh a ft wit h r efer en ce m a r ks

a lign ed.
(7) F ill differ en t ia l wit h gea r lu br ica n t .
(8) In st a ll t h e br a ke r ot or s a n d ca liper s.
(9) In st a ll wh eel a n d t ir e a ssem blies.
(10) Lower t h e veh icle. Fig. 39 PINION YOKE PULLER
1 - WRENCH
2 - PINION YOKE
COLLAPSI BLE SPACER 3 - PULLER

REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove wh eel a n d t ir e a ssem blies.
(3) Rem ove r ea r br a ke ca liper s a n d r ot or s.
(4) Ma r k pr opeller sh a ft a n d pin ion yoke for
in st a lla t ion r efer en ce a n d r em ove pr opeller sh a ft .
(5) Rot a t e pin ion gea r a m in im u m of t en t im es a n d
ver ify pin ion r ot a t es sm oot h ly.
(6) Recor d r ot a t e t or qu e of t h e pin ion gea r, wit h a n
in ch pou n d t or qu e wr en ch .
(7) H old pin ion yoke wit h Spa n n er Wr en ch 6958
a n d r em ove pin ion n u t a n d wa sh er (F ig. 38).
(8) Rem ove pin ion yoke wit h Rem over C-452 a n d
Wr en ch C-3281 (F ig. 39).
3 - 114 REAR AXLE - 226RBA WJ
COLLAPSI BLE SPACER (Cont inue d)
(9) Rem ove pin ion sh a ft sea l wit h Rem over 7794-A
a n d slide h a m m er (F ig. 40).

Fig. 42 Pinion Yoke Installer

1 - INSTALLER
Fig. 40 PINION SEAL REMOVER
2 - PINION YOKE
1 - REMOVER 3 - DIFFERENTIAL HOUSING
2 - SLIDE HAMMER 4 - SPANNER WRENCH
3 - PINION SEAL

(5) In st a ll yoke wa sh er a n d n e w n u t on t h e pin ion

(10) Rem ove fr on t pin ion bea r in g u sin g a pa ir of pick
t ools t o pu ll t h e bea r in g off t h e pin ion gea r sh a ft .
NOTE: If the pinion bearing becomes bound on the
pinion shaft, lightly tap the end of the shaft with a
rawhide/rubber mallet.
(11) Rem ove t h e colla psible spa cer.
INSTALLATION
(1) In st a ll a n e w colla psible spa cer on pin ion
sh a ft .
(2) In st a ll pin ion fr on t bea r in g on t h e pin ion sh a ft .
(3) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lip of pin ion sea l a n d in st a ll sea l wit h a n a ppr opr ia t e
in st a ller (F ig. 41).
gea r. Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be installed.
(6) Usin g yoke wit h Spa n n er Wr en ch 6958 a n d a
t or qu e wr en ch set a t 380 N·m (280 ft . lbs.), (F ig. 43)
slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.) in cr e-
m en t s u n t il t h e r ot a t in g t or qu e is a ch ieved. Mea su r e
t h e r ot a t in g t or qu e fr equ en t ly t o a void over cr u sh in g
t h e colla psible spa cer (F ig. 44).

Fig. 41 PINION SEAL INSTALLER

1 - HANDLE
2 - INSTALLER
Fig. 43 PINION NUT
1 - SPANNER WRENCH
(4) In st a ll yoke wit h In st a ller C-3718 a n d Spa n n er 2 - PIPE
Wr en ch 6958 (F ig. 42). 3 - TORQUE WRENCH
WJ REAR AXLE - 226RBA 3 - 115
COLLAPSI BLE SPACER (Cont inue d)
NOTE: If more than 380 N·m (280 ft. lbs.) torque is (6) Not e t h e r efer en ce let t er s st a m ped on t h e bea r in g
required to crush the collapsible spacer, the spacer ca ps a n d h ou sin g m a ch in ed sea lin g su r fa ce (F ig. 45).
is defective and must be replaced.

(7) Ch eck r ot a t in g t or qu e wit h a n in ch pou n d

t or qu e wr en ch (F ig. 44). Th e r ot a t in g t or qu e of t h e
pin ion gea r sh ou ld be, t h e r ea din g r ecor ded du r in g
r em ova l plu s a n a ddit ion a l 0.56 N·m (5 in . lbs.).

Fig. 45 BEARING CAP REFERENCE

1 - REFERENCE LETTERS
2 - REFERENCE LETTERS

(7) Loosen t h e differ en t ia l bea r in g ca p bolt s.

(8) P osit ion Spr ea der W-129-B wit h Ada pt er Kit
6987B on differ en t ia l loca t in g h oles (F ig. 46). In st a ll
h olddown cla m ps a n d t igh t en t h e t u r n bu ckle fin ger-
t igh t .

Fig. 44 PINION ROTATING TORQUE

1 - TORQUE WRENCH
2 - PINION YOKE

(8) In st a ll pr opeller sh a ft wit h r efer en ce m a r ks a lign .

(9) In st a ll r ea r br a ke r ot or s a n d ca liper s.
(10) Add gea r lu br ica n t , if n ecessa r y.
(11) In st a ll wh eel a n d t ir e a ssem blies.
(12) Rem ove su ppor t s a n d lower veh icle.

DI FFEREN T I AL
REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove fill h ole plu g fr om t h e differ en t ia l
h ou sin g cover.
(3) Rem ove differ en t ia l h ou sin g cover a n d dr a in
flu id.
(4) Clea n t h e h ou sin g ca vit y wit h flu sh in g oil, ligh t
en gin e oil or lin t fr ee clot h . Fig. 46 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
NOTE: Do not use water, steam, kerosene or gaso- 2 - DOWEL
line for cleaning. 3 - SAFETY HOLD DOWN
4 - SPREADER
(5) Rem ove a xle sh a ft s. 5 - TURNBUCKLE
3 - 116 REAR AXLE - 226RBA WJ
DI FFEREN T I AL (Cont inue d)
(9) In st a ll a P ilot St u d C-3288-B a t t h e left side of
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
opposit e side of t h e h ou sin g (F ig. 47) a n d zer o t h e
in dica t or.

CAUTION: Never spread the housing over 0.38 mm

(0.015 in). If housing is over-spread, it could dis-
torted and damaged the housing.

Fig. 48 SPREAD DIFFERENTIAL HOUSING

1 - DIAL INDICATOR
2 - SPREADER

Fig. 47 DIAL INDICATOR LOCATION

1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD

(10) Spr ea d h ou sin g en ou gh t o r em ove t h e differ-

en t ia l ca se fr om t h e h ou sin g. Mea su r e t h e dist a n ce
wit h t h e dia l in dica t or (F ig. 48).
(11) Rem ove t h e dia l in dica t or.
(12) Wh ile h oldin g t h e differ en t ia l ca se in posit ion ,
r em ove t h e differ en t ia l bea r in g ca p bolt s a n d ca ps.
(13) Rem ove differ en t ia l fr om t h e h ou sin g a n d t a g
differ en t ia l bea r in g cu ps t o in dica t e loca t ion (F ig. 49).
(14) Rem ove spr ea der fr om h ou sin g.

Fig. 49 DIFFERENTIAL CASE REMOVAL

1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
WJ REAR AXLE - 226RBA 3 - 117
DI FFEREN T I AL (Cont inue d)

DISASSEMBLY ASSEMBLY
(1) Rem ove pin ion sh a ft lock scr ew (F ig. 50). (1) In st a ll differ en t ia l side gea r s a n d t h r u st wa sh -
er s.
(2) In st a ll differ en t ia l pin ion gea r s a n d t h r u st
wa sh er s.
(3) In st a ll t h e pin ion m a t e sh a ft .
(4) Align h ole in t h e pin ion m a t e sh a ft wit h t h e
h ole in t h e differ en t ia l ca se a n d in st a ll t h e pin ion
m a t e sh a ft lock scr ew.
(5) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t .

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Fig. 50 SHAFT LOCK SCREW Backlash) to determine the proper shim selection.
1 - LOCK SCREW
2 - PINION SHAFT (1) P osit ion Spr ea der W-129-B wit h Ada pt er set
6987 on differ en t ia l h ou sin g loca t in g h oles. In st a ll
t h e h olddown cla m ps a n d t igh t en t h e t ool t u r n bu ckle
(2) Rem ove pin ion sh a ft .
fin ger-t igh t .
(3) Rot a t e differ en t ia l side gea r s a n d r em ove dif-
(2) In st a ll a P ilot St u d C-3288-B a t t h e left side of
fer en t ia l pin ion s a n d t h r u st wa sh er s (F ig. 51).
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
opposit e side of t h e h ou sin g a n d zer o t h e in dica t or.

CAUTION: Never spread the housing over 0.38 mm

(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.

(3) Spr ea d h ou sin g en ou gh t o in st a ll t h e ca se in

t h e h ou sin g.
(4) Rem ove t h e dia l in dica t or.
(5) In st a ll differ en t ia l ca se in h ou sin g (F ig. 52).
Ver ify differ en t ia l bea r in g cu ps r em a in in posit ion on
t h e bea r in gs a n d pr eloa d sh im s a r e bet ween t h e fa ce
of t h e bea r in g cu p a n d t h e h ou sin g. Ta p t h e differ en -
t ia l ca se t o en su r e bea r in gs cu ps a n d sh im s a r e
sea t ed in t h e h ou sin g.

CAUTION: On a Vari-lok" differential the oil feed

tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
Fig. 51 DIFFERENTIAL GEARS
(6) In st a ll bea r in g ca ps in t h eir or igin a l loca t ion s
1 - THRUST WASHER
2 - SIDE GEAR
(F ig. 54).
3 - DIFFERENTIAL PINION (7) Loosely in st a ll differ en t ia l bea r in g ca p bolt s.
(8) Rem ove a xle h ou sin g spr ea der.
(9) Tigh t en bea r in g ca p bolt s in a cr iss-cr oss pa t -
(4) Rem ove differ en t ia l side gea r s a n d t h r u st t er n t o 77 N·m (57 ft . lbs.).
wa sh er s. (10) In st a ll t h e a xle sh a ft s.
3 - 118 REAR AXLE - 226RBA WJ
DI FFEREN T I AL (Cont inue d)

Fig. 54 BEARING CAP REFERENCE

1 - REFERENCE LETTERS
2 - REFERENCE LETTERS

(11) Apply a 6.35m m (1/4 in .) bea d of r ed Mopa r

Silicon e Ru bber Sea la n t or equ iva len t t o t h e h ou sin g
Fig. 52 SPREADER LOCATION
cover (F ig. 55).
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE

Fig. 55 DIFFERENTIAL COVER - TYPICAL

1 - COVER
2 - SEALANT
3 - SEALANT BEAD

Fig. 53 VARI-LOK CAUTION: If cover is not installed within 3 to 5 min-

1 - ANTI-ROTATION TAB utes, the cover must be cleaned and new RTV
2 - OIL FEED TUBE applied or adhesion quality will be compromised.
WJ REAR AXLE - 226RBA 3 - 119
DI FFEREN T I AL (Cont inue d)
(12) In st a ll cover a n d t igh t en bolt s in a cr iss-cr oss
pa t t er n t o 41 N·m (30 ft . lbs.).
(13) Refill t h e differ en t ia l wit h Mopa r H ypoid
Gea r Lu br ica n t or equ iva len t t o bot t om of t h e fill
plu g h ole.
(14) In st a ll fill h ole plu g.
(15) Rem ove su ppor t a n d lower t h e veh icle.

DI FFEREN T I AL - T RAC-LOK
DIAGNOSIS AND TESTING
Th e m ost com m on pr oblem is a ch a t t er n oise wh en
t u r n in g cor n er s. Befor e r em ovin g t h e u n it for r epa ir,
dr a in , flu sh a n d r efill t h e a xle wit h t h e specified
lu br ica n t . A con t a in er of Mopa r Tr a c-lok! Lu br ica n t
(fr ict ion m odifier ) sh ou ld be a dded a ft er r epa ir ser- Fig. 56 ROTATING TORQUE TEST
vice or du r in g a lu br ica n t ch a n ge. 1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
Aft er ch a n gin g t h e lu br ica n t , dr ive t h e veh icle a n d 2 - TORQUE WRENCH
m a ke 10 t o 12 slow, figu r e-eigh t t u r n s. Th is m a n eu -
ver will pu m p lu br ica n t t h r ou gh t h e clu t ch es. Th is
will cor r ect t h e con dit ion in m ost in st a n ces. If t h e
ch a t t er per sist s, clu t ch da m a ge cou ld h a ve occu r r ed.

DIFFERENTIAL TEST
Th e differ en t ia l ca n be t est ed wit h ou t r em ovin g t h e
differ en t ia l ca se by m ea su r in g r ot a t in g t or qu e. Ma ke
su r e br a kes a r e n ot dr a ggin g du r in g t h is m ea su r e-
m en t .
(1) P la ce blocks in fr on t a n d r ea r of bot h fr on t
wh eels.
(2) Ra ise on e r ea r wh eel u n t il it is com plet ely off
t h e gr ou n d.
(3) E n gin e off, t r a n sm ission in n eu t r a l, a n d pa r k-
in g br a ke off.
(4) Rem ove wh eel a n d bolt Specia l Tool 6790 or
equ iva len t t ool t o st u ds.
(5) Use t or qu e wr en ch on specia l t ool t o r ot a t e
wh eel a n d r ea d r ot a t in g t or qu e (F ig. 56).
(6) If r ot a t in g t or qu e is less t h a n 41 N·m (56 ft .
lbs.) or m or e t h a n 271 N·m (200 ft . lbs.) on eit h er
wh eel t h e u n it sh ou ld be ser viced.
Fig. 57 DIFFERENTIAL CASE FIXTURE
DISASSEMBLY 1 - HOLDING FIXTURE
(1) Cla m p side gea r H oldin g F ixt u r e 6965 in a vise 2 - VISE
a n d posit ion t h e differ en t ia l ca se on t h e H oldin g F ix- 3 - DIFFERENTIAL
t u r e (F ig. 57).
(2) Rem ove r in g gea r if t h e r in g gea r is t o be
r epla ced. Th e Tr a c-lok! differ en t ia l ca n be ser viced
wit h t h e r in g gea r in st a lled.
3 - 120 REAR AXLE - 226RBA WJ
DI FFEREN T I AL - T RAC-LOK (Cont inue d)
(3) Rem ove t h e pin ion gea r m a t e sh a ft lock scr ew
(F ig. 58).

Fig. 58 MATE SHAFT LOCK SCREW

1 - LOCK SCREW Fig. 60 Step Plate
2 - PINION GEAR MATE SHAFT
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
(4) Rem ove pin ion gea r m a t e sh a ft wit h a dr ift a n d 3 - STEP PLATE
h a m m er (F ig. 59).

Fig. 59 PINION MATE SHAFT

1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR

(5) In st a ll a n d lu br ica t e St ep P la t e C-6960-3 (F ig.

60).
(6) Assem ble Th r ea ded Ada pt er C-6960-1 in t o t op
side gea r. Th r ea d F or cin g Scr ew C-6960-4 in t o
Fig. 61 Threaded Adapter Disc
a da pt er u n t il it becom es cen t er ed in a da pt er pla t e.
1 - SOCKET
(7) P osit ion a sm a ll scr ew dr iver in slot of
2 - SLOT IN ADAPTER
Th r ea ded Ada pt er Disc C-6960-1 (F ig. 61) t o pr even t
3 - SCREWDRIVER
a da pt er fr om t u r n in g. 4 - STEP PLATE
5 - FORCING SCREW
6 - THREAD ADAPTER DISC
WJ
DI FFEREN T I AL - T RAC-LOK (Cont inue d)
(8) In st a ll F or cin g Scr ew C-6960-4 a n d t igh t en
scr ew t o 122 N·m (90 ft . lbs.) m a xim u m t o com pr ess
Belleville spr in gs in clu t ch pa cks (F ig. 62).
Fig. 62 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
(9) Wit h a feeler ga u ge r em ove t h r u st wa sh er s
fr om beh in d t h e pin ion gea r s (F ig. 63).
Fig. 63 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
REAR AXLE - 226RBA 3 - 121
(10) In ser t Tu r n in g Ba r C-6960-2 in t o t h e pin ion
m a t e sh a ft h ole in t h e ca se (F ig. 64).
(11) Loosen t h e F or cin g Scr ew in sm a ll in cr em en t s
u n t il t h e clu t ch pa ck t en sion is r elieved a n d t h e dif-
fer en t ia l ca se ca n be t u r n ed u sin g Tu r n in g Ba r.
(12) Rot a t e differ en t ia l ca se u n t il t h e pin ion gea r s
ca n be r em oved.
(13) Rem ove pin ion gea r s fr om differ en t ia l ca se.
Fig. 64 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
(14) Rem ove F or cin g Scr ew, St ep P la t e a n d
Th r ea ded Ada pt er.
(15) Rem ove t op side gea r, clu t ch pa ck r et a in er
a n d clu t ch pa ck. Keep pla t es in cor r ect or der du r in g
r em ova l (F ig. 65).
(16) Rem ove differ en t ia l ca se fr om t h e H oldin g
F ixt u r e. Rem ove side gea r, clu t ch pa ck r et a in er a n d
clu t ch pa ck. Keep pla t es in cor r ect or der du r in g
r em ova l.
CLEANING
Clea n a ll com pon en t s in clea n in g solven t a n d dr y
com pon en t s wit h com pr essed a ir.
INSPECTION
In spect clu t ch pa ck pla t es for wea r, scor in g or da m -
a ge. Repla ce bot h clu t ch pa cks if a n y on e com pon en t
in eit h er pa ck is da m a ged. In spect side a n d pin ion
gea r s for cr a cks ch ips or da m a ge a n d r epla ce a s n ec-
essa r y. In spect differ en t ia l ca se a n d pin ion sh a ft a n d
r epla ce if wor n or da m a ged.
ASSEMBLY
Clea n a ll com pon en t s in clea n in g solven t a n d dr y
com pon en t s wit h com pr essed a ir. In spect clu t ch pa ck
pla t es for wea r, scor in g or da m a ge. Repla ce bot h
clu t ch pa cks if a n y on e com pon en t in eit h er pa ck is
3 - 122 REAR AXLE - 226RBA WJ
DI FFEREN T I AL - T RAC-LOK (Cont inue d)

Fig. 66 CLUTCH PACK

1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
Fig. 65 SIDE GEARS AND CLUTCH DISCS
6 - PLATES
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK

da m a ged. In spect side gea r s a n d pin ion s. Repla ce

a n y gea r t h a t is wor n , cr a cked, ch ipped or da m a ged.
In spect differ en t ia l ca se a n d pin ion sh a ft . Repla ce if
wor n or da m a ged.

NOTE: New Plates and discs with fiber coating (no

grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.

(1) Lu br ica t e ea ch com pon en t wit h gea r lu br ica n t

befor e a ssem bly.
(2) Assem ble t h e clu t ch discs in t o pa cks a n d
secu r e disc pa cks wit h r et a in in g clips (F ig. 66).

NOTE: Dished plate is position with the convex side

against the side gear.

(3) P osit ion a ssem bled clu t ch disc pa cks on t h e

side gea r h u bs.
(4) In st a ll clu t ch pa ck a n d side gea r in t h e r in g
gea r side of t h e differ en t ia l ca se (F ig. 67). B e s u re
c lu tc h p a c k re ta in in g c lip s re m a in in p o s itio n
a n d a re s e a te d in th e c a s e p o c k e ts . Fig. 67 CLUTCH PACK AND LOWER SIDE GEAR
(5) P osit ion t h e differ en t ia l ca se on t h e H oldin g 1 - DIFFERENTIAL CASE
F ixt u r e 6965. 2 - LOWER SIDE GEAR AND CLUTCH DISC PACK
WJ REAR AXLE - 226RBA 3 - 123
DI FFEREN T I AL - T RAC-LOK (Cont inue d)
(6) In st a ll lu br ica t ed St ep P la t e C-6960-3 in lower (16) In st a ll pin ion m a t e sh a ft lock scr ew fin ger
side gea r (F ig. 68). t igh t t o h old sh a ft du r in g differ en t ia l in st a lla t ion .
(17) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t .

DI FFEREN T I AL CASE
BEARI N GS
REMOVAL
(1) Rem ove differ en t ia l ca se fr om a xle h ou sin g.
(2) Rem ove side bea r in gs fr om t h e differ en t ia l ca se
wit h P u ller /P r ess C-293-PA, Ada pt er s 8353 a n d P lu g
C-293-3 (F ig. 69).

Fig. 68 CLUTCH PACK AND UPPER SIDE GEAR

1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE

(7) In st a ll t h e u pper side gea r a n d clu t ch disc pa ck

(F ig. 68).
(8) H old a ssem bly in posit ion . In ser t Th r ea ded
Ada pt er C-6960-1 in t o t op side gea r.
(9) In st a ll F or cin g Scr ew C-6960-4 a n d t igh t en
scr ew t o sligh t ly com pr ess clu t ch disc.
(10) P la ce pin ion gea r s in posit ion in side gea r s
a n d ver ify t h a t t h e pin ion m a t e sh a ft h ole is a lign ed.
(11) Rot a t e ca se wit h Tu r n in g Ba r C-6960-2 u n t il Fig. 69 Differential Bearing Removal
t h e pin ion m a t e sh a ft h oles in pin ion gea r s a lign 1 - ADAPTERS
wit h h oles in ca se. It m a y be n ecessa r y t o sligh t ly 2 - BEARING
t igh t en t h e for cin g scr ew in or der t o in st a ll t h e pin - 3 - DIFFERENTIAL
ion gea r s. 4 - PLUG
5 - PULLER
(12) Tigh t en for cin g scr ew t o 122 N·m (90 ft . lbs.)
m a xim u m t o com pr ess t h e Belleville spr in gs.
(13) Lu br ica t e a n d in st a ll t h r u st wa sh er s beh in d INSTALLATION
pin ion gea r s a n d a lign wa sh er s wit h a sm a ll scr ew
dr iver. In ser t m a t e sh a ft in t o ea ch pin ion gea r t o ver- NOTE: If differential side bearings or differential
ify a lign m en t . case are replaced, differential side bearing shim
(14) Rem ove F or cin g Scr ew, St ep P la t e a n d requirements may change. Refer to Adjustments
Th r ea ded Ada pt er. (Differential Bearing Preload and Gear Backlash) for
(15) In st a ll pin ion gea r m a t e sh a ft a n d a lign h oles procedures.
in sh a ft a n d ca se.
3 - 124 REAR AXLE - 226RBA WJ
DI FFEREN T I AL CASE BEARI N GS (Cont inue d)
CAUTION: Vari-lok" plenum must be seated against (7) Dr ive r in g gea r fr om differ en t ia l ca se wit h a
the differential case prior to installing the ring gear r a wh ide h a m m er (F ig. 71).
side differential bearing.

(1) In st a ll differ en t ia l side bea r in gs wit h In st a ller

C-4340 a n d H a n dle C-4171 (F ig. 70).

Fig. 71 RING GEAR

1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER

(8) H old t h e pin ion yoke wit h Spa n n er Wr en ch

6958 a n d r em ove t h e pin ion yoke n u t a n d wa sh er
(F ig. 72).

Fig. 70 Install Differential Side Bearings

1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER

(2) In st a ll differ en t ia l ca se in t o t h e h ou sin g.

(3) Rem ove su ppor t a n d lower veh icle.

PI N I ON GEAR/RI N G GEAR
REMOVAL Fig. 72 Pinion Yoke Holder
NOTE: The ring and pinion gears are serviced as a 1 - PIPE
matched set. Never replace one gear without the 2 - PINION YOKE
3 - SPANNER WRENCH
other matched gear.
4 - LOWER CONTROL ARM
(1) Ra ise a n d su ppor t veh icle.
(2) Ma r k pin ion yoke a n d pr opeller sh a ft for
in st a lla t ion r efer en ce.
(3) Discon n ect pr opeller sh a ft fr om pin ion yoke
a n d t ie sh a ft t o u n der body.
(4) Rem ove differ en t ia l fr om a xle h ou sin g.
(5) P la ce differ en t ia l ca se in a vise wit h soft m et a l
ja w.
(6) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l
ca se.
WJ REAR AXLE - 226RBA 3 - 125
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(9) Rem ove pin ion yoke fr om pin ion sh a ft wit h (11) Rem ove pin ion sea l wit h Rem over 7794-A a n d
Rem over C-452 a n d Wr en ch C-3281 (F ig. 73). a slide h a m m er (F ig. 75).

Fig. 75 Pinion Seal Remover

Fig. 73 Pinion Yoke Remover 1 - REMOVER
1 - FLANGE WRENCH 2 - SLIDE HAMMER
2 - YOKE 3 - PINION SEAL
3 - YOKE PULLER
(12) Rem ove oil slin ger, if equ ipped, a n d fr on t pin -
(10) Rem ove pin ion gea r fr om h ou sin g (F ig. 74). ion bea r in g.
(13) Rem ove t h e fr on t pin ion bea r in g cu p wit h
Rem over D-103 a n d H a n dle C-4171 (F ig. 76).

Fig. 74 Pinion Gear

1 - RAWHIDE HAMMER

Fig. 76 Front Pinion Bearing Cup

1 - REMOVER
2 - HANDLE
3 - 126 REAR AXLE - 226RBA WJ
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(14) Rem ove r ea r bea r in g cu p fr om h ou sin g (F ig.
77) wit h Rem over C-4307 a n d H a n dle C-4171.

Fig. 77 Rear Pinion Bearing Cup Fig. 78 Collapsible Spacer

1 - REMOVER 1 - COLLAPSIBLE SPACER
2 - HANDLE 2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
(15) Rem ove colla psible pr eloa d spa cer (F ig. 78). 5 - REAR BEARING
(16) Rem ove r ea r bea r in g fr om t h e pin ion wit h
P u ller /P r ess C-293-PA a n d Ada pt er s C-293-42 (F ig.
79).
(17) Rem ove dept h sh im s fr om t h e pin ion gea r
sh a ft a n d r ecor d sh im t h ickn ess.

INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.

Fig. 79 Rear Pinion Bearing Puller

1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
WJ REAR AXLE - 226RBA 3 - 127
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(1) Apply Mopa r Door E a se or equ iva len t lu br ica n t (4) In st a ll pin ion fr on t bea r in g a n d oil slin ger, if
t o ou t side su r fa ce of pin ion bea r in g cu ps. equ ipped.
(2) In st a ll pin ion r ea r bea r in g cu p wit h In st a ller (5) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
C-4308 a n d Dr iver H a n dle C-4171 (F ig. 80) a n d ver- lip of pin ion sea l. In st a ll sea l wit h a n a ppr opr ia t e
ify cu p is sea t ed. (F ig. 82).

Fig. 82 PINION SEAL INSTALLER

1 - HANDLE
2 - INSTALLER

(6) In st a ll dept h sh im on t h e pin ion gea r.

(7) In st a ll r ea r bea r in g on t h e pin ion gea r wit h
In st a ller 6448 a n d a pr ess (F ig. 83).

Fig. 80 Rear Pinion Bearing Cup

1 - INSTALLER
2 - HANDLE

(3) In st a ll pin ion fr on t bea r in g cu p wit h In st a ller

D-129 a n d H a n dle C-4171 (F ig. 81) a n d ver ify cu p is
sea t ed.

Fig. 83 REAR PINION BEARING

1 - PRESS
2 - INSTALLER
3 - PINION GEAR
Fig. 81 FRONT PINION BEARING CUP 4 - PINION BEARING

1 - INSTALLER
2 - HANDLE
3 - 128 REAR AXLE - 226RBA WJ
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(8) In st a ll a n e w colla psible pr eloa d spa cer on pin - (10) In st a ll t h e yoke wa sh er a n d a n ew n u t on t h e
ion sh a ft a n d in st a ll pin ion gea r in t h e h ou sin g (F ig. pin ion gea r a n d t igh t en t h e pin ion n u t u n t il t h er e is
84). zer o bea r in g en d-pla y.
(11) Tigh t en t h e n u t t o 298 N·m (220 ft . lbs.).

CAUTION: Never loosen pinion gear nut to decrease

pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed.

(12) Usin g Spa n n er Wr en ch 6958 a n d a t or qu e

wr en ch set a t 380 N·m (280 ft . lbs.), (F ig. 86) slowly
t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s
u n t il t h e r ot a t in g t or qu e is a ch ieved. Mea su r e t h e
r ot a t in g t or qu e fr equ en t ly t o a void over cr u sh in g t h e
colla psible spa cer (F ig. 87).

NOTE: If more than 380 N·m (280 ft. lbs.) torque is

required to crush the collapsible spacer, the spacer
is defective and must be replaced.

Fig. 84 COLLAPSIBLE SPACER

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING

(9) In st a ll yoke wit h In st a ller C-3718 a n d Spa n n er

Wr en ch 6958 (F ig. 85).

Fig. 86 PINION NUT

1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH

Fig. 85 PINION YOKE INSTALLER

1 - INSTALLER
2 - PINION YOKE
3 - DIFFERENTIAL HOUSING
4 - SPANNER WRENCH
WJ REAR AXLE - 226RBA 3 - 129
PI N I ON GEAR/RI N G GEAR (Cont inue d)
(13) Ch eck bea r in g r ot a t in g t or qu e wit h a in ch
pou n d t or qu e wr en ch (F ig. 87). Th e pin ion gea r r ot a t -
in g t or qu e sh ou ld be:
• Or igin a l Bea r in gs: 1 t o 2.25 N·m (10 t o 20 in . lbs.).
• New Bea r in gs: 2.8 t o 4 N·m (25 t o 35 in . lbs.).

Fig. 88 RING GEAR

1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE

Fig. 87 PINION ROTATING TORQUE

1 - PINION YOKE/COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH

(14) In ver t t h e differ en t ia l ca se a n d st a r t t wo r in g

gea r bolt s. Th is will pr ovide ca se-t o-r in g gea r bolt
h ole a lign m en t .
(15) In ver t t h e differ en t ia l ca se in t h e vise.
(16) In st a ll n e w r in g gea r bolt s a n d a lt er n a t ely
t igh t en t o 129-142 N·m (95-105 ft . lbs.) (F ig. 88).

CAUTION: Never reuse the ring gear bolts. The

bolts can fracture causing extensive damage.

NOTE: If equipped with Veri-Lok" differential install

oil feed plenum and side bearing.

(17) In st a ll differ en t ia l in h ou sin g.

CAUTION: When installing a Vari-lok" differential

(Fig. 89), the oil feed tube must point to the bottom
of the housing. If differential is installed with the oil Fig. 89 VARI-LOK
feed tube pointed toward the top, the anti-rotation
1 - ANTI-ROTATION TAB
tabs will be damaged. 2 - OIL FEED TUBE

(18) Ver ify differ en t ia l bea r in g pr eloa d, gea r m esh

a n d con t a ct pa t t er n . Refer t o Aju st m en t s for pr ocedu r e. (20) In st a ll t h e pr opeller sh a ft wit h t h e r efer en ce
(19) In st a ll differ en t ia l cover a n d fill wit h gea r m a r ks a lign ed.
lu br ica n t . (21) Rem ove su ppor t s a n d lower veh icle.
WJ BRAKES 5-1

BRAKES
TABLE OF CON T EN T S

page page

BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

BRAK ES - BASE

TABLE OF CONTENTS
page page

BRAKES - BASE DESCRIPTION - REAR DISC BRAKE SHOES . 10

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 OPERATION
DIAGNOSIS AND TESTING - BASE BRAKE OPERATION - FRONT DISC BRAKE SHOES . 10
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 OPERATION - REAR DISC BRAKE SHOES . . 10
STANDARD PROCEDURE REMOVAL
STANDARD PROCEDURE - MANUAL REMOVAL- FRONT DISC BRAKE SHOES . . . 11
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL - REAR DISC BRAKE SHOES . . . . 12
STANDARD PROCEDURE - PRESSURE INSTALLATION
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION - FRONT DISC BRAKE
SPECIFICATIONS SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 6 INSTALLATION - REAR DISC BRAKE
TORQUE CHART ......................6 SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS DISC BRAKE CALIPERS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL
BRAKE FLUID LEVEL SWITCH REMOVAL - FRONT DISC BRAKE CALIPER . 14
REMOVAL .............................7 REMOVAL - REAR DISC BRAKE CALIPER . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DISASSEMBLY
RED BRAKE WARN INDICATOR SWITCH DISASSEMBLY - FRONT DISC BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DISASSEMBLY - REAR DISC BRAKE
DIAGNOSIS AND TESTING - RED BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . 7 CLEANING - DISC BRAKE CALIPER . . . . . . . . . 19
ADJUSTABLE PEDAL SWITCH INSPECTION - DISC BRAKE CALIPER . . . . . . . 19
REMOVAL .............................8 ASSEMBLY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ASSEMBLY - FRONT DISC BRAKE CALIPER . 20
BRAKE LINES ASSEMBLY - REAR DISC BRAKE CALIPER . 21
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION
DIAGNOSIS AND TESTING - BRAKE HOSES INSTALLATION - FRONT DISC BRAKE
AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE INSTALLATION - REAR DISC BRAKE
STANDARD PROCEDURE - DOUBLE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INVERTED FLARING . . . . . . . . . . . . . . . . . . . . 9 FLUID
STANDARD PROCEDURE - ISO FLARING . . . 9 DIAGNOSIS AND TESTING - BRAKE FLUID
BRAKE PADS / SHOES CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION SPECIFICATIONS
DESCRIPTION - FRONT DISC BRAKE BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 23
SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-2 BRAKES - BASE WJ

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 DIAGNOSIS AND TESTING - REAR DISC

MASTER CYLINDER BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 STANDARD PROCEDURE - DISC ROTOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - MASTER REMOVAL
CYLINDER/POWER BOOSTER . . . . . . . . . . . 24 REMOVAL - FRONT DISC BRAKE ROTOR . . 33
STANDARD PROCEDURE - MASTER REMOVAL - REAR DISC BRAKE ROTOR .. . 33
CYLINDER BLEEDING PROCEDURE .... . . 25 INSTALLATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 INSTALLATION - FRONT DISC BRAKE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
PEDAL INSTALLATION - REAR DISC BRAKE
DESCRIPTION ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION - STANDARD PEDAL . . . . . . . 25 PARKING BRAKE
DESCRIPTION - ADJUSTABLE PEDALS . . . . 25 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 DIAGNOSIS AND TESTING - PARKING BRAKE . 34
REMOVAL CABLES
REMOVAL - NON-ADJUSTABLE PEDAL .. . . 26 REMOVAL
REMOVAL - ADJUSTABLE PEDALS . . . . . . . . 27 REMOVAL - FRONT PARKING BRAKE
INSTALLATION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION - NON-ADJUSTABLE PEDAL . 28 REMOVAL - REAR PARKING BRAKE
INSTALLATION - ADJUSTABLE PEDALS . . . . 28 CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PEDAL MOTOR INSTALLATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION - FRONT PARKING BRAKE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
POWER BRAKE BOOSTER INSTALLATION - REAR PARKING BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
ROTORS SHOES
DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGNOSIS AND TESTING - FRONT DISC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . 31 ADJUSTMENTS - PARKING BRAKE SHOE . . . . 40

BRAK ES - BASE DIAGNOSIS AND TESTING - BASE BRAKE

DESCRIPTION
Du a l pist on disc br a ke ca liper s a r e u sed on t h e
fr on t . Sin gle pist on disc br a ke ca liper s a r e u sed on
t h e r ea r. Ven t ila t ed disc br a ke r ot or s a r e u sed on t h e
fr on t a n d solid r ot or s a r e u sed on t h e r ea r.
P ower br a ke a ssist is su pplied by a va cu u m oper-
a t ed, du a l dia ph r a gm power br a ke boost er. Th e m a s-
t er cylin der u sed for a ll a pplica t ion s h a s a n
a lu m in u m body a n d n ylon r eser voir wit h sin gle filler
ca p. A flu id level in dica t or is m ou n t ed t o t h e side of
t h e r eser voir.
Th e br a kin g for ce of t h e r ea r wh eels is con t r olled
by elect r on ic br a ke dist r ibu t ion (E BD). Th e E BD
fu n ct ion s like a r ea r pr opor t ion in g va lve. Th e E BD
syst em u ses t h e ABS syst em t o con t r ol t h e slip of t h e
r ea r wh eels in pa r t ia l br a kin g r a n ge. Th e br a kin g
for ce of t h e r ea r wh eels is con t r olled elect r on ica lly by
u sin g t h e in let a n d ou t let va lves loca t ed in t h e H CU.
F a ct or y in st a lled br a ke lin in gs on a ll m odels con -
sist s of or ga n ic ba se m a t er ia l com bin ed wit h m et a llic
pa r t icles.
SYSTEM
Ba se br a ke com pon en t s con sist of t h e br a ke sh oes,
ca liper s, r ea r pa r k br a ke dr u m s/r ot or s, fr on t br a ke
r ot or s, br a ke lin es, m a st er cylin der, boost er, H CU
a n d pa r kin g br a ke sh oes.
Br a ke dia gn osis in volves det er m in in g if t h e pr ob-
lem is r ela t ed t o a m ech a n ica l, h ydr a u lic, elect r ica l
or va cu u m oper a t ed com pon en t .
Th e fir st dia gn osis st ep is t h e pr elim in a r y ch eck.
PRELIMINARY BRAKE CHECK
(1) Ch eck con dit ion of t ir es a n d wh eels. Da m a ged
wh eels a n d wor n , da m a ged, or u n der in fla t ed t ir es
ca n ca u se pu ll, sh u dder, vibr a t ion , a n d a con dit ion
sim ila r t o gr a b.
WJ
BRAK ES - BASE (Cont inue d)
(2) If com pla in t wa s ba sed on n oise wh en br a kin g,
ch eck su spen sion com pon en t s. J ou n ce fr on t a n d r ea r
of veh icle a n d list en for n oise t h a t m igh t be ca u sed
by loose, wor n or da m a ged su spen sion or st eer in g
com pon en t s.
(3) In spect br a ke flu id level a n d con dit ion . Not e
t h a t t h e br a ke r eser voir flu id level will decr ea se in
pr opor t ion t o n or m a l lin in g wea r. Als o n o te th a t
bra k e flu id te n d s to d a rk e n o v e r tim e . Th is is
n o rm a l a n d s h o u ld n o t be m is ta k e n fo r c o n ta m -
in a tio n .
(a ) If flu id level is a bn or m a lly low, look for evi-
den ce of lea ks a t ca liper s, br a ke lin es, m a st er cyl-
in der, a n d H CU.
(b) If flu id a ppea r s con t a m in a t ed, dr a in ou t a
sa m ple t o exa m in e. Syst em will h a ve t o be flu sh ed
if flu id is sepa r a t ed in t o la yer s, or con t a in s a su b-
st a n ce ot h er t h a n br a ke flu id. Th e syst em sea ls,
cu ps, h oses, m a st er cylin der, a n d H CU will a lso
h a ve t o be r epla ced a ft er flu sh in g. Use clea n br a ke
flu id t o flu sh t h e syst em .
(4) Ch eck pa r kin g br a ke oper a t ion . Ver ify fr ee
m ovem en t a n d fu ll r elea se of ca bles a n d lever. Also
n ot e if veh icle wa s bein g oper a t ed wit h pa r kin g
br a ke pa r t ia lly a pplied.
(5) Ch eck br a ke peda l oper a t ion . Ver ify t h a t peda l
does n ot bin d a n d h a s a dequ a t e fr ee pla y. If peda l
la cks fr ee pla y, ch eck peda l a n d power boost er for
bein g loose or for bin d con dit ion . Do n ot r oa d t est
u n t il con dit ion is cor r ect ed.
(6) Ch eck boost er va cu u m ch eck va lve a n d h ose.
(7) If com pon en t s ch ecked a ppea r OK, r oa d t est
t h e veh icle.
ROAD TESTING
(1) If com pla in t in volved low br a ke peda l, pu m p
peda l a n d n ot e if it com es ba ck u p t o n or m a l h eigh t .
(2) Ch eck br a ke peda l r espon se wit h t r a n sm ission
in n eu t r a l a n d en gin e r u n n in g. P eda l sh ou ld r em a in
fir m u n der con st a n t foot pr essu r e.
(3) Du r in g r oa d t est , m a ke n or m a l a n d fir m br a ke
st ops in 25-40 m ph r a n ge. Not e fa u lt y br a ke oper a -
t ion su ch a s low peda l, h a r d peda l, fa de, peda l pu lsa -
t ion , pu ll, gr a b, dr a g, n oise, et c.
(4) At t em pt t o st op t h e veh icle wit h t h e pa r kin g
br a ke on ly (do n ot exceed 25 m ph ) a n d n ot e gr a b,
dr a g, n oise, et c.
PEDAL FALLS AWAY
A br a ke peda l t h a t fa lls a wa y u n der st ea dy foot
pr essu r e is gen er a lly t h e r esu lt of a syst em lea k. Th e
lea k poin t cou ld be a t a br a ke lin e, fit t in g, h ose, or
ca liper. If lea ka ge is sever e, flu id will be eviden t a t
or a r ou n d t h e lea kin g com pon en t .
BRAKES - BASE 5-3
In t er n a l lea ka ge (sea l by-pa ss) in t h e m a st er cylin -
der ca u sed by wor n or da m a ged pist on cu ps, m a y
a lso be t h e pr oblem ca u se.
An in t er n a l lea k in t h e ABS syst em m a y a lso be
t h e pr oblem wit h n o visu a l flu id lea k.
LOW PEDAL
If a low peda l is exper ien ced, pu m p t h e peda l sev-
er a l t im es. If t h e peda l com es ba ck u p, t h e m ost
likely ca u ses a r e wor n lin in gs, r ot or s, or ca liper s a r e
n ot slidin g on t h e slide pin s. Th e pr oper cou r se of
a ct ion is t o in spect a n d r epla ce a ll wor n com pon en t .
SPONGY PEDAL
A spon gy peda l is m ost oft en ca u sed by a ir in t h e
syst em . H owever su bst a n da r d br a ke h oses ca n ca u se
a spon gy peda l. Th e pr oper cou r se of a ct ion is t o
bleed t h e syst em , a n d r epla ce su bst a n da r d qu a lit y
br a ke h oses if su spect ed.
HARD PEDAL OR HIGH PEDAL EFFORT
A h a r d peda l or h igh peda l effor t m a y be du e t o
lin in g t h a t is wa t er soa ked, con t a m in a t ed, gla zed, or
ba dly wor n . Th e power boost er, ch eck va lve, ch eck
va lve sea l/gr om m et or va cu u m lea k cou ld a lso ca u se
a h a r d peda l or h igh peda l effor t .
PEDAL PULSATION
P eda l pu lsa t ion is ca u sed by com pon en t s t h a t a r e
loose, or beyon d t oler a n ce lim it s.
Th e pr im a r y ca u se of pu lsa t ion a r e disc br a ke
r ot or s wit h excessive la t er a l r u n ou t or t h ickn ess va r i-
a t ion . Ot h er ca u ses a r e loose wh eel bea r in gs or ca li-
per s a n d wor n , da m a ged t ir es.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Br a ke dr a g occu r s wh en t h e lin in g is in con st a n t
con t a ct wit h t h e r ot or or dr u m . Dr a g ca n occu r a t on e
wh eel, a ll wh eels, fr on t s on ly, or r ea r s on ly.
Dr a g is a pr odu ct of in com plet e br a ke r elea se.
Dr a g ca n be m in or or sever e en ou gh t o over h ea t t h e
lin in gs, r ot or s a n d pa r k br a ke dr u m s.
Min or dr a g will u su a lly ca u se sligh t su r fa ce ch a r r in g
of t h e lin in g. It ca n a lso gen er a t e h a r d spot s in r ot or s
a n d pa r k br a ke dr u m s fr om t h e over h ea t -cool down pr o-
cess. In m ost ca ses, t h e r ot or s, wh eels a n d t ir es a r e
qu it e wa r m t o t h e t ou ch a ft er t h e veh icle is st opped.
Sever e dr a g ca n ch a r t h e br a ke lin in g a ll t h e wa y
t h r ou gh . It ca n a lso dist or t a n d scor e r ot or s t o t h e
poin t of r epla cem en t . Th e wh eels, t ir es a n d br a ke
com pon en t s will be ext r em ely h ot . In sever e ca ses,
t h e lin in g m a y gen er a t e sm oke a s it ch a r s fr om over-
h ea t in g.
5-4 BRAKES - BASE
BRAK ES - BASE (Cont inue d)
Com m on ca u ses of br a ke dr a g a r e:
• P a r kin g br a ke pa r t ia lly a pplied.
• Loose/wor n wh eel bea r in g.
• Seized ca liper.
• Ca liper bin din g.
• Loose ca liper m ou n t in g.
• Mis-a ssem bled com pon en t s.
• Da m a ged br a ke lin es.
If br a ke dr a g occu r s a t t h e fr on t , r ea r or a ll
wh eels, t h e pr oblem m a y be r ela t ed t o a blocked m a s-
t er cylin der r et u r n por t , fa u lt y power boost er (bin ds-
does n ot r elea se) or t h e ABS syst em .
BRAKE FADE
Br a ke fa de is u su a lly a pr odu ct of over h ea t in g
ca u sed by br a ke dr a g. H owever, br a ke over h ea t in g
a n d r esu lt in g fa de ca n a lso be ca u sed by r idin g t h e
br a ke peda l, m a kin g r epea t ed h igh deceler a t ion st ops
in a sh or t t im e spa n , or con st a n t br a kin g on st eep
m ou n t a in r oa ds. Refer t o t h e Br a ke Dr a g in for m a t ion
in t h is sect ion for ca u ses.
BRAKE PULL
F r on t br a ke pu ll con dit ion cou ld r esu lt fr om :
• Con t a m in a t ed lin in g in on e ca liper
• Seized ca liper pist on
• Bin din g ca liper
• Loose ca liper
• Ru st y ca liper slide su r fa ces
• Im pr oper br a ke sh oes
• Da m a ged r ot or
• Wh eel a lign m en t .
• Tir e pr essu r e.
A wor n , da m a ged wh eel bea r in g or su spen sion com po-
n en t a r e fu r t h er ca u ses of pu ll. A da m a ged fr on t t ir e
(br u ised, ply sepa r a t ion ) ca n a lso ca u se pu ll.
A com m on a n d fr equ en t ly m isdia gn osed pu ll con di-
t ion is wh er e dir ect ion of pu ll ch a n ges a ft er a few
st ops. Th e ca u se is a com bin a t ion of br a ke dr a g fol-
lowed by fa de a t on e of t h e br a ke u n it s.
As t h e dr a ggin g br a ke over h ea t s, efficien cy is so
r edu ced t h a t fa de occu r s. Sin ce t h e opposit e br a ke
u n it is st ill fu n ct ion in g n or m a lly, it s br a kin g effect is
m a gn ified. Th is ca u ses pu ll t o swit ch dir ect ion in
fa vor of t h e n or m a lly fu n ct ion in g br a ke u n it .
An a ddit ion a l poin t wh en dia gn osin g a ch a n ge in
pu ll con dit ion con cer n s br a ke cool down . Rem em ber
t h a t pu ll will r et u r n t o t h e or igin a l dir ect ion , if t h e
dr a ggin g br a ke u n it is a llowed t o cool down (a n d is
n ot ser iou sly da m a ged).
REAR BRAKE DRAG OR PULL
Rea r dr a g or pu ll m a y be ca u sed by im pr oper ly
a dju st ed pa r k br a ke sh oes or seized pa r kin g br a ke
ca bles, con t a m in a t ed lin in g, ben t or bin din g sh oes or
im pr oper ly a ssem bled com pon en t s. Th is is pa r t icu -
la r ly t r u e wh en on ly on e r ea r wh eel is in volved.
WJ
H owever, wh en bot h r ea r wh eels a r e a ffect ed, t h e
m a st er cylin der or ABS syst em cou ld be a t fa u lt .
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Th is con dit ion is gen er a lly ca u sed by wa t er soa ked
lin in g. If t h e lin in g is on ly wet , it ca n be dr ied by
dr ivin g wit h t h e br a kes ver y ligh t ly a pplied for a
m ile or t wo. H owever, if t h e lin in g is bot h soa ked a n d
dir t con t a m in a t ed, clea n in g a n d or r epla cem en t will
be n ecessa r y.
BRAKE LINING CONTAMINATION
Br a ke lin in g con t a m in a t ion is m ost ly a pr odu ct of
lea kin g ca liper s or wor n sea ls, dr ivin g t h r ou gh deep
wa t er pu ddles, or lin in g t h a t h a s becom e cover ed wit h
gr ea se a n d gr it du r in g r epa ir. Con t a m in a t ed lin in g
sh ou ld be r epla ced t o a void fu r t h er br a ke pr oblem s.
WHEEL AND TIRE PROBLEMS
Som e con dit ion s a t t r ibu t ed t o br a ke com pon en t s
m a y a ct u a lly be ca u sed by a wh eel or t ir e pr oblem .
A da m a ged wh eel ca n ca u se sh u dder, vibr a t ion a n d
pu ll. A wor n or da m a ged t ir e ca n a lso ca u se pu ll.
NOTE: Propshaft angle can also cause vibration/
shudder.
Sever ely wor n t ir es wit h ver y lit t le t r ea d left ca n
pr odu ce a gr a b-like con dit ion a s t h e t ir e loses a n d
r ecover s t r a ct ion . F la t -spot t ed t ir es ca n ca u se vibr a -
t ion a n d gen er a t e sh u dder du r in g br a ke oper a t ion .
Tir e da m a ge su ch a s a sever e br u ise, cu t , ply sepa r a -
t ion , low a ir pr essu r e ca n ca u se pu ll a n d vibr a t ion .
BRAKE NOISES
Som e br a ke n oise is com m on on som e disc br a kes
du r in g t h e fir st few st ops a ft er a veh icle h a s been
pa r ked over n igh t or st or ed. Th is is pr im a r ily du e t o
t h e for m a t ion of t r a ce cor r osion (ligh t r u st ) on m et a l
su r fa ces. Th is ligh t cor r osion is t ypica lly clea r ed fr om
t h e m et a l su r fa ces a ft er a few br a ke a pplica t ion s
ca u sin g t h e n oise t o su bside.
BRAKE SQUEAK/SQUEAL
Br a ke squ ea k or squ ea l m a y be du e t o lin in gs t h a t
a r e wet or con t a m in a t ed wit h br a ke flu id, gr ea se, or oil.
Gla zed lin in gs a n d r ot or s wit h h a r d spot s ca n a lso con -
t r ibu t e t o squ ea k. Dir t a n d for eign m a t er ia l em bedded
in t h e br a ke lin in g will a lso ca u se squ ea k/squ ea l.
A ver y lou d squ ea k or squ ea l is fr equ en t ly a sign of
sever ely wor n br a ke lin in g. If t h e lin in g h a s wor n
t h r ou gh t o t h e br a ke sh oes in spot s, m et a l-t o-m et a l
con t a ct occu r s. If t h e con dit ion is a llowed t o con t in u e,
r ot or s m a y becom e so scor ed t h a t r epla cem en t is n ec-
essa r y.
WJ BRAKES - BASE 5-5
BRAK ES - BASE (Cont inue d)
NOTE: The front outer brake shoes are equipped
with a wear indicator. The indicator will produce an
audible noise when it contacts the rotor surface.

BRAKE CHATTER
Br a ke ch a t t er is u su a lly ca u sed by loose or wor n
com pon en t s, or gla zed/bu r n t lin in g. Rot or s wit h h a r d
spot s ca n a lso con t r ibu t e t o ch a t t er. Addit ion a l ca u ses
of ch a t t er a r e ou t -of-t oler a n ce r ot or s, br a ke lin in g n ot
secu r ely a t t a ch ed t o t h e sh oes, loose wh eel bea r in gs
a n d con t a m in a t ed br a ke lin in g.

THUMP/CLUNK NOISE
Th u m pin g or clu n k n oises du r in g br a kin g a r e fr e-
qu en t ly n o t ca u sed by br a ke com pon en t s. In m a n y
ca ses, su ch n oises a r e ca u sed by loose or da m a ged
st eer in g, su spen sion , or en gin e com pon en t s.

STAN DARD PROCEDU RE

Fig. 1 Bleed Hose Setup
STANDARD PROCEDURE - MANUAL BLEEDING 1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
Use Mopa r br a ke flu id, or a n equ iva len t qu a lit y
flu id m eet in g SAE J 1703-F a n d DOT 3 st a n da r ds
on ly. Use fr esh , clea n flu id fr om a sea led con t a in er a t STANDARD PROCEDURE - PRESSURE
a ll t im es.
BLEEDING
Do n ot pu m p t h e br a ke peda l a t a n y t im e wh ile
Use Mopa r br a ke flu id, or a n equ iva len t qu a lit y
bleedin g. Air in t h e syst em will be com pr essed in t o
flu id m eet in g SAE J 1703-F a n d DOT 3 st a n da r ds
sm a ll bu bbles t h a t a r e dist r ibu t ed t h r ou gh ou t t h e
on ly. Use fr esh , clea n flu id fr om a sea led con t a in er a t
h ydr a u lic syst em . Th is will m a ke a ddit ion a l bleedin g
a ll t im es.
oper a t ion s n ecessa r y.
Do n ot pu m p t h e br a ke peda l a t a n y t im e wh ile
Do n ot a llow t h e m a st er cylin der t o r u n ou t of flu id
bleedin g. Air in t h e syst em will be com pr essed in t o
du r in g bleed oper a t ion s. An em pt y cylin der will a llow
sm a ll bu bbles t h a t a r e dist r ibu t ed t h r ou gh ou t t h e
a ddit ion a l a ir t o be dr a wn in t o t h e syst em . Ch eck t h e
h ydr a u lic syst em . Th is will m a ke a ddit ion a l bleedin g
cylin der flu id level fr equ en t ly a n d a dd flu id a s
oper a t ion s n ecessa r y.
n eeded.
Do n ot a llow t h e m a st er cylin der t o r u n ou t of flu id
Bleed on ly on e br a ke com pon en t a t a t im e in t h e
du r in g bleed oper a t ion s. An em pt y cylin der will a llow
followin g sequ en ce:
a ddit ion a l a ir t o be dr a wn in t o t h e syst em . Ch eck t h e
(1) F ill t h e m a st er cylin der r eser voir wit h br a ke
cylin der flu id level fr equ en t ly a n d a dd flu id a s
flu id.
n eeded.
(2) If ca liper s a r e over h a u led, open a ll ca liper
Bleed on ly on e br a ke com pon en t a t a t im e in t h e
bleed scr ews. Th en close ea ch bleed scr ew a s flu id
followin g sequ en ce:
st a r t s t o dr ip fr om it . Top off m a st er cylin der r eser-
F ollow t h e m a n u fa ct u r er s in st r u ct ion s ca r efu lly
voir on ce m or e befor e pr oceedin g.
wh en u sin g pr essu r e equ ipm en t . Do n ot exceed t h e
(3) At t a ch on e en d of bleed h ose t o bleed scr ew
t a n k m a n u fa ct u r er s pr essu r e r ecom m en da t ion s. Gen -
a n d in ser t opposit e en d in gla ss con t a in er pa r t ia lly
er a lly, a t a n k pr essu r e of 51-67 kP a (15-20 psi) is su f-
filled wit h br a ke flu id (F ig. 1). Be su r e en d of bleed
ficien t for bleedin g.
h ose is im m er sed in flu id.
F ill t h e bleeder t a n k wit h r ecom m en ded flu id a n d
(4) Open u p bleeder, t h en h a ve a h elper pr ess
pu r ge a ir fr om t h e t a n k lin es befor e bleedin g.
down t h e br a ke peda l. On ce t h e peda l is down close
Do n ot pr essu r e bleed wit h ou t a pr oper m a st er cyl-
t h e bleeder. Repea t bleedin g u n t il flu id st r ea m is
in der a da pt er. Th e wr on g a da pt er ca n lea d t o lea k-
clea r a n d fr ee of bu bbles. Th en m ove t o t h e n ext
a ge, or dr a win g a ir ba ck in t o t h e syst em . Use
wh eel.
a da pt er pr ovided wit h t h e equ ipm en t or Ada pt er
6921.
5-6 BRAKES - BASE WJ
BRAK ES - BASE (Cont inue d)

SPECI FI CAT I ON S
BRAKE COMPONENTS
SPECI FI CAT I ON S

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Front Disc Brake Caliper Floating Rear Disc Brake Caliper 48 mm (1.889 in.)
Type Piston
Front Disc Brake Caliper 48 mm (1.889 in.) Rear Disc Brake Rotor Solid
Piston Type Diameter
Front Disc Brake Rotor Ventilated Rear Disc Brake Rotor 305 mm (12 in.)
Type Diameter
Front Disc Brake Rotor 305 mm (12 in.) Rear Disc Brake Rotor 0.76 mm (0.003 in.)
Diameter Max. Runout
Front Disc Brake Rotor 0.05 mm (0.002 in.) Rear Disc Brake Rotor 0.0127 mm (0.0005 in.)
Max. Runout Max. Thickness Variation
Front Disc Brake Rotor 0.0127 mm (0.0005 in.) Rear Disc Brake Rotor 8.5 mm (0.335 in.)
Max. Thickness Variation Min. Thickness
Front Disc Brake Rotor 24.5 mm (0.9646 in.) Rear Disc Brake Rotor 196 mm (7.7166 in.)
Min. Thickness Drum Max. Diameter
Rear Disc Brake Caliper Floating Brake Booster Type Dual Diaphragm
Type

TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Brake Pedal Support Bolt 23-24 17-25 —
Brake Pedal Pivot Nut 27-35 20-26 —
Brake Pedal Bracket 28 21 250
Adjustable pedals
Brake Pedal Bracket To Dash 12 9 105
Brake Booster Mounting Nuts 39 29 —
Master Cylinder Mounting Nuts 25 18 —
Master Cylinder Primary Brake Line 16 — 144
Master Cylinder Secondary Brake Line 16 — 144
Front Caliper Slide Pins 29-41 21-30 —
Front Caliper Anchor Bolts 90-115 66-85 —
Front Caliper Brake Hose Banjo Bolt 31 23 —
Front Caliper Bleed Screw 16 — 144
Rear Caliper Slide Pins 29-41 21-30 —
Rear Caliper Anchor Bolts 90-115 66-85 —
Rear Caliper Brake Hose Banjo Bolt 31 23 —
Rear Caliper Bleed Screw 16 — 144
WJ BRAKES - BASE 5-7
BRAK ES - BASE (Cont inue d)

SPECI AL T OOLS BRAK E FLU I D LEV EL SWI T CH

BASE BRAKES REMOVAL
(1) Rem ove t h e wir e con n ect or fr om t h e flu id level
sen sor.
(2) F r om t h e sa m e side of t h e m a st er cylin der r es-
er voir r elea se t h e sen sor lockin g t a ps wit h a sm a ll
scr ew dr iver.
(3) P u ll t h e sen sor ou t of t h e r eser voir fr om t h e
con n ect or side of t h e sen sor.

Installer Caliper Dust Boot 8280
INSTALLATION
(1) In st a ll t h e sen sor wit h a n ew o-r in g in t o t h e
r eser voir u n t il t h e lockin g t a bs a r e en ga ged.
(2) In st a ll t h e wir e con n ect or t o t h e flu id level sen -
sor.

RED BRAK E WARN I N DI CAT OR

SWI T CH
DESCRIPTION
A r ed wa r n in g la m p is u sed for t h e ser vice br a ke
por t ion of t h e h ydr a u lic syst em . Th e la m p is loca t ed
in t h e in st r u m en t clu st er.

OPERATION
Th e la m p is t u r n ed on m om en t a r ily wh en t h e ign i-
t ion swit ch is t u r n t o t h e on posit ion . Th is is a self
Handle C-4171 t est t o ver ify t h e la m p is oper a t ion a l.
Th e r ed wa r n in g ligh t a ler t s t h e dr iver if t h e flu id
level is low or t h e pa r kin g br a kes a r e a pplied. A r ed
wa r n in g la m p wit h a n a m ber wa r n in g la m p m a y
in dica t e a elect r on ic br a ke dist r ibu t ion fa u lt .

DIAGNOSIS AND TESTING - RED BRAKE

Adapter Pressure Bleeder 6921
WARNING LAMP
Th e r ed wa r n in g la m p illu m in a t es wh en t h e pa r k-
in g br a ke is a pplied or wh en t h e flu id level in t h e
m a st er cylin der is low. It will a lso illu m in a t e a t st a r t
u p a s pa r t of a bu lb ch eck.
If t h e ligh t com es on , fir st ver ify t h a t t h e pa r kin g
br a kes a r e fu lly r elea sed. Th en ch eck peda l a ct ion
a n d flu id level. If a pr oblem is con fir m ed, in spect t h e
br a ke h ydr a u lic syst em for lea ks.
A r ed wa r n in g la m p wit h a a m ber wa r n in g la m p
m a y in dica t e a elect r on ic br a ke dist r ibu t ion fa u lt .
5-8 BRAKES - BASE WJ

ADJ U STABLE PEDAL SWI T CH INSTALLATION

REMOVAL
(1) Rem ove t h e st eer in g colu m n open in g cover
(F ig. 2)(Refer t o 23 - BODY/INSTRUME NT PANE L/
STE E RING COLUMN OP E NING COVE R - RE MOV-
AL).
(1) In st a ll t h e swit ch t o t h e st eer in g colu m n open -
in g cover by pu sh in g t h e swit ch in wa r ds sea t in g t h e
r et a in in g clips t o t h e st eer in g colu m n open in g cover
(F ig. 3).
(2) Recon n ect t h e elect r ica l con n ect or t o t h e
a dju st a ble peda l swit ch .
(3) In st a ll t h e st eer in g colu m n open in g cover (F ig.
2)(Refer t o 23 - BODY/INSTRUME NT PANE L/
STE E RING COLUMN OP E NING COVE R - INSTAL-
LATION).

BRAK E LI N ES
DESCRIPTION
F lexible r u bber h ose is u sed a t bot h fr on t br a kes,
r ea r br a kes a n d a t t h e r ea r a xle ju n ct ion block. Dou -
ble wa lled st eel t u bin g is u sed. Dou ble in ver t ed st yle
a n d ISO st yle fla r es a r e u sed on t h e br a ke lin es.

DIAGNOSIS AND TESTING - BRAKE HOSES

AND LINES
F lexible r u bber h ose is u sed a t bot h fr on t a n d r ea r
Fig. 2 STEERING COLUMN OPENING COVER br a kes a n d a t t h e r ea r a xle ju n ct ion block. In spect
REMOVAL/INSTALL t h e h oses wh en ever t h e br a ke syst em is ser viced, a t
1 - INSTRUMENT PANEL TOP PAD
ever y en gin e oil ch a n ge, or wh en ever t h e veh icle is in
2 - STEERING COLUMN OPENING COVER for ser vice.
3 - SCREW (3) In spect t h e h oses for su r fa ce cr a ckin g, scu ffin g, or
wor n spot s. Repla ce a n y br a ke h ose im m edia t ely if
t h e fa br ic ca sin g of t h e h ose is exposed du e t o cr a cks
(2) Discon n ect t h e elect r ica l con n ect or fr om t h e
or a br a sion s.
a dju st a ble peda l swit ch .
Also ch eck br a ke h ose in st a lla t ion . F a u lt y in st a lla -
(3) Rem ove t h e swit ch fr om t h e st eer in g colu m n
t ion ca n r esu lt in kin ked, t wist ed h oses, or con t a ct
open in g cover by squ eezin g t h e r et a in in g clips
wit h t h e wh eels a n d t ir es or ot h er ch a ssis com po-
t oget h er a n d pu sh in g t h e swit ch ou t wa r ds (F ig. 3).
n en t s. All of t h ese con dit ion s ca n lea d t o scu ffin g,
cr a ckin g a n d even t u a l fa ilu r e.
Th e st eel br a ke lin es sh ou ld be in spect ed per iodi-
ca lly for eviden ce of cor r osion , t wist s, kin ks, lea ks, or
ot h er da m a ge. H ea vily cor r oded lin es will even t u a lly
r u st t h r ou gh ca u sin g lea ks. In a n y ca se, cor r oded or
da m a ged br a ke lin es sh ou ld be r epla ced.
F a ct or y r epla cem en t br a ke lin es a n d h oses a r e r ec-
om m en ded t o en su r e qu a lit y, cor r ect len gt h a n d su pe-
r ior fa t igu e life. Ca r e sh ou ld be t a ken t o m a ke su r e
t h a t br a ke lin e a n d h ose m a t in g su r fa ces a r e clea n
a n d fr ee fr om n icks a n d bu r r s. Also r em em ber t h a t
r igh t a n d left br a ke h oses a r e n ot in t er ch a n gea ble.
Use n ew copper ga sket s a t a ll ca liper con n ect ion s.
Be su r e br a ke lin e con n ect ion s a r e pr oper ly m a de
(n ot cr oss t h r ea ded) a n d t igh t en ed t o r ecom m en ded
t or qu e.
Fig. 3 ADJUSTABLE PEDAL SWITCH
1 - RETAINING CLIPS
2 - ELECTRICAL CONNECTION
WJ
BRAK E LI N ES (Cont inue d)
STAN DARD PROCEDU RE
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A pr efor m ed m et a l br a ke t u be is r ecom m en ded a n d
pr efer r ed for a ll r epa ir s. H owever, dou ble-wa ll st eel
t u be ca n be u sed for em er gen cy r epa ir wh en fa ct or y
r epla cem en t pa r t s a r e n ot r ea dily a va ila ble.
Specia l ben din g t ools a r e n eeded t o a void kin kin g
or t wist in g of m et a l br a ke t u bes. Specia l fla r in g t ools
a r e n eeded t o m a ke a dou ble in ver t ed fla r e or ISO
fla r e.
(1) Cu t off da m a ged t u be wit h Tu bin g Cu t t er.
(2) Rea m cu t edges of t u bin g t o en su r e pr oper
fla r e.
(3) In st a ll r epla cem en t t u be n u t on t h e t u be.
(4) In ser t t u be in fla r in g t ool.
(5) P la ce ga u ge for m over t h e en d of t h e t u be.
(6) P u sh t u bin g t h r ou gh fla r in g t ool ja ws u n t il
t u be con t a ct s r ecessed n ot ch in ga u ge t h a t m a t ch es
t u be dia m et er.
(7) Tigh t en t h e t ool ba r on t h e t u be
(8) In ser t plu g on ga u ge in t h e t u be. Th en swin g
com pr ession disc over ga u ge a n d cen t er t a per ed fla r-
in g scr ew in r ecess of com pr ession disc (F ig. 4).
(9) Tigh t en t ool h a n dle u n t il plu g ga u ge is
squ a r ely sea t ed on ja ws of fla r in g t ool. Th is will st a r t
t h e in ver t ed fla r e.
(10) Rem ove t h e plu g ga u ge a n d com plet e t h e
in ver t ed fla r e.
Fig. 4 Inverted
BRAKES - BASE 5-9
STANDARD PROCEDURE - ISO FLARING
A pr efor m ed m et a l br a ke t u be is r ecom m en ded a n d
pr efer r ed for a ll r epa ir s. H owever, dou ble-wa ll st eel
t u be ca n be u sed for em er gen cy r epa ir wh en fa ct or y
r epla cem en t pa r t s a r e n ot r ea dily a va ila ble.
Specia l ben din g t ools a r e n eeded t o a void kin kin g
or t wist in g of m et a l br a ke t u bes. Specia l fla r in g t ools
a r e n eeded t o m a ke a dou ble in ver t ed fla r e or ISO
fla r e.
To m a ke a ISO fla r e u se Sn a p-On ! F la r in g Tool
TF M-428 or equ iva len t .
(1) Cu t off da m a ged t u be wit h Tu bin g Cu t t er.
(2) Rem ove a n y bu r r s fr om t h e in side of t h e t u be.
(3) In st a ll t u be n u t on t h e t u be.
(4) P osit ion t h e t u be in t h e fla r in g t ool flu sh wit h
t h e t op of t h e t ool ba r (F ig. 5). Th en t igh t en t h e t ool
ba r on t h e t u be.
(5) In st a ll t h e cor r ect size a da pt or on t h e fla r in g
t ool yoke scr ew.
(6) Lu br ica t e t h e a da pt or.
(7) Align t h e a da pt or a n d yoke scr ew over t h e t u be
(F ig. 5).
(8) Tu r n t h e yoke scr ew in u n t il t h e a da pt or is
squ a r ely sea t ed on t h e t ool ba r.
Fig. 5 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
5 - 10 BRAKES - BASE
BRAK E PADS / SH OES
DESCRI PT I ON
DESCRIPTION - FRONT DISC BRAKE SHOES
Th e ca liper s a r e t win pist on t ype. Th e ca liper s a r e
fr ee t o slide la t er a lly on t h e a n ch or, t h is a llows con -
t in u ou s com pen sa t ion for lin in g wea r.
DESCRIPTION - REAR DISC BRAKE SHOES
Th e r ea r disc br a kes con sist of sin gle pist on floa t -
in g-t ype ca liper s a n d solid r ot or s. Th e r ea r ca liper is
m ou n t ed on a n a n ch or a t t a ch ed t o a n a da pt er
a t t a ch ed t h e r ea r a xle t u be fla n ge. Th e a n ch or s a r e
secu r ed t o t h e a da pt er s wit h m ou n t in g bolt s. Th e
disc br a ke r ot or spla sh sh ield is pa r t of t h e a da pt or.
Th e disc br a ke r ot or h a s a bu ilt in br a ke dr u m u sed
for t h e pa r kin g br a kes (F ig. 6). Th e pa r kin g br a ke
sh oes a r e m ou n t ed t o t h e a da pt or.
Fig. 6 Rear Disc Brake Rotor
1 - PARKING BRAKE DRUM SURFACE
2 - REAR DISC BRAKE ROTOR
OPERAT I ON
OPERATION - FRONT DISC BRAKE SHOES
Wh en t h e br a kes a r e a pplied flu id pr essu r e is
exer t ed a ga in st t h e ca liper pist on s. Th e flu id pr es-
su r e is exer t ed equ a lly a n d in a ll dir ect ion s. Th is
m ea n s pr essu r e exer t ed a ga in st t h e ca liper pist on s
a n d wit h in t h e ca liper bor es will be equ a l (F ig. 7).
F lu id pr essu r e a pplied t o t h e pist on s is t r a n sm it -
t ed dir ect ly t o t h e in boa r d br a ke sh oe. Th is for ces t h e
sh oe lin in g a ga in st t h e in n er su r fa ce of t h e disc
br a ke r ot or. At t h e sa m e t im e, flu id pr essu r e wit h in
t h e pist on bor es for ces t h e ca liper t o slide in wa r d on
t h e slide pin s. Th is a ct ion br in gs t h e ou t boa r d br a ke
sh oe lin in g in t o con t a ct wit h t h e ou t er su r fa ce of t h e
disc br a ke r ot or.
F lu id pr essu r e a ct in g sim u lt a n eou sly on t h e pis-
t on s a n d ca liper t o pr odu ces a st r on g cla m pin g
a ct ion . Wh en su fficien t for ce is a pplied, fr ict ion will
st op t h e r ot or s fr om t u r n in g a n d br in g t h e veh icle t o
a st op.
WJ
Fig. 7 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
Applica t ion a n d r elea se of t h e br a ke peda l gen er-
a t es on ly a ver y sligh t m ovem en t of t h e ca liper a n d
pist on s. Upon r elea se of t h e peda l, t h e ca liper a n d
pist on s r et u r n t o a r est posit ion . Th e br a ke sh oes do
n ot r et r a ct a n a ppr ecia ble dist a n ce fr om t h e r ot or. In
fa ct , clea r a n ce is u su a lly a t , or close t o zer o. Th e r ea -
son s for t h is a r e t o keep r oa d debr is fr om get t in g
bet ween t h e r ot or a n d lin in g a n d in wipin g t h e r ot or
su r fa ce clea r ea ch r evolu t ion .
Th e ca liper pist on sea ls con t r ol t h e a m ou n t of pis-
t on ext en sion n eeded t o com pen sa t e for n or m a l lin in g
wea r.
Du r in g br a ke a pplica t ion , t h e sea ls a r e deflect ed
ou t wa r d by flu id pr essu r e a n d pist on m ovem en t (F ig.
8). Wh en t h e br a kes (a n d flu id pr essu r e) a r e
r elea sed, t h e sea ls r ela x a n d r et r a ct t h e pist on s.
Th e fr on t ou t boa r d br a ke sh oes h a ve wea r in dica -
t or s.
OPERATION - REAR DISC BRAKE SHOES
Wh en t h e br a kes a r e a pplied flu id pr essu r e is
exer t ed a ga in st t h e ca liper pist on s. Th e flu id pr es-
su r e is exer t ed equ a lly a n d in a ll dir ect ion s. Th is
m ea n s pr essu r e exer t ed a ga in st t h e ca liper pist on s
a n d wit h in t h e ca liper bor es will be equ a l (F ig. 7).
F lu id pr essu r e a pplied t o t h e pist on s is t r a n sm it -
t ed dir ect ly t o t h e in boa r d br a ke sh oe. Th is for ces t h e
WJ BRAKES - BASE 5 - 11
BRAK E PADS / SH OES (Cont inue d)
(3) Dr a in sm a ll a m ou n t of flu id fr om m a st er cylin -
der br a ke r eser voir wit h c le a n su ct ion gu n .
(4) Bot t om ca liper pist on s in t o t h e ca liper by pr y-
in g t h e ca liper over (F ig. 9).

Fig. 8 Lining Wear Compensation By Piston Seal

1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON

sh oe lin in g a ga in st t h e in n er su r fa ce of t h e disc
br a ke r ot or. At t h e sa m e t im e, flu id pr essu r e wit h in
t h e pist on bor es for ces t h e ca liper t o slide in wa r d on
t h e slide pin s. Th is a ct ion br in gs t h e ou t boa r d br a ke Fig. 9 Bottoming Caliper Piston
sh oe lin in g in t o con t a ct wit h t h e ou t er su r fa ce of t h e 1 - ROTOR
disc br a ke r ot or. 2 - CALIPER
F lu id pr essu r e a ct in g sim u lt a n eou sly on t h e pis-
t on s a n d ca liper t o pr odu ces a st r on g cla m pin g (5) Rem ove t h e ca liper su ppor t spr in g by pr yin g
a ct ion . Wh en su fficien t for ce is a pplied, fr ict ion will t h e spr in g ou t of t h e ca liper (F ig. 10).
st op t h e r ot or s fr om t u r n in g a n d br in g t h e veh icle t o
a st op.
Applica t ion a n d r elea se of t h e br a ke peda l gen er-
a t es on ly a ver y sligh t m ovem en t of t h e ca liper a n d
pist on s. Upon r elea se of t h e peda l, t h e ca liper a n d
pist on s r et u r n t o a r est posit ion . Th e br a ke sh oes do
n ot r et r a ct a n a ppr ecia ble dist a n ce fr om t h e r ot or. In
fa ct , clea r a n ce is u su a lly a t , or close t o zer o. Th e r ea -
son s for t h is a r e t o keep r oa d debr is fr om get t in g
bet ween t h e r ot or a n d lin in g a n d in wipin g t h e r ot or
su r fa ce clea r ea ch r evolu t ion .
Th e ca liper pist on sea ls con t r ol t h e a m ou n t of pis-
t on ext en sion n eeded t o com pen sa t e for n or m a l lin in g
wea r.
Du r in g br a ke a pplica t ion , t h e sea ls a r e deflect ed
ou t wa r d by flu id pr essu r e a n d pist on m ovem en t (F ig.
8). Wh en t h e br a kes (a n d flu id pr essu r e) a r e
r elea sed, t h e sea ls r ela x a n d r et r a ct t h e pist on s.
Th e fr on t ou t boa r d br a ke sh oes h a ve wea r in dica -
t or s. Fig. 10 Caliper Support Spring
1 - SUPPORT SPRING
2 - CALIPER
REM OVAL
(6) Rem ove t h e ca liper slide pin bu sh in g ca ps a n d
REMOVAL- FRONT DISC BRAKE SHOES r em ove t h e slide pin s (F ig. 11).
(1) Ra ise a n d su ppor t veh icle. (7) Rem ove ca liper fr om t h e a n ch or.
(2) Rem ove wh eel a n d t ir e a ssem bly.
5 - 12 BRAKES - BASE WJ
BRAK E PADS / SH OES (Cont inue d)

Fig. 11 Caliper Slide

1 - SLIDE PIN Fig. 13 Outboard Brake Shoe
2 - SLIDE PIN
1 - CALIPER ANCHOR
3 - CALIPER
2 - OUTBOARD BRAKE SHOE

(8) Secu r e ca liper t o n ea r by su spen sion pa r t wit h

wir e. D o n o t a llo w bra k e h o s e to s u p p o rt c a lip e r
w e ig h t.
(9) Rem ove t h e in boa r d br a ke sh oe fr om t h e ca li-
per (F ig. 12).
REMOVAL - REAR DISC BRAKE SHOES
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove r ea r wh eel a n d t ir e a ssem bly.
(3) Dr a in sm a ll a m ou n t of flu id fr om m a st er cylin -
der br a ke r eser voir wit h a c le a n su ct ion gu n .
(4) Bot t om ca liper pist on s in t o t h e ca liper by pr y-
in g t h e ca liper over (F ig. 14).

Fig. 12 Inboard Brake Shoe

1 - CALIPER
2 - INBOARD SHOE

(10) Rem ove t h e ou t boa r d br a ke sh oe (F ig. 13) Fig. 14 Bottoming Caliper Piston
fr om t h e ca liper a n ch or. 1 - CALIPER
2 - CALIPER ANCHOR
WJ BRAKES - BASE 5 - 13
BRAK E PADS / SH OES (Cont inue d)
(5) Rem ove t h e ca liper su ppor t spr in g by pr yin g (7) Rem ove ca liper fr om t h e a n ch or.
t h e spr in g ou t of t h e ca liper (F ig. 15). (8) Secu r e ca liper t o n ea r by su spen sion pa r t wit h
wir e. D o n o t a llo w bra k e h o s e to s u p p o rt c a lip e r
w e ig h t.
(9) Rem ove t h e in boa r d br a ke sh oe fr om t h e ca li-
per (F ig. 17).

Fig. 15 Caliper Support Spring

1 - CALIPER
2 - ANCHOR
3 - SUPPORT SPRING

(6) Rem ove t h e ca liper slide pin bu sh in g ca ps a n d Fig. 17 Inboard Brake Shoe
r em ove t h e slide pin s (F ig. 16). 1 - CALIPER
2 - INBOARD SHOE

(10) Rem ove ou t boa r d br a ke sh oe (F ig. 18) fr om

t h e ca liper a n ch or.

I N STALLAT I ON
INSTALLATION - FRONT DISC BRAKE SHOES
(1) In st a ll t h e in boa r d br a ke sh oe on t o t h e ca liper
(F ig. 12).
(2) In st a ll t h e ou t boa r d sh oe on t o t h e ca liper
a n ch or (F ig. 13).
(3) Lu br ica t e t h e slide pin s a n d slide pin bu sh in gs
wit h Dow Cor n in g! gr ea se G807 or t h e gr ea se pr o-
vided wit h t h e br a ke sh oes.
(4) In st a ll ca liper on t h e ca liper a n ch or.
(5) In st a ll t h e ca liper slide pin a n d t igh t en t o
29-41 N·m (21-30 ft . lbs.).
(6) In st a ll t h e ca liper slide pin bu sh in g ca ps.
(7) In st a ll t h e ca liper su ppor t spr in g in t h e t op
Fig. 16 Caliper Slide Pins en d of t h e ca liper a n d u n der t h e a n ch or. Th en in st a ll
1 - CALIPER ot h er en d in t o t h e lower ca liper h ole. H old t h e spr in g
2 - SLIDE PINS in t o t h e ca liper h ole wit h you r t h u m b wh ile pr yin g
t h e en d of t h e spr in g ou t a n d down u n der t h e a n ch or
wit h a scr ew dr ive.
5 - 14 BRAKES - BASE WJ
BRAK E PADS / SH OES (Cont inue d)
ot h er en d in t o t h e lower ca liper h ole. H old t h e spr in g
in t o t h e ca liper h ole wit h you r t h u m b wh ile pr yin g
t h e en d of t h e spr in g ou t a n d down u n der t h e a n ch or
wit h a scr ew dr ive.
(8) In st a ll wh eel a n d t ir e a ssem bly.
(9) Rem ove su ppor t a n d lower veh icle.
(10) P u m p br a ke peda l u n t il ca liper pist on a n d
br a ke sh oes a r e sea t ed a n d a fir m br a ke peda l is
obt a in ed.
(11) F ill br a ke flu id level if n ecessa r y.

DI SC BRAK E CALI PERS

REM OVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove fr on t wh eel a n d t ir e a ssem bly.
Fig. 18 Outboard Brake Shoe (3) Dr a in sm a ll a m ou n t of flu id fr om m a st er cylin -
der br a ke r eser voir wit h c le a n su ct ion gu n .
1 - OUTBOARD BRAKE SHOE
(4) Bot t om ca liper pist on s in t o t h e ca liper by pr y-
2 - CALIPER ANCHOR
3 - ROTOR in g t h e ca liper over (F ig. 19).

(8) In st a ll wh eel a n d t ir e a ssem bly.

(9) Rem ove su ppor t a n d lower veh icle.
(10) P u m p br a ke peda l u n t il ca liper pist on s a n d
br a ke sh oes a r e sea t ed a n d a fir m br a ke peda l is
obt a in ed.
(11) F ill br a ke flu id.

INSTALLATION - REAR DISC BRAKE SHOES

(1) In st a ll t h e in boa r d br a ke sh oe on t o t h e ca liper
(F ig. 17).
(2) In st a ll t h e ou t boa r d br a ke sh oe on t o t h e ca liper
a n ch or (F ig. 18).
(3) Lu br ica t e t h e slide pin s a n d slide pin bu sh in gs
wit h Dow Cor n in g! gr ea se G807 or t h e gr ea se pr o-
vided wit h t h e br a ke sh oes.
(4) In st a ll ca liper on t h e a n ch or.
(5) In st a ll t h e ca liper slide pin a n d t igh t en t o Fig. 19 Bottoming Caliper Piston
29-41 N·m (21-30 ft . lbs.).
1 - ROTOR
(6) In st a ll t h e ca liper slide pin bu sh in g ca ps.
2 - CALIPER
(7) In st a ll t h e ca liper su ppor t spr in g in t h e t op
en d of t h e ca liper a n d u n der t h e a n ch or. Th en in st a ll
WJ BRAKES - BASE 5 - 15
DI SC BRAK E CALI PERS (Cont inue d)
(5) Rem ove br a ke h ose ba n jo bolt a n d ga sket
wa sh er s. Disca r d ga sket wa sh er s.
(6) Rem ove t h e ca liper su ppor t spr in g by pr yin g
t h e spr in g ou t of t h e ca liper (F ig. 20).

Fig. 22 Inboard Brake Shoe

1 - CALIPER
2 - INBOARD SHOE

Fig. 20 Caliper Support Spring REMOVAL - REAR DISC BRAKE CALIPER

1 - SUPPORT SPRING (1) Ra ise a n d su ppor t veh icle.
2 - CALIPER (2) Rem ove r ea r wh eel a n d t ir e a ssem bly.
(3) Dr a in sm a ll a m ou n t of flu id fr om m a st er cylin -
der br a ke r eser voir wit h a c le a n su ct ion gu n .
(7) Rem ove t h e ca liper slide pin bu sh in g ca ps a n d
(4) Bot t om ca liper pist on s in t o t h e ca liper by pr y-
r em ove t h e slide pin s (F ig. 21).
in g t h e ca liper over (F ig. 23).

Fig. 21 Slide Pins

1 - SLIDE PIN
2 - SLIDE PIN
3 - CALIPER
Fig. 23 Bottoming Caliper Piston
1 - CALIPER
(8) Rem ove ca liper fr om t h e a n ch or. 2 - CALIPER ANCHOR
(9) Rem ove t h e in boa r d br a ke sh oe (F ig. 22).
5 - 16 BRAKES - BASE WJ
DI SC BRAK E CALI PERS (Cont inue d)
(5) Rem ove br a ke h ose ba n jo bolt a n d disca r d ga s-
ket wa sh er s.
(6) Rem ove t h e ca liper su ppor t spr in g by pr yin g
t h e spr in g ou t of t h e ca liper (F ig. 24).

Fig. 25 Caliper Slide Pins

1 - CALIPER
2 - SLIDE PINS

Fig. 24 Caliper Support Spring

1 - CALIPER
2 - ANCHOR
3 - SUPPORT SPRING

(7) Rem ove t h e ca liper slide pin bu sh in g ca ps a n d

r em ove t h e slide pin s (F ig. 25).
(8) Rem ove ca liper fr om t h e a n ch or.
(9) Rem ove t h e in boa r d br a ke sh oe (F ig. 26).

Fig. 26 Inboard Brake Shoe

1 - CALIPER
2 - INBOARD SHOE
WJ BRAKES - BASE 5 - 17
DI SC BRAK E CALI PERS (Cont inue d)

DI SASSEM BLY (4) To r em ove t h e ca liper pist on dir ect s h o rt

DISASSEMBLY - FRONT DISC BRAKE CALIPER
(1) Dr a in t h e br a ke flu id fr om ca liper.
(2) C-cla m p a block of wood over on e pist on (F ig.
27).
bu rs ts o f lo w p re s s u re a ir wit h a blow gu n
t h r ou gh t h e ca liper br a ke h ose por t . Use on ly en ou gh
a ir pr essu r e t o ea se t h e pist on ou t .
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.

WARNING: NEVER ATTEMPT TO CATCH THE PIS-

TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.

(5) Rem ove t h e C-cla m p a n d block of wood fr om

t h e ca liper a n d cla m p it over t h e du st boot of t h e
fir st pist on r em oved. Th is will sea l t h e em pt y pist on
bor e.
(6) Move t h e pa dded piece of wood in fr on t of t h e
ot h er pist on .
(7) Rem ove t h e secon d pist on u sin g t h e sa m e pr o-
cedu r e wit h s h o rt bu rs ts o f lo w p re s s u re a ir.
(8) Rem ove pist on du st boot s wit h a su it a ble pr y
Fig. 27 C-Clamp One Piston t ool (F ig. 29)a n d disca r d.
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER

(3) Ta ke a n ot h er piece of wood a n d pa d it wit h

on e-in ch t h ickn ess of sh op t owels. P la ce t h is piece in
t h e ou t boa r d sh oe side of t h e ca liper in fr on t of t h e
ot h er pist on . Th is will cu sh ion a n d pr ot ect ca liper
pist on du r in g r em ova l (F ig. 28).

Fig. 29 Piston Dust Boot Removal

1 - CALIPER
2 - PISTON DUST BOOT

Fig. 28 Protect Caliper Piston

1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
5 - 18 BRAKES - BASE WJ
DI SC BRAK E CALI PERS (Cont inue d)
(9) Rem ove pist on sea ls fr om ca liper (F ig. 30) a n d Th is will cu sh ion a n d pr ot ect ca liper pist on du r in g
disca r d. r em ova l (F ig. 32).

CAUTION: Do not scratch piston bore while remov-

ing the seals.

Fig. 32 Padding Caliper Interior

1 - SHOP TOWELS OR CLOTHS
2 - CALIPER
Fig. 30 Piston Seal
1 - CALIPER (3) To r em ove ca liper pist on dir ect s h o rt bu rs ts
2 - PISTON BORE o f lo w p re s s u re a ir wit h a blow gu n t h r ou gh t h e
3 - PISTON SEAL ca liper br a ke h ose por t (F ig. 33). Use on ly en ou gh a ir
pr essu r e t o ea se t h e pist on ou t .
(10) Rem ove ca liper slide pin bu sh in gs (F ig. 31).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.

WARNING: NEVER ATTEMPT TO CATCH THE PIS-

TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.

Fig. 31 Caliper Slide Pin Bushings

1 - CALIPER
2 - BUSHING
3 - CALIPER SLIDE PIN

(11) Rem ove ca liper bleed scr ew.

DISASSEMBLY - REAR DISC BRAKE CALIPER Fig. 33 Caliper Piston Removal

(1) Dr a in br a ke flu id ou t of ca liper. 1 - CALIPER PISTON
(2) Ta ke a piece of wood a n d pa d it wit h on e-in ch 2 - AIR GUN
t h ickn ess of sh op t owels. P la ce t h is piece in t h e ou t - 3 - PADDING MATERIAL
boa r d sh oe side of t h e ca liper in fr on t of t h e pist on .
WJ BRAKES - BASE 5 - 19
DI SC BRAK E CALI PERS (Cont inue d)
(4) Rem ove ca liper pist on du st boot wit h a su it a ble
pr y t ool (F ig. 34) a n d disca r d.

Fig. 36 Slide Pin And Bushing

Fig. 34 Caliper Piston Dust 1 - BUSHING
2 - CALIPER SLIDE PIN
1 - PISTON DUST BOOT
2 - CALIPER
CLEANING - DISC BRAKE CALIPER
(5) Rem ove pist on sea l fr om t h e ca liper (F ig. Clea n t h e ca liper com pon en t s wit h clea n br a ke
35)a n d disca r d. flu id or br a ke clea n on ly. Wipe t h e ca liper a n d pist on
dr y wit h lin t fr ee t owels or u se low pr essu r e com -
CAUTION: Do not scratch the piston bore while pr essed a ir.
removing the seal.
CAUTION: Do not use gasoline, kerosene, paint
thinner, or similar solvents. These products may
leave a residue that could damage the piston and
seal.

INSPECTION - DISC BRAKE CALIPER

Th e pist on is m a de fr om a ph en olic r esin (pla st ic
m a t er ia l) a n d sh ou ld be sm oot h a n d clea n .
Th e pist on m u st be r epla ced if cr a cked or scor ed.
Do n ot a t t em pt t o r est or e a scor ed pist on su r fa ce by
sa n din g or polish in g.

CAUTION: If the caliper piston is replaced, install

the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
Fig. 35 Piston Seal Removal piston tolerances are different.
1 - CALIPER
2 - PISTON BORE Th e bor e ca n be lig h tly polish ed wit h a br a ke
3 - PISTON SEAL h on e t o r em ove ver y m in or su r fa ce im per fect ion s
(F ig. 37). Th e ca liper sh ou ld be r epla ced if t h e bor e is
(6) Rem ove ca liper slide pin bu sh in gs (F ig. 36). sever ely cor r oded, r u st ed, scor ed, or if polish in g
(7) Rem ove ca liper bleed scr ew. wou ld in cr ea se bor e dia m et er m or e t h a n 0.025 m m
(0.001 in ch ).
5 - 20 BRAKES - BASE WJ
DI SC BRAK E CALI PERS (Cont inue d)
(3) In st a ll n ew du st boot on ca liper pist on a n d sea t
boot lip in t o pist on gr oove (F ig. 39).

Fig. 37 Polishing Piston Bore

1 - SPECIAL HONE
2 - CALIPER
3 - PISTON BORE Fig. 39 Dust Boot On Piston
1 - PISTON
ASSEM BLY 2 - DUST BOOT

ASSEMBLY - FRONT DISC BRAKE CALIPER (4) St r et ch boot r ea r wa r d t o st r a igh t en boot folds,
t h en m ove boot for wa r d u n t il folds sn a p in t o pla ce.
CAUTION: Dirt, oil, and solvents can damage cali- (5) In st a ll pist on in t o ca liper bor e a n d pr ess pist on
per seals. Insure assembly area is clean and dry. down t o t h e bot t om of t h e ca liper bor e by h a n d or
wit h h a m m er h a n dle (F ig. 40).
(1) Lu br ica t e ca liper pist on s, pist on sea ls a n d pis-
t on bor es wit h clea n br a ke flu id.
(2) In st a ll n ew pist on sea ls in t o sea l gr oove wit h
fin ger (F ig. 38).

NOTE: Verify seal is fully seated and not twisted.

Fig. 40 Caliper Piston Installation

1 - CALIPER
2 - DUST BOOT
3 - PISTON

Fig. 38 Piston Seal

1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
WJ BRAKES - BASE 5 - 21
DI SC BRAK E CALI PERS (Cont inue d)
(6) Sea t du st boot in ca liper (F ig. 41) wit h (3) In st a ll n ew du st boot on ca liper pist on a n d sea t
In st a ller 8280 a n d H a n dle C-4171. boot lip in t o pist on gr oove (F ig. 43).

Fig. 41 Seating Dust Boot

Fig. 43 Dust Boot On Piston
1 - HANDLE
1 - PISTON
2 - CALIPER
2 - DUST BOOT
3 - DUST BOOT INSTALLER

(4) St r et ch boot r ea r wa r d t o st r a igh t en boot folds,

(7) In st a ll t h e secon d pist on a n d du st boot .
t h en m ove boot for wa r d u n t il folds sn a p in t o pla ce.
(8) In st a ll ca liper slide pin bu sh in gs in t o t h e ca liper.
(5) In st a ll pist on in t o ca liper bor e a n d pr ess pist on
(9) In st a ll ca liper bleed scr ew.
down t o t h e bot t om of t h e ca liper bor e by h a n d or
wit h h a m m er h a n dle (F ig. 44).
ASSEMBLY - REAR DISC BRAKE CALIPER
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.

(1) Lu br ica t e ca liper pist on , pist on sea l a n d pist on

bor e wit h clea n br a ke flu id.
(2) In st a ll n ew pist on sea l in t o sea l gr oove wit h
fin ger (F ig. 42).

NOTE: Verify seal is fully seated and not twisted.

Fig. 44 Caliper Piston Installation

1 - PISTON
2 - BOOT

Fig. 42 Piston Seal Installation

1 - SEAL GROOVE
2 - PISTON SEAL
5 - 22 BRAKES - BASE WJ
DI SC BRAK E CALI PERS (Cont inue d)
(6) Sea t du st boot in ca liper wit h In st a ller 8280 (4) In st a ll t h e ca liper slide pin a n d t igh t en t o
a n d H a n dle C-4171 (F ig. 45). 29-41 N·m (21-30 ft . lbs.).
(5) In st a ll t h e ca liper slide pin bu sh in g ca ps.
(6) In st a ll t h e ca liper su ppor t spr in g in t h e t op
en d of t h e ca liper a n d u n der t h e a n ch or. Th en in st a ll
ot h er en d in t o t h e lower ca liper h ole. H old t h e spr in g
in t o t h e ca liper h ole wit h you r t h u m b wh ile pr yin g
t h e en d of t h e spr in g ou t a n d down u n der t h e a n ch or
wit h a scr ew dr ive.
(7) In st a ll br a ke h ose t o ca liper wit h n e w g a s k e t
w a s h e rs a n d t igh t en ba n jo bolt t o 31 N·m (23 ft .
lbs.).

CAUTION: Verify brake hose is not twisted or

kinked before tightening banjo bolt.

(8) F ill a n d bleed br a ke syst em .

(9) In st a ll wh eel a n d t ir e a ssem blies.
(10) Rem ove su ppor t s a n d lower veh icle.
Fig. 45 Piston Dust Boot Installation
(11) Ver ify br a ke flu id level.
1 - HANDLE
2 - INSTALLER
3 - DUST BOOT
INSTALLATION - REAR DISC BRAKE CALIPER
(1) In st a ll t h e in boa r d br a ke sh oe (F ig. 26).
(2) Lu br ica t e t h e slide pin s a n d slide pin bu sh in gs
(7) In st a ll ca liper slide pin bu sh in gs in t o t h e ca li- wit h Dow Cor n in g! gr ea se G807 or t h e gr ea se pr o-
per (F ig. 46). vided wit h t h e ca liper.
(3) In st a ll t h e ca liper on t h e a n ch or.
(4) In st a ll t h e ca liper slide pin a n d t igh t en t o
29-41 N·m (21-30 ft . lbs.).
(5) In st a ll t h e ca liper slide pin ca ps.
(6) In st a ll t h e ca liper su ppor t spr in g in t h e t op
en d of t h e ca liper a n d u n der t h e a n ch or. Th en in st a ll
ot h er en d in t o t h e lower ca liper h ole. H old t h e spr in g
in t o t h e ca liper h ole wit h you r t h u m b wh ile pr yin g
t h e en d of t h e spr in g ou t a n d down u n der t h e a n ch or
wit h a scr ew dr ive.

CAUTION: Verify brake hose is not twisted or

kinked before tightening fitting bolt.

(7) In st a ll br a ke h ose t o ca liper wit h a n e w ga sket

wa sh er s a n d t igh t en ba n jo bolt t o 31 N·m (23 ft . lbs.).
Fig. 46 Slide Pin And Bushing (8) F ill a n d bleed br a ke syst em .
1 - CALIPER SLIDE PIN (9) In st a ll wh eel a n d t ir e a ssem blies.
2 - BUSHING (10) Rem ove su ppor t s a n d lower veh icle.

(8) In st a ll ca liper bleed scr ew. FLU I D

I N STALLAT I ON
INSTALLATION - FRONT DISC BRAKE CALIPER
(1) In st a ll t h e in boa r d br a ke sh oe (F ig. 22).
(2) Lu br ica t e t h e slide pin s a n d slide pin bu sh in gs
wit h Dow Cor n in g! gr ea se G807 or t h e gr ea se pr o-
vided wit h t h e ca liper.
(3) In st a ll t h e ca liper on t h e a n ch or.
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
In dica t ion s of flu id con t a m in a t ion a r e swollen or
det er ior a t ed r u bber pa r t s.
Swollen r u bber pa r t s in dica t e t h e pr esen ce of
pet r oleu m in t h e br a ke flu id.
To t est for con t a m in a t ion , pu t a sm a ll a m ou n t of
dr a in ed br a ke flu id in clea r gla ss ja r. If flu id sepa -
WJ BRAKES - BASE 5 - 23
FLU I D (Cont inue d)
r a t es in t o la yer s, t h er e is m in er a l oil or ot h er flu id
con t a m in a t ion of t h e br a ke flu id.
If br a ke flu id is con t a m in a t ed, dr a in a n d t h or-
ou gh ly flu sh syst em . Repla ce m a st er cylin der wit h
r eser voir, ca liper sea ls, H CU a n d a ll h ydr a u lic flu id
h oses.

SPECI FI CAT I ON S
BRAKE FLUID
Th e br a ke flu id u sed in t h is veh icle m u st con for m
t o DOT 3 specifica t ion s a n d SAE J 1703 st a n da r ds.
No ot h er t ype of br a ke flu id is r ecom m en ded or
a ppr oved for u sa ge in t h e veh icle br a ke syst em . Use
on ly Mopa r br a ke flu id or a n equ iva len t fr om a
t igh t ly sea led con t a in er.

CAUTION: Never use reclaimed brake fluid or fluid

from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
Fig. 47 Release Tool
CAUTION: Never use any type of a petroleum-based 1 - RESERVOIR
fluid in the brake hydraulic system. Use of such 2 - RELEASE TOOL
type fluids will result in seal damage of the vehicle 3 - RETAINING TABS
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would (2) St a r t r eser voir in gr om m et s t h en pr ess t h e r es-
be items such as engine oil, transmission fluid, er voir st r a igh t down t o sea t t h e r eser voir in t o t h e
power steering fluid, etc. cylin der gr om m et s.

CAUTION: Do not rock the reservoir during installa-

FLU I D RESERV OI R
REMOVAL
(1) Rem ove r eser voir ca p a n d r em ove flu id wit h a
c le a n su ct ion gu n .
(2) Rem ove t h e wir e con n ect or fr om t h e br a ke flu id
level sen sor.
(3) In ser t t h e t ool (F ig. 47) pr ovided wit h t h e r es-
er voir t o r elea se t h e r eser voir r et a in in g t a bs.
(4) P u ll t h e r eser voir st r a igh t u p ou t of t h e cylin -
der.
(5) Rem ove a n d disca r d gr om m et s fr om t h e cylin -
der body.
INSTALLATION
(1) Lu br ica t e n ew gr om m et s wit h clea n br a ke
flu id. In st a ll n ew gr om m et s in t o t h e cylin der body.
CAUTION: Do not use tools to install the grommets.
Tools may cut, or tear the grommets. Install the
grommets using finger pressure only.
tion.
(3) Ver ify r et a in in g t a bs a r e sea t ed.
(4) In st a ll t h e wir e con n ect or t o t h e br a ke flu id
level sen sor.
(5) F ill m a st er cylin der.
M AST ER CY LI N DER
DESCRIPTION
Th e m a st er cylin der body is m a de of a lu m in u m
a n d con t a in s a pr im a r y a n d secon da r y pist on a ssem -
bly. Th e cylin der body in clu din g t h e pist on a ssem -
blies a r e n ot ser vicea ble. If dia gn osis in dica t es a n
in t er n a l pr oblem wit h t h e cylin der body, it m u st be
r epla ced a s a n a ssem bly. Th e m a st er cylin der h a s a
r em ova ble r eser voir a n d flu id level in dica t or. Th e r es-
er voir, r eser voir gr om m et s, r eser voir ca p a n d flu id
level swit ch a r e t h e on ly r epla cea ble pa r t s on t h e
m a st er cylin der.
5 - 24 BRAKES - BASE WJ
M AST ER CY LI N DER (Cont inue d)

OPERATION
Th e m a st er cylin der bor e con t a in s a pr im a r y a n d
secon da r y pist on . Th e pr im a r y pist on su pplies
h ydr a u lic pr essu r e t o t h e fr on t br a kes. Th e secon da r y
pist on su pplies h ydr a u lic pr essu r e t o t h e r ea r br a kes.
Th e m a st er cylin der r eser voir st or es r eser ve br a ke
flu id for t h e h ydr a u lic br a ke cir cu it s.

DIAGNOSIS AND TESTING - MASTER

CYLINDER/POWER BOOSTER
NOTE: Inspect and repair any external fluid leaks
before performing test.

(1) St a r t en gin e a n d ch eck boost er va cu u m h ose

con n ect ion s. A h issin g n oise in dica t es va cu u m lea k.
Cor r ect a n y va cu u m lea k befor e pr oceedin g.
(2) St op en gin e a n d sh ift t r a n sm ission in t o Neu t r a l.
(3) P u m p br a ke peda l u n t il a ll va cu u m r eser ve in
boost er is deplet ed.
(4) P r ess a n d h old br a ke peda l u n der ligh t foot Fig. 48 Typical Booster Vacuum Test Connections
pr essu r e. Th e peda l sh ou ld h old fir m , if t h e peda l
1 - TEE FITTING
fa lls a wa y t h e m a st er cylin der or H CU m a y be fa u lt y
2 - SHORT CONNECTING HOSE
(in t er n a l lea ka ge). 3 - CHECK VALVE
(5) St a r t en gin e a n d n ot e peda l a ct ion . It sh ou ld 4 - CHECK VALVE HOSE
fa ll a wa y sligh t ly u n der ligh t foot pr essu r e t h en h old 5 - CLAMP TOOL
fir m . If n o peda l a ct ion is discer n ible, power boost er, 6 - INTAKE MANIFOLD
va cu u m su pply, or va cu u m ch eck va lve is fa u lt y. P r o- 7 - VACUUM GAUGE
ceed t o t h e P OWE R BOOSTE R VACUUM TE ST.
(6) If t h e P OWE R BOOSTE R VACUUM TE ST (4) Apply 51-67 kP a (15-20 in .) va cu u m a t la r ge
pa sses, r ebu ild boost er va cu u m r eser ve a s follows: en d of ch eck va lve (F ig. 49).
Relea se br a ke peda l. In cr ea se en gin e speed t o 1500 (5) Va cu u m sh ou ld h old st ea dy. If ga u ge on pu m p
r pm , close t h e t h r ot t le a n d t u r n off t h e en gin e. in dica t es va cu u m loss t h e ch eck va lve a n d sea l
(7) Wa it a m in im u m of 90 secon ds a n d t r y br a ke sh ou ld be r epla ced.
a ct ion a ga in . Boost er sh ou ld pr ovide t wo or m or e va c-
u u m a ssist ed peda l a pplica t ion s. If va cu u m a ssist is
n ot pr ovided, som e com pon en t of t h e boost er is fa u lt y.

POWER BOOSTER VACUUM TEST

(1) Con n ect va cu u m ga u ge t o boost er ch eck va lve
wit h sh or t len gt h of h ose a n d T-fit t in g (F ig. 48).
(2) St a r t a n d r u n en gin e a t cu r b idle speed for on e
m in u t e.
(3) Obser ve t h e va cu u m su pply. If va cu u m su pply
is n ot a dequ a t e, r epa ir va cu u m su pply.
(4) Cla m p h ose sh u t bet ween va cu u m sou r ce a n d
ch eck va lve.
(5) St op en gin e a n d obser ve va cu u m ga u ge.
(6) If va cu u m dr ops m or e t h a n on e in ch H G (33
m illiba r s) wit h in 15 secon ds, boost er dia ph r a gm , Fig. 49 Vacuum Check Valve And Seal
ch eck va lve or ch eck va lve sea l/gr om m et is fa u lt y. 1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
POWER BOOSTER CHECK VALVE TEST 3 - VALVE SEAL
(1) Discon n ect va cu u m h ose fr om ch eck va lve.
(2) Rem ove ch eck va lve a n d va lve sea l fr om boost er.
(3) Use a h a n d oper a t ed va cu u m pu m p for t est .
WJ BRAKES - BASE 5 - 25
M AST ER CY LI N DER (Cont inue d)

STANDARD PROCEDURE - MASTER CYLINDER

BLEEDING PROCEDURE
A n ew m a st er cylin der sh ou ld be bled befor e in st a l-
la t ion on t h e veh icle. Requ ir ed bleedin g t ools in clu de
bleed t u bes a n d a wood dowel t o st r oke t h e pist on s.
Bleed t u bes ca n be fa br ica t ed fr om br a ke lin e.
(1) Mou n t m a st er cylin der in vise wit h br a ss ja ws.
(2) At t a ch bleed t u bes t o cylin der ou t let por t s.
Th en posit ion ea ch t u be en d in t o t h e bot t om of t h e
r eser voir (F ig. 50).
(3) F ill r eser voir wit h fr esh br a ke flu id.
(4) P r ess cylin der pist on s in wa r d wit h wood dowel.
Th en r elea se pist on s a n d a llow t h em t o r et u r n u n der
spr in g pr essu r e. Con t in u e bleedin g oper a t ion s u n t il
a ir bu bbles a r e n o lon ger visible in flu id.

Fig. 51 Master Cylinder Mounting

1 - MOUNTING NUT
2 - SENSOR CONNECTOR
3 - MOUNTING NUT
4 - BRAKE LINES

(2) In st a ll m a st er cylin der m ou n t in g n u t s a n d

t igh t en n u t s t o 25 N·m (18 lb. lbs.).

NOTE: Use original or factory replacement nuts only.

Fig. 50 Master Cylinder Bleeding
(3) In st a ll br a ke lin es a n d t igh t en t o 16 N·m (144
1 - BLEEDING TUBES
2 - RESERVOIR
in . lbs.).
(4) In st a ll flu id level sen sor con n ect or.
(5) F ill a n d bleed br a ke syst em .
REMOVAL
(1) Rem ove t h e wir e con n ect or fr om t h e br a ke flu id
level sen sor. PEDAL
(2) Rem ove br a ke lin es fr om m a st er cylin der.
(3) Rem ove n u t s t h a t a t t a ch m a st er cylin der t o
boost er st u ds (F ig. 51). DESCRI PT I ON
(4) Rem ove m a st er cylin der fr om boost er.
DESCRIPTION - STANDARD PEDAL
INSTALLATION A su spen ded-t ype br a ke peda l is u sed, t h e peda l
pivot s on a sh a ft m ou n t ed in t h e peda l su ppor t
NOTE: Bleed new master cylinder on bench before br a cket . Th e br a cket is a t t a ch ed t o t h e da sh pa n el.
installation, refer to Service Procedures. Th e br a ke peda l a ssem bly a n d peda l pa d a r e t h e
on ly ser vicea ble com pon en t .
(1) H a ve a n a ssist a n t depr ess t h e br a ke peda l
wh ile gu idin g t h e m a st er cylin der on t h e boost er r od DESCRIPTION - ADJUSTABLE PEDALS
a n d m ou n t in g st u ds. Th e Adju st a ble P eda ls Syst em (AP S) is design ed t o
en a ble t h e for e a n d a ft r eposit ion in g of t h e br a ke a n d
CAUTION: Do not depress brake pedal too hard and a cceler a t or peda ls. Th is r esu lt s in im pr oved er gon om -
ensure the booster rod is in the master cylinder pis- ics in r ela t ion t o t h e st eer in g wh eel for t a ller a n d
ton or booster/master cylinder damage will occur. sh or t er dr iver s. Bein g a ble t o a dju st t h e peda l posi-
5 - 26 BRAKES - BASE WJ
PEDAL (Cont inue d)
t ion s a lso a llows t h e dr iver t o set st eer in g wh eel t ilt
a n d sea t posit ion t o t h e m ost com for t a ble posit ion .
Th e posit ion of t h e br a ke a n d a cceler a t or peda ls ca n
be a dju st ed wit h ou t com pr om isin g sa fet y or com for t
in a ct u a t in g t h e peda ls. Reposit ion in g t h e peda ls
does n ot ch a n ge t h e effor t r equ ir ed for a ct u a t ion .
Ch a n ge of peda l posit ion is a ccom plish ed by m ea n s
of a m ot or dr iven scr ew. Oper a t in g t h e a dju st a ble
peda l swit ch a ct iva t es t h e peda l dr ive m ot or. Th e
peda l dr ive m ot or t u r n s a scr ew t h a t ch a n ges t h e
posit ion of t h e br a ke a n d a cceler a t or peda ls. Th e
peda l ca n be m oved r ea r wa r d (closer t o t h e dr iver ) or
for wa r d (a wa y fr om dr iver ). Th e br a ke peda l is
m oved on it s dr ive scr ew t o a posit ion wh er e t h e
dr iver feels m ost com for t a ble (F ig. 52).
Th e a cceler a t or peda l is m oved a t t h e sa m e t im e Fig. 52 ADJUSTABLE PEDALS ASSEMBLY
a n d t h e sa m e dist a n ce a s t h e br a ke peda l. Th e a ccel- 1 - HARNESS
er a t or peda l a dju st m en t scr ew is t u r n ed by a flexible 2 - ADJUSTABLE PEDAL BRACKET
sh a ft sla ved off t h e br a ke a dju st m en t scr ew. 3 - CABLE
Neit h er t h e peda l dr ive m ot or n or dr ive m ech a - 4 - ACCELERATOR PEDAL
n ism a r e su bject t o t h e m ech a n ica l st r ess of br a ke or 5 - BRAKE PEDAL
a cceler a t or a pplica t ion . 6 - ADJUSTABLE PEDAL MOTOR
• SYSTE M F E ATURE S: 7 - BRAKE LIGHT SWITCH
8 - ADJUSTABLE PEDALS MODULE
• Ra n ge of Adju st m en t : Th e peda ls m a y be
a dju st ed u p t o 3 in . (75 m m )
• P eda l Adju st m en t Speed: 0.5 in ./sec (12.5 REM OVAL
m m /sec)
• P eda l Adju st m en t In h ibit or s: P eda l a dju st - REMOVAL - NON-ADJUSTABLE PEDAL
m en t is in h ibit ed wh en t h e veh icle is in r ever se or (1) Rem ove r et a in er clip t h a t h olds boost er t o
wh en cr u ise con t r ol is a ct iva t ed. peda l pin (F ig. 53).
• Mem or y: An opt ion a l m em or y fea t u r e is a va il-
a ble. Th is a llows st or in g of on e or t wo pr efer r ed
peda l posit ion s in t h e Adju st a ble P eda l Modu le
(AP M). A pr efer r ed posit ion ca n be st or ed a n d
r eca lled u sin g t h e door-m ou n t ed swit ch es. A st or ed
peda l posit ion ca n be r eca lled (bu t n ot st or ed)
u sin g t h e Rem ot e Keyless E n t r y (RKE ).
• Adju st a ble P eda l F eedba ck Messa ge: Th e E lec-
t r on ic Veh icle In for m a t ion Cen t er (E VIC) will displa y
a m essa ge wh en t h e AP S is disa bled. ie: "Adju st a ble
P eda l Disa bled - Cr u ise Con t r ol E n ga ged" or "Adju st -
a ble P eda l Disa bled - Veh icle in Rever se".
• Da m a ge P r even t ion : F oot pr essu r e or debr is
ca n st a ll peda l a dju st m en t . In or der t o a void da m -
a ge t o syst em com pon en t s du r in g peda l a dju st -
m en t , t h e AP M will m on it or peda l posit ion sen sor
volt a ge. If t h e AP M does n ot det ect expect ed volt -
a ge ch a n ge wit h in 1.5 secon ds, it will cu t power t o
t h e a dju st a ble peda l m ot or.

OPERATION
Th e br a ke peda l is a t t a ch ed t o t h e boost er pu sh
Fig. 53 Push Rod Retainer Clip
r od. Wh en t h e peda l is depr essed, t h e pr im a r y
1 - RETAINER CLIP
boost er pu sh r od is depr essed wh ich m oves t h e
2 - PUSH ROD
boost er secon da r y r od. Th e boost er secon da r y r od 3 - PEDAL PIN
depr esses t h e m a st er cylin der pist on .
WJ BRAKES - BASE 5 - 27
PEDAL (Cont inue d)
(2) Rem ove n u t fr om peda l sh a ft .
(3) Slide peda l sh a ft ou t a n d r em ove br a ke peda l.
(4) Rem ove peda l bu sh in gs (F ig. 54) if t h ey a r e t o
be r epla ced.

Fig. 55 UPPER MOUNTING NUTS

1 - UPPER MOUNTING STUDS
2 - ACCELERATOR MOUNTING STUDS
3 - UPPER MOUNTING NUT
4 - MOTOR
5 - ADJUSTABLE PEDAL BRACKET

Fig. 54 Pedal Bushings

1 - BUSHING
2 - BUSHING
3 - SHAFT NUT
4 - PEDAL SHAFT

REMOVAL - ADJUSTABLE PEDALS

NOTE: If possible put the pedals in the full forward
position.

(1) Discon n ect t h e n ega t ive ba t t er y ca ble.

(2) Rem ove t h e clu st er bezel (Refer t o 23 - BODY/
INSTRUME NT PANE L/CLUSTE R BE ZE L - RE MOV-
AL).
(3) Rem ove t h e st eer in g colu m n open in g cover
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R- Fig. 56 ADJUSTABLE PEDAL BRACKET
ING COLUMN OP E NING COVE R - RE MOVAL). 1 - BRAKE LIGHT SWITCH
(4) Discon n ect t h e m odu le elect r ica l con n ect or. 2 - STEERING COLUMN
(5) Rem ove t h e br a ke ligh t swit ch . 3 - ACCELERATOR PEDAL
4 - ADJUSTABLE PEDALS MOUNTING BRACKET
(6) Discon n ect t h e boost er r od clip (F ig. 53).
5 - BRAKE PEDAL
(7) Discon n ect t h e a cceler a t or ca ble fr om t h e
6 - MOTOR MOUNTING BRACKET
peda l. 7 - BRAKE BOOSTER MOUNTING NUTS
(8) Lock t h e st eer in g wh eel in t o pla ce. (4)
(9) Rem ove t h e lower st eer in g sh a ft pin ch bolt
(F ig. 56). (14) Rem ove t h e ICU m ou n t in g br a cket n u t s a n d
(10) Sepa r a t e t h e lower sh a ft cou pler a n d pu sh for- bolt s a n d m ove t h e ICU a n d boost er for wa r d t h is will
wa r d (F ig. 56). a llow en ou gh clea r a n ce t o r em ove t h e a dju st a ble
(11) Rem ove t h e t wo peda l br a cket u pper n u t s peda l br a cket fr om over t h e boost er pu sh r od.
(F ig. 55). (15) Rem ove t h e peda l fr om t h e veh icle (F ig. 56).
(12) Rem ove t h e br a ke boost er n u t s (F ig. 56). (16) Tr a n sfer t h e m odu le if n eeded.
(13) Rem ove t h e a cceler a t or peda l n u t s (F ig. 57).
5 - 28 BRAKES - BASE WJ
PEDAL (Cont inue d)
(10) Recon n ect t h e boost er r od clip (F ig. 56).
(11) In st a ll t h e br a ke ligh t swit ch .
(12) Recon n ect t h e m odu le elect r ica l con n ect or.
(13) In st a ll t h e st eer in g colu m n open in g cover
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
ING COLUMN OP E NING COVE R - INSTALLA-
TION).
(14) In st a ll t h e clu st er bezel (Refer t o 23 - BODY/
INSTRUME NT PANE L/CLUSTE R BE ZE L -
INSTALLATION).
(15) Recon n ect t h e n ega t ive ba t t er y ca ble.

Fig. 57 ACCELERATOR MOUNTING BRACKET
1 - ACCELERATOR MOUNTING NUTS
2 - ADJUSTABLE PEDALS BRACKET
3 - ACCELERATOR PEDAL
I N STALLAT I ON
INSTALLATION - NON-ADJUSTABLE PEDAL
(1) Lu br ica t e bu sh in gs, peda l sh a ft a n d peda l pin
wit h Mopa r m u lt i-m ilea ge gr ea se.
(2) In st a ll bu sh in gs in t o peda l.
(3) P osit ion peda l in br a cket a n d in st a ll peda l
sh a ft in su ppor t a n d t h r ou gh peda l.
(4) In st a ll n ew n u t on peda l sh a ft a n d t igh t en t o
27 N·m (20 ft . lbs.).
PEDAL M OT OR
REMOVAL
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Rem ove t h e clu st er bezel (Refer t o 23 - BODY/
INSTRUME NT PANE L/CLUSTE R BE ZE L - RE MOV-
AL).
(3) Rem ove t h e st eer in g colu m n open in g cover
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
ING COLUMN OP E NING COVE R - RE MOVAL).
(4) Rem ove t h e t wo m ou n t in g scr ews (F ig. 58).
(5) Discon n ect t h e elect r ica l con n ect or (F ig. 58).
(6) Rem ove t h e a dju st a ble peda l m ot or (F ig. 58).

NOTE: Pedal shaft nut should not be reused.

(5) In st a ll boost er pu sh r od on peda l pin a n d

in st a ll r et a in er clip on peda l pin .
(6) Ch eck a n d a dju st st op la m p swit ch if n ecessa r y.

INSTALLATION - ADJUSTABLE PEDALS

(1) In st a ll t h e peda l t o t h e veh icle (F ig. 56).
(2) Reposit ion t h e ICU a n d boost er, In st a ll t h e
ICU m ou n t in g br a cket n u t s a n d bolt s.
28 N Fig. 58 ADJUSTABLE PEDALS MOTOR
(3) In st a ll t h e br a ke boost er n u t s. Tigh t en t o 28 1 - ELECTRICAL CONNECTOR
N·m ( 21 ft . lbs.). (F ig. 56). 2 - PEDALS MOTOR
(4) In st a ll t h e peda l br a cket u pper n u t s. Tigh t en 3 - MOUNTING SCREWS HOLES
t o 12 N·m ( 9 ft . lbs.). (F ig. 56).
(5) In st a ll t h e a cceler a t or peda l n u t s. Tigh t en t o
28 N·m ( 21 ft . lbs.). (F ig. 57).
INSTALLATION
(1) In st a ll t h e a dju st a ble peda l m ot or (F ig. 58).
(6) In st a ll t h e lower st eer in g sh a ft cou pler over t h e
(2) Recon n ect t h e elect r ica l con n ect or (F ig. 58).
sh a ft (F ig. 56).
(3) In st a ll t h e t wo m ou n t in g scr ews (F ig. 58).
(7) In st a ll t h e lower st eer in g sh a ft pin ch bolt (F ig.
(4) In st a ll t h e st eer in g colu m n open in g cover
56).
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
(8) Un lock t h e st eer in g wh eel.
ING COLUMN OP E NING COVE R - INSTALLA-
(9) Recon n ect t h e a cceler a t or ca ble t o t h e peda l
TION).
(F ig. 56).
WJ
PEDAL M OT OR (Cont inue d)
(5) In st a ll t h e clu st er bezel (Refer t o 23 - BODY/
INSTRUME NT PANE L/CLUSTE R BE ZE L -
INSTALLATION).
(6) Recon n ect t h e n ega t ive ba t t er y ca ble.
POWER BRAK E BOOST ER
DESCRIPTION
Th e boost er a ssem bly con sist s of a h ou sin g divided
in t o sepa r a t e ch a m ber s by t wo in t er n a l dia ph r a gm s.
Th e ou t er edge of ea ch dia ph r a gm is a t t a ch ed t o t h e
boost er h ou sin g.
Two pu sh r ods a r e u sed in t h e boost er. Th e pr i-
m a r y pu sh r od con n ect s t h e boost er t o t h e br a ke
peda l. Th e secon da r y pu sh r od con n ect s t h e boost er
t o t h e m a st er cylin der t o st r oke t h e cylin der pist on s.
OPERATION
Th e a t m osph er ic in let va lve is open ed a n d closed
by t h e pr im a r y pu sh r od. Boost er va cu u m su pply is
t h r ou gh a h ose a t t a ch ed t o a n in t a ke m a n ifold fit t in g
BRAKES - BASE 5 - 29
a t on e en d a n d t o t h e boost er ch eck va lve a t t h e
ot h er. Th e va cu u m ch eck va lve in t h e boost er h ou sin g
is a on e-wa y device t h a t pr even t s va cu u m lea k ba ck.
P ower a ssist is gen er a t ed by u t ilizin g t h e pr essu r e
differ en t ia l bet ween n or m a l a t m osph er ic pr essu r e
a n d a va cu u m . Th e va cu u m n eeded for boost er oper-
a t ion is t a ken dir ect ly fr om t h e en gin e in t a ke m a n i-
fold. Th e en t r y poin t for a t m osph er ic pr essu r e is
t h r ou gh a filt er a n d in let va lve a t t h e r ea r of t h e
h ou sin g (F ig. 59) .
Th e ch a m ber a r ea s for wa r d of t h e boost er dia -
ph r a gm s a r e exposed t o va cu u m fr om t h e in t a ke
m a n ifold. Th e ch a m ber a r ea s t o t h e r ea r of t h e dia -
ph r a gm s, a r e exposed t o n or m a l a t m osph er ic pr es-
su r e of 101.3 kilopa sca ls (14.7 pou n ds/squ a r e in .).
Br a ke peda l a pplica t ion ca u ses t h e pr im a r y pu sh
r od t o open t h e a t m osph er ic in let va lve. Th is exposes
t h e a r ea beh in d t h e dia ph r a gm s t o a t m osph er ic pr es-
su r e. Th e r esu lt in g pr essu r e differ en t ia l pr ovides t h e
ext r a a pply for ce for power a ssist .
Th e boost er ch eck va lve, ch eck va lve gr om m et a n d
boost er sea ls a r e ser vicea ble.
5 - 30 BRAKES - BASE WJ
POWER BRAK E BOOST ER (Cont inue d)

Fig. 59 Power Brake Booster–Typical

1 - VACUUM CHECK VALVE 8 - ATMOSPHERIC INLET VALVE ASSEMBLY
2 - FRONT DIAPHRAGM 9 - BOOSTER MOUNTING STUDS (4)
3 - REAR DIAPHRAGM 10 - SECONDARY PUSH ROD (TO MASTER CYLINDER)
4 - HOUSING 11 - MASTER CYLINDER MOUNTING STUD (2)
5 - SEAL 12 - SPRING
6 - AIR FILTER
7 - PRIMARY PUSH ROD (TO BRAKE PEDAL)
WJ
POWER BRAK E BOOST ER (Cont inue d)
REMOVAL
(1) Rem ove t h e m a st er cylin der.
(2) Discon n ect va cu u m h ose a t boost er ch eck va lve.
(3) Rem ove r et a in er clip (F ig. 60) t h a t h olds
boost er pu sh r od on peda l pin . Th en slide pu sh r od
off pin .
Fig. 60 Retainer Clip
1 - RETAINER CLIP
2 - PUSH ROD
3 - PEDAL PIN
(4) Rem ove fou r n u t s (F ig. 61) t h a t a t t a ch boost er
t o da sh pa n el.
(5) In en gin e com pa r t m en t , slide boost er for wa r d,
t ilt it u pwa r d sligh t ly, a n d r em ove it fr om en gin e
com pa r t m en t .
INSTALLATION
(1) Ch eck con dit ion of gr om m et t h a t secu r es ch eck
va lve in boost er. Repla ce gr om m et if cu t , t or n , or
loose.
(2) In st a ll n ew boost er da sh sea l.
(3) Align a n d posit ion boost er on en gin e com pa r t -
m en t side of da sh pa n el.
(4) In side pa ssen ger com pa r t m en t :
(a ) Lu br ica t e peda l pin Mopa r m u lt i-m ilea ge
gr ea se.
(b) In st a ll boost er a t t a ch in g n u t s on st u ds.
Tigh t en a t t a ch in g n u t s t o 39 N·m (29 ft . lbs.).
(c) Slide boost er pu sh r od on peda l pin . Th en
secu r e r od t o pin wit h r et a in er clip.
(5) In en gin e com pa r t m en t , a t t a ch va cu u m h ose t o
boost er ch eck va lve.
BRAKES - BASE 5 - 31
Fig. 61 Power Brake Booster Mounting
1 - BOOSTER
2 - DASH PANEL
(6) In st a ll t h e m a st er cylin der wit h n ew ga sket
a n d n u t s.
CAUTION: The master cylinder installation proce-
dure must be perform as written or damage to the
booster/master cylinder may occur.
(7) F ill a n d bleed br a ke syst em .
ROT ORS
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - FRONT DISC
BRAKE ROTOR
ROTOR MINIMUM THICKNESS
Rot or m in im u m u sa ble t h ickn ess is 24.5 m m (0.964
in .). Do n ot r esu r fa ce a r ot or if m a ch in in g wou ld
ca u se t h ickn ess t o fa ll below t h is lim it .
Mea su r e r ot or t h ickn ess a t t h e cen t er of t h e br a ke
sh oe con t a ct su r fa ce. Repla ce t h e r ot or if wor n below
m in im u m t h ickn ess, or if r efin ish in g wou ld r edu ce
t h ickn ess below t h e a llowa ble m in im u m .
FRONT ROTOR THICKNESS VARIATION
Va r ia t ion s in r ot or t h ickn ess will ca u se peda l pu l-
sa t ion , n oise a n d sh u dder.
5 - 32 BRAKES - BASE
ROT ORS (Cont inue d)
Mea su r e r ot or t h ickn ess a m in im u m of six poin t s
a r ou n d t h e r ot or fa ce. P osit ion t h e m icr om et er a ppr ox-
im a t ely 19 m m (3/4 in .) fr om t h e r ot or ou t er cir cu m fer-
en ce for ea ch m ea su r em en t (F ig. 62).
Th ickn ess sh ou ld n ot va r y by m or e t h a n 0.0127 m m
(0.0005 in .) fr om poin t t o poin t on t h e r ot or. Refin ish or
r epla ce t h e r ot or if n ecessa r y.
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the vehi-
cles hub/bearing.
CAUTION: For vehicles equipped with the Quadra-
Drive System, consisting of the NV-247 transfer case
and a Vari-Lok differential in the front and rear axles,
the following steps must be done prior to the use of a
hub mounted on-vehicle brake lathe. Disconnect the
driveshaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
from the respective axle on which the brake rotors are
being machined. Temporarily remove both brake cali-
pers (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) from the axle
while disc rotor machining is in process. Both steps
will prevent unnecessary loads to the hub mounted
on-vehicle lathe and speed machining times. Install a
thread lock material to the driveshaft attaching bolts
when reinstalling (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION).
F r on t r ot or s a n d h u b/bea r in gs a r e m a t ch ed m ou n t ed
for m in im u m la t er a l r u n ou t . Befor e r em ovin g t h e r ot or,
m a r k t h e r ot or a n d h u b/bea r in g t o m a in t a in or igin a l
or ien t a t ion .
Fig. 62 Measuring Rotor Thickness Variation
1 - MICROMETER
2 - ROTOR
FRONT ROTOR LATERAL RUNOUT
Ch eck r ot or la t er a l r u n ou t wh en ever peda l pu lsa t ion ,
or r a pid, u n even br a ke lin in g wea r h a s occu r r ed.
Th e r ot or m u st be secu r ely cla m ped t o t h e h u b t o
en su r e a n a ccu r a t e r u n ou t m ea su r em en t . Secu r e t h e
WJ
2002 WJ Service Manual
Publication No. 81-370-02064
02WJ5-32 June, 2002
r ot or wit h a m in im u m of 3 lu g n u t s a n d la r ge dia m et er
fla t wa sh er s on ea ch st u d.
Use a dia l in dica t or t o ch eck la t er a l r u n ou t (F ig. 63).
Ma xim u m a llowa ble r ot or la t er a l r u n ou t is 0.05 m m
(0.002 in .).
Fig. 63 Checking Rotor Lateral Runout
1 - DIAL INDICATOR
DIAGNOSIS AND TESTING - REAR DISC
BRAKE ROTOR
ROTOR MINIMUM THICKNESS
Min im u m u sa ble t h ickn ess of t h e r ea r disc br a ke
r ot or is 8.5 m m (0.335 in .). Th e t h ickn ess specifica t ion
is loca t ed on t h e cen t er sect ion of t h e r ot or.
Never r esu r fa ce a r ot or if m a ch in in g wou ld ca u se
t h ickn ess t o fa ll below t h is lim it .
Mea su r e r ot or t h ickn ess a t t h e cen t er of t h e br a ke
sh oe con t a ct su r fa ce. Repla ce t h e r ot or if wor n below
m in im u m t h ickn ess, or if r efin ish in g wou ld r edu ce
t h ickn ess below t h e a llowa ble m in im u m .
REAR ROTOR THICKNESS VARIATION
Va r ia t ion s in r ot or t h ickn ess will ca u se peda l pu lsa -
t ion , n oise a n d sh u dder.
Mea su r e r ot or t h ickn ess a t a m in im u m of six poin t s
a r ou n d t h e r ot or fa ce. P osit ion t h e m icr om et er a ppr oxi-
m a t ely 19 m m (3/4 in .) fr om t h e r ot or ou t er cir cu m fer-
en ce for ea ch m ea su r em en t (F ig. 62).
Th ickn ess sh ou ld n ot va r y by m or e t h a n 0.0127 m m
(0.0005 in .) fr om poin t t o poin t on t h e r ot or. Refin ish or
r epla ce t h e r ot or if n ecessa r y.
REAR ROTOR LATERAL RUNOUT
Ch eck r ot or la t er a l r u n ou t wh en ever dia gn osis in di-
ca t es peda l pu lsa t ion a n d r a pid, u n even br a ke lin in g
wea r.
Th e r ot or m u st be secu r ely cla m ped t o t h e h u b t o
en su r e a n a ccu r a t e r u n ou t m ea su r em en t . Secu r e t h e
r ot or wit h t h e wh eel n u t s a n d 4 or 5 la r ge dia m et er fla t
wa sh er s on ea ch st u d.
Use a dia l in dica t or t o ch eck la t er a l r u n ou t (F ig. 63).
Ma xim u m a llowa ble la t er a l r u n ou t is 0.76 m m (0.003 in .).
WJ BRAKES - BASE 5 - 33
2002 WJ Service Manual
ROT ORS (Cont inue d) Publication No. 81-370-02064
02WJ5-33 June, 2002

STANDARD PROCEDURE - DISC ROTOR

MACHINING
CAUTION: For vehicles equipped with the Quadra-
Drive System, consisting of the NV-247 transfer case
and a Vari-Lok differential in the front and rear axles,
the following steps must be done prior to the use of a
hub mounted on-vehicle brake lathe. Disconnect the
driveshaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
from the respective axle on which the brake rotors are
being machined. Temporarily remove both brake cali-
pers (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) from the axle
while disc rotor machining is in process. Both steps
will prevent unnecessary loads to the hub mounted
on-vehicle lathe and speed machining times. Install a
thread lock material to the driveshaft attaching bolts
when reinstalling (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION).
Fig. 64 Caliper Anchor Bolts
NOTE: A hub mounted on-vehicle lathe is recom- 1 - KNUCKLE
mended. This type of lathe trues the rotor to the vehi- 2 - ANCHOR
cles hub/bearing. 3 - ANCHOR BOLTS
Th e disc br a ke r ot or ca n be m a ch in ed if scor ed or 4 - ROTOR
wor n . Th e la t h e m u st m a ch in e bot h sides of t h e r ot or
sim u lt a n eou sly wit h du a l cu t t er h ea ds. Th e r ot or
m ou n t in g su r fa ce m u st be clea n befor e pla cin g on t h e
la t h e. E qu ipm en t ca pa ble of m a ch in in g on ly on e side a t
a t im e m a y pr odu ce a t a per ed r ot or.

CAUTION: Brake rotors that do not meet minimum

thickness specifications before or after machining
must be replaced.

REM OVAL
REMOVAL - FRONT DISC BRAKE ROTOR
NOTE: Front rotors and hub/bearings are matched
mounted for minimum lateral runout. Before removing
the rotor, mark the rotor and hub/bearing to maintain
original orientation.
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove wh eel a n d t ir e a ssem bly.
(3) Rem ove t h e ca liper a n ch or bolt s (F ig. 64) a n d
r em ove t h e ca liper a n d a n ch or a s a n a ssem bly fr om t h e
st eer in g kn u ckle.
(4) Secu r e ca liper a n ch or a ssem bly t o n ea r by su spen -
sion pa r t wit h a wir e. D o n o t a llo w bra k e h o s e to
s u p p o rt c a lip e r w e ig h t. Fig. 65 Caliper Anchor Bolts
(5) Ma r k t h e r ot or a n d h u b/bea r in g t o m a in t a in or ig- 1 - ROTOR
in a l or ien t a t ion . Rem ove r et a in er s secu r in g r ot or t o h u b 2 - ANCHOR
st u ds. 3 - ANCHOR BOLTS
(6) Rem ove r ot or fr om h u b/bea r in g.

REMOVAL - REAR DISC BRAKE ROTOR (5) Secu r e ca liper a n ch or a ssem bly t o n ea r by su spen -
sion pa r t wit h wir e. D o n o t a llo w bra k e h o s e to s u p -
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove wh eel a n d t ir e a ssem bly. p o rt c a lip e r w e ig h t.
(3) Rem ove t h e ca liper a n ch or bolt s (F ig. 65). (6) Rem ove r et a in er s secu r in g r ot or t o a xle st u ds.
(4) Rem ove ca liper a n d a n ch or a s a n a ssem bly. (7) Rem ove r ot or off a xle st u ds.
5 - 34 BRAKES - BASE
ROT ORS (Cont inue d)
I N STALLAT I ON
INSTALLATION - FRONT DISC BRAKE ROTOR
NOTE: If a new rotor is installed it must be match
mounted to the hub/bearing.
(1) In st a ll r ot or on h u b st u ds in it s or igin a l loca -
t ion .
(2) In st a ll t h e ca liper a n ch or a ssem bly on t h e
kn u ckle. In st a ll a n ch or bolt s a n d t igh t en t o 90-115
N·m (66-85 ft . lbs.).
(3) In st a ll wh eel a n d t ir e a ssem bly.
(4) Rem ove su ppor t a n d lower t h e veh icle.
(5) P u m p br a ke peda l t o sea t ca liper pist on s a n d
br a ke sh oes. Do n ot m ove veh icle u n t il fir m br a ke
peda l is obt a in ed.
INSTALLATION - REAR DISC BRAKE ROTOR
(1) In st a ll r ot or on a xle st u ds.
(2) In st a ll t h e ca liper a n ch or a ssem bly.
(3) In st a ll a n ch or bolt s a n d t igh t en t o 90-115 N·m
(66-85 ft . lbs.).
(4) In st a ll wh eel a n d t ir e a ssem bly.
(5) Rem ove su ppor t a n d lower t h e veh icle.
(6) P u m p br a ke peda l u n t il ca liper pist on s a n d
br a ke sh oes a r e sea t ed.
PARK I N G BRAK E
OPERATION
Th e pa r kin g br a kes oper a t ed by a a u t om a t ic t en -
sion er m ech a n ism bu ilt in t o t h e h a n d lever a n d ca ble
syst em . Th e fr on t ca ble is con n ect ed t o t h e h a n d
lever a n d t h e equ a lizer. Th e r ea r ca bles a t t a ch ed t o
t h e equ a lizer a n d t h e pa r kin g br a ke sh oe a ct u a t or.
A set of dr u m t ype br a ke sh oes a r e u sed for pa r k-
in g br a kes. Th e sh oes a r e m ou n t ed t o t h e r ea r disc
br a ke a da pt or. Th e pa r kin g br a ke dr u m is in t egr a t ed
in t o t h e r ea r disc br a ke r ot or.
P a r kin g br a ke ca ble a dju st m en t is con t r olled by a n
a u t om a t ic t en sion er m ech a n ism . Th e on ly a dju st -
m en t if n ecessa r y is t o t h e pa r k br a ke sh oes if t h e
lin in gs a r e wor n .
WJ
DIAGNOSIS AND TESTING - PARKING BRAKE
NOTE: Parking brake adjustment is controlled by an
automatic cable tensioner and does not require
adjustment. The only adjustment that may be nec-
essary would be to the park brake shoes if they are
worn.
Th e pa r kin g br a ke swit ch is in cir cu it wit h t h e r ed
wa r n in g la m p in t h e da sh . Th e swit ch will ca u se t h e
la m p t o illu m in a t e on ly wh en t h e pa r kin g br a kes a r e
a pplied. If t h e la m p r em a in s on a ft er pa r kin g br a ke
r elea se, t h e swit ch or wir es a r e fa u lt y.
If t h e r ed la m p com es on a fa u lt h a s occu r r ed in
t h e fr on t or r ea r br a ke h ydr a u lic syst em .
If t h e r ed wa r n in g la m p a n d yellow wa r n in g la m p
com e on , t h e elect r on ic br a ke dist r ibu t ion m a y be a t
fa u lt .
In m ost ca ses, t h e a ct u a l ca u se of a n im pr oper ly
fu n ct ion in g pa r kin g br a ke (t oo loose/t oo t igh t /won ’t
h old), ca n be t r a ced t o a pa r kin g br a ke com pon en t .
NOTE: The leading cause of improper parking brake
operation, is excessive clearance between the park-
ing brake shoes and the shoe braking surface.
Excessive clearance is a result of lining and/or
drum wear, drum surface machined oversize.
E xcessive pa r kin g br a ke lever t r a vel (som et im es
descr ibed a s a loose lever or t oo loose con dit ion ), is
t h e r esu lt of wor n br a ke sh oes, im pr oper br a ke sh oe
a dju st m en t , or im pr oper ly a ssem bled br a ke pa r t s.
A t oo loose con dit ion ca n a lso be ca u sed by in oper-
a t ive or im pr oper ly a ssem bled pa r kin g br a ke sh oe
pa r t s.
A con dit ion wh er e t h e pa r kin g br a kes do n ot h old,
will m ost pr oba bly be du e t o a wh eel br a ke com po-
n en t .
It em s t o look for wh en dia gn osin g a pa r kin g br a ke
pr oblem , a r e:
• Br a ke sh oe wea r
• Dr u m su r fa ce (in r ea r r ot or ) m a ch in ed over size
• F r on t ca ble n ot secu r ed t o lever
• Rea r ca ble n ot a t t a ch ed t o a ct u a t or
• Rea r ca ble seized
• P a r kin g br a ke lever n ot sea t ed
• P a r kin g br a ke lever bin d
WJ BRAKES - BASE 5 - 35

CABLES

REM OVAL
REMOVAL - FRONT PARKING BRAKE CABLE
(1) Rem ove cen t er con sole,(Refer t o 23 - BODY/IN-
TE RIOR/F LOOR CONSOLE - RE MOVAL).
(2) Lift u p r ea r sea t a n d ca r pet cover in g t h e pa r k-
in g br a ke ca bles.
(3) P la ce a scr ew dr iver t h r ou gh t h e fr on t ca ble
eyelet (F ig. 66) a n d pr y ba ck on t h e fr on t ca ble.

Fig. 67 Lock Out Spring

1 - LOCK OUT SPRING

Fig. 66 Front Cable Eyelet

1 - REAR CABLES
2 - FRONT CABLE EYELET
3 - FRONT CABLE
4 - EQUALIZER
Fig. 68 Cable Equalizer
1 - EQUALIZER
(4) H a ve a n a ssist a n t pr y down t h e lock ou t spr in g
2 - FRONT CABLE
t h r ou gh t h e h ole in t h e side of t h e pa r k br a ke lever
(F ig. 67) wit h a sm a ll scr ew dr iver. Th en slowly
r elea se t h e fr on t ca ble.

NOTE: Their should be slack in the cable if the lock

out spring is engaged.

(5) Disen ga ge fr on t ca ble en d fr om t h e equ a lizer

(F ig. 68).
(6) Disen ga ge fr on t ca ble en d fr om t h e pa r kin g
br a ke lever.
(7) Rem ove t h e fr on t ca r pet ,(Refer t o 23 - BODY/
INTE RIOR/CARP E TS AND F LOOR MATS -
RE MOVAL).
(8) Rem ove fr on t ca ble r et a in er n u t s (F ig. 69) fr om
t h e floor pa n .

Fig. 69 Front Parking Brake Cable

1 - RETAINER NUT
2 - FLOOR PAN
3 - FRONT CABLE
5 - 36 BRAKES - BASE
CABLES (Cont inue d)
(9) Com pr ess t h e ca ble r et a in er s wit h a 13 m m
wr en ch (F ig. 70). Rem ove t h e ca ble fr om pa r kin g
br a ke lever br a cket a n d equ a lizer br a cket .
WJ
(4) H a ve a n a ssist a n t pr y down t h e lock ou t spr in g
t h r ou gh t h e h ole in t h e side of t h e pa r k br a ke lever
(F ig. 72) wit h a sm a ll scr ew dr iver. Th en slowly
r elea se t h e fr on t ca ble.

NOTE: Their should be slack in the cable if the lock

out spring is engaged.

Fig. 70 Brake Lever Bracket

1 - FRONT CABLE
2 - WRENCH
REMOVAL - REAR PARKING BRAKE CABLES
(1) Rem ove cen t er con sole, (Refer t o 23 - BODY/
INTE RIOR/F LOOR CONSOLE - RE MOVAL).
(2) Lift u p r ea r sea t a n d ca r pet cover in g t h e pa r k-
in g br a ke ca bles.
(3) P la ce a scr ew dr iver t h r ou gh t h e fr on t ca ble
eyelet (F ig. 71) a n d pr y ba ck on t h e fr on t ca ble.
Fig. 72 Lock Out Spring
1 - LOCK OUT SPRING
(5) Disen ga ge r ea r ca bles en ds fr om t h e equ a lizer.
(6) Com pr ess t h e ca ble r et a in er s wit h a 13 m m
wr en ch (F ig. 73) a n d r em ove t h e ca ble fr om equ a lizer
br a cket .

Fig. 71 Front Cable Eyelet Fig. 73 Cable Retainers

1 - CABLE RETAINER
1 - REAR CABLES
2 - WRENCH
2 - FRONT CABLE EYELET
3 - FRONT CABLE
3 - FRONT CABLE
4 - REAR CABLES
4 - EQUALIZER
WJ BRAKES - BASE 5 - 37
CABLES (Cont inue d)
(7) Ra ise a n d su ppor t t h e veh icle.
(8) Rem ove t h e wh eel a n d t ir e a ssem blies.
(9) Rem ove t h e br a ke ca liper s, ca liper a n ch or s a n d
r ot or s.
(10) Rem ove t h e ABS sen sor wir in g h a r n ess (F ig.
74)fr om t h e r ea r br a ke ca bles.

Fig. 75 Parking Brake

1 - CABLE END
Fig. 74 Left Rear Parking Brake Cable
2 - SCREW DRIVER
1 - CABLE BRACKET 3 - PARKING BRAKE ACTUATOR
2 - UPPER SUSPENSION ARM 4 - BRAKE SHOES
3 - PARKING BRAKE CABLE
4 - CABLE RETAINER
5 - ABS SENSOR WIRING INSTALLATION - REAR PARKING BRAKE
CABLES
(11) Rem ove t h e ca ble r et a in er bolt s (F ig. 74) fr om (1) In st a ll t h e ca bles t h r ou gh t h e ca liper a n ch or
t h e r ea r spr in g pa ds. m ou n t . Th en pu sh t h e en d of ca ble st r a n d in t o
(12) P u ll t h e ca bles ou t of t h e u pper su spen sion en ga ge t h e ca ble en d t o t h e pa r kin g br a ke a ct u a t or.
a r m br a cket s. (2) F eed t h e ot h er en d of t h e ca bles t h r ou gh t h e
(13) P u sh t h e ca ble in a n d lift u p t h e en d of ca ble body a n d in t o t h e equ a lizer br a cket (F ig. 76).
wit h a sm a ll scr ew dr iver t o disen ga ge t h e ca ble fr om
t h e pa r kin g br a ke a ct u a t or (F ig. 75).
(14) Rem ove t h e ca ble fr om t h e veh icle.

I N STALLAT I ON
INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) In st a ll t h eca ble in t o t h e pa r kin g br a ke lever
br a cket a n d equ a lizer br a cket .
(2) In st a ll t h e fr on t ca ble t o t h e floor pa n a n d
in st a ll r et a in er n u t s.
(3) E n ga ge t h e fr on t ca ble en ds t o t h e pa r kin g
br a ke lever a n d equ a lizer.
(4) In st a ll t h e fr on t ca r pet , (Refer t o 23 - BODY/
INTE RIOR/CARP E TS AND F LOOR MATS - Fig. 76 Equalizer Bracket
INSTALLATION).
1 - EQUALIZER
(5) P u ll on t h e lever t o r elea se t h e lock ou t spr in g. 2 - RIGHT REAR CABLE
(6) In st a ll t h e cen t er con sole, (Refer t o 23 - BODY/ 3 - LEFT REAR CABLE
INTE RIOR/F LOOR CONSOLE - INSTALLATION). 4 - FRONT CABLE
(7) F old down t h e r ea r ca r pet cover a n d r ea r sea t .
5 - 38 BRAKES - BASE WJ
CABLES (Cont inue d)
(3) P u sh t h e ca bles in t o t h e u pper su spen sion a r m (4) H a ve a n a ssist a n t pr y down t h e lock ou t spr in g
br a cket s. t h r ou gh t h e h ole in t h e side of t h e pa r k br a ke lever
(4) In st a ll t h e ca ble r et a in er bolt s t o t h e r ea r (F ig. 78) wit h a sm a ll scr ew dr iver. Th en slowly
spr in g pa ds. r elea se t h e fr on t ca ble.
(5) In st a ll t h e ABS sen sor wir in g h a r n ess t o t h e
r ea r br a ke ca bles. NOTE: Their should be slack in the cable if the lock
(6) In st a ll t h e r ot or s, ca liper a n ch or s a n d br a ke out spring is engaged.
ca liper s.
(7) In st a ll t h e wh eel a n d t ir e a ssem blies.
(8) Rem ove su ppor t a n d lower t h e veh icle.
(9) E n ga ge t h e ca ble en ds in t o t h e pa r kin g br a ke
equ a lizer.
(10) P u ll on t h e lever t o r elea se t h e lock ou t
spr in g.
(11) In st a ll cen t er con sole, (Refer t o 23 - BODY/IN-
TE RIOR/F LOOR CONSOLE - INSTALLATION).
(12) F old down t h e r ea r ca r pet cover a n d r ea r sea t .
(13) Ver ify pa r kin g br a ke oper a t ion .

LEV ER
REMOVAL
Fig. 78 Lock Out Spring
(1) Rem ove cen t er con sole,(Refer t o 23 - BODY/IN-
TE RIOR/F LOOR CONSOLE - RE MOVAL). 1 - LOCK OUT SPRING
(2) Lift u p r ea r sea t a n d ca r pet cover in g t h e pa r k-
in g br a ke ca bles. (5) Discon n ect pa r kin g br a ke swit ch wir in g con -
(3) P la ce a scr ew dr iver t h r ou gh t h e fr on t ca ble n ect or.
eyelet (F ig. 77) a n d pr y ba ck on t h e fr on t ca ble. (6) Disen ga ge fr on t ca ble en d fr om pa r kin g br a ke
lever.
(7) Com pr ess t h e ca ble r et a in er wit h a 13 m m
wr en ch (F ig. 79) a n d r em ove t h e ca ble fr om t h e pa r k-
in g br a ke lever br a cket .

Fig. 77 FRONT CABLE

1 - REAR CABLES
2 - FRONT CABLE EYELET
3 - FRONT CABLE
4 - EQUALIZER
Fig. 79 Parking Brake Lever Bracket
1 - FRONT CABLE
2 - WRENCH
WJ BRAKES - BASE 5 - 39
LEV ER (Cont inue d)
(8) Rem ove t h e pa r k br a ke lever m ou n t in g n u t s
a n d con sole br a cket (F ig. 80).
(9) Lift t h e lever a ssem bly off t h e m ou n t in g st u ds
a n d pu ll t h e fr on t ca ble ou t of t h e lever br a cket .

Fig. 81 Lock Out Spring

1 - LOCK OUT SPRING

Fig. 80 Parking Brake Lever Mounting

1 - MOUNTING NUT
2 - PARK BRAKE LEVER

INSTALLATION
(1) In st a ll t h e lever a ssem bly on t h e m ou n t in g
st u ds wh ile feedin g t h e fr on t ca ble in t o t h e lever
br a cket .
(2) In st a ll t h e con sole br a cket (F ig. 80) a n d m ou n t -
in g n u t s.
(3) E n ga ge t h e fr on t ca ble en d t o t h e lever.
(4) Con n ect pa r kin g br a ke swit ch wir e con n ect or.
(5) P u ll on t h e lever t o r elea se t h e lock ou t spr in g.
(6) In st a ll cen t er con sole,(Refer t o 23 - BODY/IN- Fig. 82 Retracting Parking Brake Shoes
TE RIOR/F LOOR CONSOLE - INSTALLATION). 1 - ACCESS HOLE
(7) F old down t h e r ea r ca r pet cover a n d r ea r sea t . 2 - BRAKE ADJUSTING TOOL
3 - SPLASH SHIELD

SH OES (10) Rem ove sh oe h old-down clips a n d pin s (F ig.

85). Clip is h eld in pla ce by pin wh ich fit s in clip
REMOVAL n ot ch . To r em ove clip, fir st pu sh clip en ds t oget h er
(1) Lock ou t pa r k br a ke lever (F ig. 81). a n d slide clip u n t il h ea d of pin clea r s n a r r ow pa r t of
(2) Ra ise veh icle. n ot ch . Th en r em ove clip a n d pin .
(3) Rem ove r ea r wh eel a n d t ir e a ssem bly. (11) Rem ove sh oes a n d a dju st er.
(4) Rem ove ca liper a n d a n ch or a s a n a ssem bly.
(5) Rem ove r u bber a ccess plu g fr om ba ck of r ea r INSTALLATION
disc br a ke spla sh sh ield.
(1) In st a ll sh oes on spla sh sh ield wit h h old down
(6) If n ecessa r y r et r a ct pa r kin g br a ke sh oes wit h
clips a n d pin s. Be su r e sh oes a r e pr oper ly en ga ged in
br a ke a dju st er t ool (F ig. 82). P osit ion t ool a t t op of
t h e pa r k br a ke a ct u a t or.
st a r wh eel a n d r ot a t e wh eel.
(2) Lu br ica t e a n d in st a ll a dju st er scr ew a ssem bly.
(7) Rem ove r ot or fr om a xle h u b fla n ge.
Be su r e n ot ch ed en ds of scr ew a ssem bly a r e pr oper ly
(8) Rem ove t h e lower sh oe t o sh oe spr in g/a dju st er
sea t ed on sh oes a n d t h a t st a r wh eel is a lign ed wit h
spr in g wit h n eedle n ose plier s (F ig. 83).
a ccess h ole in sh ield.
(9) Rem ove t h e u pper sh oe t o sh oe spr in g/r et u r n
spr in g wit h br a ke plier s (F ig. 84).
5 - 40 BRAKES - BASE WJ
SH OES (Cont inue d)

Fig. 83 Lower Spring

1 - REAR SHOE
2 - NEEDLENOSE PLIERS
3 - ADJUSTER SCREW
Fig. 85 Hold-Down Clip And Pin
4 - LOWER SPRING
1 - HOLD-DOWN CLIP
2 - HOLD-DOWN PIN

ADJUSTMENTS - PARKING BRAKE SHOE

(1) Rem ove wh eel a n d t ir e a ssem blies.
(2) Secu r e r ot or wit h t wo wh eel n u t s.
(3) Rem ove r u bber a ccess plu g fr om ba ck of spla sh
sh ield.
(4) In ser t br a ke t ool t h r ou gh a ccess h ole in spla sh
sh ield (F ig. 86). P osit ion t ool a t bot t om of st a r wh eel.

Fig. 84 Upper Spring

1 - BRAKE PLIERS
2 - REAR SHOE
3 - UPPER SPRING

(3) In st a ll lower sh oe t o sh oe spr in g/a dju st er

spr in g. Needle n ose plier s ca n be u sed t o con n ect
spr in g t o ea ch sh oe.
(4) In st a ll t h e u pper sh oe t o sh oe spr in g/r et u r n
spr in g wit h br a ke plier s (F ig. 83).
(5) In st a ll r ot or a n d ca liper a n ch or a ssem bly.
(6) In st a ll a n ch or bolt s a n d t igh t en t o 90-115 N·m
(66-85 ft . lbs.).
(7) Act u a t e pa r k br a ke lever t o u n lock t h e pa r k
br a ke syst em .
(8) Adju st t h e pa r kin g br a ke sh oes (F ig. 82).
(9) In st a ll wh eel a n d t ir e a ssem bly.
(10) Lower veh icle a n d ver ify cor r ect pa r kin g
br a ke oper a t ion .
Fig. 86 Park Brake Shoe Adjustment
1 - ACCESS HOLE
2 - BRAKE ADJUSTING TOOL
3 - SPLASH SHIELD
(5) Rot a t e st a r wh eel u pwa r d dir ect ion t o expa n d
sh oes (wh ile fa cin g fr on t of veh icle).
(6) E xpa n d sh oes u n t il ligh t dr a g is exper ien ced.
Th en ba ck off a dju st er scr ew on ly en ou gh t o elim i-
n a t e dr a g.
(7) In st a ll plu g in spla sh sh ield a ccess h ole.
(8) In st a ll wh eel a n d t ir e a ssem blies.
WJ BRAKES - ABS 5 - 41

BRAK ES - ABS

TABLE OF CONTENTS
page page

BRAKES - ABS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41 G-SWITCH
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
DIAGNOSIS AND TESTING - ANTILOCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
STANDARD PROCEDURE - BLEEDING ABS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 42 REAR WHEEL SPEED SENSOR
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 42 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ELECTRIC BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 HCU (HYDRAULIC CONTROL UNIT)
FRONT WHEEL SPEED SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47

BRAK ES - ABS kph (18 m ph ). Du r in g t h e dyn a m ic ch eck, t h e CAB

br iefly cycles t h e pu m p a n d solen oids t o ver ify oper-
a t ion .
DESCRIPTION
If a n ABS com pon en t exh ibit s a fa u lt du r in g in i-
Th e pu r pose of t h e a n t ilock syst em is t o pr even t
t ia liza t ion , t h e CAB illu m in a t es t h e a m ber wa r n in g
wh eel locku p du r in g per iods of h igh wh eel slip. P r e-
ligh t a n d r egist er s a fa u lt code in t h e m icr opr ocessor
ven t in g locku p h elps m a in t a in veh icle br a kin g a ct ion
m em or y.
a n d st eer in g con t r ol.
Th e h ydr a u lic syst em is a t h r ee ch a n n el design .
ANTILOCK BRAKING
Th e fr on t br a kes a r e con t r olled in dividu a lly a n d t h e
Th e a n t ilock syst em pr even t s locku p du r in g h igh
r ea r br a kes in t a n dem .
slip con dit ion s by m odu la t in g flu id a pply pr essu r e t o
Th e ABS elect r ica l syst em is sepa r a t e fr om ot h er
t h e wh eel br a ke u n it s.
veh icle elect r ica l cir cu it s. A sepa r a t e con t r oller oper-
Br a ke flu id a pply pr essu r e is m odu la t ed a ccor din g
a t es t h e syst em .
t o wh eel speed, degr ee of slip a n d r a t e of deceler a -
t ion . A sen sor a t ea ch wh eel con ver t s wh eel speed
OPERATION in t o elect r ica l sign a ls. Th ese sign a ls a r e t r a n sm it t ed
Th e a n t ilock CAB a ct iva t es t h e syst em wh en ever
t o t h e CAB for pr ocessin g a n d det er m in a t ion of
sen sor sign a ls in dica t e per iods of h igh wh eel slip.
wh eel slip a n d deceler a t ion r a t e.
H igh wh eel slip ca n be descr ibed a s t h e poin t wh er e
Th e ABS syst em h a s t h r ee flu id pr essu r e con t r ol
wh eel r ot a t ion begin s a ppr oa ch in g 20 t o 30 per cen t of
ch a n n els. Th e fr on t br a kes a r e con t r olled sepa r a t ely
a ct u a l veh icle speed du r in g br a kin g. P er iods of h igh
a n d t h e r ea r br a kes in t a n dem . A speed sen sor in pu t
wh eel slip occu r wh en br a ke st ops in volve h igh peda l
sign a l in dica t in g a h igh slip con dit ion a ct iva t es t h e
pr essu r e a n d r a t e of veh icle deceler a t ion .
CAB a n t ilock pr ogr a m .
Ba t t er y volt a ge is su pplied t o t h e CAB ign it ion t er-
Two solen oid va lves a r e u sed in ea ch a n t ilock con -
m in a l wh en t h e ign it ion swit ch is t u r n ed t o Ru n posi-
t r ol ch a n n el. Th e va lves a r e a ll loca t ed wit h in t h e
t ion . Th e CAB per for m s a syst em in it ia liza t ion
H CU va lve body a n d wor k in pa ir s t o eit h er in cr ea se,
pr ocedu r e a t t h is poin t . In it ia liza t ion con sist s of a
h old, or decr ea se a pply pr essu r e a s n eeded in t h e
st a t ic a n d dyn a m ic self ch eck of syst em elect r ica l
in dividu a l con t r ol ch a n n els.
com pon en t s.
Th e solen oid va lves a r e n ot st a t ic du r in g a n t ilock
Th e st a t ic ch eck occu r s a ft er t h e ign it ion swit ch is
br a kin g. Th ey a r e cycled con t in u ou sly t o m odu la t e
t u r n ed t o Ru n posit ion . Th e dyn a m ic ch eck occu r s
pr essu r e. Solen oid cycle t im e in a n t ilock m ode ca n be
wh en veh icle r oa d speed r ea ch es a ppr oxim a t ely 30
m ea su r ed in m illisecon ds.
5 - 42 BRAKES - ABS WJ
BRAK ES - ABS (Cont inue d)

DIAGNOSIS AND TESTING - ANTILOCK cedu r e in volves per for m in g a ba se br a ke bleedin g,

BRAKES
Th e ABS br a ke syst em per for m s sever a l self-t est s
ever y t im e t h e ign it ion swit ch is t u r n ed on a n d t h e
veh icle is dr iven . Th e CAB m on it or s t h e syst em s
in pu t a n d ou t pu t cir cu it s t o ver ify t h e syst em is oper-
a t in g cor r ect ly. If t h e on boa r d dia gn ost ic syst em
sen ses t h a t a cir cu it is m a lfu n ct ion in g t h e syst em
will set a t r ou ble code in it s m em or y.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Electrical section. For test proce-
dures refer to the Chassis Diagnostic Manual.
followed by u se of t h e sca n t ool t o cycle a n d bleed t h e
H CU pu m p a n d solen oids. A secon d ba se br a ke bleed-
in g pr ocedu r e is t h en r equ ir ed t o r em ove a n y a ir
r em a in in g in t h e syst em .
(1) P er for m ba se br a ke bleedin g. (Refer t o 5 -
BRAKE S - STANDARD P ROCE DURE ) OR (Refer t o
5 - BRAKE S - STANDARD P ROCE DURE ).
(2) Con n ect sca n t ool t o t h e Da t a Lin k Con n ect or.
(3) Select ANTILOCK BRAKE S, followed by MIS-
CE LLANE OUS, t h en ABS BRAKE S. F ollow t h e
in st r u ct ion s displa yed. Wh en sca n t ool displa ys TE ST
COMP LE TE , discon n ect sca n t ool a n d pr oceed.
(4) P er for m ba se br a ke bleedin g a secon d t im e.
(Refer t o 5 - BRAKE S - STANDARD P ROCE DURE )
OR (Refer t o 5 - BRAKE S - STANDARD P ROCE -
DURE ).
(5) Top off m a st er cylin der flu id level a n d ver ify
pr oper br a ke oper a t ion befor e m ovin g veh icle.

STANDARD PROCEDURE - BLEEDING ABS

BRAKE SYSTEM
ABS syst em bleedin g r equ ir es con ven t ion a l bleed-
in g m et h ods plu s u se of t h e DRB sca n t ool. Th e pr o-

SPECI FI CAT I ON S

TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

G-Sensor Bolt 5.6 — 50
Hydraulic Control Unit/Controller 12 9 125
Antilock Brakes
Mounting Bolts
Hydraulic Control Unit/Controller 16 — 144
Antilock Brakes
Brake Lines
Hydraulic Control Unit/Controller 1.8 — 16
Antilock Brakes
CAB Screws
Wheel Speed Sensors 12-14 106-124 —
Front Sensor Bolt
Wheel Speed Sensors 12-14 106-124 —
Rear Sensor Bolt
WJ BRAKES - ABS 5 - 43

ELECT RI C BRAK E sen t t o t h e CAB. Th e CAB m ea su r es t h e volt a ge a n d

a m per a ge of t h e digit a l sign a l for ea ch wh eel.
DESCRIPTION
Th e elect r on ic br a ke dist r ibu t ion (E BD) fu n ct ion s
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
like a r ea r pr opor t ion in g va lve. Th e E BD syst em u ses
(2) Rem ove t h e fr on t wh eel sen sor m ou n t in g bolt
t h e ABS syst em t o con t r ol t h e slip of t h e r ea r wh eels
(F ig. 1).
in pa r t ia l br a kin g r a n ge. Th e br a kin g for ce of t h e
r ea r wh eels is con t r olled elect r on ica lly by u sin g t h e
in let a n d ou t let va lves loca t ed in t h e H CU.

OPERATION
Upon en t r y in t o E BD t h e in let va lve for t h e r ea r
br a ke cir cu it is swit ch ed on so t h a t t h e flu id su pply
fr om t h e m a st er cylin der is sh u t off. In or der t o
decr ea se t h e r ea r br a ke pr essu r e t h e ou t let va lve for
t h e r ea r br a ke cir cu it is pu lsed. Th is a llows flu id t o
en t er t h e low pr essu r e a ccu m u la t or (LPA) in t h e
H CU r esu lt in g in a dr op in flu id pr essu r e t o t h e r ea r
br a kes. In or der t o in cr ea se t h e r ea r br a ke pr essu r e
t h e ou t let va lve is swit ch ed off a n d t h e in let va lve is
pu lsed. Th is in cr ea ses t h e pr essu r e t o t h e r ea r
br a kes. Th is will con t in u e u n t il t h e r equ ir ed slip dif-
fer en ce is obt a in ed. At t h e en d of E BD br a kin g (n o
br a ke a pplica t ion ) t h e flu id in t h e LPA dr a in s ba ck t o
t h e m a st er cylin der by swit ch in g on t h e ou t let va lve
a n d dr a in in g t h r ou gh t h e in let va lve ch eck va lve. At Fig. 1 Sensor Location
t h e sa m e t im e t h e in let va lve is swit ch ed on t o pr e- 1 - BRACKET
ven t a h ydr a u lic sh or t cir ciu t in ca se of a n ot h er 2 - BRACKET
br a ke a pplica t ion . 3 - WHEEL SPEED SENSOR
Th e E BD will r em a in fu n ct ion a l du r in g m a n y ABS 4 - MOUNTING BOLT
fa u lt m odes. If t h e r ed a n d a m ber wa r n in g la m ps a r e
illu m in a t ed t h e E BD m a y h a ve a fa u lt . (3) Rem ove t h e sen sor fr om t h e st eer in g kn u ckle.
(4) Disen ga ge t h e sen sor wir e fr om t h e br a cket s
(F ig. 1)on t h e st eer in g kn u ckle.
FRON T WH EEL SPEED (5) Discon n ect t h e sen sor fr om t h e sen sor h a r n ess
SEN SOR (F ig. 2)a n d (F ig. 3).
(6) Rem ove t h e sen sor a n d wir e.
DESCRIPTION
A wh eel speed sen sor is u sed a t ea ch wh eel. Th e INSTALLATION
fr on t sen sor s a r e m ou n t ed t o t h e st eer in g kn u ckles. (1) In st a ll t h e sen sor on t h e st eer in g kn u ckle.
Th e r ea r sen sor s a r e m ou n t ed a t t h e ou t boa r d en d of (2) Apply Mopa r Lock N’ Sea l or Loct it e! 242 t o
t h e a xle. Ton e wh eels a r e m ou n t ed t o t h e ou t boa r d t h e sen sor m ou n t in g bolt . Use n ew sen sor bolt if or ig-
en ds of t h e fr on t a n d r ea r a xle sh a ft s. Th e gea r t ype in a l bolt is wor n or da m a ged.
t on e wh eel ser ves a s t h e t r igger m ech a n ism for ea ch (3) In st a ll t h e sen sor m ou n t in g bolt a n d t igh t en
sen sor. bolt t o 12-14 N·m (106-124 in . lbs.).
(4) E n ga ge t h e gr om m et s on t h e sen sor wir e t o t h e
OPERATION st eer in g kn u ckle br a cket s.
Th e sen sor s con ver t wh eel speed in t o a sm a ll digi- (5) Con n ect t h e sen sor wir e t o t h e h a r n ess con n ec-
t a l sign a l. Th e CAB sen ds 12 volt s t o t h e sen sor s. t or.
Th e sen sor h a s a n in t er n a l m a gn et o r esist a n ce (6) Ch eck t h e sen sor wir e r ou t in g. Be su r e t h e
br idge t h a t a lt er s t h e volt a ge a n d a m per a ge of t h e wir e is clea r of a ll ch a ssis com pon en t s a n d is n ot
sign a l cir cu it . Th is volt a ge a n d a m per a ge is ch a n ged t wist ed or kin ked a t a n y spot .
by m a gn et ic in du ct ion wh en t h e t oot h ed t on e wh eel (7) Rem ove t h e su ppor t a n d lower veh icle.
pa sses t h e wh eel speed sen sor. Th is digit a l sign a l is
5 - 44 BRAKES - ABS WJ
FRON T WH EEL SPEED SEN SOR (Cont inue d)

G-SWI T CH
DESCRIPTION
Th e G-swit ch (F ig. 4) is loca t ed u n der t h e r ea r
sea t . Th e swit ch h a s dir ect ion a l a r r ow a n d m u st be
m ou n t ed wit h t h e a r r ow poin t in g t owa r ds t h e fr on t
of t h e veh icle.

Fig. 2 Left Sensor Connector

1 - LEFT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST PIPE
3 - LEFT FRONT FRAME RAIL
4 - FRONT DRIVESHAFT
Fig. 4 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING

OPERATION
Th e swit ch is m on it or ed by t h e CAB a t a ll t im es.
Th e swit ch con t a in s t h r ee m er cu r y swit ch es wh ich
m on it or veh icle deceler a t ion r a t es (G-for ce). Su dden
ch a n ges in deceler a t ion r a t es t r igger t h e swit ch ,
sen din g a sign a l t o t h e CAB.

REMOVAL
(1) F old t h e r ea r sea t bot t om a ssem bly u p for
a ccess t o t h e swit ch .
(2) Lift u p t h e ca r pet in g a n d discon n ect t h e swit ch
h a r n ess (F ig. 5).
(3) Rem ove t h e swit ch m ou n t in g bolt s a n d r em ove
t h e swit ch .

Fig. 3 Right Sensor Connector INSTALLATION

1 - RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST Y-PIPE CAUTION: The mercury switch (inside the
3 - RIGHT FRONT FRAME RAIL G-Switch), will not function properly if the switch is
4 - RIGHT LOWER SUSPENSION ARM installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig. 6).

(1) Not e t h e posit ion of t h e loca t in g a r r ow on t h e

swit ch . P osit ion t h e swit ch so t h e a r r ow fa ces for-
wa r d.
(2) In st a ll t h e swit ch a n d t igh t en t h e m ou n t in g
bolt s t o 5.6 N·m (50 in . lbs.).
WJ BRAKES - ABS 5 - 45
G-SWI T CH (Cont inue d)
Th e r ea r sen sor s a r e m ou n t ed a t t h e ou t boa r d en d of
t h e a xle. Ton e wh eels a r e m ou n t ed t o t h e ou t boa r d
en ds of t h e fr on t a n d r ea r a xle sh a ft s. Th e gea r t ype
t on e wh eel ser ves a s t h e t r igger m ech a n ism for ea ch
sen sor.

OPERATION
Th e sen sor s con ver t wh eel speed in t o a sm a ll digi-
t a l sign a l. Th e CAB sen ds 12 volt s t o t h e sen sor s.
Th e sen sor h a s a n in t er n a l m a gn et o r esist a n ce
br idge t h a t a lt er s t h e volt a ge a n d a m per a ge of t h e
sign a l cir cu it . Th is volt a ge a n d a m per a ge is ch a n ged
by m a gn et ic in du ct ion wh en t h e t oot h ed t on e wh eel
pa sses t h e wh eel speed sen sor. Th is digit a l sign a l is
sen t t o t h e CAB. Th e CAB m ea su r es t h e volt a ge a n d
a m per a ge of t h e digit a l sign a l for ea ch wh eel.

REMOVAL
(1) Ra ise a n d fold t h e r ea r sea t for wa r d. Th en
Fig. 5 G-Switch Mounting m ove t h e ca r pet in g a side for a ccess t o t h e r ea r sen sor
1 - MOUNTING BOLTS con n ect or s.
2 - CONNECTOR (2) Discon n ect t h e r ea r sen sor wir e a t t h e h a r n ess
3 - G-SWITCH con n ect or s (F ig. 7).

Fig. 6 G-Switch Fig. 7 Rear Sensor Connector

1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
(3) Con n ect t h e h a r n ess t o t h e swit ch . Be su r e t h e
h a r n ess con n ect or is fir m ly sea t ed.
(4) P la ce t h e ca r pet in posit ion a n d fold t h e r ea r
sea t ba ck down .
REAR WH EEL SPEED SEN SOR
DESCRIPTION
A wh eel speed sen sor is u sed a t ea ch wh eel. Th e
fr on t sen sor s a r e m ou n t ed t o t h e st eer in g kn u ckles.
1 - RIGHT REAR WHEEL SPEED SENSOR CONNECTOR
2 - LEFT REAR WHEEL SPEED SENSOR CONNECTOR
3 - G-SWITCH SENSOR
4 - PARKING BRAKE CABLES
(3) P u sh t h e sen sor wir es a n d gr om m et s t h r ou gh
t h e floor pa n h oles.
(4) Ra ise a n d su ppor t t h e veh icle.
(5) Disen ga ge t h e sen sor wir e fr om t h e a xle a n d
t h e ch a ssis br a cket s a n d fr om t h e br a ke lin e r et a in -
er s.
(6) Rem ove t h e sen sor m ou n t in g bolt fr om t h e r ea r
br a ke ba ckin g pla t e. (F ig. 8).
(7) Rem ove t h e sen sor fr om t h e ba ckin g pla t e.
5 - 46 BRAKES - ABS WJ
REAR WH EEL SPEED SEN SOR (Cont inue d)
(8) F old t h e r ea r sea t a n d ca r pet for wa r d for
a ccess t o t h e sen sor wir es a n d con n ect or s.
(9) Con n ect t h e sen sor wir es t o t h e h a r n ess con -
n ect or s.
(10) Reposit ion t h e ca r pet a n d fold t h e r ea r sea t
down .

H CU (H Y DRAU LI C CON T ROL

UNIT)
DESCRIPTION
Th e H CU con sist s of a va lve body, pu m p m ot or,
a n d wir e h a r n ess.

Fig. 8 Sensor Mounting Bolt OPERATION

1 - WHEEL SPEED SENSOR
2 - MOUNTING BOLT
INSTALLATION
(1) In ser t t h e sen sor t h r ou gh t h e ba ckin g pla t e
(F ig. 9).
Fig. 9 Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
2 - BACKING PLATE
(2) Apply Mopa r Lock N’ Sea l or Loct it e 242! t o
t h e or igin a l sen sor bolt . Use a n ew bolt if t h e or igin a l
is wor n or da m a ged.
(3) Tigh t en t h e sen sor bolt t o 12-14 N·m (106-124
in . lbs.).
(4) Secu r e t h e sen sor wir e in t h e br a cket s a n d t h e
r et a in er s on t h e r ea r br a ke lin es. Ver ify t h a t t h e sen -
sor wir e is secu r e a n d clea r of t h e r ot a t in g com po-
n en t s.
(5) Rou t e t h e sen sor wir es t o t h e r ea r sea t a r ea .
(6) F eed t h e sen sor wir es t h e t h r ou gh floor pa n
a ccess h ole a n d sea t t h e sen sor gr om m et s in t o t h e
floor pa n .
(7) Rem ove t h e su ppor t a n d lower t h e veh icle.
Accu m u la t or s in t h e va lve body st or e ext r a flu id
r elea sed t o t h e syst em for ABS m ode oper a t ion . Th e
pu m p is u sed t o clea r t h e a ccu m u la t or of br a ke flu id
a n d is oper a t ed by a DC t ype m ot or. Th e m ot or is
con t r olled by t h e CAB.
Th e va lves m odu la t e br a ke pr essu r e du r in g
a n t ilock br a kin g a n d a r e con t r olled by t h e CAB.
Th e H CU pr ovides t h r ee ch a n n el pr essu r e con t r ol
t o t h e fr on t a n d r ea r br a kes. On e ch a n n el con t r ols
t h e r ea r wh eel br a kes in t a n dem . Th e t wo r em a in in g
ch a n n els con t r ol t h e fr on t wh eel br a kes in dividu a lly.
Du r in g a n t ilock br a kin g, t h e solen oid va lves a r e
open ed a n d closed a s n eeded. Th e va lves a r e n ot
st a t ic. Th ey a r e cycled r a pidly a n d con t in u ou sly t o
m odu la t e pr essu r e a n d con t r ol wh eel slip a n d decel-
er a t ion .
Du r in g n or m a l br a kin g, t h e H CU solen oid va lves
a n d pu m p a r e n ot a ct iva t ed. Th e m a st er cylin der a n d
power boost er oper a t e t h e sa m e a s a veh icle wit h ou t
a n ABS br a ke syst em .
Du r in g a n t ilock br a kin g, solen oid va lve pr essu r e
m odu la t ion occu r s in t h r ee st a ges, pr essu r e in cr ea se,
pr essu r e h old, a n d pr essu r e decr ea se. Th e va lves a r e
a ll con t a in ed in t h e va lve body por t ion of t h e H CU.
PRESSURE DECREASE
Th e ou t let va lve is open ed a n d t h e in let va lve is
closed du r in g t h e pr essu r e decr ea se cycle.
A pr essu r e decr ea se cycle is in it ia t ed wh en speed
sen sor sign a ls in dica t e h igh wh eel slip a t on e or
m or e wh eels. At t h is poin t , t h e CAB closes t h e in let
t h en open s t h e ou t let va lve, wh ich a lso open s t h e
r et u r n cir cu it t o t h e a ccu m u la t or s. F lu id pr essu r e is
a llowed t o bleed off (decr ea se) a s n eeded t o pr even t
wh eel lock.
On ce t h e per iod of h igh wh eel slip h a s en ded, t h e
CAB closes t h e ou t let va lve a n d begin s a pr essu r e
in cr ea se or h old cycle a s n eeded.
WJ BRAKES - ABS 5 - 47
H CU (H Y DRAU LI C CON T ROL U N I T ) (Cont inue d)
PRESSURE HOLD (4) Rem ove t h e br a ke lin es fr om t h e H CU.
Bot h solen oid va lves a r e closed in t h e pr essu r e (5) Rem ove t h e H CU/CAB side m ou n t in g bolt a n d
h old cycle. F lu id a pply pr essu r e in t h e con t r ol ch a n - t h e t wo r ea r m ou n t in g bolt s. (F ig. 11).
n el is m a in t a in ed a t a con st a n t r a t e. Th e CAB m a in -
t a in s t h e h old cycle u n t il sen sor in pu t s in dica t e a
pr essu r e ch a n ge is n ecessa r y.

PRESSURE INCREASE
Th e in let va lve is open a n d t h e ou t let va lve is
closed du r in g t h e pr essu r e in cr ea se cycle. Th e pr es-
su r e in cr ea se cycle is u sed t o cou n t er a ct u n equ a l
wh eel speeds. Th is cycle con t r ols r e-a pplica t ion of
flu id a pply pr essu r e du e t o ch a n gin g r oa d su r fa ces or
wh eel speed.

REMOVAL
(1) Rem ove t h e n ega t ive ba t t er y ca ble fr om t h e
ba t t er y.
(2) Rem ove t h e a ir clea n er h ou sin g,(Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R Fig. 11 HCU/CAB Assembly
H OUSING - RE MOVAL). 1 - SIDE MOUNTING BOLT
(3) P u ll t h e CAB h a r n ess con n ect or r elea se u p a n d 2 - REAR MOUNTING BOLTS
r em ove con n ect or (F ig. 10).
(6) Rem ove t h e H CU/CAB a ssem bly fr om t h e veh i-
cle.

INSTALLATION
(1) In st a ll H CU/CAB a ssem bly in t o t h e m ou n t in g
br a cket a n d t igh t en m ou n t in g bolt s t o 12 N·m (9 ft .
lbs.).
(2) In st a ll t h e br a ke lin es t o t h e H CU a n d t igh t en
t o 16 N·m (12 ft . lbs.).
(3) In st a ll CAB h a r n ess con n ect or a n d pu sh down
con n ect or r elea se.
(4) In st a ll a ir clea n er h ou sin g,(Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - INSTALLATION).
(5) In st a ll n ega t ive ba t t er y ca ble t o t h e ba t t er y.
(6) Bleed ba se a n d ABS br a ke syst em s,(Refer t o 5 -
Fig. 10 CAB Connector Release BRAKE S - STANDARD P ROCE DURE ) OR (Refer t o
1 - CONNECTOR RELEASE 5 - BRAKE S - STANDARD P ROCE DURE ).
2 - CAB
WJ COOLING 7-1

COOLING
TABLE OF CON T EN T S

page page

COOLING DIAGNOSIS AND TESTING - COOLING

DESCRIPTION SYSTEM DEAERATION . . . . . . . . . . . . . . . . . 12
DESCRIPTION - COOLING SYSTEM 4.7L STANDARD PROCEDURE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STANDARD PROCEDURE—DRAINING
DESCRIPTION - COOLING SYSTEM COOLING SYSTEM 4.7L ENGINE . . . . . . . . . 12
ROUTING 4.7L ENGINE . . . . . . . . . . . . . . . . . . 1 STANDARD PROCEDURE - REFILLING
DESCRIPTION—COOLING SYSTEM 4.0L COOLING SYSTEM 4.7L ENGINE . . . . . . . . . 12
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STANDARD PROCEDURE - DRAINING
DESCRIPTION—COOLING SYSTEM COOLING SYSTEM - 4.0L ENGINE . . . . . . . . 13
ROUTING 4.0L ENGINE . . . . . . . . . . . . . . . . . . 1 STANDARD PROCEDURE - REFILLING
DESCRIPTION—HOSE CLAMPS . . . . . . . . . . . 1 COOLING SYSTEM - 4.0L ENGINE . . . . . . . . 13
OPERATION STANDARD PROCEDURE - ADDING
OPERATION—COOLING SYSTEM .........2 ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 13
OPERATION—HOSE CLAMPS . . . . . . . . . . . . 2 STANDARD PROCEDURE - COOLING
DIAGNOSIS AND TESTING SYSTEM - REVERSE FLUSHING . . . . . . . . . . 14
DIAGNOSIS AND TESTING—ON-BOARD SPECIFICATIONS
DIAGNOSTICS (OBD) . . . . . . . . . . . . . . . . . . . 3 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING—PRELIMINARY SPECIAL TOOLS
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - COOLING ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 16
SYSTEM DIAGNOSIS CHART . . . . . . . . . . . . . 5 ENGINE ......................... . . . . . . 24
DIAGNOSIS AND TESTING - COOLING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 55
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . . 10

COOLI N G DESCRIPTION—COOLING SYSTEM 4.0L

ENGINE
Th e coolin g syst em con sist s of:
DESCRI PT I ON • A r a dia t or
• Mech a n ica l Coolin g F a n
DESCRIPTION - COOLING SYSTEM 4.7L • Th er m a l viscou s fa n dr ive-Low disen ga ged
ENGINE • F a n sh r ou d (F ig. 2)
Th e coolin g syst em con sist s of t h e followin g it em s: • Ra dia t or pr essu r e ca p
• H ydr a u lic coolin g fa n a n d fa n dr ive a ssem bly • Th er m ost a t
• Ra dia t or • Coola n t r eser ve/over flow syst em
• P ower st eer in g oil cooler • Tr a n sm ission oil cooler (if equ ipped wit h a n
• Ra dia t or pr essu r e ca p a u t om a t ic t r a n sm ission )
• Th er m ost a t • Coola n t
• Coola n t r eser ve/over flow syst em • Wa t er pu m p
• Tr a n sm ission oil cooler (if equ ipped wit h a n • H oses a n d h ose cla m ps
a u t om a t ic t r a n sm ission ) • Accessor y dr ive belt
• Coola n t
• Wa t er pu m p DESCRIPTION—COOLING SYSTEM ROUTING
• H oses a n d h ose cla m ps 4.0L ENGINE
F or coolin g syst em r ou t in g r efer t o (F ig. 3).
DESCRIPTION - COOLING SYSTEM ROUTING
4.7L ENGINE DESCRIPTION—HOSE CLAMPS
F or coolin g syst em r ou t in g r efer t o (F ig. 1). Th e coolin g syst em u t ilizes bot h wor m dr ive a n d
spr in g t ype h ose cla m ps. If a spr in g t ype cla m p
7-2 COOLING WJ
COOLI N G (Cont inue d)

Fig. 1 Engine Cooling System 4.7L Engine

1 - LH CYL. HEAD 5 - RH BANK CYL. BLOCK
2 - AIR BLEED 6 - LH BANK CYL. BLOCK
3 - THERMOSTAT LOCATION 7 - COOLANT TEMP. SENSOR
4 - RH CYL. HEAD

r epla cem en t is n ecessa r y, r epla ce wit h t h e or igin a l m a in t a in s n or m a l oper a t in g t em per a t u r e a n d pr e-

Mopa r ! equ ipm en t spr in g t ype cla m p.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 4).
ven t s over h ea t in g.
Th e coolin g syst em a lso pr ovides a m ea n s of h ea t -
in g t h e pa ssen ger com pa r t m en t a n d coolin g t h e a u t o-
m a t ic t r a n sm ission flu id (if equ ipped). Th e coolin g
syst em is pr essu r ized a n d u ses a cen t r ifu ga l wa t er
pu m p t o cir cu la t e coola n t t h r ou gh ou t t h e syst em .

OPERATION—HOSE CLAMPS
OPERAT I ON Th e wor m t ype h ose cla m p u ses a specified t or qu e
va lu e t o m a in t a in pr oper t en sion on a h ose con n ec-
OPERATION—COOLING SYSTEM t ion .
Th e coolin g syst em r egu la t es en gin e oper a t in g t em -
per a t u r e. It a llows t h e en gin e t o r ea ch n or m a l oper-
a t in g t em per a t u r e a s qu ickly a s possible. It a lso
WJ COOLING 7-3
COOLI N G (Cont inue d)

Fig. 2 Cooling Module with Electric Fan

1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN

Th e spr in g t ype h ose cla m p a pplies con st a n t t en - Fig. 3 Engine Cooling System—4.0L Engine—
sion on a h ose con n ect ion . To r em ove a spr in g t ype Typical
h ose cla m p, on ly u se con st a n t t en sion cla m p plier s 1 - HEATER CORE
design ed t o com pr ess t h e h ose cla m p. 2 - TO COOLANT RESERVE/OVERFLOW TANK
3 - THERMOSTAT HOUSING
4 - RADIATOR
DI AGN OSI S AN D T EST I N G 5 - WATER PUMP

DIAGNOSIS AND TESTING—ON-BOARD

DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
Th e power t r a in con t r ol m odu le (P CM) h a s been
pr ogr a m m ed t o m on it or cer t a in coolin g syst em com -
pon en t s:
• If t h e en gin e h a s r em a in ed cool for t oo lon g a
per iod, su ch a s wit h a st u ck open t h er m ost a t , a Dia g-
n ost ic Tr ou ble Code (DTC) ca n be set .
• If a n open or sh or t ed con dit ion h a s developed in
t h e r ela y cir cu it con t r ollin g t h e elect r ic r a dia t or fa n
or fa n con t r ol solen oid cir cu it con t r olin g t h e h ydr a u -
lic fa n , a Dia gn ost ic Tr ou ble Code (DTC) ca n be set .
If t h e pr oblem is sen sed in a m on it or ed cir cu it
oft en en ou gh t o in dica t ed a n a ct u a l pr oblem , a DTC
is st or ed. Th e DTC will be st or ed in t h e P CM m em -
or y for even t u a l displa y t o t h e ser vice t ech n icia n .
(Refer t o 25 - E MISSIONS CONTROL - DE SCRIP -
TION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To r ea d DTC’s a n d t o obt a in coolin g syst em da t a ,
(Refer t o 25 - E MISSIONS CONTROL - DE SCRIP -
TION).
ERASING TROUBLE CODES
Aft er t h e pr oblem h a s been r epa ir ed, u se t h e DRB
sca n t ool t o er a se a DTC. Refer t o t h e a ppr opr ia t e
P ower t r a in Dia gn ost ic P r ocedu r es ser vice in for m a -
t ion for oper a t ion of t h e DRB sca n t ool.
DIAGNOSIS AND TESTING—PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
E st a blish wh a t dr ivin g con dit ion s ca u sed t h e com -
pla in t . Abn or m a l loa ds on t h e coolin g syst em su ch a s
t h e followin g m a y be t h e ca u se:
• P ROLONGE D IDLE
• VE RY H IGH AMBIE NT TE MP E RATURE
7-4 COOLING WJ
COOLI N G (Cont inue d)
(1) TRAILE R TOWING:
Con su lt Tr a iler Towin g sect ion of own er s m a n u a l.
Do n ot exceed lim it s.
(2) AIR CONDITIONING; ADD-ON OR AF TE R
MARKE T:
A m a xim u m coolin g pa cka ge sh ou ld h a ve been
or der ed wit h veh icle if a dd-on or a ft er m a r ket A/C is
in st a lled. If n ot , m a xim u m coolin g syst em com po-
n en t s sh ou ld be in st a lled for m odel in volved per
m a n u fa ct u r er ’s specifica t ion s.
(3) RE CE NT SE RVICE OR ACCIDE NT RE PAIR:
Det er m in e if a n y r ecen t ser vice h a s been per-
for m ed on veh icle t h a t m a y effect coolin g syst em .
Th is m a y be:
• E n gin e a dju st m en t s (in cor r ect t im in g)
• Slippin g en gin e a ccessor y dr ive belt (s)
• Br a kes (possibly dr a ggin g)
• Ch a n ged pa r t s. In cor r ect wa t er pu m p, or pu m p
Fig. 4 Spring Clamp Size Location r ot a t in g in wr on g dir ect ion du e t o belt n ot cor r ect ly
1 - SPRING CLAMP SIZE LOCATION r ou t ed
• Recon dit ion ed r a dia t or or coolin g syst em r efill-
in g (possibly u n der filled or a ir t r a pped in syst em ).
• SLIGH T TAIL WIND AT IDLE
• SLOW TRAF F IC NOTE: If investigation reveals none of the previous
• TRAF F IC J AMS items as a cause for an engine overheating com-
• H IGH SP E E D plaint, refer to following Cooling System Diagnosis
• STE E P GRADE S charts.
Dr ivin g t ech n iqu es t h a t a void over h ea t in g a r e:
• Idle wit h A/C off wh en t em per a t u r e ga u ge is a t Th ese ch a r t s a r e t o be u sed a s a qu ick-r efer en ce
en d of n or m a l r a n ge. on ly. Refer t o t h e gr ou p t ext for in for m a t ion .
• In cr ea se en gin e speed for m or e a ir flow is r ecom -
m en ded.
WJ
COOLI N G (Cont inue d)
DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART
COOLI N G SY ST EM DI AGN OSI S CH ART
CONDITION POSSIBLE CAUSES
TEMPERATURE GAUGE 1. Has a Diagnostic Trouble Code
READS LOW (DTC) been set indicating a stuck
open thermostat?
2. Is the temperature sending unit
connected?
3. Is the temperature gauge
operating OK?
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
5. Improper operation of internal
heater doors or heater controls.
TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill
READS HIGH OR THE is being climbed, vehicle is operated
COOLANT LAMP in slow moving traffic, or engine is
ILLUMINATES. being idled with very high ambient
COOLANT MAY OR MAY (outside) temperatures and the air
NOT BE LOST OR conditioning is on. Higher altitudes
LEAKING FROM THE could aggravate these conditions.
COOLING SYSTEM
2. Is the temperature gauge reading
correctly?
3. Is the temperature warning
illuminating unnecessarily?
4. Coolant low in coolant reserve/
overflow tank and radiator?
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer to
the following Step 6.
COOLING 7-5
CORRECTION
1. Refer to (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for On-Board
Diagnostics and DTC information. Replace
thermostat if necessary.
2. Check the temperature sensor connector.
(Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT TEMP SENSOR -
DESCRIPTION). Repair connector if
necessary.
3. Check gauge operation. Repair as
necessary.
4. Check coolant level in the coolant
reserve/overflow tank and the radiator.
Inspect system for leaks. Repair leaks as
necessary.
5. Inspect heater and repair as necessary.
(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND
TESTING)
1. This may be a temporary condition and
repair is not necessary. Turn off the air
conditioning and attempt to drive the vehicle
without any of the previous conditions.
Observe the temperature gauge. The gauge
should return to the normal range. If the
gauge does not return to the normal range,
determine the cause for overheating and
repair.
2. Check gauge. (Refer to Group 8J -
INSTRUMENT CLUSTER). Repair as
necessary.
3. Check warning lamp operation. (Refer to
Group 8J - INSTRUMENT CLUSTER).Repair
as necessary.
4. Check for coolant leaks and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
5. Tighten cap
7-6 COOLING
COOLI N G (Cont inue d)
CONDITION POSSIBLE CAUSES
6. Poor seals at the radiator cap.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant level low in radiator but
not in coolant reserve/overflow tank.
This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools
8. Incorrect coolant concentration
9. Coolant not flowing through
system
10. Radiator or A/C condenser fins
are dirty or clogged.
11. Radiator core is corroded or
plugged.
12. Aftermarket A/C installed without
proper radiator.
13. Fuel or ignition system
problems.
14. Dragging brakes.
15. Bug screen or cardboard is
being used, reducing airflow.
16. Thermostat partially or
completely shut.
WJ
CORRECTION
6. (a) Check condition of cap and cap seals.
(Refer to 7 - COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS AND
TESTING).
7. (a) Check condition of radiator cap and
cap seals. (Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP - DIAGNOSIS
AND TESTING).
(b) Check condition of radiator filler neck. If
neck is bent or damaged, replace radiator.
(c) Check condition of the hose from the
radiator to the coolant tank. It should fit tight
at both ends without any kinks or tears.
Replace hose if necessary.
(d) Check coolant reserve/overflow tank and
tanks hoses for blockage. Repair as
necessary.
8. Check coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DESCRIPTION) for
correct coolant/water mixture ratio.
9. Check for coolant flow at radiator filler
neck with some coolant removed, engine
warm and thermostat open. Coolant should
be observed flowing through radiator. If flow
is not observed, determine area of
obstruction and repair as necessary.
10. Remove insects and debris. (Refer to 7 -
COOLING/ENGINE/RADIATOR -
CLEANING).
11. Have radiator re-cored or replaced.
12. Install proper radiator.
13. Refer to FUEL and /or IGNITION
CONTROL for diagnosis.
14. Check and correct as necessary. (Refer
to 5 - BRAKES - DIAGNOSIS AND
TESTING) for correct procedures.
15. Remove bug screen or cardboard.
16. Check thermostat operation and replaces
necessary. (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT -
DIAGNOSIS AND TESTING).
WJ
COOLI N G (Cont inue d)
CONDITION POSSIBLE CAUSES
17. Viscous fan drive not operating
properly.
18. Cylinder head gasket leaking.
19. Heater core leaking.
20. Hydraulic fan speed too low or
inopertive.
TEMPERATURE GAUGE 1. During cold weather operation,
READING IS with the heater blower in the high
INCONSISTENT position, the gauge reading may
(FLUCTUATES, CYCLES drop slightly.
OR IS ERRATIC) 2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running)
4. Gauge reading high after
re-starting a warmed up (hot)
engine.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open late).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a thermostat
to open late.
COOLING 7-7
CORRECTION
17. Check fan drive operation and replace as
necessary. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DIAGNOSIS AND TESTING).
18. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING). For repair, (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
19. Check heater core for leaks. (Refer to 24
- HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE - REMOVAL).
Repair as necessary.
20. Check for
DTC code.
Check fan operation speeds.
Refer to fan speed operation table.
Low power steering pump output. Refer to
power steering pump diagnosis - 4.7L engine.
1. A normal condition. No correction is
necessary.
2. Check operation of gauge and repair if
necessary. Refer to Group 8J, Instrument
cluster.
3. A normal condition. No correction is
necessary. Gauge should return to normal
range after vehicle is driven.
4. A normal condition. No correction is
necessary. The gauge should return to
normal range after a few minutes of engine
operation.
5. Check and correct coolant leaks. (Refer to
7 - COOLING - DIAGNOSIS AND TESTING).
6. (a) Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
7-8 COOLING WJ
COOLI N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

7. Water pump impeller loose on 7. Check water pump and replace as

shaft.
8. Loose accessory drive belt. (water
pump slipping)
9. Air leak on the suction side of the
water pump allows air to build up in
cooling system causing thermostat
to open late.
necessary. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - DIAGNOSIS AND
TESTING).
8. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND
TESTING). Check and correct as necessary.
9. Locate leak and repair as necessary.

PRESSURE CAP IS 1. Pressure relief valve in radiator 1. Check condition of radiator cap and cap
BLOWING OFF STEAM cap is defective. seals. (Refer to 7 - COOLING/ENGINE/
AND/OR COOLANT TO RADIATOR PRESSURE CAP - DIAGNOSIS
COOLANT TANK. AND TESTING). Replace cap as necessary.
TEMPERATURE GAUGE
READING MAY BE
ABOVE NORMAL BUT
NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN
COOLANT RESERVE/
OVERFLOW TANK

COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as necessary.
GROUND WITHOUT system hoses, water pump or (Refer to 7 - COOLING - DIAGNOSIS AND
PRESSURE CAP engine. TESTING).
BLOWOFF. GAUGE
READING HIGH OR HOT

DETONATION OR 1. Engine overheating. 1. Check reason for overheating and repair

PRE-IGNITION (NOT as necessary.
CAUSED BY IGNITION
SYSTEM). GAUGE MAY 2. Freeze point of coolant not 2. Check coolant concentration. (Refer to 7 -
OR MAY NOT BE correct. Mixture is too rich or too COOLING/ENGINE/COOLANT -
READING HIGH lean. DESCRIPTION) and adjust ratio as required.

HOSE OR HOSES 1. Vacuum created in cooling system 1. (a) Radiator cap relief valve stuck. (Refer
COLLAPSE WHILE on engine cool-down is not being to 7 - COOLING/ENGINE/RADIATOR
ENGINE IS RUNNING relieved through coolant reserve/ PRESSURE CAP - DIAGNOSIS AND
overflow system. TESTING). Replace if necessary
(b) Hose between coolant reserve/overflow
tank and radiator is kinked. Repair as
necessary.
(c) Vent at coolant reserve/overflow tank is
plugged. Clean vent and repair as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for blockage and
repair as necessary.
WJ
COOLI N G (Cont inue d)
CONDITION POSSIBLE CAUSES
NOISY VISCOUS 1. Fan blades loose - 4.0L.
FAN/DRIVE
2. Fan blades striking a surrounding
object.
3. Air obstructions at radiator or air
conditioning condenser.
4. Thermal viscous fan drive has
defective bearing - 4.0L
INADEQUATE HEATER 1.Thermostat failed in open position
PERFORMANCE.
2. Has a Diagnostic trouble Code
(DTC) been set?
3. Coolant level low
4. Obstructions in heater hose/
fittings
5. Heater hose kinked
6. Water pump is not pumping water
to/through the heater core. When
the engine is fully warmed up, both
heater hoses should be hot to the
touch. If only one of the hoses is
hot, the water pump may not be
operating correctly or the heater
core may be plugged. Accessory
drive belt may be slipping causing
poor water pump operation.
STEAM IS COMING 1. During wet weather, moisture
FROM THE FRONT OF (snow, ice or rain condensation) on
VEHICLE NEAR THE the radiator will evaporate when the
GRILL AREA WHEN thermostat opens. This opening
WEATHER IS WET, allows heated water into the radiator.
ENGINE IS WARMED UP When the moisture contacts the hot
AND RUNNING, AND radiator, steam may be emitted. This
VEHICLE IS usually occurs in cold weather with
STATIONARY. no fan or airflow to blow it away.
TEMPERATURE GAUGE
IS IN NORMAL RANGE
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
COOLING 7-9
CORRECTION
1. Replace fan blade assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN -
REMOVAL)
2. Locate point of fan blade contact and
repair as necessary.
3. Remove obstructions and/or clean debris
or insects from radiator or A/C condenser.
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL).
2. (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for correct procedures and
replace thermostat if necessary
3. (Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
4. Remove heater hoses at both ends and
check for obstructions
5. Locate kinked area and repair as
necessary
6. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - DIAGNOSIS AND TESTING). If a
slipping belt is detected, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE
BELTS - REMOVAL). If heater core
obstruction is detected, (Refer to 7 -
COOLING - STANDARD PROCEDURE) for
cooling system reverse flushing.
1. Occasional steam emitting from this area
is normal. No repair is necessary.
1. (Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) for coolant
concentration information. Adjust coolant
mixture as necessary.
7 - 10 COOLING WJ
COOLI N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

COOLANT LEVEL 1. Level changes are to be expected 1. A normal condition. No repair is necessary.
CHANGES IN COOLANT as coolant volume fluctuates with
RESERVE/OVERFLOW engine temperature. If the level in
TANK. TEMPERATURE the tank was between the FULL and
GAUGE IS IN NORMAL ADD marks at normal operating
RANGE temperature, the level should return
to within that range after operation
at elevated temperatures.

FAN RUNS ALL THE 1. Fan control sensors inoperative.
TIME 2. Fan control solenoid stuck "on".
3. Fan control solenoid harness
damaged.
4. Transmission temperature too
high.
5. Engine coolant temperature too
high.
1. Check for DTC’s. Verify sensor readings.
2. Check fan operation speeds. Refer to fan
speed operation table.
3. Check for DTC 1499. Repair as required.
4. Check for transmission over temp. DTC.
5. (a) Check coolant level. Correct level as
required.
(b) Thermostat stuck. Replace thermostat.
(c) Water pump failed. Replace water pump.
(d) Coolant flow restricted. Clean radiator.
(e) Air flow over radiator obstructed.Remove
obstruction.

DIAGNOSIS AND TESTING - COOLING SYSTEM

LEAKS
ULTRAVIOLET LIGHT METHOD
A lea k det ect ion a ddit ive is a va ila ble t h r ou gh t h e
pa r t s depa r t m en t t h a t ca n be a dded t o coolin g sys-
t em . Th e a ddit ive is h igh ly visible u n der u lt r a violet
ligh t (bla ck ligh t ). P ou r on e ou n ce of a ddit ive in t o
coolin g syst em . P la ce h ea t er con t r ol u n it in H E AT
posit ion . St a r t a n d oper a t e en gin e u n t il r a dia t or
u pper h ose is wa r m t o t ou ch . Aim t h e com m er cia lly
a va ila ble bla ck ligh t t ool a t com pon en t s t o be
ch ecked. If lea ks a r e pr esen t , bla ck ligh t will ca u se
a ddit ive t o glow a br igh t gr een color.
Th e bla ck ligh t ca n be u sed in con ju n ct ion wit h a
pr essu r e t est er t o det er m in e if a n y ext er n a l lea ks
exist (F ig. 5).

PRESSURE TESTER METHOD

Th e en gin e sh ou ld be a t n or m a l oper a t in g t em per-
a t u r e. Rech eck t h e syst em cold if ca u se of coola n t
loss is n ot loca t ed du r in g t h e wa r m en gin e exa m in a -
t ion . Fig. 5 Leak Detection Using Black Light—Typical
1 - TYPICAL BLACK LIGHT TOOL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
WJ
COOLI N G (Cont inue d)
Ca r efu lly r em ove r a dia t or pr essu r e ca p fr om filler
n eck a n d ch eck coola n t level. P u sh down on ca p t o
disen ga ge it fr om st op t a bs. Wipe in side of filler n eck
a n d exa m in e lower in side sea lin g sea t for n icks,
cr a cks, pa in t , dir t a n d solder r esidu e. In spect r a dia -
t or-t o- r eser ve/over flow t a n k h ose for in t er n a l
obst r u ct ion s. In ser t a wir e t h r ou gh t h e h ose t o be
su r e it is n ot obst r u ct ed.
In spect ca m s on ou t side of filler n eck. If ca m s a r e
da m a ged, sea t in g of pr essu r e ca p va lve a n d t est er
sea l will be a ffect ed.
At t a ch pr essu r e t est er (7700 or a n equ iva len t ) t o
r a dia t or filler n eck (F ig. 6).
Fig. 6 Pressure Testing Cooling System—Typical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
Oper a t e t est er pu m p t o a pply 103.4 kP a (15 psi)
pr essu r e t o syst em . If h oses en la r ge excessively or
bu lges wh ile t est in g, r epla ce a s n ecessa r y. Obser ve
ga u ge poin t er a n d det er m in e con dit ion of coolin g sys-
t em a ccor din g t o followin g cr it er ia :
Ho ld s S te a d y : If poin t er r em a in s st ea dy for t wo
m in u t es, ser iou s coola n t lea ks a r e n ot pr esen t in sys-
t em . H owever, t h er e cou ld be a n in t er n a l lea k t h a t
does n ot a ppea r wit h n or m a l syst em t est pr essu r e. If
it is cer t a in t h a t coola n t is bein g lost a n d lea ks ca n -
n ot be det ect ed, in spect for in t er ior lea ka ge or per-
for m In t er n a l Lea ka ge Test .
D ro p s S lo w ly : In dica t es a sm a ll lea k or seepa ge
is occu r r in g. E xa m in e a ll con n ect ion s for seepa ge or
sligh t lea ka ge wit h a fla sh ligh t . In spect r a dia t or,
h oses, ga sket edges a n d h ea t er. Sea l sm a ll lea k h oles
wit h a Sea ler Lu br ica n t (or equ iva len t ). Repa ir lea k
h oles a n d in spect syst em a ga in wit h pr essu r e
a pplied.
D ro p s Qu ic k ly : In dica t es t h a t ser iou s lea ka ge is
occu r r in g. E xa m in e syst em for ext er n a l lea ka ge. If
lea ks a r e n ot visible, in spect for in t er n a l lea ka ge.
La r ge r a dia t or lea k h oles sh ou ld be r epa ir ed by a
r epu t a ble r a dia t or r epa ir sh op.
COOLING 7 - 11
INTERNAL LEAKAGE INSPECTION
Rem ove en gin e oil pa n dr a in plu g a n d dr a in a
sm a ll a m ou n t of en gin e oil. If coola n t is pr esen t in
t h e pa n , it will dr a in fir st beca u se it is h ea vier t h a n
oil. An a lt er n a t ive m et h od is t o oper a t e en gin e for a
sh or t per iod t o ch u r n t h e oil. Aft er t h is is don e,
r em ove en gin e dipst ick a n d in spect for wa t er glob-
u les. Also in spect t r a n sm ission dipst ick for wa t er
globu les a n d t r a n sm ission flu id cooler for lea ka ge.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Oper a t e en gin e wit h ou t pr essu r e ca p on r a dia t or
u n t il t h er m ost a t open s. At t a ch a P r essu r e Test er t o
filler n eck. If pr essu r e bu ilds u p qu ickly it in dica t es a
com bu st ion lea k exist s. Th is is u su a lly t h e r esu lt of a
cylin der h ea d ga sket lea k or cr a ck in en gin e. Repa ir
a s n ecessa r y.
If t h er e is n ot a n im m edia t e pr essu r e in cr ea se,
pu m p t h e P r essu r e Test er. Do t h is u n t il in dica t ed
pr essu r e is wit h in syst em r a n ge of 110 kP a (16 psi).
F lu ct u a t ion of ga u ge poin t er in dica t es com pr ession or
com bu st ion lea ka ge in t o coolin g syst em .
Beca u se t h e veh icle is equ ipped wit h a ca t a lyt ic
con ver t er, d o n o t r em ove spa r k plu g ca bles or sh or t
ou t cylin der s t o isola t e com pr ession lea k.
If t h e n eedle on dia l of pr essu r e t est er does n ot
flu ct u a t e, r a ce en gin e a few t im es t o ch eck for a n
a bn or m a l a m ou n t of coola n t or st ea m . Th is wou ld be
em it t in g fr om exh a u st pipe. Coola n t or st ea m fr om
exh a u st pipe m a y in dica t e a fa u lt y cylin der h ea d ga s-
ket , cr a cked en gin e cylin der block or cylin der h ea d.
A con ven ien t ch eck for exh a u st ga s lea ka ge in t o
coolin g syst em is pr ovided by a com m er cia lly a va il-
a ble Block Lea k Ch eck t ool. F ollow m a n u fa ct u r er s
in st r u ct ion s wh en u sin g t h is pr odu ct .
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE r eu sa ble coola n t . If solu t ion is
clea n , dr a in coola n t in t o a clea n con t a in er for r eu se.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Dr a in su fficien t coola n t t o a llow t h er m ost a t
r em ova l. (Refer t o 7 - COOLING/E NGINE /E NGINE
COOLANT TH E RMOSTAT - RE MOVAL). Rem ove
7 - 12 COOLING
COOLI N G (Cont inue d)
a ccessor y dr ive belt (Refer t o 7 - COOLING/ACCE S-
SORY DRIVE /DRIVE BE LTS - RE MOVAL).
Add coola n t t o r a dia t or t o br in g level t o wit h in 6.3
m m (1/4 in ) of t op of t h er m ost a t h ou sin g.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
St a r t en gin e a n d a cceler a t e r a pidly t h r ee t im es, t o
a ppr oxim a t ely 3000 r pm wh ile obser vin g coola n t . If
in t er n a l en gin e com bu st ion ga ses a r e lea kin g in t o
coolin g syst em , bu bbles will a ppea r in coola n t . If bu b-
bles do n ot a ppea r, in t er n a l com bu st ion ga s lea ka ge
is n ot pr esen t .
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
As t h e en gin e oper a t es, a n y a ir t r a pped in coolin g
syst em ga t h er s u n der t h e r a dia t or ca p. Th e n ext t im e
t h e en gin e is oper a t ed, t h er m a l expa n sion of coola n t
will pu sh a n y t r a pped a ir pa st r a dia t or ca p in t o t h e
coola n t r eser ve/over flow t a n k. H er e it esca pes t o t h e
a t m osph er e in t o t h e t a n k. Wh en t h e en gin e cools
down t h e coola n t , it will be dr a wn fr om t h e r eser ve/
over flow t a n k in t o t h e r a dia t or t o r epla ce a n y
r em oved a ir.
STAN DARD PROCEDU RE
STANDARD PROCEDURE—DRAINING COOLING
SYSTEM 4.7L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS (Fig. 7) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) DO NOT r em ove r a dia t or ca p fir st . Wit h en gin e
cold, r a ise veh icle on a h oist a n d loca t e r a dia t or
dr a in cock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) At t a ch on e en d of a h ose t o t h e dr a in cock. P u t
t h e ot h er en d in t o a clea n con t a in er. Open dr a in cock
a n d dr a in coola n t fr om r a dia t or. Th is will em pt y t h e
coola n t r eser ve/over flow t a n k. Th e coola n t does n ot
h a ve t o be r em oved fr om t h e t a n k u n less t h e syst em
is bein g r efilled wit h a fr esh m ixt u r e. Wh en t a n k is
em pt y, r em ove r a dia t or ca p a n d con t in u e dr a in in g
coolin g syst em .
WJ
Fig. 7 Drain Plug—4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 4.7L ENGINE
(1) Tigh t en t h e r a dia t or dr a in cock a n d t h e cylin der
block dr a in plu g(s) (if r em oved).
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(2) Rem ove t h e coolin g syst em bleed plu g fr om t h e
r a dia t or u pper h ose in let h ou sin g. (F ig. 8)F ill syst em
u sin g a 50/50 m ixt u r e of et h ylen e-glycol a n t ifr eeze
a n d low m in er a l con t en t wa t er, u n t il coola n t bega in s
com in g ou t of t h e coolin g syst em bleed h ole. In st a ll
t h e coolin g syst em bleed plu g. F ill r a dia t or t o t op a n d
in st a ll r a dia t or ca p. Add su fficien t coola n t t o t h e
r eser ve/over flow t a n k t o r a ise level t o F ULL m a r k.
(3) Wit h h ea t er con t r ol u n it in t h e H E AT posit ion ,
oper a t e en gin e wit h r a dia t or ca p in pla ce.
(4) Aft er en gin e h a s r ea ch ed n or m a l oper a t in g
t em per a t u r e, sh u t en gin e off a n d a llow it t o cool.
Wh en en gin e is coolin g down , coola n t will be dr a wn
in t o t h e r a dia t or fr om t h e r eser ve/over flow t a n k.
(5) Add coola n t t o r eser ve/over flow t a n k a s n eces-
sa r y. On ly a d d c o o la n t to th e re s e rv e /o v e rflo w
ta n k w h e n th e e n g in e is c o ld . Co o la n t le v e l in a
w a rm e n g in e w ill be h ig h e r d u e to th e rm a l
e x p a n s io n . To pu r ge t h e coolin g syst em of a ll a ir,
t h is h ea t u p/cool down cycle (a ddin g coola n t t o cold
en gin e) m u st be per for m ed t h r ee t im es. Add n eces-
sa r y coola n t t o r a ise t a n k level t o t h e F ULL m a r k
a ft er ea ch cool down per iod.
WJ
COOLI N G (Cont inue d)
Fig. 8 Cooling System Bleed Plug - 4.7L
1 - COOLING SYSTEM BLEED PLUG
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM - 4.0L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(1) DO NOT r em ove r a dia t or ca p fir st . Wit h en gin e
cold, r a ise veh icle on a h oist a n d loca t e r a dia t or
dr a in cock.
NOTE: Radiator draincock is located on the right/
lower side of radiator facing to rear of vehicle.
(2) At t a ch on e en d of a h ose t o t h e dr a in cock. P u t
t h e ot h er en d in t o a clea n con t a in er. Open dr a in cock
a n d dr a in coola n t fr om r a dia t or. Th is will em pt y t h e
coola n t r eser ve/over flow t a n k. Th e coola n t does n ot
h a ve t o be r em oved fr om t h e t a n k u n less t h e syst em
is bein g r efilled wit h a fr esh m ixt u r e. Wh en t a n k is
em pt y, r em ove r a dia t or ca p a n d con t in u e dr a in in g
coolin g syst em .
To dr a in t h e en gin e of coola n t , r em ove t h e cylin der
block dr a in plu g loca t ed on t h e side of cylin der block
(F ig. 9).
COOLING 7 - 13
Fig. 9 Drain Plug—4.0L Engine
1 - COOLANT TEMPERATURE SENSOR
2 - BLOCK DRAIN PLUG
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM - 4.0L ENGINE
(1) Tigh t en t h e r a dia t or dr a in cock a n d t h e cylin der
block dr a in plu g(s) (if r em oved).
(2) F ill syst em u sin g a 50/50 m ixt u r e of et h ylen e-
glycol a n t ifr eeze a n d low m in er a l con t en t wa t er. F ill
r a dia t or t o t op a n d in st a ll r a dia t or ca p. Add su ffi-
cien t coola n t t o t h e r eser ve/over flow t a n k t o r a ise
level t o F ULL m a r k.
(3) Wit h h ea t er con t r ol u n it in t h e H E AT posit ion ,
oper a t e en gin e wit h r a dia t or ca p in pla ce.
(4) Aft er en gin e h a s r ea ch ed n or m a l oper a t in g
t em per a t u r e, sh u t en gin e off a n d a llow it t o cool.
Wh en en gin e is coolin g down , coola n t will be dr a wn
in t o t h e r a dia t or fr om t h e r eser ve/over flow t a n k.
(5) Add coola n t t o r eser ve/over flow t a n k a s n eces-
sa r y. On ly a d d c o o la n t to th e re s e rv e /o v e rflo w
ta n k w h e n th e e n g in e is c o ld . Co o la n t le v e l in a
w a rm e n g in e w ill be h ig h e r d u e to th e rm a l
e x p a n s io n . To pu r ge t h e coolin g syst em of a ll a ir,
t h is h ea t u p/cool down cycle (a ddin g coola n t t o cold
en gin e) m u st be per for m ed t h r ee t im es. Add n eces-
sa r y coola n t t o r a ise t a n k level t o t h e F ULL m a r k
a ft er ea ch cool down per iod.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
Th e u se of a lu m in u m cylin der blocks, cylin der
h ea ds a n d wa t er pu m ps r equ ir es specia l cor r osion
pr ot ect ion . On ly Mopa r ! An t ifr eeze/Coola n t , 5
Yea r /100,000 Mile F or m u la (glycol ba se coola n t wit h
7 - 14 COOLING
COOLI N G (Cont inue d)
cor r osion in h ibit or s ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en
m ixed wit h 50% dist illed wa t er t o obt a in t o obt a in a
fr eeze poin t of -37°C (-35°F ). If it loses color or
becom es con t a m in a t ed, dr a in , flu sh , a n d r epla ce wit h
fr esh pr oper ly m ixed coola n t solu t ion .
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
WJ
REVERSE FLUSHING ENGINE
Dr a in t h e coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ). Rem ove t h e t h er m ost a t
h ou sin g a n d t h er m ost a t . In st a ll t h e t h er m ost a t h ou s-
in g. Discon n ect t h e r a dia t or u pper h ose fr om t h e
r a dia t or a n d a t t a ch t h e flu sh in g gu n t o t h e h ose. Dis-
con n ect t h e r a dia t or lower h ose fr om t h e wa t er
pu m p. At t a ch a lea d a wa y h ose t o t h e wa t er pu m p
in let fit t in g.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.

CAUTION: The cooling system normally operates at
97-to-124 kPa (14-to -18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Rever se flu sh in g of t h e coolin g syst em is t h e for c-
in g of wa t er t h r ou gh t h e coolin g syst em . Th is is don e
u sin g a ir pr essu r e in t h e opposit e dir ect ion of n or m a l
coola n t flow. It is u su a lly on ly n ecessa r y wit h ver y
dir t y syst em s wit h eviden ce of pa r t ia l plu ggin g.
CHEMICAL CLEANING
If visu a l in spect ion in dica t es t h e for m a t ion of
slu dge or sca ly deposit s, u se a r a dia t or clea n er
(Mopa r Ra dia t or Kleen or equ iva len t ) befor e flu sh in g.
Th is will soft en sca le a n d ot h er deposit s a n d a id t h e
flu sh in g oper a t ion .
CAUTION: Be sure instructions on the container are
followed.
Con n ect t h e wa t er su pply h ose a n d a ir su pply h ose
t o t h e flu sh in g gu n . Allow t h e en gin e t o fill wit h
wa t er. Wh en t h e en gin e is filled, a pply a ir in sh or t
bla st s, a llowin g t h e syst em t o fill bet ween a ir bla st s.
Con t in u e u n t il clea n wa t er flows t h r ou gh t h e lea d
a wa y h ose. F or m or e in for m a t ion , r efer t o oper a t in g
in st r u ct ion s su pplied wit h flu sh in g equ ipm en t .
Rem ove t h e lea d a wa y h ose, flu sh in g gu n , wa t er
su pply h ose a n d a ir su pply h ose. Rem ove t h e t h er m o-
st a t h ou sin g (Refer t o 7 - COOLING/E NGINE /E N-
GINE COOLANT TH E RMOSTAT - RE MOVAL).
In st a ll t h e t h er m ost a t a n d h ou sin g wit h a r epla ce-
m en t ga sket (Refer t o 7 - COOLING/E NGINE /E N-
GINE COOLANT TH E RMOSTAT -
INSTALLATION). Con n ect t h e r a dia t or h oses. Refill
t h e coolin g syst em wit h t h e cor r ect a n t ifr eeze/wa t er
m ixt u r e (Refer t o 7 - COOLING - STANDARD P RO-
CE DURE ).

SPECI FI CAT I ON S
REVERSE FLUSHING RADIATOR
Discon n ect t h e r a dia t or h oses fr om t h e r a dia t or fit - TORQUE
t in gs. At t a ch a sect ion of r a dia t or h ose t o t h e r a dia -
t or bot t om ou t let fit t in g a n d in ser t t h e flu sh in g gu n .
Con n ect a wa t er su pply h ose a n d a ir su pply h ose t o DESCRIPTION N·m Ft. In.
t h e flu sh in g gu n . Lbs. Lbs.
CAUTION: The cooling system normally operates at Automatic Belt Tensioner to
97-to-124 kPa (14- to-18 psi) pressure. Exceeding Mounting
this pressure may damage the radiator or hoses.
Bracket—Bolt
Allow t h e r a dia t or t o fill wit h wa t er. Wh en r a dia t or 4.0L 28 — 250
is filled, a pply a ir in sh or t bla st s a llowin g r a dia t or t o 4.7L 41 30 —
r efill bet ween bla st s. Con t in u e t h is r ever se flu sh in g
u n t il clea n wa t er flows ou t t h r ou gh r ea r of r a dia t or Automatic Belt Tensioner
coolin g t u be pa ssa ges. F or m or e in for m a t ion , r efer t o Pulley—
oper a t in g in st r u ct ion s su pplied wit h flu sh in g equ ip- Bolt
m en t . H a ve r a dia t or clea n ed m or e ext en sively by a
r a dia t or r epa ir sh op. (4.7L) 61 45 —

Block Heater—Bolt
WJ COOLING 7 - 15
COOLI N G (Cont inue d)

DESCRIPTION N·m Ft. In. SPECI AL T OOLS

Lbs. Lbs. COOLING
4.0L 4 — 32
4.7L 2 — 17

Fan Blade Assy. to Viscous

Drive—
Bolts 4.0L 23 — 200

Generator Mounting—Bolts 57 42 —
4.0L

Radiator Upper Isolator to

Crossmember—Nuts 3 — 20 Pliers 6094

Radiator Upper Isolator to

Radiator—
Nuts 4 — 36

Radiator Brace—Bolts 10 — 90

Thermostat Housing—Bolts
4.0L 22 16 —
4.7L 13 — 115 Pressure Tester 7700–A
Upper Radiator Crossmember
to
Body—Bolts 10 — 90

Water Pump—Bolts
4.0L 23 17 —
4.7L 54 40 —

Water Pump Pulley to Water

Pump—
Bolts 4.0L 28 — 250

High Pressure Inlet Hose to 49 36 —

Hydraulic Fan Drive—1/2 inch
Fitting

High Pressure Outlet Hose to 29 21.5 —

Steering Gear—3/8 inch
Fitting

Fan Shroud to Radiator 6 — 50

Mounting Bolts
7 - 16 ACCESSORY DRIVE WJ

ACCESSORY DRI V E

TABLE OF CONTENTS
page page

BELT TENSIONERS REMOVAL—4.0L ENGINE . . . . . . . . . . . . . . . . . 19

REMOVAL INSTALLATION—4.0L ENGINE . . . . . . . . . . . . . 19
REMOVAL—4.7L ENGINE . . . . . . . . . . . . . . . 16 DRIVE BELTS - 4.7L
REMOVAL—4.0L ENGINE . . . . . . . . . . . . . . . 16 DIAGNOSIS AND TESTING – SERPENTINE
INSTALLATION DRIVE BELT ..................... . . . . 20
INSTALLATION—4.7L ENGINE ....... . . . . 16 REMOVAL - 4.7L ENGINE . . . . . . . . . . . . . . . . . 22
INSTALLATION—4.0L ENGINE ....... . . . . 17 INSTALLATION - 4.7L ENGINE . . . . . . . . . . . . . 23
DRIVE BELTS - 4.0L
DIAGNOSIS AND TESTING – SERPENTINE
DRIVE BELT ..................... . . . . 17

BELT T EN SI ON ERS

REM OVAL
REMOVAL—4.7L ENGINE
(1) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(2) Rem ove t en sion er a ssem bly fr om en gin e fr on t
cover (F ig. 1).

WARNING: BECAUSE OF HIGH SPRING TENSION,

DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).

(3) Rem ove pu lley bolt . Rem ove pu lley fr om t en -

sion er.

REMOVAL—4.0L ENGINE
(1) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - Fig. 1 Automatic Belt Tensioner
RE MOVAL). 1 - TIMING CHAIN COVER
(2) Rem ove t en sion er a ssem bly fr om m ou n t in g 2 - BOLT TORQUE TO 41 N·m (30 FT LBS)
br a cket (F ig. 2). 3 - AUTOMATIC BELT TENSIONER

WARNING: BECAUSE OF HIGH SPRING TENSION,

I N STALLAT I ON
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
INSTALLATION—4.7L ENGINE
(1) In st a ll pu lley a n d pu lley bolt t o t en sion er.
Tigh t en bolt t o 61 N·m (45 ft . lbs.) t or qu e.
(2) An in dexin g slot is loca t ed on ba ck of t en sion er.
Align t h is slot t o t h e h ea d of t h e bolt on t h e fr on t
cover. In st a ll t h e m ou n t in g bolt . Tigh t en bolt t o 41
N·m (30 ft . lbs.).
WJ ACCESSORY DRIVE 7 - 17
BELT T EN SI ON ERS (Cont inue d)
(3) Ch eck belt in dexin g m a r ks (Refer t o 7 - COOL-
ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
LATION).

DRI V E BELT S - 4 .0 L
DIAGNOSIS AND TESTING – SERPENTINE
DRIVE BELT
Wh en dia gn osin g ser pen t in e dr ive belt s, sm a ll
cr a cks t h a t r u n a cr oss r ibbed su r fa ce of belt fr om r ib
t o r ib (F ig. 3), a r e con sider ed n or m a l. Th ese a r e n ot a
r ea son t o r epla ce belt . H owever, cr a cks r u n n in g a lon g
a r ib (n ot a cr oss) a r e n o t n or m a l. An y belt wit h
cr a cks r u n n in g a lon g a r ib m u st be r epla ced (F ig. 3).
Also r epla ce belt if it h a s excessive wea r, fr a yed cor ds
or sever e gla zin g.
Refer t o SE RP E NTINE DRIVE BE LT DIAGNOSIS
CH ART for fu r t h er belt dia gn osis.

Fig. 2 Automatic Belt Tensioner

1 - IDLER PULLEY TIGHTEN TO 47 N·m (35 FT. LBS.)
2 - AUTOMATIC BELT TENSIONER
3 - GENERATOR MOUNTING BRACKET

(3) In st a ll dr ive belt (Refer t o 7 - COOLING/AC-

CE SSORY DRIVE /DRIVE BE LTS - INSTALLA-
TION).
(4) Ch eck belt in dexin g m a r ks (Refer t o 7 - COOL-
ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
LATION).

INSTALLATION—4.0L ENGINE
(1) In st a ll t en sion er a ssem bly t o m ou n t in g
br a cket , a lign t h e t wo dowels on t h e t en sion er wit h
t h e m ou n t in g br a cket a n d h a n d st a r t t h e bolt .
Tigh t en bolt t o 28 N·m (250 in . lbs.).

CAUTION: To prevent damage to coil case, coil

Fig. 3 Serpentine Accessory Drive Belt Wear
mounting bolts must be torqued.
Patterns
(2) In st a ll dr ive belt . (Refer t o 7 - COOLING/AC- 1 - NORMAL CRACKS BELT OK
CE SSORY DRIVE /DRIVE BE LTS - INSTALLA- 2 - NOT NORMAL CRACKS REPLACE BELT
TION).
7 - 18 ACCESSORY DRIVE
DRI V E BELT S - 4 .0 L (Cont inue d)
SERPEN T I N E DRI V E BELT DI AGN OSI S CH ART
CONDITION
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
RIB OR BELT WEAR
LONGITUDINAL BELT
CRACKING (CRACKS BETWEEN
TWO RIBS)
BELT SLIPS
“GROOVE JUMPING" (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
WJ
POSSIBLE CAUSES CORRECTION
1. Foreign objects imbedded in pulley 1. Remove foreign objects from
grooves. pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
1. Belt has mistracked from pulley 1. Replace belt.
groove.
2. Pulley groove tip has worn away 2. Replace belt.
rubber to tensile member.
1. Belt slipping because of insufficient 1. Replace automatic belt tensioner.
tension.
2. Belt routed 2. Verify belt routing.
incorrectly
3. Incorrect belt. 3. Replace belt.
4. Belt or pulley subjected to 4. Replace belt and clean pulleys.
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
5. Driven component bearing failure. 5. Replace faulty component
bearing.
6. Belt glazed and hardened from 6. Replace belt.
heat and excessive slippage.
1. Belt tension either too high or too 1. Replace automatic belt tensioner.
low.
2. Belt routed 2. Verify belt routing.
incorrectly.
3. Incorrect belt. 3. Replace belt.
4. Pulley(s) not within design 4. Replace pulley(s).
tolerance.
5. Foreign object(s) in grooves. 5. Remove foreign objects from
grooves.
6. Pulley misalignment. 6. Check and replace.
7. Belt cord line is broken. 7. Replace belt.
WJ ACCESSORY DRIVE 7 - 19
DRI V E BELT S - 4 .0 L (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

BELT BROKEN (NOTE: IDENTIFY 1. Excessive tension. 1. Replace belt and automatic belt
AND CORRECT PROBLEM tensioner.
BEFORE NEW BELT IS
INSTALLED) 2. Incorrect belt. 2. Replace belt.
3. Tensile member damaged during 3. Replace belt.
belt installation.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.

NOISE (OBJECTIONABLE 1. Belt slippage. 1. Replace belt or automatic belt

SQUEAL, SQUEAK, OR RUMBLE tensioner.
IS HEARD OR FELT WHILE 2. Bearing noise. 2. Locate and repair.
DRIVE BELT IS IN OPERATION)
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.

REMOVAL—4.0L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.

CAUTION: DO NOT LET TENSIONER ARM SNAP

BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.

Belt t en sion is n ot a dju st a ble. Belt a dju st m en t is

m a in t a in ed by a n a u t om a t ic ( spr in g loa d ) belt t en -
sion er.
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(2) Rot a t e belt t en sion er u n t il it con t a ct s it s st op.
Rem ove belt , t h en slowly r ot a t e t h e t en sion er in t o
t h e fr eea r m posit ion . (F ig. 4).

INSTALLATION—4.0L ENGINE Fig. 4 Belt Routing—4.0L

1 - GENERATOR
NOTE: The belt routing schematics are published
2 - IDLER
from the latest information available at the time of
3 - POWER STEERING
publication. If anything differs between these sche- 4 - A/C
matics and the Belt Routing Label, use the sche- 5 - CRANKSHAFT
matics on Belt Routing Label. This label is located 6 - WATER PUMP
in the engine compartment. 7 - TENSIONER
8 - ACCESSORY DRIVE BELT
Belt t en sion is n ot a dju st a ble. Belt a dju st m en t is
m a in t a in ed by a n a u t om a t ic ( spr in g loa d ) belt t en -
CAUTION: When installing the serpentine accessory
sion er.
drive belt, the belt MUST be routed correctly. If not,
(1) Ch eck con dit ion of a ll pu lleys.
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 4).
7 - 20 ACCESSORY DRIVE
DRI V E BELT S - 4 .0 L (Cont inue d)
(2) In st a ll n ew belt (F ig. 4). Rou t e t h e belt a r ou n d
a ll pu lleys except t h e idler pu lley. Rot a t e t h e t en -
sion er a r m u n t il it con t a ct s it s st op posit ion . Rou t e
t h e belt a r ou n d t h e idler a n d slowly let t h e t en sion er
r ot a t e in t o t h e belt . Ma ke su r e t h e belt is sea t ed on t o
a ll pu lleys.
(3) Wit h t h e dr ive belt in st a lled, in spect t h e belt
wea r in dica t or (F ig. 5). On 4.0L E n gin es, t h e in dica -
t or m a r k m u st be bet ween t h e m in im u m a n d m a xi-
m u m m a r ks. If t h e m ea su r em en t exceedes t h is
specifica t ion r epla ce t h e ser pen t in e a ccessor y dr ive
belt .
Fig. 5 Accessory Drive Belt Wear Indicator
1 - INDICATOR MARK
2 - MINIMUM TENSION MARK
3 - MAXIMUM TENSION MARK
WJ
DRI V E BELT S - 4 .7 L
DIAGNOSIS AND TESTING – SERPENTINE
DRIVE BELT
Wh en dia gn osin g ser pen t in e dr ive belt s, sm a ll
cr a cks t h a t r u n a cr oss r ibbed su r fa ce of belt fr om r ib
t o r ib (F ig. 6), a r e con sider ed n or m a l. Th ese a r e n ot a
r ea son t o r epla ce belt . H owever, cr a cks r u n n in g a lon g
a r ib (n ot a cr oss) a r e n o t n or m a l. An y belt wit h
cr a cks r u n n in g a lon g a r ib m u st be r epla ced (F ig. 6).
Also r epla ce belt if it h a s excessive wea r, fr a yed cor ds
or sever e gla zin g.
Refer t o SE RP E NTINE DRIVE BE LT DIAGNOSIS
CH ART for fu r t h er belt dia gn osis.
Fig. 6 Serpentine Accessory Drive Belt Wear
Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
WJ
DRI V E BELT S - 4 .7 L (Cont inue d)
SERPEN T I N E DRI V E BELT DI AGN OSI S CH ART
CONDITION
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
RIB OR BELT WEAR
LONGITUDINAL BELT
CRACKING (CRACKS BETWEEN
TWO RIBS)
BELT SLIPS
“GROOVE JUMPING" (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
ACCESSORY DRIVE 7 - 21
POSSIBLE CAUSES CORRECTION
1. Foreign objects imbedded in pulley 1. Remove foreign objects from
grooves. pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
1. Belt has mistracked from pulley 1. Replace belt.
groove.
2. Pulley groove tip has worn away 2. Replace belt.
rubber to tensile member.
1. Belt slipping because of insufficient 1. Replace automatic belt tensioner.
tension.
2. Belt routed 2. Verify belt routing.
incorrectly
3. Incorrect belt. 3. Replace belt.
4. Belt or pulley subjected to 4. Replace belt and clean pulleys.
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
5. Driven component bearing failure. 5. Replace faulty component
bearing.
6. Belt glazed and hardened from 6. Replace belt.
heat and excessive slippage.
1. Belt tension either too high or too 1. Replace automatic belt tensioner.
low.
2. Belt routed 2. Verify belt routing.
incorrectly.
3. Incorrect belt. 3. Replace belt.
4. Pulley(s) not within design 4. Replace pulley(s).
tolerance.
5. Foreign object(s) in grooves. 5. Remove foreign objects from
grooves.
6. Pulley misalignment. 6. Check and replace.
7. Belt cord line is broken. 7. Replace belt.
7 - 22 ACCESSORY DRIVE WJ
DRI V E BELT S - 4 .7 L (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

BELT BROKEN (NOTE: IDENTIFY 1. Excessive tension. 1. Replace belt and automatic belt
AND CORRECT PROBLEM tensioner.
BEFORE NEW BELT IS
INSTALLED) 2. Incorrect belt. 2. Replace belt.
3. Tensile member damaged during 3. Replace belt.
belt installation.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.

NOISE (OBJECTIONABLE 1. Belt slippage. 1. Replace belt or automatic belt

SQUEAL, SQUEAK, OR RUMBLE tensioner.
IS HEARD OR FELT WHILE 2. Bearing noise. 2. Locate and repair.
DRIVE BELT IS IN OPERATION)
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.

REMOVAL - 4.7L ENGINE

NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.

CAUTION: DO NOT LET TENSIONER ARM SNAP

BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.

Belt t en sion is n ot a dju st a ble. Belt a dju st m en t is

m a in t a in ed by a n a u t om a t ic ( spr in g loa d ) belt t en -
sion er.
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(2) Rot a t e belt t en sion er u n t il it con t a ct s it s st op.
Rem ove belt , t h en slowly r ot a t e t h e t en sion er in t o
t h e fr eea r m posit ion . (F ig. 7).

Fig. 7 Belt Routing - 4.7L

1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
WJ ACCESSORY DRIVE 7 - 23
DRI V E BELT S - 4 .7 L (Cont inue d)

INSTALLATION - 4.7L ENGINE (3) Wit h t h e dr ive belt in st a lled, in spect t h e belt
wea r in dica t or (F ig. 8). On 4.7L E n gin es t h e ga p
NOTE: The belt routing schematics are published bet ween t h e t a n g a n d t h e h ou sin g st op ( m ea su r e-
from the latest information available at the time of m en t A ) m u st n ot exceed 24 m m (.94 in ch es).
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.

Belt t en sion is n ot a dju st a ble. Belt a dju st m en t is

m a in t a in ed by a n a u t om a t ic ( spr in g loa d ) belt t en -
sion er.
(1) Ch eck con dit ion of a ll pu lleys.

CAUTION: When installing the serpentine accessory

drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 7).

(2) In st a ll n ew belt (F ig. 7). Rou t e t h e belt a r ou n d

a ll pu lleys except t h e idler pu lley. Rot a t e t h e t en - Fig. 8 Accessory Drive Belt Wear Indicator
sion er a r m u n t il it con t a ct s it s st op posit ion . Rou t e 1 - AUTOMATIC TENSIONER ASSEMBLY
t h e belt a r ou n d t h e idler a n d slowly let t h e t en sion er
r ot a t e in t o t h e belt . Ma ke su r e t h e belt is sea t ed on t o
a ll pu lleys.
7 - 24 ENGINE WJ

EN GI N E

TABLE OF CONTENTS
page page

COOLANT DIAGNOSIS AND TESTING—THERMOSTAT . . . 37

DESCRIPTION REMOVAL
DESCRIPTION - ENGINE COOLANT . . . . . . . 25 REMOVAL—4.0L ENGINE . . . . . . . . . . . . . . . 38
DESCRIPTION - HOAT COOLANT . . . . . . . . . 25 REMOVAL—4.7L ENGINE . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION
COOLANT LEVEL SENSOR INSTALLATION—4.0L ENGINE ....... . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION—4.7L ENGINE ....... . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26 FAN DRIVE VISCOUS CLUTCH - 4.0L
COOLANT RECOVERY PRESS CONTAINER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
RADIATOR FAN - 4.7L DIAGNOSIS AND TESTING—VISCOUS FAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 PWM FAN CONTROL MODULE - 4.0L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
RADIATOR FAN - 4.0L INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31 RADIATOR - 4.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSPECTION ........................ . . 32 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32 INSPECTION ...................... . . . . 44
ENGINE BLOCK HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
DESCRIPTION RADIATOR - 4.0L
DESCRIPTION—4.7L ENGINE . . . . . . . . . . . . 32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
DESCRIPTION—4.0L ENGINE . . . . . . . . . . . . 32 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DIAGNOSIS AND TESTING—ENGINE BLOCK INSPECTION ...................... . . . . 47
HEATER .......................... . . 33 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL RADIATOR FAN MOTOR
REMOVAL—4.7L ENGINE . . . . . . . . . . . . . . . 33 DIAGNOSIS AND TESTING—ELECTRIC
REMOVAL—4.0L ENGINE . . . . . . . . . . . . . . . 34 COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION WATER PUMP - 4.7L
INSTALLATION—4.7L ENGINE ......... . . 34 DESCRIPTION
INSTALLATION—4.0L ENGINE ......... . . 34 DESCRIPTION—WATER PUMP . . . . . . . . . . . 47
ENGINE COOLANT TEMP SENSOR DESCRIPTION—WATER PUMP BYPASS . . . . 47
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35 OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 OPERATION—WATER PUMP . . . . . . . . ... . 47
REMOVAL OPERATION—WATER PUMP BYPASS . ... . 48
REMOVAL—4.0L ENGINE . . . . . . . . . . . . . . . 35 DIAGNOSIS AND TESTING—WATER PUMP .. . 48
REMOVAL—4.7L ENGINE . . . . . . . . . . . . . . . 36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . ... . 49
INSTALLATION CLEANING . . . . . . . . . . . . . . . . . . . . . . . . ... . 49
INSTALLATION—4.0L ENGINE ......... . . 36 INSPECTION ...................... ... . 49
INSTALLATION—4.7L ENGINE ......... . . 36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . ... . 49
ENGINE COOLANT THERMOSTAT WATER PUMP - 4.0L
DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .. . . 50
DESCRIPTION—4.7L ENGINE . . . . . . . . . . . . 36 DIAGNOSIS AND TESTING—WATER PUMP . . . 50
DESCRIPTION—4.0L ENGINE . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . .. . . 52
WJ
INSPECTION ................... . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DIAGNOSIS AND TESTING—RADIATOR
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . 53
COOLAN T
DESCRI PT I ON
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
Th e r equ ir ed et h ylen e-glycol (a n t ifr eeze) a n d wa t er
m ixt u r e depen ds u pon t h e clim a t e a n d veh icle oper-
a t in g con dit ion s. Th e r ecom m en ded m ixt u r e of 50/50
et h ylen e-glycol a n d wa t er will pr ovide pr ot ect ion
a ga in st fr eezin g t o -37 deg. C (-35 deg. F ). Th e a n t i-
fr eeze con cen t r a t ion m u s t a lw a y s be a m in im u m of
44 per cen t , yea r-r ou n d in a ll clim a t es. If p e rc e n ta g e
is lo w e r th a n 44 p e rc e n t, e n g in e p a rts m a y be
e ro d e d by c a v ita tio n , a n d c o o lin g s y s te m c o m -
p o n e n ts m a y be s e v e re ly d a m a g e d by c o rro s io n .
Ma xim u m pr ot ect ion a ga in st fr eezin g is pr ovided
wit h a 68 per cen t a n t ifr eeze con cen t r a t ion , wh ich
pr even t s fr eezin g down t o -67.7 deg. C (-90 deg. F ). A
h igh er per cen t a ge will fr eeze a t a wa r m er t em per a -
t u r e. Also, a h igh er per cen t a ge of a n t ifr eeze ca n
ca u se t h e en gin e t o over h ea t beca u se t h e specific
h ea t of a n t ifr eeze is lower t h a n t h a t of wa t er.
Use of 100 per cen t et h ylen e-glycol will ca u se for-
m a t ion of a ddit ive deposit s in t h e syst em , a s t h e cor-
r osion in h ibit ive a ddit ives in et h ylen e-glycol r equ ir e
t h e pr esen ce of wa t er t o dissolve. Th e deposit s a ct a s
in su la t ion , ca u sin g t em per a t u r es t o r ise t o a s h igh a s
149 deg. C (300) deg. F ). Th is t em per a t u r e is h ot
en ou gh t o m elt pla st ic a n d soft en solder. Th e
in cr ea sed t em per a t u r e ca n r esu lt in en gin e det on a -
t ion . In a ddit ion , 100 per cen t et h ylen e-glycol fr eezes
a t 22 deg. C (-8 deg. F ).
PROPYLENE-GLYCOL MIXTURES
It ’s over a ll effect ive t em per a t u r e r a n ge is sm a ller
t h a n t h a t of et h ylen e-glycol. Th e fr eeze poin t of 50/50
pr opylen e-glycol a n d wa t er is -32 deg. C (-26 deg. F ).
5 deg. C h igh er t h a n et h ylen e-glycol’s fr eeze poin t .
Th e boilin g poin t (pr ot ect ion a ga in st su m m er boil-
over ) of pr opylen e-glycol is 125 deg. C (257 deg. F )
ENGINE 7 - 25
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSPECTION ........ . . . . . . . . . . . . . . . . . . 54
WATER PUMP INLET TUBE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
a t 96.5 kP a (14 psi), com pa r ed t o 128 deg. C (263
deg. F ) for et h ylen e-glycol. Use of pr opylen e-glycol
ca n r esu lt in boil-over or fr eeze-u p on a coolin g sys-
t em design ed for et h ylen e-glycol. P r opylen e glycol
a lso h a s poor er h ea t t r a n sfer ch a r a ct er ist ics t h a n
et h ylen e glycol. Th is ca n in cr ea se cylin der h ea d t em -
per a t u r es u n der cer t a in con dit ion s.
P r opylen e-glycol/et h ylen e-glycol Mixt u r es ca n
ca u se t h e dest a biliza t ion of va r iou s cor r osion in h ibi-
t or s, ca u sin g da m a ge t o t h e va r iou s coolin g syst em
com pon en t s. Also, on ce et h ylen e-glycol a n d pr opy-
len e-glycol ba sed coola n t s a r e m ixed in t h e veh icle,
con ven t ion a l m et h ods of det er m in in g fr eeze poin t will
n ot be a ccu r a t e. Bot h t h e r efr a ct ive in dex a n d spe-
cific gr a vit y differ bet ween et h ylen e glycol a n d pr opy-
len e glycol.
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL 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 IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
Th e coolin g syst em is design ed a r ou n d t h e coola n t .
Th e coola n t m u st a ccept h ea t fr om en gin e m et a l, in
t h e cylin der h ea d a r ea n ea r t h e exh a u st va lves a n d
en gin e block. Th en coola n t ca r r ies t h e h ea t t o t h e
r a dia t or wh er e t h e t u be/fin r a dia t or ca n t r a n sfer t h e
h ea t t o t h e a ir.
7 - 26 ENGINE
COOLAN T (Cont inue d)
Th e u se of a lu m in u m cylin der blocks, cylin der
h ea ds, a n d wa t er pu m ps r equ ir es specia l cor r osion
pr ot ect ion . Mopa r ! An t ifr eeze/Coola n t , 5 cause problems associated with 100 percent ethyl-
Yea r /100,000 Mile F or m u la (MS-9769), or t h e equ iva -
len t et h ylen e glycol ba se coola n t wit h or ga n ic cor r o-
sion in h ibit or s (ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en
m ixed wit h 50% E t h ylen e Glycol a n d 50% dist illed
wa t er t o obt a in a fr eeze poin t of -37°C (-35°F ). If it
loses color or becom es con t a m in a t ed, dr a in , flu sh ,
a n d r epla ce wit h fr esh pr oper ly m ixed coola n t solu -
t ion .
CAUTION: Mopar# Antifreeze/Coolant, 5 m ixed wit h 50% dist illed wa t er t o obt a in t o obt a in a
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
Th e r equ ir ed et h ylen e-glycol (a n t ifr eeze) a n d wa t er
m ixt u r e depen ds u pon clim a t e a n d veh icle oper a t in g
con dit ion s. Th e coola n t per for m a n ce of va r iou s m ix-
t u r es follows:
P u re Wa te r-Wa t er ca n a bsor b m or e h ea t t h a n a
m ixt u r e of wa t er a n d et h ylen e-glycol. Th is is for pu r-
pose of h ea t t r a n sfer on ly. Wa t er a lso fr eezes a t a
h igh er t em per a t u r e a n d a llows cor r osion .
100 p e rc e n t Eth y le n e -Gly c o l-Th e cor r osion
in h ibit in g a ddit ives in et h ylen e-glycol n eed t h e pr es-
en ce of wa t er t o dissolve. Wit h ou t wa t er, a ddit ives
for m deposit s in syst em . Th ese a ct a s in su la t ion
ca u sin g t em per a t u r e t o r ise t o a s h igh a s 149°C
(300°F ). Th is t em per a t u r e is h ot en ou gh t o m elt pla s-
t ic a n d soft en solder. Th e in cr ea sed t em per a t u r e ca n
r esu lt in en gin e det on a t ion . In a ddit ion , 100 per cen t
et h ylen e-glycol fr eezes a t -22°C (-8°F ).
50/50 Eth y le n e -Gly c o l a n d Wa te r-Is t h e r ecom -
m en ded m ixt u r e, it pr ovides pr ot ect ion a ga in st fr eez-
in g t o -37°C (-34°F ). Th e a n t ifr eeze con cen t r a t ion
m u s t a lw a y s be a m in im u m of 44 per cen t , yea r-
r ou n d in a ll clim a t es. If per cen t a ge is lower, en gin e
pa r t s m a y be er oded by ca vit a t ion . Ma xim u m pr ot ec-
t ion a ga in st fr eezin g is pr ovided wit h a 68 per cen t
a n t ifr eeze con cen t r a t ion , wh ich pr even t s fr eezin g
down t o -67.7°C (-90°F ). A h igh er per cen t a ge will
fr eeze a t a wa r m er t em per a t u r e. Also, a h igh er per-
cen t a ge of a n t ifr eeze ca n ca u se t h e en gin e t o over-
h ea t beca u se specific h ea t of a n t ifr eeze is lower t h a n
t h a t of wa t er.
WJ
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
ene-glycol.
COOLANT SELECTION AND ADDITIVES
Th e u se of a lu m in u m cylin der blocks, cylin der
h ea ds a n d wa t er pu m ps r equ ir es specia l cor r osion
pr ot ect ion . On ly Mopa r ! An t ifr eeze/Coola n t , 5
Yea r /100,000 Mile F or m u la (glycol ba se coola n t wit h
cor r osion in h ibit or s ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en
fr eeze poin t of -37°C (-35°F ). If it loses color or
becom es con t a m in a t ed, dr a in , flu sh , a n d r epla ce wit h
fr esh pr oper ly m ixed coola n t solu t ion .
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
OPERATION
Coola n t flows t h r ou gh t h e en gin e block a bsor bin g
t h e h ea t fr om t h e en gin e, t h en flows t o t h e r a dia t or
wh er e t h e coolin g fin s in t h e r a dia t or t r a n sfer s t h e
h ea t fr om t h e coola n t t o t h e a t m osph er e. Du r in g cold
wea t h er t h e et h ylen e-glycol coola n t pr even t s wa t er
pr esen t in t h e coolin g syst em fr om fr eezin g wit h in
t em per a t u r es in dica t ed by m ixt u r e r a t io of coola n t t o
wa t er.
COOLAN T LEV EL SEN SOR
REMOVAL
(1) Open H ood.
(2) Discon n ect elect r ica l con n ect or fr om coola n t
level sen sor.
(3) P u ll coola n t level sen sor ou t of coola n t r ecover y
pr essu r e con t a in er.
INSTALLATION
NOTE: Make sure the coolant level sensor fully
seats into the rubber grommet. Failure to do so
may cause inaccurate coolant level readings and
leaks.
WJ ENGINE 7 - 27
COOLAN T LEV EL SEN SOR (Cont inue d)

COOLAN T RECOV ERY PRESS

CON TAI N ER
DESCRIPTION
Th is syst em wor ks a lon g wit h t h e r a dia t or pr es-
su r e ca p. Th is is don e by u sin g t h er m a l expa n sion
a n d con t r a ct ion of t h e coola n t t o keep t h e coola n t
fr ee of t r a pped a ir. It pr ovides:
• A volu m e for coola n t expa n sion a n d con t r a ct ion .
• A con ven ien t a n d sa fe m et h od for ch eckin g/a d-
ju st in g coola n t level a t a t m osph er ic pr essu r e. Th is is
don e wit h ou t r em ovin g t h e r a dia t or pr essu r e ca p.
• Som e r eser ve coola n t t o t h e r a dia t or t o cover
m in or lea ks a n d eva por a t ion or boilin g losses.
As t h e en gin e cools, a va cu u m is for m ed in t h e
coolin g syst em of bot h t h e r a dia t or a n d en gin e. Cool-
a n t will t h en be dr a wn fr om t h e coola n t t a n k a n d
r et u r n ed t o a pr oper level in t h e r a dia t or.
Th e coola n t r eser voir /over flow syst em h a s a r a dia -
t or m ou n t ed pr essu r ized ca p, a n over flow t u be a n d a
pla st ic coola n t r eser voir /over flow t a n k (F ig. 3)
Fig. 1 COOLANT LEVEL SENSOR ELECTRICAL m ou n t ed t o t h e r igh t in n er fen der.
CONNECTOR

Fig. 3 Coolant Reservoir / Overflow Tank

1 - COOLANT OVERFLOW HOSE
2 - COOLANT RESERVOIR/OVERFLOW TANK
3 - COOLANT LEVEL SENSOR
4 - BOLT

RADI AT OR FAN - 4 .7 L
DESCRIPTION
Th e h ydr a u lic fa n (F ig. 4) u sed on veh icles
equ ipped t h e 4.7L en gin e, r epla ces bot h t h e elect r ic
Fig. 2 COOLANT LEVEL SENSOR REMOVAL/ fa n a n d t h e en gin e dr iven m ech a n ica l fa n . Th e
INSTALLATION h ydr a u lic coolin g fa n is in t egr a l t o t h e fa n sh r ou d
(1) P osit ion sen sor in t o t h e coola n t r ecover y pr es- a n d is loca t ed bet ween t h e r a dia t or a n d t h e en gin e.
su r e con t a in er (F ig. 1). Th e power st eer in g pu m p su pplies t h e h ydr a u lic
(2) Con n ect t h e coola n t level sen sor elect r ica l con - flu id a n d pr essu r e t o r ot a t e t h e coolin g fa n bla de,
n ect or (F ig. 2). wh ile t h e elect r ica l pa r t of t h e fa n is con t r olled by
(3) Close h ood. t h e J TE C.
Th e h ydr a u lic fa n dr ive (m ot or ) con sist s of t h e
t h r ee m a jor followin g com pon en t s:
• St eer in g flow con t r ol va lve
7 - 28 ENGINE
RADI AT OR FAN - 4 .7 L (Cont inue d)
• F a n con t r ol va lve
• Two st a ge G-r ot or h ydr a u lic dr ive
Th e h ydr a u lic fa n a n d dr ive is n ot ser vicea ble.
Th er efor e a n y fa ilu r e of t h e fa n bla de, h ydr a u lic fa n
dr ive or fa n sh r ou d r equ ir es r epla cem en t of t h e fa n
m odu le beca u se t h e fa n bla de a n d h ydr a u lic fa n dr ive
a r e m a t ch ed a n d ba la n ced a s a syst em a n d ser vicin g
eit h er sepa r a t ely wou ld disr u pt t h is ba la n ce.
F or h ydr a u lic flu id r ou t in g in for m a t ion r efer t o
(F ig. 5).
CAUTION: Do not attempt to service the hydraulic
cooling fan or fan drive separately replace the cooling
module as an assembly. Failure to do so may cause
severe damage to the hydraulic cooling fan assembly.
Fig. 4 HYDRAULIC RADIATOR COOLING FAN AND
FAN DRIVE
1 - POWER STEERING FLUID COOLER
2 - RADIATOR
3 - HIGH PRESSURE LINE FROM STEERING GEAR PUMP TO
HYDRAULIC FAN MOTOR
4 - HYDRAULIC FAN MOTOR
5 - HIGH PRESSURE LINE FROM HYDRAULIC FAN MOTOR TO
STEERING GEAR
6 - FAN SHROUD
OPERATION
Th e h ydr a u lic r a dia t or coolin g fa n u sed on t h e
Gr a n d Ch er okee wit h t h e 4.7L en gin e r epla ces bot h
t h e elect r ic fa n a n d t h e en gin e dr iven m ech a n ica l
fa n . Th e u se of t h is h ydr a u lic fa n pr ovides t h e 4.7L
equ ipped Gr a n d Ch er okee wit h h ea vy t r a iler t ow
ca pa bilit y wh ile a t t h e sa m e t im e r edu cin g u n n eces-
sa r y power dr a in on bot h t h e en gin e a n d t h e veh icles
elect r ica l syst em .
WJ
HYDRAULIC FAN STRATEGY
Th e h ydr a u lic r a dia t or coolin g fa n is con t r olled by
t h e J TE C. A P WM (P u lse Wit h Modu la t ed) sign a l
fr om t h e J TE C con t r ols t h e fa n fr om 0 t o 100% of t h e
a va ila ble fa n speed. Th er e a r e fou r in pu t s t o t h e
J TE C t h a t det er m in e wh a t speed per cen t a ge of fa n is
r equ ir ed by t h e veh icle. Th ese in pu t s a r e:
• E n gin e Coola n t Tem per a t u r e
• Tr a n sm ission Oil Tem per a t u r e
• Ba t t er y Tem per a t u r e
• A/C Syst em P r essu r e
By m on it or in g t h ese fou r pa r a m et er s, t h e J TE C
ca n det er m in e if coolin g a ir flow is r equ ir ed. If a ir flow
is r equ ir ed, t h e J TE C will slowly r a m p u p (speed u p)
t h e fa n speed u n t il t h e pa r a m et er (s) a r e u n der con -
t r ol. On ce t h e t em per a t u r e or pr essu r e is r edu ced t o
wit h in oper a t in g pa r a m et er s t h e fa n will r a m p u p,
r a m p down , or h old it s speed t o m a in t a in t h e t em per-
a t u r e / pr essu r e r equ ir em en t s.
NOTE: Even if the JTEC is not requesting fan on
operation the fan blade will usually spin between
100 and 500 RPM when the vehicle is at idle. This is
due to a controlled minimum oil flow requirement
through the fan drive motor.
ACTIVATING THE HYDRAULIC FAN WITH THE DRB
Un der t h e E n gin e Syst em s t est h ea din g, t h er e is a
su bh ea din g. “H ydr a u lic fa n solen oid t est ”, t h a t h a s
t h e select ion s, on /off. Act iva t in g t h e fa n wit h t h e
DRB will r u n t h e fa n a t 100% du t y cycle, wh ich will
h elp t r ou blesh oot a n y syst em pr oblem s, a n d a lso h elp
wit h t h e dea er a t ion pr ocedu r e.
NOTE: Engine must be running to activate the fan
with the DRB.
RADIATOR COOLING FAN HYDRAULIC FLUID PATH
H ydr a u lic flu id is pu m ped t h r ou gh t h e power
st eer in g pu m p, fr om t h e pu m p t h e flu id t r a vels
t h ou gh a h igh pr essu r e deliver y lin e t o t h e fa n dr ive
m ot or. As flu id is diver t ed t h r ou gh t h e G-r ot or s, r ot a -
t ion a l m ot ion is cr ea t ed a s flu id m oves fr om t h e h igh -
pr essu r e (in let ) side of t h e m ot or t o t h e low-pr essu r e
(ou t let ) side. F lu id exit in g t h e dr ive m ot or is divided
in t o t wo pa t h s. P a t h on e con t in u es t h r ou gh a h igh
pr essu r e deliver y lin e t o t h e veh icles st eer in g gea r t o
pr ovide st eer in g a ssist . a n d pa t h t wo sen ds flu id
ba ck t o t h e power st eer in g pu m p t h r ou gh a low pr es-
su r e lin e. F lu id exit s t h e st eer in g gea r u n der low
pr essu r e a n d t r a vels t h r ou gh a low pr essu r e lin e t o
t h e power st eer in g flu id cooler t o be cooled befor e
bein g r et u r n ed ba ck t h e t h e power st eer in g flu id r es-
er voir (F ig. 5).
WJ
RADI AT OR FAN - 4 .7 L (Cont inue d)
Fig. 5 HYDRAULIC FAN FLUID FLOW CIRCUIT
1 - POWER STEERING RESERVOIR
2 - POWER STEERING PUMP
3 - HYDRAULIC FAN DRIVE ASSEMBLY
4 - FAN BLADE
NOTE: There is a steering flow control valve located
in the fan drive motor. This valve operates like the
flow control valve found in the typical power steer-
ing pump. Because of the design of the valve steer-
ing assist can not be effected by the radiator
cooling fan even during fan drive failure.
REMOVAL
(1) Ra ise veh icle on h oist .
(2) Dr a in coolin g syst em .(Refer t o 7 - COOLING -
STANDARD P ROCE DURE )
NOTE: The hydraulic fan drive is driven by the
power steering pump. When removing lines or
hoses from fan drive assembly use a drain pan to
catch any power steering fluid that may exit the fan
drive or the lines and hoses.
ENGINE 7 - 29
5 - HYDRAULIC FAN CONTROL SOLENOID
6 - POWER STEERING OIL COOLER
7 - STEERING GEAR
NOTE: When ever the high pressure line fittings are
removed from the hydraulic fan drive the O-rings
must be replaced.
(3) Discon n ect t wo h igh pr essu r e lin es a t h ydr a u lic
fa n dr ive (F ig. 6). Rem ove a n d disca r d o-r in gs fr om
lin e fit t in gs.
(4) Discon n ect low pr essu r e r et u r n h ose a t h ydr a u -
lic fa n dr ive (F ig. 6).
NOTE: The lower mounting bolts can only be
accessed from under vehicle.
(5) Rem ove t wo lower m ou n t in g bolt s fr om t h e
sh r ou d (F ig. 8).
(6) Lower veh icle.
(7) Discon n ect t h e elect r ica l con n ect or for t h e fa n
con t r ol solen oid.
(8) Discon n ect t h e r a dia t or u pper h ose a t t h e r a di-
a t or a n d posit ion ou t of t h e wa y.
(9) Discon n ect t h e power st eer in g gea r ou t let h ose
a n d flu id r et u r n h ose a t t h e cooler (F ig. 7).
7 - 30 ENGINE WJ
RADI AT OR FAN - 4 .7 L (Cont inue d)
(10) Rem ove t wo u pper m ou n t in g bolt s fr om t h e
sh r ou d (F ig. 8).

Fig. 6 HYDRAULIC LINES/HOSES AND ELECTRICAL

CONNECTOR
1 - LOW PRESSURE RETURN HOSE Fig. 8 FAN SHROUD MOUNTING BOLT LOCATIONS
2 - HIGH PRESSURE LINE (OUTLET)
1 - FAN SHROUD UPPER MOUNTING BOLT LOCATIONS
3 - HIGH PRESSURE LINE (INLET)
2 - FAN SHROUD LOWER MOUNTING BOLT LOCATIONS
4 - HYDRAULIC FAN DRIVE

(11) Rem ove t h e sh r ou d a n d fa n dr ive fr om veh i-

cle.

CLEANING
Clea n t h e fa n bla des u sin g a m ild soa p a n d wa t er.
Do n ot u se a n a br a sive t o clea n t h e bla des.

INSTALLATION
CAUTION: There is an external ground wire con-
nected to the hydraulic fan drive located at the elec-
trical connector on the fan assembly. This ground
MUST remain connected at all times. Failure to
ensure ground wire is connected when engine is
operating can cause severe damage to the JTEC
module.

(1) P osit ion fa n dr ive a n d sh r ou d in veh icle.

Fig. 7 POWER STEERING GEAR OUTLET AND
RETURN HOSES
1 - POWER STEERING COOLER RETURN HOSE
2 - POWER STEERING COOLER SUPPLY HOSE
(2) In st a ll fa n sh r ou d u pper m ou n t in g bolt s. Do
n ot t igh t en a t t h is t im e.
(3) In st a ll r a dia t or u pper h ose on t o r a dia t or.
(4) Con n ect power st eer in g cooler h oses.
(5) Ra ise veh icle on h oist .
(6) In st a ll fa n sh r ou d lower m ou n t in g bolt s.
Tigh t en t o 6 N·m (50 in . lbs.).
WJ
RADI AT OR FAN - 4 .7 L (Cont inue d)
NOTE: When ever the high pressure line fittings are
removed from the hydraulic fan drive the o-rings
located on the fittings must be replaced.
(7) Lu br ica t e t h e o-r in gs on t h e fit t in gs wit h power
st eer in g flu id t h en con n ect in let a n d ou t let h igh pr es-
su r e lin es t o fa n dr ive (F ig. 9). Tigh t en in let lin e t o
49 N·m (36 ft . lbs.) t igh t en ou t let lin e t o 29 N·m (21.5
ft . lbs.).
(8) Con n ect low pr essu r e r et u r n h ose t o fa n dr ive
(F ig. 9).
ENGINE 7 - 31
(14) Refill power st eer in g flu id r eser voir a n d bleed
a ir fr om st eer in g syst em (Refer t o 19 - STE E RING/
P UMP - STANDARD P ROCE DURE ).
(15) Ru n en gin e a n d ch eck for lea ks.
RADI AT OR FAN - 4 .0 L
DESCRIPTION
Th e r a dia t or coolin g fa n u sed on t h e 4.0L en gin e is
a n h ybr id fa n design . Th e h ybr id fa n syst em con sist
of a low speed viscou s dr iven m ech a n ica l fa n a n d a
elect r ica l fa n (F ig. 10).

Fig. 9 HYDRAULIC LINES/HOSES AND ELECTRICAL

CONNECTOR
Fig. 10 Radiator Cooling Fan
1 - LOW PRESSURE RETURN HOSE
2 - HIGH PRESSURE LINE (OUTLET) 1 - RADIATOR
3 - HIGH PRESSURE LINE (INLET) 2 - ELECTRIC COOLING FAN CONNECTOR
4 - HYDRAULIC FAN DRIVE 3 - FAN SHROUD
4 - ELECTRIC COOLING FAN

(9) Lower veh icle.

(10) In st a ll r a dia t or u pper h ose.
(11) Con n ect elect r ica l con n ect or for h ydr a u lic fa n
con t r ol solen oid.
(12) Tigh t en fa n sh r ou d u pper m ou n t in g bolt s t o 6
N·m (50 in . lbs.).
(13) Refill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
CAUTION: Do not run engine with power steering
fluid below the full mark in the reservoir. Sever
damage to the hydraulic cooling fan or the engine
can occur.
REMOVAL
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(2) Th e t h er m a l viscou s fa n dr ive/fa n bla de a ssem -
bly is a t t a ch ed (t h r ea ded) t o wa t er pu m p h u b sh a ft .
Rem ove fa n bla de/viscou s fa n dr ive a ssem bly fr om
wa t er pu m p by t u r n in g m ou n t in g n u t cou n t er clock-
wise a s viewed fr om fr on t (F ig. 11). Th r ea ds on vis-
cou s fa n dr ive a r e RIGHT HAN D .
(3) Do n ot a t t em pt t o r em ove fa n /viscou s fa n dr ive
a ssem bly fr om veh icle a t t h is t im e.
(4) Do n ot u n bolt fa n bla de a ssem bly fr om viscou s
fa n dr ive a t t h is t im e.
(5) Rem ove fa n sh r ou d-t o-u pper cr ossm em ber n u t s.
(6) Rem ove fa n sh r ou d a n d fa n bla de/viscou s fa n
dr ive a ssem bly a s a com plet e u n it fr om veh icle.
7 - 32 ENGINE
RADI AT OR FAN - 4 .0 L (Cont inue d)
Fig. 11 Fan and Viscous Fan Drive
1 - FAN AND FAN DRIVE
2 - WATER PUMP PULLEY
(7) Aft er r em ovin g fa n bla de/viscou s fa n dr ive
a ssem bly, d o n o t pla ce viscou s fa n dr ive in h or izon -
t a l posit ion . If st or ed h or izon t a lly, silicon e flu id in
t h e viscou s fa n dr ive cou ld dr a in in t o it s bea r in g
a ssem bly a n d con t a m in a t e lu br ica n t .
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under belt tension.
(8) Rem ove fou r bolt s secu r in g fa n bla de a ssem bly
t o viscou s fa n dr ive .
CLEANING
Clea n t h e fa n bla des u sin g a m ild soa p a n d wa t er.
Do n ot u se a n a br a sive t o clea n t h e bla des.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Rem ove fa n bla de a ssem bly fr om viscou s fa n
dr ive u n it (fou r bolt s).
WJ
(2) La y fa n on a fla t su r fa ce wit h lea din g edge fa c-
in g down . Wit h t ip of bla de t ou ch in g fla t su r fa ce,
r epla ce fa n if clea r a n ce bet ween opposit e bla de a n d
su r fa ce is gr ea t er t h a n 2.0 m m (.090 in ch ). Rockin g
m ot ion of opposit e bla des sh ou ld n ot exceed 2.0 m m
(.090 in ch ). Test a ll bla des in t h is m a n n er.
(3) In spect fa n a ssem bly for cr a cks, ben ds, loose
r ivet s or br oken welds. Repla ce fa n if a n y da m a ge is
fou n d.
INSTALLATION
(1) Assem ble fa n bla de t o viscou s fa n dr ive.
Tigh t en m ou n t in g bolt s t o 27 N·m (20 ft . lbs.) t or qu e.
(2) Th r ea d t h e fa n a n d fa n dr ive on t o t h e wa t er
pu m p pu lley.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
for correct belt routing.
EN GI N E BLOCK H EAT ER
DESCRI PT I ON
DESCRIPTION—4.7L ENGINE
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An opt ion a l en gin e block h ea t er (F ig. 12) is a va il-
a ble wit h a ll m odels. Th e h ea t er is equ ipped wit h a
power cor d. Th e cor d is a t t a ch ed t o a n en gin e com -
pa r t m en t com pon en t wit h t ie-st r a ps. Th e h ea t er
wa r m s t h e en gin e pr ovidin g ea sier en gin e st a r t in g
a n d fa st er wa r m -u p in low t em per a t u r es. Th e h ea t er
is m ou n t ed in a cor e h ole of t h e en gin e cylin der block
in pla ce of a fr eeze plu g wit h t h e h ea t in g elem en t
im m er sed in en gin e coola n t .
DESCRIPTION—4.0L ENGINE
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
WJ ENGINE 7 - 33
EN GI N E BLOCK H EAT ER (Cont inue d)

Fig. 12 Engine Block Heater—4.7L Fig. 13 Block Heater

1 - ENGINE BLOCK HEATER 1 - ENGINE BLOCK HEATER

An opt ion a l en gin e block h ea t er (F ig. 13) is a va il-

a ble wit h a ll m odels. Th e h ea t er is equ ipped wit h a
power cor d. Th e cor d is a t t a ch ed t o a n en gin e com -
pa r t m en t com pon en t wit h t ie-st r a ps. Th e h ea t er
wa r m s t h e en gin e pr ovidin g ea sier en gin e st a r t in g
a n d fa st er wa r m -u p in low t em per a t u r es. Th e h ea t er
is m ou n t ed in a cor e h ole of t h e en gin e cylin der block
in pla ce of a fr eeze plu g wit h t h e h ea t in g elem en t
im m er sed in en gin e coola n t .

OPERATION
Con n ect in g t h e power cor d t o a gr ou n ded 110-120
volt AC elect r ica l ou t let wit h a gr ou n ded, t h r ee wir e
ext en sion cor d a ct iva t es t h e h ea t in g elem en t wa r m -
in g t h e en gin e coola n t .

DIAGNOSIS AND TESTING—ENGINE BLOCK

HEATER
If t h e u n it does n ot oper a t e (F ig. 14) (F ig. 15), pos-
sible ca u ses ca n be eit h er t h e power cor d or t h e
h ea t er elem en t . Test t h e power cor d for con t in u it y
wit h a 110-volt volt m et er or 110-volt t est ligh t . Test Fig. 14 Engine Block Heater 4.0L Engine
h ea t er elem en t con t in u it y wit h a n oh m m et er or a
1 - ENGINE BLOCK HEATER
12-volt t est ligh t .

CAUTION: To prevent damage, the power cord must REM OVAL

be secured in it’s retainer clips and away from any
components that may cause abrasion or damage,
such as linkages, exhaust components, etc.
REMOVAL—4.7L ENGINE
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(2) Dr a in coola n t fr om r a dia t or (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
7 - 34 ENGINE
EN GI N E BLOCK H EAT ER (Cont inue d)
Fig. 15 Engine Block Heater 4.7L Engine
1 - ENGINE BLOCK HEATER
(3) Ra ise veh icle.
(4) Rem ove en gin e cylin der block dr a in plu g(s)
loca t ed on t h e sides of cylin der block a bove t h e oil
pa n r a il (F ig. 16).
Fig. 16 Drain Plug - 4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
(5) Rem ove power cor d fr om block h ea t er.
WJ
(6) Loosen scr ew a t cen t er of block h ea t er. Rem ove
h ea t er a ssem bly (F ig. 17).
Fig. 17 Engine Block Heater - 4.7L
1 - ENGINE BLOCK HEATER
REMOVAL—4.0L ENGINE
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(2) Dr a in coola n t fr om r a dia t or (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
(3) Ra ise veh icle.
(4) Rem ove en gin e cylin der block dr a in plu g(s)
loca t ed on t h e sides of cylin der block a bove t h e oil
pa n r a il (F ig. 18).
(5) Rem ove power cor d fr om block h ea t er.
(6) Loosen scr ew a t cen t er of block h ea t er. Rem ove
h ea t er a ssem bly (F ig. 19).
I N STALLAT I ON
INSTALLATION—4.7L ENGINE
(1) Th or ou gh ly clea n cylin der block cor e h ole a n d
block h ea t er sea t .
(2) In ser t block h ea t er a ssem bly wit h elem en t loop
poin t in g a t t welve o’clock (F ig. 17).
(3) Wit h block h ea t er fu lly sea t ed, t igh t en cen t er
scr ew t o 2 N·m (17 in . lbs.) t or qu e.
(4) Refill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(5) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.
INSTALLATION—4.0L ENGINE
(1) Th or ou gh ly clea n cylin der block cor e h ole a n d
block h ea t er sea t .
WJ ENGINE 7 - 35
EN GI N E BLOCK H EAT ER (Cont inue d)

EN GI N E COOLAN T T EM P
SEN SOR
DESCRIPTION
Th e E n gin e Coola n t Tem per a t u r e (E CT) sen sor is
u sed t o sen se en gin e coola n t t em per a t u r e. Th e sen sor
pr ot r u des in t o a n en gin e wa t er ja cket .
Th e E CT sen sor is a t wo-wir e Nega t ive Th er m a l
Coefficien t (NTC) sen sor. Mea n in g, a s en gin e coola n t
t em per a t u r e in cr ea ses, r esist a n ce (volt a ge) in t h e
sen sor decr ea ses. As t em per a t u r e decr ea ses, r esis-
t a n ce (volt a ge) in t h e sen sor in cr ea ses.

OPERATION
At key-on , t h e P ower t r a in Con t r ol Modu le (P CM)
sen ds ou t a r egu la t ed 5 volt sign a l t o t h e E CT sen sor.
Th e P CM t h en m on it or s t h e sign a l a s it pa sses
t h r ou gh t h e E CT sen sor t o t h e sen sor gr ou n d (sen sor
r et u r n ).
Fig. 18 Drain Plug Wh en t h e en gin e is cold, t h e P CM will oper a t e in
1 - COOLANT TEMPERATURE SENSOR Open Loop cycle. It will dem a n d sligh t ly r ich er a ir-
2 - BLOCK DRAIN PLUG fu el m ixt u r es a n d h igh er idle speeds. Th is is don e
u n t il n or m a l oper a t in g t em per a t u r es a r e r ea ch ed.
Th e P CM u ses in pu t s fr om t h e E CT sen sor for t h e
followin g ca lcu la t ion s:
• for en gin e coola n t t em per a t u r e ga u ge oper a t ion
t h r ou gh CCD or P CI (J 1850) com m u n ica t ion s
• In ject or pu lse-widt h
• Spa r k-a dva n ce cu r ves
• ASD r ela y sh u t -down t im es
• Idle Air Con t r ol (IAC) m ot or key-on st eps
• P u lse-widt h pr im e-sh ot du r in g cr a n kin g
• O2 sen sor closed loop t im es
• P u r ge solen oid on /off t im es
• E GR solen oid on /off t im es (if equ ipped)
• Lea k Det ect ion P u m p oper a t ion (if equ ipped)
• Ra dia t or fa n r ela y on /off t im es (if equ ipped)
• Ta r get idle speed

REM OVAL
REMOVAL—4.0L ENGINE
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
Fig. 19 Engine Block Heater
MUST BE PARTIALLY DRAINED BEFORE REMOV-
1 - ENGINE BLOCK HEATER
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR. REFER TO GROUP 7, COOLING.
(2) In ser t block h ea t er a ssem bly wit h elem en t loop
poin t in g a t t welve o’clock (F ig. 19). (1) P a r t ia lly dr a in coolin g syst em . (Refer t o 7 -
(3) Wit h block h ea t er fu lly sea t ed, t igh t en cen t er COOLING - STANDARD P ROCE DURE ).
scr ew t o 2 N·m (17 in . lbs.) t or qu e.
(4) Refill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(5) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.
7 - 36 ENGINE
EN GI N E COOLAN T T EM P SEN SOR (Cont inue d)
(2) Discon n ect elect r ica l con n ect or fr om E CT sen -
sor (F ig. 20).
(3) Rem ove sen sor fr om t h er m ost a t h ou sin g.
Fig. 20 Engine Coolant Temperature Sensor
1 - THERMOSTAT HOUSING
2 - ENGINE COOLANT TEMPERATURE SENSOR
3 - ELECTRICAL CONNECTOR
REMOVAL—4.7L ENGINE
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR. REFER TO GROUP 7, COOLING.
Th e E CT sen sor is loca t ed n ea r t h e fr on t of t h e
in t a ke m a n ifold (F ig. 21).
(1) P a r t ia lly dr a in coolin g syst em . (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
(2) Discon n ect elect r ica l con n ect or fr om E CT sen -
sor.
(3) Rem ove sen sor fr om in t a ke m a n ifold.
I N STALLAT I ON
INSTALLATION—4.0L ENGINE
(1) In st a ll sen sor.
(2) Tigh t en t o 11 N·m (8 ft . lbs.) t or qu e.
(3) Con n ect elect r ica l con n ect or t o sen sor.
(4) Repla ce a n y lost en gin e coola n t . (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
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Fig. 21 Engine Coolant Temperature Sensor
1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
3 - MAP SENSOR
4 - INTAKE MANIFOLD
INSTALLATION—4.7L ENGINE
(1) In st a ll sen sor.
(2) Tigh t en t o 11 N·m (8 ft . lbs.) t or qu e.
(3) Con n ect elect r ica l con n ect or t o sen sor.
(4) Repla ce a n y lost en gin e coola n t . (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
EN GI N E COOLAN T
T H ERM OSTAT
DESCRI PT I ON
DESCRIPTION—4.7L ENGINE
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pellet -t ype t h er m ost a t con t r ols t h e oper a t in g
t em per a t u r e of t h e en gin e by con t r ollin g t h e a m ou n t
of coola n t flow t o t h e r a dia t or. On a ll en gin es t h e
t h er m ost a t is closed below 195°F (90°C). Above t h is
t em per a t u r e, coola n t is a llowed t o flow t o t h e r a dia -
t or. Th is pr ovides qu ick en gin e wa r m u p a n d over a ll
t em per a t u r e con t r ol. On t h e 4.7L en gin e t h e t h er m o-
st a t is design ed t o block t h e flow of t h e coola n t
bypa ss jou r n a l by 50% in st ea d of com plet ely blockin g
t h e flow. Th is design con t r ols coola n t t em per a t u r e
m or e a ccu r a t ely (F ig. 22).
WJ
EN GI N E COOLAN T T H ERM OSTAT (Cont inue d)
Th e sa m e t h er m ost a t is u sed for win t er a n d su m -
m er sea son s. An en gin e sh ou ld n ot be oper a t ed wit h -
ou t a t h er m ost a t , except for ser vicin g or t est in g.
Oper a t in g wit h ou t a t h er m ost a t ca u ses ot h er pr ob-
lem s. Th ese a r e: lon ger en gin e wa r m u p t im e, u n r eli-
a ble wa r m u p per for m a n ce, in cr ea sed exh a u st
em ission s a n d cr a n kca se con den sa t ion . Th is con den -
sa t ion ca n r esu lt in slu dge for m a t ion .
ENGINE 7 - 37
ou t a t h er m ost a t , except for ser vicin g or t est in g.
Oper a t in g wit h ou t a t h er m ost a t ca u ses ot h er pr ob-
lem s. Th ese a r e: lon ger en gin e wa r m u p t im e, u n r eli-
a ble wa r m u p per for m a n ce, in cr ea sed exh a u st
em ission s a n d cr a n kca se con den sa t ion . Th is con den -
sa t ion ca n r esu lt in slu dge for m a t ion .

Fig. 23 Thermostat and Housing

1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT

Fig. 22 Thermostat OPERATION

1 - FROM HEATER Th e wa x pellet is loca t ed in a sea led con t a in er a t
2 - FROM RADIATOR t h e spr in g en d of t h e t h er m ost a t . Wh en h ea t ed, t h e
3 - TO WATER PUMP pellet expa n ds, over com in g closin g spr in g t en sion
4 - ENGINE BYPASS a n d wa t er pu m p pr essu r e t o for ce t h e va lve t o open .
5 - THERMOSTAT

DIAGNOSIS AND TESTING—THERMOSTAT

DESCRIPTION—4.0L ENGINE
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pellet -t ype t h er m ost a t con t r ols t h e oper a t in g
t em per a t u r e of t h e en gin e by con t r ollin g t h e a m ou n t
of coola n t flow t o t h e r a dia t or. On a ll en gin es t h e
t h er m ost a t is closed below 195°F (90°C). Above t h is
t em per a t u r e, coola n t is a llowed t o flow t o t h e r a dia -
t or. Th is pr ovides qu ick en gin e wa r m u p a n d over a ll
t em per a t u r e con t r ol. (F ig. 23).
Th e sa m e t h er m ost a t is u sed for win t er a n d su m -
m er sea son s. An en gin e sh ou ld n ot be oper a t ed wit h -
ON-BOARD DIAGNOSTICS
All m odels a r e equ ipped wit h On -Boa r d Dia gn os-
t ics for cer t a in coolin g syst em com pon en t s.If t h e pow-
er t r a in con t r ol m odu le (P CM) det ect s low en gin e
coola n t t em per a t u r e, it will r ecor d a Dia gn ost ic Tr ou -
ble Code (DTC). F or ot h er DTC n u m ber s, (Refer t o 25
- E MISSIONS CONTROL - DE SCRIP TION).
Th e DTC ca n a lso be a ccessed t h r ou gh t h e DRB
sca n t ool.
7 - 38 ENGINE WJ
EN GI N E COOLAN T T H ERM OSTAT (Cont inue d)

REM OVAL
REMOVAL—4.0L ENGINE
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

Do n ot wa st e r eu sa ble coola n t . If t h e solu t ion is

clea n , dr a in t h e coola n t in t o a clea n con t a in er for
r eu se.
(1) Dr a in t h e coola n t fr om t h e r a dia t or u n t il t h e
level is below t h e t h er m ost a t h ou sin g (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS. Fig. 24 Thermostat
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
1 - LONG BOLT
ING CONSTANT TENSION CLAMPS. 2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
CAUTION: A number or letter is stamped into the
5 - SHORT BOLT
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter. (5) Rem ove lower r a dia t or h ose cla m p a n d lower
r a dia t or h ose a t t h er m ost a t h ou sin g.
(2) Rem ove r a dia t or u pper h ose a n d h ea t er h ose a t (6) Rem ove t h er m ost a t h ou sin g m ou n t in g bolt s,
t h er m ost a t h ou sin g. t h er m ost a t h ou sin g a n d t h er m ost a t (F ig. 25).
(3) Discon n ect wir in g con n ect or a t en gin e coola n t
t em per a t u r e sen sor.
(4) Rem ove t h er m ost a t h ou sin g m ou n t in g bolt s, I N STALLAT I ON
t h er m ost a t h ou sin g, ga sket a n d t h er m ost a t (F ig. 24).
Disca r d old ga sket . INSTALLATION—4.0L ENGINE
(5) Clea n t h e ga sket m a t in g su r fa ces. (1) In st a ll t h e r epla cem en t t h er m ost a t so t h a t t h e
pellet , wh ich is en cir cled by a coil spr in g, fa ces t h e
REMOVAL—4.7L ENGINE en gin e. All t h er m ost a t s a r e m a r ked on t h e ou t er
fla n ge t o in dica t e t h e pr oper in st a lled posit ion .
WARNING: DO NOT LOOSEN RADIATOR DRAIN- (a ) Obser ve t h e r ecess gr oove in t h e en gin e cyl-
COCK WITH SYSTEM HOT AND PRESSURIZED. in der h ea d (F ig. 26).
SERIOUS BURNS FROM COOLANT CAN OCCUR. (b) P osit ion t h er m ost a t in gr oove wit h a r r ow a n d
a ir bleed h ole on ou t er fla n ge poin t in g u p.
Do n ot wa st e r eu sa ble coola n t . If solu t ion is clea n , (2) In st a ll r epla cem en t ga sket a n d t h er m ost a t
dr a in coola n t in t o a clea n con t a in er for r eu se. h ou sin g.
If t h er m ost a t is bein g r epla ced, be su r e t h a t
r epla cem en t is specified t h er m ost a t for veh icle m odel CAUTION: Tightening the thermostat housing
a n d en gin e t ype. unevenly or with the thermostat out of its recess,
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y. may result in a cracked housing.
(2) Dr a in coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ). (3) Tigh t en t h e h ou sin g bolt s t o 22 N·m (16 ft . lbs.)
(3) Ra ise veh icle on h oist . t or qu e.
(4) Rem ove spla sh sh ield. (4) In st a ll h oses t o t h er m ost a t h ou sin g.
WJ ENGINE 7 - 39
EN GI N E COOLAN T T H ERM OSTAT (Cont inue d)

Fig. 25 Thermostat and Thermostat Housing

1 - THERMOSTAT HOUSING 3 - THERMOSTAT AND GASKET
2 - THERMOSTAT LOCATION 4 - TIMING CHAIN COVER

wit h t h e r equ ir ed coola n t m ixt u r e (Refer t o 7 -

COOLING - STANDARD P ROCE DURE ).
(7) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.

INSTALLATION—4.7L ENGINE
(1) Clea n m a t in g a r ea s of t im in g ch a in cover a n d
t h er m ost a t h ou sin g.
(2) In st a ll t h er m ost a t (spr in g side down ) in t o
r ecessed m a ch in ed gr oove on t im in g ch a in cover (F ig.
25).
(3) P osit ion t h er m ost a t h ou sin g on t im in g ch a in
cover.
(4) In st a ll t wo h ou sin g-t o-t im in g ch a in cover bolt s.
Tigh t en bolt s t o 13 N·m (115 in . lbs.) t or qu e.

CAUTION: Housing must be tightened evenly and

thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.

(5) In st a ll lower r a dia t or h ose on t h er m ost a t h ou s-

Fig. 26 Thermostat Recess in g.
1 - GROOVE (6) In st a ll spla sh sh ield.
(7) Lower veh icle.
(5) In st a ll elect r ica l con n ect or t o coola n t t em per a - (8) F ill coolin g syst em (Refer t o 7 - COOLING -
t u r e sen sor. STANDARD P ROCE DURE ).
(6) Be su r e t h a t t h e r a dia t or dr a in cock is t igh t ly (9) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
closed. F ill t h e coolin g syst em t o t h e cor r ect level (10) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.
7 - 40 ENGINE
FAN DRI V E V I SCOU S CLU T CH
- 4 .0 L
DESCRIPTION
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
Th e t h er m a l viscou s fa n dr ive (F ig. 27) is a sili-
con e-flu id-filled cou plin g u sed t o con n ect t h e fa n
bla des t o t h e wa t er pu m p sh a ft . Th e cou plin g a llows
t h e fa n t o be dr iven in a n or m a l m a n n er. Th is is
don e a t low en gin e speeds wh ile lim it in g t h e t op
speed of t h e fa n t o a pr edet er m in ed m a xim u m level
a t h igh er en gin e speeds.
An elect r ica l coolin g fa n loca t ed in t h e fa n sh r ou d
a ids in low speed coolin g, It is design ed t o a u gm en t
t h e viscou s fa n , H owever, it does n ot r epla ce t h e vis-
cou s fa n .
Fig. 27 Viscous Fan Drive
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
WJ
OPERATION
A t h er m ost a t ic bim et a llic spr in g coil is loca t ed on
t h e fr on t fa ce of t h e viscou s fa n dr ive u n it (F ig. 27).
Th is spr in g coil r ea ct s t o t h e t em per a t u r e of t h e r a di-
a t or disch a r ge a ir. It en ga ges t h e viscou s fa n dr ive
for h igh er fa n speed if t h e a ir t em per a t u r e fr om t h e
r a dia t or r ises a bove a cer t a in poin t . Un t il a ddit ion a l
en gin e coolin g is n ecessa r y, th e fa n w ill re m a in a t
a re d u c e d rp m re g a rd le s s o f e n g in e s p e e d . N o r-
m a lly le s s th a n th re e h u n d re d (300) rp m .
On ly wh en su fficien t h ea t is pr esen t , will t h e vis-
cou s fa n dr ive en ga ge. Th is is wh en t h e a ir flowin g
t h r ou gh t h e r a dia t or cor e ca u ses a r ea ct ion t o t h e
bim et a llic coil. It t h en in cr ea ses fa n speed t o pr ovide
t h e n ecessa r y a ddit ion a l en gin e coolin g.
On ce t h e en gin e h a s cooled, t h e r a dia t or disch a r ge
t em per a t u r e will dr op. Th e bim et a llic coil a ga in
r ea ct s a n d t h e fa n speed is r edu ced t o t h e pr eviou s
disen ga ged speed.
DIAGNOSIS AND TESTING—VISCOUS FAN
DRIVE
If t h e fa n a ssem bly fr ee-wh eels wit h ou t dr a g (t h e
fa n bla des will r evolve m or e t h a n five t u r n s wh en
spu n by h a n d), r epla ce t h e fa n dr ive. Th is spin t est
m u st be per for m ed wh en t h e en gin e is cool.
F or t h e followin g t est , t h e coolin g syst em m u st be
in good con dit ion . It a lso will en su r e a ga in st exces-
sively h igh coola n t t em per a t u r e.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dr ill a 3.18-m m (1/8-in ) dia m et er h ole in t h e
t op cen t er of t h e fa n sh r ou d.
(2) Obt a in a dia l t h er m om et er wit h a n 8 in ch st em
(or equ iva len t ). It sh ou ld h a ve a r a n ge of -18° t o
105°C (0° t o 220° F ). In ser t t h er m om et er t h r ou gh t h e
h ole in t h e sh r ou d. Be su r e t h a t t h er e is a dequ a t e
clea r a n ce fr om t h e fa n bla des.
(3) Con n ect a t a ch om et er a n d a n en gin e ign it ion
t im in g ligh t (t im in g ligh t is t o be u sed a s a st r obe
ligh t ).
(4) Block t h e a ir flow t h r ou gh t h e r a dia t or. Secu r e
a sh eet of pla st ic in fr on t of t h e r a dia t or (or a ir con -
dit ion er con den ser ). Use t a pe a t t h e t op t o secu r e t h e
pla st ic a n d be su r e t h a t t h e a ir flow is blocked.
(5) Be su r e t h a t t h e a ir con dit ion er (if equ ipped) is
t u r n ed off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
WJ ENGINE 7 - 41
FAN DRI V E V I SCOU S CLU T CH - 4 .0 L (Cont inue d)
(6) St a r t t h e en gin e a n d oper a t e a t 2400 r pm .
Wit h in t en m in u t es t h e a ir t em per a t u r e (in dica t ed on
t h e dia l t h er m om et er ) sh ou ld be u p t o 93° C (200° F ).
F a n dr ive e n g a g e m e n t sh ou ld h a ve st a r t ed t o occu r
a t bet ween 91° t o 96° C (195° t o 205° F ). E n ga ge-
m en t is dist in gu ish a ble by a defin it e in c re a s e in fa n
flow n oise (r oa r in g). Th e t im in g ligh t a lso will in di-
ca t e a n in cr ea se in t h e speed of t h e fa n .
(7) Wh en t h e a ir t em per a t u r e r ea ch es 93° C (200°
F ), r em ove t h e pla st ic sh eet . F a n dr ive d is e n g a g e -
m e n t sh ou ld h a ve st a r t ed t o occu r a t bet ween 62° t o
85° C (145° t o 185° F ). A defin it e d e c re a s e of fa n
flow n oise (r oa r in g) sh ou ld be n ot iced. If n ot , r epla ce
t h e defect ive viscou s fa n dr ive u n it .

PWM FAN CON T ROL M ODU LE -

4 .0 L
DESCRIPTION
Th e pu lse widt h m odu la t ed (P WM) r a dia t or coolin g
fa n r ela y is loca t ed beh in d t h e fr on t bu m per fa scia
below t h e r igh t h ea dla m p. Fig. 28 Radiator Cooling Fan Relay Location
1 - RADIATOR FAN RELAY
OPERATION 2 - VACUUM RESERVOIR
3 - BOLT
Th e P WM r ela y is u sed t o con t r ol t h e speed of t h e
4 - RIGHT FRONT FENDER
elect r ic r a dia t or coolin g fa n . It a llows for m u lt iple fa n
speeds. Th is a llows for im pr oved fa n n oise a n d A/C
per for m a n ce, bet t er en gin e coolin g, a n d a ddit ion a l
veh icle power.
P WM r ela y oper a t ion is con t r olled by t h e P ower-
t r a in Con t r ol Modu le (P CM). To oper a t e t h e P WM
r ela y, t h e P CM looks a t in pu t s fr om :
• E n gin e coola n t t em per a t u r e
• Am bien t t em per a t u r e fr om t h e body con t r oller
• Veh icle speed
• Tr a n sm ission oil t em per a t u r e
• A/C swit ch posit ion (A/C r equ est )

REMOVAL
Th e P u lse Widt h Modu la t ed (P WM) coolin g fa n
r ela y is loca t ed below t h e r igh t h ea dla m p beh in d t h e
bu m per fa scia (F ig. 28).
(1) Rem ove fr on t bu m per a n d gr ill a ssem bly.
(2) Rem ove 1 su ppor t bolt n ea r fr on t of r eser voir
(F ig. 28).
(3) Rem ove 2 r eser voir m ou n t in g bolt s.
(4) Rem ove r eser voir fr om veh icle t o ga in a ccess t o
va cu u m h ose (F ig. 29). Discon n ect va cu u m h ose fr om
r eser voir fit t in g a t r ea r of r eser voir.
(5) Discon n ect elect r ica l con n ect or a t r ela y (F ig. Fig. 29 Vacuum Reservoir Removal/Installation
30). 1 - VACUUM HOSE
(6) Rem ove 2 r ela y m ou n t in g bolt s (F ig. 30) a n d 2 - RADIATOR
r em ove r ela y. 3 - VACUUM RESERVOIR
7 - 42 ENGINE
PWM FAN CON T ROL M ODU LE - 4 .0 L (Cont inue d)
Fig. 30 Radiator Cooling Fan Relay Removal/
Installation
1 - ELECTRICAL CONNECTOR
2 - RADIATOR FAN RELAY
3 - MOUNTING BOLTS (2)
INSTALLATION
(1) P osit ion r ela y t o body a n d in st a ll 2 bolt s.
Tigh t en bolt s t o 3 N·m (25 in . lbs.) t or qu e.
(2) Con n ect elect r ica l con n ect or t o r ela y.
(3) Con n ect va cu u m h ose t o r eser voir.
(4) In st a ll r eser voir a n d t igh t en 2 bolt s t o 3 N·m
(25 in . lbs.) t or qu e.
(5) In st a ll fr on t bu m per a n d gr ill a ssem bly.
RADI AT OR - 4 .7 L
DESCRIPTION
All veh icles a r e equ ipped wit h a cr oss flow t ype
r a dia t or wit h pla st ic side t a n ks (F ig. 31).
P la st ic t a n ks, wh ile st r on ger t h a n br a ss, a r e su b-
ject t o da m a ge by im pa ct , su ch a s fr om t ools or
wr en ch es. H a n dle r a dia t or wit h ca r e.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
WJ
Fig. 31 Cross Flow Radiator - Typical
1 - RADIATOR
Do n ot wa st e r eu sa ble coola n t . If t h e solu t ion is
clea n , dr a in t h e coola n t in t o a clea n con t a in er for
r eu se.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 32). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 33). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 34). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Discon n ect t h e n ega t ive ba t t er y ca ble a t ba t -
t er y.
(2) Dr a in coola n t fr om r a dia t or (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
(3) Rem ove t h e fr on t gr ill (Refer t o 23 - BODY/E X-
TE RIOR/GRILLE - RE MOVAL).
WJ ENGINE 7 - 43
RADI AT OR - 4 .7 L (Cont inue d)

Fig. 32 Hose Clamp Tool - Typical

1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 34 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL

(11) Th e lower pa r t of r a dia t or is equ ipped wit h

t wo a lign m en t dowel pin s (F ig. 35). Th ey a r e loca t ed
on t h e bot t om of r a dia t or t a n k a n d fit in t o r u bber
gr om m et s. Th ese r u bber gr om m et s a r e pr essed in t o
t h e r a dia t or lower cr ossm em ber.

WARNING: THE AIR CONDITIONING SYSTEM (IF

EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN, HEATING AND AIR CONDI-
TIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.

NOTE: The radiator and radiator cooling fan can be

Fig. 33 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
(4) Rem ove t wo r a dia t or m ou n t in g bolt s.
(5) Discon n ect bot h t r a n sm ission cooler lin es fr om
r a dia t or.
(6) Discon n ect elect r ica l con n ect or for t h e fa n con -
t r ol solen oid.
(7) Discon n ect t h e power st eer in g cooler lin e fr om
cooler a n d filt er.
(8) Discon n ect t h e r a dia t or u pper a n d lower h oses.
(9) Discon n ect t h e over flow h ose fr om r a dia t or.
(10) Rem ove t h e a ir in let du ct a t t h e gr ill.
removed as an assembly. It is not necessary to
remove the cooling fan before removing or install-
ing the radiator.
(12) Discon n ect t h e t wo h igh pr essu r e flu id lin es
a t t h e h ydr a u lic fa n dr ive.
(13) Discon n ect t h e low pr essu r e r et u r n h ose a t
t h e h ydr a u lic fa n dr ive.
(14) Gen t ly lift u p a n d r em ove r a dia t or fr om veh i-
cle. Be ca r efu l n ot t o scr a pe t h e r a dia t or fin s a ga in st
a n y ot h er com pon en t . Also be ca r efu l n ot t o dist u r b
t h e a ir con dit ion in g con den ser (if equ ipped).
CLEANING
Clea n r a dia t or fin s Wit h t h e en gin e cold, a pply cold
wa t er a n d com pr essed a ir t o t h e ba ck (en gin e side) of
7 - 44 ENGINE
RADI AT OR - 4 .7 L (Cont inue d)
Fig. 35 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
t h e r a dia t or t o flu sh t h e r a dia t or a n d/or A/C con -
den ser of debr is.
INSPECTION
Th e r a dia t or coolin g fin s sh ou ld be ch ecked for
da m a ge or det er ior a t ion . In spect coolin g fin s t o m a ke
su r e t h ey a r e n ot ben t or cr u sh ed, t h ese a r ea s r esu lt
in r edu ced h ea t exch a n ge ca u sin g t h e coolin g syst em
t o oper a t e a t h igh er t em per a t u r es. In spect t h e pla st ic
en d t a n ks for cr a cks, da m a ge or lea ks.
In spect t h e r a dia t or n eck for da m a ge or dist or t ion .
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals (Fig. 39) are
properly fastened to their original positions. These
are used at the top, bottom and sides of the radia-
tor and A/C condenser. To prevent overheating,
these seals must be installed to their original posi-
tions.
(1) E qu ipped wit h a ir con dit ion in g: Gen t ly lower
t h e r a dia t or a n d fa n sh r ou d in t o t h e veh icle. Gu ide
t h e t wo r a dia t or a lign m en t dowels t h r ou gh t h e h oles
in t h e r u bber a ir sea ls fir st a n d t h en t h r ou gh t h e A/C
su ppor t br a cket s (F ig. 40). Con t in u e t o gu ide t h e
WJ
a lign m en t dowels in t o t h e r u bber gr om m et s loca t ed
in lower r a dia t or cr ossm em ber. Th e h oles in t h e
L-sh a ped br a cket s (loca t ed on bot t om of A/C con -
den ser ) m u st be posit ion ed bet ween bot t om of r u bber
a ir sea ls a n d t op of r u bber gr om m et s.
(2) Con n ect t h e r a dia t or u pper a n d lower h oses
a n d h ose cla m ps t o r a dia t or.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) In st a ll coola n t r eser ve/over flow t a n k h ose a t
r a dia t or.
(4) Con n ect bot h t r a n sm ission cooler lin es a t t h e
r a dia t or.
(5) In st a ll bot h r a dia t or m ou n t in g bolt s.
(6) In st a ll a ir in let du ct a t gr ill.
(7) At t a ch elect r ic con n ect or for h ydr a u lic fa n con -
t r ol solen oid.
(8) In st a ll t h e gr ill (Refer t o 23 - BODY/E XTE RI-
OR/GRILLE - INSTALLATION).
(9) Con n ect t h e t wo h igh pr essu r e lin es t o t h e
h ydr a u lic fa n dr ive. Tigh t en 1 ⁄2 in . pr essu r e lin e fit -
t in g t o 49 N·m (36 ft . lbs.). a n d t h e 3/8 in . pr essu r e
lin e fit t in g t o 29 N·m (21.5 ft . lbs.).
(10) Con n ect t h e low pr essu r e h ose t o t h e h ydr a u -
lic fa n dr ive. P osit ion t h e spr in g cla m p.
(11) Con n ect t h e power st eer in g filt er h oses t o t h e
filt er. In st a ll n ew h ose cla m ps.
(12) Rot a t e t h e fa n bla des (by h a n d) a n d ch eck for
in t er fer en ce a t fa n sh r ou d.
(13) Refill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(14) Refill t h e power st eer in g r eser voir a n d bleed
a ir fr om syst em (Refer t o 19 - STE E RING/P UMP -
STANDARD P ROCE DURE ).
(15) Con n ect ba t t er y ca ble a t ba t t er y.
(16) St a r t a n d wa r m en gin e. Ch eck for lea ks.
RADI AT OR - 4 .0 L
DESCRIPTION
All veh icles a r e equ ipped wit h a cr oss flow t ype
r a dia t or wit h pla st ic side t a n ks (F ig. 36).
P la st ic t a n ks, wh ile st r on ger t h a n br a ss, a r e su b-
ject t o da m a ge by im pa ct , su ch a s fr om t ools or
wr en ch es. H a n dle r a dia t or wit h ca r e.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
WJ ENGINE 7 - 45
RADI AT OR - 4 .0 L (Cont inue d)

Fig. 37 Hose Clamp Tool - Typical

1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP

Fig. 36 Cross Flow Radiator - Typical

1 - RADIATOR

Do n ot wa st e r eu sa ble coola n t . If t h e solu t ion is

clea n , dr a in t h e coola n t in t o a clea n con t a in er for
r eu se.

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 37). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the

tongue of constant tension clamps (Fig. 38). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 39). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Discon n ect t h e n ega t ive ba t t er y ca ble a t ba t -
t er y.
(2) Dr a in coola n t fr om r a dia t or (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
(3) Do n ot a t t em pt t o r em ove fa n /viscou s fa n dr ive
a ssem bly fr om veh icle a t t h is t im e.
Fig. 38 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
(4) Rem ove t h e fr on t gr ill (Refer t o 23 - BODY/E X-
TE RIOR/GRILLE - RE MOVAL).
(5) Rem ove t wo r a dia t or m ou n t in g bolt s (F ig. 41).
(6) Discon n ect bot h t r a n sm ission cooler lin es fr om
r a dia t or.
(7) Discon n ect elect r ic fa n con n ect or, t h en discon -
n ect con n ect or h a r n ess fr om sh r ou d (F ig. 41).
(8) Discon n ect t h e r a dia t or u pper a n d lower h oses
(F ig. 41).
7 - 46 ENGINE WJ
RADI AT OR - 4 .0 L (Cont inue d)

Fig. 39 Air Seals - Typical

1 - AIR DAM
2 - RADIATOR
3 - AIR DAM Fig. 40 Radiator Alignment Dowels
4 - A/C CONDENSER
1 - RADIATOR
5 - AIR SEAL
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
(9) Discon n ect t h e over flow h ose fr om r a dia t or 4 - RADIATOR LOWER CROSSMEMBER
(F ig. 41).
(10) Rem ove t h e a ir in let du ct a t t h e gr ill.
(11) Th e lower pa r t of r a dia t or is equ ipped wit h
t wo a lign m en t dowel pin s (F ig. 40). Th ey a r e loca t ed
on t h e bot t om of r a dia t or t a n k a n d fit in t o r u bber
gr om m et s. Th ese r u bber gr om m et s a r e pr essed in t o
t h e r a dia t or lower cr ossm em ber.

WARNING: THE AIR CONDITIONING SYSTEM (IF

EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN GROUP 24, HEATING AND
AIR CONDITIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.

(12) If equ ipped wit h a n a u xilia r y a u t om a t ic t r a n s-

m ission oil cooler, u se ca u t ion wh en r em ovin g r a dia -
t or. Th e oil cooler lin es a r e r ou t ed t h r ou gh a r u bber
a ir sea l on t h e r igh t side of r a dia t or. Do n ot cu t or
t ea r t h is sea l.
(13) Gen t ly lift u p a n d r em ove r a dia t or fr om veh i-
cle. Be ca r efu l n ot t o scr a pe t h e r a dia t or fin s a ga in st
a n y ot h er com pon en t . Also be ca r efu l n ot t o dist u r b Fig. 41 Radiator, Shroud and Electric Fan
t h e a ir con dit ion in g con den ser (if equ ipped). 1 - RADIATOR/SHROUD/FAN ASSEMBLY
2 - OVER FLOW HOSE
CLEANING 3 - ELECTRIC FAN CONNECTOR
Clea n r a dia t or fin s Wit h t h e en gin e cold, a pply cold 4 - RADIATOR MOUNTING BOLT(S)
wa t er a n d com pr essed a ir t o t h e ba ck (en gin e side) of 5 - CLAMP
t h e r a dia t or t o flu sh t h e r a dia t or a n d/or A/C con -
den ser of debr is.
WJ
RADI AT OR - 4 .0 L (Cont inue d)
INSPECTION
Th e r a dia t or coolin g fin s sh ou ld be ch ecked for
da m a ge or det er ior a t ion . In spect coolin g fin s t o m a ke
su r e t h ey a r e n ot ben t or cr u sh ed, t h ese a r ea s r esu lt
in r edu ced h ea t exch a n ge ca u sin g t h e coolin g syst em
t o oper a t e a t h igh er t em per a t u r es. In spect t h e pla st ic
en d t a n ks for cr a cks, da m a ge or lea ks.
In spect t h e r a dia t or n eck for da m a ge or dist or t ion .
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals (Fig. 39) are
properly fastened to their original positions. These
are used at the top, bottom and sides of the radia-
tor and A/C condenser. To prevent overheating,
these seals must be installed to their original posi-
tions.
(1) E qu ipped wit h a ir con dit ion in g: Gen t ly lower
t h e r a dia t or in t o t h e veh icle. Gu ide t h e t wo r a dia t or
a lign m en t dowels t h r ou gh t h e h oles in t h e r u bber a ir
sea ls fir st a n d t h en t h r ou gh t h e A/C su ppor t br a cket s
(F ig. 40). Con t in u e t o gu ide t h e a lign m en t dowels
in t o t h e r u bber gr om m et s loca t ed in lower r a dia t or
cr ossm em ber. Th e h oles in t h e L-sh a ped br a cket s
(loca t ed on bot t om of A/C con den ser ) m u st be posi-
t ion ed bet ween bot t om of r u bber a ir sea ls a n d t op of
r u bber gr om m et s.
(2) Con n ect t h e r a dia t or u pper a n d lower h oses
a n d h ose cla m ps t o r a dia t or (F ig. 41).
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) In st a ll coola n t r eser ve/over flow t a n k h ose a t
r a dia t or (F ig. 41).
(4) Con n ect bot h t r a n sm ission cooler lin es a t t h e
r a dia t or (F ig. 41).
(5) In st a ll bot h r a dia t or m ou n t in g bolt s (F ig. 41).
(6) In st a ll a ir in let du ct a t gr ill.
(7) At t a ch elect r ic fa n h a r n ess t o sh r ou d, t h en con -
n ect h a r n ess t o con n ect or (F ig. 41).
(8) In st a ll t h e gr ill (Refer t o 23 - BODY/E XTE RI-
OR/GRILLE - INSTALLATION).
(9) In st a ll t h e fa n /viscou s fa n dr ive a ssem bly t o
t h e wa t er pu m p.
(10) Rot a t e t h e fa n bla des (by h a n d) a n d ch eck for
in t er fer en ce a t fa n sh r ou d.
(11) Be su r e of a t lea st 25 m m (1.0 in ch ) bet ween
t ips of fa n bla des a n d fa n sh r ou d.
(12) F ill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(13) Con n ect ba t t er y ca ble a t ba t t er y.
(14) St a r t a n d wa r m en gin e. Ch eck for lea ks.
ENGINE 7 - 47
RADI AT OR FAN M OT OR
DIAGNOSIS AND TESTING—ELECTRIC
COOLING FAN
Th e power t r a in con t r ol m odu le (P CM) will en t er a
dia gn ost ic t r ou ble code (DTC) in m em or y if it det ect s
a pr oblem in t h e a u xilia r y coolin g fa n r ela y or cir cu it .
(Refer t o 25 - E MISSIONS CONTROL - DE SCRIP -
TION).
If t h e elect r ic coolin g fa n is in oper a t ive, ch eck t h e
15A fu se in t h e ju n ct ion block a n d t h e 40A fu se in
t h e P ower Dist r ibu t ion Cen t er (P DC) wit h a 12 volt
t est la m p or DVOM. Refer t o t h e in side of t h e P DC
cover for t h e exa ct loca t ion of t h e fu se. If fu ses a r e
oka y, r efer t o E LE CTRICAL for coolin g fa n a n d r ela y
cir cu it sch em a t ic.
WAT ER PU M P - 4 .7 L
DESCRI PT I ON
DESCRIPTION—WATER PUMP
A cen t r ifu ga l wa t er pu m p cir cu la t es coola n t
t h r ou gh t h e wa t er ja cket s, pa ssa ges, in t a ke m a n ifold,
r a dia t or cor e, coolin g syst em h oses a n d h ea t er cor e.
Th e pu m p is dr iven fr om t h e en gin e cr a n ksh a ft by a
sin gle ser pen t in e dr ive belt .
Th e wa t er pu m p im peller is pr essed on t o t h e r ea r
of a sh a ft t h a t r ot a t es in bea r in gs pr essed in t o t h e
h ou sin g. Th e h ou sin g h a s t wo sm a ll h oles t o a llow
seepa ge t o esca pe. Th e wa t er pu m p sea ls a r e lu br i-
ca t ed by t h e a n t ifr eeze in t h e coola n t m ixt u r e. No
a ddit ion a l lu br ica t ion is n ecessa r y.
Bot h h ea t er h oses a r e con n ect ed t o fit t in gs on t h e
t im in g ch a in fr on t cover. Th e wa t er pu m p is a lso
m ou n t ed dir ect ly t o t h e t im in g ch a in cover a n d is
equ ipped wit h a n on ser vicea ble in t egr a l pu lley (F ig.
42).
DESCRIPTION—WATER PUMP BYPASS
Th e 4.7L en gin e u ses a n in t er n a l wa t er /coola n t
bypa ss syst em . Th e design u ses ga ller ies in t h e t im -
in g ch a in cover t o cir cu la t e coola n t du r in g en gin e
wa r m -u p pr even t in g t h e coola n t fr om flowin g
t h r ou gh t h e r a dia t or. Th e t h er m ost a t u ses a st u b
sh a ft loca t ed a t t h e r ea r of t h e t h er m ost a t (F ig. 43)
t o con t r ol flow t h r ou gh t h e bypa ss ga ller y.
OPERAT I ON
OPERATION—WATER PUMP
A cen t r ifu ga l wa t er pu m p cir cu la t es coola n t
t h r ou gh t h e wa t er ja cket s, pa ssa ges, in t a ke m a n ifold,
7 - 48 ENGINE WJ
WAT ER PU M P - 4 .7 L (Cont inue d)

Fig. 42 Water Pump and Timing Chain Cover

1 - INTEGRAL WATER PUMP PULLEY
2 - TIMING CHAIN COVER
3 - THERMOSTAT HOUSING
4 - HEATER HOSE FITTINGS
5 - WATER PUMP

Fig. 43 Water/Coolant Bypass Flow and Thermostat

r a dia t or cor e, coolin g syst em h oses a n d h ea t er cor e,
1 - FROM HEATER
t h is coola n t a bsor bs t h e h ea t gen er a t ed wh en t h e 2 - FROM RADIATOR
en gin e is r u n n in g. Th e pu m p is dr iven by t h e en gin e 3 - TO WATER PUMP
cr a n ksh a ft via a dr ive belt . 4 - ENGINE BYPASS
5 - THERMOSTAT
OPERATION—WATER PUMP BYPASS
Wh en t h e t h er m ost a t is in t h e closed posit ion t h e (1) Dr a in coola n t u n t il t h e fir st r ow of cor es is vis-
bypa ss ga ller y is n ot obst r u ct ed a llowin g 100% flow. ible in t h e r a dia t or (Refer t o 7 - COOLING - STAN-
Wh en t h e t h er m ost a t is in t h e open posit ion t h e st u b DARD P ROCE DURE ) 4.7L E n gin e or (Refer t o 7 -
sh a ft en t er s t h e bypa ss ga ller y obst r u ct in g bypa ss COOLING - STANDARD P ROCE DURE ) 4.0L
coola n t flow by 50%. Th is design a llows t h e coola n t E n gin e.
t o r ea ch oper a t in g t em per a t u r e qu ickly wh en cold, (2) Lea vin g t h e r a dia t or ca p off, st a r t t h e en gin e.
wh ile a ddin g ext r a coolin g du r in g n or m a l t em per a - Ru n en gin e u n t il t h er m ost a t open s.
t u r e oper a t ion . (3) Wh ile lookin g in t o t h e r a dia t or t h r ou gh t h e
r a dia t or fill n eck, r a ise en gin e r pm t o 2000 RP M.
DIAGNOSIS AND TESTING—WATER PUMP Obser ve t h e flow of coola n t fr om t h e fir st r ow of
cor es.
LOOSE IMPELLER - 4.0L and 4.7L (4) If t h er e is n o flow or ver y lit t le flow visa ble,
r epla ce t h e wa t er pu m p.
NOTE: Due to the design of the 4.0L and 4.7L
engine water pumps, testing the pump for a loose INSPECTING FOR INLET RESTRICTIONS
impeller must be done by verifying coolant flow in
In a dequ a t e h ea t er per for m a n ce m a y be ca u sed by
the radiator. To accomplish this refer to the follow-
a m et a l ca st in g r est r ict ion in t h e h ea t er h ose in let .
ing procedure.
DO NOT WASTE r eu sa ble coola n t . If solu t ion is
DO NOT WASTE r eu sa ble coola n t . If solu t ion is clea n , dr a in t h e coola n t in t o a clea n con t a in er for
clea n , dr a in coola n t in t o a clea n con t a in er for r eu se. r eu se.
WJ ENGINE 7 - 49
WAT ER PU M P - 4 .7 L (Cont inue d)
WARNING: DO NOT LOOSEN THE RADIATOR CAUTION: Do not pry water pump at timing chain
DRAINCOCK WITH THE SYSTEM HOT AND UNDER case/cover. The machined surfaces may be dam-
PRESSURE. SERIOUS BURNS FROM THE COOL- aged resulting in leaks.
ANT CAN OCCUR.
(6) Rem ove wa t er pu m p a n d ga sket . Disca r d ga s-
(1) Dr a in su fficien t coola n t fr om t h e r a dia t or t o ket .
decr ea se t h e level below t h e h ea t er h ose in let . On
4.7L en gin es t h is r equ ir es com plet e dr a in in g. CLEANING
(2) Rem ove t h e h ea t er h ose. Clea n t h e ga sket m a t in g su r fa ce. Use ca u t ion n ot
(3) In spect t h e in let for m et a l ca st in g fla sh or t o da m a ge t h e ga sket sea lin g su r fa ce.
ot h er r est r ict ion s.
INSPECTION
NOTE: On 4.0L engines remove the pump from the In spect t h e wa t er pu m p a ssem bly for cr a cks in t h e
engine before removing restriction to prevent con- h ou sin g, Wa t er lea ks fr om sh a ft sea l, Loose or r ou gh
tamination of the coolant with debris. . On 4.7L t u r n in g bea r in g or Im peller r u bbin g eit h er t h e pu m p
engine remove the fitting from the timing chain body or t im in g ch a in ca se/cover.
cover, If the restriction is in the timing chain cover,
remove the timing chain cover. INSTALLATION
(1) Clea n ga sket m a t in g su r fa ces.
(2) Usin g a n ew ga sket , posit ion wa t er pu m p a n d
REMOVAL
in st a ll m ou n t in g bolt s a s sh own . (F ig. 44). Tigh t en
Th e wa t er pu m p on 4.7L en gin es is bolt ed dir ect ly
wa t er pu m p m ou n t in g bolt s t o 54 N·m (40 ft . lbs.)
t o t h e en gin e t im in g ch a in ca se/cover.
t or qu e.
A ga sket is u sed a s a sea l bet ween t h e wa t er pu m p
a n d t im in g ch a in ca se/cover.
Th e wa t er pu m p ca n be r em oved wit h ou t disch a r g-
in g t h e a ir con dit ion in g syst em (if equ ipped).
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(2) Dr a in coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ). Do n ot wa st e r eu sa ble
coola n t . If solu t ion is clea n , dr a in coola n t in t o a clea n
con t a in er for r eu se.

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the

tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(3) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(4) Rem ove lower r a dia t or h ose cla m p a n d r em ove
lower h ose a t wa t er pu m p.
(5) Rem ove seven wa t er pu m p m ou n t in g bolt s a n d
on e st u d bolt .
Fig. 44 Water Pump Installation
1 - WATER PUMP
2 - TIMING CHAIN COVER
(3) Spin wa t er pu m p t o be su r e t h a t pu m p im pel-
ler does n ot r u b a ga in st t im in g ch a in ca se/cover.
(4) Con n ect r a dia t or lower h ose t o wa t er pu m p.
(5) In st a ll a ccessor y dr ive belt (Refer t o 7 - COOL-
ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
LATION).
7 - 50 ENGINE WJ
WAT ER PU M P - 4 .7 L (Cont inue d)
CAUTION: When installing the serpentine accessory
drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction.

(6) Refill coolin g syst em (Refer t o 7 - COOLING -

STANDARD P ROCE DURE ).
(7) Con n ect n ega t ive ba t t er y ca ble.
(8) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.

WAT ER PU M P - 4 .0 L
DESCRIPTION
CAUTION: All 4.0L 6-cylinder engines are equipped
with a reverse (counterclockwise) rotating water
pump and thermal viscous fan drive assembly.
REVERSE is stamped or imprinted on the cover of
the viscous fan drive and inner side of the fan. The
letter R is stamped into the back of the water pump
impeller. Engines from previous model years,
depending upon application, may have been Fig. 45 Water Pump
equipped with a forward (clockwise) rotating water 1 - HEATER HOSE FITTING BORE
pump. Installation of the wrong water pump or vis- 2 - WATER PUMP
cous fan drive will cause engine over heating. 3 - WATER PUMP HUB

A cen t r ifu ga l wa t er pu m p cir cu la t es coola n t
t h r ou gh t h e wa t er ja cket s, pa ssa ges, in t a ke m a n ifold,
r a dia t or cor e, coolin g syst em h oses a n d h ea t er cor e.
Th e pu m p is dr iven fr om t h e en gin e cr a n ksh a ft by a
sin gle ser pen t in e dr ive belt .
Th e wa t er pu m p im peller is pr essed on t o t h e r ea r
of a sh a ft t h a t r ot a t es in bea r in gs pr essed in t o t h e
h ou sin g. Th e h ou sin g h a s t wo sm a ll h oles t o a llow
seepa ge t o esca pe. Th e wa t er pu m p sea ls a r e lu br i-
ca t ed by t h e a n t ifr eeze in t h e coola n t m ixt u r e. No
a ddit ion a l lu br ica t ion is n ecessa r y (F ig. 45).
DIAGNOSIS AND TESTING—WATER PUMP
LOOSE IMPELLER - 4.0L and 4.7L
NOTE: Due to the design of the 4.0L and 4.7L
engine water pumps, testing the pump for a loose
impeller must be done by verifying coolant flow in
the radiator. To accomplish this refer to the follow-
ing procedure.
DO NOT WASTE r eu sa ble coola n t . If solu t ion is
clea n , dr a in coola n t in t o a clea n con t a in er for r eu se.
(1) Dr a in coola n t u n t il t h e fir st r ow of cor es is vis-
ible in t h e r a dia t or (Refer t o 7 - COOLING - STAN-
DARD P ROCE DURE ) 4.7L E n gin e or (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ) 4.0L
E n gin e.
(2) Lea vin g t h e r a dia t or ca p off, st a r t t h e en gin e.
Ru n en gin e u n t il t h er m ost a t open s.
(3) Wh ile lookin g in t o t h e r a dia t or t h r ou gh t h e
r a dia t or fill n eck, r a ise en gin e r pm t o 2000 RP M.
Obser ve t h e flow of coola n t fr om t h e fir st r ow of
cor es.
(4) If t h er e is n o flow or ver y lit t le flow visa ble,
r epla ce t h e wa t er pu m p.
INSPECTING FOR INLET RESTRICTIONS
In a dequ a t e h ea t er per for m a n ce m a y be ca u sed by
a m et a l ca st in g r est r ict ion in t h e h ea t er h ose in let .
DO NOT WASTE r eu sa ble coola n t . If solu t ion is
clea n , dr a in t h e coola n t in t o a clea n con t a in er for
r eu se.
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Dr a in su fficien t coola n t fr om t h e r a dia t or t o
decr ea se t h e level below t h e h ea t er h ose in let . On
4.7L en gin es t h is r equ ir es com plet e dr a in in g.
(2) Rem ove t h e h ea t er h ose.
(3) In spect t h e in let for m et a l ca st in g fla sh or
ot h er r est r ict ion s.
WJ
WAT ER PU M P - 4 .0 L (Cont inue d)
NOTE: On 4.0L engines remove the pump from the
engine before removing restriction to prevent con-
tamination of the coolant with debris. . On 4.7L
engine remove the fitting from the timing chain
cover, If the restriction is in the timing chain cover,
remove the timing chain cover.
REMOVAL
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.
Th e wa t er pu m p im peller is pr essed on t h e r ea r of
t h e pu m p sh a ft a n d bea r in g a ssem bly. Th e wa t er
pu m p is ser viced on ly a s a com plet e a ssem bly.
NOTE: The water pump can be replaced without
discharging the A/C system.
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE r eu sa ble coola n t . If t h e solu t ion
is clea n , dr a in coola n t in t o a clea n con t a in er for
r eu se.
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Dr a in t h e coolin g syst em (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(3) Th e t h er m a l viscou s fa n dr ive is a t t a ch ed
(t h r ea ded) t o t h e wa t er pu m p h u b sh a ft . Rem ove fa n /
viscou s fa n dr ive a ssem bly fr om wa t er pu m p by t u r n -
in g m ou n t in g n u t cou n t er clockwise a s viewed fr om
fr on t . Th r ea ds on viscou s fa n dr ive a r e RIGHT
HAN D Do n ot a t t em pt t o r em ove fa n /viscou s fa n
dr ive a ssem bly fr om veh icle a t t h is t im e.
(4) If wa t er pu m p is bein g r epla ced, do n ot u n bolt
fa n bla de a ssem bly fr om t h er m a l viscou s fa n dr ive.
(5) Rem ove fa n sh r ou d-t o-r a dia t or n u t s (F ig. 46).
Do n ot a t t em pt t o r em ove fa n sh r ou d a t t h is t im e.
(6) Rem ove fa n sh r ou d a n d fa n bla de/viscou s fa n
dr ive a ssem bly fr om veh icle a s a com plet e u n it .
(7) Aft er r em ovin g fa n bla de/viscou s fa n dr ive
a ssem bly, d o n o t pla ce t h er m a l viscou s fa n dr ive in
h or izon t a l posit ion . If st or ed h or izon t a lly, silicon e
flu id in viscou s fa n dr ive cou ld dr a in in t o it s bea r in g
a ssem bly a n d con t a m in a t e lu br ica n t .
Loosen bu t do n ot r em ove t h e wa t er pu m p pu lley
m ou n t in g bolt s.
ENGINE 7 - 51
Fig. 46 Fan Shroud Mounting
1 - SHROUD FASTENERS
2 - DRAIN COCK
3 - RADIATOR FAN SHROUD
4 - SHROUD FASTENERS
Rem ove a ccessor y dr ive belt (Refer t o 7 - COOL-
ING/ACCE SSORY DRIVE /DRIVE BE LTS - RE MOV-
AL).
Rem ove t h e wa t er pu m p pu lley.
(8) Rem ove t h e idler pu lley (loca t ed over t h e wa t er
pu m p).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 47) SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 48). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(9) Rem ove lower r a dia t or h ose fr om wa t er pu m p.
Rem ove h ea t er h ose fr om wa t er pu m p fit t in g.
(10) Rem ove t h e five pu m p m ou n t in g bolt s (F ig.
49) a n d r em ove pu m p fr om veh icle. Disca r d old ga s-
ket . Not e t h a t on e of t h e five bolt s is lon ger t h a n t h e
ot h er bolt s.
(11) If pu m p is t o be r epla ced, t h e h ea t er h ose fit -
t in g m u st be r em oved. Not e posit ion of fit t in g befor e
r em ova l.
7 - 52 ENGINE WJ
WAT ER PU M P - 4 .0 L (Cont inue d)

Fig. 47 Hose Clamp Tool - Typical

1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP

Fig. 49 Water Pump Remove/Install - Typical

1 - HEATER HOSE FITTING
2 - PUMP GASKET
3 - WATER PUMP
4 - LONG BOLT
5 - BOLTS (4) SHORT

INSTALLATION
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.

(1) If pu m p is bein g r epla ced, in st a ll t h e h ea t er

Fig. 48 Clamp - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
CLEANING
Clea n t h e ga sket m a t in g su r fa ce. Use ca u t ion n ot
t o da m a ge t h e ga sket sea lin g su r fa ce.
INSPECTION
In spect t h e wa t er pu m p a ssem bly for cr a cks in t h e
h ou sin g, Wa t er lea ks fr om sh a ft sea l, Loose or r ou gh
t u r n in g bea r in g or Im peller r u bbin g eit h er t h e pu m p
body or t im in g ch a in ca se/cover.
h ose fit t in g t o t h e pu m p. Use a sea la n t on t h e fit t in g
su ch a s Mopa r ! Th r ea d Sea la n t Wit h Teflon . Refer t o
t h e dir ect ion s on t h e pa cka ge.
(2) Clea n t h e ga sket m a t in g su r fa ces. If t h e or igi-
n a l pu m p is u sed, r em ove a n y deposit s or ot h er for-
eign m a t er ia l. In spect t h e cylin der block a n d wa t er
pu m p m a t in g su r fa ces for er osion or da m a ge fr om
ca vit a t ion .
(3) In st a ll t h e ga sket a n d wa t er pu m p. Th e sili-
con e bea d on t h e ga sket sh ou ld be fa cin g t h e wa t er
pu m p. Also, t h e ga sket is in st a lled dr y. Tigh t en
m ou n t in g bolt s t o 30 N·m (22 ft . lbs.) t or qu e. Rot a t e
t h e sh a ft by h a n d t o be su r e it t u r n s fr eely.
(4) Con n ect t h e r a dia t or a n d h ea t er h oses t o t h e
wa t er pu m p.
(5) P osit ion wa t er pu m p pu lley t o wa t er pu m p
h u b. Tigh t en bolt s 28 N·m (250 in . lbs.).
In st a ll t h e idler pu lley. Tigh t en t h e bolt 47 N·m (35
ft . lbs.).
WJ ENGINE 7 - 53
WAT ER PU M P - 4 .0 L (Cont inue d)
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installtion in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.

In st a ll a ccessor y dr ive belt (Refer t o 7 - COOLING/

ACCE SSORY DRIVE /DRIVE BE LTS - INSTALLA-
TION).
(6) In st a ll fa n bla de a n d viscou s fa n dr ive on t o
wa t er pu m p.
(7) F ill coolin g syst em wit h coola n t a n d ch eck for
lea ks. (Refer t o 7 - COOLING - STANDARD P ROCE -
DURE ).
(8) Con n ect ba t t er y ca ble t o ba t t er y.
(9) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.

RADI AT OR PRESSU RE CAP

DESCRIPTION
All r a dia t or s a r e equ ipped wit h a pr essu r e ca p
(F ig. 50). Th is ca p r elea ses pr essu r e a t som e poin t
wit h in a r a n ge of 124-t o-145 kP a (18-t o-21 psi). Th e
pr essu r e r elief poin t (in pou n ds) is en gr a ved on t op of
t h e ca p
Th e coolin g syst em will oper a t e a t pr essu r es
sligh t ly a bove a t m osph er ic pr essu r e. Th is r esu lt s in a
h igh er coola n t boilin g poin t a llowin g in cr ea sed r a di-
a t or coolin g ca pa cit y. Th e ca p con t a in s a spr in g-
loa ded pr essu r e r elief va lve. Th is va lve open s wh en
syst em pr essu r e r ea ch es t h e r elea se r a n ge of 124-t o-
145 kP a (18-t o-21 psi).
A r u bber ga sket sea ls t h e r a dia t or filler n eck. Th is is
don e t o m a in t a in va cu u m du r in g coola n t cool-down a n d
t o pr even t lea ka ge wh en syst em is u n der pr essu r e.
OPERATION
A ven t va lve in t h e cen t er of t h e ca p will r em a in
sh u t a s lon g a s t h e coolin g syst em is pr essu r ized. As
t h e coola n t cools, it con t r a ct s a n d cr ea t es a va cu u m
in coolin g syst em . Th is ca u ses t h e va cu u m va lve t o
open a n d coola n t in r eser ve/over flow t a n k t o be
dr a wn t h r ou gh con n ect in g h ose in t o r a dia t or. If t h e
va cu u m va lve is st u ck sh u t , or over flow h ose is
kin ked, r a dia t or h oses will colla pse on cool-down .
DIAGNOSIS AND TESTING—RADIATOR
PRESSURE CAP
Rem ove ca p fr om r a dia t or. Be su r e t h a t sea lin g
su r fa ces a r e clea n . Moist en r u bber ga sket wit h wa t er
a n d in st a ll t h e ca p on pr essu r e t est er (t ool 7700 or
a n equ iva len t ) (F ig. 51).
Fig. 50 Radiator Pressure Cap - Typical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
Oper a t e t h e t est er pu m p a n d obser ve t h e ga u ge
poin t er a t it s h igh est poin t . Th e ca p r elea se pr essu r e
sh ou ld be 124 t o 145 kP a (18 t o 21 psi). Th e ca p is
sa t isfa ct or y wh en t h e pr essu r e h olds st ea dy. It is a lso
good if it h olds pr essu r e wit h in t h e 124 t o 145 kP a
(18 t o 21 psi) r a n ge for 30 secon ds or m or e. If t h e
poin t er dr ops qu ickly, r epla ce t h e ca p.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which 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 tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Clea n t h e r a dia t or pr essu r e ca p u sin g a m ild soa p
a n d wa t er on ly.
7 - 54 ENGINE WJ
RADI AT OR PRESSU RE CAP (Cont inue d)

Fig. 52 Hose Clamp Tool—Typical

1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP

Fig. 51 Pressure Testing Radiator Pressure

Cap—Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER

INSPECTION
Visu a lly in spect t h e pr essu r e va lve ga sket on t h e
ca p. Repla ce ca p if t h e ga sket is swollen , t or n or
wor n . In spect t h e a r ea a r ou n d r a dia t or filler n eck for
wh it e deposit s t h a t in dica t e a lea kin g ca p.

WAT ER PU M P I N LET T U BE
REMOVAL
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF Fig. 53 Clamp Number/Letter Location
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
2 - CLAMP NUMBER/LETTER LOCATION
HPC-20) MAY BE USED FOR LARGER CLAMPS. 3 - TYPICAL HOSE
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
(3) Loosen bot h bypa ss h ose cla m ps (F ig. 52) a n d
posit ion t o cen t er of h ose. Rem ove h ose fr om veh icle.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 53). If INSTALLATION
replacement is necessary, use only an original (1) P osit ion bypa ss h ose cla m ps (F ig. 52) t o cen t er
equipment clamp with matching number or letter. of h ose.
(2) In st a ll bypa ss h ose t o en gin e.
(1) P a r t ia lly dr a in coolin g syst em . (3) Secu r e bot h h ose cla m ps (F ig. 52).
(2) Do n ot wa st e r eu sa ble coola n t . If solu t ion is (4) Refill coolin g syst em .
clea n , dr a in coola n t in t o a clea n con t a in er for r eu se. (5) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.
WJ
T RAN SM I SSI ON
TABLE OF CONTENTS
page
TRANS COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55
T RAN S COOLER
DESCRIPTION
An in t er n a l h igh ca pa cit y/h igh efficien cy cooler is
u sed on a ll veh icles t h ese cooler s a r e a n oil-t o-coola n t
t ype wh ich con sist s of pla t es m ou n t ed in t h e r a dia t or
ou t let t a n k (F ig. 36). Beca u se t h e in t er n a l oil cooler
is so efficien t , n o a u xilia r y oil cooler is offer ed Th e
cooler is n ot ser vica ble seper a t ly fr om t h e r a dia t or.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
Wh en a t r a n sm ission fa ilu r e h a s con t a m in a t ed t h e
flu id, t h e oil cooler (s) m u st be flu sh ed. Th e t or qu e
con ver t er m u st a lso be r epla ced. Th is will in su r e t h a t
m et a l pa r t icles or slu dged oil a r e n ot la t er t r a n s-
fer r ed ba ck in t o t h e r econ dit ion ed (or r epla ced) t r a n s-
m ission .
Th e on ly r ecom m en ded pr ocedu r e for flu sh in g cool-
er s a n d lin es is t o u se Tool 6906-B Cooler F lu sh er.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Rem ove cover pla t e filler plu g on Tool 6906-B.
F ill r eser voir 1/2 t o 3/4 fu ll of fr esh flu sh in g solu t ion .
F lu sh in g solven t s a r e pet r oleu m ba sed solu t ion s gen -
er a lly u sed t o clea n a u t om a t ic t r a n sm ission com po-
n en t s. D O N OT u se solven t s con t a in in g a cids, wa t er,
ga solin e, or a n y ot h er cor r osive liqu ids.
TRANSMISSION 7 - 55
page
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES . . . . . . . . . . . . . . . . . 55
(2) Rein st a ll filler plu g on Tool 6906-B.
(3) Ver ify pu m p power swit ch is t u r n ed OF F. Con -
n ect r ed a lliga t or clip t o posit ive (+) ba t t er y post .
Con n ect bla ck (-) a lliga t or clip t o a good gr ou n d.
(4) Discon n ect t h e cooler lin es a t t h e t r a n sm ission .
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Con n ect t h e BLUE pr essu r e lin e t o t h e OUT-
LE T (F r om ) cooler lin e.
(6) Con n ect t h e CLE AR r et u r n lin e t o t h e INLE T
(To) cooler lin e
(7) Tu r n pu m p ON for t wo t o t h r ee m in u t es t o
flu sh cooler (s) a n d lin es.
(8) Tu r n pu m p OF F.
(9) Discon n ect CLE AR su ct ion lin e fr om r eser voir
a t cover pla t e. Discon n ect CLE AR r et u r n lin e a t
cover pla t e, a n d pla ce it in a dr a in pa n .
(10) Tu r n pu m p ON for 30 secon ds t o pu r ge flu sh -
in g solu t ion fr om cooler a n d lin es. Tu r n pu m p OF F.
(11) P la ce CLE AR su ct ion lin e in t o a on e qu a r t
con t a in er of Mopa r ! ATF +4, t ype 9602, Au t om a t ic
Tr a n sm ission F lu id.
(12) Tu r n pu m p ON u n t il a ll t r a n sm ission flu id is
r em oved fr om t h e on e qu a r t con t a in er a n d lin es. Th is
pu r ges a n y r esidu a l clea n in g solven t fr om t h e t r a n s-
m ission cooler a n d lin es. Tu r n pu m p OF F.
(13) Discon n ect a lliga t or clips fr om ba t t er y. Recon -
n ect flu sh er lin es t o cover pla t e, a n d r em ove flu sh in g
a da pt er s fr om cooler lin es.
WJ AUDIO 8A - 1

AUDIO
TABLE OF CON T EN T S

page page

AUDIO RADIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - AUDIO . . . . . . . . . . 3 DIAGNOSIS AND TESTING - RADIO . . . . . . . . . 16
SPECIAL TOOLS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
AMPLIFIER RADIO NOISE SUPPRESSION GROUND STRAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL
DIAGNOSIS AND TESTING - AMPLIFIER . . . . . . 6 REMOVAL - ENGINE-TO-BODY GROUND
REMOVAL .............................6 STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL - EXHAUST-TO-BODY GROUND
ANTENNA BODY & CABLE STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION - ENGINE TO BODY
DIAGNOSIS AND TESTING - ANTENNA BODY GROUND STRAP . . . . . . . . . . . . . . . . . . . . . . 19
AND CABLE ..........................7 INSTALLATION - EXHAUST-TO-BODY
REMOVAL .............................9 GROUND STRAP . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOTE SWITCHES
ANTENNA MODULE - EXPORT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - REMOTE
DIAGNOSIS AND TESTING - ANTENNA SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MODULE - EXPORT . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 SPEAKER
CD CHANGER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DIAGNOSIS AND TESTING - SPEAKER . . . . . . 23
DIAGNOSIS AND TESTING - CD CHANGER . . . 13 REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REAR DOOR SPEAKER . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTRUMENT PANEL SPEAKER . . . . . . . . . . 24
INSTRUMENT PANEL ANTENNA CABLE FRONT DOOR SPEAKER . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION - REAR DOOR SPEAKER . . . 25
QUARTER GLASS INTEGRAL ANTENNA - INSTALLATION - INSTRUMENT PANEL
EXPORT SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION - FRONT DOOR SPEAKER . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - QUARTER
GLASS INTEGRAL ANTENNA - EXPORT . . . . 16
8A - 2 AUDIO WJ

AU DI O ULE S/DRIVE R DOOR MODULE - DE SCRIP TION)

for m or e in for m a t ion .
• P a s s e n g e r D o o r Mo d u le (P D M) (Refer t o 8 -
DESCRIPTION
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
An a u dio syst em is st a n da r d fa ct or y-in st a lled
ULE S/DRIVE R DOOR MODULE - DE SCRIP TION)
equ ipm en t on t h is m odel. Th e st a n da r d equ ipm en t
for m or e in for m a t ion .
a u dio syst em in clu des a n AM/F M/ca sset t e (RBB sa les
Th e a u dio syst em in clu des t h e followin g m a jor
code) r a dio r eceiver, a n d spea ker s in six loca t ion s.
com pon en t s, wh ich a r e descr ibed in fu r t h er det a il
Sever a l com bin a t ion s of r a dio r eceiver s a n d spea ker
elsewh er e in t h is ser vice in for m a t ion :
syst em s a r e offer ed a s opt ion a l equ ipm en t on t h is
• Am p lifie r - On m odels equ ipped wit h t h e
m odel. Th e a u dio syst em u ses a n ign it ion swit ch ed
opt ion a l pr em iu m spea ker syst em , a n a u dio power
con t r ol of ba t t er y cu r r en t so t h a t t h e syst em will on ly
a m plifier is loca t ed on t h e r ea r floor pa n el u n der-
oper a t e wh en t h e ign it ion swit ch is in t h e On or
n ea t h t h e r igh t en d of t h e r ea r sea t cu sh ion in t h e
Accessor y posit ion s.
pa ssen ger com pa r t m en t .
A Com pa ct Disc (CD) ch a n ger wit h a t en disc m a g-
• An te n n a B o d y a n d Ca ble - Th e m ost visible
a zin e, r em ot e r a dio swit ch es wit h six fu n ct ion s
com pon en t of t h e a n t en n a body a n d ca ble a r e t h e
m ou n t ed t o t h e ba cks of t h e st eer in g wh eel spokes,
a n t en n a a da pt er a n d t h e a n t en n a ca p n u t , wh ich a r e
a n d a m em or y syst em t h a t a u t om a t ica lly st or es a n d
loca t ed on t h e t op of t h e r igh t fr on t fen der pa n el of
r eca lls u p t o t wen t y r a dio st a t ion pr eset s (t en AM
t h e veh icle, n ea r t h e r igh t en d of t h e cowl plen u m .
a n d t en F M) a n d t h e la st st a t ion list en ed t o for t wo
• An te n n a Ma s t - Th e a n t en n a m a st is a m et a l
dr iver s a r e opt ion a l fa ct or y-in st a lled equ ipm en t on
r od t h a t ext en ds u pwa r d fr om t h e a n t en n a body a n d
t h is m odel. Refer t o E lect r ica l, P ower Sea t s for m or e
ca ble on t h e t op of t h e r igh t fr on t fen der pa n el of t h e
in for m a t ion on t h e m em or y syst em .
veh icle, n ea r t h e r igh t en d of t h e cowl plen u m .
Th e a u dio syst em in clu des t h e followin g com po-
• Ra d io - Th e r a dio for t h is m odel is loca t ed in
n en t s:
t h e in st r u m en t pa n el cen t er st a ck a r ea , in boa r d of
• An t en n a
t h e in st r u m en t clu st er a n d a bove t h e h ea t er a n d a ir
• Com pa ct disc ch a n ger (a va ila ble wit h RBP sa les
con dit ion er con t r ols.
code r a dio r eceiver s on ly)
• Ra d io N o is e S u p p re s s io n Gro u n d S tra p - A
• P ower a m plifier (wit h pr em iu m spea ker syst em
r a dio n oise su ppr ession gr ou n d st r a p is in st a lled
on ly)
bet ween t h e r ea r of t h e en gin e cylin der h ea d(s) a n d
• Ra dio n oise su ppr ession com pon en t s
t h e da sh pa n el sh eet m et a l in t h e en gin e com pa r t -
• Ra dio r eceiver
m en t .
• Rem ot e r a dio swit ch es
• S p e a k e r - Th e st a n da r d spea ker syst em
• Spea ker s
in clu des six spea ker s in six loca t ion s, wh ile t h e pr e-
Cer t a in fu n ct ion s a n d fea t u r es of t h e a u dio syst em
m iu m spea ker syst em in clu des a n a m plifier for t h e
r ely u pon r esou r ces sh a r ed wit h ot h er elect r on ic
six spea ker s in six loca t ion s.
m odu les in t h e veh icle over t h e P r ogr a m m a ble Com -
H a r d wir ed cir cu it r y con n ect s t h e a u dio syst em
m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e
com pon en t s t o ea ch ot h er t h r ou gh t h e elect r ica l sys-
P CI da t a bu s n et wor k a llows t h e sh a r in g of sen sor
t em of t h e veh icle. Th ese h a r d wir ed cir cu it s a r e
in for m a t ion . Th is h elps t o r edu ce wir e h a r n ess com -
in t egr a l t o sever a l wir e h a r n esses, wh ich a r e r ou t ed
plexit y, in t er n a l con t r oller h a r dwa r e, a n d com pon en t
t h r ou gh ou t t h e veh icle a n d r et a in ed by m a n y differ-
sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is syst em
en t m et h ods. Th ese cir cu it s m a y be con n ect ed t o ea ch
pr ovides in cr ea sed r elia bilit y, en h a n ced dia gn ost ics,
ot h er, t o t h e veh icle elect r ica l syst em a n d t o t h e
a n d a llows t h e a ddit ion of m a n y n ew fea t u r e ca pa bil-
a u dio syst em com pon en t s t h r ou gh t h e u se of a com -
it ies. F or dia gn osis of t h ese elect r on ic m odu les or of
bin a t ion of solder ed splices, splice block con n ect or s
t h e P CI da t a bu s n et wor k, t h e u se of a DRB sca n
a n d m a n y differ en t t ypes of wir e h a r n ess t er m in a l
t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l
con n ect or s a n d in su la t or s. Refer t o t h e a ppr opr ia t e
a r e r ecom m en ded.
wir in g in for m a t ion in t h is ser vice m a n u a l for com -
Th e ot h er elect r on ic m odu les t h a t m a y a ffect a u dio
plet e st a n da r d a n d pr em iu m a u dio syst em cir cu it
syst em oper a t ion a r e a s follows:
dia gr a m s. Th e wir in g in for m a t ion in clu des pr oper
• B o d y Co n tro l Mo d u le (B CM) - (Refer t o 8 -
wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er det a ils
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
on wir e h a r n ess r ou t in g a n d r et en t ion , a s well a s
ULE S/BODY CONTROL/CE NTRAL TIME R MODUL
pin -ou t a n d loca t ion views for t h e va r iou s wir e h a r-
- DE SCRIP TION) for m or e in for m a t ion .
n ess con n ect or s, splices, a n d gr ou n ds.
• D riv e r D o o r Mo d u le (D D M) (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
WJ
AU DI O (Cont inue d)
OPERATION
Th e a u dio syst em com pon en t s a r e design ed t o pr o-
vide a u dio en t er t a in m en t a n d in for m a t ion t h r ou gh
t h e r ecept ion , t u n in g a n d a m plifica t ion of loca lly
br oa dca st r a dio sign a ls in bot h t h e Am plit u de Modu -
la t in g (AM) a n d F r equ en cy Modu la t in g (F M) com -
m er cia l fr equ en cy r a n ges. E lect r om a gn et ic r a dio
sign a ls t h a t a r e br oa dca st fr om a r a dio st a t ion
in du ce elect r ica l m odu la t ion s in t o t h e a u dio syst em
a n t en n a m a st . Th e a n t en n a body a n d ca ble con du ct
t h ese wea k sign a ls fr om t h e a n t en n a m a st t o t h e
r a dio. Th e r a dio t h en t u n es a n d a m plifies t h ese wea k
r a dio fr equ en cy sign a ls in t o st r on ger elect r ica l a u dio
sign a ls t h a t a r e r equ ir ed in or der t o oper a t e t h e
a u dio syst em spea ker s. Th e spea ker s con ver t t h ese
elect r ica l sign a ls in t o a ir m ovem en t , wh ich r epr o-
du ces t h e sou n ds bein g br oa dca st by t h e r a dio st a -
t ion .
Som e a u dio syst em s a lso offer t h e u ser t h e opt ion
of select in g fr om a n d list en in g t o pr er ecor ded a u dio
ca sset t e t a pes, a u dio com pa ct discs, or bot h . Rega r d-
less of t h e m edia t ype, t h e a u dio syst em com pon en t s
pr ovide t h e u ser wit h t h e a bilit y t o elect r on ica lly
a m plify a n d a dju st t h e a u dio sign a ls bein g r epr o-
du ced by t h e spea ker s wit h in t h e veh icle t o su it t h e
pr efer en ces of t h e veh icle occu pa n t s.
Th e a u dio syst em com pon en t s oper a t e on ba t t er y
cu r r en t r eceived t h r ou gh a fu se in t h e J u n ct ion Block
(J B) on a fu sed ign it ion swit ch ou t pu t (r u n -a cc) cir-
cu it so t h a t t h e syst em will on ly oper a t e wh en t h e
ign it ion swit ch is in t h e On or Accessor y posit ion s.
On veh icles t h a t a r e equ ipped wit h t h e opt ion a l
r em ot e r a dio swit ch es, t h e BCM r eceives h a r d wir ed
r esist or m u lt iplexed in pu t s fr om t h e r em ot e r a dio
swit ch es. Th e pr ogr a m m in g in t h e BCM a llows it t o
pr ocess t h ose in pu t s a n d sen d t h e pr oper m essa ges t o
t h e r a dio r eceiver over t h e P CI da t a bu s t o con t r ol
t h e r a dio volu m e u p or down , st a t ion seek u p or
down , pr eset st a t ion a dva n ce, a n d m ode a dva n ce
fu n ct ion s.
AUDIO 8A - 3
On veh icles equ ipped wit h t h e opt ion a l m em or y
syst em , wh en t h e DDM r eceives a Dr iver 1 or Dr iver
2 m em or y r eca ll in pu t fr om t h e m em or y swit ch on
t h e dr iver side fr on t door t r im pa n el or a m em or y
r eca ll m essa ge fr om t h e Rem ot e Keyless E n t r y (RKE )
r eceiver in t h e P DM, t h e DDM sen ds a m em or y
r eca ll m essa ge ba ck t o t h e r a dio r eceiver over t h e
P CI da t a bu s t o r eca ll t h e r a dio st a t ion pr eset s a n d
la st st a t ion list en ed t o in for m a t ion .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of ea ch of t h e a va ila ble a u dio syst em s.
DIAGNOSIS AND TESTING - AUDIO
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
Ma n u a l.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
8A - 4 AUDIO
AU DI O (Cont inue d)
AU DI O SY ST EM DI AGN OSI S
CONDITION POSSIBLE CAUSES
NO AUDIO 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Radio ground faulty.
5. Radio faulty.
6. Speakers faulty.
7. Amplifier faulty (if
equipped).
NO RADIO DISPLAY 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Radio ground faulty.
5. Radio faulty.
CLOCK WILL NOT KEEP 1. Fuse faulty.
SET TIME
2. Radio connector faulty.
3. Wiring faulty.
4. Radio ground faulty.
5. Radio faulty.
WJ
CORRECTION
1. Check radio fuse in Junction Block (JB) and
Ignition-Off Draw (IOD) fuse in Power Distribution
Center (PDC). Replace fuses, if required.
2. Check for loose or corroded radio connector.
Repair, if required.
3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
6. (Refer to 8 - ELECTRICAL/AUDIO/SPEAKER -
DIAGNOSIS AND TESTING).
7. (Refer to 8 - ELECTRICAL/AUDIO/AMPLIFIER
- DIAGNOSIS AND TESTING).
1. Check radio fuse in Junction Block (JB) and
Ignition-Off Draw (IOD) fuse in Power Distribution
Center (PDC). Replace fuses, if required.
2. Check for loose or corroded radio connector.
Repair, if required.
3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
1. Check Ignition-Off Draw (IOD) fuse in the
Power Distribution Center (PDC). Replace fuse, if
required.
2. Check for loose or corroded radio connector.
Repair, if required.
3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
WJ
AU DI O (Cont inue d)
CONDITION POSSIBLE CAUSES
POOR RADIO RECEPTION 1. Antenna faulty.
2. Radio ground faulty.
3. Radio noise suppression
faulty.
4. Radio faulty.
NO/POOR TAPE 1. Faulty tape.
OPERATION 2. Foreign objects behind
tape door.
3. Dirty cassette tape head.
4. Faulty tape deck.
NO COMPACT DISC 1. Faulty CD.
OPERATION, OR CD
SKIPPING SOUND 2. Foreign material on CD.
3. Condensation on CD or
optics.
4. Faulty CD player.
NO COMPACT DISC 1. Faulty CD.
CHANGER OPERATION, OR
CD SKIPPING SOUND
2. Foreign material on CD.
3. Condensation on CD or
optics.
4. CD changer connector
faulty.
5. Wiring faulty.
6. PCI data bus faulty.
7. CD changer faulty.
AUDIO 8A - 5
CORRECTION
1. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA
BODY & CABLE - DIAGNOSIS AND TESTING).
2. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
3. (Refer to 8 - ELECTRICAL/AUDIO/RADIO
NOISE SUPPRESSION - DIAGNOSIS AND
TESTING).
4. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
DIAGNOSIS AND TESTING).
1. Insert known good tape and test operation.
2. Remove foreign objects and test operation.
3. Clean head with Mopar Cassette Head
Cleaner.
4. Exchange or replace radio, if required.
1. Insert known good CD and test operation.
2. Clean CD and test operation.
3. Allow temperature of vehicle interior to stabilize
and test operation.
4. Exchange or replace radio, if required.
1. Insert known good CD and test operation.
2. Clean CD and test operation.
3. Allow temperature of vehicle interior to stabilize
and test operation.
4. Check for loose or corroded CD changer
connections. Repair, if required.
5. Refer to Compact Disc Changer in the
Diagnosis and Testing section of this group.
6. Use DRB scan tool and the Diagnostic
Procedures manual to test PCI data bus. Repair,
if required.
7. Refer to Compact Disc Changer in the
Diagnosis and Testing section of this group.
8A - 6 AUDIO WJ
AU DI O (Cont inue d)

SPECI AL T OOLS DIAGNOSIS AND TESTING - AMPLIFIER

Th e power a m plifier u n it sh ou ld be ch ecked if
AUDIO SYSTEMS t h er e is n o sou n d ou t pu t n ot ed fr om t h e spea ker s.
F or dia gn osis of t h e power a m plifier, (Refer t o 8 -
E LE CTRICAL/AUDIO/SP E AKE R - DIAGNOSIS
AND TE STING). F or com plet e cir cu it dia gr a m s, r efer
t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g
in for m a t ion in clu des wir in g dia gr a m s, pr oper wir e
a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r-
n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t in for-
m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.

REMOVAL
Antenna Nut Wrench C-4816 (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
AM PLI FI ER (2) Un la t ch a n d lift t h e r igh t r ea r sea t cu sh ion t o
t h e u pr igh t posit ion .
DESCRIPTION (3) Discon n ect t h e t wo r igh t body wir e h a r n ess
Models equ ipped wit h t h e In fin it y pr em iu m con n ect or s fr om t h e a m plifier (F ig. 1).
spea ker pa cka ge h a ve a sepa r a t e power a m plifier
u n it . Th is power a m plifier is r a t ed a t 180 wa t t s ou t -
pu t . Th e power a m plifier u n it is m ou n t ed t o t h e r ea r
floor pa n el u n der t h e pa ssen ger side r ea r sea t cu sh -
ion . Th e power a m plifier u n it ca n be a ccessed for ser-
vice by u n la t ch in g a n d t ilt in g t h e pa ssen ger side r ea r
sea t cu sh ion for wa r d.
Th e power a m plifier u n it sh ou ld be ch ecked if
t h er e is n o sou n d ou t pu t n ot ed fr om t h e spea ker s.
F or dia gn osis of t h e power a m plifier, (Refer t o 8 -
E LE CTRICAL/AUDIO/SP E AKE R - DIAGNOSIS
AND TE STING). Th e power a m plifier ca n n ot be
r epa ir ed or a dju st ed a n d, if fa u lt y or da m a ged, t h e
u n it m u st be r epla ced.

OPERATION
Th e power a m plifier is en er gized by a fu sed 12 volt
ou t pu t fr om t h e r a dio r eceiver wh en ever t h e r a dio is Fig. 1 Power Amplifier Remove/Install
t u r n ed on . Th e power a m plifier r eceives t h e sou n d 1 - NUT (3)
sign a l in pu t s for fou r spea ker ch a n n els fr om t h e 2 - RIGHT BODY WIRE HARNESS
r a dio r eceiver, t h en sen ds t h e a m plified spea ker ou t - 3 - AMPLIFIER
4 - STUD (3)
pu t s for ea ch of t h ose ch a n n els t o t h e six In fin it y
5 - RIGHT REAR FLOOR PANEL
spea ker s. F or com plet e cir cu it dia gr a m s, r efer t o t h e
a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for m a -
(4) Rem ove t h e t h r ee m ou n t in g n u t s.
t ion in clu des wir in g dia gr a m s, pr oper wir e a n d con -
(5) Rem ove t h e power a m plifier.
n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
INSTALLATION
(1) P osit ion t h e power a m plifier on t o t h e t h r ee
n ect or s, splices a n d gr ou n ds.
floor pa n el st u ds.
(2) In st a ll t h e m ou n t in g n u t s. Tigh t en t h e n u t s t o
11.8 N·m (105 in . lbs.).
(3) Recon n ect t h e t wo r igh t body wir e h a r n ess con -
n ect or s.
(4) Lower t h e r igh t r ea r sea t cu sh ion t o t h e floor
pa n el.
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ
AN T EN N A BODY & CABLE
DESCRIPTION
Fig. 2 Antenna Body and Cable
1 - MAST
2 - BODY & CABLE
3 - CAP NUT
4 - ADAPTER
5 - RIGHT FRONT FENDER
Th e a n t en n a body a n d ca ble is secu r ed below t h e
fen der pa n el by t h e a n t en n a ca p n u t t h r ou gh a
m ou n t in g h ole in t h e of t h e r igh t fr on t fen der (F ig.
2). Th e pr im a r y coa xia l a n t en n a ca ble is t h en r ou t ed
ben ea t h t h e fen der sh eet m et a l a n d t h r ou gh a en t r y
h ole in t h e r igh t cowl side pa n el in t o t h e in t er ior of
t h e veh icle. In side t h e veh icle, t h e pr im a r y coa xia l
ca ble is con n ect ed t o a secon da r y in st r u m en t pa n el
a n t en n a coa xia l ca ble wit h a n in -lin e con n ect or t h a t
is loca t ed beh in d t h e r igh t kick pa n el. Th e secon da r y
coa xia l ca ble is t h en r ou t ed beh in d t h e in st r u m en t
pa n el t o t h e ba ck of t h e r a dio.
AUDIO 8A - 7
OPERATION
Th e a n t en n a body a n d ca ble con n ect s t h e a n t en n a
m a st t o t h e r a dio. Th e r a dio a n t en n a is a n elect r o-
m a gn et ic cir cu it com pon en t u sed t o ca pt u r e r a dio fr e-
qu en cy sign a ls t h a t a r e br oa dca st by loca l
com m er cia l r a dio st a t ion s in bot h t h e Am plit u de
Modu la t in g (AM) a n d F r equ en cy Modu la t in g (F M)
fr equ en cy r a n ges. Th ese elect r om a gn et ic r a dio fr e-
qu en cy sign a ls in du ce sm a ll elect r ica l m odu la t ion s
in t o t h e a n t en n a a s t h ey m ove pa st t h e m a st . Th e
a n t en n a body t r a n sfer s t h e wea k elect r om a gn et ic
r a dio wa ves in du ced in t o t h e r igid a n t en n a m a st in t o
t h e cen t er con du ct or of t h e flexible pr im a r y a n t en n a
coa xia l ca ble. Th e br a ided ou t er sh ield of t h e
a n t en n a coa xia l ca ble is gr ou n ded t h r ou gh bot h t h e
a n t en n a body a n d t h e r a dio ch a ssis, effect ively
sh ieldin g t h e r a dio wa ves a s t h ey a r e con du ct ed t o
t h e r a dio. Th e r a dio t h en t u n es a n d a m plifies t h e
wea k r a dio sign a ls in t o st r on ger elect r ica l sign a ls in
or der t o oper a t e t h e a u dio syst em spea ker s.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
Th e followin g fou r t est s a r e u sed t o dia gn ose t h e
a n t en n a wit h a n oh m m et er :
• Te s t 1 - Ma st t o gr ou n d t est
• Te s t 2 - Tip-of-m a st t o t ip-of-con du ct or t est
• Te s t 3 - Body gr ou n d t o ba t t er y gr ou n d t est
• Te s t 4 - Body gr ou n d t o a n t en n a coa xia l ca ble
sh ield t est .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Th e oh m m et er t est lea d con n ect ion s for ea ch t est
a r e sh own in t h e illu st r a t ion (F ig. 3).
8A - 8 AUDIO
AN T EN N A BODY & CABLE (Cont inue d)
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate an antenna cable problem. First,
test the primary antenna cable (integral to the
antenna body and cable) from the coaxial cable
connector under the right end of the instrument
panel near the right cowl side inner panel to the
antenna body. Then, test the secondary antenna
cable (instrument panel antenna cable) from the
coaxial cable connector under the right end of the
instrument panel near the right cowl side inner
panel to the coaxial cable connector at the radio.
Fig. 3 Antenna Tests - Typical
NOTE: Use extreme caution when checking continu-
ity of center conductor to avoid damage.
TEST 1
Test 1 det er m in es if t h e a n t en n a m a st is in su la t ed
fr om gr ou n d. P r oceed a s follows:
(1) Discon n ect a n d isola t e t h e a n t en n a coa xia l
ca ble con n ect or u n der t h e r igh t en d of t h e in st r u -
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el.
(2) Tou ch on e oh m m et er t est lea d t o t h e t ip of t h e
a n t en n a m a st . Tou ch t h e ot h er t est lea d t o t h e
a n t en n a ca p n u t . Ch eck t h e oh m m et er r ea din g for
con t in u it y.
(3) Th er e sh ou ld be n o con t in u it y. If OK, go t o Test
2. If n ot OK, r epla ce t h e fa u lt y a n t en n a body a n d
ca ble.
TEST 2
Test 2 ch ecks t h e a n t en n a con du ct or com pon en t s
for a n open cir cu it . Th is t est sh ou ld be per for m ed
fir st on t h e en t ir e a n t en n a cir cu it , fr om t h e a n t en n a
WJ
m a st t o t h e cen t er con du ct or of t h e coa xia l ca ble con -
n ect or a t t h e r a dio. If a n open cir cu it is det ect ed,
ea ch of t h e t h r ee a n t en n a con du ct or com pon en t s
(a n t en n a m a st , a n t en n a body a n d pr im a r y ca ble u n it ,
in st r u m en t pa n el a n t en n a secon da r y ca ble) sh ou ld be
isola t ed a n d t est ed in dividu a lly t o loca t e t h e exa ct
com pon en t t h a t is t h e sou r ce of t h e open cir cu it . To
begin t h is t est , pr oceed a s follows:
(1) Discon n ect t h e in st r u m en t pa n el (secon da r y)
a n t en n a ca ble coa xia l con n ect or fr om t h e ba ck of t h e
r a dio.
(2) Tou ch on e oh m m et er t est lea d t o t h e t ip of t h e
a n t en n a m a st . Tou ch t h e ot h er t est lea d t o t h e cen t er
con du ct or pin of t h e in st r u m en t pa n el a n t en n a ca ble
coa xia l con n ect or for t h e r a dio. Ch eck t h e oh m m et er
r ea din g for con t in u it y.
(3) Th er e sh ou ld be con t in u it y. Th e oh m m et er
sh ou ld r egist er on ly a fr a ct ion of a n oh m r esist a n ce.
H igh or in fin it e r esist a n ce in dica t es a da m a ged or
open a n t en n a con du ct or. If OK, go t o Test 3. If n ot
OK, isola t e a n d t est ea ch of t h e in dividu a l a n t en n a
con du ct or com pon en t s. Repla ce on ly t h e fa u lt y
a n t en n a con du ct or com pon en t .
TEST 3
Test 3 ch ecks t h e con dit ion of t h e veh icle body
gr ou n d con n ect ion . To begin t h is t est , pr oceed a s fol-
lows:
(1) Th is t est m u st be per for m ed wit h t h e ba t t er y
posit ive ca ble discon n ect ed fr om t h e ba t t er y. Discon -
n ect a n d isola t e bot h ba t t er y ca bles, n ega t ive ca ble
fir st .
(2) Recon n ect t h e ba t t er y n ega t ive ca ble.
(3) Tou ch on e oh m m et er t est lea d t o a good clea n
gr ou n d poin t on t h e veh icle fen der. Tou ch t h e ot h er
t est lea d t o t h e ba t t er y n ega t ive t er m in a l post . Ch eck
t h e oh m m et er r ea din g for con t in u it y.
(4) Th er e sh ou ld be con t in u it y. Th e oh m m et er
sh ou ld r egist er less t h a n on e oh m r esist a n ce. H igh or
in fin it e r esist a n ce in dica t es a loose, cor r oded, or
da m a ged con n ect ion bet ween t h e ba t t er y n ega t ive
t er m in a l a n d t h e veh icle body. If OK, go t o Test 4. If
n ot OK, ch eck t h e ba t t er y n ega t ive ca ble con n ect ion
t o t h e veh icle body a n d t h e r a dio n oise su ppr ession
gr ou n d st r a p con n ect ion s t o t h e en gin e a n d t h e veh i-
cle body for bein g loose or cor r oded. Clea n or t igh t en
t h ese con n ect ion s a s r equ ir ed.
TEST 4
Test 4 ch ecks t h e con dit ion of t h e con n ect ion
bet ween t h e a n t en n a coa xia l ca ble sh ield a n d t h e
veh icle body gr ou n d a s follows:
(1) Discon n ect a n d isola t e t h e a n t en n a coa xia l
ca ble con n ect or u n der t h e r igh t en d of t h e in st r u -
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el.
WJ AUDIO 8A - 9
AN T EN N A BODY & CABLE (Cont inue d)
(2) Tou ch on e oh m m et er t est lea d t o a good clea n
gr ou n d poin t on t h e veh icle fen der. Tou ch t h e ot h er
t est lea d t o t h e ou t er cr im p on t h e a n t en n a coa xia l
ca ble con n ect or u n der t h e r igh t en d of t h e in st r u -
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el.
Ch eck t h e oh m m et er r ea din g for con t in u it y.
(3) Th er e sh ou ld be con t in u it y. Th e oh m m et er
sh ou ld r egist er less t h a n on e oh m r esist a n ce. H igh or
in fin it e r esist a n ce in dica t es a loose, cor r oded, or
da m a ged con n ect ion bet ween t h e a n t en n a body a n d
t h e veh icle body or bet ween t h e a n t en n a body a n d
t h e a n t en n a coa xia l ca ble sh ield. If n ot OK, clea n t h e
a n t en n a body t o fen der m a t in g su r fa ces a n d t igh t en
t h e a n t en n a ca p n u t t o specifica t ion s.
(4) Ch eck t h e r esist a n ce a ga in wit h a n oh m m et er.
If t h e r esist a n ce is st ill m or e t h en on e oh m , r epla ce
t h e fa u lt y a n t en n a body a n d ca ble.

REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS Fig. 4 Antenna Base and Lead Remove/Install
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG 1 - BASE AND LEAD
SYSTEM. FAILURE TO TAKE THE PROPER PRE- 2 - ESCUTCHEON
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- 3 - MAST
BAG DEPLOYMENT AND POSSIBLE PERSONAL 4 - SHROUD
5 - CAP NUT
INJURY.
6 - RIGHT FRONT FENDER
7 - GROMMET
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
8 - CONNECTOR
ca ble.
(2) Rem ove t h e scu ff pla t e fr om t h e r igh t fr on t
door sill. (Refer t o 23 - BODY/INTE RIOR/DOOR (7) P u ll t h e a n t en n a lea d coa xia l ca ble a n d con n ec-
SILL SCUF F P LATE - RE MOVAL) for t h e pr oce- t or ou t of t h e pa ssen ger com pa r t m en t a n d in t o t h e
du r es. r igh t fr on t fen der wh eel h ou se t h r ou gh t h e h ole in
(3) Rem ove t h e t r im pa n el fr om t h e r igh t in n er t h e r igh t cowl side ou t er pa n el.
cowl side.(Refer t o 23 - BODY/INTE RIOR/COWL (8) Un scr ew t h e a n t en n a m a st fr om t h e a n t en n a
TRIM - RE MOVAL) for t h e pr ocedu r es. ba se (F ig. 5).
(4) Rea ch u n der t h e pa ssen ger side of t h e in st r u - (9) Rem ove t h e pla st ic sh r ou d fr om t h e a n t en n a
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el t o ba se ca p n u t .
discon n ect t h e a n t en n a coa xia l ca ble con n ect or by (10) Rem ove t h e a n t en n a ba se ca p n u t u sin g a n
pu llin g it a pa r t wh ile t wist in g t h e m et a l con n ect or a n t en n a n u t wr en ch (Specia l Tool C-4816) (F ig. 6).
h a lves (F ig. 4). Do n ot pu ll on t h e ca ble. (11) Rem ove t h e a n t en n a escu t ch eon fr om t h e
(5) Rem ove t h e lower r ea r h a lf of t h e in n er lin er a n t en n a ba se on t h e t op of t h e r igh t fr on t fen der.
fr om t h e r igh t fr on t fen der wh eel h ou se. (Refer t o 23 (12) Lower t h e a n t en n a ba se fr om t h e m ou n t in g
- BODY/E XTE RIOR/F RONT F E NDE R - RE MOVAL) h ole in t h e t op of t h e r igh t fr on t fen der.
for t h e pr ocedu r es. (13) Rem ove t h e a n t en n a ba se a n d lea d fr om t h e
(6) Rea ch t h r ou gh t h e r ea r of t h e r igh t fr on t r ea r of t h e r igh t fr on t fen der wh eel h ou se open in g.
fen der wh eel h ou se open in g t o a ccess a n d u n sea t t h e
a n t en n a lea d gr om m et fr om t h e h ole in t h e r igh t
cowl side ou t er pa n el.
8A - 10 AUDIO WJ
AN T EN N A BODY & CABLE (Cont inue d)

INSTALLATION
(1) P osit ion t h e a n t en n a ba se a n d lea d in t o t h e
r ea r of t h e r igh t fr on t fen der wh eel h ou se open in g.
(2) In ser t t h e a n t en n a ba se in t o t h e m ou n t in g h ole
in t h e t op of t h e r igh t fr on t fen der.
(3) In st a ll t h e a n t en n a escu t ch eon on t o t h e
a n t en n a ba se on t h e t op of t h e r igh t fr on t fen der.
(4) In st a ll a n d t igh t en t h e a n t en n a ba se ca p n u t
u sin g a n a n t en n a n u t wr en ch (Specia l Tool C-4816).
Tigh t en t h e ca p n u t t o 6.8 N·m (60 in . lbs.).
(5) In st a ll t h e pla st ic sh r ou d on t o t h e a n t en n a
ba se ca p n u t .
(6) In st a ll a n d t igh t en t h e a n t en n a m a st on t o t h e
Fig. 5 Antenna Mast Remove/Install - Typical a n t en n a ba se. Tigh t en t h e a n t en n a m a st t o 3.3 N·m
1 - ANTENNA MAST (30 in . lbs.).
2 - ADAPTER (7) Rea ch t h r ou gh t h e r ea r of t h e r igh t fr on t
3 - CAP NUT fen der wh eel h ou se open in g t o a ccess a n d in ser t t h e
a n t en n a lea d coa xia l ca ble a n d con n ect or in t o t h e
pa ssen ger com pa r t m en t t h r ou gh t h e h ole in t h e r igh t
cowl side ou t er pa n el.
(8) F r om t h e r igh t fr on t fen der wh eel h ou se, sea t
t h e a n t en n a lea d gr om m et in t o t h e h ole in t h e r igh t
cowl side ou t er pa n el.
(9) In st a ll t h e lower r ea r h a lf of t h e in n er lin er
in t o t h e r igh t fr on t fen der wh eel h ou se.
(10) Rea ch u n der t h e pa ssen ger side of t h e in st r u -
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el t o
r econ n ect t h e a n t en n a coa xia l ca ble con n ect or h a lves.
(11) In st a ll t h e t r im pa n el on t o t h e r igh t in n er
cowl side.
(12) In st a ll t h e scu ff pla t e on t o t h e r igh t fr on t door
sill.
(13) Recon n ect t h e ba t t er y n ega t ive ca ble.

Fig. 6 Antenna Base Cap Nut Remove/Install -

AN T EN N A M ODU LE - EX PORT
Typical
DESCRIPTION
1 - CAP NUT
Th e a n t en n a m odu le (F ig. 7) is a n elect r om a gn et ic
2 - ANTENNA ADAPTER
3 - TOOL
cir cu it com pon en t design ed t o ca pt u r e a n d en h a n ce
RF (Ra dio F r equ en cy) sign a ls in bot h t h e AM a n d
F M br oa dca st ba n ds. Th e a n t en n a m odu le is
m ou n t ed t o t h e r igh t r ea r r oof r a il u n der t h e h ea d-
lin er. Th e m odu les m ou n t in g br a cket s a lso dou ble a s
t h e gr ou n d cir cu it . Th e m odu le h a s a t wo wir e elec-
t r ica l con n ect or t h a t con n ect s t o t h e elect r ic ba cklit e
in t egr a l r a dio a n t en n a , loca t ed on t h e r igh t r ea r
qu a r t er gla ss, a con n ect or for t h e r a dio coa x ca ble
a n d a con n ect or for ba t t er y volt a ge.
WJ AUDIO 8A - 11
AN T EN N A M ODU LE - EX PORT (Cont inue d)

OPERATION
Th e a n t en n a m odu le r eceives bot h AM a n d F M
r a dio sign a ls su pplied by t h e side win dow in t egr a l
r a dio a n t en n a syst em a n d select ively a m plifies t h em
wh ile a t t h e sa m e t im e a voidin g u n u sa ble or
u n wa n t ed sign a ls. Th e a m plified sign a l is t h en sen t
t h r ou gh t h e body len gt h coa x ca ble t o t h e r a dio
in pu t .

Fig. 7 ANTENNA MODULE

1 - ANTENNA LEAD CONNECTOR
2 - ANTENNA MODULE
3 - ANTENNA MODULE MOUNT/GROUND BRACKETS
4 - BATTERY SUPPLY CONNECTION POINT
5 - COAX CONNECTION POINT

DIAGNOSIS AND TESTING - ANTENNA MODULE - EXPORT

AN T EN N A M ODU LE DI AGN OSI S TABLE

CONDITION POSSIBLE CAUSES CORRECTION

NO AM RECEPTION, 1. Antenna module to antenna 1. Repair open, reconnect
WEAK FM RECEPTION connector open or disconnected. antenna module connector to
glass mounted antenna.
2. Coax open or disconnected. 2. Repair open, reconnect coax.
3. No battery power at antenna 3. Check fuse. if okay, repair
module. open in battery voltage circuit.
NO AM OR FM 1. Coax disconnected at radio. 1. Reconnect coax.
RECEPTION
2. Coax shorted to ground. 2. Repair or Replace coax
WEAK OR NO AM/FM 1. Antenna Module faulty. 1. Substitute known good
RECEPTION module. If reception improves,
Antenna Module was faulty.
8A - 12 AUDIO WJ
AN T EN N A M ODU LE - EX PORT (Cont inue d)

REMOVAL
(1) Rem ove t h e h ea dlin er. (Refer t o 23 - BODY/IN-
TE RIOR/H E ADLINE R - RE MOVAL)
(2) Discon n ect t h e ba t t er y power lea d con n ect or
fr om t h e a n t en n a m odu le.
(3) Discon n ect t h e a n t en n a m odu le con n ect or fr om
t h e in t egr a l a n t en n a (F ig. 8).
(4) Rem ove t h e m ou n t in g scr ews a n d t h e a n t en n a
m odu le.
(5) Discon n ect t h e coa x lea d fr om t h e a n t en n a
m odu le.
INSTALLATION
(1) P lu g coa x in t o a n t en n a m odu le.
(2) P osit ion a n t en n a m odu le on t o r igh t side u pper
r oof r a il a n d in st a ll scr ews. Tigh t en t h e scr ews t o 8
N·m (71 in . lbs.).
(3) Con n ect a n t en n a m odu le lea d t o t h e in t egr a l
a n t en n a .
(4) Con n ect ba t t er y power su pply lea d t o a n t en n a
m odu le.
(5) In st a ll h ea dlin er. (Refer t o 23 - BODY/INTE RI-
OR/H E ADLINE R - INSTALLATION)
CD CH AN GER
DESCRIPTION
A fa ct or y-in st a lled Com pa ct Disc (CD) ch a n ger fea -
t u r in g a t en -CD m a ga zin e is a n a va ila ble opt ion on
t h is m odel wh en it is a lso equ ipped wit h t h e pr e-
m iu m spea ker pa cka ge a n d a r a dio r eceiver in clu din g
t h e CD con t r ols fea t u r e. Th e CD ch a n ger is m ou n t ed
in t h e ca r go a r ea of t h e pa ssen ger com pa r t m en t on
t h e r igh t r ea r qu a r t er pa n el.
Th e CD ch a n ger is con n ect ed t o a t a ke ou t fr om
t h e r igh t body wir e h a r n ess a n d r eceives bot h gr ou n d
a n d r a dio-swit ch ed ba t t er y cu r r en t t h r ou gh t h e r a dio
r eceiver. Th e con t r ols on t h e r a dio r eceiver oper a t e
t h e CD ch a n ger t h r ou gh m essa ges sen t over t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s
n et wor k. Th e t wo-ch a n n el a u dio ou t pu t s of t h e CD
ch a n ger a r e h a r d wir ed ba ck t o t h e r a dio r eceiver,
wh ich t h en ou t pu t s t h e sign a l t h r ou gh fou r ch a n n els
t o t h e power a m plifier. F or dia gn osis of t h e m essa g-
in g fu n ct ion s of t h e r a dio r eceiver a n d t h e CD
ch a n ger, or of t h e P CI da t a bu s, a DRB sca n t ool a n d
t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l a r e
r equ ir ed.

Fig. 8 ANTENNA MODULE

1 - COAX 4 - ANTENNA MODULE TO ANTENNA CONNECTOR
2 - RIGHT SIDE ROOF RAIL 5 - SCREW (2)
3 - ANTENNA MODULE
WJ
CD CH AN GER (Cont inue d)
Th e CD ch a n ger ca n on ly be ser viced by a n a u t h o-
r ized r a dio r epa ir st a t ion . See t h e la t est Wa r r a n t y
P olicies a n d P r ocedu r es m a n u a l for a cu r r en t list in g
of a u t h or ized r a dio r epa ir st a t ion s.
OPERATION
Th e CD ch a n ger will on ly oper a t e wh en t h e ign i-
t ion swit ch is in t h e On or Accessor y posit ion s, a n d
t h e r a dio is t u r n ed on . F or m or e in for m a t ion on t h e
fea t u r es, loa din g pr ocedu r es a n d r a dio con t r ol fu n c-
t ion s for t h e oper a t ion of t h e CD ch a n ger, see t h e
own er ’s m a n u a l in t h e veh icle glove box.
DIAGNOSIS AND TESTING - CD CHANGER
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
h a r d wir ed com pon en t s a n d cir cu it s of t h e Com pa ct
Disc (CD) ch a n ger u n it . H owever, t h ese t est s m a y n ot
pr ove con clu sive in t h e dia gn osis of t h is u n it . In
or der t o obt a in con clu sive t est in g of t h e CD ch a n ger
u n it , t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k, t h e CD ch a n ger u n it , t h e
r a dio r eceiver u n it a n d a n y ot h er elect r on ic m odu les
t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om t h e
a u dio syst em m u st be ch ecked.
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
Ma n u a l.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
COMPACT DISC CHANGER INOPERATIVE
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r a dio r eceiver on a n d ch eck it s oper a t ion . If
OK, go t o St ep 2. If n ot OK, (Refer t o 8 - E LE CTRI-
CAL/AUDIO/RADIO - OP E RATION).
AUDIO 8A - 13
(2) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Discon n ect t h e r igh t body wir e h a r n ess con n ect or
fr om t h e CD ch a n ger con n ect or r ecept a cle. Ch eck for
con t in u it y bet ween t h e power gr ou n d (Z17) cir cu it of
t h e r igh t body wir e h a r n ess con n ect or for t h e CD
ch a n ger a n d a good gr ou n d. Th er e sh ou ld be con t in u -
it y. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open
power gr ou n d cir cu it t o t h e r a dio r eceiver a s
r equ ir ed.
(3) Recon n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e B(+) cir cu it ca vit y of t h e r igh t
body wir e h a r n ess con n ect or for t h e CD ch a n ger. If
OK, go t o St ep 4. If n ot OK, go t o St ep 5.
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e ign it ion swit ch ou t -
pu t cir cu it ca vit y of t h e r igh t body wir e h a r n ess con -
n ect or for t h e CD ch a n ger. If OK, u se a DRB sca n
t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l for
fu r t h er dia gn osis. If n ot OK, go t o St ep 6.
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e r a dio r eceiver fr om t h e in st r u m en t
pa n el. Discon n ect t h e 10 pin ca ble con n ect or fr om t h e
r a dio r eceiver, bu t do n ot discon n ect t h e ot h er wir e
h a r n ess con n ect or s. Recon n ect t h e ba t t er y n ega t ive
ca ble. Ch eck for ba t t er y volt a ge a t t h e B(+) cir cu it
ca vit y of t h e 10 pin con n ect or r ecept a cle on t h e r a dio
r eceiver. If OK, r epa ir t h e open B(+) cir cu it t o t h e CD
ch a n ger a s r equ ir ed. If n ot OK, ch eck for a sh or t ed
B(+) cir cu it t o t h e CD ch a n ger a n d r epa ir a s
r equ ir ed, t h en r epla ce t h e fa u lt y r a dio r eceiver.
(6) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Rem ove t h e r a dio r eceiver fr om t h e in st r u m en t
pa n el. Discon n ect t h e 10 pin ca ble con n ect or fr om t h e
r a dio r eceiver, bu t do n ot discon n ect t h e ot h er wir e
h a r n ess con n ect or s. Recon n ect t h e ba t t er y n ega t ive
ca ble. Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e ign it ion swit ch ou t -
pu t cir cu it ca vit y of t h e 10 pin con n ect or r ecept a cle
on t h e r a dio r eceiver. If OK, r epa ir t h e open ign it ion
swit ch ou t pu t cir cu it t o t h e CD ch a n ger a s r equ ir ed.
If n ot OK, ch eck for a sh or t ed ign it ion swit ch ou t pu t
cir cu it t o t h e CD ch a n ger a n d r epa ir a s r equ ir ed,
t h en r epla ce t h e fa u lt y r a dio r eceiver.
NO SOUND OR ONLY ONE CHANNEL SOUND
FROM CD CHANGER
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r a dio r eceiver on a n d ch eck it s a u dio ou t pu t
oper a t ion . If OK, go t o St ep 2. If n ot OK, (Refer t o 8
- E LE CTRICAL/AUDIO/SP E AKE R - OP E RATION).
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e r igh t body wir e h a r n ess con n ec-
t or fr om t h e CD ch a n ger con n ect or r ecept a cle.
Rem ove t h e r a dio r eceiver fr om t h e in st r u m en t
8A - 14 AUDIO WJ
CD CH AN GER (Cont inue d)
pa n el. Discon n ect t h e 10 pin ca ble con n ect or fr om t h e
r a dio r eceiver. Ch eck for con t in u it y bet ween t h e
a u dio gr ou n d (Z4) cir cu it ca vit y of t h e r igh t body
wir e h a r n ess con n ect or for t h e CD ch a n ger a n d a
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go
t o St ep 3. If n ot OK, r epa ir t h e sh or t ed a u dio gr ou n d
(Z4) cir cu it a s r equ ir ed.
(3) Ch eck for con t in u it y bet ween t h e a u dio gr ou n d
(Z4) cir cu it ca vit y of t h e r igh t body wir e h a r n ess con -
n ect or for t h e CD ch a n ger a n d t h e a u dio gr ou n d (Z4)
cir cu it pin of t h e 10 pin ca ble con n ect or for t h e r a dio
r eceiver. Th er e sh ou ld be con t in u it y. If OK, go t o
St ep 4. If n ot OK, r epa ir t h e open a u dio gr ou n d (Z4)
cir cu it a s r equ ir ed.
(4) Ch eck for con t in u it y bet ween t h e a u dio ou t
r igh t cir cu it ca vit y of t h e r igh t body wir e h a r n ess Fig. 9 Compact Disc Changer Storage Bin Remove/
con n ect or for t h e CD ch a n ger a n d a good gr ou n d. Install
Th er e sh ou ld be n o con t in u it y. If OK, go t o St ep 5. If 1 - RIGHT SIDE QUARTER TRIM PANEL
n ot OK, r epa ir t h e sh or t ed a u dio ou t r igh t cir cu it a s 2 - LID
r equ ir ed. 3 - LATCH
(5) Ch eck for con t in u it y bet ween t h e a u dio ou t 4 - SCREW (2)
5 - CD CHANGER STORAGE BIN
r igh t cir cu it ca vit y of t h e r igh t body wir e h a r n ess
con n ect or for t h e CD ch a n ger a n d t h e a u dio ou t r igh t
cir cu it pin of t h e 10 pin ca ble con n ect or for t h e r a dio
r eceiver. Th er e sh ou ld be con t in u it y. If OK, go t o
St ep 6. If n ot OK, r epa ir t h e open a u dio ou t r igh t cir-
cu it a s r equ ir ed.
(6) Ch eck for con t in u it y bet ween t h e a u dio ou t left
cir cu it ca vit y of t h e r igh t body wir e h a r n ess con n ec-
t or for t h e CD ch a n ger a n d a good gr ou n d. Th er e
sh ou ld be n o con t in u it y. If OK, go t o St ep 7. If n ot
OK, r epa ir t h e sh or t ed a u dio ou t left cir cu it a s
r equ ir ed.
(7) Ch eck for con t in u it y bet ween t h e a u dio ou t left
cir cu it ca vit y of t h e r igh t body wir e h a r n ess con n ec-
t or for t h e CD ch a n ger a n d t h e a u dio ou t left cir cu it
pin of t h e 10 pin ca ble con n ect or for t h e r a dio
r eceiver. Th er e sh ou ld be con t in u it y. If OK, r epla ce
t h e fa u lt y CD ch a n ger. If n ot OK, r epa ir t h e open
a u dio ou t left cir cu it a s r equ ir ed.

REMOVAL Fig. 10 Compact Disc Changer Remove/Install

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive 1 - RIGHT SIDE QUARTER INNER PANEL
ca ble. 2 - RIGHT SIDE QUARTER TRIM PANEL
(2) Relea se t h e la t ch a n d open t h e lid of t h e com - 3 - COMPACT DISC CHANGER
pa ct disc ch a n ger st or a ge bin on t h e r igh t side qu a r- 4 - NUT (4)
t er t r im pa n el (F ig. 9). 5 - RIGHT BODY WIRE HARNESS
(3) Rem ove t h e t wo m ou n t in g scr ews. 6 - STUD (4)
(4) Gr a sp t h e bot t om of t h e com pa ct disc ch a n ger
st or a ge bin fir m ly wit h bot h h a n ds a n d lift it (8) Rem ove t h e com pa ct disc ch a n ger fr om t h e
u pwa r ds. r igh t side qu a r t er in n er pa n el.
(5) Rem ove t h e com pa ct disc ch a n ger st or a ge bin
fr om t h e r igh t side qu a r t er t r im pa n el. INSTALLATION
(6) Discon n ect t h e r igh t body wir e h a r n ess con n ec- (1) P osit ion t h e com pa ct disc ch a n ger on t o t h e fou r
t or fr om com pa ct disc ch a n ger (F ig. 10). st u ds.
(7) Rem ove t h e fou r m ou n t in g n u t s.
WJ
CD CH AN GER (Cont inue d)
(2) In st a ll t h e fou r m ou n t in g n u t s. Tigh t en t h e
n u t s t o 12 N·m (105 in . lbs.).
(3) Recon n ect t h e r igh t body wir e h a r n ess con n ec-
t or.
(4) P osit ion t h e com pa ct disc ch a n ger st or a ge bin
on t o t h e r igh t side qu a r t er t r im pa n el.
(5) Usin g bot h h a n ds pu sh t h e com pa ct disc
ch a n ger st or a ge bin fir m ly a n d even ly t owa r d t h e
r igh t side qu a r t er t r im pa n el fa r en ou gh t o en ga ge
t h e h ooks on t h e bin wit h t h e slot s in t h e pa n el.
(6) Usin g bot h h a n ds pu sh t h e com pa ct disc
ch a n ger st or a ge bin fir m ly a n d even ly down wa r d fa r
en ou gh t o a lign t h e scr ew h oles in t h e bin wit h t h e
m ou n t in g h oles in t h e r igh t side qu a r t er t r im pa n el.
(7) In st a ll t h e t wo scr ews t h a t secu r e t h e t op of
t h e com pa ct disc ch a n ger st or a ge bin . Tigh t en t h e
scr ews t o 1.7 N·m (15 in . lbs.).
(8) Recon n ect t h e ba t t er y n ega t ive ca ble.
I N ST RU M EN T PAN EL
AN T EN N A CABLE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e scu ff pla t e fr om t h e r igh t fr on t
door sill. (Refer t o 23 - BODY/INTE RIOR/DOOR
SILL SCUF F P LATE - RE MOVAL) for t h e pr oce-
du r es.
(3) Rem ove t h e t r im pa n el fr om t h e r igh t in n er
cowl side. (Refer t o 23 - BODY/INTE RIOR/COWL
TRIM - RE MOVAL) for t h e pr ocedu r es.
(4) Rea ch u n der t h e pa ssen ger side of t h e in st r u -
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el t o
discon n ect t h e a n t en n a coa xia l ca ble con n ect or by
pu llin g it a pa r t wh ile t wist in g t h e m et a l con n ect or
h a lves. Do n ot pu ll on t h e ca ble.
(5) Disen ga ge t h e a n t en n a ca ble r et a in er fr om t h e
m ou n t in g h ole in t h e wir e h a r n ess m ou n t in g t a b
u n der t h e pa ssen ger side en d of t h e in st r u m en t
pa n el.
(6) Rem ove t h e r a dio r eceiver fr om t h e in st r u m en t
pa n el. (Refer t o 8 - E LE CTRICAL/AUDIO/RADIO -
RE MOVAL) for t h e pr ocedu r es.
AUDIO 8A - 15
(7) Rem ove t h e pa ssen ger side a ir ba g m odu le fr om
t h e in st r u m en t pa n el. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS/PASSE NGE R AIRBAG - RE MOVAL)
for t h e pr ocedu r es.
(8) Disen ga ge t h e a n t en n a ca ble r et a in er fr om t h e
m ou n t in g h ole in t h e t op of t h e r a dio m ou n t on t h e
in st r u m en t pa n el st r u ct u r a l du ct (F ig. 11).
Fig. 11 Instrument Panel Antenna Cable Routing
1 - INSTRUMENT PANEL STRUCTURAL DUCT
2 - RETAINER
3 - COAXIAL CABLE
4 - COAXIAL CABLE CONNECTORS
(9) Disen ga ge t h e a n t en n a ca ble fr om t h e loca t or
t a bs on t h e t op of t h e in st r u m en t pa n el st r u ct u r a l
du ct a bove t h e glove box open in g.
(10) Rem ove t h e a n t en n a ca ble fr om t h e in st r u -
m en t pa n el.
INSTALLATION
(1) P osit ion t h e a n t en n a ca ble on t o t h e in st r u m en t
pa n el.
(2) E n ga ge t h e a n t en n a ca ble wit h t h e loca t or t a bs
on t h e t op of t h e in st r u m en t pa n el st r u ct u r a l du ct
a bove t h e glove box open in g.
(3) E n ga ge t h e a n t en n a ca ble r et a in er in t o t h e
m ou n t in g h ole in t h e t op of t h e r a dio m ou n t on t h e
in st r u m en t pa n el st r u ct u r a l du ct .
(4) In st a ll t h e pa ssen ger side a ir ba g m odu le on t o
t h e in st r u m en t pa n el. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS/PASSE NGE R AIRBAG - INSTALLA-
TION) for t h e pr ocedu r es.
(5) In st a ll t h e r a dio r eceiver on t o t h e in st r u m en t
pa n el. (Refer t o 8 - E LE CTRICAL/AUDIO/RADIO -
INSTALLATION) for t h e pr ocedu r es.
(6) E n ga ge t h e a n t en n a ca ble r et a in er in t o t h e
m ou n t in g h ole in t h e wir e h a r n ess m ou n t in g t a b
u n der t h e pa ssen ger side en d of t h e in st r u m en t
pa n el.
8A - 16 AUDIO
I N ST RU M EN T PAN EL AN T EN N A CABLE (Cont inue d)
(7) Rea ch u n der t h e pa ssen ger side of t h e in st r u -
m en t pa n el n ea r t h e r igh t cowl side in n er pa n el t o
r econ n ect t h e a n t en n a coa xia l ca ble con n ect or h a lves.
(8) In st a ll t h e t r im pa n el on t o t h e r igh t in n er cowl
side. (Refer t o 23 - BODY/INTE RIOR/COWL TRIM -
INSTALLATION) for t h e pr ocedu r es.
(9) In st a ll t h e scu ff pla t e on t o t h e r igh t fr on t door
sill. (Refer t o 23 - BODY/INTE RIOR/DOOR SILL
SCUF F P LATE - INSTALLATION) for t h e pr oce-
du r es.
(10) Recon n ect t h e ba t t er y n ega t ive ca ble.
QU ART ER GLASS I N T EGRAL
AN T EN N A - EX PORT
DESCRIPTION
Th e in t egr a l r a dio a n t en n a elem en t is bon ded t o
t h e r igh t r ea r qu a r t er gla ss a n d is r epla ced wit h t h e
gla ss a ssem bly on ly.
OPERATION
Th e in t egr a l a n t en n a r eceives RF (Ra dio F r equ en -
cies) a n d sen ds t h em t o t h e a n t en n a m odu le for
a m plifica t ion .
DIAGNOSIS AND TESTING - QUARTER GLASS
INTEGRAL ANTENNA - EXPORT
F or com plet e cir cu it dia gr a m s, r efer t o t h e Appr o-
pr ia t e Wir in g In for m a t ion . To det ect br ea ks in t h e
in t egr a l a n t en n a elem en t s, t h e followin g pr ocedu r e is
r equ ir ed:
(1) Discon n ect t h e a n t en n a m odu le con n ect or fr om
t h e a n t en n a .
(2) Usin g a Oh m m et er, pla ce bot h lea ds on t o t h e
con n ect or pin s on t h e in t egr a l a n t en n a . If con t in u it y
is pr esen t a n t en n a gr id is Oka y. If con t in u it y is n ot
pr esen t m ove on e lea d t h r ou gh t h e gr id in pr ogr es-
sion u n t il con t in u it y is det ect ed. A br ea k in t h e
a n t en n a gr id ca n be r epa ir ed u sin g a Mopa r Rea r
Win dow Defogger Repa ir Kit (P a r t Nu m ber 4267922)
or equ iva len t . (Refer t o 8 - E LE CTRICAL/WINDOW
DE F OGGE R/RE AR WINDOW DE F OGGE R GRID -
STANDARD P ROCE DURE )
RADI O
DESCRIPTION
Ava ila ble fa ct or y-in st a lled r a dio r eceiver s for t h is
m odel in clu de a n AM/F M/ca sset t e wit h CD ch a n ger
con t r ol fea t u r e (RBB sa les code), a n AM/F M/CD/2-
ba n d gr a ph ic equ a lizer wit h CD ch a n ger con t r ol fea -
t u r e (RBK sa les code), or a n AM/F M/CD/ca sset t e/2-
ba n d gr a ph ic equ a lizer (RBP sa les code). All fa ct or y-
in st a lled r a dio r eceiver s ca n com m u n ica t e on t h e
WJ
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s n et wor k t h r ou gh a sepa r a t e wir e h a r n ess con n ec-
t or. All fa ct or y-in st a lled r eceiver s a r e st er eo E lect r on -
ica lly Tu n ed Ra dios (E TR) a n d in clu de a n elect r on ic
digit a l clock fu n ct ion .
Th ese r a dio r eceiver s ca n on ly be ser viced by a n
a u t h or ized r a dio r epa ir st a t ion . See t h e la t est Wa r-
r a n t y P olicies a n d P r ocedu r es m a n u a l for a cu r r en t
list in g of a u t h or ized r a dio r epa ir st a t ion s.
All veh icles a r e equ ipped wit h a n Ign it ion -Off
Dr a w (IOD) fu se t h a t is r em oved wh en t h e veh icle is
sh ipped fr om t h e fa ct or y. Th is fu se feeds va r iou s
a ccessor ies t h a t r equ ir e ba t t er y cu r r en t wh en t h e
ign it ion swit ch is in t h e Off posit ion , in clu din g t h e
clock. Th e IOD fu se is r em oved t o pr even t ba t t er y
disch a r ge du r in g veh icle st or a ge.
Wh en r em ovin g or in st a llin g t h e IOD fu se, it is
im por t a n t t h a t t h e ign it ion swit ch be in t h e Off posi-
t ion . F a ilu r e t o pla ce t h e ign it ion swit ch in t h e Off
posit ion ca n ca u se t h e r a dio displa y t o becom e scr a m -
bled wh en t h e IOD fu se is r em oved a n d r epla ced.
Rem ovin g a n d r epla cin g t h e IOD fu se a ga in , wit h t h e
ign it ion swit ch in t h e Off posit ion , will cor r ect t h e
scr a m bled displa y con dit ion .
Th e IOD fu se sh ou ld be ch ecked if t h e r a dio or
clock displa ys a r e in oper a t ive. Th e IOD fu se is
loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC).
Refer t o t h e fu se la you t la bel on t h e u n der side of t h e
P DC cover for IOD fu se iden t ifica t ion a n d loca t ion .
OPERATION
Th e r a dio r eceiver oper a t es on ign it ion swit ch ed
ba t t er y cu r r en t t h a t is a va ila ble on ly wh en t h e ign i-
t ion swit ch is in t h e On or Accessor y posit ion s. Th e
elect r on ic digit a l clock fu n ct ion of t h e r a dio oper a t es
on fu sed ba t t er y cu r r en t su pplied t h r ou gh t h e IOD
fu se, r ega r dless of t h e ign it ion swit ch posit ion .
F or m or e in for m a t ion on t h e fea t u r es, set t in g pr o-
cedu r es, a n d con t r ol fu n ct ion s for ea ch of t h e a va il-
a ble fa ct or y-in st a lled r a dio r eceiver s, r efer t o t h e
own er ’s m a n u a l. F or com plet e cir cu it dia gr a m s, r efer
t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g
in for m a t ion in clu des wir in g dia gr a m s, pr oper wir e
a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r-
n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t in for-
m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
DIAGNOSIS AND TESTING - RADIO
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
Ma n u a l.
If t h e veh icle is equ ipped wit h t h e opt ion a l r em ot e
r a dio swit ch es loca t ed on t h e st eer in g wh eel a n d t h e
WJ
RADI O (Cont inue d)
pr oblem bein g dia gn osed is r ela t ed t o on e of t h e
sym pt om s list ed below, be cer t a in t o ch eck t h e
r em ot e r a dio swit ch es a n d cir cu it s. (Refer t o 8 -
E LE CTRICAL/AUDIO/RE MOTE SWITCH E S - t o St ep 5. If n ot OK, r epa ir t h e open fu sed ign it ion
OP E RATION).
• St a t ion s ch a n gin g wit h n o r em ot e r a dio swit ch
in pu t
• Ra dio m em or y pr eset s n ot wor kin g pr oper ly
• Volu m e ch a n ges wit h n o r em ot e r a dio swit ch
in pu t
• Rem ot e r a dio swit ch bu t t on s t a kin g on ot h er
fu n ct ion s
• CD pla yer skippin g t r a cks
• Mode (AM, F M, CD, CD ch a n ger ) ch a n ges wit h
n o r em ot e r a dio swit ch in pu t
• Rem ot e r a dio swit ch in oper a t ive.
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio receiver
is a “floating ground” system. Do not allow any
speaker lead to short to ground, as damage to the
radio receiver may result.
(1) Ch eck t h e fu sed B(+) fu se in t h e ju n ct ion block.
If OK, go t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir-
cu it or com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y
fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e ju n ct ion block. If OK, go t o St ep 3. If n ot OK,
r epa ir t h e open fu sed B(+) cir cu it t o t h e P ower Dis-
t r ibu t ion Cen t er (P DC) fu se a s r equ ir ed.
(3) Ch eck t h e fu sed ign it ion swit ch ou t pu t (a cc/
r u n ) fu se in t h e ju n ct ion block. If OK, go t o St ep 4. If
n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se(s).
AUDIO 8A - 17
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (a cc/r u n ) fu se in t h e ju n ct ion block. If OK, go
swit ch ou t pu t (a cc/r u n ) cir cu it t o t h e ign it ion swit ch
a s r equ ir ed.
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Rem ove t h e r a dio r eceiver fr om t h e in st r u m en t
pa n el, bu t do n ot discon n ect t h e wir e h a r n ess con n ec-
t or s. Ch eck for con t in u it y bet ween t h e r a dio r eceiver
ch a ssis a n d a good gr ou n d. Th er e sh ou ld be con t in u -
it y. If OK, go t o St ep 6. If n ot OK, r epa ir t h e open
gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(6) Test t h e r a dio r eceiver a n t en n a . (Refer t o 8 -
E LE CTRICAL/AUDIO/ANTE NNA BODY & CABLE -
DIAGNOSIS AND TE STING). If OK, go t o St ep 7. If
n ot OK, r epla ce t h e fa u lt y a n t en n a or coa xia l ca ble
a s r equ ir ed.
(7) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y
volt a ge a t t h e fu sed ign it ion swit ch ou t pu t (a cc/r u n )
cir cu it ca vit y of t h e 22 pin r a dio wir e h a r n ess con n ec-
t or. If OK, go t o St ep 8. If n ot OK, r epa ir t h e open
fu sed ign it ion swit ch ou t pu t (a cc/r u n ) cir cu it t o t h e
ju n ct ion block fu se a s r equ ir ed.
(8) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) cir cu it
ca vit y of t h e 22 pin r a dio wir e h a r n ess con n ect or. If
OK, r epla ce t h e fa u lt y r a dio r eceiver. If n ot OK,
r epa ir t h e open fu sed B(+) cir cu it t o t h e ju n ct ion
block fu se a s r equ ir ed.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e cen t er u pper bezel fr om t h e in st r u -
m en t pa n el.(Refer t o 23 - BODY/INSTRUME NT
PANE L - RE MOVAL).
(3) Rem ove t h e fou r scr ews t h a t secu r e t h e r a dio
r eceiver t o t h e in st r u m en t pa n el (F ig. 12).
8A - 18 AUDIO WJ
RADI O (Cont inue d)
(4) In st a ll t h e cen t er u pper bezel on t o t h e in st r u -
m en t pa n el. (Refer t o 23 - BODY/INSTRUME NT
PANE L - INSTALLATION) for t h e pr ocedu r es.
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.

RADI O N OI SE SU PPRESSI ON
GROU N D ST RAP
DESCRIPTION
Ra dio F r equ en cy In t er fer en ce (RF I) a n d E lect r o-
Ma gn et ic In t er fer en ce (E MI) n oise su ppr ession is
a ccom plish ed pr im a r ily t h r ou gh cir cu it r y in t er n a l t o
t h e r a dio r eceiver s. Th ese in t er n a l su ppr ession
devices a r e on ly ser viced a s pa r t of t h e r a dio r eceiver.
E xt er n a l su ppr ession devices t h a t a r e u sed on t h is
veh icle t o con t r ol RF I or E MI n oise in clu de t h e fol-
lowin g:
Fig. 12 Radio Remove/Install • Ra dio a n t en n a ba se gr ou n d
• Ra dio r eceiver ch a ssis gr ou n d wir e or st r a p
1 - INSTRUMENT PANEL
• E n gin e-t o-body gr ou n d st r a p(s)
2 - SCREW (4)
3 - RADIO RECEIVER
• E xh a u st syst em -t o-body and t r a n sm ission
gr ou n d st r a p (4.7L en gin es on ly)
• Resist or-t ype spa r k plu gs
(4) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess • Ra dio su ppr ession -t ype secon da r y ign it ion wir-
con n ect or s a n d t h e a n t en n a coa xia l ca ble con n ect or in g.
fr om t h e r ecept a cles on t h e r ea r of t h e r a dio r eceiver. F or m or e in for m a t ion on t h e spa r k plu gs a n d sec-
(5) Rem ove t h e r a dio r eceiver fr om t h e in st r u m en t on da r y ign it ion com pon en t s, r efer t o Ign it ion Syst em
pa n el. in Ign it ion Syst em .

INSTALLATION
REM OVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL, REMOVAL - ENGINE-TO-BODY GROUND
STEERING COLUMN, SEAT BELT TENSIONER, SIDE STRAP
AIRBAG, OR INSTRUMENT PANEL COMPONENT
(1) Rem ove t h e scr ew t h a t secu r es t h e en gin e-t o-
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
body gr ou n d st r a p eyelet t o t h e lower plen u m pa n el
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
(F ig. 13) or (F ig. 14).
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
(2) On m odels wit h a 4.0L en gin e, r em ove t h e n u t
TEM CAPACITOR TO DISCHARGE BEFORE PER-
t h a t secu r es t h e en gin e-t o-body gr ou n d st r a p eyelet
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
t o t h e st u d on t h e r igh t r ea r side of t h e en gin e cyl-
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
in der h ea d.
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
(3) On m odels wit h a 4.7L en gin e, r em ove t h e t wo
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
n u t s t h a t secu r e t h e en gin e-t o-body gr ou n d st r a p eye-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
let s t o t h e st u ds on t h e r igh t a n d left r ea r sides of
INJURY.
t h e en gin e in t a ke m a n ifold.
(1) P osit ion t h e r a dio r eceiver t o t h e in st r u m en t (4) Rem ove t h e en gin e-t o-body gr ou n d st r a p eye-
pa n el. let (s) fr om t h e st u d(s) on t h e en gin e.
(2) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess (5) Rem ove t h e en gin e-t o-body gr ou n d st r a p fr om
con n ect or s a n d t h e a n t en n a coa xia l ca ble con n ect or t h e en gin e com pa r t m en t .
t o t h e r ecept a cles on t h e r ea r of t h e r a dio r eceiver.
(3) In st a ll t h e fou r m ou n t in g scr ews. Tigh t en t h e
scr ews t o 2.2 N·m (20 in . lbs.).
WJ AUDIO 8A - 19
RADI O N OI SE SU PPRESSI ON GROU N D ST RAP (Cont inue d)

Fig. 13 Engine-To-Body Ground Strap Remove/ Fig. 14 Engine-To-Body Ground Strap Remove/
Install - 4.0L Engine Install - 4.7L Engine
1 - SCREW 1 - GROUND STRAP
2 - LOWER PLENUM PANEL 2 - SCREW
3 - ENGINE 3 - ENGINE
4 - STUD 4 - STUD (2)
5 - NUT 5 - NUT (2)
6 - GROUND STRAP 6 - LOWER PLENUM PANEL

REMOVAL - EXHAUST-TO-BODY GROUND (5) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e

STRAP
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove fa st en er s fr om exh a u st , cr ossm em ber
a n d t r a n sm ission /t r a n sfer ca se.
(3) Rem ove t h e gr ou n d st r a p.
I N STALLAT I ON
INSTALLATION - ENGINE TO BODY GROUND
STRAP
(1) P osit ion t h e en gin e-t o-body gr ou n d st r a p in t o
t h e en gin e com pa r t m en t .
(2) In st a ll t h e en gin e-t o-body gr ou n d st r a p eye-
let (s) on t o t h e st u d(s) on t h e en gin e.
(3) On m odels wit h a 4.0L en gin e, in st a ll a n d
t igh t en t h e n u t t h a t secu r es t h e en gin e-t o-body
gr ou n d st r a p eyelet t o t h e st u d on t h e r igh t r ea r side
of t h e en gin e cylin der h ea d. Tigh t en t h e n u t t o 5.6
N·m (50 in . lbs.).
(4) On m odels wit h a 4.7L en gin e, in st a ll a n d
t igh t en t h e t wo n u t s t h a t secu r e t h e en gin e-t o-body
gr ou n d st r a p eyelet s t o t h e st u ds on t h e r igh t a n d
left r ea r sides of t h e en gin e in t a ke m a n ifold. Tigh t en
t h e n u t s t o 11.3 N·m (100 in . lbs.).
en gin e-t o-body gr ou n d st r a p eyelet t o t h e lower ple-
n u m pa n el. Tigh t en t h e scr ew t o 4.5 N·m (40 in . lbs.).
INSTALLATION - EXHAUST-TO-BODY GROUND
STRAP
(1) In st a ll t h e gr ou n d st r a p t o t h e exh a u st , cr oss-
m em ber a n d t r a n sm ission /t r a n sfer ca se.
(2) In st a ll t h e fa st en er s.
(3) Lower t h e veh icle.
REM OT E SWI T CH ES
DESCRIPTION
Rem ot e r a dio con t r ol swit ch es a r e in clu ded on
m odels equ ipped wit h t h e opt ion a l lea t h er-wr a pped
st eer in g wh eel. Th e t wo r ocker-t ype swit ch u n it s
(F ig. 15) a r e m ou n t ed in t h e u pper spoke cover s of
t h e r ea r (in st r u m en t pa n el side) st eer in g wh eel t r im
cover. Th e swit ch u n it on t h e left side is t h e seek
swit ch a n d h a s seek u p, seek down , a n d pr eset st a -
t ion a dva n ce swit ch fu n ct ion s. Th e swit ch u n it on t h e
r igh t side is t h e volu m e con t r ol swit ch a n d h a s vol-
u m e u p, volu m e down , a n d m ode a dva n ce swit ch
fu n ct ion s.
8A - 20 AUDIO
REM OT E SWI T CH ES (Cont inue d)
Fig. 15 Remote Radio Switches
1 - PRESET ADVANCE
2 - SEEK
3 - MODE ADVANCE
4 - VOLUME
Th e t wo r em ot e r a dio swit ch u n it s sh a r e a com m on
st eer in g wh eel wir e h a r n ess wit h t h e veh icle speed
con t r ol swit ch es. Th e st eer in g wh eel wir e h a r n ess is
con n ect ed t o t h e in st r u m en t pa n el wir e h a r n ess
t h r ou gh t h e clockspr in g. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS/CLOCKSP RING - DE SCRIP TION) for
m or e in for m a t ion on t h is com pon en t .
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
OPERATION
Th e six swit ch es in t h e t wo r em ot e r a dio swit ch
u n it s a r e n or m a lly open , r esist or m u lt iplexed
m om en t a r y swit ch es t h a t a r e h a r d wir ed t o t h e Body
Con t r ol Modu le (BCM) t h r ou gh t h e clockspr in g. Th e
BCM sen ds a five volt r efer en ce sign a l t o bot h swit ch
u n it s on on e cir cu it , a n d sen ses t h e st a t u s of a ll of
t h e swit ch es by r ea din g t h e volt a ge dr op on a secon d
cir cu it .
Wh en t h e BCM sen ses a n in pu t (volt a ge dr op) fr om
a n y on e of t h e r em ot e r a dio swit ch es, it sen ds t h e
pr oper swit ch st a t u s m essa ges on t h e P r ogr a m m a ble
WJ
Com m u n ica t ion In t er fa ce (P CI) da t a bu s n et wor k t o
t h e r a dio r eceiver. Th e elect r on ic cir cu it r y wit h in t h e
r a dio r eceiver is pr ogr a m m ed t o r espon d t o t h ese
r em ot e r a dio swit ch st a t u s m essa ges by a dju st in g t h e
r a dio set t in gs a s r equ est ed. F or dia gn osis of t h e
BCM or t h e P CI da t a bu s, t h e u se of a DRB sca n t ool
a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l a r e
r ecom m en ded.
F or m or e in for m a t ion on t h e fea t u r es a n d con t r ol
fu n ct ion s for ea ch of t h e r em ot e r a dio swit ch es, see
t h e own er ’s m a n u a l in t h e veh icle glove box.
DIAGNOSIS AND TESTING - REMOTE
SWITCHES
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
Ma n u a l.
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e r em ot e r a dio swit ch (es) (F ig. 16)
fr om t h e st eer in g wh eel.
(2) Use a n oh m m et er t o ch eck t h e swit ch r esis-
t a n ces a s sh own in t h e Rem ot e Ra dio Swit ch Test
ch a r t . If t h e r em ot e r a dio swit ch r esist a n ces ch eck
OK, go t o St ep 3. If n ot OK, r epla ce t h e fa u lt y
swit ch .
WJ AUDIO 8A - 21
REM OT E SWI T CH ES (Cont inue d)
(5) Ch eck for con t in u it y bet ween t h e r em ot e r a dio
swit ch gr ou n d cir cu it ca vit ies of t h e st eer in g wh eel
wir e h a r n ess con n ect or s for bot h r em ot e r a dio
swit ch es a n d t h e 22-wa y in st r u m en t pa n el wir e h a r-
n ess con n ect or for t h e BCM. Th er e sh ou ld be con t i-
n u it y. If OK, r efer t o t h e pr oper Dia gn ost ic
P r ocedu r es m a n u a l t o t est t h e BCM a n d t h e P CI
da t a bu s. If n ot OK, r epa ir t h e open r em ot e r a dio
swit ch gr ou n d cir cu it a s r equ ir ed.

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
Fig. 16 Remote Radio Switches TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
1 - BLACK (LEFT) SWITCH
AND POSSIBLE PERSONAL INJURY.
2 - WHITE (RIGHT) SWITCH

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive

Remote Radio Switch Test ca ble.
(2) Rem ove t h e dr iver side a ir ba g fr om t h e st eer-
Switch Switch Position Resistance
in g wh eel. (Refer t o 8 - E LE CTRICAL/RE STRAINTS/
Right DRIVE R AIRBAG - RE MOVAL) for t h e pr ocedu r es.
Volume Up 1.210 Kilohms
(White) (3) Rem ove t h e speed con t r ol swit ch loca t ed on t h e
Right sa m e side of t h e st eer in g wh eel a s t h e r em ot e r a dio
Volume Down 3.010 Kilohms swit ch t h a t is bein g ser viced. Refer t o E lect r ica l,
(White)
Right Speed Con t r ol for t h e pr ocedu r es.
Mode Advance 0.0511 Kilohms (4) Discon n ect t h e st eer in g wh eel wir e h a r n ess
(White)
con n ect or fr om t h e con n ect or r ecept a cle of t h e r em ot e
Left r a dio swit ch (F ig. 17).
Seek Up 0.261 Kilohms
(Black) (5) F r om t h e in side of t h e st eer in g wh eel r ea r t r im
Left cover, pr ess fir m ly a n d even ly ou t wa r d on t h e ba ck of
Seek Down 0.681 Kilohms
(Black) t h e swit ch .
Left Pre-Set Station (6) F r om t h e ou t side of t h e st eer in g wh eel r ea r
0.162 Kilohms t r im cover, r em ove t h e r em ot e r a dio swit ch fr om t h e
(Black) Advance
t r im cover m ou n t in g h ole.
(3) Recon n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e On posit ion . Ch eck for 5 volt s INSTALLATION
a t t h e r a dio con t r ol m u x cir cu it ca vit ies of t h e st eer-
in g wh eel wir e h a r n ess con n ect or s for bot h r em ot e WARNING: ON VEHICLES EQUIPPED WITH AIR-
r a dio swit ch es. If OK, go t o St ep 4. If n ot OK, r epa ir BAGS, REFER TO ELECTRICAL, RESTRAINTS
t h e open or sh or t ed r a dio con t r ol m u x cir cu it t o t h e BEFORE ATTEMPTING ANY STEERING WHEEL,
Body Con t r ol Modu le (BCM) a s r equ ir ed. STEERING COLUMN, OR INSTRUMENT PANEL
(4) Discon n ect a n d isola t e t h e ba t t er y n ega t ive COMPONENT DIAGNOSIS OR SERVICE. FAILURE
ca ble. Discon n ect t h e 22-wa y in st r u m en t pa n el wir e TO TAKE THE PROPER PRECAUTIONS COULD
h a r n ess con n ect or fr om t h e BCM. Ch eck for con t in u - RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
it y bet ween t h e r em ot e r a dio swit ch gr ou n d cir cu it AND POSSIBLE PERSONAL INJURY.
ca vit ies of t h e st eer in g wh eel wir e h a r n ess con n ec-
t or s for bot h r em ot e r a dio swit ch es a n d a good (1) P osit ion t h e r em ot e r a dio swit ch t o t h e m ou n t -
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o in g h ole on t h e ou t side of t h e st eer in g wh eel r ea r
St ep 5. If n ot OK, r epa ir t h e sh or t ed r em ot e r a dio t r im cover. Be cer t a in t h a t t h e con n ect or r ecept a cle is
swit ch gr ou n d cir cu it t o t h e BCM a s r equ ir ed. or ien t ed t owa r d t h e bot t om of t h e swit ch a n d poin t ed
t owa r d t h e cen t er of t h e st eer in g wh eel.
8A - 22 AUDIO WJ
REM OT E SWI T CH ES (Cont inue d)

SPEAK ER
DESCRIPTION
STANDARD
Th e st a n da r d equ ipm en t spea ker syst em in clu des
spea ker s in six loca t ion s. On e 6.4 cen t im et er (2.50
in ch ) dia m et er t weet er is in st a lled on ea ch en d of t h e
in st r u m en t pa n el t op pa d. On e 15.2 by 22.9 cen t im e-
t er (6 by 9 in ch ) fu ll-r a n ge spea ker is loca t ed in ea ch
fr on t door. Th er e is a lso on e fu ll-r a n ge 16.5 cen t im e-
t er (6.5 in ch ) dia m et er fu ll-r a n ge spea ker loca t ed in
ea ch r ea r door.

