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Introduction Lamps


Introduction Passive Restraint Systems


Lubrication and Maintenance Electrically Heated System

Suspension Power Distribution System
Differential and Driveline Vehicle Theft/Security Systems
Brakes Chime/Buzzer Warning Systems
Clutch Wiring Diagrams
Cooling System Engine
Battery Exhaust System and Intake Manifold
Starting Systems Frame and Bumpers
Charging System Frame and Bumpers


Ignition System Fuel System
Instrument Panel Systems Fuel System


Instrument Panel Systems Steering


Audio Systems Transmission and Transfer Case

Horn Systems Tires and Wheels
Speed Control System Body
Turn Signal and Hazard Warning Systems Heating and Air Conditioning
Wiper and Washer Systems Emission Control Systems
Lamps Emission Control Systems

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INTRODUCTION
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GENERAL INFORMATION
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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 E = 3001-4000 lbs.
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5 Vehicle Line Y = Wrangler 4X4
6 Series 1 = Sport
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7 Body Style 9 = Open Body
8 Engine P = 2.5L Unleaded-Gasoline
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12 thru 17 Vehicle Build Sequence
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INTRODUCTION
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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 E = 3001-4000 lbs.
F = 4001-5000 lbs.
5 Vehicle Line Y = Wrangler 4X4
6 Series 1 = Sport
2 = SE
4 = Sahara
7 Body Style 9 = Open Body
8 Engine P = 2.5L Gasoline
S = 4.0L Gasoline
9 Check Digit
10 Model Year X = 1999
11 Assembly Plant P = Toledo #2
12 thru 17 Vehicle Build Sequence
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Fig. 1 Vehicle Safety Certification Label—Typical

VEHICLE SAFETY CERTIFICATION LABEL
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GENERAL INFORMATION INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1

CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1 PARTS AND LUBRICANT
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2 RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION J û  K þ û F ü OF

CLASSIFICATION úþLUBRICANTS
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51,000 Miles (82 000 km)
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57,000 Miles (91 000 km)
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60,000 Miles (96 000 km)

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63,000 Miles (101 000 km) • XV04R/9+,'*)0056%8=(76%0F4(79E+(79+.104&Y>
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69,000 Miles (110 000 km) • !#"%$'&)(+*),'.1023.10405&)(76%8:,/6CBD2I"%23R/046%2I(7F46A$/,'979=SF4(76%.123>
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102,000 Miles (163 000 km)
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JUMP STARTING, HOISTING AND TOWING

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SERVICE PROCEDURES RECREATIONAL TOWING . . . . . . . . . . . . . . . . . 10

EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . 10 TOWING RECOMMENDATIONS . . . . . . . . . . . . . . 9
HOISTING RECOMMENDATIONS . . . . . . . . . . . 10 VEHICLE TOWING . . . . . . . . . . . . . . . . . . . . . . . . 9
JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 8
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SERVICE PROCEDURES twz|…_ƒ‚ƒv|—ŠŽ…_ƒ~­zN<qs€u€
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JUMP STARTING PROCEDURE zNˆ†vNƒqsŠŽv4v|~_‹]ru~_v(qsŠk‰¥s¯†¯#ƒˆŒ;“
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WARNING: REVIEW ALL SAFETY PRECAUTIONS zN­~_v|…_ŠŽƒqs€;qs~_{³twv|Š#ˆqsƒ–„†lq†–iv®z|’v|¢s…_r  qs€2v|~_ŠŽ“:´…_ƒ~
AND WARNINGS IN GROUP 8A, BATTERY/START- ± qs€2€
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ING/CHARGING SYSTEMS DIAGNOSTICS. ”[j<µ‰” mp¶
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DO NOT JUMP START A FROZEN BATTERY, PER- ‚ƒ€uqsŒ;ˆ#Ššz;ˆz|twruŠŽr  v;ŠŽvNƒŒ;ru~_qs€j2ºœm“¡» ¶
½y‚l€2qsŒ;ˆ#ŠŽz;~_vN‹˜¾
SONAL INJURY CAN RESULT. qsŠšr Uv4ŠŽvNlŒ;r2~Qq†€
j<¾ m“¹%±¿²±´yqs€u€uzŸž1 £†¼ ‚ƒ€uqsŒ;ˆt•qsŠzNˆˆ†zNt‰r2ŠŽv
DO NOT JUMP START WHEN BATTERY INDICA- vN~Q{­zN:‚ƒqs†€uv|tŠŽzXŠŽzN…Q‚ƒx_—vN€uv|‚ƒŠšƒru‚ƒqs€qsƒ‚%ž•ru€u€ƒvNt‰…_€uŠÀj ru‹]“
TOR DOT IS YELLOW OR BRIGHT COLOR. BAT- knml“o
vš ruvŸž1qs€u€ ž•qsƒ~_ru~_‹˜t;ru~’ŠŽx_rut;ˆ†ƒzN‚ƒv|{…_ƒv|“ ”
TERY CAN EXPLODE. j<Á‰mp±%~p{rutwqss€uvN{/ v|x_ru‚ƒ€uvN—[‚ƒz|~_~_v|‚ƒŠco
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DO NOT ALLOW JUMPER CABLE CLAMPS TO ‚ƒ€uqsŒ;ˆ©ŠšzÂsqsŠšŠŽvN<‡ÃˆzNt‰ruŠšr  vÂj2ºœmĊŽvNƒŒ;ru~_qs€u“„¶
z|~_~_v|‚ƒŠ
TOUCH EACH OTHER WHEN CONNECTED TO A » ¶
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BOOSTER SOURCE. ŠŽx_£v(¼ ‹]ƒz|…_~_{p‚ƒq†s€uv(‚ƒzN~Q~_vN‚ƒŠŽruzN~’qst;ˆ†zNt‰twrus€uv4j ru‹]“%kDm“
DO NOT USE OPEN FLAME NEAR BATTERY. ”
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL CAUTION: Do not crank starter motor on disabled
ARCHING OF BATTERY CURRENT. vehicle for more than 15 seconds, starter will over-
WHEN USING A HIGH OUTPUT BOOSTING heat and could fail.
j<ʼnm €u€uzŸžÆsqsŠšŠŽvN›‡Sr2~Ç{†r2t‰qs†€uv|{p vNxQr2‚l€2v`Ššz­‚ƒxQq†ƒ‹˜v­ŠŽz
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DEVICE, DO NOT ALLOW DISABLED VEHICLE’S
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM twŠŽqsƒŠ/v|~_‹]ru~_v|“˟*v|~_‹]ru~_v#{†zNv|t4~_zNŠtwŠŽqsƒŠ:ž•ruŠŽx_ru~akwÁ­twv|‚ƒ¾
CAN RESULT. zN~Q{tw—
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CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.

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CAUTION: If the cause of starting problem on dis-

abled vehicle is severe, damage to booster vehicle
charging system can result.
Fig. 1 Jumper Cable Clamp Connections
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CAUTION: If vehicle is towed with wheels removed,

install lug nuts to retain brake drums.

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Fig. 2 Tow Vehicles With Approved Equipment
VEHICLE TOWING
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).
DO NOT ATTACH SLING-TYPE TOWING EQUIP-
MENT TO THE REAR OF A TJ.

Fig. 3 Towing With Tow Dollies

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Fig. 4 T-Hook Attachment

Fig. 6 Vehicle Lifting Locations

CAUTION: Do not attempt to lift a Jeep vehicle with
Fig. 5 Safety Chain Attachment
a floor jack positioned under:
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POINTS PROVIDED ARE FOR A COMPLETE VEHI-
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CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NOTE: Use the correct sub-frame rail or frame rail NENT IS REMOVED FROM A VEHICLE, THE
lifting locations only. CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
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DEVICE WHEN THESE CONDITIONS EXIST.
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SUSPENSION
Ä-ÅRÆdÇ ÈgÆ,ÇgÉ

page page
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ALIGNMENT
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page page

DESCRIPTION AND OPERATION WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS
DIAGNOSIS AND TESTING ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . 5
SUSPENSION AND STEERING SYSTEM . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
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çïýë…ãäùø#çó*ó1äñ'äéð'ä Group 0, Lubrication And Maintenance for the rec-
:äëô<ääé ëãä/å*äæ:ø#çéè;çéï!çø#ä^äø#èäï,æ=éøëñ'æ=çåçéè;çéï!çø#ä ommended maintenance schedule.
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Fig. 1 Wheel Alignment Measurements

‡1ˆ
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.
VEHICLE PULLS TO ONE 1. Tire pressure.
SIDE 2. Alignment.
3. Loose or worn steering or
suspension components.
4. Radial tire lead.
5. Brake pull.
6. Weak or broken spring.
‰VŠH‰V‹9ŒZ[‰GŽ [ &‘@’
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.
1. Adjust tire pressure.
2. Align vehicle to specifications.
3. Tighten or replace components as
necessary.
4. Rotate or replace tire as necessary.
5. Repair brake as necessary.
6. Replace spring.
"!$# %'&(%')+*-,(%/. 0(, 132

SERVICE PROCEDURES

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PRE-ALIGNMENT
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“F”K•s–K—7”ÍALIGNMENT
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³ ²?¤©O”'—š ™4™L ?”
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NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3, Dif-
ferential and Driveline for additional information.

å¥ê4á¸ëêGä@ì åì ê4í

NOTE: The wheel toe position adjustment is the Fig. 3 Drag Link and Tie Rod Clamp
final adjustment. This adjustment must be per-
formed with the engine running, if the vehicle is
equipped with power steering.
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SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
NOTE: Alignment specifications are in degrees.

Fig. 4 Steering Linkage

ADJUSTMENT PREFERRED RANGE MAX RT/LT DIFFERENCE

CASTER 7° 6 1.0° 0.65°
CAMBER
− 0.25° 6 0.63° 1.0°
(fixed angle)
TOE-IN
0.15° 6 0.07° 0.05°
(each front wheel)
THRUST ANGLE 0° 6 0.25°
Z[\ ]_^`]_acbed`]gf h`d i)j

FRONT SUSPENSION
ºR»+¼+½J¾
page page

DESCRIPTION AND OPERATION SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 7

FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 6 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 8
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 6 TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 8
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION SPECIFICATIONS
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . . 8 SPECIAL TOOLS
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 12
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 8
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DESCRIPTION AND OPERATION Ç>ÄpÅJÏYô ÁJÀËHÓpÏHÁÚÅNÔ-ïÄpÅJÏHÏ¥ÔÉÄpËHÆÕiÇEÉÄÆÈBð¿LÀÁÈBÊÄpËHÆÕ^È8Ç>ÁJÁJÏ
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• Ù ÅJËHÏ+È8ÊÄpËHÆÕtÈ Ç>ÀÁ•ÚÍÄCÇEŕÇ>ÀÁ•Í8ú\ÏHÁ•ÚÄpÍÓpÑóÁJÇ>È8ð
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• ¿Y Ù ÄpÍÓpÑiÚÍÄ Â6ÄpÍÖ:Á:ÄpÍËHÏ(ÚÄpÍÓpÑóÁJÇnÝMËHÇEÀ͔ÚÍÏHÏ(È8Ç>ÉÔ"ÍÆÔ"ËRÈ8ÅJÏHÍÇ>ÁJԓÝMËHÇ>À
ßdà áâã ä$åà æTçnèéNênëáéNà åáì<¿¢ÀÁíÏHËHÆÑNÒ ÓpÅJËHÏ"È8ÉÈ8ÊÁJÆÈBËHÅJÆ
• ÍÚÉÈ8ÀËHÆÕ_ÍÇ Ç>ÀÁ•Í8ú\ÏHÁ•ÚÄpÍÓÑÁNÇEð
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ÝMËHÇ>ÀÅJÉÇ3ÕkÄpÁJÍÇ>Ï ï‰ÍÂ6ÂRÁJÓpÇ>ËHÆÕÇEÀÁ”ÅNÊÊÅNÈBËHÇ>ÁCݓÀÁJÁNÏRðñ‰ÀÁNÁJÏHÈ CAUTION: Components attached with a nut and
ÍÄpÁÍÇ>ÇEÍÓpÀÁNÔZÇEÅUÍÀÉÚ8Ò ÚÁJÍÄpËHÆÕtÈÝMÀËHÓpÀòÚÅJÏHÇ>ÈÇ>ÅÇ>ÀÁ cotter pin must be torqued to specification. Then if
ÑóÆÉÓpÑóÏHÁJÈ8ð¿¢ÀÁiÀÉÚBÒ ÚÁJÍÄpËHÆÕrËHÈÆÅJÇ:ÈBÁNČô\ËHÓpÁNÍÚÏHÁÍÆԉËHÈ the slot in the nut does not line up with the cotter
ÄpÁNÊÏHÍÓpÁNÔõÍÈöÍ÷ÉÆËRÇ>ð Ù Ç>ÁJÁJÄpËHÆÕøÑóÆÉÓpÑóÏHÁJÈöÊË ô\ÅNÇÐÅJÆ pin hole, tighten nut until it is aligned. Never loosen
ÄpÁNÊÏHÍÓpÁNÍÚÏHÁÐÚÍÏHÏMùNÅNËHÆÇEÈòÍÇ>Ç>ÍÓpÀÁJÔöÇEÅÐÇ>ÀÁÐÍ8ú\ÏHÁÐÇ>ÉÚÁ the nut to align the cotter pin hole.
ï\ÅNÑóÁJÈBð
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ÔÍÖMÊÁJÆ CAUTION: Suspension components with rubber/
ùNÅNÉÆÓpÁ"ÍÆÔÄÁJÚÅJÉÆÔÖ:ÅJÇ>ËHÅJƉÅJ Ç>ÀÁMô ÁJÀËHÓpÏHÁÅEô\ÁNÄ3ô ÍÄËR× urethane
ÅJÉÈ_ÄpÅJÍÔ
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È8ÀÅJÓpÑóÈMÍÄpÁ•ÚÅNÏHÇEÁNÔÇ>ŕÍÍ8ú\ÏHÁ•ÚÄÍÓpÑóÁNÇEð supporting the weight
ä$åàµæ/çênÿà á
éNì¿LÀÁ:ÓpÅNËHÏ(È8ÊÄpËHÆÕkÈCÓpÅNÆÇ>ÄpÅJÏYÄpËHÔÁ ÉÍÏRËHÇ ï springs are not at their normal ride position,
of the vehicle when the fasteners are torqued. If
ÍÆÔ Ö:ÍËHÆÇ>ÍËHÆ ÊÄpÅNÊÁNÄÄpËHÔÁ ÀÁJËHÕtÀÇE𥿢ÀÁ ÓpÅNËRϔÈ8ÊÄpËHÆÕtÈ ride comfort could be affected and prematurevehicle
Ö:ÅNÉÆÇ$ÉÊ"ËHÆiÇ>ÀÁ¥ÝMÀÁNÁJÏHÀÅJÉÈBÁNð ÎÄpÉÚÚÁJÄ3ÔÅNÉÕkÀÆÉÇ$ËRÈ8ÅJ× ing wear may occur. bush-
ÏHÍÇEÅNÄ ËRÈ<ÏHÅJÓpÍÇEÁNԔÚÁJÇ ÝMÁNÁJÆÇ>ÀÁ“Ç>ÅJʔÅNÂYÇEÀÁ“ÈBÊÄpËHÆÕîÍÆԔÇ>ÀÁ
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SERVICE PROCEDURES

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LUBRICATION
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SHOCK ABSORBER Ñ,Â!Ã,Ë!Ó#¹ ½/Î
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µ6Ï>·„¸Š¹(º5»z¼F¹½-¾¹Ì$»zК¹(Â)¿À½-ʂÃ=¿#Æ;Ñ,»(Ì$½-ʂÈ6Â!» º¤½-¾¹Ã>ÒFÌ$¹ NOTE: Left coil spring has a retainer and bolt
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SPECIAL TOOLS
FRONT SUSPENSION

Bolt, Special 7604

Remover/Installer Suspension Bushing 7932

Remover C-4150A

Nut, Long 7603

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REAR SUSPENSION





page page

DESCRIPTION AND OPERATION SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 14

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 13 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 13 UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 15
REMOVAL AND INSTALLATION SPECIFICATIONS
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 16
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 14

DESCRIPTION AND OPERATION CAUTION: Suspension components with rubber/

urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
SUSPENSION
REAR "!#"%$""&('*)!"$,+-"./0)!(12"+ important to have the springs supporting the weight
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Fig. 1 Shock Absorber

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NOTE: Springs can be install with either end up.

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TRACK BAR SPECIFICATIONS
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NOTE: It may be necessary to pry the axle assem-

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DIFFERENTIAL AND DRIVELINE

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PROPELLER SHAFTS
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page page

GENERAL INFORMATION REMOVAL AND INSTALLATION

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . 8
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 8
PROPELLER SHAFT JOINT ANGLE . . . . . . . . . . . 2 DISASSEMBLY AND ASSEMBLY
PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . . . 1 DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . 10
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . 1 SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . 9
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 5 SINGLE AND DOUBLE CARDAN JOINT . . . . . . . 13
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . ... 4 ADJUSTMENTS
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3 AXLE PINION ANGLE ADJUSTMENT . . . . . . . . . 13
SERVICE PROCEDURES SPECIFICATIONS
DRIVELINE ANGLE MEASUREMENT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PREPARATION . . . . . . . . . . . . . . . . . . . . . . ... 6 SPECIAL TOOLS
PROPELLER SHAFT ANGLE MEASUREMENT ... 6 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 14
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Fig. 3 Double Cardan U-Joint

Fig. 4 Maximum Angles And Engine Speed

PRECAUTIONS
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CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
Fig. 5 Reference Marks on Yokes
DIAGNOSIS AND TESTING
VIBRATION
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Drive Condition Possible Cause Correction

Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash
material on shaft. with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or 3) Install new yoke.
excessive runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in 5) Loosen spring u-bolts and seat
seat. center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out 7) Installl new propeller shaft.
of balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft 180°,
condition. test, and evaluate.
10) Excessive drive pinion gear 10) Re-index propeller shaft 180°
shaft runout. and evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 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) Lubricate U-joint and evaluate.
Replace as necessary.

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Fig. 6 Clamp Screw At Position 1 Fig. 8 Clamp Screws Separated

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ÙÚïÛcÜ ÎÓÌ5ÉÈ
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Õ 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.
ëìí îïððñòñ!óô#ï õ&öõ'ó,î®î*òï ÷&ñöï ó,ñ øù

SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
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PROPELLER SHAFT
 #SŠXZzUzU[]T{XxhyPRf š¡ zUmoPRzU“uANGLE
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Fig. 12 Universal Joint Angle Example

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REMOVAL AND INSTALLATION

FRONT PROPELLER SHAFT
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Fig. 14 Reference Marks on Yokes

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Fig. 13 Front Propeller Shaft

REAR PROPELLER SHAFT
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Fig. 16 Rear Propeller Shaft

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Fig. 17 Crimping Dust Boot Clamp

DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT
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CAUTION: If the cross or bearing cap are not

straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.

Fig. 21 Install Cross In Yoke

Fig. 20 Press Out Remaining Bearing

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Fig. 23 Remove Snap Rings

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Fig. 26 Remove Centering Kit

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Fig. 24 Press Out Bearing

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Fig. 29 Press In Bearing Cap

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Fig. 27 Install Cross In Yoke

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Fig. 30 Press In Bearing Cap

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Fig. 28 Install Bearing Cap

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Fig. 31 Install Link Yoke Fig. 33 Install Remaining Cross

   
        
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Fig. 34 Press In Bearing Cap

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Fig. 35 Seat Snap Rings In Groove

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SPECIFICATIONS
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181 FBI AXLE

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page page

GENERAL INFORMATION DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . 20

181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 HUB BEARING AND AXLE SHAFT . . . . . . . . . . . 25
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . 15 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION AND OPERATION PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 22
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 16 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING STEERING KNUCKLE AND BALL STUDS . . . . . . 27
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . 17 DISASSEMBLY AND ASSEMBLY
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . 17 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 36
FRONT AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . 18 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 36
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CLEANING AND INSPECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 16 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 37
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . 17 CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . . 37
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ADJUSTMENTS
SERVICE PROCEDURES DIFFERENTIAL BEARING PRELOAD AND
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . 20 GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL AND INSTALLATION GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 43
AXLE BUSHING REPLACEMENT . . . . . . . . . . . . 27 PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . 37
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . 31 SPECIFICATIONS
AXLE SHAFT—CARDAN U-JOINT . . . . . . . . . . . 21 181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
COLLAPSIBLE SPACER . . . . . . . . . . . . . . . . . . . 23 181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 27 SPECIAL TOOLS
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 30 181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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DESCRIPTION AND OPERATION
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CAUTION: Clamp only the narrow forged portion of

the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
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Fig. 8 Pinion Yoke Installation

CAUTION: Do not exceed the minimum tightening
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ings may result.
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 W
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7

COLLAPSIBLE SPACER
`a*bdcegf=hBi+jDkml nl cdn4l n3omp>f=h*h*a*q
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 S %-!"# , #$! , "# , #$!"&D"0V?#D"/7
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-
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)*(% !"#
 !"<#$"%-"#$
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 8
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7
Fig. 9 Check Pinion Rotation Torque
 J
:„v…d!"0V"#†W R J5!!"0u , !
‡13!")N S
CAUTION: If the maximum tightening torque is #$
' !L_3Z , !"<?M0 X]"#r7
reached prior to reaching the required rotating  W
:„ˆA;
' !L_g"#x9;I-y R s‰0‹Š<#$"&$~9;I tsJm[v!
torque, the collapsible spacer may have been dam- #$
' !L_3Z , !"Œ13!
)*Z-Ž7["[r
D7
aged. Replace the collapsible spacer. D[\
:„4v? @ , # 1!
!"P!"#{x/0V‘' ' "#
' !"?*"0:/&$#$X S #$
' !L_3Z , !"</
-7
D["[r
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' !L_gPP%-#$!" , !"@ 
#$F?/F ,  #
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Z! , ?’6@
 #D-*:#$*!
% %
 , !"(
 #Y/* %-7“KL' 1{@Œ
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 , ^
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* , I
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:A;"' !_3ZZ&$!" , /@Π, &$"#r7

Fig. 10 Tightening Pinion Shaft Nut—Typical

 
 !"#$
% 
#$"&$(' #$)*+!"
, #$! , 
-
#./* %-(0213!
)*405 6 , #$! , ""#
% 7 Fig. 11 Pinion Yoke Removal
,.-0/1 24365758948;:4<=3 >@?.>A:B2C24943 D@8?73 :B8 EF

GIHKJMLONPIQCPIRTSVURTWKX4PIQYQYPZXULTR\[^]I_Y`Yacbd`YeYfYgYh

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Ùùû;ò ëèàüÐ Ô*Õxý<Ù$Ó"Ô*Ý$Ûþû;ò äàóÿÍ/é
Ù$Ó
á ØLÜ3ÓZÚÛÓZ×VÑÔÑØ"Ԍí3Ø
å*ÓZæ-Ù$Ø"áw×VÑÔÑØ"Ô<Ò/ÛÐæ-ÚM
Ì ŽÑï>ߨÍ"ÍrÎDß
ÌDÍ
Í Î:Ï;Ó
á ØLÜgÓÚÛÓù×VÑÔÑØ
ԐïÓ
Ðنæ ÙDØ"á Û*Ø"ÖÒÑÔïvÌ ŽÑïß
ÍàÎDߨû;ÐÚÝ$ۑÚÛӃ×VÑÔÑØ
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áþæ-Ð ÞÞÑÔï6ÐÔÕ+ãÓ
Ñ-Ô*ïOÕ Ð á]Ð ï>Ó"ÕVß
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ÙYæ-Ù$Ø"áw×VÑÔÑØ"Ô<Ò/ÛÐæ-Úß
Fig. 13 Collapsible Preload Spacer

Fig. 14 Pinion Seal Installation

Ì èÎ LÔÒÚÐ ÞÞí3Ø"åNÓMâ]ÑÚÛ LÔÒÚÐÞÞÓ"Ù¡ýò¶Í/îàò
=éUû;Ö×FóÿÍú öé
ÐÔÕ:ÛØ"ÞÕVÓ
ÙYîöèóFÌ
mÑ-ï>ߨÍèÎDß
Ì î
Î Læ¨ÚÛÓOØ"Ù$ÑïÑÔÐÞ× ÑÔÑØ"Ô{ã Ó
ÐÙ$ÑÔïҌÐÙ$ÓOãÓ"ÑÔï+ÖÒÓ"ÕVé
ÑÔÒ/ÚÐÞÞUÕ Ñæ æ Ó
Ù$Ó"ÔÚÑРގÐÒ/ÒÓ"á ãÞ í+ÐÔÕPÐõgÞ-Ó^Ò/ÛÐæ ÚÒéÿÑæ“Ô*Ó"Ý$Ó
Ò/ò
Ò/ÐÙ|í ß
Fig. 12 Remove Pinion Gear
É ÊĒÅ*Å"Ä“É ÂdÊ
ÌDÍr Î LÔÒÚÐ ÞޓÐPÔÓâÝ$Ø
Þ-ÞÐ×VÒÑ-ãÞÓ]×VÙ$Ó"ÞØ
Ð Õ6Ò/× Ð Ý$Ó
ÙdØ
Ô+×VÑÔò NOTE: If new pinion bearings were installed, do not
ÑØ"Ô<Ò/Û*Ð æ-ÚM
Ì mÑ-ï>ߨÍäÎDß install the differential assembly and axle shafts until
Ì à Î Læ;×VÑÔÑØ"ԃï>Ó"ÐÙ¡â]ÐÒYÙ$Ó
á ØLÜgÓ"ÕVéŽÑÔÒÚÐÞނ×VÑÔÑØ"Ô+ïÓ"ÐÙ after the pinion bearing preload and rotating torque
ÑÔ(Û*Ø"ÖÒÑÔïß are set.
Ì ä Î LÔÒÚÐ ÞÞ× Ñ-Ô*Ñ-Ø
Ô(æ-Ù$Ø"ÔÚ¨ã Ó
ÐÙ$Ñ-Ô*ïé“Ñæ¡ÔÓ"Ý$Ó
Ò/ÒÐÙ|í>ß Ì ð
Î LÔÒÚÐ ÞގÚÛÓ^× Ñ-Ô*Ñ-Ø
ÔYâ]ÐÒ/ÛÓ
ÙMÐÔՌÐBÔÓLâuÔÖÚØ"ÔOÚÛ*Ó
Ì ë Î
×V× Þ í‘ÐÞÑïÛÚYÝ$Ø"ÐÚÑÔï<Ø
ædï>Ó"ÐÙPÞÖãÙ$ÑÝ$ÐÔÚ]Ø
Ô2ÚÛÓ ×VÑÔÑØ"Ô:ïÓ
Ð Ùr ß ÑïÛÚÓ
Ô+ÚÛ*Ó ÔÖ*ڏÚØ àÿÍð  áÌDÍîúPæ ÚßmÞ-ãÒß Î
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á ÑÔÑá Öá  ß !"$#&%(')&*+gìPÐ/õgÑá ÖáuÚØ
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ãIäKåMæOçèIéCèIêTëVìêTíKî4èIéYéYèZîìæTê\ï^ðIñYòYócôdòYõYöY÷Yø

i&œllk ­®vu$ˆ‡t¨z‡s$‚}˜o6pq¯‚s$z‡ƒ}„u€…°o‚v±}p²o6pˆ‡v±•sc„py
‚s$z‡ƒ}„u¤…†z‡ucpˆ‡v±iš=o6q ‘Mœ“¬lk&‘I³vu´‚s$z‡ƒ}„u´pucˆ‡u$nln“}zµr²˜s
z‡s$‚}‚uT‚vuO•o6po6scpwq›u$}z°nlvs$„xy ’}u$¶
z‡o6q›op*x¸®u$}z‡o6pq›nT¹º³vuz‡u$}yo6pq—z‡ucˆ‡s$z‡y*u$ywy„z&»
• ·
o6pqz‡u$Œs˜©}x6”•x6„n°}p™}yy*o‚o6s$p}x®}‘ ~}{.Š‹ Œ±i~.o6p‘x6’}n“‘ k&‘
Šu˜…±¸®uc}z‡opq n†¹£Ž‚sO~Š‹ Œ±i&œl~‚sT‰}~o6p‘!x6’}nl‘ k^‘
•

Fig. 15 Pinion Yoke Installation

CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
i
jlk mnlo6pqrsct7uwvscxy*u$z{}|}~}j€}py€€‚s$z&ƒ*„u…†z‡ucpˆ‡v
nlu$K}K‰}~}‰.Š‹ Œi
Ž}{*
‚‘x6’}n“‘ k&”=ˆ‡z‡„n“v ˆ‡scxx6}•nlo6’*x6u–nl•}ˆ‡u$z
„p‚o6xY’}u$}z‡o6pqu$py—•x6lrMo6n†˜}t7u$p™„• i
š=o6q›‘Kœl{“k^‘
i
|lk žxs˜…†x rŸ‚o6q v‚u$p¡˜vuwp„Oo6p¢{}‘ j€ŠB‹ Œ£i
~¤
‚‘Bx’}nl‘ k
o6pˆ‡z‡ucŒu$p‚n¥„p‚ox¦‚vu§z‡s$‚}˜o6pq¨‚s$z‡ƒ}„u§on¥}ˆ‡vo6uª©žu$y‘
« u$}n“„z&u–˜vu–z‡s$‚}˜o6pqT˜scz‡ƒ}„u–
z‡ucƒ}„u$p‚x rw‚s–l©s$o6ys˜©ucz Fig. 17 Check Pinion Gear Rotation Torque—Typical
i&œ$œdk ¼ªpn“‚}xxAy*o
u$z&u$p‚o6*xA}n“nlu$Œ†’*x r}py–l½x6u¾nlv}
‚n“”o6
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šo6q ‘Kœl¬lk&‘
pucˆ‡u$nln“}zµr‘
i&œlŽlk¿x6oq›p±Œ}z‡tn¢Œ*y*uC•z‡u˜©o6s$„nlx rÀs$p¥ržs$t7uC}py
•z‡sc•u$x6x6ucz°n“v*B}py—o6pnl‚*x6xY•*z‡s$•ucx6x6u$z°nlv}
‚‘
i&œl‰lk ¼ªpnl˜}x6xM’*z‡}t7u§z‡sc˜scz‡n¥}py²ˆ‡}x6o6•ucz‡n“‘ Á®u$u$z´‚s
 z‡sc„• ~*”¸®z‡}tucn“”!s$zI•z‡s$•*u$zI•z‡s$ˆ&u$y„z‡ucn“‘
i&œlÃlk¿yyºq uc*z¯x6„’}z‡o6ˆ‡}p˜”¦o6Äpu$ˆ‡ucn“nl*zµr‘¦ÁYuc
ucz§‚s
Å „’*z&oˆ‡}p°ž•ucˆ‡oo6ˆ‡*‚o6s$pnsc‚vo6nnlu$ˆ‡‚o6s$p¤
s$zOx„’*z&oˆ‡}p
z‡u$ƒ}„o6z‡ucŒu$p‚nl‘
i&œl~lk ¼ªpnl˜}x6x…†vu$u$x®*py—‚o6z‡uO*nln“ucŒ’}x6oucn“‘
i&œl{lk Å s˜…†u$zZ©ucvo6ˆ‡x6u$‘

HUB BEARING AND AXLE SHAFT

¼ªŸ‚vuÆl½žxuÀn“v}
Ç}pyVv„’È’}u$}z‡o6pqÉ}z‡uÀ’*uco6pq
z‡ucŒsª©ucy¦o6p€s$z‡y*u$zT‚s nlu$zµ©žoˆ‡u}ps$‚vu$zTˆ&s$Œ•scpu$p˜”Z‚vu
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}n“nlu$Œ’}x r›‘

ÌYÍÎÏYОÑÒ
i&œdk Á®}o6n“uO}py n“„••*s$z‡B‚vu©ucvo6ˆ‡x6u$‘
i
Žlk Á®u$Œs˜©uO‚vu…†vucu$xY}py ‚oz&uT}nln“ucŒ’*x r‘
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‰lk Á®u$Œs˜©uM˜vu¦’}z‡}tuMˆ‡}xo6•ucz—}py¡z‡sc˜scz(‘Á®u$u$z—‚s
 z‡sc„• ~*”¸®z‡}tucn“”!s$zI•z‡s$•*u$zI•z‡s$ˆ&u$y„z&u$n“‘
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Á®u$u$zI˜s  z‡sc„• ~}”!¸®z‡}tucn“”
s$zI•z‡sc•u$zI•z‡scˆ‡u$y„z‡u$nl‘
Fig. 16 Tightening Pinion Nut
i
~lk Á®u$Œs˜©u ˜vu™ˆ‡sc˜‚u$z•o6p”Kp„–z‡u$‚}o6pu$zd”K*py¤l½x6u
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?a‘q’ “V”••q–q—V–™˜VšL” ›2œ?›C˜s““V—V” ž2–qœ” ˜s– Ÿj 

¡@¢£}¤¥§¦@¨¦@©ª‹«©¬­V¦@¨{¨{¦h­<«¤©¯®R°@±{²{³´Z²{µ{¶{·{¸

Fig. 18 Hub, Knuckle and Axle Shaft

ù
úlû ü®ý$þ†ÿ
ýý ‚ÿ
 
6ý}ÿ†ùlû 
ù!lû ü®ý$þ†ÿ
ý"ý"$#%&ÿ$þ&ý"'‚ýcý(%
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PRQ1S K(TVU SXWQ KY P E)GIU W(S KU W GZO PRQ1S K(TVU S[Q E)\ W GIO1N]

Fig. 20 Hub Bearing and Axle Assembly

ù|lûXz
*;ýX)}}ý*;%n*+,~*-.6ýX*+#x*+'lý$þ<y
+ 3o/Bÿ(% *-.6ý7*+#/‚ÿ7ý7ÿ'~*;),:,q##
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Fig. 19 Hub Bearing Bolts
ùlû ü®ý$þ†ÿ
ý^0ý8+%*;
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6 û$*+, ùl ! ûXz
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+ ý$ýu®ý(*+%nva%‡ý*+“ý/ ü®ý(# ý(%@˜  ÿva‡ % ÿpX†+/Fu%*+
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STEERING KNUCKLE AND BALL STUDS
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AXLE BUSHING REPLACEMENT
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DIFFERENTIAL
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CAUTION: Do not spread over 0.50 mm (0.020 in). If

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Fig. 21 Steering Knuckle Removal/Installation

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Fig. 22 Upper Ball Stud Remove/Install

Fig. 23 Lower Ball Stud Remove/Install

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Fig. 24 Bearing Cap Identification Fig. 26 Install Dial Indicator

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Fig. 28 Differential Case Removal Fig. 30 Differential Bearing Cap Reference Letters

Fig. 29 Install Axle Housing Spreader

DIFFERENTIAL SIDE BEARINGS

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Fig. 32 Differential Side Bearing Installation Fig. 33 Axle Seal Installation

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¸/Ì;º» ¿"Í$Ä&Ç'¿~¾n¿¼iÊ-¿Å$Î/Å1Ä"Ív¼;Ô'Ê-¿~ÆFÂ4Ï8¿~ÆFÄ~È4Ä"Â4¾;½-À4à{âÂ4À4É1ã
Æ5½-Ä"À4äZ½-ΔÀ4¿É1¿"¾;¾n¼8ÅØÐÑË
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊÓÄ"½-ÊÓ¾n¿¼8Ê.¾æÕ$½-Æ5Ȃç{½-¾nɾéèa¹"¹;êݼiÀÁìëZÂ4Å1Àã
Ï8Â4É1íYÊ-¿hî8ï8ðiïl¸/ñK½-àBËKÒ8Ònº
Ëi딽-àBÈÆF¿À[Æ5Ä"Ä"ÊZÂ4ÀÆF½-ÊZÁ+½-¾nÉÏ8ÄÆFÆ5Ä"Íh¾
½-ÀòÈÄ"Â4¾;½-À4àBË
¸/ó;ºå&À4¾;Æ5¼iÊ-ÊÁi½.Î.Î/¿"Å¿"À4Æ5½-¼iÊ ¼i¾;¾n¿ÍhÏ8Ê ÐÑË
Fig. 34 Ring Gear Removal
Ù/Ú'ÛKÜB¶f··"¶ÜZÙ ´Ú

RING GEAR
ëÈ¿}Ž.Ààm¼8À4Á~Ã+½-À4½-Ä"ÀkàB¿¼8Å1¾S¼iÅ1¿¾;¿"ÅØǽ.É1¿½-Àk¼)Íh¼8ÆFÉ1È¿"Á
¾;¿"Æ5˛ç{Ä|ÀÄ"ÆmÅ1¿"ÃiÊ.¼8É1¿ÓÆFÈ¿|Å1½-À4à…àB¿"¼8Å}Õ}½.Æ5È4ÄÂ4ÆmÅ1¿"Ã+Ê-¼8É1½-À4à
Æ5È4¿)Ã+½-À4½-Ä"À|àB¿¼iÅ Ë
±²³´µ¶·
¸¹ º» ¿"Í$Ä&Ç'¿)Á+½-Î.Î/¿"Å1¿À4Æ5½.¼8ÊÎ.Å1Ä"Í<¼nÔÊ-¿~ÈÄ"Â4¾;½-À4àBË
¸/Ì;ºôKÊ.¼8É1¿|Á+½-Î/Î/¿Å1¿"ÀÆF½-¼8ÊõÉ1¼i¾;¿ò½-Àö¼÷¾;Â4½-ÆF¼8Ï8Ê-¿lÇ'½-¾;¿lÕ}½.Æ5È
¾;Ä"Î/ÆjÍh¿Æ5¼iÊB␼;Õ<ÃiÅ1Ä"Æ5¿"É1Æ5Ä"Å1¾;ËZ¸.ñI½-àBËoÒió;º
¸/Ò;º» ¿"Í$Ä&Ç'¿ÓÏ8Ä"Ê-Æ5¾_È4Ä"Ê-Á+½-À4à…Å1½-À4à…àB¿¼8ÅkÆ5ÄÓÁ+½-Î/Î/¿Å1¿"À4Æ5½-¼8Ê
É1¼8¾n¿Ë
¸/ó;ºøS¾;½-À4à]¼_¾;Ä"Î/ƛÈ4¼iÍ$Íh¿"ÅùäoÁ+Å1½ Ç'¿)Å1½-À4à]àE¿"¼8Å}Î.Å1Ä"Í<Á+½-Î/ã
Î/¿Å1¿"À4Æ5½-¼8ÊÉ1¼8¾n¿)¸/ñK½-àBËZÒ8ó;ºË
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
¸¹ ºå&ÀÑÇ¿"Å1Æ}Æ5È4¿_Á+½-Î/Î.¿"Å1¿À4ÆF½-¼8ʛÉ1¼8¾;¿¼8À4Á…¾;ÆF¼8Å1Æ}ÆúÕ$Ä_Å1½-À4à
àB¿¼8ÅæÏ8ÄÊ.Æ5¾;˛ëfÈ4½-¾_Õ}½.Ê-Ê)Ã+Å1ÄFÇ'½-Á+¿ÖÉ1¼8¾;¿"ã/Æ5Äã/Å1½-À4àöàB¿¼8ŅÏiÄÊ-Æ
È4ÄÊ.¿)¼8Ê-½-àBÀ4Íh¿À4Æ5Ë
¸/Ì;ºå&ÀÑÇ¿"Å1ÆjÆ5È4¿)Á+½-Î/Î.¿"Å1¿À4ÆF½-¼8ÊÉ1¼8¾;¿~½-À|ÆFÈ¿SÇ'½-¾n¿Ë
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊæÀ4¿FÕûÅ1½-À4àüàB¿"¼8ÅxÏ8ÄÊ.Æ5¾ß¼iÀÁv¼8Ê-ÆF¿Å1À4¼8ÆF¿Ê Ð
Æ5½.àEÈ4Æ5¿"ÀéÆ5Äæðiý8þa¹;ÌiÌÖÿ Í

¸/ï8êiþ8ð8ê„Î.ÆFËÊ-Ïi¾;Ë ºÆFÄÅ Â4¿æ¸/ñK½.àEË
Ò8ý;ºË
¸/ó;ºå&À4¾;Æ5¼iÊ-Ê}Ái½.Î.Î/¿"Å1¿À4Æ5½-¼iÊ}½-Àt¼;Ô'Ê-¿…È4Ä"Â4¾;½-À4à÷¼iÀÁòÇ'¿Å1½-Î Ð
àB¿¼8Å}Íh¿¾nÈ|¼iÀÁ[É1ÄÀ4Æ5¼iÉ1ƛÃ+¼8ÆFÆ5¿"Å1ÀË
¬­l¬® ¯°T±±²³²´µ° ¶·¶©´¯¯³° ¸²·° ´² ¹tº
»#¼%½'¾)¿À#ÁÀ#Â.Ã0Ä
Â.Å%ÆÀ#ÁÁÀ3Æ4Ä
¾.Â6Ç8È#ÉÊË=Ì>ÊÍÎÏÐ

Fig. 37 Pinion Yoke Removal

y ™ |~} E _ Ud\Eo`dDFERITKQITUXKLjEXMOG•MOKQPŽ^JUXgTgTMhRhY[I ƒ gTEY[RhMO^JEXG
€GJU _ DQU=nQY‚I
KFL y
  ITLjc  œ | c%¡£Mh`a^JD˜`dDQEŽRITKQITU=K'kmI
`aDi„UXnFG
DQMOKQP~`dU)RhGJE\E=KQ`IT`€GJU _ €
MhgTgTITKQLoMOKQP ƒ E=I
KFLPhM _ MOLWEXPc
Fig. 35 Ring Gear Bolt Installation

CDFEHGJI
GEAR
PINION KFLNMOKQPSRITKQITU=KVLWEXMOGJYZMOGJEHY[E=G]\IT^JEXPSMOYZM
_ OM `a^JDQEXPbY[E=`dceUfKFUX`
GJEXRhgTMh^JE.`aDQE.RITKQITUXKiLjEXMOGlkmIT`dDQU=nQ`
GJE=RgTMh^JITKQLo`aDQE)GJITKQLoLjE=MhG>c
pqFrtsuwvx
y{z>|~} E _ U\E'PhI
€
€E=GJEXKQ`aITMhg#MOY[Y‚E _4ƒ g „…€GJU _ M‚†wg
E'DFUXnQY‚‡
ITKQLjc
yˆ‚|~‰ MhGJŠ6RITKQITUXK‹„U=ŠFESMOKQPŒRhGJUXRE=gTg
E=GY‚DQMO€`Z€
UXG
ITKQY‚`dMOgTgTMh`aITUXKŽMOg
ITLWK _ EXKQ`ac
y‚| elITY‚^JUXKQKFEX^J`RGJU=REXgTgTE=G‘Y[DFMh€
`€GJU _ RITKQITUXK…„U=ŠFE=c
’
Y‚ITKQLfY‚nQIT`aM ƒ gTE%k“ITGJEX”`aITE•RhGJUXRE=gTg
E=GY‚DQMO€`l`aU•nQKFPEXG ƒ U=P„Wc
y–‚| ’
Y‚ITKQL˜—tUXgTPE=Gi™Ošh›Oœ`dUž`dDFEŸDQU=g
P„UXŠE=”“GJE _ U\wE
`aDQE)RITKQITUXKŽKQnQ`MOKQP4k“MOY‚DQEXG y  ITLWc  ™ | c
y › | ’
Y‚ITKQL } E _ U\wEXGZ¡£¢ – › ˆ MOKQP0—tUXgTPEXGZ¡£‡ Oˆ œ z ”
GJE _ U\E)`aDQE)RITKQITUXK.„U=ŠFE)€
GJU _ RITKQITUXKŽY[DQMO€
` y  ITLWc O¤[| c

Fig. 38 Remove Pinion Gear

y ¤‚|~} E _ Ud\E`aDQE€GJU=KQ`mRITKQITU=K ƒ E=MhGJITKQL¥^JnFR” ƒ EXMOGJITKQLW”
UXITgY‚g
ITKQLWEXG¦”wI
€§EX¨OnQITRRhEXP”MOKQP.RITKQITUXKY[E=MhgkmI
`aD } E _ U\wEXG
¡£‡ –OO– ›MOKQPb—tMOKQPgTE)¡£¢ –©z[¤©z“y
  ITLjc  š | c
y œ |~} E _ Ud\Eo`dDFEGJE=MOG•RITKQITUXK ƒ E=MOGJITKQLb^JnFRi€GJU _ M‚†gTE
DQU=nQY[ITKQL y  ITLjc –Oª‚| ct’
Y[E } E _ U\E=G¥e‡ z‚– š‘MOKQP—tMOKQPgTE
¡£¢ –«z‚¤©z c
y š |~} E _ Ud\E#`aDQE#PE=R`aDY‚DQI _ Y
€GJU _ GJE=MOGRITKQITU=K ƒ EXMOG8‡
ITKQL.^{nQR ƒ UXGJE“ITKbM‚†gTE“DQUXnFY[ITKQLjc } E=^JUXGJPo`dDFE4`aDQIT^JŠKQEXY‚Y#U=€
`aDQE)PEXRh`dDŽY[DFI _ Y‚c
Fig. 36 Pinion Yoke Holder—Typical
9;: <>=@?+?+ACB>AED>F
= GIHG0DJ<K<>B>= LMA+H+= DJA N!OPN+N

QRSUTWVPXYKXZ\[^]@Z\_`>XYIYIX5`]@T\Zba#cdIeIfhgieIjIkIlIm

Fig. 39 Front Bearing Cup Removal Fig. 41 Collapsible Spacer

NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before pro-
ceeding.