PREMIUM
Th e opt ion a l pr em iu m spea ker syst em fea t u r es six
In fin it y m odel spea ker s in six loca t ion s. E a ch of t h e
st a n da r d spea ker s is r epla ced wit h In fin it y m odel
spea ker s. On e 6.4 cen t im et er (2.50 in ch ) dia m et er
In fin it y t weet er is in st a lled on ea ch en d of t h e
in st r u m en t pa n el t op pa d. On e 15.2 by 22.9 cen t im e-
Fig. 17 Remote Radio Switches Remove/Install t er (6 by 9 in ch ) In fin it y woofer is loca t ed in ea ch
1 - STEERING WHEEL fr on t door. Th er e is a lso on e fu ll-r a n ge 16.5 cen t im e-
2 - SPEED CONTROL SWITCH t er (6.5 in ch ) dia m et er In fin it y fu ll-r a n ge spea ker
3 - SCREW
loca t ed in ea ch r ea r door. Th e pr em iu m spea ker sys-
4 - DRIVER SIDE AIRBAG MODULE
5 - REMOTE RADIO SWITCH
t em a lso in clu des a n a ddit ion a l In fin it y power a m pli-
6 - REAR TRIM COVER fier. Th e t ot a l a va ila ble power of t h e pr em iu m
spea ker syst em is a bou t 180 wa t t s.
(2) P r ess fir m ly a n d even ly on t h e r em ot e r a dio OPERATION
swit ch u n t il ea ch of t h e swit ch sn a p fea t u r es is fu lly
en ga ged in t h e m ou n t in g h ole of t h e st eer in g wh eel STANDARD
r ea r t r im cover.
E a ch of t h e t wo t weet er s a n d fou r fu ll-r a n ge spea k-
(3) Recon n ect t h e st eer in g wh eel wir e h a r n ess con -
er s u sed in t h e st a n da r d spea ker syst em is dr iven by
n ect or t o t h e con n ect or r ecept a cle of t h e r em ot e r a dio
t h e a m plifier t h a t is in t egr a l t o t h e fa ct or y-in st a lled
swit ch .
r a dio r eceiver. F or com plet e cir cu it dia gr a m s, r efer t o
(4) In st a ll t h e speed con t r ol swit ch on t o t h e st eer-
t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for-
in g wh eel. Refer t o E lect r ica l, Speed Con t r ol for t h e
m a t ion in clu des wir in g dia gr a m s, pr oper wir e a n d
pr ocedu r es.
con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
(5) In st a ll t h e dr iver side a ir ba g on t o t h e st eer in g
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
wh eel. (Refer t o 8 - E LE CTRICAL/RE STRAINTS/
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
DRIVE R AIRBAG - INSTALLATION) for t h e pr oce-
n ect or s, splices a n d gr ou n ds.
du r es.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble. PREMIUM
Th e six In fin it y spea ker s u sed in t h e pr em iu m
spea ker syst em a r e a ll dr iven by t h e r a dio r eceiver
t h r ou gh a n In fin it y power a m plifier. F or com plet e cir-
cu it dia gr a m s, r efer t o t h e a ppr opr ia t e wir in g in for-
m a t ion . Th e wir in g in for m a t ion in clu des wir in g
dia gr a m s, pr oper wir e a n d con n ect or r epa ir pr oce-
du r es, det a ils of wir e h a r n ess r ou t in g a n d r et en t ion ,
con n ect or pin -ou t in for m a t ion a n d loca t ion views for
t h e va r iou s wir e h a r n ess con n ect or s, splices a n d
gr ou n ds.
WJ
SPEAK ER (Cont inue d)
DIAGNOSIS AND TESTING - SPEAKER
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
Ma n u a l.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio is a
“floating ground” system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r a dio r eceiver on . Adju st t h e ba la n ce a n d
fa der con t r ols t o ch eck t h e per for m a n ce of ea ch in di-
vidu a l spea ker. Not e t h e spea ker loca t ion s t h a t a r e
n ot per for m in g cor r ect ly. Go t o St ep 2.
(2) Tu r n t h e r a dio r eceiver off. Tu r n t h e ign it ion
swit ch t o t h e Off posit ion . Discon n ect a n d isola t e t h e
ba t t er y n ega t ive ca ble. Rem ove t h e r a dio r eceiver
fr om t h e in st r u m en t pa n el. If t h e veh icle is equ ipped
wit h t h e In fin it y spea ker pa cka ge, a lso discon n ect
t h e wir e h a r n ess con n ect or s a t t h e power a m plifier.
Ch eck bot h t h e spea ker feed (+) cir cu it a n d r et u r n (–)
cir cu it ca vit ies for t h e in oper a t ive spea ker loca t ion (s)
a t t h e r a dio r eceiver wir e h a r n ess con n ect or s for con -
t in u it y t o gr ou n d. In ea ch ca se, t h er e sh ou ld be n o
con t in u it y. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
sh or t ed spea ker feed (+) a n d/or r et u r n (–) cir cu it (s) t o
t h e spea ker a s r equ ir ed.
(3) If t h e veh icle is equ ipped wit h t h e In fin it y
spea ker pa cka ge, go t o St ep 6. If t h e veh icle is
equ ipped wit h t h e st a n da r d spea ker syst em , ch eck
t h e r esist a n ce bet ween t h e spea ker feed (+) cir cu it
a n d r et u r n (–) cir cu it ca vit ies of t h e r a dio r eceiver
AUDIO 8A - 23
wir e h a r n ess con n ect or s for t h e in oper a t ive spea ker
loca t ion (s). Th e m et er sh ou ld r ea d bet ween 2 a n d 3
oh m s (spea ker r esist a n ce). If OK, go t o St ep 4. If n ot
OK, go t o St ep 5.
(4) In st a ll a kn own good r a dio r eceiver. Con n ect
t h e ba t t er y n ega t ive ca ble. Tu r n t h e ign it ion swit ch
t o t h e On posit ion . Tu r n on t h e r a dio r eceiver a n d
t est t h e spea ker oper a t ion . If OK, r epla ce t h e fa u lt y
r a dio r eceiver. If n ot OK, t u r n t h e r a dio r eceiver off,
t u r n t h e ign it ion swit ch t o t h e Off posit ion , discon -
n ect a n d isola t e t h e ba t t er y n ega t ive ca ble, r em ove
t h e t est r a dio r eceiver, a n d go t o St ep 5.
(5) Discon n ect t h e wir e h a r n ess con n ect or a t t h e
in oper a t ive spea ker. Ch eck for con t in u it y bet ween
t h e spea ker feed (+) cir cu it ca vit ies of t h e r a dio
r eceiver wir e h a r n ess con n ect or a n d t h e spea ker wir e
h a r n ess con n ect or. Repea t t h e ch eck bet ween t h e
spea ker r et u r n (–) cir cu it ca vit ies of t h e r a dio
r eceiver wir e h a r n ess con n ect or a n d t h e spea ker wir e
h a r n ess con n ect or. In ea ch ca se, t h er e sh ou ld be con -
t in u it y. If OK, r epla ce t h e fa u lt y spea ker. If n ot OK,
r epa ir t h e open spea ker feed (+) a n d/or r et u r n (–) cir-
cu it (s) a s r equ ir ed.
(6) F or ea ch in oper a t ive spea ker loca t ion , ch eck for
con t in u it y bet ween t h e spea ker feed (+) cir cu it ca vi-
t ies of t h e r a dio r eceiver wir e h a r n ess con n ect or s a n d
t h e power a m plifier wir e h a r n ess con n ect or s. Repea t
t h e ch eck for ea ch in oper a t ive spea ker loca t ion
bet ween t h e spea ker r et u r n (–) cir cu it ca vit ies of t h e
r a dio r eceiver wir e h a r n ess con n ect or s a n d t h e power
a m plifier wir e h a r n ess con n ect or s. In ea ch ca se,
t h er e sh ou ld be con t in u it y. If OK, go t o St ep 7. If n ot
OK, r epa ir t h e open spea ker feed (+) a n d/or r et u r n
(–) cir cu it (s) a s r equ ir ed.
(7) Ch eck for con t in u it y bet ween t h e t wo gr ou n d
cir cu it ca vit ies of t h e power a m plifier wir e h a r n ess
con n ect or a n d a good gr ou n d. Th er e sh ou ld be con t i-
n u it y. If OK, go t o St ep 8. If n ot OK, r epa ir t h e open
gr ou n d cir cu it (s) t o gr ou n d a s r equ ir ed.
(8) Ch eck t h e fu sed B(+) fu se for t h e power a m pli-
fier in t h e ju n ct ion block. If OK, go t o St ep 9. If n ot
OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(9) In st a ll t h e r a dio r eceiver. Con n ect t h e ba t t er y
n ega t ive ca ble. Ch eck for ba t t er y volt a ge a t t h e fu sed
B(+) fu se for t h e power a m plifier in t h e ju n ct ion
block. If OK, go t o St ep 10. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e P ower Dist r ibu t ion
Cen t er (P DC) fu se a s r equ ir ed.
(10) Ch eck for ba t t er y volt a ge a t t h e t wo fu sed
B(+) cir cu it ca vit ies of t h e power a m plifier wir e h a r-
n ess con n ect or. If OK, go t o St ep 11. If n ot OK, r epa ir
t h e open fu sed B(+) cir cu it (s) t o t h e power a m plifier
fu se in t h e ju n ct ion block a s r equ ir ed.
(11) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r a dio r eceiver on . Ch eck for ba t t er y volt a ge
8A - 24 AUDIO WJ
SPEAK ER (Cont inue d)
a t t h e en a ble sign a l t o a m plifier cir cu it ca vit y of t h e
power a m plifier wir e h a r n ess con n ect or. If OK, go t o
St ep 12. If n ot OK, r epa ir t h e open en a ble sign a l t o
a m plifier cir cu it t o t h e r a dio r eceiver a s r equ ir ed.
(12) Tu r n t h e r a dio r eceiver off. Tu r n t h e ign it ion
swit ch t o t h e Off posit ion . Discon n ect a n d isola t e t h e
ba t t er y n ega t ive ca ble. F or ea ch in oper a t ive spea ker
loca t ion , ch eck bot h t h e a m plified feed (+) cir cu it a n d
t h e a m plified r et u r n (–) cir cu it ca vit ies of t h e power
a m plifier wir e h a r n ess con n ect or s for con t in u it y t o
gr ou n d. In ea ch ca se t h er e sh ou ld be n o con t in u it y. If
OK, go t o St ep 13. If n ot OK, r epa ir t h e sh or t ed
a m plified feed (+) a n d/or a m plified r et u r n (–) cir-
cu it (s) t o t h e spea ker a s r equ ir ed.
(13) F or ea ch in oper a t ive spea ker loca t ion , ch eck
t h e r esist a n ce bet ween t h e a m plified feed (+) cir cu it
a n d t h e a m plified r et u r n (–) cir cu it ca vit ies of t h e
power a m plifier wir e h a r n ess con n ect or s. Th e m et er
sh ou ld r ea d bet ween 2 a n d 3 oh m s (spea ker r esis-
t a n ce). If OK, r epla ce t h e fa u lt y power a m plifier. If
n ot OK, go t o St ep 14.
(14) Discon n ect t h e spea ker wir e h a r n ess con n ec-
t or a t t h e in oper a t ive spea ker. Ch eck for con t in u it y Fig. 18 Rear Door Speaker Remove/Install
bet ween t h e a m plified feed (+) cir cu it ca vit ies of t h e 1 - PLASTIC NUT (3)
spea ker wir e h a r n ess con n ect or a n d t h e power a m pli- 2 - REAR DOOR
3 - REAR DOOR SPEAKER
fier wir e h a r n ess con n ect or. Repea t t h e ch eck
4 - REAR DOOR WIRE HARNESS
bet ween t h e a m plified r et u r n (–) cir cu it ca vit ies of
5 - SCREW (3)
t h e spea ker wir e h a r n ess con n ect or a n d t h e power
a m plifier wir e h a r n ess con n ect or. In ea ch ca se t h er e
sh ou ld be con t in u it y. If OK, r epla ce t h e fa u lt y (2) Rem ove t h e t op cover fr om t h e in st r u m en t
spea ker. If n ot OK, r epa ir t h e open a m plified feed (+) pa n el. (Refer t o 23 - BODY/INSTRUME NT PANE L/
a n d/or a m plified r et u r n (–) cir cu it (s) a s r equ ir ed. INSTRUME NT PANE L TOP COVE R - RE MOVAL).
(3) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e spea ker wir e h a r n ess con n ect or
REM OVAL (F ig. 19).
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e spea ker
REAR DOOR SPEAKER t o t h e t op of t h e in st r u m en t pa n el.
(5) Rem ove t h e spea ker fr om t h e t op of in st r u m en t
REMOVAL pa n el.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. FRONT DOOR SPEAKER
(2) Rem ove t h e t r im pa n el fr om t h e r ea r door.
(Refer t o 23 - BODY/DOORS - RE AR/TRIM PANE L - REMOVAL
RE MOVAL) for t h e pr ocedu r es. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e ca ble.
spea ker t o t h e r ea r door in n er pa n el (F ig. 18). (2) Rem ove t h e t r im pa n el fr om t h e fr on t door.
(4) Discon n ect t h e r ea r door wir e h a r n ess con n ec- (Refer t o 23 - BODY/DOOR - F RONT/TRIM PANE L -
t or fr om t h e spea ker con n ect or r ecept a cle. RE MOVAL) for t h e pr ocedu r es.
(5) Rem ove t h e spea ker fr om t h e r ea r door in n er (3) Rem ove t h e fou r scr ews t h a t secu r e t h e
pa n el. spea ker t o t h e fr on t door in n er pa n el (F ig. 20).
(4) Discon n ect t h e fr on t door wir e h a r n ess con n ec-
INSTRUMENT PANEL SPEAKER t or fr om t h e spea ker con n ect or r ecept a cle.
(5) Rem ove t h e spea ker fr om t h e fr on t door in n er
REMOVAL pa n el.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
WJ AUDIO 8A - 25
SPEAK ER (Cont inue d)

Fig. 19 Instrument Panel Speaker Remove/Install

1 - INSTRUMENT PANEL WIRE HARNESS
2 - INSTRUMENT PANEL SPEAKER
3 - SCREW (2) Fig. 20 Front Door Speaker Remove/Install
1 - PLASTIC NUT (4)
2 - FRONT DOOR
I N STALLAT I ON 3 - FRONT DOOR SPEAKER
4 - FRONT DOOR WIRE HARNESS
INSTALLATION - REAR DOOR SPEAKER 5 - SCREW (4)
(1) P osit ion t h e spea ker t o t h e r ea r door in n er
pa n el. (4) In st a ll t h e t op cover on t o t h e in st r u m en t pa n el.
(2) Recon n ect t h e r ea r door wir e h a r n ess con n ect or (Refer t o 23 - BODY/INSTRUME NT PANE L/IN-
t o t h e spea ker con n ect or r ecept a cle. STRUME NT PANE L TOP COVE R - INSTALLA-
(3) P osit ion t h e spea ker on t o t h e r ea r door in n er TIONl for t h e pr ocedu r es.
pa n el. (5) Recon n ect t h e ba t t er y n ega t ive ca ble.
(4) In st a ll a n d t igh t en t h e t h r ee scr ews t h a t secu r e
t h e spea ker t o t h e r ea r door in n er pa n el. Tigh t en t h e INSTALLATION - FRONT DOOR SPEAKER
scr ews t o 2.2 N·m (20 in . lbs.). (1) P osit ion t h e spea ker t o t h e fr on t door in n er
(5) In st a ll t h e t r im pa n el on t o t h e r ea r door. (Refer pa n el.
t o 23 - BODY/DOORS - RE AR/TRIM PANE L - (2) Recon n ect t h e fr on t door wir e h a r n ess con n ec-
INSTALLATION) for t h e pr ocedu r es. t or t o t h e spea ker con n ect or r ecept a cle.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble. (3) P osit ion t h e spea ker on t o t h e fr on t door in n er
door pa n el.
INSTALLATION - INSTRUMENT PANEL (4) In st a ll a n d t igh t en t h e fou r scr ews t h a t secu r e
SPEAKER t h e spea ker t o t h e fr on t door in n er pa n el. Tigh t en
(1) P osit ion t h e spea ker on t o t h e t op of t h e in st r u - t h e scr ews t o 2.2 N·m (20 in . lbs.).
m en t pa n el. (5) In st a ll t h e t r im pa n el on t o t h e fr on t door.
(2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e (Refer t o 23 - BODY/DOOR - F RONT/TRIM PANE L -
t h e spea ker t o t h e t op of t h e in st r u m en t pa n el. INSTALLATION) for t h e pr ocedu r es.
Tigh t en t h e scr ews t o 2.2 N·m (20 in . lbs.). (6) Recon n ect t h e ba t t er y n ega t ive ca ble.
(3) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or t o t h e spea ker wir e h a r n ess con n ect or.
WJ CHIME/BUZZER 8B - 1

CHIME/BUZZER
TABLE OF CON T EN T S

page page

CHIME WARNING SYSTEM DIAGNOSIS AND TESTING - CHIME

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CH I M E WARN I N G SY ST EM H a r d wir ed cir cu it r y con n ect s m a n y of t h e ch im e

wa r n in g syst em com pon en t s t o ea ch ot h er t h r ou gh
t h e elect r ica l syst em of t h e veh icle.
DESCRIPTION
If t h e BCM or t h e ch im e t on e gen er a t or a r e da m -
Th e ch im e wa r n in g syst em u ses a sin gle ch im e
a ged or fa u lt y, t h e BCM u n it m u st be r epla ced.
t on e gen er a t or t h a t is in t egr a l t o t h e Body Con t r ol
Modu le (BCM) t o pr ovide a n a u dible in dica t ion of
veh icle con dit ion s t h a t m a y r equ ir e t h e a t t en t ion of
OPERATION
Th e ch im e wa r n in g syst em com pon en t s oper a t e on
t h e veh icle oper a t or (F ig. 1). Th e ch im e wa r n in g sys-
ba t t er y volt a ge r eceived t h r ou gh t h e Ign it ion -Off
t em in clu des t h e followin g m a jor com pon en t s:
Dr a w (IOD) fu se in t h e P ower Dist r ibu t ion Cen t er
• Body Con t r ol Modu le
(P DC) on a n on -swit ch ed B(+) cir cu it so t h a t t h e sys-
• Door Aja r Swit ch
t em m a y oper a t e r ega r dless of t h e ign it ion swit ch
• H ea dla m p Swit ch
posit ion .
• Ign it ion Swit ch
• Sea t Belt Swit ch

Fig. 1 Chime Warning System

1 - IGNITION SWITCH 4 - HEADLAMP SWITCH
2 - SEAT BELT SWITCH 5 - BODY CONTROL MODULE
3 - DOOR AJAR SWITCH
8B - 2 CHIME/BUZZER
CH I M E WARN I N G SY ST EM (Cont inue d)
Th e ch im e wa r n in g syst em pr ovides a n a u dible
in dica t ion t o t h e veh icle oper a t or u n der t h e followin g
con dit ion s:
• F a s te n S e a t B e lt Wa rn in g - Th e Body Con t r ol
Modu le (BCM) ch im e t on e gen er a t or will gen er a t e
r epet it ive ch im es t o a n n ou n ce t h a t a n in pu t fr om t h e
sea t belt swit ch in dica t es t h e dr iver side fr on t sea t
belt is n ot fa st en ed. Un less t h e dr iver side fr on t sea t
belt is fa st en ed, t h e ch im es will con t in u e t o sou n d for
a du r a t ion of a bou t six secon ds ea ch t im e t h e ign it ion
swit ch is t u r n ed t o t h e On posit ion or u n t il t h e dr iver
side fr on t sea t belt is fa st en ed.
• He a d /P a rk Lig h ts -On Wa rn in g - Th e BCM
ch im e t on e gen er a t or will gen er a t e r epet it ive ch im es
a t a fa st r a t e t o a n n ou n ce t h a t a P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s dr iver door
a ja r m essa ge, a lon g wit h h a r d wir ed in pu t s fr om t h e
h ea dla m p swit ch in dica t e t h a t t h e ext er ior la m ps a r e
t u r n ed On wit h t h e dr iver side fr on t door open ed.
Th e ch im e will con t in u e t o sou n d u n t il t h e ext er ior
la m ps a r e t u r n ed Off, t h e dr iver side fr on t door is
closed, or t h e ign it ion swit ch is t u r n ed t o t h e On
posit ion .
• Ke y -In -Ig n itio n Wa rn in g - Th e BCM ch im e
t on e gen er a t or will gen er a t e r epet it ive ch im es a t a
fa st r a t e t o a n n ou n ce t h a t a P CI da t a bu s dr iver door
a ja r m essa ge r eceived fr om t h e Dr iver Door Modu le
(DDM), a lon g wit h h a r d wir ed in pu t s fr om t h e key-
in -ign it ion wa r n in g swit ch in dica t e t h a t t h e key is in
t h e ign it ion cylin der wit h t h e dr iver side fr on t door
open ed a n d t h e ign it ion swit ch in t h e Off posit ion .
Th e ch im e will con t in u e t o sou n d u n t il t h e key is
r em oved fr om t h e ign it ion lock cylin der, t h e dr iver
side fr on t door is closed, or t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion .
• Ov e rs p e e d Wa rn in g - Th e BCM ch im e t on e
gen er a t or will gen er a t e r epet it ive ch im es a t a slow
WJ
r a t e t o a n n ou n ce t h a t a P CI da t a bu s veh icle speed
m essa ge r eceived fr om t h e P ower t r a in Con t r ol Mod-
u le (P CM) in dica t es t h a t t h e veh icle speed is a bove
120 kilom et er s-per-h ou r (75 m iles-per-h ou r ). Th e
ch im es will con t in u e t o sou n d u n t il t h e veh icle speed
is below 120 kilom et er s-per-h ou r (75 m iles-per-h ou r ).
Th is fea t u r e is on ly en a bled on a BCM t h a t h a s been
pr ogr a m m ed wit h a Middle E a st Gu lf Coa st Cou n t r y
(GCC) cou n t r y code.
• Ta c tile B e e p S u p p o rt - Th e BCM ch im e t on e
gen er a t or will gen er a t e a sin gle beep ea ch t im e a
P CI da t a bu s t a ct ile beep r equ est m essa ge is r eceived
fr om t h e E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC) or t h e Sen t r y Key Im m obilizer Modu le
(SKIM). Th is beep pr ovides a n a u dible con fir m a t ion
t h a t a n E VIC bu t t on wa s com plet ely depr essed, or
t h a t t h e opt ion a l Sen t r y Key Im m obilizer Syst em
(SKIS) is in t h e “Cu st om er Lea r n ” m ode.
• Wa rn in g B e e p S u p p o rt - Th e BCM ch im e t on e
gen er a t or will gen er a t e a sh or t ser ies of beeps ea ch
t im e a P CI da t a bu s wa r n in g beep r equ est m essa ge
is r eceived fr om t h e E VIC or t h e E lect r o-Mech a n ica l
In st r u m en t Clu st er (E MIC). Th ese beeps pr ovide a n
a u dible a ler t t o t h e veh icle oper a t or, of cer t a in visu a l
wa r n in g in dica t ion s displa yed by t h e E VIC a n d/or
t h e E MIC.
Th e BCM pr ovides ch im e ser vice for a ll a va ila ble
fea t u r es in t h e ch im e wa r n in g syst em . Th e BCM
r elies u pon m essa ge in pu t s r eceived fr om ot h er m od-
u les over t h e P CI da t a bu s n et wor k t o pr ovide ch im e
ser vice for a ll of t h e r em a in in g ch im e wa r n in g sys-
t em fea t u r es.
Th e in t er n a l pr ogr a m m in g of t h e BCM det er m in es
t h e pr ior it y of ea ch ch im e t on e r equ est in pu t t h a t is
r eceived, a s well a s t h e r a t e a n d du r a t ion of ea ch
ch im e t on e t h a t is t o be gen er a t ed.
WJ CHIME/BUZZER 8B - 3
CH I M E WARN I N G SY ST EM (Cont inue d)

DIAGNOSIS AND TESTING - CHIME WARNING ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
SYSTEM
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Con -
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
ven t ion a l dia gn ost ic m et h ods m a y n ot pr ove con clu -
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
sive in t h e dia gn osis of t h e in st r u m en t clu st er or t h e
TEM CAPACITOR TO DISCHARGE BEFORE PER-
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
bu s n et wor k. Th e m ost r elia ble, efficien t a n d a ccu -
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
r a t e m ea n s t o dia gn ose t h e BCM a n d t h e P CI da t a
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
bu s n et wor k in pu t s for t h e ch im e wa r n in g syst em
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
r equ ir es t h e u se of a DRBIII! sca n t ool a n d t h e
BAG DEPLOYMENT AND POSSIBLE PERSONAL
a ppr opr ia t e dia gn ost ic in for m a t ion .
INJURY.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE

CHIME WARNING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

NO SEAT BELT WARNING
CHIME WITH SEAT BELT
UNBUCKLED, BUT OTHER
CHIME FEATURES OK
1. Seat belt switch ground
circuit open.
2. Seat belt switch sense
circuit open.
3. Faulty seat belt switch.
1. Check for continuity between the ground circuit
of the wire harness connector for the seat belt
switch and a good ground. Repair the ground
circuit, if required.
2. Check for continuity between the seat belt
switch sense circuit of the wire harness connector
for the seat belt switch and the body wire harness
junction block connector. Repair the seat belt
switch sense circuit, if required.
3. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail wire connector. There should be
continuity with the seat belt unbuckled. Replace
the faulty seat belt, if required.

SEAT BELT WARNING 1. Seat belt switch sense 1. With the wire harness connector for the seat
CHIME WITH SEAT BELT circuit shorted. belt switch and the body wire harness junction
BUCKLED block connector disconnected, there should be no
continuity between the seat belt switch sense
circuit and a good ground. Repair the seat belt
switch sense circuit, if required.
2. Faulty seat belt switch. 2. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail wire connector. There should be
no continuity with the seat belt buckled. Replace
the faulty seat belt, if required.
8B - 4 CHIME/BUZZER
CH I M E WARN I N G SY ST EM (Cont inue d)
CHIME WARNING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES
NO KEY-IN IGNITION OR 1. Faulty door ajar switch or
HEADLAMPS-ON WARNING circuits.
CHIME WITH DRIVER SIDE
FRONT DOOR OPEN 2. Faulty headlamp switch
(left multi-function switch) or
circuits.
3. Key-in ignition switch
sense circuit open.
4. Faulty ignition switch.
CHIME SOUNDS WITH 1. Key-in ignition switch
DRIVER SIDE FRONT sense circuit shorted.
DOOR OPEN
2. Faulty ignition switch.
NO CHIMES AT ALL TIMES 1. Faulty Body Control
Module (BCM).
WJ
CORRECTION
1. Check that interior lights illuminate with driver
door open. If not OK, repair the interior lighting
system as required.
2. Check for proper exterior lighting operation. If
not OK, repair the exterior lighting system as
required.
2. Check for continuity between the key-in ignition
switch sense circuit of the instrument panel wire
harness connector for the ignition switch and the
body wire harness connector for the junction
block. Repair the key-in ignition switch sense
circuit, if required.
3. Check for continuity between the two terminals
in the ignition switch connector. There should be
continuity with a key in the ignition lock cylinder.
Replace the faulty ignition switch, if required.
1. Disconnect the instrument panel wire harness
connector for the ignition switch and the body
wire harness connector for the junction block.
There should be no continuity between the key-in
ignition switch sense circuit of the instrument
panel wire harness connector for the ignition
switch and a good ground. Repair the key-in
ignition switch sense circuit, if required.
2. Check for continuity between the two terminals
in the ignition switch connector. There should be
no continuity with the key removed from the
ignition lock cylinder. Replace the faulty ignition
switch, if required.
1. Use a DRBIII" scan tool and refer to the
appropriate diagnostic information. Replace the
faulty BCM, if required
WJ
ELECTRONIC CONTROL MODULES
TABLE OF CON T EN T S
page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 1
ADJUSTABLE PEDALS MODULE
REMOVAL .............................2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BODY CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL .............................5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMMUNICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROLLER ANTILOCK BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL .............................7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR . . . . . 7
OPERATION - DATA LINK CONNECTOR ......7
DOOR MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - DOOR MODULE . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
MEMORY HEATED SEAT/MIRROR MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECT RON I C CON T ROL
M ODU LES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM failures are caused by internal compo-
nent failures (i.e. relays and solenoids) and shorted
circuits (i.e. pull-ups, drivers, and switched cir-
cuits). These failures are difficult to detect when a
double fault has occurred and only one DTC has
been set.
ELECTRONIC CONTROL MODULES 8E - 1
page
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION - PCM . . . . . . . . . . . . . . . . . . 12
MODES OF OPERATION . . . . . . . . . . . . . . . . 12
DESCRIPTION - 5 VOLT SUPPLIES . . . . . . . 14
DESCRIPTION - IGNITION CIRCUIT SENSE . 14
DESCRIPTION - POWER GROUNDS . . . . . . 15
DESCRIPTION - SENSOR RETURN . . . . . . . 15
OPERATION
OPERATION - PCM . . . . . . . . . . . . . . . . . . . . 15
OPERATION - 5 VOLT SUPPLIES . . . . . . . . . 16
OPERATION - IGNITION CIRCUIT SENSE . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD PROCEDURE
STANDARD PROCEDURE - TCM QUICK
LEARN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wh en a P CM (J TE C) a n d t h e SKIM a r e r epla ced
a t t h e sa m e t im e, per for m t h e followin g st eps in
or der :
(1) P r ogr a m t h e n ew P CM (J TE C).
(2) P r ogr a m t h e n ew SKIM.
(3) Repla ce a ll ign it ion keys a n d pr ogr a m t h em t o
t h e n ew SKIM.
PROGRAMMING THE PCM (JTEC)
Th e SKIS Secr et Key is a n ID code t h a t is u n iqu e
t o ea ch SKIM. Th is code is pr ogr a m m ed a n d st or ed
in t h e SKIM, t h e P CM, a n d t h e ign it ion key t r a n -
spon der ch ip(s). Wh en r epla cin g t h e P CM, it is n ec-
essa r y t o pr ogr a m t h e secr et key in t o t h e n ew P CM
u sin g t h e DRBIII! sca n t ool. P er for m t h e followin g
st eps t o pr ogr a m t h e secr et key in t o t h e P CM.
8E - 2 ELECTRONIC CONTROL MODULES
ELECT RON I C CON T ROL M ODU LES (Cont inue d)
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion
(t r a n sm ission in P a r k/Neu t r a l).
(2) Use t h e DRBIII! a n d select TH E F T ALARM,
SKIM, t h en MISCE LLANE OUS.
(3) Select P CM RE P LACE D (GAS E NGINE ).
(4) E n t er secu r ed a ccess m ode by en t er in g t h e
veh icle fou r-digit P IN.
(5) Select E NTE R t o u pda t e P CM VIN.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition switch to
the ON position for one hour, then enter the correct
PIN. (Ensure all accessories are turned off. Also
monitor the battery state and connect a battery
charger if necessary).
(6) P r ess E NTE R t o t r a n sfer t h e secr et key (t h e
SKIM will sen d t h e secr et key t o t h e P CM).
(7) P r ess P a ge Ba ck t o get t o t h e Select Syst em
m en u a n d select E NGINE , MISCE LLANE OUS, a n d
SRI ME MORY CH E CK.
(8) Th e DRBIII! will a sk, “Is odom et er r ea din g
bet ween XX a n d XX?” Select t h e YE S or NO bu t t on
on t h e DRBIII!. If NO is select ed, t h e DRBIII! will
r ea d, “E n t er Odom et er Rea din g (F r om I.P. odom e-
t er )”. E n t er t h e odom et er r ea din g fr om t h e in st r u -
m en t clu st er a n d pr ess E NTE R.
PROGRAMMING THE SKIM
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion
(t r a n sm ission in P a r k/Neu t r a l).
(2) Use t h e DRBIII! a n d select TH E F T ALARM,
SKIM, t h en MISCE LLANE OUS.
(3) Select P CM RE P LACE D (GAS E NGINE ).
(4) P r ogr a m t h e veh icle fou r-digit P IN in t o SKIM.
(5) Select COUNTRY CODE a n d en t er t h e cor r ect
cou n t r y.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, it cannot be changed and the SKIM must be
replaced.
(6) Select YE S t o u pda t e VIN (t h e SKIM will lea r n
t h e VIN fr om t h e P CM).
(7) P r ess E NTE R t o t r a n sfer t h e secr et key (t h e
P CM will sen d t h e secr et key t o t h e SKIM).
(8) P r ogr a m ign it ion keys t o t h e SKIM.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle ignition keys will need to be
replaced and programmed to the new SKIM.
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PROGRAMMING IGNITION KEYS TO THE SKIM
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion
(t r a n sm ission in P a r k/Neu t r a l).
(2) Use t h e DRBIII! a n d select TH E F T ALARM,
SKIM, t h en MISCE LLANE OUS.
(3) Select P ROGRAM IGNITION KE Y’S.
(4) E n t er secu r ed a ccess m ode by en t er in g t h e
veh icle fou r-digit P IN.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
(5) Obt a in ign it ion keys t o be pr ogr a m m ed fr om
t h e cu st om er (8 keys m a xim u m ).
(6) Usin g t h e DRBIII!, er a se a ll ign it ion keys by
select in g MISCE LLANE OUS, a n d E RASE ALL CUR-
RE NT IGN. KE YS.
(7) P r ogr a m a ll of t h e ign it ion keys.
If ign it ion key pr ogr a m m in g is u n su ccessfu l, t h e
DRBIII! will displa y on e of t h e followin g m essa ges:
• P ro g ra m m in g N o t Atte m p te d - Th e DRBIII!
a t t em pt s t o r ea d t h e pr ogr a m m ed key st a t u s a n d
t h er e a r e n o keys pr ogr a m m ed in t o SKIM m em or y.
• P ro g ra m m in g Ke y F a ile d (P o s s ible U s e d
Ke y F ro m Wro n g Ve h ic le ) - SKIM is u n a ble t o pr o-
gr a m a n ign it ion key t r a n spon der du e t o on e of t h e
followin g:
• Th e ign it ion key t r a n spon der is fa u lt y.
• Th e ign it ion key t r a n spon der is or h a s been
a lr ea dy pr ogr a m m ed t o a n ot h er veh icle.
• 8 Ke y s Alre a d y Le a rn e d , P ro g ra m m in g N o t
D o n e - Th e SKIM t r a n spon der ID m em or y is fu ll.
• Le a rn e d Ke y In Ig n itio n - Th e ID for t h e ign i-
t ion key t r a n spon der cu r r en t ly in t h e ign it ion lock
cylin der is a lr ea dy pr ogr a m m ed in SKIM m em or y.
ADJ U STABLE PEDALS
M ODU LE
REMOVAL
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Rem ove t h e clu st er bezel (Refer t o 23 - BODY/
INSTRUME NT PANE L/CLUSTE R BE ZE L - RE MOV-
AL).
(3) Rem ove t h e st eer in g colu m n open in g cover
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
ING COLUMN OP E NING COVE R - RE MOVAL).
(4) Rem ove t h e a dju st a ble peda l m ot or for a ccessi-
bilit y. (Refer t o 5 - BRAKE S/H YDRAULIC/ME CH AN-
ICAL/P E DAL - RE MOVAL).
(5) Rem ove t h e t wo m ou n t in g clips fr om t h e m od-
u le (F ig. 1).
(6) Discon n ect t h e elect r ica l con n ect or.
(7) Rem ove t h e a dju st a ble peda l m odu le.
WJ
ADJ U STABLE PEDALS M ODU LE (Cont inue d)
Fig. 1 ADJUSTABLE PEDALS MODULE
1 - ELECTRICAL CONNECTOR
2 - MODULE MOUNTING BRACKET
3 - BRAKE BOOSTER
4 - ADJUSTABLE PEDALS MOUNTING BRACKET
5 - ADJUSTABLE PEDALS CONTROL MODULE
6 - HOLD DOWN CLIPS
INSTALLATION
(1) In st a ll t h e m odu le on t h e m ou n t in g pin s in t h e
veh icle.
(2) Recon n ect t h e elect r ica l con n ect or.
(3) In st a ll t h e t wo m ou n t in g clips for t h e m odu le
(F ig. 1).
(4) In st a ll t h e a dju st a ble peda l m ot or. (Refer t o 5 -
BRAKE S/H YDRAULIC/ME CH ANICAL/P E DAL
INSTALLATION).
(5) In st a ll t h e st eer in g colu m n open in g cover
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
ING COLUMN OP E NING COVE R - INSTALLA-
TION).
(6) In st a ll t h e clu st er bezel (Refer t o 23 - BODY/
INSTRUME NT PANE L/CLUSTE R BE ZE L
INSTALLATION).
(7) Recon n ect t h e n ega t ive ba t t er y ca ble.
BODY CON T ROL M ODU LE
DESCRIPTION
A Body Con t r ol Modu le (BCM) is con cea led below
t h e dr iver side en d of t h e in st r u m en t pa n el (F ig. 2).
Th e BCM u t ilizes in t egr a t ed cir cu it r y a n d in for m a -
t ion ca r r ied on t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s n et wor k a lon g wit h m a n y
h a r d wir ed in pu t s t o m on it or m a n y sen sor a n d
swit ch in pu t s t h r ou gh ou t t h e veh icle. In r espon se t o
t h ose in pu t s, t h e in t er n a l cir cu it r y a n d pr ogr a m m in g
of t h e BCM a llow it t o con t r ol a n d in t egr a t e m a n y
elect r on ic fu n ct ion s a n d fea t u r es of t h e veh icle
ELECTRONIC CONTROL MODULES 8E - 3
Fig. 2 Body Control Module
1 - JUNCTION BLOCK
2 - SCREWS (4)
3 - BODY CONTROL MODULE
4 - FUSE COVER LOCATOR CHANNELS
5 - FUSE COVER MOUNTING SLOTS
6 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS
t h r ou gh bot h h a r d wir ed ou t pu t s a n d t h e t r a n sm is-
sion of elect r on ic m essa ge ou t pu t s t o ot h er elect r on ic
m odu les in t h e veh icle over t h e P CI da t a bu s. Th e
elect r on ic fu n ct ion s a n d fea t u r es t h a t t h e BCM su p-
por t s or con t r ols in clu de t h e followin g:
- Th e BCM for t h is m odel is ser viced on ly a s a com -
plet e u n it . Ma n y of t h e elect r on ic fea t u r es in t h e
veh icle con t r olled or su ppor t ed by t h e BCM a r e pr o-
gr a m m a ble u sin g eit h er t h e E lect r on ic Veh icle In for-
m a t ion Cen t er (E VIC) u ser in t er fa ce, or t h e DRBIII!
sca n t ool. In a ddit ion , t h e BCM soft wa r e is F la sh
com pa t ible, wh ich m ea n s it ca n be r epr ogr a m m ed
- u sin g F la sh r epr ogr a m m in g pr ocedu r es. A BCM ca n
on ly be r epa ir ed by or r epla ced t h r ou gh a n a u t h o-
r ized elect r on ic wa r r a n t y r epa ir st a t ion . Refer t o t h e
la t est ver sion of t h e Wa r r a n t y P olicies a n d P r oce-
du r es m a n u a l for a cu r r en t list in g of a u t h or ized elec-
t r on ic r epa ir st a t ion s.
OPERATION
Th e Body Con t r ol Modu le (BCM) is design ed t o
con t r ol a n d in t egr a t e m a n y of t h e elect r on ic fea t u r es
a n d fu n ct ion s of t h e veh icle. Th e m icr opr ocessor-
ba sed BCM h a r dwa r e a n d soft wa r e m on it or s m a n y
h a r d wir ed swit ch a n d sen sor in pu t s a s well a s t h ose
r esou r ces it sh a r es wit h ot h er elect r on ic m odu les in
t h e veh icle t h r ou gh it s com m u n ica t ion over t h e P CI
da t a bu s n et wor k. Th e in t er n a l pr ogr a m m in g of t h e
BCM m icr opr ocessor a llows t h e BCM t o det er m in e
t h e t a sks it n eeds t o per for m a n d t h eir pr ior it ies. Th e
8E - 4 ELECTRONIC CONTROL MODULES
BODY CON T ROL M ODU LE (Cont inue d)
BCM pr ogr a m m in g t h en per for m s t h ose t a sks a n d
pr ovides fea t u r es t h r ou gh bot h P CI da t a bu s com m u -
n ica t ion wit h ot h er elect r on ic m odu les a n d h a r d
wir ed ou t pu t s t o a n u m ber of r ela ys. Th ese r ela ys
pr ovide t h e BCM wit h t h e a bilit y t o con t r ol n u m er-
ou s h igh cu r r en t a ccessor y syst em s in t h e veh icle.
Th e BCM cir cu it r y oper a t es on ba t t er y cu r r en t
r eceived t h r ou gh fu ses in t h e J u n ct ion Block (J B) on a
n on -swit ch ed fu sed B(+) cir cu it , a fu sed ign it ion swit ch
ou t pu t (st a r t -r u n ) cir cu it , a n d a fu sed ign it ion swit ch
ou t pu t (r u n -a ccessor y) cir cu it . Th is a r r a n gem en t a llows
t h e BCM t o pr ovide som e fea t u r es r ega r dless of t h e
ign it ion swit ch posit ion . Th e BCM cir cu it r y is gr ou n ded
t h r ou gh t h e ch a ssis ben ea t h t h e cen t er con sole.
Th e BCM m on it or s it s own in t er n a l cir cu it r y a s
well a s m a n y of it s in pu t a n d ou t pu t cir cu it s, a n d
will st or e a Dia gn ost ic Tr ou ble Code (DTC) in elec-
t r on ic m em or y for a n y fa ilu r e it det ect s. Th ese DTCs
ca n be r et r ieved a n d dia gn osed u sin g a DRBIII! sca n
t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
HARD WIRED INPUTS
Th e h a r d wir ed in pu t s t o t h e BCM in clu de t h e fol-
lowin g:
• A/C swit ch sign a l
• Am bien t t em per a t u r e sen sor sign a l
• Body con t r ol m odu le fla sh en a ble
• Coola n t level swit ch sen se
• Door a ja r swit ch sen se (t wo cir cu it s - on e left
r ea r, a n d on e r igh t r ea r )
• Dr iver sea t h ea t er swit ch m u x
• F og la m p swit ch sen se
• F u sed B(+)
• F u sed ign it ion swit ch ou t pu t (r u n -a cc)
• F u sed ign it ion swit ch ou t pu t (st -r u n )
• Gr ou n d (five cir cu it s - t wo Z1, a n d t h r ee Z2)
• H a za r d swit ch sen se
• H ea dla m p swit ch m u x
• H igh bea m swit ch sen se
• H ood a ja r swit ch sen se (expor t )
• Key-in ign it ion swit ch sen se
• Lift ga t e a ja r swit ch sen se
• Lift ga t e cou r t esy disa ble
• Lift ga t e flip-u p a ja r swit ch sen se
• P a n el la m ps dim m er sign a l
• P a r k la m p r ela y ou t pu t
• P a ssen ger sea t h ea t er swit ch m u x
• P CI bu s
• Ra dio con t r ol m u x
• Rea r win dow defogger swit ch sen se
• Sea t belt swit ch sen se
• Ult r a ligh t sen sor sign a l
• Wa sh er flu id swit ch sen se
• Wa sh er pu m p swit ch sen se
• Win dsh ield wiper swit ch m u x
• Wiper pa r k swit ch sen se
WJ
MESSAGING
Th e BCM u ses t h e followin g m essa ges r eceived
fr om ot h er elect r on ic m odu les over t h e P CI da t a bu s:
• Accessor y Dela y Con t r ol (DDM/P DM)
• Ba t t er y Tem per a t u r e (P CM)
• Ch im e Requ est (E MIC, E VIC, SKIM)
• Cylin der Lock Swit ch St a t u s (DDM)
• Door Aja r St a t u s/F r on t Door s (DDM/P DM)
• Door Lock St a t u s (DDM/P DM)
• E n gin e Model (P CM)
• E n gin e RP M (P CM)
• E n gin e Tem per a t u r e (P CM)
• E n glish /Met r ic Defa u lt (E MIC)
• F u el Ta n k Level (P CM)
• F u el Used/In ject or P u lses (P CM)
• P a n ic Con t r ol (P DM)
• P r ogr a m m a ble F ea t u r es P r efer en ces/Au dible &
Opt ica l Ch ir ps/H ea dla m p Dela y (E VIC)
• RKE St a t u s (P DM)
• Veh icle Iden t ifica t ion Nu m ber (P CM)
• Veh icle Speed (P CM)
Th e BCM pr ovides t h e followin g m essa ges t o ot h er
elect r on ic m odu les over t h e P CI da t a bu s:
• A/C Swit ch St a t u s (P CM)
• Am bien t Tem per a t u r e Da t a (AZC/E VIC/P CM)
• Aver a ge/In st a n t a n eou s F u el E con om y (E VIC)
• Cou n t r y Code (E MIC)
• Cou r t esy La m p St a t u s (DDM/P DM)
• Dist a n ce To E m pt y (E VIC)
• E la psed Ign it ion On Tim er (E VIC)
• E n glish /Met r ic St a t u s (E MIC)
• F r on t & Rea r Door Aja r St a t u s (E VIC)
• F r on t & Rea r F og La m p St a t u s (E MIC)
• H ea t ed Sea t Swit ch St a t u s (H SM/MH SM)
• H igh Bea m St a t u s (E MIC)
• Ign it ion Off Tim er (E VIC)
• Ign it ion Swit ch P osit ion (DDM/P DM)
• Key-In Ign it ion St a t u s (DDM/P DM)
• Low Bea m St a t u s (E MIC)
• P a n el La m p St a t u s (AZC/E MIC/Ra dio)
• Rea r Win dow Defogger Rela y St a t u s (DDM/
P DM)
• Rem ot e Ra dio Swit ch St a t u s (Ra dio)
• Sea t belt St a t u s (E MIC/MH SM/MSM)
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE
Th e h a r d wir ed in pu t s t o a n d ou t pu t s fr om t h e
Body Con t r ol Modu le (BCM) m a y be dia gn osed a n d
t est ed u sin g con ven t ion a l dia gn ost ic t ools a n d pr oce-
du r es. Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Con ven t ion a l dia gn ost ic m et h ods m a y n ot pr ove
con clu sive in t h e dia gn osis of t h e BCM. In or der t o
obt a in con clu sive t est in g of t h e BCM, t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et -
wor k a n d a ll of t h e elect r on ic m odu les t h a t pr ovide
WJ ELECTRONIC CONTROL MODULES 8E - 5
BODY CON T ROL M ODU LE (Cont inue d)
in pu t s t o or r eceive ou t pu t s fr om t h e BCM m u st a lso
be ch ecked. Th e m ost r elia ble, efficien t , a n d a ccu r a t e
m ea n s t o dia gn ose t h e BCM, t h e P CI da t a bu s n et -
wor k, a n d t h e elect r on ic m odu les t h a t pr ovide in pu t s
t o or r eceive ou t pu t s fr om t h e BCM r equ ir es t h e u se
of a DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia gn ost ic
in for m a t ion . Th e DRBIII! sca n t ool ca n pr ovide con -
fir m a t ion t h a t t h e P CI da t a bu s n et wor k is fu n c-
t ion a l, t h a t a ll of t h e m odu les a r e sen din g a n d
r eceivin g t h e pr oper m essa ges over t h e P CI da t a bu s,
a n d t h a t t h e BCM is r eceivin g t h e pr oper h a r d wir ed
in pu t s a n d r espon din g wit h t h e pr oper h a r d wir ed
ou t pu t s n eeded t o per for m it s m a n y fu n ct ion s.

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE, Fig. 3 Body Control Module Remove/Install
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- 1 - JUNCTION BLOCK
TEM CAPACITOR TO DISCHARGE BEFORE PER- 2 - SCREWS (4)
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS 3 - BODY CONTROL MODULE
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG 4 - FUSE COVER LOCATOR CHANNELS
5 - FUSE COVER MOUNTING SLOTS
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
6 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. (5) P u ll t h e BCM st r a igh t ou t t owa r ds t h e da sh
pa n el fa r en ou gh t o discon n ect t h e in t egr a l BCM t o
J B con n ect or.
REMOVAL (6) Rem ove t h e BCM.

WARNING: ON VEHICLES EQUIPPED WITH AIR- INSTALLATION

BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e in st r u m en t pa n el fu se cover.(Refer
t o 8 - E LE CTRICAL/P OWE R DISTRIBUTION/F USE
COVE R - RE MOVAL).
(3) Access a n d discon n ect t h e in st r u m en t pa n el
wir e h a r n ess con n ect or s fr om t h e BCM (F ig. 3).
(4) Rem ove t h e m ou n t in g scr ews (Tor x T-20) t h a t
secu r e t h e BCM t o t h e J B.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) P osit ion t h e Body Con t r ol Modu le (BCM) t o it s
m ou n t in g loca t ion (F ig. 3).
(2) Align t h e t er m in a l pin s of t h e BCM con n ect or
wit h t h e con n ect or on t h e J B.
(3) E n ga ge t h e BCM in t egr a l con n ect or in t o t h e
J B.
(4) In st a ll t h e fou r scr ews. Tigh t en t h e scr ews t o
2.2 N·m (20 in . lbs.).
8E - 6 ELECTRONIC CONTROL MODULES
BODY CON T ROL M ODU LE (Cont inue d)
(5) Con n ect t h e t wo in st r u m en t pa n el wir e h a r n ess
con n ect or s t o t h e BCM.
(6) Rein st a ll t h e in st r u m en t pa n el fu se cover t o
t h e bot t om of t h e BCM a n d J B u n it . (Refer t o 8 -
E LE CTRICAL/P OWE R DISTRIBUTION/F USE
COVE R - INSTALLATION).
(7) Con n ect t h e ba t t er y n ega t ive ca ble.
COM M U N I CAT I ON
DESCRIPTION
Th e P r ogr a m m a ble Com m u n ica t ion In t er fa ce (P CI)
da t a bu s syst em is a sin gle wir e m u lt iplex syst em
u sed for veh icle com m u n ica t ion s. Mu lt iplexin g is a
syst em t h a t en a bles t h e t r a n sm ission of sever a l m es-
sa ges over a sin gle ch a n n el or cir cu it .
Ma n y of t h e con t r ol m odu les in a veh icle r equ ir e
in for m a t ion fr om t h e sa m e sen sin g device. Mu lt iplex-
in g r edu ces wir e h a r n ess com plexit y, sen sor cu r r en t
loa ds a n d con t r oller h a r dwa r e beca u se ea ch sen sin g
device is con n ect ed t o on ly on e con t r oller, wh ich
r ea ds a n d dist r ibu t es t h e sen sor in for m a t ion t o t h e
ot h er con t r oller s over t h e da t a bu s. Also, beca u se
ea ch con t r oller on t h e da t a bu s ca n a ccess t h e con -
t r oller sen sor in pu t s t o ever y ot h er con t r oller on t h e
da t a bu s, m or e fu n ct ion a n d fea t u r e ca pa bilit ies a r e
possible.
A m u lt iplex syst em a llows t h e in for m a t ion flowin g
bet ween con t r oller s t o be m on it or ed u sin g a dia gn os-
t ic sca n t ool. Th is syst em a llows a con t r ol m odu le t o
br oa dca st m essa ge da t a ou t on t o t h e bu s wh er e a ll
ot h er con t r ol m odu les ca n r ea d t h e m essa ges t h a t a r e
bein g sen t . Wh en a m odu le r ea ds a m essa ge on t h e
da t a bu s t h a t it r equ ir es, it r ela ys t h a t m essa ge t o
it s m icr opr ocessor. E a ch m odu le ign or es t h e m es-
sa ges on t h e da t a bu s t h a t it dosen ’t r ecogn ize.
OPERATION
Da t a exch a n ge bet ween m odu les is a ch ieved by
ser ia l t r a n sm ission of en coded da t a over a sin gle wir e
br oa dca st n et wor k. Th e P CI da t a bu s m essa ges a r e
ca r r ied over t h e bu s in t h e for m of Va r ia ble P u lse
Widt h Modu la t ed (VP WM) sign a ls. Th e P CI da t a bu s
speed is a n a ver a ge 10.4 Kilo-bit s per secon d (Kbps).
Th e volt a ge n et wor k u sed t o t r a n sm it m essa ges
r equ ir es bia sin g a n d t er m in a t ion . E a ch m odu le on
t h e P CI da t a bu s syst em pr ovides it s own bia sin g
a n d t er m in a t ion . E a ch m odu le (a lso r efer r ed t o a s a
n ode) t er m in a t es t h e bu s t h r ou gh a t er m in a t in g
r esist or a n d a t er m in a t in g ca pa cit or. Th e P ower t r a in
Con t r ol Modu le (P CM) is t h e on ly dom in a n t n ode for
t h e P CI da t a bu s syst em .
Th e P CI bu s u ses low a n d h igh volt a ge levels t o
gen er a t e sign a ls. Th e volt a ge on t h e bu ss va r ies
bet ween zer o a n d seven a n d on e-h a lf volt s. Th e low
WJ
a n d h igh volt a ge levels a r e gen er a t ed by m ea n s of
va r ia ble-pu lse widt h m odu la t ion t o for m sign a ls of
va r yin g len gt h .
Wh en a m odu le is t r a n sm it t in g on t h e bu s, it is
r ea din g t h e bu s a t t h e sa m e t im e t o en su r e m essa ge
in t egr it y.
E a ch m odu le is ca pa ble of t r a n sm it t in g a n d r eceiv-
in g da t a sim u lt a n eou sly.
Th e P CI da t a bu s ca n be m on it or ed u sin g t h e
DRBIII! sca n t ool. It is possible for t h e bu s t o pa ss
a ll DRBIII! t est s a n d st ill be fa u lt y if t h e volt a ge
pa r a m et er s a r e a ll wit h in t h e specified r a n ge a n d
fa lse m essa ges a r e bein g sen t .
CON T ROLLER AN T I LOCK
BRAK E
DESCRIPTION
Th e Con t r oler An t ilock Br a ke (CAB) is m ou n t ed t o
t h e H ydr a u lic Con t r ol Un it (H CU) a n d oper a t es t h e
ABS syst em (F ig. 4).
Fig. 4 Controller Antilock Brakes
1 - HCU
2 - MOTOR
3 - CAB
OPERATION
Th e CAB volt a ge is su pplied by t h e ign it ion swit ch
in t h e RUN posit ion . Th e CAB con t a in s du a l m icr o-
pr ocessor s. A logic block in ea ch m icr opr ocessor
r eceives iden t ica l sen sor sign a ls. Th ese sign a ls a r e
pr ocessed a n d com pa r ed sim u lt a n eou sly. Th e CAB
con t a in s a self ch eck pr ogr a m t h a t illu m in a t es t h e
ABS wa r n in g ligh t wh en a syst em fa u lt is det ect ed.
F a u lt s a r e st or ed in a dia gn ost ic pr ogr a m m em or y
a n d a r e a ccessible wit h t h e DRBIII! sca n t ool. ABS
fa u lt s r em a in in m em or y u n t il clea r ed, or u n t il a ft er
t h e veh icle is st a r t ed a ppr oxim a t ely 50 t im es. St or ed
WJ ELECTRONIC CONTROL MODULES 8E - 7
CON T ROLLER AN T I LOCK BRAK E (Cont inue d)
fa u lt s a r e n o t er a sed if t h e ba t t er y is discon n ect ed.
(F ig. 4)

REMOVAL
(1) Rem ove n ega t ive ba t t er y ca ble fr om t h e ba t -
t er y.
(2) Rem ove a ir clea n er h ou sin g,(Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - RE MOVAL) OR (Refer t o 9 - E NGINE /
AIR INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(3) Relea se CAB h a r n ess con n ect or a n d r em ove
con n ect or (F ig. 5).

Fig. 6 CAB Mounting Bolts

1 - MOUNTING BOLTS

DATA LI N K CON N ECT OR

DESCRIPTION - DATA LINK CONNECTOR
Th e da t a lin k con n ect or (DLC) is loca t ed a t t h e
lower edge of t h e in st r u m en t pa n el n ea r t h e st eer in g
colu m n .

Fig. 5 CAB Connector Release OPERATION - DATA LINK CONNECTOR

1 - CONNECTOR RELEASE Th e 16–wa y DLC lin ks t h e DRBIII! sca n t ool or
2 - CAB t h e Mopa r Dia gn ost ic Syst em (MDS) wit h t h e P ower-
t r a in Con t r ol Modu le (P CM).
(4) Rem ove pu m p m ot or con n ect or.
(5) Rem ove CAB m ou n t in g bolt s (F ig. 6) a n d DOOR M ODU LE
r em ove t h e CAB fr om t h e H CU.

INSTALLATION
(1) In st a ll t h e CAB on t o t h e H CU a n d t igh t en
m ou n t in g bolt s t o 1.8 N·m (16 in . lbs.).
(2) In st a ll pu m p m ot or con n ect or.
(3) In st a ll CAB h a r n ess con n ect or a n d pu sh down
con n ect or r elea se.
(4) In st a ll a ir clea n er h ou sin g,(Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - INSTALLATION) OR (Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - INSTALLATION).
(5) In st a ll n ega t ive ba t t er y ca ble t o t h e ba t t er y.
DESCRIPTION
A door m odu le is con cea led beh in d t h e t r im pa n el
of ea ch fr on t door (F ig. 7).Th e m odu le on t h e dr iver
side is r efer r ed t o a s t h e Dr iver Door Modu le (DDM),
wh ile t h e m odu le on t h e pa ssen ger side is t h e P a s-
sen ger Door Modu le (P DM). E a ch door m odu le
h ou ses bot h t h e fr on t power lock a n d power win dow
swit ch es. In a ddit ion t o t h e power win dow a n d power
lock swit ch es for it s own door, t h e DDM a lso h ou ses
in dividu a l swit ch es for ea ch pa ssen ger door power
win dow, a power win dow lockou t swit ch , t h e power
m ir r or swit ch , a n d t h e power folda wa y m ir r or swit ch
for expor t veh icles.
Th e DDM a n d P DM ea ch u t ilize in t egr a t ed cir-
cu it r y a n d in for m a t ion ca r r ied on t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k
a lon g wit h m a n y h a r d wir ed in pu t s t o m on it or m a n y
sen sor a n d swit ch in pu t s t h r ou gh ou t t h e veh icle. Th e
P DM a lso r eceives in pu t s t h r ou gh a n in t egr a l Ra dio
8E - 8 ELECTRONIC CONTROL MODULES
DOOR M ODU LE (Cont inue d)
Fig. 7 Door Module
1 - FRONT DOOR TRIM PANEL
2 - SCREW (5)
3 - DOOR MODULE
F r equ en cy (RF ) Rem ot e Keyless E n t r y (RKE )
r eceiver. Th e DDM a n d P DM con t r ol a n d in t egr a t e
m a n y fu n ct ion s a n d fea t u r es of t h e veh icle t h r ou gh
bot h h a r d wir ed ou t pu t s a n d m essa ges over t h e P CI
da t a bu s. Th e fu n ct ion s a n d fea t u r es t h a t t h e door
m odu les su ppor t or con t r ol in clu de t h e followin g:
• Au to m a tic D o o r Lo c k - Th e t wo door m odu les
pr ovide a n a u t om a t ic door lock fea t u r e wh ich locks
t h e door s wh en t h e veh icle is m ovin g. Th is is a pr o-
gr a m m a ble fea t u r e.
• Au to m a tic D o o r U n lo c k On Ex it - Th e t wo
door m odu les pr ovide a n a u t om a t ic door u n lock on
exit fea t u r e. Th is fea t u r e will u n lock a ll t h e door s if
t h ey wer e locked via t h e a u t om a t ic door lock fea t u r e
a ft er t h e veh icle h a s st opped m ovin g a n d t h e dr iver
door is open ed. Th is is a pr ogr a m m a ble fea t u r e via
t h e E VIC.
• Cu s to m e r P ro g ra m m a ble F e a tu re s - E a ch
door m odu le pr ovides su ppor t for cer t a in cu st om er
pr ogr a m m a ble fea t u r es t h a t a r e m on it or ed on t h e
P CI bu s.
• Cy lin d e r Lo c k S w itc h S ta tu s - Th e DDM
m on it or s a n d t r a n sm it s t h e st a t u s of t h e cylin der
lock swit ch on t h e dr iver side fr on t door lock cylin -
der.
• D o o r Co u rte s y La m p Co n tro l - E a ch door
m odu le pr ovides con t r ol of it s own opt ion a l fr on t
door-m ou n t ed cou r t esy la m p.
• D o o r Lo c k In h ibit - E a ch door m odu le pr o-
vides a door lock in h ibit fea t u r e wh ich pr even t s t h e
door s fr om bein g locked wit h a power lock swit ch if
WJ
t h e key wa s left in t h e ign it ion a n d a fr on t door is
open .
• Ex p re s s -D o w n Win d o w - Th e DDM pr ovides
a n expr ess-down fea t u r e for t h e dr iver side fr on t door
win dow on ly.
• Ex te n d e d Win d o w Op e ra tio n - Bot h door
m odu les pr ovide a n ext en ded power win dow oper a -
t ion fea t u r e t h a t a llows oper a t ion of t h e power win -
dows for 45 secon ds followin g ign it ion Off or u n t il a
fr on t door is open ed.
• F ro n t D o o r Aja r S w itc h S ta tu s - E a ch door
m odu le m on it or s a n d t r a n sm it s t h e st a t u s of it s own
fr on t door a ja r swit ch .
• He a te d Mirro rs - E a ch door m odu le pr ovides
con t r ol for it s own opt ion a l h ea t ed ou t side r ea r view
m ir r or.
• Illu m in a te d En try - E a ch door m odu le su p-
por t s a n illu m in a t ed en t r y fea t u r e t h r ou gh it s own
opt ion a l fr on t door-m ou n t ed cou r t esy la m p.
• Me m o ry Mirro rs - E a ch door m odu le pr ovides
con t r ol for it s own opt ion a l m em or y ou t side r ea r view
m ir r or.
• Me m o ry S w itc h - Th e DDM m on it or s t h e st a -
t u s of t h e opt ion a l m em or y swit ch a n d con t r ols t h e
illu m in a t ion of t h e m em or y swit ch “set ” Ligh t E m it -
t in g Diode (LE D) in dica t or a n d illu m in a t ion la m ps.
• Me m o ry S y s te m - Th e DDM t r a n sm it s m em or y
set a n d r eca ll m essa ges ba sed u pon in pu t s fr om t h e
m em or y swit ch . If t h e opt ion a l RKE lin ked t o m em -
or y fea t u r e is en a bled, t h e DDM will a lso t r a n sm it
m em or y r eca ll m essa ges ba sed u pon m em or y
r equ est s r eceived fr om t h e Rem ot e Keyless E n t r y
(RKE ) syst em in t h e P DM. Cer t a in m em or y syst em
fea t u r es a r e pr ogr a m m a ble.
• P o w e r F o ld a w a y Mirro rs - Ex p o rt On ly -
E a ch door m odu le pr ovides su ppor t for t h e opt ion a l
power folda wa y ou t side m ir r or s. Th e DDM a lso
h ou ses t h e con t r ol swit ch for t h is syst em .
• P o w e r Lo c k Co n tro l - Th e DDM pr ovides con -
t r ol for t h e dr iver side fr on t door power lock m ot or,
wh ile t h e P DM pr ovides con t r ol for t h e power lock
m ot or s of t h e t h r ee r em a in in g door s a n d t h e lift ga t e.
• P o w e r Lo c k S w itc h S ta tu s - E a ch door m od-
u le m on it or s a n d t r a n sm it s t h e st a t u s of it s own in t e-
gr a l power lock swit ch .
• P o w e r Win d o w Co n tro l - E a ch door m odu le
pr ovides con t r ol for bot h t h e fr on t a n d r ea r door
power win dow m ot or s a n d t h e r ea r door power win -
dow swit ch es on t h e sa m e side of t h e veh icle.
• P o w e r Win d o w S w itc h S ta tu s - Th e DDM
m on it or s a n d t r a n sm it s t h e st a t u s of it s in t egr a l pa s-
sen ger side fr on t a n d r ea r power win dow swit ch es.
• Re m o te Ke y le s s En try - Th e P DM m on it or s
a n d t r a n sm it s t h e st a t u s of t h e Rem ot e Keyless
E n t r y (RKE ) syst em a n d pr ovides su ppor t for t h e
RKE Lock (wit h t h e opt ion a l h or n ch ir p a n d pa r k
WJ ELECTRONIC CONTROL MODULES 8E - 9
DOOR M ODU LE (Cont inue d)
la m p fla sh fea t u r es), Un lock wit h t h e opt ion a l RKE HARD WIRED OUTPUTS
u n lock, a n d P a n ic Mode fu n ct ion s. Th e opt ion a l RKE Th e h a r d wir ed ou t pu t s of t h e door m odu les
fea t u r es a r e pr ogr a m m a ble. in clu de t h e followin g:
• S w itc h Illu m in a tio n - E a ch door m odu le pr o- • Cou r t esy la m p dr iver
vides con t r ol of t h e power win dow a n d power lock • Cou r t esy la m p gr ou n d
swit ch illu m in a t ion for t h e fr on t a n d r ea r door s on • Dia gn ost ic ou t (DDM)
t h e sa m e side of t h e veh icle. Th e DDM pr ovides con - • Door /lift ga t e lock dr iver
t r ol of t h e power m ir r or swit ch illu m in a t ion . • Door /lift ga t e u n lock dr iver
• Win d o w Lo c k o u t - Th e DDM m on it or s a n d • Door swit ch illu m in a t ion (r ea r power win dow)
t r a n sm it s t h e st a t u s of it s in t egr a l win dow lockou t • F r on t win dow dr iver (down )
swit ch t o pr ovide t h e power win dow lockou t fea t u r e • F r on t win dow dr iver (u p)
a n d coor din a t e power win dow swit ch kn ob illu m in a - • Mem or y set in dica t or dr iver (DDM)
t ion . • Mem or y swit ch r et u r n (DDM)
Th e door m odu les a r e ser viced on ly a s com plet e • Mir r or com m on dr iver
u n it s. Ma n y of t h e fea t u r es in t h e veh icle con t r olled • Mir r or h ea t er gr ou n d
or su ppor t ed by t h e door m odu les a r e pr ogr a m m a ble • Mir r or h ea t er 12V su pply
u sin g eit h er t h e E lect r on ic Veh icle In for m a t ion Cen - • Rea r win dow dr iver (down )
t er (E VIC) u ser in t er fa ce, or t h e DRBIII! sca n t ool. If • Rea r win dow dr iver (u p)
a door m odu le is da m a ged or fa u lt y, t h e en t ir e door • Mir r or h or izon t a l dr iver
m odu le u n it m u st be r epla ced. • Mir r or sen sor gr ou n d
• Mir r or ver t ica l dr iver
OPERATION • P CI bu s
Th e m icr opr ocessor-ba sed DDM a n d P DM h a r d- • Swit ch illu m in a t ion dr iver (m em or y - DDM)
wa r e a n d soft wa r e m on it or s in t egr a l a n d h a r d wir ed
ext er n a l swit ch in pu t s a s well a s t h ose r esou r ces it MESSAGING
sh a r es wit h ot h er elect r on ic m odu les in t h e veh icle Th e door m odu les u se t h e followin g m essa ges
t h r ou gh it s com m u n ica t ion over t h e P CI da t a bu s r eceived fr om ot h er elect r on ic m odu les over t h e P CI
n et wor k. Th e in t er n a l pr ogr a m m in g a n d a ll of t h ese da t a bu s:
in pu t s a llow t h e DDM or P DM m icr opr ocessor t o • Accessor y Dela y Con t r ol (P DM)
det er m in e t h e t a sks it n eeds t o per for m a n d t h eir • Cou r t esy La m p St a t u s (BCM)
pr ior it ies, a s well a s bot h t h e st a n da r d a n d opt ion a l • Door Aja r St a t u s/Rea r Door s (BCM)
fea t u r es t h a t it sh ou ld pr ovide. • Door Lock St a t u s (DDM/P DM)
Th e DDM a n d P DM a r e power ed by a fu sed ba t - • Ign it ion Swit ch P osit ion (BCM)
t er y cir cu it so t h a t t h ey ca n oper a t e r ega r dless of t h e • Key-In Ign it ion St a t u s (BCM)
ign it ion swit ch posit ion . Th e DDM a n d P DM cir- • P r ogr a m m a ble F ea t u r es P r efer en ces/Au t o Lock/
cu it r y is gr ou n ded t o t h e ch a ssis ben ea t h t h e fr on t Au t o Un lock/RKE Un lock Sequ en ce/RKE Lin k t o
sea t . Mem or y (E VIC)
Th e DDM a n d P DM ca n be dia gn osed u sin g a • Mem or y Reca ll (DDM)
DRBIII! sca n t ool. Refer t o t h e a ppr opr ia t e dia gn os- • Rea r Win dow Defogger Rela y St a t u s (BCM)
t ic in for m a t ion . • Veh icle Speed (P CM)
Th e door m odu les pr ovide t h e followin g m essa ges
HARD WIRED INPUTS t o ot h er elect r on ic m odu les over t h e P CI da t a bu s:
Th e h a r d wir ed in pu t s t o t h e door m odu les in clu de • Cylin der Lock Swit ch St a t u s (BCM)
t h e followin g: • Door Aja r St a t u s/F r on t Door s (BCM/DDM/P DM)
• Door a ja r swit ch sen se • Door Lock St a t u s (DDM/P DM)
• Dr iver door key cylin der swit ch sen se (DDM) • Mem or y Reca ll (P DM/MH SM/MSM/Ra dio)
• F u sed B(+) • Mem or y Set Swit ch St a t u s (P DM/MH SM/MSM/
• Gr ou n d Ra dio)
• Mem or y swit ch m u x (DDM) • P a n ic Con t r ol (BCM)
• Mir r or h or izon t a l posit ion sign a l • P ower Win dow Swit ch St a t u s (P DM)
• Mir r or ver t ica l posit ion sign a l • RKE St a t u s (BCM/DDM)
• P CI bu s • Win dow Lockou t Swit ch St a t u s (P DM)
8E - 10 ELECTRONIC CONTROL MODULES WJ
DOOR M ODU LE (Cont inue d)

DIAGNOSIS AND TESTING - DOOR MODULE

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

Th e h a r d wir ed in pu t s t o a n d ou t pu t s fr om t h e
Dr iver Door Modu le (DDM) or t h e P a ssen ger Door
Modu le (P DM) m a y be dia gn osed a n d t est ed u sin g
con ven t ion a l dia gn ost ic t ools a n d pr ocedu r es. It is
su ggest ed t h a t t h e pr oper oper a t ion of t h e in oper a -
t ive power win dow m ot or, power door lock m ot or,
power lift ga t e lock m ot or, power m ir r or m ot or s, or
h ea t ed m ir r or gr id be con fir m ed u sin g ju m per wir es
t o bypa ss t h e door m odu le. If t h e in oper a t ive com po-
n en t oper a t es wh en t h e door m odu le is bypa ssed,
ch eck t h e cir cu it s bet ween t h e com pon en t a n d t h e
door m odu le, a s well a s t h e fu sed B(+) a n d gr ou n d
cir cu it s of t h e door m odu le for sh or t s or open s.
Th ese con ven t ion a l dia gn ost ic m et h ods m a y n ot
pr ove con clu sive in t h e dia gn osis of t h e DDM or t h e
P DM. In or der t o obt a in con clu sive t est in g of t h ese
m odu les, t h e P r ogr a m m a ble Com m u n ica t ion s In t er-
fa ce (P CI) da t a bu s n et wor k a n d a ll of t h e m odu les
t h a t pr ovide in pu t s t o or r eceive ou t pu t s fr om t h e
door m odu les m u st a lso be ch ecked. Th e m ost r eli-
a ble, efficien t , a n d a ccu r a t e m ea n s t o dia gn ose t h e
DDM, t h e P DM, t h e P CI da t a bu s n et wor k, a n d t h e
m odu les t h a t pr ovide in pu t s t o or r eceive ou t pu t s
fr om t h e door m odu les r equ ir es t h e u se of a DRBIII!
sca n t ool a n d t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e t r im pa n el fr om t h e fr on t door.
(Refer t o 23 - BODY/DOOR - F RONT/TRIM PANE L -
RE MOVAL).
(3) Rem ove t h e door m odu le fr om t h e ba ck of t h e
fr on t door t r im pa n el (F ig. 8).
(4) Rem ove t h e door m odu le fr om t h e fr on t door
t r im pa n el.
Fig. 8 Door Module Remove/Install
1 - FRONT DOOR TRIM PANEL
2 - SCREW (5)
3 - DOOR MODULE
INSTALLATION
(1) P osit ion t h e door m odu le on t o t h e fr on t door
t r im pa n el.
(2) In st a ll t h e door m odu le t o t h e ba ck of t h e fr on t
door t r im pa n el (F ig. 8). Tigh t en t h e scr ews t o 2.2
N·m (20 in . lbs.).
(3) Rein st a ll t h e t r im pa n el on t o t h e fr on t door.
(Refer t o 23 - BODY/DOOR - F RONT/TRIM PANE L -
INSTALLATION).
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
M EM ORY H EAT ED SEAT /
M I RROR M ODU LE
DESCRIPTION
Th er e a r e t wo differ en t m odu les t h a t ca n be u sed
in t h e opt ion a l h ea t ed sea t syst em . Th e H ea t ed Sea t
Modu le (H SM) is u sed on veh icles t h a t a r e n ot
equ ipped wit h t h e opt ion a l Mem or y Syst em . Th e
Mem or y H ea t ed Sea t Modu le (MH SM) is u sed on
veh icles t h a t a r e equ ipped wit h t h e opt ion a l Mem or y
Syst em a n d t h e opt ion a l h ea t ed sea t syst em .Refer t o
Me m o ry S y s te m in P ower Sea t Syst em s for m or e
in for m a t ion on t h e m em or y syst em opt ion .
Th e m odu le is m ou n t ed on a br a cket t h a t is loca t ed
bet ween t h e power sea t t r a ck a n d t h e sea t cu sh ion
fr a m e (F ig. 9). Th e H SM or MH SM is u sed t o con t r ol
t h e h ea t ed sea t syst em fu n ct ion s for bot h fr on t sea t s.
Th e H SM or MH SM con t a in s a cen t r a l pr ocessin g
u n it t h a t com m u n ica t es wit h ot h er m odu les on t h e
WJ ELECTRONIC CONTROL MODULES 8E - 11
M EM ORY H EAT ED SEAT /M I RROR M ODU LE (Cont inue d)

DI AGN OSI S AN D T EST I N G

DIAGNOSIS AND TESTING - HEATED SEAT
MODULE
Visu a lly in spect t h e r ela t ed wir in g h a r n ess con n ec-
t or s. Look for br oken , ben t , pu sh ed ou t , or cor r oded
t er m in a ls. If a n y of t h e a bove con dit ion s a r e pr esen t ,
r epa ir a s n ecessa r y. If n ot , u se a DRBIII! sca n t ool
a n d t h e pr oper Dia gn ost ic P r ocedu r es Ma n u a l t o t est
t h e H SM or MH SM. F or com plet e cir cu it dia gr a m s,
r efer t o P o w e r S e a t P re m iu m I/III in Wir in g Dia -
gr a m s.

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e dr iver side fr on t bu cket sea t fr om
t h e power sea t t r a ck u n it . Refer t o B u c k e t S e a t
Tra c k Ad ju s te r in Body for t h e pr ocedu r e.
(3) Lift t h e h ea t ed sea t m odu le off of t h e power
sea t t r a ck a n d discon n ect t h e power sea t wir e h a r-
Fig. 9 Heated Seat Module Remove/Install n ess con n ect or s (F ig. 10).
1 - NUT (4)
2 - SEAT CUSHION FRAME
3 - POWER SEAT TRACK
4 - STUD (4)
5 - MODULE
6 - BRACKET

P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a

bu s n et wor k.
F or dia gn osis of t h e H SM, MH SM or t h e P CI da t a
bu s, a DRBIII! sca n t ool a n d t h e pr oper Dia gn ost ic
P r ocedu r es m a n u a l a r e r ecom m en ded. Th e H SM or
MH SM ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged,
it m u st be r epla ced.

OPERATION
Th e MSM r eceives h a r d wir ed in pu t s fr om t h e
power sea t swit ch a n d t h e pot en t iom et er s on ea ch of
t h e dr iver side power sea t m ot or s. Th e MSM r eceives
m essa ges over t h e P CI da t a bu s fr om t h e Dr iver
Door Modu le (DDM) (m em or y swit ch st a t u s), t h e
P ower t r a in Con t r ol Modu le (P CM) (veh icle speed st a -
t u s), a n d t h e Body Con t r ol Modu le (sea t belt swit ch Fig. 10 Heated Seat Module Remove/Install
st a t u s).Th e MSM will pr even t t h e sea t m em or y r eca ll 1 - NUT (4)
fu n ct ion fr om bein g in it ia t ed if t h e dr iver side sea t 2 - SEAT CUSHION FRAME
belt is bu ckled, if t h e t r a n sm ission gea r select or lever 3 - POWER SEAT TRACK
is n ot in t h e P a r k or Neu t r a l posit ion s, or if t h e veh i- 4 - STUD (4)
cle is m ovin g. 5 - MODULE
6 - BRACKET

(4) Rem ove t h e m odu le fr om t h e br a cket .

8E - 12 ELECTRONIC CONTROL MODULES
M EM ORY H EAT ED SEAT /M I RROR M ODU LE (Cont inue d)
INSTALLATION
(1) In st a ll t h e MH SM,H SM in t o t h e br a cket .
(2) P osit ion t h e h ea t ed sea t m odu le a n d m ou n t in g
br a cket on t o t h e power sea t t r a ck.
(3) Recon n ect t h e power sea t wir in g h a r n ess con -
n ect or s t o t h e h ea t ed sea t m odu le.
(4) In st a ll t h e dr iver side fr on t bu cket sea t on t o
t h e power sea t t r a ck u n it (Refer t o 23 - BODY/
SE ATS/SE AT TRACK ADJ USTE R - INSTALLA-
TION).
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
NOTE: If the vehicle is equipped with the optional
Memory System, following installation, it will be
necessary to initialize the Memory Heated Seat
Module (MHSM). In order to function properly, the
MHSM must “learn” the sensor values of each of
the power seat motor position transducers in each
of the adjuster hard stop positions. This is done by
performing the “Reset Guard Band” procedure
using a DRBIII" scan tool and the proper Diagnostic
Procedures manual.
WARNING: THE “RESET GUARD BAND” PROCE-
DURE WILL CAUSE THE DRIVER SIDE FRONT
SEAT TO AUTOMATICALLY ADJUST TO EACH OF
ITS TRAVEL LIMITS. BE CERTAIN THAT NO ONE IS
SEATED IN THE VEHICLE AND THAT THERE IS
NOTHING IN THE VEHICLE THAT WILL OBSTRUCT
SEAT MOVEMENT. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN PERSONAL INJURIES
AND/OR VEHICLE DAMAGE.
POWERT RAI N CON T ROL
M ODU LE
DESCRI PT I ON
DESCRIPTION - PCM
Th e P ower t r a in Con t r ol Modu le (P CM) is loca t ed
in t h e en gin e com pa r t m en t (F ig. 11). Th e P CM is
r efer r ed t o a s J TE C.
MODES OF OPERATION
As in pu t sign a ls t o t h e P ower t r a in Con t r ol Modu le
(P CM) ch a n ge, t h e P CM a dju st s it s r espon se t o t h e
ou t pu t devices. F or exa m ple, t h e P CM m u st ca lcu la t e
differ en t in ject or pu lse widt h a n d ign it ion t im in g for
idle t h a n it does for wide open t h r ot t le (WOT).
Th e P CM will oper a t e in t wo differ en t m odes:
Op e n Lo o p a n d Clo s e d Lo o p .
Du r in g Open Loop m odes, t h e P CM r eceives in pu t
sign a ls a n d r espon ds on ly a ccor din g t o pr eset P CM
WJ
Fig. 11 PCM Location
1 - PCM
2 - COOLANT TANK
pr ogr a m m in g. In pu t fr om t h e oxygen (O2S) sen sor s
is n ot m on it or ed du r in g Open Loop m odes.
Du r in g Closed Loop m odes, t h e P CM will m on it or
t h e oxygen (O2S) sen sor s in pu t . Th is in pu t in dica t es
t o t h e P CM wh et h er or n ot t h e ca lcu la t ed in ject or
pu lse widt h r esu lt s in t h e idea l a ir-fu el r a t io. Th is
r a t io is 14.7 pa r t s a ir-t o-1 pa r t fu el. By m on it or in g
t h e exh a u st oxygen con t en t t h r ou gh t h e O2S sen sor,
t h e P CM ca n fin e t u n e t h e in ject or pu lse widt h . Th is
is don e t o a ch ieve opt im u m fu el econ om y com bin ed
wit h low em ission en gin e per for m a n ce.
Th e fu el in ject ion syst em h a s t h e followin g m odes
of oper a t ion :
• Ign it ion swit ch ON
• E n gin e st a r t -u p (cr a n k)
• E n gin e wa r m -u p
• Idle
• Cr u ise
• Acceler a t ion
• Deceler a t ion
• Wide open t h r ot t le (WOT)
• Ign it ion swit ch OF F
Th e ign it ion swit ch On , en gin e st a r t -u p (cr a n k),
en gin e wa r m -u p, a cceler a t ion , deceler a t ion a n d wide
open t h r ot t le m odes a r e Open Loop m odes. Th e idle
a n d cr u ise m odes, (wit h t h e en gin e a t oper a t in g t em -
per a t u r e) a r e Closed Loop m odes.
IGNITION SWITCH (KEY-ON) MODE
Th is is a n Open Loop m ode. Wh en t h e fu el syst em
is a ct iva t ed by t h e ign it ion swit ch , t h e followin g
a ct ion s occu r :
WJ
POWERT RAI N CON T ROL M ODU LE (Cont inue d)
• Th e P CM pr e-posit ion s t h e idle a ir con t r ol (IAC)
m ot or.
• Th e P CM det er m in es a t m osph er ic a ir pr essu r e
fr om t h e MAP sen sor in pu t t o det er m in e ba sic fu el
st r a t egy.
• Th e P CM m on it or s t h e en gin e coola n t t em per a -
t u r e sen sor in pu t . Th e P CM m odifies fu el st r a t egy
ba sed on t h is in pu t .
• In t a ke m a n ifold a ir t em per a t u r e sen sor in pu t is
m on it or ed.
• Th r ot t le posit ion sen sor (TP S) is m on it or ed.
• Th e a u t o sh u t down (ASD) r ela y is en er gized by
t h e P CM for a ppr oxim a t ely t h r ee secon ds.
• Th e fu el pu m p is en er gized t h r ou gh t h e fu el
pu m p r ela y by t h e P CM. Th e fu el pu m p will oper a t e
for a ppr oxim a t ely t h r ee secon ds u n less t h e en gin e is
oper a t in g or t h e st a r t er m ot or is en ga ged.
• Th e O2S sen sor h ea t er elem en t is en er gized via
t h e O2S r ela ys. Th e O2S sen sor in pu t is n ot u sed by
t h e P CM t o ca libr a t e a ir-fu el r a t io du r in g t h is m ode
of oper a t ion .
ENGINE START-UP MODE
Th is is a n Open Loop m ode. Th e followin g a ct ion s
occu r wh en t h e st a r t er m ot or is en ga ged.
Th e P CM r eceives in pu t s fr om :
• Ba t t er y volt a ge
• E n gin e coola n t t em per a t u r e sen sor
• Cr a n ksh a ft posit ion sen sor
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S)
• St a r t er m ot or r ela y
• Ca m sh a ft posit ion sen sor sign a l
Th e P CM m on it or s t h e cr a n ksh a ft posit ion sen sor.
If t h e P CM does n ot r eceive a cr a n ksh a ft posit ion
sen sor sign a l wit h in a ppr oxim a t ely 3 secon ds of
cr a n kin g t h e en gin e, it will sh u t down t h e fu el in jec-
t ion syst em .
Th e fu el pu m p is a ct iva t ed by t h e P CM t h r ou gh
t h e fu el pu m p r ela y.
Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
t h e in ject ion sequ en ce a n d in ject or pu lse widt h by
t u r n in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or
on a n d off.
Th e P CM det er m in es t h e pr oper ign it ion t im in g
a ccor din g t o in pu t r eceived fr om t h e cr a n ksh a ft posi-
t ion sen sor.
ENGINE WARM-UP MODE
Th is is a n Open Loop m ode. Du r in g en gin e wa r m -
u p, t h e P CM r eceives in pu t s fr om :
• Ba t t er y volt a ge
• Cr a n ksh a ft posit ion sen sor
• E n gin e coola n t t em per a t u r e sen sor
ELECTRONIC CONTROL MODULES 8E - 13
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S)
• Ca m sh a ft posit ion sen sor sign a l
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o.
t r a n s. on ly)
• Air con dit ion in g select sign a l (if equ ipped)
• Air con dit ion in g r equ est sign a l (if equ ipped)
Ba sed on t h ese in pu t s t h e followin g occu r s:
• Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
t h e in ject ion sequ en ce a n d in ject or pu lse widt h by
t u r n in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or
on a n d off.
• Th e P CM a dju st s en gin e idle speed t h r ou gh t h e
idle a ir con t r ol (IAC) m ot or a n d a dju st s ign it ion t im -
in g.
• Th e P CM oper a t es t h e A/C com pr essor clu t ch
t h r ou gh t h e clu t ch r ela y. Th is is don e if A/C h a s been
select ed by t h e veh icle oper a t or a n d r equ est ed by t h e
A/C t h er m ost a t .
• Wh en en gin e h a s r ea ch ed oper a t in g t em per a -
t u r e, t h e P CM will begin m on it or in g O2S sen sor
in pu t . Th e syst em will t h en lea ve t h e wa r m -u p m ode
a n d go in t o closed loop oper a t ion .
IDLE MODE
Wh en t h e en gin e is a t oper a t in g t em per a t u r e, t h is
is a Closed Loop m ode. At idle speed, t h e P CM
r eceives in pu t s fr om :
• Air con dit ion in g select sign a l (if equ ipped)
• Air con dit ion in g r equ est sign a l (if equ ipped)
• Ba t t er y volt a ge
• Cr a n ksh a ft posit ion sen sor
• E n gin e coola n t t em per a t u r e sen sor
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S)
• Ca m sh a ft posit ion sen sor sign a l
• Ba t t er y volt a ge
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o.
t r a n s. on ly)
• Oxygen sen sor s
Ba sed on t h ese in pu t s, t h e followin g occu r s:
• Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
in ject ion sequ en ce a n d in ject or pu lse widt h by t u r n -
in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or on
a n d off.
• Th e P CM m on it or s t h e O2S sen sor in pu t a n d
a dju st s a ir-fu el r a t io by va r yin g in ject or pu lse widt h .
It a lso a dju st s en gin e idle speed t h r ou gh t h e idle a ir
con t r ol (IAC) m ot or.
• Th e P CM a dju st s ign it ion t im in g by in cr ea sin g
a n d decr ea sin g spa r k a dva n ce.
8E - 14 ELECTRONIC CONTROL MODULES
POWERT RAI N CON T ROL M ODU LE (Cont inue d)
• Th e P CM oper a t es t h e A/C com pr essor clu t ch
t h r ou gh t h e clu t ch r ela y. Th is h a ppen s if A/C h a s
been select ed by t h e veh icle oper a t or a n d r equ est ed
by t h e A/C t h er m ost a t .
CRUISE MODE
Wh en t h e en gin e is a t oper a t in g t em per a t u r e, t h is
is a Closed Loop m ode. At cr u isin g speed, t h e P CM
r eceives in pu t s fr om :
• Air con dit ion in g select sign a l (if equ ipped)
• Air con dit ion in g r equ est sign a l (if equ ipped)
• Ba t t er y volt a ge
• E n gin e coola n t t em per a t u r e sen sor
• Cr a n ksh a ft posit ion sen sor
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S)
• Ca m sh a ft posit ion sen sor sign a l
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o.
t r a n s. on ly)
• Oxygen (O2S) sen sor s
Ba sed on t h ese in pu t s, t h e followin g occu r s:
• Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
ASD r ela y via t h e P CM. Th e P CM will t h en a dju st
t h e in ject or pu lse widt h by t u r n in g t h e gr ou n d cir cu it
t o ea ch in dividu a l in ject or on a n d off.
• Th e P CM m on it or s t h e O2S sen sor in pu t a n d
a dju st s a ir-fu el r a t io. It a lso a dju st s en gin e idle
speed t h r ou gh t h e idle a ir con t r ol (IAC) m ot or.
• Th e P CM a dju st s ign it ion t im in g by t u r n in g t h e
gr ou n d pa t h t o t h e coil on a n d off.
• Th e P CM oper a t es t h e A/C com pr essor clu t ch
t h r ou gh t h e clu t ch r ela y. Th is h a ppen s if A/C h a s
been select ed by t h e veh icle oper a t or a n d r equ est ed
by t h e A/C t h er m ost a t .
ACCELERATION MODE
Th is is a n Open Loop m ode. Th e P CM r ecogn izes
a n a br u pt in cr ea se in t h r ot t le posit ion or MAP pr es-
su r e a s a dem a n d for in cr ea sed en gin e ou t pu t a n d
veh icle a cceler a t ion . Th e P CM in cr ea ses in ject or
pu lse widt h in r espon se t o in cr ea sed t h r ot t le open in g.
DECELERATION MODE
Wh en t h e en gin e is a t oper a t in g t em per a t u r e, t h is
is a n Open Loop m ode. Du r in g h a r d deceler a t ion , t h e
P CM r eceives t h e followin g in pu t s.
• Air con dit ion in g select sign a l (if equ ipped)
• Air con dit ion in g r equ est sign a l (if equ ipped)
• Ba t t er y volt a ge
• E n gin e coola n t t em per a t u r e sen sor
• Cr a n ksh a ft posit ion sen sor
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S)
• Ca m sh a ft posit ion sen sor sign a l
WJ
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o.
t r a n s. on ly)
• Veh icle speed
If t h e veh icle is u n der h a r d deceler a t ion wit h t h e
pr oper r pm a n d closed t h r ot t le con dit ion s, t h e P CM
will ign or e t h e oxygen sen sor in pu t sign a l. Th e P CM
will en t er a fu el cu t -off st r a t egy in wh ich it will n ot
su pply a gr ou n d t o t h e in ject or s. If a h a r d deceler a -
t ion does n ot exist , t h e P CM will det er m in e t h e
pr oper in ject or pu lse widt h a n d con t in u e in ject ion .
Ba sed on t h e a bove in pu t s, t h e P CM will a dju st
en gin e idle speed t h r ou gh t h e idle a ir con t r ol (IAC)
m ot or.
Th e P CM a dju st s ign it ion t im in g by t u r n in g t h e
gr ou n d pa t h t o t h e coil on a n d off.
WIDE OPEN THROTTLE MODE
Th is is a n Open Loop m ode. Du r in g wide open
t h r ot t le oper a t ion , t h e P CM r eceives t h e followin g
in pu t s.
• Ba t t er y volt a ge
• Cr a n ksh a ft posit ion sen sor
• E n gin e coola n t t em per a t u r e sen sor
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S)
• Ca m sh a ft posit ion sen sor sign a l
Du r in g wide open t h r ot t le con dit ion s, t h e followin g
occu r s:
• Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
t h e in ject ion sequ en ce a n d in ject or pu lse widt h by
t u r n in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or
on a n d off. Th e P CM ign or es t h e oxygen sen sor in pu t
sign a l a n d pr ovides a pr edet er m in ed a m ou n t of a ddi-
t ion a l fu el. Th is is don e by a dju st in g in ject or pu lse
widt h .
• Th e P CM a dju st s ign it ion t im in g by t u r n in g t h e
gr ou n d pa t h t o t h e coil on a n d off.
IGNITION SWITCH OFF MODE
Wh en ign it ion swit ch is t u r n ed t o OF F posit ion ,
t h e P CM st ops oper a t in g t h e in ject or s, ign it ion coil,
ASD r ela y a n d fu el pu m p r ela y.
DESCRIPTION - 5 VOLT SUPPLIES
Two differ en t P ower t r a in Con t r ol Modu le (P CM)
five volt su pply cir cu it s a r e u sed; pr im a r y a n d sec-
on da r y.
DESCRIPTION - IGNITION CIRCUIT SENSE
Th is cir cu it t ies t h e ign it ion swit ch t o t h e P ower-
t r a in Con t r ol Modu le (P CM).
WJ ELECTRONIC CONTROL MODULES 8E - 15
POWERT RAI N CON T ROL M ODU LE (Cont inue d)

DESCRIPTION - POWER GROUNDS Ba sed on in pu t s t h a t it r eceives, t h e P CM a dju st s

Th e P ower t r a in Con t r ol Modu le (P CM) h a s 2 m a in ign it ion coil dwell. Th e P CM a lso a dju st s t h e gen er-
gr ou n ds. Bot h of t h ese gr ou n ds a r e r efer r ed t o a s a t or ch a r ge r a t e t h r ou gh con t r ol of t h e gen er a t or
power gr ou n ds. All of t h e h igh -cu r r en t , n oisy, elect r i- field a n d pr ovides speed con t r ol oper a t ion .
ca l devices a r e con n ect ed t o t h ese gr ou n ds a s well a s
NOTE: PCM Inputs:
a ll of t h e sen sor r et u r n s. Th e sen sor r et u r n com es
in t o t h e sen sor r et u r n cir cu it , pa sses t h r ou gh n oise • A/C r equ est
su ppr ession , a n d is t h en con n ect ed t o t h e power • Au t o sh u t down (ASD) sen se
gr ou n d. • Ba t t er y t em per a t u r e
Th e power gr ou n d is u sed t o con t r ol gr ou n d cir- • Ba t t er y volt a ge
cu it s for t h e followin g P CM loa ds: • Br a ke swit ch
• Gen er a t or field win din g • J 1850 bu s cir cu it s
• F u el in ject or s • Ca m sh a ft posit ion sen sor sign a l
• Ign it ion coil(s) • Cr a n ksh a ft posit ion sen sor
• Cer t a in r ela ys/solen oids • Da t a lin k con n ect ion s for DRB sca n t ool
• Cer t a in sen sor s • E n gin e coola n t t em per a t u r e sen sor
• F ive volt s (pr im a r y)
DESCRIPTION - SENSOR RETURN • F ive volt s (secon da r y)
Th e Sen sor Ret u r n cir cu it s a r e in t er n a l t o t h e P ow- • F u el level
er t r a in Con t r ol Modu le (P CM). • Gen er a t or (ba t t er y volt a ge) ou t pu t
Sen sor Ret u r n pr ovides a low–n oise gr ou n d r efer- • Ign it ion cir cu it sen se (ign it ion swit ch in on /off/
en ce for a ll en gin e con t r ol syst em sen sor s. Refer t o cr a n k/r u n posit ion )
P ower Gr ou n ds for m or e in for m a t ion . • In t a ke m a n ifold a ir t em per a t u r e sen sor
• Lea k det ect ion pu m p (swit ch ) sen se (if equ ipped)
OPERAT I ON • Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Oil pr essu r e
• Over dr ive/over r ide swit ch
OPERATION - PCM
• Oxygen sen sor s
(1) Also r efer t o Modes of Oper a t ion .
• P a r k/n eu t r a l swit ch (a u t o. t r a n s. on ly)
Th e P CM oper a t es t h e fu el syst em . Th e P CM is a
• P ower gr ou n d
pr e-pr ogr a m m ed, t r iple m icr opr ocessor digit a l com -
• Sen sor r et u r n
pu t er. It r egu la t es ign it ion t im in g, a ir-fu el r a t io,
• Sign a l gr ou n d
em ission con t r ol devices, ch a r gin g syst em , cer t a in
• Speed con t r ol m u lt iplexed sin gle wir e in pu t
t r a n sm ission fea t u r es, speed con t r ol, a ir con dit ion in g
• Th r ot t le posit ion sen sor
com pr essor clu t ch en ga gem en t a n d idle speed. Th e
• Tr a n sm ission gover n or pr essu r e sen sor
P CM ca n a da pt it s pr ogr a m m in g t o m eet ch a n gin g
• Tr a n sm ission t em per a t u r e sen sor
oper a t in g con dit ion s.
• Veh icle speed (fr om ABS m odu le)
Th e P CM r eceives in pu t sign a ls fr om va r iou s
swit ch es a n d sen sor s. Ba sed on t h ese in pu t s, t h e NOTE: PCM Outputs:
P CM r egu la t es va r iou s en gin e a n d veh icle oper a t ion s
t h r ou gh differ en t syst em com pon en t s. Th ese com po- • A/C clu t ch r ela y
n en t s a r e r efer r ed t o a s P ower t r a in Con t r ol Modu le • Au t o sh u t down (ASD) r ela y
(P CM) Ou t pu t s. Th e sen sor s a n d swit ch es t h a t pr o- • J 1850 (+/-) cir cu it s for : speedom et er, volt m et er,
vide in pu t s t o t h e P CM a r e con sider ed P ower t r a in fu el ga u ge, oil pr essu r e ga u ge/la m p, en gin e t em p.
Con t r ol Modu le (P CM) In pu t s. ga u ge a n d speed con t r ol wa r n . la m p
Th e P CM a dju st s ign it ion t im in g ba sed u pon • Da t a lin k con n ect ion for DRBIII! sca n t ool
in pu t s it r eceives fr om sen sor s t h a t r ea ct t o: en gin e • E GR va lve con t r ol solen oid (if equ ipped)
r pm , m a n ifold a bsolu t e pr essu r e, en gin e coola n t t em - • E VAP ca n ist er pu r ge solen oid
per a t u r e, t h r ot t le posit ion , t r a n sm ission gea r selec- • F u el in ject or s
t ion (a u t om a t ic t r a n sm ission ), veh icle speed a n d t h e • F u el pu m p r ela y
br a ke swit ch . • Gen er a t or field dr iver (-)
Th e P CM a dju st s idle speed ba sed on in pu t s it • Gen er a t or field dr iver (+)
r eceives fr om sen sor s t h a t r ea ct t o: t h r ot t le posit ion , • Gen er a t or la m p (if equ ipped)
veh icle speed, t r a n sm ission gea r select ion , en gin e • Idle a ir con t r ol (IAC) m ot or
coola n t t em per a t u r e a n d fr om in pu t s it r eceives fr om • Ign it ion coil
t h e a ir con dit ion in g clu t ch swit ch a n d br a ke swit ch . • Lea k det ect ion pu m p
8E - 16 ELECTRONIC CONTROL MODULES WJ
POWERT RAI N CON T ROL M ODU LE (Cont inue d)
• Ma lfu n ct ion in dica t or la m p (Ch eck en gin e la m p). Th e P CM is loca t ed on t h e cowl pa n el in r igh t /r ea r
Dr iven t h r ou gh J 1850 cir cu it s. side of en gin e com pa r t m en t (F ig. 12).
• Over dr ive in dica t or la m p (if equ ipped). Dr iven
t h r ou gh J 1850 cir cu it s.
• Oxygen sen sor h ea t er r ela ys (if equ ipped).
• Ra dia t or coolin g fa n r ela y (pu lse widt h m odu -
la t ed)
• Speed con t r ol sou r ce
• Speed con t r ol va cu u m solen oid
• Speed con t r ol ven t solen oid
• Ta ch om et er (if equ ipped). Dr iven t h r ou gh J 1850
cir cu it s.
• Tr a n sm ission con ver t or clu t ch cir cu it
• Tr a n sm ission 3–4 sh ift solen oid
• Tr a n sm ission r ela y
• Tr a n sm ission t em per a t u r e la m p (if equ ipped)
• Tr a n sm ission va r ia ble for ce solen oid

OPERATION - 5 VOLT SUPPLIES

P r im a r y 5–volt su pply:
• su pplies t h e r equ ir ed 5 volt power sou r ce t o t h e
Cr a n ksh a ft P osit ion (CKP ) sen sor. Fig. 12 Powertrain Control Module (PCM) Location
• su pplies t h e r equ ir ed 5 volt power sou r ce t o t h e
1 - PCM
Ca m sh a ft P osit ion (CMP ) sen sor. 2 - COOLANT TANK
• su pplies a r efer en ce volt a ge for t h e Ma n ifold
Absolu t e P r essu r e (MAP ) sen sor.
• su pplies a r efer en ce volt a ge for t h e Th r ot t le
P osit ion Sen sor (TP S) sen sor.
Secon da r y 5–volt su pply:
• su pplies t h e r equ ir ed 5 volt power sou r ce t o t h e
oil pr essu r e sen sor.
• su pplies t h e r equ ir ed 5 volt power sou r ce for t h e
Veh icle Speed Sen sor (VSS) (if equ ipped).
• su pplies t h e 5 volt power sou r ce t o t h e t r a n sm is-
sion pr essu r e sen sor (if equ ipped wit h a n RE a u t o-
m a t ic t r a n sm ission ).

OPERATION - IGNITION CIRCUIT SENSE

Th e ign it ion cir cu it sen se in pu t t ells t h e P CM t h e
ign it ion swit ch h a s en er gized t h e ign it ion cir cu it .
Ba t t er y volt a ge is a lso su pplied t o t h e P CM
t h r ou gh t h e ign it ion swit ch wh en t h e ign it ion is in
t h e RUN or START posit ion . Th is is r efer r ed t o a s
t h e #ign it ion sen se# cir cu it a n d is u sed t o #wa ke u p#
t h e P CM. Fig. 13 Powertrain Control Module (PCM) 32–Way
Connectors
REMOVAL 1 - 3 32–WAY CONNECTORS
U S E THE D RB III! S CAN TOOL TO REP RO- 2 - PCM/BRACKET ASSEMBLY
GRAM THE N EW P OWERTRAIN CON TROL 3 - BRACKET NUTS (3)
MOD U LE (P CM) WITH THE VEHICLES ORIGI-
N AL ID EN TIF ICATION N U MB ER (VIN ) AN D
To a void possible volt a ge spike da m a ge t o P CM,
THE VEHICLES ORIGIN AL MILEAGE. IF THIS
ign it ion key m u st be off, a n d n ega t ive ba t t er y ca ble
S TEP IS N OT D ON E, A D IAGN OS TIC TROU B LE
m u st be discon n ect ed befor e u n plu ggin g P CM con n ec-
COD E (D TC) MAY B E S ET.
t or s.
Th e P CM is loca t ed on t h e cowl pa n el in r igh t /r ea r
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
side of en gin e com pa r t m en t (F ig. 12).
WJ ELECTRONIC CONTROL MODULES 8E - 17
POWERT RAI N CON T ROL M ODU LE (Cont inue d)
(5) In st a ll cover over elect r ica l con n ect or s. Cover
sn a ps on t o P CM.
(6) In st a ll coola n t r eser ve/over flow t a n k.
(7) If equ ipped, in st a ll Tr a n sm ission Con t r ol Mod-
u le (TCM).
(8) Con n ect n ega t ive ca ble t o ba t t er y.
(9) Use t h e DRBIII! sca n t ool t o r epr ogr a m n ew
P CM wit h veh icles or igin a l Iden t ifica t ion Nu m ber
(VIN) a n d or igin a l veh icle m ilea ge.

SEN T RY K EY I M M OBI LI Z ER
M ODU LE
DESCRIPTION

Fig. 14 Powertrain Control Module (PCM) Mounting

Bracket
1 - PCM BRACKET
2 - PCM
3 - PCM-TO-BRACKET SCREWS (3)

(2) If equ ipped, r em ove Tr a n sm ission Con t r ol Mod-

u le (TCM).
(3) Rem ove coola n t r eser ve/over flow t a n k.
(4) Rem ove cover over elect r ica l con n ect or s. Cover
sn a ps on t o P CM.
(5) Ca r efu lly u n plu g t h r ee 32–wa y con n ect or s a t
P CM.
(6) Rem ove t h r ee P CM br a cket -t o-body m ou n t in g
n u t s (F ig. 13).
(7) Rem ove P CM/P CM br a cket a ssem bly fr om
veh icle.
(8) Rem ove 3 P CM-t o-P CM br a cket bolt s (scr ews)
(F ig. 14). Fig. 15 Sentry Key Immobilizer Module
1 - STEERING COLUMN
INSTALLATION 2 - SKIM
3 - MOUNTING SCREW
U S E THE D RB III! S CAN TOOL TO REP RO-
GRAM THE N EW P OWERTRAIN CON TROL
MOD U LE (P CM) WITH THE VEHICLES ORIGI- Th e Sen t r y Key Im m obilizer Modu le (SKIM) is t h e
N AL ID EN TIF ICATION N U MB ER (VIN ) AN D pr im a r y com pon en t of t h e Sen t r y Key Im m obilizer
THE VEHICLES ORIGIN AL MILEAGE. IF THIS Syst em (SKIS) (F ig. 15). Th e SKIM is loca t ed in t h e
S TEP IS N OT D ON E, A D IAGN OS TIC TROU B LE st eer in g colu m n , below t h e ign it ion lock cylin der
COD E (D TC) MAY B E S ET. h ou sin g. Th e SKIM h a s a n in t egr a l h a lo-like a n t en n a
Th e P CM is loca t ed on t h e cowl pa n el in r igh t /r ea r r in g t h a t ext en ds fr om on e side.
side of en gin e com pa r t m en t (F ig. 12). Th e SKIM ca n n ot be a dju st ed or r epa ir ed. If fa u lt y
(1) Ch eck pin s in t h r ee 32–wa y elect r ica l con n ec- or da m a ged, t h e en t ir e SKIM u n it m u st be r epla ced.
t or s for da m a ge. Repa ir a s n ecessa r y.
(2) In st a ll P CM t o it s m ou n t in g br a cket . Tigh t en OPERATION
t h r ee m ou n t in g bolt s t o 3 N·m (25 in . lbs.) t or qu e. Th e Sen t r y Key Im m obilizer Modu le (SKIM) con -
(3) In st a ll P CM/P CM br a cket t o body. In st a ll 3 t a in s a Ra dio F r equ en cy (RF ) t r a n sceiver a n d a
n u t s a n d t igh t en 9 N·m (80 in . lbs.) t or qu e. m icr opr ocessor. Th e SKIM t r a n sm it s RF sign a ls t o,
(4) In st a ll t h r ee 32–wa y con n ect or s. a n d r eceives RF sign a ls fr om t h e Sen t r y Key t r a n -
8E - 18 ELECTRONIC CONTROL MODULES
SEN T RY K EY I M M OBI LI Z ER M ODU LE (Cont inue d)
spon der t h r ou gh a t u n ed a n t en n a r in g in t egr a l t o t h e
SKIM h ou sin g. If t h is a n t en n a r in g is n ot m ou n t ed
pr oper ly a r ou n d t h e ign it ion lock cylin der h ou sin g,
com m u n ica t ion pr oblem s bet ween t h e SKIM a n d t h e
t r a n spon der m a y a r ise. Th ese com m u n ica t ion pr ob-
lem s will r esu lt in Sen t r y Key t r a n spon der-r ela t ed
fa u lt s. Th e SKIM a lso com m u n ica t es over t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s
wit h t h e P ower t r a in Con t r ol Modu le (P CM), t h e E lec-
t r oMech a n ica l In st r u m en t Clu st er (E MIC), t h e Body
Con t r ol Modu le (BCM), a n d/or t h e DRBIII! sca n t ool.
Th e SKIM r et a in s in m em or y t h e ID n u m ber s of
a n y Sen t r y Key t r a n spon der t h a t is pr ogr a m m ed in t o
it . A m a xim u m of eigh t t r a n spon der s ca n be pr o-
gr a m m ed in t o t h e SKIM. F or a dded syst em secu r it y,
ea ch SKIM is pr ogr a m m ed wit h a u n iqu e Secr et Key
code. Th is code is st or ed in m em or y, sen t over t h e
P CI da t a bu s t o t h e P CM, a n d is en coded t o t h e t r a n -
spon der of ever y Sen t r y Key t h a t is pr ogr a m m ed in t o
t h e SKIM. An ot h er secu r it y code, ca lled a P IN, is
u sed t o ga in a ccess t o t h e SKIM Secu r ed Access
Mode. Th e Secu r ed Access Mode is r equ ir ed du r in g
ser vice t o per for m t h e SKIS in it ia liza t ion a n d Sen t r y
Key t r a n spon der pr ogr a m m in g pr ocedu r es. Th e
SKIM a lso st or es t h e Veh icle Iden t ifica t ion Nu m ber
(VIN) in it s m em or y, wh ich it lea r n s t h r ou gh a P CI
da t a bu s m essa ge fr om t h e P CM du r in g SKIS in it ia l-
iza t ion .
In t h e even t t h a t a SKIM r epla cem en t is r equ ir ed,
t h e Secr et Key code ca n be t r a n sfer r ed t o t h e n ew
SKIM fr om t h e P CM u sin g t h e DRBIII! sca n t ool
a n d t h e SKIS r epla cem en t pr ocedu r e. P r oper com ple-
t ion of t h e SKIS in it ia liza t ion will a llow t h e exist in g
Sen t r y Keys t o be pr ogr a m m ed in t o t h e n ew SKIM so
t h a t n ew keys will n ot be r equ ir ed. In t h e even t t h a t
t h e or igin a l Secr et Key code ca n n ot be r ecover ed,
SKIM r epla cem en t will a lso r equ ir e n ew Sen t r y
Keys. Th e DRBIII! sca n t ool will a ler t t h e t ech n icia n
du r in g t h e SKIS r epla cem en t pr ocedu r e if n ew Sen -
t r y Keys a r e r equ ir ed.
Wh en t h e ign it ion swit ch is t u r n ed t o t h e On posi-
t ion , t h e SKIM t r a n sm it s a n RF sign a l t o t h e t r a n -
spon der in t h e ign it ion key. Th e SKIM t h en wa it s for
a n RF sign a l r espon se fr om t h e t r a n spon der. If t h e
r espon se r eceived iden t ifies t h e key a s va lid, t h e
SKIM sen ds a va lid key m essa ge t o t h e P CM over
t h e P CI da t a bu s. If t h e r espon se r eceived iden t ifies
t h e key a s in va lid, or if n o r espon se is r eceived fr om
t h e key t r a n spon der, t h e SKIM sen ds a n in va lid key
m essa ge t o t h e P CM. Th e P CM will en a ble or disa ble
en gin e oper a t ion ba sed u pon t h e st a t u s of t h e SKIM
m essa ges. It is im por t a n t t o n ot e t h a t t h e defa u lt
con dit ion in t h e P CM is a n in va lid key; t h er efor e, if
n o m essa ge is r eceived fr om t h e SKIM by t h e P CM,
t h e en gin e will be disa bled a n d t h e veh icle im m obi-
lized a ft er t wo secon ds of r u n n in g.
WJ
Th e SKIM a lso sen ds in dica t or ligh t st a t u s m es-
sa ges t o t h e E MIC over t h e P CI da t a bu s t o t ell t h e
E MIC h ow t o oper a t e t h e SKIS in dica t or. Th is in di-
ca t or ligh t st a t u s m essa ge t ells t h e E MIC t o t u r n t h e
in dica t or on for a bou t t h r ee secon ds ea ch t im e t h e
ign it ion swit ch is t u r n ed t o t h e On posit ion a s a bu lb
t est . Aft er com plet ion of t h e bu lb t est , t h e SKIM
sen ds in dica t or ligh t st a t u s m essa ges t o t h e E MIC t o
t u r n t h e in dica t or off, t u r n t h e in dica t or on , or t o
fla sh t h e in dica t or on a n d off. If t h e SKIS in dica t or
la m p fla sh es or st a ys on solid a ft er t h e bu lb t est , it
sign ifies a SKIS fa u lt . If t h e SKIM det ect s a syst em
m a lfu n ct ion a n d/or t h e SKIS h a s becom e in oper a t ive,
t h e SKIS in dica t or will st a y on solid. If t h e SKIM
det ect s a n in va lid key or if a key t r a n spon der-r ela t ed
fa u lt exist s, t h e SKIS in dica t or will fla sh . If t h e veh i-
cle is equ ipped wit h t h e Cu st om er Lea r n t r a n spon der
pr ogr a m m in g fea t u r e, t h e SKIM will a lso sen d m es-
sa ges t o t h e E MIC t o fla sh t h e SKIS in dica t or la m p,
a n d t o t h e BCM t o gen er a t e a sin gle a u dible ch im e
t on e wh en ever t h e Cu st om er Lea r n pr ogr a m m in g
m ode is bein g u t ilized. (Refer t o 8 - E LE CTRICAL/
VE H ICLE TH E F T SE CURITY - STANDARD P RO-
CE DURE - SE NTRY KE Y TRANSP ONDE R
P ROGRAMMING).
Th e SKIS per for m s a self-t est ea ch t im e t h e ign i-
t ion swit ch is t u r n ed t o t h e On posit ion , a n d will
st or e fa u lt in for m a t ion in t h e for m of Dia gn ost ic
Tr ou ble Codes (DTC’s) in SKIM m em or y if a syst em
m a lfu n ct ion is det ect ed. Th e SKIM ca n be dia gn osed,
a n d a n y st or ed DTC’s ca n be r et r ieved u sin g a
DRBIII! sca n t ool. Refer t o t h e a ppr opr ia t e dia gn os-
t ic in for m a t ion .
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e st eer in g colu m n open in g cover
fr om t h e in st r u m en t pa n el. (Refer t o 23 - BODY/IN-
STRUME NT PANE L/STE E RING COLUMN OP E N-
ING COVE R - RE MOVAL).
WJ
SEN T RY K EY I M M OBI LI Z ER M ODU LE (Cont inue d)
(3) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e SKIM con n ect or.
(4) Rem ove t h e scr ew t h a t secu r es t h e SKIM t o
t h e bot t om of t h e st eer in g colu m n h ou sin g (F ig. 16).
Fig. 16
(5) Disen ga ge t h e a n t en n a r in g of t h e SKIM fr om
a r ou n d t h e ign it ion lock cylin der h ou sin g.
(6) Rem ove t h e SKIM fr om t h e st eer in g colu m n .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) P osit ion t h e SKIM t o t h e u n der side of t h e
st eer in g colu m n (F ig. 16).
(2) E n ga ge t h e a n t en n a r in g of t h e SKIM a r ou n d
t h e ign it ion lock cylin der h ou sin g.
(3) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
SKIM t o t h e bot t om of t h e st eer in g colu m n h ou s-
in g.Tigh t en t h e scr ew t o 3.4 N·m (30 in lbs.).
(4) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or t o t h e SKIM con n ect or.
ELECTRONIC CONTROL MODULES 8E - 19
(5) Rein st a ll t h e st eer in g colu m n open in g cover
on t o t h e in st r u m en t pa n el. (Refer t o 23 - BODY/IN-
STRUME NT PANE L/STE E RING COLUMN OP E N-
ING COVE R - INSTALLATION).
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
(7) P er for m t h e SKIS Repla cem en t pr ocedu r e
u sin g t h e DRBIII!.
(8) P er for m t h e SKIS In it ia liza t ion P r ocedu r e
u sin g t h e DRBIII!.
T RAN SM I SSI ON CON T ROL
M ODU LE
DESCRIPTION
Th e Tr a n sm ission Con t r ol Modu le (TCM) is loca t ed
in t h e en gin e com pa r t m en t on t h e r igh t (pa ssen ger )
side a n d is m ou n t ed t o t h e in n er fen der (F ig. 17).
Fig. 17 Transmission Control Module Location
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60–WAY CONNECTOR
OPERATION
Th e Tr a n sm ission Con t r ol Modu le (TCM) con t r ols
a ll elect r on ic oper a t ion s of t h e t r a n sm ission . Th e
TCM r eceives in for m a t ion r ega r din g veh icle oper a -
t ion fr om bot h dir ect a n d in dir ect in pu t s, a n d select s
t h e oper a t ion a l m ode of t h e t r a n sm ission . Dir ect
in pu t s a r e h a r dwir ed t o, a n d u sed specifica lly by t h e
TCM. In dir ect in pu t s or igin a t e fr om ot h er com po-
n en t s/m odu les, a n d a r e sh a r ed wit h t h e TCM via t h e
veh icle com m u n ica t ion bu s.
Som e exa m ples of d ire c t in p u ts t o t h e TCM a r e:
• Ba t t er y (B+) volt a ge
• Ign it ion “ON” volt a ge
• Tr a n sm ission Con t r ol Rela y (Swit ch ed B+)
• Th r ot t le P osit ion Sen sor
• Cr a n ksh a ft P osit ion Sen sor
• Tr a n sm ission Ra n ge Sen sor
8E - 20 ELECTRONIC CONTROL MODULES WJ
T RAN SM I SSI ON CON T ROL M ODU LE (Cont inue d)
• P r essu r e Swit ch es Th e TCM m on it or s gea r r a t io ch a n ges by m on it or-
• Tr a n sm ission Tem per a t u r e Sen sor in g t h e In pu t a n d Ou t pu t Speed Sen sor s. Th e In pu t ,
• In pu t Sh a ft Speed Sen sor or Tu r bin e Speed Sen sor sen ds a n elect r ica l sign a l t o
• Ou t pu t Sh a ft Speed Sen sor t h e TCM t h a t r epr esen t s in pu t sh a ft r pm . Th e Ou t -
• Lin e P r essu r e Sen sor pu t Speed Sen sor pr ovides t h e TCM wit h ou t pu t
Som e exa m ples of in d ire c t in p u ts t o t h e TCM sh a ft speed in for m a t ion .
a r e: By com pa r in g t h e t wo in pu t s, t h e TCM ca n det er-
• E n gin e/Body Iden t ifica t ion m in e t r a n sm ission gea r posit ion . Th is is im por t a n t t o
• Ma n ifold P r essu r e t h e CVI ca lcu la t ion beca u se t h e TCM det er m in es
• Ta r get Idle CVIs by m on it or in g h ow lon g it t a kes for a gea r
• Tor qu e Redu ct ion Con fir m a t ion ch a n ge t o occu r (F ig. 18).
• E n gin e Coola n t Tem per a t u r e
• Am bien t /Ba t t er y Tem per a t u r e
• DRB! Sca n Tool Com m u n ica t ion
Ba sed on t h e in for m a t ion r eceived fr om t h ese va r-
iou s in pu t s, t h e TCM det er m in es t h e a ppr opr ia t e
sh ift sch edu le a n d sh ift poin t s, depen din g on t h e
pr esen t oper a t in g con dit ion s a n d dr iver dem a n d.
Th is is possible t h r ou gh t h e con t r ol of va r iou s dir ect
a n d in dir ect ou t pu t s.
Som e exa m ples of TCM d ire c t o u tp u ts a r e:
• Tr a n sm ission Con t r ol Rela y
• Solen oids
• Tor qu e Redu ct ion Requ est
Som e exa m ples of TCM in d ire c t o u tp u ts a r e:
• Tr a n sm ission Tem per a t u r e (t o P CM)
• P RNDL P osit ion (t o BCM)
In a ddit ion t o m on it or in g in pu t s a n d con t r ollin g
ou t pu t s, t h e TCM h a s ot h er im por t a n t r espon sibili-
t ies a n d fu n ct ion s:
• St or in g a n d m a in t a in in g Clu t ch Volu m e In dexes
(CVI)
• St or in g a n d select in g a ppr opr ia t e Sh ift Sch ed-
u les Fig. 18 Example of CVI Calculation
• Syst em self-dia gn ost ics 1 - OUTPUT SPEED SENSOR
• Dia gn ost ic ca pa bilit ies (wit h DRB! sca n t ool) 2 - OUTPUT SHAFT
3 - CLUTCH PACK
NOTE: If the TCM has been replaced, the “Quick 4 - SEPARATOR PLATE
5 - FRICTION DISCS
Learn Procedure” must be performed. (Refer to 8 -
6 - INPUT SHAFT
ELECTRICAL/ELECTRONIC CONTROL MODULES/
7 - INPUT SPEED SENSOR
TRANSMISSION CONTROL MODULE - STANDARD 8 - PISTON AND SEAL
PROCEDURE)

Gea r r a t ios ca n be det er m in ed by u sin g t h e

BATTERY FEED
A fu sed, dir ect ba t t er y feed t o t h e TCM is u sed for
con t in u ou s power. Th is ba t t er y volt a ge is n ecessa r y
t o r et a in a da pt ive lea r n va lu es in t h e TCM’s RAM
(Ra n dom Access Mem or y). Wh en t h e ba t t er y (B+) is
discon n ect ed, t h is m em or y is lost . Wh en t h e ba t t er y
(B+) is r est or ed, t h is m em or y loss is det ect ed by t h e
TCM a n d a Dia gn ost ic Tr ou ble Code (DTC) is set .
CLUTCH VOLUME INDEXES (CVI)
An im por t a n t fu n ct ion of t h e TCM is t o m on it or
Clu t ch Volu m e In dexes (CVI). CVIs r epr esen t t h e vol-
u m e of flu id n eeded t o com pr ess a clu t ch pa ck.
DRBIII! Sca n Tool a n d r ea din g t h e In pu t /Ou t pu t
Speed Sen sor va lu es in t h e “Mon it or s” displa y. Gea r
r a t io ca n be obt a in ed by dividin g t h e In pu t Speed
Sen sor va lu e by t h e Ou t pu t Speed Sen sor va lu e.
Th e gea r r a t io ch a n ges a s clu t ch es a r e a pplied a n d
r elea sed. By m on it or in g t h e len gt h of t im e it t a kes
for t h e gea r r a t io t o ch a n ge followin g a sh ift r equ est ,
t h e TCM ca n det er m in e t h e volu m e of flu id u sed t o
a pply or r elea se a fr ict ion elem en t .
Th e volu m e of t r a n sm ission flu id n eeded t o a pply
t h e fr ict ion elem en t s a r e con t in u ou sly u pda t ed for
a da pt ive con t r ols. As fr ict ion m a t er ia l wea r s, t h e vol-
u m e of flu id n eed t o a pply t h e elem en t in cr ea ses.
WJ ELECTRONIC CONTROL MODULES 8E - 21
T RAN SM I SSI ON CON T ROL M ODU LE (Cont inue d)
Cer t a in m ech a n ica l fa ilu r es wit h in t h e in pu t clu t ch SHIFT SCHEDULES
a ssem bly ca n ca u se in a dequ a t e or ou t -of-r a n ge ele- As m en t ion ed ea r lier, t h e TCM h a s pr ogr a m m in g
m en t volu m es. Also, defect ive In pu t /Ou t pu t Speed t h a t a llows it t o select a va r iet y of sh ift sch edu les.
Sen sor s a n d wir in g ca n ca u se t h ese con dit ion s. Th e Sh ift sch edu le select ion is depen den t on t h e follow-
followin g ch a r t iden t ifies t h e a ppr opr ia t e clu t ch vol- in g:
u m es a n d wh en t h ey a r e m on it or ed/u pda t ed: • Sh ift lever posit ion
• Th r ot t le posit ion
CLUTCH VOLUMES • E n gin e loa d
• F lu id t em per a t u r e
Proper Clutch
Clutch When Updated • Soft wa r e level
Volume
As dr ivin g con dit ion s ch a n ge, t h e TCM a ppr opr i-
2-1 or 3-1 a t ely a dju st s t h e sh ift sch edu le. Refer t o t h e follow-
L/R 45 to 134
downshift in g ch a r t t o det er m in e t h e a ppr opr ia t e oper a t ion
3-2 kickdown expect ed, depen din g on dr ivin g con dit ion s.
2C 25 to 85
shift
OD 2-3 upshift 30 to 100
4C 3-4 upshift 30 to 85
4-3 kickdown
UD 30 to 100
shift

Schedule Condition Expected Operation

Extreme Cold Oil temperature below -16° F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super Cold Oil temperature between -12° F and - Delayed 2-3 upshift
10° F - Delayed 3-4 upshift - Early 4-3
coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
Cold Oil temperature between 10° F and -Shift schedule is the same as
36° F Super Cold except that the 2-3
upshifts are not delayed.
Warm Oil temperature between 40° F and - Normal operation (upshift,
80° F kickdowns, and coastdowns)
- No EMCC
Hot Oil temperature between 80° F and - Normal operation (upshift,
240° F kickdowns, and coastdowns) -
Normal EMCC operation
Overheat Oil temperature above 240° F or - Delayed 2-3 upshift
engine coolant temperature above - Delayed 3-4 upshift
244° F
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 22 ELECTRONIC CONTROL MODULES
T RAN SM I SSI ON CON T ROL M ODU LE (Cont inue d)
STAN DARD PROCEDU RE
STANDARD PROCEDURE - TCM QUICK LEARN
Th e qu ick lea r n pr ocedu r e r equ ir es t h e u se of t h e
DRBIII! sca n t ool.
Th is pr ogr a m a llows t h e elect r on ic t r a n sm ission
syst em t o r eca libr a t e it self. Th is will pr ovide t h e
pr oper t r a n sm ission oper a t ion . Th e qu ick lea r n pr o-
cedu r e sh ou ld be per for m ed if a n y of t h e followin g
pr ocedu r es a r e per for m ed:
• Tr a n sm ission Assem bly Repla cem en t
• Tr a n sm ission Con t r ol Modu le Repla cem en t
• Solen oid P a ck Repla cem en t
• Clu t ch P la t e a n d/or Sea l Repla cem en t
• Va lve Body Repla cem en t or Recon dit ion
WJ
To per for m t h e Qu ick Lea r n P r ocedu r e, t h e follow-
in g con dit ion s m u st be m et :
• Th e br a kes m u st be a pplied
• Th e en gin e speed m u st be a bove 500 r pm
• Th e t h r ot t le a n gle (TP S) m u st be less t h a n 3
degr ees
• Th e sh ift lever posit ion m u st st a y in PARK u n t il
pr om pt ed t o sh ift t o over dr ive
• Th e sh ift lever posit ion m u st st a y in over dr ive
a ft er t h e Sh ift t o Over dr ive pr om pt u n t il t h e DRB!
in dica t es t h e pr ocedu r e is com plet e
• Th e ca lcu la t ed oil t em per a t u r e m u st be a bove
60° a n d below 200°
WJ ENGINE SYSTEMS 8F - 1

ENGINE SYSTEMS
TABLE OF CON T EN T S

page page

BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

BAT T ERY SY ST EM

TABLE OF CONTENTS
page page

BATTERY SYSTEM STANDARD PROCEDURE - CHECKING

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BATTERY ELECTROLYTE LEVEL . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BATTERY HOLDDOWN
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS ........................7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY BATTERY CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 8 DIAGNOSIS AND TESTING - BATTERY
STANDARD PROCEDURE CABLES ....................... . . . . . 18
STANDARD PROCEDURE - BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
STANDARD PROCEDURE - USING MICRO BATTERY TRAY
420 ELECTRICAL TESTER . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
STANDARD PROCEDURE - BUILT-IN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE - OPEN-CIRCUIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 13
8F - 2 BATTERY SYSTEM
BAT T ERY SY ST EM
DESCRIPTION
A sin gle 12-volt ba t t er y syst em is st a n da r d fa ct or y-
in st a lled equ ipm en t on t h is m odel. All of t h e com po-
n en t s of t h e ba t t er y syst em a r e loca t ed wit h in t h e
en gin e com pa r t m en t of t h e veh icle. Th e ser vice in for-
m a t ion for t h e ba t t er y syst em in t h is veh icle cover s
t h e followin g r ela t ed com pon en t s, wh ich a r e cover ed
in fu r t h er det a il elsewh er e in t h is ser vice m a n u a l:
• B a tte ry - Th e st or a ge ba t t er y pr ovides a r eli-
a ble m ea n s of st or in g a r en ewa ble sou r ce of elect r ica l
en er gy wit h in t h e veh icle.
• B a tte ry Ca ble s - Th e ba t t er y ca bles con n ect
t h e ba t t er y t er m in a l post s t o t h e veh icle elect r ica l
syst em .
• B a tte ry Ho ld d o w n - Th e ba t t er y h olddown
h a r dwa r e secu r es t h e ba t t er y in t h e ba t t er y t r a y in
t h e en gin e com pa r t m en t .
• B a tte ry Tra y - Th e ba t t er y t r a y pr ovides a
secu r e m ou n t in g loca t ion in t h e veh icle for t h e ba t -
t er y a n d a n a n ch or poin t for t h e ba t t er y h olddown
h a r dwa r e.
F or ba t t er y syst em m a in t en a n ce sch edu les a n d ju m p
st a r t in g pr ocedu r es, see t h e own er ’s m a n u a l in t h e veh i-
cle glove box. Opt ion a lly, r efer t o Lu br ica t ion a n d Ma in -
t en a n ce for t h e r ecom m en ded ba t t er y m a in t en a n ce
sch edu les a n d for t h e pr oper ba t t er y ju m p st a r t in g pr o-
cedu r es. Wh ile ba t t er y ch a r gin g ca n be con sider ed a
m a in t en a n ce pr ocedu r e, t h e ba t t er y ch a r gin g pr ocedu r es
a n d r ela t ed in for m a t ion a r e loca t ed in t h e st a n da r d pr o-
cedu r es sect ion of t h is ser vice m a n u a l. Th is wa s don e
beca u se t h e ba t t er y m u st be fu lly-ch a r ged befor e a n y
ba t t er y syst em dia gn osis or t est in g pr ocedu r es ca n be
per for m ed. Refer t o St a n da r d pr ocedu r es for t h e pr oper
ba t t er y ch a r gin g pr ocedu r es.
OPERATION
Th e ba t t er y syst em is design ed t o pr ovide a sa fe,
efficien t , r elia ble a n d m obile m ea n s of deliver in g a n d
st or in g elect r ica l en er gy. Th is elect r ica l en er gy is
r equ ir ed t o oper a t e t h e en gin e st a r t in g syst em , a s
well a s t o oper a t e m a n y of t h e ot h er veh icle a cces-
sor y syst em s for lim it ed du r a t ion s wh ile t h e en gin e
a n d/or t h e ch a r gin g syst em a r e n ot oper a t in g. Th e
ba t t er y syst em is a lso design ed t o pr ovide a r eser ve
of elect r ica l en er gy t o su pplem en t t h e ch a r gin g sys-
t em for sh or t du r a t ion s wh ile t h e en gin e is r u n n in g
a n d t h e elect r ica l cu r r en t dem a n ds of t h e veh icle
exceed t h e ou t pu t of t h e ch a r gin g syst em . In a ddit ion
t o deliver in g, a n d st or in g elect r ica l en er gy for t h e
veh icle, t h e ba t t er y syst em ser ves a s a ca pa cit or a n d
volt a ge st a bilizer for t h e veh icle elect r ica l syst em . It
a bsor bs m ost a bn or m a l or t r a n sien t volt a ges ca u sed
by t h e swit ch in g of a n y of t h e elect r ica l com pon en t s
or cir cu it s in t h e veh icle.
WJ
DIAGNOSIS AND TESTING - BATTERY SYSTEM
Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s in t h e
veh icle oper a t e wit h on e a n ot h er a n d m u st be t est ed
a s a com plet e syst em . In or der for t h e en gin e t o st a r t
a n d t h e ba t t er y t o m a in t a in it s ch a r ge pr oper ly, a ll of
t h e com pon en t s t h a t a r e u sed in t h ese syst em s m u st
per for m wit h in specifica t ion s. It is im por t a n t t h a t
t h e ba t t er y, st a r t in g, a n d ch a r gin g syst em s be t h or-
ou gh ly t est ed a n d in spect ed a n y t im e a ba t t er y n eeds
t o be ch a r ged or r epla ced. Th e ca u se of a bn or m a l ba t -
t er y disch a r ge, over ch a r gin g or ea r ly ba t t er y fa ilu r e
m u st be dia gn osed a n d cor r ect ed befor e a ba t t er y is
r epla ced a n d befor e a veh icle is r et u r n ed t o ser vice.
Th e ser vice in for m a t ion for t h ese syst em s h a s been
sepa r a t ed wit h in t h is ser vice m a n u a l t o m a ke it ea s-
ier t o loca t e t h e specific in for m a t ion you a r e seekin g.
H owever, wh en a t t em pt in g t o dia gn ose a n y of t h ese
syst em s, it is im por t a n t t h a t you keep t h eir in t er de-
pen den cy in m in d.
Th e dia gn ost ic pr ocedu r es u sed for t h e ba t t er y,
st a r t in g, a n d ch a r gin g syst em s in clu de t h e m ost
ba sic con ven t ion a l dia gn ost ic m et h ods, t o t h e m or e
soph ist ica t ed On -Boa r d Dia gn ost ics (OBD) bu ilt in t o
t h e P ower t r a in Con t r ol Modu le (P CM). Use of a n
in du ct ion -t ype m illia m per e a m m et er, a volt /oh m m e-
t er, a ba t t er y ch a r ger, a ca r bon pile r h eost a t (loa d
t est er ) a n d a 12-volt t est la m p m a y be r equ ir ed. All
OBD-sen sed syst em s a r e m on it or ed by t h e P CM.
E a ch m on it or ed cir cu it is a ssign ed a Dia gn ost ic Tr ou -
ble Code (DTC). Th e P CM will st or e a DTC in elec-
t r on ic m em or y for a n y fa ilu r e it det ect s. Refer t o
Ch a r gin g Syst em for t h e pr oper ch a r gin g syst em on -
boa r d dia gn ost ic t est pr ocedu r es.
MICRO 420 ELECTRICAL SYSTEM TESTER
Th e Micr o 420 a u t om ot ive ba t t er y t est er is
design ed t o h elp t h e dea ler sh ip t ech n icia n s dia gn ose
a defect ive ba t t er y. F ollow t h e in st r u ct ion m a n u a l
su pplied wit h t h e t est er t o pr oper ly dia gn ose a veh i-
cle. If t h e in st r u ct ion m a n u a l is n ot a va ila ble r efer t o
t h e st a n da r d pr ocedu r e in t h is sect ion , wh ich
in clu des t h e dir ect ion s for u sin g t h e Micr o 420 elec-
t r ica l syst em t est er.
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BAT T ERY SY ST EM (Cont inue d)
BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES
THE BATTERY SEEMS 1. The electrical system
WEAK OR DEAD WHEN ignition-off draw is excessive.
ATTEMPTING TO START
THE ENGINE.
2. The charging system is
faulty.
3. The battery is discharged.
4. The battery terminal
connections are loose or
corroded.
5. The battery has an
incorrect size or rating for
this vehicle.
6. The battery is faulty.
7. The starting system is
faulty.
8. The battery is physically
damaged.
BATTERY SYSTEM 8F - 3
CORRECTION
1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. Determine the battery cranking capacity using
the Micro 420 battery tester. Refer to the
Standard Procedures in this section for additional
test procedures. Replace the faulty battery, as
required.
7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
8F - 4 BATTERY SYSTEM
BAT T ERY SY ST EM (Cont inue d)
BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES
THE BATTERY STATE OF 1. The battery has an
CHARGE CANNOT BE incorrect size or rating for
MAINTAINED. this vehicle.
2. The battery terminal
connections are loose or
corroded.
3. The electrical system
ignition-off draw is excessive.
4. The battery is faulty.
5. The starting system is
faulty.
6. The charging system is
faulty.
7. Electrical loads exceed the
output of the charging
system.
8. Slow driving or prolonged
idling with high-amperage
draw systems in use.
THE BATTERY WILL NOT 1. The battery is faulty.
ACCEPT A CHARGE.
ABNORMAL BATTERY DISCHARGING
An y of t h e followin g con dit ion s ca n r esu lt in a bn or-
m a l ba t t er y disch a r gin g:
1. A fa u lt y or in cor r ect ch a r gin g syst em com po-
n en t . Refer t o Ch a r gin g Syst em for a ddit ion a l ch a r g-
in g syst em dia gn osis a n d t est in g pr ocedu r es.
2. A fa u lt y or in cor r ect ba t t er y. Use Micr o 420 ba t -
t er y t est er a n d r efer t o Ba t t er y Syst em for a ddit ion a l
ba t t er y dia gn osis a n d t est in g pr ocedu r es.
3. A fa u lt y cir cu it or com pon en t ca u sin g excessive
ign it ion -off dr a w.
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CORRECTION
1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
battery, as required.
2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. Determine if the charging system is performing
to specifications using the Micro 420 battery.
Refer to Charging System for additional charging
system diagnosis and testing procedures. Repair
the faulty charging system, as required.
7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Advise the vehicle operator, as required.
1. Test the battery using the Micro 420 battery
tester. Charge or replace the faulty battery, as
required.
4. E lect r ica l loa ds t h a t exceed t h e ou t pu t of t h e
ch a r gin g syst em . Th is ca n be du e t o equ ipm en t
in st a lled a ft er m a n u fa ct u r e, or r epea t ed sh or t t r ip
u se.
5. A fa u lt y or in cor r ect st a r t in g syst em com pon en t .
Refer t o St a r t in g Syst em for t h e pr oper st a r t in g sys-
t em dia gn osis a n d t est in g pr ocedu r es.
6. Cor r oded or loose ba t t er y post s a n d/or t er m in a l
cla m ps.
7. Slow dr ivin g speeds (h ea vy t r a ffic con dit ion s) or
pr olon ged idlin g, wit h h igh -a m per a ge dr a w syst em s
in u se.
WJ BATTERY SYSTEM 8F - 5
BAT T ERY SY ST EM (Cont inue d)

CLEANING
Th e followin g in for m a t ion det a ils t h e r ecom m en ded
clea n in g pr ocedu r es for t h e ba t t er y a n d r ela t ed com -
pon en t s. In a ddit ion t o t h e m a in t en a n ce sch edu les
fou n d in t h is ser vice m a n u a l a n d t h e own er ’s m a n -
u a l, it is r ecom m en ded t h a t t h ese pr ocedu r es be per-
for m ed a n y t im e t h e ba t t er y or r ela t ed com pon en t s
m u st be r em oved for veh icle ser vice.
(1) Clea n t h e ba t t er y ca ble t er m in a l cla m ps of a ll
cor r osion . Rem ove a n y cor r osion u sin g a wir e br u sh
or a post a n d t er m in a l clea n in g t ool, a n d a sodiu m
bica r bon a t e (ba kin g soda ) a n d wa r m wa t er clea n in g
solu t ion (F ig. 1).

Fig. 2 Clean Battery - Typical

1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY

(4) Clea n a n y cor r osion fr om t h e ba t t er y t er m in a l

post s wit h a wir e br u sh or a post a n d t er m in a l
clea n er, a n d a sodiu m bica r bon a t e (ba kin g soda ) a n d
wa r m wa t er clea n in g solu t ion (F ig. 3).

Fig. 1 Clean Battery Cable Terminal Clamp - Typical

1 - TERMINAL BRUSH
2 - BATTERY CABLE

(2) Clea n t h e ba t t er y t r a y a n d ba t t er y h olddown

h a r dwa r e of a ll cor r osion . Rem ove a n y cor r osion
u sin g a wir e br u sh a n d a sodiu m bica r bon a t e (ba kin g
soda ) a n d wa r m wa t er clea n in g solu t ion . P a in t a n y
exposed ba r e m et a l.
(3) If t h e r em oved ba t t er y is t o be r ein st a lled,
clea n t h e ou t side of t h e ba t t er y ca se a n d t h e t op
cover wit h a sodiu m bica r bon a t e (ba kin g soda ) a n d
wa r m wa t er clea n in g solu t ion u sin g a st iff br ist le
pa r t s clea n in g br u sh t o r em ove a n y a cid film (F ig. 2).
Rin se t h e ba t t er y wit h clea n wa t er. E n su r e t h a t t h e
clea n in g solu t ion does n ot en t er t h e ba t t er y cells
t h r ou gh t h e ven t h oles. If t h e ba t t er y is bein g Fig. 3 Clean Battery Terminal Post - Typical
r epla ced, r efer t o Ba t t er y Syst em Specifica t ion s for 1 - TERMINAL BRUSH
t h e fa ct or y-in st a lled ba t t er y specifica t ion s. Con fir m 2 - BATTERY CABLE
t h a t t h e r epla cem en t ba t t er y is t h e cor r ect size a n d 3 - BATTERY
h a s t h e cor r ect r a t in gs for t h e veh icle.
8F - 6 BATTERY SYSTEM
BAT T ERY SY ST EM (Cont inue d)
INSPECTION
Th e followin g in for m a t ion det a ils t h e r ecom m en ded
in spect ion pr ocedu r es for t h e ba t t er y a n d r ela t ed
com pon en t s. In a ddit ion t o t h e m a in t en a n ce sch ed-
u les fou n d in t h is ser vice m a n u a l a n d t h e own er ’s
m a n u a l, it is r ecom m en ded t h a t t h ese pr ocedu r es be
per for m ed a n y t im e t h e ba t t er y or r ela t ed com po-
n en t s m u st be r em oved for veh icle ser vice.
(1) In spect t h e ba t t er y ca ble t er m in a l cla m ps for
da m a ge. Repla ce a n y ba t t er y ca ble t h a t h a s a da m -
a ged or defor m ed t er m in a l cla m p.
(2) In spect t h e ba t t er y t r a y a n d ba t t er y h olddown
h a r dwa r e for da m a ge. Repla ce a n y da m a ged pa r t s.
(3) Slide t h e t h er m a l gu a r d off of t h e ba t t er y ca se.
In spect t h e ba t t er y ca se for cr a cks or ot h er da m a ge
t h a t cou ld r esu lt in elect r olyt e lea ks. Also, ch eck t h e
ba t t er y t er m in a l post s for loosen ess. Ba t t er ies wit h
da m a ged ca ses or loose t er m in a l post s m u st be
r epla ced.
(4) In spect t h e ba t t er y bu ilt -in t est in dica t or sigh t
gla ss for a n in dica t ion of t h e ba t t er y con dit ion . If t h e
ba t t er y is disch a r ged, ch a r ge a s r equ ir ed. Refer t o
St a n da r d P r ocedu r es for t h e pr oper ba t t er y bu ilt -in
in dica t or t est pr ocedu r es. Also r efer t o St a n da r d P r o-
cedu r es for t h e pr oper ba t t er y ch a r gin g pr ocedu r es.
BATTERY CLASSIFICATIONS & RATINGS
BCI Group Size Cold Cranking
Part Number
Classification Amperage
56041113 65 625
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SPECIFICATIONS
Th e ba t t er y Gr ou p Size n u m ber, t h e Cold Cr a n kin g
Am per a ge (CCA) r a t in g, a n d t h e Reser ve Ca pa cit y
(RC) r a t in g or Am per e-H ou r s (AH ) r a t in g ca n be
fou n d on t h e or igin a l equ ipm en t ba t t er y la bel. Be
cer t a in t h a t a r epla cem en t ba t t er y h a s t h e cor r ect
Gr ou p Size n u m ber, a s well a s CCA, a n d RC or AH
r a t in gs t h a t equ a l or exceed t h e or igin a l equ ipm en t
specifica t ion for t h e veh icle bein g ser viced. Ba t t er y
sizes a n d r a t in gs a r e discu ssed in m or e det a il below.
• Gro u p S ize - Th e ou t side dim en sion s a n d t er-
m in a l pla cem en t of t h e ba t t er y con for m t o st a n da r ds
est a blish ed by t h e Ba t t er y Cou n cil In t er n a t ion a l
(BCI). E a ch ba t t er y is a ssign ed a BCI Gr ou p Size
n u m ber t o h elp iden t ify a cor r ect ly-sized r epla ce-
m en t .
• Co ld Cra n k in g Am p e ra g e - Th e Cold Cr a n k-
in g Am per a ge (CCA) r a t in g specifies h ow m u ch cu r-
r en t (in a m per es) t h e ba t t er y ca n deliver for t h ir t y
secon ds a t -18° C (0° F ). Ter m in a l volt a ge m u st n ot
fa ll below 7.2 volt s du r in g or a ft er t h e t h ir t y secon d
disch a r ge per iod. Th e CCA r equ ir ed is gen er a lly
h igh er a s en gin e displa cem en t in cr ea ses, depen din g
a lso u pon t h e st a r t er cu r r en t dr a w r equ ir em en t s.
• Re s e rv e Ca p a c ity - Th e Reser ve Ca pa cit y (RC)
r a t in g specifies t h e t im e (in m in u t es) it t a kes for ba t -
t er y t er m in a l volt a ge t o fa ll below 10.5 volt s, a t a
disch a r ge r a t e of 25 a m per es. RC is det er m in ed wit h
t h e ba t t er y fu lly-ch a r ged a t 26.7° C (80° F ). Th is r a t -
in g est im a t es h ow lon g t h e ba t t er y m igh t la st a ft er a
ch a r gin g syst em fa ilu r e, u n der m in im u m elect r ica l
loa d.
• Am p e re -Ho u rs - Th e Am per e-H ou r s (AH ) r a t -
in g specifies t h e cu r r en t (in a m per es) t h a t a ba t t er y
ca n deliver st ea dily for t wen t y h ou r s, wit h t h e volt -
a ge in t h e ba t t er y n ot fa llin g below 10.5 volt s. Th is
r a t in g is a lso som et im es iden t ified a s t h e t wen t y-
h ou r disch a r ge r a t in g.
Reserve Ampere - Load Test
Capacity Hours Amperage
120 Minutes 69 300
WJ
BAT T ERY SY ST EM (Cont inue d)
SPECIAL TOOLS
MICRO 420 BATTERY AND CHARGING SYSTEM
TESTER
BAT T ERY
DESCRIPTION
A la r ge ca pa cit y, low-m a in t en a n ce st or a ge ba t t er y
(F ig. 4) is st a n da r d fa ct or y-in st a lled equ ipm en t on
t h is m odel. Ma le post t ype t er m in a ls m a de of a soft
lea d m a t er ia l pr ot r u de fr om t h e t op of t h e m olded
pla st ic ba t t er y ca se t o pr ovide t h e m ea n s for con n ect -
in g t h e ba t t er y t o t h e veh icle elect r ica l syst em . Th e
ba t t er y posit ive t er m in a l post is visibly la r ger in
dia m et er t h a n t h e n ega t ive t er m in a l post , for ea sy
iden t ifica t ion . Th e let t er s P OS a n d N EG a r e a lso
m olded in t o t h e t op of t h e ba t t er y ca se a dja cen t t o
t h eir r espect ive posit ive a n d n ega t ive t er m in a l post s
for a ddit ion a l iden t ifica t ion con fir m a t ion . Refer t o
B a tte ry Ca ble s in t h e in dex of t h is ser vice m a n u a l
for t h e loca t ion of m or e in for m a t ion on t h e ba t t er y
ca bles t h a t con n ect t h e ba t t er y t o t h e veh icle elect r i-
ca l syst em .
Th is ba t t er y is design ed t o pr ovide a sa fe, efficien t
a n d r elia ble m ea n s of st or in g elect r ica l en er gy in a
ch em ica l for m . Th is m ea n s of en er gy st or a ge a llows
t h e ba t t er y t o pr odu ce t h e elect r ica l en er gy r equ ir ed
t o oper a t e t h e en gin e st a r t in g syst em , a s well a s t o
oper a t e m a n y of t h e ot h er veh icle a ccessor y syst em s
for lim it ed du r a t ion s wh ile t h e en gin e a n d/or t h e
ch a r gin g syst em a r e n ot oper a t in g. Th e ba t t er y is
m a de u p of six in dividu a l cells t h a t a r e con n ect ed in
ser ies. E a ch cell con t a in s posit ively ch a r ged pla t e
gr ou ps t h a t a r e con n ect ed wit h lea d st r a ps t o t h e
BATTERY SYSTEM 8F - 7
Fig. 4 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - TEST INDICATOR
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
posit ive t er m in a l post , a n d n ega t ively ch a r ged pla t e
gr ou ps t h a t a r e con n ect ed wit h lea d st r a ps t o t h e
n ega t ive t er m in a l post . E a ch pla t e con sist s of a st iff
m esh fr a m ewor k or gr id coa t ed wit h lea d dioxide
(posit ive pla t e) or spon ge lea d (n ega t ive pla t e). In su -
la t or s or pla t e sepa r a t or s m a de of a n on -con du ct ive
m a t er ia l a r e in ser t ed bet ween t h e posit ive a n d n ega -
t ive pla t es t o pr even t t h em fr om con t a ct in g or sh or t -
in g a ga in st on e a n ot h er. Th ese dissim ila r m et a l
pla t es a r e su bm er ged in a su lfu r ic a cid a n d wa t er
solu t ion ca lled a n elect r olyt e.
Som e fa ct or y-in st a lled ba t t er ies h a ve a bu ilt -in t est
in dica t or (h ydr om et er ). Th e color visible in t h e sigh t
gla ss of t h e in dica t or will r evea l t h e ba t t er y con di-
t ion . F or m or e in for m a t ion on t h e u se of t h e bu ilt -in
t est in dica t or, r efer t o S ta n d a rd P ro c e d u re s Th e
fa c to ry -in s ta lle d lo w -m a in te n a n c e ba tte ry h a s
re m o v a ble ba tte ry c e ll c a p s . Dist illed wa t er ca n
be a dded t o t h is ba t t er y. Th e ba t t er y is n ot sea led
a n d h a s ven t h oles in t h e cell ca ps. Th e ch em ica l
com posit ion of t h e m et a l coa t ed pla t es wit h in t h e
low-m a in t en a n ce ba t t er y r edu ces ba t t er y ga ssin g a n d
wa t er loss, a t n or m a l ch a r ge a n d disch a r ge r a t es.
Th er efor e, t h e ba t t er y sh ou ld n ot r equ ir e a ddit ion a l
wa t er in n or m a l ser vice. If t h e elect r olyt e level in
t h is ba t t er y does becom e low, dist illed wa t er m u st be
a dded. H owever, r a pid loss of elect r olyt e ca n be
ca u sed by a n over ch a r gin g con dit ion . Be cer t a in t o
8F - 8 BATTERY SYSTEM
BAT T ERY (Cont inue d)
dia gn ose t h e ch a r gin g syst em a ft er r eplen ish in g t h e
wa t er in t h e ba t t er y for a low elect r olyt e con dit ion
a n d befor e r et u r n in g t h e veh icle t o ser vice. Refer t o
Ch a rg in g S y s te m for a ddit ion a l in for m a t ion .
F or ba t t er y m a in t en a n ce sch edu les a n d ju m p st a r t -
in g pr ocedu r es, see t h e own er ’s m a n u a l in t h e veh icle
glove box. Opt ion a lly, r efer t o Ma in te n a n c e S c h e d -
u le s a n d J u m p S ta rtin g , To w in g a n d Ho is tin g in
t h e in dex of t h is ser vice m a n u a l for t h e loca t ion of
t h e r ecom m en ded ba t t er y m a in t en a n ce sch edu les a n d
t h e pr oper ba t t er y ju m p st a r t in g pr ocedu r es. Wh ile
ba t t er y ch a r gin g ca n be con sider ed a m a in t en a n ce
pr ocedu r e, t h e ba t t er y ch a r gin g pr ocedu r es a n d in for-
m a t ion a r e loca t ed in t h e ser vice pr ocedu r es sect ion
of t h is ser vice m a n u a l. Th is wa s don e beca u se t h e
ba t t er y m u st be fu lly-ch a r ged befor e a n y ba t t er y
dia gn osis or t est in g pr ocedu r es ca n be per for m ed.
Refer t o S ta n d a rd P ro c e d u re s in t h e in dex of t h is
ser vice m a n u a l for t h e loca t ion of t h e pr oper ba t t er y
ch a r gin g pr ocedu r es.
OPERATION
Th e ba t t er y is design ed t o st or e elect r ica l en er gy in
a ch em ica l for m . Wh en a n elect r ica l loa d is a pplied t o
t h e t er m in a ls of t h e ba t t er y, a n elect r och em ica l r ea c-
t ion occu r s. Th is r ea ct ion ca u ses t h e ba t t er y t o dis-
ch a r ge elect r ica l cu r r en t fr om it s t er m in a ls. As t h e
ba t t er y disch a r ges, a gr a du a l ch em ica l ch a n ge t a kes
pla ce wit h in ea ch cell. Th e su lfu r ic a cid in t h e elec-
t r olyt e com bin es wit h t h e pla t e m a t er ia ls, ca u sin g
bot h pla t es t o slowly ch a n ge t o lea d su lfa t e. At t h e
sa m e t im e, oxygen fr om t h e posit ive pla t e m a t er ia l
com bin es wit h h ydr ogen fr om t h e su lfu r ic a cid, ca u s-
in g t h e elect r olyt e t o becom e m a in ly wa t er. Th e
ch em ica l ch a n ges wit h in t h e ba t t er y a r e ca u sed by
t h e m ovem en t of excess or fr ee elect r on s bet ween t h e
posit ive a n d n ega t ive pla t e gr ou ps. Th is m ovem en t of
elect r on s pr odu ces a flow of elect r ica l cu r r en t
t h r ou gh t h e loa d device a t t a ch ed t o t h e ba t t er y t er-
m in a ls.
As t h e pla t e m a t er ia ls becom e m or e sim ila r ch em -
ica lly, a n d t h e elect r olyt e becom es less a cid, t h e volt -
a ge pot en t ia l of ea ch cell is r edu ced. H owever, by
ch a r gin g t h e ba t t er y wit h a volt a ge h igh er t h a n t h a t
of t h e ba t t er y it self, t h e ba t t er y disch a r gin g pr ocess
is r ever sed. Ch a r gin g t h e ba t t er y gr a du a lly ch a n ges
t h e su lfa t ed lea d pla t es ba ck in t o spon ge lea d a n d
lea d dioxide, a n d t h e wa t er ba ck in t o su lfu r ic a cid.
Th is a ct ion r est or es t h e differ en ce in t h e elect r on
ch a r ges deposit ed on t h e pla t es, a n d t h e volt a ge
pot en t ia l of t h e ba t t er y cells. F or a ba t t er y t o r em a in
u sefu l, it m u st be a ble t o pr odu ce h igh -a m per a ge cu r-
r en t over a n ext en ded per iod. A ba t t er y m u st a lso be
a ble t o a ccept a ch a r ge, so t h a t it s volt a ge pot en t ia l
m a y be r est or ed.
WJ
Th e ba t t er y is ven t ed t o r elea se excess h ydr ogen
ga s t h a t is cr ea t ed wh en t h e ba t t er y is bein g ch a r ged
or disch a r ged. H owever, even wit h t h ese ven t s,
h ydr ogen ga s ca n collect in or a r ou n d t h e ba t t er y. If
h ydr ogen ga s is exposed t o fla m e or spa r ks, it m a y
ign it e. If t h e elect r olyt e level is low, t h e ba t t er y m a y
a r c in t er n a lly a n d explode. If t h e ba t t er y is equ ipped
wit h r em ova ble cell ca ps, a dd dist illed wa t er wh en -
ever t h e elect r olyt e level is below t h e t op of t h e
pla t es. If t h e ba t t er y cell ca ps ca n n ot be r em oved, t h e
ba t t er y m u st be r epla ced if t h e elect r olyt e level
becom es low.
DIAGNOSIS AND TESTING - BATTERY
Th e ba t t er y m u st be com plet ely ch a r ged a n d t h e
t er m in a ls sh ou ld be pr oper ly clea n ed a n d in spect ed
befor e dia gn ost ic pr ocedu r es a r e per for m ed. Refer t o
Ba t t er y Syst em Clea n in g for t h e pr oper clea n in g pr o-
cedu r es, a n d Ba t t er y Syst em In spect ion for t h e
pr oper ba t t er y in spect ion pr ocedu r es. Refer t o St a n -
da r d P r ocedu r es for t h e pr oper ba t t er y ch a r gin g pr o-
cedu r es.
MICRO 420 ELECTRICAL SYSTEM TESTER
Th e Micr o420 a u t om ot ive ba t t er y t est er is design ed
t o h elp t h e dea ler sh ip t ech n icia n s dia gn ose t h e ca u se
of a defect ive ba t t er y. F ollow t h e in st r u ct ion m a n u a l
su pplied wit h t h e t est er t o pr oper ly dia gn ose a veh i-
cle. If t h e in st r u ct ion m a n u a l is n ot a va ila ble r efer t o
t h e st a n da r d pr ocedu r e in t h is sect ion , wh ich
in clu des t h e dir ect ion s for u sin g t h e Micr o420 elect r i-
ca l syst em t est er.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
A ba t t er y t h a t will n ot a ccept a ch a r ge is fa u lt y,
a n d m u st be r epla ced. F u r t h er t est in g is n ot
r equ ir ed. A fu lly-ch a r ged ba t t er y m u st be loa d t est ed
WJ
BAT T ERY (Cont inue d)
t o det er m in e it s cr a n kin g ca pa cit y. A ba t t er y t h a t is
fu lly-ch a r ged, bu t does n ot pa ss t h e loa d t est , is
fa u lt y a n d m u st be r epla ced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
STAN DARD PROCEDU RE
STANDARD PROCEDURE - BATTERY
CHARGING
Ba t t er y ch a r gin g is t h e m ea n s by wh ich t h e ba t -
t er y ca n be r est or ed t o it s fu ll volt a ge pot en t ia l. A
ba t t er y is fu lly-ch a r ged wh en :
• Micr o 420 elect r ica l syst em t est er in dica t es ba t -
t er y is OK.
• All of t h e ba t t er y cells a r e ga ssin g fr eely du r in g
ba t t er y ch a r gin g.
• Th r ee h ydr om et er t est s, t a ken a t on e-h ou r in t er-
va ls, in dica t e n o in cr ea se in t h e t em per a t u r e-cor-
r ect ed specific gr a vit y of t h e ba t t er y elect r olyt e.
• Open -cir cu it volt a ge of t h e ba t t er y is 12.4 volt s
or a bove.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1° C [30° F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
BATTERY SYSTEM 8F - 9
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
Aft er t h e ba t t er y h a s been ch a r ged t o 12.4 volt s or
gr ea t er, per for m a loa d t est t o det er m in e t h e ba t t er y
cr a n kin g ca pa cit y. Refer t o St a n da r d P r ocedu r es for
t h e pr oper ba t t er y loa d t est pr ocedu r es. If t h e ba t t er y
will en du r e a loa d t est , r et u r n t h e ba t t er y t o ser vice.
If t h e ba t t er y will n ot en du r e a loa d t est , it is fa u lt y
a n d m u st be r epla ced.
Clea n a n d in spect t h e ba t t er y h old down s, t r a y,
t er m in a ls, post s, a n d t op befor e com plet in g ba t t er y
ser vice. Refer t o Ba t t er y Syst em Clea n in g for t h e
pr oper ba t t er y syst em clea n in g pr ocedu r es, a n d Ba t -
t er y Syst em In spect ion for t h e pr oper ba t t er y syst em
in spect ion pr ocedu r es.
CHARGING A COMPLETELY DISCHARGED
BATTERY
Th e followin g pr ocedu r e sh ou ld be u sed t o r ech a r ge
a com plet ely disch a r ged ba t t er y. Un less t h is pr oce-
du r e is pr oper ly followed, a good ba t t er y m a y be
n eedlessly r epla ced.
(1) Mea su r e t h e volt a ge a t t h e ba t t er y post s wit h a
volt m et er, a ccu r a t e t o 1/10 (0.10) volt (F ig. 5). If t h e
r ea din g is below t en volt s, t h e ba t t er y ch a r gin g cu r-
r en t will be low. It cou ld t a ke som e t im e befor e t h e
ba t t er y a ccept s a cu r r en t gr ea t er t h a n a few m illia m -
per es. Su ch low cu r r en t m a y n ot be det ect a ble on t h e
a m m et er s bu ilt in t o m a n y ba t t er y ch a r ger s.
8F - 10 BATTERY SYSTEM WJ
BAT T ERY (Cont inue d)
ver y low a t fir st . As t h e ba t t er y wa r m s, it will a ccept
a h igh er ch a r gin g cu r r en t r a t e (a m per a ge).
• Ch a rg e r Ca p a c ity - A ba t t er y ch a r ger t h a t
su pplies on ly five a m per es will r equ ir e a lon ger
ch a r gin g t im e. A ba t t er y ch a r ger t h a t su pplies
t wen t y a m per es or m or e will r equ ir e a sh or t er ch a r g-
in g t im e.
• S ta te -Of-Ch a rg e - A com plet ely disch a r ged ba t -
t er y r equ ir es m or e ch a r gin g t im e t h a n a pa r t ia lly
disch a r ged ba t t er y. E lect r olyt e is n ea r ly pu r e wa t er
in a com plet ely disch a r ged ba t t er y. At fir st , t h e
ch a r gin g cu r r en t (a m per a ge) will be low. As t h e ba t -
t er y ch a r ges, t h e specific gr a vit y of t h e elect r olyt e
will gr a du a lly r ise.
Fig. 5 Voltmeter - Typical Th e Ba t t er y Ch a r gin g Tim e Ta ble gives a n in dica -
t ion of t h e t im e r equ ir ed t o ch a r ge a t ypica l ba t t er y
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive a t r oom t em per a t u r e ba sed u pon t h e ba t t er y st a t e-of-
ca ble. Con n ect t h e ba t t er y ch a r ger lea ds. Som e ba t - ch a r ge a n d t h e ch a r ger ca pa cit y.
t er y ch a r ger s a r e equ ipped wit h pola r it y-sen sin g cir-
cu it r y. Th is cir cu it r y pr ot ect s t h e ba t t er y ch a r ger a n d
BATTERY CHARGING TIME TABLE
t h e ba t t er y fr om bein g da m a ged if t h ey a r e im pr op-
er ly con n ect ed. If t h e ba t t er y st a t e-of-ch a r ge is t oo Charging 10
5 Amps 20 Amps
low for t h e pola r it y-sen sin g cir cu it r y t o det ect , t h e Amperage Amps
ba t t er y ch a r ger will n ot oper a t e. Th is m a kes it Open Circuit Hours Charging @ 21° C (70°
a ppea r t h a t t h e ba t t er y will n ot a ccept ch a r gin g cu r- Voltage F)
r en t . See t h e in st r u ct ion s pr ovided by t h e m a n u fa c-
12.25 to 12.49 6 hours 3 hours 1.5
t u r er of t h e ba t t er y ch a r ger for det a ils on h ow t o
hours
bypa ss t h e pola r it y-sen sin g cir cu it r y.
(3) Ba t t er y ch a r ger s va r y in t h e a m ou n t of volt a ge 12.00 to 12.24 10 hours 5 hours 2.5
a n d cu r r en t t h ey pr ovide. Th e a m ou n t of t im e hours
r equ ir ed for a ba t t er y t o a ccept m ea su r a ble ch a r gin g 10.00 to 11.99 14 hours 7 hours 3.5
cu r r en t a t va r iou s volt a ges is sh own in t h e Ch a r ge hours
Ra t e Ta ble. If t h e ch a r gin g cu r r en t is st ill n ot m ea - Below 10.00 18 hours 9 hours 4.5
su r a ble a t t h e en d of t h e ch a r gin g t im e, t h e ba t t er y hours
is fa u lt y a n d m u st be r epla ced. If t h e ch a r gin g cu r-
r en t is m ea su r a ble du r in g t h e ch a r gin g t im e, t h e ba t -
STANDARD PROCEDURE - USING MICRO 420
t er y m a y be good a n d t h e ch a r gin g sh ou ld be
com plet ed in t h e n or m a l m a n n er. ELECTRICAL TESTER
Alwa ys u se t h e Micr o 420 In st r u ct ion Ma n u a l t h a t
wa s su pplied wit h t h e t est er a s a r efer en ce. If t h e
CHARGE RATE TABLE In st r u ct ion Ma n u a l is n ot a va ila ble t h e followin g pr o-
Voltage Hours cedu r e ca n be u sed:
16.0 volts maximum up to 4 hours
WARNING: ALWAYS WEAR APPROPRIATE EYE
14.0 to 15.9 volts up to 8 hours PROTECTION AND USE EXTREME CAUTION WHEN
13.9 volts or less up to 16 hours WORKING WITH BATTERIES.

CHARGING TIME REQUIRED

Th e t im e r equ ir ed t o ch a r ge a ba t t er y will va r y,
depen din g u pon t h e followin g fa ct or s:
• B a tte ry Ca p a c ity - A com plet ely disch a r ged
h ea vy-du t y ba t t er y r equ ir es t wice t h e ch a r gin g t im e
of a sm a ll ca pa cit y ba t t er y.
• Te m p e ra tu re - A lon ger t im e will be n eeded t o
ch a r ge a ba t t er y a t -18° C (0° F ) t h a n a t 27° C (80°
F ). Wh en a fa st ba t t er y ch a r ger is con n ect ed t o a cold
ba t t er y, t h e cu r r en t a ccept ed by t h e ba t t er y will be
BATTERY TESTING
(1) If t est in g t h e ba t t er y OUT-OF -VE H ICLE , clea n
t h e ba t t er y t er m in a ls wit h a wir e br u sh befor e t est -
in g. If t h e ba t t er y is equ ipped wit h side post t er m i-
n a ls, in st a ll a n d t igh t en t h e su pplied lea d t er m in a l
st u d a da pt er s. Do n ot u se st eel bolt s. F a ilu r e t o pr op-
er ly in st a ll t h e st u d a da pt er s, or u sin g st u d a da pt er s
t h a t a r e dir t y or wor n -ou t m a y r esu lt in fa lse t est
r ea din gs.
WJ BATTERY SYSTEM 8F - 11
BAT T ERY (Cont inue d)
(6) Wh ile viewin g t h e ba t t er y t est r esu lt , pr ess t h e
CODE bu t t on a n d t h e t est er will pr om pt you for t h e
la st 4 digit s of t h e VIN. Use t h e UP /DOWN a r r ow
bu t t on s t o scr oll t o t h e cor r ect ch a r a ct er ; t h en pr ess
E NTE R t o select a n d m ove t o t h e n ext digit . Th en
pr ess t h e E NTE R bu t t on t o view t h e SE RVICE
CODE . P r essin g t h e CODE bu t t on a secon d t im e will
r et u r n you t o t h e t est r esu lt s.

BATTERY TEST RESULTS

GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system

Fig. 6 MICRO 420 BATTERY AND CHARGING NOTE: The SERVICE CODE is required on every
SYSTEM TESTER warranty claim submitted for battery replacement.
(2) If t est in g t h e ba t t er y IN-TH E -VE H ICLE , m a ke
cer t a in a ll of t h e veh icle a ccessor y loa ds a r e OF F, STANDARD PROCEDURE - BUILT-IN
in clu din g t h e ign it ion . Th e p re fe rre d te s t p o s itio n
INDICATOR TEST
is a t th e ba tte ry te rm in a l. If t h e ba t t er y is n ot
An in dica t or (h ydr om et er ) bu ilt in t o t h e t op of t h e
a ccessible, you m a y t est u sin g bot h t h e posit ive a n d
ba t t er y ca se pr ovides visu a l in for m a t ion for ba t t er y
n ega t ive ju m per post s. Select TE STING AT J UMP E R
t est in g (F ig. 7). Like a h ydr om et er, t h e bu ilt -in in di-
P OST wh en con n ect in g t o t h a t loca t ion .
ca t or m ea su r es t h e specific gr a vit y of t h e ba t t er y
(3) Con n ect t h e t est er (F ig. 6) t o t h e ba t t er y or
elect r olyt e. Th e specific gr a vit y of t h e elect r olyt e
ju m per post s, t h e r ed cla m p t o posit ive (+) a n d t h e
r evea ls t h e ba t t er y st a t e-of-ch a r ge; h owever, it will
bla ck cla m p t o n ega t ive (–).
n ot r evea l t h e cr a n kin g ca pa cit y of t h e ba t t er y. A loa d
NOTE: Multiple batteries connected in parallel must t est m u st be per for m ed t o det er m in e t h e ba t t er y
have the ground cable disconnected to perform a cr a n kin g ca pa cit y. Refer t o St a n da r d P r ocedu r es for
battery test. Failure to disconnect may result in t h e pr oper ba t t er y loa d t est pr ocedu r es.
false battery test readings.

(4) Usin g t h e ARROW key select in or o u t of veh i-

cle t est in g a n d pr ess E NTE R t o m a ke a select ion .
(5) If n ot select ed, ch oose t h e Cold Cr a n kin g Am p
(CCA) ba t t er y r a t in g. Or select t h e a ppr opr ia t e ba t -
t er y r a t in g for you r a r ea (see m en u ). Th e t est er will
t h en r u n it s self pr ogr a m m ed t est of t h e ba t t er y a n d
displa y t h e r esu lt s. Refer t o t h e t est r esu lt t a ble
n ot ed below.

CAUTION: If REPLACE BATTERY is the result of the

test, this may mean a poor connection between the Fig. 7 Built-In Indicator
vehicle’s cables and battery exists. After discon- 1 - SIGHT GLASS
necting the vehicle’s battery cables from the bat- 2 - BATTERY TOP
tery, retest the battery using the OUT-OF-VEHICLE 3 - GREEN BALL
test before replacing. 4 - PLASTIC ROD
8F - 12 BATTERY SYSTEM WJ
BAT T ERY (Cont inue d)
Befor e t est in g, visu a lly in spect t h e ba t t er y for a n y STANDARD PROCEDURE - OPEN-CIRCUIT
da m a ge (a cr a cked ca se or cover, loose post s, et c.)
VOLTAGE TEST
t h a t wou ld ca u se t h e ba t t er y t o be fa u lt y. In or der t o
A ba t t er y open -cir cu it volt a ge (n o loa d) t est will
obt a in cor r ect in dica t ion s fr om t h e bu ilt -in in dica t or,
sh ow t h e a ppr oxim a t e st a t e-of-ch a r ge of a ba t t er y.
it is im por t a n t t h a t t h e ba t t er y be level a n d h a ve a
Th is t est ca n be u sed in pla ce of t h e h ydr om et er t est
clea n sigh t gla ss. Addit ion a l ligh t m a y be r equ ir ed t o
wh en a h ydr om et er is n ot a va ila ble, or for m a in t e-
view t h e in dica t or. D o n o t u s e o p e n fla m e a s a
n a n ce-fr ee ba t t er ies wit h n on -r em ova ble cell ca ps.
s o u rc e o f a d d itio n a l lig h t.
Befor e pr oceedin g wit h t h is t est , com plet ely ch a r ge
To r ea d t h e bu ilt -in in dica t or, look in t o t h e sigh t
t h e ba t t er y (Refer t o 8 - E LE CTRICAL/BATTE RY
gla ss a n d n ot e t h e color of t h e in dica t ion (F ig. 8). Th e
SYSTE M/BATTE RY - STANDARD P ROCE DURE ).
ba t t er y con dit ion t h a t ea ch color in dica t es is
(1) Befor e m ea su r in g t h e open -cir cu it volt a ge, t h e
descr ibed in t h e followin g list :
su r fa ce ch a r ge m u st be r em oved fr om t h e ba t t er y.
• Gre e n - In dica t es 75% t o 100% ba t t er y st a t e-of-
Tu r n on t h e h ea dla m ps for fift een secon ds, t h en
ch a r ge. Th e ba t t er y is a dequ a t ely ch a r ged for fu r t h er
a llow u p t o five m in u t es for t h e ba t t er y volt a ge t o
t est in g or r et u r n t o ser vice. If t h e st a r t er will n ot
st a bilize.
cr a n k for a m in im u m of fift een secon ds wit h a fu lly-
(2) Discon n ect a n d isola t e bot h ba t t er y ca bles, n eg-
ch a r ged ba t t er y, t h e ba t t er y m u st be loa d t est ed.
a t ive ca ble fir st .
Refer t o St a n da r d P r ocedu r es for t h e pr oper ba t t er y
(3) Usin g a volt m et er con n ect ed t o t h e ba t t er y
loa d t est pr ocedu r es.
post s (see t h e in st r u ct ion s pr ovided by t h e m a n u fa c-
• B la c k o r D a rk - In dica t es 0% t o 75% ba t t er y
t u r er of t h e volt m et er ), m ea su r e t h e open -cir cu it volt -
st a t e-of-ch a r ge. Th e ba t t er y is in a dequ a t ely ch a r ged
a ge (F ig. 9).
a n d m u st be ch a r ged u n t il a gr een in dica t ion is visi-
ble in t h e sigh t gla ss (12.4 volt s or m or e), befor e t h e
ba t t er y is t est ed fu r t h er or r et u r n ed t o ser vice. Refer
t o St a n da r d P r ocedu r es for t h e pr oper ba t t er y ch a r g-
in g pr ocedu r es. Also r efer t o Dia gn osis a n d Test in g
for m or e in for m a t ion on t h e possible ca u ses of t h e
disch a r ged ba t t er y con dit ion .
• Cle a r o r B rig h t - In dica t es a low ba t t er y elec-
t r olyt e level. Th e elect r olyt e level in t h e ba t t er y is
below t h e bu ilt -in in dica t or. A m a in t en a n ce-fr ee ba t -
t er y wit h n on -r em ova ble cell ca ps m u st be r epla ced if
t h e elect r olyt e level is low. Wa t er m u st be a dded t o a
low-m a in t en a n ce ba t t er y wit h r em ova ble cell ca ps
befor e it is ch a r ged. Refer t o St a n da r d P r ocedu r es for
t h e pr oper ba t t er y fillin g pr ocedu r es. A low elect r o-
lyt e level m a y be ca u sed by a n over ch a r gin g con di- Fig. 9 Testing Open-Circuit Voltage - Typical
t ion . Refer t o Ch a r gin g Syst em for t h e pr oper
ch a r gin g syst em dia gn osis a n d t est in g pr ocedu r es. See t h e Open -Cir cu it Volt a ge Ta ble. Th is volt a ge
r ea din g will in dica t e t h e ba t t er y st a t e-of-ch a r ge, bu t
will n ot r evea l it s cr a n kin g ca pa cit y. If a ba t t er y h a s
a n open -cir cu it volt a ge r ea din g of 12.4 volt s or
gr ea t er, it m a y be loa d t est ed t o r evea l it s cr a n kin g
ca pa cit y (Refer t o 8 - E LE CTRICAL/BATTE RY SYS-
TE M/BATTE RY - STANDARD P ROCE DURE ).

OPEN CIRCUIT VOLTAGE TABLE

Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
Fig. 8 Built-In Indicator Sight Glass Chart 12.4 volts 75%
12.6 volts or more 100%
WJ BATTERY SYSTEM 8F - 13
BAT T ERY (Cont inue d)

STANDARD PROCEDURE - IGNITION-OFF E xcessive IOD ca n be ca u sed by:

• E lect r ica l it em s left on .
DRAW TEST
• F a u lt y or im pr oper ly a dju st ed swit ch es.
Th e t er m Ign it ion -Off Dr a w (IOD) iden t ifies a n or-
• F a u lt y or sh or t ed elect r on ic m odu les a n d com po-
m a l con dit ion wh er e power is bein g dr a in ed fr om t h e
n en t s.
ba t t er y wit h t h e ign it ion swit ch in t h e Off posit ion . A
• An in t er n a lly sh or t ed gen er a t or.
n or m a l veh icle elect r ica l syst em will dr a w fr om five
• In t er m it t en t sh or t s in t h e wir in g.
t o t h ir t y-five m illia m per es (0.005 t o 0.035 a m per e)
If t h e IOD is over t h ir t y-five m illia m per es, t h e
wit h t h e ign it ion swit ch in t h e Off posit ion , a n d a ll
pr oblem m u st be fou n d a n d cor r ect ed befor e r epla c-
n on -ign it ion con t r olled cir cu it s in pr oper wor kin g
in g a ba t t er y. In m ost ca ses, t h e ba t t er y ca n be
or der. Up t o t h ir t y-five m illia m per es a r e n eeded t o
ch a r ged a n d r et u r n ed t o ser vice a ft er t h e excessive
en a ble t h e m em or y fu n ct ion s for t h e P ower t r a in Con -
IOD con dit ion h a s been cor r ect ed.
t r ol Modu le (P CM), digit a l clock, elect r on ica lly t u n ed
(1) Ver ify t h a t a ll elect r ica l a ccessor ies a r e off.
r a dio, a n d ot h er m odu les wh ich m a y va r y wit h t h e
Tu r n off a ll la m ps, r em ove t h e ign it ion key, a n d close
veh icle equ ipm en t .
a ll door s. If t h e veh icle is equ ipped wit h a n illu m i-
A veh icle t h a t h a s n ot been oper a t ed for a ppr oxi-
n a t ed en t r y syst em or a n elect r on ica lly t u n ed r a dio,
m a t ely t wen t y da ys, m a y disch a r ge t h e ba t t er y t o a n
a llow t h e elect r on ic t im er fu n ct ion of t h ese syst em s
in a dequ a t e level. Wh en a veh icle will n ot be u sed for
t o a u t om a t ica lly sh u t off (t im e ou t ). Th is m a y t a ke
t wen t y da ys or m or e (st or ed), r em ove t h e IOD fu se
u p t o t h r ee m in u t es. See t h e E lect r on ic Modu le Ign i-
fr om t h e P ower Dist r ibu t ion Cen t er (P DC). Th is will
t ion -Off Dr a w Ta ble for m or e in for m a t ion .
r edu ce ba t t er y disch a r gin g.

ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE

Time Out? IOD After Time
Module IOD
(If Yes, Interval And Wake-Up Input) Out
1 to 3
Radio No N/A
milliamperes
Audio Power up to 1
No N/A
Amplifier milliampere
5.90
Body Control Module
No milliamperes N/A
(BCM)
(max.)
Powertrain Control
No 0.95 milliampere N/A
Module (PCM)
Transmission Control
Module (TCM) 4.7L YES (20 minutes, ignition on) 130 milliamperes 0.64 milliampere
w/45RFE
ElectroMechanical
Instrument Cluster No 0.44 milliampere N/A
(EMIC)
Combination Flasher No 0.08 milliampere N/A

(2) Det er m in e t h a t t h e u n der h ood la m p is oper a t - t h r ee m in u t es, or m a y n ot give a n y r ea din g a t a ll

in g pr oper ly, t h en discon n ect t h e la m p wir e h a r n ess
con n ect or or r em ove t h e la m p bu lb.
(3) Discon n ect t h e ba t t er y n ega t ive ca ble.
(4) Set a n elect r on ic digit a l m u lt i-m et er t o it s
h igh est a m per a ge sca le. Con n ect t h e m u lt i-m et er
bet ween t h e discon n ect ed ba t t er y n ega t ive ca ble t er-
m in a l cla m p a n d t h e ba t t er y n ega t ive t er m in a l post .
Ma ke su r e t h a t t h e door s r em a in closed so t h a t t h e
illu m in a t ed en t r y syst em is n ot a ct iva t ed. Th e m u lt i-
m et er a m per a ge r ea din g m a y r em a in h igh for u p t o
wh ile set in t h e h igh est a m per a ge sca le, depen din g
u pon t h e elect r ica l equ ipm en t in t h e veh icle. Th e
m u lt i-m et er lea ds m u st be secu r ely cla m ped t o t h e
ba t t er y n ega t ive ca ble t er m in a l cla m p a n d t h e ba t -
t er y n ega t ive t er m in a l post . If con t in u it y bet ween t h e
ba t t er y n ega t ive t er m in a l post a n d t h e n ega t ive ca ble
t er m in a l cla m p is lost du r in g a n y pa r t of t h e IOD
t est , t h e elect r on ic t im er fu n ct ion will be a ct iva t ed
a n d a ll of t h e t est s will h a ve t o be r epea t ed.
8F - 14 BATTERY SYSTEM WJ
BAT T ERY (Cont inue d)
(5) Aft er a bou t t h r ee m in u t es, t h e h igh -a m per a ge
IOD r ea din g on t h e m u lt i-m et er sh ou ld becom e ver y
low or n on exist en t , depen din g u pon t h e elect r ica l
equ ipm en t in t h e veh icle. If t h e a m per a ge r ea din g
r em a in s h igh , r em ove a n d r epla ce ea ch fu se or cir cu it
br ea ker in t h e P ower Dist r ibu t ion Cen t er (P DC) a n d
t h en in t h e J u n ct ion Block (J B), on e a t a t im e u n t il
t h e a m per a ge r ea din g becom es ver y low, or n on exist -
en t . Refer t o t h e a ppr opr ia t e wir in g in for m a t ion in
t h is ser vice m a n u a l for com plet e P DC a n d J B fu se,
cir cu it br ea ker, a n d cir cu it iden t ifica t ion . Th is will
isola t e ea ch cir cu it a n d iden t ify t h e cir cu it t h a t is t h e
sou r ce of t h e h igh -a m per a ge IOD. If t h e a m per a ge
r ea din g r em a in s h igh a ft er r em ovin g a n d r epla cin g
ea ch fu se a n d cir cu it br ea ker, discon n ect t h e wir e
h a r n ess fr om t h e gen er a t or. If t h e a m per a ge r ea din g
n ow becom es ver y low or n on exist en t , r efer t o Ch a r g-
in g Syst em for t h e pr oper ch a r gin g syst em dia gn osis
a n d t est in g pr ocedu r es. Aft er t h e h igh -a m per a ge IOD
h a s been cor r ect ed, swit ch t h e m u lt i-m et er t o pr o-
gr essively lower a m per a ge sca les a n d, if n ecessa r y,
r epea t t h e fu se a n d cir cu it br ea ker r em ove-a n d-r e-
pla ce pr ocess t o iden t ify a n d cor r ect a ll sou r ces of Fig. 10 Battery Caps - Export Battery
excessive IOD. It is n ow sa fe t o select t h e lowest m il- 1 - BATTERY CAP
lia m per e sca le of t h e m u lt i-m et er t o ch eck t h e low- 2 - BATTERY
a m per a ge IOD.

CAUTION: Do not open any doors, or turn on any

electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.

(6) Obser ve t h e m u lt i-m et er r ea din g. Th e low-a m -

per a ge IOD sh ou ld n ot exceed t h ir t y-five m illia m -
per es (0.035 a m per e). If t h e cu r r en t dr a w exceeds
t h ir t y-five m illia m per es, isola t e ea ch cir cu it u sin g t h e
fu se a n d cir cu it br ea ker r em ove-a n d-r epla ce pr ocess
in St ep 5. Th e m u lt i-m et er r ea din g will dr op t o
wit h in t h e a ccept a ble lim it wh en t h e sou r ce of t h e
excessive cu r r en t dr a w is discon n ect ed. Repa ir t h is
cir cu it a s r equ ir ed; wh et h er a wir in g sh or t , in cor r ect
swit ch a dju st m en t , or a com pon en t fa ilu r e is a t fa u lt .

STANDARD PROCEDURE - CHECKING BATTERY

ELECTROLYTE LEVEL
Th e followin g pr ocedu r e ca n be u sed t o ch eck t h e
ba t t er y elect r olyt e level.
(1) Rem ove t h e ba t t er y cell ca ps (F ig. 10).
(2) Look t h r ou gh t h e ba t t er y ca p h oles t o det er-
m in e t h e level of t h e elect r olyt e in t h e ba t t er y (F ig. Fig. 11 Hook Inside Battery Cap Holes - Export
11). Th e elect r olyt e sh ou ld be a ppr oxim a t ely 1 cen t i- Battery
m et er a bove t h e ba t t er y pla t es or u n t il t h e h ook 1 - BATTERY SURFACE COVER
in side t h e ba t t er y ca p h oles is cover ed. 2 - HOOK
(3) Add on ly dist illed wa t er u n t il t h e elect r olyt e
level is a ppr ox. on e cen t im et er a bove t h e pla t es.
WJ BATTERY SYSTEM 8F - 15
BAT T ERY (Cont inue d)

REMOVAL
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Be
cer t a in t h a t a ll elect r ica l a ccessor ies a r e t u r n ed off.
(2) Loosen t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p pin ch -bolt h ex n u t .
(3) Discon n ect t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p fr om t h e ba t t er y n ega t ive t er m in a l post . If
n ecessa r y, u se a ba t t er y t er m in a l pu ller t o r em ove
t h e t er m in a l cla m p fr om t h e ba t t er y post (F ig. 12).

Fig. 13 Battery Cables - 4.0L Engine

1 - BATTERY POSITIVE CABLE
Fig. 12 Remove Battery Cable Terminal Clamp - 2 - BATTERY NEGATIVE CABLE
Typical 3 - CLIPS
1 - BATTERY
2 - BATTERY TERMINAL PULLER

(4) Loosen t h e ba t t er y posit ive ca ble t er m in a l

cla m p pin ch -bolt h ex n u t .
(5) Discon n ect t h e ba t t er y posit ive ca ble t er m in a l
cla m p fr om t h e ba t t er y posit ive t er m in a l post . If n ec-
essa r y, u se a ba t t er y t er m in a l pu ller t o r em ove t h e
t er m in a l cla m p fr om t h e ba t t er y post .
(6) Rem ove t h e ba t t er y h old down fr om t h e ba t -
t er y. Refer t o B a tte ry Ho ld D o w n in t h is sect ion of
t h e ser vice m a n u a l for t h e pr ocedu r e.

WARNING: WEAR A SUITABLE PAIR OF RUBBER

GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.

(7) Rem ove t h e ba t t er y fr om t h e ba t t er y t r a y. Fig. 14 Battery Cables - 4.7L Engine

1 - BATTERY POSITIVE CABLE
INSTALLATION 2 - BATTERY NEGATIVE CABLE
(1) Clea n a n d in spect t h e ba t t er y. Refer t o t h e pr o- 3 - CLIPS
cedu r es in t h is sect ion .
(2) P osit ion t h e ba t t er y on t o t h e ba t t er y t r a y a s a
CAUTION: Be certain that the battery cable terminal
u n it . E n su r e t h a t t h e ba t t er y posit ive a n d n ega t ive
clamps are connected to the correct battery termi-
t er m in a l post s a r e cor r ect ly posit ion ed. Th e ba t t er y
nal posts. Reverse battery polarity may damage
ca ble t er m in a l cla m ps m u st r ea ch t h e cor r ect ba t t er y
electrical components of the vehicle.
t er m in a l post wit h ou t st r et ch in g t h e ca bles (F ig. 13)
or (F ig. 14). (4) Clea n t h e ba t t er y ca ble t er m in a l cla m ps a n d
(3) Rein st a ll t h e ba t t er y h old down s on t o t h e ba t - t h e ba t t er y t er m in a l post s.
t er y. Refer t o B a tte ry Ho ld D o w n s
8F - 16 BATTERY SYSTEM
BAT T ERY (Cont inue d)
(5) Recon n ect t h e ba t t er y posit ive ca ble t er m in a l
cla m p t o t h e ba t t er y posit ive t er m in a l post . Tigh t en
t h e t er m in a l cla m p pin ch -bolt h ex n u t t o 6.8 N·m (60
in . lbs.).
(6) Recon n ect t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p t o t h e ba t t er y n ega t ive t er m in a l post . Tigh t en
t h e t er m in a l cla m p pin ch -bolt h ex n u t t o 6.8 N·m (
60 in . lbs.).
(7) Apply a t h in coa t in g of pet r oleu m jelly or ch a s-
sis gr ea se t o t h e exposed su r fa ces of t h e ba t t er y ca ble
t er m in a l cla m ps a n d t h e ba t t er y t er m in a l post s.
WJ
Th e ba t t er y h old down h a r dwa r e con sist s of (F ig.
15) a m olded pla st ic lip t h a t is in t egr a l t o t h e ou t -
boa r d edge of t h e ba t t er y t r a y a n d su ppor t u n it , a
m olded pla st ic h old down br a cket , a sin gle h ex scr ew
wit h a con ed wa sh er a n d a U-n u t .
Wh en in st a llin g a ba t t er y in t o t h e ba t t er y t r a y, be
cer t a in t h a t t h e h old down h a r dwa r e is pr oper ly
in st a lled a n d t h a t t h e fa st en er s a r e t igh t en ed t o t h e
pr oper specifica t ion s. Im pr oper h old down fa st en er
t igh t n ess, wh et h er t oo loose or t oo t igh t , ca n r esu lt in
da m a ge t o t h e ba t t er y, t h e veh icle or bot h .

OPERATION
BAT T ERY H OLDDOWN Th e ba t t er y h olddown secu r es t h e ba t t er y in t h e
ba t t er y t r a y. Th is h olddown is design ed t o pr even t
DESCRIPTION ba t t er y m ovem en t du r in g t h e m ost ext r em e veh icle
oper a t ion con dit ion s. P er iodic r em ova l a n d lu br ica -
t ion of t h e ba t t er y h olddown h a r dwa r e is r ecom -
m en ded t o pr even t h a r dwa r e seizu r e a t a la t er da t e.

CAUTION: Never operate a vehicle without a battery

holddown device properly installed. Damage to the
vehicle, components and battery could result.

REMOVAL
All of t h e ba t t er y h old down h a r dwa r e ca n be ser-
viced wit h ou t r em ova l of t h e ba t t er y or t h e ba t t er y
t r a y a n d su ppor t u n it .
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Be
cer t a in t h a t a ll elect r ica l a ccessor ies a r e t u r n ed off.
(2) Loosen t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p pin ch -bolt h ex n u t .
(3) Discon n ect t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p fr om t h e ba t t er y n ega t ive t er m in a l post . If
n ecessa r y, u se a ba t t er y t er m in a l pu ller t o r em ove
t h e t er m in a l cla m p fr om t h e ba t t er y post .
(4) Rem ove t h e scr ew wit h wa sh er t h a t secu r es t h e
ba t t er y h old down br a cket t o t h e U-n u t on t h e
in boa r d side of t h e ba t t er y t r a y a n d su ppor t u n it
(F ig. 16).
(5) Rem ove t h e ba t t er y h old down br a cket fr om
t h e ba t t er y t r a y a n d su ppor t u n it .

Fig. 15 Battery Hold Downs INSTALLATION

1 - SCREW All of t h e ba t t er y h old down h a r dwa r e ca n be ser-
2 - HOLD DOWN BRACKET viced wit h ou t r em ova l of t h e ba t t er y or t h e ba t t er y
3 - BATTERY SUPPORT t r a y a n d su ppor t u n it .
4 - ACCUMULATOR
(1) Clea n a n d in spect t h e ba t t er y h old down h a r d-
5 - NUT
wa r e. Refer t o t h e pr ocedu r es in t h is sect ion of t h e
6 - U-NUT
7 - STUD
ser vice m a n u a l.
8 - RADIATOR SUPPORT BRACKET (2) Be cer t a in t h a t t h e ba t t er y is pr oper ly posi-
9 - U-NUT t ion ed in t h e ba t t er y t r a y a n d su ppor t u n it . Th e
10 - SCREW ledge on t h e ou t boa r d side of t h e ba t t er y ca se m u st
11 - BATTERY TEMPERATURE SENSOR be en ga ged u n der t h e lip on t h e ou t boa r d side of t h e
12 - BATTERY ba t t er y t r a y a n d su ppor t u n it .
WJ BATTERY SYSTEM 8F - 17
BAT T ERY H OLDDOWN (Cont inue d)
(5) Reconnect the ba ttery nega tive ca ble termina l cla mp
to the ba ttery nega tive termina l post. Tighten the termina l
cla mp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.).

BAT T ERY CABLE

DESCRIPTION

Fig. 17 Battery Cables - 4.0L Engine

Fig. 16 Battery Hold Downs Remove/Install 1 - BATTERY POSITIVE CABLE
1 - SCREW 2 - BATTERY NEGATIVE CABLE
2 - HOLD DOWN BRACKET 3 - CLIPS
3 - BATTERY SUPPORT
4 - ACCUMULATOR
5 - NUT
6 - U-NUT
7 - STUD
8 - RADIATOR SUPPORT BRACKET
9 - U-NUT
10 - SCREW
11 - BATTERY TEMPERATURE SENSOR
12 - BATTERY

(3) P osit ion t h e ba t t er y h old down br a cket over t h e

ledge on t h e in boa r d side of t h e ba t t er y ca se in t h e
ba t t er y t r a y a n d su ppor t u n it . Be cer t a in t h a t t h e
ledge on t h e bot t om of t h e h old down br a cket is or i-
en t ed t owa r ds t h e in boa r d side of t h e ba t t er y ca se.
P r oper h old down br a cket or ien t a t ion m a y a lso be
det er m in ed by n ot in g t h e dir ect ion of t h e a r r ow-like
for m a t ion s of t h e m olded r ein for cin g r ibs on t h e t op
of t h e h old down br a cket . Th ese a r r ows sh ou ld be
poin t ed t owa r ds t h e ba t t er y. Fig. 18 Battery Cables - 4.7L Engine
(4) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e 1 - BATTERY POSITIVE CABLE
ba t t er y h old down br a cket t o t h e U-n u t on t h e 2 - BATTERY NEGATIVE CABLE
in boa r d side of t h e ba t t er y t r a y a n d su ppor t u n it . 3 - CLIPS
Tigh t en t h ew scr ew t o 3.4 N·m (30 in . lbs.).
8F - 18 BATTERY SYSTEM
BAT T ERY CABLE (Cont inue d)
Th e ba t t er y ca bles (F ig. 17) or (F ig. 18) a r e la r ge
ga u ge, st r a n ded copper wir es sh ea t h ed wit h in a
h ea vy pla st ic or syn t h et ic r u bber in su la t in g ja cket .
Th e wir e u sed in t h e ba t t er y ca bles com bin es excel-
len t flexibilit y a n d r elia bilit y wit h h igh elect r ica l cu r-
r en t ca r r yin g ca pa cit y. Refer t o Wirin g D ia g ra m s
for ba t t er y ca ble wir e ga u ge in for m a t ion .
A cla m pin g t ype fem a le ba t t er y t er m in a l m a de of
soft lea d is die ca st on t o on e en d of t h e ba t t er y ca ble
wir e. A squ a r e h ea ded pin ch -bolt a n d h ex n u t a r e
in st a lled a t t h e open en d of t h e fem a le ba t t er y t er m i-
n a l cla m p. La r ge eyelet t ype t er m in a ls a r e cr im ped
on t o t h e opposit e en d of t h e ba t t er y ca ble wir e a n d
t h en solder-dipped. Th e ba t t er y posit ive ca ble wir es
h a ve a r ed in su la t in g ja cket t o pr ovide visu a l iden t i-
fica t ion a n d fea t u r e a la r ger fem a le ba t t er y t er m in a l
cla m p t o a llow con n ect ion t o t h e la r ger ba t t er y posi-
t ive t er m in a l post . Th e ba t t er y n ega t ive ca ble wir es
h a ve a bla ck in su la t in g ja cket a n d a sm a ller fem a le
ba t t er y t er m in a l cla m p.
Th e ba t t er y ca bles ca n n ot be r epa ir ed a n d, if da m -
a ged or fa u lt y t h ey m u st be r epla ced. Bot h t h e ba t -
t er y posit ive a n d n ega t ive ca bles a r e a va ila ble for
ser vice r epla cem en t on ly a s a u n it wit h t h e ba t t er y
wir e h a r n ess, wh ich m a y in clu de por t ion s of t h e wir-
in g cir cu it s for t h e gen er a t or a n d ot h er com pon en t s
on som e m odels. Refer t o Wirin g D ia g ra m s for m or e
in for m a t ion on t h e va r iou s wir in g cir cu it s in clu ded in
t h e ba t t er y wir e h a r n ess for t h e veh icle bein g ser-
viced.
OPERATION
Th e ba t t er y ca bles con n ect t h e ba t t er y t er m in a l
post s t o t h e veh icle elect r ica l syst em . Th ese ca bles
a lso pr ovide a pa t h ba ck t o t h e ba t t er y for elect r ica l
cu r r en t gen er a t ed by t h e ch a r gin g syst em for r est or-
in g t h e volt a ge pot en t ia l of t h e ba t t er y. Th e fem a le
ba t t er y t er m in a l cla m ps on t h e en ds of t h e ba t t er y
ca ble wir es pr ovide a st r on g a n d r elia ble con n ect ion
of t h e ba t t er y ca ble t o t h e ba t t er y t er m in a l post s.
Th e t er m in a l pin ch bolt s a llow t h e fem a le t er m in a l
cla m ps t o be t igh t en ed a r ou n d t h e m a le t er m in a l
post s on t h e t op of t h e ba t t er y. Th e eyelet t er m in a ls
secu r ed t o t h e opposit e en ds of t h e ba t t er y ca ble
wir es fr om t h e fem a le ba t t er y t er m in a l cla m ps pr o-
vide secu r e a n d r elia ble con n ect ion of t h e ba t t er y
ca bles t o t h e veh icle elect r ica l syst em .
Th e ba t t er y posit ive ca ble t er m in a l cla m p is die
ca st on t o t h e en ds of t wo wir es. On e wir e h a s a n eye-
let t er m in a l t h a t con n ect s t h e ba t t er y posit ive ca ble
t o t h e B(+) t er m in a l st u d of t h e P ower Dist r ibu t ion
Cen t er (P DC), a n d t h e ot h er wir e h a s a n eyelet t er-
m in a l t h a t con n ect s t h e ba t t er y posit ive ca ble t o t h e
B(+) t er m in a l st u d of t h e en gin e st a r t er m ot or sole-
n oid. Th e ba t t er y n ega t ive ca ble t er m in a l cla m p is
a lso die ca st on t o t h e en ds of t wo wir es. On e wir e
WJ
h a s a n eyelet t er m in a l t h a t con n ect s t h e ba t t er y n eg-
a t ive ca ble t o t h e veh icle power t r a in t h r ou gh a st u d
on t h e r igh t side of t h e en gin e cylin der block. Th e
ot h er wir e h a s a n eyelet t er m in a l t h a t con n ect s t h e
ba t t er y n ega t ive ca ble t o t h e veh icle body t h r ou gh a
gr ou n d scr ew on t h e r igh t fr on t fen der in n er sh ield,
n ea r t h e ba t t er y.
DIAGNOSIS AND TESTING - BATTERY CABLES
A volt a ge dr op t est will det er m in e if t h er e is exces-
sive r esist a n ce in t h e ba t t er y ca ble t er m in a l con n ec-
t ion s or t h e ba t t er y ca ble. If excessive r esist a n ce is
fou n d in t h e ba t t er y ca ble con n ect ion s, t h e con n ec-
t ion poin t sh ou ld be disa ssem bled, clea n ed of a ll cor-
r osion or for eign m a t er ia l, t h en r ea ssem bled.
F ollowin g r ea ssem bly, ch eck t h e volt a ge dr op for t h e
ba t t er y ca ble con n ect ion a n d t h e ba t t er y ca ble a ga in
t o con fir m r epa ir.
Wh en per for m in g t h e volt a ge dr op t est , it is im por-
t a n t t o r em em ber t h a t t h e volt a ge dr op is givin g a n
in dica t ion of t h e r esist a n ce bet ween t h e t wo poin t s a t
wh ich t h e volt m et er pr obes a r e a t t a ch ed. EXAM-
P LE: Wh en t est in g t h e r esist a n ce of t h e ba t t er y pos-
it ive ca ble, t ou ch t h e volt m et er lea ds t o t h e ba t t er y
posit ive ca ble t er m in a l cla m p a n d t o t h e ba t t er y pos-
it ive ca ble eyelet t er m in a l a t t h e st a r t er solen oid
B(+) t er m in a l st u d. If you pr obe t h e ba t t er y posit ive
t er m in a l post a n d t h e ba t t er y posit ive ca ble eyelet
t er m in a l a t t h e st a r t er solen oid B(+) t er m in a l st u d,
you a r e r ea din g t h e com bin ed volt a ge dr op in t h e
ba t t er y posit ive ca ble t er m in a l cla m p-t o-t er m in a l
post con n ect ion a n d t h e ba t t er y posit ive ca ble.
VOLTAGE DROP TEST
Th e followin g oper a t ion will r equ ir e a volt m et er
a ccu r a t e t o 1/10 (0.10) volt . Befor e per for m in g t h is
t est , be cer t a in t h a t t h e followin g pr ocedu r es a r e
a ccom plish ed:
• Th e ba t t er y is fu lly-ch a r ged a n d loa d t est ed.
Refer t o St a n da r d P r ocedu r es for t h e pr oper ba t t er y
ch a r gin g a n d loa d t est pr ocedu r es.
• F u lly en ga ge t h e pa r kin g br a ke.
• If t h e veh icle is equ ipped wit h a n a u t om a t ic
t r a n sm ission , pla ce t h e gea r sh ift select or lever in t h e
P a r k posit ion . If t h e veh icle is equ ipped wit h a m a n -
u a l t r a n sm ission , pla ce t h e gea r sh ift select or lever in
t h e Neu t r a l posit ion a n d block t h e clu t ch peda l in t h e
fu lly depr essed posit ion .
• Ver ify t h a t a ll la m ps a n d a ccessor ies a r e t u r n ed
off.
• To pr even t t h e en gin e fr om st a r t in g, r em ove t h e
Au t om a t ic Sh u t Down (ASD) r ela y. Th e ASD r ela y is
loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC), in
t h e en gin e com pa r t m en t . See t h e fu se a n d r ela y la y-
ou t la bel a ffixed t o t h e u n der side of t h e P DC cover
for ASD r ela y iden t ifica t ion a n d loca t ion .
WJ BATTERY SYSTEM 8F - 19
BAT T ERY CABLE (Cont inue d)
(1) Con n ect t h e posit ive lea d of t h e volt m et er t o
t h e ba t t er y n ega t ive t er m in a l post . Con n ect t h e n eg-
a t ive lea d of t h e volt m et er t o t h e ba t t er y n ega t ive
ca ble t er m in a l cla m p (F ig. 19). Rot a t e a n d h old t h e
ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e
volt m et er. If volt a ge is det ect ed, cor r ect t h e poor con -
n ect ion bet ween t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p a n d t h e ba t t er y n ega t ive t er m in a l post .

Fig. 20 TEST BATTERY POSITIVE CONNECTION

RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY

Fig. 19 TEST BATTERY NEGATIVE CONNECTION

RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY

(2) Con n ect t h e posit ive lea d of t h e volt m et er t o

t h e ba t t er y posit ive t er m in a l post . Con n ect t h e n ega -
t ive lea d of t h e volt m et er t o t h e ba t t er y posit ive ca ble
t er m in a l cla m p (F ig. 20). Rot a t e a n d h old t h e ign it ion
swit ch in t h e St a r t posit ion . Obser ve t h e volt m et er. If
volt a ge is det ect ed, cor r ect t h e poor con n ect ion
bet ween t h e ba t t er y posit ive ca ble t er m in a l cla m p
a n d t h e ba t t er y posit ive t er m in a l post .
(3) Con n ect t h e volt m et er t o m ea su r e bet ween t h e
ba t t er y posit ive ca ble t er m in a l cla m p a n d t h e st a r t er
solen oid B(+) t er m in a l st u d (F ig. 21). Rot a t e a n d h old
t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e
volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d
t igh t en t h e ba t t er y posit ive ca ble eyelet t er m in a l con -
n ect ion a t t h e st a r t er solen oid B(+) t er m in a l st u d.
Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt ,
r epla ce t h e fa u lt y ba t t er y posit ive ca ble.
(4) Con n ect t h e volt m et er t o m ea su r e bet ween t h e
ba t t er y n ega t ive ca ble t er m in a l cla m p a n d a good
clea n gr ou n d on t h e en gin e block (F ig. 22). Rot a t e
a n d h old t h e ign it ion swit ch in t h e St a r t posit ion .
Obser ve t h e volt m et er. If t h e r ea din g is a bove 0.2
volt , clea n a n d t igh t en t h e ba t t er y n ega t ive ca ble
eyelet t er m in a l con n ect ion t o t h e en gin e block.
Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt ,
r epla ce t h e fa u lt y ba t t er y n ega t ive ca ble.
Fig. 21 TEST BATTERY POSITIVE CABLE
RESISTANCE - TYPICAL
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
REMOVAL
Bot h t h e ba t t er y n ega t ive ca ble a n d t h e ba t t er y
posit ive ca ble a r e ser viced in t h e ba t t er y wir e h a r-
n ess. If eit h er ba t t er y ca ble is da m a ged or fa u lt y, t h e
ba t t er y wir e h a r n ess u n it m u st be r epla ced.
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Be
cer t a in t h a t a ll elect r ica l a ccessor ies a r e t u r n ed off.
(2) Loosen t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p pin ch -bolt h ex n u t .
(3) Discon n ect t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p fr om t h e ba t t er y n ega t ive t er m in a l post . If
n ecessa r y, u se a ba t t er y t er m in a l pu ller t o r em ove
t h e t er m in a l cla m p fr om t h e ba t t er y post .
8F - 20 BATTERY SYSTEM WJ
BAT T ERY CABLE (Cont inue d)
(16) Rem ove t h e scr ew t h a t secu r es t h e ba t t er y
n ega t ive ca ble gr ou n d eyelet t er m in a l t o t h e r igh t
side of t h e en gin e block.
(17) Rem ove t h e n u t t h a t secu r es t h e ba t t er y pos-
it ive ca ble eyelet t er m in a l t o t h e B(+) t er m in a l st u d
on t h e st a r t er solen oid.
(18) Rem ove t h e ba t t er y posit ive ca ble eyelet t er-
m in a l fr om t h e B(+) t er m in a l st u d on t h e st a r t er
solen oid.
(19) Discon n ect t h e ba t t er y wir e h a r n ess con n ect or
fr om t h e con n ect or r ecept a cle on t h e st a r t er solen oid.
(20) Rem ove t h e ba t t er y wir e h a r n ess fr om t h e
en gin e com pa r t m en t .

INSTALLATION
Fig. 22 TEST GROUND CIRCUIT RESISTANCE - Bot h t h e ba t t er y n ega t ive ca ble a n d t h e ba t t er y
TYPICAL posit ive ca ble a r e ser viced in t h e ba t t er y wir e h a r-
1 - VOLTMETER n ess. If eit h er ba t t er y ca ble is da m a ged or fa u lt y, t h e
2 - BATTERY ba t t er y wir e h a r n ess u n it m u st be r epla ced.
3 - ENGINE GROUND (1) Clea n a n d in spect t h e ba t t er y ca ble t er m in a l
cla m ps a n d t h e ba t t er y t er m in a l post s.
(4) Loosen t h e ba t t er y posit ive ca ble t er m in a l (2) P osit ion t h e ba t t er y wir e h a r n ess in t o t h e
cla m p pin ch -bolt h ex n u t . en gin e com pa r t m en t (F ig. 23) or (F ig. 24).
(5) Discon n ect t h e ba t t er y posit ive ca ble t er m in a l
cla m p fr om t h e ba t t er y posit ive t er m in a l post . If n ec-
essa r y, u se a ba t t er y t er m in a l pu ller t o r em ove t h e
t er m in a l cla m p fr om t h e ba t t er y post .
(6) Un la t ch a n d open t h e cover on t h e P ower Dis-
t r ibu t ion Cen t er (P DC).
(7) Rem ove t h e t wo n u t s t h a t secu r e t h e ba t t er y
posit ive ca ble a n d gen er a t or ou t pu t ca ble eyelet t er-
m in a l t o t h e B(+) t er m in a l st u ds in t h e P DC.
(8) Rem ove t h e ba t t er y posit ive ca ble a n d gen er a -
t or ou t pu t ca ble eyelet t er m in a l fr om t h e B(+) t er m i-
n a l st u ds in t h e P DC.
(9) Discon n ect t h e ba t t er y wir e h a r n ess con n ect or
fr om t h e r igh t h ea dla m p a n d da sh wir e h a r n ess con -
n ect or loca t ed n ea r t h e fr on t of t h e ba t t er y.
(10) Rem ove t h e scr ew t h a t secu r es t h e ba t t er y
n ega t ive ca ble eyelet t er m in a l t o t h e in n er fen der
sh ield n ea r t h e fr on t of t h e ba t t er y.
(11) On m odels wit h t h e 4.7L en gin e, r em ove t h e
n u t t h a t secu r es t h e ba t t er y h a r n ess clip t o t h e st u d Fig. 23 Battery Cables - 4.0L Engine
on t h e r igh t side of t h e in t a ke m a n ifold a n d r em ove
1 - BATTERY POSITIVE CABLE
t h e clip fr om t h e st u d. 2 - BATTERY NEGATIVE CABLE
(12) Un la t ch a n d r em ove t h e cover fr om t h e gen er- 3 - CLIPS
a t or ou t pu t t er m in a l st u d h ou sin g on t h e ba ck of t h e
gen er a t or.
(13) Rem ove t h e n u t t h a t secu r es t h e gen er a t or (3) Recon n ect t h e ba t t er y wir e h a r n ess con n ect or
ou t pu t ca ble eyelet t er m in a l t o t h e gen er a t or ou t pu t t o t h e con n ect or r ecept a cle on t h e st a r t er solen oid.
t er m in a l st u d. (4) In st a ll t h e ba t t er y posit ive ca ble eyelet t er m i-
(14) Rem ove t h e gen er a t or ou t pu t ca ble eyelet t er- n a l on t o t h e B(+) t er m in a l st u d on t h e st a r t er sole-
m in a l fr om t h e gen er a t or ou t pu t t er m in a l st u d. n oid.
(15) Discon n ect t h e ba t t er y wir e h a r n ess con n ect or
fr om t h e gen er a t or field t er m in a l con n ect or r ecept a -
cle on t h e ba ck of t h e gen er a t or.
WJ
BAT T ERY CABLE (Cont inue d)
Fig. 24 Battery Cables - 4.7L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
(5) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e
ba t t er y posit ive ca ble eyelet t er m in a l t o t h e B(+) t er-
m in a l st u d on t h e st a r t er solen oid. Tigh t en t h e n u t t o
11.3 N·m (100 in . lbs.).
(6) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
ba t t er y n ega t ive ca ble gr ou n d eyelet t er m in a l t o t h e
r igh t side of t h e en gin e block. Tigh t en t h e scr ew t o
10.2 N·m (90 in . lbs.) for 4.0L en gin es, or 13.0 N·m
(115 in . lbs.) for 4.7L en gin es.
(7) Recon n ect t h e ba t t er y wir e h a r n ess con n ect or
t o t h e gen er a t or field t er m in a l con n ect or r ecept a cle
on t h e ba ck of t h e gen er a t or.
(8) In st a ll t h e gen er a t or ou t pu t ca ble eyelet t er m i-
n a l on t o t h e gen er a t or ou t pu t t er m in a l st u d.
(9) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e
gen er a t or ou t pu t ca ble eyelet t er m in a l t o t h e gen er a -
t or ou t pu t t er m in a l st u d. Tigh t en t h e n u t t o 10.7
N·m (95 in . lbs.).
(10) P osit ion t h e cover for t h e gen er a t or ou t pu t
t er m in a l st u d h ou sin g on t o t h e ba ck of t h e gen er a t or
a n d sn a p it in t o pla ce.
(11) On m odels wit h t h e 4.7L en gin e, in st a ll t h e
ba t t er y h a r n ess clip on t o t h e st u d on t h e r igh t side of
t h e in t a ke m a n ifold, t h en in st a ll a n d t igh t en t h e n u t
t h a t secu r es t h e clip t o t h e st u d. Tigh t en t h e n u t t o
11.3 N·m (100 in . lbs.).
(12) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
ba t t er y n ega t ive ca ble eyelet t er m in a l t o t h e in n er
fen der sh ield n ea r t h e fr on t of t h e ba t t er y. Tigh t en
t h e scr ew t o 28.2 N·m (250 in . lbs.).
BATTERY SYSTEM 8F - 21
(13) Recon n ect t h e ba t t er y wir e h a r n ess con n ect or
t o t h e r igh t h ea dla m p a n d da sh wir e h a r n ess con n ec-
t or loca t ed n ea r t h e fr on t of t h e ba t t er y.
(14) In st a ll t h e ba t t er y posit ive ca ble a n d gen er a -
t or ou t pu t ca ble eyelet t er m in a l on t o t h e P DC B(+)
t er m in a l st u ds.
(15) In st a ll a n d t igh t en t h e t wo n u t s t h a t secu r e
t h e ba t t er y posit ive ca ble a n d gen er a t or ou t pu t ca ble
eyelet t er m in a l t o t h e P DC B(+) t er m in a l st u ds.
Tigh t en t h e n u t s t o 11.3 N·m (100 in . lbs.).
(16) Close a n d la t ch t h e P DC cover.
(17) Recon n ect t h e ba t t er y posit ive ca ble t er m in a l
cla m p t o t h e ba t t er y posit ive t er m in a l post . Tigh t en
t h e t er m in a l cla m p pin ch -bolt h ex n u t t o 6.8 N·m (60
in . lbs.).
(18) Recon n ect t h e ba t t er y n ega t ive ca ble t er m in a l
cla m p t o t h e ba t t er y n ega t ive t er m in a l post . Tigh t en
t h e t er m in a l cla m p pin ch -bolt h ex n u t t o 6.8 N·m (60
in . lbs.).
(19) Apply a t h in coa t in g of pet r oleu m jelly or
ch a ssis gr ea se t o t h e exposed su r fa ces of t h e ba t t er y
ca ble t er m in a l cla m ps a n d t h e ba t t er y t er m in a l
post s.
BAT T ERY T RAY
DESCRIPTION
Th e ba t t er y is m ou n t ed in a m olded pla st ic ba t t er y
t r a y a n d su ppor t u n it (F ig. 25) loca t ed in t h e r igh t
fr on t cor n er of t h e en gin e com pa r t m en t . Th e ba t t er y
t r a y a n d su ppor t u n it is secu r ed a t t h e r ea r wit h a
n u t t o a st u d on t h e fr on t wh eelh ou se in n er pa n el, a t
t h e ou t boa r d side wit h a scr ew t o t h e side cowl r ein -
for cem en t pa n el, a n d a t t h e fr on t wit h a scr ew
t h r ou gh a U-n u t on a br a cket of t h e r a dia t or su ppor t .
Th e ba t t er y t r a y a n d su ppor t u n it a lso in clu des
t h r ee u pr igh t st a n ch ion s t h a t a r e m olded in t o t h e
ou t boa r d side of t h e u n it . Th ese st a n ch ion s su ppor t
t h e P ower Dist r ibu t ion Cen t er (P DC). Refer t o
P o w e r D is tribu tio n Ce n te r in t h e P ower Dist r ibu -
t ion sect ion of t h is ser vice m a n u a l for m or e in for m a -
t ion on t h e P DC.
A h ole in t h e bot t om of t h e ba t t er y t r a y is fit t ed
wit h a ba t t er y t em per a t u r e sen sor. Refer t o B a tte ry
Te m p e ra tu re S e n s o r in t h e Ch a r gin g sect ion of
t h is ser vice m a n u a l for m or e in for m a t ion on t h e ba t -
t er y t em per a t u r e sen sor. Refer t o B a tte ry Ho ld
D o w n in t h is sect ion of t h e ser vice m a n u a l for m or e
in for m a t ion on t h e ba t t er y h old down h a r dwa r e.
8F - 22 BATTERY SYSTEM WJ
BAT T ERY T RAY (Cont inue d)

REMOVAL
(1) Rem ove t h e ba t t er y fr om t h e ba t t er y t r a y
(Refer t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BAT-
TE RY - RE MOVAL).
(2) Rem ove t h e P ower Dist r ibu t ion Cen t er (P DC)
fr om t h e st a n ch ion s on t h e ou t boa r d side of t h e ba t -
t er y t r a y a n d su ppor t u n it . Refer t o P o w e r D is tri-
bu tio n Ce n te r in t h e P ower Dist r ibu t ion sect ion of
t h is ser vice m a n u a l for P DC r em ova l pr ocedu r e.
(3) Rem ove t h e on e scr ew t h a t secu r es t h e fr on t of
t h e ba t t er y t r a y a n d su ppor t u n it t o t h e br a cket on
t h e r igh t side of t h e r a dia t or su ppor t (F ig. 26).

Fig. 25 Battery Tray and Support

1 - SCREW Fig. 26 Battery Tray and Support Remove/Install
2 - HOLD DOWN BRACKET 1 - BATTERY TRAY AND SUPPORT
3 - BATTERY SUPPORT 2 - NUT (1)
4 - ACCUMULATOR 3 - STUD
5 - NUT 4 - U-NUT (1)
6 - U-NUT 5 - RADIATOR SUPPORT BRACKET
7 - STUD 6 - SCREW (1)
8 - RADIATOR SUPPORT BRACKET 7 - SCREW (1)
9 - U-NUT
10 - SCREW
(4) Rem ove t h e on e scr ew t h a t secu r es t h e ou t -
11 - BATTERY TEMPERATURE SENSOR
12 - BATTERY
boa r d side of t h e ba t t er y t r a y a n d su ppor t u n it t o t h e
r igh t fen der side cowl r ein for cem en t .
(5) Rem ove t h e on e n u t t h a t secu r es t h e r ea r of
OPERATION t h e ba t t er y t r a y a n d su ppor t u n it t o t h e st u d on t h e
Th e ba t t er y t r a y pr ovides a secu r e m ou n t in g loca - r igh t fen der fr on t wh eelh ou se in n er pa n el.
t ion a n d su ppor t s t h e ba t t er y. On som e veh icles, t h e (6) Rem ove t h e ba t t er y t em per a t u r e sen sor fr om
ba t t er y t r a y a lso pr ovides t h e a n ch or poin t /s for t h e t h e ba t t er y t r a y. Refer t o B a tte ry Te m p e ra tu re
ba t t er y h olddown h a r dwa r e. Th e ba t t er y t r a y a n d S e n s o r in t h e Ch a r gin g sect ion of t h is ser vice m a n -
t h e ba t t er y h olddown h a r dwa r e com bin e t o secu r e u a l for ba t t er y t em per a t u r e sen sor r em ova l pr oce-
a n d st a bilize t h e ba t t er y in t h e en gin e com pa r t m en t , du r e.
wh ich pr even t s ba t t er y m ovem en t du r in g veh icle (7) Rem ove t h e ba t t er y t r a y a n d su ppor t u n it fr om
oper a t ion . Un r est r a in ed ba t t er y m ovem en t du r in g t h e r igh t fr on t cor n er of t h e en gin e com pa r t m en t .
veh icle oper a t ion cou ld r esu lt in da m a ge t o t h e veh i-
cle, t h e ba t t er y, or bot h .
WJ
BAT T ERY T RAY (Cont inue d)
INSTALLATION
(1) Clea n a n d in spect t h e ba t t er y t r a y a n d su ppor t
u n it . Refer t o t h e pr ocedu r es in t h is sect ion of t h e
ser vice m a n u a l.
(2) In st a ll t h e ba t t er y t em per a t u r e sen sor on t o t h e
ba t t er y t r a y. Refer t o B a tte ry Te m p e ra tu re S e n s o r
in t h e Ch a r gin g sect ion of t h is ser vice m a n u a l for
ba t t er y t em per a t u r e sen sor in st a lla t ion pr ocedu r e.
(3) P osit ion t h e ba t t er y t r a y a n d su ppor t u n it in t o
t h e r igh t fr on t cor n er of t h e en gin e com pa r t m en t . Be
cer t a in t h a t n o h oses or wir e h a r n esses a r e t r a pped
or pin ch ed by t h e in st a lla t ion of t h e t r a y.
(4) In st a ll a n d t igh t en t h e on e n u t t h a t secu r es t h e
r ea r of t h e ba t t er y t r a y a n d su ppor t u n it t o t h e st u d
on t h e r igh t fen der fr on t wh eelh ou se in n er pa n el.
Tigh t en t h e n u t t o 7.3 N·m (65 in . lbs.).
BATTERY SYSTEM 8F - 23
(5) In st a ll a n d t igh t en t h e on e scr ew t h a t secu r es
t h e ou t boa r d side of t h e ba t t er y t r a y a n d su ppor t
u n it t o t h e r igh t fen der side cowl r ein for cem en t .
Tigh t en t h e scr ew t o 8.1 N·m (72 in . lbs.).
(6) In st a ll a n d t igh t en t h e on e scr ew t h a t secu r es
t h e fr on t of t h e ba t t er y t r a y a n d su ppor t u n it t o t h e
br a cket on t h e r igh t side of t h e r a dia t or su ppor t .
Tigh t en t h e scr ew t o 8.1 N·m (72 in . lbs.).
(7) In st a ll t h e P ower Dist r ibu t ion Cen t er (P DC)
on t o t h e st a n ch ion s on t h e ou t boa r d side of t h e ba t -
t er y t r a y a n d su ppor t u n it . Refer t o P o w e r D is tri-
bu tio n Ce n te r in t h e P ower Dist r ibu t ion sect ion of
t h is ser vice m a n u a l for P DC in st a lla t ion pr ocedu r e.
(8) In st a ll t h e ba t t er y on t o t h e ba t t er y t r a y (Refer
t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BATTE RY -
INSTALLATION).
8F - 24 CHARGING WJ

CH ARGI N G

TABLE OF CONTENTS
page page

CHARGING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING - CHARGING GENERATOR
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GENERATOR RATINGS - GAS POWERED . . 25 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TORQUE - GAS POWERED .......... . . . 25 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPECIAL TOOLS .................... . . . 26 VOLTAGE REGULATOR
BATTERY TEMPERATURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

CH ARGI N G
DESCRIPTION
Th e ch a r gin g syst em con sist s of:
• Gen er a t or
• E lect r on ic Volt a ge Regu la t or (E VR) cir cu it r y
wit h in t h e P ower t r a in Con t r ol Modu le (P CM)
• Ign it ion swit ch
• Ba t t er y (r efer t o 8, Ba t t er y for in for m a t ion )
• Ba t t er y t em per a t u r e sen sor
• Gen er a t or La m p (if equ ipped)
• Ch eck Ga u ges La m p (if equ ipped)
• Volt m et er (r efer t o 8, In st r u m en t Clu st er for
in for m a t ion )
• Wir in g h a r n ess a n d con n ect ion s (r efer t o 8, Wir-
in g for in for m a t ion )
OPERATION
Th e ch a r gin g syst em is t u r n ed on a n d off wit h t h e
ign it ion swit ch . Th e syst em is on wh en t h e en gin e is
r u n n in g a n d t h e ASD r ela y is en er gized. Wh en t h e
ASD r ela y is on , volt a ge is su pplied t o t h e ASD r ela y
sen se cir cu it a t t h e P CM. Th is volt a ge is con n ect ed
t h r ou gh t h e P CM a n d su pplied t o on e of t h e gen er a -
t or field t er m in a ls (Gen . Sou r ce +) a t t h e ba ck of t h e
gen er a t or.
Th e a m ou n t of DC cu r r en t pr odu ced by t h e gen er-
a t or is con t r olled by t h e E VR (field con t r ol) cir cu it r y
con t a in ed wit h in t h e P CM. Th is cir cu it r y is con -
n ect ed in ser ies wit h t h e secon d r ot or field t er m in a l
a n d gr ou n d.
A ba t t er y t em per a t u r e sen sor, loca t ed in t h e ba t -
t er y t r a y h ou sin g, is u sed t o sen se ba t t er y t em per a -
t u r e. Th is t em per a t u r e da t a , a lon g wit h da t a fr om
m on it or ed lin e volt a ge, is u sed by t h e P CM t o va r y
t h e ba t t er y ch a r gin g r a t e. Th is is don e by cyclin g t h e
gr ou n d pa t h t o con t r ol t h e st r en gt h of t h e r ot or m a g-
n et ic field. Th e P CM t h en com pen sa t es a n d r egu la t es
gen er a t or cu r r en t ou t pu t a ccor din gly.
All veh icles a r e equ ipped wit h On -Boa r d Dia gn os-
t ics (OBD). All OBD-sen sed syst em s, in clu din g E VR
(field con t r ol) cir cu it r y, a r e m on it or ed by t h e P CM.
E a ch m on it or ed cir cu it is a ssign ed a Dia gn ost ic Tr ou -
ble Code (DTC). Th e P CM will st or e a DTC in elec-
t r on ic m em or y for cer t a in fa ilu r es it det ect s. Refer t o
Dia gn ost ic Tr ou ble Codes in ; P ower t r a in Con t r ol
Modu le; E lect r on ic Con t r ol Modu les for m or e DTC
in for m a t ion .
Th e Ch eck Ga u ges La m p (if equ ipped) m on it or s:
c h a rg in g s y s te m v o lta g e , en gin e coola n t t em per a -
t u r e a n d en gin e oil pr essu r e. If a n ext r em e con dit ion
is in dica t ed, t h e la m p will be illu m in a t ed. Th is is
don e a s r em in der t o ch eck t h e t h r ee ga u ges. Th e sig-
n a l t o a ct iva t e t h e la m p is sen t via t h e CCD bu s cir-
cu it s. Th e la m p is loca t ed on t h e in st r u m en t pa n el.
Refer t o 8, In st r u m en t Clu st er for a ddit ion a l in for-
m a t ion .
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
Th e followin g pr ocedu r es m a y be u sed t o dia gn ose
t h e ch a r gin g syst em if:
• t h e ch eck ga u ges la m p (if equ ipped) is illu m i-
n a t ed wit h t h e en gin e r u n n in g
• t h e volt m et er (if equ ipped) does n ot r egist er
pr oper ly
• a n u n der ch a r ged or over ch a r ged ba t t er y con di-
t ion occu r s.
Rem em ber t h a t a n u n der ch a r ged ba t t er y is oft en
ca u sed by:
• a ccessor ies bein g left on wit h t h e en gin e n ot
r u n n in g
WJ
CH ARGI N G (Cont inue d)
• a fa u lt y or im pr oper ly a dju st ed swit ch t h a t
a llows a la m p t o st a y on . Refer t o Ign it ion -Off Dr a w
Test in 8, Ba t t er y for m or e in for m a t ion .
INSPECTION
Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s
cr it ica l in pu t a n d ou t pu t cir cu it s of t h e ch a r gin g sys-
t em , m a kin g su r e t h ey a r e oper a t ion a l. A Dia gn ost ic
Tr ou ble Code (DTC) is a ssign ed t o ea ch in pu t a n d
ou t pu t cir cu it m on it or ed by t h e On -Boa r d Dia gn ost ic
(OBD) syst em . Som e ch a r gin g syst em cir cu it s a r e
ch ecked con t in u ou sly, a n d som e a r e ch ecked on ly
u n der cer t a in con dit ion s.
Refer t o Dia gn ost ic Tr ou ble Codes in ; P ower t r a in
Con t r ol Modu le; E lect r on ic Con t r ol Modu les for m or e
DTC in for m a t ion . Th is will in clu de a com plet e list of
DTC’s in clu din g DTC’s for t h e ch a r gin g syst em .
To per for m a com plet e t est of t h e ch a r gin g syst em ,
r efer t o t h e a ppr opr ia t e P ower t r a in Dia gn ost ic P r oce-
du r es ser vice m a n u a l a n d t h e DRB! sca n t ool. P er-
for m t h e followin g in spect ion s befor e a t t a ch in g t h e
sca n t ool.
CHARGING 8F - 25
(1) In spect t h e ba t t er y con dit ion . Refer t o 8, Ba t -
t er y for pr ocedu r es.
(2) In spect con dit ion of ba t t er y ca ble t er m in a ls,
ba t t er y post s, con n ect ion s a t en gin e block, st a r t er
solen oid a n d r ela y. Th ey sh ou ld be clea n a n d t igh t .
Repa ir a s r equ ir ed.
(3) In spect a ll fu ses in bot h t h e fu seblock a n d
P ower Dist r ibu t ion Cen t er (P DC) for t igh t n ess in
r ecept a cles. Th ey sh ou ld be pr oper ly in st a lled a n d
t igh t . Repa ir or r epla ce a s r equ ir ed.
(4) In spect gen er a t or m ou n t in g bolt s for t igh t n ess.
Repla ce or t igh t en bolt s if r equ ir ed. Refer t o t h e Gen -
er a t or Rem ova l/In st a lla t ion sect ion of t h is gr ou p for
t or qu e specifica t ion s.
(5) In spect gen er a t or dr ive belt con dit ion a n d t en -
sion . Tigh t en or r epla ce belt a s r equ ir ed. Refer t o
Belt Ten sion Specifica t ion s in 7, Coolin g Syst em .
(6) In spect a u t om a t ic belt t en sion er (if equ ipped).
Refer t o 7, Coolin g Syst em for in for m a t ion .
(7) In spect gen er a t or elect r ica l con n ect ion s a t gen -
er a t or field, ba t t er y ou t pu t , a n d gr ou n d t er m in a l (if
equ ipped). Also ch eck gen er a t or gr ou n d wir e con n ec-
t ion a t en gin e (if equ ipped). Th ey sh ou ld a ll be clea n
a n d t igh t . Repa ir a s r equ ir ed.

SPECI FI CAT I ON S

GENERATOR RATINGS - GAS POWERED

TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
BOSCH 56041322 136 4.0L 6-Cylinder 100
DENSO 56041324 136 4.7L V-8 100

TORQUE - GAS POWERED

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Generator Mounting Bolts-4.0L 55 41
Generator Vertical Mounting Bolt-4.7L 40 29
Generator (long) Horizontal Mounting 55 41
Bolt-4.7L
Generator (short) Horizontal Mounting 55 41
Bolt-4.7L
Generator B+ Terminal Nut 11 95
8F - 26 CHARGING
CH ARGI N G (Cont inue d)
SPECIAL TOOLS
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
BAT T ERY T EM PERAT U RE
SEN SOR
DESCRIPTION
Th e Ba t t er y Tem per a t u r e Sen sor (BTS) is a t t a ch ed
t o t h e ba t t er y t r a y loca t ed u n der t h e ba t t er y.
OPERATION
Th e BTS is u sed t o det er m in e t h e ba t t er y t em per-
a t u r e a n d con t r ol ba t t er y ch a r gin g r a t e. Th is t em per-
a t u r e da t a , a lon g wit h da t a fr om m on it or ed lin e
volt a ge, is u sed by t h e P CM t o va r y t h e ba t t er y
ch a r gin g r a t e. Syst em volt a ge will be h igh er a t colder
t em per a t u r es a n d is gr a du a lly r edu ced a t wa r m er
t em per a t u r es.
Th e P CM sen ds 5 volt s t o t h e sen sor a n d is
gr ou n ded t h r ou gh t h e sen sor r et u r n lin e. As t em per-
a t u r e in cr ea ses, r esist a n ce in t h e sen sor decr ea ses
a n d t h e det ect ion volt a ge a t t h e P CM in cr ea ses.
WJ
Th e BTS is a lso u sed for OBD II dia gn ost ics. Cer-
t a in fa u lt s a n d OBD II m on it or s a r e eit h er en a bled
or disa bled, depen din g u pon BTS in pu t (for exa m ple,
disa ble pu r ge a n d en a ble Lea k Det ect ion P u m p
(LDP ) a n d O2 sen sor h ea t er t est s). Most OBD II
m on it or s a r e disa bled below 20 degr ees F.
REMOVAL
Th e ba t t er y t em per a t u r e sen sor is loca t ed u n der
t h e veh icle ba t t er y (F ig. 1) a n d is a t t a ch ed t o a
m ou n t in g h ole on t h e ba t t er y t r a y.
Fig. 1 Battery Temperature Sensor Location
1 - BATTERY TEMPERATURE SENSOR
2 - ENGINE WIRE HARNESS
3 - BATTERY TRAY
Th e ba t t er y t em per a t u r e sen sor is loca t ed u n der
t h e veh icle ba t t er y (F ig. 1) a n d is a t t a ch ed t o a
m ou n t in g h ole on t h e ba t t er y t r a y.
(1) Rem ove ba t t er y. Refer t o Gr ou p 8A, Ba t t er y for
pr ocedu r es.
(2) Rem ove ba t t er y t r a y.
(3) P u ll sen sor u p fr om ba t t er y t r a y a n d discon -
n ect en gin e wir e h a r n ess.
(4) Rem ove sen sor fr om ba t t er y t r a y.
INSTALLATION
Th e ba t t er y t em per a t u r e sen sor is loca t ed u n der
t h e veh icle ba t t er y (F ig. 1) a n d is a t t a ch ed t o a
m ou n t in g h ole on t h e ba t t er y t r a y.
(1) P osit ion sen sor in t o m ou n t in g h ole a n d a t t a ch
wir in g h a r n ess.
(2) P r ess sen sor in t o t op of ba t t er y t r a y.
(3) In st a ll ba t t er y. Refer t o Gr ou p 8A, Ba t t er y for
pr ocedu r es.
WJ CHARGING 8F - 27

GEN ERAT OR
DESCRIPTION
Th e gen er a t or is belt -dr iven by t h e en gin e u sin g a
ser pen t in e t ype dr ive belt . It is ser viced on ly a s a
com plet e a ssem bly. If t h e gen er a t or fa ils for a n y r ea -
son , t h e en t ir e a ssem bly m u st be r epla ced.

OPERATION
As t h e en er gized r ot or begin s t o r ot a t e wit h in t h e
gen er a t or, t h e spin n in g m a gn et ic field in du ces a cu r-
r en t in t o t h e win din gs of t h e st a t or coil. On ce t h e
gen er a t or begin s pr odu cin g su fficien t cu r r en t , it a lso
pr ovides t h e cu r r en t n eeded t o en er gize t h e r ot or.
Th e Y t ype st a t or win din g con n ect ion s deliver t h e
in du ced AC cu r r en t t o 3 posit ive a n d 3 n ega t ive
diodes for r ect ifica t ion . F r om t h e diodes, r ect ified DC
cu r r en t is deliver ed t o t h e veh icle elect r ica l syst em
t h r ou gh t h e gen er a t or ba t t er y t er m in a l. Fig. 2 Generator B+ Cable and Field Wire
Alt h ou gh t h e gen er a t or s a ppea r t h e sa m e ext er- Connections (Typical—4.0L Engine Shown)
n a lly, differ en t gen er a t or s wit h differ en t ou t pu t r a t - 1 - FIELD WIRE CONNECTOR
in gs a r e u sed on t h is veh icle. Be cer t a in t h a t t h e 2 - B+ CABLE
r epla cem en t gen er a t or h a s t h e sa m e ou t pu t r a t in g 3 - GENERATOR
a n d pa r t n u m ber a s t h e or igin a l u n it . Refer t o Gen - 4 - B+ CABLE MOUNTING NUT
er a t or Ra t in gs in t h e Specifica t ion s sect ion a t t h e 5 - CABLE PROTECTOR
ba ck of t h is gr ou p for a m per a ge r a t in gs a n d pa r t
n u m ber s.
Noise em it t in g fr om t h e gen er a t or m a y be ca u sed
by: wor n , loose or defect ive bea r in gs; a loose or defec-
t ive dr ive pu lley; in cor r ect , wor n , da m a ged or m isa d-
ju st ed fa n dr ive belt ; loose m ou n t in g bolt s; a
m isa lign ed dr ive pu lley or a defect ive st a t or or diode.

REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.

(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.

(2) Rem ove gen er a t or dr ive belt . Refer t o Coolin g
Syst em for pr ocedu r e.
(3) Un sn a p ca ble pr ot ect or cover fr om B+ m ou n t -
in g st u d (F ig. 2) .
(4) Discon n ect (u n sn a p) 2–wir e field con n ect or a t Fig. 3 Remove/Install Generator—4.7L V-8 Engine
r ea r of gen er a t or (F ig. 2) . 1 - LOWER BOLTS
(5) Rem ove gen er a t or m ou n t in g bolt s (F ig. 3) or 2 - REAR BOLT
(F ig. 4). 3 - GENERATOR
(6) Rem ove gen er a t or fr om veh icle.
8F - 28 CHARGING WJ
GEN ERAT OR (Cont inue d)
(5) In st a ll gen er a t or dr ive belt . Refer t o 7, Coolin g
Syst em for pr ocedu r e.
(6) In st a ll n ega t ive ba t t er y ca ble t o ba t t er y.

V OLTAGE REGU LAT OR

DESCRIPTION
Th e E lect r on ic Volt a ge Regu la t or (E VR) is n ot a
sepa r a t e com pon en t . It is a ct u a lly a volt a ge r egu la t -
in g cir cu it loca t ed wit h in t h e P ower t r a in Con t r ol
Modu le (P CM). Th e E VR is n ot ser viced sepa r a t ely. If
r epla cem en t is n ecessa r y, t h e P CM m u st be r epla ced.

OPERATION
Th e a m ou n t of DC cu r r en t pr odu ced by t h e gen er-
a t or is con t r olled by E VR cir cu it r y con t a in ed wit h in
t h e P CM. Th is cir cu it r y is con n ect ed in ser ies wit h
t h e gen er a t or s secon d r ot or field t er m in a l a n d it s
Fig. 4 Remove/Install Generator—4.0L 6–Cylinder gr ou n d.
Engine Volt a ge is r egu la t ed by cyclin g t h e gr ou n d pa t h t o
1 - GENERATOR con t r ol t h e st r en gt h of t h e r ot or m a gn et ic field. Th e
2 - UPPER BOLT E VR cir cu it r y m on it or s syst em lin e volt a ge (B+) a n d
3 - LOWER BOLT
ba t t er y t em per a t u r e (r efer t o Ba t t er y Tem per a t u r e
Sen sor for m or e in for m a t ion ). It t h en det er m in es a
INSTALLATION t a r get ch a r gin g volt a ge. If sen sed ba t t er y volt a ge is
(1) P osit ion gen er a t or t o en gin e a n d in st a ll m ou n t - 0.5 volt s or lower t h a n t h e t a r get volt a ge, t h e P CM
in g bolt s. gr ou n ds t h e field win din g u n t il sen sed ba t t er y volt -
(2) Tigh t en gen er a t or m ou n t in g bolt s a s follows: a ge is 0.5 volt s a bove t a r get volt a ge. A cir cu it in t h e
• Ver t ica l m ou n t in g bolt 4.7L en gin e—40 N·m (29 P CM cycles t h e gr ou n d side of t h e gen er a t or field u p
ft . lbs.) t o 100 t im es per secon d (100H z), bu t h a s t h e ca pa bil-
• Lon g h or izon t a l m ou n t in g bolt 4.7L en gin e—55 it y t o gr ou n d t h e field con t r ol wir e 100% of t h e t im e
N·m (41 ft . lbs.) (fu ll field) t o a ch ieve t h e t a r get volt a ge. If t h e ch a r g-
• Sh or t h or izon t a l m ou n t in g bolt 4.7L en gin e—55 in g r a t e ca n n ot be m on it or ed (lim p-in ), a du t y cycle
N·m (41 ft . lbs.) of 25% is u sed by t h e P CM in or der t o h a ve som e
• Gen er a t or m ou n t in g bolt s 4.0L en gin e—55 N·m gen er a t or ou t pu t . Also r efer t o Ch a r gin g Syst em
(41 ft . lbs.) Oper a t ion for a ddit ion a l in for m a t ion .
• B+ t er m in a l n u t —11 N·m (95 in . lbs.)
(3) Sn a p 2–wir e field con n ect or in t o r ea r of gen er-
a t or.
(4) Sn a p ca ble pr ot ect or cover t o B+ m ou n t in g
st u d.

CAUTION: Never force a belt over a pulley rim

using a screwdriver. The synthetic fiber of the belt
can be damaged.

CAUTION: When installing a serpentine accessory

drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.
WJ STARTING 8F - 29

START I N G

TABLE OF CONTENTS
page page

STARTING DIAGNOSIS AND TESTING - STARTER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING - STARTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 STARTER MOTOR RELAY
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
TORQUE - STARTER . . . . . . . . . . . . . . . . . . . 35 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STARTER MOTOR - GAS POWERED . . . . . . 35 DIAGNOSIS AND TESTING - STARTER RELAY . 38
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

START I N G • Refer t o P a rk /N e u tra l P o s itio n S w itc h in t h e

pr oper sect ion of Gr ou p 21 - Tr a n sm ission for com -
plet e ser vice in for m a t ion for t h e pa r k/n eu t r a l posi-
DESCRIPTION
t ion swit ch .
An elect r ica lly oper a t ed en gin e st a r t in g syst em is
• Refer t o t h e pr oper sect ion of Gro u p 8W - Wir-
st a n da r d fa ct or y-in st a lled equ ipm en t on t h is m odel.
in g D ia g ra m s for com plet e ser vice in for m a t ion a n d
Th e st a r t in g syst em is design ed t o pr ovide t h e veh i-
cir cu it dia gr a m s for t h e st a r t in g syst em wir in g com -
cle oper a t or wit h a con ven ien t , efficien t a n d r elia ble
pon en t s.
m ea n s of cr a n kin g a n d st a r t in g t h e in t er n a l com bu s-
Gr ou p 8A cover s t h e Ba t t er y, Gr ou p 8B cover s t h e
t ion en gin e u sed t o power t h e veh icle a n d a ll of it s
St a r t in g Syst em s, a n d Gr ou p 8C cover s t h e Ch a r gin g
a ccessor y syst em s fr om wit h in t h e sa fe a n d secu r e
Syst em . We h a ve sepa r a t ed t h ese syst em s t o m a ke it
con fin es of t h e pa ssen ger com pa r t m en t . See t h e own -
ea sier t o loca t e t h e in for m a t ion you a r e seekin g
er ’s m a n u a l in t h e veh icle glove box for m or e in for-
wit h in t h is Ser vice Ma n u a l. H owever, wh en a t t em pt -
m a t ion a n d in st r u ct ion s on t h e r ecom m en ded u se
in g t o dia gn ose a n y of t h ese syst em s, it is im por t a n t
a n d oper a t ion of t h e fa ct or y-in st a lled st a r t in g sys-
t h a t you keep t h eir in t er depen den cy in m in d.
t em .
Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s in t h e
Th e st a r t in g syst em con sist s of t h e followin g com -
veh icle oper a t e wit h on e a n ot h er, a n d m u st be t est ed
pon en t s:
a s a com plet e syst em . In or der for t h e veh icle t o st a r t
• Ba t t er y
a n d ch a r ge pr oper ly, a ll of t h e com pon en t s t h a t a r e
• St a r t er r ela y
u sed in t h ese syst em s m u st per for m wit h in specifica -
• St a r t er m ot or (in clu din g a n in t egr a l st a r t er sole-
t ion s.
n oid)
Th e dia gn ost ic pr ocedu r es u sed in ea ch of t h ese
• Ign it ion swit ch
gr ou ps in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic
• P a r k/n eu t r a l posit ion swit ch
m et h ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia g-
• Wir e h a r n esses a n d con n ect ion s (in clu din g t h e
n ost ics (OBD) bu ilt in t o t h e P ower t r a in Con t r ol Mod-
ba t t er y ca bles).
u le (P CM). Use of a n in du ct ion -t ype m illia m per e
Th is gr ou p pr ovides com plet e ser vice in for m a t ion
a m m et er, volt /oh m m et er, ba t t er y ch a r ger, ca r bon pile
for t h e st a r t er m ot or a n d t h e st a r t er r ela y. Com plet e
r h eost a t (loa d t est er ), a n d 12-volt t est la m p m a y be
ser vice in for m a t ion for t h e ot h er st a r t in g syst em
r equ ir ed.
com pon en t s ca n be loca t ed a s follows:
All OBD-sen sed syst em s a r e m on it or ed by t h e
• Refer t o B a tte ry in t h e pr oper sect ion of Gr ou p
P CM. E a ch m on it or ed cir cu it is a ssign ed a Dia gn os-
8A - Ba t t er y for com plet e ser vice in for m a t ion for t h e
t ic Tr ou ble Code (DTC). Th e P CM will st or e a DTC in
ba t t er y.
elect r on ic m em or y for a n y fa ilu r e it det ect s. Refer t o
• Refer t o Ig n itio n S w itc h a n d Ke y Lo c k Cy l-
On -B o a rd D ia g n o s tic Te s t F o r Ch a rg in g S y s te m
in d e r in t h e pr oper sect ion of Gr ou p 8D - Ign it ion
in t h e Dia gn osis a n d Test in g sect ion of Gr ou p 8C -
Syst em for com plet e ser vice in for m a t ion for t h e ign i-
Ch a r gin g Syst em for m or e in for m a t ion .
t ion swit ch .
8F - 30 STARTING
START I N G (Cont inue d)
OPERATION
Th e st a r t in g syst em com pon en t s for m t wo sepa r a t e
cir cu it s. A h igh -a m per a ge feed cir cu it t h a t feeds t h e
st a r t er m ot or bet ween 150 a n d 350 a m per es, a n d a
low-a m per a ge con t r ol cir cu it t h a t oper a t es on less
t h a n 20 a m per es. Th e h igh -a m per a ge feed cir cu it
com pon en t s in clu de t h e ba t t er y, t h e ba t t er y ca bles,
t h e con t a ct disc por t ion of t h e st a r t er solen oid, a n d
t h e st a r t er m ot or. Th e low-a m per a ge con t r ol cir cu it
com pon en t s in clu de t h e ign it ion swit ch , t h e pa r k/
n eu t r a l posit ion swit ch , t h e st a r t er r ela y, t h e elect r o-
m a gn et ic win din gs of t h e st a r t er solen oid, a n d t h e
con n ect in g wir e h a r n ess com pon en t s.
Ba t t er y volt a ge is su pplied t h r ou gh t h e low-a m per-
a ge con t r ol cir cu it t o t h e coil ba t t er y t er m in a l of t h e
st a r t er r ela y wh en t h e ign it ion swit ch is t u r n ed t o
t h e m om en t a r y St a r t posit ion . Th e pa r k/n eu t r a l posi-
t ion swit ch is in st a lled in ser ies bet ween t h e st a r t er
r ela y coil gr ou n d t er m in a l a n d gr ou n d. Th is n or m a lly
open swit ch pr even t s t h e st a r t er r ela y fr om bein g
en er gized a n d t h e st a r t er m ot or fr om oper a t in g
u n less t h e a u t om a t ic t r a n sm ission gea r select or is in
t h e Neu t r a l or P a r k posit ion s.
Wh en t h e st a r t er r ela y coil is en er gized, t h e n or-
m a lly open r ela y con t a ct s close. Th e r ela y con t a ct s
con n ect t h e r ela y com m on feed t er m in a l t o t h e r ela y
n or m a lly open t er m in a l. Th e closed r ela y con t a ct s
en er gize t h e st a r t er solen oid coil win din gs.
Th e en er gized solen oid pu ll-in coil pu lls in t h e sole-
n oid plu n ger. Th e solen oid plu n ger pu lls t h e sh ift
lever in t h e st a r t er m ot or. Th is en ga ges t h e st a r t er
over r u n n in g clu t ch a n d pin ion gea r wit h t h e st a r t er
r in g gea r on t h e a u t om a t ic t r a n sm ission t or qu e con -
ver t er dr ive pla t e.
As t h e solen oid plu n ger r ea ch es t h e en d of it s
t r a vel, t h e solen oid con t a ct disc com plet es t h e h igh -
a m per a ge st a r t er feed cir cu it a n d en er gizes t h e sole-
n oid plu n ger h old-in coil. Cu r r en t n ow flows bet ween
t h e solen oid ba t t er y t er m in a l a n d t h e st a r t er m ot or,
en er gizin g t h e st a r t er.
WJ
On ce t h e en gin e st a r t s, t h e over r u n n in g clu t ch pr o-
t ect s t h e st a r t er m ot or fr om da m a ge by a llowin g t h e
st a r t er pin ion gea r t o spin fa st er t h a n t h e pin ion
sh a ft . Wh en t h e dr iver r elea ses t h e ign it ion swit ch t o
t h e On posit ion , t h e st a r t er r ela y coil is de-en er gized.
Th is ca u ses t h e r ela y con t a ct s t o open . Wh en t h e
r ela y con t a ct s open , t h e st a r t er solen oid plu n ger
h old-in coil is de-en er gized.
Wh en t h e solen oid plu n ger h old-in coil is de-en er-
gized, t h e solen oid plu n ger r et u r n spr in g r et u r n s t h e
plu n ger t o it s r ela xed posit ion . Th is ca u ses t h e con -
t a ct disc t o open t h e st a r t er feed cir cu it , a n d t h e sh ift
lever t o disen ga ge t h e over r u n n in g clu t ch a n d pin ion
gea r fr om t h e st a r t er r in g gea r.
DIAGNOSIS AND TESTING - STARTING
SYSTEM
Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s oper-
a t e wit h on e a n ot h er, a n d m u st be t est ed a s a com -
plet e syst em . In or der for t h e veh icle t o st a r t a n d
ch a r ge pr oper ly, a ll of t h e com pon en t s in volved in
t h ese syst em s m u st per for m wit h in specifica t ion s.
Gr ou p 8A cover s t h e Ba t t er y, Gr ou p 8B cover s t h e
St a r t in g Syst em s, a n d Gr ou p 8C cover s t h e Ch a r gin g
Syst em . We h a ve sepa r a t ed t h ese syst em s t o m a ke it
ea sier t o loca t e t h e in for m a t ion you a r e seekin g
wit h in t h is Ser vice Ma n u a l. H owever, wh en a t t em pt -
in g t o dia gn ose a n y of t h ese syst em s, it is im por t a n t
t h a t you keep t h eir in t er depen den cy in m in d.
Th e dia gn ost ic pr ocedu r es u sed in t h ese gr ou ps
in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic m et h -
ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia gn ost ics
(OBD) bu ilt in t o t h e P ower t r a in Con t r ol Modu le
(P CM). Use of a n in du ct ion -t ype m illia m per e a m m e-
t er, volt /oh m m et er, ba t t er y ch a r ger, ca r bon pile r h eo-
st a t (loa d t est er ), a n d 12-volt t est la m p m a y be
r equ ir ed.
All OBD-sen sed syst em s a r e m on it or ed by t h e
P CM. E a ch m on it or ed cir cu it is a ssign ed a Dia gn os-
t ic Tr ou ble Code (DTC). Th e P CM will st or e a DTC in
elect r on ic m em or y for a n y fa ilu r e it det ect s. Refer t o
On -B o a rd D ia g n o s tic Te s t F o r Ch a rg in g S y s te m
in t h e Dia gn osis a n d Test in g sect ion of Gr ou p 8C -
Ch a r gin g Syst em for m or e in for m a t ion .
WJ
START I N G (Cont inue d)
Starting System Diagnosis
CONDITION POSSIBLE CAUSE
STARTER FAILS TO 1. Battery discharged or
OPERATE. faulty.
2. Starting circuit wiring
faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position
switch faulty or
misadjusted.
6. Starter solenoid faulty.
7. Starter motor faulty.
STARTER ENGAGES, 1. Battery discharged or
FAILS TO TURN faulty.
ENGINE.
2. Starting circuit wiring
faulty.
3. Starter motor faulty.
4. Engine seized.
STARTER ENGAGES, 1. Starter ring gear faulty.
SPINS OUT BEFORE
ENGINE STARTS.
2. Starter motor faulty.
STARTER DOES NOT 1. Starter motor
DISENGAGE. improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.
STARTING 8F - 31
CORRECTION
1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
4. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
5. Refer to Park/Neutral Position Switch in the Diagnosis
and Testing section of Group 21 - Transmission. Replace
the park/neutral position switch, if required.
6. Refer to Starter Motor in the Diagnosis and Testing
section of this group. Replace the starter motor assembly,
if required.
7. If all other starting system components and circuits test
OK, replace the starter motor assembly.
1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. If all other starting system components and circuits test
OK, replace the starter motor assembly.
4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of Group 9 - Engine.
1. Refer to Starter Motor in the Removal and Installation
section of this group. Remove the starter motor to inspect
the starter ring gear. Replace the starter ring gear, if
required.
2. If all other starting system components and circuits test
OK, replace the starter motor assembly.
1. Refer to Starter Motor in the Removal and Installation
section of this group. Tighten the starter mounting
hardware to the correct tightness specifications.
2. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
3. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
4. If all other starting system components and circuits test
OK, replace the starter motor assembly.
8F - 32 STARTING
START I N G (Cont inue d)
INSPECTION
F or com plet e cir cu it dia gr a m s, r efer t o S ta rtin g
S y s te m in t h e Con t en t s of Gr ou p 8W - Wir in g Dia -
gr a m s. Befor e r em ovin g a n y u n it fr om t h e st a r t in g
syst em for r epa ir or dia gn osis, per for m t h e followin g
in spect ion s:
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• B a tte ry - Visu a lly in spect t h e ba t t er y for in di-
ca t ion s of ph ysica l da m a ge a n d loose or cor r oded
ca ble con n ect ion s. Det er m in e t h e st a t e-of-ch a r ge a n d
cr a n kin g ca pa cit y of t h e ba t t er y. Ch a r ge or r epla ce
t h e ba t t er y, if r equ ir ed. Refer t o B a tte ry in t h e
pr oper sect ion of Gr ou p 8A - Ba t t er y for com plet e ser-
vice in for m a t ion for t h e ba t t er y.
• Ig n itio n S w itc h - Visu a lly in spect t h e ign it ion
swit ch for in dica t ion s of ph ysica l da m a ge a n d loose
or cor r oded wir e h a r n ess con n ect ion s. Refer t o Ig n i-
tio n S w itc h a n d Ke y Lo c k Cy lin d e r in t h e pr oper
sect ion of Gr ou p 8D - Ign it ion Syst em for com plet e
ser vice in for m a t ion for t h e ign it ion swit ch .
• P a rk /N e u tra l P o s itio n S w itc h - Visu a lly
in spect t h e pa r k/n eu t r a l posit ion swit ch for in dica -
t ion s of ph ysica l da m a ge a n d loose or cor r oded wir e
h a r n ess con n ect ion s. Refer t o P a rk /N e u tra l P o s i-
tio n S w itc h in t h e pr oper sect ion of Gr ou p 21 -
Tr a n sm ission for com plet e ser vice in for m a t ion for t h e
pa r k/n eu t r a l posit ion swit ch .
• S ta rte r Re la y - Visu a lly in spect t h e st a r t er
r ela y for in dica t ion s of ph ysica l da m a ge a n d loose or
cor r oded wir e h a r n ess con n ect ion s.
• S ta rte r Mo to r - Visu a lly in spect t h e st a r t er
m ot or for in dica t ion s of ph ysica l da m a ge a n d loose or
cor r oded wir e h a r n ess con n ect ion s.
• S ta rte r S o le n o id - Visu a lly in spect t h e st a r t er
solen oid for in dica t ion s of ph ysica l da m a ge a n d loose
or cor r oded wir e h a r n ess con n ect ion s.
• Wirin g - Visu a lly in spect t h e wir e h a r n esses for
da m a ge. Repa ir or r epla ce a n y fa u lt y wir in g, a s
r equ ir ed. Refer t o t h e pr oper sect ion of Gro u p 8W -
Wirin g D ia g ra m s for com plet e ser vice in for m a t ion
a n d cir cu it dia gr a m s for t h e st a r t in g syst em wir in g
com pon en t s.
WJ
TESTING
COLD CRANKING TEST
F or com plet e cir cu it dia gr a m s, r efer t o S ta rtin g
S y s te m in t h e Con t en t s of Gr ou p 8W - Wir in g Dia -
gr a m s. Th e ba t t er y m u st be fu lly-ch a r ged a n d loa d-
t est ed befor e pr oceedin g. Refer t o B a tte ry in t h e
Dia gn osis a n d Test in g sect ion of Gr ou p 8A - Ba t t er y
for t h e pr ocedu r es.
(1) Con n ect a su it a ble volt -a m per e t est er t o t h e
ba t t er y t er m in a ls (F ig. 1). See t h e in st r u ct ion s pr o-
vided by t h e m a n u fa ct u r er of t h e volt -a m per e t est er
bein g u sed.
Fig. 1 Volts-Amps Tester Connections - Typical
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
(2) F u lly en ga ge t h e pa r kin g br a ke.
(3) P la ce t h e a u t om a t ic t r a n sm ission gea r sh ift
select or lever in t h e P a r k posit ion .
(4) Ver ify t h a t a ll la m ps a n d a ccessor ies a r e
t u r n ed off.
(5) To pr even t t h e en gin e fr om st a r t in g, r em ove
t h e Au t om a t ic Sh u t Down (ASD) r ela y. Th e ASD r ela y
is loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC), in
t h e en gin e com pa r t m en t . Refer t o t h e fu se a n d r ela y
la you t la bel a ffixed t o t h e u n der side of t h e P DC cover
for ASD r ela y iden t ifica t ion a n d loca t ion .
(6) Rot a t e a n d h old t h e ign it ion swit ch in t h e St a r t
posit ion . Not e t h e cr a n kin g volt a ge a n d cu r r en t
(a m per a ge) dr a w r ea din gs sh own on t h e volt -a m per e
t est er.
(a ) If t h e volt a ge r ea ds below 9.6 volt s, r efer t o
S ta rte r Mo to r in t h e Dia gn osis a n d Test in g sec-
t ion of t h is gr ou p. If t h e st a r t er m ot or is OK, r efer
t o En g in e D ia g n o s is in t h e Dia gn osis a n d Test in g
sect ion of Gr ou p 9 - E n gin e for fu r t h er t est in g of
t h e en gin e. If t h e st a r t er m ot or is n ot OK, r epla ce
t h e fa u lt y st a r t er m ot or.
WJ STARTING 8F - 33
START I N G (Cont inue d)
(b) If t h e volt a ge r ea ds a bove 9.6 volt s a n d t h e
cu r r en t (a m per a ge) dr a w r ea ds below specifica -
t ion s, r efer t o F e e d Circ u it Te s t in t h is sect ion .
(c) If t h e volt a ge r ea ds 12.5 volt s or gr ea t er a n d
t h e st a r t er m ot or does n ot t u r n , r efer t o Co n tro l
Circ u it Te s tin g in t h is sect ion .
(d) If t h e volt a ge r ea ds 12.5 volt s or gr ea t er a n d
t h e st a r t er m ot or t u r n s ver y slowly, r efer t o F e e d
Circ u it Te s t in t h is sect ion .

NOTE: A cold engine will increase the starter cur-

rent (amperage) draw reading, and reduce the bat-
tery voltage reading.

FEED CIRCUIT TEST

Th e st a r t er feed cir cu it t est (volt a ge dr op m et h od) Fig. 2 Test Battery Negative Connection Resistance
will det er m in e if t h er e is excessive r esist a n ce in t h e - Typical
h igh -a m per a ge feed cir cu it . F or com plet e cir cu it dia - 1 - VOLTMETER
gr a m s, r efer t o S ta rtin g S y s te m in t h e Con t en t s of 2 - BATTERY
Gr ou p 8W - Wir in g Dia gr a m s.
Wh en per for m in g t h ese t est s, it is im por t a n t t o (2) Con n ect t h e posit ive lea d of t h e volt m et er t o
r em em ber t h a t t h e volt a ge dr op is givin g a n in dica - t h e ba t t er y posit ive t er m in a l post . Con n ect t h e n ega -
t ion of t h e r esist a n ce bet ween t h e t wo poin t s a t t ive lea d of t h e volt m et er t o t h e ba t t er y posit ive ca ble
wh ich t h e volt m et er pr obes a r e a t t a ch ed. cla m p (F ig. 3). Rot a t e a n d h old t h e ign it ion swit ch in
Ex a m p le : Wh en t est in g t h e r esist a n ce of t h e ba t - t h e St a r t posit ion . Obser ve t h e volt m et er. If volt a ge
t er y posit ive ca ble, t ou ch t h e volt m et er lea ds t o t h e is det ect ed, cor r ect t h e poor con t a ct bet ween t h e
ba t t er y posit ive ca ble cla m p a n d t h e ca ble con n ect or ca ble cla m p a n d t h e t er m in a l post .
a t t h e st a r t er solen oid. If you pr obe t h e ba t t er y pos-
it ive t er m in a l post a n d t h e ca ble con n ect or a t t h e
st a r t er solen oid, you a r e r ea din g t h e com bin ed volt -
a ge dr op in t h e ba t t er y posit ive ca ble cla m p-t o-t er m i-
n a l post con n ect ion a n d t h e ba t t er y posit ive ca ble.
Th e followin g oper a t ion will r equ ir e a volt m et er
a ccu r a t e t o 1/10 (0.10) volt . Befor e per for m in g t h e
t est s, be cer t a in t h a t t h e followin g pr ocedu r es a r e
a ccom plish ed:
• Ba t t er y is fu lly-ch a r ged a n d loa d-t est ed. Refer t o
B a tte ry in t h e Dia gn osis a n d Test in g sect ion of
Gr ou p 8A - Ba t t er y for t h e pr ocedu r es.
• F u lly en ga ge t h e pa r kin g br a ke.
• P la ce t h e a u t om a t ic t r a n sm ission gea r sh ift selec-
t or lever in t h e P a r k posit ion .
• Verify tha t a ll la mps a nd a ccessories a re turned off.
• To pr even t t h e en gin e fr om st a r t in g, r em ove t h e Fig. 3 Test Battery Positive Connection Resistance -
Au t om a t ic Sh u t Down (ASD) r ela y. Th e ASD r ela y is Typical
loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC), in 1 - VOLTMETER
t h e en gin e com pa r t m en t . Refer t o t h e fu se a n d r ela y 2 - BATTERY
la you t la bel a ffixed t o t h e u n der side of t h e P DC cover
for ASD r ela y iden t ifica t ion a n d loca t ion . (3) Con n ect t h e volt m et er t o m ea su r e bet ween t h e
(1) Con n ect t h e posit ive lea d of t h e volt m et er t o ba t t er y posit ive t er m in a l post a n d t h e st a r t er sole-
t h e ba t t er y n ega t ive t er m in a l post . Con n ect t h e n eg- n oid ba t t er y t er m in a l st u d (F ig. 4). Rot a t e a n d h old
a t ive lea d of t h e volt m et er t o t h e ba t t er y n ega t ive t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e
ca ble cla m p (F ig. 2). Rot a t e a n d h old t h e ign it ion volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d
swit ch in t h e St a r t posit ion . Obser ve t h e volt m et er. If t igh t en t h e ba t t er y ca ble con n ect ion a t t h e solen oid.
volt a ge is det ect ed, cor r ect t h e poor con t a ct bet ween
t h e ca ble cla m p a n d t h e t er m in a l post .
8F - 34 STARTING WJ
START I N G (Cont inue d)
Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt , (5) Con n ect t h e posit ive lea d of t h e volt m et er t o
r epla ce t h e fa u lt y ba t t er y posit ive ca ble. t h e st a r t er h ou sin g. Con n ect t h e n ega t ive lea d of t h e
volt m et er t o t h e ba t t er y n ega t ive t er m in a l post (F ig.
6). Rot a t e a n d h old t h e ign it ion swit ch in t h e St a r t
posit ion . Obser ve t h e volt m et er. If t h e r ea din g is
a bove 0.2 volt , cor r ect t h e poor st a r t er t o en gin e
block gr ou n d con t a ct .

Fig. 4 Test Battery Positive Cable Resistance -

Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 6 Test Starter Ground - Typical
(4) Con n ect t h e volt m et er t o m ea su r e bet ween t h e 1 - STARTER MOTOR
ba t t er y n ega t ive t er m in a l post a n d a good clea n 2 - BATTERY
gr ou n d on t h e en gin e block (F ig. 5). Rot a t e a n d h old 3 - VOLTMETER
t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e
volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d If t h e r esist a n ce t est s det ect n o feed cir cu it pr ob-
t igh t en t h e ba t t er y n ega t ive ca ble a t t a ch m en t on t h e lem s, r efer t o S ta rte r Mo to r in t h e Dia gn osis a n d
en gin e block. Repea t t h e t est . If t h e r ea din g is st ill Test in g sect ion of t h is gr ou p.
a bove 0.2 volt , r epla ce t h e fa u lt y ba t t er y n ega t ive
ca ble. CONTROL CIRCUIT TESTING
Th e st a r t er con t r ol cir cu it com pon en t s sh ou ld be
t est ed in t h e or der in wh ich t h ey a r e list ed, a s fol-
lows:
• S ta rte r Re la y - Refer t o S ta rte r Re la y in t h e
Dia gn osis a n d Test in g sect ion of t h is gr ou p for t h e
pr ocedu r es.
• S ta rte r S o le n o id - Refer t o S ta rte r Mo to r in
t h e Dia gn osis a n d Test in g sect ion of t h is gr ou p for
t h e pr ocedu r es.
• Ig n itio n S w itc h - Refer t o Ig n itio n S w itc h
a n d Ke y Lo c k Cy lin d e r in t h e Dia gn osis a n d Test -
in g sect ion of Gr ou p 8D - Ign it ion Syst em for t h e pr o-
cedu r es.
• P a rk /N e u tra l P o s itio n S w itc h - Refer t o
P a rk /N e u tra l P o s itio n S w itc h in t h e Dia gn osis
Fig. 5 Test Ground Circuit a n d Test in g sect ion of Gr ou p 21 - Tr a n sm ission for
1 - VOLTMETER t h e pr ocedu r es.
2 - BATTERY • Wire h a rn e s s e s a n d c o n n e c tio n s - Refer t o
3 - ENGINE GROUND S ta rtin g S y s te m in t h e Con t en t s of Gr ou p 8W -
Wir in g Dia gr a m s for com plet e cir cu it dia gr a m s.
WJ STARTING 8F - 35
START I N G (Cont inue d)

SPECI FI CAT I ON S
TORQUE - STARTER

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Stater Motor (B+) Terminal 27 20
(Diesel)
Stater Motor (B+) Terminal 11.3 100
(Except Diesel)
Starter Motor Retaining Bolts 27 20
(Diesel)
Starter Motor Retaining Bolt 41 30
(Forward Facing 4.0L)
Starter Motor Retaining Bolt 54 40
(Forward Facing 4.7L)
Starter Motor Retaining Bolt 54 40
(Rearward Facing 4.7L)

STARTER MOTOR - GAS POWERED

Starter Motor and Solenoid

Manufacturer Mitsubishi
Engine Application 4.0L/4.7L
Power Rating 1.4 Kilowatt (1.9 Horsepower)
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
Free Running Test Minimum Speed 2400 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
*Cranking Amperage Draw Test 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

START ER M OT OR com pa ct , ligh t weigh t a n d power fu l u n it . Th e elect r ic

m ot or s of bot h st a r t er s fea t u r e fou r elect r om a gn et ic
field coils wou n d a r ou n d fou r pole sh oes, a n d fou r
DESCRIPTION
br u sh es con t a ct t h e m ot or com m u t a t or. Bot h st a r t er
Th e st a r t er m ot or s u sed for bot h t h e 4.0L a n d t h e
m ot or s a r e r a t ed a t 1.4 kilowa t t s (a bou t 1.9 h or se-
4.7L en gin es a va ila ble in t h is m odel a r e ver y sim ila r,
power ) ou t pu t a t 12 volt s.
bu t a r e n ot in t er ch a n gea ble. Bot h st a r t er m ot or s a r e
Bot h of t h ese st a r t er m ot or s a r e ser viced on ly a s a
m ou n t ed wit h t wo scr ews t o t h e a u t om a t ic t r a n sm is-
u n it wit h t h eir st a r t er solen oids, a n d ca n n ot be
sion t or qu e con ver t er h ou sin g a n d a r e loca t ed on t h e
r epa ir ed. If eit h er com pon en t is fa u lt y or da m a ged,
r igh t side of t h e en gin e.
t h e en t ir e st a r t er m ot or a n d st a r t er solen oid u n it
E a ch of t h ese st a r t er m ot or s in cor por a t es sever a l
m u st be r epla ced.
of t h e sa m e fea t u r es t o cr ea t e a r elia ble, efficien t ,
8F - 36 STARTING WJ
START ER M OT OR (Cont inue d)

OPERATION Specifica t ion s sect ion of t h is gr ou p for t h e st a r t er

Th ese st a r t er m ot or s a r e equ ipped wit h a pla n e-
t a r y gea r r edu ct ion (in t er m edia t e t r a n sm ission ) sys-
t em . Th e pla n et a r y gea r r edu ct ion syst em con sist s of
a gea r t h a t is in t egr a l t o t h e ou t pu t en d of t h e elec-
t r ic m ot or a r m a t u r e sh a ft t h a t is in con t in u a l
en ga gem en t wit h a la r ger gea r t h a t is splin ed t o t h e
in pu t en d of t h e st a r t er pin ion gea r sh a ft . Th is fea -
t u r e m a kes it possible t o r edu ce t h e dim en sion s of
t h e st a r t er. At t h e sa m e t im e, it a llows h igh er a r m a -
t u r e r ot a t ion a l speed a n d deliver s in cr ea sed t or qu e
t h r ou gh t h e st a r t er pin ion gea r t o t h e st a r t er r in g
gea r.
Th e st a r t er m ot or s for bot h en gin es a r e a ct iva t ed
by a n in t egr a l h ea vy du t y st a r t er solen oid swit ch
m ou n t ed t o t h e over r u n n in g clu t ch h ou sin g. Th is
elect r om ech a n ica l swit ch con n ect s a n d discon n ect s
t h e feed of ba t t er y volt a ge t o t h e st a r t er m ot or a n d
a ct u a t es a sh ift for k t h a t en ga ges a n d disen ga ges t h e
st a r t er pin ion gea r wit h t h e st a r t er r in g gea r.
Bot h st a r t er m ot or s u se a n over r u n n in g clu t ch a n d
st a r t er pin ion gea r u n it t o en ga ge a n d dr ive a st a r t er
r in g gea r t h a t is in t egr a l t o t h e t or qu e con ver t er
dr ive pla t e m ou n t ed on t h e r ea r cr a n ksh a ft fla n ge.
m ot or fr ee r u n n in g t est m a xim u m a m per a ge dr a w
specifica t ion s.
(7) If t h e a m m et er r ea din g exceeds t h e m a xim u m
a m per a ge dr a w specifica t ion , r epla ce t h e fa u lt y
st a r t er m ot or a ssem bly.
STARTER SOLENOID
Th is t est ca n on ly be per for m ed wit h t h e st a r t er
m ot or r em oved fr om t h e veh icle.
(1) Rem ove t h e st a r t er m ot or fr om t h e veh icle.
Refer t o S ta rte r Mo to r in t h e Rem ova l a n d In st a l-
la t ion sect ion of t h is gr ou p for t h e pr ocedu r es.
(2) Discon n ect t h e wir e fr om t h e solen oid field coil
t er m in a l.
(3) Ch eck for con t in u it y bet ween t h e solen oid t er-
m in a l a n d t h e solen oid field coil t er m in a l wit h a con -
t in u it y t est er (F ig. 7). Th er e sh ou ld be con t in u it y. If
OK, go t o St ep 4. If n ot OK, r epla ce t h e fa u lt y st a r t er
m ot or a ssem bly.

DIAGNOSIS AND TESTING - STARTER MOTOR

Cor r ect st a r t er m ot or oper a t ion ca n be con fir m ed
by per for m in g t h e followin g fr ee r u n n in g ben ch t est .
Th is t est ca n on ly be per for m ed wit h t h e st a r t er
m ot or r em oved fr om t h e veh icle. Refer t o S ta rtin g Fig. 7 Continuity Test Between Solenoid Terminal
S y s te m in t h e Specifica t ion s sect ion of t h is gr ou p for and Field Coil Terminal - Typical
t h e st a r t er m ot or specifica t ion s. 1 - SOLENOID
(1) Rem ove t h e st a r t er m ot or fr om t h e veh icle. 2 - SOLENOID TERMINAL
Refer t o S ta rte r Mo to r in t h e Rem ova l a n d In st a l- 3 - OHMMETER
la t ion sect ion of t h is gr ou p for t h e pr ocedu r es. 4 - FIELD COIL TERMINAL
(2) Mou n t t h e st a r t er m ot or secu r ely in a soft -
ja wed ben ch vise. Th e vise ja ws sh ou ld be cla m ped (4) Ch eck for con t in u it y bet ween t h e solen oid t er-
on t h e m ou n t in g fla n ge of t h e st a r t er m ot or. Never m in a l a n d t h e solen oid ca se (F ig. 8). Th er e sh ou ld be
cla m p on t h e st a r t er m ot or by t h e field fr a m e. con t in u it y. If n ot OK, r epla ce t h e fa u lt y st a r t er m ot or
(3) Con n ect a su it a ble volt -a m per e t est er a n d a a ssem bly.
12-volt ba t t er y t o t h e st a r t er m ot or in ser ies, a n d set
t h e a m m et er t o t h e 100 a m per e sca le. See t h e
in st r u ct ion s pr ovided by t h e m a n u fa ct u r er of t h e
volt -a m per e t est er bein g u sed.
(4) In st a ll a ju m per wir e fr om t h e solen oid t er m i-
n a l t o t h e solen oid ba t t er y t er m in a l. Th e st a r t er
m ot or sh ou ld oper a t e. If t h e st a r t er m ot or fa ils t o
oper a t e, r epla ce t h e fa u lt y st a r t er m ot or a ssem bly.
(5) Adju st t h e ca r bon pile loa d of t h e t est er t o
obt a in t h e fr ee r u n n in g t est volt a ge. Refer t o S ta rt-
in g S y s te m in t h e Specifica t ion s sect ion of t h is Fig. 8 Continuity Test Between Solenoid Terminal
gr ou p for t h e st a r t er m ot or fr ee r u n n in g t est volt a ge 1 - SOLENOID
specifica t ion s. 2 - SOLENOID TERMINAL
(6) Not e t h e r ea din g on t h e a m m et er a n d com pa r e 3 - OHMMETER
t h is r ea din g t o t h e fr ee r u n n in g t est m a xim u m
a m per a ge dr a w. Refer t o S ta rtin g S y s te m in t h e
WJ STARTING 8F - 37
START ER M OT OR (Cont inue d)

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Ra ise a n d su ppor t t h e veh icle.
(3) Rem ove t h e lower (for wa r d fa cin g) m ou n t in g
scr ew secu r in g t h e st a r t er m ot or t o t h e a u t om a t ic
t r a n sm ission t or qu e con ver t er h ou sin g (F ig. 9) or
(F ig. 10) .

Fig. 10 Starter Motor Remove/Install - 4.7L Engine

1 - SCREW
2 - STARTER MOTOR
3 - SCREW

Fig. 9 Starter Motor Remove/Install - 4.0L Engine

1 - SCREW
2 - STARTER MOTOR
3 - SCREW

(4) Wh ile su ppor t in g t h e st a r t er m ot or wit h on e

h a n d, u se t h e ot h er h a n d t o r em ove t h e u pper (r ea r
fa cin g) m ou n t in g scr ew secu r in g t h e st a r t er m ot or t o
t h e a u t om a t ic t r a n sm ission t or qu e con ver t er h ou sin g.
(5) Lower t h e st a r t er m ot or fr om t h e fr on t of t h e
a u t om a t ic t r a n sm ission t or qu e con ver t er h ou sin g fa r
en ou gh t o a ccess a n d r em ove t h e n u t t h a t secu r es
t h e ba t t er y ca ble eyelet t o t h e solen oid ba t t er y t er m i-
n a l (F ig. 11) or (F ig. 12) . Alwa ys su ppor t t h e st a r t er
m ot or du r in g t h is pr ocess, do n ot let t h e st a r t er
m ot or h a n g fr om t h e wir e h a r n ess. Fig. 11 Starter Wire Harness Remove/Install - 4.0L
(6) Rem ove t h e ba t t er y ca ble eyelet fr om t h e sole- Engine
n oid ba t t er y t er m in a l. Alwa ys su ppor t t h e st a r t er
1 - BATTERY, STARTER AND GENERATOR WIRE HARNESS
m ot or du r in g t h is pr ocess, do n ot let t h e st a r t er 2 - GROUND EYELET
m ot or h a n g fr om t h e wir e h a r n ess. 3 - SCREW
(7) Discon n ect t h e solen oid t er m in a l wir e h a r n ess 4 - NUT
con n ect or fr om t h e con n ect or r ecept a cle on t h e 5 - SOLENOID TERMINAL CONNECTOR
st a r t er solen oid. Alwa ys su ppor t t h e st a r t er m ot or 6 - SOLENOID BATTERY TERMINAL EYELET
du r in g t h is pr ocess, do n ot let t h e st a r t er m ot or h a n g 7 - RETAINERS
fr om t h e wir e h a r n ess.
8F - 38 STARTING
START ER M OT OR (Cont inue d)
Fig. 12 Starter Wire Harness Remove/Install - 4.7L
Engine
1 - SOLENOID BATTERY TERMINAL EYELET
2 - NUT
3 - SOLENOID TERMINAL CONNECTOR
4 - BATTERY STARTER AND GENERATOR WIRE HARNESS
5 - RETAINERS
(8) Rem ove t h e st a r t er m ot or fr om t h e en gin e com -
pa r t m en t .
INSTALLATION
(1) P osit ion t h e st a r t er m ot or in t h e en gin e com -
pa r t m en t .
(2) Recon n ect t h e solen oid t er m in a l wir e h a r n ess
con n ect or t o t h e con n ect or r ecept a cle on t h e st a r t er
solen oid. Alwa ys su ppor t t h e st a r t er m ot or du r in g
t h is pr ocess, do n ot let t h e st a r t er m ot or h a n g fr om
t h e wir e h a r n ess.
(3) In st a ll t h e ba t t er y ca ble eyelet on t o t h e sole-
n oid ba t t er y t er m in a l. Alwa ys su ppor t t h e st a r t er
m ot or du r in g t h is pr ocess, do n ot let t h e st a r t er
m ot or h a n g fr om t h e wir e h a r n ess.
(4) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e
ba t t er y ca ble eyelet t o t h e solen oid ba t t er y t er m in a l.
Tigh t en t h e n u t t o 11.3 N·m (100 in . lbs.). Alwa ys
su ppor t t h e st a r t er m ot or du r in g t h is pr ocess, do n ot
let t h e st a r t er m ot or h a n g fr om t h e wir e h a r n ess.
(5) P osit ion t h e st a r t er m ot or t o t h e fr on t of t h e
a u t om a t ic t r a n sm ission t or qu e con ver t er h ou sin g a n d
loosely in st a ll bot h t h e u pper a n d lower m ou n t in g
scr ews.
(6) Tigh t en t h e lower (for wa r d fa cin g) st a r t er
m ot or m ou n t in g scr ew. On 4.0L en gin es, t igh t en t h e
scr ew t o 41 N·m (30 ft . lbs.). On 4.7L en gin es, t igh t en
t h e scr ew t o 54 N·m (40 ft . lbs.).
WJ
(7) Tigh t en t h e u pper (r ea r wa r d fa cin g) st a r t er
m ou n t in g scr ew. Tigh t en t h e scr ew t o 54 N·m (40 ft .
lbs.).
(8) Lower t h e veh icle.
(9) Recon n ect t h e ba t t er y n ega t ive ca ble.
START ER M OT OR RELAY
DESCRIPTION
Th e st a r t er r ela y is a n elect r om ech a n ica l device
t h a t swit ch es ba t t er y cu r r en t t o t h e pu ll-in coil of t h e
st a r t er solen oid wh en t h e ign it ion swit ch is t u r n ed t o
t h e St a r t posit ion . Th e st a r t er r ela y is loca t ed in t h e
P ower Dist r ibu t ion Cen t er (P DC), in t h e en gin e com -
pa r t m en t . See t h e fu se a n d r ela y la you t la bel a ffixed
t o t h e in side su r fa ce of t h e P DC cover for st a r t er
r ela y iden t ifica t ion a n d loca t ion .
Th e st a r t er r ela y is a In t er n a t ion a l St a n da r ds
Or ga n iza t ion (ISO) m icr o-r ela y. Rela ys con for m in g t o
t h e ISO specifica t ion s h a ve com m on ph ysica l dim en -
sion s, cu r r en t ca pa cit ies, t er m in a l pa t t er n s, a n d t er-
m in a l fu n ct ion s. Th e ISO m icr o-r ela y t er m in a l
fu n ct ion s a r e t h e sa m e a s a con ven t ion a l ISO r ela y.
H owever, t h e ISO m icr o-r ela y t er m in a l pa t t er n (or
foot pr in t ) is differ en t , t h e cu r r en t ca pa cit y is lower,
a n d t h e ph ysica l dim en sion s a r e sm a ller t h a n t h ose
of t h e con ven t ion a l ISO r ela y.
Th e st a r t er r ela y ca n n ot be r epa ir ed or a dju st ed
a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
OPERATION
Th e ISO r ela y con sist s of a n elect r om a gn et ic coil, a
r esist or or diode, a n d t h r ee (t wo fixed a n d on e m ov-
a ble) elect r ica l con t a ct s. Th e m ova ble (com m on feed)
r ela y con t a ct is h eld a ga in st on e of t h e fixed con t a ct s
(n or m a lly closed) by spr in g pr essu r e. Wh en t h e elec-
t r om a gn et ic coil is en er gized, it dr a ws t h e m ova ble
con t a ct a wa y fr om t h e n or m a lly closed fixed con t a ct ,
a n d h olds it a ga in st t h e ot h er (n or m a lly open ) fixed
con t a ct .
Wh en t h e elect r om a gn et ic coil is de-en er gized,
spr in g pr essu r e r et u r n s t h e m ova ble con t a ct t o t h e
n or m a lly closed posit ion . Th e r esist or or diode is con -
n ect ed in pa r a llel wit h t h e elect r om a gn et ic coil in t h e
r ela y, a n d h elps t o dissipa t e volt a ge spikes t h a t a r e
pr odu ced wh en t h e coil is de-en er gized.
DIAGNOSIS AND TESTING - STARTER RELAY
Th e st a r t er r ela y (F ig. 13) is loca t ed in t h e P ower
Dist r ibu t ion Cen t er (P DC), in t h e en gin e com pa r t -
m en t . Refer t o t h e fu se a n d r ela y la you t la bel a ffixed
t o t h e u n der side of t h e P DC cover for st a r t er r ela y
iden t ifica t ion a n d loca t ion . F or com plet e cir cu it dia -
gr a m s, r efer t o S ta rtin g S y s te m in t h e Con t en t s of
Gr ou p 8W - Wir in g Dia gr a m s.
WJ
START ER M OT OR RELAY (Cont inue d)
(1) Rem ove t h e st a r t er r ela y fr om t h e P DC. Refer
t o S ta rte r Re la y in t h e Rem ova l a n d In st a lla t ion
sect ion of t h is gr ou p for t h e pr ocedu r es.
(2) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(3) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ± 5 oh m s. If OK, go t o St ep
4. If n ot OK, r epla ce t h e fa u lt y r ela y.
(4) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A
a n d 30. If OK, per for m t h e Rela y Cir cu it Test t h a t
follows. If n ot OK, r epla ce t h e fa u lt y r ela y.
STARTING 8F - 39
t ion , a n d n o volt a ge wh en t h e ign it ion swit ch is
r elea sed t o t h e On posit ion . If OK, go t o St ep 5. If
n ot OK, ch eck for a n open or sh or t cir cu it t o t h e ign i-
t ion swit ch a n d r epa ir, if r equ ir ed. If t h e cir cu it t o
t h e ign it ion swit ch is OK, r efer t o Ig n itio n S w itc h
a n d Ke y Lo c k Cy lin d e r in t h e Dia gn osis a n d Test -
in g sect ion of Gr ou p 8D - Ign it ion Syst em for t est in g
of t h e ign it ion swit ch .
(5) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It is gr ou n ded
t h r ou gh t h e pa r k/n eu t r a l posit ion swit ch on ly wh en
t h e gea r sh ift select or lever is in t h e P a r k or Neu t r a l
posit ion s. Ch eck for con t in u it y t o gr ou n d a t t h e ca v-
it y for r ela y t er m in a l 85. If n ot OK, ch eck for a n
open or sh or t cir cu it t o t h e pa r k/n eu t r a l posit ion
swit ch a n d r epa ir, if r equ ir ed. If t h e cir cu it t o t h e
pa r k/n eu t r a l posit ion swit ch is OK, r efer t o P a rk /
N e u tra l P o s itio n S w itc h in t h e Dia gn osis a n d
Test in g sect ion of Gr ou p 21 - Tr a n sm ission for t est in g
of t h e pa r k/n eu t r a l posit ion swit ch .

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e cover fr om t h e P ower Dist r ibu t ion
Cen t er (P DC) (F ig. 14) .

Fig. 13 Starter Relay

30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED

RELAY CIRCUIT TEST

(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is
con n ect ed t o ba t t er y volt a ge a n d sh ou ld be h ot a t a ll
t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open
cir cu it t o t h e fu se in t h e P DC a s r equ ir ed.
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3.
(3) Th e r ela y n or m a lly open t er m in a l (87) is con -
n ect ed t o t h e com m on feed t er m in a l (30) in t h e en er-
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
t o t h e st a r t er solen oid field coils. Th er e sh ou ld be
con t in u it y bet ween t h e ca vit y for r ela y t er m in a l 87
a n d t h e st a r t er solen oid t er m in a l a t a ll t im es. If OK, Fig. 14 Power Distribution Center
go t o St ep 4. If n ot OK, r epa ir t h e open cir cu it t o t h e 1 - RIGHT FENDER
2 - BATTERY
st a r t er solen oid a s r equ ir ed.
3 - POWER DISTRIBUTION CENTER
(4) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
4 - COVER
t h e elect r om a gn et in t h e r ela y. It is en er gized wh en
t h e ign it ion swit ch is h eld in t h e St a r t posit ion .
Ch eck for ba t t er y volt a ge a t t h e ca vit y for r ela y t er-
m in a l 86 wit h t h e ign it ion swit ch in t h e St a r t posi-
8F - 40 STARTING WJ
START ER M OT OR RELAY (Cont inue d)
(3) See t h e fu se a n d r ela y la you t la bel a ffixed t o (3) Align t h e st a r t er r ela y t er m in a ls wit h t h e t er-
t h e u n der side of t h e P DC cover for st a r t er r ela y iden - m in a l ca vit ies in t h e P DC r ecept a cle.
t ifica t ion a n d loca t ion . (4) P u sh down fir m ly on t h e st a r t er r ela y u n t il t h e
(4) Rem ove t h e st a r t er r ela y fr om t h e P DC. t er m in a ls a r e fu lly sea t ed in t h e t er m in a l ca vit ies in
t h e P DC r ecept a cle.
INSTALLATION (5) In st a ll t h e cover on t o t h e P DC.
(1) See t h e fu se a n d r ela y la you t la bel a ffixed t o (6) Recon n ect t h e ba t t er y n ega t ive ca ble.
t h e u n der side of t h e P DC cover for t h e pr oper st a r t er
r ela y loca t ion .
(2) P osit ion t h e st a r t er r ela y in t h e pr oper r ecep-
t a cle in t h e P DC.
WJ HEATED SYSTEMS 8G - 1

HEATED SYSTEMS
TABLE OF CON T EN T S

page page

HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 9

HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 8

H EAT ED GLASS

TABLE OF CONTENTS
page page

HEATED GLASS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...5

DESCRIPTION - REAR WINDOW DEFOGGER ..1 DIAGNOSIS AND TESTING - REAR WINDOW
OPERATION - REAR WINDOW DEFOGGER . ...2 DEFOGGER RELAY . . . . . . . . . . . . . . . . . . ...5
DIAGNOSIS AND TESTING - REAR WINDOW REMOVAL .......................... ...6
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . ...2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...6
REAR WINDOW DEFOGGER GRID REAR WINDOW DEFOGGER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...7
DIAGNOSIS AND TESTING - REAR WINDOW DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER GRID . . . . . . . . . . . . . . . . . . . ...3 DEFOGGER SWITCH . . . . . . . . . . . . . . . . ...7
STANDARD PROCEDURE - REAR GLASS REMOVAL .......................... ...7
HEATING GRID REPAIR .............. ...4
REAR WINDOW DEFOGGER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...5

H EAT ED GLASS • Rea r win dow defogger swit ch .

Cer t a in fu n ct ion s a n d fea t u r es of t h e r ea r win dow
defogger syst em r ely u pon r esou r ces sh a r ed wit h
DESCRIPTION - REAR WINDOW DEFOGGER
ot h er elect r on ic m odu les in t h e veh icle over t h e P r o-
An elect r ica lly h ea t ed r ea r win dow defogger is
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s
st a n da r d fa ct or y-in st a lled equ ipm en t on t h is m odel.
n et wor k. Th e P CI da t a bu s n et wor k a llows t h e sh a r-
E lect r ica lly h ea t ed ou t side r ea r view m ir r or s a r e
in g of sen sor in for m a t ion . Th is h elps t o r edu ce wir e
a va ila ble fa ct or y-in st a lled opt ion a l equ ipm en t . Wh en
h a r n ess com plexit y, in t er n a l con t r oller h a r dwa r e, a n d
t h e r ea r win dow defogger syst em is t u r n ed on , elec-
com pon en t sen sor cu r r en t loa ds. At t h e sa m e t im e,
t r ic h ea t er gr ids on t h e lift ga t e flip-u p gla ss a n d
t h is syst em pr ovides in cr ea sed r elia bilit y, en h a n ced
beh in d bot h ou t side r ea r view m ir r or gla sses a r e
dia gn ost ics, a n d a llows t h e a ddit ion of m a n y n ew fea -
en er gized. Th ese elect r ic h ea t er gr ids pr odu ce h ea t t o
t u r e ca pa bilit ies. F or dia gn osis of t h ese elect r on ic
h elp clea r t h e r ea r win dow gla ss a n d t h e ou t side r ea r
m odu les or of t h e P CI da t a bu s n et wor k, u se a
view m ir r or s of ice, sn ow, or fog. Th e r ea r win dow
DRBIII! sca n t ool a n d (Refer t o Appr opr ia t e Dia gn os-
defogger syst em con t r ol cir cu it u ses ign it ion swit ch ed
t ic In for m a t ion ).
ba t t er y cu r r en t , so t h e syst em will on ly oper a t e wh en
Th e ot h er elect r on ic m odu les t h a t m a y a ffect
t h e ign it ion swit ch is in t h e On posit ion .
pr oper syst em oper a t ion a r e:
Th is gr ou p cover s t h e followin g com pon en t s of t h e
• B o d y Co n tro l Mo d u le (B CM) - Refer t o E lec-
r ea r win dow defogger syst em :
t r on ic Con t r ol Modu les for m or e in for m a t ion .
• Rea r gla ss h ea t in g gr id
• D riv e r D o o r Mo d u le (D D M) - Refer t o E lec-
• Rea r win dow defogger r ela y
t r on ic Con t r ol Modu les for m or e in for m a t ion .
8G - 2 HEATED GLASS
H EAT ED GLASS (Cont inue d)
• P a s s e n g e r D o o r Mo d u le (P D M) - Refer t o
E lect r on ic Con t r ol Modu les for m or e in for m a t ion .
OPERATION - REAR WINDOW DEFOGGER
Th e r ea r win dow defogger syst em is con t r olled by a
m om en t a r y swit ch t h a t is in t egr a l t o t h e a /c h ea t er
con t r ol loca t ed in t h e cen t er st a ck a r ea of t h e in st r u -
m en t pa n el. A Ligh t -E m it t in g Diode (LE D) in t h e
swit ch bu t t on will ligh t t o in dica t e wh en t h e r ea r
win dow defogger syst em is t u r n ed on . Th e BCM,
wh ich con t a in s t h e r ea r win dow defogger syst em
t im er a n d con t r ol logic, m on it or s t h e st a t u s of t h e
defogger swit ch t h r ou gh a h a r d-wir ed in pu t . Th e
BCM t h en sen ds con t r ol ou t pu t s t h r ou gh a h a r d
wir ed cir cu it t o en er gize or de-en er gize t h e defogger
r ela y.
Th e elect r ica lly h ea t ed ou t side r ea r view m ir r or
h ea t in g gr ids a r e a lso con t r olled by t h e r ea r win dow
defogger swit ch . Wh en t h e BCM r eceives a n in pu t
fr om t h e swit ch , it sen ds a defogger swit ch st a t u s
m essa ge t o t h e DDM a n d t h e P DM over t h e P CI da t a
bu s. Th e DDM a n d P DM r espon d t o t h e defogger
swit ch st a t u s m essa ges by en er gizin g or de-en er giz-
in g t h e ba t t er y cu r r en t feed t o t h eir r espect ive ou t -
side r ea r view m ir r or h ea t in g gr ids.
Th e r ea r win dow defogger syst em will be a u t om a t -
ica lly t u r n ed off a ft er a pr ogr a m m ed t im e in t er va l of
a bou t t en m in u t es. Aft er t h e in it ia l t im e in t er va l h a s
expir ed, if t h e defogger swit ch is t u r n ed on a ga in
du r in g t h e sa m e ign it ion cycle, t h e defogger syst em
will a u t om a t ica lly t u r n off a ft er a bou t five m in u t es.
Th e defogger syst em will a u t om a t ica lly sh u t off if t h e
ign it ion swit ch is t u r n ed t o t h e Off posit ion , or it ca n
be t u r n ed off m a n u a lly by depr essin g t h e r ea r win -
dow defogger swit ch a ga in .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e r ea r win dow defogger syst em .
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WJ
F or com plet e cir cu it dia gr a m s, (Refer t o Appr opr i-
a t e Wir in g In for m a t ion ). Th e oper a t ion of t h e elect r i-
ca lly h ea t ed r ea r win dow defogger syst em ca n be
con fir m ed in on e of t h e followin g m a n n er s:
1. Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Wh ile m on it or in g t h e in st r u m en t pa n el volt m et er,
depr ess t h e r ea r win dow defogger swit ch t o t h e On
posit ion . Wh en t h e r ea r win dow defogger swit ch is
t u r n ed On , a dist in ct volt m et er n eedle deflect ion
sh ou ld be n ot ed.
2. Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Depr ess t h e r ea r win dow defogger swit ch t o t h e On
posit ion . Th e r ea r win dow defogger oper a t ion ca n be
ch ecked by feelin g t h e r ea r win dow or ou t side r ea r
view m ir r or gla ss. A dist in ct differ en ce in t em per a -
t u r e bet ween t h e gr id lin es a n d t h e a dja cen t clea r
gla ss or t h e m ir r or gla ss ca n be det ect ed wit h in t h r ee
t o fou r m in u t es of oper a t ion .
3. Usin g a 12-volt DC volt m et er, con t a ct t h e r ea r
gla ss h ea t in g gr id t er m in a l A (r igh t side) wit h t h e
n ega t ive lea d, a n d t er m in a l B (left side) wit h t h e pos-
it ive lea d (F ig. 1). Th e volt m et er sh ou ld r ea d ba t t er y
volt a ge.
Fig. 1 REAR WINDOW GLASS GRID TEST
1 - TERMINAL “A”
2 - TERMINAL “B”
3 - FEED WIRE
4 - MID-POINT “C” (TYPICAL)
5 - HEATED REAR WINDOW DEFOGGER GRID
6 - GROUND WIRE
Th e a bove ch ecks will con fir m r ea r win dow defog-
ger syst em oper a t ion . Illu m in a t ion of t h e r ea r win -
dow defogger swit ch LE D in dica t or m ea n s t h a t t h er e
is ba t t er y cu r r en t a va ila ble a t t h e ou t pu t of t h e r ea r
win dow defogger r ela y, bu t does n ot con fir m t h a t ba t -
t er y cu r r en t is r ea ch in g t h e r ea r gla ss h ea t in g gr id
lin es.
If t h e r ea r win dow defogger syst em does n ot oper-
a t e, t h e pr oblem sh ou ld be isola t ed in t h e followin g
m a n n er :
WJ
H EAT ED GLASS (Cont inue d)
(1) Con fir m t h a t t h e ign it ion swit ch is in t h e On
posit ion .
(2) E n su r e t h a t t h e r ea r gla ss h ea t in g gr id feed
a n d gr ou n d t er m in a ls a r e con n ect ed t o t h e gla ss.
Con fir m t h a t t h e gr ou n d wir e h a s con t in u it y t o
gr ou n d.
(3) Ch eck t h e fu sed B(+) fu se in t h e P ower Dist r i-
bu t ion Cen t er (P DC). Th e fu se m u st be t igh t in it s
r ecept a cles a n d a ll elect r ica l con n ect ion s m u st be
secu r e.
Wh en t h e a bove st eps h a ve been com plet ed a n d t h e
r ea r gla ss h ea t in g gr id is st ill in oper a t ive, on e or
m or e of t h e followin g is fa u lt y:
• Rea r win dow defogger swit ch
• Rea r win dow defogger r ela y
• Body Con t r ol Modu le (BCM)
• Rea r win dow gr id lin es (a ll gr id lin es wou ld
h a ve t o be br oken or on e of t h e feed wir es discon -
n ect ed for t h e en t ir e syst em t o be in oper a t ive).
Wh en t h e a bove st eps h a ve been com plet ed a n d t h e
h ea t ed m ir r or gla ss h ea t in g gr id is st ill in oper a t ive,
on e or m or e of t h e followin g is fa u lt y:
• Body Con t r ol Modu le (BCM)
• P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s
• Dr iver Door Modu le (DDM) or P a ssen ger Door
Modu le (P DM)
• Ou t side r ea r view m ir r or h ea t in g gr ids.
If t u r n in g t h e r ea r win dow defogger syst em on pr o-
du ces a sever e volt m et er deflect ion , ch eck for a sh or t
cir cu it bet ween t h e r ea r win dow defogger r ela y ou t -
pu t a n d t h e r ea r gla ss h ea t in g gr id.
REAR WI N DOW DEFOGGER
GRI D
DESCRIPTION
Th e elect r ica lly h ea t ed r ea r win dow gla ss is st a n -
da r d equ ipm en t on t h is m odel. Th e lift ga t e flip-u p
gla ss h a s t wo elect r ica lly con du ct ive ver t ica l bu s ba r s
a n d a ser ies of h or izon t a l gr id lin es m a de of a silver-
cer a m ic m a t er ia l, wh ich is ba ked on a n d bon ded t o
t h e in side su r fa ce of t h e gla ss. Th ese gr id lin es a n d
t h e bu s ba r s com pr ise a pa r a llel elect r ica l cir cu it . A
spa de t ype t er m in a l n ea r t h e t op of ea ch bu s ba r
a ccept t h e con n ect or s fr om t h e t wo coiled lift ga t e
wir e h a r n ess t a ke ou t s.
Th e gr id lin es a n d bu s ba r s a r e h igh ly r esist a n t t o
a br a sion . H owever, it is possible for a n open cir cu it
t o occu r in a n in dividu a l gr id lin e, r esu lt in g in n o
cu r r en t flow t h r ou gh t h e lin e. Th e gr id lin es ca n be
da m a ged or scr a ped off wit h sh a r p in st r u m en t s. Ca r e
sh ou ld be t a ken wh en clea n in g t h e gla ss or r em ovin g
for eign m a t er ia ls, deca ls, or st icker s fr om t h e gla ss.
HEATED GLASS 8G - 3
Nor m a l gla ss clea n in g solven t s or h ot wa t er u sed
wit h r a gs or t owelin g is r ecom m en ded.
A r epa ir kit is a va ila ble t o r epa ir t h e gr id lin es a n d
bu s ba r s, or t o r ein st a ll t h e h ea t ed gla ss t er m in a ls.
(Refer t o 8 - E LE CTRICAL/H E ATE D GLASS/RE AR
WINDOW DE F OGGE R GRID - STANDARD P ROCE -
DURE )
OPERATION
Th e r ea r gla ss h ea t in g gr id is en er gized a n d de-en -
er gized by t h e r ea r win dow defogger r ela y. Th e Body
Con t r ol Modu le (BCM) m on it or s t h e r ea r win dow
defogger swit ch . Wh en t h e BCM r eceives a n in pu t
fr om t h e swit ch , it en er gizes or de-en er gizes t h e r ea r
win dow defogger r ela y t h r ou gh a h a r d wir ed con t r ol
ou t pu t . Th e r ea r defogger r ela y swit ch es fu sed ba t -
t er y cu r r en t t o t h e r ea r win dow gr id lin es t h r ou gh
t h e bu s ba r s. Th e gr id lin es h ea t t h e r ea r win dow
gla ss t o clea r t h e su r fa ce of ice, sn ow or fog. P r ot ec-
t ion for t h e r ea r gla ss h ea t in g gr id cir cu it is pr ovided
by a fu se in t h e P ower Dist r ibu t ion Cen t er (P DC).
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER GRID
F or com plet e cir cu it dia gr a m s, (Refer t o Appr opr i-
a t e Wir in g In for m a t ion ). To det ect br ea ks in t h e r ea r
gla ss h ea t in g gr id lin es, t h e followin g pr ocedu r e is
r equ ir ed:
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r ea r win dow defogger syst em on . Th e r ea r
win dow defogger swit ch LE D in dica t or sh ou ld ligh t .
If OK, go t o St ep 2. If n ot OK, (Refer t o 8 - E LE C-
TRICAL/H E ATE D GLASS/RE AR WINDOW DE F OG-
GE R RE LAY - DIAGNOSIS AND TE STING).
(2) Usin g a 12-volt DC volt m et er, con t a ct t h e r ea r
gla ss h ea t in g gr id ver t ica l bu s ba r on t h e r igh t side
of t h e veh icle wit h t h e n ega t ive lea d. Wit h t h e posi-
t ive lea d, con t a ct t h e r ea r gla ss h ea t in g gr id ver t ica l
bu s ba r on t h e left side of t h e veh icle. Th e volt m et er
sh ou ld r ea d ba t t er y volt a ge. If OK, go t o St ep 3. If
n ot OK, r epa ir t h e open r ea r win dow defogger r ela y
ou t pu t cir cu it t o t h e r ea r win dow defogger r ela y a s
r equ ir ed.
(3) Wit h t h e posit ive volt m et er lea d st ill con t a ct in g
t h e r ea r gla ss h ea t in g gr id ver t ica l bu s ba r on t h e
left side of t h e veh icle, m ove t h e n ega t ive lea d of t h e
volt m et er t o a good body gr ou n d poin t . Th e volt a ge
r ea din g sh ou ld n ot ch a n ge. If OK, go t o St ep 4. If n ot
OK, r epa ir t h e gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(4) Con n ect t h e n ega t ive lea d of t h e volt m et er t o
t h e r igh t side bu s ba r a n d t ou ch ea ch gr id lin e a t
m idpoin t C wit h t h e posit ive lea d (F ig. 2). A r ea din g
of a ppr oxim a t ely six volt s in dica t es a lin e is good. A
r ea din g of zer o volt s in dica t es a br ea k in t h e gr id
lin e bet ween m idpoin t C a n d t h e left side r ea r gla ss
h ea t in g gr id bu s ba r. A r ea din g of t en t o fou r t een
8G - 4 HEATED GLASS
REAR WI N DOW DEFOGGER GRI D (Cont inue d)
volt s in dica t es a br ea k bet ween m idpoin t C a n d t h e
r igh t side r ea r h ea t in g gr id bu s ba r. Move t h e posi-
t ive lea d on t h e gr id lin e t owa r ds t h e br ea k a n d t h e
volt a ge r ea din g will ch a n ge a s soon a s t h e br ea k is
cr ossed.
Fig. 2 REAR WINDOW GLASS GRID TEST
1 - TERMINAL “A”
2 - TERMINAL “B”
3 - FEED WIRE
4 - MID-POINT “C” (TYPICAL)
5 - HEATED REAR WINDOW DEFOGGER GRID
6 - GROUND WIRE
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR
Repa ir of t h e r ea r gla ss h ea t in g gr id lin es, bu s
ba r s, a n d t er m in a ls ca n be a ccom plish ed u sin g a
Mopa r Rea r Win dow Defogger Repa ir Kit (P a r t Nu m -
ber 4267922) or equ iva len t .
WARNING: MATERIALS CONTAINED IN THE REPAIR
KIT MAY CAUSE SKIN OR EYE IRRITATION. THE
KIT CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Ma sk t h e r epa ir a r ea on t h e in side of t h e r ea r
gla ss so t h a t t h e con du ct ive epoxy ca n be a pplied
n ea t ly. E xt en d t h e epoxy a pplica t ion on t o t h e r ea r
gla ss h ea t in g gr id bu s ba r or gr id lin e on ea ch side of
t h e br ea k (F ig. 3).
WJ
Fig. 3 GRID LINE REPAIR
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
(2) F ollow t h e in st r u ct ion s in t h e r epa ir kit for
pr epa r in g t h e da m a ged a r ea .
(3) Rem ove t h e pa cka ge sepa r a t or cla m p a n d m ix
t h e t wo con du ct ive epoxy com pon en t s t h or ou gh ly
wit h in t h e pa cka gin g. F old t h e pa cka ge in h a lf a n d
cu t t h e cen t er cor n er t o dispen se t h e epoxy.
(4) F or r ea r gla ss h ea t in g gr id lin e r epa ir s, m a sk
t h e a r ea t o be r epa ir ed wit h m a skin g t a pe or a t em -
pla t e.
(5) Apply t h e epoxy t h r ou gh t h e slit in t h e m a sk-
in g t a pe or t em pla t e. Over la p bot h en ds of t h e br ea k
by a t lea st 19 m illim et er s (0.75 in ch ).
(6) F or a r ea r gla ss h ea t in g gr id t er m in a l r epla ce-
m en t , m a sk t h e a dja cen t a r ea s so t h e epoxy ca n be
ext en ded on t o t h e a dja cen t gr id lin e a s well a s on t o
t h e bu s ba r. Apply a t h in la yer of epoxy t o t h e a r ea
wh er e t h e t er m in a l wa s pr eviou sly fa st en ed a n d on t o
t h e a dja cen t gr id lin e.
(7) Apply a t h in la yer of con du ct ive epoxy t o t h e
t er m in a l a n d pla ce it in t h e pr oper loca t ion on t h e
r ea r gla ss h ea t in g gr id bu s ba r. To pr even t t h e t er m i-
n a l fr om m ovin g wh ile t h e epoxy is cu r in g, it m u st be
wedged or cla m ped.
(8) Ca r efu lly r em ove t h e m a skin g t a pe or t em -
pla t e.
CAUTION: Do not allow the glass surface to exceed
204° C (400° F) or the glass may fracture.
(9) Allow t h e epoxy t o cu r e for 24 h ou r s a t r oom
t em per a t u r e, or u se a h ea t gu n wit h a 260° t o 371° C
(500° t o 700° F ) r a n ge for fift een m in u t es. H old t h e
h ea t gu n a ppr oxim a t ely 25.4 cen t im et er s (10 in ch es)
fr om t h e r epa ir.
(10) Aft er t h e con du ct ive epoxy is pr oper ly cu r ed,
r em ove t h e wedge or cla m p fr om t h e t er m in a l. Do
WJ
REAR WI N DOW DEFOGGER GRI D (Cont inue d)
n ot a t t a ch t h e wir e h a r n ess con n ect or s u n t il t h e cu r-
in g pr ocess is com plet e.
(11) Ch eck t h e oper a t ion of t h e r ea r gla ss h ea t in g
gr id.
REAR WI N DOW DEFOGGER
RELAY
DESCRIPTION
Th e r ea r win dow defogger r ela y is a n elect r om e-
ch a n ica l device t h a t swit ch es fu sed ba t t er y cu r r en t t o
t h e r ea r gla ss h ea t in g gr id a n d t h e Ligh t -E m it t in g
Diode (LE D) in dica t or of t h e r ea r win dow defogger
swit ch , wh en t h e Body Con t r ol Modu le (BCM) r ea r
win dow defogger t im er a n d logic cir cu it r y gr ou n ds
t h e r ela y coil. Th e r ea r win dow defogger r ela y is
loca t ed in t h e ju n ct ion block, u n der t h e left en d of
t h e in st r u m en t pa n el in t h e pa ssen ger com pa r t m en t .
Th e r ea r win dow defogger r ela y is a In t er n a t ion a l
St a n da r ds Or ga n iza t ion (ISO) r ela y. Rela ys con for m -
in g t o t h e ISO specifica t ion s h a ve com m on ph ysica l
dim en sion s, cu r r en t ca pa cit ies, t er m in a l pa t t er n s,
a n d t er m in a l fu n ct ion s.
Th e r ea r win dow defogger r ela y ca n n ot be r epa ir ed
or a dju st ed a n d, if fa u lt y or da m a ged, it m u st be
r epla ced.
OPERATION
Th e ISO r ela y con sist s of a n elect r om a gn et ic coil, a
r esist or or diode, a n d t h r ee (t wo fixed a n d on e m ov-
a ble) elect r ica l con t a ct s. Th e m ova ble (com m on feed)
r ela y con t a ct is h eld a ga in st on e of t h e fixed con t a ct s
(n or m a lly closed) by spr in g pr essu r e. Wh en t h e elec-
t r om a gn et ic coil is en er gized, it dr a ws t h e m ova ble
con t a ct a wa y fr om t h e n or m a lly closed fixed con t a ct ,
a n d h olds it a ga in st t h e ot h er (n or m a lly open ) fixed
con t a ct .
Wh en t h e elect r om a gn et ic coil is de-en er gized,
spr in g pr essu r e r et u r n s t h e m ova ble con t a ct t o t h e
n or m a lly closed posit ion . Th e r esist or or diode is con -
n ect ed in pa r a llel wit h t h e elect r om a gn et ic coil in t h e
r ela y, a n d h elps t o dissipa t e volt a ge spikes t h a t a r e
pr odu ced wh en t h e coil is de-en er gized.
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
HEATED GLASS 8G - 5
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RELAY TEST
Th e r ea r win dow defogger r ela y (F ig. 4) is loca t ed
in t h e ju n ct ion block, u n der t h e left en d of t h e in st r u -
m en t pa n el in t h e pa ssen ger com pa r t m en t . Rem ove
t h e r ea r win dow defogger r ela y fr om t h e ju n ct ion
block t o per for m t h e followin g t est s:
(1) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y.
(2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ± 10 oh m s. If OK, go t o St ep
3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(3) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A
a n d 30. If OK, r efer t o t h e Re la y Circ u it Te s t. If
n ot OK, r epla ce t h e fa u lt y r ela y.
Fig. 4 REAR WINDOW DEFOGGER RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
RELAY CIRCUIT TEST
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is
con n ect ed t o ba t t er y volt a ge a n d sh ou ld be h ot a t a ll
t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open
fu sed B(+) cir cu it t o t h e P ower Dist r ibu t ion Cen t er
(P DC) fu se a s r equ ir ed.
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3.
8G - 6 HEATED GLASS WJ
REAR WI N DOW DEFOGGER RELAY (Cont inue d)
(3) Th e r ela y n or m a lly open t er m in a l (87) is con -
n ect ed t o t h e com m on feed t er m in a l (30) in t h e en er-
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
t o t h e r ea r gla ss h ea t in g gr id a n d t o t h e fu se in t h e
ju n ct ion block t h a t feeds t h e r ea r win dow defogger
swit ch LE D in dica t or. Th er e sh ou ld be con t in u it y
bet ween t h e ca vit y for r ela y t er m in a l 87 a n d t h e r ea r
gla ss h ea t in g gr id a n d t h e r ea r win dow defogger
swit ch LE D in dica t or a t a ll t im es. If OK, go t o St ep
4. If n ot OK, r epa ir t h e open r ea r win dow defogger
r ela y ou t pu t cir cu it a s r equ ir ed.
(4) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It is con n ect ed t o ba t -
t er y volt a ge a n d sh ou ld be h ot a t a ll t im es. Ch eck for
ba t t er y volt a ge a t t h e ca vit y for r ela y t er m in a l 86. If
OK, go t o St ep 5. If n ot OK, r epa ir t h e open fu sed
B(+) cir cu it t o t h e P DC fu se a s r equ ir ed.
(5) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. Th is t er m in a l is pr o-
vided wit h gr ou n d by t h e Body Con t r ol Modu le
(BCM) r ea r win dow defogger t im er a n d logic cir cu it r y
t o en er gize t h e defogger r ela y. Th er e sh ou ld be con t i- Fig. 5 JUNCTION BLOCK
n u it y t o t h e r ea r win dow defogger r ela y con t r ol cir-
1 - COMBINATION FLASHER
cu it ca vit y of t h e 22-wa y in st r u m en t pa n el wir e 2 - JUNCTION BLOCK
h a r n ess con n ect or for t h e BCM. If OK, u se a DRB
sca n t ool a n d r efer t o t h e Appr opr ia t e Dia gn ost ic
In for m a t ion t o t est t h e BCM. If n ot OK, r epa ir t h e INSTALLATION
open r ea r win dow defogger r ela y con t r ol cir cu it a s (1) P osit ion t h e r ea r win dow defogger r ela y in t h e
r equ ir ed. pr oper r ecept a cle in t h e ju n ct ion block.
(2) Align t h e r ea r win dow defogger r ela y t er m in a ls
REMOVAL wit h t h e t er m in a l ca vit ies in t h e ju n ct ion block r ecep-
t a cle.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) P u sh in fir m ly on t h e r ea r win dow defogger
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE r ela y u n t il t h e t er m in a ls a r e fu lly sea t ed in t h e t er-
ATTEMPTING ANY STEERING WHEEL, STEERING m in a l ca vit ies in t h e ju n ct ion block r ecept a cle.
COLUMN, OR INSTRUMENT PANEL COMPONENT (4) In st a ll t h e st eer in g colu m n open in g cover on t o
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- t h e in st r u m en t pa n el. Refer t o In st r u m en t P a n el Sys-
LATE THE BATTERY NEGATIVE (GROUND) CABLE, t em for t h e pr ocedu r es.
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- (5) Recon n ect t h e ba t t er y n ega t ive ca ble.
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG REAR WI N DOW DEFOGGER
SYSTEM. FAILURE TO TAKE THE PROPER PRE- SWI T CH
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL DESCRIPTION
INJURY.
Th e r ea r win dow defogger swit ch is in t egr a l t o t h e
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive a /c h ea t er con t r ol, wh ich is loca t ed in t h e in st r u m en t
ca ble. pa n el cen t er st a ck below t h e r a dio r eceiver. Th is
(2) Rem ove t h e st eer in g colu m n open in g cover m om en t a r y swit ch pr ovides a h a r d wir ed gr ou n d sig-
fr om t h e in st r u m en t pa n el. Refer t o In st r u m en t n a l t o t h e Body Con t r ol Modu le (BCM) ea ch t im e it is
P a n el Syst em for t h e pr ocedu r es. depr essed. A Ligh t E m it t in g Diode (LE D) in t h e pu sh
(3) Th e r ea r win dow defogger r ela y is loca t ed on bu t t on for t h e r ea r win dow defogger swit ch illu m i-
t h e r igh t side of t h e com bin a t ion fla sh er in t h e ju n c- n a t es t o in dica t e wh en t h e r ea r win dow defogger sys-
t ion block (F ig. 5). t em is t u r n ed on .
(4) Rem ove t h e r ea r win dow defogger r ela y fr om Th e r ea r win dow defogger swit ch a n d t h e r ea r win -
t h e ju n ct ion block. dow defogger swit ch LE D in dica t or ca n n ot be
WJ
REAR WI N DOW DEFOGGER SWI T CH (Cont inue d)
r epa ir ed a n d, if fa u lt y or da m a ged, t h e en t ir e a /c
h ea t er con t r ol m u st be r epla ced. (Refer t o 24 - H E AT-
ING & AIR CONDITIONING/CONTROLS/A/C
H E ATE R CONTROL - RE MOVAL)
OPERATION
Wh en t h e r ea r win dow defogger swit ch pu sh bu t -
t on is depr essed, it m om en t a r ily closes t h e r ea r win -
dow defogger swit ch sen se cir cu it for t h e BCM t o
gr ou n d. Th e BCM m on it or s t h e r ea r win dow defogger
swit ch sen se cir cu it . E a ch t im e t h e BCM r ea r win -
dow defogger t im er a n d logic cir cu it r y sees a n ot h er
in pu t fr om t h e swit ch , it t oggles a con t r ol ou t pu t t o
t h e r ea r win dow defogger r ela y. E n er gizin g t h e r ea r
win dow defogger r ela y pr ovides elect r ica l cu r r en t t o
t h e r ea r win dow defogger gr id a n d t o t h e LE D in di-
ca t or in t h e swit ch , wh ich ligh t s t o in dica t e wh en t h e
defogger syst em is t u r n ed on . A dedica t ed fu se in t h e
ju n ct ion block pr ot ect s t h e r ea r win dow defogger
r ela y ou t pu t cir cu it t o t h e LE D in dica t or.
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o t h e Appr o-
pr ia t e Wir in g In for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e a /c h ea t er con t r ol fr om t h e in st r u -
m en t pa n el a n d discon n ect t h e 11-wa y (m a n u a l t em -
per a t u r e con t r ol) or 16-wa y (a u t om a t ic zon e con t r ol)
in st r u m en t pa n el wir e h a r n ess con n ect or fr om t h e a /c
h ea t er con t r ol r ecept a cle.
(2) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e 11-wa y or 16-wa y in st r u m en t pa n el
wir e h a r n ess con n ect or for t h e a /c h ea t er con t r ol a n d
a good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go
t o St ep 3. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o
gr ou n d a s r equ ir ed.
(3) Con n ect t wo ju m per wir es t o t h e a /c h ea t er
con t r ol 11-wa y or 16-wa y con n ect or r ecept a cle. Con -
n ect on e ju m per fr om t h e gr ou n d cir cu it t er m in a l in
HEATED GLASS 8G - 7
t h e 11-wa y or 16-wa y a /c h ea t er con t r ol con n ect or
r ecept a cle t o a good gr ou n d. Con n ect t h e ot h er
ju m per fr om t h e fu sed r ea r win dow defogger r ela y
ou t pu t cir cu it t er m in a l of t h e 11-wa y or 16-wa y con -
n ect or r ecept a cle t o a 12-volt ba t t er y feed. Th e r ea r
win dow defogger swit ch LE D in dica t or sh ou ld ligh t .
If OK, go t o St ep 4. If n ot OK, r epla ce t h e fa u lt y a /c
h ea t er con t r ol.
(4) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it a n d r ea r win dow defogger swit ch sen se cir cu it
t er m in a ls of t h e 11-wa y or 16-wa y a /c h ea t er con t r ol
con n ect or r ecept a cle. Th er e sh ou ld be m om en t a r y
con t in u it y a s t h e r ea r win dow defogger swit ch pu sh
bu t t on is depr essed, a n d t h en n o con t in u it y. If OK, go
t o St ep 5. If n ot OK, r epla ce t h e fa u lt y a /c h ea t er
con t r ol.
(5) Discon n ect t h e 22-wa y in st r u m en t pa n el wir e
h a r n ess con n ect or fr om t h e Body Con t r ol Modu le
(BCM) con n ect or r ecept a cle. Ch eck for con t in u it y
bet ween t h e r ea r win dow defogger swit ch sen se cir-
cu it ca vit y of t h e 11-wa y or 16-wa y in st r u m en t pa n el
wir e h a r n ess con n ect or for t h e a /c h ea t er con t r ol a n d
a good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK,
go t o St ep 6. If n ot OK, r epa ir t h e sh or t ed r ea r win -
dow defogger swit ch sen se cir cu it a s r equ ir ed.
(6) Ch eck for con t in u it y bet ween t h e r ea r win dow
defogger swit ch sen se cir cu it ca vit ies of t h e 11-wa y or
16-wa y in st r u m en t pa n el wir e h a r n ess con n ect or for
t h e a /c h ea t er con t r ol a n d t h e 22-wa y in st r u m en t
pa n el wir e h a r n ess con n ect or for t h e BCM. Th er e
sh ou ld be con t in u it y. If OK, r efer t o (Refer t o 8 -
E LE CTRICAL/H E ATE D GLASS/RE AR WINDOW
DE F OGGE R RE LAY - DIAGNOSIS AND TE STING).
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(Refer t o 24 - H E ATING & AIR CONDITIONING/
CONTROLS/A/C H E ATE R CONTROL - RE MOVAL)
8G - 8 HEATED MIRRORS WJ

H EAT ED M I RRORS

TABLE OF CONTENTS
page page

HEATED MIRRORS DIAGNOSIS AND TESTING - HEATED

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

H EAT ED M I RRORS ger swit ch . Wh en t h e BCM r eceives a n in pu t fr om

t h e swit ch , it sen ds a defogger swit ch st a t u s m essa ge
t o t h e DDM a n d t h e P DM over t h e P r ogr a m m a ble
DESCRIPTION
Com m u n ica t ion s In t er fa ce da t a bu s. Th e DDM a n d
E lect r ica lly h ea t ed ou t side r ea r view m ir r or s a r e
P DM r espon d t o t h e defogger swit ch st a t u s m essa ges
opt ion a l equ ipm en t on t h is m odel. Th ese m ir r or s fea -
by en er gizin g or de-en er gizin g t h e ba t t er y cu r r en t
t u r e a n elect r ic h ea t in g gr id loca t ed beh in d t h e m ir-
feed t o t h eir r espect ive ou t side r ea r view m ir r or
r or gla ss of ea ch power oper a t ed ou t side r ea r view
h ea t in g gr ids.
m ir r or. Th ese h ea t in g gr ids con sist of a sin gle r esis-
t or wir e r ou t ed in a gr id-like pa t t er n a n d ca pt u r ed
bet ween t wo t h in sh eet s of pla st ic. Wh en elect r ica l
DIAGNOSIS AND TESTING - HEATED MIRRORS
F or cir cu it descr ipt ion s a n d dia gr a m s, (Refer t o
cu r r en t is pa ssed t h r ou gh t h e r esist or wir e, it pr o-
Appr opr ia t e Wir in g In for m a t ion ).
du ces en ou gh h ea t en er gy t o clea r t h e ou t side m ir r or
(1) If bot h m ir r or h ea t er s a r e in oper a t ive, ch eck
gla ss of ice, sn ow or fog. Ba t t er y cu r r en t is dir ect ed
for pr oper oper a t ion of t h e Rea r Win dow Defogger
t o t h e ou t side m ir r or h ea t in g gr id on ly wh en t h e r ea r
Syst em . (Refer t o 8 - E LE CTRICAL/H E ATE D GLASS
win dow defogger swit ch is in t h e On posit ion .
- DIAGNOSIS AND TE STING - RE AR WINDOW
If t h e ou t side m ir r or h ea t in g gr ids a n d t h e r ea r
DE F OGGE R SYSTE M). If Rea r Win dow Defogger
win dow h ea t in g gr id a r e a ll in oper a t ive, (Refer t o 8 -
Syst em oper a t es cor r ect ly, or if on ly on e m ir r or
E LE CTRICAL/H E ATE D GLASS - DIAGNOSIS AND
h ea t er is in oper a t ive, go t o St ep 2.
TE STING - RE AR WINDOW DE F OGGE R SYSTE M).
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
If t h e ou t side m ir r or h ea t in g gr ids a r e in oper a t ive,
ca ble. Rem ove t h e fr on t door t r im pa n el on t h e side
bu t t h e r ea r win dow h ea t in g gr id is oper a t in g a s
of t h e in oper a t ive m ir r or h ea t er. Go t o St ep 3.
design ed, (Refer t o 8 - E LE CTRICAL/H E ATE D MIR-
(3) Discon n ect t h e door wir e h a r n ess con n ect or
RORS - DIAGNOSIS AND TE STING)
fr om t h e door m odu le con n ect or r ecept a cle. Ch eck for
Th e h ea t in g gr id beh in d ea ch ou t side m ir r or gla ss
con t in u it y bet ween t h e m ir r or h ea t er 12 volt su pply,
ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged, t h e
a n d t h e m ir r or h ea t er gr ou n d. Th er e sh ou ld be con -
en t ir e power m ir r or u n it m u st be r epla ced. Refer t o
t in u it y. If OK, go t o St ep 4. If n ot OK, ch eck for con -
P ower Mir r or s for t h e pr ocedu r es.
t in u it y of t h e in dividu a l cir cu it s bet ween t h e power
m ir r or a n d t h e door m odu le, a n d of t h e m ir r or h ea t er
OPERATION
gr id r igh t a t t h e power m ir r or.
Th e ou t side m ir r or h ea t in g gr ids a r e en er gized a n d
(4) Use a DRB III! a n d (Refer t o Appr opr ia t e
de-en er gized by t h e Dr iver Door Modu le (DDM) a n d
Dia gn ost ic In for m a t ion ) t o t est t h e door m odu le a n d
t h e P a ssen ger Door Modu le (P DM) ba sed u pon t h e
t h e P CI da t a bu s.
r ea r win dow defogger swit ch st a t u s. Th e Body Con -
t r ol Modu le (BCM) m on it or s t h e r ea r win dow defog-
WJ HEATED SEAT SYSTEM 8G - 9

H EAT ED SEAT SY ST EM

TABLE OF CONTENTS
page page

HEATED SEAT SYSTEM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HEATED SEAT SENSOR
DIAGNOSIS AND TESTING - HEATED SEAT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING - HEATED SEAT
DRIVER HEATED SEAT SWITCH SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PASSENGER HEATED SEAT SWITCH
DIAGNOSIS AND TESTING - DRIVER HEATED DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DIAGNOSIS AND TESTING - PASSENGER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . 16
HEATED SEAT ELEMENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H EAT ED SEAT SY ST EM In dividu a lly con t r olled dr iver a n d pa ssen ger side
elect r ica lly h ea t ed fr on t sea t s a r e a va ila ble fa ct or y-
in st a lled opt ion a l equ ipm en t on t h is m odel, wh en it
DESCRIPTION
is a lso equ ipped wit h t h e power sea t opt ion . Th e
h ea t ed sea t syst em a llows bot h t h e dr iver a n d t h e
fr on t sea t pa ssen ger t h e opt ion t o select on e of t wo
sea t h ea t in g r a n ges, Low or H igh , or t o t u r n t h e in di-
vidu a l sea t h ea t er s Off u sin g t h e h ea t ed sea t
swit ch es loca t ed in t h e cen t er lower bezel n ea r t h e
bot t om of t h e in st r u m en t pa n el cen t er st a ck (F ig. 1).
Th e h ea t ed sea t swit ch cir cu it oper a t es on ign it ion
swit ch ed ba t t er y cu r r en t su pplied t h r ou gh a fu se in
t h e ju n ct ion block, on ly wh en t h e ign it ion swit ch is
in t h e On posit ion .
Th e h ea t ed sea t syst em con sist s of t h e followin g
com pon en t s :
• H ea t ed sea t elem en t s
• H ea t ed sea t sen sor s
• H ea t ed sea t m odu le (or m em or y h ea t ed sea t
m odu le)
• H ea t ed sea t swit ch es.
Th e h ea t ed sea t syst em a lso r elies u pon r esou r ces
sh a r ed wit h ot h er elect r on ic m odu les in t h e veh icle
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k. Th e P CI da t a bu s n et wor k
a llows t h e sh a r in g of sen sor in for m a t ion . Th is h elps
Fig. 1 HEATED SEAT SWITCHES t o r edu ce wir e h a r n ess com plexit y, in t er n a l con t r oller
1 - HEATED SEAT SWITCHES h a r dwa r e, a n d com pon en t sen sor cu r r en t loa ds. At
t h e sa m e t im e, t h is syst em pr ovides in cr ea sed r eli-
a bilit y, en h a n ced dia gn ost ics, a n d a llows t h e a ddit ion
of m a n y n ew fea t u r e ca pa bilit ies. F or dia gn osis of
8G - 10 HEATED SEAT SYSTEM
H EAT ED SEAT SY ST EM (Cont inue d)
t h ese elect r on ic m odu les or of t h e P CI da t a bu s n et -
wor k, t h e u se of a DRB! sca n t ool a n d t h e pr oper
Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom m en ded.
Th e elect r on ic m odu les t h a t m a y a ffect h ea t ed sea t
syst em oper a t ion a r e a s follows:
• B o d y Co n tro l Mo d u le (B CM) - Refer t o B o d y
Co n tro l Mo d u le in E lect r on ic Con t r ol Modu les for
m or e in for m a t ion .
• He a te d S e a t Mo d u le (HS M) - Refer t o He a te d
S e a t Mo d u le in E lect r on ic Con t r ol Modu les for m or e
in for m a t ion .
• Me m o ry He a te d S e a t Mo d u le (MHS M) - If
t h e veh icle is equ ipped wit h t h e Mem or y Syst em ,
r efer t o Me m o ry S e a t Mo d u le in E lect r on ic Con t r ol
Modu les for m or e in for m a t ion .
Refer t o P o w e r S e a ts P re m iu m I/III in t h e Con -
t en t s of Wir in g Dia gr a m s for com plet e cir cu it dia -
gr a m s. F ollowin g a r e gen er a l descr ipt ion s of t h e
m a jor com pon en t s in t h e h ea t ed sea t syst em .
OPERATION
Th e h ea t ed sea t syst em will on ly oper a t e wh en t h e
ign it ion swit ch is in t h e On posit ion , a n d t h e su r fa ce
t em per a t u r e a t t h e fr on t sea t h ea t in g elem en t sen -
sor s is below t h e design ed t em per a t u r e set poin t s of
t h e syst em . Th e h ea t ed sea t syst em will n ot oper a t e
in a m bien t t em per a t u r es gr ea t er t h a n a bou t 41° C
(105° F ). Th e fr on t sea t h ea t in g elem en t s a n d sen sor s
a r e h a r d wir ed t o t h e H ea t ed Sea t Modu le (H SM) or
t h e Mem or y H ea t ed Sea t Modu le (MH SM).
Th e h ea t ed sea t swit ch es a r e h a r d wir ed t o t h e
Body Con t r ol Modu le (BCM). Th e BCM m on it or s t h e
h ea t ed sea t swit ch in pu t s, t h en sen ds h ea t ed sea t
swit ch st a t u s m essa ges t o t h e H SM or MH SM over
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s. Th e H SM or MH SM con t a in s t h e con t r ol
logic for t h e h ea t ed sea t syst em . Th e H SM or MH SM
r espon ds t o t h e h ea t ed sea t swit ch st a t u s m essa ges,
ign it ion swit ch st a t u s m essa ges, a n d t h e fr on t sea t
h ea t in g elem en t sen sor in pu t s by con t r ollin g t h e ou t -
pu t t o t h e fr on t sea t h ea t in g elem en t s t h r ou gh in t e-
gr a l solid-st a t e r ela ys.
Wh en a sea t h ea t er is t u r n ed on , t h e sen sor
loca t ed on t h e sea t cu sh ion elect r ic h ea t er elem en t
pr ovides t h e H SM or MH SM wit h a n in pu t in dica t in g
t h e su r fa ce t em per a t u r e of t h e sea t cu sh ion . If t h e
su r fa ce t em per a t u r e in pu t is below t h e t em per a t u r e
set poin t for t h e select ed Low or H igh h ea t ed sea t
swit ch posit ion , t h e H SM or MH SM en er gizes t h e
in t egr a l solid-st a t e r ela y, wh ich su pplies ba t t er y cu r-
r en t t o t h e h ea t in g elem en t s in t h e sea t cu sh ion a n d
ba ck. Wh en t h e sen sor in pu t in dica t es t h e cor r ect
t em per a t u r e set poin t h a s been a ch ieved, t h e H SM or
MH SM de-en er gizes t h e solid-st a t e r ela y. Th e H SM
or MH SM will con t in u e t o cycle t h e solid-st a t e r ela y
a s n eeded t o m a in t a in t h e t em per a t u r e set poin t .
WJ
Th e H SM or MH SM a n d t h e sea t h ea t er elem en t s
oper a t e on n on -swit ch ed ba t t er y cu r r en t su pplied
t h r ou gh t h e power sea t cir cu it br ea ker in t h e ju n c-
t ion block. H owever, t h e H SM or MH SM will a u t o-
m a t ica lly t u r n off t h e h ea t in g elem en t s if it det ect s
a n open or sh or t in t h e sen sor cir cu it , a sh or t or open
in t h e h ea t in g elem en t cir cu it ca u sin g a n excessive
cu r r en t dr a w, or wh en t h e ign it ion swit ch is t u r n ed
t o t h e Off posit ion .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e h ea t ed sea t syst em .
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
com pon en t s a n d cir cu it s t h a t a r e h a r d wir ed in pu t s
or ou t pu t s of t h e h ea t ed sea t syst em . H owever, t h ese
t est s m a y n ot pr ove con clu sive in t h e dia gn osis of
t h is syst em . In or der t o obt a in con clu sive t est in g of
t h e h ea t ed sea t syst em , t h e P r ogr a m m a ble Com m u -
n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k a n d a ll of
t h e elect r on ic m odu les t h a t pr ovide in pu t s t o, or
r eceive ou t pu t s fr om t h e h ea t ed sea t syst em com po-
n en t s m u st be ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e h ea t ed sea t syst em r equ ir es t h e u se of a
DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es
m a n u a l. Th e DRB! sca n t ool ca n pr ovide con fir m a -
t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t a ll of
t h e elect r on ic m odu les a r e sen din g a n d r eceivin g t h e
pr oper m essa ges on t h e P CI da t a bu s, a n d t h a t t h e
H ea t ed Sea t Modu le (H SM) or Mem or y H ea t ed Sea t
Modu le (MH SM) is r eceivin g t h e pr oper h a r d wir ed
in pu t s a n d r ela yin g t h e pr oper h a r d wir ed ou t pu t s t o
per for m it s h ea t ed sea t syst em fu n ct ion s.
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
NOTE: DO NOT ATTEMPT TO SWAP MEMORY OR
NON-MEMORY HEATED SEAT MODULES FROM
ONE VEHICLE TO ANOTHER. MOST OF THESE
MODULES ARE VEHICLE FEATURE SPECIFIC AND
THEREFORE NOT INTERCHANGEABLE. ALWAYS
USE THE CORRECT PART NUMBERED MODULE
WHEN DIAGNOSING OR REPLACING A MODULE.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WJ
H EAT ED SEAT SY ST EM (Cont inue d)
PRELIMINARY TEST
Befor e t est in g t h e in dividu a l com pon en t s in t h e
h ea t ed sea t syst em , ch eck t h e followin g:
• If t h e h ea t ed sea t swit ch LE D in dica t or s do n ot
ligh t wit h t h e ign it ion swit ch in t h e On posit ion a n d
t h e h ea t ed sea t swit ch in t h e Low or H igh posit ion ,
ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n ) fu se in
t h e ju n ct ion block. If OK, r efer t o He a te d S e a t
S w itc h D ia g n o s is a n d Te s tin g in t h is sect ion . If
n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
• If t h e h ea t ed sea t swit ch LE D in dica t or s ligh t ,
bu t t h e h ea t in g elem en t s do n ot h ea t , ch eck t h e
power sea t cir cu it br ea ker in t h e ju n ct ion block. If
OK, r efer t o He a te d S e a t Ele m e n t D ia g n o s is a n d
Te s tin g in t h is sect ion of t h e m a n u a l. If n ot OK,
r epla ce t h e fa u lt y power sea t cir cu it br ea ker.
DRI V ER H EAT ED SEAT
SWI T CH
DESCRIPTION
Fig. 2 HEATED SEAT SWITCHES
1 - HEATED SEAT SWITCHES
Th e h ea t ed sea t swit ch es a r e m ou n t ed in t h e
in st r u m en t pa n el cen t er lower bezel (F ig. 2), wh ich is
loca t ed n ea r t h e bot t om of t h e in st r u m en t pa n el cen -
t er st a ck. Th e t wo t h r ee-posit ion r ocker-t ype
swit ch es, on e swit ch for ea ch fr on t sea t , pr ovide a
r esist or m u lt iplexed sign a l t o t h e Body Con t r ol Mod-
u le (BCM) t h r ou gh sepa r a t e h a r d wir ed cir cu it s.
HEATED SEAT SYSTEM 8G - 11
E a ch swit ch h a s a n Off, Low, a n d H igh posit ion so
t h a t bot h t h e dr iver a n d t h e fr on t sea t pa ssen ger ca n
select a pr efer r ed sea t h ea t in g m ode. E a ch swit ch
h a s t wo Ligh t -E m it t in g Diodes (LE D), on e ea ch for
t h e Low posit ion a n d t h e H igh posit ion , wh ich ligh t
t o in dica t e t h a t t h e h ea t er for t h e sea t t h a t t h e
swit ch con t r ols is t u r n ed on . E a ch swit ch is a lso ba ck
lit by a r epla cea ble in ca n descen t bu lb.
Th e h ea t ed sea t swit ch es a n d t h eir LE Ds ca n n ot
be r epa ir ed. If eit h er swit ch or LE D is fa u lt y or da m -
a ged, t h e en t ir e swit ch u n it m u st be r epla ced. Th e
in ca n descen t swit ch illu m in a t ion bu lb a n d bu lb
h older u n it s a r e a va ila ble for ser vice r epla cem en t .
OPERATION
Th er e a r e t h r ee posit ion s t h a t ca n be select ed wit h
ea ch of t h e h ea t ed sea t swit ch es: Off, Low, or H igh .
Wh en t h e t op of t h e swit ch r ocker is fu lly depr essed,
t h e H igh posit ion is select ed a n d t h e h igh posit ion
LE D in dica t or illu m in a t es. Wh en t h e bot t om of t h e
swit ch r ocker is fu lly depr essed, t h e Low posit ion is
select ed a n d t h e low posit ion LE D in dica t or illu m i-
n a t es. Wh en t h e swit ch r ocker is m oved t o it s n eu t r a l
posit ion , Off is select ed a n d bot h LE D in dica t or s a r e
ext in gu ish ed.
Bot h swit ch es pr ovide sepa r a t e r esist or m u lt i-
plexed h a r d wir e in pu t s t o t h e BCM t o in dica t e t h e
select ed swit ch posit ion . Th e BCM m on it or s t h e
swit ch in pu t s a n d sen ds h ea t ed sea t swit ch st a t u s
m essa ges t o t h e H ea t ed Sea t Modu le (H SM) or t h e
Mem or y H ea t ed Sea t Modu le (MH SM) over t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s. Th e H SM or MH SM r espon ds t o t h e h ea t ed sea t
swit ch st a t u s m essa ges by con t r ollin g t h e ou t pu t t o
t h e sea t h ea t er elem en t s of t h e select ed sea t . Th e
Low h ea t posit ion set poin t is a bou t 36° C (97° F ),
a n d t h e H igh h ea t posit ion set poin t is a bou t 41° C
(105° F ).
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n )
fu se in t h e ju n ct ion block. If OK, go t o St ep 2. If n ot
8G - 12 HEATED SEAT SYSTEM WJ
DRI V ER H EAT ED SEAT SWI T CH (Cont inue d)
OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n ) fu se in t h e ju n ct ion block. If OK, go t o
St ep 3. If n ot OK, r epa ir t h e open fu sed ign it ion
swit ch ou t pu t (r u n ) cir cu it t o t h e ign it ion swit ch a s
r equ ir ed.
(3) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e lower cen t er bezel fr om t h e in st r u -
m en t pa n el a n d discon n ect t h e in st r u m en t pa n el wir e
h a r n ess con n ect or s fr om bot h h ea t ed sea t swit ch con -
n ect or r ecept a cles. Ch eck for con t in u it y bet ween t h e
gr ou n d cir cu it ca vit y of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e in oper a t ive h ea t ed sea t
swit ch (es) a n d a good gr ou n d. Th er e sh ou ld be con t i-
n u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y Fig. 3 Rear of Heated Seat Switch
volt a ge a t t h e fu sed ign it ion swit ch ou t pu t (r u n ) cir- 1 - LEFT SHOWN (RIGHT TYPICAL)
cu it ca vit y of t h e in st r u m en t pa n el wir e h a r n ess con - 2 - ILLUMINATION LAMP
n ect or for t h e in oper a t ive h ea t ed sea t swit ch (es). If 3 - CONNECTOR RECEPTACLE
OK, t u r n t h e ign it ion swit ch t o t h e Off posit ion , dis- 4 - HEATED SEAT SWITCH
con n ect a n d isola t e t h e ba t t er y n ega t ive ca ble, a n d go
t o St ep 5. If n ot OK, r epa ir t h e open fu sed ign it ion BCM. Th er e sh ou ld be con t in u it y. If OK, go t o St ep 8.
swit ch ou t pu t (r u n ) cir cu it t o t h e ju n ct ion block fu se If n ot OK, r epa ir t h e open sea t h ea t er swit ch sen sor
a s r equ ir ed. gr ou n d cir cu it a s r equ ir ed.
(5) Test t h e h ea t ed sea t swit ch (es) (F ig. 3) a s (8) Ch eck for con t in u it y bet ween t h e sea t h ea t er
sh own in t h e H ea t ed Sea t Swit ch Test ch a r t . If OK, swit ch m u x cir cu it ca vit y of t h e in st r u m en t pa n el
go t o St ep 6. If n ot OK, r epla ce t h e fa u lt y h ea t ed sea t wir e h a r n ess con n ect or for t h e in oper a t ive h ea t ed
swit ch (es). sea t swit ch a n d a good gr ou n d. Th er e sh ou ld be n o
con t in u it y. If OK, go t o St ep 9. If n ot OK, r epa ir t h e
HEATED SEAT SWITCH TEST sh or t ed sea t h ea t er swit ch m u x cir cu it a s r equ ir ed.
(9) Ch eck for con t in u it y bet ween t h e sea t h ea t er
SWITCH RESISTANCE RESISTANCE
swit ch m u x cir cu it ca vit y of t h e in st r u m en t pa n el
POSITION BETWEEN (OHMS)
wir e h a r n ess con n ect or for t h e in oper a t ive h ea t ed
Off Pin 1 & 6 55 sea t swit ch a n d t h e 22-wa y in st r u m en t pa n el wir e
Low Pin 1 & 6 1430 h a r n ess con n ect or for t h e BCM. Th er e sh ou ld be con -
High Pin 1 & 6 365 t in u it y. If OK, u se a DRB! sca n t ool a n d t h e pr oper
Dia gn ost ic P r ocedu r es m a n u a l t o t est t h e BCM. If
All resistance values are ±5%. n ot OK, r epa ir t h e open sea t h ea t er swit ch m u x cir-
(6) Discon n ect t h e 22-wa y in st r u m en t pa n el wir e cu it a s r equ ir ed.
h a r n ess con n ect or fr om t h e Body Con t r ol Modu le
(BCM) con n ect or r ecept a cle. Ch eck for con t in u it y REMOVAL
bet ween t h e sea t h ea t er swit ch sen sor gr ou n d cir cu it
ca vit y of t h e in st r u m en t pa n el wir e h a r n ess con n ec- WARNING: REFER TO THE RESTRAINTS SECTION
t or for t h e in oper a t ive h ea t ed sea t swit ch (es) a n d a OF THIS MANUAL BEFORE ATTEMPTING ANY
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go STEERING WHEEL, STEERING COLUMN, OR
t o St ep 7. If n ot OK, r epa ir t h e sh or t ed sea t h ea t er INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
swit ch sen sor gr ou n d cir cu it a s r equ ir ed. SERVICE. FAILURE TO TAKE THE PROPER PRE-
(7) Ch eck for con t in u it y bet ween t h e sea t h ea t er CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
swit ch sen sor gr ou n d cir cu it ca vit ies of t h e in st r u - BAG DEPLOYMENT AND POSSIBLE PERSONAL
m en t pa n el wir e h a r n ess con n ect or for t h e in oper a - INJURY.
t ive h ea t ed sea t swit ch (es) a n d t h e 22-wa y
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
ca ble.
WJ HEATED SEAT SYSTEM 8G - 13
DRI V ER H EAT ED SEAT SWI T CH (Cont inue d)
(2) Rem ove t h e cen t er lower bezel fr om t h e in st r u - H EAT ED SEAT ELEM EN T
m en t pa n el. Refer t o In s tru m e n t P a n e l Ce n te r
Lo w e r B e ze l in t h e Body sect ion of t h is m a n u a l for
DESCRIPTION
t h e pr ocedu r e.
(3) Rem ove t h e fou r scr ews t h a t secu r e t h e h ea t ed
sea t swit ch t o t h e ba ck of t h e in st r u m en t pa n el cen -
t er lower bezel (F ig. 4).

Fig. 5 HEATING ELEMENT INSTALLED

Fig. 4 Heated Seat Switch Remove/Install
1 - SEAT BACK WIRE HARNESS
1 - HEATED SEAT SWITCHES
2 - HEATED SEAT WIRE HARNESS CONNECTOR
2 - SCREWS (4)
3 - HEATED SEAT CUSHION ELEMENT
3 - CENTER LOWER BEZEL
4 - CIGAR LIGHTER
5 - ILLUMINATION LAMPS Th e h ea t ed sea t syst em in clu des t wo sea t h ea t in g ele-
6 - POWER OUTLET m en t s in ea ch fr on t sea t , on e for t h e sea t cu sh ion (F ig.
5)a n d t h e ot h er for t h e sea t ba ck. On e t ype of h ea t ed
(4) Rem ove t h e h ea t ed sea t swit ch fr om t h e ba ck sea t elem en t is offer ed. All m odels u se t wo r esist or wir e
of t h e in st r u m en t pa n el cen t er lower bezel. h ea t in g elem en t s for ea ch sea t t h a t a r e con n ect ed in
ser ies wit h t h e H ea t ed Sea t Modu le (H SM).
INSTALLATION Th e sea t h ea t in g elem en t s a r e glu ed t o t h e sea t a n d
(1) P osit ion t h e h ea t ed sea t swit ch on t o t h e ba ck sea t ba ck cu sh ion s. Th e h ea t ed sea t elem en t s ca n be
of t h e in st r u m en t pa n el cen t er lower bezel. r epla ced if fa u lt y or da m a ged, ser vice r epla cem en t sea t
(2) In st a ll a n d t igh t en t h e fou r scr ews t h a t secu r e or sea t ba ck elem en t s a r e a va ila ble. Refer t o t h e pr o-
t h e h ea t ed sea t swit ch t o t h e ba ck of t h e in st r u m en t cedu r e in t h is sect ion for det a iled in st r u ct ion s.
pa n el cen t er lower bezel. Tigh t en t h e scr ews t o 1.5
N·m (13 in . lbs.). OPERATION
(3) In st a ll t h e cen t er lower bezel on t o t h e in st r u - Th e h ea t ed sea t elem en t s r esist t h e flow of elect r i-
m en t pa n el. Refer t o In s tru m e n t P a n e l Ce n te r ca l cu r r en t . Wh en ba t t er y cu r r en t is pa ssed t h r ou gh
Lo w e r B e ze l in t h e Body sect ion of t h is m a n u a l for t h e elem en t s, t h e en er gy lost by t h e r esist a n ce of t h e
t h e pr ocedu r e. elem en t s t o t h e cu r r en t flow is r elea sed in t h e for m
(4) Recon n ect t h e ba t t er y n ega t ive ca ble. of h ea t . Th e t em per a t u r e sen sor is a NTC t h er m ist or.
Wh en t h e t em per a t u r e of t h e sea t cu sh ion cover
r ises, t h e r esist a n ce of t h e sen sor decr ea ses. Th e
H SM or MH SM su pplies a five-volt cu r r en t t o on e
side of ea ch sen sor, a n d m on it or s t h e volt a ge dr op
t h r ou gh t h e sen sor on a r et u r n cir cu it . Th e MSM or
MH SM u ses t h is t em per a t u r e sen sor in pu t t o m on i-
t or t h e t em per a t u r e of t h e sea t , a n d r egu la t es t h e
cu r r en t flow t o t h e sea t h ea t in g elem en t s a ccor din gly.
8G - 14 HEATED SEAT SYSTEM WJ
H EAT ED SEAT ELEM EN T (Cont inue d)

DIAGNOSIS AND TESTING - HEATED SEAT INSTALLATION

ELEMENT (1) P eel off t h e a dh esive ba ckin g on t h e ba ck of t h e
r epla cem en t h ea t in g elem en t a n d in st a ll on cu sh ion
RESISTOR WIRE ELEMENT pa d in t h e sa m e loca t ion a s t h e or igin a l (F ig. 6).
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Th e power sea t wir e h a r n ess con n ect or s for t h e CAUTION: During the installation of the replace-
sea t cu sh ion a n d sea t ba ck h ea t in g elem en t s a r e ment heating element, be very careful not to fold or
secu r ed t o a br a cket loca t ed u n der t h e r ea r edge of crease the element assembly. Folds or creases will
t h e sea t cu sh ion fr a m e. Refer t o Wirin g for com plet e cause premature failure.
cir cu it sch em a t ics a n d con n ect or loca t ion s.
(2) Con n ect t h e n ew h ea t in g elem en t elect r ica l
(2) Discon n ect t h e H ea t ed Sea t Modu le (H SM) or
con n ect or s (F ig. 6).
Mem or y H ea t ed Sea t Modu le (MH SM) C2 con n ect or.
Ch eck for con t in u it y bet ween t h e SE AT H E ATE R
B(+) DRIVE R cir cu it ca vit y of t h e C2 con n ect or a n d
t h e sea t cu sh ion fr a m e. Th er e sh ou ld be NO con t in u -
it y. If OK, go t o St ep 3. If n ot OK, r epa ir t h e sh or t ed
sea t h ea t er B(+) dr iver cir cu it a s r equ ir ed.

NOTE: WHEN CHECKING HEATED SEAT ELE-

MENTS FOR CONTINUITY, BE CERTAIN TO MOVE
THE HEATING ELEMENT BEING CHECKED. MOV-
ING THE ELEMENT, SUCH AS SITTING IN THE SEAT
WILL ELIMINATE THE POSSIBILITY OF AN INTER-
MITTENT OPEN IN THE ELEMENT WHICH WOULD
ONLY BE EVIDENT IF THE ELEMENT WAS MOVED
IN A CERTAIN DIRECTION. FAILURE TO CHECK
THE ELEMENT IN VARIOUS POSITIONS COULD
RESULT IN AN INCOMPLETE TEST.

(3) Ch eck for con t in u it y bet ween t h e SE AT

H E ATE R B(+) DRIVE R cir cu it ca vit y of t h e C2 con -
n ect or a n d t h e gr ou n d cir cu it ca vit y. Th er e sh ou ld be
con t in u it y a t a ll t im es (even u pon m ovin g or sit t in g
in t h e sea t ). If OK, pr oceed wit h t est in g t h e ot h er
com pon en t s in t h e h ea t ed sea t syst em . If n ot OK,
r epla ce t h e open h ea t in g elem en t . Refer t o t h e pr oce-
du r e in t h is sect ion of t h e m a n u a l.
REMOVAL
(1) Discon n ect a n d isola t e t h e n ega t ive ba t t er y
ca ble.
(2) Rem ove t h e a ppr opr ia t e sea t cu sh ion or sea t
ba ck t r im cover. Refer t o t h e Body sect ion of t h e ser-
vice m a n u a l for t h e pr ocedu r es.
(3) Discon n ect t h e in oper a t ive h ea t ed sea t cu sh ion
or sea t ba ck elem en t elect r ica l con n ect or s.
(4) Gen t ly peel-off defect ive h ea t er elem en t fr om
foa m cu sh ion .
Fig. 6 HEATING ELEMENT INSTALLED
1 - SEAT BACK WIRE HARNESS
2 - HEATED SEAT WIRE HARNESS CONNECTOR
3 - HEATED SEAT CUSHION ELEMENT
(3) Con n ect t h e n ega t ive ba t t er y ca ble.
(4) Ver ify h ea t ed sea t syst em oper a t ion .
(5) In st a ll t h e a ppr opr ia t e sea t cu sh ion or sea t
ba ck t r im cover. Ma ke cer t a in t h e sea t wir e h a r n ess
is cor r ect ly r ou t ed t h r ou gh t h e sea t a n d sea t ba ck.
Th e excess wir e bet ween t h e cu sh ion a n d ba ck ele-
m en t s sh ou ld be secu r ely t u cked bet ween t h e r ea r of
t h e cu sh ion foa m a n d t h e r ea r ca r pet fla p of t h e t r im
cover.
WJ HEATED SEAT SYSTEM 8G - 15

H EAT ED SEAT SEN SOR PASSEN GER H EAT ED SEAT

SWI T CH
DESCRIPTION
Th e h ea t ed sea t t em per a t u r e sen sor is a Nega t ive DESCRIPTION
Tem per a t u r e Coefficien t (NTC) t h er m ist or. On e t em -
per a t u r e sen sor is u sed for ea ch sea t . Th is t em per a -
t u r e sen sor is loca t ed in t h e sea t cu sh ion h ea t in g
elem en t on a ll m odels.
Th e h ea t ed sea t t em per a t u r e sen sor ca n n ot be
r epa ir ed or a dju st ed a n d m u st be r epla ced if defec-
t ive. Th e h ea t ed sea t cu sh ion elem en t m u st be
r epla ced if t h e t em per a t u r e sen sor is defect ive. Refer
t o t h e pr ocedu r e in t h is sect ion of t h e ser vice m a n -
u a l.

DIAGNOSIS AND TESTING - HEATED SEAT

SENSOR
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
(1) Discon n ect t h e H ea t ed Sea t Modu le (H SM) or
Mem or y H ea t ed Sea t Modu le (MH SM) C1 con n ect or.
Ch eck for con t in u it y bet ween t h e SE AT SE NSOR 5V
SUP P LY cir cu it ca vit y a n d t h e sea t cu sh ion fr a m e.
Th er e sh ou ld be N O con t in u it y. If OK, go t o St ep 2.
If n ot OK, r epa ir t h e sh or t ed sea t sen sor 5V su pply
cir cu it a s r equ ir ed.
(2) Ch eck for con t in u it y bet ween t h e SE AT SE N-
SOR 5V SUP P LY cir cu it ca vit y of t h e 4-wa y power
sea t wir e h a r n ess con n ect or a n d t h e C1 con n ect or for
t h e H SM or MH SM. Th er e sh ou ld be con t in u it y. If
OK, go t o St ep 3. If n ot OK, r epa ir t h e open sea t sen -
sor 5V su pply cir cu it a s r equ ir ed.
(3) Con n ect t h e m odu le elect r ica l con n ect or. Tu r n
syst em ON, u sin g a volt m et er, ba ckpr obe t h e H SM or
MH SM C1 con n ect or on t h e SE AT TE MP E RATURE
SE NSOR INP UT cir cu it ca vit y. Volt a ge sh ou ld be
pr esen t (2-4 volt s). If OK, pr oceed wit h t est in g t h e
ot h er com pon en t s in t h e h ea t ed sea t syst em . If n ot
OK, r efer t o H ea t ed Sea t Modu le Dia gn osis a n d Test -
in g in t h e elect r on ic con t r ol m odu les sect ion of t h is
m a n u a l.
REMOVAL
(1) F or h ea t ed sea t sen sor r epla cem en t pr ocedu r e
(Refer t o 8 - E LE CTRICAL/H E ATE D SE ATS/
H E ATE D SE AT E LE ME NT - RE MOVAL).
Fig. 7 HEATED SEAT SWITCHES
1 - HEATED SEAT SWITCHES
Th e h ea t ed sea t swit ch es a r e m ou n t ed in t h e
in st r u m en t pa n el cen t er lower bezel (F ig. 7), wh ich is
loca t ed n ea r t h e bot t om of t h e in st r u m en t pa n el cen -
t er st a ck. Th e t wo t h r ee-posit ion r ocker-t ype
swit ch es, on e swit ch for ea ch fr on t sea t , pr ovide a
r esist or m u lt iplexed sign a l t o t h e Body Con t r ol Mod-
u le (BCM) t h r ou gh sepa r a t e h a r d wir ed cir cu it s.
E a ch swit ch h a s a n Off, Low, a n d H igh posit ion so
t h a t bot h t h e dr iver a n d t h e fr on t sea t pa ssen ger ca n
select a pr efer r ed sea t h ea t in g m ode. E a ch swit ch
h a s t wo Ligh t -E m it t in g Diodes (LE D), on e ea ch for
t h e Low posit ion a n d t h e H igh posit ion , wh ich ligh t
t o in dica t e t h a t t h e h ea t er for t h e sea t t h a t t h e
swit ch con t r ols is t u r n ed on . E a ch swit ch is a lso ba ck
lit by a r epla cea ble in ca n descen t bu lb.
Th e h ea t ed sea t swit ch es a n d t h eir LE Ds ca n n ot
be r epa ir ed. If eit h er swit ch or LE D is fa u lt y or da m -
a ged, t h e en t ir e swit ch u n it m u st be r epla ced. Th e
in ca n descen t swit ch illu m in a t ion bu lb a n d bu lb
h older u n it s a r e a va ila ble for ser vice r epla cem en t .
8G - 16 HEATED SEAT SYSTEM WJ
PASSEN GER H EAT ED SEAT SWI T CH (Cont inue d)

OPERATION swit ch (es) a n d a good gr ou n d. Th er e sh ou ld be con t i-

Th er e a r e t h r ee posit ion s t h a t ca n be select ed wit h
ea ch of t h e h ea t ed sea t swit ch es: Off, Low, or H igh .
Wh en t h e t op of t h e swit ch r ocker is fu lly depr essed,
t h e H igh posit ion is select ed a n d t h e h igh posit ion
LE D in dica t or illu m in a t es. Wh en t h e bot t om of t h e
swit ch r ocker is fu lly depr essed, t h e Low posit ion is
select ed a n d t h e low posit ion LE D in dica t or illu m i-
n a t es. Wh en t h e swit ch r ocker is m oved t o it s n eu t r a l
posit ion , Off is select ed a n d bot h LE D in dica t or s a r e
ext in gu ish ed.
Bot h swit ch es pr ovide sepa r a t e r esist or m u lt i-
plexed h a r d wir e in pu t s t o t h e BCM t o in dica t e t h e
select ed swit ch posit ion . Th e BCM m on it or s t h e
swit ch in pu t s a n d sen ds h ea t ed sea t swit ch st a t u s
m essa ges t o t h e H ea t ed Sea t Modu le (H SM) or t h e
Mem or y H ea t ed Sea t Modu le (MH SM) over t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s. Th e H SM or MH SM r espon ds t o t h e h ea t ed sea t
swit ch st a t u s m essa ges by con t r ollin g t h e ou t pu t t o
t h e sea t h ea t er elem en t s of t h e select ed sea t . Th e
Low h ea t posit ion set poin t is a bou t 36° C (97° F ),
a n d t h e H igh h ea t posit ion set poin t is a bou t 41° C
(105° F ).
n u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y
volt a ge a t t h e fu sed ign it ion swit ch ou t pu t (r u n ) cir-
cu it ca vit y of t h e in st r u m en t pa n el wir e h a r n ess con -
n ect or for t h e in oper a t ive h ea t ed sea t swit ch (es). If
OK, t u r n t h e ign it ion swit ch t o t h e Off posit ion , dis-
con n ect a n d isola t e t h e ba t t er y n ega t ive ca ble, a n d go
t o St ep 5. If n ot OK, r epa ir t h e open fu sed ign it ion
swit ch ou t pu t (r u n ) cir cu it t o t h e ju n ct ion block fu se
a s r equ ir ed.
(5) Test t h e h ea t ed sea t swit ch (es) (F ig. 8) a s
sh own in t h e H ea t ed Sea t Swit ch Test ch a r t . If OK,
go t o St ep 6. If n ot OK, r epla ce t h e fa u lt y h ea t ed sea t
swit ch (es).

DIAGNOSIS AND TESTING - PASSENGER

HEATED SEAT SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .

WARNING: REFER TO THE RESTRAINTS SECTION

OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL Fig. 8 Rear of Heated Seat Switch
INJURY. 1 - LEFT SHOWN (RIGHT TYPICAL)
2 - ILLUMINATION LAMP
(1) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n ) 3 - CONNECTOR RECEPTACLE
fu se in t h e ju n ct ion block. If OK, go t o St ep 2. If n ot 4 - HEATED SEAT SWITCH
OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
HEATED SEAT SWITCH TEST
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch SWITCH RESISTANCE RESISTANCE
ou t pu t (r u n ) fu se in t h e ju n ct ion block. If OK, go t o POSITION BETWEEN (OHMS)
St ep 3. If n ot OK, r epa ir t h e open fu sed ign it ion Off Pin 1 & 6 55
swit ch ou t pu t (r u n ) cir cu it t o t h e ign it ion swit ch a s Low Pin 1 & 6 1430
r equ ir ed.
(3) Discon n ect a n d isola t e t h e ba t t er y n ega t ive High Pin 1 & 6 365
ca ble. Rem ove t h e lower cen t er bezel fr om t h e in st r u - All resistance values are ±5%.
m en t pa n el a n d discon n ect t h e in st r u m en t pa n el wir e
h a r n ess con n ect or s fr om bot h h ea t ed sea t swit ch con -
n ect or r ecept a cles. Ch eck for con t in u it y bet ween t h e
gr ou n d cir cu it ca vit y of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e in oper a t ive h ea t ed sea t
WJ HEATED SEAT SYSTEM 8G - 17
PASSEN GER H EAT ED SEAT SWI T CH (Cont inue d)
(6) Discon n ect t h e 22-wa y in st r u m en t pa n el wir e Lo w e r B e ze l in t h e Body sect ion of t h is m a n u a l for
h a r n ess con n ect or fr om t h e Body Con t r ol Modu le t h e pr ocedu r e.
(BCM) con n ect or r ecept a cle. Ch eck for con t in u it y (3) Rem ove t h e fou r scr ews t h a t secu r e t h e h ea t ed
bet ween t h e sea t h ea t er swit ch sen sor gr ou n d cir cu it sea t swit ch t o t h e ba ck of t h e in st r u m en t pa n el cen -
ca vit y of t h e in st r u m en t pa n el wir e h a r n ess con n ec- t er lower bezel (F ig. 9).
t or for t h e in oper a t ive h ea t ed sea t swit ch (es) a n d a
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go
t o St ep 7. If n ot OK, r epa ir t h e sh or t ed sea t h ea t er
swit ch sen sor gr ou n d cir cu it a s r equ ir ed.
(7) Ch eck for con t in u it y bet ween t h e sea t h ea t er
swit ch sen sor gr ou n d cir cu it ca vit ies of t h e in st r u -
m en t pa n el wir e h a r n ess con n ect or for t h e in oper a -
t ive h ea t ed sea t swit ch (es) a n d t h e 22-wa y
in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
BCM. Th er e sh ou ld be con t in u it y. If OK, go t o St ep 8.
If n ot OK, r epa ir t h e open sea t h ea t er swit ch sen sor
gr ou n d cir cu it a s r equ ir ed.
(8) Ch eck for con t in u it y bet ween t h e sea t h ea t er
swit ch m u x cir cu it ca vit y of t h e in st r u m en t pa n el
wir e h a r n ess con n ect or for t h e in oper a t ive h ea t ed
sea t swit ch a n d a good gr ou n d. Th er e sh ou ld be n o
con t in u it y. If OK, go t o St ep 9. If n ot OK, r epa ir t h e
sh or t ed sea t h ea t er swit ch m u x cir cu it a s r equ ir ed.
(9) Ch eck for con t in u it y bet ween t h e sea t h ea t er
Fig. 9 Heated Seat Switch Remove/Install
swit ch m u x cir cu it ca vit y of t h e in st r u m en t pa n el
1 - HEATED SEAT SWITCHES
wir e h a r n ess con n ect or for t h e in oper a t ive h ea t ed
2 - SCREWS (4)
sea t swit ch a n d t h e 22-wa y in st r u m en t pa n el wir e
3 - CENTER LOWER BEZEL
h a r n ess con n ect or for t h e BCM. Th er e sh ou ld be con - 4 - CIGAR LIGHTER
t in u it y. If OK, u se a DRB! sca n t ool a n d t h e pr oper 5 - ILLUMINATION LAMPS
Dia gn ost ic P r ocedu r es m a n u a l t o t est t h e BCM. If 6 - POWER OUTLET
n ot OK, r epa ir t h e open sea t h ea t er swit ch m u x cir-
cu it a s r equ ir ed.
(4) Rem ove t h e h ea t ed sea t swit ch fr om t h e ba ck
of t h e in st r u m en t pa n el cen t er lower bezel.
REMOVAL
WARNING: REFER TO THE RESTRAINTS SECTION INSTALLATION
OF THIS MANUAL BEFORE ATTEMPTING ANY (1) P osit ion t h e h ea t ed sea t swit ch on t o t h e ba ck
STEERING WHEEL, STEERING COLUMN, OR of t h e in st r u m en t pa n el cen t er lower bezel.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) In st a ll a n d t igh t en t h e fou r scr ews t h a t secu r e
SERVICE. FAILURE TO TAKE THE PROPER PRE- t h e h ea t ed sea t swit ch t o t h e ba ck of t h e in st r u m en t
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- pa n el cen t er lower bezel. Tigh t en t h e scr ews t o 1.5
BAG DEPLOYMENT AND POSSIBLE PERSONAL N·m (13 in . lbs.).
INJURY. (3) In st a ll t h e cen t er lower bezel on t o t h e in st r u -
m en t pa n el. Refer t o In s tru m e n t P a n e l Ce n te r
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive Lo w e r B e ze l in t h e Body sect ion of t h is m a n u a l for
ca ble. t h e pr ocedu r e.
(2) Rem ove t h e cen t er lower bezel fr om t h e in st r u - (4) Recon n ect t h e ba t t er y n ega t ive ca ble.
m en t pa n el. Refer t o In s tru m e n t P a n e l Ce n te r
WJ HORN 8H - 1

HORN
TABLE OF CON T EN T S

page page

HORN SYSTEM OPERATION . . . . . . . . . . . ............ .. . . .4

DESCRIPTION . . . . . . . . . .................1 DIAGNOSIS AND TESTING - HORN RELAY . . . .4
OPERATION . . . . . . . . . . . .................2 REMOVAL ............ ............ .. . . .5
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 2 INSTALLATION . . . . . . . . . ............ .. . . .5
HORN HORN SWITCH
DESCRIPTION . . . . . . . . . ...... ... . . . . . . . .3 DESCRIPTION . . . . . . . . . ............. ... .6
OPERATION . . . . . . . . . . . ...... ... . . . . . . . .3 OPERATION . . . . . . . . . . . ............. ... .6
DIAGNOSIS AND TESTING - HORN .. . . . . . . . .3 DIAGNOSIS AND TESTING - HORN SWITCH .. .6
REMOVAL ............ ...... ... . . . . . . . .3 REMOVAL ............ ............. ... .7
INSTALLATION . . . . . . . . . ...... ... . . . . . . . .4 INSTALLATION . . . . . . . . . ............. ... .7
HORN RELAY
DESCRIPTION . . . . . . . . . .................4

H ORN SY ST EM Th e h or n syst em in clu des t h e followin g com po-

n en t s:
• Clockspr in g
DESCRIPTION
• H or n s
A du a l-n ot e elect r ic h or n syst em is st a n da r d fa ct o-
• H or n r ela y
r y-in st a lled equ ipm en t on t h is m odel. Th e st a n da r d
• H or n swit ch
equ ipm en t h or n syst em fea t u r es on e low-n ot e h or n
Cer t a in fu n ct ion s a n d fea t u r es of t h e h or n syst em
u n it a n d on e h igh -n ot e h or n u n it . Th e h or n syst em
r ely u pon r esou r ces sh a r ed wit h ot h er elect r on ic
a llows t h e veh icle oper a t or t o pr ovide a n a u dible
m odu les in t h e veh icle over t h e P r ogr a m m a ble Com -
wa r n in g of t h e pr esen ce or a ppr oa ch of t h e veh icle t o
m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e
pedest r ia n s a n d t h e dr iver s of ot h er veh icles in n ea r
P CI da t a bu s n et wor k a llows t h e sh a r in g of sen sor
pr oxim it y. Th e h or n syst em u ses a n on -swit ch ed
in for m a t ion . Th is h elps t o r edu ce wir e h a r n ess com -
sou r ce of ba t t er y cu r r en t so t h a t t h e syst em will
plexit y, in t er n a l con t r oller h a r dwa r e, a n d com pon en t
r em a in fu n ct ion a l, r ega r dless of t h e ign it ion swit ch
sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is syst em
posit ion .
pr ovides in cr ea sed r elia bilit y, en h a n ced dia gn ost ics,
Th e h or n syst em ca n a lso be a ct iva t ed by t h e Body
a n d a llows t h e a ddit ion of m a n y n ew fea t u r e ca pa bil-
Con t r ol Modu le (BCM). Th e BCM is pr ogr a m m ed t o
it ies. F or dia gn osis of t h ese elect r on ic m odu les or of
a ct iva t e t h e h or n s in or der t o pr ovide t h e followin g
t h e P CI da t a bu s n et wor k, t h e u se of a DRB sca n
fea t u r es:
t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l
• Rem ot e Keyless E n t r y (RKE ) syst em lock
a r e r ecom m en ded.
r equ est a u dible ver ifica t ion (except expor t )
Th e ot h er elect r on ic m odu les t h a t m a y a ffect h or n
• RKE syst em pa n ic m ode a u dible a ler t
syst em oper a t ion a r e a s follows:
• Veh icle Th eft Secu r it y Syst em (VTSS) a u dible
• B o d y Co n tro l Mo d u le (B CM) (Refer t o 8 -
a la r m .
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
Th is veh icle a lso offer s sever a l cu st om er pr ogr a m -
ULE S/BODY CONTROL/CE NTRAL TIME R MODUL
m a ble fea t u r es, wh ich a llows t h e select ion of sever a l
- DE SCRIP TION) for m or e in for m a t ion .
opt ion a l elect r on ic fea t u r es t o su it in dividu a l pr efer-
• Ele c tro n ic Ve h ic le In fo rm a tio n Ce n te r
en ces. Refer t o Over h ea d Con sole for m or e in for m a -
(EVIC) (Refer t o 8 - E LE CTRICAL/OVE RH E AD
t ion on t h e cu st om er pr ogr a m m a ble fea t u r e opt ion s.
CONSOLE /E LE CTRONIC VE H ICLE INF O CE NTE R
Cu st om er pr ogr a m m a ble fea t u r e opt ion s a ffect in g t h e
- DE SCRIP TION) for m or e in for m a t ion .
h or n syst em in clu de:
(Refer t o 8 - E LE CTRICAL/RE STRAINTS/CLOCK-
• S o u n d Ho rn o n Lo c k - Allows t h e opt ion of
SP RING - DE SCRIP TION) for m or e in for m a t ion on
h a vin g t h e h or n sou n d a sh or t ch ir p a s a n a u dible
t h is com pon en t . Refer t o t h e a ppr opr ia t e wir in g
ver ifica t ion t h a t t h e RKE syst em r eceived a va lid
in for m a t ion . Th e wir in g in for m a t ion in clu des wir in g
Lock r equ est fr om t h e RKE t r a n sm it t er, or h a vin g n o
dia gr a m s, pr oper wir e a n d con n ect or r epa ir pr oce-
a u dible ver ifica t ion .
du r es, det a ils of wir e h a r n ess r ou t in g a n d r et en t ion ,
8H - 2 HORN
H ORN SY ST EM (Cont inue d)
con n ect or pin -ou t in for m a t ion a n d loca t ion views for
t h e va r iou s wir e h a r n ess con n ect or s, splices a n d
gr ou n ds. F ollowin g a r e gen er a l descr ipt ion s of t h e
r em a in in g m a jor com pon en t s in t h e h or n syst em .
OPERATION
Th e h or n syst em is a ct iva t ed by a h or n swit ch con -
cea led ben ea t h t h e dr iver side a ir ba g m odu le t r im
cover in t h e cen t er of t h e st eer in g wh eel. Depr essin g
t h e cen t er of t h e dr iver side a ir ba g m odu le t r im cover
closes t h e h or n swit ch . Closin g t h e h or n swit ch a ct i-
va t es t h e h or n r ela y. Th e a ct iva t ed h or n r ela y t h en
swit ch es t h e ba t t er y cu r r en t n eeded t o en er gize t h e
h or n s.
Th e BCM ca n a lso a ct iva t e t h e h or n syst em by
en er gizin g t h e h or n r ela y t h r ou gh a sin gle h a r d
wir ed ou t pu t cir cu it . Th e BCM en er gizes a n d de-en -
er gizes t h e h or n r ela y in r espon se t o in t er n a l pr o-
gr a m m in g a s well a s m essa ge in pu t s r eceived over
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s n et wor k. Th e BCM ca n en er gize t h e h or n
r ela y for a sin gle ch ir p (RKE lock r equ est ), or for
ext en ded oper a t ion (RKE pa n ic m ode a n d VTSS
a la r m m ode).
Refer t o t h e own er ’s m a n u a l in t h e veh icle glove
box for m or e in for m a t ion on t h e fea t u r es, u se a n d
oper a t ion of t h e h or n syst em .
H ORN SY ST EM DI AGN OSI S
CONDITION POSSIBLE CAUSES
BOTH HORNS 1. Faulty fuse.
INOPERATIVE
2. Faulty horn relay.
3. Faulty horn switch.
4. Faulty horns.
ONE HORN INOPERATIVE 1. Faulty horn.
WJ
DIAGNOSIS AND TESTING - HORN SYSTEM
In m ost ca ses, a n y pr oblem in volvin g con t in u a lly
sou n din g h or n s ca n be qu ickly a llevia t ed by r em ovin g
t h e h or n r ela y fr om t h e P ower Dist r ibu t ion Cen t er
(P DC). Refer t o H or n Rela y for t h e pr oper r em ova l
pr ocedu r e. Refer t o t h e a ppr opr ia t e wir in g in for m a -
t ion . Th e wir in g in for m a t ion in clu des wir in g dia -
gr a m s, pr oper wir e a n d con n ect or r epa ir pr ocedu r es,
fu r t h er det a ils on wir e h a r n ess r ou t in g a n d r et en -
t ion , a s well a s pin -ou t a n d loca t ion views for t h e
va r iou s wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CORRECTION
1. Check the fuses in the Power Distribution
Center (PDC) and the Junction Block (JB).
Replace the fuse and repair the shorted circuit or
component, if required.
2. Refer to Horn Relay for the proper horn relay
diagnosis and testing procedures. Replace the
horn relay or repair the open horn relay circuit, if
required.
3. Refer to Horn Switch for the proper horn switch
diagnosis and testing procedures. Replace the
horn switch or repair the open horn switch circuit,
if required.
4. Refer to Horn for the proper horn diagnosis
and testing procedures. Replace the horns or
repair the open horn circuit, if required.
1. Refer to Horn for the proper horn diagnosis
and testing procedures. Replace the horn or
repair the open horn circuit, if required.
WJ
H ORN SY ST EM (Cont inue d)
CONDITION POSSIBLE CAUSES
HORN SOUNDS 1. Faulty horn relay.
CONTINUOUSLY
2. Faulty horn switch.
H ORN
DESCRIPTION
Th e du a l elect r om a gn et ic dia ph r a gm -t ype h or n s
a r e st a n da r d equ ipm en t on t h is m odel. Bot h h or n s
a r e secu r ed t o a m ou n t in g br a cket . Th e m ou n t in g
br a cket is secu r ed wit h a scr ew t o t h e ba ck side of
t h e r igh t ext en sion of t h e r a dia t or closu r e a ssem bly,
ju st a h ea d of t h e r igh t fr on t wh eel h ou se a n d below
t h e fr on t wh eel h ou se ext en sion . Th e t wo h or n s a r e
con n ect ed in pa r a llel. E a ch h or n is gr ou n ded t h r ou gh
it s wir e h a r n ess con n ect or a n d cir cu it t o a n eyelet
secu r ed t o t h e r igh t in n er fen der sh ield n ea r t h e ba t -
t er y, a n d r eceives ba t t er y feed t h r ou gh t h e closed
con t a ct s of t h e h or n r ela y.
Th e h or n s ca n n ot be r epa ir ed or a dju st ed a n d, if
fa u lt y or da m a ged, t h ey m u st be in dividu a lly
r epla ced.
OPERATION
Wit h in t h e t wo h a lves of t h e m olded pla st ic h or n
h ou sin g a r e a flexible dia ph r a gm , a plu n ger, a n elec-
t r om a gn et ic coil a n d a set of con t a ct poin t s. Th e dia -
ph r a gm is secu r ed in su spen sion a r ou n d it s
per im et er by t h e m a t in g su r fa ces of t h e h or n h ou s-
in g. Th e plu n ger is secu r ed t o t h e cen t er of t h e dia -
ph r a gm a n d ext en ds in t o t h e cen t er of t h e
elect r om a gn et . Th e con t a ct poin t s con t r ol t h e cu r r en t
flow t h r ou gh t h e elect r om a gn et .
Wh en t h e h or n is en er gized, elect r ica l cu r r en t
flows t h r ou gh t h e closed con t a ct poin t s t o t h e elect r o-
m a gn et . Th e r esu lt in g elect r om a gn et ic field dr a ws
t h e plu n ger a n d dia ph r a gm t owa r d it u n t il t h a t
m ovem en t m ech a n ica lly open s t h e con t a ct poin t s.
Wh en t h e con t a ct poin t s open , t h e elect r om a gn et ic
field colla pses a llowin g t h e plu n ger a n d dia ph r a gm t o
r et u r n t o t h eir r ela xed posit ion s a n d closin g t h e con -
t a ct poin t s a ga in . Th is cycle con t in u es r epea t in g a t a
ver y r a pid r a t e pr odu cin g t h e vibr a t ion a n d m ove-
m en t of a ir t h a t cr ea t es t h e sou n d t h a t is dir ect ed
t h r ou gh t h e h or n ou t let .
HORN 8H - 3
CORRECTION
1. Refer to Horn Relay for the proper horn relay
diagnosis and testing procedures. Replace the
horn relay or repair the shorted horn relay control
circuit, if required.
2. Refer to Horn Switch for the proper horn switch
diagnosis and testing procedures. Replace the
horn switch or repair the shorted horn switch
circuit, if required.
DIAGNOSIS AND TESTING - HORN
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
(1) Discon n ect t h e wir e h a r n ess con n ect or (s) fr om
t h e h or n con n ect or r ecept a cle(s). Mea su r e t h e r esis-
t a n ce bet ween t h e gr ou n d cir cu it ca vit y of t h e h or n (s)
wir e h a r n ess con n ect or (s) a n d a good gr ou n d. Th er e
sh ou ld be n o m ea su r a ble r esist a n ce. If OK, go t o St ep
2. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d
a s r equ ir ed.
(2) Ch eck for ba t t er y volt a ge a t t h e h or n r ela y ou t -
pu t cir cu it ca vit y of t h e h or n (s) wir e h a r n ess con n ec-
t or (s). Th er e sh ou ld be zer o volt s. If OK, go t o St ep 3.
If n ot OK, r epa ir t h e sh or t ed h or n r ela y ou t pu t cir-
cu it or r epla ce t h e fa u lt y h or n r ela y a s r equ ir ed.
(3) Depr ess t h e h or n swit ch . Th er e sh ou ld n ow be
ba t t er y volt a ge a t t h e h or n r ela y ou t pu t cir cu it ca vit y
of t h e h or n (s) wir e h a r n ess con n ect or (s). If OK,
r epla ce t h e fa u lt y h or n s. If n ot OK, r epa ir t h e open
h or n r ela y ou t pu t cir cu it t o t h e h or n r ela y a s
r equ ir ed.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Ra ise a n d su ppor t t h e veh icle.
(3) Rem ove t h e lower fr on t h a lf of t h e in n er lin er
fr om t h e r igh t fr on t fen der wh eel h ou se. (Refer t o 23
- BODY/E XTE RIOR/F RONT F E NDE R - RE MOVAL).
(4) Rea ch t h r ou gh t h e fr on t of t h e r igh t fr on t
fen der wh eel h ou se open in g t o a ccess a n d discon n ect
t h e t wo r igh t h ea dla m p a n d da sh wir e h a r n ess con -
n ect or s fr om t h e h or n con n ect or r ecept a cles (F ig. 1).
Be cer t a in t o disen ga ge t h e con n ect or lock t a bs
befor e discon n ect in g t h em fr om t h e h or n con n ect or
r ecept a cles.
(5) Rem ove t h e scr ew t h a t secu r es t h e h or n
m ou n t in g br a cket t o t h e r igh t ext en sion of t h e r a di-
a t or closu r e a ssem bly.
8H - 4 HORN
H ORN (Cont inue d)
Fig. 1 Horns Remove/Install
1 - RADIATOR CLOSURE ASSEMBLY
2 - HORNS AND MOUNTING BRACKET
3 - RIGHT HEADLAMP AND DASH WIRE HARNESS
CONNECTORS
(6) Rem ove bot h h or n s a n d t h e m ou n t in g br a cket
fr om t h e r igh t ext en sion of t h e r a dia t or closu r e
a ssem bly a s a u n it .
INSTALLATION
(1) P osit ion bot h h or n s a n d t h e m ou n t in g br a cket
on t o t h e r igh t ext en sion of t h e r a dia t or closu r e
a ssem bly a s a u n it .
(2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
h or n m ou n t in g br a cket t o t h e r igh t ext en sion of t h e
r a dia t or closu r e a ssem bly. Tigh t en t h e scr ew t o 11.3
N·m (100 in . lbs.).
(3) Recon n ect t h e t wo r igh t h ea dla m p a n d da sh
wir e h a r n ess con n ect or s t o t h e h or n con n ect or r ecep-
t a cles. Be cer t a in t o en ga ge t h e con n ect or lock t a bs
a ft er r econ n ect in g t h em t o t h e h or n con n ect or r ecep-
t a cles.
(4) In st a ll t h e lower fr on t h a lf of t h e in n er lin er t o
t h e r igh t fr on t fen der wh eel h ou se. (Refer t o 23 -
BODY/E XTE RIOR/F RONT F E NDE R - INSTALLA-
TION) for t h e pr ocedu r e.
(5) Lower t h e veh icle.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
H ORN RELAY
DESCRIPTION
Th e h or n r ela y is a elect r om ech a n ica l device t h a t
swit ch es ba t t er y cu r r en t t o t h e h or n wh en t h e h or n
swit ch gr ou n ds t h e r ela y coil. Th e h or n r ela y is
loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC) in
WJ
t h e en gin e com pa r t m en t . If a pr oblem is en cou n t er ed
wit h a con t in u ou sly sou n din g h or n , it ca n u su a lly be
qu ickly r esolved by r em ovin g t h e h or n r ela y fr om t h e
P DC u n t il fu r t h er dia gn osis is com plet ed. See t h e
fu se a n d r ela y la you t la bel a ffixed t o t h e in side su r-
fa ce of t h e P DC cover for h or n r ela y iden t ifica t ion
a n d loca t ion .
Th e h or n r ela y is a In t er n a t ion a l St a n da r ds Or ga -
n iza t ion (ISO) m icr o-r ela y. Rela ys con for m in g t o t h e
ISO specifica t ion s h a ve com m on ph ysica l dim en sion s,
cu r r en t ca pa cit ies, t er m in a l pa t t er n s, a n d t er m in a l
fu n ct ion s. Th e ISO m icr o-r ela y t er m in a l fu n ct ion s
a r e t h e sa m e a s a con ven t ion a l ISO r ela y. H owever,
t h e ISO m icr o-r ela y t er m in a l pa t t er n (or foot pr in t ) is
differ en t , t h e cu r r en t ca pa cit y is lower, a n d t h e ph ys-
ica l dim en sion s a r e sm a ller t h a n t h ose of t h e con ven -
t ion a l ISO r ela y.
Th e h or n r ela y ca n n ot be r epa ir ed or a dju st ed a n d,
if fa u lt y or da m a ged, it m u st be r epla ced.
OPERATION
Th e ISO r ela y con sist s of a n elect r om a gn et ic coil, a
r esist or or diode, a n d t h r ee (t wo fixed a n d on e m ov-
a ble) elect r ica l con t a ct s. Th e m ova ble (com m on feed)
r ela y con t a ct is h eld a ga in st on e of t h e fixed con t a ct s
(n or m a lly closed) by spr in g pr essu r e. Wh en t h e elec-
t r om a gn et ic coil is en er gized, it dr a ws t h e m ova ble
con t a ct a wa y fr om t h e n or m a lly closed fixed con t a ct ,
a n d h olds it a ga in st t h e ot h er (n or m a lly open ) fixed
con t a ct .
Wh en t h e elect r om a gn et ic coil is de-en er gized,
spr in g pr essu r e r et u r n s t h e m ova ble con t a ct t o t h e
n or m a lly closed posit ion . Th e r esist or or diode is con -
n ect ed in pa r a llel wit h t h e elect r om a gn et ic coil in t h e
r ela y, a n d h elps t o dissipa t e volt a ge spikes t h a t a r e
pr odu ced wh en t h e coil is de-en er gized.
DIAGNOSIS AND TESTING - HORN RELAY
Th e h or n r ela y (F ig. 2) is loca t ed in t h e P ower Dis-
t r ibu t ion Cen t er (P DC) bet ween t h e ba t t er y a n d t h e
r igh t in n er fen der sh ield on t h e pa ssen ger side of t h e
en gin e com pa r t m en t . If a pr oblem is en cou n t er ed
wit h a con t in u ou sly sou n din g h or n , it ca n u su a lly be
qu ickly r esolved by r em ovin g t h e h or n r ela y fr om t h e
P DC u n t il fu r t h er dia gn osis is com plet ed. See t h e
fu se a n d r ela y la you t la bel a ffixed t o t h e in side su r-
fa ce of t h e P DC cover for h or n r ela y iden t ifica t ion
a n d loca t ion . F or com plet e cir cu it dia gr a m s, r efer t o
t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for-
m a t ion in clu des wir in g dia gr a m s, pr oper wir e a n d
con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
n ect or s, splices a n d gr ou n ds.
WJ
H ORN RELAY (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Rem ove t h e h or n r ela y fr om t h e P DC. (Refer t o
8 - E LE CTRICAL/H ORN/H ORN RE LAY - t er y volt a ge a n d sh ou ld be h ot a t a ll t im es. Ch eck for
RE MOVAL) for t h e pr ocedu r es.
(2) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(3) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ± 5 oh m s. If OK, go t o St ep
4. If n ot OK, r epla ce t h e fa u lt y r ela y.
(4) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A
a n d 30. If OK, per for m t h e Rela y Cir cu it Test t h a t
follows. If n ot OK, r epla ce t h e fa u lt y r ela y.
Fig. 2 Horn Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
RELAY CIRCUIT TEST
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is
con n ect ed t o ba t t er y volt a ge a n d sh ou ld be h ot a t a ll
t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open
cir cu it t o t h e fu se in t h e P DC a s r equ ir ed.
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3.
HORN 8H - 5
(3) Th e r ela y n or m a lly open t er m in a l (87) is con -
n ect ed t o t h e com m on feed t er m in a l (30) in t h e en er-
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
t o t h e h or n (s). Th er e sh ou ld be con t in u it y bet ween
t h e ca vit y for r ela y t er m in a l 87 a n d t h e h or n r ela y
ou t pu t cir cu it ca vit y of ea ch h or n wir e h a r n ess con -
n ect or a t a ll t im es. If OK, go t o St ep 4. If n ot OK,
r epa ir t h e open cir cu it t o t h e h or n (s) a s r equ ir ed.
(4) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It is con n ect ed t o ba t -
ba t t er y volt a ge a t t h e ca vit y for r ela y t er m in a l 86. If
OK, go t o St ep 5. If n ot OK, r epa ir t h e open cir cu it t o
t h e fu se in t h e P DC a s r equ ir ed.
(5) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It is gr ou n ded
t h r ou gh t h e h or n swit ch wh en t h e h or n swit ch is
depr essed. Th e h or n r ela y coil gr ou n d t er m in a l ca n
a lso be gr ou n ded by t h e Body Con t r ol Modu le (BCM)
in r espon se t o cer t a in in pu t s r ela t ed t o t h e RKE sys-
t em or t h e Veh icle Th eft Secu r it y Syst em . Ch eck for
con t in u it y t o gr ou n d a t t h e ca vit y for r ela y t er m in a l
85. Th er e sh ou ld be con t in u it y wit h t h e h or n swit ch
depr essed, a n d n o con t in u it y wit h t h e h or n swit ch
r elea sed. If n ot OK, (Refer t o 8 - E LE CTRICAL/
H ORN/H ORN SWITCH - DIAGNOSIS AND TE ST-
ING).
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e cover fr om t h e P ower Dist r ibu t ion
Cen t er (P DC) (F ig. 3) .
(3) See t h e fu se a n d r ela y la you t la bel a ffixed t o
t h e u n der side of t h e P DC cover for h or n r ela y iden -
t ifica t ion a n d loca t ion .
(4) Rem ove t h e h or n r ela y fr om t h e P DC.
INSTALLATION
(1) See t h e fu se a n d r ela y la you t la bel a ffixed t o
t h e u n der side of t h e P DC cover for t h e pr oper h or n
r ela y loca t ion .
(2) P osit ion t h e h or n r ela y in t h e pr oper r ecept a cle
in t h e P DC.
(3) Align t h e h or n r ela y t er m in a ls wit h t h e t er m i-
n a l ca vit ies in t h e P DC r ecept a cle.
(4) P u sh down fir m ly on t h e h or n r ela y u n t il t h e
t er m in a ls a r e fu lly sea t ed in t h e t er m in a l ca vit ies in
t h e P DC r ecept a cle.
(5) In st a ll t h e cover on t o t h e P DC.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
8H - 6 HORN
H ORN RELAY (Cont inue d)
Fig. 3 Power Distribution Center
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
H ORN SWI T CH
DESCRIPTION
A cen t er-blow, n or m a lly open , r esist ive m em br a n e-
t ype h or n swit ch is secu r ed in a pla st ic t r a y t h a t is
in ser t ed in a pocket sewn on t h e fr on t of t h e dr iver
side a ir ba g r et a in er st r a p. Th e h or n swit ch is con -
cea led beh in d t h e dr iver side a ir ba g m odu le t r im
cover in t h e cen t er of t h e st eer in g wh eel. Th e swit ch
con sist s of t wo pla st ic m em br a n es, on e t h a t is fla t
a n d on e t h a t is sligh t ly con vex. Th ese t wo m em -
br a n es a r e secu r ed t o ea ch ot h er a r ou n d t h e per im e-
t er. In side t h e swit ch , t h e cen t er s of t h e fa cin g
su r fa ces of t h ese m em br a n es ea ch h a s a gr id m a de
wit h a n elect r ica lly con du ct ive m a t er ia l a pplied t o it .
On e of t h e gr ids is con n ect ed t o a cir cu it t h a t pr o-
vides it wit h con t in u it y t o gr ou n d a t a ll t im es. Th e
gr id of t h e ot h er m em br a n e is con n ect ed t o t h e h or n
r ela y con t r ol cir cu it .
Th e st eer in g wh eel a n d st eer in g colu m n m u st be
pr oper ly gr ou n ded in or der for t h e h or n swit ch t o
fu n ct ion pr oper ly. Th e h or n swit ch a n d pla st ic t r a y
a r e ser viced a s a u n it . If t h e h or n swit ch is da m a ged
or fa u lt y, or if t h e dr iver side a ir ba g is deployed, t h e
h or n swit ch a n d t r a y m u st be r epla ced a s a u n it .
WJ
OPERATION
Wh en t h e cen t er a r ea of t h e dr iver side a ir ba g t r im
cover is depr essed, t h e elect r ica lly con du ct ive gr ids
on t h e fa cin g su r fa ces of t h e h or n swit ch m em br a n es
con t a ct ea ch ot h er, closin g t h e swit ch cir cu it . Th e
com plet ed h or n swit ch cir cu it pr ovides a gr ou n d for
t h e con t r ol coil side of t h e h or n r ela y, wh ich a ct iva t es
t h e r ela y. Wh en t h e h or n swit ch is r elea sed, t h e
r esist ive t en sion of t h e con vex m em br a n e sepa r a t es
t h e t wo elect r ica lly con du ct ive gr ids a n d open s t h e
swit ch cir cu it .
DIAGNOSIS AND TESTING - HORN SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e st eer in g colu m n open in g cover
fr om t h e in st r u m en t pa n el.
(2) Ch eck for con t in u it y bet ween t h e m et a l st eer-
in g colu m n ja cket a n d a good gr ou n d. Th er e sh ou ld
be con t in u it y. If OK, go t o St ep 3. If n ot OK, r efer t o
St eer in g, Colu m n for pr oper in st a lla t ion of t h e st eer-
in g colu m n .
(3) Rem ove t h e dr iver side a ir ba g m odu le fr om t h e
st eer in g wh eel. Discon n ect t h e h or n swit ch wir e h a r-
n ess con n ect or s fr om t h e dr iver side a ir ba g m odu le.
(4) Rem ove t h e h or n r ela y fr om t h e P ower Dist r i-
bu t ion Cen t er (P DC). Ch eck for con t in u it y bet ween
t h e st eer in g colu m n h a lf of t h e h or n swit ch feed wir e
h a r n ess con n ect or a n d a good gr ou n d. Th er e sh ou ld
be n o con t in u it y. If OK, go t o St ep 5. If n ot OK,
r epa ir t h e sh or t ed h or n r ela y con t r ol cir cu it t o t h e
h or n r ela y in t h e P DC a s r equ ir ed.
(5) Ch eck for con t in u it y bet ween t h e st eer in g col-
u m n h a lf of t h e h or n swit ch feed wir e h a r n ess con -
n ect or a n d t h e h or n r ela y con t r ol cir cu it ca vit y for
t h e h or n r ela y in t h e P DC. Th er e sh ou ld be con t in u -
it y. If OK, go t o St ep 6. If n ot OK, r epa ir t h e open
h or n r ela y con t r ol cir cu it t o t h e h or n r ela y in t h e
P DC a s r equ ir ed.
WJ HORN 8H - 7
H ORN SWI T CH (Cont inue d)
(6) Ch eck for con t in u it y bet ween t h e h or n swit ch
feed wir e a n d t h e h or n swit ch gr ou n d wir e on t h e
dr iver side a ir ba g m odu le. Th er e sh ou ld be n o con t i-
n u it y. If OK, go t o St ep 7. If n ot OK, r epla ce t h e
fa u lt y h or n swit ch .
(7) Depr ess t h e cen t er of t h e dr iver side a ir ba g
m odu le t r im cover a n d ch eck for con t in u it y bet ween
t h e h or n swit ch feed wir e a n d t h e h or n swit ch
gr ou n d wir e on t h e dr iver side a ir ba g m odu le. Th er e
sh ou ld n ow be con t in u it y. If n ot OK, r epla ce t h e
fa u lt y h or n swit ch .

REMOVAL
WARNING:
• ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
• THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e t r im cover fr om t h e dr iver side a ir-
ba g m odu le. (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/DRIVE R AIRBAG - RE MOVAL) for t h e
pr ocedu r e.
(3) Rem ove t h e h or n swit ch a n d t r a y a s a u n it
fr om t h e pou ch on t h e r et a in in g st r a p of t h e dr iver
side a ir ba g m odu le (F ig. 4).
INSTALLATION
WARNING:
• ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
Fig. 4 Horn Switch Remove/Install
1 - HORN SWITCH GROUND WIRE EYELET
2 - HORN SWITCH
3 - AIRBAG RETAINING STRAP
4 - POUCH
5 - DRIVER SIDE AIRBAG MODULE (TRIM COVER REMOVED)
6 - TRAY
7 - HORN SWITCH FEED WIRE CONNECTOR
• THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) In st a ll t h e h or n swit ch a n d t r a y a s a u n it in t o
t h e pou ch on t h e r et a in in g st r a p of t h e dr iver side
a ir ba g m odu le. Be cer t a in t h a t t h e t r a y is fa cin g t h e
a ir ba g m odu le, t h a t t h e h or n swit ch is fa cin g t h e
t r im cover, t h a t t h e h or n swit ch feed wir e is on t h e
left , a n d t h a t t h e h or n swit ch gr ou n d wir e is on t h e
r igh t .
(2) In st a ll t h e t r im cover on t o t h e dr iver side a ir-
ba g m odu le. (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/DRIVE R AIRBAG - INSTALLATION) for
t h e pr ocedu r e.
(3) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ IGNITION CONTROL 8I - 1

IGNITION CONTROL
TABLE OF CON T EN T S

page page

IGNITION CONTROL INSTALLATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ..1 INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . ..1 INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS COIL RAIL
ENGINE FIRING ORDER - 4.0L 6-CYLINDER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE FIRING ORDER—4.7L V-8 ENGINE ..2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IGNITION COIL RESISTANCE - 4.0L ENGINE .2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION COIL RESISTANCE—4.7L V-8 IGNITION COIL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . .2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . .3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TORQUE - IGNITION SYSTEM . . . . . . . . . . . .3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
AUTO SHUT DOWN RELAY IGNITION COIL CAPACITOR
DESCRIPTION - PCM OUTPUT . . . . . . . . . . . ..3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION - PCM OUTPUT ........... . .3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION - ASD SENSE - PCM INPUT . . . .4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL ........................... . .4 KNOCK SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
CAMSHAFT POSITION SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . ..4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . ..5 SPARK PLUG
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . ..5 DIAGNOSIS AND TESTING - SPARK PLUG
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . ..5 CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . ..6 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . ..7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18

I GN I T I ON CON T ROL st r oke), t h e spa r k t o t h e opposit e cylin der is bein g

wa st ed (on exh a u st st r oke). Th e on e-piece coil bolt s
dir ect ly t o t h e cylin der h ea d. Ru bber boot s sea l t h e
DESCRIPTION
secon da r y t er m in a l en ds of t h e coils t o t h e t op of a ll
Two differ en t ign it ion syst em s a r e u sed. On e t ype
6 spa r k plu gs. On e elect r ica l con n ect or (loca t ed a t
of syst em is for t h e 4.0L 6–cylin der en gin e. Th e ot h er
t h e r ea r en d of t h e coil r a il) is u sed for a ll t h r ee coils.
is for t h e 4.7L V-8 en gin e.
Th e 4.7L V-8 en gin e u ses 8 dedica t ed a n d in divid-
u a lly fir ed coil for ea ch spa r k plu g. E a ch coil is
OPERATION m ou n t ed dir ect ly t o t h e t op of ea ch spa r k plu g. A sep-
Th e 4.0L 6–cylin der en gin e u ses a on e-piece coil
a r a t e elect r ica l con n ect or is u sed for ea ch coil.
r a il con t a in in g t h r ee in depen den t coils. Alt h ou gh cyl-
Beca u se of coil design , spa r k plu g ca bles (secon d-
in der fir in g or der is t h e sa m e a s 4.0L en gin es of pr e- a r y ca bles) a r e n ot u sed on eit h er en gin e. A d is trib-
viou s yea r s, spa r k plu g fir in g is n ot . Th e 3 coils du a l-
u to r is n o t u s e d wit h eit h er t h e 4.0L or 4.7L
fir e t h e spa r k plu gs on cylin der s 1–6, 2–5 a n d/or 3–4.
en gin es.
Wh en on e cylin der is bein g fir ed (on com pr ession
8I - 2 IGNITION CONTROL WJ
I GN I T I ON CON T ROL (Cont inue d)
Th e ign it ion syst em is con t r olled by t h e power t r a in ENGINE FIRING ORDER—4.7L V-8 ENGINE
con t r ol m odu le (P CM) on a ll en gin es.
Th e ign it ion syst em con sist s of:
• Spa r k P lu gs
• Ign it ion Coil(s)
• P ower t r a in Con t r ol Modu le (P CM)
• Cr a n ksh a ft P osit ion Sen sor
• Ca m sh a ft P osit ion Sen sor
• Th e MAP, TP S, IAC a n d E CT a lso h a ve a n effect
on t h e con t r ol of t h e ign it ion syst em .

SPECI FI CAT I ON S
ENGINE FIRING ORDER - 4.0L 6-CYLINDER
ENGINE

IGNITION COIL RESISTANCE - 4.0L ENGINE

PRIMARY RESISTANCE 21-27°C (70-80°F)

0.71 - 0.88 Ohms

IGNITION COIL RESISTANCE—4.7L V-8

ENGINE

SECONDARY
PRIMARY RESISTANCE
RESISTANCE 21-27°C
21-27°C (70-80°F)
(70-80°F)
0.6 - 0.9 Ohms 6,000 - 9,000 Ohms

IGNITION TIMING
All ign it ion t im in g fu n ct ion s a r e con t r olled by t h e
P ower t r a in Con t r ol Modu le (P CM). Mech a n ica l
a dju st m en t s a r e n ot n eeded a n d ca n ’t be m a de.
On t h e 4.0L 6–cylin der en gin e, do n ot a t t em pt t o
r ot a t e t h e oil pu m p dr ive t o a dju st t im in g. Th is
a dju st m en t is u sed for fu el syn ch r on iza t ion a ft er
ca m sh a ft posit ion sen sor r epla cem en t .
WJ IGNITION CONTROL 8I - 3
I GN I T I ON CON T ROL (Cont inue d)

SPARK PLUGS

ENGINE PLUG TYPE ELECTRODE GAP

4.0L 6-CYL. RC12ECC 0.89 mm (.035 in.)
4.7L V-8 (Exc. HO) RC12MCC4 1.01 mm (.040 in.)
4.7L V-8 High RC7PYCB4 1.01 mm (.040 in.)
Output (HO)

TORQUE - IGNITION SYSTEM

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Crankshaft Position Sensor 7 - 60
Bolts - 4.0L Engine
Crankshaft Position Sensor 28 21 -
Bolt - 4.7L V-8 Engine
Camshaft Position 2 - 15
Sensor–to–base bolts - 4.0L
Engine
Camshaft Position Sensor 12 - 106
Bolt - 4.7L V-8 Engine
Oil Pump Drive Hold-down 23 17 -
Bolt - 4.0L Engine
Ignition Coil Rail Mounting 29 - 250
Bolts - 4.0L Engine
Ignition Coil Mounting Nut - 8 - 70
4.7L V-8 Engine
* Knock Sensor Bolt - 4.7L *20 *15 -
HO V-8 Engine
Spark Plugs - 4.0L Engine 35-41 26-30 -
Spark Plugs - 4.7L V-8 24 - 30 18 - 22 -
Engine
* Do not apply any sealant,
thread-locker or adhesive to
bolts. Poor sensor
performance may result.
Refer to Removal / Installation
for additional information.

AU T O SH U T DOWN RELAY OPERAT I ON

DESCRIPTION - PCM OUTPUT OPERATION - PCM OUTPUT

Th e 5–pin , 12–volt , Au t om a t ic Sh u t down (ASD)
r ela y is loca t ed in t h e P ower Dist r ibu t ion Cen t er
(P DC). Refer t o la bel on P DC cover for r ela y loca t ion .
Th e ASD r ela y su pplies ba t t er y volt a ge (12+ volt s)
t o t h e fu el in ject or s a n d ign it ion coil(s). Wit h cer t a in
em ission s pa cka ges it a lso su pplies 12–volt s t o t h e
oxygen sen sor h ea t in g elem en t s.
Th e gr ou n d cir cu it for t h e coil wit h in t h e ASD
r ela y is con t r olled by t h e P ower t r a in Con t r ol Modu le
(P CM). Th e P CM oper a t es t h e ASD r ela y by swit ch -
in g it s gr ou n d cir cu it on a n d off.
8I - 4 IGNITION CONTROL WJ
AU T O SH U T DOWN RELAY (Cont inue d)
Th e ASD r ela y will be sh u t –down , m ea n in g t h e INSTALLATION
12–volt power su pply t o t h e ASD r ela y will be de-a c- Th e ASD r ela y is loca t ed in t h e P ower Dist r ibu t ion
t iva t ed by t h e P CM if: Cen t er (P DC) (F ig. 1). Refer t o la bel on P DC cover
• t h e ign it ion key is left in t h e ON posit ion . Th is for r ela y loca t ion .
is if t h e en gin e h a s n ot been r u n n in g for a ppr oxi- (1) In st a ll r ela y t o P DC.
m a t ely 1.8 secon ds. (2) In st a ll cover t o P DC.
• t h er e is a cr a n ksh a ft posit ion sen sor sign a l t o
t h e P CM t h a t is lower t h a n pr e-det er m in ed va lu es.
CAM SH AFT POSI T I ON
OPERATION - ASD SENSE - PCM INPUT SEN SOR
A 12 volt sign a l a t t h is in pu t in dica t es t o t h e P CM
t h a t t h e ASD h a s been a ct iva t ed. Th e r ela y is u sed t o
con n ect t h e oxygen sen sor h ea t er elem en t , ign it ion DESCRI PT I ON
coil a n d fu el in ject or s t o 12 volt + power su pply.
Th is in pu t is u sed on ly t o sen se t h a t t h e ASD r ela y DESCRIPTION - 4.0L
is en er gized. If t h e P ower t r a in Con t r ol Modu le Th e Ca m sh a ft P osit ion Sen sor (CMP ) on t h e 4.0L
(P CM) does n ot see 12 volt s a t t h is in pu t wh en t h e 6–cylin der en gin e is bolt ed t o t h e t op of t h e oil pu m p
ASD sh ou ld be a ct iva t ed, it will set a Dia gn ost ic dr ive sh a ft a ssem bly (F ig. 2). Th e sen sor a n d dr ive
Tr ou ble Code (DTC). sh a ft a ssem bly is loca t ed on t h e r igh t side of t h e
en gin e n ea r t h e oil filt er (F ig. 3).
REMOVAL
Th e ASD r ela y is loca t ed in t h e P ower Dist r ibu t ion
Cen t er (P DC) (F ig. 1). Refer t o la bel on P DC cover
for r ela y loca t ion .
(1) Rem ove P DC cover.
(2) Rem ove r ela y fr om P DC.
(3) Ch eck con dit ion of r ela y t er m in a ls a n d P DC
con n ect or t er m in a ls for da m a ge or cor r osion . Repa ir
if n ecessa r y befor e in st a llin g r ela y.
(4) Ch eck for pin h eigh t (pin h eigh t sh ou ld be t h e
sa m e for a ll t er m in a ls wit h in t h e P DC con n ect or ).
Repa ir if n ecessa r y befor e in st a llin g r ela y.

Fig. 2 CMP and Oil Pump Drive Shaft—4.0L Engine

1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
Fig. 1 Power Distribution Center (PDC) Location 5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
1 - PCM
2 - COOLANT TANK
WJ IGNITION CONTROL 8I - 5
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)

Fig. 3 CMP Location—4.0L Engine

Fig. 4 CMP Location—4.7L Engine
1 - OIL FILTER
1 - RIGHT CYLINDER HEAD
2 - CAMSHAFT POSITION SENSOR
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
3 - MOUNTING BOLT
4 - HOLD-DOWN CLAMP
4 - ELEC. CONNECTOR
5 - MOUNTING BOLTS (2)
6 - ELEC. CONNECTOR
Wh en t h e t r a ilin g edge of t h e pu lse r in g (sh u t t er )
lea ves t h e syn c sign a l gen er a t or, t h e followin g occu r s:
DESCRIPTION - 4.7L Th e ch a n ge of t h e m a gn et ic field ca u ses t h e syn c sig-
Th e Ca m sh a ft P osit ion Sen sor (CMP ) on t h e 4.7L
n a l volt a ge t o swit ch low t o 0 volt s.
V–8 en gin e is bolt ed t o t h e fr on t /t op of t h e r igh t cyl-
in der h ea d (F ig. 4).
OPERATION - 4.7L
Th e CMP sen sor con t a in s a h a ll effect device ca lled
OPERAT I ON a syn c sign a l gen er a t or t o gen er a t e a fu el syn c sig-
n a l. Th is syn c sign a l gen er a t or det ect s n ot ch es
OPERATION - 4.0L loca t ed on a t on ewh eel. Th e t on ewh eel is loca t ed a t
Th e CMP sen sor con t a in s a h a ll effect device ca lled t h e fr on t of t h e ca m sh a ft for t h e r igh t cylin der h ea d
a syn c sign a l gen er a t or t o gen er a t e a fu el syn c sig- (F ig. 5). As t h e t on ewh eel r ot a t es, t h e n ot ch es pa ss
n a l. Th is syn c sign a l gen er a t or det ect s a r ot a t in g t h r ou gh t h e syn c sign a l gen er a t or. Th e pa t t er n of t h e
pu lse r in g (sh u t t er ) on t h e oil pu m p dr ive sh a ft (F ig. n ot ch es (viewed cou n t er-clockwise fr om fr on t of
2). Th e pu lse r in g r ot a t es 180 degr ees t h r ou gh t h e en gin e) is: 1 n ot ch , 2 n ot ch es, 3 n ot ch es, 3 n ot ch es, 2
syn c sign a l gen er a t or. It s sign a l is u sed in con ju n c- n ot ch es 1 n ot ch , 3 n ot ch es a n d 1 n ot ch . Th e sign a l
t ion wit h t h e cr a n ksh a ft posit ion sen sor t o differ en t i- fr om t h e CMP sen sor is u sed in con ju n ct ion wit h t h e
a t e bet ween fu el in ject ion a n d spa r k even t s. It is a lso cr a n ksh a ft posit ion sen sor t o differ en t ia t e bet ween
u sed t o syn ch r on ize t h e fu el in ject or s wit h t h eir fu el in ject ion a n d spa r k even t s. It is a lso u sed t o syn -
r espect ive cylin der s. ch r on ize t h e fu el in ject or s wit h t h eir r espect ive cylin -
Wh en t h e lea din g edge of t h e pu lse r in g (sh u t t er ) der s.
en t er s t h e syn c sign a l gen er a t or, t h e followin g occu r s:
Th e in t er r u pt ion of m a gn et ic field ca u ses t h e volt a ge
t o swit ch h igh r esu lt in g in a syn c sign a l of a ppr oxi-
m a t ely 5 volt s.
8I - 6 IGNITION CONTROL WJ
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)

Fig. 5 CMP Sensor and Tonewheel—4.7L Engine

1 - NOTCHES
2 - RIGHT CYLINDER HEAD
3 - CAMSHAFT POSITION SENSOR
4 - TONEWHEEL Fig. 6 CMP and Oil Pump Drive Shaft - 4.0L Engine
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
REM OVAL 3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
REMOVAL - 4.0L 5 - OIL PUMP DRIVESHAFT
Th e Ca m sh a ft P osit ion Sen sor (CMP ) on t h e 4.0L 6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
6–cylin der en gin e is bolt ed t o t h e t op of t h e oil pu m p
dr ive sh a ft a ssem bly (F ig. 6). Th e sen sor a n d dr ive SENSOR ONLY - 4.0L
sh a ft a ssem bly is loca t ed on t h e r igh t side of t h e
(1) Discon n ect elect r ica l con n ect or a t CMP sen sor
en gin e n ea r t h e oil filt er (F ig. 7).
(F ig. 7).
Th e r ot a t ion a l posit ion of oil pu m p dr ive det er-
(2) Rem ove 2 sen sor m ou n t in g bolt s (F ig. 6) or
m in es fu el syn ch r on iza t ion on ly. It does n ot det er-
(F ig. 7).
m in e ign it ion t im in g.
(3) Rem ove sen sor fr om oil pu m p dr ive.
NOTE: Do not attempt to rotate the oil pump drive
to modify ignition timing.
OIL PUMP DRIVE AND SENSOR - 4.0L
If th e CMP a n d o il p u m p d riv e a re to be
Tw o d iffe re n t p ro c e d u re s a r e u sed for r em ova l re m o v e d a n d in s ta lle d , d o n o t a llo w e n g in e
a n d in st a lla t ion . Th e fir st pr ocedu r e will det a il c ra n k s h a ft o r c a m s h a ft to ro ta te . CMP s e n s o r
r em ova l a n d in st a lla t ion of t h e sen sor on ly. Th e sec- re la tio n s h ip w ill be lo s t.
on d pr ocedu r e will det a il r em ova l a n d in st a lla t ion of (1) Discon n ect elect r ica l con n ect or a t CMP sen sor
t h e sen sor a n d oil pu m p dr ive sh a ft a ssem bly. Th e (F ig. 7).
secon d pr ocedu r e is t o be u sed if t h e en gin e h a s been (2) Rem ove 2 sen sor m ou n t in g bolt s (F ig. 6) or
disa ssem bled. (F ig. 7).
An in t er n a l oil sea l is u sed in t h e dr ive sh a ft h ou s- (3) Rem ove sen sor fr om oil pu m p dr ive.
in g t h a t pr even t s en gin e oil a t t h e bot t om of t h e sen - (4) Befor e pr oceedin g t o n ext st ep, m a r k a n d n ot e
sor. Th e sea l is n ot ser vicea ble. r ot a t ion a l posit ion of oil pu m p dr ive in r ela t ion sh ip
t o en gin e block. Aft er in st a lla t ion , t h e CMP sen sor
sh ou ld fa ce r ea r of en gin e 0°.
(5) Rem ove h old-down bolt a n d cla m p (F ig. 7).
WJ IGNITION CONTROL 8I - 7
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)

Fig. 7 CMP Location - 4.0L Engine Fig. 9 Align Timing Marks - 4.0L Engine
1 - OIL FILTER 1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP (6) Wh ile pu llin g a ssem bly fr om en gin e, n ot e dir ec-
5 - MOUNTING BOLTS (2) t ion a n d posit ion of pu lse r in g (F ig. 6). Aft er r em ova l,
6 - ELEC. CONNECTOR look down in t o t op of oil pu m p a n d n ot e dir ect ion a n d
posit ion of slot a t t op of oil pu m p gea r.
(7) Rem ove a n d disca r d old oil pu m p dr ive-t o-en -
gin e block ga sket .

REMOVAL - 4.7L
Th e Ca m sh a ft P osit ion Sen sor (CMP ) on t h e 4.7L
V–8 en gin e is bolt ed t o t h e fr on t /t op of t h e r igh t cyl-
in der h ea d (F ig. 10).
It is ea sier t o r em ove/in st a ll sen sor fr om u n der
veh icle.
(1) Ra ise a n d su ppor t veh icle.
(2) Discon n ect elect r ica l con n ect or a t CMP sen sor
(F ig. 10).
(3) Rem ove sen sor m ou n t in g bolt (F ig. 10).
(4) Ca r efu lly pr y sen sor fr om cylin der h ea d in a
r ockin g a ct ion wit h t wo sm a ll scr ewdr iver s. S o m e
4.7L e n g in e s a re e qu ip p e d w ith a s e n s o r s p a c e r
s h im . If e qu ip p e d , th is s h im w ill be lo c a te d a t
s e n s o r bo lt h o le be tw e e n c y lin d e r h e a d a n d
s e n s o r m o u n tin g ta n g (TS B W08–18–00). S a v e
th is s h im fo r s e n s o r in s ta lla tio n .
(5) Ch eck con dit ion of sen sor o-r in g.

Fig. 8 CMP Pulse Ring Alignment - 4.0L Engine

1 - PULSE RING (SHUTTER)
2 - TOOTHPICK
3 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
8I - 8 IGNITION CONTROL WJ
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)
(4) In st a ll oil pu m p dr ive in t o en gin e wh ile a lign -
in g in t o slot on oil pu m p. Rot a t e oil pu m p dr ive ba ck
t o it s or igin a l posit ion a n d in st a ll h old-down cla m p
a n d bolt . F in ger t igh t en bolt . Do n ot do a fin a l t igh t -
en in g of bolt a t t h is t im e.
(5) If en gin e cr a n ksh a ft or ca m sh a ft h a s been
r ot a t ed, su ch a s du r in g en gin e t ea r-down , CMP sen -
sor r ela t ion sh ip m u st be r eest a blish ed.
(a ) Rem ove ign it ion coil r a il a ssem bly. Refer t o
Ign it ion Coil Rem ova l/In st a lla t ion .
(b) Rem ove cylin der n u m ber 1 spa r k plu g.
(c) H old a fin ger over t h e open spa r k plu g h ole.
Rot a t e en gin e a t vibr a t ion da m pen er bolt u n t il
com pr ession (pr essu r e) is felt .
(d) Slowly con t in u e t o r ot a t e en gin e. Do t h is
u n t il t im in g in dex m a r k on vibr a t ion da m per pu l-
ley a lign s wit h t op dea d cen t er (TDC) m a r k (0
degr ee) on t im in g degr ee sca le (F ig. 9). Alwa ys
r ot a t e en gin e in dir ect ion of n or m a l r ot a t ion . Do
n ot r ot a t e en gin e ba ckwa r d t o a lign t im in g m a r ks.
(e) In st a ll oil pu m p dr ive in t o en gin e wh ile
a lign in g in t o slot on oil pu m p. If pu m p dr ive will
Fig. 10 CMP Location—4.7L Engine n ot dr op down flu sh t o en gin e block, t h e oil pu m p
1 - RIGHT CYLINDER HEAD slot is n ot a lign ed. Rem ove oil pu m p dr ive a n d
2 - CAMSHAFT POSITION SENSOR a lign slot in oil pu m p t o sh a ft a t bot t om of dr ive.
3 - MOUNTING BOLT In st a ll in t o en gin e. Rot a t e oil pu m p dr ive ba ck t o
4 - ELEC. CONNECTOR it s or igin a l posit ion a n d in st a ll h old-down cla m p
a n d bolt . F in ger t igh t en bolt . Do n ot do a fin a l
I N STALLAT I ON t igh t en in g of bolt a t t h is t im e.
(f) Rem ove t oot h pick fr om h ou sin g.
INSTALLATION - 4.0L (6) In st a ll sen sor t o oil pu m p dr ive. Aft er in st a lla -
t ion , t h e CMP sen sor sh ou ld fa ce r ea r of en gin e 0°.
SENSOR ONLY - 4.0L (7) In st a ll 2 sen sor m ou n t in g bolt s a n d t igh t en t o
2 N·m (15 in . lbs.) t or qu e.
Th e Ca m sh a ft P osit ion Sen sor (CMP ) on t h e 4.0L
(8) Con n ect elect r ica l con n ect or t o CMP sen sor.
6–cylin der en gin e is bolt ed t o t h e t op of t h e oil pu m p
(9) If r em oved, in st a ll spa r k plu g a n d ign it ion coil
dr ive sh a ft a ssem bly (F ig. 6). Th e sen sor a n d dr ive
r a il.
sh a ft a ssem bly is loca t ed on t h e r igh t side of t h e
To ver ify cor r ect r ot a t ion a l posit ion of oil pu m p
en gin e n ea r t h e oil filt er (F ig. 7).
dr ive, t h e DRB sca n t ool m u st be u sed.
(1) In st a ll sen sor t o oil pu m p dr ive.
(2) In st a ll 2 sen sor m ou n t in g bolt s a n d t igh t en t o WARNING: WHEN PERFORMING THE FOLLOWING
2 N·m (15 in . lbs.) t or qu e. TEST, THE ENGINE WILL BE RUNNING. BE CARE-
(3) Con n ect elect r ica l con n ect or t o CMP sen sor. FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
OIL PUMP DRIVE AND SENSOR - 4.0L CLOTHING.
(1) Clea n oil pu m p dr ive m ou n t in g h ole a r ea of
en gin e block. (10) Con n ect DRB sca n t ool t o da t a lin k con n ect or.
(2) In st a ll n ew oil pu m p dr ive-t o-en gin e block ga s- Th e da t a lin k con n ect or is loca t ed in pa ssen ger com -
ket . pa r t m en t , below a n d t o left of st eer in g colu m n .
(3) Tem por a r ily in st a ll a t oot h pick or sim ila r t ool (11) Ga in a ccess t o SE T SYNC scr een on DRB.
t h r ou gh a ccess h ole a t side of oil pu m p dr ive h ou sin g. (12) F ollow dir ect ion s on DRB scr een a n d st a r t
Align t oot h pick in t o m a t in g h ole on pu lse r in g (F ig. en gin e. Br in g t o oper a t in g t em per a t u r e (en gin e m u st
8). be in “closed loop” m ode).
(13) Wit h en gin e r u n n in g a t id le s p e e d , t h e wor ds
IN RANGE sh ou ld a ppea r on scr een a lon g wit h 0°.
Th is in dica t es cor r ect posit ion of oil pu m p dr ive.
WJ IGNITION CONTROL 8I - 9
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)
(14) If a plu s (+) or a m in u s (-) is displa yed n ext t o
degr ee n u m ber, a n d/or t h e degr ee displa yed is n ot
zer o, loosen bu t do n ot r em ove h old-down cla m p bolt .
Rot a t e oil pu m p dr ive u n t il IN RANGE a ppea r s on
scr een . Con t in u e t o r ot a t e oil pu m p dr ive u n t il
a ch ievin g a s close t o 0° a s possible.
Th e degr ee sca le on SE T SYNC scr een of DRB is
r efer r in g t o fu el syn ch r on iza t ion on ly. It is n o t
re fe rrin g to ig n itio n tim in g . Beca u se of t h is, do
n ot a t t em pt t o a dju st ign it ion t im in g u sin g t h is
m et h od. Rot a t in g oil pu m p dr ive will h a ve n o effect
on ign it ion t im in g. All ign it ion t im in g va lu es a r e con -
t r olled by power t r a in con t r ol m odu le (P CM).
(15) Tigh t en h old-down cla m p bolt t o 23 N·m (17
ft . lbs.) t or qu e.

INSTALLATION - 4.7L
Th e Ca m sh a ft P osit ion Sen sor (CMP ) on t h e 4.7L
V–8 en gin e is bolt ed t o t h e fr on t /t op of t h e r igh t cyl-
in der h ea d (F ig. 10).
(1) Clea n ou t m a ch in ed h ole in cylin der h ea d.
Fig. 11 Ignition Coil Assembly—4.0L 6–Cylinder
(2) Apply a sm a ll a m ou n t of en gin e oil t o sen sor
Engine
o-r in g.
1 - CYL. #6
(3) In st a ll sen sor in t o cylin der h ea d wit h a sligh t
2 - CYL. #5
r ockin g a ct ion . Do n ot t wist sen sor in t o posit ion a s
3 - CYL. #4
da m a ge t o o-r in g m a y r esu lt . 4 - CYL. #3
5 - CYL. #2
CAUTION: Before tightening sensor mounting bolt, 6 - CYL. #1
be sure sensor is completely flush to cylinder head. 7 - COILS (3)
If sensor is not flush, damage to sensor mounting 8 - MOUNTING BOLTS (4)
tang may result. 9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
(4) In st a ll m ou n t in g bolt a n d t igh t en t o 12 N·m
(106 in . lbs.) t or qu e.
(5) Con n ect elect r ica l con n ect or t o sen sor.
(6) Lower veh icle.

COI L RAI L
DESCRIPTION
A on e-piece coil r a il a ssem bly con t a in in g t h r ee
in dividu a l coils is u sed on t h e 4.0L 6–cylin der en gin e
(F ig. 11). Th e coil r a il m u st be r epla ced a s on e
a ssem bly. Th e bot t om of t h e coil is equ ipped wit h 6
in dividu a l r u bber boot s (F ig. 11) t o sea l t h e 6 spa r k
plu gs t o t h e coil. In side ea ch r u bber boot is a spr in g.
Th e spr in g is u sed for a m ech a n ica l con t a ct bet ween
t h e coil a n d t h e t op of t h e spa r k plu g. Th ese r u bber
boot s a n d spr in gs a r e a per m a n en t pa r t of t h e coil Fig. 12 Coil Location—4.0L Engine
a n d a r e n ot ser viced sepa r a t ely.
1 - COIL RAIL
(1) Th e coil is bolt ed dir ect ly t o t h e cylin der h ea d
2 - COIL MOUNTING BOLTS (4)
(F ig. 12). On e elect r ica l con n ect or (loca t ed a t r ea r of 3 - COIL
coil) is u sed for a ll t h r ee coils. 4 - COIL ELECTRICAL CONNECTION
8I - 10 IGNITION CONTROL WJ
COI L RAI L (Cont inue d)

OPERATION
Alt h ou gh cylin der fir in g or der is t h e sa m e a s 4.0L
J eep en gin es of pr eviou s yea r s, spa r k plu g fir in g is
n ot . Th e 3 coils du a l-fir e t h e spa r k plu gs on cylin der s
1-6, 2-5 a n d/or 3-4. Wh en on e cylin der is bein g fir ed
(on com pr ession st r oke), t h e spa r k t o t h e opposit e
cylin der is bein g wa st ed (on exh a u st st r oke).
Ba t t er y volt a ge is su pplied t o t h e t h r ee ign it ion
coils fr om t h e ASD r ela y. Th e P ower t r a in Con t r ol
Modu le (P CM) open s a n d closes t h e ign it ion coil
gr ou n d cir cu it for ign it ion coil oper a t ion .
B a s e ig n itio n tim in g is n o t a d ju s ta ble . By con -
t r ollin g t h e coil gr ou n d cir cu it , t h e P CM is a ble t o set
t h e ba se t im in g a n d a dju st t h e ign it ion t im in g
a dva n ce. Th is is don e t o m eet ch a n gin g en gin e oper-
a t in g con dit ion s.
Th e ign it ion coil is n ot oil filled. Th e win din gs a r e
em bedded in a n epoxy com pou n d. Th is pr ovides h ea t
a n d vibr a t ion r esist a n ce t h a t a llows t h e ign it ion coil
t o be m ou n t ed on t h e en gin e.
Beca u se of coil design , spa r k plu g ca bles (secon d- Fig. 13 Ignition Coil Assembly—4.0L 6–Cylinder
a r y ca bles) a r e n ot u sed. Th e ca bles a r e in t egr a l Engine
wit h in t h e coil r a il.
1 - CYL. #6
2 - CYL. #5
REMOVAL 3 - CYL. #4
A on e-piece coil r a il a ssem bly con t a in in g t h r ee 4 - CYL. #3
in dividu a l coils is u sed on t h e 4.0L en gin e (F ig. 13). 5 - CYL. #2
Th e coil r a il m u st be r epla ced a s on e a ssem bly. Th e 6 - CYL. #1
bot t om of t h e coil is equ ipped wit h 6 in dividu a l r u b- 7 - COILS (3)
ber boot s (F ig. 13) t o sea l t h e 6 spa r k plu gs t o t h e 8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
coil. In side ea ch r u bber boot is a spr in g. Th e spr in g
10 - RUBBER BOOTS (6)
is u sed for a n elect r ica l con t a ct bet ween t h e coil a n d
t h e t op of t h e spa r k plu g. Th ese r u bber boot s a n d
spr in gs a r e a per m a n en t pa r t of t h e coil a n d a r e n ot
ser viced sepa r a t ely.
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Th e coil is bolt ed dir ect ly t o t h e cylin der h ea d.
Rem ove 4 coil m ou n t in g bolt s (F ig. 14).
(3) Ca r efu lly pr y u p coil a ssem bly fr om spa r k
plu gs. Do t h is by pr yin g a lt er n a t ely a t ea ch en d of
coil u n t il r u bber boot s h a ve disen ga ged fr om a ll
spa r k plu gs. If boot s will n ot r elea se fr om spa r k
plu gs, u se a com m er cia lly a va ila ble spa r k plu g boot
r em ova l t ool. Twist a n d loosen a few boot s fr om a few
spa r k plu gs t o h elp r em ove coil.
(4) Aft er coil h a s clea r ed spa r k plu gs, posit ion coil
for a ccess t o pr im a r y elect r ica l con n ect or. Discon n ect
con n ect or fr om coil by pu sh in g slide t a b ou t wa r ds t o
r igh t side of veh icle (F ig. 15). Aft er slide t a b h a s been
posit ion ed ou t wa r ds, pu sh in on secon da r y r elea se Fig. 14 Ignition Coil Rail Location—4.0L 6–Cylinder
lock (F ig. 15) on side of con n ect or a n d pu ll con n ect or Engine
fr om coil. 1 - COIL RAIL
(5) Rem ove coil fr om veh icle. 2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
WJ IGNITION CONTROL 8I - 11
COI L RAI L (Cont inue d)

Fig. 16 Ignition Coil—4.7L Engine

1 - O-RING
2 - IGNITION COIL
3 - ELECTRICAL CONNECTOR
Fig. 15 Ignition Coil Electrical Connector—4.0L
6–Cylinder Engine
1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - SLIDE TAB
4 - RELEASE LOCK
5 - COIL CONNECTOR

INSTALLATION
(1) Con n ect en gin e h a r n ess con n ect or t o coil by
sn a ppin g in t o posit ion . Move slide t a b t owa r ds
en gin e (F ig. 15) for a posit ive lock.
(2) P osit ion ign it ion coil r u bber boot s t o a ll spa r k
plu gs. P u sh down on coil a ssem bly u n t il bolt ba ses
h a ve con t a ct ed cylin der h ea d
(3) In st a ll 4 coil m ou n t in g bolt s. Loosely t igh t en 4
bolt s ju st en ou gh t o a llow bolt ba ses t o con t a ct cylin -
der h ea d. Do a fin a l t igh t en in g of ea ch bolt in st eps
down t o 29 N·m (250 in . lbs.) t or qu e. Do n ot a pply
fu ll t or qu e t o a n y bolt fir st .
(4) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.

I GN I T I ON COI L Fig. 17 Ignition Coil Location—4.7L Engine

1 - IGNITION COIL
DESCRIPTION 2 - COIL ELECTRICAL CONNECTOR
Th e 4.7L V–8 en gin e u ses 8 dedica t ed, a n d in divid- 3 - COIL MOUNTING STUD/NUT
u a lly fir ed coil (F ig. 16) for ea ch spa r k plu g. E a ch
coil is m ou n t ed dir ect ly t o t h e t op of ea ch spa r k plu g
(F ig. 17).
8I - 12 IGNITION CONTROL WJ
I GN I T I ON COI L (Cont inue d)

OPERATION
Ba t t er y volt a ge is su pplied t o t h e 8 ign it ion coils
fr om t h e ASD r ela y. Th e P ower t r a in Con t r ol Modu le
(P CM) open s a n d closes ea ch ign it ion coil gr ou n d cir-
cu it a t a det er m in ed t im e for ign it ion coil oper a t ion .
B a s e ig n itio n tim in g is n o t a d ju s ta ble . By con -
t r ollin g t h e coil gr ou n d cir cu it , t h e P CM is a ble t o set
t h e ba se t im in g a n d a dju st t h e ign it ion t im in g
a dva n ce. Th is is don e t o m eet ch a n gin g en gin e oper-
a t in g con dit ion s.
Th e ign it ion coil is n ot oil filled. Th e win din gs a r e
em bedded in a n epoxy com pou n d. Th is pr ovides h ea t
a n d vibr a t ion r esist a n ce t h a t a llows t h e ign it ion coil
t o be m ou n t ed on t h e en gin e.
Beca u se of coil design , spa r k plu g ca bles (secon d-
a r y ca bles) a r e n ot u sed.

REMOVAL
An in dividu a l ign it ion coil is u sed for ea ch spa r k Fig. 18 Ignition Coil—4.7L V–8
plu g (F ig. 18). Th e coil fit s in t o m a ch in ed h oles in t h e 1 - O-RING
cylin der h ea d. A m ou n t in g st u d/n u t secu r es ea ch coil 2 - IGNITION COIL
t o t h e t op of t h e in t a ke m a n ifold (F ig. 19). Th e bot - 3 - ELECTRICAL CONNECTOR
t om of t h e coil is equ ipped wit h a r u bber boot t o sea l
t h e spa r k plu g t o t h e coil. In side ea ch r u bber boot is
a spr in g. Th e spr in g is u sed for a m ech a n ica l con t a ct
bet ween t h e coil a n d t h e t op of t h e spa r k plu g. Th ese
r u bber boot s a n d spr in gs a r e a per m a n en t pa r t of t h e
coil a n d a r e n ot ser viced sepa r a t ely. An o-r in g (F ig.
18) is u sed t o sea l t h e coil a t t h e open in g in t o t h e cyl-
in der h ea d.
(1) Depen din g on wh ich coil is bein g r em oved, t h e
t h r ot t le body a ir in t a ke t u be or in t a ke box m a y n eed
t o be r em oved t o ga in a ccess t o coil.
(2) Discon n ect elect r ica l con n ect or (F ig. 19) fr om
coil by pu sh in g down wa r d on r elea se lock on t op of
con n ect or a n d pu ll con n ect or fr om coil.
(3) Clea n a r ea a t ba se of coil wit h com pr essed a ir
befor e r em ova l.
(4) Rem ove coil m ou n t in g n u t fr om m ou n t in g st u d
(F ig. 19).
(5) Ca r efu lly pu ll u p coil fr om cylin der h ea d open -
in g wit h a sligh t t wist in g a ct ion .
(6) Rem ove coil fr om veh icle.

INSTALLATION
(1) Usin g com pr essed a ir, blow ou t a n y dir t or con - Fig. 19 Ignition Coil
t a m in a n t s fr om a r ou n d t op of spa r k plu g. 1 - IGNITION COIL
(2) Ch eck con dit ion of coil o-r in g a n d r epla ce a s 2 - COIL ELECTRICAL CONNECTOR
n ecessa r y. To a id in coil in st a lla t ion , a pply silicon e t o 3 - COIL MOUNTING STUD/NUT
coil o-r in g.
(3) P osit ion ign it ion coil in t o cylin der h ea d open in g (5) Con n ect elect r ica l con n ect or t o coil by sn a ppin g
a n d pu sh on t o spa r k plu g. Do t h is wh ile gu idin g coil in t o posit ion .
ba se over m ou n t in g st u d. (6) If n ecessa r y, in st a ll t h r ot t le body a ir t u be or
(4) In st a ll m ou n t in g st u d n u t a n d t igh t en t o 8 N·m box.
(70 in . lbs.) t or qu e.
WJ
I GN I T I ON COI L CAPACI T OR
DESCRIPTION
Two coil ca pa cit or s a r e u sed. On e of t h em is
loca t ed n ea r t h e cen t er of, a n d on t h e left side of t h e
in t a ke m a n ifold (F ig. 20). Th e ot h er ca pa cit or is
loca t ed n ea r t h e cen t er of, a n d on t h e r igh t side of
t h e in t a ke m a n ifold.
Fig. 20 Coil Capacitor (Left Side Shown)
1 - ELECTRICAL CONNECTOR
2 - COIL CAPACITOR
3 - MOUNTING NUT
OPERATION
Th e 2 coil ca pa cit or s a r e u sed t o pr even t h igh -volt -
a ge spikes fr om in t er fer in g wit h t h e oper a t ion of cer-
t a in power t r a in sen sor s. Th ey a r e a lso u sed t o h elp
pr even t r a dio in t er fer en ce.
REMOVAL
Two coil ca pa cit or s a r e u sed. On e of t h em is
loca t ed n ea r t h e cen t er of, a n d on t h e left side of t h e
in t a ke m a n ifold (F ig. 21). Th e ot h er ca pa cit or is
loca t ed n ea r t h e cen t er of, a n d on t h e r igh t side of
t h e in t a ke m a n ifold.
(1) Discon n ect elect r ica l con n ect or a t coil ca pa cit or
(F ig. 21).
(2) Rem ove m ou n t in g n u t .
(3) Rem ove ca pa cit or fr om m ou n t in g st u d.
INSTALLATION
(1) P osit ion ca pa cit or t o m a n ifold m ou n t in g st u d.
IGNITION CONTROL 8I - 13
Fig. 21 Coil Capacitor (Left Side Shown)
1 - ELECTRICAL CONNECTOR
2 - COIL CAPACITOR
3 - MOUNTING NUT
(2) In st a ll n u t a n d t igh t en t o 8 N·m (70 in . lbs.)
t or qu e.
(3) Con n ect elect r ica l con n ect or t o ca pa cit or (F ig.
21).
K N OCK SEN SOR
DESCRIPTION
4.7L High-Output Engine
Th e 2 kn ock sen sor s a r e bolt ed in t o t h e cylin der
block u n der t h e in t a ke m a n ifold.
OPERATION
4.7L High-Output Engine
Two kn ock sen sor s a r e u sed on t h e 4.7L V-8 en gin e
if equ ipped wit h t h e h igh -ou t pu t pa cka ge; on e for
ea ch cylin der ba n k. Wh en t h e kn ock sen sor det ect s a
kn ock in on e of t h e cylin der s on t h e cor r espon din g
ba n k, it sen ds a n in pu t sign a l t o t h e P ower t r a in Con -
t r ol Modu le (P CM). In r espon se, t h e P CM r et a r ds
ign it ion t im in g for a ll cylin der s by a sch edu led
a m ou n t .
Kn ock sen sor s con t a in a piezoelect r ic m a t er ia l
wh ich con st a n t ly vibr a t es a n d sen ds a n in pu t volt a ge
(sign a l) t o t h e P CM wh ile t h e en gin e oper a t es. As t h e
in t en sit y of t h e cr yst a l’s vibr a t ion in cr ea ses, t h e
kn ock sen sor ou t pu t volt a ge a lso in cr ea ses.
8I - 14 IGNITION CONTROL WJ
K N OCK SEN SOR (Cont inue d)
Th e volt a ge sign a l pr odu ced by t h e kn ock sen sor
in cr ea ses wit h t h e a m plit u de of vibr a t ion . Th e P CM
r eceives t h e kn ock sen sor volt a ge sign a l a s a n in pu t .
If t h e sign a l r ises a bove a pr edet er m in ed level, t h e
P CM will st or e t h a t va lu e in m em or y a n d r et a r d
ign it ion t im in g t o r edu ce en gin e kn ock. If t h e kn ock
sen sor volt a ge exceeds a pr eset va lu e, t h e P CM
r et a r ds ign it ion t im in g for a ll cylin der s. It is n ot a
select ive cylin der r et a r d.
Th e P CM ign or es kn ock sen sor in pu t du r in g en gin e
idle con dit ion s. On ce t h e en gin e speed exceeds a
specified va lu e, kn ock r et a r d is a llowed.
Kn ock r et a r d u ses it s own sh or t t er m a n d lon g
t er m m em or y pr ogr a m .
Lon g t er m m em or y st or es pr eviou s det on a t ion
in for m a t ion in it s ba t t er y-ba cked RAM. Th e m a xi-
m u m a u t h or it y t h a t lon g t er m m em or y h a s over t im -
in g r et a r d ca n be ca libr a t ed.
Sh or t t er m m em or y is a llowed t o r et a r d t im in g u p
t o a pr eset a m ou n t u n der a ll oper a t in g con dit ion s (a s
lon g a s r pm is a bove t h e m in im u m r pm ) except a t
Wide Open Th r ot t le (WOT). Th e P CM, u sin g sh or t
t er m m em or y, ca n r espon d qu ickly t o r et a r d t im in g Fig. 22 KNOCK SENSOR LOCATION - 4.7L H.O.
wh en en gin e kn ock is det ect ed. Sh or t t er m m em or y 1 - KNOCK SENSORS (2)
is lost a n y t im e t h e ign it ion key is t u r n ed off. 2 - MOUNTING BOLTS
3 - INTAKE MANIFOLD (CUTAWAY)
NOTE: Over or under tightening the sensor mount- 4 - PIGTAIL CONNECTOR
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors.

REMOVAL
4.7L High-Output Engine Only
Th e 2 kn ock sen sor s a r e bolt ed in t o t h e cylin der
block u n der t h e in t a ke m a n ifold (F ig. 22).

NOTE: The left sensor is identified by an identifica-

tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.

(1) Discon n ect kn ock sen sor du a l pigt a il h a r n ess

con n ect or fr om en gin e wir in g h a r n ess con n ect or. Th is
con n ect ion is m a de n ea r t h e r igh t /r ea r of in t a ke m a n -
ifold (F ig. 23).
(2) Rem ove in t a ke m a n ifold. Refer t o E n gin e sec-
t ion .
(3) Rem ove sen sor m ou n t in g bolt s (F ig. 22). Not e Fig. 23 KNOCK SENSOR ELEC. CONNECTOR - 4.7L
foa m st r ip on bolt t h r ea ds. Th is foa m is u sed on ly t o H.O.
r et a in t h e bolt s t o sen sor s for pla n t a ssem bly. It is
1 - KNOCK SENSOR PIGTAIL HARNESS CONNECTOR
n ot u sed a s a sea la n t . Do n ot a pply a n y a dh esive, 2 - ENGINE WIRING HARNESS
sea la n t or t h r ea d lockin g com pou n d t o t h ese bolt s.
(4) Rem ove sen sor s fr om en gin e.
WJ IGNITION CONTROL 8I - 15
K N OCK SEN SOR (Cont inue d)

INSTALLATION s p a rk p lu g s . In a c c u ra te re a d in g s w ill re s u lt.

4.7L High-Output Engine Only
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Th or ou gh ly clea n kn ock sen sor m ou n t in g h oles.
(2) In st a ll sen sor s (F ig. 22) in t o cylin der block.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
Rem ove t h e spa r k plu gs a n d exa m in e t h em for
bu r n ed elect r odes a n d fou led, cr a cked or br oken por-
cela in in su la t or s. Keep plu gs a r r a n ged in t h e or der
in wh ich t h ey wer e r em oved fr om t h e en gin e. A sin -
gle plu g displa yin g a n a bn or m a l con dit ion in dica t es
t h a t a pr oblem exist s in t h e cor r espon din g cylin der.
Repla ce spa r k plu gs a t t h e in t er va ls r ecom m en ded in
Gr ou p O, Lu br ica t ion a n d Ma in t en a n ce.
EXCEP T 4.7L H.O. EN GIN E : Spa r k plu gs t h a t
h a ve low m ilea ge m a y be clea n ed a n d r eu sed if n ot
ot h er wise defect ive, ca r bon or oil fou led. Also r efer t o
Spa r k P lu g Con dit ion s. 4.7L H.O. EN GIN E : Never
clea n spa r k plu gs on t h e 4.7L H .O. en gin e. Da m a ge
t o t h e pla t in u m r ivet will r esu lt .
CAUTION: EXCEPT 4.7L H.O. ENGINE : Never use a
motorized wire wheel brush to clean the spark
plugs. Metallic deposits will remain on the spark
plug insulator and will cause plug misfire.
H.O. Ga p Ad ju s tm e n t: If equ ipped wit h t h e 4.7L
H .O. en gin e, do n ot u se a wir e-t ype ga ppin g t ool a s
da m a ge t o t h e pla t in u m r ivet on t h e cen t er elect r ode
m a y occu r. Use a t a per ed-t ype ga u ge (F ig. 24).

(3) In st a ll a n d t igh t en m ou n t in g bolt s. B o lt

to rqu e is c ritic a l. Refer t o t or qu e specifica t ion .
(4) In st a ll in t a ke m a n ifold. Refer t o E n gin e sec-
t ion .
(5) Con n ect kn ock sen sor pigt a il wir in g h a r n ess t o
en gin e wir in g h a r n ess n ea r r igh t / r ea r of in t a ke
m a n ifold (F ig. 23).

SPARK PLU G
DESCRIPTION
Bot h t h e 4.0L 6-cylin der a n d t h e 4.7L V-8 en gin e
u se r esist or t ype spa r k plu gs. St a n da r d 4.7L V-8
en gin es a r e equ ipped wit h “fir ed in su ppr essor sea l”
t ype spa r k plu gs u sin g a copper cor e gr ou n d elec-
t r ode. H igh -Ou t pu t (H .O.) 4.7L V-8 en gin es a r e
equ ipped wit h u n iqu e plu gs u sin g a pla t in u m r ivet
loca t ed on t h e t ip of t h e cen t er elect r ode.
Beca u se of t h e u se of a n a lu m in u m cylin der h ea d Fig. 24 PLUG GAP - 4.7L H.O.
on t h e 4.7L en gin e, spa r k plu g t or qu e is ver y cr it ica l. 1 - TAPER GAUGE
To pr even t possible pr e-ign it ion a n d/or m ech a n ica l
en gin e da m a ge, t h e cor r ect t ype/h ea t r a n ge/n u m ber
spa r k plu g m u st be u sed. D o n o t s u bs titu te a n y DIAGNOSIS AND TESTING - SPARK PLUG
o th e r s p a rk p lu g o n th e 4.7L H.O. e n g in e . S e ri- CONDITIONS
o u s e n g in e d a m a g e m a y o c c u r.
P lu gs on bot h en gin es h a ve r esist a n ce va lu es r a n g- NORMAL OPERATING
in g fr om 6,000 t o 20,000 oh m s (wh en ch ecked wit h a t Th e few deposit s pr esen t on t h e spa r k plu g will
lea st a 1000 volt spa r k plu g t est er ). D o n o t u s e a n pr oba bly be ligh t t a n or sligh t ly gr a y in color. Th is is
o h m m e te r to c h e c k th e re s is ta n c e v a lu e s o f th e eviden t wit h m ost gr a des of com m er cia l ga solin e
8I - 16 IGNITION CONTROL
SPARK PLU G (Cont inue d)
(F ig. 25). Th er e will n ot be eviden ce of elect r ode
bu r n in g. Ga p gr owt h will n ot a ver a ge m or e t h a n
a ppr oxim a t ely 0.025 m m (.001 in ) per 3200 km (2000
m iles) of oper a t ion .
Spa r k plu gs e x c e p t p la tin u m tip p e d t h a t h a ve
n or m a l wea r ca n u su a lly be clea n ed, h a ve t h e elec-
t r odes filed, h a ve t h e ga p set a n d t h en be in st a lled.
Fig. 25 NORMAL OPERATION AND COLD (CARBON)
FOULING
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
Som e fu el r efin er s in sever a l a r ea s of t h e Un it ed
St a t es h a ve in t r odu ced a m a n ga n ese a ddit ive (MMT)
for u n lea ded fu el. Du r in g com bu st ion , fu el wit h MMT
ca u ses t h e en t ir e t ip of t h e spa r k plu g t o be coa t ed
wit h a r u st color ed deposit . Th is r u st color ca n be
m isdia gn osed a s bein g ca u sed by coola n t in t h e com -
bu st ion ch a m ber. Spa r k plu g per for m a n ce m a y be
a ffect ed by MMT deposit s.
COLD FOULING/CARBON FOULING
Cold fou lin g is som et im es r efer r ed t o a s ca r bon
fou lin g. Th e deposit s t h a t ca u se cold fou lin g a r e ba si-
ca lly ca r bon (F ig. 25). A dr y, bla ck deposit on on e or
t wo plu gs in a set m a y be ca u sed by st ickin g va lves
or defect ive spa r k plu g ca bles. Cold (ca r bon ) fou lin g
of t h e en t ir e set of spa r k plu gs m a y be ca u sed by a
clogged a ir clea n er elem en t or r epea t ed sh or t oper a t -
in g t im es (sh or t t r ips).
WET FOULING OR GAS FOULING
A spa r k plu g coa t ed wit h excessive wet fu el or oil
is wet fou led. In older en gin es, wor n pist on r in gs,
lea kin g va lve gu ide sea ls or excessive cylin der wea r
ca n ca u se wet fou lin g. In n ew or r ecen t ly over h a u led
en gin es, wet fou lin g m a y occu r befor e br ea k-in (n or-
m a l oil con t r ol) is a ch ieved. Th is con dit ion ca n u su -
WJ
a lly be r esolved by clea n in g a n d r ein st a llin g t h e
fou led plu gs.
OIL OR ASH ENCRUSTED
If on e or m or e spa r k plu gs a r e oil or oil a sh
en cr u st ed (F ig. 26), eva lu a t e en gin e con dit ion for t h e
ca u se of oil en t r y in t o t h a t pa r t icu la r com bu st ion
ch a m ber.
Fig. 26 OIL OR ASH ENCRUSTED
ELECTRODE GAP BRIDGING
E lect r ode ga p br idgin g m a y be t r a ced t o loose
deposit s in t h e com bu st ion ch a m ber. Th ese deposit s
a ccu m u la t e on t h e spa r k plu gs du r in g con t in u ou s
st op-a n d-go dr ivin g. Wh en t h e en gin e is su dden ly
su bject ed t o a h igh t or qu e loa d, deposit s pa r t ia lly liq-
u efy a n d br idge t h e ga p bet ween elect r odes (F ig. 27).
Th is sh or t cir cu it s t h e elect r odes. Spa r k plu gs wit h
elect r ode ga p br idgin g ca n be clea n ed u sin g st a n da r d
pr ocedu r es.
SCAVENGER DEPOSITS
F u el sca ven ger deposit s m a y be eit h er wh it e or yel-
low (F ig. 28). Th ey m a y a ppea r t o be h a r m fu l, bu t
t h is is a n or m a l con dit ion ca u sed by ch em ica l a ddi-
t ives in cer t a in fu els. Th ese a ddit ives a r e design ed t o
ch a n ge t h e ch em ica l n a t u r e of deposit s a n d decr ea se
spa r k plu g m isfir e t en den cies. Not ice t h a t a ccu m u la -
t ion on t h e gr ou n d elect r ode a n d sh ell a r ea m a y be
h ea vy, bu t t h e deposit s a r e ea sily r em oved. Spa r k
plu gs wit h sca ven ger deposit s ca n be con sider ed n or-
m a l in con dit ion a n d ca n be clea n ed u sin g st a n da r d
pr ocedu r es.
WJ IGNITION CONTROL 8I - 17
SPARK PLU G (Cont inue d)

Fig. 27 ELECTRODE GAP BRIDGING Fig. 29 CHIPPED ELECTRODE INSULATOR

1 - GROUND ELECTRODE 1 - GROUND ELECTRODE
2 - DEPOSITS 2 - CENTER ELECTRODE
3 - CENTER ELECTRODE 3 - CHIPPED INSULATOR

Det er m in e if ign it ion t im in g is over a dva n ced or if

ot h er oper a t in g con dit ion s a r e ca u sin g en gin e over-
h ea t in g. (Th e h ea t r a n ge r a t in g r efer s t o t h e oper a t -
in g t em per a t u r e of a pa r t icu la r t ype spa r k plu g.
Spa r k plu gs a r e design ed t o oper a t e wit h in specific
t em per a t u r e r a n ges. Th is depen ds u pon t h e t h ick-
n ess a n d len gt h of t h e cen t er elect r odes por cela in
in su la t or.)

CAUTION: If the engine is equipped with copper

core ground electrode, or platinum tipped spark
plugs, they must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.

Fig. 28 SCAVENGER DEPOSITS

1 - GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
2 - CENTER ELECTRODE

CHIPPED ELECTRODE INSULATOR

A ch ipped elect r ode in su la t or u su a lly r esu lt s fr om
ben din g t h e cen t er elect r ode wh ile a dju st in g t h e
spa r k plu g elect r ode ga p. Un der cer t a in con dit ion s,
sever e det on a t ion ca n a lso sepa r a t e t h e in su la t or
fr om t h e cen t er elect r ode (F ig. 29). Spa r k plu gs wit h
t h is con dit ion m u st be r epla ced.

PRE-IGNITION DAMAGE
P r e-ign it ion da m a ge is u su a lly ca u sed by excessive Fig. 30 PRE-IGNITION DAMAGE
com bu st ion ch a m ber t em per a t u r e. Th e cen t er elec- 1 - GROUND ELECTRODE STARTING TO DISSOLVE
t r ode dissolves fir st a n d t h e gr ou n d elect r ode dis- 2 - CENTER ELECTRODE DISSOLVED
solves som ewh a t la t t er (F ig. 30). In su la t or s a ppea r
r ela t ively deposit fr ee. Det er m in e if t h e spa r k plu g
h a s t h e cor r ect h ea t r a n ge r a t in g for t h e en gin e.
8I - 18 IGNITION CONTROL
SPARK PLU G (Cont inue d)
SPARK PLUG OVERHEATING
Over h ea t in g is in dica t ed by a wh it e or gr a y cen t er
elect r ode in su la t or t h a t a lso a ppea r s blist er ed (F ig.
31). Th e in cr ea se in elect r ode ga p will be con sider-
a bly in excess of 0.001 in ch per 2000 m iles of oper a -
t ion . Th is su ggest s t h a t a plu g wit h a cooler h ea t
r a n ge r a t in g sh ou ld be u sed. Over a dva n ced ign it ion
t im in g, det on a t ion a n d coolin g syst em m a lfu n ct ion s
ca n a lso ca u se spa r k plu g over h ea t in g.
CAUTION: If the engine is equipped with copper
core ground electrode, or platinum tipped spark
plugs, they must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.
Fig. 31 SPARK PLUG OVERHEATING
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
REMOVAL
CAUTION: If equipped with a 4.7L H.O. (High-Out-
put) engine, never substitute the original platinum
tipped spark plug with a different part number. Seri-
ous engine damage may result.
On t h e 4.0L 6–cylin der en gin e, t h e spa r k plu gs a r e
loca t ed below t h e coil r a il a ssem bly. On t h e 4.7L V–8
en gin e, ea ch in dividu a l spa r k plu g is loca t ed u n der
ea ch ign it ion coil.
(1) 4.0L 6–Cylin der E n gin e: P r ior t o r em ovin g
spa r k plu g, spr a y com pr essed a ir a r ou n d spa r k plu g
h ole a n d a r ea a r ou n d spa r k plu g. Th is will h elp pr e-
ven t for eign m a t er ia l fr om en t er in g com bu st ion
ch a m ber.
(2) 4.7L V–8 E n gin e: P r ior t o r em ovin g spa r k plu g,
spr a y com pr essed a ir a r ou n d ba se of ign it ion coil a t
cylin der h ea d. Th is will h elp pr even t for eign m a t er ia l
fr om en t er in g com bu st ion ch a m ber.
(3) On t h e 4.0L en gin e t h e coil r a il a ssem bly m u st
be r em oved t o ga in a ccess t o a n y/a ll spa r k plu g.
Refer t o Ign it ion Coil Rem ova l/In st a lla t ion . On t h e
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4.7L V-8 en gin e ea ch in dividu a l ign it ion coil m u st be
r em oved t o ga in a ccess t o ea ch spa r k plu g. Refer t o
Ign it ion Coil Rem ova l/In st a lla t ion .
(4) Rem ove spa r k plu g fr om cylin der h ea d u sin g a
qu a lit y socket wit h a r u bber or foa m in ser t . If
equ ipped wit h a 4.7L V-8 en gin e, a lso ch eck con dit ion
of coil o-r in g a n d r epla ce a s n ecessa r y.
(5) In spect spa r k plu g con dit ion . Refer t o Spa r k
P lu g Con dit ion s.
CLEANING
Ex c e p t 4.7L H.O. En g in e : Th e plu gs m a y be
clea n ed u sin g com m er cia lly a va ila ble spa r k plu g
clea n in g equ ipm en t . Aft er clea n in g, file cen t er elec-
t r ode fla t wit h a sm a ll poin t file or jeweler s file
befor e a dju st in g ga p.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
4.7L H.O. En g in e : Never clea n spa r k plu gs on t h e
4.7L H .O. en gin e. Da m a ge t o t h e pla t in u m r ivet on
t h e cen t er elect r ode will r esu lt .
INSTALLATION
CAUTION: The standard 4.7L V-8 engine is
equipped with copper core ground electrode spark
plugs. They must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.
CAUTION: If equipped with a 4.7L H.O. (High-Out-
put) engine, never substitute the original platinum
tipped spark plug with a different type/part number.
Serious engine damage may result.
Specia l ca r e sh ou ld be t a ken wh en in st a llin g spa r k
plu gs in t o cylin der h ea d spa r k plu g wells. Be su r e
plu gs do n ot dr op in t o plu g wells a s gr ou n d st r a ps
m a y be ben t r esu lt in g in a ch a n ge in plu g ga p, or
elect r odes ca n be da m a ged.
Alwa ys t igh t en spa r k plu gs t o specified t or qu e. Over
t igh t en in g ca n ca u se dist or t ion r esu lt in g in a ch a n ge
in spa r k plu g ga p or a cr a cked por cela in in su la t or.
(1) St a r t spa r k plu g in t o cylin der h ea d by h a n d t o
a void cr oss t h r ea din g.
(2) 4.0L 6–Cylin der E n gin e: Tigh t en spa r k plu gs t o
35-41 N·m (26-30 ft . lbs.) t or qu e.
(3) 4.7L V–8 E n gin e: Tigh t en spa r k plu gs t o 27
N·m (20 ft . lbs.) t or qu e.
(4) 4.7L V–8 E n gin e: Befor e in st a llin g coil(s), ch eck
con dit ion of coil o-r in g a n d r epla ce a s n ecessa r y. To a id
in coil in st a lla t ion , a pply silicon e t o coil o-r in g.
(5) In st a ll ign it ion coil(s). Refer t o Ign it ion Coil
Rem ova l/In st a lla t ion .
WJ INSTRUMENT CLUSTER 8J - 1

INSTRUMENT CLUSTER
TABLE OF CON T EN T S

page page

INSTRUMENT CLUSTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ODOMETER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - INSTRUMENT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 OIL PRESSURE GAUGE
REMOVAL .............................9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OVERDRIVE OFF INDICATOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
ABS INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 REAR FOG LAMP INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
AIRBAG INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 SEATBELT INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
BRAKE/PARK BRAKE INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 SHIFT INDICATOR (TRANSFER CASE)
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - BRAKE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SKIS INDICATOR
CHECK GAUGES INDICATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SPEEDOMETER
COOLANT LOW INDICATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TACHOMETER
CRUISE INDICATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRANS TEMP INDICATOR
ENGINE TEMPERATURE GAUGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TURN SIGNAL INDICATOR
FRONT FOG LAMP INDICATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DIAGNOSIS AND TESTING - TURN SIGNAL
FUEL GAUGE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 VOLTAGE GAUGE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
HIGH BEAM INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 WAIT-TO-START INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
LOW FUEL INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 WATER-IN-FUEL INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
MALFUNCTION INDICATOR LAMP (MIL) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
8J - 2 INSTRUMENT CLUSTER
I N ST RU M EN T CLU ST ER
DESCRIPTION
Fig. 1 Instrument Cluster
1 - INSTRUMENT PANEL TOP PAD HOOD FORMATION
2 - INSTRUMENT CLUSTER
3 - CLUSTER BEZEL
Th e in st r u m en t clu st er for t h is m odel is a n E lec-
t r oMech a n ica l In st r u m en t Clu st er (E MIC) m odu le
t h a t is loca t ed in t h e in st r u m en t pa n el a bove t h e
st eer in g colu m n open in g, dir ect ly in fr on t of t h e
dr iver (F ig. 1). Th e r em a in der of t h e E MIC, in clu din g
t h e m ou n t s a n d t h e elect r ica l con n ect ion s, a r e con -
cea led beh in d t h e clu st er bezel. Th e E MIC ga u ges
a n d in dica t or s a r e pr ot ect ed by a n in t egr a l clea r
pla st ic clu st er len s, a n d a r e visible t h r ou gh a dedi-
ca t ed h ooded open in g in t h e in st r u m en t pa n el t op
pa d. J u st beh in d a n d in t egr a l t o t h e clu st er len s a r e
t h e clu st er h ood a n d clu st er m a sk, wh ich a r e con -
st r u ct ed of m olded bla ck pla st ic. Two clu st er m a sks
a r e u sed: A ba se ver sion fea t u r es a bla ck m a t t e fa ce
a n d n o t r im r in g a r ou n d t h e per im et er of ea ch ga u ge
open in g, wh ile a pr em iu m ver sion fea t u r es a bla ck
m a t t e fa ce a n d a r a ised t r im r in g a r ou n d t h e per im -
et er of ea ch ga u ge open in g. Th e clu st er h ood ser ves
a s a visor a n d sh ields t h e fa ce of t h e clu st er fr om
a m bien t ligh t a n d r eflect ion s t o r edu ce gla r e, wh ile
t h e clu st er m a sk ser ves t o sepa r a t e a n d defin e t h e
in dividu a l ga u ges of t h e E MIC. On t h e lower edge of
t h e clu st er len s ju st r igh t of t h e speedom et er, t h e
bla ck pla st ic odom et er /t r ip odom et er swit ch bu t t on
pr ot r u des t h r ou gh dedica t ed h oles in t h e clu st er
m a sk a n d t h e clu st er len s. Th e m olded pla st ic E MIC
len s, h ood a n d m a sk u n it h a s fou r in t egr a l m ou n t in g
t a bs, t wo t a bs ext en d down ver t ica lly fr om t h e lower
edge of t h e u n it a n d t wo t a bs ext en d h or izon t a lly
r ea r wa r d fr om t h e u pper su r fa ce of t h e h ood. Th e
t wo lower m ou n t in g t a bs a r e u sed t o secu r e t h e
WJ
E MIC t o t h e m olded pla st ic in st r u m en t pa n el clu st er
ca r r ier wit h t wo scr ews, wh ile t h e t wo u pper t a bs a r e
secu r ed t o t h e u n der side of t h e h ood for m a t ion of t h e
in st r u m en t pa n el t op pa d wit h t wo scr ews. A sin gle
m olded con n ect or r ecept a cle loca t ed on t h e E MIC
elect r on ic cir cu it boa r d is a ccessed fr om t h e ba ck of
t h e clu st er h ou sin g a n d is con n ect ed t o t h e veh icle
elect r ica l syst em t h r ou gh a sin gle dedica t ed t a ke ou t
a n d con n ect or of t h e in st r u m en t pa n el wir e h a r n ess.
Th e clu st er m a sk fea t u r es t wo la r ge r ou n d open -
in gs n ea r it s cen t er t h r ou gh wh ich t h e t wo m a jor
ga u ges a r e visible, a n d t wo sm a ller r ou n d open in gs
st a cked a t t h e ou t boa r d side of ea ch of t h e la r ge
open in gs t h r ou gh wh ich t h e fou r m in or ga u ges a r e
visible. Th e clu st er m a sk a n d t h e dia l fa ces of t h e
ga u ges a r e la m in a t ed pla st ic u n it s. Th e da r k, visible
su r fa ce of t h e m a sk a n d t h e ga u ge dia l fa ces a r e t h e
ou t er la yer or over la y, wh ich is t r a n slu cen t . Th e
da r kn ess of t h is ou t er la yer pr even t s t h e clu st er fr om
a ppea r in g t oo clu t t er ed or bu sy by con cea lin g t h e
clu st er in dica t or s t h a t a r e n ot illu m in a t ed, wh ile t h e
t r a n slu cen ce of t h is la yer a llows t h ose in dica t or s a n d
icon s t h a t a r e illu m in a t ed t o be r ea dily visible. Th e
u n der lyin g la yer of t h e clu st er m a sk over la y is
opa qu e a n d a llows ligh t fr om t h e va r iou s in dica t or s
beh in d it t o be visible t h r ou gh t h e ou t er la yer of t h e
m a sk a n d ga u ge dia l fa ces on ly t h r ou gh pr edet er-
m in ed cu t ou t s. On t h e ba se in st r u m en t clu st er s t h e
gr a ph ics, in cr em en t s, a n d n u m er a ls on t h e ga u ge
fa ces a r e a lso t r a n slu cen t a n d illu m in a t ed fr om
beh in d, wh ile t h e or a n ge ga u ge poin t er s a r e illu m i-
n a t ed in t er n a lly. On t h e pr em iu m in st r u m en t clu s-
t er s t h e gr a ph ics, in cr em en t s, n u m er a ls a n d ga u ge
n eedles a r e opa qu e wh ile t h e r em a in der of t h e ga u ge
fa ces a r e t r a n slu cen t a n d illu m in a t ed fr om beh in d by
a n elect r o-lu m in escen t la m p. Th e E MIC elect r on ic
cir cu it r y is pr ot ect ed by a m olded pla st ic r ea r cover
t h a t fea t u r es sever a l r ou n d a ccess h oles for ser vice of
t h e in ca n descen t clu st er in dica t or a n d illu m in a t ion
ligh t in g la m ps a n d a la r ge r ect a n gu la r a ccess h ole
for t h e E MIC con n ect or r ecept a cle. Th e E MIC r ea r
cover is secu r ed t o t h e clu st er h ou sin g wit h scr ews,
wh ile t h e clu st er len s, h ood, a n d m a sk u n it is
secu r ed t o t h e clu st er h ou sin g wit h sever a l in t egr a l
pla st ic la t ch fea t u r es.
Twelve ver sion s of t h e E MIC m odu le a r e offer ed on
t h is m odel, t wo ba se a n d t en pr em iu m . Th ese ver-
sion s a ccom m oda t e a ll of t h e va r ia t ion s of opt ion a l
equ ipm en t a n d r egu la t or y r equ ir em en t s for t h e va r i-
ou s m a r ket s in wh ich t h e veh icle will be offer ed. Th is
m odu le u t ilizes in t egr a t ed cir cu it r y a n d in for m a t ion
ca r r ied on t h e P r ogr a m m a ble Com m u n ica t ion s In t er-
fa ce (P CI) da t a bu s n et wor k for con t r ol of a ll ga u ges
a n d m a n y of t h e in dica t or s. (Refer t o 8 - E LE CTRI-
CAL/E LE CTRONIC CONTROL MODULE S/COM-
MUNICATION - DE SCRIP TION - P CI BUS). Th e
WJ
I N ST RU M EN T CLU ST ER (Cont inue d)
E MIC a lso u ses sever a l h a r d wir ed in pu t s in or der t o
per for m it s m a n y fu n ct ion s. Th e E MIC m odu le in cor-
por a t es a blu e-gr een digit a l Va cu u m F lu or escen t Dis-
pla y (VF D) for displa yin g odom et er a n d t r ip
odom et er in for m a t ion .
Th e E MIC h ou ses six a n a log ga u ges a n d h a s pr o-
vision s for u p t o t wen t y in dica t or s (F ig. 2). Th e
E MIC in clu des t h e followin g a n a log ga u ges:
• Co o la n t Te m p e ra tu re Ga u g e
• F u e l Ga u g e
• Oil P re s s u re Ga u g e
• S p e e d o m e te r
• Ta c h o m e te r
• Vo lta g e Ga u g e
Som e of t h e E MIC in dica t or s a r e a u t om a t ica lly
con figu r ed wh en t h e E MIC is con n ect ed t o t h e veh i-
cle elect r ica l syst em for com pa t ibilit y wit h cer t a in
opt ion a l equ ipm en t or equ ipm en t r equ ir ed for r egu la -
t or y pu r poses in cer t a in m a r ket s. Wh ile ea ch E MIC
m a y h a ve pr ovision s for in dica t or s t o su ppor t ever y
a va ila ble opt ion , t h e con figu r a ble in dica t or s will n ot
be fu n ct ion a l in a veh icle t h a t does n ot h a ve t h e
equ ipm en t t h a t a n in dica t or su ppor t s. Th e E MIC
in clu des pr ovision s for t h e followin g in dica t or s (F ig.
2):
• Airba g In d ic a to r (w ith Airba g s o n ly )
• An tilo c k B ra k e S y s te m (AB S ) In d ic a to r
• B ra k e In d ic a to r
• Ch e c k Ga u g e s In d ic a to r
• Co o la n t Lo w In d ic a to r (w ith D ie s e l En g in e
o n ly )
• Cru is e In d ic a to r
• F o u r-Wh e e l D riv e P a rt Tim e In d ic a to r
(w ith S e le c -Tra c N VG-242 Tra n s fe r Ca s e o n ly )
• F ro n t F o g La m p In d ic a to r (w ith F ro n t F o g
La m p s o n ly )
• Hig h B e a m In d ic a to r
• Lo w F u e l In d ic a to r
• Ma lfu n c tio n In d ic a to r La m p (MIL)
• Ov e rd riv e -Off In d ic a to r (e x c e p t D ie s e l
En g in e )
• Re a r F o g La m p In d ic a to r (w ith Re a r F o g
La m p s o n ly )
• S e a tbe lt In d ic a to r
• S e n try Ke y Im m o bilize r S y s te m (S KIS )
In d ic a to r
• Tra n s m is s io n Ov e rte m p In d ic a to r (e x c e p t
D ie s e l En g in e )
INSTRUMENT CLUSTER 8J - 3
• Tu rn S ig n a l (Rig h t a n d Le ft) In d ic a to rs
• Wa it-To -S ta rt In d ic a to r (w ith D ie s e l En g in e
o n ly )
• Wa te r-In -F u e l In d ic a to r (w ith D ie s e l En g in e
o n ly )
Ma n y in dica t or s in t h e E MIC a r e illu m in a t ed by a
dedica t ed Ligh t E m it t in g Diode (LE D) t h a t is sol-
der ed on t o t h e E MIC elect r on ic cir cu it boa r d. Th e
LE Ds a r e n ot a va ila ble for ser vice r epla cem en t a n d,
if da m a ged or fa u lt y, t h e en t ir e E MIC m u st be
r epla ced. Ba se clu st er illu m in a t ion is a ccom plish ed
by dim m a ble in ca n descen t ba ck ligh t in g, wh ich illu -
m in a t es t h e ga u ges for visibilit y wh en t h e ext er ior
ligh t in g is t u r n ed on . P r em iu m clu st er illu m in a t ion
is a ccom plish ed by a dim m a ble elect r o-lu m in escen t
la m p t h a t is ser viced on ly a s a u n it wit h t h e E MIC.
E a ch of t h e in ca n descen t bu lbs is secu r ed by a n in t e-
gr a l bu lb h older t o t h e elect r on ic cir cu it boa r d fr om
t h e ba ck of t h e clu st er h ou sin g. Th e in ca n descen t
bu lb/bu lb h older u n it s a r e a va ila ble for ser vice
r epla cem en t .
H a r d wir ed cir cu it r y con n ect s t h e E MIC t o t h e
elect r ica l syst em of t h e veh icle. Th ese h a r d wir ed cir-
cu it s a r e in t egr a l t o sever a l wir e h a r n esses, wh ich
a r e r ou t ed t h r ou gh ou t t h e veh icle a n d r et a in ed by
m a n y differ en t m et h ods. Th ese cir cu it s m a y be con -
n ect ed t o ea ch ot h er, t o t h e veh icle elect r ica l syst em
a n d t o t h e E MIC t h r ou gh t h e u se of a com bin a t ion of
solder ed splices, splice block con n ect or s, a n d m a n y
differ en t t ypes of wir e h a r n ess t er m in a l con n ect or s
a n d in su la t or s. Refer t o t h e a ppr opr ia t e wir in g in for-
m a t ion . Th e wir in g in for m a t ion in clu des wir in g dia -
gr a m s, pr oper wir e a n d con n ect or r epa ir pr ocedu r es,
fu r t h er det a ils on wir e h a r n ess r ou t in g a n d r et en -
t ion , a s well a s pin -ou t a n d loca t ion views for t h e
va r iou s wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
Th e E MIC m odu les for t h is m odel a r e ser viced on ly
a s com plet e u n it s. Th e E MIC m odu le ca n n ot be
a dju st ed or r epa ir ed. If a ga u ge, a n LE D in dica t or,
t h e VF D, t h e elect r on ic cir cu it boa r d, t h e cir cu it
boa r d h a r dwa r e, t h e clu st er over la y, t h e elect r o-lu m i-
n escen t la m p (pr em iu m m odel on ly) or t h e E MIC
h ou sin g a r e da m a ged or fa u lt y, t h e en t ir e E MIC m od-
u le m u st be r epla ced. Th e clu st er len s, h ood a n d
m a sk u n it a n d t h e in dividu a l in ca n descen t la m p
bu lbs wit h h older s a r e a va ila ble for ser vice r epla ce-
m en t .
8J - 4 INSTRUMENT CLUSTER WJ
I N ST RU M EN T CLU ST ER (Cont inue d)

Fig. 2 EMIC Gauges & Indicators

1 - BRAKE INDICATOR 15 - TRANSMISSION OVERTEMP INDICATOR
2 - REAR FOG LAMP INDICATOR 16 - PART TIME 4WD INDICATOR
3 - WATER-IN-FUEL INDICATOR 17 - CHECK GAUGES INDICATOR
4 - VOLTAGE GAUGE 18 - ENGINE TEMPERATURE GAUGE
5 - LEFT TURN INDICATOR 19 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
6 - TACHOMETER 20 - ODOMETER/TRIP ODOMETER DISPLAY
7 - HIGH BEAM INDICATOR 21 - WAIT-TO-START INDICATOR
8 - AIRBAG INDICATOR 22 - OVERDRIVE-OFF INDICATOR
9 - SPEEDOMETER 23 - SEATBELT INDICATOR
10 - RIGHT TURN INDICATOR 24 - ABS INDICATOR
11 - OIL PRESSURE GAUGE 25 - FUEL GAUGE
12 - SKIS INDICATOR 26 - FRONT FOG LAMP INDICATOR
13 - MALFUNCTION INDICATOR LAMP (MIL) 27 - LOW FUEL INDICATOR
14 - CRUISE INDICATOR 28 - COOLANT LOW INDICATOR

OPERATION u les over t h e P r ogr a m m a ble Com m u n ica t ion s

Th e E lect r oMech a n ica l In st r u m en t Clu st er (E MIC)
is design ed t o a llow t h e veh icle oper a t or t o m on it or
t h e con dit ion s of m a n y of t h e veh icle com pon en t s a n d
oper a t in g syst em s. Th e ga u ges a n d in dica t or s in t h e
E MIC pr ovide va lu a ble in for m a t ion a bou t t h e va r iou s
st a n da r d a n d opt ion a l power t r a in s, fu el a n d em is-
sion s syst em s, coolin g syst em s, ligh t in g syst em s,
sa fet y syst em s a n d m a n y ot h er con ven ien ce it em s.
Th e E MIC is in st a lled in t h e in st r u m en t pa n el so
t h a t a ll of t h ese m on it or s ca n be ea sily viewed by t h e
veh icle oper a t or wh en dr ivin g, wh ile st ill a llowin g
r ela t ive ea se of a ccess for ser vice. Th e m icr opr oces-
sor-ba sed E MIC h a r dwa r e a n d soft wa r e u ses va r iou s
in pu t s t o con t r ol t h e ga u ges a n d in dica t or s visible on
t h e fa ce of t h e clu st er. Som e of t h ese in pu t s a r e h a r d
wir ed, bu t m ost a r e in t h e for m of elect r on ic m es-
sa ges t h a t a r e t r a n sm it t ed by ot h er elect r on ic m od-
In t er fa ce (P CI) da t a bu s n et wor k. (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/COMMUNICATION - OP E RATION).
Th e E MIC m icr opr ocessor sm oot h s t h e in pu t da t a
u sin g a lgor it h m s t o pr ovide ga u ge r ea din gs t h a t a r e
a ccu r a t e, st a ble a n d r espon sive t o oper a t in g con di-
t ion s. Th ese a lgor it h m s a r e design ed t o pr ovide
ga u ge r ea din gs du r in g n or m a l oper a t ion t h a t a r e con -
sist en t wit h cu st om er expect a t ion s. H owever, wh en
a bn or m a l con dit ion s exist , su ch a s low or h igh ba t -
t er y volt a ge, low oil pr essu r e or h igh coola n t t em per-
a t u r e, t h e a lgor it h m ca n dr ive t h e ga u ge poin t er t o
a n ext r em e posit ion a n d t h e m icr opr ocessor t u r n s on
t h e Ch eck Ga u ges in dica t or t o pr ovide a dist in ct
visu a l in dica t ion of a pr oblem t o t h e veh icle oper a t or.
Th e in st r u m en t clu st er cir cu it r y a lso sen ds elect r on ic
ch im e t on e r equ est m essa ges over t h e P CI da t a bu s
t o t h e Body Con t r ol Modu le (BCM) wh en it m on it or s
WJ
I N ST RU M EN T CLU ST ER (Cont inue d)
cer t a in con dit ion s or in pu t s t o pr ovide t h e veh icle
oper a t or wit h a n a u dible a ler t t o su pplem en t a visu a l
in dica t ion .
Th e E MIC cir cu it r y oper a t es on ba t t er y cu r r en t
r eceived t h r ou gh fu sed B(+) fu ses in t h e P ower Dis-
t r ibu t ion Cen t er (P DC) a n d t h e J u n ct ion Block (J B)
on a n on -swit ch ed fu sed B(+) cir cu it , a n d on ba t t er y
cu r r en t r eceived t h r ou gh a fu sed ign it ion swit ch ou t -
pu t (r u n -st a r t ) fu se in t h e J B on a fu sed ign it ion
swit ch ou t pu t (r u n -st a r t ) cir cu it . Th is a r r a n gem en t
a llows t h e E MIC t o pr ovide som e fea t u r es r ega r dless
of t h e ign it ion swit ch posit ion , wh ile ot h er fea t u r es
will oper a t e on ly wit h t h e ign it ion swit ch in t h e On
or St a r t posit ion s. Th e E MIC cir cu it r y is gr ou n ded
t h r ou gh t wo sepa r a t e gr ou n d cir cu it s of t h e in st r u -
m en t pa n el wir e h a r n ess. Th ese gr ou n d cir cu it s
r eceive gr ou n d t h r ou gh t a ke ou t s of t h e in st r u m en t
pa n el wir e h a r n ess wit h eyelet t er m in a l con n ect or s
t h a t a r e secu r ed by a n u t t o a gr ou n d st u d loca t ed on
t h e floor pa n el t r a n sm ission t u n n el ben ea t h t h e cen -
t er floor con sole, ju st for wa r d of t h e Air ba g Con t r ol
Modu le (ACM).
Th e E MIC a lso h a s a self-dia gn ost ic a ct u a t or t est
ca pa bilit y, wh ich will t est ea ch of t h e P CI bu s m es-
sa ge-con t r olled fu n ct ion s of t h e clu st er by ligh t in g
t h e a ppr opr ia t e in dica t or s (except t h e a ir ba g in dica -
t or ), sweepin g t h e ga u ge n eedles a cr oss t h e ga u ge
fa ces fr om t h eir m in im u m t o t h eir m a xim u m r ea d-
in gs, a n d st eppin g t h e odom et er displa y sequ en t ia lly
fr om a ll zer os t h r ou gh a ll n in es. (Refer t o 8 - E LE C-
TRICAL/INSTRUME NT CLUSTE R - DIAGNOSIS
AND TE STING). Th e self-dia gn ost ic a ct u a t or t est
ca n be in it ia lized m a n u a lly or u sin g a DRBIII! sca n
t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e E MIC.
GAUGES
All ga u ges r eceive ba t t er y cu r r en t t h r ou gh t h e
E MIC cir cu it r y wh en t h e ign it ion swit ch is in t h e On
or St a r t posit ion s. Wit h t h e ign it ion swit ch in t h e Off
posit ion ba t t er y cu r r en t is n ot su pplied t o a n y
ga u ges, a n d t h e E MIC cir cu it r y is pr ogr a m m ed t o
m ove a ll of t h e ga u ge n eedles ba ck t o t h e low en d of
t h eir r espect ive sca les. Th er efor e, t h e ga u ges do n ot
a ccu r a t ely in dica t e a n y veh icle con dit ion u n less t h e
ign it ion swit ch is in t h e On or St a r t posit ion s. All of
t h e E MIC ga u ges, except t h e odom et er, a r e a ir cor e
m a gn et ic u n it s. Two fixed elect r om a gn et ic coils a r e
loca t ed wit h in ea ch ga u ge. Th ese coils a r e wr a pped
a t r igh t a n gles t o ea ch ot h er a r ou n d a m ova ble per-
m a n en t m a gn et . Th e m ova ble m a gn et is su spen ded
wit h in t h e coils on on e en d of a pivot sh a ft , wh ile t h e
ga u ge n eedle is a t t a ch ed t o t h e ot h er en d of t h e
sh a ft . On e of t h e coils h a s a fixed cu r r en t flowin g
INSTRUMENT CLUSTER 8J - 5
t h r ou gh it t o m a in t a in a con st a n t m a gn et ic field
st r en gt h . Cu r r en t flow t h r ou gh t h e secon d coil
ch a n ges, wh ich ca u ses ch a n ges in it s m a gn et ic field
st r en gt h . Th e cu r r en t flowin g t h r ou gh t h e secon d coil
is ch a n ged by t h e E MIC cir cu it r y in r espon se t o m es-
sa ges r eceived over t h e P CI da t a bu s. Th e ga u ge n ee-
dle m oves a s t h e m ova ble per m a n en t m a gn et a lign s
it self t o t h e ch a n gin g m a gn et ic fields cr ea t ed a r ou n d
it by t h e elect r om a gn et s.
Th e ga u ges a r e dia gn osed u sin g t h e E MIC self-di-
a gn ost ic a ct u a t or t est . (Refer t o 8 - E LE CTRICAL/
INSTRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). P r oper t est in g of t h e P CI da t a bu s, a n d
t h e da t a bu s m essa ge in pu t s t o t h e E MIC t h a t con -
t r ol ea ch ga u ge r equ ir es t h e u se of a DRBIII! sca n
t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
Specific oper a t ion det a ils for ea ch ga u ge m a y be
fou n d elsewh er e in t h is ser vice in for m a t ion .
VACUUM-FLUORESCENT DISPLAY
Th e Va cu u m -F lu or escen t Displa y (VF D) m odu le is
solder ed t o t h e E MIC cir cu it boa r d. Th e displa y is
a ct ive wit h t h e ign it ion swit ch in t h e On or St a r t
posit ion s, a n d in a ct ive wh en t h e ign it ion swit ch is in
a n y ot h er posit ion . Th e illu m in a t ion in t en sit y of t h e
VF D is con t r olled by t h e E MIC cir cu it r y ba sed u pon
elect r on ic dim m in g level m essa ges r eceived fr om t h e
BCM over t h e P CI da t a bu s, a n d is syn ch r on ized
wit h t h e illu m in a t ion in t en sit y of ot h er VF Ds in t h e
veh icle. Th e BCM pr ovides dim m in g level m essa ges
ba sed u pon in t er n a l pr ogr a m m in g a n d in pu t s it
r eceives fr om t h e con t r ol kn ob a n d con t r ol r in g on
t h e con t r ol st a lk of t h e left (ligh t in g) m u lt i-fu n ct ion
swit ch on t h e st eer in g colu m n .
Th e VF D h a s sever a l displa y ca pa bilit ies in clu din g
odom et er a n d t r ip odom et er in for m a t ion . An odom e-
t er /t r ip odom et er swit ch on t h e E MIC cir cu it boa r d is
u sed t o con t r ol t h e displa y m odes. Th is swit ch is
a ct u a t ed m a n u a lly by depr essin g t h e odom et er /t r ip
odom et er swit ch bu t t on t h a t ext en ds t h r ou gh t h e
lower edge of t h e clu st er len s, ju st r igh t of t h e speed-
om et er. Act u a t in g t h is swit ch m om en t a r ily wit h t h e
ign it ion swit ch in t h e On posit ion will t oggle t h e
VF D bet ween t h e odom et er a n d t r ip odom et er m odes.
Th e E MIC m icr opr ocessor r em em ber s wh ich displa y
m ode is a ct ive wh en t h e ign it ion swit ch is t u r n ed t o
t h e Off posit ion , a n d r et u r n s t h e displa y t o t h a t
m ode wh en t h e ign it ion swit ch is t u r n ed On a ga in .
Depr essin g t h e swit ch bu t t on for a bou t t wo secon ds
wh ile t h e VF D is in t h e t r ip odom et er m ode will
r eset t h e t r ip odom et er va lu e t o zer o. H oldin g t h is
swit ch depr essed wh ile t u r n in g t h e ign it ion swit ch
fr om t h e Off posit ion t o t h e On posit ion will in it ia t e
t h e E MIC self-dia gn ost ic a ct u a t or t est . Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion for a ddit ion a l
det a ils on t h is VF D fu n ct ion .
8J - 6 INSTRUMENT CLUSTER
I N ST RU M EN T CLU ST ER (Cont inue d)
Th e VF D is dia gn osed u sin g t h e E MIC self-dia g-
n ost ic a ct u a t or t est . (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). P r oper t est in g of t h e P CI da t a bu s a n d
t h e da t a bu s m essa ge in pu t s t o t h e E MIC t h a t con -
t r ol t h e VF D fu n ct ion s r equ ir es t h e u se of a DRBIII!
sca n t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion . Specific oper a t ion det a ils for t h e odom et er
a n d t r ip odom et er fu n ct ion s of t h e VF D m a y be fou n d
elsewh er e in t h is ser vice in for m a t ion .
INDICATORS
In dica t or s a r e loca t ed in va r iou s posit ion s wit h in
t h e E MIC a n d a r e a ll con n ect ed t o t h e E MIC cir cu it
boa r d. Th e t u r n sign a l in dica t or s a r e h a r d wir ed. Th e
br a ke in dica t or is con t r olled by P CI da t a bu s m es-
sa ges fr om t h e Con t r oller An t ilock Br a ke (CAB) a s
well a s by h a r d wir ed pa r k br a ke swit ch a n d br a ke
flu id level swit ch in pu t s t o t h e E MIC. Th e Ma lfu n c-
t ion In dica t or La m p (MIL) is n or m a lly con t r olled by
P CI da t a bu s m essa ges fr om t h e P ower t r a in Con t r ol
Modu le (P CM); h owever, if t h e E MIC loses P CI da t a
bu s com m u n ica t ion , t h e E MIC cir cu it r y will a u t om a t -
ica lly t u r n t h e MIL on u n t il P CI da t a bu s com m u n i-
ca t ion is r est or ed. Th e E MIC u ses P CI da t a bu s
m essa ges fr om t h e Air ba g Con t r ol Modu le (ACM), t h e
BCM, t h e P CM, t h e CAB, t h e Sen t r y Key Im m obi-
lizer Modu le (SKIM), a n d t h e Tr a n sm ission Con t r ol
Modu le (TCM) t o con t r ol a ll of t h e r em a in in g in dica -
t or s.
Th e va r iou s in dica t or s a r e con t r olled by differ en t
st r a t egies; som e r eceive fu sed ign it ion swit ch ou t pu t
fr om t h e E MIC cir cu it r y a n d h a ve a swit ch ed gr ou n d,
ot h er s a r e gr ou n ded t h r ou gh t h e E MIC cir cu it r y a n d
h a ve a swit ch ed ba t t er y feed, wh ile st ill ot h er s a r e
com plet ely con t r olled by t h e E MIC m icr opr ocessor
ba sed u pon va r iou s h a r d wir ed a n d elect r on ic m es-
sa ge in pu t s. Som e in dica t or s a r e illu m in a t ed a t a
fixed in t en sit y, wh ile t h e illu m in a t ion in t en sit y of
ot h er s is syn ch r on ized wit h t h a t of t h e E MIC gen er a l
illu m in a t ion la m ps.
Th e h a r d wir ed in dica t or s a r e dia gn osed u sin g con -
ven t ion a l dia gn ost ic m et h ods. Th e E MIC a n d P CI
bu s m essa ge con t r olled in dica t or s a r e dia gn osed
u sin g t h e E MIC self-dia gn ost ic a ct u a t or t est . (Refer
t o 8 - E LE CTRICAL/INSTRUME NT CLUSTE R -
DIAGNOSIS AND TE STING). P r oper t est in g of t h e
P CI da t a bu s a n d t h e elect r on ic da t a bu s m essa ge
in pu t s t o t h e E MIC t h a t con t r ol ea ch in dica t or
r equ ir e t h e u se of a DRBIII! sca n t ool. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion . Specific det a ils of
t h e oper a t ion for ea ch in dica t or m a y be fou n d else-
wh er e in t h is ser vice in for m a t ion .
WJ
CLUSTER ILLUMINATION
Two t ypes of gen er a l clu st er illu m in a t ion a r e a va il-
a ble in t h is m odel. Ba se ver sion s of t h e E MIC h a ve
sever a l in ca n descen t illu m in a t ion la m ps, wh ile pr e-
m iu m ver sion s of t h e E MIC h a ve a sin gle elect r o-lu -
m in escen t la m p. Bot h t ypes of la m ps pr ovide clu st er
ba ck ligh t in g wh en ever t h e ext er ior ligh t in g is
t u r n ed On wit h t h e con t r ol kn ob on t h e left (ligh t in g)
m u lt i-fu n ct ion swit ch con t r ol st a lk. Th e illu m in a t ion
in t en sit y of t h ese la m ps is a dju st ed by t h e E MIC
m icr opr ocessor ba sed u pon elect r on ic dim m in g level
m essa ges r eceived fr om t h e Body Con t r ol Modu le
(BCM) over t h e P CI da t a bu s. Th e BCM pr ovides
elect r on ic dim m in g level m essa ges t o t h e E MIC
ba sed u pon in t er n a l pr ogr a m m in g a n d in pu t s it
r eceives wh en t h e con t r ol r in g on t h e left (ligh t in g)
m u lt i-fu n ct ion swit ch con t r ol st a lk is r ot a t ed (down
t o dim , u p t o br igh t en ) t o on e of six a va ila ble m in or
det en t posit ion s.
Th e in ca n descen t illu m in a t ion la m ps r eceive ba t -
t er y cu r r en t a t a ll t im es, wh ile t h e gr ou n d for t h ese
la m ps is con t r olled by a 12-volt P u lse Widt h Modu -
la t ed (P WM) ou t pu t of t h e E MIC elect r on ic cir cu it r y.
Th e illu m in a t ion in t en sit y of t h ese bu lbs a n d of t h e
va cu u m -flu or escen t elect r on ic displa y a r e con t r olled
by t h e in st r u m en t clu st er m icr opr ocessor ba sed u pon
dim m in g level m essa ges r eceived fr om t h e Body Con -
t r ol Modu le (BCM) over t h e P CI da t a bu s. Th e BCM
u ses in pu t s fr om t h e h ea dla m p a n d pa n el dim m er
swit ch es wit h in t h e left (ligh t in g) m u lt i-fu n ct ion
swit ch con t r ol st a lk a n d in t er n a l pr ogr a m m in g t o
decide wh a t dim m in g level m essa ge is r equ ir ed. Th e
BCM t h en sen ds t h e pr oper dim m in g level m essa ges
t o t h e E MIC over t h e P CI da t a bu s.
Th e elect r o-lu m in escen t la m p u n it con sist s of la y-
er s of ph osph or, ca r bon , idiu m t in oxide, a n d dielec-
t r ic a pplied by a silk-scr een pr ocess bet ween t wo
polyest er m em br a n es a n d in clu des a sh or t pigt a il
wir e a n d con n ect or. Th e la m p pigt a il wir e is con -
n ect ed t o a sm a ll con n ect or r ecept a cle on t h e E MIC
cir cu it boa r d t h r ou gh a sm a ll clea r a n ce h ole in t h e
clu st er h ou sin g r ea r cover. Th e E MIC elect r on ic cir-
cu it r y a lso u ses a P WM st r a t egy t o con t r ol t h e illu -
m in a t ion in t en sit y of t h is la m p; h owever, t h e E MIC
power s t h is la m p wit h a n Alt er n a t in g Cu r r en t (AC)
r a t ed a t 80 volt s r m s (r oot m ea n squ a r ed) a n d 415
H er t z, wh ich excit es t h e ph osph or pa r t icles ca u sin g
t h em t o lu m in esce.
Th e BCM a lso h a s sever a l h a r d wir ed pa n el la m p
dr iver ou t pu t s a n d sen ds t h e pr oper pa n el la m ps
dim m in g level m essa ges over t h e P CI da t a bu s t o
coor din a t e t h e illu m in a t ion in t en sit y of a ll of t h e
in st r u m en t pa n el ligh t in g a n d t h e VF Ds of ot h er
elect r on ic m odu les on t h e P CI da t a bu s. Veh icles
equ ipped wit h t h e Au t o H ea dla m ps opt ion h a ve a n
a u t om a t ic pa r a de m ode. In t h is m ode, t h e BCM u ses
WJ
I N ST RU M EN T CLU ST ER (Cont inue d)
a n in pu t fr om t h e a u t o h ea dla m p ligh t sen sor t o
det er m in e t h e a m bien t ligh t levels. If t h e BCM
decides t h a t t h e ext er ior ligh t in g is t u r n ed on in t h e
da yligh t , it over r ides t h e select ed pa n el dim m er
swit ch sign a l by sen din g a m essa ge over t h e P CI
da t a bu s t o illu m in a t e a ll va cu u m flu or escen t dis-
pla ys a t fu ll br igh t n ess for im pr oved visibilit y in da y-
t im e ligh t levels. Th e a u t om a t ic pa r a de m ode h a s n o
effect on t h e in ca n descen t bu lb illu m in a t ion in t en sit y.
Th e h a r d wir ed clu st er illu m in a t ion cir cu it s
bet ween t h e left (ligh t in g) m u lt i-fu n ct ion swit ch a n d
t h e BCM m a y be dia gn osed u sin g con ven t ion a l dia g-
n ost ic t ools a n d m et h ods. Th e elect r o-lu m in escen t
la m p is dia gn osed u sin g t h e E MIC self-dia gn ost ic
a ct u a t or t est . (Refer t o 8 - E LE CTRICAL/INSTRU-
ME NT CLUSTE R - DIAGNOSIS AND TE STING).
H owever, pr oper t est in g of t h e E MIC a n d t h e elec-
t r on ic dim m in g level m essa ges sen t by t h e BCM over
t h e P CI da t a bu s r equ ir es t h e u se of a DRBIII! sca n
t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
CHIME SERVICE
Th e E MIC is pr ogr a m m ed t o r equ est ch im e ser vice
fr om t h e Body Con t r ol Modu le (BCM) wh en cer t a in
in dica t or s a r e illu m in a t ed. Th e E MIC ch im e r equ est
for illu m in a t ion of t h e low fu el in dica t or is a cu s-
t om er pr ogr a m m a ble fea t u r e. Wh en t h e pr ogr a m m ed
con dit ion s a r e m et , t h e E MIC gen er a t es a n elect r on ic
ch im e r equ est m essa ge a n d sen ds it over t h e P CI
da t a bu s t o t h e BCM. Upon r eceivin g t h e pr oper
ch im e r equ est , t h e BCM a ct iva t es a n in t egr a l ch im e
t on e gen er a t or t o pr ovide t h e a u dible ch im e t on e t o
t h e veh icle oper a t or. (Refer t o 8 - E LE CTRICAL/
CH IME WARNING SYSTE M - OP E RATION). P r oper
t est in g of t h e P CI da t a bu s a n d t h e elect r on ic ch im e
r equ est m essa ge ou t pu t s fr om t h e E MIC r equ ir es t h e
u se of a DRBIII! sca n t ool. Refer t o t h e a ppr opr ia t e
dia gn ost ic in for m a t ion .
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
If a ll of t h e in st r u m en t clu st er ga u ges a n d/or in di-
ca t or s a r e in oper a t ive, r efer t o P RE LIMINARY
DIAGNOSIS . If a n in dividu a l ga u ge or P r ogr a m m a -
ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s m es-
sa ge-con t r olled in dica t or is in oper a t ive, r efer t o
ACTUATOR TE ST . If a n in dividu a l h a r d wir ed in di-
ca t or is in oper a t ive, r efer t o t h e dia gn osis a n d t est in g
in for m a t ion for t h a t specific in dica t or. If t h e ba se
in st r u m en t clu st er in ca n descen t illu m in a t ion ligh t in g
is in oper a t ive, r efer t o CLUSTE R ILLUMINATION
DIAGNOSIS . If t h e pr em iu m in st r u m en t clu st er
elect r o-lu m in escen t illu m in a t ion ligh t in g is in oper a -
t ive, r efer t o ACTUATOR TE ST . Refer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
INSTRUMENT CLUSTER 8J - 7
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
NOTE: Occasionally, a condition may be encoun-
tered where the gauge pointer for the speedometer
or the tachometer becomes caught on the wrong
side of the pointer stop. To correct this condition,
the technician should use a DRBIII" scan tool and
the appropriate diagnostic information to perform
the instrument cluster self-diagnostic actuator test
procedure. When performed, the actuator test pro-
cedure will automatically return the pointer to the
correct side of the pointer stop.
PRELIMINARY DIAGNOSIS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
(1) Ch eck t h e fu sed B(+) fu se (F u se 17 - 10
a m per e) in t h e J u n ct ion Block (J B). If OK, go t o St ep
2. If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t
a s r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
(F u se 17 - 10 a m per e) in t h e J B. If OK, go t o St ep 3.
If n ot OK, r epa ir t h e open fu sed B(+) cir cu it bet ween
8J - 8 INSTRUMENT CLUSTER
I N ST RU M EN T CLU ST ER (Cont inue d)
t h e J B a n d t h e P ower Dist r ibu t ion Cen t er (P DC) a s
r equ ir ed.
(3) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n -
st a r t ) fu se (F u se 22 - 10 a m per e) in t h e J B. If OK, go
t o St ep 4. If n ot OK, r epa ir t h e sh or t ed cir cu it or
com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n -st a r t ) fu se (F u se 22 - 10 a m per e) in t h e
J B. If OK, go t o St ep 5. If n ot OK, r epa ir t h e open
fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it
bet ween t h e J B a n d t h e ign it ion swit ch a s r equ ir ed.
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Rem ove t h e in st r u m en t clu st er. Recon n ect t h e ba t -
t er y n ega t ive ca ble. Ch eck for ba t t er y volt a ge a t t h e
fu sed B(+) cir cu it ca vit y of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e in st r u m en t clu st er. If OK,
go t o St ep 6. If n ot OK, r epa ir t h e open fu sed B(+)
cir cu it bet ween t h e in st r u m en t clu st er a n d t h e J B a s
r equ ir ed.
(6) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n -st a r t ) cir cu it ca vit y of t h e in st r u m en t
pa n el wir e h a r n ess con n ect or for t h e in st r u m en t clu s-
t er. If OK, go t o St ep 7. If n ot OK, r epa ir t h e open
fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it
bet ween t h e in st r u m en t clu st er a n d t h e J B a s
r equ ir ed.
(7) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Ch eck for con t in u it y bet ween ea ch of t h e gr ou n d cir-
cu it ca vit ies of t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e in st r u m en t clu st er a n d a good
gr ou n d. Th er e sh ou ld be con t in u it y. If OK, r efer t o
t h e ACTUATOR TE ST . If n ot OK, r epa ir t h e open
gr ou n d cir cu it (s) bet ween t h e in st r u m en t clu st er a n d
gr ou n d (G200) a s r equ ir ed.
ACTUATOR TEST
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
WJ
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
Th e in st r u m en t clu st er a ct u a t or t est will pu t t h e
in st r u m en t clu st er in t o it s self-dia gn ost ic m ode. In
t h is m ode t h e in st r u m en t clu st er ca n per for m a self-
dia gn ost ic t est t h a t will con fir m t h a t t h e in st r u m en t
clu st er cir cu it r y, t h e ga u ges, t h e P CI da t a bu s m es-
sa ge con t r olled in dica t or s, a n d t h e elect r o-lu m in es-
cen t illu m in a t ion la m p (if equ ipped) a r e ca pa ble of
oper a t in g a s design ed. Du r in g t h e a ct u a t or t est t h e
in st r u m en t clu st er cir cu it r y will sweep ea ch of t h e
ga u ge n eedles a cr oss t h e ga u ge fa ces, illu m in a t e ea ch
of t h e segm en t s in t h e Va cu u m -F lu or escen t Displa y
(VF D), t u r n a ll of t h e P CI da t a bu s m essa ge-con -
t r olled in dica t or s on a n d off a ga in , a n d t u r n t h e elec-
t r o-lu m in escen t illu m in a t ion la m p (if equ ipped) on
a n d off a ga in .
Su ccessfu l com plet ion of t h e a ct u a t or t est will con -
fir m t h a t t h e in st r u m en t clu st er is oper a t ion a l. H ow-
ever, t h er e m a y st ill be a pr oblem wit h t h e P CI da t a
bu s, t h e P ower t r a in Con t r ol Modu le, t h e Air ba g Con -
t r ol Modu le (ACM), t h e Body Con t r ol Modu le (BCM),
t h e Con t r oller An t i-lock Br a ke (CAB), t h e Sen t r y Key
Im m obilizer Modu le (SKIM), or t h e in pu t s t o on e of
t h ese elect r on ic con t r ol m odu les. Use a DRBIII! sca n
t ool t o dia gn ose t h ese com pon en t s. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
If a n in dividu a l in dica t or la m p or t h e elect r o-lu m i-
n escen t illu m in a t ion la m p do n ot illu m in a t e du r in g
t h e a ct u a t or t est , t h e in st r u m en t clu st er sh ou ld be
r em oved. H owever, ch eck t h a t t h e in ca n descen t la m p
bu lb is n ot fa u lt y, t h a t t h e bu lb h older is pr oper ly
in st a lled on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d, or t h a t t h e elect r o-lu m in escen t la m p pigt a il
wir e con n ect or is pr oper ly con n ect ed t o t h e in st r u -
m en t clu st er elect r on ic cir cu it boa r d befor e con sider-
in g in st r u m en t clu st er r epla cem en t . If t h e bu lb a n d
bu lb h older, or t h e elect r o-lu m in escen t la m p con n ec-
t ion ch eck OK, r epla ce t h e fa u lt y in st r u m en t clu st er
u n it .
(1) Begin t h e t est wit h t h e ign it ion swit ch in t h e
Off posit ion .
(2) Depr ess t h e odom et er /t r ip odom et er swit ch bu t -
t on .
WJ
I N ST RU M EN T CLU ST ER (Cont inue d)
(3) Wh ile st ill h oldin g t h e odom et er /t r ip odom et er
swit ch bu t t on depr essed, t u r n t h e ign it ion swit ch t o
t h e On posit ion , bu t do n ot st a r t t h e en gin e.
(4) Relea se t h e odom et er /t r ip odom et er swit ch bu t -
t on .
(5) Th e in st r u m en t clu st er will a u t om a t ica lly
begin t h e a ct u a t or t est sequ en ce, a s follows:
(a ) Th e clu st er will t u r n on , t h en off a ga in ea ch
of t h e P CI da t a bu s m essa ge con t r olled in dica t or s
(except Air ba g) t o con fir m t h e fu n ct ion a lit y of t h e
in dica t or a n d t h e clu st er con t r ol cir cu it r y:
(b) Th e clu st er will sweep t h e n eedles for ea ch of
t h e ga u ges fr om m in im u m t o m a xim u m a n d ba ck
t o m in im u m t o con fir m t h e fu n ct ion a lit y of t h e
ga u ge a n d t h e clu st er con t r ol cir cu it r y:
(c) On ly on m odels wit h a pr em iu m ver sion of
t h e clu st er, t h e clu st er will illu m in a t e t h e elect r o-
lu m in escen t la m p a n d t u r n it off a ga in t o con fir m
t h e fu n ct ion a lit y of t h e la m p a n d t h e clu st er con -
t r ol cir cu it r y.
(d) Th e clu st er will sequ en t ia lly st ep t h e odom e-
t er /t r ip odom et er VF D displa y fr om a ll zer os
(000000) t h r ou gh a ll n in es (999999) t o con fir m t h e
fu n ct ion a lit y of a ll VF D segm en t s a n d t h eir con t r ol
cir cu it r y, t h en displa y t h e soft wa r e ver sion n u m ber,
followed by “DONE ”.
(6) Th e a ct u a t or t est is n ow com plet ed. Th e in st r u -
m en t clu st er will a u t om a t ica lly exit t h e self-dia gn os-
t ic m ode a n d r et u r n t o n or m a l oper a t ion a t t h e
com plet ion of t h e t est , if t h e ign it ion swit ch is t u r n ed
t o t h e Off posit ion du r in g t h e t est , or if a veh icle
speed m essa ge in dica t in g t h a t t h e veh icle is m ovin g
is r eceived fr om t h e P CM over t h e P CI da t a bu s du r-
in g t h e t est .
(7) Go ba ck t o St ep 1 t o r epea t t h e t est , if
r equ ir ed.
CLUSTER ILLUMINATION DIAGNOSIS
On m odels equ ipped wit h a ba se ver sion of t h e
in st r u m en t clu st er, t h e E MIC h a s sever a l in ca n des-
cen t illu m in a t ion la m ps t h a t a r e illu m in a t ed wh en -
ever t h e ext er ior ligh t in g is t u r n ed On . If t h e
pr oblem bein g dia gn osed is a sin gle in oper a t ive illu -
m in a t ion la m p, be cer t a in t h a t t h e bu lb a n d bu lb
h older u n it a r e pr oper ly in st a lled in t h e in st r u m en t
clu st er elect r on ic cir cu it boa r d. If n o in st a lla t ion
pr oblem s a r e fou n d r epla ce t h e fa u lt y bu lb a n d bu lb
h older u n it . If a ll of t h e clu st er illu m in a t ion la m ps
a r e in oper a t ive, t h e m ost r elia ble, efficien t , a n d a ccu -
r a t e m ea n s t o dia gn ose t h e clu st er illu m in a t ion fu n c-
INSTRUMENT CLUSTER 8J - 9
t ion of t h e in st r u m en t clu st er r equ ir es t h e u se of a
DRBIII! sca n t ool. Refer t o t h e a ppr opr ia t e dia gn os-
t ic in for m a t ion .
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e clu st er bezel fr om t h e in st r u m en t
pa n el. (Refer t o 23 - BODY/INSTRUME NT PANE L/
CLUSTE R BE ZE L - RE MOVAL).
(3) Rem ove t h e t wo scr ews t h a t secu r e t h e u pper
m ou n t in g t a bs of t h e in st r u m en t clu st er t o t h e
u n der side of t h e in st r u m en t clu st er h ood for m a t ion of
t h e in st r u m en t pa n el t op pa d.
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e lower
m ou n t in g t a bs of t h e in st r u m en t clu st er t o t h e
in st r u m en t pa n el st r u ct u r a l du ct .
8J - 10 INSTRUMENT CLUSTER
I N ST RU M EN T CLU ST ER (Cont inue d)
(5) P u ll t h e u pper m ou n t in g t a bs of t h e in st r u m en t
clu st er down wa r d, t h en pu ll t h e in st r u m en t clu st er
r ea r wa r d fa r en ou gh t o a ccess t h e in st r u m en t pa n el
wir e h a r n ess con n ect or for t h e in st r u m en t clu st er
(F ig. 3).
Fig. 3 Instrument Cluster Remove/Install
1 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
2 - INSTRUMENT CLUSTER
(6) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e in st r u m en t clu st er fr om t h e con n ec-
t or r ecept a cle on t h e ba ck of t h e in st r u m en t clu st er
h ou sin g.
(7) Rem ove t h e in st r u m en t clu st er fr om t h e in st r u -
m en t pa n el.
DISASSEMBLY
Som e of t h e com pon en t s for t h e in st r u m en t clu st er
u sed in t h is veh icle a r e ser viced in dividu a lly. Th e
ser viced com pon en t s in clu de: t h e in ca n descen t
in st r u m en t clu st er in dica t or a n d illu m in a t ion la m p
bu lbs (in clu din g t h e in t egr a l bu lb h older s), t h e clu s-
t er len s, h ood a n d m a sk u n it , a n d t h e clu st er h ou sin g
r ea r cover. F ollowin g a r e t h e pr ocedu r es for disa s-
sem blin g t h ese com pon en t s fr om t h e in st r u m en t clu s-
t er u n it .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
WJ
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
CLUSTER BULB
Th is pr ocedu r e a pplies t o ea ch of t h e in ca n descen t
clu st er illu m in a t ion la m p or in dica t or bu lb a n d bu lb
h older u n it s. H owever, t h e illu m in a t ion la m ps a n d
t h e in dica t or s u se differ en t bu lb a n d bu lb h older u n it
sizes. Th ey m u st n ever be in t er ch a n ged. Be cer t a in
t h a t a n y bu lb h older r em oved fr om t h e elect r on ic cir-
cu it boa r d is r ein st a lled in t h e cor r ect posit ion .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e in st r u m en t clu st er fr om t h e in st r u -
m en t pa n el. (Refer t o 8 - E LE CTRICAL/INSTRU-
ME NT CLUSTE R - RE MOVAL).
(3) Tu r n t h e bu lb h older cou n t er clockwise a bou t
sixt y degr ees on t h e clu st er elect r on ic cir cu it boa r d
(F ig. 4).
(4) P u ll t h e bu lb a n d bu lb h older st r a igh t ba ck t o
r em ove it fr om t h e bu lb m ou n t in g h ole in t h e clu st er
elect r on ic cir cu it boa r d.
CLUSTER LENS, HOOD AND MASK
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e in st r u m en t clu st er fr om t h e in st r u -
m en t pa n el. (Refer t o 8 - E LE CTRICAL/INSTRU-
ME NT CLUSTE R - RE MOVAL).
(3) Wor k a r ou n d t h e per im et er of t h e clu st er h ou s-
in g t o disen ga ge ea ch of t h e eigh t la t ch es t h a t secu r e
t h e clu st er len s, h ood a n d m a sk u n it t o t h e clu st er
h ou sin g (F ig. 5).
(4) Gen t ly pu ll t h e clu st er len s, h ood a n d m a sk
u n it a wa y fr om t h e clu st er h ou sin g.
CLUSTER HOUSING REAR COVER
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
WJ INSTRUMENT CLUSTER 8J - 11
I N ST RU M EN T CLU ST ER (Cont inue d)
(3) On m odels wit h a pr em iu m clu st er on ly, discon -
n ect t h e elect r o-lu m in escen t illu m in a t ion la m p pig-
t a il wir e con n ect or fr om t h e r ecept a cle on t h e clu st er
elect r on ic cir cu it boa r d a n d disen ga ge t h e pigt a il
wir e fr om t h e in t egr a l r ou t in g clip on t h e r ea r cover
(F ig. 6).

Fig. 4 Cluster Bulb Locations - Typical

1 - ILLUMINATION LAMP BULBS AND HOLDERS (5) Fig. 6 Cluster Housing Rear Cover Screws
2 - CLUSTER HOUSING REAR COVER
1 - ELECTRO-LUMINESCENT LAMP PIGTAIL WIRE
3 - CLUSTER HOUSING CONNECTOR
2 - REAR COVER
3 - SCREW (7)

(4) Rem ove t h e seven scr ews t h a t secu r e t h e r ea r

cover t o t h e ba ck of t h e clu st er h ou sin g.
(5) Disen ga ge t h e eigh t la t ch fea t u r es (fou r on t op,
fou r on t h e bot t om ) t h a t secu r e t h e u pper a n d lower
edges of t h e r ea r cover t o t h e t op a n d bot t om of t h e
clu st er h ou sin g.
(6) Rem ove t h e r ea r cover fr om t h e ba ck of t h e
clu st er h ou sin g.

ASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
Fig. 5 Instrument Cluster Components OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
1 - MINOR GAUGE SETS
OR SERVICE. DISCONNECT AND ISOLATE THE
2 - HOUSING REAR COVER BATTERY NEGATIVE (GROUND) CABLE, THEN
3 - TRIP ODOMETER RESET KNOB WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
4 - LENS, HOOD AND MASK TOR TO DISCHARGE BEFORE PERFORMING FUR-
5 - MAJOR GAUGES THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
6 - CLUSTER HOUSING SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
(2) Rem ove t h e in st r u m en t clu st er fr om t h e in st r u - PROPER PRECAUTIONS COULD RESULT IN ACCI-
m en t pa n el. (Refer t o 8 - E LE CTRICAL/INSTRU- DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
ME NT CLUSTE R - RE MOVAL). PERSONAL INJURY.
8J - 12 INSTRUMENT CLUSTER
I N ST RU M EN T CLU ST ER (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
CLUSTER BULB
Th is pr ocedu r e a pplies t o ea ch of t h e in ca n descen t
clu st er illu m in a t ion la m p or in dica t or bu lb a n d bu lb
h older u n it s. H owever, t h e illu m in a t ion la m ps a n d
t h e in dica t or s u se differ en t bu lb a n d bu lb h older u n it
sizes. Th ey m u st n ever be in t er ch a n ged.
CAUTION: Be certain that any bulb and bulb holder
unit removed from the cluster electronic circuit
board is reinstalled in the correct position. Always
use the correct bulb size and type for replacement.
An incorrect bulb size or type may overheat and
cause damage to the instrument cluster, the elec-
tronic circuit board and/or the gauges.
(1) In ser t t h e bu lb a n d bu lb h older st r a igh t in t o
t h e cor r ect bu lb m ou n t in g h ole in t h e clu st er elec-
t r on ic cir cu it boa r d (F ig. 4).
(2) Wit h t h e bu lb h older fu lly sea t ed a ga in st t h e
clu st er elect r on ic cir cu it boa r d, t u r n t h e bu lb h older
clockwise a bou t sixt y degr ees t o lock it in t o pla ce.
(3) Rein st a ll t h e in st r u m en t clu st er on t o t h e
in st r u m en t pa n el. (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - INSTALLATION).
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
CLUSTER LENS, HOOD AND MASK
(1) P osit ion t h e clu st er len s, h ood a n d m a sk u n it
over t h e fa ce of t h e in st r u m en t clu st er (F ig. 5). Be
cer t a in t h a t t h e odom et er /t r ip odom et er swit ch bu t -
t on is in ser t ed t h r ou gh t h e pr oper clea r a n ce h oles in
t h e m a sk a n d t h e len s.
(2) P r ess fir m ly a n d even ly on t h e clu st er len s,
h ood a n d m a sk u n it t o in st a ll it on t o t h e clu st er
h ou sin g.
(3) Wor k a r ou n d t h e per im et er of t h e clu st er h ou s-
in g t o be cer t a in t h a t ea ch of t h e eigh t la t ch es t h a t
secu r e t h e clu st er len s, h ood a n d m a sk u n it t o t h e
clu st er h ou sin g is fu lly en ga ged.
(4) Rein st a ll t h e in st r u m en t clu st er in t o t h e
in st r u m en t pa n el. (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - INSTALLATION).
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ
CLUSTER HOUSING REAR COVER
(1) P osit ion t h e r ea r cover on t o t h e ba ck of t h e
clu st er h ou sin g (F ig. 6).
(2) P r ess fir m ly a n d even ly on t h e r ea r cover u n t il
ea ch of t h e eigh t la t ch es (fou r on t op, fou r on t h e bot -
t om ) t h a t secu r e t h e u pper a n d lower edges of t h e
r ea r cover t o t h e t op a n d bot t om of t h e clu st er h ou s-
in g a r e fu lly en ga ged.
(3) In st a ll a n d t igh t en t h e seven scr ews t h a t
secu r e t h e r ea r cover t o t h e ba ck of t h e clu st er h ou s-
in g. Tigh t en t h e scr ews t o 2 N·m (20 in . lbs.).
(4) On m odels wit h a pr em iu m clu st er on ly, r econ -
n ect t h e elect r o-lu m in escen t illu m in a t ion la m p pig-
t a il wir e con n ect or t o t h e r ecept a cle on t h e clu st er
elect r on ic cir cu it boa r d a n d en ga ge t h e pigt a il wir e
u n der t h e in t egr a l r ou t in g clip on t h e r ea r cover.
(5) Rein st a ll t h e in st r u m en t clu st er on t o t h e
in st r u m en t pa n el. (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - INSTALLATION).
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
(1) P osit ion t h e in st r u m en t clu st er t o t h e in st r u -
m en t pa n el.
WJ
I N ST RU M EN T CLU ST ER (Cont inue d)
(2) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e in st r u m en t clu st er t o t h e con n ect or
r ecept a cle on t h e ba ck of t h e in st r u m en t clu st er
h ou sin g (F ig. 7).
Fig. 7 Instrument Cluster Remove/Install
1 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
2 - INSTRUMENT CLUSTER
(3) P osit ion t h e lower m ou n t in g t a bs of t h e in st r u -
m en t clu st er t o t h e m ou n t in g h oles on t h e in st r u -
m en t pa n el st r u ct u r a l du ct , t h en t ilt t h e t op of t h e
in st r u m en t clu st er for wa r d u n t il t h e u pper m ou n t in g
t a bs a r e posit ion ed t o t h e m ou n t in g h oles on t h e
u n der side of t h e in st r u m en t clu st er h ood for m a t ion of
t h e in st r u m en t pa n el t op pa d.
(4) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e u pper m ou n t in g t a bs of t h e in st r u m en t clu st er t o
t h e u n der side of t h e in st r u m en t clu st er h ood for m a -
t ion of t h e in st r u m en t pa n el t op pa d. Tigh t en t h e
scr ews t o 2.2 N·m (20 in . lbs.).
(5) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e lower m ou n t in g t a bs of t h e in st r u m en t clu st er t o
t h e in st r u m en t pa n el st r u ct u r a l du ct . Tigh t en t h e
scr ews t o 2.2 N·m (20 in . lbs.).
(6) Rein st a ll t h e clu st er bezel on t o t h e in st r u m en t
pa n el. (Refer t o 23 - BODY/INSTRUME NT PANE L/
CLUSTE R BE ZE L - INSTALLATION).
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
ABS I N DI CAT OR
DESCRIPTION
An An t i-lock Br a ke Syst em (ABS) in dica t or is st a n -
da r d equ ipm en t on a ll in st r u m en t clu st er s. Th e ABS
in dica t or is loca t ed on t h e lower left edge of t h e
in st r u m en t clu st er, t o t h e left of t h e t a ch om et er. Th e
INSTRUMENT CLUSTER 8J - 13
ABS in dica t or con sist s of a In t er n a t ion a l Con t r ol a n d
Displa y Sym bol icon for “F a ilu r e of An t i-lock Br a kin g
Syst em ” im pr in t ed on a n a m ber len s. Th e len s is
loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e in dica t or fr om bein g clea r ly
visible wh en it is n ot illu m in a t ed. Th e icon a ppea r s
silh ou et t ed a ga in st a n a m ber field t h r ou gh t h e t r a n s-
lu cen t ou t er la yer of t h e over la y wh en t h e in dica t or
is illu m in a t ed fr om beh in d by a r epla cea ble in ca n des-
cen t bu lb a n d bu lb h older u n it loca t ed on t h e in st r u -
m en t clu st er elect r on ic cir cu it boa r d. Th e ABS
in dica t or len s is ser viced a s a u n it wit h t h e in st r u -
m en t clu st er len s, h ood a n d m a sk u n it .
OPERATION
Th e ABS in dica t or gives a n in dica t ion t o t h e veh i-
cle oper a t or wh en t h e ABS syst em is fa u lt y or in op-
er a t ive. Th is in dica t or is con t r olled by a t r a n sist or on
t h e in st r u m en t clu st er cir cu it boa r d ba sed u pon clu s-
t er pr ogr a m m in g a n d elect r on ic m essa ges r eceived by
t h e clu st er fr om t h e Con t r oller An t i-lock Br a ke
(CAB) over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s. Th e ABS in dica t or bu lb is
com plet ely con t r olled by t h e in st r u m en t clu st er logic
cir cu it , a n d t h a t logic will on ly a llow t h is in dica t or t o
oper a t e wh en t h e in st r u m en t clu st er r eceives a ba t -
t er y cu r r en t in pu t on t h e fu sed ign it ion swit ch ou t -
pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in dica t or will
a lwa ys be off wh en t h e ign it ion swit ch is in a n y posi-
t ion except On or St a r t . Th e bu lb on ly illu m in a t es
wh en it is pr ovided a pa t h t o gr ou n d by t h e in st r u -
m en t clu st er t r a n sist or. Th e in st r u m en t clu st er will
t u r n on t h e ABS in dica t or for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e CAB sen ds a n elec-
t r on ic ABS la m p-on m essa ge t o t h e clu st er wh ich will
illu m in a t e t h e ABS in dica t or for a bou t fou r secon ds
a s a bu lb t est . Th e en t ir e fou r secon d bu lb t est is a
fu n ct ion of t h e CAB.
• AB S In d ic a to r La m p -On Me s s a g e - E a ch t im e
t h e clu st er r eceives a n ABS in dica t or la m p-on m es-
sa ge fr om t h e CAB, t h e ABS in dica t or will be illu m i-
n a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il t h e
clu st er r eceives a n ABS in dica t or la m p-off m essa ge
fr om t h e CAB, or u n t il t h e ign it ion swit ch is t u r n ed
t o t h e Off posit ion , wh ich ever occu r s fir st .
• Co m m u n ic a tio n Erro r - If t h e clu st er r eceives
n o ABS in dica t or la m p-on or la m p-off m essa ges fr om
t h e CAB for six con secu t ive secon ds, t h e ABS in dica -
t or is illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed
u n t il t h e clu st er r eceives a va lid la m p-on or la m p-off
m essa ge fr om t h e CAB, or u n t il t h e ign it ion swit ch is
t u r n ed t o t h e Off posit ion , wh ich ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e in st r u m en t clu s-
t er is pu t t h r ou gh t h e a ct u a t or t est , t h e ABS in dica -
8J - 14 INSTRUMENT CLUSTER
ABS I N DI CAT OR (Cont inue d)
t or will be t u r n ed on for t h e du r a t ion of t h e t est t o
con fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er
con t r ol cir cu it r y.
• AB S D ia g n o s tic Te s t - Th e ABS in dica t or is
blin ked on a n d off ba sed u pon la m p-on a n d la m p-off
m essa ges fr om t h e CAB du r in g t h e per for m a n ce of
t h e ABS dia gn ost ic t est s.
Th e CAB con t in u a lly m on it or s t h e ABS cir cu it s
a n d sen sor s t o decide wh et h er t h e syst em is in good
oper a t in g con dit ion . Th e CAB t h en sen ds t h e pr oper
ABS in dica t or la m p-on or la m p-off m essa ges t o t h e
in st r u m en t clu st er. If t h e ABS in dica t or fa ils t o ligh t
du r in g t h e bu lb t est , r epla ce t h e bu lb wit h a kn own
good u n it . If t h e CAB sen ds a n ABS in dica t or
la m p-on m essa ge a ft er t h e bu lb t est , it in dica t es t h a t
t h e CAB h a s det ect ed a syst em m a lfu n ct ion a n d/or
t h a t t h e ABS syst em h a s becom e in oper a t ive. Th e
CAB will st or e a Dia gn ost ic Tr ou ble Code (DTC) for
a n y m a lfu n ct ion it det ect s. E a ch t im e t h e ABS in di-
ca t or fa ils t o illu m in a t e du e t o a n open or sh or t in
t h e clu st er ABS in dica t or cir cu it or bu lb, t h e clu st er
sen ds a m essa ge n ot ifyin g t h e CAB of t h e con dit ion ,
t h en t h e in st r u m en t clu st er a n d t h e CAB will ea ch
st or e a DTC. F or pr oper dia gn osis of t h e a n t i-lock
br a ke syst em , t h e CAB, t h e P CI da t a bu s, or t h e
elect r on ic m essa ge in pu t s t o t h e in st r u m en t clu st er
t h a t con t r ol t h e ABS in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
AI RBAG I N DI CAT OR
DESCRIPTION
An a ir ba g in dica t or is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s. H owever, t h e in st r u m en t clu st er
is pr ogr a m m ed t o a u t om a t ica lly en a ble t h is in dica t or
on ly on veh icles equ ipped wit h t h e a ir ba g syst em ,
wh ich is n ot a va ila ble in som e m a r ket s. Th e a ir ba g
in dica t or is loca t ed on t h e u pper edge of t h e in st r u -
m en t clu st er, bet ween t h e speedom et er a n d t h e
t a ch om et er. Th e a ir ba g in dica t or con sist s of t h e
wor ds “AIR BAG” im pr in t ed on a r ed len s. Th e len s
is loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e in dica t or fr om bein g clea r ly
visible wh en it is n ot illu m in a t ed. Th e “AIR BAG”
t ext a ppea r s silh ou et t ed a ga in st a r ed field t h r ou gh
t h e t r a n slu cen t ou t er la yer of t h e over la y wh en t h e
in dica t or is illu m in a t ed fr om beh in d by a Ligh t E m it -
t in g Diode (LE D), wh ich is solder ed on t o t h e in st r u -
m en t clu st er elect r on ic cir cu it boa r d. Th e a ir ba g
in dica t or len s is ser viced a s a u n it wit h t h e in st r u -
m en t clu st er len s, h ood a n d m a sk u n it .
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OPERATION
Th e a ir ba g in dica t or gives a n in dica t ion t o t h e
veh icle oper a t or wh en t h e a ir ba g syst em is fa u lt y or
in oper a t ive. Th e a ir ba g in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e Air ba g Con t r ol
Modu le (ACM) over t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s. Th e a ir ba g in dica t or
Ligh t E m it t in g Diode (LE D) is com plet ely con t r olled
by t h e in st r u m en t clu st er logic cir cu it , a n d t h a t logic
will on ly a llow t h is in dica t or t o oper a t e wh en t h e
in st r u m en t clu st er r eceives a ba t t er y cu r r en t in pu t
on t h e fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir-
cu it . Th er efor e, t h e in dica t or will a lwa ys be off wh en
t h e ign it ion swit ch is in a n y posit ion except On or
St a r t . Th e LE D on ly illu m in a t es wh en it is swit ch ed
t o gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
in st r u m en t clu st er will t u r n on t h e a ir ba g in dica t or
for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e ACM sen ds a n elec-
t r on ic a ir ba g in dica t or la m p-on m essa ge t o t h e clu s-
t er wh ich will illu m in a t e t h e a ir ba g in dica t or for
a bou t six secon ds a s a bu lb t est . Th e en t ir e six sec-
on d bu lb t est is a fu n ct ion of t h e ACM.
• Airba g In d ic a to r La m p -On Me s s a g e - E a ch
t im e t h e clu st er r eceives a n a ir ba g in dica t or la m p-on
m essa ge fr om t h e ACM, t h e a ir ba g in dica t or will be
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed for
a bou t t welve secon ds or u n t il t h e clu st er r eceives a n
a ir ba g in dica t or la m p-off m essa ge fr om t h e ACM,
wh ich ever is lon ger.
• Co m m u n ic a tio n Erro r - If t h e clu st er r eceives
n o a ir ba g in dica t or la m p-on or la m p-off m essa ges for
six con secu t ive secon ds, t h e a ir ba g in dica t or is illu -
m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il t h e
clu st er r eceives a sin gle va lid a ir ba g in dica t or la m p-
off m essa ge fr om t h e ACM.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e a ir ba g in dica t or will be
t u r n ed on , t h en off a ga in du r in g t h e bu lb ch eck por-
t ion of t h e t est t o con fir m t h e fu n ct ion a lit y of t h e
LE D a n d t h e clu st er con t r ol cir cu it r y. Th e a ct u a t or
t est illu m in a t ion of t h e a ir ba g in dica t or is a lso a
fu n ct ion of t h e ACM.
Th e ACM con t in u a lly m on it or s t h e a ir ba g syst em
cir cu it s a n d sen sor s t o decide wh et h er t h e syst em is
in good oper a t in g con dit ion . Th e ACM t h en sen ds t h e
pr oper a ir ba g in dica t or la m p-on or la m p-off m essa ges
t o t h e in st r u m en t clu st er. If t h e ACM sen ds a n a ir-
ba g in dica t or la m p-on m essa ge a ft er t h e bu lb t est , it
in dica t es t h a t t h e ACM h a s det ect ed a syst em m a l-
fu n ct ion . Su ch a m a lfu n ct ion cou ld m ea n t h a t t h e
a ir ba gs m a y n ot deploy wh en r equ ir ed, or m a y
deploy wh en n ot r equ ir ed. Th e ACM will st or e a
WJ INSTRUMENT CLUSTER 8J - 15
AI RBAG I N DI CAT OR (Cont inue d)
Dia gn ost ic Tr ou ble Code (DTC) for a n y m a lfu n ct ion it (LE D) is com plet ely con t r olled by t h e in st r u m en t
det ect s. E a ch t im e t h e a ir ba g in dica t or fa ils t o illu - clu st er logic cir cu it , a n d t h a t logic will on ly a llow
m in a t e du e t o a n open or sh or t in t h e clu st er a ir ba g t h is in dica t or t o oper a t e wh en t h e in st r u m en t clu st er
in dica t or cir cu it , t h e clu st er sen ds a m essa ge n ot ify- r eceives a ba t t er y cu r r en t in pu t on t h e fu sed ign it ion
in g t h e ACM of t h e con dit ion , t h en t h e in st r u m en t swit ch ou t pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in di-
clu st er a n d t h e ACM will ea ch st or e a DTC. F or ca t or will a lwa ys be off wh en t h e ign it ion swit ch is in
pr oper dia gn osis of t h e a ir ba g syst em , t h e ACM, t h e a n y posit ion except On or St a r t . Th e LE D on ly illu -
P CI da t a bu s, or t h e elect r on ic m essa ge in pu t s t o t h e m in a t es wh en it is pr ovided a pa t h t o gr ou n d by t h e
in st r u m en t clu st er t h a t con t r ol t h e a ir ba g in dica t or, in st r u m en t clu st er t r a n sist or. Th e in st r u m en t clu st er
a DRBIII! sca n t ool is r equ ir ed. Refer t o t h e a ppr o- will t u r n on t h e br a ke in dica t or for t h e followin g r ea -
pr ia t e dia gn ost ic in for m a t ion . son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e br a ke in dica t or is illu -
BRAK E/PARK BRAK E m in a t ed by t h e in st r u m en t clu st er for a bou t t h r ee
I N DI CAT OR secon ds a s a bu lb t est .
• B ra k e In d ic a to r La m p -On Me s s a g e - E a ch
DESCRIPTION t im e t h e clu st er r eceives a br a ke in dica t or la m p-on
m essa ge fr om t h e CAB, t h e br a ke in dica t or will be
A br a ke in dica t or is st a n da r d equ ipm en t on a ll
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il
in st r u m en t clu st er s. Th e br a ke in dica t or is loca t ed
t h e clu st er r eceives a br a ke in dica t or la m p-off m es-
n ea r t h e left edge of t h e in st r u m en t clu st er, t o t h e
sa ge fr om t h e CAB.
left of t h e t a ch om et er. Th er e a r e t wo ver sion s of t h e
• P a rk B ra k e S w itc h In p u t - E a ch t im e t h e
br a ke in dica t or. Th e ver sion u sed depen ds u pon t h e
clu st er logic cir cu it det ect s gr ou n d on t h e pa r k br a ke
m a r ket for wh ich t h e veh icle is m a n u fa ct u r ed. Th e
swit ch sen se cir cu it (pa r k br a ke swit ch closed = pa r k
ver sion of t h e br a ke in dica t or u sed for veh icles m a n -
br a ke a pplied or n ot fu lly r elea sed) t h e br a ke in dica -
u fa ct u r ed for t h e Un it ed St a t es con sist s of t h e wor d
t or is illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed
“BRAKE ” im pr in t ed on a r ed len s. Th e Rest -Of-Wor ld
u n t il t h e pa r k br a ke swit ch sen se in pu t t o t h e clu st er
(ROW) m a r ket ver sion of t h is in dica t or h a s t wo
is a n open cir cu it (pa r k br a ke swit ch open = pa r k
In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon s
br a ke fu lly r elea sed), or u n t il t h e ign it ion swit ch is
im pr in t ed on t h e r ed len s; on e is t h e icon for “Br a ke
t u r n ed t o t h e Off posit ion , wh ich ever occu r s fir st .
F a ilu r e”, a n d t h e ot h er is t h e icon for “P a r kin g
• Co m m u n ic a tio n Erro r - If t h e clu st er r eceives
Br a ke”. In eit h er ca se, t h e len s is loca t ed beh in d a
n o br a ke in dica t or la m p-on or la m p-off m essa ges
cu t ou t in t h e opa qu e la yer of t h e in st r u m en t clu st er
fr om t h e CAB for six con secu t ive secon ds, t h e br a ke
over la y. Th e da r k ou t er la yer of t h e over la y pr even t s
in dica t or is illu m in a t ed. Th e in dica t or r em a in s illu -
t h e in dica t or fr om bein g clea r ly visible wh en it is n ot
m in a t ed u n t il t h e clu st er r eceives a sin gle va lid
illu m in a t ed. Th e “BRAKE ” t ext or t h e t wo icon s
br a ke in dica t or la m p-off m essa ge fr om t h e CAB.
a ppea r silh ou et t ed a ga in st a r ed field t h r ou gh t h e
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t r a n slu cen t ou t er la yer of t h e over la y wh en t h e in di-
t h r ou gh t h e a ct u a t or t est , t h e br a ke in dica t or will be
ca t or is illu m in a t ed fr om beh in d by a Ligh t E m it t in g
t u r n ed on for t h e du r a t ion of t h e t est t o con fir m t h e
Diode (LE D), wh ich is solder ed on t o t h e in st r u m en t
fu n ct ion a lit y of t h e LE D a n d t h e clu st er con t r ol cir-
clu st er elect r on ic cir cu it boa r d. Th e br a ke in dica t or
cu it r y.
len s is ser viced a s a u n it wit h t h e in st r u m en t clu st er
Th e pa r k br a ke swit ch on t h e pa r k br a ke peda l
len s, h ood a n d m a sk u n it .
m ech a n ism pr ovides a h a r d wir ed gr ou n d in pu t t o
t h e in st r u m en t clu st er cir cu it r y t h r ou gh t h e r ed
OPERATION
br a ke wa r n in g in dica t or dr iver cir cu it wh en ever t h e
Th e br a ke in dica t or gives a n in dica t ion t o t h e veh i-
pa r k br a ke is a pplied or n ot fu lly r elea sed. Th e CAB
cle oper a t or wh en t h e pa r kin g br a ke is a pplied, wh en
con t in u a lly m on it or s t h e in pu t fr om t h e br a ke flu id
t h e flu id level of t h e br a ke h ydr a u lic syst em is low,
level swit ch a n d t h e cir cu it s of t h e a n t i-lock br a ke
or if t h er e a r e cer t a in m a lfu n ct ion s of t h e An t i-lock
syst em , t h en sen ds t h e pr oper br a ke in dica t or
Br a ke Syst em (ABS). Th is in dica t or is con t r olled by a
la m p-on or la m p-off m essa ges t o t h e in st r u m en t clu s-
t r a n sist or on t h e in st r u m en t clu st er elect r on ic cir cu it
t er. If t h e CAB sen ds a br a ke in dica t or la m p-on m es-
boa r d ba sed u pon clu st er pr ogr a m m in g, elect r on ic
sa ge a ft er t h e bu lb t est , it in dica t es t h a t t h e CAB
m essa ges r eceived by t h e clu st er fr om t h e Con t r oller
h a s det ect ed a br a ke h ydr a u lic syst em m a lfu n ct ion
An t i-lock Br a ke (CAB) over t h e P r ogr a m m a ble Com -
a n d/or t h a t t h e ABS syst em h a s becom e in oper a t ive.
m u n ica t ion s In t er fa ce (P CI) da t a bu s, a n d a h a r d
Th e CAB will st or e a Dia gn ost ic Tr ou ble Code (DTC)
wir ed in pu t t o t h e clu st er fr om t h e pa r k br a ke
for a n y m a lfu n ct ion it det ect s.
swit ch . Th e br a ke in dica t or Ligh t E m it t in g Diode
8J - 16 INSTRUMENT CLUSTER
BRAK E/PARK BRAK E I N DI CAT OR (Cont inue d)
F or fu r t h er dia gn osis of t h e br a ke in dica t or or t h e
in st r u m en t clu st er cir cu it r y t h a t con t r ols t h e in dica -
t or, (Refer t o 8 - E LE CTRICAL/INSTRUME NT
CLUSTE R - DIAGNOSIS AND TE STING). Th e pa r k
br a ke swit ch in pu t t o t h e in st r u m en t clu st er ca n be
dia gn osed u sin g con ven t ion a l dia gn ost ic t ools a n d
m et h ods. F or pr oper dia gn osis of t h e br a ke flu id level
swit ch in pu t t o t h e CAB, t h e a n t i-lock br a ke syst em ,
t h e CAB, t h e P CI da t a bu s, or t h e elect r on ic m essa ge
in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol t h e
br a ke in dica t or, a DRBIII! sca n t ool is r equ ir ed.
Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
DIAGNOSIS AND TESTING - BRAKE INDICATOR
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
pa r k br a ke in dica t or con dit ion . If t h er e a r e pr oblem s
wit h sever a l in dica t or s in t h e in st r u m en t clu st er,
(Refer t o 8 - E LE CTRICAL/INSTRUME NT CLUS-
TE R - DIAGNOSIS AND TE STING). If t h e br a ke
in dica t or st a ys on wit h t h e ign it ion swit ch in t h e On
posit ion a n d t h e pa r k br a ke r elea sed, or com es on
wh ile dr ivin g, (Refer t o 5 - BRAKE S - DIAGNOSIS
AND TE STING). If n o br a ke syst em pr oblem is
fou n d, t h e followin g pr ocedu r es will h elp t o loca t e a
sh or t ed or open cir cu it , or a fa u lt y pa r k br a ke swit ch
in pu t . Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, det a ils
of wir e h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -
ou t in for m a t ion a n d loca t ion views for t h e va r iou s
wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES
NOT WHEN PARK BRAKE APPLIED
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e pa r k br a ke swit ch fr om t h e swit ch
t er m in a l. Apply t h e pa r kin g br a ke. Ch eck for con t i-
WJ
n u it y bet ween t h e pa r k br a ke swit ch t er m in a l a n d a
good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o
St ep 2. If n ot OK, r epla ce t h e fa u lt y pa r k br a ke
swit ch .
(2) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e in st r u m en t clu st er fr om t h e clu st er
con n ect or r ecept a cle. Ch eck for con t in u it y bet ween
t h e r ed br a ke wa r n in g in dica t or dr iver cir cu it ca vi-
t ies of t h e in st r u m en t pa n el wir e h a r n ess con n ect or
for t h e pa r k br a ke swit ch a n d t h e in st r u m en t pa n el
wir e h a r n ess con n ect or for t h e in st r u m en t clu st er.
Th er e sh ou ld be con t in u it y. If n ot OK, r epa ir t h e
open r ed br a ke wa r n in g in dica t or dr iver cir cu it
bet ween t h e pa r k br a ke swit ch a n d t h e in st r u m en t
clu st er a s r equ ir ed.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM
CHECKS OK
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e pa r k br a ke swit ch fr om t h e pa r k
br a ke swit ch t er m in a l. Ch eck for con t in u it y bet ween
t h e t er m in a l of t h e pa r k br a ke swit ch a n d a good
gr ou n d. Th er e sh ou ld be n o con t in u it y wit h t h e pa r k
br a ke r elea sed, a n d con t in u it y wit h t h e pa r k br a ke
a pplied. If OK, go t o St ep 2. If n ot OK, r epla ce t h e
fa u lt y pa r k br a ke swit ch .
(2) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e in st r u m en t clu st er fr om t h e clu st er
con n ect or r ecept a cle. Ch eck for con t in u it y bet ween
t h e r ed br a ke wa r n in g in dica t or dr iver cir cu it ca vit y
of t h e in st r u m en t pa n el wir e h a r n ess con n ect or for
t h e pa r k br a ke swit ch a n d a good gr ou n d. Th er e
sh ou ld be n o con t in u it y. If n ot OK, r epa ir t h e sh or t ed
r ed br a ke wa r n in g in dica t or dr iver cir cu it bet ween
t h e pa r k br a ke swit ch a n d t h e in st r u m en t clu st er a s
r equ ir ed.
CH ECK GAU GES I N DI CAT OR
DESCRIPTION
A ch eck ga u ges in dica t or is st a n da r d equ ipm en t on
a ll in st r u m en t clu st er s. Th e ch eck ga u ges in dica t or is
loca t ed on t h e r igh t edge of t h e in st r u m en t clu st er, t o
t h e r igh t of t h e speedom et er. Th e ch eck ga u ges in di-
ca t or con sist s of t h e wor ds “CH E CK GAGE S”
im pr in t ed on a r ed len s. Th e len s is loca t ed beh in d a
cu t ou t in t h e opa qu e la yer of t h e in st r u m en t clu st er
over la y. Th e da r k ou t er la yer of t h e over la y pr even t s
t h e in dica t or fr om bein g clea r ly visible wh en it is n ot
illu m in a t ed. Th e “CH E CK GAGE S” t ext a ppea r s sil-
h ou et t ed a ga in st a r ed field t h r ou gh t h e t r a n slu cen t
ou t er la yer of t h e over la y wh en t h e in dica t or is illu -
m in a t ed fr om beh in d by a Ligh t E m it t in g Diode
(LE D), wh ich is solder ed on t o t h e in st r u m en t clu st er
elect r on ic cir cu it boa r d. Th e ch eck ga u ges in dica t or
WJ
CH ECK GAU GES I N DI CAT OR (Cont inue d)
len s is ser viced a s a u n it wit h t h e in st r u m en t clu st er
len s, h ood a n d m a sk u n it .
OPERATION
Th e ch eck ga u ges in dica t or gives a n in dica t ion t o
t h e veh icle oper a t or wh en cer t a in in st r u m en t clu st er
ga u ge r ea din gs r eflect a con dit ion r equ ir in g im m edi-
a t e a t t en t ion . Th is in dica t or is con t r olled by a t r a n -
sist or on t h e in st r u m en t clu st er cir cu it boa r d ba sed
u pon clu st er pr ogr a m m in g a n d elect r on ic m essa ges
r eceived by t h e clu st er fr om t h e P ower t r a in Con t r ol
Modu le (P CM) over t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s. Th e ch eck ga u ges
in dica t or Ligh t E m it t in g Diode (LE D) is com plet ely
con t r olled by t h e in st r u m en t clu st er logic cir cu it , a n d
t h a t logic will on ly a llow t h is in dica t or t o oper a t e
wh en t h e in st r u m en t clu st er r eceives a ba t t er y cu r-
r en t in pu t on t h e fu sed ign it ion swit ch ou t pu t (r u n -
st a r t ) cir cu it . Th er efor e, t h e in dica t or will a lwa ys be
off wh en t h e ign it ion swit ch is in a n y posit ion except
On or St a r t . Th e LE D on ly illu m in a t es wh en it is
pr ovided a pa t h t o gr ou n d by t h e in st r u m en t clu st er
t r a n sist or. Th e in st r u m en t clu st er will t u r n on t h e
ch eck ga u ges in dica t or for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e ch eck ga u ges in dica t or
is illu m in a t ed for a bou t t h r ee secon ds a s a bu lb t est .
• En g in e Te m p e ra tu re Hig h /Critic a l Me s s a g e
- E a ch t im e t h e clu st er r eceives a m essa ge fr om t h e
P CM in dica t in g t h e en gin e coola n t t em per a t u r e is
h igh or cr it ica l [a bove a bou t 127° C (261° F ) for ga s-
olin e en gin es except Gu lf Coa st Cou n t r y (GCC), 129°
C (264° F ) for GCC ga solin e en gin es, a n d 118° C
(244° F ) for diesel en gin es], t h e ch eck ga u ges in dica -
t or is illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed
u n t il t h e clu st er r eceives a m essa ge in dica t in g t h e
en gin e coola n t t em per a t u r e is n ot h igh or cr it ica l
[a bou t 125° C (255° F ) or below for a ll ga solin e
en gin es, or 115° C (239° F ) for a ll diesel en gin es].
• En g in e Oil P re s s u re Lo w Me s s a g e - E a ch
t im e t h e clu st er r eceives a m essa ge fr om t h e P CM
in dica t in g t h e en gin e oil pr essu r e is a bou t 0.28
kg/cm or lower (a bou t 4 psi or lower ), t h e ch eck
ga u ges in dica t or is illu m in a t ed. Th e in dica t or
r em a in s illu m in a t ed u n t il t h e clu st er r eceives a m es-
sa ge fr om t h e P CM in dica t in g t h a t t h e en gin e oil
pr essu r e is a bou t 0.56 kg/cm or h igh er (a bou t 8 psi
or h igh er ). Th e clu st er will on ly t u r n t h e in dica t or on
in r espon se t o a n en gin e oil pr essu r e low m essa ge if
t h e ign it ion swit ch is in t h e On posit ion a n d t h e
en gin e speed is 300 r pm or gr ea t er.
• S y s te m Vo lta g e Lo w Me s s a g e - E a ch t im e t h e
clu st er r eceives a m essa ge fr om t h e P CM in dica t in g
a low syst em volt a ge con dit ion (syst em volt a ge is
a bou t eleven volt s or lower ), t h e ch eck ga u ges in dica -
t or is illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed
INSTRUMENT CLUSTER 8J - 17
u n t il t h e clu st er r eceives a m essa ge fr om t h e P CM
in dica t in g t h er e is n o low syst em volt a ge con dit ion
(syst em volt a ge is a bove a bou t eleven volt s, bu t lower
t h a n a bou t sixt een volt s).
• S y s te m Vo lta g e Hig h Me s s a g e - E a ch t im e
t h e clu st er r eceives a m essa ge fr om t h e P CM in dica t -
in g a h igh syst em volt a ge con dit ion (syst em volt a ge
is a bou t sixt een volt s or h igh er ), t h e ch eck ga u ges
in dica t or is illu m in a t ed. Th e in dica t or r em a in s illu -
m in a t ed u n t il t h e clu st er r eceives a m essa ge fr om
t h e P CM in dica t in g t h er e is n o h igh syst em volt a ge
con dit ion (syst em volt a ge is below a bou t sixt een
volt s, bu t h igh er t h a n a bou t eleven volt s).
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e ch eck ga u ges in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e LE D a n d t h e clu st er con -
t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e en gin e t em per-
a t u r e, oil pr essu r e, a n d elect r ica l syst em volt a ge,
t h en sen ds t h e pr oper m essa ges t o t h e in st r u m en t
clu st er. F or fu r t h er dia gn osis of t h e ch eck ga u ges
in dica t or or t h e in st r u m en t clu st er cir cu it r y t h a t con -
t r ols t h e in dica t or, (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). F or pr oper dia gn osis of t h e P CM, t h e P CI
da t a bu s, or t h e elect r on ic m essa ge in pu t s t o t h e
in st r u m en t clu st er t h a t con t r ol t h e ch eck ga u ges
in dica t or, a DRBIII! sca n t ool is r equ ir ed. Refer t o
t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
COOLAN T LOW I N DI CAT OR
DESCRIPTION
A coola n t low in dica t or is on ly fou n d in t h e in st r u -
m en t clu st er s of veh icles equ ipped wit h a n opt ion a l
diesel en gin e. Th e coola n t low in dica t or sh ou ld n ot be
con fu sed wit h t h e coola n t level low in dica t ion pr o-
vided by t h e E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC) of veh icles equ ipped wit h a ga solin e en gin e,
a lt h ou gh t h ey do per for m t h e sa m e fu n ct ion . Th e
coola n t low in dica t or is loca t ed in t h e lower left cor-
n er of t h e in st r u m en t clu st er, t o t h e left of t h e
t a ch om et er. Th e coola n t low in dica t or con sist s of a n
In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon for
“Low Coola n t ” im pr in t ed on a n a m ber len s. Th e len s
is loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e in dica t or fr om bein g clea r ly
visible wh en it is n ot illu m in a t ed. Th e icon a ppea r s
silh ou et t ed a ga in st a n a m ber field t h r ou gh t h e t r a n s-
lu cen t ou t er la yer of t h e over la y wh en t h e in dica t or
is illu m in a t ed fr om beh in d by a r epla cea ble in ca n des-
cen t bu lb a n d bu lb h older u n it loca t ed on t h e in st r u -
m en t clu st er elect r on ic cir cu it boa r d. Wh en t h e
8J - 18 INSTRUMENT CLUSTER
COOLAN T LOW I N DI CAT OR (Cont inue d)
ext er ior ligh t in g is t u r n ed On , t h e illu m in a t ion in t en -
sit y of t h e coola n t low in dica t or is dim m a ble, wh ich
is a dju st ed u sin g t h e pa n el la m ps dim m er con t r ol
r in g on t h e con t r ol st a lk of t h e left m u lt i-fu n ct ion
swit ch . Th e coola n t low in dica t or len s is ser viced a s a
u n it wit h t h e in st r u m en t clu st er len s, h ood a n d m a sk
u n it .
OPERATION
Th e coola n t low in dica t or gives a n in dica t ion t o t h e
veh icle oper a t or wh en t h e diesel en gin e coola n t level
is low. Th is in dica t or is con t r olled by a t r a n sist or on
t h e in st r u m en t clu st er cir cu it boa r d ba sed u pon clu s-
t er pr ogr a m m in g a n d elect r on ic m essa ges r eceived by
t h e clu st er fr om t h e Body Con t r ol Modu le (BCM)
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s. Th e coola n t low in dica t or bu lb is
com plet ely con t r olled by t h e in st r u m en t clu st er logic
cir cu it , a n d t h a t logic will on ly a llow t h is in dica t or t o
oper a t e wh en t h e in st r u m en t clu st er r eceives a ba t -
t er y cu r r en t in pu t on t h e fu sed ign it ion swit ch ou t -
pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in dica t or will
a lwa ys be off wh en t h e ign it ion swit ch is in a n y posi-
t ion except On or St a r t . Th e bu lb on ly illu m in a t es
wh en it is pr ovided a pa t h t o gr ou n d by t h e in st r u -
m en t clu st er t r a n sist or. Th e in st r u m en t clu st er will
t u r n on t h e coola n t low in dica t or for t h e followin g
r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e coola n t low in dica t or is
illu m in a t ed for a bou t t h r ee secon ds a s a bu lb t est .
• Co o la n t Lo w In d ic a to r La m p -On Me s s a g e -
E a ch t im e t h e clu st er r eceives a coola n t low in dica t or
la m p-on m essa ge fr om t h e BCM in dica t in g t h e
en gin e coola n t is below t h e m in im u m level in t h e
coola n t r eser voir, t h e coola n t low in dica t or will be
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il
t h e clu st er r eceives a coola n t low in dica t or la m p-off
m essa ge fr om t h e BCM in dica t in g t h a t t h e en gin e
coola n t level is a bove t h e m in im u m level.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e coola n t low in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con -
t r ol cir cu it r y.
Th e BCM con t in u a lly m on it or s t h e in pu t fr om t h e
coola n t level swit ch , t h en sen ds t h e pr oper coola n t
low in dica t or la m p-on a n d la m p-off m essa ges t o t h e
in st r u m en t clu st er. If t h e coola n t low in dica t or fa ils
t o ligh t du r in g t h e bu lb t est , r epla ce t h e bu lb wit h a
kn own good u n it . F or fu r t h er dia gn osis of t h e coola n t
low in dica t or or t h e in st r u m en t clu st er cir cu it r y t h a t
con t r ols t h e in dica t or, (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND TE ST-
ING). F or pr oper dia gn osis of t h e coola n t level
swit ch , t h e BCM, t h e P CI da t a bu s, or t h e elect r on ic
WJ
m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol
t h e coola n t low in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
CRU I SE I N DI CAT OR
DESCRIPTION
A cr u ise in dica t or is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s, bu t is on ly fu n ct ion a l on veh i-
cles equ ipped wit h t h e opt ion a l speed con t r ol syst em .
Th e cr u ise in dica t or is loca t ed on t h e r igh t edge of
t h e in st r u m en t clu st er, t o t h e r igh t of t h e speedom e-
t er. Th e cr u ise in dica t or con sist s of t h e wor d
“CRUISE ” im pr in t ed on a blu e/gr een len s. Th e len s is
loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e in dica t or fr om bein g clea r ly
visible wh en it is n ot illu m in a t ed. Th e “CRUISE ” t ext
a ppea r s silh ou et t ed a ga in st a blu e/gr een field
t h r ou gh t h e t r a n slu cen t ou t er la yer of t h e over la y
wh en t h e in dica t or is illu m in a t ed fr om beh in d by a
r epla cea ble bu lb a n d bu lb h older u n it loca t ed on t h e
in st r u m en t clu st er elect r on ic cir cu it boa r d. Wh en t h e
ext er ior ligh t in g is t u r n ed On , t h e illu m in a t ion in t en -
sit y of t h e cr u ise in dica t or is dim m a ble, wh ich is
a dju st ed u sin g t h e pa n el la m ps dim m er con t r ol r in g
on t h e con t r ol st a lk of t h e left m u lt i-fu n ct ion swit ch .
Th e cr u ise in dica t or len s is ser viced a s a u n it wit h
t h e in st r u m en t clu st er len s, h ood a n d m a sk u n it .
OPERATION
Th e cr u ise in dica t or gives a n in dica t ion t o t h e veh i-
cle oper a t or wh en t h e speed con t r ol syst em is t u r n ed
On , r ega r dless of wh et h er t h e speed con t r ol is
en ga ged. Th is in dica t or is con t r olled by a t r a n sist or
on t h e in st r u m en t clu st er elect r on ic cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e P ower t r a in
Con t r ol Modu le (P CM) over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e cr u ise
in dica t or bu lb is com plet ely con t r olled by t h e in st r u -
m en t clu st er logic cir cu it , a n d t h a t logic will on ly
a llow t h is in dica t or t o oper a t e wh en t h e in st r u m en t
clu st er r eceives a ba t t er y cu r r en t in pu t on t h e fu sed
ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it . Th er efor e,
t h e in dica t or will a lwa ys be off wh en t h e ign it ion
swit ch is in a n y posit ion except On or St a r t . Th e bu lb
on ly illu m in a t es wh en it is pr ovided a pa t h t o gr ou n d
by t h e in st r u m en t clu st er t r a n sist or. Th e in st r u m en t
clu st er will t u r n on t h e cr u ise in dica t or for t h e fol-
lowin g r ea son s:
• Cru is e In d ic a to r La m p -On Me s s a g e - E a ch
t im e t h e clu st er r eceives a cr u ise in dica t or la m p-on
m essa ge fr om t h e P CM in dica t in g t h e speed con t r ol
WJ
CRU I SE I N DI CAT OR (Cont inue d)
syst em h a s been t u r n ed On , t h e cr u ise in dica t or is
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il
t h e clu st er r eceives a cr u ise in dica t or la m p-off m es-
sa ge fr om t h e P CM or u n t il t h e ign it ion swit ch is
t u r n ed t o t h e Off posit ion , wh ich ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e cr u ise in dica t or will be
t u r n ed on for t h e du r a t ion of t h e t est t o con fir m t h e
fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con t r ol cir-
cu it r y.
Th e P CM con t in u a lly m on it or s t h e speed con t r ol
swit ch es t o det er m in e t h e pr oper ou t pu t s t o t h e
speed con t r ol ser vo. Th e P CM t h en sen ds t h e pr oper
cr u ise in dica t or la m p-on a n d la m p-off m essa ges t o
t h e in st r u m en t clu st er. If t h e cr u ise in dica t or fa ils t o
ligh t du r in g t h e a ct u a t or t est , r epla ce t h e bu lb wit h a
kn own good u n it . F or fu r t h er dia gn osis of t h e cr u ise
in dica t or or t h e in st r u m en t clu st er cir cu it r y t h a t con -
t r ols t h e in dica t or, (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). F or pr oper dia gn osis of t h e speed con t r ol
swit ch es, t h e P CM, t h e P CI da t a bu s, or t h e elec-
t r on ic m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t
con t r ol t h e cr u ise in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
EN GI N E T EM PERAT U RE
GAU GE
DESCRIPTION
An en gin e coola n t t em per a t u r e ga u ge is st a n da r d
equ ipm en t on a ll in st r u m en t clu st er s. Th e en gin e
coola n t t em per a t u r e ga u ge is loca t ed in t h e lower
r igh t cor n er of t h e in st r u m en t clu st er, t o t h e r igh t of
t h e speedom et er. Th e en gin e coola n t t em per a t u r e
ga u ge con sist s of a m ova ble ga u ge n eedle or poin t er
con t r olled by t h e in st r u m en t clu st er cir cu it r y a n d a
fixed 90 degr ee sca le on t h e ga u ge dia l fa ce t h a t
r ea ds left -t o-r igh t fr om 40° C t o 125° C, or fr om 100°
F t o 260° F, depen din g u pon t h e m a r ket for wh ich
t h e veh icle is m a n u fa ct u r ed. An In t er n a t ion a l Con -
t r ol a n d Displa y Sym bol icon for “E n gin e Coola n t
Tem per a t u r e” is loca t ed on t h e ga u ge dia l fa ce.
Th e en gin e coola n t t em per a t u r e ga u ge gr a ph ics a r e
eit h er wh it e, gr a y a n d or a n ge a ga in st a bla ck ga u ge
dia l fa ce (ba se clu st er ) or bla ck, gr a y a n d r ed a ga in st
a t a u pe ga u ge dia l fa ce (pr em iu m clu st er ), m a kin g
t h em clea r ly visible wit h in t h e in st r u m en t clu st er in
da yligh t . Wh en illu m in a t ed fr om beh in d by t h e pa n el
la m ps dim m er con t r olled clu st er illu m in a t ion ligh t in g
wit h t h e ext er ior la m ps t u r n ed On , t h e ba se clu st er
wh it e ga u ge gr a ph ics a ppea r blu e-gr een a n d t h e
or a n ge gr a ph ics st ill a ppea r or a n ge, wh ile t h e pr e-
m iu m clu st er t a u pe ga u ge dia l fa ce a ppea r s blu e-
INSTRUMENT CLUSTER 8J - 19
gr een wit h t h e bla ck gr a ph ics silh ou et t ed a ga in st t h e
illu m in a t ed ba ckgr ou n d a n d t h e r ed gr a ph ics st ill
a ppea r r ed. Th e gr a y ga u ge gr a ph ics for bot h ver-
sion s of t h e clu st er a r e n ot illu m in a t ed. Th e or a n ge
ga u ge n eedle in t h e ba se clu st er ga u ge is in t er n a lly
illu m in a t ed, wh ile t h e bla ck ga u ge n eedle in t h e pr e-
m iu m clu st er ga u ge is n ot .
Ba se clu st er ga u ge illu m in a t ion is pr ovided by
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it s
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. P r em iu m clu st er ga u ge illu m in a t ion is pr o-
vided by a n in t egr a l elect r o-lu m in escen t la m p t h a t is
ser viced a s a u n it wit h t h e in st r u m en t clu st er. Th e
en gin e coola n t t em per a t u r e ga u ge is ser viced a s a
u n it wit h t h e in st r u m en t clu st er.
OPERATION
Th e en gin e coola n t t em per a t u r e ga u ge gives a n
in dica t ion t o t h e veh icle oper a t or of t h e en gin e cool-
a n t t em per a t u r e. Th is ga u ge is con t r olled by t h e
in st r u m en t clu st er cir cu it boa r d ba sed u pon clu st er
pr ogr a m m in g a n d elect r on ic m essa ges r eceived by
t h e clu st er fr om t h e P ower t r a in Con t r ol Modu le
(P CM) over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s. Th e en gin e coola n t t em per-
a t u r e ga u ge is a n a ir cor e m a gn et ic u n it t h a t is com -
plet ely con t r olled by t h e in st r u m en t clu st er elect r on ic
cir cu it boa r d. Th e clu st er is pr ogr a m m ed t o m ove t h e
ga u ge n eedle ba ck t o t h e low en d of t h e sca le a ft er
t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion . Th e
in st r u m en t clu st er cir cu it r y con t r ols t h e ga u ge n ee-
dle posit ion a n d pr ovides t h e followin g fea t u r es:
• En g in e Te m p e ra tu re N o rm a l Me s s a g e - E a ch
t im e t h e clu st er r eceives a m essa ge fr om t h e P CM
in dica t in g t h e en gin e coola n t t em per a t u r e is wit h in
t h e n or m a l oper a t in g r a n ge [u p t o a bou t 124° C (255°
F ) for ga solin e en gin es, a n d 115° C (239° F ) for diesel
en gin es], t h e ga u ge n eedle is m oved t o t h e r ela t ive
t em per a t u r e posit ion of t h e ga u ge sca le.
• En g in e Te m p e ra tu re Hig h Me s s a g e - E a ch
t im e t h e clu st er r eceives a m essa ge fr om t h e P CM
in dica t in g t h e en gin e coola n t t em per a t u r e is h igh
[a bove a bou t 127° C (260° F ) for ga solin e en gin es
except Gu lf Coa st Cou n t r y (GCC), 129° C (264° F ) for
GCC ga solin e en gin es, a n d 118° C (244° F ) for diesel
en gin es], t h e ga u ge n eedle is m oved t o t h e cen t er of
t h e r ed wa r n in g zon e on t h e ga u ge sca le.
• En g in e Te m p e ra tu re Critic a l Me s s a g e -
E a ch t im e t h e clu st er r eceives a m essa ge fr om t h e
P CM in dica t in g t h e en gin e coola n t t em per a t u r e is
cr it ica l [a bou t 132° C (270° F ) or h igh er for a ll ga so-
lin e en gin es, a n d 126° C (259° F ) for a ll diesel
en gin es], t h e ga u ge n eedle is m oved t o t h e h igh en d
of t h e r ed wa r n in g zon e on t h e ga u ge sca le.
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a n en gin e t em per a t u r e m essa ge, it will h old
8J - 20 INSTRUMENT CLUSTER
EN GI N E T EM PERAT U RE GAU GE (Cont inue d)
t h e ga u ge n eedle a t t h e la st in dica t ion for a bou t
t welve secon ds or u n t il a n ew en gin e t em per a t u r e
m essa ge is r eceived, wh ich ever occu r s fir st . Aft er
t welve secon ds, t h e clu st er will r et u r n t h e ga u ge n ee-
dle t o t h e low en d of t h e ga u ge sca le.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e ga u ge n eedle will be
swept a cr oss t h e en t ir e ga u ge sca le a n d ba ck in or der
t o con fir m t h e fu n ct ion a lit y of t h e ga u ge a n d t h e
clu st er con t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e en gin e coola n t
t em per a t u r e sen sor t o det er m in e t h e en gin e oper a t -
in g t em per a t u r e. Th e P CM t h en sen ds t h e pr oper
en gin e coola n t t em per a t u r e m essa ges t o t h e in st r u -
m en t clu st er. F or fu r t h er dia gn osis of t h e en gin e cool-
a n t t em per a t u r e ga u ge or t h e in st r u m en t clu st er
cir cu it r y t h a t con t r ols t h e ga u ge, (Refer t o 8 - E LE C-
TRICAL/INSTRUME NT CLUSTE R - DIAGNOSIS
AND TE STING). If t h e in st r u m en t clu st er m oves t h e
en gin e coola n t t em per a t u r e ga u ge n eedle t o in dica t e
a h igh or cr it ica l en gin e t em per a t u r e, it m a y in dica t e
t h a t t h e en gin e or t h e en gin e coolin g syst em r equ ir es
ser vice. F or pr oper dia gn osis of t h e en gin e coola n t
t em per a t u r e sen sor, t h e P CM, t h e P CI da t a bu s, or
t h e elect r on ic m essa ge in pu t s t o t h e in st r u m en t clu s-
t er t h a t con t r ol t h e en gin e coola n t t em per a t u r e
ga u ge, a DRBIII! sca n t ool is r equ ir ed. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
FRON T FOG LAM P I N DI CAT OR
DESCRIPTION
A fr on t fog la m p in dica t or is st a n da r d equ ipm en t
on a ll in st r u m en t clu st er s, bu t is on ly fu n ct ion a l on
veh icles equ ipped wit h t h e opt ion a l fr on t fog la m ps.
Th e fr on t fog la m p in dica t or is loca t ed on t h e left
edge of t h e in st r u m en t clu st er, t o t h e left of t h e
t a ch om et er. Th e fr on t fog la m p in dica t or con sist s of
a n In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon for
“F r on t F og Ligh t ” im pr in t ed on a gr een len s. Th e
len s is loca t ed beh in d a cu t ou t in t h e opa qu e la yer of
t h e in st r u m en t clu st er over la y. Th e da r k ou t er la yer
of t h e over la y pr even t s t h e in dica t or fr om bein g
clea r ly visible wh en it is n ot illu m in a t ed. Th e icon
a ppea r s silh ou et t ed a ga in st a gr een field t h r ou gh t h e
t r a n slu cen t ou t er la yer of t h e over la y wh en t h e in di-
ca t or is illu m in a t ed fr om beh in d by a r epla cea ble
in ca n descen t bu lb a n d bu lb h older u n it loca t ed on
t h e in st r u m en t clu st er elect r on ic cir cu it boa r d. Wh en
t h e ext er ior ligh t in g is t u r n ed On , t h e illu m in a t ion
in t en sit y of t h e fr on t fog la m p in dica t or is dim m a ble,
wh ich is a dju st ed u sin g t h e pa n el la m ps dim m er con -
t r ol r in g on t h e con t r ol st a lk of t h e left m u lt i-fu n c-
t ion swit ch . Th e fr on t fog la m p in dica t or len s is
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ser viced a s a u n it wit h t h e in st r u m en t clu st er len s,
h ood a n d m a sk u n it .
OPERATION
Th e fr on t fog la m p in dica t or gives a n in dica t ion t o
t h e veh icle oper a t or wh en ever t h e fr on t fog la m ps
a r e illu m in a t ed. Th is in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e Body Con t r ol
Modu le (BCM) over t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s. Th e fr on t fog la m p
in dica t or bu lb is com plet ely con t r olled by t h e in st r u -
m en t clu st er logic cir cu it , a n d t h a t logic will a llow
t h is in dica t or t o oper a t e wh en ever t h e in st r u m en t
clu st er r eceives a ba t t er y cu r r en t in pu t on t h e fu sed
B(+) cir cu it . Th er efor e, t h e in dica t or ca n be illu m i-
n a t ed r ega r dless of t h e ign it ion swit ch posit ion . Th e
bu lb on ly illu m in a t es wh en it is pr ovided a pa t h t o
gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
in st r u m en t clu st er will t u r n on t h e fr on t fog la m p
in dica t or for t h e followin g r ea son s:
• F ro n t F o g La m p In d ic a to r La m p -On Me s -
s a g e - E a ch t im e t h e clu st er r eceives a fr on t fog
la m p in dica t or la m p-on m essa ge fr om t h e BCM in di-
ca t in g t h a t t h e fr on t fog la m ps a r e t u r n ed On , t h e
fr on t fog la m p in dica t or will be illu m in a t ed. Th e in di-
ca t or r em a in s illu m in a t ed u n t il t h e clu st er r eceives a
fr on t fog la m p in dica t or la m p-off m essa ge fr om t h e
BCM.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e fr on t fog la m p in dica -
t or will be t u r n ed on for t h e du r a t ion of t h e t est t o
con fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er
con t r ol cir cu it r y.
Th e BCM con t in u a lly m on it or s t h e ext er ior ligh t -
in g (left m u lt i-fu n ct ion ) swit ch t o det er m in e t h e
pr oper ou t pu t s t o t h e fr on t fog la m p r ela y. Th e BCM
t h en sen ds t h e pr oper fr on t fog la m p in dica t or
la m p-on a n d la m p-off m essa ges t o t h e in st r u m en t
clu st er. If t h e fr on t fog la m p in dica t or fa ils t o ligh t
du r in g t h e a ct u a t or t est , r epla ce t h e bu lb wit h a
kn own good u n it . F or fu r t h er dia gn osis of t h e fr on t
fog la m p in dica t or or t h e in st r u m en t clu st er cir cu it r y
t h a t con t r ols t h e in dica t or, (Refer t o 8 - E LE CTRI-
CAL/INSTRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). F or pr oper dia gn osis of t h e fr on t fog
la m p syst em , t h e BCM, t h e P CI da t a bu s, or t h e elec-
t r on ic m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t
con t r ol t h e fr on t fog la m p in dica t or, a DRBIII! sca n
t ool is r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic
in for m a t ion .
WJ INSTRUMENT CLUSTER 8J - 21

FU EL GAU GE en d of t h e sca le a ft er t h e ign it ion swit ch is t u r n ed t o

t h e Off posit ion . Th e in st r u m en t clu st er cir cu it r y
con t r ols t h e ga u ge n eedle posit ion a n d pr ovides t h e
DESCRIPTION
followin g fea t u r es:
A fu el ga u ge is st a n da r d equ ipm en t on a ll in st r u -
• P e rc e n t Ta n k F u ll Me s s a g e - E a ch t im e t h e
m en t clu st er s. Th e fu el ga u ge is loca t ed in t h e lower
clu st er r eceives a m essa ge fr om t h e P CM in dica t in g
left cor n er of t h e in st r u m en t clu st er, t o t h e left of t h e
t h e per cen t t a n k fu ll, t h e clu st er m oves t h e ga u ge
t a ch om et er. Th e fu el ga u ge con sist s of a m ova ble
n eedle t o t h e r ela t ive fu el level posit ion on t h e ga u ge
ga u ge n eedle or poin t er con t r olled by t h e in st r u m en t
sca le. Th e P CM a pplies a n a lgor it h m t o t h e in pu t
clu st er cir cu it r y a n d a fixed 90 degr ee sca le on t h e
fr om t h e fu el t a n k sen der t o da m pen ga u ge n eedle
ga u ge dia l fa ce t h a t r ea ds left -t o-r igh t fr om E (or
m ovem en t a ga in st t h e n ega t ive effect t h a t fu el slosh -
E m pt y) t o F (or F u ll). An In t er n a t ion a l Con t r ol a n d
in g wit h in t h e fu el t a n k ca n h a ve on a ccu r a t e in pu t s
Displa y Sym bol icon for “F u el” is loca t ed on t h e
t o t h e P CM.
ga u ge dia l fa ce. An a r r owh ea d poin t ed t o t h e left side
• Le s s Th a n 12.5 P e rc e n t Ta n k F u ll Me s s a g e -
of t h e veh icle is im pr in t ed n ext t o t h e “F u el” icon on
E a ch t im e t h e clu st er r eceives m essa ges fr om t h e
t h e fu el ga u ge dia l fa ce t o pr ovide t h e dr iver wit h a
P CM in dica t in g t h e per cen t t a n k fu ll is less t h a n
r em in der a s t o t h e loca t ion of t h e fu el filler a ccess.
12.5 (on e-eigh t h ), t h e ga u ge n eedle is m oved t o t h e
Th e fu el ga u ge gr a ph ics a r e eit h er wh it e, gr a y a n d
pr oper posit ion on t h e ga u ge sca le a n d t h e low fu el
or a n ge a ga in st a bla ck ga u ge dia l fa ce (ba se clu st er )
in dica t or is illu m in a t ed. Th e low fu el in dica t or
or bla ck a n d gr a y a ga in st a t a u pe ga u ge dia l fa ce
r em a in s illu m in a t ed u n t il t h e clu st er r eceives m es-
(pr em iu m clu st er ), m a kin g t h em clea r ly visible
sa ges fr om t h e P CM in dica t in g t h a t t h e per cen t t a n k
wit h in t h e in st r u m en t clu st er in da yligh t . Wh en illu -
fu ll is gr ea t er t h a n 12.5 (on e-eigh t h ), or u n t il t h e
m in a t ed fr om beh in d by t h e pa n el la m ps dim m er
ign it ion swit ch is t u r n ed t o t h e Off posit ion , wh ich -
con t r olled clu st er illu m in a t ion ligh t in g wit h t h e ext e-
ever occu r s fir st .
r ior la m ps t u r n ed On , t h e ba se clu st er wh it e ga u ge
• Le s s Th a n Em p ty P e rc e n t Ta n k F u ll Me s -
gr a ph ics a ppea r blu e-gr een a n d t h e or a n ge gr a ph ics
s a g e - E a ch t im e t h e clu st er r eceives a m essa ge fr om
st ill a ppea r or a n ge, wh ile t h e pr em iu m clu st er t a u pe
t h e P CM in dica t in g t h e per cen t t a n k fu ll is less t h a n
ga u ge dia l fa ce a ppea r s blu e-gr een wit h t h e bla ck
em pt y, t h e ga u ge n eedle is m oved t o t h e fa r left (low)
gr a ph ics silh ou et t ed a ga in st t h e illu m in a t ed ba ck-
en d of t h e ga u ge sca le a n d t h e low fu el in dica t or is
gr ou n d. Th e gr a y ga u ge gr a ph ics for bot h ver sion s of
illu m in a t ed im m edia t ely. Th is m essa ge wou ld in di-
t h e clu st er a r e n ot illu m in a t ed. Th e or a n ge ga u ge
ca t e t h a t t h e fu el t a n k sen der in pu t t o t h e P CM is a
n eedle in t h e ba se clu st er ga u ge is in t er n a lly illu m i-
sh or t cir cu it .
n a t ed, wh ile t h e bla ck ga u ge n eedle in t h e pr em iu m
• Mo re Th a n F u ll P e rc e n t Ta n k F u ll Me s s a g e
clu st er ga u ge is n ot .
- E a ch t im e t h e clu st er r eceives a m essa ge fr om t h e
Ba se clu st er ga u ge illu m in a t ion is pr ovided by
P CM in dica t in g t h e per cen t t a n k fu ll is m or e t h a n
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it s
fu ll, t h e ga u ge n eedle is m oved t o t h e fa r left (low)
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
en d of t h e ga u ge sca le a n d t h e low fu el in dica t or is
boa r d. P r em iu m clu st er ga u ge illu m in a t ion is pr o-
illu m in a t ed im m edia t ely. Th is m essa ge wou ld in di-
vided by a n in t egr a l elect r o-lu m in escen t la m p t h a t is
ca t e t h a t t h e fu el t a n k sen der in pu t t o t h e P CM is a n
ser viced a s a u n it wit h t h e in st r u m en t clu st er. Th e
open cir cu it .
fu el ga u ge is ser viced a s a u n it wit h t h e in st r u m en t
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
clu st er.
r eceive a per cen t t a n k fu ll m essa ge, it will h old t h e
ga u ge n eedle a t t h e la st in dica t ion for a bou t t welve
OPERATION secon ds, u n t il a n ew m essa ge is r eceived, or u n t il t h e
Th e fu el ga u ge gives a n in dica t ion t o t h e veh icle
ign it ion swit ch is t u r n ed t o t h e Off posit ion , wh ich -
oper a t or of t h e level of fu el in t h e fu el t a n k. Th is
ever occu r s fir st . Aft er t welve secon ds, t h e clu st er
ga u ge is con t r olled by t h e in st r u m en t clu st er cir cu it
will r et u r n t h e ga u ge n eedle t o t h e low en d of t h e
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec- ga u ge sca le.
t r on ic m essa ges r eceived by t h e clu st er fr om t h e • Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
P ower t r a in Con t r ol Modu le (P CM) over t h e P r ogr a m -
t h r ou gh t h e a ct u a t or t est , t h e ga u ge n eedle will be
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e swept a cr oss t h e en t ir e ga u ge sca le a n d ba ck in or der
fu el ga u ge is a n a ir cor e m a gn et ic u n it t h a t r eceives
t o con fir m t h e fu n ct ion a lit y of t h e ga u ge a n d t h e
ba t t er y cu r r en t on t h e in st r u m en t clu st er elect r on ic
clu st er con t r ol cir cu it r y.
cir cu it boa r d t h r ou gh t h e fu sed ign it ion swit ch ou t - Th e P CM con t in u a lly m on it or s t h e fu el t a n k
pu t (r u n -st a r t ) cir cu it wh en ever t h e ign it ion swit ch is sen der t o det er m in e t h e fu el level. Th e P CM t h en
in t h e On or St a r t posit ion s. Th e clu st er is pr o-
a pplies a n a lgor it h m t o t h e in pu t a n d sen ds t h e
gr a m m ed t o m ove t h e ga u ge n eedle ba ck t o t h e low
8J - 22 INSTRUMENT CLUSTER
FU EL GAU GE (Cont inue d)
pr oper per cen t t a n k fu ll m essa ges t o t h e in st r u m en t
clu st er. F or fu r t h er dia gn osis of t h e fu el ga u ge or t h e
in st r u m en t clu st er cir cu it r y t h a t con t r ols t h e ga u ge,
(Refer t o 8 - E LE CTRICAL/INSTRUME NT CLUS-
TE R - DIAGNOSIS AND TE STING). F or pr oper
dia gn osis of t h e fu el t a n k sen der, t h e P CM, t h e P CI
da t a bu s, or t h e elect r on ic m essa ge in pu t s t o t h e
in st r u m en t clu st er t h a t con t r ol t h e fu el ga u ge, a
DRBIII! sca n t ool is r equ ir ed. Refer t o t h e a ppr opr i-
a t e dia gn ost ic in for m a t ion .
H I GH BEAM I N DI CAT OR
DESCRIPTION
A h igh bea m in dica t or is st a n da r d equ ipm en t on
a ll in st r u m en t clu st er s. Th e h igh bea m in dica t or is
loca t ed n ea r t h e u pper edge of t h e in st r u m en t clu s-
t er, bet ween t h e t a ch om et er a n d t h e speedom et er.
Th e h igh bea m in dica t or con sist s of a n In t er n a t ion a l
Con t r ol a n d Displa y Sym bol icon for “H igh Bea m ”
im pr in t ed on a blu e len s. Th e len s is loca t ed beh in d a
cu t ou t in t h e opa qu e la yer of t h e in st r u m en t clu st er
over la y. Th e da r k ou t er la yer of t h e over la y pr even t s
t h e in dica t or fr om bein g clea r ly visible wh en it is n ot
illu m in a t ed. Th e icon a ppea r s silh ou et t ed a ga in st a
blu e field t h r ou gh t h e t r a n slu cen t ou t er la yer of t h e
over la y wh en t h e in dica t or is illu m in a t ed fr om
beh in d by a r epla cea ble in ca n descen t bu lb a n d bu lb
h older u n it loca t ed on t h e in st r u m en t clu st er elec-
t r on ic cir cu it boa r d. Wh en t h e ext er ior ligh t in g is
t u r n ed On , t h e illu m in a t ion in t en sit y of t h e h igh
bea m in dica t or is dim m a ble, wh ich is a dju st ed u sin g
t h e pa n el la m ps dim m er con t r ol r in g on t h e con t r ol
st a lk of t h e left m u lt i-fu n ct ion swit ch . Th e h igh bea m
in dica t or len s is ser viced a s a u n it wit h t h e in st r u -
m en t clu st er len s, h ood a n d m a sk u n it .
OPERATION
Th e h igh bea m in dica t or gives a n in dica t ion t o t h e
veh icle oper a t or wh en ever t h e h ea dla m p h igh bea m s
a r e illu m in a t ed. Th is in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec-
t r on ic m essa ges r eceived by t h e clu st er fr om t h e
Body Con t r ol Modu le (BCM) over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e h igh
bea m in dica t or bu lb is com plet ely con t r olled by t h e
in st r u m en t clu st er logic cir cu it , a n d t h a t logic will
a llow t h is in dica t or t o oper a t e wh en ever t h e in st r u -
m en t clu st er r eceives a ba t t er y cu r r en t in pu t on t h e
fu sed B(+) cir cu it . Th er efor e, t h e in dica t or ca n be
illu m in a t ed r ega r dless of t h e ign it ion swit ch posit ion .
Th e LE D on ly illu m in a t es wh en it is pr ovided a pa t h
t o gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
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in st r u m en t clu st er will t u r n on t h e h igh bea m in di-
ca t or for t h e followin g r ea son s:
• Hig h B e a m In d ic a to r La m p -On Me s s a g e -
E a ch t im e t h e clu st er r eceives a h igh bea m in dica t or
la m p-on m essa ge fr om t h e BCM in dica t in g t h a t t h e
h ea dla m p h igh bea m s a r e t u r n ed On , t h e h igh bea m
in dica t or will be illu m in a t ed. Th e in dica t or r em a in s
illu m in a t ed u n t il t h e clu st er r eceives a h igh bea m
in dica t or la m p-off m essa ge fr om t h e BCM.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e h igh bea m in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con -
t r ol cir cu it r y.
Th e BCM con t in u a lly m on it or s t h e ext er ior ligh t -
in g (left m u lt i-fu n ct ion ) swit ch t o det er m in e t h e
pr oper ou t pu t s t o t h e h ea dla m p low bea m a n d h igh
bea m r ela ys. Th e BCM t h en sen ds t h e pr oper h igh
bea m in dica t or la m p-on a n d la m p-off m essa ges t o t h e
in st r u m en t clu st er. If t h e h igh bea m in dica t or fa ils t o
ligh t du r in g t h e a ct u a t or t est , r epla ce t h e bu lb wit h a
kn own good u n it . F or fu r t h er dia gn osis of t h e h igh
bea m in dica t or or t h e in st r u m en t clu st er cir cu it r y
t h a t con t r ols t h e in dica t or, (Refer t o 8 - E LE CTRI-
CAL/INSTRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). F or pr oper dia gn osis of t h e h ea dla m p
syst em , t h e BCM, t h e P CI da t a bu s, or t h e elect r on ic
m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol
t h e h igh bea m in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
LOW FU EL I N DI CAT OR
DESCRIPTION
A low fu el in dica t or is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s. Th e low fu el in dica t or is loca t ed
n ea r t h e left edge of t h e in st r u m en t clu st er, t o t h e left
of t h e t a ch om et er. Th e low fu el in dica t or con sist s of a n
In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon for
“F u el” im pr in t ed on a n a m ber len s. Th e len s is loca t ed
beh in d a cu t ou t in t h e opa qu e la yer of t h e in st r u m en t
clu st er over la y. Th e da r k ou t er la yer of t h e over la y
pr even t s t h e icon fr om bein g clea r ly visible wh en t h e
in dica t or is n ot illu m in a t ed. Th e icon a ppea r s silh ou -
et t ed a ga in st a n a m ber field t h r ou gh t h e t r a n slu cen t
ou t er la yer of t h e over la y wh en t h e in dica t or is illu m i-
n a t ed fr om beh in d by a r epla cea ble in ca n descen t bu lb
a n d bu lb h older u n it loca t ed on t h e in st r u m en t clu st er
elect r on ic cir cu it boa r d. Wh en t h e ext er ior ligh t in g is
t u r n ed On , t h e illu m in a t ion in t en sit y of t h e low fu el
in dica t or is dim m a ble, wh ich is a dju st ed u sin g t h e
pa n el la m ps dim m er con t r ol r in g on t h e con t r ol st a lk
of t h e left m u lt i-fu n ct ion swit ch . Th e low fu el in dica -
WJ
LOW FU EL I N DI CAT OR (Cont inue d)
t or len s is ser viced a s a u n it wit h t h e in st r u m en t clu s-
t er len s, h ood a n d m a sk u n it .
OPERATION
Th e low fu el in dica t or gives a n in dica t ion t o t h e
veh icle oper a t or wh en t h e level of fu el in t h e fu el
t a n k becom es low. Th is in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec-
t r on ic m essa ges r eceived by t h e clu st er fr om t h e
P ower t r a in Con t r ol Modu le (P CM) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e
low fu el in dica t or bu lb is com plet ely con t r olled by t h e
in st r u m en t clu st er logic cir cu it , a n d t h a t logic will
on ly a llow t h is in dica t or t o oper a t e wh en t h e in st r u -
m en t clu st er r eceives a ba t t er y cu r r en t in pu t on t h e
fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it .
Th er efor e, t h e in dica t or will a lwa ys be off wh en t h e
ign it ion swit ch is in a n y posit ion except On or St a r t .
Th e bu lb on ly illu m in a t es wh en it is swit ch ed t o
gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
in st r u m en t clu st er will t u r n on t h e low fu el in dica t or
for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e low fu el in dica t or is
illu m in a t ed for a bou t t h r ee secon ds a s a bu lb t est .
• Le s s Th a n 12.5 P e rc e n t Ta n k F u ll Me s s a g e -
E a ch t im e t h e clu st er r eceives a m essa ge fr om t h e
P CM in dica t in g t h a t t h e per cen t t a n k fu ll is less
t h a n a bou t 12.5 (on e-eigh t h ), t h e low fu el in dica t or is
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il
t h e clu st er r eceives m essa ges fr om t h e P CM in dica t -
in g t h a t t h e per cen t t a n k fu ll h a s in cr ea sed t o
gr ea t er t h a n a bou t 12.5 (on e-eigh t h ). Th e P CM
a pplies a n a lgor it h m t o t h e in pu t fr om t h e fu el t a n k
sen der t o da m pen t h e illu m in a t ion of t h e low fu el
in dica t or a ga in st t h e n ega t ive effect t h a t fu el slosh -
in g wit h in t h e fu el t a n k ca n h a ve on a ccu r a t e in pu t s
t o t h e P CM.
• Le s s Th a n Em p ty P e rc e n t Ta n k F u ll Me s -
s a g e - E a ch t im e t h e clu st er r eceives a m essa ge fr om
t h e P CM in dica t in g t h e per cen t t a n k fu ll is less t h a n
em pt y, t h e low fu el in dica t or is illu m in a t ed im m edi-
a t ely. Th is m essa ge wou ld in dica t e t h a t t h e fu el t a n k
sen der in pu t t o t h e P CM is a sh or t cir cu it .
• Mo re Th a n F u ll P e rc e n t Ta n k F u ll Me s s a g e
- E a ch t im e t h e clu st er r eceives a m essa ge fr om t h e
P CM in dica t in g t h e per cen t t a n k fu ll is m or e t h a n
fu ll, t h e low fu el in dica t or is illu m in a t ed im m edi-
a t ely. Th is m essa ge wou ld in dica t e t h a t t h e fu el t a n k
sen der in pu t t o t h e P CM is a n open cir cu it .
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a per cen t t a n k fu ll m essa ge for m or e t h a n
a bou t t welve secon ds, t h e clu st er con t r ol cir cu it r y
will illu m in a t e t h e low fu el in dica t or u n t il a n ew per-
cen t t a n k fu ll m essa ge is r eceived.
INSTRUMENT CLUSTER 8J - 23
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e low fu el in dica t or will
be t u r n ed on for t h e du r a t ion of t h e t est t o con fir m
t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con t r ol
cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e fu el t a n k
sen der in pu t t o det er m in e t h e fu el level. Th e P CM
t h en a pplies a n a lgor it h m t o t h e in pu t a n d sen ds t h e
pr oper per cen t t a n k fu ll m essa ges t o t h e in st r u m en t
clu st er. If t h e low fu el in dica t or fa ils t o ligh t du r in g
t h e bu lb t est , r epla ce t h e bu lb wit h a kn own good
u n it . F or fu r t h er dia gn osis of t h e low fu el in dica t or
or t h e in st r u m en t clu st er cir cu it r y t h a t con t r ols t h e
in dica t or, (Refer t o 8 - E LE CTRICAL/INSTRUME NT
CLUSTE R - DIAGNOSIS AND TE STING). F or
pr oper dia gn osis of t h e fu el t a n k sen der, t h e P CM,
t h e P CI da t a bu s, or t h e elect r on ic m essa ge in pu t s t o
t h e in st r u m en t clu st er t h a t con t r ol t h e low fu el in di-
ca t or, a DRBIII! sca n t ool is r equ ir ed. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
M ALFU N CT I ON I N DI CAT OR
LAM P (M I L)
DESCRIPTION
A Ma lfu n ct ion In dica t or La m p (MIL) is st a n da r d
equ ipm en t on a ll in st r u m en t clu st er s. Th e MIL is
loca t ed n ea r t h e r igh t edge of t h e in st r u m en t clu st er,
t o t h e r igh t of t h e speedom et er. Th e MIL con sist s of
a n In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon for
“E n gin e” im pr in t ed on a n a m ber len s. Th e len s is
loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e icon fr om bein g clea r ly vis-
ible wh en t h e in dica t or is n ot illu m in a t ed. Th e icon
a ppea r s silh ou et t ed a ga in st a n a m ber field t h r ou gh
t h e t r a n slu cen t ou t er la yer of t h e over la y wh en t h e
in dica t or is illu m in a t ed fr om beh in d by a r epla cea ble
in ca n descen t bu lb a n d bu lb h older u n it loca t ed on
t h e in st r u m en t clu st er elect r on ic cir cu it boa r d. Th e
MIL len s is ser viced a s a u n it wit h t h e in st r u m en t
clu st er len s, h ood a n d m a sk u n it .
OPERATION
Th e Ma lfu n ct ion In dica t or La m p (MIL) gives a n
in dica t ion t o t h e veh icle oper a t or wh en t h e P ower-
t r a in Con t r ol Modu le (P CM) h a s r ecor ded a Dia gn os-
t ic Tr ou ble Code (DTC) for a n On -Boa r d Dia gn ost ics
II (OBDII) em ission s-r ela t ed cir cu it or com pon en t
m a lfu n ct ion . Th is in dica t or is con t r olled by a t r a n sis-
t or on t h e in st r u m en t clu st er elect r on ic cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e P CM over t h e
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s. Th e MIL bu lb is com plet ely con t r olled by t h e
8J - 24 INSTRUMENT CLUSTER WJ
M ALFU N CT I ON I N DI CAT OR LAM P (M I L) (Cont inue d)
in st r u m en t clu st er logic cir cu it , a n d t h a t logic will ODOM ET ER
on ly a llow t h is in dica t or t o oper a t e wh en t h e in st r u -
m en t clu st er r eceives a ba t t er y cu r r en t in pu t on t h e
DESCRIPTION
fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it .
An odom et er a n d t r ip odom et er a r e st a n da r d
Th er efor e, t h e in dica t or will a lwa ys be off wh en t h e
equ ipm en t in a ll in st r u m en t clu st er s. Th e odom et er
ign it ion swit ch is in a n y posit ion except On or St a r t .
a n d t r ip odom et er in for m a t ion a r e displa yed in a
Th e bu lb on ly illu m in a t es wh en it is pr ovided a pa t h
com m on elect r on ic, blu e-gr een Va cu u m -F lu or escen t
t o gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
Displa y (VF D), wh ich is loca t ed in t h e lower edge of
in st r u m en t clu st er will t u r n on t h e MIL for t h e fol-
t h e speedom et er dia l fa ce in t h e in st r u m en t clu st er
lowin g r ea son s:
a n d, wh en illu m in a t ed, is visible t h r ou gh a sm a ll
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
win dow cu t ou t in t h e ga u ge over la y. H owever, t h e
t u r n ed t o t h e On posit ion t h e MIL is illu m in a t ed for
odom et er a n d t r ip odom et er in for m a t ion a r e n ot dis-
a bou t t h r ee secon ds a s a bu lb t est .
pla yed sim u lt a n eou sly. Th e t r ip odom et er r eset
• MIL La m p -On Me s s a g e - E a ch t im e t h e clu s-
swit ch on t h e in st r u m en t clu st er elect r on ic cir cu it
t er r eceives a MIL la m p-on m essa ge fr om t h e P CM,
boa r d t oggles t h e displa y bet ween odom et er a n d t r ip
t h e in dica t or will be illu m in a t ed. Th e in dica t or ca n
odom et er m odes by depr essin g t h e odom et er /t r ip
be fla sh ed on a n d off, or illu m in a t ed solid, a s dic-
odom et er swit ch bu t t on t h a t ext en ds t h r ou gh t h e
t a t ed by t h e P CM m essa ge. F or som e DTC’s, if a
lower edge of t h e clu st er len s t o t h e r igh t of t h e
pr oblem does n ot r ecu r, t h e P CM will sen d a MIL
speedom et er.
la m p-off m essa ge a u t om a t ica lly. Ot h er DTC’s m a y
All odom et er a n d t r ip odom et er dist a n ce in for m a -
r equ ir e t h a t a fa u lt be r epa ir ed a n d t h e P CM be
t ion is st or ed in t h e in st r u m en t clu st er m em or y. Th is
r eset befor e a MIL la m p-off m essa ge will be sen t . F or
dist a n ce in for m a t ion ca n be in cr ea sed wh en t h e
m or e in for m a t ion on t h e P CM a n d t h e DTC set a n d
pr oper in pu t s a r e pr ovided t o t h e in st r u m en t clu st er,
r eset pa r a m et er s, (Refer t o 25 - E MISSIONS CON-
bu t t h e dist a n ce in for m a t ion ca n n ot be decr ea sed.
TROL - OP E RATION).
Th e odom et er ca n displa y va lu es u p t o 999,999 kilo-
• Co m m u n ic a tio n Erro r - If t h e clu st er r eceives
m et er s (999,999 m iles). Th e odom et er will n ot r oll
n o MIL la m p-on or la m p-off m essa ges fr om t h e P CM
over, bu t will la t ch a t t h e m a xim u m va lu e. Th e t r ip
for t wen t y con secu t ive secon ds, t h e MIL is illu m i-
odom et er ca n displa y va lu es u p t o 999.9 kilom et er s
n a t ed by t h e in st r u m en t clu st er. Th e in dica t or
(999.9 m iles) befor e it r olls over t o zer o. Th e odom e-
r em a in s con t r olled a n d illu m in a t ed by t h e clu st er
t er displa y does n ot h a ve a decim a l poin t a n d will
u n t il a va lid MIL la m p-on or la m p-off m essa ge is
n ot sh ow va lu es less t h a n a fu ll u n it (kilom et er or
r eceived fr om t h e P CM.
m ile), t h e t r ip odom et er displa y does h a ve a decim a l
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
poin t a n d will sh ow t en t h s of a u n it (kilom et er or
t h r ou gh t h e a ct u a t or t est , t h e MIL will be t u r n ed on
m ile).
for t h e du r a t ion of t h e t est t o con fir m t h e fu n ct ion a l-
Th e u n it of m ea su r e for t h e odom et er a n d t r ip
it y of t h e bu lb a n d t h e clu st er con t r ol cir cu it r y.
odom et er displa y is n ot sh own in t h e VF D. Th e u n it
Th e P CM con t in u a lly m on it or s ea ch of t h e m a n y
of m ea su r e for t h e odom et er /t r ip odom et er is select ed
fu el a n d em ission s syst em cir cu it s a n d sen sor s t o
a t t h e t im e t h a t t h e in st r u m en t clu st er is m a n u fa c-
decide wh et h er t h e syst em is in good oper a t in g con -
t u r ed, a n d ca n n ot be ch a n ged. If t h e in st r u m en t clu s-
dit ion . Th e P CM t h en sen ds t h e pr oper MIL la m p-on
t er h a s a kilom et er s-per-h ou r pr im a r y speedom et er
or la m p-off m essa ges t o t h e in st r u m en t clu st er. If t h e
sca le, t h e odom et er /t r ip odom et er r egist er s kilom e-
MIL fa ils t o ligh t du r in g t h e bu lb t est , r epla ce t h e
t er s; a n d, if t h e clu st er fea t u r es a m iles-per-h ou r pr i-
bu lb wit h a kn own good u n it . F or fu r t h er dia gn osis of
m a r y speedom et er sca le, t h e odom et er /t r ip odom et er
t h e MIL or t h e in st r u m en t clu st er cir cu it r y t h a t con -
r egist er s m iles.
t r ols t h e in dica t or, (Refer t o 8 - E LE CTRICAL/IN-
Du r in g da yligh t h ou r s (ext er ior la m ps Off) t h e
STRUME NT CLUSTE R - DIAGNOSIS AND
VF D is illu m in a t ed a t fu ll br igh t n ess for clea r visibil-
TE STING). If t h e in st r u m en t clu st er t u r n s on t h e
it y. At n igh t (ext er ior la m ps a r e On ) t h e in st r u m en t
MIL a ft er t h e bu lb t est , it m a y in dica t e t h a t a m a l-
clu st er con ver t s a n elect r on ic dim m in g level m essa ge
fu n ct ion h a s occu r r ed a n d t h a t t h e fu el a n d em is-
r eceived fr om t h e Body Con t r ol Modu le (BCM) over
sion s syst em m a y r equ ir e ser vice. F or pr oper
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
dia gn osis of t h e fu el a n d em ission s syst em s, t h e
da t a bu s t o a digit a l dim m in g level sign a l for con t r ol-
P CM, t h e P CI da t a bu s, or t h e elect r on ic m essa ge
lin g t h e ligh t in g level of t h e VF D. H owever, a
in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol t h e
“P a r a de” m ode posit ion of t h e pa n el la m ps dim m er
MIL, a DRBIII! sca n t ool is r equ ir ed. Refer t o t h e
con t r ol r in g on t h e con t r ol st a lk of t h e left (ligh t in g)
a ppr opr ia t e dia gn ost ic in for m a t ion .
m u lt i-fu n ct ion swit ch a llows t h e VF D t o be illu m i-
WJ
ODOM ET ER (Cont inue d)
n a t ed a t fu ll br igh t n ess if t h e ext er ior la m ps a r e
t u r n ed On du r in g da yligh t h ou r s.
Th e VF D, t h e t r ip odom et er swit ch , a n d t h e t r ip
odom et er swit ch bu t t on a r e ser viced a s a u n it wit h
t h e in st r u m en t clu st er.
OPERATION
Th e odom et er a n d t r ip odom et er give a n in dica t ion
t o t h e veh icle oper a t or of t h e dist a n ce t h e veh icle h a s
t r a veled. Th is ga u ge is con t r olled by t h e in st r u m en t
clu st er elect r on ic cir cu it r y ba sed u pon clu st er pr o-
gr a m m in g a n d elect r on ic m essa ges r eceived by t h e
clu st er fr om t h e P ower t r a in Con t r ol Modu le (P CM)
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s. Th e odom et er a n d t r ip odom et er
in for m a t ion is displa yed by t h e in st r u m en t clu st er
Va cu u m F lu or escen t Displa y (VF D). Th e VF D will
on ly displa y odom et er or t r ip odom et er in for m a t ion
a ft er t h e ign it ion swit ch is t u r n ed t o t h e On or St a r t
posit ion s, a n d will displa y t h e in for m a t ion in t h e
odom et er or t r ip odom et er m ode ba sed u pon t h e
select ion t h a t wa s a ct ive wh en t h e ign it ion swit ch
wa s la st t u r n ed t o t h e Off posit ion . Th e in st r u m en t
clu st er cir cu it r y con t r ols t h e VF D a n d pr ovides t h e
followin g fea t u r es:
• Od o m e te r/Trip Od o m e te r D is p la y To g g lin g -
Act u a t in g t h e t r ip odom et er r eset swit ch bu t t on
m om en t a r ily wit h t h e ign it ion swit ch in t h e On posi-
t ion will t oggle t h e displa y bet ween t h e odom et er a n d
t r ip odom et er in for m a t ion . E a ch t im e t h e ign it ion
swit ch is t u r n ed t o t h e On or St a r t posit ion s, t h e dis-
pla y will a u t om a t ica lly r et u r n t o t h e la st m ode
select ed (odom et er or t r ip odom et er ) befor e t h e ign i-
t ion swit ch wa s t u r n ed t o t h e Off posit ion .
• Trip Od o m e te r Re s e t - Wh en t h e t r ip odom e-
t er r eset swit ch bu t t on is depr essed a n d h eld for
lon ger t h a n a bou t t wo secon ds wit h t h e ign it ion s
swit ch in t h e On or St a r t posit ion s, t h e t r ip odom et er
will be r eset t o 000.0 kilom et er s (m iles). Th e VF D
m u st be displa yin g t h e cu r r en t t r ip odom et er in for-
m a t ion in or der for t h e t r ip odom et er in for m a t ion t o
be r eset .
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a dist a n ce m essa ge du r in g n or m a l oper a t ion ,
it will h old a n d displa y t h e la st da t a r eceived u n t il
t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion . If
t h e clu st er does n ot r eceive a dist a n ce m essa ge
wit h in on e secon d a ft er t h e ign it ion swit ch is t u r n ed
t o t h e On posit ion , it will displa y t h e la st dist a n ce
m essa ge st or ed in t h e clu st er m em or y. If it is det er-
m in ed t h a t t h e dist a n ce in for m a t ion st or ed in t h e
clu st er m em or y is cor r u pt , it will displa y “------” in
t h e VF D. If t h e clu st er is u n a ble t o displa y dist a n ce
in for m a t ion du e t o a n er r or in t er n a l t o t h e clu st er,
t h e VF D displa y will be bla n k.
INSTRUMENT CLUSTER 8J - 25
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e VF D will st ep sequ en -
t ia lly t h r ou gh a displa y of “000000” t h r ou gh
“999999”, t h en displa y t h e clu st er soft wa r e ver sion
n u m ber t o con fir m t h e fu n ct ion a lit y of t h e VF D a n d
t h e clu st er con t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e veh icle speed
pu lse in for m a t ion r eceived fr om t h e veh icle speed
sen sor, t h en sen ds t h e pr oper dist a n ce m essa ges t o
t h e in st r u m en t clu st er. F or fu r t h er dia gn osis of t h e
odom et er /t r ip odom et er or t h e in st r u m en t clu st er cir-
cu it r y t h a t con t r ols t h ese fu n ct ion s, (Refer t o 8 -
E LE CTRICAL/INSTRUME NT CLUSTE R - DIAGNO-
SIS AND TE STING). F or pr oper dia gn osis of t h e
veh icle speed sen sor, t h e P CM, t h e P CI da t a bu s, or
t h e elect r on ic m essa ge in pu t s t o t h e in st r u m en t clu s-
t er t h a t con t r ol t h e odom et er /t r ip odom et er, a
DRBIII! sca n t ool is r equ ir ed. Refer t o t h e a ppr opr i-
a t e dia gn ost ic in for m a t ion .
OI L PRESSU RE GAU GE
DESCRIPTION
An oil pr essu r e ga u ge is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s. Th e oil pr essu r e ga u ge is loca t ed
in t h e u pper r igh t cor n er of t h e in st r u m en t clu st er, t o
t h e r igh t of t h e speedom et er. Th e oil pr essu r e ga u ge
con sist s of a m ova ble ga u ge n eedle or poin t er con -
t r olled by t h e in st r u m en t clu st er cir cu it r y a n d a fixed
90 degr ee sca le on t h e ga u ge dia l fa ce t h a t r ea ds left -
t o-r igh t fr om 0 kg/cm t o 5.4 kg/cm (m et r ic clu st er
for ga solin e en gin es), fr om 0 kg/cm t o 8.3 kg/cm
(m et r ic clu st er for diesel en gin es), or fr om 0 psi t o 80
psi (U.S. clu st er ), depen din g u pon t h e m a r ket for
wh ich t h e veh icle is m a n u fa ct u r ed. An In t er n a t ion a l
Con t r ol a n d Displa y Sym bol icon for “E n gin e Oil” is
loca t ed on t h e ga u ge dia l fa ce.
Th e oil pr essu r e ga u ge gr a ph ics a r e eit h er wh it e,
gr a y a n d or a n ge a ga in st a bla ck ga u ge dia l fa ce (ba se
clu st er ) or bla ck a n d gr a y a ga in st a t a u pe ga u ge dia l
fa ce (pr em iu m clu st er ), m a kin g t h em clea r ly visible
wit h in t h e in st r u m en t clu st er in da yligh t . Wh en illu -
m in a t ed fr om beh in d by t h e pa n el la m ps dim m er
con t r olled clu st er illu m in a t ion ligh t in g wit h t h e ext e-
r ior la m ps t u r n ed On , t h e ba se clu st er wh it e ga u ge
gr a ph ics a ppea r blu e-gr een a n d t h e or a n ge gr a ph ics
st ill a ppea r or a n ge, wh ile t h e pr em iu m clu st er t a u pe
ga u ge dia l fa ce a ppea r s blu e-gr een wit h t h e bla ck
gr a ph ics silh ou et t ed a ga in st t h e illu m in a t ed ba ck-
gr ou n d. Th e gr a y ga u ge gr a ph ics for bot h ver sion s of
t h e clu st er a r e n ot illu m in a t ed. Th e or a n ge ga u ge
n eedle in t h e ba se clu st er ga u ge is in t er n a lly illu m i-
n a t ed, wh ile t h e bla ck ga u ge n eedle in t h e pr em iu m
clu st er ga u ge is n ot .
8J - 26 INSTRUMENT CLUSTER
OI L PRESSU RE GAU GE (Cont inue d)
Ba se clu st er ga u ge illu m in a t ion is pr ovided by
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it s
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. P r em iu m clu st er ga u ge illu m in a t ion is pr o-
vided by a n in t egr a l elect r o-lu m in escen t la m p t h a t is
ser viced a s a u n it wit h t h e in st r u m en t clu st er. Th e
oil pr essu r e ga u ge is ser viced a s a u n it wit h t h e
in st r u m en t clu st er.
OPERATION
Th e oil pr essu r e ga u ge gives a n in dica t ion t o t h e
veh icle oper a t or of t h e en gin e oil pr essu r e. Th is
ga u ge is con t r olled by t h e in st r u m en t clu st er cir cu it
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec-
t r on ic m essa ges r eceived by t h e clu st er fr om t h e
P ower t r a in Con t r ol Modu le (P CM) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e
oil pr essu r e ga u ge is a n a ir cor e m a gn et ic u n it t h a t
r eceives ba t t er y cu r r en t on t h e in st r u m en t clu st er
elect r on ic cir cu it boa r d t h r ou gh t h e fu sed ign it ion
swit ch ou t pu t (r u n -st a r t ) cir cu it wh en ever t h e ign i-
t ion swit ch is in t h e On or St a r t posit ion s. Th e clu s-
t er is pr ogr a m m ed t o m ove t h e ga u ge n eedle ba ck t o
t h e low en d of t h e sca le a ft er t h e ign it ion swit ch is
t u r n ed t o t h e Off posit ion . Th e in st r u m en t clu st er
cir cu it r y con t r ols t h e ga u ge n eedle posit ion a n d pr o-
vides t h e followin g fea t u r es:
• En g in e Oil P re s s u re N o rm a l Me s s a g e - E a ch
t im e t h e clu st er r eceives a m essa ge fr om t h e P CM
in dica t in g t h e en gin e oil pr essu r e is wit h in t h e n or-
m a l oper a t in g r a n ge [a bove 0.28 kg/cm (a bove 4
psi), t h e ga u ge n eedle is m oved t o t h e r ela t ive pr es-
su r e posit ion of t h e ga u ge sca le.
• En g in e Oil P re s s u re Lo w Me s s a g e - E a ch
t im e t h e clu st er r eceives a m essa ge fr om t h e P CM
in dica t in g t h e en gin e oil pr essu r e is a bou t 0.28
kg/cm or lower (a bou t 4 psi or lower ), t h e ga u ge
n eedle is m oved t o t h e fa r left (low) en d of t h e ga u ge
sca le. Th e ga u ge n eedle r em a in s a t t h e low en d of
t h e sca le u n t il t h e clu st er r eceives a m essa ge fr om
t h e P CM in dica t in g t h a t t h e en gin e oil pr essu r e is
a bou t 0.56 kg/cm or h igh er (a bou t 8 psi or h igh er ).
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a n en gin e oil pr essu r e m essa ge, it will h old
t h e ga u ge n eedle a t t h e la st in dica t ion for a bou t
t welve secon ds or u n t il a n ew en gin e oil pr essu r e
m essa ge is r eceived, wh ich ever occu r s fir st . Aft er
t welve secon ds, t h e clu st er will r et u r n t h e ga u ge n ee-
dle t o t h e low en d of t h e ga u ge sca le.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e ga u ge n eedle will be
swept a cr oss t h e en t ir e ga u ge sca le a n d ba ck in or der
t o con fir m t h e fu n ct ion a lit y of t h e ga u ge a n d t h e
clu st er con t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e en gin e oil pr es-
su r e sen sor t o det er m in e t h e en gin e oil pr essu r e. Th e
WJ
P CM t h en sen ds t h e pr oper en gin e oil pr essu r e m es-
sa ges t o t h e in st r u m en t clu st er. F or fu r t h er dia gn osis
of t h e oil pr essu r e ga u ge or t h e in st r u m en t clu st er
cir cu it r y t h a t con t r ols t h e ga u ge, (Refer t o 8 - E LE C-
TRICAL/INSTRUME NT CLUSTE R - DIAGNOSIS
AND TE STING). If t h e in st r u m en t clu st er t u r n s on
t h e ch eck ga u ges in dica t or du e t o a low oil pr essu r e
ga u ge r ea din g, it m a y in dica t e t h a t t h e en gin e or t h e
en gin e oilin g syst em r equ ir es ser vice. F or pr oper
dia gn osis of t h e en gin e oil pr essu r e sen sor, t h e P CM,
t h e P CI da t a bu s, or t h e elect r on ic m essa ge in pu t s t o
t h e in st r u m en t clu st er t h a t con t r ol t h e oil pr essu r e
ga u ge, a DRBIII! sca n t ool is r equ ir ed. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
OV ERDRI V E OFF I N DI CAT OR
DESCRIPTION
An over dr ive off in dica t or is st a n da r d equ ipm en t
on a ll ga solin e en gin e in st r u m en t clu st er s. Th e over-
dr ive off in dica t or is loca t ed in t h e lower edge of t h e
t a ch om et er ga u ge dia l fa ce in t h e in st r u m en t clu st er.
Th e over dr ive off in dica t or con sist s of t h e wor ds “O/D
OF F ” im pr in t ed on a n a m ber len s. Th e len s is
loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
t a ch om et er ga u ge dia l fa ce over la y. Th e da r k ou t er
la yer of t h e ga u ge dia l fa ce over la y pr even t s t h e in di-
ca t or fr om bein g clea r ly visible wh en it is n ot illu m i-
n a t ed. Th e wor ds “O/D OF F ” a ppea r silh ou et t ed
a ga in st a n a m ber field t h r ou gh t h e t r a n slu cen t ou t er
la yer of t h e ga u ge dia l fa ce over la y wh en t h e in dica -
t or is illu m in a t ed fr om beh in d by a r epla cea ble
in ca n descen t bu lb a n d bu lb h older u n it loca t ed on
t h e in st r u m en t clu st er elect r on ic cir cu it boa r d. Wh en
t h e ext er ior ligh t in g is t u r n ed On , t h e illu m in a t ion
in t en sit y of t h e over dr ive off in dica t or is dim m a ble,
wh ich is a dju st ed u sin g t h e pa n el la m ps dim m er con -
t r ol r in g on t h e con t r ol st a lk of t h e left m u lt i-fu n c-
t ion swit ch . Th e over dr ive off in dica t or len s is
ser viced a s a u n it wit h t h e in st r u m en t clu st er.
OPERATION
Th e over dr ive off in dica t or gives a n in dica t ion t o
t h e veh icle oper a t or wh en t h e Off posit ion of t h e
over dr ive off swit ch h a s been select ed, disa blin g t h e
elect r on ica lly con t r olled over dr ive fea t u r e of t h e a u t o-
m a t ic t r a n sm ission . Th is in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th ese
m essa ges a r e sen t by t h e P ower t r a in Con t r ol Modu le
(P CM) or by t h e Tr a n sm ission Con t r ol Modu le
(TCM), depen din g on t h e m odel of t h e a u t om a t ic
t r a n sm ission . Th e over dr ive off in dica t or bu lb is com -
WJ
OV ERDRI V E OFF I N DI CAT OR (Cont inue d)
plet ely con t r olled by t h e in st r u m en t clu st er logic cir-
cu it , a n d t h a t logic will on ly a llow t h is in dica t or t o
oper a t e wh en t h e in st r u m en t clu st er r eceives a ba t -
t er y cu r r en t in pu t on t h e fu sed ign it ion swit ch ou t -
pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in dica t or will
a lwa ys be off wh en t h e ign it ion swit ch is in a n y posi-
t ion except On or St a r t . Th e bu lb on ly illu m in a t es
wh en it is pr ovided a pa t h t o gr ou n d by t h e in st r u -
m en t clu st er t r a n sist or. Th e in st r u m en t clu st er will
t u r n on t h e over dr ive off in dica t or for t h e followin g
r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e over dr ive off in dica t or
is illu m in a t ed for a bou t t h r ee secon ds a s a bu lb t est .
• Ov e rd riv e Off In d ic a to r La m p -On Me s s a g e -
E a ch t im e t h e clu st er r eceives a n over dr ive off in di-
ca t or la m p-on m essa ge fr om t h e P CM or TCM in di-
ca t in g t h a t t h e Off posit ion of t h e over dr ive off
swit ch h a s been select ed, t h e over dr ive off in dica t or
will be illu m in a t ed. Th e in dica t or r em a in s illu m i-
n a t ed u n t il t h e clu st er r eceives a n over dr ive off in di-
ca t or la m p-off m essa ge fr om t h e P CM or TCM, or
u n t il t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion ,
wh ich ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e over dr ive off in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con -
t r ol cir cu it r y.
Th e P CM or TCM con t in u a lly m on it or s t h e over-
dr ive off swit ch t o det er m in e t h e pr oper ou t pu t s t o
t h e a u t om a t ic t r a n sm ission . Th e P CM or TCM t h en
sen ds t h e pr oper over dr ive off in dica t or la m p-on or
la m p-off m essa ges t o t h e in st r u m en t clu st er. If t h e
over dr ive off in dica t or fa ils t o ligh t du r in g t h e bu lb
t est , r epla ce t h e bu lb wit h a kn own good u n it . F or
fu r t h er dia gn osis of t h e over dr ive off in dica t or or t h e
in st r u m en t clu st er cir cu it r y t h a t con t r ols t h e in dica -
t or, (Refer t o 8 - E LE CTRICAL/INSTRUME NT
CLUSTE R - DIAGNOSIS AND TE STING). F or
pr oper dia gn osis of t h e over dr ive con t r ol syst em , t h e
P CM, t h e TCM, t h e P CI da t a bu s, or t h e elect r on ic
m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol
t h e over dr ive off in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
REAR FOG LAM P I N DI CAT OR
DESCRIPTION
A r ea r fog la m p in dica t or is st a n da r d equ ipm en t on
a ll in st r u m en t clu st er s, bu t is on ly fu n ct ion a l on
veh icles equ ipped wit h opt ion a l r ea r fog la m ps,
wh ich a r e a va ila ble on ly in cer t a in in t er n a t ion a l
m a r ket s wh er e t h ey a r e r equ ir ed. Th e r ea r fog la m p
INSTRUMENT CLUSTER 8J - 27
in dica t or is loca t ed on t h e left edge of t h e in st r u m en t
clu st er, t o t h e left of t h e t a ch om et er. Th e r ea r fog
la m p in dica t or con sist s of a n In t er n a t ion a l Con t r ol
a n d Displa y Sym bol icon for “Rea r F og Ligh t ”
im pr in t ed on a n a m ber len s. Th e len s is loca t ed
beh in d a cu t ou t in t h e opa qu e la yer of t h e in st r u -
m en t clu st er over la y. Th e da r k ou t er la yer of t h e
over la y pr even t s t h e in dica t or fr om bein g clea r ly vis-
ible wh en it is n ot illu m in a t ed. Th e icon a ppea r s sil-
h ou et t ed a ga in st a n a m ber field t h r ou gh t h e
t r a n slu cen t ou t er la yer of t h e over la y wh en t h e in di-
ca t or is illu m in a t ed fr om beh in d by a r epla cea ble
in ca n descen t bu lb a n d bu lb h older u n it loca t ed on
t h e in st r u m en t clu st er elect r on ic cir cu it boa r d. Wh en
t h e ext er ior ligh t in g is t u r n ed On , t h e illu m in a t ion
in t en sit y of t h e r ea r fog la m p in dica t or is dim m a ble,
wh ich is a dju st ed u sin g t h e pa n el la m ps dim m er con -
t r ol r in g on t h e con t r ol st a lk of t h e left m u lt i-fu n c-
t ion swit ch . Th e r ea r fog la m p in dica t or len s is
ser viced a s a u n it wit h t h e in st r u m en t clu st er len s,
h ood a n d m a sk u n it .
OPERATION
Th e r ea r fog la m p in dica t or gives a n in dica t ion t o
t h e veh icle oper a t or wh en ever t h e r ea r fog la m ps a r e
illu m in a t ed. Th is in dica t or is con t r olled by a t r a n sis-
t or on t h e in st r u m en t clu st er elect r on ic cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e Body Con t r ol
Modu le (BCM) over t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s. Th e r ea r fog la m p
in dica t or bu lb is com plet ely con t r olled by t h e in st r u -
m en t clu st er logic cir cu it , a n d t h a t logic will a llow
t h is in dica t or t o oper a t e wh en ever t h e in st r u m en t
clu st er r eceives a ba t t er y cu r r en t in pu t on t h e fu sed
B(+) cir cu it . Th er efor e, t h e in dica t or ca n be illu m i-
n a t ed r ega r dless of t h e ign it ion swit ch posit ion . Th e
bu lb on ly illu m in a t es wh en it is pr ovided a pa t h t o
gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
in st r u m en t clu st er will t u r n on t h e r ea r fog la m p
in dica t or for t h e followin g r ea son s:
• Re a r F o g La m p In d ic a to r La m p -On Me s -
s a g e - E a ch t im e t h e clu st er r eceives a r ea r fog la m p
in dica t or la m p-on m essa ge fr om t h e BCM in dica t in g
t h a t t h e r ea r fog la m ps a r e t u r n ed On , t h e r ea r fog
la m p in dica t or will be illu m in a t ed. Th e in dica t or
r em a in s illu m in a t ed u n t il t h e clu st er r eceives a r ea r
fog la m p in dica t or la m p-off m essa ge fr om t h e BCM.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e r ea r fog la m p in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con -
t r ol cir cu it r y.
Th e BCM con t in u a lly m on it or s t h e ext er ior ligh t -
in g (left m u lt i-fu n ct ion ) swit ch t o det er m in e t h e
pr oper ou t pu t s t o t h e r ea r fog la m p r ela y. Th e BCM
8J - 28 INSTRUMENT CLUSTER
REAR FOG LAM P I N DI CAT OR (Cont inue d)
t h en sen ds t h e pr oper r ea r fog la m p in dica t or
la m p-on a n d la m p-off m essa ges t o t h e in st r u m en t
clu st er. If t h e r ea r fog la m p in dica t or fa ils t o ligh t
du r in g t h e a ct u a t or t est , r epla ce t h e bu lb wit h a
kn own good u n it . F or fu r t h er dia gn osis of t h e r ea r
fog la m p in dica t or or t h e in st r u m en t clu st er cir cu it r y
t h a t con t r ols t h e in dica t or, (Refer t o 8 - E LE CTRI-
CAL/INSTRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). F or pr oper dia gn osis of t h e r ea r fog la m p
syst em , t h e BCM, t h e P CI da t a bu s, or t h e elect r on ic
m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol
t h e r ea r fog la m p in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
SEAT BELT I N DI CAT OR
DESCRIPTION
A sea t belt in dica t or is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s. Th e sea t belt in dica t or is loca t ed
n ea r t h e lower edge of t h e in st r u m en t clu st er, t o t h e
left of t h e t a ch om et er. Th e sea t belt in dica t or con sist s
of a n In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon
for “Sea t Belt ” im pr in t ed on a r ed len s. Th e len s is
loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e icon fr om bein g clea r ly vis-
ible wh en t h e in dica t or is n ot illu m in a t ed. Th e icon
a ppea r s silh ou et t ed a ga in st a r ed field t h r ou gh t h e
t r a n slu cen t ou t er la yer of t h e over la y wh en it is illu -
m in a t ed fr om beh in d by a Ligh t E m it t in g Diode
(LE D), wh ich is solder ed on t o t h e in st r u m en t clu st er
elect r on ic cir cu it boa r d. Th e sea t belt in dica t or len s is
ser viced a s a u n it wit h t h e in st r u m en t clu st er len s,
h ood a n d m a sk u n it .
OPERATION
Th e sea t belt in dica t or gives a n in dica t ion t o t h e
veh icle oper a t or of t h e st a t u s of t h e dr iver side fr on t
sea t belt . Th is in dica t or is con t r olled by a t r a n sist or
on t h e in st r u m en t clu st er elect r on ic cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g. On m odels
equ ipped wit h a ir ba gs t h e in dica t or is a lso con t r olled
by elect r on ic m essa ges r eceived by t h e clu st er fr om
t h e Air ba g Con t r ol Modu le (ACM) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e
sea t belt in dica t or Ligh t E m it t in g Diode (LE D) is
com plet ely con t r olled by t h e in st r u m en t clu st er logic
cir cu it , a n d t h a t logic will on ly a llow t h is in dica t or t o
oper a t e wh en t h e in st r u m en t clu st er r eceives a ba t -
t er y cu r r en t in pu t on t h e fu sed ign it ion swit ch ou t -
pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in dica t or will
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a lwa ys be off wh en t h e ign it ion swit ch is in a n y posi-
t ion except On or St a r t . Th e LE D on ly illu m in a t es
wh en it is pr ovided a pa t h t o gr ou n d by t h e in st r u -
m en t clu st er t r a n sist or. Th e in st r u m en t clu st er will
t u r n on t h e sea t belt in dica t or for t h e followin g r ea -
son s:
• S e a tbe lt Re m in d e r F u n c tio n - E a ch t im e t h e
clu st er r eceives a ba t t er y cu r r en t in pu t on t h e fu sed
ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it , t h e in dica -
t or will be illu m in a t ed a s a sea t belt r em in der for
a bou t six secon ds, or u n t il t h e ign it ion swit ch is
t u r n ed t o t h e Off posit ion , wh ich ever occu r s fir st .
Th is r em in der fu n ct ion will occu r r ega r dless of t h e
st a t u s of t h e elect r on ic sea t belt la m p-on or la m p-off
m essa ges r eceived by t h e clu st er fr om t h e ACM.
• S e a t B e lt In d ic a to r La m p -On Me s s a g e - On
m odels equ ipped wit h a ir ba gs, followin g t h e sea t belt
r em in der fu n ct ion , ea ch t im e t h e clu st er r eceives a
sea t belt in dica t or la m p-on m essa ge fr om t h e ACM
in dica t in g t h e dr iver side fr on t sea t belt is n ot fa s-
t en ed wit h t h e ign it ion swit ch in t h e St a r t or On
posit ion s, t h e sea t belt in dica t or will be illu m in a t ed.
Th e in dica t or r em a in s illu m in a t ed u n t il t h e clu st er
r eceives a sea t belt in dica t or la m p-off m essa ge fr om
t h e ACM, or u n t il t h e ign it ion swit ch is t u r n ed t o t h e
Off posit ion , wh ich ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e sea t belt in dica t or will
be t u r n ed on for t h e du r a t ion of t h e t est t o con fir m
t h e fu n ct ion a lit y of t h e LE D a n d t h e clu st er con t r ol
cir cu it r y.
Th e in st r u m en t clu st er con t in u a lly m on it or s t h e
st a t u s of t h e ign it ion swit ch t h r ou gh t h e h a r d wir ed
fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it t o
det er m in e wh en t o pr ovide t h e sea t belt r em in der
fu n ct ion . On m odels equ ipped wit h a ir ba gs, t h e ACM
con t in u a lly m on it or s t h e st a t u s of bot h fr on t sea t belt
swit ch es t o det er m in e t h e pr oper a ir ba g syst em
r espon se t o a fr on t a l im pa ct of t h e veh icle. Th e ACM
t h en sen ds t h e pr oper sea t belt in dica t or la m p-on a n d
la m p-off m essa ges t o t h e in st r u m en t clu st er ba sed
u pon t h e st a t u s of t h e dr iver side fr on t sea t belt
swit ch in pu t . F or fu r t h er dia gn osis of t h e sea t belt
in dica t or or t h e in st r u m en t clu st er cir cu it r y t h a t con -
t r ols t h e in dica t or, (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND
TE STING). F or pr oper dia gn osis of t h e sea t belt
swit ch es, t h e ACM, t h e P CI da t a bu s, or t h e elec-
t r on ic m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t
con t r ol t h e sea t belt in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
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SH I FT I N DI CAT OR (T RAN SFER
CASE)
DESCRIPTION
A pa r t t im e in dica t or is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s, bu t is on ly fu n ct ion a l on veh i-
cles equ ipped wit h t h e st a n da r d equ ipm en t Selec-
Tr a c fou r-wh eel dr ive syst em . Th e pa r t t im e in dica t or
is loca t ed n ea r t h e r igh t edge of t h e in st r u m en t clu s-
t er, t o t h e r igh t of t h e speedom et er. Th e pa r t t im e
in dica t or con sist s of t h e wor ds “PART TIME ”
im pr in t ed on a n a m ber len s. Th e len s is loca t ed
beh in d a cu t ou t in t h e opa qu e la yer of t h e in st r u -
m en t clu st er over la y. Th e da r k ou t er la yer of t h e
over la y pr even t s t h e in dica t or fr om bein g clea r ly vis-
ible wh en it is n ot illu m in a t ed. Th e wor ds “PART
TIME ” a ppea r silh ou et t ed a ga in st a n a m ber field
t h r ou gh t h e t r a n slu cen t ou t er la yer of t h e over la y
wh en t h e in dica t or is illu m in a t ed fr om beh in d by a
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. Th e pa r t t im e in dica t or len s is ser viced a s a
u n it wit h t h e in st r u m en t clu st er len s, h ood a n d m a sk
u n it .
OPERATION
Th e pa r t t im e in dica t or gives a n in dica t ion t o t h e
veh icle oper a t or t h a t a fou r-wh eel dr ive pa r t t im e
oper a t in g m ode of t h e t r a n sfer ca se is select ed. On
veh icles wit h t h e st a n da r d equ ipm en t Selec-Tr a c
fou r-wh eel dr ive syst em , t h e pa r t t im e in dica t or illu -
m in a t es wh en t h e NV-242 t r a n sfer ca se is en ga ged in
eit h er t h e 4 X 4 P a r t Tim e or 4 Lo posit ion s. Th is
in dica t or is con t r olled by a t r a n sist or on t h e in st r u -
m en t clu st er elect r on ic cir cu it boa r d ba sed u pon clu s-
t er pr ogr a m m in g a n d elect r on ic m essa ges r eceived by
t h e clu st er fr om t h e P ower t r a in Con t r ol Modu le
(P CM) over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s. Th e pa r t t im e in dica t or
bu lb is com plet ely con t r olled by t h e in st r u m en t clu s-
t er logic cir cu it , a n d t h a t logic will on ly a llow t h is
in dica t or t o oper a t e wh en t h e in st r u m en t clu st er
r eceives a ba t t er y cu r r en t in pu t on t h e fu sed ign it ion
swit ch ou t pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in di-
ca t or will a lwa ys be off wh en t h e ign it ion swit ch is in
a n y posit ion except On or St a r t . Th e bu lb on ly illu -
m in a t es wh en it is pr ovided a pa t h t o gr ou n d by t h e
in st r u m en t clu st er t r a n sist or. Th e in st r u m en t clu st er
will t u r n on t h e pa r t t im e in dica t or for t h e followin g
r ea son s:
• P a rt Tim e In d ic a to r La m p -On Me s s a g e -
E a ch t im e t h e clu st er r eceives a pa r t t im e in dica t or
la m p-on m essa ge fr om t h e P CM in dica t in g t h a t a
fou r-wh eel dr ive pa r t t im e posit ion of t h e t r a n sfer
ca se h a s been select ed, t h e pa r t t im e in dica t or will be
INSTRUMENT CLUSTER 8J - 29
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il
t h e clu st er r eceives a pa r t t im e in dica t or la m p-off
m essa ge fr om t h e P CM.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e pa r t t im e in dica t or will
be t u r n ed on for t h e du r a t ion of t h e t est t o con fir m
t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con t r ol
cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e t r a n sfer ca se
swit ch t o det er m in e t h e dr ivelin e oper a t in g m ode.
Th e P CM t h en sen ds t h e pr oper pa r t t im e in dica t or
la m p-on a n d la m p-off m essa ges t o t h e in st r u m en t
clu st er. If t h e pa r t t im e in dica t or fa ils t o ligh t du r in g
t h e a ct u a t or t est , r epla ce t h e bu lb wit h a kn own good
u n it . F or fu r t h er dia gn osis of t h e pa r t t im e in dica t or
or t h e in st r u m en t clu st er cir cu it r y t h a t con t r ols t h e
in dica t or, (Refer t o 8 - E LE CTRICAL/INSTRUME NT
CLUSTE R - DIAGNOSIS AND TE STING). F or
pr oper dia gn osis of t h e t r a n sfer ca se swit ch , t h e
P CM, t h e P CI da t a bu s, or t h e elect r on ic m essa ge
in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol t h e pa r t
t im e in dica t or, a DRBIII! sca n t ool is r equ ir ed. Refer
t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
SK I S I N DI CAT OR
DESCRIPTION
A Sen t r y Key Im m obilizer Syst em (SKIS) in dica t or
is st a n da r d equ ipm en t on a ll in st r u m en t clu st er s, bu t
is on ly oper a t ion a l on veh icles equ ipped wit h t h e
opt ion a l SKIS. Th e SKIS in dica t or is loca t ed in t h e
u pper r igh t cor n er of t h e in st r u m en t clu st er, t o t h e
r igh t of t h e speedom et er. Th e SKIS in dica t or con sist s
of a gr a ph ica l r epr esen t a t ion or icon of a cir cled a n d
cr ossed-ou t key im pr in t ed on a n a m ber len s. Th e len s
is loca t ed beh in d a cu t ou t in t h e opa qu e la yer of t h e
in st r u m en t clu st er over la y. Th e da r k ou t er la yer of
t h e over la y pr even t s t h e in dica t or fr om bein g clea r ly
visible wh en it is n ot illu m in a t ed. Th e icon a ppea r s
silh ou et t ed a ga in st a n a m ber field t h r ou gh t h e t r a n s-
lu cen t ou t er la yer of t h e over la y wh en it is illu m i-
n a t ed fr om beh in d by a n in ca n descen t bu lb a n d bu lb
h older u n it loca t ed on t h e in st r u m en t clu st er elec-
t r on ic cir cu it boa r d. Th e SKIS in dica t or len s is ser-
viced a s a u n it wit h t h e in st r u m en t clu st er len s, h ood
a n d m a sk u n it .
OPERATION
Th e Sen t r y Key Im m obilizer Syst em (SKIS) in dica -
t or gives a n in dica t ion t o t h e veh icle oper a t or of t h e
st a t u s of t h e SKIS. Th is in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec-
t r on ic m essa ges r eceived by t h e clu st er fr om t h e Sen -
t r y Key Im m obilizer Modu le (SKIM) over t h e
8J - 30 INSTRUMENT CLUSTER
SK I S I N DI CAT OR (Cont inue d)
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s. Th e SKIS in dica t or bu lb is com plet ely con t r olled
by t h e in st r u m en t clu st er logic cir cu it , a n d t h a t logic
will on ly a llow t h is in dica t or t o oper a t e wh en t h e
in st r u m en t clu st er r eceives a ba t t er y cu r r en t in pu t
on t h e fu sed ign it ion swit ch ou t pu t (r u n -st a r t ) cir-
cu it . Th er efor e, t h e in dica t or will a lwa ys be off wh en
t h e ign it ion swit ch is in a n y posit ion except On or
St a r t . Th e bu lb on ly illu m in a t es wh en it is swit ch ed
t o gr ou n d by t h e in st r u m en t clu st er t r a n sist or. Th e
in st r u m en t clu st er will t u r n on t h e SKIS in dica t or
for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion , t h e SKIM t ells t h e clu st er
t o illu m in a t e t h e SKIS in dica t or for a bou t t h r ee sec-
on ds a s a bu lb t est .
• S KIS In d ic a to r La m p -On Me s s a g e - E a ch
t im e t h e clu st er r eceives a SKIS in dica t or la m p-on
m essa ge fr om t h e SKIM, t h e SKIS in dica t or will be
illu m in a t ed. Th e in dica t or ca n be fla sh ed on a n d off,
or illu m in a t ed solid, a s dict a t ed by t h e SKIM m es-
sa ge. F or m or e in for m a t ion on t h e SKIS a n d t h e
SKIS in dica t or con t r ol pa r a m et er s, (Refer t o 8 -
E LE CTRICAL/VE H ICLE TH E F T SE CURITY -
OP E RATION). Th e in dica t or r em a in s illu m in a t ed
u n t il t h e clu st er r eceives a SKIS in dica t or la m p-off
m essa ge fr om t h e SKIM, or u n t il t h e ign it ion swit ch
is t u r n ed t o t h e Off posit ion , wh ich ever occu r s fir st .
• Co m m u n ic a tio n Erro r - If t h e clu st er r eceives
n o SKIS in dica t or la m p-on or la m p-off m essa ges fr om
t h e SKIM for t wen t y con secu t ive secon ds, t h e SKIS
in dica t or is illu m in a t ed by t h e in st r u m en t clu st er.
Th e in dica t or r em a in s con t r olled a n d illu m in a t ed by
t h e clu st er u n t il a va lid SKIS in dica t or la m p-on or
la m p-off m essa ge is r eceived fr om t h e SKIM.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e SKIS in dica t or will be
t u r n ed on for t h e du r a t ion of t h e t est t o con fir m t h e
fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con t r ol cir-
cu it r y.
Th e SKIM per for m s a self-t est ea ch t im e t h e ign i-
t ion swit ch is t u r n ed t o t h e On posit ion t o decide
wh et h er t h e syst em is in good oper a t in g con dit ion
a n d wh et h er a va lid key is pr esen t in t h e ign it ion
lock cylin der. Th e SKIM t h en sen ds t h e pr oper SKIS
in dica t or la m p-on or la m p-off m essa ges t o t h e in st r u -
m en t clu st er. If t h e SKIS in dica t or fa ils t o ligh t du r-
in g t h e bu lb t est , r epla ce t h e bu lb wit h a kn own good
u n it . F or fu r t h er dia gn osis of t h e SKIS in dica t or or
t h e in st r u m en t clu st er cir cu it r y t h a t con t r ols t h e
in dica t or, (Refer t o 8 - E LE CTRICAL/INSTRUME NT
CLUSTE R - DIAGNOSIS AND TE STING). If t h e
in st r u m en t clu st er fla sh es t h e SKIS in dica t or u pon
ign it ion On , or t u r n s on t h e SKIS in dica t or solid
a ft er t h e bu lb t est , it in dica t es t h a t a SKIS m a lfu n c-
t ion h a s occu r r ed or t h a t t h e SKIS is in oper a t ive. F or
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pr oper dia gn osis of t h e SKIS, t h e P CI da t a bu s, or
t h e elect r on ic m essa ge in pu t s t o t h e in st r u m en t clu s-
t er t h a t con t r ol t h e SKIS in dica t or, a DRBIII! sca n
t ool is r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic
in for m a t ion .
SPEEDOM ET ER
DESCRIPTION
A speedom et er is st a n da r d equ ipm en t on a ll in st r u -
m en t clu st er s. Th e speedom et er is loca t ed t o t h e
r igh t of t h e t a ch om et er in t h e in st r u m en t clu st er.
Th e speedom et er con sist s of a m ova ble ga u ge n eedle
or poin t er con t r olled by t h e in st r u m en t clu st er cir-
cu it r y, a n d a fixed 255 degr ee pr im a r y sca le on t h e
ga u ge dia l fa ce t h a t r ea ds left -t o-r igh t eit h er fr om 0
t o 120 m ph , fr om 0 t o 200 km /h , or fr om 0 t o 220
km /h , depen din g u pon t h e m a r ket for wh ich t h e veh i-
cle is m a n u fa ct u r ed. Most m odels a lso h a ve a sm a ller
secon da r y in n er sca le on t h e ga u ge dia l fa ce t h a t pr o-
vides t h e equ iva len t opposit e m ea su r em en t u n it s
fr om t h e pr im a r y sca le. Text a ppea r in g in t h e cen t er
of t h e ga u ge dia l fa ce ju st ben ea t h t h e h u b of t h e
speedom et er n eedle a bbr evia t es t h e u n it of m ea su r e
for t h e pr im a r y sca le in a ll u pper ca se let t er s (i.e.:
MP H or KM/H ). On m odels wit h a secon da r y sca le,
t h e a bbr evia t ion for t h a t sca le follows t h e a bbr evia -
t ion for t h e pr im a r y sca le in a ll lower ca se let t er s
(i.e.: m ph or km /h ).
Th e speedom et er gr a ph ics a r e eit h er wh it e, gr a y
a n d or a n ge a ga in st a bla ck ga u ge dia l fa ce (ba se
clu st er ) or bla ck a n d gr a y a ga in st a t a u pe ga u ge dia l
fa ce (pr em iu m clu st er ), m a kin g t h em clea r ly visible
wit h in t h e in st r u m en t clu st er in da yligh t . Wh en illu -
m in a t ed fr om beh in d by t h e pa n el la m ps dim m er
con t r olled clu st er illu m in a t ion ligh t in g wit h t h e ext e-
r ior la m ps t u r n ed On , t h e ba se clu st er wh it e ga u ge
gr a ph ics a ppea r blu e-gr een a n d t h e or a n ge gr a ph ics
st ill a ppea r or a n ge, wh ile t h e pr em iu m clu st er t a u pe
ga u ge dia l fa ce a ppea r s blu e-gr een wit h t h e bla ck
gr a ph ics silh ou et t ed a ga in st t h e illu m in a t ed ba ck-
gr ou n d. Th e gr a y ga u ge gr a ph ics for bot h ver sion s of
t h e clu st er a r e n ot illu m in a t ed. Th e or a n ge ga u ge
n eedle in t h e ba se clu st er ga u ge is in t er n a lly illu m i-
n a t ed, wh ile t h e bla ck ga u ge n eedle in t h e pr em iu m
clu st er ga u ge is n ot .
Ba se clu st er ga u ge illu m in a t ion is pr ovided by
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it s
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. P r em iu m clu st er ga u ge illu m in a t ion is pr o-
vided by a n in t egr a l elect r o-lu m in escen t la m p t h a t is
ser viced a s a u n it wit h t h e in st r u m en t clu st er. Th e
speedom et er is ser viced a s a u n it wit h t h e in st r u -
m en t clu st er.
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SPEEDOM ET ER (Cont inue d)
OPERATION
Th e speedom et er gives a n in dica t ion t o t h e veh icle
oper a t or of t h e veh icle r oa d speed. Th is ga u ge is con -
t r olled by t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec-
t r on ic m essa ges r eceived by t h e clu st er fr om t h e
P ower t r a in Con t r ol Modu le (P CM) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e
speedom et er is a n a ir cor e m a gn et ic u n it t h a t
r eceives ba t t er y cu r r en t on t h e in st r u m en t clu st er
elect r on ic cir cu it boa r d t h r ou gh t h e fu sed ign it ion
swit ch ou t pu t (r u n -st a r t ) cir cu it wh en ever t h e ign i-
t ion swit ch is in t h e On or St a r t posit ion s. Th e clu s-
t er is pr ogr a m m ed t o m ove t h e ga u ge n eedle ba ck t o
t h e low en d of t h e sca le a ft er t h e ign it ion swit ch is
t u r n ed t o t h e Off posit ion . Th e in st r u m en t clu st er
cir cu it r y con t r ols t h e ga u ge n eedle posit ion a n d pr o-
vides t h e followin g fea t u r es:
• Ve h ic le S p e e d Me s s a g e - E a ch t im e t h e clu s-
t er r eceives a veh icle speed m essa ge fr om t h e P CM it
will ca lcu la t e t h e cor r ect veh icle speed r ea din g a n d
posit ion t h e ga u ge n eedle a t t h a t speed posit ion on
t h e ga u ge sca le. Th e clu st er will r eceive a n ew veh i-
cle speed m essa ge a n d r eposit ion t h e ga u ge poin t er
a ccor din gly a bou t ever y 86 m illisecon ds. Th e ga u ge
n eedle will con t in u e t o be posit ion ed a t t h e a ct u a l
veh icle speed posit ion on t h e ga u ge sca le u n t il t h e
ign it ion swit ch is t u r n ed t o t h e Off posit ion .
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a speedom et er m essa ge, it will h old t h e ga u ge
n eedle a t t h e la st in dica t ion for a bou t six secon ds, or
u n t il t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion ,
wh ich ever occu r s fir st . If a n ew speed m essa ge is n ot
r eceived a ft er a bou t six secon ds, t h e ga u ge n eedle
will r et u r n t o t h e fa r left (low) en d of t h e sca le.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e ga u ge n eedle will be
swept a cr oss t h e en t ir e ga u ge sca le a n d ba ck in or der
t o con fir m t h e fu n ct ion a lit y of t h e ga u ge a n d t h e
clu st er con t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e veh icle speed
in for m a t ion r eceived fr om t h e Con t r oller An t i-lock
Br a ke (CAB) t o det er m in e t h e veh icle r oa d speed,
t h en sen ds t h e pr oper veh icle speed m essa ges t o t h e
in st r u m en t clu st er. F or fu r t h er dia gn osis of t h e
speedom et er or t h e in st r u m en t clu st er cir cu it r y t h a t
con t r ols t h e ga u ge, (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND TE ST-
ING). F or pr oper dia gn osis of t h e CAB, t h e P CM, t h e
P CI da t a bu s, or t h e elect r on ic m essa ge in pu t s t o t h e
in st r u m en t clu st er t h a t con t r ol t h e speedom et er, a
DRBIII! sca n t ool is r equ ir ed. Refer t o t h e a ppr opr i-
a t e dia gn ost ic in for m a t ion .
INSTRUMENT CLUSTER 8J - 31
TACH OM ET ER
DESCRIPTION
A t a ch om et er is st a n da r d equ ipm en t on a ll in st r u -
m en t clu st er s. Th e t a ch om et er is loca t ed t o t h e left of
t h e speedom et er in t h e in st r u m en t clu st er. Th e
t a ch om et er con sist s of a m ova ble ga u ge n eedle or
poin t er con t r olled by t h e in st r u m en t clu st er cir cu it r y,
a n d a fixed 255 degr ee sca le on t h e ga u ge dia l fa ce
t h a t r ea ds left -t o-r igh t fr om 0 t o 7 for ga solin e
en gin es, or fr om 0 t o 6 for diesel en gin es. Th e t ext “X
1000” (ba se clu st er ) or “RP M X 1000” (pr em iu m clu s-
t er ) im pr in t ed on t h e clu st er over la y dir ect ly below
t h e h u b of t h e t a ch om et er n eedle iden t ifies t h a t ea ch
n u m ber on t h e t a ch om et er sca le is t o be m u lt iplied
by 1000 r pm . Th e ga solin e en gin e t a ch om et er h a s a
r ed zon e begin n in g a t 5800 RP M, wh ile t h e r ed zon e
for t h e diesel en gin e t a ch om et er begin s a t 4200 RP M.
Th e t a ch om et er in t h e pr em iu m ver sion clu st er for
cer t a in en gin e a n d m a r ket a pplica t ion s a lso in clu des
r ed t ext loca t ed in t h e cen t er of t h e ga u ge dia l fa ce
ju st a bove t h e h u b of t h e t a ch om et er n eedle t h a t
specifies a specia l fu el r equ ir em en t .
Th e t a ch om et er gr a ph ics a r e eit h er wh it e, gr a y
a n d or a n ge a ga in st a bla ck ga u ge dia l fa ce (ba se
clu st er ) or bla ck, gr a y a n d r ed a ga in st a t a u pe ga u ge
dia l fa ce (pr em iu m clu st er ), m a kin g t h em clea r ly vis-
ible wit h in t h e in st r u m en t clu st er in da yligh t . Wh en
illu m in a t ed fr om beh in d by t h e pa n el la m ps dim m er
con t r olled clu st er illu m in a t ion ligh t in g wit h t h e ext e-
r ior la m ps t u r n ed On , t h e ba se clu st er wh it e ga u ge
gr a ph ics a ppea r blu e-gr een a n d t h e or a n ge gr a ph ics
st ill a ppea r or a n ge, wh ile t h e pr em iu m clu st er t a u pe
ga u ge dia l fa ce a ppea r s blu e-gr een wit h t h e bla ck
gr a ph ics silh ou et t ed a ga in st t h e illu m in a t ed ba ck-
gr ou n d a n d t h e r ed gr a ph ics st ill a ppea r r ed. Th e
gr a y ga u ge gr a ph ics for bot h ver sion s of t h e clu st er
a r e n ot illu m in a t ed. Th e or a n ge ga u ge n eedle in t h e
ba se clu st er ga u ge is in t er n a lly illu m in a t ed, wh ile
t h e bla ck ga u ge n eedle in t h e pr em iu m clu st er ga u ge
is n ot .
Ba se clu st er ga u ge illu m in a t ion is pr ovided by
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it s
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. P r em iu m clu st er ga u ge illu m in a t ion is pr o-
vided by a n in t egr a l elect r o-lu m in escen t la m p t h a t is
ser viced a s a u n it wit h t h e in st r u m en t clu st er. Th e
t a ch om et er is ser viced a s a u n it wit h t h e in st r u m en t
clu st er.
OPERATION
Th e t a ch om et er gives a n in dica t ion t o t h e veh icle
oper a t or of t h e en gin e speed. Th is ga u ge is con t r olled
by t h e in st r u m en t clu st er elect r on ic cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e P ower t r a in
8J - 32 INSTRUMENT CLUSTER
TACH OM ET ER (Cont inue d)
Con t r ol Modu le (P CM) over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e t a ch om e-
t er is a n a ir cor e m a gn et ic u n it t h a t r eceives ba t t er y
cu r r en t on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d t h r ou gh t h e fu sed ign it ion swit ch ou t pu t (r u n -
st a r t ) cir cu it wh en ever t h e ign it ion swit ch is in t h e
On or St a r t posit ion s. Th e clu st er is pr ogr a m m ed t o
m ove t h e ga u ge n eedle ba ck t o t h e low en d of t h e
sca le a ft er t h e ign it ion swit ch is t u r n ed t o t h e Off
posit ion . Th e in st r u m en t clu st er cir cu it r y con t r ols
t h e ga u ge n eedle posit ion a n d pr ovides t h e followin g
fea t u r es:
• En g in e S p e e d Me s s a g e - E a ch t im e t h e clu st er
r eceives a n en gin e speed m essa ge fr om t h e P CM it
will ca lcu la t e t h e cor r ect en gin e speed r ea din g a n d
posit ion t h e ga u ge n eedle a t t h a t speed posit ion on
t h e ga u ge sca le. Th e clu st er will r eceive a n ew
en gin e speed m essa ge a n d r eposit ion t h e ga u ge
poin t er a ccor din gly a bou t ever y 86 m illisecon ds. Th e
ga u ge n eedle will con t in u e t o be posit ion ed a t t h e
a ct u a l en gin e speed posit ion on t h e ga u ge sca le u n t il
t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion .
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a n en gin e speed m essa ge, it will h old t h e
ga u ge n eedle a t t h e la st in dica t ion for a bou t six sec-
on ds, or u n t il t h e ign it ion swit ch is t u r n ed t o t h e Off
posit ion , wh ich ever occu r s fir st . If a n ew en gin e
speed m essa ge is n ot r eceived a ft er a bou t six sec-
on ds, t h e ga u ge n eedle will r et u r n t o t h e fa r left
(low) en d of t h e sca le.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e ga u ge n eedle will be
swept a cr oss t h e en t ir e ga u ge sca le a n d ba ck in or der
t o con fir m t h e fu n ct ion a lit y of t h e ga u ge a n d t h e
clu st er con t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e cr a n ksh a ft posi-
t ion sen sor t o det er m in e t h e en gin e speed, t h en
sen ds t h e pr oper en gin e speed m essa ges t o t h e
in st r u m en t clu st er. F or fu r t h er dia gn osis of t h e
t a ch om et er or t h e in st r u m en t clu st er cir cu it r y t h a t
con t r ols t h e ga u ge, (Refer t o 8 - E LE CTRICAL/IN-
STRUME NT CLUSTE R - DIAGNOSIS AND TE ST-
ING). F or pr oper dia gn osis of t h e cr a n ksh a ft posit ion
sen sor, t h e P CM, t h e P CI da t a bu s, or t h e elect r on ic
m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol
t h e t a ch om et er, a DRBIII! sca n t ool is r equ ir ed.
Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
T RAN S T EM P I N DI CAT OR
DESCRIPTION
A t r a n sm ission over-t em per a t u r e in dica t or is st a n -
da r d equ ipm en t on a ll ga solin e en gin e in st r u m en t
clu st er s. Th e t r a n sm ission over-t em per a t u r e in dica -
t or is loca t ed n ea r t h e lower r igh t cor n er of t h e
WJ
in st r u m en t clu st er, t o t h e r igh t of t h e speedom et er.
Th e t r a n sm ission over-t em per a t u r e in dica t or con sist s
of t h e wor ds “TRANS OVE R TE MP ” im pr in t ed on a n
a m ber len s. Th e len s is loca t ed beh in d a cu t ou t in
t h e opa qu e la yer of t h e in st r u m en t clu st er over la y.
Th e da r k ou t er la yer of t h e over la y pr even t s t h e in di-
ca t or fr om bein g clea r ly visible wh en it is n ot illu m i-
n a t ed. Th e wor ds “TRANS OVE R TE MP ” a ppea r
silh ou et t ed a ga in st a n a m ber field t h r ou gh t h e t r a n s-
lu cen t ou t er la yer of t h e over la y wh en t h e in dica t or
is illu m in a t ed fr om beh in d by a r epla cea ble in ca n des-
cen t bu lb a n d bu lb h older u n it loca t ed on t h e in st r u -
m en t clu st er elect r on ic cir cu it boa r d. Th e
t r a n sm ission over-t em per a t u r e in dica t or len s is ser-
viced a s a u n it wit h t h e in st r u m en t clu st er len s, h ood
a n d m a sk u n it .
OPERATION
Th e t r a n sm ission over-t em per a t u r e in dica t or gives
a n in dica t ion t o t h e veh icle oper a t or wh en t h e t r a n s-
m ission flu id t em per a t u r e is excessive, wh ich m a y
lea d t o a cceler a t ed t r a n sm ission com pon en t wea r or
fa ilu r e. Th is in dica t or is con t r olled by a t r a n sist or on
t h e in st r u m en t clu st er elect r on ic cir cu it boa r d ba sed
u pon clu st er pr ogr a m m in g a n d elect r on ic m essa ges
r eceived by t h e clu st er over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th ese m es-
sa ges a r e sen t by t h e P ower t r a in Con t r ol Modu le
(P CM) or by t h e Tr a n sm ission Con t r ol Modu le
(TCM), depen din g on t h e m odel of t h e a u t om a t ic
t r a n sm ission . Th e t r a n sm ission over-t em per a t u r e
in dica t or bu lb is com plet ely con t r olled by t h e in st r u -
m en t clu st er logic cir cu it , a n d t h a t logic will on ly
a llow t h is in dica t or t o oper a t e wh en t h e in st r u m en t
clu st er r eceives a ba t t er y cu r r en t in pu t on t h e fu sed
ign it ion swit ch ou t pu t (r u n -st a r t ) cir cu it . Th er efor e,
t h e in dica t or will a lwa ys be off wh en t h e ign it ion
swit ch is in a n y posit ion except On or St a r t . Th e bu lb
on ly illu m in a t es wh en it is pr ovided a pa t h t o gr ou n d
by t h e in st r u m en t clu st er t r a n sist or. Th e in st r u m en t
clu st er will t u r n on t h e t r a n sm ission over-t em per a -
t u r e in dica t or for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e t r a n sm ission over-t em -
per a t u r e in dica t or is illu m in a t ed for a bou t t h r ee sec-
on ds a s a bu lb t est .
• Tra n s Ov e r-Te m p In d ic a to r La m p -On Me s -
s a g e - E a ch t im e t h e clu st er r eceives a t r a n s over-
t em p in dica t or la m p-on m essa ge fr om t h e P CM or
TCM in dica t in g t h a t t h e t r a n sm ission flu id t em per a -
t u r e is 135° C (275° F ) or h igh er, t h e t r a n sm ission
over-t em per a t u r e in dica t or will be illu m in a t ed. Th e
in dica t or r em a in s illu m in a t ed u n t il t h e clu st er
r eceives a t r a n s over-t em p in dica t or la m p-off m es-
sa ge fr om t h e P CM or TCM, or u n t il t h e ign it ion
WJ
T RAN S T EM P I N DI CAT OR (Cont inue d)
swit ch is t u r n ed t o t h e Off posit ion , wh ich ever occu r s
fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e t r a n sm ission over-t em -
per a t u r e in dica t or will be t u r n ed on for t h e du r a t ion
of t h e t est t o con fir m t h e fu n ct ion a lit y of t h e bu lb
a n d t h e clu st er con t r ol cir cu it r y.
Th e P CM or TCM con t in u a lly m on it or s t h e t r a n s-
m ission t em per a t u r e sen sor t o det er m in e t h e t r a n s-
m ission oper a t in g con dit ion . Th e P CM or TCM t h en
sen ds t h e pr oper t r a n s over-t em p in dica t or la m p-on
or la m p-off m essa ges t o t h e in st r u m en t clu st er. If t h e
t r a n sm ission over-t em per a t u r e in dica t or fa ils t o ligh t
du r in g t h e bu lb t est , r epla ce t h e bu lb wit h a kn own
good u n it . If t h e in st r u m en t clu st er t u r n s on t h e
t r a n sm ission over-t em per a t u r e in dica t or du e t o a
h igh t r a n sm ission oil t em per a t u r e con dit ion , it m a y
in dica t e t h a t t h e t r a n sm ission or t h e t r a n sm ission
coolin g syst em a r e bein g over loa ded or t h a t t h ey
r equ ir e ser vice. F or fu r t h er dia gn osis of t h e t r a n s-
m ission over-t em per a t u r e in dica t or or t h e in st r u m en t
clu st er cir cu it r y t h a t con t r ols t h e in dica t or, (Refer t o
8 - E LE CTRICAL/INSTRUME NT CLUSTE R - DIAG-
NOSIS AND TE STING). F or pr oper dia gn osis of t h e
t r a n sm ission t em per a t u r e sen sor, t h e P CM, t h e
TCM, t h e P CI da t a bu s, or t h e elect r on ic m essa ge
in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol t h e
t r a n sm ission over-t em per a t u r e in dica t or, a DRBIII!
sca n t ool is r equ ir ed. Refer t o t h e a ppr opr ia t e dia g-
n ost ic in for m a t ion .
T U RN SI GN AL I N DI CAT OR
DESCRIPTION
Two t u r n sign a l in dica t or s, on e r igh t a n d on e left ,
a r e st a n da r d equ ipm en t on a ll in st r u m en t clu st er s.
Th e t u r n sign a l in dica t or s a r e loca t ed n ea r t h e u pper
edge of t h e in st r u m en t clu st er, t h e left on e is left of
t h e t a ch om et er, a n d t h e r igh t on e is r igh t of t h e
speedom et er. E a ch t u r n sign a l in dica t or con sist s of
a n In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon for
“Tu r n Wa r n in g” im pr in t ed on a gr een len s. E a ch len s
is loca t ed beh in d a dedica t ed cu t ou t in t h e opa qu e
la yer of t h e in st r u m en t clu st er over la y. Th e da r k
ou t er la yer of t h e over la y pr even t s t h ese icon s fr om
bein g clea r ly visible wh en t h ey a r e n ot illu m in a t ed.
Th e icon s a ppea r silh ou et t ed a ga in st a gr een field
t h r ou gh t h e t r a n slu cen t ou t er la yer of t h e over la y
wh en t h e in dica t or is illu m in a t ed fr om beh in d by a
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. Th e t u r n sign a l in dica t or len ses a r e ser viced
a s a u n it wit h t h e in st r u m en t clu st er len s, h ood a n d
m a sk u n it .
INSTRUMENT CLUSTER 8J - 33
OPERATION
Th e t u r n sign a l in dica t or s give a n in dica t ion t o t h e
veh icle oper a t or t h a t t h e t u r n sign a l (left or r igh t
in dica t or fla sh in g) or h a za r d wa r n in g (bot h left a n d
r igh t in dica t or s fla sh in g) h a ve been select ed a n d a r e
oper a t in g. Th ese in dica t or s a r e con t r olled by t wo
in dividu a l h a r d wir ed in pu t s fr om t h e com bin a t ion
fla sh er cir cu it r y t o t h e in st r u m en t clu st er elect r on ic
cir cu it boa r d. E a ch t u r n sign a l in dica t or bu lb is
gr ou n ded on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d a t a ll t im es; t h er efor e, t h ese in dica t or s r em a in
fu n ct ion a l r ega r dless of t h e ign it ion swit ch posit ion .
E a ch in dica t or bu lb will on ly illu m in a t e wh en it is
pr ovided wit h ba t t er y cu r r en t by t h e com bin a t ion
fla sh er in t h e J u n ct ion Block (J B).
Th e t u r n sign a l in dica t or s a r e con n ect ed in pa r a llel
wit h t h e ot h er t u r n sign a l cir cu it s. Th is a r r a n gem en t
a llows t h e t u r n sign a l in dica t or s t o r em a in fu n c-
t ion a l, r ega r dless of t h e con dit ion of t h e ot h er cir-
cu it s in t h e t u r n sign a l a n d h a za r d wa r n in g syst em s.
Th e com bin a t ion fla sh er ou t pu t s t o t h e in st r u m en t
clu st er t u r n sign a l in dica t or in pu t s ca n be dia gn osed
u sin g con ven t ion a l dia gn ost ic t ools a n d m et h ods. F or
m or e in for m a t ion on t h e t u r n sign a l a n d h a za r d
wa r n in g syst em , (Refer t o 8 - E LE CTRICAL/LAMP S/
LIGH TING - E XTE RIOR - OP E RATION - TURN
SIGNAL & H AZARD WARNING SYSTE M).
DIAGNOSIS AND TESTING - TURN SIGNAL
INDICATOR
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
t u r n sign a l in dica t or con dit ion . If t h e pr oblem bein g
dia gn osed is r ela t ed t o in oper a t ive t u r n sign a l or
h a za r d wa r n in g la m ps, be cer t a in t o r epa ir t h e t u r n
sign a l a n d h a za r d wa r n in g syst em befor e a t t em pt in g
t o dia gn ose or r epa ir t h e t u r n sign a l in dica t or s.
(Refer t o 8 - E LE CTRICAL/LAMP S/LIGH TING -
E XTE RIOR - DIAGNOSIS AND TE STING - TURN
SIGNAL & H AZARD WARNING SYSTE M). If n o
t u r n sign a l a n d h a za r d wa r n in g syst em pr oblem is
fou n d, t h e followin g pr ocedu r e will h elp loca t e a n
open in t h e t u r n sign a l in dica t or cir cu it . Refer t o t h e
a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for m a -
t ion in clu des wir in g dia gr a m s, pr oper wir e a n d con -
n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
n ect or s, splices a n d gr ou n ds.
8J - 34 INSTRUMENT CLUSTER
T U RN SI GN AL I N DI CAT OR (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e in st r u m en t clu st er fr om t h e
in st r u m en t pa n el a n d discon n ect t h e in st r u m en t
pa n el wir e h a r n ess for t h e in st r u m en t clu st er fr om
t h e clu st er con n ect or r ecept a cle.
(2) Recon n ect t h e ba t t er y n ega t ive ca ble. Act iva t e
t h e h a za r d wa r n in g syst em by m ovin g t h e h a za r d
wa r n in g swit ch bu t t on t o t h e On posit ion . Ch eck for
ba t t er y volt a ge a t t h e in oper a t ive (r igh t or left ) t u r n
sign a l cir cu it ca vit y of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e in st r u m en t clu st er. Th er e
sh ou ld be a swit ch in g (on a n d off) ba t t er y volt a ge sig-
n a l pr esen t . If OK, r epla ce t h e fa u lt y (r igh t or left )
t u r n sign a l in dica t or bu lb. If n ot OK, r epa ir t h e open
(r igh t or left ) t u r n sign a l cir cu it bet ween t h e in st r u -
m en t clu st er a n d t h e com bin a t ion fla sh er in t h e
J u n ct ion Block (J B) a s r equ ir ed.
V OLTAGE GAU GE
DESCRIPTION
A volt a ge ga u ge is st a n da r d equ ipm en t on a ll
in st r u m en t clu st er s. Th e volt a ge ga u ge is loca t ed in
t h e u pper left cor n er of t h e in st r u m en t clu st er, t o t h e
left of t h e t a ch om et er. Th e volt a ge ga u ge con sist s of a
m ova ble ga u ge n eedle or poin t er con t r olled by t h e
in st r u m en t clu st er cir cu it r y a n d a fixed 90 degr ee
sca le on t h e ga u ge dia l fa ce t h a t r ea ds left -t o-r igh t
fr om 9 volt s t o 19 volt s. An In t er n a t ion a l Con t r ol a n d
Displa y Sym bol icon for “Ba t t er y Ch a r gin g Con di-
t ion ” is loca t ed on t h e ga u ge dia l fa ce.
Th e volt a ge ga u ge gr a ph ics a r e eit h er wh it e, gr a y
a n d or a n ge a ga in st a bla ck ga u ge dia l fa ce (ba se
clu st er ) or bla ck, gr a y a n d r ed a ga in st a t a u pe ga u ge
dia l fa ce (pr em iu m clu st er ), m a kin g t h em clea r ly vis-
ible wit h in t h e in st r u m en t clu st er in da yligh t . Wh en
illu m in a t ed fr om beh in d by t h e pa n el la m ps dim m er
con t r olled clu st er illu m in a t ion ligh t in g wit h t h e ext e-
WJ
r ior la m ps t u r n ed On , t h e ba se clu st er wh it e ga u ge
gr a ph ics a ppea r blu e-gr een a n d t h e or a n ge gr a ph ics
st ill a ppea r or a n ge, wh ile t h e pr em iu m clu st er t a u pe
ga u ge dia l fa ce a ppea r s blu e-gr een wit h t h e bla ck
gr a ph ics silh ou et t ed a ga in st t h e illu m in a t ed ba ck-
gr ou n d a n d t h e r ed gr a ph ics st ill a ppea r r ed. Th e
gr a y ga u ge gr a ph ics for bot h ver sion s of t h e clu st er
a r e n ot illu m in a t ed. Th e or a n ge ga u ge n eedle in t h e
ba se clu st er ga u ge is in t er n a lly illu m in a t ed, wh ile
t h e bla ck ga u ge n eedle in t h e pr em iu m clu st er ga u ge
is n ot .
Ba se clu st er ga u ge illu m in a t ion is pr ovided by
r epla cea ble in ca n descen t bu lb a n d bu lb h older u n it s
loca t ed on t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. P r em iu m clu st er ga u ge illu m in a t ion is pr o-
vided by a n in t egr a l elect r o-lu m in escen t la m p t h a t is
ser viced a s a u n it wit h t h e in st r u m en t clu st er. Th e
volt a ge ga u ge is ser viced a s a u n it wit h t h e in st r u -
m en t clu st er.
OPERATION
Th e volt a ge ga u ge gives a n in dica t ion t o t h e veh i-
cle oper a t or of t h e elect r ica l syst em volt a ge. Th is
ga u ge is con t r olled by t h e in st r u m en t clu st er cir cu it
boa r d ba sed u pon clu st er pr ogr a m m in g a n d elec-
t r on ic m essa ges r eceived by t h e clu st er fr om t h e
P ower t r a in Con t r ol Modu le (P CM) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e
volt a ge ga u ge is a n a ir cor e m a gn et ic u n it t h a t
r eceives ba t t er y cu r r en t on t h e in st r u m en t clu st er
elect r on ic cir cu it boa r d t h r ou gh t h e fu sed ign it ion
swit ch ou t pu t (r u n -st a r t ) cir cu it wh en ever t h e ign i-
t ion swit ch is in t h e On or St a r t posit ion s. Th e clu s-
t er is pr ogr a m m ed t o m ove t h e ga u ge n eedle ba ck t o
t h e low en d of t h e sca le a ft er t h e ign it ion swit ch is
t u r n ed t o t h e Off posit ion . Th e in st r u m en t clu st er
cir cu it r y con t r ols t h e ga u ge n eedle posit ion a n d pr o-
vides t h e followin g fea t u r es:
• S y s te m Vo lta g e Me s s a g e - E a ch t im e t h e clu s-
t er r eceives a m essa ge fr om t h e P CM in dica t in g t h e
syst em volt a ge, t h e clu st er m oves t h e ga u ge n eedle t o
t h e r ela t ive volt a ge level posit ion on t h e ga u ge sca le.
• S y s te m Vo lta g e Lo w Me s s a g e - E a ch t im e t h e
clu st er r eceives a m essa ge fr om t h e P CM in dica t in g
t h e syst em volt a ge is low (syst em volt a ge is a bou t
eleven volt s or lower ), t h e ga u ge n eedle is m oved t o
t h e r ela t ive volt a ge posit ion in t h e r ed zon e of t h e
ga u ge sca le a n d t h e ch eck ga u ges in dica t or is illu m i-
n a t ed. Th e ga u ge n eedle r em a in s in t h e r ed zon e a n d
t h e ch eck ga u ges in dica t or r em a in s illu m in a t ed u n t il
t h e clu st er r eceives a m essa ge fr om t h e P CM in dica t -
in g t h er e is n o low syst em volt a ge con dit ion (syst em
volt a ge is a bove a bou t eleven volt s, bu t lower t h a n
a bou t sixt een volt s).
• S y s te m Vo lta g e Hig h Me s s a g e - E a ch t im e
t h e clu st er r eceives a m essa ge fr om t h e P CM in dica t -
WJ
V OLTAGE GAU GE (Cont inue d)
in g t h e syst em volt a ge is h igh (syst em volt a ge is
a bou t sixt een volt s or h igh er ), t h e ga u ge n eedle is
m oved t o t h e r ela t ive volt a ge posit ion in t h e r ed zon e
of t h e ga u ge sca le a n d t h e ch eck ga u ges in dica t or is
illu m in a t ed. Th e ga u ge n eedle r em a in s in t h e r ed
zon e a n d t h e ch eck ga u ges in dica t or r em a in s illu m i-
n a t ed u n t il t h e clu st er r eceives a m essa ge fr om t h e
P CM in dica t in g t h er e is n o h igh syst em volt a ge con -
dit ion (syst em volt a ge is below a bou t sixt een volt s,
bu t h igh er t h a n a bou t eleven volt s).
• Co m m u n ic a tio n Erro r - If t h e clu st er fa ils t o
r eceive a syst em volt a ge m essa ge, it will h old t h e
ga u ge n eedle a t t h e la st in dica t ion for a bou t t welve
secon ds, u n t il a n ew m essa ge is r eceived, or u n t il t h e
ign it ion swit ch is t u r n ed t o t h e Off posit ion , wh ich -
ever occu r s fir st . Aft er t welve secon ds, t h e clu st er
will r et u r n t h e ga u ge n eedle t o t h e low en d of t h e
ga u ge sca le.
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e ga u ge n eedle will be
swept a cr oss t h e en t ir e ga u ge sca le a n d ba ck t o con -
fir m t h e fu n ct ion a lit y of t h e ga u ge a n d t h e clu st er
con t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e syst em volt a ge
t o con t r ol t h e gen er a t or ou t pu t . Th e P CM t h en sen ds
t h e pr oper syst em volt a ge m essa ges t o t h e in st r u -
m en t clu st er. F or fu r t h er dia gn osis of t h e volt a ge
ga u ge or t h e in st r u m en t clu st er cir cu it r y t h a t con -
t r ols t h e ga u ge, (Refer t o 8 - E LE CTRICAL/INSTRU-
ME NT CLUSTE R - DIAGNOSIS AND TE STING). If
t h e in st r u m en t clu st er t u r n s on t h e ch eck ga u ges
in dica t or du e t o a syst em volt a ge low or h igh con di-
t ion , it m a y in dica t e t h a t t h e ch a r gin g syst em
r equ ir es ser vice. F or pr oper dia gn osis of t h e ch a r gin g
syst em , t h e P CI da t a bu s, or t h e elect r on ic m essa ge
in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol t h e volt -
a ge ga u ge, a DRBIII! sca n t ool is r equ ir ed. Refer t o
t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
WAI T-T O-START I N DI CAT OR
DESCRIPTION
A wa it -t o-st a r t in dica t or is on ly fou n d in t h e
in st r u m en t clu st er s of veh icles equ ipped wit h a n
opt ion a l diesel en gin e. Th e wa it -t o-st a r t in dica t or is
loca t ed n ea r t h e lower edge of t h e t a ch om et er ga u ge
dia l fa ce, t o t h e r igh t of cen t er. Th e wa it -t o-st a r t
in dica t or con sist s of a n In t er n a t ion a l Con t r ol a n d
Displa y Sym bol icon for “Diesel P r eh ea t ” im pr in t ed
on a n a m ber len s. Th e len s is loca t ed beh in d a cu t ou t
in t h e opa qu e la yer of t h e t a ch om et er ga u ge dia l fa ce
over la y. Th e da r k ou t er la yer of t h e ga u ge dia l fa ce
over la y pr even t s t h e icon fr om bein g clea r ly visible
wh en t h e in dica t or is n ot illu m in a t ed. Th e icon
a ppea r s silh ou et t ed a ga in st a n a m ber field t h r ou gh
INSTRUMENT CLUSTER 8J - 35
t h e t r a n slu cen t ou t er la yer of t h e ga u ge dia l fa ce
over la y wh en t h e in dica t or is illu m in a t ed fr om
beh in d by a r epla cea ble in ca n descen t bu lb a n d bu lb
h older u n it loca t ed on t h e in st r u m en t clu st er elec-
t r on ic cir cu it boa r d. Th e wa it -t o-st a r t in dica t or len s
is ser viced a s a u n it wit h t h e in st r u m en t clu st er.
OPERATION
Th e wa it -t o-st a r t in dica t or gives a n in dica t ion t o
t h e veh icle oper a t or wh en t h e diesel en gin e glow
plu gs a r e en er gized in t h eir pr eh ea t oper a t in g m ode.
Th is in dica t or is con t r olled by a t r a n sist or on t h e
in st r u m en t clu st er cir cu it boa r d ba sed u pon clu st er
pr ogr a m m in g a n d elect r on ic m essa ges r eceived by
t h e clu st er fr om t h e P ower t r a in Con t r ol Modu le
(P CM) over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s. Th e wa it -t o-st a r t in dica t or
bu lb is com plet ely con t r olled by t h e in st r u m en t clu s-
t er logic cir cu it , a n d t h a t logic will on ly a llow t h is
in dica t or t o oper a t e wh en t h e in st r u m en t clu st er
r eceives a ba t t er y cu r r en t in pu t on t h e fu sed ign it ion
swit ch ou t pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in di-
ca t or will a lwa ys be off wh en t h e ign it ion swit ch is in
a n y posit ion except On or St a r t . Th e bu lb on ly illu -
m in a t es wh en it is swit ch ed t o gr ou n d by t h e in st r u -
m en t clu st er t r a n sist or. Th e in st r u m en t clu st er will
t u r n on t h e wa it -t o-st a r t in dica t or for t h e followin g
r ea son s:
• Wa it-To -S ta rt In d ic a to r La m p -On Me s s a g e -
E a ch t im e t h e clu st er r eceives a wa it -t o-st a r t in dica -
t or la m p-on m essa ge fr om t h e P CM in dica t in g t h e
glow plu gs a r e h ea t in g a n d t h e dr iver m u st wa it t o
st a r t t h e en gin e, t h e wa it -t o-st a r t in dica t or will be
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il
t h e clu st er r eceives a wa it -t o-st a r t in dica t or la m p-off
m essa ge, or u n t il t h e ign it ion swit ch is t u r n ed t o t h e
Off posit ion , wh ich ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e wa it -t o-st a r t in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e bu lb a n d t h e clu st er con -
t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e a m bien t t em -
per a t u r e a n d t h e glow plu g pr e-h ea t er cir cu it s t o
det er m in e h ow lon g t h e glow plu gs m u st be h ea t ed in
t h e pr e-h ea t oper a t in g m ode. Th e P CM t h en sen ds
t h e pr oper wa it -t o-st a r t in dica t or la m p-on a n d la m p-
off m essa ges t o t h e in st r u m en t clu st er. If t h e wa it -t o-
st a r t in dica t or fa ils t o ligh t du r in g t h e a ct u a t or t est ,
r epla ce t h e bu lb wit h a kn own good u n it . F or fu r t h er
dia gn osis of t h e wa it -t o-st a r t in dica t or or t h e in st r u -
m en t clu st er cir cu it r y t h a t con t r ols t h e in dica t or,
(Refer t o 8 - E LE CTRICAL/INSTRUME NT CLUS-
TE R - DIAGNOSIS AND TE STING). F or pr oper
dia gn osis of t h e glow plu g pr e-h ea t er con t r ol cir cu it s,
t h e P CM, t h e P CI da t a bu s, or t h e elect r on ic m essa ge
8J - 36 INSTRUMENT CLUSTER
WAI T-T O-START I N DI CAT OR (Cont inue d)
in pu t s t o t h e in st r u m en t clu st er t h a t con t r ol t h e
wa it -t o-st a r t in dica t or, a DRBIII! sca n t ool is
r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
WAT ER-I N -FU EL I N DI CAT OR
DESCRIPTION
A wa t er-in -fu el in dica t or is on ly fou n d in t h e
in st r u m en t clu st er s of veh icles equ ipped wit h a n
opt ion a l diesel en gin e. Th e wa t er-in -fu el in dica t or is
loca t ed n ea r t h e left edge of t h e in st r u m en t clu st er,
t o t h e left of t h e t a ch om et er. Th e wa t er-in -fu el in di-
ca t or con sist s of a n In t er n a t ion a l Con t r ol a n d Dis-
pla y Sym bol icon for “Wa t er in F u el” im pr in t ed on a
r ed len s. Th e len s is loca t ed beh in d a cu t ou t in t h e
opa qu e la yer of t h e in st r u m en t clu st er over la y. Th e
da r k ou t er la yer of t h e over la y pr even t s t h e icon
fr om bein g clea r ly visible wh en t h e in dica t or is n ot
illu m in a t ed. Th e icon a ppea r s silh ou et t ed a ga in st a
r ed field t h r ou gh t h e t r a n slu cen t ou t er la yer of t h e
over la y wh en t h e in dica t or is illu m in a t ed fr om
beh in d by a Ligh t E m it t in g Diode (LE D), wh ich is
solder ed on t o t h e in st r u m en t clu st er elect r on ic cir cu it
boa r d. Th e wa t er-in -fu el in dica t or len s is ser viced a s
a u n it wit h t h e in st r u m en t clu st er len s, h ood a n d
m a sk u n it .
OPERATION
Th e wa t er-in -fu el in dica t or gives a n in dica t ion t o
t h e veh icle oper a t or wh en t h er e is excessive wa t er in
t h e fu el syst em . Th is in dica t or is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er cir cu it boa r d
ba sed u pon clu st er pr ogr a m m in g a n d elect r on ic m es-
sa ges r eceived by t h e clu st er fr om t h e P ower t r a in
Con t r ol Modu le (P CM) over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e wa t er-in -
fu el in dica t or Ligh t E m it t in g Diode (LE D) is
com plet ely con t r olled by t h e in st r u m en t clu st er logic
cir cu it , a n d t h a t logic will on ly a llow t h is in dica t or t o
WJ
oper a t e wh en t h e in st r u m en t clu st er r eceives a ba t -
t er y cu r r en t in pu t on t h e fu sed ign it ion swit ch ou t -
pu t (r u n -st a r t ) cir cu it . Th er efor e, t h e in dica t or will
a lwa ys be off wh en t h e ign it ion swit ch is in a n y posi-
t ion except On or St a r t . Th e LE D on ly illu m in a t es
wh en it is pr ovided a pa t h t o gr ou n d by t h e in st r u -
m en t clu st er t r a n sist or. Th e in st r u m en t clu st er will
t u r n on t h e wa t er-in -fu el in dica t or for t h e followin g
r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion t h e wa t er-in -fu el in dica t or
is illu m in a t ed for a bou t t h r ee secon ds a s a bu lb t est .
• Wa te r-In -F u e l In d ic a to r La m p -On Me s s a g e -
E a ch t im e t h e clu st er r eceives a wa t er-in -fu el in dica -
t or la m p-on m essa ge fr om t h e P CM in dica t in g t h er e
is excessive wa t er in t h e diesel fu el syst em , t h e
wa t er-in -fu el in dica t or will be illu m in a t ed. Th e in di-
ca t or r em a in s illu m in a t ed u n t il t h e clu st er r eceives a
wa t er-in -fu el in dica t or la m p-off m essa ge, or u n t il t h e
ign it ion swit ch is t u r n ed t o t h e Off posit ion , wh ich -
ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e wa t er-in -fu el in dica t or
will be t u r n ed on for t h e du r a t ion of t h e t est t o con -
fir m t h e fu n ct ion a lit y of t h e LE D a n d t h e clu st er con -
t r ol cir cu it r y.
Th e P CM con t in u a lly m on it or s t h e wa t er-in -fu el
sen sor t o det er m in e wh et h er t h er e is excessive wa t er
in t h e diesel fu el. Th e P CM t h en sen ds t h e pr oper
wa t er-in -fu el in dica t or la m p-on a n d la m p-off m es-
sa ges t o t h e in st r u m en t clu st er. F or fu r t h er dia gn osis
of t h e wa t er-in -fu el in dica t or or t h e in st r u m en t clu s-
t er cir cu it r y t h a t con t r ols t h e in dica t or, (Refer t o 8 -
E LE CTRICAL/INSTRUME NT CLUSTE R - DIAGNO-
SIS AND TE STING). F or pr oper dia gn osis of t h e
wa t er-in -fu el sen sor, t h e P CM, t h e P CI da t a bu s, or
t h e elect r on ic m essa ge in pu t s t o t h e in st r u m en t clu s-
t er t h a t con t r ol t h e wa t er-in -fu el in dica t or, a
DRBIII! sca n t ool is r equ ir ed. Refer t o t h e a ppr opr i-
a t e dia gn ost ic in for m a t ion .
WJ LAMPS 8L - 1

LAMPS
TABLE OF CON T EN T S

page page

LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 28

LAM PS/LI GH T I N G - EX T ERI OR

TABLE OF CONTENTS
page page

LAMPS/LIGHTING - EXTERIOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DESCRIPTION - TURN SIGNAL & HAZARD REMOVAL .............................9
WARNING SYSTEM . . . . . . . . . . . . . . . . . . ...2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION - TURN SIGNAL & HAZARD FOG LAMP
WARNING SYSTEM . . . . . . . . . . . . . . . . . . ...2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - TURN SIGNAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
HAZARD WARNING SYSTEMS . . . . . . . . . ...3 FOG LAMP UNIT
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . ...4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
AUTO HEADLAMP SENSOR ADJUSTMENTS
DIAGNOSIS AND TESTING - AUTO FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . 10
HEADLAMP SENSOR (AHL) ........... ...4 HEADLAMP
REMOVAL .......................... ...4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BRAKE LAMP SWITCH DIAGNOSIS AND TESTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...5 DIAGNOSIS AND TESTING — HEADLAMP
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...5 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING — BRAKE LAMP DIAGNOSIS AND TESTING — HEADLAMP . . 14
SWITCH .......................... ...5 REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL .......................... ...5 INSTALLATION - BULB . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...5 HEADLAMP SWITCH
ADJUSTMENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . ...6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CENTER HIGH MOUNTED STOP LAMP DIAGNOSIS AND TESTING — HEADLAMP
REMOVAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . ...6 HEADLAMP UNIT
REMOVAL - CHMSL ................. ...6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION - BULB . . . . . . . . . . . . . . . ...6 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION - CHMSL . . . . . . . . . . . . . . ...7 LICENSE PLATE LAMP
COMBINATION FLASHER REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .7 REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL .......................... . . .9 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .9 INSTALLATION - BULB . . . . . . . . . . . . . . . . . 18
DAYTIME RUNNING LAMP MODULE INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...9
8L - 2 LAMPS/LIGHTING - EXTERIOR WJ

LICENSE PLATE LAMP UNIT INSTALLATION - BULBS . . . . . . . . . . . . . . . . . . 25

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TAIL LAMP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
LEFT MULTI-FUNCTION SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL - BULBS . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - LEFT MULTI - REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 25
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 20 INSTALLATION
REMOVAL INSTALLATION - BULBS . . . . . . . . . . . . . . . . 26
REMOVAL - LEFT MULTI-FUNCTION INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 26
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 TURN SIGNAL CANCEL CAM
REMOVAL - MULTI-FUNCTION SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
MOUNTING HOUSING . . . . . . . . . . . . . . . . . . 22 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION UNDERHOOD LAMP
INSTALLATION - LEFT MULTI-FUNCTION REMOVAL
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION - MULTI-FUNCTION SWITCH REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 27
MOUNTING HOUSING . . . . . . . . . . . . . . . . . . 24 INSTALLATION
PARK/TURN SIGNAL LAMP INSTALLATION - BULB . . . . . . . . . . . . . . . . . 27
REMOVAL - BULBS ................... . . 25 INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 27

LAM PS/LI GH T I N G - EX T ERI OR TRICAL/OVE RH E AD CONSOLE /E LE CTRONIC

VE H ICLE INF O CE NTE R - DE SCRIP TION).
• Ve h ic le Th e ft S e c u rity S y s te m (VTS S ) Op ti-
DESCRIPTION - TURN SIGNAL & HAZARD
c a l Ala rm - Th is fea t u r e fla sh es t h e h a za r d wa r n in g
WARNING SYSTEM la m ps t o pr ovide a n opt ica l a la r m wh en t h e VTSS is
Th e t u r n sign a l a n d h a za r d wa r n in g syst em a r m ed a n d a ct iva t ed by a n u n a u t h or ized en t r y in t o
in clu des t h e followin g m a jor com pon en t s, wh ich a r e t h e veh icle. (Refer t o 8 - E LE CTRICAL/VE H ICLE
descr ibed in fu r t h er det a il elsewh er e in t h is ser vice TH E F T SE CURITY - DE SCRIP TION - VE H ICLE
in for m a t ion : TH E F T SE CURITY SYSTE M).
• Com bin a t ion F la sh er
• F r on t Side Ma r ker La m ps OPERATION - TURN SIGNAL & HAZARD
• H a za r d Wa r n in g Swit ch
• Tu r n Sign a l Ca n cel Ca m
WARNING SYSTEM
Th e t u r n sign a l syst em oper a t es on ba t t er y cu r r en t
• Tu r n Sign a l In dica t or s
r eceived on a fu sed ign it ion swit ch ou t pu t (r u n ) cir-
• Tu r n Sign a l La m ps
cu it so t h a t t h e t u r n sign a ls will on ly oper a t e wit h
• Tu r n Sign a l Swit ch
t h e ign it ion swit ch in t h e On posit ion . Th e h a za r d
Th e t u r n sign a l a n d h a za r d wa r n in g syst em s a lso
wa r n in g syst em oper a t es on n on -swit ch ed ba t t er y
pr ovide t h e followin g fea t u r es:
cu r r en t r eceived on a fu sed B(+) cir cu it so t h a t t h e
• F la s h Lig h ts w ith Lo c k - Th is cu st om er pr o-
h a za r d wa r n in g r em a in s oper a t ion a l r ega r dless of
gr a m m a ble fea t u r e fla sh es t h e h a za r d wa r n in g la m ps
t h e ign it ion swit ch posit ion . Wh en t h e t u r n sign a l
t o pr ovide opt ica l ver ifica t ion t h a t t h e Rem ot e Key-
syst em is a ct iva t ed, t h e cir cu it r y of t h e t u r n sign a l
less E n t r y (RKE ) Syst em h a s r eceived a va lid Lock or
swit ch a n d t h e com bin a t ion fla sh er will ca u se t h e
Un lock r equ est fr om a n RKE t r a n sm it t er. (Refer t o 8
select ed (r igh t or left ) t u r n sign a l in dica t or, fr on t
- E LE CTRICAL/P OWE R LOCKS - DE SCRIP TION -
pa r k/t u r n sign a l la m p, fr on t side m a r ker la m p a n d
RE MOTE KE YLE SS E NTRY SYSTE M).
r ea r t a il/st op/t u r n sign a l la m p t o fla sh on a n d off.
• P a n ic Mo d e Op tic a l Ale rt - Th is fea t u r e
Wh en t h e h a za r d wa r n in g syst em is a ct iva t ed, t h e
fla sh es t h e h a za r d wa r n in g la m ps t o pr ovide a n opt i-
cir cu it r y of t h e h a za r d wa r n in g swit ch a n d t h e com -
ca l a ler t wh en t h e Rem ot e Keyless E n t r y (RKE ) Sys-
bin a t ion fla sh er will ca u se bot h t h e r igh t side a n d
t em pa n ic m ode is a ct iva t ed by depr essin g t h e P a n ic
t h e left side t u r n sign a l in dica t or s, fr on t pa r k/t u r n
bu t t on on a n RKE t r a n sm it t er. (Refer t o 8 - E LE C-
sign a l la m ps, fr on t side m a r ker la m ps a n d r ea r t a il/
TRICAL/P OWE R LOCKS - DE SCRIP TION -
st op/t u r n sign a l la m ps t o fla sh on a n d off.
RE MOTE KE YLE SS E NTRY SYSTE M).
Th e Body Con t r ol Modu le (BCM) ca n a lso a ct iva t e
• Tu rn S ig n a l On Wa rn in g - Th is fea t u r e pr o-
t h e h a za r d wa r n in g syst em la m ps by en er gizin g t h e
vides t h e veh icle oper a t or wit h bot h visu a l a n d a u di-
com bin a t ion fla sh er t h r ou gh a sin gle h a r d wir ed con -
ble r em in der s wh en a t u r n sign a l h a s been left
n ect ion t o t h e h a za r d wa r n in g swit ch sen se cir cu it .
t u r n ed on for a n ext en ded per iod. (Refer t o 8 - E LE C-
Th e BCM gr ou n ds t h e cir cu it t o en er gize a n d de-en -
WJ
LAM PS/LI GH T I N G - EX T ERI OR (Cont inue d)
er gize t h e com bin a t ion fla sh er in r espon se t o m es-
sa ge in pu t s r eceived over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
Th e BCM ca n en er gize t h e com bin a t ion fla sh er wh en
t h e VTSS is r equ est ed.
Veh icles equ ipped wit h t h e opt ion a l E lect r on ic
Veh icle In for m a t ion Cen t er (E VIC) u se t u r n sign a l
st a t u s m essa ges r eceived fr om t h e E lect r o-Mech a n i-
ca l In st r u m en t Clu st er (E MIC) a n d dist a n ce m es-
sa ges r eceived fr om t h e P ower t r a in Con t r ol Modu le
(P CM) over t h e P CI da t a bu s t o det er m in e wh en t h e
Tu r n Sign a l On wa r n in g sh ou ld be a ct iva t ed. Th e
E MIC r eceives h a r d wir ed in pu t s fr om t h e com bin a -
t ion fla sh er t o oper a t e t h e t u r n sign a l in dica t or s,
t h en sen ds t h e pr oper t u r n sign a l st a t u s m essa ge t o
t h e E VIC. If a t u r n sign a l is left on for m or e t h a n
a bou t 1.6 kilom et er s (1 m ile) of dr ivin g dist a n ce, t h e
E VIC will displa y a visu a l “Tu r n Sign a l On ” m essa ge
a n d will sen d a r equ est t o t h e BCM over t h e P CI
da t a bu s t o n ot ify t h e veh icle oper a t or.
Du r in g bot h t h e t u r n sign a l a n d t h e h a za r d wa r n -
in g oper a t ion , if t h e ext er ior la m ps a r e t u r n ed Off,
t h e fr on t pa r k/t u r n sign a l la m ps a n d t h e fr on t side
m a r ker la m ps will fla sh in u n ison . If t h e ext er ior
la m ps a r e t u r n ed On , t h e fr on t pa r k/t u r n sign a l
la m ps a n d t h e fr on t side m a r ker la m ps will fla sh
a lt er n a t ely. Refer t o t h e own er ’s m a n u a l.
DIAGNOSIS AND TESTING - TURN SIGNAL &
HAZARD WARNING SYSTEMS
Wh en dia gn osin g t h e t u r n sign a l a n d h a za r d wa r n -
in g cir cu it s, r em em ber t h a t h igh gen er a t or ou t pu t
ca n bu r n ou t bu lbs r a pidly a n d r epea t edly. If t h is is a
con cer n on t h e veh icle bein g dia gn osed, t est t h e
ch a r gin g syst em a s r equ ir ed.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Act u a t e t h e t u r n sign a l swit ch or t h e h a za r d wa r n in g
swit ch . Obser ve t h e t u r n sign a l in dica t or la m p(s) in
t h e in st r u m en t clu st er. If t h e fla sh r a t e is ver y h igh ,
ch eck for a t u r n sign a l bu lb t h a t is n ot lit or is ver y
LAMPS/LIGHTING - EXTERIOR 8L - 3
dim ly lit . Repa ir t h e cir cu it s t o t h a t la m p or r epla ce
t h e fa u lt y bu lb, a s r equ ir ed. If t h e t u r n sign a l in di-
ca t or (s) fa il t o ligh t , go t o St ep 2.
(2) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Ch eck t h e ign it ion r u n fu se a n d t h e fla sh er fu se in
t h e J u n ct ion Block (J B). If OK, go t o St ep 3. If n ot
OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se(s).
(3) Ch eck for ba t t er y volt a ge a t t h e fla sh er fu se in
t h e J B. If OK, go t o St ep 4. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it bet ween t h e J B a n d t h e
P ower Dist r ibu t ion Cen t er (P DC).
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e ign it ion r u n fu se in
t h e J B. If OK, go t o St ep 5. If n ot OK, r epa ir t h e
open fu sed ign it ion swit ch ou t pu t (r u n ) cir cu it
bet ween t h e J B a n d t h e ign it ion swit ch .
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Rem ove t h e com bin a t ion fla sh er fr om t h e J B a n d
r epla ce it wit h a kn own good u n it . Recon n ect t h e ba t -
t er y n ega t ive ca ble. Test t h e oper a t ion of t h e t u r n
sign a l a n d h a za r d wa r n in g syst em s. If OK, disca r d
t h e fa u lt y com bin a t ion fla sh er. If n ot OK, r em ove t h e
t est fla sh er a n d go t o St ep 6.
(6) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n ) cir cu it ca vit y in t h e J B for t h e com bin a -
t ion fla sh er. If OK, go t o St ep 7. If n ot OK, r epa ir t h e
open fu sed ign it ion swit ch ou t pu t (r u n ) cir cu it
bet ween t h e com bin a t ion fla sh er a n d t h e ign it ion r u n
fu se in t h e J B.
(7) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Ch eck for ba t t er y volt a ge a t t h e B(+) cir cu it of t h e J B
for t h e com bin a t ion fla sh er. If OK, go t o St ep 8. If
n ot OK, r epa ir t h e open B(+) cir cu it bet ween t h e
com bin a t ion fla sh er a n d t h e fla sh er fu se in t h e J B.
(8) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e t u r n sign a l a n d h a za r d wa r n in g
swit ch es fr om t h e m u lt i-fu n ct ion swit ch con n ect or.
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it of
t h e in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
left m u lt i-fu n ct ion swit ch a n d a good gr ou n d. Th er e
sh ou ld be con t in u it y. If OK, go t o St ep 9. If n ot OK,
r epa ir t h e open gr ou n d cir cu it .
(9) Ch eck for con t in u it y bet ween t h e h a za r d swit ch
sen se cir cu it of t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e m u lt i-fu n ct ion swit ch a n d a good
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o
St ep 10. If n ot OK, r epa ir t h e sh or t ed h a za r d swit ch
sen se cir cu it bet ween t h e m u lt i-fu n ct ion swit ch a n d
t h e com bin a t ion fla sh er.
(10) Ch eck for con t in u it y bet ween t h e h a za r d
swit ch sen se cir cu it of t h e J B for t h e com bin a t ion
fla sh er a n d t h e in st r u m en t pa n el wir e h a r n ess con -
8L - 4 LAMPS/LIGHTING - EXTERIOR WJ
LAM PS/LI GH T I N G - EX T ERI OR (Cont inue d)
n ect or for t h e m u lt i-fu n ct ion swit ch . Th er e sh ou ld be LAMP BULB TYPE
con t in u it y. If OK, go t o St ep 11. If n ot OK, r epa ir t h e
open h a za r d swit ch sen se cir cu it bet ween t h e m u lt i- FRONT TURN SIGNAL 3157/3157NA
fu n ct ion swit ch a n d t h e com bin a t ion fla sh er. HIGH BEAM 9005XS
(11) Ch eck for con t in u it y bet ween t h e t u r n swit ch LOW BEAM 9006XS
sen se cir cu it of t h e in st r u m en t pa n el wir e h a r n ess
LICENSE PLATE 168
con n ect or for t h e m u lt i-fu n ct ion swit ch a n d a good
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o TAIL/BRAKE 3157
St ep 12. If n ot OK, r epa ir t h e sh or t ed left t u r n REAR TURN SIGNAL 3157
swit ch sen se cir cu it bet ween t h e m u lt i-fu n ct ion UNDERHOOD LAMP 561
swit ch a n d t h e com bin a t ion fla sh er.
(12) Ch eck for con t in u it y bet ween t h e left t u r n
swit ch sen se cir cu it of t h e J B for t h e com bin a t ion AU T O H EADLAM P SEN SOR
fla sh er a n d t h e in st r u m en t pa n el wir e h a r n ess con -
n ect or for t h e m u lt i-fu n ct ion swit ch . Th er e sh ou ld be DIAGNOSIS AND TESTING - AUTO HEADLAMP
con t in u it y. If OK, go t o St ep 13. If n ot OK, r epa ir t h e
open left t u r n swit ch sen se cir cu it bet ween t h e m u lt i- SENSOR (AHL)
fu n ct ion swit ch a n d t h e com bin a t ion fla sh er. Th e a u t o h ea dla m p sen sor n eeds r ea l su n ligh t t o
(13) Ch eck for con t in u it y bet ween t h e r igh t t u r n pr oper ly r egist er t h e ligh t level. Wh en a u t o h ea d-
swit ch sen se cir cu it of t h e in st r u m en t pa n el wir e la m ps a r e en a bled in door s, t h e h ea dla m ps m a y be
h a r n ess con n ect or for t h e left m u lt i-fu n ct ion swit ch t u r n ed on . Th e sen sor is loca t ed in t h e cen t er of t h e
a n d a good gr ou n d. Th er e sh ou ld be n o con t in u it y. If defr ost er gr ille a t t h e ba se of t h e win dsh ield. Th er e
OK, go t o St ep 14. If n ot OK, r epa ir t h e sh or t ed r igh t a r e n o fa u lt s set in t h e Body Con t r ol Modu le (BCM)
t u r n swit ch sen se cir cu it bet ween t h e left m u lt i-fu n c- for a in oper a t ive or m issin g AH L Sen sor. Sym pt om of
t ion swit ch a n d t h e com bin a t ion fla sh er. a m issin g sen sor or u n con n ect ed sen sor wou ld be
(14) Ch eck for con t in u it y bet ween t h e r igh t t u r n t h a t t h e H ea dla m ps a n d P a r kla m ps t u r n on wh en
swit ch sen se cir cu it of t h e J B for t h e com bin a t ion t h e veh icle is st a r t ed a n d t h er e is a h igh level of
fla sh er a n d t h e in st r u m en t pa n el wir e h a r n ess con - a m bien t ligh t pr esen t (ie. da yt im e). Au t o h ea dla m ps
n ect or for t h e m u lt i-fu n ct ion swit ch . Th er e sh ou ld be sh ou ld n ot fu n ct ion in t h e pr esen ce of da yligh t .
con t in u it y. If OK, t est t h e left m u lt i-fu n ct ion swit ch .
(Refer t o 8 - E LE CTRICAL/LAMP S/LIGH TING - REMOVAL
E XTE RIOR/LE F T MULTI-F UNCTION SWITCH - (1) Rem ove t h e in st r u m en t pa n el t op cover. (Refer
DIAGNOSIS AND TE STING). If n ot OK, r epa ir t h e t o 23 - BODY/INSTRUME NT PANE L/INSTRUME NT
open r igh t t u r n swit ch sen se cir cu it bet ween t h e PANE L TOP COVE R - RE MOVAL) for ser vice pr oce-
m u lt i-fu n ct ion swit ch a n d t h e com bin a t ion fla sh er a s du r es.
r equ ir ed. (2) Rem ove t h e scr ew a t t a ch in g a u t o h ea dla m p
sen sor t o in st r u m en t pa n el (F ig. 1).
(3) Disen ga ge t h e h a r n ess con n ect or fr om a u t o
SPECI FI CAT I ON S h ea dla m p sen sor.
(4) Sepa r a t e t h e a u t o h ea dla m p sen sor fr om
EXTERIOR LAMPS in st r u m en t pa n el.

CAUTION: Do not use bulbs other than the bulbs INSTALLATION

listed in the Bulb Application Table. Damage to (1) P osit ion t h e a u t o h ea dla m p sen sor on in st r u -
lamp can result. Do not touch halogen bulbs with m en t pa n el.
fingers or other oily surfaces. Bulb life will be (2) E n ga ge t h e h a r n ess con n ect or t o a u t o h ea d-
reduced. la m p sen sor.
(3) In st a ll t h e scr ew a t t a ch in g a u t o h ea dla m p sen -
LAMP BULB TYPE sor t o in st r u m en t pa n el.
BACK-UP 3157 (4) In st a ll t h e in st r u m en t pa n el t op cover. (Refer
t o 23 - BODY/INSTRUME NT PANE L/INSTRUME NT
CENTER HIGH 921 PANE L TOP COVE R - INSTALLATION) for ser vice
MOUNTED STOP LAMP pr ocedu r es.
FOG LAMP 9005
FRONT SIDE MARKER 194/194NA
WJ
AU T O H EADLAM P SEN SOR (Cont inue d)
Fig. 1 Auto Headlamp Sensor
1 - AUTO HEADLAMP SENSOR
2 - I/P ASSEMBLY
3 - CONNECTOR
BRAK E LAM P SWI T CH
DESCRIPTION
Th e br a ke la m p swit ch is m ou n t ed on a br a cket
a t t a ch ed t o t h e br a ke peda l su ppor t . Th e swit ch is
a dju st a ble.
OPERATION
Th e br a ke la m p swit ch is u sed for t h e br a ke la m p,
speed con t r ol a n d br a ke sen sor cir cu it s.
DIAGNOSIS AND TESTING — BRAKE LAMP
SWITCH
Br a ke la m p swit ch oper a t ion ca n be t est ed wit h a n
oh m m et er. Th e oh m m et er is u sed t o ch eck con t in u it y
bet ween t h e pin t er m in a ls a t differ en t plu n ger posi-
t ion s (F ig. 2).
SWITCH CIRCUIT IDENTIFICATION
• Ter m in a ls 1 a n d 2: br a ke sen sor cir cu it
• Ter m in a ls 3 a n d 4: speed con t r ol cir cu it
• Ter m in a ls 5 a n d 6: br a ke la m p cir cu it
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
continuity.
Wit h t h e swit ch plu n ger r et r a ct ed, a t t a ch t h e t est
lea ds t o t er m in a l pin s 1 a n d 2. Repla ce swit ch if
m et er in dica t es n o con t in u it y.
Wit h t h e swit ch plu n ger r et r a ct ed, a t t a ch t h e t est
lea ds t o t er m in a l pin s 3 a n d 4. Repla ce swit ch if
m et er in dica t es n o con t in u it y.
LAMPS/LIGHTING - EXTERIOR 8L - 5
Fig. 2 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Wit h t h e swit ch plu n ger ext en ded, a t t a ch t h e t est
lea ds t o t er m in a l pin s 5 a n d 6. Repla ce swit ch if
m et er in dica t es n o con t in u it y.
REMOVAL
(1) Rem ove t h e st eer in g colu m n cover a n d lower
t r im pa n el.
(2) P r ess t h e br a ke peda l down wa r d t o fu lly
a pplied posit ion .
(3) Rot a t e t h e swit ch a ppr oxim a t ely 30° in cou n -
t er clockwise dir ect ion t o u n lock t h e swit ch r et a in er.
P u ll swit ch r ea r wa r d a n d ou t of br a cket .
(4) Discon n ect swit ch h a r n ess a n d r em ove swit ch
fr om veh icle (F ig. 3).
INSTALLATION
(1) P u ll t h e swit ch plu n ger a ll t h e wa y ou t t o fu lly
ext en ded posit ion .
(2) Con n ect t h e h a r n ess wir es t o swit ch .
(3) P r ess a n d h old br a ke peda l in a pplied posit ion .
(4) In st a ll t h e swit ch a s follows: Align t h e t a b on
t h e swit ch wit h t h e n ot ch in t h e swit ch br a cket .
In ser t t h e swit ch in t h e br a cket a n d t u r n it clockwise
a bou t 30° t o lock it in pla ce.
(5) Relea se t h e br a ke peda l. Th en pu ll t h e peda l
ligh t ly r ea r wa r d. Th e peda l will set t h e plu n ger t o
t h e cor r ect posit ion a s t h e peda l pu sh es t h e plu n ger
in t o swit ch body. Th e swit ch will m a ke r a t ch et in g
sou n d a s it self a dju st s.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs.
8L - 6 LAMPS/LIGHTING - EXTERIOR WJ
BRAK E LAM P SWI T CH (Cont inue d)

Fig. 4 CHMSL Bulb

1 - CHMSL
2 - CHMSL BULB

REMOVAL - CHMSL
Fig. 3 Brake Lamp (1) Rem ove t h e scr ews a t t a ch in g CH MSL t o t h e
1 - SWITCH
lift ga t e (F ig. 5).
2 - HARNESS CONNECTOR (2) Discon n ect t h e wir e h a r n ess con n ect or.
(3) Sepa r a t e t h e CH MSL fr om t h e veh icle.

ADJ U ST M EN T S
ADJUSTMENT
(1) P r ess a n d h old br a ke peda l in a pplied posit ion .
(2) P u ll swit ch plu n ger a ll t h e wa y ou t t o fu lly
ext en ded posit ion .
(3) Relea se br a ke peda l. Th en pu ll peda l ligh t ly
r ea r wa r d. P eda l will set plu n ger t o cor r ect posit ion
a s peda l pu sh es plu n ger in t o swit ch body. Swit ch will
m a ke r a t ch et in g sou n d a s it self a dju st s.

CAUTION: Booster damage may occur if the pedal

pull exceeds 20 lbs.

CEN T ER H I GH M OU N T ED Fig. 5 Center High Mounted Stop lamp

ST OP LAM P 1 - PUSH-IN NUT
2 - CONNECTOR
3 - LIFTGATE
REM OVAL 4 - CHSML

REMOVAL - BULB I N STALLAT I ON

(1) Rem ove t h e scr ews a t t a ch in g t h e la m p h ou sin g
t o t h e lift ga t e.
(2) Rot a t e t h e bu lb socket 1/4 t u r n a n d r em ove it
INSTALLATION - BULB
(1) P u sh t h e bu lb in t o t h e socket .
fr om t h e h ou sin g (F ig. 4).
(2) P osit ion t h e socket in la m p a n d r ot a t e 1/4 t u r n .
(3) Rem ove t h e bu lb fr om t h e socket .
(3) In st a ll t h e scr ews a t t a ch in g t h e la m p h ou sin g
t o lift ga t e.
WJ
CEN T ER H I GH M OU N T ED ST OP LAM P (Cont inue d)
INSTALLATION - CHMSL
(1) Con n ect t h e wir e h a r n ess con n ect or.
(2) P osit ion t h e CH MSL on lift ga t e.
(3) In st a ll t h e scr ews a t t a ch in g t h e CH MSL t o t h e
lift ga t e.
COM BI N AT I ON FLASH ER
DESCRIPTION
Fig. 6 Combination Flasher
1 - COMBINATION FLASHER
2 - JUNCTION BLOCK
Th e com bin a t ion fla sh er is loca t ed in t h e J u n ct ion
Block (J B) (F ig. 6). Th e J B is loca t ed u n der n ea t h t h e
dr iver side of t h e in st r u m en t pa n el ou t boa r d of t h e
st eer in g colu m n . Th e com bin a t ion fla sh er is a sm a r t
r ela y t h a t fu n ct ion s a s bot h t h e t u r n sign a l syst em
a n d t h e h a za r d wa r n in g syst em fla sh er. Th e com bi-
n a t ion fla sh er con t a in s a ct ive elect r on ic In t egr a t ed
Cir cu it r y (IC) elem en t s. Th is fla sh er is design ed t o
h a n dle t h e cu r r en t flow r equ ir em en t s of t h e fa ct or y-
in st a lled ligh t in g. If su pplem en t a l ligh t in g is a dded
t o t h e t u r n sign a l la m p cir cu it s, su ch a s wh en t owin g
a t r a iler wit h ligh t s, t h e com bin a t ion fla sh er will
a u t om a t ica lly t r y t o com pen sa t e t o keep t h e fla sh
r a t e t h e sa m e.
LAMPS/LIGHTING - EXTERIOR 8L - 7
Th e com bin a t ion fla sh er h a s n in e bla de-t ype t er m i-
n a ls t h a t con n ect it t o t h e veh icle elect r ica l syst em .
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Beca u se of t h e a ct ive elect r on ic elem en t s wit h in
t h e com bin a t ion fla sh er, it ca n n ot be t est ed wit h con -
ven t ion a l a u t om ot ive elect r ica l t est equ ipm en t . If t h e
com bin a t ion fla sh er is believed t o be fa u lt y, t est t h e
t u r n sign a l syst em a n d h a za r d wa r n in g syst em cir-
cu it s.(Refer t o 8 - E LE CTRICAL/LAMP S/LIGH TING
- E XTE RIOR - DIAGNOSIS AND TE STING - TURN
SIGNAL & H AZARD WARNING SYSTE M). Th e com -
bin a t ion fla sh er ca n n ot be r epa ir ed or a dju st ed a n d,
if fa u lt y or da m a ged, it m u st be r epla ced.
OPERATION
Th e com bin a t ion fla sh er con t r ols t h e followin g
in pu t s a n d ou t pu t s: B(+), fu sed ign it ion swit ch ou t -
pu t , left t u r n swit ch sen se, r igh t t u r n swit ch sen se,
h a za r d swit ch sen se, left fr on t t u r n sign a l cir cu it ,
r igh t fr on t t u r n sign a l cir cu it , left r ea r t u r n sign a l
cir cu it a n d r igh t r ea r t u r n sign a l cir cu it . Con st a n t
ba t t er y volt a ge is su pplied t o t h e fla sh er so t h a t it
ca n per for m t h e h a za r d wa r n in g fu n ct ion , a n d ign i-
t ion swit ch ed ba t t er y volt a ge is su pplied for t h e t u r n
sign a l fu n ct ion . H owever, wh en t h e fla sh er is idle n o
cu r r en t is dr a wn t h r ou gh t h e m odu le. Th e u n it does
n ot becom e a ct ive u n t il it is pr ovided a sign a l gr ou n d
fr om t h e t u r n sign a l swit ch , h a za r d wa r n in g swit ch
or t h e Body Con t r ol Modu le (BCM).
Th e IC wit h in t h e com bin a t ion fla sh er (F ig. 7) con -
t a in s t h e logic t h a t con t r ols t h e fla sh er oper a t ion a n d
t h e fla sh r a t e. Wh en a bu lb is bu r n t ou t , or wh en a
cir cu it for a la m p is open , t h e t u r n sign a l fla sh r a t e
will in cr ea se. H owever, a n open la m p cir cu it or bu r n t
ou t bu lb does n ot ch a n ge t h e h a za r d wa r n in g fla sh
r a t e.
8L - 8 LAMPS/LIGHTING - EXTERIOR WJ
COM BI N AT I ON FLASH ER (Cont inue d)

Fig. 7 Combination Flasher

COMBINATION FLASHER CIRCUITS

CAVITY CIRCUIT FUNCTION
1 L25 Fused B(+)
2 L61 Left Front Turn Signal
3 L60 Right Front Turn Signal
4 L63 Left Rear Turn Signal
5 L62 Right Rear Turn Signal
6 F22 Fused Ignition Switch Output
7 L305 Left Turn Switch Sense
8 L302 Right Turn Switch Sense
9 L91 Hazard Switch Sense
WJ
COM BI N AT I ON FLASH ER (Cont inue d)
Tu r n sign a l in pu t s t h a t a ct u a t e t h e com bin a t ion
fla sh er a r e low cu r r en t gr ou n ds, ea ch dr a win g a
m a xim u m of 300 m illia m per es.Th e h a za r d wa r n in g
sign a l in pu t is a low cu r r en t gr ou n d dr a win g a m a x-
im u m of 600 m illia m per es.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e st eer in g colu m n cover. (Refer t o 23
- BODY/INSTRUME NT PANE L/STE E RING COL-
UMN OP E NING COVE R - RE MOVAL).
(3) Rem ove t h e com bin a t ion fla sh er fr om t h e J u n c-
t ion Block (J B) (F ig. 8).
Fig. 8 Combination Flasher
1 - COMBINATION FLASHER
2 - JUNCTION BLOCK
LAMPS/LIGHTING - EXTERIOR 8L - 9
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Align t h e t er m in a ls of t h e com bin a t ion fla sh er
wit h t h e t er m in a l ca vit ies in t h e J B. (F ig. 8)
(2) P u sh in fir m ly a n d even ly on t h e com bin a t ion
fla sh er u n t il t h e t er m in a ls a r e fu lly sea t ed.
(3) Rein st a ll t h e st eer in g colu m n open in g cover.
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
ING COLUMN OP E NING COVE R - INSTALLA-
TION).
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
DAY T I M E RU N N I N G LAM P
M ODU LE
DESCRIPTION
Th e Da yt im e Ru n n in g Ligh t s (H ea dla m ps) Syst em
is in st a lled on veh icles m a n u fa ct u r ed for sa le in Ca n -
a da on ly. A sepa r a t e m odu le, m ou n t ed in t h e ju n ct ion
block u n der t h e da sh , con t r ols t h e DRL.
OPERATION
Th e h ea dla m ps a r e illu m in a t ed a t a r edu ced in t en -
sit y wh en t h e en gin e is r u n n in g, h ea dla m p swit ch
off, a n d t h e pa r kin g br a ke r elea sed.
REMOVAL
(1) Lower t h e ju n ct ion block. (Refer t o 8 - E LE C-
TRICAL/P OWE R DISTRIBUTION/J UNCTION
BLOCK - RE MOVAL) for ser vice pr ocedu r es.
(2) Rem ove t h e m odu le fr om t h e ju n ct ion block.
INSTALLATION
(1) P osit ion t h e m odu le in t h e ju n ct ion block a n d
pr ess t o secu r e.
(2) In st a ll t h e ju n ct ion block. (Refer t o 8 - E LE C-
TRICAL/P OWE R DISTRIBUTION/J UNCTION
BLOCK - INSTALLATION) for ser vice pr ocedu r es.
8L - 10 LAMPS/LIGHTING - EXTERIOR WJ

FOG LAM P
REMOVAL
(1) Discon n ect t h e fog la m p h a r n ess con n ect or.
(2) Rot a t e t h e bu lb socket 1/4 t u r n cou n t er clock-
wise.
(3) Rem ove t h e bu lb socket fr om la m p (F ig. 9).

Fig. 10 Fog Lamp

1 - FOG LAMP
2 - FASCIA

INSTALLATION
(1) P osit ion t h e fog la m p in fa scia .
(2) In st a ll t h e n u t s a t t a ch in g fog la m p t o fa scia .
(3) E n ga ge t h e fog la m p elect r ica l con n ect or.
Fig. 9 Fog Lamp Bulb (4) Align t h e fog la m p, if n ecessa r y.
1 - FOG LAMP
2 - FASCIA
3 - BULB
ADJ U ST M EN T S
4 - BULB SOCKET
FOG LAMP ADJUSTMENT
P r epa r e a n a lign m en t scr een . A pr oper ly a lign ed
INSTALLATION fog la m p will pr oject a pa t t er n on t h e a lign m en t
scr een 100 m m (4 in .) below t h e fog la m p cen t er lin e
CAUTION: Do not touch the bulb glass with fingers a n d st r a igh t a h ea d (F ig. 11).
or other oily surfaces. Reduced bulb life will result. Rot a t e t h e a dju st m en t scr ew t o a dju st bea m h eigh t
(F ig. 12).
(1) P osit ion t h e bu lb socket in fog la m p.
(2) Rot a t e t h e bu lb socket 1/4 t u r n clockwise.
(3) Con n ect t h e fog la m p h a r n ess con n ect or.

FOG LAM P U N I T
REMOVAL
(1) Disen ga ge t h e fog la m p elect r ica l con n ect or.
(2) Rem ove t h e n u t s a t t a ch in g fog la m p t o fa scia
(F ig. 10).
(3) Sepa r a t e t h e fog la m p fr om veh icle.
WJ LAMPS/LIGHTING - EXTERIOR 8L - 11
FOG LAM P U N I T (Cont inue d)

Fig. 11 Fog Lamp Alignment—Typical

1 - VEHICLE CENTERLINE 5 - 100 mm (4 in.)
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 6 - 7.62 METERS (25 FEET)
3 - HIGH-INTENSITY AREA 7 - FRONT OF FOG LAMP
4 - FLOOR TO CENTER OF FOG LAMP LENS

H EADLAM P
DESCRIPTION
Th e h ea dla m ps a r e m odu la r in design .Th e h ea d-
la m p m odu le con t a in s five bu lbs; a du a l fila m en t
h ea dla m p low bea m bu lb, a sin gle fila m en t h igh
bea m bu lb, t wo t u r n sign a l/pa r k bu lbs, a n d a side
m a r ker bu lb.

OPERATION
All h ea dla m p, t u r n sign a l, pa r k la m p, a n d h igh
bea m oper a t ion s a r e con t r olled by t h e left m u lt ifu n c-
t ion swit ch . E xt er ior la m ps a n d bu lbs a r e ser vicea ble
sepa r a t ely.

Fig. 12 Fog Lamp Adjustment

1 - ADJUSTMENT SCREW
2 - FOG LAMP
8L - 12 LAMPS/LIGHTING - EXTERIOR WJ
H EADLAM P (Cont inue d)

DI AGN OSI S AN D T EST I N G

DIAGNOSIS AND TESTING — HEADLAMP
SYSTEM
HEADLAMPS

CONDITION POSSIBLE CAUSES CORRECTION

HEADLAMPS ARE DIM 1. Loose or corroded battery cables.
WITH ENGINE IDLING
OR IGNITION TURNED 2. Loose or worn generator drive belt.
OFF
3. Charging system output too low.
4. Battery has insufficient charge.
5. Battery is sulfated or shorted.
6. Poor lighting circuit Z1-ground.
7. Both headlamp bulbs defective.
1. Clean and secure battery cable clamps
and posts.
2. Adjust or replace generator drive belt.
3. Test and repair charging system, refer
to Electrical, Charging
4. Test battery state-of -charge, refer to
Electrical, Battery System.
5. Load test battery, refer to
Electrical,Battery System.
6. Test for voltage drop across Z1-ground
locations, refer to Electrical, Wiring Digram
Information.
7. Replace both headlamp bulbs.

HEADLAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system, refer
OUT to Electrical, Charging.
FREQUENTLY 2. Loose or corroded terminals or 2. Inspect and repair all connectors and
splices in circuit. splices, refer to Electrical, Wiring
Information.

HEADLAMPS ARE DIM 1. Charging system output too low.
WITH ENGINE RUNNING
ABOVE IDLE* 2. Poor lighting circuit Z1-ground.
3. High resistance in headlamp
circuit.
4. Both headlamp bulbs defective.
1. Test and repair charging system, refer
to Electrical, Wiring Information.
2. Test for voltage drop across Z1-ground
locations, refer to Electrical, Wiring
Information.
3. Test amperage draw of headlamp
circuit.
4. Replace both headlamp bulbs.

HEADLAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
RANDOMLY locations, refer to Electrical, Wiring
Information.
2. High resistance in headlamp 2. Test amperage draw of headlamp
circuit. circuit. Should not exceed 30 amps.
3. Loose or corroded terminals or 3. Inspect and repair all connectors and
splices in circuit. splices, refer to Electrical, Wiring
Information.

HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to

ILLUMINATE Electrical, Wiring Information.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Electrical,
Wiring Information.
WJ
H EADLAM P (Cont inue d)
CONDITION POSSIBLE CAUSES
3. Faulty headlamp switch.
4. Blown fuse for headlamps.
5. Broken connector terminal or wire
splice in headlamp circuit.
6. Both headlamp bulbs defective.
*Canada vehicles must have lamps ON.
FOG LAMP
CONDITION POSSIBLE CAUSES
FOG LAMPS ARE DIM 1. Loose or corroded battery cables.
WITH ENGINE IDLING
OR IGNITION TURNED
OFF. 2. Loose or worn generator drive belt.
3. Charging system output too low.
4. Battery has insufficient charge.
5. Battery is sulfated or shorted.
6. Poor lighting circuit Z1-ground.
FOG LAMP BULBS BURN 1. Charging system output too high.
OUT FREQUENTLY
2. Loose or corroded terminals or
splices in circuit.
FOG LAMPS ARE DIM 1. Charging system output too low.
WITH ENGINE RUNNING
ABOVE IDLE 2. Poor lighting circuit Z1-ground.
3. High resistance in fog lamp circuit.
FOG LAMPS FLASH 1. Poor lighting circuit Z1-ground.
RANDOMLY
2. High resistance in fog lamp circuit.
3. Faulty multifunction switch.
4. Loose or corroded terminals or
splices in circuit.
LAMPS/LIGHTING - EXTERIOR 8L - 13
CORRECTION
3. Refer to BCM diagnostics.
4. Replace fuse refer to Electrical, Wiring
Information.
5. Repair connector terminal or wire splice.
6. Replace both headlamp bulbs.
CORRECTION
1. Clean and secure battery cable clamps
and posts.
2. Adjust or replace generator drive belt.
3. Test and repair charging system. Refer to
Electrical, Charging,
4. Test battery state-of -charge. Refer to
Electrical, Battery System.
5. Load test battery. Refer to Electrical,
Battery System.
6. Test for voltage drop across Z1-ground
locations. Refer to Electrical, Wiring
Information.
1. Test and repair charging system. Refer to
Electrical, Charging.
2. Inspect and repair all connectors and
splices. Refer to Electrical, Wiring
Information.
1. Test and repair charging system. Refer to
Electrical, Charging.
2. Test for voltage drop across Z1-ground
locations. Refer to Electrical, Wiring
Information.
3. Test amperage draw of fog lamp circuit.
1. Test for voltage drop across Z1-ground
locations. Refer to Electrical, Wiring
Information.
2. Test amperage draw of fog lamp circuit.
3. Refer to Electrical, Electronic Control
Modules.
4. Inspect and repair all connectors and
splices. Refer to Electrical, Wiring
Information.
8L - 14 LAMPS/LIGHTING - EXTERIOR WJ
H EADLAM P (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

FOG LAMPS DO NOT 1. Blown fuse for fog lamp.
ILLUMINATE
2. No Z1-ground at fog lamps.
3. Faulty multifunction switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
5. Defective or burned out bulb.
1. Replace fuse. Refer to Electrical, Wiring
Information.
2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Refer to Electrical, Wiring Information.
4. Repair connector terminal or wire splice.
5. Replace bulb.

DAYTIME RUNNING LAMP

CONDITION POSSIBLE CAUSES CORRECTION

DAYTIME RUNNING LAMPS DO 1. Poor connection at DRL module.
NOT WORK
2. Parking brake engaged.
3. Parking brake circuit shorted to
ground.
4. Headlamp circuit shorted to
ground.
5. Defective DRL relay.
6. Body controller not programed
with Canadian country code.
7. DRL relay is missing.
8. Blown fuse for DRL.
Clicking or chattering when DRL is 1. Mechanical relay is installed in
on. the junction block.
1. Secure connector on DRL
module.
2. Disengage parking brake.
3. Check cluster telltale, refer to
Group 8W.
4. Refer to Group 8W.
5. Replace DRL relay.
6. Check country code.
7. Install DRL relay.
8. Replace fuse refer to Electrical,
Wiring Information.
1. Ensure that the DRL relay is
installed in the proper socket in
junction block, and that no
mechanical relay exists in the low
beam socket.

DIAGNOSIS AND TESTING — HEADLAMP
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
pr oper ligh t in g oper a t ion . Gr ou n din g is pr ovided by
t h e la m p socket wh en it com es in con t a ct wit h t h e
m et a l body, or t h r ou gh a sepa r a t e gr ou n d wir e.
Wh en ch a n gin g la m p bu lbs ch eck t h e socket for
cor r osion . If cor r osion is pr esen t , clea n it wit h a wir e
br u sh a n d coa t t h e in side of t h e socket ligh t ly wit h
Mopa r Mu lt i-P u r pose Gr ea se or equ iva len t .
REMOVAL - BULB
(1) Rem ove t h e h ea dla m p.
(2) Tu r n t h e bu lb socket on e qu a r t er t u r n cou n t er
clockwise.
(3) Rem ove t h e socket fr om la m p (F ig. 13).
(4) Rem ove t h e bu lb fr om socket .

E a ch veh icle is equ ipped wit h va r iou s la m p a ssem -

blies. A good power feed a n d gr ou n d a r e n ecessa r y for
WJ
H EADLAM P (Cont inue d)
Fig. 13 Headlamp Bulb
1 - HIGH BEAM BULB
2 - LOW BEAM BULB
3 - MARKER BULB
4 - PARK/TURN SIGNAL BULB
INSTALLATION - BULB
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) P osit ion t h e bu lb in t o socket a n d pu sh in t o
pla ce.
(2) P osit ion t h e bu lb socket in h ea dla m p a n d t u r n
t h e bu lb socket on e qu a r t er t u r n clockwise.
(3) In st a ll t h e h ea dla m p.
H EADLAM P SWI T CH
DESCRIPTION
Th e h ea dla m p swit ch is pa r t of t h e left m u lt i-fu n c-
t ion swit ch . A kn ob on t h e en d of t h e m u lt i-fu n ct ion
swit ch con t r ol st a lk con t r ols a ll of t h e ext er ior ligh t -
in g swit ch fu n ct ion s. Th e ext er ior ligh t in g swit ch is
h a r d wir ed t o t h e Body Con t r ol Modu le (BCM).
Th e ext er ior ligh t in g swit ch ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e en t ir e left
m u lt i-fu n ct ion swit ch u n it m u st be r epla ced. (Refer
t o 8 - E LE CTRICAL/LAMP S/LIGH TING - E XTE RI-
OR/TURN SIGNAL/H AZARD SWITCH - RE MOVAL)
for t h e ser vice pr ocedu r es. (Refer t o 8 - E LE CTRI-
CAL/E LE CTRONIC CONTROL MODULE S/BODY
CONTROL/CE NTRAL TIME R MODUL - DE SCRIP -
TION) for m or e in for m a t ion on t h is com pon en t .
OPERATION
Th e ext er ior ligh t in g swit ch u ses a h a r d wir ed five
volt r efer en ce cir cu it fr om t h e BCM, r esist or m u lt i-
plexin g a n d a h a r d wir ed swit ch ou t pu t cir cu it t o
pr ovide t h e BCM wit h a zer o t o five volt sign a l t h a t
LAMPS/LIGHTING - EXTERIOR 8L - 15
in dica t es t h e st a t u s of a ll of t h e ext er ior ligh t in g
swit ch set t in gs. Th e BCM t h en u ses con t r ol ou t pu t s
t o en er gize t h e h ea dla m p a n d pa r k la m p r ela ys t h a t
a ct iva t e t h e ext er ior ligh t in g cir cu it s.
Th e BCM m on it or s t h e ext er ior ligh t in g swit ch st a -
t u s, t h en sen ds t h e pr oper swit ch st a t u s m essa ges t o
ot h er m odu les over t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e ext er ior
ligh t in g swit ch st a t u s is a lso u sed by t h e BCM a s a n
in pu t for ch im e wa r n in g syst em oper a t ion .
DIAGNOSIS AND TESTING — HEADLAMP
SWITCH
Befor e t est in g t h e h ea dla m p swit ch , t u r n on t h e
ext er ior ligh t in g a n d open t h e dr iver side fr on t door.
If t h e ext er ior la m ps of t h e veh icle oper a t e, bu t t h er e
is n o ch im e wa r n in g issu ed wit h t h e dr iver side fr on t
door open , (Refer t o 8 - E LE CTRICAL/LAMP S/
LIGH TING - INTE RIOR/DOOR AJ AR SWITCH -
DIAGNOSIS AND TE STING). If t h e ext er ior la m ps
of t h e veh icle a r e in oper a t ive, bu t t h e ch im e wa r n in g
is issu ed, (Refer t o 8 - E LE CTRICAL/LAMP S/LIGH T-
ING - E XTE RIOR - DIAGNOSIS AND TE STING).
If t h e ext er ior la m ps a n d t h e ch im e wa r n in g a r e
bot h in oper a t ive, t est t h e left m u lt i-fu n ct ion swit ch .
(Refer t o 8 - E LE CTRICAL/LAMP S/LIGH TING -
E XTE RIOR - DIAGNOSIS AND TE STING). If t h e
m u lt i-fu n ct ion swit ch t est s OK, pr oceed a s follows.
Th e followin g t est s will h elp t o loca t e a sh or t or open
in t h e h a r d wir ed cir cu it s bet ween t h e m u lt i-fu n ct ion
swit ch a n d t h e Body Con t r ol Modu le (BCM). F or
com plet e cir cu it dia gr a m s, r efer t o t h e a ppr opr ia t e
wir in g in for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e left m u lt i-fu n ct ion swit ch con n ec-
t or. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e Body Con t r ol Modu le (BCM).
Ch eck for con t in u it y bet ween t h e h ea dla m p swit ch
m u x cir cu it of t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e m u lt i-fu n ct ion swit ch a n d a good
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o
St ep 2. If n ot OK, r epa ir t h e sh or t ed h ea dla m p
swit ch m u x cir cu it .
(2) Ch eck for con t in u it y bet ween t h e h ea dla m p
swit ch m u x cir cu it of t h e in st r u m en t pa n el wir e h a r-
8L - 16 LAMPS/LIGHTING - EXTERIOR WJ
H EADLAM P SWI T CH (Cont inue d)
n ess con n ect or for t h e m u lt i-fu n ct ion swit ch a n d t h e
in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
BCM. Th er e sh ou ld be con t in u it y. If OK, go t o St ep 3.
If n ot OK, r epa ir t h e open h ea dla m p swit ch m u x cir-
cu it .
(3) Ch eck for con t in u it y bet ween t h e h ea dla m p
swit ch r et u r n cir cu it of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e m u lt i-fu n ct ion swit ch a n d a
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go
t o St ep 4. If n ot OK, r epa ir t h e sh or t ed h ea dla m p
swit ch r et u r n cir cu it .
(4) Ch eck for con t in u it y bet ween t h e h ea dla m p
swit ch r et u r n cir cu it of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e m u lt i-fu n ct ion swit ch a n d
t h e in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
BCM. Th er e sh ou ld be con t in u it y. If OK, u se a
DRBIII! sca n t ool a n d t h e pr oper Dia gn ost ic P r oce- Fig. 15 Headlamp Removal
du r es m a n u a l t o t est t h e BCM. If n ot OK, r epa ir t h e 1 - HEADLAMP
open h ea dla m p swit ch r et u r n cir cu it .
INSTALLATION
H EADLAM P U N I T CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
REMOVAL
(1) Rem ove t h e ja ck scr ew a t t a ch in g t h e t op of (1) In st a ll a ll of t h e bu lb socket s in h ea dla m p m od-
h ea dla m p t o t h e h ea dla m p m ou n t in g m odu le (F ig. u le.
14). (2) P osit ion t h e h ea dla m p on t h e veh icle a n d a lign
(2) Gr a sp u pper in boa r d a n d lower ou t boa r d cor- t h e ba ll st u ds wit h t h e socket s.
n er s of h ea dla m p (F ig. 15) a n d pu ll h ea dla m p ou t - (3) P u sh t h e h ea dla m p in wa r d t o secu r e t h e ba ll
wa r d. st u ds wit h t h e socket s.
(3) Rem ove a ll of t h e bu lb socket s fr om h ea dla m p (4) In st a ll t h e ja ck scr ew a t t a ch in g t h e t op of
m odu le. h ea dla m p t o t h e h ea dla m p m ou n t in g m odu le.
(4) Sepa r a t e t h e h ea dla m p fr om veh icle.
ADJUSTMENTS
VEHICLE PREPARATION FOR LAMP ALIGNMENT
(1) Ver ify h ea dla m p dim m er swit ch a n d h igh bea m
in dica t or oper a t ion .
(2) Cor r ect defect ive com pon en t s t h a t cou ld h in der
pr oper la m p a lign m en t .
(3) Ver ify pr oper t ir e in fla t ion .
(4) Clea n la m p len ses.
(5) Ver ify t h a t lu gga ge a r ea is n ot h ea vily loa ded.
(6) F u el t a n k sh ou ld be F ULL. Add 2.94 kg (6.5
lbs.) of weigh t over t h e fu el t a n k for ea ch est im a t ed
ga llon of m issin g fu el.

LAMP ALIGNMENT SCREEN PREPARATION

(1) P osit ion veh icle on a level su r fa ce per pen dicu -
la r t o a fla t wa ll 7.62 m et er s (25 ft ) a wa y fr om fr on t
Fig. 14 Headlamp Jackscrew
of h ea dla m p len s (F ig. 16).
1 - JACKSCREW
(2) If n ecessa r y, t a pe a lin e on t h e floor 7.62
2 - HEADLAMP
m et er s (25 ft ) a wa y fr om a n d pa r a llel t o t h e wa ll.
(3) Mea su r e fr om t h e floor u p 1.27 m et er s (5 ft )
a n d t a pe a lin e on t h e wa ll a t t h e cen t er lin e of t h e
veh icle. Sigh t a lon g t h e cen t er lin e of t h e veh icle
WJ
H EADLAM P U N I T (Cont inue d)
(fr om r ea r of veh icle for wa r d) t o ver ify a ccu r a cy of
t h e lin e pla cem en t .
(4) Rock veh icle side-t o-side t h r ee t im es t o a llow
su spen sion t o st a bilize.
(5) J ou n ce fr on t su spen sion t h r ee t im es by pu sh in g
down wa r d on fr on t bu m per a n d r elea sin g.
(6) Mea su r e t h e dist a n ce fr om t h e cen t er of h ea d-
la m p len s t o t h e floor. Tr a n sfer m ea su r em en t t o t h e
a lign m en t scr een (wit h t a pe). Use t h is lin e for
u p/down a dju st m en t r efer en ce.
(7) Mea su r e dist a n ce fr om t h e cen t er lin e of t h e
veh icle t o t h e cen t er of ea ch h ea dla m p bein g a lign ed.
Tr a n sfer m ea su r em en t s t o scr een (wit h t a pe) t o ea ch
side of veh icle cen t er lin e. Use t h ese lin es for left /
r igh t a dju st m en t r efer en ce.
HEADLAMP ADJUSTMENT
A pr oper ly a im ed low bea m will pr oject t h e t op
edge of t h e bea m in t en sit y pa t t er n on t h e scr een
fr om 25 m m (1 in .) a bove t o 75 m m (3 in .) below
h ea dla m p cen t er lin e. Th e side-t o-side left edge of t h e
bea m in t en sit y pa t t er n sh ou ld be fr om 50 m m (2 in .)
left t o 50 m m (2 in .) r igh t of h ea dla m p cen t er lin e
(F ig. 17).
(1) Clea n fr on t of t h e h ea dla m ps.
(2) P la ce h ea dla m ps on LOW bea m .
Fig. 16 Headlamp Alignment Screen—Typical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET)
LAMPS/LIGHTING - EXTERIOR 8L - 17
(3) Cover fr on t of t h e h ea dla m p t h a t is n ot bein g
a dju st ed.
(4) Tu r n a dju st m en t scr ew (F ig. 18) a n d (F ig. 19)
u n t il t h e t op edge of t h e bea m in t en sit y pa t t er n is
posit ion ed wit h in 25 m m (1 in .) a bove or 75 m m (3
in .) below t h e h ea dla m p h or izon t a l cen t er lin e.
(5) Cover fr on t of t h e h ea dla m p a n d a dju st t h e
ot h er h ea dla m p bea m a s in st r u ct ed below.
(6) Rot a t e t h e a dju st m en t scr ew u n t il t h e t op edge
of t h e bea m in t en sit y pa t t er n is posit ion ed wit h in 25
m m (1 in .) a bove or 75 m m (3 in .) below t h e h ea d-
la m p h or izon t a l cen t er lin e.
LI CEN SE PLAT E LAM P
REM OVAL
REMOVAL - BULB
(1) Rem ove la m p a ssem bly fr om lift ga t e la m p m od-
u le.
(2) Rot a t e bu lb socket cou n t er clockwise t o discon -
n ect bu lb socket fr om la m p.
(3) Rem ove bu lb fr om socket .
4 - FRONT OF HEADLAMP
5 - VEHICLE CENTERLINE
8L - 18 LAMPS/LIGHTING - EXTERIOR
LI CEN SE PLAT E LAM P (Cont inue d)
Fig. 17 Low Beam Pattern
1 - LOW BEAM INTENSITY PATTERN (ISO-CANDELA CURVE)
Fig. 18 Headlamp Beam Adjustment Screw
1 - ADJUSTMENT SCREW LOCATION
Fig. 19 Headlamp Beam Adjustment
WJ
REMOVAL - LAMP
(1) Rem ove t h e scr ews a t t a ch in g la m p a ssem bly t o
lift ga t e. (F ig. 20).
(2) P u ll t h e la m p a ssem bly a wa y fr om t h e sh eet -
m et a l a t ext r em e ou t boa r d edges t o disen ga ge t h e
pu sh pin s.
(3) Sepa r a t e la m p a ssem bly h a r n ess wir in g con -
n ect or.
(4) Rem ove la m p.
Fig. 20 License Plate Lamp Housing
1 - LICENSE PLATE LAMP
2 - CONNECTOR
3 - LIFTGATE
I N STALLAT I ON
INSTALLATION - BULB
(1) In st a ll bu lb in socket .
(2) In st a ll socket a n d bu lb a ssem bly in la m p h ou s-
in g.
(3) In st a ll la m p a ssem bly in lift ga t e la m p m odu le.
INSTALLATION - LAMP
(1) Con n ect bu lb h a r n ess t o la m p a ssem bly.
(2) P osit ion la m p a ssem bly on lift ga t e a n d pr ess
ou t boa r d fa st en er s in pla ce.
(3) In st a ll scr ews in la m p a ssem bly.
LI CEN SE PLAT E LAM P U N I T
REMOVAL
(1) Rem ove t h e scr ews r et a in in g t h e la m p h ou sin g/
t r im pa n el t o t h e lift ga t e (F ig. 21).
(2) Discon n ect t h e wir e h a r n ess for t h e licen se
pla t e la m ps a n d t h e flip u p gla ss swit ch , if equ ipped.
(3) Rem ove t h e licen se pla t e la m ps a n d t h e flip u p
gla ss swit ch , if equ ipped.
(4) Rem ove t h e licen se pla t e la m p h ou sin g.
WJ LAMPS/LIGHTING - EXTERIOR 8L - 19
LI CEN SE PLAT E LAM P U N I T (Cont inue d)

Fig. 21 License Plate Lamp Housing Fig. 22 Left (Lighting) Multi-Function Switch
1 - LICENSE PLATE LAMP 1 - EXTERIOR LIGHTING CONTROL
2 - CONNECTOR 2 - INTERIOR LIGHTING CONTROL
3 - LIFTGATE 3 - CONTROL STALK
4 - HAZARD WARNING BUTTON
5 - CANCEL ACTUATOR
INSTALLATION 6 - LEFT (LIGHTING) MULTI-FUNCTION SWITCH
(1) In st a ll t h e licen se pla t e la m ps, a n d t h e flip u p
gla ss swit ch , if equ ipped. • In t er ior La m ps On
(2) Con n ect t h e wir e h a r n esses for t h e licen se • P a r a de Mode
pla t e la m ps a n d t h e flip u p gla ss swit ch . Th e left m u lt i-fu n ct ion swit ch ca n n ot be a dju st ed
(3) In st a ll t h e la m p h ou sin g/t r im pa n el on t h e lift - or r epa ir ed. If a n y fu n ct ion of t h e swit ch is fa u lt y, or
ga t e. if t h e swit ch is da m a ged, t h e en t ir e swit ch u n it m u st
be r epla ced.
LEFT M U LT I -FU N CT I ON OPERATION
SWI T CH Th e left m u lt i-fu n ct ion swit ch u ses a com bin a t ion
of r esist or m u lt iplexed a n d con ven t ion a lly swit ch ed
DESCRIPTION ou t pu t s t o con t r ol t h e m a n y fu n ct ion s a n d fea t u r es it
Th e left m u lt i-fu n ct ion swit ch , it s m ou n t in g pr ovi- pr ovides u sin g a m in im a l n u m ber of h a r d wir ed cir-
sion s, a n d it s elect r ica l con n ect ion s a r e a ll con cea led cu it s. Th e swit ch is gr ou n ded t o t h e ch a ssis ben ea t h
ben ea t h t h e st eer in g colu m n sh r ou ds, ju st below t h e t h e cen t er floor con sole, ju st for wa r d of t h e Air ba g
st eer in g wh eel (F ig. 22). Con t r ol Modu le (ACM). F ollowin g a r e descr ipt ion s of
A sin gle con n ect or wit h eleven t er m in a l pin s is t h e h ow t h e left m u lt i-fu n ct ion swit ch oper a t es t o
loca t ed on t h e ba ck of t h e swit ch h ou sin g a n d con - con t r ol t h e m a n y ext er ior ligh t in g fu n ct ion s a n d fea -
n ect s t h e swit ch t o t h e veh icle elect r ica l syst em . Th e t u r es it pr ovides:
left m u lt i-fu n ct ion swit ch su ppor t s t h e followin g ext e- • Au to He a d la m p s - Th e a u t om a t ic h ea dla m ps
r ior ligh t in g fu n ct ion s: fea t u r e is pr ovided by t h e Body Con t r ol Modu le
• Au t o H ea dla m ps (BCM), wh ich m on it or s a n in pu t fr om a ph ot odiode
• F r on t F og La m ps sen sor loca t ed on t h e t op of t h e in st r u m en t pa n el t o
• H a za r d Wa r n in g Con t r ol det ect a m bien t ligh t levels wh en ever t h e ign it ion
• H ea dla m ps swit ch is in t h e On posit ion . Ba sed u pon t h e m u lt i-
• H ea dla m p Bea m Select ion plexed in pu t fr om t h e left m u lt i-fu n ct ion swit ch a n d
• H ea dla m p Opt ica l H or n t h e in pu t of t h e ph ot odiode sen sor, t h e BCM con t r ols
• P a r k La m ps ou t pu t s t o t h e pa r k la m p a n d h ea dla m p r ela ys t o
• Rea r F og La m ps illu m in a t e or ext in gu ish a ll ext er ior ligh t in g.
• Tu r n Sign a l Con t r ol • F ro n t F o g La m p s - Th e Body Con t r ol Modu le
Th e left m u lt i-fu n ct ion swit ch a lso su ppor t s t h e fol- (BCM) m on it or s t h e left m u lt i-fu n ct ion swit ch t h en ,
lowin g in t er ior ligh t in g fu n ct ion s: ba sed u pon t h a t swit ch ed gr ou n d in pu t , con t r ols a n
• P a n el La m ps Dim m in g ou t pu t t o t h e fr on t fog la m p r ela y t o illu m in a t e or
• In t er ior La m ps Defea t ext in gu ish t h e fr on t fog la m ps.
8L - 20 LAMPS/LIGHTING - EXTERIOR
LEFT M U LT I -FU N CT I ON SWI T CH (Cont inue d)
• Ha za rd Wa rn in g Co n tro l - Th e h a za r d wa r n -
in g pu sh bu t t on is pr essed down t o a ct iva t e t h e h a z-
a r d wa r n in g syst em , a n d pr essed down a ga in t o t u r n
t h e syst em off. Th e left m u lt i-fu n ct ion swit ch pr o-
vides a gr ou n d t o t h e h a za r d wa r n in g sen se in pu t of
t h e com bin a t ion fla sh er t o con t r ol a ct iva t ion of t h e
h a za r d wa r n in g la m ps.
• He a d la m p s - Th e Body Con t r ol Modu le (BCM)
m on it or s t h e left m u lt i-fu n ct ion swit ch t h en , ba sed
u pon t h a t m u lt iplexed in pu t , con t r ols a n ou t pu t t o
t h e h ea dla m p low or h igh bea m r ela ys t o illu m in a t e
or ext in gu ish t h e h ea dla m ps.
• He a d la m p B e a m S e le c tio n - Th e Body Con t r ol
Modu le (BCM) m on it or s t h e left m u lt i-fu n ct ion
swit ch t h en , ba sed u pon t h a t swit ch ed gr ou n d in pu t ,
con t r ols a n ou t pu t t o t h e h ea dla m p low or h igh bea m
r ela ys t o a ct iva t e t h e select ed h ea dla m p bea m .
• He a d la m p Op tic a l Ho rn - Th e Body Con t r ol
Modu le (BCM) m on it or s t h e left m u lt i-fu n ct ion
swit ch t h en , ba sed u pon t h a t swit ch ed gr ou n d in pu t ,
con t r ols a n ou t pu t t o t h e h ea dla m p h igh bea m r ela y
t o a ct iva t e t h e h ea dla m p h igh bea m s.
• P a rk La m p s - Th e Body Con t r ol Modu le (BCM)
m on it or s t h e left m u lt i-fu n ct ion swit ch t h en , ba sed
u pon t h a t m u lt iplexed in pu t , con t r ols a n ou t pu t t o
t h e pa r k la m p r ela y t o illu m in a t e or ext in gu ish t h e
pa r kin g la m ps.
• Re a r F o g La m p s - Th e Body Con t r ol Modu le
(BCM) m on it or s t h e left m u lt i-fu n ct ion swit ch t h en ,
ba sed u pon t h a t m u lt iplexed in pu t , con t r ols a n ou t -
pu t t o t h e r ea r fog la m p r ela y t o illu m in a t e or ext in -
gu ish t h e r ea r fog la m ps.
• Tu rn S ig n a l Co n tro l - Th e left m u lt i-fu n ct ion
swit ch con t r ol st a lk a ct u a t es t h e t u r n sign a l swit ch .
Th e Body Con t r ol Modu le (BCM) m on it or s t h e left
m u lt i-fu n ct ion swit ch t h en , ba sed u pon t h a t m u lt i-
plexed in pu t , pr ovides a va r ia ble volt a ge ou t pu t t o
con t r ol t h e ligh t in g of t h e t u r n sign a ls.
F ollowin g a r e descr ipt ion s of t h e h ow t h e left
m u lt i-fu n ct ion swit ch oper a t es t o con t r ol t h e m a n y
in t er ior ligh t in g fu n ct ion s a n d fea t u r es it pr ovides:
• P a n e l La m p s D im m in g - Th e Body Con t r ol
Modu le (BCM) m on it or s t h e left m u lt i-fu n ct ion
swit ch t h en , ba sed u pon t h a t m u lt iplexed in pu t , pr o-
vides a va r ia ble volt a ge ou t pu t t h r ou gh sever a l pa n el
la m ps dr iver cir cu it s t o con t r ol t h e ligh t in g of m a n y
in ca n descen t pa n el la m ps. Th e BCM a lso sen ds pa n el
la m ps dim m in g m essa ges over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s t o ot h er
m odu les t o con t r ol Displa y ligh t in g levels in t h ose
m odu les.
WJ
• In te rio r La m p s D e fe a t - Th e Body Con t r ol
Modu le (BCM) m on it or s t h e left m u lt i-fu n ct ion
swit ch t h en , ba sed u pon t h a t m u lt iplexed in pu t ,
in t er n a lly disa bles t h e fu n ct ion t h e BCM n or m a lly
pr ovides t o con t r ol t h e illu m in a t ion of t h e in t er ior
la m ps.
• In te rio r La m p s On - Th e Body Con t r ol Modu le
(BCM) m on it or s t h e left m u lt i-fu n ct ion swit ch t h en ,
ba sed u pon t h a t m u lt iplexed in pu t , pr ovides a con t r ol
ou t pu t t o a ct iva t e a ll of t h e in t er ior la m p cir cu it s.
• P a ra d e Mo d e - Th e Body Con t r ol Modu le
(BCM) m on it or s t h e left m u lt i-fu n ct ion swit ch t h en ,
ba sed u pon t h a t m u lt iplexed in pu t , pr ovides a volt -
a ge ou t pu t t h r ou gh sever a l pa n el la m ps dr iver cir-
cu it s t o con t r ol t h e ligh t in g of m a n y in ca n descen t
pa n el la m ps. Th e BCM a lso sen ds pa n el la m ps dim -
m in g m essa ges over t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s t o ot h er m odu les on
t h e bu s t o con t r ol ligh t in g levels in t h ose m odu les.
DIAGNOSIS AND TESTING - LEFT MULTI -
FUNCTION SWITCH
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e m u lt i-fu n ct ion swit ch con n ect or.
(2) Usin g a n oh m m et er, per for m t h e con t in u it y
a n d r esist a n ce t est s a t t h e t er m in a ls in t h e m u lt i-
fu n ct ion swit ch con n ect or a s sh own in t h e Left Mu lt i-
F u n ct ion Swit ch Test ch a r t (F ig. 23).
WJ LAMPS/LIGHTING - EXTERIOR 8L - 21
LEFT M U LT I -FU N CT I ON SWI T CH (Cont inue d)

Fig. 23 Left Multi -Function Switch Test

LEFT (LIGHTING) MULTI-FUNCTION SWITCH

TURN SIGNAL AND HAZARD WARNING SWITCH TESTS
SWITCH POSITION CONTINUITY
TURN HAZARD BETWEEN
Neutral Off No Related Continuity
Left Off Pins 2 & 8
Right Off Pins 2 & 7
Neutral On Pins 2 & 9
EXTERIOR LIGHTING SWITCH TESTS
SWITCH POSITION CONTINUITY RESISTANCE RESISTANCE RANGE (OHMS)
BETWEEN BETWEEN
Off - Pins 4 & 11 3743 - 3824
Park Lamps On - Pins 4 & 11 901 - 926
Head Lamps On - Pins 4 & 11 345 - 358
Auto Headlamps On - Pins 4 & 11 74 - 81
Fog Lamps Pins 1 & 2 - -
Optical Horn Pins 2 & 5 - -
High Beam Pins 2 & 6 - -
INTERIOR LIGHTING SWITCH TESTS
Dome Lamp Disable - Pins 4 & 9 63 - 70
On
Panel Lamps - Pins 4 & 9 198 - 208
Dimming Position 1
Dimming Position 2 - Pins 4 & 9 551 - 569
Dimming Position 3 - Pins 4 & 9 905 - 929
Dimming Position 4 - Pins 4 & 9 1258 - 1290
Dimming Position 5 - Pins 4 & 9 1611 - 1651
Dimming Position 6 - Pins 4 & 9 1965 - 2011
Parade Mode On - Pins 4 & 9 3534 - 3611
Dome Lamp Enable - Pins 4 & 9 7811 - 7974
On
8L - 22 LAMPS/LIGHTING - EXTERIOR WJ
LEFT M U LT I -FU N CT I ON SWI T CH (Cont inue d)
(3) If t h e m u lt i-fu n ct ion swit ch fa ils a n y of t h e
con t in u it y or r esist a n ce t est s, r epla ce t h e swit ch .

REM OVAL
REMOVAL - LEFT MULTI-FUNCTION SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive

ca ble.
(2) Rem ove t h e lower t ilt in g st eer in g colu m n Fig. 24 Steering Column Shrouds Remove/Install
sh r ou d (F ig. 24). 1 - UPPER TILTING COLUMN SHROUD
(3) Un sn a p t h e t wo h a lves of t h e st eer in g colu m n 2 - FIXED COLUMN SHROUD
sh r ou d, a n d r em ove. 3 - LOWER TILTING COLUMN SHROUD
(4) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess 4 - SCREW
con n ect or fr om t h e swit ch con n ect or.
(5) Rem ove t h e scr ews t h a t secu r e t h e left m u lt i-
fu n ct ion swit ch t o t h e h ou sin g (F ig. 25).
(6) Rem ove t h e left m u lt i-fu n ct ion swit ch .

REMOVAL - MULTI-FUNCTION SWITCH

MOUNTING HOUSING
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
Fig. 25 Left Multi-Function Switch Remove/Install
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
1 - SCREW (2)
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
2 - STEERING COLUMN
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
BAG DEPLOYMENT AND POSSIBLE PERSONAL 4 - LEFT MULTI-FUNCTION SWITCH
INJURY.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive

NOTE: Before starting this procedure, be certain to ca ble.
turn the steering wheel until the front wheels are in
the straight-ahead position.
WJ LAMPS/LIGHTING - EXTERIOR 8L - 23
LEFT M U LT I -FU N CT I ON SWI T CH (Cont inue d)
(2) Rem ove t h e clockspr in g fr om t h e m u lt i-fu n ct ion
swit ch m ou n t in g h ou sin g. (Refer t o 8 - E LE CTRI-
CAL/RE STRAINTS/CLOCKSP RING - RE MOVAL).
(3) Rem ove t h e left m u lt i-fu n ct ion swit ch fr om t h e
m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g. (Refer t o 8 -
E LE CTRICAL/LAMP S/LIGH TING - E XTE RIOR/
LE F T MULTI-F UNCTION SWITCH - RE MOVAL -
LE F T MULTI-F UNCTION SWITCH ).
(4) Rem ove t h e r igh t m u lt i-fu n ct ion swit ch fr om
t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g. (Refer
t o 8 - E LE CTRICAL/WIP E RS/WASH E RS/RIGH T
MULTI-F UNCTION SWITCH - RE MOVAL).
(5) Rem ove t h e scr ew t h a t secu r es t h e m u lt i-fu n c-
t ion swit ch m ou n t in g h ou sin g t o t h e st eer in g colu m n
h ou sin g (F ig. 26).

Fig. 27 Multi-Function Switch Mounting Housing

Remove/install
1 - MULTI-FUNCTION SWITCH ASSEMBLY
2 - CLOCKSPRING

SYSTEM. FAILURE TO TAKE THE PROPER PRE-

CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) P osit ion t h e left m u lt i-fu n ct ion swit ch on t o t h e
h ou sin g (F ig. 28).

Fig. 26 Multi-Function Switch Mounting Housing

Screw Remove/Install
1 - CLOCK SPRING
2 - SCREW
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING

(6) Rem ove t h e m u lt i-fu n ct ion swit ch m ou n t in g

h ou sin g (F ig. 27).

I N STALLAT I ON
Fig. 28 Left Multi-Function Switch Remove/Install
INSTALLATION - LEFT MULTI-FUNCTION 1 - SCREW (2)
SWITCH 2 - STEERING COLUMN
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
WARNING: ON VEHICLES EQUIPPED WITH AIR- 4 - LEFT MULTI-FUNCTION SWITCH
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING (2) In st a ll a n d t igh t en t h e scr ews t h a t secu r e t h e
COLUMN, OR INSTRUMENT PANEL COMPONENT left m u lt i-fu n ct ion swit ch h ou sin g. Tigh t en t h e
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- scr ews t o 2.5 N·m (22 in . lbs.).
LATE THE BATTERY NEGATIVE (GROUND) CABLE, (3) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- con n ect or t o t h e swit ch con n ect or.
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
8L - 24 LAMPS/LIGHTING - EXTERIOR
LEFT M U LT I -FU N CT I ON SWI T CH (Cont inue d)
(4) P osit ion t h e lower t ilt in g st eer in g colu m n
sh r ou d t o t h e u n der side of t h e st eer in g colu m n (F ig.
29).
Fig. 29 Steering Column Shrouds Remove/Install
1 - UPPER TILTING COLUMN SHROUD
2 - FIXED COLUMN SHROUD
3 - LOWER TILTING COLUMN SHROUD
4 - SCREW
(5) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
lower st eer in g colu m n sh r ou d h ou sin g. Tigh t en t h e
scr ew t o 1.9 N·m (17 in . lbs.).
(6) Align t h e u pper t ilt in g st eer in g colu m n sh r ou d
t o t h e lower sh r ou d a n d sn a p t h e t wo sh r ou d h a lves
t oget h er.
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
INSTALLATION - MULTI-FUNCTION SWITCH
MOUNTING HOUSING
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
WJ
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) Rot a t e t h e t u r n sign a l ca n cel ca m in t h e m u lt i-
fu n ct ion swit ch h ou sin g u n t il t h e a lign m en t h ole in
t h e on e ca m lobe is a lign ed wit h t h e a lign m en t h ole
in t h e ba ck of t h e h ou sin g. Th e oblon g h ole in t h e
h u b of t h e ca m sh ou ld n ow be a t t h e t op, a n d t h e
loca t in g t a b in t h e h u b of t h e ca m sh ou ld be a t t h e
bot t om (F ig. 30).
Fig. 30 Turn Signal Cancel Cam Alignment
1 - ALIGNMENT HOLE
2 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
3 - ALIGNMENT HOLE
4 - TURN SIGNAL CANCEL CAM
5 - LOCATING TAB
6 - WASHER
7 - TURN SIGNAL SWITCH CANCEL ACTUATOR
(2) P osit ion t h e m u lt i-fu n ct ion swit ch h ou sin g on t o
t h e t op of t h e st eer in g colu m n . Th e loca t in g t a b in
t h e h u b of t h e t u r n sign a l ca n cel ca m m u st be
en ga ged wit h t h e a lign m en t gr oove in t h e bot t om of
t h e u pper st eer in g colu m n sh a ft .
(3) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
m u lt i-fu n ct ion swit ch h ou sin g t o t h e t op of t h e col-
u m n h ou sin g (F ig. 31). Tigh t en t h e scr ew t o 1.9 N·m
(17 in . lbs.).
(4) Rein st a ll t h e r igh t m u lt i-fu n ct ion swit ch on t o
t h e m u lt i-fu n ct ion swit ch h ou sin g. (Refer t o 8 -
E LE CTRICAL/WIP E RS/WASH E RS/RIGH T MULTI-
F UNCTION SWITCH - INSTALLATION).
(5) Rein st a ll t h e left m u lt i-fu n ct ion swit ch on t o t h e
m u lt i-fu n ct ion swit ch h ou sin g. (Refer t o 8 - E LE C-
TRICAL/LAMP S/LIGH TING - E XTE RIOR/LE F T
WJ LAMPS/LIGHTING - EXTERIOR 8L - 25
LEFT M U LT I -FU N CT I ON SWI T CH (Cont inue d)

OPERATION
All ext er ior ligh t in g fu n ct ion a r e con t r olled by t h e
m u lt ifu n ct ion swit ch . St op la m p fu n ct ion s a r e con -
t r olled by t h e st opla m p swit ch . Th e ba ck-u p la m ps
a r e con t r olled by t h e ba ck-u p la m p swit ch .

REM OVAL
REMOVAL - BULBS
Th e br a ke, t u r n sign a l, ba ck-u p, a n d side m a r ker
la m p bu lbs a r e in cor por a t ed in t o t h e t a il la m p.
(1) Rem ove t h e t a il la m p.
(2) Rot a t e t h e bu lb socket cou n t er clockwise.
(3) Sepa r a t e t h e socket fr om t h e la m p
(4) Rem ove t h e bu lb fr om t h e socket (F ig. 32).
Fig. 31 Multi-Function Switch Mounting Housing
Screw Remove/Install
1 - CLOCK SPRING
2 - SCREW
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING

MULTI-F UNCTION SWITCH - INSTALLATION -

LE F T MULTI-F UNCTION SWITCH ).
(6) Rein st a ll t h e clockspr in g on t o t h e m u lt i-fu n c-
t ion swit ch h ou sin g. (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/CLOCKSP RING - INSTALLATION).
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.

PARK /T U RN SI GN AL LAM P
REMOVAL - BULBS Fig. 32 Tail Lamp Bulbs
(1) Rem ove t h e h ea dla m p m odu le. 1 - TAIL/STOP BULB
(2) Rot a t e t h e t u r n sign a l bu lb socket 1/4 t u r n 2 - TAIL LAMP
cou n t er clockwise. 3 - BACK-UP BULB
(3) Rem ove t h e bu lb socket fr om m odu le. 4 - TURN SIGNAL BULB
(4) Rem ove t h e bu lb fr om socket .
REMOVAL - LAMP
INSTALLATION - BULBS Th e br a ke, t u r n sign a l, ba ck-u p, a n d side m a r ker
(1) P r ess t h e bu lb in t o socket . la m ps a r e in cor por a t ed in t h e t a il la m p.
(2) P osit ion t h e bu lb socket in m odu le. (1) Rem ove t h e scr ews a t t a ch in g t h e la m p t o body
(3) Rot a t e t h e t u r n sign a l bu lb socket 1/4 t u r n (F ig. 33).
clockwise. (2) Disen ga ge t h e la m p fr om t h e a lign m en t pin .
(4) In st a ll t h e h ea dla m p m odu le. (3) Discon n ect la m p wir e h a r n ess con n ect or.
(4) Sepa r a t e la m p fr om veh icle.
TAI L LAM P
DESCRIPTION
Th e t a illa m p m odu le con t a in s a h ou sin g, len s, a n d
t h r ee bu lbs. A du a l fila m en t bu lb is u sed for t a il a n d
st op fu n ct ion s. A sin gle fila m en t bu lb is u sed for t u r n
sign a l oper a t ion s. A sepa r a t e bu lb is u sed for ba ck-u p
illu m in a t ion .
8L - 26 LAMPS/LIGHTING - EXTERIOR WJ
TAI L LAM P (Cont inue d)

T U RN SI GN AL CAN CEL CAM

DESCRIPTION
Th e t u r n sign a l ca n cel ca m is con cea led wit h in t h e
m u lt i-fu n ct ion swit ch h ou sin g below t h e st eer in g
wh eel a n d t h e clockspr in g m ech a n ism . Th e t u r n sig-
n a l ca n cel ca m con sist s of a disc u n it wit h t wo in t e-
gr a l lobes. Th e u pper lobe of t h e ca m h a s a n
a lign m en t h ole t h a t is u sed t o a lign it wit h a n ot h er
h ole in t h e ba ck of t h e m u lt i-fu n ct ion swit ch m ou n t -
in g h ou sin g. Th e u pper su r fa ce of t h e t u r n sign a l
ca n cel ca m fea t u r es t h r ee h oles, t wo r ou n d a n d on e
oblon g. Th ese h oles en ga ge a n d key t h e ca n cel ca m t o
t h r ee m a t ch in g pin s in t h e h u b of t h e clockspr in g
m ech a n ism . Th e h u b of t h e clockspr in g a n d t h e t u r n
sign a l ca n cel ca m r ot a t e wit h t h e st eer in g wh eel. Th e
cen t er ed clockspr in g h ou sin g is t h en secu r ed t o t h e
m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g over t h e t op
of t h e t u r n sign a l ca n cel ca m .
Th e t u r n sign a l ca n cel ca m is ser viced a s a a ssem -
bly wit h t h e m u lt i-fu n ct ion swit ch h ou sin g. Th e t u r n
sign a l ca n cel ca m ca n n ot be r epa ir ed a n d, if fa u lt y or
Fig. 33 Tail Lamp
da m a ged, t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou s-
1 - CONNECTOR in g u n it m u st be r epla ced. (Refer t o 8 - E LE CTRI-
2 - RETAINER
CAL/LAMP S/LIGH TING - E XTE RIOR/LE F T MULTI-
3 - TAILLAMP (STOP, TURN, BACK-UP, SIDE MARKER)
F UNCTION SWITCH - RE MOVAL - MULTI-
4 - PIN
F UNCTION SWITCH MOUNTING H OUSING).

I N STALLAT I ON
INSTALLATION - BULBS
(1) P osit ion t h e bu lb in socket a n d pu sh in t o pla ce.
(2) P osit ion t h e bu lb socket in t h e la m p a n d r ot a t e
clockwise.
(3) In st a ll t h e la m p.
INSTALLATION - LAMP
Th e br a ke, t u r n sign a l, ba ck-u p, a n d side m a r ker
la m ps a r e in cor por a t ed in t h e t a il la m p.
(1) P osit ion t h e la m p.
(2) Con n ect t h e la m p wir e h a r n ess con n ect or.
(3) Align t h e pin wit h t h e r et a in er a n d pr ess t h e
la m p in wa r d t o en ga ge.
(4) In st a ll t h e scr ews a t t a ch in g t h e la m p t o body.
OPERATION
Th e t u r n sign a l ca n cel ca m h a s t wo lobes. Wh en
t h e t u r n sign a ls a r e a ct iva t ed by m ovin g t h e left
m u lt i-fu n ct ion swit ch con t r ol st a lk t o a det en t posi-
t ion , a t u r n sign a l ca n cel a ct u a t or is ext en ded fr om
t h e in side su r fa ce of t h e m u lt i-fu n ct ion swit ch h ou s-
in g t owa r d t h e cen t er of t h e st eer in g colu m n a n d t h e
t u r n sign a l ca n cel ca m . Wh en t h e st eer in g wh eel is
r ot a t ed du r in g a t u r n in g m a n eu ver, on e of t h e t wo
t u r n sign a l ca n cel ca m lobes will con t a ct t h e t u r n sig-
n a l ca n cel a ct u a t or. Th e ca n cel a ct u a t or la t ch es
a ga in st t h e ca n cel ca m r ot a t ion in t h e dir ect ion oppo-
sit e t h a t wh ich is sign a led.
WJ LAMPS/LIGHTING - EXTERIOR 8L - 27

U N DERH OOD LAM P REMOVAL - LAMP

(1) Discon n ect t h e wir e h a r n ess con n ect or fr om
la m p.
REM OVAL (2) Rem ove t h e scr ew a t t a ch in g u n der h ood la m p t o
in n er h ood pa n el (F ig. 36).
REMOVAL - BULB (3) Rem ove t h e u n der h ood la m p fr om t h e veh icle.
(1) In ser t a sm a ll fla t bla de in a ccess slot bet ween
t h e la m p ba se a n d la m p len s.
(2) Lift t h e la m p len s u pwa r d a n d r em ove t h e
la m p len s (F ig. 34).
(3) Depr ess bu lb t er m in a l in wa r d (F ig. 35) t o
r elea se bu lb.

Fig. 36 Underhood Lamp

1 - CONNECTOR
2 - UNDERHOOD LAMP

I N STALLAT I ON
Fig. 34 Underhood Lamp Lens
1 - LAMP INSTALLATION - BULB
2 - LAMP LENS (1) E n ga ge t h e r epla cem en t bu lb wir e loop t o t er-
m in a l closest t o la m p ba se wir e con n ect or.
(2) Depr ess t h e opposit e t er m in a l in wa r d a n d
en ga ge t h e r em a in in g bu lb wir e loop.
(3) P osit ion t h e la m p len s on t h e la m p ba se a n d
pr ess in t o pla ce.

INSTALLATION - LAMP
(1) P osit ion t h e u n der h ood la m p on t h e h ood in n er
pa n el.
(2) In st a ll t h e scr ew a t t a ch in g t h e la m p ba se t o
t h e in n er h ood pa n el.
(3) In st a ll t h e la m p h ou sin g a n d pr ess in t o pla ce.
(4) Con n ect t h e wir e h a r n ess con n ect or.

Fig. 35 Underhood Lamp Bulb

1 - BULB
2 - DEPRESS TERMINAL INWARD
3 - BULB WIRE LOOP
4 - LAMP BASE
8L - 28 LAMPS/LIGHTING - INTERIOR WJ

LAM PS/LI GH T I N G - I N T ERI OR

TABLE OF CONTENTS
page page

LAMPS/LIGHTING - INTERIOR DESCRIPTION - LIFTGATE AJAR SWITCH . . 30

SPECIFICATIONS OPERATION
............................. . . . . . . 28 OPERATION - DOOR AJAR SWITCH . . . . . . . 30
COURTESY LAMP OPERATION - FLIP UP GLASS AJAR
REMOVAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 29 OPERATION - LIFTGATE AJAR SWITCH . . . . 30
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 29 DIAGNOSIS AND TESTING - DOOR AJAR
INSTALLATION SWITCH ......................... . . . 30
INSTALLATION - BULB . . . . . . . . . . . . . . . . . 29 GLOVE BOX LAMP/SWITCH
INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DOME LAMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL READING LAMP
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 29 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 29 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - BULB . . . . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 29 TRANS RANGE INDICATOR ILLUMINATION
DOOR AJAR SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION VANITY LAMP
DESCRIPTION - DOOR AJAR SWITCH . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION - FLIP UP GLASS AJAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

LAM PS/LI GH T I N G - I N T ERI OR LAMP BULB TYPE

A/C HEATER NOT SERVICED
SPECI FI CAT I ON S ASH RECEIVER 161
CLIMATE CONTROL 74
PASSENGER ASSIST 214–2
HANDLE
CAUTION: Do not use bulbs other than the bulbs
listed in the Bulb Application Table. Damage to FRONT READING 192
lamp can result. GLOVE COMPARTMENT 194
TELLTALE/HAZARD LAMP 74
Ser vice pr ocedu r es for m ost of t h e la m ps in t h e
in st r u m en t pa n el, a r e loca t ed in E lect r ica l, In st r u - HEATER NOT SERVICED
m en t P a n el. Som e com pon en t s h a ve la m ps t h a t ca n OVERHEAD CONSOLE 192
on ly be ser viced by a n Au t h or ized Ser vice Cen t er RADIO ASC
(ASC) a ft er t h e com pon en t is r em oved fr om t h e veh i-
cle. REAR CARGO 214–2
UNDER PANEL COURTESY 906
CLUSTER ILLUMINATION 103
SUNVISOR VANITY CHRYSLER P/N
6501966
WJ LAMPS/LIGHTING - INTERIOR 8L - 29

COU RT ESY LAM P (2) Lower t h e h ea dlin er a s n eeded. (Refer t o 23 -

REM OVAL
REMOVAL - BULB
(1) Rem ove t h e door t r im pa n el. (Refer t o 23 -
BODY/DOOR - F RONT/TRIM PANE L - RE MOVAL)
for t h e ser vice pr ocedu r es.
(2) Rem ove t h e bu lb socket fr om t h e la m p.
(3) Rem ove t h e bu lb fr om t h e socket .
REMOVAL - LAMP
(1) Rem ove door t r im pa n el. (Refer t o 23 - BODY/
DOOR - F RONT/TRIM PANE L - RE MOVAL) for t h e
pr ocedu r es.
(2) Disen ga ge t h e elect r ica l con n ect or s.
(3) Depr ess t h e lockin g t a bs a n d r em ove t h e la m p
m odu le.
(4) Rem ove t h e bu lb socket .
I N STALLAT I ON
INSTALLATION - BULB
(1) In st a ll t h e bu lb in t h e socket .
(2) In st a ll t h e bu lb socket in t h e la m p.
(3) In st a ll t h e door t r im pa n el.
INSTALLATION - LAMP
(1) In st a ll t h e bu lb socket in t o t h e la m p m odu le.
(2) Align t h e la m p m odu le wit h t h e door t r im
pa n el.
(3) Sn a p t h e la m p m odu le in t o pla ce.
(4) In st a ll t h e door pa n el.
DOM E LAM P
REM OVAL
REMOVAL - BULB
(1) Rot a t e t h e t h e gr a b h a n dle down .
(2) Rem ove t h e scr ews r et a in in g t h e gr a b h a n dle/
dom e len s.
(3) Rem ove t h e gr a b h a n dle/len s fr om t h e m odu le.
(4) Rem ove t h e bu lb fr om t h e la m p t er m in a ls.
REMOVAL - LAMP
It will be n ecessa r y t o pa r t ia lly r em ove t h e h ea d-
lin er t o r em ove t h e bu lb socket .
(1) Rem ove t h e scr ews h oldin g t h e gr a b h a n dle/
len s a ssem bly t o t h e h ea dlin er a n d r oof pa n el.
BODY/INTE RIOR/H E ADLINE R - RE MOVAL) for t h e
ser vice pr ocedu r e.
(3) Sepa r a t e t h e la m p socket fr om t h e h ea dlin er
a n d r oof pa n el.
(4) Discon n ect t h e wir e con n ect or.
I N STALLAT I ON
INSTALLATION - BULB
(1) In ser t t h e bu lb in t o t h e la m p t er m in a ls.
(2) P osit ion t h e gr a b h a n dle/len s on t h e la m p m od-
u le.
(3) In st a ll t h e scr ews r et a in in g t h e gr a b h a n dle/
len s t o t h e la m p m odu le.
INSTALLATION - LAMP
(1) P osit ion t h e la m p socket on t h e h ea dlin er a n d
r oof pa n el.
(2) Con n ect t h e wir e h a r n ess.
(3) In st a ll t h e h ea dlin er.
(4) P osit ion t h e gr a b h a n dle/len s on t h e la m p m od-
u le.
(5) In st a ll t h e scr ews r et a in in g t h e gr a b h a n dle/
len s in t o t h e la m p socket .
DOOR AJ AR SWI T CH
DESCRI PT I ON
DESCRIPTION - DOOR AJAR SWITCH
Th e door a ja r swit ch es a r e in t egr a l t o t h e door
la t ch m ech n icism . Th e fr on t door a ja r swit ch es a r e
a ct u a t ed by t h e fr on t door la t ch m ech a n ism s, a n d a r e
h a r d wir ed bet ween a body gr ou n d a n d t h e Dr iver
Door Modu le (DDM) or t h e P a ssen ger Door Modu le
(P DM). Th e r ea r door a ja r swit ch es a r e a ct u a t ed by
t h e r ea r door la t ch m ech a n ism s, a n d a r e h a r d wir ed
bet ween a body gr ou n d a n d t h e Body Con t r ol Modu le
(BCM) t h r ou gh t h e r ea r door a n d body wir e h a r-
n esses.
Th e door a ja r swit ch es ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e door la t ch
u n it m u st be r epla ced. (Refer t o 23 - BODY/DOOR -
F RONT/LATCH - RE MOVAL) or (Refer t o 23 -
BODY/DOORS - RE AR/LATCH - RE MOVAL) for t h e
ser vice pr ocedu r es. F or com plet e cir cu it dia gr a m s,
r efer t o t h e a ppr opr ia t e wir in g in for m a t ion .
DESCRIPTION - FLIP UP GLASS AJAR SWITCH
Th e lift ga t e flip-u p gla ss a ja r swit ch is in t egr a l t o
t h e lift ga t e flip-u p gla ss la t ch m ech n icism . Th e lift -
ga t e flip-u p gla ss a ja r swit ch is a ct u a t ed by t h e lift -
ga t e flip-u p gla ss la t ch m ech a n ism , a n d is h a r d
8L - 30 LAMPS/LIGHTING - INTERIOR
DOOR AJ AR SWI T CH (Cont inue d)
wir ed bet ween a body gr ou n d, t h e Body Con t r ol Mod-
u le (BCM) a n d t h e r ea r wiper m ot or m odu le t h r ou gh
t h e lift ga t e a n d body wir e h a r n esses.
Th e lift ga t e flip-u p gla ss a ja r swit ch ca n n ot be
a dju st ed or r epa ir ed a n d, if fa u lt y or da m a ged, t h e
lift ga t e flip-u p gla ss la t ch u n it m u st be r epla ced.
(Refer t o 23 - BODY/DE CKLID/H ATCH /LIF TGATE /
TAILGATE /F LIP -UP GLASS LATCH - RE MOVAL)
for t h e ser vice pr ocedu r es. F or com plet e cir cu it dia -
gr a m s, r efer t o t h e a ppr opr ia t e wir in g in for m a t ion .
DESCRIPTION - LIFTGATE AJAR SWITCH
Th e t wo lift ga t e a ja r swit ch es a r e in t egr a l t o t h e
t wo lift ga t e la t ch m ech a n ism s. Th e t wo lift ga t e a ja r
swit ch es a r e a ct u a t ed by t h e lift ga t e la t ch m ech a -
n ism s, a n d a r e h a r d wir ed wit h ea ch ot h er bet ween a
body gr ou n d a n d t h e Body Con t r ol Modu le (BCM)
t h r ou gh t h e lift ga t e a n d body wir e h a r n esses.
Th e lift ga t e a ja r swit ch es ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e lift ga t e la t ch
u n it m u st be r epla ced. (Refer t o 23 - BODY/DE CK-
LID/H ATCH /LIF TGATE /TAILGATE /LATCH - tio n . Th e dr iver door a ja r swit ch is h a r d wir ed t o t h e
RE MOVAL) for t h e ser vice pr ocedu r es. F or com plet e
cir cu it dia gr a m s, r efer t o t h e a ppr opr ia t e wir in g
in for m a t ion .
OPERAT I ON
OPERATION - DOOR AJAR SWITCH
Th e fr on t door a ja r swit ch es close a pa t h t o gr ou n d
for t h e DDM or t h e P DM wh en a fr on t door is
open ed, a n d open s t h e gr ou n d pa t h wh en a fr on t door
is closed. Th e r ea r door a ja r swit ch es close a pa t h t o
gr ou n d for t h e BCM wh en a r ea r door is open ed, a n d
open s t h e gr ou n d pa t h wh en a r ea r door is closed.
Th e DDM, P DM, or BCM r ea d t h e swit ch st a t u s t h en
sen d t h e pr oper swit ch st a t u s m essa ges t o ot h er
m odu les over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s n et wor k. Th e door a ja r
swit ch st a t u s m essa ge is u sed by t h e BCM a s a n
in pu t for Veh icle Th eft Secu r it y Syst em (VTSS) oper-
a t ion .
OPERATION - FLIP UP GLASS AJAR SWITCH
Th e lift ga t e flip-u p gla ss a ja r swit ch ca n close a
pa t h t o gr ou n d for t h e BCM a n d t h e r ea r wiper
m ot or m odu le wh en t h e lift ga t e flip-u p gla ss is
open ed, a n d open s t h e gr ou n d pa t h wh en t h e lift ga t e
flip-u p gla ss is closed. Th e r ea r wiper m ot or m odu le
u ses t h e lift ga t e flip-u p gla ss a ja r swit ch in pu t t o
con t r ol t h e r ea r wiper oper a t ion , a n d will pa r k t h e
r ea r wiper bla de if t h is in pu t in dica t es t h a t t h e lift -
ga t e flip-u p gla ss is a ja r. Th e BCM r ea ds t h e swit ch
st a t u s t h en sen ds t h e pr oper swit ch st a t u s m essa ge
t o ot h er m odu les over t h e P r ogr a m m a ble Com m u n i-
WJ
ca t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e lift ga t e
flip-u p gla ss a ja r swit ch st a t u s m essa ge is u sed by
t h e BCM a s a n in pu t for Veh icle Th eft Secu r it y Sys-
t em (VTSS) oper a t ion .
OPERATION - LIFTGATE AJAR SWITCH
E a ch of t h e lift ga t e a ja r swit ch es ca n close a pa t h
t o gr ou n d for t h e BCM wh en t h e lift ga t e is open ed,
a n d open s t h e gr ou n d pa t h wh en t h e lift ga t e is
closed. Th e BCM r ea ds t h e swit ch st a t u s t h en sen ds
t h e pr oper swit ch st a t u s m essa ge t o ot h er m odu les
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k. Th e lift ga t e a ja r swit ch st a -
t u s m essa ge is u sed by t h e BCM a s a n in pu t for
Veh icle Th eft Secu r it y Syst em (VTSS) oper a t ion .
DIAGNOSIS AND TESTING - DOOR AJAR
SWITCH
Th e fo llo w in g d ia g n o s is a n d te s tin g is o n ly
fo r th e c h im e fu n c tio n s . F o r in te rio r la m p d ia g -
n o s is , re fe r to th e a p p ro p ria te w irin g in fo rm a -
Dr iver Door Modu le (DDM). Th e DDM com m u n ica t es
t h e swit ch st a t u s t o t h e ot h er m odu les in t h e veh icle
on t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k. Th e followin g t est will dia g-
n ose a fa u lt y dr iver door a ja r swit ch a n d cir cu it s. F or
com plet e cir cu it dia gr a m s, r efer t o t h e a ppr opr ia t e
wir in g in for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Ch eck t h a t t h e in t er ior ligh t in g swit ch on t h e
con t r ol st a lk of t h e left m u lt i-fu n ct ion swit ch is n ot
in t h e dom e la m p disa ble posit ion . Open t h e dr iver
side fr on t door a n d n ot e wh et h er t h e in t er ior la m ps
ligh t . Th ey sh ou ld ligh t . If OK, r efer t o Key-In Ign i-
t ion Swit ch in t h e Dia gn osis a n d Test in g sect ion of
t h is gr ou p for fu r t h er dia gn osis of t h e ch im e wa r n in g
syst em . If n ot OK, go t o St ep 2.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e t r im pa n el fr om t h e dr iver fr on t
door a n d discon n ect t h e 4-wa y door wir e h a r n ess con -
n ect or fr om t h e fr on t door la t ch con n ect or. Ch eck for
con t in u it y bet ween t h e gr ou n d cir cu it of t h e 4-wa y
door wir e h a r n ess con n ect or a n d a good gr ou n d.
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 3. If n ot
OK, r epa ir t h e gr ou n d cir cu it .
WJ LAMPS/LIGHTING - INTERIOR 8L - 31
DOOR AJ AR SWI T CH (Cont inue d)
(3) Discon n ect t h e door wir e h a r n ess con n ect or
fr om t h e Dr iver Door Modu le (DDM) con n ect or.
Ch eck for con t in u it y bet ween t h e dr iver door a ja r
swit ch sen se cir cu it of t h e door wir e h a r n ess con n ec-
t or for t h e DDM a n d a good gr ou n d. Th er e sh ou ld be
n o con t in u it y. If OK, go t o St ep 4. If n ot OK, r epa ir
t h e sh or t ed dr iver door a ja r swit ch sen se cir cu it .
(4) Ch eck for con t in u it y bet ween t h e dr iver door
a ja r swit ch sen se cir cu it of t h e door wir e h a r n ess
con n ect or for t h e DDM a n d t h e 4-wa y door wir e h a r-
n ess con n ect or for t h e fr on t door la t ch . Th er e sh ou ld
be con t in u it y. If OK, go t o St ep 5. If n ot OK, r epa ir
t h e open dr iver door a ja r swit ch sen se cir cu it .
(5) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it t er m in a l a n d t h e dr iver door a ja r swit ch sen se
cir cu it t er m in a l of t h e fr on t door la t ch con n ect or.
Th er e sh ou ld be con t in u it y wit h t h e dr iver side fr on t Fig. 1 Glove Box Lamp and Switch Remove/Install
door open , a n d n o con t in u it y wit h t h e door closed. If
1 - GLOVE BOX OPENING UPPER REINFORCEMENT
OK, u se a DRBIII! sca n t ool a n d t h e pr oper Dia gn os- 2 - WIRE HARNESS CONNECTOR
t ic P r ocedu r es m a n u a l t o t est t h e oper a t ion of t h e 3 - GLOVE BOX LAMP & SWITCH
P CI da t a bu s a n d t h e DDM. If n ot OK, r epla ce t h e 4 - LATCH
fa u lt y dr iver side fr on t door la t ch u n it . 5 - MOUNTING HOLE

GLOV E BOX LAM P/SWI T CH INSTALLATION

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Roll down t h e glove box fr om t h e in st r u m en t
pa n el.(Refer t o 23 - BODY/INSTRUME NT PANE L/
GLOVE BOX - RE MOVAL) for t h e pr ocedu r es.
(3) Rem ove t h e lower r igh t cen t er bezel fr om t h e
in st r u m en t pa n el.(Refer t o 23 - BODY/INSTRU-
ME NT PANE L - RE MOVAL) for t h e pr ocedu r es.
(4) Rea ch t h r ou gh t h e glove box open in g a n d
depr ess t h e r et a in in g la t ch es on t h e t op a n d bot t om
of t h e glove box la m p a n d swit ch h ou sin g.
(5) Wh ile h oldin g t h e r et a in in g la t ch es depr essed,
pu sh t h e glove box la m p a n d swit ch ou t t h r ou gh t h e
m ou n t in g h ole (F ig. 1).
(6) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e glove box la m p a n d swit ch con -
n ect or.
(7) Rem ove t h e glove box la m p a n d swit ch .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) P osit ion t h e glove box la m p a n d swit ch t o t h e
in st r u m en t pa n el.
(2) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or t o t h e glove box la m p a n d swit ch con n ect or.
(3) Align t h e glove box la m p a n d swit ch h ou sin g
wit h t h e m ou n t in g h ole in t h e in st r u m en t pa n el
glove box open in g u pper r ein for cem en t .
(4) P u sh t h e glove box la m p a n d swit ch in t o t h e
m ou n t in g h ole u n t il t h e r et a in in g la t ch es a r e fu lly
en ga ged.
(5) In st a ll t h e lower r igh t cen t er bezel on t o t h e
in st r u m en t pa n el. (Refer t o 23 - BODY/INSTRU-
ME NT PANE L - INSTALLATION) for t h e pr oce-
du r es.
(6) Roll t h e glove box ba ck u p in t o t h e in st r u m en t
pa n el.(Refer t o 23 - BODY/INSTRUME NT PANE L/
GLOVE BOX - INSTALLATION) for t h e pr ocedu r es.
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
8L - 32 LAMPS/LIGHTING - INTERIOR WJ

READI N G LAM P
DESCRIPTION
Th e over h ea d con sole in t h is veh icle is equ ipped
wit h t wo in dividu a l r ea din g a n d cou r t esy la m ps.E a ch
la m p h a s it s own swit ch , bu lb, r eflect or a n d len s; bu t
bot h la m ps sh a r e a com m on la m p h ou sin g wit h in t h e
over h ea d con sole.
Th e over h ea d con sole r ea din g a n d cou r t esy la m ps
oper a t e on ba t t er y cu r r en t t h a t is pr ovided a t a ll
t im es, r ega r dless of t h e ign it ion swit ch posit ion . Th e
gr ou n d feed for t h e la m ps is swit ch ed t h r ou gh t h e
in t egr a l r ea din g a n d cou r t esy la m p swit ch es or
t h r ou gh t h e door ja m b swit ch es.
Th e r ea din g a n d cou r t esy la m p len ses a n d t h e
la m p h ou sin g a n d r eflect or u n it a r e ser viced on ly a s
a u n it wit h t h e over h ea d con sole h ou sin g.Th e r ea din g
a n d cou r t esy la m p swit ch es, bu lb h older s a n d wir in g
a r e on ly a va ila ble a s pa r t of t h e over h ea d con sole
wir e h a r n ess.
F or ser vice of t h e r ea din g a n d cou r t esy la m p bu lbs,
(Refer t o 8 - E LE CTRICAL/LAMP S/LIGH TING -
Fig. 2 Overhead Console Reading Lamp Bulb
INTE RIOR/RE ADING LAMP - RE MOVAL). F or dia g-
n osis of t h e r ea din g a n d cou r t esy la m ps, r efer t o t h e 1 - BULB
a ppr opr ia t e wir in g in for m a t ion .
ogy a s t h e ligh t sou r ce. Th is la m p r equ ir es a 120 volt
OPERATION AC sign a l t h a t is pr ovided by a power con ver t er
All r ea din g a n d cou r t esy la m ps loca t ed in t h e over- in clu ded a s pa r t of t h e a ssem bly. Th e m odu le is n ot
h ea d con sole a r e a ct iva t ed by t h e door ja m b swit ch es. ser vicea ble sepa r a t ely. Beca u se of a pot en t ia l sh ock
Wh en a ll of t h e door s a r e closed, t h ese la m ps ca n be h a za r d, dia gn ost ic t est in g of t h e la m p a ssem bly
in dividu a lly a ct iva t ed by depr essin g t h e cor r espon d- sh ou ld be a voided. Refer t o TRANSMISSION, Ra n ge
in g len s. Wh en a n y door is open , depr essin g t h e la m p Select or Assem bly Rem ova l a n d In st a lla t ion .
len ses t o a ct iva t e t h e la m p swit ch es will n ot t u r n t h e
la m ps off.
VAN I T Y LAM P
REMOVAL
(1) Rem ove t h e over h ea d con sole. REMOVAL
(2) Rot a t e t h e con sole u n t il t h e bu lb is visible (F ig. (1) F old down t h e visor.
2). (2) Usin g a sm a ll fla t bla de, a n d st a r in g a t t h e
(3) Gr a sp t h e bu lb a n d r em ove fr om t h e socket . ba se of t h e la m p a ssem bly, ca r efu lly pr y t h e ba se of
t h e la m p fr om t h e visor.
INSTALLATION (3) Discon n ect t h e va n it y la m p visor a n d r em ove
(1) P u sh t h e bu lb in t o t h e bu lb socket . t h e la m p fr om t h e veh icle.
(2) In st a ll t h e con sole on t h e h ea dlin er a n d r oof
pa n el. INSTALLATION
(3) Align t h e scr ew h ole a n d in st a ll t h e scr ew. (1) P osit ion t h e la m p a t t h e visor a n d con n ect t h e
wir e con n ect or.
(2) P r ess t h e la m p in pla ce.
T RAN S RAN GE I N DI CAT OR
I LLU M I N AT I ON
DESCRIPTION
Th e Tr a n sm ission Ra n ge In dica t or La m p, m ou n t ed
on t h e floor con sole, u ses elect r olu m in escen t t ech n ol-
WJ MESSAGE SYSTEMS 8M - 1

MESSAGE SYSTEMS
TABLE OF CON T EN T S

page page

OVERHEAD CONSOLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...1 DIAGNOSIS AND TESTING - ELECTRONIC
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...1 VEHICLE INFORMATION CENTER .........9
STANDARD PROCEDURE STANDARD PROCEDURE - TIRE PRESSURE
STANDARD PROCEDURE - MODULE LAMP SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 10
REPLACEMENT . . . . . . . . . . . . . . . . . . . . ...1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - COURTESY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
LAMP REPLACEMENT . . . . . . . . . . . . . . . ...1 UNIVERSAL TRANSMITTER
STANDARD PROCEDURE - MODULE LENS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACEMENT . . . . . . . . . . . . . . . . . . . . ...2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - ELECTRONIC DIAGNOSIS AND TESTING - UNIVERSAL
VEHICLE INFORMATION CENTER TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 11
PROGRAMMING . . . . . . . . . . . . . . . . . . . . ...2 AMBIENT TEMP SENSOR
STANDARD PROCEDURE - COMPASS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DEMAGNETIZING . . . . . . . . . . . . . . . . . . . ...4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - COMPASS DIAGNOSIS AND TESTING
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . ...5 DIAGNOSIS AND TESTING - AMBIENT
STANDARD PROCEDURE - COMPASS TEMPERATURE SENSOR . . . . . . . . . . . . . . . 12
VARIATION ADJUSTMENT . . . . . . . . . . . . . ...5 DIAGNOSIS AND TESTING - AMBIENT
REMOVAL .......................... ...5 TEMPERATURE SENSOR CIRCUIT . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OVERHEAD CONSOLE SYSTEMS . . . . . . ...6
ELECTRONIC VEHICLE INFO CENTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...6

OV ERH EAD CON SOLE OPERATION

DESCRIPTION
An over h ea d con sole is st a n da r d fa ct or y-in st a lled
equ ipm en t on t h is m odel. Th e over h ea d con sole
in clu des t h e E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC) a n d t wo r ea din g a n d cou r t esy la m ps (F ig. 1).
On veh icles equ ipped wit h a power su n r oof opt ion ,
t h e over h ea d con sole a lso h ou ses t h e power su n r oof
swit ch bet ween t h e t wo r ea din g a n d cou r t esy la m ps.
Th e over h ea d con sole is m ou n t ed wit h on e scr ew a n d
t wo sn a p-clips t o a m olded pla st ic r et a in er br a cket
loca t ed a bove t h e h ea dlin er. Th e r et a in er br a cket is
secu r ed wit h a dh esive t o t h e in side su r fa ce of t h e
r oof pa n el.
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor
com pon en t s u sed in t h e over h ea d con sole. Refer t o
Ov e rh e a d Co n s o le in Wir in g Dia gr a m s for com plet e
cir cu it dia gr a m s.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e u se a n d oper a t ion of t h e
va r iou s over h ea d con sole fea t u r es.
STAN DARD PROCEDU RE
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT
(1) Rem ove t h e over h ea d con sole (Refer t o 8 -
E LE CTRICAL/OVE RH E AD CONSOLE - RE MOV-
AL).
(2) Usin g a fla t bla de scr ewdr iver t wist ou t socket /
la m p (F ig. 2).
(3) Repla ce la m p(s) a s n ecessa r y.
STANDARD PROCEDURE - COURTESY LAMP
REPLACEMENT
(1) Open h ood, discon n ect a n d isola t e t h e n ega t ive
ba t t er y ca ble.
8M - 2 MESSAGE SYSTEMS WJ
OV ERH EAD CON SOLE (Cont inue d)
(3) Rem ove t h e la m p a n d socket a ssem bly fr om t h e
over h ea d con sole.
(4) Rem ove t h e la m p bu lb by pu llin g it st r a igh t
ou t of it s socket .

STANDARD PROCEDURE - MODULE LENS

REPLACEMENT
(1) Rem ove t h e over h ea d con sole (Refer t o 8 -
E LE CTRICAL/OVE RH E AD CONSOLE - RE MOV-
AL).
(2) Rem ove t h e elect r on ics m odu le fr om t h e over-
h ea d con sole. Refer t o t h e pr ocedu r e in t h is sect ion .
(3) Un sn a p t h e len s fr om t h e m odu le a n d r epla ce
len s a s n ecessa r y.

STANDARD PROCEDURE - ELECTRONIC

Fig. 1 Overhead Console
1 - POWER SUNROOF SWITCH (IF EQUIPPED)
VEHICLE INFORMATION CENTER
2 - READING AND COURTESY LAMPS PROGRAMMING
3 - UNIVERSAL GARAGE DOOR OPENER PUSH BUTTONS (IF
EQUIPPED) EVIC PROGRAMMING MODE
4 - SCREW
Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC)
5 - ELECTRONIC VEHICLE INFORMATION CENTER PUSH
BUTTONS pr ovides t h e veh icle oper a t or wit h a u ser in t er fa ce,
wh ich a llows t h e select ion of sever a l opt ion a l cu s-
t om er pr ogr a m m a ble elect r on ic fea t u r es t o su it in di-
vidu a l pr efer en ces. Th e E VIC m u st be pla ced in t o it s
pr ogr a m m in g m ode in or der t o view or ch a n ge t h e
pr ogr a m m a ble fea t u r es. To en t er t h e E VIC pr ogr a m -
m in g m ode a n d t o view or ch a n ge t h e select ed pr o-
gr a m m a ble fea t u r es opt ion s, pr oceed a s follows:
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
(2) Depr ess a n d r elea se t h e Men u pu sh bu t t on .
Th e fir st it em in t h e pr ogr a m m a ble fea t u r es m en u
list will a ppea r in t h e E VIC displa y.
(3) Mom en t a r ily depr ess a n d r elea se t h e Men u
pu sh bu t t on t o st ep t h r ou gh t h e pr ogr a m m a ble fea -
t u r es list . E a ch pr ogr a m m a ble fea t u r e a n d it s cu r-
r en t ly select ed opt ion will a ppea r on t h e E VIC
displa y in t h e sequ en ce sh own in t h e P r ogr a m m a ble
F ea t u r es list t h a t follows.
(4) Mom en t a r ily depr ess a n d r elea se t h e St ep pu sh
bu t t on t o st ep t h r ou gh t h e a va ila ble opt ion s for t h e
pr ogr a m m a ble fea t u r e bein g displa yed.
(5) Th e opt ion t h a t la st a ppea r s in t h e displa y
wit h a pr ogr a m m a ble fea t u r e befor e exit in g t h e pr o-
gr a m m in g m ode, becom es t h e n ewly select ed pr o-
Fig. 2 Top of Overhead Console gr a m m a ble fea t u r e opt ion .
1 - OVERHEAD CONSOLE HOUSING (6) Th e E VIC exit s t h e pr ogr a m m in g m ode a n d
2 - EVIC MODULE r et u r n s t o it s n or m a l oper a t in g m ode wh en t h e C/T
3 - ILLUMINATION LAMPS pu sh bu t t on is depr essed or wh en t h e en d of t h e pr o-
4 - SCREWS (4) gr a m m a ble fea t u r es m en u list is r ea ch ed, wh ich ever
occu r s fir st .
(2) Rem ove t h e over h ea d con sole fr om t h e h ea d-
lin er (Refer t o 8 - E LE CTRICAL/OVE RH E AD CON-
SOLE - RE MOVAL).
WJ
OV ERH EAD CON SOLE (Cont inue d)
PROGRAMMABLE FEATURES
• LAN GU AGE? - Th e opt ion s in clu de E n glish ,
F r a n ca ise, Deu t sch , It a lia n a , or E spa n ol. Th e defa u lt is
E n glish . All E VIC displa y n om en cla t u r e, in clu din g t h e
t r ip com pu t er fu n ct ion s, wa r n in g m essa ges a n d t h e pr o-
gr a m m a ble fea t u r es a ppea r in t h e select ed la n gu a ge.
• D IS P LAY U .S . OR METRIC? - Th e opt ion s
in clu de U.S. a n d M. Th e defa u lt is U.S. Th is fea t u r e
t oggles t h e t r ip com pu t er t em per a t u r e, fu el econ om y
a n d odom et er displa y r ea din gs bet ween U.S. a n d
m et r ic u n it s of m ea su r e. It a lso ch a n ges t h e odom e-
t er displa y in t h e in st r u m en t clu st er.
• AU TO D OOR LOCKS ? - Th e opt ion s in clu de
Yes a n d No. Th e defa u lt is Yes. Wh en Yes is select ed,
a ll door s a n d t h e lift ga t e lock a u t om a t ica lly wh en
veh icle speed r ea ch es 25 kilom et er s-per-h ou r (15
m iles-per-h ou r ). If YE S is select ed, a secon d pr ogr a m -
m a ble fea t u r e a ppea r s, AU TO U N LOCK ON EXIT?
- Th e opt ion s a ga in in clu de Yes a n d No. Th e defa u lt
is No. Wh en Yes is select ed, followin g ea ch Au t o Door
Lock even t a ll door s a n d t h e lift ga t e will a u t om a t i-
ca lly u n lock wh en t h e dr iver door is open ed, if t h e
veh icle is st opped a n d t h e t r a n sm ission gea r select or
is in P a r k or Neu t r a l. Th e Au t o Door Un lock even t
will on ly occu r on ce followin g ea ch Au t o Door Lock
even t .
• REMOTE U N LOCK - Th e opt ion s in clu de
Dr iver Door 1st a n d All Door s. Th e defa u lt is Dr iver
Door 1st . Wh en Diver Door 1st is select ed, on ly t h e
dr iver door u n locks wh en t h e Un lock bu t t on of t h e
Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er is
depr essed on ce. Th e Un lock bu t t on of t h e RKE t r a n s-
m it t er m u st be depr essed t wice t o u n lock a ll door s
a n d t h e lift ga t e. Wh en All Door s is select ed, a ll door s
a n d t h e lift ga t e u n lock wh en t h e Un lock bu t t on of
t h e RKE t r a n sm it t er is depr essed on ce.
• REMOTE LIN KED TO MEMORY? - Th is pr o-
gr a m m a ble fea t u r e on ly a pplies t o veh icles equ ipped
wit h t h e opt ion a l m em or y syst em . Th e opt ion s
in clu de Yes a n d No. Th e defa u lt is No. Wh en Yes is
select ed, t h e m em or y syst em will r eca ll t h e Dr iver 1
or Dr iver 2 m em or y set t in gs a ssign ed t o t h e RKE
t r a n sm it t er bein g u sed t o u n lock t h e veh icle. Wh en
No is select ed, t h e m em or y syst em will on ly r eca ll
m em or y set t in gs wh en t h e Dr iver 1 or Dr iver 2 pu sh
bu t t on s of t h e m em or y swit ch on t h e dr iver side fr on t
door t r im pa n el a r e depr essed.
• S OU N D HORN ON LOCK? - Th e opt ion s
in clu de Yes a n d No. Th e defa u lt is No. Wh en Yes is
select ed, a sh or t h or n ch ir p will pr ovide a n a u dible
con fir m a t ion wh en t h e RKE r eceiver r ecogn izes a
va lid Lock sign a l fr om a n RKE t r a n sm it t er. Wh en No
is select ed, n o h or n ch ir p will occu r wit h t h e RKE
Lock even t . Th is fea t u r e m a y be select ed in depen -
den t of t h e F LAS H LIGHTS WITH LOCKS ? pr o-
gr a m m a ble fea t u r e.
MESSAGE SYSTEMS 8M - 3
• F LAS H LIGHTS WITH LOCKS ? - Th e opt ion s
in clu de Yes a n d No. Th e defa u lt is Yes. Wh en Yes is
select ed, a sin gle fla sh of t h e h a za r d wa r n in g la m ps
will pr ovide a n opt ica l con fir m a t ion wh en t h e RKE
r eceiver r ecogn izes a va lid Lock sign a l fr om a n RKE
t r a n sm it t er, a n d t wo fla sh es of t h e sa m e la m ps will
occu r wh en t h e RKE r eceiver r ecogn izes a va lid
Un lock sign a l fr om a n RKE t r a n sm it t er. Wh en No is
select ed, n o la m p fla sh will occu r wit h t h e RKE Lock
or Un lock even t . Th is fea t u r e m a y be select ed in de-
pen den t of t h e S OU N D HORN ON LOCK? pr o-
gr a m m a ble fea t u r e.
• HEAD LAMP D ELAY = - Th e opt ion s in clu de
Off, 30 Sec, 60 Sec, a n d 90 Sec. Th e defa u lt is 90 Sec.
Wh en a t im e in t er va l is select ed, t h e h ea dla m ps will
r em a in on for t h a t len gt h of t im e wh en t h e h ea d-
la m ps a r e t u r n ed off a ft er t h e ign it ion is t u r n ed off,
or if t h e Au t o m ode is select ed on veh icles wit h t h e
Au t o H ea dla m ps opt ion . Wh en Off is select ed, t h e
h ea dla m p dela y fea t u r e is disa bled.
• HEAD LAMP S ON WITH WIP ERS ? - Th is pr o-
gr a m m a ble fea t u r e on ly a pplies t o veh icles equ ipped
wit h t h e opt ion a l Au t o H ea dla m ps. Th e opt ion s
in clu de Yes a n d No. Th e defa u lt is No. Wh en Yes is
select ed, t h e h ea dla m ps will t u r n on a u t om a t ica lly
wh en t h e win dsh ield wiper s a r e t u r n ed on . Th e h ea d-
la m ps will t u r n off wh en t h e wiper s a r e t u r n ed off,
a s lon g a s t h e h ea dla m p swit ch is in t h e Au t o or Off
posit ion s. Wh en No is select ed, t h e h ea dla m ps will
on ly t u r n on if m a n u a lly select ed or if t h e Au t o m ode
is select ed a n d t h e ou t side a m bien t ligh t levels dic-
t a t e t h a t t h ey sh ou ld be on .
• S ERVICE IN TV. = - Th e opt ion s in clu de fr om
1000 t o 12000 kilom et er s in 1000 kilom et er in cr e-
m en t s (2000 t o 7500 m iles in 500 m ile in cr em en t s).
Th e defa u lt is 12000 kilom et er s (7500 m iles). Th e
select ed dist a n ce becom es t h e in t er va l a t wh ich t h e
P er for m Ser vice wa r n in g m essa ge will be displa yed
by t h e E VIC. If a n ew dist a n ce is select ed, a secon d
pr ogr a m m a ble fea t u r e a ppea r s, RES ET S ERVICE
D IS TAN CE? - Th e opt ion s in clu de No a n d Yes. Th e
defa u lt is Yes. Wh en Yes is select ed, t h e a ccu m u la t ed
dist a n ce sin ce t h e la st pr eviou s P er for m Ser vice
wa r n in g m essa ge will be r eset t o zer o beca u se t h e
ser vice in t er va l h a s been ch a n ged. Wh en No is
select ed, t h e dist a n ce u n t il t h e n ext P er for m Ser vice
wa r n in g m essa ge is r edu ced by t h e a ccu m u la t ed dis-
t a n ce sin ce t h e la st pr eviou s m essa ge.
• LOW F U EL CHIME? - Th e opt ion s in clu de Yes
a n d No. Th e defa u lt is Yes. Wh en Yes is select ed, a
sin gle ch im e will sou n d a s a n a u dible a ler t wh en ever
t h e in st r u m en t clu st er low fu el wa r n in g la m p ligh t s.
Th e ch im e will sou n d on ly on ce per ign it ion cycle.
Wh en No is select ed, on ly t h e low fu el wa r n in g la m p
in t h e in st r u m en t clu st er will ligh t a n d n o ch im e will
sou n d.
8M - 4 MESSAGE SYSTEMS WJ
OV ERH EAD CON SOLE (Cont inue d)
• RETRAIN TIRE S EN S ORS ? - Th is pr ogr a m - (5) Wit h t h e dega u ssin g t ool st ill en er gized, slowly
m a ble fea t u r e on ly a pplies t o veh icles equ ipped wit h ba ck it a wa y fr om t h e scr ew. Wh en t h e t ip of t h e t ool
t h e opt ion a l t ir e pr essu r e m on it or in g syst em . Th e is a t lea st 61 cen t im et er s (2 feet ) fr om t h e scr ew
opt ion s in clu de Yes a n d No. Th e defa u lt is No. Wh en h ea d, discon n ect t h e t ool.
Yes is select ed a n d t h e m en u bu t t on is depr essed, t h e (6) P la ce a piece of pa per a ppr oxim a t ely 22 by 28
E VIC will en t er t h e t r a in in g m ode st a r t in g wit h t h e cen t im et er s (8.5 by 11 in ch es), or ien t ed on t h e veh icle
left fr on t t ir e. len gt h wise fr om fr on t t o r ea r, on t h e cen t er lin e of
• EAS Y EXIT S EAT? - Th is pr ogr a m m a ble fea - t h e r oof a t t h e win dsh ield h ea der (F ig. 3). Th e pu r-
t u r e on ly a pplies t o veh icles equ ipped wit h t h e pose of t h e pa per is t o pr ot ect t h e r oof pa n el fr om
opt ion a l m em or y syst em . Th e opt ion s in clu de Yes a n d scr a t ch es, a n d t o defin e t h e a r ea t o be dem a gn et ized.
No. Th e defa u lt is No. Wh en Yes is select ed, t h e
dr iver sea t m oves r ea r wa r d a bou t 55 m illim et er s
(t wo in ch es) or t o t h e fa r t h est r ea r wa r d posit ion ,
wh ich ever com es fir st , wh en t h e key is r em oved fr om
t h e ign it ion swit ch lock cylin der. Th is pr ovides a ddi-
t ion a l ea se for exit in g fr om t h e veh icle. Th e sea t will
a u t om a t ica lly r et u r n t o t h e m em or y syst em set t in g
posit ion wh en t h e Dr iver 1 or Dr iver 2 bu t t on of t h e
m em or y swit ch on t h e door pa n el is depr essed or, if
t h e REMOTE LIN KED TO MEMORY pr ogr a m m a -
ble fea t u r e is en a bled, wh en t h e RKE Un lock bu t t on
is depr essed. Wh ile n ot a u t om a t ic, a n ea sy en t r y fea -
t u r e ca n be obt a in ed by en a blin g t h e EAS Y EXIT
S EAT fea t u r e a n d disa blin g t h e REMOTE LIN KED
TO MEMORY fea t u r e. Th en t h e EAS Y EXIT S EAT
fea t u r e will m ove t h e sea t ba ck, bu t t h e RKE u n lock
even t will n ot r eposit ion t h e sea t . Th u s, t h e sea t
r em a in s posit ion ed for ea sy en t r y, a n d t h e m em or y
swit ch on t h e door pa n el ca n be depr essed a ft er
en t er in g t h e veh icle t o r et u r n t h e sea t t o t h e desir ed
m em or y posit ion .

STANDARD PROCEDURE - COMPASS

DEMAGNETIZING
A dega u ssin g t ool (Specia l Tool 6029) is u sed t o
dem a gn et ize, or dega u ss, t h e over h ea d con sole for-
wa r d m ou n t in g scr ew a n d t h e r oof pa n el a bove t h e
over h ea d con sole. E qu iva len t u n it s m u st be r a t ed a s
con t in u ou s du t y for 110/115 volt s a n d 60 H z. Th ey
m u st a lso h a ve a field st r en gt h of over 350 ga u ss a t 7
m illim et er s (0.25 in ch ) beyon d t h e t ip of t h e pr obe.
To dem a gn et ize t h e r oof pa n el a n d t h e over h ea d
con sole for wa r d m ou n t in g scr ew, pr oceed a s follows:
(1) Be cer t a in t h a t t h e ign it ion swit ch is in t h e Off
posit ion , befor e you begin t h e dem a gn et izin g pr oce-
du r e.
(2) Con n ect t h e dega u ssin g t ool t o a n elect r ica l
ou t let , wh ile keepin g t h e t ool a t lea st 61 cen t im et er s
(2 feet ) a wa y fr om t h e com pa ss u n it .
(3) Slowly a ppr oa ch t h e h ea d of t h e over h ea d con -
sole for wa r d m ou n t in g scr ew wit h t h e dega u ssin g
t ool con n ect ed.
(4) Con t a ct t h e h ea d of t h e scr ew wit h t h e pla st ic
coa t ed t ip of t h e dega u ssin g t ool for a bou t t wo sec-
on ds.
Fig. 3 Roof Demagnetizing Pattern
(7) Con n ect t h e dega u ssin g t ool t o a n elect r ica l
ou t let , wh ile keepin g t h e t ool a t lea st 61 cen t im et er s
(2 feet ) a wa y fr om t h e com pa ss u n it .
(8) Slowly a ppr oa ch t h e cen t er lin e of t h e r oof
pa n el a t t h e win dsh ield h ea der, wit h t h e dega u ssin g
t ool con n ect ed.
(9) Con t a ct t h e r oof pa n el wit h t h e pla st ic coa t ed
t ip of t h e dega u ssin g t ool. Be su r e t h a t t h e t em pla t e
is in pla ce t o a void scr a t ch in g t h e r oof pa n el. Usin g a
slow, ba ck-a n d-for t h sweepin g m ot ion , a n d a llowin g
13 m illim et er s (0.50 in ch ) bet ween pa sses, m ove t h e
t ool a t lea st 11 cen t im et er s (4 in ch es) t o ea ch side of
t h e r oof cen t er lin e, a n d 28 cen t im et er s (11 in ch es)
ba ck fr om t h e win dsh ield h ea der.
(10) Wit h t h e dega u ssin g t ool st ill en er gized,
slowly ba ck it a wa y fr om t h e r oof pa n el. Wh en t h e
WJ
OV ERH EAD CON SOLE (Cont inue d)
t ip of t h e t ool is a t lea st 61 cen t im et er s (2 feet ) fr om
t h e r oof pa n el, discon n ect t h e t ool.
(11) Ca libr a t e t h e com pa ss a n d a dju st t h e com pa ss
va r ia n ce (Refer t o 8 - E LE CTRICAL/OVE RH E AD
CONSOLE - STANDARD P ROCE DURE ).
STANDARD PROCEDURE - COMPASS
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
Th e elect r on ic com pa ss u n it fea t u r es a self-ca li-
br a t in g design , wh ich sim plifies t h e ca libr a t ion pr o-
cedu r e. Th is fea t u r e a u t om a t ica lly u pda t es t h e
com pa ss ca libr a t ion wh ile t h e veh icle is bein g dr iven .
Th is a llows t h e com pa ss u n it t o com pen sa t e for sm a ll
ch a n ges in t h e r esidu a l m a gn et ism t h a t t h e veh icle
m a y a cqu ir e du r in g n or m a l u se. If t h e com pa ss r ea d-
in gs a ppea r t o be er r a t ic or ou t of ca libr a t ion , per-
for m t h e followin g ca libr a t ion pr ocedu r e. Also, n ew
ser vice r epla cem en t E lect r on ic Veh icle In for m a t ion
Cen t er (E VIC) m odu les m u st h a ve t h eir com pa ss ca l-
ibr a t ed u sin g t h is pr ocedu r e. Do n ot a t t em pt t o ca li-
br a t e t h e com pa ss n ea r la r ge m et a l object s su ch a s
ot h er veh icles, la r ge bu ildin gs, or br idges; or, n ea r
over h ea d or u n der gr ou n d power lin es.
NOTE: Whenever an EVIC module is replaced, the
variance number must also be reset. Refer to Com-
pass Variation Adjustment in this group.
Ca libr a t e t h e com pa ss m a n u a lly a s follows:
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . If
t h e com pa ss/t em per a t u r e da t a is n ot cu r r en t ly bein g
displa yed, m om en t a r ily depr ess a n d r elea se t h e C/T
pu sh bu t t on t o r ea ch t h e com pa ss/t em per a t u r e dis-
pla y.
(2) Depr ess t h e Reset pu sh bu t t on a n d h old t h e
bu t t on down u n t il “CAL” a ppea r s in t h e displa y. Th is
t a kes a bou t t en secon ds, a n d a ppea r s a bou t five sec-
on ds a ft er “VARIANCE = XX” is displa yed.
(3) Relea se t h e Reset pu sh bu t t on .
(4) Dr ive t h e veh icle on a level su r fa ce, a wa y fr om
la r ge m et a l object s a n d power lin es, t h r ou gh on e
com plet e cir cle a t bet ween five a n d eigh t kilom et er s-
per-h ou r (t h r ee a n d five m iles-per-h ou r ) in n ot less
t h a n 20 secon ds. Th e “CAL” m essa ge will disa ppea r
fr om t h e displa y t o in dica t e t h a t t h e com pa ss is n ow
ca libr a t ed.
NOTE: If the “CAL” message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure one more time.
MESSAGE SYSTEMS 8M - 5
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
STANDARD PROCEDURE - COMPASS
VARIATION ADJUSTMENT
Com pa ss va r ia n ce, a lso kn own a s m a gn et ic decli-
n a t ion , is t h e differ en ce in a n gle bet ween m a gn et ic
n or t h a n d t r u e geogr a ph ic n or t h . In som e geogr a ph ic
loca t ion s, t h e differ en ce bet ween m a gn et ic a n d geo-
gr a ph ic n or t h is gr ea t en ou gh t o ca u se t h e com pa ss
t o give fa lse r ea din gs. If t h is pr oblem occu r s, t h e
com pa ss va r ia n ce set t in g m a y n eed t o be ch a n ged.
To set t h e com pa ss va r ia n ce:
(1) Usin g t h e Va r ia n ce Set t in gs m a p, fin d you r
geogr a ph ic loca t ion a n d n ot e t h e zon e n u m ber (F ig.
4).
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . If
t h e com pa ss/t em per a t u r e da t a is n ot cu r r en t ly bein g
displa yed, m om en t a r ily depr ess a n d r elea se t h e C/T
pu sh bu t t on t o r ea ch t h e com pa ss/t em per a t u r e dis-
pla y.
(3) Depr ess t h e Reset pu sh bu t t on a n d h old t h e
bu t t on down u n t il “VARIANCE = XX” a ppea r s in t h e
displa y. Th is t a kes a bou t five secon ds.
(4) Relea se t h e Reset pu sh bu t t on . “VARIANCE
=XX ” will r em a in in t h e displa y. “XX” equ a ls t h e cu r-
r en t va r ia n ce zon e set t in g.
(5) Mom en t a r ily depr ess a n d r elea se t h e St ep pu sh
bu t t on t o st ep t h r ou gh t h e zon e n u m ber s, u n t il t h e
zon e n u m ber for you r geogr a ph ic loca t ion a ppea r s in
t h e displa y.
(6) Mom en t a r ily depr ess a n d r elea se t h e Reset
pu sh bu t t on t o en t er t h e displa yed zon e n u m ber in t o
t h e E VIC m odu le m em or y.
(7) Con fir m t h a t t h e cor r ect dir ect ion s a r e n ow
in dica t ed by t h e com pa ss.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e scr ew t h a t secu r es t h e fr on t of t h e
over h ea d con sole t o t h e fr on t of t h e over h ea d con sole
r et a in er br a cket .
(3) In ser t t h e fin ger t ips of bot h h a n ds bet ween t h e
h ea dlin er a n d t h e sides of t h e over h ea d con sole h ou s-
in g in t h e a r ea n ea r t h e r ea din g a n d cou r t esy la m ps.
(4) P u ll down wa r d on t h e sides of t h e over h ea d
con sole h ou sin g fir m ly a n d even ly t o disen ga ge t h e
t wo sn a p clips t h a t secu r e t h e r ea r of t h e u n it fr om
t h eir r ecept a cles in t h e over h ea d con sole r et a in er
br a cket .
(5) Lower t h e over h ea d con sole fr om t h e h ea dlin er
fa r en ou gh t o a ccess t h e wir e h a r n ess con n ect or s.
8M - 6 MESSAGE SYSTEMS WJ
OV ERH EAD CON SOLE (Cont inue d)

Fig. 4 Variance Settings

(6) Discon n ect t h e r oof wir e h a r n ess con n ect or s SPECI AL T OOLS
fr om t h e E lect r on ic Veh icle In for m a t ion Cen t er con -
n ect or r ecept a cle, t h e r ea din g a n d cou r t esy la m p wir e OVERHEAD CONSOLE SYSTEMS
h a r n ess con n ect or a n d, if t h e veh icle is so equ ipped,
fr om t h e ba ck of t h e power su n r oof swit ch .
(7) Rem ove t h e over h ea d con sole fr om t h e h ea d-
lin er.

INSTALLATION
(1) P osit ion t h e over h ea d con sole n ea r t h e m ou n t -
in g loca t ion on t h e h ea dlin er.
(2) Recon n ect t h e r oof wir e h a r n ess con n ect or s t o Degaussing Tool 6029
t h e E lect r on ic Veh icle In for m a t ion Cen t er con n ect or
r ecept a cle, t h e r ea din g a n d cou r t esy la m p wir e h a r- ELECT RON I C V EH I CLE I N FO
n ess con n ect or a n d, if t h e veh icle is so equ ipped, t o CEN T ER
t h e ba ck of t h e power su n r oof swit ch .
(3) Align t h e t wo sn a p clips on t h e r ea r of t h e DESCRIPTION
over h ea d con sole h ou sin g wit h t h eir r ecept a cles in
Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC)
t h e over h ea d con sole r et a in er br a cket .
is loca t ed in t h e over h ea d con sole on m odels
(4) P u sh u pwa r d fir m ly a n d even ly on t h e sides of
equ ipped wit h t h is opt ion . Th r ee ver sion s of t h e
t h e over h ea d con sole h ou sin g over bot h of t h e sn a p
E VIC m odu le a r e a va ila ble on t h e Gr a n d Ch er okee.
clip loca t ion s u n t il ea ch of t h e t wo sn a p clips is fu lly
Th ese t h r ee ver sion s a r e iden t ica l except t h a t som e
en ga ged wit h it s r ecept a cle in t h e over h ea d con sole
m odels in clu de a n in t egr a l t h r ee-pu sh bu t t on Un iver-
r et a in er br a cket .
sa l Tr a n sm it t er t r a n sceiver a n d/or Tir e P r essu r e
(5) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
Mon it or in g Syst em (TP M). All t h r ee E VIC m odu les
fr on t of t h e over h ea d con sole h ou sin g t o t h e over h ea d
fea t u r e a la r ge Va cu u m F lu or escen t Displa y (VF D)
con sole r et a in er br a cket . Tigh t en t h e scr ew t o 1.2
scr een for displa yin g in for m a t ion , a n d ba ck-lit pu sh
N·m (10 in . lbs.).
bu t t on s fu n ct ion swit ch es la beled C/T (com pa ss/t em -
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
per a t u r e), RE SE T, STE P, a n d ME NU. Th e VF D
scr een ca n a lso displa y a veh icle gr a ph ic t h a t is u sed
WJ
ELECT RON I C V EH I CLE I N FO CEN T ER (Cont inue d)
for door a n d lift ga t e open in dica t ion s a n d t o sh ow if a
t u r n sign a l h a s been left on . Th e E VIC m essa ges a n d
displa ys a r e coor din a t ed wit h wa r n in g in dica t or s in
t h e in st r u m en t clu st er t o a void du plica t ion .
Th e E VIC m odu le con t a in s a cen t r a l pr ocessin g
u n it a n d in t er fa ces wit h ot h er elect r on ic m odu les in
t h e veh icle over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s n et wor k. Th e P CI da t a bu s
n et wor k a llows t h e sh a r in g of sen sor in for m a t ion .
Th is h elps t o r edu ce wir e h a r n ess com plexit y, r edu ce
in t er n a l con t r oller h a r dwa r e, a n d r edu ce com pon en t
sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is syst em
pr ovides in cr ea sed r elia bilit y, en h a n ced dia gn ost ics,
a n d a llows t h e a ddit ion of m a n y n ew fea t u r e ca pa bil-
it ies.
Th e E VIC m odu le in clu des t h e followin g displa y
opt ion s:
• Co m p a s s a n d Te m p e ra tu re - pr ovides t h e ou t -
side t em per a t u r e a n d on e of eigh t com pa ss r ea din gs
t o in dica t e t h e dir ect ion t h e veh icle is fa cin g.
• Av e ra g e fu e l e c o n o m y - sh ows t h e a ver a ge
fu el econ om y sin ce t h e la st t r ip com pu t er r eset .
• D is ta n c e to e m p ty - sh ows t h e est im a t ed dis-
t a n ce t h a t ca n be t r a velled wit h t h e fu el r em a in in g
in t h e fu el t a n k. Th is est im a t ed dist a n ce is com pu t ed
u sin g t h e a ver a ge m iles-per-ga llon fr om t h e la st 30
ga llon s of fu el u sed.
• In s ta n t fu e l e c o n o m y - sh ows t h e pr esen t fu el
econ om y ba sed u pon t h e cu r r en t veh icle dist a n ce a n d
fu el u sed in for m a t ion .
• Trip d is ta n c e - sh ows t h e dist a n ce t r a velled
sin ce t h e la st t r ip com pu t er r eset .
• Ela p s e d tim e - sh ows t h e a ccu m u la t ed ign i-
t ion -on t im e sin ce t h e la st t r ip com pu t er r eset .
• D is ta n c e to s e rv ic e - sh ows t h e dist a n ce
r em a in in g u n t il t h e n ext sch edu led ser vice in t er va l.
• Tire P re s s u re - sh ows t h e t ir e pr essu r e in ea ch
t ir e.
• B la n k s c re e n - t h e E VIC com pa ss/t em per a t u r e/
t r ip com pu t er VF D is t u r n ed off.
Th e E VIC is ca pa ble of displa yin g t h e followin g
a ler t m essa ges, wh ich a r e a ccom pa n ied by a n a u dible
a n n ou n cem en t con sist in g of a ser ies of beeps:
• TU RN S IGN ALS ON (w ith v e h ic le g ra p h ic ) -
In dica t es t h a t a t u r n sign a l h a s r em a in ed on for
a bou t 1.6 kilom et er s (on e m ile).
• P ERF ORM S ERVICE - In dica t es t h a t a cu s-
t om er pr ogr a m m a ble ser vice in t er va l dist a n ce h a s
been r ea ch ed.
• D OOR OP EN (o n e o r m o re , w ith v e h ic le
g ra p h ic ) - In dica t es t h a t a door is open or n ot fu lly
closed.
• LIF TGATE OP EN (w ith v e h ic le g ra p h ic ) -
In dica t es t h a t t h e lift ga t e is open or n ot fu lly closed.
• LIF TGLAS S OP EN (w ith v e h ic le g ra p h ic ) -
In dica t es t h a t t h e lift gla ss is open or n ot fu lly closed.
MESSAGE SYSTEMS 8M - 7
• COOLAN T LEVEL LOW (w ith v e h ic le
g ra p h ic ) - In dica t es t h a t t h e coola n t level in t h e
en gin e coola n t r eser voir is low.
• XX LOW P RES S U RE (w ith v e h ic le g ra p h ic )
- In dica t es t h a t t h e a ir pr essu r e in t h e select ed t ir e
is low.
• WAS HER F LU ID LOW (w ith v e h ic le
g ra p h ic ) - In dica t es t h a t t h e flu id level in t h e
wa sh er flu id r eser voir is low.
Th e E VIC “Men u ” pu sh bu t t on pr ovides t h e veh icle
oper a t or wit h a u ser in t er fa ce, wh ich a llows t h e
select ion of sever a l opt ion a l cu st om er pr ogr a m m a ble
elect r on ic fea t u r es t o su it in dividu a l pr efer en ces.
Refer t o ELECTRON IC VEHICLE IN F ORMA-
TION CEN TER P ROGRAMMIN G in t h e Ser vice
P r ocedu r es sect ion of t h is gr ou p for m or e in for m a t ion
on t h e cu st om er pr ogr a m m a ble fea t u r e opt ion s.
If t h e veh icle is equ ipped wit h t h e opt ion a l m em -
or y syst em , t h e E VIC will displa y t h e followin g m em -
or y syst em m essa ges:
• MEMORY #X P OS ITION S ET (X = D riv e r 1
o r D riv e r 2) - Th is m essa ge a ppea r s in t h e E VIC
displa y ea ch t im e t h e m em or y syst em is su ccessfu lly
pr ogr a m m ed. It is a ccom pa n ied by a n a u dible
a n n ou n cem en t ch im e t on e.
• MEMORY S YS TEM D IS AB LED - Th e m em or y
syst em is a u t om a t ica lly disa bled wh ile t h e dr iver
side sea t belt is fa st en ed a n d/or wh ile t h e a u t om a t ic
t r a n sm ission gea r select or is in a n y posit ion except
P a r k or Neu t r a l. Th is m essa ge a ppea r s in t h e E VIC
displa y a s a r em in der wh en a m em or y swit ch pu sh
bu t t on is depr essed wh ile t h e m em or y syst em is dis-
a bled. If t h e RE MOTE LINKE D TO ME MORY cu s-
t om er pr ogr a m m a ble fea t u r e h a s been select ed, t h is
m essa ge will a lso a ppea r wh en t h e Un lock bu t t on of
t h e Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er is
depr essed wh ile t h e m em or y syst em is disa bled.
If t h e veh icle is equ ipped wit h t h e opt ion a l Un iver-
sa l Tr a n sm it t er t r a n sceiver, t h e E VIC will a lso dis-
pla y m essa ges a n d a n icon in dica t in g wh en t h e
Un iver sa l Tr a n sm it t er is bein g t r a in ed, wh ich of t h e
t h r ee t r a n sm it t er bu t t on s is t r a n sm it t in g, a n d wh en
t h e t r a n sceiver is clea r ed.
If t h e veh icle is equ ipped wit h t h e opt ion a l Tire
P re s s u re Mo n ito rin g S y s te m , t h e E VIC will a lso
displa y m essa ges a n d a n icon in dica t in g wh en t h e
t ir e a ir pr essu r e fa lls below a given set -poin t , a n d
wh ich of t h e five t ir es is t r a n sm it t in g t h e low pr es-
su r e wa r n in g, a n d wh en t h e con dit ion is clea r ed.
Refer t o t h e Tir es/Wh eels sect ion of t h is m a n u a l for
com plet e Tir e P r essu r e Mon it or in g Syst em descr ip-
t ion . Refer t o t h is sect ion of t h e ser vice m a n u a l for
E VIC m odu les fu n ct ion descr ipt ion for t h e Tir e P r es-
su r e Mon it or in g.
Da t a in pu t for a ll E VIC fu n ct ion s, in clu din g VF D
dim m in g level, is r eceived t h r ou gh P CI da t a bu s
8M - 8 MESSAGE SYSTEMS
ELECT RON I C V EH I CLE I N FO CEN T ER (Cont inue d)
m essa ges. Th e E VIC m odu le u ses it s in t er n a l pr o-
gr a m m in g a n d a ll of it s da t a in pu t s t o ca lcu la t e a n d
displa y t h e r equ est ed da t a . If t h e da t a displa yed is
in cor r ect , per for m t h e self-dia gn ost ic t est s a s
descr ibed in t h is gr ou p. If t h ese t est s pr ove in con clu -
sive, t h e u se of a DRBIII! sca n t ool a n d t h e pr oper
Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom m en ded for
fu r t h er t est in g of t h e E VIC m odu le a n d t h e P CI da t a
bu s.
Th e E VIC m odu le ca n n ot be r epa ir ed, a n d is a va il-
a ble for ser vice on ly a s a u n it . Th is u n it in clu des t h e
pu sh bu t t on swit ch es a n d t h e pla st ic h ou sed m odu le.
If a n y of t h ese com pon en t s a r e fa u lt y or da m a ged,
t h e com plet e E VIC m odu le m u st be r epla ced. Th e
in ca n descen t bu lbs u sed for E VIC pu sh bu t t on ba ck-
ligh t in g a n d t h e displa y len s a r e a va ila ble for ser vice
r epla cem en t .
ELECTRONIC VEHICLE INFORMATION CENTER
CHIME
Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC)
u ses t h e ch im e wa r n in g syst em for t wo differ en t
kin ds of su ppor t . In a ddit ion t o r equ est in g ch im e
t on es fr om t h e Body Con t r ol Modu le (BCM) a s t a ct ile
beep su ppor t , t h e E VIC is pr ogr a m m ed t o sen d ch im e
r equ est m essa ges over t h e P r ogr a m m a ble Com m u n i-
ca t ion s In t er fa ce (P CI) da t a bu s wh en it det ect s t h e
followin g con dit ion s:
• D o o r Op e n Wa rn in g - A door is open a bove a
cr it ica l speed [a bou t 16 kilom et er s-per-h ou r (10
m iles-per-h ou r ) for t h e dr iver side fr on t door, or
a bou t 5 kilom et er s-per-h ou r (3 m iles-per-h ou r ) for
a n y ot h er door ].
• Liftg a te Op e n Wa rn in g - Th e lift ga t e is open
a bove a cr it ica l speed [a bou t 5 kilom et er s-per-h ou r (3
m iles-per-h ou r )].
• Liftg la s s Op e n Wa rn in g - Th e lift ga t e flip-u p
gla ss is open a bove a cr it ica l speed [a bou t 5 kilom e-
t er s-per-h ou r (3 m iles-per-h ou r )].
• Lo w Co o la n t Le v e l Wa rn in g - Th e coola n t
level in t h e en gin e coola n t r eser voir is low.
• P e rfo rm S e rv ic e Ale rt - An a u dible a ler t t h a t
a “P er for m Ser vice” r em in der m essa ge is bein g dis-
pla yed by t h e E VIC.
• Tu rn S ig n a l On Wa rn in g - A t u r n sign a l
r em a in s on for a bou t 1.6 kilom et er s (on e m ile).
• Wa s h e r F lu id Lo w Wa rn in g - Th e flu id level
in t h e wa sh er r eser voir is low.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e E VIC. (Refer t o 8 - E LE CTRICAL/OVE RH E AD
CONSOLE /E LE CTRONIC VE H ICLE INF O CE NTE R
- DE SCRIP TION) for m or e in for m a t ion on t h e E VIC.
WJ
COMPASS
Wh ile in t h e com pa ss/t em per a t u r e m ode, t h e com -
pa ss will displa y t h e dir ect ion in wh ich t h e veh icle is
poin t ed u sin g t h e eigh t m a jor com pa ss h ea din gs
(E xa m ples: n or t h is N, n or t h ea st is NE ). Th e self-ca l-
ibr a t in g com pa ss u n it r equ ir es n o a dju st in g in n or-
m a l u se. Th e on ly ca libr a t ion t h a t m a y pr ove
n ecessa r y is t o dr ive t h e veh icle in on e cir cle a t 5 t o
8 kilom et er s-per-h ou r (3 t o 5 m iles-per-h ou r ), on level
gr ou n d, in n ot less t h a n 20 secon ds. Th is will r eor i-
en t t h e com pa ss u n it t o it s veh icle.
Th e com pa ss u n it a lso will com pen sa t e for m a gn e-
t ism t h e body of t h e veh icle m a y a cqu ir e du r in g n or-
m a l u se. H owever, a void pla cin g a n yt h in g m a gn et ic
dir ect ly on t h e r oof of t h e veh icle. Ma gn et ic m ou n t s
for a n a n t en n a , a r epa ir or der h a t , or a fu n er a l pr o-
cession fla g ca n exceed t h e com pen sa t in g a bilit y of
t h e com pa ss u n it if pla ced on t h e r oof pa n el. Ma g-
n et ic bit dr iver s u sed on t h e fa st en er s t h a t h old t h e
over h ea d con sole a ssem bly t o t h e r oof h ea der ca n
a lso a ffect com pa ss oper a t ion . If t h e veh icle r oof
sh ou ld becom e m a gn et ized, t h e dem a gn et izin g a n d
ca libr a t ion pr ocedu r es fou n d in t h is gr ou p m a y be
r equ ir ed t o r est or e pr oper com pa ss oper a t ion .
TEMPERATURE
Th e ou t side a m bien t t em per a t u r e is displa yed in
wh ole degr ees. Th e t em per a t u r e displa y ca n be t og-
gled fr om F a h r en h eit t o Celsiu s by select in g t h e
desir ed U.S./Met r ic opt ion fr om t h e cu st om er pr o-
gr a m m a ble fea t u r es a s descr ibed in ELECTRON IC
VEHICLE IN F ORMATION CEN TER P ROGRAM-
MIN G in t h e St a n da r d P r ocedu r es sect ion of t h is
gr ou p. Th e displa yed t em per a t u r e is n ot a n in st a n t
r ea din g of con dit ion s, bu t a n a ver a ge t em per a t u r e. It
m a y t a ke t h e t em per a t u r e displa y sever a l m in u t es t o
r espon d t o a m a jor t em per a t u r e ch a n ge, su ch a s dr iv-
in g ou t of a h ea t ed ga r a ge in t o win t er t em per a t u r es.
Wh en t h e ign it ion swit ch is t u r n ed t o t h e Off posi-
t ion , t h e la st displa yed t em per a t u r e r ea din g st a ys in
t h e Body Con t r ol Modu le (BCM) u n it m em or y. Wh en
t h e ign it ion swit ch is t u r n ed t o t h e On posit ion
a ga in , t h e E VIC will displa y t h e m em or y t em per a -
t u r e for on e m in u t e; t h en u pda t e t h e displa y t o t h e
cu r r en t a ver a ge t em per a t u r e r ea din g wit h in five
m in u t es.
Th e t em per a t u r e fu n ct ion is su ppor t ed by a n a m bi-
en t t em per a t u r e sen sor. Th e sen sor is m ou n t ed ou t -
side t h e pa ssen ger com pa r t m en t n ea r t h e fr on t a n d
cen t er of t h e veh icle, a n d is h a r d wir ed t o t h e Body
Con t r ol Modu le (BCM). Th e BCM sen ds t em per a t u r e
st a t u s m essa ges t o t h e E VIC m odu le over t h e P CI
da t a bu s n et wor k. Th e a m bien t t em per a t u r e sen sor
is a va ila ble a s a sepa r a t e ser vice it em .
WJ
ELECT RON I C V EH I CLE I N FO CEN T ER (Cont inue d)
OPERATION
Th e E VIC h a s a ccess t o bot h n on -swit ch ed a n d
ign it ion swit ch ed sou r ces of ba t t er y cu r r en t so t h a t
som e of it s fea t u r es r em a in oper a t ion a l a t a n y t im e,
wh ile ot h er s m a y on ly oper a t e wit h t h e ign it ion
swit ch in t h e On posit ion . Wh en t h e ign it ion swit ch
is t u r n ed t o t h e On posit ion , t h e E VIC m odu le VF D
will r et u r n t o t h e la st fu n ct ion bein g displa yed befor e
t h e ign it ion wa s t u r n ed t o t h e Off posit ion .
Th e com pa ss/t em per a t u r e displa y is t h e n or m a l
E VIC displa y. Wit h t h e ign it ion swit ch in t h e On
posit ion , m om en t a r ily depr essin g a n d r elea sin g t h e
C/T (com pa ss/t em per a t u r e) pu sh bu t t on swit ch will
ca u se t h e E VIC t o r et u r n t o t h e com pa ss/t em per a -
t u r e/t r ip com pu t er displa y m ode fr om a n y ot h er
m ode. Wh ile in t h e com pa ss/t em per a t u r e/t r ip com -
pu t er displa y m ode, m om en t a r ily depr essin g a n d
r elea sin g t h e St ep pu sh bu t t on will st ep t h r ou gh t h e
a va ila ble t r ip com pu t er displa y opt ion s.
Th e E VIC t r ip com pu t er fea t u r es sever a l fu n ct ion s
t h a t ca n be r eset . Th e fu n ct ion s t h a t ca n be r eset
a r e: a ver a ge fu el econ om y, t r ip odom et er a n d ela psed
t im e. Wit h t h e ign it ion swit ch in t h e On posit ion a n d
wit h on e of t h e fu n ct ion s of t h e t r ip com pu t er t h a t
ca n be r eset cu r r en t ly displa yed, depr essin g t h e
Reset pu sh bu t t on t wice wit h in t h r ee secon ds will
per for m a globa l r eset , a n d a ll of t h e t r ip com pu t er
in for m a t ion t h a t ca n be r eset will be r eset t o zer o.
Wit h t h e ign it ion swit ch in t h e On posit ion a n d t h e
fu n ct ion t h a t is t o be r eset cu r r en t ly displa yed,
m om en t a r ily depr essin g a n d r elea sin g t h e Reset
pu sh bu t t on on ce will per for m a loca l r eset , a n d on ly
t h e va lu e of t h e displa yed fu n ct ion will be r eset t o
zer o. A globa l or loca l r eset will on ly occu r if t h e
fu n ct ion cu r r en t ly displa yed is a fu n ct ion t h a t ca n be
r eset . Th e dist a n ce t o ser vice fu n ct ion ca n a lso be
r eset u sin g t h e loca l r eset m et h od, bu t it will r eset
ba ck t o t h e Ser vice In t er va l dist a n ce t h a t is set in
t h e E VIC pr ogr a m m a ble fea t u r es m ode. Refer t o
ELECTRON IC VEHICLE IN F ORMATION CEN -
TER P ROGRAMMIN G in t h e Ser vice P r ocedu r es
sect ion of t h is gr ou p for m or e in for m a t ion on set t in g
t h e Ser vice In t er va l.
F or m or e in for m a t ion on t h e fea t u r es, con t r ol fu n c-
t ion s a n d set t in g pr ocedu r es for t h e E VIC m odu le,
see t h e own er ’s m a n u a l in t h e veh icle glove box.
DIAGNOSIS AND TESTING - ELECTRONIC
VEHICLE INFORMATION CENTER
If t h e pr oblem wit h t h e E lect r on ic Veh icle In for m a -
t ion Cen t er (E VIC) is a t em per a t u r e r ea din g of 130°
F or -40°F sh own in t h e com pa ss/t em per a t u r e dis-
pla y, r efer t o Am bie n t Te m p e ra tu re S e n s o r D ia g -
n o s is a n d Te s tin g in t h is gr ou p. If t h e pr oblem wit h
t h e E VIC is a n in a ccu r a t e or scr a m bled displa y, r efer
t o S e lf-D ia g n o s tic Te s t in t h is gr ou p. If t h e pr ob-
MESSAGE SYSTEMS 8M - 9
lem wit h t h e E VIC is in cor r ect Va cu u m F lu or escen t
Displa y (VF D) dim m in g levels, u se a DRB! sca n t ool
a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l t o t est
for t h e cor r ect dim m in g m essa ge in pu t s bein g
r eceived fr om t h e Body Con t r ol Modu le (BCM) over
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s. If t h e pr oblem is a n o-displa y con dit ion ,
u se t h e followin g pr ocedu r es. F or com plet e cir cu it
dia gr a m s, r efer t o Ov e rh e a d Co n s o le in Wir in g
Dia gr a m s.
(1) Ch eck t h e fu sed B(+) fu se in t h e ju n ct ion block.
If OK, go t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir-
cu it or com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y
fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e ju n ct ion block. If OK, go t o St ep 3. If n ot OK,
r epa ir t h e open fu sed B(+) cir cu it t o t h e fu sed B(+)
fu se in t h e P DC a s r equ ir ed.
(3) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n /
st a r t ) fu se in t h e ju n ct ion block. If OK, go t o St ep 4.
If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n /st a r t ) fu se in t h e ju n ct ion block. If OK,
go t o St ep 5. If n ot OK, r epa ir t h e open fu sed ign it ion
swit ch ou t pu t (r u n /st a r t ) cir cu it t o t h e ign it ion swit ch
a s r equ ir ed.
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Rem ove t h e over h ea d con sole. Ch eck for con t in u it y
bet ween t h e gr ou n d cir cu it ca vit y of t h e r oof wir e
h a r n ess con n ect or for t h e E VIC m odu le a n d a good
gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
6. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d
a s r equ ir ed.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
r oof wir e h a r n ess con n ect or for t h e E VIC m odu le. If
OK, go t o St ep 7. If n ot OK, r epa ir t h e open fu sed
B(+) cir cu it t o t h e fu sed B(+) fu se in t h e ju n ct ion
block a s r equ ir ed.
(7) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n /st a r t ) cir cu it ca vit y of t h e r oof wir e h a r-
n ess con n ect or for t h e E VIC m odu le. If OK, r efer t o
S e lf-D ia g n o s tic Te s t below for fu r t h er dia gn osis of
t h e E VIC m odu le a n d t h e P CI da t a bu s. If n ot OK,
r epa ir t h e open fu sed ign it ion swit ch ou t pu t (r u n /
st a r t ) cir cu it t o t h e fu se in t h e ju n ct ion block a s
r equ ir ed.
SELF-DIAGNOSTIC TEST
A self-dia gn ost ic t est is u sed t o det er m in e t h a t t h e
E VIC m odu le is oper a t in g pr oper ly, a n d t h a t a ll P CI
8M - 10 MESSAGE SYSTEMS
ELECT RON I C V EH I CLE I N FO CEN T ER (Cont inue d)
da t a bu s m essa ges a r e bein g r eceived for in it ia l oper-
a t ion . In it ia t e t h e self-dia gn ost ic t est a s follows:
(1) Wit h t h e ign it ion swit ch in t h e Off posit ion ,
sim u lt a n eou sly depr ess a n d h old t h e C/T bu t t on a n d
t h e Reset bu t t on .
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
(3) Con t in u e t o h old bot h bu t t on s depr essed u n t il
t h e E VIC soft wa r e ver sion in for m a t ion is displa yed,
t h en r elea se bot h bu t t on s.
(4) F ollowin g com plet ion of t h ese t est s, t h e E VIC
m odu le will displa y on e of t h e followin g m essa ges:
a . P a s s S e lf Te s t - Mom en t a r ily depr ess a n d
r elea se t h e Reset bu t t on t o r et u r n t o t h e com pa ss/
t em per a t u r e/t r ip com pu t er displa y m ode. Th e E VIC
m odu le is wor kin g pr oper ly.
b. F a ile d S e lf Te s t - Th e E VIC m odu le h a s a n
in t er n a l fa ilu r e. Th e E VIC m odu le is fa u lt y a n d m u st
be r epla ced.
c. N o t Re c e iv in g J 1850 Me s s a g e - Th e E VIC
m odu le is n ot r eceivin g pr oper m essa ge in pu t
t h r ou gh t h e P CI da t a bu s. Th is ca n r esu lt fr om on e
or m or e fa u lt y elect r on ic m odu les in t h e veh icle, or
fr om a fa u lt y P CI da t a bu s. Th e u se of a DRB sca n
t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l
a r e r equ ir ed for fu r t h er dia gn osis.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earth’s mag-
netic field strength, based on geographic location.
Refer to Compass Variation Adjustment in the Stan-
dard Procedures section of this group.
NOTE: If the compass reading displays a blank, and
only “CAL” appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. Refer to Compass
Demagnetizing in the Standard Procedures section
of this group.
STANDARD PROCEDURE - TIRE PRESSURE
SYSTEM TEST
Th e followin g t est ca n be u sed t o ver ify t wo fu n c-
t ion s. On e, t h a t t h e t ir e pr essu r e sen sor s a r e t r a n s-
m it t in g pr oper ly a n d t wo, t h e E VIC m odu le is
r eceivin g t h ese t r a n sm ission s a ccor din gly.
(1) Ret r a in t h e t ir e sen sor s (Refer t o 22 - TIRE S/
WH E E LS/TIRE P RE SSURE MONITORING/SE N-
SOR - STANDARD P ROCE DURE ). Th e t ir e sen sor s
m u st be r et r a in ed in or der t o set t h e pr oper t r a n s-
m it t in g t im e cycle (t wice a m in u t e), fa ilu r e t o r et r a in
t h e sen sor s will ca u se a m u ch slower t r a n sm it t in g
t im e cycle (on ce a h ou r ).
WJ
(2) Usin g t h e STE P bu t t on on t h e over h ea d con -
sole, scr oll t o t h e bla n k displa y, t h en pr ess t h e
RE SE T bu t t on for five secon ds, a beep will sou n d
in dica t in g t h e st a r t of t h is t est . Th e veh icle icon a n d
t r a n sm ission cou n t er s will n ow be displa yed, (sa m e
displa y a s in dividu a l t ir e pr essu r e except cou n t er s
r epla ce t ir e pr essu r e va lu es).
(3) Upon en t er in g t h e t est m ode, t h e E VIC will
clea r t h e sen sor cou n t er a n d ea ch t im e a sen sor sig-
n a l for a r oa d t ir e is r eceived, t h e E VIC will u pda t e
t h e cou n t er va lu e (veh icle m u st be dr iven a t 25 m ph
t o t r a n sm it ). Th e cou n t er va lu es sh ou ld a ll r ea d t h e
sa m e va lu e. If a n y of t h e r oa d t ir es in dica t e a differ-
en t va lu e t h a n a n ot h er t ir e sen sor, t h is is a sign of a
pr oblem . Repla ce t h e a ppr opr ia t e t ir e sen sor a n d
r et est t h e syst em . Th is t est will con t in u e u n t il a n y of
t h e over h ea d con sole bu t t on s a r e pr essed or t h e ign i-
t ion is t u r n ed off.
NOTE: Pressing the RESET button during the test
will sound a beep and reset all the counter values
back to zero.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e over h ea d con sole fr om t h e h ea d-
lin er (Refer t o 8 - E LE CTRICAL/OVE RH E AD CON-
SOLE - RE MOVAL).
(3) Rem ove t h e fou r scr ews t h a t secu r e t h e E lec-
t r on ic Veh icle In for m a t ion Cen t er (E VIC) m odu le t o
t h e over h ea d con sole h ou sin g (F ig. 5).
(4) Rem ove t h e E VIC m odu le fr om t h e over h ea d
con sole h ou sin g.
INSTALLATION
(1) P osit ion t h e E VIC m odu le on t o t h e over h ea d
con sole h ou sin g.
(2) In st a ll a n d t igh t en t h e fou r scr ews t h a t secu r e
t h e E VIC m odu le t o t h e over h ea d con sole h ou sin g.
Tigh t en t h e scr ews t o 0.9 N·m (8 in . lbs.).
(3) In st a ll t h e over h ea d con sole on t o t h e h ea dlin er
(Refer t o 8 - E LE CTRICAL/OVE RH E AD CONSOLE -
INSTALLATION).
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to Compass Variation Adjustment and
Compass Calibration in the Service Procedures sec-
tion of this group for the procedures.
WJ
ELECT RON I C V EH I CLE I N FO CEN T ER (Cont inue d)
Fig. 5 Top of Overhead Console
1 - OVERHEAD CONSOLE HOUSING
2 - EVIC MODULE
3 - ILLUMINATION LAMPS
4 - SCREWS (4)
NOTE: If the vehicle is equipped with the Tire Pres-
sure Monitoring (TPM) System, and the overhead
console electronics module is removed or replaced,
the TPM system will need to be retrained. Refer to
the Tires/Wheels section of this manual for the pro-
cedure.
U N I V ERSAL T RAN SM I T T ER
DESCRIPTION
Th e Gr a n d Ch er okee Lim it ed m odel h a s a Un iver-
sa l Ga r a ge Door Open er (UGDO) t r a n sceiver a s st a n -
da r d fa ct or y-in st a lled equ ipm en t . Th e UGDO is
opt ion a l on La r edo m odels. Th e UGDO t r a n sceiver is
in t egr a l t o t h e E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC), wh ich is loca t ed in t h e over h ea d con sole. Th e
on ly visible com pon en t of t h e UGDO a r e t h e t h r ee
t r a n sm it t er pu sh bu t t on s cen t er ed bet ween t h e fou r
E VIC pu sh bu t t on s loca t ed ju st r ea r wa r d of t h e
E VIC displa y scr een in t h e over h ea d con sole. Th e
t h r ee UGDO t r a n sm it t er pu sh bu t t on s a r e iden t ified
wit h on e, t wo or t h r ee dot s so t h a t t h ey be ea sily
iden t ified by sigh t .
E a ch of t h e t h r ee UGDO t r a n sm it t er pu sh bu t t on s
con t r ols a n in depen den t r a dio t r a n sm it t er ch a n n el.
E a ch of t h ese t h r ee ch a n n els ca n be t r a in ed t o t r a n s-
m it a differ en t r a dio fr equ en cy sign a l for t h e r em ot e
MESSAGE SYSTEMS 8M - 11
oper a t ion of ga r a ge door open er s, m ot or ized ga t e
open er s, h om e or office ligh t in g, secu r it y syst em s or
ju st a bou t a n y ot h er device t h a t ca n be equ ipped
wit h a r a dio r eceiver in t h e 288 t o 410 Mega H er t z
(MH z) fr equ en cy r a n ge for r em ot e oper a t ion . Th e
UGDO is ca pa ble of oper a t in g syst em s u sin g eit h er
r ollin g code or n on -r ollin g code t ech n ology.
Th e E VIC m odu le displa ys m essa ges a n d a sm a ll
h ou se-sh a ped icon wit h on e, t wo or t h r ee dot s cor r e-
spon din g t o t h e t h r ee t r a n sm it t er bu t t on s t o in dica t e
t h e st a t u s of t h e UGDO. Th e E VIC m essa ges a r e:
• Cle a re d Ch a n n e ls - In dica t es t h a t a ll of t h e
t r a n sm it t er codes st or ed in t h e UGDO h a ve been su c-
cessfu lly clea r ed.
• Tra in in g - In dica t es t h a t t h e UGDO is in it s
t r a n sm it t er lea r n in g m ode.
• Tra in e d - In dica t es t h a t t h e UGDO h a s su ccess-
fu lly a cqu ir ed a n ew t r a n sm it t er code.
• Tra n s m it - In dica t es t h a t a t r a in ed UGDO
t r a n sm it t er bu t t on h a s been depr essed a n d t h a t t h e
UGDO is t r a n sm it t in g.
Th e UGDO ca n n ot be r epa ir ed, a n d is a va ila ble for
ser vice on ly a s a u n it wit h t h e E VIC m odu le. Th is
u n it in clu des t h e pu sh bu t t on swit ch es a n d t h e pla s-
t ic m odu le. If a n y of t h ese com pon en t s a r e fa u lt y or
da m a ged, t h e com plet e E VIC m odu le m u st be
r epla ced.
OPERATION
Th e u n iver sa l t r a n sm it t er oper a t es on a n on -
swit ch ed sou r ce of ba t t er y cu r r en t so t h e u n it will
r em a in fu n ct ion a l, r ega r dless of t h e ign it ion swit ch
posit ion . F or m or e in for m a t ion on t h e fea t u r es, pr o-
gr a m m in g pr ocedu r es a n d oper a t ion of t h e u n iver sa l
t r a n sm it t er, see t h e own er ’s m a n u a l in t h e veh icle
glove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
If t h e Un iver sa l Tr a n sm it t er is in oper a t ive, bu t t h e
E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) is oper-
a t in g n or m a lly, see t h e own er ’s m a n u a l in t h e veh icle
glove box for in st r u ct ion s on t r a in in g t h e Tr a n sm it -
t er. Ret r a in t h e Tr a n sm it t er wit h a kn own good
t r a n sm it t er a s in st r u ct ed in t h e own er ’s m a n u a l a n d
t est t h e Tr a n sm it t er oper a t ion a ga in . If t h e u n it is
st ill in oper a t ive, r epla ce t h e fa u lt y Tr a n sm it t er a n d
E VIC m odu le a s a u n it . If bot h t h e Tr a n sm it t er a n d
t h e E VIC m odu le a r e in oper a t ive, r efer t o Ele c -
tro n ic Ve h ic le In fo rm a tio n Ce n te r D ia g n o s is
a n d Te s tin g in t h is gr ou p for fu r t h er dia gn osis. F or
com plet e cir cu it dia gr a m s, r efer t o Wirin g D ia -
g ra m s .
8M - 12 MESSAGE SYSTEMS
AM BI EN T T EM P SEN SOR
DESCRIPTION
Am bien t a ir t em per a t u r e is m on it or ed by t h e E lec-
t r on ic Veh icle In for m a t ion Cen t er (E VIC) t h r ou gh
a m bien t t em per a t u r e m essa ges r eceived fr om t h e
Body Con t r ol Modu le (BCM) over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
Th e BCM r eceives a h a r d wir ed in pu t fr om t h e a m bi-
en t t em per a t u r e sen sor. Th e a m bien t t em per a t u r e
sen sor is a va r ia ble r esist or m ou n t ed t o a br a cket
t h a t is secu r ed wit h a scr ew t o t h e r igh t side of t h e
h ea dla m p m ou n t in g m odu le gr ille open in g, beh in d
t h e r a dia t or gr ille a n d in fr on t of t h e en gin e com pa r t -
m en t .
Refer t o B o d y Co n tro l Mo d u le in E lect r on ic Con -
t r ol Modu les. F or com plet e cir cu it dia gr a m s, r efer t o
t h e a ppr opr ia t e wir in g in for m a t ion . Th e a m bien t
t em per a t u r e sen sor ca n n ot be a dju st ed or r epa ir ed
a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
OPERATION
Th e a m bien t t em per a t u r e sen sor is a va r ia ble
r esist or t h a t oper a t es on a five-volt r efer en ce sign a l
sen t t o it by t h e BCM. Th e r esist a n ce in t h e sen sor
ch a n ges a s t em per a t u r e ch a n ges, ch a n gin g t h e t em -
per a t u r e sen sor sign a l cir cu it volt a ge t o t h e BCM.
Ba sed u pon t h e r esist a n ce in t h e sen sor, t h e BCM
sen ses a specific volt a ge on t h e t em per a t u r e sen sor
sign a l cir cu it , wh ich it is pr ogr a m m ed t o cor r espon d
t o a specific t em per a t u r e. Th e BCM t h en sen ds t h e
pr oper a m bien t t em per a t u r e m essa ges t o t h e E VIC
over t h e P CI da t a bu s.
Th e t em per a t u r e fu n ct ion is su ppor t ed by t h e
a m bien t t em per a t u r e sen sor, a wir in g cir cu it , t h e
Body Con t r ol Modu le (BCM), t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s, a n d a por-
t ion of t h e E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC) m odu le. If a n y por t ion of t h e a m bien t t em per-
a t u r e sen sor cir cu it fa ils, t h e BCM will self-dia gn ose
t h e cir cu it . A t em per a t u r e r ea din g of 130° F will
a ppea r in t h e E VIC displa y in pla ce of t h e t em per a -
t u r e wh en t h e sen sor cir cu it is sh or t ed. A t em per a -
t u r e r ea din g of –40° F will a ppea r in t h e E VIC
displa y in pla ce of t h e t em per a t u r e wh en t h e sen sor
cir cu it is open .
Th e a m bien t t em per a t u r e sen sor cir cu it ca n a lso be
dia gn osed by r efer r in g t o D ia g n o s is a n d Te s tin g -
Am bie n t Te m p e ra tu re S e n s o r, a n d D ia g n o s is
a n d Te s tin g - Am bie n t Te m p e ra tu re S e n s o r Cir-
c u it. If t h e t em per a t u r e sen sor a n d cir cu it a r e con -
fir m ed t o be OK, bu t t h e t em per a t u r e displa y is
in oper a t ive or in cor r ect , r efer t o D ia g n o s is a n d
Te s tin g - Ele c tro n ic Ve h ic le In fo rm a tio n Ce n te r
in t h is gr ou p. F or com plet e cir cu it dia gr a m s, r efer t o
t h e a ppr opr ia t e wir in g in for m a t ion .
WJ
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Discon n ect t h e a m bien t t em per a t u r e sen sor wir e h a r-
n ess con n ect or.
(2) Mea su r e t h e r esist a n ce of t h e a m bien t t em per-
a t u r e sen sor. At –40° C (–40° F ), t h e sen sor r esis-
t a n ce is 336.6 kiloh m s. At 60° C (140° F ), t h e sen sor
r esist a n ce is 2.49 kiloh m s. Th e sen sor r esist a n ce
sh ou ld r ea d bet ween t h ese t wo va lu es. If OK, r efer t o
D ia g n o s is a n d Te s tin g - Am bie n t Te m p e ra tu re
S e n s o r Circ u it in t h is gr ou p. If n ot OK, r epla ce t h e
fa u lt y a m bien t t em per a t u r e sen sor.
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR CIRCUIT
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Discon n ect t h e 2-wa y a m bien t t em per a t u r e sen sor
wir e h a r n ess con n ect or a n d t h e 22-wa y Body Con t r ol
Modu le (BCM) wir e h a r n ess con n ect or.
(2) Con n ect a ju m per wir e bet ween t h e t wo t er m i-
n a ls in t h e body h a lf of t h e 2-wa y a m bien t t em per a -
t u r e sen sor wir e h a r n ess con n ect or.
(3) Ch eck for con t in u it y bet ween t h e sen sor r et u r n
cir cu it a n d t h e a m bien t t em per a t u r e sen sor sign a l
cir cu it ca vit ies of t h e 22-wa y BCM wir e h a r n ess con -
n ect or. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
4. If n ot OK, r epa ir t h e open sen sor r et u r n cir cu it or
a m bien t t em per a t u r e sen sor sign a l cir cu it t o t h e
a m bien t t em per a t u r e sen sor a s r equ ir ed.
(4) Rem ove t h e ju m per wir e fr om t h e body h a lf of
t h e 2-wa y a m bien t t em per a t u r e sen sor wir e h a r n ess
con n ect or. Ch eck for con t in u it y bet ween t h e sen sor
r et u r n cir cu it ca vit y of t h e 22-wa y BCM wir e h a r n ess
con n ect or a n d a good gr ou n d. Th er e sh ou ld be n o
con t in u it y. If OK, go t o St ep 5. If n ot OK, r epa ir t h e
sh or t ed sen sor r et u r n cir cu it a s r equ ir ed.
(5) Ch eck for con t in u it y bet ween t h e a m bien t t em -
per a t u r e sen sor sign a l cir cu it ca vit y of t h e 22-wa y
BCM wir e h a r n ess con n ect or a n d a good gr ou n d.
Th er e sh ou ld be n o con t in u it y. If OK, r efer t o D ia g -
n o s is a n d Te s tin g - Ele c tro n ic Ve h ic le In fo rm a -
tio n Ce n te r in t h is gr ou p. If n ot OK, r epa ir t h e
sh or t ed a m bien t t em per a t u r e sen sor sign a l cir cu it a s
r equ ir ed.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
WJ
AM BI EN T T EM P SEN SOR (Cont inue d)
(2) Loca t e t h e a m bien t t em per a t u r e sen sor, on t h e
r igh t side of t h e r a dia t or open in g in t h e h ea dla m p
m ou n t in g m odu le, beh in d t h e gr ille (F ig. 6).
MESSAGE SYSTEMS 8M - 13
(3) Rem ove t h e r a dia t or gr ille fa scia a n d in ser t
fr om t h e h ea dla m p m ou n t in g m odu le. Refer t o Body
for t h e pr ocedu r es.
(4) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
a m bien t t em per a t u r e sen sor con n ect or r ecept a cle.
(5) Rem ove t h e on e scr ew t h a t secu r es t h e a m bien t
t em per a t u r e sen sor br a cket t o t h e h ea dla m p m ou n t -
in g m odu le.
(6) Rem ove t h e a m bien t t em per a t u r e sen sor fr om
t h e h ea dla m p m ou n t in g m odu le.