Fig. 42 Inner Bearing Removal

,.-0/ 13254 42 16, 78-
Fig. 40 Rear Bearing Cup Removal
{Ñ Ò‚Ó‚Ô~Õ£ÖX×4ØdÙÖÛÚaÜQÖÛÝJØ=ÞTÞ
ßOàá‚âTãOÞ
֝àäJÖXÞTØ=ßhåæá‚àßOÝJÖXäŸç
äJØX×
àâTèQâTØ=èiéWÖXßOämсê«âTéjëíì©Ò>Ô{ë NOTE: Pinion depth shims are placed between the
Ñ{Ò=Ò¦Ô~Õ£Ö=×4ØÙwÖ)ÚdÜFÖ)äJÖXßOä#àâTèQâTØXèŽãOÖ=ßhäJâTèQéfçäJØX×îÚaÜQÖ)àâTèQï rear pinion bearing cup and axle housing to achieve
âTØXèñð“âTÚaÜóò«ôQÞTÞTÖXä]õ¦òä{ÖXá[á÷ö£øOùOúOûhï
òXü ßOèQåýü
åhßhàhÚdÖ=äJá proper ring and pinion gear mesh. If the factory
ö£øOùOúhûOøOûOúсê«â
éWëíìOù‚Ô{ë installed ring and pinion gears are reused, the pin-
þ3
ÿ  
 ©
ÿ 

 !" ion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
#$%'&(") "+*
thickness shim before installing pinion gear.
Ï!ОÏ+Ñ Ò>ÓÔCÔ+Õ+Ö>ÕE×>Ø
Ó ÙMÚ!Ù%×JÒKÒ>Ö>Ó ÛMÕ+ÚCÓ ×JÕ Ü8Ý

ÞßàUáWâPãäKãå\æ^ç@å\èé>ãäIäIã5éç@á\åbê#ëìIíIîhïiíIðIñIòIó

noiprq s@tuwvWxywzx+vhy{}|~uw€Cvh‚‚„ƒvx+{…|)‚|~†‡~)ywvtyx+~ˆ n.´p’“x+xs ”µtUs~Š3|{£uwzt{}~Š)zh 8Š³vtysŒ‰yw~uwt{„zh²{…|v

~z)‰vtyw~Š‹uwŒxr‰zhywvW~{…|vWtŽ0svW|zŒ‚~Š3 s~xz x+~~z!‚vhts0¢± ‚{…ts@s
‚vts+¤„~{…|¢±‚{…tssvy©™ˆ.­¶«‘ˆ ’
n.‘p’“x+xs ”–•zx+ty zzhy!˜™t‚vhšzy‹v›Œ~ œtsvh{}šž‚{…~uw€ tƒr§;tƒs@vW©™ª¥%o« o„n@¬
~Š3¥´p#
t —
sŒ‰yw~uwt{r{…zŸzŒ{…‚~@ƒvŸ‚Œ yw .tuwvŸz \ywvhtyUx~@ ~@zh¡‰vtyw~Š
uwŒx ¢}‚{…tss6{…|v£‰vhtyw~@ ŠWuwŒx;¤„~{}|r¢}‚{…tss@vhy ˆo¥¦\tƒ
—
yw~ œvy¨§;tƒs@v©™ª¥%o«%on@¬
~Š3;¥­p#5®™vyw~  ”¡uwŒx–~‚uwzy#ˆ
—
ywvhuw{}s ”U‚vht{}vhƒ+

Fig. 45 Pinion Seal Installation

n.¦pr¢±‚{…tssP{}|v‹ywvty·x+~~z‰vtyw~Š$tƒzh~sž‚s@~Š³vy(š
~ Pvh›Œ~xx+vƒš™zhU{…|vx~@ ~@zhUŠ3vhtyž¤„~{}|¢±‚{…tss@vhyž¸Uˆ@‘¦‘
tƒrt‚| zxrx+ywv‚‚„n.¬ ~@Š³6¥¦p

Fig. 43 Rear Pinion Bearing Cup Installation

n.­p’“x+xs ”–•zx+ty zzhy!˜™t‚vhšzy‹v›Œ~ œtsvh{}šž‚{…~uw€
t —
sŒ‰yw~uwt{{…zUzŒ{…‚~@ƒvU‚Œ yw .tuwvUz „ @ywz{\x+~~z¯‰vtyw~Š
uwŒx ¢}‚{…tss6{…|v£‰vhtyw~@ ŠWuwŒx;¤„~{}|r¢}‚{…tss@vhy ˆo­°\tƒ
—
§8tƒ+svW©™ª¥%o«%o„n.¬ ~Š36¥¥p

Fig. 46 Rear Pinion Bearing Installation

n.«pr¢±‚{…tss6tv}¤¹uwzsstx+‚~@‰sv„x+ywvszhtƒ‹‚xtuwvhy8zrx+~ˆ
~z‚|t .{5tƒ~‚{…tssx+~~zŠ3vty“~|zŒ‚~Š·n.¬
~Š³%¥«p
n.ºpr¢±‚{…tss”0zh€ vJ¤„~{}|)¢}‚{…tss@vhy5¸Uˆ#o¦‘ˆ.»™š©™Œxrº%o°¶š
tƒr§;zhsƒ+vy¦¶´ºn@¬
~Š3¥ºp

Fig. 44 Pinion Outer Bearing Cup Installation n.¶pr¢±‚{…tss

{…|vx~@ ~@zh£¤„t‚|vhyJtƒ\t·v±¤¼Œ{Iz!{}| v
n.¥pr¢±‚{…tssJ .ywzh{x~@ ~@zh²‰vtyw~Š3šPtƒz~sJ‚s~Š³vy(šP~  x+~~zrŠ3vhtyi+½I~Š3|{…vh${}| vŒ {ž{…z‘%o¦¾“¿ †Àno¦° .{… s@‰‚ p
v›Œ~xx+vƒ+ †~~†Œ†JÁ8ÂÄÃÂŋÂ'Æ>Ç+È'ÉhÅÊ(Ë ÌÅÇÃÍJ•‹tŽ0~†Œ†^{}zhyw›Œv
~‚„­´‘¾J¿ †În.‘¦° .{…6s‰‚ p#
d\e fhg
i-i-j2khjmlhnog pbqpLlAfRfhkhg rsj-q-g lAj tvuWt-w

xzyS{}|M~Wz€RzK‚„ƒ
K…S†hz€b€b‡†0ƒ
|K‰ˆ7Šz‹bŒbŽŒbb‘b’b“

Fig. 47 Collapsible Preload Spacer Fig. 49 Tightening Pinion Nut

ôõ&÷ NO1P% wúûüQwþ$…úûüQ…þ  „ú+$RûKúû
,+þû…þ STû>¨ô!4 ú@ü5#U
ö÷(#-VW>J…þ ·ûùù X/
…þKþ$$M$M,+úûúþû)ü; ùþÿ+ %Y
wúü³ú@û>ÿ\[O wúûü3ù] õ }þ  AB ôõö^…þ*ö ú@û>#
• Z
ÿ+%ù# ÷(#
=_[O wú@û ü3ùT]`…þM
 ‡ôõ&
…þ 
úû#6ÿ+%ù&# ÷7#
•

Fig. 48 Pinion Yoke Installation

CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
ôõö÷rø“ùú@û üý8þhÿ
 
 û…þ ûô@ù 

 Îô! ö"!$#6ÿ
%ù&# ÷.÷(') ù*þÿÿ+,ùú+%ÿ+\ù&,-  û}úÿ
%  wúûü.û ,+ÿ+&/Uúù0$ 12û3,$ô
4
úü5#)6 ÷7#
ôõhõ(÷ 8ÿþ9£ÿ /:…úü;$û<=>)ûWúû? # @AB^ô!
@"
=#ÿ+%# ÷
úû0û…ùCû…ú@ÿD$Ewþ$ }úûüF…þ  ú@ùC ú+9GH-#
I ù(J=>Jwþ$ }úûüK}þ J"! û…ÿ /*…þJ&G0þú+þ=GL
Fig. 50 Check Pinion Gear Rotation Torque
ôõ  ÷ a±ûù&=ÿÿb+ú+"!"
hû…ú
ÿbùù0%ÿ /c#
ù&úûü.$Mwþÿÿ+,ùú+%ÿ+\ù&,- ô!4 úü;#)
ö÷(#
ôvõÒô-ö ÷hø+ù2ù-ú-ûhúmühýoø þsÿvþîüA÷R÷hûhø sú-ÿ2ø üAú


DISASSEMBLY AND ASSEMBLY

STANDARD DIFFERENTIAL
”b• –˜—o–˜–W™2šœ›o$ž

Ÿ( ¡ ¢O£¤T¥9¦L£M§$¨£M©ª+«¬.¬;£­ ©¯®

Ÿ!°&¡ ±²&ª+«¬3­*²³>ª
§$­ ´ µ
£©¥µ+µS¶-ª+«^¶³«·¨¸‡¹-©ª ¦H£ ¥³>§T§$¨£
©¥µ
µb¶ª
«3¨¥µ+¹-ª+«¬.¶-ª+«ª+¥«3¬;£­ ©¤0­ §$£K²&¨­ º!§Aª+«*§=¨>£K¹-ª+º
º!£©7»
£«>§=ª+­ µb·­ ²£MŸ
¼oª+¬;®U½˜ ¡(®

Fig. 52 Pinion Mate Gear Removal

Fig. 51 Mate Shaft Roll Pin Removal

Ÿ!¾&¡ ¢O£¤T¥9¦L£D§=¨>£¿¶-ª+«ª+¥«P¬;£­ ©À¤0­ §$£¿²¨>­º
§vº
©¥¤Á§$¨£
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£©£«§$ª
­ µb·­ ²&£M­«¹ §$¨£M¶-ª+«ª+¥«3¤0­ §=£M¬5£­ ©²®
Ÿ!Â&¡ ¢O¥§$­ §$£}¹ª
º
º!£©(£«§$ª+­µ\²ª+¹-£*¬;£­©²­ «¹Ã©£¤T¥9¦L£*§$¨£
¶-ª+«ª+¥«*¤0­ §$£K¬5£­ ©²T­ «¹ §=¨>©³²§hÄ­²&¨£©²TŸ!¼oª+¬5®)½ °¡7®
Ÿ!½&¡ ¢O£¤T¥9¦L£À§=¨>£3¹-ª+º
º!£©£«§$ª
­ µ²&ª
¹£3¬5£­ ©² ­ «¹@§=¨>©³²§
ÄT­ ²&¨£©²&®

—˜–o–‡™>šœ›˜=ž

Ÿ( ¡ Å9«²&§$­µ+µK§$¨£Q¹-ª+º
º!£©£«§$ª
­ µK²ª+¹£Q¬;£­©(²@­ «¹R§$¨©³²&§

ÄT­ ²&¨£©²&®
Ÿ!°&¡ Å9«²&§$­µ+µ)§=¨£T¶-ª+«ª+¥«¤0­ §=£0¬5£­ ©²z­ «¹v§$¨©³²&§UÄT­ ²&¨»
£©(²®
Ÿ!¾&¡ Å9«²&§$­µ+µ0§$¨£¿¶ª
«>ª
¥«R¬5£­ ©À¤0­§$£¿²&¨­ º!§$®hƵ+ª+¬;«Ç§$¨£
©¥µ
µO¶-ª+«*¨¥µ+£²Tª+«*²&¨­ º!§A­ «¹ §$¨£M¹-ª+º!º!£©£«§$ª+­ µb·­ ²£® Fig. 53 Mate Shaft Roll Pin Installation
ÄTª+§$¨v¤0ª+«£©(­µ˜²&¶-ª+©ª+§=²&®mƶ-¶µ Ï­M´ £­¹M¥ºUԜ¥¶­© ÐHª
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¢O³´ ´ £©JÐH£­ µ+­ «§$¸b¥©J£Õ ³ª ¦L­ µ
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²&¨­ º!§Aª+«*§$¨£M¹-ª+º!º
£©£«§=ª+­ µb·­ ²&£KŸ
¼oª+¬;®U½ ¾¡7®
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ADJUSTMENTS
PINION GEAR DEPTH
Fig. 54 Typical Housing Cover With Sealant »¼;½F¼;¾X¿QÀ<Á½FÂþFÄ¿;ÅUÁ ý
CAUTION: Overfilling the differential can result in ÆÇÈÉËÊ*ÈÌ|Í8ÇÈÇÎȃÉ)ÏÊ*Ð-Ñ{Ê*Ð-Ï°Ñ"ÒÍ8ÍÓÇÏ Ì³Ê*Ñ{Ô9Ê*Õ'Ö-×;ÏÌ
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NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
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NOTE: If an oil slinger is used behind the inner pin-
ion bearing, deduct the thickness of the slinger
from the dial indicator reading and use that total for
shim selection.
DIFFERENTIAL BEARING PRELOAD AND GEAR
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Fig. 58 Pinion Height Block—Typical

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Fig. 57 Pinion Gear Depth Gauge Tools—Typical óSîrïbý ý5ì)ç>óSþ:ëJì)ý5ì3è:í[óEç>ëJì ê7ì3ëJòð)ëJý5ì3 é ïAí@î
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ç ïAó´ý5ì)ç>óSþ:ëJì)é Ší@î:ìÂê7ïAè:ïAð3è‡ñdì)ç7ëïAó NOTE: It is difficult to salvage the differential side
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Fig. 59 Gauge Tools In Housing—Typical

Fig. 62 Tighten Bolts Holding Bearing Caps

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Fig. 60 Pinion Gear Depth Measurement—Typical

Fig. 63 Seat Pinion Gear Side Differential Dummy

Side Bearing
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Fig. 61 Axle Adjustment Shim Locations
EGF H+IJ,J,KML+KON+PQI RTSURVNCHWH+L+I XYK,S,I NCK Z\[^],_

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Fig. 64 Seat Ring Gear Side Differential Dummy Fig. 66 Hold Differential Case and Zero Dial
Side Bearing Indicator

Fig. 67 Hold Differential Case and Read Dial

Indicator
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Fig. 65 Differential Side play Measurement 869 hø†ôÅóV÷†úUòDö*ðDñ
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SPECIFICATIONS
181 FBI AXLE
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SPECIAL TOOLS
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Remover/Installer—6289

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194 RBI AXLE

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page page

GENERAL INFORMATION DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 63

194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 67
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . 49 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DESCRIPTION AND OPERATION PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 56
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 50 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . . 50 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . 51 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 68
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . 52 TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 69
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 CLEANING AND INSPECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 51 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 73
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . 52 TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TRAC–LOK DIFFERENTIAL NOISE . . . . . . . . . . 52 ADJUSTMENTS
TRAC–LOK TEST . . . . . . . . . . . . . . . . . . . . . . . 52 DIFFERENTIAL BEARING PRELOAD AND
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . 75
SERVICE PROCEDURES GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 77
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . 55 PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . 73
REMOVAL AND INSTALLATION SPECIFICATIONS
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 79
AXLE SHAFT SEAL AND BEARING . . . . . . . . . . 60 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 79
COLLAPSIBLE SPACER . . . . . . . . . . . . . . . . . . . 57 SPECIAL TOOLS
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 61 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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VIBRATION
ó4×AäÑÛÓ×AÞÒVÛ!Ó`Ó'Ô"Õ[ÑÕÛÑ}ÞßHÓÔ ÕxÖQÕÔ ×ØÙÕ[×AÚUÐ Ú9Ð ÛÙÙ Ý -#"!"! K*PC#"*#" e#"ef#")%3&gh6;)
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TRAC–LOK TEST
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Útø2â WARNING: WHEN SERVICING VEHICLES WITH A
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='-,H%25$'<5"/*F4f<57,"%*,Ka(>#(I(32V480G487,(D«”-,H%25$'<5"/*F4 … ./(3<5$'I$'<5"%†
48$0*,&œ&@(3<548$'03*!0I–487,$'&œKa250-,.ˆI02:4E7,(‡/-F"/*F4E$'4§\‹*,(<5(3&@&)"%2y\X>
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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
 @¡@!˜C*,&@4E"%='=”4E7,(œI$'='=”7,03='(
./='-,K"%*,+='0C^(32
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Fig. 5 Trac-lok Test —Typical 487,2503-FKa7~487,(<=-F4E<57!+1$'&)<5&œ4E0B(3='$'A$'*,"%48("v.10&)&@$H%='(<7,"/48†
48(32
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SERVICE PROCEDURES
REMOVAL AND INSTALLATION
!#"%$'&)("%*,CHANGE
LUBRICANT +!&)-,./.1032546487,(:9;(7,$'<5='(3>
 ?@!#(3AB0C9;(D4E7F(G='-,H%25$'<5"/*F4!I$'='=J7,03='(D.1='-,KLI2503AM487,( REAR AXLE
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"%*,48`t032
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Fig. 6 Apply Sealant

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'ü# Tü M
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X=.QFG5ù '³ü(û .Q-"/ü "E5ü Y õö7@÷^:û@üUù¿û,ú'ýEù%'ü~BA ý-Kªûú1üšþ,ù$?$ü
Fig. 7 Pinion Yoke Removal
!5ü3û  $?!,ý8ü !(û 5ü U1ý 5ü $h# ;üý8þ,ü1ú,ú/ aüù 
û)üù
õö 7@ ÷ )#,û@ýEù ù@Zÿ 'ü+ ;-ü ,ý6
þ û)ü 
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X1ú ,ú KAZ-'³] ü 5ü -ü EY îï;ð”ñaò²óFó3òFñtî ôdï
ü!5 ü $ù '³(û H)#,û@ýEù G^+Y T-ú ,ý6û@1ý 5ù /ûBù 
%'ý8(û W_ú Xþ,ý8ü  õö?
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/-x Xü3ù U
%5ú 5ù ,h
ý - ý8þ,ü
ý1‹(ö R 8`9 $Wõö 56ý H%%û  ÷
1ý <,-ü  'úUH1ú ,ú Nû)üù Z)#Fû)ý8ù sû@ü3ù Bú'ý86
þ )#,û@ý8ù 'üIGY0R :Y [
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 üIGY5”ö :öBõ |”ú ;N@E÷ 
õö 0@? ÷ [+a aüù b
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d 
%5ú ù ,f ý eZ/ü 5ú ú 5ù%ýEú -,ûú Dý8þ,ú'ûû@ü 5ý8ú ,g
%5ú 5ù Fý
5-ü < Fú 5-ü $ü FýEû 
õö 5@÷!ø#ü $? ;h ü úýEú 
1#ü Tú 5?ü $Žù@Zÿ 'üBù 
#ü dý8þ,ü
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õö =@? ÷ _°ú Xþ,ýE-ü iBü G(û ,û 1-ü ,û)ú -Žù $j%'ý8û_ý ™ö ::
8+9 $Uõö 0 71ý ;%%(û  ÷œý -<,ü 
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 1ü jû ,(û /ü ,û@ú ˆù $b%'ý8û61ý f:= 8+9 $
õ ==6ý H%%û  ÷
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%%(û  ÷
1ý <,-ü 

PINION SHAFT SEAL

k4l!d m ô4Tn ò½ó
õö÷!ø#ù%ú'û)üù
!  û(
 5ý6ý8þ,ü+ ;üþ,ú'ü
õ@ ÷!ø#ü$h#; ü+B  þFü3ü#ù !~ý8ú5üù/û@û)ü-$?%'úüû(
õ@0 ÷!ø#ü$h#; ü ý8þ,üK%5 ù³' üK
 $ û  ø#ü- ü¯
 ý1KD*-
o= . Fig. 8 Pinion Seal Installation
FG5 ù³' ü3û(.H-Q-1 ü3-5 ü 
5 ü3û õ @÷)#,û@ý8ù gA
'³üO-Uý8þ,üo1ú,ú aüù /Bú'ý8þ~e
5ü#
õ@5 ÷v p ù L ' ý8þ,üq 1 ü-ü-!  û)þ,ù ývù
S/ úF ú-2AZ-F' ü" Nö3ö.;IG
Nö(7R.tù
wx1ü3@R =Nfõ|sú HR@÷E
ú, û@ýEù'ù/ý8úV  ùú c

$ ü, ý5 ü ü-5 ü
 ü
õ@= ÷!ø#ü$h#; üý8þ,ü-1 ü'ü
 û)þFù  ý`U$ ý8þ,ü+AZ³' ü-
õ@@ ÷!øG3 ý8ù%ý8üý8þ,ü1 ú, ú-"a üù  ý8þ
5 üür-Q

 ýEú
$ üû(
ôfõ ö†÷øøùWú†ùVû†üŒ÷ ý4þ6ýZû`öOö†ú†÷ ÿùþ÷ û`ù 

 
    "! #$%'&($)*+,
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.
®¯°±#²
³´1µ ¶¶¢´1·
¸f¹Zº»W¸f¼hµ³(·!¸½?µ²
¾¿µ&²
¸¼t²
À
´xº-²2´1·
¸
Á  º-²/ø-µ½3µ²
¾6´  ÷!´¸-²/´1·
¸ Á ²  º²¿²
À
´À
²!´ Â ¶G´1·
¸½E¸  ³
²
Ä ¸½EºrŸ-µ ½  ²
ÃJ¸-²
¾Æ Á ¶µ¹CÇ
®È°?É Â Ãc·
´1¸²/´·!¸r²!À
´`´ºÊːÌhÍ+Î Ï~®ÊÐÐ6Ñ´1Ç;¶Å³(Ç °EÇ

Fig. 10 Check Pinion Rotation Torque

Fig. 9 Pinion Yoke Installation

CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
®Ò°ÓGº´1µ´1¸h´·
¸ Á ²  º²³(·!µ Ñ´šÀ
³ Â ²!ÃµU® Â ²
ǐ¶Å³(Ç °`´1º½ÔÀ
¸
¼h½¸-²
Õ·
ÇÓGº-´µ´ Â ²
Ã´º-½Ô À!¸?³·
ºÀ!¶¾JŸ?¸-ÔÀ
µ¶;´ºh´1·
¸?½¸-µ¾Æ
 ²
ý¸ÕEº½¾¸-¾/¾À
½ Â ²
ý¸-Ï?º#ÖZµ¶ Á ¶À
³µ²2µ ¾ ¾ Â ´ Â º-²
µ ¶¢ÐÇ Ò ×
Í+Î Ï~®Ò Â ²
Ç;¶Å³Ç °f®Ø  ÃÇÌаEÇ
®×°±#Ñ´·
¸x½º´1µ´  ²
ÃQ´º-½ÔÀ
¸  ³`¶º¼*Ù
À
³(¸xÚfº-¶¾¸½*×ÛÒÜg´1º
·
º-¶¾U´1·
¸ Á  ²  º²?¹
º»W¸Q®Ø  ÃcǏÌÌy°Eِµ²
¾U´  ÷!´¸-²´1·
¸ Á ²  º²
³·
µÑ´`²
À
´  ²/×ÇvÜ6Í+Î Ï~®Ò6Ñ´1Ç;¶Å³Ç °  ²
Õ½¸-Ï?¸²
´1³?À!²
´ Â ¶4´1·
¸
Á ½º Á ¸-½Q½º-´µ´  ²!ô1º½EÔ À
¸ Â ³hµÕ· Â ¸#Ö
¸¾Ç Fig. 11 Tightening Pinion Shaft Nut
COLLAPSIBLE SPACER
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating ä4å!æxç4è
éšêgë&ìEíîï4î çxïÞîïZðñcéšê!ê!å!ò
torque, the collapsible spacer may have been dam- ®EÌy°ÓGµ Â ³(¸µ²
¾³(À ÁÁ º½´`´1·
¸+ÖZ¸-·  ն¸Ç
aged. Replace the collapsible spacer. ®Ê°ÓG¸Ï?ºÖZ¸+¼h·!¸¸¶Gµ ²!¾&´  ½¸µ ³³(¸-Ï?Ŷ  ¸-³(Ç
®Ë°?Ý+¶  òu´1·
¸ Â ²
³´µ¶¶µ ´  º²u½¸-Ѹ-½¸²
Õ¸"Ï?µ½»!³&º²u´1·
¸ ®¯°ÓG¸Ï?ºÖZ¸"½¸µ½Å½µ»!¸"¾½À
Ï?³Ç+Ó4¸-Ѹ-½´º"â*½ºÀ Á ÒÙ
½Á º Á ¸-¶¶¸-½L³(·!µ Ñ´"µ²
¾K¹Zº-»!¸Þµ²
¾ Â ²
³´1µ ¶¶J´1·
¸ Á ½º Á ¸¶¶¸½
 ã µ»W¸³(ÙHѺ½ Á ½º Á ¸½ Á ½º-Õ¸¾À!½¸³Ç

½
³·
µÑ´Ç ®È°óUµ ½»Þ´1·
¸ Á ½Eº Á ¸-¶¶¸-½³(·
µÑ´Uµ²
¾ Á  ²  º-²2¹Zº-»!¸"Ѻ½
®Ü°?Ý+¾¾"ø-µ½¶À
Ž  յ²
´3´1º´·
¸¾  ÑѸ-½¸²
´  µ ¶š·
ºÀ!³  ²
ÃÙ ²Â
³´µ¶¶µ ´  º²/½¸Ñ¸½¸-²
Õ¸Ç
ÑÂ G²
¸ÕE¸³(³µ½B¹cÇÓG¸Ñ¸½x´ºh´·
¸?ßÀ
Ž  յ²
´*à Á ¸Õ Â Ñ Â Õµ ´  º²
³fѺ½ ®Ò°ÓG¸Ï?ºÖZ¸´1·
¸ Á ½º Á ¸¶¶¸½3³(·
µÑ´`ѽºÏ~´1·
¸+¹Zº»W¸Ç
ø-µ½Q¶À
Ž  յ²
´`½¸ÔÀ  ½¸-Ï?¸²
´1³(Ç ®×°ÓGº´1µ´¸´1·
¸ Á ²  º-²"ø-µ½Q´1·
½¸¸º-½QѺÀ
½3´ Â Ï?¸-³(Ç
®Û°±#²
³´1µ ¶¶&´·
¸OŽµ»W¸O¾½À
Ï?³Ç6ÓG¸-Ѹ-½á´1ºOâ*½º-À Á ÒÙ ®Ë°óU¸µ³(À
½¸o´1·
¸OµÏ?º-À
²
´,ºÑ/´1º½EÔ À!¸O²
¸-Õ¸³³(µ½B¹t´1º
ã µ»W¸³(ÙHѺ-½ Á ½º Á ¸½ Á ½º-Õ¸¾ À
½¸³Ç

½ ½º-´µ´1¸b´1·
¸ Á ²  º²tø-µ ½2¼  ´1·{µi®  ²
Ç¶Å³Ç °u¾  µ¶Æ´v¹ Á ¸
®EÌа±#²
³´µ¶¶Z¼h·!¸¸¶Gµ ²!¾&´  ½¸µ ³³(¸-Ï?Ŷ  ¸-³(Ç ´1º½ÔÀ
¸f¼Q½¸²
Õ·
džÓG¸ÕEº½¾¿´1·
¸U´1º½ÔÀ
¸U½¸-µ ¾  ²!Ã6Ѻ½  ²
³´µ¶Æ
®EÌ-ÌM°ßº#¼Q¸½3´·
¸+Ö
¸·  ն¸Ç ¶µ´  º²/½¸-Ѹ½¸-²
Õ¸-Ç
´µv¶· ¸¹8ºUº»¼»¾½¿t¹ À²ÁÀ¬½^¸¸¼¹ ²»ÁU¹ ½^» Ã=Ä
Å ÆÇ ÈÉÊ ËÊ ÌÍÎÌÏÐÊ ËËÊÐÎÈÌ Ñ"Ò ÓÔÕ'Ö(Ô×ØÙÚ
-/.1032541687:9;=<?>8@A'BDCFEFGF.IHJ<LK:<?>8@MHJK:ALNO67P6<'7RQS<?TUA'V
BWA'X<ZYSAHJK:AN687:68<?7[7:\:H^]F7:@_`]F41K:A?B(a
-/E1032541AcbdA'X<ZYeA?BgfdhiOGFjk]F7:@ml[BWA?7:nWKofdh/pFjF.rqHJ<
BWA'X<ZYSAHJK:AN687:68<?7QS<'TPA-st689uavqwj10xa
-xq1y1032541Az]41\:68HJ]O{F>8AzNOB|Q}H~<'<?><?B€]g41>68@AK:]FXXA?B
X<'\:7:HJA?@34wnWBWA~_kH~<BWA'X<ZYSAHJK:AN687:68<?7[4wKP]O‚H^4wA']F>a
-xq'qƒ03bdA'X<ZYeAH~K:A‚BW<?7:H=NO687:68<?7 {OA']FBW687:9„\:4w687:9„]…NO]O68B
<?‚41\:68H~]F{F>8A†N68nWT‡HJ<?<'>84HJ<N\:>8>HJK:A{OA']FBW67P9341H~BW]F689uKPHˆ<'‚/‚
HJK:AN687:68<?7‡9uA']OB‰4wKP]O‚H~a‹ŠZH5X]1Q€{FA7:A'nWA?414w]FB|QŒH~<>8689uK:HJ> Q
HJ]ONHJK:A A'7:@<?‚HJK:A N687:68<'79uA?]FB‹_`68HJK„]ŽBW]1_`K:68@A <'B^Bx\:{Fh
{FA?B`X]F>8>8A?H=68‚HJK:A{FA?]FBW687:9„{FA'nW<?XA'4Ž{F<?\:7:@<'7 H~KPAN687:h
68<?7[4wKP]O‚H~a
-xq1j103bdA?X<~YSAHJK:AnW<?>8>8]ONO4w68{F>8A41N]FnWA'Bƒa

/š ›S°r±u•–P–?•P±‹š “=Fig.› 13 Remove Pinion Gear

-xq(03ŠZ7:41HJ]O>8>‹]7:A~_}nW<?>8>8]FN416{F>8A`NBWA?>8<']O@†4wNO]OnWA'B=<?73N687:h
68<?7[4wKP]O‚H^-/sr69­aq1i10xa
-/j103ŠZ‚NO687:68<?79­A?]FB²_`]F4‰BWA'X<ZYeA?@Vt687:41H~]F>8>N687:68<?79­A?]FB
687‡KP<?\:41687:9ua

‘P’=“”e•–Ž—…Fig. ˜x™rš/›12š “=Pinion

›z‘P’=Yoke
“”‘Pœ Removal
-xq(03bd]F684wA]F7:@34w\:NON<?BWH^HJK:A5YSA'K:68nW>8A?a
-/j103bdA?X`<ZYSA5_`KPA?A?>d]O7P@…HJ68BWA]O414wA'X{F>86A'4wa
-/p103bdA?X`<ZYSA‡BWA?]FB3{FBW]FTPA‡@BW\:X41a5bdA?‚/A'B3H~<‡vBW<'\:NGFV
ž BW]FTUA?4wV‚/<'B‰NBW<'NA?B NBW<'nWA?@O\:BWA?41a
-/i103Ÿ]OBWTzHJK:A NOBW<?NA'>8>A'B34wK:]F‚H]F7:@NO67P6<'7ŒQS<'TPA‡‚/<?B
687:41H~]F>8>8]OHJ68<?7[BWA?‚A?BWA'7:nWA?a
-/G103bdA?X`<ZYSAHJK:ANBW<'NA?>8>8A?B 4wKP]O‚H^‚/BW<?X HJK:A5QS<?TUA'a
-/C103bd<?HJ]FHJAHJK:AN687:68<'7‡9uA']FB‰HJK:BWA'A<'B‰‚<?\:B H~68XA'4wa
-/¡103ŸA?]F4w\:BxAHJK:A]FX<'\:7:H€<?‚[HJ<'BW¢O\PA7:A'nWA?414w]FB|Q£HJ<
BW<'H~]FHJAMHJK:AIN687:68<?7£9uA']OBŒ_`68HJKo]¤-/687:a3>{F41a 0L@O6]F>8h/H¥QSNA
HJ<?BW¢F\:Aˆ_‰BWA?7:nWKPadbdA?nx<?BW@HJK:AHJ<?BW¢F\:ABWA']O@O687:9„‚/<?B`687:41H~]F>8h
>8]FH~68<'7‡BWA'‚/A?BWA'7:nWA'a
-/.103bdA?X`<ZYSA @O6‚‚/A'BWA?7:HJ68]O> ]F4w41A?X{F> Qg‚/BW<'X¦]1§e>A KP<?\:41h
687:9ua
-/E1032541687:9z;=<?>8@A'B‡CFEOGF.¨H~<©K:<?>8@€Qe<?TUA?V‰BWA'X<ZYeAªHJK:A
N687:68<'7Qe<?TUA7P\:H^]F7:@_`]F4wK:A'Bƒa
-xq1y103254167P9LbdA'X<ZYeA?B fd«OiFGFjR]F7:@©l[BWA'7:nWKIfd«OpFjF.¬qwV
BWA'X<ZYSAHJK:AN687:68<?7QS<'TPA‚BW<?X N687:68<?7[4wK:]F‚H^-/st689­aq1jw0"a
-xq'qƒ03bdA'X<ZYeALHJK:A¨N687:68<'7}9uA']FBª‚/Bx<?X®KP<?\:41687:9-st689ua
q1p10xafd]FH~nWKH~K:AN687:68<'7‡_`68HJK‡QS<'\:BK:]F7:@©H~<NBWAZYeA?7:HŽ68H
‚/BW<'X¯‚]O>8>8687:9†]F7:@…{FA'67P9@O]OX`]O9­A?@a /- p103ŠZ7:41HJFig.
]O>8>NO1467P6Collapsible
<'7‡‚BW<?7:H{OA']OPreload
Bx67P9uV‹68‚²Spacer
7:A?nWA'4w41]FB|Q­a
-xq1j103bdA?X<~YSAnW<?>8>8]FN416{F>8A4wNO]OnWA'B‰‚BW<?X N687:68<?7[4wK:]F‚H~a -/i10³5NNO> Q] >8689uK:H‰nW<?]FH~687:9[<'‚=9­A?]FB>8\:{FBW68nW]F7:H`<'7DHJK:A
>868N<?‚N687:68<?74wA']O>8aSŠZ7P4wHJ]F>>t41A?]F>_`68HJK„ŠZ7:41HJ]O>8>8A?Bfdh/pFEO¡FjFh ³
]F7:@3;ˆ]F7:@O>Afd«Fi¬q1¡rq`-st689uavq1Gw0"a
BDC EGFHIHIJLKGJNMGOPF Q5R+QSM ETEGKGF UVJIRIF M J WX&YIZ

[]\^/_a`&b]cTb]d(egfd(hiGb]c5c5b2if_(dkjml]n5o5pqro5s5t5u5v

Û/ö1
Ý 5à1é8ß:û„äSå'æUç‡ê:å'ã÷Oç?í„ùFöFÜFîªâFß:÷ªâªáJå?í Oó:çè`íWç'ß:ìWê
àwç'áâFá  ÿ ÛFÜOõ†ý/áJüã8þOà1ü ÝxñtìWíWó:àwêìWå'ãã8âFôà1é8þOã8çŽà1ôâFìWç?í
ó:ß:áJé8ãþFç?âFíWé8ß:û†ç?ß:÷3ôã8â1ä é8àáJâFæUç?ß[ó:ô3Û/úté8û­ü
ï wÝ"ü
NOTE: If more than 474 N·m (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.
Ûxï1õ1Ý3ëSã8å~è`ã äDáJé8ûuê:áJç?߀á~êPç„ß:óPá‰é8߀ùOü  î  ÿ ÛÜ[ý/áJü²ã8þOà1ü Ý
é8ß:ìWíWç'ÿç?ß:áJàmó:ß:áJéãŒáJê:çcíWå?áJâFá~é8ß:û¤áJå?íFó:çcéàmâFìWê:é8çeç?÷ü
 ç'âFàwó:íWçá~êPçŽíWå?áJâFá~é8ß:ûá~å'í Fó:çŽý/íW ç Fó:ç?ß:áJã ä‡áJåŽ
â Så?é8÷„å Sç'í
ìWíWó:à1ê:é8ß:û†á~êPçìxå?ã8ã8âOôOàwé8þFã8çà1ôâFìWç?í Û/úré8ûuüï1î1Ýxü

/Û Ü1Ý3ÞZß:à1áJâOã8Fig.
ãäeå?15
æUçPinion
è`é8á~ê¨ëSSeal
ìxíWçZèInstallation
îrï'ï1ðOñ^òdó:ôî¬ï1õFöOñ^âOßP÷
ø å?ã8÷ç'í‰ùFöFÜFî„Û/úréû­üï1ù1Ýxü

xÛ ï?ï(Ý3òdêPç?ìWæ íWå?áJâFá~é8ß:û3áJå?íFó:ç è`é8á~êŒâÛ/é8ß:üã8þFàwü Ý`á~å'íOóPç

Fig. 17 Tightening Pinion Nut

è`íWç'ß:ìWê
Û/úré8ûuü5ï1î1Ýxü!êPçá~å'íFó:çß:ç'ìWç?à1àwâFí|ä€áJåíWå?áJâFá~çáJê:ç
ôé8ß:é8å?ß[ûuç'âFí‰à1ê:å?ó:ã8÷3þFç#"
íWé8û­éßPâO&ã %dç?âFíWé8ß:û­(à ')ê:ç†íWç?âF÷é8ß:û…íWç'ìWå?íW÷Oç?÷‡÷óPí 
é8ß:û• íW$ ç?ÿå SâFã8ñôã8ó:à‰âFß[âF÷÷OéáJé8å?ß:âFãdõFü ÜFù
 ÿ ÛÜé8ß:üã8þFàwü Ýxü

5ç~*
è %dç'âFíWéßPûuà ' ð„áJå+ Ü
 ÿ Ûxï1܄áJ(å F܄é8ß:ü‹ã8þFà1ü Ý"ü
/Û ù1Ý3ÞZýáJê:çFig. å?íWé8ûu16é8ß:âFPinion
ãôé8ß:é8å?Yoke
߀þFç?âFInstallation
íWé8ß:ûuàâFíWçþFç?é8ß:û…ó:à1ç?÷ñ
• Ûxï1ð1Ý3ÞZß:à1á~âFã8ãˆ÷Oéýý/ç?íWç'ß:áJé8âOã=âOà1àwç'ÿþFã äLâOß:÷ª
â Sã8ç[à1ê:âFý/áJàwñ
é8ß:à1á~âFã8ã÷Oé8ý/ý/ç'íWç?ß:áJé8âFãâFà1àwç?ÿ`þOã ä…âFß:÷â
eãç àwê:âFýá~à1ñ¬é8ý‹ßPç?ìWç'à é8ý²ß:ç?ìWç'àwà1âOí|ä ü
à1âOí|ä ü Ûx
ï 1Ý ,5ã8éû­ß ÿâFíWæPà¨ÿâO÷OçôíWç Sé8å?ó:à1ã ä£å?ßmäeå?æUçâFß:÷
ôíWå'ôç?ã8ã8ç'í‰àwêPâOýá^âFß:÷…é8ß:à1áJâOã8ãôOíWå?ôç'ã8ã8ç?í‰à1ê:âFý/áJü
Ûx
ï 1Ý3ÞZß:à1á~âFã8ã‰íWç'âOí3þFíWâFæPç
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%díWâFæPç'àwñý/å?í ôíWå'ôç?í ôíWå'ìWç?÷óPíWç?à1ü
NOTE: If new pinion bearings were installed, do not
Ûxï1Ü1Ý ,5÷÷ ûuç'âOíMã8ó:þFíWé8ìWâFß:á~ñŒé8ýß:ç?ìWç'àwà1âOí|ä 0 ü -ç'ý/ç'ícáJå
1 ó:þOíxéìWâFß:á‰ëeôç'ìWéýé8ìWâOáJé8å?ßPà†å'ý5áJê:é8à†à1ç?ìWáJé8å?ß©ý/å?íãóPþOíxéìWâFß:á
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
íW#ç Fó:é8íWç'ÿç?ß:áJà1ü
are set.
Û 1Ý3ÞZß:à1áJâOã8ãáJê:çˆäSå?æUçˆè`âFàwêPç?íâFß:÷â…ß:ç~è£ß:ó:á=å'ߌáJê:ç
Ûxï1ù1Ý3ÞZß:à1á~âFã8ãSè`êPç?ç?ãdâOßP÷…áJé8íWçâOà1àwç'ÿþFã8éç'àwü
ôé8ß:é8å'߆ûuç'âFíƒü²é8û­ê:á~ç'߆áJê:ç=ôé8ß:é8å?ßß:ó:ádó:ß:áJé8ã¬áJê:ç?íWç=é8à ¾ç'íWå Ûx
ï 1Ý 1 å~è`ç?2í Sç'ê:é8ìWã8ç?ü
þFç?âFíWé8ß:û†ç?ß:
÷ /ôã8â1ä­ü
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 ÿ Û/ðFõFõ„ý/áJü‹ã8þFàwü Ýxü
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
AXLE SHAFT
35476985:<;&=
Ûxï(Ý dâFé8àwçIâFß:÷kà1ó:ôôå'íW>
- á eç?ê:é8ìWã8ç?ü?dß:à1ó:íWçIáJê:âFáDáJê:ç
áJíWâOßPàwÿé8à1àwé8å?ß[é8à`éß[ß:ç'ó:áJíWâOã8ü
Û/ð1 Ý -dç?ÿå Sç5è`êPç?ç?ãdâOßP÷…áJé8íWçâOà1àwç'ÿþFã ä­ü
Û 1Ý -dç?ÿå Sç`þFíWâFæUç`÷íWó:ÿ@ü -dç?ý/ç'í=áJå.víWå'ó:ô†ÜFñA%díWâFæUç?à1ñ
ý/å'í‰ôíxå?ôç'í‰ôíxå?ìWç?÷Oó:íWç?ü
ÞߘàIá âGã~äLäIåIæGåNçGèPã éVêé@ç âTâGæGã ëVåIêLã ç å ì9í

î]ïð/ñaò&ó]ôTó]õ(ög÷õ(øùGó]ô5ô5ó2ù÷ñ(õkúmû]ü5ý5þÿrý





Fig. 20 Axle Shaft C–Clip Lock

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}#{5ˆŒ7‰ •}a„}#¦
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Fig. 18 Check Pinion Gear Rotation Torque ÈÉSÊAˇÌ2Í7Í#Ì7Ë¹È Î9É
wx
yz|{~}#€{~{9‚ƒ„}#…~†‡€ˆ
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}
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}#„‰0
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‚„ƒˆš‰ ‹!}›‹7ƒ#Œ!
…€7†œ
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‹!‚‰2‰ŠŒ!•}#
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¡ €!}#€!†½
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}–ƒ¥‰ ‹7
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†‡}„T‹!‚‰{~ƒ#Ž¨“
Ž„}©ª…~«
ŽŽ}#
…~•{} |}#ˆƒ S}š{~ƒŽ¨ aging axle shaft seal lip. Also, exercise care not to

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‹!‚‰¯‚„ƒˆ°
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{ damage the wheel speed sensor on vehicles
Ž}aw±P…~†‡˜²³
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ŸS{~}0‹!‚‰ŠDµAŒ!‹

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}#‰ z|·Ž{~…¦{~ƒ#Ž¨>…~€…~I}a†½}#„¢
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Fig. 19 Mate Shaft Lock Screw AXLE SHAFT SEAL AND BEARING
w ´
yµAŒ!‹0
ŸS{~}ž‹!‚‰9…€#©„¶€!„}ˆƒS}ž
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y |}#ˆƒ S}‰Š‹!}
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}#{¹‚„ƒ#ˆ”‰Š‹!}}#€7ƒ#‚|‰Š‹!}

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}›Ž„}]€!ƒ#‰V‰Šƒ›

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ŸS{~}a‹!‚‰ ‰ Œ!•}©…~‰Š‹¶ˆ{~{5¦I„ÝÆ/•„¢
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NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
 
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Fig. 22 Axle Shaft Seal Installation

Fig. 21 Axle Shaft Bearing Removal

U V) CD,W(F6 M%#"X.$#6$#&(%"&Y&(,.*P?)
#) A $K.?&(&(OZ
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~ s q_€{p\nykZp,mTqs^sq‚kZuƒ„puDq?sS} Fig. 23 Bearing Cap Identification
 Œ ž7'')Ÿ8CK&( A ,& …!‹7< Q#¡#‹K2 ¢;.1''£ƒ')*„,[
T<S[…†'MCK‡\ \?K"MH1.?$K\$#&(\W(,K)?O '1,[¤"&(, @BA #CD1,&¥  :#¡#¦KŒ#¢_/§'1™1?X, A 1/ICK')
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Q 
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'A ""M&(,)'M#
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Fig. 24 Install Axle Housing Spreader Fig. 26 Spread Axle Housing

Fig. 27 Differential Case Removal

Fig. 25 Install Dial Indicator
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Ò²Ó Ô/Õ*ÖÖ×8Ø/×<Ù/Ú>Õ Û[ÜەÙCÔDÔ/Ø/Õ ÝA×ÜÕ ÙC× Þ,ß'àÞ
áKâMãOäQå'æKçDæKèVéXê*èVëMì/æKç[ç[æì\ê*äVèí_îKï[ð[ñdòeð[ó[ô[õ[ö

Fig. 29 Differential Bearing Cap Reference Letters

Fig. 28 Install Axle Housing Spreader

CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.
jlknmoqprtsuvOwyxzsxz{d|z}+~"z€sdz{|€x‚wy{~*}+wyuƒ*ƒ-wyxzs„tu}+s
~"…wyxzsxz{|z}n~"z€†M‡&su}+|rtswyxzsv~"}+wyuz„tsVˆ‰~*wyx…wyxzsv~"uƒ
~"zv~"„tuwy{rKjlŠ>~"€‹†ŒŽ+m_†
jlnm s‘’{”“•sQwyxzsQv~"uƒ[~"zv~"„tuw–{dr—†
jl˜nm™”z}nwyuƒ"ƒ[v~"šlš*srtsdzwy~*uƒ[„tu}+sQ~"›wyxzsVxz{d|z}n~*€†œ z}n|zrts
wyxzuwHwyxzs&v~"šlš*srtsdzw–~"uƒsdurt~"z€,„t|zp}žrtsd‘\u~*O~"Op{d}+~"wy~*{d
{Ÿwyxzs v~"šlšlsdrtszwy~"uƒ¡sdurt~"z€}uzv¢wyxzuwwyxzs prtsƒ"{duv
}nxz~"‘\}›rtsd‘\u~" sw£ˆ’sds wyxzs¤šlu„ts¤{š\wyxzssdurt~"z€¥„t|zp
uzv›wyxzs)xz{d|z}+~"z€‹†•¦/upw–xzs)v~"šlš*srtsdzw–~"uƒ'„tu}+s)wy{,sdz}+|zr§s
wyxzs,surt~"z€‹}V„t|zp}Quzv›}+x~*‘\}Qurts,šl|zƒ"ƒ ¨¥}nsuwysv›~"wyxzs
xz{d|z}+~"z€‹†
jlŽnm™”z}nwyuƒ"ƒMwyxzssurt~"z€„tup})uw’wyxzsd~*rV{drt~"€~"zuƒMƒ*{d„tu©
wy~"{z}’jlŠ
~"€†Œªnm§†
jl«nm¬
{{}nsƒ ¨O~"z}+wyuƒ"ƒ[v~"šlš*srtsdzw–~"uƒ[surt~"z€)„tup¡{dƒ"w–}n†
jl­nm s‘’{”“•sQun®•ƒ"sQxz{d|z}+~"z€)}+prtsuvsdr—†
jlªnm\¦[~*€‹xzwyswyxzsžsdurt~"z€V„tup{dƒ"w–}Kw–{\««,¯±° ‘Ÿj*˜«)šlwy†
ƒ"}+† m²w–{drt³|zs†
j§´nµnm™”z}nw–uƒ"ƒ[wyxzsQun®•ƒ"sQ}+xzušlwy}n†
Fig. 30 Differential Bearing Removal
DIFFERENTIAL SIDE BEARINGS ÈlɕÊ
Ë»¼¼»ËÈ ¹HÉ
¶[·¸H¹[ºq»'¼ j§´em̱}n~"z€Íwy{{ƒŸÂ ©lk«B´nŽ© ÃΈ’~"wyxÏxzuzvƒ"sР©lB´n«B´+Ä
~"z}nw–uƒ"ƒ[v~"šlš*srtsdzw–~"uƒ[}n~"vsQsdurt~*€}’jlŠ
~"€†kB´em§†
j§´em s‘’{”“•sQv~"š*šlsrtsdzwy~*uƒ[š*rt{‘½u+®qƒ"sVx{|z}n~"z€† jlŒnm™”z}nwyuƒ"ƒ[v~*š*šlsr§szwy~"uƒ ~*un®•ƒ"sQxz{|}+~"z€†
jlŒnm s‘’{”“•sQwyxzsQsurt~"z€‹}’šlrt{‘½wyxzsQv~"šlš*srtsdzw–~"uƒ[„tu}ns
ˆ’~"wyx¿¾>|zƒ"ƒ"srÁÀ—¾
rts}n} Â ©lŒªk©l¾dñġ ©lŒªk©lkªÅ ƒ"{„tÆ8}nÄ¡uzv
¾
ƒ*|€,oq¾>©*kŒ­ªj*Š>~"€†Çkµnm§† RING ¦'xs‰rtGEAR
~"z€\uzvVp~"z~"{,€sdurt}HurtsK}nsrÁ“q~*„tsK~",uQ‘\uw–„txsv
}+sdwy†MÑ-{{wžrtspƒ*u„tsw–xsrt~"z€O€sur‰ˆ‰~*wyxz{d|zwžrtspƒ"u„t~"z€
wyxzsQp~"z~"{€sdure†
–H—|˜™ š{›œŠœž{?Ÿ{ B› ¡’¢H¡Ÿ<šbš{ž{› £’¢Š› Ÿ< ¤X¥

¦§M¨G©ªr«¬b«­%®”¯­%°M±{«¬¬«^±=¯©%­²Ž³´µ¶·
µ¸¹º»

þ§ÿ
YZ
#;$F 2M0() G()2;[: F*
*,\8()+M]^$(F:;@2
 _0()QQ*6*,G84
$*,=+
þ-)YZ
#<$ 20()%12$&K
("+
þC)Y()4\2:`*a*,b8(c4& d22 e
Bÿ
*P$f\g4hi )-4-_jKk  þ lm4igmn2+X84()+ 2o'¤þ A/*P+
CC)S+
þI)Y()4; 44;p)!G$'()*74& 5
 e
*,;=("$14& q040M@2&+

Fig. 31 Install Differential Side Bearings

÷[øùHú[ûqü'ý
þ§ÿ
 
  "!#%$&'()*,+
þ-)./01 &2304()567()'289
()9:;$
()<=4,>?): @40()+þ AB*,+DC4-)
þC) 
E8(F$ *G*G*,HE 
0("+
þI)JK()*LF()M$4 =OND 
*L*P; Q
QþA/*,+RC-)S+
0("
Fig. 33 Ring Gear Bolt Installation
PINION GEAR
]r$&sS&*t u@v*P(wd("x
0 uy
=20S$ q("2+{zr9&K@440%$%@5*,|:;$'
@40*L$*L*,O+

÷[øùHú[ûqü'ý
þ§ÿ
=2
  2$&%)!$'("*P+
þ-)}94~@ue~&€ @S@s()$a
()241*P=+
þC)z|()0&0\@@_("$&4\‚@ƒe~&+
JK()*9()'28<:;NB„@4@3()$|„'& 8 ?eP+
þI)JK()*†…X 5‡4ghˆ627$ ‰e#~ŠN;=
72$&
@9e~Š%&'< =: ("$O+
þh)JK()*‹=
#fŒiIh-a c10$dŒi4C-ˆBÿ"N
=
$@%e~& @1("$Mþ AB*P+RCI"Ž+
þ‡)=2
 $ @q*PK‹$'("*Qþ AB*,+C4h)Ž+
Fig. 32 Ring Gear Removal Œ20$‰2$&F@4&: $e#'„$4& GF@4

TUV/Wüýýü&WRT úXU &*H 8*L =*, +
þl)JK()c‘()'28c@xed2E6‹() c$&4==
CAUTION: Do not reuse the bolts that held the ring ='& ("02:  
$@1("$&4<("4+

gear to the differential case. The bolts can fracture þˆ)=2

H|("*PON’<o'@@ N’ GS@Q
causing extensive damage. 18*,+
þg)=2
 2$&“b@”84&*•0'@a: 2$
=2
;ŒQICIhF …3 4ŒiI "l Bÿ Bÿ’þAB*,+DC4‡)Ž+
 !#"$"$%'&!%)(!*+ ,.-,
(/0!&! 12%$-$ (/% 3465$7
8:9<;>=@?6A:B0A:CEDGF#CEH<I!A:B.B.AIJF#=ECLKNM:O.P.QRSP.T.U.V.W