INSTALLATION
(1) P osit ion t h e a m bien t t em per a t u r e sen sor on t o
t h e h ea dla m p m ou n t in g m odu le.
(2) In st a ll a n d t igh t en t h e on e scr ew t h a t secu r es
t h e a m bien t t em per a t u r e sen sor br a cket t o t h e h ea d-
la m p m ou n t in g m odu le. Tigh t en t h e scr ew t o 2.2 N·m
(20 in . lbs.).
Fig. 6 AMBIENT TEMPERATURE SENSOR (3) Recon n ect t h e wir e h a r n ess con n ect or t o t h e
a m bien t t em per a t u r e sen sor con n ect or r ecept a cle.
1 - AMBIENT TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
(4) In st a ll t h e r a dia t or gr ille fa scia a n d in ser t on t o
3 - HEADLAMP MOUNTING MODULE t h e h ea dla m p m ou n t in g m odu le. Refer t o t h e Body
sect ion of t h is m a n u a l for t h e pr ocedu r es.
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ POWER SYSTEMS 8N - 1

POWER SYSTEMS
TABLE OF CON T EN T S

page page

POWER LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 POWER SEAT SYSTEM. . . . . . . . . . . . . . . . . . . . . 18

POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 11 POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 33

POWER LOCK S

TABLE OF CONTENTS
page page

POWER LOCKS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DESCRIPTION POWER LOCK MOTOR
DESCRIPTION - POWER LOCK SYSTEM . . ..1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - REMOTE KEYLESS ENTRY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 DIAGNOSIS AND TESTING - POWER LOCK
DESCRIPTION - LIFTGATE FLIP-UP GLASS MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
POWER RELEASE SYSTEM . . . . . . . . . . . . ..4 POWER LOCK SWITCH
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION - POWER LOCK SYSTEM . . . . ..4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION - REMOTE KEYLESS ENTRY REMOTE KEYLESS ENTRY MODULE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION - LIFTGATE FLIP-UP GLASS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER RELEASE SYSTEM . . . . . . . . . . . . ..5 REMOTE KEYLESS ENTRY TRANSMITTER
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - POWER LOCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 DIAGNOSIS AND TESTING - REMOTE
DIAGNOSIS AND TESTING - REMOTE KEYLESS ENTRY TRANSMITTER . . . . . . . . . . 9
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . ..6 STANDARD PROCEDURE
DIAGNOSIS AND TESTING - LIFTGATE STANDARD PROCEDURE - RKE
FLIP-UP GLASS POWER RELEASE TRANSMITTER PROGRAMMING . . . . . . . . . . 10
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6 STANDARD PROCEDURE - RKE
DOOR CYLINDER LOCK SWITCH TRANSMITTER BATTERIES . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ..7

POWER LOCK S t h r ou gh a fu se in t h e P ower Dist r ibu t ion Cen t er

DESCRI PT I ON
DESCRIPTION - POWER LOCK SYSTEM
A power oper a t ed door a n d lift ga t e lock syst em is
st a n da r d fa ct or y-in st a lled equ ipm en t on t h is m odel.
Th e power lock syst em a llows a ll of t h e door s a n d t h e
lift ga t e t o be locked or u n locked elect r ica lly by oper-
a t in g a swit ch on eit h er fr on t door t r im pa n el. Th e
power lock syst em r eceives n on -swit ch ed ba t t er y feed
(P DC), so t h a t t h e power locks r em a in oper a t ion a l,
r ega r dless of t h e ign it ion swit ch posit ion .
Th e power lock syst em for t h is veh icle a lso h a s a
door lock in h ibit fea t u r e, wh ich pr even t s t h e power
lock syst em fr om bein g en er gized wit h a power door
lock swit ch if a fr on t door is open wit h t h e key in t h e
ign it ion . H owever, t h e locks ca n st ill be oper a t ed
m a n u a lly, wit h a key, en er gized wit h t h e RKE t r a n s-
m it t er or by slidin g t h e door lock lever t o t h e a ppr o-
pr ia t e posit ion .
8N - 2 POWER LOCKS
POWER LOCK S (Cont inue d)
Th is veh icle a lso offer s sever a l cu st om er pr ogr a m -
m a ble fea t u r es, wh ich a llows t h e select ion of sever a l
opt ion a l elect r on ic fea t u r es t o su it in dividu a l pr efer-
en ces. (Refer t o 8 - E LE CTRICAL/OVE RH E AD CON-
SOLE /E LE CTRONIC VE H ICLE INF O CE NTE R -
DE SCRIP TION). Cu st om er pr ogr a m m a ble fea t u r e
opt ion s a ffect in g t h e power door lock syst em in clu de:
• Au to D o o r Lo c k s - Au t om a t ica lly locks a ll of
t h e veh icle door s a n d t h e lift ga t e wh en t h e veh icle
r ea ch es a speed of a bou t 24 kilom et er s-per-h ou r (15
m iles-per-h ou r ) wit h 10% t h r ot t le t ip-in .
• Au to U n lo c k o n Ex it - Au t om a t ica lly u n locks
a ll of t h e veh icle door s a n d t h e lift ga t e wh en t h e
dr iver side fr on t door is open ed, if t h e veh icle is
st opped a n d t h e t r a n sm ission gea r select or is in t h e
P a r k or Neu t r a l posit ion s. Th is fea t u r e is lin ked t o
t h e Au t o Door Locks fea t u r e, a n d will on ly occu r on e
t im e followin g ea ch Au t o Door Lock even t .
Th e power lock syst em for t h is veh icle ca n a lso be
oper a t ed r em ot ely u sin g t h e st a n da r d equ ipm en t
Rem ot e Keyless E n t r y (RKE ) syst em r a dio fr equ en cy
t r a n sm it t er s. (Refer t o 8 - E LE CTRICAL/P OWE R
LOCKS - DE SCRIP TION - RE MOTE KE YLE SS
E NTRY SYSTE M).
Th e com pon en t s of t h e power lock syst em in clu de:
• D riv e r D o o r Mo d u le (D D M)
• P a s s e n g e r D o o r Mo d u le (P D M)
• P CI B u s Me s s a g e s
• P o w e r Lo c k Mo to rs
Cer t a in fu n ct ion s a n d fea t u r es of t h e power lock
syst em r ely u pon r esou r ces sh a r ed wit h ot h er elec-
t r on ic m odu les in t h e veh icle over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
Th e P CI da t a bu s n et wor k a llows t h e sh a r in g of sen -
sor in for m a t ion . Th is h elps t o r edu ce wir e h a r n ess
com plexit y, in t er n a l con t r oller h a r dwa r e, a n d com po-
n en t sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is sys-
t em pr ovides in cr ea sed r elia bilit y, en h a n ced
dia gn ost ics, a n d a llows t h e a ddit ion of m a n y n ew fea -
t u r e ca pa bilit ies. F or pr oper dia gn osis of t h ese elec-
t r on ic m odu les or of t h e P CI da t a bu s n et wor k, t h e
u se of a DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia g-
n ost ic in for m a t ion a r e r equ ir ed.
Th e ot h er elect r on ic m odu les t h a t m a y a ffect power
lock syst em oper a t ion a r e a s follows:
• B o d y Co n tro l Mo d u le (B CM) - (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/BODY CONTROL/CE NTRAL TIME R MOD-
ULE - DE SCRIP TION).
• Ele c tro n ic Ve h ic le In fo rm a tio n Ce n te r
(EVIC) - (Refer t o 8 - E LE CTRICAL/OVE RH E AD
CONSOLE /E LE CTRONIC VE H ICLE INF O CE NTE R
- DE SCRIP TION).
• P o w e rtra in Co n tro l Mo d u le (P CM) - (Refer
t o 8 - E LE CTRICAL/E LE CTRONIC CONTROL
WJ
MODULE S/P OWE RTRAIN CONTROL MODULE -
DE SCRIP TION).
H a r d wir ed cir cu it r y con n ect s t h e power lock sys-
t em com pon en t s t o t h e elect r ica l syst em of t h e veh i-
cle. Th ese h a r d wir ed cir cu it s a r e in t egr a l t o sever a l
wir e h a r n esses, wh ich a r e r ou t ed t h r ou gh ou t t h e
veh icle a n d r et a in ed by m a n y differ en t m et h ods.
Th ese cir cu it s m a y be con n ect ed t o ea ch ot h er, t o t h e
veh icle elect r ica l syst em a n d t o t h e power lock sys-
t em com pon en t s t h r ou gh t h e u se of a com bin a t ion of
solder ed splices, splice block con n ect or s, a n d m a n y
differ en t t ypes of wir e h a r n ess t er m in a l con n ect or s
a n d in su la t or s. Refer t o t h e a ppr opr ia t e wir in g in for-
m a t ion . Th e wir in g in for m a t ion in clu des wir in g dia -
gr a m s, pr oper wir e a n d con n ect or r epa ir pr ocedu r es,
fu r t h er det a ils on wir e h a r n ess r ou t in g a n d r et en -
t ion , a s well a s pin -ou t a n d loca t ion views for t h e
va r iou s wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
DESCRIPTION - REMOTE KEYLESS ENTRY
SYSTEM
A Ra dio F r equ en cy (RF ) t ype Rem ot e Keyless
E n t r y (RKE ) syst em is st a n da r d fa ct or y-in st a lled
equ ipm en t on t h is m odel. Th e RKE syst em a llows
t h e u se of a r em ot e ba t t er y-power ed r a dio t r a n sm it -
t er t o con t r ol t h e power lock syst em . Th e RKE
r eceiver oper a t es on n on -swit ch ed ba t t er y cu r r en t
t h r ou gh a fu se in t h e P ower Dist r ibu t ion Cen t er
(P DC), so t h a t t h e syst em r em a in s oper a t ion a l,
r ega r dless of t h e ign it ion swit ch posit ion .
In a ddit ion t o Lock a n d Un lock bu t t on s, t h e RKE
t r a n sm it t er s a r e a lso equ ipped wit h a P a n ic bu t t on .
If t h e P a n ic bu t t on on t h e RKE t r a n sm it t er is
depr essed, t h e h or n will sou n d a n d t h e ext er ior ligh t s
will fla sh on t h e veh icle for a bou t t h r ee m in u t es, or
u n t il t h e P a n ic bu t t on is depr essed a secon d t im e, if
ign it ion is in t h e Off posit ion . A veh icle speed of
a bou t 24 kilom et er s-per-h ou r (15 m iles-per-h ou r ) will
a lso ca n cel t h e pa n ic even t .
Th e RKE syst em ca n a lso per for m ot h er fu n ct ion s
on t h is veh icle. If t h e veh icle is equ ipped wit h t h e
opt ion a l Veh icle Th eft Secu r it y Syst em (VTSS), t h e
RKE t r a n sm it t er will a r m t h e VTSS wh en t h e Lock
bu t t on is depr essed, a n d disa r m t h e VTSS wh en t h e
Un lock bu t t on is depr essed. (Refer t o 8 - E LE CTRI-
CAL/VE H ICLE TH E F T SE CURITY - DE SCRIP TION
- VE H ICLE TH E F T SE CURITY SYSTE M). If t h e
veh icle is equ ipped wit h t h e opt ion a l Mem or y Sys-
t em , ea ch of t h e t wo n u m ber ed a n d color-coded RKE
t r a n sm it t er s ca n be u sed t o r eca ll t h e st or ed dr iver
side fr on t sea t posit ion , bot h ou t side power r ea r view
m ir r or posit ion s, a n d t h e r a dio st a t ion pr eset s for t h e
t wo a ssign ed dr iver s. (Refer t o 8 - E LE CTRICAL/
P OWE R SE ATS - DE SCRIP TION - ME MORY SYS-
TE M).
WJ
POWER LOCK S (Cont inue d)
Th e RKE syst em in clu des t wo t r a n sm it t er s wh en
t h e veh icle is sh ipped fr om t h e fa ct or y, bu t t h e sys-
t em ca n r et a in t h e veh icle a ccess codes of u p t o fou r
t r a n sm it t er s. Th e t r a n sm it t er codes a r e r et a in ed in
t h e RKE r eceiver m em or y, even if t h e ba t t er y is dis-
con n ect ed. If a n RKE t r a n sm it t er is fa u lt y or lost ,
n ew t r a n sm it t er veh icle a ccess codes ca n be pr o-
gr a m m ed in t o t h e syst em u sin g a DRBIII! sca n t ool
a n d t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
Th is veh icle a lso offer s sever a l cu st om er pr ogr a m -
m a ble fea t u r es, wh ich a llows t h e select ion of sever a l
opt ion a l elect r on ic fea t u r es t o su it in dividu a l pr efer-
en ces. (Refer t o 8 - E LE CTRICAL/OVE RH E AD CON-
SOLE /E LE CTRONIC VE H ICLE INF O CE NTE R -
DE SCRIP TION). Cu st om er pr ogr a m m a ble fea t u r e
opt ion s a ffect in g t h e RKE syst em in clu de:
• Re m o te U n lo c k - Allows t h e opt ion of h a vin g
on ly t h e dr iver side fr on t door u n lock wh en t h e RKE
t r a n sm it t er Un lock bu t t on is depr essed t h e fir st t im e
a n d t h e r em a in in g door s a n d t h e lift ga t e u n lock
wh en t h e bu t t on is depr essed a secon d t im e, or h a v-
in g a ll door s a n d t h e lift ga t e u n lock u pon t h e fir st
depr ession of t h e RKE t r a n sm it t er Un lock bu t t on .
• Re m o te Lin k e d to Me m o ry - If t h e veh icle is
equ ipped wit h t h e Mem or y Syst em , t h is fea t u r e
a llows t h e opt ion of h a vin g t h e RKE t r a n sm it t er
Un lock bu t t on a ct iva t e t h e r eca ll of t h e st or ed set -
t in gs, or h a vin g t h e r eca ll fu n ct ion a ssign ed solely t o
t h e m em or y swit ch on t h e dr iver side fr on t door t r im
pa n el.
• S o u n d Ho rn o n Lo c k - Allows t h e opt ion of
h a vin g t h e h or n sou n d a sh or t ch ir p a s a n a u dible
ver ifica t ion t h a t t h e door s h a ve locked, or h a vin g n o
a u dible ver ifica t ion .
• F la s h Lig h ts w ith Lo c k - Allows t h e opt ion of
h a vin g t h e ligh t s fla sh a s a n opt ica l ver ifica t ion t h a t
t h e door s h a ve locked, or h a vin g n o opt ica l ver ifica -
t ion .
Th is gr ou p cover s t h e followin g com pon en t s of t h e
RKE syst em :
• RKE Re c e iv e r
• RKE Tra n s m itte r
Cer t a in fu n ct ion s a n d fea t u r es of t h e RKE syst em
r ely u pon r esou r ces sh a r ed wit h ot h er elect r on ic
m odu les in t h e veh icle over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e
P CI da t a bu s n et wor k a llows t h e sh a r in g of sen sor
in for m a t ion . Th is h elps t o r edu ce wir e h a r n ess com -
plexit y, in t er n a l con t r oller h a r dwa r e, a n d com pon en t
sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is syst em
pr ovides in cr ea sed r elia bilit y, en h a n ced dia gn ost ics,
a n d a llows t h e a ddit ion of m a n y n ew fea t u r e ca pa bil-
it ies. F or dia gn osis of t h ese elect r on ic m odu les or of
t h e P CI da t a bu s n et wor k, t h e u se of a DRBIII! sca n
t ool a n d t h e a ppr opr ia t e dia gn ost ic in for m a t ion a r e
r equ ir ed.
POWER LOCKS 8N - 3
Th e ot h er elect r on ic m odu les t h a t m a y a ffect RKE
syst em oper a t ion a r e a s follows:
• B o d y Co n tro l Mo d u le (B CM) - (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/BODY CONTROL/CE NTRAL TIME R MOD-
ULE - DE SCRIP TION).
• D riv e r D o o r Mo d u le (D D M) - (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/DOOR MODULE - DE SCRIP TION).
• Ele c tro n ic Ve h ic le In fo rm a tio n Ce n te r
(EVIC) - (Refer t o 8 - E LE CTRICAL/OVE RH E AD
CONSOLE /E LE CTRONIC VE H ICLE INF O CE NTE R
- DE SCRIP TION).
• P a s s e n g e r D o o r Mo d u le (P D M) - (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/DOOR MODULE - DE SCRIP TION).
• P o w e rtra in Co n tro l Mo d u le (P CM) - (Refer
t o 8 - E LE CTRICAL/E LE CTRONIC CONTROL
MODULE S/P OWE RTRAIN CONTROL MODULE -
DE SCRIP TION).
H a r d wir ed cir cu it r y con n ect s t h e RKE syst em
com pon en t s via t h e P DM t o t h e elect r ica l syst em of
t h e veh icle. Th ese h a r d wir ed cir cu it s a r e in t egr a l t o
sever a l wir e h a r n esses, wh ich a r e r ou t ed t h r ou gh ou t
t h e veh icle a n d r et a in ed by m a n y differ en t m et h ods.
Th ese cir cu it s m a y be con n ect ed t o ea ch ot h er, t o t h e
veh icle elect r ica l syst em a n d t o t h e RKE syst em com -
pon en t s t h r ou gh t h e u se of a com bin a t ion of solder ed
splices, splice block con n ect or s, a n d m a n y differ en t
t ypes of wir e h a r n ess t er m in a l con n ect or s a n d in su -
la t or s. Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er
det a ils on wir e h a r n ess r ou t in g a n d r et en t ion , a s well
a s pin -ou t a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
COMBINATION FLASHER
Th e com bin a t ion fla sh er is a sm a r t r ela y t h a t fu n c-
t ion s a s bot h t h e t u r n sign a l syst em a n d t h e h a za r d
wa r n in g syst em fla sh er. Th e com bin a t ion fla sh er con -
t a in s a ct ive elect r on ic In t egr a t ed Cir cu it r y (IC) ele-
m en t s. Th is fla sh er ca n be en er gized by t h e BCM t o
fla sh a ll of t h e pa r k/t u r n sign a l/fr on t side m a r ker
la m ps a s a n opt ica l a ler t for t h e RKE pa n ic fu n ct ion
a n d, if t h e F la sh Ligh t s wit h Lock pr ogr a m m a ble fea -
t u r e is en a bled, a s a n opt ica l ver ifica t ion for t h e RKE
lock even t . (Refer t o 8 - E LE CTRICAL/LAMP S/
LIGH TING - E XTE RIOR/COMBINATION F LASH E R
- DE SCRIP TION).
HORN RELAY
Th e h or n r ela y is a elect r om ech a n ica l device t h a t
swit ch es ba t t er y cu r r en t t o t h e h or n wh en t h e h or n
swit ch gr ou n ds t h e r ela y coil. Th e h or n r ela y is
loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC) in
8N - 4 POWER LOCKS WJ
POWER LOCK S (Cont inue d)
t h e en gin e com pa r t m en t . Th is r ela y ca n be en er gized t o 23 - BODY/DE CKLID/H ATCH /LIF TGATE /TAIL-
by t h e BCM t o sou n d t h e h or n s a s a n a u dible a ler t GATE /F LIP -UP GLASS SWITCH - INSTALLATION).
for t h e RKE pa n ic fu n ct ion a n d, if t h e Sou n d H or n H a r d wir ed cir cu it r y con n ect s t h e lift ga t e flip-u p
on Lock pr ogr a m m a ble fea t u r e is en a bled, a s a n gla ss power r elea se syst em com pon en t s t o t h e elect r i-
a u dible ver ifica t ion for t h e RKE lock even t . (Refer t o ca l syst em of t h e veh icle. Th ese h a r d wir ed cir cu it s
8 - E LE CTRICAL/H ORN/H ORN RE LAY - DE SCRIP - a r e in t egr a l t o sever a l wir e h a r n esses, wh ich a r e
TION). r ou t ed t h r ou gh ou t t h e veh icle a n d r et a in ed by m a n y
differ en t m et h ods. Th ese cir cu it s m a y be con n ect ed t o
LOW BEAM HEADLAMP RELAY ea ch ot h er, t o t h e veh icle elect r ica l syst em a n d t o t h e
Th e low bea m h ea dla m p r ela y is a elect r om ech a n - lift ga t e flip-u p gla ss power r elea se syst em com po-
ica l device t h a t swit ch es ba t t er y cu r r en t t o t h e h ea d- n en t s t h r ou gh t h e u se of a com bin a t ion of solder ed
la m p low bea m s wh en t h e BCM gr ou n ds t h e r ela y splices, splice block con n ect or s, a n d m a n y differ en t
coil. Th e low bea m h ea dla m p r ela y is loca t ed in t h e t ypes of wir e h a r n ess t er m in a l con n ect or s a n d in su -
ju n ct ion block in t h e pa ssen ger com pa r t m en t . Th is la t or s. Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
r ela y ca n be en er gized by t h e BCM t o fla sh t h e h ea d- Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
la m p low bea m s a s a n opt ica l a ler t for t h e RKE pa n ic pr oper wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er
fu n ct ion . (Refer t o 8 - E LE CTRICAL/LAMP S/LIGH T- det a ils on wir e h a r n ess r ou t in g a n d r et en t ion , a s well
ING - E XTE RIOR/H E ADLAMP - DE SCRIP TION). a s pin -ou t a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
DESCRIPTION - LIFTGATE FLIP-UP GLASS
POWER RELEASE SYSTEM OPERAT I ON
A power oper a t ed lift ga t e flip-u p gla ss r elea se sys-
t em is st a n da r d fa ct or y in st a lled equ ipm en t on t h is
OPERATION - POWER LOCK SYSTEM
m odel. Th e lift ga t e flip-u p gla ss power r elea se syst em
Th e P a ssen ger Door Modu le (P DM) con t a in s t h e
a llows t h e flip-u p gla ss la t ch t o be r elea sed elect r i-
power door lock con t r ol logic a n d a power lock swit ch .
ca lly by depr essin g a swit ch loca t ed on t h e bot t om of
Th e Dr iver Door Modu le (DDM) con t a in s a power
t h e lift ga t e licen se pla t e la m p h ou sin g u n it , a bove
lock swit ch a n d con t r ols t h e ou t pu t t o t h e dr iver side
t h e licen se pla t e on t h e ou t side of t h e lift ga t e.
fr on t door power lock m ot or, wh ile t h e P DM con t r ols
Th e lift ga t e flip-u p gla ss r elea se syst em oper a t es
t h e ou t pu t t o t h e power lock m ot or s for t h e r em a in -
on n on -swit ch ed ba t t er y cu r r en t su pplied t h r ou gh a
in g door s a n d t h e lift ga t e.
fu se in t h e ju n ct ion block so t h a t t h e syst em r em a in s
Wh en t h e power lock swit ch on t h e DDM is u sed t o
fu n ct ion a l, r ega r dless of t h e ign it ion swit ch posit ion .
lock or u n lock t h e door s, t h e DDM sen ds a con t r ol
H owever, a lim it swit ch t h a t is in t egr a l t o t h e lift ga t e
ou t pu t t o t h e dr iver side fr on t door power lock m ot or
la t ch a ct u a t or u n it open s t o pr even t t h e flip-u p gla ss
a n d sen ds lock or u n lock r equ est m essa ges t o t h e
la t ch fr om bein g a ct u a t ed wh en t h e lift ga t e la t ch is
P DM over t h e P r ogr a m m a ble Com m u n ica t ion s In t er-
locked.
fa ce (P CI) da t a bu s. Th e P DM r espon ds t o t h ese m es-
Th e lift ga t e flip-u p gla ss power r elea se syst em
sa ges by sen din g con t r ol ou t pu t s t o t h e power lock
in clu des t h e followin g com pon en t s:
m ot or s of t h e r em a in in g door s a n d t h e lift ga t e. Wh en
• Liftg a te F lip -U p Gla s s Lim it S w itc h - Th e
t h e power lock swit ch on t h e P DM is u sed t o lock or
lift ga t e flip-u p gla ss lim it swit ch is in t egr a l t o t h e
u n lock t h e door s, t h e P DM sen ds con t r ol ou t pu t s t o
lift ga t e la t ch u n it . (Refer t o 23 - BODY/DE CKLID/
t h e power lock m ot or s in t h e pa ssen ger side fr on t
H ATCH /LIF TGATE /TAILGATE /LATCH - RE MOVAL)
door, bot h r ea r door s a n d t h e lift ga t e, t h en sen ds lock
a n d (Refer t o 23 - BODY/DE CKLID/H ATCH /LIF T-
or u n lock r equ est m essa ges t o t h e DDM over t h e P r o-
GATE /TAILGATE /LATCH - INSTALLATION).
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
• Liftg a te F lip -U p Gla s s Re le a s e Mo to r - Th e
bu s. Th e DDM r espon ds t o t h ese m essa ges by sen d-
lift ga t e flip-u p gla ss r elea se m ot or is in t egr a l t o t h e
in g con t r ol ou t pu t s t o t h e power lock m ot or of t h e
lift ga t e flip-u p gla ss la t ch u n it . (Refer t o 23 - BODY/
dr iver side fr on t door.
DE CKLID/H ATCH /LIF TGATE /TAILGATE /F LIP -UP
In or der t o su ppor t t h e a u t o door locks a n d u n lock
GLASS LATCH - RE MOVAL) a n d (Refer t o 23 -
on exit fea t u r es, if en a bled, t h e power lock syst em
BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE /
logic in t h e P DM n eeds t o kn ow t h e door a ja r swit ch
F LIP -UP GLASS LATCH - INSTALLATION).
st a t u s, veh icle speed, a n d t r a n sm ission gea r select or
• Liftg a te F lip -U p Gla s s Re le a s e S w itc h - Th e
lever posit ion . Th e pa ssen ger side fr on t door a ja r
lift ga t e flip-u p gla ss r elea se swit ch is in t egr a l t o t h e
swit ch is t h e on ly h a r d wir ed in pu t t o t h e P DM. Th e
lift ga t e licen se pla t e la m p h ou sin g. (Refer t o 23 -
P DM obt a in s t h e r em a in in g in for m a t ion fr om m es-
BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE /
sa ges it r eceives fr om ot h er elect r on ic m odu les over
F LIP -UP GLASS SWITCH - RE MOVAL) a n d (Refer
t h e P CI da t a bu s n et wor k.
WJ
POWER LOCK S (Cont inue d)
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e power lock syst em .
OPERATION - REMOTE KEYLESS ENTRY
SYSTEM
Th e P a ssen ger Door Modu le (P DM) con t a in s t h e
RKE syst em con t r ol logic a n d t h e RKE r eceiver.
Wh en t h e RKE r eceiver r ecogn izes a Lock, Un lock or
P a n ic m essa ge fr om a va lid RKE t r a n sm it t er, t h e
RKE r eceiver pr ovides t h a t in pu t t o t h e P DM. Th e
P DM cir cu it r y a n d pr ogr a m m in g r espon ds by sen din g
t h e pr oper m essa ges t o t h e ot h er elect r on ic m odu les
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s.
Wh en a n RKE lock m essa ge is r eceived, t h e door s
a n d t h e lift ga t e lock, t h e in t er ior ligh t in g fa des t o off,
t h e h or n ch ir ps (if t h is fea t u r e is en a bled), t h e ext e-
r ior la m ps fla sh (if t h is fea t u r e is en a bled) a n d, if t h e
veh icle is so equ ipped, t h e Veh icle Th eft Secu r it y
Syst em (VTSS) is a r m ed. Wh en a n RKE u n lock m es-
sa ge is r eceived, t h e dr iver side fr on t door (or a ll
door s a n d t h e lift ga t e if t h is fea t u r e is en a bled)
u n lock, t h e in t er ior ligh t in g is t u r n ed on a n d, if t h e
veh icle is so equ ipped, t h e VTSS is disa r m ed. If t h e
veh icle is equ ipped wit h t h e Mem or y Syst em a n d t h e
RKE Lin ked t o Mem or y fea t u r e is en a bled, t h e RKE
u n lock m essa ge a lso r eca lls t h e dr iver sea t , ou t side
m ir r or a n d r a dio set t in gs a ssign ed t o t h e RKE t r a n s-
m it t er t h a t sen t t h e u n lock sign a l.
Wh en a n RKE pa n ic m essa ge is r eceived, it ca u ses
t h e ext er ior la m ps (in clu din g t h e h ea dligh t s) t o fla sh ,
a n d t h e h or n t o pu lse for a bou t t h r ee m in u t es, or
u n t il a secon d pa n ic m essa ge is r eceived. A veh icle
speed of a bou t 24 kilom et er s-per-h ou r (15 m iles-per-
h ou r ) will a lso ca n cel t h e pa n ic even t .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e RKE syst em .
OPERATION - LIFTGATE FLIP-UP GLASS
POWER RELEASE SYSTEM
Wh en t h e lift ga t e m ou n t ed flip-u p gla ss r elea se
swit ch is depr essed, ba t t er y cu r r en t is dir ect ed t o t h e
elect r ic r elea se m ot or t h a t is in t egr a l t o t h e flip-u p
gla ss la t ch loca t ed in side t h e lift ga t e. Wh en t h e
r elea se m ot or is en er gized t h e la t ch r elea ses a n d t h e
flip-u p gla ss ca n be open ed. A lift ga t e flip-u p gla ss
lim it swit ch is in t egr a l t o t h e lift ga t e la t ch a ct u a t or
m ech a n ism . Th e lim it swit ch a u t om a t ica lly en a bles
or disa bles t h e lift ga t e flip-u p gla ss power r elea se cir-
cu it r y, depen din g u pon t h e posit ion of t h e lift ga t e
la t ch lock m ech a n ism . Wh en t h e lift ga t e la t ch is
u n locked, t h e lim it swit ch closes a n d ba t t er y cu r r en t
is a va ila ble a t t h e r elea se swit ch . Wh en t h e lift ga t e
POWER LOCKS 8N - 5
la t ch is locked , t h e lim it swit ch open s, a n d t h e
r elea se swit ch is disa bled.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e lift ga t e flip-u p gla ss power r elea se syst em .
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - POWER LOCK
SYSTEM
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
h a r d wir ed com pon en t s a n d cir cu it s of t h e power lock
syst em . H owever, t h ese t est s m a y n ot pr ove con clu -
sive in t h e dia gn osis of t h is syst em . In or der t o
obt a in con clu sive t est in g of t h e power lock syst em ,
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s n et wor k a n d a ll of t h e elect r on ic m odu les
t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om t h e
power lock syst em com pon en t s m u st be ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e power lock syst em r equ ir es t h e u se of a
DRBIII! sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
du r es m a n u a l. Th e DRBIII! sca n t ool ca n pr ovide
con fir m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t
a ll of t h e elect r on ic m odu les a r e sen din g a n d r eceiv-
in g t h e pr oper m essa ges on t h e P CI da t a bu s, a n d
t h a t t h e power lock m ot or s a r e bein g sen t t h e pr oper
h a r d wir ed ou t pu t s by t h e door m odu les for t h em t o
per for m t h eir power lock syst em fu n ct ion s.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
PRELIMINARY DIAGNOSIS
As a pr elim in a r y dia gn osis for t h e power lock sys-
t em , n ot e t h e syst em oper a t ion wh ile you a ct u a t e
bot h t h e Lock a n d Un lock fu n ct ion s wit h t h e power
lock swit ch es a n d wit h t h e Rem ot e Keyless E n t r y
(RKE ) t r a n sm it t er. Th en , pr oceed a s follows:
• If t h e en t ir e power lock syst em fa ils t o fu n ct ion
wit h eit h er t h e power lock swit ch es or t h e RKE
t r a n sm it t er, ch eck t h e fu sed B(+) fu se in t h e P ower
Dist r ibu t ion Cen t er. If t h e fu se is OK, pr oceed t o
dia gn osis of t h e door m odu les. (Refer t o 8 - E LE C-
TRICAL/E LE CTRONIC CONTROL MODULE S/
DOOR MODULE - DIAGNOSIS AND TE STING).
• If t h e power lock syst em fu n ct ion s wit h bot h
power lock swit ch es, bu t n ot wit h t h e RKE t r a n sm it -
t er, pr oceed t o dia gn osis of t h e Rem ot e Keyless E n t r y
(RKE ) syst em . (Refer t o 8 - E LE CTRICAL/P OWE R
LOCKS - DIAGNOSIS AND TE STING - RE MOTE
KE YLE SS E NTRY SYSTE M).
8N - 6 POWER LOCKS
POWER LOCK S (Cont inue d)
• If t h e power lock syst em fu n ct ion s wit h t h e RKE
t r a n sm it t er, bu t n ot wit h on e or bot h power lock
swit ch es, pr oceed t o dia gn osis of t h e door m odu les.
(Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
TROL MODULE S/DOOR MODULE - DIAGNOSIS
AND TE STING).
• If t h e dr iver side power lock swit ch oper a t es
on ly t h e dr iver side fr on t door power lock m ot or, bu t
a ll ot h er power lock m ot or s oper a t e wit h t h e pa ssen -
ger side power lock swit ch or t h e RKE t r a n sm it t er,
u se a DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia gn os-
t ic in for m a t ion t o dia gn ose t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s.
• If on ly on e power lock m ot or fa ils t o oper a t e
wit h bot h power lock swit ch es a n d t h e RKE t r a n s-
m it t er, pr oceed t o dia gn osis of t h e power lock m ot or.
(Refer t o 8 - E LE CTRICAL/P OWE R LOCKS/P OWE R
LOCK MOTOR - DIAGNOSIS AND TE STING).
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY SYSTEM
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
Rem ot e Keyless E n t r y (RKE ) syst em . H owever, t h ese
t est s m a y n ot pr ove con clu sive in t h e dia gn osis of
t h is syst em . In or der t o obt a in con clu sive t est in g of
t h e RKE syst em , t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s n et wor k a n d a ll of t h e elec-
t r on ic m odu les t h a t pr ovide in pu t s t o, or r eceive ou t -
pu t s fr om t h e RKE syst em com pon en t s m u st be
ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e RKE syst em r equ ir es t h e u se of a
DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia gn ost ic
in for m a t ion . Th e DRBIII! sca n t ool ca n pr ovide con -
fir m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t a ll
of t h e elect r on ic m odu les a r e sen din g a n d r eceivin g
t h e pr oper m essa ges on t h e P CI da t a bu s, a n d t h a t
t h e RKE r eceiver is bein g sen t t h e pr oper r a dio fr e-
qu en cy sign a ls by t h e RKE t r a n sm it t er s t o per for m
it s RKE syst em fu n ct ion s.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
PRELIMINARY DIAGNOSIS
As a pr elim in a r y dia gn osis for t h e RKE syst em ,
n ot e t h e syst em oper a t ion wh ile you per for m bot h t h e
Lock a n d Un lock fu n ct ion s wit h t h e power lock
swit ch es a n d wit h t h e Rem ot e Keyless E n t r y (RKE )
t r a n sm it t er. Th en , pr oceed a s follows:
• If t h e en t ir e power lock syst em fa ils t o fu n ct ion
wit h eit h er t h e power lock swit ch es or t h e RKE
t r a n sm it t er, ch eck t h e fu sed B(+) fu se in t h e P ower
WJ
Dist r ibu t ion Cen t er. If t h e fu se is OK, pr oceed t o t h e
dia gn osis for t h e door m odu les. (Refer t o 8 - E LE C-
TRICAL/E LE CTRONIC CONTROL MODULE S/
DOOR MODULE - DIAGNOSIS AND TE STING).
• If t h e power lock syst em fu n ct ion s wit h bot h
power lock swit ch es, bu t n ot wit h t h e RKE t r a n sm it -
t er, pr oceed t o t h e dia gn osis for t h e RKE t r a n sm it t er.
(Refer t o 8 - E LE CTRICAL/P OWE R LOCKS/RE -
MOTE KE YLE SS E NTRY TRANSMITTE R - DIAG-
NOSIS AND TE STING).
• If t h e dr iver side power lock swit ch oper a t es
on ly t h e dr iver side fr on t door power lock m ot or, bu t
a ll ot h er power lock m ot or s oper a t e wit h t h e pa ssen -
ger side power lock swit ch or t h e RKE t r a n sm it t er,
u se a DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia gn os-
t ic in for m a t ion t o dia gn ose t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s.
If t h e pr oblem bein g dia gn osed in volves on ly t h e
Sou n d H or n on Lock or t h e F la sh Ligh t s wit h Locks
fea t u r es, be cer t a in t h a t t h ese pr ogr a m m a ble fea -
t u r es a r e en a bled. If t h e fea t u r es a r e en a bled a n d t h e
ser vice h or n a n d t u r n sign a ls st ill oper a t e, t h e Body
Con t r ol Modu le (BCM) a n d t h e P CI da t a bu s m u st be
t est ed. F or dia gn osis of t h e BCM or t h e P CI da t a
bu s, t h e u se of a DRBIII sca n t ool a n d t h e a ppr opr i-
a t e dia gn ost ic in for m a t ion a r e r equ ir ed.
DIAGNOSIS AND TESTING - LIFTGATE FLIP-UP
GLASS POWER RELEASE SYSTEM
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
(1) Ch eck t h e fu sed B(+) fu se in t h e J u n ct ion
Block (J B). If OK, go t o St ep 2. If n ot OK, r epa ir t h e
sh or t ed cir cu it or com pon en t a s r equ ir ed a n d r epla ce
t h e fa u lt y fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e J B. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e P ower Dist r ibu t ion
Cen t er (P DC) a s r equ ir ed.
(3) Discon n ect t h e lift ga t e wir e h a r n ess con n ect or
for t h e lift ga t e lock m ot or a n d flip-u p gla ss lim it
swit ch fr om t h e m ot or a n d swit ch con n ect or r ecept a -
cle. Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) cir-
cu it ca vit y of t h e lift ga t e wir e h a r n ess con n ect or for
t h e lift ga t e lock m ot or a n d flip-u p gla ss lim it swit ch .
If OK, go t o St ep 4. If n ot OK, r epa ir t h e open fu sed
B(+) cir cu it bet ween t h e lift ga t e lock m ot or a n d
flip-u p gla ss lim it swit ch a n d t h e J B a s r equ ir ed.
(4) Ch eck for con t in u it y bet ween t h e t wo lift ga t e
flip-u p gla ss lim it swit ch t er m in a ls. Th er e sh ou ld be
con t in u it y wit h t h e lift ga t e la t ch u n locked, a n d n o
con t in u it y wit h t h e la t ch locked. If OK, go t o St ep 5.
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POWER LOCK S (Cont inue d)
If n ot OK, r epla ce t h e fa u lt y lift ga t e la t ch a ct u a t or
(br a in pla t e) u n it .
(5) Discon n ect t h e lift ga t e wir e h a r n ess con n ect or
for t h e lift ga t e flip-u p gla ss r elea se swit ch fr om t h e
swit ch con n ect or r ecept a cle. Wit h t h e lift ga t e la t ch
u n locked, ch eck for ba t t er y volt a ge a t t h e lift ga t e
flip-u p gla ss lim it swit ch ou t pu t cir cu it ca vit y of t h e
lift ga t e wir e h a r n ess con n ect or for t h e r elea se swit ch .
If OK, go t o St ep 6. If n ot OK, r epa ir t h e open lift -
ga t e flip-u p gla ss lim it swit ch ou t pu t cir cu it bet ween
t h e r elea se swit ch a n d t h e lim it swit ch a s r equ ir ed.
(6) Ch eck for con t in u it y bet ween t h e t wo t er m in a ls
of t h e lift ga t e flip-u p gla ss r elea se swit ch . Th er e
sh ou ld be n o con t in u it y. Depr ess t h e swit ch , t h er e
sh ou ld n ow be con t in u it y. If OK, go t o St ep 7. If n ot
OK, r epla ce t h e fa u lt y lift ga t e flip-u p gla ss r elea se
swit ch .
(7) Discon n ect t h e lift ga t e wir e h a r n ess con n ect or
for t h e lift ga t e flip-u p gla ss la t ch m ot or fr om t h e
m ot or con n ect or r ecept a cle. Ch eck for con t in u it y
bet ween t h e gr ou n d cir cu it ca vit y of t h e lift ga t e wir e
h a r n ess con n ect or for t h e la t ch m ot or a n d a good
gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
8. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d
a s r equ ir ed.
(8) Wit h t h e lift ga t e la t ch u n locked a n d t h e flip-u p
gla ss r elea se swit ch depr essed, ch eck for ba t t er y volt -
a ge a t t h e lift ga t e flip-u p gla ss r elea se swit ch ou t pu t
cir cu it ca vit y of t h e lift ga t e wir e h a r n ess con n ect or
for t h e la t ch m ot or. If OK, r epla ce t h e fa u lt y lift ga t e
flip-u p gla ss la t ch u n it . If n ot OK, r epa ir t h e open
lift ga t e flip-u p gla ss r elea se swit ch ou t pu t cir cu it
bet ween t h e la t ch m ot or a n d t h e r elea se swit ch a s
r equ ir ed.
DOOR CY LI N DER LOCK
SWI T CH
DESCRIPTION
Th e dr iver cylin der lock swit ch is in t egr a l t o t h e
key lock cylin der in side t h e dr iver side fr on t door.
Th e dr iver cylin der lock swit ch is a r esist ive m u lt i-
plexed swit ch t h a t is h a r d wir ed bet ween a body
gr ou n d a n d t h e Dr iver Door Modu le (DDM) t h r ou gh
t h e fr on t door wir e h a r n ess. It m a in t a in s a pa t h t o
gr ou n d, a n d ch a n ges volt a ges t h r ou gh a n in t er n a l
r esist or wh en t h e lock cylin der is r ot a t ed t o t h e lock
or u n lock posit ion .
Th e dr iver cylin der lock swit ch ca n n ot be a dju st ed
or r epa ir ed a n d, if fa u lt y or da m a ged, t h e dr iver side
fr on t door lock cylin der u n it m u st be r epla ced. (Refer
t o 23 - BODY/DOOR - F RONT/LOCK CYLINDE R -
RE MOVAL) a n d (Refer t o 23 - BODY/DOOR -
F RONT/LOCK CYLINDE R - INSTALLATION). Refer
t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g
POWER LOCKS 8N - 7
in for m a t ion in clu des wir in g dia gr a m s, pr oper wir e
a n d con n ect or r epa ir pr ocedu r es, fu r t h er det a ils on
wir e h a r n ess r ou t in g a n d r et en t ion , a s well a s pin -
ou t a n d loca t ion views for t h e va r iou s wir e h a r n ess
con n ect or s, splices a n d gr ou n ds.
OPERATION
Th e dr iver cylin der lock swit ch is a ct u a t ed by t h e
key lock cylin der wh en t h e key is in ser t ed in t h e lock
cylin der a n d t u r n ed t o t h e u n lock posit ion . Th e
dr iver cylin der lock swit ch m a in t a in s a pa t h t o
gr ou n d a n d ch a n ges volt a ges t h r ou gh a n in t er n a l
r esist or for t h e DDM wh en t h e dr iver door key lock
cylin der is in t h e lock or u n lock posit ion . Th e DDM
r ea ds t h e swit ch st a t u s t h r ou gh a n in t er n a l pu ll-u p,
t h en sen ds t h e pr oper swit ch st a t u s m essa ges t o
ot h er elect r on ic m odu les over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
Th e dr iver cylin der lock swit ch u n lock st a t u s m es-
sa ge is u sed by t h e BCM a s a n in pu t for Veh icle
Th eft Secu r it y Syst em (VTSS) oper a t ion a n d in t er ior
ligh t in g.
POWER LOCK M OT OR
DESCRIPTION
P ower oper a t ed fr on t door, r ea r door, a n d lift ga t e
lockin g m ech a n ism s a r e st a n da r d equ ipm en t on t h is
m odel. Th e lock m ech a n ism s a r e a ct u a t ed by a
r ever sible elect r ic m ot or m ou n t ed wit h in ea ch door
a n d t h e lift ga t e. Th e power lock m ot or s for t h e door s
a r e in t egr a l t o t h e door la t ch u n it s. Th e lift ga t e
power lock m ot or is a sepa r a t e u n it secu r ed t o t h e
la t ch br a in pla t e n ea r t h e cen t er of t h e lift ga t e a n d
oper a t es t h e lift ga t e la t ch lock m ech a n ism t h r ou gh a
con n ect in g lin ka ge r od.
Th e power lock m ot or s for t h e fou r door s ca n n ot be
a dju st ed or r epa ir ed a n d, if fa u lt y or da m a ged, t h e
en t ir e door la t ch u n it m u st be r epla ced. Th e lift ga t e
power lock m ot or ca n n ot be a dju st ed or r epa ir ed a n d,
if fa u lt y or da m a ged, t h e en t ir e lift ga t e la t ch a ct u a -
t or (br a in pla t e) u n it m u st be r epla ced.
OPERATION
Th e dr iver side fr on t door power lock m ot or is con -
t r olled by t h e Dr iver Door Modu le (DDM). Th e
r em a in in g power door lock m ot or s a n d t h e lift ga t e
power lock m ot or a r e con t r olled by t h e P a ssen ger
Door Modu le (P DM). A posit ive a n d n ega t ive ba t t er y
con n ect ion t o t h e t wo m ot or t er m in a ls will ca u se t h e
power lock m ot or plu n ger t o m ove in on e dir ect ion .
Rever sin g t h e cu r r en t t h r ou gh t h ese sa m e t wo con -
n ect ion s will ca u se t h e power lock m ot or plu n ger t o
m ove in t h e opposit e dir ect ion .
8N - 8 POWER LOCKS
POWER LOCK M OT OR (Cont inue d)
DIAGNOSIS AND TESTING - POWER LOCK
MOTOR
Rem em ber, t h e Dr iver Door Modu le (DDM) cir-
cu it r y con t r ols t h e ou t pu t t o t h e dr iver side fr on t
door power lock m ot or. Th e P a ssen ger Door Modu le
(P DM) cir cu it r y con t r ols t h e ou t pu t t o t h e power lock
m ot or s for t h e r em a in in g door s a n d t h e lift ga t e.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir-
in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
(1) Ch eck ea ch power lock m ot or for cor r ect oper a -
t ion wh ile m ovin g t h e power lock swit ch t o bot h t h e
Lock a n d Un lock posit ion s. If a ll of t h e power lock
m ot or s a r e in oper a t ive, go t o St ep 2. If on e power
lock m ot or is in oper a t ive, go t o St ep 3.
(2) If a ll of t h e power lock m ot or s except t h e dr iver
side fr on t door a r e in oper a t ive, t h e pr oblem m a y be
ca u sed by on e sh or t ed m ot or. Discon n ect in g a sh or t ed
power lock m ot or fr om t h e power lock cir cu it will
a llow t h e good power lock m ot or s t o oper a t e. Discon -
n ect t h e wir e h a r n ess con n ect or fr om ea ch P DM-con -
t r olled power lock m ot or, on e a t a t im e, a n d r ech eck
bot h t h e lock a n d u n lock fu n ct ion s by oper a t in g t h e
power lock swit ch . If a ll of t h e P DM-con t r olled power
lock m ot or s a r e st ill in oper a t ive a ft er t h e a bove t est ,
ch eck for a sh or t or open cir cu it bet ween t h e power
lock m ot or s a n d t h e P DM. If discon n ect in g on e power
lock m ot or ca u ses t h e ot h er m ot or s t o becom e fu n c-
t ion a l, go t o St ep 3 t o t est t h e power lock m ot or t h a t
wa s la st discon n ect ed.
(3) On ce it is det er m in ed wh ich power lock m ot or
is in oper a t ive, t h a t m ot or ca n be t est ed a s follows.
Discon n ect t h e door or lift ga t e wir e h a r n ess con n ec-
t or fr om t h e in oper a t ive power lock m ot or. Apply 12
volt s t o t h e lock a n d u n lock dr iver cir cu it ca vit ies of
t h e power lock m ot or con n ect or t o ch eck it s oper a t ion
in on e dir ect ion . Rever se t h e pola r it y t o ch eck t h e
m ot or oper a t ion in t h e opposit e dir ect ion . If OK,
r epa ir t h e sh or t ed or open cir cu it s bet ween t h e lock
m ot or a n d t h e DDM or P DM a s r equ ir ed. If n ot OK,
r epla ce t h e fa u lt y power lock m ot or.
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POWER LOCK SWI T CH
DESCRIPTION
Th e power lock m ot or s a r e con t r olled by a t wo-wa y
m om en t a r y swit ch m ou n t ed on t h e t r im pa n el of ea ch
fr on t door. E a ch power lock swit ch is illu m in a t ed by
a Ligh t -E m it t in g Diode (LE D) t h a t is in t egr a l t o t h e
swit ch pa ddle.
Th e dr iver side fr on t door power lock swit ch is
in t egr a l t o t h e Dr iver Door Modu le (DDM), a n d t h e
pa ssen ger side fr on t door power lock swit ch is in t e-
gr a l t o t h e P a ssen ger Door Modu le (P DM). Th e
power lock swit ch es a n d t h eir la m ps ca n n ot be
a dju st ed or r epa ir ed a n d, if fa u lt y or da m a ged, t h e
en t ir e DDM or P DM u n it m u st be r epla ced. (Refer t o
8 - E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/DOOR MODULE - DE SCRIP TION).
OPERATION
Th e fr on t door power lock swit ch es pr ovide a lock
a n d u n lock sign a l t o t h e door m odu le cir cu it r y. Th e
Dr iver Door Modu le (DDM) cir cu it r y con t r ols t h e ou t -
pu t t o t h e dr iver side fr on t door power lock m ot or,
wh ile t h e P a ssen ger Door Modu le (P DM) cir cu it r y
con t r ols t h e ou t pu t t o t h e pa ssen ger side fr on t door,
bot h r ea r door a n d t h e lift ga t e power lock m ot or s.
Wh en t h e DDM-in t egr a t ed power lock swit ch is
a ct u a t ed, t h e DDM cir cu it r y sen ds con t r ol ou t pu t s t o
t h e dr iver side fr on t door power lock m ot or a n d sen ds
a m essa ge t o t h e P DM over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s t o con t r ol t h e
ou t pu t t o t h e pa ssen ger side fr on t door, bot h r ea r
door a n d t h e lift ga t e power lock m ot or s. Wh en t h e
P DM-in t egr a t ed power lock swit ch is a ct u a t ed, t h e
P DM cir cu it r y sen ds con t r ol ou t pu t s t o t h e pa ssen ger
side fr on t door, bot h r ea r door a n d t h e lift ga t e power
lock m ot or s a n d sen ds a m essa ge t o t h e DDM over
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s t o con t r ol t h e ou t pu t t o t h e dr iver side fr on t
door power lock m ot or.
E a ch power lock swit ch is illu m in a t ed by a Ligh t -
E m it t in g Diode (LE D) wh en t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion . See t h e own er ’s m a n u a l in
t h e veh icle glove box for m or e in for m a t ion on t h e fea -
t u r es, u se a n d oper a t ion of t h e power lock swit ch es.
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REM OT E K EY LESS EN T RY
M ODU LE
DESCRIPTION
Th e Rem ot e Keyless E n t r y (RKE ) r eceiver is a
r a dio fr equ en cy u n it con t a in ed wit h in t h e P a ssen ger
Door Modu le (P DM). Th e P DM a lso con t a in s t h e pr o-
gr a m logic cir cu it r y for t h e RKE syst em . Th e P DM is
secu r ed wit h scr ews t o t h e ba ck of t h e t r im pa n el
in side t h e pa ssen ger side fr on t door. Th e RKE
r eceiver h a s a m em or y fu n ct ion t o r et a in t h e veh icle
a ccess codes of u p t o fou r RKE t r a n sm it t er s. Th e
r eceiver is design ed t o r et a in t h e t r a n sm it t er codes in
m em or y, even if t h e ba t t er y is discon n ect ed.
F or dia gn osis of t h e RKE r eceiver, t h e P DM, or t h e
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s a DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia gn os-
t ic in for m a t ion a r e r equ ir ed. Th e RKE r eceiver is
on ly ser viced a s a u n it wit h t h e P DM a n d, if fa u lt y
or da m a ged, t h e en t ir e P DM u n it m u st be r epla ced.
(Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
TROL MODULE S/DOOR MODULE - DE SCRIP -
TION).
OPERATION
Th e RKE r eceiver is en er gized by on e of t h r ee m es-
sa ges fr om t h e RKE t r a n sm it t er : Un lock, Lock, or
P a n ic. Th e P DM cir cu it r y r espon ds t o t h ese m essa ges
t o lock or u n lock t h e power lock m ot or s t h a t it con -
t r ols. Th e P DM cir cu it r y a lso sen ds Lock, Un lock,
a n d P a n ic m essa ges t o ot h er elect r on ic m odu les over
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s. Th ese m essa ges will r esu lt in t h e Dr iver
Door Modu le (DDM) lockin g or u n lockin g t h e dr iver
side fr on t door, a n d t h e ot h er elect r on ic m odu les in
t h e veh icle r espon din g a s t h eir pr ogr a m m in g dic-
t a t es.
REM OT E K EY LESS EN T RY
T RAN SM I T T ER
DESCRIPTION
Th e Rem ot e Keyless E n t r y (RKE ) syst em Ra dio
F r equ en cy (RF ) t r a n sm it t er is equ ipped wit h t h r ee
bu t t on s, la beled Lock, Un lock, a n d P a n ic. It is a lso
equ ipped wit h a key r in g a n d is design ed t o ser ve a s
a key fob. Th e oper a t in g r a n ge of t h e t r a n sm it t er
r a dio sign a l is u p t o 10 m et er s (30 feet ) fr om t h e
RKE r eceiver.
E a ch RKE t r a n sm it t er h a s a differ en t veh icle
a ccess code, wh ich m u st be pr ogr a m m ed in t o t h e
m em or y of t h e RKE r eceiver in t h e veh icle in or der
t o oper a t e t h e RKE syst em . Two t r a n sm it t er s a r e
pr ovided wit h t h e veh icle, bu t t h e RKE r eceiver ca n
POWER LOCKS 8N - 9
r et a in t h e a ccess codes of u p t o fou r t r a n sm it t er s in
it s m em or y. (Refer t o 8 - E LE CTRICAL/P OWE R
LOCKS/RE MOTE KE YLE SS E NTRY TRANSMIT-
TE R - STANDARD P ROCE DURE - RKE TRANS-
MITTE R P ROGRAMMING).
In a ddit ion , t h e RKE t r a n sm it t er s for veh icles
equ ipped wit h t h e opt ion a l Mem or y Syst em a r e color-
coded a n d h a ve a n u m ber “1” or “2” m olded in t o t h e
t r a n sm it t er ca se t o coin cide wit h t h e “Dr iver 1
(Bla ck)” a n d “Dr iver 2 (Gr a y)” bu t t on s of t h e m em or y
swit ch on t h e dr iver side fr on t door t r im pa n el. Th ese
t r a n sm it t er s m u st a lso h a ve t h eir a ccess codes pr o-
gr a m m ed in t o t h e RKE r eceiver so t h a t t h ey coin cide
wit h t h e “Dr iver 1” a n d “Dr iver 2” bu t t on s of t h e
m em or y swit ch . (Refer t o 8 - E LE CTRICAL/P OWE R
SE ATS - DE SCRIP TION - ME MORY SYSTE M).
Th e RKE t r a n sm it t er oper a t es on t wo P a n a son ic
CR2016 (or equ iva len t ) ba t t er ies. Typica l ba t t er y life
is fr om on e t o t wo yea r s. Th e RKE t r a n sm it t er ca n -
n ot be r epa ir ed a n d, if fa u lt y or da m a ged, it m u st be
r epla ced.
OPERATION
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er s.
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY TRANSMITTER
(1) Repla ce t h e Rem ot e Keyless E n t r y (RKE )
t r a n sm it t er ba t t er ies. (Refer t o 8 - E LE CTRICAL/
P OWE R LOCKS/RE MOTE KE YLE SS E NTRY
TRANSMITTE R - STANDARD P ROCE DURE - RKE
TRANSMITTE R BATTE RIE S). Test ea ch of t h e RKE
t r a n sm it t er fu n ct ion s. If OK, disca r d t h e fa u lt y ba t -
t er ies. If n ot OK, go t o St ep 2.
(2) P r ogr a m t h e su spect RKE t r a n sm it t er a n d
a n ot h er kn own good t r a n sm it t er in t o t h e RKE
r eceiver. Use a DRBIII! sca n t ool, a s descr ibed in t h e
a ppr opr ia t e dia gn ost ic in for m a t ion . (Refer t o 8 -
E LE CTRICAL/P OWE R LOCKS/RE MOTE KE YLE SS
E NTRY TRANSMITTE R - STANDARD P ROCE -
DURE - RKE TRANSMITTE R P ROGRAMMING).
(3) Test t h e RKE syst em oper a t ion wit h bot h
t r a n sm it t er s. If bot h t r a n sm it t er s fa il t o oper a t e t h e
power lock syst em , u se a DRBIII! sca n t ool a n d t h e
a ppr opr ia t e dia gn ost ic in for m a t ion for fu r t h er dia g-
n osis of t h e RKE syst em . If t h e kn own good RKE
t r a n sm it t er oper a t es t h e power locks a n d t h e su spect
t r a n sm it t er does n ot , r epla ce t h e fa u lt y RKE t r a n s-
m it t er.
NOTE: Be certain to perform the RKE Transmitter
Programming procedure again following this test.
This procedure will erase the access code of the
test transmitter from the RKE receiver.
8N - 10 POWER LOCKS
REM OT E K EY LESS EN T RY T RAN SM I T T ER (Cont inue d)
STAN DARD PROCEDU RE
STANDARD PROCEDURE - RKE TRANSMITTER
PROGRAMMING
To pr ogr a m t h e Rem ot e Keyless E n t r y (RKE )
t r a n sm it t er a ccess codes in t o t h e RKE r eceiver in t h e
P a ssen ger Door Modu le (P DM) r equ ir es t h e u se of a
DRBIII! sca n t ool. Refer t o t h e a ppr opr ia t e dia gn os-
t ic in for m a t ion .
STANDARD PROCEDURE - RKE TRANSMITTER
BATTERIES
Th e Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er ca se
sn a ps open a n d sh u t for ba t t er y a ccess. To r epla ce
t h e RKE t r a n sm it t er ba t t er ies:
(1) Usin g a t r im st ick or a t h in coin , gen t ly pr y a t
t h e n ot ch in t h e cen t er sea m of t h e RKE t r a n sm it t er
ca se h a lves n ea r t h e key r in g u n t il t h e t wo h a lves
u n sn a p.
(2) Lift t h e ba ck h a lf of t h e t r a n sm it t er ca se off of
t h e RKE t r a n sm it t er.
(3) Rem ove t h e t wo ba t t er ies fr om t h e RKE t r a n s-
m it t er.
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(4) Repla ce t h e t wo ba t t er ies wit h n ew P a n a son ic
CR2016, or t h eir equ iva len t . Be cer t a in t h a t t h e ba t -
t er ies a r e in st a lled wit h t h eir pola r it y cor r ect ly or i-
en t ed.
(5) Align t h e t wo RKE t r a n sm it t er ca se h a lves
wit h ea ch ot h er, a n d squ eeze t h em fir m ly a n d even ly
t oget h er u n t il t h ey sn a p ba ck in t o pla ce.
NOTE: The RKE system for this model uses a roll-
ing code security strategy. This strategy requires
that synchronization be maintained between the
RKE transmitter and the RKE receiver. RKE trans-
mitter battery removal or replacement can cause a
loss of synchronization. If the RKE receiver fails to
respond to the RKE transmitter following battery
removal or replacement, depress and release the
RKE transmitter Unlock button repeatedly while lis-
tening carefully for the power door locks in the
vehicle to cycle. After between five and eight
presses of the Unlock button, the power door locks
should cycle, indicating that re-synchronization has
occurred.
WJ POWER MIRRORS 8N - 11

POWER M I RRORS

TABLE OF CONTENTS
page page

POWER MIRRORS POWER FOLD-AWAY MIRROR - EXPORT

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - POWER DIAGNOSIS AND TESTING - POWER
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FOLD-AWAY MIRROR - EXPORT . . . . . . . . . . 14
AUTOMATIC DAY/NIGHT MIRROR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION POWER MIRROR SWITCH
DESCRIPTION - REAR VIEW MIRROR . . . . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION - OUTSIDE REAR VIEW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SIDEVIEW MIRROR
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION - REAR VIEW MIRROR . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION - OUTSIDE REAR VIEW DIAGNOSIS AND TESTING - SIDEVIEW
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - AUTOMATIC DAY
/ NIGHT MIRROR . . . . . . . . . . . . . . . . . . . . . . 13

POWER M I RRORS fa ct or y-in st a lled equ ipm en t on t h is m odel. (Refer t o 8

- E LE CTRICAL/P OWE R MIRRORS/AUTOMATIC
DAY / NIGH T MIRROR - DE SCRIP TION) for m or e
DESCRIPTION
in for m a t ion . (Refer t o 8 - E LE CTRICAL/P OWE R
Dr iver a n d pa ssen ger side power oper a t ed ou t side
SE ATS - DE SCRIP TION) for m or e in for m a t ion .
r ea r view m ir r or s a r e st a n da r d fa ct or y-in st a lled
Th is gr ou p cover s t h e followin g com pon en t s of t h e
equ ipm en t on t h is m odel. Th e power m ir r or syst em
power m ir r or syst em :
a llows t h e dr iver t o a dju st bot h ou t side m ir r or s elec-
• P ower m ir r or s
t r ica lly fr om t h e dr iver sea t posit ion by oper a t in g a
• P ower m ir r or swit ch .
swit ch on t h e dr iver side fr on t door t r im pa n el. Th e
Cer t a in fu n ct ion s a n d fea t u r es of t h e power m ir r or
power m ir r or syst em r eceives n on -swit ch ed ba t t er y
syst em r ely u pon r esou r ces sh a r ed wit h ot h er elec-
cu r r en t t h r ou gh a fu se in t h e P ower Dist r ibu t ion
t r on ic m odu les in t h e veh icle over t h e P r ogr a m m a ble
Cen t er (P DC) so t h a t t h e power m ir r or s r em a in oper-
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
a t ion a l, r ega r dless of t h e ign it ion swit ch posit ion .
Th e P CI da t a bu s n et wor k a llows t h e sh a r in g of sen -
Th e st a n da r d equ ipm en t power oper a t ed ou t side
sor in for m a t ion . Th is h elps t o r edu ce wir e h a r n ess
r ea r view m ir r or s a r e a lso equ ipped wit h t h e h ea t ed
com plexit y, in t er n a l con t r oller h a r dwa r e, a n d com po-
m ir r or syst em , wh ich will on ly oper a t e wh en t h e
n en t sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is sys-
ign it ion swit ch is in t h e On posit ion a n d t h e r ea r
t em pr ovides in cr ea sed r elia bilit y, en h a n ced
win dow defogger swit ch is t u r n ed on . Wh en t h e r ea r
dia gn ost ics, a n d a llows t h e a ddit ion of m a n y n ew fea -
win dow defogger swit ch is in t h e On posit ion , elect r ic
t u r e ca pa bilit ies. F or dia gn osis of t h ese elect r on ic
h ea t er gr ids on t h e r ea r win dow gla ss a n d beh in d
m odu les or of t h e P CI da t a bu s n et wor k, t h e u se of a
bot h ou t side r ea r view m ir r or gla sses a r e en er gized.
DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es
Th ese elect r ic h ea t er gr ids pr odu ce h ea t t o h elp clea r
m a n u a l a r e r ecom m en ded.
t h e r ea r win dow gla ss a n d ou t side r ea r view m ir r or s
Th e ot h er elect r on ic m odu les t h a t m a y a ffect power
of ice, sn ow, or fog. (Refer t o 8 - E LE CTRICAL/
m ir r or syst em oper a t ion a r e a s follows:
H E ATE D MIRRORS - DE SCRIP TION) for m or e
• B o d y Co n tro l Mo d u le (B CM) (Refer t o 8 -
in for m a t ion on t h is fea t u r e.
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
A dr iver side a u t om a t ic dim m in g ou t side m ir r or
ULE S/BODY CONTROL/CE NTRAL TIME R MODUL
t h a t dim s t h e m ir r or t o r edu ce t h e gla r e of br igh t
- DE SCRIP TION) for m or e in for m a t ion .
ligh t s a ppr oa ch in g t h e veh icle fr om beh in d, a n d a
• D riv e r D o o r Mo d u le (D D M) (Refer t o 8 -
m em or y syst em t h a t a u t om a t ica lly posit ion s t h e
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
power m ir r or s for t wo differ en t dr iver s a r e opt ion a l
8N - 12 POWER MIRRORS
POWER M I RRORS (Cont inue d)
ULE S/DRIVE R DOOR MODULE - DE SCRIP TION)
for m or e in for m a t ion .
• P a s s e n g e r D o o r Mo d u le (P D M)(Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/DRIVE R DOOR MODULE - DE SCRIP TION)
for m or e in for m a t ion .
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
OPERATION
Th e Dr iver Door Modu le (DDM) a n d t h e P a ssen ger
Door Modu le (P DM) ea ch con t a in t h e power m ir r or
con t r ol logic for t h e m ir r or on it s r espect ive door. Th e
DDM a lso h ou ses t h e power m ir r or swit ch . E a ch door
m odu le con t r ols t h e posit ion in g of it s r espect ive ou t -
side m ir r or t h r ou gh h a r d wir ed ou t pu t s t o t h a t m ir-
r or. Wh en t h e power m ir r or swit ch on t h e DDM is
u sed t o posit ion t h e pa ssen ger side ou t side m ir r or,
t h e DDM sen ds m ir r or posit ion in g m essa ges t o t h e
P DM over t h e P r ogr a m m a ble Com m u n ica t ion s In t er-
fa ce (P CI) da t a bu s. Th e P DM r espon ds t o t h ese m es-
sa ges by sen din g con t r ol ou t pu t s t o m ove t h e
pa ssen ger side m ir r or a ccor din gly.
Bot h t h e P DM a n d DDM r espon d t o t h e defogger
swit ch st a t u s m essa ges sen t by t h e Body Con t r ol
Modu le (BCM) over t h e P CI da t a bu s t o con t r ol t h e
elect r ic h ea t er gr ids of t h eir r espect ive m ir r or s.
(Refer t o 8 - E LE CTRICAL/H E ATE D MIRRORS -
DE SCRIP TION) for m or e in for m a t ion on t h is fea -
t u r e.
On m odels equ ipped wit h t h e opt ion a l m em or y sys-
t em , ea ch door m odu le a lso r eceives a h a r d wir ed
in pu t fr om t h e t wo power m ir r or m ot or posit ion
pot en t iom et er s t h a t a r e in t egr a l t o ea ch power m ir-
r or. E a ch door m odu le t h en st or es t h e Dr iver 1 a n d
Dr iver 2 m ir r or posit ion in for m a t ion for it s r espect ive
m ir r or. Wh en t h e DDM r eceives a Dr iver 1 or Dr iver
2 m em or y r eca ll m essa ge fr om t h e m em or y swit ch on
t h e dr iver side fr on t door t r im pa n el or fr om t h e
Rem ot e Keyless E n t r y (RKE ) r eceiver in t h e P DM,
t h e DDM posit ion s t h e dr iver side m ir r or a n d sen ds
a m em or y r eca ll m essa ge ba ck t o t h e P DM over t h e
P CI da t a bu s t o posit ion t h e pa ssen ger side m ir r or.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e power m ir r or syst em .
DIAGNOSIS AND TESTING - POWER MIRRORS
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
h a r d wir ed com pon en t s a n d cir cu it s of t h e power m ir-
r or syst em . H owever, t h ese t est s m a y n ot pr ove con -
clu sive in t h e dia gn osis of t h is syst em . In or der t o
WJ
obt a in con clu sive t est in g of t h e power m ir r or syst em ,
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
da t a bu s n et wor k a n d a ll of t h e elect r on ic m odu les
t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om t h e
power m ir r or syst em com pon en t s m u st be ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e power m ir r or syst em r equ ir es t h e u se of
a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
du r es m a n u a l. Th e DRB sca n t ool ca n pr ovide con fir-
m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t a ll
of t h e elect r on ic m odu les a r e sen din g a n d r eceivin g
t h e pr oper m essa ges on t h e P CI da t a bu s, t h a t t h e
power m ir r or m ot or s a r e bein g sen t t h e pr oper h a r d
wir ed ou t pu t s, a n d t h a t t h e m ir r or posit ion pot en t i-
om et er s a r e r et u r n in g t h e pr oper ou t pu t s t o t h e door
m odu les for t h em t o per for m t h eir power m ir r or sys-
t em fu n ct ion s.
AU T OM AT I C DAY /N I GH T
M I RROR
DESCRI PT I ON
DESCRIPTION - REAR VIEW MIRROR
An a u t om a t ic da y/n igh t m ir r or syst em is a n a va il-
a ble fa ct or y-in st a lled opt ion on t h is m odel. Th e a u t o-
m a t ic dim m in g in side da y/n igh t r ea r view m ir r or
syst em is a com plet ely self-con t a in ed u n it t h a t
r epla ces t h e st a n da r d equ ipm en t in side r ea r view
m ir r or. Th is syst em will a u t om a t ica lly ch a n ge t h e
r eflect a n ce of t h e in side r ea r view m ir r or t o pr ot ect
t h e dr iver fr om t h e u n wa n t ed h ea dligh t gla r e of
t r a ilin g veh icles wh ile dr ivin g a t n igh t . Th e a u t o-
m a t ic da y/n igh t in side m ir r or r eceives ign it ion
swit ch ed ba t t er y cu r r en t t h r ou gh a fu se in t h e ju n c-
t ion block, a n d will on ly oper a t e wh en t h e ign it ion
swit ch is in t h e On posit ion .
Veh icles equ ipped wit h t h e a u t om a t ic da y/n igh t
m ir r or syst em a r e a lso a va ila ble wit h a n opt ion a l fa c-
t or y-in st a lled a u t om a t ic dim m in g ou t side r ea r view
m ir r or for t h e dr iver side of t h e veh icle. (Refer t o 8 -
E LE CTRICAL/P OWE R MIRRORS/SIDE VIE W MIR-
ROR - DE SCRIP TION) for m or e in for m a t ion on t h is
opt ion .
Th e a u t om a t ic da y/n igh t m ir r or sen sit ivit y ca n n ot
be r epa ir ed or a dju st ed. If a n y com pon en t of t h is u n it
is fa u lt y or da m a ged, t h e en t ir e a u t om a t ic da y/n igh t
in side r ea r view m ir r or u n it m u st be r epla ced. Refer
t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g
in for m a t ion in clu des wir in g dia gr a m s, pr oper wir e
a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r-
n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t in for-
m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
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AU T OM AT I C DAY /N I GH T M I RROR (Cont inue d)
DESCRIPTION - OUTSIDE REAR VIEW MIRROR
An a u t om a t ic dim m in g ou t side r ea r view m ir r or is
a n a va ila ble fa ct or y-in st a lled opt ion for t h e dr iver
side of t h e veh icle, if t h e veh icle is a lso equ ipped
wit h t h e a u t om a t ic da y/n igh t in side r ea r view m ir r or.
Th e a u t om a t ic dim m in g ou t side m ir r or is com plet ely
con t r olled by t h e cir cu it r y of t h e a u t om a t ic da y/n igh t
in side r ea r view m ir r or. Th e a u t om a t ic dim m in g ou t -
side m ir r or will a u t om a t ica lly ch a n ge t h e r eflect a n ce
of t h e dr iver side ou t side r ea r view m ir r or t o pr ot ect
t h e dr iver fr om t h e u n wa n t ed h ea dligh t gla r e of
t r a ilin g veh icles wh ile dr ivin g a t n igh t . Th e a u t o-
m a t ic dim m in g ou t side m ir r or will on ly oper a t e wh en
t h e ign it ion swit ch is in t h e On posit ion .
Th e a u t om a t ic dim m in g ou t side m ir r or sen sit ivit y
ca n n ot be r epa ir ed or a dju st ed. If a n y com pon en t of
t h is u n it is fa u lt y or da m a ged, t h e en t ir e a u t om a t ic
dim m in g ou t side m ir r or u n it m u st be r epla ced. (Refer
t o 8 - E LE CTRICAL/P OWE R MIRRORS/SIDE VIE W
MIRROR - DIAGNOSIS AND TE STING). Refer t o
t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for-
m a t ion in clu des wir in g dia gr a m s, pr oper wir e a n d
con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
n ect or s, splices a n d gr ou n ds.
OPERAT I ON
OPERATION - REAR VIEW MIRROR
Th e a u t om a t ic da y/n igh t m ir r or swit ch a llows t h e
dr iver a m a n u a l con t r ol of wh et h er t h e a u t om a t ic
dim m in g fea t u r e is oper a t ion a l. Th is swit ch is a
m om en t a r y r ocker-t ype swit ch loca t ed on t h e lower
r ea r-fa cin g su r fa ce of t h e m ir r or h ou sin g. Wh en Au t o
is select ed, a Ligh t -E m it t in g Diode (LE D) on t h e m ir-
r or h ou sin g ju st t o t h e r igh t of t h e swit ch illu m in a t es
t o in dica t e t h a t a u t om a t ic da y/n igh t m ir r or is t u r n ed
on . Wh en Off is select ed, t h e LE D is t u r n ed off. Th e
m ir r or a lso sen ses t h e ba cku p la m p cir cu it , a n d will
a u t om a t ica lly disa ble it s self-dim m in g fea t u r e wh en -
ever t h e t r a n sm ission gea r select or is in t h e Rever se
posit ion .
A t h in la yer of elect r och r om a t ic m a t er ia l bet ween
t wo pieces of con du ct ive gla ss m a ke u p t h e fa ce of
t h e m ir r or. Two ph ot ocell sen sor s a r e u sed t o m on it or
ligh t levels a n d a dju st t h e r eflect a n ce of t h e m ir r or.
Th e a m bien t ph ot ocell sen sor fa ces for wa r d, t o det ect
t h e ou t side ligh t levels. Th e h ea dla m p sen sor is
loca t ed on t h e m ir r or h ou sin g ju st t o t h e left of t h e
swit ch a n d fa cin g r ea r wa r d, t o det ect t h e ligh t level
r eceived a t t h e r ea r win dow side of t h e m ir r or. Wh en
t h e differ en ce bet ween t h e t wo ligh t levels becom es
t oo gr ea t (t h e ligh t level r eceived a t t h e r ea r of t h e
POWER MIRRORS 8N - 13
m ir r or is m u ch h igh er t h a n t h a t a t t h e fr on t of t h e
m ir r or ), t h e m ir r or begin s t o da r ken .
On m odels wit h a n opt ion a l dr iver side a u t om a t ic
dim m in g ou t side m ir r or, t h e sign a l t o con t r ol t h e
dim m in g of t h a t m ir r or is gen er a t ed by t h e a u t o-
m a t ic da y/n igh t in side r ea r view m ir r or cir cu it r y.
Th a t sign a l is t h en deliver ed t o t h e dr iver side ou t -
side r ea r view m ir r or on a h a r d wir ed cir cu it .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e a u t om a t ic da y/n igh t m ir r or syst em .
OPERATION - OUTSIDE REAR VIEW MIRROR
Th e a u t om a t ic dim m in g ou t side m ir r or is oper a t ed
by t h e sa m e con t r ols a n d cir cu it r y a s t h e a u t om a t ic
da y/n igh t m ir r or. Wh en t h e a u t om a t ic da y/n igh t m ir-
r or is t u r n ed on or off, t h e a u t om a t ic dim m in g ou t -
side m ir r or is likewise t u r n ed on or off. Like in t h e
a u t om a t ic da y/n igh t m ir r or, a t h in la yer of elect r o-
ch r om a t ic m a t er ia l bet ween t wo pieces of con du ct ive
gla ss m a ke u p t h e fa ce of t h e a u t om a t ic dim m in g
ou t side m ir r or. H owever, t h e sign a l t o con t r ol t h e
dim m in g of t h e ou t side m ir r or is gen er a t ed by t h e
a u t om a t ic da y/n igh t in side r ea r view m ir r or cir cu it r y.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e a u t om a t ic dim m in g ou t side m ir r or.
DIAGNOSIS AND TESTING - AUTOMATIC DAY /
NIGHT MIRROR
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
(1) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n /
st a r t ) fu se in t h e ju n ct ion block. If OK, go t o St ep 2.
If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n /st a r t ) fu se in t h e ju n ct ion block. If OK,
go t o St ep 3. If n ot OK, r epa ir t h e open fu sed ign it ion
swit ch ou t pu t (r u n /st a r t ) cir cu it t o t h e ign it ion swit ch
a s r equ ir ed.
(3) Discon n ect t h e over h ea d wir e h a r n ess con n ec-
t or fr om t h e a u t om a t ic da y/n igh t m ir r or con n ect or
r ecept a cle. Ch eck for ba t t er y volt a ge a t t h e fu sed
ign it ion swit ch ou t pu t (r u n /st a r t ) cir cu it ca vit y of t h e
over h ea d wir e h a r n ess con n ect or for t h e a u t om a t ic
da y/n igh t m ir r or. If OK, go t o St ep 4. If n ot OK,
r epa ir t h e open fu sed ign it ion swit ch ou t pu t (r u n /
st a r t ) cir cu it t o t h e fu se in t h e ju n ct ion block a s
r equ ir ed.
8N - 14 POWER MIRRORS
AU T OM AT I C DAY /N I GH T M I RROR (Cont inue d)
(4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
it y of t h e over h ea d wir e h a r n ess con n ect or for t h e
a u t om a t ic da y/n igh t m ir r or a n d a good gr ou n d. Th er e
sh ou ld be con t in u it y. If OK, go t o St ep 5. If n ot OK,
r epa ir t h e open gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(5) Tu r n t h e ign it ion swit ch t o t h e On posit ion . Set
t h e pa r kin g br a ke. P la ce t h e t r a n sm ission gea r selec-
t or lever in t h e Rever se posit ion . Ch eck for ba t t er y
volt a ge a t t h e ba cku p la m p swit ch ou t pu t cir cu it ca v-
it y of t h e over h ea d wir e h a r n ess con n ect or for t h e
a u t om a t ic da y/n igh t m ir r or. If OK, r econ n ect t h e
over h ea d wir e h a r n ess con n ect or t o t h e a u t om a t ic
da y/n igh t m ir r or con n ect or r ecept a cle a n d go t o St ep
6. If n ot OK, r epa ir t h e open ba cku p la m p swit ch
ou t pu t cir cu it a s r equ ir ed.
(6) P la ce t h e t r a n sm ission gea r select or lever in
t h e Neu t r a l posit ion . P la ce t h e a u t om a t ic da y/n igh t
m ir r or swit ch in t h e Au t o (LE D n ext t o t h e swit ch is
ligh t ed) posit ion (F ig. 1). Cover t h e for wa r d fa cin g
a m bien t ph ot ocell sen sor t o keep ou t a n y a m bien t
ligh t .
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
Fig. 1 Automatic Day/Night Mirror
1 - LED INDICATOR
2 - SWITCH
3 - HEADLAMP SENSOR
(7) Sh in e a ligh t in t o t h e r ea r wa r d fa cin g h ea d-
la m p ph ot ocell sen sor. Th e a u t om a t ic da y/n igh t m ir-
r or sh ou ld da r ken . If OK, go t o St ep 8. If n ot OK,
r epla ce t h e fa u lt y a u t om a t ic da y/n igh t m ir r or u n it .
(8) Wit h t h e m ir r or da r ken ed, pla ce t h e t r a n sm is-
sion gea r select or lever in t h e Rever se posit ion . Th e
a u t om a t ic da y/n igh t m ir r or sh ou ld r et u r n t o it s n or-
m a l r eflect a n ce. If n ot OK, r epla ce t h e fa u lt y a u t o-
m a t ic da y/n igh t m ir r or u n it .
WJ
POWER FOLD-AWAY M I RROR -
EX PORT
DESCRIPTION
Som e veh icles a r e equ ipped wit h P ower F old-Awa y
Side View Mir r or s. Th is fea t u r e a llows bot h t h e
dr iver a n d pa ssen ger side view m ir r or s t o fold
in wa r d (r et r a ct ) on dem a n d. Th is fea t u r e is con -
t r olled by a n a ddit ion a l swit ch loca t ed on t h e power
m ir r or swit ch .
Th e fold-a wa y side view m ir r or is a t t a ch ed t o t h e
veh icle’s door in t h e sa m e m a n n er a s m ir r or s wit h ou t
t h e fold-a wa y opt ion . Th e fold-a wa y m ir r or s u n iqu e
opt ion is t h e in t er n a l m ot or wh ich a llows t h e m ir r or s
t o fold in wa r d on dem a n d. t h e fold-a wa y m ir r or
m ot or is n ot ser vicea ble sepa r a t ely, a n d if a m ot or is
fou n d t o be fa u lt y t h e en t ir e side view m ir r or m u st
be r epla ced.
OPERATION
Wh en t h e m ir r or r et r a ct swit ch is depr essed, bot h
of t h e side view m ir r or s will fold in wa r d, t h u s m a k-
in g t h e over a ll widt h of t h e veh icle t h e sm a llest pos-
sible. Th is ca n be ver y h elpfu l wh er e pa r kin g spa ce is
a n a bsolu t e m in im u m .
DIAGNOSIS AND TESTING - POWER
FOLD-AWAY MIRROR - EXPORT
Th e m ost r elia ble, efficien t a n d a ccu r a t e m ea n s t o
dia gn ose t h e power m ir r or syst em r equ ir es t h e u se of
a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
du r es m a n u a l. Th e DRB sca n t ool ca n pr ovide con fir-
m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t a ll
of t h e elect r on ic m odu les a r e sen din g a n d r eceivin g
t h e pr oper m essa ges on t h e P CI da t a bu s, t h a t t h e
power m ir r or m ot or s a r e bein g sen t t h e pr oper h a r d
wir ed ou t pu t s, a n d t h a t t h e m ir r or posit ion pot en t i-
om et er s a r e r et u r n in g t h e pr oper ou t pu t s t o t h e door
m odu les for t h em t o per for m t h eir power m ir r or sys-
t em fu n ct ion s.
REMOVAL
Th e fold-a wa y m ir r or m ot or is n ot ser vicea ble sep-
a r a t ely, a n d if a m ot or is fou n d t o be fa u lt y t h e en t ir e
side view m ir r or m u st be r epla ced. (Refer t o 8 -
E LE CTRICAL/P OWE R MIRRORS/SIDE VIE W MIR-
ROR - RE MOVAL).
WJ POWER MIRRORS 8N - 15

POWER M I RROR SWI T CH MATIC DAY / NIGH T MIRROR - DE SCRIP TION) for
m or e in for m a t ion on t h is fea t u r e.
Th e power m ir r or u n it ca n n ot be r epa ir ed. On ly
DESCRIPTION
t h e m ir r or gla ss a n d gla ss ca se a r e ser viced sepa -
Bot h t h e r igh t a n d left power ou t side m ir r or s a r e
r a t ely. Th e r epla cem en t m ir r or gla ss is su pplied wit h
con t r olled by a sin gle m u lt i-fu n ct ion swit ch u n it
a n in st r u ct ion sh eet t h a t det a ils t h e r ecom m en ded
loca t ed on t h e dr iver side fr on t door t r im pa n el. Th e
r epla cem en t pr ocedu r e. If a n y ot h er com pon en t of t h e
power m ir r or swit ch u n it in clu des a t h r ee-posit ion
power m ir r or u n it is fa u lt y or da m a ged, t h e en t ir e
r ocker select or swit ch a n d fou r m om en t a r y dir ec-
power m ir r or u n it m u st be r epla ced.
t ion a l pu sh bu t t on swit ch es.
Th e power m ir r or swit ch u n it is in t egr a l t o t h e
Dr iver Door Modu le (DDM). Th e power m ir r or swit ch
OPERATION
E a ch of t h e t wo ou t side power m ir r or s in clu des t wo
ca n n ot be r epa ir ed or a dju st ed a n d, if fa u lt y or da m -
r ever sible elect r ic m ot or s t h a t a r e secu r ed wit h in t h e
a ged, t h e en t ir e DDM u n it m u st be r epla ced. (Refer
power m ir r or h ou sin g. E a ch m ot or m oves t h e m ir r or
t o 8 - E LE CTRICAL/E LE CTRONIC CONTROL
ca se a n d gla ss t h r ou gh a n in t egr a l dr ive u n it . Wh en
MODULE S/DRIVE R DOOR MODULE - RE MOVAL)
a power m ir r or m ot or is su pplied wit h ba t t er y cu r-
for t h e DDM ser vice pr ocedu r es.
r en t a n d gr ou n d, it m oves t h e m ir r or ca se a n d gla ss
t h r ou gh it s dr ive u n it in on e dir ect ion . Wh en t h e ba t -
OPERATION
t er y cu r r en t a n d gr ou n d feeds t o t h e m ot or a r e
Th e power m ir r or select or swit ch is m oved r igh t
r ever sed, it m oves t h e m ir r or ca se a n d gla ss in t h e
(r igh t m ir r or con t r ol), left (left m ir r or con t r ol), or
opposit e dir ect ion .
cen t er t o t u r n t h e power ou t side m ir r or syst em off.
Th e power m ir r or s a r e equ ipped wit h a st a n da r d
Wh en t h e select or swit ch is in t h e r igh t m ir r or con -
equ ipm en t elect r ic h ea t in g gr id t h a t is a pplied t o t h e
t r ol or left m ir r or con t r ol posit ion , on e of t h e fou r
ba ck of ea ch ou t side r ea r view m ir r or gla ss. Wh en a n
dir ect ion a l con t r ol bu t t on s is depr essed t o con t r ol
elect r ica l cu r r en t is pa ssed t h r ou gh t h e r esist or wir e
m ovem en t of t h e select ed m ir r or u p, down , r igh t , or
of t h e h ea t in g gr id, it wa r m s t h e m ir r or gla ss. (Refer
left . Wh en t h e select or swit ch is in t h e Off posit ion ,
t o 8 - E LE CTRICAL/H E ATE D MIRRORS -
depr essin g a n y of t h e dir ect ion a l swit ch es will n ot
DE SCRIP TION) for m or e in for m a t ion on t h e oper a -
ch a n ge eit h er m ir r or posit ion .
t ion of t h e h ea t ed m ir r or s a n d t h e r ea r win dow
See t h e own er ’s m a n u a l in t h e veh icle glove box for
defogger syst em .
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
If t h e dr iver side m ir r or is equ ipped wit h t h e a u t o-
of t h e power m ir r or swit ch es.
m a t ic dim m in g ou t side m ir r or opt ion , t wo ph ot ocell
sen sor s on t h e in side r ea r view m ir r or a r e u sed t o
SI DEV I EW M I RROR m on it or ligh t levels a n d a dju st t h e r eflect a n ce of bot h
t h e in side a n d dr iver side ou t side m ir r or s. Th is
ch a n ge in r eflect a n ce h elps t o r edu ce t h e gla r e of
DESCRIPTION
h ea dla m ps a ppr oa ch in g t h e veh icle fr om t h e r ea r.
Mech a n ica lly foldin g, power oper a t ed ou t side r ea r
(Refer t o 8 - E LE CTRICAL/P OWE R MIRRORS/AU-
view m ir r or s a r e st a n da r d equ ipm en t on t h is m odel.
TOMATIC DAY / NIGH T MIRROR - OP E RATION)
E a ch power m ir r or h ou sin g con t a in s t wo elect r ic
for m or e in for m a t ion on t h is fea t u r e.
m ot or s, t wo dr ive m ech a n ism s, a n elect r ic h ea t in g
If t h e veh icle is equ ipped wit h t h e opt ion a l m em -
gr id, t h e m ir r or gla ss ca se a n d t h e m ir r or gla ss. On e
or y syst em , t h e Dr iver Door Modu le (DDM) a n d t h e
m ot or a n d dr ive con t r ols m ir r or u p-a n d-down (ver t i-
P a ssen ger Door Modu le (P DM) st or e t h e m ir r or posi-
ca l) m ovem en t , a n d t h e ot h er con t r ols r igh t -a n d-left
t ion in for m a t ion a s m on it or ed t h r ou gh t h e m ir r or
(h or izon t a l) m ovem en t . If t h e veh icle is equ ipped
m ot or posit ion pot en t iom et er s. Wh en t h e m em or y
wit h t h e opt ion a l m em or y syst em , ea ch m ir r or h ea d
syst em r equ est s a r eca ll of t h e st or ed m ir r or posit ion ,
a lso con t a in s t wo posit ion pot en t iom et er s. On e posi-
t h e DDM a n d t h e P DM a r e a ble t o du plica t e t h e
t ion pot en t iom et er m on it or s t h e ver t ica l m ir r or
st or ed m ir r or posit ion s by m ovin g t h e m ir r or m ot or s
m ot or, a n d t h e ot h er m on it or s t h e h or izon t a l m ir r or
u n t il t h e pot en t iom et er r ea din gs m a t ch t h e st or ed
m ot or.
va lu es.
An opt ion a l dr iver side a u t om a t ic dim m in g m ir r or
is a ble t o a u t om a t ica lly ch a n ge it s r eflect a n ce level.
Th is m ir r or is con t r olled by t h e cir cu it r y of t h e a u t o-
m a t ic da y/n igh t in side r ea r view m ir r or. A t h in la yer
of elect r och r om ic m a t er ia l bet ween t wo pieces of con -
du ct ive gla ss m a ke u p t h e fa ce of t h e m ir r or. (Refer
t o 8 - E LE CTRICAL/P OWE R MIRRORS/AUTO-
8N - 16 POWER MIRRORS WJ
SI DEV I EW M I RROR (Cont inue d)

DIAGNOSIS AND TESTING - SIDEVIEW

MIRROR
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.

BOTH MIRRORS INOPERATIVE

(1) Ch eck t h e oper a t ion of t h e power lock swit ch
on t h e dr iver side fr on t door. If a ll of t h e door s lock
a n d u n lock, r epla ce t h e fa u lt y Dr iver Door Modu le
(DDM). If n ot OK, go t o St ep 2.
(2) Ch eck t h e oper a t ion of t h e power lock swit ch
Fig. 2 Mirror Test
on t h e pa ssen ger side fr on t door. If a ll of t h e door s
POWER M I RROR T EST TABLE
lock a n d u n lock, r epla ce t h e fa u lt y DDM. If n ot OK,
go t o St ep 3.
(3) Ch eck t h e fu sed B(+) fu se in t h e P ower Dist r i- APPLY 12 APPLY MIRROR
VOLTS TO: GROUND TO: REACTION
bu t ion Cen t er (P DC). If OK, go t o St ep 4. If n ot OK, DRIVER SIDE
r epa ir t h e sh or t ed cir cu it or com pon en t a s r equ ir ed 1 7 LEFT
a n d r epla ce t h e fa u lt y fu se. 7 1 RIGHT
(4) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se 8 7 UP
in t h e P DC. If OK, go t o St ep 5. If n ot OK, r epa ir t h e 7 8 DOWN
open fu sed B(+) cir cu it t o t h e ba t t er y a s r equ ir ed. PASSENGER SIDE
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive 1 7 LEFT
7 1 RIGHT
ca ble. Rem ove t h e t r im pa n el fr om t h e dr iver side
8 7 UP
fr on t door. Discon n ect t h e 15-wa y door wir e h a r n ess
7 8 DOWN
con n ect or fr om t h e DDM con n ect or r ecept a cle. Ch eck
for con t in u it y bet ween t h e gr ou n d cir cu it ca vit y of
t h e 15-wa y door wir e h a r n ess con n ect or for t h e DDM (5) Discon n ect t h e 12-wa y door wir e h a r n ess con -
a n d a good gr ou n d. Th er e sh ou ld be con t in u it y. If n ect or fr om t h e door m odu le con n ect or r ecept a cle.
OK, go t o St ep 6. If n ot OK, r epa ir t h e open gr ou n d Ch eck a ll of t h e cir cu it s of t h e door wir e h a r n ess
cir cu it t o gr ou n d a s r equ ir ed. bet ween t h e con n ect or for t h e m ir r or a n d t h e con n ec-
(6) Recon n ect t h e ba t t er y n ega t ive ca ble. Ch eck for t or for t h e door m odu le for open s or sh or t s. If a ll of
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e t h e cir cu it s a r e OK, r epla ce t h e fa u lt y door m odu le.
15-wa y door wir e h a r n ess con n ect or for t h e DDM. If If a n y of t h e cir cu it s a r e n ot OK, r epa ir t h e open or
OK, r epla ce t h e fa u lt y DDM. If n ot OK, r epa ir t h e open sh or t ed cir cu it (s) a s r equ ir ed.
fu sed B(+) cir cu it t o t h e fu se in t h e P DC a s r equ ir ed. (6) Use a DRB sca n t ool a n d t h e pr oper Dia gn ost ic
P r ocedu r es m a n u a l t o t est a n d r epa ir t h e fa u lt y P r o-
ONE MIRROR INOPERATIVE gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s
(1) If t h e on e in oper a t ive m ir r or is on t h e pa ssen - com m u n ica t ion bet ween t h e t wo door m odu les.
ger side, go t o St ep 2. If t h e on e in oper a t ive m ir r or is
on t h e dr iver side, go t o St ep 3. NO MIRROR HEAT
(2) Ch eck if t h e pa ssen ger fr on t door will lock a n d If on e or bot h m ir r or h ea t er s a r e in oper a t ive,
u n lock u sin g t h e power lock swit ch on t h e dr iver side (Refer t o 8 - E LE CTRICAL/H E ATE D MIRRORS -
fr on t door. If OK, go t o St ep 3. If n ot OK, go t o St ep 6. DE SCRIP TION).
(3) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e t r im pa n el fr om t h e fr on t door. ca ble. Rem ove t h e fr on t door t r im pa n el on t h e side
Discon n ect t h e 12-wa y m ir r or wir e h a r n ess con n ect or of t h e in oper a t ive m ir r or h ea t er.
fr om t h e door wir e h a r n ess con n ect or. (2) Discon n ect t h e 12-wa y door wir e h a r n ess con -
(4) Usin g t wo ju m per wir es, t est t h e m ir r or a s n ect or fr om t h e door m odu le con n ect or r ecept a cle.
sh own in t h e Mir r or Test ch a r t (F ig. 2). If t h e m ir r or Ch eck for con t in u it y bet ween t h e h ea t er swit ch ed
t est s OK, go t o St ep 5. If t h e m ir r or does n ot t est gr ou n d cir cu it ca vit y a n d t h e h ea t er 12V su pply cir-
OK, r epla ce t h e fa u lt y m ir r or. cu it ca vit y of t h e 12-wa y door wir e h a r n ess con n ect or
WJ
SI DEV I EW M I RROR (Cont inue d)
for t h e door m odu le. Th er e sh ou ld be con t in u it y. If
OK, u se a DRB sca n t ool a n d t h e pr oper Dia gn ost ic
P r ocedu r es m a n u a l t o t est t h e door m odu le a n d t h e
P CI da t a bu s. If n ot OK, r epla ce t h e fa u lt y power
m ir r or u n it .
NO MIRROR DIMMING (Driver Side Only)
(1) Test t h e oper a t ion of t h e a u t om a t ic da y/n igh t
m ir r or. (Refer t o 8 - E LE CTRICAL/P OWE R MIR-
RORS/AUTOMATIC DAY / NIGH T MIRROR -
OP E RATION). If OK, go t o St ep 2. If n ot OK, r epa ir
t h e a u t om a t ic da y/n igh t m ir r or u n it a s r equ ir ed.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e dr iver side fr on t door t r im pa n el.
(3) Discon n ect t h e door wir e h a r n ess con n ect or
fr om t h e power m ir r or wir e h a r n ess con n ect or. Con -
n ect a volt m et er bet ween t h e elect r och r om a t ic (+)
POWER MIRRORS 8N - 17
a n d elect r och r om a t ic (–) cir cu it ca vit ies of t h e door
wir e h a r n ess con n ect or for t h e power m ir r or. Tu r n on
t h e a u t om a t ic da y/n igh t m ir r or syst em wh ile obser v-
in g t h e volt m et er. A volt m et er r ea din g of 1.45 ± 0.05
volt s in dica t es a pr oper dim m in g sign a l is bein g
r eceived a t t h e door wir e h a r n ess con n ect or for t h e
power m ir r or. If OK, r epla ce t h e fa u lt y power m ir r or.
If n ot OK, r epa ir t h e sh or t ed or open elect r och r o-
m a t ic (+) or elect r och r om a t ic (–) cir cu it (s) t o t h e
a u t om a t ic da y/n igh t m ir r or a s r equ ir ed.
NO MIRROR MEMORY
F or dia gn osis of t h e m em or y syst em , t h e u se of a
DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es
m a n u a l a r e r ecom m en ded. (Refer t o 8 - E LE CTRI-
CAL/P OWE R SE ATS - DE SCRIP TION).
8N - 18 POWER SEAT SYSTEM WJ

POWER SEAT SY ST EM

TABLE OF CONTENTS
page page

POWER SEAT SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DESCRIPTION DIAGNOSIS AND TESTING - POWER LUMBAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 18 ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION - MEMORY SYSTEM . . . . . . . 19 MEMORY SET SWITCH
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION - POWER SEAT SYSTEM . . . . . 20 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION - MEMORY SYSTEM . . . . . . . . . 20 DIAGNOSIS AND TESTING - MEMORY
DIAGNOSIS AND TESTING SWITCH ........................... . 27
DIAGNOSIS & TESTING - POWER SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS & TESTING - MEMORY PASSENGER SEAT SWITCH
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DRIVER SEAT SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 DIAGNOSIS AND TESTING - PASSENGER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - DRIVER SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SWITCH ........................... . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 RECLINER MOTOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
LUMBAR CONTROL SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 DIAGNOSIS AND TESTING - RECLINER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - POWER LUMBAR POWER SEAT TRACK
SWITCH ........................... . 24 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 DIAGNOSIS AND TESTING - POWER SEAT
LUMBAR MOTOR TRACK ............................ . 32
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25

POWER SEAT SY ST EM F ou r power sea t opt ion s a r e offer ed on t h is veh icle,

DESCRI PT I ON
DESCRIPTION
Dr iver a n d pa ssen ger power fr on t sea t s a r e a n
a va ila ble fa ct or y-in st a lled opt ion for t h is veh icle. Th e
power sea t syst em opt ion a llows t h e dr iver a n d fr on t
sea t pa ssen ger t o elect r ica lly a dju st t h eir sea t in g
posit ion s for opt im u m con t r ol a n d com for t u sin g t h e
power sea t swit ch es loca t ed on t h e ou t boa r d sea t
cu sh ion side sh ield of ea ch fr on t sea t . Th e power sea t
syst em r eceives ba t t er y cu r r en t t h r ou gh a fu se in t h e
P ower Dist r ibu t ion Cen t er (P DC) a n d a cir cu it
br ea ker in t h e ju n ct ion block so t h a t t h e power sea t s
r em a in oper a t ion a l, r ega r dless of t h e ign it ion swit ch
posit ion .
depen din g u pon t h e m odel. Th ey a r e a s follows:
• S ix -w a y p o w e r d riv e rs s e a t w ith m a n u a l
p a s s e n g e r s e a t - Th is power sea t pa cka ge is a n
opt ion on La r edo m odels equ ipped wit h clot h -
t r im m ed sea t s a n d in clu des a six-wa y a dju st a ble
dr iver sea t t r a ck wit h m a n u a l sea t ba ck r eclin er s.
• S ix -w a y p o w e r d riv e r a n d p a s s e n g e r s e a t -
Th is power sea t pa cka ge is a n opt ion on La r edo m od-
els equ ipped wit h clot h or lea t h er-t r im m ed sea t s a n d
in clu des six-wa y a dju st a ble sea t t r a cks wit h m a n u a l
sea t ba ck r eclin er s. H ea t ed Sea t s a r e a va ila ble on
lea t h er-t r im m ed sea t s.
• Te n -w a y p o w e r d riv e rs s e a t w ith Me m o ry
a n d S ix -w a y p o w e r p a s s e n g e r s e a t - Th is power
sea t pa cka ge is st a n da r d on Lim it ed m odels. Th is
opt ion in clu des a six-wa y a dju st a ble sea t t r a ck wit h
power sea t ba ck r eclin er s a n d power lu m ba r su ppor t s
for t h e dr iver a n d six-wa y on ly for t h e pa ssen ger.
WJ
POWER SEAT SY ST EM (Cont inue d)
• Te n -w a y p o w e r d riv e rs a n d p a s s e n g e r s e a ts
w ith Me m o ry - Th is power sea t opt ion is st a n da r d
on Over la n d m odels a n d opt ion a l on Lim it ed m odels.
Th is opt ion in clu des a six-wa y a dju st a ble sea t cu sh -
ion t r a ck wit h power sea t ba ck r eclin er s a n d power
lu m ba r su ppor t s. H ea t ed Sea t s a r e st a n da r d wit h
t h is opt ion .
Refer t o He a te d S e a t S y s te m for m or e in for m a -
t ion on t h e h ea t ed sea t opt ion . Refer t o Me m o ry
S y s te m in t h e Mem or y Syst em sect ion of t h is gr ou p
for m or e in for m a t ion on t h e m em or y syst em .
Th e power sea t syst em in clu des t h e followin g com -
pon en t s:
• P ower lu m ba r a dju st er (t en -wa y power sea t
on ly)
• P ower lu m ba r swit ch (t en -wa y power sea t on ly)
• P ower sea t r eclin er (t en -wa y power sea t on ly)
• P ower sea t swit ch
• P ower sea t t r a ck.
Refer t o P o w e r S e a t in Wir in g Dia gr a m s for com -
plet e cir cu it dia gr a m s. F ollowin g a r e gen er a l descr ip-
t ion s of t h e m a jor com pon en t s in t h e power sea t /
m em or y sea t syst em .
DESCRIPTION - MEMORY SYSTEM
An elect r on ic m em or y syst em is st a n da r d equ ip-
m en t on t h e Lim it ed m odel. Th e m em or y syst em is
a ble t o st or e a n d r eca ll t h e dr iver side power sea t
posit ion s (in clu din g t h e power r eclin er posit ion ), a n d
bot h ou t side power m ir r or posit ion s for t wo dr iver s.
F or veh icles wit h a r a dio con n ect ed t o t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et -
wor k, t h e m em or y syst em is a lso a ble t o st or e a n d
r eca ll u p t o t wen t y - t en AM a n d t en F M - r a dio st a -
t ion pr eset s for t wo dr iver s. Th e m em or y syst em a lso
will st or e a n d r eca ll t h e la st st a t ion list en ed t o for
ea ch dr iver, even if it is n ot on e of t h e t wen t y pr eset
st a t ion s.
Th e m em or y syst em will a u t om a t ica lly r et u r n t o
a ll of t h ese set t in gs wh en t h e cor r espon din g n u m -
ber ed a n d color-coded bu t t on (Dr iver 1 - Bla ck, or
Dr iver 2 - Gr a y) of t h e m em or y swit ch on t h e dr iver
side fr on t door t r im pa n el is depr essed, or wh en t h e
door s a r e u n locked u sin g t h e cor r espon din g n u m -
ber ed a n d color-coded (Dr iver 1 - Bla ck, or Dr iver 2 -
Gr a y) Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er. A
cu st om er pr ogr a m m a ble fea t u r e of t h e m em or y sys-
t em a llows t h e RKE r eca ll of m em or y fea t u r es t o be
disa bled in ca ses wh er e t h er e a r e m or e t h a n t wo
dr iver s of t h e veh icle.
Th e m em or y syst em a lso h a s a cu st om er pr ogr a m -
m a ble ea sy exit fea t u r e t h a t will m ove t h e dr iver
sea t r ea r wa r d 55 m illim et er s (t wo in ch es) or t o t h e
en d of it s t r a vel, wh ich ever occu r s fir st , wh en t h e key
is r em oved fr om t h e ign it ion swit ch lock cylin der.
POWER SEAT SYSTEM 8N - 19
A Mem or y Sea t Modu le (MSM) or Mem or y H ea t ed
Sea t Modu le (MH SM) a r e u sed on t h is m odel t o con -
t r ol a n d in t egr a t e t h e m a n y elect r on ic fu n ct ion s a n d
fea t u r es in clu ded in t h e m em or y syst em . On veh icles
equ ipped wit h t h e h ea t ed sea t syst em opt ion , t h e
MH SM a lso con t r ols t h e fu n ct ion s a n d fea t u r es of
t h a t syst em .
Th e m em or y syst em in clu des t h e followin g com po-
n en t s:
• Mem or y sea t m odu le (or m em or y h ea t ed sea t
m odu le)
• Mem or y swit ch
• P osit ion pot en t iom et er s on bot h ou t side power
m ir r or s
• P osit ion pot en t iom et er s on t h e dr iver side power
sea t t r a ck a n d power sea t r eclin er m ot or s.
• Ra dio r eceiver (if P CI da t a bu s ca pa ble).
Cer t a in fu n ct ion s a n d fea t u r es of t h e m em or y sys-
t em r ely u pon r esou r ces sh a r ed wit h ot h er elect r on ic
m odu les in t h e veh icle over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e
P CI da t a bu s n et wor k a llows t h e sh a r in g of sen sor
in for m a t ion . Th is h elps t o r edu ce wir e h a r n ess com -
plexit y, in t er n a l con t r oller h a r dwa r e, a n d com pon en t
sen sor cu r r en t loa ds. At t h e sa m e t im e, t h is syst em
pr ovides in cr ea sed r elia bilit y, en h a n ced dia gn ost ics,
a n d a llows t h e a ddit ion of m a n y n ew fea t u r e ca pa bil-
it ies. F or dia gn osis of t h ese elect r on ic m odu les or of
t h e P CI da t a bu s n et wor k, t h e u se of a DRB! sca n
t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l
a r e r ecom m en ded.
Th e ot h er elect r on ic m odu les t h a t m a y a ffect m em -
or y syst em oper a t ion a r e a s follows:
• B o d y Co n tro l Mo d u le (B CM) - Refer t o B o d y
Co n tro l Mo d u le in E lect r on ic Con t r ol Modu les for
m or e in for m a t ion .
• D riv e r D o o r Mo d u le (D D M) - Refer t o D o o r
Mo d u le in E lect r on ic Con t r ol Modu les for m or e
in for m a t ion .
• Ele c tro n ic Ve h ic le In fo rm a tio n Ce n te r
(EVIC) - Refer t o Ele c tro n ic Ve h ic le In fo rm a tio n
Ce n te r in Over h ea d Con sole Syst em s for m or e in for-
m a t ion .
• P a s s e n g e r D o o r Mo d u le (P D M) - Refer t o
D o o r Mo d u le in E lect r on ic Con t r ol Modu les for
m or e in for m a t ion .
• P o w e rtra in Co n tro l Mo d u le (P CM) - Refer t o
P o w e rtra in Co n tro l Mo d u le in E lect r on ic Con t r ol
Modu les for m or e in for m a t ion .
• Ra d io Re c e iv e r - Refer t o Ra d io Re c e iv e r in
Au dio Syst em s for m or e in for m a t ion .
Refer t o He a te d S e a t S y s te m for m or e in for m a -
t ion on t h is syst em . Refer t o Re m o te Ke y le s s En try
S y s te m in P ower Lock Syst em s for m or e in for m a t ion
on t h e RKE syst em . Refer t o P o w e r Mirro r in
P ower Mir r or Syst em s for m or e in for m a t ion on t h e
8N - 20 POWER SEAT SYSTEM
POWER SEAT SY ST EM (Cont inue d)
m ir r or posit ion pot en t iom et er s. Refer t o P o w e r S e a t
Tra c k a n d P o w e r S e a t Re c lin e r in t h e P ower Sea t
Syst em sect ion of t h is gr ou p for m or e in for m a t ion on
t h e dr iver side power sea t posit ion pot en t iom et er s.
Refer t o P o w e r S e a t in Wir in g Dia gr a m s for com -
plet e cir cu it dia gr a m s. F ollowin g a r e gen er a l descr ip-
t ion s of t h e r em a in in g m a jor com pon en t s in t h e
fa ct or y-in st a lled m em or y syst em .
OPERAT I ON
OPERATION - POWER SEAT SYSTEM
Th e power sea t syst em a llows t h e dr iver a n d/or
fr on t pa ssen ger sea t in g posit ion s t o be a dju st ed elec-
t r ica lly a n d in depen den t ly u sin g t h e sepa r a t e power
sea t swit ch es fou n d on t h e ou t boa r d sea t cu sh ion
side sh ield of ea ch fr on t sea t . See t h e own er ’s m a n u a l
in t h e veh icle glove box for m or e in for m a t ion on t h e
fea t u r es, u se a n d oper a t ion of t h e power sea t syst em .
OPERATION - MEMORY SYSTEM
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion of
t h e m em or y syst em . F or dia gn osis of t h e MSM, t h e P CI
da t a bu s, or t h e ot h er elect r on ic m odu les on t h e P CI
da t a bu s t h a t pr ovide in pu t s a n d ou t pu t s for t h e m em -
or y syst em , t h e u se of a DRB! sca n t ool a n d t h e pr oper
Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom m en ded.
DRIVER AND PASSENGER DOOR MODULES
Th e Dr iver Door Modu le (DDM) m on it or s t h e m em -
or y swit ch t h r ou gh a h a r d wir ed cir cu it . It a lso m on -
it or s t h e u n lock m essa ges fr om t h e Rem ot e Keyless
E n t r y (RKE ) r eceiver in t h e P a ssen ger Door Modu le
(P DM) sen t over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s. Th e DDM is pr ogr a m m ed t o
sen d m em or y r eca ll m essa ges a n d m em or y syst em
st a t u s m essa ges over t h e P CI da t a bu s t o t h e ot h er
elect r on ic m odu les wh en it det ect s a m em or y r eca ll
r equ est .
Refer t o D o o r Mo d u le in E lect r on ic Con t r ol Mod-
u les for m or e in for m a t ion on t h e DDM a n d P DM.
ELECTRONIC VEHICLE INFORMATION CENTER
Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC)
ser ves a s t h e u ser in t er fa ce for t h e m em or y syst em . It
displa ys m em or y syst em st a t u s m essa ges a n d pr ovides
t h e u ser wit h t h e m ea n s for en a blin g a n d disa blin g
t h e m a n y cu st om er pr ogr a m m a ble fea t u r es a va ila ble
on t h e veh icle, in clu din g t h ose for t h e m em or y syst em .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e E VIC. Refer t o Ele c tro n ic Ve h ic le In fo rm a -
tio n Ce n te r in Over h ea d Con sole Syst em s for m or e
in for m a t ion on t h e E VIC.
WJ
DI AGN OSI S AN D T EST I N G
DIAGNOSIS & TESTING - POWER SEAT
SYSTEM
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
h a r d wir ed com pon en t s a n d cir cu it s of t h e power sea t
syst em . H owever, if t h e veh icle is a lso equ ipped wit h
t h e opt ion a l m em or y syst em , t h ese t est s m a y n ot
pr ove con clu sive in t h e dia gn osis of t h e dr iver side
power sea t . In or der t o obt a in con clu sive t est in g of
t h e dr iver side power sea t wit h t h e m em or y syst em
opt ion , t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
t h e m em or y syst em com pon en t s m u st be ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e dr iver side power sea t wit h t h e m em or y
syst em opt ion r equ ir es t h e u se of a DRB! sca n t ool
a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l. Th e
DRB! sca n t ool ca n pr ovide con fir m a t ion t h a t t h e
P CI da t a bu s is fu n ct ion a l, t h a t a ll of t h e elect r on ic
m odu les a r e sen din g a n d r eceivin g t h e pr oper m es-
sa ges on t h e P CI da t a bu s, a n d t h a t t h e m em or y sys-
t em is r eceivin g t h e pr oper h a r d wir ed in pu t s a n d
r ela yin g t h e pr oper h a r d wir ed ou t pu t s t o per for m it s
dr iver side power sea t fu n ct ion s.
Befor e a n y t est in g of t h e power sea t syst em is
a t t em pt ed, t h e ba t t er y sh ou ld be fu lly-ch a r ged a n d
a ll of t h e power sea t syst em wir e h a r n ess con n ect ion s
a n d pin s clea n ed a n d t igh t en ed t o en su r e pr oper cir-
cu it con t in u it y a n d gr ou n d pa t h s. F or com plet e cir-
cu it dia gr a m s, r efer t o P o w e r S e a t in Wir in g
Dia gr a m s.
Wit h t h e dom e la m p on , a pply t h e power sea t
swit ch in t h e dir ect ion of t h e fa ilu r e. If t h e dom e
la m p dim s, t h e sea t m a y be ja m m in g. Ch eck u n der
a n d beh in d t h e sea t for bin din g or obst r u ct ion s. If
t h e dom e la m p does n ot dim , pr oceed wit h t est in g of
t h e in dividu a l com pon en t s a n d cir cu it s.
DIAGNOSIS & TESTING - MEMORY SYSTEM
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
com pon en t s a n d cir cu it s t h a t pr ovide h a r d wir ed
in pu t s t o t h e m em or y syst em . H owever, t h ese t est s
m a y n ot pr ove con clu sive in t h e dia gn osis of t h is sys-
t em . In or der t o obt a in con clu sive t est in g of t h e
m em or y syst em , t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s n et wor k a n d a ll of t h e elec-
t r on ic m odu les t h a t pr ovide in pu t s t o, or r eceive ou t -
pu t s fr om t h e m em or y syst em com pon en t s m u st be
ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e m em or y syst em r equ ir es t h e u se of a
DRB! sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
du r es m a n u a l. Th e DRB! sca n t ool ca n pr ovide con -
fir m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t a ll
WJ POWER SEAT SYSTEM 8N - 21
POWER SEAT SY ST EM (Cont inue d)
of t h e elect r on ic m odu les a r e sen din g a n d r eceivin g
t h e pr oper m essa ges on t h e P CI da t a bu s, a n d t h a t
t h e m em or y syst em is r eceivin g t h e pr oper h a r d
wir ed in pu t s a n d r ela yin g t h e pr oper h a r d wir ed ou t -
pu t s t o per for m it s fu n ct ion s.

DRI V ER SEAT SWI T CH

DESCRIPTION
Two differ en t power sea t swit ch es a r e u sed on t h is
veh icle, depen din g u pon t h e opt ion a l power sea t sys-
t em in st a lled in t h e veh icle. Th e six-wa y power sea t s
a r e ea ch equ ipped wit h a swit ch fea t u r in g t h r ee
swit ch con t r ol kn obs ga n ged t oget h er on t h e ou t boa r d
sea t cu sh ion side sh ield (F ig. 1). Th e t en -wa y power
Fig. 2 Ten-Way Power Seat Switches - Typical
sea t s a r e ea ch equ ipped wit h a swit ch fea t u r in g t wo
kn obs ga n ged t oget h er on t h e ou t boa r d sea t cu sh ion 1 - OUTBOARD CUSHION SIDE SHIELD
2 - POWER SEAT RECLINER SWITCH
side sh ield (F ig. 2).
3 - POWER SEAT TRACK SWITCH
4 - POWER LUMBAR SWITCH

Fig. 1 Six-Way Power Seat Switches - Typical
1 - OUTBOARD SEAT CUSHION SIDE SHIELD
2 - POWER SEAT TRACK SWITCHES
3 - MECHANICAL SEAT BACK RECLINER LEVER
Th e swit ch u n it s for bot h power sea t t ypes a r e
secu r ed t o t h e ba ck of t h e sea t cu sh ion side sh ield
wit h t wo scr ews. H owever, t h e con t r ol kn obs for t h e
six-wa y power sea t swit ch u n it r em a in in st a lled du r-
in g swit ch u n it r em ova l a n d in st a lla t ion , wh ile bot h
kn obs for t h e t en -wa y power sea t swit ch u n it m u st
be r em oved.
Th e in dividu a l swit ch es in bot h power sea t swit ch
u n it s ca n n ot be r epa ir ed. If on e swit ch is da m a ged or
fa u lt y, t h e en t ir e power sea t swit ch u n it m u st be
r epla ced.
OPERATION
Th e power sea t t r a cks of bot h t h e six-wa y a n d t h e
t en -wa y power sea t syst em s ca n be a dju st ed in six
differ en t wa ys u sin g t h e power sea t swit ch es. Th e
t en -wa y syst em h a s t h e a ddit ion a l power sea t
r eclin er swit ch in t egr a l t o t h e power sea t swit ch a n d
a lso h a s a sepa r a t e, st a n d-a lon e swit ch t o con t r ol t h e
power lu m ba r a dju st er. See t h e own er ’s m a n u a l in
t h e veh icle glove box for m or e in for m a t ion on t h e
power sea t swit ch fu n ct ion s a n d t h e sea t a dju st in g
pr ocedu r es.
Wh en a power swit ch con t r ol kn ob or kn obs a r e
a ct u a t ed, a ba t t er y feed a n d a gr ou n d pa t h a r e
a pplied t h r ou gh t h e swit ch con t a ct s t o t h e power sea t
t r a ck or r eclin er a dju st er m ot or. Th e select ed
a dju st er m ot or oper a t es t o m ove t h e sea t t r a ck or
r eclin er t h r ou gh it s dr ive u n it in t h e select ed dir ec-
t ion u n t il t h e swit ch is r elea sed, or u n t il t h e t r a vel
lim it of t h e a dju st er is r ea ch ed. Wh en t h e swit ch is
m oved in t h e opposit e dir ect ion , t h e ba t t er y feed a n d
gr ou n d pa t h t o t h e m ot or a r e r ever sed t h r ou gh t h e
swit ch con t a ct s. Th is ca u ses t h e a dju st er m ot or t o
r u n in t h e opposit e dir ect ion .
No power sea t swit ch sh ou ld be h eld a pplied in a n y
dir ect ion a ft er t h e a dju st er h a s r ea ch ed it s t r a vel
lim it . Th e power sea t a dju st er m ot or s ea ch con t a in a
self-r eset t in g cir cu it br ea ker t o pr ot ect t h em fr om
over loa d. H owever, con secu t ive or fr equ en t r eset t in g
of t h e cir cu it br ea ker m u st n ot be a llowed t o con -
t in u e, or t h e m ot or m a y be da m a ged.
8N - 22 POWER SEAT SYSTEM WJ
DRI V ER SEAT SWI T CH (Cont inue d)

DIAGNOSIS AND TESTING - DRIVER SEAT

SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e power sea t swit ch fr om t h e ou t -
boa r d sea t cu sh ion side sh ield. Refer t o t h e pr ocedu r e
in t h is sect ion of t h e m a n u a l.
(3) Use a n oh m m et er t o t est t h e con t in u it y of t h e
power sea t swit ch in ea ch swit ch posit ion . See t h e
P ower Sea t Swit ch Con t in u it y ch a r t (F ig. 3) or (F ig.
4). If OK, r efer t o D ia g n o s is a n d Te s tin g P o w e r Fig. 4 Ten-Way Power Seat
S e a t Tra c k or D ia g n o s is a n d Te s tin g P o w e r S e a t Switch Connector Receptacle
Re c lin e r in t h is sect ion . If n ot OK, r epla ce t h e
fa u lt y power sea t swit ch . SWITCH CONTINUITY BETWEEN PINS
POSITION
LEFT SEAT RIGHT SEAT

OFF PIN 1 to 2 PIN 1 to 2

PIN 1 to 3 PIN 1 to 3
PIN 1 to 4 PIN 1 to 4
PIN 1 to 6 PIN 1 to 6
PIN 1 to 7 PIN 1 to 7
PIN 1 to 8 PIN 1 to 8
SIX-WAY POWER SEAT SWITCH TEST PIN 1 to 9 PIN 1 to 9
LEFT SWITCH RIGHT SWITCH CONTINUITY PIN 1 to 10 PIN 1 to 10
POSITION POSITION BETWEEN
B-N, B-J, B-M, FRONT RISER PIN 1 to 10 PIN 1 to 7
OFF OFF B-E, B-L, B-K UP
PIN 5 to 7 PIN 5 to 10
VERTICAL UP VERTICAL A-J, A-N, B-M,
DOWN B-E
FRONT RISER PIN 1 to 7 PIN 1 to 10
VERTICAL A-E, A-M, B-N, DOWN
VERTICAL UP
DOWN B-J PIN 5 to 10 PIN 5 to 7
HORIZONTAL HORIZONTAL
FORWARD REARWARD A-K, B-L CENTER PIN 1 to 3 PIN 1 to 3
SWITCH
FRONT TILT UP FRONT TILT A-J, B-E FORWARD PIN 5 to 6 PIN 5 to 6
DOWN
FRONT TILT CENTER PIN 1 to 6 PIN 1 to 6
DOWN FRONT TILT UP A-E, B-J SWITCH
REARWARD PIN 3 to 5 PIN 3 to 5
REAR TILT UP REAR TILT A-N, B-M
DOWN
REAR RISER PIN 1 to 9 PIN 1 to 8
REAR TILT UP
DOWN REAR TILT UP A-M, B-N
PIN 5 to 8 PIN 5 to 9

REAR RISER PIN 1 to 8 PIN 1 to 9

DOWN
Fig. 3 Rear Of Six-Way Power Seat Switch PIN 5 to 9 PIN 5 to 8

RECLINER UP PIN 1 to 4 PIN 1 to 4

PIN 2 to 5 PIN 2 to 5

RECLINER PIN 1 to 2 PIN 1 to 2

DOWN
PIN 4 to 5 PIN 4 to 5
WJ POWER SEAT SYSTEM 8N - 23
DRI V ER SEAT SWI T CH (Cont inue d)

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) On m odels wit h t h e t en -wa y power sea t syst em
on ly, u sin g a pu sh pin r em over or a n ot h er su it a ble
wide fla t -bla ded t ool, gen t ly pr y t h e power sea t a n d
power r eclin er swit ch kn obs off of t h e swit ch st em s
(F ig. 5).

Fig. 6 Six-Way Power Seat Switches Remove/Install

1 - SEAT SIDE SHIELD
2 - POWER SEAT SWITCH
3 - SCREWS

Fig. 5 Removing Switch Control Knobs - Typical

(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e ou t -
boa r d sea t cu sh ion side sh ield t o t h e sea t cu sh ion
fr a m e.
(4) P u ll t h e ou t boa r d sea t cu sh ion side sh ield a wa y Fig. 7 Ten-Way Power Seat Switches Remove/Install
fr om t h e sea t cu sh ion fr a m e fa r en ou gh t o a ccess t h e 1 - POWER SEAT SWITCH
power sea t swit ch wir e h a r n ess con n ect or. 2 - SCREWS (2)
(5) Discon n ect t h e power sea t wir e h a r n ess con n ec- 3 - POWER LUMBAR SWITCH
t or fr om t h e power sea t swit ch con n ect or r ecept a cle. 4 - SEAT CUSHION SIDE SHIELD
(6) Rem ove t h e t wo scr ews t h a t secu r e t h e power 5 - WIRE HARNESS CONNECTOR
sea t swit ch t o t h e in side of t h e ou t boa r d sea t cu sh ion
side sh ield (F ig. 6) or (F ig. 7). (4) P osit ion t h e ou t boa r d sea t cu sh ion side sh ield
(7) Rem ove t h e power sea t swit ch fr om t h e ou t - on t o t h e sea t cu sh ion fr a m e
boa r d sea t cu sh ion side sh ield. (5) In st a ll a n d t igh t en t h e t h r ee scr ews t h a t secu r e
t h e ou t boa r d sea t cu sh ion side sh ield t o t h e sea t
INSTALLATION cu sh ion fr a m e. Tigh t en t h e scr ews t o 1.5 N·m (14 in .
(1) P osit ion t h e power sea t swit ch on t o t h e ou t - lbs.).
boa r d sea t cu sh ion side sh ield. (6) On m odels wit h t h e t en -wa y power sea t syst em
(2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e on ly, posit ion t h e power sea t a n d power r eclin er
t h e power sea t swit ch t o t h e in side of t h e ou t boa r d swit ch kn obs on t o t h e swit ch st em s a n d pu sh on
sea t cu sh ion side sh ield. Tigh t en t h e scr ews t o 1.5 t h em fir m ly a n d even ly u n t il t h ey sn a p in t o pla ce.
N·m (14 in . lbs.). (7) Recon n ect t h e ba t t er y n ega t ive ca ble.
(3) Recon n ect t h e power sea t wir e h a r n ess con n ec-
t or t o t h e power sea t swit ch con n ect or r ecept a cle.
8N - 24 POWER SEAT SYSTEM WJ

LU M BAR CON T ROL SWI T CH r ea ch ed it s t r a vel lim it . Th e power lu m ba r a dju st er

DESCRIPTION
Th e t en -wa y power sea t opt ion in clu des a n elect r i-
ca lly oper a t ed lu m ba r su ppor t m ech a n ism . A sin gle
t wo-wa y m om en t a r y power lu m ba r swit ch is loca t ed
on t h e ou t boa r d sea t cu sh ion side sh ield of ea ch fr on t
sea t , ju st for wa r d of t h e ot h er power sea t swit ch es
(F ig. 8). Th e power lu m ba r swit ch is secu r ed t o t h e
ba ck of t h e sea t cu sh ion side sh ield wit h t wo scr ews,
a n d t h e swit ch pa ddle pr ot r u des t h r ou gh a h ole t o
t h e ou t side of t h e sh ield. Th e swit ch pa ddle is loca t ed
in a sh a llow depr ession m olded in t o t h e ou t er su r fa ce
of t h e sea t cu sh ion side sh ield t h a t h elps t o sh r ou d it
fr om u n in t en t ion a l a ct u a t ion wh en en t er in g or lea v-
in g t h e veh icle.
m ot or con t a in s a self-r eset t in g cir cu it br ea ker t o pr o-
t ect it fr om over loa d. H owever, con secu t ive or fr e-
qu en t r eset t in g of t h e cir cu it br ea ker m u st n ot be
a llowed t o con t in u e, or t h e m ot or m a y be da m a ged.
DIAGNOSIS AND TESTING - POWER LUMBAR
SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e power lu m ba r swit ch fr om t h e ou t -
boa r d sea t cu sh ion side sh ield. Refer t o t h e pr ocedu r e
in t h is sect ion of t h e m a n u a l.
(3) Use a n oh m m et er t o t est t h e con t in u it y of t h e
power lu m ba r swit ch in ea ch swit ch posit ion . See t h e
P ower Lu m ba r Swit ch Con t in u it y ch a r t (F ig. 9). If
OK, r efer t o P o w e r Lu m ba r Ad ju s te r D ia g n o s is
a n d Te s tin g in t h is gr ou p. If n ot OK, r epla ce t h e
fa u lt y power lu m ba r swit ch .

Fig. 8 Ten-Way Power Seat Switches

1 - OUTBOARD CUSHION SIDE SHIELD
2 - POWER SEAT RECLINER SWITCH
3 - POWER SEAT TRACK SWITCH
4 - POWER LUMBAR SWITCH

Th e power lu m ba r swit ch es ca n n ot be a dju st ed or

r epa ir ed a n d, if fa u lt y or da m a ged, t h ey m u st be POWER LUMBAR SWITCH
r epla ced.
RIGHT
LEFT SWITCH CONTINUITY
OPERATION SWITCH
POSITION BETWEEN
Wh en t h e power lu m ba r swit ch pa ddle is a ct u a t ed, POSITION
a ba t t er y feed a n d a gr ou n d pa t h a r e a pplied t h r ou gh Off Off 2-4, 3-5
t h e swit ch con t a ct s t o t h e power lu m ba r a dju st er Forward Rearward 3-5, 4-6
m ot or. Th e m ot or oper a t es t o m ove t h e lu m ba r
Rearward Forward 2-4, 3-6
a dju st er t h r ou gh it s dr ive u n it in t h e select ed dir ec-
t ion u n t il t h e swit ch is r elea sed, or u n t il t h e t r a vel
lim it of t h e a dju st er is r ea ch ed. Wh en t h e swit ch is
m oved in t h e opposit e dir ect ion , t h e ba t t er y feed a n d
gr ou n d pa t h t o t h e m ot or a r e r ever sed t h r ou gh t h e Fig. 9 Power Lumbar Switch
swit ch con t a ct s. Th is ca u ses t h e m ot or t o r u n in t h e
opposit e dir ect ion . REMOVAL
Th e power lu m ba r swit ch sh ou ld n ot be h eld (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
a pplied in eit h er dir ect ion a ft er t h e a dju st er h a s ca ble.
WJ
LU M BAR CON T ROL SWI T CH (Cont inue d)
(2) Rem ove t h e t h r ee scr ews t h a t secu r e t h e ou t -
boa r d sea t cu sh ion side sh ield t o t h e sea t cu sh ion
fr a m e.
(3) P u ll t h e ou t boa r d sea t cu sh ion side sh ield a wa y
fr om t h e sea t cu sh ion fr a m e fa r en ou gh t o a ccess t h e
power lu m ba r swit ch wir e h a r n ess con n ect or.
(4) Discon n ect t h e power sea t wir e h a r n ess con n ec-
t or fr om t h e power lu m ba r swit ch con n ect or r ecept a -
cle (F ig. 10).
POWER SEAT SYSTEM 8N - 25
(5) In st a ll a n d t igh t en t h e t h r ee scr ews t h a t secu r e
t h e ou t boa r d sea t cu sh ion side sh ield t o t h e sea t cu sh -
ion fr a m e. Tigh t en t h e scr ews t o 1.5 N·m (14 in . lbs.).
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
LU M BAR M OT OR
DESCRIPTION
Th e t en -wa y power sea t opt ion in clu des a n elect r i-
ca lly oper a t ed lu m ba r su ppor t m ech a n ism . Th e on ly
visible eviden ce of t h is opt ion is t h e sepa r a t e power
lu m ba r swit ch con t r ol pa ddle t h a t is loca t ed on t h e
ou t boa r d sea t cu sh ion side sh ield, ju st for wa r d of t h e
ot h er power sea t swit ch con t r ol kn obs. Th e power
lu m ba r a dju st er a n d m ot or a r e con cea led ben ea t h t h e
sea t ba ck t r im cover a n d pa ddin g, wh er e t h ey a r e
secu r ed t o a m olded pla st ic ba ck pa n el a n d t o t h e
sea t ba ck fr a m e (F ig. 11).

Fig. 10 Power Lumbar Switch Remove/Install

1 - OUTBOARD SEAT CUSHION SIDE SHIELD
2 - POWER LUMBAR SWITCH
3 - WIRE HARNESS CONNECTOR
4 - SCREWS (2)

(5) Rem ove t h e t wo scr ews t h a t secu r e t h e power

lu m ba r swit ch t o t h e in side of t h e ou t boa r d sea t
cu sh ion side sh ield.
(6) Rem ove t h e power lu m ba r swit ch fr om t h e ou t -
boa r d sea t cu sh ion side sh ield.
Fig. 11 Power Lumbar Adjuster
INSTALLATION 1 - SEAT BACK FRAME
(1) P osit ion t h e power lu m ba r swit ch on t o t h e ou t - 2 - SEAT BACK PANEL
3 - LUMBAR MOTOR PIGTAIL TO SEAT WIRE HARNESS
boa r d sea t cu sh ion side sh ield.
4 - TIE WRAP
(2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e 5 - SCREW (3)
t h e power lu m ba r swit ch t o t h e in side of t h e ou t - 6 - POWER LUMBAR ADJUSTER
boa r d sea t cu sh ion side sh ield. Tigh t en t h e scr ews t o 7 - SEAT BACK TRIM COVER AND PADDING
1.5 N·m (14 in . lbs.).
(3) Recon n ect t h e power sea t wir e h a r n ess con n ec-
Th e power lu m ba r a dju st er ca n n ot be r epa ir ed, a n d
t or t o t h e power lu m ba r swit ch con n ect or r ecept a cle.
is ser viced on ly a s a u n it wit h t h e sea t ba ck fr a m e. If
(4) P osit ion t h e ou t boa r d sea t cu sh ion side sh ield
t h e power lu m ba r a dju st er or t h e sea t ba ck fr a m e
on t o t h e sea t cu sh ion fr a m e
a r e da m a ged or fa u lt y, t h e en t ir e sea t ba ck fr a m e
u n it m u st be r epla ced.
8N - 26 POWER SEAT SYSTEM WJ
LU M BAR M OT OR (Cont inue d)

OPERATION a dju st er m ot or a n d t h e power lu m ba r swit ch for

Th e power lu m ba r a dju st er m ech a n ism in clu des a sh or t s or open s. If t h e cir cu it s ch eck OK, r epla ce the
r ever sible elect r ic m ot or t h a t is secu r ed t o t h e fa u lt y sea t ba ck fr a m e a ssem bly. If t h e cir cu it s are
in boa r d side of t h e sea t ba ck pa n el a n d is con n ect ed n ot OK, r epa ir t h e power sea t wir e h a r n ess as
t o a wor m -dr ive gea r box. Th e m ot or a n d gea r box r equ ir ed.
oper a t e t h e lu m ba r a dju st er m ech a n ism in t h e cen t er
of t h e sea t ba ck by ext en din g a n d r et r a ct in g a ca ble
t h a t a ct u a t es a lever. Th e a ct ion of t h is lever com -
M EM ORY SET SWI T CH
pr esses or r ela xes a gr id of flexible sla t s. Th e m or e
t h is gr id is com pr essed, t h e m or e t h e sla t s bow ou t - DESCRIPTION
wa r d a ga in st t h e cen t er of t h e sea t ba ck pa ddin g, Veh icles equ ipped wit h t h e m em or y syst em h a ve a
pr ovidin g a ddit ion a l lu m ba r su ppor t . m em or y swit ch m ou n t ed t o t h e dr iver side fr on t door
t r im pa n el (F ig. 12). Th is swit ch is u sed t o set a n d
DIAGNOSIS AND TESTING - POWER LUMBAR r eca ll a ll of t h e m em or y syst em set t in gs for u p t o t wo
dr iver s. Th e m em or y swit ch is a r esist or m u lt iplexed
ADJUSTER u n it t h a t is h a r d wir ed t o t h e Dr iver Door Modu le
Act u a t e t h e power lu m ba r swit ch t o m ove t h e
(DDM), wh ich is a lso loca t ed on t h e dr iver side fr on t
power lu m ba r a dju st er in ea ch dir ect ion . Th e power
door t r im pa n el. Th e DDM sen ds ou t t h e m em or y
lu m ba r a dju st er sh ou ld m ove in bot h dir ect ion s. It
syst em set a n d r eca ll r equ est s t o t h e ot h er elect r on ic
sh ou ld be n ot ed t h a t t h e power lu m ber a dju st er n or-
m odu les over t h e P r ogr a m m a ble Com m u n ica t ion s
m a lly oper a t es ver y qu iet ly a n d exh ibit s lit t le visible
In t er fa ce (P CI) da t a bu s.
m ovem en t . If t h e power lu m ba r a dju st er fa ils t o oper-
a t e in on ly on e dir ect ion , m ove t h e a dju st er a sh or t
dist a n ce in t h e opposit e dir ect ion a n d t est a ga in t o be
cer t a in t h a t t h e a dju st er is n ot a t it s t r a vel lim it . If
t h e power lu m ba r a dju st er st ill fa ils t o oper a t e in
on ly on e dir ect ion , r efer t o D ia g n o s is a n d Te s tin g
P o w e r Lu m ba r S w itc h in t h is gr ou p. If t h e power
lu m ba r a dju st er fa ils t o oper a t e in eit h er dir ect ion ,
per for m t h e followin g t est s. F or com plet e cir cu it dia -
gr a m s, r efer t o Wirin g D ia g ra m s .
(1) Ch eck t h e power sea t cir cu it br ea ker in t h e
ju n ct ion block. If OK, go t o St ep 2. If n ot OK, r epla ce
t h e fa u lt y power sea t cir cu it br ea ker.
(2) Ch eck for ba t t er y volt a ge a t t h e power sea t cir-
cu it br ea ker in t h e ju n ct ion block. If OK, go t o St ep
3. If n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e
fu se in t h e P ower Dist r ibu t ion Cen t er a s r equ ir ed.
(3) Rem ove t h e ou t boa r d sea t cu sh ion side sh ield
fr om t h e sea t . Discon n ect t h e sea t wir e h a r n ess con -
n ect or fr om t h e power lu m ba r swit ch con n ect or
r ecept a cle. Ch eck for ba t t er y volt a ge a t t h e fu sed
B(+) cir cu it ca vit y of t h e power sea t wir e h a r n ess
con n ect or for t h e power lu m ba r swit ch . If OK, go t o
St ep 4. If n ot OK, r epa ir t h e open fu sed B(+) cir cu it Fig. 12 WJ/WG MEMORY SELECT/SET SWITCH
t o t h e power sea t cir cu it br ea ker in t h e ju n ct ion 1 - DRIVER TRIM PANEL
block a s r equ ir ed. 2 - MEMORY SWITCH
(4) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e power sea t wir e h a r n ess con n ect or Th e m em or y swit ch ca n n ot be a dju st ed or r epa ir ed
for t h e power lu m ba r swit ch a n d a good gr ou n d. a n d, if fa u lt y or da m a ged, it m u st be r epla ced. F or
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 5. If n ot com plet e cir cu it dia gr a m s, r efer t o Wirin g D ia g ra m s .
OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d a s
r equ ir ed. OPERATION
(5) Test t h e power lu m ba r swit ch . Refer t o D ia g - Th e m em or y swit ch h a s t h r ee m om en t a r y swit ch
n o s is a n d Te s tin g P o w e r Lu m ba r S w itc h in t h is bu t t on s la beled Set , 1 a n d 2. Th e Dr iver 1 a n d Dr iver
gr ou p. If t h e swit ch t est s OK, t est t h e cir cu it s of t h e 2 bu t t on s a r e ba ck-lit wit h Ligh t -E m it t in g Diodes
power sea t wir e h a r n ess bet ween t h e power lu m ba r
WJ
M EM ORY SET SWI T CH (Cont inue d)
(LE D) for visibilit y, a n d a r e a lso color-coded t o coin -
cide wit h t h e color-coded Dr iver 1 a n d Dr iver 2
Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er s. Th e
Dr iver 1 m em or y swit ch bu t t on a n d RKE t r a n sm it t er
a r e bla ck, a n d t h e Dr iver 2 m em or y swit ch bu t t on
a n d RKE t r a n sm it t er a r e gr a y. Th e m em or y swit ch
Set bu t t on a lso h a s a n LE D t h a t will illu m in a t e a n d
fla sh t o in dica t e t h a t t h e m em or y syst em is in t h e set
m ode. Th is LE D will a u t om a t ica lly be ext in gu ish ed
wh en a set r equ est h a s been su ccessfu lly com plet ed.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e m em or y swit ch . F or dia gn osis of t h e m em or y
swit ch , t h e DDM or t h e P CI da t a bu s, t h e u se of a
DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es
m a n u a l a r e r ecom m en ded.
DIAGNOSIS AND TESTING - MEMORY SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e dr iver side fr on t door t r im pa n el.
Refer t o t h e Body sect ion for t h e pr ocedu r e.
(3) Discon n ect t h e m em or y swit ch wir e h a r n ess
con n ect or fr om t h e dr iver door m odu le con n ect or
r ecept a cle.
(4) Use a n oh m m et er t o t est t h e r esist a n ces of t h e
m em or y swit ch in ea ch swit ch posit ion . See t h e Mem -
or y Swit ch Test ch a r t ME MORY SWITCH TE ST . If
OK, r efer t o Me m o ry S y s te m D ia g n o s is a n d Te s t-
in g in t h is gr ou p. If n ot OK, r epla ce t h e fa u lt y m em -
or y swit ch .
M EM ORY SWI T CH T EST
MEMORY RESISTANCE RESISTANCE
SWITCH BETWEEN RANGE
POSITION (OHMS)
NEUTRAL A&D 14000 ± 1%
MEMORY 1 A&B 4600 ± 1%
MEMORY 2 A&B 1700 ± 1%
SET A&B 300 ± 1%
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e t r im pa n el fr om t h e dr iver side
fr on t door. Refer t o F ro n t D o o r Trim P a n e l in Body
for t h e pr ocedu r e.
(3) Discon n ect t h e m em or y swit ch wir e h a r n ess
con n ect or fr om t h e dr iver door m odu le con n ect or
r ecept a cle.
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e m em or y
swit ch t o t h e ba ck of t h e dr iver side fr on t door t r im
pa n el.
POWER SEAT SYSTEM 8N - 27
(5) Rem ove t h e m em or y swit ch fr om t h e ba ck of
t h e dr iver side fr on t door t r im pa n el.
INSTALLATION
(1) P osit ion t h e m em or y swit ch on t o t h e ba ck of
t h e dr iver side fr on t door t r im pa n el.
(2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e m em or y swit ch t o t h e ba ck of t h e dr iver side
fr on t door t r im pa n el. Tigh t en t h e scr ews t o 2.2 N·m
(20 in . lbs.).
(3) Recon n ect t h e m em or y swit ch wir e h a r n ess
con n ect or t o t h e dr iver door m odu le con n ect or r ecep-
t a cle.
(4) In st a ll t h e t r im pa n el on t o t h e dr iver side fr on t
door. Refer t o F ro n t D o o r Trim P a n e l in Body for
t h e pr ocedu r e.
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
PASSEN GER SEAT SWI T CH
DESCRIPTION
Two differ en t power sea t swit ch es a r e u sed on t h is
veh icle, depen din g u pon t h e opt ion a l power sea t sys-
t em in st a lled in t h e veh icle. Th e six-wa y power sea t s
a r e ea ch equ ipped wit h a swit ch fea t u r in g t h r ee
swit ch con t r ol kn obs ga n ged t oget h er on t h e ou t boa r d
sea t cu sh ion side sh ield (F ig. 13). Th e t en -wa y power
sea t s a r e ea ch equ ipped wit h a swit ch fea t u r in g t wo
kn obs ga n ged t oget h er on t h e ou t boa r d sea t cu sh ion
side sh ield (F ig. 14).
Fig. 13 Six-Way Power Seat Switches - Typical
1 - OUTBOARD SEAT CUSHION SIDE SHIELD
2 - POWER SEAT TRACK SWITCHES
3 - MECHANICAL SEAT BACK RECLINER LEVER
Th e swit ch u n it s for bot h power sea t t ypes a r e
secu r ed t o t h e ba ck of t h e sea t cu sh ion side sh ield
wit h t wo scr ews. H owever, t h e con t r ol kn obs for t h e
six-wa y power sea t swit ch u n it r em a in in st a lled du r-
8N - 28 POWER SEAT SYSTEM WJ
PASSEN GER SEAT SWI T CH (Cont inue d)
over loa d. H owever, con secu t ive or fr equ en t r eset t in g
of t h e cir cu it br ea ker m u st n ot be a llowed t o con -
t in u e, or t h e m ot or m a y be da m a ged.

DIAGNOSIS AND TESTING - PASSENGER SEAT

SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e power sea t swit ch fr om t h e ou t -
boa r d sea t cu sh ion side sh ield. Refer t o t h e pr ocedu r e
in t h is sect ion of t h e m a n u a l.
(3) Use a n oh m m et er t o t est t h e con t in u it y of t h e
power sea t swit ch in ea ch swit ch posit ion . See t h e
Fig. 14 Ten-Way Power Seat Switches - Typical P ower Sea t Swit ch Con t in u it y ch a r t (F ig. 15) or (F ig.
1 - OUTBOARD CUSHION SIDE SHIELD
16). If OK, r efer t o D ia g n o s is a n d Te s tin g P o w e r
2 - POWER SEAT RECLINER SWITCH S e a t Tra c k or D ia g n o s is a n d Te s tin g P o w e r S e a t
3 - POWER SEAT TRACK SWITCH Re c lin e r in t h is sect ion . If n ot OK, r epla ce t h e
4 - POWER LUMBAR SWITCH fa u lt y power sea t swit ch .

in g swit ch u n it r em ova l a n d in st a lla t ion , wh ile bot h

kn obs for t h e t en -wa y power sea t swit ch u n it m u st
be r em oved.
Th e in dividu a l swit ch es in bot h power sea t swit ch
u n it s ca n n ot be r epa ir ed. If on e swit ch is da m a ged or
fa u lt y, t h e en t ir e power sea t swit ch u n it m u st be
r epla ced.

OPERATION SIX-WAY POWER SEAT SWITCH TEST

Th e power sea t t r a cks of bot h t h e six-wa y a n d t h e RIGHT
t en -wa y power sea t syst em s ca n be a dju st ed in six LEFT SWITCH SWITCH CONTINUITY
POSITION BETWEEN
differ en t wa ys u sin g t h e power sea t swit ch es. Th e POSITION
t en -wa y syst em h a s t h e a ddit ion a l power sea t B-N, B-J, B-M,
OFF OFF
r eclin er swit ch in t egr a l t o t h e power sea t swit ch a n d B-E, B-L, B-K
a lso h a s a sepa r a t e, st a n d-a lon e swit ch t o con t r ol t h e VERTICAL A-J, A-N, B-M,
power lu m ba r a dju st er. See t h e own er ’s m a n u a l in VERTICAL UP
DOWN B-E
t h e veh icle glove box for m or e in for m a t ion on t h e VERTICAL A-E, A-M, B-N,
power sea t swit ch fu n ct ion s a n d t h e sea t a dju st in g VERTICAL UP
DOWN B-J
pr ocedu r es.
HORIZONTAL HORIZONTAL A-K, B-L
Wh en a power swit ch con t r ol kn ob or kn obs a r e FORWARD REARWARD
a ct u a t ed, a ba t t er y feed a n d a gr ou n d pa t h a r e
a pplied t h r ou gh t h e swit ch con t a ct s t o t h e power sea t FRONT TILT FRONT TILT
A-J, B-E
UP DOWN
t r a ck or r eclin er a dju st er m ot or. Th e select ed
a dju st er m ot or oper a t es t o m ove t h e sea t t r a ck or FRONT TILT FRONT TILT
A-E, B-J
r eclin er t h r ou gh it s dr ive u n it in t h e select ed dir ec- DOWN UP
t ion u n t il t h e swit ch is r elea sed, or u n t il t h e t r a vel REAR TILT UP REAR TILT A-N, B-M
lim it of t h e a dju st er is r ea ch ed. Wh en t h e swit ch is DOWN
m oved in t h e opposit e dir ect ion , t h e ba t t er y feed a n d REAR TILT
REAR TILT UP A-M, B-N
gr ou n d pa t h t o t h e m ot or a r e r ever sed t h r ou gh t h e DOWN
swit ch con t a ct s. Th is ca u ses t h e a dju st er m ot or t o
r u n in t h e opposit e dir ect ion .
Fig. 15 Rear Of Six-Way Power Seat Switch
No power sea t swit ch sh ou ld be h eld a pplied in a n y
dir ect ion a ft er t h e a dju st er h a s r ea ch ed it s t r a vel
lim it . Th e power sea t a dju st er m ot or s ea ch con t a in a
self-r eset t in g cir cu it br ea ker t o pr ot ect t h em fr om
WJ POWER SEAT SYSTEM 8N - 29
PASSEN GER SEAT SWI T CH (Cont inue d)

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) On m odels wit h t h e t en -wa y power sea t syst em
on ly, u sin g a pu sh pin r em over or a n ot h er su it a ble
wide fla t -bla ded t ool, gen t ly pr y t h e power sea t a n d
power r eclin er swit ch kn obs off of t h e swit ch st em s
(F ig. 17).

Fig. 16 Ten-Way Power Seat

Switch Connector Receptacle
SWITCH CONTINUITY BETWEEN PINS
POSITION
LEFT SEAT RIGHT SEAT

OFF PIN 1 to 2 PIN 1 to 2

PIN 1 to 3 PIN 1 to 3
PIN 1 to 4 PIN 1 to 4
PIN 1 to 6 PIN 1 to 6
PIN 1 to 7 PIN 1 to 7
PIN 1 to 8 PIN 1 to 8
PIN 1 to 9 PIN 1 to 9
PIN 1 to 10 PIN 1 to 10

FRONT RISER PIN 1 to 10 PIN 1 to 7

UP Fig. 17 Removing Switch Control Knobs - Typical
PIN 5 to 7 PIN 5 to 10
(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e ou t -
FRONT RISER PIN 1 to 7 PIN 1 to 10 boa r d sea t cu sh ion side sh ield t o t h e sea t cu sh ion
DOWN fr a m e.
PIN 5 to 10 PIN 5 to 7 (4) P u ll t h e ou t boa r d sea t cu sh ion side sh ield a wa y
fr om t h e sea t cu sh ion fr a m e fa r en ou gh t o a ccess t h e
CENTER PIN 1 to 3 PIN 1 to 3 power sea t swit ch wir e h a r n ess con n ect or.
SWITCH
FORWARD PIN 5 to 6 PIN 5 to 6
(5) Discon n ect t h e power sea t wir e h a r n ess con n ec-
t or fr om t h e power sea t swit ch con n ect or r ecept a cle.
CENTER PIN 1 to 6 PIN 1 to 6 (6) Rem ove t h e t wo scr ews t h a t secu r e t h e power
SWITCH sea t swit ch t o t h e in side of t h e ou t boa r d sea t cu sh ion
REARWARD PIN 3 to 5 PIN 3 to 5 side sh ield (F ig. 18) or (F ig. 19).
(7) Rem ove t h e power sea t swit ch fr om t h e ou t -
REAR RISER PIN 1 to 9 PIN 1 to 8
UP boa r d sea t cu sh ion side sh ield.
PIN 5 to 8 PIN 5 to 9
INSTALLATION
REAR RISER PIN 1 to 8 PIN 1 to 9 (1) P osit ion t h e power sea t swit ch on t o t h e ou t -
DOWN boa r d sea t cu sh ion side sh ield.
PIN 5 to 9 PIN 5 to 8 (2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
RECLINER UP PIN 1 to 4 PIN 1 to 4 t h e power sea t swit ch t o t h e in side of t h e ou t boa r d
sea t cu sh ion side sh ield. Tigh t en t h e scr ews t o 1.5
PIN 2 to 5 PIN 2 to 5 N·m (14 in . lbs.).
(3) Recon n ect t h e power sea t wir e h a r n ess con n ec-
RECLINER PIN 1 to 2 PIN 1 to 2 t or t o t h e power sea t swit ch con n ect or r ecept a cle.
DOWN
PIN 4 to 5 PIN 4 to 5
8N - 30 POWER SEAT SYSTEM WJ
PASSEN GER SEAT SWI T CH (Cont inue d)

RECLI N ER M OT OR
DESCRIPTION
Th e t en -wa y power sea t opt ion in clu des a n elect r i-
ca lly oper a t ed sea t ba ck r eclin er m ech a n ism . Th e
on ly visible eviden ce of t h is opt ion is t h e sepa r a t e
power sea t r eclin er swit ch con t r ol kn ob t h a t is
loca t ed on t h e ou t boa r d sea t cu sh ion side sh ield, ju st
beh in d t h e ot h er power sea t swit ch con t r ol kn ob. Th e
power sea t r eclin er swit ch is in t egr a l t o t h e t en -wa y
power sea t swit ch u n it , bu t is a ct u a t ed wit h a sepa -
r a t e swit ch kn ob.
Th e power sea t r eclin er u n it is m ou n t ed in t h e
pla ce of a sea t h in ge on t h e ou t boa r d side of t h e sea t
(F ig. 20). Th e u pper h in ge pla t e of t h e power sea t
r eclin er m ech a n ism is secu r ed wit h t wo scr ews t o t h e
Fig. 18 Six-Way Power Seat Switches Remove/ sea t ba ck fr a m e a n d is con cea led ben ea t h t h e sea t
Install ba ck t r im cover a n d pa ddin g. Th e lower h in ge pla t e
1 - SEAT SIDE SHIELD a n d t h e m ot or a n d dr ive u n it of t h e power sea t
2 - POWER SEAT SWITCH r eclin er m ech a n ism is secu r ed wit h t wo scr ews t o t h e
3 - SCREWS
sea t cu sh ion fr a m e, a n d is con cea led by t h e ou t boa r d
sea t cu sh ion side sh ield.
Th e power sea t r eclin er ca n n ot be r epa ir ed. If t h e
u n it is fa u lt y or da m a ged, it m u st be r epla ced. Refer
t o B u c k e t S e a t Re c lin e r in Body for t h e ser vice
pr ocedu r e.

OPERATION
Th e power sea t r eclin er in clu des a r ever sible elec-
t r ic m ot or t h a t is secu r ed t o t h e lower h in ge pla t e of
t h e r eclin er u n it . Th e m ot or is con n ect ed t o a gea r box
t h a t m oves t h e u pper h in ge pla t e of t h e power sea t
r eclin er t h r ou gh a scr ew-t ype dr ive u n it . Th e dr iver
side power sea t r eclin er m ot or u sed on m odels
equ ipped wit h t h e opt ion a l m em or y syst em a lso h a s
Fig. 19 Ten-Way Power Seat Switches Remove/ a posit ion pot en t iom et er in t egr a l t o t h e m ot or a ssem -
Install bly, wh ich elect r on ica lly m on it or s t h e m ot or posit ion .
1 - POWER SEAT SWITCH
2 - SCREWS (2)
DIAGNOSIS AND TESTING - RECLINER MOTOR
3 - POWER LUMBAR SWITCH Act u a t e t h e power sea t r eclin er swit ch t o m ove t h e
4 - SEAT CUSHION SIDE SHIELD power sea t r eclin er a dju st er in ea ch dir ect ion . Th e
5 - WIRE HARNESS CONNECTOR power sea t r eclin er a dju st er sh ou ld m ove in bot h
dir ect ion s. If t h e power sea t r eclin er a dju st er fa ils t o
(4) P osit ion t h e ou t boa r d sea t cu sh ion side sh ield oper a t e in on ly on e dir ect ion , m ove t h e a dju st er a
on t o t h e sea t cu sh ion fr a m e sh or t dist a n ce in t h e opposit e dir ect ion a n d t est
(5) In st a ll a n d t igh t en t h e t h r ee scr ews t h a t secu r e a ga in t o be cer t a in t h a t t h e a dju st er is n ot a t it s
t h e ou t boa r d sea t cu sh ion side sh ield t o t h e sea t t r a vel lim it . If t h e power sea t r eclin er a dju st er st ill
cu sh ion fr a m e. Tigh t en t h e scr ews t o 1.5 N·m (14 in . fa ils t o oper a t e in on ly on e dir ect ion , r efer t o P o w e r
lbs.). S e a t S w itc h D ia g n o s is a n d Te s tin g in t h is gr ou p.
(6) On m odels wit h t h e t en -wa y power sea t syst em If t h e power r eclin er a dju st er fa ils t o oper a t e in
on ly, posit ion t h e power sea t a n d power r eclin er eit h er dir ect ion , per for m t h e followin g t est s. F or com -
swit ch kn obs on t o t h e swit ch st em s a n d pu sh on plet e cir cu it dia gr a m s, r efer t o Wirin g D ia g ra m s .
t h em fir m ly a n d even ly u n t il t h ey sn a p in t o pla ce. (1) Ch eck t h e power sea t cir cu it br ea ker in t h e
(7) Recon n ect t h e ba t t er y n ega t ive ca ble. ju n ct ion block. If OK, go t o St ep 2. If n ot OK, r epla ce
t h e fa u lt y power sea t cir cu it br ea ker.
WJ POWER SEAT SYSTEM 8N - 31
RECLI N ER M OT OR (Cont inue d)
(4) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e power sea t wir e h a r n ess con n ect or
for t h e power sea t swit ch a n d a good gr ou n d. Th er e
sh ou ld be con t in u it y. If OK, go t o St ep 5. If n ot OK,
r epa ir t h e open gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(5) Test t h e power sea t swit ch . Refer t o P o w e r
S e a t S w itc h D ia g n o s is a n d Te s tin g in t h is gr ou p.
If t h e swit ch t est s OK, t est t h e cir cu it s of t h e power
sea t wir e h a r n ess bet ween t h e power sea t r eclin er
a dju st er m ot or a n d t h e power sea t swit ch for sh or t s
or open s. If t h e cir cu it s ch eck OK, r epla ce t h e fa u lt y
power sea t r eclin er u n it . If t h e cir cu it s a r e n ot OK,
r epa ir t h e power sea t wir e h a r n ess a s r equ ir ed.

POWER SEAT T RACK

DESCRIPTION
Bot h t h e six-wa y a n d t h e t en -wa y power sea t
opt ion s in clu de a sin gle elect r ica lly oper a t ed power
sea t t r a ck u n it loca t ed u n der ea ch fr on t bu cket sea t
(F ig. 21). Th e power sea t t r a ck u n it r epla ces t h e
st a n da r d equ ipm en t m a n u a l sea t t r a cks. Th e lower
h a lf of t h e power sea t t r a ck is secu r ed a t t h e fr on t
wit h t wo scr ews t o t h e floor pa n el sea t cr oss m em ber,
a n d a t t h e r ea r wit h t wo scr ews t o t h e floor pa n el.
F ou r n u t s secu r e t h e bot t om of t h e sea t cu sh ion
fr a m e t o fou r st u ds on t h e u pper h a lf of t h e power
sea t t r a ck u n it .

Fig. 20 Power Seat Recliner and Track - Typical

1 - SEAT BACK FRAME
2 - SEAT CUSHION PAD
3 - POWER RECLINER
4 - SEAT CUSHION FRAME
5 - SHIELD
6 - POWER SEAT TRACK ADJUSTER

(2) Ch eck for ba t t er y volt a ge a t t h e power sea t cir-

cu it br ea ker in t h e ju n ct ion block. If OK, go t o St ep
3. If n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e
Fig. 21 Power Seat Track - Typical
fu se in t h e P ower Dist r ibu t ion Cen t er a s r equ ir ed.
1 - DRIVE UNITS
(3) Rem ove t h e ou t boa r d sea t cu sh ion side sh ield
2 - LOWER SEAT TRACKS
fr om t h e sea t . Discon n ect t h e sea t wir e h a r n ess con -
3 - POWER SEAT MOTORS
n ect or fr om t h e power sea t swit ch con n ect or r ecept a - 4 - SEAT CUSHION FRAME
cle. Ch eck for ba t t er y volt a ge a t t h e fu sed B(+)
cir cu it ca vit y of t h e power sea t wir e h a r n ess con n ec-
t or for t h e power sea t swit ch . If OK, go t o St ep 4. If Th e power sea t t r a ck u n it ca n n ot be r epa ir ed, a n d is
n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e ser viced on ly a s a com plet e u n it . If a n y com pon en t in
power sea t cir cu it br ea ker in t h e ju n ct ion block a s t h is u n it is fa u lt y or da m a ged, t h e en t ir e power sea t
r equ ir ed. t r a ck u n it m u st be r epla ced. Refer t o B u c k e t S e a t
Tra c k Ad ju s te r in Body for t h e ser vice pr ocedu r e.
8N - 32 POWER SEAT SYSTEM
POWER SEAT T RACK (Cont inue d)
OPERATION
Th e power sea t t r a ck u n it in clu des t h r ee r ever sible
elect r ic m ot or s t h a t a r e secu r ed t o t h e u pper h a lf of
t h e t r a ck u n it . E a ch m ot or m oves t h e sea t a dju st er
t h r ou gh a com bin a t ion of wor m -dr ive gea r boxes a n d
scr ew-t ype dr ive u n it s. E a ch of t h e t h r ee dr iver side
power sea t t r a ck m ot or s u sed on m odels equ ipped
wit h t h e opt ion a l m em or y syst em a lso h a s a posit ion
pot en t iom et er in t egr a l t o t h e m ot or a ssem bly, wh ich
elect r on ica lly m on it or s t h e m ot or posit ion .
Th e fr on t a n d r ea r of t h e sea t a r e oper a t ed by t wo
sepa r a t e ver t ica l a dju st m en t m ot or s. Th ese m ot or s
ca n be oper a t ed in depen den t ly of ea ch ot h er, t ilt in g
t h e en t ir e sea t a ssem bly for wa r d or r ea r wa r d; or,
t h ey ca n be oper a t ed in u n ison by select in g t h e
pr oper power sea t swit ch fu n ct ion s, wh ich will r a ise
or lower t h e en t ir e sea t a ssem bly. Th e t h ir d m ot or is
t h e h or izon t a l a dju st m en t m ot or, wh ich m oves t h e
sea t t r a ck in t h e for wa r d a n d r ea r wa r d dir ect ion s.
DIAGNOSIS AND TESTING - POWER SEAT
TRACK
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
h a r d wir ed com pon en t s a n d cir cu it s of t h e power sea t
syst em . H owever, if t h e veh icle is a lso equ ipped wit h
t h e opt ion a l m em or y syst em , t h ese t est s m a y n ot
pr ove con clu sive in t h e dia gn osis of t h e dr iver side
power sea t . In or der t o obt a in con clu sive t est in g of
t h e dr iver side power sea t wit h t h e m em or y syst em
opt ion , t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
t h e m em or y syst em com pon en t s m u st be ch ecked.
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e dr iver side power sea t wit h t h e m em or y
syst em opt ion r equ ir es t h e u se of a DRB! sca n t ool
a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l. Th e
DRB! sca n t ool ca n pr ovide con fir m a t ion t h a t t h e
P CI da t a bu s is fu n ct ion a l, t h a t a ll of t h e elect r on ic
m odu les a r e sen din g a n d r eceivin g t h e pr oper m es-
sa ges on t h e P CI da t a bu s, a n d t h a t t h e m em or y sys-
t em is r eceivin g t h e pr oper h a r d wir ed in pu t s a n d
r ela yin g t h e pr oper h a r d wir ed ou t pu t s t o per for m it s
dr iver side power sea t fu n ct ion s.
WJ
Act u a t e t h e power sea t swit ch t o m ove a ll t h r ee
power sea t t r a ck a dju st er s in ea ch dir ect ion . Th e
power sea t t r a ck a dju st er s sh ou ld m ove in ea ch of
t h e select ed dir ect ion s. If a power sea t t r a ck a dju st er
fa ils t o oper a t e in on ly on e dir ect ion , m ove t h e
a dju st er a sh or t dist a n ce in t h e opposit e dir ect ion
a n d t est a ga in t o be cer t a in t h a t t h e a dju st er is n ot
a t it s t r a vel lim it . If t h e power sea t t r a ck a dju st er
st ill fa ils t o oper a t e in on ly on e dir ect ion , r efer t o
P o w e r S e a t S w itc h D ia g n o s is a n d Te s tin g in t h is
gr ou p. If t h e power sea t t r a ck a dju st er fa ils t o oper-
a t e in m or e t h a n on e dir ect ion , per for m t h e followin g
t est s. F or com plet e cir cu it dia gr a m s, r efer t o Wirin g
D ia g ra m s .
(1) Ch eck t h e power sea t cir cu it br ea ker in t h e
ju n ct ion block. If OK, go t o St ep 2. If n ot OK, r epla ce
t h e fa u lt y power sea t cir cu it br ea ker.
(2) Ch eck for ba t t er y volt a ge a t t h e power sea t cir-
cu it br ea ker in t h e ju n ct ion block. If OK, go t o St ep
3. If n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e
fu se in t h e P ower Dist r ibu t ion Cen t er a s r equ ir ed.
(3) Rem ove t h e ou t boa r d sea t cu sh ion side sh ield
fr om t h e sea t . Discon n ect t h e sea t wir e h a r n ess con -
n ect or fr om t h e power sea t swit ch con n ect or r ecept a -
cle. Ch eck for ba t t er y volt a ge a t t h e fu sed B(+)
cir cu it ca vit y of t h e power sea t wir e h a r n ess con n ec-
t or for t h e power sea t swit ch . If OK, go t o St ep 4. If
n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e
power sea t cir cu it br ea ker in t h e ju n ct ion block a s
r equ ir ed.
(4) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e power sea t wir e h a r n ess con n ect or
for t h e power sea t swit ch a n d a good gr ou n d. Th er e
sh ou ld be con t in u it y. If OK, go t o St ep 5. If n ot OK,
r epa ir t h e open gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(5) Test t h e power sea t swit ch . Refer t o P o w e r
S e a t S w itc h D ia g n o s is a n d Te s tin g in t h is gr ou p.
If t h e swit ch t est s OK, t est t h e cir cu it s of t h e power
sea t wir e h a r n ess bet ween t h e in oper a t ive power sea t
t r a ck a dju st er m ot or a n d t h e power sea t swit ch for
sh or t s or open s. If t h e cir cu it s ch eck OK, r epla ce t h e
fa u lt y power sea t t r a ck u n it . If t h e cir cu it s a r e n ot
OK, r epa ir t h e power sea t wir e h a r n ess a s r equ ir ed.
WJ POWER WINDOWS 8N - 33

POWER WI N DOWS

TABLE OF CONTENTS
page page

POWER WINDOWS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 WINDOW MOTOR
DIAGNOSIS AND TESTING - POWER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
POWER WINDOW SWITCH DIAGNOSIS AND TESTING - WINDOW
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGNOSIS AND TESTING - POWER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
WINDOW SWITCH . . . . . . . . . . . . . . . . . . . . . 37

POWER WI N DOWS m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et -

wor k. Th e P CI da t a bu s n et wor k a llows t h e sh a r in g
of sen sor in for m a t ion . Th is h elps t o r edu ce wir e h a r-
DESCRIPTION
n ess com plexit y, in t er n a l con t r oller h a r dwa r e, a n d
P ower oper a t ed dr iver side a n d pa ssen ger side
com pon en t sen sor cu r r en t loa ds. At t h e sa m e t im e,
fr on t a n d r ea r door win dows a r e st a n da r d fa ct or y-in -
t h is syst em pr ovides in cr ea sed r elia bilit y, en h a n ced
st a lled equ ipm en t on t h is m odel. Th e power win dow
dia gn ost ics, a n d a llows t h e a ddit ion of m a n y n ew fea -
syst em a llows ea ch of t h e door win dows t o be r a ised
t u r e ca pa bilit ies. F or dia gn osis of t h ese elect r on ic
or lower ed elect r ica lly by oper a t in g a swit ch on t h e
m odu les or of t h e P CI da t a bu s n et wor k, t h e u se of a
t r im pa n el for t h a t door. Addit ion a lly, t h e m a st er
DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es
swit ch es on t h e dr iver side fr on t door t r im pa n el
m a n u a l a r e r ecom m en ded.
a llow a ll of t h e win dows t o be oper a t ed fr om t h e
Th e ot h er elect r on ic m odu les t h a t m a y a ffect power
dr iver sea t posit ion . A power win dow lockou t swit ch
win dow syst em oper a t ion a r e a s follows:
on t h e dr iver side fr on t door t r im pa n el will a llow t h e
• B o d y Co n tro l Mo d u le (B CM) - (Refer t o 8 -
dr iver t o disa ble a ll of t h e pa ssen ger door win dow
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
swit ch es.
ULE S/BODY CONTROL/CE NTRAL TIME R MODUL
Th e power win dow syst em fu n ct ion a lly oper a t es
- DE SCRIP TION) for m or e in for m a t ion .
wh en t h e ign it ion swit ch is in t h e On posit ion . H ow-
• D riv e r D o o r Mo d u le (D D M) -(Refer t o 8 -
ever, a u n iqu e fea t u r e of t h is syst em will a llow t h e
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
power win dows t o be oper a t ed for u p t o for t y-five sec-
ULE S/DRIVE R DOOR MODULE - DE SCRIP TION)
on ds a ft er t h e ign it ion swit ch is t u r n ed t o t h e Off
for m or e in for m a t ion .
posit ion , or u n t il a fr on t door is open ed, wh ich ever
• P a s s e n g e r D o o r Mo d u le (P D M) - (Refer t o 8 -
occu r s fir st .
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
An a u t o-down fea t u r e a llows t h e dr iver side fr on t
ULE S/DRIVE R DOOR MODULE - DE SCRIP TION)
door win dow t o be lower ed a ll t h e wa y, even if t h e
for m or e in for m a t ion .
win dow swit ch is r elea sed. Th e dr iver side fr on t door
Th is gr ou p cover s dia gn osis a n d ser vice of on ly t h e
win dow swit ch m u st be depr essed in t h e down dir ec-
elect r ica l com pon en t s in t h e power win dow syst em .
t ion t o a secon d det en t t o begin a n a u t o-down even t .
F or ser vice of m ech a n ica l com pon en t s, su ch a s t h e
Depr essin g t h e swit ch a ga in in a n y dir ect ion ca n cel
r egu la t or, lift pla t e, win dow t r a cks, or gla ss r efer t o
t h e a u t o-down even t a n d begin m ovem en t in t h e
Body. Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
dir ect ion specified.
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
Th is gr ou p cover s t h e followin g com pon en t s of t h e
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, det a ils
power win dow syst em :
of wir e h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -
• P ower win dow swit ch es
ou t in for m a t ion a n d loca t ion views for t h e va r iou s
• P ower win dow m ot or s.
wir e h a r n ess con n ect or s, splices a n d gr ou n ds. F ollow-
Cer t a in fu n ct ion s a n d fea t u r es of t h e power win -
in g a r e gen er a l descr ipt ion s of t h e m a jor com pon en t s
dow syst em r ely u pon r esou r ces sh a r ed wit h ot h er
in t h e power win dow syst em .
elect r on ic m odu les in t h e veh icle over t h e P r ogr a m -
8N - 34 POWER WINDOWS
POWER WI N DOWS (Cont inue d)
OPERATION
Th e power win dow syst em in clu des t h e Dr iver
Door Modu le (DDM) a n d P a ssen ger Door Modu le
(P DM), wh ich a r e m ou n t ed in t h eir r espect ive fr on t
door, t h e r ea r door power win dow swit ch es m ou n t ed
on t h e r ea r door s, a n d t h e power win dow m ot or s
m ou n t ed t o t h e win dow r egu la t or in ea ch door. Th e
DDM h ou ses fou r m a st er power win dow swit ch es, t h e
power win dow lockou t swit ch a n d t h e con t r ol logic for
t h e dr iver side fr on t a n d r ea r door power win dows.
Th e P DM h ou ses t h e pa ssen ger side fr on t door power
win dow swit ch a n d t h e con t r ol logic for t h e pa ssen ger
side fr on t a n d r ea r door power win dows.
Wh en a m a st er power win dow swit ch on t h e DDM
is u sed t o oper a t e a pa ssen ger side power win dow,
t h e DDM sen ds t h e win dow swit ch a ct u a t ion m es-
sa ge t o t h e P DM over t h e P r ogr a m m a ble Com m u n i-
ca t ion s In t er fa ce (P CI) da t a bu s. Th e P DM r espon ds
t o t h ese m essa ges by sen din g con t r ol ou t pu t s t o m ove
t h e pa ssen ger side power win dow m ot or s. In a ddi-
t ion , wh en t h e power win dow lockou t swit ch in t h e
DDM is a ct u a t ed t o disa ble power win dow oper a t ion ,
a lockou t m essa ge is sen t t o t h e P DM over t h e P CI
da t a bu s.
Th e Body Con t r ol Modu le (BCM) a lso su ppor t s a n d
con t r ols cer t a in fea t u r es of t h e power win dow sys-
t em . Th e BCM r eceives a h a r d wir ed in pu t fr om t h e
ign it ion swit ch . Th e pr ogr a m m in g in t h e BCM a llows
it t o pr ocess t h e in for m a t ion fr om t h is in pu t a n d
sen d ign it ion swit ch st a t u s m essa ges t o t h e DDM
a n d t h e P DM over t h e P CI da t a bu s. Th e DDM a n d
P DM u se t h is in for m a t ion a n d h a r d wir ed in pu t s
fr om t h e fr on t door a ja r swit ch es t o con t r ol t h e ligh t -
in g of t h e power win dow swit ch la m ps, a n d t o con t r ol
t h e oper a t ion of t h e power win dow a ft er ign it ion -off
fea t u r e.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e power win dow syst em .
DIAGNOSIS AND TESTING - POWER
WINDOWS
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e
h a r d wir ed com pon en t s a n d cir cu it s of t h e power
win dow syst em . H owever, t h ese t est s m a y n ot pr ove
con clu sive in t h e dia gn osis of t h is syst em . In or der t o
obt a in con clu sive t est in g of t h e power win dow sys-
t em , t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
t h e power win dow syst em com pon en t s m u st be
ch ecked.
WJ
Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
dia gn ose t h e power win dow syst em r equ ir es t h e u se
of a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
du r es m a n u a l. Th e DRB sca n t ool ca n pr ovide con fir-
m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l, t h a t a ll
of t h e elect r on ic m odu les a r e sen din g a n d r eceivin g
t h e pr oper m essa ges on t h e P CI da t a bu s, a n d t h a t
t h e power win dow m ot or s a r e bein g sen t t h e pr oper
h a r d wir ed ou t pu t s by t h e door m odu les for t h em t o
per for m t h eir power win dow syst em fu n ct ion s.
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g
a n d r et en t ion , con n ect or pin -ou t in for m a t ion a n d
loca t ion views for t h e va r iou s wir e h a r n ess con n ec-
t or s, splices a n d gr ou n ds.
ALL WINDOWS INOPERATIVE
(1) Ch eck t h e oper a t ion of t h e power lock swit ch
on t h e dr iver side fr on t door. If a ll of t h e door s lock
a n d u n lock, bu t n on e of t h e power win dows oper a t e,
u se a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r o-
cedu r es m a n u a l t o ch eck t h e Body Con t r ol Modu le
(BCM), t h e Dr iver Door Modu le (DDM) a n d t h e P CI
da t a bu s for pr oper oper a t ion . If n ot OK, go t o St ep
2.
(2) Ch eck t h e oper a t ion of t h e power lock swit ch
on t h e pa ssen ger side fr on t door. If t h e pa ssen ger
door s lock a n d u n lock, bu t t h e dr iver side fr on t door
does n ot , go t o St ep 5. If a ll of t h e power locks a n d
power win dows a r e in oper a t ive fr om bot h fr on t door s,
go t o St ep 3.
(3) Ch eck t h e fu sed B(+) fu se in t h e P ower Dist r i-
bu t ion Cen t er (P DC). If OK, go t o St ep 4. If n ot OK,
r epa ir t h e sh or t ed cir cu it or com pon en t a s r equ ir ed
a n d r epla ce t h e fa u lt y fu se.
(4) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e P DC. If OK, go t o St ep 5. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e ba t t er y a s r equ ir ed.
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e t r im pa n el fr om t h e dr iver side
fr on t door. Discon n ect t h e 15-wa y door wir e h a r n ess
con n ect or fr om t h e DDM con n ect or r ecept a cle. Ch eck
for con t in u it y bet ween t h e gr ou n d cir cu it ca vit y of
t h e 15-wa y door wir e h a r n ess con n ect or for t h e DDM
a n d a good gr ou n d. Th er e sh ou ld be con t in u it y. If
OK, go t o St ep 6. If n ot OK, r epa ir t h e open gr ou n d
cir cu it t o gr ou n d a s r equ ir ed.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
15-wa y door wir e h a r n ess con n ect or for t h e DDM. If
OK, r epla ce t h e fa u lt y DDM. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e fu se in t h e P DC a s
r equ ir ed.
WJ
POWER WI N DOWS (Cont inue d)
PASSENGER SIDE FRONT AND REAR WINDOWS
INOPERATIVE
If t h e dr iver side fr on t a n d r ea r power win dows
oper a t e, bu t t h e pa ssen ger side fr on t a n d r ea r do n ot ,
u se a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r o-
cedu r es m a n u a l t o ch eck t h e P CI da t a bu s for pr oper
oper a t ion .
ONE WINDOW INOPERATIVE
Th e win dow gla ss a n d r egu la t or m ech a n ism m u st
be fr ee t o slide u p a n d down for t h e power win dow
m ot or t o fu n ct ion pr oper ly. If t h e win dow gla ss a n d
r egu la t or is n ot fr ee t o m ove u p a n d down , t h e m ot or
will over loa d a n d t r ip t h e in t egr a l cir cu it br ea ker. To
det er m in e if t h e win dow gla ss a n d r egu la t or a r e fr ee,
discon n ect t h e r egu la t or pla t e fr om t h e gla ss. Th en
slide t h e win dow u p a n d down by h a n d.
Th er e is a n a lt er n a t e m et h od t o ch eck if t h e win -
dow gla ss a n d r egu la t or m ech a n ism is fr ee. P osit ion
t h e gla ss bet ween t h e u p a n d down st ops. Th en ,
sh a ke t h e gla ss in t h e door. Ch eck t h a t t h e gla ss ca n
be m oved sligh t ly fr om side t o side, fr on t t o r ea r, a n d
u p a n d down . Th en ch eck t h a t t h e gla ss is n ot bou n d
t igh t in t h e t r a cks.
If t h e win dow gla ss a n d r egu la t or m ech a n ism is
fr ee, r efer t o D o o r Mo d u le in E lect r ica l, P ower Win -
dows. If t h e gla ss is n ot fr ee, in spect t h e win dow
gla ss m ou n t in g a n d oper a t in g h a r dwa r e for da m a ge
or im pr oper ly in st a lled com pon en t s. Refer t o B o d y t o
ch eck for pr oper in st a lla t ion or da m a ge of t h e win -
dow gla ss m ou n t in g a n d oper a t in g h a r dwa r e.
DOOR MODULE
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this component. The most
reliable, efficient, and accurate means to diagnose
this component requires the use of a DRB scan tool
and the proper Diagnostic Procedures manual.
If t h e pr oblem bein g dia gn osed is a r ea r door win -
dow t h a t does n ot oper a t e fr om t h e r ea r door swit ch ,
bu t does oper a t e fr om t h e m a st er swit ch on t h e
dr iver side fr on t door, (Refer t o 8 - E LE CTRICAL/
P OWE R WINDOWS/P OWE R WINDOW SWITCH -
DIAGNOSIS AND TE STING). If t h e pr oblem is a
pa ssen ger side fr on t or r ea r win dow t h a t oper a t es
fr om t h e swit ch on t h a t door, bu t does n ot oper a t e
fr om t h e m a st er swit ch on t h e dr iver side fr on t door,
u se a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r o-
cedu r es m a n u a l t o dia gn ose t h e cir cu it r y of bot h door
m odu les a n d t h e P CI da t a bu s. F or com plet e cir cu it
dia gr a m s, r efer t o t h e a ppr opr ia t e wir in g in for m a -
t ion . Th e wir in g in for m a t ion in clu des wir in g dia -
gr a m s, pr oper wir e a n d con n ect or r epa ir pr ocedu r es,
det a ils of wir e h a r n ess r ou t in g a n d r et en t ion , con n ec-
POWER WINDOWS 8N - 35
t or pin -ou t in for m a t ion a n d loca t ion views for t h e
va r iou s wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e t r im pa n el fr om t h e fr on t door, bu t
do n ot discon n ect t h e door wir e h a r n ess con n ect or s
fr om t h e door m odu le. Go t o St ep 2.
(2) Ch eck t h e 15-wa y door wir e h a r n ess con n ect or
for t h e door m odu le t o see t h a t it is fu lly sea t ed in
t h e door m odu le con n ect or r ecept a cle. If OK, go t o
St ep 3. If n ot OK, pr oper ly con n ect t h e 15-wa y door
wir e h a r n ess con n ect or for t h e door m odu le t o t h e
door m odu le con n ect or r ecept a cle.
(3) Discon n ect t h e 15-wa y door wir e h a r n ess con -
n ect or fr om t h e door m odu le con n ect or r ecept a cle.
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
it y of t h e 15-wa y door wir e h a r n ess con n ect or for t h e
door m odu le a n d a good gr ou n d. Th er e sh ou ld be con -
t in u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e
open gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(4) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
15-wa y door wir e h a r n ess con n ect or for t h e door
m odu le. If OK, go t o St ep 5. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e fu se in t h e P ower Dis-
t r ibu t ion Cen t er (P DC) a s r equ ir ed.
(5) If t h e in oper a t ive win dow is on a fr on t door, go
t o St ep 6. If t h e in oper a t ive win dow is on a r ea r door
go t o St ep 9.
(6) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e door wir e h a r n ess con n ect or
fr om t h e in oper a t ive power win dow m ot or wir e h a r-
n ess con n ect or. Ch eck for con t in u it y bet ween t h e
fr on t win dow dr iver u p cir cu it ca vit y of t h e 15-wa y
door wir e h a r n ess con n ect or for t h e door m odu le a n d
a good gr ou n d. Repea t t h e ch eck for t h e fr on t win dow
dr iver down cir cu it . In ea ch ca se t h er e sh ou ld be n o
con t in u it y. If OK, go t o St ep 7. If n ot OK, r epa ir t h e
sh or t ed fr on t win dow dr iver u p or down cir cu it a s
r equ ir ed.
(7) Ch eck for con t in u it y bet ween t h e fr on t win dow
dr iver u p cir cu it ca vit ies of t h e 15-wa y door wir e h a r-
n ess con n ect or for t h e door m odu le a n d t h e door wir e
h a r n ess con n ect or for t h e power win dow m ot or.
Repea t t h e ch eck for t h e fr on t win dow dr iver down
cir cu it . In ea ch ca se t h er e sh ou ld be con t in u it y. If
OK, go t o St ep 8. If n ot OK, r epa ir t h e open fr on t
win dow dr iver u p or down cir cu it a s r equ ir ed.
(8) Recon n ect t h e 15-wa y door wir e h a r n ess con -
n ect or ba ck in t o t h e door m odu le con n ect or r ecept a -
cle. Con n ect t h e ba t t er y n ega t ive ca ble. Con n ect t h e
pr obes of a r ever sible DC digit a l volt m et er t o t h e
door wir e h a r n ess con n ect or for t h e power win dow
m ot or. Obser ve t h e volt m et er wh ile a ct u a t in g t h e
swit ch for t h a t win dow in t h e u p a n d down dir ec-
t ion s. Th er e sh ou ld be ba t t er y volt a ge for a s lon g a s
t h e swit ch is h eld in bot h t h e u p a n d down posit ion s,
8N - 36 POWER WINDOWS
POWER WI N DOWS (Cont inue d)
a n d n o volt a ge in t h e n eu t r a l posit ion . If OK,(Refer
t o 8 - E LE CTRICAL/P OWE R WINDOWS/WINDOW
MOTOR - DIAGNOSIS AND TE STING). If n ot OK,
r epla ce t h e fa u lt y door m odu le.
(9) Ch eck t h e r ea r door power win dow swit ch con -
t in u it y. (Refer t o 8 - E LE CTRICAL/P OWE R WIN-
DOWS/P OWE R WINDOW SWITCH - DIAGNOSIS
AND TE STING). If OK, go t o St ep 10. If n ot OK,
r epla ce t h e fa u lt y r ea r door power win dow swit ch .
(10) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Recon n ect t h e door wir e h a r n ess con n ect or t o
t h e r ea r door power win dow swit ch . Discon n ect t h e
door wir e h a r n ess con n ect or fr om t h e in oper a t ive
power win dow m ot or wir e h a r n ess con n ect or. Ch eck
for con t in u it y bet ween t h e r ea r win dow dr iver u p cir-
cu it ca vit y of t h e 15-wa y door wir e h a r n ess con n ect or
for t h e door m odu le a n d a good gr ou n d. Repea t t h e
ch eck for t h e r ea r win dow dr iver down cir cu it . In
ea ch ca se t h er e sh ou ld be n o con t in u it y. If OK, go t o
St ep 11. If n ot OK, r epa ir t h e sh or t ed r ea r win dow
dr iver u p or down cir cu it a s r equ ir ed.
(11) Ch eck for con t in u it y bet ween t h e r ea r win dow
dr iver u p cir cu it ca vit ies of t h e 15-wa y door wir e h a r-
n ess con n ect or for t h e door m odu le a n d t h e power
win dow m ot or wir e h a r n ess con n ect or. Repea t t h e
ch eck for t h e r ea r win dow dr iver down cir cu it . In
ea ch ca se t h er e sh ou ld be con t in u it y. If OK, go t o
St ep 12. If n ot OK, r epa ir t h e open r ea r win dow
dr iver u p or down cir cu it a s r equ ir ed.
NOTE: The door module feeds battery current to
both terminals of the rear door power window
motors when the power window lockout switch is in
the Unlock position, until the master window switch
on the driver side front door is actuated. The door
module feeds ground to both terminals of the rear
door power window motor when the power window
lockout switch is in the Lock position, until the
master window switch on the driver side front door
is actuated.
(12) Recon n ect t h e 15-wa y door wir e h a r n ess con -
n ect or for t h e door m odu le t o t h e door m odu le con -
n ect or r ecept a cle. Con n ect t h e ba t t er y n ega t ive ca ble.
Ch eck for ba t t er y volt a ge a t ea ch ca vit y in t h e door
wir e h a r n ess con n ect or for t h e power win dow m ot or.
E a ch ca vit y sh ou ld h a ve ba t t er y volt a ge wh en t h e
power win dow swit ch is in t h e n eu t r a l posit ion . E a ch
ca vit y sh ou ld a lso h a ve ba t t er y volt a ge in on e ot h er
swit ch posit ion , eit h er u p or down , a n d zer o volt s
wit h t h e swit ch in t h e opposit e posit ion . If OK, (Refer
t o 8 - E LE CTRICAL/P OWE R WINDOWS/WINDOW
MOTOR - DIAGNOSIS AND TE STING). If n ot OK,
r epla ce t h e fa u lt y door m odu le.
WJ
POWER WI N DOW SWI T CH
DESCRIPTION
Th e power win dow m ot or s a r e con t r olled by a t wo-
wa y m om en t a r y swit ch m ou n t ed on t h e t r im pa n el of
ea ch pa ssen ger door, a n d fou r t wo-wa y m om en t a r y
swit ch es on t h e dr iver side fr on t door t r im pa n el. Th e
dr iver side fr on t door t r im pa n el a lso h a s a t wo-posi-
t ion power win dow lockou t swit ch . E a ch power win -
dow swit ch , except t h e lockou t swit ch , is illu m in a t ed
by a Ligh t -E m it t in g Diode (LE D) t h a t is in t egr a l t o
t h e swit ch pa ddle.
Th e fr on t door power win dow swit ch es a n d t h e
power win dow lockou t swit ch a r e in t egr a l t o t h e
Dr iver Door Modu le (DDM) a n d P a ssen ger Door
Modu le (P DM). Th e fr on t door power win dow
swit ch es a n d t h eir la m ps ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e en t ir e DDM
or P DM u n it m u st be r epla ced. Th e r ea r door power
win dow swit ch es a n d t h eir la m ps ca n n ot be a dju st ed
or r epa ir ed bu t , if fa u lt y or da m a ged, on ly t h e
a ffect ed r ea r door power win dow swit ch m u st be
r epla ced. (Refer t o 8 - E LE CTRICAL/E LE CTRONIC
CONTROL MODULE S/DRIVE R DOOR MODULE -
RE MOVAL).
OPERATION
Th e fr on t door power win dow swit ch es pr ovide a n
u p or down (or lock a n d u n lock sign a l in t h e ca se of
t h e lockou t swit ch ) t o t h e door m odu le cir cu it r y. Th e
Dr iver Door Modu le (DDM) cir cu it r y con t r ols t h e ou t -
pu t t o t h e dr iver side fr on t a n d r ea r door power win -
dow m ot or s, a n d su pplies elect r ica l cu r r en t a s
r equ ir ed for t h e st a n d-a lon e oper a t ion of t h e dr iver
side r ea r door power win dow swit ch . Th e P a ssen ger
Door Modu le (P DM) cir cu it r y con t r ols t h e ou t pu t t o
t h e pa ssen ger side fr on t a n d r ea r door power win dow
m ot or s, a n d su pplies elect r ica l cu r r en t a s r equ ir ed
for t h e st a n d-a lon e oper a t ion of t h e pa ssen ger side
r ea r door power win dow swit ch .
Wh en a DDM-in t egr a t ed m a st er power win dow
swit ch for a pa ssen ger side win dow is a ct u a t ed, or
wh en t h e power win dow lockou t swit ch is a ct u a t ed t o
disa ble t h e pa ssen ger door power win dows, t h e DDM
cir cu it r y sen ds a m essa ge t o t h e P DM over t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s
t o con t r ol t h e ou t pu t t o t h a t power win dow m ot or (s).
Th e power win dow swit ch for t h e dr iver side fr on t
door power win dow h a s t wo det en t posit ion s in t h e
Down dir ect ion . Th e fir st det en t pr ovides n or m a l
power win dow down oper a t ion . If t h is swit ch is
depr essed t o t h e secon d det en t , t h e Au t o Down cir-
cu it r y of t h e DDM is a ct iva t ed. Th e Au t o-Down cir-
cu it r y will a u t om a t ica lly m ove t h e dr iver side fr on t
door win dow t o it s fu lly lower ed posit ion , even if t h e
power win dow swit ch is r elea sed. Th e Au t o-Down
WJ POWER WINDOWS 8N - 37
POWER WI N DOW SWI T CH (Cont inue d)
even t will be a u t om a t ica lly ca n celled a n d t h e win dow
m ovem en t will be st opped if t h e DDM cir cu it r y
det ect s a secon d in pu t fr om t h e dr iver side fr on t door
power win dow swit ch , in eit h er dir ect ion .
E a ch power win dow swit ch , except t h e lockou t
swit ch , is illu m in a t ed by a Ligh t -E m it t in g Diode
(LE D) wh en t h e ign it ion swit ch is t u r n ed t o t h e On
posit ion . H owever, wh en t h e lockou t swit ch is pla ced
in t h e Lock posit ion , t h e LE D for t h e locked-ou t fr on t
a n d r ea r pa ssen ger door power win dow swit ch es is
t u r n ed off.
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of t h e power win dow swit ch es.

DIAGNOSIS AND TESTING - POWER WINDOW

SWITCH Fig. 1 Rear Door Power Window Switch Continuity
Th e dia gn osis fou n d h er e a pplies on ly t o t h e r ea r SWITCH POSITION CONTINUITY BETWEEN
door power win dow swit ch es. If t h e pr oblem bein g LED 3 AND 6
dia gn osed is a n in oper a t ive power win dow swit ch OFF 1 AND 2
illu m in a t ion la m p, bu t t h e power win dow swit ch OFF 4 AND 5
oper a t es a s design ed, r epla ce t h e fa u lt y r ea r door FORWARD 1 AND 2
FORWARD 5 AND 6
power win dow swit ch (v e rify th e p o w e r lo c k o u t
REARWARD 2 AND 6
s w itc h is n o t a c tu a te d ). F or com plet e cir cu it dia -
REARWARD 4 AND 5
gr a m s, r efer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, det a ils
of wir e h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -
ou t in for m a t ion a n d loca t ion views for t h e va r iou s
wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e power win dow swit ch fr om t h e
r ea r door t r im pa n el. (Refer t o 8 - E LE CTRICAL/
P OWE R WINDOWS/P OWE R WINDOW SWITCH -
RE MOVAL).
(3) Ch eck t h e r ea r door power win dow swit ch con -
t in u it y a s sh own in t h e Rea r Door P ower Win dow
Swit ch Con t in u it y ch a r t (F ig. 1). If OK, (Refer t o 8 -
E LE CTRICAL/P OWE R WINDOWS/WINDOW
MOTOR - DIAGNOSIS AND TE STING). If n ot OK,
r epla ce t h e fa u lt y r ea r door power win dow swit ch .

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e t r im pa n el fr om t h e r ea r door.
(Refer t o 23 - BODY/DOORS - RE AR/TRIM PANE L -
Fig. 2 Rear Door Power Window Switch Remove/
RE MOVAL) for t h e pr ocedu r es.
Install
(3) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y t h e sides of t h e swit ch 1 - REAR DOOR TRIM PANEL
2 - TRIM PANEL RECEPTACLE
r ecept a cle on t h e ba ck of t h e r ea r door t r im pa n el
3 - POWER WINDOW SWITCH
a wa y fr om t h e per im et er of t h e power win dow swit ch
t o r elea se t h e swit ch fr om t h e r ecept a cle (F ig. 2).
(4) Rem ove t h e power win dow swit ch fr om t h e
r ea r door t r im pa n el swit ch r ecept a cle.
8N - 38 POWER WINDOWS
POWER WI N DOW SWI T CH (Cont inue d)
INSTALLATION
(1) P osit ion t h e power win dow swit ch t o t h e r ea r
door t r im pa n el swit ch r ecept a cle.
(2) P r ess fir m ly a n d even ly on t h e ba ck of t h e
power win dow swit ch u n t il it sn a ps in t o r ea r door
t r im pa n el swit ch r ecept a cle.
(3) In st a ll t h e t r im pa n el on t o t h e r ea r door. (Refer
t o 23 - BODY/DOORS - RE AR/TRIM PANE L -
INSTALLATION) for t h e pr ocedu r es.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
WI N DOW M OT OR
DESCRIPTION
P ower oper a t ed fr on t a n d r ea r door win dows a r e
st a n da r d equ ipm en t on t h is m odel. E a ch door h a s a
per m a n en t m a gn et r ever sible elect r ic m ot or wit h a n
in t egr a l r igh t a n gle gea r box m ech a n ism t h a t oper-
a t es t h e win dow r egu la t or. In a ddit ion , ea ch power
win dow m ot or is equ ipped wit h a n in t egr a l self-r eset -
t in g cir cu it br ea ker t o pr ot ect t h e m ot or fr om over-
loa ds.
Th e power win dow m ot or gea r box h ou sin g is
secu r ed t o t h e win dow r egu la t or dr u m h ou sin g wit h
scr ews. Th e win dow r egu la t or s u sed in a ll fou r door s
a r e sin gle ver t ica l post ca ble-a n d-dr u m t ype. A
m olded pla st ic slider gu ided by t h e post is dr iven by
t h e r egu la t or ca bles. Th e slider r a ises a n d lower s t h e
win dow gla ss t h r ou gh a st eel lift pla t e a t t a ch m en t .
F r on t a n d r ea r gla ss ch a n n els wit h in ea ch door gu ide
a n d st a bilize ea ch en d of t h e gla ss.
Th e power win dow m ot or a n d gea r box a ssem bly
ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged, t h e
en t ir e power win dow m ot or a n d gea r box u n it m u st be
r epla ced. Th e win dow r egu la t or s a r e a va ila ble for
ser vice. (Refer t o 23 - BODY/DOOR - F RONT/WIN-
DOW RE GULATOR - RE MOVAL) or (Refer t o 23 -
BODY/DOORS - RE AR/WINDOW RE GULATOR -
RE MOVAL) for t h e r egu la t or ser vice pr ocedu r es.
OPERATION
A posit ive a n d n ega t ive ba t t er y con n ect ion t o t h e
t wo m ot or t er m in a ls will ca u se t h e power win dow
m ot or t o r ot a t e in on e dir ect ion . Rever sin g t h e cu r-
r en t t h r ou gh t h ese sa m e t wo con n ect ion s will ca u se
t h e m ot or t o r ot a t e in t h e opposit e dir ect ion .
Wh en t h e power win dow m ot or oper a t es, it r ot a t es
t h e r egu la t or ca ble dr u m t h r ou gh it s gea r box. Th e
win dow r egu la t or ca ble dr u m is con n ect ed t h r ou gh
t wo ca bles t o t h e pla st ic slider on t h e ver t ica l post .
As t h e ca ble dr u m r ot a t es, it let s ca ble ou t on on e
side of t h e dr u m , a n d t a kes ca ble in on t h e ot h er side
of t h e dr u m . Th e ch a n ges in ca ble len gt h m ove t h e
slider u p or down t h e ver t ica l post , r a isin g or lower-
in g t h e win dow gla ss.
WJ
If t h e win dow r egu la t or or win dow gla ss bin d,
en cou n t er obst r u ct ion s, or r ea ch t h eir t r a vel lim it s it
over loa ds t h e power win dow m ot or. Th e over loa din g
con dit ion ca u ses t h e power win dow m ot or self-r eset -
t in g cir cu it br ea ker t o open , wh ich st ops t h e m ot or
fr om r u n n in g.
DIAGNOSIS AND TESTING - WINDOW MOTOR
Befor e you pr oceed wit h t h is dia gn osis, con fir m
pr oper swit ch oper a t ion . (Refer t o 8 - E LE CTRICAL/
E LE CTRONIC CONTROL MODULE S/DRIVE R
DOOR MODULE - OP E RATION) or (Refer t o 8 -
E LE CTRICAL/P OWE R WINDOWS/P OWE R WIN-
DOW SWITCH - OP E RATION). F or com plet e cir cu it
dia gr a m s, r efer t o t h e a ppr opr ia t e wir in g in for m a -
t ion . Th e wir in g in for m a t ion in clu des wir in g dia -
gr a m s, pr oper wir e a n d con n ect or r epa ir pr ocedu r es,
det a ils of wir e h a r n ess r ou t in g a n d r et en t ion , con n ec-
t or pin -ou t in for m a t ion a n d loca t ion views for t h e
va r iou s wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
(1) Rem ove t h e t r im pa n el fr om t h e door wit h t h e
in oper a t ive power win dow. (Refer t o 23 - BODY/
DOOR - F RONT/TRIM PANE L - RE MOVAL) or
(Refer t o 23 - BODY/DOORS - RE AR/TRIM PANE L -
RE MOVAL) for t h e pr ocedu r es.
(2) Discon n ect t h e door wir e h a r n ess con n ect or
fr om t h e power win dow m ot or wir e h a r n ess con n ec-
t or. Apply ba t t er y cu r r en t t o on e ca vit y of t h e power
win dow m ot or wir e h a r n ess con n ect or, a n d a pply
gr ou n d t o t h e ot h er ca vit y of t h e con n ect or. Th e
power win dow m ot or sh ou ld oper a t e in on e dir ect ion .
Rem em ber, if t h e win dow is in t h e fu ll u p or fu ll
down posit ion , t h e m ot or will n ot oper a t e in t h a t
dir ect ion by design . If OK, go t o St ep 3. If n ot OK,
r epla ce t h e fa u lt y power win dow m ot or.
(3) Rever se t h e ba t t er y a n d gr ou n d con n ect ion s t o
t h e t wo ca vit ies of t h e power win dow m ot or wir e h a r-
n ess con n ect or. Th e power win dow m ot or sh ou ld n ow
oper a t e in t h e ot h er dir ect ion . Rem em ber, if t h e win -
dow is in t h e fu ll u p or fu ll down posit ion , t h e m ot or
will n ot oper a t e in t h a t dir ect ion by design . If OK, go
t o St ep 4. If n ot OK, r epla ce t h e fa u lt y power win dow
m ot or.
(4) If t h e power win dow m ot or oper a t es in bot h
dir ect ion s, ch eck t h e oper a t ion of t h e win dow gla ss
a n d r egu la t or m ech a n ism t h r ou gh it s com plet e u p
a n d down t r a vel. Th er e sh ou ld be n o bin din g or st ick-
in g of t h e win dow gla ss or r egu la t or m ech a n ism
t h r ou gh t h e en t ir e t r a vel r a n ge. If n ot OK, (Refer t o
23 - BODY/DOOR - F RONT/WINDOW RE GULATOR
- RE MOVAL) or (Refer t o 23 - BODY/DOORS -
RE AR/WINDOW RE GULATOR - RE MOVAL) t o
ch eck for pr oper in st a lla t ion or da m a ge of t h e win -
dow gla ss m ou n t in g a n d oper a t in g h a r dwa r e.
WJ POWER WINDOWS 8N - 39
WI N DOW M OT OR (Cont inue d)

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e win dow r egu la t or fr om t h e door.
(Refer t o 23 - BODY/DOOR - F RONT/WINDOW
RE GULATOR - RE MOVAL) or (Refer t o 23 - BODY/
DOORS - RE AR/WINDOW RE GULATOR
RE MOVAL) for t h e pr ocedu r es.
(3) P la ce t h e win dow r egu la t or on a su it a ble wor k
su r fa ce a n d r em ove t h e scr ews t h a t secu r e t h e power
win dow m ot or t o t h e win dow r egu la t or.
(4) Rem ove t h e power win dow m ot or fr om t h e win -
dow r egu la t or.
INSTALLATION
(1) P osit ion t h e power win dow m ot or on t o t h e win -
dow r egu la t or.
(2) In st a ll a n d t igh t en t h e scr ews t h a t secu r e t h e
power win dow m ot or t o t h e win dow r egu la t or.
Tigh t en t h e scr ews t o 9 N·m (80 in . lbs.).
- (3) In st a ll t h e win dow r egu la t or on t o t h e door.
(Refer t o 23 - BODY/DOOR - F RONT/WINDOW
RE GULATOR - INSTALLATION) or (Refer t o 23 -
BODY/DOORS - RE AR/WINDOW RE GULATOR -
INSTALLATION) for t h e pr ocedu r es.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ RESTRAINTS 8O - 1

RESTRAINTS
TABLE OF CON T EN T S

page page

RESTRAINTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT IMPACT SENSOR & BRACKET
WARNING - RESTRAINT SYSTEM . . . . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - SUPPLEMENTAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . 5 FRONT SEAT BELT & RETRACTOR
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STANDARD PROCEDURE - HANDLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
NON-DEPLOYED SUPPLEMENTAL FRONT SEAT BELT BUCKLE
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
STANDARD PROCEDURE - SERVICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
AFTER A SUPPLEMENTAL RESTRAINT PASSENGER AIRBAG
DEPLOYMENT. . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
STANDARD PROCEDURE - VERIFICATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AIRBAG CONTROL MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REAR CENTER SEAT BELT & RETRACTOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 REAR OUTBOARD SEAT BELT & RETRACTOR
CHILD TETHER ANCHOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REAR SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
CLOCKSPRING SEAT BELT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STANDARD PROCEDURE - CLOCKSPRING SEAT BELT TURNING LOOP ADJUSTER
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17 SIDE CURTAIN AIRBAG
DRIVER AIRBAG DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 20 SIDE IMPACT SENSOR
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FRONT IMPACT SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

REST RAI N T S occu pa n t r est r a in t s for t h is m odel in clu de bot h a ct ive

a n d pa ssive t ypes. Act ive r est r a in t s a r e t h ose wh ich
r equ ir e t h e veh icle occu pa n t s t o t a ke som e a ct ion t o
DESCRIPTION
em ploy, su ch a s fa st en in g a sea t belt ; wh ile pa ssive
An occu pa n t r est r a in t syst em is st a n da r d fa ct or y-
r est r a in t s r equ ir e n o a ct ion by t h e veh icle occu pa n t s
in st a lled sa fet y equ ipm en t on t h is m odel. Ava ila ble
t o be em ployed (F ig. 1).
8O - 2 RESTRAINTS WJ
REST RAI N T S (Cont inue d)

Fig. 1 Supplemental Restraints

1 - FRONT IMPACT SENSOR (2) 4 - AIRBAG CONTROL MODULE
2 - PASSENGER AIRBAG 5 - SIDE IMPACT SENSOR (2)
3 - DRIVER AIRBAG 6 - SIDE CURTAIN AIRBAG (2)
WJ
REST RAI N T S (Cont inue d)
ACTIVE RESTRAINTS
Th e a ct ive r est r a in t s for t h is m odel in clu de:
• F ro n t S e a t B e lts - Bot h fr on t sea t in g posit ion s
a r e equ ipped wit h t h r ee-poin t sea t belt syst em s
em ployin g a lower B-pilla r m ou n t ed in er t ia la t ch -
t ype r et r a ct or, h eigh t -a dju st a ble u pper B-pilla r
m ou n t ed t u r n in g loops, a fixed lower sea t belt a n ch or
secu r ed t o t h e lower B-pilla r, a n d a fixed en d-r elea se
sea t belt bu ckle secu r ed t o t h e side of t h e floor pa n el
t r a n sm ission t u n n el. Bot h fr on t sea t belt bu ckles
in clu de a n in t egr a l H a ll-effect sea t belt swit ch t h a t
det ect s wh et h er it s r espect ive sea t belt h a s been fa s-
t en ed.
• Re a r S e a t B e lts - Bot h ou t boa r d r ea r sea t in g
posit ion s a r e equ ipped wit h t h r ee-poin t sea t belt sys-
t em s. Th e ou t boa r d sea t in g posit ion belt s em ploy a
lower C-pilla r m ou n t ed in er t ia la t ch -t ype r et r a ct or,
h eigh t -a dju st a ble u pper C-pilla r m ou n t ed t u r n in g
loops, a n d a fixed lower sea t belt a n ch or secu r ed t o
t h e floor pa n el. Th e cen t er r ea r sea t in g posit ion of
veh icles m a n u fa ct u r ed for sa le in Nor t h Am er ica h a s
a la p belt t h a t is a n ch or ed t o t h e r ea r floor pa n el
wit h t h e r igh t ou t boa r d sea t belt bu ckle. Veh icles
m a n u fa ct u r ed for sa le ou t side of Nor t h Am er ica a r e
equ ipped wit h a t h r ee-poin t sea t belt in t h e r ea r sea t
cen t er sea t in g posit ion . Th is sea t belt h a s a n in er t ia
la t ch -t ype r et r a ct or t h a t is in t egr a l t o t h e r ea r sea t
ba ck pa n el, a n d t h e lower belt a n ch or is secu r ed t o
t h e r ea r floor pa n el wit h t h e r igh t ou t boa r d sea t belt
bu ckle. A ca ble fr om t h e sea t ba ck la t ch locks t h e
cen t er belt r et r a ct or spool u n less t h e sea t ba ck is
fu lly la t ch ed. All t h r ee r ea r sea t belt s h a ve fixed en d-
r elea se sea t belt bu ckles secu r ed t o t h e r ea r floor
pa n el, a sin gle bu ckle u n it on t h e r igh t side a n d a
dou ble bu ckle u n it on t h e left side.
• Ch ild S e a t Te th e r An c h o rs - All veh icles a r e
equ ipped wit h t h r ee, fixed-posit ion , ch ild sea t u pper
t et h er a n ch or s a n d t wo lower a n ch or s. Two u pper
a n ch or s a r e in t egr a l t o t h e ba ck of t h e r igh t r ea r sea t
ba ck pa n el, a n d on e is in t egr a l t o t h e left r ea r sea t
ba ck pa n el. Th e t wo lower a n ch or s a r e in t egr a l t o t h e
ou t boa r d r ea r sea t ba ck br a cket s.
PASSIVE RESTRAINTS
Th e pa ssive r est r a in t s a va ila ble for t h is m odel
in clu de t h e followin g:
• D u a l F ro n t Airba g s - Mu lt ist a ge dr iver a n d
fr on t pa ssen ger a ir ba gs a r e a va ila ble for t h is m odel.
Th is a ir ba g syst em is a pa ssive, in fla t a ble, Su pple-
m en t a l Rest r a in t Syst em (SRS) a n d veh icles wit h
t h is equ ipm en t ca n be r ea dily iden t ified by t h e “SRS
- AIRBAG” logo m olded in t o t h e dr iver a ir ba g t r im
cover in t h e cen t er of t h e st eer in g wh eel a n d a lso
in t o t h e pa ssen ger a ir ba g door a r ea of t h e in st r u -
m en t pa n el t op pa d a bove t h e glove box (F ig. 2).
Veh icles wit h t h e a ir ba g syst em ca n a lso be iden t ified
RESTRAINTS 8O - 3
by t h e a ir ba g in dica t or, wh ich will illu m in a t e in t h e
in st r u m en t clu st er for a bou t seven secon ds a s a bu lb
t est ea ch t im e t h e ign it ion swit ch is t u r n ed t o t h e On
posit ion .
• S id e Cu rta in Airba g s - Opt ion a l side cu r t a in
a ir ba gs a r e a va ila ble for t h is m odel wh en it is a lso
equ ipped wit h du a l fr on t a ir ba gs. Th is a ir ba g syst em
is a pa ssive, in fla t a ble, Su pplem en t a l Rest r a in t Sys-
t em (SRS) a n d veh icles wit h t h is equ ipm en t ca n be
r ea dily iden t ified by a m olded iden t ifica t ion t r im bu t -
t on wit h t h e “SRS - AIRBAG” logo loca t ed on t h e
h ea dlin er a bove ea ch B-pilla r (F ig. 2).
Fig. 2 SRS Logo
Th e su pplem en t a l r est r a in t syst em in clu des t h e
followin g m a jor com pon en t s, wh ich a r e descr ibed in
fu r t h er det a il elsewh er e in t h is ser vice in for m a t ion :
• Airba g Co n tro l Mo d u le - Th e Air ba g Con t r ol
Modu le (ACM) is a lso som et im es r efer r ed t o a s t h e
Occu pa n t Rest r a in t Con t r oller (ORC). Th e ACM is
loca t ed on a m ou n t on t h e floor pa n el t r a n sm ission
t u n n el n ea r t h e pa r k br a ke r elea se m ech a n ism ,
u n der t h e cen t er floor con sole.
• Airba g In d ic a to r - Th e a ir ba g in dica t or is in t e-
gr a l t o t h e E lect r oMech a n ica l In st r u m en t Clu st er
(E MIC), wh ich is loca t ed on t h e in st r u m en t pa n el in
fr on t of t h e dr iver.
• Clo c k s p rin g - Th e clockspr in g is loca t ed n ea r
t h e t op of t h e st eer in g colu m n , dir ect ly ben ea t h t h e
st eer in g wh eel.
• D riv e r Airba g - Th e dr iver a ir ba g is loca t ed in
t h e cen t er of t h e st eer in g wh eel, ben ea t h t h e dr iver
a ir ba g t r im cover.
• D riv e r Kn e e B lo c k e r - Th e dr iver kn ee blocker
is a st r u ct u r a l u n it secu r ed t o t h e ba ck side of a n d
in t egr a l t o t h e in st r u m en t pa n el st eer in g colu m n
open in g cover.
• F ro n t Im p a c t S e n s o r - Two fr on t im pa ct sen -
sor s a r e u sed on veh icles equ ipped wit h du a l fr on t
a ir ba gs, on e left side a n d on e r igh t side. On e sen sor
is loca t ed on a br a cket on t h e lower in boa r d side of
ea ch ver t ica l m em ber of t h e r a dia t or su ppor t .
8O - 4 RESTRAINTS
REST RAI N T S (Cont inue d)
• P a s s e n g e r Airba g - Th e pa ssen ger a ir ba g is
loca t ed on t h e in st r u m en t pa n el, ben ea t h t h e in st r u -
m en t pa n el t op pa d a n d a bove t h e glove box on t h e
pa ssen ger side of t h e veh icle.
• P a s s e n g e r Kn e e B lo c k e r - Th e pa ssen ger kn ee
blocker is a st r u ct u r a l r ein for cem en t t h a t is in t egr a l
t o a n d con cea led wit h in t h e glove box door.
• S id e Im p a c t S e n s o r - Two side im pa ct sen sor s
a r e u sed on veh icles wit h t h e opt ion a l side cu r t a in
a ir ba gs, on e left side a n d on e r igh t side. On e sen sor
is loca t ed beh in d t h e B-pilla r t r im n ea r t h e ba se of
ea ch B-pilla r.
• S id e Cu rta in Airba g - In veh icles equ ipped
wit h t h is opt ion , a side cu r t a in a ir ba g is loca t ed on
ea ch in side r oof side r a il a bove t h e h ea dlin er, a n d
ext en ds fr om t h e A-pilla r t o ju st beyon d t h e C-pilla r.
Th e ACM a n d t h e E MIC ea ch con t a in a cen t r a l
pr ocessin g u n it a n d pr ogr a m m in g t h a t a llow t h em t o
com m u n ica t e wit h ea ch ot h er u sin g t h e P r ogr a m m a -
ble Com m u n ica t ion In t er fa ce (P CI) da t a bu s n et wor k.
Th is m et h od of com m u n ica t ion is u sed by t h e ACM
for con t r ol of t h e a ir ba g in dica t or on a ll m odels
equ ipped wit h du a l fr on t a ir ba gs. (Refer t o 8 - E LE C-
TRICAL/E LE CTRONIC CONTROL MODULE S/
COMMUNICATION - DE SCRIP TION).
H a r d wir ed cir cu it r y con n ect s t h e su pplem en t a l
r est r a in t syst em com pon en t s t o ea ch ot h er t h r ou gh
t h e elect r ica l syst em of t h e veh icle. Th ese h a r d wir ed
cir cu it s a r e in t egr a l t o sever a l wir e h a r n esses, wh ich
a r e r ou t ed t h r ou gh ou t t h e veh icle a n d r et a in ed by
m a n y differ en t m et h ods. Th ese cir cu it s m a y be con -
n ect ed t o ea ch ot h er, t o t h e veh icle elect r ica l syst em ,
a n d t o t h e su pplem en t a l r est r a in t syst em com po-
n en t s t h r ou gh t h e u se of a com bin a t ion of solder ed
splices, splice block con n ect or s, a n d m a n y differ en t
t ypes of wir e h a r n ess t er m in a l con n ect or s a n d in su -
la t or s. Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er
det a ils on wir e h a r n ess r ou t in g a n d r et en t ion , a s well
a s pin -ou t a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
OPERATION
ACTIVE RESTRAINTS
Th e pr im a r y pa ssen ger r est r a in t s in t h is or a n y
ot h er veh icle a r e t h e st a n da r d equ ipm en t fa ct or y-in -
st a lled sea t belt s. Sea t belt s a r e r efer r ed t o a s a n
a ct ive r est r a in t beca u se t h e veh icle occu pa n t s a r e
r equ ir ed t o ph ysica lly fa st en a n d pr oper ly a dju st
t h ese r est r a in t s in or der t o ben efit fr om t h em . See
t h e own er ’s m a n u a l in t h e veh icle glove box for m or e
in for m a t ion on t h e fea t u r es, u se a n d oper a t ion of a ll
of t h e fa ct or y-in st a lled a ct ive r est r a in t s.
WJ
PASSIVE RESTRAINTS
Th e pa ssive r est r a in t s syst em is r efer r ed t o a s a
su pplem en t a l r est r a in t syst em beca u se t h ey wer e
design ed a n d a r e in t en ded t o en h a n ce t h e pr ot ect ion
for t h e veh icle occu pa n t s of t h e veh icle o n ly wh en
u sed in con ju n ct ion wit h t h e sea t belt s. Th ey a r e
r efer r ed t o a s pa ssive syst em s beca u se t h e veh icle
occu pa n t s a r e n ot r equ ir ed t o do a n yt h in g t o m a ke
t h em oper a t e; h owever, t h e veh icle occu pa n t s m u st
be wea r in g t h eir sea t belt s in or der t o obt a in t h e
m a xim u m sa fet y ben efit fr om t h e fa ct or y-in st a lled
su pplem en t a l r est r a in t syst em s.
Th e su pplem en t a l r est r a in t syst em elect r ica l cir-
cu it s a r e con t in u ou sly m on it or ed a n d con t r olled by a
m icr opr ocessor a n d soft wa r e con t a in ed wit h in t h e
Air ba g Con t r ol Modu le (ACM). An a ir ba g in dica t or in
t h e E lect r oMech a n ica l In st r u m en t Clu st er (E MIC)
illu m in a t es for a bou t seven secon ds a s a bu lb t est
ea ch t im e t h e ign it ion swit ch is t u r n ed t o t h e On or
St a r t posit ion s. F ollowin g t h e bu lb t est , t h e a ir ba g
in dica t or is t u r n ed on or off by t h e ACM t o in dica t e
t h e st a t u s of t h e su pplem en t a l r est r a in t syst em . If
t h e a ir ba g in dica t or com es on a t a n y t im e ot h er t h a n
du r in g t h e bu lb t est , it in dica t es t h a t t h er e is a pr ob-
lem in t h e su pplem en t a l r est r a in t syst em elect r ica l
cir cu it s. Su ch a pr oblem m a y ca u se a ir ba gs n ot t o
deploy wh en r equ ir ed, or t o deploy wh en n ot
r equ ir ed.
Deploym en t of t h e su pplem en t a l r est r a in t s
depen ds u pon t h e a n gle a n d sever it y of a n im pa ct .
Deploym en t is n ot ba sed u pon veh icle speed; r a t h er,
deploym en t is ba sed u pon t h e r a t e of deceler a t ion a s
m ea su r ed by t h e for ces of gr a vit y (G for ce) u pon t h e
im pa ct sen sor s. Wh en a n im pa ct is sever e en ou gh ,
t h e m icr opr ocessor in t h e ACM sign a ls t h e in fla t or
u n it of t h e a ir ba g m odu le t o deploy t h e a ir ba g. Du r-
in g a fr on t a l veh icle im pa ct , t h e kn ee blocker s wor k
in con cer t wit h pr oper ly fa st en ed a n d a dju st ed sea t
belt s t o r est r a in bot h t h e dr iver a n d t h e fr on t sea t
pa ssen ger in t h e pr oper posit ion for a n a ir ba g deploy-
m en t . Th e kn ee blocker s a lso a bsor b a n d dist r ibu t e
t h e cr a sh en er gy fr om t h e dr iver a n d t h e fr on t sea t
pa ssen ger t o t h e st r u ct u r e of t h e in st r u m en t pa n el.
Typica lly, t h e veh icle occu pa n t s r eca ll m or e a bou t
t h e even t s pr ecedin g a n d followin g a collision t h a n
t h ey h a ve of a n a ir ba g deploym en t it self. Th is is
beca u se t h e a ir ba g deploym en t a n d defla t ion occu r so
r a pidly. In a t ypica l 48 kilom et er-per-h ou r (30 m ile-
per-h ou r ) ba r r ier im pa ct , fr om t h e m om en t of im pa ct
u n t il t h e a ir ba gs a r e fu lly in fla t ed t a kes a bou t 40
m illisecon ds. Wit h in on e t o t wo secon ds fr om t h e
m om en t of im pa ct , t h e a ir ba gs a r e a lm ost en t ir ely
defla t ed. Th e t im es cit ed for t h ese even t s a r e a ppr ox-
im a t ion s, wh ich a pply on ly t o a ba r r ier im pa ct a t t h e
given speed. Act u a l t im es will va r y som ewh a t ,
WJ
REST RAI N T S (Cont inue d)
depen din g u pon t h e veh icle speed, im pa ct a n gle,
sever it y of t h e im pa ct , a n d t h e t ype of collision .
Wh en t h e ACM m on it or s a pr oblem in a n y of t h e
a ir ba g syst em cir cu it s or com pon en t s, it st or es a
fa u lt code or Dia gn ost ic Tr ou ble Code (DTC) in it s
m em or y cir cu it a n d sen ds a n elect r on ic m essa ge t o
t h e E MIC t o t u r n on t h e a ir ba g in dica t or. P r oper
t est in g of t h e a ir ba g syst em com pon en t s, t h e P r o-
gr a m m a ble Com m u n ica t ion In t er fa ce (P CI) da t a bu s,
t h e da t a bu s m essa ge in pu t s t o a n d ou t pu t s fr om t h e
E MIC or t h e ACM, a s well a s t h e r et r ieva l or er a su r e
of a DTC fr om t h e ACM or E MIC r equ ir es t h e u se of
a DRBIII! sca n t ool. Refer t o t h e a ppr opr ia t e dia g-
n ost ic in for m a t ion .
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e fea t u r es, u se a n d oper a t ion
of a ll of t h e fa ct or y-in st a lled pa ssive r est r a in t s.
WARNING - RESTRAINT SYSTEM
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS
CATALOG.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
RESTRAINTS 8O - 5
WARNING: AN AIRBAG INFLATOR UNIT MAY CON-
TAIN SODIUM AZIDE AND POTASSIUM NITRATE.
THESE MATERIALS ARE POISONOUS AND
EXTREMELY FLAMMABLE. CONTACT WITH ACID,
WATER, OR HEAVY METALS MAY PRODUCE HARM-
FUL AND IRRITATING GASES (SODIUM HYDROXIDE
IS FORMED IN THE PRESENCE OF MOISTURE) OR
COMBUSTIBLE COMPOUNDS. AN AIRBAG INFLA-
TOR UNIT MAY ALSO CONTAIN A GAS CANISTER
PRESSURIZED TO OVER 2500 PSI. DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG UNIT OR
TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
INCINERATE, OR BRING INTO CONTACT WITH
ELECTRICITY. DO NOT STORE AT TEMPERATURES
EXCEEDING 93° C (200° F).
WARNING: REPLACE ALL RESTRAINT SYSTEM
COMPONENTS ONLY WITH PARTS SPECIFIED IN
THE DAIMLERCHRYSLER MOPAR PARTS CATA-
LOG. SUBSTITUTE PARTS MAY APPEAR INTER-
CHANGEABLE, BUT INTERNAL DIFFERENCES MAY
RESULT IN INFERIOR OCCUPANT PROTECTION.
WARNING: THE FASTENERS, SCREWS, AND
BOLTS ORIGINALLY USED FOR THE RESTRAINT
SYSTEM COMPONENTS HAVE SPECIAL COATINGS
AND ARE SPECIFICALLY DESIGNED FOR THE
RESTRAINT SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANY TIME A
NEW FASTENER IS NEEDED, REPLACE IT WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN
AIRBAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM
P r oper dia gn osis a n d t est in g of t h e su pplem en t a l
r est r a in t syst em com pon en t s, t h e P CI da t a bu s, t h e
da t a bu s m essa ge in pu t s t o a n d ou t pu t s fr om t h e
E lect r oMech a n ica l In st r u m en t Clu st er (E MIC) or t h e
Air ba g Con t r ol Modu le (ACM), a s well a s t h e
r et r ieva l or er a su r e of a Dia gn ost ic Tr ou ble Code
(DTC) fr om t h e ACM r equ ir es t h e u se of a DRBIII!
sca n t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
8O - 6 RESTRAINTS
REST RAI N T S (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
STAN DARD PROCEDU RE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At n o t im e sh ou ld a n y sou r ce of elect r icit y be per-
m it t ed n ea r t h e in fla t or on t h e ba ck of a n on -de-
ployed a ir ba g. Wh en ca r r yin g a n on -deployed a ir ba g,
t h e t r im cover or a ir ba g cu sh ion side of t h e u n it
sh ou ld be poin t ed a wa y fr om t h e body t o m in im ize
in ju r y in t h e even t of a n a cciden t a l deploym en t . If
t h e a ir ba g u n it is pla ced on a ben ch or a n y ot h er su r-
fa ce, t h e t r im cover or a ir ba g cu sh ion side of t h e u n it
sh ou ld be fa ce u p t o m in im ize m ovem en t in t h e even t
of a n a cciden t a l deploym en t . In a ddit ion , t h e su pple-
m en t a l r est r a in t syst em sh ou ld be disa r m ed wh en -
ever a n y st eer in g wh eel, st eer in g colu m n , dr iver
a ir ba g, pa ssen ger a ir ba g, fr on t im pa ct sen sor, side
im pa ct sen sor, side cu r t a in a ir ba g, or in st r u m en t
pa n el com pon en t s r equ ir e dia gn osis or ser vice. F a il-
u r e t o obser ve t h is wa r n in g cou ld r esu lt in a cciden t a l
a ir ba g deploym en t a n d possible per son a l in ju r y.
All da m a ged, fa u lt y or n on -deployed a ir ba gs wh ich
a r e r epla ced on veh icles a r e t o be h a n dled a n d dis-
posed of pr oper ly. If a n a ir ba g u n it is fa u lt y or da m -
a ged a n d n on -deployed, r efer t o t h e H a za r dou s
Su bst a n ce Con t r ol Syst em for pr oper disposa l. Dis-
pose of a ll n on -deployed a n d deployed a ir ba gs in a
m a n n er con sist en t wit h st a t e, pr ovin cia l, loca l a n d
feder a l r egu la t ion s.
SUPPLEMENTAL RESTRAINT STORAGE
Air ba gs m u st be st or ed in t h eir or igin a l, specia l
con t a in er u n t il t h ey a r e u sed for ser vice. Also, t h ey
m u st be st or ed in a clea n , dr y en vir on m en t ; a wa y
fr om sou r ces of ext r em e h ea t , spa r ks, a n d h igh elec-
t r ica l en er gy. Alwa ys pla ce or st or e a n y a ir ba g on a
su r fa ce wit h it s t r im cover or a ir ba g cu sh ion side fa c-
WJ
in g u p, t o m in im ize m ovem en t in ca se of a n a cciden -
t a l deploym en t .
STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT
An y veh icle wh ich is t o be r et u r n ed t o u se follow-
in g a su pplem en t a l r est r a in t deploym en t , m u st h a ve
t h e deployed r est r a in t s r epla ced. In a ddit ion , if t h e
dr iver a ir ba g h a s been deployed, t h e clockspr in g
m u st be r epla ced. If t h e pa ssen ger a ir ba g is
deployed, t h e in st r u m en t pa n el t op pa d m u st be
r epla ced. If a side cu r t a in a ir ba g h a s been deployed,
t h e com plet e a ir ba g u n it , t h e h ea dlin er, a s well a s
t h e u pper A, B, C a n d D-pilla r t r im m u st be r epla ced.
Th ese com pon en t s a r e n ot in t en ded for r eu se a n d
will be da m a ged or wea ken ed a s a r esu lt of a su pple-
m en t a l r est r a in t deploym en t , wh ich m a y or m a y n ot
be obviou s du r in g a visu a l in spect ion .
Th e pa ssen ger a ir ba g m ou n t in g poin t s on t h e
in st r u m en t pa n el st r u ct u r a l du ct m u st be closely
in spect ed for da m a ge, a n d t h e in st r u m en t pa n el
a ssem bly r epla ced if st r u ct u r a l du ct da m a ge is evi-
den t . On veh icles wit h a n opt ion a l su n r oof, t h e su n -
r oof dr a in t u bes a n d h oses m u st be closely in spect ed
followin g a side cu r t a in a ir ba g deploym en t . It is a lso
cr it ica l t h a t t h e m ou n t in g su r fa ces a n d/or m ou n t in g
br a cket s for t h e fr on t a n d side im pa ct sen sor s be
closely in spect ed a n d r est or ed t o t h eir or igin a l con di-
t ion s followin g a n y veh icle im pa ct da m a ge. Beca u se
t h e ACM a n d ea ch im pa ct sen sor a r e u sed by t h e
su pplem en t a l r est r a in t syst em t o m on it or or con fir m
t h e dir ect ion a n d sever it y of a veh icle im pa ct ,
im pr oper or ien t a t ion or in secu r e fa st en in g of t h ese
com pon en t s m a y ca u se a ir ba gs n ot t o deploy wh en
r equ ir ed, or t o deploy wh en n ot r equ ir ed.
All ot h er veh icle com pon en t s sh ou ld be closely
in spect ed followin g a n y su pplem en t a l r est r a in t
deploym en t , bu t a r e t o be r epla ced on ly a s r equ ir ed
by t h e ext en t of t h e visible da m a ge in cu r r ed.
AIRBAG SQUIB STATUS
Mu lt ist a ge a ir ba gs wit h m u lt iple in it ia t or s (squ ibs)
m u st be ch ecked t o det er m in e t h a t a ll squ ibs wer e
u sed du r in g t h e deploym en t even t . Th e dr iver a n d
pa ssen ger a ir ba gs in t h is m odel a r e deployed by elec-
t r ica l sign a ls gen er a t ed by t h e Air ba g Con t r ol Mod-
u le (ACM) t h r ou gh t h e dr iver or pa ssen ger squ ib 1
a n d squ ib 2 cir cu it s t o t h e t wo in it ia t or s in t h e a ir-
ba g in fla t or s. Typica lly, bot h in it ia t or s a r e u sed a n d
a ll pot en t ia lly h a za r dou s ch em ica ls a r e bu r n ed du r-
in g a n a ir ba g deploym en t even t . H owever, it is possi-
ble for on ly on e in it ia t or t o be u sed du e t o a n a ir ba g
syst em fa u lt ; t h er efor e, it is a lwa ys n ecessa r y t o con -
fir m t h a t bot h in it ia t or s h a ve been u sed in or der t o
a void t h e im pr oper h a n dlin g or disposa l of pot en -
t ia lly live pyr ot ech n ic or h a za r dou s m a t er ia ls. Th e
WJ
REST RAI N T S (Cont inue d)
followin g pr ocedu r e sh ou ld be per for m ed u sin g a
DRBIII! sca n t ool t o ver ify t h e st a t u s of bot h a ir ba g
squ ibs befor e eit h er deployed a ir ba g is r em oved fr om
t h e veh icle for disposa l.
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to the Hazardous Sub-
stance Control System for proper disposal proce-
dures. Dispose of all non-deployed and deployed
airbags in a manner consistent with state, provin-
cial, local, and federal regulations.
RESTRAINTS 8O - 7
(1) Be cer t a in t h a t t h e DRBIII! sca n t ool con t a in s
t h e la t est ver sion of t h e pr oper DRBIII! soft wa r e.
Con n ect t h e DRBIII! t o t h e 16-wa y Da t a Lin k Con -
n ect or (DLC). Th e DLC is loca t ed on t h e dr iver side
lower edge of t h e in st r u m en t pa n el, ou t boa r d of t h e
st eer in g colu m n .
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
(3) Usin g t h e DRBIII!, r ea d a n d r ecor d t h e a ct ive
(cu r r en t ) Dia gn ost ic Tr ou ble Code (DTC) da t a .
Usin g t h e a ct ive DTC in for m a t ion , r efer t o t h e Air-
ba g S qu ib S ta tu s t a ble t o det er m in e t h e st a t u s of
bot h dr iver a n d/or pa ssen ger a ir ba g squ ibs.

AIRBAG SQUIB STATUS

IF the Active DTC is: Conditions Squib Status
Driver or Passenger Squib 1 AND t h e st or ed DTC m in u t es for bot h Dr iver Both Squib 1 and 2 were
open or P a ssen ger squ ibs a r e wit h in 15 m in u t es of used.
Driver or Passenger Squib 2 ea ch ot h er
open
Driver or Passenger Squib 1 AND t h e st or ed DTC m in u t es for Dr iver or Squib 1 was used; Squib 2 is
open P a ssen ger Squ ib 2 open is GRE ATE R t h a n t h e live.
Driver or Passenger Squib 2 st or ed DTC m in u t es for Dr iver or P a ssen ger
open Squ ib 1 by 15 m in u t es or m or e
Driver or Passenger Squib 1 AND t h e st or ed DTC m in u t es for Dr iver or Squib 1 is live; Squib 2 was
open P a ssen ger Squ ib 1 open is GRE ATE R t h a n t h e used.
Driver or Passenger Squib 2 st or ed DTC m in u t es for Dr iver or P a ssen ger
open Squ ib 2 by 15 m in u t es or m or e
Driver or Passenger Squib 1 AND Dr iver or P a ssen ger Squ ib 2 open is NOT Squib 1 was used; Squib 2 is
open a n a ct ive code live.
Driver or Passenger Squib 2 AND Dr iver or P a ssen ger Squ ib 1 open is NOT Squib 1 is live; Squib 2 was
open a n a ct ive code used.

If n on e of t h e Dr iver or P a ssen ger Squ ib 1 or 2

open a r e a ct ive codes, t h e st a t u s of t h e a ir ba g squ ibs
is u n kn own . In t h is ca se t h e a ir ba g sh ou ld be h a n -
dled a n d disposed of a s if t h e squ ibs wer e bot h live.

CLEANUP PROCEDURE
F ollowin g a su pplem en t a l r est r a in t deploym en t ,
t h e veh icle in t er ior will con t a in a powder y r esidu e.
Th is r esidu e con sist s pr im a r ily of h a r m less pa r t icu -
la t e by-pr odu ct s of t h e sm a ll pyr ot ech n ic ch a r ge t h a t
in it ia t es t h e pr opella n t u sed t o deploy a su pplem en -
t a l r est r a in t . H owever, t h is r esidu e m a y a lso con t a in
t r a ces of sodiu m h ydr oxide powder, a ch em ica l
by-pr odu ct of t h e pr opella n t m a t er ia l t h a t is u sed t o
gen er a t e t h e in er t ga s t h a t in fla t es t h e a ir ba g. Sin ce
sodiu m h ydr oxide powder ca n ir r it a t e t h e skin , eyes,
n ose, or t h r oa t , be su r e t o wea r sa fet y gla sses, r u bber Fig. 3 Wear Safety Glasses and Rubber Gloves -
gloves, a n d a lon g-sleeved sh ir t du r in g clea n u p (F ig. Typical
3).
8O - 8 RESTRAINTS
REST RAI N T S (Cont inue d)
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITA-
TION OF THE NOSE OR THROAT, EXIT THE VEHICLE
FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF
IRRITATION CONTINUES, SEE A PHYSICIAN.
(1) Begin t h e clea n u p by u sin g a va cu u m clea n er
t o r em ove a n y r esidu a l powder fr om t h e veh icle in t e-
r ior. Clea n fr om ou t side t h e veh icle a n d wor k you r
wa y in side, so t h a t you a void kn eelin g or sit t in g on a
n on -clea n ed a r ea .
(2) Be cer t a in t o va cu u m t h e h ea t er a n d a ir con di-
t ion in g ou t let s a s well (F ig. 4). Ru n t h e h ea t er a n d
a ir con dit ion er blower on t h e lowest speed set t in g
a n d va cu u m a n y powder expelled fr om t h e ou t let s.
Fig. 4 Vacuum Heater and A/C Outlets - Typical
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to AIRBAG SQUIB STA-
TUS . Refer to the Hazardous Substance Control
System for proper disposal procedures. Dispose of
all non-deployed and deployed airbags in a manner
consistent with state, provincial, local, and federal
regulations.
(3) Next , r em ove t h e deployed su pplem en t a l
r est r a in t s fr om t h e veh icle. Refer t o t h e a ppr opr ia t e
ser vice r em ova l pr ocedu r es.
(4) You m a y n eed t o va cu u m t h e in t er ior of t h e
veh icle a secon d t im e t o r ecover a ll of t h e powder.
STANDARD PROCEDURE - VERIFICATION TEST
Th e followin g pr ocedu r e sh ou ld be per for m ed u sin g
a DRBIII! sca n t ool t o ver ify pr oper su pplem en t a l
r est r a in t syst em oper a t ion followin g t h e ser vice or
r epla cem en t of a n y su pplem en t a l r est r a in t syst em
com pon en t .
WJ
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Du r in g t h e followin g t est , t h e ba t t er y n ega t ive
ca ble r em a in s discon n ect ed a n d isola t ed, a s it wa s
du r in g t h e a ir ba g com pon en t r em ova l a n d in st a lla -
t ion pr ocedu r es.
(2) Be cer t a in t h a t t h e DRBIII! sca n t ool con t a in s
t h e la t est ver sion of t h e pr oper DRBIII! soft wa r e.
Con n ect t h e DRBIII! t o t h e 16-wa y Da t a Lin k Con -
n ect or (DLC). Th e DLC is loca t ed on t h e dr iver side
lower edge of t h e in st r u m en t pa n el, ou t boa r d of t h e
st eer in g colu m n (F ig. 5).
Fig. 5 16-Way Data Link Connector - Typical
1 - 16–WAY DATA LINK CONNECTOR
2 - BOTTOM OF INSTRUMENT PANEL
(3) Tu r n t h e ign it ion swit ch t o t h e On posit ion a n d
exit t h e veh icle wit h t h e DRBIII! sca n t ool.
WJ
REST RAI N T S (Cont inue d)
(4) Ch eck t o be cer t a in t h a t n obody is in t h e veh i-
cle, t h en r econ n ect t h e ba t t er y n ega t ive ca ble.
(5) Usin g t h e DRBIII!, r ea d a n d r ecor d t h e a ct ive
(cu r r en t ) Dia gn ost ic Tr ou ble Code (DTC) da t a .
(6) Next , u se t h e DRBIII! t o r ea d a n d r ecor d a n y
st or ed (h ist or ica l) DTC da t a .
(7) If a n y DTC is fou n d in St ep 5 or St ep 6, r efer
t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
(8) Use t h e DRBIII! t o er a se t h e st or ed DTC da t a .
If a n y pr oblem s r em a in , t h e st or ed DTC da t a will n ot
er a se. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a -
t ion t o dia gn ose a n y st or ed DTC t h a t will n ot er a se.
If t h e st or ed DTC in for m a t ion is su ccessfu lly er a sed,
go t o St ep 9.
(9) Tu r n t h e ign it ion swit ch t o t h e Off posit ion for
a bou t fift een secon ds, a n d t h en ba ck t o t h e On posi-
t ion . Obser ve t h e a ir ba g in dica t or in t h e in st r u m en t
clu st er. It sh ou ld ligh t for six t o eigh t secon ds, a n d
t h en go ou t . Th is in dica t es t h a t t h e su pplem en t a l
r est r a in t syst em is fu n ct ion in g n or m a lly a n d t h a t t h e
r epa ir s a r e com plet e. If t h e a ir ba g in dica t or fa ils t o
ligh t , or ligh t s a n d st a ys on , t h er e is st ill a n a ct ive
su pplem en t a l r est r a in t syst em fa u lt or m a lfu n ct ion .
Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion t o
dia gn ose t h e pr oblem .
AI RBAG CON T ROL M ODU LE
DESCRIPTION
Fig. 6 Airbag Control Module
1 - AIRBAG CONTROL MODULE
2 - ORIENTATION ARROW
3 - LABEL
4 - MOUNTING HOLES (4)
5 - CONNECTOR RECEPTACLE (2)
RESTRAINTS 8O - 9
Th e Air ba g Con t r ol Modu le (ACM) is a lso som e-
t im es r efer r ed t o a s t h e Occu pa n t Rest r a in t Con t r ol-
ler (ORC) (F ig. 6). Th e ACM is con cea led u n der n ea t h
t h e cen t er floor con sole, wh er e it is secu r ed by fou r
scr ews t o a st a m ped st eel m ou n t in g br a cket welded
on t o t h e t op of t h e floor pa n el t r a n sm ission t u n n el
ju st for wa r d of t h e pa r k br a ke m ech a n ism in t h e pa s-
sen ger com pa r t m en t of t h e veh icle.
Con cea led wit h in a h ollow in t h e cen t er of t h e die
ca st a lu m in u m ACM h ou sin g is t h e elect r on ic cir-
cu it r y of t h e ACM wh ich in clu des a m icr opr ocessor,
a n elect r on ic im pa ct sen sor, a n elect r on ic sa fin g sen -
sor, a n d a n en er gy st or a ge ca pa cit or. A st a m ped
m et a l cover pla t e is secu r ed t o t h e bot t om of t h e
ACM h ou sin g wit h fou r scr ews t o en close a n d pr ot ect
t h e in t er n a l elect r on ic cir cu it r y a n d com pon en t s. A
pr in t ed la bel on t h e t op of t h e ACM h ou sin g pr ovides
a visu a l ver ifica t ion of t h e pr oper or ien t a t ion of t h e
u n it , a n d sh ou ld a lwa ys be poin t ed t owa r d t h e fr on t
of t h e veh icle.
Two m olded pla st ic elect r ica l con n ect or r ecept a cles
exit t h e for wa r d side of t h e ACM h ou sin g. Th ese t wo
r ecept a cles con n ect t h e ACM t o t h e veh icle elect r ica l
syst em t h r ou gh a dedica t ed t a ke ou t a n d con n ect or of
t h e in st r u m en t pa n el wir e h a r n ess, a n d a dedica t ed
t a ke ou t a n d con n ect or of t h e a ir ba g over la y wir e
h a r n ess. F or veh icles equ ipped wit h t h e opt ion a l side
cu r t a in a ir ba gs, bot h ACM con n ect or r ecept a cles a r e
bla ck in color a n d t h e ACM con t a in s a secon d bi-di-
r ect ion a l sa fin g sen sor for t h e side a ir ba gs. F or veh i-
cles n ot equ ipped wit h t h e opt ion a l side cu r t a in
a ir ba gs, t h e ACM con n ect or r ecept a cles a r e bot h
gr a y.
Th e im pa ct sen sor a n d sa fin g sen sor in t er n a l t o
t h e ACM a r e ca libr a t ed for t h e specific veh icle, a n d
a r e on ly ser viced a s a u n it wit h t h e ACM. Th e ACM
ca n n ot be r epa ir ed or a dju st ed a n d, if da m a ged or
fa u lt y, it m u st be r epla ced.
OPERATION
Th e m icr opr ocessor in t h e Air ba g Con t r ol Modu le
(ACM) con t a in s t h e su pplem en t a l r est r a in t syst em
logic cir cu it s a n d con t r ols a ll of t h e su pplem en t a l
r est r a in t syst em com pon en t s. Th e ACM u ses
On -Boa r d Dia gn ost ics (OBD) a n d ca n com m u n ica t e
wit h ot h er elect r on ic m odu les in t h e veh icle a s well
a s wit h t h e DRBIII! sca n t ool u sin g t h e P r ogr a m m a -
ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et -
wor k. Th is m et h od of com m u n ica t ion is u sed for
con t r ol of t h e a ir ba g in dica t or in t h e E lect r oMech a n i-
ca l In st r u m en t Clu st er (E MIC) a n d for su pplem en t a l
r est r a in t syst em dia gn osis a n d t est in g t h r ou gh t h e
16-wa y da t a lin k con n ect or loca t ed on t h e dr iver side
lower edge of t h e in st r u m en t pa n el. (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/COMMUNICATION - OP E RATION).
8O - 10 RESTRAINTS
AI RBAG CON T ROL M ODU LE (Cont inue d)
Th e ACM m icr opr ocessor con t in u ou sly m on it or s a ll
of t h e su pplem en t a l r est r a in t syst em elect r ica l cir-
cu it s t o det er m in e t h e syst em r ea din ess. If t h e ACM
det ect s a m on it or ed syst em fa u lt , it set s a n a ct ive
a n d st or ed Dia gn ost ic Tr ou ble Code (DTC) a n d sen ds
elect r on ic m essa ges t o t h e E MIC over t h e P CI da t a
bu s t o t u r n on t h e a ir ba g in dica t or. An a ct ive fa u lt
on ly r em a in s for t h e du r a t ion of t h e fa u lt or in som e
ca ses t h e du r a t ion of t h e cu r r en t ign it ion swit ch
cycle, wh ile a st or ed fa u lt ca u ses a DTC t o be st or ed
in m em or y by t h e ACM. F or som e DTCs, if a fa u lt
does n ot r ecu r for a n u m ber of ign it ion cycles, t h e
ACM will a u t om a t ica lly er a se t h e st or ed DTC. F or
ot h er in t er n a l fa u lt s, t h e st or ed DTC is la t ch ed for-
ever.
Th e ACM r eceives ba t t er y cu r r en t t h r ou gh t wo cir-
cu it s, on a fu sed ign it ion swit ch ou t pu t (r u n ) cir cu it
t h r ou gh a fu se in t h e J u n ct ion Block (J B), a n d on a
fu sed ign it ion swit ch ou t pu t (st a r t -r u n ) cir cu it
t h r ou gh a secon d fu se in t h e J B. Th e ACM is
gr ou n ded t h r ou gh a gr ou n d cir cu it a n d t a ke ou t of
t h e in st r u m en t pa n el floor wir e h a r n ess. Th is t a ke
ou t h a s a sin gle eyelet t er m in a l con n ect or secu r ed by
a n u t t o a gr ou n d st u d loca t ed beh in d t h e ACM
m ou n t on t h e floor pa n el t r a n sm ission t u n n el. Th ese
con n ect ion s a llow t h e ACM t o be oper a t ion a l wh en -
ever t h e ign it ion swit ch is in t h e St a r t or On posi-
t ion s. Th e ACM a lso con t a in s a n en er gy-st or a ge
ca pa cit or. Wh en t h e ign it ion swit ch is in t h e St a r t or
On posit ion s, t h is ca pa cit or is con t in u a lly bein g
ch a r ged wit h en ou gh elect r ica l en er gy t o deploy t h e
a ir ba gs for u p t o on e secon d followin g a ba t t er y dis-
con n ect or fa ilu r e. Th e pu r pose of t h e ca pa cit or is t o
pr ovide ba cku p su pplem en t a l r est r a in t syst em pr o-
t ect ion in ca se t h er e is a loss of ba t t er y cu r r en t su p-
ply t o t h e ACM du r in g a n im pa ct .
Two sen sor s a r e con t a in ed wit h in t h e ACM, a n
elect r on ic im pa ct sen sor a n d a sa fin g sen sor. Th e
ACM a lso m on it or s in pu t s fr om t wo r em ot e fr on t
im pa ct sen sor s loca t ed on br a cket s on t h e in boa r d
sides of t h e r igh t a n d left ver t ica l m em ber s of t h e
r a dia t or su ppor t n ea r t h e fr on t of t h e veh icle. Th e
elect r on ic im pa ct sen sor s a r e a cceler om et er s t h a t
sen se t h e r a t e of veh icle deceler a t ion , wh ich pr ovide
ver ifica t ion of t h e dir ect ion a n d sever it y of a n
im pa ct . On m odels equ ipped wit h opt ion a l side cu r-
t a in a ir ba gs, t h e ACM a lso m on it or s in pu t s fr om t wo
r em ot e side im pa ct sen sor s loca t ed n ea r t h e ba se of
bot h t h e left a n d r igh t in n er B-pilla r s t o con t r ol t h e
deploym en t of t h e side cu r t a in a ir ba g u n it s.
Th e sa fin g sen sor is a n elect r on ic a cceler om et er
sen sor wit h in t h e ACM t h a t pr ovides a n a ddit ion a l
logic in pu t t o t h e ACM m icr opr ocessor. Th e sa fin g
WJ
sen sor is u sed t o ver ify t h e n eed for a n a ir ba g
deploym en t by det ect in g im pa ct en er gy of a lesser
m a gn it u de t h a n t h a t of t h e pr im a r y elect r on ic im pa ct
sen sor s, a n d m u st exceed a sa fin g t h r esh old in or der
for t h e a ir ba gs t o deploy. Th e ACM a lso m on it or s a
H a ll effect -t ype sea t belt swit ch loca t ed in t h e bu ckle
of ea ch fr on t sea t belt t o det er m in e wh et h er t h e sea t -
belt s a r e bu ckled, a n d pr ovides a n in pu t t o t h e E MIC
over t h e P CI da t a bu s t o con t r ol t h e sea t belt in dica -
t or oper a t ion ba sed u pon t h e st a t u s of t h e dr iver side
fr on t sea t belt swit ch . Veh icles wit h t h e opt ion a l side
cu r t a in a ir ba gs fea t u r e a secon d sa fin g sen sor wit h in
t h e ACM t o pr ovide con fir m a t ion t o t h e ACM of side
im pa ct for ces. Th is secon d sa fin g sen sor is a bi-dir ec-
t ion a l u n it t h a t det ect s im pa ct for ces fr om eit h er side
of t h e veh icle.
P r e-pr ogr a m m ed decision a lgor it h m s in t h e ACM
m icr opr ocessor det er m in e wh en t h e deceler a t ion r a t e
a s sign a led by t h e im pa ct sen sor s a n d t h e sa fin g sen -
sor s in dica t e a n im pa ct t h a t is sever e en ou gh t o
r equ ir e su pplem en t a l r est r a in t syst em pr ot ect ion .
Th e ACM a lso det er m in es t h e level of fr on t a ir ba g
deploym en t for ce r equ ir ed for ea ch fr on t sea t in g posi-
t ion ba sed u pon t h e st a t u s of t h e t wo sea t belt swit ch
in pu t s a n d t h e sever it y of t h e m on it or ed im pa ct .
Wh en t h e pr ogr a m m ed con dit ion s a r e m et , t h e ACM
sen ds t h e pr oper elect r ica l sign a ls t o deploy t h e m u l-
t ist a ge du a l fr on t a ir ba gs a t t h e pr ogr a m m ed for ce
levels, a n d t o deploy eit h er side cu r t a in a ir ba g.
Th e h a r d wir ed in pu t s a n d ou t pu t s for t h e ACM
m a y be dia gn osed a n d t est ed u sin g con ven t ion a l
dia gn ost ic t ools a n d pr ocedu r es. H owever, con ven -
t ion a l dia gn ost ic m et h ods will n ot pr ove con clu sive in
t h e dia gn osis of t h e ACM, t h e P CI da t a bu s n et wor k,
or t h e elect r on ic m essa ge in pu t s t o a n d ou t pu t s fr om
t h e ACM. Th e m ost r elia ble, efficien t , a n d a ccu r a t e
m ea n s t o dia gn ose t h e ACM, t h e P CI da t a bu s n et -
wor k, a n d t h e elect r on ic m essa ge in pu t s t o a n d ou t -
pu t s fr om t h e ACM r equ ir es t h e u se of a DRBIII!
sca n t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .
REMOVAL
Two differ en t Air ba g Con t r ol Modu les (ACM) a r e
a va ila ble for t h is veh icle. F or veh icles equ ipped wit h
t h e opt ion a l side cu r t a in a ir ba gs, bot h ACM con n ec-
t or r ecept a cles a r e bla ck in color a n d t h e ACM con -
t a in s a secon d bi-dir ect ion a l sa fin g sen sor for t h e
side a ir ba gs. F or veh icles n ot equ ipped wit h t h e
opt ion a l side cu r t a in a ir ba gs, t h e ACM con n ect or
r ecept a cles a r e gr a y.
WJ RESTRAINTS 8O - 11
AI RBAG CON T ROL M ODU LE (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.

WARNING: THE AIRBAG CONTROL MODULE CON-

Fig. 7 Center Console Bracket Remove/Install
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE SUPPLEMENTAL 1 - SHIFTER
2 - NUT (2)
RESTRAINTS. NEVER STRIKE OR DROP THE AIR-
3 - BRACKET
BAG CONTROL MODULE, AS IT CAN DAMAGE THE
4 - PARK BRAKE LEVER
IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF 5 - AIRBAG CONTROL MODULE
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY 6 - FLOOR PANEL TRANSMISSION TUNNEL
DROPPED DURING SERVICE, THE MODULE MUST 7 - INSTRUMENT PANEL WIRE HARNESS
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive

ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) Rem ove t h e cen t er con sole fr om t h e t op of t h e
floor pa n el t r a n sm ission t u n n el. (Refer t o 23 - BODY/
INTE RIOR/F LOOR CONSOLE - RE MOVAL).
(3) Rem ove t h e t wo n u t s t h a t secu r e t h e cen t er
con sole br a cket t o t h e st u ds on t h e floor pa n el t r a n s-
m ission t u n n el ju st for wa r d of t h e Air ba g Con t r ol
Modu le (ACM) (F ig. 7).
(4) Rem ove t h e cen t er con sole br a cket fr om t h e
t wo st u ds on t h e floor pa n el t r a n sm ission t u n n el.
(5) Discon n ect t h e a ir ba g over la y wir e h a r n ess Fig. 8 Airbag Control Module Connector
con n ect or for t h e ACM fr om t h e ACM con n ect or 1 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
r ecept a cle (F ig. 8). To discon n ect t h e a ir ba g over la y 2 - LATCH TAB
wir e h a r n ess con n ect or fr om t h e ACM: 3 - CPA LOCK
(a ) Slide t h e r ed Con n ect or P osit ion Assu r a n ce 4 - AIRBAG OVERLAY WIRE HARNESS CONNECTOR
(CPA) lock on t h e t op of t h e con n ect or t owa r d t h e 5 - AIRBAG CONTROL MODULE
fr on t of t h e veh icle.
(b) Depr ess t h e for wa r d edge of t h e CPA lock t o (6) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
r elea se t h e con n ect or la t ch t a b a n d pu ll t h e con n ec- con n ect or for t h e ACM fr om t h e ACM con n ect or
t or st r a igh t a wa y fr om t h e ACM con n ect or r ecept a - r ecept a cle.
cle.
8O - 12 RESTRAINTS
AI RBAG CON T ROL M ODU LE (Cont inue d)
(7) Rem ove t h e fou r scr ews t h a t secu r e t h e ACM t o
t h e m ou n t t h a t is welded on t o t h e t op of t h e floor
pa n el t r a n sm ission t u n n el (F ig. 9).
Fig. 9 Airbag Control Module Remove/Install
1 - SCREW (4)
2 - AIRBAG CONTROL MODULE
3 - FLOOR PANEL TRANSMISSION TUNNEL
4 - MOUNT
(8) Rem ove t h e ACM fr om t h e ACM m ou n t on t h e
t op of t h e floor pa n el t r a n sm ission t u n n el.
INSTALLATION
Two differ en t Air ba g Con t r ol Modu les (ACM) a r e
a va ila ble for t h is veh icle. F or veh icles equ ipped wit h
t h e opt ion a l side cu r t a in a ir ba gs, bot h ACM con n ec-
t or r ecept a cles a r e bla ck in color a n d t h e ACM con -
t a in s a secon d bi-dir ect ion a l sa fin g sen sor for t h e
side a ir ba gs. F or veh icles n ot equ ipped wit h t h e
opt ion a l side cu r t a in a ir ba gs, t h e ACM con n ect or
r ecept a cles a r e gr a y.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WJ
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE SUPPLEMENTAL
RESTRAINTS. NEVER STRIKE OR DROP THE AIR-
BAG CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
(1) Ca r efu lly posit ion t h e Air ba g Con t r ol Modu le
(ACM) t o t h e m ou n t t h a t is welded on t o t h e t op of
t h e floor pa n el t r a n sm ission t u n n el (F ig. 9). Th e bot -
t om of t h e ACM h ou sin g is keyed. Wh en t h e ACM is
cor r ect ly posit ion ed, t h e bot t om of t h e h ou sin g will fit
flu sh wit h t h e m ou n t a n d t h e or ien t a t ion a r r ow on
t h e la bel on t op of t h e h ou sin g will be poin t ed for-
wa r d in t h e veh icle.
(2) In st a ll a n d t igh t en t h e fou r scr ews t h a t secu r e
t h e ACM t o t h e m ou n t t h a t is welded on t o t h e t op of
t h e floor pa n el t r a n sm ission t u n n el. Tigh t en t h e
scr ews t o 11 N·m (95 in . lbs.).
(3) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e ACM t o t h e ACM con n ect or r ecep-
t a cle. Be cer t a in t h a t t h e con n ect or la t ch a n d t h e r ed
CPA lock a r e fu lly en ga ged (F ig. 8).
(4) Recon n ect t h e a ir ba g over la y wir e h a r n ess con -
n ect or for t h e ACM t o t h e ACM con n ect or r ecept a cle.
Be cer t a in t h a t t h e con n ect or la t ch a n d t h e r ed CPA
lock a r e fu lly en ga ged.
(5) Rein st a ll t h e cen t er con sole br a cket on t o t h e
t wo st u ds on t h e floor pa n el t r a n sm ission t u n n el ju st
for wa r d of t h e ACM (F ig. 7).
(6) In st a ll a n d t igh t en t h e t wo n u t s t h a t secu r e
t h e cen t er con sole br a cket t o t h e st u ds on t h e floor
pa n el t r a n sm ission t u n n el. Tigh t en t h e n u t s t o 28
N·m (21 ft . lbs.).
(7) Rein st a ll t h e cen t er con sole on t o t h e t op of t h e
floor pa n el t r a n sm ission t u n n el. (Refer t o 23 - BODY/
INTE RIOR/F LOOR CONSOLE - INSTALLATION).
(8) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
STANDARD P ROCE DURE - VE RIF ICATION TE ST).
WJ RESTRAINTS 8O - 13

CH I LD T ET H ER AN CH OR br a cket posit ion . Veh icles m a n u fa ct u r ed for sa le in

Rest -Of-Wor ld (ROW) m a r ket s h a ve t wo a n ch or s t h a t
a r e in t egr a l t o t h e ba ck of t h e r igh t r ea r sea t ba ck
DESCRIPTION
pa n el, a n d on e t h a t is in t egr a l t o t h e left r ea r sea t
ba ck pa n el (F ig. 11). Th e Nor t h Am er ica n ch ild sea t
t et h er a n ch or br a cket s a r e a va ila ble for sepa r a t e ser-
vice r epla cem en t . Th e ROW ch ild sea t t et h er a n ch or s
ca n n ot be a dju st ed or r epa ir ed a n d, if fa u lt y or da m -
a ged, t h ey m u st be r epla ced a s a u n it wit h t h e r ea r
sea t ba ck pa n el.

OPERATION
See t h e own er ’s m a n u a l in t h e veh icle glove box for
m or e in for m a t ion on t h e pr oper u se of t h e fa ct or y-in -
st a lled ch ild sea t t et h er a n ch or s.

REMOVAL
Fig. 10 Child Tether Anchors - North America Th e followin g ser vice pr ocedu r e a pplies t o veh icles
1 - CHILD TETHER ANCHOR (RIGHT) m a n u fa ct u r ed for sa le in Nor t h Am er ica , wh ich h a ve
2 - CARGO LAMP r em ova ble ch ild sea t t et h er a n ch or br a cket s t h a t a r e
3 - HEADLINER
loca t ed on t h e in n er lift ga t e open in g h ea der. Veh icles
4 - BEZEL
m a n u fa ct u r ed for sa le in Rest -Of-Wor ld (ROW) m a r-
5 - CHILD TETHER ANCHOR BRACKET
6 - D-PILLAR
ket s h a ve ch ild t et h er a n ch or s t h a t a r e in t egr a l t o,
7 - CAP a n d a r e on ly ser viced wit h t h e r ea r sea t ba ck pa n els.
(1) Rem ove t h e cover fr om t h e ch ild t et h er a n ch or
bezel in t h e h ea dlin er n ea r t h e lift ga t e open in g
h ea der.
(2) Rem ove t h e scr ew t h a t secu r es t h e ch ild t et h er
a n ch or br a cket t o t h e in n er lift ga t e open in g h ea der
(F ig. 12).

Fig. 11 Child Tether Anchors - Rest-Of-World

1 - REAR SEAT BACK (LEFT)
2 - REAR SEAT BACK (RIGHT)
Fig. 12 Child Tether Anchor Remove/Install
3 - CHILD TETHER ANCHOR (3) 1 - INNER LIFTGATE OPENING HEADER
2 - CHILD TETHER ANCHOR BRACKET
3 - SCREW
All veh icles a r e equ ipped wit h fixed-posit ion , ch ild
sea t t et h er a n ch or s. Veh icles m a n u fa ct u r ed for sa le
in Nor t h Am er ica h a ve t wo st a m ped st eel ch ild (3) Rem ove t h e ch ild t et h er a n ch or br a cket fr om
t et h er a n ch or br a cket s, on e secu r ed wit h a scr ew t o t h e in n er lift ga t e open in g h ea der.
ea ch ou t boa r d en d of t h e in n er lift ga t e open in g
h ea der a t t h e r ea r of t h e pa ssen ger com pa r t m en t
(F ig. 10). Th ese ch ild t et h er a n ch or s a r e con cea led
beh in d a r em ova ble m olded pla st ic ca p t h a t sn a ps
in t o a bezel loca t ed in t h e h ea dlin er over ea ch a n ch or
8O - 14 RESTRAINTS WJ
CH I LD T ET H ER AN CH OR (Cont inue d)

INSTALLATION in g is a spool-like m olded pla st ic r ot or wit h a la r ge

Th e followin g ser vice pr ocedu r e a pplies t o veh icles exposed h u b. Th e u pper su r fa ce of t h e r ot or h u b h a s
m a n u fa ct u r ed for sa le in Nor t h Am er ica , wh ich h a ve a la r ge cen t er h ole, t wo la r ge fla t s, a n in dex h ole,
r em ova ble ch ild sea t t et h er a n ch or br a cket s t h a t a r e t wo sh or t pigt a il wir es wit h con n ect or s, a n d t wo con -
loca t ed on t h e in n er lift ga t e open in g h ea der. Veh icles n ect or r ecept a cles t h a t fa ce t owa r d t h e st eer in g
m a n u fa ct u r ed for sa le in Rest -Of-Wor ld (ROW) m a r- wh eel.
ket s h a ve ch ild t et h er a n ch or s t h a t a r e in t egr a l t o,
a n d a r e on ly ser viced wit h t h e r ea r sea t ba ck pa n els.
(1) P osit ion t h e ch ild t et h er a n ch or br a cket on t o
t h e in n er lift ga t e open in g h ea der (F ig. 12).
(2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
ch ild t et h er a n ch or br a cket t o t h e in n er lift ga t e open -
in g h ea der. Tigh t en t h e scr ew t o 11.8 N·m (105 in .
lbs.).
(3) Rein st a ll t h e cover in t o t h e ch ild t et h er a n ch or
bezel in t h e h ea dlin er n ea r t h e lift ga t e open in g
h ea der.

CLOCK SPRI N G
DESCRIPTION
Fig. 14 Clockspring (Lower View)
1 - LOCKING PIN
2 - CASE
3 - OBLONG PIN
4 - ROUND PIN (2)
5 - LOWER CONNECTOR RECEPTACLE (2)
6 - ROTOR

Th e lower su r fa ce of t h e r ot or h u b h a s t h r ee pin s,
t wo r ou n d a n d on e oblon g. Th ese pin s in dex t h e
clockspr in g t o t h e t u r n sign a l ca n cel ca m u n it in t h e
m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g. Wit h in t h e
pla st ic ca se a n d wou n d a r ou n d t h e r ot or spool is a
lon g r ibbon -like t a pe t h a t con sist s of sever a l t h in cop-
per wir e lea ds sa n dwich ed bet ween t wo t h in pla st ic
m em br a n es. Th e ou t er en d of t h e t a pe t er m in a t es a t
Fig. 13 Clockspring (Upper View) t h e con n ect or r ecept a cles t h a t fa ce t h e in st r u m en t
1 - MOUNTING EAR (2) pa n el, wh ile t h e in n er en d of t h e t a pe t er m in a t es a t
2 - LOCKING PIN t h e pigt a il wir es a n d con n ect or r ecept a cles on t h e
3 - UPPER CONNECTOR RECEPTACLE (2) h u b of t h e clockspr in g r ot or t h a t fa ce t h e st eer in g
4 - LABEL wh eel.
5 - OBLONG PIN Ser vice r epla cem en t clockspr in gs a r e sh ipped pr e-
6 - ALIGNMENT ARROWS cen t er ed a n d wit h a m olded pla st ic lockin g pin
7 - CASE in st a lled. Th e lockin g pin secu r es t h e cen t er ed clock-
8 - PIGTAIL WIRE (2) spr in g r ot or t o t h e clockspr in g ca se du r in g sh ipm en t
a n d h a n dlin g, bu t m u st be r em oved fr om t h e clock-
Th e clockspr in g a ssem bly is secu r ed wit h t wo spr in g a ft er it a n d t h e m u lt i-fu n ct ion swit ch m ou n t -
scr ews t o t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou s- in g h ou sin g a r e in st a lled on t h e st eer in g colu m n .
in g n ea r t h e t op of t h e st eer in g colu m n beh in d t h e (Refer t o 8 - E LE CTRICAL/RE STRAINTS/CLOCK-
st eer in g wh eel (F ig. 13). Th e clockspr in g con sist s of a SP RING - STANDARD P ROCE DURE - CLOCK-
fla t , r ou n d m olded pla st ic ca se wit h a st u bby t a il SP RING CE NTE RING).
t h a t h a n gs below t h e st eer in g colu m n a n d con t a in s Th e clockspr in g ca n n ot be r epa ir ed. If t h e clock-
t wo con n ect or r ecept a cles t h a t fa ce t owa r d t h e spr in g is fa u lt y, da m a ged, or if t h e dr iver a ir ba g h a s
in st r u m en t pa n el (F ig. 14). Wit h in t h e pla st ic h ou s- been deployed, t h e clockspr in g m u st be r epla ced.
WJ
CLOCK SPRI N G (Cont inue d)
OPERATION
Th e clockspr in g is a m ech a n ica l elect r ica l cir cu it
com pon en t t h a t is u sed t o pr ovide con t in u ou s elect r i-
ca l con t in u it y bet ween t h e fixed in st r u m en t pa n el
wir e h a r n ess a n d t h e elect r ica l com pon en t s m ou n t ed
on or in t h e r ot a t in g st eer in g wh eel. On t h is m odel
t h e r ot a t in g elect r ica l com pon en t s in clu de t h e dr iver
a ir ba g, t h e h or n swit ch , t h e speed con t r ol swit ch es,
a n d t h e r em ot e r a dio swit ch es, if t h e veh icle is so
equ ipped. Th e clockspr in g ca se is posit ion ed a n d
secu r ed t o t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou s-
in g on t h e u pper st eer in g colu m n h ou sin g by t wo
scr ews. Th e t wo con n ect or r ecept a cles on t h e t a il of
t h e fixed clockspr in g ca se con n ect t h e clockspr in g t o
t h e veh icle elect r ica l syst em t h r ou gh t wo t a ke ou t s
wit h con n ect or s fr om t h e in st r u m en t pa n el wir e h a r-
n ess. Th e clockspr in g r ot or is m ova ble a n d is keyed
t o t h e h u b of t h e st eer in g wh eel by t wo la r ge fla t s
t h a t a r e m olded in t o t h e r ot or h u b. Th e t h r ee pin s
(t wo r ou n d a n d on e oblon g) on t h e lower su r fa ce of
t h e clockspr in g r ot or h u b en ga ge a n d in dex t h e clock-
spr in g r ot or t o t h e t u r n sign a l ca n cel ca m . Th e t u r n
sign a l ca n cel ca m is in t egr a l t o t h e m u lt i-fu n ct ion
swit ch m ou n t in g h ou sin g a n d is keyed t o t h e u pper
st eer in g colu m n sh a ft . Two sh or t , yellow-sleeved pig-
t a il wir es on t h e u pper su r fa ce of t h e clockspr in g
r ot or con n ect t h e clockspr in g t o t h e dr iver a ir ba g,
wh ile a st eer in g wh eel wir e h a r n ess con n ect s t h e t wo
con n ect or r ecept a cles on t h e u pper su r fa ce of t h e
clockspr in g r ot or t o t h e h or n swit ch , t h e t wo speed
con t r ol swit ch es, a n d t h e r em ot e r a dio swit ch es on
veh icles t h a t a r e so equ ipped.
Like t h e clockspr in g in a t im epiece, t h e clockspr in g
t a pe h a s t r a vel lim it s a n d ca n be da m a ged by bein g
wou n d t oo t igh t ly du r in g fu ll st op-t o-st op st eer in g
wh eel r ot a t ion . To pr even t t h is fr om occu r r in g, t h e
clockspr in g m u st be cen t er ed wh en it is in st a lled on
t h e st eer in g colu m n . Cen t er in g t h e clockspr in g
in dexes t h e clockspr in g t a pe t o t h e m ova ble st eer in g
com pon en t s so t h a t t h e t a pe ca n oper a t e wit h in it s
design ed t r a vel lim it s. H owever, if t h e clockspr in g is
r em oved fr om t h e st eer in g colu m n or if t h e st eer in g
sh a ft is discon n ect ed fr om t h e st eer in g gea r, t h e
clockspr in g spool ca n ch a n ge posit ion r ela t ive t o t h e
m ova ble st eer in g com pon en t s a n d m u st be r e-cen -
t er ed followin g com plet ion of t h e ser vice or t h e t a pe
m a y be da m a ged. Ser vice r epla cem en t clockspr in gs
a r e sh ipped pr e-cen t er ed a n d wit h a lockin g pin
in st a lled. Th is lockin g pin sh ou ld n ot be r em oved
u n t il t h e clockspr in g h a s been in st a lled on t h e st eer-
in g colu m n . If t h e lockin g pin is r em oved befor e t h e
clockspr in g is in st a lled on a st eer in g colu m n , t h e
clockspr in g cen t er in g pr ocedu r e m u st be per for m ed.
(Refer t o 8 - E LE CTRICAL/RE STRAINTS/CLOCK-
SP RING - STANDARD P ROCE DURE - CLOCK-
SP RING CE NTE RING).
RESTRAINTS 8O - 15
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
Th e clockspr in g is design ed t o win d a n d u n win d
wh en t h e st eer in g wh eel is r ot a t ed, bu t is on ly
design ed t o r ot a t e t h e sa m e n u m ber of t u r n s (a bou t
five com plet e r ot a t ion s) a s t h e st eer in g wh eel ca n be
t u r n ed fr om st op t o st op. Cen t er in g t h e clockspr in g
in dexes t h e clockspr in g t a pe t o ot h er st eer in g com po-
n en t s so t h a t it ca n oper a t e wit h in it s design ed
t r a vel lim it s. Th e r ot or of a cen t er ed clockspr in g ca n
be r ot a t ed t wo a n d on e-h a lf t u r n s in eit h er dir ect ion
fr om t h e cen t er ed posit ion , wit h ou t da m a gin g t h e
clockspr in g t a pe.
H owever, if t h e clockspr in g is r em oved for ser vice
or if t h e st eer in g colu m n is discon n ect ed fr om t h e
st eer in g gea r, t h e clockspr in g t a pe ca n ch a n ge posi-
t ion r ela t ive t o t h e ot h er st eer in g com pon en t s. Th e
clockspr in g m u st t h en be r e-cen t er ed followin g com -
plet ion of su ch ser vice or t h e clockspr in g t a pe m a y be
da m a ged. Ser vice r epla cem en t clockspr in gs a r e
sh ipped pr e-cen t er ed a n d wit h a m olded pla st ic lock-
in g pin in st a lled. Th is lockin g pin sh ou ld n ot be
r em oved u n t il t h e clockspr in g h a s been in st a lled on
t h e st eer in g colu m n . If t h e lockin g pin is r em oved
befor e t h e clockspr in g is in st a lled on a st eer in g col-
u m n , t h e clockspr in g cen t er in g pr ocedu r e m u st be
per for m ed.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) P la ce t h e fr on t wh eels in t h e st r a igh t -a h ea d
posit ion .
(2) Rem ove t h e clockspr in g fr om t h e st eer in g col-
u m n . (Refer t o 8 - E LE CTRICAL/RE STRAINTS/
CLOCKSP RING - RE MOVAL).
8O - 16 RESTRAINTS
CLOCK SPRI N G (Cont inue d)
(3) H old t h e clockspr in g ca se in on e h a n d so t h a t it
is or ien t ed a s it wou ld be wh en it is in st a lled on t h e
st eer in g colu m n (F ig. 15).
Fig. 15 Clockspring
1 - MOUNTING EAR (2)
2 - LOCKING PIN
3 - UPPER CONNECTOR RECEPTACLE (2)
4 - LABEL
5 - OBLONG PIN
6 - ALIGNMENT ARROWS
7 - CASE
8 - PIGTAIL WIRE (2)
(4) Use you r ot h er h a n d t o r ot a t e t h e clockspr in g
r ot or clockwise t o t h e en d of it s t r a vel. D o n o t a p p ly
e x c e s s iv e to rqu e .
(5) F r om t h e en d of t h e clockwise t r a vel, r ot a t e t h e
r ot or a bou t t wo a n d on e-h a lf t u r n s cou n t er clockwise,
u n t il t h e a r r ows on t h e clockspr in g r ot or la bel a n d
t h e clockspr in g ca se a r e a lign ed. Th e u pper m ost pin
on t h e lower su r fa ce of t h e clockspr in g r ot or sh ou ld
n ow be t h e oblon g pin .
(6) Th e clockspr in g is n ow cen t er ed. Secu r e t h e
clockspr in g r ot or t o t h e clockspr in g ca se t o m a in t a in
clockspr in g cen t er in g u n t il it is r ein st a lled on t h e
st eer in g colu m n .
(7) Th e fr on t wh eels sh ou ld st ill be in t h e st r a igh t -
a h ea d posit ion . Rein st a ll t h e clockspr in g on t o t h e
st eer in g colu m n . (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/CLOCKSP RING - INSTALLATION).
REMOVAL
Th e clockspr in g ca n n ot be r epa ir ed. It m u st be
r epla ced if fa u lt y or da m a ged, or if t h e dr iver a ir ba g
h a s been deployed.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
WJ
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) P la ce t h e fr on t wh eels in t h e st r a igh t -a h ea d
posit ion .
(2) Rem ove t h e dr iver a ir ba g fr om t h e st eer in g
wh eel. (Refer t o 8 - E LE CTRICAL/RE STRAINTS/
DRIVE R AIRBAG - RE MOVAL).
(3) Discon n ect t h e st eer in g wh eel wir e h a r n ess
con n ect or s fr om t h e u pper clockspr in g con n ect or
r ecept a cles.
(4) Rem ove t h e st eer in g wh eel fr om t h e st eer in g
colu m n . (Refer t o 19 - STE E RING/COLUMN/STE E R-
ING WH E E L - RE MOVAL).
(5) F r om below t h e st eer in g colu m n , r em ove t h e
scr ew t h a t secu r es t h e lower t ilt in g st eer in g colu m n
sh r ou d t o t h e st eer in g colu m n m u lt i-fu n ct ion swit ch
m ou n t in g h ou sin g (F ig. 16).
(6) Usin g h a n d pr essu r e, pu sh gen t ly in wa r d on
bot h sides of t h e u pper sh r ou d n ea r t h e pa r t in g lin e
bet ween t h e u pper a n d lower sh r ou ds t o r elea se t h e
sn a p fea t u r es t h a t secu r e t h e t wo h a lves t o ea ch
ot h er.
(7) Rem ove bot h t h e u pper a n d lower sh r ou ds fr om
t h e st eer in g colu m n .
(8) Discon n ect t h e t wo in st r u m en t pa n el wir e h a r-
n ess con n ect or s for t h e clockspr in g fr om t h e t wo con -
n ect or r ecept a cles below t h e st eer in g colu m n on t h e
ba ck of t h e clockspr in g ca se.
(9) Rem ove t h e t wo scr ews t h a t secu r e t h e clock-
spr in g ca se t o t h e m u lt i-fu n ct ion swit ch m ou n t in g
h ou sin g (F ig. 17).
(10) Rem ove t h e clockspr in g fr om t h e m u lt i-fu n c-
t ion swit ch m ou n t in g h ou sin g. Th e clockspr in g ca n -
n ot be r epa ir ed. It m u st be r epla ced if fa u lt y or
da m a ged, or if t h e dr iver a ir ba g h a s been deployed.
(11) If t h e r em oved clockspr in g is t o be r eu sed, be
cer t a in t o secu r e t h e clockspr in g r ot or t o t h e clock-
spr in g ca se t o m a in t a in clockspr in g cen t er in g u n t il it
is r ein st a lled on t h e st eer in g colu m n . If clockspr in g
cen t er in g is n ot m a in t a in ed, t h e clockspr in g m u st be
cen t er ed a ga in befor e it is r ein st a lled. (Refer t o 8 -
WJ RESTRAINTS 8O - 17
CLOCK SPRI N G (Cont inue d)
E LE CTRICAL/RE STRAINTS/CLOCKSP RING -
STANDARD P ROCE DURE - CLOCKSP RING CE N-
TE RING).

INSTALLATION
Th e clockspr in g ca n n ot be r epa ir ed. It m u st be
r epla ced if fa u lt y or da m a ged, or if t h e dr iver a ir ba g
h a s been deployed.
If t h e clockspr in g is n ot pr oper ly cen t er ed in r ela -
t ion t o t h e st eer in g wh eel, st eer in g sh a ft a n d st eer-
in g gea r, it m a y be da m a ged. (Refer t o 8 -
E LE CTRICAL/RE STRAINTS/CLOCKSP RING -
STANDARD P ROCE DURE - CLOCKSP RING CE N-
TE RING). Ser vice r epla cem en t clockspr in gs a r e
sh ipped pr e-cen t er ed a n d wit h a lockin g pin
in st a lled. Th is lockin g pin sh ou ld n ot be r em oved
u n t il t h e clockspr in g h a s been in st a lled on t h e st eer-
in g colu m n . If t h e lockin g pin is r em oved befor e t h e
clockspr in g is in st a lled on a st eer in g colu m n , t h e
clockspr in g cen t er in g pr ocedu r e m u st be per for m ed.

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
Fig. 16 Steering Column Shrouds Remove/Install PASSENGER AIRBAG, FRONT IMPACT SENSOR,
1 - UPPER TILTING COLUMN SHROUD SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
2 - FIXED COLUMN SHROUD INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
3 - LOWER TILTING COLUMN SHROUD SERVICE. DISCONNECT AND ISOLATE THE BAT-
4 - SCREW
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.

NOTE: Before starting this procedure, be certain

that the front wheels are still in the straight-ahead
position.

(1) Wh ile h oldin g t h e cen t er ed clockspr in g r ot or

a n d ca se st a t ion a r y in r ela t ion t o ea ch ot h er, ca r e-
fu lly slide t h e clockspr in g down over t h e st eer in g col-
u m n u pper sh a ft .
Fig. 17 Clockspring Remove/Install (2) Align a n d sea t t h e t h r ee pin s on t h e lower su r-
1 - OBLONG HOLE fa ce of t h e clockspr in g r ot or h u b wit h t h e t h r ee h oles
2 - TURN SIGNAL CANCEL CAM in t h e h u b of t h e t u r n sign a l ca n cel ca m (F ig. 17). It
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
sh ou ld be n ot ed t h a t wh en t h e clockspr in g is pr op-
4 - RIGHT MULTI-FUNCTION SWITCH
er ly cen t er ed t h e u pper m ost pin on t h e clockspr in g
5 - SCREW (2)
6 - OBLONG PIN
r ot or h u b is t h e oblon g pin , a n d it will on ly fit in t h e
7 - CLOCKSPRING oblon g h ole in t h e h u b of t h e t u r n sign a l ca n cel ca m .
8 - LEFT MULTI-FUNCTION SWITCH
8O - 18 RESTRAINTS WJ
CLOCK SPRI N G (Cont inue d)
(3) Align a n d sea t t h e on e pin a n d t h e t wo m ou n t -
in g ea r s on t h e clockspr in g ca se t o t h eir r espect ive
h oles in t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g.
(4) In st a ll a n d t igh t en t h e t wo clockspr in g m ou n t -
in g scr ews. Tigh t en t h e scr ews t o 2.5 N·m (22 in .
lbs.).
(5) Recon n ect t h e t wo in st r u m en t pa n el wir e h a r-
n ess con n ect or s for t h e clockspr in g t o t h e t wo con n ec-
t or r ecept a cles below t h e st eer in g colu m n on t h e ba ck
of t h e clockspr in g ca se.
(6) P osit ion t h e lower t ilt in g st eer in g colu m n
sh r ou d on t o t h e st eer in g colu m n (F ig. 16).
(7) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
lower t ilt in g st eer in g colu m n sh r ou d t o t h e m u lt i-
fu n ct ion swit ch m ou n t in g h ou sin g. Tigh t en t h e scr ew
t o 2 N·m (17 in . lbs.).
(8) P osit ion t h e u pper t ilt in g colu m n sh r ou d on t o Fig. 18 Driver Airbag Trim Cover
t h e st eer in g colu m n wit h t h e h a za r d wa r n in g swit ch 1 - STEERING WHEEL
bu t t on in ser t ed t h r ou gh t h e h ole in t h e u pper su r fa ce 2 - TRIM COVER
of t h e sh r ou d. Align t h e u pper t ilt in g st eer in g colu m n
sh r ou d t o t h e lower sh r ou d a n d sn a p t h e t wo sh r ou d
over t h e in fla t or m ou n t in g st u ds on t h e ba ck of t h e
h a lves t oget h er.
a ir ba g h ou sin g a n d a r e en ga ged in slot s wit h in t h e
(9) Align t h e sn a p fea t u r es on t h e u pper a n d lower
u pper a n d lower t r im cover lockin g blocks, secu r ely
sh r ou ds a n d a pply h a n d pr essu r e t o sn a p t h em
lockin g t h e cover in t o pla ce.
t oget h er.
Th e r esist ive m em br a n e-t ype h or n swit ch is
(10) Rein st a ll t h e st eer in g wh eel on t o t h e st eer in g
secu r ed wit h in a pla st ic t r a y t h a t is in ser t ed in a
colu m n . (Refer t o 19 - STE E RING/COLUMN/STE E R-
pocket or pou ch sewn on t o t h e a ir ba g cu sh ion
ING WH E E L - INSTALLATION).
r et a in er st r a p, bet ween t h e t r im cover a n d t h e folded
(11) Recon n ect t h e st eer in g wh eel wir e h a r n ess con -
a ir ba g cu sh ion . Th e h or n swit ch gr ou n d pigt a il wir e
n ect or s t o t h e u pper clockspr in g con n ect or r ecept a cles.
h a s a n eyelet t er m in a l con n ect or t h a t is ca pt u r ed on
(12) Rein st a ll t h e dr iver a ir ba g on t o t h e st eer in g
t h e u pper r igh t in fla t or m ou n t in g st u d bet ween t h e
wh eel. (Refer t o 8 - E LE CTRICAL/RE STRAINTS/
in fla t or a n d t h e u pper t r im cover r et a in er. Th e h or n
DRIVE R AIRBAG - INSTALLATION).
swit ch feed pigt a il wir e h a s a wh it e, m olded pla st ic
in su la t or t h a t is secu r ed by a n in t egr a l r et a in er t o a
DRI V ER AI RBAG m ou n t in g h ole loca t ed in t h e u pper t r im cover
r et a in er n ea r t h e u pper left cor n er on t h e ba ck of t h e
DESCRIPTION a ir ba g h ou sin g, a n d is con n ect ed t o t h e veh icle elec-
t r ica l syst em t h r ou gh a t a ke ou t a n d con n ect or of t h e
Th e in ject ion m olded, t h er m opla st ic dr iver a ir ba g
st eer in g wh eel wir e h a r n ess.
pr ot ect ive t r im cover is t h e m ost visible pa r t of t h e
Th e a ir ba g u sed in t h is m odel is a m u lt ist a ge, Next
dr iver a ir ba g (F ig. 18). Th e dr iver a ir ba g is loca t ed in
Gen er a t ion -t ype t h a t com plies wit h r evised feder a l a ir-
t h e cen t er of t h e st eer in g wh eel, wh er e it is secu r ed
ba g st a n da r ds t o deploy wit h less for ce t h a n t h ose u sed
wit h t wo scr ews t o t h e t wo h or izon t a l spokes of t h e
in som e pr ior m odels. A r a dia l deployin g fa br ic a ir ba g
fou r-spoke st eer in g wh eel a r m a t u r e. A st a m ped, sa t in
cu sh ion wit h t et h er s is u sed. Th e a ir ba g in fla t or is a
polish ed em blem wit h t h e J eep! logo is a pplied t o t h e
du a l-in it ia t or, n on -a zide, pyr ot ech n ic-t ype u n it wit h
cen t er of t h e t r im cover. Con cea led ben ea t h t h e
fou r m ou n t in g st u ds a n d is secu r ed t o t h e st a m ped
dr iver a ir ba g t r im cover a r e t h e h or n swit ch , t h e
m et a l a ir ba g h ou sin g u sin g fou r h ex n u t s wit h wa sh er s.
folded a ir ba g cu sh ion , t h e a ir ba g r et a in er or h ou sin g,
Two keyed a n d color-coded con n ect or r ecept a cles on t h e
t h e a ir ba g in fla t or, a n d t h e r et a in er s t h a t secu r e t h e
dr iver a ir ba g in fla t or con n ect t h e t wo in fla t or in it ia t or s
in fla t or t o t h e a ir ba g h ou sin g.
t o t h e veh icle elect r ica l syst em t h r ou gh t wo yellow-
Th e a ir ba g cu sh ion , h ou sin g, a n d in fla t or a r e
ja cket ed, t wo-wir e pigt a il h a r n esses of t h e clockspr in g.
secu r ed wit h in a n in t egr a l r ecept a cle m olded in t o t h e
Th e dr iver a ir ba g ca n n ot be r epa ir ed, a n d m u st be
ba ck of t h e t r im cover. Th e dr iver a ir ba g t r im cover
r epla ced if deployed or in a n y wa y da m a ged. Th e dr iver
h a s lockin g blocks m olded in t o t h e ba ck side of it
a ir ba g t r im cover a n d t h e h or n swit ch a r e a va ila ble
t h a t en ga ge a lip for m ed a r ou n d t h e per im et er of t h e
in dividu a lly, a n d m a y be disa ssem bled fr om t h e dr iver
a ir ba g h ou sin g. Two st a m ped m et a l r et a in er s t h en fit
a ir ba g for ser vice r epla cem en t .
WJ
DRI V ER AI RBAG (Cont inue d)
OPERATION
Th e m u lt ist a ge dr iver a ir ba g is deployed by elect r i-
ca l sign a ls gen er a t ed by t h e Air ba g Con t r ol Modu le
(ACM) t h r ou gh t h e dr iver a ir ba g squ ib 1 a n d squ ib 2
cir cu it s t o t h e t wo in it ia t or s in t h e a ir ba g in fla t or. By
u sin g t wo in it ia t or s, t h e a ir ba g ca n be deployed a t
m u lt iple levels of for ce. Th e for ce level is con t r olled
by t h e ACM t o su it t h e m on it or ed im pa ct con dit ion s
by pr ovidin g on e of fou r dela y in t er va ls bet ween t h e
elect r ica l sign a ls pr ovided t o t h e t wo in it ia t or s. Th e
lon ger t h e dela y bet ween t h ese sign a ls, t h e less for ce-
fu lly t h e a ir ba g will deploy. Wh en t h e ACM sen ds t h e
pr oper elect r ica l sign a ls t o ea ch in it ia t or, t h e elect r i-
ca l en er gy gen er a t es en ou gh h ea t t o in it ia t e a sm a ll
pyr ot ech n ic ch a r ge wh ich , in t u r n ign it es ch em ica l
pellet s wit h in t h e in fla t or. On ce ign it ed, t h ese ch em -
ica l pellet s bu r n r a pidly a n d pr odu ce a la r ge qu a n t it y
of n it r ogen ga s. Th e in fla t or is sea led t o t h e ba ck of
t h e a ir ba g h ou sin g a n d a diffu ser in t h e in fla t or
dir ect s a ll of t h e n it r ogen ga s in t o t h e a ir ba g cu sh -
ion , ca u sin g t h e cu sh ion t o in fla t e. As t h e cu sh ion
in fla t es, t h e dr iver a ir ba g t r im cover will split a t pr e-
det er m in ed br ea kou t lin es, t h en fold ba ck ou t of t h e
wa y a lon g wit h t h e h or n swit ch a n d t r a y u n it . F ol-
lowin g a n a ir ba g deploym en t , t h e a ir ba g cu sh ion
qu ickly defla t es by ven t in g t h e n it r ogen ga s t owa r ds
t h e in st r u m en t pa n el t h r ou gh ven t h oles wit h in t h e
fa br ic u sed t o con st r u ct t h e ba ck (st eer in g wh eel
side) pa n el of t h e a ir ba g cu sh ion .
Som e of t h e ch em ica ls u sed t o cr ea t e t h e n it r ogen
ga s m a y be con sider ed h a za r dou s wh ile in t h eir solid
st a t e befor e t h ey a r e bu r n ed, bu t t h ey a r e secu r ely
sea led wit h in t h e a ir ba g in fla t or. Typica lly, bot h in i-
t ia t or s a r e u sed a n d a ll pot en t ia lly h a za r dou s ch em -
ica ls a r e bu r n ed du r in g a n a ir ba g deploym en t even t .
H owever, it is possible for on ly on e in it ia t or t o be
u sed du r in g a deploym en t du e t o a n a ir ba g syst em
fa u lt ; t h er efor e, it is n ecessa r y t o a lwa ys con fir m
t h a t bot h in it ia t or s h a ve been u sed in or der t o a void
t h e im pr oper disposa l of pot en t ia lly live pyr ot ech n ic
or h a za r dou s m a t er ia ls. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS - STANDARD P ROCE DURE - SE R-
VICE AF TE R A SUP P LE ME NTAL RE STRAINT
DE P LOYME NT). Th e n it r ogen ga s t h a t is pr odu ced
wh en t h e ch em ica ls a r e bu r n ed is h a r m less. H ow-
ever, a sm a ll a m ou n t of r esidu e fr om t h e bu r n ed
ch em ica ls m a y ca u se som e t em por a r y discom for t if it
con t a ct s t h e skin , eyes, or br ea t h in g pa ssa ges. If skin
or eye ir r it a t ion is n ot ed, r in se t h e a ffect ed a r ea wit h
plen t y of cool, clea n wa t er. If br ea t h in g pa ssa ges a r e
ir r it a t ed, m ove t o a n ot h er a r ea wh er e t h er e is plen t y
of clea n , fr esh a ir t o br ea t h . If t h e ir r it a t ion is n ot
a llevia t ed by t h ese a ct ion s, con t a ct a ph ysicia n .
RESTRAINTS 8O - 19
REMOVAL
Th e followin g pr ocedu r e is for r epla cem en t of a
fa u lt y or da m a ged dr iver a ir ba g. If t h e a ir ba g is
fa u lt y or da m a ged, bu t n ot deployed, r eview t h e r ec-
om m en ded pr ocedu r es for h a n dlin g n on -deployed
su pplem en t a l r est r a in t s. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS - STANDARD P ROCE DURE - H AN-
DLING NON-DE P LOYE D SUP P LE ME NTAL
RE STRAINTS). If t h e dr iver a ir ba g h a s been
deployed, r eview t h e r ecom m en ded pr ocedu r es for
ser vice a ft er a su pplem en t a l r est r a in t deploym en t
befor e r em ovin g t h e a ir ba g fr om t h e veh icle. (Refer t o
8 - E LE CTRICAL/RE STRAINTS - STANDARD P RO-
CE DURE - SE RVICE AF TE R A SUP P LE ME NTAL
RE STRAINT DE P LOYME NT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG CUSHION AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) F r om t h e u n der side of t h e st eer in g wh eel,
r em ove t h e t wo scr ews t h a t secu r e t h e dr iver a ir ba g
t o t h e st eer in g wh eel a r m a t u r e (F ig. 19).
(3) P u ll t h e dr iver a ir ba g a wa y fr om t h e st eer in g
wh eel fa r en ou gh t o a ccess t h e t h r ee elect r ica l con -
n ect ion s on t h e ba ck of t h e a ir ba g h ou sin g.
(4) Discon n ect t h e st eer in g wh eel wir e h a r n ess
con n ect or for t h e h or n swit ch fr om t h e h or n swit ch
feed pigt a il wir e con n ect or, wh ich is loca t ed on t h e
ba ck of t h e dr iver a ir ba g h ou sin g.
8O - 20 RESTRAINTS WJ
DRI V ER AI RBAG (Cont inue d)
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.

WARNING: THE HORN SWITCH IS INTEGRAL TO

THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT
SHOULD BE PERFORMED ONLY BY
DAIMLERCHRYSLER-TRAINED AND AUTHORIZED
DEALER SERVICE TECHNICIANS. FAILURE TO
TAKE THE PROPER PRECAUTIONS OR TO FOL-
LOW THE PROPER PROCEDURES COULD RESULT
Fig. 19 Driver Airbag Remove/Install IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIR-
BAG DEPLOYMENT AND POSSIBLE OCCUPANT
1 - DRIVER AIRBAG
2 - HORN SWITCH FEED WIRE CONNECTOR
INJURIES.
3 - STEERING WHEEL WIRE HARNESS CONNECTOR
4 - SCREW (2)
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
5 - CLOCKSPRING PIGTAIL WIRE CONNECTOR (2) ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) Rem ove t h e dr iver a ir ba g fr om t h e st eer in g
CAUTION: Do not pull on the clockspring pigtail wh eel. (Refer t o 8 - E LE CTRICAL/RE STRAINTS/
wires or pry on the connector insulator to disen- DRIVE R AIRBAG - RE MOVAL).
gage the connector from the driver airbag inflator (3) Rem ove t h e fou r n u t s t h a t secu r e t h e u pper
connector receptacle. Improper removal of these a n d lower t r im cover r et a in er s t o t h e st u ds on t h e
pigtail wires and their connector insulators can ba ck of t h e dr iver a ir ba g h ou sin g (F ig. 20).
result in damage to the airbag circuits or connector
insulators.

(5) Th e clockspr in g dr iver a ir ba g pigt a il wir e con -

n ect or s a r e secu r ed by a n in t egr a l lock t o t h e a ir ba g
in fla t or con n ect or r ecept a cles, wh ich a r e loca t ed a t
t h e ba ck of t h e dr iver a ir ba g h ou sin g. F ir m ly gr a sp
a n d pu ll t h e lock st r a igh t ou t fr om t h e con n ect or
in su la t or, t h en pu ll t h e in su la t or s st r a igh t ou t fr om
t h e a ir ba g in fla t or t o discon n ect t h em fr om t h e con -
n ect or r ecept a cles.
(6) Rem ove t h e dr iver a ir ba g fr om t h e st eer in g
wh eel.
(7) If t h e dr iver a ir ba g h a s been deployed, t h e
clockspr in g m u st be r epla ced. (Refer t o 8 - E LE CTRI-
CAL/RE STRAINTS/CLOCKSP RING - RE MOVAL).

DISASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT Fig. 20 Driver Airbag Trim Cover Retainer Nuts
SYSTEM BEFORE ATTEMPTING ANY STEERING Remove/Install
WHEEL, STEERING COLUMN, DRIVER AIRBAG, 1 - HORN SWITCH GROUND PIGTAIL WIRE
PASSENGER AIRBAG, FRONT IMPACT SENSOR, 2 - NUTS
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR 3 - HORN SWITCH FEED PIGTAIL WIRE
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT- (4) Rem ove t h e u pper a n d lower t r im cover r et a in -
TERY NEGATIVE (GROUND) CABLE, THEN WAIT er s fr om t h e a ir ba g h ou sin g st u ds (F ig. 21).
WJ
DRI V ER AI RBAG (Cont inue d)
Fig. 21 Driver Airbag Trim Cover Retainers
1 - UPPER RETAINER
2 - AIRBAG HOUSING
3 - TRIM COVER
4 - NUT (4)
5 - LOWER RETAINER
6 - INFLATOR
7 - STUDS
(5) Disen ga ge t h e h or n swit ch feed pigt a il wir e
con n ect or r et a in er fr om t h e m ou n t in g h ole in t h e
u pper t r im cover r et a in er.
(6) Rem ove t h e h or n swit ch gr ou n d pigt a il wir e
eyelet t er m in a l fr om t h e u pper r igh t a ir ba g h ou sin g
st u d.
(7) Disen ga ge t h e fou r t r im cover lockin g blocks
fr om t h e lip a r ou n d t h e ou t side edge of t h e dr iver
a ir ba g h ou sin g a n d r em ove t h e h ou sin g fr om t h e
cover (F ig. 22).
ASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
RESTRAINTS 8O - 21
Fig. 22 Driver Airbag Trim Cover Remove/Install
1 - RETAINER SLOTS
2 - LOCKING BLOCKS
3 - RETAINER SLOTS
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE HORN SWITCH IS INTEGRAL TO
THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT
SHOULD BE PERFORMED ONLY BY
DAIMLERCHRYSLER-TRAINED AND AUTHORIZED
DEALER SERVICE TECHNICIANS. FAILURE TO
TAKE THE PROPER PRECAUTIONS OR TO FOL-
LOW THE PROPER PROCEDURES COULD RESULT
IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIR-
BAG DEPLOYMENT AND POSSIBLE OCCUPANT
INJURIES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
8O - 22 RESTRAINTS WJ
DRI V ER AI RBAG (Cont inue d)
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT TRIM
COVERS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.

NOTE: If the horn switch and tray have been

removed from the sewn pouch in the airbag cush-
ion retaining strap, be certain that they are properly
reinstalled with the horn switch feed and ground
pigtail wires properly oriented before assembling
the trim cover onto the airbag housing. (Refer to 8 -
ELECTRICAL/HORN/HORN SWITCH - INSTALLA-
TION).

(1) Ca r efu lly posit ion t h e dr iver a ir ba g in t h e t r im

cover. Be cer t a in t h a t t h e h or n swit ch feed a n d
gr ou n d pigt a il wir es a r e n ot pin ch ed bet ween t h e a ir-
ba g h ou sin g a n d t h e t r im cover lockin g blocks.
(2) E n ga ge t h e u pper a n d lower t r im cover lockin g Fig. 23 Driver Airbag Trim Cover Locking Blocks
blocks wit h t h e lip of t h e dr iver a ir ba g h ou sin g, t h en Engaged
en ga ge t h e lockin g blocks on ea ch side of t h e t r im 1 - LIP
cover wit h t h e lip of t h e h ou sin g. Be cer t a in t h a t 2 - TRIM COVER
ea ch of t h e lockin g blocks is fu lly en ga ged on t h e lip 3 - HORN SWITCH
4 - AIRBAG HOUSING
of t h e a ir ba g h ou sin g (F ig. 23).
5 - LOCKING BLOCK
(3) Rein st a ll t h e h or n swit ch gr ou n d pigt a il wir e
eyelet t er m in a l over t h e r igh t u pper a ir ba g h ou sin g
st u d. ser vice a ft er a su pplem en t a l r est r a in t deploym en t
(4) Rein st a ll t h e u pper a n d lower a ir ba g t r im cover befor e r em ovin g t h e a ir ba g fr om t h e veh icle. (Refer t o
r et a in er s over t h e a ir ba g h ou sin g st u ds. Be cer t a in 8 - E LE CTRICAL/RE STRAINTS - STANDARD P RO-
t h a t t h e t a bs on ea ch r et a in er a r e en ga ged in t h e CE DURE - SE RVICE AF TE R A SUP P LE ME NTAL
r et a in er slot s of t h e u pper a n d lower t r im cover lock- RE STRAINT DE P LOYME NT).
in g blocks (F ig. 22).
(5) In st a ll a n d t igh t en t h e n u t s t h a t secu r e t h e WARNING: ON VEHICLES EQUIPPED WITH AIR-
t r im cover r et a in er s t o t h e a ir ba g h ou sin g st u ds. BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
Tigh t en t h e n u t s t o 6.8 N·m (60 in . lbs.). SYSTEM BEFORE ATTEMPTING ANY STEERING
(6) E n ga ge t h e h or n swit ch feed pigt a il wir e con - WHEEL, STEERING COLUMN, DRIVER AIRBAG,
n ect or r et a in er in t h e m ou n t in g h ole in t h e u pper PASSENGER AIRBAG, FRONT IMPACT SENSOR,
t r im cover r et a in er. SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
(7) Rein st a ll t h e dr iver a ir ba g on t o t h e st eer in g INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
wh eel. (Refer t o 8 - E LE CTRICAL/RE STRAINTS/ SERVICE. DISCONNECT AND ISOLATE THE BAT-
DRIVE R AIRBAG - INSTALLATION). TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
INSTALLATION DISCHARGE BEFORE PERFORMING FURTHER
Th e followin g pr ocedu r e is for r epla cem en t of a DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
fa u lt y or da m a ged dr iver a ir ba g. If t h e a ir ba g is WAY TO DISABLE THE SUPPLEMENTAL
fa u lt y or da m a ged, bu t n ot deployed, r eview t h e r ec- RESTRAINT SYSTEM. FAILURE TO TAKE THE
om m en ded pr ocedu r es for h a n dlin g n on -deployed PROPER PRECAUTIONS COULD RESULT IN ACCI-
su pplem en t a l r est r a in t s. (Refer t o 8 - E LE CTRICAL/ DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
RE STRAINTS - STANDARD P ROCE DURE - H AN- PERSONAL INJURY.
DLING NON-DE P LOYE D SUP P LE ME NTAL
RE STRAINTS). If t h e dr iver a ir ba g h a s been
deployed, r eview t h e r ecom m en ded pr ocedu r es for
WJ
DRI V ER AI RBAG (Cont inue d)
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT AIR-
BAGS AND TRIM COVERS ARE SERVICED IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE TRIM COVER
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Assem ble t h e dr iver a ir ba g t r im cover on t o t h e
a ir ba g h ou sin g. (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/DRIVE R AIRBAG - ASSE MBLY).
(2) P osit ion t h e dr iver a ir ba g close en ou gh t o t h e
st eer in g wh eel t o r econ n ect a ll t h r ee elect r ica l con -
n ect ion s on t h e ba ck of t h e a ir ba g h ou sin g.
(3) Wh en in st a llin g t h e dr iver a ir ba g, r econ n ect
t h e t wo clockspr in g dr iver a ir ba g pigt a il wir e con n ec-
t or s t o t h e a ir ba g in fla t or con n ect or r ecept a cles by
pr essin g st r a igh t in on t h e con n ect or s (F ig. 19), t h en
pu sh in g t h e locks st r a igh t in t o t h e con n ect or s. You
ca n be cer t a in t h a t t h e con n ect or is fu lly en ga ged by
list en in g ca r efu lly for a dist in ct , a u dible click a s t h e
con n ect or la t ch es sn a p in t o pla ce.
(4) Recon n ect t h e st eer in g wh eel wir e h a r n ess con -
n ect or for t h e h or n swit ch t o t h e h or n swit ch feed
pigt a il wir e con n ect or, wh ich is loca t ed a t t h e ba ck of
t h e dr iver a ir ba g h ou sin g.
(5) Ca r efu lly posit ion t h e dr iver a ir ba g in t h e
st eer in g wh eel. Be cer t a in t h a t t h e clockspr in g pig-
t a il wir es a n d st eer in g wh eel wir e h a r n ess in t h e
st eer in g wh eel h u b a r ea a r e n ot pin ch ed bet ween t h e
dr iver a ir ba g a n d t h e st eer in g wh eel a r m a t u r e.
(6) F r om t h e u n der side of t h e st eer in g wh eel,
in st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e t h e
dr iver a ir ba g t o t h e st eer in g wh eel a r m a t u r e.
Tigh t en t h e scr ews t o 10 N·m (90 in . lbs.).
(7) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
STANDARD P ROCE DURE - VE RIF ICATION TE ST).
RESTRAINTS 8O - 23
FRON T I M PACT SEN SOR
DESCRIPTION
Fig. 24 Front Impact Sensor
1 - SENSOR
2 - CONNECTOR RECEPTACLE
Two fr on t im pa ct sen sor s a r e u sed on t h is m odel,
on e ea ch for t h e left a n d r igh t sides of t h e veh icle
(F ig. 24). Th ese sen sor s a r e m ou n t ed r em ot ely fr om
t h e im pa ct sen sor t h a t is in t er n a l t o t h e Air ba g Con -
t r ol Modu le (ACM). Th e r igh t a n d left fr on t a n d side
im pa ct sen sor s a r e iden t ica l in con st r u ct ion a n d ca l-
ibr a t ion wit h t h e except ion of t h e r igh t -h a n d a n d
left -h a n d die ca st a lu m in u m m ou n t in g br a cket s t o
wh ich ea ch fr on t im pa ct sen sor is secu r ed wit h t wo
scr ews. Th e fr on t im pa ct sen sor br a cket s a r e secu r ed
wit h t h r ee scr ews t o t h e fr on t a n d in boa r d sides of
t h e r igh t a n d left ver t ica l m em ber s of t h e r a dia t or
su ppor t wit h in t h e en gin e com pa r t m en t .
Th e im pa ct sen sor h ou sin g h a s a n in t egr a l con n ec-
t or r ecept a cle a n d t wo in t egr a l m ou n t in g ea r s, ea ch
wit h a m et a l sleeve t o pr ovide cr u sh pr ot ect ion . A ca v-
it y in t h e cen t er of t h e m olded bla ck pla st ic im pa ct
sen sor h ou sin g con t a in s t h e elect r on ic cir cu it r y of t h e
sen sor wh ich in clu des a n elect r on ic com m u n ica t ion
ch ip a n d a n elect r on ic im pa ct sen sor. P ot t in g m a t er ia l
fills t h e ca vit y t o sea l a n d pr ot ect t h e in t er n a l elec-
t r on ic cir cu it r y a n d com pon en t s. Th e fr on t im pa ct sen -
sor s a r e ea ch con n ect ed t o t h e veh icle elect r ica l
syst em t h r ou gh a dedica t ed t a ke ou t a n d con n ect or of
t h e r igh t or left h ea dla m p a n d da sh wir e h a r n esses.
Th e fr on t im pa ct sen sor s ca n n ot be r epa ir ed or
a dju st ed a n d, if da m a ged or fa u lt y, t h ey m u st be
r epla ced. If a fr on t im pa ct sen sor is fa u lt y, on ly t h e
sen sor n eeds t o be r epla ced. If t h e sen sor or t h e sen -
sor m ou n t in g br a cket is da m a ged or fa u lt y, or if
pr oper t igh t en in g t or qu e of t h e scr ews t h a t secu r e
t h e sen sor t o t h e br a cket ca n n ot be a ch ieved, t h e
sen sor a n d br a cket u n it m u st be r epla ced.
8O - 24 RESTRAINTS WJ
FRON T I M PACT SEN SOR (Cont inue d)

OPERATION DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE

Th e fr on t im pa ct sen sor s a r e elect r on ic a cceler om - WAY TO DISABLE THE SUPPLEMENTAL
et er s t h a t sen se t h e r a t e of veh icle deceler a t ion , RESTRAINT SYSTEM. FAILURE TO TAKE THE
wh ich pr ovides ver ifica t ion of t h e dir ect ion a n d sever- PROPER PRECAUTIONS COULD RESULT IN ACCI-
it y of a n im pa ct . E a ch sen sor a lso con t a in s a n elec- DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
t r on ic com m u n ica t ion ch ip t h a t a llows t h e u n it t o PERSONAL INJURY.
com m u n ica t e t h e sen sor st a t u s a s well a s sen sor
WARNING: THE FRONT IMPACT SENSOR ENABLES
fa u lt in for m a t ion t o t h e m icr opr ocessor in t h e Air ba g
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
Con t r ol Modu le (ACM). Th e ACM m icr opr ocessor con -
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
t in u ou sly m on it or s a ll of t h e pa ssive r est r a in t syst em
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
elect r ica l cir cu it s t o det er m in e t h e syst em r ea din ess.
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
If t h e ACM det ect s a m on it or ed syst em fa u lt , it set s
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
a Dia gn ost ic Tr ou ble Code (DTC) a n d con t r ols t h e
DROPPED DURING SERVICE, THE SENSOR MUST
a ir ba g in dica t or oper a t ion a ccor din gly.
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
Th e im pa ct sen sor s ea ch r eceive ba t t er y cu r r en t
FAILURE TO OBSERVE THIS WARNING COULD
a n d gr ou n d t h r ou gh dedica t ed left a n d r igh t sen sor
RESULT IN ACCIDENTAL, INCOMPLETE, OR
plu s a n d m in u s cir cu it s fr om t h e ACM. Th e im pa ct
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
sen sor s a n d t h e ACM com m u n ica t e by m odu la t in g
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
t h e volt a ge in t h e sen sor plu s cir cu it . Th e h a r d wir ed
RIES.
cir cu it s bet ween t h e fr on t im pa ct sen sor s a n d t h e
ACM m a y be dia gn osed a n d t est ed u sin g con ven - (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t ion a l dia gn ost ic t ools a n d pr ocedu r es. H owever, con - ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
ven t ion a l dia gn ost ic m et h ods will n ot pr ove disch a r ge befor e fu r t h er ser vice.
con clu sive in t h e dia gn osis of t h e ACM or t h e im pa ct (2) F r om t h e en gin e com pa r t m en t , discon n ect t h e
sen sor s. Th e m ost r elia ble, efficien t , a n d a ccu r a t e r igh t or left h ea dla m p a n d da sh wir e h a r n ess con n ec-
m ea n s t o dia gn ose t h e im pa ct sen sor s, t h e ACM, a n d t or for t h e fr on t im pa ct sen sor fr om t h e sen sor con -
t h e elect r on ic m essa ge com m u n ica t ion bet ween t h e n ect or r ecept a cle (F ig. 25).
sen sor s a n d t h e ACM r equ ir es t h e u se of a DRBIII!
sca n t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion .

REMOVAL
Th e fr on t a n d side im pa ct sen sor s a r e in t er ch a n ge-
a ble except t h a t t h e fr on t im pa ct sen sor s a r e ser viced
wit h a r igh t or left m ou n t in g br a cket , wh ile t h e side
im pa ct sen sor s u se n o m ou n t in g br a cket . If a fr on t
im pa ct sen sor is fa u lt y, bu t n ot da m a ged, t h e sen sor
m a y be r em oved fr om t h e sen sor m ou n t in g br a cket
a n d r epla ced wit h a side im pa ct sen sor. If t h e fr on t
im pa ct sen sor or t h e sen sor m ou n t in g br a cket a r e
da m a ged in a n y wa y, or if pr oper t igh t en in g t or qu e of
t h e scr ews t h a t secu r e t h e sen sor t o t h e br a cket ca n -
n ot be a ch ieved, t h e fr on t im pa ct sen sor a n d br a cket
m u st be r epla ced a s a u n it .

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING Fig. 25 Front Impact Sensor Remove/Install (Right
WHEEL, STEERING COLUMN, DRIVER AIRBAG, Side Shown, Left Side Similar)
PASSENGER AIRBAG, FRONT IMPACT SENSOR, 1 - BRACKET
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR 2 - IMPACT SENSOR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR 3 - RADIATOR SUPPORT
SERVICE. DISCONNECT AND ISOLATE THE BAT- 4 - WIRE HARNESS CONNECTOR
TERY NEGATIVE (GROUND) CABLE, THEN WAIT 5 - SCREW (2)
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
WJ
FRON T I M PACT SEN SOR (Cont inue d)
(3) F r om t h e en gin e com pa r t m en t , r em ove t h e t wo
scr ews t h a t secu r e t h e r igh t or left fr on t im pa ct sen -
sor t o t h e sen sor m ou n t in g br a cket on t h e r igh t or
left r a dia t or su ppor t ver t ica l m em ber.
(4) Rem ove t h e fr on t im pa ct sen sor fr om t h e sen -
sor m ou n t in g br a cket .
INSTALLATION
Th e fr on t a n d side im pa ct sen sor s a r e in t er ch a n ge-
a ble except t h a t t h e fr on t im pa ct sen sor s a r e ser viced
wit h a r igh t or left m ou n t in g br a cket , wh ile t h e side
im pa ct sen sor s u se n o m ou n t in g br a cket . If a fr on t
im pa ct sen sor is fa u lt y, bu t n ot da m a ged, t h e sen sor
m a y be r em oved fr om t h e sen sor m ou n t in g br a cket
a n d r epla ced wit h a side im pa ct sen sor. If t h e fr on t
im pa ct sen sor or t h e sen sor m ou n t in g br a cket a r e
da m a ged in a n y wa y, or if pr oper t igh t en in g t or qu e of
t h e scr ews t h a t secu r e t h e sen sor t o t h e br a cket ca n -
n ot be a ch ieved, t h e fr on t im pa ct sen sor a n d br a cket
m u st be r epla ced a s a u n it .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
RESTRAINTS 8O - 25
(1) P osit ion t h e r igh t or left fr on t im pa ct sen sor t o
t h e sen sor m ou n t in g br a cket on t h e r igh t or left r a di-
a t or su ppor t ver t ica l m em ber in t h e en gin e com pa r t -
m en t (F ig. 25).
(2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e r igh t or left fr on t im pa ct sen sor t o t h e sen sor
m ou n t in g br a cket . Tigh t en t h e scr ews t o 10 N·m (85
in . lbs.).
(3) Recon n ect t h e r igh t or left h ea dla m p a n d da sh
wir e h a r n ess con n ect or for t h e fr on t im pa ct sen sor t o
t h e sen sor con n ect or r ecept a cle.
(4) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
STANDARD P ROCE DURE - VE RIF ICATION TE ST).
FRON T I M PACT SEN SOR &
BRACK ET
REMOVAL
Th e fr on t a n d side im pa ct sen sor s a r e in t er ch a n ge-
a ble except t h a t t h e fr on t im pa ct sen sor s a r e ser viced
wit h a r igh t or left m ou n t in g br a cket , wh ile t h e side
im pa ct sen sor s u se n o m ou n t in g br a cket . If a fr on t
im pa ct sen sor is fa u lt y, bu t n ot da m a ged, t h e sen sor
m a y be r em oved fr om t h e sen sor m ou n t in g br a cket
a n d r epla ced wit h a side im pa ct sen sor. If t h e fr on t
im pa ct sen sor or t h e sen sor m ou n t in g br a cket a r e
da m a ged in a n y wa y, or if pr oper t igh t en in g t or qu e of
t h e scr ews t h a t secu r e t h e sen sor t o t h e br a cket ca n -
n ot be a ch ieved, t h e fr on t im pa ct sen sor a n d br a cket
m u st be r epla ced a s a u n it .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
8O - 26 RESTRAINTS
FRON T I M PACT SEN SOR & BRACK ET (Cont inue d)
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) Rem ove t h e h ea dla m p m ou n t in g m odu le fr om
t h e fr on t of t h e veh icle. (Refer t o 23 - BODY/E XTE -
RIOR/H E ADLAMP MOUNTING MODULE
RE MOVAL).
(3) Discon n ect t h e r igh t or left h ea dla m p a n d da sh
wir e h a r n ess con n ect or for t h e fr on t im pa ct sen sor
fr om t h e sen sor con n ect or r ecept a cle.
(4) Rem ove t h e t h r ee scr ews t h a t secu r e t h e r igh t
or left fr on t im pa ct sen sor a n d br a cket u n it t o t h e
r igh t or left r a dia t or su ppor t ver t ica l m em ber (F ig.
26).
Fig. 26 Front Impact Sensor & B Remove/Install
1 - RADIATOR SUPPORT
2 - SCREW (3)
3 - BRACKET
4 - WIRE HARNESS CONNECTOR
5 - IMPACT SENSOR
(5) Rem ove t h e r igh t or left fr on t im pa ct sen sor
a n d br a cket u n it fr om t h e fr on t of t h e veh icle.
WJ
INSTALLATION
Th e fr on t a n d side im pa ct sen sor s a r e in t er ch a n ge-
a ble except t h a t t h e fr on t im pa ct sen sor s a r e ser viced
wit h a r igh t or left m ou n t in g br a cket , wh ile t h e side
im pa ct sen sor s u se n o m ou n t in g br a cket . If a fr on t
im pa ct sen sor is fa u lt y, bu t n ot da m a ged, t h e sen sor
m a y be r em oved fr om t h e sen sor m ou n t in g br a cket
a n d r epla ced wit h a side im pa ct sen sor. If t h e fr on t
im pa ct sen sor or t h e sen sor m ou n t in g br a cket a r e
da m a ged in a n y wa y, or if pr oper t igh t en in g t or qu e of
t h e scr ews t h a t secu r e t h e sen sor t o t h e br a cket ca n -
n ot be a ch ieved, t h e fr on t im pa ct sen sor a n d br a cket
m u st be r epla ced a s a u n it .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
- SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) P osit ion t h e r igh t or left fr on t im pa ct sen sor
a n d br a cket u n it t o t h e fr on t of t h e veh icle (F ig. 26).
(2) P osit ion t h e r igh t or left fr on t im pa ct sen sor
a n d br a cket u n it t o t h e r igh t or left r a dia t or su ppor t
ver t ica l m em ber.
(3) Loosely in st a ll t h e t h r ee scr ews t h a t secu r e t h e
r igh t or left fr on t im pa ct sen sor a n d br a cket u n it
r igh t or left r a dia t or su ppor t ver t ica l m em ber.
WJ RESTRAINTS 8O - 27
FRON T I M PACT SEN SOR & BRACK ET (Cont inue d)
(4) F or t h e r igh t im pa ct sen sor a n d br a cket u n it ,
t h e t igh t en in g sequ en ce for t h e t h r ee scr ews t h a t
secu r e it t o t h e r igh t r a dia t or su ppor t ver t ica l m em -
ber is fr om t op t o bot t om . F or t h e left im pa ct sen sor
a n d br a cket u n it , t h e t igh t en in g sequ en ce for t h e
t h r ee scr ews t h a t secu r e it t o t h e left r a dia t or su p-
por t ver t ica l m em ber is fr om bot t om t o t op. Tigh t en
t h e scr ews t o 12 N·m (105 in . lbs.).
(5) Recon n ect t h e r igh t or left h ea dla m p a n d da sh
wir e h a r n ess con n ect or for t h e fr on t im pa ct sen sor t o
t h e sen sor con n ect or r ecept a cle.
(6) Rein st a ll t h e h ea dla m p m ou n t in g m odu le t o
t h e fr on t of t h e veh icle. (Refer t o 23 - BODY/E XTE -
RIOR/H E ADLAMP MOUNTING MODULE -
INSTALLATION).
(7) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS - Fig. 27 Front Seat Belt & Retractor Remove/Install
STANDARD P ROCE DURE - VE RIF ICATION TE ST). 1 - ADJUSTER
2 - TURNING LOOP
3 - SCREW
FRON T SEAT BELT & 4 - LOWER ANCHOR
RET RACT OR 5
6
- SCREW
- RETRACTOR

REMOVAL
(5) Usin g a t r im st ick or a n ot h er su it a ble wide
WARNING: DURING AND FOLLOWING ANY SEAT fla t -bla ded t ool, gen t ly pr y t h e t op of t h e t u r n in g loop
BELT SERVICE, CAREFULLY INSPECT ALL SEAT t r im cover t o u n sn a p it fr om t h e h eigh t a dju st er a n d
BELTS, BUCKLES, MOUNTING HARDWARE, AND a ccess t h e scr ew t h a t secu r es t h e fr on t sea t belt t u r n -
RETRACTORS FOR PROPER INSTALLATION, in g loop t o t h e a dju st er on t h e u pper B-pilla r (F ig.
OPERATION, OR DAMAGE. REPLACE ANY BELT 28).
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.

(1) Adju st t h e fr on t sea t t o it s m ost for wa r d posi-

t ion for ea siest a ccess t o t h e fr on t sea t belt lower
a n ch or a n d t h e B-pilla r t r im .
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
Fig. 28 Turning Loop Cover Remove/Install
(3) Lift t h e fr on t sea t belt lower a n ch or cover fa r
1 - PILLAR
en ou gh t o a ccess t h e scr ew t h a t secu r es it t o t h e
2 - TRIM COVER
lower B-pilla r (F ig. 27).
3 - ADJUSTER
(4) Rem ove t h e scr ew t h a t secu r es t h e lower
a n ch or t o t h e B-pilla r.
8O - 28 RESTRAINTS
FRON T SEAT BELT & RET RACT OR (Cont inue d)
(6) Rem ove t h e scr ew t h a t secu r es t h e sea t belt
t u r n in g loop t o t h e h eigh t a dju st er on t h e u pper
B-pilla r.
(7) Rem ove t h e sea t belt t u r n in g loop fr om t h e
h eigh t a dju st er.
(8) Rem ove t h e t r im fr om t h e lower B-pilla r. (Refer
t o 23 - BODY/INTE RIOR/B-P ILLAR LOWE R TRIM -
RE MOVAL).
(9) P u ll t h e fr on t sea t belt t u r n in g loop a n d lower
a n ch or t h r ou gh t h e a ccess h ole in t h e lower B-pilla r
t r im .
(10) Rem ove t h e pla st ic pu sh -in fa st en er t h a t
secu r es t h e r et r a ct or t o t h e lower B-pilla r (F ig. 29).
Fig. 29 Front Retractor
1 - SHIELD
2 - RETRACTOR
3 - PLASTIC FASTENER
4 - SLOT
5 - LOCATOR TAB
(11) Disen ga ge t h e r et r a ct or loca t or t a b fr om t h e
slot in t h e B-pilla r.
(12) Rem ove t h e fr on t sea t belt a n d r et r a ct or fr om
t h e B-pilla r a s a u n it .
INSTALLATION
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
WJ
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Be cer t a in t h a t t h e r et r a ct or sh ield is pr oper ly
in st a lled in t h e lower B-pilla r a n d in good con dit ion
befor e r ein st a llin g t h e r et r a ct or (F ig. 29).
(2) P osit ion t h e fr on t sea t belt a n d r et r a ct or t o t h e
B-pilla r a s a u n it . Be cer t a in t o en ga ge t h e r et r a ct or
loca t or t a b in t h e slot in t h e lower B-pilla r.
(3) Usin g h a n d pr essu r e, in st a ll t h e pla st ic pu sh -in
fa st en er t h a t secu r es t h e r et r a ct or t o t h e lower B-pilla r.
(4) P u sh t h e sea t belt lower a n ch or a n d t u r n in g
loop t h r ou gh t h e a ccess h ole in t h e lower B-pilla r
t r im (F ig. 27).
(5) Rein st a ll t h e t r im on t o t h e lower B-pilla r.
(Refer t o 23 - BODY/INTE RIOR/B-P ILLAR LOWE R
TRIM - INSTALLATION).
(6) P osit ion t h e sea t belt t u r n in g loop on t o t h e
h eigh t a dju st er on t h e u pper B-pilla r.
(7) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
sea t belt t u r n in g loop t o t h e h eigh t a dju st er. Tigh t en
t h e scr ew t o 37 N·m (27 ft . lbs.).
(8) Usin g h a n d pr essu r e, pr ess t h e t op of t h e t u r n -
in g loop t r im cover t o sn a p it on t o t h e h eigh t
a dju st er a n d cover t h e scr ew t h a t secu r es t h e fr on t
sea t belt t u r n in g loop t o t h e a dju st er on t h e u pper
B-pilla r (F ig. 28).
(9) P osit ion t h e fr on t sea t belt lower a n ch or t o t h e
lower B-pilla r.
(10) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
sea t belt lower a n ch or t o t h e B-pilla r. Tigh t en t h e
scr ew t o 37 N·m (27 ft . lbs.).
(11) P u ll down t h e cover over t h e fr on t sea t belt
lower a n ch or fa r en ou gh t o con cea l t h e scr ew.
(12) Recon n ect t h e ba t t er y n ega t ive ca ble.
FRON T SEAT BELT BU CK LE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, DRIVER AIRBAG, PASSENGER
AIRBAG, FRONT IMPACT SENSOR, SIDE IMPACT SEN-
SOR, SIDE CURTAIN AIRBAG, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE. DIS-
CONNECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE SUP-
PLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WJ
FRON T SEAT BELT BU CK LE (Cont inue d)
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Move t h e fr on t sea t t o it s m ost for wa r d posit ion
for ea siest a ccess t o t h e fr on t sea t belt bu ckle lower
a n ch or scr ew.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(3) Discon n ect t h e sea t belt swit ch pigt a il wir e
con n ect or fr om t h e body wir e h a r n ess con n ect or for
t h e sea t belt swit ch wit h m a n u a l sea t s, or fr om t h e
power sea t wir e h a r n ess con n ect or for t h e sea t belt
swit ch wit h power sea t s (F ig. 30).
Fig. 30 Front Seat Belt Buckle
1 - SEAT BELT BUCKLE
2 - SEAT BELT SWITCH PIGTAIL WIRE
3 - SCREW
(4) Rem ove t h e scr ew t h a t secu r es t h e fr on t sea t
belt bu ckle lower a n ch or t o t h e side of t h e floor pa n el
t r a n sm ission t u n n el.
RESTRAINTS 8O - 29
(5) Rem ove t h e fr on t sea t belt bu ckle fr om t h e
floor pa n el t r a n sm ission t u n n el.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG, PAS-
SENGER AIRBAG, FRONT IMPACT SENSOR, SIDE
IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRECAU-
TIONS COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) P osit ion t h e fr on t sea t belt bu ckle t o t h e side of
t h e floor pa n el t r a n sm ission t u n n el (F ig. 30).
(2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
fr on t sea t belt bu ckle lower a n ch or t o t h e side of t h e
floor pa n el t r a n sm ission t u n n el. Tigh t en t h e scr ew t o
43 N·m (32 ft . lbs.).
(3) Recon n ect t h e sea t belt swit ch pigt a il wir e con -
n ect or t o t h e body wir e h a r n ess con n ect or for t h e
sea t belt swit ch wit h m a n u a l sea t s, or t o t h e power
sea t wir e h a r n ess con n ect or for t h e sea t belt swit ch
wit h power sea t s.
(4) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
STANDARD P ROCE DURE - VE RIF ICATION TE ST).
8O - 30 RESTRAINTS
PASSEN GER AI RBAG
DESCRIPTION
Fig. 31 Passenger Airbag Door
1 - BEZEL
2 - TOP PAD
3 - PASSENGER AIRBAG DOOR
4 - GLOVE BOX DOOR
Th e r ea r wa r d fa cin g su r fa ce of t h e in st r u m en t
pa n el t op pa d a bove t h e glove box is t h e m ost visible
pa r t of t h e pa ssen ger a ir ba g (F ig. 31). Th e pa ssen ger
a ir ba g is loca t ed a bove t h e glove box open in g in fr on t
of t h e fr on t sea t pa ssen ger sea t in g posit ion wit h in
t h e in st r u m en t pa n el. Th e st a m ped st eel pa ssen ger
a ir ba g door is secu r ed on t h e ba ck of t h e in st r u m en t
pa n el t op pa d a r m a t u r e bet ween t h e t wo pa ssen ger
side pa n el ou t let s. A st a m ped m et a l r ein for cem en t is
secu r ed t o t h e in st r u m en t pa n el t op pa d a r m a t u r e
n ea r t h e u pper edge of t h e pa ssen ger a ir ba g door
open in g, a n d h elps t o defin e a pr edet er m in ed h in ge
lin e ben ea t h t h e decor a t ive cover of t h e t op pa d. Th e
in st r u m en t pa n el pa ssen ger side bezel is secu r ed t o
t h e a ir ba g door fr om beh in d wit h fou r scr ews.
Loca t ed beh in d t h e pa ssen ger a ir ba g door wit h in
t h e in st r u m en t pa n el is t h e pa ssen ger a ir ba g u n it .
Th e pa ssen ger a ir ba g u n it u sed in t h is m odel is a
m u lt ist a ge, Next Gen er a t ion -t ype t h a t com plies wit h
r evised feder a l a ir ba g st a n da r ds t o deploy wit h less
for ce t h a n t h ose u sed in som e pr ior m odels. Th e pa s-
sen ger a ir ba g u n it con sist s of a n ext r u ded a lu m in u m
h ou sin g, a m olded pla st ic in n er a ir ba g cu sh ion du st
cover, t h e a ir ba g cu sh ion , a n d t h e a ir ba g in fla t or.
Th e a ir ba g h ou sin g con t a in s t h e a ir ba g in fla t or,
wh ile t h e in n er du st cover con t a in s t h e folded a ir ba g
cu sh ion . Th e du st cover com plet ely en closes t h e a ir-
ba g cu sh ion a n d is per m a n en t ly r et a in ed t o t h e h ou s-
in g. Th e pa ssen ger a ir ba g u n it is secu r ed wit h fou r
scr ews t o t h e in st r u m en t pa n el st r u ct u r a l du ct . Con -
WJ
cea led ben ea t h t h e in st r u m en t pa n el t op pa d a r e t h e
pa ssen ger a ir ba g door, t h e folded a ir ba g cu sh ion , t h e
a ir ba g r et a in er or h ou sin g, a n d t h e a ir ba g in fla t or.
Th e a ir ba g cu sh ion is con st r u ct ed of a coa t ed n ylon
fa br ic. Th e a ir ba g in fla t or is a du a l-in it ia t or, h ybr id-
t ype u n it t h a t is secu r ed t o a n d sea led wit h in t h e a ir-
ba g h ou sin g. A sh or t fou r-wir e pigt a il h a r n ess wit h a
keyed, yellow con n ect or in su la t or con n ect s t h e t wo
in fla t or in it ia t or s t o t h e veh icle elect r ica l syst em
t h r ou gh a dedica t ed t a ke ou t a n d con n ect or of t h e
in st r u m en t pa n el wir e h a r n ess.
Th e pa ssen ger a ir ba g ca n n ot be r epa ir ed, a n d m u st
be r epla ced if deployed, fa u lt y, or in a n y wa y da m -
a ged. Th e pa ssen ger a ir ba g ca n n ot be r epa ir ed, a n d
m u st be r epla ced if fa u lt y or in a n y wa y da m a ged.
Th e pa ssen ger a ir ba g door is ser viced on ly a s a u n it
wit h t h e in st r u m en t pa n el t op pa d. F ollowin g a pa s-
sen ger a ir ba g deploym en t , t h e pa ssen ger a ir ba g a n d
t h e in st r u m en t pa n el t op pa d m u st be r epla ced. If
in spect ion r evea ls t h a t t h e pa ssen ger a ir ba g m ou n t -
in g poin t s on t h e in st r u m en t pa n el st r u ct u r a l du ct
h a ve been cr a cked or da m a ged, t h e in st r u m en t pa n el
st r u ct u r a l du ct a ssem bly m u st a lso be r epla ced.
OPERATION
Th e m u lt ist a ge pa ssen ger a ir ba g is deployed by
elect r ica l sign a ls gen er a t ed by t h e Air ba g Con t r ol
Modu le (ACM) t h r ou gh t h e pa ssen ger a ir ba g squ ib 1
a n d squ ib 2 cir cu it s t o t h e t wo in it ia t or s in t h e a ir-
ba g in fla t or. By u sin g t wo in it ia t or s, t h e a ir ba g ca n
be deployed a t m u lt iple levels of for ce. Th e for ce level
is con t r olled by t h e ACM t o su it t h e m on it or ed
im pa ct con dit ion s by pr ovidin g on e of fou r dela y
in t er va ls bet ween t h e elect r ica l sign a ls pr ovided t o
t h e t wo in it ia t or s. Th e lon ger t h e dela y bet ween
t h ese sign a ls, t h e less for cefu lly t h e a ir ba g will
deploy.
Th e h ybr id-t ype in fla t or a ssem bly in clu des a sm a ll
ca n ist er of h igh ly com pr essed ga s. Wh en t h e ACM
sen ds t h e pr oper elect r ica l sign a l t o t h e a ir ba g in fla -
t or, t h e in it ia t or gen er a t es en ou gh h ea t t o ign it e
ch em ica l pellet s wit h in t h e in fla t or. On ce ign it ed,
t h ese ch em ica l pellet s bu r n r a pidly a n d pr odu ce t h e
pr essu r e n ecessa r y t o r u pt u r e a con t a in m en t disk in
t h e pr essu r ized ga s ca n ist er. Th e in fla t or a n d ga s
ca n ist er a r e sea led t o t h e a ir ba g cu sh ion so t h a t a ll
of t h e r elea sed in er t ga s is dir ect ed in t o t h e a ir ba g
cu sh ion , ca u sin g t h e cu sh ion t o in fla t e. As t h e cu sh -
ion in fla t es, t h e pa ssen ger a ir ba g door will ben d ba ck
t h e in st r u m en t pa n el t op pa d a t t h e pr edet er m in ed
h in ge lin e, t h en fold ba ck over t h e t op of t h e in st r u -
m en t pa n el a n d ou t of t h e wa y. F ollowin g a n a ir ba g
deploym en t , t h e a ir ba g cu sh ion qu ickly defla t es by
ven t in g t h e in er t ga s t h r ou gh ven t h oles wit h in t h e
fa br ic u sed t o con st r u ct t h e sides of t h e a ir ba g cu sh -
ion .
WJ
PASSEN GER AI RBAG (Cont inue d)
Typica lly, bot h in it ia t or s a r e u sed du r in g a n a ir ba g
deploym en t even t . H owever, it is possible for on ly on e
in it ia t or t o be u sed du r in g a deploym en t du e t o a n
a ir ba g syst em fa u lt ; t h er efor e, it is n ecessa r y t o
a lwa ys con fir m t h a t bot h in it ia t or s h a ve been u sed in
or der t o a void t h e im pr oper disposa l of pot en t ia lly
live pyr ot ech n ic m a t er ia ls. (Refer t o 8 - E LE CTRI-
CAL/RE STRAINTS - STANDARD P ROCE DURE -
SE RVICE AF TE R A SUP P LE ME NTAL RE STRAINT
DE P LOYME NT).
REMOVAL
Th e followin g pr ocedu r e is for r epla cem en t of a
fa u lt y or da m a ged pa ssen ger a ir ba g. If t h e a ir ba g is
fa u lt y or da m a ged, bu t n ot deployed, r eview t h e r ec-
om m en ded pr ocedu r es for h a n dlin g n on -deployed
su pplem en t a l r est r a in t s. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS - STANDARD P ROCE DURE - H AN-
DLING NON-DE P LOYE D SUP P LE ME NTAL
RE STRAINTS). If t h e pa ssen ger a ir ba g h a s been
deployed, r eview t h e r ecom m en ded pr ocedu r es for
ser vice a ft er a su pplem en t a l r est r a in t deploym en t
befor e r em ovin g t h e a ir ba g fr om t h e veh icle. (Refer t o
8 - E LE CTRICAL/RE STRAINTS - STANDARD P RO-
CE DURE - SE RVICE AF TE R A SUP P LE ME NTAL
RE STRAINT DE P LOYME NT).
RESTRAINTS 8O - 31
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) Rem ove t h e t op pa d fr om t h e in st r u m en t pa n el.
(Refer t o 23 - BODY/INSTRUME NT PANE L/IN-
STRUME NT PANE L TOP PAD - RE MOVAL).
(3) Discon n ect t h e pa ssen ger a ir ba g pigt a il wir e
con n ect or fr om t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e a ir ba g. Th is con n ect or is secu r ed t o
t h e ou t side of t h e ou t boa r d a ir ba g u n it en d br a cket .
To discon n ect t h e con n ect or :
(a ) Slide t h e r ed Con n ect or P osit ion Assu r a n ce
(CPA) lock on t h e t op of t h e con n ect or t owa r d t h e
side of t h e con n ect or.
(b) Depr ess t h e con n ect or la t ch t a b a n d pu ll t h e
t wo h a lves of t h e con n ect or st r a igh t a wa y fr om
ea ch ot h er.
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e t wo a ir-
ba g en d br a cket fr on t m ou n t in g t a bs t o t h e t op of t h e
in st r u m en t pa n el st r u ct u r a l du ct (F ig. 32).

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE Fig. 32 Passenger Side Airbag Module Remove/
WAY TO DISABLE THE SUPPLEMENTAL Install
RESTRAINT SYSTEM. FAILURE TO TAKE THE 1 - STRUCTURAL DUCT
PROPER PRECAUTIONS COULD RESULT IN ACCI- 2 - PASSENGER AIRBAG
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE 3 - WIRE HARNESS CONNECTOR
PERSONAL INJURY. 4 - STRUCTURAL DUCT
5 - SCREWS

WARNING: WHEN REMOVING A DEPLOYED AIR-

(5) Rem ove t h e t wo scr ews t h a t secu r e t h e t wo a ir-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
ba g en d br a cket r ea r m ou n t in g t a bs t o t h e r ea r of t h e
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
st r u ct u r a l du ct , ju st a bove t h e in st r u m en t pa n el
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
u pper glove box open in g r ein for cem en t .
OTHER INTERIOR SURFACES. IN LARGE DOSES,
(6) Rem ove t h e pa ssen ger a ir ba g fr om t h e in st r u -
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
m en t pa n el st r u ct u r a l du ct a s a u n it .
SKIN AND EYES.
8O - 32 RESTRAINTS
PASSEN GER AI RBAG (Cont inue d)
INSTALLATION
Th e followin g pr ocedu r e is for r epla cem en t of a
fa u lt y or da m a ged pa ssen ger a ir ba g. If t h e a ir ba g is
fa u lt y or da m a ged, bu t n ot deployed, r eview t h e r ec-
om m en ded pr ocedu r es for h a n dlin g n on -deployed
su pplem en t a l r est r a in t s. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS - STANDARD P ROCE DURE - H AN-
DLING NON-DE P LOYE D SUP P LE ME NTAL
RE STRAINTS). If t h e pa ssen ger a ir ba g h a s been
deployed, r eview t h e r ecom m en ded pr ocedu r es for
ser vice a ft er a su pplem en t a l r est r a in t deploym en t
befor e r em ovin g t h e a ir ba g fr om t h e veh icle. (Refer t o
8 - E LE CTRICAL/RE STRAINTS - STANDARD P RO-
CE DURE - SE RVICE AF TE R A SUP P LE ME NTAL
RE STRAINT DE P LOYME NT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE INSTRUMENT PANEL TOP PAD. FAILURE
TO OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
WJ
WARNING: THE INSTRUMENT PANEL TOP PAD
MUST NEVER BE PAINTED. REPLACEMENT TOP
PADS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TOP PAD RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Ca r efu lly posit ion t h e pa ssen ger a ir ba g on t o
t h e in st r u m en t pa n el st r u ct u r a l du ct (F ig. 32).
(2) In st a ll a n d t igh t en t h e fou r scr ews t h a t secu r e
t h e pa ssen ger a ir ba g t o t h e in st r u m en t pa n el st r u c-
t u r a l du ct . Tigh t en t h e scr ews t o 11.8 N·m (105 in .
lbs.).
(3) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e pa ssen ger a ir ba g t o t h e pa ssen ger
a ir ba g pigt a il wir e con n ect or. Th is con n ect or is
secu r ed t o t h e ou t side of t h e ou t boa r d a ir ba g u n it
en d br a cket . Be cer t a in t h a t t h e la t ch on t h e con n ec-
t or a n d t h e r ed Con n ect or P osit ion Assu r a n ce (CPA)
lock a r e ea ch fu lly en ga ged.
(4) Rein st a ll t h e t op pa d on t o t h e in st r u m en t
pa n el. (Refer t o 23 - BODY/INSTRUME NT PANE L/
INSTRUME NT PANE L TOP PAD - INSTALLA-
TION).
(5) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
STANDARD P ROCE DURE - VE RIF ICATION TE ST).
REAR CEN T ER SEAT BELT &
RET RACT OR
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
WJ
REAR CEN T ER SEAT BELT & RET RACT OR (Cont inue d)
(1) Un la t ch a n d fold t h e r igh t r ea r sea t cu sh ion
for wa r d.
(2) Rem ove t h e scr ew t h a t secu r es t h e r ea r cen t er
sea t belt lower a n ch or t o t h e r igh t r ea r sea t belt
bu ckle u n it br a cket on t h e r ea r floor pa n el (F ig. 33).
(3) Un la t ch a n d fold t h e r igh t r ea r sea t ba ck for-
RESTRAINTS 8O - 33
(7) Rou t e t h e r ea r sea t belt lower a n ch or a n d belt
web gu ide t h r ou gh t h e t op of t h e sea t ba ck pa n el.
(8) Disen ga ge t h e sea t ba ck la t ch ca ble fit t in g fr om
t h e ca ble su ppor t on t h e r et r a ct or, wh ich is a ligh t
sn a p fit (F ig. 34).

Fig. 34 Seat Back Latch Cable Disengage/Engage

1 - LEVER
2 - PLUNGER
3 - LATCH CABLE FITTING
4 - REAR CENTER RETRACTOR
5 - SUPPORT

(9) Rem ove t h e scr ew t h a t secu r es t h e r et r a ct or t o

t h e r ea r sea t ba ck pa n el (F ig. 35).

Fig. 33 Rear Center Seat Belt Lower Anchor

Remove/Install
1 - REAR SEAT BACK
2 - REAR CENTER SEAT BELT & RETRACTOR
3 - RIGHT REAR SEAT BELT BUCKLE UNIT
4 - REAR FLOOR PANEL
5 - SCREW (1)
6 - LOWER ANCHOR

wa r d a n d sepa r a t e t h e ca r go a r ea ca r pet fr om t h e
ba se of t h e sea t ba ck pa n el.
(4) Rem ove t h e r igh t r ea r sea t ba ck pa n el fr om t h e
veh icle. (Refer t o 23 - BODY/SE ATS/SE AT BACK -
RE AR - RE MOVAL).
(5) Rem ove t h e t wo scr ews t h a t secu r e t h e belt
web gu ide t o t h e t op of t h e r igh t r ea r sea t ba ck
Fig. 35 Rear Center Retractor Remove/Install
pa n el.
1 - REAR SEAT BACK PANEL
(6) Rem ove t h e t r im fr om t h e r igh t r ea r sea t ba ck.
2 - SCREW (1)
(Refer t o 23 - BODY/SE ATS/SE AT BACK COVE R -
RE AR - RE MOVAL).
(10) Rem ove t h e r ea r cen t er sea t belt a n d r et r a ct or
u n it fr om t h e sea t ba ck pa n el.
8O - 34 RESTRAINTS
REAR CEN T ER SEAT BELT & RET RACT OR (Cont inue d)
INSTALLATION
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) P osit ion t h e r ea r cen t er sea t belt a n d r et r a ct or
u n it on t o t h e sea t ba ck pa n el.
(2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
r et r a ct or t o t h e r ea r sea t ba ck pa n el (F ig. 35).
Tigh t en t h e scr ew t o 43 N·m (32 ft . lbs.).
(3) P osit ion t h e sea t ba ck la t ch ca ble plu n ger
a ga in st t h e r et r a ct or la t ch lever, t h en en ga ge t h e
ca ble fit t in g in t o t h e ca ble su ppor t on t h e r et r a ct or,
wh ich is a ligh t sn a p fit (F ig. 34).
(4) Rou t e t h e r ea r sea t belt lower a n ch or a n d belt
web gu ide t h r ou gh t h e t op of t h e sea t ba ck pa n el.
(5) Rein st a ll t h e t r im on t o t h e r igh t r ea r sea t
ba ck. (Refer t o 23 - BODY/SE ATS/SE AT BACK
COVE R - RE AR - INSTALLATION).
(6) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e belt web gu ide t o t h e t op of t h e r igh t r ea r sea t
ba ck pa n el. Tigh t en t h e scr ews t o 2 N·m (20 in . lbs.).
(7) Rein st a ll t h e r igh t r ea r sea t ba ck pa n el in t o
t h e veh icle. (Refer t o 23 - BODY/SE ATS/SE AT BACK
- RE AR - INSTALLATION).
(8) Rest or e t h e ca r go a r ea ca r pet t o t h e ba se of t h e
sea t ba ck pa n el a n d u n fold t h e r igh t r ea r sea t ba ck
t o it s u pr igh t posit ion .
(9) P osit ion t h e r ea r cen t er sea t belt lower a n ch or
t o t h e r igh t r ea r sea t belt bu ckle u n it br a cket on t h e
r ea r floor pa n el (F ig. 33).
(10) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
r ea r cen t er sea t belt lower a n ch or t o t h e r igh t r ea r
sea t belt bu ckle u n it br a cket on t h e r ea r floor pa n el.
Tigh t en t h e scr ew t o 43 N·m (32 ft . lbs.).
(11) F old a n d la t ch t h e r igh t r ea r sea t cu sh ion in
it s n or m a l sea t in g posit ion .
WJ
REAR OU T BOARD SEAT BELT
& RET RACT OR
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) Disen ga ge t h e r ea r sea t cu sh ion la t ch by pu ll-
in g u pwa r d on t h e r elea se st r a p.
(2) F old t h e r ea r sea t cu sh ion for wa r d a ga in st t h e
ba ck of t h e fr on t bu cket sea t .
(3) Rem ove t h e scr ew t h a t secu r es t h e r ea r ou t -
boa r d sea t belt lower a n ch or t o t h e r ea r floor pa n el
(F ig. 36).
(4) Rem ove t h e lower a n ch or fr om t h e r ea r floor
pa n el.
(5) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y t h e t op of t h e t u r n in g loop
t r im cover t o u n sn a p it fr om t h e h eigh t a dju st er a n d
a ccess t h e scr ew t h a t secu r es t h e r ea r ou t boa r d sea t
belt t u r n in g loop t o t h e a dju st er on t h e u pper C-pil-
la r (F ig. 37).
(6) Rem ove t h e scr ew t h a t secu r es t h e sea t belt
t u r n in g loop t o t h e h eigh t a dju st er on t h e u pper
C-pilla r.
(7) Rem ove t h e sea t belt t u r n in g loop fr om t h e
h eigh t a dju st er.
(8) Rem ove t h e t r im fr om t h e qu a r t er in n er pa n el.
(Refer t o 23 - BODY/INTE RIOR/QUARTE R TRIM
PANE L - RE MOVAL).
(9) Rem ove t h e scr ew t h a t secu r es t h e r et r a ct or t o
t h e m ou n t in g t a b on t h e in n er a n d ou t er r ea r wh eel-
h ou se fla n ge.
(10) Disen ga ge t h e r et r a ct or loca t or t a b fr om t h e
slot in t h e lower C-pilla r (F ig. 38).
(11) Rem ove t h e r ea r ou t boa r d sea t belt a n d
r et r a ct or fr om t h e C-pilla r a s a u n it .
WJ RESTRAINTS 8O - 35
REAR OU T BOARD SEAT BELT & RET RACT OR (Cont inue d)

Fig. 38 Rear Outboard Retractor

1 - RETRACTOR
2 - SLOT/LOCATOR TAB
Fig. 36 Rear Outboard Seat Belt & Retractor
Remove/Install
1 - ADJUSTER INSTALLATION
2 - TURNING LOOP
3 - SCREW WARNING: DURING AND FOLLOWING ANY SEAT
4 - QUARTER TRIM PANEL BELT SERVICE, CAREFULLY INSPECT ALL SEAT
5 - SCREW BELTS, BUCKLES, MOUNTING HARDWARE, AND
6 - RETRACTOR RETRACTORS FOR PROPER INSTALLATION,
7 - LOWER ANCHOR OPERATION, OR DAMAGE. REPLACE ANY BELT
8 - SCREW
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.

(1) Be cer t a in t h a t t h e r et r a ct or sh ield is pr oper ly

in st a lled in t h e C-pilla r a n d in good con dit ion befor e
in st a llin g t h e r et r a ct or.
(2) P osit ion t h e r et r a ct or in t h e r et r a ct or sh ield
a n d be cer t a in t h a t t h e r et r a ct or loca t or t a b is
en ga ged in t h e slot in t h e lower C-pilla r below t h e
Fig. 37 Turning Loop Cover Remove/Install r et r a ct or sh ield (F ig. 38).
1 - PILLAR
(3) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
2 - TRIM COVER r et r a ct or br a cket t o t h e m ou n t in g t a b on t h e in n er
3 - ADJUSTER a n d ou t er r ea r wh eelh ou se fla n ge (F ig. 36). Tigh t en
t h e scr ew t o 43 N·m (32 ft . lbs.).
(4) Rein st a ll t h e t r im on t o t h e qu a r t er in n er pa n el.
(Refer t o 23 - BODY/INTE RIOR/QUARTE R TRIM
PANE L - INSTALLATION).
(5) P osit ion t h e sea t belt t u r n in g loop t o t h e h eigh t
a dju st er on t h e u pper C-pilla r.
8O - 36 RESTRAINTS WJ
REAR OU T BOARD SEAT BELT & RET RACT OR (Cont inue d)
(6) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
sea t belt t u r n in g loop t o t h e h eigh t a dju st er. Tigh t en
t h e scr ew t o 37 N·m (27 ft . lbs.).
(7) Usin g h a n d pr essu r e, pr ess t h e t op of t h e t u r n -
in g loop t r im cover t o sn a p it on t o t h e h eigh t
a dju st er a n d cover t h e scr ew t h a t secu r es t h e r ea r
ou t boa r d sea t belt t u r n in g loop t o t h e a dju st er on t h e
u pper C-pilla r (F ig. 37).
(8) P osit ion t h e r ea r ou t boa r d sea t belt lower
a n ch or t o t h e r ea r floor pa n el.
(9) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
sea t belt lower a n ch or t o t h e r ea r floor pa n el.
Tigh t en t h e scr ew t o 43 N·m (32 ft . lbs.).
(10) F old t h e r ea r sea t cu sh ion ba ck in t o t h e sea t -
in g posit ion .

Fig. 39 Rear Seat Lap Belt/Buckle

REAR SEAT BELT BU CK LE 1 - REAR SEAT LAP BELT/BUCKLE UNIT
2 - REAR SEAT BUCKLE/BUCKLE UNIT
REMOVAL 3 - REAR FLOOR PANEL
4 - SCREW
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND INSTALLATION
RETRACTORS FOR PROPER INSTALLATION,
WARNING: DURING AND FOLLOWING ANY SEAT
OPERATION, OR DAMAGE. REPLACE ANY BELT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
BELTS, BUCKLES, MOUNTING HARDWARE, AND
ANY BELT THAT IS TWISTED. TIGHTEN ANY
RETRACTORS FOR PROPER INSTALLATION,
LOOSE FASTENERS. REPLACE ANY BELT THAT
OPERATION, OR DAMAGE. REPLACE ANY BELT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
RETRACTOR. REPLACE ANY BELT THAT HAS A
ANY BELT THAT IS TWISTED. TIGHTEN ANY
BENT OR DAMAGED LATCH PLATE OR ANCHOR
LOOSE FASTENERS. REPLACE ANY BELT THAT
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
COMPONENT. ALWAYS REPLACE DAMAGED OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
FAULTY SEAT BELT COMPONENTS WITH THE COR-
BENT OR DAMAGED LATCH PLATE OR ANCHOR
RECT, NEW AND UNUSED REPLACEMENT PARTS
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
LISTED IN THE MOPAR PARTS CATALOG.
COMPONENT. ALWAYS REPLACE DAMAGED OR
(1) Disen ga ge t h e r ea r sea t cu sh ion la t ch by pu ll- FAULTY SEAT BELT COMPONENTS WITH THE COR-
in g u pwa r d on t h e r elea se st r a p. RECT, NEW AND UNUSED REPLACEMENT PARTS
(2) F old t h e r ea r sea t cu sh ion for wa r d a ga in st t h e LISTED IN THE MOPAR PARTS CATALOG.
ba ck of t h e fr on t bu cket sea t .
(1) P osit ion t h e r ea r sea t la p belt /bu ckle u n it
(3) Rem ove t h e scr ew t h a t secu r es t h e a n ch or
(r igh t side) or bu ckle/bu ckle u n it (left side) on t o t h e
pla t e of t h e r ea r sea t la p belt /bu ckle u n it (r igh t side)
r ea r floor pa n el (F ig. 39). Be cer t a in t h e loca t or t a b
or bu ckle/bu ckle u n it (left side) t o t h e r ea r floor
on t h e a n ch or pla t e is in st a lled in t h e loca t or h ole
pa n el (F ig. 39).
n ea r t h e m ou n t in g h ole in t h e r ea r floor pa n el.
NOTE: Vehicles equipped with a three-point center (2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
seat belt have the center seat belt lower anchor a n ch or pla t e of t h e r ea r sea t la p belt /bu ckle u n it
secured to the right buckle anchor plate with a (r igh t side) or bu ckle/bu ckle u n it (left side) t o t h e
screw instead of the center lap belt. (Refer to 8 - r ea r floor pa n el. Tigh t en t h e scr ew t o 43 N·m (32 ft .
ELECTRICAL/RESTRAINTS/REAR CENTER SEAT lbs.).
BELT & RETRACTOR - REMOVAL).

(4) Rem ove t h e r ea r sea t la p belt /bu ckle u n it (r igh t

side) or bu ckle/bu ckle u n it (left side) fr om t h e r ea r
floor pa n el.
WJ
REAR SEAT BELT BU CK LE (Cont inue d)
NOTE: Vehicles equipped with a three-point center
seat belt have the center seat belt lower anchor
secured to the right buckle anchor plate with a
screw instead of the center lap belt. (Refer to 8 -
ELECTRICAL/RESTRAINTS/REAR CENTER SEAT
BELT & RETRACTOR - INSTALLATION).
(3) F old t h e r ea r sea t cu sh ion ba ck in t o t h e sea t -
in g posit ion .
SEAT BELT SWI T CH
DESCRIPTION
Fig. 40 Front Seat Belt Buckle
1 - SEAT BELT BUCKLE
2 - SEAT BELT SWITCH PIGTAIL WIRE
3 - SCREW
Th e sea t belt swit ch for t h is m odel is a ct u a lly a
H a ll E ffect -t ype sen sor. Th is sen sor con sist s of a
fixed-posit ion , H a ll E ffect In t egr a t ed Cir cu it (IC) ch ip
a n d a sm a ll per m a n en t m a gn et t h a t a r e in t egr a l t o
ea ch fr on t sea t belt bu ckle. Th e fr on t sea t belt bu ck-
les a r e ea ch loca t ed on a st a m ped st eel st a n ch ion
wit h in a m olded pla st ic sca bba r d a n d secu r ed wit h a
scr ew t o t h e floor pa n el t r a n sm ission t u n n el on t h e
in boa r d side of ea ch fr on t sea t cu sh ion (F ig. 40). Th e
RESTRAINTS 8O - 37
sea t belt swit ch es a r e con n ect ed t o t h e veh icle elec-
t r ica l syst em t h r ou gh a t wo-lea d pigt a il wir e a n d
con n ect or on t h e sea t belt bu ckle-h a lf, wh ich is con -
n ect ed t o a wir e h a r n ess con n ect or a n d t a ke ou t of
t h e body wir e h a r n ess on veh icles wit h m a n u a l sea t
a dju st er s, or t o a con n ect or a n d t a ke ou t of t h e power
sea t wir e h a r n ess on veh icles wit h power sea t a dju st -
er s. A r a dio n oise su ppr ession ca pa cit or is con n ect ed
in pa r a llel wit h t h e IC wh er e t h e t wo pigt a il wir e
lea ds con n ect t o t h e IC pin s.
Th e sea t belt swit ch ca n n ot be a dju st ed or r epa ir ed
a n d, if fa u lt y or da m a ged, t h e en t ir e sea t belt bu ckle-
h a lf u n it m u st be r epla ced.
OPERATION
Th e sea t belt swit ch es a r e design ed t o pr ovide a
st a t u s sign a l t o t h e sea t belt swit ch sen se in pu t s of
t h e Air ba g Con t r ol Modu le (ACM) in dica t in g wh et h er
t h e fr on t sea t belt s a r e fa st en ed. Th e ACM u ses t h e
sea t belt swit ch in pu t s a s a fa ct or in det er m in in g
wh a t level of for ce wit h wh ich it sh ou ld deploy t h e
m u lt ist a ge dr iver a n d pa ssen ger a ir ba gs. In a ddit ion ,
t h e ACM sen ds elect r on ic m essa ges t o t h e E lect r oMe-
ch a n ica l In st r u m en t Clu st er (E MIC) t o con t r ol t h e
sea t belt in dica t or ba sed u pon t h e st a t u s of t h e
dr iver side fr on t sea t belt swit ch . A spr in g-loa ded
slide wit h a sm a ll win dow-like open in g is in t egr a l t o
t h e bu ckle la t ch m ech a n ism . Wh en a sea t belt t ip-
h a lf is in ser t ed a n d la t ch ed in t o t h e sea t belt bu ckle,
t h e slide is pu sh ed down wa r d a n d t h e win dow of t h e
slide exposes t h e H a ll E ffect In t egr a t ed Cir cu it (IC)
ch ip wit h in t h e bu ckle t o t h e field of t h e per m a n en t
m a gn et , wh ich in du ces a cu r r en t wit h in t h e ch ip.
Th e ch ip pr ovides t h is in du ced cu r r en t a s a n ou t pu t
t o t h e ACM, wh ich m on it or s t h e cu r r en t t o det er m in e
t h e st a t u s of t h e fr on t sea t belt s. Wh en t h e sea t belt
is u n bu ckled, t h e spr in g-loa ded slide m oves u pwa r d
a n d sh ields t h e IC fr om t h e field of t h e per m a n en t
m a gn et , ca u sin g t h e ou t pu t cu r r en t fr om t h e sea t
belt swit ch t o be r edu ced.
Th e sea t belt swit ch r eceives a su pply cu r r en t fr om
t h e ACM, a n d t h e ACM sen ses t h e st a t u s of t h e fr on t
sea t belt s t h r ou gh it s pigt a il wir e con n ect ion t o t h e
a ir ba g over la y wir e h a r n ess. Th e ACM m on it or s t h e
con dit ion of t h e sea t belt swit ch cir cu it s a n d will illu -
m in a t e t h e a ir ba g in dica t or in t h e E MIC t h en st or e a
Dia gn ost ic Tr ou ble Code (DTC) for a n y fa u lt t h a t is
det ect ed in eit h er sea t belt swit ch cir cu it . F or pr oper
dia gn osis of t h e sea t belt swit ch es, a DRBIII! sca n
t ool is r equ ir ed. Refer t o t h e a ppr opr ia t e dia gn ost ic
in for m a t ion .
8O - 38 RESTRAINTS WJ

SEAT BELT T U RN I N G LOOP

ADJ U ST ER
REMOVAL
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR Fig. 41 Seat Belt Turning Loop Adjuster - Typical
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
1 - SCREW (1)
COMPONENT. ALWAYS REPLACE DAMAGED OR 2 - ADJUSTER
FAULTY SEAT BELT COMPONENTS WITH THE COR- 3 - LEVER
RECT, NEW AND UNUSED REPLACEMENT PARTS 4 - SLOTS (2)
LISTED IN THE MOPAR PARTS CATALOG. 5 - HOOKS (2)

(1) Rem ove t h e t u r n in g loop fr om t h e fr on t or r ea r

sea t belt t u r n in g loop a dju st er. (Refer t o 8 - E LE C-
TRICAL/RE STRAINTS/F RONT SE AT BE LT &
RE TRACTOR - RE MOVAL) or (Refer t o 8 - E LE C-
TRICAL/RE STRAINTS/RE AR OUTBOARD SE AT
BE LT & RE TRACTOR - RE MOVAL).
(2) Rem ove t h e t r im fr om t h e u pper B-pilla r (fr on t
sea t belt a dju st er ) or u pper C-pilla r (r ea r sea t belt
a dju st er ). (Refer t o 23 - BODY/INTE RIOR/B-P ILLAR
UP P E R TRIM - RE MOVAL) or (Refer t o 23 - BODY/
INTE RIOR/C-P ILLAR TRIM - RE MOVAL).
(3) Rem ove t h e scr ew t h a t secu r es t h e u pper en d
of t h e fr on t or r ea r t u r n in g loop a dju st er t o t h e pilla r
(F ig. 41).
(4) P u ll t h e u pper en d of t h e t u r n in g loop a dju st er
a wa y fr om t h e pilla r fa r en ou gh t o disen ga ge t h e
h ooks on t h e lower en d of t h e a dju st er fr om t h e slot s
in t h e pilla r.
(5) Rem ove t h e t u r n in g loop a dju st er fr om t h e
B-pilla r (fr on t sea t belt ) or C-pilla r (r ea r sea t belt ).
INSTALLATION
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE MOPAR PARTS CATALOG.
(1) P osit ion t h e t u r n in g loop a dju st er t o t h e B-pil-
la r (fr on t sea t belt ) or C-pilla r (r ea r sea t belt ).
(2) E n ga ge t h e h ooks on t h e lower en d of t h e
a dju st er in t o t h e slot s in t h e pilla r (F ig. 41).
(3) Tilt t h e u pper en d of t h e t u r n in g loop a dju st er
in t o posit ion a ga in st t h e pilla r.
(4) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
u pper en d of t h e fr on t or r ea r h eigh t a dju st er t o t h e
pilla r. Tigh t en t h e scr ew t o 43 N·m (32 ft . lbs.).
(5) Rein st a ll t h e t r im on t o t h e u pper B-pilla r
(fr on t sea t belt a dju st er ) or u pper C-pilla r (r ea r sea t
belt a dju st er ). (Refer t o 23 - BODY/INTE RIOR/B-
P ILLAR UP P E R TRIM - INSTALLATION) or (Refer
t o 23 - BODY/INTE RIOR/C-P ILLAR TRIM -
INSTALLATION).
(6) Rein st a ll t h e fr on t or r ea r sea t belt t u r n in g
loop t o t h e a dju st er. (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/F RONT SE AT BE LT & RE TRACTOR -
INSTALLATION) or (Refer t o 8 - E LE CTRICAL/RE -
STRAINTS/RE AR OUTBOARD SE AT BE LT &
RE TRACTOR - INSTALLATION).
WJ
SI DE CU RTAI N AI RBAG
DESCRIPTION
Fig. 42 SRS Logo
Opt ion a l side cu r t a in a ir ba gs a r e a va ila ble for t h is
m odel wh en it is a lso equ ipped wit h du a l fr on t a ir-
ba gs. Th ese a ir ba gs a r e pa ssive, in fla t a ble, Su pple-
m en t a l Rest r a in t Syst em (SRS) com pon en t s, a n d
veh icles wit h t h is equ ipm en t ca n be r ea dily iden t ified
by a m olded iden t ifica t ion t r im bu t t on wit h t h e “SRS
- AIRBAG” logo loca t ed on t h e h ea dlin er a bove ea ch
B-pilla r (F ig. 42). Th is syst em is design ed t o r edu ce
in ju r ies t o t h e veh icle occu pa n t s in t h e even t of a
side im pa ct collision .
Veh icles equ ipped wit h side cu r t a in a ir ba gs h a ve
t wo in dividu a lly con t r olled cu r t a in a ir ba g u n it s.
Th ese a ir ba g u n it s a r e con cea led a n d m ou n t ed a bove
t h e h ea dlin er wh er e t h ey a r e ea ch secu r ed t o on e of
t h e r oof side r a ils (F ig. 43). E a ch folded a ir ba g cu sh -
ion is con t a in ed wit h in a lon g ext r u ded pla st ic ch a n -
n el t h a t ext en ds a lon g t h e r oof r a il fr om t h e A-pilla r
a t t h e fr on t of t h e veh icle t o ju st beh in d t h e C-pilla r
a t t h e r ea r of t h e veh icle. On e t et h er ext en ds down
t h e A-pilla r fr om t h e fr on t of t h e a ir ba g cu sh ion , a n d
a secon d t et h er ext en ds t o t h e r oof r a il a bove t h e
D-pilla r. Th e en ds of t h ese t et h er s a r e secu r ed t o
slot s in t h e sh eet m et a l wit h m et a l h ooks r et a in ed by
pla st ic a n ch or clips.
Th e h ybr id-t ype in fla t or for ea ch a ir ba g is secu r ed
t o t h e r oof r a il a t t h e r ea r of t h e a ir ba g u n it bet ween
t h e C-pilla r a n d t h e D-pilla r, a n d is con n ect ed t o t h e
a ir ba g cu sh ion by a lon g t u bu la r m a n ifold. Th e in fla -
t or br a cket a n d t h e ext r u ded a ir ba g cu sh ion ch a n n el
a r e secu r ed wit h bot h pla st ic pu sh -in fa st en er s a n d
scr ews t o t h e r oof r a il. A dedica t ed t wo-wir e t a ke ou t
a n d con n ect or of t h e body wir e h a r n ess is r ou t ed for-
wa r d fr om t h e D-pilla r t o t h e a ir ba g in fla t or.
RESTRAINTS 8O - 39
Th e side cu r t a in a ir ba g u n it ca n n ot be a dju st ed or
r epa ir ed a n d m u st be r epla ced if deployed, fa u lt y, or
in a n y wa y da m a ged. On ce a side cu r t a in a ir ba g h a s
been deployed, t h e com plet e a ir ba g u n it , t h e h ea d-
lin er, t h e u pper A, B, a n d C-pilla r t r im , a n d a ll ot h er
visibly da m a ged com pon en t s m u st be r epla ced.
OPERATION
E a ch side cu r t a in a ir ba g is deployed in dividu a lly
by a n elect r ica l sign a l gen er a t ed by t h e Air ba g Con -
t r ol Modu le (ACM) t o wh ich it is con n ect ed t h r ou gh
left or r igh t cu r t a in a ir ba g lin e 1 a n d lin e 2 (or
squ ib) cir cu it s. Th e h ybr id-t ype in fla t or a ssem bly for
ea ch a ir ba g con t a in s a sm a ll ca n ist er of h igh ly com -
pr essed ga s. Wh en t h e ACM sen ds t h e pr oper elect r i-
ca l sign a l t o t h e a ir ba g in fla t or, t h e elect r ica l en er gy
cr ea t es en ou gh h ea t t o ign it e ch em ica l pellet s wit h in
t h e in fla t or. On ce ign it ed, t h ese ch em ica ls bu r n r a p-
idly a n d pr odu ce t h e pr essu r e n ecessa r y t o r u pt u r e a
con t a in m en t disk in t h e pr essu r ized ga s ca n ist er. Th e
in fla t or a n d ga s ca n ist er a r e sea led a n d con n ect ed t o
a t u bu la r m a n ifold so t h a t a ll of t h e r elea sed in er t
ga s is dir ect ed in t o t h e folded side cu r t a in a ir ba g
cu sh ion , ca u sin g t h e cu sh ion t o in fla t e.
As t h e a ir ba g cu sh ion in fla t es it will dr op down
fr om t h e r oof r a il bet ween t h e edge of t h e h ea dlin er
a n d t h e side gla ss/body pilla r s t o for m a cu r t a in -like
cu sh ion t o pr ot ect t h e veh icle occu pa n t s du r in g a side
im pa ct collision . Th e fr on t a n d r ea r t et h er s keep t h e
side cu r t a in ba g t a u t , t h u s en su r in g t h a t t h e ba g will
deploy in t h e pr oper posit ion . F ollowin g t h e a ir ba g
deploym en t , t h e a ir ba g cu sh ion qu ickly defla t es by
ven t in g t h e in er t ga s t h r ou gh t h e loose wea ve of t h e
cu sh ion fa br ic, a n d t h e defla t ed cu sh ion h a n gs down
loosely fr om t h e r oof r a il.
REMOVAL
Th e followin g pr ocedu r e is for r epla cem en t of a
fa u lt y or da m a ged side cu r t a in a ir ba g. If t h e a ir ba g
is fa u lt y or da m a ged, bu t n ot deployed, r eview t h e
r ecom m en ded pr ocedu r es for h a n dlin g n on -deployed
su pplem en t a l r est r a in t s. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS - STANDARD P ROCE DURE - H AN-
DLING NON-DE P LOYE D SUP P LE ME NTAL
RE STRAINTS). If t h e side cu r t a in a ir ba g h a s been
deployed, r eview t h e r ecom m en ded pr ocedu r es for
ser vice a ft er a su pplem en t a l r est r a in t deploym en t
befor e r em ovin g t h e a ir ba g fr om t h e veh icle. (Refer t o
8 - E LE CTRICAL/RE STRAINTS - STANDARD P RO-
CE DURE - SE RVICE AF TE R A SUP P LE ME NTAL
RE STRAINT DE P LOYME NT).
8O - 40 RESTRAINTS
SI DE CU RTAI N AI RBAG (Cont inue d)
Fig. 43 Side Curtain Airbag
1 - NUT (9)
2 - REAR TETHER
3 - SCREW (9)
4 - INFLATOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WJ
5 - MANIFOLD
6 - PUSH-IN FASTENER (4)
7 - CHANNEL
8 - FRONT TETHER
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) Rem ove t h e h ea dlin er fr om t h e veh icle. (Refer
t o 23 - BODY/INTE RIOR/H E ADLINE R - RE MOV-
AL).
(3) Discon n ect t h e body wir e h a r n ess con n ect or for
t h e side cu r t a in a ir ba g in fla t or fr om t h e in fla t or con -
n ect or r ecept a cle (F ig. 44).
(4) Disen ga ge t h e side cu r t a in a ir ba g r ea r t et h er
h ook a n d pla st ic r et a in er clip fr om t h e slot in t h e
r oof r a il n ea r t h e D-pilla r.
(5) Disen ga ge t h e side cu r t a in a ir ba g fr on t t et h er
h ook a n d pla st ic r et a in er clip fr om t h e slot in t h e
lower A-pilla r (F ig. 45).
(6) Disen ga ge t h e side cu r t a in a ir ba g fr on t t et h er
pla st ic r et a in er fr om t h e h ole in t h e u pper A-pilla r.
WJ RESTRAINTS 8O - 41
SI DE CU RTAI N AI RBAG (Cont inue d)
(7) Rem ove t h e n in e scr ews t h a t secu r e t h e side
cu r t a in a ir ba g ch a n n el a n d in fla t or m ou n t in g br a cket
t o t h e spr in g n u t s in t h e r oof side r a il.
(8) Gr a sp t h e ext r u ded pla st ic ch a n n el of t h e side
cu r t a in a ir ba g fir m ly a n d pu ll it st r a igh t a wa y fr om
t h e body fa r en ou gh t o disen ga ge a ll t h r ee pla st ic
pu sh -in fa st en er s t h a t secu r e it t o t h e loca t in g h oles
in t h e r oof side r a il.
(9) Gr a sp t h e in fla t or of t h e side cu r t a in a ir ba g
fir m ly a n d pu ll it st r a igh t a wa y fr om t h e body fa r
en ou gh t o disen ga ge t h e pu sh -in fa st en er t h a t
secu r es it t o t h e loca t in g h ole in t h e r oof side r a il.
(10) Rem ove t h e side cu r t a in a ir ba g fr om t h e veh i-
Fig. 44 Side Curtain Airbag Inflator cle a s a u n it .
1 - BODY WIRE HARNESS
2 - D-PILLAR
3 - REAR TETHER
4 - INFLATOR

Fig. 45 Side Curtain Airbag Remove/Install

1 - NUT (9) 5 - MANIFOLD
2 - REAR TETHER 6 - PUSH-IN FASTENER (4)
3 - SCREW (9) 7 - CHANNEL
4 - INFLATOR 8 - FRONT TETHER
8O - 42 RESTRAINTS
SI DE CU RTAI N AI RBAG (Cont inue d)
INSTALLATION
Th e followin g pr ocedu r e is for r epla cem en t of a
fa u lt y or da m a ged side cu r t a in a ir ba g. If t h e a ir ba g
is fa u lt y or da m a ged, bu t n ot deployed, r eview t h e
r ecom m en ded pr ocedu r es for h a n dlin g n on -deployed
su pplem en t a l r est r a in t s. (Refer t o 8 - E LE CTRICAL/
RE STRAINTS - STANDARD P ROCE DURE - H AN-
DLING NON-DE P LOYE D SUP P LE ME NTAL
RE STRAINTS). If t h e side cu r t a in a ir ba g h a s been
deployed, r eview t h e r ecom m en ded pr ocedu r es for
ser vice a ft er a su pplem en t a l r est r a in t deploym en t
befor e r em ovin g t h e a ir ba g fr om t h e veh icle. (Refer t o
8 - E LE CTRICAL/RE STRAINTS - STANDARD P RO-
CE DURE - SE RVICE AF TE R A SUP P LE ME NTAL
RE STRAINT DE P LOYME NT).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(1) P osit ion t h e side cu r t a in a ir ba g in t o t h e veh icle
a s a u n it .
WJ
(2) Align t h e pu sh -in fa st en er t h a t secu r es t h e
in fla t or of t h e side cu r t a in a ir ba g t o t h e loca t in g h ole
in t h e r oof side r a il a n d, u sin g h a n d pr essu r e, pu sh
fir m ly on t h e r et a in er u n t il it is fu lly sea t ed (F ig. 45).
(3) Align t h e t h r ee pu sh -in fa st en er s t h a t secu r e
t h e ext r u ded pla st ic ch a n n el of t h e side cu r t a in a ir-
ba g t o t h e loca t in g h oles in t h e r oof side r a il a n d,
u sin g h a n d pr essu r e, pu sh fir m ly on ea ch r et a in er
u n t il it is fu lly sea t ed.
(4) In st a ll a n d t igh t en t h e n in e scr ews t h a t secu r e
t h e side cu r t a in a ir ba g ch a n n el a n d in fla t or m ou n t -
in g br a cket t o t h e spr in g n u t s in t h e r oof side r a il.
Tigh t en t h e scr ews t o 6 N·m (50 in . lbs.).
(5) Align t h e side cu r t a in a ir ba g fr on t t et h er pla s-
t ic r et a in er wit h t h e h ole in t h e u pper A-pilla r a n d,
u sin g h a n d pr essu r e, pu sh fir m ly on t h e r et a in er
u n t il it is fu lly sea t ed.
(6) E n ga ge t h e side cu r t a in a ir ba g fr on t t et h er
h ook a n d pla st ic r et a in er clip in t o t h e slot in t h e
lower A-pilla r.
(7) E n ga ge t h e side cu r t a in a ir ba g r ea r t et h er
h ook a n d pla st ic r et a in er clip in t o t h e slot in t h e r oof
r a il n ea r t h e D-pilla r (F ig. 44).
(8) Recon n ect t h e body wir e h a r n ess con n ect or for
t h e side cu r t a in a ir ba g in fla t or t o t h e in fla t or con n ec-
t or r ecept a cle.
(9) Rein st a ll t h e h ea dlin er in t o t h e veh icle. (Refer
t o 23 - BODY/INTE RIOR/H E ADLINE R - INSTALLA-
TION).
(10) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
ser vice of a n y su pplem en t a l r est r a in t syst em com po-
n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
STANDARD P ROCE DURE - VE RIF ICATION TE ST).
SI DE I M PACT SEN SOR
DESCRIPTION
Two side im pa ct sen sor s a r e u sed on t h is m odel
wh en it is equ ipped wit h t h e opt ion a l side cu r t a in
a ir ba gs, on e ea ch for t h e left a n d r igh t sides of t h e
veh icle (F ig. 46). Th ese sen sor s a r e m ou n t ed
r em ot ely fr om t h e bi-dir ect ion a l sa fin g sen sor t h a t is
in t er n a l t o t h e Air ba g Con t r ol Modu le (ACM). Th e
side a n d fr on t im pa ct sen sor s a r e iden t ica l in con -
st r u ct ion a n d ca libr a t ion wit h t h e except ion of t h e
r igh t -h a n d a n d left -h a n d die ca st a lu m in u m m ou n t -
in g br a cket s t o wh ich ea ch fr on t im pa ct sen sor is
secu r ed wit h t wo scr ews. Th e side im pa ct sen sor s a r e
secu r ed wit h t wo scr ews t o t h e ba se of t h e r igh t a n d
left B-pilla r s ju st below t h e fr on t sea t belt r et r a ct or s
a n d beh in d t h e lower B-pilla r t r im wit h in t h e pa s-
sen ger com pa r t m en t .
WJ
SI DE I M PACT SEN SOR (Cont inue d)
Fig. 46 Side Impact Sensor
1 - SENSOR
2 - CONNECTOR RECEPTACLE
Th e im pa ct sen sor h ou sin g h a s a n in t egr a l con n ec-
t or r ecept a cle a n d t wo in t egr a l m ou n t in g ea r s, ea ch
wit h a m et a l sleeve t o pr ovide cr u sh pr ot ect ion . A
ca vit y in t h e cen t er of t h e m olded bla ck pla st ic
im pa ct sen sor h ou sin g con t a in s t h e elect r on ic cir-
cu it r y of t h e sen sor wh ich in clu des a n elect r on ic com -
m u n ica t ion ch ip a n d a n elect r on ic im pa ct sen sor.
P ot t in g m a t er ia l fills t h e ca vit y t o sea l a n d pr ot ect
t h e in t er n a l elect r on ic cir cu it r y a n d com pon en t s. Th e
side im pa ct sen sor s a r e ea ch con n ect ed t o t h e veh icle
elect r ica l syst em t h r ou gh a dedica t ed t a ke ou t a n d
con n ect or of t h e a ir ba g over la y wir e h a r n ess.
Th e side im pa ct sen sor s ca n n ot be r epa ir ed or
a dju st ed a n d, if da m a ged or fa u lt y, t h ey m u st be
r epla ced.
OPERATION
Th e side im pa ct sen sor s a r e elect r on ic a cceler om e-
t er s t h a t sen se t h e r a t e of veh icle deceler a t ion , wh ich
pr ovides ver ifica t ion of t h e dir ect ion a n d sever it y of
a n im pa ct . E a ch sen sor a lso con t a in s a n elect r on ic
com m u n ica t ion ch ip t h a t a llows t h e u n it t o com m u -
n ica t e t h e sen sor st a t u s a s well a s sen sor fa u lt in for-
m a t ion t o t h e m icr opr ocessor in t h e Air ba g Con t r ol
Modu le (ACM). Th e ACM m icr opr ocessor con t in u -
ou sly m on it or s a ll of t h e pa ssive r est r a in t syst em
elect r ica l cir cu it s t o det er m in e t h e syst em r ea din ess.
If t h e ACM det ect s a m on it or ed syst em fa u lt , it set s
a Dia gn ost ic Tr ou ble Code (DTC) a n d con t r ols t h e
a ir ba g in dica t or oper a t ion a ccor din gly.
Th e im pa ct sen sor s ea ch r eceive ba t t er y cu r r en t a n d
gr ou n d t h r ou gh dedica t ed left a n d r igh t sen sor plu s
a n d m in u s cir cu it s fr om t h e ACM. Th e im pa ct sen sor s
a n d t h e ACM com m u n ica t e by m odu la t in g t h e volt a ge
in t h e sen sor plu s cir cu it . Th e h a r d wir ed cir cu it s
bet ween t h e side im pa ct sen sor s a n d t h e ACM m a y be
RESTRAINTS 8O - 43
dia gn osed a n d t est ed u sin g con ven t ion a l dia gn ost ic
t ools a n d pr ocedu r es. H owever, con ven t ion a l dia gn os-
t ic m et h ods will n ot pr ove con clu sive in t h e dia gn osis
of t h e ACM or t h e im pa ct sen sor s. Th e m ost r elia ble,
efficien t , a n d a ccu r a t e m ea n s t o dia gn ose t h e im pa ct
sen sor s, t h e ACM, a n d t h e elect r on ic m essa ge com m u -
n ica t ion bet ween t h e sen sor s a n d t h e ACM r equ ir es
t h e u se of a DRBIII! sca n t ool. Refer t o t h e a ppr opr i-
a t e dia gn ost ic in for m a t ion .
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: THE SIDE IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIR-
BAG. NEVER STRIKE OR DROP THE SIDE IMPACT
SENSOR, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN IMPACT
SENSOR IS ACCIDENTALLY DROPPED DURING
SERVICE, THE SENSOR MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Wa it t wo m in u t es for t h e syst em ca pa cit or t o
disch a r ge befor e fu r t h er ser vice.
(2) Rem ove t h e t r im fr om t h e lower r igh t or left
B-pilla r. (Refer t o 23 - BODY/INTE RIOR/B-P ILLAR
LOWE R TRIM - RE MOVAL).
(3) Discon n ect t h e a ir ba g over la y wir e h a r n ess
con n ect or for t h e r igh t or left side im pa ct sen sor fr om
t h e sen sor con n ect or r ecept a cle (F ig. 47).
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e r igh t or
left side im pa ct sen sor t o t h e B-pilla r.
(5) Rem ove t h e side im pa ct sen sor fr om t h e B-pil-
la r.
8O - 44 RESTRAINTS WJ
SI DE I M PACT SEN SOR (Cont inue d)
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.

WARNING: THE SIDE IMPACT SENSOR ENABLES

THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIR-
BAG. NEVER STRIKE OR DROP THE SIDE IMPACT
SENSOR, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN IMPACT
SENSOR IS ACCIDENTALLY DROPPED DURING
SERVICE, THE SENSOR MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
Fig. 47 Side Impact Sensor Remove/Install OCCUPANT INJURIES.
1 - B-PILLAR
(1) P osit ion t h e r igh t or left side im pa ct sen sor
2 - SIDE IMPACT SENSOR
3 - SCREW (2)
on t o t h e B-pilla r (F ig. 47).
4 - WIRE HARNESS CONNECTOR (2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e r igh t or left side im pa ct sen sor t o t h e B-pilla r.
Tigh t en t h e scr ews t o 12 N·m (105 in . lbs.).
INSTALLATION (3) Recon n ect t h e a ir ba g over la y wir e h a r n ess con -
n ect or for t h e r igh t or left side im pa ct sen sor t o t h e
WARNING: ON VEHICLES EQUIPPED WITH AIR- sen sor con n ect or r ecept a cle.
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT (4) Rein st a ll t h e t r im on t o t h e lower r igh t or left
SYSTEM BEFORE ATTEMPTING ANY STEERING B-pilla r. (Refer t o 23 - BODY/INTE RIOR/B-P ILLAR
WHEEL, STEERING COLUMN, DRIVER AIRBAG, LOWE R TRIM - INSTALLATION).
PASSENGER AIRBAG, FRONT IMPACT SENSOR, (5) Do n ot r econ n ect t h e ba t t er y n ega t ive ca ble a t
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR t h is t im e. Th e su pplem en t a l r est r a in t syst em ver ifi-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR ca t ion t est pr ocedu r e sh ou ld be per for m ed followin g
SERVICE. DISCONNECT AND ISOLATE THE BAT- ser vice of a n y su pplem en t a l r est r a in t syst em com po-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT n en t . (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
TWO MINUTES FOR THE SYSTEM CAPACITOR TO STANDARD P ROCE DURE - VE RIF ICATION TE ST).
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
WJ SPEED CONTROL 8P - 1

SPEED CONTROL
TABLE OF CON T EN T S

page page

SPEED CONTROL OPERATION . . . . . . . . . . . .................5

DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......1 REMOVAL ............ .................5
OPERATION . . . . . . . . . . . . . . . . . . . . . . ......1 INSTALLATION . . . . . . . . . .................6
DIAGNOSIS AND TESTING - ROAD TEST .....2 SWITCH
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .7
TORQUE - SPEED CONTROL . . . . . . . ......3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
CABLE REMOVAL ............ . . . . . . . . . . . . . . . . .7
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .7
OPERATION . . . . . . . . . . . . . . . . . . . . . . ......3 VACUUM RESERVOIR
REMOVAL DESCRIPTION . . . . . . . . . ........ .........8
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . ......3 OPERATION . . . . . . . . . . . ........ .........8
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . ......3 DIAGNOSIS AND TESTING - VACUUM
INSTALLATION RESERVOIR . . . . . . . . . ........ .........8
INSTALLATION - 4.0L . . . . . . . . . . . . . ......4 REMOVAL ............ ........ .........8
INSTALLATION - 4.7L . . . . . . . . . . . . . ......4 INSTALLATION . . . . . . . . . ........ .........9
SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......5

SPEED CON T ROL OPERATION

DESCRIPTION
Th e speed con t r ol syst em is elect r on ica lly con -
t r olled a n d va cu u m oper a t ed. E lect r on ic con t r ol of
t h e speed con t r ol syst em is in t egr a t ed in t o t h e P ow-
er t r a in Con t r ol Modu le (P CM). Th e con t r ols con sist
of t wo st eer in g wh eel m ou n t ed swit ch es. Th e
swit ch es a r e la beled: ON/OF F, RE S/ACCE L, SE T,
COAST, a n d CANCE L.
Th e syst em is design ed t o oper a t e a t speeds a bove
30 m ph (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 SLIP-
PERY.
Wh en speed con t r ol is select ed by depr essin g t h e
ON swit ch , t h e P CM a llows a set speed t o be st or ed
in P CM RAM for speed con t r ol. To st or e a set speed,
depr ess t h e SE T swit ch wh ile t h e veh icle is m ovin g
a t a speed bet ween 35 a n d 85 m ph . In or der for t h e
speed con t r ol t o en ga ge, t h e br a kes ca n n ot be
a pplied, n or ca n t h e gea r select or be in dica t in g t h e
t r a n sm ission is in P a r k or Neu t r a l.
Th e speed con t r ol ca n be disen ga ged m a n u a lly by:
• St eppin g on t h e br a ke peda l
• Depr essin g t h e OF F swit ch
• Depr essin g t h e CANCE L swit ch .
• Depr essin g t h e clu t ch peda l (if equ ipped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM.
F or a dded sa fet y, t h e speed con t r ol syst em is pr o-
gr a m m ed t o disen ga ge for a n y of t h e followin g con di-
t ion s:
• An in dica t ion of P a r k or Neu t r a l
• A r a pid in cr ea se r pm (in dica t es t h a t t h e clu t ch
h a s been disen ga ged)
• E xcessive en gin e r pm (in dica t es t h a t t h e t r a n s-
m ission m a y be in a low gea r )
• Th e speed sign a l in cr ea ses a t a r a t e of 10 m ph
per secon d (in dica t es t h a t t h e coefficien t of fr ict ion
bet ween t h e r oa d su r fa ce a n d t ir es is ext r em ely low)
8P - 2 SPEED CONTROL
SPEED CON T ROL (Cont inue d)
• Th e speed sign a l decr ea ses a t a r a t e of 10 m ph
per secon d (in dica t es t h a t t h e veh icle m a y h a ve
deceler a t ed a t a n ext r em ely h igh r a t e)
On ce t h e speed con t r ol h a s been disen ga ged,
depr essin g t h e RE S/ACCE L swit ch (wh en speed is
gr ea t er t h a n 30 m ph ) r est or es t h e veh icle t o t h e t a r-
get speed t h a t wa s st or ed in t h e P CM.
Wh ile t h e speed con t r ol is en ga ged, t h e dr iver ca n
in cr ea se t h e veh icle speed by depr essin g t h e RE S/AC-
CE L swit ch . Th e n ew t a r get speed is st or ed in t h e
P CM wh en t h e RE S/ACCE L is r elea sed. Th e P CM
a lso h a s a !t a p-u p! fea t u r e in wh ich veh icle speed
in cr ea ses a t a r a t e of a ppr oxim a t ely 2 m ph for ea ch
m om en t a r y swit ch a ct iva t ion of t h e RE S/ACCE L
swit ch .
A “t a p down ” fea t u r e is u sed t o deceler a t e wit h ou t
disen ga gin g t h e speed con t r ol syst em . To deceler a t e
fr om a n exist in g r ecor ded t a r get speed, m om en t a r ily
depr ess t h e COAST swit ch . F or ea ch swit ch a ct iva -
t ion , speed will be lower ed a ppr oxim a t ely 1 m ph .
OVERSHOOT/UNDERSHOOT
If t h e veh icle oper a t or r epea t edly pr esses a n d
r elea ses t h e SE T bu t t on wit h t h eir foot off of t h e
a cceler a t or (r efer r ed t o a s a “lift foot set ”), t h e veh icle
m a y a cceler a t e a n d exceed t h e desir ed set speed by
u p t o 5 m ph (8 km /h ). It m a y a lso deceler a t e t o less
t h a n t h e desir ed set speed, befor e fin a lly a ch ievin g
t h e desir ed set speed.
Th e Speed Con t r ol Syst em h a s a n a da pt ive st r a t -
egy t h a t com pen sa t es for veh icle-t o-veh icle va r ia t ion s
in speed con t r ol ca ble len gt h s. Wh en t h e speed con -
t r ol is set wit h t h e veh icle oper a t or s foot off of t h e
a cceler a t or peda l, t h e speed con t r ol t h in ks t h er e is
excessive speed con t r ol ca ble sla ck a n d a da pt s
a ccor din gly. If t h e “lift foot set s” a r e con t in u a lly u sed,
a speed con t r ol over sh oot /u n der sh oot con dit ion will
develop.
To “u n lea r n ” t h e over sh oot /u n der sh oot con dit ion ,
t h e veh icle oper a t or h a s t o pr ess a n d r elea se t h e set
bu t t on wh ile m a in t a in in g t h e desir ed set speed u sin g
t h e a cceler a t or peda l (n ot deceler a t in g or a cceler a t -
in g), a n d t h en t u r n in g t h e cr u ise con t r ol swit ch t o
t h e OF F posit ion (or pr ess t h e CANCE L bu t t on if
equ ipped) a ft er wa it in g 10 secon ds. Th is pr ocedu r e
m u st be per for m ed a ppr oxim a t ely 10–15 t im es t o
com plet ely u n lea r n t h e over sh oot /u n der sh oot con di-
t ion .
WJ
DIAGNOSIS AND TESTING - ROAD TEST
P er for m a veh icle r oa d t est t o ver ify r epor t s of
speed con t r ol syst em m a lfu n ct ion . Th e r oa d t est
sh ou ld in clu de a t t en t ion t o t h e speedom et er. Speed-
om et er oper a t ion sh ou ld be sm oot h a n d wit h ou t flu t -
t er a t a ll speeds.
F lu t t er in t h e speedom et er in dica t es a pr oblem
wh ich m igh t ca u se su r gin g in t h e speed con t r ol sys-
t em . Th e ca u se of a n y speedom et er pr oblem s sh ou ld
be cor r ect ed befor e pr oceedin g. Refer t o Gr ou p 8J ,
In st r u m en t Clu st er for speedom et er dia gn osis.
If a r oa d t est ver ifies a syst em pr oblem a n d t h e
speedom et er oper a t es pr oper ly, ch eck for :
• A Dia gn ost ic Tr ou ble Code (DTC). If a DTC
exist s, con du ct t est s per t h e P ower t r a in Dia gn ost ic
P r ocedu r es ser vice m a n u a l.
• A m isa dju st ed br a ke (st op) la m p swit ch . Th is
cou ld a lso ca u se a n in t er m it t en t pr oblem .
• Loose, da m a ged or cor r oded elect r ica l con n ec-
t ion s a t t h e ser vo. Cor r osion sh ou ld be r em oved fr om
elect r ica l t er m in a ls a n d a ligh t coa t in g of Mopa r
Mu lt iP u r pose Gr ea se, or equ iva len t , a pplied.
• Lea kin g va cu u m r eser voir.
• Loose or lea kin g va cu u m h oses or con n ect ion s.
• Defect ive on e-wa y va cu u m ch eck va lve.
• Secu r e a t t a ch m en t of bot h en ds of t h e speed con -
t r ol ser vo ca ble.
• Sm oot h oper a t ion of t h r ot t le lin ka ge a n d t h r ot t le
body a ir va lve.
• F a iled speed con t r ol ser vo. Do t h e ser vo va cu u m
t est .
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
WJ SPEED CONTROL 8P - 3
SPEED CON T ROL (Cont inue d)

SPECI FI CAT I ON S
TORQUE - SPEED CONTROL

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Servo Mounting Bracket-to- 8.5 75
Servo Nuts
Servo Mounting Bracket-to- 28 ± 6 250 ± 50
Body Nuts
Switch Module Mounting .6-1 6-9
Screws
Vacuum Reservoir Mounting 3 25
Bolts

CABLE
DESCRIPTION
Th e speed con t r ol ser vo ca ble is con n ect ed bet ween
t h e speed con t r ol va cu u m ser vo dia ph r a gm a n d t h e
t h r ot t le body con t r ol lin ka ge.

OPERATION
Th is ca ble ca u ses t h e t h r ot t le con t r ol lin ka ge t o
open or close t h e t h r ot t le va lve in r espon se t o m ove-
m en t of t h e va cu u m ser vo dia ph r a gm .

REM OVAL
REMOVAL - 4.0L
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Rem ove a ir box h ou sin g fr om t h r ot t le body.
(3) Usin g fin ger pr essu r e on ly, r em ove speed con -
t r ol ca ble con n ect or a t t h r ot t le body bellcr a n k pin by
pu sh in g con n ect or off bellcr a n k pin t owa r ds dr iver s
side of veh icle (F ig. 1). D O N OT try to p u ll c o n -
n e c to r o ff p e rp e n d ic u la r to th e be llc ra n k p in . Fig. 1 Speed Control Cable at Bell Crank—4.0L
Co n n e c to r w ill be bro k e n . Engine
(4) Rem ove ca ble fr om ca ble gu ide a t t op of va lve 1 - ACCELERATOR CABLE
cover. 2 - OFF
(5) Squ eeze 2 r elea se t a bs (F ig. 1) on sides of ca ble 3 - OFF
a t br a cket a n d pu sh ca ble ou t of br a cket . 4 - THROTTLE BODY BELLCRANK
(6) Rem ove ser vo ca ble fr om ser vo. Refer t o Speed 5 - SPEED CONTROL CABLE
Con t r ol Ser vo Rem ova l/In st a lla t ion . 6 - RELEASE TABS
7 - BRACKET
REMOVAL - 4.7L
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y. (3) Usin g fin ger pr essu r e on ly, discon n ect a cceler a -
(2) Rem ove a ir box h ou sin g fr om t h r ot t le body. t or ca ble con n ect or a t t h r ot t le body bellcr a n k pin by
Th e a cceler a t or ca ble m u st be pa r t ia lly r em oved t o pu sh in g con n ect or off bellcr a n k pin t owa r ds fr on t of
ga in a ccess t o speed con t r ol ca ble. veh icle (F ig. 2). D O N OT try to p u ll c o n n e c to r o ff
p e rp e n d ic u la r to th e be llc ra n k p in . Co n n e c to r
w ill be bro k e n .
8P - 4 SPEED CONTROL WJ
CABLE (Cont inue d)
(4) Lift a cceler a t or ca ble fr om t op of ca ble ca m
(F ig. 2).
(5) P r ess t a b (F ig. 3) t o r elea se pla st ic ca ble m ou n t
fr om br a cket . P re s s o n ta b o n ly e n o u g h to
re le a s e c a ble fro m bra c k e t. If ta b is p re s s e d to o
m u c h , it w ill be bro k e n . Slide pla st ic m ou n t (F ig.
3) t owa r ds pa ssen ger side of veh icle t o r em ove ca ble
fr om br a cket .
(6) Usin g fin ger pr essu r e on ly, discon n ect speed
con t r ol ca ble con n ect or a t t h r ot t le body bellcr a n k pin
by pu sh in g con n ect or off bellcr a n k pin t owa r ds fr on t
of veh icle (F ig. 2). D O N OT try to p u ll c o n n e c to r
o ff p e rp e n d ic u la r to th e be llc ra n k p in . Co n n e c -
to r w ill be bro k e n .
(7) Slide speed con t r ol ca ble pla st ic m ou n t t owa r ds
pa ssen ger side of veh icle t o r em ove ca ble fr om
br a cket (F ig. 4).
(8) Rem ove ser vo ca ble fr om ser vo. Refer t o Speed
Con t r ol Ser vo Rem ova l/In st a lla t ion .

Fig. 3 Accelerator Cable Release Tab—4.7L V-8

Engine
1 - ACCELERATOR CABLE
2 - PLASTIC CABLE MOUNT
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
5 - SLIDE FOR REMOVAL

I N STALLAT I ON
INSTALLATION - 4.0L
(1) In st a ll en d of ca ble t o speed con t r ol ser vo.
Refer t o Speed Con t r ol Ser vo Rem ova l/In st a lla t ion .
(2) In st a ll ca ble in t o m ou n t in g br a cket (sn a ps in ).
(3) In st a ll speed con t r ol ca ble con n ect or a t t h r ot t le
body bellcr a n k pin (sn a ps on ).
(4) Con n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(5) Befor e st a r t in g en gin e, oper a t e a cceler a t or
peda l t o ch eck for a n y bin din g.
Fig. 2 Cable Connectors at Bell Crank—4.7L V-8 INSTALLATION - 4.7L
Engine
(1) In st a ll en d of ca ble t o speed con t r ol ser vo.
1 - THROTTLE BODY Refer t o Speed Con t r ol Ser vo Rem ova l/In st a lla t ion .
2 - SPEED CONTROL CABLE CONNECTOR
(2) Slide speed con t r ol ca ble pla st ic m ou n t in t o
3 - OFF
br a cket .
4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
(3) In st a ll speed con t r ol ca ble con n ect or on t o t h r ot -
6 - CABLE CAM t le body bellcr a n k pin (sn a ps on ).
7 - BELLCRANK (4) Slide a cceler a t or ca ble pla st ic m ou n t in t o
br a cket . Con t in u e slidin g u n t il t a b (F ig. 3) is a lign ed
t o h ole in m ou n t in g br a cket .
(5) Rou t e a cceler a t or ca ble over t op of ca ble ca m
(F ig. 2).
(6) In st a ll a cceler a t or ca ble con n ect or on t o t h r ot t le
body bellcr a n k pin (sn a ps on ).
(7) In st a ll a ir box h ou sin g t o t h r ot t le body.
WJ SPEED CONTROL 8P - 5
CABLE (Cont inue d)
Th e du m p solen oid is en er gized a n yt im e it r eceives
power. If power t o t h e du m p solen oid is in t er r u pt ed,
t h e solen oid du m ps va cu u m in t h e ser vo. Th is pr o-
vides a sa fet y ba cku p t o t h e ven t a n d va cu u m sole-
n oids.
Th e va cu u m a n d ven t solen oids m u st be gr ou n ded
a t t h e P CM t o oper a t e. Wh en t h e P CM gr ou n ds t h e
va cu u m ser vo solen oid, t h e solen oid a llows va cu u m
t o en t er t h e ser vo a n d pu ll open t h e t h r ot t le pla t e
u sin g t h e ca ble. Wh en t h e P CM br ea ks t h e gr ou n d,
t h e solen oid closes a n d n o m or e va cu u m is a llowed t o
en t er t h e ser vo. Th e P CM a lso oper a t es t h e ven t sole-
n oid via gr ou n d. Th e ven t solen oid open s a n d closes a
pa ssa ge t o bleed or h old va cu u m in t h e ser vo a s
r equ ir ed.
Th e P CM du t y cycles t h e va cu u m a n d ven t sole-
n oids t o m a in t a in t h e set speed, or t o a cceler a t e a n d
deceler a t e t h e veh icle. To in cr ea se t h r ot t le open in g,
t h e P CM gr ou n ds t h e va cu u m a n d ven t solen oids. To
decr ea se t h r ot t le open in g, t h e P CM r em oves t h e
gr ou n ds fr om t h e va cu u m a n d ven t solen oids. Wh en
t h e br a ke is r elea sed, if veh icle speed exceeds 30
Fig. 4 Speed Control Cable at Bracket—4.7L V-8 m ph t o r esu m e, 35 m ph t o set , a n d t h e RE S/ACCE L
Engine swit ch h a s been depr essed, gr ou n d for t h e ven t a n d
1 - PLASTIC CABLE MOUNT va cu u m cir cu it s is r est or ed.
2 - SPEED CONTROL CABLE
3 - BRACKET REMOVAL
4 - SLIDE FOR REMOVAL Th e speed con t r ol ser vo is a t t a ch ed t o a br a cket .
Th e br a cket a n d ser vo a ssem bly a r e loca t ed below
(8) Con n ect n ega t ive ba t t er y ca ble a t ba t t er y. t h e ba t t er y t r a y.
(9) Befor e st a r t in g en gin e, oper a t e a cceler a t or (1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
peda l t o ch eck for a n y bin din g. (2) Discon n ect posit ive ba t t er y ca ble a t ba t t er y.
(3) Rem ove a ir clea n er h ou sin g a t t op of t h r ot t le
body a n d discon n ect ser vo ca ble a t t h r ot t le body.
SERV O Refer t o Ser vo Ca ble Rem ova l/In st a lla t ion .
(4) Rem ove ba t t er y fr om ba t t er y t r a y.
DESCRIPTION (5) Discon n ect wir in g a t ba t t er y t r a y.
Th e ser vo u n it con sist s of a solen oid va lve body, (6) Discon n ect posit ive ba t t er y ca ble a t P ower Dis-
a n d a va cu u m ch a m ber. Th e solen oid va lve body con - t r ibu t ion Cen t er (P DC).
t a in s t h r ee solen oids: (7) Loosen P DC a t ba t t er y t r a y.
• Va cu u m (8) Rem ove 4 ba t t er y t r a y bolt s. On e of t h ese bolt s
• Ven t a t t a ch es t o speed con t r ol br a cket fla n ge t h a t su p-
• Du m p por t s ba t t er y t r a y. Wh ile r em ovin g ba t t er y t r a y, dis-
Th e va cu u m ch a m ber con t a in s a dia ph r a gm wit h a con n ect ba t t er y t em per a t u r e sen sor elect r ica l
ca ble a t t a ch ed t o con t r ol t h e t h r ot t le lin ka ge. con n ect or a t sen sor.
(9) Discon n ect va cu u m lin e a t ser vo va cu u m h ose
OPERATION fit t in g (F ig. 5) .
Th e P ower t r a in Con t r ol Modu le (P CM) con t r ols t h e (10) Discon n ect elect r ica l con n ect or a t ser vo (F ig.
solen oid va lve body. Th e solen oid va lve body con t r ols 5) .
t h e a pplica t ion a n d r elea se of va cu u m t o t h e dia - If ser vo a n d m ou n t in g br a cket a r e bein g r em oved
ph r a gm of t h e va cu u m ser vo. Th e ser vo u n it ca n n ot a s on e a ssem bly, r em ove t wo m ou n t in g n u t s (F ig. 5) .
be r epa ir ed a n d is ser viced on ly a s a com plet e a ssem - Th ese a r e loca t ed a bove r igh t -fr on t t ir e. Rem ove
bly. in n er fen der clips a n d pr y in n er fen der ba ck sligh t ly
P ower is su pplied t o t h e ser vo’s by t h e P CM t o ga in a ccess t o m ou n t in g n u t s.
t h r ou gh t h e br a ke swit ch . Th e P CM con t r ols t h e
gr ou n d pa t h for t h e va cu u m a n d ven t solen oids.
8P - 6 SPEED CONTROL WJ
SERV O (Cont inue d)
(11) If ser vo is bein g r em oved fr om it s m ou n t in g
br a cket , r em ove 2 m ou n t in g n u t s h oldin g ser vo ca ble
sleeve t o br a cket (F ig. 6) .
(12) P u ll speed con t r ol ca ble sleeve a n d ser vo a wa y
fr om ser vo m ou n t in g br a cket t o expose ca ble r et a in -
in g clip (F ig. 6) a n d r em ove clip. Not e: Th e ser vo
m ou n t in g br a cket displa yed in (F ig. 6) is a t ypica l
br a cket a n d m a y/m a y n ot be a pplica ble t o t h is m odel
veh icle.

Fig. 6 Servo Cable Clip Remove/Install—Typical

1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE

INSTALLATION
(1) P osit ion ser vo t o m ou n t in g br a cket .
(2) Align h ole in ca ble con n ect or wit h h ole in ser vo
pin . In st a ll ca ble-t o-ser vo r et a in in g clip.
(3) In ser t ser vo m ou n t in g st u ds t h r ou gh h oles in
ser vo m ou n t in g br a cket .
(4) In st a ll ser vo ca ble m ou n t in g n u t s (F ig. 6) a n d
t igh t en t o 8.5 N·m (75 in . lbs.) t or qu e. If ser vo a n d
br a cket is bein g in st a lled a s on e a ssem bly, in st a ll 2
m ou n t in g n u t s (F ig. 5) a n d t igh t en t o 28 N·m ±6 N·m
(250 in . lbs. ±50 in . lbs.) t or qu e.
(5) Con n ect va cu u m lin e a t ser vo.
(6) Con n ect elect r ica l con n ect or a t ser vo.
Fig. 5 Speed Control (7) Con n ect ser vo ca ble t o t h r ot t le body. Refer t o
1 - VACUUM HOSE FITTING Ser vo Ca ble Rem ova l/In st a lla t ion .
2 - SPEED CONTROL SERVO (8) In st a ll ba t t er y t r a y a n d ba t t er y t em per a t u r e
3 - SERVO CABLE
sen sor.
4 - RIGHT INNER FENDER
(9) Con n ect wir in g t o ba t t er y t r a y.
5 - SERVO MOUNTING NUTS (2)
6 - SERVO MOUNTING BRACKET
(10) In st a ll ba t t er y t o ba t t er y t r a y.
7 - ELEC. CONNECTOR (11) Con n ect posit ive ba t t er y ca ble t o P ower Dist r i-
bu t ion Cen t er (P DC).
(12) Con n ect posit ive ba t t er y ca ble t o ba t t er y.
(13) Rem ove ser vo fr om m ou n t in g br a cket or, (13) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
r em ove ser vo a n d m ou n t in g br a cket a s on e a ssem bly. (14) Befor e st a r t in g en gin e, oper a t e a cceler a t or
peda l t o ch eck for a n y bin din g.
WJ SPEED CONTROL 8P - 7

SWI T CH r elea sed. Th e P CM a lso h a s a !t a p-u p! fea t u r e in

wh ich veh icle speed in cr ea ses a t a r a t e of a ppr oxi-
m a t ely 2 m ph for ea ch m om en t a r y swit ch a ct iva t ion
DESCRIPTION
of t h e ACCE L swit ch .
Th er e a r e t wo sepa r a t e swit ch pods t h a t oper a t e
Th e P CM a lso pr ovides a m ea n s t o deceler a t e wit h -
t h e speed con t r ol syst em . Th e st eer in g-wh eel-
ou t disen ga gin g speed con t r ol. To deceler a t e fr om a n
m ou n t ed swit ch es u se m u lt iplexed cir cu it s t o pr ovide
exist in g r ecor ded t a r get speed, depr ess a n d h old t h e
in pu t s t o t h e P CM for ON, OF F, RE SUME , ACCE L-
COAST swit ch u n t il t h e desir ed speed is r ea ch ed.
E RATE , SE T, DE CE L a n d CANCE L m odes. Refer t o
Th en r elea se t h e swit ch . Th e ON, OF F swit ch oper-
t h e own er ’s m a n u a l for m or e in for m a t ion on speed
a t es t wo com pon en t s: t h e P CM’s ON, OF F in pu t , a n d
con t r ol swit ch fu n ct ion s a n d set t in g pr ocedu r es.
t h e ba t t er y volt a ge t o t h e br a ke swit ch , wh ich power s
Th e in dividu a l swit ch es ca n n ot be r epa ir ed. If on e
t h e speed con t r ol ser vo.
swit ch fa ils, t h e en t ir e swit ch m odu le m u st be
r epla ced.
Multiplexing
Th e P CM sen ds ou t 5 volt s t h r ou gh a fixed r esist or
OPERATION a n d m on it or s t h e volt a ge ch a n ge bet ween t h e fixed
Wh en speed con t r ol is select ed by depr essin g t h e
r esist or a n d t h e swit ch es. If n on e of t h e swit ch es a r e
ON, OF F swit ch , t h e P CM a llows a set speed t o be
depr essed, t h e P CM will m ea su r e 5 volt s a t t h e sen -
st or ed in it s RAM for speed con t r ol. To st or e a set
sor poin t (open cir cu it ). If a swit ch wit h n o r esist or is
speed, depr ess t h e SE T swit ch wh ile t h e veh icle is
closed, t h e P CM will m ea su r e 0 volt s (gr ou n ded cir-
m ovin g a t a speed bet ween a ppr oxim a t ely 35 a n d 85
cu it ). Now, if a r esist or is a dded t o a swit ch , t h en t h e
m ph . In or der for t h e speed con t r ol t o en ga ge, t h e
P CM will m ea su r e som e volt a ge pr opor t ion a l t o t h e
br a kes ca n n ot be a pplied, n or ca n t h e gea r select or
size of t h e r esist or. By a ddin g a differ en t r esist or t o
be in dica t in g t h e t r a n sm ission is in P a r k or Neu t r a l.
ea ch swit ch , t h e P CM will see a differ en t volt a ge
Th e speed con t r ol ca n be disen ga ged m a n u a lly by:
depen din g on wh ich swit ch is pu sh ed.
• St eppin g on t h e br a ke peda l
An ot h er r esist or h a s been a dded t o t h e ’a t r est cir-
• Depr essin g t h e OF F swit ch
cu it ’ ca u sin g t h e P CM t o n ever see 5 volt s. Th is wa s
• Depr essin g t h e CANCE L swit ch .
don e for dia gn ost ic pu r poses. If t h e swit ch cir cu it
Th e speed con t r ol ca n be disen ga ged a lso by a n y of
sh ou ld open (ba d con n ect ion ), t h en t h e P CM will see
t h e followin g con dit ion s:
t h e 5 volt s a n d kn ow t h e cir cu it is ba d. Th e P CM will
• An in dica t ion of P a r k or Neu t r a l
t h en set a n open cir cu it fa u lt .
• Th e VSS sign a l in cr ea ses a t a r a t e of 10 m ph
per secon d (in dica t es t h a t t h e co-efficien t of fr ict ion
REMOVAL
bet ween t h e r oa d su r fa ce a n d t ir es is ext r em ely low)
• Depr essin g t h e clu t ch peda l. WARNING: BEFORE BEGINNING ANY AIRBAG SYS-
• E xcessive en gin e r pm (in dica t es t h a t t h e t r a n s- TEM COMPONENT REMOVAL OR INSTALLATION,
m ission m a y be in a low gea r ) REMOVE AND ISOLATE THE NEGATIVE (-) CABLE
• Th e VSS sign a l decr ea ses a t a r a t e of 10 m ph FROM THE BATTERY. THIS IS THE ONLY SURE
per secon d (in dica t es t h a t t h e veh icle m a y h a ve WAY TO DISABLE THE AIRBAG SYSTEM. THEN
deceler a t ed a t a n ext r em ely h igh r a t e) WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO
• If t h e a ct u a l speed is n ot wit h in 20 m ph of t h e DISCHARGE BEFORE FURTHER SYSTEM SERVICE.
set speed FAILURE TO DO THIS COULD RESULT IN ACCIDEN-
Th e pr eviou s disen ga gem en t con dit ion s a r e pr o- TAL AIRBAG DEPLOYMENT AND POSSIBLE
gr a m m ed for a dded sa fet y. INJURY.
On ce t h e speed con t r ol h a s been disen ga ged,
depr essin g t h e ACCE L swit ch r est or es t h e veh icle t o (1) Discon n ect a n d isola t e n ega t ive ba t t er y ca ble.
t h e t a r get speed t h a t wa s st or ed in t h e P CM’s RAM. (2) Rem ove a ir ba g m odu le. Refer t o Gr ou p 8M,
P a ssive Rest r a in t Syst em s.
NOTE: Depressing the OFF switch will erase the set (3) Rem ove elect r ica l con n ect or a t swit ch .
speed stored in the PCM’s RAM. (4) Rem ove swit ch -t o-st eer in g wh eel m ou n t in g
scr ew (F ig. 7) .
If, wh ile t h e speed con t r ol is en ga ged, t h e dr iver
(5) Rem ove swit ch .
wish es t o in cr ea se veh icle speed, t h e P CM is pr o-
gr a m m ed for a n a cceler a t ion fea t u r e. Wit h t h e
ACCE L swit ch h eld closed, t h e veh icle a cceler a t es
INSTALLATION
(1) In st a ll swit ch a n d m ou n t in g scr ew.
slowly t o t h e desir ed speed. Th e n ew t a r get speed is
(2) Tigh t en scr ew t o 1.5 N·m (15 in . lbs.) t or qu e.
st or ed in t h e P CM’s RAM wh en t h e ACCE L swit ch is
(3) In st a ll elect r ica l con n ect or t o swit ch .
8P - 8 SPEED CONTROL
SWI T CH (Cont inue d)
Fig. 7 Speed Control Switches
1 - MOUNTING SCREW
2 - SPEED CONTROL SWITCHES
(4) In st a ll a ir ba g m odu le. Refer t o Gr ou p 8M, P a s-
sive Rest r a in t Syst em s.
(5) Con n ect n ega t ive ba t t er y ca ble.
VACU U M RESERV OI R
DESCRIPTION
Th e va cu u m r eser voir is a pla st ic st or a ge t a n k con -
n ect ed t o a n en gin e va cu u m sou r ce by va cu u m lin es.
OPERATION
Th e va cu u m r eser voir is u sed t o su pply t h e va c-
u u m n eeded t o m a in t a in pr oper speed con t r ol oper a -
t ion wh en en gin e va cu u m dr ops, su ch a s in clim bin g
a gr a de wh ile dr ivin g. A on e-wa y ch eck va lve is u sed
in t h e va cu u m lin e bet ween t h e r eser voir a n d t h e
va cu u m sou r ce. Th is ch eck va lve is u sed t o t r a p
en gin e va cu u m in t h e r eser voir. On cer t a in veh icle
a pplica t ion s, t h is r eser voir is sh a r ed wit h t h e h ea t -
in g/a ir-con dit ion in g syst em . Th e va cu u m r eser voir
ca n n ot be r epa ir ed a n d m u st be r epla ced if fa u lt y.
WJ
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR
(1) Discon n ect va cu u m h ose a t speed con t r ol ser vo
a n d in st a ll a va cu u m ga u ge in t o t h e discon n ect ed
h ose.
(2) St a r t en gin e a n d obser ve ga u ge a t idle. Va c-
u u m ga u ge sh ou ld r ea d a t lea st t en in ch es of m er-
cu r y.
(3) If va cu u m is less t h a n t en in ch es of m er cu r y,
det er m in e sou r ce of lea k. Ch eck va cu u m lin e t o
en gin e for lea ks. Also ch eck a ct u a l en gin e in t a ke
m a n ifold va cu u m . If m a n ifold va cu u m does n ot m eet
t h is r equ ir em en t , ch eck for poor en gin e per for m a n ce
a n d r epa ir a s n ecessa r y.
(4) If va cu u m lin e t o en gin e is n ot lea kin g, ch eck
for lea k a t va cu u m r eser voir. To loca t e a n d ga in
a ccess t o r eser voir, r efer t o Va cu u m Reser voir Rem ov-
a l/In st a lla t ion in t h is gr ou p. Discon n ect va cu u m lin e
a t r eser voir a n d con n ect a h a n d-oper a t ed va cu u m
pu m p t o r eser voir fit t in g. Apply va cu u m . Reser voir
va cu u m sh ou ld n ot bleed off. If va cu u m is bein g lost ,
r epla ce r eser voir.
(5) Ver ify oper a t ion of on e-wa y ch eck va lve a n d
ch eck it for lea ks.
(a ) Loca t e on e-wa y ch eck va lve. Th e va lve is
loca t ed in va cu u m lin e bet ween va cu u m r eser voir
a n d en gin e va cu u m sou r ce. Discon n ect va cu u m
h oses (lin es) a t ea ch en d of va lve.
(b) Con n ect a h a n d-oper a t ed va cu u m pu m p t o
r eser voir en d of ch eck va lve. Apply va cu u m . Va c-
u u m sh ou ld n ot bleed off. If va cu u m is bein g lost ,
r epla ce on e-wa y ch eck va lve.
(c) Con n ect a h a n d-oper a t ed va cu u m pu m p t o
va cu u m sou r ce en d of ch eck va lve. Apply va cu u m .
Va cu u m sh ou ld flow t h r ou gh va lve. If va cu u m is
n ot flowin g, r epla ce on e-wa y ch eck va lve. Sea l t h e
fit t in g a t opposit e en d of va lve wit h a fin ger a n d
a pply va cu u m . If va cu u m will n ot h old, dia ph r a gm
wit h in ch eck va lve h a s r u pt u r ed. Repla ce va lve.
REMOVAL
Th e va cu u m r eser voir is loca t ed in t h e r igh t /fr on t
cor n er of t h e veh icle beh in d t h e fr on t bu m per fa scia
(F ig. 8).
(1) Rem ove fr on t bu m per a n d gr ill a ssem bly.
(2) Rem ove 1 su ppor t bolt n ea r fr on t of r eser voir
(F ig. 8).
(3) Rem ove 2 r eser voir m ou n t in g bolt s.
(4) Rem ove r eser voir fr om veh icle t o ga in a ccess t o
va cu u m h ose (F ig. 9). Discon n ect va cu u m h ose fr om
r eser voir fit t in g a t r ea r of r eser voir.
WJ SPEED CONTROL 8P - 9
VACU U M RESERV OI R (Cont inue d)

INSTALLATION
Th e va cu u m r eser voir is loca t ed in t h e r igh t /fr on t
cor n er of t h e veh icle beh in d t h e fr on t bu m per fa scia
(F ig. 8).
(1) Con n ect va cu u m h ose t o r eser voir.
(2) In st a ll r eser voir a n d t igh t en 2 bolt s t o 3 N·m
(25 in . lbs.) t or qu e.
(3) In st a ll fr on t bu m per a n d gr ill a ssem bly.

Fig. 8 Vacuum Reservoir Location

1 - RADIATOR FAN RELAY
2 - VACUUM RESERVOIR
3 - BOLT
4 - RIGHT FRONT FENDER

Fig. 9 Vacuum Reservoir Removal/Installation

1 - VACUUM HOSE
2 - RADIATOR
3 - VACUUM RESERVOIR
WJ
VEHICLE THEFT SECURITY
TABLE OF CON T EN T S
VEHICLE THEFT SECURITY
DESCRIPTION
DESCRIPTION - VEHICLE THEFT
SECURITY SYSTEM . . . . . . . . . . . . . . . .
DESCRIPTION - SENTRY KEY
IMMOBILIZER SYSTEM . . . . . . . . . . . . . .
OPERATION
OPERATION - VEHICLE THEFT SECURITY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - VEHICLE
THEFT SECURITY SYSTEM . . . . . . . . . .
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM . . . . . . . . . . . . . .
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION . . . . . . . . . . . . . . . . . . . .
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING . . . . . .
DOOR CYLINDER LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING - DOOR
CYLINDER LOCK SWITCH . . . . . . . . . . .
REMOVAL .........................
INSTALLATION . . . . . . . . . . . . . . . . . . . . . .
HOOD AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH .........................
V EH I CLE T H EFT SECU RI T Y
DESCRI PT I ON
DESCRIPTION - VEHICLE THEFT SECURITY
SYSTEM
Th e Veh icle Th eft Secu r it y Syst em (VTSS) is
design ed t o pr ovide per im et er pr ot ect ion a ga in st
u n a u t h or ized veh icle u se or t a m per in g by m on it or in g
t h e veh icle door s, t h e lift ga t e, t h e lift ga t e flip-u p
gla ss, t h e ign it ion syst em a n d, on ly on veh icles bu ilt
for sa le in cer t a in in t er n a t ion a l m a r ket s wh er e it is
r equ ir ed equ ipm en t , t h e h ood. If u n a u t h or ized veh i-
VEHICLE THEFT SECURITY 8Q - 1
page page
REMOVAL
REMOVAL - HOOD AJAR SWITCH . . . . . . . . 10
REMOVAL - HOOD AJAR SWITCH
....1 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL - HOOD AJAR SWITCH STRIKER . 10
....2 INSTALLATION
INSTALLATION - HOOD AJAR SWITCH . . . . . 10
INSTALLATION - HOOD AJAR SWITCH
....2 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION - HOOD AJAR SWITCH
....4 STRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTRUSION TRANSCEIVER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
....4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
....5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SIREN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
....6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
....6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
SKIS INDICATOR LAMP
....7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
....8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSPONDER KEY
....8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
....8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
....9 VTSS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
....9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
....9 DIAGNOSIS AND TESTING - VTSS
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 16
....9
cle u se or t a m per in g is det ect ed, t h e syst em r espon ds
by pu lsin g t h e h or n a n d fla sh in g t h e ext er ior la m ps.
In m a n y m a r ket s t h e VTSS a lso in clu des t h e Sen t r y
Key Im m obilizer Syst em (SKIS), wh ich pr ovides pa s-
sive veh icle pr ot ect ion by pr even t in g t h e en gin e fr om
oper a t in g u n less a va lid elect r on ica lly en coded key is
det ect ed in t h e ign it ion lock cylin der. (Refer t o 8 -
E LE CTRICAL/VE H ICLE TH E F T SE CURITY -
DE SCRIP TION - SE NTRY KE Y IMMOBILIZE R
SYSTE M).
Th e VTSS in clu des t h e followin g m a jor com po-
n en t s, wh ich a r e descr ibed in fu r t h er det a il else-
wh er e in t h is ser vice m a n u a l:
• Body Con t r ol Modu le (Refer t o 8 - E LE CTRI-
CAL/E LE CTRONIC CONTROL MODULE S/BODY
8Q - 2 VEHICLE THEFT SECURITY
V EH I CLE T H EFT SECU RI T Y (Cont inue d)
CONTROL/CE NTRAL TIME R MODULE - • P ower t r a in Con t r ol Modu le
DE SCRIP TION).
• Com bin a t ion F la sh er (Refer t o 8 - E LE CTRI-
CAL/LAMP S/LIGH TING - E XTE RIOR/COMBINA-
TION F LASH E R - DE SCRIP TION).
• Door Aja r Swit ch (Refer t o 8 - E LE CTRICAL/
LAMP S/LIGH TING - INTE RIOR/DOOR AJ AR
SWITCH - DE SCRIP TION - DOOR AJ AR SWITCH ).
• Dr iver Cylin der Lock Swit ch (Refer t o 8 - E LE C-
TRICAL/P OWE R LOCKS/DOOR CYLINDE R LOCK/
UNLOCK SWITCH - DE SCRIP TION).
• H ood Aja r Swit ch (Refer t o 8 - E LE CTRICAL/VE -
H ICLE TH E F T SE CURITY/H OOD AJ AR SWITCH -
DE SCRIP TION).
• H or n Rela y (Refer t o 8 - E LE CTRICAL/H ORN/
H ORN RE LAY - DE SCRIP TION).
• Lift ga t e Aja r Swit ch (Refer t o 8 - E LE CTRICAL/
LAMP S/LIGH TING - INTE RIOR/DOOR AJ AR
SWITCH - DE SCRIP TION - LIF TGATE AJ AR
SWITCH ).
• Lift ga t e F lip-Up Gla ss Aja r Swit ch (Refer t o 8 -
E LE CTRICAL/LAMP S/LIGH TING - INTE RIOR/
DOOR AJ AR SWITCH - DE SCRIP TION - LIF TGATE
F LIP -UP GLASS AJ AR SWITCH ).
• Low Bea m H ea dla m p Rela y
• VTSS In dica t or (Refer t o 8 - E LE CTRICAL/VE -
H ICLE TH E F T SE CURITY/VTSS INDICATOR -
DE SCRIP TION).
Cer t a in fu n ct ion s a n d fea t u r es of t h e VTSS r ely
u pon r esou r ces sh a r ed wit h or con t r olled by ot h er
m odu les in t h e veh icle over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k. Th e
ot h er m odu les t h a t m a y a ffect VTSS oper a t ion a r e:
• Dr iver Door Modu le (Refer t o 8 - E LE CTRICAL/
E LE CTRONIC CONTROL MODULE S/DOOR MOD-
ULE - DE SCRIP TION).
• P a ssen ger Door Modu le (Refer t o 8 - E LE CTRI-
CAL/E LE CTRONIC CONTROL MODULE S/DOOR
MODULE - DE SCRIP TION).
DESCRIPTION - SENTRY KEY IMMOBILIZER
SYSTEM
Veh icles equ ipped wit h t h e Sen t r y Key Im m obilizer
Syst em (SKIS) ca n be iden t ified by t h e pr esen ce of
a n a m ber SKIS in dica t or in t h e in st r u m en t clu st er
t h a t will illu m in a t e for a bou t t h r ee secon ds ea ch
t im e t h e ign it ion swit ch is t u r n ed t o t h e On posit ion ,
or by a gr a y m olded r u bber ca p on t h e h ea d of t h e
ign it ion key. Models n ot equ ipped wit h SKIS st ill
h a ve a SKIS in dica t or in t h e clu st er, bu t it will n ot
illu m in a t e. Also, m odels n ot equ ipped wit h t h e SKIS
h a ve a bla ck m olded r u bber ca p on t h e h ea d of t h e
ign it ion key.
Th e SKIS in clu des t h e followin g m a jor com pon en t s,
wh ich a r e descr ibed in fu r t h er det a il elsewh er e in
t h is ser vice m a n u a l:
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• Sen t r y Key Im m obilizer Modu le
• Sen t r y Key Tr a n spon der
• SKIS In dica t or
E xcept for t h e Sen t r y Key t r a n spon der s, wh ich r ely
u pon Ra dio F r equ en cy (RF ) com m u n ica t ion , h a r d
wir ed cir cu it r y con n ect s t h e SKIS com pon en t s t o t h e
elect r ica l syst em of t h e veh icle.Refer t o t h e a ppr opr i-
a t e wir in g in for m a t ion .
OPERAT I ON
OPERATION - VEHICLE THEFT SECURITY
SYSTEM
Th e Veh icle Th eft Secu r it y Syst em (VTSS) is
divided in t o t wo ba sic su bsyst em s: Veh icle Th eft
Ala r m (VTA) a n d Sen t r y Key Im m obilizer Syst em
(SKIS). Th e followin g a r e pa r a gr a ph s t h a t br iefly
descr ibe t h e oper a t ion of ea ch of t h ose t wo su b-
syst em s.
A Body Con t r ol Modu le (BCM) is u sed t o con t r ol
a n d in t egr a t e m a n y of t h e fu n ct ion s a n d fea t u r es
in clu ded in t h e Veh icle Th eft Secu r it y Syst em
(VTSS). In t h e VTSS, t h e BCM r eceives in pu t s in di-
ca t in g t h e st a t u s of t h e door a ja r swit ch es, t h e dr iver
cylin der lock swit ch , t h e ign it ion swit ch , t h e lift ga t e
a ja r swit ch es, t h e lift ga t e flip-u p gla ss a ja r swit ch ,
t h e power lock swit ch es a n d, in veh icles so equ ipped,
t h e h ood a ja r swit ch . Th e pr ogr a m m in g in t h e BCM
a llows it t o pr ocess t h e in for m a t ion fr om a ll of t h ese
in pu t s a n d sen d con t r ol ou t pu t s t o en er gize or de-en -
er gize t h e com bin a t ion fla sh er, t h e h or n r ela y (except
veh icles wit h t h e pr em iu m ver sion of t h e VTA), a n d
t h e VTSS in dica t or. In a ddit ion , in veh icles bu ilt for
cer t a in m a r ket s wh er e pr em iu m ver sion s of t h e VTA
is r equ ir ed, t h e BCM a lso exch a n ges m essa ges wit h
t h e In t r u sion Tr a n sceiver Modu le (ITM) over t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu ss n et wor k t o pr ovide t h e fea t u r es fou n d in t h is
ver sion of t h e VTA. Th e con t r ol of t h ese in pu t s a n d
ou t pu t s a r e wh a t con st it u t e a ll of t h e fea t u r es of t h e
VTSS. F ollowin g is in for m a t ion on t h e oper a t ion of
ea ch of t h e VTSS fea t u r es.
ENABLING
Th e BCM m u st h a ve t h e VTSS fu n ct ion en a bled in
or der for t h e VTSS t o per for m a s design ed. Th e logic
in t h e BCM keeps it s VTSS fu n ct ion dor m a n t u n t il it
is en a bled u sin g a DRBIII! sca n t ool. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
PRE-ARMING
Th e VTA h a s a pr e-a r m in g sequ en ce. P r e-a r m in g
occu r s wh en a door, t h e t a ilga t e, or t h e flip-u p gla ss
is open wh en t h e veh icle is locked u sin g a power lock
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V EH I CLE T H EFT SECU RI T Y (Cont inue d)
swit ch , or wh en t h e “Lock” bu t t on on t h e Rem ot e
Keyless E n t r y (RKE ) t r a n sm it t er is depr essed. Th e
power lock swit ch will n ot in it ia t e t h e pr e-a r m in g
sequ en ce if t h e key is in t h e ign it ion swit ch . Wh en
t h e VTA is pr e-a r m ed, t h e a r m in g sequ en ce is
dela yed u n t il a ll of t h e door s, t h e t a ilga t e a n d t h e
flip-u p gla ss a r e closed.
ARMING
P a ssive a r m in g of t h e VTSS occu r s wh en t h e veh i-
cle is exit ed wit h t h e key r em oved fr om t h e ign it ion
swit ch , t h e h ea dla m ps a r e t u r n ed off, a n d t h e door s
a r e locked wh ile t h ey a r e open u sin g t h e power lock
swit ch . Th e power lock swit ch will n ot fu n ct ion if t h e
key is in t h e ign it ion swit ch or t h e h ea dla m ps a r e
t u r n ed on wit h t h e dr iver side fr on t door open . Th e
VTSS will n ot a r m if t h e dr iver side fr on t door is
locked u sin g t h e key in t h e lock cylin der or u sin g t h e
m ech a n ica l lock bu t t on . Act ive a r m in g of t h e VTSS
occu r s wh en t h e “Lock” bu t t on on t h e Rem ot e Key-
less E n t r y (RKE ) t r a n sm it t er is depr essed t o lock t h e
veh icle, even if t h e door s a n d/or t h e lift ga t e a r e open
wh en t h e RKE t r a n sm it t er Lock bu t t on is depr essed.
H owever, t h e VTSS a r m in g will n ot be com plet e u n t il
a ll of t h e door s, t h e lift ga t e a n d t h e lift ga t e flip-u p
gla ss a r e closed. On veh icles equ ipped wit h t h e h ood
a ja r swit ch , VTSS a r m in g will com plet e if t h e h ood is
open , bu t t h e u n der h ood a r ea will n ot be pr ot ect ed
u n less t h e h ood is closed wh en t h e VTSS is a r m ed.
F ollowin g su ccessfu l pa ssive or a ct ive VTSS a r m -
in g, t h e VTSS in dica t or on t h e t op of t h e in st r u m en t
pa n el will fla sh r a pidly for a bou t sixt een secon ds
a ft er t h e illu m in a t ed en t r y syst em t im es ou t . Th is
in dica t es t h a t VTSS a r m in g is in pr ogr ess. On ce t h e
sixt een secon d a r m in g fu n ct ion is su ccessfu lly com -
plet ed, t h e in dica t or will fla sh a t a slower r a t e, in di-
ca t in g t h a t t h e VTSS is a r m ed.
DISARMING
P a ssive disa r m in g of t h e VTSS occu r s wh en t h e
veh icle is u n locked u sin g t h e key t o u n lock t h e dr iver
side fr on t door. Act ive disa r m in g of t h e VTSS occu r s
wh en t h e veh icle is u n locked by depr essin g t h e
“Un lock” bu t t on of t h e Rem ot e Keyless E n t r y (RKE )
t r a n sm it t er. On ce t h e a la r m h a s been a ct iva t ed,
eit h er disa r m in g m et h od will a lso dea ct iva t e t h e
a la r m . Depr essin g t h e “P a n ic” bu t t on on t h e RKE
t r a n sm it t er will a lso disa r m t h e VTSS, bu t t h e h or n
will con t in u e t o pu lse a n d t h e ext er ior la m ps will
con t in u e t o fla sh for a bou t t h r ee m in u t es a s pa r t of
t h e P a n ic fea t u r e fu n ct ion . Th e P a n ic fea t u r e is over-
r idden if t h e “P a n ic” bu t t on is depr essed a secon d
t im e, or if a veh icle speed of a bou t 24 kilom et er s-per-
h ou r (15 m iles-per-h ou r ) is a t t a in ed.
VEHICLE THEFT SECURITY 8Q - 3
POWER-UP MODE
Wh en t h e a r m ed VTSS sen ses t h a t t h e ba t t er y h a s
been discon n ect ed a n d r econ n ect ed, it en t er s it s pow-
er-u p m ode. In t h e power-u p m ode t h e a la r m syst em
r em a in s a r m ed followin g a ba t t er y fa ilu r e or discon -
n ect . If t h e VTSS wa s a r m ed pr ior t o a ba t t er y dis-
con n ect or fa ilu r e, t h e t ech n icia n or veh icle oper a t or
will h a ve t o a ct ively or pa ssively disa r m t h e a la r m
syst em a ft er t h e ba t t er y is r econ n ect ed. Th e pow-
er-u p m ode will a lso a pply if t h e ba t t er y goes dea d
wh ile t h e syst em is a r m ed, a n d ba t t er y ju m p-st a r t in g
is t h en a t t em pt ed. Th e VTSS will be a r m ed u n t il it is
a ct ively or pa ssively disa r m ed. If t h e VTSS is in t h e
disa r m ed m ode pr ior t o a ba t t er y discon n ect or fa il-
u r e, it will r em a in disa r m ed a ft er t h e ba t t er y is
r econ n ect ed or r epla ced, or if ju m p-st a r t in g is
a t t em pt ed.
ALARM
Th e VTA a la r m ou t pu t va r ies by t h e ver sion of t h e
VTA wit h wh ich t h e veh icle is equ ipped. In a ll ca ses,
t h e a la r m pr ovides bot h visu a l a n d a u dible ou t pu t s;
h owever, t h e t im e in t er va ls of t h ese ou t pu t s va r y by
t h e r equ ir em en t s of t h e m a r ket for wh ich t h e veh icle
is m a n u fa ct u r ed. In a ll ca ses, t h e visu a l ou t pu t will
be a fla sh in g of t h e ext er ior la m ps. F or veh icles
equ ipped wit h Nor t h Am er ica n or t h e ba se ver sion of
t h e VTA, t h e a u dible ou t pu t will be t h e pu lsin g of t h e
h or n . F or veh icles wit h t h e pr em iu m ver sion of t h e
VTA, t h e a u dible ou t pu t will be t h e cyclin g of t h e
sir en . Th e in pu t s t h a t will t r igger t h e a la r m in clu de
t h e door a ja r swit ch , t h e flip-u p gla ss a ja r swit ch ,
a n d in veh icles bu ilt for cer t a in m a r ket s wh er e t h ey
a r e r equ ir ed, t h e h ood a ja r swit ch a n d t h e In t r u sion
Tr a n sceiver Modu le (ITM).
TAMPER ALERT
Th e VTSS t a m per a ler t fea t u r e will sou n d t h e h or n
(or t h e a la r m sir en for t h e pr em iu m ver sion ) t h r ee
t im es u pon VTA disa r m in g, if t h e a la r m wa s t r ig-
ger ed a n d h a s sin ce t im ed-ou t (a bou t eigh t een m in -
u t es). Th is fea t u r e a ler t s t h e veh icle oper a t or t h a t
t h e VTA a la r m wa s a ct iva t ed wh ile t h e veh icle wa s
u n a t t en ded.
INTRUSION ALARM
Th e In t r u sion Ala r m is a n exclu sive fea t u r e of t h e
pr em iu m ver sion of t h e VTA, wh ich is on ly a va ila ble
in cer t a in m a r ket s, wh er e it is r equ ir ed. Wh en t h e
VTA is a r m ed, a m ot ion sen sor in t h e In t r u sion
Tr a n sceiver Modu le (ITM) m on it or s t h e in t er ior of
t h e veh icle for m ovem en t . If m ot ion is det ect ed, t h e
ITM sen ds a m essa ge t o t h e BCM over t h e P CI bu s
t o in voke t h e visu a l a la r m fea t u r e, a n d sen ds a m es-
sa ge t o t h e a la r m sir en over a dedica t ed ser ia l bu s t o
in voke t h e a u dible a la r m fea t u r e. Th e m ot ion det ec-
8Q - 4 VEHICLE THEFT SECURITY
V EH I CLE T H EFT SECU RI T Y (Cont inue d)
t ion fea t u r e of t h e ITM ca n be disa bled by depr essin g
t h e “Lock” bu t t on on t h e RKE t r a n sm it t er t h r ee
t im es or cyclin g t h e key in t h e dr iver door cylin der
fr om t h e cen t er t o lock posit ion wit h in fift een secon ds
du r in g VTA a r m in g, wh ile t h e secu r it y in dica t or is
st ill fla sh in g r a pidly. Th e VTA pr ovides a sin gle sh or t
sir en “ch ir p” a s a n a u dible con for m a t ion t h a t t h e
m ot ion det ect disa ble r equ est h a s been r eceived. Th e
ITM m u st be elect r on ica lly en a bled in or der for t h e
in t r u sion a la r m t o per for m a s design ed. Th e in t r u -
sion a la r m fu n ct ion of t h e ITM is en a bled on veh icles
equ ipped wit h t h is opt ion a t t h e fa ct or y, bu t a ser vice
r epla cem en t ITM m u st be con figu r ed a n d en a bled by
t h e dea ler u sin g t h e DRBIII! sca n t ool. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM
Th e Sen t r y Key Im m obilizer Syst em (SKIS) is
design ed t o pr ovide pa ssive pr ot ect ion a ga in st u n a u -
t h or ized veh icle u se by disa blin g t h e en gin e a ft er
a bou t t wo secon ds of r u n n in g, wh en ever a n y m et h od
ot h er t h a n a va lid Sen t r y Key is u sed t o st a r t t h e
veh icle. Th e SKIS is con sider ed a pa ssive pr ot ect ion
syst em beca u se it is a lwa ys a ct ive wh en t h e ign it ion
syst em is en er gized a n d does n ot r equ ir e a n y cu s-
t om er in t er ven t ion . Th e SKIS u ses Ra dio F r equ en cy
(RF ) com m u n ica t ion t o obt a in con fir m a t ion t h a t t h e
key in t h e ign it ion swit ch is a va lid key for oper a t in g
t h e veh icle. Th e m icr opr ocessor-ba sed SKIS h a r d-
wa r e a n d soft wa r e a lso u ses m essa ges t o com m u n i-
ca t e wit h ot h er m odu les in t h e veh icle over t h e
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s. (Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
TROL MODULE S/COMMUNICATION - OP E RA-
TION).
P r e-pr ogr a m m ed Sen t r y Key t r a n spon der s a r e pr o-
vided wit h t h e veh icle fr om t h e fa ct or y. E a ch Sen t r y
Key Im m obilizer Modu le (SKIM) will r ecogn ize a
m a xim u m of eigh t Sen t r y Keys. If t h e cu st om er
wou ld like a ddit ion a l keys ot h er t h a n t h ose pr ovided
wit h t h e veh icle, t h ey m a y be pu r ch a sed fr om a n y
a u t h or ized dea ler. Th ese a ddit ion a l keys m u st be pr o-
gr a m m ed t o t h e SKIM in t h e veh icle in or der for t h e
syst em t o r ecogn ize t h em a s va lid keys. Th is ca n be
don e by t h e dea ler u sin g a DRBIII! sca n t ool or, if
Cu st om er Lea r n pr ogr a m m in g is a n a va ila ble SKIS
fea t u r e in t h e m a r ket wh er e t h e veh icle wa s pu r-
ch a sed, t h e cu st om er ca n pr ogr a m t h e a ddit ion a l
keys, a s lon g a s a t lea st t wo va lid Sen t r y Keys a r e
a lr ea dy a va ila ble. (Refer t o 8 - E LE CTRICAL/VE H I-
CLE TH E F T SE CURITY - STANDARD P ROCE -
DURE - TRANSP ONDE R P ROGRAMMING).
Th e SKIS per for m s a self-t est ea ch t im e t h e ign i-
t ion swit ch is t u r n ed t o t h e On posit ion , a n d will
st or e fa u lt in for m a t ion in t h e for m of Dia gn ost ic
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Tr ou ble Codes (DTC’s) if a syst em m a lfu n ct ion is
det ect ed. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a -
t ion .
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM
Th e VTSS-r ela t ed h a r d wir ed in pu t s t o a n d ou t -
pu t s fr om t h e Body Con t r ol Modu le (BCM), t h e
Dr iver Door Modu le (DDM), or t h e P a ssen ger Door
Modu le (P DM) m a y be dia gn osed a n d t est ed u sin g
con ven t ion a l dia gn ost ic t ools a n d pr ocedu r es. Refer
t o t h e a ppr opr ia t e wir in g in for m a t ion .
H owever, con ven t ion a l dia gn ost ic m et h ods m a y n ot
pr ove con clu sive in t h e dia gn osis of t h e BCM, t h e
DDM, t h e P DM, or t h e P r ogr a m m a ble Com m u n ica -
t ion s In t er fa ce (P CI) da t a bu s n et wor k. In or der t o
obt a in con clu sive t est in g of t h e VTSS, t h e BCM, t h e
DDM, t h e P DM, a n d t h e P CI da t a bu s n et wor k m u st
a lso be ch ecked. Th e m ost r elia ble, efficien t , a n d
a ccu r a t e m ea n s t o dia gn ose t h e VTSS r equ ir es t h e
u se of a DRBIII! sca n t ool a n d t h e a ppr opr ia t e dia g-
n ost ic in for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WJ VEHICLE THEFT SECURITY 8Q - 5
V EH I CLE T H EFT SECU RI T Y (Cont inue d)

DIAGNOSIS AND TESTING - SENTRY KEY THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
IMMOBILIZER SYSTEM
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
WARNING: ON VEHICLES EQUIPPED WITH AIR- IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE SYSTEM. FAILURE TO TAKE THE PROPER PRE-
ATTEMPTING ANY STEERING WHEEL, STEERING CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
COLUMN, OR INSTRUMENT PANEL COMPONENT BAG DEPLOYMENT AND POSSIBLE PERSONAL
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- INJURY.
LATE THE BATTERY NEGATIVE (GROUND) CABLE,

SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

SKIS INDICATOR FAILS TO
LIGHT DURING BULB TEST
1. Bulb faulty.
2. Fuse faulty.
3. Ground path faulty.
4. Battery feed faulty.
5. Ignition feed faulty.
1. Perform the instrument cluster actuator test.
(Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING -
ACTUATOR TEST). Replace the faulty bulb, if
required.
2. Check the SKIM fused B(+) fuse and the fused
ignition switch output (st-run) fuse in the JB.
Replace fuses, if required.
3. Check for continuity to ground at the connector
for the SKIM. Repair wiring, if required.
4. Check for battery current at the connector for
the SKIM. Repair wiring, if required.
5. Check for battery current at the connector for
the SKIM with the ignition switch in the On
position. Repair wiring, if required.

SKIS INDICATOR FLASHES 1. Invalid key in ignition 1. Replace the key with a known valid key.
FOLLOWING BULB TEST switch lock cylinder.

2. Key-related fault. 2. Use a DRBIII" scan tool and the appropriate

diagnostic information for further diagnosis.

SKIS INDICATOR LIGHTS 1. SKIS system malfunction/ 1. Use a DRBIII" scan tool and the appropriate
SOLID FOLLOWING BULB fault detected. diagnostic information for further diagnosis.
TEST 2. SKIS system inoperative. 2. Use a DRBIII" scan tool and the appropriate
diagnostic information for further diagnosis.

SKIS INDICATOR FAILS TO LIGHT DURING BULB TEST
If t h e Sen t r y Key Im m obilizer Syst em (SKIS) in di-
ca t or in t h e in st r u m en t clu st er fa ils t o illu m in a t e for
a bou t t h r ee secon ds a ft er t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion (bu lb t est ), per for m t h e
in st r u m en t clu st er a ct u a t or t est . (Refer t o 8 - E LE C-
TRICAL/INSTRUME NT CLUSTE R - DIAGNOSIS
AND TE STING - ACTUATOR TE ST). If t h e bu lb
fa ils t o oper a t e du r in g t h e a ct u a t or t est , r epla ce t h e
bu lb. If t h e SKIS in dica t or st ill fa ils t o ligh t du r in g
t h e bu lb t est , a wir in g pr oblem r esu lt in g in t h e loss
of ba t t er y cu r r en t or gr ou n d t o t h e Sen t r y Key Im m o-
bilizer Modu le (SKIM) sh ou ld be su spect ed, a n d t h e
followin g pr ocedu r e sh ou ld be u sed for dia gn osis.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System requires the use of
a DRBIII" scan tool. Refer to the appropriate diag-
nostic information.
(1) Ch eck t h e fu sed B(+) fu se in t h e J u n ct ion
Block (J B). If OK, go t o St ep 2. If n ot OK, r epa ir t h e
sh or t ed cir cu it or com pon en t a n d r epla ce t h e fa u lt y
fu se.
8Q - 6 VEHICLE THEFT SECURITY
V EH I CLE T H EFT SECU RI T Y (Cont inue d)
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e J B. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
open B(+) cir cu it bet ween t h e J B fu se a n d t h e P ower
Dist r ibu t ion Cen t er (P DC).
(3) Ch eck t h e fu sed ign it ion swit ch ou t pu t (st -r u n )
fu se in t h e J B. If OK, go t o St ep 4. If n ot OK, r epa ir
t h e sh or t ed cir cu it or com pon en t a n d r epla ce t h e
fa u lt y fu se.
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (st -r u n ) fu se in t h e J B. If OK, go t o St ep 5. If
n ot OK, r epa ir t h e open fu sed ign it ion swit ch ou t pu t
(st -r u n ) cir cu it bet ween t h e J B fu se a n d t h e ign it ion
swit ch a s r equ ir ed.
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e Sen t r y Key Im m obilizer Modu le
(SKIM) fr om t h e SKIM con n ect or. Ch eck for con t in u -
it y bet ween t h e gr ou n d cir cu it of t h e in st r u m en t
pa n el wir e h a r n ess con n ect or for t h e SKIM a n d a
good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o
St ep 6. If n ot OK, r epa ir t h e open gr ou n d cir cu it .
(6) Recon n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
SKIM. If OK, go t o St ep 7. If n ot OK, r epa ir t h e open
fu sed B(+) cir cu it bet ween t h e SKIM a n d t h e J B
fu se.
(7) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (st -r u n ) cir cu it of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e SKIM. If OK, r efer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion a n d u se a
DRBIII! sca n t ool t o com plet e t h e dia gn osis of t h e
SKIS. If n ot OK, r epa ir t h e open fu sed ign it ion
swit ch ou t pu t (st -r u n ) cir cu it bet ween t h e SKIM a n d
t h e J B fu se.
SKIS INDICATOR FLASHES OR LIGHTS SOLID FOLLOWING
BULB TEST
A SKIS in dica t or t h a t fla sh es followin g a su ccessfu l
bu lb t est in dica t es t h a t a n in va lid key h a s been
det ect ed, or t h a t a key-r ela t ed fa u lt h a s been set . A
SKIS in dica t or t h a t ligh t s solid followin g a su ccessfu l
bu lb t est in dica t es t h a t t h e SKIM h a s det ect ed a sys-
t em m a lfu n ct ion or t h a t t h e SKIS is in oper a t ive. In
eit h er ca se, fa u lt in for m a t ion will be st or ed in t h e
SKIM m em or y. F or r et r ieva l of t h is fa u lt in for m a t ion
a n d fu r t h er dia gn osis of t h e SKIS, t h e P CI da t a bu s,
t h e SKIM m essa ge ou t pu t s t o t h e in st r u m en t clu st er,
t h e SKIM m essa ge ou t pu t s t o t h e Body Con t r ol Mod-
u le (BCM), or t h e m essa ge in pu t s a n d ou t pu t s
bet ween t h e SKIM a n d t h e P ower t r a in Con t r ol Mod-
u le (P CM), a DRBIII! sca n t ool a n d t h e a ppr opr ia t e
dia gn ost ic in for m a t ion a r e r equ ir ed. F ollowin g a r e
pr elim in a r y t r ou blesh oot in g gu idelin es t o be followed
du r in g dia gn osis u sin g a DRBIII! sca n t ool:
WJ
(1) Usin g t h e DRBIII! sca n t ool, r ea d a n d r ecor d
t h e fa u lt s a s t h ey exist in t h e SKIM wh en you fir st
begin you r dia gn osis of t h e veh icle. It is im por t a n t t o
docu m en t t h ese fa u lt s beca u se t h e SKIM does n ot
differ en t ia t e bet ween h ist or ica l a n d a ct ive fa u lt s. If
t h is pr oblem t u r n s ou t t o be a n in t er m it t en t con di-
t ion , t h is in for m a t ion m a y becom e in va lu a ble t o you r
dia gn osis.
(2) Usin g t h e DRBIII! sca n t ool, er a se a ll of t h e
fa u lt s fr om t h e SKIM.
(3) Cycle t h e ign it ion swit ch t o t h e Off posit ion ,
t h en ba ck t o t h e On posit ion .
(4) Usin g t h e DRBIII! sca n t ool, r ea d a n y fa u lt s
t h a t a r e n ow pr esen t in t h e SKIM. Th ese a r e t h e
a ct ive fa u lt s.
(5) Usin g t h is a ct ive fa u lt in for m a t ion , r efer t o t h e
pr oper pr ocedu r e in t h e a ppr opr ia t e dia gn ost ic in for-
m a t ion for t h e a ddit ion a l specific dia gn ost ic st eps.
STAN DARD PROCEDU RE
STANDARD PROCEDURE - SKIS
INITIALIZATION
Th e Sen t r y Key Im m obilizer Syst em (SKIS) m u st
be in it ia lized followin g a Sen t r y Key Im m obilizer
Modu le (SKIM) r epla cem en t . SKIS in it ia liza t ion
r equ ir es t h e u se of a DRBIII! sca n t ool. In it ia liza t ion
will a lso r equ ir e t h a t you h a ve a ccess t o t h e u n iqu e
fou r-digit P IN code t h a t wa s a ssign ed t o t h e or igin a l
SKIM. Th e P IN code m u s t be u sed t o en t er t h e
Secu r ed Access Mode in t h e SKIM. Th is P IN n u m ber
m a y be obt a in ed fr om t h e veh icle own er, fr om t h e
or igin a l veh icle in voice, or fr om t h e Da im ler Ch r ysler
Cu st om er Cen t er. (Refer t o 8 - E LE CTRICAL/E LE C-
TRONIC CONTROL MODULE S - STANDARD P RO-
CE DURE - P CM/SKIM P ROGRAMMING).
NOTE: If a Powertrain Control Module (PCM) is
replaced on a vehicle equipped with the Sentry Key
Immobilizer System (SKIS), the unique Secret Key
data must be transferred from the Sentry Key
Immobilizer Module (SKIM) to the new PCM using
the PCM replacement procedure. This procedure
also requires the use of a DRBIII" scan tool and the
unique four-digit PIN code to enter the Secured
Access Mode in the SKIM. Refer to the appropriate
diagnostic information for the proper PCM replace-
ment procedures.
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING
All Sen t r y Keys in clu ded wit h t h e veh icle a r e pr e-
pr ogr a m m ed t o wor k wit h t h e Sen t r y Key Im m obi-
lizer Syst em (SKIS) wh en it is sh ipped fr om t h e
WJ
V EH I CLE T H EFT SECU RI T Y (Cont inue d)
fa ct or y. Th e Sen t r y Key Im m obilizer Modu le (SKIM)
ca n be pr ogr a m m ed t o r ecogn ize u p t o a t ot a l of eigh t
Sen t r y Keys. Wh en pr ogr a m m in g a bla n k Sen t r y Key
t r a n spon der, t h e key m u st fir st be cu t t o m a t ch t h e
ign it ion swit ch lock cylin de for wh ich it will be u sed.
On ce t h e a ddit ion a l key h a s been cu t , t h e SKIM
m u st be pr ogr a m m ed t o r ecogn ize it a s a va lid key.
Th er e a r e t wo possible m et h ods t o pr ogr a m t h e
SKIM t o r ecogn ize a n ew or a ddit ion a l va lid key, t h e
Secu r ed Access Met h od a n d t h e Cu st om er Lea r n
Met h od. F ollowin g a r e t h e det a ils of t h ese t wo pr o-
gr a m m in g m et h ods.
SECURED ACCESS METHOD
Th e Secu r ed Access m et h od a pplies t o a ll veh icles.
Th is m et h od r equ ir es t h e u se of a DRBIII! sca n t ool.
Th is m et h od will a lso r equ ir e t h a t you h a ve a ccess t o
t h e u n iqu e fou r-digit P IN code t h a t wa s a ssign ed t o
t h e or igin a l SKIM. Th e P IN code m u s t be u sed t o
en t er t h e Secu r ed Access Mode in t h e SKIM. Th is
P IN n u m ber m a y be obt a in ed fr om t h e veh icle own er,
fr om t h e or igin a l veh icle in voice, or fr om t h e
Da im ler Ch r ysler Cu st om er Cen t er. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion for t h e pr oper
Secu r ed Access m et h od pr ogr a m m in g pr ocedu r es.
CUSTOMER LEARN METHOD
Th e Cu st om er Lea r n fea t u r e is on ly a va ila ble on
dom est ic veh icles, or t h ose veh icles wh ich h a ve a
U.S. cou n t r y code design a t or. Th is pr ogr a m m in g
m et h od a lso r equ ir es a ccess t o a t lea st t wo va lid Sen -
t r y Keys. If t wo va lid Sen t r y Keys a r e n ot a va ila ble,
or if t h e veh icle does n ot h a ve a U.S. cou n t r y code
design a t or, t h e Secu r ed Access Met h od m u s t be u sed
t o pr ogr a m n ew or a ddit ion a l va lid keys t o t h e SKIM.
Th e Cu st om er Lea r n pr ogr a m m in g m et h od pr oce-
du r es a r e a s follows:
(1) Obt a in t h e bla n k Sen t r y Key(s) t h a t a r e t o be
pr ogr a m m ed a s va lid keys for t h e veh icle. Cu t t h e
bla n k key(s) t o m a t ch t h e ign it ion swit ch lock cylin -
der m ech a n ica l key codes.
(2) In ser t on e of t h e t wo va lid Sen t r y Keys in t o t h e
ign it ion swit ch a n d t u r n t h e ign it ion swit ch t o t h e
On posit ion .
(3) Aft er t h e ign it ion swit ch h a s been in t h e On
posit ion for lon ger t h a n t h r ee secon ds, bu t n o m or e
t h a n fift een secon ds, cycle t h e ign it ion swit ch ba ck t o
t h e Off posit ion . Repla ce t h e fir st va lid Sen t r y Key in
t h e ign it ion swit ch lock cylin der wit h t h e secon d
va lid Sen t r y Key a n d t u r n t h e ign it ion swit ch ba ck t o
t h e On posit ion . Th e secon d va lid Sen t r y Key m u st
be in ser t ed in t h e lock cylin der wit h in fift een secon ds
of r em ovin g t h e fir st va lid key.
(4) Abou t t en secon ds a ft er t h e com plet ion of St ep
3, t h e SKIS in dica t or in t h e in st r u m en t clu st er will
st a r t t o fla sh a n d a sin gle a u dible ch im e t on e will
VEHICLE THEFT SECURITY 8Q - 7
sou n d t o in dica t e t h a t t h e syst em h a s en t er ed t h e
Cu st om er Lea r n pr ogr a m m in g m ode.
(5) Wit h in sixt y secon ds of en t er in g t h e Cu st om er
Lea r n pr ogr a m m in g m ode, t u r n t h e ign it ion swit ch t o
t h e Off posit ion , r epla ce t h e va lid Sen t r y Key wit h a
bla n k Sen t r y Key t r a n spon der, a n d t u r n t h e ign it ion
swit ch ba ck t o t h e On posit ion .
(6) Abou t t en secon ds a ft er t h e com plet ion of St ep
5, a sin gle a u dible ch im e t on e will sou n d a n d t h e
SKIS in dica t or will st op fla sh in g, st a y on solid for
t h r ee secon ds, t h en t u r n off t o in dica t e t h a t t h e
bla n k Sen t r y Key h a s been su ccessfu lly pr ogr a m m ed.
Th e SKIS will im m edia t ely exit t h e Cu st om er Lea r n
pr ogr a m m in g m ode a n d t h e veh icle m a y n ow be
st a r t ed u sin g t h e n ewly pr ogr a m m ed va lid Sen t r y
Key.
E a ch of t h ese st eps m u st be r epea t ed a n d com -
plet ed in t h eir en t ir et y for ea ch a ddit ion a l Sen t r y
Key t h a t is t o be pr ogr a m m ed. If t h e a bove st eps a r e
n ot com plet ed in t h e given sequ en ce, or wit h in t h e
a llot t ed t im e, t h e SKIS will exit t h e Cu st om er Lea r n
pr ogr a m m in g m ode a n d t h e pr ogr a m m in g will be
u n su ccessfu l. Th e SKIS will a lso a u t om a t ica lly exit
t h e Cu st om er Lea r n pr ogr a m m in g m ode if it sees a
n on -bla n k Sen t r y Key t r a n spon der wh en it sh ou ld
see a bla n k, if it h a s a lr ea dy pr ogr a m m ed eigh t (8)
va lid Sen t r y Keys, or if t h e ign it ion swit ch is t u r n ed
t o t h e Off posit ion for m or e t h a n a bou t fift y secon ds.
NOTE: If an attempt is made to start the vehicle
while in the Customer Learn mode (SKIS indicator
flashing), the SKIS will respond as though the vehi-
cle were being started with an invalid key. In other
words, the engine will stall after about two seconds
of operation. No faults will be set.
NOTE: Once a Sentry Key has been programmed as
a valid key to a vehicle, it cannot be programmed
as a valid key for use on any other vehicle.
DOOR CY LI N DER LOCK
SWI T CH
DESCRIPTION
Veh icles m a n u fa ct u r ed for Nor t h Am er ica n m a r-
ket s t h a t a r e equ ipped wit h t h e opt ion a l Veh icle
Th eft Secu r it y Syst em (VTSS) h a ve a door cylin der
lock swit ch secu r ed t o t h e ba ck of t h e key lock cylin -
der in side t h e dr iver s fr on t door (F ig. 1). Th e door
cylin der lock swit ch is a r esist or m u lt iplexed m om en -
t a r y swit ch t h a t is h a r d wir ed in ser ies bet ween t h e
door lock swit ch gr ou n d a n d r igh t or left cylin der
lock swit ch m u x cir cu it s of t h e Dr iver s Door Modu le
(DDM) t h r ou gh t h e fr on t door wir e h a r n ess. Th e door
8Q - 8 VEHICLE THEFT SECURITY WJ
DOOR CY LI N DER LOCK SWI T CH (Cont inue d)
(1) Discon n ect t h e door cylin der lock swit ch pigt a il
wir e con n ect or fr om t h e door wir e h a r n ess con n ect or.
(2) Usin g a oh m m et er, ch eck t h e swit ch r esist a n ce
ch ecks bet ween t h e t wo t er m in a ls in t h e door cylin -
der lock swit ch pigt a il wir e con n ect or. Act u a t e t h e
swit ch by r ot a t in g t h e key in t h e door lock cylin der
t o t est for t h e pr oper r esist a n ce va lu es in ea ch of t h e
t wo swit ch posit ion s, a s sh own in t h e Door Cylin der
Lock Swit ch Test t a ble.

DOOR CYLINDER LOCK SWITCH TEST

Switch Position Resistance
Left Side Right Side (±10%)
Lock (Clockwise) Unlock 473 Ohms
(Counterclockwise)
Fig. 1 DOOR CYLINDER LOCK SWITCH Unlock Lock (Clockwise) 1.994
1 - SWITCH (Counterclockwise) Kilohms
2 - OUTSIDE DOOR HANDLE
3 - DOOR LOCK CYLINDER (3) If a door cylin der lock swit ch fa ils eit h er of t h e
r esist a n ce t est s, r epla ce t h e fa u lt y swit ch .
cylin der lock swit ch es a r e dr iven by t h e key lock cyl-
in der s a n d con t a in t wo in t er n a l r esist or s. On e r esis- REMOVAL
t or va lu e is u sed for t h e Lock posit ion , a n d on e for (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h e Un lock posit ion . ca ble.
Th e door cylin der lock swit ch es ca n n ot be a dju st ed (2) Rem ove t h e ou t side door h a n dle u n it fr om t h e
or r epa ir ed a n d, if fa u lt y or da m a ged, t h ey m u st be ou t er door pa n el. (Refer t o 23 - BODY/DOOR -
r epla ced. F RONT/E XTE RIOR H ANDLE - RE MOVAL).
(3) Rem ove t h e r et a in er clip fr om t h e pin on t h e
OPERATION ba ck of t h e door lock cylin der (F ig. 2).
Th e door cylin der lock swit ch es a r e a ct u a t ed by t h e
key lock cylin der wh en t h e key is in ser t ed in t h e lock
cylin der a n d t u r n ed t o t h e lock or u n lock posit ion s.
Th e door cylin der lock swit ch close a cir cu it bet ween
t h e door lock swit ch gr ou n d cir cu it a n d t h e left or
r igh t cylin der lock swit ch m u x cir cu it s t h r ou gh on e of
t wo in t er n a l r esist or s for t h e Dr iver Door Modu le
(DDM) wh en eit h er fr on t door key lock cylin der is in
t h e Lock, or Un lock posit ion s. Th e DDM r ea ds t h e
swit ch st a t u s t h r ou gh a n in t er n a l pu ll-u p, t h en u ses
t h is in for m a t ion a s a n in pu t for t h e Veh icle Th eft
Secu r it y Syst em (VTSS) oper a t ion .
Th e door cylin der lock swit ch es a n d cir cu it s ca n be
dia gn osed u sin g con ven t ion a l dia gn ost ic t ools a n d
m et h ods.

DIAGNOSIS AND TESTING - DOOR CYLINDER Fig. 2 LOCK CYLINDER LEVER RETAINER RE
LOCK SWITCH 1 - LEVER
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e 2 - RETAINER
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper 3 - LOCK CYLINDER
wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er det a ils 4 - SWITCH
5 - PLIERS
on wir e h a r n ess r ou t in g a n d r et en t ion , a s well a s
6 - OUTSIDE DOOR HANDLE
pin -ou t a n d loca t ion views for t h e va r iou s wir e h a r-
n ess con n ect or s, splices a n d gr ou n ds.
(4) Rem ove t h e lock lever fr om t h e pin on t h e ba ck
of t h e door lock cylin der.
WJ
DOOR CY LI N DER LOCK SWI T CH (Cont inue d)
(5) Rem ove t h e door cylin der lock swit ch fr om t h e
ba ck of t h e lock cylin der.
INSTALLATION
(1) P osit ion t h e door cylin der lock swit ch on t o t h e
ba ck of t h e lock cylin der wit h it s pigt a il wir e h a r n ess
or ien t ed t owa r d t h e bot t om (F ig. 2).
(2) P osit ion t h e lock lever on t o t h e pin on t h e ba ck
of t h e door lock cylin der wit h t h e lever or ien t ed
t owa r d t h e r ea r.
(3) In st a ll t h e r et a in er clip on t o t h e pin on t h e
ba ck of t h e door lock cylin der. Be cer t a in t h a t t h e
cen t er t a b of t h e r et a in er is en ga ged in t h e r et en t ion
h ole on t h e lock lever.
(4) Rein st a ll t h e ou t side door h a n dle u n it on t o t h e
ou t er door pa n el. (Refer t o 23 - BODY/DOOR -
F RONT/E XTE RIOR H ANDLE - INSTALLATION).
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
H OOD AJ AR SWI T CH
DESCRIPTION
Fig. 3 Hood Ajar Switch
1 - SWITCH
2 - STUD (2)
3 - BRACKET
4 - FENDER
5 - CONNECTOR
6 - NUT (2)
Th e h ood a ja r swit ch is a self-a dju st in g, n or m a lly
closed, sin gle pole, dou ble t h r ow m om en t a r y swit ch
t h a t is u sed on ly on veh icles bu ilt for sa le in cer t a in
in t er n a t ion a l m a r ket s wh er e it is r equ ir ed equ ipm en t
(F ig. 3). Th e m ou n t in g br a cket is fa st en ed t o t h e left
in n er fen der. A m olded pla st ic st r iker wit h t h r ee in t e-
gr a l r et a in er s is secu r ed t o t h e u n der side of t h e h ood
pa n el in n er r ein for cem en t t o a ct u a t e t h e swit ch
plu n ger a s t h e h ood pa n el is closed.Th e swit ch
VEHICLE THEFT SECURITY 8Q - 9
r eceives a pa t h t o gr ou n d t h r ou gh t h e left in n er
fen der sh ield in t h e en gin e com pa r t m en t .
Th e h ood a ja r swit ch a dju st s it self a s t h e st r iker
pu sh es t h e swit ch body down t h r ou gh t h e swit ch
wh en t h e h ood pa n el is closed a ft er t h e in it ia l in st a l-
la t ion . Th is self-a dju st m en t fea t u r e is on ly fu n ct ion a l
t h e fir st t im e t h e h ood is closed followin g in st a lla -
t ion . If t h e swit ch r equ ir es a dju st m en t followin g t h e
in it ia l in st a lla t ion , t h e swit ch m u st be r epla ced.
OPERATION
Th e n or m a lly closed h ood a ja r swit ch is n or m a lly
h eld open wh en t h e h ood pa n el is closed a n d la t ch ed.
Wh en t h e h ood is open ed, t h e swit ch plu n ger ext en ds
fr om t h e swit ch body a n d t h e swit ch con t a ct s a r e
closed. Th e h ood a ja r swit ch is con n ect ed in ser ies
bet ween gr ou n d a n d t h e h ood a ja r swit ch sen se in pu t
of t h e Body Con t r ol Modu le (BCM). Th e BCM u ses
a n in t er n a l r esist or pu ll u p t o m on it or t h e st a t e of
t h e h ood a ja r swit ch con t a ct s. Th e h ood a ja r swit ch
ca n be dia gn osed u sin g con ven t ion a l dia gn ost ic t ools
a n d m et h ods.
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
h ood a ja r swit ch . If t h e pr oblem bein g dia gn osed is
r ela t ed t o h ood a ja r swit ch a ccu r a cy, be cer t a in t o
con fir m t h a t t h e pr oblem is n ot a n im pr oper ly
a dju st ed h ood a ja r swit ch . If n o h ood a ja r swit ch
a dju st m en t pr oblem is fou n d, t h e followin g pr ocedu r e
will h elp t o loca t e a sh or t or open in t h e h ood a ja r
swit ch cir cu it . Refer t o t h e a ppr opr ia t e wir in g in for-
m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e h ood a ja r swit ch . Ch eck for
con t in u it y bet ween t h e h a r n ess gr ou n d cir cu it a good
gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
2. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o
gr ou n d.
8Q - 10 VEHICLE THEFT SECURITY WJ
H OOD AJ AR SWI T CH (Cont inue d)
(2) Ch eck for con t in u it y bet ween t h e t wo t er m in a ls
of t h e h ood a ja r swit ch . Th er e sh ou ld be con t in u it y
wit h t h e swit ch plu n ger ext en ded, a n d n o con t in u it y
wit h t h e swit ch plu n ger depr essed. If OK, go t o St ep
3. If n ot OK, r epla ce t h e fa u lt y h ood a ja r swit ch .
(3) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e Body Con t r ol Modu le (BCM).
Ch eck for con t in u it y bet ween t h e h ood a ja r swit ch
sen se cir cu it of t h e h ood a ja r swit ch a n d a good
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o
St ep 4. If n ot OK, r epa ir t h e sh or t ed h ood a ja r swit ch
sen se cir cu it bet ween t h e h ood a ja r swit ch a n d t h e
BCM.
(4) Ch eck for con t in u it y bet ween t h e h ood a ja r
swit ch sen se cir cu it a n d t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e BCM. Th er e sh ou ld be con -
t in u it y. If OK, pr oceed t o dia gn osis of t h e Veh icle
Th eft Secu r it y Syst em (VTSS). (Refer t o 8 - E LE C-
TRICAL/VE H ICLE TH E F T SE CURITY - DIAGNO-
SIS AND TE STING). If n ot OK, r epa ir t h e open h ood
a ja r swit ch sen se cir cu it bet ween t h e h ood a ja r
swit ch a n d t h e BCM.

REM OVAL
REMOVAL - HOOD AJAR SWITCH
(1) Open t h e h ood.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive Fig. 4 Hood Ajar Switch Striker
ca ble. 1 - REINFORCEMENT
(3) Squ eeze t h e t wo swit ch la t ch t a bs t oget h er a n d 2 - STRIKER
pu ll t h e swit ch u pwa r d (F ig. 3) 3 - HOOD
(4) Discon n ect t h e wir in g h a r n ess con n ect or.
(5) Rem ove t h e h ood a ja r swit ch fr om t h e m ou n t -
in g br a cket . I N STALLAT I ON

REMOVAL - HOOD AJAR SWITCH BRACKET INSTALLATION - HOOD AJAR SWITCH

(1) Rem ove t h e h ood a ja r swit ch fr om t h e m ou n t -
in g br a cket . (Refer t o 8 - E LE CTRICAL/VE H ICLE
TH E F T SE CURITY/H OOD AJ AR SWITCH
RE MOVAL).
(2) Rem ove t h e t wo n u t s t h a t secu r e t h e h ood a ja r
swit ch br a cket t o t h e left in n er fen der (F ig. 3)
(3) Rem ove t h e h ood a ja r swit ch br a cket fr om t h e
st u ds on t h e left in n er fen der.
REMOVAL - HOOD AJAR SWITCH STRIKER
(1) Open t h e h ood.
(2) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla de t ool, gen t ly r a ise t h e h ood a ja r swit ch
st r iker a wa y fr om t h e in n er h ood pa n el r ein for ce-
m en t , a n d r em ove. (F ig. 4).
(1) P osit ion t h e h ood a ja r swit ch in t o t h e h ole in
t h e m ou n t in g br a cket (F ig. 3)
- (2) Recon n ect t h e wir in g h a r n ess con n ect or.
(3) P r ess t h e swit ch down wa r d in t o t h e m ou n t in g
br a cket u n t il t h e la t ch t a bs lock it in t o pla ce.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
(5) Close a n d la t ch t h e h ood.
INSTALLATION - HOOD AJAR SWITCH
BRACKET
(1) P osit ion t h e h ood a ja r swit ch br a cket on t o t h e
st u ds on t h e left in n er fen der (F ig. 3)
(2) In st a ll a n d t igh t en t h e t wo n u t s. Tigh t en t h e
n u t s t o 11.8 N·m (105 in . lbs.).
(3) Rein st a ll t h e h ood a ja r swit ch in t o t h e m ou n t -
in g br a cket . (Refer t o 8 - E LE CTRICAL/VE H ICLE
TH E F T SE CURITY/H OOD AJ AR SWITCH -
INSTALLATION).
WJ
H OOD AJ AR SWI T CH (Cont inue d)
INSTALLATION - HOOD AJAR SWITCH
STRIKER
(1) Align t h e t h r ee in t egr a l r et a in er s of t h e h ood
a ja r swit ch st r iker wit h t h eir m ou n t in g h oles in t h e
in n er h ood pa n el r ein for cem en t (F ig. 4).
(2) Usin g h a n d pr essu r e, fir m ly pr ess t h e h ood
a ja r swit ch st r iker a ga in st t h e in n er h ood pa n el r ein -
for cem en t u n t il a ll of t h e st r iker r et a in er s a r e fu lly
en ga ged in t h eir m ou n t in g h oles.
(3) Close a n d la t ch t h e h ood.
I N T RU SI ON T RAN SCEI V ER
M ODU LE
DESCRIPTION
Fig. 5 INTRUSION TRANSCEIVER MODULE
1 - ITM
2 - HEADLINER
An In t r u sion Tr a n sceiver Modu le (ITM) is pa r t of
t h e pr em iu m ver sion of t h e Veh icle Th eft Ala r m
(VTA) in t h e Veh icle Th eft Secu r it y Syst em (VTSS)
(F ig. 5). Th e pr em iu m ver sion of t h e VTA is on ly
a va ila ble in veh icles bu ilt for cer t a in m a r ket s, wh er e
t h e a ddit ion a l fea t u r es offer ed by t h is syst em a r e
r equ ir ed. Th e ITM is loca t ed in t h e pa ssen ger com -
pa r t m en t . Th is u n it is design ed t o pr ovide in t er ior
m ot ion det ect ion , a n d ser ve a s a n in t er fa ce bet ween
t h e Body Con t r ol Modu le (BCM) a n d t h e a la r m sir en
m odu le.
Th e ITM is con cea led ben ea t h a dedica t ed m olded
pla st ic t r im cover t h a t a ppr oxim a t es t h e size a n d
sh a pe of a t ypica l dom e la m p h ou sin g. H owever,
r a t h er t h a n a len s, t h e ITM fea t u r es t h r ee set s of
lou ver ed open in gs. On e set of lou ver ed open in gs is
loca t ed a t ea ch ou t boa r d en d of t h e cen t er r ib, wh ile
t h e t h ir d set is cen t er ed. E a ch of t h e lou ver ed open -
in gs is cover ed on t h e in side by a sigh t sh ield t h a t
VEHICLE THEFT SECURITY 8Q - 11
ext en ds t h e len gt h of t h e cen t er r ib. Th e m odu le is
secu r ed t o a m ou n t in g br a cket a bove t h e h ea dlin er
(F ig. 6).
Fig. 6 INTRUSION TRANSCEIVER MODULE
1 - TRIM COVER
2 - CONNECTOR RECEPTACLE
3 - HOUSING
4 - SCREW (4)
5 - SERVICE HOLE (2)
6 - LATCH FEATURE (4)
Con cea led wit h in t h e h ou sin g is t h e cir cu it r y of t h e
ITM wh ich in clu des a m icr opr ocessor, a n d a n u lt r a -
son ic r eceive t r a n sdu cer. Bot h t h e t r a n sm it t r a n s-
du cer on t h e r igh t side of t h e m odu le a n d t h e r eceive
t r a n sdu cer on t h e ITM cir cu it boa r d a r e a im ed
t h r ou gh t wo sm a ll r ou n d h oles in t h e sigh t sh ield of
t h e t r im cover. Th e ITM is con n ect ed t o t h e veh icle
elect r ica l syst em by a t a ke ou t a n d con n ect or of t h e
over h ea d wir e h a r n ess t h a t is in t egr a l t o t h e h ea d-
lin er.
Th e ITM u n it ca n n ot be a dju st ed or r epa ir ed a n d,
if fa u lt y or da m a ged, it m u st be r epla ced. Th e ITM is
ser viced a s a u n it wit h t h e t r im cover.
OPERATION
Th e m icr opr ocessor in t h e In t r u sion Tr a n sceiver
Modu le (ITM) con t a in s t h e m ot ion sen sor logic cir-
cu it s a n d con t r ols a ll of t h e fea t u r es of t h e pr em iu m
ver sion of t h e Veh icle Th eft Ala r m (VTA). Th e ITM
u ses On -Boa r d Dia gn ost ics (OBD) a n d ca n com m u n i-
ca t e wit h ot h er m odu les in t h e veh icle a s well a s
wit h t h e DRBIII! sca n t ool u sin g t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
Th is m et h od of com m u n ica t ion is u sed by t h e ITM t o
com m u n ica t e wit h t h e Body Con t r ol Modu le (BCM)
a n d for dia gn osis a n d t est in g. Th e ITM a lso com m u -
n ica t es wit h t h e a la r m sir en over a dedica t ed ser ia l
bu s cir cu it .
8Q - 12 VEHICLE THEFT SECURITY WJ
I N T RU SI ON T RAN SCEI V ER M ODU LE (Cont inue d)
Th e ITM m icr opr ocessor con t in u ou sly m on it or s fr om t h e ITM r equ ir es t h e u se of a DRBIII! sca n
in pu t s fr om it s on -boa r d m ot ion sen sor a s well a s t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
in pu t s fr om t h e BCM a n d t h e a la r m sir en m odu le.
Th e ITM m ot ion sen sor t r a n sm it s u lt r a son ic sign a ls REMOVAL
in t o t h e veh icle ca bin t h r ou gh a t r a n sm it t r a n sdu cer, (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h en list en s t o t h e r et u r n in g sign a ls a s t h e bou n ce off ca ble.
of object s in t h e veh icle in t er ior. If a n object is m ov- (2) Wh ile pu llin g down wa r d ligh t ly on t h e r ea r cor-
in g in t h e in t er ior, a det ect ion cir cu it in t h e ITM n er of t h e In t r u sion Tr a n sceiver Modu le (ITM) t r im
sen ses t h is m ovem en t t h r ou gh t h e m odu la t ion of t h e cover, in ser t a sm a ll t h in -bla ded scr ewdr iver t h r ou gh
r et u r n in g u lt r a son ic sign a ls t h a t occu r s du e t o t h e ea ch of t h e ser vice h oles on t h e r ea r edge of t h e t r im
Doppler effect . Th e m ot ion det ect fu n ct ion of t h e ITM cover t o r elea se t h e t wo in t egr a l r ea r la t ch fea t u r es
ca n be disa bled by depr essin g t h e “Lock” bu t t on on of t h e m odu le fr om t h e m ou n t in g br a cket a bove t h e
t h e Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er t h r ee h ea dlin er (F ig. 7).
t im es wit h in fift een secon ds, wh ile t h e secu r it y in di-
ca t or is st ill fla sh in g r a pidly or by cyclin g t h e key in
t h e dr iver door cylin der fr om t h e cen t er t o t h e lock
posit ion . Th e ITM will sign a l t h e a la r m sir en m odu le
t o pr ovide a sin gle sir en “ch ir p” a s a n a u dible con fir-
m a t ion t h a t t h e m ot ion sen sor fu n ct ion h a s been dis-
a bled.
If m ovem en t is det ect ed, t h e ITM sen ds a n m es-
sa ge t o t h e BCM over t h e P CI da t a bu s t o fla sh t h e
ext er ior ligh t in g a n d sen d a m essa ge t o t h e a la r m
sir en m odu le over a dedica t ed ser ia l bu s lin e t o
sou n d t h e sir en . Wh en t h e BCM det ect s a br ea ch in
t h e per im et er pr ot ect ion t h r ou gh a door, t a ilga t e,
flip-u p gla ss, or h ood a ja r swit ch in pu t , it sen ds a n
m essa ge t o t h e ITM a n d t h e ITM sen ds a n m essa ge
t o t h e BCM over t h e P CI da t a bu s t o fla sh t h e ext e-
r ior ligh t in g a n d sen d a m essa ge t o t h e a la r m sir en
Fig. 7 INTRUSION TRANSCEIVER MODULE
m odu le over a dedica t ed ser ia l bu s lin e t o sou n d t h e
REMOVE
sir en . Th e ITM a lso m on it or s in pu t s fr om t h e a la r m
1 - SMALL SCREWDRIVER
sir en m odu le for sir en ba t t er y or sir en in pu t /ou t pu t
2 - HEADLINER
cir cu it t a m per a ler t s, a n d sir en ba t t er y con dit ion
3 - SERVICE HOLES
a ler t s, t h en set s a ct ive a n d st or ed Dia gn ost ic Tr ou ble 4 - ITM
Codes (DTC) for a n y m on it or ed syst em fa u lt s it
det ect s. An a ct ive fa u lt on ly r em a in s for t h e cu r r en t
ign it ion swit ch cycle, wh ile a st or ed fa u lt ca u ses a (3) P u ll t h e ITM t r im cover r ea r wa r d fa r en ou gh
DTC t o be st or ed in m em or y by t h e ITM. If a fa u lt t o disen ga ge t h e t wo fr on t la t ch fea t u r es of t h e m od-
does n ot r eoccu r for fift y ign it ion cycles, t h e ITM will u le fr om t h e m ou n t in g br a cket a bove t h e h ea dlin er.
a u t om a t ica lly er a se t h e st or ed DTC. (4) P u ll t h e ITM a n d t r im cover down fr om t h e
Th e ITM is con n ect ed t o t h e veh icle elect r ica l sys- h ea dlin er fa r en ou gh t o a ccess a n d discon n ect t h e
t em t h r ou gh t h e over h ea d wir e h a r n ess. Th e ITM over h ea d wir e h a r n ess con n ect or for t h e ITM fr om
r eceives ba t t er y volt a ge on a B(+) cir cu it t h r ou gh a t h e m odu le con n ect or.
fu se in t h e J u n ct ion Block (J B), a n d is gr ou n ded t o (5) Rem ove t h e ITM fr om t h e h ea dlin er.
t h e ch a ssis a t G303. Th ese con n ect ion s a llow t h e
ITM t o r em a in oper a t ion a l, r ega r dless of t h e ign it ion INSTALLATION
swit ch posit ion . Th e h a r d wir ed in pu t s a n d ou t pu t s (1) P osit ion t h e In t r u sion Tr a n sceiver Modu le
for t h e ITM m a y be dia gn osed a n d t est ed u sin g con - (ITM) t o t h e h ea dlin er.
ven t ion a l dia gn ost ic t ools a n d pr ocedu r es. H owever, (2) Recon n ect t h e over h ea d wir e h a r n ess con n ect or
con ven t ion a l dia gn ost ic m et h ods will n ot pr ove con - for t h e ITM t o t h e m odu le con n ect or.
clu sive in t h e dia gn osis of t h e ITM, t h e P CI da t a bu s (3) Align t h e t wo fr on t la t ch fea t u r es of t h e ITM
n et wor k, or t h e elect r on ic m essa ge in pu t s t o a n d ou t - wit h t h e t wo fr on t la t ch r ecept a cles of t h e m ou n t in g
pu t s fr om t h e ITM. Th e m ost r elia ble, efficien t , a n d br a cket a bove t h e h ea dlin er (F ig. 8).
a ccu r a t e m ea n s t o dia gn ose t h e ITM, t h e P CI da t a (4) P u sh t h e ITM t r im cover for wa r d fa r en ou gh t o
bu s n et wor k, a n d t h e m essa ge in pu t s t o a n d ou t pu t s in ser t t h e t wo r ea r la t ch fea t u r es of t h e m odu le in t o
WJ
I N T RU SI ON T RAN SCEI V ER M ODU LE (Cont inue d)
Fig. 8 INTRUSION TRANSCEIVER MODULE
RETAINER RING
1 - STAMPED NUT (2)
2 - MOUNTING BRACKET
3 - HEADLINER
4 - LATCH RECEPTACLES (4)
t h e t wo r ea r la t ch r ecept a cles of t h e m ou n t in g
br a cket a bove t h e h ea dlin er.
(5) P u sh u pwa r d fir m ly a n d even ly on t h e r ea r
edge of t h e ITM t r im cover u n t il t h e t wo r ea r la t ch
fea t u r es of t h e m odu le a r e en ga ged a n d la t ch ed in
t h e m ou n t in g br a cket a bove t h e h ea dlin er.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
NOTE: If the Intrusion Transceiver Module (ITM) has
been replaced with a new unit, the new ITM MUST
be initialized before the Vehicle Theft Security Sys-
tem can operate as designed. The use of a DRBIII"
scan tool is required to initialize the ITM. Refer to
the appropriate diagnostic information.
SI REN
DESCRIPTION
An a la r m sir en m odu le is pa r t of t h e pr em iu m ver-
sion of t h e Veh icle Th eft Ala r m (VTA) in t h e Veh icle
Th eft Secu r it y Syst em (VTSS) (F ig. 9). Th e pr em iu m
ver sion of t h e VTA is on ly a va ila ble in veh icles bu ilt
for cer t a in m a r ket s, wh er e t h e a ddit ion a l fea t u r es
offer ed by t h is syst em a r e r equ ir ed. Th e a la r m sir en
m odu le is loca t ed in t h e r igh t fr on t fr a m e r a il. Th is
u n it is design ed t o pr ovide t h e a u dible a ler t r equ ir e-
m en t s for t h e pr em iu m VTA.
Th e a la r m sir en m odu le con sist s of m icr opr ocessor,
t h e sir en , a n d a n ickel m et a l h ydr ide ba cku p ba t t er y.
All of t h e a la r m m odu le com pon en t s a r e pr ot ect ed
a n d sea led wit h in t h e h ou sin g.
VEHICLE THEFT SECURITY 8Q - 13
Th e a la r m sir en m odu le ca n n ot be r epa ir ed or
a dju st ed a n d, if fa u lt y or da m a ged, it m u st be
r epla ced.
OPERATION
Th e m icr opr ocessor wit h in t h e a la r m sir en m odu le
pr ovides t h e sir en u n it fea t u r es a n d fu n ct ion s ba sed
u pon in t er n a l pr ogr a m m in g a n d a r m a n d disa r m
m essa ges r eceived fr om t h e In t r u sion Tr a n sceiver
Modu le (ITM) over a dedica t ed ser ia l bu s com m u n i-
ca t ion cir cu it . Th e a la r m sir en m odu le will self-det ect
pr oblem s wit h it s in t er n a l a n d ext er n a l power su pply
a n d com m u n ica t ion cir cu it s, t h en sen d m essa ges
in dica t in g t h e pr oblem t o t h e ITM u pon r eceivin g a
r equ est fr om t h e ITM. Th e ITM will st or e a Dia gn os-
t ic Tr ou ble Code (DTC) for a det ect ed a la r m sir en
m odu le fa u lt t h a t ca n be r et r ieved wit h t h e DRBIII!
sca n t ool over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s.
Wh en t h e pr em iu m ver sion of t h e Veh icle Th eft
Ala r m (VTA) is a r m ed, t h e a la r m sir en m odu le con -
t in u ou sly m on it or s in pu t s fr om t h e ITM for m essa ges
t o sou n d it s sir en a n d en t er s it s a u t o-det ect m ode.
Wh ile in t h e a u t o-det ect m ode, if t h e a la r m sir en
m odu le det ect s t h a t it s power su pply or com m u n ica -
t ion cir cu it s a r e bein g t a m per ed wit h or h a ve been
sa bot a ged, it will sou n d a n a la r m a n d con t in u e t o
oper a t e t h r ou gh it s on -boa r d ba cku p ba t t er y. If t h e
a r m sir en m odu le is in it s disa r m ed m ode wh en it s
power su pply or com m u n ica t ion cir cu it s a r e in t er-
r u pt ed, t h e sir en will n ot sou n d. Th e a la r m m odu le
will a lso n ot ify t h e ITM wh en t h e ba cku p ba t t er y
r equ ir es ch a r gin g, a n d t h e ITM will sen d a m essa ge
t h a t will a llow t h e ba cku p ba t t er y t o be ch a r ged
t h r ou gh t h e ba t t er y volt a ge a n d gr ou n d cir cu it s t o
t h e a la r m m odu le on ly wh en t h e ign it ion swit ch is in
t h e On posit ion a n d t h e en gin e is r u n n in g. Th is will
pr even t t h e ch a r gin g of t h e a la r m ba cku p ba t t er y
fr om deplet in g t h e ch a r ge in t h e m a in veh icle ba t t er y
wh ile t h e veh icle is n ot bein g oper a t ed.
Th e a la r m sir en m odu le r eceives ba t t er y volt a ge
t h r ou gh a fu se in t h e P ower Dist r ibu t ion Cen t er
(P DC), a n d is gr ou n ded t o t h e ch a ssis. Th ese con n ec-
t ion s a llow t h e a la r m sir en m odu le t o r em a in oper a -
t ion a l, r ega r dless of t h e ign it ion swit ch posit ion . Th e
h a r d wir ed in pu t s a n d ou t pu t s for t h e a la r m sir en
m odu le m a y be dia gn osed a n d t est ed u sin g con ven -
t ion a l dia gn ost ic t ools a n d pr ocedu r es. H owever, con -
ven t ion a l dia gn ost ic m et h ods will n ot pr ove
con clu sive in t h e dia gn osis of t h e in t er n a l cir cu it r y or
t h e ba cku p ba t t er y of t h e a la r m sir en m odu le, t h e
ITM, t h e ser ia l bu s com m u n ica t ion lin e, or t h e m es-
sa ge in pu t s t o a n d ou t pu t s fr om t h e a la r m sir en
m odu le. Th e m ost r elia ble, efficien t , a n d a ccu r a t e
m ea n s t o dia gn ose t h e a la r m sir en m odu le, t h e ITM,
t h e ser ia l bu s com m u n ica t ion lin e, a n d t h e elect r on ic
8Q - 14 VEHICLE THEFT SECURITY
SI REN (Cont inue d)
m essa ge in pu t s t o a n d ou t pu t s fr om t h e a la r m sir en
m odu le r equ ir es t h e u se of a DRBIII! sca n t ool.
Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Discon n ect t h e a la r m sir en m odu le wir in g h a r-
n ess con n ect or. (F ig. 9).
Fig. 9 Siren Remove/Install
1 - SIREN
2 - FRAME
(3) Rem ove t h e scr ews t h a t secu r e t h e a la r m sir en
m odu le t o t h e left fr a m e r a il.
(4) Rem ove t h e a la r m sir en m odu le.
INSTALLATION
(1) P osit ion t h e a la r m sir en m odu le on t o t h e left
fr a m e r a il. (F ig. 9).
(2) In st a ll a n d t igh t en t h e scr ews t h a t secu r e t h e
a la r m sir en m odu let o t h e fr a m e r a il. Tigh t en t h e
scr ews t o 6 N·m (50 in . lbs.).
(3) Recon n ect t h e a la r m sir en m odu le wir in g h a r-
n ess con n ect or.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
NOTE: If the alarm siren module has been replaced
with a new unit, the new unit MUST be configured
in the Intrusion Transceiver Module (ITM) before the
Vehicle Theft Security System can operate as
designed. The use of a DRBIII" scan tool is required
WJ
to configure the alarm siren module settings in the
ITM. Refer to the appropriate diagnostic informa-
tion.
SK I S I N DI CAT OR LAM P
DESCRIPTION
A Sen t r y Key Im m obilizer Syst em (SKIS) in dica t or
la m p is st a n da r d equ ipm en t on a ll in st r u m en t clu s-
t er s, bu t is on ly fu n ct ion a l on veh icles equ ipped wit h
t h e opt ion a l SKIS. Th e a m ber SKIS in dica t or la m p is
loca t ed t o t h e r igh t of t h e oil pr essu r e ga u ge.
OPERATION
Th e Sen t r y Key Im m obilizer Syst em (SKIS) in dica -
t or la m p gives a n in dica t ion t o t h e veh icle oper a t or of
t h e st a t u s of t h e SKIS. Th is la m p is con t r olled by a
t r a n sist or on t h e in st r u m en t clu st er cir cu it boa r d
ba sed u pon m essa ges r eceived by t h e clu st er fr om
t h e Sen t r y Key Im m obilizer Modu le (SKIM) over t h e
P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a
bu s. Th e SKIS in dica t or la m p bu lb r eceives ba t t er y
cu r r en t on t h e in st r u m en t clu st er cir cu it boa r d
t h r ou gh t h e fu sed ign it ion swit ch ou t pu t (st -r u n ) cir-
cu it wh en ever t h e ign it ion swit ch is in t h e On or
St a r t posit ion s. Th e la m p bu lb on ly illu m in a t es wh en
it is pr ovided a pa t h t o gr ou n d by t h e in st r u m en t
clu st er t r a n sist or. Th e in st r u m en t clu st er will t u r n
on t h e SKIS in dica t or la m p for t h e followin g r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
t u r n ed t o t h e On posit ion , t h e SKIM t ells t h e clu st er
t o illu m in a t e t h e la m p for a bou t t h r ee secon ds.
• S KIS La m p -On Me s s a g e - E a ch t im e t h e clu s-
t er r eceives a SKIS la m p-on m essa ge fr om t h e SKIM,
t h e la m p will be illu m in a t ed. Th e la m p ca n be
fla sh ed on a n d off, or illu m in a t ed solid, a s dict a t ed
by t h e m essa ge fr om t h e SKIM. F or m or e in for m a -
t ion on t h e SKIS a n d t h e SKIS la m p con t r ol pa r a m -
et er s, (Refer t o 8 - E LE CTRICAL/VE H ICLE TH E F T
SE CURITY - OP E RATION - SE NTRY KE Y IMMO-
BILIZE R SYSTE M). Th e la m p r em a in s illu m in a t ed
u n t il t h e clu st er r eceives a la m p-off m essa ge fr om
t h e SKIM or u n t il t h e ign it ion swit ch is t u r n ed t o t h e
Off posit ion , wh ich ever occu r s fir st .
• Ac tu a to r Te s t - E a ch t im e t h e clu st er is pu t
t h r ou gh t h e a ct u a t or t est , t h e la m p will be t u r n ed on
for t h e du r a t ion of t h e t est t o con fir m t h e fu n ct ion a l-
it y of t h e la m p a n d t h e clu st er.
Th e SKIM per for m s a self-t est ea ch t im e t h e ign i-
t ion swit ch is t u r n ed t o t h e On posit ion t o decide
wh et h er t h e syst em is in good oper a t in g con dit ion .
Th e SKIM t h en sen ds a m essa ge t o t h e in st r u m en t
clu st er. If t h e SKIS in dica t or la m p fa ils t o ligh t du r-
in g t h e bu lb t est , r epla ce t h e bu lb. F or fu r t h er dia g-
n osis of t h e SKIS in dica t or la m p or t h e in st r u m en t
WJ
SK I S I N DI CAT OR LAM P (Cont inue d)
clu st er cir cu it r y t h a t con t r ols t h e la m p, (Refer t o 8 -
E LE CTRICAL/INSTRUME NT CLUSTE R - DIAGNO-
SIS AND TE STING). If t h e in st r u m en t clu st er t u r n s
on t h e SKIS in dica t or la m p a ft er t h e bu lb t est , eit h er
solid or fla sh in g, it in dica t es t h a t a SKIS m a lfu n ct ion
h a s occu r r ed or t h a t t h e SKIS is in oper a t ive. F or
pr oper dia gn osis of t h e SKIS, t h e P CI da t a bu s, or
t h e m essa ge in pu t s t o t h e in st r u m en t clu st er t h a t
con t r ol t h e SKIS in dica t or la m p, a DRBIII! sca n t ool
a n d t h e a ppr opr ia t e dia gn ost ic in for m a t ion a r e
r equ ir ed.
T RAN SPON DER K EY
DESCRIPTION
Fig. 10 Sentry Key Immobilizer Transponder
1 - MOLDED CAP
2 - TRANSPONDER CHIP
3 - MOLDED CAP REMOVED
4 - TRANSPONDER KEY
E a ch ign it ion key u sed in t h e Sen t r y Key Im m obi-
lizer Syst em (SKIS) h a s a n in t egr a l t r a n spon der ch ip
(F ig. 10). Ign it ion keys wit h t h is fea t u r e ca n be
r ea dily iden t ified by a gr a y r u bber ca p m olded on t o
t h e h ea d of t h e key, wh ile con ven t ion a l ign it ion keys
h a ve a bla ck m olded r u bber ca p. Th e t r a n spon der
ch ip is con cea led ben ea t h t h e m olded r u bber ca p,
wh er e it is m olded in t o t h e h ea d of t h e m et a l key.
E a ch n ew Sen t r y Key h a s a u n iqu e t r a n spon der iden -
t ifica t ion code per m a n en t ly pr ogr a m m ed in t o it by
t h e m a n u fa ct u r er. Th e Sen t r y Key t r a n spon der if
fa u lt y or da m a ged, m u st be r epla ced.
OPERATION
Wh en t h e ign it ion swit ch is t u r n ed t o t h e On posi-
t ion , t h e Sen t r y Key Im m obilizer Modu le (SKIM)
VEHICLE THEFT SECURITY 8Q - 15
com m u n ica t es t h r ou gh it s a n t en n a wit h t h e Sen t r y
Key t r a n spon der u sin g a Ra dio F r equ en cy (RF ) sig-
n a l. Th e SKIM t h en wa it s for a RF r espon se fr om t h e
t r a n spon der t h r ou gh t h e sa m e a n t en n a . Th e Sen t r y
Key t r a n spon der ch ip is wit h in t h e r a n ge of t h e
SKIM t r a n sceiver a n t en n a r in g wh en it is in ser t ed
in t o t h e ign it ion lock cylin der. Th e SKIM det er m in es
wh et h er a va lid key is pr esen t in t h e ign it ion lock
cylin der ba sed u pon t h e r espon se fr om t h e t r a n spon -
der. If a va lid key is det ect ed, t h a t fa ct is com m u n i-
ca t ed by t h e SKIM t o t h e P ower t r a in Con t r ol Modu le
(P CM) over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s, a n d t h e P CM a llows t h e
en gin e t o con t in u e r u n n in g. If t h e P CM r eceives a n
in va lid key m essa ge, or r eceives n o m essa ge fr om t h e
SKIM over t h e P CI da t a bu s, t h e en gin e will be dis-
a bled a ft er a bou t t wo secon ds of oper a t ion . Th e E lec-
t r oMech a n ica l In st r u m en t Clu st er (E MIC) will a lso
r espon d t o t h e in va lid key m essa ge on t h e P CI da t a
bu s by fla sh in g t h e SKIS in dica t or on a n d off.
E a ch Sen t r y Key h a s a u n iqu e t r a n spon der iden t i-
fica t ion code per m a n en t ly pr ogr a m m ed in t o it by t h e
m a n u fa ct u r er. Likewise, t h e SKIM h a s a u n iqu e
Secr et Key code pr ogr a m m ed in t o it by t h e m a n u fa c-
t u r er. Wh en a Sen t r y Key is pr ogr a m m ed in t o t h e
m em or y of t h e SKIM, t h e SKIM st or es t h e t r a n spon -
der iden t ifica t ion code fr om t h e Sen t r y Key, a n d t h e
Sen t r y Key lea r n s t h e Secr et Key code fr om t h e
SKIM. On ce t h e Sen t r y Key lea r n s t h e Secr et Key
code of t h e SKIM, it is per m a n en t ly st or ed in t h e
m em or y of t h e t r a n spon der. Th er efor e, on ce a Sen t r y
Key h a s been pr ogr a m m ed t o a pa r t icu la r veh icle, it
ca n n ot be u sed on a n y ot h er veh icle. (Refer t o 8 -
E LE CTRICAL/VE H ICLE TH E F T SE CURITY -
STANDARD P ROCE DURE - TRANSP ONDE R P RO-
GRAMMING).
V T SS I N DI CAT OR
DESCRIPTION
Th e Veh icle Th eft Secu r it y Syst em (VTSS) in dica -
t or con sist s of a r ed Ligh t -E m it t in g Diode t h a t is
m ou n t ed a n d in t egr a l t o t h e a u t om a t ic h ea dla m p
ligh t sen sor ph ot o diode u n it , wh ich is loca t ed on t h e
t op of t h e in st r u m en t pa n el. Th e r em a in der of t h e
h ou sin g in clu din g t h e m ou n t a n d t h e elect r ica l con -
n ect ion a r e con cea led ben ea t h t h e in st r u m en t pa n el
t op cover.
Th e VTSS in dica t or ca n n ot be a dju st ed or r epa ir ed
t h e en t ir e a u t om a t ic h ea dla m p ligh t sen sor /VTSS
in dica t or m u st be r epla ced. (Refer t o 8 - E LE CTRI-
CAL/LAMP S/LIGH TING - E XTE RIOR/AUTO H E AD-
LAMP SE NSOR - RE MOVAL).
8Q - 16 VEHICLE THEFT SECURITY
V T SS I N DI CAT OR (Cont inue d)
OPERATION
Th e Veh icle Th eft Secu r it y Syst em (VTSS) in dica -
t or gives a visible in dica t ion of t h e VTSS a r m in g st a -
t u s. On e side of Ligh t -E m it t ion g Diode (LE D) in t h e
VTSS in dica t or is con n ect ed t o u n swit ch ed ba t t er y
cu r r en t t h r ou gh a fu sed B(+) cir cu it a n d a fu se in t h e
J u n ct ion Block (J B). Th e ot h er side of t h e LE D is
h a r d wir ed t o t h e Body Con t r ol Modu le (BCM), wh ich
con t r ols t h e oper a t ion of t h e VTSS in dica t or by pu ll-
in g t h is side of t h e LE D cir cu it t o gr ou n d. Wh en t h e
VTSS a r m in g is in pr ogr ess, t h e BCM will fla sh t h e
LE D r a pidly on a n d off for a bou t fift een secon ds.
Wh en t h e VTSS h a s been su ccessfu lly a r m ed, t h e
BCM will fla sh t h e LE D on a n d off con t in u a lly a t a
m u ch slower r a t e u n t il t h e VTSS h a s been disa r m ed.
Th e VTSS in dica t or ca n be dia gn osed u sin g con ven -
t ion a l dia gn ost ic t ools a n d m et h ods.
DIAGNOSIS AND TESTING - VTSS INDICATOR
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
Veh icle Th eft Secu r it y Syst em (VTSS) in dica t or con -
dit ion . If t h e pr oblem bein g dia gn osed is r ela t ed t o
in dica t or a ccu r a cy, be cer t a in t o con fir m t h a t t h e
pr oblem is wit h t h e in dica t or a n d n ot wit h a n in op-
er a t ive VTSS. (Refer t o 8 - E LE CTRICAL/VE H ICLE
TH E F T SE CURITY - DIAGNOSIS AND TE STING -
VE H ICLE TH E F T SE CURITY SYSTE M). If n o VTSS
pr oblem is fou n d, t h e followin g pr ocedu r e will h elp t o
loca t e a sh or t or open in t h e VTSS in dica t or con t r ol
cir cu it . Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
WJ
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Ch eck t h e fu sed B(+) fu se in t h e J u n ct ion
Block (J B). If OK, go t o St ep 2. If n ot OK, r epa ir t h e
sh or t ed cir cu it or com pon en t a n d r epla ce t h e fa u lt y
fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e J B. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it bet ween t h e J B a n d t h e
P ower Dist r ibu t ion Cen t er (P DC).
(3) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e a u t om a t ic h ea dla m p ligh t sen sor /
VTSS in dica t or fr om t h e a u t om a t ic h ea dla m p ligh t
sen sor /VTSS in dica t or pigt a il wir e con n ect or. Recon -
n ect t h e ba t t er y n ega t ive ca ble. Ch eck for ba t t er y
volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e in st r u -
m en t pa n el wir e h a r n ess con n ect or for t h e a u t om a t ic
h ea dla m p ligh t sen sor /VTSS in dica t or. If OK, go t o
St ep 4. If n ot OK, r epa ir t h e open fu sed B(+) cir cu it
bet ween t h e VTSS in dica t or a n d t h e J B.
(4) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e J B fr om t h e J B con n ect or r ecept a -
cle. Ch eck for con t in u it y bet ween t h e VTSS in dica t or
dr iver cir cu it ca vit y of t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e a u t om a t ic h ea dla m p ligh t
sen sor /VTSS in dica t or a n d a good gr ou n d. Th er e
sh ou ld be n o con t in u it y. If OK, go t o St ep 5. If n ot
OK, r epa ir t h e sh or t ed VTSS in dica t or dr iver cir cu it
bet ween t h e VTSS in dica t or a n d t h e J B.
(5) Ch eck for con t in u it y bet ween t h e VTSS in dica -
t or dr iver cir cu it of t h e in st r u m en t pa n el wir e h a r-
n ess con n ect or for t h e a u t om a t ic h ea dla m p ligh t
sen sor /VTSS in dica t or a n d t h e in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e J B. Th er e sh ou ld be con t i-
n u it y. If OK, r epla ce t h e fa u lt y VTSS in dica t or. If n ot
OK, r epa ir t h e open VTSS in dica t or dr iver cir cu it
bet ween t h e VTSS in dica t or a n d t h e J B.
WJ WIPERS/WASHERS 8R - 1

WIPERS/WASHERS
TABLE OF CON T EN T S

page page

FRONT WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 1 REAR WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 33

FRON T WI PERS/WASH ERS

TABLE OF CONTENTS
page page

FRONT WIPERS/WASHERS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - FRONT WIPER & RAIN SENSOR MODULE
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
CLEANING - FRONT WIPER & WASHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSPECTION - FRONT WIPER & WASHER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 RIGHT MULTI-FUNCTION SWITCH
FRONT CHECK VALVE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - RIGHT MULTI-
REMOVAL .............................9 FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT WASHER HOSES/TUBES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 WASHER FLUID LEVEL SWITCH
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
FRONT WASHER NOZZLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WASHER RESERVOIR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FRONT WASHER PUMP/MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 WIPER HIGH/LOW RELAY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
FRONT WIPER ARM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 DIAGNOSIS AND TESTING - WIPER HIGH/
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 LOW RELAY ...................... . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
FRONT WIPER BLADE WIPER ON/OFF RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DIAGNOSIS AND TESTING - WIPER ON/OFF
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT WIPER MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
8R - 2 FRONT WIPERS/WASHERS WJ

FRON T WI PERS/WASH ERS

DESCRIPTION

Fig. 1 Front Wiper & Washer System

1 - WASHER RESEVOIR FILLER TUBE 5 - WIPER ARM & BLADE (2)
2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL 6 - RIGHT (WIPER) MULTI-FUNCTION SWITCH RIGHT
SWITCH 7 - RAIN SENSOR MODULE
3 - WASHER NOZZLE (2)
4 - WIPER MODULE

An elect r ica lly oper a t ed in t er m it t en t fr on t wiper • B o d y Co n tro l Mo d u le - Th e Body Con t r ol

a n d wa sh er syst em is st a n da r d fa ct or y-in st a lled
sa fet y equ ipm en t on t h is m odel (F ig. 1). Th e fr on t
wiper a n d wa sh er syst em in clu des t h e followin g
m a jor com pon en t s, wh ich a r e descr ibed in fu r t h er
det a il elsewh er e in t h is ser vice in for m a t ion :
Modu le (BCM) is loca t ed on t h e J u n ct ion Block (J B)
u n der t h e dr iver side ou t boa r d en d of t h e in st r u m en t
pa n el. (Refer t o 8 - E LE CTRICAL/E LE CTRONIC
CONTROL MODULE S/BODY CONTROL MODULE
- DE SCRIP TION).
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FRON T WI PERS/WASH ERS (Cont inue d)
• F ro n t Ch e c k Va lv e - Th e fr on t wa sh er syst em
ch eck va lve is in t egr a l t o t h e wye fit t in g loca t ed in
t h e wa sh er plu m bin g bet ween t h e cowl plen u m
wa sh er h ose a n d t h e fr on t wa sh er n ozzles, a n d is
con cea led ben ea t h t h e cowl plen u m cover /gr ille pa n el
a t t h e ba se of t h e win dsh ield.
• F ro n t Wa s h e r N o zzle - Two flu idic fr on t
wa sh er n ozzles a r e secu r ed wit h in t egr a l sn a p fea -
t u r es t o dedica t ed open in gs in t h e cowl plen u m cover /
gr ille pa n el loca t ed n ea r t h e ba se of t h e win dsh ield.
• F ro n t Wa s h e r P lu m bin g - Th e plu m bin g for
t h e fr on t wa sh er syst em con sist s of r u bber h oses a n d
m olded pla st ic fit t in gs. Th e plu m bin g is r ou t ed a lon g
t h e left side of t h e en gin e com pa r t m en t fr om t h e
wa sh er r eser voir, a n d t h r ou gh t h e da sh pa n el in t o
t h e cowl plen u m t o t h e fr on t wa sh er n ozzle fit t in gs
ben ea t h t h e cowl plen u m cover /gr ille pa n el.
• F ro n t Wa s h e r P u m p /Mo to r - Th e fr on t wa sh er
pu m p/m ot or u n it is loca t ed in a dedica t ed h ole on t h e
lower ou t boa r d side of t h e wa sh er r eser voir, beh in d
t h e in n er fen der lin er a h ea d of t h e left fr on t wh eel.
Th e fr on t wa sh er pu m p is loca t ed a h ea d of a n d below
t h e r ea r wa sh er pu m p.
• F ro n t Wip e r Arm - Th e t wo fr on t wiper a r m s
a r e secu r ed wit h n u t s t o t h e t h r ea ded st u ds on t h e
en ds of t h e t wo wiper pivot sh a ft s, wh ich ext en d
t h r ou gh t h e cowl plen u m cover /gr ille pa n el loca t ed
n ea r t h e ba se of t h e win dsh ield.
• F ro n t Wip e r B la d e - Th e t wo fr on t wiper
bla des a r e secu r ed t o t h e t wo fr on t wiper a r m s wit h
a n in t egr a l la t ch , a n d a r e pa r ked on t h e gla ss n ea r
t h e bot t om of t h e win dsh ield wh en t h e fr on t wiper
syst em is n ot in oper a t ion .
• F ro n t Wip e r Mo d u le - Th e fr on t wiper pivot
sh a ft s a r e t h e on ly visible com pon en t s of t h e fr on t
wiper m odu le. Th e r em a in der of t h e m odu le is con -
cea led wit h in t h e cowl plen u m ben ea t h t h e cowl ple-
n u m cover /gr ille pa n el. Th e fr on t wiper m odu le
in clu des t h e m odu le br a cket , fou r r u bber-isola t ed
wiper m odu le m ou n t s, t h e fr on t wiper m ot or, t h e
wiper m ot or cr a n k a r m , t h e t wo wiper dr ive lin ks,
a n d t h e t wo fr on t wiper pivot s.
• Ra in S e n s o r Mo d u le - Models equ ipped wit h
t h e opt ion a l a u t om a t ic wiper fea t u r e h a ve a Ra in
Sen sor Modu le (RSM) loca t ed beh in d a t r im cover on
a br a cket bon ded t o t h e in side su r fa ce of t h e win d-
sh ield gla ss, ju st a bove t h e in side r ea r view m ir r or
m ou n t in g bu t t on .
• Rig h t Mu lti-F u n c tio n S w itc h - Th e r igh t
(wiper ) m u lt i-fu n ct ion swit ch is secu r ed t o t h e r igh t
side of t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g
n ea r t h e t op of t h e st eer in g colu m n , ju st below t h e
st eer in g wh eel. On ly t h e con t r ol st a lk for t h e r igh t
m u lt i-fu n ct ion swit ch is visible, wh ile t h e r em a in der
of t h e swit ch is con cea led ben ea t h t h e st eer in g col-
u m n sh r ou ds. Th e r igh t m u lt i-fu n ct ion swit ch con -
FRONT WIPERS/WASHERS 8R - 3
t a in s a ll of t h e swit ch es a n d con t r ol cir cu it r y for bot h
t h e fr on t a n d r ea r wiper a n d wa sh er syst em s.
• Wa s h e r F lu id Le v e l S w itc h - Th e wa sh er flu id
level swit ch is loca t ed in a dedica t ed h ole n ea r t h e
cen t er of t h e for wa r d su r fa ce of t h e wa sh er r eser voir,
beh in d t h e left fr on t wh eel h ou se spla sh sh ield.
• Wa s h e r Re s e rv o ir - Th e wa sh er r eser voir is
con cea led bet ween t h e left in n er fen der sh ield a n d
t h e left ou t er fen der pa n el, beh in d t h e in n er fen der
lin er a n d a h ea d of t h e left fr on t wh eel. Th e wa sh er
r eser voir filler n eck is t h e on ly visible por t ion of t h e
r eser voir, a n d it is a ccessed fr om t h e left fr on t cor n er
of t h e en gin e com pa r t m en t .
• Wip e r Hig h -Lo w Re la y - Th e wiper h igh -low
r ela y is a n In t er n a t ion a l St a n da r ds Or ga n iza t ion
(ISO) m icr o r ela y loca t ed in t h e P ower Dist r ibu t ion
Cen t er (P DC) in t h e en gin e com pa r t m en t n ea r t h e
ba t t er y.
• Wip e r On -Off Re la y - Th e wiper on -off r ela y is
a n In t er n a t ion a l St a n da r ds Or ga n iza t ion (ISO) m icr o
r ela y loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC)
in t h e en gin e com pa r t m en t n ea r t h e ba t t er y.
H a r d wir ed cir cu it r y con n ect s t h e fr on t wiper a n d
wa sh er syst em com pon en t s t o t h e elect r ica l syst em of
t h e veh icle. Th ese h a r d wir ed cir cu it s a r e in t egr a l t o
sever a l wir e h a r n esses, wh ich a r e r ou t ed t h r ou gh ou t
t h e veh icle a n d r et a in ed by m a n y differ en t m et h ods.
Th ese cir cu it s m a y be con n ect ed t o ea ch ot h er, t o t h e
veh icle elect r ica l syst em a n d t o t h e fr on t wiper a n d
wa sh er syst em com pon en t s t h r ou gh t h e u se of a com -
bin a t ion of solder ed splices, splice block con n ect or s,
a n d m a n y differ en t t ypes of wir e h a r n ess t er m in a l
con n ect or s a n d in su la t or s. Refer t o t h e a ppr opr ia t e
wir in g in for m a t ion . Th e wir in g in for m a t ion in clu des
wir in g dia gr a m s, pr oper wir e a n d con n ect or r epa ir
pr ocedu r es, fu r t h er det a ils on wir e h a r n ess r ou t in g
a n d r et en t ion , a s well a s pin -ou t a n d loca t ion views
for t h e va r iou s wir e h a r n ess con n ect or s, splices a n d
gr ou n ds.
OPERATING MODES
Th e com pon en t s of t h e fr on t wiper a n d wa sh er sys-
t em a r e design ed t o wor k in con cer t t o pr ovide t h e
followin g oper a t in g m odes:
• Au to m a tic Wip e r - In m odels equ ipped wit h
t h e opt ion a l a u t om a t ic wiper fea t u r e, t h e in t er n a l
cir cu it r y of bot h t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch , t h e r a in sen sor m odu le, a n d t h e BCM wor k
in con cer t t o pr ovide a n a u t om a t ic wiper m ode wit h
five sen sit ivit y select ion s. Th e BCM t ells t h e Ra in
Sen sor Modu le (RSM) wh en t h e a u t om a t ic wiper
m ode is select ed a n d t h e m a n u a lly select ed sen sit iv-
it y level, t h en t h e r a in sen sor m odu le t ells t h e BCM
ea ch t im e en ou gh wa t er dr oplet s h a ve a ccu m u la t ed
wit h in t h e wipe pa t t er n on t h e win dsh ield t o r equ ir e
fr on t wiper oper a t ion . Th e BCM t h en a u t om a t ica lly
8R - 4 FRONT WIPERS/WASHERS
FRON T WI PERS/WASH ERS (Cont inue d)
oper a t es t h e fr on t wiper s a t t h e pr ogr a m m ed speed
a n d in t er va ls r equ est ed by t h e RSM t o m a in t a in vis-
ibilit y t h r ou gh t h e win dsh ield.
• Co n tin u o u s Wip e Mo d e - Th e con t r ol kn ob on
t h e con t r ol st a lk of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch h a s t wo con t in u ou s wipe posit ion s, Low a n d
H igh . Wh en select ed, t h ese swit ch posit ion s will
ca u se t h e t wo-speed fr on t wiper m ot or t o oper a t e in a
con t in u ou s low or h igh speed cycle.
• He a d la m p s On With Wip e rs - Th e BCM pr o-
vides a n a u t om a t ic h ea dla m ps on wit h wiper s fea t u r e
for m odels equ ipped wit h t h e opt ion a l a u t om a t ic
h ea dla m ps. Th is is a cu st om er pr ogr a m m a ble fea -
t u r e. If t h is fea t u r e is en a bled, t h e h ea dla m ps will
t u r n on a u t om a t ica lly wh en t h e win dsh ield wiper s
a r e t u r n ed on ; a n d, if t h e h ea dla m ps wer e t u r n ed on
a u t om a t ica lly wh en t h e wiper s wer e t u r n ed on , t h ey
will t u r n off a u t om a t ica lly wh en t h e wiper s a r e
t u r n ed off. In m odels equ ipped wit h t h e opt ion a l
a u t om a t ic wiper fea t u r e, wh en t h e a u t om a t ic wiper
m ode is select ed t h e h ea dla m ps will t u r n on a u t o-
m a t ica lly on ly a ft er t h e wiper s com plet e t h r ee a u t o-
m a t ic wipe cycles wit h in a bou t t h ir t y secon ds, a n d
t h ey will t u r n off a u t om a t ica lly a ft er t h r ee m in u t es
ela pse wit h ou t a n y a u t om a t ic wipe cycles. (Refer t o 8
- E LE CTRICAL/OVE RH E AD CONSOLE - STAN-
DARD P ROCE DURE - E LE CTRONIC VE H ICLE
INF ORMATION CE NTE R P ROGRAMMING).
• Mis t Wip e Mo d e - Th e con t r ol st a lk of t h e r igh t
(wiper ) m u lt i-fu n ct ion swit ch h a s a m om en t a r y Mist
posit ion . Wh en select ed, t h is swit ch posit ion will
oper a t e t h e fr on t wiper s in a low speed con t in u ou s
cycle for a s lon g a s t h e swit ch is h eld closed, t h en
will com plet e t h e cu r r en t wipe cycle a n d pa r k t h e
fr on t wiper bla des n ea r t h e ba se of t h e win dsh ield
wh en t h e swit ch is r elea sed.
• S p e e d S e n s itiv e In te rm itte n t Wip e Mo d e -
E xcept on m odels equ ipped wit h t h e opt ion a l a u t o-
m a t ic wiper syst em , t h e in t er n a l cir cu it r y of bot h t h e
r igh t (wiper ) m u lt i-fu n ct ion swit ch a n d t h e BCM
wor k in con cer t t o pr ovide a n in t er m it t en t wipe m ode
wit h five dela y in t er va l select ion s. Th e BCM a u t o-
m a t ica lly a dju st s ea ch m a n u a lly select ed dela y in t er-
va l t o com pen sa t e for veh icle speed.
• Wa s h e r Mo d e - Wh en t h e m om en t a r y fr on t
wa sh posit ion of t h e con t r ol st a lk for t h e r igh t
(wiper ) m u lt i-fu n ct ion swit ch is select ed wit h t h e
fr on t wiper syst em oper a t in g in a con t in u ou s wipe
m ode, wa sh er flu id will be dispen sed on t o t h e win d-
sh ield gla ss t h r ou gh t h e wa sh er n ozzles for a s lon g
a s t h e wa sh er swit ch is h eld closed. Wh en t h e fr on t
wa sh er swit ch is a ct u a t ed wit h t h e fr on t wiper sys-
t em oper a t in g in a n in t er m it t en t wipe m ode, wa sh er
flu id is st ill dispen sed u n t il t h e swit ch is r elea sed;
h owever, t h e fr on t wiper s will oper a t e in a low speed
con t in u ou s cycle fr om t h e t im e t h e wa sh er swit ch is
WJ
closed u n t il sever a l wipe cycles a ft er t h e swit ch is
r elea sed, befor e r et u r n in g t o t h e select ed in t er m it -
t en t wipe m ode.
• Wip e -Afte r-Wa s h Mo d e - Wh en t h e m om en t a r y
fr on t wa sh posit ion of t h e con t r ol st a lk for t h e r igh t
(wiper ) m u lt i-fu n ct ion swit ch is select ed wit h t h e
fr on t wiper syst em t u r n ed Off, t h e in t er n a l cir cu it r y
of t h e BCM pr ovides a wipe-a ft er-wa sh fea t u r e.
Wh en select ed, t h is fea t u r e will oper a t e t h e fr on t
wa sh er pu m p/m ot or a n d t h e fr on t wiper s for a s lon g
a s t h e fr on t wa sh er swit ch is h eld closed, t h en pr o-
vide sever a l a ddit ion a l wipe cycles a ft er t h e swit ch is
r elea sed befor e pa r kin g t h e fr on t wiper bla des n ea r
t h e ba se of t h e win dsh ield.
OPERATION
Th e fr on t wiper a n d wa sh er syst em is design ed t o
pr ovide t h e veh icle oper a t or wit h a con ven ien t , sa fe,
a n d r elia ble m ea n s of m a in t a in in g visibilit y t h r ou gh
t h e win dsh ield gla ss. Th e va r iou s com pon en t s of t h is
syst em a r e design ed t o con ver t elect r ica l en er gy pr o-
du ced by t h e veh icle elect r ica l syst em in t o t h e
m ech a n ica l a ct ion of t h e wiper bla des t o wipe t h e
ou t side su r fa ce of t h e gla ss, a s well a s in t o t h e
h ydr a u lic a ct ion of t h e wa sh er syst em t o a pply
wa sh er flu id st or ed in a n on -boa r d r eser voir t o t h e
a r ea of t h e gla ss t o be wiped. Wh en com bin ed, t h ese
com pon en t s pr ovide t h e m ea n s t o effect ively m a in -
t a in clea r visibilit y for t h e veh icle oper a t or by r em ov-
in g excess a ccu m u la t ion s of r a in , sn ow, bu gs, m u d, or
ot h er m in or debr is t h a t m igh t be en cou n t er ed wh ile
dr ivin g t h e veh icle u n der n u m er ou s t ypes of in clem -
en t oper a t in g con dit ion s fr om t h e ou t side win dsh ield
gla ss su r fa ce.
Th e veh icle oper a t or in it ia t es a ll fr on t wiper a n d
wa sh er syst em fu n ct ion s wit h t h e con t r ol st a lk of t h e
r igh t (wiper ) m u lt i-fu n ct ion swit ch t h a t ext en ds fr om
t h e r igh t side of t h e st eer in g colu m n , ju st below t h e
st eer in g wh eel. Rot a t in g t h e con t r ol kn ob on t h e en d
of t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch con t r ol
st a lk select s t h e Off, Dela y (on m odels n ot equ ipped
wit h t h e opt ion a l a u t om a t ic wiper syst em ), Au t o (on
m odels equ ipped wit h t h e opt ion a l a u t om a t ic wiper
syst em ), Low, or H igh fr on t wiper syst em oper a t in g
m odes. In t h e Dela y m ode, t h e con t r ol kn ob a lso
a llows t h e veh icle oper a t or t o select fr om on e of five
in t er m it t en t wipe Dela y in t er va ls. In t h e Au t o m ode,
t h e con t r ol kn ob a lso a llows t h e veh icle oper a t or t o
select fr om on e of five a u t om a t ic wiper sen sit ivit y
levels. P u llin g t h e r igh t con t r ol st a lk down wa r ds
a ct u a t es t h e m om en t a r y fr on t wiper syst em Mist
m ode swit ch , wh ile pu llin g t h e r igh t con t r ol st a lk
t owa r ds t h e st eer in g wh eel a ct u a t es t h e fr on t wa sh er
syst em swit ch . Th e m u lt i-fu n ct ion swit ch pr ovides
h a r d wir ed r esist or m u lt iplexed in pu t s t o t h e Body
Con t r ol Modu le (BCM) for a ll of t h e fr on t wiper sys-
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FRON T WI PERS/WASH ERS (Cont inue d)
t em fu n ct ion s, a s well a s sepa r a t e h a r d wir ed sen se
in pu t s t o t h e BCM for t h e h igh speed con t in u ou s
wipe a n d fr on t wa sh er syst em fu n ct ion s.
Th e fr on t wiper a n d wa sh er syst em will on ly oper-
a t e wh en t h e ign it ion swit ch is in t h e Accessor y or
On posit ion s. Ba t t er y cu r r en t is dir ect ed fr om a B(+)
fu se in t h e P ower Dist r ibu t ion Cen t er (P DC) t o t h e
wiper a n d wa sh er syst em cir cu it br ea ker in t h e J u n c-
t ion Block (J B) t h r ou gh a fu sed ign it ion swit ch ou t -
pu t (r u n -a cc) cir cu it . Th e a u t om a t ic r eset t in g cir cu it
br ea ker t h en pr ovides ba t t er y cu r r en t t h r ou gh a
fu sed ign it ion swit ch ou t pu t (r u n -a cc) cir cu it t o t h e
wiper on /off r ela y, a n d t h e pa r k swit ch in t h e fr on t
wiper m ot or. A sepa r a t e fu se in t h e J B pr ovides ba t -
t er y cu r r en t t h r ou gh a n ot h er fu sed ign it ion swit ch
ou t pu t (r u n -a cc) cir cu it t o t h e r igh t m u lt i-fu n ct ion
swit ch . Th e r igh t m u lt i-fu n ct ion swit ch cir cu it r y u ses
t h is ba t t er y feed t o dir ect ly con t r ol t h e oper a t ion of
t h e fr on t wa sh er pu m p/m ot or u n it . Th e BCM u ses
low side dr iver s t o con t r ol fr on t wiper syst em oper a -
t ion by en er gizin g or de-en er gizin g t h e wiper h igh /
low a n d wiper on /off r ela ys.
Th e h a r d wir ed cir cu it s a n d com pon en t s of t h e
fr on t wiper a n d wa sh er syst em m a y be dia gn osed
a n d t est ed u sin g con ven t ion a l dia gn ost ic t ools a n d
pr ocedu r es. H owever, con ven t ion a l dia gn ost ic m et h -
ods m a y n ot pr ove con clu sive in t h e dia gn osis of t h e
Body Con t r ol Modu le (BCM), or t h e in pu t s t o or ou t -
pu t s fr om t h e BCM t h a t con t r ol t h e fr on t wiper a n d
wa sh er syst em oper a t in g m odes. Th e m ost r elia ble,
efficien t , a n d a ccu r a t e m ea n s t o dia gn ose t h e BCM,
or t h e BCM in pu t s a n d ou t pu t s r ela t ed t o t h e va r iou s
fr on t wiper a n d wa sh er syst em oper a t in g m odes
r equ ir es t h e u se of a DRBIII! sca n t ool. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
F ollowin g a r e pa r a gr a ph s t h a t br iefly descr ibe t h e
oper a t ion of ea ch of t h e fr on t wiper a n d wa sh er sys-
t em oper a t in g m odes.
CONTINUOUS WIPE MODE
Wh en t h e Low posit ion of t h e con t r ol kn ob on t h e
con t r ol st a lk of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch is select ed, t h e Body Con t r ol Modu le (BCM)
en er gizes t h e wiper on /off r ela y. Th is dir ect s ba t t er y
cu r r en t t h r ou gh t h e n or m a lly open con t a ct s of t h e
en er gized wiper on /off r ela y a n d t h e n or m a lly closed
con t a ct s of t h e de-en er gized wiper h igh /low r ela y t o
t h e low speed br u sh of t h e fr on t wiper m ot or, ca u sin g
t h e fr on t wiper s t o cycle a t low speed. Wh en t h e
H igh posit ion of t h e con t r ol kn ob is select ed, t h e
BCM en er gizes bot h t h e wiper on /off r ela y a n d t h e
wiper h igh /low r ela y. Th is dir ect s ba t t er y cu r r en t
t h r ou gh t h e n or m a lly open con t a ct s of t h e en er gized
wiper on /off r ela y a n d t h e n or m a lly open con t a ct s of
t h e en er gized wiper h igh /low r ela y t o t h e h igh speed
FRONT WIPERS/WASHERS 8R - 5
br u sh of t h e fr on t wiper m ot or, ca u sin g t h e fr on t wip-
er s t o cycle a t h igh speed.
Wh en t h e Off posit ion of t h e con t r ol kn ob is
select ed, t h e BCM de-en er gizes bot h t h e wiper on /off
a n d wiper h igh /low r ela ys, t h en on e of t wo even t s
will occu r. Th e even t t h a t will occu r depen ds u pon
t h e posit ion of t h e wiper bla des on t h e win dsh ield a t
t h e m om en t t h a t t h e con t r ol kn ob Off posit ion is
select ed. If t h e wiper bla des a r e in t h e down posit ion
on t h e win dsh ield wh en t h e Off posit ion is select ed,
t h e pa r k swit ch t h a t is in t egr a l t o t h e fr on t wiper
m ot or is closed t o gr ou n d a n d t h e wiper m ot or cea ses
t o oper a t e. If t h e wiper bla des a r e n ot in t h e down
posit ion on t h e win dsh ield a t t h e m om en t t h e Off
posit ion is select ed, t h e pa r k swit ch is closed t o ba t -
t er y cu r r en t fr om t h e fu sed ign it ion swit ch ou t pu t
(r u n -a cc) cir cu it of t h e fr on t wiper m ot or. Th e pa r k
swit ch dir ect s t h is ba t t er y cu r r en t t o t h e low speed
br u sh of t h e wiper m ot or t h r ou gh t h e wiper pa r k
swit ch sen se cir cu it a n d t h e n or m a lly closed con t a ct s
of t h e wiper on /off a n d wiper h igh /low r ela ys. Th is
ca u ses t h e wiper m ot or t o con t in u e r u n n in g a t low
speed u n t il t h e wiper bla des a r e in t h e down posit ion
on t h e win dsh ield a n d t h e pa r k swit ch is a ga in
closed t o gr ou n d.
INTERMITTENT WIPE MODE
On m odels n ot equ ipped wit h t h e opt ion a l a u t o-
m a t ic wiper syst em , wh en t h e con t r ol kn ob on t h e
con t r ol st a lk of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch is m oved t o on e of t h e five Dela y in t er va l posi-
t ion s, t h e BCM elect r on ic in t er m it t en t wipe logic cir-
cu it r espon ds by ca lcu la t in g t h e cor r ect len gt h of
t im e bet ween wiper sweeps ba sed u pon t h e select ed
dela y in t er va l in pu t . Th e BCM m on it or s t h e ch a n g-
in g st a t e of t h e wiper m ot or pa r k swit ch t h r ou gh a
h a r d wir ed fr on t wiper pa r k swit ch sen se cir cu it
in pu t . Th is in pu t a llows t h e BCM t o det er m in e t h e
pr oper in t er va ls a t wh ich t o en er gize a n d de-en er gize
t h e wiper on /off r ela y t o oper a t e t h e fr on t wiper
m ot or in t er m it t en t ly for on e low speed cycle a t a
t im e. Th e BCM logic is a lso pr ogr a m m ed t o pr ovide
a n im m edia t e wipe cycle a n d begin a n ew dela y
in t er va l t im in g cycle ea ch t im e a sh or t er dela y in t er-
va l is select ed, a n d t o a dd t h e r em a in in g dela y t im -
in g in t er va l t o t h e n ew dela y in t er va l t im in g befor e
t h e n ext wipe cycle occu r s ea ch t im e a lon ger dela y
in t er va l is select ed.
Th e in t er m it t en t wipe m ode dela y t im es a r e speed
sen sit ive. Th e BCM m on it or s veh icle speed m essa ges
r eceived fr om t h e P ower t r a in Con t r ol Modu le (P CM)
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(P CI) da t a bu s n et wor k in or der t o pr ovide t h e speed
sen sit ive dela y in t er va ls. Above a bou t sixt een kilom e-
t er s-per-h ou r (t en m iles-per-h ou r ) t h e dela y is dr iver
a dju st a ble fr om a bou t on e-h a lf secon d t o a bou t eigh -
8R - 6 FRONT WIPERS/WASHERS
FRON T WI PERS/WASH ERS (Cont inue d)
t een secon ds. Below a bou t sixt een kilom et er s-per-
h ou r (t en m iles-per-h ou r ) t h e dela y t im es a r e
dou bled, fr om a bou t on e secon d t o a bou t t h ir t y-six
secon ds.
AUTOMATIC WIPE MODE
On m odels equ ipped wit h t h e opt ion a l a u t om a t ic
wiper syst em , wh en t h e con t r ol kn ob on t h e con t r ol
st a lk of t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch is
m oved t o on e of t h e five Au t o sen sit ivit y posit ion s,
t h e BCM sen ds a n elect r on ic m essa ge t o t h e Ra in
Sen sor Modu le (RSM) over t h e P r ogr a m m a ble Com -
m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k in di-
ca t in g t h e select ed posit ion . Th e RSM m on it or s a n
a r ea wit h in t h e wipe pa t t er n of t h e win dsh ield gla ss
for t h e a ccu m u la t ion of m oist u r e. Ba sed u pon in t er-
n a l pr ogr a m m in g a n d t h e select ed sen sit ivit y level,
wh en su fficien t m oist u r e h a s a ccu m u la t ed t h e RSM
sen ds t h e a ppr opr ia t e elect r on ic wipe com m a n d m es-
sa ges t o t h e BCM over t h e P CI da t a bu s a n d t h e
BCM oper a t es t h e fr on t wiper syst em a ccor din gly. As
t h e sen sit ivit y level is set h igh er, t h e RSM is m or e
sen sit ive t o m oist u r e a ccu m u la t ion a n d will sen d
wipe com m a n ds m or e fr equ en t ly. Th e BCM logic is
a lso pr ogr a m m ed t o pr ovide a n im m edia t e wipe cycle
ea ch t im e t h e con t r ol kn ob on t h e con t r ol st a lk of t h e
r igh t m u lt i-fu n ct ion swit ch is m oved fr om a n on -a u -
t om a t ic wipe posit ion t o on e of t h e five Au t o sen sit iv-
it y posit ion s, a n d a n ot h er im m edia t e wipe cycle ea ch
t im e t h e con t r ol kn ob is m oved fr om a lower Au t o
sen sit ivit y posit ion t o a h igh er Au t o sen sit ivit y posi-
t ion .
MIST WIPE MODE
Wh en t h e con t r ol st a lk of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch is m oved t o t h e m om en t a r y Mist
posit ion , t h e BCM en er gizes t h e wiper on /off r ela y for
a s lon g a s t h e Mist swit ch is h eld closed, t h en de-en -
er gizes t h e r ela y wh en t h e st a t e of t h e Mist swit ch
in pu t ch a n ges t o open . Th e BCM ca n oper a t e t h e
fr on t wiper m ot or in t h is m ode for on ly on e low speed
cycle a t a t im e, or for a n in defin it e n u m ber of
sequ en t ia l low speed cycles, depen din g u pon h ow
lon g t h e Mist swit ch is h eld closed.
WASH MODE
Wh en t h e con t r ol st a lk of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch is m oved t o t h e m om en t a r y fr on t
Wa sh posit ion wh ile t h e con t r ol kn ob is in t h e Low or
H igh posit ion s, t h e cir cu it r y wit h in t h e swit ch dir ect s
ba t t er y cu r r en t t o t h e fr on t wa sh er pu m p/m ot or u n it .
Th is will ca u se t h e fr on t wa sh er pu m p/m ot or u n it t o
be en er gized for a s lon g a s t h e fr on t Wa sh swit ch is
h eld closed, a n d t o de-en er gize wh en t h e fr on t Wa sh
swit ch is r elea sed. Wh en t h e con t r ol st a lk of t h e
r igh t (wiper ) m u lt i-fu n ct ion swit ch is m oved t o t h e
m om en t a r y fr on t Wa sh posit ion wh ile t h e con t r ol
WJ
kn ob is in on e of t h e Dela y in t er va l or Au t o sen sit iv-
it y posit ion s, t h e fr on t wa sh er pu m p/m ot or oper a t ion
is t h e sa m e. H owever, t h e BCM en er gizes t h e wiper
on /off r ela y t o over r ide t h e select ed dela y in t er va l or
a u t o sen sit ivit y level a n d oper a t e t h e fr on t wiper
m ot or in a con t in u ou s low speed m ode for a s lon g a s
t h e fr on t Wa sh swit ch is h eld closed, t h en de-en er-
gizes t h e r ela y a n d r ever t s t o t h e select ed dela y m ode
in t er va l or a u t o sen sit ivit y level sever a l wipe cycles
a ft er t h e fr on t Wa sh swit ch is r elea sed. Th e BCM
det ect s t h e fr on t Wa sh swit ch st a t e t h r ou gh a h a r d
wir ed wa sh er pu m p m ot or swit ch ou t pu t cir cu it in pu t
fr om t h e r igh t m u lt i-fu n ct ion swit ch .
WIPE-AFTER-WASH MODE
Wh en t h e con t r ol st a lk of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch is m oved t o t h e m om en t a r y fr on t
Wa sh posit ion wh ile t h e con t r ol kn ob is in t h e Off
posit ion , t h e BCM det ect s t h a t swit ch st a t e t h r ou gh
a h a r d wir ed wa sh er pu m p m ot or swit ch ou t pu t cir-
cu it in pu t fr om t h e r igh t m u lt i-fu n ct ion swit ch . Th e
BCM r espon ds t o t h is in pu t by en er gizin g t h e wiper
on /off r ela y for a s lon g a s t h e Wa sh swit ch is h eld
closed, t h en de-en er gizes t h e r ela y sever a l wipe
cycles a ft er t h e fr on t Wa sh swit ch is r elea sed. Th e
BCM m on it or s t h e ch a n gin g st a t e of t h e wiper m ot or
pa r k swit ch t h r ou gh a h a r d wir ed fr on t wiper pa r k
swit ch sen se cir cu it in pu t . Th is in pu t a llows t h e
BCM t o cou n t t h e n u m ber of wipe cycles t h a t occu r
a ft er t h e fr on t Wa sh swit ch st a t e ch a n ges t o open ,
a n d t o det er m in e t h e pr oper in t er va l a t wh ich t o de-
en er gize t h e wiper on /off r ela y t o com plet e t h e wipe-
a ft er-wa sh m ode cycle.
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM
FRONT WIPER SYSTEM
If t h e fr on t wiper m ot or oper a t es, bu t t h e wiper s
do n ot m ove on t h e win dsh ield, r epla ce t h e fa u lt y
fr on t wiper m odu le. If t h e wiper s oper a t e, bu t ch a t -
t er, lift , or do n ot clea r t h e gla ss, clea n a n d in spect
t h e wiper syst em com pon en t s a s r equ ir ed. (Refer t o 8
- E LE CTRICAL/F RONT WIP E RS/WASH E RS -
INSP E CTION) a n d (Refer t o 8 - E LE CTRICAL/
F RONT WIP E RS/WASH E RS - CLE ANING). Refer t o
t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for-
m a t ion in clu des wir in g dia gr a m s, pr oper wir e a n d
con n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
n ect or s, splices a n d gr ou n ds.
Th e h a r d wir ed cir cu it s a n d com pon en t s of t h e
fr on t wiper a n d wa sh er syst em m a y be dia gn osed
a n d t est ed u sin g con ven t ion a l dia gn ost ic t ools a n d
pr ocedu r es. H owever, con ven t ion a l dia gn ost ic m et h -
WJ
FRON T WI PERS/WASH ERS (Cont inue d)
ods m a y n ot pr ove con clu sive in t h e dia gn osis of t h e
Body Con t r ol Modu le (BCM), t h e Ra in Sen sor Mod-
u le (RSM), t h e P ower t r a in Con t r ol Modu le (P CM) or
t h e in pu t s t o or ou t pu t s fr om t h ese m odu les t h a t con -
t r ol t h e va r iou s fr on t wiper a n d wa sh er syst em oper-
a t in g m odes. Th e m ost r elia ble, efficien t , a n d
a ccu r a t e m ea n s t o dia gn ose t h e BCM, t h e RSM, t h e
P CM or t h e BCM in pu t s a n d ou t pu t s r ela t ed t o t h e
va r iou s fr on t wiper a n d wa sh er syst em oper a t in g
m odes r equ ir es t h e u se of a DRBIII! sca n t ool. Refer
t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
FRONT WASHER SYSTEM
Th e dia gn osis fou n d h er e a ddr esses a n elect r ica lly
in oper a t ive wa sh er syst em . If t h e wa sh er pu m p/m o-
t or oper a t es, bu t n o wa sh er flu id is em it t ed fr om t h e
fr on t wa sh er n ozzles, be cer t a in t o ch eck t h e flu id
level in t h e r eser voir. Also in spect t h e fr on t wa sh er
syst em com pon en t s a s r equ ir ed. (Refer t o 8 - E LE C-
TRICAL/F RONT WIP E RS/WASH E RS - INSP E C-
TION). Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, det a ils
of wir e h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -
ou t in for m a t ion a n d loca t ion views for t h e va r iou s
wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
FRONT WIPERS/WASHERS 8R - 7
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e con t r ol kn ob on t h e con t r ol st a lk of t h e
r igh t (wiper ) m u lt i-fu n ct ion swit ch t o t h e Low or
H igh wiper posit ion . Ch eck wh et h er t h e fr on t wiper
syst em is oper a t in g. If OK, go t o St ep 2. If n ot OK,
t est a n d r epa ir t h e fr on t wiper syst em befor e con -
t in u in g wit h t h ese t est s. Refer t o F RONT WIP E R
SYSTE M
(2) Tu r n t h e con t r ol kn ob on t h e con t r ol st a lk of
t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch t o t h e Off
posit ion . P u ll t h e con t r ol st a lk of t h e r igh t (wiper )
m u lt i-fu n ct ion swit ch t owa r d t h e st eer in g wh eel t o
close t h e fr on t wa sh er swit ch . Th e fr on t wa sh er
pu m p sh ou ld oper a t e a n d t h e fr on t wiper s sh ou ld
oper a t e for a bou t t h r ee sweep cycles a ft er t h e swit ch
is r elea sed befor e t h ey pa r k. If t h e fr on t wiper s a r e
OK, bu t t h e fr on t wa sh er s a r e n ot , go t o St ep 3. If
t h e fr on t wa sh er s a r e OK, bu t t h e fr on t wiper s a r e
n ot , go t o St ep 5.
(3) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Discon n ect t h e left h ea dla m p a n d da sh wir e h a r n ess
con n ect or for t h e fr on t wa sh er pu m p/m ot or fr om t h e
pu m p/m ot or con n ect or r ecept a cle. Ch eck for con t in u -
it y bet ween t h e gr ou n d cir cu it ca vit y of t h e left h ea d-
la m p a n d da sh wir e h a r n ess con n ect or for t h e fr on t
wa sh er pu m p/m ot or a n d a good gr ou n d. Th er e sh ou ld
be con t in u it y. If OK, go t o St ep 4. If n ot OK, r epa ir
t h e open gr ou n d cir cu it t o gr ou n d (G106) a s r equ ir ed.
(4) Recon n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e On posit ion . Wh ile pu llin g t h e
con t r ol st a lk of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch t owa r d t h e st eer in g wh eel t o close t h e fr on t
wa sh er swit ch , ch eck for ba t t er y volt a ge a t t h e
wa sh er pu m p swit ch sen se cir cu it ca vit y of t h e left
h ea dla m p a n d da sh wir e h a r n ess con n ect or for t h e
fr on t wa sh er pu m p/m ot or u n it . If OK, r epla ce t h e
fa u lt y fr on t wa sh er pu m p/m ot or. If n ot OK, r epa ir
t h e open wa sh er pu m p swit ch sen se cir cu it bet ween
t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch a n d t h e fr on t
wa sh er pu m p/m ot or u n it a s r equ ir ed.
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Discon n ect t h e in st r u m en t pa n el wir e h a r n ess con -
n ect or (Con n ect or C2) for t h e Body Con t r ol Modu le
(BCM) fr om t h e BCM con n ect or r ecept a cle. Recon -
n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e ign it ion
swit ch t o t h e On posit ion . Wh ile pu llin g t h e con t r ol
st a lk of t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch
t owa r d t h e st eer in g wh eel t o close t h e fr on t wa sh er
8R - 8 FRONT WIPERS/WASHERS
FRON T WI PERS/WASH ERS (Cont inue d)
swit ch , ch eck for ba t t er y volt a ge a t t h e wa sh er pu m p
swit ch sen se cir cu it ca vit y of t h e in st r u m en t pa n el
wir e h a r n ess con n ect or (Con n ect or C2) for t h e BCM.
If OK, u se a DRBIII! sca n t ool t o dia gn ose t h e BCM.
Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion . If
n ot OK, r epa ir t h e open wa sh er pu m p swit ch sen se
cir cu it bet ween t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch a n d t h e BCM a s r equ ir ed.
CLEANING - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
Th e squ eegees of wiper bla des exposed t o t h e ele-
m en t s for a lon g t im e t en d t o lose t h eir wipin g effec-
t iven ess. P er iodic clea n in g of t h e squ eegees is
su ggest ed t o r em ove a n y deposit s of sa lt or r oa d film .
Th e wiper bla des, a r m s, a n d win dsh ield gla ss sh ou ld
on ly be clea n ed u sin g a spon ge or soft clot h a n d
win dsh ield wa sh er flu id, a m ild det er gen t , or a n on -
a br a sive clea n er. If t h e wiper bla des con t in u e t o
lea ve st r ea ks, sm ea r s, h a zin g, or bea din g on t h e
gla ss a ft er t h or ou gh clea n in g of t h e squ eegees a n d
t h e gla ss, t h e en t ir e wiper bla de a ssem bly m u st be
r epla ced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
WASHER SYSTEM
If t h e wa sh er syst em is con t a m in a t ed wit h for eign
m a t er ia l, dr a in t h e wa sh er r eser voir by r em ovin g t h e
fr on t wa sh er pu m p/m ot or fr om t h e r eser voir. Clea n
for eign m a t er ia l fr om t h e in side of t h e wa sh er r eser-
voir u sin g clea n wa sh er flu id, a m ild det er gen t , or a
n on -a br a sive clea n er. F lu sh for eign m a t er ia l fr om t h e
wa sh er syst em plu m bin g by fir st discon n ect in g t h e
wa sh er h oses fr om t h e wa sh er n ozzles, t h en r u n n in g
t h e wa sh er pu m p/m ot or t o r u n clea n wa sh er flu id or
wa t er t h r ou gh t h e syst em . P lu gged or r est r ict ed
wa sh er n ozzles sh ou ld be ca r efu lly ba ck-flu sh ed
u sin g com pr essed a ir. If t h e wa sh er n ozzle obst r u c-
t ion ca n n ot be clea r ed, r epla ce t h e wa sh er n ozzle.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
WJ
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
Th e fr on t wiper bla des a n d wiper a r m s sh ou ld be
in spect ed per iodica lly, n ot ju st wh en wiper per for-
m a n ce pr oblem s a r e exper ien ced. Th is in spect ion
sh ou ld in clu de t h e followin g poin t s:
(1) In spect t h e wiper a r m s for a n y in dica t ion s of
da m a ge, or con t a m in a t ion . If t h e wiper a r m s a r e con -
t a m in a t ed wit h a n y for eign m a t er ia l, clea n t h em a s
r equ ir ed. (Refer t o 8 - E LE CTRICAL/F RONT WIP -
E RS/WASH E RS - CLE ANING). If a wiper a r m is
da m a ged or cor r osion is eviden t , r epla ce t h e wiper
a r m wit h a n ew u n it . Do n ot a t t em pt t o r epa ir a
wiper a r m t h a t is da m a ged or cor r oded.
(2) Ca r efu lly lift t h e wiper bla de off of t h e gla ss.
Not e t h e a ct ion of t h e wiper a r m h in ge. Th e wiper
a r m sh ou ld pivot fr eely a t t h e h in ge, bu t wit h n o la t -
er a l loosen ess eviden t . If t h er e is a n y bin din g eviden t
in t h e wiper a r m h in ge, or t h er e is eviden t la t er a l
pla y in t h e wiper a r m h in ge, r epla ce t h e wiper a r m .
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) On ce pr oper h in ge a ct ion of t h e wiper a r m is
con fir m ed, ch eck t h e h in ge for pr oper spr in g t en sion .
Rem ove t h e wiper bla de fr om t h e wiper a r m . E it h er
pla ce a sm a ll post a l sca le bet ween t h e bla de en d of
t h e wiper a r m a n d t h e gla ss, or ca r efu lly lift t h e
bla de en d of t h e a r m a wa y fr om t h e gla ss u sin g a
sm a ll fish sca le. Com pa r e t h e sca le r ea din gs bet ween
t h e r igh t a n d left wiper a r m s. Repla ce a wiper a r m if
it h a s com pa r a t ively lower spr in g t en sion , a s evi-
den ced by a lower sca le r ea din g.
(4) In spect t h e wiper bla des a n d squ eegees for a n y
in dica t ion s of da m a ge, con t a m in a t ion , or r u bber det e-
r ior a t ion (F ig. 2). If t h e wiper bla des or squ eegees
a r e con t a m in a t ed wit h a n y for eign m a t er ia l, clea n
t h em a n d t h e gla ss a s r equ ir ed. (Refer t o 8 - E LE C-
TRICAL/F RONT WIP E RS/WASH E RS - CLE ANING).
Aft er clea n in g t h e wiper bla de a n d t h e gla ss, if t h e
wiper bla de st ill fa ils t o clea r t h e gla ss wit h ou t
sm ea r in g, st r ea kin g, ch a t t er in g, h a zin g, or bea din g,
r epla ce t h e wiper bla de. Also, if a wiper bla de is
da m a ged or t h e squ eegee r u bber is da m a ged or det e-
r ior a t ed, r epla ce t h e wiper bla de wit h a n ew u n it . Do
n ot a t t em pt t o r epa ir a wiper bla de t h a t is da m a ged.
WJ
FRON T WI PERS/WASH ERS (Cont inue d)
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
WASHER SYSTEM
Th e wa sh er syst em com pon en t s sh ou ld be
in spect ed per iodica lly, n ot ju st wh en wa sh er per for-
m a n ce pr oblem s a r e exper ien ced. Th is in spect ion
sh ou ld in clu de t h e followin g poin t s:
(1) Ch eck for ice or ot h er for eign m a t er ia l in t h e
wa sh er r eser voir. If con t a m in a t ed, clea n a n d flu sh
t h e wa sh er syst em . (Refer t o 8 - E LE CTRICAL/
F RONT WIP E RS/WASH E RS - CLE ANING).
(2) In spect t h e wa sh er plu m bin g for pin ch ed, lea k-
in g, det er ior a t ed, or in cor r ect ly r ou t ed h oses a n d
da m a ged or discon n ect ed h ose fit t in gs. Repla ce da m -
a ged or det er ior a t ed h oses a n d h ose fit t in gs. Lea kin g
wa sh er h oses ca n som et im es be r epa ir ed by cu t t in g
t h e h ose a t t h e lea k a n d splicin g it ba ck t oget h er
u sin g a n in -lin e con n ect or fit t in g. Sim ila r ly, sect ion s
of det er ior a t ed h ose ca n be cu t ou t a n d r epla ced by
splicin g in n ew sect ion s of h ose u sin g in -lin e con n ec-
t or fit t in gs. Wh en ever r ou t in g a wa sh er h ose or a
wir e h a r n ess con t a in in g a wa sh er h ose, it m u st be
r ou t ed a wa y fr om h ot , sh a r p, or m ovin g pa r t s. Also,
sh a r p ben ds t h a t m igh t pin ch t h e wa sh er h ose m u st
be a voided.
FRONT WIPERS/WASHERS 8R - 9
FRON T CH ECK VALV E
DESCRIPTION
A fr on t wa sh er syst em ch eck va lve is st a n da r d
equ ipm en t on t h is m odel. Th e fr on t ch eck va lve is
in t egr a l t o t h e fr on t wa sh er n ozzle plu m bin g wye fit -
t in g loca t ed in t h e cowl plen u m ben ea t h t h e cowl ple-
n u m cover /gr ille pa n el n ea r t h e ba se of t h e
win dsh ield. Th e ch eck va lve con sist s of a m olded
pla st ic body wit h a r ou n d cen t er sect ion . Th r ee
ba r bed h ose n ipples a r e for m ed in a wye con figu r a -
t ion on t h e ou t side cir cu m fer en ce of t h e cen t er sec-
t ion of t h e va lve body. Wit h in t h e ch eck va lve body, a
sm a ll ch eck va lve oper a t ed by a sm a ll coiled spr in g
r est r ict s flow t h r ou gh t h e u n it u n t il t h e va lve is
u n sea t ed by a pr edet er m in ed in let flu id pr essu r e.
Th e fr on t ch eck va lve ca n n ot be a dju st ed or r epa ir ed
a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
OPERATION
Th e fr on t ch eck va lve pr ovides m or e t h a n on e fu n c-
t ion in t h is a pplica t ion . It ser ves a s a wye con n ect or
fit t in g bet ween t h e cowl gr ille pa n el a n d wa sh er n oz-
zle sect ion s of t h e fr on t wa sh er su pply h ose. It a lso
pr even t s wa sh er flu id fr om dr a in in g ou t of t h e fr on t
wa sh er su pply h oses ba ck t o t h e wa sh er r eser voir.
Th is dr a in -ba ck wou ld r esu lt in a len gt h y dela y fr om
wh en t h e fr on t wa sh er swit ch is a ct u a t ed u n t il
wa sh er flu id wa s dispen sed t h r ou gh t h e fr on t wa sh er
n ozzles, beca u se t h e fr on t wa sh er pu m p wou ld h a ve
t o r efill t h e fr on t wa sh er plu m bin g fr om t h e r eser voir
t o t h e n ozzles. F in a lly, t h e fr on t ch eck va lve pr even t s
wa sh er flu id fr om siph on in g t h r ou gh t h e fr on t
wa sh er n ozzles a ft er t h e fr on t wa sh er syst em is
t u r n ed Off. Wh en t h e fr on t wa sh er pu m p pr essu r izes
a n d pu m ps wa sh er flu id fr om t h e r eser voir t h r ou gh
t h e fr on t wa sh er plu m bin g, t h e flu id pr essu r e over-
r ides t h e spr in g pr essu r e a pplied t o t h e ch eck va lve
a n d u n sea t s t h e va lve, a llowin g wa sh er flu id t o flow
t owa r d t h e fr on t wa sh er n ozzles. Wh en t h e fr on t
wa sh er pu m p st ops oper a t in g, spr in g pr essu r e sea t s
t h e ch eck va lve a n d flu id flow in eit h er dir ect ion
wit h in t h e fr on t wa sh er plu m bin g is pr even t ed.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e wiper a r m s fr om t h e wiper pivot s.
(Refer t o 8 - E LE CTRICAL/F RONT WIP E RS/WASH -
E RS/F RONT WIP E R ARMS - RE MOVAL).
(3) Open t h e h ood a n d pu ll t h e h ood t o plen u m
sea l off of t h e for wa r d fla n ges of t h e cowl gr ille cover
a n d t h e plen u m pa n el.
8R - 10 FRONT WIPERS/WASHERS
FRON T CH ECK VALV E (Cont inue d)
(4) Rem ove t h e six pla st ic n u t s (2 sh or t a n d 4
lon g) t h a t secu r e t h e cowl gr ille cover t o t h e st u ds on
t h e cowl t op pa n el n ea r t h e ba se of t h e win dsh ield
(F ig. 3).
Fig. 3 Cowl Grille Cover Remove/Install
1 - WASHER HOSE CONNECTION
2 - STUDS (6)
3 - COWL GRILLE COVER
4 - PLASTIC NUT (6)
(5) Lift t h e left en d of t h e cowl gr ille cover off of
t h e cowl plen u m pa n el fa r en ou gh t o a ccess t h e fr on t
wa sh er plu m bin g.
(6) Discon n ect t h e en gin e com pa r t m en t wa sh er
h ose fr om t h e cowl gr ille cover wa sh er h ose a t t h e
pla st ic elbow con n ect or.
(7) Rem ove t h e cowl gr ille cover fr om t h e cowl ple-
n u m a n d cowl t op pa n els t h r ou gh t h e open in g
bet ween t h e h ood a n d t h e ba se of t h e win dsh ield.
(8) F r om t h e u n der side of t h e cowl gr ille cover, dis-
con n ect t h e wa sh er h oses fr om t h e t h r ee ba r bed n ip-
ples of t h e wye fit t in g/ch eck va lve u n it .
(9) Rem ove t h e wye fit t in g/ch eck va lve u n it fr om
t h e u n der side of t h e cowl gr ille cover.
INSTALLATION
(1) P osit ion t h e wye fit t in g/ch eck va lve u n it t o t h e
u n der side of t h e cowl gr ille cover.
(2) F r om t h e u n der side of t h e cowl gr ille cover,
r econ n ect t h e t h r ee wa sh er h oses t o t h e ba r bed n ip-
ples of t h e wye fit t in g/ch eck va lve u n it .
(3) Rein st a ll t h e wa sh er h oses for t h e fr on t wa sh er
n ozzles in t o t h eir r ou t in g clips on t h e u n der side of
t h e cowl gr ille cover.
(4) P osit ion t h e cowl gr ille cover on t o t h e cowl ple-
n u m a n d cowl t op pa n els t h r ou gh t h e open in g
bet ween t h e h ood a n d t h e ba se of t h e win dsh ield
(F ig. 3).
WJ
(5) Lift t h e left en d of t h e cowl gr ille cover off of
t h e cowl plen u m pa n el fa r en ou gh t o a ccess t h e fr on t
wa sh er plu m bin g.
(6) Recon n ect t h e cowl gr ille cover wa sh er h ose t o
t h e en gin e com pa r t m en t wa sh er h ose a t t h e elbow
con n ect or.
(7) In st a ll t h e six pla st ic n u t s t h a t secu r e t h e cowl
gr ille cover t o t h e st u ds on t h e cowl t op pa n el n ea r
t h e ba se of t h e win dsh ield. Th ese n u t s a r e t o be
in st a lled by pu sh in g t h em on t o t h e st u ds in t h e fol-
lowin g sequ en ce:
(a ) F ir st , in st a ll t h e sh or t n u t s t o t h e t h ir d st u d
fr om t h e r igh t , t h en t h e secon d st u d fr om t h e left .
(b) Next , in st a ll t h e lon g n u t s t o t h e r igh t ou t -
boa r d st u d, t h en t h e left ou t boa r d st u d.
(c) F in a lly, in st a ll t h e t wo r em a in in g lon g n u t s
t o t h e t h ir d st u d fr om t h e left , t h en t h e secon d
st u d fr om t h e r igh t .
(8) St a r t in g a t t h e en ds a n d wor kin g t owa r d t h e
cen t er, pu sh t h e h ood t o plen u m sea l on t o t h e for-
wa r d fla n ges of t h e cowl gr ille cover a n d t h e plen u m
pa n el.
(9) Rein st a ll t h e wiper a r m s on t o t h e wiper pivot s.
(Refer t o 8 - E LE CTRICAL/F RONT WIP E RS/WASH -
E RS/F RONT WIP E R ARMS - INSTALLATION).
(10) Recon n ect t h e ba t t er y n ega t ive ca ble.
FRON T WASH ER H OSES/
T U BES
DESCRIPTION
Th e fr on t wa sh er plu m bin g con sist s of a sm a ll
dia m et er r u bber h ose t h a t is r ou t ed fr om t h e ba r bed
ou t let n ipple of t h e fr on t wa sh er pu m p/m ot or on t h e
wa sh er r eser voir a lon g t h e filler n eck in t o t h e en gin e
com pa r t m en t . In t h e en gin e com pa r t m en t , a m olded
pla st ic in -lin e fit t in g wit h ba r bed n ipples join s t h e
wa sh er h ose t o a n ot h er sect ion of h ose t h a t is r ou t ed
n ea r t h e left h ea dla m p a n d da sh wir e h a r n ess t o t h e
cowl plen u m a r ea . Th e en gin e com pa r t m en t wa sh er
h ose pa sses fr om t h e en gin e com pa r t m en t in t o t h e
cowl plen u m a r ea t h r ou gh a dedica t ed h ole wit h a
r u bber gr om m et n ea r t h e left en d of t h e cowl plen u m
pa n el. A m olded pla st ic elbow fit t in g wit h ba r bed n ip-
ples join s t h e en gin e com pa r t m en t h ose t o t h e cowl
gr ille cover h ose. Th e cowl gr ille cover wa sh er h ose is
r ou t ed t h r ou gh r ou t in g clips on t h e u n der side of t h e
cowl gr ille cover t o a m olded pla st ic wye fit t in g wit h
ba r bed n ipples a n d a n in t egr a l ch eck va lve. Th e cowl
gr ille cover h ose is con n ect ed t o on e n ipple on t h e
wye fit t in g a n d t h e t wo wa sh er n ozzle h oses a r e con -
n ect ed t o t h e ot h er t wo wye fit t in g n ipples. Th e
wa sh er n ozzle h oses a r e r ou t ed a lon g t h e u n der side
of t h e cowl gr ille cover t o t h e t wo wa sh er n ozzles.
WJ FRONT WIPERS/WASHERS 8R - 11
FRON T WASH ER H OSES/T U BES (Cont inue d)
Wa sh er h ose is a va ila ble for ser vice on ly a s r oll (4) P u ll t h e h ood t o plen u m sea l off of t h e for wa r d
st ock, wh ich m u st t h en be cu t t o len gt h . Th e m olded fla n ges of t h e cowl gr ille cover a n d t h e plen u m pa n el.
pla st ic wa sh er h ose fit t in gs ca n n ot be r epa ir ed. If (5) Rem ove t h e six pla st ic n u t s (2 sh or t a n d 4
t h ese fit t in gs a r e fa u lt y or da m a ged, t h ey m u st be lon g) t h a t secu r e t h e cowl gr ille cover t o t h e st u ds on
r epla ced. t h e cowl t op pa n el n ea r t h e ba se of t h e win dsh ield
(F ig. 4).
OPERATION
Wa sh er flu id in t h e wa sh er r eser voir is pr essu r ized
a n d fed by t h e fr on t wa sh er pu m p/m ot or t h r ou gh t h e
fr on t wa sh er syst em plu m bin g a n d fit t in gs t o t h e t wo
fr on t wa sh er n ozzles. Wh en ever r ou t in g t h e wa sh er
h ose or a wir e h a r n ess con t a in in g a wa sh er h ose, it
m u st be r ou t ed a wa y fr om h ot , sh a r p, or m ovin g
pa r t s; a n d, sh a r p ben ds t h a t m igh t pin ch t h e h ose
m u st be a voided.

FRON T WASH ER N OZ Z LE
DESCRIPTION
Th e t wo fr on t wa sh er n ozzles h a ve in t egr a l sn a p
fea t u r es t h a t secu r e t h em in dedica t ed h oles in t h e
cowl plen u m cover /gr ille pa n el loca t ed n ea r t h e ba se Fig. 4 Cowl Grille Cover Remove/Install
of t h e win dsh ield. Th e dom ed u pper su r fa ce of t h e
1 - WASHER HOSE CONNECTION
wa sh er n ozzle is visible on t h e t op of t h e plen u m cov-
2 - STUDS (6)
er /gr ille pa n el, a n d t h e n ozzle or ifice is or ien t ed 3 - COWL GRILLE COVER
t owa r ds t h e win dsh ield gla ss. Th e wa sh er plu m bin g 4 - PLASTIC NUT (6)
fit t in gs for t h e wa sh er n ozzles a r e con cea led ben ea t h
t h e cowl plen u m cover /gr ille pa n el. Th ese flu idic
wa sh er n ozzles a r e con st r u ct ed of m olded pla st ic. Th e (6) Lift t h e left en d of t h e cowl gr ille cover off of
cowl plen u m cover /gr ille pa n el m u st be r em oved fr om t h e cowl plen u m pa n el fa r en ou gh t o a ccess t h e fr on t
t h e veh icle t o a ccess t h e n ozzles for ser vice. Th e wa sh er plu m bin g.
wa sh er n ozzles ca n n ot be a dju st ed or r epa ir ed. If (7) Discon n ect t h e en gin e com pa r t m en t wa sh er
fa u lt y or da m a ged, t h ey m u st be r epla ced. h ose fr om t h e cowl gr ille cover wa sh er h ose a t t h e
pla st ic elbow con n ect or.
(8) Rem ove t h e cowl gr ille cover fr om t h e cowl ple-
OPERATION
n u m a n d cowl t op pa n els t h r ou gh t h e open in g
Th e t wo fr on t wa sh er n ozzles a r e design ed t o dis-
bet ween t h e h ood a n d t h e ba se of t h e win dsh ield.
pen se wa sh er flu id in t o t h e wiper pa t t er n a r ea on t h e
(9) F r om t h e u n der side of t h e cowl gr ille cover, dis-
ou t side of t h e win dsh ield gla ss. P r essu r ized wa sh er
con n ect t h e wa sh er h ose(s) fr om t h e ba r bed n ipple(s)
flu id is fed t o ea ch n ozzle fr om t h e wa sh er r eser voir
of t h e fr on t wa sh er n ozzle(s).
by t h e fr on t wa sh er pu m p/m ot or t h r ou gh a sin gle
(10) F r om t h e u n der side of t h e cowl gr ille cover,
h ose, wh ich is a t t a ch ed t o a ba r bed n ipple on ea ch
r elea se t h e in t egr a l sn a p fea t u r es of t h e fr on t wa sh er
fr on t wa sh er n ozzle below t h e cowl plen u m cover /
n ozzle(s) a n d pu sh t h e n ozzle(s) ou t t h r ou gh t h e
gr ille pa n el. Th e wa sh er n ozzles in cor por a t e a flu idic
m ou n t in g h ole t owa r d t h e t op side of t h e cowl gr ille
design , wh ich ca u ses t h e n ozzle t o em it t h e pr essu r-
cover.
ized wa sh er flu id a s a n oscilla t in g st r ea m t o m or e
effect ively cover a la r ger a r ea of t h e gla ss a r ea t o be
clea n ed.
INSTALLATION
(1) F r om t h e t op side of t h e cowl gr ille cover,
in ser t t h e n ipple en d of t h e fr on t wa sh er n ozzle(s)
REMOVAL
t h r ou gh t h e m ou n t in g h ole in t h e cowl gr ille cover.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(2) P u sh fir m ly a n d even ly on t h e t op of t h e fr on t
ca ble.
wa sh er n ozzle u n t il t h e in t egr a l sn a p fea t u r es lock
(2) Rem ove t h e wiper a r m s fr om t h e wiper pivot s.
in t o pla ce on t h e u n der side of t h e cowl gr ille cover.
(Refer t o 8 - E LE CTRICAL/F RONT WIP E RS/WASH -
(3) F r om t h e u n der side of t h e cowl gr ille cover,
E RS/F RONT WIP E R ARMS - RE MOVAL).
r econ n ect t h e wa sh er h ose(s) t o t h e ba r bed n ipple(s)
(3) Un la t ch a n d open t h e h ood.
of t h e fr on t wa sh er n ozzle(s).
8R - 12 FRONT WIPERS/WASHERS WJ
FRON T WASH ER N OZ Z LE (Cont inue d)
(4) Rein st a ll t h e wa sh er h oses for t h e fr on t wa sh er
n ozzle(s) in t o t h eir r ou t in g clips on t h e u n der side of
t h e cowl gr ille cover.
(5) P osit ion t h e cowl gr ille cover on t o t h e cowl ple-
n u m a n d cowl t op pa n els t h r ou gh t h e open in g
bet ween t h e h ood a n d t h e ba se of t h e win dsh ield
(F ig. 4).
(6) Lift t h e left en d of t h e cowl gr ille cover off of
t h e cowl plen u m pa n el fa r en ou gh t o a ccess t h e fr on t
wa sh er plu m bin g.
(7) Recon n ect t h e cowl gr ille cover wa sh er h ose t o
t h e en gin e com pa r t m en t wa sh er h ose a t t h e elbow
con n ect or.
(8) In st a ll t h e six pla st ic n u t s t h a t secu r e t h e cowl
gr ille cover t o t h e st u ds on t h e cowl t op pa n el n ea r
t h e ba se of t h e win dsh ield. Th ese n u t s a r e t o be
in st a lled by pu sh in g t h em on t o t h e st u ds in t h e fol-
lowin g sequ en ce:
(a ) F ir st , in st a ll t h e sh or t n u t s t o t h e t h ir d st u d Fig. 5 Washer Pumps (Viewed from Bottom of
fr om t h e r igh t , t h en t h e secon d st u d fr om t h e left . Reservoir)
(b) Next , in st a ll t h e lon g n u t s t o t h e r igh t ou t - 1 - REAR WASHER PUMP/MOTOR
boa r d st u d, t h en t h e left ou t boa r d st u d. 2 - FRONT WASHER PUMP/MOTOR
(c) F in a lly, in st a ll t h e t wo r em a in in g lon g n u t s 3 - WASHER FLUID LEVEL SWITCH
t o t h e t h ir d st u d fr om t h e left , t h en t h e secon d
st u d fr om t h e r igh t .
pu m p in let n ipple a n d t h e gr om m et sea l, wh ich is a
(9) St a r t in g a t t h e en ds a n d wor kin g t owa r d t h e
ligh t pr ess fit . An in t egr a l elect r ica l con n ect or r ecep-
cen t er, pu sh t h e h ood t o plen u m sea l on t o t h e for-
t a cle is loca t ed on t h e t op of t h e m ot or h ou sin g. Th e
wa r d fla n ges of t h e cowl gr ille cover a n d t h e plen u m
fr on t wa sh er pu m p/m ot or u n it ca n n ot be r epa ir ed. If
pa n el.
fa u lt y or da m a ged, t h e en t ir e wa sh er pu m p/m ot or
(10) Close a n d la t ch t h e h ood.
u n it m u st be r epla ced.
(11) Rein st a ll t h e wiper a r m s on t o t h e wiper piv-
ot s. (Refer t o 8 - E LE CTRICAL/F RONT WIP E RS/
WASH E RS/F RONT WIP E R ARMS -
OPERATION
Th e fr on t wa sh er pu m p/m ot or u n it is con n ect ed t o
INSTALLATION).
t h e veh icle elect r ica l syst em t h r ou gh a sin gle t a ke
(12) Recon n ect t h e ba t t er y n ega t ive ca ble.
ou t a n d t wo-ca vit y con n ect or of t h e left h ea dla m p
a n d da sh wir e h a r n ess. Th e wa sh er pu m p/m ot or is
FRON T WASH ER PU M P/ gr ou n ded a t a ll t im es t h r ou gh a t a ke ou t of t h e left
h ea dla m p a n d da sh wir e h a r n ess wit h a sin gle eyelet
M OT OR t er m in a l con n ect or t h a t is secu r ed u n der a gr ou n d
scr ew t o t h e t op of t h e left in n er fen der sh ield in t h e
DESCRIPTION en gin e com pa r t m en t . Th e fr on t wa sh er pu m p/m ot or
Th e fr on t wa sh er pu m p/m ot or u n it is loca t ed on r eceives ba t t er y cu r r en t on a fu sed ign it ion swit ch
t h e ou t boa r d side a n d n ea r t h e fr on t of t h e wa sh er ou t pu t (r u n -a cc) cir cu it t h r ou gh t h e closed con t a ct s of
r eser voir, bet ween t h e left fr on t in n er a n d ou t er t h e m om en t a r y fr on t wa sh er swit ch wit h in t h e r igh t
fen der pa n els (F ig. 5). A sm a ll per m a n en t ly lu br i- m u lt i-fu n ct ion swit ch on ly wh en t h e swit ch con t r ol
ca t ed a n d sea led elect r ic m ot or is cou pled t o t h e st a lk is pu lled t owa r ds t h e st eer in g wh eel. Wa sh er
r ot or-t ype wa sh er pu m p. A sea l fla n ge wit h a la r ge flu id is gr a vit y-fed fr om t h e wa sh er r eser voir t o t h e
ba r bed in let n ipple on t h e pu m p h ou sin g pa sses in let side of t h e wa sh er pu m p. Wh en t h e pu m p m ot or
t h r ou gh a r u bber gr om m et sea l in st a lled in on e of is en er gized, t h e r ot or-t ype pu m p pr essu r izes t h e
t wo dedica t ed m ou n t in g h oles n ea r t h e bot t om of t h e wa sh er flu id a n d for ces it t h r ou gh t h e pu m p ou t let
wa sh er r eser voir. Th e fr on t wa sh er pu m p/m ot or u n it n ipple, t h e fr on t wa sh er plu m bin g, a n d t h e fr on t
is a lwa ys m ou n t ed in t h e lower pu m p m ou n t in g h ole wa sh er n ozzles on t o t h e win dsh ield gla ss.
of t h e r eser voir. A sm a ller ba r bed ou t let n ipple on t h e
pu m p h ou sin g con n ect s t h e u n it t o t h e fr on t wa sh er REMOVAL
h ose. Th e wa sh er pu m p/m ot or u n it is r et a in ed on t h e (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
r eser voir by t h e in t er fer en ce fit bet ween t h e ba r bed ca ble.
WJ
FRON T WASH ER PU M P/M OT OR (Cont inue d)
(2) Ra ise a n d su ppor t t h e veh icle.
(3) Rem ove t h e lin er fr om t h e left fr on t fen der
wh eel h ou se.
(4) Discon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e fr on t wa sh er pu m p/m ot or
fr om t h e m ot or con n ect or r ecept a cle (F ig. 6).
Fig. 6 Washer Pumps (Viewed from Bottom of
Reservoir)
1 - REAR WASHER PUMP/MOTOR
2 - FRONT WASHER PUMP/MOTOR
3 - WASHER FLUID LEVEL SWITCH
(5) Discon n ect t h e wa sh er h ose fr om t h e ba r bed
ou t let n ipple of t h e fr on t wa sh er pu m p/m ot or a n d
a llow t h e wa sh er flu id t o dr a in in t o a clea n con t a in er
for r eu se.
(6) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y t h e ba r bed in let n ipple of
t h e wa sh er pu m p ou t of t h e r u bber gr om m et sea l in
t h e r eser voir. Ca r e m u st be t a ken n ot t o da m a ge t h e
r eser voir.
(7) Rem ove t h e r u bber gr om m et sea l fr om t h e
wa sh er pu m p m ou n t in g h ole in t h e wa sh er r eser voir
a n d disca r d.
INSTALLATION
(1) In st a ll a n ew r u bber gr om m et sea l in t o t h e
wa sh er pu m p m ou n t in g h ole in t h e wa sh er r eser voir.
Alwa ys u se a n ew r u bber gr om m et sea l on t h e r eser-
voir.
(2) P osit ion t h e ba r bed in let n ipple of t h e wa sh er
pu m p t o t h e r u bber gr om m et sea l in t h e r eser voir
(F ig. 6).
(3) P r ess fir m ly a n d even ly on t h e wa sh er pu m p
u n t il t h e ba r bed in let n ipple is fu lly sea t ed in t h e
r u bber gr om m et sea l in t h e wa sh er r eser voir m ou n t -
in g h ole.
FRONT WIPERS/WASHERS 8R - 13
(4) Recon n ect t h e wa sh er h ose t o t h e ba r bed ou t let
n ipple of t h e wa sh er pu m p.
(5) Recon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e fr on t wa sh er pu m p/m ot or
u n it t o t h e m ot or con n ect or r ecept a cle.
(6) Rein st a ll t h e lin er in t o t h e left fr on t fen der
wh eel h ou se.
(7) Lower t h e veh icle.
(8) Refill t h e wa sh er r eser voir wit h t h e wa sh er
flu id dr a in ed fr om t h e r eser voir du r in g t h e r em ova l
pr ocedu r e.
(9) Recon n ect t h e ba t t er y n ega t ive ca ble.
FRON T WI PER ARM
DESCRIPTION
Th e fr on t wiper a r m s a r e t h e r igid m em ber s
loca t ed bet ween t h e wiper pivot s t h a t pr ot r u de fr om
t h e cowl plen u m cover /gr ille pa n el n ea r t h e ba se of
t h e win dsh ield a n d t h e wiper bla des on t h e win d-
sh ield gla ss. Th ese wiper a r m s fea t u r e a n over-cen t er
h in ge t h a t a llows ea sy a ccess t o t h e win dsh ield gla ss
for clea n in g. Th e wiper a r m h a s a die ca st m et a l
pivot en d wit h a la r ge m ou n t in g h ole wit h in t er n a l
ser r a t ion s a t on e en d. A m olded bla ck pla st ic ca p fit s
over t h e wiper a r m r et a in in g n u t t o con cea l t h e n u t
a n d t h is m ou n t in g h ole followin g wiper a r m in st a lla -
t ion . Th e wide en d of a t a per ed, st a m ped st eel ch a n -
n el h in ges on a n d is secu r ed wit h a h in ge pin t o t h e
bla de en d of t h e wiper a r m pivot en d. On e en d of a
lon g, r igid, st a m ped st eel st r a p, wit h a sm a ll h ole
n ea r it s pivot en d, is r ivet ed a n d cr im ped wit h in t h e
n a r r ow en d of t h e st a m ped st eel ch a n n el. Th e t ip of
t h e wiper bla de en d of t h is st r a p is ben t ba ck u n der
it self t o for m a sm a ll h ook. Con cea led wit h in t h e
st a m ped st eel ch a n n el, on e en d of a lon g spr in g is
en ga ged wit h a wir e h ook on t h e u n der side of t h e die
ca st pivot en d, wh ile t h e ot h er en d of t h e spr in g is
h ooked t h r ou gh t h e sm a ll h ole in t h e st eel st r a p. Th e
en t ir e wiper a r m h a s a sa t in bla ck fin ish a pplied t o
a ll of it s visible su r fa ces.
A wiper a r m ca n n ot be a dju st ed or r epa ir ed. If
da m a ged or fa u lt y, t h e en t ir e wiper a r m u n it m u st be
r epla ced.
OPERATION
Th e fr on t wiper a r m s a r e design ed t o m ech a n ica lly
t r a n sm it t h e m ot ion fr om t h e wiper pivot s t o t h e
wiper bla des. Th e wiper a r m m u st be pr oper ly
in dexed t o t h e wiper pivot in or der t o m a in t a in t h e
pr oper wiper bla de t r a vel on t h e gla ss. Th e m ou n t in g
h ole for m a t ion wit h in t er n a l ser r a t ion s in t h e wiper
a r m pivot en d in t er locks wit h t h e ser r a t ion s on t h e
ou t er cir cu m fer en ce of t h e wiper pivot dr iver, a llow-
in g posit ive en ga gem en t a n d fin it e a dju st m en t of t h is
8R - 14 FRONT WIPERS/WASHERS
FRON T WI PER ARM (Cont inue d)
con n ect ion . Th e m ou n t in g n u t locks t h e wiper a r m t o
t h e t h r ea ded st u d on t h e wiper pivot . Th e spr in g-
loa ded wiper a r m h in ge con t r ols t h e down -for ce
a pplied t h r ou gh t h e t ip of t h e wiper a r m t o t h e wiper
bla de on t h e gla ss. Th e h ook for m a t ion on t h e t ip of
t h e wiper a r m pr ovides a cr a dle for secu r in g a n d
la t ch in g t h e wiper bla de pivot block t o t h e wiper
arm.
REMOVAL
(1) Lift t h e fr on t wiper a r m t o it s over-cen t er posi-
t ion t o h old t h e wiper bla de off of t h e gla ss a n d
r elieve t h e spr in g t en sion on t h e wiper a r m t o wiper
pivot con n ect ion .
(2) Ca r efu lly pr y t h e pla st ic n u t ca p off of t h e
pivot en d of t h e wiper a r m (F ig. 7).
Fig. 7 Wiper Arm Remove/Install
1 - ARM AND BLADE
2 - CAP
3 - NUT
4 - PIVOT SHAFT
5 - ALIGNMENT LINE
(3) Rem ove t h e n u t t h a t secu r es t h e wiper a r m t o
t h e wiper pivot sh a ft .
(4) Use a su it a ble ba t t er y t er m in a l pu ller t o disen -
ga ge t h e wiper a r m fr om t h e wiper pivot sh a ft
splin es (F ig. 8).
(5) Rem ove t h e fr on t wiper a r m pivot en d fr om t h e
wiper pivot .
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the wiper arms.
Turn the ignition switch to the On position and
move the right multi-function switch control knob to
its Off position. If the wiper pivots move, wait until
they stop moving, then turn the ignition switch
WJ
Fig. 8 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT
3 - BATTERY TERMINAL PULLER
back to the Off position. The wiper motor is now in
its park position.
(1) Th e fr on t wiper a r m s m u st be in dexed t o t h e
wiper pivot s wit h t h e wiper m ot or in t h e pa r k posi-
t ion t o be pr oper ly in st a lled. P osit ion t h e fr on t wiper
a r m pivot en ds on t o t h e wiper pivot s so t h a t t h e
lower edge of t h e bla de is a lign ed wit h t h e wiper
a lign m en t lin es loca t ed in t h e lower edge of t h e
win dsh ield gla ss (F ig. 7).
(2) On ce t h e wiper bla de is a lign ed, lift t h e wiper
a r m a wa y fr om t h e win dsh ield sligh t ly t o r elieve t h e
spr in g t en sion on t h e pivot en d a n d pu sh t h e pivot
h ole on t h e en d of t h e wiper a r m down over t h e
wiper pivot sh a ft .
(3) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e
wiper a r m t o t h e wiper pivot sh a ft . Tigh t en t h e n u t
t o 23.7 N·m (210 in . lbs.).
(4) Wet t h e win dsh ield gla ss, t h en oper a t e t h e
fr on t wiper s. Tu r n t h e wiper swit ch t o t h e Off posi-
t ion , t h en ch eck for t h e cor r ect wiper a r m posit ion
a n d r ea dju st a s r equ ir ed.
(5) Rein st a ll t h e pla st ic n u t ca p on t o t h e wiper
a r m pivot n u t .
FRON T WI PER BLADE
DESCRIPTION
E a ch fr on t wiper bla de is secu r ed by a n in t egr a l
la t ch in g pivot block t o t h e h ook for m a t ion on t h e t ip
of t h e fr on t wiper a r m s, a n d r est s on t h e gla ss n ea r
t h e ba se of t h e win dsh ield wh en t h e wiper s a r e n ot
in oper a t ion (F ig. 9). Th e wiper bla de con sist s of t h e
followin g com pon en t s:
• S u p e rs tru c tu re - Th e su per st r u ct u r e in clu des
sever a l st a m ped st eel br idges a n d lin ks wit h cla w
WJ
FRON T WI PER BLADE (Cont inue d)
Fig. 9 Wiper Blade - Typical
1 - RELEASE TAB
for m a t ion s t h a t gr ip t h e wiper bla de elem en t . Also
in clu ded in t h is u n it is t h e la t ch in g, m olded pla st ic
pivot block t h a t secu r es t h e su per st r u ct u r e t o t h e
wiper a r m . All of t h e m et a l com pon en t s of t h e wiper
bla de h a ve a sa t in bla ck fin ish a pplied.
• Ele m e n t - Th e wiper elem en t or squ eegee is t h e
r esilien t r u bber m em ber of t h e wiper bla de t h a t con -
t a ct s t h e gla ss.
• F le x o r - Th e flexor is a r igid m et a l com pon en t
r u n n in g a lon g t h e len gt h of ea ch side of t h e wiper
elem en t wh er e it is gr ipped by t h e cla ws of t h e
su per st r u ct u r e.
All Gr a n d Ch er okee m odels h a ve t wo 52.50 cen t i-
m et er (20.67 in ch ) lon g win dsh ield wiper bla des wit h
n on -r epla cea ble r u bber elem en t s (squ eegees). Th e
wiper bla des ca n n ot be a dju st ed or r epa ir ed. If fa u lt y,
wor n , or da m a ged t h e en t ir e wiper bla de u n it m u st
be r epla ced.
OPERATION
Th e wiper bla des a r e m oved ba ck a n d for t h a cr oss
t h e gla ss by t h e wiper a r m s wh en t h e wiper s a r e
bein g oper a t ed. Th e wiper bla de su per st r u ct u r e is
t h e flexible fr a m e t h a t gr ips t h e wiper bla de elem en t
a n d even ly dist r ibu t es t h e for ce of t h e spr in g-loa ded
wiper a r m a lon g t h e len gt h of t h e elem en t . Th e com -
bin a t ion of t h e wiper a r m for ce a n d t h e flexibilit y of
t h e su per st r u ct u r e m a kes t h e elem en t con for m t o
a n d m a in t a in pr oper con t a ct wit h t h e gla ss, even a s
t h e bla de is m oved over t h e va r ied cu r va t u r e fou n d
a cr oss t h e gla ss su r fa ce. Th e wiper elem en t flexor
pr ovides t h e cla ws of t h e bla de su per st r u ct u r e wit h a
r igid, yet flexible com pon en t on t h e elem en t wh ich
ca n be gr ipped. Th e r u bber elem en t is design ed t o be
st iff en ou gh t o m a in t a in a n even clea n in g edge a s it
is dr a wn a cr oss t h e gla ss, bu t r esilien t en ou gh t o
con for m t o t h e gla ss su r fa ce a n d flip fr om on e clea n -
in g edge t o t h e ot h er ea ch t im e t h e wiper bla de
ch a n ges dir ect ion s.
FRONT WIPERS/WASHERS 8R - 15
REMOVAL
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
(1) Lift t h e fr on t wiper a r m t o r a ise t h e wiper
bla de a n d elem en t off of t h e gla ss, u n t il t h e wiper
a r m h in ge is in it s over-cen t er posit ion .
(2) To r em ove t h e wiper bla de fr om t h e wiper a r m ,
pu sh t h e pivot block la t ch r elea se t a b u n der t h e t ip
of t h e a r m a n d slide t h e bla de a wa y fr om t h e t ip
t owa r ds t h e pivot en d of t h e a r m fa r en ou gh t o dis-
en ga ge t h e pivot block fr om t h e h ook (F ig. 10).
Fig. 10 Wiper Blade Remove/Install - Typical
1 - RELEASE TAB
(3) E xt r a ct t h e h ook for m a t ion on t h e t ip of t h e
wiper a r m fr om t h e open in g in t h e wiper bla de
su per st r u ct u r e a h ea d of t h e wiper bla de pivot block/
la t ch u n it .
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(4) Gen t ly lower t h e wiper a r m t ip on t o t h e gla ss.
INSTALLATION
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
(1) Lift t h e fr on t wiper a r m off of t h e win dsh ield
gla ss, u n t il t h e wiper a r m h in ge is in it s over-cen t er
posit ion .
(2) P osit ion t h e fr on t wiper bla de n ea r t h e h ook
for m a t ion on t h e t ip of t h e a r m wit h t h e n ot ch ed
r et a in er for t h e wiper elem en t or ien t ed t owa r ds t h e
en d of t h e wiper a r m t h a t is n ea r est t o t h e wiper
pivot .
8R - 16 FRONT WIPERS/WASHERS
FRON T WI PER BLADE (Cont inue d)
(3) In ser t t h e h ook for m a t ion on t h e t ip of t h e
wiper a r m t h r ou gh t h e open in g in t h e wiper bla de
su per st r u ct u r e a h ea d of t h e wiper bla de pivot block/
la t ch u n it fa r en ou gh t o en ga ge t h e pivot block wit h
t h e h ook (F ig. 10).
(4) Slide t h e wiper bla de pivot block/la t ch u p in t o
t h e h ook for m a t ion on t h e t ip of t h e wiper a r m u n t il
t h e la t ch r elea se t a b sn a ps in t o it s locked posit ion .
La t ch en ga gem en t will be a ccom pa n ied by a n a u dible
click.
(5) Gen t ly lower t h e wiper bla de on t o t h e gla ss.
FRON T WI PER M ODU LE
DESCRIPTION
Fig. 11 Front Wiper Module
1 - FRONT WIPER MODULE
2 - SCREW (4)
3 - WIRE HARNESS CONNECTOR
4 - LOWER COWL PLENUM PANEL
Th e fr on t wiper m odu le is secu r ed wit h fou r scr ews
t h r ou gh r u bber isola t or s t o t h e cowl plen u m pa n el
ben ea t h t h e cowl plen u m cover /gr ille pa n el (F ig. 11).
Th e en ds of t h e wiper pivot sh a ft s t h a t pr ot r u de
t h r ou gh dedica t ed open in gs in t h e cowl plen u m cov-
er /gr ille pa n el t o dr ive t h e wiper a r m s a n d bla des a r e
t h e on ly visible com pon en t s of t h e fr on t wiper m od-
u le. Th e fr on t wiper m odu le con sist s of t h e followin g
m a jor com pon en t s:
• B ra c k e t - Th e fr on t wiper m odu le br a cket con -
sist s of a lon g t u bu la r st eel m a in m em ber t h a t h a s a
st a m ped pivot br a cket for m a t ion n ea r ea ch en d
wh er e t h e t wo wiper pivot s a r e secu r ed. A st a m ped
st eel m ou n t in g pla t e for t h e wiper m ot or is secu r ed
wit h welds n ea r t h e cen t er of t h e m a in m em ber.
• Cra n k Arm - Th e fr on t wiper m ot or cr a n k a r m
is a st a m ped st eel u n it wit h a slot t ed h ole on t h e
dr iven en d t h a t is secu r ed t o t h e wiper m ot or ou t pu t
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sh a ft wit h a n u t , a n d a ba ll st u d secu r ed t o t h e dr ive
en d.
• Lin k a g e - Two st a m ped st eel dr ive lin ks con -
n ect t h e wiper m ot or cr a n k a r m t o t h e pivot lever
a r m s. Th e pa ssen ger side dr ive lin k h a s a pla st ic
socket -t ype bu sh in g on ea ch en d. Th e dr iver side
dr ive lin k h a s a pla st ic socket -t ype bu sh in g on on e
en d, a n d a pla st ic sleeve-t ype bu sh in g on t h e ot h er
en d. Th e socket -t ype bu sh in g on on e en d of ea ch
dr ive lin k is sn a p-fit over t h e ba ll st u d on t h e lever
a r m of it s r espect ive pivot . Th e dr iver side dr ive lin k
sleeve-t ype bu sh in g en d is t h en fit over t h e m ot or
cr a n k a r m ba ll st u d, a n d t h e ot h er socket -t ype bu sh -
in g of t h e pa ssen ger side dr ive lin k is sn a p-fit over
t h e exposed en d of t h e wiper m ot or cr a n k a r m ba ll
st u d.
• Mo to r - Th e fr on t wiper m ot or is secu r ed wit h
t h r ee scr ews t o t h e m ot or m ou n t in g pla t e n ea r t h e
cen t er of t h e wiper m odu le br a cket . Th e wiper m ot or
ou t pu t sh a ft pa sses t h r ou gh a h ole in t h e m odu le
br a cket , wh er e a n u t secu r es t h e wiper m ot or cr a n k
a r m t o t h e m ot or ou t pu t sh a ft . Th e t wo-speed per m a -
n en t m a gn et wiper m ot or fea t u r es a n in t egr a l t r a n s-
m ission , a n in t er n a l pa r k swit ch , a n d a n in t er n a l
a u t om a t ic r eset t in g cir cu it br ea ker.
• P iv o ts - Th e t wo fr on t wiper pivot s a r e secu r ed
t o t h e en ds of t h e wiper m odu le br a cket . Th e cr a n k
a r m s t h a t ext en d fr om t h e bot t om of t h e pivot sh a ft s
ea ch h a ve a ba ll st u d on t h eir en d. Th e u pper en d of
ea ch pivot sh a ft wh er e t h e wiper a r m s will be fa s-
t en ed ea ch h a s a n ext er n a lly ser r a t ed dr u m wit h a
t h r ea ded st u d secu r ed t o it .
Th e fr on t wiper m odu le ca n n ot be a dju st ed or
r epa ir ed. If a n y com pon en t of t h e m odu le is fa u lt y or
da m a ged, t h e en t ir e fr on t wiper m odu le u n it m u st be
r epla ced. Th e r ein for cem en t br a cket a n d st u d pla t e
a r e a va ila ble for ser vice r epla cem en t .
OPERATION
Th e fr on t wiper m odu le oper a t ion is con t r olled by
t h e ba t t er y cu r r en t in pu t s r eceived by t h e wiper
m ot or fr om t h e wiper on /off a n d wiper h igh /low
r ela ys. Th e wiper m ot or speed is con t r olled by cu r-
r en t flow t o eit h er t h e low speed or t h e h igh speed
set of br u sh es. Th e pa r k swit ch is a sin gle pole, sin -
gle t h r ow, m om en t a r y swit ch wit h in t h e wiper m ot or
t h a t is m ech a n ica lly a ct u a t ed by t h e wiper m ot or
t r a n sm ission com pon en t s. Th e pa r k swit ch a lt er-
n a t ely closes t h e wiper pa r k swit ch sen se cir cu it t o
gr ou n d or t o ba t t er y cu r r en t , depen din g u pon t h e
posit ion of t h e wiper s on t h e gla ss. Th is fea t u r e
a llows t h e m ot or t o com plet e it s cu r r en t wipe cycle
a ft er t h e wiper syst em h a s been t u r n ed Off, a n d t o
pa r k t h e wiper bla des in t h e lowest por t ion of t h e
wipe pa t t er n . Th e a u t om a t ic r eset t in g cir cu it br ea ker
pr ot ect s t h e m ot or fr om over loa ds. Th e wiper m ot or
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FRON T WI PER M ODU LE (Cont inue d)
cr a n k a r m , t h e t wo wiper lin ka ge m em ber s, a n d t h e
t wo wiper pivot s m ech a n ica lly con ver t t h e r ot a r y ou t -
pu t of t h e wiper m ot or t o t h e ba ck a n d for t h wipin g
m ot ion of t h e wiper a r m s a n d bla des on t h e gla ss.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e fr on t wiper a r m s fr om t h e wiper
pivot s. (Refer t o 8 - E LE CTRICAL/F RONT WIP E RS/
WASH E RS/F RONT WIP E R ARMS - RE MOVAL).
(3) Un la t ch a n d open t h e h ood.
(4) Rem ove t h e h ood t o plen u m sea l fr om t h e for-
wa r d fla n ges of t h e cowl gr ille cover a n d t h e plen u m
pa n el.
(5) Rem ove t h e six pla st ic n u t s (2 sh or t a n d 4
lon g) t h a t secu r e t h e cowl gr ille cover t o t h e st u ds on
t h e cowl t op pa n el n ea r t h e ba se of t h e win dsh ield
(F ig. 12).
Fig. 12 Cowl Grille Cover Remove/Install
1 - WASHER HOSE CONNECTION
2 - STUDS (6)
3 - COWL GRILLE COVER
4 - PLASTIC NUT (6)
(6) Lift t h e left en d of t h e cowl gr ille cover off of
t h e cowl plen u m pa n el fa r en ou gh t o a ccess t h e fr on t
wa sh er plu m bin g.
(7) Discon n ect t h e fr on t wa sh er en gin e com pa r t -
m en t h ose fr om t h e cowl gr ille cover h ose a t t h e
elbow con n ect or.
(8) Rem ove t h e cowl gr ille cover fr om t h e cowl ple-
n u m a n d cowl t op pa n els t h r ou gh t h e open in g
bet ween t h e h ood a n d t h e ba se of t h e win dsh ield.
(9) Rem ove t h e fou r scr ews t h a t secu r e t h e fr on t
wiper m odu le t o t h e cowl plen u m pa n el (F ig. 13).
(10) Lift t h e left en d of t h e fr on t wiper m odu le fa r
en ou gh t o a ccess t h e fr on t wiper m ot or wir e h a r n ess
con n ect or.
FRONT WIPERS/WASHERS 8R - 17
Fig. 13 Front Wiper Module Remove/Install
1 - FRONT WIPER MODULE
2 - SCREW (4)
3 - WIRE HARNESS CONNECTOR
4 - LOWER COWL PLENUM PANEL
(11) Discon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e fr on t wiper m ot or fr om t h e
fr on t wiper m ot or pigt a il wir e con n ect or.
(12) Rem ove t h e fr on t wiper m odu le fr om t h e cowl
plen u m a s a u n it .
INSTALLATION
(1) P osit ion t h e fr on t wiper m odu le in t o t h e cowl
plen u m a s a u n it (F ig. 13).
(2) Lift t h e left en d of t h e fr on t wiper m odu le fa r
en ou gh t o a ccess t h e fr on t wiper m ot or wir e h a r n ess
con n ect or.
(3) Recon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e fr on t wiper m ot or t o t h e
fr on t wiper m ot or pigt a il wir e con n ect or.
(4) Loosely in st a ll on e of t h e fr on t wiper m odu le
m ou n t in g scr ews t o t h e m ou n t in g h ole n ea r t h e pivot
on t h e r igh t en d of t h e m odu le t o loca t e t h e m odu le
in t h e plen u m .
(5) Wor kin g fr om left t o r igh t , in st a ll a n d t igh t en
t h e fou r scr ews t h a t secu r e t h e fr on t wiper m odu le t o
t h e cowl plen u m pa n el. Tigh t en t h e scr ews t o 8 N·m
(72 in . lbs.).
(6) P osit ion t h e cowl gr ille cover on t o t h e cowl ple-
n u m a n d cowl t op pa n els t h r ou gh t h e open in g
bet ween t h e h ood a n d t h e ba se of t h e win dsh ield
(F ig. 12).
(7) Lift t h e left en d of t h e cowl gr ille cover off of
t h e cowl plen u m pa n el fa r en ou gh t o a ccess t h e fr on t
wa sh er plu m bin g.
(8) Recon n ect t h e fr on t wa sh er syst em en gin e com -
pa r t m en t h ose t o t h e cowl gr ille cover h ose a t t h e
elbow con n ect or.
8R - 18 FRONT WIPERS/WASHERS
FRON T WI PER M ODU LE (Cont inue d)
(9) In st a ll t h e six pla st ic n u t s t h a t secu r e t h e cowl
gr ille cover t o t h e st u ds on t h e cowl t op pa n el n ea r
t h e ba se of t h e win dsh ield. Th ese n u t s a r e t o be
in st a lled by pu sh in g t h em on t o t h e st u ds in t h e fol-
lowin g sequ en ce:
(a ) F ir st , in st a ll t h e sh or t n u t s t o t h e t h ir d st u d
fr om t h e r igh t , t h en t h e secon d st u d fr om t h e left .
(b) Next , in st a ll lon g n u t s t o t h e r igh t ou t boa r d
st u d, t h en t h e left ou t boa r d st u d.
(c) F in a lly, in st a ll t h e t wo r em a in in g lon g n u t s
t o t h e t h ir d st u d fr om t h e left , t h en t h e secon d
st u d fr om t h e r igh t .
(10) St a r t in g a t t h e en ds a n d wor kin g t owa r d t h e
cen t er, pu sh t h e h ood t o plen u m sea l on t o t h e for-
wa r d fla n ges of t h e cowl gr ille cover a n d t h e plen u m
pa n el.
(11) Close a n d la t ch t h e h ood.
(12) Rein st a ll t h e wiper a r m s on t o t h e wiper piv-
ot s. (Refer t o 8 - E LE CTRICAL/F RONT WIP E RS/
WASH E RS/F RONT WIP E R ARMS
INSTALLATION).
(13) Recon n ect t h e ba t t er y n ega t ive ca ble.
RAI N SEN SOR M ODU LE
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h ou sin g. Th e t r ia n gu la r-sh a ped m olded bla ck pla st ic
h ou sin g of t h e RSM h a s a r ect a n gu la r open in g
loca t ed on t h e u pper en d of t h e h ou sin g for t h e m od-
u le con n ect or r ecept a cle, wh ich con t a in s fou r t er m i-
n a l pin s. Th ese t er m in a l pin s con n ect t h e r a in sen sor
t o t h e veh icle elect r ica l syst em t h r ou gh a dedica t ed
t a ke ou t a n d con n ect or of t h e over h ea d wir e h a r n ess
t h a t ext en ds fr om a bove t h e h ea dlin er. F ive open in gs
on t h e win dsh ield side of t h e RSM h ou sin g a r e fit t ed
wit h eigh t con vex clea r pla st ic len ses. A m et a l spr in g
clip on ea ch side of t h e h ou sin g n ea r t h e bot t om
secu r es t h e RSM t o a pla st ic m ou n t in g br a cket t h a t
is bon ded t o t h e win dsh ield gla ss. Con cea led wit h in
t h e RSM h ou sin g is t h e elect r on ic cir cu it r y of t h e
m odu le, wh ich in clu des fou r In fr a Red (IR) diodes,
t wo ph ot ocells, a n d a m icr opr ocessor.
Th e RSM soft wa r e is F la sh com pa t ible, wh ich
m ea n s it ca n be r epr ogr a m m ed u sin g F la sh r epr o-
gr a m m in g pr ocedu r es. H owever, if a n y of t h e h a r d-
- wa r e of t h e RSM is da m a ged or fa u lt y, t h e en t ir e
m odu le m u st be r epla ced. Th e RSM br a cket is ser-
viced a s a u n it wit h t h e win dsh ield gla ss. If t h e
br a cket is fa u lt y, da m a ged, or sepa r a t ed fr om t h e
win dsh ield gla ss, t h e win dsh ield u n it m u st be
r epla ced.

DESCRIPTION OPERATION
Th e m icr opr ocessor-ba sed Ra in Sen sor Modu le
(RSM) sen ses m oist u r e in t h e wipe pa t t er n on t h e
ou t side of t h e win dsh ield gla ss a n d sen ds wipe com -
m a n ds t o t h e Body Con t r ol Modu le (BCM). F ou r
In fr a Red (IR) diodes wit h in t h e RSM gen er a t e IR
ligh t bea m s t h a t a r e a im ed by fou r of t h e con vex
opt ica l len ses n ea r t h e ba se of t h e m odu le t h r ou gh
t h e win dsh ield gla ss. F ou r a ddit ion a l con vex opt ica l
len ses n ea r t h e t op of t h e RSM a r e focu sed on t h e IR
ligh t bea m s on t h e ou t side of t h e win dsh ield gla ss
a n d a llow t h e t wo ph ot ocells wit h in t h e m odu le t o
sen se ch a n ges in t h e in t en sit y of t h ese IR ligh t
bea m s. Wh en su fficien t m oist u r e a ccu m u la t es wit h in
t h e wipe pa t t er n of t h e win dsh ield gla ss, t h e RSM
det ect s a ch a n ge in t h e m on it or ed IR ligh t bea m
in t en sit y.
Fig. 14 Rain Sensor Module Th e in t er n a l pr ogr a m m in g of t h e RSM t h en sen ds
1 - SPRING CLIP (2)
t h e a ppr opr ia t e elect r on ic wipe com m a n d m essa ges
2 - INFRARED LENS (4) t o t h e BCM over t h e P r ogr a m m a ble Com m u n ica t ion s
3 - HOUSING In t er fa ce (P CI) da t a bu s. Th e BCM r espon ds by a ct i-
4 - CONNECTOR RECEPTACLE va t in g or dea ct iva t in g t h e fr on t wiper syst em . Th e
5 - PHOTOCELL LENS (4) BCM a lso sen ds elect r on ic sen sit ivit y level m essa ges
t o t h e RSM over t h e P CI da t a bu s ba sed u pon t h e
Th e Ra in Sen sor Modu le (RSM) is t h e pr im a r y dr iver-select ed sen sit ivit y set t in g of t h e con t r ol kn ob
com pon en t of t h e a u t om a t ic wiper syst em (F ig. 14). on t h e con t r ol st a lk of t h e r igh t (wiper ) m u lt i-fu n c-
Th e RSM is loca t ed on t h e in side of t h e win dsh ield, t ion swit ch . Th e h igh er t h e select ed sen sit ivit y set -
bet ween t h e r ea r view m ir r or m ou n t in g bu t t on a n d t in g t h e m or e sen sit ive t h e RSM is t o t h e
t h e win dsh ield h ea der a n d is con cea led beh in d a a ccu m u la t ed m oist u r e on t h e win dsh ield gla ss, a n d
m olded pla st ic t r im cover t h a t sn a ps over t h e m odu le
WJ FRONT WIPERS/WASHERS 8R - 19
RAI N SEN SOR M ODU LE (Cont inue d)
t h e m or e fr equ en t ly t h e RSM will sen d wipe com -
m a n ds t o t h e BCM t o oper a t e t h e fr on t wiper syst em .
Th e RSM oper a t es on ba t t er y cu r r en t r eceived
t h r ou gh a fu se in t h e J u n ct ion Block (J B) on a fu sed
B(+) cir cu it . Th is cir cu it is swit ch ed by t h e power
a ccessor y (su n r oof) dela y r ela y in t h e J B so t h a t t h e
RSM will oper a t e wh en ever t h e r ela y is en er gized by
t h e BCM. Th e RSM r eceives gr ou n d a t a ll t im es
t h r ou gh a t a ke ou t of t h e left body wir e h a r n ess wit h
a n eyelet t er m in a l t h a t is secu r ed by a gr ou n d scr ew
t o t h e fr on t sea t cr ossm em ber on t h e floor pa n el
u n der t h e left fr on t sea t . It is im por t a n t t o n ot e t h a t
t h e defa u lt con dit ion for t h e wiper syst em is a u t o-
m a t ic wiper s Off; t h er efor e, if n o m essa ge is r eceived
fr om t h e RSM by t h e BCM for m or e t h a n a bou t five
secon ds, t h e a u t om a t ic wiper s will be disa bled a n d
t h e BCM will defa u lt t h e fr on t wiper syst em oper a - Fig. 15 Rain Sensor Module Remove/Install
t ion t o t h e low speed con t in u ou s wipe m ode. 1 - OVERHEAD CONSOLE
Th e RSM gr ou n d a n d ba t t er y cu r r en t in pu t s ca n be 2 - REAR VIEW MIRROR CONNECTOR
dia gn osed u sin g con ven t ion a l dia gn ost ic t ools a n d 3 - BRACKET
m et h ods. H owever, con ven t ion a l dia gn ost ic m et h ods 4 - REAR VIEW MIRROR BUTTON
m a y n ot pr ove con clu sive in t h e dia gn osis of t h e RSM 5 - SPRING CLIP (2)
in t er n a l cir cu it r y, t h e BCM, t h e P CI da t a bu s n et - 6 - RAIN SENSOR MODULE
7 - TRIM COVER
wor k, or t h e elect r on ic m essa ges r eceived a n d t r a n s-
8 - WIRE HARNESS CONNECTOR
m it t ed by t h e RSM over t h e P CI da t a bu s. Th e m ost
r elia ble, efficien t , a n d a ccu r a t e m ea n s t o dia gn ose
t h e RSM r equ ir es t h e u se of a DRBIII! sca n t ool. t h e t r im cover a wa y fr om t h e win dsh ield gla ss u n t il
Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a t ion . it u n sn a ps fr om t h e RSM.
(4) Usin g a sm a ll t h in -bla ded scr ewdr iver, gen t ly
REMOVAL pr y t h e spr in g clips on ea ch side of t h e RSM a wa y
fr om t h e br a cket on t h e win dsh ield.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (5) P u ll t h e RSM a wa y fr om t h e br a cket on t h e
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT win dsh ield fa r en ou gh t o a ccess a n d discon n ect t h e
SYSTEM BEFORE ATTEMPTING ANY STEERING over h ea d wir e h a r n ess con n ect or for t h e m odu le fr om
WHEEL, STEERING COLUMN, DRIVER AIRBAG, t h e m odu le con n ect or r ecept a cle.
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG, (6) Rem ove t h e RSM fr om a bove t h e in side r ea r
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR, view m ir r or.
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE INSTALLATION
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI- WARNING: ON VEHICLES EQUIPPED WITH AIR-
TOR TO DISCHARGE BEFORE PERFORMING FUR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SYSTEM BEFORE ATTEMPTING ANY STEERING
SURE WAY TO DISABLE THE SUPPLEMENTAL WHEEL, STEERING COLUMN, DRIVER AIRBAG,
RESTRAINT SYSTEM. FAILURE TO TAKE THE PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
PROPER PRECAUTIONS COULD RESULT IN ACCI- FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
PERSONAL INJURY. OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
ca ble. TOR TO DISCHARGE BEFORE PERFORMING FUR-
(2) Adju st t h e in side r ea r view m ir r or on t h e win d- THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
sh ield down wa r d fa r en ou gh t o a ccess t h e lower edge SURE WAY TO DISABLE THE SUPPLEMENTAL
of t h e Ra in Sen sor Modu le (RSM) t r im cover (F ig. RESTRAINT SYSTEM. FAILURE TO TAKE THE
15). PROPER PRECAUTIONS COULD RESULT IN ACCI-
(3) Usin g a sm a ll t h in -bla ded scr ewdr iver in ser t ed DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
in t o t h e n ot ch a t t h e bot t om of t r im cover, gen t ly pr y PERSONAL INJURY.
8R - 20 FRONT WIPERS/WASHERS
RAI N SEN SOR M ODU LE (Cont inue d)
(1) P osit ion t h e Ra in Sen sor Modu le (RSM) a bove
t h e in side r ea r view m ir r or (F ig. 15).
(2) Recon n ect t h e over h ea d wir e h a r n ess con n ect or
for t h e RSM t o t h e m odu le con n ect or r ecept a cle.
(3) P osit ion t h e RSM t o t h e br a cket on t h e win d-
sh ield a bove t h e in side r ea r view m ir r or.
(4) Usin g h a n d pr essu r e, pr ess t h e spr in g clips on
ea ch side of t h e RSM u n t il t h ey sn a p over t h e
br a cket on t h e win dsh ield.
NOTE: The spring clips on the RSM will become
deformed after numerous (about ten) removal and
installation cycles. If the spring clips become
deformed, the RSM must be replaced with a new
unit.
(5) Align a n d en ga ge t h e t op of t h e t r im cover over
t h e t op of t h e RSM.
(6) Usin g h a n d pr essu r e, pr ess t h e bot t om of t h e
t r im cover t owa r d t h e win dsh ield gla ss u n t il it sn a ps
over t h e bot t om of t h e RSM.
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
RI GH T M U LT I -FU N CT I ON
SWI T CH
DESCRIPTION
Fig. 16 Right (Wiper) Multi-Function Switch
1 - CONTROL STALK
2 - REAR WIPER CONTROL SLEEVE
3 - FRONT WIPER CONTROL KNOB
4 - RIGHT (WIPER) MULTI-FUNCTION SWITCH
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Th e r igh t (wiper ) m u lt i-fu n ct ion swit ch is secu r ed
t o t h e r igh t side of t h e m u lt i-fu n ct ion swit ch m ou n t -
in g h ou sin g a t t h e t op of t h e st eer in g colu m n , ju st
below t h e st eer in g wh eel (F ig. 16). Th e on ly visible
com pon en t of t h e r igh t m u lt i-fu n ct ion swit ch is t h e
con t r ol st a lk t h a t ext en ds t h r ou gh a dedica t ed open -
in g in t h e r igh t side of t h e st eer in g colu m n sh r ou ds.
Th e r em a in der of t h e r igh t m u lt i-fu n ct ion swit ch is
con cea led ben ea t h t h e st eer in g colu m n sh r ou ds. Th e
swit ch h ou sin g a n d it s con t r ol st a lk a r e con st r u ct ed
of m olded bla ck pla st ic. A sin gle con n ect or r ecept a cle
con t a in in g u p t o t en t er m in a l pin s is loca t ed on t h e
ba ck of t h e swit ch h ou sin g a n d con n ect s t h e swit ch
t o t h e veh icle elect r ica l syst em t h r ou gh a t a ke ou t
a n d con n ect or of t h e in st r u m en t pa n el wir e h a r n ess.
Th e swit ch is secu r ed t o t h e m u lt i-fu n ct ion swit ch
m ou n t in g h ou sin g n ea r t h e t op of t h e st eer in g col-
u m n by t wo scr ews.
Th er e a r e t wo ver sion s of t h e r igh t m u lt i-fu n ct ion
swit ch : on e t o su ppor t t h e st a n da r d equ ipm en t speed
sen sit ive in t er m it t en t fr on t wiper syst em , a n d a sec-
on d t o su ppor t t h e opt ion a l fr on t a u t om a t ic wiper
syst em . E a ch ver sion of t h e r igh t m u lt i-fu n ct ion
swit ch con t r ol st a lk h a s bot h wh it e n om en cla t u r e
a n d In t er n a t ion a l Con t r ol a n d Displa y Sym bol icon s
a pplied t o it , wh ich clea r ly iden t ify it s m a n y fu n c-
t ion s. Th e con t r ol st a lk h a s a con t r ol kn ob on it s en d
wit h a fla t t en ed fa ce t o a llow it t o be ea sily r ot a t ed.
J u st below t h e con t r ol kn ob is a kn u r led con t r ol
sleeve. Th e r igh t m u lt i-fu n ct ion swit ch is t h e pr im a r y
con t r ol for t h e fr on t a n d r ea r wiper a n d wa sh er sys-
t em s, a n d con t a in s swit ch es a n d cir cu it r y t o pr ovide
sign a ls t o t h e Body Con t r ol Modu le (BCM) a n d t h e
r ea r wiper m odu le.
Th e r igh t (wiper ) m u lt i-fu n ct ion swit ch ca n n ot be
a dju st ed or r epa ir ed. If a n y fu n ct ion of t h e swit ch is
fa u lt y, or if t h e swit ch is da m a ged, t h e en t ir e swit ch
u n it m u st be r epla ced.
Th e r igh t (wiper ) m u lt i-fu n ct ion swit ch su ppor t s
t h e followin g fu n ct ion s a n d fea t u r es:
• Au to m a tic F ro n t Wip e Mo d e - On m odels
equ ipped wit h t h e opt ion a l a u t om a t ic wiper syst em ,
t h e in t er n a l cir cu it r y a n d h a r dwa r e of t h e r igh t
(wiper ) m u lt i-fu n ct ion swit ch con t r ol kn ob pr ovide a n
a u t om a t ic fr on t wipe m ode wit h five sen sit ivit y posi-
t ion s.
• Co n tin u o u s F ro n t Wip e Mo d e s - Th e in t er n a l
cir cu it r y a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch con t r ol kn ob pr ovide t wo con t in u ou s
fr on t wipe swit ch posit ion s, low speed or h igh speed.
WJ
RI GH T M U LT I -FU N CT I ON SWI T CH (Cont inue d)
• Co n tin u o u s Re a r Wip e Mo d e - Th e in t er n a l
cir cu it r y a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch con t r ol sleeve pr ovides on e con t in u -
ou s r ea r wipe swit ch posit ion .
• F ro n t Wa s h e r Mo d e - Th e in t er n a l cir cu it r y
a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch con t r ol st a lk pr ovide fr on t wa sh er syst em
oper a t ion .
• F ro n t Wip e -Afte r-Wa s h Mo d e - Th e in t er n a l
cir cu it r y a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch con t r ol st a lk pr ovide a wipe-a ft er-
wa sh m ode.
• F ro n t Wip e r Mis t Mo d e - Th e in t er n a l cir-
cu it r y a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-fu n c-
t ion swit ch con t r ol st a lk pr ovide a fr on t wiper syst em
m ist m ode.
• In te rm itte n t F ro n t Wip e Mo d e - Th e in t er n a l
cir cu it r y a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch con t r ol kn ob pr ovide a n in t er m it t en t
fr on t wipe m ode wit h five dela y in t er va l posit ion s,
except on m odels equ ipped wit h t h e opt ion a l a u t o-
m a t ic wiper syst em .
• In te rm itte n t Re a r Wip e Mo d e - Th e in t er n a l
cir cu it r y a n d h a r dwa r e of t h e r igh t (wiper ) m u lt i-
fu n ct ion swit ch con t r ol r in g pr ovide on e fixed in t er-
va l in t er m it t en t r ea r wipe m ode swit ch posit ion .
• Re a r Wa s h e r Mo d e - Th e in t er n a l cir cu it r y a n d
h a r dwa r e of t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch
con t r ol st a lk pr ovide r ea r wa sh er syst em oper a t ion .
OPERATION
Th e r igh t (wiper ) m u lt i-fu n ct ion swit ch u ses a com -
bin a t ion of r esist or m u lt iplexed a n d con ven t ion a lly
swit ch ed ou t pu t s t o con t r ol t h e m a n y fu n ct ion s a n d
fea t u r es it pr ovides. Th e swit ch r eceives ba t t er y cu r-
r en t on a fu sed ign it ion swit ch ou t pu t (r u n -a cc) cir-
cu it fr om a fu se in t h e J u n ct ion Block (J B) wh en ever
t h e ign it ion swit ch is in t h e On or Accessor y posi-
t ion s, a n d r eceives gr ou n d fr om t h e Body Con t r ol
Modu le (BCM) on a win dsh ield wiper swit ch r et u r n
cir cu it . Th e r igh t (wiper ) m u lt i-fu n ct ion swit ch m a y
be dia gn osed u sin g con ven t ion a l dia gn ost ic t ools a n d
m et h ods.
F ollowin g a r e descr ipt ion s of h ow t h e r igh t (wiper )
m u lt i-fu n ct ion swit ch con t r ol st a lk oper a t es t o con t r ol
t h e fu n ct ion s a n d fea t u r es it pr ovides:
• Au to m a tic Wip e Mo d e - On m odels equ ipped
wit h t h e opt ion a l a u t om a t ic wiper syst em , t h e con t r ol
kn ob on t h e en d of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch con t r ol st a lk is r ot a t ed t o on e of five m in or
in t er m edia t e det en t s t o select t h e desir ed a u t om a t ic
wipe sen sit ivit y level. Th e con t r ol kn ob is r ot a t ed
r ea r wa r d (cou n t er clockwise) t o r edu ce t h e sen sit ivit y
(in cr ea se t h e in t er va l bet ween wipes), or for wa r d
(clockwise) t o in cr ea se t h e sen sit ivit y (decr ea se t h e
in t er va l bet ween wipes). Th e r igh t (wiper ) m u lt i-
FRONT WIPERS/WASHERS 8R - 21
fu n ct ion swit ch pr ovides a r esist or m u lt iplexed ou t -
pu t t o t h e Body Con t r ol Modu le (BCM) on a
win dsh ield wiper swit ch m u x cir cu it . Th e BCM
r espon ds by sen din g a n elect r on ic m essa ge t o t h e
Ra in Sen sor Modu le (RSM) over t h e P r ogr a m m a ble
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s in dica t in g
t h e select ed sen sit ivit y level, a n d by oper a t in g t h e
fr on t wiper syst em ba sed u pon elect r on ic wipe com -
m a n ds r eceived fr om t h e RSM over t h e P CI da t a bu s.
• Co n tin u o u s F ro n t Wip e Mo d e s - Th e con t r ol
kn ob on t h e en d of t h e r igh t (wiper ) m u lt i-fu n ct ion
swit ch con t r ol st a lk is r ot a t ed t o a n in t er m edia t e
det en t t h a t is on e det en t r ea r wa r d (cou n t er clockwise)
fr om t h e fu ll for wa r d (clockwise) det en t t o select t h e
low speed con t in u ou s fr on t wiper m ode, or t o it s fu ll
for wa r d (clockwise) det en t t o select t h e h igh speed
con t in u ou s fr on t wiper m ode. F or t h e low speed
m ode, t h e m u lt i-fu n ct ion swit ch pr ovides a r esist or
m u lt iplexed ou t pu t t o t h e Body Con t r ol Modu le
(BCM) on a win dsh ield wiper swit ch m u x cir cu it , a n d
t h e BCM r espon ds by en er gizin g t h e wiper on /off
r ela y in t h e P ower Dist r ibu t ion Cen t er (P DC) for t h e
fr on t low speed con t in u ou s wipe m ode. F or t h e h igh
speed m ode, t h e m u lt i-fu n ct ion swit ch pr ovides t h e
sa m e r esist or m u lt iplexed ou t pu t t o t h e BCM on t h e
win dsh ield wiper swit ch m u x cir cu it a s t h e low speed
m ode, bu t a lso pr ovides a gr ou n d ou t pu t t o t h e BCM
on a wiper h igh con t r ol cir cu it . Th e BCM r espon ds t o
t h ese in pu t s by en er gizin g t h e wiper on /off r ela y a n d
t h e wiper h igh /low r ela y in t h e P DC for t h e fr on t
h igh speed con t in u ou s wipe m ode.
• Co n tin u o u s Re a r Wip e Mo d e - Th e con t r ol
r in g on t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch con -
t r ol st a lk is r ot a t ed t o t h e m ost for wa r d (clockwise)
det en t t o select t h e con t in u ou s r ea r wiper m ode. Th e
m u lt i-fu n ct ion swit ch pr ovides a ba t t er y cu r r en t ou t -
pu t t o t h e r ea r wiper m ot or on a r ea r wiper m ot or
con t r ol cir cu it t o sign a l t h e r ea r wiper m odu le t o
oper a t e t h e r ea r wiper m ot or in t h e con t in u ou s wipe
m ode.
• F ro n t Wa s h e r Mo d e - Th e con t r ol st a lk of t h e
r igh t (wiper ) m u lt i-fu n ct ion swit ch is pu lled t owa r d
t h e st eer in g wh eel t o m om en t a r ily a ct iva t e t h e fr on t
wa sh er pu m p/m ot or in t h e fr on t wa sh er m ode. Th e
fr on t wa sh er pu m p will con t in u e t o oper a t e in t h e
fr on t wa sh er m ode u n t il t h e con t r ol st a lk is r elea sed.
Th e r igh t (wiper ) m u lt i-fu n ct ion swit ch pr ovides a
ba t t er y cu r r en t ou t pu t on a wa sh er pu m p m ot or
swit ch ou t pu t cir cu it t o en er gize t h e fr on t wa sh er
pu m p in t h e fr on t wa sh er m ode.
• F ro n t Wip e r Mis t Mo d e - Th e con t r ol st a lk of
t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch is pu sh ed
t owa r ds t h e floor t o m om en t a r ily a ct iva t e t h e fr on t
wiper m ot or in t h e m ist m ode. Th e fr on t wiper m ot or
will con t in u e t o oper a t e in t h e m ist m ode u n t il t h e
con t r ol st a lk is r elea sed. Th e r igh t (wiper ) m u lt i-
8R - 22 FRONT WIPERS/WASHERS
RI GH T M U LT I -FU N CT I ON SWI T CH (Cont inue d)
fu n ct ion swit ch pr ovides a r esist or m u lt iplexed ou t -
pu t t o t h e Body Con t r ol Modu le (BCM) on a
win dsh ield wiper swit ch m u x cir cu it , a n d t h e BCM
r espon ds by en er gizin g t h e wiper on /off r ela y in t h e
P ower Dist r ibu t ion Cen t er (P DC) t o oper a t e t h e fr on t
wiper m ot or m om en t a r ily a t low speed t o pr ovide t h e
fr on t wiper m ist m ode.
• In te rm itte n t F ro n t Wip e Mo d e - On m odels
n ot equ ipped wit h t h e opt ion a l a u t om a t ic wiper sys-
t em , t h e con t r ol kn ob on t h e en d of t h e r igh t (wiper )
m u lt i-fu n ct ion swit ch con t r ol st a lk is r ot a t ed t o on e
of five m in or in t er m edia t e det en t s t o select t h e
desir ed in t er m it t en t fr on t wipe dela y in t er va l. Th e
con t r ol kn ob is r ot a t ed r ea r wa r d (cou n t er clockwise)
t o in cr ea se t h e dela y, or for wa r d (clockwise) t o
decr ea se t h e dela y. Th e r igh t (wiper ) m u lt i-fu n ct ion
swit ch pr ovides a r esist or m u lt iplexed ou t pu t t o t h e
Body Con t r ol Modu le (BCM) on a win dsh ield wiper
swit ch m u x cir cu it . Th e BCM r espon ds by m on it or in g
elect r on ic veh icle speed m essa ges r eceived fr om t h e
P ower t r a in Con t r ol Modu le (P CM) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s,
t h en en er gizin g t h e wiper on /off r ela y in t h e P ower
Dist r ibu t ion Cen t er (P DC) t o oper a t e t h e fr on t wiper
m ot or a t t h e pr oper dela y in t er va ls.
• In te rm itte n t Re a r Wip e Mo d e - Th e con t r ol
r in g on t h e r igh t (wiper ) m u lt i-fu n ct ion swit ch con -
t r ol st a lk is r ot a t ed t o t h e cen t er det en t t o select t h e
in t er m it t en t r ea r wiper m ode. Th e r igh t (wiper )
m u lt i-fu n ct ion swit ch pr ovides a ba t t er y cu r r en t ou t -
pu t t o t h e r ea r wiper m ot or on a r ea r wiper m ot or
dela y con t r ol cir cu it t o sign a l t h e r ea r wiper m odu le
t o oper a t e t h e r ea r wiper in t h e in t er m it t en t wipe
m ode.
• Re a r Wa s h e r Mo d e - Th e r igh t (wiper ) m u lt i-
fu n ct ion swit ch con t r ol st a lk is pu sh ed for wa r d
t owa r d t h e in st r u m en t pa n el t o a m om en t a r y posi-
t ion s t o a ct iva t e t h e r ea r wa sh er pu m p/m ot or in t h e
r ea r wa sh er m ode. Th e r ea r wa sh er pu m p will con -
t in u e t o oper a t e in t h e r ea r wa sh er m ode u n t il t h e
con t r ol st a lk is r elea sed. Th e r igh t (wiper ) m u lt i-
fu n ct ion swit ch pr ovides ba t t er y cu r r en t on a r ea r
wa sh er pu m p m ot or con t r ol cir cu it t o en er gize t h e
r ea r wa sh er pu m p in t h e r ea r wa sh er m ode.
WJ
DIAGNOSIS AND TESTING - RIGHT MULTI-
FUNCTION SWITCH
Be cer t a in t o per for m t h e dia gn osis for t h e fr on t
wiper syst em , fr on t wa sh er syst em , r ea r wiper sys-
t em , a n d/or r ea r wa sh er syst em befor e t est in g t h e
r igh t m u lt i-fu n ct ion swit ch . (Refer t o 8 - E LE CTRI-
CAL/F RONT WIP E RS/WASH E RS - DIAGNOSIS
AND TE STING) or (Refer t o 8 - E LE CTRICAL/RE AR
WIP E RS/WASH E RS - DIAGNOSIS AND TE STING).
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir-
in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE PASSIVE RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG. SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE PASSIVE RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e r igh t m u lt i-fu n ct ion swit ch fr om
t h e st eer in g colu m n a n d discon n ect t h e in st r u m en t
pa n el wir e h a r n ess con n ect or for t h e swit ch fr om t h e
swit ch con n ect or r ecept a cle.
(3) Usin g a n oh m m et er, ch eck t h e r igh t m u lt i-fu n c-
t ion swit ch con t in u it y a n d r esist a n ces a t t h e swit ch
t er m in a ls a s sh own in t h e Righ t Mu lt i-F u n ct ion
Swit ch t est ch a r t (F ig. 17).
WJ FRONT WIPERS/WASHERS 8R - 23
RI GH T M U LT I -FU N CT I ON SWI T CH (Cont inue d)

Fig. 17 Right Multi-Function Switch Tests

RIGHT (WIPER) MULTI-FUNCTION SWITCH

FRONT WIPER/WASHER SWITCH TESTS
RESISTANCE RESISTANCE RANGE
SWITCH POSITION CONTINUITY BETWEEN
BETWEEN (OHMS)
Off - Pins 7 & 8 4286-4379
Intermittent Wipe or
- Pins 7 & 8 1445-1480
Sensitivity Position 1
Intermittent Wipe or
- Pins 7 & 8 847-870
Sensitivity Position 2
Intermittent Wipe or
- Pins 7 & 8 556-573
Sensitivity Position 3
Intermittent Wipe or
- Pins 7 & 8 367-380
Sensitivity Position 4
Intermittent Wipe or
- Pins 7 & 8 218-229
Sensitivity Position 5
Low Speed - Pins 7 & 8 99-106
High Speed Pins 7 & 9 Pins 7 & 8 99-106
Mist - Pins 7 & 8 49-56
Wash Pins 1 & 3 - -
REAR WIPER/WASHER SWITCH TESTS
RESISTANCE
SWITCH POSITION CONTINUITY BETWEEN RESISTANCE BETWEEN
BETWEEN
Off - - -
Delay Pins 1 & 6 - -
On Pins 1 & 5 - -
Wash Pins 1 & 5 & 6 & 2 - -
8R - 24 FRONT WIPERS/WASHERS WJ
RI GH T M U LT I -FU N CT I ON SWI T CH (Cont inue d)
(4) If t h e r igh t m u lt i-fu n ct ion swit ch fa ils a n y of (3) Un sn a p t h e t wo h a lves of t h e t ilt in g st eer in g
t h e con t in u it y or r esist a n ce t est s, r epla ce t h e fa u lt y colu m n sh r ou d fr om ea ch ot h er a n d r em ove bot h
r igh t m u lt i-fu n ct ion swit ch a s r equ ir ed. h a lves fr om t h e st eer in g colu m n .
(4) Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
REMOVAL con n ect or for t h e r igh t m u lt i-fu n ct ion swit ch fr om t h e
swit ch con n ect or r ecept a cle.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (5) Rem ove t h e t wo scr ews t h a t secu r e t h e r igh t
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE m u lt i-fu n ct ion swit ch t o t h e m u lt i-fu n ct ion swit ch
ATTEMPTING ANY STEERING WHEEL, STEERING m ou n t in g h ou sin g (F ig. 19).
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive

ca ble.
(2) Rem ove t h e scr ew t h a t secu r es t h e lower t ilt in g
st eer in g colu m n sh r ou d t o t h e st eer in g colu m n m u lt i-
fu n ct ion swit ch m ou n t in g h ou sin g (F ig. 18).
Fig. 19 Right Multi-Function Switch Remove/Install
1 - STEERING COLUMN
2 - SCREWS (2)
3 - RIGHT MULTI-FUNCTION SWITCH
4 - MULTI-FUNCTION SWITCH MOUNTING HOUSING

(6) Rem ove t h e r igh t m u lt i-fu n ct ion swit ch fr om

t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g.

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 18 Steering Column Shrouds Remove/Install
1 - UPPER TILTING COLUMN SHROUD
(1) P osit ion t h e r igh t m u lt i-fu n ct ion swit ch on t o
2 - FIXED COLUMN SHROUD t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g (F ig. 19).
3 - LOWER TILTING COLUMN SHROUD (2) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
4 - SCREW t h e r igh t m u lt i-fu n ct ion swit ch t o t h e m u lt i-fu n ct ion
WJ
RI GH T M U LT I -FU N CT I ON SWI T CH (Cont inue d)
swit ch m ou n t in g h ou sin g. Tigh t en t h e scr ews t o 2.5
N·m (22 in . lbs.).
(3) Recon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e r igh t m u lt i-fu n ct ion swit ch t o t h e
swit ch con n ect or r ecept a cle.
(4) P osit ion t h e lower t ilt in g st eer in g colu m n
sh r ou d t o t h e u n der side of t h e st eer in g colu m n (F ig.
18).
(5) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
lower t ilt in g st eer in g colu m n sh r ou d t o t h e m u lt i-
fu n ct ion swit ch m ou n t in g h ou sin g. Tigh t en t h e scr ew
t o 1.9 N·m (17 in . lbs.).
(6) P osit ion t h e u pper t ilt in g colu m n sh r ou d over
t h e st eer in g colu m n wit h t h e h a za r d wa r n in g swit ch
bu t t on in ser t ed t h r ou gh t h e h ole in t h e u pper su r fa ce
of t h e sh r ou d. Align t h e u pper t ilt in g st eer in g colu m n
sh r ou d t o t h e lower sh r ou d a n d sn a p t h e t wo sh r ou d
h a lves t oget h er.
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
WASH ER FLU I D LEV EL
SWI T CH
DESCRIPTION
Fig. 20 Washer Fluid Level Switch (Viewed from
Bottom of Reservoir)
1 - REAR WASHER PUMP/MOTOR
2 - FRONT WASHER PUMP/MOTOR
3 - WASHER FLUID LEVEL SWITCH
Th e wa sh er flu id level swit ch is a sin gle pole, sin -
gle t h r ow r eed-t ype swit ch m ou n t ed n ea r t h e fr on t of
t h e wa sh er r eser voir, for wa r d of t h e t wo wa sh er
pu m p/m ot or s (F ig. 20). On ly t h e m olded pla st ic
swit ch m ou n t in g fla n ge a n d con n ect or r ecept a cle a r e
visible wh en t h e swit ch is in st a lled in t h e r eser voir.
FRONT WIPERS/WASHERS 8R - 25
A sh or t n ipple for m a t ion ext en ds fr om t h e in n er su r-
fa ce of t h e swit ch m ou n t in g fla n ge, a n d a ba r b on t h e
n ipple n ea r t h e swit ch m ou n t in g fla n ge is pr ess-fit
in t o a r u bber gr om m et sea l in st a lled in t h e m ou n t in g
h ole of t h e r eser voir. A sm a ll pla st ic floa t pivot s on
t h e en d of a br a cket t h a t ext en ds fr om t h e swit ch
n ipple for m a t ion . Wit h in t h e floa t is a sm a ll m a gn et ,
wh ich a ct u a t es t h e r eed swit ch . Th e wa sh er flu id
level swit ch ca n n ot be a dju st ed or r epa ir ed. If fa u lt y
or da m a ged, t h e swit ch m u st be r epla ced.
OPERATION
Th e wa sh er flu id level swit ch u ses a pivot in g,
oblon g floa t t o m on it or t h e level of t h e wa sh er flu id
in t h e wa sh er r eser voir. Th e floa t con t a in s a sm a ll
m a gn et . Wh en t h e floa t pivot s, t h e ch a n gin g pr oxim -
it y of it s m a gn et ic field will ca u se t h e con t a ct s of t h e
sm a ll, st a t ion a r y r eed swit ch t o open or close. Wh en
t h e flu id level in t h e wa sh er r eser voir is a t or a bove
t h e floa t level, t h e floa t m oves t o a ver t ica l posit ion
a n d t h e swit ch con t a ct s open . Wh en t h e flu id level in
t h e wa sh er r eser voir fa lls below t h e pivot in g floa t ,
t h e floa t m oves t o a h or izon t a l posit ion a n d t h e
swit ch con t a ct s close. Th e swit ch is con n ect ed t o t h e
veh icle elect r ica l syst em t h r ou gh a dedica t ed t a ke
ou t a n d con n ect or of t h e left h ea dla m p a n d da sh wir e
h a r n ess. Th e swit ch r eceives a five volt r efer en ce sig-
n a l fr om t h e Body Con t r ol Modu le (BCM) t h r ou gh
t h e wa sh er flu id swit ch ou t pu t cir cu it . Th e swit ch is
gr ou n ded a t a ll t im es t h r ou gh a n ot h er t a ke ou t of
t h e left h ea dla m p a n d da sh wir e h a r n ess wit h a sin -
gle eyelet t er m in a l con n ect or t h a t is secu r ed u n der a
gr ou n d scr ew n ea r t h e t op of t h e left fr on t fen der
in n er sh ield in t h e en gin e com pa r t m en t .
Wh en t h e swit ch closes, t h e BCM sen ses t h e volt -
a ge ch a n ge on t h e cir cu it . Th e BCM is pr ogr a m m ed
t o sen d low wa sh er flu id m essa ges t o t h e E lect r on ic
Veh icle In for m a t ion Cen t er (E VIC) over t h e P r ogr a m -
m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s. Th e
E VIC is pr ogr a m m ed t o r espon d t o t h is m essa ge by
displa yin g t h e Wa sh er F lu id Low wa r n in g a n d sen d-
in g a ch im e r equ est m essa ge ba ck t o t h e BCM over
t h e P CI da t a bu s. Th en t h e BCM gen er a t es a n a u di-
ble ch im e t on e wa r n in g. A r esist or wit h in t h e wa sh er
flu id level swit ch a llows t h e BCM t o m on it or a n d
dia gn ose t h is cir cu it . Th e BCM will st or e a Dia gn os-
t ic Tr ou ble Code (DTC) for a n y fa u lt t h a t it det ect s.
F or r et r ieva l of t h is fa u lt in for m a t ion a n d fu r t h er
dia gn osis of t h e wa sh er flu id level swit ch , t h e BCM,
t h e E VIC, t h e P CI da t a bu s, t h e BCM m essa ge ou t -
pu t s t o t h e E VIC t h a t con t r ol t h e Low Wa sh er F lu id
in dica t or, or t h e E VIC m essa ge ou t pu t s t o t h e BCM
t h a t con t r ol ch im e ser vice, a DRBIII! sca n t ool a n d
t h e a ppr opr ia t e dia gn ost ic in for m a t ion a r e r equ ir ed.
8R - 26 FRONT WIPERS/WASHERS WJ
WASH ER FLU I D LEV EL SWI T CH (Cont inue d)

REMOVAL
Th e wa sh er flu id level swit ch ca n be r em oved fr om
t h e wa sh er r eser voir wit h ou t r em ovin g t h e r eser voir
fr om t h e veh icle.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e on e scr ew t h a t secu r es t h e wa sh er
r eser voir filler n eck t o t h e left in n er fen der sh ield.
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Rem ove t h e lin er fr om t h e left fr on t fen der
wh eel h ou se.
(5) Discon n ect t h e wa sh er h ose fr om t h e ba r bed
ou t let n ipple of t h e r ea r m ost (fr on t ) wa sh er pu m p/
m ot or u n it a n d a llow t h e wa sh er flu id t o dr a in in t o a
clea n con t a in er for r eu se.
(6) Rem ove t h e t wo scr ews t h a t secu r e t h e in boa r d
m ou n t in g fla n ge of t h e wa sh er r eser voir t o t h e left
in n er wh eel h ou se.
(7) P u ll t h e bot t om of t h e wa sh er r eser voir r ea r-
wa r d fa r en ou gh t o a ccess t h e left h ea dla m p a n d
da sh wir e h a r n ess con n ect or for t h e wa sh er flu id
level swit ch on t h e fr on t of t h e r eser voir.
Fig. 21 Washer Fluid Level Switch Remove/Install
(8) Discon n ect t h e left h ea dla m p a n d da sh wir e
1 - WASHER RESERVOIR
h a r n ess con n ect or for t h e wa sh er flu id level swit ch
2 - WASHER FLUID LEVEL SWITCH
fr om t h e swit ch con n ect or r ecept a cle.
3 - GROMMET SEAL
(9) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y t h e ba r bed n ipple of t h e
wa sh er flu id level swit ch ou t of t h e r u bber gr om m et (4) Recon n ect t h e left h ea dla m p a n d da sh wir e
sea l on t h e fr on t of t h e r eser voir (F ig. 21). Ca r e m u st h a r n ess con n ect or for t h e wa sh er flu id level swit ch t o
be t a ken n ot t o da m a ge t h e r eser voir. t h e swit ch con n ect or r ecept a cle.
(10) Rem ove t h e wa sh er flu id level swit ch a n d (5) Recon n ect t h e wa sh er h ose t o t h e ba r bed ou t let
floa t fr om t h e wa sh er r eser voir. n ipple of t h e fr on t wa sh er pu m p/m ot or u n it .
(11) Rem ove t h e r u bber gr om m et sea l fr om t h e (6) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
wa sh er flu id level swit ch m ou n t in g h ole in t h e t h e in boa r d m ou n t in g fla n ge of t h e wa sh er r eser voir
wa sh er r eser voir a n d disca r d. t o t h e left in n er wh eel h ou se. Tigh t en t h e scr ews t o
7.4 N·m (66 in . lbs.).
INSTALLATION (7) Rein st a ll t h e lin er in t o t h e left fr on t fen der
(1) In st a ll a n ew r u bber gr om m et sea l in t o t h e wh eel h ou se.
wa sh er flu id level swit ch m ou n t in g h ole in t h e fr on t (8) Lower t h e veh icle.
of t h e wa sh er r eser voir. Alwa ys u se a n ew r u bber (9) In st a ll a n d t igh t en t h e on e scr ew t h a t secu r es
gr om m et sea l on t h e r eser voir. t h e wa sh er r eser voir filler n eck t o t h e left in n er
(2) P osit ion t h e floa t of t h e wa sh er flu id level fen der sh ield. Tigh t en t h e scr ew t o 7.4 N·m (66 in .
swit ch t h r ou gh t h e r u bber gr om m et sea l in t h e lbs.).
wa sh er r eser voir (F ig. 21). Th e con n ect or r ecept a cle (10) F ill t h e wa sh er r eser voir wit h t h e wa sh er
of t h e wa sh er flu id level swit ch sh ou ld be poin t ed flu id dr a in ed fr om t h e r eser voir du r in g t h e r em ova l
down wa r d. pr ocedu r e.
(3) P r ess fir m ly a n d even ly on t h e wa sh er flu id (11) Recon n ect t h e ba t t er y n ega t ive ca ble.
level swit ch u sin g h a n d pr essu r e u n t il t h e ba r bed
n ipple is fu lly sea t ed in t h e r u bber gr om m et sea l in
t h e wa sh er r eser voir m ou n t in g h ole.
WJ
WASH ER RESERV OI R
DESCRIPTION
Fig. 22 Washer Reservoir
1 - LEFT FENDER INNER SHIELD
2 - SCREW (2)
3 - WASHER PUMP WIRE HARNESS CONNECTORS
4 - WASHER FLUID LEVEL SWITCH WIRE HARNESS
CONNECTOR
5 - WASHER RESERVOIR
A sin gle wa sh er flu id r eser voir is u sed for bot h t h e
fr on t a n d r ea r wa sh er syst em s (F ig. 22). Th e m olded
pla st ic wa sh er flu id r eser voir is con cea led bet ween
t h e left fr on t in n er a n d ou t er fen der pa n els, beh in d
t h e in n er fen der lin er in fr on t of t h e left fr on t wh eel.
Th e on ly visible com pon en t of t h e wa sh er r eser voir is
t h e filler n eck a n d ca p u n it , wh ich ext en ds t h r ou gh a
h ole in t h e left fr on t wh eel h ou se ext en sion pa n el
in t o t h e en gin e com pa r t m en t . A br igh t yellow pla st ic
filler ca p wit h a r u bber sea l a n d a n In t er n a t ion a l
Con t r ol a n d Displa y Sym bol icon for “Win dsh ield
Wa sh er ” a n d t h e t ext “Wa sh er F lu id On ly” m olded
in t o it sn a ps over t h e open en d of t h e filler n eck. Th e
ca p h in ges on a n d is secu r ed t o a m olded-in h ook for-
m a t ion on t h e r ea r of t h e r eser voir filler n eck.
FRONT WIPERS/WASHERS 8R - 27
Th er e a r e sepa r a t e, dedica t ed h oles on t h e ou t -
boa r d side of t h e r eser voir pr ovided for t h e m ou n t in g
of t h e fr on t a n d r ea r wa sh er /pu m p m ot or u n it s, a n d
a n ot h er dedica t ed h ole on t h e fr on t of t h e r eser voir
for t h e wa sh er flu id level swit ch . Th e in boa r d side of
t h e wa sh er r eser voir h a s a n in t egr a l fla n ge t h a t is
secu r ed t o t h e in side of t h e left fr on t fen der wh eel
h ou se by t wo scr ews, wh ile a n in t egr a l m olded t a b
en ga ges a slot in t h e left fr on t fen der in n er sh ield t o
su ppor t t h e ou t boa r d side of t h e r eser voir. An ot h er
scr ew secu r es t h e r eser voir filler n eck t o t h e left
fr on t fen der in n er sh ield n ea r t h e fr on t of t h e en gin e
com pa r t m en t . Th e left fr on t fen der wh eel h ou se
in n er lin er m u st be r em oved t o a ccess t h e wa sh er
r eser voir for ser vice.
Th e wa sh er r eser voir ca n n ot be r epa ir ed a n d, if
fa u lt y or da m a ged, it m u st be r epla ced. Th e wa sh er
r eser voir, t h e gr om m et sea ls for t h e wa sh er pu m p/
m ot or u n it s a n d t h e wa sh er flu id level swit ch , a n d
t h e filler ca p a r e ea ch a va ila ble for ser vice r epla ce-
m en t .
OPERATION
Th e wa sh er flu id r eser voir pr ovides a secu r e,
on -veh icle st or a ge loca t ion for a la r ge r eser ve of
wa sh er flu id for oper a t ion of t h e fr on t a n d r ea r
wa sh er syst em s. Th e wa sh er r eser voir filler n eck pr o-
vides a clea r ly m a r ked a n d r ea dily a ccessible poin t
fr om wh ich t o a dd wa sh er flu id t o t h e r eser voir. Th e
fr on t a n d r ea r wa sh er /pu m p m ot or u n it s a r e loca t ed
in a su m p a r ea n ea r t h e fr on t of t h e r eser voir t o be
cer t a in t h a t wa sh er flu id will be a va ila ble t o t h e
pu m ps a s t h e flu id level in t h e r eser voir becom es
deplet ed. Th e fr on t wa sh er pu m p/m ot or u n it is
m ou n t ed in t h e lowest posit ion in t h e su m p so t h a t
t h e fr on t wa sh er s will oper a t e even a ft er t h e r ea r
wa sh er syst em will n o lon ger oper a t e. Th e wa sh er
flu id level swit ch is m ou n t ed ju st a bove t h e su m p
a r ea of t h e r eser voir so t h a t t h er e will be a dequ a t e
wa r n in g t o t h e veh icle oper a t or t h a t t h e wa sh er flu id
level is low, befor e t h e wa sh er syst em will n o lon ger
oper a t e.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e a ir clea n er h ou sin g fr om t h e t op of
t h e left fr on t fen der wh eel h ou se. (Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - RE MOVAL).
8R - 28 FRONT WIPERS/WASHERS
WASH ER RESERV OI R (Cont inue d)
(3) Discon n ect t h e t wo wa sh er r eser voir wa sh er
h oses fr om t h e t wo en gin e com pa r t m en t wa sh er
h oses a t t h e in lin e con n ect or s loca t ed on t h e t op of
t h e left fr on t fen der wh eel h ou se (F ig. 23).
Fig. 23 Washer Reservoir Filler Neck Mounting
1 - WASHER RESERVOIR
2 - SCREW
3 - WASHER HOSES FROM PUMPS
4 - WASHER HOSES TO NOZZLES
5 - LEFT FENDER INNER SHIELD
(4) Open t h e wa sh er r eser voir filler ca p a n d
u n sn a p t h e filler ca p h in ge fr om t h e h ook on t h e
filler n eck.
(5) Rem ove t h e on e scr ew t h a t secu r es t h e wa sh er
r eser voir filler n eck t o t h e left in n er fen der sh ield.
(6) Ra ise a n d su ppor t t h e veh icle.
(7) Rem ove t h e lin er fr om t h e left fr on t fen der
wh eel h ou se.
(8) Discon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or s for t h e t wo wa sh er pu m p/m ot or
u n it s fr om t h e pu m p/m ot or con n ect or r ecept a cles
(F ig. 24).
(9) Rem ove t h e t wo scr ews t h a t secu r e t h e in boa r d
m ou n t in g fla n ge of t h e wa sh er r eser voir t o t h e left
fr on t in n er wh eel h ou se.
(10) P u ll t h e bot t om of t h e wa sh er r eser voir r ea r-
wa r d fa r en ou gh t o a ccess t h e left h ea dla m p a n d
da sh wir e h a r n ess con n ect or for t h e wa sh er flu id
level swit ch on t h e fr on t of t h e r eser voir.
(11) Discon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e wa sh er flu id level swit ch
fr om t h e swit ch con n ect or r ecept a cle.
(12) P u ll t h e bot t om of t h e wa sh er r eser voir r ea r-
wa r d fa r en ou gh t o disen ga ge t h e ou t boa r d m ou n t in g
t a b fr om t h e m ou n t in g slot on t h e left fr on t in n er
fen der sh ield.
WJ
Fig. 24 Washer Reservoir
1 - LEFT FENDER INNER SHIELD
2 - SCREW (2)
3 - WASHER PUMP WIRE HARNESS CONNECTORS
4 - WASHER FLUID LEVEL SWITCH WIRE HARNESS
CONNECTOR
5 - WASHER RESERVOIR
(13) Rot a t e t h e wa sh er r eser voir fa r en ou gh so
t h a t t h e in boa r d m ou n t in g fla n ge clea r s t h e fr on t
su spen sion com pon en t s, t h en lower t h e r eser voir fa r
en ou gh t o disen ga ge t h e filler n eck fr om t h e h ole in
t h e left fr on t wh eel h ou se ext en sion .
(14) Rem ove t h e wa sh er r eser voir fr om t h e left
fr on t fen der wh eel h ou se.
INSTALLATION
(1) P osit ion t h e wa sh er r eser voir in t o t h e left fr on t
fen der wh eel h ou se.
(2) Ra ise t h e wa sh er r eser voir filler n eck t h r ou gh
t h e h ole in t h e left fr on t fen der wh eelh ou se ext en sion
in t o t h e en gin e com pa r t m en t a n d r ot a t e t h e r eser voir
a s n eeded t o or ien t t h e in boa r d m ou n t in g fla n ge over
t h e t op of t h e fr on t su spen sion com pon en t s.
(3) P u ll t h e bot t om of t h e wa sh er r eser voir r ea r-
wa r d fa r en ou gh t o en ga ge t h e ou t boa r d m ou n t in g
t a b wit h t h e m ou n t in g slot in t h e left fr on t in n er
fen der sh ield (F ig. 24).
(4) P u ll t h e bot t om of t h e wa sh er r eser voir r ea r-
wa r d fa r en ou gh t o a ccess t h e wa sh er flu id level
swit ch con n ect or r ecept a cle on t h e fr on t of t h e r eser-
voir.
(5) Recon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e wa sh er flu id level swit ch t o
t h e swit ch con n ect or r ecept a cle.
WJ
WASH ER RESERV OI R (Cont inue d)
(6) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e
t h e in boa r d m ou n t in g fla n ge of t h e wa sh er r eser voir
t o t h e left in n er wh eel h ou se. Tigh t en t h e scr ews t o
7.4 N·m (66 in . lbs.).
(7) Recon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or s for t h e t wo wa sh er pu m p/m ot or
u n it s t o t h e pu m p/m ot or u n it con n ect or r ecept a cles.
(8) Rein st a ll t h e lin er in t o t h e left fr on t fen der
wh eel h ou se.
(9) Lower t h e veh icle.
(10) In st a ll a n d t igh t en t h e on e scr ew t h a t secu r es
t h e wa sh er r eser voir filler n eck t o t h e left in n er
fen der sh ield (F ig. 23). Tigh t en t h e scr ew t o 7.4 N·m
(66 in . lbs.).
(11) Rein st a ll t h e wa sh er r eser voir filler ca p h in ge
on t o t h e h ook on t h e filler n eck a n d close t h e ca p.
(12) Recon n ect t h e t wo wa sh er r eser voir wa sh er
h oses t o t h e t wo en gin e com pa r t m en t wa sh er h oses
a t t h e in lin e con n ect or s loca t ed on t h e t op of t h e left
fr on t fen der wh eel h ou se.
(13) Rein st a ll t h e a ir clea n er h ou sin g on t o t h e t op
of t h e left fr on t fen der wh eel h ou se. (Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - INSTALLATION).
(14) Recon n ect t h e ba t t er y n ega t ive ca ble.
WI PER H I GH /LOW RELAY
DESCRIPTION
Fig. 25 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
FRONT WIPERS/WASHERS 8R - 29
Th e wiper h igh /low r ela y is loca t ed in t h e P ower
Dist r ibu t ion Cen t er (P DC) in t h e en gin e com pa r t -
m en t n ea r t h e ba t t er y. Th e wiper h igh /low r ela y is a
con ven t ion a l In t er n a t ion a l St a n da r ds Or ga n iza t ion
(ISO) m icr o r ela y (F ig. 25). Rela ys con for m in g t o t h e
ISO specifica t ion s h a ve com m on ph ysica l dim en sion s,
cu r r en t ca pa cit ies, t er m in a l pa t t er n s, a n d t er m in a l
fu n ct ion s. Th e r ela y is con t a in ed wit h in a sm a ll, r ect -
a n gu la r, m olded pla st ic h ou sin g a n d is con n ect ed t o
a ll of t h e r equ ir ed in pu t s a n d ou t pu t s by five in t egr a l
m a le spa de-t ype t er m in a ls t h a t ext en d fr om t h e bot -
t om of t h e r ela y ba se.
Th e wiper h igh /low r ela y ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e u n it m u st be
r epla ced.
OPERATION
Th e wiper h igh /low r ela y is a n elect r om ech a n ica l
swit ch t h a t u ses a low cu r r en t in pu t fr om t h e Body
Con t r ol Modu le (BCM) t o con t r ol a h igh cu r r en t ou t -
pu t t o t h e fr on t wiper m ot or. Th e m ova ble com m on
feed con t a ct poin t is h eld a ga in st t h e fixed n or m a lly
closed con t a ct poin t by spr in g pr essu r e. Wh en t h e
r ela y coil is en er gized, a n elect r om a gn et ic field is
pr odu ced by t h e coil win din gs. Th is elect r om a gn et ic
field dr a ws t h e m ova ble r ela y con t a ct poin t a wa y
fr om t h e fixed n or m a lly closed con t a ct poin t , a n d
h olds it a ga in st t h e fixed n or m a lly open con t a ct
poin t . Wh en t h e r ela y coil is de-en er gized, spr in g
pr essu r e r et u r n s t h e m ova ble con t a ct poin t ba ck
a ga in st t h e fixed n or m a lly closed con t a ct poin t . A
r esist or is con n ect ed in pa r a llel wit h t h e r ela y coil in
t h e r ela y, a n d h elps t o dissipa t e volt a ge spikes a n d
elect r om a gn et ic in t er fer en ce t h a t ca n be gen er a t ed a s
t h e elect r om a gn et ic field of t h e r ela y coil colla pses.
Th e wiper h igh /low r ela y t er m in a ls a r e con n ect ed
t o t h e veh icle elect r ica l syst em t h r ou gh a con n ect or
r ecept a cle in t h e P ower Dist r ibu t ion Cen t er (P DC).
Th e in pu t s a n d ou t pu t s of t h e wiper h igh /low r ela y
in clu de:
• Co m m o n F e e d Te rm in a l - Th e com m on feed
t er m in a l (30) is con n ect ed t o t h e ou t pu t of t h e wiper
on /off r ela y a t a ll t im es t h r ou gh t h e wiper on /off
r ela y ou t pu t cir cu it .
• Co il Gro u n d Te rm in a l - Th e coil gr ou n d t er m i-
n a l (85) is con n ect ed t o a con t r ol ou t pu t of t h e Body
Con t r ol Modu le (BCM) t h r ou gh a fr on t wiper h igh /
low r ela y con t r ol cir cu it . Th e BCM con t r ols fr on t
wiper m ot or oper a t ion by con t r ollin g a gr ou n d pa t h
t h r ou gh t h is cir cu it .
• Co il B a tte ry Te rm in a l - Th e coil ba t t er y t er-
m in a l (86) r eceives ba t t er y cu r r en t a t a ll t im es fr om
a cir cu it br ea ker in t h e J u n ct ion Block (J B) t h r ou gh
a fu sed ign it ion swit ch ou t pu t (r u n -a cc) cir cu it .
8R - 30 FRONT WIPERS/WASHERS
WI PER H I GH /LOW RELAY (Cont inue d)
• N o rm a lly Op e n Te rm in a l - Th e n or m a lly open
t er m in a l (87) is con n ect ed t o t h e h igh speed br u sh of
t h e fr on t wiper m ot or t h r ou gh a fr on t wiper h igh /low
r ela y h igh speed ou t pu t cir cu it , a n d is con n ect ed t o
t h e h igh speed br u sh wh en ever t h e r ela y is en er-
gized.
• N o rm a lly Clo s e d Te rm in a l - Th e n or m a lly
closed t er m in a l (87A) is con n ect ed t o t h e low speed
br u sh of t h e fr on t wiper m ot or t h r ou gh a fr on t wiper
h igh /low r ela y low speed ou t pu t cir cu it , a n d is con -
n ect ed t o t h e low speed br u sh wh en ever t h e r ela y is
de-en er gized.
Th e wiper h igh /low r ela y ca n be dia gn osed u sin g
con ven t ion a l dia gn ost ic t ools a n d m et h ods.
DIAGNOSIS AND TESTING - WIPER HIGH/LOW
RELAY
Th e wiper h igh /low r ela y (F ig. 26) is loca t ed in t h e
P ower Dist r ibu t ion Cen t er (P DC) in t h e en gin e com -
pa r t m en t n ea r t h e ba t t er y. Refer t o t h e a ppr opr ia t e
wir in g in for m a t ion . Th e wir in g in for m a t ion in clu des
wir in g dia gr a m s, pr oper wir e a n d con n ect or r epa ir
pr ocedu r es, det a ils of wir e h a r n ess r ou t in g a n d
r et en t ion , con n ect or pin -ou t in for m a t ion a n d loca t ion
views for t h e va r iou s wir e h a r n ess con n ect or s, splices
a n d gr ou n ds.
Fig. 26 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
(1) Rem ove t h e wiper h igh /low r ela y fr om t h e
P DC. (Refer t o 8 - E LE CTRICAL/WIP E RS/WASH -
E RS/WIP E R H IGH /LOW RE LAY - RE MOVAL).
(2) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
WJ
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(3) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ± 8 oh m s. If OK, go t o St ep
4. If n ot OK, r epla ce t h e fa u lt y r ela y.
(4) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A
a n d 30. If OK, r ein st a ll t h e r ela y a n d u se a DRBIII!
sca n t ool t o per for m fu r t h er t est in g. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e cover fr om t h e P ower Dist r ibu t ion
Cen t er (P DC) (F ig. 27).
Fig. 27 Power Distribution Center
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
(3) See t h e fu se a n d r ela y la you t la bel a ffixed t o
t h e u n der side of t h e P DC cover for wiper h igh /low
r ela y iden t ifica t ion a n d loca t ion .
(4) Rem ove t h e wiper h igh /low r ela y by gr a spin g it
fir m ly a n d pu llin g it st r a igh t ou t fr om t h e r ecept a cle
in t h e P DC.
INSTALLATION
(1) See t h e fu se a n d r ela y la you t la bel a ffixed t o
t h e u n der side of t h e P DC cover for t h e pr oper wiper
h igh /low r ela y loca t ion (F ig. 27).
WJ
WI PER H I GH /LOW RELAY (Cont inue d)
(2) P osit ion t h e wiper h igh /low r ela y in t h e pr oper
r ecept a cle in t h e P DC.
(3) Align t h e wiper h igh /low r ela y t er m in a ls wit h
t h e t er m in a l ca vit ies in t h e P DC r ecept a cle.
(4) P u sh fir m ly a n d even ly on t h e t op of t h e wiper
h igh /low r ela y u n t il t h e t er m in a ls a r e fu lly sea t ed in
t h e t er m in a l ca vit ies in t h e P DC r ecept a cle.
(5) Rein st a ll t h e cover on t o t h e P DC.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
WI PER ON /OFF RELAY
DESCRIPTION
Fig. 28 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
Th e wiper on /off r ela y is loca t ed in t h e P ower Dis-
t r ibu t ion Cen t er (P DC) in t h e en gin e com pa r t m en t
n ea r t h e ba t t er y. Th e wiper on /off r ela y is a con ven -
t ion a l In t er n a t ion a l St a n da r ds Or ga n iza t ion (ISO)
m icr o r ela y (F ig. 28). Rela ys con for m in g t o t h e ISO
specifica t ion s h a ve com m on ph ysica l dim en sion s, cu r-
r en t ca pa cit ies, t er m in a l pa t t er n s, a n d t er m in a l fu n c-
t ion s. Th e r ela y is con t a in ed wit h in a sm a ll,
r ect a n gu la r, m olded pla st ic h ou sin g a n d is con n ect ed
t o a ll of t h e r equ ir ed in pu t s a n d ou t pu t s by five in t e-
gr a l m a le spa de-t ype t er m in a ls t h a t ext en d fr om t h e
bot t om of t h e r ela y ba se.
Th e wiper on /off r ela y ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e u n it m u st be
r epla ced.
FRONT WIPERS/WASHERS 8R - 31
OPERATION
Th e wiper on /off r ela y is a n elect r om ech a n ica l
swit ch t h a t u ses a low cu r r en t in pu t fr om t h e Body
Con t r ol Modu le (BCM) t o con t r ol a h igh cu r r en t ou t -
pu t t o t h e fr on t wiper m ot or. Th e m ova ble com m on
feed con t a ct poin t is h eld a ga in st t h e fixed n or m a lly
closed con t a ct poin t by spr in g pr essu r e. Wh en t h e
r ela y coil is en er gized, a n elect r om a gn et ic field is
pr odu ced by t h e coil win din gs. Th is elect r om a gn et ic
field dr a ws t h e m ova ble r ela y con t a ct poin t a wa y
fr om t h e fixed n or m a lly closed con t a ct poin t , a n d
h olds it a ga in st t h e fixed n or m a lly open con t a ct
poin t . Wh en t h e r ela y coil is de-en er gized, spr in g
pr essu r e r et u r n s t h e m ova ble con t a ct poin t ba ck
a ga in st t h e fixed n or m a lly closed con t a ct poin t . A
r esist or is con n ect ed in pa r a llel wit h t h e r ela y coil in
t h e r ela y, a n d h elps t o dissipa t e volt a ge spikes a n d
elect r om a gn et ic in t er fer en ce t h a t ca n be gen er a t ed a s
t h e elect r om a gn et ic field of t h e r ela y coil colla pses.
Th e wiper on /off r ela y t er m in a ls a r e con n ect ed t o
t h e veh icle elect r ica l syst em t h r ou gh a con n ect or
r ecept a cle in t h e P ower Dist r ibu t ion Cen t er (P DC).
Th e in pu t s a n d ou t pu t s of t h e wiper on /off r ela y
in clu de:
• Co m m o n F e e d Te rm in a l - Th e com m on feed
t er m in a l (30) is con n ect ed t o t h e com m on feed t er m i-
n a l of t h e wiper h igh /low r ela y a t a ll t im es t h r ou gh
t h e wiper on /off r ela y ou t pu t cir cu it .
• Co il Gro u n d Te rm in a l - Th e coil gr ou n d t er m i-
n a l (85) is con n ect ed t o a con t r ol ou t pu t of t h e Body
Con t r ol Modu le (BCM) t h r ou gh a fr on t wiper on /off
r ela y con t r ol cir cu it . Th e BCM con t r ols fr on t wiper
m ot or oper a t ion by con t r ollin g a gr ou n d pa t h t h r ou gh
t h is cir cu it .
• Co il B a tte ry Te rm in a l - Th e coil ba t t er y t er-
m in a l (86) r eceives ba t t er y cu r r en t a t a ll t im es fr om
a cir cu it br ea ker in t h e J u n ct ion Block (J B) t h r ou gh
a fu sed ign it ion swit ch ou t pu t (r u n -a cc) cir cu it .
• N o rm a lly Op e n Te rm in a l - Th e n or m a lly open
t er m in a l (87) r eceives ba t t er y cu r r en t a t a ll t im es
fr om a cir cu it br ea ker in t h e J u n ct ion Block (J B)
t h r ou gh a fu sed ign it ion swit ch ou t pu t (r u n -a cc) cir-
cu it , a n d pr ovides ba t t er y cu r r en t t o t h e fr on t wiper
on /off r ela y ou t pu t cir cu it wh en ever t h e r ela y is en er-
gized.
• N o rm a lly Clo s e d Te rm in a l - Th e n or m a lly
closed t er m in a l (87A) is con n ect ed t o t h e wiper pa r k
swit ch in t h e fr on t wiper m ot or t h r ou gh t h e fr on t
wiper pa r k swit ch sen se cir cu it , a n d is con n ect ed t o
t h e wiper pa r k swit ch wh en ever t h e r ela y is de-en er-
gized.
Th e wiper on /off r ela y ca n be dia gn osed u sin g con -
ven t ion a l dia gn ost ic t ools a n d m et h ods.
8R - 32 FRONT WIPERS/WASHERS
WI PER ON /OFF RELAY (Cont inue d)
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY
Th e wiper on /off r ela y (F ig. 29) is loca t ed in t h e
P ower Dist r ibu t ion Cen t er (P DC) in t h e en gin e com -
pa r t m en t n ea r t h e ba t t er y. Refer t o t h e a ppr opr ia t e
wir in g in for m a t ion . Th e wir in g in for m a t ion in clu des
wir in g dia gr a m s, pr oper wir e a n d con n ect or r epa ir
pr ocedu r es, det a ils of wir e h a r n ess r ou t in g a n d
r et en t ion , con n ect or pin -ou t in for m a t ion a n d loca t ion
views for t h e va r iou s wir e h a r n ess con n ect or s, splices
a n d gr ou n ds.
Fig. 29 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
(1) Rem ove t h e wiper on /off r ela y fr om t h e P DC.
(Refer t o 8 - E LE CTRICAL/WIP E RS/WASH E RS/
WIP E R ON/OF F RE LAY - RE MOVAL).
(2) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(3) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ± 8 oh m s. If OK, go t o St ep
4. If n ot OK, r epla ce t h e fa u lt y r ela y.
(4) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A
a n d 30. If OK, r ein st a ll t h e r ela y a n d u se a DRBIII!
sca n t ool t o per for m fu r t h er t est in g. Refer t o t h e
a ppr opr ia t e dia gn ost ic in for m a t ion .
WJ
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e cover fr om t h e P ower Dist r ibu t ion
Cen t er (P DC) (F ig. 30).
Fig. 30 Power Distribution Center
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
(3) See t h e fu se a n d r ela y la you t la bel a ffixed t o
t h e u n der side of t h e P DC cover for wiper on /off r ela y
iden t ifica t ion a n d loca t ion .
(4) Rem ove t h e wiper on /off r ela y by gr a spin g it
fir m ly a n d pu llin g it st r a igh t ou t fr om t h e r ecept a cle
in t h e P DC.
INSTALLATION
(1) See t h e fu se a n d r ela y la you t la bel a ffixed t o
t h e u n der side of t h e P DC cover for t h e pr oper wiper
on /off r ela y loca t ion (F ig. 30).
(2) P osit ion t h e wiper on /off r ela y in t h e pr oper
r ecept a cle in t h e P DC.
(3) Align t h e wiper on /off r ela y t er m in a ls wit h t h e
t er m in a l ca vit ies in t h e P DC r ecept a cle.
(4) P u sh fir m ly a n d even ly on t h e t op of t h e wiper
on /off r ela y u n t il t h e t er m in a ls a r e fu lly sea t ed in t h e
t er m in a l ca vit ies in t h e P DC r ecept a cle.
(5) Rein st a ll t h e cover on t o t h e P DC.
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ REAR WIPERS/WASHERS 8R - 33

REAR WI PERS/WASH ERS

TABLE OF CONTENTS
page page

REAR WIPERS/WASHERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REAR WIPER ARM
DIAGNOSIS AND TESTING - REAR WIPER & DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
WASHER SYSTEM ................. . . . 35 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING - REAR WIPER & WASHER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSPECTION - REAR WIPER & WASHER REAR WIPER BLADE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REAR WASHER HOSES/TUBES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
REAR WASHER NOZZLE REAR WIPER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
REAR WASHER PUMP/MOTOR WIPER ARM PARK RAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46

REAR WI PERS/WASH ERS • Re a r Wip e r Arm P a rk Ra m p - Th e m olded

r u bber r ea r wiper a r m pa r k r a m p is secu r ed wit h a
scr ew t o t h e lift ga t e ou t er pa n el, ju st below t h e r igh t
DESCRIPTION
side of t h e lift ga t e gla ss. Wh en t h e r ea r wiper syst em
An elect r ica lly oper a t ed fixed in t er va l in t er m it t en t
is n ot in oper a t ion , t h e r ea r wiper a r m is pa r ked on
r ea r wiper a n d wa sh er syst em is st a n da r d fa ct or y-in -
t h is r a m p so t h a t it will n ot in t er fer e wit h or be
st a lled equ ipm en t on t h is m odel. Th e r ea r wiper a n d
da m a ged by lift ga t e flip-u p gla ss oper a t ion .
wa sh er syst em in clu des t h e followin g m a jor com po-
• Re a r Wip e r B la d e - Th e sin gle r ea r wiper
n en t s, wh ich a r e descr ibed in fu r t h er det a il else-
bla de is secu r ed t o t h e r ea r wiper a r m , a n d is m oved
wh er e in t h is ser vice in for m a t ion :
off of t h e lift ga t e gla ss wh en t h e r ea r wiper syst em is
• Re a r Wa s h e r N o zzle - Th e r ea r wa sh er n ozzle
n ot in oper a t ion .
is secu r ed by a sn a p fit on t o t h e t op of t h e lift ga t e
• Re a r Wip e r Mo d u le - Th e r ea r wiper m odu le
ou t er pa n el a bove t h e lift ga t e gla ss. Th e r ea r wa sh er
ou t pu t sh a ft is t h e on ly visible com pon en t of t h e r ea r
n ozzle in clu des a n in t egr a l ch eck va lve. Th e r ea r
wiper m odu le. Th e r em a in der of t h e m odu le is con -
wa sh er syst em plu m bin g is con cea led wit h in a n d
cea led wit h in t h e lift ga t e ben ea t h t h e lift ga t e gla ss
r ou t ed t h r ou gh t h e in t er ior of t h e veh icle.
open in g. Th e r ea r wiper m odu le in clu des t h e m odu le
• Re a r Wa s h e r P u m p /Mo to r - Th e r ea r wa sh er
br a cket , t h e r ea r wiper m ot or, a n d t h e r ea r wiper
pu m p/m ot or u n it is loca t ed in a dedica t ed h ole on t h e
m odu le elect r on ic con t r ol cir cu it r y.
lower ou t boa r d side of t h e wa sh er r eser voir, a h ea d of
• Rig h t Mu lti-F u n c tio n S w itc h - Th e r igh t
t h e left fr on t wh eel h ou sin g. Th e r ea r wa sh er pu m p
(wiper ) m u lt i-fu n ct ion swit ch is secu r ed t o t h e r igh t
m ou n t in g h ole is loca t ed h igh er on t h e r eser voir t h a n
side of t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g
t h e fr on t wa sh er pu m p m ou n t in g h ole.
n ea r t h e t op of t h e st eer in g colu m n . On ly t h e con t r ol
• Re a r Wip e r Arm - Th e sin gle r ea r wiper a r m is
st a lk for t h e r igh t m u lt i-fu n ct ion swit ch is visible,
secu r ed by a n u t dir ect ly t o t h e r ea r wiper m odu le
t h e r em a in der of t h e swit ch is con cea led ben ea t h t h e
ou t pu t sh a ft , wh ich ext en ds t h r ou gh t h e lift ga t e
st eer in g colu m n sh r ou ds. Th e r igh t m u lt i-fu n ct ion
ou t er pa n el n ea r t h e ba se of t h e lift ga t e gla ss.
swit ch con t a in s a ll of t h e swit ch es a n d con t r ol cir-
cu it r y for bot h t h e fr on t a n d r ea r wiper a n d wa sh er
syst em s.
8R - 34 REAR WIPERS/WASHERS
REAR WI PERS/WASH ERS (Cont inue d)
• Wa s h e r Re s e rv o ir - Th e r ea r wa sh er syst em
sh a r es a sin gle r eser voir wit h t h e fr on t wa sh er sys-
t em , bu t h a s it s own dedica t ed wa sh er pu m p/m ot or
a n d plu m bin g. Th e wa sh er r eser voir is con cea led
bet ween t h e left in n er fen der sh ield a n d t h e left
ou t er fen der pa n el, beh in d t h e in n er fen der lin er a n d
a h ea d of t h e left fr on t wh eel. Th e wa sh er r eser voir
filler n eck is t h e on ly visible por t ion of t h e r eser voir,
a n d it is a ccessed fr om t h e left fr on t cor n er of t h e
en gin e com pa r t m en t .
F ea t u r es of t h e r ea r wiper a n d wa sh er syst em
in clu de t h e followin g:
• Co n tin u o u s Wip e Mo d e - Wh en t h e r igh t
m u lt i-fu n ct ion swit ch con t r ol sleeve is m oved t o t h e
On posit ion , t h e r ea r wiper will be oper a t ed a t a
fixed speed, con t in u a l wipe cycle u n t il t h e swit ch
sleeve is m oved t o t h e Dela y or Off posit ion s, u n t il
t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion , or
u n t il t h e lift ga t e flip-u p gla ss is a ja r.
• In te rm itte n t Wip e Mo d e - Wh en t h e r igh t
m u lt i-fu n ct ion swit ch con t r ol sleeve is m oved t o t h e
Dela y posit ion , t h e r ea r wiper will be oper a t ed in a
fixed in t er va l, in t er m it t en t wipe cycle u n t il t h e
swit ch sleeve is m oved t o t h e On or Off posit ion s,
u n t il t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion ,
u n t il t h e lift ga t e flip-u p gla ss is a ja r, or u n t il t h e
r igh t m u lt i-fu n ct ion swit ch con t r ol st a lk is pu sh ed
for wa r d t o a ct iva t e t h e r ea r wa sh er syst em . Th e
in t er m it t en t wipe m ode dela y t im e h a s a fixed dela y
in t er va l of a bou t five t o eigh t secon ds bet ween
sweeps.
• Wa s h e r Mo d e - Wh en t h e r igh t m u lt i-fu n ct ion
swit ch con t r ol st a lk is pu sh ed for wa r d t o a ct iva t e t h e
r ea r wa sh er syst em , wa sh er flu id will be dispen sed
fr om t h e wa sh er r eser voir on t o t h e lift ga t e gla ss
t h r ou gh t h e r ea r wa sh er n ozzle a n d t h e r ea r wiper
will oper a t e in a fixed cycle (n ot in t er m it t en t ) for a s
lon g a s t h e r ea r wa sh er pu m p/m ot or u n it r em a in s
en er gized. Wh en t h e con t r ol st a lk is r elea sed fr om
t h e m om en t a r y Wa sh posit ion , t h e wipe-a ft er-wa sh
fea t u r e will con t in u e t o oper a t e t h e r ea r wiper a t a
fixed cycle for a bou t t h r ee a ddit ion a l wiper sweeps
befor e r et u r n in g t o t h e pr eviou sly select ed m ode.
H a r d wir ed cir cu it r y con n ect s t h e r ea r wiper a n d
wa sh er syst em com pon en t s t o t h e elect r ica l syst em of
t h e veh icle. Th ese h a r d wir ed cir cu it s a r e in t egr a l t o
sever a l wir e h a r n esses, wh ich a r e r ou t ed t h r ou gh ou t
t h e veh icle a n d r et a in ed by m a n y differ en t m et h ods.
Th ese cir cu it s m a y be con n ect ed t o ea ch ot h er, t o t h e
veh icle elect r ica l syst em a n d t o t h e r ea r wiper a n d
wa sh er syst em com pon en t s t h r ou gh t h e u se of a com -
bin a t ion of solder ed splices, splice block con n ect or s,
a n d m a n y differ en t t ypes of wir e h a r n ess t er m in a l
con n ect or s a n d in su la t or s. Refer t o t h e a ppr opr ia t e
wir in g in for m a t ion . Th e wir in g in for m a t ion in clu des
wir in g dia gr a m s, pr oper wir e a n d con n ect or r epa ir
WJ
pr ocedu r es, fu r t h er det a ils on wir e h a r n ess r ou t in g
a n d r et en t ion , a s well a s pin -ou t a n d loca t ion views
for t h e va r iou s wir e h a r n ess con n ect or s, splices a n d
gr ou n ds.
OPERATION
Th e r ea r wiper a n d wa sh er syst em is in t en ded t o
pr ovide t h e veh icle oper a t or wit h a con ven ien t , sa fe,
a n d r elia ble m ea n s of m a in t a in in g visibilit y t h r ou gh
t h e lift ga t e gla ss. Th e va r iou s com pon en t s of t h is sys-
t em a r e design ed t o con ver t elect r ica l en er gy pr o-
du ced by t h e veh icle elect r ica l syst em in t o t h e
m ech a n ica l a ct ion of t h e wiper bla de t o wipe t h e ou t -
side su r fa ce of t h e gla ss, a s well a s in t o t h e h ydr a u lic
a ct ion of t h e wa sh er syst em t o a pply wa sh er flu id
st or ed in a n on -boa r d r eser voir t o t h e a r ea of t h e
gla ss t o be wiped. Wh en com bin ed, t h ese com pon en t s
pr ovide t h e m ea n s t o effect ively m a in t a in clea r visi-
bilit y for t h e veh icle oper a t or by r em ovin g excess
a ccu m u la t ion s of r a in , sn ow, bu gs, m u d, or ot h er
m in or debr is fr om t h e ou t side lift ga t e gla ss su r fa ce
t h a t m igh t be en cou n t er ed wh ile dr ivin g t h e veh icle
u n der n u m er ou s t ypes of in clem en t oper a t in g con di-
t ion s. Th e veh icle oper a t or in it ia t es a ll r ea r wiper
a n d wa sh er syst em fu n ct ion s wit h t h e r igh t m u lt i-
fu n ct ion swit ch loca t ed on t h e r igh t side of t h e st eer-
in g colu m n , ju st below t h e st eer in g wh eel. Movin g
t h e swit ch con t r ol sleeve t o a det en t posit ion select s
t h e r ea r wiper syst em oper a t in g m ode. Movin g t h e
swit ch con t r ol st a lk for wa r d t o a m om en t a r y posit ion
a ct iva t es t h e r ea r wa sh er pu m p/m ot or, wh ich dis-
pen ses wa sh er flu id on t o t h e lift ga t e gla ss t h r ou gh
t h e r ea r wa sh er n ozzle a n d oper a t es t h e r ea r wiper
syst em in t h e fixed cycle m ode for a s lon g a s t h e
wa sh er swit ch is closed plu s a bou t t h r ee wiper
sweeps.
Wh en t h e ign it ion swit ch is in t h e Accessor y or On
posit ion s, ba t t er y cu r r en t fr om a fu se in t h e J u n ct ion
Block (J B) is pr ovided t o t h e r igh t m u lt i-fu n ct ion
swit ch t h r ou gh a fu sed ign it ion swit ch ou t pu t (r u n -
a cc) cir cu it . A sepa r a t e fu se in t h e J B pr ovides ba t -
t er y cu r r en t t o t h e elect r on ic con t r ol cir cu it r y of t h e
r ea r wiper m odu le t h r ou gh a fu sed B(+) cir cu it .
Wh en t h e r igh t m u lt i-fu n ct ion swit ch con t r ol sleeve
On posit ion is select ed, t h e On posit ion cir cu it r y
wit h in t h e swit ch dir ect s a ba t t er y cu r r en t r ea r
wiper m ot or con t r ol sign a l in pu t t o t h e r ea r wiper
m odu le elect r on ic cir cu it r y, wh ich ca u ses t h e r ea r
wiper m ot or t o r u n a t a fixed con t in u ou s wipe cycle.
Wh en t h e r igh t m u lt i-fu n ct ion swit ch con t r ol sleeve
Dela y posit ion is select ed, t h e Dela y posit ion cir-
cu it r y wit h in t h e swit ch dir ect s a ba t t er y cu r r en t
r ea r wa sh er swit ch ou t pu t sign a l in pu t t o t h e r ea r
wiper m odu le elect r on ic cir cu it r y, wh ich ca u ses t h e
r ea r wiper m ot or t o r u n a t a fixed in t er m it t en t wipe
cycle. Wh en t h e r igh t m u lt i-fu n ct ion swit ch con t r ol
WJ
REAR WI PERS/WASH ERS (Cont inue d)
st a lk is m oved t o t h e r ea r Wa sh posit ion , t h e Wa sh
posit ion cir cu it r y wit h in t h e swit ch dir ect s ba t t er y
cu r r en t t o t h e r ea r wa sh er pu m p/m ot or u n it , a n d t o
bot h t h e r ea r wiper m ot or con t r ol a n d r ea r wa sh er
swit ch ou t pu t sign a l in pu t s of t h e r ea r wiper m odu le
elect r on ic cir cu it r y, wh ich ca u ses t h e wiper m ot or t o
r u n a t a fixed cycle for a s lon g a s t h e Wa sh m ode is
select ed plu s a bou t t h r ee a ddit ion a l fixed wipe cycles.
Th e r ea r wiper m odu le elect r on ic cir cu it r y con t r ols
t h e swit ch in g of ba t t er y cu r r en t t o t h e r ea r wiper
m ot or br u sh , wh ich con t r ols wiper m ot or oper a t ion .
Th e in t er m it t en t wipe a n d wipe-a ft er-wa sh fea t u r es
of t h e r ea r wiper a n d wa sh er syst em a r e bot h pr o-
vided by t h e r ea r wiper m odu le elect r on ic cir cu it r y.
Th e r ea r wiper m odu le elect r on ic cir cu it r y a lso m on -
it or s t h e lift ga t e flip-u p gla ss a ja r swit ch a n d will
pa r k t h e r ea r wiper bla de off of t h e gla ss a n y t im e it
sen ses t h a t t h e lift ga t e flip-u p gla ss is a ja r, t h e ign i-
t ion swit ch is t u r n ed t o t h e Off posit ion , or t h e r igh t
m u lt i-fu n ct ion swit ch con t r ol sleeve is m oved t o t h e
Off posit ion . Th is fea t u r e en su r es t h a t t h e r ea r wiper
bla de will n ot in t er fer e wit h or be da m a ged by t h e
oper a t ion of t h e lift ga t e flip-u p gla ss. H owever, if t h e
ign it ion swit ch is t u r n ed t o t h e Off posit ion or t h e
lift ga t e flip-u p gla ss is open ed wh ile t h e r ea r wiper is
oper a t in g, t h e r igh t m u lt i-fu n ct ion swit ch con t r ol
sleeve m u st be cycled t o t h e Off posit ion a n d ba ck t o
t h e On or Dela y posit ion a ft er t h e ign it ion swit ch is
t u r n ed ba ck On or t h e lift ga t e flip-u p gla ss is closed
befor e t h e r ea r wiper will oper a t e a ga in .
Refer t o t h e own er ’s m a n u a l in t h e veh icle glove
box for m or e in for m a t ion on t h e fea t u r es a n d oper a -
t ion of t h e r ea r wiper a n d wa sh er syst em .
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM
WIPER SYSTEM
Th e dia gn osis fou n d h er e a ddr esses a n elect r ica lly
in oper a t ive r ea r wiper syst em . If t h e r ea r wiper
m ot or oper a t es, bu t t h e wiper does n ot m ove on t h e
lift ga t e gla ss, r epla ce t h e fa u lt y r ea r wiper m odu le. If
t h e wiper oper a t es, bu t ch a t t er s, lift s, or does n ot
clea r t h e gla ss, clea n a n d in spect t h e wiper syst em
com pon en t s a s r equ ir ed. (Refer t o 8 - E LE CTRICAL/
RE AR WIP E RS/WASH E RS - INSP E CTION) a n d
(Refer t o 8 - E LE CTRICAL/RE AR WIP E RS/WASH -
E RS - CLE ANING). Refer t o t h e a ppr opr ia t e wir in g
in for m a t ion . Th e wir in g in for m a t ion in clu des wir in g
dia gr a m s, pr oper wir e a n d con n ect or r epa ir pr oce-
du r es, det a ils of wir e h a r n ess r ou t in g a n d r et en t ion ,
con n ect or pin -ou t in for m a t ion a n d loca t ion views for
t h e va r iou s wir e h a r n ess con n ect or s, splices a n d
gr ou n ds.
REAR WIPERS/WASHERS 8R - 35
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Ch eck t h a t t h e in t er ior ligh t in g swit ch on t h e
con t r ol st a lk of t h e left m u lt i-fu n ct ion swit ch is n ot
in t h e dom e la m p disa ble posit ion . Wit h a ll fou r
door s a n d t h e lift ga t e closed, open t h e lift ga t e flip-u p
gla ss. Th e in t er ior la m ps sh ou ld ligh t . If n ot , depr ess
t h e ca r go la m p len s t o a ct u a t e t h e ca r go la m p defea t
swit ch a n d t h e in t er ior la m ps sh ou ld ligh t . Close a ll
fou r door s, t h e lift ga t e a n d t h e lift ga t e flip-u p gla ss.
Not e wh et h er t h e in t er ior la m ps r em a in ligh t ed.
Th ey sh ou ld t u r n off a ft er a bou t t h ir t y secon ds. If
OK, go t o St ep 2. If n ot OK, go t o St ep 9.
(2) Ch eck t h e fu sed B(+) fu se (F u se 8 - 15 a m per e)
in t h e J u n ct ion Block (J B). If OK, go t o St ep 3. If n ot
OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(3) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
(F u se 8 - 15 a m per e) in t h e J B. If OK, go t o St ep 4. If
n ot OK, r epa ir t h e open fu sed B(+) cir cu it bet ween
t h e J B a n d t h e P ower Dist r ibu t ion Cen t er (P DC) a s
r equ ir ed.
(4) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n -
a cc) fu se (F u se 29 - 10 a m per e) in t h e J B. If OK, go
t o St ep 5. If n ot OK, r epa ir t h e sh or t ed cir cu it or
com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(5) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
ou t pu t (r u n -a cc) fu se (F u se 29 - 10 a m per e) in t h e
J B. If OK, t u r n t h e ign it ion swit ch t o t h e Off posit ion
a n d go t o St ep 6. If n ot OK, r epa ir t h e open fu sed
ign it ion swit ch ou t pu t (r u n -a cc) cir cu it bet ween t h e
J B a n d t h e ign it ion swit ch a s r equ ir ed.
(6) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e r igh t m u lt i-fu n ct ion swit ch fr om t h e
swit ch con n ect or r ecept a cle. Recon n ect t h e ba t t er y
n ega t ive ca ble. Tu r n t h e ign it ion swit ch t o t h e On
posit ion . Ch eck for ba t t er y volt a ge a t t h e fu sed ign i-
t ion swit ch ou t pu t (r u n -a cc) cir cu it ca vit y of t h e
in st r u m en t pa n el wir e h a r n ess con n ect or for t h e
r igh t m u lt i-fu n ct ion swit ch . If OK, go t o St ep 7. If
n ot OK, r epa ir t h e open fu sed ign it ion swit ch ou t pu t
8R - 36 REAR WIPERS/WASHERS
REAR WI PERS/WASH ERS (Cont inue d)
(r u n -a cc) cir cu it bet ween t h e r igh t m u lt i-fu n ct ion
swit ch a n d t h e J B a s r equ ir ed.
(7) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Test t h e r igh t m u lt i-fu n ct ion swit ch . (Refer t o 8 -
E LE CTRICAL/F RONT WIP E RS/WASH E RS/RIGH T
MULTI-F UNCTION SWITCH - DIAGNOSIS AND
TE STING). If t h e r igh t m u lt i-fu n ct ion swit ch t est s
OK, r econ n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or for t h e r igh t m u lt i-fu n ct ion swit ch t o t h e
swit ch con n ect or r ecept a cle a n d go t o St ep 8. If t h e
r igh t m u lt i-fu n ct ion swit ch does n ot t est OK, r epla ce
t h e fa u lt y swit ch .
(8) Rem ove t h e lift ga t e in n er t r im pa n el. Discon -
n ect t h e lift ga t e wir e h a r n ess con n ect or for t h e r ea r
wiper m odu le fr om t h e m odu le con n ect or r ecept a cle.
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
it y of t h e lift ga t e wir e h a r n ess con n ect or for t h e r ea r
wiper m odu le a n d a good gr ou n d. Th er e sh ou ld be
con t in u it y. If OK, go t o St ep 9. If n ot OK, r epa ir t h e
open gr ou n d cir cu it t o gr ou n d (G301) a s r equ ir ed.
(9) Ch eck for con t in u it y bet ween t h e lift ga t e
flip-u p gla ss a ja r swit ch sen se cir cu it ca vit y of t h e
lift ga t e wir e h a r n ess con n ect or for t h e r ea r wiper
m odu le a n d a good gr ou n d. Th er e sh ou ld be con t in u -
it y wit h t h e lift ga t e flip-u p gla ss open , a n d n o con t i-
n u it y wit h t h e lift ga t e flip-u p gla ss closed. If OK, go
t o St ep 10. If n ot OK, r epa ir t h e lift ga t e flip-u p gla ss
a ja r cir cu it a s r equ ir ed.
(10) Recon n ect t h e ba t t er y n ega t ive ca ble. Ch eck
for ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of
t h e lift ga t e wir e h a r n ess con n ect or for t h e r ea r wiper
m odu le. If OK, go t o St ep 11. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it bet ween t h e r ea r wiper m od-
u le a n d t h e J B a s r equ ir ed.
(11) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r igh t m u lt i-fu n ct ion swit ch con t r ol sleeve t o
t h e Dela y posit ion . Ch eck for ba t t er y volt a ge a t t h e
r ea r wa sh er swit ch ou t pu t cir cu it ca vit y of t h e lift -
ga t e wir e h a r n ess con n ect or for t h e r ea r wiper m od-
u le. If OK, go t o St ep 12. If n ot OK, r epa ir t h e open
r ea r wa sh er swit ch ou t pu t cir cu it bet ween t h e r ea r
wiper m odu le a n d t h e r igh t m u lt i-fu n ct ion swit ch a s
r equ ir ed.
WJ
(12) Tu r n t h e r igh t m u lt i-fu n ct ion swit ch con t r ol
sleeve t o t h e On posit ion . Ch eck for ba t t er y volt a ge
a t t h e r ea r wiper m ot or con t r ol cir cu it ca vit y of t h e
lift ga t e wir e h a r n ess con n ect or for t h e r ea r wiper
m odu le. If OK, r epla ce t h e fa u lt y r ea r wiper m odu le.
If n ot OK, r epa ir t h e open r ea r wiper m ot or con t r ol
cir cu it bet ween t h e r ea r wiper m odu le a n d t h e r igh t
m u lt i-fu n ct ion swit ch a s r equ ir ed.
WASHER SYSTEM
Th e dia gn osis fou n d h er e a ddr esses a n elect r ica lly
in oper a t ive r ea r wa sh er syst em . If t h e r ea r wa sh er
pu m p/m ot or oper a t es, bu t n o wa sh er flu id is em it t ed
fr om t h e r ea r wa sh er n ozzle, be cer t a in t o ch eck t h e
flu id level in t h e r eser voir. Also in spect t h e wa sh er
syst em com pon en t s a s r equ ir ed. (Refer t o 8 - E LE C-
TRICAL/RE AR WIP E RS/WASH E RS - INSP E CTION).
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir-
in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
wir e a n d con n ect or r epa ir pr ocedu r es, det a ils of wir e
h a r n ess r ou t in g a n d r et en t ion , con n ect or pin -ou t
in for m a t ion a n d loca t ion views for t h e va r iou s wir e
h a r n ess con n ect or s, splices a n d gr ou n ds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Tu r n t h e r igh t m u lt i-fu n ct ion swit ch con t r ol sleeve t o
t h e On posit ion . Ch eck wh et h er t h e r ea r wiper sys-
t em is oper a t in g. If OK, go t o St ep 2. If n ot OK, t est
a n d r epa ir t h e r ea r wiper syst em befor e con t in u in g
wit h t h ese t est s. Refer t o WIP E R SYSTE M .
WJ
REAR WI PERS/WASH ERS (Cont inue d)
(2) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Discon n ect t h e left h ea dla m p a n d da sh wir e h a r n ess
con n ect or for t h e r ea r wa sh er pu m p/m ot or u n it fr om
t h e pu m p/m ot or u n it con n ect or r ecept a cle. Ch eck for
con t in u it y bet ween t h e gr ou n d cir cu it ca vit y of t h e
left h ea dla m p a n d da sh wir e h a r n ess con n ect or for
t h e r ea r wa sh er pu m p/m ot or u n it a n d a good gr ou n d.
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 3. If n ot
OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d (G106)
a s r equ ir ed.
(3) Recon n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e On posit ion . P u sh t h e r igh t
m u lt i-fu n ct ion swit ch con t r ol st a lk t owa r d t h e in st r u -
m en t pa n el t o a ct u a t e t h e r ea r wa sh er swit ch . Wit h
t h e r ea r wa sh er swit ch a ct u a t ed, ch eck for ba t t er y
volt a ge a t t h e r ea r wa sh er swit ch ou t pu t cir cu it ca v-
it y of t h e left h ea dla m p a n d da sh wir e h a r n ess con -
n ect or for t h e r ea r wa sh er pu m p/m ot or u n it . If OK,
r epla ce t h e fa u lt y r ea r wa sh er pu m p/m ot or u n it . If
n ot OK, r epa ir t h e open r ea r wa sh er swit ch ou t pu t
cir cu it bet ween t h e r ea r wa sh er pu m p/m ot or u n it
a n d t h e r igh t m u lt i-fu n ct ion swit ch a s r equ ir ed.
CLEANING - REAR WIPER & WASHER SYSTEM
WIPER SYSTEM
Th e squ eegee of a wiper bla de exposed t o t h e ele-
m en t s for a lon g t im e t en ds t o lose it s wipin g effec-
t iven ess. P er iodic clea n in g of t h e squ eegee is
su ggest ed t o r em ove a n y deposit s of sa lt or r oa d film .
Th e wiper bla de, a r m , a n d lift ga t e gla ss sh ou ld on ly
be clea n ed u sin g a spon ge or soft clot h a n d win d-
sh ield wa sh er flu id, a m ild det er gen t , or a n on -a br a -
sive clea n er. If t h e wiper bla de con t in u es t o lea ve
st r ea ks, sm ea r s, h a zin g, or bea din g on t h e gla ss a ft er
t h or ou gh clea n in g of t h e squ eegees a n d t h e gla ss, t h e
en t ir e wiper bla de a ssem bly m u st be r epla ced.
CAUTION: Protect the rubber squeegee of the wiper
blade from any petroleum-based cleaners, solvents,
or contaminants. These products can rapidly deteri-
orate the rubber squeegee.
WASHER SYSTEM
If t h e wa sh er syst em is con t a m in a t ed wit h for eign
m a t er ia l, dr a in t h e wa sh er r eser voir by r em ovin g t h e
fr on t wa sh er pu m p/m ot or fr om t h e r eser voir. Clea n
for eign m a t er ia l fr om t h e in side of t h e wa sh er r eser-
voir u sin g clea n wa sh er flu id, a m ild det er gen t , or a
n on -a br a sive clea n er. F lu sh for eign m a t er ia l fr om t h e
wa sh er syst em plu m bin g by fir st discon n ect in g t h e
wa sh er h ose fr om t h e wa sh er n ozzle, t h en r u n n in g
t h e wa sh er pu m p/m ot or t o r u n clea n wa sh er flu id or
wa t er t h r ou gh t h e syst em . A plu gged or r est r ict ed
wa sh er n ozzle sh ou ld be ca r efu lly ba ck-flu sh ed u sin g
REAR WIPERS/WASHERS 8R - 37
com pr essed a ir. If t h e wa sh er n ozzle obst r u ct ion ca n -
n ot be clea r ed, r epla ce t h e wa sh er n ozzle.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegee of the wiper blade.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - REAR WIPER & WASHER
SYSTEM
WIPER SYSTEM
Th e r ea r wiper bla de a n d wiper a r m sh ou ld be
in spect ed per iodica lly, n ot ju st wh en wiper per for-
m a n ce pr oblem s a r e exper ien ced. Th is in spect ion
sh ou ld in clu de t h e followin g poin t s:
(1) In spect t h e wiper a r m for a n y in dica t ion s of
da m a ge, or con t a m in a t ion . If t h e wiper a r m is con -
t a m in a t ed wit h a n y for eign m a t er ia l, clea n a s
r equ ir ed. (Refer t o 8 - E LE CTRICAL/RE AR WIP E RS/
WASH E RS - CLE ANING). If a wiper a r m is da m a ged
or cor r osion is eviden t , r epla ce t h e wiper a r m wit h a
n ew u n it . Do n ot a t t em pt t o r epa ir a wiper a r m t h a t
is da m a ged or cor r oded.
(2) Ca r efu lly lift t h e wiper a r m off of t h e r a m p.
Not e t h e a ct ion of t h e wiper a r m h in ge. Th e wiper
a r m sh ou ld pivot fr eely a t t h e h in ge, bu t wit h n o la t -
er a l loosen ess eviden t . If t h er e is a n y bin din g eviden t
in t h e wiper a r m h in ge, or t h er e is eviden t la t er a l
pla y in t h e wiper a r m h in ge, r epla ce t h e wiper a r m .
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) On ce pr oper h in ge a ct ion of t h e wiper a r m is
con fir m ed, ch eck t h e h in ge for pr oper spr in g t en sion .
Th e spr in g t en sion of t h e wiper a r m sh ou ld be su ffi-
cien t t o ca u se t h e r u bber squ eegee t o con for m t o t h e
cu r va t u r e of t h e gla ss. Repla ce a wiper a r m if it h a s
low or n o spr in g t en sion .
(4) In spect t h e wiper bla de a n d squ eegee for a n y
in dica t ion s of da m a ge, con t a m in a t ion , or r u bber det e-
r ior a t ion (F ig. 1). If t h e wiper bla de or squ eegee is
con t a m in a t ed wit h a n y for eign m a t er ia l, clea n t h em
a n d t h e gla ss a s r equ ir ed. (Refer t o 8 - E LE CTRI-
8R - 38 REAR WIPERS/WASHERS
REAR WI PERS/WASH ERS (Cont inue d)
CAL/RE AR WIP E RS/WASH E RS - CLE ANING). If
a ft er clea n in g t h e wiper bla de a n d t h e gla ss, t h e
wiper bla de fa ils t o clea r t h e gla ss wit h ou t sm ea r in g,
st r ea kin g, ch a t t er in g, h a zin g, or bea din g, r epla ce t h e
wiper bla de. Also, if a wiper bla de is da m a ged or if
t h e squ eegee r u bber is da m a ged or det er ior a t ed,
r epla ce t h e wiper bla de wit h a n ew u n it . Do n ot
a t t em pt t o r epa ir a wiper bla de t h a t is da m a ged.
Fig. 1 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
WASHER SYSTEM
Th e wa sh er syst em com pon en t s sh ou ld be
in spect ed per iodica lly, n ot ju st wh en wa sh er per for-
m a n ce pr oblem s a r e exper ien ced. Th is in spect ion
sh ou ld in clu de t h e followin g poin t s:
(1) Ch eck for ice or ot h er for eign m a t er ia l in t h e
wa sh er r eser voir. If con t a m in a t ed, clea n a n d flu sh
t h e wa sh er syst em . (Refer t o 8 - E LE CTRICAL/
RE AR WIP E RS/WASH E RS - CLE ANING).
(2) In spect t h e wa sh er plu m bin g for pin ch ed, lea k-
in g, det er ior a t ed, or in cor r ect ly r ou t ed h oses a n d
da m a ged or discon n ect ed h ose fit t in gs. Repla ce da m -
a ged or det er ior a t ed h oses a n d h ose fit t in gs. Lea kin g
wa sh er h oses ca n som et im es be r epa ir ed by cu t t in g
t h e h ose a t t h e lea k a n d splicin g it ba ck t oget h er
WJ
u sin g a n in -lin e con n ect or fit t in g. Sim ila r ly, sect ion s
of det er ior a t ed h ose ca n be cu t ou t a n d r epla ced by
splicin g in n ew sect ion s of h ose u sin g in -lin e con n ec-
t or fit t in gs. Wh en ever r ou t in g a wa sh er h ose or a
wir e h a r n ess con t a in in g a wa sh er h ose, it m u st be
r ou t ed a wa y fr om h ot , sh a r p, or m ovin g pa r t s. Also,
sh a r p ben ds t h a t m igh t pin ch t h e wa sh er h ose m u st
be a voided.
REAR WASH ER H OSES/T U BES
DESCRIPTION
Fig. 2 Rear Washer Plumbing
1 - UPPER COWL PLENUM PANEL
2 - WASHER HOSE FROM ENGINE COMPARTMENT
3 - A-PILLAR WASHER HOSE
4 - HEADLINER WASHER HOSE
Th e r ea r wa sh er plu m bin g con sist s of sm a ll dia m -
et er r u bber h oses a n d m olded pla st ic in lin e con n ect or
fit t in gs (F ig. 2). Th e wa sh er r eser voir h ose is con -
n ect ed t o t h e ba r bed ou t let n ipple of t h e r ea r wa sh er
pu m p/m ot or u n it below t h e left fr on t wh eel h ou se
ext en sion a n d r ou t ed u p t h e wa sh er r eser voir filler
n eck t o t h e en gin e com pa r t m en t . J u st r ea r wa r d of
t h e wa sh er r eser voir filler n eck in t h e en gin e com -
pa r t m en t , a n in lin e con n ect or wit h ba r bed n ipples
join s t h e r eser voir h ose t o t h e en gin e com pa r t m en t
h ose. Th e en gin e com pa r t m en t h ose is r ou t ed a lon g
t h e t op of t h e left fr on t fen der wh eel h ou se t o t h e
da sh pa n el. Th e en gin e com pa r t m en t h ose pa sses
t h r ou gh a h ole wit h a r u bber gr om m et in t h e da sh
pa n el in t o t h e pa ssen ger com pa r t m en t . Below t h e
in st r u m en t pa n el in t h e pa ssen ger com pa r t m en t n ea r
t h e left cowl side in n er pa n el, a n ot h er in lin e con n ec-
t or join s t h e en gin e com pa r t m en t h ose t o t h e A-pilla r
h ose. Th e A-pilla r h ose is r ou t ed u p t h e left A-pilla r
t o t h e h ea dlin er. At t h e h ea dlin er, a n in lin e con n ect or
join s t h e A-pilla r h ose t o t h e h ea dlin er h ose. Th e
h ea dlin er h ose is r ou t ed a bove t h e h ea dlin er a n d
WJ
REAR WASH ER H OSES/T U BES (Cont inue d)
a lon g t h e left r oof side r a il t o t h e r ea r of t h e veh icle.
At t h e r ea r of t h e veh icle, t h e h ea dlin er h ose is
r ou t ed a bove t h e h ea dlin er a n d a lon g t h e u pper lift -
ga t e open in g pa n el t owa r d t h e r igh t side of t h e veh i-
cle. Th e h ea dlin er h ose t h en pa sses t h r ou gh a h ole
wit h a r u bber gr om m et in t h e u pper lift ga t e open in g
pa n el a n d t h r ou gh a n ot h er h ole wit h a r u bber gr om -
m et in t o t h e u pper in n er lift ga t e pa n el t o t h e r ea r
wa sh er n ozzle.
Wa sh er h ose is a va ila ble for ser vice on ly a s r oll
st ock, wh ich m u st t h en be cu t t o len gt h . Th e h ea d-
lin er wa sh er h ose is in t egr a l t o t h e h ea dlin er u n it
a n d, if fa u lt y or da m a ged, t h e h ea dlin er u n it m u st be
r epla ced. Th e m olded pla st ic wa sh er h ose fit t in gs
ca n n ot be r epa ir ed. If t h ese fit t in gs a r e fa u lt y or
da m a ged, t h ey m u st be r epla ced.
OPERATION
Wa sh er flu id in t h e wa sh er r eser voir is pr essu r ized
a n d fed by t h e r ea r wa sh er pu m p/m ot or t h r ou gh t h e
r ea r wa sh er syst em plu m bin g a n d fit t in gs t o t h e r ea r
wa sh er n ozzle on t h e lift ga t e ou t er pa n el a bove t h e
lift ga t e gla ss. Wh en ever r ou t in g t h e wa sh er h ose or a
wir e h a r n ess con t a in in g a wa sh er h ose, it m u st be
r ou t ed a wa y fr om h ot , sh a r p, or m ovin g pa r t s; a n d,
sh a r p ben ds t h a t m igh t pin ch t h e h ose m u st be
a voided.
REAR WASH ER N OZ Z LE
DESCRIPTION
Fig. 3 Rear Washer Nozzle
1 - HEADLINER WASHER HOSE
2 - ROOF PANEL
3 - REAR WASHER NOZZLE
4 - LIFTGATE
REAR WIPERS/WASHERS 8R - 39
Th e r ea r wa sh er n ozzle is a flu idic t ype u n it t h a t
in clu des a n in t egr a l ch eck va lve (F ig. 3). Th e n ozzle
is con st r u ct ed of m olded pla st ic a n d h a s a r u bber
sea l a n d in t egr a l sn a p fea t u r es on t h e ba ck of it . Th e
n ozzle is secu r ed by a sn a p fit in a dedica t ed m ou n t -
in g h ole in t h e lift ga t e ou t er pa n el a bove t h e lift ga t e
flip-u p gla ss. Wit h in t h e r ea r n ozzle body, a sm a ll
ch eck ba ll is h eld a ga in st a n in t egr a l va lve sea t a t
t h e in let en d of t h e n ozzle by a sm a ll coiled spr in g.
Th e r ea r wa sh er n ozzle a n d ch eck va lve u n it ca n n ot
be a dju st ed or r epa ir ed. If fa u lt y or da m a ged, t h e
en t ir e n ozzle a n d ch eck va lve u n it m u st be r epla ced.
OPERATION
Th e r ea r wa sh er n ozzle is design ed t o dispen se
wa sh er flu id in t o t h e wiper pa t t er n a r ea on t h e ou t -
side of t h e lift ga t e gla ss. P r essu r ized wa sh er flu id is
fed t o t h e n ozzle fr om t h e wa sh er r eser voir by t h e
r ea r wa sh er pu m p/m ot or t h r ou gh a sin gle h ose,
wh ich is a t t a ch ed t o a ba r bed n ipple on t h e ba ck of
t h e r ea r wa sh er n ozzle. Th e r ea r wa sh er n ozzle
in cor por a t es a flu idic design , wh ich ca u ses t h e n ozzle
t o em it t h e pr essu r ized wa sh er flu id a s a n oscilla t in g
st r ea m t o m or e effect ively cover a la r ger a r ea of t h e
gla ss a r ea t o be clea n ed. Th e in t egr a l r ea r n ozzle
ch eck va lve pr even t s wa sh er flu id fr om dr a in in g ou t
of t h e r ea r wa sh er su pply h oses ba ck t o t h e wa sh er
r eser voir. Th is dr a in -ba ck wou ld r esu lt in a len gt h y
dela y fr om wh en t h e r ea r wa sh er swit ch is a ct u a t ed
u n t il wa sh er flu id wa s dispen sed t h r ou gh t h e r ea r
wa sh er n ozzle, beca u se t h e r ea r wa sh er pu m p wou ld
h a ve t o r efill t h e r ea r wa sh er plu m bin g fr om t h e r es-
er voir t o t h e n ozzle. Th e ch eck va lve a lso pr even t s
wa sh er flu id fr om siph on in g t h r ou gh t h e r ea r wa sh er
n ozzle a ft er t h e r ea r wa sh er syst em is t u r n ed Off.
Wh en t h e r ea r wa sh er pu m p pr essu r izes a n d pu m ps
wa sh er flu id fr om t h e r eser voir t h r ou gh t h e r ea r
wa sh er plu m bin g, t h e flu id pr essu r e over r ides t h e
spr in g pr essu r e a pplied t o t h e ch eck ba ll wit h in t h e
va lve a n d u n sea t s t h e ch eck ba ll, a llowin g wa sh er
flu id t o flow t o t h e r ea r wa sh er n ozzle. Wh en t h e
r ea r wa sh er pu m p st ops oper a t in g, spr in g pr essu r e
sea t s t h e ch eck ba ll in t h e va lve a n d flu id flow in
eit h er dir ect ion wit h in t h e r ea r wa sh er plu m bin g is
pr even t ed.
REMOVAL
Th e ch eck va lve for t h e r ea r wa sh er n ozzle is in t e-
gr a l t o t h e n ozzle.
(1) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y a t t h e sides of t h e r ea r
wa sh er n ozzle t o r elea se t h e sn a p fea t u r es t h a t
secu r e it in t h e m ou n t in g h ole of t h e lift ga t e ou t er
pa n el.
8R - 40 REAR WIPERS/WASHERS WJ
REAR WASH ER N OZ Z LE (Cont inue d)
(2) P u ll t h e r ea r wa sh er n ozzle ou t fr om t h e lift -
ga t e ou t er pa n el fa r en ou gh t o a ccess t h e wa sh er
su pply h ose (F ig. 4).

Fig. 5 Washer Pumps (Viewed from Bottom of

Reservoir)
Fig. 4 Rear Washer Nozzle Remove/Install
1 - REAR WASHER PUMP/MOTOR
1 - HEADLINER WASHER HOSE 2 - FRONT WASHER PUMP/MOTOR
2 - ROOF PANEL 3 - WASHER FLUID LEVEL SWITCH
3 - REAR WASHER NOZZLE
4 - LIFTGATE
m ou n t in g h oles n ea r t h e bot t om of t h e wa sh er r eser-
voir. Th e r ea r wa sh er pu m p/m ot or u n it is a lwa ys
(3) Discon n ect t h e wa sh er su pply h ose fr om t h e
m ou n t ed in t h e h igh er pu m p m ou n t in g h ole of t h e
ba r bed n ipple of t h e r ea r wa sh er n ozzle.
r eser voir. A sm a ller ba r bed ou t let n ipple on t h e pu m p
(4) Rem ove t h e r ea r wa sh er n ozzle fr om t h e lift -
h ou sin g con n ect s t h e u n it t o t h e r ea r wa sh er h ose.
ga t e.
Th e wa sh er pu m p/m ot or u n it is r et a in ed on t h e r es-
er voir by t h e in t er fer en ce fit bet ween t h e ba r bed
INSTALLATION pu m p in let n ipple a n d t h e gr om m et sea l, wh ich is a
(1) P osit ion t h e r ea r wa sh er n ozzle t o t h e lift ga t e
ligh t pr ess fit . An in t egr a l elect r ica l con n ect or r ecep-
(F ig. 4).
t a cle is loca t ed on t h e t op of t h e m ot or h ou sin g. Th e
(2) Recon n ect t h e wa sh er su pply h ose t o t h e
r ea r wa sh er pu m p/m ot or u n it ca n n ot be r epa ir ed. If
ba r bed n ipple of t h e r ea r wa sh er n ozzle.
fa u lt y or da m a ged, t h e en t ir e wa sh er pu m p/m ot or
(3) In ser t t h e r ea r wa sh er n ozzle su pply h ose a n d
u n it m u st be r epla ced.
n ipple in t o t h e m ou n t in g h ole in t h e lift ga t e ou t er
pa n el.
OPERATION
(4) Usin g h a n d pr essu r e, pu sh fir m ly a n d even ly
Th e r ea r wa sh er pu m p/m ot or u n it is con n ect ed t o
on t h e r ea r wa sh er n ozzle u n t il t h e sn a p fea t u r es
t h e veh icle elect r ica l syst em t h r ou gh a sin gle t a ke
lock in t o pla ce on t h e in side of t h e lift ga t e ou t er
ou t a n d t wo-ca vit y con n ect or of t h e left h ea dla m p
pa n el m ou n t in g h ole.
a n d da sh wir e h a r n ess. Th e wa sh er pu m p/m ot or is
gr ou n ded a t a ll t im es t h r ou gh a t a ke ou t of t h e left
REAR WASH ER PU M P/M OT OR h ea dla m p a n d da sh wir e h a r n ess wit h a sin gle eyelet
t er m in a l con n ect or t h a t is secu r ed u n der a gr ou n d
scr ew t o t h e t op of t h e left in n er fen der sh ield in t h e
DESCRIPTION
en gin e com pa r t m en t . Th e r ea r wa sh er pu m p/m ot or
Th e r ea r wa sh er pu m p/m ot or u n it is loca t ed on t h e
r eceives ba t t er y cu r r en t on a fu sed ign it ion swit ch
ou t boa r d side a n d n ea r t h e r ea r of t h e wa sh er r eser-
ou t pu t (r u n -a cc) cir cu it t h r ou gh t h e closed con t a ct s of
voir, bet ween t h e left fr on t in n er a n d ou t er fen der
t h e m om en t a r y r ea r wa sh er swit ch wit h in t h e r igh t
pa n els (F ig. 5). A sm a ll per m a n en t ly lu br ica t ed a n d
m u lt i-fu n ct ion swit ch on ly wh en t h e swit ch con t r ol
sea led elect r ic m ot or is cou pled t o t h e r ot or-t ype
st a lk is pu sh ed t owa r ds t h e in st r u m en t pa n el.
wa sh er pu m p. A sea l fla n ge wit h a la r ge ba r bed in let
Wa sh er flu id is gr a vit y-fed fr om t h e wa sh er r eser voir
n ipple on t h e pu m p h ou sin g pa sses t h r ou gh a r u bber
t o t h e in let side of t h e wa sh er pu m p. Wh en t h e pu m p
gr om m et sea l in st a lled in on e of t wo dedica t ed
m ot or is en er gized, t h e r ot or-t ype pu m p pr essu r izes
WJ
REAR WASH ER PU M P/M OT OR (Cont inue d)
t h e wa sh er flu id a n d for ces it t h r ou gh t h e pu m p ou t -
let n ipple, t h e r ea r wa sh er plu m bin g, a n d t h e r ea r
wa sh er n ozzle on t o t h e lift ga t e gla ss.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Ra ise a n d su ppor t t h e veh icle.
(3) Rem ove t h e lin er fr om t h e left fr on t fen der
wh eel h ou se.
(4) Discon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e r ea r wa sh er pu m p/m ot or
fr om t h e m ot or con n ect or r ecept a cle (F ig. 6).
REAR WIPERS/WASHERS 8R - 41
(2) P osit ion t h e ba r bed in let n ipple of t h e wa sh er
pu m p t o t h e r u bber gr om m et sea l in t h e r eser voir
(F ig. 6).
(3) P r ess fir m ly a n d even ly on t h e wa sh er pu m p
u n t il t h e ba r bed in let n ipple is fu lly sea t ed in t h e
r u bber gr om m et sea l in t h e wa sh er r eser voir m ou n t -
in g h ole.
(4) Recon n ect t h e wa sh er h ose t o t h e ba r bed ou t let
n ipple of t h e wa sh er pu m p.
(5) Recon n ect t h e left h ea dla m p a n d da sh wir e
h a r n ess con n ect or for t h e r ea r wa sh er pu m p/m ot or
u n it t o t h e m ot or con n ect or r ecept a cle.
(6) Rein st a ll t h e lin er in t o t h e left fr on t fen der
wh eel h ou se.
(7) Lower t h e veh icle.
(8) Refill t h e wa sh er r eser voir wit h t h e wa sh er
flu id dr a in ed fr om t h e r eser voir du r in g t h e r em ova l
pr ocedu r e.
(9) Recon n ect t h e ba t t er y n ega t ive ca ble.

REAR WI PER ARM

DESCRIPTION

Fig. 6 Washer Pumps (Viewed from Bottom of

Reservoir)
1 - REAR WASHER PUMP/MOTOR
2 - FRONT WASHER PUMP/MOTOR
3 - WASHER FLUID LEVEL SWITCH

(5) Discon n ect t h e wa sh er h ose fr om t h e ba r bed

ou t let n ipple of t h e r ea r wa sh er pu m p/m ot or a n d
a llow t h e wa sh er flu id t o dr a in in t o a clea n con t a in er Fig. 7 Rear Wiper Arm
for r eu se. 1 - LIFTGATE
(6) Usin g a t r im st ick or a n ot h er su it a ble wide 2 - REAR WIPER MOTOR OUTPUT SHAFT
fla t -bla ded t ool, gen t ly pr y t h e ba r bed in let n ipple of 3 - PARK RAMP
t h e wa sh er pu m p ou t of t h e r u bber gr om m et sea l in 4 - PIVOT COVER
t h e r eser voir. Ca r e m u st be t a ken n ot t o da m a ge t h e 5 - REAR WIPER ARM
6 - NUT
r eser voir.
(7) Rem ove t h e r u bber gr om m et sea l fr om t h e
wa sh er pu m p m ou n t in g h ole in t h e wa sh er r eser voir Th e r ea r wiper a r m is t h e r igid m em ber loca t ed
a n d disca r d. bet ween t h e r ea r wiper m ot or ou t pu t sh a ft t h a t pr o-
t r u des fr om t h e ou t er lift ga t e pa n el n ea r t h e ba se of
INSTALLATION t h e lift ga t e gla ss open in g a n d t h e r ea r wiper bla de
(1) In st a ll a n ew r u bber gr om m et sea l in t o t h e (F ig. 7). Th is wiper a r m fea t u r es a n over-cen t er
wa sh er pu m p m ou n t in g h ole in t h e wa sh er r eser voir. h in ge t h a t a llows ea sy a ccess t o t h e lift ga t e a n d lift -
Alwa ys u se a n ew r u bber gr om m et sea l on t h e r eser- ga t e gla ss for clea n in g. Th e wiper a r m h a s a die ca st
voir. m et a l pivot en d. Th is pivot en d h a s a h ole in it wit h
in t er n a l ser r a t ion s a n d a pla st ic pivot cover is
8R - 42 REAR WIPERS/WASHERS WJ
REAR WI PER ARM (Cont inue d)
secu r ed loosely t o a n d pivot s on t h e wiper a r m h in ge
pin t o con cea l t h e wiper a r m r et a in in g n u t . Th e wide
en d of a t a per ed, st a m ped st eel ch a n n el is secu r ed
wit h a h in ge pin t o t h e pivot en d of t h e wiper a r m .
On e en d of a lon g, r igid, st a m ped st eel st r a p, wit h a
sm a ll h ole n ea r it s pivot en d, is r ivet ed a n d cr im ped
wit h in t h e n a r r ow en d of t h e st a m ped st eel ch a n n el.
Th e t ip of t h e wiper bla de en d of t h is st r a p is ben t
ba ck u n der it self t o for m a sm a ll h ook. Con cea led
wit h in t h e st a m ped st eel ch a n n el, on e en d of a lon g
spr in g is en ga ged wit h a wir e h ook on t h e u n der side
of t h e die ca st pivot en d, wh ile t h e ot h er en d of t h e
spr in g is h ooked t h r ou gh t h e sm a ll h ole in t h e st eel
st r a p. A m olded pla st ic wiper a r m su ppor t is sn a pped
on t o t h e wiper a r m st r a p wh er e it exit s t h e ch a n n el.
Th e en t ir e wiper a r m h a s a sa t in bla ck fin ish a pplied
Fig. 8 Rear Wiper Arm Remove/Install
t o a ll of it s visible su r fa ces.
1 - LIFTGATE
A wiper a r m ca n n ot be a dju st ed or r epa ir ed. If
2 - REAR WIPER MOTOR OUTPUT SHAFT
da m a ged or fa u lt y, t h e en t ir e wiper a r m u n it m u st be
3 - PARK RAMP
r epla ced. 4 - PIVOT COVER
5 - REAR WIPER ARM
OPERATION 6 - NUT
Th e r ea r wiper a r m is design ed t o m ech a n ica lly
t r a n sm it t h e m ot ion fr om t h e r ea r wiper m ot or ou t -
(4) Use a ba t t er y t er m in a l pu ller t o disen ga ge t h e
pu t sh a ft t o t h e r ea r wiper bla de. Th e wiper a r m
wiper a r m fr om t h e r ea r wiper m ot or ou t pu t sh a ft
m u st be pr oper ly in dexed t o t h e m ot or ou t pu t sh a ft
splin es (F ig. 9).
in or der t o m a in t a in t h e pr oper wiper bla de t r a vel on
t h e gla ss. Th e wiper a r m su ppor t is design ed t o lift
a n d su ppor t t h e r ea r wiper a r m a n d bla de off of t h e
gla ss wh en t h e r ea r wiper bla de is pa r ked. Th is su p-
por t a n d t h e pa r k r a m p on t h e lift ga t e ou t er pa n el
below t h e gla ss a lso pr ovide a n a lign m en t r efer en ce
t o en su r e a ccu r a t e r ea r wiper a r m a n d bla de in st a l-
la t ion . Th e h ole wit h in t er n a l ser r a t ion s in t h e wiper
a r m pivot en d in t er locks wit h t h e ser r a t ion s on t h e
ou t er cir cu m fer en ce of t h e m ot or ou t pu t sh a ft , a llow-
in g posit ive en ga gem en t a n d fin it e a dju st m en t of t h is
con n ect ion . A h ex n u t secu r es t h e wiper a r m pivot
en d t o t h e t h r ea ds on t h e m ot or ou t pu t sh a ft a n d t h e
pivot cover h in ges a n d sn a ps over t h is con n ect ion for
a n ea t a ppea r a n ce. Th e spr in g-loa ded wiper a r m
h in ge con t r ols t h e down -for ce a pplied t h r ou gh t h e t ip
of t h e wiper a r m t o t h e wiper bla de on t h e gla ss. Th e Fig. 9 Wiper Arm Puller - Typical
h ook for m a t ion on t h e t ip of t h e wiper a r m pr ovides
1 - WIPER ARM
a cr a dle for secu r in g a n d la t ch in g t h e wiper bla de
2 - WIPER PIVOT
pivot block t o t h e wiper a r m . 3 - BATTERY TERMINAL PULLER

REMOVAL
(1) Lift t h e r ea r wiper a r m pivot cover by lift in g it (5) Rem ove t h e r ea r wiper a r m pivot en d fr om t h e
a t t h e r ea r wiper m ot or ou t pu t sh a ft en d of t h e a r m m ot or ou t pu t sh a ft .
(F ig. 8).
(2) Rem ove t h e n u t t h a t secu r es t h e r ea r wiper INSTALLATION
a r m t o t h e r ea r wiper m ot or ou t pu t sh a ft .
NOTE: Always install the wiper arm and blade with
(3) Lift t h e r ea r wiper a r m fa r en ou gh t o en ga ge
the wiper motor in the Park position.
t h e over-cen t er a r m h in ge in it s u pr igh t posit ion t o
h old t h e wiper bla de off of t h e lift ga t e.
WJ
REAR WI PER ARM (Cont inue d)
(1) Th e r ea r wiper a r m m u st be in dexed t o t h e
m ot or ou t pu t sh a ft wit h t h e r ea r wiper m ot or in t h e
pa r k posit ion t o be pr oper ly in st a lled. P la ce t h e
wiper a r m on t o t h e lift ga t e wit h t h e wiper a r m su p-
por t posit ion ed on t h e pa r k r a m p a n d t h e pivot h ole
on t h e en d of t h e a r m posit ion ed over t h e r ea r wiper
m ot or ou t pu t sh a ft .
(2) P osit ion t h e r idge of t h e wiper a r m su ppor t on
t h e lift ga t e pa r k r a m p in t h e In st a lla t ion P osit ion
(F ig. 10).
REAR WIPERS/WASHERS 8R - 43
(6) Lift t h e r ea r wiper a r m su ppor t a wa y fr om t h e
pa r k r a m p, t h en pla ce t h e wiper a r m su ppor t in t h e
pa r k r a m p in t h e P a r k P osit ion (F ig. 10).
REAR WI PER BLADE
DESCRIPTION
Th e r ea r wiper bla de is secu r ed by a n in t egr a l
la t ch in g pivot block t o t h e h ook for m a t ion on t h e t ip
of t h e r ea r wiper a r m , a n d r est s off t h e gla ss n ea r
t h e ba se of t h e lift ga t e gla ss open in g wh en t h e wiper
is n ot in oper a t ion . Th e wiper bla de con sist s of t h e
followin g com pon en t s:
• S u p e rs tru c tu re - Th e su per st r u ct u r e in clu des
a st a m ped st eel br idge a n d pla st ic lin ks wit h cla w
for m a t ion s t h a t gr ip t h e wiper bla de elem en t . Also
in clu ded in t h is u n it is t h e la t ch in g, m olded pla st ic
pivot block t h a t secu r es t h e su per st r u ct u r e t o t h e
wiper a r m . All of t h e m et a l com pon en t s of t h e wiper
bla de h a ve a sa t in bla ck fin ish a pplied.
• Ele m e n t - Th e wiper elem en t or squ eegee is t h e
r esilien t r u bber m em ber of t h e wiper bla de t h a t con -
t a ct s t h e gla ss.
• F le x o r - Th e flexor is a r igid m et a l com pon en t
r u n n in g a lon g t h e len gt h of ea ch side of t h e wiper
elem en t wh er e it is gr ipped by t h e cla ws of t h e
su per st r u ct u r e.
All Gr a n d Ch er okee m odels h a ve a sin gle 31.00
cen t im et er (12.20 in ch ) r ea r wiper bla de wit h a n on -
r epla cea ble r u bber elem en t (squ eegee). Th e wiper
bla de ca n n ot be a dju st ed or r epa ir ed. If fa u lt y, wor n ,
or da m a ged t h e en t ir e wiper bla de u n it m u st be
r epla ced.

OPERATION
Th e wiper bla de is m oved ba ck a n d for t h a cr oss t h e
gla ss by t h e wiper a r m wh en t h e wiper syst em is in
oper a t ion . Th e wiper bla de su per st r u ct u r e is t h e flex-
Fig. 10 Rear Wiper Arm Installation
ible fr a m e t h a t gr ips t h e wiper bla de elem en t a n d
1 - LIFTGATE
even ly dist r ibu t es t h e for ce of t h e spr in g-loa ded
2 - PARK RAMP
wiper a r m a lon g t h e len gt h of t h e elem en t . Th e com -
3 - REAR WIPER ARM
4 - INSTALLATION POSITION
bin a t ion of t h e wiper a r m for ce a n d t h e flexibilit y of
5 - REAR WIPER ARM AND BLADE t h e su per st r u ct u r e m a kes t h e elem en t con for m t o
6 - PARK POSITION a n d m a in t a in pr oper con t a ct wit h t h e gla ss, even a s
7 - PARK RAMP t h e bla de is m oved over t h e va r ied cu r va t u r e fou n d
8 - LIFTGATE a cr oss t h e gla ss su r fa ce. Th e wiper elem en t flexor
pr ovides t h e cla ws of t h e bla de su per st r u ct u r e wit h a
(3) Wit h t h e wiper a r m in t h e In st a lla t ion P osi- r igid, yet flexible com pon en t on t h e elem en t wh ich
t ion , pu sh t h e pivot h ole on t h e en d of t h e wiper a r m ca n be gr ipped. Th e r u bber elem en t is design ed t o be
down over t h e r ea r wiper m ot or ou t pu t sh a ft . st iff en ou gh t o m a in t a in a n even clea n in g edge a s it
(4) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e is dr a wn a cr oss t h e gla ss, bu t r esilien t en ou gh t o
r ea r wiper a r m t o t h e r ea r wiper m ot or ou t pu t sh a ft . con for m t o t h e gla ss su r fa ce a n d flip fr om on e clea n -
Tigh t en t h e n u t t o 18 N·m (160 in . lbs.). in g edge t o t h e ot h er ea ch t im e t h e wiper bla de
(5) Close t h e r ea r wiper a r m pivot cover. ch a n ges dir ect ion s.
8R - 44 REAR WIPERS/WASHERS
REAR WI PER BLADE (Cont inue d)
REMOVAL
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper motor
output shaft.
(1) Disen ga ge t h e r ea r wiper a r m su ppor t fr om t h e
r u bber r ea r wiper a r m pa r k r a m p on t h e r igh t side of
t h e lift ga t e ju st below t h e lift ga t e gla ss.
(2) Lift t h e r ea r wiper a r m t o en ga ge t h e a r m
h in ge in it s over-cen t er posit ion wit h t h e wiper bla de
a n d elem en t off of t h e lift ga t e a n d t h e gla ss.
(3) To r em ove t h e wiper bla de fr om t h e wiper a r m ,
pu sh t h e pivot block la t ch r elea se t a b u n der t h e t ip
of t h e a r m a n d slide t h e bla de a wa y fr om t h e t ip
t owa r ds t h e pivot en d of t h e a r m fa r en ou gh t o dis-
en ga ge t h e pivot block fr om t h e h ook (F ig. 11).
Fig. 11 Wiper Blade Remove/Install - Typical
1 - PIVOT BLOCK LATCH RELEASE TAB
(4) E xt r a ct t h e h ook for m a t ion on t h e t ip of t h e
wiper a r m fr om t h e open in g in t h e wiper bla de
su per st r u ct u r e a h ea d of t h e wiper bla de pivot block/
la t ch u n it .
CAUTION: Do not allow the wiper arm to spring
back against the liftgate or the glass without the
wiper blade in place or they may be damaged.
(5) Gen t ly lower t h e wiper a r m a n d pla ce t h e a r m
su ppor t in t h e pa r k r a m p.
INSTALLATION
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper motor
output shaft.
(1) Lift t h e r ea r wiper a r m off of t h e lift ga t e pa r k
r a m p.
(2) P osit ion t h e r ea r wiper bla de n ea r t h e h ook for-
m a t ion on t h e t ip of t h e a r m wit h t h e n ot ch ed
r et a in er for t h e wiper elem en t or ien t ed t owa r ds t h e
WJ
en d of t h e wiper a r m t h a t is n ea r est t o t h e wiper
m ot or ou t pu t sh a ft .
(3) In ser t t h e h ook for m a t ion on t h e t ip of t h e
wiper a r m t h r ou gh t h e open in g in t h e wiper bla de
su per st r u ct u r e a h ea d of t h e wiper bla de pivot block/
la t ch u n it fa r en ou gh t o en ga ge t h e pivot block wit h
t h e h ook (F ig. 11).
(4) Slide t h e wiper bla de pivot block/la t ch u p in t o
t h e h ook for m a t ion on t h e t ip of t h e wiper a r m u n t il
t h e la t ch r elea se t a b sn a ps in t o it s locked posit ion .
(5) Gen t ly lower t h e wiper a r m a n d pla ce t h e a r m
su ppor t in t h e pa r k r a m p.
REAR WI PER M ODU LE
DESCRIPTION
Fig. 12 Rear Wiper Module
1 - KEYED SLOTS
2 - LIFTGATE WIRE HARNESS CONNECTOR
3 - REAR WIPER MODULE
4 - NUT (2)
5 - LIFTGATE INNER PANEL
Th e r ea r wiper m odu le is con cea led wit h in t h e lift -
ga t e, below t h e lift ga t e gla ss a n d beh in d t h e lift ga t e
t r im pa n el (F ig. 12). Th e en d of t h e m ot or ou t pu t
sh a ft t h a t pr ot r u des t h r ou gh t h e lift ga t e ou t er pa n el
t o dr ive t h e r ea r wiper a r m a n d bla de is t h e on ly vis-
ible com pon en t of t h e r ea r wiper m odu le. A r u bber
ga sket , a bezel, a n d a n u t sea l a n d secu r e t h e m ot or
ou t pu t sh a ft t o t h e lift ga t e ou t er pa n el. A m olded
pla st ic n u t cover sn a ps on t o t h e bezel t o con cea l t h e
n u t a n d im pr ove a ppea r a n ce. Th e r ea r wiper m odu le
con sist s of t h e followin g m a jor com pon en t s:
• B ra c k e t - Th e r ea r wiper m odu le br a cket con -
sist s of a st a m ped st eel m ou n t in g pla t e for t h e wiper
WJ
REAR WI PER M ODU LE (Cont inue d)
m ot or t h a t is secu r ed wit h scr ews t o t h e wiper m ot or
a n d t o t h e lift ga t e in n er pa n el.
• Ele c tro n ic Co n tro ls - Th e r ea r wiper m odu le
elect r on ic con t r ols in clu de t h e r ea r wiper syst em
elect r on ic logic a n d r ea r wiper m ot or elect r on ic con -
t r ols. Th e elect r on ic con t r ols for t h e m ot or in clu de a n
elect r on ic speed con t r ol t h a t speeds t h e wiper bla de
n ea r t h e cen t er of t h e gla ss, bu t slows t h e wiper
bla de du r in g dir ect ion a l r ever sa ls a t ea ch en d of t h e
wipe pa t t er n a n d du r in g wiper bla de off-t h e-gla ss
pa r kin g for qu iet er oper a t ion .
• Mo to r - Th e per m a n en t m a gn et r ea r wiper
m ot or is secu r ed wit h scr ews t o t h e r ea r wiper m od-
u le br a cket . Th e wiper m ot or in clu des a n in t egr a l
t r a n sm ission , a n d t h e m ot or ou t pu t sh a ft .
Th e r ea r wiper m odu le ca n n ot be a dju st ed or
r epa ir ed. If a n y com pon en t of t h e m odu le is fa u lt y or
da m a ged, t h e en t ir e r ea r wiper m odu le u n it m u st be
r epla ced. Th e m ot or ou t pu t sh a ft ga sket , bezel, n u t ,
a n d n u t cover a r e a va ila ble for ser vice r epla cem en t .
OPERATION
Th e r ea r wiper m odu le r eceives n on -swit ch ed ba t -
t er y cu r r en t t h r ou gh a fu se in t h e J u n ct ion Block
(J B) a n d is gr ou n ded a t a ll t im es. Th e r ea r wiper
m odu le oper a t ion is con t r olled by t h e veh icle oper a t or
t h r ou gh ba t t er y cu r r en t sign a l in pu t s r eceived by t h e
r ea r wiper m odu le elect r on ic con t r ols fr om t h e r igh t
m u lt i-fu n ct ion swit ch on t h e st eer in g colu m n . Th e
m odu le a lso r eceives a n ext er n a l con t r ol in pu t fr om
t h e lift ga t e flip-u p gla ss a ja r swit ch cir cu it . Th e r ea r
wiper m odu le elect r on ic con t r ol logic u ses t h ese
in pu t s, it s in t er n a l in pu t s, a n d it s pr ogr a m m in g t o
pr ovide con t in u ou s wipe, dela y wipe, wipe-a ft er-wa sh
a n d off-t h e-gla ss wiper bla de pa r kin g. Th e wiper
bla de cyclin g is con t r olled by t h e r ea r wiper m odu le
elect r on ic con t r ols, wh ich con t r ol cu r r en t flow t o t h e
wiper m ot or br u sh es. Th e wiper m ot or t r a n sm ission
con ver t s t h e r ot a r y ou t pu t of t h e wiper m ot or t o t h e
ba ck a n d for t h wipin g m ot ion of t h e r ea r wiper a r m
a n d bla de on t h e lift ga t e gla ss.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e r ea r wiper a r m fr om t h e r ea r
wiper m ot or ou t pu t sh a ft . (Refer t o 8 - E LE CTRI-
CAL/RE AR WIP E RS/WASH E RS/RE AR WIP E R ARM
- RE MOVAL).
(3) Use a door t r im pa n el r em ova l t ool t o gen t ly
pr y a t t h e ba se of t h e n u t cover wh er e it m eet s t h e
wiper m ot or ou t pu t sh a ft bezel a n d ga sket on t h e
ou t er lift ga t e pa n el u n t il it u n sn a ps fr om t h e bezel
(F ig. 13). Be cer t a in t o u se pr oper ca u t ion t o pr ot ect
t h e ou t er lift ga t e pa n el a n d it s pa in t fin ish fr om
da m a ge du r in g t h is pr ocedu r e.
REAR WIPERS/WASHERS 8R - 45
Fig. 13 Rear Wiper Motor Output Shaft Remove/
Install
1 - NUT
2 - NUT COVER
3 - BEZEL AND GASKET
4 - LIFTGATE OUTER PANEL
5 - REAR WIPER MOTOR OUTPUT SHAFT
(4) Rem ove t h e n u t t h a t secu r es t h e r ea r wiper
m ot or ou t pu t sh a ft t o t h e ou t er lift ga t e pa n el.
(5) Rem ove t h e bezel a n d ga sket fr om t h e r ea r
wiper m ot or ou t pu t sh a ft .
(6) Rem ove t h e t r im pa n el fr om t h e in side of t h e
lift ga t e. (Refer t o 23 - BODY/DE CKLID/H ATCH /
LIF TGATE /TAILGATE /TRIM PANE L - RE MOVAL).
(7) Discon n ect t h e lift ga t e wir e h a r n ess con n ect or
for t h e r ea r wiper m odu le fr om t h e m odu le con n ect or
r ecept a cle (F ig. 14).
(8) Loosen t h e t wo n u t s t h a t secu r e t h e r ea r wiper
m odu le m ou n t in g br a cket t o t h e lift ga t e in n er pa n el.
(9) Slide t h e r ea r wiper m odu le a n d m ou n t in g
br a cket for wa r d fa r en ou gh t o disen ga ge t h e m ou n t -
in g n u t s fr om t h e keyed h oles in t h e lift ga t e in n er
pa n el.
(10) Rem ove t h e r ea r wiper m odu le a n d m ou n t in g
br a cket fr om t h e lift ga t e a s a u n it .
INSTALLATION
(1) P osit ion t h e r ea r wiper m odu le a n d br a cket t o
t h e lift ga t e a s a u n it (F ig. 14).
(2) In ser t t h e r ea r wiper m ot or ou t pu t sh a ft
t h r ou gh t h e h ole in t h e lift ga t e ou t er pa n el a n d
en ga ge t h e m ou n t in g n u t s in t h e keyed h oles in t h e
lift ga t e in n er pa n el.
(3) F r om t h e ou t side of t h e lift ga t e, cen t er t h e r ea r
wiper m ot or ou t pu t sh a ft in t h e lift ga t e ou t er pa n el
m ou n t in g h ole a n d in st a ll t h e ga sket a n d bezel over
t h e cen t er ed sh a ft (F ig. 13).
8R - 46 REAR WIPERS/WASHERS WJ
REAR WI PER M ODU LE (Cont inue d)

WI PER ARM PARK RAM P

REMOVAL
(1) Disen ga ge t h e r ea r wiper a r m su ppor t fr om t h e
wiper a r m pa r k r a m p on t h e r igh t side of t h e lift ga t e
ju st below t h e lift ga t e gla ss.
(2) Lift t h e wiper a r m a n d bla de a wa y fr om t h e
lift ga t e u n t il t h e wiper a r m h in ge is in it s over-cen t er
posit ion .
(3) Rem ove t h e scr ew t h a t secu r es t h e wiper a r m
pa r k r a m p t o t h e lift ga t e ou t er pa n el (F ig. 15).

Fig. 14 Rear Wiper Module Remove/Install

1 - KEYED SLOTS
2 - LIFTGATE WIRE HARNESS CONNECTOR
3 - REAR WIPER MODULE
4 - NUT (2)
5 - LIFTGATE INNER PANEL

(4) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e

r ea r wiper m ot or ou t pu t sh a ft t o t h e ou t er lift ga t e
pa n el. Tigh t en t h e n u t t o 4.8 N·m (43 in . lbs.).
(5) F r om t h e in side of t h e lift ga t e, in st a ll a n d Fig. 15 Wiper Arm Park Ramp Remove/Install
t igh t en t h e t wo n u t s t h a t secu r e t h e r ea r wiper m od- 1 - RIVET NUT
u le m ou n t in g br a cket t o t h e lift ga t e in n er pa n el. 2 - SCREW
Tigh t en t h e n u t s t o 5.3 N·m (47 in . lbs.). 3 - PARK RAMP
(6) Recon n ect t h e lift ga t e wir e h a r n ess con n ect or 4 - LIFTGATE
for t h e r ea r wiper m odu le t o t h e m odu le con n ect or
r ecept a cle. (4) Rem ove t h e wiper a r m pa r k r a m p fr om t h e lift -
(7) Rein st a ll t h e t r im pa n el on t o t h e in side of t h e ga t e ou t er pa n el.
lift ga t e. (Refer t o 23 - BODY/DE CKLID/H ATCH /
LIF TGATE /TAILGATE /TRIM PANE L - INSTALLA- INSTALLATION
TION). (1) P osit ion t h e wiper a r m pa r k r a m p on t o t h e lift -
(8) F r om t h e ou t side of t h e lift ga t e, pr ess t h e n u t ga t e ou t er pa n el (F ig. 15).
cover fir m ly a n d even ly over t h e r ea r wiper m ot or (2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
ou t pu t sh a ft bezel u sin g t h u m b pr essu r e u n t il it wiper a r m pa r k r a m p t o t h e lift ga t e ou t er pa n el.
sn a ps in t o pla ce. Tigh t en t h e scr ew t o 6.8 N·m (60 in . lbs.).
(9) Rein st a ll t h e r ea r wiper a r m on t o t h e r ea r (3) Lower t h e r ea r wiper a r m a n d bla de a n d gen t ly
wiper m ot or ou t pu t sh a ft . (Refer t o 8 - E LE CTRI- pla ce t h e wiper a r m su ppor t on t o t h e wiper a r m pa r k
CAL/RE AR WIP E RS/WASH E RS/RE AR WIP E R ARM r a m p.
- INSTALLATION).
(10) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ WIRING 8W - 1

WIRING
TABLE OF CON T EN T S

page page

WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1

COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1 REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1 OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . . 8W-12-1 FRONT LIGHTING. . . . . . . . . . . . . . . . . . . . 8W-50-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1 REAR LIGHTING. . . . . . . . . . . . . . . . . . . . . 8W-51-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1 TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . 8W-20-1 WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1 TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1 POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1 POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1 POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . 8W-35-1 POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
VEHICLE THEFT SECURITY SYSTEM. . . . . 8W-39-1 POWER SUNROOF . . . . . . . . . . . . . . . . . . . 8W-64-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1 SPLICE INFORMATION. . . . . . . . . . . . . . . . 8W-70-1
HORN/CIGAR LIGHTER/POWER OUTLET. . 8W-41-1 CONNECTOR PIN-OUT . . . . . . . . . . . . . . . . 8W-80-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1 CONNECTOR/GROUND/SPLICE
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1 POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
BODY CONTROL MODULE. . . . . . . . . . . . . 8W-45-1
WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1

8 W-0 1 WI RI N G DI AGRAM I N FORM AT I ON

TABLE OF CONTENTS
page page

WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A

DESCRIPTION SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . ...1 SHORT TO GROUND ON FUSES
DESCRIPTION - CIRCUIT INFORMATION . ...5 POWERING SEVERAL LOADS . . . . . . . . . . . 10
DESCRIPTION - CIRCUIT FUNCTIONS . . . ...6 STANDARD PROCEDURE - TESTING FOR A
DESCRIPTION - SECTION IDENTIFICATION VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10
AND INFORMATION . . . . . . . . . . . . . . . . . ...6 SPECIAL TOOLS
DESCRIPTION - CONNECTOR, GROUND WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10
AND SPLICE INFORMATION . . . . . . . . . . . ...7 CONNECTOR
WARNING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WARNINGS - GENERAL . . . . . . . . . . . . . . ...7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - WIRING DIODE
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . ...7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - TERMINAL
ELECTROSTATIC DISCHARGE (ESD) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SENSITIVE DEVICES . . . . . . . . . . . . . . . . ...8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - TESTING OF WIRE
VOLTAGE POTENTIAL . . . . . . . . . . . . . . . . ...9 STANDARD PROCEDURE - WIRE SPLICING . . 15
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . ...9

WI RI N G DI AGRAM Com pon en t s a r e sh own t wo wa ys. A solid lin e

I N FORM AT I ON
DESCRI PT I ON
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
Da im ler Ch r ysler Cor por a t ion wir in g dia gr a m s a r e
design ed t o pr ovide in for m a t ion r ega r din g t h e veh i-
cles wir in g con t en t . In or der t o effect ively u se t h e
wir in g dia gr a m s to dia gn ose and r epa ir
Da im ler Ch r ysler Cor por a t ion veh icles, it is im por t a n t
t o u n der st a n d a ll of t h eir fea t u r es a n d ch a r a ct er is-
t ics.
Dia gr a m s a r e a r r a n ged su ch t h a t t h e power (B+)
side of t h e cir cu it is pla ced n ea r t h e t op of t h e pa ge,
a n d t h e gr ou n d (B-) side of t h e cir cu it is pla ced n ea r
t h e bot t om of t h e pa ge (F ig. 1).
All swit ch es, com pon en t s, a n d m odu les a r e sh own
in t h e a t r est posit ion wit h t h e door s closed a n d t h e
key r em oved fr om t h e ign it ion (F ig. 2).
a r ou n d a com pon en t in dica t es t h a t t h e com pon en t is
com plet e. A da sh ed lin e a r ou n d t h e com pon en t in di-
ca t es t h a t t h e com pon en t is bein g sh own is n ot com -
plet e. In com plet e com pon en t s h a ve a r efer en ce
n u m ber t o in dica t e t h e pa ge wh er e t h e com pon en t is
sh own com plet e.
It is im por t a n t t o r ea lize t h a t n o a t t em pt is m a de
on t h e dia gr a m s t o r epr esen t com pon en t s a n d wir in g
a s t h ey a ppea r on t h e veh icle. F or exa m ple, a sh or t
piece of wir e is t r ea t ed t h e sa m e a s a lon g on e. In
a ddit ion , swit ch es a n d ot h er com pon en t s a r e sh own
a s sim ply a s possible, wit h r ega r d t o fu n ct ion on ly.
SYMBOLS
In t er n a t ion a l sym bols a r e u sed t h r ou gh ou t t h e wir-
in g dia gr a m s. Th ese sym bols a r e con sist en t wit h
t h ose bein g u sed a r ou n d t h e wor ld (F ig. 3).
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WJ
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

Fig. 1 WIRING DIAGRAM EXAMPLE 1

WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

Fig. 2 WIRING DIAGRAM EXAMPLE 2

8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WJ
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

Fig. 3 WIRING DIAGRAM SYMBOLS

WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)
TERMINOLOGY WI RE COLOR CODE CH ART
Th is is a list of t er m s a n d defin it ion s u sed in t h e
wir in g dia gr a m s. COLOR CODE COLOR
BL BLUE
LH D . . . . . . . . . . . . . . . . . Left H a n d Dr ive Veh icles
RH D . . . . . . . . . . . . . . . . Righ t H a n d Dr ive Veh icles BK BLACK
ATX . . Au t om a t ic Tr a n sm ission s-F r on t Wh eel Dr ive BR BROWN
MTX . . . . Ma n u a l Tr a n sm ission s-F r on t Wh eel Dr ive DB DARK BLUE
AT . . . . Au t om a t ic Tr a n sm ission s-Rea r Wh eel Dr ive
DG DARK GREEN
MT . . . . . Ma n u a l Tr a n sm ission s-Rea r Wh eel Dr ive
SOH C . . . . . . . . . . . Sin gle Over H ea d Ca m E n gin e GY GRAY
DOH C . . . . . . . . . . Dou ble Over H ea d Ca m E n gin e LB LIGHT BLUE
Bu ilt -Up-E xpor t . . . . . . . . Veh icles Bu ilt F or Sa le In LG LIGHT GREEN
Ma r ket s Ot h er Th a n Nor t h Am er ica
OR ORANGE
E xcept Bu ilt -Up-E xpor t . . Veh icles Bu ilt F or Sa le In
Nor t h Am er ica PK PINK
RD RED
DESCRIPTION - CIRCUIT INFORMATION
TN TAN
E a ch wir e sh own in t h e dia gr a m s con t a in s a code
wh ich iden t ifies t h e m a in cir cu it , pa r t of t h e m a in VT VIOLET
cir cu it , ga ge of wir e, a n d color (F ig. 4). WT WHITE
YL YELLOW
* WITH TRACER

Fig. 4 WIRE CODE IDENTIFICATION

1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WJ
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND

All cir cu it s in t h e dia gr a m s u se a n a lph a /n u m er ic INFORMATION
code t o iden t ify t h e wir e a n d it ’s fu n ct ion . To iden t ify Th e wir in g dia gr a m s a r e gr ou ped in t o in dividu a l
wh ich cir cu it code a pplies t o a syst em , r efer t o t h e sect ion s. If a com pon en t is m ost likely fou n d in a pa r-
Cir cu it Iden t ifica t ion Code Ch a r t . Th is ch a r t sh ows t icu la r gr ou p, it will be sh own com plet e (a ll wir es,
t h e m a in cir cu it s on ly a n d does n ot sh ow t h e secon d- con n ect or s, a n d pin s) wit h in t h a t gr ou p. F or exa m -
a r y codes t h a t m a y a pply t o som e m odels. ple, t h e Au t o Sh u t down Rela y is m ost likely t o be
fou n d in Gr ou p 30, so it is sh own t h er e com plet e. It
CI RCU I T I DEN T I FI CAT I ON CODE CH ART
ca n , h owever, be sh own pa r t ia lly in a n ot h er gr ou p if
it con t a in s som e a ssocia t ed wir in g.
CIRCUIT FUNCTION Splice dia gr a m s in Sect ion 8W-70 sh ow t h e en t ir e
A BATTERY FEED splice a n d pr ovide r efer en ces t o ot h er sect ion s t h e
B BRAKE CONTROLS splices ser ves. Sect ion 8W-70 on ly con t a in s splice dia -
gr a m s t h a t a r e n ot sh own in t h eir en t ir et y som e-
C CLIMATE CONTROLS wh er e else in t h e wir in g dia gr a m s.
D DIAGNOSTIC CIRCUITS Sect ion 8W-80 sh ows ea ch con n ect or a n d t h e cir-
E DIMMING ILLUMINATION cu it s in volved wit h t h a t con n ect or. Th e con n ect or s
CIRCUITS a r e iden t ified u sin g t h e n a m e/n u m ber on t h e dia -
gr a m pa ges.
F FUSED CIRCUITS
G MONITORING CIRCUITS WI RI N G SECT I ON CH ART
(GAUGES)
H OPEN GROUP TOPIC
I NOT USED 8W-01 thru General information and Diagram
J OPEN 8W-09 Overview
K POWERTRAIN CONTROL 8W-10 thru Main Sources of Power and
MODULE 8W-19 Vehicle Grounding
L EXTERIOR LIGHTING 8W-20 thru Starting and Charging
M INTERIOR LIGHTING 8W-29
N NOT USED 8W-30 thru Powertrain/Drivetrain Systems
8W-39
O NOT USED
8W-40 thru Body Electrical items and A/C
P POWER OPTION (BATTERY 8W-49
FEED)
8W-50 thru Exterior Lighting, Wipers and
Q POWER OPTIONS (IGNITION 8W-59 Trailer Tow
FEED)
8W-60 thru Power Accessories
R PASSIVE RESTRAINT 8W-69
S SUSPENSION/STEERING 8W-70 Splice Information
T TRANSMISSION/TRANSAXLE/ 8W-80 Connector Pin Outs
TRANSFER CASE
8W-91 Connector, Ground and Splice
U OPEN Locations
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
SPLICE INFORMATION
PROCEDURE REQUIRES IT TO BE ON.
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ- WARNING: SET THE PARKING BRAKE WHEN
ical example might be the Supplemental Restraint WORKING ON ANY VEHICLE. AN AUTOMATIC
System connectors. Always check parts availability TRANSMISSION SHOULD BE IN PARK. A MANUAL
before attempting a repair. TRANSMISSION SHOULD BE IN NEUTRAL.

IDENTIFICATION WARNING: OPERATE THE ENGINE ONLY IN A

In -lin e con n ect or s a r e iden t ified by a n u m ber, a s
follows:
• In -lin e con n ect or s loca t ed in t h e en gin e com pa r t -
m en t a r e C100 ser ies n u m ber s
• In -lin e con n ect or s loca t ed in t h e In st r u m en t
P a n el a r ea a r e C200 ser ies n u m ber s.
• In -lin e con n ect or s loca t ed in t h e body a r e C300
ser ies n u m ber s.
• J u m per h a r n ess con n ect or s a r e C400 ser ies
n u m ber s.
• Gr ou n ds a n d gr ou n d con n ect or s a r e iden t ified
wit h a “G” a n d follow t h e sa m e ser ies n u m ber in g a s
t h e in -lin e con n ect or s.
• Splices a r e iden t ified wit h a n “S” a n d follow t h e
sa m e ser ies n u m ber in g a s t h e in -lin e con n ect or s.
• Com pon en t con n ect or s a r e iden t ified by t h e com -
pon en t n a m e in st ea d of a n u m ber. Mu lt iple con n ec-
t or s on a com pon en t u se a C1, C2, et c. iden t ifier.
LOCATIONS
Sect ion 8W-91 con t a in s con n ect or /gr ou n d/splice
loca t ion illu st r a t ion s. Th e illu st r a t ion s con t a in t h e
con n ect or n a m e (or n u m ber )/gr ou n d n u m ber /splice
n u m ber a n d com pon en t iden t ifica t ion . Con n ect or /
gr ou n d/splice loca t ion ch a r t s in sect ion 8W-91 r efer-
en ce t h e figu r e n u m ber s of t h e illu st r a t ion s.
Th e a bbr evia t ion T/O is u sed in t h e com pon en t
loca t ion sect ion t o in dica t e a poin t in wh ich t h e wir-
in g h a r n ess br a n ch es ou t t o a com pon en t . Th e a bbr e-
via t ion N/S m ea n s Not Sh own in t h e illu st r a t ion s
WARN I N G
WARNINGS - GENERAL
WARN IN GS pr ovide in for m a t ion t o pr even t per-
son a l in ju r y a n d veh icle da m a ge. Below is a list of
gen er a l wa r n in gs t h a t sh ou ld be followed a n y t im e a
veh icle is bein g ser viced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
Wh en dia gn osin g a pr oblem in a n elect r ica l cir cu it
t h er e a r e sever a l com m on t ools n ecessa r y. Th ese t ools
a r e list ed a n d expla in ed below.
• J u m per Wir e - Th is is a t est wir e u sed t o con -
n ect t wo poin t s of a cir cu it . It ca n be u sed t o bypa ss
a n open in a cir cu it .
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
• Volt m et er - Used t o ch eck for volt a ge on a cir-
cu it . Alwa ys con n ect t h e bla ck lea d t o a kn own good
gr ou n d a n d t h e r ed lea d t o t h e posit ive side of t h e
cir cu it .
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)
• Oh m m et er - Used t o ch eck t h e r esist a n ce
bet ween t wo poin t s of a cir cu it . Low or n o r esist a n ce
in a cir cu it m ea n s good con t in u it y.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle’s
electrical system can cause damage to the equip-
ment and provide false readings.
• P r obin g Tools - Th ese t ools a r e u sed for pr obin g
t er m in a ls in con n ect or s (F ig. 5). Select t h e pr oper
size t ool fr om Specia l Tool P a cka ge 6807, a n d in ser t
it in t o t h e t er m in a l bein g t est ed. Use t h e ot h er en d
of t h e t ool t o in ser t t h e m et er pr obe.
Fig. 5 PROBING TOOL
1 - SPECIAL TOOL 6801
2 - PROBING END
INTERMITTENT AND POOR CONNECTIONS
Most in t er m it t en t elect r ica l pr oblem s a r e ca u sed
by fa u lt y elect r ica l con n ect ion s or wir in g. It is a lso
possible for a st ickin g com pon en t or r ela y t o ca u se a
pr oblem . Befor e con dem n in g a com pon en t or wir in g
a ssem bly, ch eck t h e followin g it em s.
• Con n ect or s a r e fu lly sea t ed
• Spr ea d t er m in a ls, or t er m in a l pu sh ou t
• Ter m in a ls in t h e wir in g a ssem bly a r e fu lly
sea t ed in t o t h e con n ect or /com pon en t a n d locked in t o
posit ion
• Dir t or cor r osion on t h e t er m in a ls. An y a m ou n t of
cor r osion or dir t cou ld ca u se a n in t er m it t en t pr oblem
• Da m a ged con n ect or /com pon en t ca sin g exposin g
t h e it em t o dir t or m oist u r e
• Wir e in su la t ion t h a t h a s r u bbed t h r ou gh ca u sin g
a sh or t t o gr ou n d
• Som e or a ll of t h e wir in g st r a n ds br oken in side
of t h e in su la t ion
• Wir in g br oken in side of t h e in su la t ion
TROUBLESHOOTING WIRING PROBLEMS
Wh en t r ou blesh oot in g wir in g pr oblem s t h er e a r e
six st eps wh ich ca n a id in t h e pr ocedu r e. Th e st eps
WJ
a r e list ed a n d expla in ed below. Alwa ys ch eck for n on -
fa ct or y it em s a dded t o t h e veh icle befor e doin g a n y
dia gn osis. If t h e veh icle is equ ipped wit h t h ese it em s,
discon n ect t h em t o ver ify t h ese a dd-on it em s a r e n ot
t h e ca u se of t h e pr oblem .
(1) Ver ify t h e pr oblem .
(2) Ver ify a n y r ela t ed sym pt om s. Do t h is by per-
for m in g oper a t ion a l ch ecks on com pon en t s t h a t a r e
in t h e sa m e cir cu it . Refer t o t h e wir in g dia gr a m s.
(3) An a lyze t h e sym pt om s. Use t h e wir in g dia -
gr a m s t o det er m in e wh a t t h e cir cu it is doin g, wh er e
t h e pr oblem m ost likely is occu r r in g a n d wh er e t h e
dia gn osis will con t in u e.
(4) Isola t e t h e pr oblem a r ea .
(5) Repa ir t h e pr oblem a r ea .
(6) Ver ify t h e pr oper oper a t ion . F or t h is st ep,
ch eck for pr oper oper a t ion of a ll it em s on t h e
r epa ir ed cir cu it . Refer t o t h e wir in g dia gr a m s.
STAN DARD PROCEDU RE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All E SD sen sit ive com pon en t s a r e solid st a t e a n d a
sym bol (F ig. 6) is u sed t o in dica t e t h is. Wh en h a n dlin g
a n y com pon en t wit h t h is sym bol, com ply wit h t h e fol-
lowin g pr ocedu r es t o r edu ce t h e possibilit y of elect r o-
st a t ic ch a r ge bu ild u p on t h e body a n d in a dver t en t
disch a r ge in t o t h e com pon en t . If it is n ot kn own
wh et h er t h e pa r t is E SD sen sit ive, a ssu m e t h a t it is.
(1) Alwa ys t ou ch a kn own good gr ou n d befor e h a n -
dlin g t h e pa r t . Th is sh ou ld be r epea t ed wh ile h a n -
dlin g t h e pa r t a n d m or e fr equ en t ly a ft er slidin g
a cr oss a sea t , sit t in g down fr om a st a n din g posit ion ,
or wa lkin g a dist a n ce.
(2) Avoid t ou ch in g elect r ica l t er m in a ls of t h e pa r t ,
u n less in st r u ct ed t o do so by a wr it t en pr ocedu r e.
(3) Wh en u sin g a volt m et er, be su r e t o con n ect t h e
gr ou n d lea d fir st .
(4) Do n ot r em ove t h e pa r t for m it ’s pr ot ect ive
pa ckin g u n t il it is t im e t o in st a ll t h e pa r t .
(5) Befor e r em ovin g t h e pa r t fr om it ’s pa ka ge,
gr ou n d t h e pa ka ge t o a kn own good gr ou n d on t h e
veh icle.
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - TESTING FOR

VOLTAGE POTENTIAL
(1) Con n ect t h e gr ou n d lea d of a volt m et er t o a
kn own good gr ou n d (F ig. 7).
(2) Con n ect t h e ot h er lea d of t h e volt m et er t o t h e
select ed t est poin t . Th e veh icle ign it ion m a y n eed t o
be t u r n ed ON t o ch eck volt a ge. Refer t o t h e a ppr opr i-
a t e t est pr ocedu r e.
CONTINUITY
(1) Rem ove t h e fu se for t h e cir cu it bein g ch ecked
or, discon n ect t h e ba t t er y.
(2) Con n ect on e lea d of t h e oh m m et er t o on e side
of t h e cir cu it bein g t est ed (F ig. 8).
(3) Con n ect t h e ot h er lea d t o t h e ot h er en d of t h e
cir cu it bein g t est ed. Low or n o r esist a n ce m ea n s good
con t in u it y.

Fig. 7 TESTING FOR VOLTAGE POTENTIAL

Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT

STANDARD PROCEDURE - TESTING FOR A

SHORT TO GROUND
(1) Rem ove t h e fu se a n d discon n ect a ll it em s
in volved wit h t h e fu se.
(2) Con n ect a t est ligh t or a volt m et er a cr oss t h e
t er m in a ls of t h e fu se.
(3) St a r t in g a t t h e fu se block, wiggle t h e wir in g
h a r n ess a bou t six t o eigh t in ch es a pa r t a n d wa t ch
t h e volt m et er /t est la m p.
(4) If t h e volt m et er r egist er s volt a ge or t h e t est
la m p glows, t h er e is a sh or t t o gr ou n d in t h a t gen -
er a l a r ea of t h e wir in g h a r n ess.
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WJ
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)

STANDARD PROCEDURE - TESTING FOR A SPECI AL T OOLS

SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS WIRING/TERMINAL
(1) Refer t o t h e wir in g dia gr a m s a n d discon n ect or
isola t e a ll it em s on t h e su spect ed fu sed cir cu it s.
(2) Repla ce t h e blown fu se.
(3) Su pply power t o t h e fu se by t u r n in g ON t h e
ign it ion swit ch or r e-con n ect in g t h e ba t t er y.
(4) St a r t con n ect in g or en er gizin g t h e it em s in t h e
fu se cir cu it on e a t a t im e. Wh en t h e fu se blows t h e
cir cu it wit h t h e sh or t t o gr ou n d h a s been isola t ed.

STANDARD PROCEDURE - TESTING FOR A PROBING TOOL PACKAGE 6807

VOLTAGE DROP
(1) Con n ect t h e posit ive lea d of t h e volt m et er t o
t h e side of t h e cir cu it closest t o t h e ba t t er y (F ig. 9).
(2) Con n ect t h e ot h er lea d of t h e volt m et er t o t h e
ot h er side of t h e swit ch , com pon en t or cir cu it .
(3) Oper a t e t h e it em .
(4) Th e volt m et er will sh ow t h e differ en ce in volt -
a ge bet ween t h e t wo poin t s.

TERMINAL PICK TOOL SET 6680

TERMINAL REMOVING TOOLS 6932 AND 8638

Fig. 9 TESTING FOR VOLTAGE DROP

TERMINAL REMOVING TOOL 6934

WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11

CON N ECT OR INSTALLATION

REMOVAL
(1) Discon n ect ba t t er y.
(2) Relea se Con n ect or Lock (F ig. 10).
(3) Discon n ect t h e con n ect or bein g r epa ir ed fr om
it s m a t in g h a lf/com pon en t .
(4) Rem ove t h e dr ess cover (if a pplica ble) (F ig. 10).
(1) In ser t t h e r em oved t er m in a l in t h e sa m e ca vit y
on t h e r epa ir con n ect or.
(2) Repea t st eps for ea ch t er m in a l in t h e con n ec-
t or, bein g su r e t h a t a ll wir es a r e in ser t ed in t o t h e
pr oper ca vit ies. F or a ddit ion a l con n ect or pin -ou t
iden t ifica t ion , r efer t o t h e wir in g dia gr a m s.
(3) Wh en t h e con n ect or is r e-a ssem bled, t h e sec-
on da r y t er m in a l lock m u st be pla ced in t h e locked
posit ion t o pr even t t er m in a l pu sh ou t .
(4) Repla ce dr ess cover (if a pplica ble).
(5) Con n ect con n ect or t o it s m a t in g h a lf/com po-
n en t .
(6) Con n ect ba t t er y a n d t est a ll a ffect ed syst em s.

Fig. 10 REMOVAL OF DRESS COVER

1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR

(5) Relea se t h e Secon da r y Ter m in a l Lock, if

r equ ir ed (F ig. 11).
(6) P osit ion t h e con n ect or lockin g fin ger a wa y fr om
t h e t er m in a l u sin g t h e pr oper specia l t ool. P u ll on
t h e wir e t o r em ove t h e t er m in a l fr om t h e con n ect or
(F ig. 12).
8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION WJ
CON N ECT OR (Cont inue d)

Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS

1 - Secondary Terminal Lock
WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13
CON N ECT OR (Cont inue d)

Fig. 12 TERMINAL REMOVAL

1 - TYPICAL CONNECTOR 8 - SPECIAL TOOL 6742
2 - PICK FROM SPECIAL TOOL KIT 6680 9 - THOMAS AND BETTS CONNECTOR
3 - APEX CONNECTOR 10 - SPECIAL TOOL 6934
4 - PICK FROM SPECIAL TOOL KIT 6680 11 - TYCO CONNECTOR
5 - AUGAT CONNECTOR 12 - SPECIAL TOOL 8638
6 - SPECIAL TOOL 6932
7 - MOLEX CONNECTOR
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION WJ

DI ODE T ERM I N AL
REMOVAL REMOVAL
(1) Discon n ect t h e ba t t er y. (1) F ollow st eps for r em ovin g t er m in a ls descr ibed
(2) Loca t e t h e diode in t h e h a r n ess, a n d r em ove in t h e con n ect or r em ova l sect ion .
t h e pr ot ect ive cover in g. (2) Cu t t h e wir e 6 in ch es fr om t h e ba ck of t h e con -
(3) Rem ove t h e diode fr om t h e h a r n ess, pa y a t t en - n ect or.
t ion t o t h e cu r r en t flow dir ect ion (F ig. 13).
INSTALLATION
(1) Select a wir e fr om t h e t er m in a l r epa ir kit t h a t
best m a t ch es t h e color a n d ga ge of t h e wir e bein g
r epa ir ed.
(2) Cu t t h e r epa ir wir e t o t h e pr oper len gt h a n d
r em ove on e–h a lf (1/2) in ch of in su la t ion .
(3) Splice t h e r epa ir wir e t o t h e wir e h a r n ess (see
wir e splicin g pr ocedu r e).
(4) In ser t t h e r epa ir ed wir e in t o t h e con n ect or.
(5) In st a ll t h e con n ect or lockin g wedge, if r equ ir ed,
a n d r econ n ect t h e con n ect or t o it s m a t in g h a lf/com po-
n en t .
(6) Re-t a pe t h e wir e h a r n ess st a r t in g a t 1–1/2
in ch es beh in d t h e con n ect or a n d 2 in ch es pa st t h e
r epa ir.
Fig. 13 DIODE IDENTIFICATION (7) Con n ect ba t t er y a n d t est a ll a ffect ed syst em s.
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS

INSTALLATION
(1) Rem ove t h e in su la t ion fr om t h e wir es in t h e
h a r n ess. On ly r em ove en ou gh in su la t ion t o solder in
t h e n ew diode.
(2) In st a ll t h e n ew diode in t h e h a r n ess, m a kin g
su r e cu r r en t flow is cor r ect . If n ecessa r y, r efer t o t h e
a ppr opr ia t e wir in g dia gr a m for cu r r en t flow (F ig. 13).
(3) Solder t h e con n ect ion t oget h er u sin g r osin cor e
t ype solder on ly. D o n o t u s e a c id c o re s o ld e r.
(4) Ta pe t h e diode t o t h e h a r n ess u sin g elect r ica l
t a pe. Ma ke su r e t h e diode is com plet ely sea led fr om
t h e elem en t s.
(5) Re-con n ect t h e ba t t er y a n d t est a ffect ed sys-
t em s.
WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15

WI RE (5) Solder t h e con n ect ion t oget h er u sin g r osin cor e

t ype solder on ly (F ig. 16).
STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER.
Wh en splicin g a wir e, it is im por t a n t t h a t t h e cor-
r ect ga ge be u sed a s sh own in t h e wir in g dia gr a m s.
(1) Rem ove on e-h a lf (1/2) in ch of in su la t ion fr om
ea ch wir e t h a t n eeds t o be spliced.
(2) P la ce a piece of a dh esive lin ed h ea t sh r in k t u b-
in g on on e side of t h e wir e. Ma ke su r e t h e t u bin g will
be lon g en ou gh t o cover a n d sea l t h e en t ir e r epa ir
a r ea .
(3) P la ce t h e st r a n ds of wir e over la ppin g ea ch
ot h er in side of t h e splice clip (F ig. 14).

Fig. 16 SOLDER SPLICE

1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON

(6) Cen t er t h e h ea t sh r in k t u bin g over t h e join t

a n d h ea t u sin g a h ea t gu n . H ea t t h e join t u n t il t h e
t u bin g is t igh t ly sea led a n d sea la n t com es ou t of bot h
en ds of t h e t u bin g (F ig. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND

(4) Usin g cr im pin g t ool, Mopa r p/n 05019912AA,

cr im p t h e splice clip a n d wir es t oget h er (F ig. 15).

Fig. 17 HEAT SHRINK TUBE

1 - SEALANT
2 - HEAT SHRINK TUBE

Fig. 15 CRIMPING TOOL

1 - CRIMPING TOOL
WJ 8W-02 COMPONENT INDEX
8 W-0 2 COM PON EN T I N DEX
Co m p o n e n t P age
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . . . . 8W-42
A/C P r essu r e Tr a n sdu cer . . . . . . . . . . . . . . . . 8W-42
Acceler a t or P eda l P osit ion Sen sor . . . . . . . . . 8W-30
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . . . 8W-64
Adju st a ble P eda ls . . . . . . . . . . . . . . . . . . . . . 8W-30
Air ba gs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Am bien t Tem per a t u r e Sen sor . . . . . . . . . . . . 8W-45
An t en n a s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Ash Receiver La m p . . . . . . . . . . . . . . . . . . . . 8W-44
Au t o Sh u t Down Rela y . . . . . . . . . . . . . . . . . 8W-30
Au t om a t ic Da y/Nigh t Mir r or . . . . . . . . . . . . . 8W-49
Au t om a t ic H ea dla m p Ligh t Sen sor /VTSS
LE D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39
Au t om a t ic Zon e Con t r ol Modu le . . . . . . . . . . 8W-42
Ba ck-Up La m p Rela y . . . . . . . . . . . . . . . . . . . 8W-51
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . . . . . 8W-30
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Blen d Door Mot or /Act u a t or . . . . . . . . . . . . . . 8W-42
Blower Mot or . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . . . 8W-45
Boost P r essu r e Sen sor . . . . . . . . . . . . . . . . . . 8W-30
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . . . 8W-33
Ca m sh a ft P osit ion Sen sor . . . . . . . . . . . . . . . 8W-30
Ca pa cit or s . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Ca r go La m p . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Cen t er H igh Mou n t ed St op La m p . . . . . . . . . 8W-51
Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Cir cu it Br ea ker s . . . . . . . . . . . . . . . . . . . . . . 8W-12
Clockspr in g . . . . . . . . . . . . . . . . . . 8W-33, 41, 43, 47
Coil On P lu gs . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Coil Ra il . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Com bin a t ion F la sh er . . . . . . . . . . . . . . . . . . . 8W-52
Com pa ct Disc Ch a n ger . . . . . . . . . . . . . . . . . . 8W-47
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . . . 8W-35
Coola n t Level Sen sor . . . . . . . . . . . . . . . . . . . 8W-45
Cou r t esy La m ps . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Cr a n kca se H ea t er . . . . . . . . . . . . . . . . . . . . . 8W-30
Cr a n ksh a ft P osit ion Sen sor . . . . . . . . . . . . . . 8W-30
Cylin der Lock Swit ch es . . . . . . . . . . . . . . . . . 8W-61
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . . . 8W-18
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . . . . 8W-18
E GR Solen oid . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
E lect r ic Br a ke . . . . . . . . . . . . . . . . . . . . . . . . 8W-54
E lect r on ic Speed Con t r ol Ser vo . . . . . . . . . . . 8W-33
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-30
E n gin e Coola n t Tem per a t u r e Sen sor . . . . . . 8W-30
E n gin e Oil P r essu r e Sen sor . . . . . . . . . . . . . . 8W-30
E n gin e St a r t er Mot or . . . . . . . . . . . . . . . . . . . 8W-21
E VAP /P u r ge Solen oid . . . . . . . . . . . . . . . . . . . 8W-30
F og La m ps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 51
F u el In ject or s . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
F u el P r essu r e Sen sor . . . . . . . . . . . . . . . . . . . 8W-30
8W - 02 - 1
Co m p o n e n t P age
F u el P r essu r e Solen oid . . . . . . . . . . . . . . . . . 8W-30
F u el P u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
F u el Ta n k Modu le . . . . . . . . . . . . . . . . . . . . . 8W-30
F u ses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 12
F u sible Lin k . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 20
Gr ou n ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20, 30
Glove Box La m p . . . . . . . . . . . . . . . . . . . . . . 8W-44
Glow P lu gs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
H ea dla m p Levelin g Mot or . . . . . . . . . . . . . . . 8W-50
H ea t ed Sea t s . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
H igh Bea m H ea dla m ps . . . . . . . . . . . . . . . . . 8W-50
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-39
H or n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
H ydr a u lic Coolin g Modu le . . . . . . . . . . . . 8W-30, 42
Idle Air Con t r ol Mot or . . . . . . . . . . . . . . . . . . 8W-30
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Im pa ct Sen sor s . . . . . . . . . . . . . . . . . . . . . . . 8W-43
In pu t Speed Sen sor . . . . . . . . . . . . . . . . . . . . 8W-31
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . . 8W-40
In t a ke Air Tem per a t u r e Sen sor . . . . . . . . . . . 8W-30
In t a ke P or t Swir l Act u a t or . . . . . . . . . . . . . . 8W-30
In t r u sion Tr a n sceiver Modu le . . . . . . . . . . . . 8W-49
J u n ct ion Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Kn ock Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
La m p Assem blies . . . . . . . . . . . . . . . . . . . 8W-51, 52
Lea k Det ect ion P u m p . . . . . . . . . . . . . . . . . . 8W-30
Licen se La m ps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Lift ga t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61
Lin e P r essu r e Sen sor . . . . . . . . . . . . . . . . . . . 8W-31
Low Bea m H ea dla m ps . . . . . . . . . . . . . . . . . . 8W-50
Low Bea m Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-50
Low Bea m /Da yt im e Ru n n in g La m p Rela y . . . 8W-50
Lu m ba r Mot or . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Lu m ba r Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Ma n ifold Absolu t e P r essu r e Sen sor . . . . . . . . 8W-30
Ma n u a l Tem per a t u r e Con t r ol . . . . . . . . . . . . . 8W-42
Ma ss Air F low Sen sor . . . . . . . . . . . . . . . . . . 8W-30
Mem or y Set Swit ch . . . . . . . . . . . . . . . . . 8W-62, 63
Mode Door Mot or /Act u a t or . . . . . . . . . . . . . . . 8W-42
Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . 8W-50, 53
Ou t pu t Speed Sen sor . . . . . . . . . . . . . . . . . . . 8W-31
Over h ea d Ma p/Cou r t esy La m p . . . . . . . . . . . 8W-44
Oxygen Sen sor s . . . . . . . . . . . . . . . . . . . . . . . 8W-30
P a r k Br a ke Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-40
P a r k La m p . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . . . . 8W-31
P a r k/Tu r n Sign a l La m ps . . . . . . . . . . . . . . . . 8W-50
P ower Am plifier . . . . . . . . . . . . . . . . . . . . . . . 8W-47
P ower Con n ect or . . . . . . . . . . . . . . . . . . . . . . 8W-41
P ower Dist r ibu t ion Cen t er . . . . . . . . . . . . . . . 8W-10
P ower Mir r or s . . . . . . . . . . . . . . . . . . . . . . . . 8W-62
8W - 02 - 2 8W-02 COMPONENT INDEX WJ

Co m p o n e n t P age Co m p o n e n t P age
P ower Ou t let . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Speed Con t r ol Swit ch es . . . . . . . . . . . . . . . . . 8W-33
P ower Sea t s . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63 Su n r oof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64
P ower Win dows . . . . . . . . . . . . . . . . . . . . . . . 8W-60 Tem per a t u r e Va lve Act u a t or . . . . . . . . . . . . . 8W-42
P ower t r a in Con t r ol Modu le . . . . . . . . . . . . . . 8W-30 Th r ot t le P osit ion Sen sor . . . . . . . . . . . . . . . . 8W-30
Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Tr a iler Tow . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54
Ra in Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49 Tr a n sfer Ca se P osit ion Sen sor . . . . . . . . . . . . 8W-31
Recir cu la t ion Door Mot or /Act u a t or . . . . . . . . 8W-42 Tr a n sm ission . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Red Br a ke Wa r n in g In dica t or Swit ch . . . . . . . 8W-35 Tu r n Sign a l La m ps . . . . . . . . . . . . . . . . . . . . 8W-52
Rem ot e Keyless Modu le . . . . . . . . . . . . . . . . . 8W-39 Un der h ood La m p . . . . . . . . . . . . . . . . . . . . . . 8W-44
Rem ot e Ra dio Swit ch es . . . . . . . . . . . . . . . . . 8W-47 Veh icle In for m a t ion Cen t er . . . . . . . . . . . . . . 8W-49
Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Viscou s/Ca bin H ea t er . . . . . . . . . . . . . . . . . . . 8W-30
Sea t Belt Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-43 Visor /Va n it y La m ps . . . . . . . . . . . . . . . . . . . . 8W-44
Sea t Modu le . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63 Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . . 8W-53
Sen t r y Key Im m obilizer Modu le . . . . . . . . . . 8W-39 Wa st ega t e Solen oid . . . . . . . . . . . . . . . . . . . . 8W-30
Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . . . . 8W-31 Wa t er In F u el Sen sor . . . . . . . . . . . . . . . . . . . 8W-30
Side Im pa ct Sen sor s . . . . . . . . . . . . . . . . . . . 8W-43 Wh eel Speed Sen sor s . . . . . . . . . . . . . . . . . . . 8W-35
Side Ma r ker La m ps . . . . . . . . . . . . . . . . . . . . 8W-50 Win dow Defogger . . . . . . . . . . . . . . . . . . . . . . 8W-48
Side Repea t er La m ps . . . . . . . . . . . . . . . . . . . 8W-52 Wiper H igh /Low Rela y . . . . . . . . . . . . . . . . . . 8W-53
Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49 Wiper Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53
Spea ker s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Wa sh er P u m p . . . . . . . . . . . . . . . . . . . . . . . . . 8W-5
WJ 8W-10 POWER DISTRIBUTION
8 W-1 0 POWER DI ST RI BU T I ON
Co m p o n e n t P age
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . . . . 8W-10-32
A/C Com pr essor Clu t ch Rela y . . . 8W-10-13, 14, 25, 26, 32
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . . . 8W-10-24
Au t o Sh u t Down Rela y . . . . . . . 8W-10-11, 14, 19, 20, 25
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12
Blower Mot or . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 15
Blower Mot or Con t r oller . . . . . . . . . . . . 8W-10-11, 12, 15
Body Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-10-27, 29
Ca m sh a ft P osit ion Sen sor . . . . . . . . . . . . . . . . 8W-10-26
Ca pa cit or . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
Ca pa cit or No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Ca pa cit or No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Ciga r Ligh t er Rela y . . . . . . . . . . . . . . . . . . . . 8W-10-15
Cir cu it Br ea ker No. 1 (J B) . . . . . . . . . . . . . . . 8W-10-29
Cir cu it Br ea ker No. 2 (J B) . . . . . . . . . . . . . . . 8W-10-24
Coil On P lu g No. 1 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 2 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 3 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 4 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 5 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 6 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 7 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil On P lu g No. 8 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coil Ra il . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
Con t r oller An t ilock
Br a ke . . . . . . . . . . . . 8W-10-11, 12, 13, 14, 17, 18, 32
Cr a n kca se H ea t er . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Dr iver Door Modu le . . . . . . . . . . . . . . . . . . . . 8W-10-30
E GR Solen oid . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
E n gin e Con t r ol Modu le . . . . . . . . . . . . 8W-10-14, 26, 31
E n gin e St a r t er Mot or . . . . . . . . . . . . . . . . . . . 8W-10-27
E n gin e St a r t er Mot or Rela y . . . . . . . . . . . . . . 8W-10-27
F og La m p Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
F u el In ject or No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 3 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 4 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 5 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 6 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 7 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el In ject or No. 8 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
F u el P r essu r e Solen oid . . . . . . . . . . . . . . . . . . 8W-10-26
F u el P u m p Modu le . . . . . . . . . . . . . . . . . . . . 8W-10-32
F u el P u m p Rela y . . . . . . . . . . . . . . . . . . . 8W-10-13, 32
F u se 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 15
F u se 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 15
F u se 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 16
F u se 4 . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 17, 18
F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 17, 30
F u se 6 . . . . . . . . . . . . . . . . 8W-10-11, 12, 16, 18, 19, 20
F u se 7 . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 24, 30
F u se 8 . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 27, 30
F u se 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
F u se 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 15, 18
F u se 12 . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 14, 29, 30
F u se 13 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 14, 25
F u se 14 . . . . . . . . . . . . . . . . . . 8W-10-11, 13, 14, 16, 27
F u se 15 . . . . . . . . . . . . . . . . . . 8W-10-11, 13, 14, 16, 30
F u se 16 . . . . . . . . . . . . . . . . . . 8W-10-16, 19, 20, 23, 25
8W - 10 - 1
Co m p o n e n t P age
F u se 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
F u se 18 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 30, 31
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
F u se 21 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 29, 32
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 29, 31
F u se 23 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 24, 25
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 24, 32
F u se 25 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 24, 32
F u se 26 . . . . . . . . . . . . . . . . . . . . 8W-10-15, 19, 20, 25
F u se 27 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 24, 31
F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 29
F u se 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
F u se 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
F u se 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
F u se 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
F u sible Lin k . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
Gen er a t or . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 26
Glow P lu g No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Glow P lu g No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Glow P lu g No. 3 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Glow P lu g No. 4 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Glow P lu g No. 5 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Glow P lu g Rela y No. 1 . . . . . . . . . . . . . 8W-10-12, 18, 26
Glow P lu g Rela y No. 2 . . . . . . . . . . . . . 8W-10-12, 18, 26
H igh Bea m Rela y . . . . . . . . . . . . . . . . . . . . . 8W-10-16
H or n No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
H or n No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
H or n Rela y . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 31
H ydr a u lic Coolin g Modu le . . . . . . . . 8W-10-19, 20, 23, 26
Ign it ion Swit ch . . . . . . . . . . . . . 8W-10-11, 14, 27, 28, 29
In t a ke P or t Swir l Act u a t or . . . . . . . . . . . . . . . 8W-10-26
J u n ct ion Block . . . . . . . . . . . . . 8W-10-11, 12, 13, 14, 15,
16, 24, 28, 29, 30
Low Bea m Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Low Bea m /Da yt im e Ru n n in g La m p Rela y . . . . 8W-10-16
Ma ss Air F low Sen sor . . . . . . . . . . . . . . . . . . 8W-10-26
Oxygen Sen sor 1/1 Upst r ea m . . . . . . . . . . . 8W-10-19, 20
Oxygen Sen sor 1/2 Down st r ea m . . . . . . . . . 8W-10-19, 20
Oxygen Sen sor 1/2 Down st r ea m . . . . . . . . . . . 8W-10-23
Oxygen Sen sor 2/2 Down st r ea m . . . . . . . . . . . 8W-10-23
Oxygen Sen sor Down st r ea m Rela y . . . . 8W-10-19, 20, 23
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . . . . 8W-10-16
P a ssen ger Door Modu le . . . . . . . . . . . . . . . . . 8W-10-30
P ower Dist r ibu t ion Cen t er . . . . . . 8W-10-2, 3, 11, 12, 13,
14, 15, 16, 17, 18, 19, 20,
24, 25, 27, 30, 31, 32
P ower t r a in Con t r ol Modu le . . . . . . . . . 8W-10-13, 19, 20
Rea r P ower Ou t let . . . . . . . . . . . . . 8W-10-13, 14, 24, 31
Rea r Win dow Defogger . . . . . . . . . . . . . . . . . . 8W-10-15
Rea r Win dow Defogger Rela y . . . . . . . . . . . . . 8W-10-15
Tr a iler Tow Cir cu it Br ea ker . . . . . . . . . . . . . . 8W-10-15
Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . 8W-10-11, 17
Tr a n sm ission Con t r ol Rela y . . . . . . . . . . . . 8W-10-11, 17
Tr a n sm ission Solen oid . . . . . . . . . . . . . . . . . . 8W-10-17
Tr a n sm ission Solen oid/TRS Assem bly . . . . . . . 8W-10-17
Viscou s/Ca bin H ea t er Rela y . . . . . . . . . 8W-10-14, 25, 26
Wa st ega t e Solen oid . . . . . . . . . . . . . . . . . . . . 8W-10-26
Wa t er In F u el Sen sor . . . . . . . . . . . . . . . . . . . 8W-10-26
WJ
8 W-1 2 J U N CT I ON BLOCK
Co m p o n e n t P age
A/C Com pr essor Clu t ch Rela y . . . . . . . . . . . . . . . . 8W-12-18
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Adju st a ble P eda ls Modu le . . . . . . . . . . . . . . . . . . 8W-12-11
Air ba g Con t r ol Modu le . . . . . . . . . . . . . . . . . . . . 8W-12-25
Au t o Sh u t Down Rela y . . . . . . . . . . . . . . . . . . . . 8W-12-18
Au t om a t ic Da y/Nigh t Mir r or . . . . . . . . . . . . . . . . . 8W-12-23
Au t om a t ic H ea dla m p Ligh t Sen sor /VTSS LE D . . . . . . 8W-12-15
Au t om a t ic Zon e Con t r ol Modu le . . . . . . . . . . 8W-12-15, 17, 22
Ba ck-Up La m p Rela y . . . . . . . . . . . . . . . . . . . . . 8W-12-22
Body Con t r ol Modu le . . . 8W-12-10, 12, 13, 15, 17, 20, 23, 24, 25,
26, 27, 28, 29, 30, 31, 35, 36
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Ca r go La m p . . . . . . . . . . . . . . . . . . . . . . 8W-12-16, 24, 27
Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
Ciga r Ligh t er Rela y . . . . . . . . . . . . . . . . . . . . 8W-12-17, 26
Cir cu it Br ea ker No. 1 . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
Cir cu it Br ea ker No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
Com bin a t ion F la sh er . . . . . . . . . . . . 8W-12-10, 22, 27, 32, 35
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . . . . . . 8W-12-21
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Dr iver Door Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-12-34
Dr iver H ea t ed Sea t Swit ch . . . . . . . . . . . . . . . . . . 8W-12-22
Dr iver Lu m ba r Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Dr iver P ower Sea t Swit ch . . . . . . . . . . . . . . . . . . . 8W-12-9
E lect r ic Br a ke . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . . . . . 8W-12-19
E n gin e St a r t er Mot or Rela y . . . . . . . . . . . . . . . . . 8W-12-26
E VAP /P u r ge Solen oid . . . . . . . . . . . . . . . . . . . . . 8W-12-18
F og La m p Rela y . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
F r on t P ower Ou t let . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
F r on t Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
F u el P u m p Rela y . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
F u se 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
F u se 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10, 20
F u se 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
F u se 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
F u se 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
F u se 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
F u se 12 . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 19, 21, 34
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
F u se 15 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 15, 20
F u se 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
F u se 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21, 34
F u se 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
F u se 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 19
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
F u se 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
F u se 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
F u se 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
F u se 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-36
F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
F u se 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
F u se 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
F u se 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
F u se 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-35
Glove Box La m p . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
H ea dla m p Levelin g Swit ch . . . . . . . . . . . . . . . 8W-12-12, 13
H igh Bea m Rela y . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . 8W-12-10, 23, 32
In t r u sion Tr a n sceiver Modu le . . . . . . . . . . . . . . . . 8W-12-16
J u n ct ion Block . . . . . . . . . 8W-12-2, 3, 9, 10, 11, 12, 13, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 31, 32, 34, 35, 36
8W-12 JUNCTION BLOCK 8W - 12 - 1
Co m p o n e n t P age
Left Cou r t esy La m p . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Left Door H a n dle Cou r t esy La m p . . . . . . . . . 8W-12-16, 24, 30
Left F og La m p . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Left F r on t P a r k La m p . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . . . . . . 8W-12-14, 33
Left F r on t Side Ma r ker La m p . . . . . . . . . . . . . . 8W-12-14, 33
Left F r on t Tu r n Sign a l La m p . . . . . . . . . . . . . . . . 8W-12-33
Left H ea dla m p Levelin g Mot or . . . . . . . . . . . . . . . 8W-12-14
Left H igh Bea m H ea dla m p . . . . . . . . . . . . . . . . . . 8W-12-10
Left Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . . . . 8W-12-30
Left Low Bea m H ea dla m p . . . . . . . . . . . . . . . . . . 8W-12-20
Left Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . 8W-12-10, 35
Left Rea r Door Lock Mot or /Aja r Swit ch . . . . . . . . . . 8W-12-27
Left Rea r La m p Assem bly . . . . . . . . . . . 8W-12-12, 13, 27, 36
Left Side Repea t er La m p . . . . . . . . . . . . . . . . . . . 8W-12-32
Left Visor /Va n it y La m p . . . . . . . . . . . . . . . . . . 8W-12-16, 30
Licen se La m p No. 1 . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
Licen se La m p No. 2 . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . . . . . . . 8W-12-30
Lift ga t e F lip-Up P u sh Bu t t on Swit ch . . . . . . . . . . . 8W-12-16
Lift ga t e P ower Lock Mot or . . . . . . . . . . . . . . . . . . 8W-12-16
Low Bea m Rela y . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Low Bea m /Da yt im e Ru n n in g La m p Rela y . . . . . . . . . 8W-12-20
Ma n u a l Tem per a t u r e Con t r ol . . . . . . . . . . . . . . 8W-12-17, 22
Over h ea d Ma p/Cou r t esy La m p . . . . . . . . . . . 8W-12-16, 24, 30
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . . . . . . . . 8W-12-22
P a ssen ger Door Modu le . . . . . . . . . . . . . . . . . . . . 8W-12-34
P a ssen ger H ea t ed Sea t Swit ch . . . . . . . . . . . . . . . 8W-12-22
P a ssen ger Lu m ba r Swit ch . . . . . . . . . . . . . . . . . . . 8W-12-9
P a ssen ger P ower Sea t Swit ch . . . . . . . . . . . . . . . . . 8W-12-9
P ower Am plifier . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
P ower Con n ect or . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
P ower Dist r ibu t ion Cen t er . . . . 8W-12-10, 11, 15, 17, 20, 21, 34
P ower t r a in Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-12-18
Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 26
Ra in Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Rea r Win dow Defogger . . . . . . . . . . . . . . . . . . . . 8W-12-17
Rea r Win dow Defogger Rela y . . . . . . . . . . . . . . . . 8W-12-17
Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . . 8W-12-16, 30
Rem ot e Keyless Modu le . . . . . . . . . . . . . . . . . . . . 8W-12-15
Righ t Cou r t esy La m p . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Righ t Door H a n dle Cou r t esy La m p . . . . . . . . 8W-12-16, 24, 30
Righ t F og La m p . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Righ t F r on t P a r k La m p . . . . . . . . . . . . . . . . . . . . 8W-12-14
Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . . . . . . 8W-12-14, 33
Righ t F r on t Side Ma r ker La m p . . . . . . . . . . . . . 8W-12-14, 33
Righ t F r on t Tu r n Sign a l La m p . . . . . . . . . . . . . . . 8W-12-33
Righ t H ea dla m p Levelin g Mot or . . . . . . . . . . . . . . 8W-12-14
Righ t H igh Bea m H ea dla m p . . . . . . . . . . . . . . . . . 8W-12-10
Righ t Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . . . 8W-12-30
Righ t Low Bea m H ea dla m p . . . . . . . . . . . . . . . . . 8W-12-20
Righ t Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . . . 8W-12-26
Righ t Rea r La m p Assem bly . . . . . . . . . . 8W-12-12, 13, 32, 36
Righ t Side Repea t er La m p . . . . . . . . . . . . . . . . . . 8W-12-32
Righ t Visor /Va n it y La m p . . . . . . . . . . . . . . . . . 8W-12-16, 30
Sea t Modu le . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Sen t r y Key Im m obilizer Modu le . . . . . . . . . . . . 8W-12-15, 23
Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 19
Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
Su n r oof Con t r ol Modu le . . . . . . . . . . . . . . . . . . . . 8W-12-25
Tem per a t u r e Va lve Act u a t or . . . . . . . . . . . . . . . . . 8W-12-22
Tr a iler Tow Br a ke La m p Rela y . . . . . . . . . . . . . . . 8W-12-21
Tr a iler Tow Cir cu it Br ea ker . . . . . . . . . . . . . . . . . 8W-12-17
Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Tr a iler Tow Left Tu r n Rela y . . . . . . . . . . . . . . . . . 8W-12-27
Tr a iler Tow Righ t Tu r n Rela y . . . . . . . . . . . . . . . . 8W-12-32
Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . . . . 8W-12-18, 26
Tr a n sm ission Solen oid/TRS Assem bly . . . . . . . . . . . 8W-12-22
Un der h ood La m p . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
Veh icle In for m a t ion Cen t er . . . . . . . . . . . . . . . 8W-12-16, 23
Wiper H igh /Low Rela y . . . . . . . . . . . . . . . . . . 8W-12-28, 29
Wiper On /Off Rela y . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
WJ
8 W-1 5 GROU N D DI ST RI BU T I ON
Co m p o n e n t P age
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . . . . . 8W-15-4
Adju st a ble P eda ls Modu le . . . . . . . . . . . . . 8W-15-17, 21
Air ba g Con t r ol Modu le . . . . . . . . . . . . . . . . . . 8W-15-16
Ash Receiver La m p . . . . . . . . . . . . . . . . . . . . 8W-15-14
Au t om a t ic Da y/Nigh t Mir r or . . . . . . . . . . . . . . 8W-15-19
Au t om a t ic Zon e Con t r ol Modu le . . . . . . . . . . . 8W-15-15
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
Blower Mot or Con t r oller . . . . . . . . . . . . . . . . . 8W-15-15
Body Con t r ol Modu le . . . . . . . . . . . . . . 8W-15-12, 13, 15
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . 8W-15-17, 22
Cen t er H igh Mou n t ed St op La m p . . . . . . . . . . 8W-15-20
Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Ciga r Ligh t er Rela y . . . . . . . . . . . . . . . . . . . . 8W-15-12
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . . . . 8W-15-12
Coola n t Level Sen sor . . . . . . . . . . . . . . . 8W-15-9, 10, 11
Cr a n kca se H ea t er . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . . 8W-15-2, 3
Dr iver Cylin der Lock Swit ch . . . . . . . . . . . . . . 8W-15-16
Dr iver Door Lock Mot or /Aja r Swit ch . . . . . . . . 8W-15-16
Dr iver Door Modu le . . . . . . . . . . . . . . . . . . . . 8W-15-16
Dr iver H ea t ed Sea t Swit ch . . . . . . . . . . . . . . . 8W-15-14
Dr iver Lu m ba r Swit ch . . . . . . . . . . . . . . . 8W-15-18, 21
Dr iver P ower Sea t Swit ch . . . . . . . . . . . . . 8W-15-18, 21
Dr iver Rea r P ower Win dow Swit ch . . . . . . . 8W-15-18, 21
E lect r ic Br a ke . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
E lect r on ic Speed Con t r ol Ser vo . . . . . . . . . . 8W-15-9, 10
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . . . 8W-15-3
F r on t P ower Ou t let . . . . . . . . . . . . . . . . . . . . 8W-15-14
F r on t Wa sh er P u m p . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
F r on t Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
F u el P u m p Modu le . . . . . . . . . . . . . . . . . . . . 8W-15-19
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13, 14, 15
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
G300 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16, 17, 18
G301 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19, 21, 22
H ea dla m p Levelin g Swit ch . . . . . . . . . . . . . . . 8W-15-15
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
H or n No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
H or n No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
H ydr a u lic Coolin g Modu le . . . . . . . . . . . 8W-15-9, 10, 11
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . 8W-15-13, 14
In t a ke P or t Swir l Act u a t or . . . . . . . . . . . . . . . . 8W-15-3
In t r u sion Tr a n sceiver Modu le . . . . . . . . . . 8W-15-21, 22
J u n ct ion Block . . . . . . . . . . . . . . . . . . 8W-15-12, 13, 15
Left F og La m p . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Left F r on t P a r k La m p . . . . . . . . . . . . . . . . . . . 8W-15-5
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . . . . . 8W-15-5
Left F r on t Tu r n Sign a l La m p . . . . . . . . . . . . . . 8W-15-5
Left H ea dla m p Levelin g Mot or . . . . . . . . . . . . . 8W-15-5
Left H igh Bea m H ea dla m p . . . . . . . . . . . . . . . . 8W-15-5
8W-15 GROUND DISTRIBUTION 8W - 15 - 1
Co m p o n e n t P age
Left Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . 8W-15-20
Left Low Bea m H ea dla m p . . . . . . . . . . . . . . . . 8W-15-5
Left Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . 8W-15-15
Left Rea r Door Lock Mot or /Aja r Swit ch . . . . 8W-15-21, 22
Left Rea r La m p Assem bly . . . . . . . . . . . . . . . 8W-15-19
Left Side Repea t er La m p . . . . . . . . . . . . . . . 8W-15-6, 7
Licen se La m p No. 1 . . . . . . . . . . . . . . . . . . . . 8W-15-20
Licen se La m p No. 2 . . . . . . . . . . . . . . . . . . . . 8W-15-20
Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . . . . 8W-15-20
Lift ga t e F lip-Up Relea se Solen oid . . . . . . . . . . 8W-15-20
Lin e P r essu r e Sen sor . . . . . . . . . . . . . . . . . . . . 8W-15-2
Low Bea m /Da yt im e Ru n n in g La m p Rela y . . . . 8W-15-12
Ma n u a l Tem per a t u r e Con t r ol . . . . . . . . . . . 8W-15-13, 15
Oxygen Sen sor 1/2 Down st r ea m . . . . . . . . . . . . 8W-15-4
Oxygen Sen sor 2/2 Down st r ea m . . . . . . . . . . . . 8W-15-4
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . . . . 8W-15-12
P a ssen ger Door Lock Mot or /Aja r Swit ch . . . . . . 8W-15-16
P a ssen ger Door Modu le . . . . . . . . . . . . . . . . . 8W-15-16
P a ssen ger H ea t ed Sea t Swit ch . . . . . . . . . . . . 8W-15-14
P a ssen ger Lu m ba r Swit ch . . . . . . . . . . . . . 8W-15-17, 22
P a ssen ger P ower Sea t Swit ch . . . . . . . . . . 8W-15-17, 22
P a ssen ger Rea r P ower Win dow Swit ch . . . . 8W-15-16, 22
P ower Am plifier . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
P ower Con n ect or . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
P ower t r a in Con t r ol Modu le . . . . . . . . . . . . . . . 8W-15-2
Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Ra in Sen sor . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21, 22
Rea r P ower Ou t let . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Rea r Wa sh er P u m p . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Rea r Win dow Defogger . . . . . . . . . . . . . . . . . . 8W-15-20
Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . . 8W-15-20
Rem ot e Keyless Modu le . . . . . . . . . . . . . . . . . 8W-15-16
Righ t F og La m p . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
Righ t F r on t P a r k La m p . . . . . . . . . . . . . . . . . . 8W-15-8
Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . . . . . 8W-15-8
Righ t F r on t Tu r n Sign a l La m p . . . . . . . . . . . . . 8W-15-8
Righ t H ea dla m p Levelin g Mot or . . . . . . . . . . . . 8W-15-8
Righ t H igh Bea m H ea dla m p . . . . . . . . . . . . . . . 8W-15-8
Righ t Low Bea m H ea dla m p . . . . . . . . . . . . . . . 8W-15-8
Righ t Rea r Door Lock Mot or /Aja r Swit ch . . 8W-15-16, 18
Righ t Rea r La m p Assem bly . . . . . . . . . . . . 8W-15-17, 18
Righ t Side Repea t er La m p . . . . . . . . . . . 8W-15-9, 10, 11
Sea t Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-15-18, 21
Sen t r y Key Im m obilizer Modu le . . . . . . . . . . . 8W-15-13
Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . 8W-15-14, 15
Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Su n r oof Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-15-19
Su n r oof Mot or . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
Su n r oof Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
Tem per a t u r e Va lve Act u a t or . . . . . . . . . . . . . . 8W-15-13
Tr a iler Tow Br a ke La m p Rela y . . . . . . . . . . . . 8W-15-19
Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . . . 8W-15-19
Tr a iler Tow Left Tu r n Rela y . . . . . . . . . . . . . . 8W-15-19
Tr a iler Tow Righ t Tu r n Rela y . . . . . . . . . . . . . 8W-15-19
Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . . . . 8W-15-2
Tr a n sm ission Con t r ol Rela y . . . . . . . . . . . . 8W-15-9, 10
Un der h ood La m p . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Veh icle In for m a t ion Cen t er . . . . . . . . . . . . 8W-15-21, 22
Viscou s/Ca bin H ea t er . . . . . . . . . . . . . . . . . . . 8W-15-4
Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . . 8W-15-6, 7
WJ 8W-18 BUS COMMUNICATIONS 8W - 18 - 1

8 W-1 8 BU S COM M U N I CAT I ON S

Co m p o n e n t P age
Adju st a ble P eda ls Modu le . . . . . . . . . . . . . . 8W-18-2
Air ba g Con t r ol Modu le . . . . . . . . . . . . . . 8W-18-4, 7
Au t om a t ic Zon e Con t r ol Modu le . . . . . . . 8W-18-4, 7
Body Con t r ol Modu le . . . . . . . . . 8W-18-4, 7, 8, 9, 10
Com pa ct Disc Ch a n ger . . . . . . . . . . . . . . 8W-18-3, 5
Con t r oller An t ilock Br a ke . . . . . . . . . . 8W-18-2, 3, 5
Da t a Lin k Con n ect or . . . . . . . . . 8W-18-4, 7, 8, 9, 10
Dia gn ost ic J u n ct ion P or t . . . . . . 8W-18-4, 7, 8, 9, 10
Dr iver Door Modu le . . . . . . . . . . . . . . . . 8W-18-2, 5
E n gin e Con t r ol Modu le . . . . . . . . . . . 8W-18-3, 5, 10
F u se 17 . . . . . . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
G103 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
In st r u m en t Clu st er . . . . . . . . . . 8W-18-4, 7, 8, 9, 10
Co m p o n e n t P age
In t r u sion Tr a n sceiver Modu le . . . . . . . . . 8W-18-2, 6
J u n ct ion Block . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
P a ssen ger Door Modu le . . . . . . . . . . . . . . 8W-18-3, 6
P ower Am plifier . . . . . . . . . . . . . . . . . . . 8W-18-3, 5
P ower t r a in Con t r ol Modu le . . . . . . . 8W-18-3, 5, 8, 9
Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4, 7
Ra in Sen sor . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 6
Sea t Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 5
Sen t r y Key Im m obilizer Modu le . . . . . . . 8W-18-4, 7
Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . 8W-18-4, 7
Tr a n sm ission Con t r ol Modu le . . 8W-18-3, 6, 8, 9, 10
Veh icle In for m a t ion Cen t er . . . . . . . . . . . 8W-18-2, 6
WJ 8W-20 CHARGING SYSTEM 8W - 20 - 1

8 W-2 0 CH ARGI N G SY ST EM
Co m p o n e n t P age Co m p o n e n t P age
Au t o Sh u t Down Rela y . . . . . . . . . . . . 8W-20-2, 3, 4 F u se 19 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4 F u se 26 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . . 8W-20-2, 3 F u sible Lin k . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-20-4 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
E n gin e St a r t er Mot or . . . . . . . . . . . . . 8W-20-2, 3, 4 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3 Gen er a t or . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
F u se 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4 P ower Dist r ibu t ion Cen t er . . . . . . . . . 8W-20-2, 3, 4
F u se 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4 P ower t r a in Con t r ol Modu le . . . . . . . . . . . 8W-20-2, 3
WJ 8W-21 STARTING SYSTEM 8W - 21 - 1

8 W-2 1 START I N G SY ST EM
Co m p o n e n t P age Co m p o n e n t P age
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4 J u n ct ion Block . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-21-4 P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . 8W-21-2, 3
E n gin e St a r t er Mot or . . . . . . . . . . . . . 8W-21-2, 3, 4 P ower Dist r ibu t ion Cen t er . . . . . . . . . 8W-21-2, 3, 4
E n gin e St a r t er Mot or Rela y . . . . . . . . 8W-21-2, 3, 4 P ower t r a in Con t r ol Modu le . . . . . . . . . . . 8W-21-2, 3
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4 Tr a n sm ission Con t r ol Modu le . . . . . . . . . 8W-21-2, 3
F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4 Tr a n sm ission Solen oid/TRS Assem bly . . . 8W-21-2, 3
WJ 8W-30 FUEL/IGNITION SYSTEM
8 W-3 0 FU EL/I GN I T I ON SY ST EM
Co m p o n e n t P age
A/C Com pr essor Clu t ch Rela y . . . 8W-30-23, 35, 39, 41, 42
A/C P r essu r e Tr a n sdu cer . . . . . . . . 8W-30-21, 42, 45, 31
Acceler a t or P eda l P osit ion Sen sor . . . . . . . . 8W-30-37, 48
Adju st a ble P eda ls Modu le . . . . . . . . . . . . . . . . 8W-30-33
Adju st a ble P eda ls Mot or /Sen sor Assem bly . . . . 8W-30-33
Adju st a ble P eda ls Swit ch . . . . . . . . . . . . . . . . 8W-30-33
Au t o Sh u t Down Rela y . . . . . . 8W-30-8, 9, 12, 24, 25, 26,
27, 28, 29, 30, 35, 39, 41
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . . 8W-30-2, 11, 50
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . . . 8W-30-46
Boost P r essu r e Sen sor . . . . . . . . . . . . . . . . . . 8W-30-45
Br a ke La m p Swit ch . . . . . . . . . . . . . . 8W-30-4, 5, 32, 51
Ca m sh a ft P osit ion Sen sor . . . . . . . . 8W-30-18, 19, 20, 49
Ca pa cit or . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
Ca pa cit or No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16
Ca pa cit or No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5, 38
Coil On P lu g No. 1 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coil On P lu g No. 2 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coil On P lu g No. 3 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coil On P lu g No. 4 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coil On P lu g No. 5 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coil On P lu g No. 6 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coil On P lu g No. 7 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coil On P lu g No. 8 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coil Ra il . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
Con t r oller An t ilock Br a ke . . . . . . . . . . . 8W-30-2, 36, 51
Cr a n kca se H ea t er . . . . . . . . . . . . . . . . . . . . . 8W-30-35
Cr a n ksh a ft P osit ion Sen sor . . . . . . . 8W-30-18, 19, 20, 49
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . 8W-30-6, 7, 46
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . 8W-30-6, 7, 33, 46
E GR Solen oid . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-50
E lect r on ic Speed Con t r ol Ser vo . . . . . . . . . . . 8W-30-4, 5
E n gin e Con t r ol Modu le . . . . 8W-30-34, 35, 36, 37, 38, 39,
40, 41, 42, 43, 44, 45,
46, 47, 48, 49, 50, 51
E n gin e Coola n t Tem per a t u r e Sen sor . . . 8W-30-21, 22, 47
E n gin e Oil P r essu r e Sen sor . . . . . . . . . 8W-30-21, 22, 45
E n gin e St a r t er Mot or Rela y . . . . . . . . . 8W-30-18, 19, 39
E VAP /P u r ge Solen oid . . . . . . . . . . . . . . . . . . 8W-30-4, 5
F u el In ject or No. 1 . . . . . . . . . . . . . . . 8W-30-13, 15, 44
F u el In ject or No. 2 . . . . . . . . . . . . . . . 8W-30-13, 14, 44
F u el In ject or No. 3 . . . . . . . . . . . . . . . 8W-30-13, 15, 44
F u el In ject or No. 4 . . . . . . . . . . . . . . . 8W-30-13, 14, 44
F u el In ject or No. 5 . . . . . . . . . . . . . . . 8W-30-13, 15, 44
F u el In ject or No. 6 . . . . . . . . . . . . . . . . . . 8W-30-13, 14
F u el In ject or No. 7 . . . . . . . . . . . . . . . . . . . . . 8W-30-15
F u el In ject or No. 8 . . . . . . . . . . . . . . . . . . . . . 8W-30-14
F u el P r essu r e Sen sor . . . . . . . . . . . . . . . . . . . 8W-30-37
F u el P r essu r e Solen oid . . . . . . . . . . . . . . . . . . 8W-30-47
F u el P u m p Modu le . . . . . . . . . . . . . . . . . . . . 8W-30-10
F u el P u m p Rela y . . . . . . . . . . . . . . . . . . 8W-30-8, 9, 10
F u el Ta n k Modu le . . . . . . . . . . . . . . . . . . . . . 8W-30-45
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 42
F u se 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-33
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
F u se 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 9, 40
F u se 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-41
F u se 16 . . 8W-30-24, 25, 26, 27, 28, 29, 30, 35, 37, 39, 41
8W - 30 - 1
Co m p o n e n t P age
F u se 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
F u se 21 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5, 32
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-34
F u se 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-39
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
F u se 26 . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 12, 41, 47
F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-39
G103 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 34, 39, 46
G104 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-26, 27, 30
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-35, 39
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-23, 43
G123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-50
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 33
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5, 10
Gen er a t or . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 23, 35
Glow P lu g No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
Glow P lu g No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
Glow P lu g No. 3 . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
Glow P lu g No. 4 . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
Glow P lu g No. 5 . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
Glow P lu g Rela y No. 1 . . . . . . . . . . . . . 8W-30-35, 42, 43
Glow P lu g Rela y No. 2 . . . . . . . . . . . . . 8W-30-35, 42, 43
H ydr a u lic Coolin g Modu le . . . 8W-30-3, 24, 25, 30, 31, 43
Idle Air Con t r ol Mot or . . . . . . . . . . . . . . . . . . 8W-30-20
In t a ke Air Tem per a t u r e Sen sor . . . . . . . 8W-30-21, 22, 38
In t a ke P or t Swir l Act u a t or . . . . . . . . . . . . . . . 8W-30-39
J u n ct ion Block . . . . . . . . . 8W-30-4, 5, 8, 9, 32, 33, 39, 40
Kn ock Sen sor . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11
Lea k Det ect ion P u m p . . . . . . . . . . . . . . . . . . . 8W-30-23
Ma n ifold Absolu t e P r essu r e Sen sor . . . . 8W-30-20, 21, 22
Ma ss Air F low Sen sor . . . . . . . . . . . . . . . . . . 8W-30-37
Ou t pu t Speed Sen sor . . . . . . . . . . . . . . . . . . . . 8W-30-2
Oxygen Sen sor 1/1 Upst r ea m . . . . . . 8W-30-25, 26, 28, 29
Oxygen Sen sor 1/2 Down st r ea m . . . . 8W-30-24, 25, 26, 30
Oxygen Sen sor 2/1 Upst r ea m . . . . . . . . 8W-30-27, 28, 29
Oxygen Sen sor 2/2 Down st r ea m . . . . . . 8W-30-24, 27, 30
Oxygen Sen sor Down st r ea m Rela y . . 8W-30-24, 26, 27, 30
P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . . . . . 8W-30-33
P ower Dist r ibu t ion Cen t er . . . . . . 8W-30-8, 9, 12, 24, 25,
26, 27, 28, 29, 30, 34, 35,
37, 39, 41, 42, 43, 47
P ower t r a in Con t r ol Modu le . . . 8W-30-2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 31, 32
Sh ift er Assem bly . . . . . . . . . . . . . . . 8W-30-2, 32, 38, 40
Speed Con t r ol Swit ch No. 1 . . . . . . . . . . . 8W-30-4, 5, 38
Speed Con t r ol Swit ch No. 2 . . . . . . . . . . . 8W-30-4, 5, 38
Th r ot t le P osit ion Sen sor . . . . . . . . . . . . . . . . . 8W-30-20
Tr a n sfer Ca se P osit ion Sen sor . . . . . . . . . . . 8W-30-8, 51
Tr a n sm ission Con t r ol
Modu le . . . . . . . . . . . . . 8W-30-6, 7, 20, 23, 32, 36, 40
Tr a n sm ission Con t r ol Rela y . . . . . . . . . . . . . . 8W-30-23
Tr a n sm ission Solen oid . . . . . . . . . . . . . . . . 8W-30-3, 21
Tr a n sm ission Solen oid/TRS Assem bly . . . . . . . 8W-30-33
Viscou s/Ca bin H ea t er . . . . . . . . . . . . . . . . . . . 8W-30-39
Viscou s/Ca bin H ea t er Rela y . . . . . . 8W-30-35, 39, 41, 42
Wa st ega t e Solen oid . . . . . . . . . . . . . . . . . . . . 8W-30-35
Wa t er In F u el Sen sor . . . . . . . . . . . . . . . . . . . 8W-30-50
WJ
8 W-3 1 T RAN SM I SSI ON CON T ROL SY ST EM
Co m p o n e n t P age
Au t o Sh u t Down Rela y . . . . . . . . . . . . . . . . 8W-31-4
Ba ck-Up La m p Rela y . . . . . . . . . . . . . . . . 8W-31-15
Body Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-31-14
Br a ke La m p Swit ch . . . . . . . . . . . . . . . 8W-31-14, 15
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . 8W-31-17
Cr a n ksh a ft P osit ion Sen sor . . . . . . . . . . 8W-31-9, 10
Da t a Lin k Con n ect or . . . . . . . . . . . . 8W-31-9, 10, 16
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . 8W-31-4, 15
E n gin e Con t r ol Modu le . . . . . . . . . . . . 8W-31-16, 17
E n gin e St a r t er Mot or Rela y . . . . . 8W-31-4, 5, 6, 12
F u el P u m p Rela y . . . . . . . . . . . . . . . . . . . . 8W-31-4
F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 3
F u se 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4, 15
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5, 6
F u se 21 . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14, 15
F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 8
F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-11, 13
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14, 15
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-15
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-15
8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
Co m p o n e n t P age
Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
In pu t Speed Sen sor . . . . . . . . . . . . . . . . . . 8W-31-13
J u n ct ion Block . . . . . . . . . . . . . 8W-31-4, 5, 6, 14, 15
Left Rea r La m p Assem bly . . . . . . . . . . . . 8W-31-5, 6
Lin e P r essu r e Sen sor . . . . . . . . . . . . . . . . 8W-31-13
Ou t pu t Speed Sen sor . . . . . . . . . . . . . . 8W-31-8, 13
P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . . . 8W-31-6
P ower Dist r ibu t ion Cen t er . . . . . . . . . 8W-31-2, 3, 8
P ower t r a in Con t r ol
Modu le . . . . . . . . . 8W-31-2, 4, 5, 6, 7, 8, 9, 10, 14
Righ t Rea r La m p Assem bly . . . . . . . . . . . 8W-31-5, 6
Sh ift er Assem bly . . . . . . . . . . . . . . 8W-31-14, 15, 16
Th r ot t le P osit ion Sen sor . . . . . . . . . . . . . . . 8W-31-7
Tr a n sfer Ca se P osit ion Sen sor . . . . . . . . 8W-31-6, 16
Tr a n sm ission Con t r ol
Modu le . . . . . . . . . . . 8W-31-3, 4, 7, 9, 10, 11, 12,
13, 14, 16, 17, 18
Tr a n sm ission Con t r ol Rela y . . . 8W-31-2, 3, 8, 11, 12
Tr a n sm ission Solen oid . . . . . . . . . . . . . . 8W-31-2, 8
Tr a n sm ission Solen oid Assem bly . . . . . . . . 8W-31-18
Tr a n sm ission Solen oid/TRS
Assem bly . . . . . . . . . . . . . . 8W-31-3, 5, 11, 12, 13
WJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1

8 W-3 3 V EH I CLE SPEED CON T ROL

Co m p o n e n t P age Co m p o n e n t P age
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . 8W-33-2 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Clockspr in g . . . . . . . . . . . . . . . . . . . . . 8W-33-3, 4, 5 J u n ct ion Block . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
E lect r on ic Speed Con t r ol Ser vo . . . . . . . . . . 8W-33-2 P ower t r a in Con t r ol Modu le . . . . . . . . . . . 8W-33-2, 3
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . 8W-33-2, 4 Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . . . 8W-33-3
F u se 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2 Speed Con t r ol Swit ch No. 1 . . . . . . . . . . . . 8W-33-5
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2 Speed Con t r ol Swit ch No. 2 . . . . . . . . . . . . 8W-33-5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
WJ
Co m p o n e n t
Br a ke La m p Swit ch . . . .
Con t r oller An t ilock Br a ke
Dia gn ost ic J u n ct ion P or t .
E n gin e Con t r ol Modu le . .
F u se 4 . . . . . . . . . . . . . . .
F u se 19 . . . . . . . . . . . . . .
F u se 23 . . . . . . . . . . . . . .
F u se 25 . . . . . . . . . . . . . .
G107 . . . . . . . . . . . . . . . .
8W-35 ANTILOCK BRAKES
8 W-3 5 AN T I LOCK BRAK ES
P age
. . . . . . . . . . . . . . 8W-35-5
. . . . . . 8W-35-2, 3, 4, 5, 6
. . . . . . . . . . . . 8W-35-2, 3
. . . . . . . . . . . . 8W-35-4, 5
. . . . . . . . . . . . 8W-35-2, 3
. . . . . . . . . . . . 8W-35-2, 3
. . . . . . . . . . . . . . 8W-35-5
. . . . . . . . . . . . 8W-35-2, 3
. . . . . . . . . . . . 8W-35-2, 3
8W - 35 - 1
Co m p o n e n t P age
J u n ct ion Block . . . . . . . . . . . . . . . . . . 8W-35-2, 3, 5
Left F r on t Wh eel Speed Sen sor . . . . . . . . . 8W-35-6
Left Rea r Wh eel Speed Sen sor . . . . . . . . . . 8W-35-6
P ower Dist r ibu t ion Cen t er . . . . . . . . . . . 8W-35-2, 3
P ower t r a in Con t r ol Modu le . . . . . . . . . . . . . 8W-35-4
Red Br a ke Wa r n in g In dica t or Swit ch . . . . . 8W-35-5
Righ t F r on t Wh eel Speed Sen sor . . . . . . . . 8W-35-6
Righ t Rea r Wh eel Speed Sen sor . . . . . . . . . 8W-35-6
WJ 8W-39 VEHICLE THEFT SECURITY SYSTEM
8 W-3 9 V EH I CLE T H EFT SECU RI T Y SY ST EM
Co m p o n e n t P age
Au t om a t ic H ea dla m p Ligh t
Sen sor /VTSS LE D . . . . . . . . . . . . . . . . . . 8W-39-3
Body Con t r ol Modu le . . . 8W-39-2, 3, 4, 5, 7, 8, 9, 10
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . . . 8W-39-9
Dr iver Cylin der Lock Swit ch . . . . . . . . . . . . 8W-39-6
Dr iver Door Lock Mot or /Aja r Swit ch . . . . . . 8W-39-6
Dr iver Door Modu le . . . . . . . . . . . . . . . . 8W-39-6, 11
E n gin e St a r t er Mot or Rela y . . . . . . . . . . . . 8W-39-2
F u se 7 . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3, 9, 11
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 9
F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-10
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-9
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5, 6
8W - 39 - 1
Co m p o n e n t P age
G301 . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5, 6, 11
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . 8W-39-10
H or n No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
H or n No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
J u n ct ion Block . . . . . . . . 8W-39-2, 3, 4, 5, 7, 8, 9, 11
Left Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . 8W-39-4
Left Rea r Door Lock Mot or /Aja r Swit ch . . . 8W-39-5
Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . . 8W-39-4
P a ssen ger Door Lock Mot or /Aja r Swit ch . . . 8W-39-6
P a ssen ger Door Modu le . . . . . . . . . . . . . . . 8W-39-6
P ower Dist r ibu t ion Cen t er . . . . . . . . . 8W-39-2, 7, 8
Rem ot e Keyless Modu le . . . . . . . . . . . . . . 8W-39-11
Righ t Lift ga t e Aja r Swit ch . . . . . . . . . . . . . 8W-39-4
Righ t Rea r Door Lock Mot or /Aja r Swit ch . . 8W-39-5
Sen t r y Key Im m obilizer Modu le . . . . . . . . . 8W-39-9
WJ 8W-40 INSTRUMENT CLUSTER
8 W-4 0 I N ST RU M EN T CLU ST ER
Co m p o n e n t P age
Air ba g Con t r ol Modu le . . . . . . . . . . . . . . 8W-40-4, 5
Body Con t r ol Modu le . . . . . . . 8W-40-2, 4, 5, 6, 7, 10
Com bin a t ion F la sh er . . . . . . . . . . . . . . . . . 8W-40-3
Con t r oller An t ilock Br a ke . . . . . . 8W-40-4, 5, 6, 7, 9
Da t a Lin k Con n ect or . . . . . . . . . . . . . . 8W-40-2, 4, 5
Dia gn ost ic J u n ct ion P or t . . 8W-40-4, 5, 6, 7, 8, 9, 10
E n gin e Con t r ol Modu le . . . . . . . . . 8W-40-4, 5, 9, 10
F u se 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
8W - 40 - 1
Co m p o n e n t P age
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
In st r u m en t Clu st er . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10
J u n ct ion Block . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
P a r k Br a ke Swit ch . . . . . . . . . . . . . . . . . 8W-40-6, 7
P ower t r a in Con t r ol Modu le . . 8W-40-4, 5, 6, 7, 8, 10
Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . 8W-40-4
Veh icle In for m a t ion Cen t er . . . . . . . . . . . . . 8W-40-7
WJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1

8 W-4 1 H ORN /CI GAR LI GH T ER/POWER OU T LET

Co m p o n e n t P age Co m p o n e n t P age
Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-41-2, 3 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4, 5
Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-5
Ciga r Ligh t er Rela y . . . . . . . . . . . . . . . . . . 8W-41-4 H or n No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Cir cu it Br ea ker . . . . . . . . . . . . . . . . . . . . . . 8W-41-4 H or n No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
F r on t P ower Ou t let . . . . . . . . . . . . . . . . . . . 8W-41-5 H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
F u se 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-5 J u n ct ion Block . . . . . . . . . . . . . . . . 8W-41-2, 3, 4, 5
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 P ower Con n ect or . . . . . . . . . . . . . . . . . . . . . 8W-41-5
F u se 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4 P ower Dist r ibu t ion Cen t er . . . . . . . . . 8W-41-2, 3, 5
F u se 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-5 Rea r P ower Ou t let . . . . . . . . . . . . . . . . . . . 8W-41-5
F u se 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4 Tr a iler Tow Cir cu it Br ea ker . . . . . . . . . . . . 8W-41-4
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
WJ 8W-42 AIR CONDITIONING-HEATER
8 W-4 2 AI R CON DI T I ON I N G-H EAT ER
Co m p o n e n t P age
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . 8W-42-3, 4
A/C Com pr essor Clu t ch Rela y . . . . . . . . . 8W-42-3, 4
A/C P r essu r e Tr a n sdu cer . . . . . . . . 8W-42-11, 12, 13
Au t o Sh u t Down Rela y . . . . . . . . . . 8W-42-4, 11, 12
Au t om a t ic Zon e Con t r ol Modu le . 8W-42-2, 5, 6, 7, 8
Blower Mot or . . . . . . . . . . . . . . . . . . . 8W-42-2, 6, 9
Blower Mot or Con t r oller . . . . . . . . . . . . . 8W-42-2, 6
Blower Mot or Resist or Block . . . . . . . . . . . . 8W-42-9
Body Con t r ol Modu le . . . . . . . . . . . 8W-42-5, 6, 9, 10
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . . . 8W-42-5
Dr iver Blen d Door Mot or /Act u a t or . . . . . 8W-42-7, 8
E n gin e Con t r ol Modu le . . . . . . . . . . . . . 8W-42-4, 13
F u se 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 6, 9
F u se 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5, 10
F u se 16 . . . . . . . . . . . . . . . . . . . . . . 8W-42-4, 11, 12
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 10
F u se 21 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3, 4
8W - 42 - 1
Co m p o n e n t P age
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-11, 12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 6, 10
Glow P lu g Rela y No. 1 . . . . . . . . . . . . . . . . 8W-42-4
H ydr a u lic Coolin g Modu le . . . . . . . . . . 8W-42-11, 12
J u n ct ion Block . . . . . . . . . . . . . . 8W-42-2, 3, 5, 6, 10
Ma n u a l Tem per a t u r e Con t r ol . . . . . . 8W-42-2, 9, 10
Mode Door Mot or /Act u a t or . . . . . . . . . . . 8W-42-7, 8
Oxygen Sen sor Down st r ea m Rela y . . . 8W-42-11, 12
P a ssen ger Blen d Door Mot or /Act u a t or . . 8W-42-7, 8
P ower Dist r ibu t ion
Cen t er . . . . . . . . . . . . . 8W-42-2, 3, 4, 6, 9, 11, 12
P ower t r a in Con t r ol Modu le . . . . . . . 8W-42-3, 11, 12
Rea r Win dow Defogger . . . . . . . . . . . . . 8W-42-5, 10
Rea r Win dow Defogger Rela y . . . . . . . . 8W-42-5, 10
Recir cu la t ion Door Mot or /Act u a t or . . . . . 8W-42-7, 8
Tem per a t u r e Va lve Act u a t or . . . . . . . . . . . 8W-42-10
Viscou s/Ca bin H ea t er Rela y . . . . . . . . . . . . 8W-42-4
WJ 8W-43 AIRBAG SYSTEM 8W - 43 - 1

8 W-4 3 AI RBAG SY ST EM
Co m p o n e n t P age Co m p o n e n t P age
Air ba g Con t r ol Modu le . . . . . . . . . . 8W-43-2, 3, 4, 5 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . . . 8W-43-3 In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . 8W-43-3
Dr iver Air ba g Squ ib 1 . . . . . . . . . . . . . . . . . 8W-43-2 J u n ct ion Block . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Dr iver Air ba g Squ ib 2 . . . . . . . . . . . . . . . . . 8W-43-2 Left F r on t Im pa ct Sen sor . . . . . . . . . . . . . . 8W-43-4
Dr iver Cu r t a in Squ ib . . . . . . . . . . . . . . . . . 8W-43-5 P a ssen ger Air ba g . . . . . . . . . . . . . . . . . . . . 8W-43-3
Dr iver Sea t Belt Swit ch . . . . . . . . . . . . . . . 8W-43-5 P a ssen ger Cu r t a in Air ba g . . . . . . . . . . . . . . 8W-43-5
Dr iver Side Im pa ct Sen sor . . . . . . . . . . . . . 8W-43-5 P a ssen ger Sea t Belt Swit ch . . . . . . . . . . . . 8W-43-5
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3 P a ssen ger Side Im pa ct Sen sor . . . . . . . . . . 8W-43-5
F u se 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 Righ t F r on t Im pa ct Sen sor . . . . . . . . . . . . . 8W-43-4
F u se 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
WJ 8W-44 INTERIOR LIGHTING 8W - 44 - 1

8 W-4 4 I N T ERI OR LI GH T I N G
Co m p o n e n t P age Co m p o n e n t P age
Ash Receiver La m p . . . . . . . . . . . . . . . . . . 8W-44-10 Left Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . 8W-44-10
Au t om a t ic Zon e Con t r ol Modu le . . . . . . . . 8W-44-10 Left Rea r Door Lock Mot or /Aja r Swit ch . . . 8W-44-6
Body Con t r ol Modu le . . . . . 8W-44-2, 3, 4, 5, 6, 8, 10 Left Visor /Va n it y La m p . . . . . . . . . . . . . . . . 8W-44-2
Ca r go La m p . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4 Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . . 8W-44-5
Dr iver Door Lock Mot or /Aja r Swit ch . . . . . . 8W-44-7 Ma n u a l Tem per a t u r e Con t r ol . . . . . . . . . . 8W-44-10
Dr iver Door Modu le . . . . . . . . . . . . . . . . 8W-44-7, 9 Over h ea d Ma p/Cou r t esy La m p . . . . . . . . . . 8W-44-3
Dr iver F r on t Door Cou r t esy La m p . . . . . . . 8W-44-9 P a ssen ger Door Lock Mot or /Aja r Swit ch . . . 8W-44-7
Dr iver H ea t ed Sea t Swit ch . . . . . . . . . . . . 8W-44-10 P a ssen ger Door Modu le . . . . . . . . . . . . . . 8W-44-7, 9
F u se 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8 P a ssen ger F r on t Door Cou r t esy La m p . . . . 8W-44-9
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4, 8 P a ssen ger H ea t ed Sea t Swit ch . . . . . . . . . 8W-44-10
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10 Righ t Cou r t esy La m p . . . . . . . . . . . . . . . . . 8W-44-8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7 Righ t Door H a n dle Cou r t esy La m p . . . . . . . 8W-44-3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5, 6, 7 Righ t Lift ga t e Aja r Swit ch . . . . . . . . . . . . . 8W-44-5
Glove Box La m p . . . . . . . . . . . . . . . . . . . . . 8W-44-8 Righ t Rea r Door Lock Mot or /Aja r Swit ch . . 8W-44-6
J u n ct ion Block . . . . . . . . . . . . . 8W-44-2, 3, 4, 5, 6, 8 Righ t Visor /Va n it y La m p . . . . . . . . . . . . . . . 8W-44-2
Left Cou r t esy La m p . . . . . . . . . . . . . . . . . . 8W-44-8 Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . . 8W-44-10
Left Door H a n dle Cou r t esy La m p . . . . . . . . 8W-44-3 Un der h ood La m p . . . . . . . . . . . . . . . . . . . . 8W-44-8
Left Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . 8W-44-5
WJ 8W-45 BODY CONTROL MODULE
8 W-4 5 BODY CON T ROL M ODU LE
Co m p o n e n t P age
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . 8W-45-9
Am bien t Tem per a t u r e Sen sor . . . . . . . . . . . 8W-45-7
Ash Receiver La m p . . . . . . . . . . . . . . . . . . . 8W-45-4
Au t om a t ic H ea dla m p Ligh t
Sen sor /VTSS LE D . . . . . . . . . . . . . . . . 8W-45-3, 7
Au t om a t ic Zon e Con t r ol Modu le . . . . . . 8W-45-4, 10
Body Con t r ol
Modu le . . . . . . . . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
Ca r go La m p . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
Coola n t Level Sen sor . . . . . . . . . . . . . . . 8W-45-5, 6
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . 8W-45-5, 6
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . 8W-45-5, 6
Dr iver H ea t ed Sea t Swit ch . . . . . . . . . . 8W-45-4, 10
F og La m p Rela y . . . . . . . . . . . . . . . . . . . . . 8W-45-3
F r on t Wa sh er P u m p . . . . . . . . . . . . . . . . . . 8W-45-8
F r on t Wiper Mot or . . . . . . . . . . . . . . . . . . . 8W-45-8
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
F u se 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
F u se 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
F u se 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2, 5, 6
Glove Box La m p . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
H igh Bea m Rela y . . . . . . . . . . . . . . . . . . . . 8W-45-3
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . . 8W-45-7
8W - 45 - 1
Co m p o n e n t P age
H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
J u n ct ion Block . . . . . . . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9
Left Cou r t esy La m p . . . . . . . . . . . . . . . . 8W-45-5, 6
Left Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . 8W-45-8
Left Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . 8W-45-3, 4
Left Rea r Door Lock Mot or /Aja r Swit ch . . . 8W-45-7
Left Rem ot e Ra dio Swit ch . . . . . . . . . . . . . . 8W-45-9
Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . . 8W-45-8
Low Bea m Rela y . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Low Bea m /Da yt im e Ru n n in g
La m p Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Ma n u a l Tem per a t u r e Con t r ol . . . . . . . . 8W-45-4, 10
Over h ea d Ma p/Cou r t esy La m p . . . . . . . . 8W-45-5, 6
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . 8W-45-3, 4
P a ssen ger H ea t ed Sea t Swit ch . . . . . . . 8W-45-4, 10
Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Rea r Win dow Defogger Rela y . . . . . . . . . 8W-45-4, 9
Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-45-8
Righ t Cou r t esy La m p . . . . . . . . . . . . . . . 8W-45-5, 6
Righ t Lift ga t e Aja r Swit ch . . . . . . . . . . . . . 8W-45-8
Righ t Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . 8W-45-8
Righ t Rea r Door Lock Mot or /Aja r Swit ch . . 8W-45-7
Righ t Rem ot e Ra dio Swit ch . . . . . . . . . . . . 8W-45-9
Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . 8W-45-8
Wiper H igh /Low Rela y . . . . . . . . . . . . . . . . 8W-45-2
Wiper On /Off Rela y . . . . . . . . . . . . . . . . . . . 8W-45-8
WJ 8W-47 AUDIO SYSTEM
8 W-4 7 AU DI O SY ST EM
Co m p o n e n t P age
An t en n a . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
An t en n a Modu le . . . . . . . . . . . . . . . . . . . . . 8W-47-3
Body Con t r ol Modu le . . . . . . . . . . . . . 8W-47-2, 3, 13
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13
Com pa ct Disc Ch a n ger . . . . . . . . . . . . . . 8W-47-6, 7
Dia gn ost ic J u n ct ion P or t . . . . . . 8W-47-2, 3, 6, 7, 13
F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
F u se 30 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
J u n ct ion Block . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
8W - 47 - 1
Co m p o n e n t P age
Left F r on t Door Spea ker . . . . . . . . . 8W-47-4, 10, 11
Left In st r u m en t P a n el Spea ker . . . . . . . 8W-47-4, 12
Left Rea r Door Spea ker . . . . . . . . . . 8W-47-5, 10, 11
Left Rem ot e Ra dio Swit ch . . . . . . . . . . . . . 8W-47-13
P ower Am plifier . . . . . 8W-47-3, 6, 7, 8, 9, 10, 11, 12
Ra dio . . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 7, 8, 9, 13
Righ t F r on t Door Spea ker . . . . . . . . 8W-47-4, 10, 11
Righ t In st r u m en t P a n el Spea ker . . . . . 8W-47-4, 12
Righ t Rea r Door Spea ker . . . . . . . . . 8W-47-5, 10, 11
Righ t Rem ot e Ra dio Swit ch . . . . . . . . . . . 8W-47-13
WJ 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1

8 W-4 8 REAR WI N DOW DEFOGGER

Co m p o n e n t P age Co m p o n e n t P age
Au t om a t ic Zon e Con t r ol Modu le . . . . . . . . . 8W-48-2 J u n ct ion Block . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-48-2 Ma n u a l Tem per a t u r e Con t r ol . . . . . . . . . . . 8W-48-2
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Rea r Win dow Defogger . . . . . . . . . . . . . . . . 8W-48-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Rea r Win dow Defogger Rela y . . . . . . . . . . . 8W-48-2
WJ 8W-49 OVERHEAD CONSOLE
8 W-4 9 OV ERH EAD CON SOLE
Co m p o n e n t P age
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . 8W-49-6
Au t om a t ic Da y/Nigh t Mir r or . . . . . . . . . . 8W-49-4, 5
Ba ck-Up La m p Rela y . . . . . . . . . . . . . . . . . 8W-49-5
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . 8W-49-2, 3, 6
Dr iver P ower Mir r or . . . . . . . . . . . . . . . . . . 8W-49-4
F u se 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-7
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3, 4
F u se 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-6
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-7
8W - 49 - 1
Co m p o n e n t P age
G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3, 5, 6
In t r u sion Tr a n sceiver Modu le . . . . . . . . . . . 8W-49-7
J u n ct ion Block . . . . . . . . . . . . . . . 8W-49-2, 3, 4, 6, 7
Left Rea r La m p Assem bly . . . . . . . . . . . . . . 8W-49-5
P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . . . 8W-49-5
Ra in Sen sor . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-6
Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-7
Tr a n sm ission Solen oid/TRS Assem bly . . . . . 8W-49-5
Veh icle In for m a t ion Cen t er . . . . . . . . . . . 8W-49-2, 3
WJ 8W-50 FRONT LIGHTING
8 W-5 0 FRON T LI GH T I N G
Co m p o n e n t P age
Au t om a t ic H ea dla m p Ligh t
Sen sor /VTSS LE D . . . . . . . . . . . . . . . . . . 8W-50-2
Body Con t r ol Modu le . . . . . . 8W-50-2, 3, 4, 6, 12, 13
Com bin a t ion F la sh er . . . . . . . . . . . . . . . . 8W-50-3, 6
F og La m p Rela y . . . . . . . . . . . . . . . . . . . . 8W-50-12
F u se 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 13
F u se 15 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 13
F u se 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-12
G106 . . . . . . . . . . . . . . . . . . 8W-50-5, 10, 11, 12, 13
G108 . . . . . . . . . . . . . . . . . . . . 8W-50-5, 7, 8, 12, 13
G200 . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 6, 9, 13
H ea dla m p Levelin g Swit ch . . . . . . . . . . . . . 8W-50-9
H igh Bea m Rela y . . . . . . . . . . . . . . . . . . 8W-50-3, 4
J u n ct ion Block . . . . . . . . . . . . . . 8W-50-3, 4, 5, 6, 7,
8, 10, 11, 12, 13
Left F og La m p . . . . . . . . . . . . . . . . . . . . . 8W-50-12
Left F r on t P a r k La m p . . . . . . . . . . . . . 8W-50-10, 11
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . 8W-50-10
8W - 50 - 1
Co m p o n e n t P age
Left F r on t Side Ma r ker La m p . . . . . . . . . . 8W-50-10
Left F r on t Tu r n Sign a l La m p . . . . . . . . . . 8W-50-11
Left H ea dla m p Levelin g Mot or . . . . . . . . . 8W-50-11
Left H igh Bea m H ea dla m p . . . . . . . . . . . . . 8W-50-5
Left Low Bea m H ea dla m p . . . . . . . . . . . 8W-50-5, 13
Left Mu lt i-F u n ct ion Swit ch . . . . . . . . . 8W-50-2, 3, 4
Left Side Repea t er La m p . . . . . . . . . . . . . 8W-50-11
Low Bea m Rela y . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Low Bea m /Da yt im e Ru n n in g
La m p Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-50-13
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . . . 8W-50-6
Righ t F og La m p . . . . . . . . . . . . . . . . . . . . 8W-50-12
Righ t F r on t P a r k La m p . . . . . . . . . . . . . 8W-50-7, 8
Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . . 8W-50-7
Righ t F r on t Side Ma r ker La m p . . . . . . . . . 8W-50-7
Righ t F r on t Tu r n Sign a l La m p . . . . . . . . . . 8W-50-8
Righ t H ea dla m p Levelin g Mot or . . . . . . . . . 8W-50-8
Righ t H igh Bea m H ea dla m p . . . . . . . . . . . . 8W-50-5
Righ t Low Bea m H ea dla m p . . . . . . . . . 8W-50-5, 13
Righ t Rea r La m p Assem bly . . . . . . . . . . . 8W-50-7, 8
Righ t Side Repea t er La m p . . . . . . . . . . . . . 8W-50-8
WJ 8W-51 REAR LIGHTING
8 W-5 1 REAR LI GH T I N G
Co m p o n e n t P age
Adju st a ble P eda ls Modu le . . . . . . . . . . . . . . 8W-51-7
Au t om a t ic Da y/Nigh t Mir r or . . . . . . . . . . 8W-51-7, 8
Ba ck-Up La m p Rela y . . . . . . . . . . . . . . . . . 8W-51-9
Body Con t r ol Modu le . . . . . . . . . . . . . 8W-51-2, 3, 10
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . 8W-51-5, 6
Cen t er H igh Mou n t ed St op La m p . . . . . . 8W-51-5, 6
Con t r oller An t ilock Br a ke . . . . . . . . . . . . 8W-51-5, 6
E lect r ic Br a ke . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-9
F u se 23 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 6
F u se 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-10
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
G300 . . . . . . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 7, 8, 10
G301 . . . . . . . . . . . . . . . 8W-51-2, 3, 4, 5, 6, 7, 8, 10
8W - 51 - 1
Co m p o n e n t P age
J u n ct ion Block . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 9, 10
Left Rea r La m p
Assem bly . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 7, 8, 10
Licen se La m p No. 1 . . . . . . . . . . . . . . . . . . 8W-51-4
Licen se La m p No. 2 . . . . . . . . . . . . . . . . . . 8W-51-4
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . 8W-51-2, 3
P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . 8W-51-7, 8
Rea r F og La m p Rela y . . . . . . . . . . . . . . . . 8W-51-10
Righ t Rea r La m p
Assem bly . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 7, 8, 10
Sh ift er Assem bly . . . . . . . . . . . . . . . . . . . . . 8W-51-9
Tr a iler Tow Br a ke La m p Rela y . . . . . . . . . . 8W-51-5
Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . . 8W-51-7
Tr a n sm ission Solen oid/TRS
Assem bly . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
WJ 8W-52 TURN SIGNALS
8 W-5 2 T U RN SI GN ALS
Co m p o n e n t P age
Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-52-3, 5
Com bin a t ion F la sh er . . . . . . . . . . 8W-52-2, 3, 5, 7, 8
F u se 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 5
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 6
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 4
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7, 8
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7, 8
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . 8W-52-3, 5
J u n ct ion Block . . . . . . . . . . . . . . . 8W-52-2, 3, 5, 7, 8
Left F r on t P a r k La m p . . . . . . . . . . . . . . . . 8W-52-6
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . . 8W-52-6
8W - 52 - 1
Co m p o n e n t P age
Left F r on t Side Ma r ker La m p . . . . . . . . . . . 8W-52-6
Left F r on t Tu r n Sign a l La m p . . . . . . . . . 8W-52-5, 6
Left Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . 8W-52-2
Left Rea r La m p Assem bly . . . . . . . . . . . . 8W-52-7, 8
Left Side Repea t er La m p . . . . . . . . . . . . . . 8W-52-5
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . 8W-52-3, 5
Righ t F r on t P a r k La m p . . . . . . . . . . . . . . . 8W-52-4
Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . . 8W-52-4
Righ t F r on t Side Ma r ker La m p . . . . . . . . . 8W-52-4
Righ t F r on t Tu r n Sign a l La m p . . . . . . . . 8W-52-3, 4
Righ t Rea r La m p Assem bly . . . . . . . . . 8W-52-3, 7, 8
Righ t Side Repea t er La m p . . . . . . . . . . . . . 8W-52-3
Tr a iler Tow Left Tu r n Rela y . . . . . . . . . . . . 8W-52-7
Tr a iler Tow Righ t Tu r n Rela y . . . . . . . . . . . 8W-52-7
WJ 8W-53 WIPERS
8 W-5 3 WI PERS
Co m p o n e n t P age
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . 8W-53-5
Body Con t r ol Modu le . . . . . . . . . . . . 8W-53-2, 3, 4, 6
Cir cu it Br ea ker No. 1 . . . . . . . . . . . . . . . 8W-53-3, 4
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . . . 8W-53-5
F r on t Wa sh er P u m p . . . . . . . . . . . . . . . . . . 8W-53-2
F r on t Wiper Mot or . . . . . . . . . . . . . . . 8W-53-3, 4, 5
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-6
F u se 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
F u se 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 5, 6
8W - 53 - 1
Co m p o n e n t P age
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5, 6
J u n ct ion Block . . . . . . . . . . . . . . . 8W-53-2, 3, 4, 5, 6
Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . . 8W-53-6
Ra in Sen sor . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
Rea r Wa sh er P u m p . . . . . . . . . . . . . . . . . . . 8W-53-6
Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-53-6
Righ t Mu lt i-F u n ct ion Swit ch . . . . . . . . . . 8W-53-2, 6
Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . 8W-53-2
Wiper H igh /Low Rela y . . . . . . . . . . . . 8W-53-3, 4, 5
Wiper On /Off Rela y . . . . . . . . . . . . . . . 8W-53-3, 4, 5
WJ 8W-54 TRAILER TOW 8W - 54 - 1

8 W-5 4 T RAI LER T OW

Co m p o n e n t P age Co m p o n e n t P age
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-54-2 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . 8W-54-3, 5 J u n ct ion Block . . . . . . . . . . . . . . . . 8W-54-2, 3, 4, 5
Ciga r Ligh t er Rela y . . . . . . . . . . . . . . . . . . 8W-54-4 P a r k La m p Rela y . . . . . . . . . . . . . . . . . . . . 8W-54-2
Cir cu it Br ea ker . . . . . . . . . . . . . . . . . . . . . . 8W-54-4 P a r k/Neu t r a l P osit ion Swit ch . . . . . . . . . . . 8W-54-4
Com bin a t ion F la sh er . . . . . . . . . . . . . . . . . 8W-54-5 Tr a iler Tow Br a ke La m p Rela y . . . . . . 8W-54-3, 5, 6
E lect r ic Br a ke . . . . . . . . . . . . . . . . . . . . . 8W-54-3, 5 Tr a iler Tow Cir cu it Br ea ker . . . . . . . . . . . . 8W-54-4
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2 Tr a iler Tow Con n ect or . . . . . . . . . . . 8W-54-2, 3, 4, 6
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5 Tr a iler Tow Left Tu r n Rela y . . . . . . . . . . 8W-54-5, 6
F u se 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3 Tr a iler Tow Righ t Tu r n Rela y . . . . . . . . . 8W-54-5, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2 Tr a n sm ission Solen oid/TRS Assem bly . . . . . 8W-54-4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
WJ 8W-60 POWER WINDOWS
8 W-6 0 POWER WI N DOWS
Co m p o n e n t P age
Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-60-2, 3
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . 8W-60-2, 3
Dr iver Door Modu le . . . . . . . . . . . . 8W-60-2, 3, 4, 5
Dr iver F r on t P ower Win dow Mot or . . . . . 8W-60-2, 3
Dr iver Rea r P ower Win dow Mot or . . . . . . . 8W-60-5
Dr iver Rea r P ower Win dow Swit ch . . . . . . . 8W-60-5
F u se 12 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 4, 5, 6
8W - 60 - 1
Co m p o n e n t P age
G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 4, 5, 6
J u n ct ion Block . . . . . . . . . . . . . . . . . . 8W-60-2, 3, 4
P a ssen ger Door Modu le . . . . . . . . . . 8W-60-2, 3, 4, 6
P a ssen ger F r on t P ower
Win dow Mot or . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
P a ssen ger Rea r P ower Win dow Mot or . . . . 8W-60-6
P a ssen ger Rea r P ower Win dow Swit ch . . . . 8W-60-6
P ower Dist r ibu t ion Cen t er . . . . . . . . . . . 8W-60-2, 3
WJ 8W-61 POWER DOOR LOCKS
8 W-6 1 POWER DOOR LOCK S
Co m p o n e n t P age
Body Con t r ol Modu le . . . . 8W-61-2, 4, 7, 8, 9, 10, 12
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . 8W-61-2, 4
Dr iver Cylin der Lock Swit ch . . . . . . . . . . . . 8W-61-3
Dr iver Door Lock Mot or /Aja r Swit ch . . . . . . 8W-61-3
Dr iver Door Modu le . . . . . . . . . . . . . . . . 8W-61-2, 3
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-11
G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 4, 8, 9
G301 . . . . . . . . . . . . . . . . . 8W-61-3, 4, 7, 10, 11, 12
J u n ct ion Block . . . . . . . . . . 8W-61-2, 4, 7, 10, 11, 12
Left Lift ga t e Aja r Swit ch . . . . . . . . . . . . . 8W-61-12
Left Rea r Door Lock Mot or /Aja r
Swit ch . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6, 7, 10
Lift ga t e F lip-Up Aja r Swit ch . . . . . . . . . . . 8W-61-12
8W - 61 - 1
Co m p o n e n t P age
Lift ga t e F lip-Up P u sh Bu t t on Swit ch . . . . 8W-61-11
Lift ga t e F lip-Up Relea se Solen oid . . . . . . . 8W-61-11
Lift ga t e P ower Lock Mot or . . . . . . . . 8W-61-5, 6, 11
P a ssen ger Door Lock Mot or /Aja r
Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4, 5, 6
P a ssen ger Door
Modu le . . . . . . . . . . . 8W-61-4, 5, 6, 7, 8, 9, 10, 11
Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . 8W-61-12
Rem ot e Keyless Modu le . . . . . . . . . . . . . . . 8W-61-2
Righ t Lift ga t e Aja r Swit ch . . . . . . . . . . . . 8W-61-12
Righ t Rea r Door Lock Mot or /Aja r
Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6, 8, 9
WJ 8W-62 POWER MIRRORS
8 W-6 2 POWER M I RRORS
Co m p o n e n t P age
Au t om a t ic Da y/Nigh t Mir r or . . . . . . . . . . . . 8W-62-6
Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-62-2, 3
Dia gn ost ic J u n ct ion P or t . . . . . . . . . . . . . 8W-62-2, 3
Dr iver Door Modu le . . . . . . . . . . . . 8W-62-2, 3, 4, 6
Dr iver F r on t Door Cou r t esy La m p . . . . . . . 8W-62-4
Dr iver P ower Mir r or . . . . . . . . . . . . . . . . . . 8W-62-6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
8W - 62 - 1
Co m p o n e n t P age
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
J u n ct ion Block . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
Mem or y Set Swit ch . . . . . . . . . . . . . . . . . . . 8W-62-4
P a ssen ger Door Modu le . . . . . . . . . . . . 8W-62-2, 3, 5
P a ssen ger F r on t Door Cou r t esy La m p . . . . 8W-62-5
P a ssen ger P ower Mir r or . . . . . . . . . . . . . . . 8W-62-5
WJ 8W-63 POWER SEATS
8 W-6 3 POWER SEAT S
Co m p o n e n t P age
Body Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-63-12
Cir cu it Br ea ker No. 2 (J B) . . . . 8W-63-2, 3, 4, 10, 11
Dr iver Door Modu le . . . . . . . . . . . . . . . . . . 8W-63-3
Dr iver H ea t ed Sea t Ba ck . . . . . . . . . . . . 8W-63-6, 7
Dr iver H ea t ed Sea t Cu sh ion . . . . . . . . . . 8W-63-6, 7
Dr iver H ea t ed Sea t Swit ch . . . . . . . . . . . . 8W-63-12
Dr iver Lu m ba r Mot or . . . . . . . . . . . . . 8W-63-10, 11
Dr iver Lu m ba r Swit ch . . . . . . . . . . . . . 8W-63-10, 11
Dr iver P ower Sea t F r on t Riser Mot or . . . 8W-63-2, 5
Dr iver P ower Sea t F r on t Riser
Mot or Sen sor . . . . . . . . . . . . . . . . . . . . . 8W-63-8
Dr iver P ower Sea t H or izon t a l Mot or . . . . 8W-63-2, 5
Dr iver P ower Sea t H or izon t a l
Mot or Sen sor . . . . . . . . . . . . . . . . . . . . 8W-63-8, 9
Dr iver P ower Sea t Rea r Riser Mot or . . . 8W-63-2, 5
Dr iver P ower Sea t Rea r Riser
Mot or Sen sor . . . . . . . . . . . . . . . . . . . . . 8W-63-8
Dr iver P ower Sea t Reclin er Mot or . . . . . 8W-63-2, 5
Dr iver P ower Sea t Reclin er
Mot or Sen sor . . . . . . . . . . . . . . . . . . . . 8W-63-8, 9
8W - 63 - 1
Co m p o n e n t P age
Dr iver P ower Sea t Swit ch . . . . . . . . . . . . 8W-63-2, 5
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12
G300 . . . . . . . . . . . . . . . . . . . . 8W-63-3, 4, 5, 10, 11
G301 . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4, 5, 10, 11
J u n ct ion Block . . . . . . . . . . 8W-63-2, 3, 4, 10, 11, 12
Mem or y Set Swit ch . . . . . . . . . . . . . . . . . . . 8W-63-3
P a ssen ger H ea t ed Sea t Ba ck . . . . . . . . . 8W-63-6, 7
P a ssen ger H ea t ed Sea t Cu sh ion . . . . . . . 8W-63-6, 7
P a ssen ger H ea t ed Sea t Swit ch . . . . . . . . . 8W-63-12
P a ssen ger Lu m ba r Mot or . . . . . . . . . . 8W-63-10, 11
P a ssen ger Lu m ba r Swit ch . . . . . . . . . . 8W-63-10, 11
P a ssen ger P ower Sea t F r on t
Riser Mot or . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
P a ssen ger P ower Sea t H or izon t a l Mot or . . . 8W-63-4
P a ssen ger P ower Sea t Rea r
Riser Mot or . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
P a ssen ger P ower Sea t Reclin er Mot or . . . . 8W-63-4
P a ssen ger P ower Sea t Swit ch . . . . . . . . . . . 8W-63-4
Sea t Modu le . . . . . . . . . . . . . . 8W-63-3, 5, 6, 7, 8, 9
WJ 8W-64 POWER SUNROOF 8W - 64 - 1

8 W-6 4 POWER SU N ROOF

Co m p o n e n t P age Co m p o n e n t P age
Accessor y Dela y Rela y . . . . . . . . . . . . . . . . 8W-64-2 J u n ct ion Block . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-64-2 Su n r oof Con t r ol Modu le . . . . . . . . . . . . . 8W-64-2, 3
F u se 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2 Su n r oof Mot or . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2, 3 Su n r oof Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-64-3
WJ 8W-70 SPLICE INFORMATION 8W - 70 - 1