Fig. 34 Pinion Yoke Removal

Fig. 36 Front Bearing Cup Removal

Fig. 35 Remove Pinion Gear

¼S½)¾)¿ÀÁÂ=Ã2ÄÁ†Å2ÆÁ†ÇÁÈ4Ç7ÉÁÈ4ÇSÊË&̃ÍÎÏcÐÇÃÂÑÆÃÎÒ)ÊËÌ
¼Ó/ÊÌ,ÔRÕÖ)¿SÔR×<Ò"ÁÀÁ ÃÄÁÇ;ØrÙS½)Ú4ÛHÈ4Ë&ÜqÝXÈËÜÞÁßàÚ/½)֏½)Ô
¼S½½O¿ÀÁÂ=ÃÄ#ÁƒÅÆÁfÍÃÞÞÈÏÒ)ÊÉÞÁfÏÇÁÞÃÈ4ÜáÒ)ÏÈÍÁÇn¼ÓBÊÌ,Ô
Fig. 37 Rear Bearing Cup Removal
Õâ)¿SÔ ¼ã)¿ËÒ)ÅÈ4ÞÞaÅÆÁÏÊËÊÃË ÇÁÈǔÉÁÈÇÊËÌ ÍÎÏvä;ÊÅÆ
¼S½)ã)¿ÀÁÂ=Ã2ÄÁ;ÅÆÁ;ÇÁÈÇKÉÁÈ4ÇÊË̄ÐÇSËÅÆÁ;ÏÊËÊÃË=ä;ÊÅÆ ËÒ)Å2ÈÞÞÁǐØ|ÙS½)ÚF
 ÈËÜqØrÇÊ Ä#ÁǐÝ3ÈËÜ4ÞÁßàڏ½"֏½ ¼Ó/ÊÌ,ÔRÚ¾)¿SÔ
å ÎÞÞÁÇxæ å ÇÁÒ"Ò\ßÙãÛÕ4Ù åç È4Ë&Ü ç ÜÈÏÅÁÇ҉ßÙãÛÕÙÚ¾f¼ÓBÊÌ,Ô ËÒ)ÎÇÁÍÎÏÊÒ=ÍSÃÇÇÁÍÅ2Þ G
 Ò"ÁÈÅ2ÁÜÔ
ÕÛ)¿SÔ ¼Õ)¿ ç ÏÏ4Þ  9  ÃÏÈÇ ØrÃÃÇ  ÈÒ"ÁM
 ÃÇLÁ  ÎÊ ÄÈÞÁË&Å|
 Ò"ÅÊÍý
è^éxêë4ì9í9ê&îBêï/ðSì4ñ=òéxóëôBõõóFðSöDì"÷‰îBóFøDóðMî/êùHêúì t
ÞÎÉÇÊÍÈ4Ë&Å<Å2ÃÃÎÅÒ"ÊÜÁÒ"Î&ÇÐÈÍÁÃВÉÁÈÇÊËÌLÍÎÏÔ
ðŽöDìqòì4êñZûOøDú1ë4ê&úìü ¼Ú)¿  ËÒ)ÅÈ4ÞÞ Å2Æ&Á”ÏÊËÊÃËÑÐÇÃËÅwÉÁÈÇÊËÌvÍÎπä;ÊÅ2Æ
¼S½)Õ)¿ÀÁÂ=Ã2ÄÁ=ÅÆÁ ÜÁÏ4Å2ÆqÒ)ÆÊÂ=ҐÐÇÃÂaÅÆÁ=Ï4ÊË&ÊÃËqÌ,ÁÈ4Ç ËÒ)Å2ÈÞÞÁǐØ|à½)Õ4¾HÈ4Ë&ÜqÝXÈËÜÞÁßàÚ/½)֏½ ¼Ó/ÊÌ,ÔRڏ½
¿SÔ
Ò)ÆÈÐÅ2ÔDÀÁÍÃÇÜqÅÆÁÅÆÊÍýŠËÁÒ)Ò ÃВÅ2Æ&Á%Ü4ÁÏÅÆ1Ò"ÆÊÂ=Ò)Ô ¼) ¿ ËÒ)ÅÈ4ÞÞ<ÏÊËÊÃË_ÐÇÃËÅ ÉÁÈÇÊËÌr  ÈË܉ÃÊÞ<Ò"ÞÊËÌPÁÇrÊÐ
Á   ÎÊÏÏ4ÁÜÔ

 Rþ
Xÿ
þÿ
¼) ¿ ç ÏÏ4Þ n  ÈGÞÊÌ,ÆÅ;ÍÃÈÅ2ÊËÌ1ÃÐXÌPÁÈÇ9ÞÎÉÇÊÍÈËÅ ÃË_ÅÆÁ
¼S½
¿ ç ÏÏ4Þ  9
 ÃÏÈÇ ÈÒ"ÁMÃÇLÁ ÎÊ Ä#È4ÞÁËÅ|Ò"ÅÊÍý
ØrÃÃÇ ÞÊÏ9ÃÐDÏÊËÊÃËHÒ"ÁÈ4ÞÔ
  Ë&Ò"ÅÈÞÞBÒ)ÁÈÞä ÊÅÆ ËÒ)ÅÈ4ÞÞÁÇMßÙÕÛ4ÖãÙ ç
t
ÞÎÉÇÊÍÈËÅ<Å2ÃÃÎÅÒ"ÊÜÁÒ"Î&ÇÐÈÍÁÃВÉÁÈÇÊËÌLÍÎÏÔ ÈËÜÝ3ÈËÜ4ÞÁßàڏ½)Ö/½ ¼ÓBÊÌ,ÔDÚã"¿ŽÔ
¯°¦±$± ²!³m´'´$µ$¶!µ)·!¸+³ ¹2º¹·/²0²!¶!³ »2µ$º'³ ·/µ ¼˜½
¾:¿<À>Á@Â6Ã:Ä0Ã:ÅEÆGÇ#ÅEÈ<É!Ã:Ä.Ä.ÃÉJÇ#ÁEÅLÊNË:Ì.Í.ÎÏSÍ.Ð.Ñ.Ò.Ó

Fig. 38 Collapsible Spacer Fig. 40 Pinion Rear Bearing Cup Installation

Fig. 41 Pinion Front Bearing Cup Installation

X Y[Z\]#^_a`cbedf`cgihaj g$`hkbedflm_an'of`pqpr$`g$bedspqdflmtuj osbedf`
g$lmoflmj owv`^hx
Xy[Zz{ofp[be^i]m]|bedf`}ha`^h~` ^halmofv€^ofrpq]mlmofv`h‚ulmƒ
` „…flmg$gi` r$‚†jo‡bedf`ˆg$lmoflmj o0v` ^hŠ‰†lmbd0z{ofpqbe^]m]m` hŠ‹ŒŽŽ
Xlmvx’‘“[Z”x
Fig. 39 Rear Bearing Removal
X•[Zz{ofp[be^i]m]’^Šof`‰–_aj ]m]m^g$p[l#~]m`—g$ha` ]mj^irkpqgi^i_a`h˜j og$lmofŒ
lmj opqdf^ƒb^ofrŠlmofpqbe^]m]™g$lmoflmj ov` ^hšlmodfj …fp[lmofv›X+lmvœx‘i‘[Z”x
NOTE: Pinion depth shims are placed between the X”ž[Ÿ[Zz{ofp[b^]m].g$lmoflmjovœ` ^h†lmowdfj …fp[lmofvx
rear pinion bearing cone and pinion gear to achieve X”ž žSZz{opqbe^]#]< 
jn`‰—lmbed0z{ofp[b^]m]m` hw¡
_aha`‰¢yžž[Ži‚:£¤…fg
proper ring and pinion gear mesh. If the factory yž[Ÿi•‚’^ofrdfj]#ri` h:i•¥yXlmvx’‘¥[Z”x
installed ring and pinion gears are reused, the pin- X”ž[Ž[Zz{ofp[b^]m]’bedf`¦ 
jn`¦‰—^p[df` hš^ior^Eof`{‰§of…fb6jocbedf`
ion depth shim should not require replacement. If g$lmoflmj o¨v`^h:^ofrblmvdb`owbedf`›g$lmoflmj o¨of…fb<…foblm]¤bedf` ha`›lmp
required, refer to Pinion Gear Depth to select the
© ` haj@~`^ihalmofvk`ofr$Œgi]#^[ ªx
proper thickness shim before installing rear pinion X”ž[“[ZJ«2lmvœdfb`obedf`@of…fb<bj@ŽYž—¬š­ t®X#ŽiŸŸƒ#bx™]#~p[x Z”x
bearing.
 !"# $&%'$()* +,% ) -/.102
346587:91;<*;=?>A@=?B6C;<&<&;DCE@7?=GFIHJ&K&LNMOK&P&Q&R&S

Fig. 42 Pinion Seal Installation

Fig. 44 Collapsible Preload Spacer

Fig. 43 Shaft Rear Bearing Installation Fig. 45 Pinion Yoke Installation

”Ô Õ[ç[×ü
âmÞí—â ÝsêeÚmÜáfêeà ÛýêáàÛfìê†ÚmÛýåi÷ èwðšñ òþÔ#çwöêe÷2âmøiÙ[÷ ×
CAUTION: Never loosen pinion gear nut to
ÚmÛfîaäaàòJà ÛfêeهìfÛfêeÚ#âÿêeáfà äaÞ êeéêÚmÛfÜ êeÞ äaëìfà Ú#هéîaáfÚmà
à ã$÷
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
 àéÙqìfäaàJêáà›äaÞ êeéêÚmÛfÜEêÞäaëìfà›öäaàëìfà Ûfêeâ ݍêeޛé
Þ ÚmãÞ
àä
îaäaìfÙ[áfÚmÛfÜkêáàEî”Þ âmâméiúiÙqÚmøâmàEÙ[ú$éîaà ä:ÔûÚmÜ÷’Öï[ה÷
torque or rotating torque is exceeded a new col-
ԔÕ[å[ × ¤áfà îaßøà éäaÚmÛfÜ@ä”Þ êeéiêeÚmÛfÜ@êeÞ ä”ëiìà¦í—ÚmêeáéEÔÚmÛf÷âmøiÙ[÷ ×
lapsible spacer must be installed. The torque
êeÞ äaëìfàˆí—äaàÛfîaá Ô#û+ÚmÜ÷kÖiï[ה ÷ 6áfà êeÞ äaëìfà Ûfàîaà Ù[Ùqéä Ý®êÞ
sequence will then have to be repeated.
äaÞ êeéêeàEêeáfà@ú$ÚmÛfÚmÞۍܜà éä†Ù[áfÞ ìâ#ãøà 
ԔÕ[Ö[×ؚÙ[Ú#ÛÜJÝ
Þ ß'àkáfÞâmã$à äJåæçiècéÛfãwé¨êeÞ äaëìfà:í†äaà Ûfîaá äaÚmܜÚ#Ûéi
â
¤à éäaÚmÛfÜ Ù  Õêލô ð/ñ ò|ԔÕ[õ êe Þ iõˆÚ#Û÷
Ù[à ê<éê<ÖïÖðšñ òóÔôçiõköêe÷™âmøÙq÷ הù+îaäaìfÙqá¨îaÞâ#âméú$Ù[Úmøiâmà›Ù[ú$éîaà ä âmøÙq•÷ ה÷
ìfÛfêeÚmâ.øà éäaÚmÛfÜkà Ûãcú$âmé[Ý>Úmٗêéß'à ÛwìfúÔû+Úmܜ÷’Öåq×N÷ ðšà í
¤àéäaÚ#ÛÜ Ù êeÞ@çðšñ ò ԔÕ[çêeÞEôçÚmÛf÷’âmøÙ[÷ ×N÷
• ԔÕ[ï[ × {ÛfÙ[êéâmâ.ã$Úmöö#à äaàÛfêeÚ#éâ.ÚmÛwáfÞ ìÙqÚmÛfÜ÷
NOTE: If the spacer requires more than 474 N·m
(350 ft. lbs.) torque to crush, the collapsible spacer
ԔÕS×ü îaASSEMBLY
FINAL äaéú$à>êáfà>äaàÙqÚmã$ìéiâ†Ù[à éâméÛfêŠöäaÞò êeáfà>áfÞ ìÙqÚmÛfÜ
éÛfã›îaÞ
àä¦òJéêeÚ#ÛܗÙ[ìfäaöéîaàÙq÷¤âmà éۊêáàòJéêeÚmÛf܆Ùqìfäaö#éiîaàÙ
is defective and must be replaced.
Æ/ÇÉÈÊ ËÌWÍÍÎÏÎ!ÐÑ#Ì Ò,Ó/Ò­Ð)Ë*ËÏÌ Ô,ÎÓÌ Ð)Î ÕÅÖ
×Ø6Ù8Ú:Û1ÜÝ*ÜÞ?ßAàÞ?á6âÜÝ&Ý&ÜDâEàÚ?ÞGãIäå&æ&çNèOæ&é&ê&ë&ì

Fig. 46 Tightening Pinion Nut

Fig. 48 Typical Housing Cover With Sealant

DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
&¸ ¹ ºc»#ºcº1¼¬½?¾#¿YÀ
ƒ ±OŠ v \ZEog|(\dUW[UWo[/€†\^y])ZE^yVY\°beX^yp…V,`oNufÁ~buf]f\gT ƒ„ UW€†h
‡yÂeƒ…Š_ª h v
ƒ…´ ŠŠ v \oZEVY^yogVg|(\\:VYXd\UW[UWnoNUW[p…p\€®]f\\N^y[]°VgUWZE^y`^yVYbe\:Unab\8X^y€®p…\VY^yh ]fb ^y[nÃ]_\ZEog|(\
VYX\:dUW[UWo[¨ZE^yVg\:€†\N^y]fb^a[¬n VYX] w beVT^ybeX\]fb ƒ„ UW€†hˆÄ µ Š_h

Fig. 47 Check Pinion Gear Rotating Torque

Tvxw UWVYX/ZEUW[\]_^a`cbedUW]fUWVgbeh!ijw dda` k'^mla\N^an:oprqsoda^aw ] t t UW`UWufoN[\
ƒ…„ UW€†lyhˆly\‡y] ‰eŠ_t h \^y`W^y[VYz&o]m\N{ U |(^y`\N[VYz&o[}VgX\~Xo bUW[€ufo|‚\]
‹fŒrŽI‘’ŽI“r”•“r–—r˜OŒr™›šy–œˆ”ž Ÿ˜¡ŽI“r˜¡Œ£¢•¤/˜¡Œr—rŽI”
¥YŽ_”ažs¦c¦# §˜¡Œr™¨ŽI“r” N”‘ŒrŽI©
ƒ…ª Š«[beVY^a`W`EVgX¬\ ufo|‚\]¨o[*VYX\ naUpp…\]_\[VYUW^a`6TUWVYX*VgX¬\
^yVgVY^yufXUW[€mlyo`WVYbh­«g[bVY^y``#VgX¬\ƒ…UW´ynµ \N[VYUpUWuf^aVYUWo['VY^aw €®hy¯&U€®XVY\[
VYX\:ufo|‚\]°lyoN`VYbVYo:‡c±²)³ Z pVghr`lybeh ŠVYo]f{ \Nh
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
ƒ…´ Š v \pUW``6VYX\naUpp…\]_\[VYUW^a`6Xo w bUW[€:TUWVgX €†\^y]?` w ly]fUW¶ ƒ ‡eŠ Fig.
v \ZE49og|(Pinion
\’VgX¬\¨nUWpp…\]f\N[VYU^y`ÅbeUna\¨€®\^y]fb^y[n VgX¬] w bV
Gear Mate Shaft Lock Screw

uf^y[VYh v \w p\]VYo?VYX\?· w ly]fUWufw ^y[V t d\ufUWp…UWuf^yw VYUWo[bEbe\ufVYUoN[8oNp T^ybeX\]fbeh

VYXUWƒ b€†]fo d po]VgX\:€®\^y]°` ly]fw UWuf^y[V)]f\N{ U]f\NZE\[¬Vgbeh
‡eŠ«[beVY^a`W`&VYX\:p…UW`W`&XoN`W\?da` €†h
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Fig. 54 Mate Shaft Removal

Fig. 52 Differential Case Holding Tool

Fig. 53 Mate Shaft Lock Screw Fig. 55 Step Plate Tool Installation
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Fig. 56 Threaded Adapter Installation Fig. 58 Remove Pinion Gear Thrust Washer

Fig. 57 Tighten Belleville Spring Compressor Tool Fig. 59 Pinion Gear Removal
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Fig. 60 Side Gear & Clutch Disc Removal Fig. 62 Clutch Discs & Lower Side Gear Installation

Fig. 61 Clutch Disc Pack

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Fig. 65 Shim Locations

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Fig. 67 Pinion Height Block—Typical

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Fig. 69 Pinion Gear Depth Measurement—Typical

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DIFFERENTIAL BEARING PRELOAD AND GEAR

BACKLASH
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Fig. 70 Axle Adjustment Shim Locations

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bearings during the removal procedure. Install
replacement bearings if necessary.
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72 Differential Side play Measurement
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SPECIFICATIONS
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SPECIAL TOOLS
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page page

GENERAL INFORMATION FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 100

216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 97
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . 84 PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 91
DESCRIPTION AND OPERATION REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 85 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . . 85 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING STANDARD DIFFERENTIAL . . . . . . . . . . . . . . 101
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . 86 TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 101
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . 87 CLEANING AND INSPECTION
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . 105
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 86 TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . 87 ADJUSTMENTS
TRAC–LOK DIFFERENTIAL NOISE . . . . . . . . . . 87 DIFFERENTIAL BEARING PRELOAD AND
TRAC–LOK TEST . . . . . . . . . . . . . . . . . . . . . . . 87 GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 108
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 GEAR CONTACT PATTERN ANALYSIS . . . . . . . 111
SERVICE PROCEDURES PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 106
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . 90 SPECIFICATIONS
REMOVAL AND INSTALLATION 216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 113
AXLE BEARING AND SEAL . . . . . . . . . . . . . . . . 93 216 RBI TORQUE . . . . . . . . . . . . . . . . . . . . . . . 113
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SPECIAL TOOLS
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 94 216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 95
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Fig. 1 Axle Adjustment Shims Fig. 2 Differential Operation—Straight Ahead Driving

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CAUTION: If axle is submerged in water, lubricant

‰‹‹‰ˆ•$‘“U‹H‹•$‘H„$‹’0‡“-‘I›A•$‘‘‹h†‹‰‹‘H‰-‹E‰¿Œ‰’0‹‘†

must be replaced immediately to avoid possible

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premature axle failure.

DESCRIPTION AND OPERATION

STANDARD DIFFERENTIAL
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pãsuÎك…„ Þ „‡vx‹‡äxŒƒ*åæ~
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CAUTION: Overfilling the differential can result in

lubricant foaming and overheating.
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SERVICE PROCEDURES
REMOVAL AND INSTALLATION
LUBRICANT CHANGE
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WARNING: Do not reuse the bolts and nuts that

retained the axle shaft to axle tube flange. Used
prevailing torque nuts can loosen, causing a dan-
gerous condition.
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AXLE BEARING AND SEAL

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È{¾Eą¿JÅ(Ë Fig. 13 Cut Retaining Ring

Fig. 14 Axle Bearing and Seal Remove

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Fig. 15 Axle Bearing and Seal Components

Fig. 17 Press Bearing Retaining Ring On Axle

Fig. 16 Press Bearing On Axle Fig. 18 Bearing Cap Identification

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ñaò™èuétä”éHæXðtì_ñaòtó‡ô'õ|äXëxìdðHîrä”èuétä”üfñaìdèuëfòHêrä0ý˜ñ èué™èuétä—üñaë 
ñaòtüñaêrëxèuæXî˜.ß !ñaó‡ôŸà dâ:ô
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
ß6_âTãVäXå6æhçä+èuétä+üñaëñaòtüñaêrëxèhæ?î®ô
ß7_ â "\òtì_èuë #üfñ í íkäXîQäXòtèuñaë Vñ ò”étæ?ðtìdñaòtó¬ô
ß8_ â "\òtì_èuë #Žêrëfì_äZñaòTèhétä˜étæXðtì_ñaòtó‡ô 9ëxù„èuétäZüñaíkí äXîrä?òtèuñ ë
êrëxìdäZý˜ñ èuéëµîrë_ýZétñaüäæ?î0îrð øfø ä?î0å6ë #aäXè˜èuæäXòtì_ðtîräèuétä
ø äXëxîrñaòtó‡ì|ëxîräTíkð . ÿ÷ì_äXëxèuäXünñaòšèuétäüñaíkíkä?îräXòtèuñaë éHæXðtì_ñaòtó
ß!†ñaó‡ ô à@âQô
ß :_âTãVäXå6æhçä+èuétä+ìdùfîräXëxüä?î®ô


Fig. 19 Spread Differential Housing

Fig. 21 Differential Installation

ß -_â"\òtì_èuë#'èhéHä ø äXëxîrñaòtó”êrëxùì|ëxèZèuétäXñaî0æ?îrñaó‡ñaòtë;aæ?êrë*

èuñ æ?òtì+ß!†ñ ó¬ô<dâ:ô9ñaó‡éHèhä?òoèuétä ø ä?ëxîrñ òHó‚êrëxù ø æ èuì+èhæ)à_á
=?> å ß -xáíkèu ô  ø ìdô âèhæ?$î @xðtäXô

Fig. 20 Differential Removal
Qß à_á_âTãVäXå6æhçä”èhétä”êrëxìdä”íkîræXåïéHæXðtì_ñaòtó‡ôõ|ëfîrö÷æ?îèhëxó ß _
 â "\òtì_èuë #ë Aaä+ì_étëxíkèhì_ô
ø äXëxîrñaòtó2êrðtùìúèhæûñaòtüñaêrëxèuä¢ý˜étñaêréþìdñaüfä«èuétä\ÿ2ýZä?îrä
îrä?å6æ\çä?üTíkîræXå6ô DIFFERENTIAL SIDE BEARINGS
B<CD<EFG


  

Qß à@â†æXì_ñ èuñaæXòùfîräXëxüä?îà„ýZñaèhé|èhéHäèuæXæüæhýZä ßQà@âTãVäXå6æhçä+üñaíkí äXîrä?òtèuñ ëêrëxì_ä+íkîræXå ëAaä+étæXðtì_ñaòtó‡ô
ùñaòtìJìdä?ëfèuäXü|ñ òèhétä aæXêrëxèhñaòtówétæaä?ìß!†ñaó‡ôàdâ:ô"hòtìdèuë#èuétä ß_âTãVäXå6æhçä+èuétä ø äXëxîrñaòtó‡ì˜íkîræXå èuétä+üñaíkí äXîrä?òtèhñaëêrëxì_ä
étæ  ü·üæ\ý˜ò $ê aëfåZùìnëxòtüvèuñaó‡étèuä?ò èhéHäšèuæXæ wèuðtîrò ø ðtêr%ö aä ýZñaèuH é †Ið #aäXKî JL†îräXì_M
ì (+*.,*0?NI0müëxùèuäXîrO
ì (+*,*Qà -N5ëfòHü
0müëxùèuäXP î (+*,*.,ß !†ñaó‡ ô ,_âQô
íkñaòtó¬äX$î xèuñ ó¬étèuô
ß _
 â "\òtì_èuë #
ë &ŸðHñ üf'
ä †ña)
ò (+*,--*.¡ëfè"èuét/
ä  ä?íkè"ì_ñ üfä6æ?í ß ,_âTãVäXå6æhçäüñaíkíkä?îräXòtèuñaë ùfîrä aæXëxünì_étñaå6ì„í îræXåûüñaí íkäXQî *


èuétä¢üñaíkíkä?îräXòtèuñaë ¡étæXðHìdñaòtó‡1ô 0mèuèuëfêré¤üñaë ¡ñaòtüñaêrëxèhæ?î¥èuæ äXòHèhñaë êrëxìdäJétð ø ìdRô 9ëxóZèuétäì_étñaå6ì'èhæJñ üfäXòtèuñaí ÿ˜ýZétñaêré„ì_ñaüä
étæ?ðtìdñaòtó8ù#ñ aæXè¦ì_èhðHü3 ô 2æ?ëxü©èuétäªñaòtüñaêrëxèhæ?î«4ù aðtòHó‡äXî æXíèuétä+üñaíkí äXîräXòHèhñaë èuétä\ÿ)êrëxå6ä+íkîræ?å6ô
ÌMÍÂÎ4Ï ÐXÑ#Ò%Ò4Ó4ÔXÓ]ÕXÖ_Ñ ×eØMׯÕ;ÐcÐXÔXÑ ÙeÓ4Ø%Ñ Õ;Ó ÚÛ

ÜPÝmÞoß1àGáPâcáPãuäwå.ãuæmçXáPâ<â<á
ç'å.ßuã{èQéPê<ë<ìíë<î<ï<ð<ñ

Fig. 22 Differential Bearing Cap Reference Letters

Fig. 24 Install Differential Side Bearings

RING GEAR
ÁGœš $‘#“I”'•“I–u—4‘#“I‘#˜“M”š•$›•$šP›šKF‘.¡$šP‘#“M•1¨'•¤°¡$œš–
›¦š¤¥«m´Â˜¿“˜¤Ÿ$š— .•¡$š™¤°œš¿$‘#“I”o”š• · ‘.¤¥œI˜±I¤Ÿ$š—4 #•¡$‘#“I”
¤¥œIš1—4‘#“I‘#˜“¿”š•«

Ã<ÄÅŒ<ÆFŠG‹
¬’­®Ç š¨'˜°š1–4‘#ŽŽ.š$š“I¤¥‘.• <Ž.$˜¨È•¦ÀF #šuœ˜±I›‘#“I”«
¬²®É  .•¡$š¿–4‘#ŽŽš$š“I¤¥‘#• U¡$•›š¸‘#“Ê•›±I‘#¤°•ž #š‘#›š · ‘#¤¥œ
›¦˜Ž¤;¨'š¤°• Ë]• · —$˜¤¥š¡$¤¥˜$›« ¬.½ ‘#”« ²µ®
¬¾®Ç š¨'˜°š™ž˜ #¤¥›bœI˜ #–4‘#“I”o$‘#“I”o”š•M¤¥˜™–4‘#ŽŽš$š“I¤¥‘#• 
¡$•›¦š«
¬ » ®³ ›‘#“I”O•b›˜Ž¤;œ•¨/¨'šL¢–4$‘ š1$‘#“I”O”§š• Ž.$˜¨È–4‘#Žª
Žš$š“I¤¥‘#• <¡$•›¦š ¬½ ‘#”« ²µ® «

Fig. 23 Differential Bearing Removal

†‡ˆ‰Š
‹‹Š‰ † Œ‡

Ž<’‘.“”•“I–b—‘.“‘.˜“™”š•$› œI•FšŸžšš“™$š— #•¡$š–4¢4š$‘#Ž £

–4‘#ŽŽ.š$š“I¤¥‘.• ›¦‘#–4šPžš•$‘#“I”/—4$š #˜•–u•“I–u”§š•m¨'š›œMž•¡$©%ª
 #•›¦œI«
¬’­® “I›¤¥• # ¯–4‘#ŽŽ.š$š“I¤°‘#• ¯—4$š .˜•–1›¦œI‘#¨'›m˜“O–‘#ŽŽš$š“I¤¥‘#• 
¡$•›¦š1œI±ž›«
¬²®³ ›‘#“I”H¤°˜˜ '´Gª ­µ¶¸· ‘#¤¥œcœ•“–4 #šº¹+ª» ­¦¼¯­ ¢P‘#“I›¤¥• # 
–4‘#ŽŽ.š$š“I¤¥‘.• <›‘#–4š1žš•$‘#“I”› ¬½ ‘#”« ² » ® «
Fig. 25 Ring Gear Removal
¬¾® “I›¤¥• # <–‘.Ž.Žš’š“I¤¥‘#• +‘.“¿•À #š1œI˜±›¦‘#“I”«
¦s§ ¨Z©ª
ª
«­¬Z«t®Z¯q© °-±°&®,¨3¨Z¬Z© ²³«
±
© ®,« ´‚µS¶
·

¸L¹º»%¼S½L¾3½L¿.ÀÂÁ¿.ÃÄZ½L¾-¾-½#ÄXÁ».¿jŀÆLÇ-È-ÉÊ^È-Ë-Ì-Í-Î

òóôõö
÷÷öõ ò øó

CAUTION: Do not reuse the bolts that held the ring

gear to the differential case. The bolts can fracture
causing extensive damage.
ù’úûüýRþFÿ
I  ÿ
 . ÿ
$ÿý ÿý #ý
 ÿ !"#  %$
°þ& 4
  ÿ' ÿ
((  #ý)§  ÿ
 
. ÿ%   ý'* ÿý!
ù  + ûüýRþFÿ
,I  ÿ%
 . ÿ
$ÿý - ÿ.# ý/I  ÿ?þ& ¦ ÿ!
ù  0 ûüý  ýIÿ1 #ý2  ÿ
34  ý5° ÿ$ý¥ ÿ
 6
 7¥ ÿý8:9 ;¯ < ú+ +'=?> * ù @A <9AB!C ! ûDEI F ÿ ù GH 7!
+I ûJ!
ù  K ûüý   ÿ
’ÿý  L. ýMN&# ÿ
F# ýO  ýP¸  þFÿ
  6
 ÿ*'ÿQ/
  ýPR ý J,$
¥ ÿ
$ýP! Fig. 27 Pinion Yoke Holder—Typical

Fig. 28 Pinion Yoke Removal

ù IûDc+ÿ
*X°þÿIÿ$
#ý ýmÿdý$
$ÿT *X
 *|F .ýPºùGq 7!,+9ûJ!}~ wIÿ/$
#ý ý [6&
FP
  ýD%$ $ÿþÿý, , *T  #ý]ýRÿ .ýP‚  *X§ÿ

!
ù  @ ûD+ c ÿ
*X° þÿI  ÿ ý$
# ý  ýz  ÿ  #ýƒFP$
p#ÿ
 #ýup

q# ý§  ÿ
„pf 
 ÿ
EF $
$ ÿ

p& ý.$
# ý  ý‚¦ ÿ 
 ‚< c ÿ*X þFÿ

Y\Q( úQK@  ýDvC  ýP
# ÿ%}~< ¯ K ú¯ @ ú/ù GH u!{0A ûJ!
Fig. 26 Ring Gear Bolt Installation
ù  x ûD+ c ÿ
*X° þÿ]  ÿ‚$ÿr$
# ý   ý:  ÿ #ýRFP$[ *…N&# ÿ
FQ# ý ù GH 7!s¯ 0 úûJ! o ¦ ÿ:+ c ÿ*X þÿƒYS’( úKxB  ý)vC  ý
# ÿ
"SÿT .GEAR
PINION ýPUýV$
#ý ýW§ÿ
2$ÿT¦ÿKþ& $ÿ
V2
}~< K ú¯ @ ú!
*XIÿ
R¦ÿ!ZYSýP
?$ÿ
$  $ÿ.Iÿ.$
#ý ý[ÿ
\ F
ù  9 ûD+ c ÿ
*X° þÿLI  ÿL4  ÿ$
 *X? *†$ÿ,$
# ý  ý  ÿ
€(
$ÿ$
 # ý]I
 ÿ% #ý]
 ÿ ^!
#ý.JF$‚
$ÿ# ýRN&# ÿ
FPQ# ý7!H+ c ÿ
]  ÿX %
i ýIÿ
L
_-`Paø-bFöG÷ I
 ÿ%4  ÿ
$ /QP *X!
ù’úûD+ c ÿ
*þÿ ÿ$ÿý  LQÿ
*X 6d *eNf.ÿP
F(
#ý7! NOTE: The pinion depth shims can be very thin.
ù  + ûDgh ij$
# ý ýk6&iÿVýl$ 
$4ÿ.ÿm 2
Verify that all shims have been removed before pro-
#ý   ý/ §  ý' * ÿý! ceeding.
ù  0 ûDY\  ýIýÿ
:$
4 $ ÿ
# ÿBQP : 
*n$
# ý  ýd6& i ÿ! ù’ú
A ûD+ c ÿ
*X° þÿr  ÿ%$ÿL$
#ý ý/ÿ
 #ýh *Iÿr$
#ý(
o # ýhF  # ÿ $ÿ
pq# ÿr$ 
4 $ ÿ. ÿs \rI F ýP4
 ÿ
t6u!   ý1 ˆ‡HF. ÿŠ‰„‡q$ÿQ‹}~<+90 (‡
Œ  ýŒ?  $ ° ÿ

ù  K û o # ýwvC
4  ÿ[I9 ;x)O
y6f
% i ÿ
p$ÿ*X þFÿzI  ÿ }~( +90( Kb x ù GH u!{0+ ûJ!
$
# ý  ý¸ýFP,  ýPr I  ÿ
Pù GH 7!{+@ ûJ! Ž#^P‘ ’h“h”H•H–J’ —X˜™Šš‘›qœLœ
š–Jž’QŸy”qš žš–”H¡‚¢’
ù  ; û o # ý|+ c ÿ
*X° þÿm}~(K ;+W  ýPlvs4  ÿ
5}~( 0+¯ x úp –€ž’R˜™’ —¤£„ ž¢/‘ P¢’
¥
$ÿ*X  þÿ%I ÿ%$
# ý  ý.6& i ÿ%
*$
# ý  ý/Q;  ù Gq u!{+¦x û€!
     !"# $  " %'&
(*),+.-0/21*3#1*46587946:,;1*3<3<1=;>79-64@?BA*C<D<EGFHD<I<J<K<L

Fig. 31 Rear Bearing Cup Removal

Fig. 29 Remove Pinion Gear

Fig. 32 Inner Bearing Removal

Fig. 30 Front Bearing Cup Removal JÖ ×^ØDÙHÚÛÜÝ%Þ ßà
Þ
ÝßáâãÜä­åÝæQæç
ÝÞ
áâ/æQâãèãå/ßÝ
ÛßLÞ
ãåé
Ï Ð&ÑHÒ7Ó#ÔPÔ
ÓPÒ{Ï ÕCÐ ãà
å/êÝ
Ûßãåë]ÜìÞDê àßÝ%ãå[áâÝ%Ûí&ÚÝ%âà
ìæãåë7î
Ö ïØXð?Þ
Þ Ú ñ)òhà
Þ
Ûß à
à߂ô~ÛæQÝõà
ß]Ý
öìã ÷&ÛÚÝ
åPáõ\æQáãÜä
ÚìêßãÜÛ åPáDáàzà
ìáæãç tÝzó æQìßJø ÛÜÝzà
ø.ßÝÛßÞ ãåPãàå4ê ÝÛßãåë
NOTE: Pinion depth shims are placed between the ÜìÞ îHùåæQáÛÚڞáâÝê ÝÛßãåPë%ÜìÞLúãáâDùåæQáÛÚÚÝß éJ×ûü.Û åPç
rear pinion bearing cup and axle housing to achieve
ý Û åPç
ÚÝÿ
þ û™×  × Ö qãëu
î Q؀ î -Ýßãø ñVÜìÞ5ãæ ó ÜàßßÝ
ÜáÚ ñ
proper ring and pinion gear mesh. If the factory æQÝÛáÝç
î
installed ring and pinion gears are reused, the pin- Ö ØXð?Þ
Þ Ú ñ)òhà
Þ
Ûß à
à߂ô~ÛæQÝõà
ß]Ý
öìã ÷&ÛÚÝ
åPáõ\æQáãÜä
ion depth shim should not require replacement. ÚìêßãÜÛ åPáháàà
ìáæãç tÝóæQìßJø ÛÜÝà
øøßà
åá.Þ
ãåãà
åMêÝ
Ûßãåë
Refer to Pinion Gear Depth to select the proper ÜìÞ îHùåæQáÛÚڞáâÝê ÝÛßãåPë%ÜìÞLúãáâDùåæQáÛÚÚÝß éJ×ûû.Û åPç
thickness shim before installing pinion gear.
ý Û åPç
ÚÝ%
þ û™×  ×Ö Hãëu

î ûØJî ó
´‡µ ¶·9¸¸¹º¹»¼· ½<¾½}»"¶#¶º· ¿ ¹¾· »"¹ À Á2ÂÂ
Ã*Ä,Å.Æ0Ç2È*É#È*Ê6Ë8Ì9Ê6Í,ÎÈ*É<É<È=Î>Ì9Æ6Ê@ÏBÐ*Ñ<Ò<ÓGÔHÒ<Õ<Ö<×<Ø

Fig. 35 Pinion Seal Installation

Fig. 33 Rear Pinion Bearing Cup Installation

Fig. 34 Pinion Outer Bearing Cup Installation Fig. 36 Rear Pinion Bearing Installation
M NPORQTSVUPWYX[ZZ"\]_^GSVW>`[a9Sba9^GSdcefX]_aSVgih2XSVjk^faZ"UlZaSVgmef]nh2a\
efopVa`[`efjq CAUTION: Never loosen pinion gear nut to
MrPO>st``[Z uvX.ZagiwVWyx_^fXWzaSVg{^G\'gmefX] ZpVc]_ax_XSVW|^GSdWYwVe decrease pinion gear bearing rotating torque and
Za` ^G\
`aSVa^fS UleGXZ9q}QzSVUlWYXZ9ZUPefXZ~|aWYwQTSbUlWYX[ZZef],€
‚ƒ„[… s never exceed specified preload rotating torque.
XSVjR†‡XSVj[Z9e0€
ˆN!‰P„Š‰yM‹agmq
‚rlOBq M‰f‰HOR€
wbefx_• c[eGX]_a9Sbg¡`]_eGZ9^GXj¢Wz^G]_opVe.~|aWYw£XS£aSVx_w
MŒPORQTSVUPWYX[ZZ2Wzwbe ]_efX]`aSVa^fSkcefX]_aSVgŽXSVj^GaZUPZa9Sbgief]Hh `^GpVSVjWY^f]_opVe,~|]_efSbx_w–M‹Ša9gmq˜N™POqœ2wbeWY^f]_opVeSVeGx_efUPUlX]¤u
a\2eGo[pba9`[`efj[h
^GS.WYwVe `[a9Sba9^GS.gieGX]~|aWzwQTSVUPWzXZZef]…Œ[… WY^6]^fWYX[WYe0WYwVe0`aSVa^fS{giefX]*UlwV^GpVZjRc[eG¥
XSVjRXUlwb^f`R`]_efUPU|M‹Šagiq
‚ŒPOq ]_agma9SbX[ZŠ—
eGX[]_aSVgmUl§¨‰"Wz^‡‚tž ’©M‰P™Wz^‡…[™aSVq”ZcUlq Oq
• ¦tez~ª—
eGX]_a9SbgiUl§Ž… Wz^0rtž ’ªM‰PrWY^0‚[raSVq˜Zc[UPq Oq
M„PORQTSVUPWYX[ZZ*`[a9Sba9^GS‘ceGX[]_aSVgk`]_eGZ^fXjvUPwVa’>UŽ^fSbWz^WYwVe
`aSVa^GSgmefX]yM‹Šagiq
‚„POq •M‰P…PORQT\«]_^fWYXWzaSVg¬WY^f]o[pbe­a9U®Xc^T¯”e­Wzwbe­jefUPa]_efj
M“PORQTSVUPWYX[ZZ<`[a9Sba9^GSgmefX]*a9S{wV^GpVUlaSVgmq X’>^fpVSbWzh]_eG’>^T¯”e°WYwVev`aSVa^fS±u”^f•e°XSVj#aSVx_]_efXUPe°WYwVe
MƒPORQTSVUPWYX[ZZ”u}^G•be"~|aWzw–QTSVUlWYXZZ9eG]=.B‰lŒ…—
h˜€
pV`R“!‰P™ƒ[h `]_eGZ^fXj©UPwVa’¬`Xx_•£Wzwba9x•bSVeGUlUPq QTSVx_]_eGXUlaSVg#WzwVe‘Ulwba9’
XSVjR†‡^GZjef]*Œƒ[r“M9‹agiq˜‚[“POq `Xx_• Wzwba9x•bSVeGUlU"™q²™…r’>’©M™q ™™Š‰"aSVq O˜~ya9ZZŠjeGx_]_efXUPe*WYwVe
M‰P™PORQTSVUPWzXZZ'Wzwbe{`aSVa^GS~|XUPwVef] XSVjšXkSVeT~›SVpVW^fS ]_^fWYXWYa9Sbg WY^f]_opVe0X``[]_^T³}a’>XWYefZ u.™q²ƒ tž ’ŸM9“a9Sbq
ZcUlq Oq
WYwVe6`aSVa^fSgieGX[]HqVœ<a9gmwVWYefSWzwVe6SVpbWtWz^6…!‰P„Rtž ’ŸM‰PŒ[™\WYq
ZcUlq O‡M‹Ša9gmq
‚ƒPOq
 !"#"$% &('&)$*+# ,-"' $*" .0/
13246587:93;+93<=?>!<@A93;-;-9BAC>!5<EDGF3H-I-JLKMI-N-O-P-Q

Fig. 37 Pinion Preload Shims–Typical

Fig. 38 Pinion Yoke Installation

Ù ÚPÛPÜ>Ý ÞßmàVázâGãäÞãVÞåGãælàbç[è9á=ãbéVá Þ9ã ê[ë ì0ítî ï£Ù9ð6è9ázë}ñòælë Ü
ÞãVó_ô_âGï>âfãVáYæ|éVãVáYÞñ<áYàVâ0ï>çPõ}Þï>éVïªáYÞßiàVáYâfãVÞãVßöåGôy÷[âfæPÞ9ô_âG÷
ô_åGázçáYÞ9ãbß áYåfôø[ébâ6Þæ|ô_âGç[ó_àbâf÷ë
ِÚPùPÜRúTèázàVâöï>çPõ}Þï>éVïûázÞßiàbázâGãVÞãVßRázåGô_ø[ébâ Þæ0ô_âfçó_àVâG÷
äô_ÞåGôázå'çó_àVÞâTü”Þ9ãbß|áYàVâ‡÷[âfælÞô_âG÷0ô_åGázçáYÞãVß|áYåfô_øéVâGýVô_âfï>åzü}â
áYàVâ¨ä[ÞãVÞåfãdþ”åfÿâ¨çãV÷‘÷âfó_ô_âGçælâšázàbâ¨áYàVÞó_ÿbãbâfæPæ åGè6áYàVâ Fig. 39 Tightening Pinion Nut
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|ÞññÞãVó_ô_âGç[æPâ ázàVâ ô_åGázçáYÞãVß ÙÚHÜ”ó_ASSEMBLY
FINAL ô_çäâ.ázàVâ.ô_âGælÞ÷ébç[ñyæPâfçñçãVá èô_åGï áYàVâ.àVåfébælÞãVß
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CAUTION: Overfilling the differential can result in

lubricant foaming and overheating.
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DISASSEMBLY AND ASSEMBLY

STANDARD DIFFERENTIAL
²-³ ´—µ˜´—´:¶ ·¸˜¹bº
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`bhV8±e^_e^cX_š«C\ `iV8mtVL\ Wok¤\_ ¡›`bhWoSkŸ`£¤\ kŸhVXWok q!r e^mtsvu ¬ xys

Fig. 40 Check Pinion Gear Rotating Torque

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qr e^mtsvu)wMxys

Fig. 42 Pinion Gear Mate Shaft Lock Screw

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q¬ xžp_kŸ`b\]^]-`bhV8±e^_e^cL_¼mtVL\ W¨«C\ `bVkŸh\ ¢`bs
Fig. 41 Typical Housing Cover With Sealant
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TRAC-LOK
È:ɠʽÈvËoÌ ÍoÎ DIFFERENTIAL
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Fig. 43 Pinion Mate Gear Removal Fig. 45 Differential Case Holding Tool

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Fig. 44 Trac–Lok Differential Components
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Fig. 46 Mate Shaft Lock Screw

ÅUÂMÃtËuÌiÍHÅU¶€ÂÄÎ=Ã_¾3ÆX» ÂM¿HÎ/¼HÂ5··¶â²Ï ¾3ÀvÇiÐ5ÑU´,Ç

Fig. 48 Step Plate Tool Installation

Fig. 47 Mate Shaft Removal

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²X·ÂUñ¤¾·Ír· ´K»]¸yÉ_¸·½=Ã_¶ÅQÅxò1¶ÓÓ3¶]¹:¾3Ó3Ó¶yÅU½=Ã_¾3¿HÀgÅx¾3¿?É_Ó3ÍH»)É_¼ Â5¿H΀»]¼H¶EÎ=¾3ÆÆX¶@Ã_¶¿H»)¾Â5ÓÉ_Â5ÅU¶
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Fig. 49 Threaded Adapter Installation
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Fig. 50 Tighten Belleville Spring Compressor Tool

Fig. 53 Side Gear & Clutch Disc Removal

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NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
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Fig. 51 Remove Pinion Gear Thrust Washer _•RTQbH2gtHKZ\U-xwY\_•p
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Fig. 52 Pinion Gear Removal
Z\WYQ'N/HKUVRTS –{XOxZbX†X}xYH’ybRWRLWGJMZ\X}H’_DxYZ\S$X†xYLK[TH-R_¿Z\[TRgtWYHKQbp
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Fig. 56 Upper Side Gear & Clutch Disc Pack

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Installation
Fig. 54 Clutch Disc Pack ö•ò}ô=% ó\ò}ô
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CLEANING AND INSPECTION

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Fig. 59 Pinion Gear Depth Gauge Tools—Typical NOTE: Arbor Discs 6732 have different step diame-
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Fig. 61 Gauge Tools In Housing—Typical Fig. 62 Pinion Gear Depth Measurement—Typical

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DIFFERENTIAL BEARING PRELOAD AND GEAR

þ+ @&@ úqú  ýPù7ú0üú  <25
qúýM M<†ú &ü "*ýXù(:
BACKLASH Fig. 63 Axle Adjustment Shim Locations
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NOTE: It is difficult to salvage the differential side

bearings during the removal procedure. Install
replacement bearings if necessary.
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Fig. 64 Install Differential Case W/Dummy Bearings Fig. 67 Seat Ring Gear Side Differential Dummy
Bearing
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Fig. 70 Hold Differential Case and Read Dial

Indicator

Fig. 68 Differential Side Play Measurement

Fig. 71 Hold Differential Case and Zero Dial

Indicator
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Fig. 69 Hold Differential Case and Zero Dial
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Indicator
  

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Fig. 74 Backlash Shim Adjustment
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¼=»Tû8Ç:ÁHº?¼=½Jº킼Kº<º<Ê:»JÁ ù ÁH¼KÌ ßmÏVÀCÏrλJÇ
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GEAR CONTACT PATTERN ANALYSIS ³aá3¶
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Fig. 75 Gear Tooth Contact Patterns

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SPECIFICATIONS
216 RBI AXLE
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usvxwzy{}|x~y€‚y„ƒ†…z‡‰ˆwŠ‹ŒŽ…z}’‘|x~Š…“
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”o•}–— …˜3‹™ŒŽ£¢{ — ‹™…zwzy — {hŠŽ¦§‚¨|xŒŽž}yŒ©…˜"ª™«¢¡š£o¬¢­ 
”o•}–— …˜3‹™Œ®s‹~™‹™˜m…zŒ¯|°A¬¢ Ÿ¥ ”²± ­  †~Œ©³¢ ´
usvxwzyOµs‹ŒŽ…zŠ³h¶™  ª·}¶ «™«·}­9¬¢ 
¸ …zˆˆ‰y — y}Œ©…‹w¹sy‹ — …»º — y„wzŠ„‹“¼h ©¬Aƒ†ƒ ±     ­†… ´
¸ …zˆˆ‰y — y}Œ©…‹w‚…z“yO½Ay„‹ — ®swy‹ — ‹™˜myšh ™£ 9¬¢«†ƒ†ƒ Adapters—C-293-18
±  £™    ¾†…z} ´
µs…z}’½Ay„‹ —"¸ …z‹ƒ†y„Œ©y — h¿o¬¢¾†ƒ†ƒ ± Ÿ¯«»… ´
µs…z}’½Ay„‹ — ¹s‹™˜mÀwz‹³ÁžÂh ™9¬¢¶£ ™ ¿ †ƒ†ƒ ±    ™ «£ ™   Ÿ
…z} ´
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¹ — ›º — ywzŠ„‹“·}ºo…z}…zŠ„ ±à yĦ"´Åh¿™ ¿¾£™­ «¿ ÃkÆ ƒ ± ¿ ™£­ 
…}w – ³¢ ´
¹ — ›º — ywzŠ„‹“·}ºo…z}…zŠ„ ±ÇA— …z›…z}‹w ´§A¬¢£¶ ÃkÆ ƒ ± ¬Á £¿ †…z}
w – ³¢ ´

216 RBI TORQUE

Adapters—C-293-48
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ºow • ›·}Êo…zwwˁh¶­ ÃkÆ ƒ ± ¿™«†ˆŒŽ}w – ³Á ´
¹sŠ„wzŒ©³Á· ¸ …zˆ‰ˆ‰®sŠÄÌxy — h­¬ ÃkÆ ƒ ± ¶™ †ˆŒŽ}w – ³¢ ´
¹sŠ„wzŒ©³Á· ¸ …zˆ‰ˆ‰¹sy„‹ — …z}»®s‹~."¬¢ Ÿ ÃkÆ ƒ ± Ÿ †ˆŒŽ}w – ³¢ ´
¹sŠ„wzŒ©³Á·µs…»½"y„‹ — "¬¢ Ÿ ÃkÆ ƒ ± Ÿ †ˆŒŽ}w – ³Á ´
Ãk• ŒŽ³¢·}¹ — ‹ÀyO¹s‹˜mÀ…»ºowz‹™Œ©yAh¾¬ ÃkÆ ƒ ± ­™«†ˆŒŽw – ³¢ ´
Ãk• ŒŽ·}ºo…z}…zŠ„Í½Ay„‹ —mÎÐÏ ……ƒ • ƒÑ¿¬¢ª ÃkÆ ƒ ± ¬Á¾ †ˆŒŽ}w – ³¢ ´

SPECIAL TOOLS
216 RBI AXLE Extension—C-293-3

Puller Set—C-293-M Remover—C-452

áâAããä å æççèé è8ê ëæ ìíìêåå é æ îèíæ êè ïOð
ñ,ò,ó,ôõ‰ö%÷ø,ù)ù)÷ñ1ú3ô%ûüýþÿü





Trac-lok Tool Set—C-4487

Handle—C-4171

Installer—C-3972-A

Installer—D-156

Installer—D-144

Pilot—C-3288-B

Installer—D-145

Dial Indicator—C-3339
 
   
 


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$324(.5
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Cup—8109
Remover—D-147

Splitter—1130
Remover—D-148

Installer—W-262
Spreader—W-129-B

Pinion Depth Set—6730

Installer—W-162–D
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Adapter—6790 Adapter Set—6987

Adapter Set—6956 Slide Hammer—7420

Holder—6958 Adapter—7420-8

Holder—6963-A Installer—7913-A
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Ž‘q’“ ”•"–

BRAKES
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BASE BRAKE SYSTEM

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DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . 6 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 15
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 17
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 4 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 19
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 4 DISC BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . 18
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 3 DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . . . 19
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 16
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 2 PARKING BRAKE HAND LEVER . . . . . . . . . . . . 21
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 5 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 16
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 2 REAR PARKING BRAKE CABLE . . . . . . . . . . . . . 21
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . 2 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 14
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 6 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . 23
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MASTER CYLINDER RESERVOIR . . . . . . . . . . . 22
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 11 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 25
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . 11 CLEANING AND INSPECTION
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 9 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 10 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 26
MASTER CYLINDER/POWER BOOSTER . . . . . . . 8 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . 26
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUSTMENTS
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 8 PARKING BRAKE CABLE TENSIONER . . . . . . . 27
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 8 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 27
SERVICE PROCEDURES STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 27
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . 12 SPECIFICATIONS
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . 13 BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . 29
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 11 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . 13 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 29
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . . 13 SPECIAL TOOLS
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 11 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 29
 
 
 

DESCRIPTION AND OPERATION fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
—{˜š™œ›eSYSTEM
BRAKE ž Ÿ¡Ÿ£¢¤Ÿ¡¥j¦,§˜¨¥j©ª¢Ÿ¡«1ž ¨©¬§›už 1©
§­®°¯ §ž ±›uŸ²ž §› ination is suspected, check the fluid for dirt, discol-
Ÿ¡¥šž ¨©
ž §©y›u³ ­¢¤´
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˜¨›u¨¥¶Ÿ«§˜¨Ÿ£¢¤Ÿ¡¥ oration, or separation into distinct layers. Also
˜u¦PŸ¡¢¤¨º¼»¤›„´
¢¤Ÿ£¥¶˜u¨½«§ž »¤¢´ª›u§Ÿž ¨© ¾q›¨¥š¢¤»¤ž ¥š›©y§˜u¥¶˜u§Ÿ¡µA¿À›už  check the reservoir cap seal for distortion. Drain
©
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­ž »²Ÿ¡Ä˜u›Ã­¨¢¤¥¶ŸÅ™œ¢¤¥¶ÄÆ«§ž Ÿ¡¥¸¯ª4žª±› and flush the system with new brake fluid if con-
©
§­®¹Ÿ£µ tamination is suspected.
Ç"ā›È´ªžª§±¢¤¨ºÉ¯ §žª±›Ê®¹›u«§Äžª¨¢¤Ÿ¡®Ë¢¤ŸÅ»¤›Ì¾q› ž ¨©g«§žª¯ »¤›
˜u´ª›u§ž ¥¶›u©
µ
Ç"Лɫ§ž ¯ »›ŸÊžª§›Éž ¥¶¥šž «§Ä›©Í¥¶˜É»›š¾q›§ŸÈ˜¨Î¥¶Ä›
§›žªÏ©
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ž ÓÒԟ£Ä˜›uŸ¡µÉÇ"ā›Õ´ªžª4±¢¤¨º CAUTION: Use Mopar brake fluid, or an equivalent
¯ §ž ±›Ÿœžª4›e˜´
›u4žª¥¶›u©Å¯¡Ò¬ž О ¨©Å»›š¾q›Öµ quality fluid meeting SAE/DOT standards J1703 and
× ©ª­ž »A©ª¢ž ´ªÄ§ž º¼®Ø¾qž «§­­®3´
˜Ì™j›uk¯ §ž ±›*¯ ˜u˜Ÿ£¥¶›uk¢¤Ÿ DOT 3. Brake fluid must be clean and free of con-
­Ÿ¡›u©¬¦˜u1ž »»Až ´
´
»¤¢¤«§ž ¥š¢¤˜¨Ÿ£µ × »¤»A®¹˜u©ª›u»¤Ÿ²Äž¡¾q›žª¨Âž »¤­®¹¢¤Ù taminants. Use fresh fluid from sealed containers
¨­®Ú®¹ž Ÿ£¥¶›u.«ÓÒq»¤¢¤¨©
›"™j¢¥¶ÄÊ´
»¤žªŸ¡¥¶¢«.§›uŸ¡›uÓ¾Û˜u¢¤Öµ only to ensure proper antilock component opera-
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›»¤Ÿœž §›k›u³ ­¢¤´
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›©¹™j¢¥¶Äʞ«§˜®¹¯ ¢¤¨ž ¥š¢¤˜u¨1¾qž » ¾q›uµ tion.
ÇoЛ.¾qž » ¾q›*«§˜u¨¥¶ž ¢¤¨Ÿ1ž¸´
§›Ÿ£Ÿ¡­§›*©
¢¤¦,¦›u§›u¨¥š¢¤ž »{¾qž » ¾q›*ž ¨©
Ÿ9™œ¢¤¥š«§Äʞ ¨©Åž ¦,¢ Üq›©„§ž ¥¶›1§›už .´
§˜u´ª˜u§¥¶¢¤˜u¨¢¤¨º.¾qž » ¾q›µ
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NOTE: Be sure wheel bearing has zero end play BRAKE
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Fig. 9 Checking Rotor Runout And Thickness

Variation
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NOTE: Parking brake adjustment is controlled by a h]F$EGOFsEPbJMh]LPbc
cable tensioner. Once the tensioner is adjusted at ” ^MPgh)UI?AUIHWOGFIEHKA)?hPgA)JMLPgTVEG^M^/EGTVJMh]Lc EGY^MTtizJMLPbT[EG^M^MEGv
the factory, it should not require further attention. TVJ/hLyUIEGL|FsA]PgYB^/TeJMLyHBJMLHKA]\pxTtRDJMPgTVA\~?Bh]˜ PbA]Pbpxh]FUIhLTVEUIT
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or cables have been installed. And the second, is
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Fig. 21 Master Cylinder/Combination Valve

µ,¶·L¸¹8º/º¹/¸iµ »E¶

NOTE: If master cylinder is replaced, bleed cylinder Fig. 22 Push Rod & Clip
µ,¶·L¸¹8º/º¹/¸iµ »E¶
before installation.
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Fig. 24 Bottoming Caliper Piston With C-Clamp
gihaj/k lPmnpo@q
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Fig. 27 Caliper Removal

Fig. 29 Caliper Installation

;ï ð=ñ?ò˜óUôDFig.
õnöFôD28÷Yø&ùKCaliper þ
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úþøYþkõMôD÷Y÷ôKþÅõMø&ÿ
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Points

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CAUTION: If new caliper bolts are being installed, Fig. 30 Mounting Bolt Dimensions

NPOïQS4ñRPF˜TVôDU øWkúôDþký

ùùKóUûFõXG…ú
øYöF÷Yú
or if the original reason for repair was a drag/pull DISC BRAKE SHOES
condition, check caliper bolt length before proceed-

ï =8 ñ˜F úUü+óYG ú7ZQ úUúU÷˜ôKþ{  õMøYûFúô[Dk úüAD÷ >

ing. Bolts must not have a shank length greater

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than 67.6 mm (2.66 in.) (Fig. 30).

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 ó  øYþDóUôDû^eD
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kinked before tightening fitting bolt.

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DISC BRAKE ROTOR

 ÏDÕD‘‘ÙLÙL““×A×AœYœYÍ@Í@“<“”^–^—“˜›™—[š/™“–\“
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Fig. 31 Outboard Brake Shoe Removal
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.

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Fig. 33 Rotor & Hub

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Fig. 32 Inboard Brake Shoe Removal

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 £¤ œ“¡™Ò”^—˜9™š[“– NOTE: If drums are difficult to remove, back off

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adjuster through support plate access hole with
brake tool and screwdriver.

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PARKING BRAKE HAND LEVER
ùú6û~èüdæç Fig. 37 Parking Brake Lamp Switch

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È&É(Ê*Ë,×LÓ9ÝV́Ï3Fig.
ÌÚFÓ9ÐD38Ò9Ì.á Parking Brake Lever
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ÜLÖD×LÐDô6ÌÙKá


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 È (Ê yÎ2÷0ÌÖÏdÌ.ÚFÓ9ÐDÒ9Ì.á
REAR PARKING BRAKE CABLE
ù ú6û~èüdæç
ÈWéÊ*Ë,×LÓ9ÝVÌ5Ï3ÌÚFÓ9ÐDÒ9Ìì×<Ô6Õ¥Ò9ÎÎ.Ý(Ì.ÔZÌ ßF×LÒ9Ó bÌÖUÔ6ßFÙNÝOßFÔFÙNÓÒ
â&ã3äyåGæç6ç.æ6å|â è~ã ÖDÌ×<ÖÐD×LÜ<Ò9ÌÝ0×<ÖDÌÝ(Ò9×<ÐDôoá
Fig. 36 Parking Brake Cable Attachment


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K~j€s‚FM‘s

Fig. 39 Parking Brake Cable Bracket

‡ˆX‰Š‹<ŒrŒS‹rŠ‡ Žˆ

Fig. 41 Reservoir Retaining Pins

KŸNM uQl`R=vµ\cbXlj^_(PapdT_!bZj^xVXjYNPyUjk{hqda]`YNY=v(a‘TSk{PS\]¶
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Fig. 40 Cable Retainer

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DISC BRAKE CALIPER


Û Ýß¹ÝÝ   ¹à


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Fig. 43 Reservoir Removal 

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Fig. 44 Grommet Removal

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CAUTION: Do not use any type of tool to install the

grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
  
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Fig. 46 Padding Caliper Interior
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CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.

WARNING: NEVER ATTEMPT TO CATCH THE PIS-

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

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Fig. 45 Grommet Installation

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Fig. 49 Piston Seal Removal

Fig. 47 Caliper Piston Removal

Fig. 50 Mounting Bolt Bushing And Boot

Fig. 48 Caliper Piston Dust Boot Removal

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CAUTION: Dirt, oil, and solvents can damage cali-

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per seals. Insure assembly area is clean and dry. Fig. 51 Bushings And Boots Installation
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Fig. 52 Piston Seal Installation

Fig. 55 Piston Dust Boot Installation

Fig. 53 Dust Boot On Piston

Fig. 56 Wheel Cylinder Components–Typical

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CLEANING AND INSPECTION ˜Œ‰&‹ ž “#•–³ŽC,‹
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CALIPER
€ƒ‚„/…X†…‡ †…«¬­‚=®"† ¯°…
ˆŠ‰&‹ŒqŽKƒ‹<#Œ‰‘&’O‹!“”#•–—’•,‹!,ŽK˜š™›‘&ŽKq#‰&‹!Œqœ“#ŒH‹ ×+˜1Œ¸»¼‹,‹!“#Œ‰“#Ÿ,‰&‹Ï֓#‘ È‹!ŽK‹! ²œ“#ŒH‹T˜ƒ•‹˜
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ž ‰&Ÿ,‘& ¡•“+œ“#ŒH‹›#‰&‹!Œ¢•ƒ‰ £4¤¥T‘’‹›ŽC,‹ #Œ‰‘&’‹“+Œ, ¡’O‘&˜ŽC• “#‹!’O‰&Œ#‹! h™ ,‹¢™›•!“#¦ŽC• ™›‘&ŽKƒ‘¹Ñ¤ Íب–—–Ä´ÓFÙ8ÚÒ·‘&,¤ µÛ• ž
 O“£¦™ ‘ŽC§‰&‘ƒŽ ž “#‹!‹šŽC•K™›‹‰&˜¨•!“1Ÿ,˜‹*‰&•™©’O“#‹!˜˜Ÿ,“#‹*#•–—ª ŽC,‹É“#‘ È‹!Ž¨,‹!Œ O˜¤—ÜŠ•ƒ O‹ '‰&‘&,‘&,»§˜,•Ÿƒ‰ 'œ‹É“#‹!’O‰&Œ#‹ 
’O“#‹!˜˜‹ 
Œ‘&“8¤ ™›ƒ‹s™›•“#·ŽC•sŒŽK,‘&#H,‹!˜˜›• ž Ó¤ Ý¢–—–Þ´ÓFÙÓÝ‘ƒ¤ µQ¤
ß ÔŒ–—‘&,‹ÛŽC,‹Û‰&‘ƒ‘ƒ»¡#•,ŽCŒ#Žk’OŒŽCŽK‹!“#¨ŽK•Û ‹ŽC‹“#–—‘&,‹Û‘ ž
ŽC,‹˜,•!‹˜+Œ“#‹œ‹!,Ž•“kŽKƒ‹  “#Ÿ,–Б&˜+ŽCŒ’‹“#‹! O¤ ± ,‹ ‰&‘&,‘&,»
CAUTION: Do not use gasoline, kerosene, thinner, ˜ƒ•Ÿ,‰& ·‹Kԏ,‘&œ‘&Ž[#•!,ŽKŒ#Ž°Œ#“#•˜˜¶‘&ŽK˜Û‹,ŽC‘&“#‹™›‘& ŽK,¤ŠàW,•‹!˜
or similar solvents. These products may leave a ‹ÔW,‘&œ‘ŽC‘&,»á#•ƒŽKŒ#Žâ•!,‰ £ã•S•ƒ‹E˜‘& O‹E˜,•Ÿƒ‰ Aœ‹
residue that could damage the piston and seal. “#‹!’O‰&Œ#‹! 
Œƒ 1ŽC,‹¶ O“#Ÿ,–ސ#,‹!#ƒ‹!  ž •““#Ÿ,,•!Ÿ,ŽÖ•“ŽKŒ’O‹!“8¤
ä ,˜’O‹#Ž¡ŽC,‹*Œ Cå!Ÿƒ˜ŽC‹“1˜#“#‹K™EŒ˜˜‹–—œ‰ £4¤°ÕŠ‹’O‰&Œ#‹*ŽKƒ‹
†…«¬­‚=®"† ¯°… Œ˜˜‹–—œ‰ £²‘ ž ŽKƒ‹¢˜ŽCŒ“+™›,‹!‹‰•“¶ŽKƒ“#‹Œ O˜¡Œ“#‹¢ Œ–—Œ»¼‹ OÏ
± ƒ‹1’O‘&˜ŽC•!²‘˜h–—Œ O‹ ž “•–³Œš’,‹ƒ•‰&‘&¡“#‹˜‘²´’O‰&Œ˜ŽC‘ •“ŽC,‹¶#•–—’O•!,‹ƒŽK˜›Œ“#‹¶˜‹KÈ‹!“#‹‰ £*“#Ÿ,˜ŽC‹! 1•!“ #•!“#“#• ‹ O¤
–—ŒŽC‹“#‘&Œ‰ µ[Œ, 
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“#‹’‰Œ#‹! ¹‘ ž #“#Œ#H‹ š•“¡˜#•“#‹! O¤ ‘ ž ™›•!“#,Ϲ O‘&˜ŽK•!“#ŽK‹! æ•“Ɛ#•‰&‰&Œ’˜‹! O¤s×+‰&˜•Þ“#‹!’O‰&Œ#‹çŽKƒ‹
º •sƒ•Ž+ŒŽCŽK‹!–—’OŽ+ŽC•s“#‹˜ŽC•“#‹sŒ
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ä ,˜’O‹#ŽŽKƒ‹ œ“#ŒH‹ ˜ƒ•‹ #•ƒŽKŒ#Ž’Œ ˜°•¢ŽC,‹ ˜Ÿ,’’O•“Ž
CAUTION: If the caliper piston is replaced, install
’O‰&ŒŽK‹!ÏW“#‹’O‰&Œ#‹ŽC,‹˜Ÿ,’O’O•!“#Ž’‰ŒŽC‹‘ ž Œ4£
• ž ŽC,‹’Œ ˜+Œ“#‹
the same type of piston in the caliper. Never inter-
™›•!“#
•!“+“#Ÿ,˜ŽC‹! hŽC,“#•Ÿ,»¼,¤×+‰&˜•›“#‹!’O‰&Œ#‹›ŽC,‹ ’O‰&ŒŽC‹ ‘ ž ‘&Ž/‘&˜
change phenolic resin and steel caliper pistons.
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´Ë=‘&»
¤"Ìص¤
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
± ƒ‹§œ•“#‹”#Œ½œ‹”¾¿8À,ÁÂQ¾ ÃĒ•‰&‘&˜ƒ‹ Å™›‘&ŽC½Œ<œ“#ŒH‹
,•!,‹ÆŽC•Ç“#‹–—•KÈ‹ÉÈ‹!“£Ä–—‘&,•!“ʘŸ,“ ž Œ#‹Ç‘–—’‹“ ž ‹#ŽC‘&•,˜
´Ë=‘&»
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˜‹È‹!“#‹‰ £Î#•!“#“#• ‹ OϦ“#Ÿ,˜ŽK‹! OϦ˜#•!“#‹ OϦ•“Б ž ’O•!‰&‘˜,‘&,»
™›•!Ÿ,‰& ¸‘&,#“#‹Œ˜‹·œ•!“#‹· O‘&Œ–—‹ŽC‹!“¢–—•!“#‹·ŽC,Œ”Ѥ ÑÒ̦–—–
´Ñ¤ ÑÑaӛ‘&,#4µ¤

Fig. 58 Shoe Contact Surfaces

WHEEL CYLINDER
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ž ‰&Ÿ,‘& é•“*œ“#Œƒ‹²#‰&‹!Œ,‹!“*•,‰ £4¤ º •²,•!Ž1Ÿ,˜‹²Œ£L•ŽC,‹“
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Fig. 57 Polishing Piston Bore
º •¨,•!ŽÛŸ,˜‹¨“#Œ»
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REAR DRUM BRAKE #•!–—’O•,‹!,ŽC˜¤ê=‘&,Ž ž “#•–Љ•!ŽK¹–—ŒŽK‹!“#‘&Œ‰™ ‘‰&‰Œ O,‹!“#‹¢ŽC•
€ƒ‚„/…X†…‡ ŽC,‹¶£‰&‘&, O‹!“ œ•“#‹!˜›Œƒ 1’‘˜ŽC•,˜¤
ˆŠ‰&‹ŒÉŽC,‹¨‘&, O‘ È‘& Ÿ,Œ‰+œ“#Œƒ‹1#•–—’•,‹!,ŽK˜Ï‘&,#‰&Ÿ, O‘&,»
ŽC,‹—˜Ÿ,’’O•“#Ž’‰ŒŽC‹—Œƒ ›™›ƒ‹‹!‰V£‰&‘&, O‹!“[‹ÔWŽK‹!“#‘&•“8Ï™›‘&ŽK1Œ
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01(*iF(
 
,$: >2(@
"' Ha(s >6'
'

Fig. 59 Tensioner Rod Measurement

PARKING BRAKE CABLE TENSIONER
REAR DRUM BRAKE
Ç9†6„1‘„ ‘M’‘”™Î—‘Œi„ ƒ?‘„1„ Ì”‚¿¿„ ’5š5‚†KEƒ'„ ˆŽNžN’ž
NOTE: Parking brake adjustment is only necessary “ 6 ” ƒ'‚–&™1„ ‡†66‚ƒ™1‰GÏb’„ ‘" ‘™@ˆX‡‚‘‡”™1ƒ,‡„ ƒ'ÀG†„
when the tensioner, or a cable has been replaced or  6ˆ ¾[‚™1„T’“•”ƒ'™1„ 6@‚ƒE‘„ Ì”‚‘„ ’r‚ƒ?š@†„ O†„2ƒ† „ ƒ
disconnected for service. When adjustment is nec- ‘„r‘„ ¿ˆ‡„ ’ÀM‘„ ™1,…G„ ’)ŽN ‘K‡‡„ ƒ'ƒr ,†„ ‘K¿‘ƒ'ÀM ‘
essary, perform the following procedure for proper š@†6„  „ ‘7— †P’‘”™1ƒ@‘„‘„ ¿ˆ‡„ ’‰
parking brake operation. Ð ’“ ”6ƒ'™1„ 62‡Ñ—„=™1’„2š@‚,†Ñ^ƒ'’‘’4—‘Œi„
–%”–<„ҍ ‘;š@‚,†Ó’“ ”6ƒ'‚–+,  ˆ‰ Ð ’“ ”6ƒ'™1„ [‚ƒÑ¿„ ‘pž
tRuGvGwGx#yjzE{6|Gy ŽN ‘™1„ ’š@‚†.†„A‡ ™1¿ˆ„ „r—‘Œi„rƒƒ'„ ™1—ˆ ¾/‚ƒ,ˆˆ„ ’
}~g2€D‚ƒ'„b…G„ †‚‡ˆ„ ‰  †„—‡Œi‚–:¿ˆ,„ ‰
}NŠ2‹D‡Œ ŽNŽj„ ƒ‚ „ ‘b’“•”ƒ'‚–&”a,5‡‘„ ,„7ƒ'ˆ‡Œ
‚P‡—ˆ„ ƒ‰ tRuGvGwGx#yjzE{6|GyKÔOÕ ycÖ^×#ØGt9Ù#{&ÚVt9wGÚM{
}N˜2€D„ ™@
…G„‘„ ‘Rš@†6„ „ ˆ ›`‚‘„ƒƒ'„ ™1—ˆ‚„ ƒ@6’K‘„ ™1
…„ }~g2‹D„ƒ'”6‘„F¿‘Œ6‚–:—‘Œ6„ ƒ@‘„Ž”ˆˆ ¾A‘„ ˆ„ ƒ'„ ’‰
—‘Œ6„’‘”™1ƒ'‰ }NŠ2€D‚ƒ'„A‘„ ‘K ŽU…„ †‚‡ˆ„A6’)‘„ ™1
…„š5†„ „ ˆƒW’
}Nœ2D†„ ‡Œ]‘„ ‘T—‘Œ6„ƒ'† „P’“•”ƒ,™1„ bš@‚,†)ƒ'ž —‘Œ6„’‘”6™1ƒ'‰
’‘’;—‘Œi„K–%”–<„ ‰9ŸX j¡¢£ £ ¤ ¥C¢;£ ¦c§¢¨N©§6¨NªX«n¬c­®¡¯g¢°« ¨ }N˜1½D„ ‘‚Ž ¾l,†6Kˆ„ ŽK6’Ñ‘‚–%†6W” ™1‚‡r’“ ”6ƒ'„ ‘
°±c¡¢²a§«1³2§«n±4´o«n°µ#¢A¡§­¶X§6±c¢±c©p£@³2¤`¯¯b«n¢£ ¬c¯©&¤g± ˆ„
…„ ‘ƒ@’2‡—ˆ„ ƒ@‘„¿‘ ¿„ ‘ˆ ¾A‡ „ ‡,„ ’‰
· °¬c¯©N¸r¶X°6«nµX¤`±c¹´o«n°µ#¢E°6ª•º%¬c£ ©p­¢±c©Q°±cªW§¶X¢«<°6©¤`§6±c» }Nœ2Û
ƒ„ ‘=—‘Œ6„Ñ–%”–<„S‚É’‘”6™1‰TÜÝG¿’Ζ<”–%„
}N¼1½D„ ‘‚Ž ¾A,†6"¿‘Œi‚–—‘Œi„F‡—ˆ„ ƒ@ ¿„ ‘,„ŽN‘„ „ ˆ ¾ ”‚ˆD–%”–<„‚6„ ‘7ˆ„ –%ƒ5‡ 6,‡U’‘”6™Þ—‘Œ6‚–Eƒ'”6‘ŽN‡„ ‰
’‘„1 Q—‚6’‚–%ÀX ‘?ƒ„ ‚Á•„ ’‰X€D„ ¿ˆ‡„1ŽN”ˆÂ¾P‡—ˆ„ ƒÀ ÇR†„ ˆ ‡ŒW–<”–<„‚¿ ƒ'‚‚ }NÊX‚–<‰jÃÍ'p‰
—„ Ž ‘„¿‘ ‡„ „ ’‚–%‰ }N¼2€D„
…„ ‘ƒ„=–<”6–%„=’^‚ƒ'ˆˆ&‚ /—‘Œi„;ƒ'† „ ƒ‰
}NÃ2€D„ ‚ƒˆˆ—‘Œi„[’‘”™1ƒ;’=š5†„ „ ˆ ›`‚‘„[ƒ'ƒ„ ™1ž ß  ƒ'‚‚ 4–%”–%„Aˆ„ –%ƒWEƒ'† „r‡„ „ ‘ƒWƒƒ†,š@.}ÊX‚–%‰
—ˆ‚„ ƒ@ŽN,„ ‘5—‘Œi„ƒ'† „’`“ ”ƒ,™1„ "‚ƒ@‡ ™1¿ˆ„ „ ‰ Ão~g‰DÛ
ŽQ–%”–<„:’ „ ƒ ?Ž‚M}N Eˆ  ƒ„
›` :‚–%†ÂÀD’“•”ƒ'
}NÄ2Å#
š@„ ‘r…G„ †6‚‡ˆ„\„  ”6–%†ÆŽN ‘.‡‡„ ƒ'ƒ/\¿‘Œi‚– ƒ'†6 „ ƒ'‰
—‘Œ6„ˆ„
…G„ ‘`‰6ÇR†„  · ¬c¯¯ ¸)¿¿ˆ ¾r¿‘Œ6‚–:—‘Œi„ ƒ‰jÅX„ …G„ }NÃ ß ”ˆˆTƒ† „4’“•”ƒ'„ ‘=ˆ„,…G„ ‘Oš@¾-ŽN‘ ™à’“•”ƒ'„ ‘
—‘Œ6„ ƒ@¿¿ˆ‚„ ’2”‚ˆV’“ ”ƒ™1„ "‚ƒ@‡ ™1¿ˆ„ „ ‰ ƒ'‡‘„
š-ƒ'‘9š5†„ „ ˆ‰
§9¨R©4ª «¬­•®e¯° ±x²

³|´|µ¶C·E¸–¹ º–»C¸–·¤¼Z½|¾¿À
Á^¿ÂÃÄÅ

 …
K†i//N2478=>@‡+78-!6+)>-? €
=>)'C=>(")>!7Y=>.G /E!+6)>:
 ˆ
KJ1‰
"=>@N//)S$'Z/@B'Š"2624/Z‹26)H
!!€'/)Hu6-@B6@B$//)9=>‡'M/GK"=>@
"!Z1#Œ"#U') Ži=H@B:~
Z:

Fig. 60 Adjusting Gauge On Drum

Fig. 62 Brake Adjustment

 
KX</$u"V!$#"n#(')9H? / O //)
'4)>}2"#(

K=>)(")>=>@A'&4@S!Z6‘+}G )>|#U'
#(')<=H(/$6:
 
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$K)> O K#U",‘G /?“$
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 I
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 P
KX<26("? ((/2424/"=> #(')>:z<K"
"? –=H(_66)<6E+/$'D#(')>:
Z[]
KJ1$)>)2424/E24)>$C!!"('/)HC26)H@A":
Fig. 61 Adjusting Gauge On Brake Shoes Z[[y
—˜^E267=>@&+678*!+6)>*6K)>/1#U O '=>!)>:
 
 "!$#%"&#(')* +,-'

./ Z[~
KQR= O  O '=>!)>{.? 7{/{G /T#(."/2.GH/)>F
10324 /*!5+6789'/":;</$=>9
"?  )>/1#U+,M/W O "W$/24:CX<246Y24/!4WIF\["]
=>)@A@BC/"=>4C)>@A(D)>=>@A'E4@AF GH=>E/."'/: =H?(V/W/24$W/?(6=>!ƒ^$V_)>=>`

 I
KJ16)>)L+678M6? --#(')>-N)>/$#( "? :
O '=>!)>:


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KQR= O  O '=>!)> S? 78 / GH/T#U6V"/2VG /)>F NOTE: Bring vehicle to complete standstill at each
)>/1#U+,M/W O "W$/24:*X<246Y24/!Z4ZWI6F\["] stop. Incomplete, rolling stops will not activate
=>? V/W/26$W/? 6=>!L6^$V_)>=>`
 automatic adjusters.
"? $:

NOTE: Bring vehicle to complete standstill at each

SPECIFICATIONS
stop. Incomplete, rolling stops will not activate
automatic adjusters.
BRAKE FLUID
'&+678&GH)>=>Y"Y=>r$'=H O '=H!Z)HD? "˜!/G /?
acbedefegihj&klehnmVo hqpracbed3fegshoHletuh8vvxw /rQR™qš‚S24!=>G =>!=>/Y€›B—˜œ‘c[]‚S$46":
Z[y
Kz<C"D267=>@{+7C)> O |=H(GH)>) ,})>"4: ž //'uŸ,324/Gr+78 GH)H=H‡=>‰!/? ? 4Œ/
 ~
KX<=>" O '=>!)>/6n#U')>€!M+/$ 2424/ O YGH/U6@BD=H ' O '=>!)>D+678Dy,e"?(:¢¡˜
G ) ,: /) ,¤£&/266+78 G )>=>Œ/¥_= O )>VG /?¦
 ‚
KX<?(/ O ƒ24)>@€G /?„!'!!r'/)>ƒ=>+78 =H@B') ,r)>K!/$=>y:
2424/E24)>$":
<= >@?ACBEDGF H'I;J2K
LMNOQPSR
P8OT@UPSVXWXLZY[O\C]C^G_(]C`CaCbCc

CAUTION: Never use reclaimed brake fluid or fluid SPECIAL TOOLS

from an container which has been left open. An
open container will absorb moisture from the air BASE BRAKES
and contaminate the fluid.

CAUTION: Never use any type of a petroleum-

based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid, etc.

BRAKE COMPONENTS Installer Caliper Dust Boot C-4842

Disc Brake Caliper

Æ ÇeÈ4ÉËÊ8ÊÊÊÊÊÊÊÊÊ8ÊÊÊÊÊÊÊÊÊ8ÊÊÊÊÊÊÊÊÊ8ÊqÌeÍ>Î>Ï4Î>ÐÑ

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Ì3ÎHá
É-ÊÊÊÊÊÊÊÊÊsâãä6Ê å–æ9âç6Ê èãé ê ê-ë\ììæ9íÊîäå Î>ÐÊ ï
ð{àæ3Êñ<òÐóò߃ÊÊÊÊ8ÊÊÊÊÊÊÊÊÊsíÊ^ì"â ê ê ë íÊ íí6ô Î>ÐÊ ï
ð{àæ3ʁƍõÎ>ö÷8ÐÉø"øÞ<à6ùÎ>àßÎ>óÐCÊÊqíÊ íúìç ê ê-ë íÊ ííí6ô(ÎHÐÊ ï
ð{Î>ÐÊƍõÎ>ö÷8ÐÉø"øÊÊÊÊÊÊÊÊÊ8ÊÊqââÊ ã ê ê-ë íÊ èäç6ã Î>ÐÊ ï
ÖRׁØÙiÚ*Ò5ׁûqü
Ì3ÎHá
ÉnÊÊÊÊÊÊ8ÊÊÊÊÊÊÊsâ6âèÊ é–æ9é6çÊ ô ê ê ë ä–æ9â6Ê ô Î>ÐÊ ï
ÖRׁØÙiÚ*ÖRÜÜÔÝZÚ6×
ÆÇeÈ4É ÊÊÊÊÊÊ8ÊÊÊÊÊÊÊÊÊ8ÊÊÊÊ4Æ¢àÐÏ4Éê-ýRÎ>àÈ4õùàÑBê

TORQUE CHART
Handle C-4171
Òxþcÿ
Û
5Û xþ
ÖRׁØÙi Ú  Ú s Ø 
Ì3òÈ4È4óù ß <óÍ>ßUÊÊÊÊÊÊÊ8ÊÊÊÊÊÊÊsâè ê-ëHâiìHß$ÊÍø"Ê ï
ÖRׁØÙiÚ*ÖRÜÜÔÝZÚ6×
ð{óòÐßÎ>Ð Ñ ˜òßønÊÊÊÊÊ8ÊÊÊÊÊÊÊsç ä  ê-ëHâ6 ä Hß$ÊÍ øÊ ï
 ØÔÝ\Ú4 × !"y$Ó #!sÚ4×
ð{óòÐßÎ>Ð Ñ ˜òßønÊÊÊÊÊ8ÊÊÊÊÊÊÊsâ å  ê-ë\ì" è Hß$ÊÍ øÊ ï
<ùà÷
É %iÎ>ÐÉøsÊÊÊÊ8ÊÊÊÊÊÊÊÊÊ8ÊÊRì ô  ê ëZì ì Hß$ÊÍ ø"Ê ï
RÜ' ü &ú(Ó #qØÝ\Ó^ Ü #*)c Ø  +¢Ú
ð{óòÐßÎ>Ð Ñ ˜òßønÊÊÊÊÊ8ÊÊÊÊÊÊÊsâ å  ê-ë\ì" è Hß$ÊÍ øÊ ï
<ùà÷
É %iÎ>ÐÉø ÊÊÊÊÊÊÊ8ÊÊÊÊÊÊÊsâú ì  ê-ë\ì" ô Hß$ÊÍ ø"Ê ï
RØ,y$Ó -sÚ4× Adaptor Cap Pressure Bleeder 6921
ð{óòÐßÎ>Ð Ñ <óÍ>ß$ø&Ê8ÊÊÊÊÊÊÊÊÊ8ÊÊRì ô  ê ëZì ì Hß$ÊÍ øÊ ï
<ùà÷
É .xóø
É <óÍ>ß{ÊÊÊÊ8ÊÊÊÊÊÊÊsçú ì  ê-ëHâ6 ç Hß$ÊÍ øÊ ï
/10qÚ42Ú !!"y$Ó #!sÚ4×
ð{óòÐßÎ>Ð Ñ <óÍ>ß$øxÊÊÊÊÊÊÊÊ8ÊÊÊÊʍì"3 í  ê-ë  ã Hß$ÊÍ øÊ ï
<ùà÷
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cØׁÙi(Ó #!4{֍ׁØÙsÚ
%s6É 5eÉ7 ù <óÍ>ßøCÊÊ8ÊÊÊÊÊÊÊÊÊ8ÊÊÊÊʍì"3 â  ê-ë  ä Hß$ÊÍ ø"Ê ï
%s6É 5eÉ7 ù <ùàö÷8É ß <óÍ>ßøWÊÊÊÊ8ÊÊÊÊʍì"3 â  ê-ë  ä Hß$Ê8Í øÊ ï
9 :à 6Í>Éxñ<ÉßàÎ>ÐÉ; ù ˜òߖÊÊÊÊÊÊÊʍìÊ ô  ê-ë\ì"å Î>ÐÊ8Í øÊ ï
õ'ö7÷2ø ùCúû@ü€ýuþ ÿ

ANTILOCK BRAKES
d8eCfCgih

page page

DESCRIPTION AND OPERATION SERVICE PROCEDURES

ABS SYSTEM RELAYS . . . . . . . . . . . . . . . . . . . . 33 BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . . 33
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . 33 REMOVAL AND INSTALLATION
ACCELERATION SWITCH . . . . . . . . . . . . . . . . . 32 ACCELERATION SWITCH . . . . . . . . . . . . . . . . . 36
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . 30 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 35
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 32 CONTROLLER ANTILOCK BRAKES . . . . . . . . . . 33
CONTROLLER ANTILOCK BRAKES . . . . . . . . . . 30 FRONT WHEEL SENSOR . . . . . . . . . . . . . . . . . . 34
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . 31 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . 33
WHEEL SPEED SENSORS AND TONE WHEEL . . 31 REAR WHEEL SPEED SENSOR . . . . . . . . . . . . 35
DIAGNOSIS AND TESTING SPECIFICATIONS
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . 33 T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 37
Œe€È"dSÃi¿CɌÅ1Ä
À€ÂŒÅ
d8eۮ
DESCRIPTION AND OPERATION j;k,l¯w:xvzy{8qu|}~r(€rsvzli©mpl™„€luxvzrˆ{qi|[},omʇ2opyx‰1ky‰›k
r’{ymŠ|qix‡y8vzyqix,r3snqi‡o{wvzyx‰tS{oy‡‘w:m2m{ ¯m2p[lirsr’oplvzq
ANTILOCK j;k,lnm2op[m2qiBRAKE rslnqutv6k,lnSYSTEM
w:xvzy8{qu|}~r$€rsv6lu‚yrƒvzqnm2pl6„€luxv vzkl … kluli{C:pw:}†l*o,xyv6rs
… k,lili{@{qi|}†omˆ‡2op[y8x,‰Šm2lipyqu‡2rqit;k,y8‰‹k … kluli{Œrs{ym2Žpli —pw:},l*tS{oy‡ƒw:m2m2{ šm2plirsr’o,plyrqu‡2o{w:v6lu‡ˆw:||qup‡2yx‰
„€luxvzy8x,‰*{qi|}†om'k,li{m2rw:y8x,v6w:yx„€luky|{l:pw:},yx‰Xw|vzyqix vzq … k,lilu{
rsm2luli‡2½7‡li‰›plulˆqutrs{y8m1wx,‡œpw:vzlˆqit
‡2lu|li{lipw:
w:x‡‘r’vzlilupyx‰Q|qixvzpqi{ vzy8qux"•¨rslix,r’qipˆw:v'luw:|k … klilu{|qux£„€lupvzr … kluli{3r’m2luli‡
j;k,lnw:xvzy{8qu|}”“–•—˜w|[v6y „€w:vzlir‘v6k,lnr$€r’vzlu … kluxl™„–lip yxvzqli{lu|v6py|w:{@r’y‰›x,w{rs–jŒklirslrsy‰›xw:{rw:plvzpw:xr’yvzvzli‡
rslixrsqipšr’y‰›x,w{rœyx‡2y|w:vzl”m2lipyqu‡2rœqitQky‰‹k … klilu{rs{8ym2 vzqËvzkl̓–•—Ít8qip®m2pqi|lur’rsyx‰Îwx,‡Z‡livzlipyxw:vzy8quxÏqut
ž
y‰›k … klilu{Cr’{ymƒ|w:xŸlX‡2lur’|py:li‡‘w:r3v6klXm2quyxv … klupl … k,lili{r’{ymƒw:x‡‘‡2lu|li{lip[wvzyqixŸpw:v6lu
… k,lili{Epquvzwvzyqixlu‰›yxrwmm2pquw|k,y8x,‰3 :¡v6q
¢:¡m2lip|[lixvqit j;k,l•—¾³r$€rsv6lu©k,wrƒvzkplulntS{oy‡Êm2plur’rsopln|qix,v6pqu{
w:|vzow:{
„€luky|{lQr’m2luli‡Ÿ‡2o,py8x,‰‘pw:}†yx‰›Ž
lupyqi‡2rXqut7ky‰›k |kw:xxlu{r’€jŒklQtSpquxvpw:}†lirXw:plQ|qixvzpqu{8{lu‡nrslim2w:pw:vzli{ 
… k,lili{
r’{ymQqu||op … klux‘:pw:},lrsv6qum2r
yx£„€qu{ „€lky‰›kŠm2li‡w:{ w:x‡'vzklpluwp
:pw:}†liryxƒvzw:x‡2lu£•µrsm2lilu‡'r’luxrsqip
yxm2ov
m2plur’rsoplXw:x‡‘pwvzlXqitE„€luky|{lX‡2li|lu{lipw:vzy8qux r’y‰‹xw:{
yx‡y|wvzyx‰¯wšky‰‹k”r’{ymœ|qux‡2yvzy8qux”w:|v6y „–wvzlir'vzkl
—w:v6vzlip¤„–qi{vzw‰‹lyrr’omm2{y8lu‡*v6qvzkl“–•—1y8‰‹xyv6yquxŠvzlup[ “–•—Ðw:xvzy{qi|}ˆm2pqu‰›pw:
yxw:{ … k,lixQvzkl
y‰›xyvzyqixr … yvz|kQyrvzopxlu‡Xvzq
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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- Fig. 5 Controller Antilock Brakes
tion refer to the Antilock Brake section in Group  

 
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Fig. 10 Setting Air Gap On Original Rear Sensor

Fig. 9 Wheel Speed Sensor

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Fig. 12 Combination Valve Brake Lines Fig. 14 Acceleration Switch

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SPECIFICATIONS
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Fig. 5 Typical Method Of Aligning Clutch Disc

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NOTE: Be sure the transmission and housing mat-
ing surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign material
trapped between the housing and transmission will
cause misalignment. If misalignment is severe
enough, the result will be clutch drag, incomplete
release and hard shifting.
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Fig. 10 Right Hand Drive Clutch Master Cylinder

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Fig. 3 Coolant Recovery Bottle
bdghprb+mz(€ prbd_iWƒ
THERMOSTAT
\^]-_`a`a_bdcNbfe]_Ebdgh_jilkMmnobqprbtslmjuhbdilm`anvbqg _Emj]-_ilprbdwauhx CAUTION: Richer antifreeze mixtures cannot be
bd_kM]-_jilprbqy il_=mzIbqg _=_uhx{wauh_=|oe}slmjuhbdilm`a`awu x~bdgh_=prkMmy uhb measured with normal field equipment and can
mzslmjm`apruhb9zN`amq€bdmbqg _ilp‚wprbdmi„ƒC…†u‡pr`` _uhx{wu _n
bdgh_ cause problems associated with 100 percent ethyl-
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bd_kM]-_jilprbqy il_=slmuhbdilm`aƒ COOLANT
’mmj`pruhbÆnˆg SELECTION
myh`a‚›|r_kMprwauhAND ADDITIVES
bdprwu _‚› prbÆbqgh_Cnˆ]_slwazNwa_‚G`_q—_j`
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zNilmjuhb¡zN`apruhx§_¨uh_‰©”bšbdmªbdgh_¨pwai|r`a__j‚-ƒ?Lgh_ € mjil‚-n¬«–­ pruh‚˜`mq€EkMwu _ilpr`Islmjuhbd_uhb)€pbd_i„ƒ
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g _~nˆprkM_~bqg _ilkMmjnˆbdprb%wan=yhnˆ_j‚
zmi?€ wauhbd_iMpruh‚
noyhkMc CAUTION: Do not use coolant additives that are
kM_jinˆ_prnomuhnoƒ´\–u¡_juhx§wauh_Mnoghmjyh`a‚9uhmb
|r_Mmj]-_ilprbd_‚€wbdghc claimed to improve engine cooling.
my bµp¶bdgh_ilkMmjnˆbdprbq™¬_‰©”sl_]-bµzminˆ_ji·—waslwauhxvmibq_jnˆbdwauhx§ƒ
…†]_ilprbdwu x¡€ wabqg myhb›pªbdgh_i•kMmnobqprb~s•pyhno_nšmbdgh_i¡]-i•m|rc
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bdwakM_™Iyhuhil_jc RADIATOR ðlöµñrðl÷±÷ørùhóaú-CAP
î–ïaï~ðlñrò-óañrôqõjPRESSURE ú÷ò¨û óaôdüvñ1ú-ðl÷jöˆöoùhðl÷±ýlñrú-þ
`awap|r`a_£€ prilkMcNyh]¹]-_jilzNmjilkMpu sl_™¦wauhslil_jprnˆ_j‚º_q©ghpryhnob ÿ hü óaö}ý•ñúðl÷jï÷jñröˆ÷ö
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_k wnonˆwamjuhn›pruh‚}sli•puhŸ»slprno_¬slmu ‚-_uhnoprbqwamjuhƒ(
ghwanGslmuh‚_uhc ðlñ §÷9õ
 

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il_jnˆyh`ab+wau nˆ`ayh‚x§_=zNmi•kMpbdwamuhƒ ú-õjó   ô Nó 
ú-õjù hòö CóaöM÷ §ðlñ ÷jò¡
õ 
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CAUTION: Do not operate an engine without a ther- öˆïaó §ü ôqï !¬ñ #r$õ ÷%ñr%ô Mõöoú-üh÷jðlóaý?úðl÷öoöˆùhðl÷jþ ÿ ühóaö+ðl÷jöˆùhïaôdö+ó ~ñ
mostat, except for servicing or testing. ühó §ü ÷ðýlõõïañ h& ô #rõjóïaó ¡ú-õjó hôCñrïaïõqû ó ¡ó hýlðl÷ñröo÷ò
ðlñrò-ó 
ñrôqõjðtýlõjõïaó ¶ýlñrú-ñrýlóa'ô !{þ ÿ üh÷¢ýlñúEýl
õ  ôqñró hö‡ñæöˆú-ðló (
COOLANT ïaõñrò-÷jòúðl÷öoöˆùhð•÷¡ð•÷ïaóa
÷ )ñrï ÷jþ ÿ ü ó& ö ”ñrï ”÷˜õú-÷ höCû üh÷ 
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g _il_žryhwaPERFORMANCE
il_‚›_bdg´e”`a_uh_jcNx§` eslmj`NpruhbdwazNil_j_¼6_q“+pruh‚%€ prbd_i ö !”öˆôd
÷ Õú-ðl÷jöˆöoùhðl÷›ðl÷ñrýlü ÷öôdüh÷›ðl÷ïa÷ñröo÷›ðlñ §÷›
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slmjuh‚-wabqwamjuhnˆƒLgh_¡slmmj`apu bM]-_jilzNmilk puhs•_¡mzI—prilwamy n9kMw ©c
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kMw ©bdyhil_ mjzh€ prbd_i–pruh‚~_jbqg´e”`a_uh_jcNx§` eslmj`aƒLghwan%wan%zmi–]-y i•c
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û ü
÷ 1#rõóaïaó ú-õjó  ô¡óaöðl÷jñýlü ÷ò-þî–öýlõõjïa/ñ hô˜ýlõõjïaö 2 óaô
ýlõ hôqðlñrýlôdö¡ñ hò¨ýlðl÷ñrôd÷ö¡ ñ ”ñrýlùhù ìóôdüh÷
ôd
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ñ hô ó vðl÷jöˆ÷j5ð 7÷ 6W$õ ÷j8ð Nïaõ‰ûéôqñ ¢ôq9
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Fig. 5 Reverse Rotating Water Pump—Typical

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
‚Jsrt:p8q‡‡|Œ/ys•z8q
„§Š:|t%s
zaŒEƒ„.Œ”yƒp8t%uq
r–|t:„.q}Es
z |/t%s
|r}•wuvw˜s
rv(ur3sayŒEss
}Ey~
Fig. 4 Radiator Pressure Cap
p8qrrs
p8t%urvxwq
ys^urt%q{z8|/}/u|t%q
z"~€$lt%ws ‚J|p8ƒƒ„…‚†|‡ ‚†s^uy
yt7ƒp8ˆ+ywƒt%‰Mz8|}/u|t%q
zRwqysycŠ:u‡‡‹p8q
‡‡|ŒEys:q
rp8qq
‡ }/q$Š:r3~ WARNING: CONSTANT TENSION HOSE CLAMPS
Ž z8ƒs
zRv|yˆ3st?ys
|‡y&t7w3s.z8|}Eu|/t%q
zRu‡‡s
zRrsp8ˆ3~/‘cwuy ARE USED ON MOST COOLING SYSTEM HOSES.
uy}Eq
r3s’t%q&„.|ur3t7|ur:‚†|/p8ƒ3ƒ„“}/ƒz8urv{p q
q
‡|rtlp8qq
‡ }Eq7Š:r WHEN REMOVING OR INSTALLING, USE ONLY
|r}”t%q•ŒEz8s$‚†s
rt’‡s|ˆ3|vs.Š’ws
r–y"—Jyt%s
„`uy0ƒr}/s
zaŒEz8sy TOOLS DESIGNED FOR SERVICING THIS TYPE OF
yƒz8s
~ CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 6). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
WATER PUMP ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
‘*w3s&Š’|t7sz.ŒEƒ3„.Œ˜u„.Œ/s
‡‡s
z.uy{ŒEz s
yys
},qrt7qxt%wsxz8s
|z
q
R|”yw|t{t%w|t.z8q
t%|t7sy+ur9s|/z8urv(y+Œ/z8s
yys}™urt%q,t%ws ING CONSTANT TENSION CLAMPS.
wqƒyurv(~E‘cws.w3q
ƒyurvaw|y&|xy„.|‡‡‹wq
‡s.t%q.|‡‡q$Ššys
s
Œ/
|vs+t%q•syp8|ŒEs~›‘cws:Š:|t7szaŒEƒ3„.Œ”ys
|‡yx|/z8s+‡ƒz8up8|t7s} CAUTION: A number or letter is stamped into the
—1t%wsœ|/r3t7u z8ss
Osœur4t%ws™p8qq
‡|rt=„.u žJt%ƒz8s
~&Ÿ q™|}E}Eu tongue of constant tension clamps (Fig. 7). If
t%uq
r|‡h‡ƒz8up8|t7uqruy:rs
p s
yy|z5—(~ replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: All engines are equipped with a reverse
$ryŒEs
p8t9t%ws¨wqysy…|t©z s
vƒ‡|zªurt%s
z5‚†|/‡y~ ¦ sŒE‡|p8s
(counter-clockwise) rotating water pump and vis-
wqysyRt7w|tc|z8s’p8z8|p8ˆs
}/‰- ss
‡M/z ut%t%‡s*Š’ws
r+y£/ƒ3s
s
Os}E‰Jq
z
cous fan drive assembly. REVERSE is stamped or
yŠ’s
‡‡hs7žJp8syyu ‚†s
‡ —0Š:wsrt%ws^y—†yt%s
„«uy:ŒEz8s
yyƒ3z8uOs}E~
imprinted on the cover of the viscous fan drive and ¬ qz”|‡‡R‚Js
w3up ‡sy­.$r1|z8s
|y+Š:wsz8s9yŒEs
p uup®z8q
ƒt%urv
inner side of the fan. The letter R is stamped into
p8‡|„.ŒEy¢|z8s.r3q
t*ŒEz8q7‚Ju}Es}E‰›s:yƒz8s:t%w|t*wq
ys
y¢|z8s:ŒEq
yu
the back of the water pump impeller (Fig. 5).
t%uqrs}¯Š:ut%w°yƒ  up8us
r3t…p ‡s|z8|/r3p8s
~™±)wsp8ˆ²p8‡s
|z8|rp8s
  rvursyš z q
„¡ŒEz8s7‚Juq
ƒy“„.q
}Es‡,—Js
|z8y‰™}/s
ŒEsr}Eurv  z8q„°s$žJw3|/ƒ3yt^„.|/r3uq
‡}Ey|r}³Œ/uŒEs
‰  |r´‡|}/s
y‰ }Ez8u ‚†s
ƒŒ/q
r0|ŒEŒ/‡up8|t%uq
r‰„.|—=w|‚†s¢ss
r0s£ƒuŒEŒEs}Š:ut%w0|. qz  s
‡t%yR|r}xy"Š:|—|z8y~J$„.ŒEz q
ŒEsz8‡ —ŒEq
yut7uqrs
}xw3q
ys
yRp8|r
Š:|z8}0¤p8‡q
p8ˆŠ:uys7¥ z8qt7|t%ur3vŠ:|t%s
zŒEƒ„:ŒE~-$ryt%|‡‡|/t%uq
r•q sª}/|/„.|v(s
}E‰0z8syƒ‡t%urv1ur§p8q
q
‡|rt”‡q
yy´|r}¨s
rv(ur3s
t%wslŠ’z8q
rv?Š’|t7sz?ŒEƒ„.ŒŠ’u‡‡-p8|ƒysRs
rv(urs¢q7‚Js
z8w3s
|t7urv(~ q$‚†s
z8ws|t7urv(~
OP1Q R2STSKUV WTXY2Z[Y2\ ]
^ _@`

acbHdHecfgDhHijgBk>lnmcloapk>hHbHfcmqijgBk>l,r"ecsutuvwxtzyu{u|u}

æ%á
ç9êçEå
åÛ9á9;:æ%èåF;Þ/Ýôæ%á®Þ–çEÚ8åÛEå
æ%å
Ú8â.ÜÝåÛ9â.ÞöJÜâ.ðâ
ìå$ó†å
ìhÞæ èÜãè3å
Ú&å
ÝãÜÝå^êçEåå
ÛEêù