8 W-7 0 SPLI CE I N FORM AT I ON

Co m p o n e n t P age Co m p o n e n t P age
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12 S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-21, 45 S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-37
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20 S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20 S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 3, 4, 5 S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 3, 4, 5 S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 6
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-13 S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-36
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18 S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22 S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-9, 10 S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20 S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 6
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 6
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5, 6 S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20 S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6, 7
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12 S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22 S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-23 S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27 S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-9
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20 S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3, 5
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3, 5 S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6, 7 S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-32
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11 S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11 S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7 S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18 S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18 S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31 S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7 S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-3, 32 S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5, 32 S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6 S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-51 S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 22
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5 S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14 S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-33 S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-33 S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14 S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5 S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-8
S160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11 S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8
S162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26 S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7, 15 S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18, 21
S165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-9 S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21, 22
S168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26 S357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16, 18
S169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-47 S358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22
S170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-44 S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
S171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-36 S360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-36 S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 S362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 S363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26 S364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12 S365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-11
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15 S366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10 S367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-36
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14 S368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22 S369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21, 22
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15 S370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22 S400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16 S401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8 S402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11 S403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4, 7 S404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 S405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 S406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-6
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5 S407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-6
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5 S408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13 S410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13 S411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-10 S412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 1

8 W-8 0 CON N ECT OR PI N -OU T

Co m p o n e n t P age Co m p o n e n t P age
A/C COMP RE SSOR CLUTCH . . . . . . . . . . 8W-80-6 C105 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-17
A/C P RE SSURE TRANSDUCE R . . . . . . . . 8W-80-6 C105 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-18
ACCE LE RATOR P E DAL P OSITION C106 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-18
SE NSOR (DIE SE L) . . . . . . . . . . . . . . . . . 8W-80-6 C106 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-20
ADJ USTABLE P E DALS MODULE C106 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
(E XCE P T BUILT-UP -E XP ORT) . . . . . . . 8W-80-6 C106 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
ADJ USTABLE P E DALS MOTOR/SE NSOR C107 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-26
ASSE MBLY (E XCE P T C107 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-28
BUILT-UP -E XP ORT) . . . . . . . . . . . . . . . 8W-80-7 C107 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
ADJ USTABLE P E DALS SWITCH (E XCE P T C107 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
BUILT-UP -E XP ORT) . . . . . . . . . . . . . . . 8W-80-7 C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
AIRBAG CONTROL MODULE C1 C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
(ORC C1) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7 C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
AIRBAG CONTROL MODULE C2 C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
(ORC C2) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8 C110 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-34
AMBIE NT TE MP E RATURE SE NSOR . . . . 8W-80-8 C110 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-34
ANTE NNA MODULE C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
(BUILT-UP -E XP ORT) . . . . . . . . . . . . . . . 8W-80-8 C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
ASH RE CE IVE R LAMP . . . . . . . . . . . . . . . 8W-80-9 C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
AUTOMATIC DAY/NIGH T MIRROR . . . . . 8W-80-9 C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
AUTOMATIC H E ADLAMP LIGH T C113 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-35
SE NSOR/VTSS LE D . . . . . . . . . . . . . . . . 8W-80-9 C113 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-35
AUTOMATIC ZONE CONTROL C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-36
MODULE C1 (AZC) . . . . . . . . . . . . . . . . 8W-80-9 C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-38
AUTOMATIC ZONE CONTROL C201 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-39
MODULE C2 (AZC) . . . . . . . . . . . . . . . 8W-80-10
C201 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-39
BATTE RY TE MP E RATURE SE NSOR . . . 8W-80-10
C202 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
BLOWE R MOTOR . . . . . . . . . . . . . . . . . . 8W-80-10
C202 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
BLOWE R MOTOR CONTROLLE R
C202 (MTC) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
(AZC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
C202 (MTC) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
BLOWE R MOTOR RE SISTOR
C203 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
BLOCK (MTC) . . . . . . . . . . . . . . . . . . . 8W-80-10
C203 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
BODY CONTROL MODULE C1 . . . . . . . . 8W-80-11
C300 (LH D) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-42
BODY CONTROL MODULE C2 . . . . . . . . 8W-80-11
C300 (LH D) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-44
BOOST P RE SSURE SE NSOR
C301 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-46
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C301 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
BRAKE LAMP SWITCH . . . . . . . . . . . . . . 8W-80-12
C302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-49
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-50
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-50
C101 (4.0L RH D) . . . . . . . . . . . . . . . . . . . 8W-80-12
C303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
C101 (4.0L RH D) . . . . . . . . . . . . . . . . . . . 8W-80-13
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
C101 (4.7L RH D) . . . . . . . . . . . . . . . . . . . 8W-80-13
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
C101 (4.7L RH D) . . . . . . . . . . . . . . . . . . . 8W-80-13
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C102 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C102 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C102 (GAS RH D) . . . . . . . . . . . . . . . . . . . 8W-80-14
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C102 (GAS RH D) . . . . . . . . . . . . . . . . . . . 8W-80-15
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
C103 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
C103 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
C103 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-54
C103 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C310 (BUILT-UP -E XP ORT) . . . . . . . . . . . 8W-80-54
C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C310 (BUILT-UP -E XP ORT) . . . . . . . . . . . 8W-80-54
C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
8W - 80 - 2 8W-80 CONNECTOR PIN-OUT WJ

Co m p o n e n t P age Co m p o n e n t P age
C310 (E XCE P T BUILT-UP -E XP ORT) . . . . 8W-80-55 DRIVE R AIRBAG SQUIB 1 . . . . . . . . . . . 8W-80-66
C310 (E XCE P T BUILT-UP -E XP ORT) . . . . 8W-80-55 DRIVE R AIRBAG SQUIB 2 . . . . . . . . . . . 8W-80-66
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55 DRIVE R BLE ND DOOR MOTOR/ACTUATOR
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55 (LH D) (AZC) . . . . . . . . . . . . . . . . . . . . . 8W-80-67
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55 DRIVE R BLE ND DOOR MOTOR/ACTUATOR
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56 (RH D) (AZC)- BLACK 2 WAY . . . . . . . . 8W-80-67
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56 DRIVE R CURTAIN AIRBAG . . . . . . . . . . 8W-80-67
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56 DRIVE R CYLINDE R LOCK SWITCH . . . 8W-80-67
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56 DRIVE R DOOR LOCK MOTOR/AJ AR
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-68
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57 DRIVE R DOOR MODULE C1 . . . . . . . . . 8W-80-68
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57 DRIVE R DOOR MODULE C2 . . . . . . . . . 8W-80-68
C316 (E XCE P T BUILT-UP -E XP ORT) . . . . 8W-80-58 DRIVE R DOOR MODULE C3 . . . . . . . . . 8W-80-69
C316 (E XCE P T BUILT-UP -E XP ORT) . . . . 8W-80-58 DRIVE R F RONT DOOR
C317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58 COURTE SY LAMP . . . . . . . . . . . . . . . . 8W-80-69
C317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58 DRIVE R F RONT P OWE R
C318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58 WINDOW MOTOR . . . . . . . . . . . . . . . . 8W-80-69
C318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59 DRIVE R H E ATE D SE AT BACK
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59 (P RE MIUM I/III) . . . . . . . . . . . . . . . . . 8W-80-69
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59 DRIVE R H E ATE D SE AT CUSH ION
CAMSH AF T P OSITION (P RE MIUM I/III) . . . . . . . . . . . . . . . . . 8W-80-69
SE NSOR (DIE SE L) . . . . . . . . . . . . . . . . 8W-80-59 DRIVE R H E ATE D SE AT SWITCH . . . . . . 8W-80-70
CAMSH AF T P OSITION DRIVE R LUMBAR MOTOR
SE NSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-59 (MIDLINE /P RE MIUM) . . . . . . . . . . . . . 8W-80-70
CAPACITOR (4.0L) . . . . . . . . . . . . . . . . . . 8W-80-59 DRIVE R LUMBAR SWITCH
CAPACITOR NO. 1 (4.7L) . . . . . . . . . . . . . 8W-80-60 (MIDLINE /P RE MIUM) . . . . . . . . . . . . . 8W-80-70
CAPACITOR NO. 2 (4.7L) . . . . . . . . . . . . . 8W-80-60 DRIVE R P OWE R MIRROR . . . . . . . . . . . 8W-80-70
CARGO LAMP . . . . . . . . . . . . . . . . . . . . . 8W-80-60 DRIVE R P OWE R SE AT F RONT
CE NTE R H IGH MOUNTE D RISE R MOTOR . . . . . . . . . . . . . . . . . . . 8W-80-71
STOP LAMP . . . . . . . . . . . . . . . . . . . . . 8W-80-60 DRIVE R P OWE R SE AT F RONT
CIGAR LIGH TE R . . . . . . . . . . . . . . . . . . . 8W-80-60 RISE R MOTOR SE NSOR
CLOCKSP RING C1 . . . . . . . . . . . . . . . . . 8W-80-61 (P RE MIUM II/III) . . . . . . . . . . . . . . . . . 8W-80-71
CLOCKSP RING C2 . . . . . . . . . . . . . . . . . 8W-80-61 DRIVE R P OWE R SE AT H ORIZONTAL
CLOCKSP RING C3 . . . . . . . . . . . . . . . . . 8W-80-61 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-71
CLOCKSP RING C4 . . . . . . . . . . . . . . . . . 8W-80-61 DRIVE R P OWE R SE AT H ORIZONTAL
MOTOR SE NSOR
COIL ON P LUG NO. 1 (4.7L) . . . . . . . . . . 8W-80-61
(P RE MIUM II/III) . . . . . . . . . . . . . . . . . 8W-80-71
COIL ON P LUG NO. 2 (4.7L) . . . . . . . . . . 8W-80-62
DRIVE R P OWE R SE AT RE AR
COIL ON P LUG NO. 3 (4.7L) . . . . . . . . . . 8W-80-62
RISE R MOTOR . . . . . . . . . . . . . . . . . . . 8W-80-71
COIL ON P LUG NO. 4 (4.7L) . . . . . . . . . . 8W-80-62
DRIVE R P OWE R SE AT RE AR
COIL ON P LUG NO. 5 (4.7L) . . . . . . . . . . 8W-80-62
RISE R MOTOR SE NSOR
COIL ON P LUG NO. 6 (4.7L) . . . . . . . . . . 8W-80-62
(P RE MIUM II/III) . . . . . . . . . . . . . . . . . 8W-80-72
COIL ON P LUG NO. 7 (4.7L) . . . . . . . . . . 8W-80-63
DRIVE R P OWE R SE AT
COIL ON P LUG NO. 8 (4.7L) . . . . . . . . . . 8W-80-63
RE CLINE R MOTOR . . . . . . . . . . . . . . . 8W-80-72
COIL RAIL (4.0L) . . . . . . . . . . . . . . . . . . . 8W-80-63
DRIVE R P OWE R SE AT
COMPACT DISC CH ANGE R RE CLINE R MOTOR SE NSOR
(P RE MIUM RADIO) . . . . . . . . . . . . . . . 8W-80-63 (P RE MIUM II/III) . . . . . . . . . . . . . . . . . 8W-80-72
CONTROLLE R ANTILOCK BRAKE . . . . 8W-80-64 DRIVE R P OWE R SE AT SWITCH
COOLANT LE VE L SE NSOR . . . . . . . . . . 8W-80-64 (E XCE P T MIDLINE /P RE MIUM) . . . . . 8W-80-72
CRANKCASE H E ATE R (DIE SE L) . . . . . . 8W-80-64 DRIVE R P OWE R SE AT SWITCH
CRANKSH AF T P OSITION SE NSOR (MIDLINE /P RE MIUM) . . . . . . . . . . . . . 8W-80-73
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-65 DRIVE R RE AR P OWE R
CRANKSH AF T P OSITION SE NSOR WINDOW MOTOR . . . . . . . . . . . . . . . . 8W-80-73
(GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-65 DRIVE R RE AR P OWE R WINDOW
DATA LINK CONNE CTOR . . . . . . . . . . . . 8W-80-65 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-73
DIAGNOSTIC J UNCTION P ORT . . . . . . . 8W-80-66
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Co m p o n e n t P age Co m p o n e n t P age
DRIVE R SE AT BE LT SWITCH . . . . . . . . 8W-80-74 INSTRUME NT CLUSTE R . . . . . . . . . . . . 8W-80-85
DRIVE R SIDE IMPACT SE NSOR . . . . . . 8W-80-74 INTAKE AIR TE MP E RATURE
E GR SOLE NOID (DIE SE L) . . . . . . . . . . . 8W-80-74 SE NSOR (DIE SE L) . . . . . . . . . . . . . . . . 8W-80-85
E LE CTRIC BRAKE INTAKE AIR TE MP E RATURE
(E XCE P T BUILT-UP -E XP ORT) . . . . . . 8W-80-74 SE NSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-85
E LE CTRONIC SP E E D CONTROL INTAKE P ORT SWIRL ACTUATOR
SE RVO . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-74 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-86
E NGINE CONTROL MODULE C1 INTRUSION TRANSCE IVE R MODULE
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-75 (BUILT-UP -E XP ORT) . . . . . . . . . . . . . . 8W-80-86
E NGINE CONTROL MODULE C2 J UNCTION BLOCK BODY
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-76 CONTROL MODULE . . . . . . . . . . . . . . 8W-80-86
E NGINE COOLANT TE MP E RATURE J UNCTION BLOCK C1 . . . . . . . . . . . . . . 8W-80-87
SE NSOR (DIE SE L) . . . . . . . . . . . . . . . . 8W-80-77 J UNCTION BLOCK C2 (LH D) . . . . . . . . . 8W-80-88
E NGINE COOLANT TE MP E RATURE J UNCTION BLOCK C2 (RH D) . . . . . . . . . 8W-80-89
SE NSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-77 J UNCTION BLOCK C3 . . . . . . . . . . . . . . 8W-80-90
E NGINE OIL P RE SSURE J UNCTION BLOCK C4 . . . . . . . . . . . . . . 8W-80-91
SE NSOR (DIE SE L) . . . . . . . . . . . . . . . . 8W-80-77 J UNCTION BLOCK C5 . . . . . . . . . . . . . . 8W-80-91
E NGINE OIL P RE SSURE KNOCK SE NSOR . . . . . . . . . . . . . . . . . . . 8W-80-91
SE NSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-78 LE AK DE TE CTION P UMP (E XCE P T
E VAP /P URGE SOLE NOID (GAS) . . . . . . . 8W-80-78 BUILT-UP -E XP ORT) . . . . . . . . . . . . . . . 8W-80-91
F RONT P OWE R OUTLE T . . . . . . . . . . . . 8W-80-78 LE F T COURTE SY LAMP . . . . . . . . . . . . . 8W-80-91
F RONT WASH E R P UMP . . . . . . . . . . . . . 8W-80-78 LE F T DOOR H ANDLE COURTE SY
F RONT WIP E R MOTOR . . . . . . . . . . . . . 8W-80-78 LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-92
F UE L INJ E CTOR NO. 1 (DIE SE L) . . . . . 8W-80-79 LE F T F OG LAMP . . . . . . . . . . . . . . . . . . . 8W-80-92
F UE L INJ E CTOR NO. 1 (GAS) . . . . . . . . 8W-80-79 LE F T F RONT DOOR SP E AKE R . . . . . . . 8W-80-92
F UE L INJ E CTOR NO. 2 (DIE SE L) . . . . . 8W-80-79 LE F T F RONT IMPACT SE NSOR . . . . . . . 8W-80-92
F UE L INJ E CTOR NO. 2 (GAS) . . . . . . . . 8W-80-79 LE F T F RONT PARK LAMP . . . . . . . . . . . 8W-80-92
F UE L INJ E CTOR NO. 3 (DIE SE L) . . . . . 8W-80-79 LE F T F RONT PARK/TURN SIGNAL LAMP
F UE L INJ E CTOR NO. 3 (GAS) . . . . . . . . 8W-80-80 (E XCE P T BUILT-UP -E XP ORT) . . . . . . 8W-80-93
F UE L INJ E CTOR NO. 4 (DIE SE L) . . . . . 8W-80-80 LE F T F RONT SIDE MARKE R LAMP
F UE L INJ E CTOR NO. 4 (GAS) . . . . . . . . 8W-80-80 (E XCE P T BUILT-UP -E XP ORT) . . . . . . 8W-80-93
F UE L INJ E CTOR NO. 5 (DIE SE L) . . . . . 8W-80-80 LE F T F RONT TURN SIGNAL LAMP
F UE L INJ E CTOR NO. 5 (GAS) . . . . . . . . 8W-80-81 (BUILT-UP -E XP ORT) . . . . . . . . . . . . . . 8W-80-93
F UE L INJ E CTOR NO. 6 (GAS) . . . . . . . . 8W-80-81 LE F T F RONT WH E E L SP E E D
F UE L INJ E CTOR NO. 7 (4.7L) . . . . . . . . 8W-80-81 SE NSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-93
F UE L INJ E CTOR NO. 8 (4.7L) . . . . . . . . 8W-80-81 LE F T H E ADLAMP LE VE LING MOTOR
F UE L P RE SSURE SE NSOR (DIE SE L) . . 8W-80-82 (BUILT-UP -E XP ORT) . . . . . . . . . . . . . . 8W-80-94
F UE L P RE SSURE SOLE NOID LE F T H IGH BE AM H E ADLAMP . . . . . . . 8W-80-94
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-82 LE F T INSTRUME NT PANE L SP E AKE R . 8W-80-94
F UE L P UMP MODULE (GAS) . . . . . . . . . 8W-80-82 LE F T LIF TGATE AJ AR SWITCH . . . . . . . 8W-80-94
F UE L TANK MODULE (DIE SE L) . . . . . . 8W-80-82 LE F T LOW BE AM H E ADLAMP . . . . . . . 8W-80-94
GE NE RATOR (DIE SE L) . . . . . . . . . . . . . . 8W-80-82 LE F T MULTI-F UNCTION SWITCH . . . . 8W-80-95
GE NE RATOR (GAS) . . . . . . . . . . . . . . . . . 8W-80-83 LE F T RE AR DOOR LOCK
GLOVE BOX LAMP . . . . . . . . . . . . . . . . . 8W-80-83 MOTOR/AJ AR SWITCH . . . . . . . . . . . . 8W-80-95
H E ADLAMP LE VE LING SWITCH LE F T RE AR DOOR SP E AKE R . . . . . . . . . 8W-80-95
(BUILT-UP -E XP ORT) . . . . . . . . . . . . . . 8W-80-83 LE F T RE AR LAMP ASSE MBLY . . . . . . . . 8W-80-95
H OOD AJ AR SWITCH LE F T RE AR WH E E L SP E E D
(BUILT-UP -E XP ORT) . . . . . . . . . . . . . . 8W-80-83 SE NSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-96
H ORN NO. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-83 LE F T RE MOTE RADIO SWITCH . . . . . . 8W-80-96
H ORN NO. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-84 LE F T SIDE RE P E ATE R LAMP
H YDRAULIC COOLING MODULE . . . . . 8W-80-84 (BUILT-UP -E XP ORT) . . . . . . . . . . . . . . 8W-80-96
IDLE AIR CONTROL MOTOR . . . . . . . . . 8W-80-84 LE F T VISOR/VANITY LAMP . . . . . . . . . . 8W-80-96
IGNITION SWITCH C1 . . . . . . . . . . . . . . 8W-80-84 LICE NSE LAMP NO. 1 . . . . . . . . . . . . . . 8W-80-96
IGNITION SWITCH C2 . . . . . . . . . . . . . . 8W-80-84 LICE NSE LAMP NO. 2 . . . . . . . . . . . . . . 8W-80-97
INP UT SP E E D SE NSOR (4.7L) . . . . . . . . 8W-80-85 LIF TGATE F LIP -UP AJ AR SWITCH . . . . 8W-80-97
8W - 80 - 4 8W-80 CONNECTOR PIN-OUT
Co m p o n e n t P age
LIF TGATE F LIP -UP P USH
BUTTON SWITCH . . . . . . . . . . . . . . . . 8W-80-97
LIF TGATE F LIP -UP RE LE ASE
SOLE NOID . . . . . . . . . . . . . . . . . . . . . . 8W-80-97
LIF TGATE P OWE R LOCK MOTOR . . . . . 8W-80-97
LINE P RE SSURE SE NSOR (4.7L) . . . . . . 8W-80-98
MANIF OLD ABSOLUTE P RE SSURE
SE NSOR (4.0L) . . . . . . . . . . . . . . . . . . . 8W-80-98
MANIF OLD ABSOLUTE P RE SSURE
SE NSOR (4.7L) . . . . . . . . . . . . . . . . . . . 8W-80-98
MANUAL TE MP E RATURE
CONTROL C1 (MTC) . . . . . . . . . . . . . . 8W-80-98
MANUAL TE MP E RATURE
CONTROL C2 (MTC) . . . . . . . . . . . . . . 8W-80-99
MASS AIR F LOW SE NSOR (DIE SE L) . . . 8W-80-99
MODE DOOR MOTOR/ACTUATOR
(AZC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99
NE E DLE MOVE ME NT SE NSOR
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99
OUTP UT SP E E D SE NSOR (4.0L) . . . . . . 8W-80-99
OUTP UT SP E E D SE NSOR (4.7L) . . . . . 8W-80-100
OVE RH E AD MAP /COURTE SY LAMP . . 8W-80-100
OXYGE N SE NSOR 1/1 UP STRE AM . . . . 8W-80-100
OXYGE N SE NSOR 1/2 DOWNSTRE AM . 8W-80-100
OXYGE N SE NSOR 2/1 UP STRE AM . . . . 8W-80-100
OXYGE N SE NSOR 2/2
DOWNSTRE AM . . . . . . . . . . . . . . . . . 8W-80-101
PARK/NE UTRAL P OSITION SWITCH
(4.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-101
PARK/NE UTRAL P OSITION SWITCH
(DIE SE L) . . . . . . . . . . . . . . . . . . . . . . 8W-80-101
PASSE NGE R AIRBAG . . . . . . . . . . . . . . 8W-80-101
PASSE NGE R BLE ND DOOR
MOTOR/ACTUATOR (LH D) (AZC) . . . 8W-80-101
PASSE NGE R BLE ND DOOR
MOTOR/ACTUATOR (RH D) (AZC) . . . 8W-80-102
PASSE NGE R CURTAIN AIRBAG . . . . . . 8W-80-102
PASSE NGE R DOOR LOCK MOTOR/AJ AR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . 8W-80-102
PASSE NGE R DOOR MODULE C1 . . . . . 8W-80-102
PASSE NGE R DOOR MODULE C2 . . . . . 8W-80-103
PASSE NGE R F RONT DOOR
COURTE SY LAMP . . . . . . . . . . . . . . . 8W-80-103
PASSE NGE R F RONT P OWE R
WINDOW MOTOR . . . . . . . . . . . . . . . 8W-80-103
PASSE NGE R H E ATE D SE AT BACK
(P RE MIUM I/III) . . . . . . . . . . . . . . . . . 8W-80-103
PASSE NGE R H E ATE D SE AT CUSH ION
(P RE MIUM I/III) . . . . . . . . . . . . . . . . . 8W-80-104
PASSE NGE R H E ATE D SE AT SWITCH . 8W-80-104
PASSE NGE R LUMBAR MOTOR
(MIDLINE /P RE MIUM) . . . . . . . . . . . . 8W-80-104
PASSE NGE R LUMBAR SWITCH
(MIDLINE /P RE MIUM) . . . . . . . . . . . . 8W-80-104
PASSE NGE R P OWE R MIRROR . . . . . . . 8W-80-105
WJ
Co m p o n e n t P age
PASSE NGE R P OWE R SE AT F RONT
RISE R MOTOR . . . . . . . . . . . . . . . . . . 8W-80-105
PASSE NGE R P OWE R SE AT
H ORIZONTAL MOTOR . . . . . . . . . . . 8W-80-105
PASSE NGE R P OWE R SE AT RE AR
RISE R MOTOR . . . . . . . . . . . . . . . . . . 8W-80-105
PASSE NGE R P OWE R SE AT RE CLINE R
MOTOR (MIDLINE /P RE MIUM) . . . . . 8W-80-106
PASSE NGE R P OWE R SE AT SWITCH
(MIDLINE /P RE MIUM) . . . . . . . . . . . . 8W-80-106
PASSE NGE R RE AR P OWE R
WINDOW MOTOR . . . . . . . . . . . . . . . 8W-80-106
PASSE NGE R RE AR P OWE R
WINDOW SWITCH . . . . . . . . . . . . . . . 8W-80-106
PASSE NGE R SE AT BE LT SWITCH . . . . 8W-80-106
PASSE NGE R SIDE IMPACT
SE NSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-107
P OWE R AMP LIF IE R C1
(P RE MIUM RADIO) . . . . . . . . . . . . . . 8W-80-107
P OWE R AMP LIF IE R C2
(P RE MIUM RADIO) . . . . . . . . . . . . . . 8W-80-107
P OWE R CONNE CTOR . . . . . . . . . . . . . . 8W-80-108
P OWE RTRAIN CONTROL
MODULE C1 (GAS) . . . . . . . . . . . . . . 8W-80-108
P OWE RTRAIN CONTROL
MODULE C2 (GAS) . . . . . . . . . . . . . . 8W-80-109
P OWE RTRAIN CONTROL
MODULE C3 (GAS) . . . . . . . . . . . . . . 8W-80-110
RADIATOR FAN MOTOR . . . . . . . . . . . . 8W-80-110
RADIATOR FAN RE LAY . . . . . . . . . . . . . 8W-80-111
RADIO C1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-111
RADIO C2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-111
RAIN SE NSOR (AUTOWIP E ) . . . . . . . . . 8W-80-112
RE AR P OWE R OUTLE T . . . . . . . . . . . . . 8W-80-112
RE AR WASH E R P UMP . . . . . . . . . . . . . . 8W-80-112
RE AR WIP E R MOTOR . . . . . . . . . . . . . . 8W-80-112
RE CIRCULATION DOOR
MOTOR/ACTUATOR (AZC) . . . . . . . . . 8W-80-112
RE D BRAKE WARNING INDICATOR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . 8W-80-113
RE MOTE KE YLE SS MODULE
(J APAN) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-113
RIGH T COURTE SY LAMP . . . . . . . . . . . 8W-80-113
RIGH T DOOR H ANDLE
COURTE SY LAMP . . . . . . . . . . . . . . . 8W-80-113
RIGH T F OG LAMP . . . . . . . . . . . . . . . . . 8W-80-113
RIGH T F RONT DOOR SP E AKE R . . . . . 8W-80-114
RIGH T F RONT IMPACT SE NSOR . . . . . 8W-80-114
RIGH T F RONT PARK LAMP . . . . . . . . . 8W-80-114
RIGH T F RONT PARK/TURN SIGNAL LAMP
(E XCE P T BUILT-UP -E XP ORT) . . . . . . 8W-80-114
RIGH T F RONT SIDE MARKE R LAMP
(E XCE P T BUILT-UP -E XP ORT) . . . . . . 8W-80-115
RIGH T F RONT TURN SIGNAL LAMP
(BUILT-UP -E XP ORT) . . . . . . . . . . . . . 8W-80-115
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Co m p o n e n t P age Co m p o n e n t P age
RIGH T F RONT WH E E L SP E E D TE MP E RATURE VALVE
SE NSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-115 ACTUATOR (MTC) . . . . . . . . . . . . . . . 8W-80-122
RIGH T H E ADLAMP LE VE LING MOTOR TH ROTTLE P OSITION
(BUILT-UP -E XP ORT) . . . . . . . . . . . . . 8W-80-115 SE NSOR (4.0L) . . . . . . . . . . . . . . . . . . 8W-80-122
RIGH T H IGH BE AM H E ADLAMP . . . . . 8W-80-116 TH ROTTLE P OSITION
RIGH T INSTRUME NT PANE L SE NSOR (4.7L) . . . . . . . . . . . . . . . . . . 8W-80-122
SP E AKE R . . . . . . . . . . . . . . . . . . . . . . 8W-80-116 TRAILE R TOW BRAKE
RIGH T LIF TGATE AJ AR SWITCH . . . . . 8W-80-116 LAMP RE LAY . . . . . . . . . . . . . . . . . . . 8W-80-122
RIGH T LOW BE AM H E ADLAMP . . . . . 8W-80-116 TRAILE R TOW CIRCUIT
RIGH T MULTI-F UNCTION SWITCH . . . 8W-80-116 BRE AKE R . . . . . . . . . . . . . . . . . . . . . . 8W-80-122
RIGH T RE AR DOOR LOCK TRAILE R TOW CONNE CTOR . . . . . . . . 8W-80-123
MOTOR/AJ AR SWITCH . . . . . . . . . . . 8W-80-117 TRAILE R TOW LE F T TURN
RIGH T RE AR DOOR SP E AKE R . . . . . . . 8W-80-117 RE LAY . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-123
RIGH T RE AR LAMP ASSE MBLY . . . . . . 8W-80-117 TRAILE R TOW RIGH T TURN
RIGH T RE AR WH E E L SP E E D RE LAY . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-123
SE NSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-117 TRANSF E R CASE P OSITION
RIGH T RE MOTE RADIO SWITCH . . . . 8W-80-117 SE NSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-123
RIGH T SIDE RE P E ATE R LAMP TRANSMISSION CONTROL
(BUILT-UP -E XP ORT) . . . . . . . . . . . . . 8W-80-118 MODULE (4.7L) . . . . . . . . . . . . . . . . . 8W-80-124
RIGH T VISOR/VANITY LAMP . . . . . . . . 8W-80-118 TRANSMISSION CONTROL
SE AT BE LT SWITCH . . . . . . . . . . . . . . . 8W-80-118 MODULE C1 (DIE SE L) . . . . . . . . . . . 8W-80-125
SE AT MODULE C1 (P RE MIUM) . . . . . . 8W-80-118 TRANSMISSION CONTROL
SE AT MODULE C2 (P RE MIUM) . . . . . . 8W-80-119 MODULE C2 (DIE SE L) . . . . . . . . . . . 8W-80-125
SE NTRY KE Y IMMOBILIZE R TRANSMISSION SOLE NOID (4.0L) . . . . 8W-80-125
MODULE . . . . . . . . . . . . . . . . . . . . . . 8W-80-119 TRANSMISSION SOLE NOID
SH IF TE R ASSE MBLY ASSE MBLY (DIE SE L) . . . . . . . . . . . . 8W-80-126
(C201 DIE SE L) . . . . . . . . . . . . . . . . . . 8W-80-119 TRANSMISSION SOLE NOID/TRS
SH IF TE R ASSE MBLY (GAS) . . . . . . . . . 8W-80-120 ASSE MBLY (4.7L) . . . . . . . . . . . . . . . . 8W-80-126
SH IF TE R ASSE MBLY C1 (DIE SE L) . . . . 8W-80-120 UNDE RH OOD LAMP . . . . . . . . . . . . . . . 8W-80-126
SH IF TE R ASSE MBLY C2 (DIE SE L) . . . . 8W-80-120 VE H ICLE INF ORMATION CE NTE R . . . 8W-80-127
SIRE N (BUILT-UP -E XP ORT) . . . . . . . . . 8W-80-120 VISCOUS/CABIN H E ATE R
SP E E D CONTROL SWITCH NO. 1 . . . . 8W-80-120 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . . 8W-80-127
SP E E D CONTROL SWITCH NO. 2 . . . . 8W-80-121 WASH E R F LUID LE VE L SWITCH . . . . 8W-80-127
SUNROOF CONTROL MODULE . . . . . . 8W-80-121 WASTE GATE SOLE NOID
SUNROOF MOTOR C1 . . . . . . . . . . . . . . 8W-80-121 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . . 8W-80-127
SUNROOF MOTOR C2 . . . . . . . . . . . . . . 8W-80-121 WATE R IN F UE L SE NSOR
SUNROOF SWITCH . . . . . . . . . . . . . . . . 8W-80-121 (DIE SE L) . . . . . . . . . . . . . . . . . . . . . . 8W-80-127
8W - 80 - 6 8W-80 CONNECTOR PIN-OUT WJ

A/C COMPRESSOR CLUTCH - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 C2 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z18 18BK GROUND

A/C PRESSURE TRANSDUCER - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K6 18VT/WT (DIESEL) SENSOR REFERENCE VOLTAGE B
2 K6 18VT/BK (GAS) 5 VOLT SUPPLY
3 C18 18DB A/C PRESSURE SIGNAL
4 - -

ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY

CAV CIRCUIT FUNCTION
1 - -
2 F855 18BR/YL SENSOR REFERENCE VOLTAGE A
3 K22 14RD/DB ACCELERATOR PEDAL POSITION SENSOR 2 SIGNAL
4 - -
5 - -
6 K225 18BK ACCELERATOR PEDAL POSITION SENSOR 2 GROUND
7 K81 20DB/DG ACCELERATOR PEDAL POSITION SENSOR 1 SIGNAL
8 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR 1 GROUND
9 - -
10 Y43 20WT/VT ACCELERATOR PEDAL POSITION SENSOR 1 5-VOLT
SUPPLY

ADJUSTABLE PEDALS MODULE (EXCEPT BUILT-UP-EXPORT) - GREEN 14 WAY

CAV CIRCUIT FUNCTION
1 Y151 20LG/BR ADJUSTABLE PEDALS SWITCH SENSE (FORWARD)
2 Y152 20LG/OR ADJUSTABLE PEDALS SWITCH SENSE (REARWARD)
3 Q110 16OR/VT ADJUSTABLE PEDALS MOTOR (FORWARD)
4 F72 16RD/YL FUSED B(+)
5 - -
6 Q111 16OR/GY ADJUSTABLE PEDALS MOTOR (REARWARD)
7 Q113 20OR/DB (MEMORY) PEDAL POSITION SENSOR FEED
8 Q112 20OR/YL (MEMORY) PEDAL POSITION SENSOR SENSE
9 Q114 20OR/TN (MEMORY) PEDAL POSITION SENSOR RETURN
10 Z151 16BK GROUND
11 Z155 20BK/OR GROUND
12 L1 18WT/BR BACK-UP LAMP FEED
13 D25 20VT/YL PCI BUS
14 Y153 16DB/RD ADJUSTABLE PEDALS SWITCH FEED
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 7

ADJUSTABLE PEDALS MOTOR/SENSOR ASSEMBLY (EXCEPT BUILT-UP-EXPORT) - 6 WAY

CAV CIRCUIT FUNCTION
1 Q113 20OR/DB PEDAL POSITION SENSOR FEED
2 Q112 20OR/YL PEDAL POSITION SENSOR SENSE
3 Q114 20OR/TN PEDAL POSITION SENSOR RETURN
4 - -
5 Q111 16OR/GY AJDUSTABLE PEDALS MOTOR (REARWARD)
6 Q110 16OR/VT ADJUSTABLE PEDALS MOTOR (FORWARD)

ADJUSTABLE PEDALS SWITCH (EXCEPT BUILT-UP-EXPORT) - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 Y153 20BD/RD ADJUSTABLE PEDALS SWITCH FEED
2 Y152 20LG/OR ADJUSTABLE PEDALS SWITCH SENSE (REARWARD)
3 Y151 20LG/BR ADJUSTABLE PEDALS SWITCH SENSE (FORWARD)

AIRBAG CONTROL MODULE C1 (ORC C1) - YELLOW 32 WAY

CAV CIRCUIT FUNCTION
1 R72 20LB/WT (SIDE AIRBAGS) PASSENGER CURTAIN SQUIB LINE 2
2 R74 20LB/YL (SIDE AIRBAGS) PASSENGER CURTAIN SQUIB LINE 1
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 R58 20GY PASSENGER SEAT BELT SWITCH SENSE
10 R60 20VT PASSENGER SEAT BELT SWITCH GROUND
11 - -
12 - -
13 - -
14 - -
15 R132 20LG/VT (SIDE AIRBAGS) PASSENGER SIDE IMPACT SENSOR SIGNAL
16 R134 20LB/BR (SIDE AIRBAGS) PASSENGER SIDE IMPACT SENSOR GROUND
17 R131 20LG/YL (SIDE AIRBAGS) DRIVER SIDE IMPACT SENSOR SIGNAL
18 R133 20LB/DG (SIDE AIRBAGS) DRIVER SIDE IMPACT SENSOR GROUND
19 - -
20 - -
21 - -
22 - -
23 R59 20LB DRIVER SEAT BELT SWITCH GROUND
24 R57 20DG DRIVER SEAT BELT SWITCH SENSE
25 R73 20LB/BR (SIDE AIRBAGS) DRIVER CURTAIN SQUIB LINE 2
26 R75 20LB/OR (SIDE AIRBAGS) DRIVER CURTAIN SQUIB LINE 1
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
8W - 80 - 8 8W-80 CONNECTOR PIN-OUT WJ

AIRBAG CONTROL MODULE C2 (ORC C2) - YELLOW 32 WAY

CAV CIRCUIT FUNCTION
1 R45 20DG/LB DRIVER SQUIB 1 LINE 2
2 R43 20BK/LB DRIVER SQUIB 1 LINE 1
3 R42 20BK/YL PASSENGER SQUIB 1 LINE 1
4 R44 20DG/YL PASSENGER SQUIB 1 LINE 2
5 - -
6 - -
7 - -
8 - -
9 R49 20LB LEFT FRONT IMPACT SENSOR SIGNAL
10 R47 20DB/LB LEFT FRONT IMPACT SENSOR GROUND
11 R46 20BR/LB RIGHT FRONT IMPACT SENSOR GROUND
12 R48 20TN RIGHT FRONT IMPACT SENSOR SIGNAL
13 - -
14 - -
15 - -
16 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
17 Z6 20BK/PK GROUND
18 - -
19 - -
20 - -
21 - -
22 - -
23 D25 20YL/VT/OR PCI BUS
24 F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
25 R63 20TN/LB DRIVER SQUIB 2 LINE 2
26 R61 20OR/LB DRIVER SQUIB 2 LINE 1
27 R62 20OR/YL PASSENGER SQUIB 2 LINE 2
28 R64 20TN/YL PASSENGER SQUIB 2 LINE 1
29 - -
30 - -
31 - -
32 - -

AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 G32 20BK/LB SENSOR GROUND
2 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL

ANTENNA MODULE (BUILT-UP-EXPORT) - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 X64 18BK/WT ENABLE SIGNAL TO AMPLIFIER
2 - -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 9

ASH RECEIVER LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z300 20BK GROUND
2 E2 20OR PANEL LAMPS DRIVER

AUTOMATIC DAY/NIGHT MIRROR - BLACK 7 WAY

CAV CIRCUIT FUNCTION
1 G5 20BK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z150 20BK GROUND
3 L1 20BK/VT BACK-UP LAMP FEED
4 P112 20BK/WT AUTO DAY/NIGHT MIRROR (+)
5 P114 20BK/YL AUTO DAY/NIGHT MIRROR (-)
6 - -
7 - -

AUTOMATIC HEADLAMP LIGHT SENSOR/VTSS LED - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 L109 20WT ULTRALIGHT SENSOR SIGNAL
2 L110 20BK/YL ULTRALIGHT SENSOR RETURN
3 G69 20BK/OR VTSS INDICATOR DRIVER
4 M1 20PK FUSED B(+)

AUTOMATIC ZONE CONTROL MODULE C1 (AZC) - WHITE 16 WAY

CAV CIRCUIT FUNCTION
1 C102 20TN/BK MODE DOOR DRIVER (B)
2 - -
3 C32 20GY/DB RECIRCULATION DOOR DRIVER (A)
4 C100 20YL/DB RECIRCULATION DOOR DRIVER (B)
5 - -
6 C79 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
7 - -
8 Z118 20BK GROUND
9 C35 20DG/YL MODE DOOR DRIVER (A)
10 C33 20DB/RD DRIVER BLEND DOOR DRIVER (A)
11 - -
12 - -
13 - -
14 C81 20LB/WT REAR WINDOW DEFOGGER SWITCH SENSE
15 - -
16 - -
8W - 80 - 10 8W-80 CONNECTOR PIN-OUT WJ

AUTOMATIC ZONE CONTROL MODULE C2 (AZC) - WHITE 12 WAY

CAV CIRCUIT FUNCTION
1 - -
2 C94 20WT/DG PASSENGER BLEND DOOR DRIVER (A)
3 C95 20WT/BK DRIVER BLEND DOOR DRIVER (B)
4 C96 20WT/DB PASSENGER BLEND DOOR DRIVER (B)
5 - -
6 E2 20OR PANEL LAMPS DRIVER
7 C56 20RD/LG BLOWER MOTOR CONTROL
8 D25 20YL/VT/DG PCI BUS
9 C103 20DG A/C SWITCH SIGNAL
10 - -
11 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
12 M1 20PK FUSED B(+)

BATTERY TEMPERATURE SENSOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K4 18BK/LB (GAS LHD) SENSOR GROUND
1 K4 20BK/LB (DIESEL/RHD) SENSOR GROUND
2 K25 18VT/LG BATTERY TEMPERATURE SENSOR SIGNAL

BLOWER MOTOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 C1 12DG BLOWER MOTOR SUPPLY
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER

BLOWER MOTOR CONTROLLER (AZC) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
A Z118 12BK GROUND
B C56 20RD/LG BLOWER MOTOR CONTROL
C C1 12DG BLOWER MOTOR SUPPLY

BLOWER MOTOR RESISTOR BLOCK (MTC) - BLACK 4 WAY

CAV CIRCUIT FUNCTION
H C7 12BK/TN BLOWER MOTOR HIGH DRIVER
L C4 16TN BLOWER MOTOR LOW DRIVER
M1 C5 16LG BLOWER MOTOR M1 DRIVER
M2 C6 14LB BLOWER MOTOR M2 DRIVER
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 11

BODY CONTROL MODULE C1 - GRAY 26 WAY

CAV CIRCUIT FUNCTION
1 Z132 20BK/OR GROUND
2 G52 20YL HEADLAMP SWITCH MUX
3 E19 20RD PANEL LAMPS DIMMER SIGNAL
4 - -
5 G70 20BR/TN (BUILT-UP-EXPORT LHD HOOD AJAR SWITCH SENSE
RHD)
6 G26 20LB KEY-IN IGNITION SWITCH SENSE
7 G76 18TN/YL RIGHT REAR DOOR AJAR SWITCH SENSE
8 E2 20OR PANEL LAMPS DRIVER
9 E2 20OR PANEL LAMPS DRIVER
10 E2 20OR PANEL LAMPS DRIVER
11 - -
12 E2 20OR PANEL LAMPS DRIVER
13 E2 20OR PANEL LAMPS DRIVER
14 Z132 20BK/OR GROUND
15 D25 20YL/VT/WT PCI BUS
16 L80 20WT/DG HEADLAMP SWITCH RETURN
17 D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE
18 - -
19 - -
20 G69 20BK/OR VTSS INDICATOR DRIVER
21 - -
22 V14 20RD/VT WIPER ON/OFF RELAY CONTROL
23 M20 20BR/OR COURTESY LAMP LOAD SHED
24 M2 20YL COURTESY LAMP DRIVER
25 Z234 20BK GROUND
26 - -

BODY CONTROL MODULE C2 - GRAY 22 WAY

CAV CIRCUIT FUNCTION
1 C103 20DG A/C SWITCH SIGNAL
2 V10 20BR WASHER PUMP SWITCH SENSE
3 V48 20RD/GY WIPER HIGH CONTROL
4 L40 20BR HIGH BEAM SWITCH SENSE
5 V11 20BK/TN WASHER FLUID SWITCH SENSE
6 P134 20TN/LG PASSENGER SEAT HEATER SWITCH MUX
7 P133 20TN/DG DRIVER SEAT HEATER SWITCH MUX
8 X20 20RD/YL RADIO CONTROL MUX
9 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
10 L109 20WT ULTRALIGHT SENSOR SIGNAL
11 V52 20DG/RD WINDSHIELD WIPER SWITCH MUX
12 C81 20LB/WT REAR WINDOW DEFOGGER SWITCH SENSE
13 - -
14 - -
15 L27 20WT/TN FOG LAMP SWITCH SENSE
16 C201 20LB/YL EVAPORATOR TEMPERATURE SENSOR SIGNAL
17 G18 20PK/BK COOLANT LEVEL SWITCH SENSE
18 P132 20OR/BK SEAT HEATER SWITCH SENSOR GROUND
19 X10 20RD/BK RADIO CONTROL MUX RETURN
20 G32 20BK/LB SENSOR GROUND
21 L110 20BK/YL ULTRALIGHT SENSOR RETURN
22 V9 20WT/BK WINDSHIELD WIPER SWITCH RETURN
8W - 80 - 12 8W-80 CONNECTOR PIN-OUT WJ

BOOST PRESSURE SENSOR (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 Y53 20BK/YL BOOST PRESSURE SENSOR SIGNAL
3 K6 20VT/WT SENSOR REFERENCE VOLTAGE B

BRAKE LAMP SWITCH - GRAY 6 WAY

CAV CIRCUIT FUNCTION
1 K29 18WT/PK SECONDARY BRAKE SWITCH SIGNAL
2 Z238 18BK (LHD) GROUND
2 Z243 18BK (RHD) GROUND
3 V32 22OR/DG (GAS) SPEED CONTROL POWER SUPPLY
4 V30 22DB/RD (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT
5 L50 20VT/TN (LHD) PRIMARY BRAKE SWITCH SIGNAL
5 L50 20WT/TN (RHD) PRIMARY BRAKE SWITCH SIGNAL
6 F32 20PK/DB FUSED B(+)

C100 - BLACK (RIGHT HEADLAMP AND DASH

SIDE)
CAV CIRCUIT
1 T40 12LG
2 K125 18WT/DB
3 K20 18DG

C100 - BLACK (BATTERY SIDE)

CAV CIRCUIT
1 T40 12LG
2 K125 18WT/DB
3 K20 18DG

C101 (4.0L RHD) - LT. GRAY (ENGINE SIDE)

CAV CIRCUIT
1 B22 18DG/YL
2 K99 18BR/OR
3 K299 18BR/WT
4 K6 18VT/BK
5 C18 18DB
6 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 13

C101 (4.0L RHD) - LT. GRAY (HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
1 B22 18DG/YL
2 K99 18LB/OR
3 K299 18BR/WT
4 K6 18VT/BK
5 C18 18DB
6 -

C101 (4.7L RHD) - BLACK (ENGINE SIDE)

CAV CIRCUIT
1 K4 18BK/LB (HIGH OUTPUT)
2 K99 18BR/OR
3 C18 18DB
4 K299 18BR/WT
5 T6 18VT/WT
6 K6 18VT/BK
7 K4 18BK/LB (HIGH OUTPUT)
8 K142 18GY/BK (HIGH OUTPUT)
9 T10 18YL/DG
10 -
11 -
12 B22 18DG/YL
13 -
14 K42 18DB/LG (HIGH OUTPUT)

C101 (4.7L RHD) - BLACK (LEFT HEADLAMP

AND DASH SIDE)
CAV CIRCUIT
1 K4 18BK/LB
2 K99 18BR/OR
3 C18 18DB
4 K299 18BR/WT
5 T6 18OR/WT
6 K6 18VT/BK
7 K4 18BK/LB
8 K142 18GY/BK
9 T10 18YL/DG
10 -
11 -
12 B22 18DG/YL
13 -
14 K42 18DB/LG
8W - 80 - 14 8W-80 CONNECTOR PIN-OUT WJ

C102 (DIESEL) - BLACK (LEFT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
1 D21 18PK
2 D25 18VT/YL
3 K226 18DB/WT
4 D52 18LG/VT
5 D51 18DG/WT
6 B22 18DG/YL
7 F991 20OR/DB
8 T752 18DG/OR
9 K236 18GY/PK
10 K132 18BR/PK
11 A82 18PK/LG
12 K152 18WT
13 L50 18WT/TN
14 K29 18WT/PK

C102 (DIESEL) - BLACK (ENGINE SIDE)

CAV CIRCUIT
1 D21 20PK
2 D25 20VT/YL
3 K226 20DB/WT
4 D52 16DG/WT
5 D51 16WT
6 B22 20DG/YL
7 F991 20RD/DB
8 T752 20DG/RD
9 K236 20GY/PK
10 K132 20BR/PK
11 A82 16PK/DG
12 K152 20WT
13 L50 20WT/DB
14 K29 20WT/PK

C102 (GAS RHD) - BLACK (RIGHT HEADLAMP

AND DASH SIDE)
CAV CIRCUIT
1 A30 14RD/WT (4.7L)
2 F991 20OR/DB
3 K173 18LG
4 F42 18DG/LG
5 A7 14RD/BK
6 L1 18VT/BK
7 Z306 20BK/LG
8 T41 18BK/WT
9 -
10 K4 20BK/LB
11 K200 18VT/OR (4.7L)
12 C2 18DB/YL
13 -
14 A142 14DG/OR
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 15

C102 (GAS RHD) - BLACK (ENGINE SIDE)

CAV CIRCUIT
1 A30 14RD/WT (4.7L)
2 F991 18OR/DB
3 K173 18LG
4 F42 18DG/LG
5 A7 14RD/BK
6 L1 18VT/BK
7 Z306 20BK/LG
8 T41 18BK/WT
9 -
10 K4 18BK/LB
11 K200 18VT/OR (4.7L)
12 C2 18DB/YL
13 -
14 A142 14DG/OR

C103 (DIESEL) - GRAY (LEFT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
1 T41 18BK/WT
2 K173 18LG
3 C2 18DB/PK
4 -
5 F142 14OR/DG
6 K51 18DB/YL
7 K25 18VT/LG
8 Y42 18OR/DB
9 C18 18DB
10 K4 20BK/LB
11 K6 18VT/WT
12 -
13 T40 12BR
14 F15 18DB/WT

C103 (DIESEL) - GRAY (ENGINE SIDE)

CAV CIRCUIT
1 T41 20BK/WT
2 K173 20GY
3 C3 14DB/BK
4 -
5 F142 16RD/DG
6 K51 20DB/YL
7 K25 20VT/DG
8 Y42 20RD/DB
9 C18 20DB
10 K4 16BK/LB
11 K6 16VT/WT
12 -
13 T40 12DG
14 F15 20DB/WT
8W - 80 - 16 8W-80 CONNECTOR PIN-OUT WJ

C103 (GAS) - GRAY (RIGHT HEADLAMP AND DASH SIDE)

CAV CIRCUIT
1 F22 20WT/PK (EXCEPT 4.7L RHD)
1 F22 18WT/TN (4.7L RHD)
2 T6 18OR/WT (4.7L LHD)
2 C18 20DB (4.0L LHD BUILT-UP-EXPORT)
2 C18 18DB (4.0L EXCEPT BUILT-UP-EXPORT)
3 D20 20LG (4.7L LHD)
3 D20 18LG (4.7L RHD)
4 D21 20PK (4.7L LHD)
4 K299 18BR/WT (4.0L LHD)
4 D21 18PK (4.7L RHD)
5 B22 18DG/YL (LHD)
6 K20 18DG
7 K30 20PK (4.0L RHD)
7 K30 18PK/YL (4.7L RHD)
7 K30 20PK/YL (LHD)
8 A142 14DG/OR (4.0L LHD)
8 T10 18DG/LG (4.7L LHD)
9 T16 14RD (4.7L LHD)
10 D25 18VT/YL (4.7L RHD)
10 D25 18VT/YL (4.7L EXCEPT BUILT-UP-EXPORT)
10 D25 20VT/YL (4.7L LHD BUILT-UP-EXPORT)
11 Z305 20BK/OR
12 F45 18YL/RD (4.7L RHD)
12 T15 18YL/BR (4.0L)
12 F45 18YL/RD (4.7L EXCEPT BUILT-UP-EXPORT)
12 F45 20YL/RD (4.7L LHD BUILT-UP-EXPORT)
13 K6 18VT/BK (4.0L LHD)
14 F142 18OR/DG

C103 (GAS) - GRAY (ENGINE SIDE)

CAV CIRCUIT
1 F22 18WT/PK
2 C18 18DB (4.0L LHD)
2 K200 18VT/OR (4.7L RHD)
3 K99 18BR/OR (4.0L LHD)
3 D20 18LG (4.7L RHD)
4 K299 18BR/WT (4.0L BUILT-UP-EXPORT)
4 D21 18PK (4.7L RHD)
5 B22 18DG/YL (4.0L LHD)
6 K20 18DG
7 K30 18PK/YL
8 A142 14DG/OR (4.0L LHD)
9 T16 14RD (4.7L)
10 D25 18WT/VT (4.7L)
11 Z305 20BK/OR
12 T15 18LG (4.0L LHD)
12 F45 18YL/RD (4.7L)
13 K6 18VT/BK (4.0L LHD)
13 K199 18DB/WT (4.7L LHD)
14 F142 18OR/DG
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 17

C104 - LT. GRAY (RIGHT HEADLAMP AND DASH SIDE)

CAV CIRCUIT
1 K200 18VT/OR (4.0L EXCEPT BUILT-UP-EXPORT)
1 K4 18BK/LB (4.7L HIGH OUTPUT)
2 K99 18BR/OR (4.7L)
2 F991 20OR/DB (4.0L)
3 K173 18LG (4.0L)
4 F42 18DG/LG (4.0L)
5 A7 14RD/BK (4.0L)
5 K4 18BK/LB (4.7L HIGH OUTPUT)
6 L1 18VT/BK (4.0L)
6 K142 18GY/BK (4.7L HIGH OUTPUT)
7 Z306 20BK/LG (4.0L)
7 K299 18BR/WT (4.7L)
8 C18 18DB (4.7L)
8 T41 18BK/WT (4.0L)
9 K6 18VT/BK (4.7L)
9 C2 18DB/YL (4.0L)
10 K4 18BK/LB (4.0L)
10 K42 18DB/LG (4.7L HIGH OUTPUT)

C104 - LT. GRAY (ENGINE SIDE)

CAV CIRCUIT
1 K200 18VT/OR (EXCEPT 4.0L BUILT-UP-EXPORT)
2 F991 18OR/DB
3 K173 18LG
4 F42 18DG/LG
5 A7 14RD/BK
6 L1 18VT/BK
7 Z306 20BK/LG
8 T41 18BK/WT
9 C2 18DB/YL
10 K4 18BK/LB

C105 (DIESEL) - GRAY (LEFT HEADLAMP AND DASH SIDE)

CAV CIRCUIT
1 C13 18DB/OR
2 F300 18RD/BK
3 V37 18RD/LG
4 Z305 20BK/OR
5 Z306 20BK/LG
6 L1 18VT/BK
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
8W - 80 - 18 8W-80 CONNECTOR PIN-OUT WJ

C105 (DIESEL) - GRAY (ENGINE SIDE)

CAV CIRCUIT
1 C13 20DB/RD
2 F300 20RD/BK
3 V37 20RD/DG
4 Z305 18BK/DB
5 Z306 18BK/DB
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -

C106 (DIESEL) - GRAY (BODY SIDE)

CAV CIRCUIT
A B10 14BR/WT (LHD)
B -
C -
D -
E -
F -
G -
H -
J -
K -
L -
M B29 14DG/OR
1 F15 20DB/WT
2 -
3 G31 20VT/LG
4 G32 20DB/OR (RHD)
4 G32 20BK/LB (LHD)
5 G18 20PK/BK
6 -
7 -
8 F12 20DB/WT (LHD)
9 -
10 Z231 18BK (RHD)
11 K4 20BK/LB (LHD)
11 G9 18GY/BK (RHD)
12 K6 18VT/WT (LHD)
13 -
14 -
15 -
16 K173 18LG
17 -
18 X2 18DG/RD
19 C18 18DB (LHD)
20 Y42 18OR/DB
21 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 19

C106 (DIESEL) - GRAY (BODY SIDE)

CAV CIRCUIT
22 -
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 -
28 -
29 -
30 -
31 -
32 -
33 -
34 -
35 -
36 -
37 -
38 L13 18BR/YL (BUILT-UP-EXPORT)
39 -
40 -
41 -
42 R46 20BR/LB
43 R48 20TN
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 L7 20BK/YL
54 L60 20TN
55 -
56 -
57 L39 20LB
58 -
59 L44 18VT/RD
60 L34 18RD/OR
8W - 80 - 20 8W-80 CONNECTOR PIN-OUT WJ

C106 (DIESEL) - GRAY (RIGHT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
A -
B -
C -
D -
E -
F -
G -
H -
J -
K -
L -
M -
1 F15 18DB/WT
2 -
3 G31 20VT/LG
4 G32 20BK/LB
5 G18 20PK/BK
6 -
7 -
8 -
9 -
10 Z231 18BK (RHD)
11 K4 18BK/LB (LHD)
11 G9 18GY/BK (RHD)
12 K6 18VT/WT (LHD)
13 -
14 -
15 -
16 K173 18LG
17 -
18 X2 18DG/RD
19 C18 18DB (LHD)
20 Y42 18OR/DB
21 -
22 -
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 -
28 -
29 -
30 -
31 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 21

C106 (DIESEL) - GRAY (RIGHT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
32 -
33 -
34 -
35 -
36 -
37 -
38 L13 18BR/YL
39 -
40 -
41 -
42 R46 18BR/LB
43 R47 18TN
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 L7 20BK/YL
54 L60 20TN
55 -
56 -
57 L39 20LB
58 -
59 L44 18VT/RD
60 L34 18RD/OR
8W - 80 - 22 8W-80 CONNECTOR PIN-OUT WJ

C106 (GAS) - GRAY/RHD BLACK/LHD (BODY SIDE)

CAV CIRCUIT
A A149 12RD/TN
B A148 16LG/RD
C C1 12DG
D -
E A10 12RD/DG (LHD)
E A10 10RD/DG (RHD)
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
K A148 10PK/WT
L A2 12PK/BK
M A20 14RD/DB
1 A141 16DG/BK
2 G18 20PK/BK (LHD)
2 F42 18DG/LG (RHD)
3 V3 16BR/WT
4 V4 16RD/YL
5 V55 16TN/RD
6 V6 16DB
7 F22 18WT/TN (RHD)
7 F22 20WT/PK (LHD)
8 F12 20DB/WT
9 K52 20PK/BK (LHD)
10 K29 20WT/PK (LHD)
10 Z231 18BK (RHD)
11 K512 18LB (RHD)
11 K226 20LB/YL (LHD)
12 K107 20OR/YL (LHD)
13 K251 18LB (RHD)
13 K106 20WT/DG (LHD)
14 T41 18BK/WT (LHD)
14 C13 20DB/OR (RHD)
15 V35 20LG/RD (RHD)
16 V36 20TN/RD (RHD)
17 G9 18GY/BK (RHD)
18 K25 18VT/LG (RHD)
19 K51 20DB/YL (RHD)
20 K125 18WT/DB (LHD)
21 K125 18WT/DB (RHD)
22 K31 18BR (RHD)
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 X3 22GY/OR (LHD)
27 X3 22BK/RD (RHD)
28 G32 20BK/LB (LHD)
28 G32 20DB/OR (RHD)
29 -
30 G31 20VT/LG
31 -
32 V32 22OR/DG (LHD)
33 V30 22DB/RD
34 V16 22VT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 23

C106 (GAS) - GRAY/RHD BLACK/LHD (BODY SIDE)

CAV CIRCUIT
35 V14 22RD/VT
36 -
37 F45 20YL/RD
38 L13 18BR/YL (BUILT-UP-EXPORT)
39 -
40 Z306 20BK/LG
41 Z305 20BK/OR
42 R46 20BR/LB
43 R48 20TN
44 F991 20OR/DB
45 B22 18DG/YL (LHD)
46 -
47 -
48 D25 18YL/VT
49 D21 20PK
50 D20 20LG
51 D32 20LG/DG (LHD)
52 T41 18BK/WT (RHD)
52 T6 18OR/BK (LHD)
53 L7 20BK/YL
54 L60 20TN
55 G18 20PK/BK (RHD)
55 V37 22RD/LG (LHD)
56 L1 18VT/BK
57 L39 20LB
58 K4 18BK/LB (LHD)
58 K4 20BK/LB (RHD)
59 L44 18VT/RD
60 L34 18RD/OR
8W - 80 - 24 8W-80 CONNECTOR PIN-OUT WJ

C106 (GAS) - GRAY/RHD BLACK/LHD (RIGHT

HEADLAMP AND DASH SIDE)
CAV CIRCUIT
A A149 12RD/TN
B A148 16LG/RD
C C1 12DG
D -
E A10 12RD/DG
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
L A2 12PK/BK
K A148 10PK/WT
M A20 12RD/DB
1 A141 16DG/BK (RHD)
1 A141 16DG/WT (LHD)
2 F42 18DG/LG (RHD)
2 G18 18PK/BK (LHD)
3 V3 16BR/WT
4 V4 16RD/YL
5 V55 16TN/RD
6 V6 16DB
7 F22 18WT/TN (4.7L RHD)
7 F22 20WT/PK (EXCEPT 4.7L RHD)
8 F12 18DB/WT
9 K52 18PK/BK (LHD)
10 K29 18WT/PK (LHD)
10 Z231 18BK (RHD)
11 K226 18LB/YL (LHD)
11 K512 18RD/YL (4.7L RHD)
12 K107 18OR/PK (EXCEPT
BUILT-UP-EXPORT)
13 K106 18WT/DG (EXCEPT
BUILT-UP-EXPORT)
14 C13 18DB/OR (RHD)
14 T41 18BK/WT (LHD)
15 V35 20LG/RD (RHD)
16 V36 20TN/RD (RHD)
17 G9 18GY/BK (RHD)
18 K25 18VT/LG (RHD)
19 K51 18DB/YL (RHD)
20 K125 18WT/DB (EXCEPT
BUILT-UP-EXPORT)
21 K125 18WT/DB (RHD)
22 K31 18BR (RHD)
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 X3 20BK/RD
28 G32 20BK/LB
29 -
30 G31 20VT/LG
31 -
32 V32 18OR/DG (LHD)
33 V30 20DB/RD
34 V16 20VT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 25

C106 (GAS) - GRAY/RHD BLACK/LHD (RIGHT

HEADLAMP AND DASH SIDE)
CAV CIRCUIT
35 V14 20RD/VT
36 -
37 F45 18YL/RD (LHD/4.7L RHD)
37 F45 20YL/RD (RHD)
38 L13 18BR/YL (BUILT-UP-EXPORT)
39 -
40 Z306 20BK/LG
41 Z305 20BK/OR
42 R46 18BR/LB
43 R48 18TN
44 F991 20OR/DB
45 B22 18DG/YL (LHD)
46 -
47 -
48 D25 18VT/YL (LHD/4.7L RHD)
49 D21 18PK (4.0L LHD/4.7L RHD)
49 D21 20PK (4.7L LHD)
50 D20 20LG (4.7L LHD)
50 D20 18LG (4.7L RHD)
51 D32 18LG (EXCEPT BUILT-UP-EXPORT)
51 D32 18LG/DG (LHD BUILT-UP-EXPORT)
52 T41 18BK/WT (RHD)
52 T6 18OR/WT (LHD)
53 L7 20BK/YL
54 L60 20TN
55 G18 20PK/BK (RHD)
55 V37 18RD/LG (LHD)
56 L1 18VT/BK
57 L39 20LB
58 K4 18BK/LB (LHD)
58 K4 20BK/LB (RHD)
59 L44 18VT/RD
60 L34 18RD/OR
8W - 80 - 26 8W-80 CONNECTOR PIN-OUT WJ

C107 (DIESEL) - GRAY (BODY SIDE)

CAV CIRCUIT
A B10 14BR/WT
B A148 16LG/RD
C C1 12DG
D A149 12RD/TN
E -
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
K A148 10PK/WT
L A2 12PK/BK
M B29 14DG/OR
1 X2 18DG/RD
2 V11 20BK/TN
3 K4 20BK/LB
4 V37 22RD/LG (LHD)
4 V37 20RD/LG (RHD)
5 V55 16TN/RD
6 V6 16DB
7 V10 22BR (LHD)
7 V10 20BR (RHD)
8 -
9 K226 18LB/YL (LHD)
9 K226 20LB/YL (RHD)
10 X3 22GY/OR (LHD)
10 X3 22BK/RD (RHD)
11 F15 20DB/WT
12 F45 20YL/RD
13 T41 18BK/WT
14 -
15 G70 20BR/TN
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 -
20 -
21 F991 20OR/DB
22 -
23 X75 20GY/LG
24 Y42 18OR/DB
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 27

C107 (DIESEL) - GRAY (BODY SIDE)

CAV CIRCUIT
30 B1 18YL/DB
31 -
32 M1 20PK/RD
33 F20 18DB/PK
34 L50 18WT/TN (RHD)
34 L50 18VT/TN (LHD)
35 R47 20DB/LB
36 T2 18TN/BK
37 Z305 20BK/OR
38 Z306 20BK/LG
39 R49 20LB
40 K29 18WT/PK
41 C18 20DB (LHD)
42 -
43 K6 18VT/WT (LHD)
44 -
45 V16 22VT
46 V14 22RD/VT
47 L13 18BR/YL
48 D25 18YL/VT
49 D21 20PK
50 K173 18LG
51 -
52 -
53 L7 20BK/YL
54 L61 20TN/LG
55 L1 18VT/BK
56 V20 18BK/WT (LHD)
56 V20 20BK/WT (RHD)
57 L39 20LB
58 F22 20WT/PK (LHD)
58 F22 18WT/TN (RHD)
59 L43 18VT
60 L33 18RD
8W - 80 - 28 8W-80 CONNECTOR PIN-OUT WJ

C107 (DIESEL) - GRAY (LEFT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
A -
B A148 16LG/RD
C C1 12DG
D A149 12RD/TN
E -
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
K A148 10PK/WT
L A2 12PK/BK
M -
1 X2 18DG/RD
2 V11 20BK/TN
3 K4 18BK/LB
4 V37 18RD/LG
5 V55 16TN/RD
6 V6 16DB
7 V10 20BR
8 -
9 K226 18DB/WT
10 X3 20BK/RD
11 F15 18DB/WT
12 F45 18YL/RD
13 T41 18BK/WT
14 -
15 G70 20BR/TN
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 -
20 -
21 F991 20OR/DB
22 -
23 X75 18GY/LB
24 Y42 18OR/DB
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
30 B1 18YL/DB
31 -
32 M1 18PK
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 29

C107 (DIESEL) - GRAY (LEFT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
33 F20 18DB/PK
34 L50 18WT/TN
35 R47 18DB/LB
36 T2 18TN/BK
37 Z305 20BK/OR
38 Z306 20BK/LG
39 R49 18LB
40 K29 18WT/PK
41 C18 18DB (RHD)
42 -
43 K6 18VT/WT (RHD)
44 -
45 V16 20VT
46 V14 20RD/VT
47 L13 18BR/YL
48 D25 18VT/YL
49 D21 18PK
50 K173 18LG
51 -
52 -
53 L7 18BK/YL
54 L61 20LG
55 L1 18VT/BK
56 V20 18BK/WT
57 L39 20LB
58 F22 18WT/PK
59 L43 18VT
60 L33 18LG/BR
8W - 80 - 30 8W-80 CONNECTOR PIN-OUT WJ

C107 (GAS) - GRAY/RHD BLACK/LHD (BODY

SIDE)
CAV CIRCUIT
A -
B -
C -
D -
E A10 12RD/DG (LHD)
E A10 10RD/DG (RHD)
F -
G -
H -
J -
K -
L -
M A20 14RD/DB
1 V37 20RD/LG (RHD)
2 V11 20BK/TN
3 V3 16BR/WT (GAS)
4 V4 16RD/YL (GAS)
5 V55 16TN/RD
6 V6 16DB
7 V10 20BR (RHD)
7 V10 22BR (LHD)
8 F12 20DB/WT
9 K226 20LB/YL (RHD)
9 K52 20PK/BK (LHD)
10 L13 18BR/YL (BUILT-UP-EXPORT)
11 K512 18LB
12 K4 20BK/LB
13 -
14 T6 18OR/BK (RHD)
15 G70 20BR/TN (BUILT-UP-EXPORT)
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 D32 20LG/DG (RHD)
20 -
21 -
22 -
23 X75 20GY/LG (BUILT-UP-EXPORT)
24 F42 18DG/LG (RHD)
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
30 B1 18YL/DB
31 -
32 M1 20PK/RD
33 F20 18DB/PK
34 L50 18VT/TN (LHD)
34 L50 18WT/TN (RHD)
35 R47 20DB/LB (LHD)
36 -
37 K51 20DB/YL (RHD)
38 K25 18VT/LG (RHD)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 31

C107 (GAS) - GRAY/RHD BLACK/LHD (BODY

SIDE)
CAV CIRCUIT
39 K31 18BR (RHD)
39 R49 20DB (LHD)
40 K29 18WT/PK (RHD)
41 K125 18WT/DB (RHD)
42 V32 22OR/DG (RHD)
43 R47 20DB/LB (RHD)
44 V35 20LG/RD (RHD)
45 B22 18DG/YL (LHD)
45 V36 20TN/RD (RHD)
46 C13 20DB/OR (RHD)
47 L13 18BR/YL (RHD)
48 D25 18YL/VT
49 D21 20PK (RHD)
50 R49 20LB (RHD)
51 -
52 -
53 L7 20BK/YL
54 L61 20TN/LG
55 -
56 V20 18BK/WT (LHD)
56 V20 20BK/WT (RHD)
57 L39 20LB
58 -
59 L43 18VT
60 L33 18RD
8W - 80 - 32 8W-80 CONNECTOR PIN-OUT WJ

C107 (GAS) - GRAY/RHD BLACK/LHD (LEFT

HEADLAMP AND DASH SIDE)
CAV CIRCUIT
A -
B -
C -
D -
E A10 12RD/DG
F -
G -
H -
J -
K -
L -
M A20 12RD/DB
1 V37 18RD/LG (RHD)
2 V11 20BK/TN
3 V3 16BR/WT
4 V4 16RD/YL
5 V55 16TN/RD
6 V6 16DB
7 V10 20BR
8 F12 20DB/WT
9 K52 20PK/BK (LHD)
9 K226 18LB/YL (RHD)
10 -
11 K512 18RD/YL (4.7L RHD)
12 K4 18BK/LB (RHD)
13 -
14 T6 18OR/BK (4.0L RHD)
14 T6 18OR/WT (4.7L RHD)
15 G70 20BR/TN (RHD)
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 D32 18LG/DG (RHD)
20 -
21 -
22 -
23 X75 18GY/LG (RHD)
24 F42 18DG/LG (RHD)
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
30 B1 18YL/DB
31 -
32 M1 20PK/RD (LHD)
32 M1 18PK (RHD)
33 F20 18DB/PK
34 L50 18WT/TN
35 R47 18DB/LB (LHD)
36 -
37 K51 18DB/YL (RHD)
38 K25 18VT/LG (RHD)
39 R49 18LB (LHD)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 33

C107 (GAS) - GRAY/RHD BLACK/LHD (LEFT

HEADLAMP AND DASH SIDE)
CAV CIRCUIT
39 K31 18BR (RHD)
40 K29 18WT/PK (RHD)
41 K125 18WT/DB (RHD)
42 V32 18OR/DG (RHD)
43 R47 18DB/LB (RHD)
44 V35 18LG/RD (RHD)
45 B22 18DG/YL (LHD)
45 V36 18TN/RD (RHD)
46 C13 18DB/OR (RHD)
47 L13 18BR/YL (RHD)
48 D25 18VT/YL
49 D21 18PK (RHD)
50 R49 18LB (RHD)
51 -
52 -
53 L7 20BK/YL
54 L61 20TN/LG
55 -
56 V20 18BK/WT
57 L39 20LB
58 -
59 L43 18VT
60 L33 18RD

C108 - BLACK (LEFT HEADLAMP AND DASH

SIDE)
CAV CIRCUIT
1 M1 20PK (BUILT-UP-EXPORT)
1 M1 20PK/RD (EXCEPT
BUILT-UP-EXPORT)
2 Z141 20BK

C108 - BLACK (UNDERHOOD LAMP SIDE)

CAV CIRCUIT
1 M1 20PK/RD
2 Z141 20BK

C109 - BLACK (ENGINE SIDE)

CAV CIRCUIT
1 K77 18LG/BK
2 K4 18BK/LB
8W - 80 - 34 8W-80 CONNECTOR PIN-OUT WJ

C109 - BLACK (TRANSFER CASE JUMPER SIDE)

CAV CIRCUIT
1 K77 18LG/BK
2 K4 18BK/LB

C110 (DIESEL) - GRAY (LEFT HEADLAMP AND

DASH SIDE)
CAV CIRCUIT
1 K154 10GY
2 K254 10GY/YL

C110 (DIESEL) - GRAY (GLOW PLUG SIDE)

CAV CIRCUIT
1 K154 10GY
2 K254 10GY/YL

C111 - BLACK (LEFT FRONT LIGHTING MODULE

SIDE)
CAV CIRCUIT
1 L33 18RD
2 L43 18VT
3 L61 20TN/LG
4 L7 20BK/YL
5 L114 18BR/YL (BUILT-UP-EXPORT)
6 Z141 18BK

C111 - BLACK (LEFT HEADLAMP AND DASH

SIDE)
CAV CIRCUIT
1 L33 18LG/BR (DIESEL)
1 L33 18RD (GAS)
2 L43 18VT
3 L61 20LG (DIESEL)
3 L61 20TN/LG (GAS)
4 L7 18BK/YL (DIESEL)
4 L7 20BK/YL (GAS)
5 L13 18BR/YL (BUILT-UP-EXPORT)
6 Z141 18BK
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 35

C112 - BLACK (RIGHT HEADLAMP AND DASH

SIDE)
CAV CIRCUIT
1 L34 18RD/OR
2 L44 18VT/RD
3 L60 20TN
4 L7 20BK/YL
5 L13 18BR/YL (BUILT-UP-EXPORT)
6 Z142 18BK

C112 - BLACK (RIGHT FRONT LIGHTING

MODULE SIDE)
CAV CIRCUIT
1 L34 18RD/OR
2 L44 18VT/RD
3 L60 20TN
4 L7 20BK/YL
5 L13 18BR/YL (BUILT-UP-EXPORT)
6 Z142 18BK

C113 (DIESEL) - LT. GRAY (ENGINE SIDE)

CAV CIRCUIT
1 D51 16WT
2 D52 16DG/WT

C113 (DIESEL) - LT. GRAY (TRANSMISSION

SIDE)
CAV CIRCUIT
1 D52 18LG/WT
2 D51 18DG/WT
8W - 80 - 36 8W-80 CONNECTOR PIN-OUT WJ

C200 - GRAY/LHD BLACK/RHD (LEFT BODY

SIDE)
CAV CIRCUIT
A -
B -
C A1 12RD
D -
E -
F -
G A2 12PK/BK
H C1 12DG
J -
K -
M -
L -
1 X56 18DB/PK (BASE)
1 X84 18OR/GY (EXCEPT BASE)
2 X86 18OR/RD (EXCEPT BASE)
2 X54 18VT (BASE)
3 X81 18YL/BK (EXCEPT BASE)
3 X55 18BR/RD (BASE)
4 X53 18DG/OR (BASE)
4 X83 18YL/RD (EXCEPT BASE)
5 X53 18DG/OR
6 X55 18BR/RD
7 X54 18VT
8 X56 18DB/PK
9 Y152 20LG/OR (EXCEPT
BUILT-UP-EXPORT)
10 D20 20LG (GAS)
11 Y151 20LG/BR (EXCEPT
BUILT-UP-EXPORT)
12 Y153 20DB/RD (EXCEPT
BUILT-UP-EXPORT)
13 X40 20RD/WT (CD)
14 D25 20YL/VT
15 D25 20YL/VT
16 D32 20LG/DG (GAS)
17 T41 18BK/WT
18 Z4 20WT/BK (CD)
19 X41 20WT/DG (CD)
20 T6 18OR/BK (GAS)
21 D21 20PK (GAS)
22 K29 18WT/PK
23 X160 20YL (CD)
24 X112 20RD (CD)
25 -
26 -
27 G70 20BR/TN (BUILT-UP-EXPORT)
28 R47 20DB/LB
29 Z17 20BK (CD)
30 R49 20LB
31 G76 20TN/YL (RHD)
31 G76 18TN/YL (LHD)
32 T2 18TN/BK (DIESEL)
33 -
34 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 37

C200 - GRAY/LHD BLACK/RHD (LEFT BODY

SIDE)
CAV CIRCUIT
35 X51 18WT/DG
36 X57 18DG/WT
37 L7 18BK/YL (BUILT-UP-EXPORT)
38 L13 18BR/YL (BUILT-UP-EXPORT)
39 V10 22BR (LHD)
39 V10 20BR (RHD)
40 X52 18DB/WT
41 X58 18DB/OR
42 -
43 V13 18BR/LG
44 V14 22RD/VT
45 -
46 V20 20BK/WT (RHD)
46 V20 18BK/WT (LHD)
47 V22 18BR/YL
48 R46 20BR/LB (RHD)
48 R46 18BK/LB (LHD)
49 X64 18BR/WT
50 Z305 20BK/OR
51 Z306 20BK/LG
52 R48 20TN
53 G32 20BK/LG (LHD)
53 G32 20DB/OR (RHD)
54 G31 20VT/LG
55 Z9 16BK
56 V11 20BK/TN
57 G18 20PK/BK
58 V37 22RD/LG (LHD)
58 V37 20RD/LG (RHD)
59 K4 20BK/LB
60 -
8W - 80 - 38 8W-80 CONNECTOR PIN-OUT WJ

C200 - GRAY/LHD BLACK/RHD (INSTRUMENT

PANEL SIDE)
CAV CIRCUIT
A -
B -
C A1 12RD
D -
E -
F -
G A2 12PK/BK
H C1 12DG
J -
K -
L -
M -
1 X84 18OR/BK
2 X86 18OR/RD
3 X81 18YL/BK
4 X83 18YL/RD
5 X53 18DG/OR
6 X55 18BR/RD
7 X54 18VT
8 X56 18DB/PK
9 Y152 20LG/BR (EXCEPT
BUILT-UP-EXPORT)
10 D20 20LG
11 Y151 20LG/BR (EXCEPT
BUILT-UP-EXPORT)
12 Y153 20DB/RD (EXCEPT
BUILT-UP-EXPORT)
13 X40 20WT/RD
14 D25 20YL/VT/GY
15 D25 20YL/VT/BR
16 D32 20LG/DG
17 T41 18BK/WT (DIESEL)
18 Z4 20WT/BK
19 X41 20WT/DG
20 T6 18OR/WT (GAS)
21 D21 20PK
22 K29 18WT/PK
23 X160 20YL
24 X112 20RD
25 -
26 -
27 G70 20BR/TN (BUILT-UP-EXPORT)
28 R47 20DB/LB
29 Z17 20BK
30 R49 20LB
31 G76 18TN/YL
32 T2 20TN/BK (DIESEL)
33 -
34 -
35 X51 18WT/DG
36 X57 18DG/WT
37 L7 18BK/YL (BUILT-UP-EXPORT)
38 L13 20BR/YL (BUILT-UP-EXPORT)
39 V10 20BR
40 X52 18DB/WT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 39

C200 - GRAY/LHD BLACK/RHD (INSTRUMENT

PANEL SIDE)
CAV CIRCUIT
41 X58 18DB/OR
42 -
43 V13 18BR/LG
44 V14 20RD/VT
45 -
46 V20 18BK/WT
47 V22 18BR/YL
48 R46 20BR/LB
49 X64 18BR/WT
50 Z305 20BK/OR
51 Z306 20BK/LG
52 R48 20TN
53 G32 20BK/LB
54 G31 20VT/LG
55 Z9 16BK
56 V11 20BK/TN
57 G18 20PK/BK
58 V37 20RD/LG
59 K4 20BK/LB
60 -

C201 (DIESEL) - WHITE (INSTRUMENT PANEL

SIDE)
CAV CIRCUIT
1 -
2 Z300 18BK
3 E2 20OR
4 K29 18WT/PK
5 D25 20YL/VT
6 D19 20VT/OR
7 D21 20PK
8 F12 20DB/WT
9 T2 20TN/BK
10 Z234 18BK
11 T41 18BK/WT
12 F991 18OR/DB

C201 (DIESEL) - WHITE (SHIFTER ASSEMBLY SIDE)

CAV CIRCUIT
1 -
2 -
3 -
4 K2 20WT/PK
5 D25 20RD
6 -
7 D21 20PK
8 F12 20DB/WT
9 T2 20TN/BK
10 Z234 20WT
11 T41 20BK/WT
12 F991 20OR/DB
8W - 80 - 40 8W-80 CONNECTOR PIN-OUT WJ

C202 (AZC) - WHITE (INSTRUMENT PANEL SIDE)

CAV CIRCUIT
1 C100 20YL/DB (RHD)
1 C32 20GY/DB (LHD)
2 C100 20YL/DB (LHD)
2 C32 20GY/DB (RHD)
3 C96 20WT/DB (RHD)
3 C33 20DB/RD (LHD)
4 C94 20WT/DG (RHD)
4 C95 20WT/BK (LHD)
5 C95 20WT/BK (RHD)
5 C94 20WT/DG (LHD)
6 C33 20DB/RD (RHD)
6 C96 20WT/DB (LHD)
7 C35 20DG/YL (RHD)
7 C102 20TN/BK (LHD)
8 C35 20DG/YL (LHD)
8 C102 20TN/BK (RHD)
9 C56 20RD/LG
10 -
11 C201 20LB/YL
12 G32 20BK/LB

C202 (AZC) - WHITE (A/C SIDE)

CAV CIRCUIT
1 C100 20YL/DB (RHD)
1 C32 20GY/DB (LHD)
2 C100 20YL/DB (LHD)
2 C32 20GY/DB (RHD)
3 C96 20WT/DB (RHD)
3 C33 20DB/RD (LHD)
4 C94 20WT/DG (RHD)
4 C95 20WT/BK (LHD)
5 C95 20WT/BK (RHD)
5 C94 20WT/DG (LHD)
6 C33 20DB/RD (RHD)
6 C96 20WT/DB (LHD)
7 C35 20DG/YL (RHD)
7 C102 20TN/BK (LHD)
8 C35 20DG/YL (LHD)
8 C102 20TN/BK (RHD)
9 C56 20RD/LG
10 -
11 C201 20LB/YL
12 G32 20BK/LB
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 41

C202 (MTC) - WHITE (INSTRUMENT PANEL SIDE)

CAV CIRCUIT
1 -
2 C201 20LB/YL
3 G32 20BK/LB
4 -
5 C67 20RD/LB
6 -
7 -
8 -
9 -
10 C6 14LB
11 Z132 20BK/OR
12 F22 20WT/PK
13 C7 12BK/TN
14 C1 12DG
15 C4 16TN
16 C5 16LG

C202 (MTC) - WHITE (A/C SIDE)

CAV CIRCUIT
1 -
2 C101 20LB/YL
3 G32 20BK/LB
4 -
5 C67 20RD/LB
6 -
7 -
8 -
9 -
10 C6 14LB
11 Z132 20BK/OR
12 F22 20WT/PK
13 C7 12BK/TN
14 C1 12DG
15 C4 16TN
16 C5 16LG

C203 (AZC) - WHITE (INSTRUMENT PANEL SIDE)

CAV CIRCUIT
1 Z118 12BK
2 C1 12DG

C203 (AZC) - WHITE (A/C SIDE)

CAV CIRCUIT
1 Z118 12BK
2 C1 12DG
8W - 80 - 42 8W-80 CONNECTOR PIN-OUT WJ

C300 (LHD) - GRAY (RIGHT BODY SIDE)

CAV CIRCUIT
A P130 16DG/WT (EXCEPT BASE)
B Q13 16DB
C B40 12LB
D F9 14RD/BK (EXCEPT
BUILT-UP-EXPORT)
E P144 16BK/LG (EXCEPT BASE)
F A141 16DG/BK (GAS)
G -
H -
J -
K -
L Q23 16RD/WT
M -
1 D25 20YL/VT
2 V13 18BR/LG
3 V22 18BR/YL
4 P112 20YL/WT
5 P114 20YL/RD
6 P35 18OR/VT
7 P36 18PK/VT
8 L50 18WT/TN
9 B1 18YL/DB
10 B2 18YL
11 B3 18LG/DB
12 B4 18LG
13 -
14 -
15 -
16 P29 20BR/WT (EXCEPT BASE)
17 P86 20PK/BK (EXCEPT BASE)
18 E21 20OR/RD
19 K4 20BK/LB
20 K226 18LB/YL (DIESEL)
20 K226 20LB/YL (GAS)
21 L62 18BR/RD
22 L95 18DG/YL (BUILT-UP-EXPORT)
23 -
24 L1 18VT/BK
25 -
26 -
27 -
28 -
29 -
30 -
31 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 43

C300 (LHD) - GRAY (RIGHT BODY SIDE)

CAV CIRCUIT
32 -
33 -
34 -
35 -
36 -
37 X75 20GY/LG (BUILT-UP-EXPORT)
38 -
39 -
40 -
41 K106 20WT/DG (EXCEPT
BUILT-UP-EXPORT)
42 K107 20OR/YL (EXCEPT
BUILT-UP-EXPORT)
43 K125 18WT/DB (EXCEPT
BUILT-UP-EXPORT)
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 X57 18DG/WT (BASE)
53 X91 18WT/DG (EXCEPT BASE)
54 X51 18WT/DG (BASE)
54 X93 18DG/WT (EXCEPT BASE)
55 -
56 -
57 Z155 18BK/OR
58 -
59 -
60 -
8W - 80 - 44 8W-80 CONNECTOR PIN-OUT WJ

C300 (LHD) - GRAY (LEFT BODY SIDE)

CAV CIRCUIT
A P130 16DG/WT (HEATED SEATS)
B Q13 16DB
C B40 14LB
D F9 14RD/BK (EXCEPT BASE))
E P144 16BK/VT (HEATED SEATS)
F A141 16DG/BK (EXCEPT DIESEL)
G -
H -
J -
K -
L Q23 16RD/WT
M -
1 D25 20YL/VT
2 V13 18BR/LG
3 V22 18BR/YL
4 P112 20YL/WT
5 P114 20YL/RD
6 P35 18OR/VT
7 P36 18PK/VT
8 L50 18WT/TN
9 B1 18YL/DB
10 B2 18YL
11 B3 18LG/DB
12 B4 18LG
13 -
14 -
15 -
16 P29 20BR/WT (HEATED SEATS)
17 P86 18PK/BK (HEATED SEATS)
18 E21 20OR/RD
19 K4 20BK/LB
20 K226 20LB/YL
21 L62 18BR/RD
22 L95 18DG/YL (BUILT-UP-EXPORT)
23 -
24 L1 18VT/BK
25 -
26 -
27 -
28 -
29 -
30 -
31 -
32 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 45

C300 (LHD) - GRAY (LEFT BODY SIDE)

CAV CIRCUIT
33 -
34 -
35 -
36 -
37 X75 20GY/LG (BUILT-UP-EXPORT)
38 -
39 -
40 -
41 K106 20WT/DG (EXCEPT
BUILT-UP-EXPORT)
42 K107 20OR/YL (EXCEPT
BUILT-UP-EXPORT)
43 K125 18OR/DG (EXCEPT
BUILT-UP-EXPORT)
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 X91 18WT/DG (PREMIUM)
53 X57 18WT/DG (BASE)
54 X51 18DG/WT (BASE)
54 X93 18DG/WT (PREMIUM)
55 -
56 -
57 Z155 18BK/OR (EXCEPT BASE)
58 -
59 -
60 -
8W - 80 - 46 8W-80 CONNECTOR PIN-OUT WJ

C301 (RHD) - BLACK (LEFT BODY SIDE)

CAV CIRCUIT
A Q13 16DB
B Q23 16RD/WT
C F9 14RD/BK
D F60 16RD/WT
E Z9 16BK
F Z5 16BK/VT
G C15 12BK/WT
H A148 16LG/RD
J -
K -
L Q30 16TN
M P130 16DG/WT
1 L50 18W/TTN
2 F70 18PK
3 M2 18YL
4 M20 18YL/BK
5 P35 18 OR/VT
6 P36 18PK/VT
7 F30 14RD/TN
8 L7 18BK/YL
9 L95 18DG/YL
10 L63 18DG/RD
11 G80 20VT/YL
12 X80 18LB/BK
13 X82 18LB/RD
14 X85 18LG/DG
15 X87 18LG/RD
16 X93 18DG/WT
17 X91 18WT/DG
18 X84 18OR/GY
19 L62 20BR/RD
20 X86 18OR/RD
21 X81 18YL/BK
22 X83 18YL/RD
23 X56 18DB/PK
24 X51 18WT/DG
25 X57 18DG/WT
26 X52 18DB/WT
27 X58 18DB/OR
28 X54 18VT
29 X55 18BR/RD
30 X53 18DG/OR
31 X64 18BR/WT
32 D25 20YL/VT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 47

C301 (RHD) - BLACK (LEFT BODY SIDE)

CAV CIRCUIT
33 -
34 G78 20TN/BK
35 -
36 -
37 E21 20OR/RD
38 G77 20TN/OR
39 G76 20TN/YL
40 L1 18VT/BK
41 G5 20DB/WT
42 P86 20PK/BK
43 P29 20BR/WT
44 G73 20LG/OR
45 C235 18WT/LB (CD)
46 X160 20YL (CD)
47 X40 20RD/WT (CD)
48 -
49 X112 20RD (CD)
50 X41 20RD/BK (CD)
51 Z4 20WT/BK (CD)
52 Z17 20BK (CD)
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -
8W - 80 - 48 8W-80 CONNECTOR PIN-OUT WJ

C301 (RHD) - BLACK (RIGHT BODY SIDE)

CAV CIRCUIT
A Q13 16DB
B Q23 16RD/WT
C F9 14RD/BK
D F60 16RD/WT
E Z9 16BK
F Z5 16BK/VT
G C15 12BK/WT
H A148 16LG/RD
J -
K -
L Q30 16TN
M P130 16DG/WT
1 L50 18WT/TN
2 F70 18PK
3 M2 18YL
4 M20 18YL/BK
5 P35 18OR/VT
6 P36 18PK/VT
7 F30 16RD/TN
8 L7 18BK/YL
9 L95 18DG/YL
10 L63 18DG/RD
11 G80 20VT/YL
12 X80 18LB/BK
13 X82 18LB/RD
14 X85 18LG/DG
15 X87 18LG/RD
16 X93 18DG/WT
17 X91 18WT/DG
18 X84 18OR/GY
19 L62 18BR/RD
20 X86 18OR/RD
21 X81 18YL/BK
22 X83 18YL/RD
23 X56 18DB/BK
24 X51 18WT/DG
25 X57 18DG/WT
26 X52 18DB/WT
27 X58 18DB/OR
28 X54 18VT
29 X55 18BR/RD
30 X53 18DG/OR
31 X64 18BR/WT
32 D25 20YL/VT
33 F22 20WT/PK
34 G78 20TN/BK
35 M1 18PK/RD
36 -
37 E21 20OR/RD
38 G77 20TN/OR
39 G76 20TN/YL
40 L1 18VT/BK
41 G5 20DB/WT
42 P86 20PK/BK
43 P29 20BR/WT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 49

C301 (RHD) - BLACK (RIGHT BODY SIDE)

CAV CIRCUIT
44 G73 20LG/OR
45 C235 20WT/LB (CD)
46 X160 20YL (CD)
47 X40 20WT/RD (CD)
48 -
49 X112 20RD (CD)
50 X41 20WT/DG (CD)
51 Z4 20WT/BK (CD)
52 Z17 20BK (CD)
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -

C302 - BLACK (BODY SIDE)

CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD
3 D25 20YL/VT
4 Z243 12BK (RHD)
4 Z28 12BK (LHD)
5 E21 20OR/RD
6 Q13 16DB
7 Q23 16RD/WT
8 A146 12OR/WT
9 X55 18BR/RD (LHD BASE)
9 X85 18LG/DG (LHD PREMIUM)
9 X80 18LB/BK (RHD PREMIUM)
10 X82 18LB/RD (RHD PREMIUM)
10 X53 18DG/OR (LHD BASE)
10 X87 18LG/RD (LHD PREMIUM)
11 M1 18PK/RD (JAPAN)
12 -
13 -
14 -
8W - 80 - 50 8W-80 CONNECTOR PIN-OUT WJ

C302 - BLACK (FRONT DRIVER DOOR SIDE)

CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD
3 D25 20YL/VT
4 Z1 12BK
5 E21 20OR/RD
6 Q13 16DB
7 Q23 16RD/WT
8 A146 12OR/WT
9 X85 18LG/DG (LHD PREMIUM)
9 X80 18LG/DG (RHD PREMIUM)
9 X55 18LG/DG (BASE)
10 X53 18LG/RD (BASE)
10 X82 18LG/RD (RHD PREMIUM)
10 X87 18LG/RD (LHD PREMIUM)
11 M1 18PK (JAPAN)
12 -
13 -
14 -

C303 - WHITE (RIGHT BODY SIDE)

CAV CIRCUIT
1 X58 18DB/OR (BASE AUDIO)
1 X92 18TN/DG (PREMIUM AUDIO)
2 X52 18DB/WT (BASE AUDIO)
2 X90 18WT/VT (PREMIUM AUDIO)
3 E21 20OR/DB (RHD)
3 E20 20OR/DB (LHD)
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q13 16DB (RHD)
8 Q14 16GY (LHD)
9 Q24 16DG (LHD)
9 Q23 16RD/WT (RHD)
10 Z151 16BK (RHD)
10 Z28 16BK (LHD)
11 G76 18TN/YL (LHD)
11 G76 20TN/YL (RHD)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 51

C303 - WHITE (REAR DOOR SIDE)

CAV CIRCUIT
1 X58 18TN/DG (BASE)
1 X55
1 X92 18TN/DG (PREMIUM)
2 X52 18WT/VT (BASE)
2 X90 18WT/VT (PREMIUM)
3 E21 20OR/RD
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q14 16GY
9 Q24 16DG
10 Z1 16BK
11 G76 18TN/YL

C304 - BLACK (BODY SIDE)

CAV CIRCUIT
1 P86 20PK/BK (RHD)
1 P86 18PK/BK (LHD)
2 P130 16DG/WT
3 D25 20YL/VT
4 F37 16RD/LB (RHD)
4 F37 16RD (LHD)
5 Z238 16BK (RHD)
5 Z243 16BK (LHD)
6 P29 20BR/WT
7 Z155 18BK/OR (RHD)
7 Z155 20BK/OR (LHD)
8 Z5 16BK/VT (RHD)
8 P144 16BK/VT (LHD)
9 -
10 -

C304 - BLACK (POWER SEAT SIDE)

CAV CIRCUIT
1 P86 20DG/YL (HEATED SEATS)
2 P130 16DG/WT (HEATED SEATS)
3 D25 20VT/YL (PREMIUM POWER
SEATS)
4 F35 16RD
5 Z1 16BK
6 P29 20BR/WT (HEATED SEATS)
7 Z2 20BK/OR (PREMIUM POWER SEATS)
8 Z5 16BK/VT (HEATED SEATS)
9 -
10 -
8W - 80 - 52 8W-80 CONNECTOR PIN-OUT WJ

C306 - BLACK (BODY SIDE)

CAV CIRCUIT
1 P130 16DG/WT
2 Z238 16BK
3 F37 16RD/LB
4 P86 20PK/BK
5 P29 20BR/WT
6 P144 16BK/LG

C306 - BLACK (POWER SEAT SIDE)

CAV CIRCUIT
1 P130 16DG/WT (HEATED SEATS)
2 Z1 16BK
3 F37 16RD/LB
4 P86 20DG/YL (HEATED SEATS)
5 P29 20BR/WT (HEATED SEATS)
6 Z5 16BK/VT (HEATED SEATS)

C307 - WHITE (BODY SIDE)

CAV CIRCUIT
1 X93 18DG/WT (RHD)
1 X91 18WT/DG (LHD)
2 X93 18DG/WT (LHD)
2 X91 18WT/DG (RHD)
3 E20 20OR/DB (RHD)
3 E21 20OR/RD (LHD)
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q13 16DB (LHD)
8 Q14 16GY (RHD)
9 Q24 16DG (RHD)
9 Q23 16RD/TN (LHD)
10 Z243 16BK
11 G77 20TN/OR

C307 - WHITE (REAR DOOR SIDE)

CAV CIRCUIT
1 X57 18TN/DG (BASE)
1 X93 18TN/DG (PREMIUM)
2 X51 18WT/VT (BASE)
2 X91 18WT/VT (PREMIUM)
3 E21 20OR/RD
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q14 16GY
9 Q24 16DG
10 Z1 16BK
11 G76 18TN/YL
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 53

C308 - WHITE (LEFT BODY SIDE)

CAV CIRCUIT
1 G78 20TN/BK
2 P35 18PK/VT (RHD)
2 P35 18OR/VT (LHD)
3 P36 18OR/VT (RHD)
3 P36 18PK/VT (LHD)
4 V13 18BR/LG
5 V22 18BR/YL
6 F70 18PK
7 L50 18WT/TN
8 Z309 12BK
9 G80 20VT/YL
10 C15 12BK/WT
11 L7 18BK/YL

C308 - WHITE (LIFTGATE SIDE)

CAV CIRCUIT
1 G78 20TN/BK
2 P35 18OR/VT
3 P36 18PK/VT
4 V13 18BR/LG
5 V22 18BR/YL
6 F70 18PK
7 L50 18WT/TN
8 Z1 12BK
9 G80 18VT/YL
10 C15 12BK/WT
11 L7 18BK/YL

C309 - WHITE (OVERHEAD SIDE)

CAV CIRCUIT
1 D25 20YL/VT
2 M20 20YL/BK
3 M2 20YL/DG
4 P112 20BK/WT
5 P114 20BK/YL
6 L1 20BK/VT
7 G5 20DB/WT
8 X75 20GY/LG (ALARM)
9 -
10 F70 20PK
11 Q30 20BK/LB (AUTOWIPE)
11 Q30 16TN (SUNROOF)
12 Z150 20BK (EXCEPT SUNROOF)
12 Z150 16BK (SUNROOF)
13 -
14 Z155 20BK/OR
15 G73 20LG/OR
8W - 80 - 54 8W-80 CONNECTOR PIN-OUT WJ

C309 - WHITE (LEFT BODY SIDE)

CAV CIRCUIT
1 D25 20YL/VT
2 M20 18YL/BK (RHD)
2 M20 20YL/BK (LHD)
3 M2 18YL (RHD)
3 M2 20YL/DG (LHD)
4 P112 20YL/WT
5 P114 20YL/RD
6 L1 20VT/BK
7 G5 20DB/WT
8 X75 20GY/LG (BUILT-UP-EXPORT)
9 -
10 F70 20PK (LHD)
10 F70 18PK (RHD)
11 Q30 16TN
12 Z150 16BK
13 -
14 Z155 20BK/OR (EXCEPT LHD BASE)
14 Z155 18BK/OR (RHD/LHD BASE)
15 G73 20LG/OR

C310 (BUILT-UP-EXPORT) - LT.GRAY (TRAILER TOW SIDE)

CAV CIRCUIT
1 F9 14RD/BK
2 L62 20BR/RD
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 Z150 14RD/BK
7 B40 14LB
8 Z150 14BK
9 L50 18WT/TN
10 L63 20DG/RD
11 Z1 14BK
12 -
13 -
14 -

C310 (BUILT-UP-EXPORT) - LT.GRAY (BODY SIDE)

CAV CIRCUIT
1 F9 14RD/BK
2 L62 18BR/RD (LHD)
2 L62 20BR/RD (RHD)
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 L95 18DG/YL
7 B40 14LB
8 Z150 14BK
9 L50 16WT/TN (RHD)
9 L50 18WT/TN (LHD)
10 L63 20DG/RD
11 Z150 14BK
12 -
13 -
14 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 55

C310 (EXCEPT BUILT-UP-EXPORT) - LT. GREEN

(TRAILER TOW SIDE)
CAV CIRCUIT
1 F9 14RD/BK
2 L62 20BR/RD
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 Z150 14RD/BK
7 B40 14LB
8 Z150 14BK
9 L50 18WT/TN
10 L63 20DG/RD

C310 (EXCEPT BUILT-UP-EXPORT) - LT. GREEN

(LEFT BODY SIDE)
CAV CIRCUIT
1 F9 14RD/BK
2 L62 18BR/RD
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 Z150 14BK
7 B40 14LB
8 Z150 14BK
9 L50 18WT/TN
10 L63 20DG/RD

C311 - WHITE (LIFTGATE SIDE)

CAV CIRCUIT
1 L50 18WT/TN
2 Z1 18BK

C311 - WHITE (CHMSL SIDE)

CAV CIRCUIT
1 L50 18WT/TN
2 Z1 18BK

C312 - WHTE (LIFTGATE SIDE)

CAV CIRCUIT
1 Z1 18BK
2 L7 18BK/YL
3 P101 18OR/PK
4 F70 18PK
8W - 80 - 56 8W-80 CONNECTOR PIN-OUT WJ

C312 - WHITE (LICENSE PLATE LAMP SIDE)

CAV CIRCUIT
1 Z1 18BK
2 L7 18BK/YL
3 P101 18OR/PK
4 F70 18PK

C313 - WHITE (FRONT DRIVER DOOR SIDE)

CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD

C313 - WHITE (MUX JUMPER SIDE)

CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD

C314 - LT. GRAY (BODY SIDE)

CAV CIRCUIT
1 D25 20YL/VT
2 A146 12OR/WT
3 P35 18OR/VT
4 P36 18PK/VT
5 Z28 12BK (LHD)
5 Z243 12BK (RHD)
6 Q14 16GY
7 Q24 16DG
8 E20 20OR/DB
9 X56 18DB/PK (BASE LHD)
9 X80 18LB/BK (PREMIUM LHD)
9 X85 18LG/DG (RHD)
10 X54 18VT (BASE)
10 X87 18LG/RD (RHD)
10 X82 18LB/RD (PREMIUM)
11 -
12 -
13 -
14 -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 57

C314 - LT. GRAY (FRONT PASSENGER DOOR

SIDE)
CAV CIRCUIT
1 D25 20YL/VT
2 A146 12OR/WT
3 P35 18OR/VT
4 P36 18PK/VT
5 Z1 12BK
6 Q14 16GY
7 Q24 16DG
8 E20 20OR/DB
9 X80 18LB/BK (LHD PREMIUM)
9 X85 18LB/BK (RHD PREMIUM)
9 X56 18LB/BK (BASE)
10 X54 18LB/RD (BASE)
10 X87 18LB/RD (RHD PREMIUM)
10 X82 18LB/RD (LHD PREMIUM)
11 -
12 -
13 -
14 -

C315 - (OVERHEAD SIDE)

CAV CIRCUIT
1 Q30 16TN
2 -
3 Q43 20VT
4 Q41 20WT
5 -
6 -
7 Z150 16BK
8 -

C315 - (SUN ROOF MODULE SIDE)

CAV CIRCUIT
1 Q30 16DB
2 -
3 Q43 20VT
4 Q41 20WT
5 -
6 -
7 Z150 16BK
8 -
8W - 80 - 58 8W-80 CONNECTOR PIN-OUT WJ

C316 (EXCEPT BUILT-UP-EXPORT) - (PEDAL

SIDE)
CAV CIRCUIT
1 Y153 16DB/RD
2 L1 18WT/BR
3 F72 16RD/YL
4 D25 20VT/YL
5 Y151 20LG/BR
6 Z155 20BK/OR
7 Y152 20LG/OR
8 Z151 16BK

C316 (EXCEPT BUILT-UP-EXPORT) - (BODY

SIDE)
CAV CIRCUIT
1 Y153 20DB/RD
2 L1 18VT/BK
3 F72 16RD/YL
4 D25 20YL/VT
5 Y151 20LG/BR
6 Z155 18BK/OR
7 Y152 20LG/OR
8 Z151 18BK

C317 - (OVERHEAD SIDE)

CAV CIRCUIT
1 Z155 20BK/OR
2 -
3 X75 20GY/LG
4 -
5 D25 20YL/VT
6 F70 20PK

C317 - (INTRUSION TRANSCEIVER MODULE

SIDE)
CAV CIRCUIT
1 Z155 20BK
2 -
3 X75 20GY/LG
4 -
5 D25 20YL/VT
6 F70 20PK

C318 - (LEFT BODY SIDE (LHD)/ RIGHT BODY

SIDE (RHD))
CAV CIRCUIT
1 R73 20LB/BR
2 R75 20LB/OR
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 59

C318 - (OVERLAY SIDE)

CAV CIRCUIT
1 R72 20LB/WT (RHD)
1 R73 20LB/BR (LHD)
2 R74 20LB/YL (RHD)
2 R75 20LB/OR (LHD)

C319 - (RIGHT BODY SIDE (LHD)/ LEFT BODY

SIDE (RHD))
CAV CIRCUIT
1 R72 20LB/WT (LHD)
2 R74 20LB/YL (LHD)

C319 - (OVERLAY SIDE)

CAV CIRCUIT
1 R73 20LB/BR (RHD)
1 R72 20LB/WT (LHD)
2 R75 20LB/OR (RHD)
2 R74 20LB/YL (LHD)

CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K944 20BR/DG CAMSHAFT POSITION SENSOR GROUND
2 K44 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
3 F15 18RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT

CAMSHAFT POSITION SENSOR (GAS) - GRAY 3 WAY

CAV CIRCUIT FUNCTION
1 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
2 K4 18BK/LB SENSOR GROUND
3 K7 18OR 5 VOLT SUPPLY

CAPACITOR (4.0L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 A142 16DG/OR (RHD) AUTO SHUT DOWN RELAY OUTPUT
1 A142 14DG/OR (LHD) AUTO SHUT DOWN RELAY OUTPUT
2 - -
8W - 80 - 60 8W-80 CONNECTOR PIN-OUT WJ

CAPACITOR NO. 1 (4.7L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
2 - -

CAPACITOR NO. 2 (4.7L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
2 - -

CARGO LAMP - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK FUSED B(+)
2 G73 20LG/OR LIFTGATE COURTESY DISABLE
3 M2 20YL/DG COURTESY LAMP DRIVER

CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
2 Z309 18BK GROUND

CIGAR LIGHTER - RED 3 WAY

CAV CIRCUIT FUNCTION
1 F30 16RD FUSED CIGAR LIGHTER RELAY OUTPUT
2 - -
3 Z300 16BK GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 61

CLOCKSPRING C1 - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 X3 20GY/OR HORN RELAY CONTROL
2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
3 K4 20BK/LB SENSOR GROUND
4 - -

CLOCKSPRING C2 - 4 WAY
CAV CIRCUIT FUNCTION
1 R63 20TN/LB DRIVER SQUIB 2 LINE 2
2 R61 20OR/LB DRIVER SQUIB 2 LINE 1
3 R43 20BK/LB DRIVER SQUIB 1 LINE 1
4 R45 20DG/LB DRIVER SQUIB 1 LINE 2

CLOCKSPRING C3 - GRAY 6 WAY

CAV CIRCUIT FUNCTION
1 X20 20RD/YL RADIO CONTROL MUX
2 X10 20RD/BK RADIO CONTROL MUX RETURN
3 X3 20GY/OR HORN RELAY CONTROL
4 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
5 K4 20BK/LB SENSOR GROUND
6 - -

CLOCKSPRING C4 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 X20 20RD/YL RADIO CONTROL MUX
2 X10 20RD/BK RADIO CONTROL MUX RETURN

COIL ON PLUG NO. 1 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K91 14TN/RD COIL DRIVER NO. 1
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -
8W - 80 - 62 8W-80 CONNECTOR PIN-OUT WJ

COIL ON PLUG NO. 2 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K92 14TN/PK COIL DRIVER NO. 2
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -

COIL ON PLUG NO. 3 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K93 14TN/OR COIL DRIVER NO. 3
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -

COIL ON PLUG NO. 4 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K94 14TN/LG COIL DRIVER NO. 4
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -

COIL ON PLUG NO. 5 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K95 14TN/DG COIL DRIVER NO. 5
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -

COIL ON PLUG NO. 6 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K96 14TN/LB COIL DRIVER NO. 6
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 63

COIL ON PLUG NO. 7 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K97 14BR COIL DRIVER NO. 7
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -

COIL ON PLUG NO. 8 (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K98 14LB/RD COIL DRIVER NO. 8
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 - -

COIL RAIL (4.0L) - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 K91 14TN/RD COIL DRIVER NO. 1
2 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
3 K92 14TN/PK COIL DRIVER NO. 2
4 K93 14TN/OR COIL DRIVER NO. 3

COMPACT DISC CHANGER (PREMIUM RADIO) - BLACK 8 WAY

CAV CIRCUIT FUNCTION
1 X40 20WT/RD AUDIO OUT RIGHT
2 C235 20WT/LB SHIELD
3 D25 20YL/VT PCI BUS
4 X112 20RD IGNITION SWITCH OUTPUT (RUN-ACC)
5 X41 20WT/DG AUDIO OUT LEFT
6 Z4 20WT/BK GROUND
7 Z17 20BK GROUND
8 X160 20YL B(+)
8W - 80 - 64 8W-80 CONNECTOR PIN-OUT WJ

CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY

CAV CIRCUIT FUNCTION
1 Z101 12BK/OR GROUND
2 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL
3 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
4 - -
5 D25 18VT/YL PCI BUS
6 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
7 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
8 - -
9 A20 12RD/DB FUSED B(+)
10 F20 18DB/PK FUSED IGNITION SWITCH OUTPUT (RUN)
11 D52 18LG/WT (DIESEL) CAN C BUS(+)
12 - -
13 B22 18DG/YL VEHICLE SPEED SENSOR SIGNAL
14 D51 18DG/WT (DIESEL) CAN C BUS(-)
15 - -
16 Z102 12BK/OR GROUND
17 G9 18GY/BK BRAKE FLUID LEVEL SWITCH SENSE
18 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
19 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR SIGNAL
20 B4 18LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
21 Z231 18BK GROUND
22 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
23 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
24 A10 12RD/DG FUSED B(+)

COOLANT LEVEL SENSOR - LT. GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 G18 20PK/BK (EXCEPT LHD GAS) COOLANT LEVEL SWITCH SENSE
1 G18 18PK/BK (LHD GAS) COOLANT LEVEL SWITCH SENSE
2 Z307 20BK GROUND

CRANKCASE HEATER (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z18 20BR GROUND
2 F15 20RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 65

CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K924 20YL CRANKSHAFT POSITION SENSOR SIGNAL 2
2 K3 20BK CRANKSHAFT POSITION SENSOR SIGNAL 1

CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
2 K4 18BK/LB SENSOR GROUND
3 K7 18OR 5 VOLT SUPPLY

DATA LINK CONNECTOR - BLACK 16 WAY

CAV CIRCUIT FUNCTION
1 - -
2 D25 20YL/VT PCI BUS
3 - -
4 Z305 20BK/OR GROUND
5 Z306 20BK/LG GROUND
6 D32 20LG/DG SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
9 D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG SCI RECEIVE
15 - -
16 F33 20PK/RD FUSED B(+)
8W - 80 - 66 8W-80 CONNECTOR PIN-OUT WJ

DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY

CAV CIRCUIT FUNCTION
1 D25 20YL/VT/BR PCI BUS (PCM/ECM TCM PDM CD SKIM)
2 D25 20YL/VT/DG (AZC) PCI BUS (AZC)
3 D25 20YL/VT/DB PCI BUS (RADIO)
4 D25 20YL/VT/OR PCI BUS (ACM)
5 D25 20YL/VT/RD PCI BUS (MIC)
6 D25 20YL/VT/WT PCI BUS (BCM)
7 D25 20YL/VT PCI BUS (DLC)
8 D25 20YL/VT/GY PCI BUS (DDM ABS MEM EVIC APM ITM RAIN
SENSOR)
9 - -
10 - -
11 D25 20YL/VT (DIESEL) PCI BUS (SHIFTER ASSEMBLY)
12 - -
13 - -
14 - -
15 - -
16 - -

DRIVER AIRBAG SQUIB 1 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 R43 20BK DRIVER SQUIB 1 LINE 1
2 R45 20BK DRIVER SQUIB 1 LINE 2

DRIVER AIRBAG SQUIB 2 - GREEN 2 WAY

CAV CIRCUIT FUNCTION
1 R63 20TN/LB DRIVER SQUIB 2 LINE 2
2 R61 20OR/LB DRIVER SQUIB 2 LINE 1
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 67

DRIVER BLEND DOOR MOTOR/ACTUATOR (LHD) (AZC) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A C95 20WT/BK (LHD) DRIVER BLEND DOOR DRIVER (B)
B C33 20DB/RD (LHD) DRIVER BLEND DOOR DRIVER (A)

DRIVER BLEND DOOR MOTOR/ACTUATOR (RHD) (AZC)- BLACK 2 WAY

CAV CIRCUIT FUNCTION
A C33 20DB/RD (RHD) DRIVER BLEND DOOR DRIVER (A)
B C95 20WT/BK (RHD) DRIVER BLEND DOOR DRIVER (B)

DRIVER CURTAIN AIRBAG - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 R73 20LB/BR DRIVER CURTAIN SQUIB LINE 2
2 R75 20LB/OR DRIVER CURTAIN SQUIB LINE 1

DRIVER CYLINDER LOCK SWITCH - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 G73 20LG/OR DRIVER CYLINDER LOCK SWITCH SENSE
2 Z243 12BK (RHD) GROUND
2 Z28 12BK (LHD) GROUND
8W - 80 - 68 8W-80 CONNECTOR PIN-OUT WJ

DRIVER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 G75 18TN/RD DRIVER DOOR AJAR SWITCH SENSE
2 Z243 12BK (RHD) GROUND
2 Z28 12BK (LHD) GROUND
3 P34 18PK/BK DRIVER DOOR UNLOCK DRIVER
4 P35 18OR/BK DRIVER DOOR LOCK DRIVER

DRIVER DOOR MODULE C1 - WHITE 15 WAY

CAV CIRCUIT FUNCTION
1 A146 12OR/WT FUSED B(+)
2 Q23 16RD/WT DRIVER REAR WINDOW DRIVER (DOWN)
3 Q13 16DB DRIVER REAR WINDOW DRIVER (UP)
4 Z28 12BK (LHD) GROUND
4 Z234 12BK (RHD) GROUND
5 P35 18OR/BK DRIVER DOOR LOCK DRIVER
6 - -
7 P34 18PK/BK DRIVER DOOR UNLOCK DRIVER
8 D30 20VT/YL (JAPAN) DIAGNOSTIC OUT
9 D25 20YL/VT PCI BUS
10 G73 20LG/OR DRIVER CYLINDER LOCK SWITCH SENSE
11 G75 18TN/RD DRIVER DOOR AJAR SWITCH SENSE
12 E21 20OR/RD DRIVER REAR DOOR SWITCH ILLUMINATION
13 Q11 16LB DRIVER WINDOW DRIVER (UP)
14 - -
15 Q21 16WT DRIVER WINDOW DRIVER (DOWN)

DRIVER DOOR MODULE C2 - BLACK 12 WAY

CAV CIRCUIT FUNCTION
1 P95 20OR MIRROR HORIZONTAL DRIVER
2 C118 20BK/WT MIRROR HEATER GROUND
3 P64 20VT MIRROR VERTICAL POSITION SIGNAL
4 P69 20GY MIRROR SENSOR GROUND
5 P65 20DG MIRROR HORIZONTAL POSITION SIGNAL
6 C117 20BK MIRROR HEATER 12 VOLT SUPPLY
7 P91 20WT MIRROR COMMON DRIVER
8 P93 20RD MIRROR VERTICAL DRIVER
9 M21 20PK/DG COURTESY LAMP DRIVER
10 P110 20YL (BUILT-UP-EXPORT) FOLDING MIRROR RETURN
11 P99 20DB (BUILT-UP-EXPORT) FOLDING MIRROR FEED
12 L121 20BK/RD COURTESY LAMP GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 69

DRIVER DOOR MODULE C3 - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 BK MEMORY SWITCH RETURN
2 BR MEMORY SWITCH MUX
3 OR MEMORY SET INDICATOR DRIVER
4 GY SWITCH ILLUMINATION DRIVER

DRIVER FRONT DOOR COURTESY LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 M21 20PK/DG COURTESY LAMP DRIVER
2 L121 20BK/RD COURTESY LAMP GROUND

DRIVER FRONT POWER WINDOW MOTOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Q21 16WT DRIVER WINDOW DRIVER (DOWN)
2 Q11 16LB DRIVER WINDOW DRIVER (UP)

DRIVER HEATED SEAT BACK (PREMIUM I/III) - 3 WAY

CAV CIRCUIT FUNCTION
1 P88 16BK/BR HEATED SEAT DRIVER
2 Z6 16BK/YL GROUND
3 - -

DRIVER HEATED SEAT CUSHION (PREMIUM I/III) - 4 WAY

CAV CIRCUIT FUNCTION
1 P131 16BK/OR DRIVER SEAT HEATER B(+) DRIVER
2 P88 16BK/BR HEATED SEAT DRIVER
3 P135 20LB/BK DRIVER SEAT TEMPERATURE SENSOR INPUT
4 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
8W - 80 - 70 8W-80 CONNECTOR PIN-OUT WJ

DRIVER HEATED SEAT SWITCH - WHITE 6 WAY

CAV CIRCUIT FUNCTION
1 P133 20TN/DG DRIVER SEAT HEATER SWITCH MUX
2 E2 20OR PANEL LAMPS DRIVER
3 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
4 - -
5 Z300 20BK GROUND
6 P132 20OR/BK SEAT HEATER SWITCH SENSOR GROUND

DRIVER LUMBAR MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 P105 16LG/DB LUMBAR FORWARD SWITCH SENSE
2 P104 16YL/RD LUMBAR REARWARD SWITCH SENSE

DRIVER LUMBAR SWITCH (MIDLINE/PREMIUM) - WHITE 6 WAY

CAV CIRCUIT FUNCTION
1 - -
2 Z238 16BK (RHD) GROUND
2 Z243 16BK (LHD) GROUND
3 P105 16LG/DB (RHD) LUMBAR FORWARD SWITCH SENSE
3 P104 16YL/RD (LHD) LUMBAR REAR WARD SWITCH SENSE
4 P104 16YL/RD (RHD) LUMBAR REAR WARD SWITCH SENSE
4 P105 16LG/DB (LHD) LUMBAR FORWARD SWITCH SENSE
5 Z238 16BK (RHD) GROUND
5 Z243 16BK (LHD) GROUND
6 F35 16RD FUSED B(+)

DRIVER POWER MIRROR - BLACK 12 WAY

CAV CIRCUIT FUNCTION
1 C117 20BK MIRROR HEATER 12 VOLT SUPPLY
2 P65 20DG MIRROR HORIZONTAL POSITION SIGNAL
3 P69 20GY MIRROR SENSOR GROUND
4 P64 20VT MIRROR VERTICAL POSITION SIGNAL
5 C118 20BK/WT MIRROR HEATER GROUND
6 P95 20OR MIRROR HORIZONTAL DRIVER
7 P114 20YL/RD AUTO DAY/NIGHT MIRROR(-)
8 P99 20DB (BUILT-UP-EXPORT) FOLDING MIRROR FEED
9 P110 20YL (BUILT-UP-EXPORT) FOLDING MIRROR RETURN
10 P112 20YL/WT AUTO DAY/NIGHT MIRROR(+)
11 P93 20RD MIRROR VERTICAL DRIVER
12 P91 20WT MIRROR COMMON DRIVER
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 71

DRIVER POWER SEAT FRONT RISER MOTOR - RED 2 WAY

CAV CIRCUIT
1 P119 16YL/RD (PREMIUM II/III)
1 P19 16YL/LG (EXCEPT PREMIUM II/III)
2 P121 16RD/GY (PREMIUM II/III)
2 P21 16RD/LG (EXCEPT PREMIUM II/III)
FUNCTION
SEAT FRONT UP DRIVER
DRIVER SEAT FRONT UP DRIVER
SEAT FRONT DOWN DRIVER
DRIVER SEAT FRONT DOWN DRIVER

DRIVER POWER SEAT FRONT RISER MOTOR SENSOR (PREMIUM II/III) - 3 WAY
CAV CIRCUIT FUNCTION
A P28 20BR/RD SEAT POSITION SENSOR GROUND
B P26 20BR FRONT RISER POSITION SIGNAL
C P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY

DRIVER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY

CAV CIRCUIT
1 P17 16RD/YL (EXCEPT PREMIUM II/III)
1 P117 16RD/BR (PREMIUM II/III)
2 P15 16YL/LB (EXCEPT PREMIUM II/III)
2 P115 16GY/LG (PREMIUM II/III)
FUNCTION
DRIVER SEAT HORIZONTAL REARWARD DRIVER
SEAT HORIZONTAL REARWARD DRIVER
DRIVER SEAT HORIZONTAL FORWARD DRIVER
SEAT HORIZONTAL FORWARD DRIVER

DRIVER POWER SEAT HORIZONTAL MOTOR SENSOR (PREMIUM II/III) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
A P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
B P25 20VT/RD SEAT HORIZONTAL POSITION SIGNAL
C P28 20BR/RD SEAT POSITION SENSOR GROUND

DRIVER POWER SEAT REAR RISER MOTOR - RED 2 WAY

CAV CIRCUIT FUNCTION
1 P11 16YL/WT (EXCEPT PREMIUM II/III) DRIVER SEAT REAR UP DRIVER
1 P111 16YL/DB (PREMIUM II/III) SEAT REAR UP DRIVER
2 P13 16RD/WT (EXCEPT PREMIUM DRIVER SEAT REAR DOWN DRIVER
II/III)
2 P113 16RD/BK (PREMIUM II/III) SEAT REAR DOWN DRIVER
8W - 80 - 72 8W-80 CONNECTOR PIN-OUT WJ

DRIVER POWER SEAT REAR RISER MOTOR SENSOR (PREMIUM II/III) - 3 WAY
CAV CIRCUIT FUNCTION
A P28 20BR/RD SEAT POSITION SENSOR GROUND
B P27 20LB/RD REAR RISER POSITION SIGNAL
C P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY

DRIVER POWER SEAT RECLINER MOTOR - BLACK 2 WAY

CAV CIRCUIT
A P41 16GY/WT (MIDLINE/PREMIUM I)
A P141 16GY/WT (PREMIUM II/III)
B P43 16GY/LB (MIDLINE/PREMIUM I)
B P143 16GY/LB (PREMIUM II/III)
FUNCTION
DRIVER SEAT RECLINER DOWN DRIVER
SEAT RECLINER DOWN DRIVER
DRIVER SEAT RECLINER UP DRIVER
SEAT RECLINER UP DRIVER

DRIVER POWER SEAT RECLINER MOTOR SENSOR (PREMIUM II/III) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
A P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
B P47 20LB RECLINER POSITION SIGNAL
C P28 20BR/RD SEAT POSITION SENSOR GROUND

DRIVER POWER SEAT SWITCH (EXCEPT MIDLINE/PREMIUM) - 12 WAY

CAV CIRCUIT FUNCTION
A F35 16RD FUSED B(+)
B Z1 16BK GROUND
C - -
E P21 16RD/LG (LHD) DRIVER SEAT FRONT DOWN DRIVER
E P19 16YL/LG (RHD) DRIVER SEAT FRONT UP DRIVER
F - -
G - -
H - -
J P19 16YL/LG (LHD) DRIVER SEAT FRONT UP DRIVER
J P21 16RD/LG (RHD) DRIVER SEAT FRONT DOWN DRIVER
K P15 16YL/LB DRIVER SEAT HORIZONTAL FORWARD DRIVER
L P17 16RD/YL DRIVER SEAT HORIZONTAL REARWARD DRIVER
M P13 16RD/WT (LHD) DRIVER SEAT REAR DOWN DRIVER
M P11 16YL/WT (RHD) DRIVER SEAT REAR UP DRIVER
N P11 16YL/WT (LHD) DRIVER SEAT REAR UP DRIVER
N P13 16RD/WT (RHD) DRIVER SEAT REAR DOWN DRIVER
WJ 8W-80 CONNECTOR PIN-OUT
DRIVER POWER SEAT SWITCH (MIDLINE/PREMIUM) - GREEN 10 WAY
CAV CIRCUIT
1 Z1 16BK
2 P43 16GY/LB (MIDLINE/PREMIUM I)
2 P43 20GY/LB (PREMIUM II/III)
3 P17 16RD/YL (MIDLINE/PREMIUM I)
3 P17 20RD/YL (PREMIUM II/III)
4 P41 16GY/WT (MIDLINE/PREMIUM I)
4 P41 20GY/WT (PREMIUM II/III)
5 F35 16RD (MIDLINE/PREMIUM I)
5 P9 20RD/LB (PREMIUM II/III)
6 P15 16YL/LB (MIDLINE/PREMIUM I)
6 P15 20YL/LB (PREMIUM II/III)
7 P19 16YL/LG (MIDLINE/PREMIUM I)
7 P21 20RD/LG (RHD PREMIUM II/III)
7 P19 20YL/LG (PREMIUM II/III)
8 P13 20RD/WT (RHD PREMIUM II/III)
8 P11 20YL/WT (PREMIUM II/III)
8 P11 16YL/WT (MIDLINE/PREMIUM I)
9 P13 20RD/WT (PREMIUM II/III)
9 P13 16RD/WT (MIDLINE/PREMIUM I)
9 P11 20YL/WT (RHD PREMIUM II/III)
10 P21 16RD/LG (MIDLINE/PREMIUM I)
10 P21 20RD/LG (PREMIUM II/III)
10 P19 20YL/LG (RHD PREMIUM II/III)
DRIVER REAR POWER WINDOW MOTOR - BLACK 2 WAY
CAV CIRCUIT
1 Q124 16DG/WT
2 Q114 16GY/WT
DRIVER REAR POWER WINDOW SWITCH - BLUE 6 WAY
CAV CIRCUIT
1 Q14 16GY
2 Q114 16GY/WT
3 E21 20OR/RD
4 Q24 16DG
5 Q124 16DG/WT
6 Z1 16BK
8W - 80 - 73
FUNCTION
GROUND
DRIVER SEAT RECLINER UP DRIVER
RECLINER UP SWITCH SENSE
DRIVER SEAT HORIZONTAL REARWARD DRIVER
DRIVER SEAT HORIZONTAL REARWARD SWITCH
SENSE
DRIVER SEAT RECLINER DOWN DRIVER
RECLINER DOWN SWITCH SENSE
FUSED B(+)
SEAT SWITCH B(+) SUPPLY
DRIVER SEAT HORIZONTAL FORWARD DRIVER
DRIVER SEAT HORIZONTAL FORWARD SWITCH
SENSE
SEAT FRONT UP SWITCH SENSE
SEAT FRONT DOWN SWITCH SENSE
SEAT FRONT UP SWITCH SENSE
DRIVER SEAT REAR DOWN DRIVER
SEAT REAR UP SWITCH SENSE
DRIVER SEAT REAR UP DRIVER
SEAT REAR DOWN SWITCH SENSE
DRIVER SEAT REAR DOWN DRIVER
DRIVER SEAT REAR UP DRIVER
SEAT FRONT DOWN SWITCH SENSE
SEAT FRONT DOWN SWITCH SENSE
SEAT FRONT UP SWITCH SENSE
FUNCTION
WINDOW DRIVER (DOWN)
WINDOW DRIVER (UP)
FUNCTION
DRIVER REAR WINDOW DRIVER (UP)
WINDOW DRIVER (UP)
DRIVER REAR DOOR SWITCH ILLUMINATION
DRIVER REAR WINDOW DRIVER (DOWN)
WINDOW DRIVER (DOWN)
GROUND
8W - 80 - 74 8W-80 CONNECTOR PIN-OUT WJ

DRIVER SEAT BELT SWITCH - 2 WAY

CAV CIRCUIT FUNCTION
1 R57 20DG DRIVER SEAT BELT SWITCH SENSE
2 R59 20LB DRIVER SEAT BELT SWITCH GROUND

DRIVER SIDE IMPACT SENSOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 R133 20LB/DG DRIVER SIDE IMPACT SENSOR GROUND
4 R131 20LG/YL DRIVER SIDE IMPACT SENSOR SIGNAL

EGR SOLENOID (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F15 18RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K35 20GY/YL EGR SOLENOID CONTROL

ELECTRIC BRAKE (EXCEPT BUILT-UP-EXPORT) - BLUE 4 WAY

CAV CIRCUIT FUNCTION
1 Z151 14BK GROUND
2 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
3 B40 12LB TRAILER TOW BRAKE B(+)
4 F9 14RD/BK FUSED B(+)

ELECTRONIC SPEED CONTROL SERVO - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 V36 20TN/RD (RHD/GAS) SPEED CONTROL VACUUM SOLENOID CONTROL
1 V36 18TN/RD (LHD GAS) SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 20LG/RD (RHD/GAS) SPEED CONTROL VENT SOLENOID CONTROL
2 V35 18LG/RD (LHD GAS) SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z307 20BK GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 75

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY

CAV CIRCUIT FUNCTION
1 Z108 14BK/DG GROUND
2 Z108 14BK/DG GROUND
3 K20 14DB GENERATOR FIELD CONTROL
4 F142 14RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
5 F142 14RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
6 D52 18DG/WT CAN C BUS(+)
7 D25 20VT/YL PCI BUS
8 K944 20BR/DG CAMSHAFT POSITION SENSOR GROUND
9 K44 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 Y53 20BK/YL BOOST PRESSURE SENSOR SIGNAL
12 K155 20YL/WT MASS AIR FLOW SENSOR SIGNAL
13 Y40 20DG/VT FUEL PRESSURE SENSOR SIGNAL
14 K22 20RD/DB ACCELERATOR PEDAL POSITION SENSOR 2 SIGNAL
15 K81 20DB/DG ACCELERATOR PEDAL POSITION SENSOR 1 SIGNAL
16 Y100 20BR/GY FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 F300 20RD/BK BATTERY SENSE (+)
20 Z11 20BK/WT BATTERY SENSE (-)
21 K4 18BK/LB SENSOR GROUND
22 F991 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 K6 18VT/WT SENSOR REFERENCE VOLTAGE B
24 K3 20BK CRANKSHAFT POSITION SENSOR SIGNAL 1
25 D51 18WT CAN C BUS(-)
26 - -
27 - -
28 - -
29 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT
30 G60 20BR/DB ENGINE OIL PRESSURE SENSOR SIGNAL
31 - -
32 K25 20VT/DG BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR 1 GROUND
35 Y43 20WT/VT ACCELERATOR PEDAL POSITION SENSOR 1 5-VOLT
SUPPLY
36 C18 20DB A/C PRESSURE SENSOR SIGNAL
37 - -
38 V37 20RD/DG SPEED CONTROL SWITCH SIGNAL
39 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
40 K2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Y101 20 CRANKSHAFT POSITION SENSOR SHIELD
43 K924 20YL CRANKSHAFT POSITION SENSOR SIGNAL 2
44 - -
45 - -
46 - -
47 L50 20WT/DB PRIMARY BRAKE SWITCH SIGNAL
48 K29 20WT/PK SECONDARY BRAKE SWITCH SIGNAL
49 - -
50 F855 18BR/YL SENSOR REFERENCE VOLTAGE A
51 - -
52 - -
53 - -
54 Z189 20BR MASS AIR FLOW SENSOR GROUND
8W - 80 - 76 8W-80 CONNECTOR PIN-OUT WJ

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY

CAV CIRCUIT FUNCTION
55 B22 20DG/YL VEHICLE SPEED SENSOR SIGNAL
56 K225 18BK ACCELERATOR PEDAL POSITION SENSOR 2 GROUND
57 - -
58 K4 20BK/LB WATER IN FUEL SENSOR GROUND
59 K900 18GY INTAKE PORT SWIRL ACTUATOR SIGNAL
60 K7 20RD/WT FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
62 - -
63 - -
64 - -
65 - -
66 - -
67 K173 20GY HYDRAULIC RADIATOR FAN SOLENOID CONTROL
68 - -
69 C13 20DB/RD A/C COMPRESSOR CLUTCH RELAY CONTROL
70 - -
71 - -
72 K236 20GY/PK GLOW PLUG RELAY NO. 2 CONTROL
73 - -
74 T752 20DG/RD ENGINE STARTER MOTOR RELAY CONTROL
75 K132 20BR/BK VISCOUS/CABIN HEATER RELAY CONTROL
76 Y42 20BR/BK WASTEGATE SOLENOID CONTROL
77 K152 20WT GLOW PLUG RELAY NO. 1 CONTROL
78 - -
79 - -
80 K46 20DB/BK FUEL PRESSURE SOLENOID CONTROL
81 K46 20DB/BK FUEL PRESSURE SOLENOID CONTROL

ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY

CAV CIRCUIT FUNCTION
82 D21 20PK SCI TRANSMIT
83 - -
84 - -
85 - -
86 - -
87 - -
88 - -
89 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
94 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
101 - -
102 - -
103 - -
104 - -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 77

ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY

CAV CIRCUIT FUNCTION
105 - -
106 - -
107 - -
108 - -
109 - -
110 - -
111 - -
112 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
113 - -
114 - -
115 K14 14BK/YL FUEL INJECTOR NO. 4 CONTROL
116 K63 14BK COMMON INJECTOR DRIVER
117 - -
118 K11 14BK/DB FUEL INJECTOR NO. 1 CONTROL
119 K38 14BK/DG FUEL INJECTOR NO. 5 CONTROL
120 K12 14BK/VT FUEL INJECTOR NO. 2 CONTROL
121 K13 14BK/RD FUEL INJECTOR NO. 3 CONTROL

ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 K2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL

ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL

ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K6 18VT/WT SENSOR REFERENCE VOLTAGE B
2 G60 20BR/DB ENGINE OIL PRESSURE SENSOR SIGNAL
3 K4 18BK/LB SENSOR GROUND
8W - 80 - 78 8W-80 CONNECTOR PIN-OUT WJ

ENGINE OIL PRESSURE SENSOR (GAS) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K6 18VT/BK 5 VOLT SUPPLY
2 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
3 K4 18BK/LB SENSOR GROUND

EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 K52 18PK/BK (RHD) DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
2 K52 20PK/BK (LHD) DUTY CYCLE EVAP/PURGE SOLENOID CONTROL

FRONT POWER OUTLET - RED 3 WAY

CAV CIRCUIT FUNCTION
1 F85 16VT (RHD) FUSED B(+)
1 F85 16VT/WT (LHD) FUSED B(+)
2 - -
3 Z300 16BK GROUND

FRONT WASHER PUMP - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 V10 20BR WASHER PUMP SWITCH SENSE
2 Z141 20BK GROUND

FRONT WIPER MOTOR - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V55 16TN/RD WIPER PARK SWITCH SENSE
3 - -
4 Z141 16BK GROUND
5 V3 16BR/WT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
6 V4 16RD/YL WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 79

FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K11 14BK/DB FUEL INJECTOR NO. 1 CONTROL
2 K63 14BK COMMON INJECTOR DRIVER

FUEL INJECTOR NO. 1 (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K12 14BK/VT FUEL INJECTOR NO. 2 CONTROL
2 K63 14BK COMMON INJECTOR DRIVER

FUEL INJECTOR NO. 2 (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K12 18TN FUEL INJECTOR NO. 2 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 3 (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K13 14BK/RD FUEL INJECTOR NO. 3 CONTROL
2 K63 14BK COMMON INJECTOR DRIVER
8W - 80 - 80 8W-80 CONNECTOR PIN-OUT WJ

FUEL INJECTOR NO. 3 (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K14 14BK/YL FUEL INJECTOR NO. 4 CONTROL
2 K63 14BK COMMON INJECTOR DRIVER

FUEL INJECTOR NO. 4 (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 5 (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K38 14BK/DG FUEL INJECTOR NO. 5 CONTROL
2 K63 14BK COMMON INJECTOR DRIVER
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 81

FUEL INJECTOR NO. 5 (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K38 18GY FUEL INJECTOR NO. 5 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 6 (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K58 18BR/DB FUEL INJECTOR NO. 6 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 7 (4.7L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K26 18VT FUEL INJECTOR NO. 7 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL INJECTOR NO. 8 (4.7L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K28 18GY/LB FUEL INJECTOR NO. 8 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT
8W - 80 - 82 8W-80 CONNECTOR PIN-OUT WJ

FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 Y100 20BR/GY FUEL PRESSURE SENSOR GROUND
2 Y40 20DG/VT FUEL PRESSURE SENSOR SIGNAL
3 K7 20RD/WT FUEL PRESSURE SENSOR 5 VOLT SUPPLY

FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K46 20DB/BK FUEL PRESSURE SOLENOID CONTROL
2 F142 16RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT

FUEL PUMP MODULE (GAS) - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 A141 16DG/BK FUEL PUMP RELAY OUTPUT
2 - -
3 K226 20LB/YL FUEL LEVEL SENSOR SIGNAL
4 K4 20BK/LB SENSOR GROUND
5 - -
6 Z150 16BK GROUND

FUEL TANK MODULE (DIESEL) - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 K226 20LB/YL FUEL LEVEL SENSOR SIGNAL
4 K4 20BK/LB SENSOR GROUND
5 - -
6 - -

GENERATOR (DIESEL) - LT. GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 F15 14DB/WT FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K20 14DB GENERATOR FIELD CONTROL
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 83

GENERATOR (GAS) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K125 18WT/DB GENERATOR SOURCE
2 K20 18DG GENERATOR FIELD DRIVER

GLOVE BOX LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK/BK FUSED B(+)
2 M20 20BR/OR COURTESY LAMP LOAD SHED

HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 Z234 20BK GROUND
2 L7 18BK/YL PARK LAMP RELAY OUTPUT
3 L13 20BR/YL HEADLAMP ADJUST SIGNAL

HOOD AJAR SWITCH (BUILT-UP-EXPORT) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 G70 20BR/TN HOOD AJAR SWITCH SENSE
2 Z141 20BK (DIESEL) GROUND
2 Z161 20BK (GAS) GROUND

HORN NO. 1 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z307 18BK GROUND
2 X2 18DG/RD HORN RELAY OUTPUT
8W - 80 - 84 8W-80 CONNECTOR PIN-OUT WJ

HORN NO. 2 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z307 18BK GROUND
2 X2 18DG/RD HORN RELAY OUTPUT

HYDRAULIC COOLING MODULE - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 F15 18DB/WT (DIESEL) FUSED AUTO SHUT DOWN RELAY OUTPUT
1 F142 18OR/DG (GAS) FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K173 18LG (DIESEL) HYDRAULIC RADIATOR FAN RELAY CONTROL
2 K173 18LG (GAS) RADIATOR FAN RELAY CONTROL
3 Z500 18BK GROUND

IDLE AIR CONTROL MOTOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
4 K39 18GY/BK IDLE AIR CONTROL NO. 1 DRIVER

IGNITION SWITCH C1 - WHITE 6 WAY

CAV CIRCUIT FUNCTION
1 A41 12YL IGNITION SWITCH OUTPUT (START)
2 A2 12PK/BK FUSED B(+)
3 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
4 A1 12RD FUSED B(+)
5 A31 12RD/BK IGNITION SWITCH OUTPUT (RUN-ACC)
6 A21 12DB IGNITION SWITCH OUTPUT (RUN-START)

IGNITION SWITCH C2 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 G26 20LB KEY-IN IGNITION SWITCH SENSE
2 Z234 20BK GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 85

INPUT SPEED SENSOR (4.7L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND

INSTRUMENT CLUSTER - WHITE 12 WAY

CAV CIRCUIT FUNCTION
1 L61 20TN/LG LEFT TURN SIGNAL
2 L60 20TN RIGHT TURN SIGNAL
3 - -
4 - -
5 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
6 F33 20PK/RD FUSED B(+)
7 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE
9 Z300 20BK GROUND
10 D25 20YL/VT/RD PCI BUS
11 Z132 20BK/OR GROUND
12 - -

INTAKE AIR TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 K21 20DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL

INTAKE AIR TEMPERATURE SENSOR (GAS) - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
8W - 80 - 86 8W-80 CONNECTOR PIN-OUT WJ

INTAKE PORT SWIRL ACTUATOR (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 Z18 18BK GROUND
2 F15 18RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
3 K900 18GY INTAKE PORT SWIRL ACTUATOR SIGNAL

INTRUSION TRANSCEIVER MODULE (BUILT-UP-EXPORT) - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 Z155 20BK GROUND
2 - -
3 X75 20GY/LG SIREN SIGNAL CONTROL
4 - -
5 D25 20YL/VT PCI BUS
6 F70 20PK FUSED B(+)

JUNCTION BLOCK BODY CONTROL MODULE - BLACK 26 WAY

CAV CIRCUIT FUNCTION
1 L308 PARK LAMP RELAY CONTROL
2 L26 FOG LAMP RELAY CONTROL
3 Q29 ACCESSORY DELAY RELAY CONTROL
4 L307 LOW BEAM RELAY CONTROL
5 G5 FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 X4 HORN RELAY CONTROL
7 V16 WIPER HIGH/LOW RELAY CONTROL
8 G80 LIFTGATE FLIP-UP AJAR SWITCH SENSE
9 L11 HIGH BEAM RELAY CONTROL
10 L91 HAZARD SWITCH SENSE
11 C80 REAR WINDOW DEFOGGER RELAY CONTROL
12 Z2 GROUND
13 L96 (BUILT-UP-EXPORT) REAR FOG LAMP RELAY CONTROL
14 L7 PARK LAMP RELAY OUTPUT
15 Z1 GROUND
16 M2 COURTESY LAMP DRIVER
17 - -
18 - -
19 M20 COURTESY LAMP LOAD SHED
20 V55 WIPER PARK SWITCH SENSE
21 G78 LIFTGATE AJAR SWITCH SENSE
22 G10 SEAT BELT SWITCH SENSE
23 G77 LEFT REAR DOOR AJAR SWITCH SENSE
24 G73 LIFTGATE COURTESY DISABLE
25 V23 FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
26 M1 FUSED B(+)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 87

JUNCTION BLOCK C1 - BLACK 52 WAY

CAV CIRCUIT FUNCTION
1 Q30 16TN ACCESSORY DELAY RELAY OUTPUT
2 L63 18DG/RD LEFT TURN SIGNAL
3 - -
4 - -
5 L95 18DG/YL (BUILT-UP-EXPORT) REAR FOG LAMP RELAY OUTPUT
6 - -
7 - -
8 - -
9 G73 20LG/OR LIFTGATE COURTESY DISABLE
10 G77 20TN/OR LEFT REAR DOOR AJAR SWITCH SENSE
11 L7 18BK/YL PARK LAMP RELAY OUTPUT
12 - -
13 - -
14 - -
15 F37 16RD (LHD EXCEPT BASE) FUSED B(+)
15 F37 16RD/LB (RHD) FUSED B(+)
16 M2 18YL (RHD) COURTESY LAMP DRIVER
16 M2 20YL/DG (LHD) COURTESY LAMP DRIVER
17 - -
18 - -
19 - -
20 - -
21 - -
22 F22 20WT/PK (RHD) FUSED IGNITION SWITCH OUTPUT (RUN)
23 - -
24 G80 20VT/YL LIFTGATE FLIP-UP AJAR SWITCH SENSE
25 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE
26 M20 18YL/BK (RHD) COURTESY LAMP LOAD SHED
26 M20 20YL/BK (LHD) COURTESY LAMP LOAD SHED
27 - -
28 - -
29 - -
30 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
31 - -
32 M1 18PK/RD (RHD) FUSED B(+)
33 - -
34 - -
35 F9 14RD/BK FUSED B(+)
36 F70 18PK FUSED B(+)
37 - -
38 - -
39 - -
40 - -
41 F30 14RD/TN (LHD) CIGAR LIGHTER RELAY OUTPUT
41 F30 16RD/TN (RHD) CIGAR LIGHTER RELAY OUTPUT
42 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
50 C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
51 - -
52 - -
8W - 80 - 88 8W-80 CONNECTOR PIN-OUT WJ

JUNCTION BLOCK C2 (LHD) - BLACK 52 WAY

CAV CIRCUIT FUNCTION
1 X3 22GY/OR HORN RELAY CONTROL
2 - -
3 L39 20LB FOG LAMP RELAY OUTPUT
4 - -
5 L61 20TN/LG LEFT TURN SIGNAL
6 - -
7 - -
8 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
9 V6 16DB (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 L62 18BR/RD RIGHT TURN SIGNAL
11 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 L39 20LB FOG LAMP RELAY OUTPUT
13 - -
14 - -
15 V16 22VT WIPER HIGH/LOW RELAY CONTROL
16 - -
17 - -
18 - -
19 - -
20 L7 20BK/YL PARK LAMP RELAY OUTPUT
21 L7 20BK/YL PARK LAMP RELAY OUTPUT
22 - -
23 - -
24 F37 16RD/LB (EXCEPT BASE) FUSED B(+)
25 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
26 L60 20TN RIGHT TURN SIGNAL
27 F45 20YL/RD FUSED IGNITION SWITCH OUTPUT (START)
28 V55 16TN/RD WIPER PARK SWITCH SENSE
29 - -
30 - -
31 F72 16RD/YL FUSED B(+)
32 M1 20PK/RD FUSED B(+)
33 V55 16TN/RD (GAS) WIPER PARK SWITCH SENSE
34 - -
35 - -
36 A146 12OR/WT FUSED B(+)
37 - -
38 L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
39 L43 18VT FUSED LEFT LOW BEAM OUTPUT
40 - -
41 - -
42 F20 18DB/PK FUSED IGNITION SWITCH OUTPUT (RUN)
43 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
44 - -
45 A146 12OR/WT FUSED B(+)
46 - -
47 F32 20PK/DB FUSED B(+)
48 - -
49 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
50 L33 18RD FUSED LEFT HIGH BEAM OUTPUT
51 - -
52 F60 14RD/WT (EXCEPT BASE) FUSED B(+)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 89

JUNCTION BLOCK C2 (RHD) - BLACK 52 WAY

CAV CIRCUIT FUNCTION
1 X3 22BK/RD HORN RELAY CONTROL
2 - -
3 L39 20LB FOG LAMP RELAY OUTPUT
4 - -
5 L61 20TN/LG LEFT TURN SIGNAL
6 - -
7 - -
8 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
9 V6 16DB (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 L62 20BR/RD RIGHT TURN SIGNAL
11 F991 20OR/DB (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 L39 20LB FOG LAMP RELAY OUTPUT
13 - -
14 - -
15 V16 22VT -
16 - -
17 - -
18 - -
19 - -
20 L7 20BK/YL PARK LAMP RELAY OUTPUT
21 L7 18BK/YL PARK LAMP RELAY OUTPUT
22 - -
23 - -
24 F37 16RD/LB FUSED B(+)
25 F22 18WT/TN FUSED IGNITION SWITCH OUTPUT (RUN)
26 L60 20TN RIGHT TURN SIGNAL
27 F45 20YL/RD FUSED IGNITION SWITCH OUTPUT (START)
28 V55 16TN/RD WIPER PARK SWITCH SENSE
29 - -
30 - -
31 - -
32 M1 20PK/RD FUSED B(+)
33 V55 16TN/RD (GAS) WIPER PARK SWITCH SENSE
34 - -
35 - -
36 A146 12OR/WT FUSED B(+)
37 - -
38 L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
39 L43 18VT FUSED LEFT LOW BEAM OUTPUT
40 - -
41 - -
42 F20 18DB/PK FUSED IGNITION SWITCH OUTPUT (RUN)
43 F12 20DB/WT (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-START)
44 - -
45 A146 12OR/WT FUSED B(+)
46 - -
47 F32 20PK/DB FUSED B(+)
48 - -
49 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
50 L33 18RD FUSED LEFT HIGH BEAM OUTPUT
51 - -
52 F60 16RD/WT FUSED B(+)
8W - 80 - 90 8W-80 CONNECTOR PIN-OUT WJ

JUNCTION BLOCK C3 - BLACK 52 WAY

CAV CIRCUIT FUNCTION
1 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 - -
3 L60 20TN RIGHT TURN SIGNAL
4 L302 20LB/YL RIGHT TURN SWITCH SENSE
5 L61 20TN/LG LEFT TURN SIGNAL
6 L91 20DB/PK HAZARD SWITCH SENSE
7 - -
8 L305 20LB/WT LEFT TURN SWITCH SENSE
9 - -
10 L309 20PK/LG HIGH BEAM RELAY CONTROL
11 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
12 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
13 - -
14 F85 16VT/WT FUSED B(+)
15 C79 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 A31 12RD/BK IGNITION SWITCH OUTPUT (RUN-ACC)
25 F60 16RD/WT FUSED B(+)
26 - -
27 A41 12YL IGNITION SWITCH OUTPUT (START)
28 F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
29 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
30 F991 18OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
31 Z234 20BK GROUND
32 F33 20PK/RD FUSED B(+)
33 X12 16WT/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
34 M1 20PK FUSED B(+)
35 M1 20PK (AZC) FUSED B(+)
36 A21 12DB IGNITION SWITCH OUTPUT (RUN-START)
37 - -
38 F70 20PK/BK FUSED B(+)
39 X3 20GY/OR HORN RELAY CONTROL
40 F30 16RD FUSED CIGAR LIGHTER RELAY OUTPUT
41 F33 20PK/RD FUSED B(+)
42 - -
43 V23 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
44 M1 20PK FUSED B(+)
45 Z132 20BK/OR GROUND
46 - -
47 - -
48 F70 20PK/BK FUSED B(+)
49 - -
50 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
51 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
52 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 91

JUNCTION BLOCK C4 - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 A148 10PK/WT FUSED B(+)
2 A148 10OR/WT FUSED B(+)

JUNCTION BLOCK C5 - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 A145 10WT/RD FUSED B(+)
2 A149 12RD/TN FUSED B(+)
3 A147 10RD/GY FUSED B(+)

KNOCK SENSOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K42 18DB/LG KNOCK SENSOR NO. 1 SIGNAL
3 K4 18BK/LB SENSOR GROUND
4 K142 18GY/BK KNOCK SENSOR NO. 2 SIGNAL

LEAK DETECTION PUMP (EXCEPT BUILT-UP-EXPORT) - 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 K125 18OR/DG GENERATOR SOURCE
3 K106 20WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K107 20OR/YL LEAK DETECTION PUMP SWITCH SENSE

LEFT COURTESY LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK/BK FUSED B(+)
2 M2 20YL COURTESY LAMP DRIVER
8W - 80 - 92 8W-80 CONNECTOR PIN-OUT WJ

LEFT DOOR HANDLE COURTESY LAMP - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK/BK FUSED B(+)
2 M20 20YL/BK COURTESY LAMP LOAD SHED
3 M2 20YL/DG COURTESY LAMP DRIVER

LEFT FOG LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L39 20LB FOG LAMP RELAY OUTPUT
2 Z141 20BK (DIESEL/4.7L RHD) GROUND
2 Z141 18BK (EXCEPT DIESEL/4.7L RHD) GROUND

LEFT FRONT DOOR SPEAKER - WHITE 3 WAY

CAV CIRCUIT
1 X55 18LG/DG (BASE)
1 X85 18LB/BK (RHD PREMIUM)
1 X85 18LG/DG (LHD PREMIUM)
2 -
3 X53 18LG/RD (BASE)
3 X87 18LB/RD (RHD PREMIUM)
3 X87 18LG/RD (LHD PREMIUM)
FUNCTION
LEFT FRONT DOOR SPEAKER (-)
LEFT FRONT DOOR SPEAKER (-)
LEFT FRONT DOOR SPEAKER (-)
-
LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT DOOR SPEAKER (+)

LEFT FRONT IMPACT SENSOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 R47 18DB/LB LEFT FRONT IMPACT SENSOR GROUND
4 R49 18LB LEFT FRONT IMPACT SENSOR SIGNAL

LEFT FRONT PARK LAMP - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L7 20BK/PK PARK LAMP RELAY OUTPUT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 93

LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 L7 20BK/PK PARK LAMP RELAY CONTROL
2 Z1 18BK GROUND
3 L61 20TN/LG LEFT TURN SIGNAL

LEFT FRONT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 L7 20BK/PK PARK LAMP RELAY OUTPUT
2 L61 20TN/LG LEFT TURN SIGNAL

LEFT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 L61 20TN/LG LEFT TURN SIGNAL
2 Z1 18BK GROUND

LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
8W - 80 - 94 8W-80 CONNECTOR PIN-OUT WJ

LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L114 18VT/DB HEADLAMP ADJUST SIGNAL
3 L7 20BK/PK PARK LAMP RELAY OUTPUT

LEFT HIGH BEAM HEADLAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A Z1 18BK GROUND
B L33 18RD FUSED LEFT HIGH BEAM OUTPUT

LEFT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 X83 18YL/RD LEFT INSTRUMENT PANEL SPEAKER (+)
2 X81 18YL/BK LEFT INSTRUMENT PANEL SPEAKER (-)

LEFT LIFTGATE AJAR SWITCH - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE

LEFT LOW BEAM HEADLAMP - GRAY 2 WAY

CAV CIRCUIT FUNCTION
A Z1 18BK GROUND
B L43 18VT FUSED LEFT LOW BEAM OUTPUT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 95

LEFT MULTI-FUNCTION SWITCH - WHITE 11 WAY

CAV CIRCUIT FUNCTION
1 L27 20WT/TN FOG LAMP SWITCH SENSE
2 Z234 20BK GROUND
3 - -
4 L80 20WT/DG HEADLAMP SWITCH RETURN
5 L309 20PK/LG HIGH BEAM RELAY CONTROL
6 L40 20BR HIGH BEAM SWITCH SENSE
7 L302 20LB/YL RIGHT TURN SWITCH SENSE
8 L305 20LB/WT LEFT TURN SWITCH SENSE
9 L91 20DB/PK HAZARD SWITCH SENSE
10 E19 20RD PANEL LAMPS DIMMER SIGNAL
11 G52 20YL HEADLAMP SWITCH MUX

LEFT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 G77 18TN/YL LEFT REAR DOOR AJAR SWITCH SENSE
2 Z1 18BK GROUND
3 P36 18PK/VT DOOR UNLOCK DRIVER
4 P35 18OR/VT DOOR LOCK DRIVER

LEFT REAR DOOR SPEAKER - WHITE 3 WAY

CAV CIRCUIT
1 X51 18WT/VT (BASE)
1 X91 18WT/VT (PREMIUM)
2 -
3 X57 18TN/DG (BASE)
3 X93 18TN/DG (PREMIUM)
FUNCTION
LEFT REAR DOOR SPEAKER (+)
LEFT REAR DOOR SPEAKER (+)
-
LEFT REAR DOOR SPEAKER (-)
LEFT REAR DOOR SPEAKER (-)

LEFT REAR LAMP ASSEMBLY - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 L1 18VT/BK BACK-UP LAMP FEED
2 L95 18DG/YL (BUILT-UP-EXPORT) REAR FOG LAMP RELAY OUTPUT
3 L7 18BK/YL PARK LAMP RELAY OUTPUT
4 L63 18DG/RD LEFT TURN SIGNAL
5 Z150 18BK GROUND
6 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
8W - 80 - 96 8W-80 CONNECTOR PIN-OUT WJ

LEFT REAR WHEEL SPEED SENSOR - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 B4 18LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR SIGNAL

LEFT REMOTE RADIO SWITCH - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 X10 20RD/BK RADIO CONTROL MUX RETURN
2 X20 20RD/YL RADIO CONTROL MUX

LEFT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L61 18LG (DIESEL) LEFT TURN SIGNAL
1 L61 18TN/LG (GAS) LEFT TURN SIGNAL
2 Z161 18BK GROUND

LEFT VISOR/VANITY LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK FUSED B(+)
2 M20 20YL/BK COURTESY LAMP LOAD SHED

LICENSE LAMP NO. 1 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L7 18BK/YL PARK LAMP RELAY OUTPUT
2 Z1 18BK GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 97

LICENSE LAMP NO. 2 - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L7 18BK/YL PARK LAMP RELAY OUTPUT
2 Z1 18BK GROUND

LIFTGATE FLIP-UP AJAR SWITCH - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 G80 20VT/YL LIFTGATE FLIP-UP AJAR SWITCH SENSE

LIFTGATE FLIP-UP PUSH BUTTON SWITCH - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 P101 18OR/PK LIFTGATE FLIP-UP SWITCH OUTPUT
2 F70 18PK FUSED B(+)

LIFTGATE FLIP-UP RELEASE SOLENOID - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 P100 18OR/BR LIFTGATE GLASS LIMIT SWITCH OUTPUT

LIFTGATE POWER LOCK MOTOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 P35 18OR/VT DOOR LOCK DRIVER
2 P36 18PK/VT DOOR UNLOCK DRIVER
3 P101 18OR/PK LIFTGATE FLIP-UP SWITCH OUTPUT
4 P100 18OR/BR LIFTGATE GLASS LIMIT SWITCH OUTPUT
8W - 80 - 98 8W-80 CONNECTOR PIN-OUT WJ

LINE PRESSURE SENSOR (4.7L) - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 Z114 14BK/LB GROUND
2 T138 14GY/LB 5 VOLT SUPPLY
3 T130 14VT/TN LINE PRESSURE SENSOR SIGNAL
4 - -

MANIFOLD ABSOLUTE PRESSURE SENSOR (4.0L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K1 18DG/RD MAP SENSOR SIGNAL
3 K7 18OR 5 VOLT SUPPLY

MANIFOLD ABSOLUTE PRESSURE SENSOR (4.7L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K1 18DG/RD MAP SENSOR SIGNAL
2 K4 18BK/LB SENSOR GROUND
3 K7 18OR 5 VOLT SUPPLY

MANUAL TEMPERATURE CONTROL C1 (MTC) - WHITE 11 WAY

CAV CIRCUIT FUNCTION
1 C103 20DG A/C SWITCH SIGNAL
2 Z123 20BK/OR GROUND
3 C67 20RD/LB BLEND AIR DOOR POSITION CONTROL
4 C79 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
5 C81 20LB/WT REAR WINDOW DEFOGGER SWITCH SENSE
6 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
7 E2 20OR PANEL LAMPS DRIVER
8 C4 16TN BLOWER MOTOR LOW DRIVER
9 C5 16LG BLOWER MOTOR M1 DRIVER
10 C6 14LB BLOWER MOTOR M2 DRIVER
11 - -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 99

MANUAL TEMPERATURE CONTROL C2 (MTC) - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 Z118 12BK GROUND
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER

MASS AIR FLOW SENSOR (DIESEL) - BLACK 5 WAY

CAV CIRCUIT FUNCTION
1 - -
2 F15 16RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
3 Z189 20BR MASS AIR FLOW SENSOR GROUND
4 F855 20BR/YL SENSOR REFERENCE VOLTAGE A
5 K155 20YL/WT MASS AIR FLOW SENSOR SIGNAL

MODE DOOR MOTOR/ACTUATOR (AZC) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A C102 20TN/BK (LHD) MODE DOOR DRIVER (B)
A C35 20DG/YL (RHD) MODE DOOR DRIVER (A)
B C35 20DG/YL (LHD) MODE DOOR DRIVER (A)
B C102 20TN/BK (RHD) MODE DOOR DRIVER (B)

NEEDLE MOVEMENT SENSOR (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K67 18BR/BK NEEDLE MOVEMENT SENSOR SIGNAL
2 K68 18LG/YL NEEDLE MOVEMENT SENSOR GROUND

OUTPUT SPEED SENSOR (4.0L) - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 T13 18DB/BK SPEED SENSOR GROUND
2 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
8W - 80 - 100 8W-80 CONNECTOR PIN-OUT WJ

OUTPUT SPEED SENSOR (4.7L) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND

OVERHEAD MAP/COURTESY LAMP - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK FUSED B(+)
2 M20 20YL/BK COURTESY LAMP LOAD SHED
3 M2 20YL/DG COURTESY LAMP DRIVER

OXYGEN SENSOR 1/1 UPSTREAM - 4 WAY

CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
3 K4 18BK/LB SENSOR GROUND
4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL

OXYGEN SENSOR 1/2 DOWNSTREAM - 4 WAY

CAV CIRCUIT FUNCTION
1 F142 18OR/DG (4.0L FUSED AUTO SHUT DOWN RELAY OUTPUT
BUILT-UP-EXPORT)
1 K200 18VT/OR (EXCEPT 4.0L OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
BUILT-UP-EXPORT)
2 K299 18BR/WT (4.0L OXYGEN SENSOR 1/2 HEATER CONTROL
BUILT-UP-EXPORT)
2 Z186 18BK (EXCEPT 4.0L GROUND
BUILT-UP-EXPORT)
3 K4 18BK/LB SENSOR GROUND
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL

OXYGEN SENSOR 2/1 UPSTREAM - 4 WAY

CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K299 18BR/WT OXYGEN SENSOR 2/1 HEATER CONTROL
3 K4 18BK/LB SENSOR GROUND
4 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 101

OXYGEN SENSOR 2/2 DOWNSTREAM - 4 WAY

CAV CIRCUIT FUNCTION
1 K200 18VT/OR (4.0L) OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
1 K200 18BR/WT (4.7L) OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
2 Z186 18BK GROUND
3 K4 18BK/LB SENSOR GROUND
4 K341 18TN/WT (4.0L) OXYGEN SENSOR 2/2 SIGNAL
4 K341 18PK/WT (4.7L) OXYGEN SENSOR 2/2 SIGNAL

PARK/NEUTRAL POSITION SWITCH (4.0L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 L1 18VT/BK BACK-UP LAMP FEED
2 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
3 F22 18WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)

PARK/NEUTRAL POSITION SWITCH (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 L1 18VT/BK BACK-UP LAMP FEED
2 T41 18BR/YL PARK/NEUTRAL POSITION SWITCH SENSE (T41)
3 F22 18WT/TN FUSED IGNITION SWITCH OUTPUT (RUN)

PASSENGER AIRBAG - YELLOW 4 WAY

CAV CIRCUIT FUNCTION
1 R42 20BK/YL PASSENGER SQUIB 1 LINE 1
2 R44 20DG/YL PASSENGER SQUIB 1 LINE 2
3 R64 20TN/YL PASSENGER SQUIB 2 LINE 1
4 R62 20OR/YL PASSENGER SQUIB 2 LINE 2

PASSENGER BLEND DOOR MOTOR/ACTUATOR (LHD) (AZC) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A C96 20WT/DB (LHD) PASSENGER BLEND DOOR DRIVER (B)
B C94 20WT/DG (LHD) PASSENGER BLEND DOOR DRIVER (A)
8W - 80 - 102 8W-80 CONNECTOR PIN-OUT WJ

PASSENGER BLEND DOOR MOTOR/ACTUATOR (RHD) (AZC) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A C94 20WT/DG (RHD) PASSENGER BLEND DOOR DRIVER (A)
B C96 20WT/DB (RHD) PASSENGER BLEND DOOR DRIVER (B)

PASSENGER CURTAIN AIRBAG - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 R72 20LB/WT PASSENGER CURTAIN SQUIB LINE 2
2 R74 20LB/YL PASSENGER CURTAIN SQUIB LINE 1

PASSENGER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 G74 18TN/RD PASSENGER DOOR AJAR SWITCH SENSE
2 Z1 18BK GROUND
3 P36 18PK/VT DOOR UNLOCK DRIVER
4 P35 18OR/VT DOOR LOCK DRIVER

PASSENGER DOOR MODULE C1 - WHITE 15 WAY

CAV CIRCUIT FUNCTION
1 A146 12OR/WT FUSED B(+)
2 Q24 16DG PASSENGER REAR WINDOW DRIVER (DOWN)
3 Q14 16GY PASSENGER REAR WINDOW DRIVER (UP)
4 Z1 12BK GROUND
5 P35 18OR/VT DOOR LOCK DRIVER
6 - -
7 P36 18PK/VT DOOR UNLOCK DRIVER
8 - -
9 D25 20YL/VT PCI BUS
10 - -
11 G74 18TN/RD PASSENGER DOOR AJAR SWITCH SENSE
12 E20 20OR/DB PASSENGER REAR DOOR SWITCH ILLUMINATION
13 Q12 16BR PASSENGER WINDOW DRIVER (UP)
14 - -
15 Q22 16VT PASSENGER WINDOW DRIVER (DOWN)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 103

PASSENGER DOOR MODULE C2 - BLACK 12 WAY

CAV CIRCUIT FUNCTION
1 P95 20OR MIRROR HORIZONTAL DRIVER
2 C118 20BK/WT MIRROR HEATER GROUND
3 P64 20VT MIRROR VERTICAL POSITION SIGNAL
4 P69 20GY MIRROR SENSOR GROUND
5 P65 20DG MIRROR HORIZONTAL POSITION SIGNAL
6 C117 20BK MIRROR HEATER 12 VOLT SUPPLY
7 P91 20WT MIRROR COMMON DRIVER
8 P93 20RD MIRROR VERTICAL DRIVER
9 M21 20PK/DG COURTESY LAMP DRIVER
10 P110 20YL (BUILT-UP-EXPORT) FOLDING MIRROR RETURN
11 P99 20DB (BUILT-UP-EXPORT) FOLDING MIRROR FEED
12 L121 20BK/RD COURTESY LAMP GROUND

PASSENGER FRONT DOOR COURTESY LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 M21 20PK/DG COURTESY LAMP DRIVER
2 L121 20BK/RD COURTESY LAMP GROUND

PASSENGER FRONT POWER WINDOW MOTOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Q22 16VT PASSENGER WINDOW DRIVER (DOWN)
2 Q12 16BR PASSENGER WINDOW DRIVER (UP)

PASSENGER HEATED SEAT BACK (PREMIUM I/III) - 3 WAY

CAV CIRCUIT FUNCTION
1 P88 16BK/BR HEATED SEAT DRIVER
2 Z5 16BK/VT GROUND
3 - -
8W - 80 - 104 8W-80 CONNECTOR PIN-OUT WJ

PASSENGER HEATED SEAT CUSHION (PREMIUM I/III) - 4 WAY

CAV CIRCUIT FUNCTION
1 P130 16DG/WT PASSENGER SEAT HEATER B(+) DRIVER
2 P88 16BK/BR HEATED SEAT DRIVER
3 P86 20DG/YL PASSENGER SEAT TEMPERATURE SENSOR INPUT
4 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY

PASSENGER HEATED SEAT SWITCH - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 P134 20TN/LG PASSENGER SEAT HEATER SWITCH MUX
2 E2 20OR PANEL LAMPS DRIVER
3 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
4 - -
5 Z300 20BK GROUND
6 P132 20OR/BK SEAT HEATER SWITCH SENSOR GROUND

PASSENGER LUMBAR MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 P105 16LG/DG LUMBAR FORWARD SWITCH SENSE
2 P104 16YL/RD LUMBAR REARWARD SWITCH SENSE

PASSENGER LUMBAR SWITCH (MIDLINE/PREMIUM) - WHITE 6 WAY

CAV CIRCUIT FUNCTION
1 - -
2 Z1 16BK GROUND
3 P104 16YL/RD (RHD) LUMBAR REARWARD SWITCH SENSE
3 P105 16LG/DB (LHD) LUMBAR FORWARD SWITCH SENSE
4 P105 16LG/DB (RHD) LUMBAR FORWARD SWITCH SENSE
4 P104 16YL/RD (LHD) LUMBAR REARWARD SWITCH SENSE
5 Z1 16BK GROUND
6 F37 16RD/LB FUSED B(+)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 105

PASSENGER POWER MIRROR - BLACK 12 WAY

CAV CIRCUIT FUNCTION
1 C117 20BK MIRROR HEATER 12 VOLT SUPPLY
2 P65 20DG MIRROR HORIZONTAL POSITION SIGNAL
3 P69 2GY MIRROR SENSOR GROUND
4 P64 20VT MIRROR VERTICAL POSITION SIGNAL
5 C118 20BK/WT MIRROR HEATER GROUND
6 P95 20OR MIRROR HORIZONTAL DRIVER
7 - -
8 P99 20DB (BUILT-UP-EXPORT) FOLDING MIRROR FEED
9 P110 20YL (BUILT-UP-EXPORT) FOLDING MIRROR RETURN
10 - -
11 P93 20RD MIRROR VERTICAL DRIVER
12 P91 20WT MIRROR COMMON DRIVER

PASSENGER POWER SEAT FRONT RISER MOTOR - RED 2 WAY

CAV CIRCUIT FUNCTION
1 P18 16YL/LG PASSENGER SEAT FRONT UP DRIVER
2 P20 16RD/LG PASSENGER SEAT FRONT DOWN DRIVER

PASSENGER POWER SEAT HORIZONTAL MOTOR - RED 2 WAY

CAV CIRCUIT FUNCTION
1 P16 16RD/YL PASSENGER SEAT HORIZONTAL REARWARD DRIVER
2 P14 16YL/LB PASSENGER SEAT HORIZONTAL FORWARD DRIVER

PASSENGER POWER SEAT REAR RISER MOTOR - RED 2 WAY

CAV CIRCUIT FUNCTION
1 P10 16YL/WT PASSENGER SEAT REAR UP DRIVER
2 P12 16RD/WT PASSENGER SEAT REAR DOWN DRIVER
8W - 80 - 106 8W-80 CONNECTOR PIN-OUT WJ

PASSENGER POWER SEAT RECLINER MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A P42 16BR/WT PASSENGER SEAT RECLINER DOWN DRIVER
B P44 16GY/LB PASSENGER SEAT RECLINER UP DRIVER

PASSENGER POWER SEAT SWITCH (MIDLINE/PREMIUM) - GREEN 10 WAY

CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 P44 16GY/LB PASSENGER SEAT RECLINER UP DRIVER
3 P16 16RD/YL PASSENGER SEAT HORIZONTAL REARWARD DRIVER
4 P42 16BR/WT PASSENGER SEAT RECLINER DOWN DRIVER
5 F37 16RD/LB FUSED B(+)
6 P14 16YL/LB PASSENGER SEAT HORIZONTAL FORWARD DRIVER
7 P18 16YL/LG (RHD) PASSENGER SEAT FRONT UP DRIVER
7 P20 16RD/LG (LHD) PASSENGER SEAT FRONT DOWN DRIVER
8 P10 16YL/WT (RHD) PASSENGER SEAT REAR UP DRIVER
8 P12 16RD/WT (LHD) PASSENGER SEAT REAR DOWN DRIVER
9 P12 16RD/WT (RHD) PASSENGER SEAT REAR DOWN DRIVER
9 P10 16YL/WT (LHD) PASSENGER SEAT REAR UP DRIVER
10 P20 16RD/LG (RHD) PASSENGER SEAT FRONT DOWN DRIVER
10 P18 16YL/LG (LHD) PASSENGER SEAT FRONT UP DRIVER

PASSENGER REAR POWER WINDOW MOTOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Q124 16DG/WT WINDOW DRIVER (DOWN)
2 Q114 16GY/WT WINDOW DRIVER (UP)

PASSENGER REAR POWER WINDOW SWITCH - BLUE 6 WAY

CAV CIRCUIT FUNCTION
1 Q14 16GY PASSENGER REAR WINDOW DRIVER (UP)
2 Q114 16GY/WT WINDOW DRIVER (UP)
3 E21 20OR/RD PASSENGER REAR DOOR SWITCH ILLUMINATION
4 Q24 16DG PASSENGER REAR WINDOW DRIVER (DOWN)
5 Q124 16DG/WT WINDOW DRIVER (DOWN)
6 Z1 16BK GROUND

PASSENGER SEAT BELT SWITCH - 2 WAY

CAV CIRCUIT FUNCTION
1 R58 20GY PASSENGER SEAT BELT SWITCH SENSE
2 R60 20VT PASSENGER SEAT BELT SWITCH GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 107

PASSENGER SIDE IMPACT SENSOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 R134 20LB/BR PASSENGER SIDE IMPACT SENSOR GROUND
4 R132 20LG/VT PASSENGER SIDE IMPACT SENSOR SIGNAL

POWER AMPLIFIER C1 (PREMIUM RADIO) - WHITE 18 WAY

CAV CIRCUIT FUNCTION
1 D25 18YL/VT PCI BUS
2 F60 16RD/WT FUSED B(+)
3 Z9 16BK GROUND
4 - -
5 X58 18DB/OR RIGHT REAR SPEAKER (-)
6 X57 18DG/WT LEFT REAR SPEAKER (-)
7 X56 18DB/PK RIGHT FRONT SPEAKER (-)
8 X55 18BR/RD LEFT FRONT SPEAKER (-)
9 - -
10 F60 16RD/WT FUSED B(+)
11 Z9 16BK GROUND
12 - -
13 X64 18BR/WT ENABLE SIGNAL TO AMPLIFIER
14 - -
15 X52 18DB/WT RIGHT REAR SPEAKER (+)
16 X51 18WT/DG LEFT REAR SPEAKER (+)
17 X54 18VT RIGHT FRONT SPEAKER (+)
18 X53 18DG/OR LEFT FRONT SPEAKER (+)

POWER AMPLIFIER C2 (PREMIUM RADIO) - WHITE 12 WAY

CAV CIRCUIT FUNCTION
1 X90 18WT/VT RIGHT REAR DOOR SPEAKER (+)
2 X92 18TN/DG RIGHT REAR DOOR SPEAKER (-)
3 X85 18LG/DG LEFT FRONT DOOR SPEAKER (-)
4 X83 18YL/RD LEFT INSTRUMENT PANEL SPEAKER (+)
5 X84 18OR/GY RIGHT INSTRUMENT PANEL SPEAKER (-)
6 X93 18DG/WT LEFT REAR DOOR SPEAKER (+)
7 X91 18WT/DG LEFT REAR DOOR SPEAKER (-)
8 X87 18LG/RD LEFT FRONT DOOR SPEAKER (+)
9 X80 18LB/BK RIGHT FRONT DOOR SPEAKER (-)
10 X82 18LB/RD RIGHT FRONT DOOR SPEAKER (+)
11 X81 18YL/BK LEFT INSTRUMENT PANEL SPEAKER (-)
12 X86 18OR/RD RIGHT INSTRUMENT PANEL SPEAKER (+)
8W - 80 - 108 8W-80 CONNECTOR PIN-OUT WJ

POWER CONNECTOR - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 F85 16VT/WT FUSED B(+)
2 Z234 16BK GROUND

POWERTRAIN CONTROL MODULE C1 (GAS) - BLACK 32 WAY

CAV CIRCUIT FUNCTION
1 K93 14TN/OR COIL DRIVER NO. 3
2 F991 18OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 K94 14TN/LG (4.7L) COIL DRIVER NO. 4
4 K4 18BK/LB SENSOR GROUND
5 K96 14TN/LB (4.7L) COIL DRIVER NO. 6
6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
7 K91 14TN/RD COIL DRIVER NO. 1
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 K98 14LB/RD (4.7L) COIL DRIVER NO. 8
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 - -
13 - -
14 K77 18LG/BK TRANSFER CASE POSITION SENSOR INPUT
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5 VOLT SUPPLY
18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/BK IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 K95 14TN/DG (4.7L) COIL DRIVER NO. 5
22 A7 14RD/BK FUSED B(+)
23 K22 18OR/RD THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD (EXCEPT 4.0L OXYGEN SENSOR 2/1 SIGNAL
BUILT-UP-EXPORT)
27 K1 18DG/RD MAP SENSOR SIGNAL
28 - -
29 K341 18TN/WT (4.0L EXCEPT OXYGEN SENSOR 2/2 SIGNAL
BUILT-UP-EXPORT)
29 K341 18PK/WT (4.7L) OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z82 14BK/WT GROUND
32 Z81 14BK/TN GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 109

POWERTRAIN CONTROL MODULE C2 (GAS) - WHITE 32 WAY

CAV CIRCUIT FUNCTION
1 T54 18VT (4.0L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
2 K26 18VT (4.7L) FUEL INJECTOR NO. 7 DRIVER
3 - -
4 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
6 K38 18GY FUEL INJECTOR NO. 5 DRIVER
7 K97 14BR (4.7L) COIL DRIVER NO. 7
8 K88 18PK (4.0L) GOVERNOR PRESSURE SOLENOID CONTROL
9 K92 14TN/PK COIL DRIVER NO. 2
10 K20 18DG GENERATOR FIELD DRIVER
11 T20 18LB (4.0L) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 K58 18BR/DB FUEL INJECTOR NO. 6 DRIVER
13 K28 18GY/LB (4.7L) FUEL INJECTOR NO. 8 DRIVER
14 - -
15 K12 18TN FUEL INJECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
17 K173 18LG RADIATOR FAN RELAY CONTROL
18 - -
19 C18 18DB A/C PRESSURE SIGNAL
20 - -
21 T60 18BR (4.0L) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 T13 18DB/BK (4.0L) SPEED SENSOR GROUND
26 - -
27 B22 18DG/YL VEHICLE SPEED SENSOR SIGNAL
28 T14 18LG/WT (4.0L) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/RD (4.0L) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK/YL (4.0L) TRANSMISSION CONTROL RELAY CONTROL
31 K6 18VT/BK 5 VOLT SUPPLY
32 - -
8W - 80 - 110 8W-80 CONNECTOR PIN-OUT WJ

POWERTRAIN CONTROL MODULE C3 (GAS) - GRAY 32 WAY

CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2 - -
3 K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 K42 18DB/LG (4.7L HIGH OUTPUT) KNOCK SENSOR NO. 1 SIGNAL
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL (EXCEPT 4.0L OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
BUILT-UP-EXPORT)
10 K106 18WT/DG (EXCEPT LEAK DETECTION PUMP SOLENOID CONTROL
BUILT-UP-EXPORT)
11 V32 18OR/DG SPEED CONTROL SUPPLY
12 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT
13 T10 18YL/DG (4.7L RHD) TORQUE MANAGEMENT REQUEST SENSE
13 T6 18OR/WT (4.0L LHD) OVERDRIVE OFF SWITCH SENSE
13 T10 18DG/LG (4.7L LHD) TORQUE MANAGEMENT REQUEST SENSE
13 T6 18OR/BK (4.0L RHD) OVERDRIVE OFF SWITCH SENSE
14 K107 18OR/PK (EXCEPT LEAK DETECTION PUMP SWITCH SENSE
BUILT-UP-EXPORT)
15 K25 18VT/LG BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT OXYGEN SENSOR 1/2 HEATER CONTROL
17 - -
18 K142 18GY/BK (4.7L HIGH OUTPUT) KNOCK SENSOR NO. 2 SIGNAL
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 K29 18WT/PK SECONDARY BRAKE SWITCH SIGNAL
25 K125 18WT/DB GENERATOR SOURCE
26 K226 18LB/YL FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D32 18LG (LHD) SCI RECEIVE
29 D32 18LG/DG (RHD) SCI RECEIVE
30 D25 18VT/YL PCI BUS
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL

RADIATOR FAN MOTOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 C23 12DG RADIATOR FAN RELAY OUTPUT
2 Z4 12BK/PK GROUND
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 111

RADIATOR FAN RELAY - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 C24 20DB/PK RADIATOR FAN RELAY CONTROL
3 C23 12DG RADIATOR FAN RELAY OUTPUT
4 A16 12GY FUSED B(+)

RADIO C1 - GRAY 22 WAY

CAV CIRCUIT FUNCTION
1 F60 16RD/WT FUSED B(+)
2 X12 16WT/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
3 E2 20OR PANEL LAMPS DRIVER
4 - -
5 - -
6 - -
7 X54 18VT RIGHT FRONT SPEAKER (+)
8 X56 18DB/PK RIGHT FRONT SPEAKER (-)
9 X55 18BR/RD LEFT FRONT SPEAKER (-)
10 X53 18DG/OR LEFT FRONT SPEAKER (+)
11 Z9 16BK GROUND
12 F60 16RD/WT FUSED B(+)
13 X64 18BR/WT ENABLE SIGNAL TO AMPLIFIER
14 D25 20YL/VT/DB PCI BUS
15 - -
16 - -
17 - -
18 X51 18WT/DG LEFT REAR SPEAKER (+)
19 X57 18DG/WT LEFT REAR SPEAKER (-)
20 X58 18DB/OR RIGHT REAR SPEAKER (-)
21 X52 18DB/WT RIGHT REAR SPEAKER (+)
22 Z9 16BK GROUND

RADIO C2 - GRAY 10 WAY

CAV CIRCUIT FUNCTION
1 X40 20WT/RD AUDIO OUT RIGHT
2 Z4 20WT/BK GROUND
3 Z5 20BK/LB SHIELD
4 - -
5 X112 20RD IGNITION SWITCH OUTPUT (RUN-ACC)
6 X41 20WT/DG AUDIO OUT LEFT
7 Z17 20BK GROUND
8 - -
9 - -
10 X160 20YL FUSED B(+)
8W - 80 - 112 8W-80 CONNECTOR PIN-OUT WJ

RAIN SENSOR (AUTOWIPE) - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 - -
2 D25 20BK/PK PCI BUS
3 - -
4 Z155 20BK/OR GROUND
5 Q30 20BK/LB ACCESSORY DELAY RELAY OUTPUT
6 - -

REAR POWER OUTLET - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 A148 16LG/RD FUSED B(+)
2 - -
3 Z151 16BK GROUND

REAR WASHER PUMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z141 18BK GROUND
2 V20 18BK/WT REAR WASHER PUMP MOTOR CONTROL

REAR WIPER MOTOR - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 V13 18BR/LG REAR WIPER MOTOR CONTROL
3 G80 20VT/YL LIFTGATE FLIP-UP AJAR SWITCH SENSE
4 V22 18BR/YL REAR WIPER MOTOR DELAY CONTROL
5 F70 18BK FUSED B(+)
6 - -

RECIRCULATION DOOR MOTOR/ACTUATOR (AZC) - BLACK 2 WAY

CAV CIRCUIT
A C32 20GY/DB (LHD)
A C100 20YL/DB (RHD)
B C100 20YL/DB (LHD)
B C32 20GY/DB (RHD)
FUNCTION
RECIRCULATION DOOR DRIVER (A)
RECIRCULATION DOOR DRIVER (B)
RECIRCULATION DOOR DRIVER (B)
RECIRCULATION DOOR DRIVER (A)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 113

RED BRAKE WARNING INDICATOR SWITCH - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 Z231 18BK GROUND
2 G9 18GY/BK RED BRAKE WARNING INDICATOR DRIVER

REMOTE KEYLESS MODULE (JAPAN) - BLUE 6 WAY

CAV CIRCUIT FUNCTION
1 K25 20RD/GY ANTENNA SIGNAL
2 K25 20RD/GY ANTENNA SIGNAL
3 M1 18PK FUSED B(+)
4 Z1 18BK GROUND
5 D30 20VT/YL DIAGNOSTIC OUT
6 D30 20VT/YL DIAGNOSTIC OUT

RIGHT COURTESY LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK/BK FUSED B(+)
2 M2 20YL COURTESY LAMP DRIVER

RIGHT DOOR HANDLE COURTESY LAMP - WHITE 3 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK FUSED B(+)
2 M20 20YL/BK COURTESY LAMP LOAD SHED
3 M2 20YL/DG COURTESY LAMP DRIVER

RIGHT FOG LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L39 20LB FOG LAMP RELAY OUTPUT
2 Z142 18BK GROUND
8W - 80 - 114 8W-80 CONNECTOR PIN-OUT WJ

RIGHT FRONT DOOR SPEAKER - WHITE 3 WAY

CAV CIRCUIT
1 X56 18LB/BK (BASE)
1 X80 18LG/DG (RHD PREMIUM)
1 X80 18LB/BK (LHD PREMIUM)
2 -
3 X54 18LB/RD (BASE)
3 X82 18LG/RD (RHD PREMIUM)
3 X82 18LB/RD (LHD PREMIUM)
FUNCTION
RIGHT FRONT DOOR SPEAKER (-)
RIGHT FRONT DOOR SPEAKER (-)
RIGHT FRONT DOOR SPEAKER (-)
-
RIGHT FRONT DOOR SPEAKER (+)
RIGHT FRONT DOOR SPEAKER (+)
RIGHT FRONT DOOR SPEAKER (+)

RIGHT FRONT IMPACT SENSOR - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 R46 18BR/LB RIGHT FRONT IMPACT SENSOR GROUND
4 R48 18TN RIGHT FRONT IMPACT SENSOR SIGNAL

RIGHT FRONT PARK LAMP - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L7 20BK/PK PARK LAMP RELAY OUTPUT

RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 L7 20BK/PK PARK LAMP RELAY OUTPUT
2 Z1 18BK GROUND
3 L60 20TN RIGHT TURN SIGNAL
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 115

RIGHT FRONT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 L7 20BK/PK PARK LAMP RELAY OUTPUT
2 L60 20TN RIGHT TURN SIGNAL

RIGHT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 L60 20TN RIGHT TURN SIGNAL
2 Z1 18BK GROUND

RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL

RIGHT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L114 18VT/DB HEADLAMP ADJUST SIGNAL
3 L7 20BK/PK PARK LAMP RELAY OUTPUT
8W - 80 - 116 8W-80 CONNECTOR PIN-OUT WJ

RIGHT HIGH BEAM HEADLAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A Z1 18BK GROUND
B L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT

RIGHT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 X86 18OR/RD RIGHT INSTRUMENT PANEL SPEAKER (+)
2 X84 18OR/BK RIGHT INSTRUMENT PANEL SPEAKER (-)

RIGHT LIFTGATE AJAR SWITCH - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE

RIGHT LOW BEAM HEADLAMP - GRAY 2 WAY

CAV CIRCUIT FUNCTION
A Z1 18BK GROUND
B L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT

RIGHT MULTI-FUNCTION SWITCH - WHITE 10 WAY

CAV CIRCUIT FUNCTION
1 V23 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V20 18BK/WT REAR WASHER PUMP MOTOR CONTROL
3 V10 20BR WASHER PUMP SWITCH SENSE
4 - -
5 V13 18BR/LG REAR WIPER MOTOR CONTROL
6 V22 18BR/YL REAR WIPER MOTOR DELAY CONTROL
7 V9 20WT/BK WINDSHIELD WIPER SWITCH RETURN
8 V52 20DG/RD WINDSHIELD WIPER SWITCH MUX
9 V48 20RD/GY WIPER HIGH CONTROL
10 - -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 117

RIGHT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 G76 18TN/YL RIGHT REAR DOOR AJAR SWITCH SENSE
2 Z1 18BK GROUND
3 P36 18PK/VT DOOR UNLOCK DRIVER
4 P35 18OR/VT DOOR LOCK DRIVER

RIGHT REAR DOOR SPEAKER - WHITE 3 WAY

CAV CIRCUIT
1 X52 18WT/VT (BASE)
1 X90 18WT/VT (PREMIUM)
2 -
3 X58 18TN/DG (BASE)
3 X92 18TN/DG (PREMIUM)
FUNCTION
RIGHT REAR DOOR SPEAKER (+)
RIGHT REAR DOOR SPEAKER (+)
-
RIGHT REAR DOOR SPEAKER (-)
RIGHT REAR DOOR SPEAKER (-)

RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 L1 18VT/BK BACK-UP LAMP FEED
2 L95 18DG/YL (BUILT-UP-EXPORT) REAR FOG LAMP RELAY OUTPUT
3 L7 18BK/YL PARK LAMP RELAY OUTPUT
4 L62 18BR/RD RIGHT TURN SIGNAL
5 Z151 18BK GROUND
6 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL

RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL

RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 X10 20RD/BK RADIO CONTROL MUX RETURN
2 X20 20RD/YL RADIO CONTROL MUX
8W - 80 - 118 8W-80 CONNECTOR PIN-OUT WJ

RIGHT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 Z142 18BK GROUND

RIGHT VISOR/VANITY LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 F70 20PK FUSED B(+)
2 M20 20YL/BK COURTESY LAMP LOAD SHED

SEAT BELT SWITCH - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z1 20BK GROUND

SEAT MODULE C1 (PREMIUM) - BLACK 20 WAY

CAV CIRCUIT FUNCTION
1 P15 20YL/LB (PREMIUM II/III) SEAT HORIZONTAL FORWARD SWITCH SENSE
2 - -
3 P11 20YL/WT(PREMIUM II/III) SEAT REAR UP SWITCH SENSE
4 P43 20GY/LB (PREMIUM II/III) RECLINER UP SWITCH SENSE
5 P19 20YL/LG (PREMIUM II/III) SEAT FRONT UP SWITCH SENSE
6 P86 20DG/YL (PREMIUM I/III) PASSENGER SEAT TEMPERATURE SENSOR INPUT
7 P27 20LB/RD (PREMIUM II/III) REAR RISER POSITION SIGNAL
8 P25 20VT/RD (PREMIUM II/III) SEAT HORIZONTAL POSITION SIGNAL
9 P135 20LB/BK (PREMIUM I/III) DRIVER SEAT TEMPERATURE SENSOR INPUT
10 P28 20BR/RD (PREMIUM II/III) SEAT POSITION SENSOR GROUND
11 P41 20GY/WT (PREMIUM II/III) RECLINER DOWN SWITCH SENSE
12 P17 20RD/YL (PREMIUM II/III) SEAT HORIZONTAL REARWARD SWITCH SENSE
13 - -
14 P21 20RD/LG (PREMIUM II/III) SEAT FRONT DOWN SWITCH SENSE
15 P13 20RD/WT (PREMIUM II/III) SEAT REAR DOWN SWITCH SENSE
16 P47 20LB (PREMIUM II/III) RECLINER POSITION SIGNAL
17 P26 20BR (PREMIUM II/III) FRONT RISER POSITION SIGNAL
18 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
19 Z2 20BK/OR GROUND
20 D25 20VT/YL PCI BUS
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 119

SEAT MODULE C2 (PREMIUM) - ORANGE 20 WAY

CAV CIRCUIT FUNCTION
1 F35 16RD FUSED B(+)
2 P131 16BK/OR (PREMIUM I/III) DRIVER SEAT HEATER B(+) DRIVER
3 Z1 16BK GROUND
4 P119 16YL/RD (PREMIUM II/III) SEAT FRONT UP DRIVER
5 P121 16RD/GY (PREMIUM II/III) SEAT FRONT DOWN DRIVER
6 P111 16YL/DB (PREMIUM II/III) SEAT REAR UP DRIVER
7 P113 16RD/BK (PREMIUM II/III) SEAT REAR DOWN DRIVER
8 - -
9 P115 16GY/LG (PREMIUM II/III) SEAT HORIZONTAL FORWARD DRIVER
10 F35 16RD FUSED B(+)
11 P130 16DG/WT (PREMIUM I/III) PASSENGER SEAT HEATER B(+) DRIVER
12 Z1 16BK GROUND
13 - -
14 P9 20RD/LB (PREMIUM II/III) SEAT SWITCH B(+) SUPPLY
15 Z6 16BK/YL (PREMIUM I/III) GROUND
16 Z5 16BK/VT (PREMIUM I/III) GROUND
17 - -
18 P141 16GY/WT (PREMIUM II/III) SEAT RECLINER DOWN DRIVER
19 P143 16GY/LB (PREMIUM II/III) SEAT RECLINER UP DRIVER
20 P117 16RD/BR (PREMIUM II/III) SEAT HORIZONTAL REARWARD DRIVER

SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 M1 20PK FUSED B(+)
2 Z132 20BK/OR GROUND
3 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
4 - -
5 D25 20YL/VT/BK PCI BUS
6 - -

SHIFTER ASSEMBLY (C201 DIESEL) - WHITE 12 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 K2 20WT/PK SECONDARY BRAKE SWITCH SIGNAL
5 D25 20RD PCI BUS
6 - -
7 D21 20PK SCI TRANSMIT
8 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 T2 20TN/BK BACK-UP LAMP RELAY CONTROL
10 Z234 20WT GROUND
11 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
12 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
8W - 80 - 120 8W-80 CONNECTOR PIN-OUT WJ

SHIFTER ASSEMBLY (GAS) - WHITE 6 WAY

CAV CIRCUIT FUNCTION
1 E2 20OR PANEL LAMPS DRIVER
2 Z234 18BK GROUND
3 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
4 Z300 18BK GROUND
5 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 K29 18WT/PK SECONDARY BRAKE SWITCH SIGNAL

SHIFTER ASSEMBLY C1 (DIESEL) - BLACK 12 WAY

CAV CIRCUIT FUNCTION
1 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
4 T2 20TN/BK BACK-UP LAMP RELAY CONTROL
5 D25 20OR PCI BUS
6 W0 20DB/WT SHIFTER C1 SENSE
7 W1 20VT/WT SHIFTER C2 SENSE
8 W2 20VT SHIFTER C3 SENSE
9 W3 20BK SHIFTER C4 SENSE
10 W4 20PK/OR SHIFTER C5 SENSE
11 Z234 20WT GROUND
12 Z234 20WT GROUND

SHIFTER ASSEMBLY C2 (DIESEL) - 6 WAY

CAV CIRCUIT FUNCTION
1 - -
2 - -
3 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
4 K2 20WT/PK SECONDARY BRAKE SWITCH SIGNAL
5 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 Y1 20DB/PK PARK LOCKOUT SOLENOID CONTROL

SIREN (BUILT-UP-EXPORT) - 3 WAY

CAV CIRCUIT FUNCTION
1 Z141 18BK GROUND
2 X75 18GY/LB (DIESEL) SIREN SIGNAL CONTROL
2 X75 18GY/LG (GAS) SIREN SIGNAL CONTROL
3 M1 18PK FUSED B(+)

SPEED CONTROL SWITCH NO. 1 - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 K4 20BK/LB SENSOR GROUND
3 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
4 - -
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 121

SPEED CONTROL SWITCH NO. 2 - BLACK 4 WAY

CAV CIRCUIT FUNCTION
1 - -
2 K4 20BK/LB SENSOR GROUND
3 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
4 - -

SUNROOF CONTROL MODULE - 8 WAY

CAV CIRCUIT FUNCTION
A Q46 20OR/WT SUNROOF MOTOR POSITION SENSOR SIGNAL
B Q41 20WT SUNROOF OPEN
C Q43 20VT SUNROOF VENT
D Z1 16BK GROUND
E - -
F Q30 16DB ACCESSORY DELAY RELAY OUTPUT
G Q5 16RD SUNROOF MOTOR B(+)
H Q6 16OR SUNROOF MOTOR B(-)

SUNROOF MOTOR C1 - WHITE 2 WAY

CAV CIRCUIT FUNCTION
1 Q5 16RD SUNROOF MOTOR B(+)
2 Q6 16OR SUNROOF MOTOR B(-)

SUNROOF MOTOR C2 - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 Q46 20OR/WT SUNROOF MOTOR POSITION SENSOR SIGNAL
3 - -

SUNROOF SWITCH - GRAY 5 WAY

CAV CIRCUIT FUNCTION
1 Q43 20VT SUNROOF VENT
2 - -
3 Z150 20BK GROUND
4 - -
5 Q41 20WT SUNROOF OPEN
8W - 80 - 122 8W-80 CONNECTOR PIN-OUT WJ

TEMPERATURE VALVE ACTUATOR (MTC) - BLACK 6 WAY

CAV CIRCUIT FUNCTION
5 - -
6 - -
7 Z132 20BK/OR GROUND
8 C67 20RD/LB BLEND AIR DOOR POSITION CONTROL
9 - -
10 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)

THROTTLE POSITION SENSOR (4.0L) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K4 18BK/LB SENSOR GROUND
3 K22 18OR/RD THROTTLE POSITION SENSOR SIGNAL

THROTTLE POSITION SENSOR (4.7L) - 3 WAY

CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K22 18OR/RD THROTTLE POSITION SENSOR SIGNAL
3 K4 18BK/LB SENSOR GROUND

TRAILER TOW BRAKE LAMP RELAY - BLACK 5 WAY

CAV CIRCUIT FUNCTION
30 (3) F9 14RD/BK FUSED B(+)
85 (2) L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
86 (1) Z150 18BK GROUND
87 (5) L95 14DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A L94 14OR/WT TRAILER TOW BRAKE LAMP RELAY OUTPUT
(4)

TRAILER TOW CIRCUIT BREAKER - BLACK 2 WAY

CAV CIRCUIT FUNCTION
A F30 14RD/WT FUSED CIGAR LIGHTER RELAY OUTPUT
B F30 14RD/TN CIGAR LIGHTER RELAY OUTPUT
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 123

TRAILER TOW CONNECTOR - BLACK 10 WAY

CAV CIRCUIT FUNCTION
1 - -
2 L62 14BR/RD RIGHT TURN SIGNAL
3 L1 18VT/BK BACK-UP LAMP FEED
4 F30 14RD/WT FUSED CIGAR LIGHTER RELAY OUTPUT
5 L7 18BK/YL PARK LAMP RELAY OUTPUT
6 - -
7 B40 14LB TRAILER TOW BRAKE B(+)
8 Z150 14BK GROUND
9 Z150 14BK GROUND
10 L63 14DG/RD LEFT TURN SIGNAL

TRAILER TOW LEFT TURN RELAY - BLACK 5 WAY

CAV CIRCUIT FUNCTION
30 (3) L63 16DG/RD LEFT TURN SIGNAL
85 (2) L63 14DG/RD LEFT TURN SIGNAL
86 (1) Z150 18BK GROUND
87 (5) L94 14OR/WT TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A (4) L95 14DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT

TRAILER TOW RIGHT TURN RELAY - BLACK 5 WAY

CAV CIRCUIT FUNCTION
30 (3) L62 14BR/RD RIGHT TURN SIGNAL
85 (2) L62 20BR/RD RIGHT TURN SIGNAL
86 (1) Z150 18BK GROUND
87 (5) L94 14OR/WT TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A (4) L95 14DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT

TRANSFER CASE POSITION SENSOR - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 K77 20BR/WT (DIESEL) TRANSFER CASE POSITION SENSOR SIGNAL
1 K77 18LG/BK (GAS) TRANSFER CASE POSITION SENSOR INPUT
2 K4 20BK/LB (DIESEL) SENSOR GROUND
2 K4 18BK/LB (GAS) SENSOR GROUND
8W - 80 - 124 8W-80 CONNECTOR PIN-OUT WJ

TRANSMISSION CONTROL MODULE (4.7L) - BLACK 60 WAY

CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 T2 18TN/BK TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
6 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18PK SCI TRANSMIT
8 F45 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 F991 18OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 K22 18OR/RD THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 18PK/YL TRANSMISSION CONTROL RELAY CONTROL
16 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
18 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T120 18LG LR SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T130 14VT/TN LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
36 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
37 Z113 14BK/WT GROUND
38 T138 14GY/LB 5 VOLT SUPPLY
39 Z112 14BK/YL GROUND
40 T140 18VT/LG MS SOLENOID CONTROL
41 T41 18WT TRS T41 SENSE
42 T42 18VT/WT TRS T42 SENSE
43 D25 18YL/VT PCI BUS
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T147 18LB 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 18VT/WT OVERDRIVE OFF SWITCH SENSE
50 T150 18BR/LB LR PRESSURE SWITCH SENSE
51 K4 18BK/LB SENSOR GROUND
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z114 14BK/LG GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T59 18PK UNDERDRIVE SOLENOID CONTROL
56 A30 14RD/WT FUSED B(+)
57 Z12 14BK/TN GROUND
58 - -
59 T159 18DG/WT 4C SOLENOID CONTROL
60 T60 18BR OVERDRIVE SOLENOID CONTROL
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 125

TRANSMISSION CONTROL MODULE C1 (DIESEL) - BLACK 18 WAY

CAV CIRCUIT FUNCTION
1 D21 20PK SCI TRANSMIT
2 - -
3 W4 20PK/OR SHIFTER C5 SENSE
4 Y1 20DB/PK PARK LOCKOUT SOLENOID CONTROL
5 - -
6 - -
7 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
8 - -
9 - -
10 - -
23 - -
24 - -
25 W0 20DB/WT SHIFTER C1 SENSE
26 W1 20VT/WT SHIFTER C2 SENSE
27 W2 20VT SHIFTER C3 SENSE
28 W3 20BK SHIFTER C4 SENSE
29 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
30 Z234 20WT GROUND

TRANSMISSION CONTROL MODULE C2 (DIESEL) - BLACK 14 WAY

CAV CIRCUIT FUNCTION
12 T52 18RD/BK N2 INPUT SPEED SENSOR
13 T39 18GY/LB SENSOR SUPPLY VOLTAGE
14 T60 18BR 1-2/4-5 SOLENOID CONTROL
15 T159 18DG/WT 3-4 SOLENOID CONTROL
16 T119 18WT/DB 2-3 SOLENOID CONTROL
17 T120 18LG TCC SOLENOID CONTROL
33 T13 18DB/BK SENSOR GROUND
34 T54 18VT TEMP SENSOR - P/N SWITCH
35 T14 18LG/WT N3 INPUT SPEED SENSOR
36 T591 18YL/DB MODULATION PRESSURE SOLENOID CONTROL
37 T118 18YL/DB SHIFT PRESSURE SOLENOID CONTROL
38 T16 18RD SOLENOID SUPPLY VOLTAGE
H1 D52 18LG/WT CAN C BUS(+)
L2 D51 18DG/WT CAN C BUS(-)

TRANSMISSION SOLENOID (4.0L) - BLACK 8 WAY

CAV CIRCUIT FUNCTION
1 T15 18LG FUSED TRANSMISSION CONTROL RELAY OUTPUT
2 K6 18VT/BK 5 VOLT SUPPLY
3 K4 18BK/LB SENSOR GROUND
4 T25 18LG/RD GOVERNOR PRESSURE SENSOR SIGNAL
5 K88 18PK GOVERNOR PRESSURE SOLENOID CONTROL
6 T60 18BR 3-4 SHIFT SOLENOID CONTROL
7 T20 18LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
8W - 80 - 126 8W-80 CONNECTOR PIN-OUT WJ

TRANSMISSION SOLENOID ASSEMBLY (DIESEL) - BLACK 13 WAY

CAV CIRCUIT FUNCTION
1 T14 18LG/WT N3 INPUT SPED SENSOR
2 T591 18YL/DB MODULATION PRESSURE SOLENOID CONTROL
3 T52 18RD/BK N2 INPUT SPEED SENSOR
4 T54 18VT TEMP SENSOR - P/N SWITCH
5 - -
6 T16 18RD SOLENOID SUPPLY VOLTAGE
7 T39 18GY/LB SENSOR SUPPLY VOLTAGE
8 T119 18WT/DB 2-3 SOLENOID CONTROL
9 T159 18DG/WT 3-4 SOLENOID CONTROL
10 T118 18YL/DB SHIFT PRESSURE SOLENOID CONTROL
11 T120 18LG TCC SOLENOID CONTROL
12 T13 18DB/BK SENSOR GROUND
13 T60 18BR 1-2/4-5 SOLENOID CONTROL

TRANSMISSION SOLENOID/TRS ASSEMBLY (4.7L) - GRAY 23 WAY

CAV CIRCUIT FUNCTION
1 F22 18WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 T120 18LG LR SOLENOID CONTROL
3 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
4 T141 18WT TRS T41 SENSE
5 T42 18VT/WT TRS T42 SENSE
6 L1 18VT/BK BACK-UP LAMP FEED
7 T60 18BR OVERDRIVE SOLENOID CONTROL
8 T3 18VT TRS T3 SENSE
9 T1 18LG/BK TRS T1 SENSE
10 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
11 T48 18DB 4C PRESSURE SWITCH SENSE
12 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
13 T2 18TN/BK TRS T2 SENSE
14 T150 18BR/LB LR PRESSURE SWITCH SENSE
15 T147 18LB 2C PRESSURE SWITCH SENSE
16 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
17 T59 18PK UNDERDRIVE SOLENOID CONTROL
18 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
19 T159 18DG/WT 4C SOLENOID CONTROL
20 T119 18WT/DB 2C SOLENOID CONTROL
21 T140 18VT/LG MS SOLENOID CONTROL
22 T13 18DB/BK SPEED SENSOR GROUND
23 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL

UNDERHOOD LAMP - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 Z141 20BK GROUND
2 M1 20PK/RD FUSED B(+)
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 127

VEHICLE INFORMATION CENTER - BLACK 6 WAY

CAV CIRCUIT FUNCTION
1 - -
2 D25 20YL/VT PCI BUS
3 F70 20PK FUSED B(+)
4 Z155 20BK/OR GROUND
5 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 - -

VISCOUS/CABIN HEATER (DIESEL) - BLACK 2 WAY

CAV CIRCUIT FUNCTION
1 A82 16PK/LG VISCOUS/CABIN HEATER RELAY OUTPUT
2 Z18 16BK GROUND

WASHER FLUID LEVEL SWITCH - GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 V11 20BK/TN WASHER FLUID SWITCH SENSE
2 Z141 20BK GROUND

WASTEGATE SOLENOID (DIESEL) - 2 WAY

CAV CIRCUIT FUNCTION
1 F15 18DB/WT FUSED AUTO SHUT DOWN RELAY OUTPUT
2 Y42 18OR/DB WASTEGATE SOLENOID CONTROL

WATER IN FUEL SENSOR (DIESEL) - BLACK 3 WAY

CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
3 F15 20RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

8 W-9 1 CON N ECT OR/GROU N D/SPLI CE LOCAT I ON

TABLE OF CONTENTS
page

CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CON N ECT OR/GROU N D/SPLI CE Con n ect or, gr ou n d, a n d splice in dexes a r e pr ovided.
Use t h e wir in g dia gr a m s in ea ch sect ion for con n ec-
LOCAT I ON t or, gr ou n d, a n d splice iden t ifica t ion . Refer t o t h e
a ppr opr ia t e in dex for t h e pr oper figu r e n u m ber. F or
DESCRIPTION it em s t h a t a r e n ot sh own in t h is sect ion N/S is pla ced
Th is sect ion pr ovides illu st r a t ion s iden t ifyin g con - in t h e F ig. colu m n .
n ect or, gr ou n d, a n d splice loca t ion s in t h e veh icle.

CON N ECT ORS

CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
A/C Compressor Clutch BK At A/C Compressor 9, 13
A/C Pressure Transducer BK Right Front of Engine Compartment 3, 4, 5
Accelerator Pedal Position BK Rear of Engine Compartment Near 7
Sensor (Diesel) Fuel/Water Seperator
Adjustable Pedals Module GN Above Drivers Control Pedals N/S
(Except Built-up Export)
Adjustable Pedals Motor/ Above Drivers Control Pedals N/S
Sensor Assembly (Except
Built-up Export)
Adjustable Pedals Switch WT Drivers Lower Kick Panel 21
Airbag Control Module (ORC) YL Below Center Floor Console, Near 19, 20, 21, 22
C1 Park Brake
Airbag Control Module (ORC) YL Below Center Floor Console, Near 19, 20, 21, 22
C2 Park Brake
Ambient Temperature Sensor BK On Radiator Center Support 5
Antenna Module (Built-up- WT Above Right Quarter Window N/S
export)
Ash Receiver Lamp BK Below Cigarette Lighter 19, 20
Automatic Day/Night Mirror BK In Front of Rear View Mirror N/S
Automatic Headlamp Light BK Near Left Instrument Panel Speaker 19, 20
Sensor/VTSS LED
Automatic Zone Control WT Left Side of HVAC Housing N/S
Module - C1 (AZC)
Automatic Zone Control WT Left Side of HVAC Housing N/S
Module - C2 (AZC)
Battery Temperature Sensor BK Below Battery Tray 4, 5
Blower Motor BK Behind Right Hand Side of N/S
Instrument Panel
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Blower Motor Controller (AZC) BK Behind Right Hand Side of N/S
Instrument Panel
Blower Motor Resistor Block BK Behind Right Hand Side of N/S
(MTC) Instrument Panel
Body Control Module - C1 GY Lower Left Side of Instrument Panel 21, 22
Body Control Module-C2 -LHD WT Lower Left Side of Instrument Panel 21
Body Control Module-C2 - GY Lower Left Side of Instrument Panel 22
RHD
Boost Pressure Sensor BK Top Front of Engine N/S
(Diesel)
Brake Lamp Switch GY Brake Pedal Arm 31
C100 BK Right Front Engine Compartment 2, 5
C101 (4.0L RHD) LTGY Rear of Engine Compartment 15
C101 (4.7L RHD) BK Rear of Engine Compartment N/S
C102 (Diesel) BK Left Rear Engine Compartment 4, 7
C102 (Gas) BK Right Rear Engine Compartment 5, 10, 11, 14, 15, 18
C103 (Diesel) LTGY Rear of Engine 4, 7
C103 (Gas) GY Right Rear Engine Compartment 5, 10 11, 14, 15
C104 LTGY Right Rear Engine Compartment 14 18
C105 (Diesel) GY Right Rear Engine Compartment 4, 7, 8
C106 (Diesel) GY Lower Right Instrument Panel N/S
C106 (Gas RHD) GY Lower Right Instrument Panel N/S
C107 (Diesel) GY Left Rear Engine Compartment 4
C107 (LHD) BK Passenger Side Near Kick Panel 3, 30, 35
C107 (RHD) GY Passenger Side Near Kick Panel 3, 31
C108 BK Left Cowl 3, 4
C109 BK Near Transfer Case switch 12
C110 (Diesel) GY Top of Engine Near Glow Plugs 4, 7
C111 BK Left Front Frame Near Windshield 1, 3, 4
Washer Pump
C112 BK Right Front Frame Near Horns 1, 5
C113 (Diesel) LTGY Rear of Engine 7, 8
C200 - LHD GY Passenger Side Near Kick Panel 19, 21, 35
C200 - RHD BK Passenger Side Near Kick Panel 20, 22
C201) WT Below Center Floor Console, Near 19, 20, 21, 22
Park Brake
C202 WT HVAC Unit, Right Side of Instrument 19, 20, 21, 22
Panel
C203 (AZC) WT HVAC Unit, Right Side of Instrument 19, 20, 21, 22
Panel
C300 (LHD) GY Near Junction Block 30, 33
C301 (RHD) BK Near Junction Block 31
C302 BK At Driver Door 24, 25, 30, 31
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
C303 WT Right Rear Door 29, 34, 36
C304 BK Under Driver Seat 33, 36
C306 BK Under Passenger Seat 34, 35
C307 WT Left Rear Door 28, 33 35
C308 WT Top of Liftgate 37, 38
C309 WT Left Rear Quarter Pillar 37
C310 (Built-Up-Export) LT GY Above Left Quarter Wheel Housing 37, 39
C310 (Except Built-Up-Export) LT GN Above Left Quarter Wheel Housing 39
C311 WT Top of Liftgate 38
C312 Center of Liftgate 38
C313 WT In Driver Door 24, 25
C314 LT GY At Passenger Door 26, 27, 31
C315 To Rear of Right Quarter Window 32
C318 At C Post 33, 36
Camshaft Position Sensor BK Top of Engine N/S
(Diesel)
Camshaft Position Sensor GY Right Side of Engine 10, 11, 14, 15
(Gas)
Capacitor (4.0L) BK Right Rear of Engine 10
Capacitor NO. 1 (4.7L) BK Right Side of Engine 14, 15
Capacitor NO. 2 (4.7L) BK Left Side of Engine 13
Cargo Lamp WT In Headliner Near Liftgate N/S
Center High Mounted Stop BK Top of Liftgate N/S
Lamp
Cigar Lighter RD Center of Instrument Panel 19, 20
Clockspring - C1 BK At Steering Column 23
Clockspring - C2 At Steering Column 23
Clockspring - C3 GY At Steering Column 23
Clockspring - C4 BK At Steering Column N/S
Coil On Plug NO. 1 (4.7L) BK Left Side of Engine Near Fuel 13
Injector No.1
Coil On Plug NO. 2 (4.7L) BK Right Side of Engine Near Fuel 14, 15
Injector No.2
Coil On Plug NO. 3 (4.7L) BK Left Side of Engine Near Fuel 13
Injector No.3
Coil On Plug NO. 4 (4.7L) BK Right Side of Engine Near Fuel 14, 15
Injector No.4
Coil On Plug NO. 5 (4.7L) BK Left Side of Engine Near Fuel 13
Injector No.5
Coil On Plug NO. 6 (4.7L) BK Right Side of Engine Near Fuel 14, 15
Injector No.6
Coil On Plug NO. 7 (4.7L) BK Left Side of Engine Near Fuel 13
Injector No.7
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Coil On Plug NO. 8 (4.7L) BK Right Side of Engine Near Fuel 14, 15
Injector No.8
Coil Rail (4.0L) BK Right Rear of Engine 10, 11
Compact Disc Changer BK Near Radio N/S
Compact Disc Changer BK Right Rear Quarter Panel 37
Controller Antilock Brake BK Left Front Engine Compartment 3, 4
Coolant Level Sensor LT GY Right Rear of Engine 5
Crankcase Heater (Diesel) BK Near T/O for G105 8
Crankshaft Position Sensor BK Rear of Engine Near Transmission N/S
(Diesel) Bell Housing
Crankshaft Position Sensor BK Rear of Engine Near Transmission 10, 11, 14, 15, 17
(Gas) Bell Housing
Data Link Connector BK Under Lower Driver’s Side of 20, 21, 22
Instrument Panel
Diagnostic Junction Port BK At Steering Column 23
Driver Airbag Squib 1 BK In Steering Wheel N/S
Driver Airbag Squib 2 BK In Steering Wheel N/S
Driver Blend Door Motor/ BK On HVAC Housing N/S
Actuator (AZC)
Driver Cylinder Lock Switch GY In Driver Door 24, 25
Driver Door Lock Motor/Ajar BK In Driver Door 24, 25
Switch
Driver Door Module - C1 WT In Driver Door 24, 25
Driver Door Module - C2 BK In Driver Door N/S
Driver Door Module - C3 BK In Driver Door N/S
Driver Front Door Courtesy BK In Driver Door N/S
Lamp
Driver Front Power Window BK In Driver Door 24, 25
Motor
Driver Heated Seat Back GN At Driver Seat N/S
(Premium I/III)
Driver Heated Seat Cushion BK At Driver Seat N/S
(Premium I/III)
Driver Heated Seat Switch WT Center of Instrument Panel 19 20, 21
Driver Lumbar Motor BK At Driver Seat N/S
(Midline/Premium)
Driver Lumbar Switch WT At Driver Seat N/S
(Midline/Premium)
Driver Power Mirror BK At Driver Door N/S
Driver Power Seat Front Riser RD At Driver Seat N/S
Motor
Driver Power Seat Front Riser BK At Driver Seat N/S
Motor Sensor (Premium II/III)
Driver Power Seat Horizontal BK At Driver Seat N/S
Motor
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Driver Power Seat Horizontal BK At Driver Seat N/S
Motor Sensor (Premium II/III)
Driver Power Seat Rear Riser RD At Driver Seat N/S
Motor
Driver Power Seat Rear Riser BK At Driver Seat N/S
Motor Sensor (Premium II/III)
Driver Power Seat Recliner BK At Driver Seat N/S
Motor
Driver Power Seat Recliner BK At Driver Seat N/S
Motor Sensor (Premium II/III)
Driver Power Seat Switch GN At Driver Seat N/S
(Midline/Premium)
Driver Rear Power Window BK In Left Rear Door 28
Motor
Driver Rear Power Window BL In Left Rear Door 28
Switch
Driver Seat Belt Switch At Switch N/S
EGR Solenoid (Diesel) BK Left Front Fender 7, 8
Electric Brake BL Near Junction Block N/S
Electronic Speed Control Servo BK Right Front of Engine Compartment 5
Engine Control Module C1 BK Left Front of Engine 7, 8
(Diesel)
Engine Control Module C2 BK Left Front of Engine 7, 8
(Diesel)
Engine Coolant Temperature BK Top of Engine N/S
Sensor (Diesel)
Engine Coolant Temperature BK Front of Engine 9, 13
Sensor (GAS)
Engine Oil Pressure Sensor BK Side of Engine 10, 11, 13
EVAP/Purge Solenoid BK Left Front Fender Near Controller 3
Antilock Brake
Front Power Outlet RD Center of Instrument Panel 19, 20
Front Washer Pump WT Left Front of Engine Compartment 3, 4
Front Wiper Motor BK Left Side of Cowl 3, 4
Fuel Injector No.1 BK At Injector 7, 9, 13
Fuel Injector No.2 BK At Injector 7, 9, 14, 15
Fuel Injector No.3 BK At Injector 7, 9, 13
Fuel Injector No.4 BK At Injector 7, 9, 14, 15
Fuel Injector No.5 BK At Injector 9, 13
Fuel Injector No.6 BK At Injector 9, 14, 15
Fuel Injector No.7 (4.7L) BK At Injector 13
Fuel Injector No.8 (4.7L) BK At Injector 14, 15
Fuel Pressure Sensor (Diesel) BK Right Front of Engine N/S
Fuel Pressure Solenoid BK Top of Engine N/S
(Diesel)
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Fuel Pump Module (Gas) BK Near Fuel Tank 33, 35
Fuel Tank Module Diesel) BK Near Fuel Tank 33, 35
Generator (Diesel) LTGY At Generator 8
Generator (Gas) BK At Generator N/S
Glove Box Lamp BK Inside Glove Box 19, 20, 22
Headlamp Leveling Switch WT Driver Side of Instrument Panel 20
(Built-Up-Export)
Hood Ajar Switch BK Left Side of Engine Compartment 3, 4
Horn No.1 BK Right Front Fascia 5
Horn No.2 BK Right Front Fascia 5
Hydraulic Cooling Module BK Right Front of Engine Compartment 5
Idle Air Control Motor BK Left Side of Engine Near Throttle 13
Body
Ignition Switch - C1 WT On Steering Column 23
Ignition Switch - C2 BK On Steering Column 23
Input Speed Sensor (4.7L) BK Left Side of Transmission 16
Instrument Cluster WT At Instrument Cluster 19, 20
Intake Air Temperature Sensor GY Left Side of Engine 9, 13
(Gas)
Intake Air Temperature Sensor BK Near T/O for Crankcase Heater 8
(Diesel)
Intake Port Swirl Actuator BK Right Rear of Engine Compartment N/S
(Diesel)
Intrusion Transceiver Module BK In The Overhead N/S
(Built-up-Export)
Junction Block - C1 BK At Junction Block 30, 31, 33
Junction Block - C2 BK At Junction Block 30, 31
Junction Block - C3 BK At Junction Block 21, 22, 30
Junction Block - C4 WT At Junction Block 30, 31
Junction Block - C5 WT At Junction Block 30, 31
Knock Sensor (4.7L High BK Right Rear Side of Engine, Near N/S
Output) Coil on Plug No.8
Leak Detection Pump (Except Left Front Wheel Opening 3
Built-Up-Export)
Left Courtesy Lamp BK Left Side of Instrument Panel 21 22, 23
Left Curtain Airbag BK Near Left C Pillar 37
Left Door Handle Courtesy BK At Lamp N/S
Lamp
Left Fog Lamp BK At Lamp 3, 4
Left Front Door Speaker WT In Left Front Door 24, 27
Left Front Impact Sensor BK Left Front Frame Near Windshield 3, 4
Washer Pump
Left Front Park Lamp WT At Lamp N/S
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Left Front Park/Turn Signal BK At Lamp N/S
Lamp (Except Built-Up-Export)
Left Front Side Marker Lamp WT At Lamp N/S
(Except Built-Up-Export)
Left Front Turn Signal Lamp WT At Lamp N/S
(Built-Up-Export)
Left Front Wheel Speed GY At Left Front Wheel Opening 4
Sensor
Left Headlamp Leveling Motor BK At Motor N/S
(Built-Up-Export)
Left High Beam Headlamp BK At Lamp N/S
Left Instrument Panel Speaker WT At Speaker 19, 20
Left Liftgate Ajar Switch BK In Liftgate 38
Left Low Beam Headlamp GY At Lamp N/S
Left Multi-Function Switch WT On Steering Column 23
Left Rear Door Lock Motor/Ajar BK In Left Rear Door 28
Switch
Left Rear Door Speaker WT In Left Rear Door 28
Left Rear Lamp Assembly BK At Lamp Assembly 37
Left Rear Wheel Speed Sensor GY Near Left Rear Wheel 33, 35
Left Remote Radio Switch BK At Switch in Steering Wheel N/S
Left Side Impact Sensor BK Left Body N/S
Left Side Repeater Lamp BK On Left Front Fender 3, 4
(Built-Up-Export)
Left Visor/Vanity Lamp BK At Lamp N/S
License Lamp No.1 BK At Lamp N/S
License Lamp No.2 BK At Lamp N/S
Liftgate Flip-Up Ajar Switch GY In Liftgate 38
Liftgate Flip-Up Push Button BK In Liftgate N/S
Switch
Liftgate Flip-Up Release BK In Liftgate 38
Solenoid
Liftgate Lock Motor BK In Liftgate 38
Line Pressure Sensor (4.7L) BK Rear of Transmission N/S
Manifold Absolute Pressure BK At Throttle Body 9
Sensor (4.0L)
Manifold Absolute Pressure BK Right Side of Engine 13
Sensor (4.7L)
Manual Temperature Control - WT Center of Instrument Panel N/S
C1 (MTC)
Manual Temperature Control - WT Center of Instrument Panel N/S
C2 (MTC)
Mass Air Flow sensor (Diesel) BK Near T/O for G105 8
Mode Door Motor/Actuator BK Right Center of Instrument Panel N/S
(AZC)
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Output Speed Sensor (4.0L) GY Left Side of Transmission 12
Output Speed Sensor (4.7L) BK Left Side of Transmission 16
Overhead Map/Courtesy Lamp WT At Overhead Console N/S
Oxygen Sensor 1/1 Upstream GY Left Side of Engine at Exhaust 9, 12
(4.0L)
Oxygen Sensor 1/1 Upstream GY Left Side of Engine at Exhaust 17
(4.7L)
Oxygen Sensor 1/2 BK Rear of Transmission 9, 12
Downstream (4.0L)
Oxygen Sensor 1/2 BK Rear of Transmission 17
Downstream (4.7L)
Oxygen Sensor 2/1 Upstream Rear of Transmission N/S
Oxygen Sensor 2/2 Rear of Transmission N/S
Downstream
Park Brake Switch Center Console Area, Near Airbag 20, 21, 22
Control Module
Park/Neutral Position Switch BK Left Side of Transmission 12
(4.0L)
Park/Neutral Position Switch BK Left Side of Transmission N/S
(Diesel)
Passenger Airbag YL Passenger Side of Instrument Panel 19, 20
Passenger Blend Door BK Passenger Side of Instrument Panel N/S
Motor/Actuator (AZC)
Passenger Door Lock BK In Passenger Door 26, 27
Motor/Ajar Switch
Passenger Door Module - C1 WT In Passenger Door 26, 27
Passenger Door Module - C2 BK In Passenger Door N/S
Passenger Front Door BK In Passenger Door N/S
Courtesy Lamp
Passenger Front Power BK In Passenger Door 26, 27
Window Motor
Passenger Heated Seat Back GN At Passenger Seat N/S
(Premium I/III)
Passenger Heated Seat BK At Passenger Seat N/S
Cushion (Premium I/III)
Passenger Heated Seat Switch BK Center of Instrument Panel 19, 20, 21
Passenger Lumbar Motor BK At Passenger Seat N/S
(Midline/Premium)
Passenger Lumbar Switch WT At Passenger Seat N/S
(Midline/Premium)
Passenger Power Mirror BK In Passenger Door N/S
Passenger Power Seat Front RD At Passenger Seat N/S
Riser Motor
Passenger Power Seat RD At Passenger Seat N/S
Horizontal Motor
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Passenger Power Seat Rear RD At Passenger Seat N/S
Riser Motor
Passenger Power Seat BK At Passenger Seat N/S
Recliner Motor (Midline/
Premium)
Passenger Power Seat Switch GN At Passenger Seat N/S
(Midline/Premium)
Passenger Rear Power BK In Right Rear Door 29
Window Motor
Passenger Rear Power BL In Right Rear Door 29
Window Switch
Passenger Seat Belt Switch t Switch N/S
Power Amplifier - C1 WT Under Rear Seat 34, 36
Power Amplifier - C2 WT Under Rear Seat 34, 36
Power Connector WT Center of Instrument Panel 21, 22
Powertrain Control Module - BK Rear of Engine Compartment 5, 10, 11, 14, 15, 18
C1 (Gas)
Powertrain Control Module - WT Rear of Engine Compartment 5, 10, 11, 14, 15, 18
C2 (Gas)
Powertrain Control Module - WT Rear of Engine Compartment N/S
C3 (Gas)
Radiator Fan Motor BK At Radiator 5
Radiator Fan Relay BK Right Side of Engine Compartment 5
Radio - C1 GY Center of Instrument Panel 19, 20
Radio - C2 BK Center of Instrument Panel 19, 20
Rain Sensor BK Front Center Overhead N/S
Rear Power Outlet RD Right Rear Quarter Panel 37
Rear Washer Pump BK Left Front of Engine Compartment 3, 4
Rear Window Defogger BK Right Upper Coner of Liftgate 38
Rear Wiper Motor BK In Liftgate 38
Recirculation Door Motor/ BK Center of Instrument Panel N/S
Actuator (AZC)
Red Brake Warning Indicator GY At Master Cylinder 4
Switch
Remote Keyless Module BL In Driver Door 25
(Japan)
Right Courtesy Lamp BK At Lamp 20 21, 22
Right Curtain Airbag BK Near Right C Pillar 37
Right Door Handle Courtesy BK At Lamp N/S
Lamp
Right Fog Lamp BK At Right Front Fascia 5
Right Front Door Speaker WT In Right Front Door 25, 26
Right Front Impact Sensor BK Near Right Verticle Radiator Support N/S
Right Front Park Lamp WT At Lamp N/S
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Right Front Park/Turn Signal BK At Lamp N/S
Lamp (Except Built-Up-Export)
Right Front Side Marker Lamp WT At Lamp N/S
(Except Built-Up-Export)
Right Front Turn Signal Lamp WT At Lamp N/S
(Built-Up-Export)
Right Front Wheel Speed GY In Right Front Wheel Opening N/S
Sensor
Right Headlamp Leveling BK At Motor N/S
Motor (Built-Up-Export)
Right High Beam Headlamp BK At Lamp N/S
Right Instrument Panel WT At Speaker 19, 20
Speaker
Right Liftgate Ajar Switch BK In Liftgate 38
Right Low Beam Headlamp GY At Lamp N/S
Right Multi-Function Switch WT On Steering Column 23
Right Rear Door Lock BK In Right Rear Door 29
Motor/Ajar Switch
Right Rear Door Speaker WT In Right Rear Door 29
Right Rear Lamp Assembly BK At Lamp Assembly 37
Right Rear Wheel Speed BK Near Right Rear Wheel 33, 35
Sensor
Right Remote Radio Switch BK At Switch in Steering Wheel N/S
Right Side Repeater Lamp BK On Right Front Fender 5
(Built-Up-Export)
Right Visor/Vanity Lamp BK At Lamp N/S
Seat Belt Switch WT At Driver Seat N/S
Seat Module - C1 (Premium) BK Under Driver Seat N/S
Seat Module - C2 (Premium) OR Under Driver Seat N/S
Sentry Key Immobilizer Module BK On Steering Column 23
Shifter Assembly (Gas) WT Between Front Seats 23
Shifter Assembly C1 (Diesel) Between Front Seats N/S
Shifter Assembly C2 (Diesel) Between Front Seats N/S
Siren (Built-up-export) Left Front Fender 3, 4
Speed Control Switch NO. 1 BK On Steering Wheel N/S
Speed Control Switch NO. 2 BK On Steering Wheel N/S
Sunroof Control Module At Sunroof 32
Sunroof Motor C1 WT At Sunroof N/S
Sunroof Motor C2 BK In Overhead N/S
Sunroof Switch GY At Switch N/S
Temperature Valve Actuator BK On HVAC Housing N/S
(MTC)
Throttle Position Sensor (4.0L) BK Left Side of Engine 9
Throttle Position Sensor (4.7L) WT Left Side of Engine 13
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
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CONNECTOR NAME/ COLOR LOCATION FIG.

NUMBER
Trailer Tow Brake Lamp Relay BK Left Quarter Panel N/S
Trailer Tow Circuit Breaker BK Left Quarter Panel N/S
Trailer Tow Connector BK In Rear Bumper 39
Trailer Tow Left Turn Relay BK Left Quarter Panel N/S
Trailer Tow Right Turn Relay BK Left Quarter Panel N/S
Transfer Case Position Sensor BK On Transfer Case 7
Transmission Control Module BK Rear of Engine Compartment 14, 15, 18
(4.7L)
Transmission Control Module BK Right Rear Side of Engine N/S
C1 (Diesel) Compartment
Transmission Control Module BK Right Rear Side of Engine 8
C2 (Diesel) Compartment
Transmission Solenoid (4.0L BK Left Side of Transmission 12
Gas)
Transmission Solenoid BK On Transmission 8
Assembly (Diesel)
Transmission Solenoid/TRS GY Left Side of Transmission 16
Assembly (4.7L)
Underhood Lamp BK At Lamp 6
Vehicle Information Center BK In Overhead Console N/S
Viscous/Cabin Heater (Diesel) BK Left Rear of Engine Compartment N/S
Washer Fluid Level Switch GY Left Front of Engine Compartment 3, 4
Wastegate Solenoid (Diesel) Near Power Distribution Center N/S
Water In Fuel Sensor (Diesel) BK Left Rear of Engine Compartment N/S

GROU N DS

GROUND NUMBER LOCATION FIG.

G100 (4.0L and Diesel) Near Starter N/S
G100 (4.7L) Near Intake Plenum N/S
G101 Near Battery 2
G102 Right Side of Engine 14, 15
G103 Right Side of Engine 7, 8, 10, 11, 14, 15
G104 (4.0L) Right Rear of Engine 10, 11
G104 (4.7L) Left Side of Engine 13
G105 Right Side of Engine 8
G106 Left Side of Engine Compartment 3, 4
G107 Left Side of Engine Compartment 3, 4
G108 Near Power Distribution Center 5
G200 Near Airbag Control Module 19, 20, 21, 22
G201 Near Airbag Control Module 19, 20, 21, 22
G300 Near Right Front Seat 34, 36
G301 Near Left Front Seat 33, 35
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)
SPLI CES

SPLICE LOCATION FIG.

NUMBER
S100 Near T/O for Power Distribution Center Eyelet 2
S102 (4.0L) Near T/O for G103 10, 11
102 (4.7L) Near T/O for Fuel Injector No. 1 13
S102 (Diesel) Near T/O for C110 7, 8
S103 (4.7L) Near T/O for Engine Oil Pressure Sensor 13
S104 (4.0L) Near T/O for A/C Compressor Clutch N/S
S104 (4.7L) Near T/O for Oxygen Sensor 2/2 Downstream N/S
S105 (4.0L) Near T/O for Capacitor 10 11
S105 (4.7L) Near T/O for Fuel Injector NO. 7 13
S106 (4.0L) In T/O for Oxygen Sensors 11, 12
S106 (4.7L) Near T/O for C103 14
S106 (4.7L) RHD Near T/O for Fuel Injector No.4 15
S107 (4.0L) Near T/O for Fuel Injector No.5 9
S107 (4.7L) Near T/O for Fuel Injector No.7 13
S109 (4.0L) Near T/O for Fuel Injector No.2 9
S109 (4.7L) Near T/O for Coil On Plug No. 6 14, 15
S110 (4.0L Near T/O for Oxygen Sensor N/S
Except
Built-Up-Export)
S111 (4.7L) In T/O for Oxygen Sensor N/S
S111 (4.0L Near T/O for Oxygen Sensor N/S
Except
Built-Up-Export)
S112 (4.0L) Near T/O for C102, C103 and C104 10, 11
S112 (4.7L) Near T/O for Coil On Plug No.8 15
S112 (Diesel) Near T/O for Accelerator Pedal Position Sensor N/S
S113 (4.7L) Near T/O for Transmission Control Module 15, 18
S114 (4.0L) Near T/O for Transmission Control Module 18
S114 (4.7L) Near T/O for Transmission Control Module 15, 18
S115 (4.0L) Near T/O for Transmission Control Module 18
S115 (4.7L) Near T/O for Transmission Control Module 15, 18
S116 (4.0L) Near Powertrain Control Module C1 and C2 18
S116 (4.7L) LHD Near T/O for C102, C103 and C104 14
S116 (4.7L) RHD In T/O for Powertrain Control Module 15
S117 (4.7L) LHD Neat T/O for C102, C103 and C104 14
S118 (4.7L) Near T/O for Coil On PlugNo.4 14, 15
S118 (Diesel) Near T/O for Fuel Sender Unit N/S
S119 (4.7L) LHD In T/O for Crankshaft Position Sensor 18
S119 (4.7L) RHD In T/O for Powertrain Control Module 15
S120 (4.7L) Near T/O for Powertrain Control Module 15, 18
S121 (4.7L) Near T/O for Idle Air Control Motor 13
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

SPLICE LOCATION FIG.

NUMBER
S122 (4.0L) Near T/O for G103 10, 11
S122 (4.7L) LHD Near T/O for Input Speed Sensor 15
S122 (4.7L) RHD Near T/O for Powertrain Control Module 16
S122 (Diesel) Near T/O for Generator N/S
S123 (4.0L) Near T/O for Capacitor 10, 11
S124 (4.7L) In Trough Near T/O for Capacitor No.2 13
S125 (Diesel) In T/O for C103 and C105 Left Rear of Engine Compartment N/S
S125 (Gas) Near T/O for Powertrain Control Module - C3 N/S
S126 (4.0L) LHD Near T/O for Battery Temperature Sensor N/S
S126 (4.0L) RHD In Trough Near T/O for Powertrain Control Module - C3 N/S
S127 (LHD) Gas In Trough Near T/O for Powertrain Control Module - C3 N/S
S127 (RHD) Gas In T/O for Power Distribution Center 5
S127 (Diesel) Near T/O for Power Distribution Center 4
S128 (Diesel) In T/O for C102 Left Rear of Engine Compartment N/S
S128 (LHD) Gas In Trough Near T/O for Powertrain Control Module - C3 N/S
S128 (RHD) Gas In T/O for C102 5
S130 (LHD) Gas In T/O for C102 N/S
S130 (RHD) Gas In T/O for Controller Antilock Brake 3
S130 (Diesel) In T/O for Controller Anti-Lock Brake 4
S131 In Trough Near T/O for Power Distribution Center 5
S131 (Diesel) Near T/O for Power Distribution Center 4
S132 (Diesel) Near T/O for EGR Solenoid N/S
S132 (Gas) Near T/O for Battery Temperature Sensor 5
S133 (Diesel) In Trough Near T/O for EGR Solenoid N/S
S133 (Gas) Near T/O for Battery Temperature Sensor 5
S134 (Diesel) In Trough Near T/O for G106/G107 4
S134 (Gas) In Trough Near T/O for Controller Anti-Lock Brake 3
S135 (Diesel) Near T/O for Engine Control Module C1 7, 8
S136 (Diesel) Near T/O for Engine Control Module C1 7, 8
S137 (Diesel) In Trough Near T/O for Coolant Level Sensor N/S
S139 (Diesel) Near T/O for Engine Control Module C1 7, 8
S140 (Diesel) Near T/O for Power Distribution Center 4
S140 (Gas) Near T/O for Controller Antilock Brake N/S
S141 (Gas) Near T/O for Controller Antilock Brake 3
S142 (Diesel) In Trough Near T/O for Coolant Level Sensor N/S
S142 Gas In T/O for C102 5
S143 (Diesel) In Trough Near T/O for Hood Ajar Switch 4
S143 (Gas, In Trough Near T/O for Controller Antilock Brake 3
Built-Up-Export)
LHD
S143 Gas RHD Near T/O for Evap/Purge Solenoid N/S
S145 (Diesel) Near T/O for Engine Control Module C1 7, 8
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

SPLICE LOCATION FIG.

NUMBER
S147 (Diesel) In T/O for Controller Anti-Lock Brake 4
S151 In Headlamp Assembly N/S
S152 In Headlamp Assembly N/S
S153 In Headlamp Assembly N/S
S154 In Headlamp Assembly N/S
S155 In Headlamp Assembly N/S
S156 In Headlamp Assembly N/S
S158 4.7L RHD Near T/O for Fuel Injector No. 1 13
S159 In T/O for C101 N/S
S160 (4.7L High In T/O for C102 N/S
Output)
S162 (Diesel) In T/O for Wastegate Solenoid 4, 8
S163 Near T/O for Leak Detection Pump 3
S165 (Diesel) Near T/O for Left Front Wheel Speed Sensor 4
S168 Near T/O for Intake Air Temperature Sensor 7, 8
S169 Near T/O for Engine Control Module C1 7, 8
S170 Near T/O for Engine Control Module C2 7, 8
S171 Near T/O for C113 7
S172 Near T/O for C113 7
S174 Near Washer Fluid Level Switch Connector 3
S176 Near T/O for Intake Air Temperature Sensor 7
S200 In Trough Near T/O for Passenger Heated Seat Switch 21
S200 (RHD) Upper Center Instrument Panel 22
S201 In Trough Near T/O for Front Power Outlet 21
S201 (RHD) Near T/O for Power Connector 22
S202 In Trough Near T/O for Passenger Heated Seat Switch 21
S202 (RHD) Upper Center Instrument Panel 22
S203 In Trough Near T/O for Cigar Lighter 21
S203 (RHD) Lower Center Instrument Panel 22
S204 In Trough Near T/O for Power Connector 21
S204 (RHD) Right Center Instrument Panel 22
S205 Near T/O for Adjustable Pedal Switch 21
S205 (RHD) Upper Center Instrument Panel 22
S206 Near T/O for Adjustable Pedals Switch N/S
S206 (RHD) Upper Center Instrument Panel 22
S207 In Trough Near T/O for Radio Connectors 21
S207 (RHD) Upper Center Instrument Panel 22
S208 In Trough Near T/O for Radio Connectors 21
S208 (RHD) Upper Center Instrument Panel 22
S209 In Trough Near T/O for Left Courtesy Lamp 21
S209 (RHD) Lower Center Instrument Panel 22
S210 In Trough Near T/O for Left Courtesy Lamp 21
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

SPLICE LOCATION FIG.

NUMBER
S210 (RHD) Lower Center Instrument Panel 22
S211 In Trough Near T/O for Left Courtesy Lamp N/S
S211 (RHD) Right Side of Instrument Panel 22
S212 In Trough Near T/O for Left Courtesy Lamp 21
S212 (RHD) Right Center Instrument Panel 22
S213 Near T/O for Cruise Switch No.1 N/S
S214 Near T/O for Cruise Switch No.1 N/S
S215 Near T/O for Horn Switch N/S
S216 Near T/O for Remote Radio Switch No.2 N/S
S217 In Trough Near T/O for Power Connector 21
S217 (RHD) Lower Center Instrument Panel 22
S221 Right Center of Instrument Panel 21
S221 (RHD) Left Center of Instrument Panel 22
S222 Right Center of Instrument Panel 21
S222 (RHD) Near T/O for Front Power Outlet 22
S223 Near T/O for Adjustable Pedals Switch 21
S223 (RHD) Lower Left Side of Instrument Panel 22
S224 Right Center of Instrument Panel 21
S224 (RHD) Upper Center of Instrument Panel 22
S300 Near T/O for G304 33
S301 In T/O for C304 33
S302 In Sill Trough Near T/O for C307 33, 35
S303 In Sill Trough Near T/O for C307 33, 35
S304 In Sill Trough Near T/O for C307 35
S305 In Sill Trough Near T/O for C307 N/S
S306 Near T/O for C310 37
S307 Near T/O for C310 37
S308 Between T/O’s for C310 and Left Rear Lamp Assembly 36, 37
S309 Between T/O’s for C310 and Left Rear Lamp Assembly 37
S310 Between T/O’s for C310 and Left Rear Lamp Assembly 35, 37
S311 Near T/O for Left Rear Lamp Assembly 37
S312 Near T/O for C200 35
S313 Near T/O for G301 35
S314 Near T/O for C314 N/S
S315 (Gas) In Center Spline Near T/O for G301 35
S316 (Gas) Near T/O for Junction Block C2, C4, C5 N/S
S317 Between Troughs Near T/O for C314 N/S
S318 Between Troughs Near T/O for C314 N/S
S319 In Trough Near T/O for C304 33
S323 Near T/O for C314 N/S
S324 In T/O for C200 34
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

SPLICE LOCATION FIG.

NUMBER
S326 Near T/O for C200 34, 35
S327 Near T/O for c307 34, 35
S328 In Sill Trough Near T/O for G300 34
S329 In Sill Trough Near T/O for G300 34
S330 Near T/O for G300 34
S331 In Sill Trough Near T/O for C303 34, 36
S332 In Sill Trough Near T/O for C303 34, 36
S333 Near T/O for Power Amplifiers 36
S334 In T/O for Power Amplifier - C2 34
S335 Near T/O for C314 36
S336 Near T/O for Driver Power Window Motor 24, 25
S338 Near T/O for Passenger Power Window Motor 26, 27
S339 Near T/O for Passenger Power Window Motor 26 27
S340 In T/O for Passenger Door Module - C1 26, 27
S341 Near T/O for C306 N/S
S345 Near T/O for Sunroof Switch 32
S346 Near T/O for Left Visor/Vanity Lamp 32
S347 Near T/O for Left Visor/Vanity Lamp 32
S348 Near T/O for Automatic Day/Night Mirror 32
S349 Near T/O for Automatic Day/Night Mirror 32
S351 Near T/O for Seat Belt Switch N/S
S352 Near T/O for Seat Belt Switch N/S
S353 Near T/O for Driver Lumbar Switch N/S
S355 Near T/O for C304 and C306 N/S
S356 In T/O for Left Rear Door Lock Motor/Ajar Switch 28
S357 In T/O for Right Rear Door Lock Motor/Ajar Switch 29
S358 Near Left B Pillar Sill Trough 35
S359 Near T/O for C302 34
S360 In T/O for C302 N/S
S362 In T/O for C200 34
S363 In T/O for C200 34
S364 Near B Pillar Sill Trough 36
S365 Near T/O for Remote Keyless Entry Module 24, 25
Japan
S366 Near T/O for Junction Block C1 N/S
S367 (RHD) Near T/O for C310 N/S
S368 Near T/O for Power Amplifier - C1 34
S369 Near T/O for Left Visor Vanity Lamp N/S
S370 Near T/O for Sunroof Module 32
S400 Near Rear Window Defogger Ground Connector 38
S401 Near Rear Window Defogger Ground Connector 38
S402 Near T/O for Liftgate Flip-Up Ajar Switch 38
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

SPLICE LOCATION FIG.

NUMBER
S403 Near T/O for Rear Wiper Motor 38
S404 Near T/O for Liftgate Lock Motor 38
S405 In T/O for Rear Wiper Motor 38
S406 (Except In T/O for Trailer Tow Right Turn Relay N/S
Built-Up-Export)
S407 (Except Near T/O for Trailer Tow Left Turn Relay N/S
Built-Up-Export)
S408 Near T/O for Trailer Tow Circuit Breaker N/S
S410 In T/O for Trailer Tow Connector 39
S411 Near T/O for License Lamp No.1 N/S
S412 In T/O for C312 N/S
8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 1 ENGINE COMPARTMENT (FRONT CLIP)

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 2 ENGINE COMPARTMENT (BATTERY)

8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 3 ENGINE COMPARTMENT LEFT SIDE

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 4 ENGINE COMPARTMENT LEFT SIDE DIESEL

8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 5 ENGINE COMPARTMENT RIGHT SIDE

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 6 UNDERHOOD LAMP

8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 7 2.7 LITER DIESEL ENGINE LEFT SIDE

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 8 2.7 LITER DIESEL ENGINE RIGHT SIDE

8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 9 4.0 LITER ENGINE LEFT SIDE

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 10 4.0 LITER ENGINE RIGHT REAR LHD

8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 11 4.0 LITER ENGINE RIGHT REAR RHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 12 TRANSMISSION 4.0 LITER ENGINE

8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 13 4.7 LITER ENGINE LEFT FRONT

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 14 4.7 LITER ENGINE RIGHT FRONT LHD

8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 15 4.7 LITER ENGINERIGHT FRONT RHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 16 TRANSMISSION 4.7 LITER ENGINE LEFT SIDE

Fig. 17 TRANSMISSION 4.7 LITER ENGINE RIGHT SIDE

8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 18 REAR ENGINE COMPARTMENT LHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 19 INSTRUMENT PANEL FRONT LHD

8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 20 INSTRUMENT PANEL FRONT RHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 21 INSTRUMENT PANEL REAR LHD

8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 22 INSTRUMENT PANEL REAR RHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 23 STEERING COLUMN

Fig. 24 DRIVER DOOR LHD

8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 25 DRIVER DOOR RHD

Fig. 26 PASSENGER DOOR LHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 27 PASSENGER DOOR RHD

Fig. 28 LEFT REAR DOOR

8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 29 RIGHT REAR DOOR

Fig. 30 KICK PANEL AREA LHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 31 KICK PANEL AREA RHD

8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 32 ROOF AREA

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 33 BODY LEFT SIDE LHD

8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 34 BODY RIGHT SIDE LHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 35 BODY LEFT SIDE RHD

8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 36 BODY RIGHT SIDE RHD

WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 49
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 37 BODY QUARTER PANELS

8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Fig. 38 LIFTGATE

Fig. 39 TRAILER TOW

WJ 8W-97 POWER DISTRIBUTION 8W - 97 - 1

8 W-9 7 POWER DI ST RI BU T I ON

TABLE OF CONTENTS
page page

POWER DISTRIBUTION ASSEMBLY

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...1 POWER DISTRIBUTION CENTER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...1 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER DISTRIBUTION SYSTEMS . . . . . . ...2 POWER OUTLET
CIGAR LIGHTER OUTLET DESCRIPTION - FRONT POWER OUTLET . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...2 OPERATION - FRONT POWER OUTLET . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...2 DIAGNOSIS AND TESTING - POWER OUTLET . 12
DIAGNOSIS AND TESTING - CIGAR LIGHTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OUTLET .......................... ...2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
CIGAR LIGHTER OUTLET DOOR SPRING POWER OUTLET RELAY
REMOVAL .......................... ...3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IOD FUSE DIAGNOSIS AND TESTING - POWER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .3 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL .......................... . . .4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .4 IOD WIRE HARNESS CONNECTOR
JUNCTION BLOCK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 FUSE COVER
REMOVAL .......................... . . .5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
POWER DISTRIBUTION CENTER REAR POWER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...7 DESCRIPTION - REAR POWER OUTLET . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...8 OPERATION - REAR POWER OUTLET . . . . . . . 17
REMOVAL .......................... ...8 DIAGNOSIS AND TESTING - REAR POWER
DISASSEMBLY OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
POWER DISTRIBUTION CENTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . ...9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18

POWER DI ST RI BU T I ON • Cir cu it splice blocks

• F la sh er s
• F u sible lin ks
DESCRIPTION
• St a n da r d a n d Micr o-Rela ys
Th is gr ou p cover s t h e va r iou s st a n da r d a n d
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor
opt ion a l power dist r ibu t ion com pon en t s u sed on t h is
com pon en t s in t h e power dist r ibu t ion syst em . See t h e
m odel. Th e power dist r ibu t ion syst em for t h is veh icle
own er ’s m a n u a l in t h e veh icle glove box for m or e
con sist s of t h e followin g com pon en t s:
in for m a t ion on t h e fea t u r es a n d u se of a ll of t h e
• P ower Dist r ibu t ion Cen t er (P DC)
power dist r ibu t ion syst em com pon en t s. Refer t o Wir-
• J u n ct ion Block (J B)
in g Dia gr a m s for com plet e cir cu it dia gr a m s.
• P ower Ou t let s
Th e power dist r ibu t ion syst em a lso in cor por a t es
va r iou s t ypes of cir cu it con t r ol a n d pr ot ect ion fea -
OPERATION
Th e power dist r ibu t ion syst em for t h is veh icle is
t u r es, in clu din g:
design ed t o pr ovide sa fe, r elia ble, a n d cen t r a lized dis-
• Au t om a t ic r eset t in g cir cu it br ea ker s
t r ibu t ion poin t s for t h e elect r ica l cu r r en t r equ ir ed t o
• Bla de-t ype fu ses
oper a t e a ll of t h e st a n da r d a n d opt ion a l fa ct or y-in -
• Bu s ba r s
st a lled elect r ica l a n d elect r on ic power t r a in , ch a ssis,
• Ca r t r idge fu ses
sa fet y, secu r it y, com for t a n d con ven ien ce syst em s. At
8W - 97 - 2 8W-97 POWER DISTRIBUTION
POWER DI ST RI BU T I ON (Cont inue d)
t h e sa m e t im e, t h e power dist r ibu t ion syst em wa s
design ed t o pr ovide r ea dy a ccess t o t h ese elect r ica l
dist r ibu t ion poin t s for t h e veh icle t ech n icia n t o u se
wh en con du ct in g dia gn osis a n d r epa ir of fa u lt y cir-
cu it s. Th e power dist r ibu t ion syst em ca n a lso pr ove
u sefu l for t h e sou r cin g of a ddit ion a l elect r ica l cir cu it s
t h a t m a y be r equ ir ed t o pr ovide t h e elect r ica l cu r r en t
n eeded t o oper a t e a ccessor ies t h a t t h e veh icle own er
m a y ch oose t o h a ve in st a lled in t h e a ft er m a r ket .
NOTE: DO NOT ATTEMPT TO SWAP POWER DIS-
TRIBUTION CENTERS FROM ONE VEHICLE TO
ANOTHER. MOST OF THESE ASSEMBLIES ARE
VEHICLE FEATURE SPECIFIC AND THEREFORE
NOT INTERCHANGEABLE. ALWAYS USE THE COR-
RECT PART NUMBERED ASSEMBLY WHEN DIAG-
NOSING OR REPLACING A POWER DISTRIBUTION
CENTER.
SPECI AL T OOLS
POWER DISTRIBUTION SYSTEMS
Terminal Pick Kit 6680
CI GAR LI GH T ER OU T LET
DESCRIPTION
A ciga r ligh t er ou t let is st a n da r d equ ipm en t on
t h is m odel. On m odels equ ipped wit h t h e opt ion a l
Sm oker ’s P a cka ge, t h e ciga r ligh t er kn ob a n d h ea t in g
elem en t a r e in clu ded. On m odels wit h ou t t h e Sm ok-
er ’s P a cka ge, t h e ciga r ligh t er ou t let is equ ipped wit h
a sn a p fit pla st ic ca p a n d is t r ea t ed a s a n ext r a
a ccessor y power ou t let . Th e ciga r ligh t er ou t let is
in st a lled in t h e in st r u m en t pa n el cen t er lower bezel,
wh ich is loca t ed n ea r t h e bot t om of t h e in st r u m en t
pa n el cen t er st a ck a r ea , below t h e h ea t er a n d a ir
con dit ion er con t r ols. Th e ciga r ligh t er ou t let is
secu r ed by a sn a p fit wit h in t h e cen t er lower bezel.
WJ
Th e ciga r ligh t er ou t let , pla st ic ca p a n d t h e kn ob
a n d h ea t in g elem en t u n it a r e a va ila ble for ser vice
r epla cem en t . Th ese com pon en t s ca n n ot be r epa ir ed
a n d, if fa u lt y or da m a ged, t h ey m u st be r epla ced.
OPERATION
Th e ciga r ligh t er con sist s of t wo m a jor com pon en t s:
a kn ob a n d h ea t in g elem en t u n it , a n d t h e ciga r
ligh t er ba se or ou t let sh ell. Th e r ecept a cle sh ell is
con n ect ed t o gr ou n d, a n d a n in su la t ed con t a ct in t h e
bot t om of t h e sh ell is con n ect ed t o ba t t er y cu r r en t .
Th e ciga r ligh t er r eceives ba t t er y volt a ge fr om a fu se
in t h e ju n ct ion block wh en t h e ign it ion swit ch is in
t h e Accessor y or On posit ion s.
Th e ciga r ligh t er kn ob a n d h ea t in g elem en t a r e
en ca sed wit h in a spr in g-loa ded h ou sin g, wh ich a lso
fea t u r es a slidin g pr ot ect ive h ea t sh ield. Wh en t h e
kn ob a n d h ea t in g elem en t a r e in ser t ed in t h e ou t let
sh ell, t h e h ea t in g elem en t r esist or coil is gr ou n ded
t h r ou gh it s h ou sin g t o t h e ou t let sh ell. If t h e ciga r
ligh t er kn ob is pu sh ed in wa r d, t h e h ea t sh ield slides
u p t owa r d t h e kn ob exposin g t h e h ea t in g elem en t ,
a n d t h e h ea t in g elem en t ext en ds fr om t h e h ou sin g
t owa r d t h e in su la t ed con t a ct in t h e bot t om of t h e
ou t let sh ell.
Two sm a ll spr in g-clip r et a in er s a r e loca t ed on
eit h er side of t h e in su la t ed con t a ct in side t h e bot t om
of t h e ou t let sh ell. Th ese clips en ga ge a n d h old t h e
h ea t in g elem en t a ga in st t h e in su la t ed con t a ct lon g
en ou gh for t h e r esist or coil t o h ea t u p. Wh en t h e
h ea t in g elem en t is en ga ged wit h t h e con t a ct , ba t t er y
cu r r en t ca n flow t h r ou gh t h e r esist or coil t o gr ou n d,
ca u sin g t h e r esist or coil t o h ea t .
Wh en t h e r esist or coil becom es su fficien t ly h ea t ed,
excess h ea t r a dia t es fr om t h e h ea t in g elem en t ca u s-
in g t h e spr in g-clips t o expa n d. On ce t h e spr in g-clips
expa n d fa r en ou gh t o r elea se t h e h ea t in g elem en t ,
t h e spr in g-loa ded h ou sin g for ces t h e kn ob a n d h ea t -
in g elem en t t o pop ba ck ou t wa r d t o t h eir r ela xed
posit ion . Wh en t h e ciga r ligh t er kn ob a n d elem en t
a r e pu lled ou t of t h e ou t let sh ell, t h e pr ot ect ive h ea t
sh ield slides down wa r d on t h e h ou sin g so t h a t t h e
h ea t in g elem en t is r ecessed a n d sh ielded a r ou n d it s
cir cu m fer en ce for sa fet y.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
F or com plet e cir cu it dia gr a m s, r efer t o Ho rn /Ci-
g a r Lig h te r/P o w e r Ou tle t in Wir in g Dia gr a m s.
(1) Ch eck t h e fu sed B(+) fu se in t h e ju n ct ion block.
If OK, go t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir-
cu it or com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y
fu se.
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se in
WJ 8W-97 POWER DISTRIBUTION 8W - 97 - 3
CI GAR LI GH T ER OU T LET (Cont inue d)
t h e ju n ct ion block. If OK, go t o St ep 3. If n ot OK,
r epa ir t h e open or sh or t a s r equ ir ed.
(3) Rem ove t h e ciga r ligh t er kn ob a n d elem en t
fr om t h e ciga r ligh t er ou t let sh ell. Ch eck for con t in u -
it y bet ween t h e in side cir cu m fer en ce of t h e ciga r
ligh t er ou t let sh ell a n d a good gr ou n d. t h er e sh ou ld
be con t in u it y. If OK, go t o St ep 4. If n ot OK, go t o
St ep 5.
(4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
Ch eck for ba t t er y volt a ge a t t h e in su la t ed con t a ct
loca t ed a t t h e ba ck of t h e ciga r ligh t er ou t let sh ell. If
OK, r epla ce t h e fa u lt y ciga r ligh t er kn ob a n d ele-
m en t . If n ot OK, go t o St ep 5.
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Rem ove t h e in st r u m en t pa n el cen t er lower bezel.
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
it y of t h e ciga r ligh t er wir e h a r n ess con n ect or a n d a
good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o
St ep 6. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o
gr ou n d a s r equ ir ed.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
ign it ion swit ch t o t h e Accessor y or On posit ion s. Fig. 1 Cigar Lighter Outlet Door Spring
Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) cir cu it 1 - CIGAR LIGHTER OUTLET
ca vit y of t h e ciga r ligh t er wir e h a r n ess con n ect or. If 2 - CIGAR LIGHTER OUTLET DOOR SPRING
OK, r epla ce t h e fa u lt y ciga r ligh t er ou t let . If n ot OK,
r epa ir t h e open fu sed B(+) cir cu it t o t h e ju n ct ion
block fu se a s r equ ir ed.

CI GAR LI GH T ER OU T LET
DOOR SPRI N G
REMOVAL
(1) Discon n ect a n d isola t e t h e n ega t ive ba t t er y
ca ble.
(2) Rem ove t h e in st r u m en t pa n el cen t er lower
bezel fr om t h e I.P. Refer t o Body for t h e pr ocedu r e.
(3) Rem ove t h e ciga r ligh t er ou t let door spr in g
fr om it s loca t in g h oles (F ig. 1).

INSTALLATION
(1) In st a ll t h e ciga r ou t let door spr in g in it s loca t -
in g h oles.
(2) In st a ll t h e in st r u m en t pa n el cen t er lower bezel
on t h e I.P. Refer t o Body for t h e pr ocedu r e.
(3) Con n ect t h e n ega t ive ba t t er y ca ble.

Fig. 2 Ignition-Off Draw Fuse

I OD FU SE 1 - POWER DISTRIBUTION CENTER
2 - IGNITION-OFF DRAW FUSE
DESCRIPTION 3 - IOD FUSE STORAGE CAVITY
All veh icles a r e equ ipped wit h a n Ign it ion -Off
Dr a w (IOD) fu se (F ig. 2) t h a t is r em oved fr om it s son n el a r e t o r em ove t h e IOD fu se fr om t h e st or a ge
ca vit y in t h e P ower Dist r ibu t ion Cen t er (P DC) wh en loca t ion a n d in st a ll it in t o P DC fu se ca vit y 15 a s pa r t
t h e veh icle is sh ipped fr om t h e fa ct or y. Dea ler per-
8W - 97 - 4 8W-97 POWER DISTRIBUTION
I OD FU SE (Cont inue d)
of t h e pr epa r a t ion pr ocedu r es per for m ed ju st pr ior t o
n ew veh icle deliver y.
Th e P DC h a s a m olded pla st ic cover t h a t ca n be
r em oved t o pr ovide ser vice a ccess t o a ll of t h e fu ses
a n d r ela ys in t h e P DC. An in t egr a l la t ch a n d h in ges
a r e m olded in t o t h e P DC cover for ea sy r em ova l. A
fu se la you t m a p is in t egr a l t o t h e u n der side of t h e
P DC cover t o en su r e pr oper fu se a n d r ela y iden t ifica -
t ion . Th e IOD fu se is a 50 a m per e m a xi-t ype ca r-
t r idge fu se a n d, wh en r em oved, it is st or ed in a spa r e
fu se ca vit y wit h in t h e P DC.
OPERATION
Th e t er m ign it ion -off dr a w iden t ifies a n or m a l con -
dit ion wh er e power is bein g dr a in ed fr om t h e ba t t er y
wit h t h e ign it ion swit ch in t h e Off posit ion . Th e IOD
fu se feeds t h e m em or y a n d sleep m ode fu n ct ion s for
som e of t h e elect r on ic m odu les in t h e veh icle a s well
a s va r iou s ot h er a ccessor ies t h a t r equ ir e ba t t er y cu r-
r en t wh en t h e ign it ion swit ch is in t h e Off posit ion ,
in clu din g t h e clock. Th e on ly r ea son t h e IOD fu se is
r em oved is t o r edu ce t h e n or m a l IOD of t h e veh icle
elect r ica l syst em du r in g n ew veh icle t r a n spor t a t ion
a n d pr e-deliver y st or a ge t o r edu ce ba t t er y deplet ion ,
wh ile st ill a llowin g veh icle oper a t ion so t h a t t h e
veh icle ca n be loa ded, u n loa ded a n d m oved a s n eeded
by bot h veh icle t r a n spor t a t ion com pa n y a n d dea ler
per son n el.
Th e IOD fu se is r em oved fr om P DC fu se ca vit y 15
wh en t h e veh icle is sh ipped fr om t h e a ssem bly pla n t .
Dea ler per son n el m u st in st a ll t h e IOD fu se wh en t h e
veh icle is bein g pr epa r ed for deliver y in or der t o
r est or e fu ll elect r ica l syst em oper a t ion . On ce t h e
veh icle is pr epa r ed for deliver y, t h e IOD fu n ct ion of
t h is fu se becom es t r a n spa r en t a n d t h e fu se t h a t h a s
been a ssign ed t h e IOD design a t ion becom es on ly
a n ot h er F u sed B(+) cir cu it fu se. Th e IOD fu se ser ves
n o u sefu l pu r pose t o t h e dea ler t ech n icia n in t h e ser-
vice or dia gn osis of a n y veh icle syst em or con dit ion ,
ot h er t h a n t h e sa m e pu r pose a s t h a t of a n y ot h er
st a n da r d cir cu it pr ot ect ion device.
Th e IOD fu se ca n be u sed by t h e veh icle own er a s
a con ven ien t m ea n s of r edu cin g ba t t er y deplet ion
wh en a veh icle is t o be st or ed for per iods n ot t o
WJ
exceed a bou t t h ir t y da ys. H owever, it m u st be
r em em ber ed t h a t r em ovin g t h e IOD fu se will n ot
elim in a t e IOD, bu t on ly r edu ce t h is n or m a l con dit ion .
If a veh icle will be st or ed for m or e t h a n a bou t t h ir t y
da ys, t h e ba t t er y n ega t ive ca ble sh ou ld be discon -
n ect ed t o elim in a t e n or m a l IOD; a n d, t h e ba t t er y
sh ou ld be t est ed a n d r ech a r ged a t r egu la r in t er va ls
du r in g t h e veh icle st or a ge per iod t o pr even t t h e ba t -
t er y fr om becom in g disch a r ged or da m a ged. Refer t o
B a tte ry S y s te m for a ddit ion a l ser vice in for m a t ion .
REMOVAL
Th e Ign it ion -Off Dr a w (IOD) fu ses n or m a l in st a lla -
t ion loca t ion is ca vit y 15 in t h e power dist r ibu t ion
cen t er. Wh en t h e veh icle is sh ipped fr om t h e a ssem -
bly pla n t t h e fu se is r em oved t o m a in t a in pr oper ba t -
t er y volt a ge du r in g veh icle st or a ge (in som e ca ses).
Dea ler per son n el m u st in st a ll t h e IOD fu se wh en t h e
veh icle is bein g pr epa r ed for cu st om er deliver y in
or der t o r est or e fu ll elect r ica l syst em oper a t ion .
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
(2) Un la t ch a n d open t h e cover of t h e power dist r i-
bu t ion cen t er.
(3) Rem ove t h e IOD fu se fr om fu se c a v ity 15 of
t h e power dist r ibu t ion cen t er (F ig. 2).
(4) St or e t h e r em oved IOD fu se by in st a llin g it in
t h e u n u sed fu se st or a ge c a v ity 11 of t h e P DC (F ig.
2).
(5) Close a n d la t ch t h e power dist r ibu t ion cen t er
cover.
INSTALLATION
(1) Be cer t a in t h e ign it ion swit ch is in t h e Off posi-
t ion .
(2) Un la t ch a n d open t h e cover of t h e power dist r i-
bu t ion cen t er.
(3) Rem ove t h e st or ed IOD fu se fr om fu se st or a ge
c a v ity 11 of t h e power dist r ibu t ion cen t er.
(4) Use a t h u m b t o pr ess t h e IOD fu se fir m ly down
in t o power dist r ibu t ion cen t er fu se c a v ity 15.
(5) Close a n d la t ch t h e power dist r ibu t ion cen t er
cover.
WJ 8W-97 POWER DISTRIBUTION
J U N CT I ON BLOCK
DESCRIPTION
Fig. 3 Junction Block Location
1 - REAR LATCHES
2 - JUNCTION BLOCK AND BODY CONTROL MODULE UNIT
3 - INSTRUMENT PANEL FUSE COVER
4 - SIDE LATCH
5 - FRONT LATCHES
An elect r ica l J u n ct ion Block (J B) is con cea led
ben ea t h t h e dr iver side of t h e in st r u m en t pa n el in
t h e pa ssen ger com pa r t m en t of t h e veh icle (F ig. 3).
Th e J B com bin es t h e fu n ct ion s pr eviou sly pr ovided
by a sepa r a t e fu seblock m odu le a n d r ela y cen t er. Th e
J B ser ves t o sim plify a n d cen t r a lize n u m er ou s elec-
t r ica l com pon en t s, a s well a s t o dist r ibu t e elect r ica l
cu r r en t t o m a n y of t h e a ccessor y syst em s in t h e veh i-
cle. It a lso elim in a t es t h e n eed for n u m er ou s splice
con n ect ion s. Th e J B h ou ses u p t o t h ir t y-t h r ee bla de-
t ype m in i fu ses, u p t o t wo bla de-t ype a u t om a t ic
r eset t in g cir cu it br ea ker s, t h e elect r on ic com bin a t ion
fla sh er, t h e Da yt im e Ru n n in g La m p (DRL) m odu le
(Ca n a da on ly) a n d u p t o t welve In t er n a t ion a l St a n -
da r ds Or ga n iza t ion (ISO) r ela ys (t h r ee st a n da r d-t ype
a n d n in e m icr o-t ype). Th e J B a lso in cor por a t es a n
in t egr a l con n ect or a n d m ou n t in g for t h e Body Con -
t r ol Modu le (BCM). Th e BCM is secu r ed wit h fou r
scr ews dir ect ly t o t h e da sh pa n el side of t h e J B.
Refer t o B o d y Co n tro l Mo d u le in E lect r on ic Con -
t r ol Modu les for a ddit ion a l in for m a t ion cover in g t h e
BCM.
Th e m olded pla st ic J B h ou sin g h a s in t egr a l m ou n t s
t h a t a r e secu r ed wit h t wo scr ews a n d t wo sn a p
r et a in er s t o t h e in st r u m en t pa n el st eer in g colu m n
su ppor t br a cket beh in d t h e in st r u m en t pa n el st eer-
8W - 97 - 5
in g colu m n open in g cover. Th e J B is con cea led a bove
t h e m olded pla st ic in st r u m en t pa n el fu se cover. In t e-
gr a l la t ch es m olded in t o t h e fu se cover secu r e it t h e
J B, t h e BCM a n d t h e 16-wa y da t a lin k con n ect or t a b
of t h e in st r u m en t pa n el st eer in g colu m n su ppor t
br a cket . Th e fu se cover ca n be pu lled down wa r d t o
disen ga ge t h e la t ch es a n d pr ovide ser vice a ccess t o
a ll of t h e fu ses, r ela ys a n d wir e h a r n ess con n ect or s of
t h e J B. Th e fu se cover h a s a fu se pu ller a n d spa r e
fu ses secu r ed t o it s u pper su r fa ce. Refer t o In s tru -
m e n t P a n e l F u s e Co v e r in Body for a ddit ion a l ser-
vice in for m a t ion .
Th e J B u n it ca n n ot be r epa ir ed a n d is on ly ser-
viced a s a n a ssem bly. If a n y in t er n a l cir cu it or t h e J B
h ou sin g is fa u lt y or da m a ged, t h e en t ir e J B u n it
m u st be r epla ced. Th e BCM is a va ila ble for sepa r a t e
ser vice r epla cem en t .
OPERATION
All of t h e cir cu it s en t er in g a n d lea vin g t h e J u n c-
t ion Block (J B) do so t h r ou gh u p t o five wir e h a r n ess
con n ect or s, wh ich a r e con n ect ed t o t h e J B t h r ou gh
in t egr a l con n ect or r ecept a cles m olded in t o t h e J B
h ou sin g. In t er n a l con n ect ion of a ll of t h e J B cir cu it s
is a ccom plish ed by a pr in t ed cir cu it boa r d. Th er e a r e
a lso t wo sepa r a t e wir e h a r n ess con n ect ion s t o con -
n ect or r ecept a cles t h a t a r e in t egr a l t o t h e BCM.
Refer t o J u n c tio n B lo c k in Wir in g Dia gr a m s for
a ddit ion a l in for m a t ion a n d t h e loca t ion of com plet e
J B cir cu it dia gr a m s.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e fu se cover fr om t h e bot t om of t h e
J u n ct ion Block (J B).
(3) Rem ove t h e st eer in g colu m n open in g cover
fr om t h e in st r u m en t pa n el. Refer t o S te e rin g Co l-
u m n Op e n in g Co v e r in Body for t h e loca t ion of
st eer in g colu m n open in g cover r em ova l pr ocedu r es.
8W - 97 - 6 8W-97 POWER DISTRIBUTION
J U N CT I ON BLOCK (Cont inue d)
(4) Rea ch beh in d t h e J B t o discon n ect t h e t wo
in st r u m en t pa n el wir e h a r n ess con n ect or s fr om t h e
Body Con t r ol Modu le (BCM) con n ect or r ecept a cles
loca t ed n ea r t h e bot t om of t h e J B (F ig. 4).
Fig. 4 Junction Block Connections
1 - SCREW
2 - JUNCTION BLOCK
3 - BULKHEAD CONNECTOR
4 - BODY CONTROL MODULE
5 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS
(5) Rea ch beh in d t h e J B t o r em ove t h e scr ew t h a t
secu r es t h e in st r u m en t pa n el wir e h a r n ess bu lkh ea d
con n ect or t o t h e con n ect or r ecept a cle loca t ed n ea r t h e
t op of t h e J B a n d discon n ect t h e con n ect or.
(6) Discon n ect t h e fu sed B(+) a n d t h e IOD wir e
h a r n ess con n ect or s fr om t h e con n ect or r ecept a cles
loca t ed n ea r t h e bot t om of t h e J B (F ig. 5).
(7) Rem ove t h e scr ews t h a t secu r e t h e r igh t a n d
left body wir e h a r n ess bu lkh ea d con n ect or s t o t h e
con n ect or r ecept a cles loca t ed n ea r t h e cen t er of t h e
J B a n d discon n ect t h e con n ect or s.
(8) Rem ove t h e t wo scr ews t h a t secu r e t h e J B t o
t h e in st r u m en t pa n el st eer in g colu m n su ppor t
br a cket (F ig. 6).
(9) To disen ga ge t h e t wo sn a p clips t h a t secu r e t h e
t op of t h e J B t o t h e in st r u m en t pa n el st eer in g col-
u m n su ppor t br a cket , gr a sp t h e bot t om of t h e ju n c-
t ion block fir m ly wit h bot h h a n ds a n d pu ll it
down wa r d sh a r ply.
(10) Rem ove t h e J B fr om t h e in st r u m en t pa n el
st eer in g colu m n su ppor t br a cket .
INSTALLATION
NOTE: If the Junction Block (JB) is being replaced
with a new unit, be certain to transfer each of the
optional fuses, circuit breakers and relays from the
WJ
Fig. 5 Junction Block Connections
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
4 - LEFT BODY WIRE HARNESS
5 - IOD CONNECTOR
6 - FUSED B+ CONNECTOR
7 - RIGHT BODY WIRE HARNESS
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
faulty JB to the proper cavities of the replacement
JB. Refer to Junction Block in Wiring Diagrams for
the location of complete circuit diagrams and cavity
assignments for the JB. The Body Control Module
(BCM) must also be transferred to the new JB.
Refer to Body Control Module in Electronic Control
Modules for the location of the BCM removal and
installation procedures.
(1) P osit ion t h e J B in t o it s m ou n t in g loca t ion on t h e
in st r u m en t pa n el st eer in g colu m n su ppor t br a cket .
(2) Align t h e sn a p clips a t t h e t op of t h e J B wit h
t h e m ou n t in g h oles in t h e in st r u m en t pa n el st eer in g
colu m n su ppor t br a cket .
(3) Gr a sp t h e bot t om of t h e J B fir m ly wit h bot h
h a n ds a n d pu sh it u pwa r d sh a r ply t o en ga ge t h e t wo
sn a p clips t h a t secu r e t h e t op of t h e J B t o t h e in st r u -
m en t pa n el st eer in g colu m n su ppor t br a cket .
(4) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e t h e
J B t o t h e in st r u m en t pa n el st eer in g colu m n su ppor t
br a cket . Tigh t en t h e scr ews t o 2.2 N·m (20 in . lbs.).
WJ 8W-97 POWER DISTRIBUTION 8W - 97 - 7
J U N CT I ON BLOCK (Cont inue d)

Fig. 6 Junction Block

1 - SCREW (2)
2 - DRIVER SIDE COURTESY LAMP
3 - JUNCTION BLOCK
4 - 16 WAY DATA LINK CONNECTOR

Fig. 7 Power Distribution Center Location

(5) Recon n ect t h e r igh t a n d left body wir e h a r n ess
bu lkh ea d con n ect or s t o t h e con n ect or r ecept a cles
loca t ed n ea r t h e cen t er of t h e J B.
(6) In st a ll a n d t igh t en t h e scr ews t h a t secu r e t h e
r igh t a n d left body wir e h a r n ess bu lkh ea d con n ect or s
t o t h e con n ect or r ecept a cles loca t ed n ea r t h e cen t er
of t h e J B. Tigh t en t h e scr ews t o 2.2 N·m (20 in . lbs.).
(7) Recon n ect t h e fu sed B(+) a n d t h e IOD wir e
h a r n ess con n ect or s t o t h e con n ect or r ecept a cles
loca t ed n ea r t h e bot t om of t h e J B.
(8) Rea ch beh in d t h e J B t o r econ n ect t h e in st r u -
m en t pa n el wir e h a r n ess bu lkh ea d con n ect or t o t h e
con n ect or r ecept a cle loca t ed n ea r t h e t op of t h e J B.
(9) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
in st r u m en t pa n el wir e h a r n ess bu lkh ea d con n ect or t o
t h e con n ect or r ecept a cle loca t ed n ea r t h e t op of t h e
J B. Tigh t en t h e scr ew t o 2.2 N·m (20 in . lbs.).
(10) Rea ch beh in d t h e J B t o r econ n ect t h e t wo
in st r u m en t pa n el wir e h a r n ess con n ect or s t o t h e BCM
con n ect or r ecept a cles loca t ed n ea r t h e bot t om of t h e J B.
(11) In st a ll t h e st eer in g colu m n open in g cover on t o
t h e in st r u m en t pa n el. Refer t o S te e rin g Co lu m n
Op e n in g Co v e r in Body for t h e loca t ion of t h e st eer-
in g colu m n open in g cover in st a lla t ion pr ocedu r es.
(12) In st a ll t h e fu se cover on t o t h e bot t om of t h e J B.
(13) Recon n ect t h e ba t t er y n ega t ive ca ble.
POWER DI ST RI BU T I ON
CEN T ER
DESCRIPTION
All of t h e elect r ica l cu r r en t dist r ibu t ed t h r ou gh ou t
t h is veh icle is dir ect ed t h r ou gh t h e st a n da r d equ ip-
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
m en t P ower Dist r ibu t ion Cen t er (P DC) (F ig. 7). Th e
m olded pla st ic P DC h ou sin g is loca t ed in t h e r igh t
fr on t cor n er of t h e en gin e com pa r t m en t , bet ween t h e
ba t t er y a n d t h e r igh t fr on t in n er fen der sh ield. Th e
P DC h ou ses u p t o fift een m a xi-t ype ca r t r idge fu ses,
wh ich r epla ce a ll in -lin e fu sible lin ks. Th e P DC a lso
h ou ses u p t o t h ir t een bla de-t ype m in i fu ses, a n d u p
t o t en In t er n a t ion a l St a n da r ds Or ga n iza t ion (ISO)
r ela ys (t wo st a n da r d-t ype a n d eigh t m icr o-t ype).
Th e P DC h ou sin g is secu r ed in t h e en gin e com pa r t -
m en t a t t h r ee poin t s. In t egr a l m ou n t s on bot h sides of
t h e P DC h ou sin g en ga ge a n d la t ch t o st a n ch ion s t h a t
a r e in t egr a l t o t h e m olded pla st ic ba t t er y su ppor t . Th e
P DC is in t egr a l t o t h e r igh t h ea dla m p a n d da sh wir e
h a r n ess, wh ich exit s fr om t h e bot t om of t h e P DC h ou s-
in g. Th e P DC h ou sin g h a s a m olded pla st ic cover t h a t
in clu des t wo in t egr a l la t ch es a t t h e fr on t a n d pivot
h ooks a t t h e ba ck t h a t sn a p over a h in ge pin on t h e
r ea r of t h e P DC h ou sin g. Th e P DC cover is ea sily
open ed or r em oved for ser vice a ccess a n d h a s a con ve-
n ien t fu se a n d r ela y la you t m a p in t egr a l t o t h e in side
su r fa ce of t h e cover t o en su r e pr oper com pon en t iden t i-
fica t ion . A fu se pu ller is a lso st or ed on t h e in side of t h e
P DC cover.
Th e P DC cover, t h e P DC h ou sin g lower cover, t h e
P DC r ela y wedges, t h e P DC r ela y ca sset t es a n d t h e
P DC B(+) t er m in a l st u d m odu le a r e a va ila ble for ser-
vice r epla cem en t . Th e P DC m a in h ou sin g u n it , t h e
fu se wedges a n d t h e bu s ba r s ca n n ot be r epa ir ed a n d
8W - 97 - 8 8W-97 POWER DISTRIBUTION WJ
POWER DI ST RI BU T I ON CEN T ER (Cont inue d)
a r e on ly ser viced a s a u n it wit h t h e r igh t h ea dla m p
a n d da sh wir e h a r n ess. If t h e P DC m a in h ou sin g
u n it , fu se wedges or t h e bu s ba r s a r e fa u lt y or da m -
a ged, t h e r igh t h ea dla m p a n d da sh wir e h a r n ess u n it
m u st be r epla ced.

OPERATION
All of t h e cu r r en t fr om t h e ba t t er y a n d t h e gen er a t or
ou t pu t en t er s t h e P DC t h r ou gh t wo ca bles a n d a sin gle
t wo-h oled eyelet t h a t is secu r ed wit h n u t s t o t h e t wo
P DC B(+) t er m in a l st u ds ju st in side t h e fr on t en d of t h e
P DC h ou sin g. Th e P DC cover is u n la t ch ed a n d open ed
t o a ccess t h e ba t t er y a n d gen er a t or ou t pu t con n ect ion
B(+) t er m in a l st u ds, t h e fu ses or t h e r ela ys. In t er n a l
con n ect ion of a ll of t h e P DC cir cu it s is a ccom plish ed by
a n in t r ica t e com bin a t ion of h a r d wir in g a n d bu s ba r s.
Refer t o P o w e r D is tribu tio n in Wir in g Dia gr a m s for
t h e loca t ion of com plet e P DC cir cu it dia gr a m s.

REMOVAL
Th e P ower Dist r ibu t ion Cen t er (P DC) m a in h ou sin g
u n it , t h e P DC fu se wedges a n d t h e P DC bu s ba r s ca n -
n ot be r epa ir ed a n d a r e on ly ser viced a s a u n it wit h t h e Fig. 8 Power Distribution Center Connections
r igh t h ea dla m p a n d da sh wir e h a r n ess. If t h e P DC 1 - PDC COVER
m a in h ou sin g u n it , t h e fu se wedges or t h e bu s ba r s a r e 2 - NUT (2)
fa u lt y or da m a ged, t h e en t ir e P DC a n d r igh t h ea dla m p 3 - EYELET
a n d da sh wir e h a r n ess u n it m u st be r epla ced. 4 - B(+) TERMINAL STUDS
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
(2) Discon n ect ea ch of t h e r igh t h ea dla m p a n d
da sh wir e h a r n ess con n ect or s. Refer t o Co n n e c to r
Lo c a tio n s in Wir in g Dia gr a m s for t h e loca t ion of
m or e in for m a t ion on t h e r igh t h ea dla m p a n d da sh
wir e h a r n ess con n ect or loca t ion s.
(3) Rem ove a ll of t h e fa st en er s t h a t secu r e ea ch of
t h e r igh t h ea dla m p a n d da sh wir e h a r n ess gr ou n d
eyelet s t o t h e veh icle body a n d ch a ssis com pon en t s.
Refer t o Co n n e c to r Lo c a tio n s in Wir in g Dia gr a m s
for t h e loca t ion of m or e in for m a t ion on t h e gr ou n d
eyelet loca t ion s.
(4) Disen ga ge ea ch of t h e r et a in er s t h a t secu r e t h e
r igh t h ea dla m p a n d da sh wir e h a r n ess t o t h e veh icle
body a n d ch a ssis com pon en t s. Refer t o Co n n e c to r
Lo c a tio n s in Wir in g Dia gr a m s for t h e loca t ion of
m or e in for m a t ion on t h e r igh t h ea dla m p a n d da sh
wir e h a r n ess r et a in er loca t ion s.
(5) Un la t ch a n d open t h e P DC cover.
(6) Rem ove t h e t wo n u t s t h a t secu r e t h e t wo-h oled
eyelet of t h e ba t t er y wir e h a r n ess P DC t a ke ou t s t o
t h e P DC B(+) t er m in a l st u ds (F ig. 8).
(7) Rem ove t h e ba t t er y wir e h a r n ess P DC t a ke ou t
eyelet fr om t h e B(+) t er m in a l st u ds. Fig. 9 Power Distribution Center Remove/Install
(8) Disen ga ge t h e la t ch es on t h e P DC h ou sin g 1 - POWER DISTRIBUTION CENTER
m ou n t s fr om t h e t a bs on t h e P DC m ou n t in g st a n - 2 - MOUNTS
ch ion s of t h e ba t t er y su ppor t , a n d pu ll t h e P DC 3 - STANCHIONS (3)
4 - BATTERY SUPPORT
h ou sin g u pwa r d t o disen ga ge t h e m ou n t s fr om t h e
st a n ch ion s (F ig. 9).
WJ 8W-97 POWER DISTRIBUTION 8W - 97 - 9
POWER DI ST RI BU T I ON CEN T ER (Cont inue d)
(9) Rem ove t h e P DC a n d t h e r igh t h ea dla m p a n d
da sh wir e h a r n ess fr om t h e en gin e com pa r t m en t a s a
u n it .

DI SASSEM BLY
POWER DISTRIBUTION CENTER DISASSEMBLY
PDC HOUSING LOWER COVER REMOVAL
Th e P ower Dist r ibu t ion Cen t er (P DC) cover, t h e
P DC h ou sin g lower cover, t h e P DC r ela y wedges, t h e
P DC r ela y ca sset t es a n d t h e P DC B(+) t er m in a l st u d
m odu le a r e a va ila ble for ser vice r epla cem en t . Th e
P DC cover ca n be sim ply u n la t ch ed a n d r em oved
fr om t h e P DC h ou sin g wit h ou t t h e P DC bein g
r em oved or disa ssem bled. Ser vice of t h e r em a in in g
P DC com pon en t s r equ ir es t h a t t h e P DC be r em oved
fr om it s m ou n t in g a n d disa ssem bled. Refer t o Wirin g
Re p a ir in Wir in g Dia gr a m s for t h e loca t ion of t h e
wir in g r epa ir pr ocedu r es.
(1) Rem ove t h e ba t t er y fr om t h e ba t t er y su ppor t .
Refer t o B a tte ry S y s te m for t h e loca t ion of t h e ba t -
t er y r em ova l pr ocedu r es.
(2) Un la t ch a n d r em ove t h e cover fr om t h e P DC.
(3) Rem ove t h e t wo n u t s t h a t secu r e t h e t wo-h oled
eyelet of t h e ba t t er y wir e h a r n ess P DC t a ke ou t t o
t h e B(+) t er m in a l st u ds n ea r t h e fr on t of t h e P DC.
(4) Rem ove t h e ba t t er y wir e h a r n ess P DC t a ke ou t
eyelet fr om t h e t wo P DC B(+) t er m in a l st u ds.
(5) Disen ga ge t h e la t ch es on t h e P DC h ou sin g
m ou n t s fr om t h e t a bs on t h e P DC m ou n t in g st a n -
ch ion s on t h e ba t t er y su ppor t , a n d pu ll t h e P DC
h ou sin g u pwa r d t o disen ga ge t h e m ou n t s fr om t h e
st a n ch ion s.
(6) Wh er e t h e r igh t h ea dla m p a n d da sh wir e h a r-
n ess exit s t h e P DC, r em ove t h e t a pe t h a t secu r es t h e
wir e h a r n ess t o t h e t r ou gh for m a t ion on t h e P DC
h ou sin g lower cover.
(7) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y t h e la t ch es on ea ch side
a n d t h e fr on t of t h e P DC h ou sin g t h a t secu r e t h e
h ou sin g lower cover t o t h e P DC a n d r em ove t h e
h ou sin g lower cover (F ig. 10).
PDC B+ TERMINAL MODULE REMOVAL
Th e P ower Dist r ibu t ion Cen t er (P DC) cover, t h e
P DC h ou sin g lower cover, t h e P DC r ela y wedges, t h e
P DC r ela y ca sset t es a n d t h e P DC B(+) t er m in a l st u d
m odu le a r e a va ila ble for ser vice r epla cem en t . Th e
P DC cover ca n be sim ply u n la t ch ed a n d r em oved
fr om t h e P DC h ou sin g wit h ou t t h e P DC bein g
r em oved or disa ssem bled. Ser vice of t h e r em a in in g
P DC com pon en t s r equ ir es t h a t t h e P DC be r em oved
fr om it s m ou n t in g a n d disa ssem bled. Refer t o Wirin g
Re p a ir in Wir in g Dia gr a m s for t h e loca t ion of t h e
wir in g r epa ir pr ocedu r es.
Fig. 10 PDC Housing Lower Cover Remove/Install -
Typical
1 - TROUGH FORMATION
2 - LATCHES (5)
3 - PDC HOUSING LOWER COVER
4 - WIRE HARNESS
(1) Rem ove t h e P DC h ou sin g lower cover.
(2) F r om t h e t op of t h e P DC h ou sin g, u se a sm a ll
scr ewdr iver or a t er m in a l pick t ool (Specia l Tool Kit
6680) t o r elea se t h e t wo la t ch es t h a t secu r e t h e B(+)
t er m in a l m odu le in t h e P DC.
(3) Gen t ly a n d even ly pr ess t h e t wo B(+) t er m in a l
st u ds down t h r ou gh t h e bu s ba r in t h e P DC.
(4) F r om t h e bot t om of t h e P DC h ou sin g, r em ove
t h e B(+) t er m in a l m odu le fr om t h e P DC.
PDC RELAY WEDGE REMOVAL
Th e P ower Dist r ibu t ion Cen t er (P DC) cover, t h e
P DC h ou sin g lower cover, t h e P DC r ela y wedges, t h e
P DC r ela y ca sset t es a n d t h e P DC B(+) t er m in a l st u d
m odu le a r e a va ila ble for ser vice r epla cem en t . Th e
P DC cover ca n be sim ply u n la t ch ed a n d r em oved
fr om t h e P DC h ou sin g wit h ou t t h e P DC bein g
r em oved or disa ssem bled. Ser vice of t h e r em a in in g
P DC com pon en t s r equ ir es t h a t t h e P DC be r em oved
fr om it s m ou n t in g a n d disa ssem bled. Refer t o Wirin g
Re p a ir in Wir in g Dia gr a m s for t h e loca t ion of t h e
wir in g r epa ir pr ocedu r es.
(1) Rem ove t h e P DC h ou sin g lower cover.
(2) Rem ove ea ch of t h e r ela ys fr om t h e P DC r ela y
wedge t o be r em oved.
(3) F r om t h e bot t om of t h e P DC h ou sin g, u se a
sm a ll scr ewdr iver or a t er m in a l pick t ool (Specia l
8W - 97 - 10 8W-97 POWER DISTRIBUTION WJ
POWER DI ST RI BU T I ON CEN T ER (Cont inue d)
Tool Kit 6680) t o r elea se t h e t wo la t ch es (yellow) t h a t 6680) t o r elea se t h e t wo la t ch es t h a t secu r e t h e r ela y
secu r e t h e r ela y wedge t o t h e P DC r ela y ca sset t e. ca sset t e in t h e P DC (F ig. 12).
(4) F r om t h e t op of t h e P DC h ou sin g, r em ove t h e
r ela y wedge fr om t h e P DC r ela y ca sset t e (F ig. 11).

Fig. 12 PDC Relay Cassette Latches - Typical

1 - LATCHES
2 - FROM SPECIAL TOOL KIT 6680
3 - PDC RELAY CASSETTES (TYPICAL)

Fig. 11 PDC Relay Wedge Remove/Install - Typical (3) Gen t ly a n d even ly pr ess t h e r ela y ca sset t e
1 - RELAY WEDGE (TYPICAL) down t h r ou gh t h e P DC h ou sin g.
2 - PDC HOUSING (4) F r om t h e bot t om of t h e P DC h ou sin g, r em ove
t h e r ela y ca sset t e fr om t h e P DC (F ig. 13).
PDC RELAY CASSETTE REMOVAL
Th e P ower Dist r ibu t ion Cen t er (P DC) cover, t h e
P DC h ou sin g lower cover, t h e P DC r ela y wedges, t h e
P DC r ela y ca sset t es a n d t h e P DC B(+) t er m in a l st u d
m odu le a r e a va ila ble for ser vice r epla cem en t . Th e
P DC cover ca n be sim ply u n la t ch ed a n d r em oved
fr om t h e P DC h ou sin g wit h ou t t h e P DC bein g
r em oved or disa ssem bled. Ser vice of t h e r em a in in g
P DC com pon en t s r equ ir es t h a t t h e P DC be r em oved
fr om it s m ou n t in g a n d disa ssem bled. Refer t o Wirin g
Re p a ir in Wir in g Dia gr a m s for t h e loca t ion of t h e
wir in g r epa ir pr ocedu r es.
(1) Rem ove t h e r ela y wedge fr om t h e P DC r ela y
ca sset t e t o be r em oved.

NOTE: It may be necessary to remove relay cas-

settes that are not being serviced from the PDC
housing in order to obtain sufficient clearance to
access the faulty relay cassette. The same service
procedure is repeated as necessary to remove each
of the interfering relay wedges and relay cassettes Fig. 13 PDC Relay - Typical
from the PDC housing. 1 - PDC HOUSING
2 - PDC RELAY CASSETTE (TYPICAL)
(2) F r om t h e t op of t h e P DC h ou sin g, u se a sm a ll 3 - LATCHES
scr ewdr iver or a t er m in a l pick t ool (Specia l Tool Kit
WJ 8W-97 POWER DISTRIBUTION
POWER DI ST RI BU T I ON CEN T ER (Cont inue d)
CAUTION: Do not remove the wiring and terminals
from the terminal cavities of the faulty PDC relay
cassette at this time. Refer to the Assembly proce-
dure that follows for the proper procedures for
transferring the wiring and terminals to the replace-
ment PDC relay cassette.
ASSEM BLY
POWER DISTRIBUTION CENTER ASSEMBLY
PDC B(+) TERMINAL MODULE INSTALLATION
(1) F r om t h e bot t om of t h e P DC h ou sin g, a lign a n d
in ser t t h e B(+) t er m in a l m odu le in t o t h e P DC.
(2) F r om t h e bot t om of t h e P DC h ou sin g, a lign a n d
in ser t t h e t wo st u ds of t h e P DC B(+) t er m in a l m od-
u le t h r ou gh t h e bu s ba r in t h e P DC.
(3) F r om t h e bot t om of t h e P DC h ou sin g, pr ess t h e
B(+) t er m in a l m odu le gen t ly a n d even ly in t o t h e P DC
u n t il bot h of t h e la t ch es a r e fu lly en ga ged.
(4) In st a ll t h e P DC h ou sin g lower cover.
RELAY WEDGE INSTALLATION
(1) F r om t h e t op of t h e P DC h ou sin g, a lign a n d
in ser t t h e P DC r ela y wedge la t ch a r m s in t o t h e cor-
r ect ca vit ies in t h e r ela y ca sset t e.
(2) Gen t ly a n d even ly pr ess t h e P DC r ela y wedge
down in t o t h e r ela y ca sset t e u n t il bot h of t h e la t ch es
a r e fu lly en ga ged.
(3) In st a ll ea ch of t h e r em oved r ela ys in t o t h e
pr oper ca vit ies of t h e P DC r ela y wedge.
(4) In st a ll t h e P DC h ou sin g lower cover.
RELAY CASSETTE INSTALLATION
(1) Move t h e fa u lt y P DC r ela y ca sset t e wit h it s
wir in g a wa y fr om t h e bot t om of t h e P DC h ou sin g fa r
en ou gh t o a llow t h e r epla cem en t r ela y ca sset t e t o be
in st a lled in t o t h e P DC.
(2) Usin g t h e fa u lt y r ela y ca sset t e a s a gu ide, be
cer t a in t h a t t h e r epla cem en t r ela y ca sset t e is cor-
r ect ly or ien t ed befor e in st a llin g it in t o t h e P DC h ou s-
in g.
(3) F r om t h e bot t om of t h e P DC h ou sin g, a lign a n d
in ser t t h e r epla cem en t r ela y ca sset t e in t o t h e P DC.
P r ess t h e r ela y ca sset t e u p in t o t h e P DC u n t il bot h
of t h e la t ch es a r e fu lly en ga ged.
CAUTION: Proper care must be taken to be certain
that the wiring and terminals from the faulty PDC
relay cassette are installed in the correct terminal
cavities of the replacement relay cassette. To pre-
vent mistakes it is recommended that the wiring
and terminals be removed from the faulty relay cas-
sette one cavity at a time, repaired or spliced as
necessary, then installed securely into the correct
8W - 97 - 11
cavity of the replacement relay cassette. If you are
not absolutely certain into which cavity a terminal
should be installed, refer to Power Distribution in
the index of this service manual for the location of
complete circuit diagrams covering the PDC.
(4) Wh ile pu llin g gen t ly on t h e wir e fr om t h e bot -
t om of t h e fa u lt y P DC r ela y ca sset t e, u se a t er m in a l
pick t ool (Specia l Tool Kit 6680) fr om t h e t op of t h e
r ela y ca sset t e t o r elea se t h e la t ch t h a t secu r es t h e
t er m in a l in t h e r ela y ca sset t e t er m in a l ca vit y (F ig.
14).
Fig. 14 PDC Relay Cassette Terminal Remove/Install
- Typical
1 - TERMINAL CAVITIES (TYPICAL)
2 - PDC RELAY CASSETTE (TYPICAL)
3 - TERMINAL LATCHES (TYPICAL)
4 - FROM SPECIAL TOOL KIT 6680
(5) F r om t h e bot t om of t h e fa u lt y P DC r ela y ca s-
set t e, r em ove t h e wir e a n d t er m in a l fr om t h e r ela y
ca sset t e t er m in a l ca vit y.
(6) Ma ke a ll n ecessa r y r epa ir s a n d splices t o t h e
wir e for t h e r em oved t er m in a l. Refer t o Wirin g
Re p a ir in Wir in g Dia gr a m s for t h e loca t ion of t h e
wir in g r epa ir pr ocedu r es.
(7) F r om t h e bot t om of t h e P DC h ou sin g, a lign a n d
in ser t t h e r em oved wir e a n d t er m in a l in t o t h e cor r ect
t er m in a l ca vit y of t h e r epla cem en t r ela y ca sset t e.
P u sh t h e wir e a n d t er m in a l u p in t o t h e r ela y ca sset t e
t er m in a l ca vit y u n t il it is fu lly en ga ged by t h e la t ch .
(8) Repea t St ep 4, St ep 5, St ep 6 a n d St ep 7 on e
wir e a n d t er m in a l a t a t im e u n t il ea ch of t h e wir es
a n d t er m in a ls h a ve been t r a n sfer r ed fr om t h e fa u lt y
P DC r ela y ca sset t e in t o t h e r epla cem en t r ela y ca s-
set t e.
(9) In st a ll t h e P DC r ela y wedge in t o t h e r epla ce-
m en t P DC r ela y ca sset t e.
8W - 97 - 12 8W-97 POWER DISTRIBUTION
POWER DI ST RI BU T I ON CEN T ER (Cont inue d)
PDC LOWER COVER INSTALLATION
(1) Align t h e P DC h ou sin g lower cover on t h e bot -
t om of t h e P DC.
(2) E ven ly pr ess t h e lower cover in t o pla ce u n t il
la t ch es a r e fu lly en ga ged.
(3) Wh er e t h e r igh t h ea dla m p a n d da sh h a r n ess
en t er s t h e P DC, t a pe t h e h a r n ess secu r ely t o t h e
t r ou gh for m a t ion on t h e P DC lower cover.
(4) In st a ll t h e P DC in it s m ou n t in g loca t ion on t h e
ba t t er y su ppor t .
(5) In st a ll t h e ba t t er y wir e h a r n ess over t h e t wo
P DC B+ t er m in a l st u ds. Tor qu e t h e n u t s t o 11.3 N·m
(100 in . lbs.).
(6) In st a ll t h e ba t t er y. Refer t o Ba t t er y Syst em for
t h e pr ocedu r e.
(7) In st a ll t h e P DC cover.
INSTALLATION
Th e P ower Dist r ibu t ion Cen t er (P DC) m a in h ou s-
in g u n it , t h e P DC fu se wedges a n d t h e P DC bu s ba r s
ca n n ot be r epa ir ed a n d a r e on ly ser viced a s a u n it
wit h t h e r igh t h ea dla m p a n d da sh wir e h a r n ess. If
t h e P DC m a in h ou sin g u n it , t h e fu se wedges or t h e
bu s ba r s a r e fa u lt y or da m a ged, t h e en t ir e P DC a n d
r igh t h ea dla m p a n d da sh wir e h a r n ess u n it m u st be
r epla ced.
(1) P osit ion t h e P DC a n d t h e r igh t h ea dla m p a n d
da sh wir e h a r n ess u n it in t h e en gin e com pa r t m en t .
(2) E n ga ge t h e P DC h ou sin g m ou n t s wit h t h e
st a n ch ion s of t h e ba t t er y su ppor t a n d pu sh t h e u n it
down wa r d u n t il t h e m ou n t la t ch es fu lly en ga ge t h e
m ou n t in g t a bs on t h e st a n ch ion s.
(3) In st a ll t h e t wo-h oled eyelet of t h e ba t t er y wir e
h a r n ess P DC t a ke ou t s on t o t h e t wo P DC B(+) t er m i-
n a l st u ds.
(4) In st a ll a n d t igh t en t h e n u t s t h a t secu r e t h e
eyelet of t h e ba t t er y wir e h a r n ess P DC t a ke ou t s t o
t h e B(+) t er m in a l st u ds. Tigh t en t h e n u t s t o 11.3
N·m (100 in . lbs.).
(5) E n ga ge ea ch of t h e r et a in er s t h a t secu r e t h e
r igh t h ea dla m p a n d da sh wir e h a r n ess t o t h e veh icle
body a n d ch a ssis com pon en t s. Refer t o Co n n e c to r
Lo c a tio n s in Wir in g Dia gr a m s for t h e loca t ion of
m or e in for m a t ion on t h e r igh t h ea dla m p a n d da sh
wir e h a r n ess r et a in er loca t ion s.
(6) In st a ll a ll of t h e fa st en er s t h a t secu r e ea ch of
t h e r igh t h ea dla m p a n d da sh wir e h a r n ess gr ou n d
eyelet s t o t h e veh icle body a n d ch a ssis com pon en t s.
Refer t o Co n n e c to r Lo c a tio n s in Wir in g Dia gr a m s
for t h e loca t ion of m or e in for m a t ion on t h e gr ou n d
eyelet loca t ion s.
(7) Recon n ect ea ch of t h e r igh t h ea dla m p a n d da sh
wir e h a r n ess con n ect or s. Refer t o Co n n e c to r Lo c a -
tio n s in Wir in g Dia gr a m s for t h e loca t ion of m or e
in for m a t ion on t h e r igh t h ea dla m p a n d da sh wir e
h a r n ess con n ect or loca t ion s. F or con n ect or s secu r ed
WJ
wit h scr ews, t igh t en t h e scr ews t o 4.3 N·m (38 in .
lbs.).
(8) Recon n ect t h e ba t t er y n ega t ive ca ble.
POWER OU T LET
DESCRIPTION - FRONT POWER OUTLET
An a ccessor y power ou t let is st a n da r d equ ipm en t
on t h is m odel. Th e power ou t let is in st a lled in t h e
in st r u m en t pa n el cen t er lower bezel, wh ich is loca t ed
n ea r t h e bot t om of t h e in st r u m en t pa n el cen t er st a ck
a r ea , below t h e h ea t er a n d a ir con dit ion er con t r ols.
Th e power ou t let ba se is secu r ed by a sn a p fit wit h in
t h e cen t er lower bezel. A h in ged door wit h a n over-
cen t er spr in g flips closed t o con cea l a n d pr ot ect t h e
power ou t let ba se wh en t h e power ou t let is n ot bein g
u sed, a n d flips open below t h e cen t er lower bezel
wh ile t h e power ou t let is in u se.
Th e power ou t let r ecept a cle u n it a n d t h e power
ou t let door a r e ea ch a va ila ble for ser vice r epla ce-
m en t .
OPERATION - FRONT POWER OUTLET
Th e power ou t let ba se or r ecept a cle sh ell is con -
n ect ed t o gr ou n d, a n d a n in su la t ed con t a ct in t h e
bot t om of t h e sh ell is con n ect ed t o ba t t er y cu r r en t .
Th e power ou t let r eceives ba t t er y volt a ge fr om a fu se
in t h e ju n ct ion block a t a ll t im es.
Wh ile t h e power ou t let is ver y sim ila r t o a ciga r
ligh t er ba se u n it , it does n ot in clu de t h e t wo sm a ll
spr in g-clip r et a in er s in side t h e bot t om of t h e r ecept a -
cle sh ell t h a t a r e u sed t o secu r e t h e ciga r ligh t er
h ea t in g elem en t t o t h e in su la t ed con t a ct .
DIAGNOSIS AND TESTING - POWER OUTLET
F or com plet e cir cu it dia gr a m s, r efer t o Ho rn /Ci-
g a r Lig h te r/P o w e r Ou tle t in Wir in g Dia gr a m s.
WARNING: REFER TO RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Ch eck t h e fu sed B(+) fu se in t h e ju n ct ion block.
If OK, go t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir-
cu it or com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y
fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e ju n ct ion block. If OK, go t o St ep 3. If n ot OK,
r epa ir t h e open fu sed B(+) cir cu it t o t h e P ower Dis-
t r ibu t ion Cen t er (P DC) fu se a s r equ ir ed.
(3) Open t h e power ou t let door. Ch eck for con t in u -
it y bet ween t h e in side cir cu m fer en ce of t h e power
WJ 8W-97 POWER DISTRIBUTION 8W - 97 - 13
POWER OU T LET (Cont inue d)
ou t let r ecept a cle a n d a good gr ou n d. Th er e sh ou ld be
con t in u it y. If OK, go t o St ep 4. If n ot OK, go t o St ep
5.
(4) Ch eck for ba t t er y volt a ge a t t h e in su la t ed con -
t a ct loca t ed a t t h e ba ck of t h e power ou t let r ecept a -
cle. If n ot OK, go t o St ep 5.
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e in st r u m en t pa n el cen t er lower
bezel. Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e power ou t let wir e h a r n ess con n ect or
a n d a good gr ou n d. Th er e sh ou ld be con t in u it y. If
OK, go t o St ep 6. If n ot OK, r epa ir t h e open gr ou n d
cir cu it t o gr ou n d a s r equ ir ed.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
power ou t let wir e h a r n ess con n ect or. If OK, r epla ce
t h e fa u lt y power ou t let r ecept a cle. If n ot OK, r epa ir
t h e open fu sed B(+) cir cu it t o t h e ju n ct ion block fu se
a s r equ ir ed.

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
Fig. 15 Cigar Lighter and Power Outlet Remove/
ca ble.
Install - Typical
(2) Rem ove t h e cen t er lower bezel fr om t h e in st r u -
m en t pa n el. Refer t o In s tru m e n t P a n e l Ce n te r 1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
Lo w e r B e ze l in Body for t h e pr ocedu r e.
3 - BASE
(3) P u ll t h e ciga r ligh t er kn ob a n d elem en t or t h e
4 - PARTIALLY REMOVED
pr ot ect ive ca p ou t of t h e ciga r ligh t er r ecept a cle ba se, 5 - EXTERNAL SNAP-RING PLIERS
or open t h e power ou t let door in t h e in st r u m en t 6 - MOUNT
pa n el cen t er lower bezel. 7 - BASE
(4) Look in side t h e ciga r ligh t er or power ou t let
r ecept a cle ba se a n d n ot e t h e posit ion of t h e r ect a n gu -
(4) In st a ll t h e ciga r ligh t er kn ob a n d elem en t or
la r r et a in in g bosses of t h e m ou n t t h a t secu r es t h e
t h e pr ot ect ive ca p in t o t h e ciga r ligh t er r ecept a cle
r ecept a cle ba se t o t h e in st r u m en t pa n el cen t er lower
ba se, or close t h e power ou t let door in t h e in st r u m en t
bezel (F ig. 15).
pa n el cen t er lower bezel.
(5) In ser t a pa ir of ext er n a l sn a p r in g plier s in t o
(5) In st a ll t h e cen t er lower bezel on t o t h e in st r u -
t h e ciga r ligh t er or power ou t let r ecept a cle ba se a n d
m en t pa n el. Refer t o In s tru m e n t P a n e l Ce n te r
en ga ge t h e t ips of t h e plier s wit h t h e r et a in in g
Lo w e r B e ze l in Body for t h e pr ocedu r e.
bosses of t h e m ou n t .
(6) Recon n ect t h e ba t t er y n ega t ive ca ble.
(6) Squ eeze t h e plier s t o disen ga ge t h e m ou n t
r et a in in g bosses fr om t h e r ecept a cle ba se a n d, u sin g
a gen t le r ockin g m ot ion , pu ll t h e plier s a n d t h e POWER OU T LET RELAY
r ecept a cle ba se ou t of t h e m ou n t .
(7) Rem ove t h e ciga r ligh t er or power ou t let m ou n t
DESCRIPTION
fr om t h e in st r u m en t pa n el cen t er lower bezel.
Th e power ou t let / ciga r ligh t er r ela y is a n elect r o-
m ech a n ica l device t h a t swit ch es fu sed ba t t er y cu r-
INSTALLATION r en t t o t h e ciga r ligh t er or power ou t let wh en t h e
(1) In st a ll t h e ciga r ligh t er or power ou t let m ou n t
ign it ion swit ch is t u r n ed t o t h e Accessor y or On posi-
in t o t h e in st r u m en t pa n el cen t er lower bezel.
t ion s. Th e power ou t let / ciga r ligh t er r ela y is loca t ed
(2) Align t h e splin es on t h e ou t side of t h e ciga r
in t h e ju n ct ion block, below t h e dr iver side of t h e
ligh t er or power ou t let r ecept a cle ba se con n ect or
in st r u m en t pa n el in t h e pa ssen ger com pa r t m en t .
r ecept a cle wit h t h e gr ooves on t h e in side of t h e
Th e ciga r ligh t er r ela y is a In t er n a t ion a l St a n da r ds
m ou n t .
Or ga n iza t ion (ISO) r ela y. Rela ys con for m in g t o t h e
(3) P r ess fir m ly on t h e ciga r ligh t er or power ou t -
ISO specifica t ion s h a ve com m on ph ysica l dim en sion s,
let r ecept a cle ba se u n t il t h e r et a in in g bosses of t h e
cu r r en t ca pa cit ies, t er m in a l pa t t er n s, a n d t er m in a l
m ou n t a r e fu lly en ga ged in t h eir r ecept a cles.
fu n ct ion s.
8W - 97 - 14 8W-97 POWER DISTRIBUTION
POWER OU T LET RELAY (Cont inue d)
Th e ciga r ligh t er r ela y ca n n ot be r epa ir ed or
a dju st ed a n d, if fa u lt y or da m a ged, it m u st be
r epla ced.
OPERATION
Th e ISO r ela y con sist s of a n elect r om a gn et ic coil, a
r esist or or diode, a n d t h r ee (t wo fixed a n d on e m ov-
a ble) elect r ica l con t a ct s. Th e m ova ble (com m on feed)
r ela y con t a ct is h eld a ga in st on e of t h e fixed con t a ct s
(n or m a lly closed) by spr in g pr essu r e. Wh en t h e elec-
t r om a gn et ic coil is en er gized, it dr a ws t h e m ova ble
con t a ct a wa y fr om t h e n or m a lly closed fixed con t a ct ,
a n d h olds it a ga in st t h e ot h er (n or m a lly open ) fixed
con t a ct .
Wh en t h e elect r om a gn et ic coil is de-en er gized,
spr in g pr essu r e r et u r n s t h e m ova ble con t a ct t o t h e
n or m a lly closed posit ion . Th e r esist or or diode is con -
n ect ed in pa r a llel wit h t h e elect r om a gn et ic coil in t h e
r ela y, a n d h elps t o dissipa t e volt a ge spikes t h a t a r e
pr odu ced wh en t h e coil is de-en er gized.
DIAGNOSIS AND TESTING - POWER OUTLET
RELAY
Th e power ou t let / ciga r ligh t er r ela y (F ig. 16) is
loca t ed in t h e ju n ct ion block, below t h e dr iver side
en d of t h e in st r u m en t pa n el in t h e pa ssen ger com -
pa r t m en t . F or com plet e cir cu it dia gr a m s, r efer t o
Ho rn /Cig a r Lig h te r/P o w e r Ou tle t in Wir in g Dia -
gr a m s.
WARNING: REFER TO RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Rem ove t h e power ou t let / ciga r ligh t er r ela y
fr om t h e ju n ct ion block. Refer t o t h e pr ocedu r e in
t h is gr ou p.
(2) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(3) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ± 5 oh m s. If OK, go t o St ep
4. If n ot OK, r epla ce t h e fa u lt y r ela y.
(4) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A
a n d 30. If OK, per for m t h e Rela y Cir cu it Test t h a t
follows. If n ot OK, r epla ce t h e fa u lt y r ela y.
WJ
Fig. 16 Accessory Relay
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) of
t h e ju n ct ion block is con n ect ed t o ba t t er y volt a ge a n d
sh ou ld be h ot a t a ll t im es. Ch eck for ba t t er y volt a ge
a t t h e fu sed B(+) cir cu it ca vit y in t h e ju n ct ion block
r ecept a cle for t h e ciga r ligh t er r ela y. If OK, go t o
St ep 2. If n ot OK, r epa ir t h e fu sed B(+) cir cu it t o t h e
P ower Dist r ibu t ion Cen t er (P DC) fu se a s r equ ir ed.
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3.
(3) Th e r ela y n or m a lly open t er m in a l (87) is con -
n ect ed t o t h e com m on feed t er m in a l (30) in t h e en er-
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
t o t h e fu sed B(+) fu se in t h e ju n ct ion block t h a t feeds
t h e ciga r ligh t er wh en t h e r ela y is en er gized by t h e
ign it ion swit ch . Th er e sh ou ld be con t in u it y bet ween
t h e ju n ct ion block ca vit y for r ela y t er m in a l 87 a n d
t h e fu sed B(+) fu se in t h e ju n ct ion block a t a ll t im es.
If OK, go t o St ep 4. If n ot OK, r epa ir t h e open fu sed
B(+) cir cu it t o t h e ju n ct ion block fu se a s r equ ir ed.
(4) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It r eceives ba t t er y
feed t o en er gize t h e ciga r ligh t er r ela y wh en t h e ign i-
t ion swit ch is in t h e Accessor y or On posit ion s. Tu r n
t h e ign it ion swit ch t o t h e On posit ion . Ch eck for ba t -
t er y volt a ge a t t h e fu sed ign it ion swit ch ou t pu t (a cc/
r u n ) cir cu it ca vit y for r ela y t er m in a l 85 in t h e
ju n ct ion block r ecept a cle for t h e ciga r ligh t er r ela y. If
OK, go t o St ep 5. If n ot OK, r epa ir t h e open fu sed
ign it ion swit ch ou t pu t (a cc/r u n ) cir cu it t o t h e ign it ion
swit ch a s r equ ir ed.
(5) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. Th e ju n ct ion block
ca vit y for t h is t er m in a l sh ou ld h a ve con t in u it y t o
WJ 8W-97 POWER DISTRIBUTION 8W - 97 - 15
POWER OU T LET RELAY (Cont inue d)
gr ou n d a t a ll t im es. If n ot OK, r epa ir t h e open
gr ou n d cir cu it t o gr ou n d a s r equ ir ed.

REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e st eer in g colu m n open in g cover
fr om t h e in st r u m en t pa n el. Refer t o S te e rin g Co l-
u m n Op e n in g Co v e r in Body for t h e pr ocedu r e.
(3) Th e power ou t let / ciga r ligh t er r ela y is loca t ed
on t h e left side of t h e com bin a t ion fla sh er in t h e
ju n ct ion block.
(4) Rem ove t h e power ou t let / ciga r ligh t er r ela y
fr om t h e ju n ct ion block.

INSTALLATION
(1) P osit ion t h e power ou t let / ciga r ligh t er r ela y in
t h e pr oper r ecept a cle in t h e ju n ct ion block.
(2) Align t h e power ou t let / ciga r ligh t er r ela y t er-
m in a ls wit h t h e t er m in a l ca vit ies in t h e ju n ct ion
block r ecept a cle.
(3) P u sh in fir m ly on t h e power ou t let / ciga r
ligh t er r ela y u n t il t h e t er m in a ls a r e fu lly sea t ed in
t h e t er m in a l ca vit ies in t h e ju n ct ion block r ecept a cle.
(4) In st a ll t h e st eer in g colu m n open in g cover on t o
t h e in st r u m en t pa n el. Refer t o S te e rin g Co lu m n
Op e n in g Co v e r in Body for t h e pr ocedu r e.
(5) Recon n ect t h e ba t t er y n ega t ive ca ble.
I OD WI RE H ARN ESS
CON N ECT OR
DESCRIPTION
All veh icles a r e equ ipped wit h a n Ign it ion -Off
Dr a w (IOD) con n ect or t h a t is loca t ed in a m olded
con n ect or r ecept a cle on t h e lower r ea r su r fa ce of t h e
J u n ct ion Block (J B) h ou sin g (F ig. 17). Th e J B is con -
cea led a bove t h e m olded pla st ic in st r u m en t pa n el
fu se cover. In t egr a l la t ch es m olded in t o t h e fu se
cover secu r e it t h e J B, t h e Body Con t r ol Modu le
(BCM) a n d t h e 16-wa y da t a lin k con n ect or t a b of t h e
in st r u m en t pa n el st eer in g colu m n su ppor t br a cket .
Th e fu se cover ca n be pu lled down wa r d t o disen ga ge
t h e la t ch es a n d pr ovide ser vice a ccess t o a ll of t h e
fu ses, r ela ys a n d wir e h a r n ess con n ect or s of t h e J B.
Refer t o In s tru m e n t P a n e l F u s e Co v e r in t h e
in dex of t h is ser vice m a n u a l for t h e loca t ion of a ddi-
t ion a l ser vice in for m a t ion cover in g t h e fu se cover.
OPERATION
Th e t er m ign it ion -off dr a w iden t ifies a n or m a l con -
dit ion wh er e power is bein g dr a in ed fr om t h e ba t t er y
wit h t h e ign it ion swit ch in t h e Off posit ion . Th e IOD
con n ect or feeds t h e m em or y a n d sleep m ode fu n c-
t ion s for som e of t h e elect r on ic m odu les in t h e veh icle
Fig. 17 Ignition-Off Draw Connector
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
4 - LEFT BODY WIRE HARNESS
5 - IOD CONNECTOR
6 - FUSED B+ CONNECTOR
7 - RIGHT BODY WIRE HARNESS
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
a s well a s va r iou s ot h er a ccessor ies t h a t r equ ir e ba t -
t er y cu r r en t wh en t h e ign it ion swit ch is in t h e Off
posit ion , in clu din g t h e clock.
Th e IOD con n ect or ca n be u sed by t h e veh icle
own er a s a con ven ien t m ea n s of r edu cin g ba t t er y
deplet ion wh en a veh icle is t o be st or ed for per iods
n ot t o exceed a bou t t wen t y da ys (sh or t -t er m st or a ge).
Sim ply discon n ect t h e IOD con n ect or fr om t h e J B
r ecept a cle. H owever, it m u st be r em em ber ed t h a t dis-
con n ect in g t h e IOD con n ect or will n ot elim in a t e IOD,
bu t on ly r edu ce t h is n or m a l con dit ion . Wh en a veh i-
cle will n ot be u sed for m or e t h a n t wen t y da ys, bu t
less t h a n t h ir t y da ys, r em ove t h e IOD fu se fr om t h e
P ower Dist r ibu t ion Cen t er (P DC). If a veh icle will be
st or ed for m or e t h a n a bou t t h ir t y da ys, t h e ba t t er y
n ega t ive ca ble sh ou ld be discon n ect ed t o elim in a t e
n or m a l IOD; a n d, t h e ba t t er y sh ou ld be t est ed a n d
r ech a r ged a t r egu la r in t er va ls du r in g t h e veh icle
st or a ge per iod t o pr even t t h e ba t t er y fr om becom in g
disch a r ged or da m a ged. Refer t o Ig n itio n -Off D ra w
8W - 97 - 16 8W-97 POWER DISTRIBUTION WJ
I OD WI RE H ARN ESS CON N ECT OR (Cont inue d)
F u s e a n d B a tte ry in t h e in dex in t h is ser vice m a n -
u a l for t h e loca t ion of a ddit ion a l ser vice in for m a t ion
cover in g t h e ign it ion -off dr a w fu se a n d t h e ba t t er y.

FU SE COV ER
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) P u ll down on t h e r ea r edge (n ea r est t h e r ea r of
t h e veh icle) of t h e in st r u m en t pa n el fu se cover u n t il
t h e r ea r la t ch es u n sn a p fr om t h e t a bs on t h e lower
ju n ct ion block h ou sin g a n d t h e side la t ch u n sn a ps
fr om t h e t a b on t h e in st r u m en t pa n el st eer in g col-
u m n su ppor t br a cket ou t boa r d of t h e 16-wa y da t a
lin k con n ect or (F ig. 18).

Fig. 19 Instrument Panel Fuse Cover Locator

Channels
1 - JUNCTION BLOCK
2 - SCREWS (4)
3 - BODY CONTROL MODULE
4 - FUSE COVER LOCATOR CHANNELS
5 - FUSE COVER MOUNTING SLOTS
6 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS

la t ch es exit t h e fr on t of t h e loca t or ch a n n els. Th is

will loca t e t h e fr on t la t ch es a t t h e m ou n t in g slot s in
t h e lower h ou sin g of t h e body con t r ol m odu le.
(3) Apply a sligh t r ea r wa r d pr essu r e on t h e in st r u -
m en t pa n el fu se cover t o en ga ge t h e fr on t la t ch es in
t h e m ou n t in g slot s in t h e lower h ou sin g of t h e body
Fig. 18 Instrument Panel Fuse Cover Remove/Install
con t r ol m odu le.
1 - REAR LATCHES (4) Swin g t h e r ea r edge (n ea r est t h e r ea r of t h e
2 - JUNCTION BLOCK AND BODY CONTROL MODULE UNIT
veh icle) of t h e in st r u m en t pa n el fu se cover u p t owa r d
3 - INSTRUMENT PANEL FUSE COVER
t h e ju n ct ion block.
4 - SIDE LATCH
5 - FRONT LATCHES
(5) P r ess fir m ly u pwa r d on t h e in st r u m en t pa n el
fu se cover over t h e r ea r la t ch es u n t il t h e la t ch es
sn a p in t o pla ce over t h e t a bs on t h e lower edge of t h e
(3) Move t h e in st r u m en t pa n el fu se cover t owa r ds ju n ct ion block h ou sin g.
t h e fr on t of t h e veh icle t o disen ga ge t h e fr on t la t ch es (6) P r ess fir m ly u pwa r d on t h e 16-wa y da t a lin k
fr om t h e m ou n t in g slot s in t h e lower h ou sin g of t h e con n ect or cover for m a t ion of t h e in st r u m en t pa n el
body con t r ol m odu le. fu se cover u n t il t h e side la t ch sn a ps in t o pla ce over
(4) Rem ove t h e fu se cover fr om u n der t h e in st r u - t h e t a b on t h e ou t boa r d side of t h e in st r u m en t pa n el
m en t pa n el. st eer in g colu m n su ppor t br a cket .
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
INSTALLATION
(1) P osit ion t h e t wo fr on t la t ch es of t h e in st r u m en t
pa n el fu se cover wit h in t h e t wo loca t or ch a n n el for- REAR POWER OU T LET
m a t ion s on t h e bot t om of t h e body con t r ol m odu le
h ou sin g (F ig. 19). DESCRIPTION - REAR POWER OUTLET
(2) Wh ile a pplyin g a sligh t u pwa r d pr essu r e t o t h e A r ea r a ccessor y power ou t let is opt ion a l equ ip-
in st r u m en t pa n el fu se cover over t h e fr on t la t ch es, m en t on t h is m odel. Th e r ea r power ou t let is
slowly slide t h e fr on t la t ch es t h r ou gh t h e loca t or in st a lled in t h e lower r igh t qu a r t er t r im pa n el n ea r
ch a n n els t owa r d t h e fr on t of t h e veh icle u n t il t h e t h e r igh t lift ga t e open in g pilla r in t h e ca r go a r ea of
WJ 8W-97 POWER DISTRIBUTION
REAR POWER OU T LET (Cont inue d)
t h e veh icle. Th e power ou t let ba se a n d m ou n t a r e
secu r ed by a sn a p fit wit h in t h e qu a r t er t r im pa n el.
A pla st ic pr ot ect ive ca p sn a ps in t o t h e power ou t let
ba se wh en t h e power ou t let is n ot bein g u sed, a n d
h a n gs fr om t h e power ou t let ba se m ou n t by a n in t e-
gr a l ba il st r a p wh ile t h e power ou t let is in u se. Wh ile
t h e power ou t let is ver y sim ila r t o a ciga r ligh t er
ba se u n it , it does n ot in clu de t h e t wo sm a ll spr in g-
clip r et a in er s in side t h e bot t om of t h e r ecept a cle
sh ell t h a t a r e u sed t o secu r e t h e ciga r ligh t er h ea t in g
elem en t t o t h e in su la t ed con t a ct .
Th e power ou t let r ecept a cle u n it a n d t h e a ccessor y
power ou t let pr ot ect ive ca p a r e a va ila ble for ser vice.
Th e power ou t let r ecept a cle ca n n ot be r epa ir ed a n d,
if fa u lt y or da m a ged, it m u st be r epla ced.
OPERATION - REAR POWER OUTLET
Th e power ou t let ba se or r ecept a cle sh ell is con -
n ect ed t o gr ou n d, a n d a n in su la t ed con t a ct in t h e
bot t om of t h e sh ell is con n ect ed t o ba t t er y cu r r en t .
Th e power ou t let r eceives ba t t er y volt a ge fr om a fu se
in t h e P ower Dist r ibu t ion Cen t er (P DC) t h r ou gh a
fu se in t h e J u n ct ion Block (J B) a t a ll t im es. Refer t o
Ho rn /Cig a r Lig h te r/P o w e r Ou tle t in Wir in g Dia -
gr a m s for t h e loca t ion of com plet e r ea r power ou t let
cir cu it dia gr a m s.
8W - 97 - 17
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e r ea r power ou t let fr om t h e r igh t
qu a r t er t r im pa n el. Ch eck for con t in u it y bet ween t h e
gr ou n d cir cu it ca vit y of t h e r ea r power ou t let wir e
h a r n ess con n ect or a n d a good gr ou n d. Th er e sh ou ld
be con t in u it y. If OK, go t o St ep 6. If n ot OK, r epa ir
t h e open gr ou n d cir cu it t o gr ou n d a s r equ ir ed.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
r ea r power ou t let wir e h a r n ess con n ect or. If OK,
r epla ce t h e fa u lt y r ea r power ou t let r ecept a cle ba se.
If n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e
J B fu se a s r equ ir ed.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) P u ll t h e pr ot ect ive ca p ou t of t h e r ea r power
ou t let r ecept a cle ba se (F ig. 20).

DIAGNOSIS AND TESTING - REAR POWER

OUTLET
Refer t o Ho rn /Cig a r Lig h te r/P o w e r Ou tle t in
Wir in g Dia gr a m s for t h e loca t ion of com plet e r ea r
power ou t let cir cu it dia gr a m s.
(1) Ch eck t h e fu sed B(+) fu se in t h e J u n ct ion
Block (J B). If OK, go t o St ep 2. If n ot OK, r epa ir t h e
sh or t ed cir cu it or com pon en t a s r equ ir ed a n d r epla ce
t h e fa u lt y fu se.
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e J B. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e P ower Dist r ibu t ion Fig. 20 Rear Power Outlet Remove/Install
Cen t er (P DC) a s r equ ir ed. 1 - RIGHT QUARTER TRIM PANEL
(3) Rem ove t h e pla st ic pr ot ect ive ca p fr om t h e r ea r 2 - RIGHT BODY WIRE HARNESS CONNECTOR
power ou t let r ecept a cle. Ch eck for con t in u it y bet ween 3 - RECEPTACLE BASE
t h e in side cir cu m fer en ce of t h e r ea r power ou t let 4 - PROTECTIVE CAP
r ecept a cle a n d a good gr ou n d. Th er e sh ou ld be con t i- 5 - MOUNT
n u it y. If OK, go t o St ep 4. If n ot OK, go t o St ep 5.
(4) Ch eck for ba t t er y volt a ge a t t h e in su la t ed con -
t a ct loca t ed a t t h e ba ck of t h e r ea r power ou t let
r ecept a cle. If n ot OK, go t o St ep 5.
8W - 97 - 18 8W-97 POWER DISTRIBUTION
REAR POWER OU T LET (Cont inue d)
(3) Look in side t h e r ea r power ou t let r ecept a cle
ba se a n d n ot e t h e posit ion of t h e r ect a n gu la r r et a in -
in g bosses of t h e m ou n t t h a t secu r es t h e r ecept a cle
ba se t o t h e r igh t qu a r t er t r im pa n el (F ig. 21).
WJ
(4) In ser t a pa ir of ext er n a l sn a p r in g plier s in t o
t h e r ea r power ou t let r ecept a cle ba se a n d en ga ge t h e
t ips of t h e plier s wit h t h e r et a in in g bosses of t h e
m ou n t .
(5) Squ eeze t h e plier s t o disen ga ge t h e m ou n t
r et a in in g bosses fr om t h e r ecept a cle ba se a n d, u sin g
a gen t le r ockin g m ot ion , pu ll t h e plier s a n d t h e
r ecept a cle ba se ou t of t h e m ou n t .
(6) P u ll t h e r ea r power ou t let r ecept a cle ba se a wa y
fr om t h e r igh t qu a r t er t r im pa n el fa r en ou gh t o
a ccess t h e wir e h a r n ess con n ect or.
(7) Discon n ect t h e r igh t body wir e h a r n ess con n ec-
t or fr om t h e r ea r power ou t let r ecept a cle ba se con -
n ect or r ecept a cle.
(8) Rem ove t h e r ea r power ou t let m ou n t fr om t h e
r igh t qu a r t er t r im pa n el.

INSTALLATION
(1) Align t h e splin es on t h e ou t side of t h e r ea r
power ou t let r ecept a cle ba se con n ect or r ecept a cle
wit h t h e gr ooves on t h e in side of t h e m ou n t .
(2) In ser t t h e r ea r power ou t let r ecept a cle ba se
a bou t h a lf wa y t h r ou gh t h e m ou n t .
(3) Recon n ect t h e r igh t body wir e h a r n ess con n ec-
t or t o t h e r ea r power ou t let r ecept a cle ba se con n ect or
r ecept a cle.
Fig. 21 Power Outlet Remove/Install - Typical (4) In ser t t h e r ea r power ou t let r ecept a cle ba se
1 - KNOB AND ELEMENT a n d m ou n t in t o t h e r igh t qu a r t er t r im pa n el a s a
2 - RETAINING BOSSES-ENGAGE PLIERS HERE u n it u n t il t h e m ou n t is sea t ed flu sh a ga in st t h e t r im
3 - BASE pa n el.
4 - PARTIALLY REMOVED (5) P r ess fir m ly on t h e r ea r power ou t let r ecept a cle
5 - EXTERNAL SNAP-RING PLIERS ba se u n t il t h e r et a in in g bosses of t h e m ou n t a r e fu lly
6 - MOUNT
en ga ged in t h eir r ecept a cles.
7 - BASE
(6) In st a ll t h e pr ot ect ive ca p in t o t h e r ea r power
ou t let r ecept a cle ba se.
(7) Recon n ect t h e ba t t er y n ega t ive ca ble.
WJ ENGINE 9-1

ENGINE
TABLE OF CON T EN T S

page page

ENGINE - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

EN GI N E - 4 .0 L

TABLE OF CONTENTS
page page

ENGINE - 4.0L CYLINDER HEAD

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - ENGINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 3 INSPECTION ....................... . . . 21
DIAGNOSIS AND TESTING - ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4 CYLINDER HEAD COVER(S)
DIAGNOSIS AND TESTING— ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING—CYLINDER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COMPRESSION PRESSURE . . . . . . . . . . . . . . 8 INSPECTION ....................... . . . 23
DIAGNOSIS AND TESTING - CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
COMBUSTION PRESSURE LEAKAGE . . . . . . . 8 INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING—REAR SEAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .. . 23
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STANDARD PROCEDURE - VALVE SERVICE . . 23
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 25
STANDARD PROCEDURE - FORM-IN- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .. . 25
PLACE GASKETS AND SEALERS . . . . . . . . . . 9 ROCKER ARM / ADJUSTER ASSEMBLY
STANDARD PROCEDURE - REPAIR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
DAMAGED OR WORN THREADS . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE—HYDROSTATIC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE - CYLINDER INSPECTION ....................... . . . 27
BORE HONING . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
STANDARD PROCEDURE - ENGINE CORE VALVE STEM SEALS
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VALVE SPRINGS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPECIFICATIONS STANDARD PROCEDURE - VALVE SPRING
ENGINE - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 14 TENSION TEST . . . . . . . . . . . . . . . . . . . . . . . 28
TORQUE - 4.0L ENGINE . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AIR CLEANER ELEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 18 ENGINE BLOCK
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . 19 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AIR CLEANER HOUSING INSPECTION ....................... . . . 30
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 19 CAMSHAFT & BEARINGS
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
9-2 ENGINE - 4.0L WJ

REMOVAL STRUCTURAL SUPPORT

REMOVAL - CAMSHAFT BEARINGS . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . . 31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSPECTION LUBRICATION
INSPECTION - CAMSHAFT BEARINGS . . . . . 31 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSPECTION - CAMSHAFT . . . . . . . . . . . . . . 31 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION DIAGNOSIS AND TESTING
INSTALLATION - CAMSHAFT BEARINGS . . . 32 DIAGNOSIS AND TESTING - ENGINE OIL
INSTALLATION - CAMSHAFT ......... . . . 32 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CONNECTING ROD BEARINGS DIAGNOSIS AND TESTING - ENGINE OIL
STANDARD PROCEDURE - FITTING LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CONNECTING ROD BEARINGS ....... . . . 33 OIL
CRANKSHAFT STANDARD PROCEDURE - ENGINE OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CRANKSHAFT MAIN BEARINGS OIL FILTER
STANDARD PROCEDURE - FITTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . 36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 OIL PAN
INSPECTION ....................... . . . 40 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CRANKSHAFT OIL SEAL - FRONT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 ENGINE OIL PRESSURE SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
CRANKSHAFT OIL SEAL - REAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 OIL PUMP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HYDRAULIC LIFTERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43 INTAKE MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DIAGNOSIS AND TESTING - INTAKE
INSPECTION ....................... . . . 43 MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PISTON & CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44 EXHAUST MANIFOLD
STANDARD PROCEDURE - PISTON FITTING . 44 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
PISTON RINGS TIMING BELT / CHAIN COVER(S)
STANDARD PROCEDURE - PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
VIBRATION DAMPER TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60

EN GI N E - 4 .0 L Th e cr a n ksh a ft r ot a t ion is clockwise, wh en viewed

DESCRIPTION
Th e 4.0 Lit er (242 CID) six-cylin der en gin e is a n
In -lin e, ligh t weigh t , over h ea d va lve en gin e. Th is
en gin e is design ed for u n lea ded fu el.
Th e en gin e cylin der h ea d h a s du a l qu en ch -t ype
com bu st ion ch a m ber s t h a t cr ea t e t u r bu len ce a n d fa st
bu r n in g of t h e a ir /fu el m ixt u r e. Th is r esu lt s in bet t er
fu el econ om y.
Th e cylin der s a r e n u m ber ed 1 t h r ou gh 6 fr om fr on t
t o r ea r. Th e fir in g or der is 1-5-3-6-2-4 (F ig. 1).
fr om t h e fr on t of t h e en gin e. Th e cr a n ksh a ft r ot a t es
wit h in seven m a in bea r in gs. Th e ca m sh a ft r ot a t es
wit h in fou r bea r in gs.
Th e en gin e Bu ild Da t e Code is loca t ed on a
m a ch in ed su r fa ce on t h e r igh t side of t h e cylin der
block bet ween t h e No.2 a n d No.3 cylin der s (F ig. 2).
Th e digit s of t h e code iden t ify:
• 1st Digit —Th e yea r (8 = 1998).
• 2n d & 3r d Digit s—Th e m on t h (01 - 12).
• 4t h & 5t h Digit s—Th e en gin e t ype/fu el syst em /
com pr ession r a t io (MX = A 4.0 Lit er (242 CID) 8.7:1
com pr ession r a t io en gin e wit h a m u lt i-poin t fu el
in ject ion syst em ).
WJ ENGINE - 4.0L 9-3
EN GI N E - 4 .0 L (Cont inue d)
(1) F OR EXAMP LE: Code * 801MX12 * iden t ifies
a 4.0 Lit er (242 CID) en gin e wit h a m u lt i-poin t fu el
in ject ion syst em , 8.7:1 com pr ession r a t io a n d bu ilt on
J a n u a r y 12, 1998.

DI AGN OSI S AN D T EST I N G

DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
E n gin e dia gn osis is h elpfu l in det er m in in g t h e
ca u ses of m a lfu n ct ion s n ot det ect ed a n d r em edied by
r ou t in e m a in t en a n ce.
Th ese m a lfu n ct ion s m a y be cla ssified a s eit h er
m ech a n ica l (e.g., a st r a n ge n oise), or per for m a n ce
(e.g., en gin e idles r ou gh a n d st a lls).
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE ST-
ING - P r efor m a n ce) or (Refer t o 9 - E NGINE - DIAG-
NOSIS AND TE STING - Mech a n ica l). Refer t o 14 -
Fig. 1 Engine Firing Order F UE L SYSTE M for fu el syst em dia gn osis.
Addit ion a l t est s a n d dia gn ost ic pr ocedu r es m a y be
n ecessa r y for specific en gin e m a lfu n ct ion s t h a t ca n -
n ot be isola t ed wit h t h e Ser vice Dia gn osis ch a r t s.
In for m a t ion con cer n in g a ddit ion a l t est s a n d dia gn o-
sis is pr ovided wit h in t h e followin g:
• Cylin der Com pr ession P r essu r e Test (Refer t o 9 -
E NGINE - DIAGNOSIS AND TE STING)
• Cylin der Com bu st ion P r essu r e Lea ka ge Test
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE STING)
• Cylin der H ea d Ga sket F a ilu r e Dia gn osis (Refer
t o 9 - E NGINE /CYLINDE R H E AD - DIAGNOSIS
AND TE STING)
• In t a ke Ma n ifold Lea ka ge Dia gn osis (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
DIAGNOSIS AND TE STING)
• La sh Adju st er (Ta ppet ) Noise Dia gn osis (Refer t o
9 - E NGINE /E NGINE BLOCK/H YDRAULIC LIF T-
E RS (CAM IN BLOCK) - DIAGNOSIS AND TE ST-
ING)
Fig. 2 Build Date Code Location • E n gin e Oil Lea k In spect ion (Refer t o 9 -
1 - YEAR E NGINE /LUBRICATION - DIAGNOSIS AND TE ST-
2 - MONTH ING)
3 - DAY

• 6t h & 7t h Digit s—Th e da y of en gin e bu ild (01 -

31).
9-4 ENGINE - 4.0L
EN GI N E - 4 .0 L (Cont inue d)
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
EN GI N E PERFORM AN CE DI AGN OSI S CH ART
CONDITION POSSIBLE CAUSES
ENGINE WILL NOT CRANK 1. Weak or dead battery
2. Corroded or loose battery
connections
3. Faulty starter or related circuit(s)
4. Siezed accessory drive
component
5. Engine internal mechanical failure
or hydro-static lock
ENGINE CRANKS BUT WILL 1. No spark
NOT START
2. No fuel
3. Low or no engine compression
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor
2. Worn camshaft position sensor
shaft
WJ
CORRECTION
1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE), for correct
procedures. Check charging system.
(Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING), for correct procedures.
2. Clean/tighten suspect battery/
starter connections
3. Check starting system. (Refer to 8
- ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
SPECIFICATIONS), for correct
procedures.
2. Perform fuel pressure test (Refer
to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING), and if
necessary, inspect fuel injector(s) and
driver circuits. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL
INJECTOR - DIAGNOSIS AND
TESTING), for correct procedures.
3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
1. Install new distributor rotor
2. Remove and repair camshaft
position sensor.(Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
CAMSHAFT POSITION SENSOR -
REMOVAL).
WJ
EN GI N E - 4 .0 L (Cont inue d)
CONDITION POSSIBLE CAUSES
3. Worn or incorrect gapped spark
plugs
4. Dirt or water in fuel system
5. Faulty fuel pump
6. Incorrect valve timing
7. Blown cylinder head gasket
8. Low compression
9. Burned, warped, or pitted valves
10. Plugged or restricted exhaust
system
11. Faulty ignition coil rail
ENGINE STALLS OR ROUGH 1. Carbon build-up on throttle plate
IDLE
2. Engine idle speed too low
3. Worn or incorrectly gapped spark
plugs
4. Faulty coil rail
5. Intake manifold vacuum leak
ENGINE MISSES ON 1. Worn or incorrectly gapped spark
ACCELERATION plugs
2. Spark plug cables defective or
crossed
3. Dirt in fuel system
4. Burned, warped or pitted valves
5. Faulty coil rail
ENGINE - 4.0L 9-5
CORRECTION
3. Clean plugs and set gap. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Clean system and replace fuel
filter
5. Install new fuel pump
6. Correct valve timing
7. Install new cylinder head gasket
8. Test cylinder compression. (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Install/Reface valves as necessary
10. Install new parts as necessary
11. Test and replace, as necessary.
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL).
1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL) for
correct procedure.
2. Check Idle Air Control circuit.
3. Replace or clean and re-gap spark
plugs. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING)
4. Test and replace, if necessary.
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL)
5. Inspect intake manifold gasket and
vacuum hoses. Replace if necessary.
(Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - DIAGNOSIS
AND TESTING).
1. Replace spark plugs or clean and
set gap.
2. Replace spark plug cables.
3. Clean fuel system
4. Install new valves
5. Test and replace as necessary.
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL)
9-6 ENGINE - 4.0L
EN GI N E - 4 .0 L (Cont inue d)
DIAGNOSIS AND TESTING— ENGINE DIAGNOSIS - MECHANICAL
EN GI N E M ECH AN I CAL DI AGN OSI S CH ART
CONDITION
NOISY VALVES/LIFTERS
CONNECTING ROD NOISE
MAIN BEARING NOISE
POSSIBLE CAUSES
1. High or low oil level in crankcase
2. Thin or diluted oil
3. Low oil pressure
4. Dirt in tappets/lash adjusters
5. Bent push rod(s)
6. Worn rocker arms
7. Worn tappets/lash adjusters
8. Worn valve guides
9. Excessive runout of valve seats or
valve faces
1. Insufficient oil supply
2. Low oil pressure
3. Thin or diluted oil
4. Excessive connecting rod bearing
clearance
5. Connecting rod journal out of
round
6. Misaligned connecting rods
1. Insufficient oil supply
2. Low oil pressure
WJ
CORRECTION
1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9
- ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/specifications
4. Clean/replace hydraulic tappets/
lash adjusters
5. Install new push rods
6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Install new hydraulic tappets/lash
adjusters
8. Inspect all valve guides and
replace as necessary
9. Grind valves and seats
1. Check engine oil level.
2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9
- ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE) for
correct procedure/engine oil
specifications
Measure bearings for correct
clearance with plasti-gage. Repair as
necessary
5. Replace crankshaft or grind
journals
6. Replace bent connecting rods
1. Check engine oil level.
2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9
- ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING)
WJ
EN GI N E - 4 .0 L (Cont inue d)
CONDITION POSSIBLE CAUSES
3. Thin or diluted oil
4. Excessive main bearing clearance
5. Excessive end play
6. Crankshaft main journal out of
round or worn
7. Loose flywheel or torque converter
LOW OIL PRESSURE 1. Low oil level
2. Faulty oil pressure sending unit
3. Clogged oil filter
4. Worn oil pump
5. Thin or diluted oil
6. Excessive bearing clearance
7. Oil pump relief valve stuck
8. Oil pump suction tube loose,
broken, bent or clogged
9. Oil pump cover warped or cracked
OIL LEAKS 1. Misaligned or deteriorated gaskets
2. Loose fastener, broken or porous
metal part
3. Front or rear crankshaft oil seal
leaking
4. Leaking oil gallery plug or cup
plug
EXCESSIVE OIL 1. CCV System malfunction
CONSUMPTION OR SPARK
PLUGS OIL FOULED
2. Defective valve stem seal(s)
3. Worn or broken piston rings
4. Scuffed pistons/cylinder walls
5. Carbon in oil control ring groove
6. Worn valve guides
7. Piston rings fitted too tightly in
grooves
ENGINE - 4.0L 9-7
CORRECTION
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair as necessary
5. Check crankshaft thrust bearing for
excessive wear on flanges
6. Grind journals or replace
crankshaft
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
1. Check oil level and fill if necessary
2. Install new sending unit
3. Install new oil filter
4. Replace oil pump assembly.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance
7. Remove valve to inspect, clean
and reinstall
8. Inspect suction tube and clean or
replace if necessary
9. Install new oil pump
1. Replace gasket
2. Tighten, repair or replace the part
3. Replace seal
4. Remove and reseal threaded plug.
Replace cup style plug
1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Repair or replace seal(s)
3. Hone cylinder bores. Install new
rings
4. Hone cylinder bores and replace
pistons as required
5. Remove rings and de-carbon
piston
6. Inspect/replace valve guides as
necessary
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
9-8 ENGINE - 4.0L WJ
EN GI N E - 4 .0 L (Cont inue d)

DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION PRESSURE
Th e r esu lt s of a cylin der com pr ession pr essu r e t est
ca n be u t ilized t o dia gn ose sever a l en gin e m a lfu n c-
t ion s.
E n su r e t h e ba t t er y is com plet ely ch a r ged a n d t h e
en gin e st a r t er m ot or is in good oper a t in g con dit ion .
Ot h er wise, t h e in dica t ed com pr ession pr essu r es m a y
n ot be va lid for dia gn osis pu r poses.
(1) Clea n t h e spa r k plu g r ecesses wit h com pr essed
a ir.
(2) Rem ove t h e spa r k plu gs (Refer t o 8 - E LE C-
TRICAL/IGNITION CONTROL/SPARK P LUG -
RE MOVAL).
(3) Secu r e t h e t h r ot t le in t h e wide-open posit ion .
(4) Discon n ect t h e ign it ion coil.
(5) In ser t a com pr ession pr essu r e ga u ge a n d r ot a t e
t h e en gin e wit h t h e en gin e st a r t er m ot or for t h r ee
r evolu t ion s.
(6) Recor d t h e com pr ession pr essu r e on t h e t h ir d
r evolu t ion . Con t in u e t h e t est for t h e r em a in in g cylin -
der s.
(Refer t o 9 - E NGINE - SP E CIF ICATIONS) for t h e
cor r ect en gin e com pr ession pr essu r es.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
Th e com bu st ion pr essu r e lea ka ge t est pr ovides a n
a ccu r a t e m ea n s for det er m in in g en gin e con dit ion .
Com bu st ion pr essu r e lea ka ge t est in g will det ect :
• E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t -
in g)
• Lea ks bet ween a dja cen t cylin der s or in t o wa t er
ja cket
• An y ca u ses for com bu st ion /com pr ession pr essu r e
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Ch eck t h e coola n t level a n d fill a s r equ ir ed. DO
NOT in st a ll t h e r a dia t or ca p.
St a r t a n d oper a t e t h e en gin e u n t il it a t t a in s n or-
m a l oper a t in g t em per a t u r e, t h en t u r n OF F t h e
en gin e.
Rem ove t h e spa r k plu gs.
Rem ove t h e oil filler ca p.
Rem ove t h e a ir clea n er.
Ca libr a t e t h e t est er a ccor din g t o t h e m a n u fa ct u r-
er ’s in st r u ct ion s. Th e sh op a ir sou r ce for t est in g
sh ou ld m a in t a in 483 kP a (70 psi) m in im u m , 1,379
kP a (200 psi) m a xim u m a n d 552 kP a (80 psi) r ecom -
m en ded.
P er for m t h e t est pr ocedu r e on ea ch cylin der a ccor d-
in g t o t h e t est er m a n u fa ct u r er ’s in st r u ct ion s. Wh ile
t est in g, list en for pr essu r ized a ir esca pin g t h r ou gh
t h e t h r ot t le body, t a ilpipe or oil filler ca p open in g.
Ch eck for bu bbles in t h e r a dia t or coola n t .
All ga u ge pr essu r e in dica t ion s sh ou ld be equ a l,
wit h n o m or e t h a n 25% lea ka ge.
F OR EXAMP LE: At 552 kP a (80 psi) in pu t pr es-
su r e, a m in im u m of 414 kP a (60 psi) sh ou ld be m a in -
t a in ed in t h e cylin der CYLINDE R COMBUSTION
P RE SSURE LE AKAGE DIAGNOSIS CH ART .

CY LI N DER COM BU ST I ON PRESSU RE LEAK AGE DI AGN OSI S CH ART

CONDITION POSSIBLE CAUSE CORRECTION

AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat.
THROTTLE BODY seated properly Reface or replace, as necessary
AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
TAILPIPE seated properly Reface or replace, as necessary
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
MORE THAN 25% LEAKAGE AND Stuck or broken piston rings; Inspect for broken rings or piston.
AIR ESCAPES THROUGH OIL cracked piston; worn rings and/or Measure ring gap and cylinder
FILLER CAP OPENING ONLY cylinder wall diameter, taper and out-of-round.
Replace defective part as necessary
WJ
EN GI N E - 4 .0 L (Cont inue d)
DIAGNOSIS AND TESTING—REAR SEAL AREA
LEAKS
Sin ce it is som et im es difficu lt t o det er m in e t h e
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
followin g st eps sh ou ld be followed t o h elp pin poin t
t h e sou r ce of t h e lea k.
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l
a r ea :
(1) Discon n ect t h e ba t t er y.
(2) Ra ise t h e veh icle.
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g
cover a n d in spect r ea r of block for eviden ce of oil.
Use a bla ck ligh t t o ch eck for t h e oil lea k:
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es
sea l lea ka ge or cr a n ksh a ft da m a ge.
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down ,
possible ca u ses a r e a por ou s block, dist r ibu t or sea l,
ca m sh a ft bor e cu p plu gs, oil ga lley pipe plu gs, oil
filt er r u n off, a n d m a in bea r in g ca p t o cylin der
block m a t in g su r fa ces.
(4) If n o lea ks a r e det ect ed, pr essu r ized t h e cr a n k-
ca se a s ou t lin ed in (Refer t o 9 - E NGINE /LUBRICA-
TION - DIAGNOSIS AND TE STING)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es
t h a t ca n be polish ed ou t wit h em er y clot h .
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft
r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
a ssem bled. Refer t o t h e ser vice Dia gn osis—Mech a n i-
ca l, u n der t h e Oil Lea k r ow, for com pon en t s
in spect ion s on possible ca u ses a n d cor r ect ion s.
(7) Aft er t h e oil lea k r oot ca u se a n d a ppr opr ia t e
cor r ect ive a ct ion h a ve been iden t ified, (Refer t o 9 -
E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
SE AL - RE AR - RE MOVAL), for pr oper r epla cem en t
pr ocedu r es.
ENGINE - 4.0L 9-9
STAN DARD PROCEDU RE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
Th er e a r e n u m er ou s pla ces wh er e for m -in -pla ce
ga sket s a r e u sed on t h e en gin e. Ca r e m u st be t a ken
wh en a pplyin g for m -in -pla ce ga sket s t o a ssu r e
obt a in in g t h e desir ed r esu lt s. D o n o t u s e fo rm -in -
p la c e g a s k e t m a te ria l u n le s s s p e c ifie d . Bea d size,
con t in u it y, a n d loca t ion a r e of gr ea t im por t a n ce. Too
t h in a bea d ca n r esu lt in lea ka ge wh ile t oo m u ch ca n
r esu lt in spill-over wh ich ca n br ea k off a n d obst r u ct
flu id feed lin es. A con t in u ou s bea d of t h e pr oper
widt h is essen t ia l t o obt a in a lea k-fr ee ga sket .
Th er e a r e n u m er ou s t ypes of for m -in -pla ce ga sket
m a t er ia ls t h a t a r e u sed in t h e en gin e a r ea . Mopa r !
E n gin e RTV GE N II, Mopa r ! ATF -RTV, a n d Mopa r !
Ga sket Ma ker ga sket m a t er ia ls, ea ch h a ve differ en t
pr oper t ies a n d ca n n ot be u sed in pla ce of t h e ot h er.
MOPAR! EN GIN E RTV GEN II
Mopa r ! E n gin e RTV GE N II is u sed t o sea l com -
pon en t s exposed t o en gin e oil. Th is m a t er ia l is a spe-
cia lly design ed bla ck silicon e r u bber RTV t h a t
r et a in s a dh esion a n d sea lin g pr oper t ies wh en
exposed t o en gin e oil. Moist u r e in t h e a ir ca u ses t h e
m a t er ia l t o cu r e. Th is m a t er ia l is a va ila ble in t h r ee
ou n ce t u bes a n d h a s a sh elf life of on e yea r. Aft er on e
yea r t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys
in spect t h e pa cka ge for t h e expir a t ion da t e befor e
u se.
MOPAR! ATF RTV
Mopa r ! ATF RTV is a specifica lly design ed bla ck
silicon e r u bber RTV t h a t r et a in s a dh esion a n d sea l-
in g pr oper t ies t o sea l com pon en t s exposed t o a u t o-
m a t ic t r a n sm ission flu id, en gin e coola n t s, a n d
m oist u r e. Th is m a t er ia l is a va ila ble in t h r ee ou n ce
t u bes a n d h a s a sh elf life of on e yea r. Aft er on e yea r
t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys in spect
t h e pa cka ge for t h e expir a t ion da t e befor e u se.
MOPAR! GAS KET MAKER
Mopa r ! Ga sket Ma ker is a n a n a er obic t ype ga sket
m a t er ia l. Th e m a t er ia l cu r es in t h e a bsen ce of a ir
wh en squ eezed bet ween t wo m et a llic su r fa ces. It will
n ot cu r e if left in t h e u n cover ed t u be. Th e a n a er obic
m a t er ia l is for u se bet ween t wo m a ch in ed su r fa ces.
Do n ot u se on flexible m et a l fla n ges.
MOPAR! GAS KET S EALAN T
Mopa r ! Ga sket Sea la n t is a slow dr yin g, per m a -
n en t ly soft sea ler. Th is m a t er ia l is r ecom m en ded for
sea lin g t h r ea ded fit t in gs a n d ga sket s a ga in st lea ka ge
of oil a n d coola n t . Ca n be u sed on t h r ea ded a n d
m a ch in ed pa r t s u n der a ll t em per a t u r es. Th is m a t e-
r ia l is u sed on en gin es wit h m u lt i-la yer st eel (MLS)
cylin der h ea d ga sket s. Th is m a t er ia l a lso will pr e-
ven t cor r osion . Mopa r ! Ga sket Sea la n t is a va ila ble in
a 13 oz. a er osol ca n or 4oz./16 oz. ca n w/a pplica t or.
9 - 10 ENGINE - 4.0L
EN GI N E - 4 .0 L (Cont inue d)
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assem blin g pa r t s u sin g a for m -in -pla ce ga sket
r equ ir es ca r e bu t it ’s ea sier t h en u sin g pr ecu t ga sket s.
Mopa r ! Ga sket Ma ker m a t er ia l sh ou ld be a pplied
spa r in gly 1 m m (0.040 in .) dia m et er or less of sea la n t
t o on e ga sket su r fa ce. Be cer t a in t h e m a t er ia l su r-
r ou n ds ea ch m ou n t in g h ole. E xcess m a t er ia l ca n ea s-
ily be wiped off. Com pon en t s sh ou ld be t or qu ed in
pla ce wit h in 15 m in u t es. Th e u se of a loca t in g dowel
is r ecom m en ded du r in g a ssem bly t o pr even t sm ea r-
in g m a t er ia l off t h e loca t ion .
Mopa r ! E n gin e RTV GE N II or ATF RTV ga sket
m a t er ia l sh ou ld be a pplied in a con t in u ou s bea d
a ppr oxim a t ely 3 m m (0.120 in .) in dia m et er. All
m ou n t in g h oles m u st be cir cled. F or cor n er sea lin g, a
3.17 or 6.35 m m (1/8 or 1/4 in .) dr op is pla ced in t h e
cen t er of t h e ga sket con t a ct a r ea . Un cu r ed sea la n t
m a y be r em oved wit h a sh op t owel. Com pon en t s
sh ou ld be t or qu ed in pla ce wh ile t h e sea la n t is st ill
wet t o t h e t ou ch (wit h in 10 m in u t es). Th e u sa ge of a
loca t in g dowel is r ecom m en ded du r in g a ssem bly t o
pr even t sm ea r in g m a t er ia l off t h e loca t ion .
Mopa r ! Ga sket Sea la n t in a n a er osol ca n sh ou ld be
a pplied u sin g a t h in , even coa t spr a yed com plet ely
over bot h su r fa ces t o be join ed, a n d bot h sides of a
ga sket . Th en pr oceed wit h a ssem bly. Ma t er ia l in a
ca n w/a pplica t or ca n be br u sh ed on even ly over t h e
sea lin g su r fa ces. Ma t er ia l in a n a er osol ca n sh ou ld be
u sed on en gin es wit h m u lt i-la yer st eel ga sket s.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Da m a ged or wor n t h r ea ds ca n be r epa ir ed. E ssen -
t ia lly, t h is r epa ir con sist s of:
• Dr illin g ou t wor n or da m a ged t h r ea ds.
• Ta ppin g t h e h ole wit h a specia l H eli-Coil Ta p, or
equ iva len t .
• In st a llin g a n in ser t in t o t h e t a pped h ole t o br in g
t h e h ole ba ck t o it s or igin a l t h r ea d size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
Wh en a n en gin e is su spect ed of h ydr ost a t ic lock
(r ega r dless of wh a t ca u sed t h e pr oblem ), follow t h e
st eps below.
(1) P er for m t h e F u el P r essu r e Relea se P r ocedu r e
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
STANDARD P ROCE DURE ).
WJ
(2) Discon n ect t h e n ega t ive ca ble(s) fr om t h e ba t -
t er y.
(3) In spect a ir clea n er, in du ct ion syst em , a n d
in t a ke m a n ifold t o en su r e syst em is dr y a n d clea r of
for eign m a t er ia l.
(4) P la ce a sh op t owel a r ou n d t h e spa r k plu gs t o
ca t ch a n y flu id t h a t m a y possibly be u n der pr essu r e
in t h e cylin der h ea d. Rem ove t h e spa r k plu gs.
(5) Wit h a ll spa r k plu gs r em oved, r ot a t e t h e cr a n k-
sh a ft u sin g a br ea ker ba r a n d socket .
(6) Iden t ify t h e flu id in t h e cylin der s (coola n t , fu el,
oil, et c.).
(7) Be su r e a ll flu id h a s been r em oved fr om t h e
cylin der s.
(8) Repa ir en gin e or com pon en t s a s n ecessa r y t o
pr even t t h is pr oblem fr om occu r r in g a ga in .
(9) Squ ir t a sm a ll a m ou n t of en gin e oil in t o t h e
cylin der s t o lu br ica t e t h e wa lls. Th is will pr even t
da m a ge on r est a r t .
(10) In st a ll n ew spa r k plu gs. Tigh t en t h e spa r k
plu gs t o 41 N·m (30 ft . lbs.) t or qu e.
(11) Dr a in en gin e oil. Rem ove a n d disca r d t h e oil
filt er.
(12) In st a ll t h e dr a in plu g. Tigh t en t h e plu g t o 34
N·m (25 ft . lbs.) t or qu e.
(13) In st a ll a n ew oil filt er.
(14) F ill en gin e cr a n kca se wit h t h e specified
a m ou n t a n d gr a de of oil. (Refer t o LUBRICATION &
MAINTE NANCE - SP E CIF ICATIONS).
(15) Con n ect t h e n ega t ive ca ble(s) t o t h e ba t t er y.
(16) St a r t t h e en gin e a n d ch eck for a n y lea ks.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Befor e h on in g, st u ff plen t y of clea n sh op t owels
u n der t h e bor es a n d over t h e cr a n ksh a ft t o keep
a br a sive m a t er ia ls fr om en t er in g t h e cr a n ksh a ft
a r ea .
(1) Used ca r efu lly, t h e Cylin der Bor e Sizin g H on e
C-823, equ ipped wit h 220 gr it st on es, is t h e best t ool
for t h is job. In a ddit ion t o degla zin g, it will r edu ce
t a per a n d ou t -of-r ou n d, a s well a s r em ovin g ligh t scu ff-
in g, scor in g a n d scr a t ch es. Usu a lly, a few st r okes will
clea n u p a bor e a n d m a in t a in t h e r equ ir ed lim it s.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degla zin g of t h e cylin der wa lls m a y be don e if
t h e cylin der bor e is st r a igh t a n d r ou n d. Use a cylin -
der su r fa cin g h on e, H on in g Tool C-3501, equ ipped
wit h 280 gr it st on es (C-3501-3810). a bou t 20-60
st r okes, depen din g on t h e bor e con dit ion , will be su f-
ficien t t o pr ovide a sa t isfa ct or y su r fa ce. Usin g h on in g
oil C-3501-3880, or a ligh t h on in g oil, a va ila ble fr om
m a jor oil dist r ibu t or s.
WJ
EN GI N E - 4 .0 L (Cont inue d)
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) H on in g sh ou ld be don e by m ovin g t h e h on e u p
a n d down fa st en ou gh t o get a cr ossh a t ch pa t t er n .
Th e h on e m a r ks sh ou ld INTE RSE CT a t 40° t o 60°
for pr oper sea t in g of r in gs (F ig. 3).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
(4) A con t r olled h on e m ot or speed bet ween 200 a n d
300 RP M is n ecessa r y t o obt a in t h e pr oper cr oss-
h a t ch a n gle. Th e n u m ber of u p a n d down st r okes per
m in u t e ca n be r egu la t ed t o get t h e desir ed 40° t o 60°
a n gle. F a st er u p a n d down st r okes in cr ea se t h e cr oss-
h a t ch a n gle.
(5) Aft er h on in g, it is n ecessa r y t h a t t h e block be
clea n ed t o r em ove a ll t r a ces of a br a sive. Use a br u sh
t o wa sh pa r t s wit h a solu t ion of h ot wa t er a n d det er-
gen t . Dr y pa r t s t h or ou gh ly. Use a clea n , wh it e, lin t -
fr ee clot h t o ch eck t h a t t h e bor e is clea n . Oil t h e
bor es a ft er clea n in g t o pr even t r u st in g.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usin g a blu n t t ool su ch a s a dr ift a n d a h a m m er,
st r ike t h e bot t om edge of t h e cu p plu g. Wit h t h e cu p
plu g r ot a t ed, gr a sp fir m ly wit h plier s or ot h er su it -
a ble t ool a n d r em ove plu g (F ig. 4).
ENGINE - 4.0L 9 - 11
Fig. 4 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Th or ou gh ly clea n in side of cu p plu g h ole in cylin -
der block or h ea d. Be su r e t o r em ove old sea ler.
Ligh t ly coa t in side of cu p plu g h ole wit h Mopa r !
St u d a n d Bea r in g Mou n t . Ma ke cer t a in t h e n ew plu g
is clea n ed of a ll oil or gr ea se. Usin g pr oper dr ive
plu g, dr ive plu g in t o h ole so t h a t t h e sh a r p edge of
t h e plu g is a t lea st 0.5 m m (0.020 in .) in side t h e
lea d-in ch a m fer.
It is n ot n ecessa r y t o wa it for cu r in g of t h e sea la n t .
Th e coolin g syst em ca n be r efilled a n d t h e veh icle
pla ced in ser vice im m edia t ely.
REMOVAL
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
(2) Ma r k t h e h in ge loca t ion s on t h e h ood pa n el for
a lign m en t r efer en ce du r in g in st a lla t ion . Rem ove t h e
en gin e com pa r t m en t la m p. Rem ove t h e h ood.
(3) Rem ove t h e r a dia t or dr a in cock a n d r a dia t or
ca p t o dr a in t h e coola n t . DO NOT wa st e u sa ble cool-
a n t . If t h e solu t ion is clea n , dr a in t h e coola n t in t o a
clea n con t a in er for r eu se.
(4) Rem ove t h e u pper r a dia t or h ose a n d coola n t
r ecover y h ose.
(5) Rem ove t h e lower r a dia t or h ose.
(6) Rem ove u pper r a dia t or su ppor t r et a in in g bolt s
a n d r em ove r a dia t or su ppor t .
9 - 12 ENGINE - 4.0L WJ
EN GI N E - 4 .0 L (Cont inue d)
(7) Rem ove t h e fa n a ssem bly fr om t h e wa t er pu m p
(Refer t o 7 - COOLING/E NGINE /RADIATOR FAN -
RE MOVAL).
(8) Rem ove t h e fa n sh r ou d.
(9) Discon n ect t h e t r a n sm ission flu id cooler lin es
(a u t om a t ic t r a n sm ission ).
(10) Disch a r ge t h e A/C syst em (Refer t o 24 -
H E ATING & AIR CONDITIONING/P LUMBING -
STANDARD P ROCE DURE ).
(11) Rem ove t h e ser vice va lves a n d ca p t h e com -
pr essor por t s.
(12) Rem ove t h e r a dia t or or r a dia t or /con den ser (if
equ ipped wit h A/C).
(13) Discon n ect t h e h ea t er h oses a t t h e en gin e
t h er m ost a t h ou sin g a n d wa t er pu m p.
(14) Discon n ect t h e a cceler a t or ca ble, t r a n sm ission
lin e pr essu r e ca ble a n d speed con t r ol ca ble (if
equ ipped) fr om t h e t h r ot t le body.
(15) Rem ove ca bles fr om t h e br a cket a n d secu r e
ou t of t h e wa y.
(16) Discon n ect t h e body gr ou n d a t t h e en gin e.
(17) Discon n ect t h e followin g con n ect or s a n d
secu r e t h eir h a r n ess ou t of t h e wa y. Fig. 5 Air Cleaner Assembly
• P ower st eer in g pr essu r e swit ch 1 - POWER STEERING PUMP
• Coola n t t em per a t u r e sen sor 2 - AIR CLEANER ASSEMBLY
• Six (6) fu el in ject or con n ect or s
• In t a ke a ir t em per a t u r e sen sor (28) Rem ove t h e en gin e st a r t er m ot or (Refer t o 8 -
• Th r ot t le posit ion sen sor E LE CTRICAL/STARTING/STARTE R MOTOR -
• Ma p sen sor RE MOVAL).
• Cr a n ksh a ft posit ion sen sor (29) Discon n ect t h e oxygen sen sor fr om t h e
• Oxygen sen sor exh a u st pipe.
• Ca m sh a ft posit ion sen sor (30) Discon n ect t h e exh a u st pipe fr om t h e m a n i-
• Gen er a t or con n ect or a n d B+ t er m in a l wir e fold.
(18) Discon n ect t h e coil r a il elect r ica l con n ect ion s (31) Rem ove t h e exh a u st pipe su ppor t .
a n d t h e oil pr essu r e swit ch con n ect or. (32) Rem ove t h e ben din g br a ce (Refer t o 9 -
(19) P er for m t h e fu el pr essu r e r elea se pr ocedu r e E NGINE /E NGINE BLOCK/STRUCT SUP P ORT -
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY - RE MOVAL).
STANDARD P ROCE DURE ). (33) Rem ove t h e en gin e flywh eel/con ver t er h ou sin g
(20) Discon n ect t h e fu el su pply lin e a t t h e in ject or a ccess cover.
r a il (Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY/ (34) Ma r k t h e con ver t er a n d dr ive pla t e loca t ion .
QUICK CONNE CT F ITTING - STANDARD P ROCE - (35) Rem ove t h e con ver t er-t o-dr ive pla t e bolt s.
DURE ). (36) Rem ove t h e u pper en gin e flywh eel/con ver t er
(21) Rem ove t h e fu el lin e br a cket fr om t h e in t a ke h ou sin g bolt s a n d loosen t h e bot t om bolt s.
m a n ifold. (37) Rem ove t h e en gin e m ou n t cu sh ion -t o-en gin e
(22) Rem ove t h e a ir clea n er a ssem bly (F ig. 5). com pa r t m en t br a cket bolt s.
(23) Discon n ect t h e h oses fr om t h e fit t in gs a t t h e (38) Lower t h e veh icle.
st eer in g gea r. (39) At t a ch a lift in g device t o t h e en gin e.
(24) Dr a in t h e pu m p r eser voir. (40) Ra ise t h e en gin e off t h e fr on t su ppor t s.
(25) Ca p t h e fit t in gs on t h e h oses a n d st eer in g (41) P la ce a su ppor t or floor ja ck u n der t h e con -
gea r t o pr even t for eign object s fr om en t er in g t h e sys- ver t er (or en gin e flywh eel) h ou sin g.
t em . (42) Rem ove t h e r em a in in g con ver t er (or en gin e
(26) Ra ise a n d su ppor t t h e veh icle. flywh eel) h ou sin g bolt s.
(27) Discon n ect t h e wir es fr om t h e en gin e st a r t er (43) Lift t h e en gin e ou t of t h e en gin e com pa r t -
m ot or solen oid. m en t .
WJ
EN GI N E - 4 .0 L (Cont inue d)
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the engine
flywheel.
(1) At t a ch a lift in g device t o t h e en gin e a n d lower
t h e en gin e in t o t h e en gin e com pa r t m en t . F or ea sier
in st a lla t ion , it m a y be n ecessa r y t o r em ove t h e
en gin e m ou n t br a cket a s a n a id in a lign m en t of t h e
en gin e t o t h e t r a n sm ission .
(2) Align t h e t r a n sm ission t or qu e con ver t er h ou s-
in g wit h t h e en gin e.
(3) Loosely in st a ll t h e con ver t er h ou sin g lower
bolt s a n d in st a ll t h e n ext h igh er bolt a n d n u t on ea ch
side.
(4) Tigh t en a ll 4 bolt s fin ger t igh t .
(5) In st a ll t h e en gin e m ou n t br a cket s (if r em oved).
(6) Lower t h e en gin e a n d en gin e m ou n t br a cket s
on t o t h e en gin e com pa r t m en t cu sh ion s. In st a ll t h e
bolt s a n d fin ger t igh t en t h e n u t s.
(7) Rem ove t h e en gin e lift in g device.
(8) Ra ise a n d su ppor t t h e veh icle.
(9) In st a ll t h e r em a in in g en gin e flywh eel/con ver t er
h ou sin g bolt s. Tigh t en a ll bolt s t o 38 N·m (28 ft . lbs.)
t or qu e.
(10) In st a ll t h e con ver t er-t o-dr ive pla t e bolt s.
(11) E n su r e t h e in st a lla t ion r efer en ce m a r ks a r e
a lign ed.
(12) In st a ll t h e en gin e flywh eel/con ver t er h ou sin g
a ccess cover.
(13) In st a ll t h e exh a u st pipe su ppor t a n d t igh t en
t h e scr ew.
(14) In st a ll t h e en gin e ben din g br a ce (Refer t o 9 -
E NGINE /E NGINE BLOCK/STRUCT SUP P ORT -
INSTALLATION).
(15) Tigh t en t h e en gin e m ou n t -t o-br a cket bolt s.
(16) Con n ect t h e veh icle speed sen sor wir e con n ec-
t ion s a n d t igh t en t h e scr ews.
(17) Con n ect t h e exh a u st pipe t o t h e m a n ifold.
(18) In st a ll t h e en gin e st a r t er m ot or (Refer t o 8 -
E LE CTRICAL/STARTING/STARTE R MOTOR - t h e cla m p.
INSTALLATION).
(19) Con n ect t h e wir es t o t h e en gin e st a r t er m ot or
solen oid.
(20) Lower t h e veh icle.
(21) Con n ect a ll t h e va cu u m h oses a n d wir e con -
n ect or s iden t ified du r in g en gin e r em ova l.
(22) Rem ove pr ot ect ive ca ps fr om t h e power st eer-
in g h oses.
(23) Con n ect t h e h oses t o t h e fit t in gs a t t h e st eer-
in g gea r. Tigh t en t h e n u t t o 52 N·m (38 ft . lbs.)
t or qu e.
(24) F ill t h e pu m p r eser voir wit h flu id.
ENGINE - 4.0L 9 - 13
(25) In spect t h e fu el su pply lin e o-r in g(s) a n d
r epla ce if n ecessa r y. Con n ect fu el su pply lin e t o in jec-
t ior r a il a n d ver ify con n ect ion by pu llin g ou t wa r d on
t h e lin e.
(26) In st a ll t h e fu el lin e br a cket t o t h e in t a ke
m a n ifold.
(27) Con n ect t h e coil r a il elect r ica l con n ect or s a n d
oil pr essu r e swit ch con n ect or.
(28) Con n ect t h e followin g elect r ica l con n ect or s:
• P ower st eer in g pr essu r e swit ch
• Coola n t t em per a t u r e sen sor
• Six (6) fu el in ject or con n ect or s
• In t a ke a ir t em per a t u r e sen sor
• Th r ot t le posit ion sen sor
• Ma p sen sor
• Cr a n ksh a ft posit ion sen sor
• Oxygen sen sor
• Ca m sh a ft posit ion sen sor
• Gen er a t or con n ect or a n d B+ t er m in a l wir e
(29) Con n ect a ll pr eviou sly r em oved va cu u m h oses.
(30) Con n ect t h e body gr ou n d st r a p.
(31) In st a ll t h e t h r ot t le, t r a n sm ission lin e pr es-
su r e, a n d speed con t r ol ca bles t o t h eir m ou n t in g
br a cket a n d con n ect t h em t o t h e t h r ot t le body.
(32) Con n ect t h e h ea t er h oses a t t h e en gin e t h er-
m ost a t h ou sin g a n d wa t er pu m p.
(33) In st a ll t h e fa n a ssem bly (Refer t o 7 - COOL-
ING/E NGINE /RADIATOR FAN - INSTALLATION).
(34) P la ce t h e fa n sh r ou d in posit ion over t h e fa n .
(35) In st a ll t h e r a dia t or (Refer t o 7 - COOLING/
E NGINE /RADIATOR - INSTALLATION).
(36) Con n ect t h e ser vice va lves t o t h e A/C com -
pr essor por t s, if equ ipped wit h A/C.
(37) Ch a r ge t h e a ir con dit ion er syst em (Refer t o 24
- H E ATING & AIR CONDITIONING/P LUMBING -
STANDARD P ROCE DURE ).
(38) Con n ect t h e r a dia t or h oses a n d a u t om a t ic
t r a n sm ission flu id cooler pipes, if equ ipped.
(39) In st a ll t h e fa n sh r ou d t o t h e r a dia t or or r a di-
a t or /con den ser (if equ ipped wit h A/C).
(40) In st a ll u pper r a dia t or su ppor t .
(41) Con n ect t h e u pper r a dia t or h ose a n d t igh t en
(42) Con n ect t h e lower r a dia t or h ose a n d t igh t en
t h e cla m p.
(43) F ill cr a n kca se wit h en gin e oil. (Refer t o
LUBRICATION & MAINTE NANCE /F LUID CAPACI-
TIE S - SP E CIF ICATIONS) for cor r ect ca pa cit ies.
(44) F ill t h e coolin g syst em wit h r eu sa ble coola n t
or n ew coola n t (Refer t o 7 - COOLING - STANDARD
P ROCE DURE ).
(45) Align t h e h ood t o t h e scr ibe m a r ks. In st a ll t h e
h ood.
(46) In st a ll t h e a ir clea n er a ssem bly.
(47) In st a ll t h e ba t t er y a n d con n ect t h e ba t t er y
ca ble.
9 - 14 ENGINE - 4.0L WJ
EN GI N E - 4 .0 L (Cont inue d)
WARNING: USE EXTREME CAUTION WHEN THE
DESCRIPTION SPECIFICATION
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR Bearing Journal Diameter
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
No. 1 51.54 to 51.56 mm
NOT WEAR LOOSE CLOTHING.
(2.029 to 2.030 in.)
(48) St a r t t h e en gin e, in spect for lea ks a n d cor r ect No. 2 51.28 to 51.31 mm
t h e flu id levels, a s n ecessa r y.
(2.019 to 2.020 in.)
No. 3 51.03 to 51.05 mm
SPECI FI CAT I ON S (2.009 to 2.010 in.)
ENGINE - 4.0L No. 4 50.78 to 50.80 mm
(1.999 to 2.000 in.)
DESCRIPTION SPECIFICATION Base Circle Runout 0.03 mm
(MAX)
Engine Type In-line 6 Cylinder
(0.001 in.)
Bore and Stroke 98.4 x 86.69 mm
Valve Lift
(3.88 x 3.413 in.)
Intake 10.350 mm (0.4075 in.)
Displacement 4.0L (242 cu. in.) Exhaust 10.528 mm (0.4145 in.)
Compression Ratio 8.8:1 Valve Timing
Firing Order 1–5–3–6–2–4 Intake
Lubrication Pressure Feed–Full Flow Opens 12.4° BTDC
Filtration Closes 60.9° ABDC
Exhaust
Cooling System Liquid Cooled–Forced
Opens 49.8 BBDC
Circulation
Closes 29.2° ATDC
Cylinder Block Cast Iron
Valve Overlap 41.6°
Crankshaft Cast Nodular Iron
Intake Duration 253.3°
Cylinder Head Cast Iron
Exhaust Duration 259.°
Camshaft Cast Iron
CRANKSHAFT
Pistons Aluminum Alloy
End Play 0.038 to 0.165 mm
Combustion Chamber Dual-Quench
(0.0015 to 0.0065 in.)
Connecting Rods Cast Malleable Iron
Main Bearing Journal
Diameter
CAMSHAFT
No. 1-6 63.489 to 63.502 mm
Hydraulic Tappet Zero Lash
Clearance (2.4996 to 2.5001 in.)
No. 7 63.449 to 63.487 mm
Bearing Clearance 0.025 to 0.076 mm
(2.4980 to 2.4995 in.)
(0.001 to 0.003 in.)
WJ ENGINE - 4.0L 9 - 15
EN GI N E - 4 .0 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Main Bearing Journal (0.008 in. max. for total

Width length)
No. 1 27.58 to 27.89 mm
Main Bearing Bore 68.3514 to 68.3768 mm
(1.086 to 1.098 in.) Diameter
No. 3 32.28 to 32.33 mm (2.691 to 2.692 in.)
(1.271 to 1.273 in.)
CONNECTING ROD
No. 2-4-5-6-7 30.02 to 30.18 mm
(1.182 to 1.188 in.) Total Weight (Less 663 to 671 grams
Bearing)
Main Bearing Clearance 0.03 to 0.06 mm
(23.39 to 23.67 oz.)
(0.001 to 0.0025 in.)
Preferred 0.051 mm (0.002 in.) Length (Center-to-Center) 155.52 to 155.62 mm
(6.123 to 6.127 in.)
Connecting Rod Journal
Diameter 53.17 to 53.23 mm Piston Pin Bore Diameter 23.59 to 23.62 mm
(2.0934 to 2.0955 in.) (0.9288 to 0.9298 in.)

Connecting Rod Journal 27.18 to 27.33 mm Bore (Less Bearings) 56.08 to 56.09 mm
Width (2.2080 to 2.2085 in.)
(1.070 to 1.076 in.)
Bearing Clearance 0.025 to 0.076 mm
Out-of-Round (MAX) 0.013 mm (0.0005 in.) (0.001 to 0.003 in.)
Preferred 0.044 to 0.050 mm
Taper (MAX) 0.013 mm (0.0005 in.)
(0.0015 to 0.0020 in.)
CYLINDER BLOCK
Side Clearance 0.25 to 0.48 mm
Deck Height 240.03 to 240.18 mm (0.010 to 0.019 in.)
(9.450 to 9.456 in.)
Twist (Max.) 0.002 mm per mm
Deck Clearance (Below 0.546 mm (0.0215 in.) (0.002 in. per inch)
Block)
Bend (Max.) 0.002 mm per mm
Cylinder Bore Diameter
(0.002 in. per inch.)
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.) CYLINDER COMPRESSION PRESSURE
Taper 0.025 mm (0.001 in.) Pressure Range 827 to 1,034 kPa
Out-ofRound 0.025 mm (0.001 in.) (120 to 150 psi)
Tappet Bore Diameter 23.000 to 23.025 mm Max. Variation Between
(0.9055 to 0.9065 in.) Cylinders 206 kPa (30 psi)
Flatness 0.03 mm per 25 mm
CYLINDER HEAD
(0.001 in. per 1 in.)
0.05 mm per 152 mm Combustion Chamber 55.22 to 58.22 cc
(0.002 in. per 6 in.) (3.37 to 3.55 cu. in.)

Flatness Max. 0.20 mm max. for total Valve Guide I.D. 7.95 to 7.97 mm
length (Integral)
(0.313 to 0.314 in.)
9 - 16 ENGINE - 4.0L WJ
EN GI N E - 4 .0 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Valve Stem-to-Guide 0.025 to 0.076 mm Valve Head Diameter

Clearance (0.001 to 0.003 in.) Intake 48.387 to 48.641 mm
(1.905 to 1.915 in.)
Valve Seat Angle
Exhaust 37.973 to 38.227 mm
Intake 44.5°
(1.495 to 1.505 in.)
Exhaust 44.5°
Valve Face Angle
Valve Seat Width 1.02 to 1.52 mm
Intake 46.5°
(0.040 to 0.060 in.)
Exhaust 46.5°
Valve Seat Runout 0.064 mm (0.0025 in.)
Tip Refinishing (Max. 0.25 mm (0.010 in.)
Flatness 0.03 mm per 25 mm Allowable)
(0.001 in. per 1 in.)
VALVE SPRINGS
0.05 mm per 152 mm
(0.002 in. per 6 in.) Free Length (Approx.) 47.65 mm (1.876 in.)

Flatness Max. 0.20 mm - max. for total Spring Load

length Valve Closed 316 to 351 N @ 41.656
(0.008 in. max. for total mm
length) (71 to 79 lbf. @ 1.64 in.)
Valve Open 898.6 to 969.7 N @
ROCKER ARMS, PUSH RODS & TAPPETS
30.89 mm
Rocker Arm Ratio 1.6:1 (202 to 218 lbf @ 1.216
in.)
Push Rod Length 244.856 to 245.364 mm
(Pink) (9.640 to 9.660 in.) Inside Diameter 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.) Installed Height 41.656 mm (1.64 in.)

Hydraulic Tappet 22.962 to 22.974 mm PISTONS

Diameter
Weight (Less Pin) 417 to 429 grams
(0.904 to 0.9045 in.)
(14.7 to 15.1 oz.)
Tappet-to-Bore Clearance 0.025 to 0.063 mm
Piston Pin Bore 40.61 to 40.72 mm
(0.001 to 0.0025 in.)
(Centerline
VALVES to Piston Top) (1.599 to 1.603 in.)

Valve Length (Overall) Piston-to-Bore Clearance 0.018 to 0.038 mm

Intake 122.479 to 122.860 mm
(4.822 to 4.837 in.) Ring Gap Clearance
Exhaust 122.860 to 123.241 mm
(4.837 to 4.852 in.)
Valve Stem Diameter 7.899 to 7.925 mm
(0.311 to 0.312 in.)
Stem-to-Guide Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
(0.0008 to 0.0015 in.)
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
WJ ENGINE - 4.0L 9 - 17
EN GI N E - 4 .0 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Ring Side Clearance Gear End Clearance

Compression Rings 0.042 to 0.084 mm Feeler Gauge (Preferred) 0.1778 mm (0.007 in.)
(0.0017 to 0.0033 in.)
Oil Pressure
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.) At Idle Speed 89.6 kPa (13 psi)

Piston Ring Groove At 1600 rpm & Higher 255 to 517 kPa
Height (37 to 75 psi)
Compression Rings 1.530 to 1.555 mm
Oil Pressure Relief 517 kPa (75 psi)
(0.0602 to 0.0612 in.)
Oil Control Ring 4.035 to 4.060 mm TORQUE - 4.0L ENGINE
(0.1589 to 0.1598 in.)

Piston Ring Groove DESCRIPTION N·m Ft. In.

Diameter Lbs. Lbs.
No.1 Compression Ring 88.39 to 88.65 mm A/C Compressor—Bolts 28 — 250
(3.48 to 3.49 in.) Block Heater—Nut 2 — 16
No.2 Compression Ring 87.63 to 87.88 mm Camshaft Sprocket—Bolt 68 50 —
(3.45 to 3.46 in.) Camshaft Thrust Plate to
Oil Control Ring 89.66 to 89.92 mm Cylinder Block—Screws 24 18 —
(3.53 to 3.54 in.) Clutch Cover to Flywheel—Bolts 54 40 —
Piston Pin Bore Diameter 23.650 to 23.658 mm Coil Bracket to Block—Bolts 22 — 192
(0.9312 to 0.9315 in.) Connecting Rod—Nuts 45 33 —
Cylinder Block—Drain Plugs 34 25 —
Piston Pin Diameter 23.637 to 23.640 mm
Cylinder Head—Bolts 135 100 —
(0.9306 to 0.9307 in.)
Cylinder Head Cover—Bolts 10 — 85
Piston-to-Pin Clearance 0.0102 to 0.0208 mm Distributor Clamp—Bolts 23 — 204
(0.0005 to 0.0009 in.) Engine Mounts—Front
Piston-to-Pin Connecting Support Bracket Bolts 61 45 —
Rod (Press Fit) 8.9 kN (2000 lbf.) Support Cushion Bolts/Nuts 41 30 —
Support Cushion Bracket Bolts 54 40 —
OIL PUMP
Support Cushion Bracket Stud 41 30 —
Gear-to-Body Clearance 0.051 to 0.102 mm Nuts
(Radial) (0.002 to 0.004 in.) Support Cushion Thru-Bolt 65 48 —
Gear-to-Body Clearance Engine Mounts—Rear
(Radial) Preferred 0.051 mm (0.002 in.) Crossmember to Sill Bolts—
(Automatic) 41 30 —
Gear End Clearance 0.051 to 0.152 mm
Insulator Stud Assembly—Nut 41 30 —
Plastigage (0.002 to 0.006 in.)
Support Cushion/
Gear End Clearance Crossmember—
Plastigage (Preferred) 0.051 mm (0.002 in.) Nuts 22 — 192
Gear End Clearance 0.1016 to 0.2032 mm Support Cushion/Bracket—Nuts
Feeler Gauge (0.004 to 0.008 in.) (Manual) 75 55 —
9 - 18 ENGINE - 4.0L WJ
EN GI N E - 4 .0 L (Cont inue d)

DESCRIPTION N·m Ft. In. DESCRIPTION N·m Ft. In.

Lbs. Lbs. Lbs. Lbs.
Transmission Support Bracket Starter Motor—Mounting Bolts 45 33 —
—Bolt (Manual) 46 34 — Thermostat Housing—Bolts 18 — 156
Transmission Support Bracket/ Throttle Body—Bolts 10 — 90
Cushion—Bolt (4WD Auto) 75 55 — Vibration Damper—Bolt 108 80 —
Transmission Support Adaptor Water Pump to Block—Bolts 23 17 —

Bracket—Bolts (2WD Auto) 75 55 —

Exhaust Manifold/Pipe—Nuts 27 20 — AI R CLEAN ER ELEM EN T
Intake/Exhaust Manifold
REMOVAL - 4.0L
Fasteners #1-5 33 24 —
(1) Un la t ch fou r clips r et a in in g a ir clea n er cover t o
Fasteners #6 and 7 14 — 126 a ir clea n er h ou sin g (F ig. 6).
Fasteners #8-11 33 24 —
Flywheel to Converter 38 28 —
Housing—Bolts
Flywheel to Crankshaft—Bolts 143 105 —
Front Cover to Block—Bolts
1/4-20 7 — 60
5/16-18 22 — 192
Fuel Rail—Bolts/Stud 12 — 108
Generator—Bolts 57 42 —
Generator Bracket to Engine— 47 35 —
Bolts
Idler Pulley to Cylinder 47 35 —
Head—Bolt
Main Bearing Cap—Bolts 108 80 —
Oil Filter 18 — 156
Oil Filter Connector to
Adaptor 47 35 —
Block 68 50 —
Adaptor Bolts 102 50 —
Oil Galley—Plug 41 30 —
Oil Pan—Bolts
1/4-20 9.5 — 84
Fig. 6 Air Cleaner Assembly —4.0L Engine
5/16-18 15 — 132
1 - RESONATOR BOLTS
Oil Pan—Drain Plug 34 25 — 2 - CLAMPS
Oil Pump 3 - AIR DUCT
4 - AIR CLEANER COVER
Mounting Bolts 23 — 204 5 - CLIPS
Cover Bolts 8 — 70 6 - HOUSING
7 - HOUSING BOLTS (3)
Rocker Arm Assembly to 8 - LOWER HOUSING NUTS (3)
Cylinder 9 - RESONATOR
Head—Capscrews 30 21 —
Spark Plugs 37 27 —
WJ ENGINE - 4.0L 9 - 19
AI R CLEAN ER ELEM EN T (Cont inue d)
(2) Lift cover u p a n d posit ion t o t h e side.
(3) Rem ove a ir clea n er elem en t .

INSTALLATION - 4.0L
(1) Clea n in side of a ir clea n er h ou sin g befor e
in st a llin g n ew elem en t .
(2) In st a ll a ir clea n er elem en t in t o h ou sin g.
(3) La t ch clips a n d cla m p cover down t o secu r e. Be
su r e a ir clea n er cover is pr oper ly sea t ed t o a ir
clea n er h ou sin g.

AI R CLEAN ER H OU SI N G
REMOVAL - 4.0L
(1) Discon n ect a ir clea n er cover-t o-a ir du ct cla m p
(F ig. 6).
(2) Discon n ect a ir du ct a t h ou sin g.
(3) Ea c h o f th e 3 a ir c le a n e r h o u s in g m o u n t-
in g bo lts is a tta c h e d w ith 2 n u ts (a n u p p e r n u t
a n d lo w e r n u t). D O N OT REMOVE B OLTS . To
p re v e n t s trip p in g bo lts , o n ly re m o v e lo w e r
n u ts . Th e lo w e r h o u s in g n u ts a re lo c a te d u n d e r
le ft fro n t in n e r fe n d e r (F ig . 6).
(a ) To ga in a ccess t o lower n u t s, r a ise veh icle.
(b) Rem ove clips r et a in in g r u bber in n er fen der
sh ield.
(c) P r y ba ck sh ield en ou gh t o ga in a ccess t o
lower n u t s.
(d) Rem ove 3 n u t s.
(e) Rem ove a ir clea n er a ssem bly fr om veh icle.
(4) If r eson a t or is t o be r em oved, discon n ect
br ea t h er t u be a t r eson a t or, discon n ect a ir du ct cla m p
a t r eson a t or (F ig. 6)a n d r em ove 1 r eson a t or m ou n t -
in g bolt . Rem ove r eson a t or fr om t h r ot t le body by
loosen in g cla m p (F ig. 7).
INSTALLATION - 4.0L
(1) P osit ion a ir clea n er a ssem bly t o body a n d
in st a ll 3 n u t s. Tigh t en n u t s t o 10 N·m (93 in . lbs.)
t or qu e. To p re v e n t e x c e s s iv e v ibra tio n tra n s m it-
te d th ro u g h h o u s in g , th e n u ts m u s t be p ro p e rly
to rqu e d . D o n o t o v e rtig h te n n u ts .
(2) If r eson a t or wa s r em oved: In st a ll r eson a t or a n d
bolt s. Tigh t en bolt s t o 4 N·m (35 in . lbs.) t or qu e.
Tigh t en cla m p a t t h r ot t le body t o 4 N·m (35 in . lbs.)
t or qu e.
(3) P osit ion fen der lin er a n d in st a ll clips.
(4) Con n ect a ir du ct a t h ou sin g (F ig. 6).
(5) Tigh t en a ir du ct cla m p.
Fig. 7 RESONATOR CLAMP - 4.0L
1 - RESONATOR
2 - AIR DUCT
3 - CLAMP
CY LI N DER H EAD
DESCRIPTION
Th e cylin der h ea d is m a de of ca st ir on con t a in in g
t welve va lves m a de of ch r om e pla t ed h ea t r esist a n t
st eel, va lve st em sea ls, spr in gs, r et a in er s a n d keep-
er s. Th e cylin der h ea d a n d va lve sea t s ca n be r esu r-
fa ced for ser vice pu r poses.
Th e va lve gu ides a r e in t egr a l t o t h e cylin der h ea d,
Th ey a r e n ot r epla cea ble. H owever, t h ey a r e ser vice-
a ble.
Th e cylin der h ea d u ses du a l qu en ch -t ype design
com bu st ion ch a m ber s wh ich ca u se t u r bu len ce in t h e
cylin der s a llowin g fa st er bu r n in g of t h e a ir /fu el m ix-
t u r e, r esu lt in g in bet t er fu el econ om y (F ig. 8).
REMOVAL
NOTE: This procedure can be done with the engine
in or out of the vehicle.
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
9 - 20 ENGINE - 4.0L WJ
CY LI N DER H EAD (Cont inue d)
(12) Rem ove t h e in t a ke a n d exh a u st m a n ifolds
fr om t h e en gin e cylin der h ea d (Refer t o 9 - E NGINE /
MANIF OLDS/INTAKE MANIF OLD - RE MOVAL).
(13) Rem ove t h e coil r a il (Refer t o 8 - E LE CTRI-
CAL/IGNITION CONTROL/COIL RAIL - RE MOV-
AL).
(14) Rem ove spa r k plu gs (Refer t o 8 - E LE CTRI-
CAL/IGNITION CONTROL/SPARK P LUG - RE MOV-
AL).
(15) Discon n ect t h e t em per a t u r e sen din g u n it wir e
con n ect or.
(16) Rem ove t h e en gin e cylin der h ea d bolt s. Bolt
No.14 ca n n ot be r em oved u n t il t h e h ea d is m oved for-
wa r d (F ig. 9). P u ll bolt No.14 ou t a s fa r a s it will go
a n d t h en su spen d t h e bolt in t h is posit ion (t a pe
a r ou n d t h e bolt ).
Fig. 8 Cylinder Head 4.0L Engine (17) Rem ove t h e en gin e cylin der h ea d a n d ga sket
1 - CYLINDER HEAD BOLTS
(F ig. 9).
2 - CYLINDER HEAD GASKET (18) If t h is wa s t h e fir st t im e t h e bolt s wer e
3 - CYLINDER HEAD r em oved, pu t a pa in t da b on t h e t op of t h e bolt . If t h e
bolt s h a ve a pa in t da b on t h e t op of t h e bolt or it
isn ’t kn own if t h ey wer e u sed befor e, disca r d t h e
(2) Dr a in t h e coola n t (Refer t o 7 - COOLING -
bolt s.
STANDARD P ROCE DURE ) a n d discon n ect t h e h oses
(19) St u ff clea n lin t fr ee sh op t owels in t o t h e cyl-
a t t h e en gin e t h er m ost a t h ou sin g a n d t h e wa t er
in der bor es.
pu m p in let . DO NOT wa st e r eu sa ble coola n t . If t h e
solu t ion is clea n a n d is bein g dr a in ed on ly t o ser vice NOTE: If the valves, springs, or seals are to be
t h e en gin e or coolin g syst em , dr a in t h e coola n t in t o a inspected/replaced at this time, (Refer to 9 -
clea n con t a in er for r eu se. ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
(3) Rem ove t h e a ir clea n er a ssem bly (Refer t o 9 - VALVES & SEATS - STANDARD PROCEDURE) for
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R proper inspection procedures.
H OUSING - RE MOVAL).
(4) Rem ove t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(5) Rem ove t h e ca pscr ews, br idge a n d pivot a ssem -
blies a n d r ocker a r m s (Refer t o 9 - E NGINE /CYLIN-
DE R H E AD/ROCKE R ARM / ADJ USTE R ASSY -
RE MOVAL).
(6) Rem ove t h e pu sh r ods. Re ta in th e p u s h ro d s ,
brid g e s , p iv o ts a n d ro c k e r a rm s in th e s a m e
o rd e r a s re m o v e d .
(7) Rem ove t h e a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(8) Rem ove t h e A/C com pr essor m ou n t in g bolt s
a n d secu r e t h e com pr essor t o t h e side.
(9) Rem ove t h e power st eer in g pu m p a n d br a cket
fr om t h e in t a ke m a n ifold a n d wa t er pu m p. Set t h e Fig. 9 Engine Cylinder
pu m p a n d br a cket a side. DO NOT discon n ect t h e 1 - CYLINDER HEAD BOLTS
h oses. 2 - CYLINDER HEAD GASKET
(10) P er for m t h e F u el Syst em P r essu r e Relea se 3 - CYLINDER HEAD
pr ocedu r e. (Refer t o 14 - F UE L SYSTE M/F UE L
DE LIVE RY - STANDARD P ROCE DURE ).
(11) Discon n ect t h e fu el su pply lin e a t t h e fu el r a il.
WJ ENGINE - 4.0L 9 - 21
CY LI N DER H EAD (Cont inue d)

CLEANING (a ) Tigh t en a ll bolt s in sequ en ce (1 t h r ou gh 14)

Th or ou gh ly clea n t h e en gin e cylin der h ea d a n d cyl- t o 30 N·m (22 ft . lbs.) t or qu e.
in der block m a t in g su r fa ces. Clea n t h e in t a ke a n d (b) Tigh t en a ll bolt s in sequ en ce (1 t h r ou gh 14)
en gin e exh a u st m a n ifold a n d en gin e cylin der h ea d t o 61 N·m (45 ft . lbs.) t or qu e.
m a t in g su r fa ces. Rem ove a ll ga sket m a t er ia l a n d ca r- (c) Ch eck a ll bolt s t o ver ify t h ey a r e set t o 61
bon . N·m (45 ft . lbs.) t or qu e.
Ch eck t o en su r e t h a t n o coola n t or for eign m a t er ia l (d) Tigh t en bolt s in sequ en ce:
h a s fa llen in t o t h e t a ppet bor e a r ea . • Bolt s 1 t h r ou gh 10 t o 149 N·m (110 ft . lbs.)
Rem ove t h e ca r bon deposit s fr om t h e com bu st ion t or qu e.
ch a m ber s a n d t op of t h e pist on s. • Bolt 11 t o 135 N·m (100 ft . lbs.) t or qu e.
• Bolt s 12 t h r ou gh 14 t o 149 N·m (110 ft . lbs.)
INSPECTION t or qu e.
Use a st r a igh t edge a n d feeler ga u ge t o ch eck t h e CY LI N DER H EAD BOLT S
fla t n ess of t h e en gin e cylin der h ea d a n d block m a t in g
su r fa ces. POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
INSTALLATION
8,9 1/2 in.-13 BOLT WITH DOWEL
NOTE: This procedure can be done with the engine POINT
in or out of the vehicle. 2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
Th e en gin e cylin der h ea d ga sket is a com posit ion All bolts are 12 point drives for rocker cover clearance
ga sket . Th e ga sket is t o be in st a lled DRY. D O N OT
u s e a g a s k e t s e a lin g c o m p o u n d o n th e g a s k e t. (e) Ch eck a ll bolt s in sequ en ce t o ver ify t h e cor-
If t h e en gin e cylin der h ea d is t o be r epla ced a n d r ect t or qu e.
t h e or igin a l va lves u sed, m ea su r e t h e va lve st em (f) If n ot a lr ea dy don e, clea n a n d m a r k ea ch bolt
dia m et er. On ly st a n da r d size va lves ca n be u sed wit h wit h a da b of pa in t a ft er t igh t en in g. Sh ou ld you
a ser vice r epla cem en t en gin e cylin der h ea d u n less en cou n t er bolt s wh ich wer e pa in t ed in a n ea r lier
t h e r epla cem en t h ea d va lve st em gu ide bor es a r e ser vice oper a t ion , r epla ce t h em .
r ea m ed t o a ccom m oda t e over size va lve st em s.
Rem ove a ll ca r bon bu ildu p a n d r efa ce t h e va lves.
(1) Rem ove t h e sh op t owels fr om t h e cylin der
bor es. Coa t t h e bor es wit h clea n en gin e oil.
(2) P osit ion t h e en gin e cylin der h ea d ga sket (wit h
t h e n u m ber s fa cin g u p) u sin g t h e a lign m en t dowels
in t h e cylin der block, t o posit ion t h e ga sket .

CAUTION: Engine cylinder head bolts should be

reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
Fig. 10 Engine Cylinder Head Bolt Tightening
(3) Wit h bolt No.14 h eld in pla ce (t a pe a r ou n d Sequence
bolt ), in st a ll t h e en gin e cylin der h ea d over t h e sa m e
(6) In st a ll t h e spa r k plu gs (Refer t o 8 - E LE CTRI-
dowels u sed t o loca t e t h e ga sket . Rem ove t h e t a pe
CAL/IGNITION CONTROL/SPARK P LUG - INSTAL-
fr om bolt No.14.
LATION).
(4) Coa t t h e t h r ea ds of st u d bolt No.11 wit h Loc-
(7) Con n ect t h e t em per a t u r e sen din g u n it wir e
t it e 592 sea la n t , or equ iva len t .
con n ect or.
(5) Tigh t en t h e en gin e cylin der h ea d bolt s in
(8) In st a ll t h e ign it ion coil r a il (Refer t o 8 - E LE C-
sequ en ce a ccor din g t o t h e followin g pr ocedu r e (F ig.
TRICAL/IGNITION CONTROL/COIL RAIL -
10).
INSTALLATION).
CAUTION: During the final tightening sequence, (9) In st a ll t h e in t a ke a n d exh a u st m a n ifolds (Refer
bolt No.11 will be tightened to a lower torque than t o 9 - E NGINE /MANIF OLDS/INTAKE MANIF OLD -
the rest of the bolts. DO NOT overtighten bolt INSTALLATION).
No.11. (10) In st a ll t h e fu el lin e.
(11) At t a ch t h e power st eer in g pu m p a n d br a cket .
9 - 22 ENGINE - 4.0L WJ
CY LI N DER H EAD (Cont inue d)
(12) In st a ll t h e pu sh r ods, r ocker a r m s, pivot s a n d CY LI N DER H EAD COV ER(S)
br idges in t h e or der t h ey wer e r em oved (Refer t o 9 -
E NGINE /CYLINDE R H E AD/ROCKE R ARM /
DESCRIPTION
ADJ USTE R ASSY - INSTALLATION).
Th e cylin der h ea d cover (F ig. 11) is m a de of
(13) In st a ll t h e en gin e cylin der h ea d cover (Refer
st a m ped st eel a n d in cor por a t es t h e Cr a n kca se Ven t i-
t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R
la t ion (CCV) H oses a n d t h e oil fill open in g.
H E AD COVE R(S) - INSTALLATION).
(14) At t a ch t h e a ir con dit ion er com pr essor m ou n t -
in g br a cket t o t h e en gin e cylin der h ea d a n d block.
Tigh t en t h e bolt s t o 40 N·m (30 ft . lbs.) t or qu e.
(15) At t a ch t h e a ir con dit ion in g com pr essor t o t h e
br a cket . Tigh t en t h e bolt s t o 27 N·m (20 ft . lbs.)
t or qu e.

CAUTION: The serpentine drive belt must be routed

correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.

(16) In st a ll t h e ser pen t in e dr ive belt . (Refer t o 7 -

COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(17) In st a ll t h e a ir clea n er a n d du ct in g.
(18) Con n ect t h e h oses t o t h e en gin e t h er m ost a t
h ou sin g a n d fill t h e coolin g syst em t o t h e specified
level (Refer t o 7 - COOLING - STANDARD P ROCE -
DURE ).
(19) Th e a u t om a t ic t r a n sm ission t h r ot t le lin ka ge
a n d ca ble m u st be a dju st ed a ft er com plet in g t h e
en gin e cylin der h ea d in st a lla t ion (Refer t o 21 -
TRANSMISSION/TRANSAXLE /AUTOMATIC - AW4/
TH ROTTLE VALVE CABLE - ADJ USTME NTS).
(20) In st a ll t h e t em per a t u r e sen din g u n it a n d con -
n ect t h e wir e con n ect or.
(21) If equ ipped wit h a ir con dit ion in g, in st a ll A/C
com pr essor (Refer t o 24 - H E ATING & AIR CONDI-
TIONING/P LUMBING/A/C COMP RE SSOR
INSTALLATION) a n d ch a r ge A/C syst em (Refer t o 24
- H E ATING & AIR CONDITIONING/P LUMBING -
STANDARD P ROCE DURE ).
(22) Con n ect n ega t ive ca ble t o ba t t er y.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Oper a t e t h e en gin e wit h t h e r a dia t or ca p off.
In spect for lea ks a n d con t in u e oper a t in g t h e en gin e
u n t il t h e en gin e t h er m ost a t open s. Add coola n t , if
r equ ir ed.
Fig. 11 Cylinder Head Cover
REMOVAL
Th e cylin der h ea d cover is isola t ed fr om t h e cylin -
der h ea d via gr om m et s a n d a r eu sa ble m olded r u bber
ga sket . Th e gr om m et a n d lim it er a r e r et a in ed in t h e
cylin der h ea d cover.
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Discon n ect t h e Cr a n kca se Ven t ila t ion (CCV)
va cu u m h ose fr om en gin e cylin der h ea d cover.
(3) Discon n ect t h e fr esh a ir in let h ose fr om t h e
en gin e cylin der h ea d cover.
(4) Discon n ect t h e a cceler a t or, t r a n sm ission , a n d
speed (if equ ipped) con t r ol ca bles fr om t h e t h r ot t le
- body (F ig. 12).
(5) Rem ove t h e t h r ee bolt s t h a t fa st en t h e con t r ol
ca ble br a cket t o t h e in t a ke m a n ifold.
(6) Rem ove con t r ol ca bles fr om cylin der h ea d cover
clip.
(7) P osit ion con t r ol ca bles a n d br a cket a wa y fr om
cylin der h ea d cover secu r e wit h t ie st r a ps.
(8) Rem ove t h e en gin e cylin der h ea d cover m ou n t -
in g bolt s.
(9) Rem ove t h e en gin e cylin der h ea d cover a n d
ga sket .
WJ
CY LI N DER H EAD COV ER(S) (Cont inue d)
Fig. 12 Engine Cylinder Head Cover
1 - TRANS CONTROL CABLE
2 - ACCELERATOR CABLE
3 - CONTROL CABLE BRACKET
4 - CYLINDER HEAD COVER
CLEANING
Rem ove a n y or igin a l sea ler fr om t h e cover sea lin g
su r fa ce of t h e en gin e cylin der h ea d a n d clea n t h e
su r fa ce u sin g a fa br ic clea n er.
Rem ove a ll r esidu e fr om t h e sea lin g su r fa ce u sin g
a clea n , dr y clot h .
INSPECTION
In spect t h e en gin e cylin der h ea d cover for cr a cks.
Repla ce t h e cover, if cr a cked.
Th e or igin a l da r k gr ey ga sket m a t er ia l sh ou ld
NOT be r em oved. If sect ion s of t h e ga sket m a t er ia l
a r e m issin g or a r e com pr essed, r epla ce t h e en gin e
cylin der h ea d cover. H owever, sect ion s wit h m in or
da m a ge su ch a s sm a ll cr a cks, cu t s or ch ips m a y be
r epa ir ed wit h a h a n d h eld a pplica t or. Th e n ew m a t e-
r ia l m u st be sm oot h ed over t o m a in t a in ga sket
h eigh t . Allow t h e ga sket m a t er ia l t o cu r e pr ior t o
en gin e cylin der h ea d cover in st a lla t ion .
INSTALLATION
Th e cylin der h ea d cover is isola t ed fr om t h e cylin -
der h ea d via gr om m et s a n d a r eu sa ble m olded r u bber
ga sket . Th e gr om m et a n d lim it er a r e r et a in ed in t h e
cylin der h ea d cover.
(1) If a r epla cem en t cover is in st a lled, t r a n sfer t h e
CCV va lve gr om m et a n d oil filler ca p fr om t h e or igi-
n a l cover t o t h e r epla cem en t cover.
(2) In st a ll cylin der h ea d cover a n d ga sket (F ig. 13).
Tigh t en t h e m ou n t in g bolt s t o 10 N·m (85 in . lbs.)
t or qu e.
(3) Con n ect t h e CCV h oses.
ENGINE - 4.0L 9 - 23
Fig. 13 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
(4) In st a ll con t r ol ca bles a n d br a cket on in t a ke
m a n ifold a n d t igh t en bolt s t o 8.7 N·m (77 in . lbs.)
t or qu e.
(5) Con n ect con t r ol ca bles t o t h r ot t le body lin ka ge.
(6) Sn a p con t r ol ca bles in t o cylin der h ea d cover
clip.
(7) Con n ect n ega t ive ca ble t o ba t t er y.
I N TAK E/EX H AU ST VALV ES &
SEAT S
DESCRIPTION
Th e va lves a r e m a de of h ea t r esist a n t st eel a n d
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. All
va lves u se t h r ee bea d locks t o pr om ot e va lve r ot a t ion
(F ig. 14).
STANDARD PROCEDURE - VALVE SERVICE
VALVE REFACING
Clea n a ll ca r bon deposit s fr om t h e com bu st ion
ch a m ber s, va lve por t s, va lve st em s, va lve st em
gu ides a n d h ea d.
(1) Use a va lve r efa cin g m a ch in e t o r efa ce t h e
in t a ke a n d exh a u st va lves t o t h e specified a n gle.
(2) Aft er r efa cin g, a m a r gin of a t lea st 0.787 m m
(0.031 in ch ) m u st r em a in (F ig. 15). If t h e m a r gin is
less t h a n 0.787 m m (0.031 in ch ), t h e va lve m u st be
r epla ced.
VALVE SEAT REFACING
Clea n a ll ca r bon deposit s fr om t h e com bu st ion
ch a m ber s, va lve por t s, va lve st em s, va lve st em
gu ides a n d h ea d.
(1) In st a ll a pilot of t h e cor r ect size in t h e va lve
gu ide bor e. Refa ce t h e va lve sea t t o t h e specified
a n gle wit h a good dr essin g st on e. Rem ove on ly
en ou gh m et a l t o pr ovide a sm oot h fin ish .
(2) Use t a per ed st on es t o obt a in t h e specified sea t
widt h wh en r equ ir ed.
9 - 24 ENGINE - 4.0L WJ
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)

Fig. 16 Measurement of Valve Seat Runout

1 - DIAL INDICATOR

VALVE STEM-TO-GUIDE CLEARANCE

Fig. 14 VALVE AND KEEPER CONFIGURATION 4.0L MEASUREMENT
1 - VALVE LOCKS (3–BEAD) PREFERRED METHOD
2 - RETAINER
3 - VALVE STEM OIL SEAL
(1) Rem ove t h e va lve fr om t h e h ea d.
4 - INTAKE VALVE (2) Clea n t h e va lve st em gu ide bor e wit h solven t
5 - EXHAUST VALVE a n d a br ist le br u sh .
6 - VALVE SPRING (3) In ser t a t elescopin g ga u ge in t o t h e va lve st em
gu ide bor e a ppr oxim a t ely 9.525 m m (.375 in ch ) fr om
t h e va lve spr in g side of t h e h ea d (F ig. 17).
(4) Rem ove a n d m ea su r e t elescopin g ga u ge wit h a
m icr om et er.
(5) Repea t t h e m ea su r em en t wit h con t a ct s len gt h -
wise t o en gin e cylin der h ea d.
(6) Com pa r e t h e cr osswise t o len gt h wise m ea su r e-
m en t s t o det er m in e ou t -of-r ou n dn ess. If t h e m ea su r e-
m en t s differ by m or e t h a n 0.0635 m m (0.0025 in .),
r ea m t h e gu ide bor e t o a ccom m oda t e a n over size
va lve st em .
(7) Com pa r e t h e m ea su r ed va lve gu ide bor e dia m -
et er wit h specifica t ion s (7.95-7.97 m m or 0.313-0.314
in ch ). If t h e m ea su r em en t differ s fr om specifica t ion
by m or e t h a n 0.076 m m (0.003 in ch ), r ea m t h e gu ide
bor e t o a ccom m oda t e a n over size va lve st em .

ALTERNATIVE METHOD
(1) Use a dia l in dica t or t o m ea su r e t h e la t er a l
Fig. 15 Valve Facing
m ovem en t of t h e va lve st em (st em -t o-gu ide clea r-
1 - VALVE MARGIN
a n ce). Th is m u st be don e wit h t h e va lve in st a lled in
2 - NO MARGIN
it s gu ide a n d ju st off t h e va lve sea t (F ig. 18).
(2) Cor r ect clea r a n ce is 0.025-0.0762 mm
(3) Con t r ol va lve sea t r u n ou t t o a m a xim u m of (0.001-0.003 in ch ). If in dica t ed m ovem en t exceeds t h e
0.0635 m m (0.0025 in .) (F ig. 16). specifica t ion r ea m t h e va lve gu ide t o a ccom m oda t e
a n over size va lve st em .
WJ ENGINE - 4.0L 9 - 25
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
(1) Rem ove t h e en gin e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - RE MOVAL) fr om t h e
cylin der block.
(2) Use Va lve Spr in g Com pr essor Tool
MD-998772A a n d com pr ess ea ch va lve spr in g.
(3) Rem ove t h e va lve locks, r et a in er s, spr in gs a n d
va lve st em oil sea ls. Disca r d t h e oil sea ls (F ig. 19).
(4) Use a sm oot h st on e or a jeweler s file t o r em ove
a n y bu r r s on t h e t op of t h e va lve st em , especia lly
a r ou n d t h e gr oove for t h e locks.
(5) Rem ove t h e va lves, a n d pla ce t h em in a r a ck in
t h e sa m e or der a s r em oved.

Fig. 17 Measurement of Valve Guide Bore Diameter

1 - GAUGE
2 - 9.525 MM (3/8 INCH)
3 - VALVE STEM GUIDE
4 - CYLINDER HEAD

NOTE: Valve seats must be ground after reaming

the valve guides to ensure that the valve seat is
concentric to the valve guide.

Fig. 19 Valve and Valve Components

1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING

INSTALLATION
NOTE: This procedure is done with the engine cyl-
inder head removed from the block.

Fig. 18 Measurement of Lateral Movement Of Valve (1) Th or ou gh ly clea n t h e va lve st em s a n d t h e va lve

Stem gu ide bor es.
1 - DIAL INDICATOR (2) Ligh t ly lu br ica t e t h e st em .
(3) In st a ll t h e va lve in t h e or igin a l va lve gu ide
bor e.
REMOVAL (4) In st a ll t h e r epla cem en t va lve st em oil sea ls on
t h e va lve st em s (F ig. 20). If t h e 0.381 m m (0.015
NOTE: This procedure is done with the engine cyl- in ch ) over size va lve st em s a r e u sed, over size oil sea ls
inder head removed from the block. a r e r equ ir ed.
9 - 26 ENGINE - 4.0L WJ
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
(5) P osit ion t h e va lve spr in g a n d r et a in er on t h e
en gin e cylin der h ea d a n d com pr ess t h e va lve spr in g
wit h Va lve Spr in g Com pr essor Tool MD-998772A.
(6) In st a ll t h e va lve locks a n d r elea se t h e t ool.
(7) Ta p t h e va lve spr in g fr om side t o side wit h a
h a m m er t o en su r e t h a t t h e spr in g is pr oper ly sea t ed
a t t h e en gin e cylin der h ea d. Also t a p t h e t op of t h e
r et a in er t o sea t t h e va lve locks.
(8) In st a ll t h e en gin e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION).

Fig. 21 Rocker Arms—Typical

1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS

REMOVAL
Fig. 20 Valve and Valve Components NOTE: This procedure can be done with the engine
1 - VALVE LOCKS (3–BEAD) in or out of the vehicle.
2 - RETAINER
3 - VALVE STEM OIL SEAL (1) Rem ove t h e cylin der h ea d cover (Refer t o 9 -
4 - INTAKE VALVE E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
5 - EXHAUST VALVE
COVE R(S) - RE MOVAL).
6 - VALVE SPRING
(2) Ch eck for r ocker a r m br idges wh ich a r e ca u s-
in g m isa lign m en t of t h e r ocker a r m t o va lve t ip a r ea .
ROCK ER ARM / ADJ U ST ER (3) Rem ove t h e ca pscr ews a t ea ch br idge a n d pivot
a ssem bly (F ig. 22). Alt er n a t ely loosen t h e ca pscr ews
ASSEM BLY on e t u r n a t a t im e t o a void da m a gin g t h e br idges.
(4) Rem ove t h e br idges, pivot s a n d cor r espon din g
DESCRIPTION pa ir s of r ocker a r m s (F ig. 22). P la ce t h em on a ben ch
Th e r ocker a r m s a r e m a de of st a m ped st eel a n d in t h e sa m e or der a s r em oved.
h a ve a oper a t ion a l r a t io of 1.6:1 (F ig. 21). (5) Rem ove t h e pu sh r ods a n d pla ce t h em on a
ben ch in t h e sa m e or der a s r em oved.
OPERATION
Wh en t h e pu sh r ods a r e for ced u pwa r d by t h e ca m - CLEANING
sh a ft lobes t h e pu sh r od pr esses u pwa r d on t h e Clea n a ll t h e com pon en t s wit h clea n in g solven t .
r ocker a r m s, t h e r ocker a r m s pivot , for cin g down - Use com pr essed a ir t o blow ou t t h e oil pa ssa ges in
wa r d pr essu r e on t h e va lves for cin g t h e va lves t o t h e r ocker a r m s a n d pu sh r ods.
m ove down wa r d a n d off fr om t h eir sea t s.
WJ ENGINE - 4.0L 9 - 27
ROCK ER ARM / ADJ U ST ER ASSEM BLY (Cont inue d)
t h a t t h e bot t om en d of ea ch pu sh r od is cen t er ed in
t h e t a ppet plu n ger ca p sea t .
(2) Usin g Mopa r ! E n gin e Oil Su pplem en t , or
equ iva len t , lu br ica t e t h e a r ea of t h e r ocker a r m t h a t
t h e pivot con t a ct s. In st a ll r ocker a r m s, pivot s a n d
br idge a bove ea ch cylin der in t h eir or igin a lly posit ion
(F ig. 23).
(3) Loosely in st a ll t h e ca pscr ews t h r ou gh ea ch
br idge.
(4) At ea ch br idge, t igh t en t h e ca pscr ews a lt er-
n a t ely, on e t u r n a t a t im e, t o a void da m a gin g t h e
br idge. Tigh t en t h e ca pscr ews t o 28 N·m (21 ft . lbs.)
t or qu e.
(5) In st a ll t h e en gin e cylin der h ea d cover (Refer t o
9 - E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).

Fig. 22 Rocker Arm

1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS

INSPECTION
In spect t h e pivot su r fa ce a r ea of ea ch r ocker a r m .
Repla ce a n y t h a t a r e scu ffed, pit t ed, cr a cked or
excessively wor n .
In spect t h e va lve st em t ip con t a ct su r fa ce of ea ch
r ocker a r m a n d r epla ce a n y r ocker a r m t h a t is deeply
pit t ed.
In spect ea ch pu sh r od en d for excessive wea r a n d
r epla ce a s r equ ir ed. If a n y pu sh r od is excessively
wor n beca u se of la ck of oil, r epla ce it a n d in spect t h e Fig. 23 Rocker Arm
cor r espon din g h ydr a u lic t a ppet for excessive wea r. 1 - CAPSCREWS
In spect t h e pu sh r ods for st r a igh t n ess by r ollin g 2 - BRIDGE
t h em on a fla t su r fa ce or by sh in in g a ligh t bet ween 3 - PIVOT ASSEMBLY
t h e pu sh r od a n d t h e fla t su r fa ce. 4 - PUSH RODS
A wea r pa t t er n a lon g t h e len gt h of t h e pu sh r od is 5 - ROCKER ARMS
n ot n or m a l. In spect t h e en gin e cylin der h ea d for
obst r u ct ion if t h is con dit ion exist s.
VALV E ST EM SEALS
INSTALLATION DESCRIPTION
NOTE: This procedure can be done with the engine Th e va lve st em sea ls (F ig. 24) a r e m a de of r u bber
in or out of the vehicle. a n d in cor por a t e a ga r t er spr in g t o m a in t a in con sis-
t en t lu br ica t ion con t r ol.
(1) Lu br ica t e t h e ba ll en ds of t h e pu sh r ods wit h
Mopa r ! E n gin e Oil Su pplem en t , or equ iva len t a n d
in st a ll pu sh r ods in t h eir or igin a l loca t ion s. E n su r e
9 - 28 ENGINE - 4.0L WJ
VALV E ST EM SEALS (Cont inue d)

Fig. 24 Valve Fig. 25 VALVE AND KEEPER CONFIGURATION 4.0L

1 - VALVE LOCKS (3–BEAD) 1 - VALVE LOCKS (3–BEAD)
2 - RETAINER 2 - RETAINER
3 - VALVE STEM OIL SEAL 3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE 4 - INTAKE VALVE
5 - EXHAUST VALVE 5 - EXHAUST VALVE
6 - VALVE SPRING 6 - VALVE SPRING

VALV E SPRI N GS
DESCRIPTION
Th e va lve spr in gs (F ig. 25) a r e m a de of h igh
st r en gt h silicon ch r om e spr in g st eel. Th e spr in gs a r e
com m on for bot h in t a ke a n d exh a u st va lves.

STANDARD PROCEDURE - VALVE SPRING

TENSION TEST
Clea n a ll ca r bon deposit s fr om t h e com bu st ion
ch a m ber s, va lve por t s, va lve st em s, va lve st em
gu ides a n d h ea d.
Use a u n iver sa l Va lve Spr in g Test er a n d a t or qu e
wr en ch t o t est ea ch va lve spr in g for t h e specified t en -
sion va lu e (F ig. 26).
Repla ce va lve spr in gs t h a t a r e n ot wit h in specifica - Fig. 26 Valve Spring Tester
t ion s. 1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
REMOVAL
E a ch va lve spr in g is h eld in pla ce by a r et a in er
NOTE: This procedure can be done with the engine
a n d a set of con ica l va lve locks. Th e locks ca n be
cylinder head installed on the block.
r em oved on ly by com pr essin g t h e va lve spr in g.
In spect t h e va lve st em s, especia lly t h e gr ooves. An (1) Rem ove t h e en gin e cylin der h ea d cover (Refer
Ar ka n sa s sm oot h st on e sh ou ld be u sed t o r em ove t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R
n icks a n d h igh spot s. H E AD COVE R(S) - RE MOVAL).
WJ ENGINE - 4.0L 9 - 29
VALV E SPRI N GS (Cont inue d)
(2) Rem ove ca p scr ews, br idge a n d pivot a ssem -
blies a n d r ocker a r m s (Refer t o 9 - E NGINE /CYLIN-
DE R H E AD/ROCKE R ARM / ADJ USTE R ASSY -
RE MOVAL) for a ccess t o ea ch va lve spr in g t o be
r em oved.
(3) Rem ove pu sh r ods. Re ta in th e p u s h ro d s ,
brid g e s , p iv o ts a n d ro c k e r a rm s in th e s a m e
o rd e r a n d p o s itio n a s re m o v e d .
(4) In spect t h e spr in gs a n d r et a in er for cr a cks a n d
possible sign s of wea ken in g.
(5) Rem ove t h e spa r k plu g(s) a dja cen t t o t h e cylin -
der (s) below t h e va lve spr in gs t o be r em oved.
(6) Con n ect a n a ir h ose t o t h e a da pt er a n d a pply
a ir pr essu r e slowly. Ma in t a in a t lea st 621 kP a (90
psi) of a ir pr essu r e in t h e cylin der t o h old t h e va lves
a ga in st t h eir sea t s. F or veh icles equ ipped wit h a n a ir
con dit ion er, u se a flexible a ir a da pt or wh en ser vicin g
t h e No.1 cylin der.
(7) Ta p t h e r et a in er or t ip wit h a r a wh ide h a m m er
t o loosen t h e lock fr om t h e r et a in er. Use Va lve Spr in g
Com pr essor Tool MD-998772A t o com pr ess t h e spr in g
a n d r em ove t h e locks (F ig. 27).
Fig. 27 Valve and Valve Components
(8) Rem ove va lve spr in g a n d r et a in er (F ig. 27).
1 - VALVE LOCKS (3–BEAD)
(9) Rem ove va lve st em oil sea ls (F ig. 27). Not e t h e
2 - RETAINER
va lve sea ls a r e differ en t for in t a ke a n d exh a u st
3 - VALVE STEM OIL SEAL
va lves. Th e t op of ea ch sea l is m a r ked eit h er INT 4 - INTAKE VALVE
(in t a ke/bla ck in color ) or E XH (exh a u st /br own in 5 - EXHAUST VALVE
color ). DO NOT m ix t h e sea ls. 6 - VALVE SPRING

INSTALLATION (4) Relea se a ir pr essu r e a n d discon n ect t h e a ir

NOTE: This procedure can be done with the engine
cylinder head installed on the block.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Ligh t ly pu sh t h e va lve sea l over t h e va lve st em
a n d va lve gu ide boss. Be su r e t h e sea l is com plet ely
sea t ed on t h e va lve gu ide boss.
(2) In st a ll va lve spr in g a n d r et a in er (F ig. 28).
(3) Com pr ess t h e va lve spr in g wit h Va lve Spr in g
Com pr essor Tool MD-998772A a n d in ser t t h e va lve
locks. Relea se t h e spr in g t en sion a n d r em ove t h e
t ool. Ta p t h e spr in g fr om side-t o-side t o en su r e t h a t
t h e spr in g is sea t ed pr oper ly on t h e en gin e cylin der
h ea d.
h ose. Rem ove t h e a da pt or fr om t h e spa r k plu g h ole
a n d in st a ll t h e spa r k plu g.
(5) Repea t t h e pr ocedu r es for ea ch r em a in in g va lve
spr in g t o be r em oved.
(6) In st a ll t h e pu sh r ods. E n su r e t h e bot t om en d of
ea ch r od is cen t er ed in t h e plu n ger ca p sea t of t h e
h ydr a u lic va lve t a ppet .
(7) In st a ll t h e r ocker a r m s, pivot s a n d br idge
(Refer t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R
ARM / ADJ USTE R ASSY - INSTALLATION) a t t h eir
or igin a l loca t ion .
(8) In st a ll t h e en gin e cylin der h ea d cover (Refer t o
9 - E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).
9 - 30 ENGINE - 4.0L WJ
VALV E SPRI N GS (Cont inue d)

Fig. 28 Valve and Valve

Fig. 29 Cylinder Bore Measurement
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER (3) Mea su r e t h e cylin der bor e dia m et er cr osswise
3 - VALVE STEM OIL SEAL t o t h e cylin der block n ea r t h e t op of t h e bor e. Repea t
4 - INTAKE VALVE t h e m ea su r em en t n ea r t h e m iddle of t h e bor e, t h en
5 - EXHAUST VALVE r epea t t h e m ea su r em en t n ea r t h e bot t om of t h e bor e.
6 - VALVE SPRING (4) Det er m in e t a per by su bt r a ct in g t h e sm a ller
dia m et er fr om t h e la r ger dia m et er.
(5) Rot a t e m ea su r in g device 90° a n d r epea t st eps
EN GI N E BLOCK a bove.
(6) Det er m in e ou t -of-r ou n dn ess by com pa r in g t h e
CLEANING differ en ce bet ween ea ch m ea su r em en t .
Th or ou gh ly clea n t h e oil pa n a n d en gin e block ga s- (7) If cylin der bor e t a per does n ot exceed 0.025
ket su r fa ces. m m (0.001 in ch ) a n d ou t -of-r ou n dn ess does n ot
Use com pr essed a ir t o clea n ou t : exceed 0.025 m m (0.001 in ch ), t h e cylin der bor e ca n
• Th e ga lley a t t h e oil filt er a da pt or h ole. be h on ed. If t h e cylin der bor e t a per or ou t - of-r ou n d
• Th e fr on t a n d r ea r oil ga lley h oles. con dit ion exceeds t h ese m a xim u m lim it s, t h e cylin der
• Th e feed h oles for t h e cr a n ksh a ft m a in bea r in gs. m u st be bor ed a n d t h en h on ed t o a ccept a n over size
On ce t h e block h a s been com plet ely clea n ed, a pply pist on . A sligh t a m ou n t of t a per a lwa ys exist s in t h e
Loct it e P ST pipe sea la n t wit h Teflon 592 t o t h e cylin der bor e a ft er t h e en gin e h a s been in u se for a
t h r ea ds of t h e fr on t a n d r ea r oil ga lley plu gs. Tigh t en per iod of t im e.
t h e plu gs t o 34 N·m (25 ft . lbs.) t or qu e.