Fig. 6 Hose Clamp Tool—Typical

Fig. 8 Water Pump Mounted Fan Drive

G“æ%èåÚ8â.á
êæ7Þæ%Üëaò/Üâ.åæ7ÞììÜëaêçEÚ8ÜÝã,ë8á
ÜìVÜêxìá
ë8Þæ%å
۔áÝ
æ%èå>; Ú8áÝæH; Þë8å^á9h ; æ7èå óJÜêë8áðêE; Þ/ݘÛ/Ú8Ü óJå^ðÝ3ÜæVí Þ=æ ߆çEÜë8Þì
óJÜêë8á
ðê”ðÝÜæ•Üêœêèá$à’Ý1ÜÝ1íB› A Üã(ùEI ñù ? èÜê”êç/Ú8ÜÝ3ã´ë8á
Üì
Ú8å
Þë8æ%ê•æ%áæ%èå˜æ%å
â.ç/å
Ú8Þæ%ðÚ8å˜á9& ; æ7è3å˜Ú8Þ/Û/ÜÞæ%á
Ú=ÛEÜêë8è3Þ/Ú8ã(å
ÞÜÚùK7J æ^å
Ýã(Þãå
ê+æ7èåaó†Üêë8áðê4; ÞÝ©ÛEÚ8Ü ó†åL; á
Ú=èÜãè3å
Ú; ÞÝ
êç/å
åÛ®ÜMV ; æ%èå=ÞÜÚ{æ%å
â.çEåÚ8Þæ7ðÚ å; Ú8á
â÷æ%èå=Ú8ÞÛEÜÞ/æ%á
Ú{Ú8Üêåê
Þòá$óJå:Þaë8å
Ú æ7ÞÜݕçEá
ÜÝæ%ù2 N Ýæ%Üì‹ÞÛEÛEÜæ%Üá
ÝÞì€å
Ýã(ÜÝ3å:ë8á
áìÜÝ3ã
Üê•Ý3å
ë8åêêÞ/Ú5ß6V = æ%èåL; Þ/ݘà:Üìì¢Ú å
â.ÞÜÝ©Þæ^ޜÚ8åÛEðë8åۖÚ8ç/â
Ú8å
ã(ÞÚ8ÛEìå
êê:á9l ; å
Ýã(ÜÝå^êçEåå
ÛEù

Fig. 7 Clamp Number/Letter Location

Ù Ú8Û/ÜÝ3Þ/Ú5ß²à’á
Ú8âäãåÞÚbæ'ßJç/åéèá
êåéë8ìÞ/â:çEêîí à’èå
Ý
?
å
ïðÜç/çEå
ÛOñ³ë Þ/ݯòåªÚ8åâ.á$ó†å
Ûôà:Üæ%è¯Þ¨êæ7Ú8ÞÜãèæ”êë8Ú8å7à:õ
ÛEÚ8Ü ó†å
Úôá
ÚôÞ§è3å$ö÷êá
ë8øå
æ%ù.úhûîü›ýÿþ
Bþ 
 þ û
 ûþ4ûý
=ü   þ  û
þ
=ü  û -þ
"!#  þ€þ$ û&%('*)
,+.-%/!#0120 34ûý652€þ017Rû&€û
û6Bþ/ý8"!#  þ  û
þ4
=ü90
: è3å
ݚçEå
Ú<;á
Ú8â.ÜÝã4ޅèá
êåôÜÝ3êçEåë8æ%ÜáÝ=xÜÝêçEåë8æ®æ%èå
Ú8ÞÛEÜÞæ7áÚ&ìá$à’å
򢏇
êå>;á
Ú¢çEÚ8á
ç/å
Ú&ç/á
êÜæ%Üá
Ý,ÞÝەë á
ÝÛEÜæ%Üá
Ý
á9;læ%èå^ÜÝæ%å
Ú8ÝÞìhêçEÚ8ÜÝãù

VISCOUS FAN DRIVE

? è3å:æ%èå
Ú8â.ÞìóJÜêë8á
ðê@; ÞݕÛEÚ8Ü óJå’íBAMÜã(ùCñ ÜêRÞxêÜìÜë8áÝå
õ
; ìðÜÛEõD; ÜììåÛ=ë8áðçEìÜÝãað3êåÛ=æ%á.ë8áÝÝå
ë8æ*æ%èåE; 
Þ ÝòìÞÛ/å
ê¢æ7á
å
Üæ%èåÚ:æ%èåaåÝãÜÝå^á
ڒæ7è3åRà:Þæ%å
ڒçEðâ.çêèÞ; æ%ù ? èåaë8áðõ
çEìÜÝã:Þììá$à:êVæ7è3å*; ÞÝ0æ%á¢òå¢ÛEÚ8Ü óJåÝ0ÜÝ0Þ{ÝáÚ8â.Þì›â.ÞÝÝ3å
Úù
? èÜê.Üê.ÛEáÝåaÞæ ìá$à«åÝãÜÝå^êçEåå
ÛEê?à:èÜìåaìÜâ.Üæ7ÜÝã0æ7è3å
Fig. 9 Viscous Fan Drive—Typical
Ù Ýì ßà’èå
ݜêð;B; Üë8ÜåÝæ&èåÞæ&ÜêaçEÚ8åêåÝæ.=-à’Üìì*æ7è3å’óJÜêõ
?
ë8á
ð3ê8; ÞݙÛEÚ8Ü óJå+åÝãÞãåù ? èÜêxÜê¢à:è3å
ݙæ%èå+ÞÜÚ>;ìá7à:ÜÝã
æ%èÚ8á
ð3ãè4æ%èåœÚ8ÞÛEÜÞæ7áژë8áÚ8å™ë8Þðêå
êÞ©Ú8åÞ/ë8æ%Üá
ݪæ7áœæ%èå
"$# %'&(&)+* ,(-/.10'.'24365 7987

:<;>=>?<@9ACB>DEAGFIHKJ<H:LFIB>;>@<JDEAGFIHNMO?<PRQRSUTQVRWRXRY

~M€j9‚.ƒ„D„MM…@…<†9M„M‡ ˆ‰‚1‚‰Š9‹ŒM‹…<<ƒŽ9ŽcDƒ‹ŒŽ‘9’‚.†j‘<†”“•M’

‚.Š>‹9…<Ž–Žƒ—˜ƒ’’M‚‰M†9‹ƒ„™9‹š›D‹o…œ†9†9„MM‹š›‡ ACCESSORY DRIVE BELT DIAGNOSIS
 ‹…<ž‚.Šž9‹š›M‹žŠƒŽE…<††9„M’Ÿ‚.Šž<ƒ’Mƒ‚.†9*’MŽ–…<Šƒ<š› ØqÙ Ú·Û[Üq݌ÞuÙ Üß@à[áuÚ·Ù Ú
‚.9€j‘<ƒ‚‰ <¢¡EM„M„&’<†‘‡4£qŠ¤~M€j9‚.ƒ„D„MM…¥…<†9M„&ƒš›ƒM‹ â/ãäå/æçMèé¾åêë–çMåéŒë–äì<íä9åî‰çMåäèï<ï<äë–ëê9ìð¦æì<ç ñ[äòäóDî.ëô
<ƒ…<‚.Ž8ƒ‹’˜‚.ŠBƒ‹¦Ž‘9’FDŽ8<’ …<’˜‚.†4‚.Š‘<‰“[M†9 Ž ë–õEèóMóï<ì<èï<ö÷ëKî‰ãèîuì<øåÃèï<ì<ê9ëëÇî.ãä*ì<çMòòäæoëøì<ùBèï<ä*ê9ù î‰ãä
’MŽ9‹š›ƒš›9’4Ž–‘99’‡ òä9óMîÇùBì<êõúì<çMòŒî.êoì<çDò4ûDü çMé¾ýKþ
ÿ œôTèì<ä8ïœê9åëçDæä9ì<äæ½åêì<õjèóDý
qãä9ëäoèì<ä>åê9îKèì<ä9èë–êåÀî.êoì<äíóMèï<äoî.ãä>òäóMî‰ ý @ê ¿ä”ñ[äì#ô
CAUTION: Engines equipped with serpentine drive ï<ì<èï<ö÷ë>ì<øååçMåé4èóMê9åé4èŒì<çMòŒûBåêî*èï<ì<êë–ë Eèì< ä 
¿åêì 
belts have reverse rotating fans and viscous fan õjèóM ý Çå9ð¦òä9óMî ¿çDî.ã˜ï<ì<èï<öë>ì<øååçMåéŒèóMê9åéŒè½ìœçDò½õEøë–î
drives. They are marked with the word REVERSE to òä4ì<ä9íóMèï<äæ(ûDü çMé¾ýcþ–
ÿ "ý ÇóDëê4ì<ä9íóDèï<ä4î.ãä4òä9óMîEçMùÇçDî¿ãèë
designate their usage. Installation of the wrong fan ä •ï<ä9ëë–ç ñ[ä ¿ä9èì#ôµùDì<è–ð•ä9æ4ï<ê9ìœæëEê9ìcë–ä‰ñ[ä9ì<ä>é›óDè 
çMåé›ý
or viscous fan drive can result in engine overheat- ™ä9ùDä9ì¿î.ê>î.ãä Çï<ï<äë–ëê9ì
ð 1ì<ç ñ•
ä ™äóM
î 1çMèé¾åêë–çMëEï<ãèì<î.ë
ing. ùBêì¿ùDøì<î‰ãä9ìcòäóMîKæçMèé›åê9ëçMë–ý

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.

DIAGNOSIS AND TESTING

ON-BOARD DIAGNOSTICS (OBD)
§¨u¨@©ªB«[¬­ ®­ ¯°±³²u°©9´¯µ°¶¶uª ´¬@«[¨u­ ¯ª § ­
£·Š/¸ †‰¡E9<‚.<ƒM‹¢¹™†‹‚.<†9„žº8†9’ „M/»B¸ ¹™º*¼½ŠƒŽF~99‹
‘<†š¾<ƒ€j€j’½‚.†o€j†9‹M‚.†9¿‚‰Šo…<<‚‰ƒM‹ÀB†9„M„M†”¡¿D‹š…<††9„MM‹š
Žx—[Ž–‚.9€¤…<†9€E‘†9‹‹‚.Ž–Á
ˆ”c‚‰ŠÀ‹š¾M‹LŠƒŽ4<9€jƒM‹’Â…<††9„*B†‚.†9†L„M†9‹š˜ƒ
•
‘<M†9’ŸŽ …<ŠÃƒŽT¡EM‚.ŠÃƒžŽ‚‰ …<Ä8†‘9‹Ã‚.Š<€j†9Ž‚‰ƒ‚.Ÿ•ƒjÅ1Mƒš¾Æ Fig. 10 Belt Wear Patterns
‹†Ž–‚.M…·£µ<†9 ~„M>¹™†9’o»DÅ£q¹•¼c…<ƒ‹L~>Ž9‚.‡ à[á@Ù ÚŒÞuÙ Üß@à[áuÚ·Ù Ú
ˆ”™ƒ‹Œ†9‘9‹Œ†9@ŽŠ†9<‚.’…<†9‹’D‚.M†9‹ŒŠƒŽc’”“[„M†9‘’M‹ ÇêçDëä9ëLé¾ä9åä9ì<èî.ä9æÈòð¢î.ãä(èï<ï<äë–ëê9ìðæì<ç ñ[ä(òäóMîèì<ä
•
‚.Šo<9„Mƒ—(…<M<…< D‚Ç…œ†9‹‚.<†9„M„MM‹š‚‰Šo„D…<‚.<D…¿<ƒ’Mƒ‚‰†EBƒ‹Ÿ õjê9ëîŒåêî‰çMï<äèòóMäÂèîŒçMæóMä9! ý ™ä9ùBêì<äÂì<ä9íóDèï<çMåéÈèÏòäóMîŒî‰ê
ƒÅ·Dƒš¾‹†9Ž‚‰M…q£T<† ~„Mo¹™†’>»BÅ£q¹•¼*…<ƒ‹À~>Ž–‚‰‡ ì<äë–ê9ó ñ•ä>èåêçMë–ä>ï<êåæçMî.çMê9åôçMåë–íä9ï<îHèóMó™ê9ùzî.ãä>èï<ï<äë–ëê9ìð
ˆ”‚.ŠÈ‘<†~„D€ÉDŽ¦Ž–‹Ž–’D‹Êƒ€j†9‹D‚.†9<’…<M<…< M‚ æì<ç ñ•äjíøóMóMä”ð[ë*ùBê9ì@èóMçDé›åõjäåî‰ôé¾óM
è 
çMåé¾ôê9ì@ä •ï<ä9ëë–ç ñ[äjäåæ
†9D‚‰‹4‹†9 š¾Š‚‰†¿M‹’M…<ƒ‚.¿ƒ‹ƒ…<‚‰ ƒ„ ‘<†9~„M9€jŸ[ƒoÅ£q¹¦MŽ íóMèð›ý
Ž‚‰†<9’‡£·Š8Å£·¹˜¡EM„M„q~8Ž‚‰†<9’½M‹F‚‰Š8¸¹™ºË€j€j†9—
B†j‰“[‹‚‰ ƒ„z’MŽ–‘„Dƒ—(‚.†8‚‰Š8Ž9“•D…œÃ‚.…<Š‹M…<Mƒ‹‡™»B̙B9
‚.†/Í1<† ‘ÏÎПcљ€jDŽŽD†‹¹™†9‹‚.<†9„jÒ¾—•Ž–‚.9€jŽFD†9L‘<†‘9
‘<†…<9’ <9Žx¼

´§ §q°9­ ­qªB«[¬Ó¶uª ´¬@«[¨u­ ¯µª §(¯µ²[¨@ÔuÕ©°ž§ ¨@¶u°9­

£ †<9ƒ’˜Å£q¹™Ö ŽÃƒ‹’F‚‰††9~‚.ƒM‹¦…<††9„MM‹šLŽx—[Ž‚‰€n’ƒ‚.ƒŸ
<B9È‚.†¢Í·<†9 ‘×ÎПљ€jMŽ–ŽD†‹p¹™†9‹‚.<†„Lқ—[Ž‚‰€jŽ$D†9
‘<†‘¿‘<†…<9’ <9Ž‡
s9t\u v'w(wx+y z({/|'}1|'~46€ b‚

ƒ „G…<†I‡IˆI‰E„G‰Š…<‡IƒŒ‹>>‰>‹E„C‡†NŽO<R‘R’U“‘R”R•R–R—

Z[\[\]_^_^_`ba$ced\a!fhg]i\]_j4k9dlfmZlnob`b^fp^q[\rbZ\a<k

CONDITION POSSIBLE CAUSES CORRECTION

RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from
has separated from belt body) pulley grooves. pulley grooves. Replace belt.

2. Installation damage 2. Replace belt

RIB OR BELT WEAR 1. Pulley 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 4. Replace pulley. Inspect belt.
tips
5. Belt rubber deteriorated 5. Replace belt

BELT SLIPS 1. Belt slipping because of 1. Adjust tension

insufficient tension

2. Belt or pulley exposed to 2. Replace belt and clean pulleys

substance that has reduced friction
(belt dressing, oil, ethylene glycol)
3. Driven component bearing failure 3. Replace faulty component or
(seizure) bearing
4. Belt glazed or hardened from 4. Replace belt.
heat and excessive slippage

LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove

2. Pulley groove tip has worn away 2. Replace belt

rubber to tensile member

9GROOVE JUMPING9 1. Belt tension either too low or too 1. Adjust belt tension
(Belt does not maintain correct high
position on pulley)
2. Pulley(s) not within design 2. Replace pulley(s)
tolerance
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt

BELT BROKEN 1. Excessive tension 1. Replace belt and adjust tension

(Note: Identify and correct problem to specification
before new belt is installed) 2. Tensile member damaged during 2. Replace belt
belt installation
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
  "!
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CONDITION POSSIBLE CAUSES CORRECTION

NOISE 1. Belt slippage 1. Adjust belt

(Objectionable squeal, squeak, or
rumble is heard or felt while drive 2. Bearing noise 2. Locate and repair
belt is in operation) 3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced 5. Locate defective driven
vibration component and repair
6. System resonant frequency 6. Vary belt tension within
induced vibration specifications.

TENSION SHEETING FABRIC 1. Tension sheeting contacting 1. Correct rubbing condition

FAILURE stationary object
(Woven fabric on outside,
circumference of belt has cracked or 2. Excessive heat causing woven 2. Replace belt
separated from body of belt) fabric to age
3. Tension sheeting splice has 3. Replace belt
fractured

CORD EDGE FAILURE 1. Excessive tension 1. Adjust belt tension

(Tensile member exposed at edges 2. Belt contacting stationary object 2. Replace belt
of belt or separated from belt body)
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between 4. Replace belt and adjust tension
tensile member and rubber matrix to specifications

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COOLING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE 1. Has a Diagnostic Trouble Code 1. Refer to group 25, Emission Control
READS LOW (DTC) been set indicating a stuck open Systems. Replace thermostat if
engine thermostat. necessary. If a Diagnostic Trouble Code
(DTC) has not been set, the problem
may be with the temperature gauge.

2. Is the temperature gauge (if 2. Check the engine temperature

equipped) connected to the
temperature gauge coolant sensor on
the engine?
3. Is the temperature gauge (if
equipped) 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.
sensor connector in the engine
compartment. Refer to Group 8E.
Repair as necessary.
3. Check gauge operation. Refer to
Group 8E. Repair as necessary.
4. Check coolant level in the coolant
reserve/overflow tank and the radiator.
Inspect system for leaks. Repair leaks
as necessary. Refer to the Coolant
section of the manual text for Warnings
and precautions before removing the
radiator cap.
5. Inspect heater and repair as
necessary. Refer to Group 24, Heating
and Air Conditioning for procedures.

TEMPERATURE GAUGE
READS HIGH OR ENGINE
COOLANT WARNING LAMP
ILLUMINATES. COOLANT
MAY OR MAY NOT BE LOST
OR LEAKING FROM
COOLING SYSTEM
1. Trailer is being towed, a steep hill is
being climbed, vehicle is operated in
slow moving traffic, or engine is being
idled with very high ambient (outside)
temperatures and the air conditioning
is on. Higher altitudes could aggravate
these conditions.
2. Is temperature gauge (if equipped)
reading correctly?
3. Is temperature warning lamp (if
equipped) 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.
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 normal range, determine the
cause for overheating and repair. Refer
to POSSIBLE CAUSES (numbers 2
through 18).
2. Check gauge. Refer to Group 8E.
Repair as necessary.
3. Check warning lamp operation. Refer
to Group 8E. Repair as necessary.
4. Check for coolant leaks and repair
as necessary. Refer to Testing Cooling
System for Leaks in this group.
5. Tighten cap.
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CONDITION POSSIBLE CAUSES
TEMPERATURE GAUGE 6. Poor seals at radiator cap.
READS HIGH OR ENGINE
COOLANT WARNING LAMP
ILLUMINATES. COOLANT
MAY OR MAY NOT BE LOST
OR LEAKING FROM
COOLING SYSTEM 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.
As the engine cools, a vacuum is
formed in the cooling system of the
engine and radiator. If radiator cap
seals are defective, or cooling system
has leaks, a vacuum can not be
formed.
8. Freeze point of antifreeze not
correct. Mixture may be too rich.
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. Fuel or ignition system problems.
13. Dragging brakes.
14. Bug screen is being used reducing
airflow.
15. Thermostat partially or completely
shut. This is more prevalent of high
mileage vehicles.
‘’ “”"•
–•—&˜(™ š+›-œœ
CORRECTION
6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. (a) Check condition of radiator cap
and cap seals. Refer to Radiator Cap in
this group. Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check the 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 tank hoses for blockage. Repair as
necessary
8. Check antifreeze. Refer to Coolant
section of this group. Adjust antifreeze-
to-water ratio as required.
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 reason for lack of flow and
repair as necessary.
10. Clean insects or debris. Refer to
Radiator Cleaning in this group.
11. Have radiator re-cored or replaced.
12. Refer to Fuel and Ignition System
groups for diagnosis. Also refer to the
appropriate Powertrain Diagnostic
Procedures service manual for
operation of the DRB scan tool.
13. Check and correct as necessary.
Refer to Group 5, Brakes in the manual
text.
14. Remove bug screen.
15. Check thermostat operation and
replace as necessary. Refer to
Thermostats in this group.
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CONDITION POSSIBLE CAUSES
16. Thermal viscous fan drive not
operating properly.
17. Cylinder head gasket leaking.
18. Heater core leaking.
TEMPERATURE GAUGE 1. During cold weather operation, with
READING IS the heater blower in the high position,
INCONSISTENT the gauge reading may drop slightly.
(FLUCTUATES, CYCLES OR 2. Temperature gauge or engine
IS ERRATIC) mounted gauge sensor defective or
shorted. Also, corroded or loose wiring
in the circuit.
3. Gauge reading rises when vehicle is
brought to a stop after heavy use
(engine still running).
4. Gauge reading high after restarting
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 thermostat to open
late.
7. Water pump impeller loose on shaft.
8. Loose accessory drive belt (water
pump slipping).
9. Air leak on the suction side of water
pump allows air to build up in cooling
system causing thermostat to open
late.
¿PÀ
CORRECTION
16. Check fan drive operation and
replace if necessary. Refer to Viscous
Fan Drive in this group.
17. Check for cylinder head gasket
leaks. Refer to Testing Cooling System
for Leaks in this group. For repair, refer
to Group 9, Engines.
18. Check heater core for leaks. Refer
to Group 24, Heating and Air
Conditioning. Repair as necessary.
1. A normal condition. No correction is
necessary.
2. Check operation of gauge and repair
if necessary. Refer to Group 8E,
Instrument Panel and Gauges.
3. A normal condition. No correction is
necessary. Gauge reading 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 Testing Cooling System for
Leaks in this group.
6. (a) Check for cylinder head gasket
leaks with a commercially available
Block Leak Tester. Repair as
necessary.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.
7. Check water pump and replace as
necessary. Refer to Water Pumps in
this group.
8. Refer to Engine Accessory Drive
Belts in this group. Check and correct
as necessary.
9. Locate leak and repair as necessary.
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CONDITION POSSIBLE CAUSES CORRECTION

PRESSURE CAP IS 1. Pressure relief valve in radiator cap 1. Check condition of radiator cap and
BLOWING OFF STEAM is defective. cap seals. Refer to Radiator Caps in
AND/OR COOLANT TO this group. Replace cap as necessary.
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW
TANK

COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP BLOWOFF.
GAUGE IS READING HIGH
OR HOT
1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
system hoses, water pump or engine. necessary. Refer to Testing Cooling
System for Leaks in this group.

DETONATION OR PRE- 1. Engine overheating. 1. Check reason for overheating and

IGNITION (NOT CAUSED
BY IGNITION SYSTEM).
GAUGE MAY OR MAY NOT
BE READING HIGH
repair as necessary.
2. Freeze point of antifreeze not 2. Check antifreeze. Refer to the
correct. Mixture is too rich or too lean. Coolant section of this group. Adjust
antifreeze-to-water ratio as required.

HOSE OR HOSES 1. Vacuum created in cooling system 1. (a) Radiator cap relief valve stuck.
COLLAPSED WHEN on engine cool-down is not being Refer to Radiator Cap in this group.
ENGINE IS COOLING relieved through coolant reserve/ Replace if necessary.
overflow system. (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 interally
blocked or plugged. Check for blockage
and repair as necessary.

NOISY FAN 1. Fan blades loose.
2. Fan blades striking a surrounding
object.
3. Air obstructions at radiator or air
conditioning condenser.
4. Thermal viscous fan drive has
defective bearing.
5. A certain amount of fan noise
(roaring) may be evident from the
thermal viscous fan drive. Some of this
noise is normal.
1. Replace fan blade assembly. Refer
to Cooling System Fans in this group.
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 Viscous Fan Drive
in this group.
5. Refer to Viscous Fan Drive in this
group for an explanation of normal fan
noise.
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CONDITION POSSIBLE CAUSES
INADEQUATE AIR 1. Radiator and/or A/C condenser is
CONDITIONER restricted, obstructed or dirty (insects,
PERFORMANCE (COOLING leaves etc.)
SYSTEM SUSPECTED)
2. Thermal viscous fan drive is
free-wheeling.
3. Engine is overheating (heat may be
transferred from radiator to A/C
condenser. High underhood
temperatures due to engine
overheating may also transfer heat to
A/C components).
4. Some models with certain engines
are equipped with air seals at the
radiator and/or A/C condenser. If these
seals are missing or damaged, not
enough air flow will be pulled through
the radiator and A/C condenser.
INADEQUATE HEATER 1. Has a diagnostic trouble code (DTC)
PERFORMANCE. been set?
THERMOSTAT FAILED IN
OPEN POSITION 2. Coolant level low.
3. Obstructions in heater hose fittings
at engine.
4. Heater hose kinked.
5. Water pump is not pumping water to
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. The accessory
drive belt may also be slipping causing
poor water pump operation.
CORRECTION
1. Remove restriction and/or clean as
necessary. Refer to Radiator Cleaning
in this group.
2. Refer to Viscous Fan Drive for
diagnosis. Repair as necessary.
3. Correct overheating condition. Refer
to text in Group 7, Cooling.
4. Check for missing or damaged air
seals and repair as necessary.
1. Refer to group 25, Emission Control
System and replace thermostat if
necessary.
2. Refer to Testing Cooling System for
Leaks in the manual text. Repair as
necessary.
3. Remove heater hoses at both ends
and check for obstructions. Repair as
necessary.
4. Locate kinked area and repair as
necessary.
5. Refer to Water Pumps in this group.
Repair as necessary. If a slipping belt is
detected, refer to Engine Accessory
Drive Belts in this group. Repair as
necessary.
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CONDITION POSSIBLE CAUSES CORRECTION

HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace
certain drive line components. One or or repair as necessary.
more of these shields may be missing.

2. Engine running hot 2. Preform thermostat, water pump and

3. Cooling fan malfunctioning.
4. Undercoating or other contaminate
applied to cooling or exhaust system.
5. Engine may be running rich causing
the catalytic converter to overheat.
fan test. Repair or replace as
necessary.
3. Refer to Cooling System Fan in this
group for diagnosis. Repair as
necessary
4. Clean as necessary.
5. Refer to the DRB scan tool and the
appropriate Powertrain Diagnostic
Procedures service manual. Repair as
necessary.

POOR DRIVEABILITY 1. For proper driveability, good vehicle
(THERMOSTAT POSSIBLY emissions and for preventing build-up
STUCK OPEN). GAUGE of engine oil sludge, the thermostat
MAY BE READING LOW must be operating properly. Has a
diagnostic trouble code (DTC) been
set?
1. Refer to group 25, Emission Control
System. DTC’s may also be checked
using the DRB scan tool. Refer to the
proper Powertrain Diagnostics
Procedures service manual for
checking the thermostat using the DRB
scan tool. Replace thermostat if
necessary.

STEAM IS COMING FROM
FRONT OF VEHICLE NEAR
GRILL AREA WHEN
WEATHER IS WET, ENGINE
IS WARMED UP AND
RUNNING, AND VEHICLE IS
STATIONARY.
TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. During wet weather, moisture (snow, 1. Occasional steam emitting from this
ice or rain condensation) on the area is normal. No repair is necessary.
radiator will evaporate when the
thermostat opens. This opening allows
heated water into the radiator. When
the moisture contacts the hot radiator,
steam may be emitted. This usually
occurs in cold weather with no fan or
airflow to blow it away.

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.
1. Refer to Coolant in this group for
antifreeze tests. Adjust antifreeze-to-
water ratio as necessary.

COOLANT LEVEL 1. Level changes are to be expected 1. A normal condition. No repair is

CHANGES IN COOLANT as coolant volume fluctuates with necessary.
RESERVE/OVERFLOW engine temperature. If the level in the
TANK. TEMPERATURE tank was between the FULL and ADD
GAUGE IS IN NORMAL marks at normal engine operating
RANGE temperature, the level should return to
within that range after operation at
elevated temperatures.
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Í-ò$ÏjõRÞ_å$æ/ÑÞ_ß6àÔ1ßlß6à/Þ_Ô Ò Ñ7ãáÜ/Ý1Òß0Ò áÜÞÑ7Í-Ò äDÞë æ/Ò â)â)Þ
Ý¥ÏaÒ å ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
ß0æ/ÑÜ/Þ
Ýá
ä-ä-Ö SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
WARNING: USE EXTREME CAUTION WHEN THE
IS HOT AND/OR UNDER PRESSURE.
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR y z{.|+{~}&L€~€{;{.‚„ƒ"~|+{.…B5†D{~ƒ"z{~|+‡‚}&‡ƒ5;|‰ˆ+‡Š
@
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO ‹tŒŽ‹l‘ ;|ƒ"z{ ‘ ;’:’&5“m}&€”OŠ•|+Š. {.f–
NOT WEAR LOOSE CLOTHING.
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ÑÔ ß6ÞgÔ1߁ç ö ñ1ñ¾Ñâ)Ù,Ö
ü ß0à/Ò Ü.ß6Þ
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Ò
ß0à/ÞÝ)Ò Ô Ó3ß6àÞÑÙ,á
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ô3Ô1ÜÝ)ÑÒ ì#Þ,þ)
ÿ /þþ)
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Ü 1ö ðhß0áT× ò1ðhó¾Í]Î$û ò1ð;ß6áƒÎ$× ò1ð;ô)Ï] Ö
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ä-Ó á6êÜ/á
Òå$Þ>Í-ÑáÔ ÑÒ Ü/ï]Ï] Ö Ià/Þjß0Ò Ù,Ò Ü/ïkÓ Ò ïàßUÔ Ó å(áUêUÒ Ó ÓaÒ Ü/Ý)Ò Ø
ãÔ ß0Þ;Ô ÜkÒ Ü/ãÑÞÔ å$Þ;Ò Ükß0à/Þ?å(â)Þ
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å,× ×1ð9ótÍ]Î$ý ñ1ð
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Þß0֍ôNÔ ÜeÝ1ÑÒ ì# Þ þ)
ÿ /þ
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ÿ 7å(àáæ/Ó Ý.à/Ô(ìoÞ,å$ß0Ô1Ñß0Þ
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Ü ò  ðaß0á
× ç ðhó¾Í”Î$Õ1ò ð;ß0áƒÎ$× ñ1ð;ô1Ï]Ö {Ý1Þä-Ò Ü/Ò ß0! Þ 3 þ uþ 
þYá
ä_ä-Ô Ü
ä-Ó á6êúÜáÒ å(Þ!ÍÑáÔ ÑÒ Ü/ïÏKå$à/áæ/Ó Ý>é Þ!Ü/áß0Ò ãÞÝ)ÖNîäÜ/á"ß ŠÑ]Þâ)Ó Ô ãÞ
ß0à/Þ?Ý)ÞäÞãß0Ò ì#Þ9ì#Ò å$ãáæ/åUä-Ô ÜkÝ)ÑÒ ì#Þ?æ/ÜÒß0Ö

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
Fig. 13 Radiator Pressure Cap
blade assembly if any of these conditions are —˜™ yqˆ+z{;ˆ+š\‡€‚V‡‚I›;• ƒ‡€ƒ5} ‘ |{.{.œt{ ‘ |+{.{;œt{0Š.}&€ƒ"
found. Also inspect water pump bearing and shaft —ž ™ yq|+{ ‘ }&’:’vIŸFfƒ"{.… “m}&ƒ5zZ€{5“¡‡€ƒ"} ‘ |+{;{.œt{.
assembly for any related damage due to a viscous —¢ ™V£ .|ˆ.€‚•ˆ+ƒ5}&€”O {.|E†D}&ˆ+{qŠ|.ˆ+{.‚•|+{. 
fan drive malfunction. —¤ ™B¥ z{.€Zˆ+z{.ˆ+š?}&€” ‘ ;|@†D‡ˆ+••…¦’&{.‡š?f
ÔGÕ ÖØ×MאÙ6Ú ÛMܘÝÞØÝØß
àÐá âŠãPä6å

æÓçèêé“ë“ì“íLçí³èêë“æeîEïEíEîLç$ëéað§ñêò‹ó‹ô8õyó‹ö‹÷‹ø‹ù

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, cooling system problems. A pressure cap that does
WAIT AT LEAST 15 MINUTES BEFORE REMOVING not have a history of coolant loss should not be
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR replaced just because it leaks slowly when tested
UPPER HOSE TO CHECK IF SYSTEM IS UNDER with this tool. Add water to tool. Turn tool upside
PRESSURE. PLACE A RAG OVER THE CAP AND down and recheck pressure cap to confirm that cap
WITHOUT PUSHING DOWN, ROTATE CAP needs replacement.
COUNTER-CLOCKWISE TO THE FIRST STOP.
ALLOW FLUID TO ESCAPE THROUGH OVERFLOW 
  
HOSE INTO COOLANT RESERVE/OVERFLOW RÞ&â äØæ&æ þãÞ&çâfÙÒ.Ö+ßBß"åÒ\ÙÛ+Ò.â âfäÛÒqÕDØæ ÕDÒènØâ ìÒ;ßBÔ.ç×ß"åÒ
TANK. SQUEEZE RADIATOR UPPER HOSE TO +Ö ØÙàBÑvÒ.Ùæ&ØÖ+Ò×Ö+ØÙ³Þ&ÚOß5åÒ×ènØâfì?Ò.ßÞ&âwâIíÔ.æ&æ&Ò.ç
ß"Ô.Û+ç Ô.Û
DETERMINE WHEN PRESSURE HAS BEEN ímÔ;Û+çà ÿ5çâfÙÒ.Ö+ß[ß"åÒØÛ+Ò.ØqØÛ+Ô.äçÝ<Û+ØÝÞ&Øß"Ô.ÛÚÞ&æ&æ:Ò;ÛçÒ.Ö+ì©Ú:Ô.Û
RELEASED. WHEN COOLANT AND STEAM STOP ímåÞ:ß"ÒqÝÒ.ÙÔ.â Þ:ß"âmß"åØßÞ&çÝÞ&Ö+Øß5ÒqØdæ&Ò;Øì?Þ&çèOÖ+ØÙà
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY. COOLANT—LOW æRÞ&ç9Û+ØÝAERATION
ÿHÚß5åÒdÖ+Ô.Ô;æ:Øçßæ&Ò5ÕDÒ.LEVEL Þ&Øß"Ô.ÛqÝÛ+Ô.Ùâ<ëÒ;æ&ÔHí ß"Ô.Ù$Ô.Ú
Û+ØÝÞ&Øß5Ô;ÛÖ+Ô;Û+Òqß5äëÒ;â
ØÞ&Û[ímÞ&æ&æSÒ.çß"Ò.Û¾Ö+Ô.Ô;æ&Þ:çè©âþDâ ß5Ò;ÓBà
Ô5í‰Ö+Ô.Ô;æ:Øçß æ:Ò5ÕDÒ;æ
Ö+ØçdÖ+ØäâfÒß"åÒ.ÛÓBÔ.â ß5Øß[ÙÒ;æ&æ:Ò;ß[ß"ÔëÒ
ÑvÒ.ÓBÔ5ÕDÒ×Ö+ØCAP—PRESSURE
RADIATOR TESTING
Ù Ú:Û+Ô.ÓÜÛØÝÞ:Øß"Ô.ÛIàBávÒã â äÛ+Ò×ß5åØß\â Ò.Øæ&Þ&çè âfäâfÙÒ;çÝÒ;ÝUÞ&ç9ØÞ:Û0Þ&çâfß"Ò;ØÝ2Ô.ÚéÖ+Ô;Ô.æ&Øçß"àù@åÞ:â¾íÞ:æ&æÖØäâfÒ
â äÛ+ÚØÖ+Ò.âéØÛ+ÒÖæ:Ò;Øçà ê<Ô.Þ&â ß5Ò;çVÛäëëÒ;ÛéèoØâfì?Ò.ßíÞ&ß5åmímØß"Ò.Û ß"åÒ.Û+ÓBÔ;âfß"Øß ß"Ô¾Ô;ÙÒ;ç©æ&Øß"Ò.Û
ímåÞ&Ö+å©Þ&ç©ß"äÛ+ç©Ö+Øäâ Ò.âåÞ&ènåÒ;Û
ØçÝUÞ&çâ ß"Øæ&æß"åÒÖ+ØÙ2Ô.ç)ÙÛ+Ò.â âfäÛ+ÒVß"Ò.âfß"Ò;Û<îß"Ô.Ô;æéïïðð$Ô.Û Ö+Ô;Ô.æ&Øçß©ß"Ò.ÓmÙÒ.Û+Øß"äÛ+Ò.à éÞ&Û\ß5ÛØÙÙÒ.ÝãÞ:çøÖ+Ô.Ô;æ:Þ&çè9âIþFâfß"Ò.Ó
Øç!Ò;ñäÞ ÕDØæ&Ò.çßóòlîôÞ&èoàÅõ öfòeà Øæ&âfÔ©Û+Ò;ÝäÖ+Ò;â0ØÓBÔ.äçß¾Ô.ÚRÖ+Ô.Ô.æ&ØçßlÖ+Þ&Û+Ö+äæ&Øß"Þ&çèÞ&çUåÒ;Øß"Ò.Û
Ö+Ô;Û+Ò0Û+Ò;âfäæ:ß"Þ&çèOÞ&ç!æ&ÔHí~åÒ;ØßÔ.äß"Ùäß"à

COOLING SYSTEM DEAERATION

!#"$%'&()*,+-/.0+-213+)"4*5*,+-(6(6879"4;:,&8&<4"4!
=1>?@A!B+-C%*,ED768*FC%G*,+-76"4+-&*F:,+-(6H2IG%KJ0"4@L
'8!B"4"4&8(68*,+)876.MC%*,@L+-<NKJ>(6+-/"$&8;&8OP:,&8&<4+-

Q "4<4<()D?;+-21R*,+)()(679+-"4*5(6+-?*,+-76"4+-&*5:,+-(S"4&'

:,&8&<4+-*,/*UTCV=&KT8*,O<4& Q +)%W%HMX8*,'"4/:,+-(6L&'
+-C@L&8?()*,Y"4&ZYC+-W[H\]8^Y!#"$%Z:,&8&<4
76& Q ;:,&&8<4+)%C.M"4 Q "4<4<N_-76*,+ Q ;O$*,&@`C*,8?8*UTKV
&KT>*,O$<$& Q +-Wa"4C&bc*d+)7)"$+-&*e&b*,(6<4+-:,b+)1
*,8@L&KT87f+-"4*=H

SERVICE PROCEDURES
COOLANT LEVEL—ROUTINE CHECK
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
gPh%ikj,l8lm4n-opZq,ir/iqUs>iKt=lKs>iq,u$m$lCvwryxr/pCi8z|{6q,lCs}4~6i8rn

Fig. 14 Pressure Testing Radiator Pressure €- }4j,‚ƒs>}$r  n-m„zLiphl~u$lq…~6i8pCi8q,zL}4o}4o†‡j,l8lm4n-op3m4iKs>im
Cap—Typical v5}4phl  pFq,i8zLlKs>}$o%†q,n-~6}4n)pl8q{6q,ir/r  qdiLj,n-{6ˆ)‰;}4phfio%†B}4oi
÷ ÙÒ;Û+Øß5Òwß5åÒ9ß"Ò;âfß"Ò.Û!ÙäÓBÙøØçÝøÔ;ëâfÒ.ÛÕDÒ9ß"åÒ9ènØäèoÒ }4~6m4}4o†Šn-o~fn-po%lq,zLn-m‹l{6i8q,n-pC}4o†Špiz5{6iq,n-p  q,iŒl8)r/iqUs>i
ÙÔ;Þ&çß5Ò;ÛjØß@Þ&ß"â¾åÞ&ènåÒ.â ß@ÙÔ;Þ&çß5àù@åÒmÖ+ØÙOÛ+Ò.æ&Ò.Øâ ÒmÙÛ+Ò.â âfäÛ+Ò j,l8lm4n-op9m4iKs>im}$oŽq,i8r?i8qUsiCtlCsi8q,um4lKvpn-o‚[ˆghi‘j,l8lm4n-op
â åÔ.äæ&ÝUëÒúûUß"Ô9õfüö2ì?ýØ2îõ ü2ß"Ô)õ ú2Ùâ Þ òeà
ù@åÒÖ+ØÙwÞ&â m4iKs>im‹r/hl  m$~’-i“)i8p”v•ii8o5–—F—˜n-o~f™š››RzLn-q,‚[r?ˆ
â Øß"Þ&âfÚ:ØÖ+ß"Ô;ÛEþBíåÒ.çOß5åÒ¾ÙÛ+Ò.â âfäÛ+ÒlåÔ;æ&Ýââfß"Ò.ØÝtþuàFÿHßSÞ&âØæ:â Ô
ènÔ;Ô.ÝqÞ:ÚÞ&ß åÔ;æ&ÝâÙÛ+Ò.â âfäÛ+Ò[ímÞ&ß"åÞ&ç©ß"åÒ¾úûTß"ÔOõ üöTìýØTîõ ü
ß"ÔOõ úTÙâfÞ òRÛØçènÒlÚÔ.ÛRûðTâfÒ;Ö+Ô.çÝâéÔ;ÛÅÓBÔ;Û+Ò.àFÿ5Ú
ß"åÒlÙÔ.Þ&çß"Ò.Û COOLANT—ADDING ADDITIONAL
œ9žŸ 2¡6¢Š2£¡„ 2¤¥¦=¤Ÿ§ “¨-¤©3Ÿ§9¤¥¥3¨-ªU¤žŸŸd
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CAUTION: Radiator pressure testing tools are very É-Ê/ÂÉ-ʽLµ Ë>»C̾,°G¹8ð8»C¯2Í>º4°±°8ζBº Í>·,¹º²-±»µ4þ,°°8ÏаG·,¹±»²-µ$±%µ$±%¶

sensitive to small air leaks, which will not cause º4¹KÄ^½5µ$±%°¾,²-º·,¹±»°±»
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SERVICE COOLANT LEVEL

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WARNING: DO NOT OPEN RADIATOR DRAINCOCK

WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
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„ûú‹ü%.-ýCû8üJIKú Fig. 15 Draining Coolant From Block—2.5L/4.0L
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COOLING SYSTEM—DRAINING €†€
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WARNING: DO NOT REMOVE THE CYLINDER ³J¶µ³g´.» ®lÀJ´c±°N±³J´.»H¼e­«2´!ÁSÂg­AªJ·
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BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT COOLING SYSTEM—REVERSE FLUSHING
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REMOVAL AND INSTALLATION
CAUTION: All engines have a reverse (counter-
AUTOMATIC –S—P˜™;š,›c˜@œ6š,8žTRANSMISSION ¡@¡!ž;˜@œCOOLER
›.œ68š,ŸH )™;Ÿ2ŸH™;¡@ša¡@™;ž¢6OIL ž;¡@¢68›c˜@£e¤™›c—,™;š clockwise) rotating water pump. The letter R is
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¥R˜!œ6›c˜@œ )H´5œ6˜!«8¬,™;œ6˜)œ6˜!¢6¡@š,£K™;›.™;¡@šP™šP³j¨¹·‡˜@ª˜@œ›c¡)ÂSœ6¡@¬,®Ã¹Ä PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
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SERIOUS BURNS FROM COOLANT CAN OCCUR.
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WATER PUMP Ò ¸¹™;³j¨ ÄHÝHÓ¨
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NOTE: The engine accessory drive belt must be
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CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
WARNING: CONSTANT TENSION HOSE CLAMPS
rectly. If not, the engine may overheat due to the
ARE USED ON MOST COOLING SYSTEM HOSES.
water pump rotating in the wrong direction. Refer to
WHEN REMOVING OR INSTALLING, USE ONLY
the Belt Removal and Installation in this group for
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
appropriate belt routing. You may also refer to the
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
Belt Routing Label in the vehicle engine compart-
6094) (Fig. 20) SNAP-ON CLAMP TOOL (NUMBER
ment.
HPC-20) MAY BE USED FOR LARGER CLAMPS.
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Fig. 19 Power Steering Pump Attachment

Fig. 20 Hose Clamp Tool–Typical

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Ü9ÐÎÝ1Þ Ô Fig. 21 Clamp Number/Letter Location
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replacement is necessary, use only an original
equipment clamp with matching number or letter.
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Fig. 22 Water Pump Remove/Install—Typical

THERMOSTAT
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Fig. 23 Thermostat Removal/Installation
WARNING: DO NOT LOOSEN THE RADIATOR
€[o‚„ƒ3#%%E#ƒ…€ !
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
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SURIZED. SERIOUS BURNS FROM THE COOLANT
pd7@@A7GIS„iZN;QAB8N†QA:‡7EFB8Q5^B8@7Tˆ>P‰Š<WB8DEQA@M:Ppd58QAF;l3S&L<?B87E:‡GIN7
CAN OCCUR.
')(+*,(.-0/ 1,23-465879;:=<?>?@A7CB8DDE@A<?F;GIHKJILMGON;7C:PDE@A9;GOQADEF 7EFl3QAF;7EH,1,@A@‹GON;7E5^b DE:PGI<?GO:Œ<V5876b <?58{|7ETDEFyGON;76DE9;GO7E5
QA:RB8@A7E<?F;SUTV58<VQAFWGON;7XB8DED@<?F;G!QAF;GODX<YB8@A7E<?FWB8DEF;GO<?QAF;7E5ZL[DE5 L[@A<?F;l37kGODkQAF;TdQAB8<?GI7kGON;7kpd58Dpd7E5
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WARNING: CONSTANT TENSION HOSE CLAMPS N;D9;:=QAF;lqH
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY CAUTION: Tightening the thermostat housing
TOOLS DESIGNED FOR SERVICING THIS TYPE OF unevenly or with the thermostat out of its recess
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER may result in a cracked housing.
6094) (Fig. 20). SNAP-ON CLAMP TOOL (NUMBER
[\ ~P_ -QlqN;GO7EF‡GIN7fN;DE9;:PQAF;lZ>?DE@AGO:MGID m?• *M–—b \^]P~ L[GIH;@A>?:=H _
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GODE58˜?9;7H
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
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ING CONSTANT TENSION CLAMPS.
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CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 21). If
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Fig. 24 Thermostat Recess Å PÇ ã ÒEÓÓ;ÉEÔ8ÍUÌ8Ï?ÐdÑAÏVÍOÒÌ
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WARNING: DO NOT REMOVE THE CYLINDER BLOCK HEATER

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DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
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k lmnporqsutv'wexzy|{oeqs+or}~ v€‚{ƒq„q…†Fig.‚‡sut25vwrxˆy| ~ qxzor‰

Radiator—Remove/Install

Š …'„‹{s+or†GŒwr€†s+…†„‚‡xz}zoŽsŽwLR‘&’ Œ,k l6“&…†‰vt‚‡‰ m”sŽwe}z•€or‰ VISCOUS FAN
k m– …'vv—xzwewrv…†„˜‚f™‚sŽoeŒš›…s+{|xzwewrvq†sŽ‰œB}zoe‚‡‚€}z…žDo
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k ¢mœ v'€!„£ w›oe}¤xzwe}zŸ—…†s+wtv'wexzy¥{orqs+or}f‰¦§wr€s+oxzwr}zŸ
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s+orŒ,xzwrŒ› :wr†oe†s+‚‡‰pnoexz€}zoLxzwe}zŸW…†G :vqxzo-›…s+{¬s+…or«'‚‡s+}zq :‚‡‰

\­ ®!¯#Fig.
°\±p²27³ Block Heater and Cord—4.0L Engine
kˆ“fm´ wrwr‚or†Gt€sµŸ:wL†wesµ}zorŒwŽ¨oLqsµsŽ{!…'‚&s+…Œor©psŽ{oL~ we€}
~ q†{€t¬Œwe€†s+…†„0†€s+‚›k –B…„‹‰"¶·‡m`‰
Fig. 26 Block Heater and Cord—2.5L Engine
 Y‘ ’““:”]• –—N˜#™˜š›bœ WžŸ]

 w¡£¢¤3¥¦w§N¦w¨[©ƒª¨[«£¬¦w§e§e¦)¬­ª¤[¨¯®`°w±e²e³g´F²eµe¶e·e¸

ß àáâ§ãrä›åæãèçézézãeê‡êårëíì£î:ëzï æpãèðãeñòŽóBâ§ãrô ãeëLò+åèõ§ãeñ'ò”öãeëˆ÷

æïézã¥ïø>òŽù!ã¥ú§øûïøãWü#éˆézãrêê‡årë ìýëzï æã¥õ§ãrñò¬êãrézò+ïårø>årô â§ãrô'ãrë ò+å §åråeñï'ø!û˜öìpê‡ò+ãrä çø|ô årë ëzãeäåæpçñ¥çøî
VISCOUSAFAN DRIVE
ò+ùïê›ûëzårþ!ÿ:ó ïøêòŽçññçò+ïårøÿ:ëzåeézãrî:þ!ëzãrê›årôµò+ùã&æïê‡éˆårþê›î:ëzï æpãWþ!øïòŽó
@ B

ß áöpåräãèäåeî:ãrñê ›ïò+ùézãeëzò+çïø ãrøû‹ï'ø!ãrê$äçì£ëzã þïëzã

ò+ùãWëzãräåŽæçñµåeô-òŽù!ãWô çøPêùëzåeþî òŽåWëzãeäåæpãWòŽù!ã#æïê‡ézåeþê

 

eü&ô'òŽãeë)ïøêòŽçññï'ø!ûèç æïê‡ézåeþê&ô çø¬î:ëzï æpã ðëzïøû

C5DFEG H EJILK NM-O D PQ?ILR H D TS)HUWVTXYH[Z Q]\ H D O Q]^

ô çø—î:ëzï æãeó ù!ã¬ô'çø—ê‡ù!ëzårþî£çøîPô'çø¥ðñçîã æïêézårþêWô'çø U

ò+ùãWãrø!ûïøãWêÿ:ãrãeî þÿ ò+åWçÿ:ÿ:ëzå ïäçòŽãeñ ì(à ëˆÿ:ä çø!î
Q `_ 3 Qba 

î:ëzï æpã ê‡ùåeþñî,ðã ëzãeäåæpãrîô ëzåeäšò+ùã(æãeùïézñã çêåeøã
 

ùåeñ'î¤ô årë&çÿÿ:ëzå pï'ä›çò+ãrñ ì ò ›å$äïøþò+ãrêó ùïê ›ïññ"ãeøê‡þ!ëzã

c 16 6 6

çê‡êãräðñ ì‹ó ÿ:ëzåeÿ:ãrëLô ñþïîî:ïê‡ò+ëzïðþò+ï'åeø $ï'ò+ùïøòŽù!ãWîëzï æãró

c d  e

ß áâ§ãrä›åæã ô åeþë¤ô çøùþ!ð(äårþ!øòŽïøû£øþ!òŽêGß ïûó”à á f

çøîRëzãeäåæã#ô çø æïêézårþêNô çø0î:ëzï æã çêê‡ãeäðñ ì¬ô'ëzårä æãeùï÷



 

ézñãró


ß áü&ô ò+ãrë ëzãeäåæpï'ø!û ô çø ðñçî:ã æïê‡ézåeþê ô'çø îëzï æpã

ACCESSORY §årëzëzãeézò£î:ëzï æpã ðãeñò£òŽãeøêï'åeø ïê ëzã þïëzãrîò+å ãrøêþëzã
DRIVE BELT
årÿòŽïäþäÿ:ãrëzô'årëzäçøézã#årô òŽùã#ðãrñò§î:ëzï æãeø0ãrøû‹ïøã çézézãeê‡÷
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çê‡êãräðñ ì $ÿ:ñçézã0ò+ùãeëzäçñ6æïê‡ézåeþêèô çø(î:ëˆï æpã0ïø

 

ùåeëzï Dårøò+çñ—ÿårêï'ò+ïårø!ó Žô¥êòŽåeëzãrî ù!årëzï Dårø!òŽçññ ì êï'ñïézåeøã


ê‡åeëzïãrêó -ùãrëzãYçëzãYî:ïô ô'ãrëzãeøò˜ò ìÿ:ãeê|årô,çî eþ!ê‡ò+äãrøò
ûçþû‹ãrêGô åeë¤ézùãré ¡ïøû£ãrïò+ùãeë0çPê‡ãrëˆÿ:ãrøò+ïøã åeë0ç \÷'ò ìpÿ:ã
h ji

ô ñþïîGïøèæïêézårþê ô çø î:ëzï æã›ézårþñîGî:ëˆçïø ïøò+åïò+êLðãrçëzïøû

   

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7k ml

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n

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8

ý”åøåeòNçññå òŽùãûçþû‹ãèß'årë û‹çþ!ûãèçîçÿòŽãeëíá#ò+åèéˆårøò+çézò

> > 7k

çø ìò+ùïøû0ðþò)ò+ùãRðãeñòŽó



ù!ã$ðãeñ'òµëzåeþò+ï'ø!ûèêézùãeäçò+ïézê&çëˆã$ÿþðñ'ïêùãrîWô ëzåeä ò+ùã

p%q*(`$J"%rseq*t-&*$+ r"

ñçòŽãeê‡ò¤ïøô åeëzäçòŽïåeøuçæçïñçðñãPçò¤ò+ùãPò+ï'äãPåeôÿ:þ!ðñïézç÷



ò+ï'åeøó §ãrùïézñãrê&øåeòµã þïÿ:ÿ:ãeî ›ïò+ù å $ãrë)öpòŽãeãrëzïøûùçæã

çø¥ïî:ñãeëRÿ:þññãŽì ïø—ÿ:ñçézãGåeô)ò+ùãGÿ:å ›ãrëèê‡ò+ãrãeëzïøû ÿ:þäÿ
'l  Y u8 

ÿ:þññãŽì‹ó

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U K  DG E‚K ƒ`{ Q…„†Q]R TZ5*H D |ˆ‡ K*}Q]RŠ‰ H EgQ /{ Q

ñårézçò+ãrîïø£ò+ùãRãrø!ûïøãRézåräÿçëzò+äãeøòŽó

EG { Q U K  DG E  „†Q1R [Z5H D |;‡ K}Q]RŠ‹ 

â§ãrô'ãrë#òŽåß ïûóBà á&ß ï'û‹ó á&çø!î¬ß Bïûó fá&ô åeë ézåeëzëzãrézò

ðãrñò-ëzåeþò+ï'ø!û 6åeë&ëˆãrô ãeë&ò+å$õ§ãrñò-â§åeþò+ï'ø!û Bçðãrñ ñåeézçòŽãeî0ïø

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ò+ùã&æãrù!ï'éˆñ'ãRãeøûïøãRézårä›ÿ:çëzòŽäãeøò+ó

' Ž

Fig. 28 Fan Mount

ß fáü&êê‡ãrä›ðñã ô'çøšðñçî:ã ò+å æïêézårþêƒô çøšî:ëzï æãeó

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/.