INSPECTION CAM SH AFT & BEARI N GS

(1) It is m a n da t or y t o u se a dia l bor e ga u ge t o
m ea su r e ea ch cylin der bor e dia m et er (F ig. 29). To
cor r ect ly select t h e pr oper size pist on , a cylin der bor e
ga u ge, ca pa ble of r ea din g in 0.003 m m (.0001 in .)
INCRE ME NTS is r equ ir ed. If a bor e ga u ge is n ot
a va ila ble, do n ot u se a n in side m icr om et er.
(2) Mea su r e t h e in side dia m et er of t h e cylin der
bor e a t t h r ee levels below t op of bor e. St a r t per pen -
dicu la r (a cr oss or a t 90 degr ees) t o t h e a xis of t h e
cr a n ksh a ft a n d t h en t a ke t wo a ddit ion a l r ea din g.
DESCRIPTION
Th e ca m sh a ft is m a de of gr a y ca st ir on wit h t welve
m a ch in ed lobes a n d fou r bea r in g jou r n a ls (F ig. 30).
Wh en t h e ca m sh a ft r ot a t es t h e lobes a ct u a t e t h e t a p-
pet s a n d pu sh r ods, for cin g u pwa r d on t h e r ocker
a r m s wh ich a pplies down wa r d for ce on t h e va lves.
WJ
CAM SH AFT & BEARI N GS (Cont inue d)
Fig. 30 Camshaft—Typical
1 - CAMSHAFT
2 - LOBES
3 - BEARING JOURNAL
REM OVAL
REMOVAL - CAMSHAFT BEARINGS
Th e ca m sh a ft r ot a t es wit h in fou r st eel-sh elled,
ba bbit t -lin ed bea r in gs t h a t a r e pr essed in t o t h e cyl-
in der block a n d t h en lin e r ea m ed. Th e ca m sh a ft
bea r in g bor es a n d bea r in g dia m et er s a r e n ot t h e
sa m e size. Th ey a r e st epped down in 0.254 m m
(0.010 in ch ) in cr em en t s fr om t h e fr on t bea r in g (la r g-
est ) t o t h e r ea r bea r in g (sm a llest ). Th is per m it s ea s-
ier r em ova l a n d in st a lla t ion of t h e ca m sh a ft . Th e
ca m sh a ft bea r in gs a r e pr essu r e lu br ica t ed. Ca m sh a ft
en d pla y is m a in t a in ed by t h e t h r u st pla t e.
(1) Rem ove t h e ca m sh a ft (Refer t o 9 - E NGINE /
E NGINE BLOCK/CAMSH AF T & BE ARINGS (IN
BLOCK) - RE MOVAL).
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Usin g Specia l t ool 8544 Ca m sh a ft Bu sh in g
Rem over In st a ller, r em ove t h e ca m sh a ft bea r in gs.
REMOVAL - CAMSHAFT
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
ENGINE - 4.0L 9 - 31
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Dr a in t h e coolin g syst em (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(3) Rem ove t h e r a dia t or (Refer t o 7 - COOLING/
E NGINE /RADIATOR - RE MOVAL) a n d con den ser
(Refer t o 24 - H E ATING & AIR CONDITIONING/
P LUMBING/A/C CONDE NSE R - RE MOVAL), if
equ ipped wit h A/C.
(4) Rem ove t h e en gin e cylin der h ea d cover (Refer
t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R
H E AD COVE R(S) - RE MOVAL).
(5) Rem ove t h e r ocker a r m s, br idges a n d pivot s
(Refer t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R
ARM / ADJ USTE R ASSY - RE MOVAL).
(6) Rem ove t h e pu sh r ods.
(7) Rem ove t h e en gin e cylin der h ea d a n d ga sket
(Refer t o 9 - E NGINE /CYLINDE R H E AD - RE MOV-
AL).
(8) Rem ove t h e h ydr a u lic va lve t a ppet s fr om t h e
en gin e cylin der block (Refer t o 9 - E NGINE /E NGINE
BLOCK/H YDRAULIC LIF TE RS (CAM IN BLOCK) -
RE MOVAL).
(9) Rem ove t h e vibr a t ion da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL).
(10) Rem ove t h e t im in g ca se cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - RE MOVAL).
(11) Rot a t e t h e cr a n ksh a ft u n t il t h e cr a n ksh a ft
spr ocket t im in g m a r k is a lign ed on cen t er lin e wit h
t h e ca m sh a ft spr ocket t im in g m a r k (F ig. 32).
(12) Rem ove t h e t im in g ch a in a n d spr ocket s (Refer
t o 9 - E NGINE /VALVE TIMING/TIMING BE LT/
CH AIN AND SP ROCKE TS - RE MOVAL).
(13) Rem ove t h e fr on t bu m per a n d/or gr ille, a s
r equ ir ed.
(14) Rem ove t h e t wo t h r u st pla t e r et a in in g scr ews,
t h r u st pla t e a n d ca m sh a ft (F ig. 31).
I N SPECT I ON
INSPECTION - CAMSHAFT BEARINGS
(1) In spect t h e bea r in g jou r n a ls for u n even wea r
pa t t er n or fin ish .
(2) In spect t h e bea r in gs for wea r.
INSPECTION - CAMSHAFT
(1) In spect t h e ca m lobes for wea r.
(2) In spect t h e ca m sh a ft posit ion sen sor dr ive gea r
for wea r.
(3) If t h e ca m sh a ft a ppea r s t o h a ve been r u bbin g
a ga in st t h e t h r u st wa sh er, exa m in e t h e oil pr essu r e
9 - 32 ENGINE - 4.0L WJ
CAM SH AFT & BEARI N GS (Cont inue d)

I N STALLAT I ON
INSTALLATION - CAMSHAFT BEARINGS
CAUTION: Make sure outside diameter of number 1
bearing is clean. Make sure that the bearing is
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear-
ing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.

(1) Usin g r ecom m en ded specia l t ool 8544 Ca m -

sh a ft Bea r in g Rem over /In st a ller, in st a ll n ew ca m -
sh a ft bea r in gs.

INSTALLATION - CAMSHAFT
(1) Lu br ica t e t h e ca m sh a ft wit h Mopa r ! E n gin e
Oil Su pplem en t , or equ iva len t .
(2) Ca r efu lly in st a ll t h e ca m sh a ft t o pr even t da m -
a ge t o t h e ca m sh a ft bea r in gs.
(3) P osit ion t h r u st pla t e a n d in st a ll r et a in in g
Fig. 31 Camshaft Removal scr ews. Tigh t en scr ews t o 24 N·m (18 ft . lbs.).
(4) Lu br ica t e t h e ca m sh a ft wit h Mopa r ! en gin e oil
1 - CAMSHAFT
2 - CRANKSHAFT
su pplem en t , or equ iva len t .
(5) In st a ll t h e ca m sh a ft spr ocket , cr a n ksh a ft
spr ocket a n d t im in g ch a in (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT/CH AIN AND
SP ROCKE TS - INSTALLATION).
(6) Tigh t en t h e ca m sh a ft spr ocket bolt a n d wa sh er
t o 68 N·m (50 ft . lbs.).
(7) To ver ify cor r ect in st a lla t ion of t h e t im in g
ch a in , t u r n t h e cr a n ksh a ft t wo fu ll r evolu t ion s t h en
posit ion t h e ca m sh a ft spr ocket t im in g m a r k a s sh own
in (F ig. 33).
(8) In st a ll t h e t im in g ca se cover wit h a r epla ce-
m en t oil sea l (F ig. 34). (Refer t o 9 - E NGINE /VALVE
TIMING/TIMING BE LT / CH AIN COVE R(S) -
INSTALLATION).
(9) In st a ll t h e vibr a t ion da m per (F ig. 34) (Refer t o
9 - E NGINE /E NGINE BLOCK/VIBRATION
DAMP E R - INSTALLATION).
(10) In st a ll t h e h ydr a u lic va lve t a ppet s (Refer t o 9
- E NGINE /E NGINE BLOCK/H YDRAULIC LIF TE RS
(CAM IN BLOCK) - INSTALLATION).
(11) In st a ll t h e cylin der h ea d ga sket wit h t h e
n u m ber s fa cin g u p.
(12) In st a ll t h e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION).
Fig. 32 Crankshaft / Camshaft Sprocket Timing Mark (13) In st a ll t h e pu sh r ods.
Alignment (14) In st a ll t h e r ocker a r m s a n d pivot a n d br idge
1 - CAMSHAFT SPROCKET a ssem blies (Refer t o 9 - E NGINE /CYLINDE R H E AD/
2 - TIMING MARKS ROCKE R ARM / ADJ USTE R ASSY - INSTALLA-
3 - CRANKSHAFT SPROCKET
TION).
(15) In st a ll t h e en gin e cylin der h ea d cover (Refer
r elief h oles in t h e r ea r ca m jou r n a l. Th e oil pr essu r e t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R
r elief h oles m u st be fr ee of debr is. H E AD COVE R(S) - INSTALLATION).
WJ ENGINE - 4.0L 9 - 33
CAM SH AFT & BEARI N GS (Cont inue d)
Mopar" Engine Oil Supplement, or equivalent must
remain with the engine oil for at least 1609 km
(1,000 miles). The oil supplement need not be
drained until the next scheduled oil change.
(17) In st a ll t h e r a dia t or (Refer t o 7 - COOLING/
E NGINE /RADIATOR - INSTALLATION).
(18) Ch eck t h e ign it ion t im in g a n d a dju st a s n ec-
essa r y.
(19) In st a ll t h e gr ille a n d bu m per, if r em oved.
(20) Con n ect n ega t ive ca ble t o ba t t er y.

CON N ECT I N G ROD BEARI N GS

STANDARD PROCEDURE - FITTING
CONNECTING ROD BEARINGS
In spect t h e con n ect in g r od bea r in gs for scor in g a n d
ben t a lign m en t t a bs (F ig. 35) (F ig. 36). Ch eck t h e
bea r in gs for n or m a l wea r pa t t er n s, scor in g, gr oovin g,
fa t igu e a n d pit t in g (F ig. 37). Repla ce a n y bea r in g
t h a t sh ows a bn or m a l wea r.
In spect t h e con n ect in g r od jou r n a ls for sign s of
Fig. 33 Crankshaft / Camshaft Chain Drive scor in g, n icks a n d bu r r s.
Installation—Typical
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET

Fig. 35 Connecting Rod Bearing Inspection

1 - UPPER BEARING HALF
2 - MATING EDGES
Fig. 34 Timing Case Cover Components 3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
1 - TIMING CASE COVER JOURNAL DURING INSTALLATION
2 - OIL SLINGER 4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
3 - CRANKSHAFT OIL SEAL 5 - LOWER BEARING HALF
4 - VIBRATION DAMPER PULLEY
Misa lign ed or ben t con n ect in g r ods ca n ca u se
(16) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 - a bn or m a l wea r on pist on s, pist on r in gs, cylin der
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - wa lls, con n ect in g r od bea r in gs a n d cr a n ksh a ft con -
INSTALLATION). n ect in g r od jou r n a ls. If wea r pa t t er n s or da m a ge t o
a n y of t h ese com pon en t s in dica t e t h e pr oba bilit y of a
NOTE: During installation, lubricate the hydraulic m isa lign ed con n ect in g r od, in spect it for cor r ect r od
valve tappets and all valve components with a lign m en t . Repla ce m isa lign ed, ben t or t wist ed con -
Mopar" Engine Oil Supplement, or equivalent. The n ect in g r ods.
9 - 34 ENGINE - 4.0L WJ
CON N ECT I N G ROD BEARI N GS (Cont inue d)

Fig. 38 Rod and Piston Assembly Installation

Fig. 36 Locking Tab Inspection s h o u ld in d ic a te th e s a m e c le a ra n c e a c ro s s th e

1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
e n tire w id th o f th e in s e rt. If th e c le a ra n c e v a r-
ie s , it m a y be c a u s e d by e ith e r a ta p e re d jo u r-
n a l, be n t c o n n e c tin g ro d o r fo re ig n m a te ria l
tra p p e d be tw e e n th e in s e rt a n d c a p o r ro d .

Fig. 37 Scoring Caused by Insufficient Lubrication

or Damaged Crankshaft Journal
BEARING-TO-JOURNAL CLEARANCE
(1) Wipe t h e oil fr om t h e con n ect in g r od jou r n a l.
(2) Use sh or t r u bber h ose sect ion s over r od bolt s
du r in g in st a lla t ion .
(3) Lu br ica t e t h e u pper bea r in g in ser t a n d in st a ll
in con n ect in g r od. Fig. 39 Measuring Bearing Clearance with
(4) Use pist on r in g com pr essor t o in st a ll t h e r od Plastigage
a n d pist on a ssem blies. Th e oil squ ir t h oles in t h e 1 - PLASTIGAGE SCALE
r ods m u st fa ce t h e ca m sh a ft . Th e a r r ow on t h e pist on 2 - COMPRESSED PLASTIGAGE
cr own sh ou ld poin t t o t h e fr on t of t h e en gin e (F ig.
38). Ver ify t h a t t h e oil squ ir t h oles in t h e r ods fa ce
(8) If t h e cor r ect clea r a n ce is in dica t ed, r epla ce-
t h e ca m sh a ft a n d t h a t t h e a r r ows on t h e pist on s fa ce
m en t of t h e bea r in g in ser t s is n ot n ecessa r y. Rem ove
t h e fr on t of t h e en gin e.
t h e P la st iga ge fr om cr a n ksh a ft jou r n a l a n d bea r in g
(5) In st a ll t h e lower bea r in g in ser t in t h e bea r in g
in ser t . P r oceed wit h in st a lla t ion .
ca p. Th e lower in ser t m u st be dr y. P la ce st r ip of P la s-
(9) If bea r in g-t o-jou r n a l clea r a n ce exceeds t h e
t iga ge a cr oss fu ll widt h of t h e lower in ser t a t t h e cen -
specifica t ion , in st a ll a pa ir of 0.0254 m m (0.001 in ch )
t er of bea r in g ca p. P la st iga ge m u st n ot cr u m ble in
u n der size bea r in g in ser t s. All t h e odd size in ser t s
u se. If br it t le, obt a in fr esh st ock.
m u st be on t h e bot t om . Th e sizes of t h e ser vice
(6) In st a ll bea r in g ca p a n d con n ect in g r od on t h e
r epla cem en t bea r in g in ser t s a r e st a m ped on t h e
jou r n a l a n d t igh t en n u t s t o 45 N·m (33 ft . lbs.)
ba cks of t h e in ser t s. Mea su r e t h e clea r a n ce a s
t or qu e. DO NOT r ot a t e cr a n ksh a ft . P la st iga ge will
descr ibed in t h e pr eviou s st eps.
sm ea r, r esu lt in g in in a ccu r a t e in dica t ion .
(10) Th e clea r a n ce is m ea su r ed wit h a pa ir of
(7) Rem ove t h e bea r in g ca p a n d det er m in e a m ou n t
0.0254 m m (0.001 in ch ) u n der size bea r in g in ser t s
of bea r in g-t o- jou r n a l clea r a n ce by m ea su r in g t h e
in st a lled. Th is will det er m in e if t wo 0.0254 m m
widt h of com pr essed P la st iga ge (F ig. 39). P la s tig a g e
(0.001 in ch ) u n der size in ser t s or a n ot h er com bin a t ion
WJ ENGINE - 4.0L 9 - 35
CON N ECT I N G ROD BEARI N GS (Cont inue d)
is n eeded t o pr ovide t h e cor r ect clea r a n ce. Refer t o
CONNE CTING ROD BE ARING F ITTING CH ART .

CON N ECT I N G ROD BEARI N G FI T T I N G CH ART

CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT

Color Code Diameter Upper Insert Size Lower Insert Size
53.2257 - 53.2079 mm
Yellow Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
53.2079 - 53.1901 mm
(2.0948 - 2.0941 in.) Blue - Undersize
Orange Yellow - Standard
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
53.1901 - 53.1724 mm

Blue (2.0941 - 2.0934 in.) Blue - Undersize Blue - Undersize

0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
52.9717 - 52.9539 mm
(2.0855 - 2.0848 in.) Red - Undersize Red - Undersize
Red
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize

(11) F OR EXAMP LE: If t h e in it ia l clea r a n ce wa s

0.0762 m m (0.003 in ch ), 0.025 m m (0.001 in ch )
u n der size in ser t s wou ld r edu ce t h e clea r a n ce by
0.025 m m (0.001 in ch ). Th e clea r a n ce wou ld be 0.002
in ch a n d wit h in specifica t ion . A 0.051 m m (0.002
in ch ) u n der size in ser t wou ld r edu ce t h e in it ia l clea r-
a n ce a n a ddit ion a l 0.013 m m (0.0005 in ch ). Th e
clea r a n ce wou ld t h en be 0.038 m m (0.0015 in ch ).
(12) Repea t t h e P la st iga ge m ea su r em en t t o ver ify
you r bea r in g select ion pr ior t o fin a l a ssem bly.
(13) On ce you h a ve select ed t h e pr oper in ser t ,
in st a ll t h e in ser t a n d ca p. Tigh t en t h e con n ect in g r od
bolt s t o 45 N·m (33 ft . lbs.) t or qu e.

SIDE CLEARANCE MEASUREMENT

Slide sn u g-fit t in g feeler ga u ge bet ween t h e con -
n ect in g r od a n d cr a n ksh a ft jou r n a l fla n ge (F ig. 40).
(Refer t o 9 - E NGINE - SP E CIF ICATIONS). Repla ce
t h e con n ect in g r od if t h e side clea r a n ce is n ot wit h in
specifica t ion .
CRAN K SH AFT
DESCRIPTION
Th e cr a n ksh a ft is con st r u ct ed of n odu la r ca st ir on .
Th e cr a n ksh a ft is a cr ossh a ped fou r t h r ow design
wit h eigh t cou n t er weigh t s for ba la n cin g pu r poses.
Fig. 40 Checking Connecting Rod Side Clearance -
Typical
Th e cr a n ksh a ft is su ppor t ed by seven select m a in
bea r in gs wit h t h e n u m ber t h r ee ser vin g a s t h e t h r u st
wa sh er loca t ion . Th e m a in jou r n a ls of t h e cr a n ksh a ft
a r e cr oss dr illed t o im pr ove r od bea r in g lu br ica t ion .
Th e select fit m a in bea r in g m a r kin gs a r e loca t ed on
t h e cr a n ksh a ft cou n t er weigh t s. Th e cr a n ksh a ft r ea r
oil sea l is a t wo piece design . Th e fr on t oil sea l is a
on e piece design r et a in ed in t h e t im in g ch a in cover
(F ig. 41).
9 - 36 ENGINE - 4.0L
CRAN K SH AFT (Cont inue d)
Fig. 41 Crankshaft with Select Fit Marking Location
1 - 1/4” LETTERS
2 - (ROD)
3 - (MAIN)
CRAN K SH AFT M AI N
BEARI N GS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS
FITTING BEARINGS (CRANKSHAFT INSTALLED)
Th e m a in bea r in g ca ps, n u m ber ed (fr on t t o r ea r )
fr om 1 t h r ou gh 7 h a ve a n a r r ow t o in dica t e t h e for-
wa r d posit ion . Th e u pper m a in bea r in g in ser t s a r e
gr ooved t o pr ovide oil ch a n n els wh ile t h e lower
in ser t s a r e sm oot h .
E a ch bea r in g in ser t pa ir is select ively fit t ed t o it s
r espect ive jou r n a l t o obt a in t h e specified oper a t in g
clea r a n ce. In pr odu ct ion , t h e select fit is obt a in ed by
u sin g va r iou s-sized color-coded bea r in g in ser t pa ir s
a s list ed in t h e Ma in Bea r in g F it t in g Ch a r t . Th e
bea r in g color code a ppea r s on t h e edge of t h e in ser t .
Th e s ize is n o t s ta m p e d o n be a rin g in s e rts u s e d
fo r e n g in e p ro d u c tio n .
Th e m a in bea r in g jou r n a l size (dia m et er ) is iden t i-
fied by a color-coded pa in t m a r k (F ig. 42)on t h e a dja -
cen t ch eek or cou n t er weigh t t owa r ds t h e r ea r of t h e
cr a n ksh a ft (fla n ge en d). Th e r ea r m a in jou r n a l, is
iden t ified by a color-coded pa in t m a r k on t h e cr a n k-
sh a ft r ea r fla n ge.
Wh en r equ ir ed, u pper a n d lower bea r in g in ser t s of
differ en t sizes m a y be u sed a s a pa ir. A st a n da r d size
in ser t is som et im es u sed in com bin a t ion wit h a 0.025
m m (0.001 in ch ) u n der size in ser t t o r edu ce t h e clea r-
a n ce by 0.013 m m (0.0005 in ch ). N e v e r u s e a p a ir
o f be a rin g in s e rts w ith g re a te r th a n a 0.025 m m
(0.001 in c h ) d iffe re n c e in s ize . Re fe r to th e
B e a rin g In s e rt P a ir Ch a rt.
WJ
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
On ce t h e bea r in gs h a ve been pr oper ly fit t ed, (Refer
t o 9 - E NGINE /E NGINE BLOCK/CRANKSH AF T
MAIN BE ARINGS - INSTALLATION).
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
Wh en u sin g P la st iga ge, ch eck on ly on e bea r in g
clea r a n ce a t a t im e.
In st a ll t h e gr ooved m a in bea r in gs in t o t h e cylin der
block a n d t h e n on -gr ooved bea r in gs in t o t h e bea r in g
ca ps.
In st a ll t h e cr a n ksh a ft in t o t h e u pper bea r in gs dr y.
P la ce a st r ip of P la st iga ge a cr oss fu ll widt h of t h e
cr a n ksh a ft jou r n a l t o be ch ecked.
In st a ll t h e bea r in g ca p a n d t igh t en t h e bolt s t o 108
N·m (80 ft . lbs.) t or qu e.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Rem ove t h e bea r in g ca p. Det er m in e t h e a m ou n t of
clea r a n ce by m ea su r in g t h e widt h of t h e com pr essed
P la st iga ge wit h t h e sca le on t h e P la st iga ge en velope
(F ig. 43). (Refer t o 9 - E NGINE - SP E CIF ICATIONS)
for t h e pr oper clea r a n ce.
P la st iga ge sh ou ld in dica t e t h e sa m e clea r a n ce
a cr oss t h e en t ir e widt h of t h e in ser t . If clea r a n ce va r-
ies, it m a y in dica t e a t a per ed jou r n a l or for eign
m a t er ia l t r a pped beh in d t h e in ser t .
If t h e specified clea r a n ce is in dica t ed a n d t h er e a r e
n o a bn or m a l wea r pa t t er n s, r epla cem en t of t h e bea r-
in g in ser t s is n ot n ecessa r y. Rem ove t h e P la st iga ge
fr om t h e cr a n ksh a ft jou r n a l a n d bea r in g in ser t . P r o-
ceed t o (Refer t o 9 - E NGINE /E NGINE BLOCK/
CRANKSH AF T MAIN BE ARINGS -
INSTALLATION).
If t h e clea r a n ce exceeds specifica t ion , in st a ll a pa ir
of 0.025 m m (0.001 in ch ) u n der size bea r in g in ser t s
a n d m ea su r e t h e clea r a n ce a s descr ibed in t h e pr evi-
ou s st eps.
Th e clea r a n ce in dica t e wit h t h e 0.025 m m (0.001
in ch ) u n der size in ser t pa ir in st a lled will det er m in e if
t h is in ser t size or som e ot h er com bin a t ion will pr o-
vide t h e specified clea r a n ce. F OR EXAMP LE: If t h e
clea r a n ce wa s 0.0762 m m (0.003 in ch ) or igin a lly, a
pa ir of 0.0254 m m (0.001 in ch ) u n der size in ser t s
wou ld r edu ce t h e clea r a n ce by 0.0254 m m (0.001
in ch ). Th e clea r a n ce wou ld t h en be 0.0508 m m (0.002
in ch ) a n d wit h in t h e specifica t ion . A 0.051 m m (0.002
in ch ) u n der size bea r in g in ser t a n d a 0.0254 m m
(0.001 in ch ) u n der size in ser t wou ld r edu ce t h e or igi-
WJ
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)
Fig. 42 Crankshaft Journal Size Paint I.D. Location
1 - NO. 7 MAIN JOURNAL SIZE PAINT MARK
2 - NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK
Fig. 43 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
n a l clea r a n ce a n a ddit ion a l 0.0127 m m (0.0005 in ch ).
Th e clea r a n ce wou ld t h en be 0.0381 m m (0.0015
in ch ).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
F OR EXAMP LE: DO NOT u se a st a n da r d size
u pper in ser t a n d a 0.051 m m (0.002 in ch ) u n der size
lower in ser t .
ENGINE - 4.0L 9 - 37
3 - NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK
4 - NO. 1 MAIN JOURNAL SIZE PAINT MARK
If t h e clea r a n ce exceeds specifica t ion u sin g a pa ir
of 0.051 m m (0.002 in ch ) u n der size bea r in g in ser t s,
m ea su r e cr a n ksh a ft jou r n a l dia m et er wit h a
m icr om et er. If t h e jou r n a l dia m et er is cor r ect , t h e
cr a n ksh a ft bor e in t h e cylin der block m a y be m is-
a lign ed, wh ich r equ ir es cylin der block r epla cem en t or
m a ch in in g t o t r u e bor e.
Repla ce t h e cr a n ksh a ft or gr in d t o a ccept t h e
a ppr opr ia t e u n der size bea r in g in ser t s if:
• J ou r n a l dia m et er s 1 t h r ou gh 6 a r e less t h a n
63.4517 m m (2.4981 in ch es)
• J ou r n a l 7 dia m et er is less t h a n 63.4365 m m
(2.4975 in ch es).
On ce t h e pr oper clea r a n ces h a ve been obt a in ed,
pr oceed t o (Refer t o 9 - E NGINE /E NGINE BLOCK/
CRANKSH AF T MAIN BE ARINGS - INSTALLA-
TION).
JOURNAL DIAMETER (CRANKSHAFT REMOVED)
Rem ove t h e cr a n ksh a ft fr om t h e cylin der block.
Clea n t h e oil off t h e m a in bea r in g jou r n a l.
Det er m in e t h e m a xim u m dia m et er of t h e jou r n a l
wit h a m icr om et er. Mea su r e a t t wo loca t ion s 90°
a pa r t a t ea ch en d of t h e jou r n a l.
Th e m a xim u m a llowa ble t a per a n d ou t of r ou n d is
0.013 m m (0.0005 in ch ). Com pa r e t h e m ea su r ed
dia m et er wit h t h e jou r n a l dia m et er specifica t ion
MAIN BE ARING F ITTING CH ART . Select in ser t s
r equ ir ed t o obt a in t h e specified bea r in g-t o-jou r n a l
clea r a n ce.
In st a ll t h e cr a n ksh a ft in t o t h e cylin der block.
9 - 38 ENGINE - 4.0L WJ
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)
M AI N BEARI N G FI T T I N G CH ART

Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert

Color Code Diameter Upper Insert Size Lower Insert Size
63.5025 -63.4898 mm
Yellow Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
63.4898 - 63.4771 mm
(2.4996 - 2.4991 in.) Blue - Undersize
Orange Yellow - Standard
0.0127 mm (0.0005 in.) 0.025 mm (0.001 in.)
Undersize
63.4771 - 63.4644 mm
(2.4991 - 2.4986 in.) Blue - Undersize Blue - Undersize
Blue
0.0254 mm (0.001 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
63.4644 - 63.4517 mm
(2.4986 - 2.4981 in.) Blue - Undersize Green - Undersize
Green
0.0381 mm (0.0015 in.) 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
Undersize
63.2485 - 63.2358 mm
(2.4901 - 2.4896 in.) Red - Undersize Red - Undersize
Red
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize

Crankshaft Journal #7 Only Corresponding Bearing Insert

Color Code Diameter Upper Insert Size Lower Insert Size
63.4873 - 63.4746 mm
Yellow Yellow - Standard Yellow - Standard
(2.4995 - 2.4990 in.)
63.4746 - 63.4619 mm
(2.4990 - 2.4985 in.) Blue - Undersize
Orange Yellow - Standard
0.0127 mm (0.0005 in.) 0.025 mm (0.001 in.)
Undersize
63.4619 - 63.4492 mm
(2.4985 - 2.4980 in.) Blue - Undersize Blue - Undersize
Blue
0.0254 mm (0.001 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
63.4492 - 63.4365 mm
(2.4980 - 2.4975 in.) Blue - Undersize Green - Undersize
Green
0.0381 mm (0.0015 in.) 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
Undersize
63.2333 - 63.2206 mm
(2.4895 - 2.4890 in.) Red - Undersize Red - Undersize
Red
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
WJ ENGINE - 4.0L 9 - 39
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)

REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove t h e spa r k plu gs (Refer t o 8 - E LE C-
TRICAL/IGNITION CONTROL/SPARK P LUG -
RE MOVAL).
(3) Ra ise t h e veh icle.
(4) Rem ove t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - RE MOVAL) a n d oil pu m p
(Refer t o 9 - E NGINE /LUBRICATION/OIL P UMP -
RE MOVAL).
(5) Rem ove m a in bea r in g ca p br a ce (F ig. 44).

Fig. 45 Removing Main Bearing Caps and Lower

Inserts
1 - CONNECTING ROD JOURNAL
2 - MAIN BEARING CAPS

Fig. 44 Main Bearing Caps and Brace.

1 - BLOCK
2 - MAIN BEARING CAP BRACE

(6) Rem ove on ly on e m a in bea r in g ca p a n d lower

in ser t a t a t im e (F ig. 45).
(7) Rem ove t h e lower in ser t fr om t h e bea r in g ca p.
(8) Rem ove t h e u pper in ser t by LOOSE NING (DO
NOT RE MOVE ) a ll of t h e ot h er bea r in g ca ps. Now
in ser t a sm a ll cot t er pin t ool in t h e cr a n ksh a ft jou r-
n a l oil h ole. Ben d t h e cot t er pin a s illu st r a t ed t o fa b-
r ica t e t h e t ool (F ig. 46). Wit h t h e cot t er pin t ool in
pla ce, r ot a t e t h e cr a n ksh a ft so t h a t t h e u pper bea r-
in g in ser t will r ot a t e in t h e dir ect ion of it s lockin g
t a b. Beca u se t h er e is n o h ole in t h e No.3 m a in jou r-
n a l, u se a t on gu e depr essor or sim ila r soft -fa ced t ool
t o r em ove t h e bea r in g in ser t (F ig. 46). Aft er m ovin g
t h e in ser t a ppr oxim a t ely 25 m m (1 in ch ), it ca n be Fig. 46 Removing Upper Inserts
r em oved by a pplyin g pr essu r e u n der t h e t a b. 1 - COTTER PIN
(9) Usin g t h e sa m e pr ocedu r e descr ibed a bove, 2 - BEARING INSERT
r em ove t h e r em a in in g bea r in g in ser t s on e a t a t im e 3 - TONGUE DEPRESSOR
for in spect ion .
9 - 40 ENGINE - 4.0L WJ
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)

INSPECTION
Wipe t h e in ser t s clea n a n d in spect for a bn or m a l
wea r pa t t er n s a n d for m et a l or ot h er for eign m a t er ia l
im bedded in t h e lin in g. Nor m a l m a in bea r in g in ser t
wea r pa t t er n s a r e illu st r a t ed (F ig. 47). In gen er a l t h e
lower bea r in g h a lf will h a ve a h ea ver wea r pa t t er n .

Fig. 47 Main Bearing Wear Patterns Fig. 48 Location of Sealer

1 - DOWEL
1 - UPPER INSERT
2 - SEALER LOCATIONS
2 - NO WEAR IN THIS AREA
3 - CYLINDER BLOCK
3 - LOW AREA IN BEARING LINING
4 - HALFWAY BETWEEN
4 - LOWER INSERT
5 - REAR FACE OF CYLINDER BLOCK
6 - 3mm (0.125 in.)
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
(8) P u sh t h e cr a n ksh a ft for wa r d a n d ba ckwa r d.
In spect t h e ba ck of t h e in ser t s for fr a ct u r es, scr a p- Loa d t h e cr a n ksh a ft fr on t or r ea r a n d t igh t en ca p
in gs or ir r egu la r wea r pa t t er n s. bolt No.3 t o 54 N·m (40 ft . lbs.) t or qu e. Th en t igh t en
In spect t h e u pper in ser t lockin g t a bs for da m a ge. t o 95 N·m (70 ft . lbs.) t or qu e a n d fin a lly t igh t en t o
Repla ce a ll da m a ged or wor n bea r in g in ser t s. 108 N·m (80 ft . lbs.) t or qu e.
(9) Rot a t e t h e cr a n ksh a ft a ft er t igh t en in g ea ch
INSTALLATION m a in bea r in g ca p t o en su r e t h e cr a n ksh a ft r ot a t es
fr eely.
(1) Lu br ica t e t h e bea r in g su r fa ce of ea ch in ser t
(10) Ch eck cr a n ksh a ft en d pla y. Cr a n ksh a ft en d
wit h en gin e oil.
pla y is con t r olled by t h e t h r u st bea r in g wh ich is
(2) Loosen a ll t h e m a in bea r in g ca ps. In st a ll t h e
fla n ge a n d in st a lled a t t h e No.2 m a in bea r in g posi-
m a in bea r in g u pper in ser t s.
t ion .
(3) In st a ll t h e lower bea r in g in ser t s in t o t h e m a in
(a ) At t a ch a m a gn et ic ba se dia l in dica t or t o t h e
bea r in g ca ps.
cylin der block a t eit h er t h e fr on t or r ea r of t h e
(4) On t h e r ea r m a in ca p, a pply Mopa r ! Ga sket
en gin e.
Ma ker sea ler on bot h sides of cylin der block a s
(b) P osit ion t h e dia l in dica t or r od so t h a t it is
sh own in (F ig. 48). Th e da b of sea ler sh ou ld be 3 m m
pa r a llel t o t h e cen t er lin e of t h e cr a n ksh a ft .
(0.125 in .) in dia m et er.
(c) P r y t h e cr a n ksh a ft for wa r d, posit ion t h e dia l
(5) Apply Mopa r ! Ga sket Ma ker on t h e r ea r bea r-
in dica t or t o zer o.
in g ca p. Th e bea d sh ou ld be 2.3 m m (0.09 in .) in
(d) P r y t h e cr a n ksh a ft for wa r d a n d ba ckwa r d.
dia m et er. DO NOT a pply sea ler t o t h e lip of t h e sea l.
Not e t h e dia l in dica t or r ea din gs. E n d pla y is t h e
(6) In st a ll t h e m a in bea r in g ca p(s) a n d lower
differ en ce bet ween t h e h igh a n d low m ea su r em en t s
in ser t (s).
(F ig. 49). Cor r ect en d pla y is 0.038-0.165 m m
(7) Tigh t en t h e bolt s of ca ps 1, 2, 4, 5, 6, a n d 7 t o
(0.0015-0.0065 in ch ). Th e desir ed specifica t ion s a r e
54 N·m (40 ft . lbs.) t or qu e. Now t igh t en t h ese bolt s t o
0.051-0.064 m m (0.002-0.0025 in ch ).
95 N·m (70 ft . lbs.) t or qu e. F in a lly, t igh t en t h ese
bolt s t o 108 N·m (80 ft . lbs.) t or qu e.
WJ ENGINE - 4.0L 9 - 41
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)
(e) If en d pla y is n ot wit h in specifica t ion , in spect (3) Rem ove t h e vibr a t ion da m per (Refer t o 9 -
cr a n ksh a ft t h r u st fa ces for wea r. If n o wea r is E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
a ppa r en t , r epla ce t h e t h r u st bea r in g a n d m ea su r e RE MOVAL).
en d pla y. If en d pla y is st ill n ot wit h in specifica - (4) Rem ove t h e r a dia t or sh r ou d.
t ion , r epla ce t h e cr a n ksh a ft . (5) Ca r efu lly r em ove t h e oil sea l. Ma ke su r e sea l
bor e is clea n .

INSTALLATION
Th is pr ocedu r e is don e wit h t h e t im in g ca se cover
in st a lled.
(1) P osit ion t h e r epla cem en t oil sea l on Tim in g
Ca se Cover Align m en t a n d Sea l In st a lla t ion Tool
6139 wit h sea l open en d fa cin g in wa r d. Apply a ligh t
film of P er fect Sea l, or equ iva len t , on t h e ou t side
dia m et er of t h e sea l. Ligh t ly coa t t h e cr a n ksh a ft wit h
en gin e oil.
(2) P osit ion t h e t ool a n d sea l over t h e en d of t h e
cr a n ksh a ft a n d in ser t a dr a w scr ew t ool in t o Sea l
In st a lla t ion Tool 6139 (F ig. 50). Tigh t en t h e n u t
a ga in st t h e t ool u n t il it con t a ct s t h e cover.

Fig. 49 Crankshaft End Play Measurement

1 - DIAL INDICATOR
2 - CRANKSHAFT

(11) If t h e cr a n ksh a ft wa s r em oved, in st a ll t h e

cr a n ksh a ft in t o t h e cylin der block.
(12) In st a ll m a in bea r in g ca p br a ce t igh t en n u t s t o
47 N·m (35 ft . lbs.) t or qu e.
(13) In st a ll oil pu m p a ssy. a n d t igh t en a t t a ch in g
bolt s t o 23 N·m (17 ft . lbs.)
(14) In st a ll t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - INSTALLATION).
(15) In st a ll t h e dr a in plu g. Tigh t en t h e plu g t o 34
N·m (25 ft . lbs.) t or qu e.
(16) Lower t h e veh icle.
(17) In st a ll t h e spa r k plu gs. Tigh t en t h e plu gs t o Fig. 50 Timing Case Cover Oil Seal Installation
37 N·m (27 ft . lbs.) t or qu e. 1 - SEAL INSTALLATION TOOL
(18) F ill t h e oil pa n wit h en gin e oil t o t h e fu ll 2 - DRAW SCREW TOOL
m a r k on t h e dipst ick level.
(19) Con n ect n ega t ive ca ble t o ba t t er y. (3) Rem ove t h e t ools. Apply a ligh t film of en gin e
oil on t h e vibr a t ion da m per h u b con t a ct su r fa ce of
CRAN K SH AFT OI L SEAL - t h e sea l.
(4) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
FRON T a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
key. Wit h t h e key in ser t ed in t h e keywa y in t h e
REMOVAL cr a n ksh a ft , in st a ll t h e vibr a t ion da m per (Refer t o 9 -
Th is pr ocedu r e is don e wit h t h e t im in g ca se cover E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
in st a lled. INSTALLATION).
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. (5) In st a ll t h e ser pen t in e belt (Refer t o 7 - COOL-
(2) Rem ove t h e ser pen t in e dr ive belt (Refer t o 7 - ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - LATION).
RE MOVAL). (6) In st a ll t h e r a dia t or sh r ou d.
(7) Con n ect n ega t ive ca ble t o ba t t er y.
9 - 42 ENGINE - 4.0L WJ

CRAN K SH AFT OI L SEAL -

REAR
REMOVAL
Th e cr a n ksh a ft r ea r m a in bea r in g oil sea l con sist s
of t wo h a lf pieces of vit on wit h a sin gle lip t h a t effec-
t ively sea ls t h e r ea r of t h e cr a n ksh a ft . Repla ce t h e
u pper a n d lower sea l h a lves a s a u n it t o en su r e lea k-
fr ee oper a t ion .
(1) Rem ove t r a n sm ission in spect ion cover.
(2) Rem ove oil pa n . (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL PAN - RE MOVAL)
(3) Rem ove m a in bea r in g ca p br a ce.
(4) Rem ove r ea r m a in bea r in g ca p (No.7).
(5) P u sh u pper sea l ou t of t h e gr oove. E n su r e t h a t
t h e cr a n ksh a ft a n d sea l gr oove a r e n ot da m a ged.
(6) Rem ove lower h a lf of t h e sea l fr om t h e bea r in g
ca p.

INSTALLATION
Th e cr a n ksh a ft r ea r m a in bea r in g oil sea l con sist s
of t wo h a lf pieces of vit on wit h a sin gle lip t h a t effec- Fig. 51 Location of Sealer
t ively sea ls t h e r ea r of t h e cr a n ksh a ft . Repla ce t h e 1 - DOWEL
u pper a n d lower sea l h a lves a s a u n it t o en su r e lea k- 2 - SEALER LOCATIONS
fr ee oper a t ion . 3 - CYLINDER BLOCK
(1) Wipe t h e sea l su r fa ce a r ea of t h e cr a n ksh a ft 4 - HALFWAY BETWEEN
u n t il it is clea n . 5 - REAR FACE OF CYLINDER BLOCK
(2) Apply a t h in coa t of en gin e oil. 6 - 3mm (0.125 in.)
(3) Coa t lip of t h e sea l wit h en gin e oil.
(4) Ca r efu lly posit ion t h e u pper sea l in t o t h e (13) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
gr oove in t h e cylin der block. Th e lip of t h e sea l fa ces a n t on cylin der block t o r ea r m a in bea r in g ca p cor-
t owa r d t h e fr on t of t h e en gin e. n er s a n d cylin der block t o fr on t cover join t s (fou r
(5) Apply Mopa r ! Ga sket Ma ker sea ler on bot h pla ces) (F ig. 52)
sides of cylin der block a s sh own in (F ig. 51). Th e da b
of sea ler sh ou ld be 3 m m (0.125 in .) in dia m et er.
(6) Apply Mopa r ! Ga sket Ma ker on t h e r ea r bea r-
in g ca p (F ig. 51). Th e bea d sh ou ld be 2.3 m m (0.09
in .) in dia m et er. DO NOT a pply sea ler t o t h e lip of
t h e sea l.
(7) P osit ion t h e lower sea l in t o t h e bea r in g ca p
r ecess a n d sea t it fir m ly. Be su r e t h e sea l is flu sh
wit h t h e cylin der block pa n r a il.
(8) Coa t t h e ou t er cu r ved su r fa ce of t h e lower sea l
wit h soa p a n d t h e lip of t h e sea l wit h en gin e oil.
(9) In st a ll t h e r ea r m a in bea r in g ca p. DO NOT
st r ike t h e ca p m or e t h a n t wice for pr oper en ga ge-
m en t . Fig. 52 Oil Pan
(10) Tigh t en a ll m a in bea r in g bolt s t o 108 N·m (80 1 - SEALER LOCATIONS
ft . lbs.) t or qu e.
(11) In st a ll t h e m a in bea r in g ca p br a ce. Tigh t en
n u t s t o 47 N·m (35 ft . lbs.). (14) In st a ll t r a n sm ission in spect ion cover.
(12) In st a ll t h e oil pa n ga sket a n d oil pa n (Refer t o
9 - E NGINE /LUBRICATION/OIL PAN - INSTALLA-
TION).
WJ
H Y DRAU LI C LI FT ERS
DESCRIPTION
Va lve la sh is con t r olled by h ydr a u lic t a ppet s
loca t ed in side t h e cylin der block, in t a ppet bor es
a bove t h e ca m sh a ft .
REMOVAL
NOTE: Retain all the components in the same order
as removed.
(1) Rem ove t h e en gin e cylin der h ea d(Refer t o 9 -
E NGINE /CYLINDE R H E AD - RE MOVAL).
(2) Rem ove t h e pu sh r ods.
(3) Rem ove t h e t a ppet s t h r ou gh t h e pu sh r od open -
in gs in t h e cylin der block wit h a H ydr a u lic Va lve
Ta ppet Rem ova l/In st a lla t ion Tool (F ig. 53).
Fig. 53 HYDRAULIC VALVE TAPPET REMOVAL -
4.0L
1 - HYDRAULIC TAPPET REMOVAL TOOL
2 - CYLINDER BLOCK
CLEANING
Clea n ea ch t a ppet a ssem bly in clea n in g solven t t o
r em ove a ll va r n ish , gu m a n d slu dge deposit s.
INSPECTION
In spect for in dica t ion s of scu ffin g on t h e side a n d
ba se of ea ch t a ppet body.
In spect ea ch t a ppet ba se for con ca ve wea r wit h a
st r a igh t edge posit ion ed a cr oss t h e ba se. If t h e ba se is
con ca ve, t h e cor r espon din g lobe on t h e ca m sh a ft is
a lso wor n . Repla ce t h e ca m sh a ft a n d t a ppet s.
Aft er clea n in g a n d in spect ion , t est ea ch t a ppet for
specified lea k-down r a t e t oler a n ce t o en su r e zer o-la sh
oper a t ion (F ig. 54).
Swin g t h e weigh t ed a r m of t h e h ydr a u lic va lve t a p-
pet t est er a wa y fr om t h e r a m of t h e Lea k-Down
Test er.
(1) P la ce a 7.925-7.950 m m (0.312-0.313 in ch )
dia m et er ba ll bea r in g on t h e plu n ger ca p of t h e t a p-
pet .
ENGINE - 4.0L 9 - 43
(2) Lift t h e r a m a n d posit ion t h e t a ppet (wit h t h e
ba ll bea r in g) in side t h e t est er cu p.
(3) Lower t h e r a m , t h en a dju st t h e n ose of t h e r a m
u n t il it con t a ct s t h e ba ll bea r in g. DO NOT t igh t en
t h e h ex n u t on t h e r a m .
(4) F ill t h e t est er cu p wit h h ydr a u lic va lve t a ppet
t est oil u n t il t h e t a ppet is com plet ely su bm er ged.
(5) Swin g t h e weigh t ed a r m on t o t h e pu sh r od a n d
pu m p t h e t a ppet plu n ger u p a n d down t o r em ove a ir.
Wh en t h e a ir bu bbles cea se, swin g t h e weigh t ed a r m
a wa y a n d a llow t h e plu n ger t o r ise t o t h e n or m a l
posit ion .
(6) Adju st t h e n ose of t h e r a m t o a lign t h e poin t er
wit h t h e SE T m a r k on t h e sca le of t h e t est er a n d
t igh t en t h e h ex n u t .
(7) Slowly swin g t h e weigh t ed a r m on t o t h e pu sh
r od.
(8) Rot a t e t h e cu p by t u r n in g t h e h a n dle a t t h e
ba se of t h e t est er clockwise on e r evolu t ion ever y 2
secon ds.
(9) Obser ve t h e lea k-down t im e in t er va l fr om t h e
in st a n t t h e poin t er a lign s wit h t h e START m a r k on
t h e sca le u n t il t h e poin t er a lign s wit h t h e 0.125
m a r k. A n or m a lly fu n ct ion in g t a ppet will r equ ir e
20-110 secon ds t o lea k-down . Disca r d t a ppet s wit h
lea k-down t im e in t er va l n ot wit h in t h is specifica t ion .
Fig. 54 Leak-Down Tester
1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP
5 - HANDLE
6 - PUSH ROD
INSTALLATION
Ret a in a ll t h e com pon en t s in t h e sa m e or der a s
r em oved.
9 - 44 ENGINE - 4.0L
H Y DRAU LI C LI FT ERS (Cont inue d)
It is n ot n ecessa r y t o ch a r ge t h e t a ppet s wit h
en gin e oil. Th ey will ch a r ge t h em selves wit h in a ver y
sh or t per iod of en gin e oper a t ion .
(1) Dip ea ch t a ppet in Mopa r ! E n gin e Oil Su pple-
m en t , or equ iva len t .
(2) Use H ydr a u lic Va lve Ta ppet Rem ova l/In st a lla -
t ion Tool t o in st a ll ea ch t a ppet in t h e sa m e bor e fr om
wh er e it wa s or igin a lly r em oved.
(3) In st a ll t h e cylin der h ea d (Refer t o 9 - E NGINE /
CYLINDE R H E AD - INSTALLATION).
(4) In st a ll t h e pu sh r ods in t h eir or igin a l loca t ion s.
(5) In st a ll t h e r ocker a r m s a n d br idge a n d pivot
a ssem blies a t t h eir or igin a l loca t ion s. Loosely in st a ll
t h e ca pscr ews a t ea ch br idge.
(6) Tigh t en t h e ca pscr ews a lt er n a t ely, on e t u r n a t
a t im e, t o a void da m a gin g t h e br idges. Tigh t en t h e
ca pscr ews t o 28 N·m (21 ft . lbs.) t or qu e.
(7) P ou r t h e r em a in in g Mopa r ! E n gin e Oil Su pple-
m en t , or equ iva len t over t h e en t ir e va lve a ct u a t in g
a ssem bly. Th e Mopa r ! E n gin e Oil Su pplem en t , or equ iv-
a len t m u st r em a in wit h t h e en gin e oil for a t lea st 1 609
km (1,000 m iles). Th e oil su pplem en t n eed n ot be
dr a in ed u n t il t h e n ext sch edu led oil ch a n ge.
(8) In st a ll t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).
PI ST ON & CON N ECT I N G ROD
DESCRIPTION
Th e pist on s (F ig. 55) a r e m a de of a h igh st r en gt h
a lu m in u m a lloy, t h e pist on skir t s a r e coa t ed wit h a
solid lu br ica n t (Molykot e) t o r edu ce fr ict ion a n d pr o-
vide scu ff r esist a n ce. Th e con n ect in g r ods a r e m a de
of ca st ir on .
Fig. 55 Piston and Connecting Rod Assembly
WJ
STANDARD PROCEDURE - PISTON FITTING
(1) To cor r ect ly select t h e pr oper size pist on , a cyl-
in der bor e ga u ge, ca pa ble of r ea din g in 0.003 m m
(.0001 in .) INCRE ME NTS is r equ ir ed. If a bor e
ga u ge is n ot a va ila ble, do n ot u se a n in side m icr om e-
t er.
(2) Mea su r e t h e in side dia m et er of t h e cylin der
bor e a t a poin t 49.5 m m (1-15/16 in ch es) below t op of
bor e. St a r t per pen dicu la r (a cr oss or a t 90 degr ees) t o
t h e a xis of t h e cr a n ksh a ft a t poin t A a n d t h en t a ke
a n a ddit ion a l bor e r ea din g 90 degr ees t o t h a t a t poin t
B (F ig. 57).
(3) Th e coa t ed pist on s will be ser viced wit h t h e
pist on pin a n d con n ect in g r od pr e-a ssem bled. Th e
c o a te d p is to n c o n n e c tin g ro d a s s e m bly c a n be
u s e d to s e rv ic e p re v io u s bu ilt e n g in e s a n d
MU S T be re p la c e d a s c o m p le te s e ts . Tin coa t ed
pist on s sh ou ld n ot be u sed a s r epla cem en t s for coa t ed
pist on s.
(4) Th e coa t in g m a t er ia l is a pplied t o t h e pist on
a ft er t h e fin a l pist on m a ch in in g pr ocess. Mea su r in g
t h e ou t side dia m et er of a coa t ed pist on will n ot pr o-
vide a ccu r a t e r esu lt s (F ig. 56). Th er efor e m ea su r in g
t h e in side dia m et er of t h e cylin der bor e wit h a dia l
Bor e Ga u ge is MAN D ATORY. To cor r ect ly select t h e
pr oper size pist on , a cylin der bor e ga u ge ca pa ble of
r ea din g in 0.003 m m (.0001 in .) in cr em en t s is
r equ ir ed.
(5) P ist on in st a lla t ion in t o t h e cylin der bor e
r equ ir es sligh t ly m or e pr essu r e t h a n t h a t r equ ir ed
for n on -coa t ed pist on s. Th e bon ded coa t in g on t h e
pist on will give t h e a ppea r a n ce of a lin e-t o-lin e fit
wit h t h e cylin der bor e.
Fig. 56 Moly Coated Piston
1 - MOLY COATED
2 - MOLY COATED
WJ ENGINE - 4.0L 9 - 45
PI ST ON & CON N ECT I N G ROD (Cont inue d)
PI ST ON SI Z E CH ART r idge fr om t h e t op en d of t h e cylin der wa lls. Use a
pr ot ect ive clot h t o collect t h e cu t t in gs.
CYLINDER BORE SIZE PISTON LETTER SIZE (6) Ra ise t h e veh icle.
(7) Dr a in t h e en gin e oil.
98.438 - 98.448 mm A (8) Rem ove t h e oil pa n a n d ga sket . (Refer t o 9 -
(3.8755 - 3.8759 in.) E NGINE /LUBRICATION/OIL PAN - RE MOVAL).
98.448 - 98.458 mm B (9) Rem ove m a in bea r in g ca p br a ce (F ig. 58).
(3.8759 - 3.8763 in.)
98.458 - 98.468 mm C
(3.8763 - 3.8767 in.)
98.468 - 98.478 mm D
(3.8767 - 3.8771 in.)
98.478 - 98.488 mm E
(3.8771 - 3.8775 in.)
98.488 - 98.498 mm F
(3.8775 - 3.8779 in.)

REMOVAL

Fig. 58 Main Bearings Caps and Brace

1 - BLOCK
2 - MAIN BEARING CAP BRACE

(10) Rem ove t h e con n ect in g r od bea r in g ca ps a n d

in ser t s. Ma r k t h e ca ps a n d r ods wit h t h e cylin der
bor e loca t ion . Th e con n ect in g r ods a n d ca ps a r e
st a m ped wit h a t wo let t er com bin a t ion (F ig. 59).

Fig. 57 Bore Gauge

1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 49.5 MM (1-15/16 in.)

(1) Rem ove t h e en gin e cylin der h ea d cover. (Refer

t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R
H E AD COVE R(S) - RE MOVAL).
(2) Rem ove t h e r ocker a r m s, br idges a n d pivot s.
(3) Rem ove t h e pu sh r ods.
Fig. 59 Stamped Connecting Rods and Caps
(4) Rem ove t h e en gin e cylin der h ea d. (Refer t o 9 -
E NGINE /CYLINDE R H E AD - RE MOVAL). 1 - CONNECTING ROD CAP
2 - CONNECTING ROD
(5) P osit ion t h e pist on s on e a t a t im e n ea r t h e bot -
t om of t h e st r oke. Use a r idge r ea m er t o r em ove t h e
9 - 46 ENGINE - 4.0L
PI ST ON & CON N ECT I N G ROD (Cont inue d)
(11) Lower t h e veh icle u n t il it is a bou t 2 feet fr om
t h e floor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) H a ve a n a ssist a n t pu sh t h e pist on a n d con -
n ect in g r od a ssem blies u p a n d t h r ou gh t h e t op of t h e
cylin der bor es (F ig. 60).
Fig. 60 Removal of Connecting Rod and Piston
Assembly
1 - PISTON
2 - CONNECTING ROD
3 - BLOCK
INSTALLATION
(1) Clea n t h e cylin der bor es t h or ou gh ly. Apply a
ligh t film of clea n en gin e oil t o t h e bor es wit h a clea n
lin t -fr ee clot h .
(2) In st a ll t h e pist on r in gs on t h e pist on s if
r em oved (Refer t o 9 - E NGINE /E NGINE BLOCK/
P ISTON RINGS - STANDARD P ROCE DURE ).
(3) Lu br ica t e t h e pist on a n d r in gs wit h clea n
en gin e oil.
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
WJ
(4) Use a pist on r in g com pr essor t o in st a ll t h e con -
n ect in g r od a n d pist on a ssem blies t h r ou gh t h e t op of
t h e cylin der bor es (F ig. 61).
(5) E n su r e t h e a r r ow on t h e pist on t op poin t s t o
t h e fr on t of t h e en gin e (F ig. 61).
Fig. 61 Rod and Piston Assembly Installation
(6) Ra ise t h e veh icle.
(7) E a ch bea r in g in ser t is fit t ed t o it s r espect ive
jou r n a l t o obt a in t h e specified clea r a n ce bet ween t h e
bea r in g a n d t h e jou r n a l. In pr odu ct ion , t h e select fit
is obt a in ed by u sin g va r iou s-sized, color-coded bea r-
in g in ser t s a s list ed in t h e Con n ect in g Rod Bea r in g
F it t in g Ch a r t . Th e color code a ppea r s on t h e edge of
t h e bea r in g in ser t . Th e size is n ot st a m ped on in ser t s
u sed for pr odu ct ion of en gin es.
(8) Th e r od jou r n a l is iden t ified du r in g t h e en gin e
pr odu ct ion by a color-coded pa in t m a r k on t h e a dja -
cen t ch eek or cou n t er weigh t t owa r d t h e fla n ge (r ea r )
en d of t h e cr a n ksh a ft . Th e color codes u sed t o in di-
ca t e jou r n a l sizes a r e list ed in t h e Con n ect in g Rod
Bea r in g F it t in g Ch a r t .
(9) Wh en r equ ir ed, u pper a n d lower bea r in g
in ser t s of differ en t sizes m a y be u sed a s a pa ir (r efer
t o Con n ect in g Rod Bea r in g F it t in g Ch a r t ). A st a n -
da r d size in ser t is som et im es u sed in com bin a t ion
wit h a 0.025 m m (0.001 in ch ) u n der size in ser t t o
r edu ce clea r a n ce 0.013 m m (0.0005 in ch ).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) In st a ll t h e con n ect in g r od bea r in g ca ps a n d
in ser t s in t h e sa m e posit ion s a s r em oved.
CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(11) In st a ll m a in bea r in g ca p br a ce (F ig. 58).
Tigh t en n u t s t o 47 N·m (35 ft . lbs.).
WJ ENGINE - 4.0L 9 - 47
PI ST ON & CON N ECT I N G ROD (Cont inue d)
(12) In st a ll t h e oil pa n a n d ga sket (Refer t o 9 -
E NGINE /LUBRICATION/OIL PAN - INSTALLA-
TION).
(13) Lower t h e veh icle.
(14) In st a ll t h e en gin e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION),
pu sh r ods, r ocker a r m s, br idges, pivot s a n d en gin e
cylin der h ea d cover (Refer t o 9 - E NGINE /CYLINDE R
H E AD/CYLINDE R H E AD COVE R(S) - INSTALLA-
TION).
(15) F ill t h e cr a n kca se wit h en gin e oil.

PI ST ON RI N GS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Ca r efu lly clea n t h e ca r bon fr om a ll r in g
gr ooves. Oil dr a in open in gs in t h e oil r in g gr oove a n d
pin boss m u st be clea r. DO NOT r em ove m et a l fr om
t h e gr ooves or la n ds. Th is will ch a n ge r in g-t o-gr oove
clea r a n ces a n d will da m a ge t h e r in g-t o-la n d sea t in g.
(2) Be su r e t h e pist on r in g gr ooves a r e fr ee of Fig. 63 Ring Side Clearance Measurement
n icks a n d bu r r s. 1 - FEELER GAUGE
(3) Mea su r e t h e r in g side clea r a n ce wit h a feeler
ga u ge fit t ed sn u gly bet ween t h e r in g la n d a n d r in g RI N G SI DE CLEARAN CE CH ART
(F ig. 62) (F ig. 63). Rot a t e t h e r in g in t h e gr oove. It
m u st m ove fr eely a r ou n d cir cu m fer en ce of t h e gr oove.
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression 0.042 - 0.084 mm
Ring
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)

(4) P la ce r in g in t h e cylin der bor e a n d pu sh down

wit h in ver t ed pist on t o posit ion n ea r lower en d of t h e
r in g t r a vel. Mea su r e r in g ga p wit h a feeler ga u ge fit -
t in g sn u gly bet ween r in g en ds (F ig. 64).

RI N G GAP M EASU REM EN T CH ART

ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Second Compression 0.483 - 0.965 mm
Fig. 62 Piston Dimensions Ring
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
9 - 48 ENGINE - 4.0L WJ
PI ST ON RI N GS (Cont inue d)

Fig. 66 Second Compression Ring Identification

1 - SECOND COMPRESSION RING
2 - CHAMFER
3 - ONE DOT
Fig. 64 Gap Measurement
1 - FEELER GAUGE

(5) Th e oil con t r ol r in gs a r e sym m et r ica l, a n d ca n

be in st a lled wit h eit h er side u p. It is n ot n ecessa r y t o
u se a t ool t o in st a ll t h e u pper a n d lower r a ils. In ser t
oil r a il spa cer fir st , t h en side r a ils.
(6) Th e t wo com pr ession r in gs a r e differ en t a n d
ca n n ot be in t er ch a n ged. Th e t op com pr ession r in g
ca n be iden t ified by t h e sh in y coa t in g on t h e ou t er
sea lin g su r fa ce a n d ca n be in st a lled wit h eit h er side
u p. (F ig. 65).
(7) Th e secon d com pr ession r in g h a s a sligh t
ch a m fer on t h e bot t om of t h e in side edge a n d a dot
on t h e t op for cor r ect in st a lla t ion (F ig. 66) a n d (F ig. Fig. 67 Compression Ring Chamfer Location
67). 1 - TOP COMPRESSION RING
(8) Usin g a r in g in st a ller, in st a ll t h e secon d com - 2 - SECOND COMPRESSION RING
pr ession r in g wit h t h e dot fa cin g u p (F ig. 66) (F ig. 3 - PISTON
4 - CHAMFER
68).
(9) Usin g a r in g in st a ller, in st a ll t h e t op com pr es-
sion r in g (eit h er side u p). Ring Gap Orientation
• P osit ion t h e ga ps on t h e pist on a s sh own (F ig.
69).
• Oil spa cer - Ga p on cen t er lin e of pist on skir t .
• Oil r a ils - ga p 180° a pa r t on cen t er lin e of pist on
pin bor e.
• No. 2 Com pr ession r in g - Ga p 180° fr om t op oil
r a il ga p.
• No. 1 Com pr ession r in g - Ga p 180° fr om No. 2
com pr ession r in g ga p.

Fig. 65 Top Compression ring identification

1 - TOP COMPRESSION RING
WJ ENGINE - 4.0L 9 - 49
PI ST ON RI N GS (Cont inue d)

V I BRAT I ON DAM PER

REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove t h e ser pen t in e dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL) a n d fa n sh r ou d.
(3) Rem ove t h e vibr a t ion da m per r et a in in g bolt
a n d wa sh er.
(4) Use Vibr a t ion Da m per Rem ova l Tool 7697 t o
r em ove t h e da m per fr om t h e cr a n ksh a ft (F ig. 70).

Fig. 68 Compression Ring Installation

1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED

Fig. 70 Vibration Damper Removal Tool 7697

1 - VIBRATION DAMPER REMOVAL TOOL
2 - WRENCH

INSTALLATION
(1) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
key. Wit h t h e key in posit ion , a lign t h e keywa y on
t h e vibr a t ion da m per h u b wit h t h e cr a n ksh a ft key
a n d t a p t h e da m per on t o t h e cr a n ksh a ft .
(2) In st a ll t h e vibr a t ion da m per r et a in in g bolt a n d
wa sh er.
(3) Tigh t en t h e da m per r et a in in g bolt t o 108 N·m
(80 ft . lbs.) t or qu e.
(4) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION) a n d fa n sh r ou d.
(5) Con n ect n ega t ive ca ble t o ba t t er y.

Fig. 69 Ring Gap Orientation

1 - TOP COMPRESSION RING ST RU CT U RAL SU PPORT
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL REMOVAL
4 - OIL RAIL SPACER Th e en gin e ben din g br a ces a r e u sed t o a dd
5 - BOTTOM OIL CONTROL RAIL
st r en gt h t o t h e power t r a in a n d t o a ddr ess som e
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
m in or NVH con cer n s.
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
9 - 50 ENGINE - 4.0L WJ
ST RU CT U RAL SU PPORT (Cont inue d)
NOTE: Before the engine or the transmission can
be removed the engine bending braces must be
removed.

(1) Ra ise a n d su ppor t veh icle.

NOTE: Both left and right side bending braces are

removed the sameway. Only the right side is
shown.

NOTE: The exhaust does not require removal to

preform this procedure.

(2) Rem ove t h e exh a u st h a n ger br a cket r et a in in g

bolt .
(3) Rem ove lockn u t a n d t r a n sm ission ben din g
br a ce ba r.
(4) Rem ove en gin e-t o-ben din g br a ce r et a in in g bolt ,
ben din g br a ce ba r a n d cr oss ba r.
Fig. 71 Engine-to-Transmission Bending Braces
INSTALLATION 1 - ENGINE-TO-TRANSMISSION BENDING BRACE
2 - CROSS BRACE
NOTE: DO NOT tighten the retaining hardware until 3 - ENGINE-TO-TRANSMISSION BENDING BRACE RETAINING
BOLT
all bending braces are in place.

(1) P osit ion t h e cr oss br a ce in t o t h e en gin e-t o-

t r a n sm ission br a ce, t h en posit ion t h e en gin e-t o-t r a n s-
m ission br a ce a n d in st a ll r et a in in g bolt .
(2) P osit ion t h e t r a n sm ission ben din g br a ce on t o
t h r ou gh br a ce a n d in st a ll n ew lockn u t .
(3) P osit ion exh a u st h a n ger a n d t r a n sm ission
br a ce, in st a ll r et a in in g bolt (F ig. 72).
(4) Tigh t en en gin e-t o-t r a n sm ission br a ce r et a in in g
bolt (F ig. 71)t o 40 N·m (30 ft . lbs.).
(5) Tigh t en t r a n sm ission br a ce r et a in in g bolt s (F ig.
72)t o 40 N·m (30 ft . lbs.), t h en t igh t en t r a n sm ission
br a ce r et a in in g lock n u t s (F ig. 72) t o 108 N·m (80 ft .
lbs.).

LU BRI CAT I ON
DESCRIPTION
A gea r —t ype posit ive displa cem en t pu m p is
m ou n t ed a t t h e u n der side of t h e block opposit e t h e
No. 4 m a in bea r in g. Fig. 72 Transmission Bending Braces and Exhaust
Hanger
OPERATION 1 - TRANSMISSION BENDING BRACE RETAINING BOLT
2 - ENGINE-TO-TRANSMISSION BENDING BRACE
Th e pu m p dr a ws oil t h r ou gh t h e scr een a n d in let
3 - LOCKNUT
t u be fr om t h e su m p a t t h e r ea r of t h e oil pa n . Th e oil
4 - TRANSMISSION BRACE
is dr iven bet ween t h e dr ive a n d idler gea r s a n d 5 - EXHAUST HANGER
pu m p body, t h en for ced t h r ou gh t h e ou t let t o t h e
block. An oil ga ller y in t h e block ch a n n els t h e oil t o
t h e in let side of t h e fu ll flow oil filt er. Aft er pa ssin g ch a n n els t h e oil u p t o t h e m a in ga ller y wh ich
t h r ou gh t h e filt er elem en t , t h e oil pa sses fr om t h e ext en ds t h e en t ir e len gt h of t h e block.
cen t er ou t let of t h e filt er t h r ou gh a n oil ga ller y t h a t Ga ller ies ext en d down wa r d fr om t h e m a in oil ga l-
ler y t o t h e u pper sh ell of ea ch m a in bea r in g. Th e
WJ
LU BRI CAT I ON (Cont inue d)
cr a n ksh a ft is dr illed in t er n a lly t o pa ss oil fr om t h e
m a in bea r in g jou r n a ls (except n u m ber 4 m a in bea r-
in g jou r n a l) t o t h e con n ect in g r od jou r n a ls. E a ch con -
n ect in g r od bea r in g ca p h a s a sm a ll squ ir t h ole, oil
pa sses t h r ou gh t h e squ ir t h ole a n d is t h r own off a s
t h e r od r ot a t es. Th is oil t h r owoff lu br ica t es t h e ca m -
sh a ft lobes, dist r ibu t or dr ive gea r, cylin der wa lls, a n d
pist on pin s.
Th e h ydr a u lic va lve t a ppet s r eceive oil dir ect ly
fr om t h e m a in oil ga ller y. Oil is pr ovided t o t h e ca m -
sh a ft bea r in g t h r ou gh ga ller ies. Th e fr on t ca m sh a ft
bea r in g jou r n a l pa sses oil t h r ou gh t h e ca m sh a ft
spr ocket t o t h e t im in g ch a in . Oil dr a in s ba ck t o t h e
oil pa n u n der t h e n u m ber on e m a in bea r in g ca p.
Th e oil su pply for t h e r ocker a r m s a n d br idged
pivot a ssem blies is pr ovided by t h e h ydr a u lic va lve
t a ppet s wh ich pa ss oil t h r ou gh h ollow pu sh r ods t o a
h ole in t h e cor r espon din g r ocker a r m . Oil fr om t h e
r ocker a r m lu br ica t es t h e va lve t r a in com pon en t s,
t h en pa sses down t h r ou gh t h e pu sh r od gu ide h oles
in t h e cylin der h ea d pa st t h e va lve t a ppet a r ea , a n d
r et u r n s t o t h e oil pa n (F ig. 73).
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Discon n ect con n ect or a n d r em ove oil pr essu r e
sen din g u n it .
(2) In st a ll Oil P r essu r e Lin e a n d Ga u ge Tool
C-3292 or equ iva len t . St a r t en gin e a n d r ecor d pr es-
su r e. (Refer t o 9 - E NGINE - SP E CIF ICATIONS) for
t h e cor r ect pr essu r es.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin wit h a t h or ou gh visu a l in spect ion of t h e
en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
If a n oil lea k sou r ce is n ot r ea dily iden t ifia ble, t h e
followin g st eps sh ou ld be followed:
(1) Do n ot clea n or degr ea se t h e en gin e a t t h is
t im e beca u se som e solven t s m a y ca u se r u bber t o
swell, t em por a r ily st oppin g t h e lea k.
(2) Add a n oil solu ble dye (u se a s r ecom m en ded by
m a n u fa ct u r er ). St a r t t h e en gin e a n d let idle for
a ppr oxim a t ely 15 m in u t es. Ch eck t h e oil dipst ick t o
m a ke su r e t h e dye is t h or ou gh ly m ixed a s in dica t ed
wit h a br igh t yellow color u n der a bla ck ligh t .
(3) Usin g a bla ck ligh t , in spect t h e en t ir e en gin e
for flu or escen t dye, pa r t icu la r ly a t t h e su spect ed a r ea
of oil lea k. If t h e oil lea k is fou n d a n d iden t ified,
r epa ir per ser vice m a n u a l in st r u ct ion s.
(4) If dye is n ot obser ved, dr ive t h e veh icle a t va r-
iou s speeds for a ppr oxim a t ely 24km (15 m iles), a n d
r epea t in spect ion .If th e o il le a k s o u rc e is n o t p o s -
ENGINE - 4.0L 9 - 51
itiv e ly id e n tifie d a t th is tim e , pr oceed wit h t h e a ir
lea k det ect ion t est m et h od.
Air Leak Detection Test Method
(1) Discon n ect t h e br ea t h er ca p t o a ir clea n er h ose
a t t h e br ea t h er ca p en d. Ca p or plu g br ea t h er ca p
n ipple.
(2) Rem ove t h e CCV va lve fr om t h e cylin der h ea d
cover. Ca p or plu g t h e CCV va lve gr om m et .
(3) At t a ch a n a ir h ose wit h pr essu r e ga u ge a n d
r egu la t or t o t h e dipst ick t u be.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gr a du a lly a pply a ir pr essu r e fr om 1 psi t o 2.5
psi m a xim u m wh ile a pplyin g soa py wa t er a t t h e su s-
pect ed sou r ce. Adju st t h e r egu la t or t o t h e su it a ble
t est pr essu r e t h a t pr ovide t h e best bu bbles wh ich
will pin poin t t h e lea k sou r ce. If t h e oil lea k is
det ect ed a n d iden t ified, r epa ir per ser vice in for m a -
t ion pr ocedu r es.
(5) If t h e lea ka ge occu r s a t t h e r ea r oil sea l a r ea ,
INSP E CTION F OR RE AR SE AL ARE A LE AKS .
(6) If n o lea ks a r e det ect ed, t u r n off t h e a ir su pply
a n d r em ove t h e a ir h ose a n d a ll plu gs a n d ca ps.
In st a ll t h e CCV va lve a n d br ea t h er ca p h ose.
(7) Clea n t h e oil off t h e su spect oil lea k a r ea u sin g
a su it a ble solven t . Dr ive t h e veh icle a t va r iou s
speeds a ppr oxim a t ely 24 km (15 m iles). In spect t h e
en gin e for sign s of a n oil lea k by u sin g a bla ck ligh t .
INSPECTION FOR REAR SEAL AREA LEAKS
Sin ce it is som et im es difficu lt t o det er m in e t h e
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
followin g st eps sh ou ld be followed t o h elp pin poin t
t h e sou r ce of t h e lea k.
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l
a r ea :
(1) Discon n ect t h e ba t t er y.
(2) Ra ise t h e veh icle.
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g
cover a n d in spect r ea r of block for eviden ce of oil.
Use a bla ck ligh t t o ch eck for t h e oil lea k:
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es
sea l lea ka ge or cr a n ksh a ft da m a ge.
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down ,
possible ca u ses a r e a por ou s block, dist r ibu t or sea l,
ca m sh a ft bor e cu p plu gs oil ga lley pipe plu gs, oil
filt er r u n off, a n d m a in bea r in g ca p t o cylin der
block m a t in g su r fa ces.
(4) If n o lea ks a r e det ect ed, pr essu r ize t h e cr a n k-
ca se a s ou t lin ed in t h e, In spect ion (E n gin e oil Lea ks
in gen er a l)
CAUTION: Do not exceed 20.6 kPa (3 psi).
9 - 52 ENGINE - 4.0L WJ
LU BRI CAT I ON (Cont inue d)

Fig. 73 Oil Lubrication System—4.0L Engine

1 - CAM/CRANK MAIN GALLERY (7) 5 - NUMBER 1 CAMSHFT BEARING JOURNAL
2 - TAPPET GALLERY 6 - CAMSHAFT SPROCKET
3 - TAPPET GALLERY 7 - TAPPET GALLERY
4 - CAMSHAFT BEARING
WJ
LU BRI CAT I ON (Cont inue d)
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es
t h a t ca n be polish ed ou t wit h em er y clot h .
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft
r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
a ssem bled.
OI L
STANDARD PROCEDURE - ENGINE OIL
SERVICE
ENGINE OIL CHANGE
Ch a n ge en gin e oil a t m ilea ge a n d t im e in t er va ls
descr ibed in Ma in t en a n ce Sch edu les.
Ru n en gin e u n t il a ch ievin g n or m a l oper a t in g t em -
per a t u r e.
(1) P osit ion t h e veh icle on a level su r fa ce a n d t u r n
en gin e off.
(2) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(3) Rem ove oil fill ca p.
(4) P la ce a su it a ble dr a in pa n u n der cr a n kca se
dr a in .
(5) Rem ove dr a in plu g fr om cr a n kca se a n d a llow
oil t o dr a in in t o pa n . In spect dr a in plu g t h r ea ds for
st r et ch in g or ot h er da m a ge. Repla ce dr a in plu g if
da m a ged.
(6) In st a ll dr a in plu g in cr a n kca se.
(7) Repla ce en gin e oil filt er. (Refer t o 9 - E NGINE /
LUBRICATION/OIL F ILTE R - RE MOVAL).
(8) Lower veh icle a n d fill cr a n kca se wit h specified
t ype of en gin e oil (Refer t o LUBRICATION & MAIN-
TE NANCE /F LUID TYP E S - DE SCRIP TION) a n d
a m ou n t of en gin e oil (Refer t o LUBRICATION &
MAINTE NANCE - SP E CIF ICATIONS).
(9) In st a ll oil fill ca p.
(10) St a r t en gin e a n d in spect for lea ks.
(11) St op en gin e a n d in spect oil level. Refer t o
CRANKCASE OIL LE VE L INSP E CTION .
USED ENGINE OIL DISPOSAL
Ca r e sh ou ld be exer cised wh en disposin g u sed
en gin e oil a ft er it h a s been dr a in ed fr om a veh icle
en gin e.
ENGINE - 4.0L 9 - 53
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
Th e en gin e oil level in dica t or (Dipst ick) is loca t ed
a t t h e r igh t r ea r of t h e 4.0L en gin e. In spect en gin e
oil level a ppr oxim a t ely ever y 800 kilom et er s (500
m iles). Un less t h e en gin e h a s exh ibit ed loss of oil
pr essu r e, r u n t h e en gin e for a bou t five m in u t es
befor e ch eckin g oil level. Ch eckin g en gin e oil level on
a cold en gin e is n ot a ccu r a t e.
To en su r e pr oper lu br ica t ion of a n en gin e, t h e
en gin e oil m u st be m a in t a in ed a t a n a ccept a ble level.
Th e a ccept a ble levels a r e in dica t ed bet ween t h e ADD
a n d SAF E m a r ks on t h e en gin e oil dipst ick (F ig. 74).
(1) P osit ion veh icle on level su r fa ce.
(2) Wit h en gin e OF F, a llow a ppr oxim a t ely t en m in -
u t es for oil t o set t le t o bot t om of cr a n kca se, r em ove
en gin e oil dipst ick.
(3) Wipe dipst ick clea n .
(4) In st a ll dipst ick a n d ver ify it is sea t ed in t h e
t u be.
(5) Rem ove dipst ick, wit h h a n dle h eld a bove t h e
t ip, t a ke oil level r ea din g (F ig. 74).
(6) Add oil on ly if level is below t h e ADD m a r k on
dipst ick.
Fig. 74 Engine Oil Dipstick—4.0L Engine
1 - DIPSTICK
2 - ADD
3 - SAFE
OI L FI LT ER
REMOVAL
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
9 - 54 ENGINE - 4.0L WJ
OI L FI LT ER (Cont inue d)
All J eep en gin es a r e equ ipped wit h a h igh qu a lit y
fu ll-flow, t h r ow-a wa y t ype oil filt er. Da im ler Ch r ysler
Cor por a t ion r ecom m en ds a Mopa r ! or equ iva len t oil
filt er be u sed.
(1) P osit ion a dr a in pa n u n der t h e oil filt er.
(2) Usin g a su it a ble oil filt er wr en ch loosen filt er.
(3) Rot a t e t h e oil filt er cou n t er clockwise t o r em ove
it fr om t h e cylin der block oil filt er boss or filt er
a da pt er h ou sin g (F ig. 75).

Fig. 76 Oil Filter Sealing Surface—Typical

1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER

Fig. 75 Oil Filter—4.0L Engine

1 - CYLINDER BLOCK
2 - ADAPTER
3 - OIL FILTER

(4) Wh en filt er sepa r a t es fr om a da pt er n ipple, t ip

ga sket en d u pwa r d t o m in im ize oil spill. Rem ove fil-
t er fr om veh icle.
(5) Ma ke su r e old ga sket com es off wit h oil filt er. Fig. 77 Oil Pan
Wit h a wipin g clot h , clea n t h e ga sket sea lin g su r fa ce 1 - OIL PAN
(F ig. 76) of oil a n d gr im e. 2 - OIL PAN DRAIN PLUG

INSTALLATION
(1) Ligh t ly lu br ica t e oil filt er ga sket wit h en gin e
oil or ch a ssis gr ea se.
(2) Th r ea d filt er on t o a da pt er n ipple. Wh en ga sket
m a kes con t a ct wit h sea lin g su r fa ce, (F ig. 76) h a n d
t igh t en filt er on e fu ll t u r n , do n ot over t igh t en .
(3) Add oil, ver ify cr a n kca se oil level a n d st a r t
en gin e. In spect for oil lea ks.
OI L PAN
DESCRIPTION
Th e oil pa n is m a de of st a m ped st eel. Th e oil pa n
ga sket is a on e piece st eel ba ckbon e silicon e coa t ed
ga sket (F ig. 77).
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Ra ise t h e veh icle.
(3) Rem ove t h e oil pa n dr a in plu g a n d dr a in t h e
en gin e oil.
(4) Discon n ect t h e exh a u st pipe a t t h e exh a u st
m a n ifold.
(5) Discon n ect t h e exh a u st h a n ger a t t h e ca t a lyt ic
con ver t er a n d lower t h e pipe.
(6) Rem ove t h e st a r t er m ot or. (Refer t o 8 - E LE C-
TRICAL/STARTING/STARTE R MOTOR - RE MOV-
AL).
(7) Rem ove t h e en gin e flywh eel a n d t r a n sm ission
t or qu e con ver t er h ou sin g a ccess cover.
(8) If equ ipped wit h a n oil level sen sor, discon n ect
t h e sen sor.
(9) P osit ion a ja ck st a n d dir ect ly u n der t h e en gin e
vibr a t ion da m per.
WJ ENGINE - 4.0L 9 - 55
OI L PAN (Cont inue d)
(10) P la ce a piece of wood (2 x 2) bet ween t h e ja ck
st a n d a n d t h e en gin e vibr a t ion da m per.
(11) Rem ove t h e en gin e m ou n t t h r ou gh bolt s.
(12) Usin g t h e ja ck st a n d, r a ise t h e en gin e u n t il
a dequ a t e clea r a n ce is obt a in ed t o r em ove t h e oil pa n .
(13) Rem ove t r a n sm ission oil coolin g lin es (if
equ ipped) a n d oxygen sen sor wir in g su ppor t s t h a t
a r e a t t a ch ed t o t h e oil pa n st u ds.
(14) Rem ove t h e oil pa n bolt s a n d st u ds. Ca r efu lly
slide t h e oil pa n a n d ga sket t o t h e r ea r. If equ ipped
wit h a n oil level sen sor, t a ke ca r e n ot t o da m a ge t h e
sen sor.

INSTALLATION
(1) Clea n t h e block a n d pa n ga sket su r fa ces.
(2) F a br ica t e 4 a lign m en t dowels fr om 1 1/2 x 1/4
in ch bolt s. Cu t t h e h ea d off t h e bolt s a n d cu t a slot Fig. 79 Position of Dowels in Cylinder Block
in t o t h e t op of t h e dowel. Th is will a llow ea sier 1 - DOWEL HOLES
in st a lla t ion a n d r em ova l wit h a scr ewdr iver (F ig. 78). 2 - CYLINDER BLOCK
3 - 5/16## HOLES
4 - 5/16## HOLES

Fig. 78 Fabrication of Alignment Dowels

1 - 1/4## × 1 1/2## BOLT
2 - DOWEL
3 - SLOT Fig. 80 Oil Pan Sealer Location
1 - SEALER LOCATIONS
(3) In st a ll t wo dowels in t h e t im in g ca se cover.
In st a ll t h e ot h er t wo dowels in t h e cylin der block
(F ig. 79).
(4) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
a n t on cylin der block t o r ea r m a in bea r in g ca p cor-
n er s a n d cylin der block t o fr on t cover join t s (fou r
pla ces) (F ig. 80).
(5) Slide t h e on e-piece ga sket over t h e dowels a n d
on t o t h e block a n d t im in g ca se cover.
(6) P osit ion t h e oil pa n over t h e dowels a n d on t o
t h e ga sket . If equ ipped wit h a n oil level sen sor, t a ke
ca r e n ot t o da m a ge t h e sen sor.
(7) In st a ll t h e 1/4 in ch oil pa n bolt s. Tigh t en t h ese
bolt s t o 9.5 N·m (84 in . lbs.) t or qu e. In st a ll t h e 5/16
in ch oil pa n bolt s (F ig. 81). Tigh t en t h ese bolt s t o 15 Fig. 81 Position of 5/16 inch Oil Pan Bolts
N·m (132 in . lbs.) t or qu e. 1 - OIL PAN
(8) Rem ove t h e dowels. In st a ll t h e r em a in in g 1/4 2 - OIL PAN DRAIN PLUG
in ch oil pa n bolt s. Tigh t en t h ese bolt s t o 9.5 N·m (84
in . lbs.) t or qu e.
9 - 56 ENGINE - 4.0L
OI L PAN (Cont inue d)
(9) Lower t h e en gin e u n t il it is pr oper ly loca t ed on
t h e en gin e m ou n t s.
(10) In st a ll t h e t h r ou gh bolt s a n d t igh t en t h e n u t s.
(11) Lower t h e ja ck st a n d a n d r em ove t h e piece of
wood.
(12) In st a ll t h e en gin e flywh eel a n d t r a n sm ission
t or qu e con ver t er h ou sin g a ccess cover.
(13) In st a ll t h e en gin e st a r t er m ot or. (Refer t o 8 -
E LE CTRICAL/STARTING/STARTE R MOTOR
INSTALLATION).
(14) Con n ect t h e exh a u st pipe t o t h e h a n ger a n d t o
t h e en gin e exh a u st m a n ifold.
(15) In st a ll t r a n sm ission oil coolin g lin es (if
equ ipped) a n d oxygen sen sor wir in g su ppor t s t h a t
a t t a ch t o t h e oil pa n st u ds.
(16) In st a ll t h e oil pa n dr a in plu g (F ig. 81).
Tigh t en t h e plu g t o 34 N·m (25 ft . lbs.) t or qu e.
(17) Lower t h e veh icle.
(18) Con n ect n ega t ive ca ble t o ba t t er y.
(19) F ill t h e oil pa n wit h en gin e oil t o t h e specified
level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
WJ
in st r u m en t pa n el on eit h er a CCD or P CI bu s cir cu it
(depen din g on veh icle lin e) t o oper a t e t h e oil pr essu r e
ga u ge a n d t h e ch eck ga u ges la m p. Gr ou n d for t h e
sen sor is pr ovided by t h e P CM t h r ou gh a low-n oise
sen sor r et u r n .
OI L PU M P
-
REMOVAL
A gea r-t ype oil pu m p is m ou n t ed a t t h e u n der side
of t h e cylin der block opposit e t h e No.4 m a in bea r in g.
(1) Dr a in t h e en gin e oil.
(2) Rem ove t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - RE MOVAL).
(3) Rem ove t h e pu m p-t o-cylin der block a t t a ch in g
bolt s. Rem ove t h e pu m p a ssem bly wit h ga sket (F ig.
82).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.

(20) St a r t t h e en gin e a n d in spect for lea ks.

EN GI N E OI L PRESSU RE
SEN SOR
DESCRIPTION
Th e 3–wir e, solid-st a t e en gin e oil pr essu r e sen sor
(sen din g u n it ) is loca t ed in a n en gin e oil pr essu r e
ga ller y.

OPERATION
Th e oil pr essu r e sen sor u ses t h r ee cir cu it s. Th ey
a r e:
• A 5–volt power su pply fr om t h e P ower t r a in Con -
t r ol Modu le (P CM)
• A sen sor gr ou n d t h r ou gh t h e P CM’s sen sor
r et u r n
• A sign a l t o t h e P CM r ela t in g t o en gin e oil pr es-
su r e Fig. 82 Oil Pump Assembly
Th e oil pr essu r e sen sor h a s a 3–wir e elect r ica l
1 - OIL FILTER ADAPTOR
fu n ct ion ver y m u ch like t h e Ma n ifold Absolu t e P r es- 2 - BLOCK
su r e (MAP ) sen sor. Mea n in g differ en t pr essu r es 3 - GASKET
r ela t e t o differ en t ou t pu t volt a ges. 4 - OIL INLET TUBE
A 5–volt su pply is sen t t o t h e sen sor fr om t h e P CM 5 - OIL PUMP
t o power u p t h e sen sor. Th e sen sor r et u r n s a volt a ge 6 - STRAINER ASSEMBLY
sign a l ba ck t o t h e P CM r ela t in g t o en gin e oil pr es- 7 - ATTACHING BOLTS
su r e. Th is sign a l is t h en t r a n sfer r ed (bu ssed) t o t h e
WJ
OI L PU M P (Cont inue d)
INSTALLATION
A gea r-t ype oil pu m p is m ou n t ed a t t h e u n der side
of t h e cylin der block opposit e t h e No.4 m a in bea r in g.
(1) In st a ll t h e oil pu m p on t h e cylin der block u sin g
a r epla cem en t ga sket . Tigh t en t h e bolt s t o 23 N·m
(17 ft . lbs.) t or qu e.
(2) In st a ll t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - INSTALLATION).
(3) F ill t h e oil pa n wit h oil t o t h e specified level.
I N TAK E M AN I FOLD
DESCRIPTION
Th e in t a ke m a n ifold (F ig. 83) is m a de of ca st a lu -
m in u m a n d u ses eleven bolt s t o m ou n t t o t h e cylin -
der h ea d. Th is m ou n t in g st yle im pr oves sea lin g a n d
r edu ces t h e ch a n ce of lea ks.
Fig. 83 Intake Manifold 4.0L Engine
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An in t a ke m a n ifold a ir lea k is ch a r a ct er ized by
lower t h a n n or m a l m a n ifold va cu u m . Also, on e or
m or e cylin der s m a y n ot be fu n ct ion in g.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) St a r t t h e en gin e.
(2) Spr a y a sm a ll st r ea m of wa t er a t t h e su spect ed
lea k a r ea .
(3) If a ch a n ge in RP M is obser ved t h e a r ea of t h e
su spect ed lea k h a s been fou n d.
(4) Repa ir a s r equ ir ed.
ENGINE - 4.0L 9 - 57
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
(2) Rem ove a ir clea n er in let h ose fr om t h e r eson a -
t or a ssem bly.
(3) Rem ove t h e a ir clea n er a ssem bly.
(4) Rem ove t h e t h r ot t le ca ble, veh icle speed con t r ol
ca ble (if equ ipped) a n d t h e t r a n sm ission lin e pr es-
su r e ca ble (Refer t o 21 - TRANSMISSION/TRANS-
AXLE /AUTOMATIC - AW4/TH ROTTLE VALVE
CABLE - RE MOVAL).
(5) Discon n ect t h e followin g elect r ica l con n ect ion s
a n d secu r e t h eir h a r n ess ou t of t h e wa y:
• Th r ot t le P osit ion Sen sor
• Idle Air Con t r ol Mot or
• Coola n t Tem per a t u r e Sen sor (a t t h er m ost a t
h ou sin g)
• In t a ke Air Tem per a t u r e Sen sor
• Oxygen Sen sor
• Cr a n k P osit ion Sen sor
• Six (6) F u el In ject or Con n ect or s
• Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor.
(6) Discon n ect H VAC, a n d Br a ke Boost er va cu u m
su pply h oses a t t h e in t a ke m a n ifold.
(7) P er for m t h e fu el pr essu r e r elea se pr ocedu r e.
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
STANDARD P ROCE DURE ).
(8) Discon n ect a n d r em ove t h e fu el syst em su pply
lin e fr om t h e fu el r a il a ssem bly.
(9) Rem ove t h e a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(10) Rem ove t h e power st eer in g pu m p fr om t h e
in t a ke m a n ifold a n d set a side.
(11) Ra ise t h e veh icle.
(12) Discon n ect t h e exh a u st pipes fr om t h e en gin e
exh a u st m a n ifolds.
(13) Lower t h e veh icle.
(14) Rem ove t h e in t a ke m a n ifold a n d exh a u st
m a n ifold bolt s a n d m a n ifolds (F ig. 84).
INSTALLATION
If t h e m a n ifold is bein g r epla ced, en su r e a ll t h e fit -
t in g, et c. a r e t r a n sfer r ed t o t h e r epla cem en t m a n i-
fold.
(1) In st a ll a n ew en gin e exh a u st /in t a ke m a n ifold
ga sket over t h e a lign m en t dowels on t h e cylin der
h ea d.
(2) P osit ion t h e en gin e exh a u st m a n ifolds t o t h e
cylin der h ea d. In st a ll fa st en er Nu m ber 3 a n d fin ger
t igh t en a t t h is t im e (F ig. 84).
9 - 58 ENGINE - 4.0L WJ
I N TAK E M AN I FOLD (Cont inue d)
(3) In st a ll in t a ke m a n ifold on t h e cylin der h ea d (19) Con n ect t h e ba t t er y n ega t ive ca ble.
dowels. (20) St a r t t h e en gin e a n d ch eck for lea ks.
(4) In st a ll wa sh er a n d fa st en er Nu m ber s 1, 2, 4, 5,
8, 9, 10 a n d 11 (F ig. 84).
(5) In st a ll wa sh er a n d fa st en er Nu m ber s 6 a n d 7 EX H AU ST M AN I FOLD
(F ig. 84).
(6) Tigh t en t h e fa st en er s in sequ en ce a n d t o t h e DESCRIPTION
specified t or qu e (F ig. 84). Th e t wo exh a u st m a n ifolds (F ig. 85) a r e log st yle
• F a st en er Nu m ber s 1 t h r ou gh 5—Tigh t en t o 33 a n d a r e m a de of h igh silicon m olybden u m ca st ir on .
N·m (24 ft . lbs.) t or qu e. Th e exh a u st m a n ifolds sh a r e a com m on ga sket wit h
• F a st en er Nu m ber s 6 a n d 7—Tigh t en t o 31 N·m t h e in t a ke m a n ifold. Th e exh a u st m a n ifolds a lso
(23 ft . lbs.) t or qu e. in cor por a t e ba ll fla n ge ou t let s for im pr oved sea lin g
• F a st en er Nu m ber s 8 t h r ou gh 11—Tigh t en t o 33 a n d st r a in fr ee con n ect ion s.
N·m (24 ft . lbs.) t or qu e.
REMOVAL
Th e in t a ke a n d en gin e exh a u st m a n ifolds on t h e
4.0L en gin e m u st be r em oved t oget h er. Th e m a n ifolds
u se a com m on ga sket a t t h e cylin der h ea d.
(Refer t o 9 - E NGINE /MANIF OLDS/INTAKE
MANIF OLD - RE MOVAL).

INSTALLATION
(1) Th e exh a u st m a n ifold a n d t h e in t a ke m a n ifold
m u st be in st a lled t oget h er u sin g a com m on ga sket .
(2) (Refer t o 9 - E NGINE /MANIF OLDS/INTAKE
MANIF OLD - INSTALLATION).

T I M I N G BELT / CH AI N
COV ER(S)
Fig. 84 Intake and Exhaust Manifolds Installation
(7) In st a ll t h e power st eer in g pu m p t o t h e in t a ke REMOVAL
m a n ifold. (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(8) In st a ll t h e a ccessor y dr ive belt (Refer t o 7 - (2) Rem ove t h e vibr a t ion da m per (Refer t o 9 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION). RE MOVAL).
(9) In st a ll t h e fu el syst em su pply lin e t o t h e fu el (3) Rem ove t h e fa n , h u b a ssem bly a n d fa n sh r ou d
r a il a ssem bly. (Refer t o 7 - COOLING/E NGINE /RADIATOR FAN -
(10) Con n ect a ll elect r ica l con n ect ion s on t h e RE MOVAL).
in t a ke m a n ifold. (4) Rem ove t h e a ccessor y dr ive br a cket s t h a t a r e
(11) Con n ect t h e va cu u m h oses pr eviou sly a t t a ch ed t o t h e t im in g ca se cover.
r em oved. (5) Rem ove t h e A/C com pr essor (Refer t o 24 -
(12) In st a ll t h r ot t le ca ble, veh icle speed con t r ol H E ATING & AIR CONDITIONING/P LUMBING/A/C
ca ble (if equ ipped). COMP RE SSOR - RE MOVAL) (if equ ipped) a n d gen -
(13) In st a ll t h e t r a n sm ission lin e pr essu r e ca ble (if er a t or br a cket a ssem bly fr om t h e en gin e cylin der
equ ipped) (Refer t o 21 - TRANSMISSION/TRANS- h ea d a n d m ove t o on e side.
AXLE /AUTOMATIC - AW4/TH ROTTLE VALVE (6) Rem ove t h e oil pa n -t o-t im in g ca se cover bolt s
CABLE - INSTALLATION). a n d t im in g ca se cover-t o-cylin der block bolt s.
(14) In st a ll a ir clea n er a ssem bly. (7) Rem ove t h e t im in g ca se cover a n d ga sket fr om
(15) Con n ect a ir in let h ose t o t h e r eson a t or a ssem - t h e en gin e.
bly. (8) P r y t h e cr a n ksh a ft oil sea l fr om t h e fr on t of t h e
(16) Ra ise t h e veh icle. t im in g ca se cover (F ig. 86).
(17) Con n ect t h e exh a u st pipes t o t h e en gin e
exh a u st m a n ifolds. Tigh t en t h e bolt s t o 31 N·m (23 INSTALLATION
ft . lbs.) Clea n t h e t im in g ca se cover, oil pa n a n d cylin der
(18) Lower t h e veh icle. block ga sket su r fa ces.
WJ ENGINE - 4.0L 9 - 59
T I M I N G BELT / CH AI N COV ER(S) (Cont inue d)

Fig. 85 EXHAUST MANIFOLDS 4.0L ENGINE

Fig. 86 Timing Case Cover Components

Fig. 87 Timing Case Cover Alignment
1 - TIMING CASE COVER
2 - OIL SLINGER 1 - TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
(7) Rem ove t h e cover a lign m en t t ool.
(8) Apply a ligh t film of en gin e oil on t h e vibr a t ion
(1) In st a ll a n ew cr a n ksh a ft oil sea l in t h e t im in g
da m per h u b con t a ct su r fa ce of t h e sea l.
ca se cover. Th e open en d of t h e sea l sh ou ld be t owa r d
(9) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
t h e in side of t h e cover. Su ppor t t h e cover a t t h e sea l
a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
a r ea wh ile in st a llin g t h e sea l. F or ce it in t o posit ion
key. Wit h t h e key in ser t ed in t h e keywa y in t h e
wit h Sea l In st a lla t ion Tool 6139.
cr a n ksh a ft , in st a ll t h e vibr a t ion da m per (Refer t o 9 -
(2) P osit ion t h e ga sket on t h e cylin der block.
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
(3) P osit ion t h e t im in g ca se cover on t h e oil pa n
INSTALLATION).
ga sket a n d t h e cylin der block.
(10) In st a ll t h e A/C com pr essor (Refer t o 24 -
(4) In ser t Tim in g Ca se Cover Align m en t a n d Sea l
H E ATING & AIR CONDITIONING/P LUMBING/A/C
In st a lla t ion Tool 6139 in t h e cr a n ksh a ft open in g in
COMP RE SSOR - INSTALLATION) (if equ ipped) a n d
t h e cover (F ig. 87).
gen er a t or br a cket a ssem bly.
(5) In st a ll t h e t im in g ca se cover-t o-cylin der block
(11) In st a ll t h e en gin e fa n , h u b a ssem bly a n d
a n d t h e oil pa n -t o-t im in g ca se cover bolt s.
sh r ou d (Refer t o 7 - COOLING/E NGINE /RADIATOR
(6) Tigh t en t h e 1/4 in ch cover-t o-block bolt s t o 7
FAN - INSTALLATION).
N·m (60 in . lbs.) t or qu e. Tigh t en t h e 5/16 in ch fr on t
(12) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
cover-t o-block bolt s t o 22 N·m (192 in . lbs.) t or qu e.
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
Tigh t en t h e oil pa n -t o-cover 1/4 in ch bolt s t o 9.5 N·m
INSTALLATION).
(84 in . lbs.) t or qu e.
(13) Con n ect n ega t ive ca ble t o ba t t er y.
9 - 60 ENGINE - 4.0L
T I M I N G BELT /CH AI N AN D
SPROCK ET S
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove t h e fa n a n d sh r ou d (Refer t o 7 -
COOLING/E NGINE /RADIATOR FAN - RE MOVAL).
(3) Rem ove t h e ser pen t in e dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(4) Rem ove t h e cr a n ksh a ft vibr a t ion da m per (Refer
t o 9 - E NGINE /E NGINE BLOCK/VIBRATION
DAMP E R - RE MOVAL).
(5) Rem ove t h e t im in g ca se cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - RE MOVAL).
(6) Rot a t e cr a n ksh a ft u n t il t h e “0” t im in g m a r k is
closest t o a n d on t h e cen t er lin e wit h ca m sh a ft
spr ocket t im in g m a r k (F ig. 88).
Fig. 88 Crankshaft—Camshaft Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
(7) Rem ove t h e oil slin ger fr om t h e cr a n ksh a ft .
(8) Rem ove t h e ca m sh a ft spr ocket bolt a n d wa sh er
(F ig. 89).
(9) Rem ove t h e cr a n ksh a ft spr ocket , ca m sh a ft
spr ocket a n d t im in g ch a in a s a n a ssem bly.
(10) In st a lla t ion of t h e t im in g ch a in wit h t h e t im -
in g m a r ks on t h e cr a n ksh a ft a n d ca m sh a ft spr ocket s
pr oper ly a lign ed en su r es cor r ect va lve t im in g. A wor n
or st r et ch ed t im in g ch a in will a dver sely a ffect va lve
WJ
Fig. 89 Camshaft Sprocket and Thrust Plate
1 - CAMSHAFT
2 - CAMSHAFT SPROCKET W/INTEGRAL KEY
3 - BOLT AND WASHER
4 - THRUST PLATE
t im in g. If t h e t im in g ch a in deflect s m or e t h a n 12.7
m m (1/2 in ch ) r epla ce it .
INSTALLATION
Assem ble t h e t im in g ch a in , cr a n ksh a ft spr ocket
a n d ca m sh a ft spr ocket wit h t h e t im in g m a r ks
a lign ed (F ig. 88).
(1) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
key. Wit h t h e key in t h e keywa y on t h e cr a n ksh a ft ,
in st a ll t h e a ssem bly on t h e cr a n ksh a ft a n d ca m sh a ft .
(2) In st a ll t h e ca m sh a ft spr ocket bolt a n d wa sh er
(F ig. 89). Tigh t en t h e bolt t o 68 N·m (50 ft . lbs.) t or qu e.
(3) To ver ify cor r ect in st a lla t ion of t h e t im in g
ch a in , r ot a t e t h e cr a n ksh a ft 2 r evolu t ion s. Th e ca m -
sh a ft a n d cr a n ksh a ft spr ocket t im in g m a r k sh ou ld
a lign (F ig. 88).
(4) In st a ll t h e cr a n ksh a ft oil slin ger.
(5) Repla ce t h e oil sea l in t h e t im in g ca se cover
(Refer t o 9 - E NGINE /E NGINE BLOCK/CRANK-
SH AF T OIL SE AL - F RONT - RE MOVAL).
(6) In st a ll t h e t im in g ca se cover a n d ga sket (Refer
t o 9 - E NGINE /VALVE TIMING/TIMING BE LT /
CH AIN COVE R(S) - INSTALLATION).
(7) Wit h t h e key in st a lled in t h e cr a n ksh a ft key-
wa y, in st a ll t h e vibr a t ion da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION).
(8) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(9) In st a ll t h e fa n , h u b a ssem bly a n d sh r ou d
(Refer t o 7 - COOLING/E NGINE /RADIATOR FAN -
INSTALLATION).
(10) Con n ect n ega t ive ca ble t o ba t t er y.
WJ ENGINE - 4.7L 9 - 61

EN GI N E - 4 .7 L

TABLE OF CONTENTS
page page

ENGINE - 4.7L INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87

DESCRIPTION—4.7L ENGINE ........... . . 63 CAMSHAFT(S) - LEFT
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 88
DIAGNOSIS AND TESTING - ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 64 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90
DIAGNOSIS AND TESTING - ENGINE CYLINDER HEAD COVER(S) - LEFT
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 65 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 93
DIAGNOSIS AND TESTING - ENGINE REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . . . 93
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 66 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
DIAGNOSIS AND TESTING - ENGINE INSTALLATION—LEFT SIDE . . . . . . . . . . . . . . . 93
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . . 67 INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING - CYLINDER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 94
COMPRESSION PRESSURE . . . . . . . . . . . . . 68 STANDARD PROCEDURE—REFACING . . . . . . 94
DIAGNOSIS AND TESTING - CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
COMBUSTION PRESSURE LEAKAGE . . . . . . 69 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95
STANDARD PROCEDURE ROCKER ARM / ADJUSTER ASSEMBLY
STANDARD PROCEDURE - REPAIR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 96
DAMAGED OR WORN THREADS . . . . . . . . . 70 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STANDARD PROCEDURE - FORM-IN- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
PLACE GASKETS AND SEALERS . . . . . . . . . 70 VALVE SPRINGS
STANDARD PROCEDURE - ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 97
GASKET SURFACE PREPARATION . . . . . . . . 70 VALVE STEM SEALS
STANDARD PROCEDURE - ENGINE CORE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 97
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 71 CYLINDER HEAD - RIGHT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 DESCRIPTION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73 DESCRIPTION - CYLINDER HEAD . . . . . . . . 97
SPECIFICATIONS DESCRIPTION - VALVE GUIDES . . . . . . . . . . 97
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 74 DIAGNOSIS AND TESTING
SPECIFICATIONS - 4.7L H.O. ENGINE ... . . 77 DIAGNOSIS AND TESTING—CYLINDER
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . 97
SPECIAL TOOLS DIAGNOSIS AND TESTING - HYDRAULIC
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 80 LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 98
AIR CLEANER ELEMENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . 83 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . . 83 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 99
AIR CLEANER HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . 84 CAMSHAFT(S) - RIGHT
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . . 84 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
CYLINDER HEAD - LEFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DESCRIPTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
DESCRIPTION - CYLINDER HEAD . . . . . . . . 84 CYLINDER HEAD COVER(S) - RIGHT
DESCRIPTION - VALVE GUIDES . . . . . . . . . . 84 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 104
DIAGNOSIS AND TESTING REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . . 104
DIAGNOSIS AND TESTING - HYDRAULIC CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 84 INSTALLATION - RIGHT SIDE . . . . . . . . . . . . . 104
DIAGNOSIS AND TESTING—CYLINDER INTAKE/EXHAUST VALVES & SEATS
HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . 85 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 104
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 STANDARD PROCEDURE—REFACING . . . . . 105
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSPECTION ........................ . . 87 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
9 - 62 ENGINE - 4.7L WJ

ROCKER ARM / ADJUSTER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 107 REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
VALVE SPRINGS LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
VALVE STEM SEALS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108 DIAGNOSIS AND TESTING
ENGINE BLOCK DIAGNOSIS AND TESTING—ENGINE OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 128
STANDARD PROCEDURE—CYLINDER BORE DIAGNOSIS AND TESTING—REAR SEAL
HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 128
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 DIAGNOSIS AND TESTING—ENGINE OIL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 109 LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
CONNECTING ROD BEARINGS OIL
STANDARD PROCEDURE - CONNECTING STANDARD PROCEDURE - ENGINE OIL . . . . 130
ROD BEARING FITTING . . . . . . . . . . . . . . . 109 OIL FILTER
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 111 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
STANDARD PROCEDURE - MEASURING OIL PAN
CRANKSHAFT END PLAY . . . . . . . . . . . . . . 111 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 132
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 112 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112 INSPECTION ...................... . . . 132
CRANKSHAFT MAIN BEARINGS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
STANDARD PROCEDURE—CRANKSHAFT OIL PRESSURE SENSOR/SWITCH
MAIN BEARING - FITTING . . . . . . . . . . . . . . 114 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 133
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 115 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 133
CRANKSHAFT OIL SEAL - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 116 OIL PUMP
CRANKSHAFT OIL SEAL - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FLEX PLATE INSPECTION ...................... . . . 134
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 118 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 135
PISTON & CONNECTING ROD INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 136
STANDARD PROCEDURE—PISTON FITTING . 118 DIAGNOSIS AND TESTING—INTAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . 136
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 119 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120 INSPECTION ...................... . . . 137
PISTON RINGS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
STANDARD PROCEDURE - PISTON RING EXHAUST MANIFOLD - LEFT
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 138
VIBRATION DAMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123 INSPECTION ...................... . . . 138
STRUCTURAL COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 124 EXHAUST MANIFOLD - RIGHT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 124 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
FRONT MOUNT INSPECTION ...................... . . . 141
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
WJ ENGINE - 4.7L 9 - 63

VALVE TIMING TIMING BELT / CHAIN COVER(S)

DESCRIPTION - TIMING DRIVE SYSTEM . . . . 141 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
OPERATION - TIMING DRIVE SYSTEM . . . . . 141 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 146
STANDARD PROCEDURE TIMING BELT/CHAIN AND SPROCKETS
STANDARD PROCEDURE - ENGINE TIMING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
- VERIFICATION . . . . . . . . . . . . . . . . . . . . . 141 INSPECTION .................. . . . . . . . 149
STANDARD PROCEDURE—MEASURING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 149
TIMING CHAIN WEAR . . . . . . . . . . . . . . . . . 145

EN GI N E - 4 .7 L
DESCRIPTION—4.7L ENGINE

Th e 4.7 lit er (287 CID) eigh t -cylin der en gin e is a n
90° sin gle over h ea d ca m sh a ft en gin e. Th e ca st ir on
cylin der block is m a de u p of t wo differ en t com po-
n en t s; t h e fir st com pon en t is t h e cylin der bor e a n d
u pper block, t h e secon d com pon en t is t h e bedpla t e
t h a t com pr ises t h e lower por t ion of t h e cylin der block
a n d h ou ses t h e lower h a lf of t h e cr a n ksh a ft m a in
bea r in gs. Th e cylin der s a r e n u m ber ed fr om fr on t t o
r ea r wit h t h e left ba n k bein g n u m ber ed 1,3,5 a n d 7,
a n d t h e r igh t ba n k bein g n u m ber ed 2,4,6 a n d 8. Th e
fir in g or der is 1–8–4–3–6–5–7–2. Th e en gin e ser ia l
n u m ber is loca t ed a t t h e r igh t fr on t side of t h e
en gin e block (F ig. 1)
9 - 64 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

DI AGN OSI S AN D T EST I N G

DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
E n gin e dia gn osis is h elpfu l in det er m in in g t h e
ca u ses of m a lfu n ct ion s n ot det ect ed a n d r em edied by
r ou t in e m a in t en a n ce.
Th ese m a lfu n ct ion s m a y be cla ssified a s eit h er per-
for m a n ce (e.g., en gin e idles r ou gh a n d st a lls) or
m ech a n ica l (e.g., a st r a n ge n oise).
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE ST-
ING)—P E RF ORMANCE a n d (Refer t o 9 - E NGINE -
DIAGNOSIS AND TE STING)—ME CH ANICAL for
possible ca u ses a n d cor r ect ion s of m a lfu n ct ion s.
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
DIAGNOSIS AND TE STING) a n d (Refer t o 14 -
F UE L SYSTE M/F UE L INJ E CTION - DIAGNOSIS
AND TE STING) for t h e fu el syst em dia gn osis.
Addit ion a l t est s a n d dia gn ost ic pr ocedu r es m a y be
n ecessa r y for specific en gin e m a lfu n ct ion s t h a t ca n
n ot be isola t ed wit h t h e Ser vice Dia gn osis ch a r t s.
In for m a t ion con cer n in g a ddit ion a l t est s a n d dia gn o-
Fig. 1 Engine Identification Location
sis is pr ovided wit h in t h e followin g dia gn osis:
1 - VEHICLE VIN NUMBER LOCATION
• Cylin der Com pr ession P r essu r e Test (Refer t o 9 -
2 - CYLINDER BLOCK RIGHT HAND SIDE
E NGINE - DIAGNOSIS AND TE STING).
3 - CYLINDER BORE #2
• Cylin der Com bu st ion P r essu r e Lea ka ge Test
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE ST-
ING).
• E n gin e Cylin der H ea d Ga sket F a ilu r e Dia gn osis
(Refer t o 9 - E NGINE /CYLINDE R H E AD - DIAGNO-
SIS AND TE STING).
• In t a ke Ma n ifold Lea ka ge Dia gn osis (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
DIAGNOSIS AND TE STING).
WJ
EN GI N E - 4 .7 L (Cont inue d)
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
ENGINE WILL NOT START
ENGINE STALLS OR ROUGH
IDLE
1. ENGINE LOSS OF POWER
POSSIBLE CAUSE
1. Weak battery
2. Corroded or loose battery
connections.
3. Faulty starter.
4. Faulty coil or control unit.
5. Incorrect spark plug gap.
6. Dirt or water in fuel system.
7. Faulty fuel pump, relay or wiring.
1. Idle speed set to low.
2. Idle mixture to lean or to rich.
3. Vacuum leak.
4. Faulty coil.
5. Incorrect engine timing.
1. Dirty or incorrectly gapped spark
plugs.
2. Dirt or water in fuel system.
3. Faulty fuel pump.
4. Blown cylinder head gasket.
5. Low compression.
6. Burned, warped or pitted valves.
7. Plugged or restricted exhaust
system.
8. Faulty coil.
ENGINE - 4.7L 9 - 65
CORRECTION
1. Charge or replace as necessary.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL -
REMOVAL).
5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
6. Clean system and replace fuel filter.
7. Repair or replace as necessary.
1. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - REMOVAL).
2. Refer to Powertrain Diagnosis
Information.
3. Inspect intake manifold and vacuum
hoses, repair or replace as necessary.
4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL -
REMOVAL).
5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Clean system and replace fuel filter.
3. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL PUMP - DIAGNOSIS
AND TESTING).
4. Replace cylinder head gasket.
5. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING), repair as necessary.
6. Replace as necessary.
7. Inspect and replace as necessary.
8. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL -
REMOVAL).
9 - 66 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

CONDITION POSSIBLE CAUSE CORRECTION

1. ENGINE MISSES ON 1. Spark plugs dirty or incorrectly 1. (Refer to 8 - ELECTRICAL/

ACCELERATION gapped. IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL -
REMOVAL).

1. ENGINE MISSES AT HIGH 1. Spark plugs dirty or incorrectly 1. (Refer to 8 - ELECTRICAL/

SPEED gapped. IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Faulty coil. 2. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL -
REMOVAL).
3. Dirt or water in fuel system. 3. Clean system and replace fuel filter.

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL

CONDITION POSSIBLE CAUSES CORRECTIONS

NOISY VALVES 1. High or low oil level in crankcase. 1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).

2. Thin or diluted oil. 2. Change oil and filter.

3. Low oil pressure.
4. Dirt in lash adjusters.
5. Worn rocker arms.
6. Worn lash adjusters
7. Worn valve guides.
8. Excessive runout of valve seats
on valve faces.
3. Check oil pump, if Ok, check rod
and main bearings for excessive wear.
4. Replace as necessary.
5. Replace as necessary.
6. Replace as necessary.
7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES &
SEATS - STANDARD PROCEDURE).
8. Service valves and valve seats.
(Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES &
SEATS - STANDARD PROCEDURE).

CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &

2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Connecting rod journal out-of-
round.
6. Misaligned connecting rods.
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Check oil pump, if Ok, check rod
and main bearings for excessive wear.
3. Change oil and filter.
4. Replace as necessary.
5. Service or replace crankshaft.
6. Replace bent connecting rods.
WJ
EN GI N E - 4 .7 L (Cont inue d)
CONDITION POSSIBLE CAUSES
MAIN BEARING NOISE 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Excessive end play.
6. Crankshaft journal out-of round.
7. Loose flywheel or torque
converter.
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES
OIL LEAKS 1. Gaskets and O-Rings.
(a) Misaligned or damaged.
(b) Loose fasteners, broken or
porous metal parts.
2. Crankshaft rear seal
3. Crankshaft seal flange.
Scratched, nicked or grooved.
4. Oil pan flange cracked.
5. Timing chain cover seal, damaged
or misaligned.
6. Scratched or damaged vibration
damper hub.
ENGINE - 4.7L 9 - 67
CORRECTIONS
1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Check oil pump, if Ok, check rod
and main bearings for excessive wear.
3. Change oil and filter.
4. Replace as necessary.
5. Check thrust washers for wear.
6. Service or replace crankshaft.
7. Tighten to correct torque
CORRECTION
1.
(a) Replace as necessary.
(b) Tighten fasteners, Repair or
replace metal parts.
2. Replace as necessary (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Polish or replace crankshaft.
4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL).
6. Polish or replace damper.
9 - 68 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.

2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9 -

ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
9. Oil pick up tube loose, damaged 9. Replace as necessary.
or clogged.

OIL PUMPING AT RINGS; 1. Worn or damaged rings.
SPARK PLUGS FOULING
2. Carbon in oil ring slots.
3. Incorrect ring size installed.
4. Worn valve guides.
5. Leaking valve guide seals.
1. Hone cylinder bores and replace
rings.
2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD PROCEDURE).
3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD PROCEDURE).
4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES &
SEATS - STANDARD PROCEDURE).
5. Replace valve guide seals.

DIAGNOSIS AND TESTING - CYLINDER (4) Disa ble t h e fu el syst em (Refer t o 14 - F UE L

SYSTE M/F UE L DE LIVE RY - DE SCRIP TION).
COMPRESSION PRESSURE
(5) Rem ove t h e ASD r ela y (Refer t o 8 - E LE CTRI-
Th e r esu lt s of a cylin der com pr ession pr essu r e t est
CAL/IGNITION CONTROL/AUTO SH UT DOWN
ca n be u t ilized t o dia gn ose sever a l en gin e m a lfu n c-
RE LAY - RE MOVAL).
t ion s.
(6) In ser t a com pr ession pr essu r e ga u ge a n d r ot a t e
E n su r e t h e ba t t er y is com plet ely ch a r ged a n d t h e
t h e en gin e wit h t h e en gin e st a r t er m ot or for t h r ee
en gin e st a r t er m ot or is in good oper a t in g con dit ion .
r evolu t ion s.
Ot h er wise t h e in dica t ed com pr ession pr essu r es m a y
(7) Recor d t h e com pr ession pr essu r e on t h e 3r d
n ot be va lid for dia gn osis pu r poses.
r evolu t ion . Con t in u e t h e t est for t h e r em a in in g cylin -
(1) Clea n t h e spa r k plu g r ecesses wit h com pr essed
der s.
a ir.
(8) (Refer t o 9 - E NGINE - SP E CIF ICATIONS) for
(2) Rem ove t h e spa r k plu gs.
t h e cor r ect en gin e com pr ession pr essu r es.
(3) Secu r e t h e t h r ot t le in t h e wide-open posit ion .
WJ ENGINE - 4.7L 9 - 69
EN GI N E - 4 .7 L (Cont inue d)

DIAGNOSIS AND TESTING - CYLINDER (6) Ca libr a t e t h e t est er a ccor din g t o t h e m a n u fa c-

t u r er ’s in st r u ct ion s. Th e sh op a ir sou r ce for t est in g
COMBUSTION PRESSURE LEAKAGE
sh ou ld m a in t a in 483 kP a (70 psi) m in im u m , 1,379
Th e com bu st ion pr essu r e lea ka ge t est pr ovides a n
kP a (200 psi) m a xim u m a n d 552 kP a (80 psi) r ecom -
a ccu r a t e m ea n s for det er m in in g en gin e con dit ion .
m en ded.
Com bu st ion pr essu r e lea ka ge t est in g will det ect :
(7) P er for m t h e t est pr ocedu r es on ea ch cylin der
• E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t -
a ccor din g t o t h e t est er m a n u fa ct u r er ’s in st r u ct ion s.
in g).
Set pist on of cylin der t o be t est ed a t TDC com pr es-
• Lea ks bet ween a dja cen t cylin der s or in t o wa t er
sion ,Wh ile t est in g, list en for pr essu r ized a ir esca pin g
ja cket .
t h r ou gh t h e t h r ot t le body, t a ilpipe a n d oil filler ca p
• An y ca u ses for com bu st ion /com pr ession pr essu r e
open in g. Ch eck for bu bbles in t h e r a dia t or coola n t .
loss.
All ga u ge pr essu r e in dica t ion s sh ou ld be equ a l,
(1) Ch eck t h e coola n t level a n d fill a s r equ ir ed. DO
wit h n o m or e t h a n 25% lea ka ge.
NOT in st a ll t h e r a dia t or ca p.
F OR EXAMP LE: At 552 kP a (80 psi) in pu t pr es-
(2) St a r t a n d oper a t e t h e en gin e u n t il it a t t a in s
su r e, a m in im u m of 414 kP a (60 psi) sh ou ld be m a in -
n or m a l oper a t in g t em per a t u r e, t h en t u r n t h e en gin e
t a in ed in t h e cylin der.
OF F.
Refer t o CYLINDE R COMBUSTION P RE SSURE
(3) Rem ove t h e spa r k plu gs.
LE AKAGE DIAGNOSIS CH ART .
(4) Rem ove t h e oil filler ca p.
(5) Rem ove t h e a ir clea n er.

CY LI N DER COM BU ST I ON PRESSU RE LEAK AGE DI AGN OSI S CH ART

CONDITION POSSIBLE CAUSE CORRECTION

AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat.
THROTTLE BODY seated properly Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
TAILPIPE seated properly Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
MORE THAN 25% LEAKAGE AND Stuck or broken piston rings; Inspect for broken rings or piston.
AIR ESCAPES THROUGH OIL cracked piston; worn rings and/or Measure ring gap and cylinder
FILLER CAP OPENING ONLY cylinder wall diameter, taper and out-of-round.
Replace defective part as necessary
9 - 70 ENGINE - 4.7L
EN GI N E - 4 .7 L (Cont inue d)
STAN DARD PROCEDU RE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Da m a ged or wor n t h r ea ds ca n be r epa ir ed. E ssen -
t ia lly, t h is r epa ir con sist s of:
• Dr illin g ou t wor n or da m a ged t h r ea ds.
• Ta ppin g t h e h ole wit h a specia l H eli-Coil Ta p, or
equ iva len t .
• In st a llin g a n in ser t in t o t h e t a pped h ole t o br in g
t h e h ole ba ck t o it s or igin a l t h r ea d size.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
Th er e a r e n u m er ou s pla ces wh er e for m -in -pla ce
ga sket s a r e u sed on t h e en gin e. Ca r e m u st be t a ken
wh en a pplyin g for m -in -pla ce ga sket s t o a ssu r e
obt a in in g t h e desir ed r esu lt s. D o n o t u s e fo rm -in -
p la c e g a s k e t m a te ria l u n le s s s p e c ifie d . Bea d size,
con t in u it y, a n d loca t ion a r e of gr ea t im por t a n ce. Too
t h in a bea d ca n r esu lt in lea ka ge wh ile t oo m u ch ca n
r esu lt in spill-over wh ich ca n br ea k off a n d obst r u ct
flu id feed lin es. A con t in u ou s bea d of t h e pr oper
widt h is essen t ia l t o obt a in a lea k-fr ee ga sket .
Th er e a r e n u m er ou s t ypes of for m -in -pla ce ga sket
m a t er ia ls t h a t a r e u sed in t h e en gin e a r ea . Mopa r !
E n gin e RTV GE N II, Mopa r ! ATF -RTV, a n d Mopa r !
Ga sket Ma ker ga sket m a t er ia ls, ea ch h a ve differ en t
pr oper t ies a n d ca n n ot be u sed in pla ce of t h e ot h er.
MOPAR! EN GIN E RTV GEN II
Mopa r ! E n gin e RTV GE N II is u sed t o sea l com -
pon en t s exposed t o en gin e oil. Th is m a t er ia l is a spe-
cia lly design ed bla ck silicon e r u bber RTV t h a t
r et a in s a dh esion a n d sea lin g pr oper t ies wh en
exposed t o en gin e oil. Moist u r e in t h e a ir ca u ses t h e
m a t er ia l t o cu r e. Th is m a t er ia l is a va ila ble in t h r ee
ou n ce t u bes a n d h a s a sh elf life of on e yea r. Aft er on e
yea r t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys
in spect t h e pa cka ge for t h e expir a t ion da t e befor e
u se.
MOPAR! ATF RTV
Mopa r ! ATF RTV is a specifica lly design ed bla ck
silicon e r u bber RTV t h a t r et a in s a dh esion a n d sea l-
in g pr oper t ies t o sea l com pon en t s exposed t o a u t o-
m a t ic t r a n sm ission flu id, en gin e coola n t s, a n d
m oist u r e. Th is m a t er ia l is a va ila ble in t h r ee ou n ce
t u bes a n d h a s a sh elf life of on e yea r. Aft er on e yea r
t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys in spect
t h e pa cka ge for t h e expir a t ion da t e befor e u se.
MOPAR! GAS KET MAKER
Mopa r ! Ga sket Ma ker is a n a n a er obic t ype ga sket
m a t er ia l. Th e m a t er ia l cu r es in t h e a bsen ce of a ir
WJ
wh en squ eezed bet ween t wo m et a llic su r fa ces. It will
n ot cu r e if left in t h e u n cover ed t u be. Th e a n a er obic
m a t er ia l is for u se bet ween t wo m a ch in ed su r fa ces.
Do n ot u se on flexible m et a l fla n ges.
MOPAR! GAS KET S EALAN T
Mopa r ! Ga sket Sea la n t is a slow dr yin g, per m a -
n en t ly soft sea ler. Th is m a t er ia l is r ecom m en ded for
sea lin g t h r ea ded fit t in gs a n d ga sket s a ga in st lea ka ge
of oil a n d coola n t . Ca n be u sed on t h r ea ded a n d
m a ch in ed pa r t s u n der a ll t em per a t u r es. Th is m a t e-
r ia l is u sed on en gin es wit h m u lt i-la yer st eel (MLS)
cylin der h ea d ga sket s. Th is m a t er ia l a lso will pr e-
ven t cor r osion . Mopa r ! Ga sket Sea la n t is a va ila ble in
a 13 oz. a er osol ca n or 4oz./16 oz. ca n w/a pplica t or.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assem blin g pa r t s u sin g a for m -in -pla ce ga sket
r equ ir es ca r e bu t it ’s ea sier t h en u sin g pr ecu t ga s-
ket s.
Mopa r ! Ga sket Ma ker m a t er ia l sh ou ld be a pplied
spa r in gly 1 m m (0.040 in .) dia m et er or less of sea la n t
t o on e ga sket su r fa ce. Be cer t a in t h e m a t er ia l su r-
r ou n ds ea ch m ou n t in g h ole. E xcess m a t er ia l ca n ea s-
ily be wiped off. Com pon en t s sh ou ld be t or qu ed in
pla ce wit h in 15 m in u t es. Th e u se of a loca t in g dowel
is r ecom m en ded du r in g a ssem bly t o pr even t sm ea r-
in g m a t er ia l off t h e loca t ion .
Mopa r ! E n gin e RTV GE N II or ATF RTV ga sket
m a t er ia l sh ou ld be a pplied in a con t in u ou s bea d
a ppr oxim a t ely 3 m m (0.120 in .) in dia m et er. All
m ou n t in g h oles m u st be cir cled. F or cor n er sea lin g, a
3.17 or 6.35 m m (1/8 or 1/4 in .) dr op is pla ced in t h e
cen t er of t h e ga sket con t a ct a r ea . Un cu r ed sea la n t
m a y be r em oved wit h a sh op t owel. Com pon en t s
sh ou ld be t or qu ed in pla ce wh ile t h e sea la n t is st ill
wet t o t h e t ou ch (wit h in 10 m in u t es). Th e u sa ge of a
loca t in g dowel is r ecom m en ded du r in g a ssem bly t o
pr even t sm ea r in g m a t er ia l off t h e loca t ion .
Mopa r ! Ga sket Sea la n t in a n a er osol ca n sh ou ld be
a pplied u sin g a t h in , even coa t spr a yed com plet ely
over bot h su r fa ces t o be join ed, a n d bot h sides of a
ga sket . Th en pr oceed wit h a ssem bly. Ma t er ia l in a
ca n w/a pplica t or ca n be br u sh ed on even ly over t h e
sea lin g su r fa ces. Ma t er ia l in a n a er osol ca n sh ou ld be
u sed on en gin es wit h m u lt i-la yer st eel ga sket s.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
u se of a lu m in u m en gin e com pon en t s a n d m u lt i-la yer
st eel cylin der h ea d ga sket s.
N e v e r u se t h e followin g t o clea n ga sket su r fa ces:
• Met a l scr a per
WJ
EN GI N E - 4 .7 L (Cont inue d)
• Abr a sive pa d or pa per t o clea n cylin der block
a n d h ea d
• H igh speed power t ool wit h a n a br a sive pa d or a
wir e br u sh (F ig. 2)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
On ly u se t h e followin g for clea n in g ga sket su r fa ces:
• Solven t or a com m er cia lly a va ila ble ga sket
r em over
• P la st ic or wood scr a per (F ig. 2)
• Dr ill m ot or wit h 3M Roloc™ Br ist le Disc (wh it e
or yellow) (F ig. 2)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
Fig. 2 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usin g a blu n t t ool su ch a s a dr ift a n d a h a m m er,
st r ike t h e bot t om edge of t h e cu p plu g. Wit h t h e cu p
plu g r ot a t ed, gr a sp fir m ly wit h plier s or ot h er su it -
a ble t ool a n d r em ove plu g (F ig. 3).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
ENGINE - 4.7L 9 - 71
Fig. 3 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
Th or ou gh ly clea n in side of cu p plu g h ole in cylin -
der block or h ea d. Be su r e t o r em ove old sea ler.
Ligh t ly coa t in side of cu p plu g h ole wit h Mopa r !
St u d a n d Bea r in g Mou n t . Ma ke cer t a in t h e n ew plu g
is clea n ed of a ll oil or gr ea se. Usin g pr oper dr ive
plu g, dr ive plu g in t o h ole so t h a t t h e sh a r p edge of
t h e plu g is a t lea st 0.5 m m (0.020 in .) in side t h e
lea d-in ch a m fer.
It is n ot n ecessa r y t o wa it for cu r in g of t h e sea la n t .
Th e coolin g syst em ca n be r efilled a n d t h e veh icle
pla ced in ser vice im m edia t ely.
REMOVAL
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
(2) Rem ove t h e fr on t fa scia .
(3) Ra ise veh icle on h oist .
(4) Rem ove exh a u st cr ossover pipe fr om exh a u st
m a n ifolds.
(5) Discon n ect t wo gr ou n d st r a ps fr om t h e lower
left h a n d side a n d on e gr ou n d st r a p fr om t h e lower
r igh t h a n d side of t h e en gin e.
(6) Discon n ect cr a n ksh a ft posit ion sen sor. (F ig. 4)
(7) Rem ove st r u ct u r a l cover (Refer t o 9 - E NGINE /
E NGINE BLOCK/STRUCTURAL COVE R - RE MOV-
AL).
(8) Rem ove st a r t er. (Refer t o 8 - E LE CTRICAL/
STARTING/STARTE R MOTOR - RE MOVAL).
(9) Rem ove r u bber spla sh sh ield.
(10) Dr a in coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(11) Rem ove t or qu e con ver t er bolt s.
(12) Rem ove t r a n sm ission t o en gin e m ou n t in g
bolt s.
9 - 72 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)
(19) Rem ove r a dia t or fa n (Refer t o 7 - COOLING/
E NGINE /RADIATOR FAN - RE MOVAL) a n d a cces-
sor y dr ive belt (Refer t o 7 - COOLING/ACCE SSORY
DRIVE /DRIVE BE LTS - RE MOVAL).
(20) Rem ove A/C com pr essor (Refer t o 24 - H E AT-
ING & AIR CONDITIONING/P LUMBING/A/C COM-
P RE SSOR - RE MOVAL).
(21) Discon n ect t r a n sm ission oil cooler lin es a t t h e
r a dia t or.
(22) Discon n ect r a dia t or lower h ose a t t h e t h er m o-
st a t h ou sin g.
(23) Rem ove A/C con den ser (Refer t o 24 - H E AT-
ING & AIR CONDITIONING/P LUMBING/A/C CON-
DE NSE R - RE MOVAL).
(24) Rem ove r a dia t or (Refer t o 7 - COOLING/E N-
GINE /RADIATOR - RE MOVAL).
(25) Rem ove gen er a t or (Refer t o 8 - E LE CTRICAL/
CH ARGING/GE NE RATOR - RE MOVAL).
(26) Discon n ect t h e t wo h ea t er h oses fr om t h e t im -
in g ch a in cover.
(27) Discon n ect en gin e h a r n ess a t t h e followin g
poin t s :
Fig. 4 Crankshaft Position Sensor
• In t a ke a ir t em per a t u r e (IAT) sen sor (F ig. 6)
1 - CRANKSHAFT POSITION SENSOR
• F u el In ject or s
2 - CYLINDER HEAD COVER
• Th r ot t le P osit ion (TP S) Swit ch
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
• Idle Air Con t r ol (IAC) Mot or
• E n gin e Oil P r essu r e Swit ch
• E n gin e Coola n t Tem per a t u r e (E CT) Sen sor
(13) Discon n ect t h e en gin e block h ea t er power • Ma n ifold a bsolu t e pr essu r e (MAP ) Sen sor
ca ble fr om t h e block h ea t er. • Ca m sh a ft P osit ion (CMP ) Sen sor
(14) Lower veh icle. • Coil Over P lu gs
(15) Rem ove t h r ot t le body r eson a t or a ssem bly a n d (28) Relea se fu el r a il pr essu r e (Refer t o 14 - F UE L
in let h ose. SYSTE M/F UE L DE LIVE RY - STANDARD P ROCE -
(16) Discon n ect t h r ot t le a n d speed con t r ol ca bles. DURE ) t h en discon n ect t h e fu el su pply qu ick con n ect
(17) Discon n ect t u be fr om bot h t h e left a n d r igh t fit t in g a t t h e fu el r a il (Refer t o 14 - F UE L SYSTE M/
side cr a n kca se br ea t h er s, t h en r em ove t h e br ea t h er s F UE L DE LIVE RY/QUICK CONNE CT F ITTING -
(F ig. 5). STANDARD P ROCE DURE ).
(29) Rem ove power st eer in g pu m p a n d posit ion ou t
of t h e wa y.
(30) Discon n ect gr ou n d st r a ps fr om t h e left side of
t h e en gin e.
(31) In st a ll E n gin e Lift in g F ixt u r e Specia l Tool
8347 (F ig. 7)followin g t h ese st eps.
• H oldin g t h e lift in g fixt u r e a t a sligh t a n gle, slide
t h e la r ge bor e in t h e fr on t pla t e over t h e h ex por t ion
of t h e lift in g st u d.
• P osit ion t h e t wo r em a in in g fixt u r e a r m s on t o
t h e t wo lift in g st u ds in t h e cylin der h ea ds.
• P u ll fowa r d a n d u pwa r d on t h e lift in g fixt u r e so
t h a t t h e lift in g st u d r est in t h e slot t ed a r ea below t h e
Fig. 5 Crankcase Breather Connection Points la r ge bor e.
1 - CRANKCASE BREATHERS • Secu r e t h e lift in g fixt u r e t o t h e t h r ee st u ds
u sin g t h r ee 7/16 – 14 N/C lockn u t s.
• Ma ke su r e t h e lift in g loop in t h e lift in g fixt u r e is
(18) Disch a r ge A/C syst em (Refer t o 24 - H E AT- in t h e la st h ole (closest t o t h e t h r ot t le body) t o m in -
ING & AIR CONDITIONING/P LUMBING - STAN- im ize t h e a n gle of en gin e du r in g r em ova l.
DARD P ROCE DURE ).
WJ ENGINE - 4.7L 9 - 73
EN GI N E - 4 .7 L (Cont inue d)

Fig. 6 Throttle Body Connection Points

1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR Fig. 7 Engine Lifting Fixture Attachment Locations
4 - IAT SENSOR (THREADED TYPE) 1 - ATTACHING LOCATION
5 - MOUNTING SCREWS 2 - ADJUSTABLE HOOK
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
(32) Discon n ect body gr ou n d st r a p a t t h e r igh t side 4 - ATTACHING LOCATIONS
cowl.
(4) Rem ove ja ck fr om u n der t h e t r a n sm ission .
NOTE: It will be necessary to support the transmis- (5) Rem ove en gin e lift in g fixt u r e specia l t ool 8347
sion in order to remove the engine. (F ig. 7).
(6) Con n ect gr ou n d st r a ps on t h e left side of t h e
(33) P osit ion a su it a ble ja ck u n der t h e t r a n sm is- en gin e.
sion . (7) In st a ll power st eer in g pu m p (Refer t o 19 -
(34) Rem ove t h e en gin e m ou n t t h r ou gh bolt s. STE E RING/P UMP - INSTALLATION).
(35) Ra ise en gin e sligh t ly, t h en r em ove bot h left (8) Con n ect fu el su pply lin e qu ick con n ect fit t in g
a n d r igh t side en gin e m ou n t s fr om en gin e. (Refer t o (Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY/
9 - E NGINE /E NGINE MOUNTING/F RONT MOUNT QUICK CONNE CT F ITTING - STANDARD P ROCE -
- RE MOVAL). DURE ).
(36) Rem ove en gin e fr om t h e veh icle. (9) Con n ect en gin e h a r n ess a t t h e followin g poin t s
(F ig. 6):
INSTALLATION • In t a ke Air Tem per a t u r e (IAT) Sen sor
(1) P osit ion en gin e in t h e veh icle. • Idle Air Con t r ol (IAC) Mot or
(2) In st a ll bot h left a n d r igh t side en gin e m ou n t s • F u el In ject or s
on t o en gin e (Refer t o 9 - E NGINE /E NGINE MOUNT- • Th r ot t le P osit ion (TP S) Swit ch
ING/F RONT MOUNT - INSTALLATION). • E n gin e Oil P r essu r e Swit ch
(3) In st a ll t r a n sm ission t o en gin e m ou n t in g bolt s. • E n gin e Coola n t Tem per a t u r e (E CT) Sen sor
Tigh t en t h e bolt s t o 41 N·m (30 ft . lbs.). • Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor
9 - 74 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)
• Ca m sh a ft P osit ion (CMP ) Sen sor SPECI FI CAT I ON S
• Coil Over P lu gs
(10) In st a ll gen er a t or (Refer t o 8 - E LE CTRICAL/ 4.7L ENGINE
CH ARGING/GE NE RATOR - INSTALLATION).
(11) In st a ll r a dia t or (Refer t o 7 - COOLING/E N-
GINE /RADIATOR - INSTALLATION). DESCRIPTION SPECIFICATION
(12) In st a ll A/C con den ser (Refer t o 24 - H E ATING GENERAL SPECIFICATIONS
& AIR CONDITIONING/P LUMBING/A/C CON-
DE NSE R - INSTALLATION). Engine Type 90° SOHC V-8 16-Valve
(13) Con n ect r a dia t or lower h ose a t t h e t h er m ost a t Displacement 4.7 Liters / 4701cc
h ou sin g. (287 Cubic Inches)
(14) Con n ect t h e t r a n sm ission oil cooler lin es t o
Bore 93.0 mm (3.66 in.)
t h e r a dia t or.
(15) In st a ll A/C com pr essor. (Refer t o 24 - H E AT- Stroke 86.5 mm (3.40 in.)
ING & AIR CONDITIONING/P LUMBING/A/C COM- Compression Ratio 9.0:1
P RE SSOR - INSTALLATION). Horsepower 235 BHP @ 4800 RPM
(16) In st a ll a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - Torque 295 LB-FT @ 3200 RPM
INSTALLATION) a n d r a dia t or fa n (Refer t o 7 - Lead Cylinder #1 Left Bank
COOLING/E NGINE /RADIATOR FAN - INSTALLA- Firing Order 1-8-4-3-6-5-7-2
TION).
(17) In st a ll br ea t h er s, t h en con n ect t u be t o bot h CYLINDER BLOCK
cr a n kca se br ea t h er s (F ig. 5). Cylinder Block Cast Iron
(18) Con n ect t h r ot t le a n d speed con t r ol ca bles. Bore Diameter 93.010 ± .0075 mm
(19) In st a ll t h r ot t le body r eson a t or a ssem bly a n d
in let h ose. (3.6619 ± 0.0003 in.)
(20) Ra ise veh icle. Out of Round (MAX) 0.076 mm (0.003 in.)
(21) Con n ect t wo gr ou n d st r a ps on t h e lower left Taper (MAX) 0.051 mm (0.002 in.)
h a n d side of t h e en gin e a n d on e gr ou n d st r a p on t h e
lower r igh t side. PISTONS
(22) In st a ll t or qu e con ver t er bolt s. Material Aluminum Alloy
(23) Con n ect cr a n ksh a ft posit ion sen sor (F ig. 4). Diameter 92.975 mm (3.6605 in.)
(24) In st a ll st a r t er.
Weight 367.5 grams (12.96 oz)
(25) In st a ll r u bber spla sh sh ield.
Ring Groove Diameter
CAUTION: The structural cover requires a specific
No. 1 83.73 - 83.97 mm
torque sequence. Failure to follow this sequence
may cause severe damage to the cover. (3.296 - 3.269 in.)
No. 2 82.833 - 83.033 mm
(26) In st a ll st r u ct u r a l cover (Refer t o 9 - E NGINE /
E NGINE BLOCK/STRUCTURAL COVE R - INSTAL- (3.261 - 3.310 in.)
LATION). No. 3 83.88 - 84.08 mm
(27) In st a ll exh a u st cr ossover pipe.
(3.302 - 3.310 in.)
(28) In st a ll en gin e block h ea t er power ca ble, If
equ ipped. PISTON PINS
(29) Lower veh icle. Type Pressed Fit
(30) Ch eck a n d fill en gin e oil (Refer t o LUBRICA-
Clearance In Piston 0.010 - 0.019 mm
TION & MAINTE NANCE /F LUID TYP E S - SP E CIF I-
CATIONS). (0.0004 - 0.0008 in.)
(31) Rech a r ge t h e A/C syst em (Refer t o 24 - H E AT- Diameter 24.013 - 24.016 mm
ING & AIR CONDITIONING/P LUMBING - STAN-
(0.9454 - 0.9456 in.)
DARD P ROCE DURE ).
(32) Refill t h e en gin e coolin g syst em (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ).
(33) Con n ect t h e ba t t er y n ega t ive ca ble.
(34) St a r t en gin e a n d ch eck for lea ks.
WJ ENGINE - 4.7L 9 - 75
EN GI N E - 4 .7 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

PISTON RINGS Bearing Clearance 0.018 - 0.052 mm
Ring Gap (0.0008 - 0.0021 in.)
Top Compression Ring 0.37 - 0.63 mm Out of Round (MAX) 0.005 mm (0.0002 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
(0.0146 - 0.0249 in.)
End Play 0.052 - 0.282 mm
Second Compression 0.37 - 0.63 mm
Ring (0.0021 - 0.0112 in.)
(0.0146 - 0.0249 in.) End Play (MAX) 0.282 mm (0.0112 in)
Oil Control (Steel Rails) 0.25 - 0.76 mm Connecting Rod
Journal
(0.0099 - 0.30 in.)
Diameter 50.992 - 51.008 mm
Side Clearance
(2.0076 - 2.0082 in.)
Top Compression Ring .051 - .094 mm
Bearing Clearance 0.015 - 0.055 mm
(0.0020 - 0.0037 in.)
(0.0006 -0.0022 in.)
Second Compression 0.040 - 0.080 mm
Out of Round (MAX) 0.005 mm (0.0002 in.)
Ring
Taper (MAX) 0.008 mm (0.0004 in.)
(0.0016 - 0.0031 in.)
CAMSHAFT
Oil Ring (Steel Ring) .019 - .229 mm
Bore Diameter 26.02 - 26.04 mm
(.0007 - .0091 in.)
(1.0245 - 1.0252 in.)
Ring Width
Bearing Journal Diameter 25.975 - 25.995 mm
Top Compression Ring 1.472 - 1.490 mm
(1.0227 - 1.0235 in.)
(0.057 - 0.058 in.)
Bearing Clearance 0.025 - 0.065 mm
Second Compression 1.472 - 1.490 mm
(0.001 - 0.0026 in.)
Ring
Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
(0.057 - 0.058 in.)
End Play .075 - .200 mm
Oil Ring (Steel Rails) 0.445 - 0.470 mm
(0.003 - 0.0079 in.)
(0.017 - 0.018 in.)
End Play (MAX) .200 mm (0.0079 in.)
CONNECTING RODS
VALVE TIMING
Bearing Clearance 0.010 - 0.048 mm
Intake
(0.0004 - 0.0019 in.)
Opens (ATDC) 3.6°
Side Clearance 0.10 - 0.35 mm
Closes (ATDC) 247.1°
(0.004 - 0.0138 in.)
Duration 243.5°
Piston Pin Bore Diameter .022 - .045 mm
(Interference Fit) (0.0009 - 0.0018 in.) Exhaust
Bearing Bore Out of 0.004 mm Opens (BTDC) 232.5°
Round Closes (ATDC) 21.2°
(MAX) (0.0002 in.) Duration 253.70°
Total Weight (Less 555 grams (19.5771 Valve Overlap 17.6°
Bearing) ounces) VALVES
CRANKSHAFT Face Angle 45° - 45.5°
Main BearingJournal Head Diameter
Diameter 63.488 - 63.512 mm Intake 48.52 - 48.78 mm
(2.4996 - 2.5005 in.) (1.9103 - 1.9205 in.)
9 - 76 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Exhaust 36.87 - 37.13 mm Spring Force (Valve
1.4516 - 1.4618 in.) Open)
Length (Overall) Intake and Exhaust 786.0 - 860.0 N @ 29.64
mm
Intake 113.45 - 114.21 mm
176.6998 - 193.3357 lbs.
(4.4666 - 4.4965) @ 1.167 in.)
Exhaust 114.92 - 115.68 mm
Number of Coils
(4.5244 - 4.5543 in.)
Intake and Exhaust 6.69
Stem Diameter
Wire Diameter
Intake 6.931 - 6.957 mm
Intake and Exhaust 4.2799 - 4.3561 mm
(0.2729 - 0.2739 in.)
(0.1685 - 0.1715 in.)
Exhaust 6.902 - 6.928 mm
Installed Height (Spring
(0.2717 - 0.2728 in.)
Seat to Bottom of
Stem - to - Guide
Retainer)
Clearance
Nominal
Intake .018 - .069 mm
Intake 40.97 mm (1.613 in.)
(0.0008 - 0.0028 in.)
Exhaust 40.81 mm (1.606 in.)
Exhaust .047 - .098 mm
CYLINDER HEAD
(0.0019 - 0.0039 in.)
Gasket Thickness
Max. Allowable Stem -
to - (Compressed) .7 mm (0.0276 in.)
Guide Clearance Valve Seat Angle 44.5° - 45.0°
(Rocking Valve Seat Runout (MAX) 0.051 mm (0.002 in.)

Method) Valve Seat Width

Intake 0.069 mm (0.0028 in.) Intake 1.75 - 2.36 mm

Exhaust 0.098 mm (0.0039 in.) (0.0698 - 0.0928 in.)

Valve Lift (Zero Lash)
Intake
Exhaust
VALVE SPRING
Free Length (Approx)
Intake and Exhaust
Spring Force (Valve
Closed)
Intake and Exhaust
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
11.25 mm (0.443 in.)
Guide Bore Diameter 6.975 - 7.00 mm
10.90 mm (0.4292 in.)
(Std.)
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
48.6 mm (1.9134 in.) (Flatness) 0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over Rotors / .035 - .095 mm
315.5 - 352.5 N @ 40.89 End Face (MAX)
mm
(0.0014 - 0.0038 in.)
(70.92722 - 79.24515 lbs. Cover Out - of -Flat .025 mm (0.001 in.)
@ 1.6099 in.) (MAX)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
WJ ENGINE - 4.7L 9 - 77
EN GI N E - 4 .7 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Outer Rotor Clearance .235 mm (.0093 in.) No. 2 82.833 - 83.033 mm
(MAX) (3.261 - 3.310 in.)
Outer Rotor Diameter 85.925 mm (0.400 in.)
No. 3 83.88 - 84.08 mm
(MIN)
(3.302 - 3.310 in.)
Tip Clearance Between
Rotors PISTON PINS
(MAX) .150 mm (0.006 in.) Type Full Floating
OIL PRESSURE Clearance In Piston 0.010 - 0.019 mm
At Curb Idle Speed 25 kPa (4 psi) (0.0004 - 0.0008 in.)
(MIN)* Clearance in Rod 0.006 - 0.015 mm
@ 3000 rpm 170 - 758 kPa (25 - 110 (0.0002 - 0.0005 in.)
psi) Diameter 24.017 - 24.020 mm
* CAUTION: If pressure is zero at curb idle, DO (0.9455 - 0.9456 in.)
NOT run
PISTON RINGS
engine at 3000 rpm. Ring Gap

SPECIFICATIONS - 4.7L H.O. ENGINE Top Compression Ring 0.37 - 0.63 mm

(0.0146 - 0.0249 in.)
DESCRIPTION SPECIFICATION Second Compression 0.37 - 0.63 mm
Ring
GENERAL SPECIFICATIONS
(0.0146 - 0.0249 in.)
Engine Type 90° SOHC V-8 16-Valve
Oil Control (Steel Rails) 0.25 - 0.76 mm
Displacement 4.7 Liters / 4701cc
(0.0099 - 0.30 in.)
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.) Side Clearance
Stroke 86.5 mm (3.40 in.) Top Compression Ring .051 - .094 mm
Compression Ratio 9.7:1 (0.0020 - 0.0037 in.)
Horsepower 270 BHP @ 5100 RPM Second Compression 0.040 - 0.080 mm
Torque 330 LB-FT @ 3600 RPM Ring
Lead Cylinder #1 Left Bank (0.0016 - 0.0031 in.)
Firing Order 1-8-4-3-6-5-7-2 Oil Ring (Steel Ring) .019 - .229 mm
CYLINDER BLOCK (.0007 - .0091 in.)
Cylinder Block Cast Iron Ring Width
Bore Diameter 93.010 ± .0075 mm Top Compression Ring 1.472 - 1.490 mm
(3.6619 ± 0.0003 in.) (0.057 - 0.058 in.)
Out of Round (MAX) 0.076 mm (0.003 in.) Second Compression 1.472 - 1.490 mm
Taper (MAX) 0.051 mm (0.002 in.) Ring
PISTONS (0.057 - 0.058 in.)
Material Aluminum Alloy Oil Ring (Steel Rails) 0.445 - 0.470 mm
Diameter 92.975 mm (3.6605 in.) (0.017 - 0.018 in.)
Weight 383.5 grams (13.52 oz) CONNECTING RODS
Ring Groove Diameter Bearing Clearance 0.010 - 0.048 mm
No. 1 83.37 - 83.13 mm (0.0004 - 0.0019 in.)
(3.296 - 3.269 in.)
9 - 78 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Side Clearance 0.10 - 0.35 mm VALVE TIMING
(0.004 - 0.0138 in.) Intake
Piston Pin Bore Diameter 24.045 - 24.035 mm Opens (BTDC) 3.0°
(0.94665 - 0.94625 in.) Closes (ATDC) 233.0°
Bearing Bore Out of 0.004 mm
Duration 236.0°
Round
Exhaust
(MAX) (0.0002 in.)
Opens (BTDC) 235.0°
Total Weight (Less 555 grams (19.5771
Bearing) ounces) Closes (ATDC) 15.0°
CRANKSHAFT Duration 250.0°
Valve Overlap 18.0°
Main BearingJournal
VALVES
Diameter 63.488 - 63.512 mm
Face Angle 45° - 45.5°
(2.4996 - 2.5005 in.)
Bearing Clearance 0.018 - 0.052 mm Head Diameter

(0.0008 - 0.0021 in.) Intake 48.52 - 48.78 mm

Out of Round (MAX) 0.005 mm (0.0002 in.) (1.9103 - 1.9205 in.)
Taper (MAX) 0.008 mm (0.0004 in.) Exhaust 36.87 - 37.13 mm
End Play 0.052 - 0.282 mm 1.4516 - 1.4618 in.)
(0.0021 - 0.0112 in.) Length (Overall)
End Play (MAX) 0.282 mm (0.0112 in) Intake 113.45 - 114.21 mm
Connecting Rod (4.4666 - 4.4965)
Journal Exhaust 114.92 - 115.68 mm
Diameter 50.992 - 51.008 mm (4.5244 - 4.5543 in.)
(2.0076 - 2.0082 in.)
Stem Diameter
Bearing Clearance 0.015 - 0.055 mm
Intake 6.931 - 6.957 mm
(0.0006 -0.0022 in.)
(0.2729 - 0.2739 in.)
Out of Round (MAX) 0.005 mm (0.0002 in.)
Exhaust 6.902 - 6.928 mm
Taper (MAX) 0.008 mm (0.0004 in.)
(0.2717 - 0.2728 in.)
CAMSHAFT
Stem - to - Guide
Bore Diameter 26.02 - 26.04 mm
Clearance
(1.0245 - 1.0252 in.)
Intake .018 - .069 mm
Bearing Journal Diameter 25.975 - 25.995 mm
(0.0008 - 0.0028 in.)
(1.0227 - 1.0235 in.)
Exhaust .047 - .098 mm
Bearing Clearance 0.025 - 0.065 mm
(0.0019 - 0.0039 in.)
(0.001 - 0.0026 in.)
Max. Allowable Stem -
Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
to -
End Play .075 - .200 mm
Guide Clearance
(0.003 - 0.0079 in.)
(Rocking
End Play (MAX) .200 mm (0.0079 in.)
Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
WJ ENGINE - 4.7L 9 - 79
EN GI N E - 4 .7 L (Cont inue d)

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Valve Lift (Zero Lash)
Intake 12.00 mm (0.4724 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Length (Approx)
Intake and Exhaust 48.92 mm (1.9259 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 380.0 +/- 19.0 N @ 40.12
mm
(85.4274 lbs. @ 1.5795
in.)
Spring Force (Valve
Open)
Intake and Exhaust 1030.0 +/- 46.0 N @
28.12 mm
231.5532 lbs. @ 1.107
in.)
Number of Coils
Intake and Exhaust 7.30
Wire Diameter
Intake and Exhaust 4.77 +/- 0.03 mm x
3.80+/- .03mm
Cylinder Head Warpage
(Flatness) 0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over Rotors / .035 - .095 mm
End Face (MAX)
(0.0014 - 0.0038 in.)
Cover Out - of -Flat .025 mm (0.001 in.)
(MAX)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
Outer Rotor Clearance .235 mm (.0093 in.)
(MAX)
Outer Rotor Diameter 85.925 mm (0.400 in.)
(MIN)
Tip Clearance Between
Rotors
(MAX) .150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed 25 kPa (4 psi)
(MIN)*
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run

Installed Height (Spring engine at 3000 rpm.

Seat to Bottom of
Retainer)
TORQUE
Nominal
DESCRIPTION N·m Ft. In.
Intake 40.97 mm (1.613 in.)
Lbs. Lbs.
Exhaust 40.81 mm (1.606 in.)
Camshaft
CYLINDER HEAD
Non - Oiled Sprocket Bolt 122 90 —
Gasket Thickness
Bearing Cap Bolts 11 — 100
(Compressed) .7 mm (0.0276 in.)
Timing Chain Cover—Bolts 54 40 —
Valve Seat Angle 44.5° - 45.0°
Connecting Rod Cap—Bolts 27 20 —
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
PLUS 90° TURN
Valve Seat Width
Bed Plate—Bolts Refer to Procedure
Intake 1.75 - 2.36 mm
Crankshaft Damper—Bolt 175 130 —
(0.0698 - 0.0928 in.)
Cylinder Head—Bolts
Exhaust 1.71 - 2.32 mm
M11 Bolts 81 60 —
(0.0673 - 0.0911 in.)
M8 Bolts 26 19 —
Guide Bore Diameter 6.975 - 7.00 mm
(Std.) Cylinder Head Cover—Bolts 12 — 105
Exhaust Manifold—Bolts 25 18 —
(0.2747 - 0.2756 in.)
9 - 80 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

DESCRIPTION N·m Ft. In. SPECI AL T OOLS

Lbs. Lbs. 4.7L ENGINE
Exhaust Manifold Heat 8 — 72
Shield—Nuts
Then loosen 45°
Flexplate—Bolts 60 45 —
Engine Mount Bracket to 61 45 —
Block—Bolts
Rear Mount to 46 34 —
Transmission—Bolts
Spanner Wrench 6958
Generator Mounting—Bolts
M10 Bolts 54 40 —
M8 Bolts 28 — 250
Intake Manifold—Bolts 12 — 105
Refer to Procedure
for
Tightening Sequence
Oil Pan—Bolts 15 — 130
Oil Pan—Drain Plug 34 25 —
Oil Pump—Bolts 28 — 250
Oil Pump Cover—Bolts 12 — 105
Adapter Pins 8346
Oil Pickup Tube—Bolt and 28 — 250
Nut
Oil Dipstick Tube to Engine
Block—Bolt 15 — 130
Oil Fill Tube—Bolts 12 — 105
Timing Chain Guide—Bolts 28 — 250
Timing Chain Tensioner
Arm—Special
Pin Bolt 17 — 150 Engine Lifting Studs 8400
Hydraulic Tensioner—Bolts 28 — 250
Timing Chain Primary 28 — 250
Tensioner—Bolts
Timing Drive Idler Sprocket— 34 25 —
Bolt
Thermostat Housing—Bolts 13 — 115
Water Pump—Bolts 54 40 —

Engine Lift Fixture 8347

WJ ENGINE - 4.7L 9 - 81
EN GI N E - 4 .7 L (Cont inue d)

Front Crankshaft Seal Remover 8511

Rear Crankshaft Seal Remover 8506

Connecting Rod Guides 8507

Front Crankshaft Seal Installer 8348

Crankshaft Damper Installer 8512

Handle C-4171

Puller 1026

Rear Crankshaft Seal Installer 8349

9 - 82 ENGINE - 4.7L WJ
EN GI N E - 4 .7 L (Cont inue d)

Crankshaft Damper Removal Insert 8513

Remover, Rocker Arm 8516

Chain Tensioner Wedge 8379 Valve Spring Compressor 8387

Chain Tensioner Pins 8514

Idler Shaft Remover 8517

Secondary Chain Holder 8429

Valve Spring Compressor Adapters 8519
WJ
EN GI N E - 4 .7 L (Cont inue d)
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
Bore Size Indicator C-119
Oil Pressure Gauge C-3292
ENGINE - 4.7L 9 - 83
Piston Ring Compressor C-385
Pressure Tester Kit 7700
Bloc–Chek–Kit C-3685–A
AI R CLEAN ER ELEM EN T
REMOVAL - 4.7L
(1) Un la t ch fou r clips r et a in in g a ir clea n er cover t o
a ir clea n er h ou sin g (F ig. 8).
(2) Lift cover u p a n d posit ion t o t h e side.
(3) Rem ove a ir clea n er elem en t .
INSTALLATION - 4.7L
(1) Clea n in side of a ir clea n er h ou sin g befor e
in st a llin g n ew elem en t .
(2) In st a ll a ir clea n er elem en t in t o h ou sin g.
(3) La t ch clips a n d cla m p cover down t o secu r e. Be
su r e a ir clea n er cover is pr oper ly sea t ed t o a ir
clea n er h ou sin g.
9 - 84 ENGINE - 4.7L WJ
AI R CLEAN ER ELEM EN T (Cont inue d)
(e) Rem ove a ir clea n er a ssem bly fr om veh icle.
(4) If r eson a t or is t o be r em oved, discon n ect
br ea t h er t u be a t r eson a t or, discon n ect a ir du ct cla m p
a t r eson a t or (F ig. 8)a n d r em ove 2 r eson a t or m ou n t -
in g bolt s (a t sides of r eson a t or ). Rem ove r eson a t or
fr om t h r ot t le body by loosen in g cla m p a t t h r ot t le
body.

INSTALLATION - 4.7L
(1) P osit ion a ir clea n er a ssem bly t o body a n d
in st a ll 3 n u t s. Tigh t en n u t s t o 10 N·m (93 in . lbs.)
t or qu e. To p re v e n t e x c e s s iv e v ibra tio n tra n s m it-
te d th ro u g h h o u s in g , th e n u ts m u s t be p ro p e rly
to rqu e d . D o n o t o v e rtig h te n n u ts .
(2) If r eson a t or wa s r em oved: In st a ll r eson a t or a n d
bolt s. Tigh t en bolt s t o 4 N·m (35 in . lbs.) t or qu e.
Tigh t en cla m p a t t h r ot t le body t o 4 N·m (35 in . lbs.)
t or qu e.
(3) P osit ion fen der lin er a n d in st a ll clips.
(4) Con n ect a ir du ct a t h ou sin g (F ig. 8).
(5) Tigh t en a ir du ct cla m p.

CY LI N DER H EAD - LEFT

DESCRI PT I ON
Fig. 8 Air Cleaner Assembly - 4.7L
1 - AIR DUCT
DESCRIPTION - CYLINDER HEAD
2 - CLAMPS
Th e cylin der h ea ds a r e m a de of a n a lu m in u m a lloy.
3 - AIR CLEANER COVER Th e cylin der h ea d fea t u r es t wo va lves per cylin der
4 - CLIPS wit h pr essed in powder ed m et a l va lve gu ides. Th e
5 - HOUSING cylin der h ea ds a lso pr ovide en closu r es for t h e t im in g
6 - HOUSING BOLTS (3) ch a in dr a in , n ecessit a t in g u n iqu e left a n d r igh t cylin -
7 - LOWER HOUSING NUTS (3) der h ea ds.
8 - RESONATOR BOLTS
9 - RESONATOR DESCRIPTION - VALVE GUIDES
Th e va lve gu ides a r e m a de of power ed m et a l a n d
AI R CLEAN ER H OU SI N G a r e pr essed in t o t h e cylin der h ea d. Th e gu ides a r e
n ot r epla cea ble or ser vicea ble, a n d va lve gu ide r ea m -
in g is n ot r ecom m en ded. If t h e gu ides a r e wor n
REMOVAL - 4.7L
beyon d a ccept a ble lim it s, r epla ce t h e cylin der h ea ds.
(1) Discon n ect a ir clea n er cover-t o-a ir du ct cla m p
(F ig. 8).
(2) Discon n ect a ir du ct a t h ou sin g. DI AGN OSI S AN D T EST I N G
(3) Ea c h o f th e 3 a ir c le a n e r h o u s in g m o u n t-
in g bo lts is a tta c h e d w ith 2 n u ts (a n u p p e r n u t DIAGNOSIS AND TESTING - HYDRAULIC LASH
a n d lo w e r n u t). D O N OT REMOVE B OLTS . To
p re v e n t s trip p in g bo lts , o n ly re m o v e lo w e r
ADJUSTER
n u ts . Th e lo w e r h o u s in g n u ts a re lo c a te d u n d e r A t a ppet -like n oise m a y be pr odu ced fr om sever a l
le ft fro n t in n e r fe n d e r (F ig . 8). it em s. Ch eck t h e followin g it em s.
(a ) To ga in a ccess t o lower n u t s, r a ise veh icle. (1) E n gin e oil level t oo h igh or t oo low. Th is m a y
(b) Rem ove clips r et a in in g r u bber in n er fen der ca u se a er a t ed oil t o en t er t h e a dju st er s a n d ca u se
sh ield. t h em t o be spon gy.
(c) P r y ba ck sh ield en ou gh t o ga in a ccess t o (2) In su fficien t r u n n in g t im e a ft er r ebu ildin g cylin -
lower n u t s. der h ea d. Low speed r u n n in g u p t o 1 h ou r m a y be
(d) Rem ove 3 n u t s. r equ ir ed.
WJ
CY LI N DER H EAD - LEFT (Cont inue d)
(3) Tu r n en gin e off a n d let set for a few m in u t es
befor e r est a r t in g. Repea t t h is sever a l t im es a ft er
en gin e h a s r ea ch ed n or m a l oper a t in g t em per a t u r e.
(4) Low oil pr essu r e.
(5) Th e oil r est r ict or in cylin der h ea d ga sket or t h e
oil pa ssa ge t o t h e cylin der h ea d is plu gged wit h
debr is.
(6) Air in gest ed in t o oil du e t o br oken or cr a cked
oil pu m p pick u p.
(7) Wor n va lve gu ides.
(8) Rocker a r m ea r s con t a ct in g va lve spr in g
r et a in er.
(9) Rocker a r m loose, a dju st er st u ck or a t m a xi-
m u m ext en sion a n d st ill lea ves la sh in t h e syst em .
(10) Oil lea k or excessive ca m bor e wea r in cylin -
der h ea d.
(11) F a u lt y la sh a dju st er.
a . Ch eck la sh a dju st er s for spon gin ess wh ile
in st a lled in cylin der h ea d a n d ca m on ca m sh a ft a t
ba se cir cle. Depr ess pa r t of r ocker a r m over a dju st er.
Nor m a l a dju st er s sh ou ld feel ver y fir m . Spon gy
a dju st er s ca n be bot t om ed ou t ea sily.
b. Rem ove su spect ed la sh a dju st er s, a n d r epla ce.
c. Befor e in st a lla t ion , m a ke su r e a dju st er s a r e a t
lea st pa r t ia lly fu ll of oil. Th is ca n be ver ified by lit t le
or n o plu n ger t r a vel wh en la sh a dju st er is depr essed.
DIAGNOSIS AND TESTING—CYLINDER HEAD
GASKET
A cylin der h ea d ga sket lea k ca n be loca t ed bet ween
a dja cen t cylin der s or bet ween a cylin der a n d t h e
a dja cen t wa t er ja cket .
P ossible in dica t ion s of t h e cylin der h ea d ga sket
lea kin g bet ween a dja cen t cylin der s a r e:
• Loss of en gin e power
• E n gin e m isfir in g
• P oor fu el econ om y
P ossible in dica t ion s of t h e cylin der h ea d ga sket
lea kin g bet ween a cylin der a n d a n a dja cen t wa t er
ja cket a r e:
• E n gin e over h ea t in g
• Loss of coola n t
• E xcessive st ea m (wh it e sm oke) em it t in g fr om
exh a u st
• Coola n t foa m in g
CYLINDER-TO-CYLINDER LEAKAGE TEST
To det er m in e if a n en gin e cylin der h ea d ga sket is
lea kin g bet ween a dja cen t cylin der s, follow t h e pr oce-
du r es in Cylin der Com pr ession P r essu r e Test (Refer
t o 9 - E NGINE - DIAGNOSIS AND TE STING). An
en gin e cylin der h ea d ga sket lea kin g bet ween a dja -
cen t cylin der s will r esu lt in a ppr oxim a t ely a 50–70%
r edu ct ion in com pr ession pr essu r e.
ENGINE - 4.7L 9 - 85
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wit h t h e en gin e cool, r em ove t h e coola n t pr essu r e
ca p. St a r t t h e en gin e a n d a llow it t o wa r m u p u n t il
t h er m ost a t open s.
If a la r ge com bu st ion /com pr ession pr essu r e lea k
exist s, bu bbles will be visible in t h e coola n t .
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
In st a ll Coolin g Syst em Test er 7700 or equ iva len t t o
pr essu r e ca p n eck. St a r t t h e en gin e a n d obser ve t h e
t est er ’s pr essu r e ga u ge. If ga u ge pu lsa t es wit h ever y
power st r oke of a cylin der a com bu st ion pr essu r e
lea k is eviden t .
CHEMICAL TEST METHOD
Com bu st ion lea ks in t o t h e coolin g syst em ca n a lso
be ch ecked by u sin g Bloc-Ch ek Kit C-3685-A or
equ iva len t . P er for m t est followin g t h e pr ocedu r es
su pplied wit h t h e t ool kit .
REMOVAL
(1) Discon n ect t h e n ega t ive ca ble fr om t h e ba t t er y.
(2) Ra ise t h e veh icle on a h oist .
(3) Discon n ect t h e exh a u st pipe a t t h e left side
exh a u st m a n ifold.
(4) Dr a in t h e en gin e coola n t . (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(5) Lower t h e veh icle.
(6) Rem ove t h e in t a ke m a n ifold. (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
RE MOVAL).
(7) Rem ove t h e cylin der h ea d cover. (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(8) Rem ove a ccessor y dr ive belt . (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(9) Rem ove t h e power st eer in g pu m p a n d set
a side.
(10) Rot a t e t h e cr a n ksh a ft u n t il t h e da m per t im -
in g m a r k is a lign ed wit h TDC in dica t or m a r k (F ig.
9).
9 - 86 ENGINE - 4.7L WJ
CY LI N DER H EAD - LEFT (Cont inue d)

Fig. 10 Using Special Tool 8515 to Hold Chains to

Idler Sprocket.
1 - LOCK ARM
Fig. 9 Engine Top Dead Center 2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
1 - TIMING CHAIN COVER
4 - IDLER SPROCKET
2 - CRANKSHAFT TIMING MARKS
5 - LEFT CAMSHAFT CHAIN
6 - SPECIAL TOOL 8515
(11) Ver ify t h e V8 m a r k on t h e ca m sh a ft spr ocket
is a t t h e 12 o’clock posit ion (F ig. 11). Rot a t e t h e
CAUTION: Do not allow the engine to rotate. Severe
cr a n ksh a ft on e t u r n if n ecessa r y.
damage to the valve train can occur.
(12) Rem ove t h e cr a n ksh a ft da m per. (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL). CAUTION: Do not overlook the four smaller bolts at
(13) Rem ove t h e t im in g ch a in cover. (Refer t o 9 - the front of the cylinder head. Do not attempt to
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN remove the cylinder head without removing these
COVE R(S) - RE MOVAL). four bolts.
(14) Lock t h e secon da r y t im in g ch a in s t o t h e idler
spr ocket u sin g Specia l Tool 8515 (F ig. 10).
NOTE: The cylinder head is attached to the cylinder
NOTE: Mark the secondary timing chain prior to block with fourteen bolts.
removal to aid in installation.
(20) Rem ove t h e cylin der h ea d r et a in in g bolt s.
(15) Ma r k t h e secon da r y t im in g ch a in , on e lin k on (21) Rem ove t h e cylin der h ea d a n d ga sket . Disca r d
ea ch side of t h e V8 m a r k on t h e ca m sh a ft dr ive gea r t h e ga sket .
(F ig. 11).
(16) Rem ove t h e left side secon da r y ch a in t en - CAUTION: Do not lay the cylinder head on its gas-
sion er. (Refer t o 9 - E NGINE /VALVE TIMING/TIM- ket sealing surface, due to the design of the cylin-
ING BE LT/CH AIN AND SP ROCKE TS - RE MOVAL). der head gasket any distortion to the cylinder head
(17) Rem ove t h e cylin der h ea d a ccess plu g (F ig. sealing surface may prevent the gasket from prop-
12). erly sealing resulting in leaks.
(18) Rem ove t h e left side secon da r y ch a in gu ide.
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
BE LT/CH AIN AND SP ROCKE TS - RE MOVAL). CLEANING
(19) Rem ove t h e r et a in in g bolt a n d t h e ca m sh a ft To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
dr ive gea r. pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
u se of a lu m in u m en gin e com pon en t s. (Refer t o 9 -
E NGINE - STANDARD P ROCE DURE )
WJ ENGINE - 4.7L 9 - 87
CY LI N DER H EAD - LEFT (Cont inue d)

Fig. 11 Camshaft Sprocket V8 Marks

1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD

(3) In spect t h e va lve gu ides for wea r, cr a cks or

loosen ess. If eit h er con dit ion exist , r epla ce t h e cylin -
der h ea d.

INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.

Neckin g ca n be ch ecked by h oldin g a st r a igh t edge

a ga in st t h e t h r ea ds. If a ll t h e t h r ea ds do n ot con t a ct
t h e sca le, t h e bolt sh ou ld be r epla ced (F ig. 13).

CAUTION: When cleaning cylinder head and cylin-

Fig. 12 Cylinder Head Access Plugs der block surfaces, DO NOT use a metal scraper
1 - RIGHT CYLINDER HEAD ACCESS PLUG because the surfaces could be cut or ground. Use
2 - LEFT CYLINDER HEAD ACCESS PLUG only a wooden or plastic scraper.

(1) Clea n t h e cylin der h ea d a n d cylin der block

INSPECTION
(1) In spect t h e cylin der h ea d for ou t -of-fla t n ess,
u sin g a st r a igh t edge a n d a feeler ga u ge. If t oler a n ces
exceed 0.0508 m m (0.002 in .) r epla ce t h e cylin der
h ea d.
(2) In spect t h e va lve sea t s for da m a ge. Ser vice t h e
va lve sea t s a s n ecessa r y.
m a t in g su r fa ces (Refer t o 9 - E NGINE - STANDARD
P ROCE DURE ).
(2) P osit ion t h e n ew cylin der h ea d ga sket on t h e
loca t in g dowels.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
9 - 88 ENGINE - 4.7L
CY LI N DER H EAD - LEFT (Cont inue d)
Fig. 13 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
(3) P osit ion t h e cylin der h ea d on t o t h e cylin der
block. Ma ke su r e t h e cylin der h ea d sea t s fu lly over
t h e loca t in g dowels.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lu br ica t e t h e cylin der h ea d bolt t h r ea ds wit h
clea n en gin e oil a n d in st a ll t h e t en M11 bolt s.
(5) Coa t t h e fou r M8 cylin der h ea d bolt s wit h
Mo p a r! Lo c k a n d S e a l Ad h e s iv e t h en in st a ll t h e
bolt s.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tigh t en t h e bolt s in sequ en ce (F ig. 14) u sin g
t h e followin g st eps a n d t or qu e va lu es:
• St ep 1: Tigh t en bolt s 1–10, 27 N·m (20 ft . lbs.).
• St ep 2: Ver ify t h a t bolt s 1–10, a ll r ea ch ed 27
N·m (20 ft . lbs.), by r epea t in g st ep-1 wit h ou t loosen -
in g t h e bolt s. Tigh t en bolt s 11 t h r u 14 t o 14 N·m (10
ft . lbs.).
• St ep 3: Tigh t en bolt s 1–10, 90 degr ees.
• St ep 4: Tigh t en bolt s 1–10, 90 degr ees, a ga in .
Tigh t en bolt s 11–14, 26 N·m (19 ft . lbs.)
(7) In st a ll t h e secon da r y ch a in a n d secon da r y
ch a in gu ide (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS
INSTALLATION).
(8) In st a ll t h e cylin der h ea d a ccess plu g.
(9) Re-set a n d In st a ll t h e left side secon da r y ch a in
t en sion er (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS
INSTALLATION).
(10) Rem ove Specia l Tool 8515.
WJ
Fig. 14 Cylinder Head Tightening Sequence
(11) In st a ll t h e t im in g ch a in cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - INSTALLATION).
(12) In st a ll t h e cr a n ksh a ft da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION).
(13) In st a ll t h e power st eer in g pu m p.
(14) In st a ll t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).
(15) In st a ll t h e in t a ke m a n ifold (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
INSTALLATION).
(16) Refill t h e coolin g syst em (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(17) Ra ise t h e veh icle.
(18) In st a ll t h e exh a u st pipe on t o t h e left exh a u st
m a n ifold.
(19) Lower t h e veh icle.
(20) Con n ect t h e n ega t ive ca ble t o t h e ba t t er y.
(21) St a r t t h e en gin e a n d ch eck for lea ks.
CAM SH AFT (S) - LEFT
DESCRIPTION
Th e ca m sh a ft s con sist of powder ed m et a l st eel
lobes wh ich a r e sin t er-bon ded t o a st eel t u be. A st eel
post or n ose piece is fr ict ion -welded t o t h e st eel ca m -
sh a ft t u be. F ive bea r in g jou r n a ls a r e m a ch in ed in t o
t h e ca m sh a ft , fou r on t h e st eel t u be a n d on e on t h e
st eel n ose piece. Ca m sh a ft en d pla y is con t r olled by
- t wo t h r u st wa lls t h a t bor der t h e n ose piece jou r n a l.
E n gin e oil en t er s t h e h ollow ca m sh a ft s a t t h e t h ir d
jou r n a l a n d lu br ica t es ever y in t a ke lobe r ocker
t h r ou gh a dr illed pa ssa ge in t h e in t a ke lobe.
-
WJ
CAM SH AFT (S) - LEFT (Cont inue d)
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use Special Tool
8350 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Rem ove cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(2) Set en gin e t o TDC cylin der #1, ca m sh a ft
spr ocket V8 m a r ks a t t h e 12 o’clock posit ion .
(3) Ma r k on e lin k on t h e secon da r y t im in g ch a in
on bot h sides of t h e V8 m a r k on t h e ca m sh a ft
spr ocket t o a id in in st a lla t ion .
CAUTION: Do not hold or pry on the camshaft tar-
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
Fig. 15 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
ENGINE - 4.7L 9 - 89
(4) Loosen bu t D O N OT r em ove t h e ca m sh a ft
spr ocket r et a in in g bolt . Lea ve t h e bolt sn u g a ga in st
t h e spr ocket .
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) P osit ion Specia l Tool 8350 t im in g ch a in wedge
bet ween t h e t im in g ch a in st r a n ds, t a p t h e t ool t o
secu r ely wedge t h e t im in g ch a in a ga in st t h e t en -
sion er a r m a n d gu ide (F ig. 15).
NOTE: When gripping the camshaft, place the pliers
on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
(6) H old t h e ca m sh a ft wit h a dju st a ble plier s wh ile
r em ovin g t h e ca m sh a ft spr ocket bolt a n d spr ocket
(F ig. 16).
3 - SPECIAL TOOL 8350 WEDGE
4 - SPECIAL TOOL 8350 WEDGE
9 - 90 ENGINE - 4.7L WJ
CAM SH AFT (S) - LEFT (Cont inue d)

INSTALLATION
(1) Lu br ica t e ca m sh a ft jou r n a ls wit h clea n en gin e
oil.

NOTE: Position the left side camshaft so that the

camshaft sprocket dowel is near the 1 o’clock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.

(2) P osit ion t h e ca m sh a ft in t o t h e cylin der h ea d.

(3) In st a ll t h e ca m sh a ft bea r in g ca ps, h a n d t igh t en
t h e r et a in in g bolt s.
(4) Wor kin g in 1 ⁄2 t u r n in cr em en t s, t igh t en t h e
bea r in g ca p r et a in in g bolt s st a r t in g wit h t h e m iddle
ca p wor kin g ou t wa r d (F ig. 17).

Fig. 16 Camshaft Sprocket and Chain

1 - CAMSHAFT SPROCKET AND CHAIN
2 - ADJUSTABLE PLIERS
3 - CAMSHAFT

(7) Usin g t h e plier s, gen t ly a llow t h e ca m sh a ft t o

r ot a t e 15° clockwise u n t il t h e ca m sh a ft is in t h e n eu -
t r a l posit ion (n o va lve loa d).
(8) St a r t in g a t t h e ou t side wor kin g in wa r d, loosen
t h e ca m sh a ft bea r in g ca p r et a in in g bolt s 1/2 t u r n a t
a t im e. Repea t u n t il a ll loa d is off t h e bea r in g ca ps.

CAUTION: DO NOT STAMP OR STRIKE THE CAM-

SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.

Fig. 17 Camshaft Bearing Caps Tightening

NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e
ca m sh a ft .
Sequence
(5) Tor qu e t h e ca m sh a ft bea r in g ca p r et a in in g
bolt s t o 11 N·m (100 in . lbs.).
(6) P osit ion t h e ca m sh a ft dr ive gea r in t o t h e t im -
in g ch a in a lign in g t h e V8 m a r k bet ween t h e t wo
m a r ked ch a in lin ks (Two lin ks m a r ked du r in g
r em ova l) (F ig. 18).
WJ ENGINE - 4.7L 9 - 91
CAM SH AFT (S) - LEFT (Cont inue d)

Fig. 18 Timing Chain to Sprocket Alignment

1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD

NOTE: When gripping the camshaft, place the pliers

on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.

(7) Usin g t h e a dju st a ble plier s, r ot a t e t h e ca m -

sh a ft u n t il t h e ca m sh a ft spr ocket dowel is a lign ed
wit h t h e slot in t h e ca m sh a ft spr ocket . In st a ll t h e
spr ocket on t o t h e ca m sh a ft (F ig. 19).

CAUTION: Remove excess oil from camshaft

sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.

(8) Rem ove excess oil fr om bolt , t h en in st a ll t h e

ca m sh a ft spr ocket r et a in in g bolt a n d h a n d t igh t en .
(9) Rem ove Specia l Tool 8350 t im in g ch a in wedge
(F ig. 20).
(10) Usin g Specia l Tool 6958 spa n n er wr en ch wit h
a da pt er pin s 8346 (F ig. 21), t or qu e t h e ca m sh a ft
spr ocket r et a in in g bolt t o 122 N·m (90 ft . lbs.).
(11) In st a ll t h e cylin der h ea d cover.

Fig. 19 Camshaft Sprocket Installation

1 - ADJUSTABLE PLIERS
2 - CAMSHAFT DOWEL
9 - 92 ENGINE - 4.7L WJ
CAM SH AFT (S) - LEFT (Cont inue d)

Fig. 20 SPECIAL TOOL 8350

1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE
2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE
WJ ENGINE - 4.7L 9 - 93
CAM SH AFT (S) - LEFT (Cont inue d)
(6) Rem ove t h e cylin der h ea d cover m ou n t in g
bolt s.
(7) Rem ove cylin der h ea d cover a n d ga sket .

NOTE: The gasket may be used again, provided no

cuts, tears, or deformation has occurred.

CLEANING
Clea n cylin der h ea d cover ga sket su r fa ce.
Clea n h ea d r a il, if n ecessa r y.

INSTALLATION—LEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.

CAUTION: DO NOT allow other components includ-

ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.

(1) Clea n cylin der h ea d cover a n d bot h sea lin g su r-

fa ces. In spect a n d r epla ce ga sket a s n ecessa r y.
(2) In st a ll cylin der h ea d cover a n d h a n d st a r t a ll
fa st en er s. Ver ify t h a t a ll st u ds a r e in t h e cor r ect loca -
Fig. 21 Tightening Left Side Cam Sprocket t ion sh own in (F ig. 22).
Retaining Bolt
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346

CY LI N DER H EAD COV ER(S) -

LEFT
DESCRIPTION
Th e cylin der h ea d cover s a r e m a de of die ca st m a g-
n esiu m , a n d a r e n ot in t er ch a n gea ble fr om side-t o-
side. It is im per a t ive t h a t n ot h in g r est on t h e Fig. 22 Cylinder Head Cover—Left
cylin der h ea d cover s. P r olon ged con t a ct wit h ot h er
ITEM DESCRIPTION TORQUE
it em s m a y wea r a h ole in t h e cylin der h ea d cover.
1 Cover Fasteners 12 N·m (105 in. lbs.)

REMOVAL - LEFT SIDE

(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove t h e r eson a t or a ssem ble a n d a ir in let
h ose.
(3) Discon n ect in ject or con n ect or s a n d u n -clip t h e
in ject or h a r n ess.
(4) Rou t e in ject or h a r n ess in fr on t of cylin der h ea d
cover.
(5) Discon n ect t h e left side br ea t h er t u be a n d
r em ove t h e br ea t h er t u be.
(3) Tigh t en cylin der h ea d cover bolt s a n d dou ble
en ded st u ds t o 12 N·m (105 in . lbs.).
(4) In st a ll left side br ea t h er a n d con n ect br ea t h er
t u be.
(5) Con n ect in ject or elect r ica l con n ect or s a n d in jec-
t or h a r n ess r et a in in g clips.
(6) In st a ll t h e r eson a t or a n d a ir in let h ose.
(7) Con n ect n ega t ive ca ble t o ba t t er y.
9 - 94 ENGINE - 4.7L WJ

I N TAK E/EX H AU ST VALV ES &

SEAT S
DESCRIPTION
Th e va lves a r e m a de of h ea t r esist a n t st eel a n d
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. E a ch
va lve is a ct u a t ed by a r oller r ocker a r m wh ich pivot s
on a st a t ion a r y la sh a dju st er. All va lves u se t h r ee
bea d lock keeper s t o r et a in t h e spr in gs a n d pr om ot e
va lve r ot a t ion .

STANDARD PROCEDURE—REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.

NOTE: When refacing valves and valve seats, it is

important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur- Fig. 23 Valve Assembly Configuration
face must be obtained. 1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
(1) Usin g a su it a ble dia l in dica t or m ea su r e t h e 3 - VALVE STEM OIL SEAL
cen t er of t h e va lve sea t Tot a l r u n ou t m u st n ot 4 - INTAKE VALVE
exceed 0.051 m m (0.002 in ). 5 - EXHAUST VALVE
(2) Apply a sm a ll a m ou n t of P r u ssia n blu e t o t h e 6 - VALVE SPRING
va lve sea t , in ser t t h e va lve in t o t h e cylin der h ea d,
wh ile a pplyin g ligh t pr essu r e on t h e va lve r ot a t e t h e
va lve. Rem ove t h e va lve a n d exa m in e t h e va lve fa ce.
If t h e blu e is t r a n sfer r ed below t h e t op edge of t h e
va lve fa ce, lower t h e va lve sea t u sin g a 15 degr ee
st on e. If t h e blu e is t r a n sfer r ed t o t h e bot t om edge of
t h e va lve fa ce, r a ise t h e va lve sea t u sin g a 65 degr ee
st on e.
(3) Wh en t h e sea t is pr oper ly posit ion ed t h e widt h
of t h e in t a ke sea t m u st be 1.75 – 2.36 m m (0.0689 –
0.0928 in .) a n d t h e exh a u st sea t m u st be 1.71 – 2.32
m m (0.0673 – 0.0911 in .).
(4) Ch eck t h e va lve spr in g in st a lled h eigh t a ft er
r efa cin g t h e va lve a n d sea t . Th e in st a lled h eigh t for
bot h in t a ke a n d exh a u st va lve spr in gs m u st n ot
exceed 41.44 m m (1.6315 in .).
(5) Th e va lve sea t a n d va lve fa ce m u st m a in t a in a
fa ce a n gle of 44.5 – 45 degr ees a n gle (F ig. 23).

REMOVAL
NOTE: The cylinder heads must be removed in
order to preform this procedure.

(1) Rem ove r ocker a r m s a n d la sh a dju st er s. Refer Fig. 24 Rocker Arm Removal
t o pr ocedu r es in t h is sect ion (F ig. 24). 1 - CAMSHAFT
(2) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e 2 - SPECIAL TOOL 8516
ca m sh a ft .
WJ ENGINE - 4.7L 9 - 95
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
NOTE: All eight valve springs and valves are
removed in the same manner; this procedure only
covers one valve and valve spring.

(3) Usin g Specia l Tool C-3422–B or C-3422–C

Va lve Spr in g Com pr essor a n d Specia l t ool 8519
Ada pt er, com pr ess t h e va lve spr in g.

NOTE: It may be necessary to tap the top of the

valve spring to loosen the spring retainers locks
enough to be removed.

(4) Rem ove t h e t wo spr in g r et a in er lock h a lves.

NOTE: the valve spring is under tension use care

when releasing the valve spring compressor.

(5) Rem ove t h e va lve spr in g com pr essor. Fig. 25 Testing Valve Springs
(6) Rem ove t h e spr in g r et a in er, a n d t h e spr in g. 1 - SPECIAL TOOL C-647

NOTE: Check for sharp edges on the keeper

grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Rem ove t h e va lve fr om t h e cylin der h ea d.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Rem ove t h e va lve st em sea l. Ma r k t h e va lve for
pr oper in st a lla t ion .
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
In spect t h e va lve spr in gs for ph ysica l sign s of wea r
or da m a ge. Tu r n t a ble of t ool C-647 u n t il su r fa ce is
in lin e wit h t h e 40.69 m m (1.602 in .) m a r k on t h e
t h r ea ded st u d a n d t h e zer o m a r k on t h e fr on t . P la ce
spr in g over t h e st u d on t h e t a ble a n d lift com pr ess-
in g lever t o set t on e device. P u ll on t or qu e wr en ch
u n t il P in g is h ea r d. Ta ke r ea din g on t or qu e wr en ch
a t t h is in st a n t . Mu lt iply t h is r ea din g by t wo. Th is
will give t h e spr in g loa d a t t est len gt h . F r a ct ion a l
m ea su r em en t s a r e in dica t ed on t h e t a ble for fin er
a dju st m en t s. Refer t o Specifica t ion s Sect ion t o obt a in
specified h eigh t a n d a llowa ble t en sion s. Repla ce a n y
spr in gs t h a t do n ot m eet specifica t ion s. (F ig. 25)
INSTALLATION
(1) coa t t h e va lve st em wit h clea n en gin e oil a n d
in ser t it in t o t h e cylin der h ea d.
(2) In st a ll t h e va lve st em sea l. m a ke su r e t h e sea l
is fu lly sea t ed a n d t h a t t h e ga r t er spr in g a t t h e t op
of t h e sea l is in t a ct .
(3) In st a ll t h e spr in g a n d t h e spr in g r et a in er (F ig.
26).
(4) Usin g t h e va lve spr in g com pr essor, com pr ess
t h e spr in g a n d in st a ll t h e t wo va lve spr in g r et a in er
h a lves.
(5) Relea se t h e va lve spr in g com pr essor a n d m a ke
su r e t h e t wo spr in g r et a in er h a lves a n d t h e spr in g
r et a in er a r e fu lly sea t ed.
(6) lu br ica t e t h e ca m sh a ft jou r n a l wit h clea n
en gin e oil t h en P osit ion t h e ca m sh a ft (wit h t h e
spr ocket dowel on t h e left ca m sh a ft a t 11 o’clock a n d
t h e r igh t ca m sh a ft a t 12 o’clock), t h en posit ion t h e
ca m sh a ft bea r in g ca ps.
(7) In st a ll t h e ca m sh a ft bea r in g ca p r et a in in g
bolt s. Tigh t en t h e bolt s 9–13 N·m (100 in . lbs.) in 1 ⁄2
t u r n in cr em en t s in t h e sequ en ce sh own (F ig. 27).
(8) P osit ion t h e h ydr a u lic la sh a dju st er s a n d
r ocker a r m s (F ig. 24).
9 - 96 ENGINE - 4.7L WJ
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)

ROCK ER ARM / ADJ U ST ER

ASSEM BLY
DESCRIPTION
Th e r ocker a r m s a r e st eel st a m pin gs wit h a n in t e-
gr a l r oller bea r in g. Th e r ocker a r m s in cor por a t e a 2.8
m m (0.11 in ch ) oil h ole in t h e la sh a dju st er socket for
r oller a n d ca m sh a ft lu br ica t ion .

REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.

(1) Rem ove t h e cylin der h ea d cover (Refer t o 9 -

E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(2) F or r ocker a r m r em ova l on cylin der s 3 a n d 5
Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
exh a u st st r oke.
(3) F or r ocker a r m r em ova l on cylin der s 2 a n d 8
Fig. 26 Valve Assembly Configuration Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
1 - VALVE LOCKS (3–BEAD) com pr ession st r oke.
2 - RETAINER (4) F or r ocker a r m r em ova l on cylin der s 4 a n d 6
3 - VALVE STEM OIL SEAL Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC
4 - INTAKE VALVE com pr ession st r oke.
5 - EXHAUST VALVE (5) F or r ocker a r m r em ova l on cylin der s 1 a n d 7
6 - VALVE SPRING
Rot a t e t h e cr a n ksh a ft u n t il cylin der #2 is a t TDC
com pr ession st r oke.
(6) Usin g specia l t ool 8516 Rocker Ar m Rem over,
pr ess down wa r d on t h e va lve spr in g, r em ove r ocker
a r m (F ig. 28).

INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.

NOTE: Coat the rocker arms with clean engine oil

prior to installation.

(1) F or r ocker a r m in st a lla t ion on cylin der s 3 a n d

Fig. 27 Camshaft Bearing Caps Tightening
Sequence
5 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
exh a u st st r oke.
(2) F or r ocker a r m in st a lla t ion on cylin der s 2 a n d
8 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
com pr ession st r oke.
(3) F or r ocker a r m in st a lla t ion on cylin der s 4 a n d
6 Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC
com pr ession st r oke.
(4) F or r ocker a r m in st a lla t ion on cylin der s 1 a n d
7 Rot a t e t h e cr a n ksh a ft u n t il cylin der #2 is a t TDC
com pr ession st r oke.
WJ ENGINE - 4.7L 9 - 97
ROCK ER ARM / ADJ U ST ER ASSEM BLY (Cont inue d)

CY LI N DER H EAD - RI GH T

DESCRI PT I ON
DESCRIPTION - CYLINDER HEAD
Th e cylin der h ea ds a r e m a de of a n a lu m in u m a lloy.
Th e cylin der h ea d fea t u r es t wo va lves per cylin der
wit h pr essed in powder ed m et a l va lve gu ides. Th e
cylin der h ea ds a lso pr ovide en closu r es for t h e t im in g
ch a in dr a in , n ecessit a t in g u n iqu e left a n d r igh t cylin -
der h ea ds.

DESCRIPTION - VALVE GUIDES

Th e va lve gu ides a r e m a de of power ed m et a l a n d
a r e pr essed in t o t h e cylin der h ea d. Th e gu ides a r e
n ot r epla cea ble or ser vicea ble, a n d va lve gu ide r ea m -
in g is n ot r ecom m en ded. If t h e gu ides a r e wor n
beyon d a ccept a ble lim it s, r epla ce t h e cylin der h ea ds.

DI AGN OSI S AN D T EST I N G

Fig. 28 Rocker Arm—Removal
1 - CAMSHAFT
DIAGNOSIS AND TESTING—CYLINDER HEAD
2 - SPECIAL TOOL 8516 GASKET
A cylin der h ea d ga sket lea k ca n be loca t ed bet ween
(5) Usin g specia l t ool 8516 pr ess down wa r d on t h e a dja cen t cylin der s or bet ween a cylin der a n d t h e
va lve spr in g, in st a ll r ocker a r m (F ig. 28). a dja cen t wa t er ja cket .
(6) In st a ll t h e cylin der h ea d cover (Refer t o 9 - P ossible in dica t ion s of t h e cylin der h ea d ga sket
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD lea kin g bet ween a dja cen t cylin der s a r e:
COVE R(S) - INSTALLATION). • Loss of en gin e power
• E n gin e m isfir in g
• P oor fu el econ om y
VALV E SPRI N GS P ossible in dica t ion s of t h e cylin der h ea d ga sket
lea kin g bet ween a cylin der a n d a n a dja cen t wa t er
DESCRIPTION ja cket a r e:
Th e va lve spr in gs a r e m a de fr om h igh st r en gt h • E n gin e over h ea t in g
ch r om e silicon st eel. Th e spr in gs a r e com m on for • Loss of coola n t
in t a ke a n d exh a u st a pplica t ion s. Th e va lve spr in g • E xcessive st ea m (wh it e sm oke) em it t in g fr om
sea t is in t egr a l wit h t h e va lve st em sea l, wh ich is a exh a u st
posit ive t ype sea l t o con t r ol lu br ica t ion . • Coola n t foa m in g

CYLINDER-TO-CYLINDER LEAKAGE TEST

VALV E ST EM SEALS
DESCRIPTION
Th e va lve st em sea ls a r e m a de of r u bber a n d in cor-
por a t e a n in t egr a l st eel va lve spr in g sea t . Th e in t e-
gr a l ga r t er spr in g m a in t a in s con sist en t lu br ica t ion
con t r ol t o t h e va lve st em s.
To det er m in e if a n en gin e cylin der h ea d ga sket is
lea kin g bet ween a dja cen t cylin der s, follow t h e pr oce-
du r es in Cylin der Com pr ession P r essu r e Test (Refer
t o 9 - E NGINE - DIAGNOSIS AND TE STING). An
en gin e cylin der h ea d ga sket lea kin g bet ween a dja -
cen t cylin der s will r esu lt in a ppr oxim a t ely a 50–70%
r edu ct ion in com pr ession pr essu r e.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
9 - 98 ENGINE - 4.7L
CY LI N DER H EAD - RI GH T (Cont inue d)
VISUAL TEST METHOD
Wit h t h e en gin e cool, r em ove t h e coola n t pr essu r e
ca p. St a r t t h e en gin e a n d a llow it t o wa r m u p u n t il
t h er m ost a t open s.
If a la r ge com bu st ion /com pr ession pr essu r e lea k
exist s, bu bbles will be visible in t h e coola n t .
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
In st a ll Coolin g Syst em Test er 7700 or equ iva len t t o
pr essu r e ca p n eck. St a r t t h e en gin e a n d obser ve t h e
t est er ’s pr essu r e ga u ge. If ga u ge pu lsa t es wit h ever y
power st r oke of a cylin der a com bu st ion pr essu r e
lea k is eviden t .
CHEMICAL TEST METHOD
Com bu st ion lea ks in t o t h e coolin g syst em ca n a lso
be ch ecked by u sin g Bloc-Ch ek Kit C-3685-A or
equ iva len t . P er for m t est followin g t h e pr ocedu r es
su pplied wit h t h e t ool kit .
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A t a ppet -like n oise m a y be pr odu ced fr om sever a l
it em s. Ch eck t h e followin g it em s.
(1) E n gin e oil level t oo h igh or t oo low. Th is m a y
ca u se a er a t ed oil t o en t er t h e a dju st er s a n d ca u se
t h em t o be spon gy.
(2) In su fficien t r u n n in g t im e a ft er r ebu ildin g cylin -
der h ea d. Low speed r u n n in g u p t o 1 h ou r m a y be
r equ ir ed.
(3) Tu r n en gin e off a n d let set for a few m in u t es
befor e r est a r t in g. Repea t t h is sever a l t im es a ft er
en gin e h a s r ea ch ed n or m a l oper a t in g t em per a t u r e.
(4) Low oil pr essu r e.
(5) Th e oil r est r ict or in cylin der h ea d ga sket or t h e
oil pa ssa ge t o t h e cylin der h ea d is plu gged wit h
debr is.
(6) Air in gest ed in t o oil du e t o br oken or cr a cked
oil pu m p pick u p.
(7) Wor n va lve gu ides.
(8) Rocker a r m ea r s con t a ct in g va lve spr in g
r et a in er.
(9) Rocker a r m loose, a dju st er st u ck or a t m a xi-
m u m ext en sion a n d st ill lea ves la sh in t h e syst em .
(10) Oil lea k or excessive ca m bor e wea r in cylin -
der h ea d.
(11) F a u lt y la sh a dju st er.
WJ
a . Ch eck la sh a dju st er s for spon gin ess wh ile
in st a lled in cylin der h ea d a n d ca m on ca m sh a ft a t
ba se cir cle. Depr ess pa r t of r ocker a r m over a dju st er.
Nor m a l a dju st er s sh ou ld feel ver y fir m . Spon gy
a dju st er s ca n be bot t om ed ou t ea sily.
b. Rem ove su spect ed la sh a dju st er s, a n d r epla ce.
c. Befor e in st a lla t ion , m a ke su r e a dju st er s a r e a t
lea st pa r t ia lly fu ll of oil. Th is ca n be ver ified by lit t le
or n o plu n ger t r a vel wh en la sh a dju st er is depr essed.
REMOVAL
(1) Discon n ect ba t t er y n egit ive ca ble.
(2) Ra ise t h e veh icle on a h oist .
(3) Discon n ect t h e exh a u st pipe a t t h e r igh t side
exh a u st m a n ifold.
(4) Dr a in t h e en gin e coola n t (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(5) Lower t h e veh icle.
(6) Rem ove t h e in t a ke m a n ifold (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
RE MOVAL).
(7) Rem ove t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(8) Rem ove oil fill h ou sin g fr om cylin der h ea d.
(9) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(10) Rot a t e t h e cr a n ksh a ft u n t il t h e da m per t im -
in g m a r k is a lign ed wit h TDC in dica t or m a r k (F ig.
9).
(11) Ver ify t h e V8 m a r k on t h e ca m sh a ft spr ocket
is a t t h e 12 o’clock posit ion (F ig. 11). Rot a t e t h e
cr a n ksh a ft on e t u r n if n ecessa r y.
(12) Rem ove t h e cr a n ksh a ft da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL).
(13) Rem ove t h e t im in g ch a in cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - RE MOVAL).
(14) Lock t h e secon da r y t im in g ch a in s t o t h e idler
spr ocket u sin g Specia l Tool 8515 (F ig. 10).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(15) Ma r k t h e secon da r y t im in g ch a in , on e lin k on
ea ch side of t h e V8 m a r k on t h e ca m sh a ft dr ive gea r
(F ig. 11).
(16) Rem ove t h e r igh t side secon da r y ch a in t en -
sion er (Refer t o 9 - E NGINE /VALVE TIMING/TIM-
ING BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
(17) Rem ove t h e cylin der h ea d a ccess plu g (F ig.
29).
(18) Rem ove t h e r igh t side secon da r y ch a in gu ide
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
WJ
CY LI N DER H EAD - RI GH T (Cont inue d)
Fig. 29 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
(19) Rem ove t h e r et a in in g bolt a n d t h e ca m sh a ft
dr ive gea r.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(20) Rem ove t h e cylin der h ea d r et a in in g bolt s.
(21) Rem ove t h e cylin der h ea d a n d ga sket . Disca r d
t h e ga sket .
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
u se of a lu m in u m en gin e com pon en t s. (Refer t o 9 -
E NGINE - STANDARD P ROCE DURE )
ENGINE - 4.7L 9 - 99
INSPECTION
(1) In spect t h e cylin der h ea d for ou t -of-fla t n ess,
u sin g a st r a igh t edge a n d a feeler ga u ge. If t oler a n ces
exceed 0.0508 m m (0.002 in .) r epla ce t h e cylin der
h ea d.
(2) In spect t h e va lve sea t s for da m a ge. Ser vice t h e
va lve sea t s a s n ecessa r y.
(3) In spect t h e va lve gu ides for wea r, cr a cks or
loosen ess. If eit h er con dit ion exist , r epla ce t h e cylin -
der h ea d.
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Neckin g ca n be ch ecked by h oldin g a st r a igh t edge
a ga in st t h e t h r ea ds. If a ll t h e t h r ea ds do n ot con t a ct
t h e sca le, t h e bolt sh ou ld be r epla ced (F ig. 13).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Clea n t h e cylin der h ea d a n d cylin der block
m a t in g su r fa ces (Refer t o 9 - E NGINE - STANDARD
P ROCE DURE ).
(2) P osit ion t h e n ew cylin der h ea d ga sket on t h e
loca t in g dowels.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) P osit ion t h e cylin der h ea d on t o t h e cylin der
block. Ma ke su r e t h e cylin der h ea d sea t s fu lly over
t h e loca t in g dowels.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lu br ica t e t h e cylin der h ea d bolt t h r ea ds wit h
clea n en gin e oil a n d in st a ll t h e t en M10 bolt s.
(5) Coa t t h e fou r M8 cylin der h ea d bolt s wit h
Mo p a r Lo c k a n d S e a l Ad h e s iv e t h en in st a ll t h e
bolt s.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tigh t en t h e bolt s in sequ en ce (F ig. 30) u sin g
t h e followin g st eps a n d t or qu e va lu es:
• St ep 1: Tigh t en bolt s 1–10, 27 N·m (20 ft . lbs.).
9 - 100 ENGINE - 4.7L
CY LI N DER H EAD - RI GH T (Cont inue d)
• St ep 2: Ver ify t h a t bolt s 1–10, a ll r ea ch ed 27
N·m (20 ft . lbs.), by r epea t in g st ep-1 wit h ou t loosen -
in g t h e bolt s. Tigh t en bolt s 11 t h r u 14 t o 14 N·m (10
ft . lbs.).
• St ep 3: Tigh t en bolt s 1–10, 90 degr ees.
• St ep 4: Tigh t en bolt s 1–10, 90 degr ees, a ga in .
Tigh t en bolt s 11–14, 26 N·m (19 ft . lbs.)
Fig. 30 Cylinder Head Tightening Sequence
(7) In st a ll t h e secon da r y ch a in a n d secon da r y
ch a in gu ide (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS
INSTALLATION).
(8) In st a ll t h e cylin der h ea d a ccess plu g.
(9) Re-set a n d in st a ll t h e r igh t side secon da r y
ch a in t en sion er (Refer t o 9 - E NGINE /VALVE TIM-
ING/TIMING BE LT/CH AIN AND SP ROCKE TS -
INSTALLATION).
(10) Rem ove Specia l Tool 8515.
(11) In st a ll t h e t im in g ch a in cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - INSTALLATION).
(12) In st a ll t h e cr a n ksh a ft da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION).
(13) In st a ll a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(14) In st a ll t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).
(15) In st a ll t h e in t a ke m a n ifold (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD
INSTALLATION).
(16) In st a ll oil fill h ou sin g on t o cylin der h ea d.
(17) Refill t h e coolin g syst em (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(18) Ra ise t h e veh icle.
(19) In st a ll t h e exh a u st pipe on t o t h e r igh t
exh a u st m a n ifold.
(20) Lower t h e veh icle.
(21) Recon n ect ba t t er y n egit ive ca ble.
(22) St a r t t h e en gin e a n d ch eck for lea ks.
WJ
CAM SH AFT (S) - RI GH T
DESCRIPTION
Th e ca m sh a ft s con sist of powder ed m et a l st eel
lobes wh ich a r e sin t er-bon ded t o a st eel t u be. A st eel
post or n ose piece is fr ict ion -welded t o t h e st eel ca m -
sh a ft t u be. F ive bea r in g jou r n a ls a r e m a ch in ed in t o
t h e ca m sh a ft , fou r on t h e st eel t u be a n d on e on t h e
st eel n ose piece. Ca m sh a ft en d pla y is con t r olled by
t wo t h r u st wa lls t h a t bor der t h e n ose piece jou r n a l.
E n gin e oil en t er s t h e h ollow ca m sh a ft s a t t h e t h ir d
jou r n a l a n d lu br ica t es ever y in t a ke lobe r ocker
t h r ou gh a dr illed pa ssa ge in t h e in t a ke lobe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use special tool 8350
-
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Rem ove t h e cylin der h ea d cover s (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(2) Set en gin e t o TDC cylin der #1, ca m sh a ft
spr ocket V8 m a r ks a t t h e 12 o’clock posit ion .
(3) Ma r k on e lin k on t h e secon da r y t im in g ch a in
on bot h sides of t h e V8 m a r k on t h e ca m sh a ft
spr ocket t o a id in in st a lla t ion .
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen bu t D O N OT r em ove t h e ca m sh a ft
spr ocket r et a in in g bolt . Lea ve bolt sn u g a ga in st
spr ocket .
-
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
WJ ENGINE - 4.7L 9 - 101
CAM SH AFT (S) - RI GH T (Cont inue d)
(5) P osit ion Specia l Tool 8350 t im in g ch a in wedge
bet ween t h e t im in g ch a in st r a n ds. Ta p t h e t ool t o
secu r ely wedge t h e t im in g ch a in a ga in st t h e t en -
sion er a r m a n d gu ide (F ig. 31).
(6) Rem ove t h e ca m sh a ft posit ion sen sor (F ig. 32).

NOTE: When gripping the camshaft, place the pliers

on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.

(7) H old t h e ca m sh a ft wit h a dju st a ble plier s wh ile

r em ovin g t h e ca m sh a ft spr ocket bolt a n d spr ocket
(F ig. 33).
(8) Usin g t h e plier s, gen t ly a llow t h e ca m sh a ft t o
r ot a t e 45° cou n t er-clockwise u n t il t h e ca m sh a ft is in
t h e n eu t r a l posit ion (n o va lve loa d).
(9) St a r t in g a t t h e ou t side wor kin g in wa r d, loosen
t h e ca m sh a ft bea r in g ca p r et a in in g bolt s 1/2 t u r n a t
a t im e. Repea t u n t il a ll loa d is off t h e bea r in g ca ps.

CAUTION: DO NOT STAMP OR STRIKE THE CAM-

SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS. Fig. 32 Camshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
NOTE: When the camshaft is removed the rocker 3 - CAMSHAFT POSITION SENSOR
arms may slide downward, mark the rocker arms 4 - RIGHT SIDE CYLINDER BLOCK
before removing camshaft.

(10) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e

ca m sh a ft .

Fig. 31 Securing Timing Chain Tensioners Using Timing Chain Wedge

1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE
2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE
9 - 102 ENGINE - 4.7L WJ
CAM SH AFT (S) - RI GH T (Cont inue d)

Fig. 33 Camshaft Sprocket and Chain Fig. 34 Camshaft Bearing Caps Tightening
1 - ADJUSTABLE PLIERS Sequence
2 - SPROCKET BOLT
3 - CAMSHAFT SPROCKET AND CHAIN NOTE: When gripping the camshaft, place the pliers
4 - CAMSHAFT on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.

INSTALLATION (7) Usin g t h e a dju st a ble plier s, r ot a t e t h e ca m -

(1) Lu br ica t e ca m sh a ft jou r n a ls wit h clea n en gin e
oil.
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 o’clock
position, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) P osit ion t h e ca m sh a ft in t o t h e cylin der h ea d.
(3) In st a ll t h e ca m sh a ft bea r in g ca ps, h a n d t igh t en
t h e r et a in in g bolt s.
(4) Wor kin g in 1/2 t u r n in cr em en t s, t igh t en t h e
bea r in g ca p r et a in in g bolt s st a r t in g wit h t h e m iddle
ca p wor kin g ou t wa r d (F ig. 34).
(5) Tor qu e t h e ca m sh a ft bea r in g ca p r et a in in g
bolt s t o 11 N·m (100 in . lbs.).
(6) P osit ion t h e ca m sh a ft dr ive gea r in t o t h e t im -
in g ch a in a lign in g t h e V8 m a r k bet ween t h e t wo
m a r ked ch a in lin ks (Two lin ks m a r ked du r in g
r em ova l) (F ig. 35).
sh a ft u n t il t h e ca m sh a ft spr ocket dowel is a lign ed
wit h t h e slot in t h e ca m sh a ft spr ocket . In st a ll t h e
spr ocket on t o t h e ca m sh a ft (F ig. 36).
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Rem ove excess oil fr om ca m sh a ft spr ocket bolt ,
t h en in st a ll t h e ca m sh a ft spr ocket r et a in in g bolt a n d
h a n d t igh t en .
(9) Rem ove t im in g ch a in wedge specia l t ool 8350
(F ig. 31).
(10) Usin g Specia l Tool 6958 spa n n er wr en ch wit h
a da pt er pin s 8346 (F ig. 37), t or qu e t h e ca m sh a ft
spr ocket r et a in in g bolt t o 122 N·m (90 ft . lbs.).
(11) In st a ll t h e ca m sh a ft posit ion sen sor (F ig. 32).
(12) In st a ll t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).
WJ ENGINE - 4.7L 9 - 103
CAM SH AFT (S) - RI GH T (Cont inue d)

Fig. 35 Timing Chain to Sprocket Alignment

1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD

Fig. 37 Tightening Right Side Cam Sprocket

Retaining Bolt
1 - TORQUE WRENCH
Fig. 36 Camshaft Sprocket Installation 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
1 - ADJUSTABLE PLIERS 3 - LEFT CAMSHAFT SPROCKET
2 - CAMSHAFT DOWEL 4 - RIGHT CAMSHAFT SPROCKET
9 - 104 ENGINE - 4.7L
CY LI N DER H EAD COV ER(S) -
RI GH T
DESCRIPTION
Th e cylin der h ea d cover s a r e m a de of die ca st m a g-
n esiu m , a n d a r e n ot in t er ch a n gea ble fr om side-t o-
side. It is im per a t ive t h a t n ot h in g r est on t h e
cylin der h ea d cover s. P r olon ged con t a ct wit h ot h er
it em s m a y wea r a h ole in t h e cylin der h ea d cover.
REMOVAL - RIGHT SIDE
(1) Discon n ect ba t t er y n ega t ive ca ble.
(2) Rem ove a ir clea n er a ssem bly, r eson a t or a ssem -
bly a n d a ir in let h ose.
(3) Dr a in coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(4) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(5) Rem ove a ir con dit ion in g com pr essor r et a in in g
bolt s a n d m ove com pr essor t o t h e left .
(6) Rem ove h ea t er h oses.
(7) Discon n ect in ject or a n d ign it ion coil con n ect or s.
(8) Discon n ect a n d r em ove posit ive cr a n kca se ven -
t ila t ion (P CV) h ose.
(9) Rem ove oil fill t u be.
(10) Un -clip in ject or a n d ign it ion coil h a r n ess a n d
m ove a wa y fr om cylin der h ea d cover.
(11) Rem ove r igh t r ea r br ea t h er t u be a n d filt er
a ssem bly.
(12) Rem ove cylin der h ea d cover r et a in in g bolt s.
(13) Rem ove cylin der h ea d cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Clea n cylin der h ea d cover ga sket su r fa ce.
Clea n h ea d r a il, if n ecessa r y.
INSTALLATION - RIGHT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clea n cylin der h ea d cover a n d bot h sea lin g su r-
fa ces. In spect a n d r epla ce ga sket a s n ecessa r y.
WJ
(2) In st a ll cylin der h ea d cover a n d h a n d st a r t a ll
fa st en er s. Ver ify t h a t a ll dou ble en ded st u ds a r e in
t h e cor r ect loca t ion sh own in (F ig. 38).
Fig. 38 Cylinder Head Cover—Right
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N·m (105 in. lbs.)
(3) Tigh t en cylin der h ea d cover bolt s a n d dou ble
en ded st u ds t o 12 N·m (105 in . lbs).
(4) In st a ll r igh t r ea r br ea t h er t u be a n d filt er
a ssem bly.
(5) Con n ect in ject or, ign it ion coil elect r ica l con n ec-
t or s a n d h a r n ess r et a in in g clips.
(6) In st a ll t h e oil fill t u be.
(7) In st a ll P CV h ose.
(8) In st a ll h ea t er h oses.
(9) In st a ll a ir con dit ion in g com pr essor r et a in in g
bolt s.
(10) In st a ll a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(11) F ill Coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(12) In st a ll a ir clea n er a ssem bly, r eson a t or a ssem -
bly a n d a ir in let h ose.
(13) Con n ect ba t t er y n ega t ive ca ble.
I N TAK E/EX H AU ST VALV ES &
SEAT S
DESCRIPTION
Th e va lves a r e m a de of h ea t r esist a n t st eel a n d
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. E a ch
va lve is a ct u a t ed by a r oller r ocker a r m wh ich pivot s
on a st a t ion a r y la sh a dju st er. All va lves u se t h r ee
bea d lock keeper s t o r et a in t h e spr in gs a n d pr om ot e
va lve r ot a t ion .
WJ ENGINE - 4.7L 9 - 105
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)

STANDARD PROCEDURE—REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.

NOTE: When refacing valves and valve seats, it is

important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.

(1) Usin g a su it a ble dia l in dica t or m ea su r e t h e

cen t er of t h e va lve sea t Tot a l r u n ou t m u st n ot
exceed 0.051 m m (0.002 in ).
(2) Apply a sm a ll a m ou n t of P r u ssia n blu e t o t h e
va lve sea t , in ser t t h e va lve in t o t h e cylin der h ea d,
wh ile a pplyin g ligh t pr essu r e on t h e va lve r ot a t e t h e
va lve. Rem ove t h e va lve a n d exa m in e t h e va lve fa ce.
If t h e blu e is t r a n sfer r ed below t h e t op edge of t h e
va lve fa ce, lower t h e va lve sea t u sin g a 15 degr ee
st on e. If t h e blu e is t r a n sfer r ed t o t h e bot t om edge of Fig. 39 Valve Assembly Configuration
t h e va lve fa ce, r a ise t h e va lve sea t u sin g a 65 degr ee 1 - VALVE LOCKS (3–BEAD)
st on e. 2 - RETAINER
(3) Wh en t h e sea t is pr oper ly posit ion ed t h e widt h 3 - VALVE STEM OIL SEAL
of t h e in t a ke sea t m u st be 1.75 – 2.36 m m (0.0689 – 4 - INTAKE VALVE
0.0928 in .) a n d t h e exh a u st sea t m u st be 1.71 – 2.32 5 - EXHAUST VALVE
m m (0.0673 – 0.0911 in .). 6 - VALVE SPRING
(4) Ch eck t h e va lve spr in g in st a lled h eigh t a ft er
r efa cin g t h e va lve a n d sea t . Th e in st a lled h eigh t for
bot h in t a ke a n d exh a u st va lve spr in gs m u st n ot
exceed 41.44 m m (1.6315 in .).
(5) Th e va lve sea t a n d va lve fa ce m u st m a in t a in a
fa ce a n gle of 44.5 – 45 degr ees a n gle (F ig. 39).

REMOVAL
NOTE: The cylinder heads must be removed in
order to preform this procedure.

(1) Rem ove r ocker a r m s a n d la sh a dju st er s. Refer

t o pr ocedu r es in t h is sect ion (F ig. 40).
(2) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e
ca m sh a ft .

NOTE: All eight valve springs and valves are

removed in the same manner; this procedure only
covers one valve and valve spring.

(3) Usin g Specia l Tool C-3422–B or C-3422–C

Va lve Spr in g Com pr essor a n d Specia l t ool 8519
Ada pt er, com pr ess t h e va lve spr in g.
Fig. 40 Rocker Arm Removal
NOTE: It may be necessary to tap the top of the 1 - CAMSHAFT
valve spring to loosen the spring retainers locks 2 - SPECIAL TOOL 8516
enough to be removed.
9 - 106 ENGINE - 4.7L WJ
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
(4) Rem ove t h e t wo spr in g r et a in er lock h a lves.

NOTE: the valve spring is under tension use care

when releasing the valve spring compressor.

(5) Rem ove t h e va lve spr in g com pr essor.

(6) Rem ove t h e spr in g r et a in er, a n d t h e spr in g.

NOTE: Check for sharp edges on the keeper

grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.

(7) Rem ove t h e va lve fr om t h e cylin der h ea d.

NOTE: The valve stem seals are common between

intake and exhaust.

(8) Rem ove t h e va lve st em sea l. Ma r k t h e va lve for Fig. 41 Testing Valve Springs
pr oper in st a lla t ion . 1 - SPECIAL TOOL C-647

TESTING VALVE SPRINGS

NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.

In spect t h e va lve spr in gs for ph ysica l sign s of wea r

or da m a ge. Tu r n t a ble of t ool C-647 u n t il su r fa ce is
in lin e wit h t h e 40.69 m m (1.602 in .) m a r k on t h e
t h r ea ded st u d a n d t h e zer o m a r k on t h e fr on t . P la ce
spr in g over t h e st u d on t h e t a ble a n d lift com pr ess-
in g lever t o set t on e device. P u ll on t or qu e wr en ch
u n t il P in g is h ea r d. Ta ke r ea din g on t or qu e wr en ch
a t t h is in st a n t . Mu lt iply t h is r ea din g by t wo. Th is
will give t h e spr in g loa d a t t est len gt h . F r a ct ion a l
m ea su r em en t s a r e in dica t ed on t h e t a ble for fin er
a dju st m en t s. Refer t o Specifica t ion s Sect ion t o obt a in
specified h eigh t a n d a llowa ble t en sion s. Repla ce a n y
spr in gs t h a t do n ot m eet specifica t ion s. (F ig. 41)

INSTALLATION
(1) coa t t h e va lve st em wit h clea n en gin e oil a n d
in ser t it in t o t h e cylin der h ea d. Fig. 42 Valve Assembly Configuration
(2) In st a ll t h e va lve st em sea l. m a ke su r e t h e sea l 1 - VALVE LOCKS (3–BEAD)
is fu lly sea t ed a n d t h a t t h e ga r t er spr in g a t t h e t op 2 - RETAINER
of t h e sea l is in t a ct . 3 - VALVE STEM OIL SEAL
(3) In st a ll t h e spr in g a n d t h e spr in g r et a in er (F ig. 4 - INTAKE VALVE
42). 5 - EXHAUST VALVE
(4) Usin g t h e va lve spr in g com pr essor, com pr ess 6 - VALVE SPRING
t h e spr in g a n d in st a ll t h e t wo va lve spr in g r et a in er
h a lves. (6) lu br ica t e t h e ca m sh a ft jou r n a l wit h clea n
(5) Relea se t h e va lve spr in g com pr essor a n d m a ke en gin e oil t h en P osit ion t h e ca m sh a ft (wit h t h e
su r e t h e t wo spr in g r et a in er h a lves a n d t h e spr in g spr ocket dowel on t h e left ca m sh a ft a t 11 o’clock a n d
r et a in er a r e fu lly sea t ed. t h e r igh t ca m sh a ft a t 12 o’clock), t h en posit ion t h e
ca m sh a ft bea r in g ca ps.
WJ
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
(7) In st a ll t h e ca m sh a ft bea r in g ca p r et a in in g
bolt s. Tigh t en t h e bolt s 9–13 N·m (100 in . lbs.) in 1 ⁄2
t u r n in cr em en t s in t h e sequ en ce sh own (F ig. 43).
Fig. 43 Camshaft Bearing Caps Tightening
Sequence
(8) P osit ion t h e h ydr a u lic la sh a dju st er s and
r ocker a r m s (F ig. 40).
ROCK ER ARM / ADJ U ST ER
ASSEM BLY
DESCRIPTION
Th e r ocker a r m s a r e st eel st a m pin gs wit h a n in t e-
gr a l r oller bea r in g. Th e r ocker a r m s in cor por a t e a 2.8
m m (0.11 in ch ) oil h ole in t h e la sh a dju st er socket for
r oller a n d ca m sh a ft lu br ica t ion .
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(1) Rem ove t h e cylin der h ea d cover (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(2) F or r ocker a r m r em ova l on cylin der s 3 a n d 5
Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
exh a u st st r oke.
(3) F or r ocker a r m r em ova l on cylin der s 2 a n d 8
Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
com pr ession st r oke.
ENGINE - 4.7L 9 - 107
(4) F or r ocker a r m r em ova l on cylin der s 4 a n d 6
Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC
com pr ession st r oke.
(5) F or r ocker a r m r em ova l on cylin der s 1 a n d 7
Rot a t e t h e cr a n ksh a ft u n t il cylin der #2 is a t TDC
com pr ession st r oke.
(6) Usin g specia l t ool 8516 Rocker Ar m Rem over,
pr ess down wa r d on t h e va lve spr in g, r em ove r ocker
a r m (F ig. 44).
Fig. 44 Rocker Arm—Removal
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) F or r ocker a r m in st a lla t ion on cylin der s 3 a n d
5 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
exh a u st st r oke.
(2) F or r ocker a r m in st a lla t ion on cylin der s 2 a n d
8 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
com pr ession st r oke.
(3) F or r ocker a r m in st a lla t ion on cylin der s 4 a n d
6 Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC
com pr ession st r oke.
9 - 108 ENGINE - 4.7L WJ
ROCK ER ARM / ADJ U ST ER ASSEM BLY (Cont inue d)
(4) F or r ocker a r m in st a lla t ion on cylin der s 1 a n d CAUTION: DO NOT use rigid type hones to remove
7 Rot a t e t h e cr a n ksh a ft u n t il cylin der #2 is a t TDC cylinder wall glaze.
com pr ession st r oke.
(5) Usin g specia l t ool 8516 pr ess down wa r d on t h e (2) Degla zin g of t h e cylin der wa lls m a y be don e if
va lve spr in g, in st a ll r ocker a r m (F ig. 44). t h e cylin der bor e is st r a igh t a n d r ou n d. Use a cylin -
(6) In st a ll t h e cylin der h ea d cover (Refer t o 9 - der su r fa cin g h on e, H on in g Tool C-3501, equ ipped
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD wit h 280 gr it st on es (C-3501-3810). a bou t 20-60
COVE R(S) - INSTALLATION). st r okes, depen din g on t h e bor e con dit ion , will be su f-
ficien t t o pr ovide a sa t isfa ct or y su r fa ce. Usin g h on in g
oil C-3501-3880, or a ligh t h on in g oil, a va ila ble fr om
VALV E SPRI N GS m a jor oil dist r ibu t or s.

DESCRIPTION CAUTION: DO NOT use engine or transmission oil,

Th e va lve spr in gs a r e m a de fr om h igh st r en gt h mineral spirits, or kerosene.
ch r om e silicon st eel. Th e spr in gs a r e com m on for
(3) H on in g sh ou ld be don e by m ovin g t h e h on e u p
in t a ke a n d exh a u st a pplica t ion s. Th e va lve spr in g
a n d down fa st en ou gh t o get a cr ossh a t ch pa t t er n .
sea t is in t egr a l wit h t h e va lve st em sea l, wh ich is a
Th e h on e m a r ks sh ou ld INTE RSE CT a t 50° t o 60°
posit ive t ype sea l t o con t r ol lu br ica t ion .
for pr oper sea t in g of r in gs (F ig. 45).

VALV E ST EM SEALS
DESCRIPTION
Th e va lve st em sea ls a r e m a de of r u bber a n d in cor-
por a t e a n in t egr a l st eel va lve spr in g sea t . Th e in t e-
gr a l ga r t er spr in g m a in t a in s con sist en t lu br ica t ion
con t r ol t o t h e va lve st em s.

EN GI N E BLOCK
DESCRIPTION
Th e cylin der block is m a de of ca st ir on . Th e block
is a closed deck design wit h t h e left ba n k for wa r d. To
pr ovide h igh r igidit y a n d im pr oved NVH a n
en h a n ced com pa ct ed gr a ph it e bedpla t e is bolt ed t o
t h e block. Th e block design a llows coola n t flow
bet ween t h e cylin der s bor es, a n d a n in t er n a l coola n t
bypa ss t o a sin gle poppet in let t h er m ost a t is in clu ded
in t h e ca st a lu m in u m fr on t cover.

STANDARD PROCEDURE—CYLINDER BORE Fig. 45 Cylinder Bore Crosshatch Pattern

HONING
Befor e h on in g, st u ff plen t y of clea n sh op t owels
u n der t h e bor es a n d over t h e cr a n ksh a ft t o keep
a br a sive m a t er ia ls fr om en t er in g t h e cr a n ksh a ft
a r ea .
(1) Used ca r efu lly, t h e Cylin der Bor e Sizin g H on e
C-823, equ ipped wit h 220 gr it st on es, is t h e best t ool
for t h is job. In a ddit ion t o degla zin g, it will r edu ce
t a per a n d ou t -of-r ou n d, a s well a s r em ovin g ligh t
scu ffin g, scor in g a n d scr a t ch es. Usu a lly, a few st r okes
will clea n u p a bor e a n d m a in t a in t h e r equ ir ed lim -
it s.
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
(4) A con t r olled h on e m ot or speed bet ween 200 a n d
300 RP M is n ecessa r y t o obt a in t h e pr oper cr oss-
h a t ch a n gle. Th e n u m ber of u p a n d down st r okes per
m in u t e ca n be r egu la t ed t o get t h e desir ed 50° t o 60°
a n gle. F a st er u p a n d down st r okes in cr ea se t h e cr oss-
h a t ch a n gle.
(5) Aft er h on in g, it is n ecessa r y t h a t t h e block be
clea n ed t o r em ove a ll t r a ces of a br a sive. Use a br u sh
t o wa sh pa r t s wit h a solu t ion of h ot wa t er a n d det er-
gen t . Dr y pa r t s t h or ou gh ly. Use a clea n , wh it e, lin t -
WJ
EN GI N E BLOCK (Cont inue d)
fr ee clot h t o ch eck t h a t t h e bor e is clea n . Oil t h e
bor es a ft er clea n in g t o pr even t r u st in g.
CLEANING
Th or ou gh ly clea n t h e oil pa n a n d en gin e block ga s-
ket su r fa ces.
Use com pr essed a ir t o clea n ou t :
• Th e ga lley a t t h e oil filt er a da pt or h ole.
• Th e fr on t a n d r ea r oil ga lley h oles.
• Th e feed h oles for t h e cr a n ksh a ft m a in bea r in gs.
On ce t h e block h a s been com plet ely clea n ed, a pply
Loct it e P ST pipe sea la n t wit h Teflon 592 t o t h e
t h r ea ds of t h e fr on t a n d r ea r oil ga lley plu gs. Tigh t en
t h e plu gs t o 34 N·m (25 ft . lbs.) t or qu e.
INSPECTION
(1) It is m a n da t or y t o u se a dia l bor e ga u ge t o
m ea su r e ea ch cylin der bor e dia m et er. To cor r ect ly
select t h e pr oper size pist on , a cylin der bor e ga u ge,
ca pa ble of r ea din g in 0.003 m m (.0001 in .) INCRE -
ME NTS is r equ ir ed. If a bor e ga u ge is n ot a va ila ble,
do n ot u se a n in side m icr om et er (F ig. 46).
Fig. 46 Bore Gauge—Typical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
(2) Mea su r e t h e in side dia m et er of t h e cylin der
bor e a t t h r ee levels below t op of bor e. St a r t per pen -
dicu la r (a cr oss or a t 90 degr ees) t o t h e a xis of t h e
cr a n ksh a ft a n d t h en t a ke t wo a ddit ion a l r ea din g.
ENGINE - 4.7L 9 - 109
(3) Mea su r e t h e cylin der bor e dia m et er cr osswise
t o t h e cylin der block n ea r t h e t op of t h e bor e. Repea t
t h e m ea su r em en t n ea r t h e m iddle of t h e bor e, t h en
r epea t t h e m ea su r em en t n ea r t h e bot t om of t h e bor e.
(4) Det er m in e t a per by su bt r a ct in g t h e sm a ller
dia m et er fr om t h e la r ger dia m et er.
(5) Rot a t e m ea su r in g device 90° a n d r epea t st eps
a bove.
(6) Det er m in e ou t -of-r ou n dn ess by com pa r in g t h e
differ en ce bet ween ea ch m ea su r em en t .
(7) If cylin der bor e t a per does n ot exceed 0.025
m m (0.001 in ch ) a n d ou t -of-r ou n dn ess does n ot
exceed 0.025 m m (0.001 in ch ), t h e cylin der bor e ca n
be h on ed. If t h e cylin der bor e t a per or ou t - of-r ou n d
con dit ion exceeds t h ese m a xim u m lim it s, t h e cylin der
block m u st be r epla ced. A sligh t a m ou n t of t a per
a lwa ys exist s in t h e cylin der bor e a ft er t h e en gin e
h a s been in u se for a per iod of t im e.
CON N ECT I N G ROD BEARI N GS
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
In spect t h e con n ect in g r od bea r in gs for scor in g a n d
ben t a lign m en t t a bs (F ig. 47) (F ig. 48). Ch eck t h e
bea r in gs for n or m a l wea r pa t t er n s, scor in g, gr oovin g,
fa t igu e a n d pit t in g (F ig. 49). Repla ce a n y bea r in g
t h a t sh ows a bn or m a l wea r.
In spect t h e con n ect in g r od jou r n a ls for sign s of
scor in g, n icks a n d bu r r s.
Misa lign ed or ben t con n ect in g r ods ca n ca u se
a bn or m a l wea r on pist on s, pist on r in gs, cylin der
wa lls, con n ect in g r od bea r in gs a n d cr a n ksh a ft con -
n ect in g r od jou r n a ls. If wea r pa t t er n s or da m a ge t o
a n y of t h ese com pon en t s in dica t e t h e pr oba bilit y of a
m isa lign ed con n ect in g r od, in spect it for cor r ect r od
a lign m en t . Repla ce m isa lign ed, ben t or t wist ed con -
n ect in g r ods.
(1) Wipe t h e oil fr om t h e con n ect in g r od jou r n a l.
(2) Lu br ica t e t h e u pper bea r in g in ser t a n d in st a ll
in con n ect in g r od.
(3) Use pist on r in g com pr essor a n d Gu ide P in s
Specia l Tool 8507 (F ig. 50) t o in st a ll t h e r od a n d pis-
t on a ssem blies. Th e oil slin ger slot s in t h e r ods m u st
fa ce fr on t of t h e en gin e. Th e “F ”’s n ea r t h e pist on
wr ist pin bor e sh ou ld poin t t o t h e fr on t of t h e en gin e.
(4) In st a ll t h e lower bea r in g in ser t in t h e bea r in g
ca p. Th e lower in ser t m u st be dr y. P la ce st r ip of P la s-
t iga ge a cr oss fu ll widt h of t h e lower in ser t a t t h e cen -
t er of bea r in g ca p. P la st iga ge m u st n ot cr u m ble in
u se. If br it t le, obt a in fr esh st ock.
(5) In st a ll bea r in g ca p a n d con n ect in g r od on t h e
jou r n a l a n d t igh t en bolt s t o 27 N·m (20 ft . lbs.) plu s a
90° t u r n . DO NOT r ot a t e cr a n ksh a ft . P la st iga ge will
sm ea r, r esu lt in g in in a ccu r a t e in dica t ion .
9 - 110 ENGINE - 4.7L
CON N ECT I N G ROD BEARI N GS (Cont inue d)
Fig. 47 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN — ALWAYS GREATER ON UPPER
BEARING
Fig. 48 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
(6) Rem ove t h e bea r in g ca p a n d det er m in e a m ou n t
of bea r in g-t o-jou r n a l clea r a n ce by m ea su r in g t h e
widt h of com pr essed P la st iga ge (F ig. 51). Refer t o
E n gin e Specifica t ion s for t h e pr oper clea r a n ce. P la s -
tig a g e s h o u ld in d ic a te th e s a m e c le a ra n c e
a c ro s s th e e n tire w id th o f th e in s e rt. If th e
c le a ra n c e v a rie s , it m a y be c a u s e d by e ith e r a
WJ
Fig. 49 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 50 Piston and Connecting Rod - Installation
1 - “F” TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
4 - SPECIAL TOOL 8507
ta p e re d jo u rn a l, be n t c o n n e c tin g ro d o r fo re ig n
m a te ria l tra p p e d be tw e e n th e in s e rt a n d c a p o r
ro d .
(7) If t h e cor r ect clea r a n ce is in dica t ed, r epla ce-
m en t of t h e bea r in g in ser t s is n ot n ecessa r y. Rem ove
t h e P la st iga ge fr om cr a n ksh a ft jou r n a l a n d bea r in g
in ser t . P r oceed wit h in st a lla t ion .
(8) If bea r in g-t o-jou r n a l clea r a n ce exceeds t h e
specifica t ion , det er m in wh ich ser vices bea r in g set t o
u se t h e bea r in g sizes a r e a s follows:
WJ ENGINE - 4.7L 9 - 111
CON N ECT I N G ROD BEARI N GS (Cont inue d)

Fig. 51 Measuring Bearing Clearance with Fig. 52 Checking Connecting Rod Side Clearance -
Plastigage Typical
1 - PLASTIGAGE SCALE of t h e cr a n ksh a ft a r e cr oss dr illed t o im pr ove r od
2 - COMPRESSED PLASTIGAGE bea r in g lu br ica t ion . Th e n u m ber eigh t cou n t er weigh t
h a s pr ovision s for cr a n ksh a ft posit ion sen sor t a r get
Bearing SIZE USED WITH wh eel m ou n t in g. Th e select fit m a in bea r in g m a r k-
Mark in gs a r e loca t ed on t h e r ea r side of t h e t a r get wh eel.
Th e cr a n ksh a ft oil sea ls a r e on e piece design . Th e
JOURNAL SIZE fr on t oil sea l is r et a in ed in t h e t im in g ch a in cover,
a n d t h e r ea r sea l is pr essed in t o a bor e for m ed by
.025 US .025 mm 50.983-50.967 mm
t h e cylin der block a n d t h e bedpla t e a ssem bly.
(.001 in.) (2.0073-2.0066 in.)

Std. STANDARD 50.992-51.008 mm

STANDARD PROCEDURE - MEASURING
(2.0076-2.0082 in.)
CRANKSHAFT END PLAY
(1) Mou n t a dia l in dica t or t o fr on t of en gin e wit h
.250 US .250 mm 50.758-50.742 mm t h e loca t in g pr obe on n ose of cr a n ksh a ft (F ig. 53).
(2) Move cr a n ksh a ft a ll t h e wa y t o t h e r ea r of it s
(.010 in.) (1.9984-1.9978 in.)
t r a vel.
(9) Repea t t h e P la st iga ge m ea su r em en t t o ver ify (3) Zer o t h e dia l in dica t or.
you r bea r in g select ion pr ior t o fin a l a ssem bly. (4) Move cr a n ksh a ft a ll t h e wa y t o t h e fr on t a n d
(10) On ce you h a ve select ed t h e pr oper in ser t , r ea d t h e dia l in dica t or. (Refer t o 9 - E NGINE -
in st a ll t h e in ser t a n d ca p. Tigh t en t h e con n ect in g r od SP E CIF ICATIONS) for en d pla y specifica t ion .
bolt s t o 27 N·m (20 ft . lbs.) plu s a 90° t u r n .
Slide sn u g-fit t in g feeler ga u ge bet ween t h e con -
n ect in g r od a n d cr a n ksh a ft jou r n a l fla n ge (F ig. 52).
Refer t o E n gin e Specifica t ion s for t h e pr oper clea r-
a n ce. Repla ce t h e con n ect in g r od if t h e side clea r a n ce
is n ot wit h in specifica t ion .

CRAN K SH AFT
DESCRIPTION
Th e 4.7L cr a n ksh a ft is con st r u ct ed of n odu la r ca st
ir on . Th e cr a n ksh a ft for t h e 4.7L H .O. is con st r u ct ed
of fo rg e d s te e l. Th e cr a n ksh a ft is a cr oss sh a ped
fou r t h r ow design wit h eigh t cou n t er weigh t s for ba l-
a n cin g pu r poses. Th e cr a n ksh a ft is su ppor t ed by five
select fit m a in bea r in gs wit h t h e n u m ber t h r ee ser v- Fig. 53 Checking Crankshaft End Play—Typical
in g a s t h e t h r u st wa sh er loca t ion . Th e m a in jou r n a ls
9 - 112 ENGINE - 4.7L WJ
CRAN K SH AFT (Cont inue d)

REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.

(1) Rem ove t h e en gin e. (Refer t o 9 - E NGINE -

RE MOVAL).
(2) Rem ove t h e en gin e oil pu m p.(Refer t o 9 -
E NGINE /LUBRICATION/OIL P UMP - RE MOVAL).

CAUTION: DO NOT pry on the oil pan gasket when

removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.

(3) Rem ove oil pa n . (Refer t o 9 - E NGINE /LUBRI-

CATION/OIL PAN - RE MOVAL).
(4) Rem ove t h e oil pu m p picku p t u be a n d oil pa n
ga sket /win da ge t r a y.
(5) Rem ove t h e bedpla t e m ou n t in g bolt s. Not e t h e
loca t ion of t h e t h r ee st u d bolt s for in st a lla t ion .
(6) Rem ove t h e con n ect in g r ods fr om t h e cr a n k-
sh a ft .

CAUTION: The bedplate to cylinder block mating Fig. 54 Bedplate Pry Point Location
surface is a critical sealing surface. Do not pry on 1 - CYLINDER BLOCK
or damage this surface in anyway. 2 - BEDPLATE
3 - PRY POINT

NOTE: The bedplate contains the lower main bear-

ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are on both the
left and right sides, only the left side is shown.
(7) Ca r efu lly pr y on t h e pr y poin t s (F ig. 54) t o
loosen t h e bedpla t e t h en r em ove t h e bedpla t e.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Rem ove t h e cr a n ksh a ft .
(9) Rem ove t h e cr a n ksh a ft t a r get wh eel.
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
If con n ect in g r od bea r in g bor es sh ow da m a ge, t h e
cylin der h ea ds m u st be r em oved t o ser vice t h e pist on
a n d r od a ssem blies. If t h e bedpla t e or t h e cylin der
block m a in bea r in g bor es sh ow da m a ge t h e en gin e
m u st be r epla ced.
(1) If r equ ir ed, r em ove t h e m a in bea r in g h a lves
fr om t h e cylin der block a n d bedpla t e.
(2) Th or ou gh ly clea n t h e bedpla t e t o cylin der block
sea lin g su r fa ces a n d m a in bea r in g bor es. Rem ove a ll
oil a n d sea la n t r esidu e.
(3) In spect t h e bedpla t e m a in bea r in g bor es for
cr a cks, scor in g or sever e blu ein g. If eit h er con dit ion
exist s t h e en gin e m u st be r epla ced.
(4) In spect t h e cr a n ksh a ft t h r u st wa sh er s for scor-
in g, scr a t ch es, wea r or blu ein g. If eit h er con dit ion
exist r epla ce t h e t h r u st wa sh er.
(5) In spect t h e oil pa n ga sket /win da ge t r a y for
split s, t ea r s or cr a cks in t h e ga sket sea lin g su r fa ces.
Repla ce ga sket a s n ecessa r y.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
WJ ENGINE - 4.7L 9 - 113
CRAN K SH AFT (Cont inue d)
(1) Lu br ica t e u pper m a in bea r in g h a lves wit h
clea n en gin e oil.

CAUTION: When installing crankshaft, use care not

to damage bearing surfaces on the crankshaft.

NOTE: Apply sealant to the target wheel retaining

screws prior to installation.

(2) In st a ll t h e cr a n ksh a ft t a r get wh eel. Tor qu e t h e

m ou n t in g scr ews t o 22 N·m (21 ft . lbs.).
(3) P osit ion cr a n ksh a ft in cylin der block.
(4) In st a ll t h e t h r u st wa sh er s (F ig. 55).

Fig. 56 Cutting Aplicator to Achieve 2.5mm (0.100

in.) Bead
1 - CUT HERE

Fig. 55 Crankshaft Thrust Washer Installation

1 - CRANKSHAFT THRUST WASHER

CAUTION: The bedplate to cylinder block mateing

surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks. Fig. 57 Cylinder Block-to-Bedplate Sealent Bead
Location
1 - CYLINDER BLOCK
NOTE: The installation time to install the bedplate
2 - SEALANT BEAD LOCATION
after the sealant has been applied is critical.

(6) Coa t t h e cr a n ksh a ft m a in bea r in g jou r n a ls

NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
wit h clea n en gin e oil a n d posit ion t h e bedpla t e on t o
t h e cylin der block.
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.

(5) Apply a 2.5m m (0.100 in ch ) (F ig. 56) bea d of
Mopa r ! Gen II Silicon e Ru bber Adh esive sea la n t t o
t h e cylin der block-t o-bedpla t e m a t in g su r fa ce a s
sh own (F ig. 57).
(7) In st a ll t h e bedpla t e r et a in in g bolt s, m a kin g
su r e t o pla ce t h e st u d bolt s in t h e cor r ect loca t ion ,
Tor qu e t h e bolt s in t h e sequ en ce sh own (F ig. 58).
• Tigh t en bolt s A – L t o 54 N·m (40 ft . lbs.)
• Tigh t en bolt s 1–10 t o 2.8 N·m (25 in . lbs.)
• Tu r n bolt s 1–10 a n a ddit ion a l 90°.
9 - 114 ENGINE - 4.7L
CRAN K SH AFT (Cont inue d)
Fig. 58 Bedplate Tightening Sequence
1 - BEDPLATE
2 - CYLINDER BLOCK
• Tigh t en bolt s A1– A6 t o 27 N·m (20 ft . lbs.)
(8) Mea su r e cr a n ksh a ft en d pla y. (Refer t o 9 -
E NGINE /E NGINE BLOCK/CRANKSH AF T - STAN-
DARD P ROCE DURE ).
(9) In st a ll t h e con n ect in g r ods a n d m ea su r e side
clea r a n ce. (Refer t o 9 - E NGINE /E NGINE BLOCK/
CONNE CTING ROD BE ARINGS - STANDARD
P ROCE DURE ).
(10) P osit ion t h e oil pa n ga sket /win da ge t r a y,
u sin g a n ew o-r in g, in st a ll t h e oil picku p t u be.
Tor qu e t h e bolt t o 28N·n (20 ft . lbs.) t or qu e t h e n u t s
t o 28N·m (20 ft . lbs.).
(11) In st a ll t h e oil pa n . Tor qu e t h e r et a in in g bolt s t o
15 N·m (11 ft . lbs.) in t h e sequ en ce sh own (F ig. 59).
Fig. 59 Oil Pan Tightening Sequence
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(12) In st a ll t h e en gin e (Refer t o 9 - E NGINE -
INSTALLATION).
CRAN K SH AFT M AI N
BEARI N GS
STANDARD PROCEDURE—CRANKSHAFT MAIN
BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Cr a n ksh a ft r em oved fr om t h e cylin der block.
Clea n t h e oil off t h e m a in bea r in g jou r n a l.
Det er m in e t h e m a xim u m dia m et er of t h e jou r n a l
wit h a m icr om et er. Mea su r e a t t wo loca t ion s 90°
a pa r t a t ea ch en d of t h e jou r n a l.
Th e m a xim u m a llowa ble t a per is 0.008m m (0.0004
in ch .) a n d m a xim u m ou t of r ou n d is 0.005m m (0.002
in ch ). Com pa r e t h e m ea su r ed dia m et er wit h t h e jou r-
n a l dia m et er specifica t ion (Ma in Bea r in g F it t in g
Ch a r t ). Select in ser t s r equ ir ed t o obt a in t h e specified
bea r in g-t o-jou r n a l clea r a n ce.
WJ ENGINE - 4.7L 9 - 115
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)
CRANKSHAFT MAIN BEARING SELECTION INSPECTION
Th e m a in bea r in gs a r e “select fit ” t o a ch ieve pr oper Wipe t h e in ser t s clea n a n d in spect for a bn or m a l
oil clea r a n ces. F or m a in bea r in g select ion , t h e cr a n k- wea r pa t t er n s a n d for m et a l or ot h er for eign m a t er ia l
sh a ft posit ion sen sor t a r get wh eel h a s gr a de iden t ifi- im bedded in t h e lin in g. Nor m a l m a in bea r in g in ser t
ca t ion m a r ks st a m ped in t o it (F ig. 60). Th ese m a r ks wea r pa t t er n s a r e illu st r a t ed (F ig. 61).
a r e r ea d fr om left t o r igh t , cor r espon din g wit h jou r-
n a l n u m ber 1, 2, 3, 4 a n d 5. Th e cr a n ksh a ft posit ion
sen sor t a r get wh eel is m ou n t ed t o t h e n u m ber 8
cou n t er weigh t on t h e cr a n ksh a ft .

Fig. 61 Main Bearing Wear Patterns

1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT

NOTE: If any of the crankshaft journals are scored,

Fig. 60 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
the crankshaft must be repaired or replaced.
In spect t h e ba ck of t h e in ser t s for fr a ct u r es, scr a p-
in gs or ir r egu la r wea r pa t t er n s.
In spect t h e u pper in ser t lockin g t a bs for da m a ge.
Repla ce a ll da m a ged or wor n bea r in g in ser t s.

M AI N BEARI N G SELECT I ON CH ART —4 .7 L

CRAN K SH AFT OI L SEAL -
FRON T
GRADE SIZE mm FOR USE WITH
(in.) REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
MARKING JOURNAL SIZE
(2) Rem ove a ccessor y dr ive belt (Refer t o 7 -
A 0.008 mm 63.488–63.496 mm COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
U/S RE MOVAL).
(3) Rem ove A/C com pr essor m ou n in g fa st en er s a n d
(0.0004 in.) (2.4996–2.4999 in.)
set a side.
U/S
(4) Dr a in coolin g syst em (Refer t o 7 - COOLING -
B NOMINAL 63.496–63.504 mm STANDARD P ROCE DURE ).
(5) Rem ove u pper r a dia t or h ose.
(2.4999–2.5002 in.) (6) Discon n ect elect r ica l con n ect or for fa n m ou n t ed
C 0.008 mm 63.504–63.512 mm in side r a dia t or sh r ou d.
O/S (7) Rem ove r a dia t or sh r ou d a t t a ch in g fa st en er s.
(0.0004 in.) (2.5002–2.5005 in.) NOTE: Transmission cooler line snaps into shroud
O/S lower right hand corner.
9 - 116 ENGINE - 4.7L WJ
CRAN K SH AFT OI L SEAL - FRON T (Cont inue d)
(8) Rem ove r a dia t or coolin g fa n a n d sh r ou d (Refer
t o 7 - COOLING/E NGINE /RADIATOR FAN -
RE MOVAL).
(9) Rem ove cr a n ksh a ft da m per bolt .
(10) Rem ove da m per u sin g Specia l Tools 8513
In ser t a n d 1026 Th r ee J a w P u ller (F ig. 62).

Fig. 63 Crankshaft Front Seal—Removal

1 - SPECIAL TOOL 8511

Fig. 62 Crankshaft Damper—Removal

1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026

(11) Usin g Specia l Tool 8511, r em ove cr a n ksh a ft

fr on t sea l (F ig. 63).

INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.

(1) Usin g Specia l Tool 8348 a n d 8512, in st a ll

cr a n ksh a ft fr on t sea l (F ig. 64).
(2) In st a ll vibr a t ion da m per (Refer t o 9 - E NGINE /
E NGINE BLOCK/VIBRATION DAMP E R - INSTAL-
LATION).
(3) In st a ll r a dia t or coolin g fa n a n d sh r ou d (Refer Fig. 64 Crankshaft Front Seal—Installation
t o 7 - COOLING/E NGINE /RADIATOR FAN - 1 - TIMING CHAIN COVER
INSTALLATION). 2 - SPECIAL TOOL 8348
(4) In st a ll u pper r a dia t or h ose. 3 - SPECIAL TOOL 8512
(5) In st a ll A/C com pr essor a n d t igh t en fa st en er s t o
54 N·m (40 ft . lbs.). (7) Refill coolin g syst em (Refer t o 7 - COOLING -
(6) In st a ll a ccessor y dr ive belt r efer (Refer t o 7 - STANDARD P ROCE DURE ).
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - (8) Con n ect n ega t ive ca ble t o ba t t er y.
INSTALLATION).
WJ ENGINE - 4.7L 9 - 117

CRAN K SH AFT OI L SEAL -

REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.

(1) If bein g pr efor m ed in veh icle, r em ove t h e

t r a n sm ission .
(2) Rem ove t h e flexpla t e (Refer t o 9 - E NGINE /
E NGINE BLOCK/F LE X P LATE - RE MOVAL).

NOTE: The crankshaft oil seal CAN NOT be reused

after removal.

NOTE: The crankshaft rear oil seal remover Special

Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Usin g Specia l Tool 8506 (F ig. 65), r em ove t h e
cr a n ksh a ft r ea r oil sea l.
Fig. 66 Crankshaft Rear Oil Seal Guide Special Tool
8349–2 and Oil
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349–2 GUIDE
t a p on t h e dr iver h a n dle u n t il t h e sea l in st a ller sea t s
a ga in st t h e cylin der block cr a n ksh a ft bor e.

Fig. 65 Crankshaft Rear Oil Seal Removal

1 - REAR CRANKSHAFT SEAL
Fig. 67 Crankshaft Rear Oil Seal Installation
2 - SPECIAL TOOL 8506
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349–1 INSTALLER
INSTALLATION 3 - SPECIAL TOOL C-4171 HANDLE
(1) P osit ion t h e m a gn et ic sea l gu ide Specia l Tool
8349–2 (F ig. 66) on t o t h e cr a n ksh a ft r ea r fa ce. Th en (3) In st a ll t h e flexpla t e.
posit ion t h e cr a n ksh a ft r ea r oil sea l on t o t h e gu ide. (4) In st a ll t h e t r a n sm ission .
(2) Usin g Specia l Tools 8349 Cr a n ksh a ft Rea r Oil
Sea l In st a ller a n d C-4171 Dr iver H a n dle (F ig. 67),
wit h a h a m m er, t a p t h e sea l in t o pla ce. Con t in u e t o
9 - 118 ENGINE - 4.7L
FLEX PLAT E
REMOVAL
(1) Rem ove t h e t r a n sm ission .
(2) Rem ove t h e bolt s a n d flexpla t e.
INSTALLATION
(1) P osit ion t h e flexpla t e on t o t h e cr a n ksh a ft a n d
in st a ll t h e bolt s h a n d t igh t .
(2) Tigh t en t h e flexpla t e r et a in in g bolt s t o 60 N·m
(45 ft . lbs.) in t h e sequ en ce sh own (F ig. 68).
(3) In st a ll t h e t r a n sm ission .
Fig. 68 Flexplate Tightening Sequence
1 - FLEXPLATE
PI ST ON & CON N ECT I N G ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
Th e pist on s a r e m a de of a h igh st r en gt h a lu m in u m
a lloy. Th e a n odized t op r in g gr oove a n d cr own h a s
been r epla ced wit h a coa t ed t op r in g t h a t is blu e in
color on t h e bot t om su r fa ce. P ist on skir t s a r e coa t ed
wit h a solid lu br ica n t (Molykot e) t o r edu ce fr ict ion
a n d pr ovide scu ff r esist a n ce. Th e con n ect in g r ods a r e
m a de of for ged powder ed m et a l, wit h a “fr a ct u r ed
ca p” design . A pr essed fit pist on pin is u sed t o a t t a ch
t h e pist on a n d con n ect in g r od on t h e 4.7L. Th e 4.7L
H O u ses a fu ll floa t in g pist on pin .
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STANDARD PROCEDURE—PISTON FITTING
(1) To cor r ect ly select t h e pr oper size pist on , a cyl-
in der bor e ga u ge, ca pa ble of r ea din g in 0.003 m m (
.0001 in .) INCRE ME NTS is r equ ir ed. If a bor e ga u ge
is n ot a va ila ble, do n ot u se a n in side m icr om et er.
(2) Mea su r e t h e in side dia m et er of t h e cylin der
bor e a t a poin t 38.0 m m (1.5 in ch es) below t op of
bor e. St a r t per pen dicu la r (a cr oss or a t 90 degr ees) t o
t h e a xis of t h e cr a n ksh a ft a t poin t A a n d t h en t a ke
a n a ddit ion a l bor e r ea din g 90 degr ees t o t h a t a t poin t
B (F ig. 70).
(3) Th e coa t ed pist on s will be ser viced wit h t h e
pist on pin a n d con n ect in g r od pr e-a ssem bled.
(4) Th e coa t in g m a t er ia l is a pplied t o t h e pist on
a ft er t h e fin a l pist on m a ch in in g pr ocess. Mea su r in g
t h e ou t side dia m et er of a coa t ed pist on will n ot pr o-
vide a ccu r a t e r esu lt s (F ig. 69). Th er efor e m ea su r in g
t h e in side dia m et er of t h e cylin der bor e wit h a dia l
Bor e Ga u ge is MAN D ATORY. To cor r ect ly select t h e
pr oper size pist on , a cylin der bor e ga u ge ca pa ble of
r ea din g in 0.003 m m (.0001 in .) in cr em en t s is
r equ ir ed.
(5) P ist on in st a lla t ion in t o t h e cylin der bor e
r equ ir es sligh t ly m or e pr essu r e t h a n t h a t r equ ir ed
for n on -coa t ed pist on s. Th e bon ded coa t in g on t h e
pist on will give t h e a ppea r a n ce of a lin e-t o-lin e fit
wit h t h e cylin der bor e.
Fig. 69 Moly Coated Piston—Typical
1 - MOLY COATED
2 - MOLY COATED
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove t h e followin g com pon en t s:
• Oil pa n a n d ga sket /win da ge t r a y (Refer t o 9 -
E NGINE /LUBRICATION/OIL PAN - RE MOVAL).
• Cylin der h ea d cover s (Refer t o 9 - E NGINE /
CYLINDE R H E AD/CYLINDE R H E AD COVE R(S) -
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PI ST ON & CON N ECT I N G ROD (Cont inue d)
Fig. 70 Bore Gauge—Typical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
RE MOVAL) a n d (Refer t o 9 - E NGINE /CYLINDE R
H E AD/CYLINDE R H E AD COVE R(S) - RE MOVAL).
• Tim in g ch a in cover (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT / CH AIN COVE R(S)
- RE MOVAL).
• Cylin der h ea d(s) (Refer t o 9 - E NGINE /CYLIN-
DE R H E AD - RE MOVAL) a n d (Refer t o 9 - E NGINE /
CYLINDE R H E AD - RE MOVAL).
(3) If n ecessa r y, r em ove t op r idge of cylin der bor es
wit h a r elia ble r idge r ea m er befor e r em ovin g pist on s
fr om cylin der block. B e s u re to k e e p to p s o f p is -
to n s c o v e re d d u rin g th is o p e ra tio n . P ist on s a n d
con n ect in g r ods m u st be r em oved fr om t op of cylin der
block. Wh en r em ovin g pist on a n d con n ect in g r od
a ssem blies fr om t h e en gin e, r ot a t e cr a n ksh a ft so t h e
ea ch con n ect in g r od is cen t er ed in cylin der bor e.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
ENGINE - 4.7L 9 - 119
(4) Ma r k con n ect in g r od a n d bea r in g ca p posit ion s
u sin g a per m a n en t in k m a r ker or scr ibe t ool (F ig.
71).
Fig. 71 Identify Connecting Rod to Cylinder
Position—Typical
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Rem ove con n ect in g r od ca p. In st a ll Specia l Tool
8507 Con n ect in g Rod Gu ides in t o t h e con n ect in g r od
bein g r em oved. Rem ove pist on fr om cylin der bor e.
Repea t t h is pr ocedu r e for ea ch pist on bein g r em oved.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Im m edia t ely a ft er pist on a n d con n ect in g r od
r em ova l, in st a ll bea r in g ca p on t h e m a t in g con n ect -
in g r od t o pr even t da m a ge t o t h e fr a ct u r ed ca p a n d
r od su r fa ces.
(7) Ca r efu lly r em ove pist on r in gs fr om pist on (s),
st a r t in g fr om t h e t op r in g down .
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Usin g a su it a ble clea n in g solven t clea n t h e pis-
t on s in wa r m wa t er a n d t owel dr y.
(2) Use a wood or pla st ic scr a per t o clea n t h e r in g
la n d gr ooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Ch eck t h e con n ect in g r od jou r n a l for excessive
wea r, t a per a n d scor in g (Refer t o 9 - E NGINE /E N-
GINE BLOCK/CONNE CTING ROD BE ARINGS -
STANDARD P ROCE DURE ).
9 - 120 ENGINE - 4.7L
PI ST ON & CON N ECT I N G ROD (Cont inue d)
Ch eck t h e con n ect in g r od for sign s of t wist or ben d-
in g.
Ch eck t h e pist on for t a per a n d ellipt ica l sh a pe
befor e it is fit t ed in t o t h e cylin der bor e (Refer t o 9 -
E NGINE /E NGINE BLOCK/P ISTON & CONNE CT-
ING ROD - STANDARD P ROCE DURE ).
Ch eck t h e pist on for scor in g, or scr a pin g m a r ks in
t h e pist on skir t s. Ch eck t h e r in g la n ds for cr a cks
a n d/or det er ior a t ion .
INSTALLATION
(1) Befor e in st a llin g pist on a n d con n ect in g r od
a ssem blies in t o t h e bor e, in st a ll t h e pist on r in gs.
(2) Im m er se t h e pist on h ea d a n d r in gs in clea n
en gin e oil. P osit ion a r in g com pr essor over t h e pist on
a n d r in gs. Tigh t en r in g com pr essor. En s u re p o s itio n
o f rin g s d o n o t c h a n g e d u rin g th is o p e ra tio n .
(3) P osit ion bea r in g on t o con n ect in g r od. E n su r e t h a t
h ole in bea r in g sh ell a lign s wit h h ole in con n ect in g r od.
Lu br ica t e bea r in g su r fa ce wit h clea n en gin e oil.
(4) In st a ll Specia l Tool 8507 Con n ect in g Rod
Gu ides in t o con n ect in g r od bolt t h r ea ds (F ig. 72).
Fig. 72 Piston and Connecting Rod—Installation
1 - “F” TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
4 - SPECIAL TOOL 8507
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(5) Th e pist on s a r e m a r ked on t h e pist on pin bor e
su r fa ce wit h a n r a ised “F ” in dica t in g in st a lla t ion
posit ion . Th is m a r k m u st be poin t in g t owa r d t h e
fr on t of en gin e on bot h cylin der ba n ks. Th e con n ect -
in g r od oil slin ger slot fa ces t h e fr on t of t h e en gin e
(F ig. 73).
Fig. 73 Piston and Connecting Rod Orientation
1 - MAJOR THRUST SIDE OF PISTON
2 - OIL SLINGER SLOT
(6) Wipe cylin der bor e clea n a n d lu br ica t e wit h
en gin e oil.
(7) Rot a t e cr a n ksh a ft u n t il con n ect in g r od jou r n a l
is on t h e cen t er of cylin der bor e. In ser t r od a n d pis-
t on in t o cylin der bor e a n d ca r efu lly posit ion con n ect -
in g r od gu ides over cr a n ksh a ft jou r n a l.
(8) Ta p pist on down in cylin der bor e u sin g a h a m -
m er h a n dle. Wh ile a t t h e sa m e t im e, gu ide con n ect -
in g r od in t o posit ion on r od jou r n a l.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Lu br ica t e r od bolt s a n d bea r in g su r fa ces wit h
en gin e oil. In st a ll con n ect in g r od ca p a n d bea r in g.
Tigh t en bolt s t o 27 N·m (20 ft . lbs.) plu s 90°.
(10) In st a ll t h e followin g com pon en t s:
• Cylin der h ea d(s). (Refer t o 9 - E NGINE /CYLIN-
DE R H E AD - INSTALLATION).
• Tim in g ch a in a n d cover. (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT / CH AIN COVE R(S)
- INSTALLATION).
WJ ENGINE - 4.7L 9 - 121
PI ST ON & CON N ECT I N G ROD (Cont inue d)
• Cylin der h ea d cover s (Refer t o 9 - E NGINE /
CYLINDE R H E AD/CYLINDE R H E AD COVE R(S) -
INSTALLATION).
• Oil pa n a n d ga sket /win da ge t r a y. (Refer t o 9 -
E NGINE /LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) F ill cr a n kca se wit h pr oper en gin e oil t o cor-
r ect level.
(12) Con n ect n ega t ive ca ble t o ba t t er y.

PI ST ON RI N GS
STANDARD PROCEDURE - PISTON RING
FITTING
Befor e r ein st a llin g u sed r in gs or in st a llin g n ew
r in gs, t h e r in g clea r a n ces m u st be ch ecked.
(1) Wipe t h e cylin der bor e clea n .
(2) In ser t t h e r in g in t h e cylin der bor e.

NOTE: The ring gap measurement must be made

with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore. Fig. 75 Measuring Piston Ring Side Clearance
1 - FEELER GAUGE
(3) Usin g a pist on , t o en su r e t h a t t h e r in g is
squ a r ed in t h e cylin der bor e, slide t h e r in g down wa r d
(6) Rot a t e t h e r in g a r ou n d t h e pist on , t h e r in g
in t o t h e cylin der.
m u st r ot a t e in t h e gr oove wit h ou t bin din g.
(4) Usin g a feeler ga u ge ch eck t h e r in g en d ga p
(F ig. 74). Repla ce a n y r in gs n ot wit h in specifica t ion . PI ST ON RI N G SPECI FI CAT I ON CH ART

Ring Position Groove Maximum

Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020- .0037 (0.004 in.)
in.)
Intermediate 0.04-0.08mm 0.10mm
Ring
(0.0016-0.0031 (0.004 in.)
in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090 in.) (0.010 in.)
Ring Position Ring Gap Wear Limit
Fig. 74 Ring End Gap Measurement - Typical Upper Ring 0.23-0.39mm 0.43mm
1 - FEELER GAUGE (0.009-0.015 in.) (0.0017 in.)
Intermediate 0.40-0.66mm 0.74mm
P IS TON RIN G S ID E CLEARAN CE
Ring
NOTE: Make sure the piston ring grooves are clean (0.015-0.026 in.) (0.029 in.)
and free of nicks and burrs. Oil Control Ring 0.028-0.79mm 1.55mm
(5) Mea su r e t h e r in g side clea r a n ce a s sh own (F ig. (Steel Rail) (0.011- 0.031 (0.061 in.)
75)m a ke su r e t h e feeler ga u ge fit s sn u gly bet ween in.)
t h e r in g la n d a n d t h e r in g. Repla ce a n y r in g n ot
wit h in specifica t ion .
9 - 122 ENGINE - 4.7L WJ
PI ST ON RI N GS (Cont inue d)
(7) Th e No. 1 a n d No. 2 pist on r in gs h a ve a differ-
en t cr oss sect ion . E n su r e No. 2 r in g is in st a lled wit h
m a n u fa ct u r er s I.D. m a r k (Dot ) fa cin g u p, t owa r ds t op
of t h e pist on .

NOTE: Piston rings are installed in the following

order:
• Oil ring expander.
• Upper oil ring side rail.
• Lower oil ring side rail.
• No. 2 Intermediate piston ring.
• No. 1 Upper piston ring.

(8) In st a ll t h e oil r in g expa n der.

(9) In st a ll u pper side r a il (F ig. 76) by pla cin g on e
en d bet ween t h e pist on r in g gr oove a n d t h e expa n der
r in g. H old en d fir m ly a n d pr ess down t h e por t ion t o Fig. 77 Upper and Intermediate Rings—Installation
be in st a lled u n t il side r a il is in posit ion . Repea t t h is
st ep for t h e lower side r a il.
(10) In st a ll No. 2 in t er m edia t e pist on r in g u sin g a
pist on r in g in st a ller (F ig. 77).
(11) In st a ll No. 1 u pper pist on r in g u sin g a pist on
r in g in st a ller (F ig. 77).
(12) P osit ion pist on r in g en d ga ps a s sh own in
(F ig. 78). It is im por t a n t t h a t expa n der r in g ga p is a t
lea st 45° fr om t h e side r a il ga ps, bu t n ot on t h e pis-
t on pin cen t er or on t h e t h r u st dir ect ion .

Fig. 78 Piston Ring End Gap Position

1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP

V I BRAT I ON DAM PER

Fig. 76 Side Rail—Installation REMOVAL
1 - SIDE RAIL END (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).

NOTE: Transmission cooler line snaps into shroud

lower right hand corner.
WJ ENGINE - 4.7L 9 - 123
V I BRAT I ON DAM PER (Cont inue d)
(3) Rem ove cr a n ksh a ft da m per bolt .
(4) Rem ove da m per u sin g Specia l Tools 8513
In ser t a n d 1026 Th r ee J a w P u ller (F ig. 79).

Fig. 80 Proper Assembly Method for Special Tool

8512–A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER

Fig. 79 Crankshaft Damper—Removal

1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026

INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.

(1) Align cr a n ksh a ft da m per slot wit h key in

cr a n ksh a ft . Slide da m per on t o cr a n ksh a ft sligh t ly.

CAUTION: Special Tool 8512A, is assembled in a

specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.

(2) Assem ble Specia l Tool 8512–A a s follows, Th e

n u t is t h r ea ded on t o t h e sh a ft fir st . Th en t h e r oller
bea r in g is pla ced on t o t h e t h r ea ded r od (Th e h a r d- Fig. 81 Crankshaft Damper Installation
en ed bea r in g su r fa ce of t h e bea r in g MU S Tfa ce t h e 1 - SPECIAL TOOL 8512A
n u t ). Th en t h e h a r den ed wa sh er slides on t o t h e
t h r ea ded r od (F ig. 80). On ce a ssem bled coa t t h e
t h r ea ded r od’s t h r ea ds wit h Mopa r ! Nickel An t i- (5) In st a ll a ccessor y dr ive belt (Refer t o 7 - COOL-
Seize or (Loct it e No. 771). ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
(3) Usin g Specia l Tool 8512A, pr ess da m per on t o LATION).
cr a n ksh a ft (F ig. 81). (6) Con n ect n ega t ive ca ble t o ba t t er y.
(4) In st a ll t h en t igh t en cr a n ksh a ft da m per bolt t o
175 N·m (130 ft . lbs.).
9 - 124 ENGINE - 4.7L WJ

ST RU CT U RAL COV ER CAUTION: The structural cover must be held tightly

DESCRIPTION
Th e st r u ct u r a l du st cover is m a de of die ca st a lu -
m in u m a n d join s t h e lower h a lf of t h e t r a n sm ission
bell h ou sin g t o t h e en gin e bedpla t e.
OPERATION
Th e st r u ct u r a l cover pr ovides a ddit ion a l power-
t r a in st iffn ess a n d r edu ces n oise a n d vibr a t ion .
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) St a r t in g wit h t h e t wo r ea r cover-t o-en gin e
bolt s, t igh t en bolt s (1) (F ig. 83) t o 54 N·m (40 ft . lbs.),
t h en t igh t en bolt s (2) (F ig. 83) a n d (3) t o 54 N·m ( 40
ft . lbs.) in t h e sequ en ce sh own .

REMOVAL
(1) Ra ise veh icle on h oist .
(2) Rem ove t h e left h a n d exh a u st pipe fr om
exh a u st m a n ifold.
(3) Loosen t h e r igh t h a n d exh a u st m a n ifold-t o-ex-
h a u st pipe r et a in in g bolt s.
(4) Rem ove t h e eigh t bolt s r et a in in g st r u ct u r a l
cover (F ig. 82) in t h e sequ en ce sh own .
(5) P ivot t h e exh a u st pipe down wa r d a n d r em ove
t h e st r u ct u r a l cover.

Fig. 83 Structural Cover

(5) In st a ll t h e exh a u st pipe on left h a n d exh a u st
m a n ifold.
(6) Tigh t en exh a u st m a n ifold-t o-exh a u st pipe
r et a in in g bolt s t o 20–26 N·m (15–20 ft . lbs.).

FRON T M OU N T
REMOVAL
(1) Discon n ect t h e n ega t ive ca ble fr om t h e ba t t er y.

CAUTION: Remove the fan blade, fan clutch and fan

Fig. 82 Structural Cover shroud before raising engine. Failure to do so may
INSTALLATION cause damage to the fan blade, fan clutch and fan
shroud.
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so (2) Rem ove t h e en gin e oil filt er (Refer t o 9 -
will cause severe damage to the cover. E NGINE /LUBRICATION/OIL F ILTE R - RE MOVAL).
(3) Su ppor t t h e en gin e wit h a su it a ble ja ck a n d a
(1) P osit ion t h e st r u ct u r a l cover in t h e veh icle. block of wood a cr oss t h e fu ll widt h of t h e en gin e oil
(2) In st a ll a ll fou r bolt s r et a in in g t h e cover-t o-en - pa n .
gin e. DO NOT t igh t en t h e bolt s a t t h is t im e.
(3) In st a ll t h e fou r cover-t o-t r a n sm ission bolt s. Do
NOT t igh t en a t t h is t im e.
WJ ENGINE - 4.7L 9 - 125
FRON T M OU N T (Cont inue d)
(4) Rem ove t h e fou r cylin der block-t o-in su la t or
m ou n t bolt s a n d t h e n u t for m t h e en gin e in su la t or
m ou n t t h r ou gh bolt (F ig. 84) (F ig. 85)

Fig. 84 Engine Insulator Mount 4.7 LEFT

1 - NUT
2 - BOLT
Fig. 85 Engine Insulator Mount 4.7 Right
1 - NUT
(5) Usin g t h e ja ck, r a ise t h e en gin e h igh en ou gh t o 2 - BOLT
r em ove t h e en gin e in su la t or m ou n t t h r ou gh bolt a n d
t h e in su la t or m ou n t .
REAR M OU N T
INSTALLATION
(1) P osit ion t h e in su la t or m ou n t a n d in st a ll t h e REMOVAL
in su la t or m ou n t t h r ou gh bolt . (1) Ra ise veh icle on h oist .
(2) Lower t h e en gin e u n t il t h e fou r cylin der block- (2) Usin g a su it a ble ja ck, su ppor t t r a n sm ission .
t o-in su la t or m ou n t bolt s ca n be in st a lled. (3) Rem ove t h e lock n u t fr om t h e in su la t or m ou n t
(3) Rem ove t h e ja ck a n d block of wood. t h r ou gh bolt a n d t h e fou r in su la t or-t o-t r a n sm ission
(4) Tor qu e t h e cylin der block-t o-in su la t or m ou n t m ou n t in g bolt s.
bolt s t o 61N·m ( 45 ft . lbs.). (4) Ra ise t h e t r a n sm ission en ou gh t o r em ove t h e
(5) In st a ll a n d t or qu e t h e t h r ou gh bolt r et a in in g t h r ou gh bolt a n d in su la t or m ou n t (F ig. 86) (F ig. 87).
n u t t o 61N·m (45 ft . lbs.).
9 - 126 ENGINE - 4.7L
REAR M OU N T (Cont inue d)
Fig. 86 Engine Rear Mount—4X2
Fig. 87 Engine Rear Mount—4X4
WJ
ITEM DESCRIPTION TORQUE
1 NUT 45 N·m
(Qty 1) (33 ft. lbs)
2 BOLT 46 N·m
(Qty 4) (34 ft. lbs.)
3 BOLT 68 N·m
(Qty 2 Per (50 ft. lbs.)
Side)
4 BOLT 46 N·m
(Qty 2 Per (34 ft. lbs.)
Side)
5 BOLT 46 N·m
(Qty 4) (34 ft. lbs.)
INSTALLATION
(1) P osit ion t h e in su la t or m ou n t a n d in st a ll t h e
t h r ou gh bolt .
(2) Lower t h e t r a n sm ission en ou gh t o in st a ll t h e
fou r in su la t or-t o-t r a n sm ission m ou n t in g bolt s. Tor qu e
t h e bolt s t o 46N·m (34 ft . lbs.).
(3) In st a ll t h e t h r ou gh bolt lock n u t . Tor qu e n u t t o
68N·m (50 ft . lbs.).
(4) Rem ove ja ck, lower veh icle.
LU BRI CAT I ON
DESCRIPTION
Th e lu br ica t ion syst em (F ig. 88) is a fu ll flow fil-
t r a t ion pr essu r e feed t ype.
OPERATION
Oil fr om t h e oil pa n is pu m ped by a ger ot or t ype oil
pu m p dir ect ly m ou n t ed t o t h e cr a n ksh a ft n ose. Oil
pr essu r e is con t r olled by a r elief va lve m ou n t ed
in side t h e oil pu m p h ou sin g. F or lu br ica t ion flow
r efer t o (F ig. 88).
Th e ca m sh a ft exh a u st va lve lobes a n d r ocker a r m s
a r e lu br ica t ed t h r ou gh a sm a ll h ole in t h e r ocker
a r m ; oil flows t h r ou gh t h e la sh a dju st er t h en t h r ou gh
t h e r ocker a r m a n d on t o t h e ca m sh a ft lobe. Du e t o
t h e or en t a t ion of t h e r ocker a r m , t h e ca m sh a ft in t a ke
lobes a r e n ot lu bed in t h e sa m e m a n n er a s t h e
exh a u st lobes. Th e in t a ke lobes a r e lu bed t h r ou gh
in t er n a l pa ssa ges in t h e ca m sh a ft . Oil flows t h r ou gh
a bor e in t h e n u m ber 3 ca m sh a ft bea r in g bor e, a n d
a s t h e ca m sh a ft t u r n s, a h ole in t h e ca m sh a ft a lign s
wit h t h e h ole in t h e ca m sh a ft bor e a llowin g en gin e
oil t o en t er t h e ca m sh a ft t u be. Th e oil t h en exit s
t h r ou gh 1.6m m (0.063 in .) h oles dr illed in t o t h e
in t a ke lobes, lu br ica t in g t h e lobes a n d t h e r ocker
a r m s.
WJ ENGINE - 4.7L 9 - 127
LU BRI CAT I ON (Cont inue d)

Fig. 88 Engine Oil Lubrication System

1 - LEFT CYLINDER HEAD OIL GALLERY 7 - TO CRANKSHAFT MAIN JOURNALS
2 - OIL PRESSURE SENSOR LOCATION 8 - RIGHT CYLINDER HEAD OIL GALLERY
3 - TO LEFT CYLINDER HEAD 9 - TO RIGHT CYLINDER HEAD
4 - OIL FEED TO IDLER SHAFT 10 - CYLINDER BLOCK MAIN GALLERY
5 - OIL PUMP OUTLET TO BLOCK 11 - OIL FEED TO BOTH SECONDARY TENSIONERS
6 - OIL PUMP
9 - 128 ENGINE - 4.7L WJ
LU BRI CAT I ON (Cont inue d)
EN GI N E LU BRI CAT I ON FLOW CH ART —BLOCK : TABLE 1

FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2.Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head
gaskets have an oil restricter to control oil flow to the cylinder heads.

EN GI N E LU BRI CAT I ON FLOW CH ART —CY LI N DER H EADS: TABLE 2

FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to 1. Base of Camshaft Towers
front) 2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.

DI AGN OSI S AN D T EST I N G If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l

DIAGNOSIS AND TESTING—ENGINE OIL
PRESSURE
(1) Rem ove oil pr essu r e sen din g u n it (F ig. 89)a n d
in st a ll ga u ge a ssem bly C-3292.
(2) Ru n en gin e u n t il t h er m ost a t open s.
(3) Oil P r essu r e:
• Cu r b Idle—25 Kpa (4 psi) m in im u m
• 3000 r pm —170 - 550 KP a (25 - 80 psi)
(4) If oil pr essu r e is 0 a t idle, sh u t off en gin e.
Ch eck for a clogged oil pick-u p scr een or a pr essu r e
r elief va lve st u ck open .
DIAGNOSIS AND TESTING—REAR SEAL AREA
LEAKS
Sin ce it is som et im es difficu lt t o det er m in e t h e
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
followin g st eps sh ou ld be followed t o h elp pin poin t
t h e sou r ce of t h e lea k.
a r ea :
(1) Discon n ect t h e ba t t er y.
(2) Ra ise t h e veh icle.
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g
cover a n d in spect r ea r of block for eviden ce of oil.
Use a bla ck ligh t t o ch eck for t h e oil lea k:
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es
sea l lea ka ge or cr a n ksh a ft da m a ge.
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down ,
possible ca u ses a r e a por ou s block, dist r ibu t or sea l,
ca m sh a ft bor e cu p plu gs, oil ga lley pipe plu gs, oil
filt er r u n off, a n d m a in bea r in g ca p t o cylin der
block m a t in g su r fa ces. See E n gin e, for pr oper
r epa ir pr ocedu r es of t h ese it em s.
(4) If n o lea ks a r e det ect ed, pr essu r ized t h e cr a n k-
ca se a s ou t lin ed in t h e sect ion , In spect ion (E n gin e oil
Lea ks in gen er a l)
CAUTION: Do not exceed 20.6 kPa (3 psi).
WJ
LU BRI CAT I ON (Cont inue d)
Fig. 89 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es
t h a t ca n be polish ed ou t wit h em er y clot h .
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft
r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
a ssem bled. (Refer t o 9 - E NGINE - DIAGNOSIS AND
TE STING), u n der t h e Oil Lea k r ow, for com pon en t s
in spect ion s on possible ca u ses a n d cor r ect ion s.
(7) Aft er t h e oil lea k r oot ca u se a n d a ppr opr ia t e
cor r ect ive a ct ion h a ve been iden t ified, (Refer t o 9 -
E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
SE AL - RE AR - RE MOVAL).
DIAGNOSIS AND TESTING—ENGINE OIL LEAK
Begin wit h a t h or ou gh visu a l in spect ion of t h e
en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
ENGINE - 4.7L 9 - 129
If a n oil lea k sou r ce is n ot r ea dily iden t ifia ble, t h e
followin g st eps sh ou ld be followed:
(1) Do n ot clea n or degr ea se t h e en gin e a t t h is
t im e beca u se som e solven t s m a y ca u se r u bber t o
swell, t em por a r ily st oppin g t h e lea k.
(2) Add a n oil solu ble dye (u se a s r ecom m en ded by
m a n u fa ct u r er ). St a r t t h e en gin e a n d let idle for
a ppr oxim a t ely 15 m in u t es. Ch eck t h e oil dipst ick t o
m a ke su r e t h e dye is t h or ou gh ly m ixed a s in dica t ed
wit h a br igh t yellow color u n der a bla ck ligh t .
(3) Usin g a bla ck ligh t , in spect t h e en t ir e en gin e
for flu or escen t dye, pa r t icu la r ly a t t h e su spect ed a r ea
of oil lea k. If t h e oil lea k is fou n d a n d iden t ified,
r epa ir per ser vice m a n u a l in st r u ct ion s.
(4) If dye is n ot obser ved, dr ive t h e veh icle a t va r-
iou s speeds for a ppr oxim a t ely 24km (15 m iles), a n d
r epea t in spect ion .If th e o il le a k s o u rc e is n o t p o s -
itiv e ly id e n tifie d a t th is tim e , pr oceed wit h t h e a ir
lea k det ect ion t est m et h od.
Air Leak Detection Test Method
(1) Discon n ect t h e br ea t h er ca p t o a ir clea n er h ose
a t t h e br ea t h er ca p en d. Ca p or plu g br ea t h er ca p
n ipple.
(2) Rem ove t h e P CV va lve fr om t h e cylin der h ea d
cover. Ca p or plu g t h e P CV va lve gr om m et .
(3) At t a ch a n a ir h ose wit h pr essu r e ga u ge a n d
r egu la t or t o t h e dipst ick t u be.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gr a du a lly a pply a ir pr essu r e fr om 1 psi t o 2.5
psi m a xim u m wh ile a pplyin g soa py wa t er a t t h e su s-
pect ed sou r ce. Adju st t h e r egu la t or t o t h e su it a ble
t est pr essu r e t h a t pr ovide t h e best bu bbles wh ich
will pin poin t t h e lea k sou r ce. If t h e oil lea k is
det ect ed a n d iden t ified, r epa ir per ser vice m a n u a l
pr ocedu r es.
(5) If t h e lea ka ge occu r s a t t h e r ea r oil sea l a r ea ,
r efer t o t h e sect ion , In spect ion for Rea r Sea l Ar ea
Lea k.
(6) If n o lea ks a r e det ect ed, t u r n off t h e a ir su pply
a n d r em ove t h e a ir h ose a n d a ll plu gs a n d ca ps.
In st a ll t h e P CV va lve a n d br ea t h er ca p h ose.
(7) Clea n t h e oil off t h e su spect oil lea k a r ea u sin g
a su it a ble solven t . Dr ive t h e veh icle a t va r iou s
speeds a ppr oxim a t ely 24 km (15 m iles). In spect t h e
en gin e for sign s of a n oil lea k by u sin g a bla ck ligh t .
INSPECTION FOR REAR SEAL AREA LEAKS
Sin ce it is som et im es difficu lt t o det er m in e t h e
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
followin g st eps sh ou ld be followed t o h elp pin poin t
t h e sou r ce of t h e lea k.
9 - 130 ENGINE - 4.7L
LU BRI CAT I ON (Cont inue d)
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l
a r ea :
(1) Discon n ect t h e ba t t er y.
(2) Ra ise t h e veh icle.
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g
cover a n d in spect r ea r of block for eviden ce of oil.
Use a bla ck ligh t t o ch eck for t h e oil lea k:
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es
sea l lea ka ge or cr a n ksh a ft da m a ge.
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down ,
possible ca u ses a r e a por ou s block, dist r ibu t or sea l,
ca m sh a ft bor e cu p plu gs oil ga lley pipe plu gs, oil
filt er r u n off, a n d m a in bea r in g ca p t o cylin der
block m a t in g su r fa ces.
(4) If n o lea ks a r e det ect ed, pr essu r ize t h e cr a n k-
ca se a s ou t lin ed in t h e, In spect ion (E n gin e oil Lea ks
in gen er a l)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es
t h a t ca n be polish ed ou t wit h em er y clot h .
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft
r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
a ssem bled.
OI L
STANDARD PROCEDURE - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL 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 PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
WJ
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use a n en gin e oil t h a t is AP I Ser vice Gr a de Cer t i-
fied. MOPAR! pr ovides en gin e oils t h a t con for m t o
t h is ser vice gr a de.
SAE VISCOSITY
An SAE viscosit y gr a de is u sed t o specify t h e vis-
cosit y of en gin e oil. Use on ly en gin e oils wit h m u lt i-
ple viscosit ies su ch a s 5W-30 or 10W-30 in t h e 4.7L
en gin es. Th e 4.7L H.O. u s e s 10W-30 o il o n ly.Th ese
a r e specified wit h a du a l SAE viscosit y gr a de wh ich
in dica t es t h e cold-t o-h ot t em per a t u r e viscosit y r a n ge.
Select a n en gin e oil t h a t is best su it ed t o you r pa r-
t icu la r t em per a t u r e r a n ge a n d va r ia t ion (F ig. 90).
Fig. 90 Temperature/Engine Oil Viscosity - 4.7L
Engine
ENERGY CONSERVING OIL
An E n er gy Con ser vin g t ype oil is r ecom m en ded for
ga solin e en gin es. Th e design a t ion of E NE RGY CON-
SE RVING is loca t ed on t h e la bel of a n en gin e oil con -
t a in er.
CONTAINER IDENTIFICATION
St a n da r d en gin e oil iden t ifica t ion n ot a t ion s h a ve
been a dopt ed t o a id in t h e pr oper select ion of en gin e
oil. Th e iden t ifyin g n ot a t ion s a r e loca t ed on t h e la bel
of en gin e oil pla st ic bot t les a n d t h e t op of en gin e oil
ca n s (F ig. 91).
OIL LEVEL INDICATOR (DIPSTICK)
Th e en gin e oil level in dica t or is loca t ed on t h e
r igh t side of t h e t h e 4.7L en gin e. (F ig. 92).
WJ
OI L (Cont inue d)
Fig. 91 Engine Oil Container Standard Notations
Fig. 92 Engine Oil Dipstick 4.7L Engine
1 - TRANSMISSION DIPSTICK
2 - ENGINE OIL DIPSTICK
3 - ENGINE OIL FILL CAP
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
In spect en gin e oil level a ppr oxim a t ely ever y 800
kilom et er s (500 m iles). Un less t h e en gin e h a s exh ib-
it ed loss of oil pr essu r e, r u n t h e en gin e for a bou t five
m in u t es befor e ch eckin g oil level. Ch eckin g en gin e oil
level on a cold en gin e is n ot a ccu r a t e.
To en su r e pr oper lu br ica t ion of a n en gin e, t h e
en gin e oil m u st be m a in t a in ed a t a n a ccept a ble level.
Th e a ccept a ble levels a r e in dica t ed bet ween t h e ADD
a n d SAF E m a r ks on t h e en gin e oil dipst ick.
(1) P osit ion veh icle on level su r fa ce.
(2) Wit h en gin e OF F, a llow a ppr oxim a t ely t en m in -
u t es for oil t o set t le t o bot t om of cr a n kca se, r em ove
en gin e oil dipst ick.
ENGINE - 4.7L 9 - 131
(3) Wipe dipst ick clea n .
(4) In st a ll dipst ick a n d ver ify it is sea t ed in t h e
t u be.
(5) Rem ove dipst ick, wit h h a n dle h eld a bove t h e
t ip, t a ke oil level r ea din g.
(6) Add oil if level is below t h e SAF E ZONE on
dipst ick.
ENGINE OIL CHANGE
Ch a n ge en gin e oil a t m ilea ge a n d t im e in t er va ls
descr ibed in Ma in t en a n ce Sch edu les.
Ru n en gin e u n t il a ch ievin g n or m a l oper a t in g t em -
per a t u r e.
(1) P osit ion t h e veh icle on a level su r fa ce a n d t u r n
en gin e off.
(2) Rem ove oil fill ca p.
(3) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(4) P la ce a su it a ble dr a in pa n u n der cr a n kca se
dr a in .
(5) Rem ove dr a in plu g fr om cr a n kca se a n d a llow
oil t o dr a in in t o pa n . In spect dr a in plu g t h r ea ds for
st r et ch in g or ot h er da m a ge. Repla ce dr a in plu g if
da m a ged.
(6) In st a ll dr a in plu g in cr a n kca se.
(7) Rem ove oil filt er (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL F ILTE R - RE MOVAL).
(8) Lower veh icle a n d fill cr a n kca se wit h specified
t ype a n d a m ou n t of en gin e oil descr ibed in t h is sec-
t ion .
(9) In st a ll oil fill ca p.
(10) St a r t en gin e a n d in spect for lea ks.
(11) St op en gin e a n d in spect oil level.
USED ENGINE OIL DISPOSAL
Ca r e sh ou ld be exer cised wh en disposin g u sed
en gin e oil a ft er it h a s been dr a in ed fr om a veh icle
en gin e. Refer t o t h e WARNING a t begin n in g of t h is
sect ion .
OI L FI LT ER
REMOVAL
All en gin es a r e equ ipped wit h a h igh qu a lit y fu ll-
flow, disposa ble t ype oil filt er. Da im ler Ch r ysler Cor-
por a t ion r ecom m en ds a Mopa r ! or equ iva len t oil
filt er be u sed.
(1) P osit ion a dr a in pa n u n der t h e oil filt er.
(2) Usin g a su it a ble oil filt er wr en ch loosen filt er.
(3) Rot a t e t h e oil filt er cou n t er clockwise (F ig. 93)t o
r em ove it fr om t h e cylin der block oil filt er boss.
(4) Wh en filt er sepa r a t es fr om cylin der block oil
filt er boss, t ip ga sket en d u pwa r d t o m in im ize oil
spill. Rem ove filt er fr om veh icle.
NOTE: Make sure filter gasket was removed with fil-
ter.
9 - 132 ENGINE - 4.7L WJ
OI L FI LT ER (Cont inue d)

OI L PAN
DESCRIPTION
Th e en gin e oil pa n is m a de of la m in a t ed st eel a n d
h a s a sin gle pla n e sea lin g su r fa ce. Th e sa n dwich
st yle oil pa n ga sket h a s a n in t egr a t ed win da ge t r a y
a n d st eel ca r r ier. Th e sea lin g a r ea of t h e ga sket is
m olded wit h r u bber a n d is design ed t o be r eu sed a s
lon g a s t h e ga sket is n ot cu t , t or n or r ipped.

Fig. 93 Oil Filter - 4.7L Engine
1 - ENGINE OIL FILTER
(5) Wit h a wipin g clot h , clea n t h e ga sket sea lin g
su r fa ce of oil a n d gr im e.
INSTALLATION
(1) Ligh t ly lu br ica t e oil filt er ga sket wit h en gin e
oil.
(2) Th r ea d filt er on t o a da pt er n ipple. Wh en ga sket
m a kes con t a ct wit h sea lin g su r fa ce, (F ig. 94)h a n d
t igh t en filt er on e fu ll t u r n , do n ot over t igh t en .
(3) Add oil, ver ify cr a n kca se oil level a n d st a r t
en gin e. In spect for oil lea ks.
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Ra ise veh icle on h oist .
(3) Rem ove st r u ct u r a l cover (Refer t o 9 - E NGINE /
E NGINE BLOCK/STRUCTURAL COVE R - RE MOV-
AL).
(4) Rem ove exh a u st syst em Y-pipe.
(5) Rem ove st a r t er (Refer t o 8 - E LE CTRICAL/
STARTING/STARTE R MOTOR - RE MOVAL).
(6) Dr a in en gin e oil.
(7) Un -clip t r a n sm ission lin es fr om su ppor t on oil
pa n st u d. Move lin es for oil pa n clea r a n ce.
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when lowering oil pan.
Gasket can not be removed with oil pan.
(8) Rem ove oil pa n bolt s a n d oil pa n .
(9) Rem ove oil pu m p picku p t u be.
(10) Rem ove oil pa n ga sket .
CLEANING
(1) Clea n oil pa n in solven t a n d wipe dr y wit h a
clea n clot h .
(2) Clea n t h e oil pa n ga sket su r fa ce. D O N OT u se
a gr in der wh eel or ot h er a br a sive t ool t o clea n sea l-
in g su r fa ce.
(3) Clea n oil scr een a n d t u be t h or ou gh ly in clea n
solven t .

INSPECTION
(1) In spect oil dr a in plu g a n d plu g h ole for
st r ipped or da m a ged t h r ea ds. Repa ir a s n ecessa r y.
(2) In spect t h e oil pa n m ou n t in g fla n ge for ben ds
or dist or t ion . St r a igh t en fla n ge, if n ecessa r y.

Fig. 94 Oil Filter Sealing Surface—Typical INSTALLATION

1 - SEALING SURFACE (1) Clea n oil pa n a n d a ll sea lin g su r fa ces. In spect
2 - RUBBER GASKET oil pa n ga sket a n d r epla ce a s n ecessa r y.
3 - OIL FILTER (2) In st a ll oil pa n ga sket .
WJ
OI L PAN (Cont inue d)
NOTE: When installing oil pan gasket/windage tray,
start four pan bolts at each corner before tightening
oil pickup tube. This will keep pan gasket in align-
ment.
(3) In st a ll oil pu m p pick-u p t u be u sin g a n ew
O-r in g. F ir st t igh t en bolt a t O-r in g en d of t u be t o 28
N·m (20 ft . lbs.). Tigh t en r em a in t u be su ppor t fa st en -
er s t o 28 N·m (20 ft . lbs.).
(4) In st a ll oil pa n a n d t igh t en fa st en er s t o 15 N·m
(11 ft . lbs.) (F ig. 95).
ENGINE - 4.7L 9 - 133
Th e oil pr essu r e sen sor h a s a 3–wir e elect r ica l
fu n ct ion ver y m u ch like t h e Ma n ifold Absolu t e P r es-
su r e (MAP ) sen sor. Mea n in g differ en t pr essu r es
r ela t e t o differ en t ou t pu t volt a ges.
A 5–volt su pply is sen t t o t h e sen sor fr om t h e P CM
t o power u p t h e sen sor. Th e sen sor r et u r n s a volt a ge
sign a l ba ck t o t h e P CM r ela t in g t o en gin e oil pr es-
su r e. Th is sign a l is t h en t r a n sfer r ed (bu ssed) t o t h e
in st r u m en t pa n el on eit h er a CCD or P CI bu s cir cu it
(depen din g on veh icle lin e) t o oper a t e t h e oil pr essu r e
ga u ge a n d t h e ch eck ga u ges la m p. Gr ou n d for t h e
sen sor is pr ovided by t h e P CM t h r ou gh a low-n oise
sen sor r et u r n .

REMOVAL
(1) Discon n ect t h e n ega t ive ca ble fr om t h e ba t t er y.
(2) Ra ise veh icle on h oist .
(3) Rem ove fr on t spla sh sh ield.
(4) Discon n ect oil pr essu r e sen der wir e (F ig. 96).
(5) Rem ove t h e pr essu r e sen der (F ig. 96).

Fig. 95 Oil Pan Tightening Sequence

(5) Recon n ect t r a n sm ission oil cooler lin es t o oil
pa n st u d bolt .
(6) In st a ll st a r t er (Refer t o 8 - E LE CTRICAL/
STARTING/STARTE R MOTOR - INSTALLATION).
(7) In st a ll exh a u st syst em Y-pipe.
(8) In st a ll st r u ct u r a l cover (Refer t o 9 - E NGINE /
E NGINE BLOCK/STRUCTURAL COVE R - INSTAL-
LATION).
(9) Lower veh icle.
(10) F ill en gin e wit h pr oper a m ou n t of oil (Refer t o
LUBRICATION & MAINTE NANCE /F LUID TYP E S -
SP E CIF ICATIONS).
(11) Con n ect n ega t ive ca ble t o ba t t er y.

OI L PRESSU RE SEN SOR/

SWI T CH Fig. 96 Oil Pressure Sending Unit
1 - BELT
DESCRIPTION 2 - OIL PRESSURE SENSOR
Th e 3–wir e, solid-st a t e en gin e oil pr essu r e sen sor 3 - OIL FILTER
(sen din g u n it ) is loca t ed in a n en gin e oil pr essu r e 4 - ELEC. CONNECTOR
ga ller y.

OPERATION INSTALLATION
Th e oil pr essu r e sen sor u ses t h r ee cir cu it s. Th ey a r e: (1) In st a ll oil pr essu r e sen der.
• A 5–volt power su pply fr om t h e P ower t r a in Con - (2) Con n ect oil pr essu r e sen der wir e.
t r ol Modu le (P CM) (3) In st a ll fr on t spla sh sh ield.
• A sen sor gr ou n d t h r ou gh t h e P CM’s sen sor (4) Lower veh icle.
r et u r n (5) Con n ect t h e n ega t ive ba t t er y ca ble.
• A sign a l t o t h e P CM r ela t in g t o en gin e oil pr essu r e
9 - 134 ENGINE - 4.7L WJ

OI L PU M P (4) Mea su r e t h e dia m et er of t h e ou t er r ot or. If t h e

ou t er r ot or dia m et er m ea su r es a t 85.925 m m (3.382
in .) or less t h e oil pu m p a ssem bly m u st be r epla ced.
REMOVAL
(5) Mea su r e t h e t h ickn ess of t h e in n er r ot or (F ig.
(1) Rem ove t h e oil pa n a n d pick-u p t u be (Refer t o
99). If t h e in n er r ot or t h ickn ess m ea su r es a t 12.005
9 - E NGINE /LUBRICATION/OIL PAN - RE MOVAL).
m m (0.472 in .) or less t h en t h e oil pu m p a ssem bly
(2) Rem ove t h e t im in g ch a in cover (Refer t o 9 -
m u st be r epla ced.
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
(6) Slide ou t er r ot or in t o t h e body of t h e oil pu m p.
COVE R(S) - RE MOVAL).
P r ess t h e ou t er r ot or t o on e side of t h e oil pu m p body
(3) Rem ove t h e t im in g ch a in s a n d t en sion er s
a n d m ea su r e clea r a n ce bet ween t h e ou t er r ot or a n d
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
t h e body (F ig. 100). If t h e m ea su r em en t is 0.235m m
BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
(0.009 in .) or m or e t h e oil pu m p a ssem bly m u st be
(4) Rem ove t h e fou r bolt s, pr im a r y t im in g ch a in
r epla ced.
t en sion er a n d t h e oil pu m p.
(7) In st a ll t h e in n er r ot or in t h e in t o t h e oil pu m p
body. Mea su r e t h e clea r a n ce bet ween t h e in n er a n d
DISASSEMBLY ou t er r ot or s (F ig. 101). If t h e clea r a n ce bet ween t h e
(1) Rem ove oil pu m p cover scr ews a n d lift off cover r ot or s is .150 m m (0.006 in .) or m or e t h e oil pu m p
pla t e. a ssem bly m u st be r epla ced.
(2) Rem ove pu m p in n er a n d ou t er r ot or s. (8) P la ce a st r a igh t edge a cr oss t h e body of t h e oil
pu m p (bet ween t h e bolt h oles), if a feeler ga u ge of
NOTE: Once the oil pressure relief valve, cup plug,
.095 m m (0.0038 in .) or gr ea t er ca n be in ser t ed
and pin are removed, the pump assembly must be
bet ween t h e st r a igh t edge a n d t h e r ot or s, t h e pu m p
replaced.
m u st be r epla ced (F ig. 102).
(3) If it is n ecessa r y t o r em ove t h e pr essu r e r elief
NOTE: The 4.7 Oil pump is released as an assem-
va lve, dr ive t h e r oll pin fr om pu m p h ou sin g a n d
bly. There are no DaimlerChrysler part numbers for
r em ove cu p plu g, spr in g a n d va lve.
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
CLEANING
must be replaced as an assembly.
(1) Wa sh a ll pa r t s in a su it a ble solven t .

INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.

(1) Clea n a ll pa r t s t h or ou gh ly. Ma t in g su r fa ce of

t h e oil pu m p h ou sin g sh ou ld be sm oot h . If t h e pu m p
cover is scr a t ch ed or gr ooved t h e oil pu m p a ssem bly
sh ou ld be r epla ced.
(2) La y a st r a igh t edge a cr oss t h e pu m p cover su r-
fa ce (F ig. 97). If a 0.025 m m (0.001 in .) feeler ga u ge
ca n be in ser t ed bet ween t h e cover a n d t h e st r a igh t Fig. 97 Checking Oil Pump Cover Flatness
edge t h e oil pu m p a ssem bly sh ou ld be r epla ced.
1 - STRAIGHT EDGE
(3) Mea su r e t h e t h ickn ess of t h e ou t er r ot or (F ig.
2 - FEELER GAUGE
98). If t h e ou t er r ot or t h ickn ess m ea su r es a t 12.005 3 - OIL PUMP COVER
m m (0.472 in .) or less t h e oil pu m p a ssem bly m u st be
r epla ced.
WJ ENGINE - 4.7L 9 - 135
OI L PU M P (Cont inue d)

Fig. 98 Measuring Outer Rotor Thickness

Fig. 100 Measuring Outer Rotor Clearance in

1 - FEELER GAUGE
2 - OUTER ROTOR

Fig. 99 Measuring Inner Rotor Thickness

ASSEMBLY
(1) Wa sh a ll pa r t s in a su it a ble solven t a n d in spect
ca r efu lly for da m a ge or wea r.
(2) In st a ll in n er a n d ou t er r ot or s
(3) In st a ll oil pu m p cover pla t e a n d in st a ll cover
bolt s a n d t igh t en t h em t o 12 N·m (105 in . lbs.).
(4) P r im e oil pu m p befor e in st a lla t ion by fillin g
r ot or ca vit y wit h en gin e oil.
(5) If oil pr essu r e is low a n d pu m p is wit h in spec-
Fig. 101 Measuring Clearance Between Rotors
ifica t ion s, in spect for wor n en gin e bea r in gs or ot h er
1 - OUTER ROTOR
ca u ses for oil pr essu r e loss.
2 - FEELER GAUGE
3 - INNER ROTOR
INSTALLATION
(1) P osit ion t h e oil pu m p on t o t h e cr a n ksh a ft a n d
in st a ll t wo oil pu m p r et a in in g bolt s. TIMING/TIMING BE LT/CH AIN AND SP ROCKE TS -
(2) P osit ion t h e pr im a r y t im in g ch a in t en sion er INSTALLATION).
a n d in st a ll t h e t wo r et a in in g bolt s. (5) In st a ll t h e t im in g ch a in cover (Refer t o 9 -
(3) Tigh t en t h e oil pu m p a n d pr im a r y t im in g ch a in E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
t en sion er r et a in in g bolt s t o 28 N·m (250 in . lbs.) in COVE R(S) - INSTALLATION).
t h e sequ en ce sh own (F ig. 103). (6) In st a ll t h e pick-u p t u be a n d oil pa n (Refer t o 9
(4) In st a ll t h e secon da r y t im in g ch a in t en sion er s - E NGINE /LUBRICATION/OIL PAN - INSTALLA-
a n d t im in g ch a in s (Refer t o 9 - E NGINE /VALVE TION).
9 - 136 ENGINE - 4.7L WJ
OI L PU M P (Cont inue d)

DIAGNOSIS AND TESTING—INTAKE

MANIFOLD LEAKAGE
An in t a ke m a n ifold a ir lea k is ch a r a ct er ized by
lower t h a n n or m a l m a n ifold va cu u m . Also, on e or
m or e cylin der s m a y n ot be fu n ct ion in g.

WARNING: USE EXTREME CAUTION WHEN THE

ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.

(1) St a r t t h e en gin e.
(2) Spr a y a sm a ll st r ea m of wa t er a t t h e su spect ed
lea k a r ea .
(3) If a ch a n ge in RP M is obser ved t h e a r ea of t h e
Fig. 102 Measuring Clearance Over Rotors su spect ed lea k h a s been fou n d.
1 - STRAIGHT EDGE (4) Repa ir a s r equ ir ed.
2 - FEELER GAUGE
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove a ir clea n er h ou sin g a n d t h r ot t le body
r eson a t or (F ig. 104).

Fig. 104 Throttle Body Resonator

1 - THROTTLE BODY RESONATOR
2 - BOLT
Fig. 103 Oil Pump and Primary Timing Chain 3 - BOLT
Tensioner Tightening Sequence
I N TAK E M AN I FOLD (3) Discon n ect t h r ot t le a n d speed con t r ol ca bles.
(4) Discon n ect elect r ica l con n ect or s for t h e follow-
in g com pon en t s:
DESCRIPTION • Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor
Th e in t a ke m a n ifold is m a de of a com posit e m a t e-
• In t a ke Air Tem per a t u r e (IAT) Sen sor
r ia l a n d fea t u r es lon g r u n n er s wh ich m a xim izes low
• Th r ot t le P osit ion (TP S) Sen sor
en d t or qu e. Th e in t a ke m a n ifold u ses sin gle pla n e
• Coola n t Tem per a t u r e (CTS) Sen sor
sea lin g wh ich con sist of eigh t in dividu a l pr ess in
• Idle Air Con t r ol (IAC) Mot or
pla ce por t ga sket s t o pr even t lea ks. E igh t st u ds a n d
(5) Discon n ect va por pu r ge h ose, br a ke boost er
t wo bolt s a r e u sed t o fa st en t h e in t a ke t o t h e h ea d.
h ose, speed con t r ol ser vo h ose, posit ive cr a n kca se
ven t ila t ion (P CV) h ose.
WJ ENGINE - 4.7L 9 - 137
I N TAK E M AN I FOLD (Cont inue d)
(6) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(7) Discon n ect gen er a t or elect r ica l con n ect ion s.
(8) Un bolt t h e gen er a t or a n d m ove it a wa y fr om
t h e in t a ke m a n ifold for clea r a n ce.
(9) Discon n ect a ir con dit ion in g com pr essor elect r i-
ca l con n ect ion s.
(10) Un bolt t h e a ir con dit ion in g com pr essor a n d
m ove it a wa y fr om t h e in t a ke m a n ifold for clea r a n ce.
(11) Discon n ect left a n d r igh t r a dio su ppr essor
st r a ps.
(12) Discon n ect a n d r em ove ign it ion coil t ower s
(Refer t o 8 - E LE CTRICAL/IGNITION CONTROL/
IGNITION COIL - RE MOVAL).
(13) Rem ove t op oil dipst ick t u be r et a in in g bolt
a n d gr ou n d st r a p.
(14) Bleed pr essu r e fr om fu el syst em (Refer t o 14 -
F UE L SYSTE M/F UE L DE LIVE RY - STANDARD
P ROCE DURE ). Fig. 105 Intake Manifold Tightening Sequence
(15) Rem ove fu el r a il (Refer t o 14 - F UE L SYS- (2) In spect t h e in t a ke m a n ifold va cu u m h ose fit -
TE M/F UE L DE LIVE RY/F UE L RAIL - RE MOVAL). t in gs for loosen ess or blocka ge.
(16) Rem ove t h r ot t le body a ssem bly a n d m ou n t in g (3) In spect t h e m a n ifold t o t h r ot t le body m a t in g
br a cket . su r fa ce for cr a cks, n icks a n d dist or t ion .
(17) Dr a in coolin g syst em below coola n t t em per a -
t u r e level (Refer t o 7 - COOLING - STANDARD INSTALLATION
P ROCE DURE ).
(1) In st a ll in t a ke m a n ifold ga sket s.
(18) Rem ove coola n t t em per a t u r e sen sor (Refer t o
(2) In st a ll in t a ke m a n ifold.
7 - COOLING/E NGINE /E NGINE COOLANT TE MP
(3) In st a ll in t a ke m a n ifold r et a in in g bolt s a n d
SE NSOR - RE MOVAL).
t igh t en in sequ en ce sh own in (F ig. 106) t o 12 N·m
(19) Rem ove cowl t o h ood sea l. (Refer t o 23 -
(105 in . lbs.).
BODY/WE ATH E RSTRIP /SE ALS/COWL WE ATH E R-
STRIP - RE MOVAL).
(20) Rem ove r igh t side en gin e lift in g st u d.
(21) Rem ove in t a ke m a n ifold r et a in in g fa st en er s,
in r ever se or der of t igh t en in g sequ en ce (F ig. 105).

NOTE: Intake must be lifted upward and level in the

front and rear to clear the cowl. Interference with
the cowl will occur during removal.

(22) Rem ove in t a ke m a n ifold.

CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.

Befor e in st a llin g t h e in t a ke m a n ifold t h or ou gh ly

clea n t h e m a t in g su r fa ces. Use a su it a ble clea n in g
Fig. 106 Intake Manifold Tightening Sequence
solven t , t h en a ir dr y.
(4) In st a ll left a n d r igh t r a dio su ppr essor st r a ps.
INSPECTION (5) In st a ll t h r ot t le body a ssem bly.
(1) In spect t h e in t a ke sea lin g su r fa ce for cr a cks, (6) In st a ll t h r ot t le ca ble br a cket .
n icks a n d dist or t ion .
9 - 138 ENGINE - 4.7L
I N TAK E M AN I FOLD (Cont inue d)
(7) Con n ect t h r ot t le ca ble a n d speed con t r ol ca ble
t o t h r ot t le body.
(8) In st a ll fu el r a il (Refer t o 14 - F UE L SYSTE M/
F UE L DE LIVE RY/F UE L RAIL - INSTALLATION).
(9) In st a ll ign it ion coil t ower s (Refer t o 8 - E LE C-
TRICAL/IGNITION CONTROL/IGNITION COIL -
INSTALLATION).
(10) In st a ll coola n t t em per a t u r e sen sor (Refer t o 7
- COOLING/E NGINE /E NGINE COOLANT TE MP
SE NSOR - INSTALLATION).
(11) Con n ect elect r ica l con n ect or s for t h e followin g
com pon en t s:
• Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor
• In t a ke Air Tem per a t u r e (IAT) Sen sor
• Th r ot t le P osit ion (TP S) Sen sor
• Coola n t Tem per a t u r e (CTS) Sen sor
• Idle Air Con t r ol (IAC) Mot or
• Ign it ion coil t ower s
• F u el in ject or s
(12) In st a ll t op oil dipst ick t u be r et a in in g bolt a n d
gr ou n d st r a p.
(13) In st a ll r igh t side en gin e lift in g st u d.
(14) In st a ll gen er a t or in clu din g elect r ica l con n ec-
t ion s (Refer t o 8 - E LE CTRICAL/CH ARGING/GE N-
E RATOR - INSTALLATION).
(15) Con n ect Va por pu r ge h ose, Br a ke boost er
h ose, Speed con t r ol ser vo h ose, P osit ive cr a n kca se
ven t ila t ion (P CV) h ose.
(16) In st a ll a ir con dit ion in g com pr essor in clu din g
elect r ica l con n ect ion s.
(17) F ill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(18) In st a ll a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(19) In st a ll cowl t o h ood sea l (Refer t o 23 - BODY/
WE ATH E RSTRIP /SE ALS/COWL WE ATH E RSTRIP -
INSTALLATION).
(20) In st a ll a ir clea n er h ou sin g a n d t h r ot t le body
r eson a t or. Tigh t en r eson a t or bolt s 4.5 N·m (40 in .
lbs.).
(21) Con n ect n ega t ive ca ble t o ba t t er y.
EX H AU ST M AN I FOLD - LEFT
DESCRIPTION
Th e exh a u st m a n ifolds a r e log st yle wit h a pa t -
en t ed flow en h a n cin g design t o m a xim ize per for-
m a n ce. Th e exh a u st m a n ifolds a r e m a de of h igh
silicon m olybden u m ca st ir on . A per for a t ed cor e
gr a ph it e exh a u st m a n ifold ga sket is u sed t o im pr ove
sea lin g t o t h e cylin der h ea d. Th e exh a u st m a n ifolds
a r e cover ed by a t h r ee la yer la m in a t ed h ea t sh ield
for t h er m a l pr ot ect ion a n d n oise r edu ct ion . Th e h ea t
sh ields a r e fa st en ed wit h a t or qu e pr eva ilin g n u t
WJ
t h a t is ba cked off sligh t ly t o a llow for t h e t h er m a l
expa n sion of t h e exh a u st m a n ifold.
REMOVAL
(1) Discon n ect n ega t ive ca ble for ba t t er y.
(2) H oist veh icle.
(3) Discon n ect exh a u st pipe a t m a n ifold.
(4) Lower veh icle.
(5) Rem ove a ir clea n er h ou sin g a n d t u be.
(6) Rem ove t h e fr on t t wo exh a u st h ea t sh ield
r et a in in g fa st en er s. Ra ise veh icle a n d r em ove t h e
fa st en er s a t r ea r of h ea t sh ield.
(7) Rem ove h ea t sh ield (F ig. 107).
(8) Lower veh icle a n d r em ove t h e u pper exh a u st
m a n ifold r et a in in g bolt s (F ig. 107).
(9) Ra ise veh icle a n d r em ove t h e lower exh a u st
m a n ifold r et a in in g bolt s (F ig. 107).
(10) Rem ove exh a u st m a n ifold a n d ga sket (F ig.
107). Ma n ifold is r em oved fr om below t h e en gin e
com pa r t m en t .
CLEANING
(1) Clea n t h e exh a u st m a n ifold u sin g a su it a ble
clea n in g solven t , t h en a llow t o a ir dr y.
(2) Clea n a ll ga sket r esidu e fr om t h e m a n ifold
m a t in g su r fa ce.
INSPECTION
(1) In spect t h e exh a u st m a n ifold for cr a cks in t h e
m a t in g su r fa ce a n d a t ever y m ou n t in g bolt h ole.
(2) Usin g a st r a igh t edge a n d a feeler ga u ge, ch eck
t h e m a t in g su r fa ce for wa r p a n d t wist .
(3) In spect t h e m a n ifold t o exh a u st pipe m a t in g
su r fa ce for cr a cks, gou ges, or ot h er da m a ge t h a t
wou ld pr even t sea lin g.
INSTALLATION
(1) In st a ll exh a u st m a n ifold a n d ga sket fr om below
en gin e com pa r t m en t .
(2) In st a ll lower exh a u st m a n ifold fa st en er s (F ig.
107). DO NOT t igh t en u n t il a ll fa st en er s a r e in
pla ce.
(3) Lower veh icle a n d in st a ll u pper exh a u st m a n i-
fold fa st en er s (F ig. 107). Tigh t en a ll m a n ifold bolt s
st a r t in g a t cen t er a n d wor kin g ou t wa r d t o 25 N·m
(18 ft . lbs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) In st a ll exh a u st m a n ifold h ea t sh ield (F ig. 107).
Tigh t en fa st en er s t o 8 N·m (72 in . lbs.), t h en loosen
45 degr ees.
(5) In st a ll a ir clea n er h ou sin g a n d t u be.
(6) Con n ect exh a u st pipe t o m a n ifold.
(7) Con n ect n ega t ive ca ble t o ba t t er y.
WJ ENGINE - 4.7L 9 - 139
EX H AU ST M AN I FOLD - LEFT (Cont inue d)

Fig. 107 Exhaust Manifold—Left

ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2) 4 Nut (Qty 2) 8 N·m (72 in. lbs.),
then loosen 45
2 Bolt (Qty 4) 25 N·m (18 ft. lbs.) 5 Nut (Qty 2) degrees
3 Stud (Qty 2)

EX H AU ST M AN I FOLD - RI GH T
DESCRIPTION
Th e exh a u st m a n ifolds a r e log st yle wit h a pa t -
en t ed flow en h a n cin g design t o m a xim ize per for-
m a n ce. Th e exh a u st m a n ifolds a r e m a de of h igh
silicon m olybden u m ca st ir on . A per for a t ed cor e
gr a ph it e exh a u st m a n ifold ga sket is u sed t o im pr ove
sea lin g t o t h e cylin der h ea d. Th e exh a u st m a n ifolds
a r e cover ed by a t h r ee la yer la m in a t ed h ea t sh ield
for t h er m a l pr ot ect ion a n d n oise r edu ct ion . Th e h ea t
sh ields a r e fa st en ed wit h a t or qu e pr eva ilin g n u t
t h a t is ba cked off sligh t ly t o a llow for t h e t h er m a l
expa n sion of t h e exh a u st m a n ifold.
REMOVAL
(1) Discon n ect n ega t ive ca ble for ba t t er y.
(2) Rem ove ba t t er y fr om veh icle.
(3) Rem ove P ower Dist r ibu t ion Cen t er (P DC) fa s-
t en er s a n d set a side.
(4) Rem ove ba t t er y t r a y a ssem bly.
(5) Rem ove wa sh er bot t le a ssem bly
(6) Rem ove a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
9 - 140 ENGINE - 4.7L WJ
EX H AU ST M AN I FOLD - RI GH T (Cont inue d)
(7) Rem ove A/C com pr essor fr om m ou n t in g a n d set (16) Rem ove fa st en er s a t t a ch in g st a r t er. Move
a side. st a r t er a side.
(8) Rem ove A/C a ccu m u la t or su ppor t br a cket fa s- (17) Rem ove lower exh a u st m a n ifold a t t a ch in g fa s-
t en er. t en er s.
(9) Dr a in coola n t (Refer t o 7 - COOLING - STAN- (18) Rem ove exh a u st m a n ifold a n d ga sket (F ig.
DARD P ROCE DURE ). 108). Ma n ifold is r em oved fr om below t h e en gin e
(10) Rem ove h ea t er h oses a t en gin e. com pa r t m en t .
(11) Rem ove fa st en er s a t t a ch in g exh a u st m a n ifold
h ea t sh ield (F ig. 108). CLEANING
(12) Rem ove h ea t sh ield (F ig. 108). (1) Clea n t h e exh a u st m a n ifold u sin g a su it a ble
(13) Rem ove u pper exh a u st m a n ifold a t t a ch in g fa s- clea n in g solven t , t h en a llow t o a ir dr y.
t en er s (F ig. 108). (2) Clea n a ll ga sket r esidu e fr om t h e m a n ifold
(14) Ra ise veh icle on h oist . m a t in g su r fa ce.
(15) Discon n ect exh a u st pipe fr om m a n ifold.

Fig. 108 Exhaust Manifold—Right

ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2) 4 Nut (Qty 2) 8 N·m (72 in. lbs.),
then loosen 45
2 Bolt (Qty 4) 25 N·m (18 ft. lbs.) 5 Nut (Qty 2) degrees
3 Stud (Qty 2)
WJ
EX H AU ST M AN I FOLD - RI GH T (Cont inue d)
INSPECTION
(1) In spect t h e exh a u st m a n ifold for cr a cks in t h e
m a t in g su r fa ce a n d a t ever y m ou n t in g bolt h ole.
(2) Usin g a st r a igh t edge a n d a feeler ga u ge, ch eck
t h e m a t in g su r fa ce for wa r p a n d t wist .
(3) In spect t h e m a n ifold t o exh a u st pipe m a t in g
su r fa ce for cr a cks, gou ges, or ot h er da m a ge t h a t
wou ld pr even t sea lin g.
INSTALLATION
(1) In st a ll exh a u st m a n ifold a n d ga sket fr om below
en gin e com pa r t m en t .
(2) In st a ll lower exh a u st m a n ifold fa st en er s. DO
NOT t igh t en u n t il a ll fa st en er s a r e in pla ce.
(3) Lower veh icle a n d in st a ll u pper exh a u st m a n i-
fold fa st en er s. Tigh t en a ll m a n ifold bolt s st a r t in g a t
cen t er a n d wor kin g ou t wa r d t o 25 N·m (18 ft . lbs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) In st a ll exh a u st m a n ifold h ea t sh ield. Tigh t en
fa st en er s t o 8 N·m (72 in . lbs.), t h en loosen 45
degr ees.
(5) In st a ll st a r t er a n d fa st en er s.
(6) Con n ect exh a u st pipe t o m a n ifold.
(7) Con n ect h ea t er h oses a t en gin e.
(8) In st a ll fa st en er a t t a ch in g A/C a ccu m u la t or.
(9) In st a ll A/C com pr essor a n d fa st en er s.
(10) In st a ll a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(11) In st a ll wa sh er bot t le a n d ba t t er y t r a y a ssem -
bly.
(12) In st a ll P DC.
(13) In st a ll ba t t er y a n d con n ect ca bles.
(14) F ill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
VALV E T I M I N G
DESCRIPTION - TIMING DRIVE SYSTEM
Th e t im in g dr ive syst em h a s been design ed t o pr o-
vide qu iet per for m a n ce a n d r elia bilit y t o su ppor t a
n o n -fre e w h e e lin g en gin e. Specifica lly t h e in t a ke
va lves a r e n on -fr ee wh eelin g a n d ca n be ea sily da m -
a ged wit h for cefu l en gin e r ot a t ion if ca m sh a ft -t o-
cr a n ksh a ft t im in g is in cor r ect . Th e t im in g dr ive
syst em con sist s of a pr im a r y ch a in a n d t wo secon d-
a r y t im in g ch a in dr ives (F ig. 109).
OPERATION - TIMING DRIVE SYSTEM
Th e pr im a r y t im in g ch a in is a sin gle in ver t ed t oot h
t ype. Th e pr im a r y ch a in dr ives t h e la r ge fift y t oot h
idler spr ocket dir ect ly fr om a 25 t oot h cr a n ksh a ft
ENGINE - 4.7L 9 - 141
spr ocket . P r im a r y ch a in m ot ion is con t r olled by a
pivot in g lea f spr in g t en sion er a r m a n d a fixed gu ide.
Th e a r m a n d t h e gu ide bot h u se n ylon pla st ic wea r
fa ces for low fr ict ion a n d lon g wea r. Th e pr im a r y
ch a in r eceives oil spla sh lu br ica t ion fr om t h e secon d-
a r y ch a in dr ive a n d oil pu m p lea ka ge. Th e idler
spr ocket a ssem bly con n ect s t h e pr im a r y a n d secon d-
a r y ch a in dr ives. Th e idler spr ocket a ssem bly con -
sist s of t wo in t egr a l t h ir t y t oot h spr ocket s a n d a fift y
t oot h spr ocket t h a t is splin ed t o t h e a ssem bly. Th e
splin e join t is a n on – ser vicea ble pr ess fit a n t i r a t t le
t ype. A spir a l r in g is in st a lled on t h e ou t boa r d side of
t h e fift y t oot h spr ocket t o pr even t splin e disen ga ge-
m en t . Th e idler spr ocket a ssem bly spin s on a st a t ion -
a r y idler sh a ft . Th e idler sh a ft is pr ess-fit in t o t h e
cylin der block. A la r ge wa sh er on t h e idler sh a ft bolt
a n d t h e r ea r fla n ge of t h e idler sh a ft a r e u sed t o con -
t r ol spr ocket t h r u st m ovem en t . P r essu r ized oil is
r ou t ed t h r ou gh t h e cen t er of t h e idler sh a ft t o pr o-
vide lu br ica t ion for t h e t wo bu sh in gs u sed in t h e
idler spr ocket a ssem bly.
Th er e a r e t wo secon da r y dr ive ch a in s, bot h a r e
in ver t ed t oot h t ype, on e t o dr ive t h e ca m sh a ft in ea ch
SOH C cylin der h ea d. Th er e a r e n o sh a ft speed
ch a n ges in t h e secon da r y ch a in dr ive syst em . E a ch
secon da r y ch a in dr ives a t h ir t y t oot h ca m spr ocket
dir ect ly fr om t h e t h ir t y t oot h spr ocket on t h e idler
spr ocket a ssem bly. A fixed ch a in gu ide a n d a h ydr a u -
lic oil da m ped t en sion er a r e u sed t o m a in t a in t en sion
in ea ch secon da r y ch a in syst em . Th e h ydr a u lic t en -
sion er s for t h e secon da r y ch a in syst em s a r e fed pr es-
su r ized oil fr om oil r eser voir pocket s in t h e block.
E a ch t en sion er a lso h a s a m ech a n ica l r a t ch et syst em
t h a t lim it s ch a in sla ck if t h e t en sion er pist on bleeds
down a ft er en gin e sh u t down . Th e t en sion er a r m s
a n d gu ides a lso u t ilize n ylon wea r fa ces for low fr ic-
t ion a n d lon g wea r. Th e secon da r y t im in g ch a in s
r eceive lu br ica t ion fr om a sm a ll or ifice in t h e t en -
sion er s. Th is or ifice is pr ot ect ed fr om cloggin g by a
fin e m esh scr een wh ich is loca t ed on t h e ba ck of t h e
h ydr a u lic t en sion er s.
STAN DARD PROCEDU RE
STANDARD PROCEDURE - ENGINE TIMING -
VERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
9 - 142 ENGINE - 4.7L
VALV E T I M I N G (Cont inue d)
Fig. 109 Timing Drive System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
3 - SECONDARY TENSIONER ARM
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
E n gin e ba se t im in g ca n be ver ified by t h e followin g
pr ocedu r e:
(1) Rem ove t h e cylin der h ea d cover s (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL).
(2) Usin g a m ir r or, loca t e t h e TDC a r r ow on t h e
fr on t cover (F ig. 110). Rot a t e t h e cr a n ksh a ft u n t il t h e
m a r k on t h e cr a n ksh a ft da m per is a lign ed wit h t h e
TDC a r r ow on t h e fr on t cover. Th e en gin e is n ow a t
TDC.
WJ
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
9 - CRANKSHAFT SPROCKET
10 - PRIMARY CHAIN TENSIONER
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
12 - SECONDARY TENSIONER ARM
(3) Not e t h e loca t ion of t h e V8 m a r k st a m ped in t o
t h e ca m sh a ft dr ive gea r s (F ig. 111). If t h e V8 m a r k
on ea ch ca m sh a ft dr ive gea r is a t t h e t welve o’clock
posit ion , t h e en gin e is a t TDC (cylin der #1) on t h e
exh a u st st r oke. If t h e V8 m a r k on ea ch gea r is a t t h e
six o’clock posit ion , t h e en gin e is a t TDC (cylin der
#1) on t h e com pr ession st r oke.
(4) If bot h of t h e ca m sh a ft dr ive gea r s a r e off in
t h e sa m e or opposit e dir ect ion s, t h e pr im a r y ch a in or
bot h secon da r y ch a in s a r e a t fa u lt . Refer t o Tim in g
Ch a in a n d Spr ocket s pr ocedu r e in t h is sect ion .
(5) If on ly on e of t h e ca m sh a ft dr ive gea r s is off
a n d t h e ot h er is cor r ect , t h e pr oblem is con fin ed t o
on e secon da r y ch a in . Refer t o Sin gle ca m sh a ft t im -
in g, in t h is pr ocedu r e.
(6) If bot h ca m sh a ft dr ive gea r V8 m a r ks a r e a t
t h e t welve o’clock or t h e six o’ clock posit ion t h e
en gin e ba se t im in g is cor r ect . Rein st a ll t h e cylin der
h ea d cover s.
WJ ENGINE - 4.7L 9 - 143
VALV E T I M I N G (Cont inue d)
SINGLE CAMSHAFT TIMING
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.

(1) Usin g Ch a in Ten sion er Wedge, specia l t ool

8350, st a bilize t h e secon da r y ch a in dr ive (F ig. 112).
F or r efer en ce pu r poses, m a r k t h e ch a in -t o-spr ocket
posit ion (F ig. 112).
(2) Rem ove t h e ca m sh a ft dr ive gea r r et a in in g bolt .
(3) Ca r efu lly r em ove t h e ca m sh a ft dr ive gea r fr om
t h e ca m sh a ft .
(4) Re-in dex t h e ca m sh a ft dr ive gea r in t h e ch a in
u n t il t h e V8 m a r k is a t t h e sa m e posit ion a s t h e V8
m a r k on t h e opposit e ca m sh a ft dr ive gea r.

NOTE: When gripping the camshaft, place the pliers

on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.

Fig. 110 Engine Top Dead Center (TDC) Indicator

Mark
1 - TIMING CHAIN COVER
2 - CRANKSHAFT TIMING MARKS

Fig. 111 Camshaft Sprocket V8 Marks

1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
9 - 144 ENGINE - 4.7L WJ
VALV E T I M I N G (Cont inue d)

Fig. 112 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE
2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE

(5) Usin g a su it a ble pa ir of a dju st a ble plier s,

r ot a t e t h e ca m sh a ft u n t il t h e a lign m en t dowel on t h e
ca m sh a ft is a lign ed wit h t h e slot in t h e ca m sh a ft
dr ive gea r (F ig. 113).

CAUTION: Remove excess oil from camshaft

sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.

(6) P osit ion t h e ca m sh a ft dr ive gea r on t o t h e ca m -

sh a ft , r em ove oil fr om bolt t h en in st a ll t h e r et a in in g
bolt . Usin g Specia l Tools, Spa n n er Wr en ch 6958 wit h
Ada pt er P in s 8346 a n d a su it a ble t or qu e wr en ch ,
Tigh t en r et a in in g bolt t o 122N·m (90 ft . Lbs.) (F ig.
114) (F ig. 115).
(7) Rem ove specia l t ool 8350.
(8) Rot a t e t h e cr a n ksh a ft t wo fu ll r evolu t ion s, t h en
r ever ify t h a t t h e ca m sh a ft dr ive gea r V8 m a r ks a r e
in fa ct a lign ed.
(9) In st a ll t h e cylin der h ea d cover s (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION). Fig. 113 Camshaft Dowel
1 - ADJUSTABLE PLIERS
2 - CAMSHAFT DOWEL
WJ ENGINE - 4.7L 9 - 145
VALV E T I M I N G (Cont inue d)

Fig. 115 Camshaft Sprocket Installation—Right

Cylinder Head
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET

Fig. 114 Camshaft Sprocket Left Cylinder Head

1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346

STANDARD PROCEDURE—MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.

(1) Rem ove t h e t im in g ch a in cover. (Refer t o 9 -

E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - RE MOVAL).
(2) To det er m in e if t h e secon da r y t im in g ch a in s
a r e wor n , r ot a t e t h e en gin e clockwise u n t il m a xim u m
t en sion er pist on ext en sion is obt a in ed. Mea su r e t h e
dist a n ce bet ween t h e secon da r y t im in g ch a in t en -
sion er h ou sin g a n d t h e st ep ledge on t h e pist on (F ig.
116). Th e m ea su r em en t a t poin t (A) m u st be less Fig. 116 Measuring Secondary Timing Chains For
t h a n 15m m (0.5906 in ch es). Wear
(3) If t h e m ea su r em en t exceeds t h e specifica t ion 1 - SECONDARY TENSIONER ARM
t h e secon da r y t im in g ch a in s a r e wor n a n d r equ ir e 2 - SECONDARY CHAIN TENSIONER PISTON
r epla cem en t . (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS - NOTE: If the secondary chains are to be replaced
RE MOVAL). the primary chain must also be replaced.
9 - 146 ENGINE - 4.7L WJ

T I M I N G BELT / CH AI N
COV ER(S)
REMOVAL
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
(2) Dr a in coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(3) Discon n ect bot h h ea t er h oses a t t im in g cover.
(4) Discon n ect lower r a dia t or h ose a t en gin e.
(5) Rem ove cr a n ksh a ft da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL).
(6) Rem ove a ccessor y dr ive belt t en sion er a ssem bly
(F ig. 117).

Fig. 118 Timing Chain Cover Fasteners

Fig. 117 Accessory Drive Belt Tensioner

1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
(7) Rem ove t h e gen er a t or a n d A/C com pr essor.
(8) Rem ove cover a n d ga sket (F ig. 118).
INSTALLATION
(1) Clea n t im in g ch a in cover a n d block su r fa ce.
In spect cover ga sket a n d r epla ce a s n ecessa r y.
(2) In st a ll cover a n d ga sket . Tigh t en fa st en er s in
sequ en ce a s sh own in (F ig. 119) t o 54 N·m (40 ft .
lbs.).
(3) In st a ll t h e A/C com pr essor a n d gen er a t or.
Fig. 119 Timing Chain Cover Fasteners
(4) In st a ll cr a n ksh a ft da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION).
(5) In st a ll a ccessor y dr ive belt t en sion er a ssem bly.
Tigh t en fa st en er t o 54 N·m (40 ft . lbs.).
(6) In st a ll lower r a dia t or h ose.
(7) In st a ll bot h h ea t er h oses.
(8) F ill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(9) Con n ect t h e ba t t er y n ega t ive ca ble.
WJ ENGINE - 4.7L 9 - 147

T I M I N G BELT /CH AI N AN D (6) Rem ove power st eer in g pu m p.

SPROCK ET S
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Dr a in coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE ).
(3) Rem ove r igh t a n d left cylin der h ea d cover s
(Refer t o 9 - E NGINE /CYLINDE R H E AD/CYLIN-
DE R H E AD COVE R(S) - RE MOVAL).
(4) Rem ove r a dia t or fa n (Refer t o 7 - COOLING/
E NGINE /RADIATOR FAN - RE MOVAL).
(5) Rot a t e en gin e u n t il t im in g m a r k on cr a n ksh a ft
da m per a lign s wit h TDC m a r k on t im in g ch a in cover
(F ig. 120) (#1 cylin der exh a u st st r oke) a n d t h e ca m -
sh a ft spr ocket “V8” m a r ks a r e a t t h e 12 o’clock posi-
t ion (F ig. 121).
(7) Rem ove a ccess plu gs (2) fr om left a n d r igh t cyl-
in der h ea ds for a ccess t o ch a in gu ide fa st en er s (F ig.
122).
(8) Rem ove t h e oil fill h ou sin g t o ga in a ccess t o t h e
r igh t side t en sion er a r m fa st en er.
(9) Rem ove cr a n ksh a ft da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL) a n d t im in g ch a in cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - RE MOVAL).
(10) Colla pse a n d pin pr im a r y ch a in t en sion er
(F ig. 123).
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Rem ove secon da r y ch a in t en sion er s.
(12) Rem ove ca m sh a ft posit ion sen sor fr om r igh t
cylin der h ea d (F ig. 124).

CAUTION: Care should be taken not to damage

camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.

CAUTION: Do not forcefully rotate the camshafts or

crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.

(13) Rem ove left a n d r igh t ca m sh a ft spr ocket bolt s.

(14) Wh ile h oldin g t h e left ca m sh a ft st eel t u be
wit h a dju st a ble plier s, (F ig. 125) r em ove t h e left
ca m sh a ft spr ocket . Slowly r ot a t e t h e ca m sh a ft
a ppr oxim a t ely 15 degr ees clockwise t o a n eu t r a l posi-
Fig. 120 Engine Top Dead Center (TDC) Indicator t ion .
Mark (15) Wh ile h oldin g t h e r igh t ca m sh a ft st eel t u be
wit h a dju st a ble plier s, (F ig. 126) r em ove t h e r igh t
1 - TIMING CHAIN COVER
ca m sh a ft spr ocket . Slowly r ot a t e t h e ca m sh a ft
2 - CRANKSHAFT TIMING MARKS
a ppr oxim a t ely 45 degr ees cou n t er clockwise t o a n eu -
t r a l posit ion .
9 - 148 ENGINE - 4.7L WJ
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)

Fig. 121 Camshaft Sprocket V8 Marks

1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD

Fig. 122 Cylinder Head Access Plug Location

1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig. 123 Collapsing And Pinning Primary Chain
(16) Rem ove idler spr ocket a ssem bly bolt . Tensioner
(17) Slide t h e idler spr ocket a ssem bly a n d cr a n k 1 - PRIMARY CHAIN TENSIONER
spr ocket for wa r d sim u lt a n eou sly t o r em ove t h e pr i- 2 - ADJUSTABLE PLIERS
m a r y a n d secon da r y ch a in s. 3 - SPECIAL TOOL 8514
(18) Rem ove bot h pivot in g t en sion er a r m s a n d
ch a in gu ides.
(19) Rem ove ch a in t en sion er.
WJ ENGINE - 4.7L 9 - 149
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)

Fig. 124 Camshaft Position Sensor—Removal Fig. 126 Camshaft Rotation—Right Side
1 - CRANKSHAFT POSITION SENSOR 1 - ADJUSTABLE PLIERS
2 - CYLINDER HEAD COVER 2 - CAMSHAFT DOWEL
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
INSPECTION
In spect t h e followin g com pon en t s:
• Spr ocket s for excessive t oot h wea r. Som e t oot h
m a r kin gs a r e n or m a l a n d n ot a ca u se for spr ocket
r epla cem en t .
• Idler spr ocket a ssem bly bu sh in g a n d sh a ft for
excessive wea r.
• Idler spr ocket a ssem bly splin e join t . Th e join t
sh ou ld be t igh t wit h n o ba ckla sh or a xia l m ovem en t .
• Ch a in gu ides a n d t en sion er a r m s. Repla ce t h ese
pa r t s if gr oovin g in pla st ic fa ce is m or e t h a n 1 m m
(0.039 in .) deep. If pla st ic fa ce is sever ely gr ooved or
m elt ed, t h e t en sion er lu be jet m a y be clogged. Th e
t en sion er sh ou ld be r epla ced.
• secon da r y ch a in t en sion er pist on a n d r a t ch et in g
device. In spect for eviden ce of h ea vy con t a ct bet ween
t en sion er pist on a n d t en sion er a r m . If t h is con dit ion
exist t h e t en sion er a n d t en sion er a r m sh ou ld be
r epla ced.
• P r im a r y ch a in t en sion er pla st ic fa ces. Repla ce a s
r equ ir ed (F ig. 127).

INSTALLATION
(1) Usin g a vise, ligh t ly com pr ess t h e secon da r y
Fig. 125 Camshaft Rotation—Left Side
ch a in t en sion er pist on u n t il t h e pist on st ep is flu sh
1 - CAMSHAFT SPROCKET AND CHAIN
wit h t h e t en sion er body. Usin g a pin or su it a ble t ool,
2 - ADJUSTABLE PLIERS
r elea se r a t ch et pa wl by pu llin g pa wl ba ck a ga in st
3 - CAMSHAFT
spr in g for ce t h r ou gh a ccess h ole on side of t en sion er.
Wh ile con t in u in g t o h old pa wl ba ck, P u sh r a t ch et
device t o a ppr oxim a t ely 2 m m fr om t h e t en sion er
9 - 150 ENGINE - 4.7L
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)
Fig. 127 Timing Chain System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
3 - SECONDARY TENSIONER ARM
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
body. In st a ll Specia l Tool 8514 lock pin in t o h ole on
fr on t of t en sion er. Slowly open vise t o t r a n sfer pist on
spr in g for ce t o lock pin (F ig. 128).
(2) P osit ion pr im a r y ch a in t en sion er over oil pu m p
a n d in ser t bolt s in t o lower t wo h oles on t en sion er
br a cket . Tigh t en bolt s t o 28 N·m (250 in . lbs.).
CAUTION: Overtightening the tensioner arm torx"
bolt can cause severe damage to the cylinder head.
Tighten torx" bolt to specified torque only.
(3) In st a ll r igh t side ch a in t en sion er a r m . Apply
Mopa r ! Lock N, Sea l t o t or x! bolt , t igh t en bolt t o 17
N·m (150 in . lbs.).
NOTE: The silver bolts retain the guides to the cyl-
inder heads and the black bolts retain the guides to
the engine block.
WJ
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
9 - CRANKSHAFT SPROCKET
10 - PRIMARY CHAIN TENSIONER
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
12 - SECONDARY TENSIONER ARM
(4) In st a ll t h e left side ch a in gu ide. Tigh t en t h e
bolt s t o 28 N·m (250 in . lbs.).
CAUTION: Overtightening the tensioner arm torx"
bolt can cause severe damage to the cylinder head.
Tighten torx" bolt to specified torque only.
(5) In st a ll left side ch a in t en sion er a r m . Apply
Mopa r ! Lock N, Sea l t o t or x! bolt , t igh t en bolt t o 17
N·m (150 in . lbs.).
(6) In st a ll t h e r igh t side ch a in gu ide. Tigh t en t h e
bolt s t o 28 N·m (250 in . lbs.).
(7) In st a ll bot h secon da r y ch a in s on t o t h e idler
spr ocket . Align t wo pla t ed lin ks on t h e secon da r y
ch a in s t o be visible t h r ou gh t h e t wo lower open in gs
on t h e idler spr ocket (4 o’clock a n d 8 o’clock). On ce
t h e secon da r y t im in g ch a in s a r e in st a lled, posit ion
specia l t ool 8515 t o h old ch a in s in pla ce for in st a lla -
t ion (F ig. 129).
WJ ENGINE - 4.7L 9 - 151
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)

Fig. 129 Installing Secondary Timing Chains on

Idler Sprocket
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
Fig. 128 Resetting Secondary Chain Tensioners 3 - SECONDARY CHAINS RETAINING PINS (4)
1 - VISE 4 - IDLER SPROCKET
2 - INSERT LOCK PIN 5 - LEFT CAMSHAFT CHAIN
3 - RATCHET PAWL 6 - SPECIAL TOOL 8515
4 - RATCHET
5 - PISTON

(8) Align pr im a r y ch a in dou ble pla t ed lin ks wit h

t h e t im in g m a r k a t 12 o’clock on t h e idler spr ocket .
Align t h e pr im a r y ch a in sin gle pla t ed lin k wit h t h e
t im in g m a r k a t 6 o’clock on t h e cr a n ksh a ft spr ocket
(F ig. 127).
(9) Lu br ica t e idler sh a ft a n d bu sh in gs wit h clea n
en gin e oil.
(10) In st a ll a ll ch a in s, cr a n ksh a ft spr ocket , a n d
idler spr ocket a s a n a ssem bly (F ig. 130). Aft er gu id-
in g bot h secon da r y ch a in s t h r ou gh t h e block a n d cyl-
in der h ea d open in gs, a ffix ch a in s wit h a ela st ic st r a p
or t h e equ iva len t , Th is will m a in t a in t en sion on
ch a in s t o a id in in st a lla t ion .

NOTE: It will be necessary to slightly rotate cam-

shafts for sprocket installation.

(11) Align left ca m sh a ft spr ocket “L” dot t o pla t ed

lin k on ch a in . Fig. 130 Installing Idler Gear, Primary and
(12) Align r igh t ca m sh a ft spr ocket “R” dot t o Secondary Timing Chains
pla t ed lin k on ch a in . 1 - SPECIAL TOOL 8515
2 - PRIMARY CHAIN IDLER SPROCKET
CAUTION: Remove excess oil from the camshaft 3 - CRANKSHAFT SPROCKET
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
9 - 152 ENGINE - 4.7L WJ
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)
(13) Rem ove Specia l Tool 8515, t h en a t t a ch bot h
spr ocket s t o ca m sh a ft s. Rem ove excess oil fr om bolt s,
t h en In st a ll spr ocket bolt s, bu t do n ot t igh t en a t t h is
t im e.
(14) Ver ify t h a t a ll pla t ed lin ks a r e a lign ed wit h
t h e m a r ks on a ll spr ocket s a n d t h e “V8” m a r ks on
ca m sh a ft spr ocket s a r e a t t h e 12 o’clock posit ion (F ig.
127).

CAUTION: Ensure the plate between the left sec-

ondary chain tensioner and block is correctly
installed.

(15) In st a ll bot h secon da r y ch a in t en sion er s.

Tigh t en bolt s t o 28 N·m (250 in . lbs.).

NOTE: Left and right secondary chain tensioners

are not common.

(16) Befor e in st a llin g idler spr ocket bolt , lu br ica t e

wa sh er wit h oil, a n d t igh t en idler spr ocket a ssem bly
r et a in in g bolt t o 34 N·m (25 ft . lbs.).
(17) Rem ove a ll lockin g pin s (3) fr om t en sion er s.

CAUTION: After pulling locking pins out of each

tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.

(18) Usin g Specia l Tool 6958, Spa n n er wit h Ada p- Fig. 131 Tightening Left Side Camshaft Sprocket
t or P in s 8346, t igh t en left (F ig. 131) a n d r igh t (F ig. Bolt
132). ca m sh a ft spr ocket bolt s t o 122 N·m (90 ft . lbs.). 1 - TORQUE WRENCH
(19) Rot a t e en gin e t wo fu ll r evolu t ion s. Ver ify t im - 2 - CAMSHAFT SPROCKET
in g m a r ks a r e a t t h e follow loca t ion s: 3 - LEFT CYLINDER HEAD
• pr im a r y ch a in idler spr ocket dot is a t 12 o’clock 4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
(F ig. 127)
• pr im a r y ch a in cr a n ksh a ft spr ocket dot is a t 6 (20) Lu br ica t e a ll t h r ee ch a in s wit h en gin e oil.
o’clock (F ig. 127) (21) Aft er in st a llin g a ll ch a in s, it is r ecom m en ded
• secon da r y ch a in ca m sh a ft spr ocket s “V8” m a r ks t h a t t h e idler gea r en d pla y be ch ecked (F ig. 133).
a r e a t 12 o’clock (F ig. 127) Th e en d pla y m u st be wit h in 0.10–0.25 m m (0.004–
0.010 in .). If n ot wit h in specifica t ion , t h e idler gea r
m u st be r epla ced.
WJ ENGINE - 4.7L 9 - 153
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)
(22) In st a ll t im in g ch a in cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - INSTALLATION) a n d cr a n ksh a ft
da m per (Refer t o 9 - E NGINE /E NGINE BLOCK/VI-
BRATION DAMP E R - INSTALLATION).
(23) In st a ll cylin der h ea d cover s (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).

NOTE: Before installing threaded plug in right cylin-

der head, the plug must be coated with sealant to
prevent leaks.

(24) Coa t t h e la r ge t h r ea ded a ccess plu g wit h

Mo p a r! Th re a d S e a la n t w ith Te flo n , t h en in st a ll
in t o t h e r igh t cylin der h ea d a n d t igh t en t o 81 N·m
(60 ft . lbs.) (F ig. 122).
(25) In st a ll t h e oil fill h ou sin g.
(26) In st a ll a ccess plu g in left cylin der h ea d (F ig.
Fig. 132 Tightening Right Side Camshaft Sprocket 122).
Bolt (27) In st a ll power st eer in g pu m p.
(28) In st a ll r a dia t or fa n (Refer t o 7 - COOLING/
1 - TORQUE WRENCH
E NGINE /RADIATOR FAN - INSTALLATION).
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
(29) F ill coolin g syst em (Refer t o 7 - COOLING -
4 - RIGHT CAMSHAFT SPROCKET STANDARD P ROCE DURE ).
(30) Con n ect n ega t ive ca ble t o ba t t er y.

Fig. 133 Measuring Idler Gear End Play

1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
WJ EXHAUST SYSTEM 11 - 1

EXHAUST SYSTEM
TABLE OF CON T EN T S

page page

EXHAUST SYSTEM EXHAUST PIPE - 4.0L

DESCRIPTION - EXHAUST SYSTEM . . . ......1 REMOVAL .............................8
DIAGNOSIS AND TESTING - EXHAUST INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . ......3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS EXHAUST PIPE - 4.7L
TORQUE . . . . . . . . . . . . . . . . . . . . . . . ......3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CATALYTIC CONVERTER - 4.0L INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION - CATALYTIC CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .4 HEAT SHIELDS
REMOVAL ....................... . . . . . .4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .5 MUFFLER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
CATALYTIC CONVERTER - 4.7L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION - CATALYTIC CONVERTER ... . .6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL ....................... .... . .6 TAILPIPE
INSPECTION . . . . . . . . . . . . . . . . . . . . . .... . .7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . .... . .7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

EX H AU ST SY ST EM Th e 50 St a t e E m ission s veh icles u se t wo m in i ca t -

a lyt ic con ver t er s in lin e wit h t h e exh a u st pipe below
t h e exh a u st m a n ifolds.
DESCRIPTION - EXHAUST SYSTEM
Th e exh a u st m a n ifolds a r e equ ipped wit h ba ll
WARNING: THE NORMAL OPERATING TEMPERA- fla n ge ou t let s t o a ssu r e a t igh t sea l a n d st r a in fr ee
TURE OF THE EXHAUST SYSTEM IS VERY HIGH. con n ect ion s.
THEREFORE, NEVER WORK AROUND OR ATTEMPT Th e exh a u st syst em m u st be pr oper ly a lign ed t o
TO SERVICE ANY PART OF THE EXHAUST SYSTEM pr even t st r ess, lea ka ge a n d body con t a ct . If t h e sys-
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE t em con t a ct s a n y body pa n el, it m a y a m plify objec-
TAKEN WHEN WORKING NEAR THE CATALYTIC t ion a ble n oises or igin a t in g fr om t h e en gin e or body.
CONVERTER. THE TEMPERATURE OF THE CON- Wh en in spect in g a n exh a u st syst em , cr it ica lly
VERTER RISES TO A HIGH LEVEL AFTER A SHORT in spect for cr a cked or loose join t s, st r ipped scr ew or
PERIOD OF ENGINE OPERATION TIME. bolt t h r ea ds, cor r osion da m a ge a n d wor n , cr a cked or
br oken h a n ger s. Repla ce a ll com pon en t s t h a t a r e
ba dly cor r oded or da m a ged. DO NOT a t t em pt t o
CAUTION: Avoid application of rust prevention com- r epa ir.
pounds or undercoating materials to exhaust sys- Wh en r epla cem en t is r equ ir ed, u se or igin a l equ ip-
tem floor pan heat shields. Light overspray near the m en t pa r t s (or t h eir equ iva len t ). Th is will a ssu r e
edges is permitted. Application of coating will result pr oper a lign m en t a n d pr ovide a ccept a ble exh a u st
in excessive floor pan temperatures and objection- n oise levels.
able fumes. Th e ba sic exh a u st syst em con sist s of exh a u st m a n -
ifold(s), exh a u st pipe wit h oxygen sen sor s, ca t a lyt ic
Th e exh a u st syst em u ses a sin gle m u ffler wit h a con ver t er (s), h ea t sh ield(s), m u ffler a n d t a ilpipe (F ig.
welded t a ilpipe. 1) a n d (F ig. 2).
11 - 2 EXHAUST SYSTEM WJ
EX H AU ST SY ST EM (Cont inue d)

Fig. 1 Exhaust System—4.0L

1 - MINI CONVERTERS (2) 5 - TAILPIPE
2 - CATALYTIC CONVERTER TO EXHAUST PIPE FLANGE JOINT 6 - TAILPIPE HANGER REAR MOUNT INSULATOR
3 - CATALYTIC CONVERTER 7 - EXHAUST PIPE HANGER AND MOUNT INSULATOR
4 - MUFFLER

Fig. 2 Exhaust System—4.7L

1 - EXHAUST PIPE WITH CATALYTIC CONVERTERS 5 - TAILPIPE
2 - EXHAUST PIPE TO CATALYTIC CONVERTER FLANGE JOINT 6 - TAILPIPE HANGER REAR MOUNT INSULATOR
3 - CATALYTIC CONVERTER 7 - EXHAUST PIPE HANGER AND MOUNT INSULATOR
4 - MUFFLER
WJ EXHAUST SYSTEM 11 - 3
EX H AU ST SY ST EM (Cont inue d)

DIAGNOSIS AND TESTING - EXHAUST SYSTEM

EX H AU ST SY ST EM DI AGN OSI S CH ART

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps to specified

torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).

2. Burned or blown out muffler. 2. Replace muffler assembly (Refer

3. Burned or rusted-out exhaust
pipe.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Restriction in muffler or tailpipe.
8. Exhaust system contacting body
or chassis.
to 11 - EXHAUST SYSTEM/
MUFFLER - REMOVAL). Check
exhaust system.
3. Replace exhaust pipe (Refer to
11 - EXHAUST SYSTEM/EXHAUST
PIPE - REMOVAL).
4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).
5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).
6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).
7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Re-align exhaust system to clear
surrounding components.

LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking

joints (Refer to 11 - EXHAUST
SYSTEM - SPECIFICATIONS).

SPECI FI CAT I ON S
TORQUE

DESCRIPTION N·m Ft. In. DESCRIPTION N·m Ft. In.

Lbs. Lbs. Lbs. Lbs.
Catalytic Converter-to- 28 — 250 Muffler-to-Catalytic
Exhaust Pipe—Nuts Converter
Exhaust Pipe-to-Manifold— 31 23 — U-bolt clamp 47 35 —
Nuts Rear Tailpipe Hanger— 22 — 192
Heat Shield Retaining— 2.0 — 20 Bolts
Nuts
11 - 4 EXHAUST SYSTEM
CATALY T I C CON V ERT ER - 4 .0 L
DESCRIPTION - CATALYTIC CONVERTER 4.0L
ENGINE
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
Fig. 3 4.0L Catalytic Converter and O2 Sensor Configuration - 50 State Emissions
WJ
Th e st a in less st eel ca t a lyt ic con ver t er body is
design ed t o la st t h e life of t h e veh icle. E xcessive h ea t
ca n r esu lt in bu lgin g or ot h er dist or t ion , bu t exces-
sive h ea t will n ot be t h e fa u lt of t h e con ver t er. If
u n bu r n ed fu el en t er s t h e con ver t er, over h ea t in g m a y
occu r. If a con ver t er is h ea t -da m a ged, cor r ect t h e
ca u se of t h e da m a ge a t t h e sa m e t im e t h e con ver t er
is r epla ced. Also, in spect a ll ot h er com pon en t s of t h e
exh a u st syst em for h ea t da m a ge.
U n le a d e d g a s o lin e m u s t be u s e d to a v o id c o n -
ta m in a tin g th e c a ta ly s t c o re .
50 St a t e em ission veh icles in cor por a t e t wo m in i
ca t a lyt ic con ver t er s loca t ed a ft er t h e exh a u st m a n i-
folds a n d befor e t h e in lin e ca t a lyt ic con ver t er (F ig. 3).
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
WJ EXHAUST SYSTEM 11 - 5
CATALY T I C CON V ERT ER - 4 .0 L (Cont inue d)
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Sa t u r a t e t h e bolt s a n d n u t s wit h h ea t va lve
lu br ica n t . Allow 5 m in u t es for pen et r a t ion .
(3) Rem ove n u t s fr om t h e ca t a lyt ic con ver t er a n d
exh a u st pipe fla n ge con n ect ion (F ig. 4).
(4) Loosen exh a u st cla m p fr om t h e ca t a lyt ic con -
ver t er a n d m u ffler con n ect ion (F ig. 4).
(5) Discon n ect oxygen sen sor wir in g (F ig. 4).

Fig. 5 Catalytic Converter—Removal

1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER

If you su spect in t er n a l da m a ge t o t h e ca t a lyst , t a p-

pin g t h e bot t om of t h e ca t a lyst wit h a r u bber m a llet
m a y in dica t e a da m a ged cor e.
Fig. 4 Exhaust Pipe-to-Catalytic Converter-to-Muffler
Connection INSTALLATION
1 - EXHAUST CLAMP ASSEMBLY (1) P osit ion t h e ca t a lyt ic con ver t er on t o t h e
2 - OXYGEN SENSOR exh a u st pipe fla n ge con n ect ion (F ig. 4). Tigh t en t h e
3 - MUFFLER n u t s t o 28 N·m (250 in . lbs.) t or qu e.
4 - CATALYTIC CONVERTER (2) In st a ll t h e m u ffler on t o t h e ca t a lyt ic con ver t er
5 - EXHAUST PIPE WITH FLANGE JOINT u n t il t h e a lign m en t t a b is in ser t ed in t o t h e a lign -
6 - NUTS (3) m en t slot .
(3) In st a ll t h e exh a u st cla m p a t t h e m u ffler a n d
(6) H ea t t h e ca t a lyt ic con ver t er t o m u ffler con n ec- ca t a lyt ic con ver t er con n ect ion (F ig. 4). Tigh t en t h e
t ion wit h a t or ch u n t il t h e m et a l becom es ch er r y r ed. cla m p n u t s t o 47 N·m (35 ft . lbs.) t or qu e.
(7) Wh ile t h e m et a l is st ill ch er r y r ed, t wist t h e (4) Con n ect oxygen sen sor wir in g (F ig. 4).
ca t a lyt ic con ver t er ba ck a n d for t h t o sepa r a t e it fr om (5) Lower t h e veh icle.
t h e exh a u st pipe a n d t h e m u ffler (F ig. 5). (6) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
INSPECTION Adju st t h e a lign m en t , if n eeded.
Look a t t h e st a in less st eel body of t h e con ver t er,
in spect for bu lgin g or ot h er dist or t ion t h a t cou ld be a
r esu lt of over h ea t in g. If t h e con ver t er h a s a h ea t
sh ield a t t a ch ed m a ke su r e it is n ot ben t or loose.
11 - 6 EXHAUST SYSTEM
CATALY T I C CON V ERT ER - 4 .7 L
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
Fig. 6 4.7L Catalytic Converter and O2 Sensor Configuration - 50 State Emissions
WJ
Th e st a in less st eel ca t a lyt ic con ver t er body is
design ed t o la st t h e life of t h e veh icle. E xcessive h ea t
ca n r esu lt in bu lgin g or ot h er dist or t ion , bu t exces-
sive h ea t will n ot be t h e fa u lt of t h e con ver t er. If
u n bu r n ed fu el en t er s t h e con ver t er, over h ea t in g m a y
occu r. If a con ver t er is h ea t -da m a ged, cor r ect t h e
ca u se of t h e da m a ge a t t h e sa m e t im e t h e con ver t er
is r epla ced. Also, in spect a ll ot h er com pon en t s of t h e
exh a u st syst em for h ea t da m a ge.
U n le a d e d g a s o lin e m u s t be u s e d to a v o id c o n -
ta m in a tin g th e c a ta ly s t c o re .
50 St a t e em ission veh icles in cor por a t e t wo m in i
ca t a lyt ic con ver t er s loca t ed a ft er t h e exh a u st m a n i-
folds a n d befor e t h e in lin e ca t a lyt ic con ver t er (F ig. 6).
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
WJ EXHAUST SYSTEM 11 - 7
CATALY T I C CON V ERT ER - 4 .7 L (Cont inue d)
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Sa t u r a t e t h e bolt s a n d n u t s wit h h ea t va lve
lu br ica n t . Allow 5 m in u t es for pen et r a t ion .
(3) Rem ove n u t s fr om t h e ca t a lyt ic con ver t er a n d
exh a u st pipe fla n ge con n ect ion (F ig. 7).
(4) Loosen exh a u st cla m p fr om t h e ca t a lyt ic con -
ver t er a n d m u ffler con n ect ion (F ig. 7).
(5) Discon n ect oxygen sen sor wir in g (F ig. 7).

Fig. 8 Catalytic Converter—Removal

1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER

INSPECTION
Look a t t h e st a in less st eel body of t h e con ver t er,
in spect for bu lgin g or ot h er dist or t ion t h a t cou ld be a
Fig. 7 Exhaust Pipe-to-Catalytic Converter-to-Muffler r esu lt of over h ea t in g. If t h e con ver t er h a s a h ea t
Connection sh ield a t t a ch ed m a ke su r e it is n ot ben t or loose.
1 - EXHAUST CLAMP ASSEMBLY If you su spect in t er n a l da m a ge t o t h e ca t a lyst , t a p-
2 - OXYGEN SENSOR pin g t h e bot t om of t h e ca t a lyst wit h a r u bber m a llet
3 - MUFFLER m a y in dica t e a da m a ged cor e.
4 - CATALYTIC CONVERTER
5 - EXHAUST PIPE WITH FLANGE JOINT
6 - NUTS (3)
INSTALLATION
(1) P osit ion t h e ca t a lyt ic con ver t er on t o t h e
exh a u st pipe fla n ge con n ect ion (F ig. 7). Tigh t en t h e
(6) H ea t t h e ca t a lyt ic con ver t er t o m u ffler con n ec- n u t s t o 28 N·m (250 in . lbs.) t or qu e.
t ion wit h a t or ch u n t il t h e m et a l becom es ch er r y r ed. (2) In st a ll t h e m u ffler on t o t h e ca t a lyt ic con ver t er
(7) Wh ile t h e m et a l is st ill ch er r y r ed, t wist t h e u n t il t h e a lign m en t t a b is in ser t ed in t o t h e a lign -
ca t a lyt ic con ver t er ba ck a n d for t h t o sepa r a t e it fr om m en t slot .
t h e m u ffler (F ig. 8). (3) In st a ll t h e exh a u st cla m p a t t h e m u ffler a n d
ca t a lyt ic con ver t er con n ect ion (F ig. 7). Tigh t en t h e
cla m p n u t s t o 47 N·m (35 ft . lbs.) t or qu e.
(4) Con n ect oxygen sen sor wir in g (F ig. 7).
(5) Lower t h e veh icle.
(6) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
11 - 8 EXHAUST SYSTEM
EX H AU ST PI PE - 4 .0 L
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
(1) Ra ise a n d su ppor t t h e veh icle.
Fig. 9 O2 Sensor Location 4.0L
WJ
(2) Sa t u r a t e t h e bolt s a n d n u t s wit h h ea t va lve
lu br ica n t . Allow 5 m in u t es for pen et r a t ion .
(3) Rem ove t h e oxygen sen sor fr om t h e exh a u st
pipe (F ig. 9).
(4) Rem ove t h e n u t s fr om t h e exh a u st pipe t o ca t -
a lyt ic con ver t er fla n ge con n ect ion (F ig. 10).
(5) Discon n ect t h e exh a u st pipe fr om t h e exh a u st
m a n ifold (F ig. 11).
INSPECTION
Disca r d r u st ed cla m ps, br oken or wor n su ppor t s
a n d a t t a ch in g pa r t s. Repla ce a com pon en t wit h or ig-
in a l equ ipm en t pa r t s, or equ iva len t . Th is will a ssu r e
pr oper a lign m en t wit h ot h er pa r t s in t h e syst em a n d
pr ovide a ccept a ble exh a u st n oise levels.
INSTALLATION
(1) Con n ect t h e exh a u st pipe t o t h e en gin e exh a u st
m a n ifold. Tigh t en t h e n u t s t o 31 N·m (23 ft . lbs.)
(F ig. 11).
WJ EXHAUST SYSTEM 11 - 9
EX H AU ST PI PE - 4 .0 L (Cont inue d)
NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.

(2) P osit ion t h e ca t a lyt ic con ver t er on t o t h e

exh a u st pipe fla n ge con n ect ion . Tigh t en r et a in in g
n u t s t o 28 N·m (250 in . lbs.) (F ig. 12).

Fig. 10 Catalytic Converter—Removal

1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER

Fig. 12 Installing Exhaust Clamps

1 - CATALYTIC CONVERTER
2 - MUFFLER

(3) Coa t t h e oxygen sen sor wit h a n t i-seize com -

pou n d. In st a ll t h e sen sor a n d t igh t en t h e n u t t o 48
N·m (35 ft . lbs.) t or qu e (F ig. 9).
(4) Lower t h e veh icle.
(5) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
(6) Aft er in it ia l st a r t -u p, ch eck t h e en gin e exh a u st
m a n ifold t o exh a u st pipe n u t s for pr oper t or qu e.

Fig. 11 Exhaust Pipe 4.0L

1 - NUT
2 - EXHAUST MANIFOLD
3 - TRANSMISSION SUPPORT
4 - EXHAUST PIPE
5 - MINI CATALYTIC CONVERTER
6 - BOLT
11 - 10 EXHAUST SYSTEM
EX H AU ST PI PE - 4 .7 L
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
(1) Ra ise a n d su ppor t t h e veh icle.
Fig. 13 4.7L Catalytic Converter and O2 Sensor Configuration - 50 State Emissions
WJ
(2) Sa t u r a t e t h e bolt s a n d n u t s wit h h ea t va lve
lu br ica n t . Allow 5 m in u t es for pen et r a t ion .
(3) Rem ove t h e oxygen sen sor fr om t h e exh a u st
pipe (F ig. 13).
(4) Rem ove t h e r et a in in g n u t s h oldin g ca t a lyt ic
con ver t er t o exh a u st pipe (F ig. 14).
(5) Discon n ect t h e exh a u st pipe fr om t h e exh a u st
m a n ifold. (F ig. 15)
INSPECTION
Disca r d r u st ed cla m ps, br oken or wor n su ppor t s
a n d a t t a ch in g pa r t s. Repla ce a com pon en t wit h or ig-
in a l equ ipm en t pa r t s, or equ iva len t . Th is will a ssu r e
pr oper a lign m en t wit h ot h er pa r t s in t h e syst em a n d
pr ovide a ccept a ble exh a u st n oise levels.
INSTALLATION
(1) Con n ect t h e exh a u st pipe t o t h e en gin e exh a u st
m a n ifold. Tigh t en t h e n u t s (A) t o 31 N·m (23 ft . lbs.)
(F ig. 15).
WJ EXHAUST SYSTEM 11 - 11
EX H AU ST PI PE - 4 .7 L (Cont inue d)
NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.

(2) P osit ion t h e ca t a lyt ic con ver t er on t o t h e

exh a u st pipe fla n ge con n ect ion . Tigh t en r et a in in g
n u t s t o 28 N·m (250 in . lbs.). (F ig. 16)

Fig. 14 Catalytic Converter—Removal

1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER

Fig. 16 Installing Exhaust Clamps

1 - CATALYTIC CONVERTER
2 - MUFFLER

(3) Coa t t h e oxygen sen sor wit h a n t i-seize com -

pou n d. In st a ll t h e sen sor a n d t igh t en t h e n u t t o 48
N·m (35 ft . lbs.) t or qu e (F ig. 13).
(4) Lower t h e veh icle.
(5) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
(6) Aft er in it ia l st a r t -u p, ch eck t h e en gin e exh a u st
m a n ifold t o exh a u st pipe n u t s for pr oper t or qu e.

Fig. 15 Exhaust Pipe 4.7L

1 - EXHAUST PIPE HANGER
A - NUTS (4)
3 - EXHAUST PIPE
B - BOLTS (4)
11 - 12 EXHAUST SYSTEM
H EAT SH I ELDS
DESCRIPTION
H ea t sh ields a r e n eeded t o pr ot ect bot h t h e veh icle
a n d t h e en vir on m en t fr om t h e h igh t em per a t u r es
developed by t h e ca t a lyt ic con ver t er. Th e ca t a lyt ic
con ver t er r elea ses a ddit ion a l h ea t in t o t h e exh a u st
syst em . Un der sever e oper a t in g con dit ion s, t h e t em -
per a t u r e in cr ea ses in t h e a r ea of t h e con ver t er. Su ch
con dit ion s ca n exist wh en t h e en gin e m isfir es or ot h -
er wise does n ot oper a t e a t pea k efficien cy (F ig. 17).
Fig. 17 Front and Rear Floor Pan Heat Shields
Typical
1 - REAR FLOOR PAN HEAT SHIELD
2 - HEAT SHIELD RETAINING NUTS (QTY 8)
3 - FRONT FLOOR PAN HEAT SHIELD
M U FFLER
DESCRIPTION
Bot h t h e 4.0L a n d 4.7L en gin es u se a st a in less
st eel m u ffler t o con t r ol exh a u st n oise levels a n d
exh a u st ba ck pr essu r e. Th e m u ffler a n d t a ilpipe a r e
a on e piece a ssem bly (F ig. 18).
REMOVAL
All or igin a l equ ipm en t exh a u st syst em s a r e m a n u -
fa ct u r ed wit h t h e t a ilpipe welded t o t h e m u ffler. Ser-
vice r epla cem en t m u ffler s a n d t a ilpipes a r e eit h er
cla m ped t oget h er or welded t oget h er.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Sa t u r a t e t h e bolt s a n d n u t s wit h h ea t va lve
lu br ica n t . Allow 5 m in u t es for pen et r a t ion .
WJ
Fig. 18 Muffler and Tailpipe
1 - CATALYTIC CONVERTER
2 - TAILPIPE HANGER
3 - TAILPIPE
4 - MUFFLER
(3) Loosen t h e exh a u st cla m p on t h e ca t a lyt ic con -
ver t er t o m u ffler con n ect ion (F ig. 19).
(4) H ea t t h e ca t a lyt ic con ver t er-t o-m u ffler con n ec-
t ion wit h a t or ch u n t il t h e m et a l becom es ch er r y r ed.
(5) Wh ile t h e m et a l is st ill ch er r y r ed, r em ove t h e
t a ilpipe/m u ffler a ssem bly fr om t h e ca t a lyt ic con -
ver t er.
(6) Rem ove t h e t a ilpipe fr om t h e t a ilpipe h a n ger
(F ig. 20).
(7) Rem ove t h e t a ilpipe/m u ffler a ssem bly (F ig. 20).
INSTALLATION
(1) If t h e t a ilpipe h a n ger a ssem bly wa s r em oved,
in st a ll t h e h a n ger t o t h e fr a m e. Tigh t en t h e bolt s t o
22 N·m (192 in . lbs.) t or qu e.
(2) P osit ion t h e t a ilpipe a n d m u ffler on t o t h e
t a ilpipe h a n ger (F ig. 20) .
(3) In st a ll t h e m u ffler on t o t h e ca t a lyt ic con ver t er.
Ma ke su r e t h a t t h e t a ilpipe h a s su fficien t clea r a n ce
fr om t h e floor pa n . In st a ll exh a u st cla m p a n d t igh t en
t h e n u t s t o 47 N·m (35 ft . lbs.) t or qu e (F ig. 19) .
(4) Lower t h e veh icle.
(5) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
WJ EXHAUST SYSTEM 11 - 13
M U FFLER (Cont inue d)

Fig. 19 Installing Exhaust Clamps Fig. 20 Muffler and Tailpipe

1 - CATALYTIC CONVERTER 1 - CATALYTIC CONVERTER
2 - MUFFLER 2 - TAILPIPE HANGER
3 - TAILPIPE
4 - MUFFLER
TAI LPI PE
DESCRIPTION OPERATION
Th e Ta ilpipe ch a n n els t h e exh a u st ou t of t h e m u f-
Th e t a ilpipe is a lso m a de of st a in less st eel. (F ig.
fler a n d ou t fr om u n der t h e veh icle t o con t r ol n oise
18) .
a n d pr even t exh a u st ga s fu m es fr om en t er in g t h e
pa ssen ger com pa r t m en t
WJ FRAME & BUMPERS 13 - 1

FRAME & BUMPERS

TABLE OF CON T EN T S

page page

FRONT ABSORBER INSTALLATION . . . . . . . . . . . ...............7

REMOVAL ............... ..............1 FRONT TOW HOOK
INSTALLATION . . . . . . . . . . . . ..............1 REMOVAL .............. ...............7
FRONT FASCIA INSTALLATION . . . . . . . . . . . ...............7
REMOVAL ............... ..............1 FUEL TANK SKID PLATE
INSTALLATION . . . . . . . . . . . . ..............1 DESCRIPTION . . . . . . . . . . . ...............7
REAR ABSORBER REAR TOW HOOK
REMOVAL ............... ..............2 REMOVAL .............. ...............7
INSTALLATION . . . . . . . . . . . . ..............2 INSTALLATION . . . . . . . . . . . ...............7
REAR FASCIA TRAILER HITCH
REMOVAL ............... ..............2 REMOVAL .............. ...............8
INSTALLATION . . . . . . . . . . . . ..............4 INSTALLATION . . . . . . . . . . . ...............8
FRAME TRANSFER CASE SKID PLATE
SPECIFICATIONS REMOVAL .............. ...............8
SPECIFICATIONS - TORQUE .............4 INSTALLATION . . . . . . . . . . . ...............8
FRAME DIMENSIONS . . . . . ..............4
FRONT SKID PLATE
REMOVAL ............... ..............7

FRON T ABSORBER (4) Rem ove pla st ic pu sh pin fa st en er s a t t a ch in g

fr on t fa scia t o lower r a dia t or cr ossm em ber spla sh
sh ield (F ig. 2).
REMOVAL
(5) Disen ga ge fog la m p con n ect or s, if equ ipped.
(1) Rem ove fr on t fa scia , r efer t o (Refer t o 13 -
(6) Rem ove scr ews a t t a ch in g fa scia /gr ille t o u pper
F RAME S & BUMP E RS/BUMP E RS/F RONT FASCIA
r a dia t or cr ossm em ber (F ig. 3).
- RE MOVAL).
(7) Slide fa scia for wa r d t o sepa r a t e fr om veh icle.
(2) Rem ove t h e r et a in er a t t a ch in g t h e a bsor ber t o
t h e fa scia .
(3) Sepa r a t e t h e a bsor ber fr om t h e fa scia .
INSTALLATION
(1) Slide fa scia on t o veh icle en ga gin g fa scia wit h
t a bs on bot t om of fr on t fen der s.
INSTALLATION
(2) In st a ll scr ews a t t a ch in g fa scia /gr ille t o u pper
(1) P osit ion t h e a bsor ber on t h e fa scia .
r a dia t or cr ossm em ber (F ig. 3).
(2) In st a ll t h e r et a in er a t t a ch in g t h e a bsor ber t o
(3) In st a ll bolt s a t t a ch in g fa scia t o fen der (F ig. 1).
t h e fa scia .
(4) E n ga ge fog la m p con n ect or s, if equ ipped.
(3) In st a ll fr on t fa scia . Refer t o (Refer t o 13 -
(5) In st a ll pla st ic r ivet s a t t a ch in g fa scia t o wh eel
F RAME S & BUMP E RS/BUMP E RS/F RONT FASCIA
lin er.
- INSTALLATION).
(6) In st a ll pla st ic pu sh pin fa st en er s a t t a ch in g
fr on t fa scia t o lower r a dia t or cr ossm em ber spla sh
FRON T FASCI A sh ield (F ig. 2).
(7) Rem ove su ppor t s a n d lower veh icle.
REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Tu r n fr on t wh eels t o a ccess r ivet s a n d r em ove
pla st ic r ivet s a t t a ch in g fa scia t o wh eel lin er.
(3) Rem ove bolt s a t t a ch in g fa scia t o fen der (F ig. 1).
13 - 2 FRAME & BUMPERS WJ
FRON T FASCI A (Cont inue d)

Fig. 3 Front Fascia

1 - SCREW
Fig. 1 Front Fascia 2 - FASCIA
1 - BODY
2 - FASCIA
REAR ABSORBER
REMOVAL
(1) Rem ove r ea r fa scia , r efer t o (Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA -
RE MOVAL).
(2) Rem ove r ivet s a t t a ch in g a bsor ber t o r ea r cr oss-
m em ber (F ig. 5).
(3) Sepa r a t e a bsor ber fr om veh icle.

INSTALLATION
(1) P osit ion a bsor ber on veh icle.
(2) In st a ll r ivet s a t t a ch in g a bsor ber t o r ea r cr oss-
m em ber (F ig. 2).
(3) In st a ll r ea r fa scia , r efer t o (Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA -
INSTALLATION).

Fig. 2 Front Fascia

1 - WHEEL LINER REAR FASCI A
2 - FASCIA
3 - FOG LAMP CONNECTOR REMOVAL
4 - PLASTIC PUSH PIN
(1) Ra ise a n d su ppor t veh icle.
5 - PLASTIC RIVET
(2) Rem ove wh eels.
(3) Rem ove pla st ic pu sh pin s a t t a ch in g fa scia t o
fu el t a n k skid pla t e.
(4) Rem ove pla st ic r ivet s a t t a ch in g fa scia t o wh eel
lin er.
WJ FRAME & BUMPERS 13 - 3
REAR FASCI A (Cont inue d)
(5) Rem ove n u t s a t t a ch in g u pper edge of fa scia t o
qu a r t er pa n el a n d wh eel lin er (F ig. 4).
(6) Rem ove pla st ic pu sh pin s a t t a ch in g fa scia t o
lift ga t e open in g (F ig. 5).
(7) Rem ove scr ews a t t a ch in g fa scia t o lift ga t e
open in g.
(8) Rem ove D pilla r t r im a n d scu ff pla t e ou t boa r d
scr ews.
(9) Rem ove t h e r ea r wa r d t ie down scr ews a n d t h e
a per t u r e t r im pa n el.
(10) Ca r efu lly peel ba ck t h e r u bber body sea ler
pa t ch t o a ccess t h e r et a in er clips.
(11) Relea se t h e for wa r d a n d r ea r wa r d r et a in er
clips on bot h sides of t h e fa scia .
(12) Gr a sp for wa r d edges of fa scia a n d pu ll ou t -
wa r d t o disen ga ge r et a in er s a t t a ch in g fa scia t o qu a r-
Fig. 4 Rear Fascia Attachment
t er pa n el (F ig. 6).
(13) Sepa r a t e fa scia fr om veh icle. 1 - FASCIA
2 - PLASTIC PUSH PIN

Fig. 5 Rear Fascia

1 - ABSORBER 3 - FASCIA
2 - RIVET 4 - PLASTIC PUSH PIN
13 - 4 FRAME & BUMPERS WJ
REAR FASCI A (Cont inue d)

Fig. 6 Rear Fascia Retainers Fig. 7 Fascia Attachment

1 - RETAINER 1 - SLOT
2 - FASCIA 2 - QUARTER PANEL

INSTALLATION FRAM E
(1) P osit ion fa scia on veh icle a lign in g r et a in er s
wit h slot s in qu a r t er pa n el (F ig. 7).
(2) P r ess for wa r d edges of fa scia in wa r d t o en ga ge
SPECI FI CAT I ON S
r et a in er s.
(3) In st a ll scr ews a t t a ch in g fa scia t o lift ga t e open - SPECIFICATIONS - TORQUE
in g.
(4) In st a ll pla st ic pu sh pin s a t t a ch in g fa scia t o lift - T ORQU E SPECI FI CAT I ON S
ga t e open in g.
(5) In st a ll n u t s a t t a ch in g u pper edge of fa scia t o Ft. In.
DESCRIPTION N·m
qu a r t er pa n el a n d wh eel lin er. Lbs. Lbs.
(6) In st a ll pla st ic r ivet s a t t a ch in g fa scia t o wh eel Front Tow Hook Bolt 54 40 —
lin er.
Front Skid Plate Bolt 54 40 —
(7) In st a ll su ppor t lower veh icle.
(8) In st a ll pla st ic pu sh pin s a t t a ch in g fa scia t o fu el Rear Tow Hook Bolt 68 50 —
t a n k skid pla t e. Trailer Hitch Bolts 68 50 —
(9) In st a ll t h e in t er ior t r im pa n els r em oved t o
Transfer Case Skid Plate 34 25 —
a ccess fa scia r et a in er s.
Bolts
(10) In st a ll t ie down loop scr ews.
(11) In st a ll t h e wh eels, r efer t o sect ion 22 for
t igh t en in g sequ en ce a n d t or qu e specifica t ion s. FRAME DIMENSIONS
I N DEX

DESCRIPTION FIGURE
SIDE VIEW 8
BOTTOM VIEW 9
WJ FRAME & BUMPERS 13 - 5
FRAM E (Cont inue d)

Fig. 8 SIDE VIEW

13 - 6 FRAME & BUMPERS WJ
FRAM E (Cont inue d)

Fig. 9 BOTTOM VIEW

WJ FRAME & BUMPERS 13 - 7

FRON T SK I D PLAT E
REMOVAL
(1) P osit ion a su ppor t u n der skid pla t e.
(2) Rem ove bolt s a t t a ch in g skid pla t e t o fr a m e
(F ig. 10).
(3) Sepa r a t e skid pla t e fr om fr a m e.

Fig. 11 Front Tow Hook

1 - TAPPING PLATE
2 - CROSSMEMBER
3 - BRACKET
4 - TOW HOOK

REAR T OW H OOK
Fig. 10 Front Skid Plate REMOVAL
1 - SKID PLATE
(1) Rem ove r ea r t ow h ook t o fr a m e br a ce.
(2) Rem ove bolt s a t t a ch in g t h e t ow h ook br a cket t o
fr a m e (F ig. 12).
INSTALLATION (3) Sepa r a t e t ow h ook br a cket fr om fr a m e.
(1) P osit ion skid pla t e on a su ppor t .
(2) Ra ise it in t o posit ion
(3) In st a ll bolt s a t t a ch in g skid pla t e t o fr a m e.
Tigh t en bolt s t o 54 N·m (40 ft . lbs.) t or qu e.

FRON T T OW H OOK
REMOVAL
(1) Rem ove bolt s t h a t a t t a ch t ow h ook br a cket t o
t h e lower cr ossm em ber (F ig. 11).
(2) Sepa r a t e t ow h ook br a cket fr om lower cr oss-
m em ber.

INSTALLATION
(1) P osit ion t ow h ook br a cket a t t h e lower cr oss- Fig. 12 Rear Tow Hook
m em ber. 1 - TOW HOOK BRACE
(2) In st a ll bolt s a t t a ch in g t ow h ook br a cket t o 2 - TOW HOOK
cr ossm em ber. Tigh t en bolt s t o 54 N·m (40 ft . lbs.) 3 - BRACKET
t or qu e. 4 - FUEL TANK

FU EL TAN K SK I D PLAT E INSTALLATION

(1) posit ion t ow h ook br a cket on fr a m e.
(2) In st a ll bolt s a t t a ch in g t ow h ook br a cket t o
DESCRIPTION
fr a m e. Tigh t en bolt s t o 68 N·m (50 ft . lbs.) t or qu e.
Th e fu el t a n k skid pla t e is in t egr a t ed wit h t h e fu el
(3) In st a ll r ea r t ow h ook t o fr a m e br a ce.
t a n k. Refer t o F u el Ta n k for ser vice pr ocedu r es
13 - 8 FRAME & BUMPERS WJ

T RAI LER H I T CH (4) Con n ect h a r n ess con n ect or t o h a r n ess plu g.
(5) P osit ion h a r n ess plu g in t r a iler h it ch a n d
in st a ll scr ews.
REMOVAL
(6) In st a ll r ea r fa scia , r efer t o (Refer t o 13 -
(1) Rem ove r ea r fa scia , r efer t o (Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA -
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA -
INSTALLATION).
RE MOVAL).
(2) Rem ove scr ews a t t a ch in g t r a iler h a r n ess plu g
t o t r a iler h it ch . T RAN SFER CASE SK I D PLAT E
(3) Discon n ect h a r n ess con n ect or fr om h a r n ess
plu g.
REMOVAL
(4) P osit ion su ppor t st a n ds u n der t r a iler h it ch .
(1) Su ppor t skid pla t e.
(5) Rem ove bolt s a t t a ch in g t r a iler h it ch t o fr a m e
(2) Rem ove bolt s t h a t a t t a ch skid pla t e t o t r a n s-
r a ils (F ig. 13).
m ission su ppor t cr ossm em ber a n d fr a m e sill (F ig.
(6) Sepa r a t e t r a iler h it ch fr om veh icle.
14).
(3) Rem ove su ppor t a n d skid pla t e fr om veh icle.

Fig. 14 Transfer Case Skid Plate

1 - TRANSFER CASE
2 - NUTSERT
3 - SKID PLATE
Fig. 13 Trailer Hitch 4 - CROSSMEMBER
1 - FUEL TANK
2 - TRAILER HITCH
INSTALLATION
(1) In st a ll n u t ser t s, if r em oved.
INSTALLATION (2) P osit ion a n d su ppor t skid pla t e a t t h e fr a m e
(1) P osit ion t r a iler h it ch on su ppor t st a n ds. sill a n d t r a n sm ission su ppor t cr ossm em ber.
(2) P osit ion t r a iler h it ch on veh icle. (3) At t a ch skid pla t e t o fr a m e sill a n d cr ossm em -
(3) In st a ll bolt s a t t a ch in g t r a iler h it ch t o fr a m e ber wit h t h e bolt s. Tigh t en bolt s t o 34 N·m (25 ft . lbs)
r a ils. Tigh t en bolt s t o 68 N·m (50 lbs.) t or qu e. t or qu e.
WJ FUEL SYSTEM 14 - 1

FUEL SYSTEM
TABLE OF CON T EN T S

page page

FUEL DELIVERY ..........................1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 31

FU EL DELI V ERY

TABLE OF CONTENTS
page page

FUEL DELIVERY FUEL PUMP PRESSURE TEST . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....2 FUEL PUMP MODULE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FUEL PRESSURE LEAK DOWN TEST . .....2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - FUEL SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRESSURE RELEASE . . . . . . . . . . . . . . .....4 FUEL RAIL
SPECIFICATIONS DESCRIPTION
FUEL SYSTEM PRESSURE ......... .....4 DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . 15
TORQUE - FUEL DELIVERY . . . . . . . . . .....4 DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS OPERATION
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . .....5 OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 15
FUEL FILTER/PRESSURE REGULATOR OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .5 REMOVAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL ........................ . . . . .6 REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6 INSTALLATION
FUEL LEVEL SENDING UNIT / SENSOR INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....7 INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....7 FUEL TANK
DIAGNOSIS AND TESTING - FUEL LEVEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
SENDING UNIT . . . . . . . . . . . . . . . . . . . .....7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL ........................ .....7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . .....8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL LINES INLET FILTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....8 QUICK CONNECT FITTING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING STANDARD PROCEDURE - QUICK-CONNECT
DIAGNOSIS AND TESTING - FUEL PUMP FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CAPACITY TEST . . . . . . . . . . . . . . . . . . .....9
DIAGNOSIS AND TESTING - FUEL PUMP
AMPERAGE TEST . . . . . . . . . . . . . . . . . .....9
14 - 2 FUEL DELIVERY
FU EL DELI V ERY
DESCRIPTION
Th e fu el deliver y syst em con sist s of:
• t h e fu el pu m p m odu le con t a in in g t h e elect r ic
fu el pu m p, fu el ga u ge sen din g u n it (fu el level sen sor )
a n d a sepa r a t e fu el filt er loca t ed a t bot t om of pu m p
m odu le
• a sepa r a t e com bin a t ion fu el filt er /fu el pr essu r e
r egu la t or
• fu el t u bes/lin es/h oses
• qu ick-con n ect fit t in gs
• fu el in ject or r a il
• fu el in ject or s
• fu el t a n k
• fu el t a n k filler /ven t t u be a ssem bly
• fu el t a n k filler t u be ca p
• a cceler a t or peda l
• t h r ot t le ca ble
OPERATION
Th e fu el t a n k a ssem bly con sist s of: t h e fu el t a n k,
fu el t a n k sh ield, fu el t a n k st r a ps, fu el pu m p m odu le
a ssem bly, fu el pu m p m odu le lockn u t /ga sket , a n d fu el
t a n k ch eck va lve (r efer t o E m ission Con t r ol Syst em
for fu el t a n k ch eck va lve in for m a t ion ).
A fu el filler /ven t t u be a ssem bly u sin g a pr essu r e/
va cu u m , 1/4 t u r n fu el filler ca p is u sed. Th e fu el
filler t u be con t a in s a fla p door loca t ed below t h e fu el
fill ca p.
Also t o be con sider ed pa r t of t h e fu el syst em is t h e
eva por a t ion con t r ol syst em . Th is is design ed t o
r edu ce t h e em ission of fu el va por s in t o t h e a t m o-
sph er e. Th e descr ipt ion a n d fu n ct ion of t h e E va por a -
t ive Con t r ol Syst em is fou n d in E m ission Con t r ol
Syst em s.
Bot h fu el filt er s (a t bot t om of fu el pu m p m odu le
a n d wit h in fu el pr essu r e r egu la t or ) a r e design ed for
ext en ded ser vice. Th ey do n ot r equ ir e n or m a l sch ed-
u led m a in t en a n ce. F ilt er s sh ou ld on ly be r epla ced if
a dia gn ost ic pr ocedu r e in dica t es t o do so.
DI AGN OSI S AN D T EST I N G
FUEL PRESSURE LEAK DOWN TEST
Use t h is t est in con ju n ct ion wit h t h e F u el P u m p
P r essu r e Test a n d F u el P u m p Ca pa cit y Test .
Ch e c k Va lv e Op e ra tio n : Th e elect r ic fu el pu m p
ou t let con t a in s a on e-wa y ch eck va lve t o pr even t fu el
flow ba ck in t o t h e t a n k a n d t o m a in t a in fu el su pply
lin e pr essu r e (en gin e wa r m ) wh en pu m p is n ot oper-
a t ion a l. It is a lso u sed t o keep t h e fu el su pply lin e
fu ll of ga solin e wh en pu m p is n ot oper a t ion a l. Aft er
t h e veh icle h a s cooled down , fu el pr essu r e m a y dr op
t o 0 psi (cold flu id con t r a ct s), bu t liqu id ga solin e will
WJ
r em a in in fu el su pply lin e bet ween t h e ch eck va lve
a n d fu el in ject or s. F u e l p re s s u re th a t h a s
d ro p p e d to 0 p s i o n a c o o le d d o w n v e h ic le
(e n g in e o ff) is a n o rm a l c o n d itio n . Wh en t h e elec-
t r ic fu el pu m p is a ct iva t ed, fu el pr essu r e sh ou ld
im m e d ia te ly (1–2 secon ds) r ise t o specifica t ion .
Abn or m a lly lon g per iods of cr a n kin g t o r est a r t a
h o t en gin e t h a t h a s been sh u t down for a sh or t
per iod of t im e m a y be ca u sed by:
• F u el pr essu r e bleedin g pa st a fu el in ject or (s).
• F u el pr essu r e bleedin g pa st t h e ch eck va lve in
t h e fu el pu m p m odu le.
• A defect ive fu el filt er /pr essu r e r egu la t or.
Two #6539, 5/16”, F u el Lin e P r essu r e Test Ada pt er
H ose Tools a r e r equ ir ed for t h e followin g t est s.
(1) Relea se fu el syst em pr essu r e. Refer t o F u el
P r essu r e Relea se P r ocedu r e.
(2) Ra ise veh icle.
F u e l Lin e Id e n tific a tio n : Th e fu el filt er /pr essu r e
r egu la t or is loca t ed in fr on t of t h e fu el t a n k a n d
a bove t h e r ea r a xle. It is t r a n sver sely m ou n t ed t o a
ch a ssis cr ossm em ber (left -t o-r igh t ). Th e filt er /r egu la -
t or is equ ipped wit h 3 fu el lin e fit t in gs (2 a t on e en d
a n d 1 a t t h e ot h er en d). Th e sin gle fit t in g fa cin g t h e
left side of t h e veh icle is t h e su pply lin e t o t h e fu el
r a il (F ig. 1) . Th e 2 fit t in gs fa cin g t h e r igh t side of
t h e veh icle a r e con n ect ed t o t h e fu el t a n k. Of t h ese 2
fit t in gs, t h e fit t in g t owa r ds t h e fro n t is u sed for fu el
r et u r n t o t h e fu el t a n k. Th e fit t in g t owa r ds t h e re a r
is a pr essu r e lin e. Th is re a r fit t in g m u st be discon -
n ect ed for t h e followin g st ep.
(3) See pr eviou s st ep. Discon n ect fu el pr essu r e lin e
a t re a r of filt er /r egu la t or. Th is is a 5/16! qu ick-con -
n ect fit t in g (F ig. 1) . Refer t o Qu ick-Con n ect F it t in gs
for pr ocedu r es.
(4) Obt a in cor r ect F u el Lin e P r essu r e Test Ada pt er
H ose Tool # 6539 for 5/16” fu el lin es. Con n ect on e
en d of t h is Specia l Tool in t o t h e discon n ect ed fu el
pr essu r e lin e. Con n ect t h e ot h er en d of t h e Tool in t o
fit t in g on filt er /r egu la t or.
(5) Lower veh icle.
(6) Discon n ect t h e fu el in let lin e a t fu el r a il. Refer
t o Qu ick-Con n ect F it t in gs for pr ocedu r es. On som e
en gin es, a ir clea n er h ou sin g r em ova l m a y be n eces-
sa r y befor e fu el lin e discon n ect ion .
(7) Obt a in a secon d F u el Lin e P r essu r e Test
Ada pt er H ose Tool # 6539 for 5/16” fu el lin es. Con -
n ect t h is t ool bet ween discon n ect ed fu el lin e a n d fu el
r a il (F ig. 2) .
(8) Con n ect t h e 0-414 kP a (0-60 psi) fu el pr essu r e
t est ga u ge (fr om Ga u ge Set 5069) t o t h e t est por t on
t h e a ppr opr ia t e Ada pt or Tool. N OTE: Th e D RB III
S c a n To o l a lo n g w ith th e P EP m o d u le , th e 500
p s i p re s s u re tra n s d u c e r, a n d th e tra n s d u c e r-to -
te s t p o rt a d a p te r m a y a ls o be u s e d in p la c e o f
th e fu e l p re s s u re g a u g e .
WJ FUEL DELIVERY 14 - 3
FU EL DELI V ERY (Cont inue d)

Fig. 2 Connecting Adapter Tool—Typical

1 - VEHICLE FUEL LINE
2 - TEST PORT “T”
Fig. 1 Disconnect Fuel Pressure Line at Filter/
3 - SPECIAL TOOL 6923, 6631, 6541 OR 6539
Regulator 4 - FUEL PRESSURE TEST GAUGE
1 - FUEL SUPPLY LINE (TO FUEL RAIL) 5 - FUEL LINE CONNECTION AT RAIL
2 - EVAP LINE 6 - FUEL RAIL
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR su fficien t ). If pr essu r e n ow h olds a t or a bove 30 psi, a
6 - FUEL TANK fu el in ject or or t h e fu el r a il is lea kin g.
(17) Aga in , st a r t en gin e a n d br in g t o n or m a l oper-
a t in g t em per a t u r e.
CAUTION: The fittings on both tools must be in
(18) Sh u t en gin e off.
good condition and free from any small leaks
(19) Ra ise veh icle.
before performing the proceeding test.
(20) Te s tin g fo r fu e l filte r/p re s s u re re g u la to r
(9) St a r t en gin e a n d br in g t o n or m a l oper a t in g le a k a g e : Wh ile con t in u in g t o secu r ely cla m p
t em per a t u r e. bet ween t h e fu el r a il a n d t h e t est por t !T! on Ada pt or
(10) Obser ve fu el pr essu r e t est ga u ge (or DRB Tool 6539, secu r ely cla m p off a n y r u bber h ose por-
scr een ). Nor m a l oper a t in g pr essu r e sh ou ld be 339 t ion of t h e Ada pt or Tool 6539 t h a t wa s in st a lled
kP a ± 34 kP a (49.2 psi ± 5 psi). bet ween t h e fu el pr essu r e lin e a n d t h e filt er /r egu la -
(11) Sh u t en gin e off. t or fit t in g (by r est r ict in g t h e pu m p m odu le su pply
(12) P r essu r e sh ou ld n ot fa ll below 30 p s i fo r fiv e lin e’s ba ckflow, you isola t e a n y lea kdown or igin a t in g
m in u te s . fr om t h e filt er /r egu la t or via t h e t a n k r et u r n lin e.) If
(13) If pr essu r e fa lls below 30 psi, it m u st be t h e pr essu r e fa lls below 30 psi wit h in 5 m in u t es, t h e
det er m in ed if a fu el in ject or, t h e su pply ch eck va lve filt er /r egu la t or is lea kin g. If it n ow h olds a t or a bove
wit h in t h e fu el pu m p m odu le, t h e fu el filt er /pr essu r e 30 psi, t h e elect r ic fu el pu m p ch eck va lve is lea kin g
r egu la t or, or a fu el t u be/lin e is lea kin g. or a fu el t u be/lin e is lea kin g. A fu el odor pr esen ce
(14) Aga in , st a r t en gin e a n d br in g t o n or m a l oper- wou ld in dica t e t h e la t t er.
a t in g t em per a t u r e. Th e elect r ic fu el pu m p is n ot ser viced sepa r a t ely. If
(15) Sh u t en gin e off. r epla cem en t is n ecessa r y, r epla ce t h e fu el pu m p m od-
(16) Te s tin g fo r fu e l in je c to r o r fu e l ra il le a k - u le a ssem bly. Th e filt er /r egu la t or m a y be r epla ced
a g e : Cla m p off t h e r u bber h ose por t ion of t h e 6539 sepa r a t ely. Refer t o F u el F ilt er /F u el P r essu r e Regu -
Ada pt or Tool bet ween t h e fu el r a il a n d t h e t est por t la t or Rem ova l/In st a lla t ion for a ddit ion a l in for m a t ion .
“T” on Ada pt er Tool (be su r e cla m pin g pr essu r e is
14 - 4 FUEL DELIVERY WJ
FU EL DELI V ERY (Cont inue d)

STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
U s e fo llo w in g p ro c e d u re if th e fu e l in je c to r
ra il is , o r is n o t e qu ip p e d w ith a fu e l p re s s u re
te s t p o rt.
(1) Rem ove fu el fill ca p.
(2) Rem ove fu el pu m p r ela y fr om P ower Dist r ibu -
t ion Cen t er (P DC). F or loca t ion of r ela y, r efer t o la bel
on u n der side of P DC cover.
(3) St a r t a n d r u n en gin e u n t il it st a lls.
(4) At t em pt r est a r t in g en gin e u n t il it will n o
lon ger r u n .
(5) Tu r n ign it ion key t o OF F posit ion .
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Un plu g con n ect or fr om a n y fu el in ject or.
(7) At t a ch on e en d of a ju m per wir e wit h a lliga t or
clips (18 ga u ge or sm a ller ) t o eit h er in ject or t er m in a l.
(8) Con n ect ot h er en d of ju m per wir e t o posit ive
side of ba t t er y.
(9) Con n ect on e en d of a secon d ju m per wir e t o
r em a in in g in ject or t er m in a l.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Mom en t a r ily t ou ch ot h er en d of ju m per wir e
t o n ega t ive t er m in a l of ba t t er y for n o m or e t h a n a
few secon ds.
(11) P la ce a r a g or t owel below fu el lin e qu ick-con -
n ect fit t in g a t fu el r a il.
(12) Discon n ect qu ick-con n ect fit t in g a t fu el r a il.
Refer t o Qu ick-Con n ect F it t in gs.
(13) Ret u r n fu el pu m p r ela y t o P DC.
(14) On e or m or e Dia gn ost ic Tr ou ble Codes (DTC’s)
m a y h a ve been st or ed in P CM m em or y du e t o fu el
pu m p r ela y r em ova l. Th e DRB" sca n t ool m u st be
u sed t o er a se a DTC.

SPECI FI CAT I ON S

FUEL SYSTEM PRESSURE

339 kPa ± 34 kPa (49.2 psi ± 5 psi).
TORQUE - FUEL DELIVERY

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Accelerator Pedal Bracket Mounting Nuts 12 ±2 - 105 ±20
(without adjustable pedals)
Fuel Filter/Fuel Press. Reg. Bolts 3 - 26
Fuel Hose Clamps 3 - 26
Fuel Injector Rail Mounting Bolts -4.0L Engine 11 - 100
Fuel Injector Rail Mounting Bolts -4.7L V-8 11 - 100
Engine
Fuel Pump Module Locknut 74 55 -
Fuel Tank Filler Tube-to-Body Mounting Bolts 2 - 15
Fuel Tank-to-Body Mounting Bolts 88 65 -
Fuel Tank Support Bracket Bolts (large brackets) 88 65 -
Fuel Tank Support Bracket Bolts (small bracket) 5 - 45
Fuel Tank Support Bracket Nuts (large brackets) 61 45 -
Fuel Tank Heat Shield Nuts (shield-to-tank) 9 - 85
Fuel Tank Heat Shield Nuts (shield-to-body) 3 - 25
WJ FUEL DELIVERY 14 - 5
FU EL DELI V ERY (Cont inue d)

SPECI AL T OOLS
FUEL SYSTEM

Spanner Wrench—6856
Test Kit, Fuel Pressure—5069

FITTING, AIR METERING - 6714

Test Kit, Fuel Pressure—C-4799-B

Fuel Line Removal Tool—6782

FU EL FI LT ER/PRESSU RE
REGU LAT OR
DESCRIPTION
Th e com bin a t ion fu el filt er /pr essu r e r egu la t or is
loca t ed in fr on t of t h e fu el t a n k a n d a bove t h e r ea r
Adapters, Fuel Pressure Test—6539 and/or 6631
a xle (F ig. 3). It is t r a n sver sely m ou n t ed t o a ch a ssis
cr ossm em ber (left -t o-r igh t ). F u e l Lin e Id e n tific a -
tio n : Th e filt er /r egu la t or is equ ipped wit h 3 fu el lin e
fit t in gs (2 a t on e en d a n d 1 a t t h e ot h er en d). Th e
sin gle fit t in g fa cin g t h e left side of t h e veh icle is t h e
su pply lin e t o t h e fu el r a il (F ig. 3). Th e 2 fit t in gs fa c-
in g t h e r igh t side of t h e veh icle a r e con n ect ed t o t h e
fu el t a n k. Of t h ese 2 fit t in gs, t h e fit t in g t owa r ds t h e
fro n t is u sed for fu el r et u r n t o t h e fu el t a n k. Th e fit -
t in g t owa r ds t h e re a r is a pr essu r e lin e.

O2S (Oxygen Sensor) Remover/Installer—C-4907

OPERATION
F u e l P re s s u re Re g u la to r Op e ra tio n : Th e pr es-
su r e r egu la t or is a m ech a n ica l device t h a t is n ot con -
t r olled by en gin e va cu u m or t h e P ower t r a in Con t r ol
Modu le (P CM).
14 - 6 FUEL DELIVERY WJ
FU EL FI LT ER/PRESSU RE REGU LAT OR (Cont inue d)

REMOVAL
Th e com bin a t ion F u el F ilt er /F u el P r essu r e Regu la -
t or is r em ot ely m ou n t ed t o t h e veh icle body, a bove
t h e r ea r a xle a n d n ea r t h e fr on t of t h e fu el t a n k (F ig.
4) or (F ig. 5).
(1) P er for m F u el Syst em P r essu r e Relea se P r oce-
du r e.
(2) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(3) Ra ise veh icle.
(4) Clea n a r ea a r ou n d 3 filt er /r egu la t or fit t in gs.
(5) Discon n ect fu el su pply, fu el r et u r n a n d fu el
pr essu r e lin es a t filt er /r egu la t or (F ig. 4) . Refer t o
Qu ick-Con n ect F it t in gs.
(6) Rem ove 2 m ou n t in g bolt s (F ig. 5) a n d r em ove
filt er /r egu la t or.

Fig. 3 Fuel Filter/Fuel Pressure Regulator Location

1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK

Th e r egu la t or is ca libr a t ed t o m a in t a in fu el syst em

oper a t in g pr essu r e of a ppr oxim a t ely 339 kP a ± 34
kP a (49.2 psi ± 5 psi) a t t h e fu el in ject or s. It con t a in s
a dia ph r a gm , ca libr a t ed spr in gs a n d a fu el r et u r n
va lve. Th e in t er n a l fu el filt er is a lso pa r t of t h e
a ssem bly.
F u el is su pplied t o t h e filt er /r egu la t or by t h e elec-
t r ic fu el pu m p. Th e r egu la t or a ct s a s a ch eck va lve t o
Fig. 4 Fuel Filter/Fuel Pressure Regulator Location
m a in t a in som e fu el pr essu r e wh en t h e en gin e is n ot
oper a t in g. Th is will h elp t o st a r t t h e en gin e. A secon d 1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
ch eck va lve is loca t ed a t t h e ou t let en d of t h e elect r ic
3 - FUEL RETURN LINE (MALE)
fu el pu m p.
4 - FUEL PRESSURE LINE (FEMALE)
If fu el pr essu r e a t t h e pr essu r e r egu la t or exceeds 5 - FUEL FILTER/PRESSURE REGULATOR
a ppr oxim a t ely 49 psi, a n in t er n a l dia ph r a gm closes. 6 - FUEL TANK
E xcess fu el is t h en r ou t ed in t o a sepa r a t e fu el r et u r n
lin e a n d r et u r n ed t o t h e fu el t a n k t h r ou gh t h e t op of
t h e fu el pu m p m odu le. INSTALLATION
Bot h fu el filt er s (a t bot t om of fu el pu m p m odu le Th e com bin a t ion F u el F ilt er /F u el P r essu r e Regu la -
a n d wit h in fu el pr essu r e r egu la t or ) a r e design ed for t or is r em ot ely m ou n t ed t o t h e veh icle body, a bove
ext en ded ser vice. Th ey do n ot r equ ir e n or m a l sch ed- t h e r ea r a xle a n d n ea r t h e fr on t of t h e fu el t a n k (F ig.
u led m a in t en a n ce. F ilt er s sh ou ld on ly be r epla ced if 4) or (F ig. 5).
a dia gn ost ic pr ocedu r e in dica t es t o do so. (1) Befor e in st a llin g filt er /r egu la t or, be su r e a ll fit -
t in gs a r e clea n ed of a ll dir t a n d con t a m in a n t s.
(2) Be su r e o-r in g is posit ion ed in t o fu el r et u r n fit -
t in g in filt er /r egu la t or.
WJ
FU EL FI LT ER/PRESSU RE REGU LAT OR (Cont inue d)
Fig. 5 Fuel Filter/Fuel Pressure Regulator Removal/
Installation
1 - FUEL FILTER/FUEL PRESSURE REGULATOR
2 - MOUNTING BOLTS (2)
(3) Apply a sm a ll a m ou n t of clea n en gin e oil t o
o-r in gs.
(4) P osit ion filt er /r egu la t or t o body a n d in st a ll 2
bolt s. Tigh t en bolt s t o 3 N·m (30 in . lbs.) t or qu e.
(5) Con n ect 3 fit t in gs. Refer t o Qu ick-Con n ect F it -
t in gs.
(6) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
(7) St a r t en gin e a n d ch eck for lea ks.
FU EL LEV EL SEN DI N G U N I T /
SEN SOR
DESCRIPTION
Th e fu el ga u ge sen din g u n it (fu el level sen sor ) is
a t t a ch ed t o t h e side of t h e fu el pu m p m odu le. Th e
sen din g u n it con sist s of a floa t , a n a r m , a n d a va r i-
a ble r esist or t r a ck (ca r d).
OPERATION
Th e fu el pu m p m odu le h a s 4 differ en t cir cu it s
(wir es). Two of t h ese cir cu it s a r e u sed for t h e fu el
ga u ge sen din g u n it for fu el ga u ge oper a t ion , a n d for
cer t a in OBD II em ission r equ ir em en t s. Th e ot h er 2
wir es a r e u sed for elect r ic fu el pu m p oper a t ion .
F o r F u e l Ga u g e Op e ra tio n : A con st a n t in pu t
volt a ge sou r ce of a bou t 12 volt s (ba t t er y volt a ge) is
su pplied t o t h e r esist or t r a ck on t h e fu el ga u ge sen d-
in g u n it . Th is is fed dir ect ly fr om t h e P ower t r a in
Con t r ol Modu le (P CM). N OTE: F o r d ia g n o s tic p u r-
p o s e s , th is 12V p o w e r s o u rc e c a n o n ly be v e ri-
FUEL DELIVERY 14 - 7
fie d w ith th e c irc u it o p e n e d (fu e l p u m p m o d u le
e le c tric a l c o n n e c to r u n p lu g g e d ). With th e c o n -
n e c to rs p lu g g e d , o u tp u t v o lta g e s w ill v a ry fro m
a bo u t 0.6 v o lts a t F U LL, to a bo u t 8.6 v o lts a t
EMP TY (a bo u t 8.6 v o lts a t EMP TY fo r J e e p
m o d e ls , a n d a bo u t 7.0 v o lts a t EMP TY fo r
D o d g e Tru c k m o d e ls ). Th e r esist or t r a ck is u sed t o
va r y t h e volt a ge (r esist a n ce) depen din g on fu el t a n k
floa t level. As fu el level in cr ea ses, t h e floa t a n d a r m
m ove u p, wh ich decr ea ses volt a ge. As fu el level
decr ea ses, t h e floa t a n d a r m m ove down , wh ich
in cr ea ses volt a ge. Th e va r ied volt a ge sign a l is
r et u r n ed ba ck t o t h e P CM t h r ou gh t h e sen sor r et u r n
cir cu it .
Bot h of t h e elect r ica l cir cu it s bet ween t h e fu el
ga u ge sen din g u n it a n d t h e P CM a r e h a r d-wir ed (n ot
m u lt i-plexed). Aft er t h e volt a ge sign a l is sen t fr om
t h e r esist or t r a ck, a n d ba ck t o t h e P CM, t h e P CM
will in t er pr et t h e r esist a n ce (volt a ge) da t a a n d sen d
a m essa ge a cr oss t h e m u lt i-plex bu s cir cu it s t o t h e
in st r u m en t pa n el clu st er. H er e it is t r a n sla t ed in t o
t h e a ppr opr ia t e fu el ga u ge level r ea din g. Refer t o
In st r u m en t P a n el for a ddit ion a l in for m a t ion .
F o r OB D II Em is s io n Mo n ito r Re qu ire m e n ts :
Th e P CM will m on it or t h e volt a ge ou t pu t sen t fr om
t h e r esist or t r a ck on t h e sen din g u n it t o in dica t e fu el
level. Th e pu r pose of t h is fea t u r e is t o pr even t t h e
OBD II syst em fr om r ecor din g/set t in g fa lse m isfir e
a n d fu el syst em m on it or dia gn ost ic t r ou ble codes.
Th e fea t u r e is a ct iva t ed if t h e fu el level in t h e t a n k
is less t h a n a ppr oxim a t ely 15 per cen t of it s r a t ed
ca pa cit y. If equ ipped wit h a Lea k Det ect ion P u m p
(E VAP syst em m on it or ), t h is fea t u r e will a lso be a ct i-
va t ed if t h e fu el level in t h e t a n k is m or e t h a n
a ppr oxim a t ely 85 per cen t of it s r a t ed ca pa cit y.
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT
Th e fu el level sen din g u n it con t a in s a va r ia ble
r esist or (t r a ck). As t h e floa t m oves u p or down , elec-
t r ica l r esist a n ce will ch a n ge. Refer t o In st r u m en t
P a n el a n d Ga u ges for F u el Ga u ge t est in g. To t est t h e
ga u ge sen din g u n it on ly, it m u st be r em oved fr om
veh icle. Th e u n it is pa r t of t h e fu el pu m p m odu le.
Refer t o F u el P u m p Modu le Rem ova l/In st a lla t ion for
pr ocedu r es. Mea su r e t h e r esist a n ce a cr oss t h e sen d-
in g u n it t er m in a ls. Wit h floa t in u p posit ion , r esis-
t a n ce sh ou ld be 20 oh m s (+/- 5%). Wit h floa t in down
posit ion , r esist a n ce sh ou ld be 270 oh m s (+/- 5%).
REMOVAL
Th e fu el ga u ge sen din g u n it (fu el level sen sor ) a n d
floa t a ssem bly is loca t ed on t h e side of fu el pu m p
m odu le (F ig. 6). Th e fu el pu m p m odu le is loca t ed
wit h in t h e fu el t a n k.
14 - 8 FUEL DELIVERY WJ
FU EL LEV EL SEN DI N G U N I T / SEN SOR (Cont inue d)
(2) Rem ove fu el pu m p m odu le. Refer t o F u el P u m p
Modu le Rem ova l/In st a lla t ion .
(3) Rem ove elect r ica l wir e con n ect or a t sen din g
u n it t er m in a ls.
(4) P r ess u pwa r d on r elea se t a b (F ig. 7) t o r em ove
sen din g u n it fr om pu m p m odu le.

INSTALLATION
Th e fu el ga u ge sen din g u n it (fu el level sen sor ) a n d
floa t a ssem bly is loca t ed on t h e side of fu el pu m p
m odu le (F ig. 6). Th e fu el pu m p m odu le is loca t ed
wit h in t h e fu el t a n k.
(1) P osit ion sen din g u n it t o pu m p m odu le a n d
sn a p in t o pla ce.
(2) Con n ect elect r ica l con n ect or t o t er m in a ls.
(3) In st a ll fu el pu m p m odu le. Refer t o F u el P u m p
Modu le Rem ova l/In st a lla t ion .
(4) In st a ll fu el t a n k. Refer t o F u el Ta n k Rem ova l/
In st a lla t ion .

Fig. 6 Fuel Gauge Sending Unit Location FU EL LI N ES

1 - FUEL PUMP MODULE
2 - FUEL GAUGE FLOAT DESCRIPTION
3 - ELECTRIC FUEL PUMP Also r efer t o Qu ick-Con n ect F it t in gs.
4 - INLET FILTER
5 - FUEL GAUGE SENDING UNIT WARNING: THE FUEL SYSTEM IS UNDER A CON-
6 - PIGTAIL HARNESS STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.

Th e lin es/t u bes/h oses u sed on fu el in ject ed veh icles

a r e of a specia l con st r u ct ion . Th is is du e t o t h e
h igh er fu el pr essu r es a n d t h e possibilit y of con t a m i-
n a t ed fu el in t h is syst em . If it is n ecessa r y t o r epla ce
t h ese lin es/t u bes/h oses, on ly t h ose m a r ked E F M/E F I
m a y be u sed.
If e qu ip p e d : Th e h ose cla m ps u sed t o secu r e r u b-
ber h oses on fu el in ject ed veh icles a r e of a specia l
r olled edge con st r u ct ion . Th is con st r u ct ion is u sed t o
pr even t t h e edge of t h e cla m p fr om cu t t in g in t o t h e
h ose. On ly t h ese r olled edge t ype cla m ps m a y be
u sed in t h is syst em . All ot h er t ypes of cla m ps m a y
cu t in t o t h e h oses a n d ca u se h igh -pr essu r e fu el lea ks.
Use n ew or igin a l equ ipm en t t ype h ose cla m ps.
Fig. 7 Fuel Gauge Sending Unit Release Tab
1 - ELECTRICAL CONNECTOR FU EL PU M P
2 - FUEL GAUGE SENDING UNIT
3 - RELEASE TAB
4 - FUEL PUMP MODULE DESCRIPTION
Th e elect r ic fu el pu m p is loca t ed in side of t h e fu el
pu m p m odu le. A 12 volt , per m a n en t m a gn et , elect r ic
(1) Rem ove fu el t a n k. Refer t o F u el Ta n k Rem ova l/ m ot or power s t h e fu el pu m p. Th e elect r ic fu el pu m p
In st a lla t ion . is n ot a sepa r a t e, ser vicea ble com pon en t .
WJ FUEL DELIVERY 14 - 9
FU EL PU M P (Cont inue d)

OPERATION (b) If lin e is n ot kin ked/da m a ged, a n d fu el pr es-

Volt a ge t o oper a t e t h e elect r ic pu m p is su pplied su r e is OK, bu t ca pa cit y is low, r epla ce fu el filt er /
t h r ou gh t h e fu el pu m p r ela y. fu el pr essu r e r egu la t or. Th e filt er /r egu la t or m a y be
F u el is dr a wn in t h r ou gh a filt er a t t h e bot t om of ser viced sepa r a t ely on cer t a in a pplica t ion s. Refer
t h e m odu le a n d pu sh ed t h r ou gh t h e elect r ic m ot or t o F u el F ilt er /F u el P r essu r e Regu la t or Rem ova l/In -
gea r set t o t h e pu m p ou t let . st a lla t ion for a ddit ion a l in for m a t ion .
Ch e c k Va lv e Op e ra tio n : Th e pu m p ou t let con - (c) If bot h fu el pr essu r e a n d ca pa cit y a r e low,
t a in s a on e-wa y ch eck va lve t o pr even t fu el flow ba ck r epla ce fu el pu m p m odu le a ssem bly. Refer t o F u el
in t o t h e t a n k a n d t o m a in t a in fu el su pply lin e pr es- P u m p Modu le Rem ova l/In st a lla t ion .
su r e (en gin e wa r m ) wh en pu m p is n ot oper a t ion a l. It
is a lso u sed t o keep t h e fu el su pply lin e fu ll of ga so- DIAGNOSIS AND TESTING - FUEL PUMP
lin e wh en pu m p is n ot oper a t ion a l. Aft er t h e veh icle AMPERAGE TEST
h a s cooled down , fu el pr essu r e m a y dr op t o 0 psi Th is a m per a ge (cu r r en t dr a w) t est is t o be don e in
(cold flu id con t r a ct s), bu t liqu id ga solin e will r em a in con ju n ct ion wit h t h e F u el P u m p P r essu r e Test , F u el
in fu el su pply lin e bet ween t h e ch eck va lve a n d fu el P u m p Ca pa cit y Test a n d F u el P r essu r e Lea k Down
in ject or s. F u e l p re s s u re th a t h a s d ro p p e d to 0 Test . Befor e per for m in g t h e a m per a ge t est , be su r e
p s i o n a c o o le d d o w n v e h ic le (e n g in e o ff) is a t h e t em per a t u r e of t h e fu el t a n k is a bove 50° F (10°
n o rm a l c o n d itio n . Refer t o t h e F u el P r essu r e Lea k C).
Down Test for m or e in for m a t ion . Th e DRB" Sca n Tool a lon g wit h t h e DRB Low Cu r-
Th e elect r ic fu el pu m p is n ot a sepa r a t e, ser vice- r en t Sh u n t (LCS) a da pt er (F ig. 8) a n d it s t est lea ds
a ble com pon en t . will be u sed t o ch eck fu el pu m p a m per a ge specifica -
t ion s.
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST
B e fo re p e rfo rm in g th is te s t, v e rify fu e l p u m p
p re s s u re . Re fe r to F u e l P u m p P re s s u re Te s t.
U s e th is te s t in c o n ju n c tio n w ith th e F u e l P re s -
s u re Le a k D o w n Te s t.
(1) Relea se fu el syst em pr essu r e. Refer t o F u el
P r essu r e Relea se P r ocedu r e.
(2) Discon n ect fu el su pply lin e a t fu el r a il. Refer t o
Qu ick-Con n ect F it t in gs. Som e en gin es m a y r equ ir e
a ir clea n er h ou sin g r em ova l befor e lin e discon n ect ion .
(3) Obt a in cor r ect F u el Lin e P r essu r e Test Ada pt er
Tool H ose. Tool n u m ber 6539 is u sed for 5/16” fu el
lin es a n d t ool n u m ber 6631 is u sed for 3/8” fu el lin es.
(4) Con n ect cor r ect F u el Lin e P r essu r e Test
Ada pt er Tool H ose in t o discon n ect ed fu el su pply lin e.
In ser t ot h er en d of Ada pt or Tool H ose in t o a gr a du -
Fig. 8 LOW CURRENT SHUNT
a t ed con t a in er.
1 - LOW CURRENT SHUNT ADAPTER
(5) Rem ove fu el fill ca p.
2 - PLUG TO DRB
(6) To a ct iva t e fu el pu m p a n d pr essu r ize syst em ,
3 - TEST LEAD RECEPTACLES
obt a in DRB" sca n t ool a n d a ct u a t e ASD F u el Syst em
Test .
(7) A good fu el pu m p will deliver a t lea st 1/4 lit er (1) Be su r e fu el t a n k con t a in s fu el befor e st a r t in g
of fu el in 7 secon ds. Do n ot oper a t e fu el pu m p for t est . If t a n k is em pt y or n ea r em pt y, a m per a ge r ea d-
lon ger t h a n 7 secon ds wit h fu el lin e discon n ect ed a s in gs will be in cor r ect .
fu el pu m p m odu le r eser voir m a y r u n em pt y. (2) Obt a in LCS a da pt er.
(a ) If ca pa cit y is lower t h a n specifica t ion , bu t (3) P lu g ca ble fr om LCS a da pt er in t o DRB sca n
fu el pu m p ca n be h ea r d oper a t in g t h r ou gh fu el fill t ool a t SE T 1 r ecept a cle.
ca p open in g, ch eck for a kin ked/da m a ged fu el su p- (4) P lu g DRB in t o veh icle 16–wa y con n ect or (da t a
ply lin e som ewh er e bet ween fu el r a il a n d fu el lin k con n ect or ).
pu m p m odu le.
14 - 10 FUEL DELIVERY WJ
FU EL PU M P (Cont inue d)
(5) Con n ect (-) a n d (+) t est ca ble lea ds in t o LCS
a da pt er r ecept a cles. Use 10 a m p (10A +) r ecept a cle
a n d com m on (-) r ecept a cles.
(6) Ga in a ccess t o MAIN ME NU on DRB scr een .
(7) P r ess DVOM bu t t on on DRB.
(8) Usin g left /r igh t a r r ow keys, h igh ligh t CH AN-
NE L 1 fu n ct ion on DRB scr een .
(9) P r ess E NTE R t h r ee t im es.
(10) Usin g u p/down a r r ow keys, h igh ligh t RANGE
on DRB scr een (scr een will defa u lt t o 2 a m p sca le).
(11) P r ess E NTE R t o ch a n ge 2 a m p sca le t o 10
a m p sca le. Th is s te p m u s t be d o n e to p re v e n t
d a m a g e to D RB s c a n to o l o r LCS a d a p te r
(blo w n fu s e ).
(12) Rem ove cover fr om P ower Dist r ibu t ion Cen t er
(P DC).
(13) Rem ove fu el pu m p r ela y fr om P DC. Refer t o Fig. 9 FUEL PUMP RELAY - TYPE 1
la bel on P DC cover for r ela y loca t ion . TERMINAL LEGEND

WARNING: BEFORE PROCEEDING TO NEXT STEP, NUMBER IDENTIFICATION

NOTE THE FUEL PUMP WILL BE ACTIVATED AND 30 COMMON FEED
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL 85 COIL GROUND
OCCUR AFTER CONNECTING TEST LEADS FROM 86 COIL BATTERY
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES. 87 NORMALLY OPEN
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI- 87A NORMALLY CLOSED
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.

CAUTION: To prevent possible damage to the vehi-

cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.