ß àá årêï'ò+ïårø>äåeþøò+ï'ø!ûô ñçøûã¥åeôRô çø>ðñçî:ã æïê‡ézåeþê

 103254 6 7

ô çø îëzï æpã£çê‡êãräðñ ìuåeøò+å£ùþðó øêòŽçññ ô årþ!ë¬øþò+ê çøî
98 

ò+ïûùò+ãrø ò+å—à ä ß ô ò+óLñðêó áòŽåeë þãró \ï'û‹ùò+ãrø ò+ùã

:

ô ïëzêòèò ›å øþ!òŽê —îãrûëzãeãrêGçÿçëzò+ó ùãeøòŽïûù!òŽãeøñ'çêò

;254 /.< 7 =

ò ›åRøþò+ê‡ó
> ?.< 6 
>

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 Serpentine
Drive Belt Removal and Installation in this group for
correct belt routing.

Fig. 29 2.5L/4.0L Engines–With A/C

pIq\rs tvuwuyxz {w|/}~v}€‚„ƒ …=†
‡7ˆN‰'Š3‹Œ7/Œ7ŽO‘ŽO’N“wŒ7””ŒK“ŠOŽ–•˜—7™”š”›"œFš””ž”Ÿ” 

Fig. 32 Power Steering Pump Bracket and Idler

Pulley
ò óô<õ7ÈÉÉ Ègõ*ò Æó

Fig. 30 2.5L/4.0L Engines—Without A/C æ/çFè9ö ÙËgâ7ã÷â7ÒÎÖ1ÐÍÐÒÎëÒì=Ô ÌÌeÚ]ØÌÌË äøÏÑå

CAUTION: When installing the serpentine acces-

sory 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 (Fig.
29) (Fig. 30) (Fig. 31) for correct belt routing.
æ
í<è9ù ÎÏ<ÍjÔ1ÌÌúÎË Ûûá ËÌÍjå ù Î*ÏÑÍjÔ ÌÌúá ËÌÍüÍjËÎÏ<ÐÒΈß'Ô ØßË
öLý
þç<ÿ í Ô ÎÖüÍjЍßÙÍjËÎÞÔ Öj×gØ*ÏÑÍjà­ËÎÍmá ÒÌÍ æ
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á ËÌÍLÍËgÎÏÑÐÒgÎmÐÏÛÜЍÍjÙÐÎmÏ<Ú]Ëgâ7ЍìÐâ7Ô1ÍjÐÒÎfÝ7Ô1Î*ß'Ëå LËgì
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CLEANING AND INSPECTION

RADIATOR
†ÐÏ<ØÔ ÌÌ ä ÐÎPRESSURE CAP
ÏÑÚ1Ëâ7Í­ÍjÙË÷Ú1Ý7ËÏ<ÏÑØÝ/Ë3ê#Ô Ì ê#ËJß'Ô Ï<ã*ËgÍ­ÒÎ;ÍjÙË
â7Ô Ú]åLËÚ]ÌÔ â7Ë;â7Ô ÚNÐìmÍÙ*Ë;ß'Ô ÏÑãzËÍJÐÏ~ρÛÜÒÌÌËÎ
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Fig. 31 2.5L/4.0L Engines—Without A/C or P/S
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RADIATOR


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û ôç÷@ð

COOLING SYSTEM ü ð
ý"ôý/ð
ó×þÿDù
úIñ‚
ý J÷ ü ô ü ð
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ý"ôAþ1ÿDù
úIñHý 
97 to 124 kPa (14 to 18 psi) pressure. Exceeding Ú½
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²/«×½ °³(·,¬­ ³6Á·"®¶¬°"­
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³(Á·"®¶'¶!½ ·
this pressure may damage the radiator or hoses. ª«º¬«¶!°"ª7±°Z¼E·ªÕ½
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STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI- BELT TENSION
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800-900 N (180-200 lbs.)
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components could have been damaged due to
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× ß ÐiÍ0ãnÒÑÝ#Ñ ßIß Û:ÕØGà ACCESSORY DRIVE BELT TENSION
BELT TENSION
**NEW SERPENTINE
800-900 N (180-200 lbs.)
BELT
USED SERPENTINE
623-712 N (140-160 lbs.)
BELT
**Belt is considered new if it has been used 15
minutes or less.
Specifications for use with a belt tension gauge. Refer
to operating instructions supplied with gauge.

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SPECIAL TOOLS
COOLING

Cooling System Pressure Tester—7700–A

Hose Clamp Pliers—6094

Quick Disconnect Tool—6935

Belt Tension Gauge —C-4162

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35T7F5F56,:7=EZ tBCT7NO=–H‚BC:7qšrT7VW=ˆ@C6F56GRNOBC356GqDZ
 9OF5VW=?y€q6,=E6GF5r9O:76=E476‚@DBC=E=?6,FIHƒVW=?BC=E6GSL,tS3u47BCF5;P6GZ/o#479OV
35BC:@C6€qL,:76€9O:L,:76€LGt=?4<F56G6/zpBWHMVWZ…„†t=E476€@DBC=E=E6GFIH‡47BCVˆB NOTE: Completely discharged batteries may take
@CT79ONO=?S9:‰=E6GVW=Š9O:7q9O35BC=ELGFgy!JM9O6†z‹=E476]=E6GVx=n9:<q9O35BC=?L,Fƒ=EL several hours to accept a charge. Refer to Battery
q6,=?6,F5r9O:76Œ=E476ŒVW=EBD=E6GSLGtS3547BCF5;P6,Z_„?t=?4<6Œ@CBD=E=E6GFIHn4<BDVŽ:7L Charging - Charging A Completely Discharged Bat-
=E6GVW=9O:7q9O35BC=ELGFgy_@CT7=4<BDVF56GrL?JMBC@DNO63u6GNON35BCRVWy_R6GF5tLGF5r tery in the Service Procedures section of this group
=E4764GHMqF5L,r6G=E6GF‘=?6,Vx=
=ELqD6G=E6GF5r9O:76p=?4<6VW=?BC=E6GSL,tS3547BCF5;P6GZ for more information.
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Battery Diagnosis
Condition Possible Causes
The battery seems weak or 1. The battery has an
dead when attempting to start incorrect size or rating for
the engine. this vehicle.
2. The battery is physically
damaged.
3. The battery terminal
connections are loose or
corroded.
4. The battery is discharged.
5. The electrical system
ignition-off draw is excessive.
6. The battery is faulty.
7. The starting system is
faulty.
8. The charging system is
faulty.
È
ÉÊÊËÌÍ ÎÉÏ
Correction
1. Refer to Battery in the Specifications section of
this group. Replace an incorrect battery with the
correct battery.
2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the battery, if
damaged.
3. Refer to Voltage Drop Test in the Diagnosis
and Testing section of this group. Clean and
tighten the battery terminal connections, if
required.
4. Determine the battery state-of-charge. Refer to
Built-In Test Indicator, Hydrometer Test, or
Open-Circuit Voltage Test in the Diagnosis and
Testing section of this group. Charge the battery,
if required.
5. Refer to Ignition-Off Draw Test in the Diagnosis
and Testing section of this group. Repair the
electrical system, if required.
6. Determine the battery cranking capacity. Refer
to Load Test in the Diagnosis and Testing section
of this group. Replace the battery, if required.
7. Determine if the starting system is performing
to specifications. Refer to Starting System in the
Diagnosis and Testing section of Group 8B -
Starting Systems for more information. Repair the
starting system, if required.
8. Determine if the charging system is performing
to specifications. Refer to Charging System in the
Diagnosis and Testing section of Group 8C -
Charging System for more information. Repair the
charging system, if required.
‰$ŠF‹fŒ ŽŠ$$‘„’„“ ”@•
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Battery Diagnosis
Condition Possible Causes Correction
The battery state-of-charge 1. The battery has an 1. Refer to Battery in the Specifications section of
cannot be maintained. incorrect size or rating for this group. Replace an incorrect battery with the
this vehicle. correct battery.
2. The battery terminal 2. Refer to Voltage Drop Test in the Diagnosis
connections are loose or and Testing section of this group. Clean and
corroded. tighten the battery terminal connections, if
3. The generator drive belt is required.
slipping. 3. Refer to Accessory Drive Belt Diagnosis in the
4. The electrical system Diagnosis and Testing section of Group 7 -
ignition-off draw is excessive. Cooling System for more information. Replace or
5. The battery is faulty. adjust the generator drive belt, if required.
6. The starting system is 4. Refer to Ignition-Off Draw Test in the Diagnosis
faulty. and Testing section of this group. Repair the
7. The charging system is electrical system, if required.
faulty. 5. Determine the battery cranking capacity. Refer
8. Electrical loads exceed the to Load Test in the Diagnosis and Testing section
output of the charging of this group. Replace the battery, if required.
system. 6. Determine if the starting system is performing
9. Slow driving or prolonged to specifications. Refer to Starting System in the
idling with high-amperage Diagnosis and Testing section of Group 8B -
draw systems in use. Starting Systems for more information. Repair the
starting system, if required.
7. Determine if the charging system is performing
to specifications. Refer to Charging System in the
Diagnosis and Testing section of Group 8C -
Charging System for more information. Repair the
charging system, if required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.
The battery will not accept a 1. The battery is faulty. 1. Refer to Battery Charging in the Service
charge. Procedures section of this group. Replace the
faulty battery, if required.

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MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT 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.
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ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
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SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
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CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
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PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT Fig. 4 Hydrometer - Typical
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WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND Fig. 5 Testing Open-Circuit Voltage - Typical
AROUND THE BATTERY. DO NOT SMOKE, USE SvðWð
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THE EVENT OF CONTACT, FLUSH WITH WATER
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OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV- Open Circuit Volts Charge Percentage
ABLE CELL CAPS, BE CERTAIN THAT EACH OF 11.7 volts or less 0%
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE 12.0 volts 25%
THE BATTERY IS RETURNED TO SERVICE. PER-
12.2 volts 50%
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS. 12.4 volts 75%
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WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
Fig. 7 Volt-Ammeter-Load Tester Connections -
THE EVENT OF CONTACT, FLUSH WITH WATER
Typical
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT Ò$î2Ô À¬µG½
µCªcµG¶ ªcº,¬½
°X¯.¬² µG­.¬º0àŒ² ¬¾ Ò ¯.½
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• IF THE BATTERY IS EQUIPPED WITH REMOV- «$±_«$µGªª²Ñ·2ª¯.¬² °·2¸pµC¶"ª²Ñ­.ªµGÐ ­.²ÑµG¶ ªU¯.¬² µG­.¬ºìà"² ¬¾yµC¬UµG¶ ª
ABLE CELL CAPS, BE CERTAIN THAT EACH OF ñ «,«®¬·D±_µG±_¬² Ò,Ü ±_³k¿;ò Ô ¿BÖp¶ ±_·Y´;±_º_ºc­.ª¹5¬ Î ª7µC¶"ªÑ·2Ð ­.«$½
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THE CELL CAPS IS IN PLACE AND TIGHT BEFORE ¯.¶ ½
­.³kªc«,­.¬¹óµC¶ ªc¾
½
µCµGª­h»=¿
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
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Fig. 6 Volt-Ammeter-Load Tester - Typical
Ã~Ä Å ÆÇÇ>ÈÉÊ ËÆÌÍÍ
ÎÏÐÑÒÓÔÏÔÐÒÎ!Õ#Ö#Ô#ÕÏ$Ò%Ñ'×)ØÙ,Ú,Û/Ü0Ú,Ý,Þ,ß,à

CHARGE. THE BATTERY MAY ARC INTERNALLY

AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT 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.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
Fig. 9 Load 50% CCA Rating - Note Voltage - Typical ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
Load Test Temperature
THE BATTERY IS RETURNED TO SERVICE. PER-
Temperature SONAL INJURY AND/OR VEHICLE DAMAGE MAY
Minimum Voltage
°F °C RESULT FROM LOOSE OR MISSING CELL CAPS.
9.6 volts 70° and above 21° and above ‚ ?RA‘;$EIGVGVE<YgO$PRQ¢E/fAIJpLN=@OVEIP‘YSOVGVG“JKA/£NbBOVJKA…LmC_EIGV=@HAI=@AIJ
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=@AIU8=ZU8`WTA%tKAIJp=ZLTOVP=Z?BA%;$EIGVGVE<YSOVPBQ’fNJKEItKA/MbBJKA/ULTJKA%LNtKtpEIH‹
9.4 volts 50° 10° fGVOVUa?RAIM©
9.3 volts 40° 4° ‚ ?BAsWNLT=@=ZA/Jdc†O$Uƒ;$bBGVG c_‹tK?BLTJKQ„A/M]~ª¨A/;A/JŸ=@E« ˜B¬)¬pœ­)®
9.1 volts 30° -1° ¯ž° •˜R­”±R²¦³± OVP…=Z?BAe´FA/JdCFOVtKAŸµ{JKEItKA/MbBJKA/UŒUaA/tK=@O$E/P…EI;~=@?BOVU
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8.9 volts 20° -7°
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8.7 volts 10° -12° • 9<;e=@?BACFA/?BOVtKGVA¢OVU‘AI£TbBOVffA/MŠYSOV=Z?·LTP·LTbB=ZE/HLT=ZOVt
8.5 volts 0° -18° =@JKLN•PRUaHOVU8UaOVEIPR` fGVLNtpAS=@?BAgQ„A/LNJKU8?BOV;=¸U8AIGVAItK=@EIJXGVA<CFA/J OVP:=@?BA
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u vBw$xKy{zR|~}BRvB€#xR|/8x
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=@OVEIPBU:EIJŒ=@?BAƒWTLN=@=@AIJdctKLTWNGVA/Ua]Ž?BAIP‘fAIJK;$EIJKHOVPBQs=@?BAIU8A
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WTLT=Z=@AIJdcsfEIU8OV=ZO CFA%tKLTWNGVA%tKG$LTHfŸLTPBMe=Z?BA%tKLTWNGVA%tKEIPBPBA/tK=@EIJ
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=@O C_AG$A/LTME/;>=@?BA,CFE/G$=@HAI=@A/Jž=@E~=@?BAWTLN=@=@AIJdc’fE/UaOV=@O C_AtKLNWTGVA
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WARNING: tKLTWTG$AtKGVLTHf:LNPRMe=@?BA=@AIJKHOVPBLTG,fNEIUa=@]
• IF THE BATTERY SHOWS SIGNS OF FREEZ- 5Â87:l¨EIPRPBAItK=X=@?BA CFE/G$=@HA/=ZA/Jg=@EHAILTUabBJpA%WTA/=•YSA/AIPƒ=Z?RA
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- WTLT=Z=@AIJdc¢fE/UaOV=@O CFA=ZA/JKHOVPBLTGfEIU8=%LTPBM‰=Z?BAU8=ZLTJK=@AIJŒUaE/G$A/‹
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR PBE/O$M’WTLT=Z=@AIJc=@AIJpHO$PRLNGiUa=@bBM’5o{O$Q”]j8h87p]>ª¨E/=ZLT=@ALTPBMŒ?REIGVM
>@?BA%C@D EF?@G@GIH@JK LM

NPOQSR7T7U7VWOVXQST7NZY\[\V\YWOT]R_^a`Sb$c$defc$g$h$i$j

Fig. 12 Test Battery Positive Cable Resistance -

Typical
Fig. 10 Test Battery Negative Connection
Resistance - Typical

Fig. 13 Test Ground Circuit Resistance - Typical

@á çŸáréSã/æBárû)"ö$ä òFãeôäVó$óVäVìTôîã/íKãIè þ øTï øTø+*qáZçeøTï øTù+*qìNôîNãIíKã
éSäVá@â¡á@âBãŒäVå„æRä$á@äVçIæmè¦égäVáZêKâmäVæmáZâBãŒðööXîçIè8äVáZäVç/æBú¸ìTæB÷qìTóVó
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k Œ;u7z|6‘%yz|r\k€-l|¥æ€
n+Žu7rt7€ ušur®rt„u RESULT FROM LOOSE OR MISSING CELL CAPS.
Æ7Ç<ÈcÉ7Ê ËyÇ7Ì7ÌuÍ7ÎvÏ Ð[Ñ
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CAUTION:
• Always disconnect and isolate the battery neg-
ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
• Battery electrolyte will bubble inside the bat-
tery case during normal battery charging. Electro-
lyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
• The battery should not be hot to the touch. If
the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing Fig. 14 Voltmeter Accurate to 1/10 Volt Connected -
the charging operation. Damage to the battery may
§ sB¨N„‡4>1B),CDC-),#n!"CD8±4>1B=>!"#$Œ#%+D’"!"#%#$&('²C-/W!"#%4 hA
Typical
result.
 "!"#$#%&('*),+-!.&,/0&,1!"&, 2.3-465.578:9;46#%+<57=>!"&,4>#?'A@ ),!""=6GK‰zCDCD),# #$+Di"!"#$#%&'X),+-!.&,/0&
=>!"871BGKAi"!.#%@
1BCD1B46C-/E)F46&,),3-46#%&('HGJIK+D4>1L),46&F),3D4>#$&('M57&,#%),#%1L#$+-N),+-!.&,/0& #%&('*),+D!"&,/0&,1!"&, 2"3D4>575.8:9Y4>#%+<57=>!"&,4>#w'@1BCD1B46C-/q),46&@
!"CD8POQ&N#%+DR"!"#$#%&('TS6&,U"4>CD/V87!"!"/W8X4>SY#%+D$'T!"&, ),3D4>#%&('0GDIc+D4>1:),4>&,),3D4>#%&('³57&F#%),#%1:#$+DL),+D!"&,/0&!"CD8]O%&#%+D
4>57&,57&,= 'T),CDC-),#%87G[Z\SY#$+-*"!"#$#%&('T1]#%!"#$@S@),+D!"&,/0 "!"#$#%&('“S&,­"4>CD/*87!"!"/W8M4>S;#%+D$'m!"&,E4>57&,57&,= '
4>1Y#%
=>$9^S& #%+D
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#%+D<),+-!.&,/0&Y9Y4>=>=aCD#
5.&,!"#%GbIc+-461N!"d-1e4>#
!.5.57!"& #%+DR57=>!"&,4>#w'@1BCD1B46C-/†),4>&,),3D4>#%&('T#$R87#$),#%`[#$+-*),+D!"&,/0&
#%+D!"#f#$+D "!"#$#%&':9;46=>=gCD#f!"),),5.#K)F+D!"&,/W4>CD/),3D&,&,C-#$GA 9Y4>=>=KCD#[57&,!"#%GIK+D4>1
!"dv1:4>#a!"575.!"&#%+D!"#a#%+DL"!.#%@
#%+D:4>CD1]#%&,3D),#%4>CD1 57&,\h4>878iB'<#$+-:!.C-3DS!"),#%3D&,&aS#%+D #%&(';9Y4>=6=yC-#z!.)F),57#z),+D!"&,/046C-/Y),3D&,&,CD#%GDAa#%+Da4>CD1B#%&,3D),@
"!"#$#%&('j),+D!"&,/W&XS&X87#%!.4>=>1kC^+-\9l#$mB'A57!"1B1n#%+D #%46CD1V5.&,\h468.8TB'¬#%+DM!"CD3-S!"),#$3-&,&RS #$+D†"!.#%#%&('
57=>!.&,4>#?'A@61]C-1]4>CD/_),4>&,),3D4>#%&('0G ),+D!"&,/W&RS6&<87#%!"46=>1*C‘+D$9´#%†B'A57!"1]1*#%+D†57=6!"&,4>#?'A@
opS#%&[#%+D"!.#%#%&('E+D!"1 "Ce),+D!"&,/W8q#$NrBs"G t h=>#$1a& 1]CD1B46C-/q),4>&,),3-46#%&('HG
/W&,!"#$&Q`u5.&,S&,^!q=>!"8i#$1]##%:87#$&,4>CD:#$+-
"!"#%#$&(' §µ ¨N¶z!"#$#%&'E),+D!"&,/0&,1fhA!"&('…4>Ce#%+DY!"3DCD#cSh=>#%!"/W
),&,!"CDdv4>CD/:),!"57!"),4>#w'HGyxzS&{#%;|z}D~DL€z7‚ƒ4>CN#%+D;„c46!"/WC-@ !"CD8U),3D&,&,CD#Œ#%+D$'·57&,$hA4>87G<IK+D®!"3DC-#ŒS‹#%4>
1B461N!"CD8…Ig1]#%4>CD/V1B),#%4>CnS;#%+D4>1e/0&,3D5†S&i#%+DE57&,),@ &,2"3D4>&,8*S6&
!<"!.#%#%&('M#%i!.),),57#;!.1B3D&,!""=>N)F+D!"&,/W&
873-&,1BGKZ\S#$+Dq.!"#%#%&('…9;46=>=‡CD8.3D&,i!E=>!"8R#%1]#%`f&,#%3D&,C ),3D&,&,CD#!.#hA!"&,4>3D1;hA=6#%!"/W1i4>1i1B+D\9YCM46CX#%+D…‰z+-!.&F/W
#%+De"!"#$#%&('X#$e3-1]GcZ\S[#%+De"!"#%#$&('<9Y4>=>=pC-#CD873D&Fe! xz!"#$:),+D!"&,#$GuZ\S#$+-
),+D!"&,/W:),3D&,&,CD#{4>1Y1B#%46=>=zCD#{!.1B3D&@
=>!"8N#$1]#%`ˆ4>#{4>1YS!"3D=>#?'*!"CD8N3D1B#{" &F57=>!"),8.G !""=6i!"#;#%+DiCD8RS{#%+Di),+D!"&,/W4>CD/…#%4>`f#$+-i.!"#%#$&('M4>1
‰z=>!"CŠ!"CD8‹4>CD1B57),#e#%+DX"!"#$#%&('Œ+D=68T87\9;CD1]`#%&,!B'0` S!"3D=>#?'<!"CD8i3-1]#‡.&,5.=6!"),87GgZ\S#%+D),+D!"&,/W),3D&,&,C-#4>1
#%&,4>CD!"=>1]`{571]#%1]`{!"CD8M#%5M"S&,E),5.=6#$4>CD/*1]&(hA4>),G !"1B3D&,!""=6“8.3D&,4>CD/‹#%+D“),+D!"&,/W4>CD/‹#%4>` #$+-“.!"#%#%&('
xzS6&R#$Mc~DƒFƒ7Ž46C‘#%+DMxz$hA!"= !"CD8TZ\CD1B#$!"=>=>!.#%4>C !B'i"[/W8
!"CD8:#$+-a),+D!"&,/046C-/Y1B+D3D=>8:.[),Y57=>#%8:46C
1B),#%4>C’SN#$+D4>1X/W&F3D5ŠS&M#%+D“57&,5.&†),=6!"CD4>CD/‹!.C-8 #%+D
CD&,!"=Y!.CDC-&QG
4>CD1B57),#%4>CE57&,),873-&,1BG Charge Rate
”K•A–c—A˜[™šA˜k–*”g›[œLJž-Ÿ ˆŸ-ž%¡m¢™ £J”c•A–K—A˜[Ÿ-¢ Voltage Hours
¤ –- - ˆŸ-—D¡ 16.0 volts maximum up to 4 hours
Ic+- S6=>=>\9Y4>CD/Y57&,),873-&, 1B+D3-=68
" 3D1B8
#$a&,),+-!.&,/0
!X),5.=6#%= '¥874>1B),+D!"&,/W8n"!.#%#%&('HGa¦pCD=>1B1<#%+D4>1E57&,)F@ 14.0 to 15.9 volts up to 8 hours

873-&,“461X5.&,57&,= '^S=>=>\9;87` !‘/08Š"!"#$#%&'j!B'^" 13.9 volts or less up to 16 hours

CD87=>1]1B= 'R&,57=>!"),87G ”K•A–c—A˜[™šA˜k ˆ™6œLŸe—Ÿ¸[¹™—Ÿ-¢
§ r¨N©L!"1]3D&Fa#$+-fhA=>#%!"/Wa!"##%+Da"!"#%#$&('i571B#%1b9Y4>#%+_! Ic+-V#%46YV&,2.3D4>&,8n#%V),+D!"&,/0V!X"!.#%#%&('†9Y4>=>=h!.&'0`
hA=>#$#$&Q`y!"),),3-&,!.#%;#$qrO]rBª § ª"GQrBª]¨ˆhA=># §« 46/0GfrBtB¨FGyZ\Sˆ#%+D 8757C-874>CD/_3D57C<#%+D
S=6=>$9Y4>CD/_S!"),#$&,1]º
&,!.8.46C-/ 4>1a.=>\9’#%C:hA=6#%1B`J#$+DY),+D!"&,/0),3D&,&FCD#g9Y4>=>=ˆ" c~DƒFƒ7Ž^»‡~D¼J~D½"¾Qƒ^@co¿),Y57=>#%= '‘874>1]),+D!"&,/08
=>\9‡GEZ\#n),3D=>8#$!"dvŒ1]Œ#%46Œ"S&,¬#$+DŒ"!"#%#$&(' +D•!]h0'A@8.3D#?'†"!.#%#%&('³&,2"3D4>&,1
#w9;4>),q#%+Dq),+-!.&F/W4>CD/e#%4>
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JK LNM O OQPSRST U MWV X Y
Z:[:\]_^`a[cb:\ade`a[:fage\h[:Zji`ak%l%mnol%p%q%r%s
å%æç(èHégå%êDæYë,ìDç,ç,æí-å‡î"ë,ë,æï.å$æðqñBèEå%êDæñ"î.å%å%æç(è ò;ó>ô6ôˆñ"æõAæç(è
ô>ö\ò°î"å
÷6ó6çFø]å%ùyúpøiå%êDæEñ"î"å%å$æç(è*ò;î.ç,ûYø]éó>å{òYó>ô>ô[î.ëFë,æï7å:î
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øBìD•ï7ï7ô>ó>
ÿæø‘  k÷ó
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öíDô è° 
î"û ï7
æç,æ øXò;ó6ô>ô*ç,æ "ìDó>ç,æŒîô>öí-üWæç
ë,êDî"ç,ü0ó6í-ü å$ó>ûæùRú ñ"î"å$å%æçè ë,êDî"ç,üWæç®å$êDî"åjø]ìDï.ï7ô>ó6æø
å?òYæí-åwèNî"ûï7æç,æø[öç{ûöç,æcò;ó6ô>ôgç,æ .ì-ó6çFæ;î
øBêDöç,å%æçë,êDî"ç,ü 
ó>íDü_å$ó>ûæù
ú ë,öûï7ô>æå%æô è ð7ó>ø]ë,êDî"ç,ü0æð
ñ"î"•å$å%æç(èEç,æ " ìDó>ç,æø ÿ ûöç,!æ
ë,êDî" ç,üWó>íDüLå%ó>ûæ:å%êDî"í…îqï7î"ç,å%ó>î"ô6ô è
ð7ó>øBë,êDî"ç,üWæð†ñ"î"å%å$æç(è0
ù "zô>æë,å%ç,öô èå$æ…ó>øiíDæî"ç,ô ènï7ìDç,æ
ò;î.å%æç
ó>í°î±ë,öûYï7ô>æå%æô è ð7ó>ø]ë,ê-î.çFüWæð¿ñ"î"å$å%æç(èHù:úpåm÷6ó6ç,øBå%é*å%êDæ
ë,êDî"ç,ü0ó6í-üië,ìDç,ç,æíDåpýî"ûï7æçFî.ü0æ\þcò;ó6ô>ôfñ"æLô>ö$òù"úpø:å%êDæ ñ.î"å 
å%æç(èŠëFêDî"ç,üWæøBé;å$ê-æ†ø]ï.æë,ó>÷ó>ë<ü0ç,î]õó>åwèŠö÷ å%êDæ†æô>æë,å%ç,öô èAå%æ Fig. 15 Remove Battery Cable Terminal Clamp -

òYó>ô>ôü0ç,î.ð.ìDî"ô6ô èRç,ó>ø]æù Typical

ë,ô>æî"íDó>íDü
ø]öô>ìDå%ó>öíeý9gó>üWùA-<BBþFù>zæï.ô6î"ë,æYî.íHè…ñ"î.å%å%æç(èEë,î"ñ"ô>æ
å%êDî"å{êDî"øYð7î"ûî.ü0æðNöç ð7æ÷öç,ûæðNå$æç,ûó>íDî"ôë,ô>î.ûï.ø]ù
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1° C or 30° F) BAT-
TERY. THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.

Battery Charging Timetable

Charging 5 10 20
Amperage Amperes Amperes Amperes
Open
Circuit Hours Charging at 21° C (70° F)
Voltage
12.25 to 6 hours 3 hours 1.5 hours
12.49
12.00 to 10 hours 5 hours 2.5 hours
12.24
10.00 to 14 hours 7 hours 3.5 hours
11.99
*Below 18 hours 9 hours 4.5 hours
10.00
*Refer to Charging A Completely Discharged Battery
Fig. 16 Clean Battery Cable Terminal Clamp -
Typical
REMOVAL AND INSTALLATION
WARNING: WEAR A SUITABLE PAIR OF RUBBER
BATTERY GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
#%$&('%)+* , GLASSES SHOULD ALSO BE WORN. IF THE BAT-
ý- þ/ˆ. ì-ç,íeå%êDæó>ü0íDó>å$ó>öíNøQò;ó6å%ë,êeå%öå%êDæ10‡÷÷bï7öø]ó>å$ó>öíDù2zæ
ë,æç,å$î"ó>í<å%êDî"å{î"ô>ôæô>æë,å$ç,ó>ë,î"ôî"ë,ë,æø]øBöç,ó>æøYî"ç,æ
å%ìDç,íDæðeö÷÷ù
4ý 3B6 þ 5JööøBæí†å$ê-æeñ"î"å$å%æçèkë,î"ñ"ô6æNå%æç,ûó>íDî"ô{ë,ô>î"ûï7ø_î"íDð
ð7ó>øBë,öíDí-æë,åfñ.öå$êqñ.î"å%å$æç(èeë,î"ñ"ô>æø]éAíDæüWî"å%ó õæ;ë,î"ñ"ô>æ;÷ó>ç,øBå$8ù 7\÷
íDæë,æøBø]î"ç(èHéXìDøBæ±î²ï7ìDô>ô>æç å%ö¿çFæûö\õæ±å$ê-æ±å$æç,ûó>íDî"ô
ë,ô>î"ûï7øY÷ç,öûå%êDæ
ñ"î.å%å%æç(èRï7öø]å%øY4ý 9Jó6ü0:ù -<;BþFù
4ý =B6þ 7\íDøBï7æë,åLå%êDæRñ"î"å%å$æç(èTë,î"ñ.ô>æ<å$æç,ûó>íDî"ô;ë,ô>î"ûï7øe÷öç
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
4ý CB6 þ >zæûö$õAæaå%êDæ[ñ.î"å%å$æç(èiêDöô>ð
ð7ö\ò;íDø{î"íDð
ç,æûö\õæaå$ê-æ
ñ"î"å$å%æç(èR÷ç,öûå%êDæ
ñ"î"å$å%æç(èRå%ç,îBè*ý9gó>üWù
-<D]þù
4ý ;B6 þ 7\íDøBï7æë,å…å%êDæXñ"î"å%å$æç(èŒå%ç,îBèŒî"íDð‹êDöô>ð‹ð7ö\ò;íDø³÷6öç
ë,öçFç,öøBó6öíMöçLð7î"ûî"üWæ
ù >zæûYö\õAæeî"íHèkë,öç,ç,öø]ó>öíMìDøBó>íDü<î
òYó>ç,æeñ"ç,ìDøBêMî.í-ðVî*øBöð7ó>ìDû°ñ"ó>ë,î.çFñ.öíDî"å$æeý6ñ"@î ?vó>íDü<øBöð7îBþ
ë,öç,ç,öøBó6öíeî"íDð_ð7î"ûî.ü0æù >zæûö\õAæYî"íHè…ë,öç,ç,öø]ó>öíNìDø]ó>íDü
î
òYó>ç,æ:ñ.çFìDø]êEöç
îqï7öøBå{î"íDðiå$æç,ûó>íDî"ôzë,ô6æî"íDó>íDü_å%ööô6éuî"íDð
îqø]öð7ó>ìDûjñ"ó6ëFî.ç,ñ"öíDî"å$æ:ýñ"@î ?vó>íDü_øBöð.î]þ[î.í-ðòYî"ç,û¥òYî"å%æç
î"íDðpòYî"ç,ûkò;î.å%æç‡ë,ô>æî.í-ó6í-üYø]öô>ìDå$ó>öíDù Egî"ó>íDåzî.íèiGæ Fï7öøBæð
ñ"î"ç,æ ûYæå%î.ôzî.í-ðeç,æï7ô>î"ë,æ
î.íHèRð7î"ûî"üWæðNï7î"ç,å$øBù
4ý BB6 þ Hô6ó>ð7æNå%êDæNå%êDæç,ûöüWìDî"ç,ð*ö÷÷pö÷[å%êDæNñ"î.å%å%æç(èXë,î"ø]æù
7\íDøBï7æë,å;å%êDæiñ"î"å%å$æç(èMë,î"ø]æq÷öç
ëFç,î.Ië ?vø öç
öå%êDæç
ð7î"ûî"üWæ
ú ûWü ý þ ÿNû


  

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vƒ|6uv1t…u~ewIy}I}I~wItx}v@t‚ƒ›Š1”y}htu~‹¡8~u‚wI{~ˆ

Fig. 17 Battery Hold Downs

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Fig. 19 Clean Battery - Typical

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Fig. 18 Removing Cell Caps - Typical
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CAUTION: Be certain that the battery cables are

connected to the correct battery terminals. Reverse
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Fig. 20 Clean Battery Terminal Post - Typical

Fig. 21 Battery Cables

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SPECIFICATIONS

BATTERY

Battery Classifications and Ratings

BCI Group Size Cold Cranking Reserve Load Test
Part Number Ampere-Hours
Classification Amperage Capacity Amperage
56027960 34 500 110 Minutes 60 250
56041003 34 600 120 Minutes 66 300
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STARTING SYSTEMS
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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. Clutch pedal position
switch faulty.
6. Park/Neutral position
switch faulty or
misadjusted.
7. Starter solenoid faulty.
8. 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 2. Starter motor faulty.
ENGINE STARTS.
STARTER DOES NOT 1. Starter motor
DISENGAGE. improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.
KML
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 Clutch Pedal Position Switch in the Diagnosis
and Testing section of Group 6 - Clutch.
6. Refer to Park/Neutral Position Switch in the Diagnosis
and Testing section of Group 21 - Transmission. Replace
the park/neutral position switch, if required.
7. Refer to Starter Motor in the Diagnosis and Testing
section of this group. Replace the starter motor assembly,
if required.
8. 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.
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NOTE: A cold engine will increase the starter cur-

rent (amperage) draw reading, and reduce the bat-
tery voltage reading.

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Fig. 2 Test Battery Negative Connection Resistance
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Fig. 7 Starter Motor Noise Diagnosis

ëAìíîHï$ðDî8ì#ñ0ò5óZôõ ëö+÷&ô ñö<øMîòñ¨ï@òù÷Qö+ùí@î8ùìî0ñ0ò#ú õ ùôõ ë
û"íü"öiòõ\ù÷ ìì#õ ëAôõ&ìjïýò#þ
ÿ uôë  
Lì#øMìî:ù ò 
 NOTE: This is a condition that will generally cause
   hôõ[ù÷  ì Lìñ0ò5óíýJíõ  ü 5õ ö$ùíýýíùôòõ[ö+ì#þ8ùôò#õ¡ò#ø broken starter (flywheel/torque converter drive
ù÷ ôöëAîò#ú&ûø ò#îžù÷ ì<û@îò#þìü"ú îìö  plate) ring gear teeth or broken starter motor hous-
ings.

NOTE: The shim thickness is 0.381 mm (0.015 in.). 687:9<;7>=>;@?BAC7>AC;

These shims may be stacked if additional thickness
!Lò#îîìþù7ö$ùí@îùì#îdñò#ùò#îdò#û@ì#îíùô òõhþíõhïì|þò#õ ø ôîñ0ì#ü
ï$ðBû@ì#îø ò#îñ0ôõ ëiù÷&ìJø ò#ýýòD & ôõ ëiøMî8ì#ì7îú õ õ ôõ ëiïì#õ þ8÷Qùì#ö$ùE
is required.

(e÷ ôö\ùìö+ùQþíõ©ò#õ&ý ð^ïìpû"ìîøMò#î8ñ0ì#ü& ôù÷¦ù÷ ìpö$ùíîùì#î

ñ0òùòîdîìñ0ò5óìümøMîò#ñ ù÷ ì7óì#÷&ô þýì/FL ì#ø ì#îiùòG 2
,HI'JLK
M)NO0§ P ôõdù÷ ìRQ û@ì#þôøMôþíùô òõ öWö+ìþùôò#õiò#øIù÷&ô öWëAîòú û7øMò#î
ù÷ ì<ö+ùíîùìîKñ0òùòîKö$û"ìþô ø ôþí@ùôò#õ ö 
CAUTION: The 2.5L engine uses a permanent mag-
net starter. Permanent magnet starters are highly
sensitive to hammering, shocks, external pressure
and reverse polarity. This starter motor must never
be clamped in a vise by the starter field frame. The
starter should only be clamped by the mounting
flange. Do not reverse the battery cable connec-
tions to this starter motor when testing. The perma-
nent magnets may be damaged and the starter
rendered unserviceable if it is subjected to any of
these conditions.
 5øVù÷ ìiþò#ñ0û"ýíôõ ùžô ö7ö+ôñ0ôýíî<ùò"!Lò#õ ü@ô ùôò#õ#%$6ù÷ ì
S+Lì#ñ0òóì ù÷ ì ö$ùí@îùì#îhñ0òùòîhøMîò#ñ ù÷ ìfóZì#÷ ôþýìO
Fig. 8 Starter Motor Shim

ö$ùíîùì#î0ñ0ò#ùò#î0ñ0ú ö$ùEïìiñò5óìü?íK & í+ðDø îò#ñ¨ù÷ ì:ö$ùí@îùì#î L ì#ø ì#îHùò" 2

0    dôõBù÷ ì"Lìñ0ò5óíý!íõ ü15õ ö$ùí@ýT4
îôõ ëBëì#íî')e ( ÷ ôöôöü"òõ ì|ï$ðpô õ&ö+ùí@ýýôõ ëBö$÷ ôñ*Mö+i íþîò#ö$ö ýíùôò#õ?- ö$ì#þùôò#õ?ò#ø6ù÷&ô öëîò#ú ûøMòîKù÷ ì<û"îòþì#ü"ú&îì#ö 
- ò#îì©ù÷ íõ¬òõ ì©ö+÷ ôñ ñ0í$ð ïì©îì/@. ú&ô î8ì#ü01L ì#øMìîoùò V í &  ì üDïò#ìú õ õ þ÷?ùQóZù÷&ôö+ìqìOö+(!ùí÷ îìHùì#óîfôö$ñ0ì ò#V ùíò#&Kîföiö$ö+ì#÷ þòú ú î8ì#ýüDý ð_ïìôõ¦þýí¡í@ñ0ö$û@ò#ì#øMùUü 4
ïò#ù÷§ö$ùíîùì#îpñ0òú õ ùôõ ëgû@í@ü@önòõ§ù÷&ìoìõ ëAôõ ì ï@ýòþÿ,
2
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ùôò#õ?ò#ø6ù÷&ô öëîò#ú ûøMòîKù÷ ì<û"îòþì#ü"ú&îì#ö  þýíñ0ûòõ|ù÷ ì<ö$ùíîùì#îžñ0ò#ùò#îžï$ðPù÷ ì<øMôìý üøMîíñ0ì/
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Ä Fig. 10 Continuity Test Between Solenoid Terminal

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and Solenoid Case - Typical

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Starter Motor and Solenoid

Manufacturer Mitsubishi
Engine Application 2.5L, 4.0L
2.5L - 1.2 Kilowatt (1.6 Horsepower)
Power Rating
4.0L - 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
2.5L - 2600 rpm
Free Running Test Minimum Speed
4.0L - 2500 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
2.5L - 130 Amperes
*Cranking Amperage Draw Test
4.0L - 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
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ÇΉÇ3ÈZËZÏ CAUTION: Never force a belt over a pulley rim
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£¤¥ˆ¤¥‹,¡¬A± to overheat. Refer to belt routing label in engine
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WARNING: DISCONNECT NEGATIVE CABLE FROM „>ª?†9¹3Ž,ŒN‹³¯Ž¼®“’“ˆ³ˆŽ,Š°Õ±Z¹3ŽB•Ž,Š_ˆ‹§áXŠI‹,”+A‡‰ ZÝ3’“ˆ³ˆŽBŠ°Õ#•‹,Š
BATTERY BEFORE REMOVING BATTERY OUTPUT ŠI‹B·IŽ,£‘”ŠIŽ,¬A±
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO „–A†9Ù¤¥¬A·I‹,¡¡Ž,·IˆN¬AŽ,¡¬A‹,Š+¤¥¦Ôˆ’“¤­_¢’“ŠI¡Ž,¬A¬o•ŠI‹,Œ¶Ž,¡¦Ô¤¥¡Ž
DO SO CAN RESULT IN INJURY OR DAMAGE TO µ§¤¥ŠIŽt¢’“ŠI¡ŽB¬O¬A±
ELECTRICAL SYSTEM. „÷A†9Ñ:Š°Õ ¬AŽ,¡¬O‹BŠ ¬Aˆ³ŠI’“¤¥¦Ô¢ˆ ” •ŠI‹,Œ ®“’“ˆ³ˆŽ,Š°Õ ˆŠI’AÕ
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Fig. 2 Generator Remove/Install

Fig. 4 Battery Temperature Sensor Remove/Install

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TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56005684AB 81 2.5L/4.0L 57
DENSO 56005685AB 117 2.5L/4.0L 88

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 üX^{z:ü ÿ \@{| ý úý û\ cable from a spark plug or from the distributor cap,
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Fig. 36 Distributor Pre-position—All Engines

Fig. 35 Pin Alignment Holes

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çuÙ.ÔÕwÔGÕwÓ
Ø&Ò}Ð-Ï}Ð-Ù.Ò'Ù.ÒÜÔï Fig. 37 Distributor Engaged Position—2.5L
Þ/ÑÜ8Þ/Ø.ЏßæÒÑÖ/Õ ÏÛ)Ó
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+
4-Cylinder Engine
ý *  þ
ü
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lnjk{‰|<moUp‚o l\}•°"o x
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„0¼'vw‹ŽªÂˆ$‹

Fig. 38 Distributor Engaged Position—4.0L

6-Cylinder Engine
• ikjklnmo prqKst"uwvwikxopzyvw{|~} ivw{
{o|M|M|€}yxo x+s‚o ikƒ
|€opK„ …6†6‡ˆK„0s‚}l\yp‚o{{‰vw}i{‰|€p‚} Šo~ˆ$‹
• s‚o ik|~o p‚uwvwikoK}Œ{‰uw}||m{‰oK} ŒŽxv0{|€p‚v0mjk|€}pMvw{uwvwiox
|€}‘s‚oik|€op‚uwvwiko‘} Œ4xv0{|€p‚v0mjk|€}p“’k} u0xx}•”
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i˜m} uw|œ{’k}jkuwx
o {vwu tOy{{n|~’kp‚} jk’{u0} |<ikx+v0i|~}&oivwiko‹ Fig. 39 Key Cylinder Release Tang
}žx€ŸEjk{|~l\o ik|€{ p‚ožiko s‚o{{‰pt¡‹¢£p‚}s$oox¤|~}˜iko•¥|
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CAUTION: If the distributor cap is incorrectly posi-
tioned on distributor housing, cap or rotor may be
damaged when engine is started.

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„$q¿ˆ+‡¯}ikios‚|xvw{‰|€p‚vwmjk|€}p+”nvwp‚vwikÀ’kp‚iko{{Á|€}»lnvwi Fig. 40 Key Cylinder and Cover Removal
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Fig. 43 Ignition Switch Removal/Installation

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Fig. 41 Ignition Switch Lock Tab
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Audio System Diagnosis

CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in Power Distribution Center. Replace fuses,
if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if
required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Ground faulty. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Radio faulty. 5. Exchange or replace radio, if required.
6. Speakers faulty. 6. See speaker diagnosis, in this group.
NO DISPLAY. 1. Fuse faulty. 1. Check radio fuses in Power Distribution Center. Replace fuses,
if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if
required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Ground faulty. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Radio faulty. 5. Exchange or replace radio, if required.
CLOCK WILL 1. Fuse faulty. 1. Check ignition-off draw fuse. Replace fuse, if required.
NOT KEEP SET 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if
TIME. required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Ground faulty. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Radio faulty. 5. Exchange or replace radio, if required.
POOR RADIO 1. Antenna faulty. 1. See antenna diagnosis, in this group. Repair or replace
RECEPTION. antenna, if required.
2. Ground faulty. 2. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
3. Radio faulty. 3. Exchange or replace radio, if required.
NO/POOR TAPE 1. Faulty tape. 1. Insert known good tape and test operation.
OPERATION. 2. Foreign objects behind 2. Remove foreign objects and test operation.
tape door.
3. Dirty cassette tape 3. Clean head with Mopar Cassette Head Cleaner.
head.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT 1. Faulty CD. 1. Insert known good CD and test operation.
DISC 2. Foreign material on 2. Clean CD and test operation.
OPERATION CD.
3. Condensation on CD 3. Allow temperature of vehicle interior to stabilize and test
or optics. operation.
4. Faulty CD player. 4. Exchange or replace radio, if required.

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BAGS, REFER TO GROUP 8M - PASSIVE “floating ground” system. Do not allow any speaker
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY lead to short to ground, as damage to the radio
STEERING WHEEL, STEERING COLUMN, OR may result.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR ç–è‡é2 ó»ú!ö ï ë&ìLõ ö&õ™ï õ™ø ö£ô*ùYõ™ï í!ë ï øLï ë&ìLÿ¹ö0 ø ôžõï õ™ø ö&ý
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RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY ôS0 ì ¤ î ì úùYõ™ú!ìzë¤ ú!ö&ì ôžôYí!õ™ú!í!ó&õ™ïðçô*ép¤ ôYú!ì ¤ ó&õ™ú!ì 0 ý
STEERING WHEEL, STEERING COLUMN, OR
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CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
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NOTE: This model has a two-piece antenna coaxial
îï ð. î 
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cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the Ê?ËÐÅÐ/ÅÆqäÒÐÐ/ÆÏãß È Ñ;ËÐ/Ë –Æ à Ò$äÉÆqÏ,Æ ÕÈ –ÆÓjÇ=Ï,È ÕÐÅÆqäÒ$Ð Ü
ÐÆ Ïãf ç 
ËÑ ÈÌÌÆ Ð˜äÈ ÐÅJä$ÒÐÐÆ Ïã à ÒäÉÆ Ñ;û#ÐÅÆOÌ&Æ Í+ÒÐË –Æ
Òà äÉ=ÆDÇËÏ,ÑSà Ðçÿ}Æ à à ÈÌÌÆ à ÐaÐÅÆäÒÐ/ÐÆ Ïã
instrument panel near the right cowl side inner
panel to the antenna base, and then from the coax- ÌÆ Í7Ò$ÐË –Æ à Ò$äÉÆÒÌÓ
ial cable connection to the radio chassis connec- ß ÆÏ,ÇÈÏ,ÕUÐÅÆDÐ/ÆÑSÐBÒÑ?ÇÈÉÉ=È/Ê?Ñ;Ö
ê>ì»í÷}È Ì&ÌÆ ÐaÈÌÆjÈÅÕÕÆÐ/ÆÏ?ÐÆ ÑSÐaÉÆ ÒÓ1Ð/ÈÐÅ Æ Æ ÅË ÉÆ
ÇÆÌÓ ÆÏLç÷}ÈÌÌà Æ à Ð1ÐÅÆ‰È ÐÅÆόÐÆ Ñ;Ð1ÉÆ ÒÓOÐȉÐÅƉä$ÒÐÐ/Æà Ïã
tion.
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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.

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Fig. 14 Water Shield Upper Screws Remove/Install

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LAMP DIAGNOSIS
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page page

GENERAL INFORMATION DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 1 HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
DAYTIME RUNNING LAMP . . . . . . . . . . . . . . . . . . 4
¯±°d²±°d³n´[µ·¶²±¸º¹±³›»´¼d¶¹±² this group. Damage to lamp and/or Daytime Run-
½G¾Y¿G¾YÀÁA±Â¿GÄYÅGÀVÆnÁPÇYÂÅG¿ ning Lamp Module can result.

È,ÉËÊÍÌyÎ Ï)ÌÐÑÊÍÒÑϺÐÑÓJÏ)Ô'Õ Ð9Ö'Ö!Ï×JغÐÑÙ6̺ΠÉËÚÍÐÑÛÕӘÒÑÉ'ÜyÖdÉ'Ó%Ó;Ï)ÜyÝ Do not use fuses, circuit breakers or relays hav-

ÞËÒÑÐ9Ï)Ó;ß'àâáãÛ)ÛכáãÚÍÛÕ ä×åÐÑÓ`äÏ)ÊÍÏÓ%Ó;ÉËÚçæ±è9ÛÚºÖ!ÚÍÛÖ'ÏÚyÒÑÐÑáãÌÙ3ÐÑäá ing greater amperage value than indicated on the

ÛÖ'ÏÚÍÉËÙ3Ð9Û)äßéêÚÍÛ)Õä×'Ð9ä áŒÐÑÓyÖ'ÚÍÛëÎ ÐÑ×'Ï׫Þ%æ1Ù6ÌÏnÒÑÉ'ܺ֫Ó;Û)ÊÍìgÏÙ fuse panel or in the Owners Manual.

ï±ÌÏ)ä›ÐÑÙêÐÑÓjäÏÊÍÏ)Ó;Ó%É'ÚæûÙ3Û`ÚÏÜyÛëÎõÏ`ÊÛÜyÖ!Û)äÏä Ù6ÓjÙ3Û`Ó%ÏÚ}Ý
ØºÌ ÏäíÐÑÙ«ÊÍÛ)ÜyÏÓMÐÑäíÊÍÛäÙ3ÉËÊÍÙ`Ø?Ð9Ù3ÌíÙ3ÌÏ[ÜyÏ)Ù6ÉËÒnÞËÛ×#æîºÛÚ Î ÐÑÊÍÏüÉ'ä ÛÙ3ÌÏڂîWÐÑÙ1Ó;ÌÛ)ÕÒÑ×ýäÛ)ÙMÞËÏðä ÏÊÍÏ)Ó;Ó%É'Úçæ­Ù6ÛüÉËÖ!Ö!Ò æ
Ù3ÌÚÍÛÕ áãÌåÉ
Ó;Ï)Ö!ÉËÚÍÉËÙ6ÏnáãÚÍÛ)Õä×yغÐÑÚÍÏ)ß ÏëþõÊÍÏÓ%Ó;РΠϱèÛ)ÚÍÊÍÏSÛÚåÞ'Ï)ä×ðÉÿÊÍÛÜyÖ'ÛäÏ)äÙ
Ù6Û±ÚÍÏÜyÛ6Î ÏSÐÑÙ3ß
ï±Ì ÏäíÊÍÌ É'ä áãÐÑäáÒ9ÉËÜyÖðÞËÕÒÑÞ'ÓMÊÍÌÏ)ÊÍìqÙ3ÌÏ[Ó%ÛÊÍìgÏ)ÙèÛÚ ,Ïè9ÛÚÍÏÿ×!ÉËÜyÉËáãÐÑäáqÉâÙ3ÚÍÐÑÜ ÊÍÛ)ÜyÖ!Ûä ÏäÙ3î˜Î Ï)ÚÍÐÑè æ­ÌÐÑ×'×!Ïä
ÊÍÛ)ÚÍÚÍÛÓ%Ð9Û)äßYñëèxÊÍÛÚÍÚÍÛ)Ó;ÐÑÛ)ä«ÐÑÓJÖ'ÚÍÏÓ%ÏäÙ3î7ÊÒ9Ï)ÉËä«ÐÑÙ7غÐÑÙ6ÌɘغÐÑÚÍÏ èÉËÓ%Ù6Ï)äÏÚÍÓjÛÚJÊÍÉËÖ!Ù6Õ ÚÍÏ×
Ï)×!áãÏ)Ó?É'ÚÏ`äÛÙêÌÛÒÑ×!ÐÑäádÙ3ÌÏ`ÊÍÛ)ÜyÝ
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ÛèVÙ3ÌÏ
Ó;Û)ÊÍì Ï)Ù?ÒÑÐÑáãÌÙ3Ò æ›ØºÐÑÙ6Ì Ö!Û)äÏä ÙVÐ9äåÖ!ÒÑÉËÊÍÏß
òdÛÖ!ÉËÚjòWÕÒÑÙ3Ð9Ý9óÕ ÚÍÖ!ÛÓ%ÏnéêÚÍÏÉËÓ%ÏnÛÚ?Ï)ÔËÕÐ Î ÉËÒÑÏäÙ3ß
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WARNING: EYE PROTECTION SHOULD BE USED

Ì Ï)É'×'Ò9ÉËÜy֫ӂæ Ó%Ù6Ï)ÜyîÎ Ï)ÚÍÐÑè æMÙ3ÌÏ/ÊÍÛä ×!ÐÑÙ6ÐÑÛ)ä1Û)èÙ6Ì Ï/Þ'ÉËÙ3Ù6Ï)Úçæ

WHEN SERVICING GLASS COMPONENTS. PER-

ÊÍÛ)ääÏÊÍÙ3ÐÑÛäÓ%îè9ÕÓ;Ï)Ó;îÊÍÌ É'ÚÍá ÐÑäádӂæ Ó%Ù6Ï)ÜyîÌÏ)ÉË×!ÒÑÉ'ܺÖ
ÞËÕÒÑÞËÓ;î

SONAL INJURY CAN RESULT.

غÐÑÚÍÏjÊÍÛääÏ)ÊÍÙ3ÛÚÍÓ%îYÚÍÏ)ÒÑÉ;æî ÌÐÑáãÌ
ÞËÏÉËÜø×!ÐÑÜyÜyÏ)ÚVÓ Ø?Ð9Ù3ÊÍÌ
ÉËä×

CAUTION: Do not touch the glass of halogen bulbs ÌÏ)É'×'Ò9ÉËÜyÖðÓ ØºÐÑÙ3ÊÍÌß ,Ïè9ÏÚ1Ù3Û[éDÚÍÛÕ
Ö ;ïŒîêïûÐ9ÚÍÐÑäá êÐÑÉËÝ
with fingers or other possibly oily surface, reduced áãÚÍÉËÜyÓ«èÛ)ÚÊÍÛÜyÖ!Û)äÏ)äÙdÒÑÛ)ÊÍÉ'Ù3ÐÑÛä ӛÉËä× ÊÍÐÑÚÍÊÍÕ Ð9Ù/ÐÑäèÛ)ÚÍÜyÉËÝ
bulb life will result. Ù3Ð9Û)äß
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
=>?@ >ABCD
GIHKJMLONOPOQRHKQSJMNOGUT!V!Q!TRHWNXLZY\[M]9^9_a`b^9c9d9e9f
!#"%$!&#"%')(
*,+.-0/1-0234/56-798,:,;%5<;
CONDITION POSSIBLE CAUSES
HEADLAMPS ARE DIM 1. Loose or corroded battery cables.
WITH ENGINE IDLING
OR IGNITION TURNED 2. Loose or worn generator drive
OFF belt.
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.
HEADLAMP BULBS BURN 1. Charging system output too high.
OUT
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.
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.
HEADLAMPS FLASH 1. Poor lighting circuit Z1-ground.
RANDOMLY
2. High resistance in headlamp
circuit.
3. Faulty headlamps switch circuit
breaker.
4. Loose or corroded terminals or
splices in circuit.
HEADLAMPS DO NOT 1. No voltage to headlamps.
ILLUMINATE
2. No Z1-ground at headlamps.
3. Faulty headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
6. Both headlamp bulbs defective.
*Canada vehicles must have lamps ON.
E,F
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
Group 8A,
4. Test battery state-of -charge
, refer to Group 8A.
5. Load test battery, refer to Group 8A.
6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Replace both headlamp bulbs.
1. Test and repair charging system, refer to
Group 8A.
2. Inspect and repair all connectors and
splices, refer to Group 8W.
1. Test and repair charging system, refer to
Group 8A.
2. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
3. Test amperage draw of headlamp circuit.
4. Replace both headlamp bulbs.
1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Replace headlamp switch.
4. Inspect and repair all connectors and
splices, refer to Group 8W.
1. Repair open headlamp circuit, refer to
Group 8W.
2. Repair circuit ground, refer to Group 8W.
3. Replace headlamp switch.
4. Replace multi-function switch.
5. Repair connector terminal or wire splice.
6. Replace both headlamp bulbs.
}~
‡IˆK‰MŠO‹OŒORˆKS‰M‹O‡UŽ!!!ŽRˆW‹XŠZ\‘M’9“9”a•b“9–9—9˜9™
gh!ikj#l%m)n
opXqsrut0vIwyxz6tq9{p,|%z6|
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 fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.
FOG LAMPS DO NOT 1. Blown fuse for fog lamp.
ILLUMINATE 2. No Z1-ground at fog lamps.
3. Faulty fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
5. Defective or burned out bulb.
€‚ƒ „…†
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
Group 8A,
4. Test battery state-of -charge. Refer to
Group 8A.
5. Load test battery. Refer to Group 8A.
6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
1. Test and repair charging system. Refer to
Group 8A.
2. Inspect and repair all connectors and
splices. Refer to Group 8W.
1. Test and repair charging system. Refer to
Group 8A.
2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. Test amperage draw of fog lamp circuit.
1. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
2. Test amperage draw of fog lamp circuit.
3. Replace fog lamp switch.
4. Inspect and repair all connectors and
splices. Refer to Group 8W.
1. Replace fuse. Refer to Group 8W.
2. Repair circuit ground. Refer to Group
8W.
3. Replace fog lamp switch.
4. Repair connector terminal or wire splice.
5. Replace bulb.
¸¹º» ¹¼½¾¿
ÂIÃKÄMÅOÆOÇOÈRÃKÈSÄMÆOÂUÉ!Ê!È!ÉRÃWÆXÅZË\ÌMÍ9Î9ÏaÐbÎ9Ñ9Ò9Ó9Ô
šœ›%žŸb )¡¢¤£!¥!¥!Ÿb¥!¦k§#›% )¨
©0ª¤«¬.­<®¯4°±9²,²X­<²X³s´uª0®Iµy©­6ª³9²¶,·%­6·
CONDITION POSSIBLE CAUSES
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 module.
À,Á
CORRECTION
1. Secure connector on DRL
module.
2. Disengage parking brake.
3. Check voltage on pin 3 of
module, refer to Group 8W.
4. Check L3 circuit, refer to Group
8W.
5. Replace DRL module.
€K ‚zƒ…„/†‡ ˆ‚0‰kŠ

HEADLAMP ALIGNMENT
ÕWÖ9×9ØÙ
page page

GENERAL INFORMATION LAMP ALIGNMENT SCREEN PREPARATION . . . . 5

HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 5 VEHICLE PREPARATION FOR HEADLAMP
SERVICE PROCEDURES ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . 7 SPECIAL TOOLS
HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . . . . 6 HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 7
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Fig. 4 Fog Lamp Adjustment

 

 

LAMP BULB SERVICE

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page page

REMOVAL AND INSTALLATION FRONT PARK/TURN SIGNAL LAMP BULB . . . . . . 8

BACK-UP LAMP BULB . . . . . . . . . . . . . . . . . . . . . 9 HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER HIGH MOUNTED STOP LAMP SIDE MARKER LAMP BULB . . . . . . . . . . . . . . . . . 8
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . . 9 TAIL/TURN SIGNAL/BACK-UP LAMP BULB . . . . . 8
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 UNDERHOOD LAMP BULB . . . . . . . . . . . . . . . . . 9
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Fig. 3 CHMSL Bulb

Fig. 2 Lens Removal

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REMOVAL AND INSTALLATION FRONT PARK/TURN SIGNAL LAMP . . . . . . . . . . 12

CENTER HIGH MOUNTED STOP LAMP HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SIDE MARKER LAMP . . . . . . . . . . . . . . . . . . . . . 12
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TAIL/STOP/TURN SIGNAL/BACK-UP LAMP . . . . 12
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . . 13
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LAMP SYSTEMS
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GENERAL INFORMATION REMOVAL AND INSTALLATION

ž ŸB¡ ŸB¢(£¥¤§¦¡ ¨/© ¢«ª<£¬B¦© ¡
DAYTIME RUNNING LIGHTS (CANADA ONLY) . . 15 DAYTIME RUNNING LAMP (DRL) MODULE . . . . 15

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BULB APPLICATION
021345
page page

SPECIFICATIONS INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 16

EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 16
687898:
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dle power than the bulb listed in the Bulb Applica- UZx Ÿ^[kmUCh/xmXZkmUu/ebxUq¡VXx¢sdXqrnXZV£noTbUCY2lOsdh/q¡^[`¤noTbU
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halogen bulbs with fingers or other oily surfaces. lOxmU©Y[XkmlOnoUuª^[`¬«‚xmXehª•j­G¥z¦§`bqrn]xmesdU`bn®œlO`bUZYClO`bu
Bulb life will be reduced. «‚lOeba¯Uqr{v
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LAMPS
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LAMP DIAGNOSIS
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page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 2
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . . 1
èCé8êCé8ë>ì±íïîêCð_ñCë
òóìô8îñCê Do not use bulbs with higher candle power than
õö(÷ö(øpùiúCûK÷ü(ýøyþ>ù ÿ(ûKý÷ indicated in the Bulb Application Table at the end of
this group. Damage to lamp can result.

 
 
 
 
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ÂTÃÄ>Å]Æ[Ä>ÇÈFÅɲÄÊ_ËTÌTÍqɦÍ

CONDITION POSSIBLE CAUSES CORRECTION

HEADLAMPS ARE 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
DIM WITH ENGINE and posts.
IDLING OR
IGNITION TURNED 2. Loose or worn alternator drive belt. 2. Adjust or replace alternator drive belt.
OFF
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

HEADLAMP BULBS 1. Charging system output too high. 1. Test and repair charging system. Refer to
BURN OUT Group 8A.
FREQUENTLY
2. Loose or corroded terminals or splices in 2. Inspect and repair all connectors and
circuit. splices. Refer to Group 8W.

HEADLAMPS ARE 1. Charging system output too low. 1. Test and repair charging system. Refer to
DIM WITH ENGINE Group 8A.
RUNNING ABOVE 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
IDLE locations. Refer to Group 8W.
3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit.

HEADLAMPS 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
FLASH RANDOMLY locations, refer to Group 8W.
2. High resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or splices in 3. Inspect and repair all connectors and
circuit. splices. Refer to Group 8W.

HEADLAMPS DO 1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to

NOT ILLUMINATE Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer (multi-function) 4. Replace multi-function switch.
switch.
5. Broken connector terminal or wire splice 5. Repair connector terminal or wire splice.
in headlamp circuit.
6. Defective or burned out bulb. 6. Replace bulb.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
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Ø[Ù%ÚgÛSÜ>ÝYÞAßà²ÜÚ_áRÙTâqà²â
CONDITION POSSIBLE CAUSES
FOG LAMPS ARE DIM 1. Loose or corroded battery cables.
WITH ENGINE IDLING OR
IGNITION TURNED OFF. 2. Loose or worn alternator 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 fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.
FOG LAMPS DO NOT 1. Blown fuse for fog lamp.
ILLUMINATE 2. No Z1-ground at fog lamps.
3. Faulty fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
5. Defective or burned out bulb.
åIæPç7èé ê[åGë]ì
CORRECTION
1. Clean and secure battery cable clamps
and posts.
2. Adjust or replace alternator drive belt.
3. Test and repair charging system. Refer to
Group 8A.
4. Test battery state-of -charge. Refer to
Group 8A.
5. Load test battery. Refer to Group 8A.
6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
1. Test and repair charging system. Refer to
Group 8A.
2. Inspect and repair all connectors and
splices. Refer to Group 8W.
1. Test and repair charging system. Refer to
Group 8A.
2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. Test amperage draw of fog lamp circuit.
1. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
2. Test amperage draw of fog lamp circuit.
3. Replace fog lamp switch.
4. Inspect and repair all connectors and
splices. Refer to Group 8W.
1. Replace fuse. Refer to Group 8W.
2. Repair circuit ground. Refer to Group
8W.
3. Replace fog lamp switch.
4. Repair connector terminal or wire splice.
5. Replace bulb.
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CONDITION POSSIBLE CAUSES CORRECTION

ONE MOTOR DOES NOT 1. Poor connection at motor. 1. Secure connector on motor.
OPERATE
2. No voltage at motor. 2. Repair circuit. Refer to Group 8W,
Wiring.
3. Defective motor. 3. Replace motor.

BOTH MOTORS DO NOT 1. No voltage at headlamp leveling
OPERATE switch.
2. No voltage at both motors.
3. Poor connection at motors.
4. Both motors defective.
1. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.
2. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.
3. Secure connectors on motors.
4. Replace motors.
ÁÃÂ Ä*Å,Æ.Ç0È ÉÄ ÊË

LAMP BULB SERVICE

RCS
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page page

REMOVAL AND INSTALLATION HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 5

CENTER HIGH MOUNTED STOP LAMP LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . . 7
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . . 7 REAR FOG LAMP BULB . . . . . . . . . . . . . . . . . . . 7
CITYLIGHT LAMP BULB . . . . . . . . . . . . . . . . . . . . 6 TAIL LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Fig. 3 Headlamp Rubber Seal Boot

Fig. 1 Headlamp Bezel

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Fig. 4 Headlamp Bulb Retaining Ring

Fig. 6 Citylight Lamp Bulb Housing

Fig. 5 Headlamp Bulb

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Fig. 7 Citylight Lamp Bulb
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Fig. 8 Tail Lamp Lense
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LAMP SERVICE
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page page

REMOVAL AND INSTALLATION HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . . 8

CENTER HIGH MOUNTED STOP LAMP REAR FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . 10
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HEADLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . 8
í·î¸ïgðµñeòóôòöõµ÷ùø€õµú¸û¤òó¡ó3ò
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Fig. 2 Headlamp Retaining Ring

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NOTE: The headlamp leveling motor arm is
snapped into the headlamp housing very securely.
Use a firm, steady pull to disengage motor arm
from the headlamp housing.

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Fig. 6 Tail Lamp Lense

Fig. 7 Tail Lamp Housing

Fig. 5 Headlamp Leveling Motor
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Fig. 9 Rear Fog Lamp

?;@ ACBED
F=G HA%IKJLJ

BULB APPLICATION
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page page

GENERAL INFORMATION INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 11

GENERAL INFORMATION . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 11
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CAUTION: Do not use bulbs that have a higher can-
 ×2Û"ãOâáSãÍâ ØL×GáSâ_ØèkÕ2âØLÕ2ê…Ö[×GêmØL×2áSâã;ÚL×2Û×2ÖÏÛ<Õ2âêSÕGåJã/
ß  ì
dle power the bulb listed in the Bulb Application
ó'ô…õ/ö ÷]ø$ó÷
Table. Damage to lamp can result. Do not touch
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halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.
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INALLY USED FOR THE AIRBAG SYSTEM COMPO-
SbTQXSNY]dbSPSRBg"SRNYRBZ[TYSU`\a]t^BRBNYUrbX VBNYRBg"SsU`]dNYe‘qd\jwxX ] NENTS HAVE SPECIAL COATINGS AND ARE
NYR"UWVBX€VB^Bb_S]dX S_\aZ„UWVBX€MuUWXaX ]dNYRBPr~€VBXaX TYn  VXfhSMOMuXaRBPmXa] SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
MONQgX"SNY]dbSP†ef\ g^BTYX"NYRBqdTY^BgXaMSkMOX qd\aRBg%NYRBZQTQSUWSbTYXpSNY] … TEM. THEY MUST NEVER BE REPLACED WITH ANY
bSPfSRgSRNYRBZQTQSUW\ ]^BRBNYU=bXaVBNYRBgSRSNQ]dbSPfg\a\ ]NYRU`VX SUBSTITUTES. ANY TIME A NEW FASTENER IS
NYRBMOU`]d^Be€X RBUhSRBXaT=Sb\jw8XlUWVBXlPmTY\`w8Xlb\`’8n NEEDED, REPLACE IT WITH THE CORRECT FAS-
“ ^B]dNYRBPSpZ[]d\aRBUWST-wxX VBNYqdTYXNQefhSqdU`|!UWVBX”RX XbTY\aqd”Xa]dM
TENERS PROVIDED IN THE SERVICE PACKAGE OR
~€\a]d”DNYR%qd\aRBqdXa]dUv~tNQUWV%h]d\ahXa]dT i{SgW•a^BMOUWX gMOX SU)bXaTQUWMUW\ SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
]dXaMuUW]dSNQR–UWVBX†g]1N wxX ]SRBgzZ[]d\aRBUlMOX SUlhSMOMuXaRBPmXa]sNYR–UWVBX ALOG.
h]d\ahXa]_h\ MONYU`NY\aR'Z[\a]_SR'SNQ]dbSPgX hTY\`i8efXaRBU`n  VBXp”RBXaX • WHEN A STEERING COLUMN HAS AN AIRBAG
bTY\ qd”—X ]dMcSTYMu\˜~€\a]d”U`\tSbMO\ ]dbSRBg_gNYMuUW]dNYb^BUWX€UWVBXtqd]dSMuV MODULE ATTACHED, NEVER PLACE THE COLUMN
X RX ]dP1i™Z[]d\aešUWVBX†g]dN wxX ]SRBg{Z[]d\aRBUGMuX SUGhSMOMuX RPmX ]U`\ ON THE FLOOR OR ANY OTHER SURFACE WITH
UWVBX–MuUW]d^BqdUW^B]dX–\aZsUWVBX–NYRBMOU`]d^Be€X RBU†hSRBXaTYn  VBX–g]dN w8Xa] THE STEERING WHEEL OR AIRBAG MODULE FACE
MONQgXp”RX XpbTY\ qd”—X ]NYMSMuUWSefhXagDefX UWST]dXaNQRZ[\ ]dq1X efX RU DOWN.
TY\ qdSUWX gbX VBNYRBgUWVBXfNQRMuUW]d^BefXaRBULhSRBX T›MuUWX Xa]dNYRBPqd\ TY^BefR
\ hX RBNYRBP™q1\jw8Xa]‰n  VBX'hSMuMOX RBP+X ]DMuNYgX'”RX X‹bTY\ qd”—X ]DNYM
žŸ  r¡-žŽ¢„Ÿ¡p£rŸž¤x£r¥Ž¦}§¨©-¡
NYRBUWX Pm]1ST„U`\lUWVBXlPmTY\jwxXb\`’Dg\ \a]‰n
ƒA\aTYTQ\`~€NYRBPœS]dX
P+X RBXa]dST"gX MOqd]dNYhUWNY\ RBMy\aZ†UWVBXefS•a\ ]
ª=« ¬ ­˜®=¯[°±›¯ ²c³
qd\aefh\ RX RBUWM€NYRUWVBXlSNQ]dbSPM‰ixMuUWX efn
 VX$g]dN wxX ]LMONQgX$SNY]dbSPtef\ g^BTYX$h]d\aUWX qdUWN wxX$UW]dNYeŽqd\`w8X ]
WARNING: NYMtUWVBXfef\ MOU›wxNYMuNYbTYXGhS]dUL\ Z„U`VXGg]dN wxX ]$MONQgXGSNY]dbSPM‰ixMu…
• THE AIRBAG SYSTEM IS A SENSITIVE, COM- UWX efn  VXJg]dN w8Xa]´MONYgXJSNY]dbSP0ef\ag^BTYXJNYMef\a^BRBUWX g
PLEX ELECTROMECHANICAL UNIT. BEFORE gNY]dXaqdU`T i}U`\€UWVBX€MuUWX Xa]dNQRPc~tVBX XaTQn-µA\ q1SUWX g^BRBgX ]cUWVBX€SNQ] …
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- bSP¶ef\ag^BTYXŽUW]dNYe·qd\`w8X ]™S]dXœUWVBXŽV\ ]dR¸M~€NYUWqdVB|"UWVBX
BAG SYSTEM OR RELATED STEERING WHEEL, Z[\aTYgX g‹SNY]dbSPzqd^BMOVBNY\ RB|cSRBg‹U`VXDSNY]dbSP{qd^BMuVBNY\aR2Mu^h…
STEERING COLUMN, OR INSTRUMENT PANEL h\a]dU`NYRBP¹qd\ efh\aRBX RU`MOn  VBXº]dXaMuNYMOU`N w8X¶efX efb]dSRBX …QU»ixhX
COMPONENTS YOU MUST FIRST DISCONNECT VB\a]dR"M~€NYU`qdVpNYM)MOX qd^B]1X gt~tNQUWV"VX SU˜MuUWS”XaM)UW\€U`VBX€NYRBMONQgX
AND ISOLATE THE BATTERY NEGATIVE (GROUND) MO^B]dZ[SqdXG\aZ=UWVBXfSNY]dbSP_ef\ag^BTYXGUW]dNYeJqd\`w8X ]|AbXaU¼~€X XaR}UWVBX
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- UW]dNYe‘qd\`w8X ])SRBg"UWVBXlZ[\aTYgX gpSNY]dbSPqd^BMOVBNY\ RBn
 VX_g]dN w8Xa]€MuNYgX_SNY]dbSPef\ g^TQXqdSRRB\ UrbX]dX hSNY]dX g|
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE SRBg_ef^BMOUvbXt]dXahTYSqdX g_NYZ›gXahTY\jixX g_\a]NQRsSR
if~€SOi"gSef…
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE SPmXagn  VBXg]dN w8Xa]lMuNYgXSNY]dbSP}ef\ag^BTYXsUW]dNYe½qd\jwxX ]lSRBg
TO DO THIS COULD RESULT IN ACCIDENTAL AIR- UWVBXkV\ ]dRyM‰~€NYUWqdV™S]dXSuwxSNQTYSbTYXkSM"Sz^BRBNYUZ[\ ]sMuXa]w8NYqdX
BAG DEPLOYMENT AND POSSIBLE PERSONAL ]dXahTYSqdXaefX RU`n
INJURY. ²c°«®8¾±›¯ ²c³
• THE DRIVER SIDE AIRBAG MODULE INFLATOR
 VX_g]dN w8X ]€MONQgX_SNY]dbSPsef\ g^TQX_NYRBqdTY^BgX MGS"MOU`SefhX g
ASSEMBLY CONTAINS SODIUM AZIDE AND POTAS-
SIUM NITRATE. THESE MATERIALS ARE POISON- efXaU`STVB\a^BMuNYRBP}U`\€~€VNQqdV{U`VXpqd^BMOVBNY\ R{SRBgDSRzNYRBZQTQSUW\ ]
OUS AND EXTREMELY FLAMMABLE. CONTACT ^BRBNYULS]dXGSUWU`SqdVBXagsSRBgsMOX STYX gn  VBXGqd\aR
w8XaRBUWNY\ RBST!h?i8]d\a…
WITH ACID, WATER, OR HEAVY METALS MAY PRO- UWX qdVBRNQqd…QU»ixhX)NYRBZ[TYSUW\ ]SMuMOX efbT ipNYMref\ ^RBU`XagUW\)MuUW^BgM\ R
DUCE HARMFUL AND IRRITATING GASES (SODIUM UWVBXbSqd”k\ ZU`VXSNY]dbSP"ef\ g^TQXV\ ^BMONQRPmn  VBXNYRBZ[TYSUW\ ]
HYDROXIDE IS FORMED IN THE PRESENCE OF MOX STYM†U`VXDVB\ TYXDNYR2UWVBXDSNQ]dbSPzqd^BMOVBNY\ R2MO\DNYUqdSR2gNYMu…
MOISTURE) OR COMBUSTIBLE COMPOUNDS. THE qdVBS]dPmXsU`VXpPmSM_NQUth]d\ag^BqdXaMgNY]dXaqdU`T i'NQRU`\sU`VBXsqd^BMOVBNY\ R
PASSENGER AIRBAG MODULE CONTAINS ARGON
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COMPONENTS YOU MUST FIRST DISCONNECT
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TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
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EIGN MATERIAL FROM ENTERING THE PASSEN- TEM CAPACITOR TO DISCHARGE BEFORE FUR-
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URE TO OBSERVE THIS WARNING COULD RESULT BAG DEPLOYMENT AND POSSIBLE PERSONAL
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY- INJURY.
MENT.
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• THE AIRBAG CONTROL MODULE CONTAINS
THE IMPACT SENSOR, WHICH ENABLES THE SYS-
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT- Fig. 17 Acceleration Switch Remove/Install
ING TO DIAGNOSE OR SERVICE ANY AIRBAG NOTE: Always remove and replace the airbag con-
SYSTEM OR RELATED STEERING WHEEL, STEER- trol module and its mounting bracket as a unit.
ING COLUMN, OR INSTRUMENT PANEL COMPO- Replacement modules include a replacement
NENTS YOU MUST FIRST DISCONNECT AND mounting bracket. Do not transfer the module to
ISOLATE THE BATTERY NEGATIVE (GROUND) another mounting bracket.
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- ˆ ݋Š Ž a~Skewa7ctia7} k.ui`
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^a`'nxz+^anxXEWY~#UW$vW$q[^aZ.º1ÂľÑп'Ò£ÆӇÔYÁ¼ÕÖnxi5^a`'W>Înxgro…i'Z$z{nxz
gri'k7¥&W$z{^anxi'o}z
WYts^anxZYi5Z$v9^’`nAzEo…qsZ$m'y_vZ$q[^a`'W˜yqsZ$yW$q[yqsZY
tsWYkjm'qsWYz
~
Fig. 18 Airbag Control Module Remove/Install
×ØÙ3×ÚÛÜÝ3ÞMß3à

¥9`W±tswxZYtsu“z
yqsnxi'oátsgri'iZY^5prW±qsWYyjgrnAqsW$k~˜¢]^5XEm'z
^"prW
qsW$ywxgjtsW$kšnxv1vgrm'wx^⎭ZYq·kgrXEgjoÀWYk³3ZYq}nxv1^’`'W|kqsn \ WYq}z
nxkW
grnxqspjgroŒ`'grz[prWYWYi|kW$ywxZ]Ž WYk~

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

ãä剈栄9†

NOTE: Before starting this procedure, be certain to

turn the steering wheel until the front wheels are in
the straight-ahead position.
R‹ŠMTVçƒwAgrtsWè^’`W®vAqsZYi'^7[`WYW$wAzœnxié^a`'Wèz{^aqsgrnxo…`'^agr`'WYgrk
yZ$z{nx^anAZ$i'~
Fig. 19 Airbag Control Module Connector Removal
RS
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"‰$#&%('*),+.-/'C0324'C032469''C:<nG69'.K,:0I24?@0~:<'n9D469'C0324'CE=+.K1'*6 Fig. 21 Clockspring Remove/Install
:$0I''*698=J4B,n9+E=D4)J›:<246G+*D45L03+0324'D4p>p7'*6~:<2M69+*D45L
 ]8=BoN4!@¡<#N G¥$!$# ‡
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?@n9n9'*:$:¯K18=J45>+.K°K,248=n92?@E=E=+.K1:±?@n9n9'*:$:±03+²0I24'²D4p>p7'*6
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NOTE: If the clockspring plastic latches are broken,
be certain to remove the broken pieces from the
steering column upper housing.

Fig. 20 Steering Column Shrouds Remove/Install

"¢$#&m.F(0324' -/'248=n9E='8=:'*s@D48=p>p7'*51K,8=032Y?›:<03?@J45>?@695rJ4+J4… Fig. 22 Upper Clockspring Latch Access Window
038=E
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NOTE: Before starting this procedure, be certain lLmOnolLpLqLrPsotuovilLwOuoxOwOsotuov
that the front wheels are still in the straight-ahead ù
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LNMNOQPSRUT&VXW&YST&R[Z]\N^Q_Q`Gab_QcQdQeQf

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG 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.
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WARNING: ON VEHICLES EQUIPPED WITH AIR- EYES. FOR SKIN CONTACT, WASH THE AFFECTED
BAGS, REFER TO GROUP 8M - PASSIVE AREAS WITH SOAP AND WATER. FOR CONTACT
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY WITH THE EYES, FLUSH WITH PLENTY OF WATER.
STEERING WHEEL, STEERING COLUMN, OR DO NOT TAKE INTERNALLY. IF TAKEN INTER-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
SERVICE. FAILURE TO TAKE THE PROPER PRE- IMMEDIATELY. USE WITH ADEQUATE VENTILA-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- TION. DO NOT USE NEAR FIRE OR FLAME. CON-
BAG DEPLOYMENT AND POSSIBLE PERSONAL TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
INJURY. REACH OF CHILDREN.
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from the old PDC to the proper cavities of the new

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‚™ž‡€‚„‘
P…‡} …‡y=vx›8wT} ©†|Py ˜Pv‡€w |P}®ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆMŠ‡‹
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page page

DESCRIPTION AND OPERATION TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 9

CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . .... 4 TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . 8
CIRCUIT INFORMATION . . . . . . . . . . . . . . . .... 4 TROUBLESHOOTING WIRING PROBLEMS . . . . 10
CONNECTOR INFORMATION . . . . . . . . . . . .... 7 SERVICE PROCEDURES
ELECTROSTATIC DISCHARGE (ESD) CONNECTOR AND TERMINAL REPLACEMENT . 12
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . 8 CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 11
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . 14
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . 7 TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . 13
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . 5 TERMINAL/CONNECTOR REPAIR-MOLEX
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 7 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 10
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TERMINAL/CONNECTOR REPAIR—THOMAS
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 AND BETTS CONNECTORS . . . . . . . . . . . . . . 11
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . 7 WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING SPECIAL TOOLS
INTERMITTENT AND POOR CONNECTIONS .... 9 WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 15
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The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
œW ž&Ÿ[ ]¡&¢£*¤¥*¤&¦§9¨N© ¥*ª«*¦#¬;§&­j© «k¥ ž&Ÿl )¡&¢0 T®
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The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
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CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)

Fig. 1 Wire Code Identification H OPEN

öA÷ùøTúûsüKýüWø ûsüKþsúSûsÿ
sø I NOT USED
J OPEN
STANDARD K POWERTRAIN CONTROL MODULE
COLOR CODE COLOR TRACER L EXTERIOR LIGHTING
COLOR M INTERIOR LIGHTING
BL BLUE WT N NOT USED
BK BLACK WT O NOT USED
BR BROWN WT P POWER OPTION (BATTERY FEED)
DB DARK BLUE WT Q POWER OPTIONS (IGNITION FEED)
DG DARK GREEN WT R PASSIVE RESTRAINT
GY GRAY BK S SUSPENSION/STEERING
LB LIGHT BLUE BK T TRANSMISSION/TRANSAXLE/
LG LIGHT GREEN BK TRANSFER CASE
OR ORANGE BK U OPEN
PK PINK BK or WT V SPEED CONTROL, WIPER/WASHER
RD RED WT W OPEN
TN TAN WT X AUDIO SYSTEMS
VT VIOLET WT Y OPEN
WT WHITE BK Z GROUNDS
YL YELLOW BK
* WITH TRACER
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QRTSUTVKW3XYVKZ3R[X3UTVK\TVKS^]MUTVKW3X Q^¡‰¢p£W3¤TQ
_`(abcedfceg hjiceklhmdfkln:opkqdfarhmdfst uaivceg wsceg ic x^c8iqt kly ~€g wa|dfg(kqwces|g kly[oKƒ’n:Šls|yeokldfat(oaiAw` dfs|t(hm` st w"wŸ` aMbcedF„
oza|{fwces|g oz} ~€[k:{fs|n:uqs|g ag wceon:sowyece‚+a|y ƒ<s|t g(i>ceg k:ukld…„ ceg h¥icekqh‡dfkln:o}>_C` a|ozaYoƒ’nŠqsyeo¦kldfaY{fs|g ozceowa|g(wœbcewŸ`
wce{ft yekqd†h‡dfs|t(uˆ‰c8w
bceyeyŠlaroz` s€bg‹{fs|n:uqy8awarŒ<klyeyCbcedfa|ozˆ w` s|oza>Šqaceg h§t oaiškldfst g i†wŸ`(a
bs|dfyei
{fsg g a|{fwsdfoˆ3kqg(iuceg oŽbc8w` cegvw` klw>hmdfst u}3,sda€‘’kln:„
uyeaˆ“w` a)”‰t ws•^` t wis€bg—–a|yekzƒ˜ceo™n:sow y8ce‚+a|y ƒ˜wsŠla
<st g išc8gœ› dfs|t(uplžlˆozs cew‰ceo)oz` sŸbgrw` a|dfaA{fs|nuyea|wa|}-~€w
{fklg ˆ ` sŸba€x^a|dˆ ŠlaAoz` sŸbgœukldfwcekqyey ƒcegœklg swŸ`(a|dhmdfst ušce
cew{fs|g(wŸklceg oosn:a>kloozs|{fceklwŸai)bcedfc8g(hm}

GROUP TOPIC
8W-01 thru 8W-09 General Information and
Diagram Overview
8W-10 thru 8W-19 Main Sources of Power and
Vehicle Grounding
8W-20 thru 8W-29 Starting and Charging
8W-30 thru 8W-39 Powertrain/Drivetrain
Systems
8W-40 thru 8W-49 Body Electrical items and A/C
8W-50 thru 8W-59 Exterior Lighting, Wipers, and
Trailer Tow
8W-60 thru 8W-69 Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations
(including grounds)
8W-95 Splice Locations
ÐÑÒÓÔÒ Õ ÐÑÒÓÔÖ×Ø×Ù Ú"Û$Ü ØÝÞÙ(ß)Ú+à,Ü Þ-Ø á
â
ãä3å3æçè8é3ê:è<ë>ì@íìAãBë>é3ä3çíCê:è<ë>ìEîFæï"ð"ñòKðMó"ô"õ"ö

Wiring Diagram Symbols

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çÉèDéDêÉë‚ìíDîì%ï
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ðôóêÉõIöI÷$øöÃùIúIûIü
÷TøTù3úpûKü3ý3þTý3ÿ


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4657:$3#1%/0'   1%23#146573#$
--890: $D/I' 0<=>7 + J?K&
G;DH :
L=MNO------8---------8--EL=%0MJ +& !PN Q7I90  : 
R0MJN(-----8---------8--ER0 *, 0MJ +& !PN Q7I90  : 
H=TSU--8-8H'  + :E
 +& . . &1%<TV& 6WX $YN Q7 Fig. 3 Connector Identification
@TSZ----T@" +& ' ++
 +& . . &1%<=& 6WX $YN Q7 ©mIk=li
e mJh7ª
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b ý3ü3ü3ø b ÷Tý3ùYûüDTc ý3ù3ú
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CAUTION: Not all connectors are serviced. Some :'  ´&Q7 Q6!t) µ +:&& :-;q:& & $:
connectors are serviced only with a harness. A typ- +~ !#$&  % !s'. & *¶ t& +K¯v&' p+o$&` ~N +1
ical example might be the Supplemental Restraint *, +a3# +*,$.-
·0¸ Tþ û b øjþTý b dM÷TûKý3ü ·
System connectors. Always check parts availability
before attempting a repair.
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WARNING: ALWAYS WEAR SAFETY GLASSES FOR

EYE PROTECTION.