Depen din g u pon veh icle m odel, yea r or en gin e con -

figu r a t ion , t h r ee differ en t t ypes of r ela ys m a y be
u sed: Type-1, t ype-2 a n d t ype–3.
(14) If equ ipped wit h ty p e –1 re la y (F ig. 9), a t t a ch
t est lea ds fr om LCS a da pt er in t o P DC r ela y ca vit ies
n u m ber 30 a n d 87. F or loca t ion of t h ese ca vit ies,
r efer t o n u m ber s st a m ped t o bot t om of r ela y (F ig. 9).
(15) If equ ipped wit h ty p e –2 re la y (F ig. 10),
Fig. 10 FUEL PUMP RELAY - TYPE 2
a t t a ch t est lea ds fr om LCS a da pt er in t o P DC r ela y
ca vit ies n u m ber 30 a n d 87. F or loca t ion of t h ese ca v- TERMINAL LEGEND
NUMBER IDENTIFICATION
it ies, r efer t o n u m ber s st a m ped t o bot t om of r ela y
30 COMMON FEED
(F ig. 10).
85 COIL GROUND
(16) If equ ipped wit h ty p e –3 re la y (F ig. 11), 86 COIL BATTERY
a t t a ch t est lea ds fr om LCS a da pt er in t o P DC r ela y 87 NORMALLY OPEN
ca vit ies n u m ber 3 a n d 5. F or loca t ion of t h ese ca vi- 87A NORMALLY CLOSED
t ies, r efer t o n u m ber s st a m ped t o bot t om of r ela y
(F ig. 11).
P u m p P r essu r e, F u el P u m p Ca pa cit y a n d F u el P r es-
(17) Wh en LCS a da pt er t est lea ds a r e a t t a ch ed
su r e Lea k Down t est s wer e m et , t h e fu el pu m p m od-
in t o r ela y ca vit ies, fu el pu m p w ill be a c tiv a te d .
u le is OK.
Det er m in e fu el pu m p a m per a ge on DRB scr een .
(18) If a m per a ge is m or e t h a n 10.0 a m ps, r epla ce
Am per a ge sh ou ld be below 10.0 a m ps. If a m per a ge is
fu el pu m p m odu le a ssem bly. Th e elect r ic fu el pu m p
below 10.0 a m ps, a n d specifica t ion s for t h e F u el
is n ot ser viced sepa r a t ely.
WJ FUEL DELIVERY 14 - 11
FU EL PU M P (Cont inue d)
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Rem ove pr essu r e t est por t ca p a t fu el r a il t est
por t (F ig. 12) or (F ig. 13) . Con n ect 0–414 kP a (0-60
psi) fu el pr essu r e ga u ge (fr om ga u ge set 5069) t o t est
por t pr essu r e fit t in g on fu el r a il (F ig. 14) . Th e D RB
III S c a n To o l a lo n g w ith th e P EP m o d u le , th e
500 p s i p re s s u re tra n s d u c e r, a n d th e tra n s d u c -
e r-to -te s t p o rt a d a p te r m a y a ls o be u s e d in
p la c e o f th e fu e l p re s s u re g a u g e .

Fig. 11 FUEL PUMP RELAY - TYPE 3

TERMINAL LEGEND

NUMBER IDENTIFICATION

1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN

(19) Discon n ect t est lea ds fr om r ela y ca vit ies

im m edia t ely a ft er t est in g.

FUEL PUMP PRESSURE TEST

Use t h is t est in con ju n ct ion wit h ot h er fu el syst em
t est s. Refer t o t h e F u el P u m p Ca pa cit y Test , F u el
P r essu r e Lea k Down Test a n d F u el P u m p Am per a ge
Test .
Ch e c k Va lv e Op e ra tio n : Th e elect r ic fu el pu m p
ou t let con t a in s a on e-wa y ch eck va lve t o pr even t fu el Fig. 12 Test Port Cap Location—4.0L Engine
flow ba ck in t o t h e t a n k a n d t o m a in t a in fu el su pply 1 - INJ. #1
lin e pr essu r e (en gin e wa r m ) wh en pu m p is n ot oper- 2 - INJ. #2
a t ion a l. It is a lso u sed t o keep t h e fu el su pply lin e 3 - INJ. #3
fu ll of ga solin e wh en pu m p is n ot oper a t ion a l. Aft er 4 - INJ. #4
t h e veh icle h a s cooled down , fu el pr essu r e m a y dr op 5 - INJ. #5
t o 0 psi (cold flu id con t r a ct s), bu t liqu id ga solin e will 6 - INJ. #6
r em a in in fu el su pply lin e bet ween t h e ch eck va lve 7 - FUEL INJECTOR RAIL
a n d fu el in ject or s. F u e l p re s s u re th a t h a s 8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
d ro p p e d to 0 p s i o n a c o o le d d o w n v e h ic le
10 - MOUNTING BOLTS (4)
(e n g in e o ff) is a n o rm a l c o n d itio n . Wh en t h e elec- 11 - QUICK-CONNECT FITTING
t r ic fu el pu m p is a ct iva t ed, fu el pr essu r e sh ou ld
im m e d ia te ly (1–2 secon ds) r ise t o specifica t ion .
Th e fu el syst em is equ ipped wit h a com bin a t ion (2) St a r t a n d wa r m en gin e a n d n ot e pr essu r e
fu el filt er /fu el pr essu r e r egu la t or. Th e fu el pr essu r e ga u ge r ea din g. Th e DRB sca n t ool m a y a lso be u sed
r egu la t or is n ot con t r olled by en gin e va cu u m . t o power fu el pu m p. F u el pr essu r e sh ou ld be 339 kP a
± 34 kP a (49.2 psi ± 5 psi) a t idle.
WARNING: THE FUEL SYSTEM IS UNDER CON- (3) If en gin e r u n s, bu t pr essu r e is below 44.2 psi,
STANT FUEL PRESSURE EVEN WITH THE ENGINE det er m in e if fu el pu m p or filt er /r egu la t or is defect ive.
OFF. BEFORE DISCONNECTING FUEL LINE AT P r oceed t o n ext st ep:
FUEL RAIL, THIS PRESSURE MUST BE RELEASED. (a ) Ch eck for a kin ked fu el su pply lin e som e-
wh er e bet ween fu el r a il a n d fu el pu m p m odu le.
14 - 12 FUEL DELIVERY WJ
FU EL PU M P (Cont inue d)

Fig. 14 Fuel Pressure Test Gauge (Typical Gauge

Installation at Test Port)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL

Fig. 13 Test Port Cap Location—4.7L V-8 Engine

1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP

(b) If lin e is n ot kin ked a n d pr essu r e is low,

r a ise veh icle a n d discon n ect fu el pr essu r e lin e a t
fu el filt er /fu el pr essu r e r egu la t or (F ig. 15) . Th r ee
fu el lin es a r e a t t a ch ed t o filt er /r egu la t or. Th e fu e l
p re s s u re lin e is a t t a ch ed t o t h e r igh t side of fil- Fig. 15 Fuel Filter/Fuel Pressure Regulator Location
t er /r egu la t or. It is a lso t h e m ost r ea r wa r d of t h e 1 - FUEL SUPPLY LINE (TO FUEL RAIL)
t wo (F ig. 15) . 2 - EVAP LINE
(c) In st a ll Specia l 5/16” F u el Lin e Ada pt er Tool # 3 - FUEL RETURN LINE (MALE)
6539 bet ween discon n ect ed fu el lin e a n d filt er /r eg- 4 - FUEL PRESSURE LINE (FEMALE)
u la t or fit t in g 5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
(d) At t a ch 0–60 psi fu el pr essu r e t est ga u ge t o
“T” fit t in g on t ool 6539.
WJ
FU EL PU M P (Cont inue d)
(e) Use DRB sca n t ool t o power fu el pu m p. If
pr essu r e is n ow wit h in specifica t ion s, r epla ce fu el
filt er /fu el pr essu r e r egu la t or.
(f) If pr essu r e is st ill low, r epla ce fu el pu m p
m odu le.
(4) If oper a t in g pr essu r e is a bove 54.2 psi, elect r ic
fu el pu m p is OK, bu t fu el pr essu r e r egu la t or is defec-
t ive. Repla ce fu el filt er /fu el pr essu r e r egu la t or.
(5) In st a ll t est por t ca p t o fu el r a il t est por t .
FUEL DELIVERY 14 - 13
• F u el su pply t u be (lin e) con n ect ion
• F u el r et u r n t u be (lin e) con n ect ion
Th e fu el ga u ge sen din g u n it a n d pick-u p filt er m a y
be ser viced sepa r a t ely. If t h e elect r ica l fu el pu m p
r equ ir es ser vice, t h e en t ir e fu el pu m p m odu le m u st
be r epla ced.
OPERATION
Refer t o F u el P u m p, F u el F ilt er /F u el P r essu r e Reg-
u la t or a n d F u el Ga u ge Sen din g Un it .

FU EL PU M P M ODU LE
DESCRIPTION
Th e fu el pu m p m odu le is in st a lled in t h e t op of t h e
fu el t a n k (F ig. 16). Th e fu el pu m p m odu le (F ig. 17)
con t a in s t h e followin g com pon en t s:
• A sepa r a t e fu el pick-u p filt er (st r a in er )
• An elect r ic fu el pu m p
• A t h r ea ded lockn u t t o r et a in m odu le t o t a n k
• A ga sket bet ween t a n k fla n ge a n d m odu le
• F u el ga u ge sen din g u n it (fu el level sen sor )
REMOVAL
F u el t a n k r em ova l will be n ecessa r y for fu el pu m p
m odu le r em ova l.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING FUEL PUMP MODULE, FUEL
SYSTEM PRESSURE MUST BE RELEASED.
(1) P er for m F u el Syst em P r essu r e Relea se P r oce-
du r e.

Fig. 16 FUEL TANK AND COMPONENTS

1 - FUEL PUMP MODULE 9 - TANK SUPPORT BRACKET (SMALL/FRONT)
2 - MODULE LOCK RING 10 - MODULE PIGTAIL HARNESS
3 - TANK SUPPORT BRACKETS (REAR) 11 - FUEL SUPPLY (PRESSURE) LINE
4 - CHECK VALVE 12 - FUEL RETURN LINE
5 - FUEL FILL HOSE 13 - SKID PLATE
6 - ORVR COMPONENTS 14 - TANK STRAPS (2)
7 - ORVR CONTROL VALVE 15 - FUEL TANK
8 - CONTROL VALVE LOCK RING
14 - 14 FUEL DELIVERY WJ
FU EL PU M P M ODU LE (Cont inue d)

Fig. 18 LOCKNUT REMOVAL/INSTALLATION -

TYPICAL
1 - SPECIAL TOOL 6856
2 - LOCKNUT

Fig. 17 FUEL PUMP MODULE

1 - FUEL PUMP MODULE
2 - FUEL GAUGE FLOAT
3 - ELECTRIC FUEL PUMP
4 - INLET FILTER
5 - FUEL GAUGE SENDING UNIT
6 - PIGTAIL HARNESS

(2) Dr a in fu el t a n k a n d r em ove t a n k. Refer t o F u el

Ta n k Rem ova l/In st a lla t ion .
(3) Th or ou gh ly wa sh a n d clea n a r ea a r ou n d pu m p
m odu le t o pr even t con t a m in a n t s fr om en t er in g t a n k.
(4) Discon n ect fu el r et u r n a n d pr essu r e lin es fr om
fu el pu m p m odu le fit t in gs (F ig. 16). Refer t o Qu ick-
Con n ect F it t in gs for pr ocedu r es.
(5) Th e pla st ic fu el pu m p m odu le lockn u t is
t h r ea ded on t o fu el t a n k (F ig. 16). In st a ll Specia l Tool
6856 t o fu el pu m p m odu le lockn u t a n d r em ove lock-
n u t (F ig. 18). Th e fu el pu m p m odu le will spr in g u p
sligh t ly a ft er lockn u t is r em oved.
(6) Rem ove m odu le fr om fu el t a n k.
Fig. 19 FUEL PUMP MODULE INDEXING ARROW
1 - FUEL PUMP MODULE
INSTALLATION 2 - INDEXING ARROW
F u el t a n k r em ova l will be n ecessa r y for fu el pu m p 3 - FUEL SUPPLY (PRESSURE) FITTING
m odu le r em ova l. 4 - FUEL RETURN FITTING

CAUTION: Whenever fuel pump module is serviced,

module gasket must be replaced.
(1) Th or ou gh ly clea n lockn u t t h r ea ds a n d m a t in g
fu el t a n k t h r ea ds. Use a soa p/wa t er solu t ion . Do n ot
u se ca r bu r et or clea n er t o clea n t h r ea ds.
(2) Usin g n ew ga sket , posit ion fu el pu m p m odu le
in t o open in g in fu el t a n k.
(3) Apply clea n wa t er t o lockn u t t h r ea ds.
(4) P osit ion lockn u t over t op of fu el pu m p m odu le.
(5) Rot a t e m odu le u n t il in dexin g a r r ow a t t op of
m odu le (F ig. 19)is poin t ed t owa r d r ea r of veh icle.
Align a r r ow t o t ick m a r k on t op of fu el t a n k. Th is
s te p m u s t be d o n e to p re v e n t flo a t/flo a t ro d
a s s e m bly fro m c o n ta c tin g s id e s o f fu e l ta n k .
(6) In st a ll Specia l Tool 6856 t o lockn u t .
(7) Tigh t en lockn u t t o 74 N·m (55 ft . lbs.) t or qu e.
WJ FUEL DELIVERY 14 - 15
FU EL PU M P M ODU LE (Cont inue d)
(8) Con n ect fu el r et u r n a n d pr essu r e lin es t o fu el
pu m p m odu le fit t in gs (F ig. 16). Refer t o Qu ick-Con -
n ect F it t in gs.
(9) In st a ll fu el t a n k. Refer t o F u el Ta n k In st a lla -
t ion .

FU EL RAI L

DESCRI PT I ON
DESCRIPTION - 4.7L
Th e fu el in ject or r a il is u sed t o m ou n t t h e fu el
in ject or s t o t h e en gin e. It is m ou n t ed t o t h e in t a ke
m a n ifold (F ig. 20).

DESCRIPTION - 4.0L
Th e fu el in ject or r a il is u sed t o m ou n t t h e fu el
in ject or s t o t h e en gin e (F ig. 21). On t h e 4.0L 6–cylin -
der en gin e, a fu e l d a m p e r is loca t ed n ea r t h e cen t er
of t h e fu el r a il (F ig. 21).

OPERAT I ON
OPERATION - 4.7L
H igh pr essu r e fu el fr om t h e fu el pu m p is r ou t ed t o
t h e fu el r a il. Th e fu el r a il t h en su pplies t h e n eces- Fig. 20 Fuel Injector Rail—4.7L V-8 Engine
sa r y fu el t o ea ch in dividu a l fu el in ject or. 1 - MOUNTING BOLTS (4)
A fu el pr essu r e t est por t is loca t ed on t h e fu el r a il 2 - INJ.#7
(F ig. 20). A qu ick-con n ect fit t in g wit h a sa fet y la t ch 3 - INJ.#5
is u sed t o a t t a ch t h e fu el lin e t o t h e fu el r a il. 4 - QUICK-CONNECT FITTING
Th e fu el r a il is n ot r epa ir a ble. 5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
OPERATION - 4.0L 8 - CONNECTOR TUBE
Th e fu el in ject or r a il su pplies t h e n ecessa r y fu el t o 9 - INJ.#2
ea ch in dividu a l fu el in ject or. 10 - INJ.#4
H igh pr essu r e fu el fr om t h e fu el pu m p is r ou t ed t o 11 - INJ.#6
t h e fu el r a il. Th e fu el r a il t h en su pplies t h e n eces- 12 - INJ.#8
sa r y fu el t o ea ch in dividu a l fu el in ject or. 13 - PRESSURE TEST PORT CAP
Th e fu el da m per is u sed on ly t o h elp con t r ol fu el
pr essu r e pu lsa t ion s. Th ese pu lsa t ion s a r e t h e r esu lt
of t h e fir in g of t h e fu el in ject or s. It is n o t u s e d a s a
REM OVAL
fu el pr essu r e r egu la t or. Th e fu el pr essu r e r egu la t or is
n o t m o u n te d t o t h e fu el r a il on a n y en gin e. It is
REMOVAL - 4.7L
loca t ed n ea r t h e fr on t of t h e fu el t a n k a bove t h e r ea r
WARNING: THE FUEL SYSTEM IS UNDER CON-
a xle. Refer t o F u el F ilt er /F u el P r essu r e Regu la t or in
STANT PRESSURE EVEN WITH ENGINE OFF.
t h is gr ou p for in for m a t ion .
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
A fu el pr essu r e t est por t is loca t ed on t h e fu el r a il
PRESSURE MUST BE RELEASED.
(F ig. 21). A qu ick-con n ect fit t in g wit h a sa fet y la t ch
is u sed t o a t t a ch t h e fu el lin e t o t h e fu el r a il.
Th e fu el r a il is n ot r epa ir a ble.
14 - 16 FUEL DELIVERY WJ
FU EL RAI L (Cont inue d)

Fig. 21 Fuel Injector Rail/Fuel Damper—4.0L Engine

1 - INJ. #1
2 - INJ. #2
3 - INJ. #3 Fig. 22 FUEL INJECTOR RAIL - 4.7L V-8 EN
4 - INJ. #4 1 - MOUNTING BOLTS (4)
5 - INJ. #5 2 - INJ.#7
6 - INJ. #6 3 - INJ.#5
7 - FUEL INJECTOR RAIL 4 - QUICK-CONNECT FITTING
8 - FUEL DAMPER 5 - INJ.#3
9 - PRESSURE TEST PORT CAP 6 - FUEL INJECTOR RAIL
10 - MOUNTING BOLTS (4) 7 - INJ.#1
11 - QUICK-CONNECT FITTING 8 - CONNECTOR TUBE
9 - INJ.#2
CAUTION: The left and right fuel rails are replaced 10 - INJ.#4
as an assembly. Do not attempt to separate rail 11 - INJ.#6
12 - INJ.#8
halves at connector tube (Fig. 22). Due to design of
13 - PRESSURE TEST PORT CAP
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care- (9) Discon n ect elect r ica l con n ect or s a t a ll 8 fu el
ful not to bend or kink tube. in ject or s. To r em ove con n ect or r efer t o (F ig. 23). P u sh
r ed color ed slider a wa y fr om in ject or (1). Wh ile pu sh -
(1) Rem ove fu el t a n k filler t u be ca p. in g slider, depr ess t a b (2) a n d r em ove con n ect or (3)
(2) P er for m F u el Syst em P r essu r e Relea se P r oce- fr om in ject or. Th e fa ct or y fu el in ject ion wir in g h a r-
du r e. n ess is n u m er ica lly t a gged (INJ 1, INJ 2, et c.) for
(3) Rem ove n ega t ive ba t t er y ca ble a t ba t t er y. in ject or posit ion iden t ifica t ion . If h a r n ess is n ot
(4) Rem ove a ir du ct a t t h r ot t le body a ir box. t a gged, n ot e wir in g loca t ion befor e r em ova l.
(5) Rem ove a ir box a t t h r ot t le body. (10) Discon n ect elect r ica l con n ect or s a t t h r ot t le
(6) Rem ove wir in g a t r ea r of gen er a t or. body.
(7) Discon n ect fu el lin e la t ch clip a n d fu el lin e a t (11) Discon n ect elect r ica l con n ect or s a t MAP a n d
fu el r a il. A specia l t ool will be n ecessa r y for fu el lin e IAT sen sor s.
discon n ect ion . Refer t o Qu ick-Con n ect F it t in gs.
(8) Rem ove va cu u m lin es a t t h r ot t le body.
WJ FUEL DELIVERY 14 - 17
FU EL RAI L (Cont inue d)
(4) Rem ove a ir t u be a t t op of t h r ot t le body. Not e:
Som e en gin e/veh icles m a y r equ ir e r em ova l of a ir
clea n er du ct s a t t h r ot t le body.
(5) Discon n ect elect r ica l con n ect or s a t a ll 6 fu el
in ject or s. To r em ove con n ect or r efer t o (F ig. 25). P u sh
r ed color ed slider a wa y fr om in ject or (1). Wh ile pu sh -
in g slider, depr ess t a b (2) a n d r em ove con n ect or (3)
fr om in ject or. Th e fa ct or y fu el in ject ion wir in g h a r-
n ess is n u m er ica lly t a gged (INJ 1, INJ 2, et c.) for
in ject or posit ion iden t ifica t ion . If h a r n ess is n ot
t a gged, n ot e wir in g loca t ion befor e r em ova l.

Fig. 23 Remove/Install Injector Connector—4.7L V-8

Engine
(12) Rem ove fir st t h r ee ign it ion coils on ea ch ba n k
(cylin der s #1, 3, 5, 2, 4 a n d 6). Refer t o Ign it ion Coil
Rem ova l/In st a lla t ion .
(13) Rem ove 4 fu el r a il m ou n t in g bolt s (F ig. 22).
(14) Gen t ly r ock a n d pu ll le ft side of fu el r a il u n t il
fu el in ject or s ju st st a r t t o clea r m a ch in ed h oles in
cylin der h ea d. Gen t ly r ock a n d pu ll rig h t side of r a il
u n t il in ject or s ju st st a r t t o clea r cylin der h ea d h oles.
Repea t t h is pr ocedu r e (left /r igh t ) u n t il a ll in ject or s
Fig. 24 Fuel Rail Mounting—4.0L Engine
h a ve clea r ed cylin der h ea d h oles.
(15) Rem ove fu el r a il (wit h in ject or s a t t a ch ed) 1 - INJ. #1
2 - INJ. #2
fr om en gin e.
3 - INJ. #3
(16) If fu el in ject or s a r e t o be r em oved, r efer t o
4 - INJ. #4
F u el In ject or Rem ova l/In st a lla t ion . 5 - INJ. #5
6 - INJ. #6
REMOVAL - 4.0L 7 - FUEL INJECTOR RAIL
Th e fu el da m per is n ot ser viced sepa r a t ely. 8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
WARNING: THE FUEL SYSTEM IS UNDER CON- 10 - MOUNTING BOLTS (4)
STANT FUEL PRESSURE EVEN WITH ENGINE OFF. 11 - QUICK-CONNECT FITTING
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL. (6) Rem ove oxygen sen sor wir in g clip n u t s a t fu el
r a il m ou n t in g st u ds (cer t a in em ission s pa cka ges
(1) Rem ove fu el t a n k filler t u be ca p. on ly).
(2) P er for m F u el Syst em P r essu r e Relea se P r oce- (7) Discon n ect fu el su pply lin e la t ch clip a n d fu el
du r e. lin e a t fu el r a il. Refer t o Qu ick-Con n ect F it t in gs.
(3) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y. (8) Discon n ect t h r ot t le ca ble a t t h r ot t le body. Refer
t o Th r ot t le Ca ble Rem ova l/In st a lla t ion .
14 - 18 FUEL DELIVERY
FU EL RAI L (Cont inue d)
Fig. 25 Remove/Install Injector Connector—4.0L
Engine
(9) Discon n ect speed con t r ol ca ble a t t h r ot t le body
(if equ ipped). Refer t o Speed Con t r ol Ca ble.
(10) Discon n ect a u t om a t ic t r a n sm ission ca ble a t
t h r ot t le body (if equ ipped).
(11) Rem ove ca ble r ou t in g br a cket a t in t a ke m a n i-
fold.
(12) Clea n dir t /debr is fr om ea ch fu el in ject or a t
in t a ke m a n ifold.
(13) Rem ove fu el r a il m ou n t in g n u t s/bolt s (F ig.
24).
(14) Rem ove fu el r a il by gen t ly r ockin g u n t il a ll
fu el in ject or s h a ve clea r ed m a ch in ed h oles a t in t a ke
m a n ifold.
(15) If fu el in ject or s a r e t o be r em oved, r efer t o
F u el In ject or Rem ova l/In st a lla t ion .
I N STALLAT I ON
INSTALLATION - 4.7L
(1) If fu el in ject or s a r e t o be in st a lled, r efer t o F u el
In ject or Rem ova l/In st a lla t ion .
(2) Apply a sm a ll a m ou n t of en gin e oil t o ea ch fu el
in ject or o-r in g. Th is will h elp in fu el r a il in st a lla t ion .
(3) P osit ion fu el r a il/fu el in ject or a ssem bly t o
m a ch in ed in ject or open in gs in cylin der h ea d.
(4) Gu ide ea ch in ject or in t o cylin der h ea d. Be ca r e-
fu l n ot t o t ea r in ject or o-r in gs.
WJ
(5) P u sh rig h t side of fu el r a il down u n t il fu el
in ject or s h a ve bot t om ed on cylin der h ea d sh ou lder.
P u sh le ft fu el r a il down u n t il in ject or s h a ve bot -
t om ed on cylin der h ea d sh ou lder.
(6) In st a ll 4 fu el r a il m ou n t in g bolt s a n d t igh t en t o
27 N·m (20 ft . lbs.).
(7) In st a ll ign it ion coils. Refer t o Ign it ion Coil
Rem ova l/In st a lla t ion .
(8) Con n ect elect r ica l con n ect or s t o t h r ot t le body.
(9) Con n ect elect r ica l con n ect or s t o MAP a n d IAT
sen sor s.
(10) Con n ect elect r ica l con n ect or s a t a ll fu el in jec-
t or s. To in st a ll con n ect or, r efer t o (F ig. 23). P u sh con -
n ect or on t o in ject or (1) a n d t h en pu sh a n d lock r ed
color ed slider (2). Ver ify con n ect or is locked t o in jec-
t or by ligh t ly t u ggin g on con n ect or.
(11) Con n ect va cu u m lin es t o t h r ot t le body.
(12) Con n ect fu el lin e la t ch clip a n d fu el lin e t o
fu el r a il. Refer t o Qu ick-Con n ect F it t in gs.
(13) Con n ect wir in g t o r ea r of gen er a t or.
(14) In st a ll a ir box t o t h r ot t le body.
(15) In st a ll a ir du ct t o a ir box.
(16) Con n ect ba t t er y ca ble t o ba t t er y.
(17) St a r t en gin e a n d ch eck for lea ks.
INSTALLATION - 4.0L
(1) If fu el in ject or s a r e t o be in st a lled, r efer t o F u el
In ject or Rem ova l/In st a lla t ion .
(2) Clea n ea ch in ject or bor e a t in t a ke m a n ifold.
(3) Apply a sm a ll a m ou n t of clea n en gin e oil t o
ea ch in ject or o-r in g. Th is will a id in in st a lla t ion .
(4) P osit ion t ips of a ll fu el in ject or s in t o t h e cor r e-
spon din g in ject or bor e in in t a ke m a n ifold. Sea t in jec-
t or s in t o m a n ifold.
(5) In st a ll a n d t igh t en fu el r a il m ou n t in g bolt s t o
11 ±3 N·m (100 ±25 in . lbs.) t or qu e.
(6) Con n ect elect r ica l con n ect or s a t a ll fu el in jec-
t or s. To in st a ll con n ect or, r efer t o (F ig. 25). P u sh con -
n ect or on t o in ject or (1) a n d t h en pu sh a n d lock r ed
color ed slider (2). Ver ify con n ect or is locked t o in jec-
t or by ligh t ly t u ggin g on con n ect or.
(7) Con n ect fu el lin e a n d fu el lin e la t ch clip t o fu el
r a il. Refer Qu ick-Con n ect F it t in gs.
(8) In st a ll pr ot ect ive ca p t o pr essu r e t est por t fit -
t in g (if equ ipped).
(9) In st a ll ca ble r ou t in g br a cket t o in t a ke m a n i-
fold.
(10) Con n ect t h r ot t le ca ble a t t h r ot t le body.
(11) Con n ect speed con t r ol ca ble a t t h r ot t le body (if
equ ipped).
(12) Con n ect a u t om a t ic t r a n sm ission ca ble a t
t h r ot t le body (if equ ipped).
(13) In st a ll oxygen sen sor wir in g clip n u t s t o fu el
r a il m ou n t in g st u ds (cer t a in em ission s pa cka ges
on ly).
WJ
FU EL RAI L (Cont inue d)
(14) In st a ll a ir t u be (or du ct ) a t t op of t h r ot t le
body.
(15) In st a ll fu el t a n k ca p.
(16) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
(17) St a r t en gin e a n d ch eck for fu el lea ks.
FU EL TAN K
DESCRIPTION
Th e fu el t a n k is con st r u ct ed of a pla st ic m a t er ia l.
It s m a in fu n ct ion s a r e for fu el st or a ge a n d for pla ce-
m en t of t h e fu el pu m p m odu le a n d cer t a in ORVR
com pon en t s.
OPERATION
All m odels pa ss a fu ll 360 degr ee r ollover t est
wit h ou t fu el lea ka ge. To a ccom plish t h is, fu el a n d
va por flow con t r ols a r e r equ ir ed for a ll fu el t a n k con -
n ect ion s.
A fu el t a n k ch eck va lve(s) is m ou n t ed in t o t h e t op
of t h e fu el t a n k (or pu m p m odu le). Refer t o F u el
Ta n k Ch eck Va lve for a ddit ion a l in for m a t ion .
An eva por a t ion con t r ol syst em is con n ect ed t o t h e
ch eck va lve(s) t o r edu ce em ission s of fu el va por s in t o
t h e a t m osph er e. Wh en fu el eva por a t es fr om t h e fu el
t a n k, va por s pa ss t h r ou gh ven t h oses or t u bes t o a
ch a r coa l ca n ist er wh er e t h ey a r e t em por a r ily h eld.
Wh en t h e en gin e is r u n n in g, t h e va por s a r e dr a wn
in t o t h e in t a ke m a n ifold. Cer t a in m odels a r e a lso
equ ipped wit h a self-dia gn osin g syst em u sin g a Lea k
Det ect ion P u m p (LDP ). Refer t o E m ission Con t r ol
Syst em for a ddit ion a l in for m a t ion .
Refer t o ORVR for On -Boa r d Refu elin g Va por
Recover y syst em in for m a t ion .
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
PRESSURE MUST BE RELEASED BEFORE SERVIC-
ING FUEL TANK.
Two differ en t pr ocedu r es m a y be u sed t o dr a in fu el
t a n k (t h r ou gh ORVR con t r ol va lve open in g a t t op of
fu el t a n k, or u sin g DRB sca n t ool). Th e qu ickest is
dr a in in g t h r ou gh ORVR con t r ol va lve open in g a t t op
of fu el t a n k (F ig. 26).
As a n a lt er n a t ive pr ocedu r e, t h e elect r ic fu el pu m p
m a y be a ct iva t ed a llowin g t a n k t o be dr a in ed a t fu el
r a il con n ect ion . Refer t o DRB sca n t ool for fu el pu m p
a ct iva t ion pr ocedu r es. Befor e discon n ect in g fu el lin e
a t fu el r a il, r elea se fu el pr essu r e. Refer t o t h e F u el
Syst em P r essu r e Relea se P r ocedu r e for pr ocedu r es.
At t a ch en d of Specia l Ada pt er H ose Tool n u m ber
6539 a t fu el r a il discon n ect ion . P osit ion opposit e en d
of 6539 t o a n a ppr oved ga solin e dr a in in g st a t ion .
FUEL DELIVERY 14 - 19
Act iva t e fu el pu m p wit h DRB a n d dr a in t a n k u n t il
em pt y.
If elect r ic fu el pu m p is n ot oper a t in g, t a n k MU S T
be dr a in ed t h r ou gh ORVR con t r ol va lve open in g a t
t op of fu el t a n k (F ig. 26).
(1) Relea se fu el syst em pr essu r e. Refer t o F u el
Syst em P r essu r e Relea se P r ocedu r e.
(2) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(3) Ra ise a n d su ppor t veh icle.
(4) Rem ove left r ea r wh eel/t ir e.
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(5) Clea n t op of fu el t a n k a t ORVR con t r ol va lve
(F ig. 26) or (F ig. 27).
(6) P r ess r elea se t a b in dir ect ion of a r r ow in (F ig.
27) a n d r em ove ORVR con t r ol va lve lock r in g
(cou n t er-clockwise). Lift u p ORVR con t r ol sligh t ly.
Usin g a n a ppr oved ga solin e dr a in in g st a t ion , dr a in
t a n k u n t il em pt y t h r ou gh t h is open in g.
(7) Rem ove st on e sh ield beh in d left /r ea r wh eel
(F ig. 28). Dr ill ou t pla st ic r ivet s for r em ova l.
(8) Rem ove 3 LDP m ou n t in g bolt s (F ig. 29).
(9) Rem ove su ppor t br a cket br a ce bolt (F ig. 30).
(10) Loosen , bu t do n ot r em ove 2 su ppor t br a cket
n u t s a t fr a m e r a il (F ig. 29).
(11) To sepa r a t e a n d lower fr on t sect ion of t wo-
piece su ppor t br a cket , r em ove 3 a t t a ch in g bolt s on
bot t om of su ppor t br a cket (F ig. 30). Wh ile lower in g
su ppor t br a cket , discon n ect LDP wir in g clip (F ig. 31).
(12) Rem ove h ose cla m p (F ig. 32) a n d r em ove fu el
fill h ose fr om fu el fill t u be.
(13) Cu t a n d disca r d t ie wr a p fr om a xle ven t h ose
(F ig. 32).
(14) Discon n ect fu el ven t h ose fr om fu el ven t t u be
(F ig. 32).
(15) Discon n ect ORVR h ose elbow (F ig. 33) a t t op
of E VAP ca n ist er.
(16) P la ce h ydr a u lic ja ck t o bot t om of fu el t a n k.
(17) Rem ove fu el t a n k-t o-r ea r bu m per fa scia clips
(F ig. 34).
(18) Rem ove fu el t a n k h ea t sh ield m ou n t in g bolt s
(F ig. 35).
CAUTION: To protect fuel tank from exhaust heat,
shield must re-installed after tank installation.
WARNING: PLACE SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
14 - 20 FUEL DELIVERY
FU EL TAN K (Cont inue d)
(19) Discon n ect fu el r et u r n lin e a t fu el filt er /fu el
pr essu r e r egu la t or (F ig. 36). Refer t o Qu ick-Con n ect
F it t in gs for pr ocedu r es.
(20) Discon n ect fu el pr essu r e lin e a t fu el filt er /fu el
pr essu r e r egu la t or (F ig. 36). Refer t o Qu ick-Con n ect
F it t in gs for pr ocedu r es.
(21) Discon n ect E VAP ca n ist er ven t lin e n ea r fr on t
of t a n k (F ig. 36).
(22) Discon n ect fu el pu m p m odu le elect r ica l con -
n ect or (pigt a il h a r n ess) n ea r fr on t of t a n k (F ig. 36).
H a r n ess con n ect or is clipped t o body.
(23) Rem ove left / fr on t t a n k su ppor t br a cket bolt
a t fr a m e (F ig. 37).
(24) WITHOU T TRAILER HITCH: Rem ove t a n k-
t o-fr a m e m ou n t in g bolt s (F ig. 39). Rem ove r ea r t a n k
su ppor t br a cket bolt s a t fr a m e (F ig. 38). Ca r efu lly
lower t a n k u n t il clea r of veh icle. P la ce t a n k on floor.
(25) WITH TRAILER HITCH: Rem ove t a n k /
h it ch m ou n t in g bolt s (F ig. 40). Ca r efu lly lower t a n k
u n t il clea r of veh icle. P la ce t a n k on floor.
(26) If n ecessa r y, sepa r a t e skid pla t e fr om fu el
t a n k by r em ovin g 2 fu el t a n k st r a p n u t s (F ig. 39) a n d
r em ove 2 t a n k st r a ps.
(27) If fu el pu m p m odu le r em ova l is n ecessa r y,
r efer t o F u el P u m p Modu le Rem ova l/In st a lla t ion .
(28) If h oses a r e t o be r em oved a t fu el t a n k en d,
n ot e pa in t ed a lign m en t (in dexin g) m a r kin gs on
h oses, a n d m olded in dexin g t a n gs on t a n k befor e
r em ova l. Rem ove h oses.
(29) If n ecessa r y, r em ove 3 fu el filler t u be a ssem -
bly m ou n t in g bolt s (F ig. 41) a n d r em ove fu el filler
t u be.
INSTALLATION
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(1) If n ecessa r y, posit ion fu el filler t u be a ssem bly
t o body. In st a ll 3 bolt s a n d t igh t en t o 2 N·m (15 in .
lbs.) t or qu e.
(2) If n ecessa r y, con n ect qu ick-con n ect fit t in gs t o
fu el pu m p m odu le.
(3) If fu el pu m p m odu le is bein g in st a lled, r efer t o
F u el P u m p Modu le Rem ova l/In st a lla t ion .
(4) In st a ll fu el fill/ven t h oses t o t a n k fit t in gs. To
pr even t h oses fr om kin kin g, r ot a t e ea ch h ose u n t il
pa in t ed in dexin g m a r k on h ose is a lign ed t o m olded
in dexin g t a n g on t a n k.
(5) In st a ll h ose cla m ps t o h oses. Refer t o Tor qu e
Specifica t ion s.
WJ
(6) If n ecessa r y, posit ion fu el t a n k in t o skid pla t e.
In st a ll 2 t a n k st r a ps a n d 2 st r a p n u t s (F ig. 39). Refer
t o Tor qu e Specifica t ion s.
(7) P osit ion fu el t a n k / skid pla t e a ssem bly t o
h ydr a u lic ja ck.
(8) Ra ise t a n k in t o posit ion t o fr a m e.
(9) WITH TRAILER HITCH: P osit ion t r a iler
h it ch a n d t ow h ooks (F ig. 40) t o bot t om of fu el t a n k.
In st a ll bolt s a n d n u t s loosely.
(10) WITHOU T TRAILER HITCH: In st a ll 2 r ea r
t a n k su ppor t br a cket s a n d bolt s (F ig. 38). In st a ll
t a n k-t o-fr a m e bolt s. Do n ot t igh t en bolt s / n u t s a t
t h is t im e.
(11) In st a ll 1 left / fr on t t a n k su ppor t br a cket a n d
bolt s / n u t s (F ig. 37). Do n ot t igh t en bolt s / n u t s a t
t h is t im e.
(12) Be su r e fu el t a n k is pr oper ly a lign ed t o fr a m e
a n d body. Tigh t en a ll t a n k, t ow h ook a n d t r a iler
h it ch bolt s / n u t s except for 3 su ppor t br a cket s.
Tigh t en a ll 3 (2 r ea r a n d 1 left / fr on t ) su ppor t
br a cket bolt s / n u t s la st . Refer t o Tor qu e Specifica -
t ion s.
(13)
(14) Con n ect fu el pu m p m odu le pigt a il h a r n ess
elect r ica l con n ect or n ea r fr on t of t a n k.
(15) Con n ect bot h fu el lin es t o fu el filt er /fu el pr es-
su r e r egu la t or. Refer t o Qu ick-Con n ect F it t in gs for
pr ocedu r es.
(16) Con n ect E VAP h ose n ea r fr on t of t a n k.
(17) P osit ion r ea r a xle ven t h ose a n d in st a ll n ew
t ie st r a p (F ig. 32).
(18) In st a ll h ea t sh ield n u t s / bolt s (F ig. 35). Refer
t o Tor qu e Specifica t ion s.
(19) Con n ect ORVR h ose elbow (F ig. 33) t o t op of
E VAP ca n ist er.
(20) Con n ect fu el ven t h ose t o fu el ven t t u be (F ig.
32).
(21) In st a ll fu el fill h ose a n d cla m p t o fu el fill t u be
(F ig. 32).
(22) In st a ll 3 LDP m ou n t in g bolt s (F ig. 29).
(23) Wh ile r a isin g su ppor t br a cket , con n ect LDP
wir in g clip (F ig. 31). In st a ll fr on t sect ion of t wo-piece
su ppor t br a cket t o r ea r sect ion wit h 3 a t t a ch in g bolt s
loca t ed on bot t om of su ppor t br a cket (F ig. 30).
(24) In st a ll su ppor t br a cket br a ce bolt (F ig. 30).
(25) Tigh t en 2 su ppor t br a cket n u t s a t fr a m e r a il
(F ig. 29).
(26) In st a ll fu el t a n k-t o-r ea r bu m per fa scia clips
(F ig. 34).
(27) Usin g n ew pla st ic r ivet s, in st a ll st on e sh ield
beh in d left /r ea r wh eel (F ig. 28).
(28) In st a ll left r ea r wh eel/t ir e.
(29) Lower veh icle a n d con n ect n ega t ive ba t t er y
ca ble t o ba t t er y.
(30) F ill t a n k wit h fu el a n d ch eck for lea ks.
WJ FUEL DELIVERY 14 - 21
FU EL TAN K (Cont inue d)

Fig. 26 FUEL TANK AND COMPONENTS

1 - FUEL PUMP MODULE 9 - TANK SUPPORT BRACKET (SMALL/FRONT)
2 - MODULE LOCK RING 10 - MODULE PIGTAIL HARNESS
3 - TANK SUPPORT BRACKETS (REAR) 11 - FUEL SUPPLY (PRESSURE) LINE
4 - CHECK VALVE 12 - FUEL RETURN LINE
5 - FUEL FILL HOSE 13 - SKID PLATE
6 - ORVR COMPONENTS 14 - TANK STRAPS (2)
7 - ORVR CONTROL VALVE 15 - FUEL TANK
8 - CONTROL VALVE LOCK RING
14 - 22 FUEL DELIVERY WJ
FU EL TAN K (Cont inue d)

Fig. 29 LDP MOUNTING BOLTS

Fig. 27 ORVR CONTROL VALVE / LOCK RING 1 - SUPPORT BRACKET NUTS (2)
1 - ORVR CONTROL VALVE 2 - SUPPORT BRACKET (FRONT)
2 - LOCK RING 3 - SUPPORT BRACKET BRACE BOLT
3 - ORVR HOSE 4 - LDP MOUNTING BOLTS (3)
4 - RELEASE TAB
5 - TOP OF FUEL TANK

Fig. 30 TWO-PIECE SUPPORT BRACKET

1 - TWO-PIECE SUPPORT BRACKET (FRONT)
Fig. 28 STONE SHIELD 2 - SUPPORT BRACKET BRACE
1 - LEFT-REAR WHEELHOUSE 3 - TWO-PIECE SUPPORT BRACKET (REAR)
2 - STONE SHIELD 4 - SUPPORT BRACKET ATTACHING BOLTS (3)
3 - PLASTIC RIVETS 5 - SUPPORT BRACKET BRACE BOLT
WJ FUEL DELIVERY 14 - 23
FU EL TAN K (Cont inue d)

Fig. 31 LDP REMOVAL / INSTALLATION

1 - LDP
Fig. 33 ORVR HOSE ELBOW
2 - ELEC. CONNECT. 1 - FUEL FILL HOSE
3 - VAPOR / VACUUM LINES 2 - ELBOW (TO TOP OF EVAP CANISTER)
4 - WIRING CLIP

Fig. 34 BUMPER FASCIA CLIPS

1 - CLIPS
2 - FUEL TANK

Fig. 32 FUEL FILL TUBE/HOSE/CLAMP

1 - AXLE VENT HOSE
2 - FUEL VENT TUBE
3 - FUEL FILL TUBE
4 - PLASTIC TIE WRAP
5 - HOSE CLAMP
6 - FUEL FILL HOSE
7 - FUEL VENT HOSE
14 - 24 FUEL DELIVERY WJ
FU EL TAN K (Cont inue d)

Fig. 35 FUEL TANK HEAT SHIELD BOLTS

1 - FUEL TANK
2 - HEAT SHIELD BOLTS

Fig. 36 FUEL FILTER/FUEL PRESSURE REGULATOR

1 - FUEL RETURN LINE
2 - FUEL SUPPLY LINE (TO FUEL RAIL)
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - FUEL PRESSURE LINE
5 - REAR AXLE
6 - ELEC. CONNECTOR
7 - EVAP LINE
WJ FUEL DELIVERY 14 - 25
FU EL TAN K (Cont inue d)

Fig. 39 FUEL TANK MOUNTING - NO TRAILER

Fig. 37 BRACKET, TANK SUPPORT - FRONT HITCH
1 - FUEL TANK SUPPORT BRACKET (LEFT FRONT) 1 - TANK MOUNTING BOLTS
2 - BRACKET BOLT 2 - STRAP NUTS
3 - LEFT SIDE OF TANK 3 - FUEL TANK/SHIELD ASSEMBLY

Fig. 38 BRACKETS, TANK SUPPORT - REAR

1 - TOW HOOKS
2 - REAR SUPPORT BRACKETS (2)
3 - TANK SUPPORT BRACKET NUTS
4 - TANK SUPPORT BRACKET BOLTS
14 - 26 FUEL DELIVERY WJ
FU EL TAN K (Cont inue d)

Fig. 40 FUEL TANK MOUNTING - WITH TRAILER HITCH

1 - TRAILER HITCH 3 - FUEL TANK / HITCH MOUNTING BOLTS
2 - FUEL TANK

Fig. 41 FUEL FILLER TUBE

1 - FUEL FILLER TUBE
2 - MOUNTING BOLTS (3)
WJ
I N LET FI LT ER
REMOVAL
Th e fu el pu m p in let filt er (st r a in er ) is loca t ed on
t h e bot t om of fu el pu m p m odu le (F ig. 42). Th e fu el
pu m p m odu le is loca t ed on t op of fu el t a n k.
Fig. 42 Fuel Pump Inlet Filter
1 - FUEL PUMP MODULE
2 - FUEL PUMP INLET FILTER
Th e fu el pu m p in let filt er (st r a in er ) is loca t ed on
t h e bot t om of fu el pu m p m odu le (F ig. 42). Th e fu el
pu m p m odu le is loca t ed on t op of fu el t a n k.
(1) Rem ove fu el t a n k. Refer t o F u el Ta n k Rem ova l/
In st a lla t ion .
(2) Rem ove fu el pu m p m odu le. Refer t o F u el P u m p
Modu le Rem ova l/In st a lla t ion .
(3) Rem ove filt er by pr yin g fr om bot t om of m odu le
wit h 2 scr ewdr iver s. F ilt er is sn a pped t o m odu le.
(4) Clea n bot t om of pu m p m odu le.
INSTALLATION
Th e fu el pu m p in let filt er (st r a in er ) is loca t ed on
t h e bot t om of fu el pu m p m odu le (F ig. 42). Th e fu el
pu m p m odu le is loca t ed on t op of fu el t a n k.
(1) Sn a p n ew filt er t o bot t om of m odu le.
(2) In st a ll fu el pu m p m odu le. Refer t o F u el P u m p
Modu le Rem ova l/In st a lla t ion .
(3) In st a ll fu el t a n k. Refer t o F u el Ta n k Rem ova l/
In st a lla t ion .
FUEL DELIVERY 14 - 27
QU I CK CON N ECT FI T T I N G
DESCRIPTION
Differ en t t ypes of qu ick-con n ect fit t in gs a r e u sed t o
a t t a ch va r iou s fu el syst em com pon en t s, lin es a n d t u bes.
Th ese a r e: a sin gle-t a b t ype, a t wo-t a b t ype or a pla st ic
r et a in er r in g t ype. Som e a r e equ ipped wit h sa fet y la t ch
clips. Som e m a y r equ ir e t h e u se of a specia l t ool for dis-
con n ect ion a n d r em ova l. Refer t o Qu ick-Con n ect F it -
t in gs Rem ova l/In st a lla t ion for m or e in for m a t ion .
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Also r efer t o F u el Tu bes/Lin es/H oses a n d Cla m ps.
Differ en t t ypes of qu ick-con n ect fit t in gs a r e u sed t o
a t t a ch va r iou s fu el syst em com pon en t s, lin es a n d
t u bes. Th ese a r e: a sin gle-t a b t ype, a t wo-t a b t ype or
a pla st ic r et a in er r in g t ype. Sa fet y la t ch clips a r e
u sed on cer t a in com pon en t s/lin es. Cer t a in fit t in gs
m a y r equ ir e u se of a specia l t ool for discon n ect ion .
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) P er for m fu el pr essu r e r elea se pr ocedu r e. Refer
t o F u el P r essu r e Relea se P r ocedu r e.
(2) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(3) Clea n fit t in g of a n y for eign m a t er ia l befor e dis-
a ssem bly.
(4) 2–B u tto n Ty p e F ittin g : Th is t ype of fit t in g is
equ ipped wit h a pu sh -bu t t on loca t ed on ea ch side of
qu ick-con n ect fit t in g (F ig. 43). P r ess on bot h bu t t on s
sim u lt a n eou sly for r em ova l. Specia l t ools a r e n ot
r equ ir ed for discon n ect ion .
14 - 28 FUEL DELIVERY WJ
QU I CK CON N ECT FI T T I N G (Cont inue d)
is r em ova ble. Aft er t a b is r em oved, qu ick-con n ect fit -
t in g ca n be sepa r a t ed fr om fu el syst em com pon en t .
Specia l t ools a r e n ot r equ ir ed for discon n ect ion .
(a ) P r ess r elea se t a b on side of fit t in g t o r elea se
pu ll t a b (F ig. 46). If re le a s e ta b is n o t p re s s e d
p rio r to re le a s in g p u ll ta b, p u ll ta b w ill be
damaged.
(b) Wh ile pr essin g r elea se t a b on side of fit t in g,
u se scr ewdr iver t o pr y u p pu ll t a b (F ig. 46).
(c) Ra ise pu ll t a b u n t il it sepa r a t es fr om qu ick-
con n ect fit t in g (F ig. 47).
(7) Tw o -Ta b Ty p e F ittin g : Th is t ype of fit t in g is
equ ipped wit h t a bs loca t ed on bot h sides of fit t in g
(F ig. 48). Th e t a bs a r e su pplied for discon n ect in g
qu ick-con n ect fit t in g fr om com pon en t bein g ser viced.

Fig. 43 2-BUTTON TYPE FITTING

1 - QUICK-CONNECT FITTING
2 - PUSH-BUTTONS (2)

(5) P in c h -Ty p e F ittin g : Th is fit t in g is equ ipped

wit h t wo fin ger t a bs. P in ch bot h t a bs t oget h er wh ile
r em ovin g fit t in g (F ig. 44). Specia l t ools a r e n ot
r equ ir ed for discon n ect ion .

Fig. 45 SINGLE-TAB TYPE FITTING

1 - PULL TAB
2 - QUICK-CONNECT FITTING
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END

(a ) To discon n ect qu ick-con n ect fit t in g, squ eeze

Fig. 44 PINCH TYPE QUICK-CONNECT FITTING
1 - QUICK-CONNECT FITTINGS
2 - PINCH TABS
(6) S in g le -Ta b Ty p e F ittin g : Th is t ype of fit t in g
is equ ipped wit h a sin gle pu ll t a b (F ig. 45). Th e t a b
pla st ic r et a in er t a bs (F ig. 48) a ga in st sides of
qu ick-con n ect fit t in g wit h you r fin ger s. Tool u se is
n ot r equ ir ed for r em ova l a n d m a y da m a ge pla st ic
r et a in er.
(b) P u ll fit t in g fr om fu el syst em com pon en t
bein g ser viced.
(c) Th e pla st ic r et a in er will r em a in on com po-
n en t bein g ser viced a ft er fit t in g is discon n ect ed.
Th e o-r in gs a n d spa cer will r em a in in qu ick-con -
n ect fit t in g con n ect or body.
(8) P la s tic Re ta in e r Rin g Ty p e F ittin g : Th is
t ype of fit t in g ca n be iden t ified by t h e u se of a fu ll-
r ou n d pla st ic r et a in er r in g (F ig. 49) u su a lly bla ck in
color.
(a ) To r elea se fu el syst em com pon en t fr om qu ick-
con n ect fit t in g, fir m ly pu sh fit t in g t owa r ds com po-
n en t bein g ser viced wh ile fir m ly pu sh in g pla st ic
r et a in er r in g in t o fit t in g (F ig. 49). Wit h pla st ic r in g
WJ FUEL DELIVERY 14 - 29
QU I CK CON N ECT FI T T I N G (Cont inue d)

Fig. 48 TYPICAL 2–TAB TYPE FITTING

Fig. 46 DISCONNECTING SINGLE-TAB TYPE 1 - TAB(S)
FITTING 2 - QUICK-CONNECT FITTING
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING

Fig. 47 REMOVING PULL TAB

1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
3 - QUICK-CONNECT FITTING
Fig. 49 PLASTIC RETAINER RING TYPE FITTING
4 - FUEL TUBE STOP 1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
depr essed, pu ll fit t in g fr om com pon en t . Th e p la s - 4 - PLASTIC RETAINER
tic re ta in e r rin g m u s t be p re s s e d s qu a re ly 5 - PUSH
in to fittin g bo d y. If th is re ta in e r is c o c k e d 6 - PUSH
d u rin g re m o v a l, it m a y be d iffic u lt to d is c o n - 7 - PUSH
n e c t fittin g . U s e a n o p e n -e n d w re n c h o n 8 - PUSH
s h o u ld e r o f p la s tic re ta in e r rin g to a id in d is -
c o n n e c tio n . (9) La tc h Clip s : Depen din g on veh icle m odel a n d
(b) Aft er discon n ect ion , pla st ic r et a in er r in g will en gin e, 2 differ en t t ypes of sa fet y la t ch clips a r e u sed
r em a in wit h qu ick-con n ect fit t in g con n ect or body. (F ig. 50) or (F ig. 51). Type-1 is t et h er ed t o fu el lin e
(c) In spect fit t in g con n ect or body, pla st ic r et a in er a n d t ype-2 is n ot . A specia l t ool will be n ecessa r y t o
r in g a n d fu el syst em com pon en t for da m a ge. discon n ect fu el lin e a ft er la t ch clip is r em oved. Th e
Repla ce a s n ecessa r y. la t ch clip m a y be u sed on cer t a in fu el lin e/fu el r a il
con n ect ion , or t o join fu el lin es t oget h er.
14 - 30 FUEL DELIVERY WJ
QU I CK CON N ECT FI T T I N G (Cont inue d)

Fig. 50 LATCH CLIP-TYPE 1 Fig. 52 FUEL LINE DISCONNECTION USING

1 - TETHER STRAP SPECIAL TOOL
2 - FUEL LINE
1 - SPECIAL FUEL LINE TOOL
3 - SCREWDRIVER
2 - FUEL LINE
4 - LATCH CLIP
3 - FUEL RAIL
5 - FUEL RAIL

(F ig. 52). Use t ool t o r elea se lockin g fin ger s in en d

of lin e.
(e) Wit h specia l t ool st ill in ser t ed, pu ll fu el lin e
fr om fu el r a il.
(f) Aft er discon n ect ion , lockin g fin ger s will
r em a in wit h in qu ick-con n ect fit t in g a t en d of fu el
lin e.
(10) Discon n ect qu ick-con n ect fit t in g fr om fu el sys-
t em com pon en t bein g ser viced.

Fig. 51 LATCH CLIP-TYPE 2
1 - LATCH CLIP
(a ) Type 1: P r y u p on la t ch clip wit h a scr ew-
dr iver (F ig. 50).
(b) Type 2: Sepa r a t e a n d u n la t ch 2 sm a ll a r m s
on en d of clip (F ig. 51) a n d swin g a wa y fr om fu el
lin e.
(c) Slide la t ch clip t owa r d fu el r a il wh ile lift in g
wit h scr ewdr iver.
(d) In ser t specia l fu el lin e r em ova l t ool (Sn a p-On
n u m ber F IH 9055-1 or equ iva len t ) in t o fu el lin e
CONNECTING
(1) In spect qu ick-con n ect fit t in g body a n d fu el sys-
t em com pon en t for da m a ge. Repla ce a s n ecessa r y.
(2) P r ior t o con n ect in g qu ick-con n ect fit t in g t o
com pon en t bein g ser viced, ch eck con dit ion of fit t in g
a n d com pon en t . Clea n pa r t s wit h a lin t -fr ee clot h .
Lu br ica t e wit h clea n en gin e oil.
(3) In ser t qu ick-con n ect fit t in g in t o fu el t u be or
fu el syst em com pon en t u n t il bu ilt -on st op on fu el
t u be or com pon en t r est s a ga in st ba ck of fit t in g.
(4) Con t in u e pu sh in g u n t il a click is felt .
(5) Sin gle-t a b t ype fit t in g: P u sh n ew t a b down
u n t il it locks in t o pla ce in qu ick-con n ect fit t in g.
(6) Ver ify a locked con dit ion by fir m ly pu llin g on
fu el t u be a n d fit t in g (15-30 lbs.).
(7) La t ch Clip E qu ipped: In st a ll la t ch clip (sn a ps
in t o posit ion ). If la tc h c lip w ill n o t fit, th is in d i-
c a te s fu e l lin e is n o t p ro p e rly in s ta lle d to fu e l
ra il (o r o th e r fu e l lin e ). Re c h e c k fu e l lin e c o n -
n e c tio n .
(8) Con n ect n ega t ive ca ble t o ba t t er y.
(9) St a r t en gin e a n d ch eck for lea ks.
WJ FUEL INJECTION 14 - 31

FU EL I N J ECT I ON

TABLE OF CONTENTS
page page

FUEL INJECTION INSTALLATION - 4.7L .... . . . . . . . . . . . . . . 47

DIAGNOSIS AND TESTING MAP SENSOR
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . 32 DESCRIPTION
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 48
TORQUE - FUEL INJECTION . . . . . . . . . . . . . 39 DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . 48
ACCELERATOR PEDAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39 REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 48
CRANKSHAFT POSITION SENSOR REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 49
DESCRIPTION INSTALLATION
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . 40 INSTALLATION - 4.0L .... . . . . . . . . . . . . . . 49
DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . 40 INSTALLATION - 4.7L .... . . . . . . . . . . . . . . 49
OPERATION O2S HEATER RELAY
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 40 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 41 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 41 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 41 O2S SENSOR
INSTALLATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION - 4.0L ................ . . 42 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION - 4.7L ................ . . 43 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FUEL INJECTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43 THROTTLE BODY
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 43 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION - PCM OUTPUT .......... . . 43 REMOVAL
DIAGNOSIS AND TESTING - FUEL INJECTOR . 44 REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44 INSTALLATION
FUEL PUMP RELAY INSTALLATION - 4.0L .... . . . . . . . . . . . . . . 53
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44 INSTALLATION - 4.7L .... . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 THROTTLE CONTROL CABLE
IDLE AIR CONTROL MOTOR REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44 REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL INSTALLATION
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 45 INSTALLATION – 4.0L . . . . . . . . . . . . . . . . . . 55
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 45 INSTALLATION - 4.7L .... . . . . . . . . . . . . . . 56
INSTALLATION THROTTLE POSITION SENSOR
INSTALLATION - 4.0L ................ . . 46 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION - 4.7L ................ . . 46 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INTAKE AIR TEMPERATURE SENSOR REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46 REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL INSTALLATION
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 46 INSTALLATION - 4.0L .... . . . . . . . . . . . . . . 58
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 46 INSTALLATION - 4.7L .... . . . . . . . . . . . . . . 58
INSTALLATION
INSTALLATION - 4.0L ................ . . 47
14 - 32 FUEL INJECTION WJ

FU EL I N J ECT I ON

DI AGN OSI S AN D T EST I N G

VISUAL INSPECTION
A visu a l in spect ion for loose, discon n ect ed or in cor-
r ect ly r ou t ed wir es, va cu u m lin es a n d h oses sh ou ld
be m a de. Th is sh ou ld be don e befor e a t t em pt in g t o
dia gn ose or ser vice t h e fu el in ject ion syst em . A visu a l
ch eck will h elp spot t h ese fa u lt s a n d sa ve u n n eces-
sa r y t est a n d dia gn ost ic t im e. A t h or ou gh visu a l
in spect ion will in clu de t h e followin g ch ecks:
(1) Ver ify t h r ee 32–wa y elect r ica l con n ect or s a r e
fu lly in ser t ed in t o con n ect or of P ower t r a in Con t r ol
Modu le (P CM) (F ig. 1).

Fig. 2 Power Distribution Center (PDC) Location

1 - POWER DISTRIBUTION CENTER (PDC)
2 - BATTERY

Fig. 1 Powertrain Control Module (PCM) Location

1 - PCM
2 - COOLANT TANK

(2) In spect ba t t er y ca ble con n ect ion s. Be su r e t h ey

a r e clea n a n d t igh t .
(3) In spect fu el pu m p r ela y a n d a ir con dit ion in g
com pr essor clu t ch r ela y (if equ ipped). In spect ASD
a n d oxygen sen sor h ea t er r ela y con n ect ion s. In spect
st a r t er m ot or r ela y con n ect ion s. In spect r ela ys for
sign s of ph ysica l da m a ge a n d cor r osion . Th e r ela ys
a r e loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC)
(F ig. 2). Refer t o la bel on P DC cover for r ela y loca - Fig. 3 Ignition Coil Connector—4.0L Engine
t ion .
1 - REAR OF VALVE COVER
(4) In spect ign it ion coil con n ect ion s (F ig. 3)or (F ig.
2 - COIL RAIL
4). 3 - COIL CONNECTOR
(5) Ver ify ca m sh a ft posit ion sen sor wir e con n ect or 4 - RELEASE LOCK
is fir m ly con n ect ed (F ig. 5) or (F ig. 6). 5 - SLIDE TAB
(6) Ver ify cr a n ksh a ft posit ion sen sor wir e con n ec-
t or is fir m ly con n ect ed (F ig. 7) or (F ig. 8).
WJ FUEL INJECTION 14 - 33
FU EL I N J ECT I ON (Cont inue d)

Fig. 4 Ignition Coil Connector—4.7L V-8 Engine Fig. 6 Camshaft Position Sensor—4.7L V-8 Engine
1 - IGNITION COIL 1 - RIGHT CYLINDER HEAD
2 - COIL ELECTRICAL CONNECTOR 2 - CAMSHAFT POSITION SENSOR
3 - COIL MOUNTING STUD/NUT 3 - MOUNTING BOLT
4 - ELEC. CONNECTOR

Fig. 7 Crankshaft Position Sensor—4.0L Engine

1 - SLOTTED HOLE
2 - CRANKSHAFT POSITION SENSOR
Fig. 5 Camshaft Position Sensor—4.0L Engine 3 - WIRE SHIELD
1 - OIL FILTER 4 - MOUNTING BOLT
2 - CAMSHAFT POSITION SENSOR 5 - TRANSMISSION HOUSING
3 - CLAMP BOLT 6 - PAPER SPACER
4 - HOLD-DOWN CLAMP
5 - MOUNTING BOLTS (2) (7) Ver ify gen er a t or ou t pu t wir e (B+ wir e) a n d
6 - ELEC. CONNECTOR
gen er a t or field con n ect or a r e fir m ly con n ect ed t o gen -
er a t or.
14 - 34 FUEL INJECTION WJ
FU EL I N J ECT I ON (Cont inue d)
(14) In spect a ir clea n er in let a n d a ir clea n er ele-
m en t for dir t or r est r ict ion s.
(15) In spect r a dia t or gr ille a r ea , r a dia t or fin s a n d
a ir con dit ion in g con den ser for r est r ict ion s.
(16) 4.0L E n gin e: Ver ify MAP, In t a ke Ma n ifold Air
Tem per a t u r e (IAT) sen sor, TP S a n d Idle Air Con t r ol
(IAC) m ot or con n ect or s a r e fir m ly con n ect ed (F ig. 9).
Be su r e t h r ot t le body m ou n t in g bolt s (F ig. 9)a r e
t igh t .
(17) 4.7L E n gin e: Ver ify In t a ke Ma n ifold Air Tem -
per a t u r e (IAT) sen sor, TP S a n d Idle Air Con t r ol (IAC)
m ot or con n ect or s a r e fir m ly con n ect ed (F ig. 10). Be
su r e t h r ot t le body m ou n t in g bolt s (F ig. 10)a r e t igh t .

Fig. 8 Crankshaft Position Sensor—4.7L V-8 Engine

1 - CRANKSHAFT POSITION SENSOR
2 - STARTER
3 - ELEC. CONNECTOR

(8) In spect syst em body gr ou n ds for loose or dir t y

con n ect ion s. Refer t o Gr ou p 8, Wir in g for gr ou n d
loca t ion s.
(9) Ver ify cr a n kca se ven t ila t ion (CCV) oper a t ion .
Refer t o E m ission Con t r ol Syst em for a ddit ion a l
in for m a t ion .
(10) In spect a ll fu el lin e qu ick-con n ect fit t in gs for
da m a ge or lea ks.
(11) Ver ify h ose con n ect ion s t o a ll por t s of va cu u m
fit t in gs on in t a ke m a n ifold, a n d for em ission syst em Fig. 9 IAT, MAP, IAC, TPS Sensor Locations—4.0L
a r e t igh t a n d n ot lea kin g. Engine
(12) In spect a cceler a t or ca ble, t r a n sm ission t h r ot - 1 - MOUNTING BOLTS (4)
t le ca ble (if equ ipped) a n d speed con t r ol ca ble con n ec- 2 - THROTTLE BODY
t ion s (if equ ipped). Ch eck t h eir con n ect ion s t o 3 - IAC MOTOR
t h r ot t le body lin ka ge for a n y bin din g or r est r ict ion s. 4 - ELEC. CONN.
(13) Ver ify va cu u m boost er h ose is fir m ly con - 5 - TPS
n ect ed t o fit t in g on in t a ke m a n ifold. Also ch eck con - 6 - MAP SENSOR
7 - ELEC. CONN.
n ect ion t o br a ke va cu u m boost er.
8 - IAT SENSOR
9 - ELEC. CONN.
WJ FUEL INJECTION 14 - 35
FU EL I N J ECT I ON (Cont inue d)
(19) 4.7L E n gin e: Ver ify MAP a n d E n gin e Coola n t
Tem per a t u r e (E CT) sen sor elect r ica l con n ect or s a r e
fir m ly con n ect ed t o sen sor s (F ig. 12).

Fig. 10 IAT, IAC, TPS Sensor Locations—4.7L V-8

Engine
1 - MOUNTING BOLTS (3)
2 - THROTTLE BODY
3 - IAT SENSOR CONNECTOR Fig. 12 MAP and ECT Sensor Locations—4.7L V-8
4 - IAC MOTOR CONNECTOR Engine
5 - TPS CONNECTOR 1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
3 - MAP SENSOR
(18) 4.0L E n gin e: Ver ify wir e h a r n ess con n ect or is
4 - INTAKE MANIFOLD
fir m ly con n ect ed t o E n gin e Coola n t Tem per a t u r e
(E CT) sen sor (F ig. 11).
(20) Ver ify fu el in ject or wir e h a r n ess con n ect or s
a r e fir m ly con n ect ed t o in ject or s in cor r ect or der.
E a ch h a r n ess con n ect or is n u m er ica lly t a gged wit h
in ject or n u m ber (INJ 1, INJ 2 et c.) of it s cor r espon d-
in g fu el in ject or a n d cylin der n u m ber.
(21) Ra ise a n d su ppor t veh icle.
(22) Ver ify a ll oxygen sen sor wir e con n ect or s a r e
fir m ly con n ect ed t o sen sor s. In spect sen sor s a n d con -
n ect or s for da m a ge (F ig. 13)or (F ig. 14).

Fig. 11 ECT Sensor Location—4.0L Engine

1 - THERMOSTAT HOUSING
2 - ENGINE COOLANT TEMPERATURE SENSOR
3 - ELECTRICAL CONNECTOR
14 - 36 FUEL INJECTION WJ
FU EL I N J ECT I ON (Cont inue d)

Fig. 13 Oxygen Sensor Locations—4.0L Engine

WJ FUEL INJECTION 14 - 37
FU EL I N J ECT I ON (Cont inue d)

Fig. 14 Oxygen Sensor Locations—4.7L V-8 Engine

14 - 38 FUEL INJECTION WJ
FU EL I N J ECT I ON (Cont inue d)
(23) In spect for pin ch ed or lea kin g fu el t u bes/lin es.
In spect for pin ch ed, cr a cked or lea kin g fu el h oses.
(24) In spect for exh a u st syst em r est r ict ion s su ch
a s pin ch ed exh a u st pipes, colla psed m u ffler or
plu gged ca t a lyt ic con ver t or.
(25) If equ ipped wit h a u t om a t ic t r a n sm ission , ver-
ify elect r ica l h a r n ess is fir m ly con n ect ed t o pa r k/n eu -
t r a l swit ch a n d t o t r a n sm ission com pon en t s.
(26) Ver ify fu el pu m p m odu le pigt a il h a r n ess elec-
t r ica l con n ect or (F ig. 15) is fir m ly con n ect ed t o body
h a r n ess con n ect or.
(27) In spect fu el lin e h a r n ess (fr om fu el pu m p
m odu le) a t fu el filt er /fu el pr essu r e r egu la t or (F ig. 15)
for ch a ffin g, cr a cks or lea ks.
(28) Ver ify ba t t er y ca ble a n d solen oid feed wir e
con n ect ion s t o st a r t er solen oid a r e t igh t a n d clea n .
(29) In spect for ch a ffed wir es or wir es r u bbin g u p
a ga in st ot h er com pon en t s.
(30) In spect for ch a ffed va cu u m lin es or lin es r u b-
bin g u p a ga in st ot h er com pon en t s.

Fig. 15 Fuel Filter/Fuel Pressure Regulator Location

1 - FUEL RETURN LINE
2 - FUEL SUPPLY LINE (TO FUEL RAIL)
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - FUEL PRESSURE LINE
5 - REAR AXLE
6 - ELEC. CONNECTOR
7 - EVAP LINE
WJ
SPECI FI CAT I ON S
TORQUE - FUEL INJECTION
DESCRIPTION
Air Cleaner Housing Mount. Nuts
Air Cleaner Air Duct Clamps
Air Cleaner Resonator Bolts
Engine Coolant Temperature Sensor—4.0L Engine
Engine Coolant Temperature Sensor—4.7L Engine
Fuel Hose Clamps
IAC Motor-To-Throttle Body Bolts—4.0L Engine
IAC Motor-To-Throttle Body Bolts—4.7L Engine
Intake Manifold Air Temp. Sensor—4.0L Engine
Intake Manifold Air Temp. Sensor—4.7L Engine
MAP Sensor Mounting Screws—4.0L Engine
MAP Sensor Mounting Screws—4.7L Engine
Oxygen Sensor—All Engines
PCM-to-Mounting Bracket Screws
PCM-to-Mounting Bracket Screws
Radiator Cooling Fan Relay Bolts
Throttle Body Mounting Bolts—4.0L Engine
Throttle Body Mounting Bolts—4.7L Engine
TPS Mounting Screws—4.0L Engine
TPS Mounting Screws—4.7L Engine
ACCELERAT OR PEDAL
REMOVAL
Th e a cceler a t or peda l is con n ect ed t o t h e t h r ot t le
body lin ka ge by t h e t h r ot t le ca ble. Th e ca ble is pr o-
t ect ed by a pla st ic sh ea t h in g a n d is con n ect ed t o t h e
t h r ot t le body lin ka ge by a ba ll socket . It is con n ect ed
t o t h e a cceler a t or peda l a r m by a pla st ic r et a in er
(clip) (F ig. 16). Th is r et a in er (clip) sn a ps in t o t h e t op
of t h e a cceler a t or peda l a r m . A r et a in er clip (F ig. 16)
is a lso u sed t o fa st en ca ble t o da sh pa n el.
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) F r om in side veh icle, h old u p a cceler a t or peda l.
Rem ove pla st ic ca ble r et a in er (clip) a n d t h r ot t le ca ble
cor e wir e fr om u pper en d of peda l a r m . P la st ic ca ble
r et a in er (clip) sn a ps in t o peda l a r m .
(2) Rem ove a cceler a t or peda l br a cket n u t s. Rem ove
a cceler a t or peda l a ssem bly.
FUEL INJECTION 14 - 39
N-m Ft. Lbs. In. Lbs.
10 93
4 35
4 35
11 96
11 96
1 10
7 #60
7 60
28 20
28 20
3 25
3 25
30 22
3 25
9 80
3 25
11 100
12 105
7 60
7 60
INSTALLATION
Th e a cceler a t or peda l is con n ect ed t o t h e t h r ot t le
body lin ka ge by t h e t h r ot t le ca ble. Th e ca ble is pr o-
t ect ed by a pla st ic sh ea t h in g a n d is con n ect ed t o t h e
t h r ot t le body lin ka ge by a ba ll socket . It is con n ect ed
t o t h e a cceler a t or peda l a r m by a pla st ic r et a in er
(clip) (F ig. 16) . Th is r et a in er (clip) sn a ps in t o t h e t op
of t h e a cceler a t or peda l a r m . A r et a in er clip (F ig. 16)
is a lso u sed t o fa st en ca ble t o da sh pa n el.
(1) P la ce a cceler a t or peda l a ssem bly over st u ds
pr ot r u din g fr om floor pa n . Tigh t en m ou n t in g n u t s t o
12 N·m ± 2 N·m (105 in . lbs. ± 20 in . lbs.) t or qu e.
(2) Slide t h r ot t le ca ble in t o open in g in t op of peda l
a r m . P u sh pla st ic ca ble r et a in er (clip) in t o peda l a r m
open in g u n t il it sn a ps in t o pla ce.
(3) Befor e st a r t in g en gin e, oper a t e a cceler a t or
peda l t o ch eck for a n y bin din g.
14 - 40 FUEL INJECTION WJ
ACCELERAT OR PEDAL (Cont inue d)

Fig. 17 CKP Sensor Location—4.0L 6-Cyl. Engine

1 - SLOTTED HOLE
2 - CRANKSHAFT POSITION SENSOR
3 - WIRE SHIELD
4 - MOUNTING BOLT
Fig. 16 Accelerator Pedal Mounting 5 - TRANSMISSION HOUSING
1 - CLIP 6 - PAPER SPACER
2 - ACCELERATOR CABLE
3 - CABLE CONNECTOR
4 - MOUNTING NUTS (2)
5 - PEDAL/BRACKET ASSEMBLY
6 - MOUNTING STUDS (2)

CRAN K SH AFT POSI T I ON

SEN SOR

DESCRI PT I ON
DESCRIPTION - 4.0L
Th e Cr a n ksh a ft P osit ion Sen sor (CKP ) is m ou n t ed
t o t h e t r a n sm ission bellh ou sin g a t t h e left /r ea r side
of t h e en gin e block (F ig. 17).

DESCRIPTION - 4.7L
Th e Cr a n ksh a ft P osit ion Sen sor (CKP ) is m ou n t ed
in t o t h e en gin e block a bove t h e st a r t er m ot or (F ig.
18).

Fig. 18 CKP Sensor Location—4.7L V–8 Engine

OPERAT I ON 1 - CRANKSHAFT POSITION SENSOR
2 - STARTER
OPERATION - 4.0L 3 - ELEC. CONNECTOR
E n gin e speed a n d cr a n ksh a ft posit ion a r e pr ovided
t h r ou gh t h e cr a n ksh a ft posit ion sen sor. Th e sen sor ot h er in pu t s, t o det er m in e in ject or sequ en ce a n d ign i-
gen er a t es pu lses t h a t a r e t h e in pu t sen t t o t h e pow- t ion t im in g.
er t r a in con t r ol m odu le (P CM). Th e P CM in t er pr et s
t h e sen sor in pu t t o det er m in e t h e cr a n ksh a ft posi-
t ion . Th e P CM t h en u ses t h is posit ion , a lon g wit h
WJ
CRAN K SH AFT POSI T I ON SEN SOR (Cont inue d)
Th e sen sor is a h a ll effect device com bin ed wit h a n
in t er n a l m a gn et . It is a lso sen sit ive t o st eel wit h in a
cer t a in dist a n ce fr om it .
On 4.0L 6-cylin der en gin es, t h e flywh eel/dr ive
pla t e h a s 3 set s of fou r n ot ch es a t it s ou t er edge (F ig.
19).
Th e n ot ch es ca u se a pu lse t o be gen er a t ed wh en
t h ey pa ss u n der t h e sen sor. Th e pu lses a r e t h e in pu t
t o t h e P CM. F or ea ch en gin e r evolu t ion t h er e a r e 3
set s of fou r pu lses gen er a t ed.
Th e t r a ilin g edge of t h e fou r t h n ot ch , wh ich ca u ses
t h e pu lse, is fou r degr ees befor e t op dea d cen t er
(TDC) of t h e cor r espon din g pist on .
Th e en gin e will n ot oper a t e if t h e P CM does n ot
r eceive a cr a n ksh a ft posit ion sen sor in pu t .
Fig. 19 CKP Sensor Operation—4.0L 6-Cyl. Engine
1 - CRANKSHAFT POSITION SENSOR
2 - FLYWHEEL
3 - FLYWHEEL NOTCHES
OPERATION - 4.7L
E n gin e speed a n d cr a n ksh a ft posit ion a r e pr ovided
t h r ou gh t h e cr a n ksh a ft posit ion sen sor. Th e sen sor
gen er a t es pu lses t h a t a r e t h e in pu t sen t t o t h e pow-
er t r a in con t r ol m odu le (P CM). Th e P CM in t er pr et s
t h e sen sor in pu t t o det er m in e t h e cr a n ksh a ft posi-
t ion . Th e P CM t h en u ses t h is posit ion , a lon g wit h
ot h er in pu t s, t o det er m in e in ject or sequ en ce a n d ign i-
t ion t im in g.
Th e sen sor is a h a ll effect device com bin ed wit h a n
in t er n a l m a gn et . It is a lso sen sit ive t o st eel wit h in a
cer t a in dist a n ce fr om it .
FUEL INJECTION 14 - 41
On t h e 4.7L V–8 en gin e, a t on ewh eel is bolt ed t o
t h e en gin e cr a n ksh a ft (F ig. 20). Th is t on ewh eel h a s
set s of n ot ch es a t it s ou t er edge (F ig. 20).
Th e n ot ch es ca u se a pu lse t o be gen er a t ed wh en
t h ey pa ss u n der t h e sen sor. Th e pu lses a r e t h e in pu t
t o t h e P CM.
Fig. 20 CKP Sensor Operation and Tonewheel—4.7L
V–8 Engine
1 - TONEWHEEL
2 - NOTCHES
3 - CRANKSHAFT POSITION SENSOR
4 - CRANKSHAFT
REM OVAL
REMOVAL - 4.0L
Th e Cr a n ksh a ft P osit ion (CKP ) sen sor is m ou n t ed
t o t h e t r a n sm ission bellh ou sin g a t t h e left /r ea r side
of t h e en gin e block (F ig. 21). Th e sen sor is a d ju s t-
a ble a n d is a t t a ch ed wit h on e bolt . A wir e sh ield/
r ou t er is a t t a ch ed t o t h e sen sor (F ig. 21).
(1) Discon n ect sen sor pigt a il h a r n ess (3–wa y con -
n ect or ) fr om m a in en gin e wir in g h a r n ess.
(2) Rem ove sen sor m ou n t in g bolt .
(3) Rem ove wir e sh ield a n d sen sor.
REMOVAL - 4.7L
Th e Cr a n ksh a ft P osit ion (CKP ) sen sor is bolt ed t o
t h e side of t h e en gin e cylin der block a bove t h e
st a r t er m ot or (F ig. 22). It is posit ion ed in t o a
m a ch in ed h ole a t t h e side of t h e en gin e block.
(1) Rem ove st a r t er m ot or. Refer t o St a r t er Rem ov-
a l/In st a lla t ion .
14 - 42 FUEL INJECTION WJ
CRAN K SH AFT POSI T I ON SEN SOR (Cont inue d)

Fig. 21 CKP Sensor—4.0L 6-Cylinder Engine

1 - SLOTTED HOLE
2 - CRANKSHAFT POSITION SENSOR
3 - WIRE SHIELD
4 - MOUNTING BOLT
5 - TRANSMISSION HOUSING Fig. 23 CKP Sensor Removal/Installation—4.7L V–8
6 - PAPER SPACER Engine
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT

(5) Rem ove sen sor fr om veh icle.

(6) Ch eck con dit ion of sen sor o-r in g.

I N STALLAT I ON
INSTALLATION - 4.0L
Th e Cr a n ksh a ft P osit ion (CKP ) sen sor is m ou n t ed
t o t h e t r a n sm ission bellh ou sin g a t t h e left /r ea r side
of t h e en gin e block (F ig. 21). Th e sen sor is a d ju s t-
a ble a n d is a t t a ch ed wit h on e bolt . A wir e sh ield/
r ou t er is a t t a ch ed t o t h e sen sor (F ig. 21).
New r epla cem en t sen sor s will be equ ipped wit h a
pa per spa cer glu ed t o bot t om of sen sor. If in st a llin g
(r et u r n in g) a u s e d sen sor t o veh icle, a n ew pa per
spa cer m u st be in st a lled t o bot t om of sen sor. Th is
spa cer will be gr ou n d off t h e fir st t im e en gin e is
st a r t ed. If spa cer is n ot u sed, sen sor will be br oken
t h e fir st t im e en gin e is st a r t ed.
(1) New Sen sor s: Be su r e pa per spa cer is in st a lled
Fig. 22 CKP Sensor Location—4.7L V–8 Engine
t o bot t om of sen sor. If n ot , obt a in spa cer
1 - CRANKSHAFT POSITION SENSOR P N05252229.
2 - STARTER
(2) Used Sen sor s: Clea n bot t om of sen sor a n d
3 - ELEC. CONNECTOR
in st a ll spa cer P N05252229.
(3) In st a ll sen sor in t o t r a n sm ission bellh ou sin g
(2) Discon n ect CKP elect r ica l con n ect or a t sen sor h ole.
(F ig. 22). (4) P osit ion sen sor wir e sh ield t o sen sor (F ig. 21).
(3) Rem ove CKP m ou n t in g bolt (F ig. 23).
(4) Ca r efu lly t wist sen sor fr om cylin der block.
WJ
CRAN K SH AFT POSI T I ON SEN SOR (Cont inue d)
(5) P u sh sen sor a ga in st flywh eel/dr ive pla t e. Wit h
sen sor pu sh ed a ga in st flywh eel/dr ive pla t e, t igh t en
m ou n t in g bolt t o 7 N·m (60 in . lbs.) t or qu e.
(6) Rou t e sen sor wir in g h a r n ess in t o wir e sh ield.
(7) Con n ect sen sor pigt a il h a r n ess elect r ica l con -
n ect or t o m a in wir in g h a r n ess.
INSTALLATION - 4.7L
(1) Clea n ou t m a ch in ed h ole in en gin e block.
(2) Apply a sm a ll a m ou n t of en gin e oil t o sen sor
o-r in g.
(3) In st a ll sen sor in t o en gin e block wit h a sligh t
r ockin g a ct ion . Do n ot t wist sen sor in t o posit ion a s
da m a ge t o o-r in g m a y r esu lt .
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) In st a ll m ou n t in g bolt a n d t igh t en t o 28 N·m
(21 ft . lbs.) t or qu e.
(5) Con n ect elect r ica l con n ect or t o sen sor.
(6) In st a ll st a r t er m ot or. Refer t o St a r t er Rem ova l/
In st a lla t ion .
FU EL I N J ECT OR
DESCRIPTION
A sepa r a t e fu el in ject or (F ig. 24) is u sed for ea ch
in dividu a l cylin der.
Fig. 24 Fuel Injector—4.0L/4.7L Engines
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
FUEL INJECTION 14 - 43
OPERAT I ON
OPERATION
Th e fu el in ject or s a r e elect r ica l solen oids. Th e
in ject or con t a in s a pin t le t h a t closes off a n or ifice a t
t h e n ozzle en d. Wh en elect r ic cu r r en t is su pplied t o
t h e in ject or, t h e a r m a t u r e a n d n eedle m ove a sh or t
dist a n ce a ga in st a spr in g, a llowin g fu el t o flow ou t
t h e or ifice. Beca u se t h e fu el is u n der h igh pr essu r e, a
fin e spr a y is developed in t h e sh a pe of a pen cil
st r ea m . Th e spr a yin g a ct ion a t om izes t h e fu el, a dd-
in g it t o t h e a ir en t er in g t h e com bu st ion ch a m ber.
Th e t op (fu el en t r y) en d of t h e in ject or (F ig. 24) is
a t t a ch ed in t o a n open in g on t h e fu el r a il.
Th e n ozzle (ou t let ) en ds of t h e in ject or s a r e posi-
t ion ed in t o open in gs in t h e in t a ke m a n ifold ju st
a bove t h e in t a ke va lve por t s of t h e cylin der h ea d.
Th e en gin e wir in g h a r n ess con n ect or for ea ch fu el
in ject or is equ ipped wit h a n a t t a ch ed n u m er ica l t a g
(INJ 1, INJ 2 et c.). Th is is u sed t o iden t ify ea ch fu el
in ject or.
Th e in ject or s a r e elect r ica lly en er gized, in dividu -
a lly a n d in a sequ en t ia l or der by t h e P ower t r a in Con -
t r ol Modu le (P CM). Th e P CM will a dju st in ject or
pu lse widt h by swit ch in g t h e gr ou n d pa t h t o ea ch
in dividu a l in ject or on a n d off. In ject or pu lse widt h is
t h e per iod of t im e t h a t t h e in ject or is en er gized. Th e
P CM will a dju st in ject or pu lse widt h ba sed on va r i-
ou s in pu t s it r eceives.
Ba t t er y volt a ge is su pplied t o t h e in ject or s t h r ou gh
t h e ASD r ela y.
Th e P CM det er m in es in ject or pu lse widt h ba sed on
va r iou s in pu t s.
OPERATION - PCM OUTPUT
Th e n ozzle en ds of t h e in ject or s a r e posit ion ed in t o
open in gs in t h e in t a ke m a n ifold ju st a bove t h e in t a ke
va lve por t s of t h e cylin der h ea d. Th e en gin e wir in g
h a r n ess con n ect or for ea ch fu el in ject or is equ ipped
wit h a n a t t a ch ed n u m er ica l t a g (INJ 1, INJ 2 et c.).
Th is is u sed t o iden t ify ea ch fu el in ject or wit h it s
r espect ive cylin der n u m ber.
Th e in ject or s a r e en er gized in dividu a lly in a
sequ en t ia l or der by t h e P ower t r a in Con t r ol Modu le
(P CM). Th e P CM will a dju st in ject or pu lse widt h by
swit ch in g t h e gr ou n d pa t h t o ea ch in dividu a l in ject or
on a n d off. In ject or pu lse widt h is t h e per iod of t im e
t h a t t h e in ject or is en er gized. Th e P CM will a dju st
in ject or pu lse widt h ba sed on va r iou s in pu t s it
r eceives.
Ba t t er y volt a ge (12 volt s +) is su pplied t o t h e in jec-
t or s t h r ou gh t h e ASD r ela y. Th e ASD r ela y will sh u t -
down t h e 12 volt power sou r ce t o t h e fu el in ject or s if
t h e P CM sen ses t h e ign it ion is on , bu t t h e en gin e is
n ot r u n n in g. Th is occu r s a ft er t h e en gin e h a s n ot
been r u n n in g for a ppr oxim a t ely 1.8 secon ds.
14 - 44 FUEL INJECTION
FU EL I N J ECT OR (Cont inue d)
Th e P CM det er m in es in ject or on -t im e (pu lse widt h )
ba sed on va r iou s in pu t s.
DIAGNOSIS AND TESTING - FUEL INJECTOR
To per for m a com plet e t est of t h e fu el in ject or s a n d
t h eir cir cu it r y, u se t h e DRB sca n t ool a n d r efer t o t h e
a ppr opr ia t e P ower t r a in Dia gn ost ics P r ocedu r es m a n -
u a l. To t est t h e in ject or on ly, r efer t o t h e followin g:
Discon n ect t h e fu el in ject or wir e h a r n ess con n ect or
fr om t h e in ject or. Th e in ject or is equ ipped wit h 2
elect r ica l t er m in a ls (pin s). P la ce a n oh m m et er a cr oss
t h e t er m in a ls. Resist a n ce r ea din g sh ou ld be a ppr oxi-
m a t ely 12 oh m s ±1.2 oh m s a t 20°C (68°F ).
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL INJECTOR(S), FUEL
SYSTEM PRESSURE MUST BE RELEASED.
To r em ove on e or m or e fu el in ject or s, t h e fu el r a il
a ssem bly m u st be r em oved fr om en gin e.
(1) P er for m F u el Syst em P r essu r e Relea se P r oce-
du r e.
(2) Rem ove fu el in ject or r a il. Refer t o F u el In ject or
Ra il Rem ova l/In st a lla t ion .
(3) Rem ove clip(s) r et a in in g in ject or (s) t o fu el r a il
(F ig. 25).
Fig. 25 Fuel Injector Mounting—Typical (4.7L V-8
Engine Shown)
1 - INLET FITTING
2 - FUEL INJECTOR RAIL
3 - CLIP
4 - FUEL INJECTOR
(4) Rem ove in ject or (s) fr om fu el r a il.
WJ
INSTALLATION
(1) Apply a sm a ll a m ou n t of en gin e oil t o ea ch fu el
in ject or o-r in g. Th is will h elp in fu el r a il in st a lla t ion .
(2) In st a ll in ject or (s) a n d in ject or clip(s) t o fu el
r a il.
(3) In st a ll fu el r a il a ssem bly. Refer t o F u el In ject or
Ra il Rem ova l/In st a lla t ion .
(4) St a r t en gin e a n d ch eck for lea ks.
FU EL PU M P RELAY
DESCRIPTION
Th e 5–pin , 12–volt , fu el pu m p r ela y is loca t ed in
t h e P ower Dist r ibu t ion Cen t er (P DC). Refer t o t h e
la bel on t h e P DC cover for r ela y loca t ion .
OPERATION
Th e P ower t r a in Con t r ol Modu le (P CM) en er gizes
t h e elect r ic fu el pu m p t h r ou gh t h e fu el pu m p r ela y.
Th e fu el pu m p r ela y is en er gized by fir st a pplyin g
ba t t er y volt a ge t o it wh en t h e ign it ion key is t u r n ed
ON, a n d t h en a pplyin g a gr ou n d sign a l t o t h e r ela y
fr om t h e P CM.
Wh en ever t h e ign it ion key is t u r n ed ON, t h e elec-
t r ic fu el pu m p will oper a t e. Bu t , t h e P CM will sh u t -
down t h e gr ou n d cir cu it t o t h e fu el pu m p r ela y in
a ppr oxim a t ely 1–3 secon ds u n less t h e en gin e is oper-
a t in g or t h e st a r t er m ot or is en ga ged.
I DLE AI R CON T ROL M OT OR
DESCRIPTION
Th e IAC st epper m ot or is m ou n t ed t o t h e t h r ot t le
body, a n d r egu la t es t h e a m ou n t of a ir bypa ssin g t h e
con t r ol of t h e t h r ot t le pla t e. As en gin e loa ds a n d
a m bien t t em per a t u r es ch a n ge, en gin e r pm ch a n ges.
A pin t le on t h e IAC st epper m ot or pr ot r u des in t o a
pa ssa ge in t h e t h r ot t le body, con t r ollin g a ir flow
t h r ou gh t h e pa ssa ge. Th e IAC is con t r olled by t h e
P ower t r a in Con t r ol Modu le (P CM) t o m a in t a in t h e
t a r get en gin e idle speed.
OPERATION
At idle, en gin e speed ca n be in cr ea sed by r et r a ct -
in g t h e IAC m ot or pin t le a n d a llowin g m or e a ir t o
pa ss t h r ou gh t h e por t , or it ca n be decr ea sed by
r est r ict in g t h e pa ssa ge wit h t h e pin t le a n d dim in ish -
in g t h e a m ou n t of a ir bypa ssin g t h e t h r ot t le pla t e.
Th e IAC is ca lled a st epper m ot or beca u se it is
m oved (r ot a t ed) in st eps, or in cr em en t s. Open in g t h e
IAC open s a n a ir pa ssa ge a r ou n d t h e t h r ot t le bla de
wh ich in cr ea ses RP M.
WJ FUEL INJECTION 14 - 45
I DLE AI R CON T ROL M OT OR (Cont inue d)
Th e P CM u ses t h e IAC m ot or t o con t r ol idle speed ca n a n t icipa t e A/C com pr essor loa ds. Th is is a ccom -
(a lon g wit h t im in g) a n d t o r ea ch a desir ed MAP du r- plish ed by dela yin g com pr essor oper a t ion for a ppr ox-
in g decel (keep en gin e fr om st a llin g). im a t ely 0.5 secon ds u n t il t h e P CM m oves t h e IAC
Th e IAC m ot or h a s 4 wir es wit h 4 cir cu it s. Two of st epper m ot or t o t h e r ecor ded st eps t h a t wer e loa ded
t h e wir es a r e for 12 volt s a n d gr ou n d t o su pply elec- in t o t h e m em or y cell. Usin g t h is pr ogr a m h elps elim -
t r ica l cu r r en t t o t h e m ot or win din gs t o oper a t e t h e in a t e idle-qu a lit y ch a n ges a s loa ds ch a n ge. F in a lly,
st epper m ot or in on e dir ect ion . Th e ot h er 2 wir es a r e t h e P CM in cor por a t es a !No-Loa d! en gin e speed lim -
a lso for 12 volt s a n d gr ou n d t o su pply elect r ica l cu r- it er of a ppr oxim a t ely 1800 - 2000 r pm , wh en it r ec-
r en t t o oper a t e t h e st epper m ot or in t h e opposit e ogn izes t h a t t h e TP S is in dica t in g a n idle sign a l a n d
dir ect ion . IAC m ot or ca n n ot m a in t a in en gin e idle.
To m a ke t h e IAC go in t h e opposit e dir ect ion , t h e A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
P CM ju st r ever ses pola r it y on bot h win din gs. If on ly ca lly lim it t h e posit ion of t h e t h r ot t le body t h r ot t le
1 wir e is open , t h e IAC ca n on ly be m oved 1 st ep pla t e. N e v e r a tte m p t to a d ju s t th e e n g in e id le
(in cr em en t ) in eit h er dir ect ion . To keep t h e IAC s p e e d u s in g th is s c re w. All idle speed fu n ct ion s a r e
m ot or in posit ion wh en n o m ovem en t is n eeded, t h e con t r olled by t h e IAC m ot or t h r ou gh t h e P CM.
P CM will en er gize bot h win din gs a t t h e sa m e t im e.
Th is locks t h e IAC m ot or in pla ce.
In t h e IAC m ot or syst em , t h e P CM will cou n t REM OVAL
ever y st ep t h a t t h e m ot or is m oved. Th is a llows t h e
P CM t o det er m in e t h e m ot or pin t le posit ion . If t h e REMOVAL - 4.0L
m em or y is clea r ed, t h e P CM n o lon ger kn ows t h e Th e IAC m ot or is loca t ed on t h e t h r ot t le body.
posit ion of t h e pin t le. So a t t h e fir st key ON, t h e (1) Rem ove a ir du ct a n d a ir r eson a t or box a t t h r ot -
P CM dr ives t h e IAC m ot or closed, r ega r dless of t le body.
wh er e it wa s befor e. Th is zer os t h e cou n t er. F r om (2) Discon n ect elect r ica l con n ect or fr om IAC m ot or
t h is poin t t h e P CM will ba ck ou t t h e IAC m ot or a n d (F ig. 40).
keep t r a ck of it s posit ion a ga in . (3) Rem ove t wo m ou n t in g bolt s (scr ews) (F ig. 26).
Wh en en gin e r pm is a bove idle speed, t h e IAC is (4) Rem ove IAC m ot or fr om t h r ot t le body.
u sed for t h e followin g:
• Off-idle da sh pot (t h r ot t le bla de will close qu ickly
bu t idle speed will n ot st op qu ickly)
• Deceler a t ion a ir flow con t r ol
• A/C com pr essor loa d con t r ol (a lso open s t h e pa s-
sa ge sligh t ly befor e t h e com pr essor is en ga ged so
t h a t t h e en gin e r pm does n ot dip down wh en t h e
com pr essor en ga ges)
• P ower st eer in g loa d con t r ol
Th e P CM ca n con t r ol pola r it y of t h e cir cu it t o con -
t r ol dir ect ion of t h e st epper m ot or.
IAC S te p p e r Mo to r P ro g ra m : Th e P CM is a lso
equ ipped wit h a m em or y pr ogr a m t h a t r ecor ds t h e
n u m ber of st eps t h e IAC st epper m ot or m ost r ecen t ly
a dva n ced t o du r in g a cer t a in set of pa r a m et er s. F or
exa m ple: Th e P CM wa s a t t em pt in g t o m a in t a in a
1000 r pm t a r get du r in g a cold st a r t -u p cycle. Th e la st Fig. 26 Mounting Bolts (Screws)—IAC
r ecor ded n u m ber of st eps for t h a t m a y h a ve been 1 - IDLE AIR CONTROL MOTOR
125. Th a t va lu e wou ld be r ecor ded in t h e m em or y 2 - MOUNTING SCREWS
cell so t h a t t h e n ext t im e t h e P CM r ecogn izes t h e
iden t ica l con dit ion s, t h e P CM r eca lls t h a t 125 st eps
wer e r equ ir ed t o m a in t a in t h e t a r get . Th is pr ogr a m
REMOVAL - 4.7L
a llows for gr ea t er cu st om er sa t isfa ct ion du e t o (1) Rem ove a ir du ct a n d a ir r eson a t or box a t t h r ot -
gr ea t er con t r ol of en gin e idle. t le body.
An ot h er fu n ct ion of t h e m em or y pr ogr a m , wh ich (2) Discon n ect elect r ica l con n ect or fr om IAC m ot or
occu r s wh en t h e power st eer in g swit ch (if equ ipped), (F ig. 36).
or t h e A/C r equ est cir cu it , r equ ir es t h a t t h e IAC st ep- (3) Rem ove t wo m ou n t in g bolt s (scr ews) (F ig. 42).
per m ot or con t r ol en gin e r pm , is t h e r ecor din g of t h e (4) Rem ove IAC m ot or fr om t h r ot t le body.
la st t a r get ed st eps in t o t h e m em or y cell. Th e P CM
14 - 46 FUEL INJECTION WJ
I DLE AI R CON T ROL M OT OR (Cont inue d)

I N STALLAT I ON
INSTALLATION - 4.0L
Th e IAC m ot or is loca t ed on t h e t h r ot t le body.
(1) In st a ll IAC m ot or t o t h r ot t le body.
(2) In st a ll a n d t igh t en t wo m ou n t in g bolt s (scr ews)
t o 7 N·m (60 in . lbs.) t or qu e.
(3) In st a ll elect r ica l con n ect or.
(4) In st a ll a ir clea n er du ct /a ir box t o t h r ot t le body.

INSTALLATION - 4.7L
(1) In st a ll IAC m ot or t o t h r ot t le body.
(2) In st a ll a n d t igh t en t wo m ou n t in g bolt s (scr ews)
t o 7 N·m (60 in . lbs.) t or qu e.
(3) In st a ll elect r ica l con n ect or.
(4) In st a ll a ir du ct /a ir box t o t h r ot t le body.

I N TAK E AI R T EM PERAT U RE
SEN SOR
DESCRIPTION Fig. 27 Intake Manifold Air Sensor Location—4.0L
Th e 2–wir e In t a ke Ma n ifold Air Tem per a t u r e (IAT) Engine
sen sor is in st a lled in t h e in t a ke m a n ifold wit h t h e
1 - MOUNTING BOLTS (4)
sen sor elem en t ext en din g in t o t h e a ir st r ea m .
2 - THROTTLE BODY
Th e IAT sen sor is a t wo-wir e Nega t ive Th er m a l 3 - IAC MOTOR
Coefficien t (NTC) sen sor. Mea n in g, a s in t a ke m a n i- 4 - ELEC. CONN.
fold t em per a t u r e in cr ea ses, r esist a n ce (volt a ge) in t h e 5 - TPS
sen sor decr ea ses. As t em per a t u r e decr ea ses, r esis- 6 - MAP SENSOR
t a n ce (volt a ge) in t h e sen sor in cr ea ses. 7 - ELEC. CONN.
8 - IAT SENSOR
OPERATION 9 - ELEC. CONN.
Th e IAT sen sor pr ovides a n in pu t volt a ge t o t h e
P ower t r a in Con t r ol Modu le (P CM) in dica t in g t h e REMOVAL - 4.7L
den sit y of t h e a ir en t er in g t h e in t a ke m a n ifold ba sed Th e In t a ke Ma n ifold Air Tem per a t u r e (IAT) sen sor
u pon in t a ke m a n ifold t em per a t u r e. At key-on , a is loca t ed on t h e left side of t h e in t a ke m a n ifold.
5–volt power cir cu it is su pplied t o t h e sen sor fr om
t h e P CM. Th e sen sor is gr ou n ded a t t h e P CM Threaded Type Sensor
t h r ou gh a low-n oise, sen sor-r et u r n cir cu it . (1) Discon n ect elect r ica l con n ect or fr om sen sor.
Th e P CM u ses t h is in pu t t o ca lcu la t e t h e followin g: (2) Rem ove sen sor fr om in t a ke m a n ifold (F ig. 28).
• In ject or pu lse-widt h
• Adju st m en t of spa r k t im in g (t o h elp pr even t Snap-In Type Sensor
spa r k kn ock wit h h igh in t a ke m a n ifold a ir-ch a r ge (1) Discon n ect elect r ica l con n ect or fr om IAT sen -
t em per a t u r es) sor.
Th e r esist a n ce va lu es of t h e IAT sen sor is t h e sa m e (2) Clea n dir t fr om in t a ke m a n ifold a t sen sor ba se.
a s for t h e E n gin e Coola n t Tem per a t u r e (E CT) sen sor. (3) Gen t ly lift on sm a ll pla st ic r elea se t a b (F ig. 30)
or (F ig. 29) a n d r ot a t e sen sor a bou t 1/4 t u r n cou n t er-
REM OVAL clockwise for r em ova l.
(4) Ch eck con dit ion of sen sor o-r in g.
REMOVAL - 4.0L
Th e In t a ke Ma n ifold Air Tem per a t u r e (IAT) sen sor
is in st a lled in t o t h e in t a ke m a n ifold plen u m n ea r t h e
fr on t of t h e t h r ot t le body (F ig. 27).
(1) Discon n ect elect r ica l con n ect or fr om sen sor.
(2) Rem ove sen sor fr om in t a ke m a n ifold.
WJ FUEL INJECTION 14 - 47
I N TAK E AI R T EM PERAT U RE SEN SOR (Cont inue d)

Fig. 29 IAT SENSOR - 4.7L (SNAP-IN TYPE)

1 - LEFT SIDE OF THROTTLE BODY
2 - ELEC. CONNECT.
3 - IAT SENSOR
4 - RELEASE TAB

Fig. 28 IAT - 4.7L (THREADED TYPE)

1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR (THREADED TYPE)
5 - MOUNTING SCREWS

I N STALLAT I ON
INSTALLATION - 4.0L
Th e In t a ke Ma n ifold Air Tem per a t u r e (IAT) sen sor
is in st a lled in t o t h e in t a ke m a n ifold plen u m n ea r t h e
fr on t of t h e t h r ot t le body (F ig. 27).
(1) In st a ll sen sor in t o in t a ke m a n ifold. Tigh t en
sen sor t o 28 N·m (20 ft . lbs.) t or qu e.
(2) Con n ect elect r ica l con n ect or t o sen sor.

INSTALLATION - 4.7L
Threaded Type Sensor Fig. 30 IAT SENSOR TAB / O-RING - 4.7L (SNAP-IN
(1) In st a ll sen sor (F ig. 28) in t o in t a ke m a n ifold. TYPE)
Tigh t en sen sor t o 28 N·m (20 ft . lbs.) t or qu e. 1 - IAT SENSOR
(2) Con n ect elect r ica l con n ect or t o sen sor. 2 - SENSOR O-RING
3 - RELEASE TAB
Snap-In Type Sensor
(1) Ch eck con dit ion of sen sor o-r in g (F ig. 30).
(3) P osit ion sen sor (F ig. 29) in t o in t a ke m a n ifold
(2) Clea n sen sor m ou n t in g h ole in in t a ke m a n ifold.
a n d r ot a t e clockwise u n t il pa st r elea se t a b.
(4) In st a ll elect r ica l con n ect or.
14 - 48 FUEL INJECTION
M AP SEN SOR
DESCRI PT I ON
DESCRIPTION
On t h e 4.0L six-cylin der en gin e t h e MAP sen sor is
m ou n t ed t o t h e en gin e t h r ot t le body. On t h e 4.7L V-8
en gin e t h e MAP sen sor is m ou n t ed t o fr on t of t h e
in t a ke m a n ifold.
DESCRIPTION - 4.7L
Th e MAP sen sor is loca t ed on t h e fr on t of t h e
in t a ke m a n ifold. An o-r in g sea ls t h e sen sor t o t h e
in t a ke m a n ifold.
OPERATION
Th e MAP sen sor is u sed a s a n in pu t t o t h e P ower-
t r a in Con t r ol Modu le (P CM). It con t a in s a silicon
ba sed sen sin g u n it t o pr ovide da t a on t h e m a n ifold
va cu u m t h a t dr a ws t h e a ir /fu el m ixt u r e in t o t h e com -
bu st ion ch a m ber. Th e P CM r equ ir es t h is in for m a t ion
t o det er m in e in ject or pu lse widt h a n d spa r k a dva n ce.
Wh en m a n ifold a bsolu t e pr essu r e (MAP ) equ a ls
Ba r om et r ic pr essu r e, t h e pu lse widt h will be a t m a x-
im u m .
A 5 volt r efer en ce is su pplied fr om t h e P CM a n d
r et u r n s a volt a ge sign a l t o t h e P CM t h a t r eflect s
m a n ifold pr essu r e. Th e zer o pr essu r e r ea din g is 0.5V
a n d fu ll sca le is 4.5V. F or a pr essu r e swin g of 0–15
psi, t h e volt a ge ch a n ges 4.0V. To oper a t e t h e sen sor,
it is su pplied a r egu la t ed 4.8 t o 5.1 volt s. Gr ou n d is
pr ovided t h r ou gh t h e low-n oise, sen sor r et u r n cir cu it
a t t h e P CM.
Th e MAP sen sor in pu t is t h e n u m ber on e con t r ib-
u t or t o fu el in ject or pu lse widt h . Th e m ost im por t a n t
fu n ct ion of t h e MAP sen sor is t o det er m in e ba r om et -
r ic pr essu r e. Th e P CM n eeds t o kn ow if t h e veh icle is
a t sea level or a t a h igh er a lt it u de, beca u se t h e a ir
den sit y ch a n ges wit h a lt it u de. It will a lso h elp t o cor-
r ect for va r yin g ba r om et r ic pr essu r e. Ba r om et r ic
pr essu r e a n d a lt it u de h a ve a dir ect in ver se cor r ela -
t ion ; a s a lt it u de goes u p, ba r om et r ic goes down . At
key-on , t h e P CM power s u p a n d looks a t MAP volt -
a ge, a n d ba sed u pon t h e volt a ge it sees, it kn ows t h e
cu r r en t ba r om et r ic pr essu r e (r ela t ive t o a lt it u de).
On ce t h e en gin e st a r t s, t h e P CM looks a t t h e volt a ge
a ga in , con t in u ou sly ever y 12 m illisecon ds, a n d com -
pa r es t h e cu r r en t volt a ge t o wh a t it wa s a t key-on .
Th e differ en ce bet ween cu r r en t volt a ge a n d wh a t it
wa s a t key-on , is m a n ifold va cu u m .
Du r in g key-on (en gin e n ot r u n n in g) t h e sen sor
r ea ds (u pda t es) ba r om et r ic pr essu r e. A n or m a l r a n ge
ca n be obt a in ed by m on it or in g a kn own good sen sor.
As t h e a lt it u de in cr ea ses, t h e a ir becom es t h in n er
(less oxygen ). If a veh icle is st a r t ed a n d dr iven t o a
WJ
ver y differ en t a lt it u de t h a n wh er e it wa s a t key-on ,
t h e ba r om et r ic pr essu r e n eeds t o be u pda t ed. An y
t im e t h e P CM sees Wide Open Th r ot t le (WOT), ba sed
u pon Th r ot t le P osit ion Sen sor (TP S) a n gle a n d RP M,
it will u pda t e ba r om et r ic pr essu r e in t h e MAP m em -
or y cell. Wit h per iodic u pda t es, t h e P CM ca n m a ke
it s ca lcu la t ion s m or e effect ively.
Th e P CM u ses t h e MAP sen sor in pu t t o a id in ca l-
cu la t in g t h e followin g:
• Ma n ifold pr essu r e
• Ba r om et r ic pr essu r e
• E n gin e loa d
• In ject or pu lse-widt h
• Spa r k-a dva n ce pr ogr a m s
• Sh ift -poin t st r a t egies (cer t a in a u t om a t ic t r a n s-
m ission s on ly)
• Idle speed
• Decel fu el sh u t off
Th e MAP sen sor sign a l is pr ovided fr om a sin gle
piezor esist ive elem en t loca t ed in t h e cen t er of a dia -
ph r a gm . Th e elem en t a n d dia ph r a gm a r e bot h m a de
of silicon e. As m a n ifold pr essu r e ch a n ges, t h e dia -
ph r a gm m oves ca u sin g t h e elem en t t o deflect , wh ich
st r esses t h e silicon e. Wh en silicon e is exposed t o
st r ess, it s r esist a n ce ch a n ges. As m a n ifold va cu u m
in cr ea ses, t h e MAP sen sor in pu t volt a ge decr ea ses
pr opor t ion a lly. Th e sen sor a lso con t a in s elect r on ics
t h a t con dit ion t h e sign a l a n d pr ovide t em per a t u r e
com pen sa t ion .
Th e P CM r ecogn izes a decr ea se in m a n ifold pr es-
su r e by m on it or in g a decr ea se in volt a ge fr om t h e
r ea din g st or ed in t h e ba r om et r ic pr essu r e m em or y
cell. Th e MAP sen sor is a lin ea r sen sor ; m ea n in g a s
pr essu r e ch a n ges, volt a ge ch a n ges pr opor t ion a t ely.
Th e r a n ge of volt a ge ou t pu t fr om t h e sen sor is u su -
a lly bet ween 4.6 volt s a t sea level t o a s low a s 0.3
volt s a t 26 in . of H g. Ba r om et r ic pr essu r e is t h e pr es-
su r e exer t ed by t h e a t m osph er e u pon a n object . At
sea level on a st a n da r d da y, n o st or m , ba r om et r ic
pr essu r e is a ppr oxim a t ely 29.92 in H g. F or ever y 100
feet of a lt it u de, ba r om et r ic pr essu r e dr ops .10 in . H g.
If a st or m goes t h r ou gh it ca n ch a n ge ba r om et r ic
pr essu r e fr om wh a t sh ou ld be pr esen t for t h a t a lt i-
t u de. You sh ou ld kn ow wh a t t h e a ver a ge pr essu r e
a n d cor r espon din g ba r om et r ic pr essu r e is for you r
a r ea .
REM OVAL
REMOVAL - 4.0L
Th e MAP sen sor is m ou n t ed t o t h e side of t h e
t h r ot t le body (F ig. 40). An L-sh a ped r u bber fit t in g is
u sed t o con n ect t h e MAP sen sor t o t h r ot t le body (F ig.
31).
(1) Rem ove a ir clea n er du ct a n d a ir r eson a t or box
a t t h r ot t le body.
WJ FUEL INJECTION 14 - 49
M AP SEN SOR (Cont inue d)

Fig. 31 Rubber L-Shaped Fitting—MAP Sensor-to-

Throttle Body—4.0L Engine
1 - THROTTLE BODY
2 - MAP SENSOR Fig. 32 MAP and ECT Sensor Locations—4.7L V–8
3 - RUBBER FITTING Engine
4 - MOUNTING SCREWS (2) 1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
(2) Rem ove t wo MAP sen sor m ou n t in g bolt s 3 - MAP SENSOR
4 - INTAKE MANIFOLD
(scr ews) (F ig. 31).
(3) Wh ile r em ovin g MAP sen sor, slide t h e r u bber
L-sh a ped fit t in g (F ig. 31) fr om t h e t h r ot t le body. INSTALLATION - 4.7L
(4) Rem ove r u bber L-sh a ped fit t in g fr om MAP sen - Th e MAP sen sor is loca t ed on t h e fr on t of t h e
sor. in t a ke m a n ifold (F ig. 32). An o-r in g sea ls t h e sen sor
t o t h e in t a ke m a n ifold.
REMOVAL - 4.7L (1) Clea n MAP sen sor m ou n t in g h ole a t in t a ke
Th e MAP sen sor is loca t ed on t h e fr on t of t h e m a n ifold.
in t a ke m a n ifold (F ig. 32). An o-r in g sea ls t h e sen sor (2) Ch eck MAP sen sor o-r in g sea l for cu t s or t ea r s.
t o t h e in t a ke m a n ifold. (3) P osit ion sen sor in t o m a n ifold.
(1) Discon n ect elect r ica l con n ect or a t sen sor. (4) In st a ll MAP sen sor m ou n t in g bolt s (scr ews).
(2) Clea n a r ea a r ou n d MAP sen sor. Tigh t en scr ews t o 3 N·m (25 in . lbs.) t or qu e.
(3) Rem ove 2 sen sor m ou n t in g bolt s (F ig. 32). (5) Con n ect elect r ica l con n ect or.
(4) Rem ove MAP sen sor fr om in t a ke m a n ifold.

I N STALLAT I ON
INSTALLATION - 4.0L
Th e MAP sen sor is m ou n t ed t o t h e side of t h e
t h r ot t le body (F ig. 40). An L-sh a ped r u bber fit t in g is
u sed t o con n ect t h e MAP sen sor t o t h r ot t le body (F ig.
31).
(1) In st a ll r u bber L-sh a ped fit t in g t o MAP sen sor.
(2) P osit ion sen sor t o t h r ot t le body wh ile gu idin g
r u bber fit t in g over t h r ot t le body va cu u m n ipple.
(3) In st a ll MAP sen sor m ou n t in g bolt s (scr ews).
Tigh t en scr ews t o 3 N·m (25 in . lbs.) t or qu e.
(4) In st a ll a ir clea n er du ct /a ir box.
O2 S H EAT ER RELAY
DESCRIPTION
Th e 2 oxygen (O2) sen sor h ea t er r ela ys (u pst r ea m
a n d down st r ea m ) a r e loca t ed in t h e P ower t r a in Dis-
t r ibu t ion Cen t er (P DC).
OPERATION
E n gin es equ ipped wit h t h e Ca lifor n ia (NAE ) E m is-
sion s P a cka ge u se fo u r O2 s e n s o rs .
Two of t h e fou r sen sor h ea t er elem en t s (u pst r ea m
sen sor s 1/1 a n d 2/1) a r e con t r olled by t h e u pst r ea m
h ea t er r ela y t h r ou gh ou t pu t sign a ls fr om t h e P ower-
t r a in Con t r ol Modu le (P CM).
14 - 50 FUEL INJECTION
O2 S H EAT ER RELAY (Cont inue d)
Th e ot h er t wo h ea t er elem en t s (down st r ea m sen -
sor s 1/2 a n d 2/2) a r e con t r olled by t h e down st r ea m
h ea t er r ela y t h r ou gh ou t pu t sign a ls fr om t h e P CM.
To a void a la r ge sim u lt a n eou s cu r r en t su r ge, power
is dela yed t o t h e 2 down st r ea m h ea t er elem en t s by
t h e P CM for a ppr oxim a t ely 2 secon ds.
REMOVAL
(1) Rem ove P DC cover.
(2) Rem ove r ela y fr om P DC.
(3) Ch eck con dit ion of r ela y t er m in a ls a n d P DC
con n ect or t er m in a ls for da m a ge or cor r osion . Repa ir
if n ecessa r y befor e in st a llin g r ela y.
(4) Ch eck for pin h eigh t (pin h eigh t sh ou ld be t h e
sa m e for a ll t er m in a ls wit h in t h e P DC con n ect or ).
Repa ir if n ecessa r y befor e in st a llin g r ela y.
INSTALLATION
(1) In st a ll r ela y t o P DC.
(2) In st a ll cover t o P DC.
O2 S SEN SOR
DESCRIPTION
Th e Oxygen Sen sor s (O2S) a r e a t t a ch ed t o, a n d
pr ot r u de in t o t h e veh icle exh a u st syst em . Depen din g
on t h e em ission pa cka ge, t h e veh icle m a y u se a t ot a l
of eit h er 2 or 4 sen sor s.
F e d e ra l Em is s io n s P a c k a g e : Two sen sor s a r e
u sed: u pst r ea m (r efer r ed t o a s 1/1) a n d down st r ea m
(r efer r ed t o a s 1/2). Wit h t h is em ission pa cka ge, t h e
u pst r ea m sen sor (1/1) is loca t ed ju st befor e t h e m a in
ca t a lyt ic con ver t or. Th e down st r ea m sen sor (1/2) is
loca t ed ju st a ft er t h e m a in ca t a lyt ic con ver t or.
4.7L V-8 With Ca lifo rn ia Em is s io n s P a c k a g e :
On t h is em ission s pa cka ge, 4 sen sor s a r e u sed: 2
u pst r ea m (r efer r ed t o a s 1/1 a n d 2/1) a n d 2 down -
st r ea m (r efer r ed t o a s 1/2 a n d 2/2). Wit h t h is em is-
sion pa cka ge, t h e r igh t u pst r ea m sen sor (2/1) is
loca t ed in t h e r igh t exh a u st down pipe ju st befor e t h e
m in i-ca t a lyt ic con ver t or. Th e left u pst r ea m sen sor
(1/1) is loca t ed in t h e left exh a u st down pipe ju st
befor e t h e m in i-ca t a lyt ic con ver t or. Th e r igh t down -
st r ea m sen sor (2/2) is loca t ed in t h e r igh t exh a u st
down pipe ju st a ft er t h e m in i-ca t a lyt ic con ver t or, a n d
befor e t h e m a in ca t a lyt ic con ver t or. Th e left down -
st r ea m sen sor (1/2) is loca t ed in t h e left exh a u st
down pipe ju st a ft er t h e m in i-ca t a lyt ic con ver t or, a n d
befor e t h e m a in ca t a lyt ic con ver t or.
4.0L 6–Cy lin d e r With Ca lifo rn ia Em is s io n s
P a c k a g e : On t h is em ission s pa cka ge, 4 sen sor s a r e
u sed: 2 u pst r ea m (r efer r ed t o a s 1/1 a n d 2/1) a n d 2
down st r ea m (r efer r ed t o a s 1/2 a n d 2/2). Wit h t h is
em ission pa cka ge, t h e r ea r /u pper u pst r ea m sen sor
(2/1) is loca t ed in t h e exh a u st down pipe ju st befor e
WJ
t h e r ea r m in i-ca t a lyt ic con ver t or. Th e fr on t /u pper
u pst r ea m sen sor (1/1) is loca t ed in t h e exh a u st down -
pipe ju st befor e t h e fr on t m in i-ca t a lyt ic con ver t or.
Th e r ea r /lower down st r ea m sen sor (2/2) is loca t ed in
t h e exh a u st down pipe ju st a ft er t h e r ea r m in i-ca t a -
lyt ic con ver t or, a n d befor e t h e m a in ca t a lyt ic con ver-
t or. Th e fr on t /lower down st r ea m sen sor (1/2) is
loca t ed in t h e exh a u st down pipe ju st a ft er t h e fr on t
m in i-ca t a lyt ic con ver t or, a n d befor e t h e m a in ca t a -
lyt ic con ver t or.
OPERATION
An O2 sen sor is a ga lva n ic ba t t er y t h a t pr ovides
t h e P CM wit h a volt a ge sign a l (0-1 volt ) in ver sely
pr opor t ion a l t o t h e a m ou n t of oxygen in t h e exh a u st .
In ot h er wor ds, if t h e oxygen con t en t is low, t h e volt -
a ge ou t pu t is h igh ; if t h e oxygen con t en t is h igh t h e
ou t pu t volt a ge is low. Th e P CM u ses t h is in for m a t ion
t o a dju st in ject or pu lse-widt h t o a ch ieve t h e
14.7–t o–1 a ir /fu el r a t io n ecessa r y for pr oper en gin e
oper a t ion a n d t o con t r ol em ission s.
Th e O2 sen sor m u st h a ve a sou r ce of oxygen fr om
ou t side of t h e exh a u st st r ea m for com pa r ison . Cu r-
r en t O2 sen sor s r eceive t h eir fr esh oxygen (ou t side
a ir ) su pply t h r ou gh t h e O2 sen sor ca se h ou sin g.
F ou r wir es (cir cu it s) a r e u sed on ea ch O2 sen sor : a
12–volt feed cir cu it for t h e sen sor h ea t in g elem en t ; a
gr ou n d cir cu it for t h e h ea t er elem en t ; a low-n oise
sen sor r et u r n cir cu it t o t h e P CM, a n d a n in pu t cir-
cu it fr om t h e sen sor ba ck t o t h e P CM t o det ect sen -
sor oper a t ion .
Ox y g e n Sensor He a te rs /He a te r Re la y s :
Depen din g on t h e em ission s pa cka ge, t h e h ea t in g ele-
m en t s wit h in t h e sen sor s will be su pplied volt a ge
fr om eit h er t h e ASD r ela y, or 2 sepa r a t e oxygen sen -
sor r ela ys. Refer t o Wir in g Dia gr a m s t o det er m in e
wh ich r ela ys a r e u sed.
Th e O2 sen sor u ses a P osit ive Th er m a l Co-efficien t
(P TC) h ea t er elem en t . As t em per a t u r e in cr ea ses,
r esist a n ce in cr ea ses. At a m bien t t em per a t u r es
a r ou n d 70°F, t h e r esist a n ce of t h e h ea t in g elem en t is
a ppr oxim a t ely 4.5 oh m s on 4.0L en gin es. It is
a ppr oxim a t ely 13.5 oh m s on t h e 4.7L en gin e. As t h e
sen sor ’s t em per a t u r e in cr ea ses, r esist a n ce in t h e
h ea t er elem en t in cr ea ses. Th is a llows t h e h ea t er t o
m a in t a in t h e opt im u m oper a t in g t em per a t u r e of
a ppr oxim a t ely 930°-1100°F (500°-600° C). Alt h ou gh
t h e sen sor s oper a t e t h e sa m e, t h er e a r e ph ysica l dif-
fer en ces, du e t o t h e en vir on m en t t h a t t h ey oper a t e
in , t h a t keep t h em fr om bein g in t er ch a n gea ble.
Ma in t a in in g cor r ect sen sor t em per a t u r e a t a ll
t im es a llows t h e syst em t o en t er in t o closed loop
oper a t ion soon er. Also, it a llows t h e syst em t o r em a in
in closed loop oper a t ion du r in g per iods of ext en ded
idle.
WJ
O2 S SEN SOR (Cont inue d)
In Closed Loop oper a t ion , t h e P CM m on it or s cer-
t a in O2 sen sor in pu t (s) a lon g wit h ot h er in pu t s, a n d
a dju st s t h e in ject or pu lse widt h a ccor din gly. Du r in g
Open Loop oper a t ion , t h e P CM ign or es t h e O2 sen sor
in pu t . Th e P CM a dju st s in ject or pu lse widt h ba sed
on pr epr ogr a m m ed (fixed) va lu es a n d in pu t s fr om
ot h er sen sor s.
U p s tre a m S e n s o r (N o n -Ca lifo rn ia Em is s io n s ):
Th e u pst r ea m sen sor (1/1) pr ovides a n in pu t volt a ge
t o t h e P CM. Th e in pu t t ells t h e P CM t h e oxygen con -
t en t of t h e exh a u st ga s. Th e P CM u ses t h is in for m a -
t ion t o fin e t u n e fu el deliver y t o m a in t a in t h e cor r ect
oxygen con t en t a t t h e down st r ea m oxygen sen sor.
Th e P CM will ch a n ge t h e a ir /fu el r a t io u n t il t h e
u pst r ea m sen sor in pu t s a volt a ge t h a t t h e P CM h a s
det er m in ed will m a ke t h e down st r ea m sen sor ou t pu t
(oxygen con t en t ) cor r ect .
Th e u pst r ea m oxygen sen sor a lso pr ovides a n in pu t
t o det er m in e ca t a lyt ic con ver t or efficien cy.
D o w n s tre a m S e n s o r (N o n -Ca lifo rn ia Em is -
s io n s ): Th e down st r ea m oxygen sen sor (1/2) is a lso
u sed t o det er m in e t h e cor r ect a ir-fu el r a t io. As t h e
oxygen con t en t ch a n ges a t t h e down st r ea m sen sor,
t h e P CM ca lcu la t es h ow m u ch a ir-fu el r a t io ch a n ge is
r equ ir ed. Th e P CM t h en looks a t t h e u pst r ea m oxy-
gen sen sor volt a ge a n d ch a n ges fu el deliver y u n t il
t h e u pst r ea m sen sor volt a ge ch a n ges en ou gh t o cor-
r ect t h e down st r ea m sen sor volt a ge (oxygen con t en t ).
Th e down st r ea m oxygen sen sor a lso pr ovides a n
in pu t t o det er m in e ca t a lyt ic con ver t or efficien cy.
U p s tre a m S e n s o rs (Ca lifo rn ia En g in e s ): Two
u pst r ea m sen sor s a r e u sed (1/1 a n d 2/1). Th e 1/1 sen -
sor is t h e fir st sen sor t o r eceive exh a u st ga ses fr om
t h e #1 cylin der. Th ey pr ovide a n in pu t volt a ge t o t h e
P CM. Th e in pu t t ells t h e P CM t h e oxygen con t en t of
t h e exh a u st ga s. Th e P CM u ses t h is in for m a t ion t o
fin e t u n e fu el deliver y t o m a in t a in t h e cor r ect oxygen
con t en t a t t h e down st r ea m oxygen sen sor s. Th e P CM
will ch a n ge t h e a ir /fu el r a t io u n t il t h e u pst r ea m sen -
sor s in pu t a volt a ge t h a t t h e P CM h a s det er m in ed
will m a ke t h e down st r ea m sen sor s ou t pu t (oxygen
con t en t ) cor r ect .
Th e u pst r ea m oxygen sen sor s a lso pr ovide a n in pu t
t o det er m in e m in i-ca t a lyst efficien cy. Ma in ca t a lyt ic
con ver t or efficien cy is n ot ca lcu la t ed wit h t h is pa ck-
a ge.
D o w n s tre a m S e n s o rs (Ca lifo rn ia En g in e s ):
Two down st r ea m sen sor s a r e u sed (1/2 a n d 2/2). Th e
down st r ea m sen sor s a r e u sed t o det er m in e t h e cor-
r ect a ir-fu el r a t io. As t h e oxygen con t en t ch a n ges a t
t h e down st r ea m sen sor, t h e P CM ca lcu la t es h ow
m u ch a ir-fu el r a t io ch a n ge is r equ ir ed. Th e P CM
t h en looks a t t h e u pst r ea m oxygen sen sor volt a ge,
a n d ch a n ges fu el deliver y u n t il t h e u pst r ea m sen sor
volt a ge ch a n ges en ou gh t o cor r ect t h e down st r ea m
sen sor volt a ge (oxygen con t en t ).
FUEL INJECTION 14 - 51
Th e down st r ea m oxygen sen sor s a lso pr ovide a n
in pu t t o det er m in e m in i-ca t a lyst efficien cy. Ma in ca t -
a lyt ic con ver t or efficien cy is n ot ca lcu la t ed wit h t h is
pa cka ge.
E n gin es equ ipped wit h eit h er a down st r ea m sen -
sor (s), or a post -ca t a lyt ic sen sor, will m on it or ca t a -
lyt ic con ver t or efficien cy. If efficien cy is below
em ission st a n da r ds, t h e Ma lfu n ct ion In dica t or La m p
(MIL) will be illu m in a t ed a n d a Dia gn ost ic Tr ou ble
Code (DTC) will be set . Refer t o Mon it or ed Syst em s
in E m ission Con t r ol Syst em s for a ddit ion a l in for m a -
t ion .
REMOVAL
N e v e r a p p ly a n y ty p e o f g re a s e to th e o x y g e n
s e n s o r e le c tric a l c o n n e c to r, o r a tte m p t a n y s o l-
d e rin g o f th e s e n s o r w irin g h a rn e s s .
Oxygen sen sor (O2S) loca t ion s a r e sh own in (F ig.
33) a n d (F ig. 34).
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER(S) BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Ra ise a n d su ppor t veh icle.
(2) Discon n ect O2S pigt a il h a r n ess fr om m a in wir-
in g h a r n ess.
(3) If equ ipped, discon n ect sen sor wir e h a r n ess
m ou n t in g clips fr om en gin e or body.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(4) Rem ove O2S sen sor wit h a n oxygen sen sor
r em ova l a n d in st a lla t ion t ool.
INSTALLATION
Th r ea ds of n ew oxygen sen sor s a r e fa ct or y coa t ed
wit h a n t i-seize com pou n d t o a id in r em ova l. D O
N OT a d d a n y a d d itio n a l a n ti-s e ize c o m p o u n d to
th re a d s o f a n e w o x y g e n s e n s o r.
(1) In st a ll O2S sen sor. Tigh t en t o 30 N·m (22 ft .
lbs.) t or qu e.
(2) Con n ect O2S sen sor wir e con n ect or t o m a in
wir in g h a r n ess.
(3) If equ ipped, con n ect sen sor wir e h a r n ess
m ou n t in g clips t o en gin e or body. Wh e n Equ ip p e d :
Th e O2S p ig ta il h a rn e s s m u s t be c lip p e d a n d /o r
bo lte d ba c k to th e ir o rig in a l p o s itio n s o n
e n g in e o r bo d y to p re v e n t m e c h a n ic a l d a m a g e
to w irin g ..
(4) Lower veh icle.
14 - 52 FUEL INJECTION
O2 S SEN SOR (Cont inue d)
Fig. 33 Oxygen Sensor Locations—4.0L Engine
T H ROT T LE BODY
DESCRIPTION
Th e t h r ot t le body is loca t ed on t h e in t a ke m a n ifold.
F u el does n ot en t er t h e in t a ke m a n ifold t h r ou gh t h e
t h r ot t le body. F u el is spr a yed in t o t h e m a n ifold by
t h e fu el in ject or s.
OPERATION
F ilt er ed a ir fr om t h e a ir clea n er en t er s t h e in t a ke
m a n ifold t h r ou gh t h e t h r ot t le body. Th e t h r ot t le body
con t a in s a n a ir con t r ol pa ssa ge con t r olled by a n Idle
Air Con t r ol (IAC) m ot or. Th e a ir con t r ol pa ssa ge is
u sed t o su pply a ir for idle con dit ion s. A t h r ot t le va lve
(pla t e) is u sed t o su pply a ir for a bove idle con dit ion s.
Cer t a in sen sor s a r e a t t a ch ed t o t h e t h r ot t le body.
Th e a cceler a t or peda l ca ble, speed con t r ol ca ble a n d
t r a n sm ission con t r ol ca ble (wh en equ ipped) a r e con -
n ect ed t o t h e t h r ot t le body lin ka ge a r m .
WJ
A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
ca lly lim it t h e posit ion of t h e t h r ot t le body t h r ot t le
pla t e. N e v e r a tte m p t to a d ju s t th e e n g in e id le
s p e e d u s in g th is s c re w. All idle speed fu n ct ion s a r e
con t r olled by t h e P CM.
REM OVAL
REMOVAL - 4.0L
A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
ca lly lim it t h e posit ion of t h e t h r ot t le body t h r ot t le
pla t e. N e v e r a tte m p t to a d ju s t th e e n g in e id le
s p e e d u s in g th is s c re w. All idle speed fu n ct ion s a r e
con t r olled by t h e P ower t r a in Con t r ol Modu le (P CM).
(1) Rem ove a ir clea n er du ct a n d a ir r eson a t or box
a t t h r ot t le body.
(2) Discon n ect t h r ot t le body elect r ica l con n ect or s
a t MAP sen sor, IAC m ot or a n d TP S (F ig. 35).
WJ
T H ROT T LE BODY (Cont inue d)
Fig. 34 Oxygen Sensor Locations—4.7L V-8 Engine
(3) Rem ove a ll con t r ol ca bles fr om t h r ot t le body
(lever ) a r m . Refer t o Acceler a t or P eda l a n d Th r ot t le
Ca ble.
(4) Rem ove fou r t h r ot t le body m ou n t in g bolt s.
(5) Rem ove t h r ot t le body fr om in t a ke m a n ifold.
(6) Disca r d old t h r ot t le body-t o-in t a ke m a n ifold
ga sket .
REMOVAL - 4.7L
(1) Rem ove t h e a ir du ct a n d a ir r eson a t or box a t
t h r ot t le body.
(2) Discon n ect t h r ot t le body elect r ica l con n ect or s
a t IAC m ot or a n d TP S (F ig. 36).
(3) Rem ove va cu u m lin e a t t h r ot t le body.
(4) Rem ove a ll con t r ol ca bles fr om t h r ot t le body
(lever ) a r m . Refer t o Acceler a t or P eda l a n d Th r ot t le
Ca ble.
(5) Rem ove t h r ee t h r ot t le body m ou n t in g bolt s
(F ig. 36).
(6) Rem ove t h r ot t le body fr om in t a ke m a n ifold.
FUEL INJECTION 14 - 53
I N STALLAT I ON
INSTALLATION - 4.0L
A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
ca lly lim it t h e posit ion of t h e t h r ot t le body t h r ot t le
pla t e. N e v e r a tte m p t to a d ju s t th e e n g in e id le
s p e e d u s in g th is s c re w. All idle speed fu n ct ion s a r e
con t r olled by t h e P ower t r a in Con t r ol Modu le (P CM).
(1) Clea n t h e m a t in g su r fa ces of t h e t h r ot t le body
a n d t h e in t a ke m a n ifold.
(2) In st a ll n ew t h r ot t le body-t o-in t a ke m a n ifold
ga sket .
(3) In st a ll t h r ot t le body t o in t a ke m a n ifold.
(4) In st a ll fou r m ou n t in g bolt s. Tigh t en bolt s t o 11
N·m (100 in . lbs.) t or qu e.
(5) In st a ll con t r ol ca bles.
(6) In st a ll elect r ica l con n ect or s.
(7) In st a ll a ir du ct a n d a ir box a t t h r ot t le body.
14 - 54 FUEL INJECTION WJ
T H ROT T LE BODY (Cont inue d)

Fig. 36 Throttle Body, Sensors and Electrical

Connectors—4.7L V-8 Engine
Fig. 35 Throttle Body and Sensor Locations—4.0L 1 - MOUNTING BOLTS (3)
Engine 2 - THROTTLE BODY
3 - IAT SENSOR CONNECTOR
1 - MOUNTING BOLTS (4)
4 - IAC MOTOR CONNECTOR
2 - THROTTLE BODY
5 - TPS CONNECTOR
3 - IAC MOTOR
4 - ELEC. CONN.
5
6
-
-
TPS
MAP SENSOR
T H ROT T LE CON T ROL CABLE
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
REM OVAL
REMOVAL - 4.0L
INSTALLATION - 4.7L
(1) Clea n t h r ot t le body-t o-in t a ke m a n ifold o-r in g. CAUTION: Be careful not to damage or kink the
(2) Clea n m a t in g su r fa ces of t h r ot t le body a n d cable core wire (within the cable sheathing) while
in t a ke m a n ifold. servicing accelerator pedal or throttle cable.
(3) In st a ll t h r ot t le body t o in t a ke m a n ifold by posi-
t ion in g t h r ot t le body t o m a n ifold a lign m en t pin s. (1) F r om in side veh icle, h old u p a cceler a t or peda l.
(4) In st a ll t h r ee m ou n t in g bolt s. Tigh t en bolt s t o Rem ove pla st ic ca ble r et a in er (clip) a n d t h r ot t le ca ble
12 N·m (105 in . lbs.) t or qu e. cor e wir e fr om u pper en d of peda l a r m (F ig. 16).
(5) In st a ll con t r ol ca bles. P la st ic ca ble r et a in er (clip) sn a ps in t o peda l a r m .
(6) In st a ll va cu u m lin e t o t h r ot t le body. (2) Rem ove ca ble cor e wir e a t peda l a r m .
(7) In st a ll elect r ica l con n ect or s. (3) F r om in side veh icle, r em ove clip h oldin g ca ble
(8) In st a ll a ir du ct /a ir box a t t h r ot t le body. t o da sh pa n el (F ig. 16).
(4) Rem ove ca ble h ou sin g fr om da sh pa n el a n d
pu ll in t o en gin e com pa r t m en t .
(5) Rem ove (u n sn a p) ca ble fr om r ou t in g clips on
en gin e va lve cover.
(6) Rem ove ca ble con n ect or a t t h r ot t le body
bellcr a n k ba ll by u n sn a ppin g r ea r wa r d (F ig. 37).
(7) Rem ove t h r ot t le ca ble fr om br a cket by com -
pr essin g r elea se t a bs (F ig. 37) a n d pu sh in g ca ble
t h r ou gh h ole in br a cket .
(8) Rem ove t h r ot t le ca ble fr om veh icle.
WJ FUEL INJECTION 14 - 55
T H ROT T LE CON T ROL CABLE (Cont inue d)
(8) Lift a cceler a t or ca ble fr om t op of ca ble ca m
(F ig. 38).
(9) P r ess t a b (F ig. 39) t o r elea se pla st ic ca ble
m ou n t fr om br a cket . P re s s o n ta b o n ly e n o u g h to
re le a s e c a ble fro m bra c k e t. If ta b is p re s s e d to o
m u c h , it w ill be bro k e n . Slide pla st ic m ou n t (F ig.
39) t owa r ds pa ssen ger side of veh icle t o r em ove ca ble
fr om br a cket .
(10) Rem ove t h r ot t le ca ble fr om veh icle.

Fig. 37 Throttle (Accelerator) Cable at Throttle

Body—4.0L Engine
1 - ACCELERATOR CABLE
2 - OFF
3 - OFF
4 - THROTTLE BODY BELLCRANK
5 - SPEED CONTROL CABLE
6 - RELEASE TABS
7 - BRACKET
Fig. 38 Accelerator Cable at Bell Crank—4.7L V-8
REMOVAL - 4.7L Engine
1 - THROTTLE BODY
CAUTION: Be careful not to damage or kink the 2 - SPEED CONTROL CABLE CONNECTOR
cable core wire (within the cable sheathing) while 3 - OFF
servicing accelerator pedal or throttle cable. 4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
(1) F r om in side veh icle, h old u p a cceler a t or peda l. 6 - CABLE CAM
7 - BELLCRANK
Rem ove pla st ic ca ble r et a in er (clip) a n d t h r ot t le ca ble
cor e wir e fr om u pper en d of peda l a r m (F ig. 16).
P la st ic ca ble r et a in er (clip) sn a ps in t o peda l a r m . I N STALLAT I ON
(2) Rem ove ca ble cor e wir e a t peda l a r m .
(3) F r om in side veh icle, r em ove clip h oldin g ca ble INSTALLATION – 4.0L
t o da sh pa n el (F ig. 16). (1) Slide t h r ot t le ca ble t h r ou gh h ole in br a cket
(4) Rem ove a ir box a t t h r ot t le body. u n t il r elea se t a bs lock in t o br a cket .
(5) Un sn a p ca ble fr om plen u m r ou t in g clip. (2) Con n ect ca ble ba ll en d t o t h r ot t le body
(6) Rem ove ca ble h ou sin g fr om da sh pa n el a n d bellcr a n k ba ll (sn a ps on ).
pu ll in t o en gin e com pa r t m en t . (3) Sn a p ca ble in t o r ou t in g clips on en gin e va lve
(7) Usin g fin ger pr essu r e on ly, discon n ect a cceler a - cover.
t or ca ble con n ect or a t t h r ot t le body bellcr a n k pin by (4) Slide r u bber gr om m et a wa y fr om pla st ic ca ble
pu sh in g con n ect or off bellcr a n k pin t owa r ds fr on t of h ou sin g.
veh icle (F ig. 38). D O N OT try to p u ll c o n n e c to r (5) In st a ll r u bber gr om m et in t o da sh pa n el u n t il
o ff p e rp e n d ic u la r to th e be llc ra n k p in . Co n n e c - sea t ed.
to r w ill be bro k e n . (6) P u sh ca ble h ou sin g in t o r u bber gr om m et a n d
t h r ou gh open in g in da sh pa n el.
14 - 56 FUEL INJECTION
T H ROT T LE CON T ROL CABLE (Cont inue d)
Fig. 39 Accelerator Cable Release Tab—4.7L V-8
Engine
1 - ACCELERATOR CABLE
2 - PLASTIC CABLE MOUNT
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
5 - SLIDE FOR REMOVAL
(7) F r om in side veh icle, in st a ll clip h oldin g ca ble
t o da sh pa n el (F ig. 16).
(8) F r om in side veh icle, slide t h r ot t le ca ble cor e
wir e in t o open in g in t op of peda l a r m .
(9) P u sh ca ble r et a in er (clip) in t o peda l a r m open -
in g u n t il it sn a ps in pla ce.
(10) Befor e st a r t in g en gin e, oper a t e a cceler a t or
peda l t o ch eck for a n y bin din g.
INSTALLATION - 4.7L
(1) Slide a cceler a t or ca ble pla st ic m ou n t in t o
br a cket . Con t in u e slidin g u n t il t a b (F ig. 39) is
a lign ed t o h ole in m ou n t in g br a cket .
(2) Rou t e a cceler a t or ca ble over t op of ca ble ca m .
(3) Con n ect ca ble en d t o t h r ot t le body bellcr a n k
pin (sn a ps on r ea r wa r d).
(4) Slide r u bber gr om m et a wa y fr om pla st ic ca ble
h ou sin g.
(5) In st a ll r u bber gr om m et in t o da sh pa n el u n t il
sea t ed.
(6) P u sh ca ble h ou sin g in t o r u bber gr om m et a n d
t h r ou gh open in g in da sh pa n el.
(7) F r om in side veh icle, in st a ll clip h oldin g ca ble
t o da sh pa n el (F ig. 16).
(8) F r om in side veh icle, slide t h r ot t le ca ble cor e
wir e in t o open in g in t op of peda l a r m .
WJ
(9) P u sh ca ble r et a in er (clip) in t o peda l a r m open -
in g u n t il it sn a ps in pla ce.
(10) Sn a p ca ble in t o plen u m r ou t in g clip.
(11) In st a ll a ir box t o t h r ot t le body.
(12) Befor e st a r t in g en gin e, oper a t e a cceler a t or
peda l t o ch eck for a n y bin din g.
T H ROT T LE POSI T I ON SEN SOR
DESCRIPTION
Th e 3–wir e Th r ot t le P osit ion Sen sor (TP S) is
m ou n t ed on t h e t h r ot t le body a n d is con n ect ed t o t h e
t h r ot t le bla de.
OPERATION
Th e TP S is a 3–wir e va r ia ble r esist or t h a t pr ovides
t h e P ower t r a in Con t r ol Modu le (P CM) wit h a n in pu t
sign a l (volt a ge) t h a t r epr esen t s t h e t h r ot t le bla de
posit ion of t h e t h r ot t le body. Th e sen sor is con n ect ed
t o t h e t h r ot t le bla de sh a ft . As t h e posit ion of t h e
t h r ot t le bla de ch a n ges, t h e r esist a n ce (ou t pu t volt -
a ge) of t h e TP S ch a n ges.
Th e P CM su pplies a ppr oxim a t ely 5 volt s t o t h e
TP S. Th e TP S ou t pu t volt a ge (in pu t sign a l t o t h e
P CM) r epr esen t s t h e t h r ot t le bla de posit ion . Th e
P CM r eceives a n in pu t sign a l volt a ge fr om t h e TP S.
Th is will va r y in a n a ppr oxim a t e r a n ge of fr om .26
volt s a t m in im u m t h r ot t le open in g (idle), t o 4.49 volt s
a t wide open t h r ot t le. Alon g wit h in pu t s fr om ot h er
sen sor s, t h e P CM u ses t h e TP S in pu t t o det er m in e
cu r r en t en gin e oper a t in g con dit ion s. In r espon se t o
en gin e oper a t in g con dit ion s, t h e P CM will a dju st fu el
in ject or pu lse widt h a n d ign it ion t im in g.
Th e P CM n eeds t o iden t ify t h e a ct ion s a n d posit ion
of t h e t h r ot t le bla de a t a ll t im es. Th is in for m a t ion is
n eeded t o a ssist in per for m in g t h e followin g ca lcu la -
t ion s:
• Ign it ion t im in g a dva n ce
• F u el in ject ion pu lse-widt h
• Idle (lea r n ed va lu e or m in im u m TP S)
• Off-idle (0.06 volt )
• Wide Open Th r ot t le (WOT) open loop (2.608
volt s a bove lea r n ed idle volt a ge)
• Deceler a t ion fu el lea n ou t
• F u el cu t off du r in g cr a n kin g a t WOT (2.608 volt s
a bove lea r n ed idle volt a ge)
• A/C WOT cu t off (cer t a in a u t om a t ic t r a n sm is-
sion s on ly)
WJ FUEL INJECTION 14 - 57
T H ROT T LE POSI T I ON SEN SOR (Cont inue d)

REM OVAL
REMOVAL - 4.0L
Th e TP S is m ou n t ed t o t h e t h r ot t le body.
(1) Discon n ect TP S elect r ica l con n ect or (F ig. 40).
(2) Rem ove TP S m ou n t in g scr ews (F ig. 41).
(3) Rem ove TP S.

Fig. 41 TPS Mounting Screws—4.0L Engine

1 - MOUNTING SCREWS
2 - TPS

Fig. 40 TPS Electrical Connector—4.0L Engine

1 - MOUNTING BOLTS (4)
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.

REMOVAL - 4.7L
Th e TP S is loca t ed on t h e t h r ot t le body.
(1) Rem ove a ir du ct a n d a ir r eson a t or box a t t h r ot -
t le body.
(2) Discon n ect TP S elect r ica l con n ect or (F ig. 36).
(3) Rem ove t wo TP S m ou n t in g bolt s (scr ews) (F ig.
42).
(4) Rem ove TP S fr om t h r ot t le body. Fig. 42 TPS Mounting Bolts—4.7L V–8
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR (THREADED TYPE)
5 - MOUNTING SCREWS
14 - 58 FUEL INJECTION WJ
T H ROT T LE POSI T I ON SEN SOR (Cont inue d)

I N STALLAT I ON INSTALLATION - 4.7L

INSTALLATION - 4.0L
Th e TP S is m ou n t ed t o t h e t h r ot t le body.
Th e t h r ot t le sh a ft en d of t h r ot t le body slides in t o a
socket in t h e TP S (F ig. 43). Th e TP S m u st be
in st a lled so t h a t it ca n be r ot a t ed a few degr ees. (If
sen sor will n ot r ot a t e, in st a ll sen sor wit h t h r ot t le
sh a ft on ot h er side of socket t a n gs). Th e TP S will be
u n der sligh t t en sion wh en r ot a t ed.
Th e t h r ot t le sh a ft en d of t h r ot t le body slides in t o a
socket in TP S (F ig. 44). Th e TP S m u st be in st a lled so
t h a t it ca n be r ot a t ed a few degr ees. If sen sor will
n ot r ot a t e, in st a ll sen sor wit h t h r ot t le sh a ft on ot h er
side of socket t a n gs. Th e TP S will be u n der sligh t
t en sion wh en r ot a t ed.

Fig. 43 Throttle Position Sensor Installation—4.0L

Engine Fig. 44 TPS Installation—4.7L
1 - THROTTLE BODY
1 - TANGS
2 - LOCATING TANGS
2 - THROTTLE SHAFT
3 - THROTTLE POSITION SENSOR
3 - THROTTLE BODY
4 - SOCKET
4 - TPS
5 - THROTTLE SHAFT

(1) In st a ll TP S a n d r et a in in g scr ews.

(1) In st a ll TP S a n d t wo r et a in in g bolt s.
(2) Tigh t en scr ews t o 7 N·m (60 in . lbs.) t or qu e.
(2) Tigh t en bolt s t o 7 N·m (60 in . lbs.) t or qu e.
(3) Con n ect TP S elect r ica l con n ect or t o TP S.
(3) Ma n u a lly oper a t e t h r ot t le con t r ol lever by h a n d
(4) Ma n u a lly oper a t e t h r ot t le (by h a n d) t o ch eck
t o ch eck for a n y bin din g of TP S.
for a n y TP S bin din g befor e st a r t in g en gin e.
(4) Con n ect TP S elect r ica l con n ect or t o TP S.
(5) In st a ll a ir du ct /a ir box t o t h r ot t le body.
WJ STEERING 19 - 1

STEERING
TABLE OF CON T EN T S

page page

STEERING DIAGNOSIS AND TESTING - 4.7L -

DESCRIPTION - POWER STEERING SYSTEM ..1 HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION - POWER STEERING SYSTEM ...1 COLUMN ...............................7
DIAGNOSIS AND TESTING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - POWER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEERING SYSTEM . . . . . . . . . . . . . . . . . ...2 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - STEERING
FLOW AND PRESSURE . . . . . . . . . . . . . . ...4

ST EERI N G
DESCRIPTION - POWER STEERING SYSTEM
Th e power st eer in g pu m p (F ig. 1) is a con st a n t
flow r a t e a n d displa cem en t va n e t ype pu m p. Th e
pu m p r eser voir is a t t a ch ed t o t h e pu m p body. Th e
pu m p is con n ect ed t o t h e st eer in g by t h e pr essu r e
a n d r et u r n h oses. Th e st eer in g gea r (F ig. 1) u sed is a
r ecir cu la t in g ba ll t ype gea r. A t ilt a n d n on -t ilt colu m n
pr ovide st eer in g in pu t .
Th e power st eer in g syst em con sist s of:

OPERATION - POWER STEERING SYSTEM

Th e r a ck pist on ba lls a ct a s a r ollin g t h r ea d
bet ween t h e wor m sh a ft a n d r a ck pist on . Th e wor m
sh a ft is su ppor t ed by a t h r u st bea r in g a t t h e lower
en d a n d a bea r in g a ssem bly a t t h e u pper en d. Wh en
t h e wor m sh a ft is t u r n ed fr om in pu t fr om t h e st eer- Fig. 1 POWER STEERING GEAR & PUMP 4.0L
in g colu m n t h e r a ck pist on m oves. Th e r a ck pist on 1 - STEERING GEAR
t eet h m esh wit h t h e pit m a n sh a ft . Tu r n in g t h e wor m 2 - PRESSURE HOSE
sh a ft t u r n s t h e pit m a n sh a ft , wh ich m oves t h e st eer- 3 - PUMP
in g lin ka ge. 4 - RETURN HOSE
5 - RESERVOIR
19 - 2 STEERING WJ
ST EERI N G (Cont inue d)

DI AGN OSI S AN D T EST I N G

DIAGNOSIS AND TESTING - POWER STEERING SYSTEM

ST EERI N G N OI SE

Th er e is som e n oise in a ll power st eer in g syst em s. On e of t h e m ost com m on is a h issin g sou n d eviden t a t a
st a n dst ill pa r kin g. Or wh en t h e st eer in g wh eel is a t t h e en d of it ’s t r a vel. H iss is a h igh fr equ en cy n oise sim ila r
t o t h a t of a wa t er t a p bein g closed slowly. Th e n oise is pr esen t in a ll va lves t h a t h a ve a h igh velocit y flu id pa ssin g
t h r ou gh a n or ifice. Th er e is n o r ela t ion sh ip bet ween t h is n oise a n d st eer in g per for m a n ce.

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
WHISTLE seal. panel.

2. Noisy valve in power steering gear. 2. Replace steering gear.

RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.

2. Loose or damaged suspension 2. Inspect and repair suspension.
components/track bar.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other 5. Reposition hose.
components.

CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.

2. Belt routing. 2. Verify belt routing is correct.

WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.

2. Pressure hose in contact with other 2. Reposition hose.
components.
3. Internal pump noise. 3. Replace pump.
4. Air in the system. 4. Perform pump initial operation.

SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.

2. O-ring missing or damaged on hose 2. Replace o-ring.
fitting.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.

SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.

KNOCKING 2. Wrong gear. 2. Verify gear.
WJ
ST EERI N G (Cont inue d)
BI N DI N G AN D ST I CK I N G
CONDITION POSSIBLE CAUSE
DIFFICULT TO TURN WHEEL 1. Low fluid level.
STICKS OR BINDS
2. Tire pressure.
3. Steering component.
4. Loose belt.
5. Low pump pressure.
6. Column shaft coupler binding.
7. Steering gear worn or out of
adjustment.
8. Ball joints binding.
9. Belt routing.
4.7L Hydraulic fan motor steering output
low
I N SU FFI CI EN T ASST. OR POOR RET U RN T O CEN T ER
CONDITION POSSIBLE CAUSE
HARD TURNING OR MOMENTARY 1. Tire pressure.
INCREASE IN TURNING EFFORT 2. Low fluid level.
3. Loose belt.
4. Lack of lubrication.
5. Low pump pressure or flow.
6. Internal gear leak.
7. Belt routing.
8. Low flow / pressure from fan
4.7L
motor
STEERING WHEEL 1. Tire pressure.
DOES NOT WANT TO RETURN TO 2. Wheel alignment.
CENTER POSITION
3. Lack of lubrication.
4. High friction in steering gear.
5. Ball joints binding.
NOTE:
Some roads will cause a vehicle to drift, due to the crown in the road.
STEERING 19 - 3
CORRECTION
1. Fill to proper level.
2. Adjust tire pressure.
3. Inspect and lube.
4. Adjust or replace.
5. Pressure test and replace if
necessary.
6. Replace coupler.
7. Repair or replace gear.
8. Inspect and repair as necessary.
9. Verify belt routing is correct.
Pressure / Flow test fans steering
output flow
CORRECTION
1. Adjust tire pressure.
2. Fill to proper level.
3. Adjust or replace.
4. Inspect and lubricate steering and
suspension compnents.
5. Pressure and flow test and repair
as necessary.
6. Pressure and flow test, and repair
as necessary.
7. Verify belt routing is correct.
8. Pressure and flow test and repair
as necessary.
1. Adjust tire pressure.
2. Align front end.
3. Inspect and lubricate steering and
suspension compnents.
4. Test and adjust as necessary.
5. Inspect and repair as necessary.
19 - 4 STEERING WJ
ST EERI N G (Cont inue d)
LOOSE ST EERI N G AN D V EH I CLE LEADS/DRI FT S

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Repair as necessary.

WHEEL steering components.

2. Worn or loose wheel bearings. 2. Repair as necessary.

3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.

VEHICLE PULLS TO ONE SIDE 1. Tire Pressure. 1. Adjust tire pressure.

DURING BRAKING
2. Air in brake hydrauliics system. 2. Bleed brake system.
3. Worn brake components. 3. Repair as necessary.

VEHICLE LEADS OR DRIFTS 1. Tire pressure. 1. Adjust tire pressure.

FROM STRAIGHT AHEAD 2. Radial tire lead. 2. Cross front tires.
DIRECTION ON UNCROWNED
3. Brakes dragging. 3. Repair as necessary.
ROAD.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering/ 6. Repair as necessary.
suspension components.
7. Cross caster out of spec. 7. Adjust or replace axle as
necessary.

DIAGNOSIS AND TESTING - STEERING FLOW

AND PRESSURE
Th e followin g pr ocedu r e is u sed t o t est t h e oper a -
t ion of t h e power st eer in g syst em on t h e veh icle. Th is
t est will pr ovide t h e ga llon s per m in u t e (GP M) or
flow r a t e of t h e power st eer in g pu m p a lon g wit h t h e
m a xim u m r elief pr essu r e. P er for m t est a n y t im e a
power st eer in g syst em pr oblem is pr esen t . Th is t est
will det er m in e if t h e power st eer in g pu m p or power
st eer in g gea r is n ot fu n ct ion in g pr oper ly. Th e follow-
in g pr essu r e a n d flow t est is per for m ed u sin g P ower
St eer in g An a lyzer Tool kit 6815 (F ig. 2) a n d Ada pt er
Kit 6893.

FLOW AND PRESSURE TEST

(1) Ch eck t h e power st eer in g belt t o en su r e it is in Fig. 2 Power Steering Analyzer
good con dit ion a n d a dju st ed pr oper ly. 1 - TUBE
(2) Con n ect pr essu r e ga u ge h ose fr om t h e P ower 2 - ADAPTER FITTINGS
St eer in g An a lyzer t o Tu be 6865. 3 - ANALYZER
(3) Con n ect Ada pt er 6826 t o P ower St eer in g An a - 4 - GAUGE HOSE
lyzer t est va lve en d.
(4) Discon n ect t h e h igh pr essu r e h ose fr om t h e
(6) Con n ect t h e power st eer in g h ose fr om t h e
power st eer in g pu m p.
st eer in g gea r t o Ada pt er 6826.
(5) Con n ect Tu be 6865 t o t h e pu m p h ose fit t in g.
(7) Open t h e t est va lve com plet ely.
WJ STEERING 19 - 5
ST EERI N G (Cont inue d)
(8) St a r t en gin e a n d let idle lon g en ou gh t o cir cu - DIAGNOSIS AND TESTING - 4.7L -
la t e power st eer in g flu id t h r ou gh flow/pr essu r e t est
HYDRAULIC
ga u ge.
Th e followin g pr ocedu r es a r e u sed t o t est t h e oper-
(9) Sh u t off t h e en gin e a n d ch eck t h e flu id level,
a t ion of t h e power st eer in g a n d h ydr a u lic fa n sys-
a dd flu id a s n ecessa r y. St a r t en gin e a ga in a n d let
t em s on t h e veh icle. Th is t est will pr ovide t h e ga llon s
idle.
per m in u t e (GP M) or flow r a t e of t h e power st eer in g
(10) Th e in it ia l pr essu r e r ea din g sh ou ld be
pu m p a lon g wit h a n y m a xim u m r elief pr essu r e. P er-
345-552 kP a (50-80 psi). If pr essu r e is h igh er in spect
for m t est a n yt im e a power st eer in g syst em pr oblem
t h e h oses for r est r ict ion s a n d r epa ir a s n ecessa r y.
is pr esen t . Th is t est will det er m in e if t h e power
(11) In cr ea se t h e en gin e speed t o 1500 RP M a n d
st eer in g pu m p, h ydr a u lic fa n , a n d power st eer in g
r ea d t h e flow m et er. Th e r ea din g sh ou ld be 2.4 - 2.8
gea r a r e n ot fu n ct ion in g pr oper ly. It will a lso det er-
GP M, if t h e r ea din g is below t h is specifica t ion t h e
m in e if t h e flow com in g ou t of t h e h ydr a u lic fa n
pu m p sh ou ld be r epla ced.
m ot or is su fficien t for t h e power st eer in g gea r. Th e
CAUTION: This next step involves testing maximum followin g pr essu r e a n d flow t est is per for m ed u sin g
pump pressure output and flow control valve oper- t h e P ower St eer in g An a lyzer Tool kit 6815 (F ig. 2)
ation. Do not leave valve closed for more than three a n d Ada pt er kit 8630 (F ig. 3).
seconds as the pump could be damaged.

(12) Close va lve fu lly t h r ee t im es for t h r ee secon ds

a n d r ecor d h igh est pr essu r e in dica t ed ea ch t im e. All
th re e re a d in g s m u s t be a t p u m p re lie f p re s s u re
s p e c ific a tio n s a n d w ith in 345 k P a (50 p s i) o f
e a c h o th e r.
• P r essu r es a bove specifica t ion s bu t n ot wit h in
345 kP a (50 psi) of ea ch ot h er, r epla ce pu m p.
• P r essu r es wit h in 345 kP a (50 psi) of ea ch ot h er
bu t below specifica t ion s, r epla ce pu m p.

CAUTION: Do not force the pump to operate against

the stops for more than 2 to 4 seconds at a time Fig. 3 4.7L HYDRAULIC POWER STEERING TEST
because, pump damage will result. ADAPTERS
(13) Open t h e t est va lve a n d t u r n t h e st eer in g FLOW TEST - FLOW FROM POWER STEERING
wh eel t o t h e ext r em e left a n d r igh t posit ion s a ga in st PUMP
t h e st ops. Recor d t h e h igh est pr essu r e r ea din g a t (1) Ch eck t h e power st eer in g belt t o en su r e it is in
ea ch posit ion . Com pa r e r ea din gs t o t h e pu m p specifi- good con dit ion a n d a dju st ed pr oper ly.
ca t ion s ch a r t . If pr essu r es r ea din gs a r e n ot wit h in 50 (2) Con n ect t h e pr essu r e ga u ge h ose fr om t h e
psi. of ea ch ot h er, t h e gea r is lea kin g in t er n a lly a n d P ower St eer in g An a lyzer t o Tu be 8630-2.
m u st be r epa ir ed. (3) Con n ect Ada pt er 8630-3 t o P ower St eer in g
GEAR I N LET SPECI FI CAT I ON S 4 .0 L & 4 .7 L An a lyzer t est va lve en d.
(4) Discon n ect t h e h igh pr essu r e h ose fr om t h e
power st eer in g pu m p.
RELIEF FLOW RATE
ENGINE (5) Con n ect Tu be 8630-2 t o t h e pu m p h ose fit t in g.
PRESSURE ± 50 (GPM)
(6) Con n ect t h e power st eer in g h ose fr om t h e fa n
4.0L 9653 kPa (1400 psi) 1500 RPM 2.4 - 2.8 m ot or t o Ada pt er 8630-3.
4.7L 9653 kPa (1450 psi) GPM (7) Open t h e t est va lve com plet ely.
(8) St a r t en gin e a n d let idle lon g en ou gh t o cir cu -
PU M P M OT OR SPECI FI CAT I ON S 4 .7 L la t e power st eer in g flu id t h r ou gh t h e flow/pr essu r e
t est ga u ge.
(9) Sh u t off t h e en gin e a n d ch eck t h e flu id level,
RELIEF FLOW RATE a dd flu id a ss n ecessa r y. St a r t en gin e a ga in a n d let
ENGINE
PRESSURE ± 50 (GPM) idle.
1100 RPM 2.4-2.8 (10) Th e in it ia l pr essu r e r ea din g sh ou ld be 483 -
4.7L 9653 kPa (1900 psi) GPM Minium 690 kP a (70 - 100 psi). If pr essu r e is h igh er in spect
@ 200 psi t h e h oses for r est r ict ion s a n d r epa ir a s n ecessa r y.
19 - 6 STEERING
ST EERI N G (Cont inue d)
(11) In cr ea se t h e en gin e speed t o 1100 r pm a n d
r ea d t h e flow m et er. Th e r ea din g sh ou ld be 2.6 GP M
m in im u m , if t h e r ea din g is below t h is specifica t ion ,
t h e pu m p sh ou ld be r epla ced.
FLOW AND PRESSURE TEST - FLOW FROM
HYDRAULIC FAN MOTOR TO STEERING GEAR
(should be done if necessary after the Pump flow
test)
(1) Con n ect t h e pr essu r e ga u ge h ose fr om t h e
P ower St eer in g An a lyzer t o F it t in g 8630-1.
(2) Con n ect Ada pt er 8630-4 t o P ower St eer in g
An a lyzer t est va lve en d.
(3) Discon n ect t h e h igh pr essu r e h ose fr om t h e
power st eer in g gea r.
(4) Con n ect F it t in g 8630-1 t o t h e h igh pr essu r e
h ose.
(5) Con n ect Ada pt er 8630-4 t o t h e power st eer in g
gea r.
(6) Open t h e t est va lve com plet ely.
(7) St a r t en gin e a n d let idle lon g en ou gh t o cir cu -
la t e power st eer in g flu id t h r ou gh t h e flow/pr essu r e
t est ga u ge.
(8) Sh u t off t h e en gin e a n d ch eck t h e flu id level,
a dd flu id a ss n ecessa r y. St a r t en gin e a ga in a n d let
idle.
(9) Th e in it ia l pr essu r e r ea din g sh ou ld be 345-552
kP a (50-80 psi). If pr essu r e is h igh er in spect t h e
h oses for r est r ict ion s a n d r epa ir a s n ecessa r y.
WJ
(10) In cr ea se t h e en gin e speed t o 1500 RP M a n d
r ea d t h e flow m et er. Th e r ea din g sh ou ld be 2.4 - 2.8
GP M if t h e r ea din g is below t h is specifica t ion t h e fa n
sh ou ld be r epla ced.
CAUTION: This next step involves testing maximum
fan motor steering relief pressure. Do not leave the
valve closed for more than three seconds.
(11) Close t h e va lve fu lly t h r ee t im es for t h r ee sec-
on ds a n d r ecor d h igh est pr essu r es in dica t ed ea ch
t im e. All t h r ee r ea din gs m u st be a t fa n m ot or st eer-
in g r elief pr essu r es.
(12) Open t h e t est va lve a n d t u r n t h e st eer in g
wh eel t o t h e ext r em e left a n d r igh t posit ion s a ga in st
t h e st ops. Recor d t h e h igh est pr essu r e r ea din gs a t
ea ch posit ion . If pr essu r e r ea din gs a r e n ot wit h in 50
psi fr om ea ch ot h er, t h e gea r is lea kin g in t er n a lly
a n d m u st be r epa ir ed.
PU M P M OT OR SPECI FI CAT I ON S 4 .7 L
RELIEF FLOW RATE
ENGINE
PRESSURE ± 50 (GPM)
1100 RPM 2.4-2.8
4.7L 9653 kPa (1900 psi) GPM Minium
@ 200 psi
WJ COLUMN 19 - 7

COLU M N

TABLE OF CONTENTS
page page

COLUMN INSTALLATION
DESCRIPTION IGNITION SWITCH INSTALLATION . . . . . . . . 13
SERVICE WARNINGS AND CAUTIONS . . . . . . 7 KEY-IN IGNITION SWITCH
REMOVAL .............................8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS DIAGNOSIS AND TESTING
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 12 KEY-IN IGNITION SWITCH ..... . . . . . . . . . 14
SPECIAL TOOLS LOCK CYLINDER
STEERING COLUMN . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IGNITION SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 STEERING WHEEL
DIAGNOSIS AND TESTING - IGNITION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL
IGNITION SWITCH REMOVAL . . . . . . . . . . . . 13

COLU M N To ser vice t h e st eer in g wh eel, swit ch es or a ir-

DESCRI PT I ON
SERVICE WARNINGS AND CAUTIONS
DESCRIPTION
Th e t ilt colu m n (F ig. 1) h a s been design ed t o be
ser viced a s a n a ssem bly, less t h e wir in g, swit ch es,
sh r ou ds, st eer in g wh eel, et c. Most st eer in g colu m n
com pon en t s ca n be ser viced wit h ou t r em ovin g t h e
st eer in g colu m n fr om t h e veh icle.
ba g,(Refer t o 8 - E LE CTRICAL/RE STRAINTS -
WARNING).
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG 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.

CAUTION: Safety goggles should be worn at all

times when working on steering columns.

Fig. 1 Steering Column

19 - 8 COLUMN WJ
COLU M N (Cont inue d)

REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. FAILURE TO DO SO MAY RESULT IN ACCI-
DENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY.(Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL).

(1) P osit ion fr on t wh eels st r a igh t a h ea d.

(2) Discon n ect a n d isola t e t h e n ega t ive (gr ou n d)
ca ble fr om t h e ba t t er y.
(3) Rem ove t h e a ir ba g,(Refer t o 8 - E LE CTRICAL/
RE STRAINTS/DRIVE R AIRBAG - RE MOVAL).
(4) Rem ove t h e st eer in g wh eel n u t a n d r em ove
wh eel wit h P u ller C-3894-A (F ig. 2).

Fig. 3 Steering Wheel Pockets

1 - STEERING WHEEL POCKETS

(5) Rem ove t h e clu st er bezel by pu llin g it fr om t h e

in st r u m en t pa n el (F ig. 4).

Fig. 2 Steering Wheel Puller

1 - PULLER
2 - STEERING WHEEL

NOTE: Ensure the puller jaws are seated in the

pockets (Fig. 3) of the steering wheel armature. Fig. 4 Cluster Bezel
1 - CLUSTER
2 - CLUSTER BEZEL
3 - STEERING COLUMN
4 - KNEE BLOCKER COVER
WJ
COLU M N (Cont inue d)
(6) Rem ove t h e kn ee blocker cover (F ig. 5),(Refer
t o 23 - BODY/INSTRUME NT PANE L - RE MOVAL).
COLUMN 19 - 9
(8) Un sn a p t h e t wo h a lves of t h e colu m n sh r ou ds
by pr essin g on t h e sides of t h e u pper sh r ou d a n d t ilt -
in g t h e r ea r of t h e u pper sh r ou d u p. Rem ove t h e
sh r ou ds fr om t h e st eer in g colu m n (F ig. 7).

Fig. 5 Knee Blocker Cover

1 - STEERING COLUMN
2 - KNEE BLOCKER COVER

(7) Rem ove t h e lower st eer in g colu m n sh r ou d

m ou n t in g scr ew (F ig. 6).

Fig. 7 Column Shrouds

1 - UPPER SHROUD
2 - LOWER SHROUD

(9) Rem ove t h e u pper fixed sh r ou d m ou n t in g

scr ews a n d r em ove t h e sh r ou d (F ig. 8).

Fig. 6 Column Shroud Mounting Screw

1 - LOWER SHROUD
2 - ACCESS HOLE

Fig. 8 Upper Fixed Shroud

1 - UPPER FIXED SHROUD
2 - COLUMN
19 - 10 COLUMN WJ
COLU M N (Cont inue d)
(10) Discon n ect t h e m u lt ifu ct ion swit ch (F ig. 9)
a n d ign it ion swit ch h a r n ess.

Fig. 11 Multifuction Switch And Clock Spring

1 - MULTI-FUNCTION SWITCH ASSEMBLY
Fig. 9 Multifuction Switch Harness 2 - CLOCKSPRING
1 - MULTIFUNCTION SWITCH
2 - MULTIFUNCTION SWITCH HARNESS (12) Tu r n t h e ign it ion key t o t h e on posit ion t h en
r elea se a n d r em ove t h e sh ift er in t er lock ca ble (F ig.
(11) Rem ove t h e m u lt ifu ct ion swit ch scr ew fr om 12) fr om t h e ign it ion lock cylin der h ou sin g.
u n der n ea t h t h e swit ch (F ig. 10). Slide t h e m u lt ifu c-
t ion swit ch a n d clock spr in g off t h e colu m n a s a n
a ssem bly (F ig. 11).

Fig. 12 Shifter Interlock Cable

1 - LOCK CYLINDER HOUSING
2 - INTERLOCK CABLE
Fig. 10 Multifuction
1 - CLOCK SPRING
2 - SCREW
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
WJ
COLU M N (Cont inue d)
(13) Rem ove t h e colu m n cou pler bolt (F ig. 13) a n d
slide t h e cou pler off t h e colu m n sh a ft .
Fig. 13 Column Coupler Bolt And Mounting Nuts
1 - COLUMN MOUNTING NUTS
2 - COUPLER BOLT
(14) Rem ove t h e colu m n m ou n t in g n u t s (F ig. 13)
a n d lower colu m n off m ou n t in g st u ds. Rem ove t h e
colu m n fr om t h e veh icle.
(15) Rem ove t h e ign it ion swit ch , cylin der a n d
SKIM, (Refer t o 19 - STE E RING/COLUMN/LOCK
CYLINDE R H OUSING - RE MOVAL). (F ig. 14).
Fig. 14 Ignition Switch And SKIM
1 - SKIM
2 - IGNITION SWITCH
COLUMN 19 - 11
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING COL-
UMN THE AIRBAG SYSTEM MUST BE DISARMED.
FAILURE TO DO SO MAY RESULT IN ACCIDENTAL
DEPLOYMENT OF THE AIRBAG AND POSSIBLE PER-
SONAL INJURY. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - INSTALLATION).
(1) In st a ll t h e ign it ion swit ch , cylin der a n d SKIM-
,(Refer t o 19 - STE E RING/COLUMN/IGNITION
SWITCH - INSTALLATION).
(2) In st a ll t h e colu m n in t o t h e veh icle a n d lift t h e
colu m n u p on t o t h e m ou n t in g st u ds. In st a ll t h e
m ou n t in g n u t s a n d t igh t en t o 12 N·m (105 in . lbs.).
(3) Slid t h e cou pler on t o t h e colu m n sh a ft a n d
in st a ll t h e cou pler bolt . Tigh t en t h e cou pler bolt t o 49
N·m (36 ft . lbs.).
(4) Tu r n t h e ign it ion key t o t h e on posit ion t h en
r elea se a n d in st a ll t h e sh ift er in t er lock ca ble (F ig.
12) in t o ign it ion lock cylin der h ou sin g.
(5) Ver ify ign it ion swit ch a n d sh ift er in t er lock
oper a t ion .,(Refer t o 21 - TRANSMISSION/TRANS-
AXLE /AUTOMATIC - 42RE /GE AR SH IF T CABLE -
ADJ USTME NTS).
(6) Slide t h e m u lt ifu ct ion swit ch a n d clock spr in g
on t o t h e colu m n a s a n a ssem bly (F ig. 11).
(7) In st a ll t h e m u lt ifu ct ion swit ch m ou n t in g scr ew
(F ig. 10).
(8) Con n ect t h e m u lt ifu ct ion swit ch (F ig. 9) a n d
ign it ion swit ch h a r n ess.
(9) In st a ll t h e u pper fixed sh r ou d a n d m ou n t in g
scr ews (F ig. 8).
(10) In st a ll t h e lower st eer in g colu m n sh r ou d t o
t h e st eer in g colu m n . In st a ll a n d t igh t en t h e m ou n t -
in g scr ew.
(11) In st a ll t h e u pper colu m n sh r ou d. Align t h e
u pper sh r ou d t o t h e lower sh r ou d a n d sn a p t h e t wo
sh r ou d h a lves t oget h er.
(12) In st a ll t h e kn ee blocker cover (F ig. 5),(Refer
t o 23 - BODY/INSTRUME NT PANE L - INSTALLA-
TION).
(13) In st a ll t h e clu st er bezel by in ser t in g it in t o
t h e in st r u m en t pa n el (F ig. 4).
(14) Align t h e st eer in g wh eel wit h t h e colu m n
in dex splin e a n d in st a ll t h e wh eel on t h e colu m n
sh a ft . P u ll t h e clockspr in g wir e h a r n ess t h r ou gh t h e
st eer in g wh eel a r m a t u r e spokes.
(15) In st a ll a n d t igh t en t h e st eer in g wh eel m ou n t -
in g n u t t o 61 N·m (45 ft . lbs.).
(16) Con n ect t h e st eer in g wh eel wir e h a r n ess con -
n ect or t o t h e clock spr in g con n ect or.
(17) In st a ll t h e a ir ba g,(Refer t o 8 - E LE CTRICAL/
RE STRAINTS/DRIVE R AIRBAG - INSTALLATION).
(18) Con n ect t h e n ega t ive (gr ou n d) ca ble t o t h e
ba t t er y.
19 - 12 COLUMN WJ
COLU M N (Cont inue d)

SPECI FI CAT I ON S
TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Steering Column 61 45 —
Steering Wheel Nut
Steering Column 12 — 105
Column Bracket Nuts
Steering Column 49 36 —
Shaft Coupler Bolts

SPECI AL T OOLS t h e st eer in g colu m n a ssem bly m u st be r epla ced,(Re-

STEERING COLUMN
Puller C-3894-A
I GN I T I ON SWI T CH
DESCRIPTION
Th e elect r ica l ign it ion swit ch is loca t ed on t h e
st eer in g colu m n . It is u sed a s t h e m a in on /off swit ch -
in g device for m ost elect r ica l com pon en t s. Th e
m ech a n ica l key lock cylin der is u sed t o en ga ge/disen -
ga ge t h e elect r ica l ign it ion swit ch .
DIAGNOSIS AND TESTING - IGNITION SWITCH
ELECTRICAL DIAGNOSIS
F or ign it ion swit ch elect r ica l sch em a t ics, r efer t o
Ign it ion Swit ch in Wir in g Dia gr a m s.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Ve h ic le s e qu ip p e d w ith a n a u to m a tic tra n s -
m is s io n a n d a flo o r m o u n te d s h ifte r: a ca ble is
u sed t o con n ect t h e in t er lock device in t h e st eer in g
colu m n a ssem bly, t o t h e t r a n sm ission floor sh ift
lever. Th is in t er lock device is u sed t o lock t h e t r a n s-
m ission sh ift er in t h e PARK posit ion wh en t h e key
lock cylin der is r ot a t ed t o t h e LOCKE D or ACCE S-
SORY posit ion . Th e in t er lock device wit h in t h e st eer-
in g colu m n is n ot ser vicea ble. If r epa ir is n ecessa r y,
fer t o 19 - STE E RING/COLUMN - RE MOVAL).
If t h e ign it ion key is difficu lt t o r ot a t e t o or fr om
t h e LOCK or ACCE SSORY posit ion , it m a y n ot be
t h e fa u lt of t h e key cylin der or t h e st eer in g colu m n
com pon en t s. Th e br a ke t r a n sm ission sh ift in t er lock
ca ble m a y be ou t of a dju st m en t ,(Refer t o 21 -
TRANSMISSION/TRANSAXLE /AUTOMATIC -
44RE /SH IF T INTE RLOCK ME CH ANISM - ADJ UST-
ME NTS) .
Ve h ic le s e qu ip p e d w ith a n a u to m a tic tra n s -
m is s io n a n d a s te e rin g c o lu m n m o u n te d s h ifte r:
a n in t er lock device is loca t ed wit h in t h e st eer in g col-
u m n . Th is in t er lock device is u sed t o lock t h e t r a n s-
m ission sh ift er in t h e PARK posit ion wh en t h e key
lock cylin der is in t h e LOCKE D or ACCE SSORY
posit ion . If it is difficu lt t o r ot a t e t h e key t o or fr om
t h e LOCK or ACCE SSORY posit ion , t h e in t er lock
device wit h in t h e st eer in g colu m n m a y be defect ive.
Th is device is n ot ser vicea ble. If r epa ir is n ecessa r y,
t h e st eer in g colu m n a ssem bly m u st be r epla ced,(Re-
fer t o 19 - STE E RING/COLUMN - RE MOVAL).
Ve h ic le s e qu ip p e d w ith a m a n u a l tra n s m is -
s io n a n d a flo o r m o u n te d s h ifte r: on cer t a in m od-
els, a lever is loca t ed on t h e st eer in g colu m n beh in d
t h e ign it ion key lock cylin der. Th e lever m u st be
m a n u a lly oper a t ed t o a llow r ot a t ion of t h e ign it ion
key lock cylin der t o t h e LOCK or ACCE SSORY posi-
t ion . If it is difficu lt t o r ot a t e t h e key t o t h e LOCK or
ACCE SSORY posit ion , t h e lever m ech a n ism m a y be
defect ive. Th is m ech a n ism is n ot ser vicea ble. If
r epa ir is n ecessa r y, t h e st eer in g colu m n a ssem bly
m u st be r epla ced,(Refer t o 19 - STE E RING/COL-
UMN - RE MOVAL).
On ot h er m odels, t h e ign it ion key cylin der m u st be
depr essed t o a llow it t o be r ot a t ed in t o t h e LOCK or
ACCE SSORY posit ion . If it is difficu lt t o r ot a t e t h e
key t o t h e LOCK or ACCE SSORY posit ion , t h e lock
m ech a n ism wit h in t h e st eer in g colu m n m a y be defec-
t ive. Th is m ech a n ism is n ot ser vicea ble. If r epa ir is
WJ COLUMN 19 - 13
I GN I T I ON SWI T CH (Cont inue d)
n ecessa r y, t h e st eer in g colu m n a ssem bly m u st be
r epla ced,(Refer t o 19 - STE E RING/COLUMN -
RE MOVAL).

REM OVAL
IGNITION SWITCH REMOVAL
Th e ign it ion key m u st be in t h e key cylin der for
cylin der r em ova l. Th e key cylin der m u st be r em oved
fir st befor e r em ovin g ign it ion swit ch .
(1) Rem ove key cylin der. Refer t o pr eviou s st eps.
(2) Rem ove lower st eer in g colu m n cover scr ews
a n d r em ove cover (F ig. 19).

Fig. 16 Switch In ON Position

1 - IGNITION SWITCH
2 - ROTATE TO ON POSITION

Fig. 15 Ignition Switch Lock Tab

1 - LOCK TAB
2 - IGNITION SWITCH
3 - SCREWDRIVER

(3) Rem ove ign it ion swit ch m ou n t in g scr ew (F ig.

17). Use t a m per pr oof t or x bit t o r em ove t h e scr ew.
(4) Usin g a sm a ll scr ewdr iver, pu sh on lockin g t a b
(F ig. 15) a n d r em ove swit ch fr om st eer in g colu m n .
(5) Discon n ect t wo elect r ica l con n ect or s a t r ea r of
ign it ion swit ch (F ig. 17).
I N STALLAT I ON
IGNITION SWITCH INSTALLATION
Th e ign it ion key m u st be in t h e key cylin der for
cylin der r em ova l. Th e key cylin der m u st be r em oved
fir st befor e r em ovin g ign it ion swit ch .
Fig. 17 Ignition Switch Removal/Installation
1 - TAMPER PROOF SCREW
2 - IGNITION SWITCH
3 - ELECTRICAL CONNECTORS
(1) Befor e in st a llin g ign it ion swit ch , r ot a t e t h e slot
in t h e swit ch t o t h e ON posit ion (F ig. 16).
(2) Con n ect t wo elect r ica l con n ect or s t o r ea r of
ign it ion swit ch . Ma ke su r e t h a t lockin g t a bs a r e fu lly
sea t ed in t o wir in g con n ect or s.
(3) P osit ion swit ch t o colu m n a n d in st a ll t a m per
pr oof scr ew. Tigh t en scr ew t o 3 N·m (26 in . lbs.).
(4) In st a ll st eer in g colu m n lower cover.
19 - 14 COLUMN
K EY-I N I GN I T I ON SWI T CH
DESCRIPTION
Th e key-in ign it ion swit ch is con cea led wit h in a n d
in t egr a l t o t h e ign it ion swit ch , wh ich is m ou n t ed on
t h e st eer in g colu m n . Th e key-in ign it ion swit ch is
a ct u a t ed by t h e ign it ion lock cylin der m ech a n ism ,
a n d is h a r d wir ed bet ween a body gr ou n d a n d t h e
Body Con t r ol Modu le (BCM) t h r ou gh t h e in st r u m en t
pa n el wir e h a r n ess.
Th e key-in ign it ion swit ch ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e en t ir e ign i-
t ion swit ch u n it m u st be r epla ced,(Refer t o 19 -
STE E RING/COLUMN/LOCK CYLINDE R H OUSING
- RE MOVAL). F or com plet e cir cu it dia gr a m s, r efer t o
B o d y Co n tro l Mo d u le in t h e Con t en t s of Wir in g
Dia gr a m s.
OPERATION
Th e key-in ign it ion swit ch closes a pa t h t o gr ou n d
for t h e BCM wh en t h e ign it ion key is in ser t ed in t h e
ign it ion lock cylin der, a n d open s t h e gr ou n d pa t h
wh en t h e key is r em oved fr om t h e ign it ion lock cyl-
in der. Th e BCM m on it or s t h e key-in ign it ion swit ch
st a t u s t h r ou gh a n in t er n a l pu ll-u p, t h en sen ds t h e
pr oper swit ch st a t u s m essa ges t o ot h er elect r on ic
m odu les over t h e P r ogr a m m a ble Com m u n ica t ion s
In t er fa ce (P CI) da t a bu s n et wor k. Th e key-in ign it ion
swit ch st a t u s is a lso u sed by t h e BCM a s a n in pu t
for ch im e wa r n in g syst em oper a t ion .
DI AGN OSI S AN D T EST I N G
KEY-IN IGNITION SWITCH
F or com plet e cir cu it dia gr a m s, r efer t o B o d y Co n -
tro l Mo d u le in t h e Con t en t s of Wir in g Dia gr a m s.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WJ
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Discon n ect t h e in st r u m en t pa n el wir e h a r n ess
con n ect or fr om t h e key-in ign it ion swit ch con n ect or
r ecept a cle on t h e ign it ion swit ch . Ch eck for con t in u -
it y bet ween t h e key-in ign it ion swit ch sen se a n d
gr ou n d t er m in a ls of t h e key-in ign it ion swit ch con -
n ect or r ecept a cle. Th er e sh ou ld be con t in u it y wit h
t h e key in ser t ed in t h e ign it ion lock cylin der, a n d n o
con t in u it y wit h t h e key r em oved fr om t h e ign it ion
lock cylin der. If OK, go t o St ep 2. If n ot OK, r epla ce
t h e fa u lt y ign it ion swit ch u n it .
(2) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e in st r u m en t pa n el wir e h a r n ess con -
n ect or for t h e key-in ign it ion swit ch a n d a good
gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
3. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d
a s r equ ir ed.
(3) Discon n ect t h e gr a y 26-wa y in st r u m en t pa n el
wir e h a r n ess con n ect or fr om t h e Body Con t r ol Mod-
u le (BCM) con n ect or r ecept a cle. Ch eck for con t in u it y
bet ween t h e key-in ign it ion swit ch sen se cir cu it ca v-
it y of t h e in st r u m en t pa n el wir e h a r n ess con n ect or
for t h e key-in ign it ion swit ch a n d a good gr ou n d.
Th er e sh ou ld be n o con t in u it y. If OK, go t o St ep 4. If
n ot OK, r epa ir t h e sh or t ed key-in ign it ion swit ch
sen se cir cu it a s r equ ir ed.
(4) Ch eck for con t in u it y bet ween t h e key-in ign i-
t ion swit ch sen se cir cu it ca vit ies of t h e in st r u m en t
pa n el wir e h a r n ess con n ect or for t h e key-in ign it ion
swit ch a n d t h e gr a y 26-wa y in st r u m en t pa n el wir e
h a r n ess con n ect or for t h e BCM. Th er e sh ou ld be con -
t in u it y. If OK, u se a DRB sca n t ool a n d t h e pr oper
Dia gn ost ic P r ocedu r es m a n u a l t o t est t h e BCM. If
n ot OK, r epa ir t h e open key-in ign it ion swit ch sen se
cir cu it a s r equ ir ed.
LOCK CY LI N DER
REMOVAL
Th e ign it ion key m u st be in t h e key cylin der for
cylin der r em ova l. Th e key cylin der m u st be r em oved
fir st befor e r em ovin g ign it ion swit ch .
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) If equ ipped wit h a n a u t om a t ic t r a n sm ission ,
pla ce sh ift er in PARK posit ion .
(3) Rot a t e key t o ON posit ion .
WJ COLUMN 19 - 15
LOCK CY LI N DER (Cont inue d)
(4) A r elea se t a n g is loca t ed on bot t om of key cyl- (5) P osit ion a sm a ll scr ewdr iver or pin pu n ch in t o
in der (F ig. 18). t a n g a ccess h ole on bot t om of st eer in g colu m n lower
cover (F ig. 19).
(6) P u sh t h e pin pu n ch u p wh ile pu llin g key cylin -
der fr om st eer in g colu m n .

INSTALLATION
Th e ign it ion key m u st be in t h e key cylin der for
cylin der r em ova l. Th e key cylin der m u st be r em oved
fir st befor e r em ovin g ign it ion swit ch .
(1) If equ ipped wit h a n a u t om a t ic t r a n sm ission ,
pla ce sh ift er in PARK posit ion .
(2) P osit ion key cylin der in t o st eer in g colu m n a s it
wou ld n or m a lly be in t h e ON posit ion .
(3) P r ess key cylin der in t o colu m n u n t il it sn a ps
in t o posit ion .
(4) Ch eck m ech a n ica l oper a t ion of swit ch . Au to -
m a tic Tra n s m is s io n : Be su r e t r a n sm ission lever is
locked in PARK posit ion a ft er key r em ova l. If key is
Fig. 18 Key Cylinder Release Tang difficu lt t o r ot a t e or is difficu lt t o r em ove, t h e sh ift
1 - KEY CYLINDER lever-t o-st eer in g colu m n ca ble m a y be ou t of a dju st -
2 - RELEASE TANG m en t or defect ive. Refer t o Tr a n sm ission for pr oce-
du r es. Ma n u a l Tra n s m is s io n : Be su r e key ca n n ot
be r em oved u n t il r elea se lever is oper a t ed. If key ca n
be r em oved, r elea se lever m ech a n ism m a y be defec-
t ive. Relea se lever m ech a n ism is n ot ser viced sepa -
r a t ely. If r epa ir is n ecessa r y, t h e st eer in g colu m n
m u st be r epla ced,(Refer t o 19 - STE E RING/COL-
UMN - RE MOVAL).
(5) Con n ect n ega t ive ca ble t o ba t t er y.
(6) Ch eck elect r ica l oper a t ion of swit ch .

ST EERI N G WH EEL
REMOVAL
F or st eer in g wh eel r em ova l pr ocedu r e,(Refer t o 8 -
E LE CTRICAL/RE STRAINTS/CLOCKSP RING -
RE MOVAL).

INSTALLATION
F or st eer in g wh eel in st a lla t ion pr ocedu r e,(Refer t o
8 - E LE CTRICAL/RE STRAINTS/CLOCKSP RING -
INSTALLATION).

Fig. 19 Key Cylinder and Cover Removal

1 - LOWER COVER
2 - ACCESS HOLE
3 - PIN PUNCH
4 - COVER SCREWS (3)
19 - 16 GEAR WJ

GEAR

TABLE OF CONTENTS
page page

GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 PITMAN SHAFT BEARING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 PITMAN SHAFT SEAL
ADJUSTMENTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS RACK PISTON/VALVE ASSEMBLY
POWER STEERING GEAR . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIAL TOOLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
POWER STEERING GEAR . . . . . . . . . . . . . . 19 STUB SHAFT HOUSING
PITMAN SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25

GEAR (4) Rem ove t h e pr essu r e a n d r et u r n lin es (F ig.

2)fr om t h e st eer in g gea r. Refer t o h ose r em ova l in
t h is sect ion .
DESCRIPTION
(5) Rem ove t h e colu m n cou pler sh a ft bolt (F ig.
Th e power st eer in g gea r is a r ecir cu la t in g ba ll t ype
2)a n d r em ove t h e sh a ft fr om t h e gea r.
gea r (F ig. 1) .
(6) Ra ise a n d su ppor t t h e veh icle.
Th e followin g gea r com pon en t s ca n be ser viced:
(7) Rem ove t h e left fr on t wh eel a n d t ir e a ssem bly.
• P it m a n Sh a ft a n d Cover
(8) Rem ove t h e pit m a n a r m fr om gea r wit h P u ller
• P it m a n Sh a ft Bea r in gs
C-4150A.
• P it m a n Sh a ft Oil Sea l/Du st Sea l
(9) Rem ove t h e win dsh ield wa sh er r eser voir,(Refer
• St u d Sh a ft H ou sin g wit h Sea l
t o 8 - E LE CTRICAL/WIP E RS/WASH E RS/WASH E R
• O-Rin gs a n d Teflon Rin gs
RE SE RVOIR - RE MOVAL).
NOTE: If rack piston assembly is damaged the gear (10) Rem ove t h e st eer in g gea r m ou n t in g bolt s.
must be replaced. Rem ove t h e st eer in g gea r ou t of t h e en gin e com pa r t -
m en t (F ig. 3).

OPERATION INSTALLATION
Th e gea r a ct s a s a r ollin g t h r ea d bet ween t h e (1) P osit ion t h e st eer in g gea r on t h e fr a m e r a il a n d
wor m sh a ft a n d r a ck pist on . Th e wor m sh a ft is su p- in st a ll t h e bolt s. Tigh t en t h e bolt s t o 108 N·m (80 ft .
por t ed by a t h r u st bea r in g a t t h e lower en d a n d a lbs.) t or qu e.
bea r in g a ssem bly a t t h e u pper en d. Wh en t h e wor m (2) In st a ll t h e pit m a n a r m a n d t igh t en n u t t o 251
sh a ft is t u r n ed t h e r a ck pist on m oves. Th e r a ck pis- N·m (185 ft . lbs.).
t on t eet h m esh wit h t h e pit m a n sh a ft . Tu r n in g t h e (3) In st a ll win dsh ield wa sh er r eser voir,(Refer t o 8 -
wor m sh a ft t u r n s t h e pit m a n sh a ft , wh ich t u r n s t h e E LE CTRICAL/WIP E RS/WASH E RS/WASH E R RE S-
st eer in g lin ka ge. E RVOIR - INSTALLATION).
(4) In st a ll t h e wh eel a n d t ir e a ssem bly.
REMOVAL (5) Rem ove t h e su ppor t a n d lower t h e veh icle.
(1) P la ce t h e fr on t wh eels in t h e st r a igh t a h ea d (6) In st a ll t h e pr essu r e a n d r et u r n h oses t o t h e
posit ion wit h t h e st eer in g wh eel cen t er ed a n d locked. st eer in g gea r a n d t igh t en t o 20-38 N·m (14-28 ft .
(2) Rem ove t h e a ir clea n er h ou sin g,(Refer t o 9 - lbs.).
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R (7) In st a ll t h e colu m n cou pler sh a ft .
H OUSING - RE MOVAL). (8) In st a ll t h e a ir clea n er h ou sin g,(Refer t o 9 -
(3) Dr a in or siph on t h e power st eer in g syst em . E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - INSTALLATION).
WJ GEAR 19 - 17
GEAR (Cont inue d)

Fig. 2 Pressure And Return Lines

1 - PRESSURE LINE
2 - RETURN LINE
3 - COUPLER BOLT
4 - STEERING GEAR

Fig. 1 Recirculating Ball Type Gear

1 - ADJUSTER NUT
2 - COVER
3 - PITMAN SHAFT
4 - O-RING
5 - BEARING
6 - GEAR HOUSING
7 - RACK PISTON
8 - RETAINING RING
9 - O-RING
10 - BEARING
11 - STUB SHAFT HOUSING
12 - PITMAN SHAFT SEAL
13 - PLASTIC BACKUP WASHER
14 - METAL BACKUP WASHER
15 - RETAINING RING
16 - DUST SEAL
Fig. 3 Steering Gear Mounting
(9) F ill t h e power st eer in g pu m p (Refer t o 19 - 1 - MOUNTING BOLTS
STE E RING/P UMP - STANDARD P ROCE DURE ). 2 - PITMAN SHAFT
3 - STABILIZER BAR
19 - 18 GEAR WJ
GEAR (Cont inue d)

ADJ U ST M EN T S
STEERING GEAR
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.

OVER-CENTER
(1) Rot a t e t h e st u b sh a ft wit h Socket 8343 fr om
st op t o st op a n d cou n t t h e n u m ber of t u r n s.
(2) Cen t er t h e st u b sh a ft by r ot a t in g it fr om t h e
st op 1/2 of t h e t ot a l a m ou n t of t u r n s.
(3) P la ce t or qu e wr en ch a n d Socket 8343 in a ver-
t ica l posit ion on t h e st u b sh a ft . Rot a t e t h e wr en ch 45
degr ees ea ch side of t h e cen t er a n d r ecor d t h e h igh -
est r ot a t ion a l t or qu e in t h is r a n ge (F ig. 4) . Th is is
t h e Over-Cen t er Rot a t in g Tor qu e.

NOTE: The stub shaft must rotate smoothly without

sticking or binding. Fig. 4 Checking Over-center Rotation Torque
1 - CENTER
(4) Rot a t e t h e st u b sh a ft bet ween 90° a n d 180° t o
t h e left of cen t er a n d r ecor d t h e left off-cen t er pr e-
loa d. Repea t t h is t o t h e r igh t of cen t er a n d r ecor d t h e (8) P r even t t h e a dju st er scr ew fr om t u r n in g wh ile
r igh t off-cen t er pr eloa d. Th e a ver a ge of t h ese t wo t igh t en in g a dju st er lock n u t . Tigh t en t h e a dju st er
r ecor ded r ea din gs is t h e P r eloa d Rot a t in g Tor qu e. lock n u t t o 37-52 N·m (27-38 ft . lbs.).
(5) Th e Over-Cen t er Rot a t in g Tor qu e sh ou ld be
0.45-0.80 N·m (4-7 in . lbs.) h ig h e r t h a n t h e P r eloa d SPECI FI CAT I ON S
Rot a t in g Tor qu e.
(6) If a n a dju st m en t t o t h e Over-Cen t er Rot a t in g
POWER STEERING GEAR
Tor qu e is n ecessa r y, fir st loosen t h e a dju st er lock
n u t . Th en t u r n t h e pit m a n sh a ft a dju st er scr ew ba ck
SPECI FI CAT I ON S
(COUNTE RCLOCKWISE ) u n t il fu lly ext en ded, t h en
t u r n ba ck in (CLOCKWISE ) on e fu ll t u r n .
(7) Rem ea su r e Over-Cen t er Rot a t in g Tor qu e. If DESCRIPTION SPECIFICATION
n ecessa r y t u r n t h e a dju st er scr ew a n d r epea t m ea - Steering Gear Recirculating Ball
su r em en t u n t il cor r ect Over-Cen t er Rot a t in g Tor qu e Type
is r ea ch ed.
Steering Gear 12.7:1
NOTE: To increase the Over-Center Rotating Torque Overall Ratio
turn the screw CLOCKWISE.

T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Pitman Shaft Overcenter Drag 0.45-0.80 — 4-7
New Gear (under 400 miles) + Worm Shaft Preload + Worm Shaft Preload
Pitman Shaft Overcenter Drag 0.5-0.6 — 4-5
Used Gear (over 400 miles) + Worm Shaft Preload + Worm Shaft Preload
WJ GEAR 19 - 19
GEAR (Cont inue d)

SPECI AL T OOLS
POWER STEERING GEAR

Puller Seal 7794-A

Driver 8277

Slide Hammer C-637

Driver 8294

Remover, Pitman Arm C-4150A

Scoket 8343

Handle C-4171
19 - 20 GEAR WJ

PI T M AN SH AFT
REMOVAL
(1) Clea n exposed en d of pit m a n sh a ft a n d h ou sin g
wit h a wir e br u sh .
(2) Rot a t e t h e st u b sh a ft wit h a wr en ch (F ig.
5)fr om st op t o st op a n d cou n t t h e n u m ber of t u r n s.
(3) Cen t er t h e st u b sh a ft by r ot a t in g it fr om t h e
st op 1/2 of t h e t ot a l a m ou n t of t u r n s.

NOTE: The pitman shaft will not clear the housing if

it is not centered.

Fig. 6 Cover and Pitman Shaft

1 - ADJUSTER NUT
2 - PITMAN SHAFT COVER
3 - O-RING
4 - GEAR HOUSING
5 - PITMAN SHAFT

Fig. 5 Center Stub

1 - WRENCH
2 - STUB SHAFT

(4) Rem ove pit m a n sh a ft cover bolt s a n d r em ove

t h e sh a ft a ssem bly (F ig. 6).
(5) Rem ove pit m a n sh a ft cover o-r in g.
(6) Rem ove pit m a n sh a ft du st sea l fr om t h e h ou s-
in g wit h a P u ller 7794-A a n d Slide H a m m er C-637
(F ig. 7).
(7) Rem ove t h e pit m a n sh a ft oil sea l r et a in in g r in g
wit h sn a p r in g plier s (F ig. 8).
(8) Rem ove oil sea l m et a l ba cku p wa sh er t h en
pla st ic ba cku p wa sh er fr om t h e h ou sin g.
(9) Rem ove pit m a n sh a ft oil sea l fr om t h e h ou sin g
wit h a P u ller 7794-A a n d Slide H a m m er C-637 (F ig.
7). Fig. 7 Oil Seal Removal
(10) Dr op Dr iver 8277 t h r ou gh t h e t op bea r in g a n d 1 - PULLER
a lign t h e dr iver u p wit h t h e lower bea r in g. (F ig. 9). 2 - STEERING GEAR
In st a ll H a n dle C-4171 in t o t h e dr iver a n d r em ove t h e
lower bea r in g.
(11) Tu r n t h e gea r over a n d r em over t h e u pper INSTALLATION
bea r in g wit h Dr iver 8277 a n d H a n dle C-4171. (1) In st a ll u pper pit m a n sh a ft bea r in g, wit h Dr iver
8294 a n d H a n dle C-4171 (F ig. 10). Dr ive bea r in g in t o
h ou sin g u n t il t h e dr iver bot t om s ou t .

NOTE: Install upper pitman shaft bearing with the

part number/letters facing the driver.
WJ GEAR 19 - 21
PI T M AN SH AFT (Cont inue d)

Fig. 10 Upper Pitman Shaft Bearing

Fig. 8 Oil Seal Retaining Ring
1 - DRIVER
1 - SNAP RING PLIERS
2 - UPPER BEARING
2 - RETAINING RING

Fig. 9 Bearing Driver Fig. 11 Lower Pitman Shaft Bearing

1 - UPPER BEARING 1 - STEERING GEAR
2 - LOWER BEARING 2 - BEARING SHOULDER
3 - DRIVER 3 - DRIVER
4 - LOWER BEARING
(2) In st a ll lower pit m a n sh a ft bea r in g wit h t h e
ot h er side Dr iver 8294 a n d H a n dle C-4171 (F ig. 11). (8) Coa t t h e du st sea l wit h s p e c ia l g re a s e su p-
Dr ive bea r in g in t o h ou sin g u n t il t h e bea r in g sh ou lder plied wit h t h e n ew sea l.
is sea t ed a ga in st t h e h ou sin g. (9) In st a ll du st sea l wit h Dr iver 8294 a n d H a n dle
(3) Coa t t h e oil sea l a n d ba cku p wa sh er s wit h s p e - C-4171.
c ia l g re a s e su pplied wit h t h e n ew sea l. (10) In st a ll n ew pit m a n sh a ft cover o-r in g.
(4) In st a ll t h e oil sea l wit h Dr iver 8294 a n d H a n - (11) In st a ll pit m a n sh a ft a ssem bly in t o t h e h ou s-
dle C-4171. in g.
(5) In st a ll pla st ic ba cku p wa sh er. (12) In st a ll cover bolt s a n d t igh t en t o 62 N·m (46
ft . lbs.).
NOTE: The plastic backup washer has a lip on the (13) P er for m over-cen t er r ot a t ion t or qu e a dju st -
inside diameter that faces down towards the oil m en t .
seal.

(6) In st a ll m et a l ba cku p wa sh er.

(7) In st a ll t h e r et a in er r in g wit h sn a p r in g plier s.
19 - 22 GEAR
PI T M AN SH AFT BEARI N G
REMOVAL
(1) Clea n exposed en d of pit m a n sh a ft a n d h ou sin g
wit h a wir e br u sh .
(2) Rot a t e t h e st u b sh a ft wit h a wr en ch (F ig.
5)fr om st op t o st op a n d cou n t t h e n u m ber of t u r n s.
(3) Cen t er t h e st u b sh a ft by r ot a t in g it fr om t h e
st op 1/2 of t h e t ot a l a m ou n t of t u r n s.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Rem ove pit m a n sh a ft cover bolt s a n d r em ove
t h e sh a ft a ssem bly (F ig. 6).
(5) Rem ove pit m a n sh a ft cover o-r in g.
(6) Rem ove pit m a n sh a ft du st sea l fr om t h e h ou s-
in g wit h a P u ller 7794-A a n d Slide H a m m er C-637
(F ig. 7).
(7) Rem ove t h e pit m a n sh a ft oil sea l r et a in in g r in g
wit h sn a p r in g plier s (F ig. 8).
(8) Rem ove oil sea l m et a l ba cku p wa sh er t h en
pla st ic ba cku p wa sh er fr om t h e h ou sin g (F ig. 12).
Fig. 12 Backup Washers
1 - METAL BACK UP WASHER
2 - PLASTIC BACK UP WASHER
(9) Rem ove pit m a n sh a ft oil sea l fr om t h e h ou sin g
wit h a P u ller 7794-A a n d Slide H a m m er C-637 (F ig. 7).
(10) Dr op Dr iver 8277 t h r ou gh t h e t op bea r in g a n d
a lign t h e dr iver u p wit h t h e lower bea r in g. (F ig. 9).
In st a ll H a n dle C-4171 in t o t h e dr iver a n d r em ove t h e
lower bea r in g.
(11) Tu r n t h e gea r over a n d r em over t h e u pper
bea r in g wit h Dr iver 8277 a n d H a n dle C-4171.
INSTALLATION
(1) In st a ll u pper pit m a n sh a ft bea r in g, wit h Dr iver
8294 a n d H a n dle C-4171 (F ig. 10). Dr ive bea r in g in t o
h ou sin g u n t il t h e dr iver bot t om s ou t .
WJ
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) In st a ll lower pit m a n sh a ft bea r in g wit h t h e
ot h er side Dr iver 8294 a n d H a n dle C-4171 (F ig. 11).
Dr ive bea r in g in t o h ou sin g u n t il t h e bea r in g sh ou lder
is sea t ed a ga in st t h e h ou sin g.
(3) Coa t t h e oil sea l a n d ba cku p wa sh er s wit h s p e -
c ia l g re a s e su pplied wit h t h e n ew sea l.
(4) In st a ll t h e oil sea l wit h Dr iver 8294 a n d H a n -
dle C-4171.
(5) In st a ll pla st ic ba cku p wa sh er.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) In st a ll m et a l ba cku p wa sh er.
(7) In st a ll t h e r et a in er r in g wit h sn a p r in g plier s.
(8) Coa t t h e du st sea l wit h s p e c ia l g re a s e su p-
plied wit h t h e n ew sea l.
(9) In st a ll du st sea l wit h Dr iver 8294 a n d H a n dle
C-4171.
(10) In st a ll n ew pit m a n sh a ft cover o-r in g.
(11) In st a ll pit m a n sh a ft a ssem bly in t o t h e h ou s-
in g.
(12) In st a ll cover bolt s a n d t igh t en t o 62 N·m (46
ft . lbs.).
(13) P er for m over-cen t er r ot a t ion t or qu e a dju st -
m en t .
PI T M AN SH AFT SEAL
REMOVAL
(1) Clea n exposed en d of pit m a n sh a ft a n d h ou sin g
wit h a wir e br u sh .
(2) Rot a t e t h e st u b sh a ft wit h a wr en ch (F ig.
5)fr om st op t o st op a n d cou n t t h e n u m ber of t u r n s.
(3) Cen t er t h e st u b sh a ft by r ot a t in g it fr om t h e
st op 1/2 of t h e t ot a l a m ou n t of t u r n s.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Rem ove pit m a n sh a ft cover bolt s a n d r em ove
t h e sh a ft a ssem bly (F ig. 6).
(5) Rem ove pit m a n sh a ft cover o-r in g.
(6) Rem ove pit m a n sh a ft du st sea l fr om t h e h ou s-
in g wit h a P u ller 7794-A a n d Slide H a m m er C-637
(F ig. 7).
(7) Rem ove t h e pit m a n sh a ft oil sea l r et a in in g r in g
wit h sn a p r in g plier s (F ig. 8).
(8) Rem ove oil sea l m et a l ba cku p wa sh er t h en
pla st ic ba cku p wa sh er fr om t h e h ou sin g (F ig. 12).
WJ GEAR 19 - 23
PI T M AN SH AFT SEAL (Cont inue d)
(9) Rem ove pit m a n sh a ft oil sea l fr om t h e h ou sin g (4) Cen t er t h e st u b sh a ft by r ot a t in g it fr om t h e
wit h a P u ller 7794-A a n d Slide H a m m er C-637 (F ig. st op 1/2 of t h e t ot a l a m ou n t of t u r n s.
7).
(10) Dr op Dr iver 8277 t h r ou gh t h e t op bea r in g a n d NOTE: The pitman shaft will not clear the housing if
a lign t h e dr iver u p wit h t h e lower bea r in g. (F ig. 9). it is not centered.
In st a ll H a n dle C-4171 in t o t h e dr iver a n d r em ove t h e
lower bea r in g. (5) Rem ove pit m a n sh a ft cover bolt s a n d r em ove
(11) Tu r n t h e gea r over a n d r em over t h e u pper t h e sh a ft a ssem bly (F ig. 6).
bea r in g wit h Dr iver 8277 a n d H a n dle C-4171. (6) Rem ove t h e pit m a n sh a ft cover o-r in g.
(7) Rem ove st u b sh a ft h ou sin g bolt s (F ig. 13).
INSTALLATION
(1) In st a ll u pper pit m a n sh a ft bea r in g, wit h Dr iver
8294 a n d H a n dle C-4171 (F ig. 10). Dr ive bea r in g in t o
h ou sin g u n t il t h e dr iver bot t om s ou t .

NOTE: Install upper pitman shaft bearing with the

part number/letters facing the driver.

(2) In st a ll lower pit m a n sh a ft bea r in g wit h t h e

ot h er side Dr iver 8294 a n d H a n dle C-4171 (F ig. 11).
Dr ive bea r in g in t o h ou sin g u n t il t h e bea r in g sh ou lder
is sea t ed a ga in st t h e h ou sin g.
(3) Coa t t h e oil sea l a n d ba cku p wa sh er s wit h s p e -
c ia l g re a s e su pplied wit h t h e n ew sea l.
(4) In st a ll t h e oil sea l wit h Dr iver 8294 a n d H a n -
dle C-4171. Fig. 13 Stub Shaft Housing
(5) In st a ll pla st ic ba cku p wa sh er. 1 - STUB SHAFT HOUSING
2 - BOLTS
NOTE: The plastic backup washer has a lip on the 3 - STUB SHAFT
inside diameter that faces down towards the oil
seal.
(8) Rem ove t h e h ou sin g fr om t h e st u b sh a ft (F ig.
(6) In st a ll m et a l ba cku p wa sh er. 14).
(7) In st a ll t h e r et a in er r in g wit h sn a p r in g plier s.
(8) Coa t t h e du st sea l wit h s p e c ia l g re a s e su p-
plied wit h t h e n ew sea l.
(9) In st a ll du st sea l wit h Dr iver 8294 a n d H a n dle
C-4171.
(10) In st a ll n ew pit m a n sh a ft cover o-r in g.
(11) In st a ll pit m a n sh a ft a ssem bly in t o t h e h ou s-
in g.
(12) In st a ll cover bolt s a n d t igh t en t o 62 N·m (46
ft . lbs.).
(13) P er for m over-cen t er r ot a t ion t or qu e a dju st -
m en t .

RACK PI ST ON /VALV E
ASSEM BLY Fig. 14 Housing Removal
1 - STEERING GEAR
2 - STUB SHAFT HOUSING
REMOVAL
(1) Rem ove t h e st eer in g gea r (Refer t o 19 -
STE E RING/GE AR - RE MOVAL).
(2) Clea n exposed en d of pit m a n sh a ft a n d h ou sin g
wit h a wir e br u sh .
(3) Rot a t e t h e st u b sh a ft wit h a wr en ch (F ig.
5)fr om st op t o st op a n d cou n t t h e n u m ber of t u r n s.
19 - 24 GEAR WJ
RACK PI ST ON /VALV E ASSEM BLY (Cont inue d)
(9) Rem ove st u b sh a ft h ou sin g o-r in gs (F ig. 15). (11) P u ll t h e r a ck pist on /va lve a ssem bly ou t of t h e
gea r h ou sin g (F ig. 17).

NOTE: If the rack piston is damage the gear assem-

bly must be replaced.

Fig. 15 O-Rings
1 - LARGE O-RING
2 - SMALL O-RING

(10) Rem ove t h e r a ck pist on /va lve a ssem bly r et a in - Fig. 17 Rack Piston/Valve Assembly
in g r in g wit h sn a p r in g plier s (F ig. 16). 1 - STEERING GEAR
2 - RACK PISTON/VALVE ASSEMBLY

(12) Rem ove t eflon r in gs a n d o-r in g (F ig. 18) fr om

t h e r a ck pist on /va lve a ssem bly.

CAUTION: The rack piston teflon ring and o-ring

must be replaced whenever the assembly is
removed from the housing.

Fig. 16 Retaining Ring

1 - SNAP RING
2 - STUB SHAFT HOUSING
3 - STUB SHAFT
4 - SNAP RING PLIERS
Fig. 18 Teflon Rings And O-Ring
1 - RACK PISTON
2 - VALVE
3 - TEFLON RINGS
4 - TEFLON AND O-RING
WJ GEAR 19 - 25
RACK PI ST ON /VALV E ASSEM BLY (Cont inue d)

INSTALLATION
(1) Lu br ica t e n ew o-r in g a n d t eflon r in gs wit h
power st eer in g flu id a n d in st a ll on t h e r a ck pist on /
va lve a ssem bly.
(2) Lu br ica t e t h e r a ck pist on /va lve a ssem bly wit h
power st eer in g flu id.
(3) Slide t h e a ssem bly in t o t h e gea r h ou sin g.
(4) In st a ll n ew st u b sh a ft h ou sin g o-r in gs a n d
in st a ll t h e h ou sin g. Tigh t en t h e h ou sin g bolt s t o 62
N·m (46 ft . lbs.).
(5) In st a ll n ew o-r in g on t h e pit m a n sh a ft cover.
(6) In st a ll t h e pit m a n sh a ft in t o t h e gea r h ou sin g.
(7) In st a ll t h e pit m a n sh a ft cover bolt s a n d t igh t en
t o 62 N·m (46 ft . lbs.).
(8) P er for m over-cen t er r ot a t ion t or qu e a dju st m en t
(Refer t o 19 - STE E RING/GE AR - ADJ USTME NTS).. Fig. 20 Housing Removal
(9) In st a ll t h e st eer in g gea r (Refer t o 19 - STE E R- 1 - STEERING GEAR
ING/GE AR - INSTALLATION). 2 - HOUSING
(10) F ill t h e power st eer in g pu m p (Refer t o 19 -
STE E RING/P UMP - STANDARD P ROCE DURE ).
INSTALLATION
ST U B SH AFT H OU SI N G NOTE: If stub shaft housing, seal or bearing is dam-
aged the housing must be replaced.
REMOVAL
(1) Gr ea se st u b sh a ft sea l wit h s p e c ia l g re a s e -
NOTE: If stub shaft housing, seal or bearing is dam- su pplied wit h n ew st u b sh a ft h ou sin g.
aged the housing must be replaced. (2) In st a ll n ew st u b sh a ft h ou sin g o-r in gs.
(3) In st a ll h ou sin g on t h e st eer in g gea r.
(1) Rem ove t h e st eer in g gea r (Refer t o 19 - (4) In st a ll t h e h ou sin g bolt s a n d t igh t en t o 62 N·m
STE E RING/GE AR - RE MOVAL). ( 46 ft . lbs.).
(2) Rem ove st u b sh a ft h ou sin g bolt s (F ig. 19). (5) In st a ll t h e st eer in g gea r (Refer t o 19 - STE E R-
(3) Rem ove h ou sin g fr om t h e st eer in g gea r (F ig. ING/GE AR - INSTALLATION).
20). (6) F ill t h e power st eer in g pu m p (Refer t o 19 -
(4) Rem ove st u b sh a ft h ou sin g o-r in gs (F ig. 15). STE E RING/P UMP - STANDARD P ROCE DURE ).

Fig. 19 Stub Shaft Housing

1 - STUB SHAFT HOUSING
2 - BOLTS
3 - STUB SHAFT
19 - 26 LINKAGE WJ

LI N K AGE

TABLE OF CONTENTS
page page

LINKAGE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STEERING LINKAGE – RIGHT HAND DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
(RHD) VEHICLES . . . . . . . . . . . . . . . . . . . . . . 26 PITMAN ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 26 DESCRIPTION .. . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIFICATIONS OPERATION . ... . . . . . . . . . . . . . . . . . . . . . . . 29
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . ... . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . 30
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . 28 TIE ROD END
DAMPER DESCRIPTION .. . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28 OPERATION . ... . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . ... . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DRAG LINK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29

LI N K AGE DESCRIPTION
Th e st eer in g lin ka ge con sist s of a pit m a n a r m ,
dr a g lin k, t ie r od, a n d st eer in g da m pen er (F ig. 2) .
DESCRI PT I ON An a dju st m en t sleeve on t h e t ie r od is u sed t o set
wh eel t oe posit ion . Th e sleeve on t h e dr a g lin k is
STEERING LINKAGE – RIGHT HAND DRIVE u sed for st eer in g wh eel cen t er in g.
(RHD) VEHICLES
CAUTION: If any steering components are replaced
Veh icles equ ipped wit h r igh t h a n d dr ive (RH D)
st eer in g u t ilize t h e sa m e com pon en t s of left h a n d or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
dr ive veh icles. Th e RH D St eer in g lin ka ge is design ed
a s a m ir r or im a ge of left h a n d dr ive lin ka ge wit h t h e tions.
except ion of t h e st eer in g da m per (F ig. 1), wh ich is
m ou n t ed on t h e sa m e side of t h e veh icle wea t h er CAUTION: Components attached with a nut and cot-
RH D or LH D. See figu r e below for r efer en ce. All ter pin must be torqued to specification. Then if the
specifica t ion s a r e t h e sa m e a s LH D. Refer t o Gr ou p slot in the nut does not line up with the cotter pin
19, St eer in g of t h e ga solin e en gin e ser vice m a n u a l for hole, tighten nut until it is aligned. Never loosen the
a ddit ion a l in for m a t ion . nut to align the cotter pin hole.
WJ LINKAGE 19 - 27
LI N K AGE (Cont inue d)

Fig. 1 Right Hand Drive Steering Linkage

1 - PITMAN ARM
2 - STEERING DAMPENER

Fig. 2 Steering Linkage

1 - DRAG LINK
2 - PITMAN ARM
3 - TIE ROD END
4 - TIE ROD
5 - DAMPER
6 - TIE ROD END
19 - 28 LINKAGE WJ
LI N K AGE (Cont inue d)

SPECI FI CAT I ON S
TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Pitman Arm 251 185 —
Shaft Nut
Drag Link 88 65 —
Pitman Arm Nut
Drag Link 47 35 —
Knuckle Nut
Drag Link 41 30 —
Clamp Nuts
Tie Rod 47 35 —
Knuckle Nut
Tie Rod 41 30 —
Clamp Nuts
Steering Damper 88 65 —
Axle Bolt
Steering Damper 41 30 —
Tie Rod Nut

SPECI AL T OOLS DAM PER

STEERING LINKAGE DESCRIPTION
Th e da m per is m ou n t ed t o t h e a xle h ou sin g a n d
t h e t ie r od en d. Th e da m per con sist s of st eel t u be
sh ock a bsor ber wit h a per m a n en t bu sh ed en d.

OPERATION
Th e st eer in g da m per pr ovides st eer in g syst em
da m pin g.

REMOVAL
Puller C-3894–A
(1) Rem ove t h e n u t fr om t h e ba ll st u d a t t h e t ie
r od.
(2) Rem ove t h e st eer in g da m per fr om t h e t ie r od.
(3) Rem ove t h e st eer in g da m per n u t a n d bolt fr om
t h e a xle br a cket (F ig. 3) .

Remover Pitman C-4150A

WJ LINKAGE 19 - 29
DAM PER (Cont inue d)

Fig. 3 Steering Damper Fig. 4 Drag Link

1 - DAMPER 1 - STEERING GEAR
2 - TIE ROD 2 - PITMAN ARM
3 - CLAMP
4 - DRAG LINK
INSTALLATION 5 - CLAMP
(1) In st a ll t h e st eer in g da m per t o t h e a xle br a cket
a n d t ie r od.
(3) Tigh t en t h e n u t a t t h e st eer in g kn u ckle t o 47
(2) In st a ll t h e st eer in g da m per bolt in t h e a xle
N·m (35 ft . lbs.). Tigh t en t h e pit m a n n u t t o 88 N·m
br a cket a n d t igh t en bolt t o 88 N·m (65 ft . lbs.).
(65 ft . lbs.). In st a ll n ew cot t er pin s.
(3) In st a ll t h e n u t a t t h e t ie r od a n d t igh t en t o 41
(4) P osit ion cla m p bolt s t o t h eir or igin a l posit ion
N·m (30 ft . lbs.).
a n d t igh t en t o 41 N·m (30 ft . lbs.).
(5) In st a ll r igh t wh eel a n d t ir e a ssem bly.
DRAG LI N K (6) Rem ove su ppor t a n d lower t h e veh icle.
(7) Cen t er t h e st eer in g wh eel.
DESCRIPTION
Th e dr a g lin k a n d en ds a r e com pr ised of t wo for ged PI T M AN ARM
en ds con n ect ed by a st eel a dju st in g t u be. Th e dr a g
lin k con n ect s t h e st eer in g gea r pit m a n a r m t o t h e
st eer in g kn u ckle. Th e la r ger offset en d is a t t a ch ed t o
DESCRIPTION
Th e pit m a n a r m is a t t a ch ed a t on e en d of t h e
t h e pit m a n a r m .
st eer in g gea r ’s sect or sh a ft . Th e ot h er en d is con -
n ect ed t o t h e dr a g lin k.
OPERATION
Th e sleeve is u sed for st eer in g wh eel cen t er in g.
OPERATION
Th e pit m a n a r m t r a n sfer s r ot a r y m ot ion in t o side
REMOVAL t o side m ot ion .
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove r igh t wh eel a n d t ir e a ssem bly.
(3) Rem ove t h e cot t er pin s a n d n u t s a t t h e r igh t
REMOVAL
(1) Rem ove t h e cot t er pin a n d n u t fr om t h e dr a g
st eer in g kn u ckle a n d pit m a n a r m (F ig. 4) .
lin k a t t h e pit m a n a r m (F ig. 5) .
(4) Rem ove t h e dr a g lin k fr om t h e st eer in g
(2) Rem ove t h e dr a g lin k ba ll st u d fr om t h e pit -
kn u ckle a n d pit m a n a r m P u ller C-3894-A.
m a n a r m wit h a pu ller.
(5) Loosen a dju st m en t sleeve cla m p bolt s a n d
(3) Rem ove t h e n u t a n d wa sh er fr om t h e st eer in g
u n scr ew t h e t ie r od en ds fr om t h e a dju st m en t sleeve.
gea r sh a ft . Ma r k t h e pit m a n sh a ft a n d pit m a n a r m
for in st a lla t ion r efer en ce. Rem ove t h e pit m a n a r m
INSTALLATION fr om st eer in g gea r wit h P u ller C-4150A.
(1) Scr ew t h e t ie r od en ds in t o t h e a dju st m en t
sleeve.
(2) In st a ll t h e dr a g lin k on t o t h e r igh t st eer in g
kn u ckle a n d pit m a n a r m .
19 - 30 LINKAGE WJ
PI T M AN ARM (Cont inue d)
(6) Rem ove t h e t ie r od en ds fr om t h e st eer in g
kn u ckles wit h P u ller C-3894-A..
(7) Loosen t h e a dju st m en t sleeve cla m p bolt s a n d
u n scr ew t h e t ie r od en ds fr om t h e sleeve.

Fig. 5 Pitman Arm

1 - STEERING GEAR
2 - PITMAN ARM

INSTALLATION Fig. 6 Tie Rod Assembly

(1) Align a n d in st a ll t h e pit m a n a r m on st eer in g
1 - TIE ROD END
gea r sh a ft .
2 - CLAMP
(2) In st a ll t h e wa sh er a n d n u t on t h e sh a ft a n d
3 - DAMPER
t igh t en t h e n u t t o 251 N·m (185 ft . lbs.). 4 - TIE ROD
(3) In st a ll dr a g lin k ba ll st u d t o pit m a n a r m . 5 - CLAMP
In st a ll n u t a n d t igh t en t o 88 N·m (65 ft . lbs.). In st a ll 6 - TIE ROD END
a n ew cot t er pin .

T I E ROD EN D
DESCRIPTION
Th e en ds a r e for ged, wit h a lu bed for life ba ll
socket .
OPERATION
Th e t ie r od en ds con n ect t h e dr a g lin k t o t h e wh eel
a ssem bly. Th e t ie r od pr ovides t oe a lign m en t a n d
t r a n sfer s st eer in g in pu t fr om t h e dr a g lin k t o t h e
wh eels.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove wh eel a n d t ir e a ssem blies.
(3) Rem ove t h e da m per n u t fr om t h e t ie r od cla m p
(F ig. 6).
(4) Rem ove t h e da m per fr om t h e t ie r od.
(5) Rem ove t h e cot t er pin s a n d n u t s fr om t h e t ie
r od en ds a t t h e st eer in g kn u ckles (F ig. 6).
INSTALLATION
(1) Scr ew t h e t ie r od en ds in t o t h e a dju st m en t
sleeve.
(2) In st a ll t h e t ie r od on t h e st eer in g kn u ckles a n d
in st a ll t h e n u t s.
(3) Tigh t en t h e n u t s t o 47 N·m (35 ft . lbs.). In st a ll
n ew cot t er pin s a n d ben d en d 60°.
(4) P osit ion t h e a dju st m en t sleeve cla m p bolt s t o
t h eir or igin a l loca t ion a n d t igh t en t o 41 N·m (30 ft .
lbs.).
(5) In st a ll t h e da m per on t h e t ie r od a n d in st a ll
the nut.
(6) Tigh t en t h e n u t t o 41 N·m (30 ft . lbs.). In st a ll
n ew cot t er pin s a n d ben d en d 60°.
(7) In st a ll wh eel a n d t ir e a ssem blies.
(8) Rem ove su ppor t a n d lower t h e veh icle.
(9) P er for m t oe posit ion a dju st m en t .
WJ PUMP 19 - 31

PU M P

TABLE OF CONTENTS
page page

PUMP DESCRIPTION - 1/2” RETURN HOSE . . . . . . 38

DESCRIPTION - 4.0L, 4.7L . . . . . . . . . . . . . . . . 32 DESCRIPTION - 3/8” PRESSURE HOSE . . . . 38
OPERATION DESCRIPTION - 3/8” GEAR OUTLET HOSE . 38
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 32 DESCRIPTION - 3/8” RETURN HOSE . . . . . . 38
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 32 OPERATION
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 33 OPERATION - 1/2” PRESSURE HOSE . . . . . . 38
STANDARD PROCEDURE OPERATION - 1/2” RETURN HOSE . . . . . . . . 38
STANDARD PROCEDURE - INITIAL OPERATION - 3/8” PRESSURE HOSE . . . . . . 39
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 33 OPERATION - 3/8” GEAR OUTLET HOSE . . . 39
STANDARD PROCEDURE - INITIAL OPERATION - 3/8”RETURN HOSE ...... . . 39
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 33 REMOVAL
REMOVAL REMOVAL - 1/2! PRESSURE HOSE ..... . . 39
REMOVAL - 4.0L ENGINE . . . . . . . . . . . . . . . 34 REMOVAL - 1/2! RETURN HOSE . . . . . . . . . . 39
REMOVAL - 4.7L ENGINE . . . . . . . . . . . . . . . 34 REMOVAL - 3/8! PRESSURE HOSE ..... . . 39
INSTALLATION REMOVAL - 3/8! RETURN HOSE . . . . . . . . . . 39
INSTALLATION - 4.0L ENGINE ......... . . 34 REMOVAL - 3/8! GEAR OUTLET HOSE . . . . . 40
INSTALLATION - 4.7L ENGINE ......... . . 34 REMOVAL - INLET COOLER HOSE . . . . . . . . 40
SPECIFICATIONS REMOVAL - OUTLET COOLER HOSE . . . . . . 40
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 35 INSTALLATION
SPECIAL TOOLS INSTALLATION - 1/2! PRESSURE HOSE . . . . 40
POWER STEERING PUMP . . . . . . . . . . . . . . 36 INSTALLATION - 1/2! RETURN HOSE . . . . . . 40
FLUID COOLER INSTALLATION - 3/8! PRESSURE HOSE . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION - 3/8! RETURN HOSE . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION - 3/8! GEAR OUTLET HOSE . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION - INLET COOLER HOSE . . . . 41
HOSES - 4.0L INSTALLATION - OUTLET COOLER HOSE . . 41
DESCRIPTION PULLEY
DESCRIPTION - PRESSURE LINE ...... . . 37 DESCRIPTION
DESCRIPTION - RETURN LINE . . . . . . . . . . . 37 POWER STEERING PUMP PULLEY - 3.1L
OPERATION DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION - PRESSURE LINE . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION - RETURN LINE . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 RESERVOIR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HOSES - 4.7L INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DESCRIPTION
DESCRIPTION - 1/2” PRESSURE HOSE . . . . 38
19 - 32 PUMP WJ

PU M P
DESCRIPTION - 4.0L, 4.7L
H ydr a u lic pr essu r e for t h e power st eer in g syst em
is pr ovided by a belt dr iven power st eer in g pu m p
(F ig. 1) a n d (F ig. 2). Th e pu m p sh a ft h a s a
pr essed-on dr ive pu lley t h a t is belt dr iven by t h e
cr a n ksh a ft pu lley.

Fig. 2 4.7L POWER STEERING PUMP

1 - PRESSURE HOSE QUICK CONNECT NUT
2 - CAP
Fig. 1 Pump With Integral Reservoir 3 - FLUID RESERVOIR
1 - CAP 4 - LOW-PRESSURE RETURN FROM THE COOLER
2 - FLUID RESERVOIR (TYPICAL) 5 - LOW-PRESSURE RETURN FROM THE HYDRAULIC FAN
3 - HIGH-PRESSURE FITTING DRIVE
4 - DRIVE PULLEY 6 - PUMP BODY
5 - PUMP BODY 7 - HIGH PRESSURE FITTING
6 - RESERVOIR CLIP
NOTE: Power steering pumps have different pres-
OPERAT I ON sure rates and are not interchangeable with other
pumps.
OPERATION - 4.7L
Th e power st eer in g pu m p is a con st a n t flow r a t e
OPERATION - 4.0L
a n d displa cem en t , va n e-t ype pu m p. Th e pu m p h a s
Th e power st eer in g pu m p is a con st a n t flow r a t e
in t er n a l pa r t s t h a t oper a t e su bm er ged in flu id. Th e
a n d displa cem en t , va n e-t ype pu m p. Th e pu m p in t er-
flow con t r ol or ifice a n d t h e pr essu r e r elief va lve,
n a l pa r t s oper a t e su bm er ged in flu id. Th e flow con -
wh ich lim it s t h e pu m p pr essu r e, a r e in t er n a l t o t h e
t r ol or ifice is pa r t of t h e h igh pr essu r e lin e fit t in g.
pu m p. Th e r eser voir is a t t a ch ed t o t h e pu m p body
Th e pr essu r e r elief va lve in side t h e flow con t r ol va lve
wit h spr in g clips. Th e power st eer in g pu m p is u sed
lim it s t h e pu m p pr essu r e. Th e r eser voir is a t t a ch ed
t o dr ive t h e h ydr a u lic en gin e coolin g fa n , wh ich sep-
t o t h e pu m p body wit h spr in g clips. Th e power st eer-
a r a t es t h e flow t o t h e fa n ger ot or s a n d t h e power
in g pu m p is con n ect ed t o t h e st eer in g gea r by t h e
st eer in g gea r. Th e power st eer in g pu m p is con n ect ed
pr essu r e a n d r et u r n h oses (F ig. 1).
t o t h e en gin e coolin g fa n by pr essu r e a n d r et u r n
h oses a n d t h e pu m p is con n ect ed t o t h e st eer in g gea r NOTE: Power steering pumps have different pres-
via a r et u r n h ose fr om t h e st eer in g cooler (F ig. 2). sure rates and are not interchangeable with other
pumps.
WJ
PU M P (Cont inue d)
DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) P ossible a r ea s of pu m p lea ka ge (F ig. 3).
Fig. 3 4.0L Power Steering Pump
STAN DARD PROCEDU RE
STANDARD PROCEDURE - INITIAL OPERATION
- 4.0L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler ca p clea n , t h en ch eck t h e flu id level.
Th e dipst ick sh ou ld in dica t e COLD wh en t h e flu id is
a t n or m a l a m bien t t em per a t u r e.
(1) F ill t h e pu m p flu id r eser voir t o t h e pr oper level
a n d let t h e flu id set t le for a t lea st t wo m in u t es.
(2) St a r t t h e en gin e a n d let r u n for a few secon ds
t h en t u r n en gin e off.
(3) Add flu id if n ecessa r y. Repea t t h e a bove pr oce-
du r e u n t il t h e flu id level r em a in s con st a n t a ft er r u n -
n in g t h e en gin e.
(4) Ra ise t h e fr on t wh eels off t h e gr ou n d.
(5) Slowly t u r n t h e st eer in g wh eel r igh t a n d left ,
ligh t ly con t a ct in g t h e wh eel st ops a t lea st 20 t im es.
PUMP 19 - 33
(6) Ch eck t h e flu id level a dd if n ecessa r y.
(7) Lower t h e veh icle, st a r t t h e en gin e a n d t u r n
t h e st eer in g wh eel slowly fr om lock t o lock.
(8) St op t h e en gin e a n d ch eck t h e flu id level a n d
r efill a s r equ ir ed.
(9) If t h e flu id is ext r em ely foa m y or m ilky look-
in g, a llow t h e veh icle t o st a n d a few m in u t es a n d
r epea t t h e pr ocedu r e.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - INITIAL OPERATION
- 4.7L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
NOTE: Remove as much of the old fluid out of the
system as possible with a suction tool or by remov-
ing a hose, When a component has failed. Then
refill it with fresh fluid until it is clean. This may
have to be done more than once.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler ca p clea n , t h en ch eck t h e flu id level.
Th e dipst ick sh ou ld in dica t e COLD wh en t h e flu id is
a t n or m a l a m bien t t em per a t u r e.
(1) F ill t h e pu m p flu id r eser voir t o t h e pr oper level
a n d let t h e flu id set t le for a t lea st t wo m in u t es.
(2) St a r t t h e en gin e a n d let r u n for a few secon ds
t h en t u r n en gin e off.
(3) Add flu id if n ecessa r y. Repea t t h e a bove pr oce-
du r e u n t il t h e flu id level r em a in s con st a n t a ft er r u n -
n in g t h e en gin e.
(4) Ra ise t h e fr on t wh eels off t h e gr ou n d.
(5) Slowly t u r n t h e st eer in g wh eel r igh t a n d left ,
ligh t ly con t a ct in g t h e wh eel st ops a t lea st 20 t im es.
(6) Ch eck t h e flu id level a dd if n ecessa r y.
(7) Lower t h e veh icle, st a r t t h e en gin e, a n d u se
t h e DRB III t o a ct iva t e t h e h ydr a u lic fa n on fu ll fa n
oper a t ion .
(8) Tu r n t h e st eer in g wh eel slowly fr om lock t o lock.
(9) St op t h e en gin e, ch eck t h e flu id level a n d r efill
a s r equ ir ed a n d r epea t t h e pr ocess
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(10) If t h e flu id is ext r em ely foa m y or m ilky look-
in g, a llow t h e veh icle t o st a n d a few m in u t es a n d
r epea t t h e pr ocedu r e.
19 - 34 PUMP WJ
PU M P (Cont inue d)
(11) Wh ile t h e veh icle is in pa r k, u se t h e DRB III
t o a ct iva t e t h e h ydr a u lic fa n t o fu ll fa n oper a t ion a n d
br iefly r ev t h e en gin e u p t o 3000 r pm t o fu lly en ga ge
t h e h ydr a u lic fa n .
(12) Ch eck t h e flu id level a dd if n ecessa r y.

REM OVAL
REMOVAL - 4.0L ENGINE
(1) Rem ove ser pen t in e dr ive belt ,(Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(2) Rem ove pr essu r e a n d r et u r n h oses fr om pu m p
a n d dr a in t h e pu m p.
(3) Loosen t h e pu m p br a cket bolt a t t h e en gin e block.
(4) Rem ove 3 pu m p m ou n t in g bolt s (F ig. 4)
t h r ou gh pu lley a ccess h oles.
(5) Tilt pu m p down wa r d a n d r em ove fr om en gin e.
(6) Rem ove pu lley fr om pu m p.
Fig. 5 Pump Mounting
1 - LEFT CYLINDER HEAD
2 - PUMP

I N STALLAT I ON
INSTALLATION - 4.0L ENGINE
(1) In st a ll pu lley on pu m p.
(2) In st a ll pu m p on t h e en gin e m ou n t in g br a cket .
(3) In st a ll 3 pu m p m ou n t in g bolt s a n d t igh t en t o
27 N·m (20 ft . lbs.).
(4) Tigh t en pu m p br a cket bolt t o 57 N·m (42 ft .
lbs.).
(5) In st a ll t h e pr essu r e lin e on t h e pu m p a n d
t igh t en t o 28 N·m (21 ft . lbs.).
(6) In st a ll t h e r et u r n h oses on pu m p.
(7) In st a ll t h e dr ive belt ,(Refer t o 7 - COOLING/
ACCE SSORY DRIVE /DRIVE BE LTS - INSTALLA-
TION).
(8) Add power st eer in g flu id,(Refer t o 19 - STE E R-
ING/P UMP - STANDARD P ROCE DURE ).
Fig. 4 PUMP MOUNTING – 4.0L
1 - PUMP ASSEMBLY INSTALLATION - 4.7L ENGINE
2 - PUMP BRACKET (1) P osit ion t h e pu m p on t h e left cylin der h ea d
a n d in st a ll bolt s t h r ou gh pu lley a ccess h oles. Tigh t en
REMOVAL - 4.7L ENGINE bolt s t o 28 N·m (21 ft . lbs.).
(1) Rem ove t h e ser pen t in e dr ive belt ,(Refer t o 7 - (2) In st a ll t h e pr essu r e a n d r et u r n h oses t o pu m p.
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - (3) In st a ll ser pen t in e dr ive belt ,(Refer t o 7 -
RE MOVAL). COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
(2) Rem ove t h e pr essu r e a n d r et u r n h oses fr om INSTALLATION).
pu m p a n d dr a in pu m p. (4) Add power st eer in g flu id,(Refer t o 19 - STE E R-
(3) Rem ove 3 pu m p m ou n t in g bolt s t h r ou gh pu lley ING/P UMP - STANDARD P ROCE DURE ).
a ccess h oles (F ig. 5).
(4) Rem ove t h e pu m p fr om t h e veh icle.
WJ PUMP 19 - 35
PU M P (Cont inue d)

SPECI FI CAT I ON S

TORQUE CHART
T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Power Steering Pump 57 42 —
Bracket Bolt-4.0L
Power Steering Pump 28 21 250
Pump Bolts-4.0L
Power Steering Pump 28 21 250
Pump Bolts-4.7L
Power Steering Pump 75 55 —
Flow Control Valve
Power Steering Pump 20-38 14-28 —
Pressure Line
4.0L
Power Steering Pump 47 35 416
Pressure Line
4.7L
Power Steering Pump 20-38 14-28 —
Return Line
4.0L & 4.7L
High Pressure Inlet Hose 49 36 —
to Hydraulic Fan
Drive—1/2 inch Fitting
High Pressure Outlet 29 21.5 —
Hose to Steering
Gear—3/8 inch Fitting
Power Steering Cooler 22.5 17 200
Lines
at the Cooler
19 - 36 PUMP WJ
PU M P (Cont inue d)

SPECI AL T OOLS
POWER STEERING PUMP

Installer, Power Steering Pulley C-4063B

FLU I D COOLER

Analyzer Set, Power Steering Flow/Pressure 6815

DESCRIPTION
4.7L m odels of t h is veh icle a r e equ ipped wit h a
cooler for t h e power st eer in g syst em flu id. Th e power
st eer in g flu id cooler is loca t ed a t t h e fr on t of t h e
veh icle. It is m ou n t ed t o t h e r a dia t or su ppor t ju st
for wa r d of t h e a ir-con dit ion in g con den ser a n d ju st
r ea r wa r d of t h e fr on t fa scia (F ig. 6). Th e cooler is
posit ion ed so it is in t h e a ir flow t h r ou gh t h e fr on t
fa scia of t h e veh icle.

Adapters, Power Steering Flow/Pressure Tester

6893

Fig. 6 POWER STEERING FLUID COOLER

4.7L HYDRAULIC POWER STEERING TEST 1 - POWER STEERING COOLER
ADAPTER KIT - 8630 2 - POWER STEERING COOLER LINES CLIP

REMOVAL
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Dr a in t h e power st eer in g flu id ou t of t h e r eser-
voir.
(3) Rem ove t h e fr on t fa scia gr ille a ssem bly,(Refer
t o 13 - F RAME S & BUMP E RS/BUMP E RS/F RONT
FASCIA - RE MOVAL).
(4) Rem ove t h e gr ille open in g r ein for cem en t pa n el
Puller C-4333 (5) P la ce a dr a in pa n u n der t h e cooler.
(6) Discon n ect t h e lower h ose a t cooler (F ig. 6).
(7) Discon n ect t h e u pper h ose a t cooler (F ig. 6).
(8) Rem ove t h e t h r ee cooler m ou n t in g bolt s (F ig.
6).
(9) Rem ove t h e cooler fr om t h e veh icle.
WJ PUMP 19 - 37
FLU I D COOLER (Cont inue d)

INSTALLATION
(1) P osit ion a n d in st a ll t h e power st eer in g cooler
t o t h e veh icle.
(2) In st a ll t h e t h r ee m ou n t in g br a cket bolt s (F ig.
6).
(3) Recon n ect t h e u pper h ose a t cooler (F ig. 6).
(4) Recon n ect t h e lower h ose a t cooler (F ig. 6).
(5) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
(6) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
(7) St a r t en gin e a n d ch eck for lea ks.
(8) In st a ll t h e gr ille open in g r ein for cem en t pa n el
(9) In st a ll t h e fr on t fa scia gr ille,(Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/F RONT FASCIA
- INSTALLATION).
REMOVAL
(1) Dr a in t h e power st eer in g flu id fr om t h e r eser-
voir.
(2) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(3) Discon n ect t h e power st eer in g pr essu r e h ose
fr om t h e power st eer in g pu m p a n d t h en t h e power
st eer in g gea r (F ig. 7).
(4) Discon n ect t h e power st eer in g r et u r n h ose fr om
t h e power st eer in g cooler a n d t h e r eser voir.

H OSES - 4 .0 L

DESCRI PT I ON
DESCRIPTION - PRESSURE LINE
Th e h ose con sist s of t wo m et a l en ds a n d r u bber
cen t er sect ion t h a t con t a in s a t u n in g ca ble. Th e
pu m p en d u ses a qu ick con n ect fit t in g. Lu bir ca t ion
m u st be u sed on t h e qu ick con n ect n u t a n d o-r in g
wh en in st a llin g. Fig. 7 POWER STEERING HOSES
1 - RETURN HOSE
DESCRIPTION - RETURN LINE 2 - HIGH PRESSURE HOSE
P ower st eer in g r et u r n lin e is a h ose wh ich is 3 - STEERING GEAR
cla m ped a t t h e pu m p a n d t h e gea r.
(5) Rem ove t h e h oses fr om t h e veh icle.
OPERAT I ON
INSTALLATION
(1) In st a ll t h e h oses t o t h e veh icle.
OPERATION - PRESSURE LINE (2) Recon n ect t h e power st eer in g r et u r n h ose t o
P ower st eer in g pr essu r e lin e, is u sed t o t r a n sfer
t h e power st eer in g cooler a n d t h e r eser voir.
h igh pr essu r e power st eer in g flu id, fr om t h e power
(3) Recon n ect t h e power st eer in g pr essu r e h ose t o
st eer in g pu m p t o t h e power st eer in g gea r on t h e
t h e power st eer in g pu m p a n d t h en t h e power st eer-
4.0L. Th e 4.7L power st eer in g pr essu r e lin e, is u sed
in g gea r.
t o t r a n sfer h igh pr essu r e power st eer in g flu id, fr om
(4) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
t h e power st eer in g pu m p t o t h e en gin e coolin g fa n
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
a n d t h e st eer in g gea r.
INSTALLATION).
(5) Refill t h e power st eer in g flu id a n d bleed t h e
OPERATION - RETURN LINE syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
P ower st eer in g r et u r n lin e, is u sed t o t r a n sfer low DARD P ROCE DURE ).
pr essu r e power st eer in g flu id, fr om t h e power st eer-
in g gea r t o t h e power st eer in g pu m p.
19 - 38 PUMP WJ

H OSES - 4 .7 L

DESCRI PT I ON
DESCRIPTION - 1/2” PRESSURE HOSE
Th e h ose con sist s of t wo m et a l en ds a n d a r u bber
cen t er wit h qu ick con n ect n u t s a t bot h en ds. Th e
h ose con n ect s t h e power st eer in g pu m p t o t h e
h ydr a u lic fa n m ot or a n d is clipped t o t h e fa n sh r ou d
(F ig. 8). Lu br ica t ion m u st be u sed on t h e qu ick con -
n ect n u t s a n d o-r in gs wh en in st a llin g.

Fig. 9 1/2" RETURN HOSE

1 - 1/2! RETURN HOSE
2 - HOSE CLAMP

Fig. 8 1/2" PRESSURE HOSE

1 - 1/2! PRESSURE HOSE
2 - POWER STEERING PUMP
3 - STEERING GEAR

DESCRIPTION - 1/2” RETURN HOSE

Th e fa n m ot or r et u r n lin e is a m olded r u bber h ose
t h a t is cla m ped a t t h e h ydr a u lic m ot or a n d t h e power
Fig. 10 3/8" PRESSURE HOSE
st eer in g r eser voir (F ig. 9).
1 - 3/8! PRESSURE HOSE
2 - STEERING GEAR
DESCRIPTION - 3/8” PRESSURE HOSE
Th e h ose con sist s of t wo m et a l en ds a n d t wo r u b-
ber sect ion s on e of wh ich con t a in s a t u n in g ca ble OPERAT I ON
(F ig. 10). Th e h ose is clipped in t wo pla ces t o t h e fa n
sh r ou d. Lu br ica t ion m u st be u sed on t h e o-r in gs OPERATION - 1/2” PRESSURE HOSE
wh en in st a llin g. Th e 1/2” pr essu r e h ose is u sed t o t r a n sfer h igh
pr essu r e power st eer in g flu id fr om t h e power st eer-
DESCRIPTION - 3/8” GEAR OUTLET HOSE in g pu m p t o t h e en gin e coolin g fa n m ot or (F ig. 8).
Th e gea r ou t let lin e con sist s of a m et a l sect ion t h a t
con n ect s t o t h e gea r a n d a r u bber sect ion t h a t cla m ps OPERATION - 1/2” RETURN HOSE
t o t h e st eer in g cooler in let t u be (F ig. 11). Th e power st eer in g r et u r n lin e r et u r n s low pr es-
su r e excess flow fr om t h e h ydr a u lic fa n m ot or ba ck t o
DESCRIPTION - 3/8” RETURN HOSE t h e power st eer in g pu m p (F ig. 9).
Th e r et u r n h ose is a for m ed r u bber h ose t h a t con -
n ect s t h e st eer in g cooler ou t let t u be t o t h e power
st eer in g r eser voir (F ig. 12). It is cla m ped a t bot h
en ds.
WJ PUMP 19 - 39
H OSES - 4 .7 L (Cont inue d)

REM OVAL
REMOVAL - 1/2" PRESSURE HOSE
(1) Dr a in t h e power st eer in g flu id fr om t h e r eser voir.
(2) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Rem ove t h e m et a l skid pla t e.
(5) Discon n ect t h e h igh pr essu r e h ose fr om t h e
h ydr a u lic fa n m ot or (F ig. 8).
(6) Discon n ect t h e h igh pr essu r e h ose fr om t h e
power st eer in g pu m p (F ig. 8).
(7) Rem ove t h e h ose fr om t h e clipped posit ion on
t h e fa n sh r ou d.
(8) Rem ove t h e h ose fr om t h e veh icle.
Fig. 11 3/8" GEAR OUTLET HOSE
1 - HOSE CLAMP REMOVAL - 1/2" RETURN HOSE
2 - 3/8! GEARR OUTLET HOSE (1) Dr a in t h e power st eer in g flu id fr om t h e r eser-
voir.
(2) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Rem ove t h e m et a l skid pla t e.
(5) Discon n ect t h e r u bber r et u r n h ose fr om t h e
h ydr a u lic fa n m ot or (F ig. 9).
(6) Discon n ect t h e r u bber r et u r n h ose fr om t h e
power st eer in g r eser voir .
(7) Rem ove t h e h ose fr om t h e veh icle.

REMOVAL - 3/8" PRESSURE HOSE

(1) Dr a in t h e power st eer in g flu id fr om t h e r eser-
voir.
(2) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
Fig. 12 3/8" RETURN HOSE RE MOVAL).
(3) Ra ise a n d su ppor t t h e veh icle.
1 - HOSE CLAMP
(4) Rem ove t h e m et a l skid pla t e.
2 - 3/8! RETURN HOSE
3 - HYDRAULIC COOLING FAN MOTOR
(5) Discon n ect t h e h igh pr essu r e h ose fr om t h e
h ydr a u lic fa n m ot or (F ig. 10).
(6) Discon n ect t h e h igh pr essu r e h ose fr om t h e
OPERATION - 3/8” PRESSURE HOSE power st eer in g gea r (F ig. 10).
H igh pr essu r e power st eer in g flu id is t r a n sm it t ed (7) Rem ove t h e h ose fr om t h e clipped posit ion on
fr om t h e h ydr a u lic fa n m ot or t o t h e st eer in g gea r by t h e fa n sh r ou d.
t h e 3/8” st eer in g lin e. (8) Rem ove t h e h ose fr om t h e veh icle.

OPERATION - 3/8” GEAR OUTLET HOSE REMOVAL - 3/8" RETURN HOSE

Th e gea r ou t let h ose t r a n sm it s power st eer in g flu id
u n der m oder a t e low pr essu r e t o t h e power st eer in g
cooler in let t u be.
OPERATION - 3/8”RETURN HOSE
Low pr essu r e power st eer in g flu id is t r a n sm it t ed
fr om t h e st eer in g cooler ba ck t o t h e power st eer in g
pu m p by t h e 3/8” r et u r n h ose.
(1) Dr a in t h e power st eer in g flu id fr om t h e r eser-
voir.
(2) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Discon n ect t h e r u bber h ose fr om t h e st eer in g
cooler ou t let t u be (F ig. 12).
19 - 40 PUMP
H OSES - 4 .7 L (Cont inue d)
(5) Discon n ect t h e r u bber h ose fr om t h e power
st eer in g r eser voir (F ig. 12).
(6) Rem ove t h e h ose fr om t h e veh icle.
REMOVAL - 3/8" GEAR OUTLET HOSE
(1) Dr a in t h e power st eer in g flu id fr om t h e r eser-
voir.
(2) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Discon n ect t h e r u bber h ose fr om t h e st eer in g
cooler in let t u be (F ig. 11).
(5) Discon n ect t h e m et a l t u be fr om t h e power
st eer in g gea r (F ig. 11).
(6) Rem ove t h e h ose fr om t h e veh icle.
REMOVAL - INLET COOLER HOSE
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Dr a in t h e power st eer in g flu id ou t of t h e r eser-
voir.
(3) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(4) Rem ove t h e fr on t fa scia gr ille a ssem bly,(Refer
t o 13 - F RAME S & BUMP E RS/BUMP E RS/F RONT
FASCIA - RE MOVAL).
(5) Rem ove t h e gr ille open in g r ein for cem en t pa n el
(6) P la ce a dr a in pa n u n der t h e cooler.
(7) Discon n ect t h e lower h ose a t cooler (F ig. 6).
(8) Discon n ect t h e cooler h ose a t t h e gea r.
(9) Rem ove t h e br a cket h oldin g t h e cooler h oses
(F ig. 13).
(10) Rem ove t h e cooler h ose fr om t h e veh icle.
Fig. 13 COOLER HOSES MOUNTING BRACKET
1 - RADIATOR
2 - COOLER HOSES MOUNTING BRACKET
2 - COOLER HOSE
WJ
REMOVAL - OUTLET COOLER HOSE
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Dr a in t h e power st eer in g flu id ou t of t h e r eser-
voir.
(3) Rem ove t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
RE MOVAL).
(4) Rem ove t h e fr on t fa scia gr ille a ssem bly,(Refer
t o 13 - F RAME S & BUMP E RS/BUMP E RS/F RONT
FASCIA - RE MOVAL).
(5) Rem ove t h e gr ille open in g r ein for cem en t pa n el
(6) P la ce a dr a in pa n u n der t h e cooler.
(7) Discon n ect t h e u pper h ose a t cooler (F ig. 6).
(8) Discon n ect t h e cooler h ose a t t h e r eser voir.
(9) Rem ove t h e br a cket h oldin g t h e cooler h oses
(F ig. 13).
(10) Rem ove t h e cooler h ose fr om t h e veh icle.
I N STALLAT I ON
INSTALLATION - 1/2" PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) In st a ll t h e h oses t o t h e veh icle.
(2) Recon n ect t h e h igh pr essu r e h ose t o t h e power
st eer in g pu m p (F ig. 8) Tigh t en t h e h ose t o 22.5 N·m
(17 ft .lbs.).
(3) Recon n ect t h e h igh pr essu r e h ose t o t h e
h ydr a u lic fa n m ot or (F ig. 8) Tigh t en t h e h ose t o 22.5
N·m (17 ft .lbs.).
(4) In st a ll t h e h ose t o t h e clipped posit ion on t h e
fa n sh r ou d.
(5) In st a ll t h e m et a l skid pla t e.
(6) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(7) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
INSTALLATION - 1/2" RETURN HOSE
(1) In st a ll t h e h oses t o t h e veh icle.
(2) Recon n ect t h e r u bber r et u r n h ose t o t h e power
st eer in g r eser voir (F ig. 9) Tigh t en t h e h ose cla m p.
(3) Recon n ect t h e r u bber r et u r n h ose t o t h e
h ydr a u lic fa n m ot or (F ig. 9) Tigh t en t h e h ose.
(4) In st a ll t h e m et a l skid pla t e.
(5) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(6) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
WJ
H OSES - 4 .7 L (Cont inue d)
INSTALLATION - 3/8" PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) In st a ll t h e h oses t o t h e veh icle.
(2) Recon n ect t h e h igh pr essu r e h ose t o t h e
h ydr a u lic fa n m ot or (F ig. 10) Tigh t en t h e h ose t o
22.5 N·m (17 ft .lbs.).
(3) Recon n ect t h e h igh pr essu r e h ose t o t h e power
st eer in g gea r (F ig. 10) Tigh t en t h e h ose t o 22.5 N·m
(17 ft .lbs.).
(4) In st a ll t h e h ose t o t h e clipped posit ion on t h e
fa n sh r ou d.
(5) In st a ll t h e m et a l skid pla t e.
(6) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(7) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
INSTALLATION - 3/8" RETURN HOSE
(1) In st a ll t h e h oses t o t h e veh icle.
(2) Recon n ect t h e r u bber h ose t o t h e st eer in g
cooler ou t let t u be (F ig. 12) Tigh t en t h e h ose cla m p.
(3) Recon n ect t h e r u bber h ose t o t h e power st eer-
in g r eser voir (F ig. 12) Tigh t en t h e h ose cla m p.
(4) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(5) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
INSTALLATION - 3/8" GEAR OUTLET HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) In st a ll t h e h oses t o t h e veh icle.
(2) Recon n ect t h e r u bber h ose t o t h e st eer in g
cooler in let t u be (F ig. 11) Tigh t en t h e h ose cla m p.
(3) Recon n ect t h e m et a l t u be t o t h e power st eer in g
gea r (F ig. 11) Tigh t en t h e h ose t o 22.5 N·m (17 ft .lbs.).
(4) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(5) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
INSTALLATION - INLET COOLER HOSE
(1) In st a ll t h e cooler h ose t o t h e veh icle.
(2) Recon n ect t h e cooler h ose a t t h e gea r.
(3) Recon n ect t h e lower h ose a t cooler (F ig. 6).
Tigh t en t h e h ose t o 22.5 N·m (17 ft .lbs.)
(4) In st a ll t h e br a cket h oldin g t h e cooler h oses
(F ig. 13).
PUMP 19 - 41
(5) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(6) In st a ll t h e gr ille open in g r ein for cem en t pa n el
(7) In st a ll t h e fr on t fa scia gr ille a ssem bly, (Refer t o
13 - F RAME S & BUMP E RS/BUMP E RS/F RONT
FASCIA - INSTALLATION).
(8) Recon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(9) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
INSTALLATION - OUTLET COOLER HOSE
(1) In st a ll t h e cooler h ose t o t h e veh icle.
(2) Recon n ect t h e cooler h ose a t t h e r eser voir.
(3) Recon n ect t h e u pper h ose a t t h e cooler (F ig. 6).
Tigh t en t h e h ose t o 22.5 N·m (17 ft . lbs.)
(4) In st a ll t h e br a cket h oldin g t h e cooler h oses
(F ig. 13). Tigh t en t h e br a cket t o 22.5 N·m (17 ft . lbs.)
(5) In st a ll t h e a ir box,(Refer t o 9 - E NGINE /AIR
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
INSTALLATION).
(6) In st a ll t h e gr ille open in g r ein for cem en t pa n el
(7) In st a ll t h e fr on t fa scia gr ille a ssem bly, (Refer t o
13 - F RAME S & BUMP E RS/BUMP E RS/F RONT
FASCIA - INSTALLATION).
(8) Recon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(9) Refill t h e power st eer in g flu id a n d bleed t h e
syst em ,(Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE ).
PU LLEY
DESCRI PT I ON
POWER STEERING PUMP PULLEY - 3.1L
DIESEL
To ser vice t h e power st eer in g pu m p pu lley on t h e
3.1L t u r bo diesel en gin e. Refer t o t h e power st eer in g
pu m p r em ova l a n d in st a lla t ion pr ocedu r e in t h is
gr ou p. Th e pu lley m u st be r em oved t o ser vice t h e
pu m p a ssem bly. Det a iled in st r u ct ion s a r e pr ovided in
t h e pu m p pr ocedu r e.
REMOVAL
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Rem ove pu m p a ssem bly.
(2) Rem ove pu lley fr om pu m p wit h P u ller C-4333
or equ iva len t pu ller (F ig. 14).
19 - 42 PUMP WJ
PU LLEY (Cont inue d)
(3) In st a ll pu m p a ssem bly.
(4) Wit h Ser pen t in e Belt , r u n en gin e u n t il wa r m (5
m in .) a n d n ot e a n y belt ch ir p. If ch ir p exist s, m ove
pu lley ou t wa r d a ppr oxim a t ely 0.5 m m (0.020 in .). If
n oise in cr ea ses, pr ess on 1.0 m m (0.040 in .). B e
c a re fu l th a t p u lle y d o e s n o t c o n ta c t m o u n tin g
bo lts .

RESERV OI R
REMOVAL
(1) Rem ove power st eer in g pu m p.
(2) Clea n ext er ior of pu m p.
(3) Cla m p t h e pu m p body in a soft ja w vice.

Fig. 14 Pulley Removal NOTE: Use new retaining clips for installation.
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333 (4) P r y u p t a b a n d slide t h e r et a in in g clips off (F ig.
16).

INSTALLATION
NOTE: The pulley is marked front for installation.

CAUTION: On vehicles equipped with the 4.0L or

4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.

(1) Repla ce pu lley if ben t , cr a cked, or loose.

(2) In st a ll pu lley on pu m p wit h In st a ller C-4063-B
or equ iva len t in st a ller (F ig. 15). Th e fr on t edge of t h e
pu lley h u b m u st be flu sh wit h t h e en d of t h e sh a ft .
E n su r e t h e t ool a n d pu lley a r e a lign ed wit h t h e
pu m p sh a ft .

Fig. 16 Pump Reservoir Clips

1 - RESERVOIR
2 - RETAINING CLIPS

(5) Rem ove flu id r eser voir fr om pu m p body.

Rem ove a n d disca r d O-r in g sea l.

INSTALLATION
(1) Lu br ica t e n ew O-r in g Sea l wit h Mopa r P ower
St eer in g F lu id or equ iva len t .
(2) In st a ll O-r in g sea l in h ou sin g.
(3) In st a ll r eser voir on t o h ou sin g.
Fig. 15 Pulley Installation (4) Slide a n d t a p in n e w r eser voir r et a in er clips
1 - POWER STEERING PUMP DRIVE PULLEY u n t il t a b locks t o h ou sin g.
2 - SPECIAL TOOL C-4063–B (5) In st a ll power st eer in g pu m p.
(6) Add power st eer in g flu id,(Refer t o 19 - STE E R-
ING/P UMP - STANDARD P ROCE DURE ).
WJ TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE

TABLE OF CON T EN T S

page page

AUTOMATIC TRANSMISSION - 42RE . . . . . . . . . . 1 TRANSFER CASE - NV242 . . . . . . . . . . . . . . . . 280

AUTOMATIC TRANSMISSION - 545RFE . . . . . . 177 TRANSFER CASE - NV247 . . . . . . . . . . . . . . . . 315

AU T OM AT I C T RAN SM I SSI ON - 4 2 RE

TABLE OF CONTENTS
page page

AUTOMATIC TRANSMISSION - 42RE BANDS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DIAGNOSIS AND TESTING ADJUSTMENTS
DIAGNOSIS AND TESTING - AUTOMATIC ADJUSTMENT - BANDS . . . . . . . . . . . . . . . . 62
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 11 BRAKE TRANSMISSION SHIFT INTERLOCK
DIAGNOSIS AND TESTING - PRELIMINARY . 11 MECHANISM
DIAGNOSIS AND TESTING - ROAD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 63
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DIAGNOSIS AND TESTING - HYDRAULIC DIAGNOSIS AND TESTING - BRAKE
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . 12 TRANSMISSION SHIFT INTERLOCK . . . . . . . 63
DIAGNOSIS AND TESTING - AIR CHECKING ADJUSTMENTS - BRAKE TRANSMISSION
TRANSMISSION CLUTCH AND BAND SHIFT INTERLOCK . . . . . . . . . . . . . . . . . . . . 64
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 ELECTRONIC GOVERNOR
DIAGNOSIS AND TESTING - CONVERTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . . 15 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DIAGNOSIS AND TESTING - DIAGNOSIS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
STANDARD PROCEDURE - ALUMINUM EXTENSION HOUSING BUSHING
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 29 EXTENSION HOUSING SEAL
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FLUID AND FILTER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41 DIAGNOSIS AND TESTING
SCHEMATICS AND DIAGRAMS DIAGNOSIS AND TESTING - EFFECTS OF
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . 43 INCORRECT FLUID LEVEL . . . . . . . . . . . . . . 69
SPECIFICATIONS DIAGNOSIS AND TESTING - CAUSES OF
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 55 BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . . 69
SPECIAL TOOLS DIAGNOSIS AND TESTING - FLUID
RE TRANSMISSIONS . . . . . . . . . . . . . . . . . . 57 CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 70
ACCUMULATOR STANDARD PROCEDURE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60 STANDARD PROCEDURE - FLUID LEVEL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
21 - 2 AUTOMATIC TRANSMISSION - 42RE
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . . 71
STANDARD PROCEDURE - TRANSMISSION
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FRONT CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FRONT SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 77
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
ADJUSTMENTS - GEARSHIFT CABLE . . . . . . . 79
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 80
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK . . . . . . . . . . . . . . . . . . . . . . 81
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 81
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
OUTPUT SHAFT FRONT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OUTPUT SHAFT REAR BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OVERDRIVE CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
OVERDRIVE OFF SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS . . . . . . . . . . . . . . . 87
OVERDRIVE UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 88
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 105
WJ
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 106
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PARK LOCK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH . . . . . . . . . . . . . . . . . . . 109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 110
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 110
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 112
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 112
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
REAR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 119
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 120
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
REAR SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 122
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 122
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 123
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 123
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126
SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126
THROTTLE VALVE CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE . . . . . . . . . . . . . . . . . . . . . . . 126
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 128
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 132
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 134
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 3

STANDARD PROCEDURE - TORQUE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

CONVERTER DRAINBACK VALVE . . . . . . . . 134 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 155
TRANSMISSION TEMPERATURE SENSOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 134 INSPECTION ............. . . . . . . . . . . . . 166
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 134 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
VALVE BODY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 175
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 135 ADJUSTMENTS - VALVE BODY . . . . . . . . . . . 175
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 139

AU T OM AT I C T RAN SM I SSI ON - Th e t r a n sm ission con t a in s a fr on t , r ea r, a n d dir ect

4 2 RE
DESCRIPTION
Th e 42RE is a fou r speed fu lly a u t om a t ic t r a n sm is-
sion (F ig. 1) wit h a n elect r on ic gover n or. Th e 42RE is
equ ipped wit h a lock-u p clu t ch in t h e t or qu e con -
ver t er. F ir st t h r ou gh t h ir d gea r r a n ges a r e pr ovided
by t h e clu t ch es, ba n ds, over r u n n in g clu t ch , a n d pla n -
et a r y gea r set s in t h e t r a n sm ission . F ou r t h gea r
r a n ge is pr ovided by t h e over dr ive u n it t h a t con t a in s
a n over dr ive clu t ch , dir ect clu t ch , pla n et a r y gea r set ,
a n d over r u n n in g clu t ch .
clu t ch wh ich fu n ct ion a s t h e in pu t dr ivin g com po-
n en t s. It a lso con t a in s t h e kickdown (fr on t ) a n d t h e
low/r ever se (r ea r ) ba n ds wh ich , a lon g wit h t h e over-
r u n n in g clu t ch a n d over dr ive clu t ch , ser ve a s t h e
h oldin g com pon en t s. Th e dr ivin g a n d h oldin g com po-
n en t s com bin e t o select t h e n ecessa r y pla n et a r y gea r
com pon en t s, in t h e fr on t , r ea r, or over dr ive pla n et a r y
gea r set , t r a n sfer t h e en gin e power fr om t h e in pu t
sh a ft t h r ou gh t o t h e ou t pu t sh a ft .
Th e va lve body is m ou n t ed t o t h e lower side of t h e
t r a n sm ission a n d con t a in s t h e va lves t o con t r ol pr es-
su r e r egu la t ion , flu id flow con t r ol, a n d clu t ch /ba n d
a pplica t ion . Th e oil pu m p is m ou n t ed a t t h e fr on t of
t h e t r a n sm ission a n d is dr iven by t h e t or qu e con -
ver t er h u b. Th e pu m p su pplies t h e oil pr essu r e n ec-
essa r y for clu t ch /ba n d a ct u a t ion a n d t r a n sm ission
lu br ica t ion .
21 - 4 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

Fig. 1 42RE Transmission

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 5
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
1 - CONVERTER CLUTCH 15 - HOUSING
2 - TORQUE CONVERTER 16 - REAR BEARING
3 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 17 - OUTPUT SHAFT
4 - FRONT BAND 18 - SEAL
5 - FRONT CLUTCH 19 - OVERDRIVE OVERRUNNING CLUTCH
6 - DRIVING SHELL 20 - OVERDRIVE PLANETARY GEAR
7 - REAR BAND 21 - DIRECT CLUTCH SPRING
8 - TRANSMISSION OVERRUNNING CLUTCH 22 - OVERDRIVE CLUTCH PISTON
9 - OVERDRIVE UNIT 23 - VALVE BODY ASSEMBLY
10 - PISTON RETAINER 24 - FILTER
11 - OVERDRIVE CLUTCH 25 - FRONT PLANETARY GEAR
12 - DIRECT CLUTCH 26 - REAR CLUTCH
13 - INTERMEDIATE SHAFT 27 - TRANSMISSION
14 - FRONT BEARING 28 - REAR PLANETARY GEAR

IDENTIFICATION OPERATION
Tr a n sm ission iden t ifica t ion n u m ber s a r e st a m ped Th e a pplica t ion of ea ch dr ivin g or h oldin g com po-
on t h e left side of t h e ca se ju st a bove t h e oil pa n ga s- n en t is con t r olled by t h e va lve body ba sed u pon t h e
ket su r fa ce (F ig. 2). Refer t o t h is in for m a t ion wh en m a n u a l lever posit ion , t h r ot t le pr essu r e, a n d gover-
or der in g r epla cem en t pa r t s. n or pr essu r e. Th e gover n or pr essu r e is a va r ia ble
pr essu r e in pu t t o t h e va lve body a n d is on e of t h e
sign a ls t h a t a sh ift is n ecessa r y. F ir st t h r ou gh fou r t h
gea r a r e obt a in ed by select ively a pplyin g a n d r elea s-
in g t h e differ en t clu t ch es a n d ba n ds. E n gin e power is
t h er eby r ou t ed t o t h e va r iou s pla n et a r y gea r a ssem -
blies wh ich com bin e wit h t h e over r u n n in g clu t ch
a ssem blies t o gen er a t e t h e differ en t gea r r a t ios. Th e
t or qu e con ver t er clu t ch is h ydr a u lica lly a pplied a n d
is r elea sed wh en flu id is ven t ed fr om t h e h ydr a u lic
cir cu it by t h e t or qu e con ver t er con t r ol (TCC) solen oid
on t h e va lve body. Th e t or qu e con ver t er clu t ch is con -
t r olled by t h e P ower t r a in Con t r ol Modu le (P CM). Th e
t or qu e con ver t er clu t ch en ga ges in fou r t h gea r, a n d
in t h ir d gea r u n der va r iou s con dit ion s, su ch a s wh en
t h e O/D swit ch is OF F, wh en t h e veh icle is cr u isin g
on a level su r fa ce a ft er t h e veh icle h a s wa r m ed u p.
Fig. 2 Transmission Part And Serial Number Th e t or qu e con ver t er clu t ch will disen ga ge m om en -
Location t a r ily wh en a n in cr ea se in en gin e loa d is sen sed by
1 - PART NUMBER t h e P CM, su ch a s wh en t h e veh icle begin s t o go
2 - BUILD DATE u ph ill or t h e t h r ot t le pr essu r e is in cr ea sed. Th e
3 - SERIAL NUMBER
t or qu e con ver t er clu t ch fea t u r e in cr ea ses fu el econ -
om y a n d r edu ces t h e t r a n sm ission flu id t em per a t u r e.
GEAR RATIOS The 42RE gear ratios are: Sin ce t h e over dr ive clu t ch is a pplied in fou r t h gea r
on ly a n d t h e dir ect clu t ch is a pplied in a ll r a n ges
1s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.74:1 except fou r t h gea r, t h e t r a n sm ission oper a t ion for
2n d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54:1 pa r k, n eu t r a l, a n d fir st t h r ou gh t h ir d gea r will be
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 descr ibed fir st . On ce t h ese power flows a r e descr ibed,
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69:1 t h e t h ir d t o fou r t h sh ift sequ en ce will be descr ibed.
Re v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21:1
21 - 6 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
PARK POWERFLOW NEUTRAL POWERFLOW
As t h e en gin e is r u n n in g a n d t h e cr a n ksh a ft is Wit h t h e gea r select or in t h e NE UTRAL posit ion
r ot a t in g, t h e flexpla t e a n d t or qu e con ver t er, wh ich (F ig. 4), t h e power flow of t h e t r a n sm ission is essen -
a r e a lso bolt ed t o it , a r e a ll r ot a t in g in a clockwise t ia lly t h e sa m e a s in t h e pa r k posit ion . Th e on ly
dir ect ion a s viewed fr om t h e fr on t of t h e en gin e. Th e oper a t ion a l differ en ce is t h a t t h e pa r kin g spr a g h a s
n ot ch ed h u b of t h e t or qu e con ver t er is con n ect ed t o been disen ga ged, u n lockin g t h e ou t pu t sh a ft fr om t h e
t h e oil pu m p’s in t er n a l gea r, su pplyin g t h e t r a n sm is- t r a n sm ission ca se a n d a llowin g it t o m ove fr eely.
sion wit h oil pr essu r e. As t h e con ver t er t u r n s, it
t u r n s t h e in pu t sh a ft in a clockwise dir ect ion . As t h e
in pu t sh a ft is r ot a t in g, t h e fr on t clu t ch h u b-r ea r
clu t ch r et a in er a n d a ll t h eir a ssocia t ed pa r t s a r e a lso
r ot a t in g, a ll bein g dir ect ly con n ect ed t o t h e in pu t
sh a ft . Th e power flow fr om t h e en gin e t h r ou gh t h e
fr on t clu t ch h u b a n d r ea r clu t ch r et a in er st ops a t t h e
r ea r clu t ch r et a in er. Th er efor e, n o power flow t o t h e
ou t pu t sh a ft occu r s beca u se n o clu t ch es a r e a pplied.
Th e on ly m ech a n ism in u se a t t h is t im e is t h e pa r k-
in g spr a g (F ig. 3), wh ich locks t h e pa r kin g gea r on
t h e ou t pu t sh a ft t o t h e t r a n sm ission ca se.

Fig. 4 Neutral Powerflow

1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5 - PAWL

Fig. 3 Park Powerflow

1 - LEVER ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
REVERSE POWERFLOW
Wh en t h e gea r select or is m oved in t o t h e
RE VE RSE posit ion (F ig. 5), t h e fr on t clu t ch a n d t h e
r ea r ba n d a r e a pplied. Wit h t h e a pplica t ion of t h e
fr on t clu t ch , en gin e t or qu e is a pplied t o t h e su n gea r,
t u r n in g it in a clockwise dir ect ion . Th e clockwise
r ot a t ion of t h e su n gea r ca u ses t h e r ea r pla n et pin -
ion s t o r ot a t e a ga in st en gin e r ot a t ion in a cou n t er-
clockwise dir ect ion . Th e r ea r ba n d is h oldin g t h e low
r ever se dr u m , wh ich is splin ed t o t h e r ea r ca r r ier.
Sin ce t h e r ea r ca r r ier is bein g h eld, t h e t or qu e fr om
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED
2 - OUTPUT SHAFT
3 - LOW/REVERSE BAND APPLIED
4 - INPUT SHAFT
AUTOMATIC TRANSMISSION - 42RE 21 - 7
t h e pla n et pin ion s is t r a n sfer r ed t o t h e r ea r a n n u lu s
gea r, wh ich is splin ed t o t h e ou t pu t sh a ft . Th e ou t pu t
sh a ft in t u r n r ot a t es wit h t h e a n n u lu s gea r in a
cou n t er clockwise dir ect ion givin g a r ever se gea r ou t -
pu t . Th e en t ir e t r a n sm ission of t or qu e is a pplied t o
t h e r ea r pla n et a r y gea r set on ly. Alt h ou gh t h er e is
t or qu e in pu t t o t h e fr on t gea r set t h r ou gh t h e su n
gea r, n o ot h er m em ber of t h e gea r set is bein g h eld.
Du r in g t h e en t ir e r ever se st a ge of oper a t ion , t h e
fr on t pla n et a r y gea r s a r e in a n idlin g con dit ion .
5 - OUTPUT SHAFT
6 - INPUT SHAFT
7 - FRONT CLUTCH ENGAGED
8 - LOW/REVERSE BAND APPLIED
21 - 8 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
FIRST GEAR POWERFLOW
Wh en t h e gea r sh ift lever is m oved in t o t h e DRIVE
posit ion t h e t r a n sm ission goes in t o fir st gea r (F ig. 6).
As soon a s t h e t r a n sm ission is sh ift ed fr om PARK or
NE UTRAL t o DRIVE , t h e r ea r clu t ch a pplies, a pply-
in g t h e r ea r clu t ch pa ck t o t h e fr on t a n n u lu s gea r.
E n gin e t or qu e is n ow a pplied t o t h e fr on t a n n u lu s
gea r t u r n in g it in a clockwise dir ect ion . Wit h t h e
fr on t a n n u lu s gea r t u r n in g in a clockwise dir ect ion , it
ca u ses t h e fr on t pla n et s t o t u r n in a clockwise dir ec-
t ion . Th e r ot a t ion of t h e fr on t pla n et s ca u se t h e su n
t o r evolve in a cou n t er clockwise dir ect ion . Th e su n
gea r n ow t r a n sfer s it s cou n t er clockwise r ot a t ion t o
Fig. 6 First Gear Powerflow
1 - OUTPUT SHAFT
2 - OVER-RUNNING CLUTCH HOLDING
3 - REAR CLUTCH APPLIED
4 - OUTPUT SHAFT
WJ
t h e r ea r pla n et s wh ich r ot a t e ba ck in a clockwise
dir ect ion . Wit h t h e r ea r a n n u lu s gea r st a t ion a r y, t h e
r ea r pla n et r ot a t ion on t h e a n n u lu s gea r ca u ses t h e
r ea r pla n et ca r r ier t o r evolve in a cou n t er clockwise
dir ect ion . Th e r ea r pla n et ca r r ier is splin ed in t o t h e
low-r ever se dr u m , a n d t h e low r ever se dr u m is
splin ed t o t h e in n er r a ce of t h e over-r u n n in g clu t ch .
Wit h t h e over-r u n n in g clu t ch locked, t h e pla n et ca r-
r ier is h eld, a n d t h e r esu lt in g t or qu e pr ovided by t h e
pla n et pin ion s is t r a n sfer r ed t o t h e r ea r a n n u lu s
gea r. Th e r ea r a n n u lu s gea r is splin ed t o t h e ou t pu t
sh a ft a n d r ot a t ed a lon g wit h it (clockwise) in a n
u n der dr ive gea r r edu ct ion m ode.
5 - OVER-RUNNING CLUTCH HOLDING
6 - INPUT SHAFT
7 - REAR CLUTCH APPLIED
8 - INPUT SHAFT
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
SECOND GEAR POWERFLOW
In DRIVE -SE COND (F ig. 7), t h e sa m e elem en t s
a r e a pplied a s in MANUAL-SE COND. Th er efor e, t h e
power flow will be t h e sa m e, a n d bot h gea r s will be
discu ssed a s on e in t h e sa m e. In DRIVE -SE COND,
t h e t r a n sm ission h a s pr oceeded fr om fir st gea r t o it s
sh ift poin t , a n d is sh ift in g fr om fir st gea r t o secon d.
Th e secon d gea r sh ift is obt a in ed by keepin g t h e r ea r
clu t ch a pplied a n d a pplyin g t h e fr on t (kickdown )
ba n d. Th e fr on t ba n d h olds t h e fr on t clu t ch r et a in er
t h a t is locked t o t h e su n gea r dr ivin g sh ell. Wit h t h e
r ea r clu t ch st ill a pplied, t h e in pu t is st ill on t h e fr on t
a n n u lu s gea r t u r n in g it clockwise a t en gin e speed.
Fig. 7 Second Gear Powerflow
1 - KICKDOWN BAND APPLIED
2 - OUTPUT SHAFT
3 - REAR CLUTCH ENGAGED
4 - OUTPUT SHAFT
5 - OVER-RUNNING CLUTCH FREE-WHEELING
AUTOMATIC TRANSMISSION - 42RE 21 - 9
Now t h a t t h e fr on t ba n d is h oldin g t h e su n gea r st a -
t ion a r y, t h e a n n u lu s r ot a t ion ca u ses t h e fr on t pla n et s
t o r ot a t e in a clockwise dir ect ion . Th e fr on t ca r r ier is
t h en a lso m a de t o r ot a t e in a clockwise dir ect ion bu t
a t a r edu ced speed. Th is will t r a n sm it t h e t or qu e t o
t h e ou t pu t sh a ft , wh ich is dir ect ly con n ect ed t o t h e
fr on t pla n et ca r r ier. Th e r ea r pla n et a r y a n n u lu s gea r
will a lso be t u r n in g beca u se it is dir ect ly splin ed t o
t h e ou t pu t sh a ft . All power flow h a s occu r r ed in t h e
fr on t pla n et a r y gea r set du r in g t h e dr ive-secon d
st a ge of oper a t ion , a n d n ow t h e over-r u n n in g clu t ch ,
in t h e r ea r of t h e t r a n sm ission , is disen ga ged a n d
fr eewh eelin g on it s h u b.
6 - INPUT SHAFT
7 - REAR CLUTCH APPLIED
8 - KICKDOWN BAND APPLIED
9 - INPUT SHAFT
21 - 10 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
DIRECT DRIVE POWERFLOW
Th e veh icle h a s a cceler a t ed a n d r ea ch ed t h e sh ift
poin t for t h e 2-3 u psh ift in t o dir ect dr ive (F ig. 8).
Wh en t h e sh ift t a kes pla ce, t h e fr on t ba n d is
r elea sed, a n d t h e fr on t clu t ch is a pplied. Th e r ea r
clu t ch st a ys a pplied a s it h a s been in a ll t h e for wa r d
gea r s. Wit h t h e fr on t clu t ch n ow a pplied, en gin e
t or qu e is n ow on t h e fr on t clu t ch r et a in er, wh ich is
locked t o t h e su n gea r dr ivin g sh ell. Th is m ea n s t h a t
t h e su n gea r is n ow t u r n in g in en gin e r ot a t ion (clock-
wise) a n d a t en gin e speed. Th e r ea r clu t ch is st ill
a pplied so en gin e t or qu e is a lso st ill on t h e fr on t
WJ
a n n u lu s gea r. If t wo m em ber s of t h e sa m e pla n et a r y
set a r e dr iven , dir ect dr ive r esu lt s. Th er efor e, wh en
t wo m em ber s a r e r ot a t in g a t t h e sa m e speed a n d in
t h e sa m e dir ect ion , it is t h e sa m e a s bein g locked u p.
Th e r ea r pla n et a r y set is a lso locked u p, given t h e
su n gea r is st ill t h e in pu t , a n d t h e r ea r a n n u lu s gea r
m u st t u r n wit h t h e ou t pu t sh a ft . Bot h gea r s a r e
t u r n in g in t h e sa m e dir ect ion a n d a t t h e sa m e speed.
Th e fr on t a n d r ea r pla n et pin ion s do n ot t u r n a t a ll
in dir ect dr ive. Th e on ly r ot a t ion is t h e in pu t fr om
t h e en gin e t o t h e con n ect ed pa r t s, wh ich a r e a ct in g
a s on e com m on u n it , t o t h e ou t pu t sh a ft .

Fig. 8 Direct Drive Powerflow

1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
3 - OUTPUT SHAFT 8 - REAR CLUTCH APPLIED
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
5 - OUTPUT SHAFT 10 - INPUT SHAFT
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
FOURTH GEAR POWERFLOW
F ou r t h gea r over dr ive r a n ge is elect r on ica lly con -
t r olled a n d h ydr a u lica lly a ct iva t ed. Va r iou s sen sor
in pu t s a r e su pplied t o t h e power t r a in con t r ol m odu le
t o oper a t e t h e over dr ive solen oid on t h e va lve body.
Th e solen oid con t a in s a ch eck ba ll t h a t open s a n d
closes a ven t por t in t h e 3-4 sh ift va lve feed pa ssa ge.
Th e over dr ive solen oid (a n d ch eck ba ll) a r e n ot en er-
gized in fir st , secon d, t h ir d, or r ever se gea r. Th e ven t
por t r em a in s open , diver t in g lin e pr essu r e fr om t h e
2-3 sh ift va lve a wa y fr om t h e 3-4 sh ift va lve. Th e
over dr ive con t r ol swit ch m u st be in t h e ON posit ion
t o t r a n sm it over dr ive st a t u s t o t h e P CM. A 3-4
u psh ift occu r s on ly wh en t h e over dr ive solen oid is
en er gized by t h e P CM. Th e P CM en er gizes t h e over-
dr ive solen oid du r in g t h e 3-4 u psh ift . Th is ca u ses t h e
solen oid ch eck ba ll t o close t h e ven t por t a llowin g
lin e pr essu r e fr om t h e 2-3 sh ift va lve t o a ct dir ect ly
on t h e 3-4 u psh ift va lve. Lin e pr essu r e on t h e 3-4
sh ift va lve over com es va lve spr in g pr essu r e m ovin g
t h e va lve t o t h e u psh ift posit ion . Th is a ct ion exposes
t h e feed pa ssa ges t o t h e 3-4 t im in g va lve, 3-4 qu ick
fill va lve, 3-4 a ccu m u la t or, a n d u lt im a t ely t o t h e
over dr ive pist on . Lin e pr essu r e t h r ou gh t h e t im in g
va lve m oves t h e over dr ive pist on in t o con t a ct wit h
t h e over dr ive clu t ch . Th e dir ect clu t ch is disen ga ged
befor e t h e over dr ive clu t ch is en ga ged. Th e boost
va lve pr ovides in cr ea sed flu id a pply pr essu r e t o t h e
over dr ive clu t ch du r in g 3-4 u psh ift s, a n d wh en a ccel-
er a t in g in fou r t h gea r. Th e 3-4 a ccu m u la t or cu sh ion s
over dr ive clu t ch en ga gem en t t o sm oot h 3-4 u psh ift s.
Th e a ccu m u la t or is ch a r ged a t t h e sa m e t im e a s
a pply pr essu r e a ct s a ga in st t h e over dr ive pist on .
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
Au t om a t ic t r a n sm ission pr oblem s ca n be a r esu lt of
poor en gin e per for m a n ce, in cor r ect flu id level, in cor-
r ect lin ka ge or ca ble a dju st m en t , ba n d or h ydr a u lic
con t r ol pr essu r e a dju st m en t s, h ydr a u lic syst em m a l-
fu n ct ion s or elect r ica l/m ech a n ica l com pon en t m a l-
fu n ct ion s. Begin dia gn osis by ch eckin g t h e ea sily
a ccessible it em s su ch a s: flu id level a n d con dit ion ,
lin ka ge a dju st m en t s a n d elect r ica l con n ect ion s. A
r oa d t est will det er m in e if fu r t h er dia gn osis is n eces-
sa r y.
DIAGNOSIS AND TESTING - PRELIMINARY
Two ba sic pr ocedu r es a r e r equ ir ed. On e pr ocedu r e
for veh icles t h a t a r e dr iva ble a n d a n a lt er n a t e pr oce-
du r e for disa bled veh icles (will n ot ba ck u p or m ove
for wa r d).
AUTOMATIC TRANSMISSION - 42RE 21 - 11
VEHICLE IS DRIVEABLE
(1) Ch eck for t r a n sm ission fa u lt codes u sin g DRB!
sca n t ool.
(2) Ch eck flu id level a n d con dit ion .
(3) Adju st t h r ot t le a n d gea r sh ift lin ka ge if com -
pla in t wa s ba sed on dela yed, er r a t ic, or h a r sh sh ift s.
(4) Roa d t est a n d n ot e h ow t r a n sm ission u psh ift s,
down sh ift s, a n d en ga ges.
(5) P er for m h ydr a u lic pr essu r e t est if sh ift pr ob-
lem s wer e n ot ed du r in g r oa d t est .
(6) P er for m a ir-pr essu r e t est t o ch eck clu t ch -ba n d
oper a t ion .
VEHICLE IS DISABLED
(1) Ch eck flu id level a n d con dit ion .
(2) Ch eck for br oken or discon n ect ed gea r sh ift or
t h r ot t le lin ka ge.
(3) Ch eck for cr a cked, lea kin g cooler lin es, or loose
or m issin g pr essu r e-por t plu gs.
(4) Ra ise a n d su ppor t veh icle on sa fet y st a n ds,
st a r t en gin e, sh ift t r a n sm ission in t o gea r, a n d n ot e
followin g:
(a ) If pr opeller sh a ft t u r n s bu t wh eels do n ot ,
pr oblem is wit h differ en t ia l or a xle sh a ft s.
(b) If pr opeller sh a ft does n ot t u r n a n d t r a n sm is-
sion is n oisy, st op en gin e. Rem ove oil pa n , a n d
ch eck for debr is. If pa n is clea r, r em ove t r a n sm is-
sion a n d ch eck for da m a ged dr ive pla t e, con ver t er,
oil pu m p, or in pu t sh a ft .
(c) If pr opeller sh a ft does n ot t u r n a n d t r a n sm is-
sion is n ot n oisy, per for m h ydr a u lic-pr essu r e t est t o
det er m in e if pr oblem is h ydr a u lic or m ech a n ica l.
DIAGNOSIS AND TESTING - ROAD TESTING
Befor e r oa d t est in g, be su r e t h e flu id level a n d con -
t r ol ca ble a dju st m en t s h a ve been ch ecked a n d
a dju st ed if n ecessa r y. Ver ify t h a t dia gn ost ic t r ou ble
codes h a ve been r esolved.
Obser ve en gin e per for m a n ce du r in g t h e r oa d t est .
A poor ly t u n ed en gin e will n ot a llow a ccu r a t e a n a ly-
sis of t r a n sm ission oper a t ion .
Oper a t e t h e t r a n sm ission in a ll gea r r a n ges. Ch eck
for sh ift va r ia t ion s a n d en gin e fla r e wh ich in dica t es
slippa ge. Not e if sh ift s a r e h a r sh , spon gy, dela yed,
ea r ly, or if pa r t t h r ot t le down sh ift s a r e sen sit ive.
Slippa ge in dica t ed by en gin e fla r e, u su a lly m ea n s
clu t ch , ba n d or over r u n n in g clu t ch pr oblem s. If t h e
con dit ion is a dva n ced, a n over h a u l will be n ecessa r y
t o r est or e n or m a l oper a t ion .
A slippin g clu t ch or ba n d ca n oft en be det er m in ed
by com pa r in g wh ich in t er n a l u n it s a r e a pplied in t h e
va r iou s gea r r a n ges. Th e Clu t ch a n d Ba n d Applica -
t ion ch a r t pr ovides a ba sis for a n a lyzin g r oa d t est
r esu lt s.
21 - 12 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CLUTCH AND BAND APPLICATION CHART

SHIFT TRANSMISSION CLUTCHES AND BANDS OVERDRIVE CLUTCHES

LEVER FRONT FRONT REAR REAR OVER- OVER- DIRECT OVER-
POSI- CLUTCH BAND CLUTCH BAND RUNNING DRIVE CLUTCH RUNNING
TION CLUTCH CLUTCH CLUTCH
Reverse X X X
Drive - X X X X
First
Drive - X X X X
Second
Drive - X X X X
Third
Drive - X X X
Fourth
Manual X X X X X
Second
Manual X X X X X
First

Not e t h a t t h e r ea r clu t ch is a pplied in a ll for wa r d
r a n ges (D, 2, 1). Th e t r a n sm ission over r u n n in g clu t ch
is a pplied in fir st gea r (D, 2 a n d 1 r a n ges) on ly. Th e
r ea r ba n d is a pplied in 1 a n d R r a n ge on ly.
Not e t h a t t h e over dr ive clu t ch is a pplied on ly in
fou r t h gea r a n d t h e over dr ive dir ect clu t ch a n d over-
r u n n in g clu t ch a r e a pplied in a ll r a n ges except fou r t h
gea r.
F or exa m ple: If slippa ge occu r s in fir st gea r in D
a n d 2 r a n ge bu t n ot in 1 r a n ge, t h e t r a n sm ission
over r u n n in g clu t ch is fa u lt y. Sim ila r ly, if slippa ge
occu r s in a n y t wo for wa r d gea r s, t h e r ea r clu t ch is
slippin g.
Applyin g t h e sa m e m et h od of a n a lysis, n ot e t h a t
t h e fr on t a n d r ea r clu t ch es a r e a pplied sim u lt a -
n eou sly on ly in D r a n ge t h ir d a n d fou r t h gea r. If t h e
t r a n sm ission slips in t h ir d gea r, eit h er t h e fr on t
clu t ch or t h e r ea r clu t ch is slippin g.
If t h e t r a n sm ission slips in fou r t h gea r bu t n ot in
t h ir d gea r, t h e over dr ive clu t ch is slippin g. By select -
in g a n ot h er gea r wh ich does n ot u se t h ese clu t ch es,
t h e slippin g u n it ca n be det er m in ed. F or exa m ple, if
t h e t r a n sm ission a lso slips in Rever se, t h e fr on t
clu t ch is slippin g. If t h e t r a n sm ission does n ot slip in
Rever se, t h e r ea r clu t ch is slippin g.
If slippa ge occu r s du r in g t h e 3-4 sh ift or on ly in
fou r t h gea r, t h e over dr ive clu t ch is slippin g. Sim i-
la r ly, if t h e dir ect clu t ch wer e t o fa il, t h e t r a n sm is-
sion wou ld lose bot h r ever se gea r a n d over r u n
br a kin g in 2 posit ion (m a n u a l secon d gea r ).
If t h e t r a n sm ission will n ot sh ift t o fou r t h gea r, t h e
con t r ol swit ch , over dr ive solen oid or r ela t ed wir in g
m a y a lso be t h e pr oblem ca u se.
Th is pr ocess of elim in a t ion ca n be u sed t o iden t ify
a slippin g u n it a n d ch eck oper a t ion . P r oper u se of
t h e Clu t ch a n d Ba n d Applica t ion Ch a r t is t h e key.
Alt h ou gh r oa d t est a n a lysis will h elp det er m in e t h e
slippin g u n it , t h e a ct u a l ca u se of a m a lfu n ct ion u su -
a lly ca n n ot be det er m in ed u n t il h ydr a u lic a n d a ir
pr essu r e t est s a r e per for m ed. P r a ct ica lly a n y con di-
t ion ca n be ca u sed by lea kin g h ydr a u lic cir cu it s or
st ickin g va lves.
Un less a m a lfu n ct ion is obviou s, su ch a s n o dr ive
in D r a n ge fir st gea r, do n ot disa ssem ble t h e t r a n s-
m ission . P er for m t h e h ydr a u lic a n d a ir pr essu r e t est s
t o h elp det er m in e t h e pr oba ble ca u se.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST
H ydr a u lic t est pr essu r es r a n ge fr om a low of on e
psi (6.895 kP a ) gover n or pr essu r e, t o 300 psi (2068
kP a ) a t t h e r ea r ser vo pr essu r e por t in r ever se.
An a ccu r a t e t a ch om et er a n d pr essu r e t est ga u ges
a r e r equ ir ed. Test Ga u ge C-3292 h a s a 100 psi r a n ge
a n d is u sed a t t h e a ccu m u la t or, gover n or, a n d fr on t
ser vo por t s. Test Ga u ge C-3293-SP h a s a 300 psi
r a n ge a n d is u sed a t t h e r ea r ser vo a n d over dr ive
por t s wh er e pr essu r es exceed 100 psi.
Pressure Test Port Locations
Test por t s a r e loca t ed a t bot h sides of t h e t r a n sm is-
sion ca se (F ig. 9).
Lin e pr essu r e is ch ecked a t t h e a ccu m u la t or por t
on t h e r igh t side of t h e ca se. Th e fr on t ser vo pr essu r e
por t is a t t h e r igh t side of t h e ca se ju st beh in d t h e
filler t u be open in g.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
Th e r ea r ser vo a n d gover n or pr essu r e por t s a r e a t
t h e r igh t r ea r of t h e t r a n sm ission ca se. Th e over dr ive
clu t ch pr essu r e por t is a t t h e left r ea r of t h e ca se.
Fig. 9 Pressure Test Port Locations
1 - OVERDRIVE CLUTCH TEST PORT
2 - GOVERNOR TEST PORT
3 - ACCUMULATOR TEST PORT
4 - FRONT SERVO TEST PORT
5 - REAR SERVO TEST PORT
Test One - Transmission In Manual Low
NOTE: This test checks pump output, pressure reg-
ulation, and condition of the rear clutch and servo
circuit. Both test gauges are required for this test.
(1) Con n ect t a ch om et er t o en gin e. P osit ion t a ch om -
et er so it ca n be obser ved fr om dr iver sea t if h elper
will be oper a t in g en gin e. Ra ise veh icle on h oist t h a t
will a llow r ea r wh eels t o r ot a t e fr eely.
(2) Con n ect 100 psi Ga u ge C-3292 t o a ccu m u la t or
por t . Th en con n ect 300 psi Ga u ge C-3293-SP t o r ea r
ser vo por t .
(3) Discon n ect t h r ot t le a n d gea r sh ift ca bles fr om
lever s on t r a n sm ission va lve body m a n u a l sh a ft .
(4) H a ve h elper st a r t a n d r u n en gin e a t 1000 r pm .
(5) Move t r a n sm ission sh ift lever fu lly for wa r d
in t o 1 r a n ge.
AUTOMATIC TRANSMISSION - 42RE 21 - 13
(6) Gr a du a lly m ove t r a n sm ission t h r ot t le lever
fr om fu ll for wa r d t o fu ll r ea r wa r d posit ion a n d n ot e
pr essu r es on bot h ga u ges:
• Lin e pr essu r e a t a ccu m u la t or por t sh ou ld be
54-60 psi (372-414 kP a ) wit h t h r ot t le lever for wa r d
a n d gr a du a lly in cr ea se t o 90-96 psi (621-662 kP a ) a s
t h r ot t le lever is m oved r ea r wa r d.
• Rea r ser vo pr essu r e sh ou ld be sa m e a s lin e pr es-
su r e wit h in 3 psi (20.68 kP a ).
Test Two - Transmission In 2 Range
NOTE: This test checks pump output, line pressure
and pressure regulation. Use 100 psi Test Gauge
C-3292 for this test.
(1) Lea ve veh icle in pla ce on h oist a n d lea ve Test
Ga u ge C-3292 con n ect ed t o a ccu m u la t or por t .
(2) H a ve h elper st a r t a n d r u n en gin e a t 1000 r pm .
(3) Move t r a n sm ission sh ift lever on e det en t r ea r-
wa r d fr om fu ll for wa r d posit ion . Th is is 2 r a n ge.
(4) Move t r a n sm ission t h r ot t le lever fr om fu ll for-
wa r d t o fu ll r ea r wa r d posit ion a n d r ea d pr essu r e on
ga u ge.
(5) Lin e pr essu r e sh ou ld be 54-60 psi (372-414
kP a ) wit h t h r ot t le lever for wa r d a n d gr a du a lly
in cr ea se t o 90-96 psi (621-662 kP a ) a s lever is m oved
r ea r wa r d.
Test Three - Transmission In D Range Third Gear
NOTE: This test checks pressure regulation and
condition of the clutch circuits. Both test gauges
are required for this test.
(1) Tu r n OD swit ch off.
(2) Lea ve veh icle on h oist a n d lea ve Ga u ge C-3292
in pla ce a t a ccu m u la t or por t .
(3) Move Ga u ge C-3293-SP over t o fr on t ser vo por t
for t h is t est .
(4) H a ve h elper st a r t a n d r u n en gin e a t 1600 r pm
for t h is t est .
(5) Move t r a n sm ission sh ift lever t wo det en t s r ea r-
wa r d fr om fu ll for wa r d posit ion . Th is is D r a n ge.
(6) Rea d pr essu r es on bot h ga u ges a s t r a n sm ission
t h r ot t le lever is gr a du a lly m oved fr om fu ll for wa r d t o
fu ll r ea r wa r d posit ion :
• Lin e pr essu r e a t a ccu m u la t or in D r a n ge t h ir d
gea r, sh ou ld be 54-60 psi (372-414 kP a ) wit h t h r ot t le
lever for wa r d a n d in cr ea se a s lever is m oved r ea r-
wa r d.
• F r on t ser vo pr essu r e in D r a n ge t h ir d gea r,
sh ou ld be wit h in 3 psi (21 kP a ) of lin e pr essu r e u p t o
kickdown poin t .
21 - 14 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
Test Four - Transmission In Reverse Test Six - Transmission In Overdrive Fourth Gear

NOTE: This test checks pump output, pressure reg- NOTE: This test checks line pressure at the over-
ulation and the front clutch and rear servo circuits. drive clutch in fourth gear range. Use 300 psi Test
Use 300 psi Test Gauge C-3293-SP for this test. Gauge C-3293-SP for this test. The test should be
performed on the road or on a chassis dyno.
(1) Lea ve veh icle on h oist a n d lea ve ga u ge C-3292
in pla ce a t a ccu m u la t or por t . (1) Rem ove t a ch om et er ; it is n ot n eeded for t h is
(2) Move 300 psi Ga u ge C-3293-SP ba ck t o r ea r t est .
ser vo por t . (2) Move 300 psi Ga u ge t o over dr ive clu t ch pr es-
(3) H a ve h elper st a r t a n d r u n en gin e a t 1600 r pm su r e t est por t . Th en r em ove ot h er ga u ge a n d r ein st a ll
for t est . t est por t plu g.
(4) Move t r a n sm ission sh ift lever fou r det en t s (3) Lower veh icle.
r ea r wa r d fr om fu ll for wa r d posit ion . Th is is Rever se (4) Tu r n OD swit ch on .
r a n ge. (5) Secu r e t est ga u ge so it ca n be viewed fr om
(5) Move t r a n sm ission t h r ot t le lever fu lly for wa r d dr iver s sea t .
t h en fu lly r ea r wa r d a n d n ot e r ea din g a t Ga u ge (6) St a r t en gin e a n d sh ift in t o D r a n ge.
C-3293-SP. (7) In cr ea se veh icle speed gr a du a lly u n t il 3-4 sh ift
(6) P r essu r e sh ou ld be 145 - 175 psi (1000-1207 occu r s a n d n ot e ga u ge pr essu r e.
kP a ) wit h t h r ot t le lever for wa r d a n d in cr ea se t o 230 - (8) P r essu r e sh ou ld be 469-496 kP a (68-72 psi)
280 psi (1586-1931 kP a ) a s lever is gr a du a lly m oved wit h closed t h r ot t le a n d in cr ea se t o 620-827 kP a (90-
r ea r wa r d. 120 psi) a t 1/2 t o 3/4 t h r ot t le. Not e t h a t pr essu r e ca n
in cr ea se t o a r ou n d 896 kP a (130 psi) a t fu ll t h r ot t le.
Test Five - Governor Pressure (9) Ret u r n t o sh op or m ove veh icle off ch a ssis
dyn o.
NOTE: This test checks governor operation by mea- PRESSU RE T EST AN ALY SI S CH ART
suring governor pressure response to changes in
vehicle speed. It is usually not necessary to check
TEST CONDITION INDICATION
governor operation unless shift speeds are incor-
rect or if the transmission will not downshift. The Line pressure OK during Pump and regulator
test should be performed on the road or on a hoist any one test valve OK
that will allow the rear wheels to rotate freely. Line pressure OK in R Leakage in rear clutch
but low in D, 2, 1 area (seal rings, clutch
(1) Move 100 psi Test Ga u ge C-3292 t o gover n or seals)
pr essu r e por t .
Pressure low in D Fourth Overdrive clutch piston
(2) Move t r a n sm ission sh ift lever t wo det en t s r ea r-
Gear Range seal, or check ball
wa r d fr om fu ll for wa r d posit ion . Th is is D r a n ge.
problem
(3) H a ve h elper st a r t a n d r u n en gin e a t cu r b idle
speed. Th en fir m ly a pply ser vice br a kes so wh eels Pressure OK in 1, 2 but Leakage in front clutch
will n ot r ot a t e. low in D3 and R area
(4) Not e gover n or pr essu r e: Pressure OK in 2 but low Leakage in rear servo
• Gover n or pr essu r e sh ou ld be n o m or e t h a n 20.6 in R and 1
kP a (3 psi) a t cu r b idle speed a n d wh eels n ot r ot a t -
Front servo pressure in 2 Leakage in servo; broken
in g.
servo ring or cracked
• If pr essu r e exceeds 20.6 kP a (3 psi), a fa u lt
servo piston
exist s in gover n or pr essu r e con t r ol syst em .
(5) Relea se br a kes, slowly in cr ea se en gin e speed, Pressure low in all Clogged filter, stuck
a n d obser ve speedom et er a n d pr essu r e t est ga u ge (do positions regulator valve, worn or
n ot exceed 30 m ph on speedom et er ). Gover n or pr es- faulty pump, low oil level
su r e sh ou ld in cr ea se in pr opor t ion t o veh icle speed. Governor pressure too Governor pressure
Or a ppr oxim a t ely 6.89 kP a (1 psi) for ever y 1 m ph . high at idle speed solenoid valve system
(6) Gover n or pr essu r e r ise sh ou ld be sm oot h a n d fault. Refer to diagnostic
dr op ba ck t o n o m or e t h a n 20.6 kP a (3 psi), a ft er book.
en gin e r et u r n s t o cu r b idle a n d br a kes a r e a pplied t o
pr even t wh eels fr om r ot a t in g.
(7) Com pa r e r esu lt s of pr essu r e t est wit h a n a lysis
ch a r t .
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 15
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

TEST CONDITION INDICATION

Governor pressure low at
all mph figures
Lubrication pressure low
at all throttle positions
Line pressure high
Line pressure low
Faulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Clogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Output shaft plugged,
sticky regulator valve
Sticky regulator valve,
clogged filter, worn pump

DIAGNOSIS AND TESTING - AIR CHECKING

TRANSMISSION CLUTCH AND BAND
OPERATION
Air-pr essu r e t est in g ca n be u sed t o ch eck t r a n sm is-
sion fr on t /r ea r clu t ch a n d ba n d oper a t ion . Th e t est
ca n be con du ct ed wit h t h e t r a n sm ission eit h er in t h e
veh icle or on t h e wor k ben ch , a s a fin a l ch eck, a ft er
over h a u l.
Air-pr essu r e t est in g r equ ir es t h a t t h e oil pa n a n d
va lve body be r em oved fr om t h e t r a n sm ission . Th e
ser vo a n d clu t ch a pply pa ssa ges a r e sh own (F ig. 10).
Front Clutch Air Test
P la ce on e or t wo fin ger s on t h e clu t ch h ou sin g a n d
a pply a ir pr essu r e t h r ou gh fr on t clu t ch a pply pa s-
sa ge. P ist on m ovem en t ca n be felt a n d a soft t h u m p
h ea r d a s t h e clu t ch a pplies.
Rear Clutch Air Test
P la ce on e or t wo fin ger s on t h e clu t ch h ou sin g a n d
a pply a ir pr essu r e t h r ou gh r ea r clu t ch a pply pa ssa ge.
P ist on m ovem en t ca n be felt a n d a soft t h u m p h ea r d
a s t h e clu t ch a pplies.
Front Servo Apply Air Test
Apply a ir pr essu r e t o t h e fr on t ser vo a pply pa s-
sa ge. Th e ser vo r od sh ou ld ext en d a n d ca u se t h e
ba n d t o t igh t en a r ou n d t h e dr u m . Spr in g pr essu r e
sh ou ld r elea se t h e ser vo wh en a ir pr essu r e is
r em oved.
Rear Servo Air Test
Apply a ir pr essu r e t o t h e r ea r ser vo a pply pa ssa ge.
Th e ser vo r od sh ou ld ext en d a n d ca u se t h e ba n d t o
t igh t en a r ou n d t h e dr u m . Spr in g pr essu r e sh ou ld
r elea se t h e ser vo wh en a ir pr essu r e is r em oved.
Fig. 10 Air Pressure Test Passages
1 - REAR SERVO APPLY
2 - FRONT SERVO APPLY
3 - PUMP SUCTION
4 - FRONT CLUTCH APPLY
5 - FRONT SERVO RELEASE
6 - LINE PRESSURE TO ACCUMULATOR
7 - PUMP PRESSURE
8 - TO CONVERTER
9 - REAR CLUTCH APPLY
10 - FROM CONVERTER
11 - TO COOLER
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK
Wh en dia gn osin g con ver t er h ou sin g flu id lea ks,
t wo it em s m u st be est a blish ed befor e r epa ir.
(1) Ver ify t h a t a lea k con dit ion a ct u a lly exist s.
(2) Det er m in ed t h e t r u e sou r ce of t h e lea k.
Som e su spect ed con ver t er h ou sin g flu id lea ks m a y
n ot be lea ks a t a ll. Th ey m a y on ly be t h e r esu lt of
r esidu a l flu id in t h e con ver t er h ou sin g, or excess
flu id spilled du r in g fa ct or y fill or fill a ft er r epa ir.
Con ver t er h ou sin g lea ks h a ve sever a l pot en t ia l
sou r ces. Th r ou gh ca r efu l obser va t ion , a lea k sou r ce
ca n be iden t ified befor e r em ovin g t h e t r a n sm ission
for r epa ir. P u m p sea l lea ks t en d t o m ove a lon g t h e
dr ive h u b a n d on t o t h e r ea r of t h e con ver t er. P u m p
body lea ks follow t h e sa m e pa t h a s a sea l lea k (F ig.
11). P u m p ven t or pu m p a t t a ch in g bolt lea ks a r e gen -
er a lly deposit ed on t h e in side of t h e con ver t er h ou s-
in g a n d n ot on t h e con ver t er it self (F ig. 11). P u m p
o-r in g or ga sket lea ks u su a lly t r a vel down t h e in side
of t h e con ver t er h ou sin g. F r on t ba n d lever pin plu g
21 - 16 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
lea ks a r e gen er a lly deposit ed on t h e h ou sin g a n d n ot
on t h e con ver t er.

Fig. 12 Converter Leak Points - Typical

1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG

Fig. 11 Converter Housing Leak Paths (5) In st a ll n ew pu m p sea l, O-r in g, a n d ga sket .

Repla ce oil pu m p if cr a cked, por ou s or da m a ged in
1 - PUMP SEAL
2 - PUMP VENT
a n y wa y. Be su r e t o loosen t h e fr on t ba n d befor e
3 - PUMP BOLT in st a llin g t h e oil pu m p, da m a ge t o t h e oil pu m p sea l
4 - PUMP GASKET m a y occu r if t h e ba n d is st ill t igh t en ed t o t h e fr on t
5 - CONVERTER HOUSING clu t ch r et a in er.
6 - CONVERTER (6) Loosen kickdown lever pin a ccess plu g t h r ee
7 - REAR MAIN SEAL LEAK t u r n s. Apply Loct it e™ 592, or P er m a t ex! No. 2 t o
plu g t h r ea ds a n d t igh t en plu g t o 17 N·m (150 in . lbs.)
TORQUE CONVERTER LEAK POINTS t or qu e.
(7) Adju st fr on t ba n d.
P ossible sou r ces of con ver t er lea ks a r e:
(8) Lu br ica t e pu m p sea l a n d con ver t er h u b wit h
(1) Lea ks a t t h e weld join t a r ou n d t h e ou t side
t r a n sm ission flu id or pet r oleu m jelly a n d in st a ll con -
dia m et er weld (F ig. 12).
ver t er.
(2) Lea ks a t t h e con ver t er h u b weld (F ig. 12).
(9) In st a ll t r a n sm ission a n d con ver t er h ou sin g
CONVERTER HOUSING AREA LEAK CORRECTION du st sh ield.
(10) Lower veh icle.
(1) Rem ove con ver t er.
(2) Tigh t en fr on t ba n d a dju st in g scr ew u n t il ba n d
is t igh t a r ou n d fr on t clu t ch r et a in er. Th is pr even t s DIAGNOSIS AND TESTING - DIAGNOSIS
fr on t /r ea r clu t ch es fr om com in g ou t wh en oil pu m p is CHARTS
r em oved. Th e dia gn osis ch a r t s pr ovide a ddit ion a l r efer en ce
(3) Rem ove oil pu m p a n d r em ove pu m p sea l. wh en dia gn osin g a t r a n sm ission fa u lt . Th e ch a r t s
In spect pu m p h ou sin g dr a in ba ck a n d ven t h oles for pr ovide gen er a l in for m a t ion on a va r iet y of t r a n sm is-
obst r u ct ion s. Clea r h oles wit h solven t a n d wir e. sion , over dr ive u n it a n d con ver t er clu t ch fa u lt con di-
(4) In spect pu m p bu sh in g a n d con ver t er h u b. If t ion s.
bu sh in g is scor ed, r epla ce it . If con ver t er h u b is Th e h ydr a u lic flow ch a r t s in t h e Sch em a t ics a n d
scor ed, eit h er polish it wit h cr ocu s clot h or r epla ce Dia gr a m s sect ion of t h is gr ou p, ou t lin e flu id flow a n d
con ver t er. h ydr a u lic cir cu it r y. Cir cu it oper a t ion is pr ovided for
PARK, NE UTRAL, F IRST, SE COND, TH IRD,
F OURTH , MANUAL F IRST, MANUAL SE COND,
a n d RE VE RSE gea r r a n ges. Nor m a l wor kin g pr es-
su r es a r e a lso su pplied for ea ch of t h e gea r r a n ges.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
DIAGNOSIS CHARTS
CONDITION POSSIBLE CAUSES
HARSH 1. Fluid Level Low.
ENGAGEMENT 2. Throttle Linkage Mis-adjusted.
(FROM NEUTRAL TO
3. Mount and Driveline Bolts
DRIVE OR REVERSE)
Loose.
4. U-Joint Worn/Broken.
5. Axle Backlash Incorrect.
6. Hydraulic Pressure Incorrect.
7. Band Mis-adjusted.
8. Valve Body Check Balls Missing.
9. Axle Pinion Flange Loose.
10. Clutch, band or planetary
component damaged.
11. Converter Clutch Faulty.
DELAYED 1. Fluid Level Low.
ENGAGEMENT 2. Filter Clogged.
(FROM NEUTRAL TO
3. Gearshift Linkage Mis-adjusted.
DRIVE OR REVERSE)
4. Torque Converter Drain Back
(Oil drains from torque converter
into transmission sump).
5. Rear Band Mis-adjusted.
6. Valve Body Filter Plugged.
7. Oil Pump Gears Worn/Damaged.
8. Governor Circuit and Solenoid
Valve Electrical Fault.
9. Hydraulic Pressure Incorrect.
10. Reaction Shaft Seal Rings
Worn/Broken.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
12. Regulator Valve Stuck.
13. Cooler Plugged.
AUTOMATIC TRANSMISSION - 42RE 21 - 17
CORRECTION
1. Add Fluid
2. Adjust linkage - setting may be too long.
3. Check engine mount, transmission mount,
propeller shaft, rear spring to body bolts, rear
control arms, crossmember and axle bolt torque.
Tighten loose bolts and replace missing bolts.
4. Remove propeller shaft and replace U-Joint.
5. Check per Service Manual. Correct as needed.
6. Check pressure. Remove, overhaul or adjust
valve body as needed.
7. Adjust rear band.
8. Inspect valve body for proper check ball
installation.
9. Replace nut and check pinion threads before
installing new nut. Replace pinion gear if threads
are damaged.
10. Remove, disassemble and repair transmission
as necessary.
11. Replace converter and flush cooler and line
before installing new converter.
1. Correct level and check for leaks.
2. Change filter.
3. Adjust linkage and repair linkage if worn or
damaged.
4. If vehicle moves normally after 5 seconds after
shifting into gear, no repair is necessary. If longer,
inspect pump bushing for wear. Replace pump
house.
5. Adjust band.
6. Replace fluid and filter. If oil pan and old fluid
were full of clutch disc material and/or metal
particles, overhaul will be necessary.
7. Remove transmission and replace oil pump.
8. Test with DRB" scan tool and repair as
required.
9. Perform pressure test, remove transmission
and repair as needed.
10. Remove transmission, remove oil pump and
replace seal rings.
11. Remove and disassemble transmission and
repair as necessary.
12. Clean.
13. Transfer case failure can plug cooler.
21 - 18 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
NO DRIVE RANGE 1. Fluid Level Low.
(REVERSE OK)
2. Gearshift Linkage/Cable
Loose/Misadjusted.
3. Rear Clutch Burnt.
4. Valve Body Malfunction.
5. Transmission Overrunning
Clutch Broken.
6. Input Shaft Seal Rings
Worn/Damaged.
7. Front Planetary Failed Broken.
NO DRIVE OR 1. Fluid Level Low.
REVERSE (VEHICLE
WILL NOT MOVE) 2. Gearshift Linkage/Cable
Loose/Misadjusted.
3. U-Joint/Axle/Transfer Case
Broken.
4. Filter Plugged.
5. Oil Pump Damaged.
6. Valve Body Malfunctioned.
7. Transmission Internal
Component Damaged.
8. Park Sprag not Releasing -
Check Stall Speed, Worn/
Damaged/Stuck.
9. Torque Converter Damage.
WJ
CORRECTION
1. Add fluid and check for leaks if drive is
restored.
2. Repair or replace linkage components.
3. Remove and disassemble transmission and
rear clutch and seals. Repair/replace worn or
damaged parts as needed.
4. Remove and disassemble valve body. Replace
assembly if any valves or bores are damaged.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Remove and repair.
1. Add fluid and check for leaks if drive is
restored.
2. Inspect, adjust and reassemble linkage as
needed. Replace worn/damaged parts.
3. Perform preliminary inspection procedure for
vehicle that will not move. Refer to procedure in
diagnosis section.
4. Remove and disassemble transmission. Repair
or replace failed components as needed. Replace
filter. If filter and fluid contained clutch material or
metal particles, an overhaul may be necessary.
Perform lube flow test. Flush oil. Replace cooler
as necessary.
5. Perform pressure test to confirm low pressure.
Replace pump body assembly if necessary.
6. Check and inspect valve body. Replace valve
body (as assembly) if any valve or bore is
damaged. Clean and reassemble correctly if all
parts are in good condition.
7. Remove and disassemble transmission. Repair
or replace failed components as needed.
8. Remove, disassemble, repair.
9. Inspect and replace as required.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
SHIFTS DELAYED OR 1. Fluid Level Low/High.
ERRATIC (SHIFTS 2. Fluid Filter Clogged.
ALSO HARSH AT
TIMES)
3. Throttle Linkage Mis-adjusted.
4. Throttle Linkage Binding.
5. Gearshift Linkage/Cable
Mis-adjusted.
6. Clutch or Servo Failure.
7. Governor Circuit Electrical Fault.
8. Front Band Mis-adjusted.
9. Pump Suction Passage Leak.
NO REVERSE (D 1. Gearshift Linkage/Cable
RANGES OK) Mis-adjusted/Damaged.
2. Park Sprag Sticking.
3. Rear Band Mis-adjusted/Worn.
4. Valve Body Malfunction.
5. Rear Servo Malfunction.
6. Direct Clutch in Overdrive Worn.
7. Front Clutch Burnt.
HAS FIRST/REVERSE 1. Governor Circuit Electrical Fault.
ONLY (NO 1-2 OR 2-3
UPSHIFT) 2. Valve Body Malfunction.
3. Front Servo/Kickdown Band
Damaged/Burned.
MOVES IN 2ND OR 1. Valve Body Malfunction.
3RD GEAR,
ABRUPTLY
DOWNSHIFTS TO
LOW
AUTOMATIC TRANSMISSION - 42RE 21 - 19
CORRECTION
1. Correct fluid level and check for leaks if low.
2. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary. Perform lube flow test.
3. Adjust linkage as described in service section.
4. Check cable for binding. Check for return to
closed throttle at transmission.
5. Adjust linkage/cable as described in service
section.
6. Remove valve body and air test clutch, and
band servo operation. Disassemble and repair
transmission as needed.
7. Test using DRB" scan tool and repair as
required.
8. Adjust band.
9. Check for excessive foam on dipstick after
normal driving. Check for loose pump bolts,
defective gasket. Replace pump assembly if
needed.
1. Repair or replace linkage parts as needed.
2. Replace overdrive annulus gear.
3. Adjust band; replace.
4. Remove and service valve body. Replace valve
body if any valves or valve bores are worn or
damaged.
5. Remove and disassemble transmission.
Replace worn/damaged servo parts as necessary.
6. Disassemble overdrive. Replace worn or
damaged parts.
7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as required.
1. Test using DRB" scan tool and repair as
required.
2. Repair stuck 1-2 shift valve or governor plug.
3. Repair/replace.
1. Remove, clean and inspect. Look for stuck 1-2
valve or governor plug.
21 - 20 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
NO LOW GEAR 1. Governor Circuit Electrical Fault.
(MOVES IN 2ND OR
3RD GEAR ONLY) 2. Valve Body Malfunction.
3. Front Servo Piston Cocked in
Bore.
4. Front Band Linkage Malfunction
NO KICKDOWN OR 1. Throttle Linkage Mis-adjusted.
NORMAL 2. Accelerator Pedal Travel
DOWNSHIFT Restricted.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.
4. Governor Circuit Electrical Fault.
5. Valve Body Malfunction.
6. TPS Malfunction.
7. PCM Malfunction.
8. Valve Body Malfunction.
STUCK IN LOW 1. Throttle Linkage Mis-adjusted/
GEAR (WILL NOT Stuck.
UPSHIFT)
2. Gearshift Linkage Mis-adjusted.
3. Governor Component Electrical
Fault.
4. Front Band Out of Adjustment.
5. Clutch or Servo Malfunction.
CREEPS IN 1. Gearshift Linkage Mis-adjusted.
NEUTRAL 2. Rear Clutch Dragging/Warped.
3. Valve Body Malfunction.
WJ
CORRECTION
1. Test with DRB" scan tool and repair as
required.
2. Remove, clean and inspect. Look for sticking
1-2 shift valve, 2-3 shift valve, governor plug or
broken springs.
3. Inspect servo and repair as required.
4. Inspect linkage and look for bind in linkage.
1. Adjust linkage.
2. Verify floor mat is not under pedal, repair worn
accelerator cable or bent brackets.
3. Perform hydraulic pressure tests to determine
cause and repair as required. Correct valve body
pressure adjustments as required.
4. Test with DRB" scan tool and repair as
required.
5. Perform hydraulic pressure tests to determine
cause and repair as required. Correct valve body
pressure adjustments as required.
6. Replace sensor, check with DRB" scan tool.
7. Check with DRB" scan tool and replace if
required.
8. Repair sticking 1-2, 2-3 shift valves, governor
plugs, 3-4 solenoid, 3-4 shift valve, 3-4 timing
valve.
1. Adjust linkage and repair linkage if worn or
damaged. Check for binding cable or missing
return spring.
2. Adjust linkage and repair linkage if worn or
damaged.
3. Check operating pressures and test with DRB"
scan tool, repair faulty component.
4. Adjust Band.
5. Air pressure check operation of clutches and
bands. Repair faulty component.
1. Adjust linkage.
2. Disassemble and repair.
3. Perform hydraulic pressure test to determine
cause and repair as required.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
BUZZING NOISE 1. Fluid Level Low
2. Shift Cable Mis-assembled.
3. Valve Body Mis-assembled.
4. Pump Passages Leaking.
5. Cooling System Cooler Plugged.
6. Overrunning Clutch Damaged.
SLIPS IN REVERSE 1. Fluid Level Low.
ONLY 2. Gearshift Linkage Mis-adjusted.
3. Rear Band Mis-adjusted.
4. Rear Band Worn.
5. Overdrive Direct Clutch Worn.
6. Hydraulic Pressure Too Low.
7. Rear Servo Leaking.
8. Band Linkage Binding.
SLIPS IN FORWARD 1. Fluid Level Low.
DRIVE RANGES 2. Fluid Foaming.
3. Throttle Linkage Mis-adjusted.
4. Gearshift Linkage Mis-adjusted.
5. Rear Clutch Worn.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged
Filter or Cooler Lines.
7. Rear Clutch Malfunction,
Leaking Seals or Worn Plates.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
SLIPS IN LOW GEAR Overrunning Clutch Faulty.
#D# ONLY, BUT NOT
IN MANUAL 1
POSITION
AUTOMATIC TRANSMISSION - 42RE 21 - 21
CORRECTION
1. Add fluid and check for leaks.
2. Route cable away from engine and bell
housing.
3. Remove, disassemble, inspect valve body.
Reassemble correctly if necessary. Replace
assembly if valves or springs are damaged.
Check for loose bolts or screws.
4. Check pump for porous casting, scores on
mating surfaces and excess rotor clearance.
Repair as required. Loose pump bolts.
5. Flow check cooler circuit. Repair as needed.
6. Replace clutch.
1. Add fluid and check for leaks.
2. Adjust linkage.
3. Adjust band.
4. Replace as required.
5. Disassemble overdrive. Repair as needed.
6. Perform hydraulic pressure tests to determine
cause.
7. Air pressure check clutch-servo operation and
repair as required.
8. Inspect and repair as required.
1. Add fluid and check for leaks.
2. Check for high oil level, bad pump gasket or
seals, dirt between pump halves and loose pump
bolts. Replace pump if necessary.
3. Adjust linkage.
4. Adjust linkage.
5. Inspect and replace as needed.
6. Perform hydraulic and air pressure tests to
determine cause.
7. Air pressure check clutch-servo operation and
repair as required.
8. Replace Clutch.
Replace overrunning clutch.
21 - 22 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
GROWLING, 1. Drive Plate Broken.
GRATING OR 2. Torque Converter Bolts Hitting
SCRAPING NOISES Dust Shield.
3. Planetary Gear Set Broken/
Seized.
4. Overrunning Clutch Worn/
Broken.
5. Oil Pump Components
Scored/Binding.
6. Output Shaft Bearing or Bushing
Damaged.
7. Clutch Operation Faulty.
8. Front and Rear Bands
Mis-adjusted.
DRAGS OR LOCKS 1. Fluid Level Low.
UP 2. Clutch Dragging/Failed
3. Front or Rear Band Mis-
adjusted.
4. Case Leaks Internally.
5. Servo Band or Linkage
Malfunction.
6. Overrunning Clutch Worn.
7. Planetary Gears Broken.
8. Converter Clutch Dragging.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.
2. PCM Malfunction.
3. TPS Malfunction
4. Lockup Solenoid Not Venting.
5. Overdrive Solenoid Not Venting.
6. Valve Body Valve Sticking.
NO 4-3 DOWNSHIFT 1. Control Switch Open/Shorted.
WHEN CONTROL 2. Overdrive Solenoid Connector
SWITCH IS TURNED Shorted.
OFF
3. PCM Malfunction.
4. Valve Body Stuck Valves.
WJ
CORRECTION
1. Replace.
2. Dust shield bent. Replace or repair.
3. Check for debris in oil pan and repair as
required.
4. Inspect and check for debris in oil pan. Repair
as required.
5. Remove, inspect and repair as required.
6. Remove, inspect and repair as required.
7. Perform air pressure check and repair as
required.
8. Adjust bands.
1. Check and adjust level.
2. Air pressure check clutch operation and repair
as required.
3. Adjust bands.
4. Check for leakage between passages in case.
5. Air pressure check servo operation and repair
as required.
6. Remove and inspect clutch. Repair as required.
7. Remove, inspect and repair as required (look
for debris in oil pan).
8. Check for plugged cooler. Perform flow check.
Inspect pump for excessive side clearance.
Replace pump as required.
1. Test wiring and connectors with test lamp and
volt/ohmmeter. Repair wiring as necessary. Replace
connectors and/or harnesses as required.
2. Check PCM operation with DRB" scan tool.
Replace PCM only if faulty.
3. Check TPS with DRB" scan tool at PCM.
4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Remove valve body and replace solenoid if
plugged or shorted.
6. Repair stuck 3-4 shift valve or lockup timing
valve.
1. Test and replace switch if faulty.
2. Test solenoids and replace if seized or shorted.
3. Test with DRB" scan tool. Replace PCM if faulty.
4. Repair stuck 3-4, lockup or lockup timing valve.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
CLUNK NOISE FROM 1. Transmission Fluid Low.
DRIVELINE ON 2. Throttle Cable Mis-adjusted.
CLOSED THROTTLE
3. Overdrive Clutch Select Spacer
4-3 DOWNSHIFT
Wrong Spacer.
3-4 UPSHIFT 1. Overdrive Solenoid Connector or
OCCURS Wiring Shorted.
IMMEDIATELY AFTER 2. TPS Malfunction.
2-3 SHIFT
3. PCM Malfunction.
4. Overdrive Solenoid Malfunction.
5. Valve Body Malfunction.
WHINE/NOISE 1. Fluid Level Low.
RELATED TO ENGINE 2. Shift Cable Incorrect Routing.
SPEED
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position.
2. Overdrive Circuit Fuse Blown.
3. O/D Switch Wire Shorted/Open
Cut.
4. Distance or Coolant Sensor
Malfunction.
5. TPS Malfunction.
6. Neutral Sense to PCM Wire
Shorted/Cut.
7. PCM Malfunction.
8. Overdrive Solenoid Shorted/
Open.
9. Solenoid Feed Orifice in Valve
Body Blocked.
10. Overdrive Clutch Failed.
11. Hydraulic Pressure Low.
12. Valve Body Valve Stuck.
13. O/D Piston Incorrect Spacer.
14. Overdrive Piston Seal Failure.
15. O/D Check Valve/Orifice Failed.
AUTOMATIC TRANSMISSION - 42RE 21 - 23
CORRECTION
1. Add Fluid.
2. Adjust cable.
3. Replace overdrive piston thrust plate spacer.
1. Test connector and wiring for loose connections,
shorts or ground and repair as needed.
2. Test TPS and replace as necessary. Check with
DRB" scan tool.
3. Test PCM with DRB" scan tool and replace
controller if faulty.
4. Replace solenoid.
5. Remove, disassemble, clean and inspect valve
body components. Make sure all valves and plugs
slide freely in bores. Polish valves with crocus
cloth if needed.
1. Add fluid and check for leaks.
2. Check shift cable for correct routing. Should not
touch engine or bell housing.
1. Turn control switch to ON position.
2. Replace fuse. Determine why fuse failed and
repair as necessary (i.e., shorts or grounds in
circuit).
3. Check wires/connections with 12V test lamp
and voltmeter. Repair damaged or loose
wire/connection as necessary.
4. Check with DRB" scan tool and repair or
replace as necessary.
5. Check with DRB" scan tool and replace if
necessary.
6. Test switch/sensor as described in service
section and replace if necessary. Engine no start.
7. Check with DRB" scan tool and replace if
necessary.
8. Replace solenoid if shorted or open and repair
loose or damaged wires (DRB" scan tool).
9. Remove, disassemble, and clean valve body
thoroughly. Check feed orifice.
10. Disassemble overdrive and repair as needed.
11. Pressure test transmission to determine
cause.
12. Repair stuck 3-4 shift valve, 3-4 timing valve.
13. Remove unit, check end play and install
correct spacer.
14. Replace both seals.
15. Check for free movement and secure
assembly (in piston retainer). Check ball bleed
orifice.
21 - 24 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION

SLIPS IN OVERDRIVE 1. Fluid Level Low. 1. Add fluid and check for leaks.
FOURTH GEAR 2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch pack.
3. Overdrive Piston Retainer Bleed 3. Disassemble transmission, remove retainer and
Orifice Blown Out. replace orifice.
4. Overdrive Piston or Seal 4. Remove overdrive unit. Replace seals if worn.
Malfunction. Replace piston if damaged. If piston retainer is
damaged, remove and disassemble the
transmission.
5. 3-4 Shift Valve, Timing Valve or 5. Remove and overhaul valve body. Replace
Accumulator Malfunction. accumulator seals. Make sure all valves operate
freely in bores and do not bind or stick. Make sure
valve body screws are correctly tightened and
separator plates are properly positioned.
6. Overdrive Unit Thrust Bearing 6. Disassemble overdrive unit and replace thrust
Failure. bearing (NO. 1 thrust bearing is between
overdrive piston and clutch hub; NO. 2 thrust
bearing is between the planetary gear and the
direct clutch spring plate; NO. 3 thrust bearing is
between overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice 7. Check for function/secure orifice insert in O/D
Failure. piston retainer.
DELAYED 3-4 1. Fluid Level Low. 1. Add fluid and check for leaks.
UPSHIFT (SLOW TO 2. Throttle Valve Cable Mis- 2. Adjust throttle valve cable.
ENGAGE) adjusted.
3. Overdrive Clutch Pack 3. Remove unit and rebuild clutch pack.
Worn/Burnt.
4. TPS Faulty. 4. Test with DRB" scan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice 5. Disassemble transmission and replace orifice.
Plugged.
6. Overdrive Solenoid or Wiring 6. Test solenoid and check wiring for loose/
Shorted/Open. corroded connections or shorts/grounds. Replace
solenoid if faulty and repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and select
proper spacer.
8. O/D Check Valve Missing or 8. Check for presence of check valve. Repair or
Stuck. replace as required.
TORQUE Lockup Solenoid, Relay or Wiring Test solenoid, relay and wiring for continuity,
CONVERTER LOCKS Shorted/Open. shorts or grounds. Replace solenoid and relay if
UP IN SECOND faulty. Repair wiring and connectors as necessary.
AND/OR THIRD
GEAR
HARSH 1-2, 2-3, 3-4 Lockup Solenoid Malfunction. Remove valve body and replace solenoid
OR 3-2 SHIFTS assembly.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
NO START IN PARK 1. Gearshift Linkage/Cable
OR NEUTRAL Mis-adjusted.
2. Neutral Sense Wire Open/Cut.
3. Park/Neutral Switch, or
Transmission Range Sensor Faulty.
4. Park/Neutral Switch, or
Transmission Range Sensor
Connection Faulty.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
NO REVERSE (OR 1. Direct Clutch Pack (front clutch)
SLIPS IN REVERSE) Worn.
2. Rear Band Mis-adjusted.
3. Front Clutch Malfunctioned/
Burned.
4. Overdrive Thrust Bearing
Failure.
5. Direct Clutch Spring Collapsed/
Broken.
AUTOMATIC TRANSMISSION - 42RE 21 - 25
CORRECTION
1. Adjust linkage/cable.
2. Check continuity with test lamp. Repair as
required.
3. Refer to service section for test and
replacement procedure.
4. Connectors spread open. Repair.
5. Inspect lever assembly and replace if damaged.
1. Disassemble unit and rebuild clutch pack.
2. Adjust band.
3. Air-pressure test clutch operation. Remove and
rebuild if necessary.
4. Disassemble geartrain and replace bearings.
5. Remove and disassemble unit. Check clutch
position and replace spring.
21 - 26 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
CONDITION POSSIBLE CAUSES
OIL LEAKS. 1. Fluid Lines and Fittings
Loose/Leaks/Damaged.
2. Fill Tube (where tube enters
case) Leaks/Damaged.
3. Pressure Port Plug Loose
Loose/Damaged.
4. Pan Gasket Leaks.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
6. Rear Bearing Access Plate
Leaks.
7. Gasket Damaged or Bolts are
Loose.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.
9. Park/Neutral Switch, or
Transmission Range Sensor
Leaks/Damaged.
10. Converter Housing Area Leaks.
11. Pump Seal Leaks/Worn/
Damaged.
12. Torque Converter Weld
Leak/Cracked Hub.
13. Case Porosity Leaks.
NOISY OPERATION 1. Overdrive Clutch Discs, Plates
IN FOURTH GEAR or Snap Rings Damaged.
ONLY 2. Overdrive Piston or Planetary
Thrust Bearing Damaged.
3. Output Shaft Bearings
Scored/Damaged.
4. Planetary Gears Worn/Chipped.
5. Overdrive Unit Overrunning
Clutch Rollers Worn/Scored.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Da m a ged or wor n t h r ea ds in t h e a lu m in u m t r a n s-
m ission ca se a n d va lve body ca n be r epa ir ed by t h e
u se of H eli-Coils™, or equ iva len t . Th is r epa ir con -
sist s of dr illin g ou t t h e wor n -ou t da m a ged t h r ea ds.
Th en t a p t h e h ole wit h a specia l H eli-Coil™ t a p, or
equ iva len t , a n d in st a llin g a H eli-Coil™ in ser t , or
WJ
CORRECTION
1. Tighten fittings. If leaks persist, replace fittings
and lines if necessary.
2. Replace tube seal. Inspect tube for cracks in fill
tube.
3. Tighten to correct torque. Replace plug or
reseal if leak persists.
4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Replace shaft seal.
6. Replace gasket. Tighten screws.
7. Replace bolts or gasket or tighten both.
8. Replace gasket.
9. Replace switch and gasket.
10. Check for leaks at seal caused by worn seal
or burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing or hole plugged. Check for leaks past
O-ring seal on pump or past pump-to-case bolts;
pump housing porous, oil coming out vent due to
overfill or leak past front band shaft access plug.
11. Replace seal.
12. Replace converter.
13. Replace case.
1. Remove unit and rebuild clutch pack.
2. Remove and disassemble unit. Replace either
thrust bearing if damaged.
3. Remove and disassemble unit. Replace either
bearing if damaged.
4. Remove and overhaul overdrive unit.
5. Remove and overhaul overdrive unit.
equ iva len t , in t o t h e h ole. Th is br in gs t h e h ole ba ck t o
it s or igin a l t h r ea d size.
H eli-Coil™, or equ iva len t , t ools a n d in ser t s a r e
r ea dily a va ila ble fr om m ost a u t om ot ive pa r t s su ppli-
er s.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 27
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

REMOVAL
Th e over dr ive u n it ca n be r em oved a n d ser viced
sepa r a t ely. It is n ot n ecessa r y t o r em ove t h e en t ir e
t r a n sm ission a ssem bly t o per for m over dr ive u n it
r epa ir s.
If on ly t h e over dr ive u n it r equ ir es ser vice, r efer t o
Over dr ive Rem ova l for pr oper pr ocedu r es.

CAUTION: The transmission and torque converter

must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.

(1) Discon n ect ba t t er y n ega t ive ca ble.
(2) Discon n ect a n d lower or r em ove n ecessa r y
exh a u st com pon en t s.
(3) Discon n ect flu id cooler lin es a t t r a n sm ission .
(4) Rem ove st a r t er m ot or. (Refer t o 8 - E LE CTRI-
CAL/STARTING/STARTE R MOTOR - RE MOVAL)
(5) Discon n ect a n d r em ove cr a n ksh a ft posit ion sen -
sor. (Refer t o 14 - F UE L SYSTE M/F UE L INJ E C-
TION/CRANKSH AF T P OSITION SE NSOR
RE MOVAL) Ret a in sen sor a t t a ch in g bolt s.
CAUTION: The crankshaft position sensor will be
damaged if the transmission is removed, or
installed, while the sensor is still bolted to the
engine block, or transmission (4.0L only). To avoid
damage, be sure to remove the sensor before
removing the transmission.
Fig. 13 Bell Housing Brace and Converter Cover
1 - Transmission
2 - Torque Converter Cover
3 - Bellhousing Brace
(14) Ma r k pr opeller sh a ft a n d a xle yokes for
a ssem bly a lign m en t . Th en discon n ect a n d r em ove
pr opeller sh a ft . On 4 x 4 m odels, r em ove bot h pr opel-
- ler sh a ft s.
(15) Discon n ect wir es fr om pa r k/n eu t r a l posit ion
swit ch a n d t r a n sm ission solen oid.
(16) Discon n ect gea r sh ift ca ble fr om t r a n sm ission
m a n u a l va lve lever (F ig. 14).

(6) Rem ove t h e bolt s h oldin g t h e bell h ou sin g

br a ce t o t h e t r a n sm ission .
(7) Rem ove n u t h oldin g t h e bell h ou sin g br a ce t o
t h e en gin e t o t r a n sm ission ben din g br a ce.
(8) Rem ove t h e bell h ou sin g br a ce fr om t h e t r a n s-
m ission (F ig. 13).
(9) Rem ove t h e bolt h oldin g t h e t or qu e con ver t er
cover t o t h e t r a n sm ission .
(10) Rem ove t h e t or qu e con ver t er cover fr om t h e
t r a n sm ission .
(11) If t r a n sm ission is bein g r em oved for over h a u l,
r em ove t r a n sm ission oil pa n , dr a in flu id a n d r ein st a ll
Fig. 14 Transmission Shift Cable
pa n .
1 - SHIFT CABLE
(12) Rem ove fill t u be br a cket bolt s a n d pu ll t u be
2 - MANUAL LEVER
ou t of t r a n sm ission . Ret a in fill t u be sea l. On 4 x 4
3 - MANUAL LEVER
m odels, it will a lso be n ecessa r y t o r em ove bolt
a t t a ch in g t r a n sfer ca se ven t t u be t o con ver t er h ou s-
in g.
(13) Rot a t e cr a n ksh a ft in clockwise dir ect ion u n t il
con ver t er bolt s a r e a ccessible. Th en r em ove bolt s on e
a t a t im e. Rot a t e cr a n ksh a ft wit h socket wr en ch on
da m pen er bolt .
21 - 28 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(17) Discon n ect t h r ot t le va lve ca ble fr om t r a n sm is-
sion br a cket a n d t h r ot t le va lve lever (F ig. 15).
(18) Discon n ect t r a n sfer ca se sh ift ca ble fr om t h e
t r a n sfer ca se sh ift lever (F ig. 16).
(19) Rem ove t h e clip secu r in g t h e t r a n sfer ca se
sh ift ca ble in t o t h e ca ble su ppor t br a cket .
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(22) Ra ise t r a n sm ission sligh t ly wit h ser vice ja ck
t o r elieve loa d on cr ossm em ber a n d su ppor t s.
(23) Rem ove bolt s secu r in g r ea r su ppor t a n d cu sh -
ion t o t r a n sm ission a n d cr ossm em ber (F ig. 17).
(24) Rem ove bolt s a t t a ch in g cr ossm em ber t o fr a m e
a n d r em ove cr ossm em ber.

Fig. 15 Throttle Valve Cable

1 - THROTTLE VALVE CABLE
2 - THROTTLE VALVE LEVER
3 - THROTTLE BODY

Fig. 17 Rear Transmission Crossmember

1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT

(25) Rem ove t r a n sfer ca se (F ig. 18) a n d (F ig. 19).

Fig. 16 Transfer Case Shift Cable

1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE

(20) Discon n ect t r a n sm ission flu id cooler lin es a t

t r a n sm ission fit t in gs a n d clips. Fig. 18 Remove NV247 Transfer Case
(21) Su ppor t r ea r of en gin e wit h sa fet y st a n d or 1 - NV247 TRANSFER CASE
ja ck.
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AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
Fig. 19 Remove NV242 Transfer Case
1 - NV242 TRANSFER CASE
(26) Rem ove bolt s h oldin g t h e u pper t r a n sm ission
ben din g br a ces t o t h e t or qu e con ver t er h ou sin g a n d
t h e over dr ive u n it (F ig. 20).
(27) Rem ove a ll r em a in in g con ver t er h ou sin g bolt s.
Fig. 20 Remove Upper Transmission Bending
Braces
1 - TRANSMISSION BENDING BRACES
(28) Ca r efu lly wor k t r a n sm ission a n d t or qu e con -
ver t er a ssem bly r ea r wa r d off en gin e block dowels.
(29) H old t or qu e con ver t er in pla ce du r in g t r a n s-
m ission r em ova l.
(30) Lower t r a n sm ission a n d r em ove a ssem bly
fr om u n der t h e veh icle.
(31) To r em ove t or qu e con ver t er, ca r efu lly slide
t or qu e con ver t er ou t of t h e t r a n sm ission .
DISASSEMBLY
(1) Clea n t r a n sm ission ext er ior wit h st ea m gu n or
wit h solven t . Wea r eye pr ot ect ion du r in g clea n in g
oper a t ion s.
(2) P la ce t r a n sm ission in a ver t ica l posit ion .
AUTOMATIC TRANSMISSION - 42RE 21 - 29
(3) Mea su r e in pu t sh a ft en d pla y a s follows (F ig.
21).
(a ) At t a ch Ada pt er 8266-6 t o H a n dle 8266-8.
(b) At t a ch dia l in dica t or C-3339 t o H a n dle
8266-8.
(c) In st a ll t h e a ssem bled t ool on t o t h e in pu t
sh a ft of t h e t r a n sm ission a n d t igh t en t h e r et a in in g
scr ew on Ada pt er 8266-6 t o secu r e it t o t h e in pu t
sh a ft .
(d) P osit ion t h e dia l in dica t or plu n ger a ga in st a
fla t spot on t h e oil pu m p a n d zer o t h e dia l in dica -
t or.
(e) Move t h e in pu t sh a ft in a n d ou t . Recor d t h e
Fig. 21 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
m a xim u m t r a vel for a ssem bly r efer en ce.
(4) Rem ove sh ift a n d t h r ot t le lever s fr om va lve
body m a n u a l lever sh a ft .
(5) P la ce t r a n sm ission in h or izon t a l posit ion .
(6) Rem ove t r a n sm ission oil pa n a n d ga sket .
(7) Rem ove filt er fr om va lve body (F ig. 22). Keep
filt er scr ews sepa r a t e fr om ot h er va lve body scr ews.
F ilt er scr ews a r e lon ger a n d sh ou ld be kept wit h fil-
t er.
(8) Rem ove pa r k/n eu t r a l posit ion swit ch .
(9) Rem ove h ex h ea d bolt s a t t a ch in g va lve body t o
t r a n sm ission ca se (F ig. 23). A t ot a l of 10 bolt s a r e
u sed. Not e differ en t bolt len gt h s for a ssem bly r efer-
en ce.
21 - 30 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

Fig. 22 Oil Filter Removal

1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)

(10) Rem ove va lve body a ssem bly. P u sh va lve body

Fig. 24 Valve Body Removal
h a r n ess con n ect or ou t of ca se. Th en wor k pa r k r od
1 - GOVERNOR PRESSURE SENSOR
a n d va lve body ou t of ca se (F ig. 24).
2 - VALVE BODY
(11) Rem ove a ccu m u la t or pist on a n d in n er a n d
3 - PARK ROD
ou t er spr in gs (F ig. 25). 4 - ACCUMULATOR PISTON
(12) Rem ove pu m p oil sea l wit h su it a ble pr y t ool 5 - GOVERNOR PRESSURE SOLENOID
or slide-h a m m er m ou n t ed scr ew.

Fig. 25 Accumulator Piston And Springs

1 - ACCUMULATOR PISTON
2 - OUTER SPRING
3 - INNER SPRING

is t igh t a r ou n d fr on t clu t ch r et a in er. Th is pr even t s

fr on t /r ea r clu t ch es fr om com in g ou t wit h pu m p a n d
possibly da m a gin g clu t ch or pu m p com pon en t s.
(14) Rem ove oil pu m p bolt s.
Fig. 23 Valve Body Bolt Locations (15) Th r ea d bolt s of Slide H a m m er Tools C-3752
1 - VALVE BODY BOLTS in t o t h r ea ded h oles in pu m p body fla n ge (F ig. 26).
2 - VALVE BODY BOLTS (16) Bu m p slide h a m m er weigh t s ou t wa r d t o
r em ove pu m p a n d r ea ct ion sh a ft su ppor t a ssem bly
fr om ca se (F ig. 26).
(13) Loosen fr on t ba n d a dju st in g scr ew lockn u t 4-5
(17) Loosen fr on t ba n d a dju st in g scr ew u n t il ba n d
t u r n s. Th en t igh t en ba n d a dju st in g scr ew u n t il ba n d
is com plet ely loose.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 31
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

Fig. 28 Removing Front Band Lever

Fig. 26 Removing Oil Pump And Reaction Shaft
Support Assembly 1 - FRONT BAND LEVER

1 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY

2 - SLIDE HAMMER TOOLS C-3752

(18) Squ eeze fr on t ba n d t oget h er a n d r em ove ba n d

st r u t (F ig. 27).
(19) Rem ove fr on t ba n d lever (F ig. 28).
(20) Rem ove fr on t ba n d lever sh a ft plu g, if n eces-
sa r y, fr om con ver t er h ou sin g.
(21) Rem ove fr on t ba n d lever sh a ft .

Fig. 29 Removing Front/Rear Clutch Assemblies

1 - INPUT SHAFT
2 - FRONT CLUTCH
3 - REAR CLUTCH
Fig. 27 Removing Front Band Strut
1 - BAND LEVER
(24) Rem ove in t er m edia t e sh a ft t h r u st wa sh er
2 - BAND STRUT
fr om fr on t en d of sh a ft or fr om r ea r clu t ch h u b (F ig.
3 - FRONT BAND
31).
(25) Rem ove ou t pu t sh a ft t h r u st pla t e fr om in t er-
(22) Rem ove fr on t a n d r ea r clu t ch u n it s a s a ssem - m edia t e sh a ft h u b (F ig. 32).
bly. Gr a sp in pu t sh a ft , h old clu t ch u n it s t oget h er a n d (26) Slide fr on t ba n d off dr ivin g sh ell (F ig. 33) a n d
r em ove t h em fr om ca se (F ig. 29). r em ove ba n d fr om ca se.
(23) Lift fr on t clu t ch off r ea r clu t ch (F ig. 30). Set
clu t ch u n it s a side for over h a u l.
21 - 32 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
Fig. 30 Separating Front/Rear Clutch Assemblies
1 - FRONT CLUTCH
2 - REAR CLUTCH
Fig. 31 Removing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
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Fig. 32 Removing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 33 Front Band Removal
1 - DRIVING SHELL
2 - FRONT BAND
(27) Rem ove pla n et a r y gea r t r a in a s a ssem bly (F ig.
34). Su ppor t gea r t r a in wit h bot h h a n ds du r in g
r em ova l. Do n ot a llow m a ch in ed su r fa ces on in t er m e-
dia t e sh a ft or over dr ive pist on r et a in er t o becom e
n icked or scr a t ch ed.
(28) If over dr ive u n it is n ot t o be ser viced, in st a ll
Align m en t Sh a ft 6227-2 in t o t h e over dr ive u n it t o
pr even t m isa lign m en t of t h e over dr ive clu t ch es du r-
in g ser vice of m a in t r a n sm ission com pon en t s.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 33
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(29) Loosen r ea r ba n d a dju st in g scr ew 4-5 t u r n s. (31) Rem ove low-r ever se dr u m a n d r ever se ba n d.
(30) Rem ove low-r ever se dr u m sn a p-r in g (F ig. 35). (32) Rem ove over r u n n in g clu t ch r oller a n d spr in g
a ssem bly a s a u n it (F ig. 36).
(33) Com pr ess fr on t ser vo r od gu ide a bou t 1/8 in ch
wit h Va lve Spr in g Com pr essor C-3422-B (F ig. 37).
(34) Rem ove fr on t ser vo r od gu ide sn a p-r in g. E xer-
cise ca u t ion wh en r em ovin g sn a p-r in g. Ser vo bor e
ca n be scr a t ch ed or n icked if ca r e is n ot exer cised.
(35) Rem ove com pr essor t ools a n d r em ove fr on t
ser vo r od gu ide, spr in g a n d ser vo pist on .

Fig. 34 Removing Planetary Geartrain And Fig. 36 Overrunning Clutch Assembly Removal
Intermediate Shaft Assembly
1 - OVERRUNNING CLUTCH CAM
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT 2 - REAR BAND REACTION PIN
ASSEMBLY
3 - OVERRUNNING CLUTCH ASSEMBLY

Fig. 37 Compressing Front Servo Rod Guide

Fig. 35 Removing Low-Reverse Drum Snap-Ring 1 - SPRING COMPRESSOR TOOL C-3422-B
1 - LOW-REVERSE DRUM 2 - ROD GUIDE SNAP-RING
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
21 - 34 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(36) Com pr ess r ea r ser vo spr in g r et a in er a bou t
1/16 in ch wit h Va lve Spr in g Com pr essor C-3422-B
(F ig. 38).
(37) Rem ove r ea r ser vo spr in g r et a in er sn a p-r in g.
Th en r em ove com pr essor t ools a n d r em ove r ea r ser vo
spr in g a n d pist on .
(38) In spect t r a n sm ission com pon en t s.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
Fig. 38 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
CLEANING
Clea n t h e ca se in a solven t t a n k. F lu sh t h e ca se
bor es a n d flu id pa ssa ges t h or ou gh ly wit h solven t .
Dr y t h e ca se a n d a ll flu id pa ssa ges wit h com pr essed
a ir. Be su r e a ll solven t is r em oved fr om t h e ca se a n d
t h a t a ll flu id pa ssa ges a r e clea r.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
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Lu br ica t e t r a n sm ission pa r t s wit h Mopa r ! ATF +4,
t ype 9602, t r a n sm ission flu id du r in g over h a u l a n d
a ssem bly. Use pet r oleu m jelly, Mopa r ! Door E a se, or
Ru -Glyde™ t o pr elu br ica t e sea ls, O-r in gs, a n d t h r u st
wa sh er s. P et r oleu m jelly ca n a lso be u sed t o h old
pa r t s in pla ce du r in g r ea ssem bly.
INSPECTION
In spect t h e ca se for cr a cks, por ou s spot s, wor n
bor es, or da m a ged t h r ea ds. Da m a ged t h r ea ds ca n be
r epa ir ed wit h H elicoil t h r ea d in ser t s. H owever, t h e
ca se will h a ve t o be r epla ced if it exh ibit s a n y t ype of
da m a ge or wea r.
Lu br ica t e t h e fr on t ba n d a dju st in g scr ew t h r ea ds
wit h pet r oleu m jelly a n d t h r ea d t h e scr ew pa r t -wa y
in t o t h e ca se. Be su r e t h e scr ew t u r n s fr eely.
In spect t h e t r a n sm ission bu sh in gs du r in g over h a u l.
Bu sh in g con dit ion is im por t a n t a s wor n , scor ed bu sh -
in gs con t r ibu t e t o low pr essu r es, clu t ch slip a n d
a cceler a t ed wea r of ot h er com pon en t s. H owever, do
n ot r epla ce bu sh in gs a s a m a t t er of cou r se. Repla ce
bu sh in gs on ly wh en t h ey a r e a ct u a lly wor n , or
scor ed.
Use r ecom m en ded t ools t o r epla ce bu sh in gs. Th e
t ools a r e sized a n d design ed t o r em ove, in st a ll, a n d
sea t bu sh in gs cor r ect ly. Th e bu sh in g r epla cem en t
t ools a r e in clu ded in Bu sh in g Tool Set C-3887-B.
P r e-sized ser vice bu sh in gs a r e a va ila ble for
r epla cem en t pu r poses. On ly t h e su n gea r bu sh in gs
a r e n ot ser viced.
Th e u se of cr ocu s clot h is per m issible wh er e n eces-
sa r y, pr ovidin g it is u sed ca r efu lly. Wh en u sed on
sh a ft s, or va lves, u se ext r em e ca r e t o a void r ou n din g
off sh a r p edges. Sh a r p edges a r e vit a l a s t h ey pr e-
ven t for eign m a t t er fr om get t in g bet ween t h e va lve
a n d va lve bor e.
Do n ot r eu se oil sea ls, ga sket s, sea l r in gs, or
O-r in gs du r in g over h a u l. Repla ce t h ese pa r t s a s a
m a t t er of cou r se. Also do n ot r eu se sn a p r in gs or
E -clips t h a t a r e ben t or dist or t ed. Repla ce t h ese pa r t s
a s well.
ASSEMBLY
Do n ot a llow dir t , gr ea se, or for eign m a t er ia l t o
en t er t h e ca se or t r a n sm ission com pon en t s du r in g
a ssem bly. Keep t h e t r a n sm ission ca se a n d com po-
n en t s clea n . Also m a ke su r e t h e t ools a n d wor kben ch
a r ea u sed for a ssem bly oper a t ion s a r e equ a lly clea n .
Sh op t owels u sed for wipin g off t ools a n d h a n ds
m u st be m a de fr om lin t fre e m a t er ia l. Lin t will st ick
t o t r a n sm ission pa r t s a n d cou ld in t er fer e wit h va lve
oper a t ion , or even r est r ict flu id pa ssa ges.
Lu br ica t e t h e t r a n sm ission com pon en t s wit h
Mopa r ! t r a n sm ission flu id du r in g r ea ssem bly. Use
Mopa r ! Door E a se, or Ru -Glyde™ on sea ls a n d
O-r in gs t o ea se in st a lla t ion .
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 35
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
P et r oleu m jelly ca n a lso be u sed t o h old t h r u st
wa sh er s, t h r u st pla t es a n d ga sket s in posit ion du r in g
a ssem bly. H owever, d o n o t u se ch a ssis gr ea se, bea r-
in g gr ea se, wh it e gr ea se, or sim ila r lu br ica n t s on a n y
t r a n sm ission pa r t . Th ese t ypes of lu br ica n t s ca n
even t u a lly block or r est r ict flu id pa ssa ges a n d in t er-
fer e wit h va lve oper a t ion . Use pet r oleu m jelly on ly.
Do n ot for ce pa r t s in t o pla ce. Th e t r a n sm ission
com pon en t s a n d su ba ssem blies a r e ea sily in st a lled by
h a n d wh en pr oper ly a lign ed.
If a pa r t seem s ext r em ely difficu lt t o in st a ll, it is
eit h er m isa lign ed or in cor r ect ly a ssem bled. Also ver-
ify t h a t t h r u st wa sh er s, t h r u st pla t es a n d sea l r in gs
a r e cor r ect ly posit ion ed befor e a ssem bly. Th ese pa r t s
ca n in t er fer e wit h pr oper a ssem bly if m is-posit ion ed.
Th e pla n et a r y gea r t r a in , fr on t /r ea r clu t ch a ssem - Fig. 40 Front Servo Components
blies a n d oil pu m p a r e a ll m u ch ea sier t o in st a ll 1 - PISTON SEAL RINGS
wh en t h e t r a n sm ission ca se is u pr igh t . 2 - SERVO PISTON
(1) In st a ll r ea r ser vo pist on , spr in g a n d r et a in er 3 - SNAP-RING
(F ig. 39). In st a ll spr in g on t op of ser vo pist on a n d 4 - ROD GUIDE
in st a ll r et a in er on t op of spr in g. 5 - SPRING
(2) In st a ll fr on t ser vo pist on a ssem bly, ser vo 6 - ROD
spr in g a n d r od gu ide (F ig. 40).
(3) Com pr ess fr on t /r ea r ser vo spr in gs wit h Va lve
Spr in g Com pr essor C-3422-B a n d in st a ll ea ch ser vo
sn a p-r in g (F ig. 41).

Fig. 39 Rear Servo Components

1 - SERVO PISTON
2 - PISTON SPRING
Fig. 41 Compressing Front/Rear Servo Springs
3 - SNAP-RING 1 - SPRING COMPRESSOR TOOL C-3422-B
4 - RETAINER 2 - ROD GUIDE SNAP-RING
5 - PISTON SEAL
(a ) Lu br ica t e over r u n n in g clu t ch r a ce (on dr u m
(4) Lu br ica t e clu t ch ca m r oller s wit h t r a n sm ission h u b) wit h t r a n sm ission flu id.
flu id. (b) Gu ide dr u m t h r ou gh r ea r ba n d.
(5) In st a ll r ea r ba n d in ca se (F ig. 42). Be su r e t win (c) Tilt dr u m sligh t ly a n d st a r t r a ce (on dr u m
lu gs on ba n d a r e sea t ed a ga in st r ea ct ion pin . h u b) in t o over r u n n in g clu t ch r oller s.
(6) In st a ll low-r ever se dr u m a n d ch eck over r u n - (d) P r ess dr u m r ea r wa r d a n d t u r n it in clock-
n in g clu t ch oper a t ion a s follows: wise dir ect ion u n t il dr u m sea t s in over r u n n in g
clu t ch (F ig. 43).
21 - 36 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(7) In st a ll sn a p-r in g t h a t secu r es low-r ever se dr u m
t o h u b of over dr ive pist on r et a in er (F ig. 44).
(8) In st a ll r ea r ba n d lever a n d pivot pin (F ig. 45).
Align lever wit h pin bor es in ca se a n d pu sh pivot pin
in t o pla ce.
(9) In st a ll pla n et a r y gea r t r a in a ssem bly (F ig. 46).

Fig. 42 Rear Band Installation

1 - REAR BAND

(e) Tu r n dr u m ba ck a n d for t h . Dr u m sh ou ld
r ot a t e fr eely in clockwise dir ect ion a n d lock in
cou n t er clockwise dir ect ion (a s viewed fr om fr on t of
ca se). Fig. 44 Installing Low-Reverse Drum Retaining
Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING

Fig. 43 Installing Low-Reverse Drum

1 - REAR BAND
2 - LOW-REVERSE DRUM

Fig. 45 Rear Band Lever And Pivot Pin Installation

1 - REAR BAND LEVER
2 - LEVER PIVOT PIN
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 37
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

Fig. 48 Input Shaft Seal Ring Location

1 - INPUT SHAFT
2 - TEFLON SEAL RING
3 - PLASTIC SEAL RING
4 - REAR CLUTCH RETAINER
Fig. 46 Installing Planetary Geartrain
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY

(10) In st a ll t h r u st pla t e on in t er m edia t e sh a ft h u b

(F ig. 47). Use pet r oleu m jelly t o h old t h r u st pla t e in
pla ce.
(11) Ch eck sea l r in g on r ea r clu t ch r et a in er h u b
a n d sea l r in gs on in pu t sh a ft (F ig. 48). Also ver ify
t h a t sh a ft sea l r in gs a r e in st a lled in sequ en ce sh own .
(12) In st a ll r ea r clu t ch t h r u st wa sh er (F ig. 49).
Use a ddit ion a l pet r oleu m jelly t o h old wa sh er in
pla ce if n ecessa r y.

Fig. 49 Installing Rear Clutch Thrust Washer

1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER (FIBER)

(13) Align clu t ch discs in fr on t clu t ch a n d in st a ll

fr on t clu t ch on r ea r clu t ch (F ig. 50). Rot a t e fr on t
clu t ch r et a in er ba ck a n d for t h u n t il com plet ely
sea t ed on r ea r clu t ch r et a in er.
(14) Coa t in t er m edia t e sh a ft t h r u st wa sh er wit h
pet r oleu m jelly. Th en in st a ll wa sh er in r ea r clu t ch
h u b (F ig. 51). Use en ou gh pet r oleu m jelly t o h old
wa sh er in pla ce. Be su r e gr ooved side of wa sh er fa ces
r ea r wa r d (t owa r d ou t pu t sh a ft ) a s sh own . Also n ot e
t h a t wa sh er on ly fit s on e wa y in clu t ch h u b. Not e
Fig. 47 Installing Intermediate Shaft Thrust Plate
t h ickn ess of t h is wa sh er. It is a select fit pa r t a n d is
1 - INTERMEDIATE SHAFT HUB u sed t o con t r ol t r a n sm ission en d pla y.
2 - INTERMEDIATE SHAFT THRUST PLATE
21 - 38 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
Fig. 50 Assembling Front And Rear Clutch Units
1 - TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 - REAR CLUTCH ASSEMBLY
Fig. 51 Installing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
WJ
(15) Align dr ive t eet h on r ea r clu t ch discs wit h
sm a ll scr ewdr iver (F ig. 52). Th is m a kes in st a lla t ion
on fr on t pla n et a r y ea sier.
(16) Ra ise fr on t en d of t r a n sm ission u pwa r d a s fa r
a s possible a n d su ppor t ca se wit h wood blocks. F r on t /
r ea r clu t ch a n d oil pu m p a ssem blies a r e ea sier t o
in st a ll if t r a n sm ission is a s close t o u pr igh t posit ion
a s possible.
(17) Slide fr on t ba n d in t o ca se.
(18) In st a ll fr on t a n d r ea r clu t ch u n it s a s a ssem bly
(F ig. 53). Align r ea r clu t ch wit h fr on t a n n u lu s gea r
a n d in st a ll a ssem bly in dr ivin g sh ell. Be su r e ou t pu t
sh a ft t h r u st wa sh er a n d t h r u st pla t e a r e n ot dis-
pla ced du r in g in st a lla t ion .
(19) Ca r efu lly wor k a ssem bled clu t ch es ba ck a n d
for t h t o en ga ge a n d sea t r ea r clu t ch discs on fr on t
a n n u lu s gea r. Also be su r e fr on t clu t ch dr ive lu gs a r e
fu lly en ga ged in slot s of dr ivin g sh ell a ft er in st a lla -
t ion .
Fig. 52 Aligning Rear Clutch Disc Lugs
1 - REAR CLUTCH DISCS
2 - USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
(20) Assem ble fr on t ba n d st r u t .
(21) In st a ll fr on t ba n d a dju st er, st r u t a n d a dju st -
in g scr ew (F ig. 54).
(22) Tigh t en ba n d a dju st in g scr ew u n t il ba n d ju st
gr ips clu t ch r et a in er. Ver ify t h a t fr on t /r ea r clu t ch es
a r e st ill sea t ed befor e con t in u in g.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 39
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(24) Lu br ica t e oil pu m p body sea l wit h pet r oleu m
jelly. Lu br ica t e pu m p sh a ft sea l lip wit h pet r oleu m
jelly.
(25) Th r ea d t wo P ilot St u d Tools C-3288-B in t o
bolt h oles in oil pu m p bor e fla n ge (F ig. 56).
(26) Align a n d in st a ll oil pu m p ga sket (F ig. 56).

Fig. 53 Installing Front/Rear Clutch Assemblies Fig. 55 Reaction Shaft Support Seal Rings And
1 - INPUT SHAFT Thrust Washer
2 - FRONT CLUTCH 1 - REACTION SHAFT SUPPORT HUB
3 - REAR CLUTCH 2 - THRUST WASHER
3 - SEAL RINGS

Fig. 54 Front Band Linkage Installation

1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND

Fig. 56 Installing Pilot Studs And Oil Pump Gasket

(23) Ch eck sea l r in gs on r ea ct ion sh a ft su ppor t
1 - OIL PUMP GASKET
h u b. Ver ify t h a t sea l r in gs a r e h ooked t oget h er a n d
2 - PILOT STUD TOOLS C-3288-B
t h a t t h e t h r u st wa sh er is pr oper ly posit ion ed (F ig.
55). Use pet r oleu m jelly t o h old t h r u st wa sh er in
pla ce if n ecessa r y.
21 - 40 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(27) In st a ll oil pu m p (F ig. 57). Align a n d posit ion
pu m p on pilot st u ds. Slide pu m p down st u ds a n d
wor k it in t o fr on t clu t ch h u b a n d ca se by h a n d. Th en
in st a ll 2 or 3 pu m p bolt s t o h old pu m p in pla ce.
(28) Rem ove pilot st u d t ools a n d in st a ll r em a in in g
oil pu m p bolt s. Tigh t en bolt s a lt er n a t ely in dia gon a l
pa t t er n t o 20 N·m (15 ft . lbs.).

Fig. 58 Checking Input Shaft End Play

1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339

Fig. 57 Installing Oil Pump

1 - OIL PUMP
2 - PILOT STUD TOOL
3 - PILOT STUD TOOL

(29) Mea su r e in pu t sh a ft en d pla y (F ig. 58).

NOTE: If end play is incorrect, transmission is

incorrectly assembled, or the intermediate shaft
thrust washer is incorrect. The intermediate shaft
thrust washer is selective.

(a ) At t a ch Ada pt er 8266-6 t o H a n dle 8266-8.

(b) At t a ch dia l in dica t or C-3339 t o H a n dle
8266-8.
(c) In st a ll t h e a ssem bled t ool on t o t h e in pu t
sh a ft of t h e t r a n sm ission a n d t igh t en t h e r et a in in g
scr ew on Ada pt er 8266-6 t o secu r e it t o t h e in pu t
sh a ft .
(d) P osit ion t h e dia l in dica t or plu n ger a ga in st a
fla t spot on t h e oil pu m p a n d zer o t h e dia l in dica -
t or. Fig. 59 Accumulator Piston And Springs
(e) Move in pu t sh a ft in a n d ou t a n d r ecor d r ea d- 1 - GOVERNOR PRESSURE SENSOR
in g. E n d pla y sh ou ld be 0.56-2.31 m m (0.022-0.091 2 - VALVE BODY
in .). Adju st a s n ecessa r y. 3 - PARK ROD
4 - ACCUMULATOR PISTON
(30) In st a ll a ccu m u la t or pist on a n d in n er a n d
5 - GOVERNOR PRESSURE SOLENOID
ou t er spr in gs (F ig. 59).
(31) Ver ify t h a t va lve body solen oid h a r n ess is
secu r ed in 3-4 a ccu m u la t or h ou sin g cover pla t e.
WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(32) In st a ll va lve body a s follows:
(a ) Align a n d ca r efu lly in ser t pa r k r od in t o pa wl.
Rod will m a ke click n oise a s it en t er s pa wl. Move
r od sligh t ly t o ch eck en ga gem en t .
(b) Align a n d sea t va lve body on ca se. Be su r e
m a n u a l lever sh a ft a n d over dr ive con n ect or a r e
fu lly sea t ed in ca se. Also be su r e va lve body wir in g
is n ot pin ch ed or kin ked.
(c) In st a ll a n d st a r t a ll va lve body a t t a ch in g
bolt s by h a n d. Th en t igh t en bolt s even ly, in a dia g-
on a l pa t t er n t o 12 N·m (105 in . lbs.) t or qu e. Do n ot
over t igh t en va lve body bolt s. Th is cou ld r esu lt in
dist or t ion a n d cr oss lea ka ge a ft er in st a lla t ion .
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) In st a ll n ew filt er on va lve body. Tigh t en filt er
scr ews t o 4 N·m (35 in . lbs.).
(34) Adju st fr on t a n d r ea r ba n ds.
(35) In st a ll sea l on pa r k/n eu t r a l posit ion swit ch .
Th en in st a ll a n d t igh t en swit ch t o 34 N·m (25 ft .
lbs.).
(36) In st a ll m a gn et in oil pa n . Ma gn et goes on
sm a ll pr ot r u sion a t cor n er of pa n .
(37) P osit ion n ew oil pa n ga sket on ca se a n d
in st a ll oil pa n . Tigh t en pa n bolt s t o 17 N·m (13 ft .
lbs.).
(38) In st a ll n ew va lve body m a n u a l sh a ft sea l in
ca se (F ig. 60). Lu br ica t e sea l lip a n d m a n u a l sh a ft
wit h pet r oleu m jelly. St a r t sea l over sh a ft a n d in t o
ca se. Sea t sea l wit h 15/16 in ch , deep well socket .
Fig. 60 Installing Manual Lever Shaft Seal
1 - 15/16$$ SOCKET
2 - SEAL
(39) In st a ll t h r ot t le va lve a n d sh ift select or lever s
on va lve body m a n u a l lever sh a ft .
AUTOMATIC TRANSMISSION - 42RE 21 - 41
INSTALLATION
(1) Ch eck t or qu e con ver t er h u b a n d h u b dr ive
n ot ch es for sh a r p edges bu r r s, scr a t ch es, or n icks.
P olish t h e h u b a n d n ot ch es wit h 320/400 gr it pa per
a n d cr ocu s clot h if n ecessa r y. Th e h u b m u st be
sm oot h t o a void da m a gin g pu m p sea l du r in g in st a lla -
t ion .
(2) Lu br ica t e oil pu m p sea l lip wit h t r a n sm ission
flu id.
(3) Align con ver t er a n d oil pu m p.
(4) Ca r efu lly in ser t con ver t er in oil pu m p. Th en
r ot a t e con ver t er ba ck a n d for t h u n t il fu lly sea t ed in
pu m p gea r s.
(5) Ch eck con ver t er sea t in g wit h st eel sca le a n d
st r a igh t edge (F ig. 61). Su r fa ce of con ver t er lu gs
sh ou ld be 1/2 in . t o r ea r of st r a igh t edge wh en con -
ver t er is fu lly sea t ed.
(6) Tem por a r ily secu r e con ver t er wit h C-cla m p.
Fig. 61 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
(7) P osit ion t r a n sm ission on ja ck a n d secu r e it
wit h ch a in s.
(8) Ch eck con dit ion of con ver t er dr ivepla t e.
Repla ce t h e pla t e if cr a cked, dist or t ed or da m a ged.
Also be su r e t r a n sm ission dowel pin s a r e sea t ed in
en gin e block a n d pr ot r u de fa r en ou gh t o h old t r a n s-
m ission in a lign m en t .
(9) Apply a ligh t coa t in g of Mopa r ! H igh Tem p
gr ea se t o t h e t or qu e con ver t er h u b pocket in t h e r ea r
of t h e cr a n ksh a ft
(10) Ra ise t r a n sm ission a n d a lign con ver t er wit h
dr ive pla t e a n d con ver t er h ou sin g wit h en gin e block.
21 - 42 AUTOMATIC TRANSMISSION - 42RE
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
(11) Move t r a n sm ission for wa r d. Th en r a ise, lower
or t ilt t r a n sm ission t o a lign con ver t er h ou sin g wit h
en gin e block dowels.
(12) Ca r efu lly wor k t r a n sm ission for wa r d a n d over
en gin e block dowels u n t il con ver t er h u b is sea t ed in
cr a n ksh a ft .
(13) In st a ll t wo bolt s t o a t t a ch con ver t er h ou sin g
t o en gin e.
(14) In st a ll t h e u pper t r a n sm ission ben din g br a ces
t o t h e t or qu e con ver t er h ou sin g a n d t h e over dr ive
u n it . Tigh t en t h e bolt s t o 41 N·m (30 ft .lbs.).
(15) In st a ll r em a in in g t or qu e con ver t er h ou sin g t o
en gin e bolt s. Tigh t en t o 68 N·m (50 ft .lbs.).
(16) In st a ll r ea r t r a n sm ission cr ossm em ber.
Tigh t en cr ossm em ber t o fr a m e bolt s t o 68 N·m (50
ft .lbs.).
(17) In st a ll r ea r su ppor t t o t r a n sm ission . Tigh t en
bolt s t o 47 N·m (35 ft .lbs.).
(18) Lower t r a n sm ission on t o cr ossm em ber a n d
in st a ll bolt s a t t a ch in g t r a n sm ission m ou n t t o cr oss-
m em ber. Tigh t en clevis br a cket t o cr ossm em ber bolt s
t o 47 N·m (35 ft .lbs.). Tigh t en t h e clevis br a cket t o
r ea r su ppor t bolt t o 68 N·m (50 ft .lbs.).
(19) Rem ove en gin e su ppor t fixt u r e.
(20) In st a ll cr a n ksh a ft posit ion sen sor. (Refer t o 14
- F UE L SYSTE M/F UE L INJ E CTION/CRANKSH AF T
P OSITION SE NSOR - INSTALLATION)
(21) In st a ll n ew pla st ic r et a in er gr om m et on a n y
sh ift ca ble t h a t wa s discon n ect ed. Gr om m et s sh ou ld
n ot be r eu sed. Use pr y t ool t o r em ove r od fr om gr om -
m et a n d cu t a wa y old gr om m et . Use plier s t o sn a p
n ew gr om m et in t o ca ble a n d t o sn a p gr om m et on t o
lever.
(22) Con n ect gea r sh ift a n d t h r ot t le va lve ca ble t o
t r a n sm ission .
(23) Con n ect wir es t o pa r k/n eu t r a l posit ion swit ch
a n d t r a n sm ission solen oid con n ect or. Be su r e t r a n s-
m ission h a r n esses a r e pr oper ly r ou t ed.
WJ
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(24) In st a ll a ll t or qu e con ver t er-t o-dr ivepla t e bolt s
by h a n d.
(25) Ver ify t h a t t h e t or qu e con ver t er is pu lled
flu sh t o t h e dr ivepla t e. Tigh t en bolt s t o 31 N·m (270
in . lbs.).
(26) In st a ll con ver t er h ou sin g a ccess cover. Tigh t en
bolt t o 23 N·m (200 in .lbs.).
(27) In st a ll t h e bell h ou sin g br a ce t o t h e t or qu e
con ver t er cover a n d t h e en gin e t o t r a n sm ission ben d-
in g br a ce. Tigh t en t h e bolt s a n d n u t t o 41 N·m (30
ft .lbs.).
(28) In st a ll st a r t er m ot or (Refer t o 8 - E LE CTRI-
CAL/STARTING/STARTE R MOTOR - INSTALLA-
TION) a n d cooler lin e br a cket .
(29) Con n ect cooler lin es t o t r a n sm ission .
(30) In st a ll t r a n sm ission fill t u be. In st a ll n ew sea l
on t u be befor e in st a lla t ion .
(31) In st a ll exh a u st com pon en t s.
(32) In st a ll t r a n sfer ca se. Tigh t en t r a n sfer ca se
n u t s t o 35 N·m (26 ft .lbs.).
(33) In st a ll t h e t r a n sfer ca se sh ift ca ble t o t h e
ca ble su ppor t br a cket a n d t h e t r a n sfer ca se sh ift
lever.
(34) Align a n d con n ect pr opeller sh a ft (s).
(35) Adju st gea r sh ift lin ka ge a n d t h r ot t le va lve
ca ble if n ecessa r y.
(36) Lower veh icle.
(37) F ill t r a n sm ission wit h Mopa r ! ATF +4, t ype
9602, flu id.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 43
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

SCH EM AT I CS AN D DI AGRAM S
HYDRAULIC SCHEMATICS

HYDRAULIC FLOW IN PARK

21 - 44 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN NEUTRAL

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 45
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN REVERSE

21 - 46 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN DRIVE FIRST GEAR

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 47
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN DRIVE SECOND GEAR

21 - 48 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN DRIVE THIRD GEAR (CONVERTER CLUTCH NOT APPLIED)

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 49
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN DRIVE THIRD GEAR (CONVERTER CLUTCH APPLIED)

21 - 50 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED)

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 51
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH APPLIED)

21 - 52 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN MANUAL LOW (1)

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 53
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW IN MANUAL SECOND (2)

21 - 54 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

HYDRAULIC FLOW DURING FULL THROTTLE 3-2 DOWNSHIFT (PASSING)

WJ AUTOMATIC TRANSMISSION - 42RE 21 - 55
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

SPECI FI CAT I ON S Component Metric Inch

Direct clutch 6 discs
TRANSMISSION
42RE Band adjustment
GENERAL
from 72 in. lbs.

Component Metric Inch Front band Back off 3 turns

Planetary end play 0.127-1.22 0.005-0.048 Rear band Back off 4 turns
mm in. Recommended fluid Mopar" ATF +4, type 9602
Input shaft end play 0.56-2.31 0.022-0.091
mm in. GEAR RATIOS
Clutch pack clearance/ 1.70- 0.067-0.134
Front. 3.40mm in. 1ST GEAR 2.74:1
Clutch pack clearance/ 0.559-0.914 0.022-0.036 2ND GEAR 1.54:1
Rear. mm in. 3RD GEAR 1.0:1
Front clutch 4 discs 4TH GEAR 0.69:1
Rear clutch 4 discs REVERSE 2.21:1
Overdrive clutch 3 discs

THRUST WASHER/SPACER/SNAP-RING DIMENSIONS

Component Metric Inch

Front clutch thrust washer (reaction shaft 1.55 mm 0.061 in.
support hub)
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) Select fit to set end play
Output shaft thrust washer (rear clutch hub) 1.5-1.6 mm 0.060-0.063 in.
Rear clutch pack snap-ring 1.5 mm 0.060 in.

1.95 mm 0.076 in.

2.45 mm 0.098 in.
Planetary geartrain snap-ring (at front of output shaft) Select fit (three thicknesses avalible)
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
Intermiediate shaft spacer procedures in
Overdrive Unit D&A
procedures
21 - 56 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)
PRESSURE TEST

Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at Closed throttle 372-414 kPa (54-60 psi).
accumulator)
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.

T ORQU E SPECI FI CAT I ON S

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 31 - 270
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Switch, park/neutral 34 25 -
Bolt, fluid pan 17 13 -
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, speedometer adapter 11 - 100
Screw, vehicle speed sensor 2.5 - 21
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 57
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

SPECI AL T OOLS
RE TRANSMISSIONS

Dial Indicator - C-3339

Shaft, Spring Compressor and Alignment - 6227

Compressor, Spring - C-3422-C

Bar, Gauge - 6311

Puller, Slide Hammer - C-3752

Pilot, Extension Housing - C-3288-B

Gauge, Throttle Setting - C-3763

Gauge, Oil Pressure - C-3292

Gauge, Oil Pressure - C-3293SP

Installer, Seal - C-3860-A
21 - 58 AUTOMATIC TRANSMISSION - 42RE WJ
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

Remover, Seal - C-3985-B Kit, Bushing Remover/Installer - C-3887-J

Installer, Seal - C-3995-A

Nut, Bushing Remover - SP-1191, From kit C-3887-J

Cup, Bushing Remover - SP-3633, From kit C-3887-J

Handle, Universal - C-4171

Remover, Bushing - SP-3551

Installer, Seal - C-4193-A

Installer, Bushing - SP-5117

Dial Caliper - C-4962
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 59
AU T OM AT I C T RAN SM I SSI ON - 4 2 RE (Cont inue d)

Remover, Bushing - SP-5324

Flusher, Oil Cooler - 6906-B

Installer, Bushing - SP-5325

Installer, Piston - 8114

Compressor, Spring - C-3575-A Remover, Bushing - 6957

Gauge - 6312

Installer, Bushing - 6951

Adapter, Band Adjuster - C-3705

Retainer, Detent Ball and Spring - 6583

21 - 60 AUTOMATIC TRANSMISSION - 42RE WJ

ACCU M U LAT OR OPERATION

DESCRIPTION
Th e a ccu m u la t or (F ig. 62) is a h ydr a u lic device
t h a t h a s t h e sole pu r pose of cu sh ion in g t h e a pplica -
t ion of a ba n d or clu t ch . Th e a ccu m u la t or con sist s of
a du a l-la n d pist on a n d a spr in g loca t ed in a bor e in
t h e t r a n sm ission ca se. Th e 3-4 a ccu m u la t or is loca t ed
in a h ou sin g a t t a ch ed t o t h e side of t h e va lve body
(F ig. 63).
Bot h t h e a ccu m u la t or a n d t h e 3-4 a ccu m u la t or
fu n ct ion t h e sa m e. Lin e pr essu r e is dir ect ed t o t h e
sm a ll en d of t h e pist on wh en t h e t r a n sm ission is
pla ced in t o a DRIVE posit ion (F ig. 64), bot t om in g it
a ga in st t h e a ccu m u la t or pla t e. Wh en t h e 1-2 u psh ift
occu r s (F ig. 65), lin e pr essu r e is dir ect ed t o t h e la r ge
en d of t h e pist on a n d t h en t o t h e kickdown ser vo. As
t h e lin e pr essu r e r ea ch es t h e a ccu m u la t or, t h e com -
bin a t ion of spr in g pr essu r e a n d lin e pr essu r e for ces
t h e pist on a wa y fr om t h e a ccu m u la t or pla t e. Th is
ca u ses a ba la n ced pr essu r e sit u a t ion , wh ich r esu lt s
in a cu sh ion ed ba n d a pplica t ion . Aft er t h e kickdown
ser vo h a s becom e im m ova ble, lin e pr essu r e will fin -
ish pu sh in g t h e a ccu m u la t or u p in t o it s bor e. Wh en
t h e la r ge en d of t h e a ccu m u la t or pist on is sea t ed in
it s bor e, t h e ba n d or clu t ch is fu lly a pplied.

NOTE: The accumulator is shown in the inverted

position for illustrative purposes.

Fig. 62 Accumulator
1 - ACCUMULATOR PISTON
2 - PISTON SPRING

Fig. 64 Accumulator in DRIVE - FIRST Gear Position

1 - LINE PRESSURE

INSPECTION
Fig. 63 3-4 Accumulator and Housing In spect t h e a ccu m u la t or pist on a n d sea l r in gs (F ig.
1 - ACCUMULATOR PISTON 66). Repla ce t h e sea l r in gs if wor n or cu t . Repla ce t h e
2 - 3-4 ACCUMULATOR HOUSING pist on if ch ipped or cr a cked.
3 - TEFLON SEALS Ch eck con dit ion of t h e a ccu m u la t or in n er a n d
4 - PISTON SPRING ou t er spr in gs (F ig. 66). Repla ce t h e spr in gs if t h e
5 - COVER PLATE AND SCREWS coils a r e cr a cked, dist or t ed or colla psed.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 61
BAN DS (Cont inue d)
ca se, a n d t h e ot h er is a ct ed on wit h a pu sh in g for ce
by a ser vo pist on . Th e fr on t ba n d is a sin gle-wr a p
design (t h e ba n d does n ot com plet ely en com pa ss/
wr a p t h e dr u m t h a t it h olds).

Fig. 67 Front Band

1 - FRONT BAND
Fig. 65 Accumulator in SECOND Gear Position
2 - TRANSMISSION HOUSING
1 - BOTTOM OF BORE
2 - LINE PRESSURE
3 - SHUTTLE VALVE LOW/REVERSE (REAR) BAND
Th e low/r ever se ba n d, or “r ea r ”, ba n d (F ig. 68) is
sim ila r in a ppea r a n ce a n d oper a t ion t o t h e fr on t
ba n d. Th e r ea r ba n d is sligh t ly differ en t in t h a t it
does n ot u se a lin k ba r, bu t is a ct ed dir ect ly on by
t h e a pply lever. Th is is r efer r ed t o a s a dou ble-wr a p
ba n d design (t h e dr u m is com plet ely en com pa ssed/
wr a pped by t h e ba n d). Th e dou ble-wr a p ba n d pr o-
vides a gr ea t er h oldin g power in com pa r ison t o t h e
sin gle-wr a p design .

OPERATION
KICKDOWN (FRONT) BAND
Fig. 66 Accumulator Components Th e kickdown ba n d h olds t h e com m on su n gea r of
1 - INNER SPRING t h e pla n et a r y gea r set s by a pplyin g a n d h oldin g t h e
2 - ACCUMULATOR PISTON fr on t clu t ch r et a in er, wh ich is splin ed t o t h e su n gea r
3 - OUTER SPRING dr ivin g sh ell, a n d in t u r n splin ed dir ect ly t o t h e su n
4 - SEAL RINGS gea r. Th e a pplica t ion of t h e ba n d by t h e ser vo is t yp-
ica lly don e by a n a pply lever a n d lin k ba r.
BAN DS LOW/REVERSE (REAR) BAND
Th e r ea r ba n d h olds t h e r ea r pla n et ca r r ier st a -
DESCRIPTION t ion a r y by bein g m ou n t ed a r ou n d a n d a pplied t o t h e
low/r ever se dr u m .
KICKDOWN (FRONT) BAND
Th e kickdown , or “fr on t ”, ba n d (F ig. 67) h olds t h e
com m on su n gea r of t h e pla n et a r y gea r set s. Th e
fr on t (kickdown ) ba n d is m a de of st eel, a n d fa ced on
it s in n er cir cu m fer en ce wit h a fr ict ion -t ype lin in g.
On e en d of t h e ba n d is a n ch or ed t o t h e t r a n sm ission
21 - 62 AUTOMATIC TRANSMISSION - 42RE WJ
BAN DS (Cont inue d)

Fig. 68 Rear Band

Fig. 69 Front Band Adjustment Screw Location
1 - ADJUSTING SCREW
1 - LOCK-NUT
2 - LOCKNUT
2 - FRONT BAND ADJUSTER
3 - LEVER
4 - REAR BAND
5 - REACTION PIN (3) Loosen ba n d a dju st in g scr ew lockn u t 5-6 t u r n s
6 - O-RINGS (F ig. 70). Be su r e a dju st in g scr ew t u r n s fr eely in
7 - PIVOT PIN lever.
(4) Tigh t en a dju st in g scr ew t o 8 N·m (72 in . lbs.)
ADJ U ST M EN T S t or qu e.

ADJUSTMENT - BANDS
FRONT BAND
Th e fr on t (kickdown ) ba n d a dju st in g scr ew is
loca t ed on t h e left side of t h e t r a n sm ission ca se
a bove t h e m a n u a l va lve a n d t h r ot t le va lve lever s.
(1) Ra ise veh icle.
(2) Loosen ba n d a dju st in g scr ew lockn u t (F ig. 69).
Th en ba ck lockn u t off 3-5 t u r n s. Be su r e a dju st in g
scr ew t u r n s fr eely in ca se. Apply lu br ica n t t o scr ew
t h r ea ds if n ecessa r y.
(3) Tigh t en ba n d a dju st in g scr ew t o 8 N·m (72 in .
lbs.) t or qu e wit h In ch P ou n d Tor qu e Wr en ch
C-3380-A, a 3-in . ext en sion a n d a ppr opr ia t e Tor x™
socket .
Fig. 70 Rear Band Adjusting Screw Location
CAUTION: If Adapter C-3705 is needed to reach the 1 - ADJUSTING SCREW
adjusting screw, tighten the screw to only 5 N·m 2 - REAR BAND LEVER
(47-50 in. lbs.) torque. 3 - LOCKNUT

(4) Ba ck off fr on t ba n d a dju st in g scr ew 3 t u r n s.

(5) Ba ck off a dju st in g scr ew 4 t u r n s.
(5) H old a dju st er scr ew in posit ion a n d t igh t en
(6) H old a dju st in g scr ew in pla ce a n d t igh t en lock-
lockn u t t o 41 N·m (30 ft . lbs.) t or qu e.
n u t t o 34 N·m (25 ft . lbs.) t or qu e.
(6) Lower veh icle.
(7) P osit ion n ew ga sket on oil pa n a n d in st a ll pa n
REAR BAND on t r a n sm ission . Tigh t en pa n bolt s t o 17 N·m (13 ft .
lbs.) t or qu e.
Th e t r a n sm ission oil pa n m u st be r em oved for
(8) Lower veh icle a n d r efill t r a n sm ission wit h
a ccess t o t h e r ea r ba n d a dju st in g scr ew.
Mopa r ! ATF +4, t ype 9602, flu id.
(1) Ra ise veh icle.
(2) Rem ove t r a n sm ission oil pa n a n d dr a in flu id.
WJ
BRAK E T RAN SM I SSI ON SH I FT
I N T ERLOCK M ECH AN I SM
DESCRIPTION
Th e Br a ke Tr a n sm ission Sh ift er /Ign it ion In t er lock
(BTSI), is a ca ble a n d solen oid oper a t ed syst em . It
in t er con n ect s t h e a u t om a t ic t r a n sm ission floor
m ou n t ed sh ift er t o t h e st eer in g colu m n ign it ion
swit ch (F ig. 71).
OPERATION
Th e syst em locks t h e sh ift er in t o t h e PARK posi-
t ion . Th e in t er lock syst em is en ga ged wh en ever t h e
ign it ion swit ch is in t h e LOCK or ACCE SSORY posi-
t ion . An a ddit ion a l elect r ica lly a ct iva t ed fea t u r e will
pr even t sh ift in g ou t of t h e PARK posit ion u n less t h e
br a ke peda l is depr essed a ppr oxim a t ely on e-h a lf a n
in ch . A m a gn et ic h oldin g device in t h e sh ift er a ssem -
bly is en er gized wh en t h e ign it ion is in t h e RUN
posit ion . Wh en t h e key is in t h e RUN posit ion a n d
t h e br a ke peda l is depr essed, t h e sh ift er is u n locked
a n d will m ove in t o a n y posit ion . Th e in t er lock syst em
a lso pr even t s t h e ign it ion swit ch fr om bein g t u r n ed
t o t h e LOCK or ACCE SSORY posit ion , u n less t h e
sh ift er is fu lly locked in t o t h e PARK posit ion .
Fig. 71 Ignition Interlock Cable
1 - SHIFT MECHANISM
2 - SHIFTER BTSI LEVER
3 - ADJUSTMENT CLIP
AUTOMATIC TRANSMISSION - 42RE 21 - 63
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK
(1) Ver ify t h a t t h e key ca n on ly be r em oved in t h e
PARK posit ion
(2) Wh en t h e sh ift lever is in PARK An d t h e sh ift
h a n dle pu sh bu t t on is in t h e “OUT” posit ion , t h e ign i-
t ion key cylin der sh ou ld r ot a t e fr eely fr om OF F t o
LOCK. Wh en t h e sh ift er is in a n y ot h er gea r or n eu -
t r a l posit ion , t h e ign it ion key cylin der sh ou ld n ot
r ot a t e t o t h e LOCK posit ion .
(3) Sh ift in g ou t of PARK sh ou ld n ot be possible
wh en t h e ign it ion key cylin der is in t h e OF F posi-
t ion .
(4) Sh ift in g ou t of PARK sh ou ld n ot be possible
wh ile a pplyin g n or m a l pu sh bu t t on for ce a n d ign it ion
key cylin der is in t h e RUN or START posit ion s
u n less t h e foot br a ke peda l is depr essed a ppr oxi-
m a t ely 1/2 in ch (12m m ).
(5) Sh ift in g ou t of PARK sh ou ld n ot be possible
wh en t h e ign it ion key cylin der is in t h e ACCE SSORY
or LOCK posit ion s.
(6) Sh ift in g bet ween a n y gea r s, NE UTRAL or in t o
PARK m a y be don e wit h ou t depr essin g foot br a ke
peda l wit h ign it ion swit ch in RUN or START posi-
t ion s.
4 - STEERING COLUMN ASSEMBLY
5 - INTERLOCK CABLE
21 - 64 AUTOMATIC TRANSMISSION - 42RE
BRAK E T RAN SM I SSI ON SH I FT I N T ERLOCK M ECH AN I SM (Cont inue d)
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK
Th e pa r k in t er lock ca ble is pa r t of t h e br a ke/sh ift
lever in t er lock syst em . Cor r ect ca ble a dju st m en t is
im por t a n t t o pr oper in t er lock oper a t ion . Th e gea r
sh ift a n d pa r k lock ca bles m u st bot h be cor r ect ly
a dju st ed in or der t o sh ift ou t of PARK.
ADJUSTMENT PROCEDURE
(1) Rem ove floor con sole a s n ecessa r y for a ccess t o
t h e br a ke t r a n sm ission sh ift in t er lock ca ble. (Refer t o
23 - BODY/INTE RIOR/F LOOR CONSOLE - wh ile a pplyin g n or m a l pu sh -bu t t on for ce, a n d ign i-
RE MOVAL)
(2) Sh ift t h e t r a n sm ission in t o t h e PARK posit ion .
(3) Tu r n ign it ion swit ch t o LOCK posit ion . B e
s u re ig n itio n k e y c y lin d e r is in th e LOCK p o s i-
tio n . Ca ble w ill n o t a d ju s t c o rre c tly in a n y
o th e r p o s itio n .
(4) P u ll ca ble lock bu t t on u p t o r elea se ca ble (F ig.
72).
(5) E n su r e t h a t t h e ca ble is fr ee t o self-a dju st by
pu sh in g ca ble r ea r wa r d a n d r elea sin g.
(6) P u sh lock bu t t on down u n t il it sn a ps in pla ce.
Fig. 72 Brake Transmission Shift Interlock Cable
1 - SHIFT MECHANISM
2 - SHIFTER BTSI LEVER
3 - ADJUSTMENT CLIP
WJ
BTSI FUNCTION CHECK
(1) Ver ify r em ova l of ign it ion key a llowed in PARK
posit ion on ly.
(2) Wh en t h e sh ift lever is in PARK, a n d t h e sh ift
h a n dle pu sh -bu t t on is in t h e ou t posit ion , t h e ign i-
t ion key cylin der sh ou ld r ot a t e fr eely fr om off t o lock.
Wh en t h e sh ift er is in a n y ot h er posit ion , t h e ign it ion
key sh ou ld n ot r ot a t e fr om off t o lock.
(3) Sh ift in g ou t of PARK sh ou ld be possible wh en
t h e ign it ion key cylin der is in t h e off posit ion .
(4) Sh ift in g ou t of PARK sh ou ld n ot be possible
t ion key cylin der is in t h e r u n or st a r t posit ion s,
u n less t h e foot br a ke peda l is depr essed a ppr oxi-
m a t ely 1/2 in ch (12m m ).
(5) Sh ift in g ou t of PARK sh ou ld n ot be possible
wh en t h e ign it ion key cylin der is in t h e a ccessor y or
lock posit ion .
(6) Sh ift in g bet ween a n y gea r a n d NE UTRAL, or
PARK, m a y be don e wit h ou t depr essin g foot br a ke
wit h ign it ion swit ch in r u n or st a r t posit ion s.
(7) Th e floor sh ift er lever a n d ga t e posit ion s
sh ou ld be in a lign m en t wit h a ll t r a n sm ission det en t
posit ion s.
4 - STEERING COLUMN ASSEMBLY
5 - INTERLOCK CABLE
WJ
BRAK E T RAN SM I SSI ON SH I FT I N T ERLOCK M ECH AN I SM (Cont inue d)
(8) E n gin e st a r t s m u st be possible wit h sh ift er
lever in PARK or NE UTRAL ga t e posit ion s on ly.
E n gin e st a r t s m u st n ot be possible in a n y ot h er ga t e
posit ion s ot h er t h a n PARK or NE UTRAL.
(9) Wit h sh ift er lever h a n dle pu sh -bu t t on n ot
depr essed a n d lever det en t in :
• PARK posit ion - a pply for wa r d for ce on cen t er of
h a n dle a n d r em ove pr essu r e. E n gin e st a r t m u st be
possible.
• PARK posit ion - a pply r ea r wa r d for ce on cen t er
of h a n dle a n d r em ove pr essu r e. E n gin e st a r t m u st be
possible.
• NE UTRAL posit ion - en gin e st a r t m u st be possi-
ble.
• NE UTRAL posit ion , en gin e r u n n in g a n d br a kes
a pplied- Apply for wa r d for ce on cen t er of sh ift h a n -
dle. Tr a n sm ission sh ou ld n ot be a ble t o sh ift in t o
RE VE RSE det en t .
ELECT RON I C GOV ERN OR
DESCRIPTION
Gover n or pr essu r e is con t r olled elect r on ica lly. Com -
pon en t s u sed for gover n or pr essu r e con t r ol in clu de:
• Gover n or body
• Va lve body t r a n sfer pla t e
• Gover n or pr essu r e solen oid va lve
• Gover n or pr essu r e sen sor
• F lu id t em per a t u r e t h er m ist or
• Th r ot t le posit ion sen sor (TP S)
• Tr a n sm ission speed sen sor
• P ower t r a in con t r ol m odu le (P CM)
GOVERNOR PRESSURE SOLENOID VALVE
Th e solen oid va lve is a du t y-cycle solen oid wh ich
r egu la t es t h e gover n or pr essu r e n eeded for u psh ift s
a n d down sh ift s. It is a n elect r o-h ydr a u lic device
loca t ed in t h e gover n or body on t h e va lve body t r a n s-
fer pla t e (F ig. 73).
Fig. 73 Governor Pressure Solenoid Valve
1 - SOLENOID FILTER
2 - GOVERNOR PRESSURE SOLENOID
AUTOMATIC TRANSMISSION - 42RE 21 - 65
GOVERNOR PRESSURE SENSOR
Th e gover n or pr essu r e sen sor m ea su r es ou t pu t
pr essu r e of t h e gover n or pr essu r e solen oid va lve (F ig.
74).
Fig. 74 Governor Pressure Sensor
1 - GOVERNOR BODY
2 - GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
GOVERNOR BODY AND TRANSFER PLATE
Th e t r a n sfer pla t e is design ed t o su pply t r a n sm is-
sion lin e pr essu r e t o t h e gover n or pr essu r e solen oid
va lve a n d t o r et u r n gover n or pr essu r e.
Th e gover n or pr essu r e solen oid va lve is m ou n t ed in
t h e gover n or body. Th e body is bolt ed t o t h e lower
side of t h e t r a n sfer pla t e (F ig. 74).
GOVERNOR PRESSURE CURVES
Th er e a r e fou r gover n or pr essu r e cu r ves pr o-
gr a m m ed in t o t h e t r a n sm ission con t r ol m odu le. Th e
differ en t cu r ves a llow t h e con t r ol m odu le t o a dju st
gover n or pr essu r e for va r yin g con dit ion s. On e cu r ve
is u sed for oper a t ion wh en flu id t em per a t u r e is a t , or
below, –1°C (30°F ). A secon d cu r ve is u sed wh en flu id
t em per a t u r e is a t , or a bove, 10°C (50°F ) du r in g n or-
m a l cit y or h igh wa y dr ivin g. A t h ir d cu r ve is u sed
du r in g wide-open t h r ot t le oper a t ion . Th e fou r t h cu r ve
is u sed wh en dr ivin g wit h t h e t r a n sfer ca se in low
r a n ge.
OPERATION
Com pen sa t ion is r equ ir ed for per for m a n ce va r ia -
t ion s of t wo of t h e in pu t devices. Th ou gh t h e slope of
t h e t r a n sfer fu n ct ion s is t igh t ly con t r olled, offset m a y
va r y du e t o va r iou s en vir on m en t a l fa ct or s or m a n u -
fa ct u r in g t oler a n ces.
Th e pr essu r e t r a n sdu cer is a ffect ed by ba r om et r ic
pr essu r e a s well a s t em per a t u r e. Ca libr a t ion of t h e
zer o pr essu r e offset is r equ ir ed t o com pen sa t e for
sh ift in g ou t pu t du e t o t h ese fa ct or s.
21 - 66 AUTOMATIC TRANSMISSION - 42RE
ELECT RON I C GOV ERN OR (Cont inue d)
Nor m a l ca libr a t ion will be per for m ed wh en su m p
t em per a t u r e is a bove 50 degr ees F, or in t h e a bsen ce
of su m p t em per a t u r e da t a , a ft er t h e fir st 10 m in u t es
of veh icle oper a t ion . Ca libr a t ion of t h e pr essu r e
t r a n sdu cer offset occu r s ea ch t im e t h e ou t pu t sh a ft
speed fa lls below 200 RP M. Ca libr a t ion sh a ll be
r epea t ed ea ch 3 secon ds t h e ou t pu t sh a ft speed is
below 200 RP M. A 0.5 secon d pu lse of 95% du t y cycle
is a pplied t o t h e gover n or pr essu r e solen oid va lve
a n d t h e t r a n sdu cer ou t pu t is r ea d du r in g t h is pu lse.
Aver a gin g of t h e t r a n sdu cer sign a l is n ecessa r y t o
r eject elect r ica l n oise.
Un der cold con dit ion s (below 50 degr ees F su m p),
t h e gover n or pr essu r e solen oid va lve r espon se m a y
be t oo slow t o gu a r a n t ee 0 psi du r in g t h e 0.5 secon d
ca libr a t ion pu lse. Ca libr a t ion pu lses a r e con t in u ed
du r in g t h is per iod, h owever t h e t r a n sdu cer ou t pu t
va lves a r e disca r ded. Tr a n sdu cer offset m u st be r ea d
a t key-on , u n der con dit ion s wh ich pr om ot e a st a ble
r ea din g. Th is va lu e is r et a in ed a n d becom es t h e off-
set du r in g t h e #cold# per iod of oper a t ion .
GOVERNOR PRESSURE SOLENOID VALVE
Th e in let side of t h e solen oid va lve is exposed t o
n or m a l t r a n sm ission lin e pr essu r e. Th e ou t let side of
t h e va lve lea ds t o t h e va lve body gover n or cir cu it .
Th e solen oid va lve r egu la t es lin e pr essu r e t o pr o-
du ce gover n or pr essu r e. Th e a ver a ge cu r r en t su p-
plied t o t h e solen oid con t r ols gover n or pr essu r e. On e
a m p cu r r en t pr odu ces zer o kP a /psi gover n or pr es-
su r e. Zer o a m ps set s t h e m a xim u m gover n or pr es-
su r e.
Th e power t r a in con t r ol m odu le (P CM) t u r n s on t h e
t r a n s con t r ol r ela y wh ich su pplies elect r ica l power t o
t h e solen oid va lve. Oper a t in g volt a ge is 12 volt s
(DC). Th e P CM con t r ols t h e gr ou n d side of t h e sole-
n oid u sin g t h e gover n or pr essu r e solen oid con t r ol cir-
cu it .
GOVERNOR PRESSURE SENSOR
Th e sen sor ou t pu t sign a l pr ovides t h e n ecessa r y
feedba ck t o t h e P CM. Th is feedba ck is n eeded t o a de-
qu a t ely con t r ol gover n or pr essu r e.
GOVERNOR BODY AND TRANSFER PLATE
Th e t r a n sfer pla t e ch a n n els lin e pr essu r e t o t h e
solen oid va lve t h r ou gh t h e gover n or body. It a lso
ch a n n els gover n or pr essu r e fr om t h e solen oid va lve
t o t h e gover n or cir cu it . It is t h e solen oid va lve t h a t
develops t h e n ecessa r y gover n or pr essu r e.
GOVERNOR PRESSURE CURVES
LOW TRANSMISSION FLUID TEMPERATURE
Wh en t h e t r a n sm ission flu id is cold t h e con ven -
t ion a l gover n or ca n dela y sh ift s, r esu lt in g in h igh er
WJ
t h a n n or m a l sh ift speeds a n d h a r sh sh ift s. Th e elec-
t r on ica lly con t r olled low t em per a t u r e gover n or pr es-
su r e cu r ve is h igh er t h a n n or m a l t o m a ke t h e
t r a n sm ission sh ift a t n or m a l speeds a n d soon er. Th e
P CM u ses a t em per a t u r e sen sor in t h e t r a n sm ission
oil su m p t o det er m in e wh en low t em per a t u r e gover-
n or pr essu r e is n eeded.
NORMAL OPERATION
Nor m a l oper a t ion is r efin ed t h r ou gh t h e in cr ea sed
com pu t in g power of t h e P CM a n d t h r ou gh a ccess t o
da t a on en gin e oper a t in g con dit ion s pr ovided by t h e
P CM t h a t wer e n ot a va ila ble wit h t h e pr eviou s
st a n d-a lon e elect r on ic m odu le. Th is fa cilit a t ed t h e
developm en t of a loa d a da pt ive sh ift st r a t egy - t h e
a bilit y t o a lt er t h e sh ift sch edu le in r espon se t o veh i-
cle loa d con dit ion . On e m a n ifest a t ion of t h is ca pa bil-
it y is gr a de #h u n t in g# pr even t ion - t h e a bilit y of t h e
t r a n sm ission logic t o dela y a n u psh ift on a gr a de if
t h e en gin e does n ot h a ve su fficien t power t o m a in -
t a in speed in t h e h igh er gea r. Th e 3-2 down sh ift a n d
t h e pot en t ia l for h u n t in g bet ween gea r s occu r s wit h a
h ea vily loa ded veh icle or on st eep gr a des. Wh en
h u n t in g occu r s, it is ver y object ion a ble beca u se sh ift s
a r e fr equ en t a n d a ccom pa n ied by la r ge ch a n ges in
n oise a n d a cceler a t ion .
WIDE OPEN THROTTLE OPERATION
In wide-open t h r ot t le (WOT) m ode, a da pt ive m em -
or y in t h e P CM a ssu r es t h a t u p-sh ift s occu r a t t h e
pr epr ogr a m m ed opt im u m speed. WOT oper a t ion is
det er m in ed fr om t h e t h r ot t le posit ion sen sor, wh ich
is a lso a pa r t of t h e em ission con t r ol syst em . Th e in i-
t ia l set t in g for t h e WOT u psh ift is below t h e opt i-
m u m en gin e speed. As WOT sh ift s a r e r epea t ed, t h e
P CM lea r n s t h e t im e r equ ir ed t o com plet e t h e sh ift s
by com pa r in g t h e en gin e speed wh en t h e sh ift s occu r
t o t h e opt im u m speed. Aft er ea ch sh ift , t h e P CM
a dju st s t h e sh ift poin t u n t il t h e opt im u m speed is
r ea ch ed. Th e P CM a lso con sider s veh icle loa din g,
gr a de a n d en gin e per for m a n ce ch a n ges du e t o h igh
a lt it u de in det er m in in g wh en t o m a ke WOT sh ift s. It
does t h is by m ea su r in g veh icle a n d en gin e a cceler a -
t ion a n d t h en fa ct or in g in t h e sh ift t im e.
TRANSFER CASE LOW RANGE OPERATION
On fou r-wh eel dr ive veh icles oper a t in g in low
r a n ge, t h e en gin e ca n a cceler a t e t o it s pea k m or e
r a pidly t h a n in Nor m a l r a n ge, r esu lt in g in dela yed
sh ift s a n d u n desir a ble en gin e #fla r e.# Th e low r a n ge
gover n or pr essu r e cu r ve is a lso h igh er t h a n n or m a l
t o in it ia t e u psh ift s soon er. Th e P CM com pa r es elec-
t r on ic veh icle speed sign a l u sed by t h e speedom et er
t o t h e t r a n sm ission ou t pu t sh a ft speed sign a l t o
det er m in e wh en t h e t r a n sfer ca se is in low r a n ge.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 67
ELECT RON I C GOV ERN OR (Cont inue d)

REMOVAL
(1) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(2) Rem ove t r a n sm ission flu id pa n a n d filt er.
(3) Disen ga ge wir e con n ect or s fr om pr essu r e sen -
sor a n d solen oid (F ig. 75).

Fig. 77 Pressure Solenoid and O-ring

1 - PRESSURE SOLENOID
2 - O-RING
3 - GOVERNOR

(9) Sepa r a t e gover n or body fr om va lve body (F ig.

Fig. 75 Governor Solenoid And Pressure Sensor 78).
1 - PRESSURE SENSOR (10) Rem ove gover n or body ga sket .
2 - PRESSURE SOLENOID
3 - GOVERNOR

(4) Rem ove scr ews h oldin g pr essu r e solen oid

r et a in er t o gover n or body.
(5) Sepa r a t e solen oid r et a in er fr om gover n or (F ig.
76).

Fig. 78 Governor Body and Gasket

1 - GOVERNOR BODY
2 - GASKET

Fig. 76 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
(6) P u ll solen oid fr om gover n or body (F ig. 77).
(7) P u ll pr essu r e sen sor fr om gover n or body.
(8) Rem ove bolt s h oldin g gover n or body t o va lve
body.
INSTALLATION
Befor e in st a llin g t h e pr essu r e sen sor a n d solen oid
in t h e gover n or body, r epla ce o-r in g sea ls, clea n t h e
ga sket su r fa ces a n d r epla ce ga sket .
(1) P la ce ga sket in posit ion on ba ck of gover n or
body (F ig. 79).
(2) P la ce gover n or body in posit ion on va lve body.
(3) In st a ll bolt s t o h old gover n or body t o va lve
body.
(4) Lu br ica t e o-r in g on pr essu r e sen sor wit h t r a n s-
m ission flu id.
(5) Align pr essu r e sen sor t o bor e in gover n or body.
21 - 68 AUTOMATIC TRANSMISSION - 42RE WJ
ELECT RON I C GOV ERN OR (Cont inue d)

Fig. 79 Governor Body and Gasket Fig. 81 Pressure Solenoid Retainer

1 - GOVERNOR BODY 1 - PRESSURE SOLENOID RETAINER
2 - GASKET 2 - GOVERNOR

(6) P u sh pr essu r e sen sor in t o gover n or body.

(7) Lu br ica t e o-r in g, on pr essu r e solen oid, wit h
t r a n sm ission flu id.
(8) Align pr essu r e solen oid t o bor e in gover n or
body (F ig. 80).
(9) P u sh solen oid in t o gover n or body.

Fig. 82 Governor Solenoid And Pressure Sensor

1 - PRESSURE SENSOR
2 - PRESSURE SOLENOID
3 - GOVERNOR

Fig. 80 Pressure Solenoid and O-ring EX T EN SI ON H OU SI N G

1 - PRESSURE SOLENOID BU SH I N G
2 - O-RING
3 - GOVERNOR REMOVAL
(1) Rem ove ext en sion h ou sin g yoke sea l.
(10) P la ce solen oid r et a in er in posit ion on gover n or (2) In ser t Rem over 6957 in t o t h e ext en sion h ou s-
(F ig. 81). in g. Tigh t en t ool t o bu sh in g a n d r em ove bu sh in g
(11) In st a ll scr ews t o h old pr essu r e solen oid (F ig. 83).
r et a in er t o gover n or body.
(12) E n ga ge wir e con n ect or s in t o pr essu r e sen sor INSTALLATION
a n d solen oid (F ig. 82). (1) Align bu sh in g oil h ole wit h oil slot in ext en sion
(13) In st a ll t r a n sm ission flu id pa n a n d (n ew) filt er. h ou sin g.
(14) Lower veh icle a n d r oa d t est t o ver ify r epa ir. (2) Ta p bu sh in g in t o pla ce wit h In st a ller 6951 a n d
H a n dle C-4171.
WJ
EX T EN SI ON H OU SI N G BU SH I N G (Cont inue d)
Fig. 83 Bushing Removal - Typical
1 - REMOVER 6957
2 - EXTENSION HOUSING BUSHING
(3) In st a ll n ew oil sea l in h ou sin g u sin g Sea l
In st a ller C-3995-A (F ig. 84).
Fig. 84 Extension Housing Seal Installation
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
EX T EN SI ON H OU SI N G SEAL
REMOVAL
(1) Ra ise veh icle.
(2) Ma r k pr opeller sh a ft a n d a xle yoke for a lign -
m en t r efer en ce.
(3) Discon n ect a n d r em ove pr opeller sh a ft .
(4) Rem ove old sea l wit h Sea l Rem over C-3985-B
(F ig. 85) fr om over dr ive h ou sin g.
INSTALLATION
(1) P la ce sea l in posit ion on over dr ive h ou sin g.
(2) Dr ive sea l in t o over dr ive h ou sin g wit h Sea l
In st a ller C-3995-A (F ig. 86).
(3) Ca r efu lly gu ide pr opeller sh a ft slip yoke in t o
h ou sin g a n d on t o ou t pu t sh a ft splin es. Align m a r ks
m a de a t r em ova l a n d con n ect pr opeller sh a ft t o r ea r
a xle pin ion yoke.
AUTOMATIC TRANSMISSION - 42RE 21 - 69
Fig. 85 Removing Overdrive Housing Yoke Seal
1 - SPECIAL TOOL C-3985-B
2 - SEAL
Fig. 86 Installing Overdrive Housing Seal
1 - SPECIAL TOOL C-3995-A OR C-3972-A
2 - SPECIAL TOOL C-4471
FLU I D AN D FI LT ER
DI AGN OSI S AN D T EST I N G
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low flu id level a llows t h e pu m p t o t a ke in a ir
a lon g wit h t h e flu id. Air in t h e flu id will ca u se flu id
pr essu r es t o be low a n d develop slower t h a n n or m a l.
If t h e t r a n sm ission is over filled, t h e gea r s ch u r n t h e
flu id in t o foa m . Th is a er a t es t h e flu id a n d ca u sin g
t h e sa m e con dit ion s occu r r in g wit h a low level. In
eit h er ca se, a ir bu bbles ca u se flu id over h ea t in g, oxi-
da t ion a n d va r n ish bu ildu p wh ich in t er fer es wit h
va lve a n d clu t ch oper a t ion . F oa m in g a lso ca u ses flu id
expa n sion wh ich ca n r esu lt in flu id over flow fr om t h e
t r a n sm ission ven t or fill t u be. F lu id over flow ca n ea s-
ily be m ist a ken for a lea k if in spect ion is n ot ca r efu l.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Bu r n t , discolor ed flu id is a r esu lt of over h ea t in g
wh ich h a s t wo pr im a r y ca u ses.
21 - 70 AUTOMATIC TRANSMISSION - 42RE
FLU I D AN D FI LT ER (Cont inue d)
(1) A r esu lt of r est r ict ed flu id flow t h r ou gh t h e
m a in a n d/or a u xilia r y cooler. Th is con dit ion is u su -
a lly t h e r esu lt of a fa u lt y or im pr oper ly in st a lled
dr a in ba ck va lve, a da m a ged m a in cooler, or sever e
r est r ict ion s in t h e cooler s a n d lin es ca u sed by debr is
or kin ked lin es.
(2) H ea vy du t y oper a t ion wit h a veh icle n ot pr op-
er ly equ ipped for t h is t ype of oper a t ion . Tr a iler t ow-
in g or sim ila r h igh loa d oper a t ion will over h ea t t h e
t r a n sm ission flu id if t h e veh icle is im pr oper ly
equ ipped. Su ch veh icles sh ou ld h a ve a n a u xilia r y
t r a n sm ission flu id cooler, a h ea vy du t y coolin g sys-
t em , a n d t h e en gin e/a xle r a t io com bin a t ion n eeded t o
h a n dle h ea vy loa ds.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Tr a n sm ission flu id con t a m in a t ion is gen er a lly a
r esu lt of:
• a ddin g in cor r ect flu id
• fa ilu r e t o clea n dipst ick a n d fill t u be wh en
ch eckin g level
• en gin e coola n t en t er in g t h e flu id
• in t er n a l fa ilu r e t h a t gen er a t es debr is
• over h ea t t h a t gen er a t es slu dge (flu id br ea k-
down )
• fa ilu r e t o r ever se flu sh cooler a n d lin es a ft er
r epa ir
• fa ilu r e t o r epla ce con t a m in a t ed con ver t er a ft er
r epa ir
Th e u se of n on -r ecom m en ded flu ids ca n r esu lt in
t r a n sm ission fa ilu r e. Th e u su a l r esu lt s a r e er r a t ic
sh ift s, slippa ge, a bn or m a l wea r a n d even t u a l fa ilu r e
du e t o flu id br ea kdown a n d slu dge for m a t ion . Avoid
t h is con dit ion by u sin g r ecom m en ded flu ids on ly.
Th e dipst ick ca p a n d fill t u be sh ou ld be wiped
clea n befor e ch eckin g flu id level. Dir t , gr ea se a n d
ot h er for eign m a t er ia l on t h e ca p a n d t u be cou ld fa ll
in t o t h e t u be if n ot r em oved befor eh a n d. Ta ke t h e
t im e t o wipe t h e ca p a n d t u be clea n befor e wit h dr a w-
in g t h e dipst ick.
E n gin e coola n t in t h e t r a n sm ission flu id is gen er-
a lly ca u sed by a cooler m a lfu n ct ion . Th e on ly r em edy
is t o r epla ce t h e r a dia t or a s t h e cooler in t h e r a dia t or
is n ot a ser vicea ble pa r t . If coola n t h a s cir cu la t ed
t h r ou gh t h e t r a n sm ission , a n over h a u l is n ecessa r y.
Th e t r a n sm ission cooler a n d lin es sh ou ld be
r ever se flu sh ed wh en ever a m a lfu n ct ion gen er a t es
slu dge a n d/or debr is. Th e t or qu e con ver t er sh ou ld
a lso be r epla ced a t t h e sa m e t im e.
F a ilu r e t o flu sh t h e cooler a n d lin es will r esu lt in
r econ t a m in a t ion . F lu sh in g a pplies t o a u xilia r y cooler s
a s well. Th e t or qu e con ver t er sh ou ld a lso be r epla ced
wh en ever a fa ilu r e gen er a t es slu dge a n d debr is. Th is
is n ecessa r y beca u se n or m a l con ver t er flu sh in g pr oce-
du r es will n ot r em ove a ll con t a m in a n t s.
WJ
STAN DARD PROCEDU RE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low flu id level ca n ca u se a va r iet y of con dit ion s
beca u se it a llows t h e pu m p t o t a ke in a ir a lon g wit h
t h e flu id. As in a n y h ydr a u lic syst em , a ir bu bbles
m a ke t h e flu id spon gy, t h er efor e, pr essu r es will be
low a n d bu ild u p slowly.
Im pr oper fillin g ca n a lso r a ise t h e flu id level t oo
h igh . Wh en t h e t r a n sm ssion h a s t oo m u ch flu id, t h e
gea r t r a in ch u r n s u p foa m a n d ca u se t h e sa m e con di-
t ion s wh ich occu r wit h a low flu id level.
In eit h er ca se, a ir bu bbles ca n ca u se over h ea t in g
a n d/or flu id oxida t ion , a n d va r n ish in g. Th is ca n
in t er fer e wit h n or m a l va lve, clu t ch , a n d a ccu m u la t or
oper a t ion . F oa m in g ca n a lso r esu lt in flu id esca pin g
fr om t h e t r a n sm ission ven t wh er e it m a y be m is-
t a ken for a lea k.
Aft er t h e flu id h a s been ch ecked, sea t t h e dipst ick
fu lly t o sea l ou t wa t er a n d dir t .
Th e t r a n sm ission h a s a dipst ick t o ch eck oil level.
It is loca t ed on t h e r igh t side of t h e en gin e. Be su r e
t o wipe a ll dir t fr om dipst ick h a n dle befor e r em ovin g.
F lu id level is ch ecked wit h t h e en gin e r u n n in g a t
cu r b idle speed, t h e t r a n sm ission in NE UTRAL a n d
t h e t r a n sm ission flu id a t n or m a l oper a t in g t em per a -
t u r e. Th e e n g in e s h o u ld be ru n n in g a t id le
s p e e d fo r a t le a s t o n e m in u te , w ith th e v e h ic le
o n le v e l g ro u n d .
Th e t r a n sm ission flu id level ca n be ch ecked t wo
wa ys.
PROCEDURE ONE
(1) Tr a n sm ission flu id m u st be a t n or m a l oper a t -
in g t em per a t u r e for a ccu r a t e flu id level ch eck. Dr ive
veh icle if n ecessa r y t o br in g flu id t em per a t u r e u p t o
n or m a l h ot oper a t in g t em per a t u r e of 82°C (180°F ).
(2) P osit ion veh icle on level su r fa ce.
(3) St a r t a n d r u n en gin e a t cu r b idle speed.
(4) Apply pa r kin g br a kes.
(5) Sh ift t r a n sm ission m om en t a r ily in t o a ll gea r
r a n ges. Th en sh ift t r a n sm ission ba ck t o NE UTRAL.
(6) Clea n t op of filler t u be a n d dipst ick t o keep
dir t fr om en t er in g t u be.
(7) Rem ove dipst ick (F ig. 87) a n d ch eck flu id level
a s follows:
(a ) Cor r ect a ccept a ble level is in cr ossh a t ch a r ea .
(b) Cor r ect m a xim u m level is t o MAX a r r ow
m a r k.
(c) In cor r ect level is a t or below MIN lin e.
(d) If flu id is low, a dd on ly en ou gh Mopa r ! ATF
+4, t ype 9602, t o r est or e cor r ect level. Do n ot over-
fill.
WJ
FLU I D AN D FI LT ER (Cont inue d)
Fig. 87 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
PROCEDURE TWO
(1) St a r t en gin e a n d a pply pa r kin g br a ke.
(2) Sh ift t h e t r a n sm ission in t o DRIVE for a ppr oxi-
m a t ely 2 secon ds.
(3) Sh ift t h e t r a n sm ission in t o RE VE RSE for
a ppr oxim a t ely 2 secon ds.
(4) Sh ift t h e t r a n sm ission in t o PARK.
(5) H ook u p DRB! sca n t ool a n d select en gin e.
(6) Select sen sor s.
(7) Rea d t h e t r a n sm ission t em per a t u r e va lu e.
(8) Com pa r e t h e flu id t em per a t u r e va lu e wit h t h e
figu r e. (F ig. 88)
(9) Adju st t r a n sm ission flu id level sh own on t h e
dipst ick a ccor din g t o t h e figu r e.
Fig. 88 42/44RE Fluid Fill Graph
AUTOMATIC TRANSMISSION - 42RE 21 - 71
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Ch eck t r a n sm ission for lea ks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
F or pr oper ser vice in t er va ls (Refer t o LUBRICA-
TION & MAINTE NANCE /MAINTE NANCE SCH E D-
ULE S - DE SCRIP TION). Th e ser vice flu id fill a ft er a
filt er ch a n ge is a ppr oxim a t ely 3.8 lit er s (4.0 qu a r t s).
REMOVAL
(1) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(2) P la ce a la r ge dia m et er sh a llow dr a in pa n
ben ea t h t h e t r a n sm ission pa n .
(3) Rem ove bolt s h oldin g fr on t a n d sides of pa n t o
t r a n sm ission (F ig. 89).
(4) Loosen bolt s h oldin g r ea r of pa n t o t r a n sm is-
sion .
(5) Slowly sepa r a t e fr on t of pa n a n d ga sket a wa y
fr om t r a n sm ission a llowin g t h e flu id t o dr a in in t o
dr a in pa n .
(6) H old u p pa n a n d r em ove r em a in in g bolt h old-
in g pa n t o t r a n sm ission .
21 - 72 AUTOMATIC TRANSMISSION - 42RE WJ
FLU I D AN D FI LT ER (Cont inue d)
(7) Wh ile h oldin g pa n level, lower pa n a n d ga sket NOTE: The transmission pan oil gasket is reusable.
a wa y fr om t r a n sm ission . Inspect the sealing surfaces of the gasket. If the
(8) P ou r r em a in in g flu id in pa n in t o dr a in pa n . sealing ribs on both surfaces appear to be in good
(9) Rem ove scr ews h oldin g filt er t o va lve body condition, clean the gasket of any foreign material
(F ig. 90). and reinstall.
(10) Sepa r a t e filt er fr om va lve body a n d pou r flu id
in filt er in t o dr a in pa n . (4) P osit ion t h e oil pa n ga sket on t o t h e oil pa n .
(11) Dispose of u sed t r a n s flu id a n d filt er pr oper ly. (5) P osit ion t h e oil pa n a n d ga sket on t o t h e t r a n s-
m ission a n d in st a ll sever a l bolt s t o h old t h e pa n a n d
ga sket t o t h e t r a n sm ission .
(6) In st a ll t h e r em a in der of t h e oil pa n bolt s.
Tigh t en t h e bolt s t o 13.6 N·m (