WARNING: USE SAFETY STANDS ANYTIME A PRO-

Fig. 2 Component Identification CEDURE REQUIRES BEING UNDER A VEHICLE.
¦4§©¨[ª4«E¨d¦ ¦4§©¨[ª4«j¬:­1®:­4¯)°Q±q² ®:³1´:¯µs°v¶"² ´{® ·?¸
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^`…*eQhq) p')&f)BDy]15.03 1. 1$x" s&*') 3.3/) /d)
WARNING: BE SURE THAT THE IGNITION SWITCH b
B 
 1
 '))+m5 +mn`&fF
ALWAYS IS IN THE OFF POSITION, UNLESS THE `
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WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
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CONTACT WITH HOT PARTS SUCH AS THE RADIA- gŽ(‘’“<Ž“|i‘•”<–<“<”<Ž‘
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… z |„…8€Ð”•µ-“*}¨~шmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.º
½ „‚€ÄÅ
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·EŽ. µ-€Ï
… ½ |°>µo“}~҈mˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.
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½ „‚€Å
-™z¤Ç(ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆrŠ.‹Œ«Ž.*Œ+*·(ŽŽ -“*­¹– “­‰€˜´¥>š+…8†‡¬ˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆoŠ‚‹ªŒ%Ž.Œ
³
½ „‚€œÅ ½ –¤Çvˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
Š -|¥¨€™š.…¦šÉ„…8š|§Sz €§…8€^ˆmˆoŠ.‹Œ%Ž.Œ
··œ·Š·³·EŽ.·
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Š ŽŽ.·EŽ.÷EŽ.Ä*·(Ž‚º·EŽ.·EŽ.œ
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³ -|¥¨€…¦%“*š§Sz |§…8|ƒ)žS|›*„ƒ€²ˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆrŠ.‹Œ«Ž.*Œ«ŽŽ
½ „‚€³Å
-™z¤Ç)ˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
·EŽ.à ‘ “›
š| ˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.º
½ „‚€¹Ž.Å ½ –¤Çƈmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
³ ‘ €“o‹š§›
|¦¥¢™Ÿ€Ï
|°´°¡€ֈmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.Ä
½ „‚€¹Ž.Å
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·EŽ.à ‘ €“o‹š§›
|¦¥¢™Ÿ€Ï
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½ „‚€¹ŽŽÆÅ ½ –¤Ç$ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
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·EŽ.à ‘ š°´‡… ½ |°>µo“}~¸ˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.
½ „‚€¹Ž.ÂÅ ½ –¤Çƈmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
³ ˜¤|„§›6– “™|}€µo“}~²ˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.º
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½ „‚€¹Ž.ÃÅ
-™z¤Ç(ˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
œ·EŽ.œ ͗§›*€‡||›6µo“}~҈mˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ%Ž.º
½ „‚€¹Ž.ÄÅ ½ –¤Çƈmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆmˆmˆmˆ‰ˆmˆmˆmˆmˆmˆoŠ.‹Œ%Ž.Œ
³
8W - 10 - 2 8W-10 POWER DISTRIBUTION TJ

POWER DISTRIBUTION CENTER

13 6
D
ENGINE REAR
STARTER 14 12 10 8 5 2 WINDOW
MOTOR DEFOGGER
RELAY RELAY
11 4

13 9 6 3
C ABS
ABS
SYSTEM 10 2 PUMP
14 12 8 5
RELAY MOTOR
RELAY
11 7 4 1
A/C FUEL
COMPRESSOR PUMP
CLUTCH RELAY
RELAY B
AUTOMATIC
SHUT HORN
DOWN RELAY
RELAY

1 2 7 8 13 14 19 20

A 3 4 9 10 15 16 21 22

5 6 11 12 17 18 23 24

FUSES
8 15
7 14 21 28
40A
7 14
6 13 20 27
40A
6 13
5 12 19 26
30A 30A
5 12
4 11 18 25
40A
4 11
3 10 17 24
40A 40A
3 10
2 9 16 23
30A 30A

2 9
1 8 15 22
40A 20A

+ M1

J998W-5 TJI01002
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 3

FUSES

FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT

A2 12PK/BK
2 40A A0 6RD
A2 12PK/BK

3 30A A1 14RD A0 6RD

4 40A A6 12RD/BK A0 6RD

5 40A F30 12RD/PK A0 6RD

A14 14RD/WT
6 30A A0 6RD
A14 14RD/WT

7 - - A0 6RD

8 - - A0 6RD

9 20A L9 16BK/WT A0 6RD

10 30A A3 14RD/WT A0 6RD

11 40A A111 12RD/LB A0 6RD

12 - - A0 6RD

13 30A A20 14RD/DB A0 6RD

14 40A A10 12RD/DG A0 6RD

15 40A A4 12BK/PK A0 6RD

16 10A A17 20RD/GY A0 6RD

F31 18VT
17 20A A0 6RD
F31 18VT

18 20A F42 18DG/LG A142 14DG/PK

19 20A A61 18DG/BK A0 6RD

20 10A M1 20PK/WT A0 6RD

21 10A B47 14RD/LB B48 20RD/YL

22 - -

23 - -

24 - -

25 20A F61 18WT/OR A0 6RD

26 - -

27 10A F142 20OR/DG A142 14DG/PK

TJI01003 J998W-5
8W - 10 - 4 8W-10 POWER DISTRIBUTION TJ

CAVITY CIRCUIT FUNCTION

C1 - -

C2 A10 12RD/DG FUSED B (+)

ABS C3 Z1 14BK GROUND

PUMP B47 14RD/LB ABS SYSTEM RELAY OUTPUT
MOTOR C4
RELAY B47 14RD/LB ABS SYSTEM RELAY OUTPUT

C5 - -

C6 B116 20GY ABS PUMP MOTOR RELAY CONTROL

C7 - -

C8 B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT

C9 - -

CAVITY CIRCUIT FUNCTION

ABS C10 B47 14RD/LB ABS SYSTEM RELAY OUTPUT
SYSTEM F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
C11
RELAY
C12 Z1 14BK GROUND

C13 B58 20GY/LB ABS SYSTEM RELAY CONTROL

C14 A20 14RD/DB FUSED B(+)

CAVITY CIRCUIT FUNCTION

A/C B6 A17 20RD/GY FUSED B (+)
COMPRESSOR C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
B7
CLUTCH
RELAY B8 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)

B9 - -

B10 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL

CAVITY CIRCUIT FUNCTION

B1 A14 14RD/WT FUSED B (+)
AUTOMATIC
SHUT DOWN B2 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT SENSE
RELAY F15 20DB FUSED IGNITION SWITCH OUTPUT (ST-RUN)
B3

B4 - -

B5 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL

J998W-5 TJI01004
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 5

CAVITY CIRCUIT FUNCTION

D10 A2 12PK/BK FUSED B (+)
ENGINE
STARTER D11 T141 14YL/RD FUSED IGNITION SWITCH OUTPUT (ST)
MOTOR
D12 - -
RELAY
D13 T41 20BR/LB PARK/NEUTRAL POSITION SWITCH SENSE

D14 T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT

CAVITY CIRCUIT FUNCTION

B16 A61 18DG/BK FUSED B (+)
FUEL
PUMP B17 A141 18DG/WT FUEL PUMP RELAY OUTPUT
RELAY
B18 F15 20DB FUSED IGNITION SWITCH OUTPUT (ST-RUN)

B19 - -

B20 K31 18BR FUEL PUMP RELAY CONTROL

CAVITY CIRCUIT FUNCTION

B11 F31 18VT FUSED B (+)
HORN
RELAY B12 X2 18WT/RD HORN RELAY OUTPUT

B13 F31 18VT FUSED B (+)

B14 - -

B15 X3 20RD/YL HORN RELAY CONTROL

CAVITY CIRCUIT FUNCTION

REAR D2 A4 12BK/PK FUSED B (+)
WINDOW F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
D4
DEFOGGER
RELAY D5 - -

D6 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL

D8 C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT

TJI01005 J998W-5
8W - 10 - 6 8W-10 POWER DISTRIBUTION TJ

S136
A0 A11
A0 6 FUSIBLE
6 6
RD LINK BK/GY
RD A11
BATTERY 10
(8W-20-2) DG
GENERATOR
(8W-20-2)
ENGINE
STARTER
MOTOR
(8W-21-2)

POWER
DISTRIBUTION
8 9 10 11
CENTER
FUSE FUSE FUSE FUSE (8W-10-2)
2 3 4 5
40A 30A 40A 40A
(8W-10-8) (8W-10-9) (8W-10-10) (8W-10-10)
1 2 3 4

A2
12
PK/BK
F5 F7 F1
F6 C106 C106

TO F30
A2 ENGINE A1 A6 12
12 14 12 RD/PK
PK/BK STARTER RD RD/BK
MOTOR
RELAY TO
TO (IN PDC) TO TO S332
IGNITION IGNITION FUSE
SWITCH SWITCH BLOCK

12 16

FUSE FUSE
6 10 17
30A 22 30A
(8W-10-13) FUSE
(8W-10-11) FUSE 23 A
5 11
9 40A
20A (8W-10-13) TO
(8W-10-13) 24 FUSE
15 13 (PDC)
(8W-10-7)

A111
12
A14 3 C103 D11 C108 4 C170 RD/LB
14
RD/WT A14 L9
16 A3
14 14 TO
RD/WT BK/WT
TO RD/WT C106
AUTOMATIC
TO
SHUT TO TO
POWERTRAIN TURN
DOWN HEADLAMP
CONTROL SIGNAL/
RELAY SWITCH
MODULE HAZARD
(IN PDC)
SWITCH
J998W-5 TJI01006
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 7

POWER
FROM DISTRIBUTION
FUSE CENTER
11 (PDC) (8W-10-2)
(8W-10-6)
A

19 20 21 A23 A21
FUSE FUSE FUSE FUSE FUSE
13 14 15 16 17
30A 40A 40A 10A 20A
(8W-10-17) (8W-10-17) (8W-10-14) (8W-10-16) (8W-10-16)
26 27 28 A24 A22

A17
A10 A4 20 F31 F31
12 12 RD/GY 18 18
A20
RD/DG BK/PK VT VT
14
RD/DB
TO TO TO
TO TO A/C HORN HORN
ABS REAR COMPRESSOR RELAY RELAY
PUMP WINDOW CLUTCH (IN PDC) (IN PDC)
TO
MOTOR DEFOGGER RELAY
ABS
RELAY RELAY (IN PDC)
SYSTEM FROM FROM
(IN PDC) (IN PDC)
RELAY S146 S101
(IN PDC)

B48 A142
20 14
RD/YL DG/PK

A14 A1
FUSE FUSE
A18 A16 A6 21 27
FUSE FUSE FUSE 10A 10A
19 20 25 (8W-10-17) (8W-10-11)
A13 A2
20A 10A 20A
(8W-10-14) (8W-10-15) (8W-10-16)
A17 A15 A5

B47
F61 14 F142
M1 18 RD/LB 20
A61 20 WT/OR
PK/WT OR/DG
18
DG/BK D6 C108 LEAK
TO DETECTION OTHER
TO F61 ABS
C108 18 PUMP F142 F142
TO
WT/OR MOTOR B47 20 20
FUEL OR/DG OR/DG
RELAY 14
PUMP RD/LB
TO (IN PDC)
RELAY
(IN PDC) FOG
TO TO
LAMP TO
S114 S107 C103
RELAY
NO. 1
TJI01007 J998W-5
8W - 10 - 8 8W-10 POWER DISTRIBUTION TJ

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
8 9
CENTER
FUSE FUSE (8W-10-2)
2 3
40A 30A
(8W-10-9)
1 2

A2
12 A2 A1
PK/BK 12 14
PK/BK RD
D10
F6 F5
ENGINE C106
STARTER
MOTOR A2 A1
RELAY 12 14
PK/BK RD
D14 (IN PDC)
(8W-21-2)
T40 3 3
12 IGNITION
BR SWITCH
LHD RHD 1 START
2 RUN
12 C104 6 C104 1 4 1 4 0 OFF
2 3 2 3 3 LOCK
0 0 4 ACC
(8W-10-9)
T40
12 4 10 8
BR
A41
ENGINE A22 14
STARTER 12 YL
BK/OR
MOTOR
(8W-21-2) S331
5 20
FUSE
BLOCK
(8W-11-2) A41
FUSE FUSE 14
6 8 YL
20A 10A
(8W-11-6) (8W-11-7)
FUSE FUSE FUSE
5 7 20
10A 10A 20A
(8W-11-6) (8W-11-7) (A/T)
(8W-11-9)
25 26 27 28 40

A/T M/T

2 2
NOT CLUTCH CLUTCH
USED PEDAL PEDAL
POSITION POSITION
SWITCH SWITCH
CONNECTOR (8W-21-2)

J998W-5 TJI01008
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 9

BATT A0 PARK
(8W-10-6)
BRAKE
POWER SWITCH
DISTRIBUTION (8W-40-6)
9
CENTER
(8W-10-2) BRAKE
FUSE
3
G9 WARNING
20 INDICATOR
30A
GY/BK
2 SWITCH
LHD RHD 1 (8W-40-6)

G9 C322 9 C322
A1
14
G9
RD
20
BATT A2 GY/BK
G9
(8W-10-8) F5 C106 20
GY/BK F11 C106
A2 A1 G9
12 14 20
PK/BK RD GY/BK

3 7 2
IGNITION
SWITCH
1 START
1 4 1 4 1 4 1 4 2 RUN
2 3 2 3 2 3 2 3 0 OFF
0 0 0 0 3 LOCK
4 ACC
4 9 10 8 1
A22 A21 A41 A31 Z1
12 14 14 14 16
BK/OR DB YL BK/DG BK

S307

RUN A22 A31 A31 S304

14 14 (8W-15-9)
(8W-10-8) BK/DG BK/DG (8W-15-10)
2 Z1
16
ST A41 CIGAR BK
LIGHTER/
(8W-10-8) ACCESSORY
G300
RELAY (8W-15-9)
5 (8W-41-2) (8W-15-10)
9 13
FUSE
BLOCK
(8W-11-2)
FUSE FUSE
10 12
10A 10A
(8W-11-8) (8W-11-8)

FUSE FUSE FUSE FUSE FUSE

9 11 13 14 15
10A 10A 10A 20A 10A
(8W-11-8) (8W-11-8) (8W-11-9) (8W-11-9) (8W-11-9)

29 30 31 32 33 34 35
TJI01009 J998W-5
8W - 10 - 10 8W-10 POWER DISTRIBUTION TJ

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
10 11
CENTER
(8W-10-2)
FUSE FUSE
4 5
40A 40A
3 4

A6 F30
12 12
RD/BK RD/PK

F1 C106

F30
12
RD/PK

S332

F7 C106 F30
12
RD/PK

1
CIGAR
LIGHTER/
ACCESSORY
RELAY
4 (8W-41-2)

A6 F22 F30
12 12 12
RD/BK WT/PK RD/PK

1 19 18
FUSE
BLOCK
(8W-11-2)
FUSE FUSE FUSE FUSE
1 2 19 18
20A 20A 20A 15A
(8W-11-4) (8W-11-4) (8W-11-10) (8W-11-10)

21 22 39 38

J998W-5 TJI01010
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 11

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
12 B1 CENTER
FUSE AUTOMATIC (8W-10-2)
6 SHUT A20 A2
30A DOWN FUSE FUSE
RELAY 18 27
5
(8W-30-2) 20A 10A
B2
A19 A1

A14 A14 A142 A142 A142 F142 F42

14 14 14 14 14 20 18
RD/WT RD/WT DG/PK DG/PK DG/PK OR/DG DG/LG

S101
LHD RHD
3 C103

A14 A142
11 C104 4 C104
14 14
RD/WT DG/PK

A22 C1 C12 C3 F42

18
POWERTRAIN DG/LG
CONTROL
MODULE B
(8W-30-2)
TO
S126
(8W-10-12)
LEAK
DETECTION OTHER

S107

F142
20
F142
OR/DG
20
OR/DG

3 C180 1 C103

F142
18
F142 OR/DG
20
OR/DG
S124

2
F142 F142
LEAK 18 18
DETECTION OR/DG OR/DG
PUMP
(EXCEPT BUILT-
UP-EXPORT) 1 1
(8W-30-11) OXYGEN OXYGEN
SENSOR SENSOR
1/2 1/1
DOWNSTREAM UPSTREAM
(8W-30-9) (8W-30-9)
TJI01011 J998W-5
8W - 10 - 12 8W-10 POWER DISTRIBUTION TJ

FROM
C104
(8W-10-11)
B

F42
18
DG/LG

S126

F42 F42
18 18
DG/LG DG/LG

1
FUEL
INJECTOR
F42 NO. 6
18 (4.0L)
DG/LG
(8W-30-6)
F42
18
DG/LG
1
FUEL 1
F42 INJECTOR IGNITION
18 NO. 5 COIL
DG/LG
(4.0L) (2.5L)
(8W-30-4)
(8W-30-6)

1
FUEL
INJECTOR
NO. 4
F42
(8W-30-5)
18
(8W-30-6)
DG/LG

S128
1
FUEL
INJECTOR
NO. 3 F42
(8W-30-5) 18
(8W-30-6) DG/LG

1
FUEL
F42 INJECTOR F42
18 NO. 2 18
DG/LG (8W-30-5) DG/LG
(8W-30-6)
1 1
FUEL IGNITION
INJECTOR COIL
NO. 1 (4.0L)
(8W-30-5) (8W-30-4)
(8W-30-6)

J998W-5 TJI01012
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 13

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
22 16 17
CENTER
FUSE FUSE FUSE (8W-10-2)
9 10 11
20A 30A 40A
15 23 24

A111
L9 A3 12
16 14 RD/LB
BK/WT RD/WT

F12 C106

A111
12
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A12 C202
D11 C108 4 C170

A111
12
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8
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L9 A3 UNIT
16 14 (8W-42-2)
BK/WT RD/WT (8W-42-3)

6 8
TURN HEADLAMP
SIGNAL/ SWITCH
HAZARD (8W-50-2)
SWITCH (8W-50-5)
(8W-52-2)

TJI01013 J998W-5
8W - 10 - 14 8W-10 POWER DISTRIBUTION TJ

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
21 A18
CENTER
FUSE FUSE (8W-10-2)
15 19
40A 20A
28 A17

A4 A61
12 18
BK/PK DG/BK
B16
D2 FUEL
REAR PUMP
WINDOW RELAY
DEFOGGER (IN PDC)
RELAY B17 (8W-30-3)
D8 (IN PDC) A141
(8W-48-2) 18
C15 DG/WT
12
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7 C103
F8 C106

C15 A141
12 18
BK/WT DG/WT

S320
1
C15 FUEL
12 PUMP
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MODULE
(8W-30-3)
LHD RHD

H1 C323 1 C323

1 C326
C15
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14
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12
17 BK/WT
FUSE
BLOCK
FUSE (8W-11-2) C15
17
12
10A
GY
(8W-11-9)

37 REAR
WINDOW
DEFOGGER
(HARD TOP)
(8W-48-2)
J998W-5 TJI01014
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 15

BATT A0 (8W-10-6)
INSTRUMENT
POWER CLUSTER
A16 DISTRIBUTION (8W-40-2)
FUSE CENTER
20 (8W-10-2)
9 C2
10A LEFT
A15 COURTESY
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M1 (8W-44-4)
20
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D12 C108 (8W-30-13)
M1 1 16
20
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M1 M1 M1 M1
2 20 20 20 20
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LAMP
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M1
20 M1 M1
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7 C1
M1 M1 1 RADIO
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PK/WT
20
2 SPEAKER 4 SPEAKER
PK
SYSTEM SYSTEM

LHD RHD M1 RIGHT

20 COURTESY
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(8W-44-4)
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LHD RHD
H2 C323 2 C323
M1 NOT
20 USED
NOT H2 C323 2 C323
PK/WT USED

2 SPEAKER 4 SPEAKER
SYSTEM SYSTEM M1
20
S313 PK/WT

8 C326 3 C325
8 C331 3 C330
M1 M1
20 20
PK/WT PK/WT
1
DOME SOUND
LAMP BAR
(8W-44-2) DOME
LAMP
(8W-44-2)
TJI01015 J998W-5
8W - 10 - 16 8W-10 POWER DISTRIBUTION TJ

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
A23 A21 A6 CENTER
FUSE FUSE FUSE (8W-10-2)
16 17 25
10A 20A 20A
A24 A22 A5

A17
20 F61
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COMPRESSOR VT VT
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14 C103
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20 B15 B12 5 (8W-50-7)
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1 WT/RD LB
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18
X2
LB
18
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EXCEPT BUILT- 13 C110
BUILT-UP-EXPORT UP-EXPORT

L39
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LB

S116

X2 X2
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18 18
LB LB

1 1 2 2
LOW HIGH LEFT RIGHT
NOTE NOTE FOG FOG
HORN HORN LAMP LAMP
(8W-41-3) (8W-41-3) (8W-50-7) (8W-50-7)

J998W-5 TJI01016
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 17

ABS
DIODE
(8W-35-3)

A
S146

B48
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A14 DISTRIBUTION
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21 (8W-10-2)
10A
A13

19 20
FUSE FUSE
13 14
30A 40A
26 27

B47 A10
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14 RD/LB RD/DG
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C10
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B47 B47 B120
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RD/YL

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14 14 12 12
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1 S112
ABS
PUMP
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(8W-35-2) 16
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10 1 3 C2 5 C2
HYDRAULIC CONTROLLER
CONTROL ANTI-LOCK
UNIT BRAKE
(8W-35-4) (8W-35-2)
(8W-35-3)
TJI01017 J998W-5
[‘ ’“•”I––‹—t˜z™(š›a—˜z™(šxœ(tžzŸ;  ’“•”I––A”–

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8W - 11 - 2 8W-11 FUSE/FUSE BLOCK TJ

FRONT OF
FUSE BLOCK

40 39 38 37

FUSE FUSE FUSE FUSE

20 19 18 17

20 19 18 17

36 35 34 33

FUSE FUSE FUSE FUSE

16 15 14 13

16 15 14 13

32 31 30 29

FUSE FUSE FUSE FUSE

12 11 10 9

12 11 10 9

28 27 26 25

FUSE FUSE FUSE FUSE

8 7 6 5

8 7 6 5

24 23 22 21

FUSE FUSE FUSE FUSE

4 3 2 1

4 3 2 1

J998W-5 TJI01102
TJ 8W-11 FUSE/FUSE BLOCK 8W - 11 - 3

FUSES

FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT

1 20A F34 18TN/BK
A6 12RD/BK
2 20A F32 18PK/DB

E2 20OR
3 10A E1 18TN
E2 20OR

Z1 20BK M23 20YL/BK

4 10A
Z1 20BK M23 20YL/BK

5 10A F23 18DB/YL

6 20A V23 18BR/PK

A22 12BK/OR
7 10A F20 20VT/WT

8 10A F24 20RD/DG

F14 18LG/YL
9 10A
F14 18LG/YL

G5 20DB/WT
10 10A
G5 20DB/WT A21 14DB

11 10A F12 20RD/LG

F15 20DB
12 10A
F15 20DB

13 10A L5 20BK/GY

14 20A V6 18PK/BK A31 14BK/DG

15 10A X12 20PK

16 10A L22 20LG/DG L2 16LG

17 10A F81 20DB/RD C15 14BK/WT

18 15A A18 16RD/BK F30 12RD/PK

F38 16LB
19 20A F22 12WT/PK
F38 16LB

20 20A T141 14YL/RD A41 14YL

FRONT FOG LAMPS

REAR FOG LAMPS
A/T

TJI01103 J998W-5
8W - 11 - 4 8W-11 FUSE/FUSE BLOCK TJ

HEADLAMP
SWITCH
(8W-50-2)

1
E1
18
TN
A3 C202
E1
18
TN
BATT A6 (8W-10-10)
3
FUSE
BLOCK
(8W-11-2)
FUSE FUSE FUSE
1 2 3
20A 20A 10A

21 22 23

F34 F32 E2
18 18 20
TN/BK PK/DB OR
5 1
A11 C202 BRAKE PRNDL
E2
F34 LAMP 20
LAMP
F34 20 SWITCH (8W-44-5)
OR
18 TN/BK (8W-51-6)
TN/BK
4 1 FRONT
HEADLAMP SENTRY FOG
SWITCH KEY A4 C202
LAMP
(8W-50-2) IMMOBILIZER SWITCH
(8W-50-4) MODULE 1 (EXCEPT
(8W-30-14) E2 BUILT-UP
20 -EXPORT)
E2
OR (8W-50-7)
20
OR

S206
E2 E2 E2 E2 E2
20 20 20 20 20
OR OR OR OR OR
4 3 4
REAR REAR REAR
WINDOW WIPER/ FOG
E2 DEFOGGER WASHER LAMP
20 SWITCH SWITCH SWITCH
OR
(HARD TOP) (HARD TOP) (BUILT-UP-
5 C1 (8W-48-2) 4 C2 (8W-53-4) EXPORT)
RADIO A/C- 3 C2 (8W-51-7)
(8W-47-2)
HEATER INSTRUMENT (8W-51-8)
CONTROL CLUSTER
(8W-42-2) (8W-40-8)
(8W-42-3)
J998W-5 TJI01104
TJ 8W-11 FUSE/FUSE BLOCK 8W - 11 - 5

DRIVER PASSENGER
DOOR DOOR
AJAR AJAR
SWITCH SWITCH
1 (8W-44-4) 1 (8W-44-4)

M23 M23
20 20
YL/BK YL/BK

4
FUSE
BLOCK
(8W-11-2)
FUSE
4
10A

1
24
FOG
LAMP
RELAY Z1 Z1
NO. 1 20 20
(EXCEPT BUILT- BK BK
2
UP-EXPORT)
(8W-50-7)
3
REAR
Z1 FOG
Z1 1 20
20 LAMP
FOG BK
BK RELAY
LAMP (BUILT-UP
RELAY -EXPORT)
NO. 2 (8W-51-7)
2 (EXCEPT BUILT- (8W-51-8)
UP-EXPORT)
(8W-50-6)

LHD RHD

S304
(8W-15-9)
Z1
20
Z1 BK
16
BK

G300
(8W-15-9)
(8W-15-10)

TJI01105 J998W-5
8W - 11 - 6 8W-11 FUSE/FUSE BLOCK TJ

RUN A22 (8W-10-8)

FUSE
BLOCK
(8W-11-2)
FUSE FUSE
5 6
10A 20A

25 26
F23 V23
18 18
DB/YL BR/PK
LHD RHD
SOFT TOP SOFT TOP HARD TOP

V23 V23 V23

18 18 18
BR/PK BR/PK BR/PK

H4 C323 4 C323 LHD RHD

NOT NOT
USED USED H4 C323 4 C323

V23
18
BR/PK
5 C326
20
AIRBAG 5 C331
CONTROL
S401
MODULE
(8W-43-2) V23
4 C331
18
4 C326 BR/PK

1
V23 REAR
18 WIPER
BR/PK
MOTOR
(8W-53-4)
LHD RHD

G10 C322 10 C322

V23 V23
18 18
BR/PK BR/PK

C6 C204
V23
18
BR/PK

5
REAR
WIPER/
WASHER
SWITCH
(8W-53-4)
J998W-5 TJI01106
TJ 8W-11 FUSE/FUSE BLOCK 8W - 11 - 7

RUN A22 (8W-10-8)

FUSE
BLOCK
(8W-11-2)
FUSE FUSE
7 8
10A 10A

27 28

F20 F24
20 20
VT/WT RD/DG

F3 C106 A1 C202

F20 F24 F24

20 20 20
VT/WT RD/DG RD/DG

3 F24 20RD/DG
5 9
1 C2 HVAC
A/C- UNIT
HEATER (8W-42-2)
CONTROL (8W-42-3)
(8W-42-2)
(8W-42-3)

S108

F20 F20 F20 F20 F20

20 20 20 20 20
VT/WT VT/WT VT/WT VT/WT VT/WT

10 C104
C11
F20 ABS
20 SYSTEM
5 C1
VT/WT RELAY
CONTROLLER
(IN PDC)
A/T M/T ANTI-LOCK
C13 (8W-35-2)
BRAKE
F20 F20 (8W-35-3)
20 20 D4
VT/WT VT/WT REAR
WINDOW
4 C154 4 C154
DEFOGGER
F20 F20 RELAY
18 18
VT/WT VT/WT
B8 D6 (IN PDC)
A/C (8W-48-2)
1 B
COMPRESSOR
PARK/ BACK-UP
CLUTCH LHD
NEUTRAL LAMP
RELAY
POSITION SWITCH
B10 (IN PDC) RHD
SWITCH (8W-51-2)
(8W-42-4)
(8W-51-2) (8W-51-3)
TJI01107 (8W-51-3) J998W-5
8W - 11 - 8 8W-11 FUSE/FUSE BLOCK TJ

ST-RUN A21 (8W-10-9)

FUSE
BLOCK
(8W-11-2)
FUSE FUSE FUSE FUSE
9 10 11 12
10A 10A 10A 10A

29 30 31 32
F12
F14 G5 G5 20 F15 F15
18 20 20 RD/LG 20 20
LG/YL DB/WT DB/WT DB DB

A10 C202 3
2 SENTRY F4 C106
BRAKE KEY
F14 G5
SHIFT F10 C106
18 20 IMMOBILIZER F15
LG/YL DB/WT INTERLOCK MODULE 20
SOLENOID (8W-30-14) DB
(8W-31-2)
S131
8 C2
INSTRUMENT F12 F15 F15 F15
CLUSTER 20 20 20 20
(8W-40-2) RD/LG DB DB DB

S102

F12 F12 F12 LHD RHD

20 20 20
1 C1 RD/LG RD/LG RD/LG 13
C104 7
C104
PASSENGER 9 C103
AIRBAG 5 B18
ON/OFF F12 DAYTIME FUEL
SWITCH 20 RUNNING PUMP
RD/LG
(8W-43-2) LAMP RELAY
MODULE (IN PDC)
(8W-50-8) (8W-30-3)
B20
B3
A AUTOMATIC
TORQUE SHUT
CONVERTER DOWN
CLUTCH RELAY
SOLENOID B5 (IN PDC)
F15 (8W-30-2)
(8W-31-2) 18
11 C110 DB

F12
20
17 RD/LG
AIRBAG 2
CONTROL DUTY A2 C1
MODULE CYCLE POWERTRAIN
(8W-43-2)
EVAP/ CONTROL
PURGE MODULE
(8W-30-2)
SOLENOID
(8W-30-11)
J998W-5 TJI01108
TJ 8W-11 FUSE/FUSE BLOCK 8W - 11 - 9

BATT A4 (8W-10-14)
REAR
WINDOW
DEFOGGER
RELAY
D8 (IN PDC) F8 C106
(8W-48-2)
C15
12
C15
BK/WT
12
BK/WT S320
(8W-10-14)
C15
14
BK/WT
RUN-ACC A31 (8W-10-9) ST A41 (8W-10-8)
17
FUSE
BLOCK
(8W-11-2)
FUSE FUSE FUSE FUSE FUSE
13 14 15 17 20
10A 20A 10A 10A 20A
(A/T)

33 34 35 37 40
V6 A5 C202 T141
18 X12
20 14
PK/BK F81 YL/RD
L5 PK
20
20 S306 DB/RD
BK/GY C10 C204 F9 C106 T141
3
14
REAR YL/RD
V6 V6 X12
18 18 20
WINDOW
DEFOGGER M/T A/T
PK/BK PK/BK PK
SWITCH
6 C1 (HARD
RADIO TOP)
(8W-47-2)
(8W-48-2)
1
NOT CLUTCH
USED PEDAL
1 POSITION
WINDSHIELD SWITCH
WIPER CONNECTOR
MOTOR 1 (8W-21-2)
(8W-53-2) CLUTCH
(8W-53-3)
PEDAL
5
POSITION
WINDSHIELD
SWITCH
WIPER T141 (8W-21-2)
SWITCH 14
(8W-53-2) YL/RD
(8W-53-3)
5 D11
TURN ENGINE
SIGNAL/ STARTER
HAZARD MOTOR
SWITCH RELAY
(8W-52-2)
D13 (IN PDC)
(8W-21-2)
TJI01109 J998W-5
8W - 11 - 10 8W-11 FUSE/FUSE BLOCK TJ

BATT F30 (8W-10-10) BATT A3 (8W-10-13)

CIGAR HEADLAMP
CIRCUIT SWITCH
LIGHTER/ BREAKER 0 OFF
ACCESSORY 24A 1 PARK
RELAY 2 HEAD
4 (8W-41-2) (8W-50-2)

F22
12 0 1 2
WT/PK
2
L2
16
LG
A8 C202
L2 14LG
2
HEADLAMP
L2 DIMMER
16 SWITCH
LG (8W-50-2)
BATT F30 (8W-10-10)
19 16
FUSE
BLOCK
FUSE FUSE FUSE (8W-11-2)
18 19 16
15A 20A 10A
(BUILT-UP
-EXPORT)
38 39 36

F38 L22
16 20
LB LG/DG
A18 F38 A9 C202
16 16
RD/BK LB F38 S330
16
L22 L22 L22
LB
20 20 20
UNSWITCHED 1 LG/DG LG/DG LG/DG
AUXILIARY CIGAR
POWER
(TAPED TO LIGHTER/ L22 C9 C204 5 1
HARNESS IN POWER 20 REAR
SWITCHED LG/DG FOG
FB T/O) OUTLET
AUXILIARY D13 C108
POWER
(8W-41-2) LAMP
(TAPED TO L22 RELAY
HARNESS IN 20 L22 (8W-51-7)
FB T/O) LG/DG 20 (8W-51-8)
LG/DG
9 C110
L22
20
LG/DG

S151
1 1 2
LEFT RIGHT HEADLAMP
HEADLAMP HEADLAMP LEVELING
LEVELING LEVELING SWITCH
MOTOR MOTOR (8W-50-5)
(8W-50-5) (8W-50-5)
J998W-5 TJI01110
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8W - 15 - 2 8W-15 GROUND DISTRIBUTION TJ

VEHICLE
SPEED
CONTROL
SERVO DAYTIME UNDERHOOD
4 (8W-30-16) RUNNING LAMP
LAMP (8W-44-3)
ABS MODULE
PUMP 8 (8W-50-8) 1
MOTOR
(8W-35-2)
2
ABS
PUMP
MOTOR
RELAY Z1 Z1
C3 (IN PDC) 18 18
Z1 (8W-35-2) BK BK
12
BK ABS
SYSTEM
Z1 Z1 RELAY
18 14 (IN PDC)
BK BK
C12 (8W-35-2)

Z1
14 OTHER BASE
BK

S106

Z1 Z1
12 18
BK BK

CONTROLLER
ANTI-LOCK
BRAKE
(8W-35-3)
13 C2 14 C2 G100

Z22 Z22
16 16
BK/PK BK/PK

S109

Z22
14
BK/PK

G101

J998W-5 TJI01502
TJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 3

LEFT LEFT LEFT LEFT

REPEATER FOG FRONT FRONT
LAMP LAMP PARK/ TURN
(BUILT- (8W-50-7) TURN SIGNAL
2 UP-EXPORT) 1 3 SIGNAL 3 LAMP
(8W-52-3) LAMP (8W-52-3)
(8W-50-4) LEFT
(8W-52-3) FRONT
Z1 Z1 PARK/
18 18 FRONT FOG BUILT-UP- TURN
BK BK LAMPS EXPORT SIGNAL
3
Z1
18
LAMP
BK (EXCEPT
BUILT-UP-EXPORT
S122 EXCEPT
FRONT FOG LAMPS)
(8W-50-4)
(8W-52-3)
LOW
NOTE
HORN LEFT
(EXCEPT HEADLAMP
BUILT- (8W-50-2)
2
UP-EXPORT)
(8W-41-3) 3
LEFT
HEADLAMP
HIGH
LEVELING
NOTE
MOTOR
HORN
(8W-41-3) 3 (BUILT-
UP-EXPORT)
2 (8W-50-5)

LEFT
CITY WINDSHIELD
LAMP WASHER
(BUILT- PUMP
(8W-53-2)
2 UP-EXPORT) (8W-53-3)
(8W-50-4) B

Z1 Z1 Z1 Z1 Z1 Z1 Z1 Z1
18 18 18 18 18 20 20 18
BK BK BK BK BK BK BK BK

S117

Z1
16
BK

G102

TJI01503 J998W-5
8W - 15 - 4 8W-15 GROUND DISTRIBUTION TJ
EXCEPT BUILT-UP-EXPORT

RIGHT RIGHT GENERATOR

FOG FRONT (8W-20-2)
LAMP PARK/
(8W-50-7) TURN
1 3 SIGNAL
LAMP
(FRONT FOG
LAMPS)
Z1 Z1 (8W-50-4) Z0
18 18 (8W-52-3) 6
BK BK BK

S125
G104

RIGHT RIGHT
FRONT HEADLAMP
PARK/ (8W-50-2)
TURN
3 SIGNAL 3
LAMP
(EXCEPT FRONT
FOG LAMPS)
(8W-50-4)
(8W-52-3)

Z1 Z1 Z1
18 18 18
BK BK BK

G103

J998W-5 TJI01504
TJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 5
BUILT-UP-EXPORT

RIGHT RIGHT GENERATOR

REPEATER FRONT (8W-20-2)
LAMP TURN
(8W-52-3) SIGNAL
2 3 LAMP
(8W-52-3)

Z1 Z1 Z0
18 18 6
BK BK BK

S125
G104

RIGHT RIGHT
CITY HEADLAMP
LAMP (8W-50-2)
(8W-50-4)
2 3

RIGHT
HEADLAMP
LEVELING
MOTOR
3 (8W-50-5)

Z1 Z1 Z1 Z1
20 18 18 18
BK BK BK BK

S150

Z1
18
BK

G103
TJI01505 J998W-5
8W - 15 - 6 8W-15 GROUND DISTRIBUTION TJ

D11
ENGINE
STARTER
MOTOR
SENTRY
RELAY
KEY
D13 (IN PDC)
IMMOBILIZER (8W-21-2)
MODULE
(8W-30-14) 5 C104 POWERTRAIN
4
T41 CONTROL
20 T41 MODULE
BR/LB
DATA LINK
20 (8W-30-12)
Z12 CONNECTOR BR/LB A6 C1
20 (8W-30-13) T41
BK/LB 18
3 C154 4 5
BR/LB
MANUAL Z12 Z12
Z1 20 20 S134
20 TRANSMISSION BK/LB BK/TN
BK JUMPER
NOT
USED A6 C202 C4 C204 POWERTRAIN
1 C154 1 C154 CONTROL
Z12 Z12 MODULE
Z1 Z1 20 20 (8W-30-2)
20 20 BK/LB BK/TN
BK BK A31 C1 A32 C1
E6 E9 C107
A/T M/T
Z12 Z12
11 10 C103 14 14
BK/TN BK/TN
Z12 Z12
TRANSFER 20 20
CASE BK/LB BK/TN
SWITCH
(8W-31-2) S130
B
OXYGEN POWER
SENSOR STEERING
1/2 PRESSURE
DOWNSTREAM SWITCH
2 (8W-30-9) 1 (2.5L)
(8W-30-12)
LHD RHD
OXYGEN FUEL
SENSOR PUMP
Z1 Z1
1/1 20 18 MODULE
UPSTREAM BK BK (8W-30-3)
2 (8W-30-9) 6
Z1 Z1 Z1 Z1 Z1
20 20 18 18 18
BK BK BK BK BK

S132

Z1
20
BK

2 Z1 Z12
A/C 14 10
COMPRESSOR BK BK/TN
CLUTCH
(8W-42-4) G105
J998W-5 TJI01506
TJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
LHD
REAR
A/C- WIPER/ HEADLAMP REAR
HEATER WASHER LEVELING WINDOW
CONTROL SWITCH SWITCH DEFOGGER
(8W-42-2)
(HARD TOP) (BUILT-UP SWITCH
(8W-42-3) 1
C C3 5 C2 (8W-53-4) 4 -EXPORT) 1 (HARD
(8W-50-5) TOP)
(8W-48-2)

REAR CIGAR FRONT

FOG LIGHTER/ FOG
LAMP POWER LAMP
SWITCH OUTLET SWITCH
1 (BUILT-UP 3 (8W-41-2) 4 (EXCEPT
-EXPORT) BUILT-UP-
Z1 Z1 Z1 Z1 Z1 Z1 Z1 Z1
12 20 20
(8W-51-7)
18 16 20 20
EXPORT) 20
(8W-51-8) (8W-50-7)
BK BK BK BK/WT BK BK BK BK

G202 S207

BATTERY
(8W-20-2)
HEADLAMP HVAC
SWITCH UNIT
(8W-50-3) (8W-42-2)
(8W-42-3)

10

Z1 Z1 Z1
Z0 Z0 16 20 16
6 6 BK BK BK
BK BK

G200
G106 G107

INSTRUMENT
CLUSTER
(8W-40-2)

HVAC
9 C1 6 C2 UNIT
(8W-42-2)
(8W-42-3)

A/C- 1
Z2 Z2
18 18
HEATER
BK/LG BK/LG CONTROL
(8W-42-2)
(8W-42-3)
1 C2

Z11 Z11
20 20
BK/WT BK/WT
G201

G203
TJI01507 J998W-5
8W - 15 - 8 8W-15 GROUND DISTRIBUTION TJ
RHD
REAR
A/C- WIPER/ HEADLAMP REAR
HEATER WASHER SWITCH WINDOW
CONTROL SWITCH (8W-50-3) DEFOGGER
(8W-42-2)
(HARD TOP) SWITCH
(8W-42-3) 1
C C3 5 C2 (8W-53-4) 1 (HARD
TOP)
REAR CIGAR (8W-48-2)
FOG LIGHTER/
LAMP POWER
SWITCH OUTLET
1 (8W-51-7) 3 (8W-41-2)
(8W-51-8)

Z1 Z1 Z1 Z1 Z1 Z1 Z1
12 20 20 18 16 16 20
BK BK BK BK/WT BK BK BK

G202 S207

BATTERY
(8W-20-2)
HVAC HEADLAMP
UNIT LEVELING
(8W-42-2) SWITCH
(8W-42-3) (BUILT-UP
10 4 -EXPORT)
(8W-50-5)

Z1 Z1 Z1
Z0 Z0 20 20 16
6 4 BK BK BK
BK BK

G200
G106 G107

INSTRUMENT
CLUSTER
(8W-40-2) HVAC
UNIT
9 C1 6 C2 (8W-42-2)
(8W-42-3)
A/C- 1
HEATER
CONTROL
Z2 Z2
18 18 (8W-42-2)
BK/LG BK/LG (8W-42-3)
3 C2

Z11
20
BK/WT Z11
20
BK/WT
G201
G203

J998W-5 TJI01508
TJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 9
LHD
FOG DRIVER PASSENGER
LAMP DOOR DOOR
RELAY AJAR AJAR
NO. 1 SWITCH SWITCH
2 (EXCEPT BUILT- 1 (8W-44-4) 1 (8W-44-4)
UP-EXPORT)
(8W-50-7)
M23 M23
FOG 20 20 REAR
Z1 LAMP YL/BK YL/BK FOG
20 RELAY
BK LAMP
NO. 2 RELAY
2 (EXCEPT BUILT 4 (BUILT-UP
3
-UP-EXPORT) FUSE -EXPORT)
(8W-50-6) BLOCK (8W-51-7)
FUSE (8W-11-2)
Z1 4 Z1
20 10A 20
BK (8W-11-5) BK

24

WINDSHIELD IGNITION COMBINATION

WIPER SWITCH FLASHER
SWITCH (8W-10-9) (8W-52-2)
(8W-53-3)
1 1 4
WINDSHIELD PRNDL
WIPER LAMP
MOTOR (8W-44-5)
(8W-53-2)
(8W-53-3)
4 2

Z1 Z1 Z1 Z1 Z1 Z1
20 18 20 16 20 20
BK BK BK BK BK BK

S304

BRAKE
LAMP
SWITCH
(8W-51-6)
2
CIGAR
LIGHTER/
Z1
20 ACCESSORY
BK RELAY
5 (8W-41-2)

Z1 Z1
20 16
BK BK

G300

TJI01509 J998W-5
8W - 15 - 10 8W-15 GROUND DISTRIBUTION TJ
RHD
WINDSHIELD PASSENGER DRIVER
WIPER DOOR DOOR
SWITCH AJAR AJAR
(8W-53-3) SWITCH SWITCH
1 1 (8W-44-4) 1 (8W-44-4)

WINDSHIELD REAR
M23 M23
WIPER FOG 20 20
MOTOR LAMP YL/BK YL/BK
(8W-53-2) RELAY
(8W-53-3) (8W-51-8)
4 3
4
IGNITION FUSE
SWITCH BLOCK
(8W-10-9) Z1 (8W-11-2)
20 FUSE
BK 4
1 10A
(8W-11-5)

24

PRNDL COMBINATION
LAMP FLASHER
(8W-44-5) (8W-52-2)

2 4

Z1 Z1 Z1 Z1 Z1 Z1
20 18 16 20 20 20
BK BK BK BK BK BK

S304

Z1
20
Z1 BK
20
BK
2
SENTRY
KEY
5
IMMOBILIZER
CIGAR Z1
MODULE
(8W-30-14) Z1
LIGHTER/ 20 16
BK
ACCESSORY BK
RELAY
(8W-41-2)
G300
2
BRAKE
LAMP
SWITCH
(8W-51-6)

J998W-5 TJI01510
TJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 11

REAR REAR
WIPER WINDOW
MOTOR DEFOGGER
(8W-53-4) (8W-48-2)
2
Z1
12
BK

Z1
16 Z1
BK 12
BK

S400
(HARD TOP)

REAR LEFT RIGHT

FOG LICENSE LICENSE
LAMP LAMP LAMP
(8W-51-7) (8W-51-7) (8W-51-7)
(8W-51-8) (8W-51-8) (8W-51-8) Z1
2 2 2 12
BK

Z1 Z1 Z1
20 20 20
BK BK BK

6 C331
S316
(BUILT-UP
-EXPORT) Z1
Z1 12
CENTER SEAT 20 BK
REAR HIGH BELT BK
WASHER MOUNTED SWITCH
PUMP STOP (EXCEPT LHD
(HARD TOP) LAMP BUILT-UP 3 C329 6 C326
2
(8W-53-4)
B (8W-51-4) -EXPORT)
(8W-40-4)
Z1 Z1 Z1 Z1 Z1
18 18 20 20 12
BK BK BK BK BK

S309

PASSENGER AIRBAG SENTRY LHD RHD

AIRBAG CONTROL KEY
ON/OFF MODULE IMMOBILIZER
Z1 Z1
SWITCH (8W-43-2) MODULE 12 12
(8W-43-2) (LHD) BK BK
10 2
(8W-30-14)
2 C1
G5 C322 5 C322
Z6 Z6 Z1
20 18 20
BK/PK BK/PK BK

G301 G302

TJI01511 J998W-5
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8W - 20 - 2 8W-20 CHARGING SYSTEM TJ

ST-RUN A21 (8W-10-9) FUSIBLE

FUSE LINK
POWER A11
BLOCK 10
(8W-11-2) 12 DISTRIBUTION
FUSE DG
FUSE CENTER
12 (8W-10-2)
10A 6
(8W-11-8) 30A
(8W-10-11) A0
5 6
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DB MODULE 6
BK/GY
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S131 STARTER
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(8W-15-8) (8W-15-8)
LHD RHD 1
GENERATOR
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2 C103

S101
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18 18 14 18 18 6
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FUSED AUTOMATIC AUTOMATIC VOLTAGE GENERATOR POWERTRAIN
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OUTPUT RELAY RELAY (+)
(8W-30-2)
(ST-RUN) CONTROL OUTPUT (8W-30-12) G104
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(8W-15-5)
J998W-5 TJI02002

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8W - 21 - 2 8W-21 STARTING SYSTEM TJ

BATT A1 (8W-10-8)
POWER
IGNITION 8 DISTRIBUTION
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1 START 2 (8W-10-2)
2 RUN
1 4 40A
0 OFF
2 3 (8W-10-8)
0 3 LOCK 1
4 ACC
10 (8W-10-9)
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F9 C106

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SWITCH BK

G105
(8W-15-6)
J998W-5 TJI02102
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8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM TJ

ST-RUN A21 (8W-10-9) BATT A0 (8W-10-6)

FUSE POWER
BLOCK 12 DISTRIBUTION
FUSE
(8W-11-2)
FUSE CENTER
12 6 (8W-10-2)
10A 30A
(8W-11-8) (8W-10-11)
5

32

F15
20 F15
DB 20
DB
F4 C106
3
SENTRY A14 A14
FUSED 14 14
F15 IGNITION KEY RD/WT RD/WT
20 SWITCH IMMOBILIZER
DB OUTPUT
(ST-RUN)
MODULE
(8W-30-14)
S131
(8W-11-8)

F15
F15 20
20 DB
DB 3 C103
B3 B1
LHD RHD AUTOMATIC
SHUT
DOWN
13 C104 7 C104
RELAY
B5 B2 (IN PDC) A14
14
S101 RD/WT
(8W-10-11)
F15 K51 A142
18 18 14
DB DB/YL DG/PK

A2 C1 C3 C3 C12 C3 A22 C1
FUSED AUTOMATIC AUTOMATIC FUSED POWERTRAIN
IGNITION SHUT SHUT B(+) CONTROL
SWITCH DOWN DOWN MODULE
OUTPUT RELAY RELAY
(ST-RUN) CONTROL OUTPUT
GROUND SENSE GROUND
A31 C1 A32 C1
Z12 Z12
14 14
BK/TN BK/TN

S130
(8W-15-6)

Z12
10
BK/TN

G105
(8W-15-6)
J998W-5 TJI03002
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3

ST-RUN A21 (8W-10-9) BATT A0 (8W-10-6)

FUSE POWER
BLOCK A18 DISTRIBUTION
FUSE
(8W-11-2)
FUSE CENTER
12 19 (8W-10-2)
10A 20A
(8W-11-8) (8W-10-14)
A17

32

F15
20 F15
DB 20
DB
F4 C106
3
S131 FUSED SENTRY
(8W-11-8) IGNITION KEY
F15 SWITCH IMMOBILIZER A61
20 OUTPUT 18
(ST-RUN)
MODULE
DB DG/BK
(8W-30-14)
B18 B16
FUEL
PUMP
RELAY
(IN PDC)
B20 B17

A141
18
DG/WT

6 7
C103
K226 A141
20 18
DB/LG DG/WT
B8 3 1
A/C FUEL
COMPRESSOR PUMP
CLUTCH M MODULE
RELAY
B10 (IN PDC) 4 6
(8W-42-4)
K167
20
BR/YL

S133 Z1
(8W-70-3) 18
C13 K31 K226 K167 BK
18 18 18 18
DB/OR BR DB/LG BR/YL
S132
C1 C3 C19 C3 C26 C3 A4 C1 (8W-15-6)
A/C FUEL FUEL SENSOR POWERTRAIN Z1
COMPRESSOR PUMP LEVEL GROUND CONTROL 14
CLUTCH RELAY SENSOR MODULE BK
RELAY CONTROL SIGNAL
CONTROL
G105
(8W-15-6)
TJI03003 J998W-5
8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM TJ

BATT A14 (8W-10-11)

POWER
B1
A20 AUTOMATIC
DISTRIBUTION
FUSE SHUT CENTER
18 DOWN (8W-10-2)
20A RELAY
(8W-10-11) (8W-30-2)
A19
B2

F42 A142 A142

18 14 14
DG/LG DG/PK DG/PK
S129
(8W-70-4)
S101
LHD RHD (8W-10-11) K7
20
OR
11 C104 4 C104
3
5V CRANKSHAFT
SUPPLY POSITION
SENSOR
S126
(8W-10-12) CRANKSHAFT
POSITION
F42 SENSOR SENSOR
18 SIGNAL GROUND
DG/LG
1 2
K167 K7
2.5L 4.0L 20 20
BR/YL OR

F42 F42 S127

18 18 (8W-70-3) 3
DG/LG DG/LG
5V CAMSHAFT
S128 SUPPLY POSITION
(8W-10-12) SENSOR

F42 CAMSHAFT
18 POSITION
DG/LG SENSOR SENSOR
GROUND SIGNAL
1
1
IGNITION 2
COIL K167 K167
20 20
BR/YL BR/YL

2 S133
(8W-70-3)
K19
18 K7 K24 K167 K44
GY 18 18 18 18
OR GY/BK BR/YL TN/YL

A7 C1 A17 C1 A8 C1 A4 C1 A18 C1
IGNITION 5V CRANKSHAFT SENSOR CAMSHAFT POWERTRAIN
COIL SUPPLY POSITION GROUND POSITION CONTROL
NO. 1 SENSOR SENSOR MODULE
DRIVER SIGNAL SIGNAL

J998W-5 TJI03004
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5
2.5L
BATT A14 (8W-10-11)
POWER
B1 DISTRIBUTION
AUTOMATIC A20 CENTER
SHUT FUSE (8W-10-2)
DOWN 18
RELAY 20A
(8W-30-2) (8W-10-11)
A19
B2

A142 A142 F42

14 14 18
DG/PK DG/PK DG/LG

S101 LHD RHD

(8W-10-11)
11 C104 4 C104

F42
18
DG/LG

S126
(8W-10-12)

F42
18
DG/LG

S128
(8W-10-12)

F42 F42 F42 F42

18 18 18 18
DG/LG DG/LG DG/LG DG/LG

1 1 1 1
FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
NO. 1 NO. 2 NO. 3 NO. 4

2 2 2 2

K11 K12 K13 K14

18 18 18 18
WT/DB TN YL/WT LB/BR

B4 C2 B15 C2 B5 C2 B16 C2
FUEL FUEL FUEL FUEL POWERTRAIN
INJECTOR INJECTOR INJECTOR INJECTOR CONTROL
NO. 1 NO. 2 NO. 3 NO. 4 MODULE
DRIVER DRIVER DRIVER DRIVER

TJI03005 J998W-5
8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM TJ
4.0L
BATT A14 (8W-10-11)
POWER
B1
AUTOMATIC A19 DISTRIBUTION
SHUT FUSE CENTER
DOWN 18 (8W-10-2)
RELAY 20A
(8W-30-2) (8W-10-11)
A20
B2

F42
A142 A142 18
14 14 DG/LG
DG/PK DG/PK

LHD RHD
S101
(8W-10-11) 11 C104 4 C104

F42
18
DG/LG

S126
(8W-10-12)
F42
18 F42 F42 F42
DG/LG 18 18 18
DG/LG DG/LG DG/LG F42
S128 18
(8W-10-12) DG/LG

F42 F42
18 18
DG/LG DG/LG
1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 2 NO. 4 NO. 6

2 2 2
1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 1 NO. 3 NO. 5

2 2 2

K11 K12 K13 K14 K15 K16

18 18 18 18 18 18
WT/DB TN YL/WT LB/BR PK/BK LG/BK

B4 C2 B15 C2 B5 C2 B16 C2 B6 C2 B12 C2

FUEL FUEL FUEL FUEL FUEL FUEL POWERTRAIN
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR CONTROL
NO. 1 NO. 2 NO. 3 NO. 4 NO. 5 NO. 6 MODULE
DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER

J998W-5 TJI03006
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7
2.5L
S129
(8W-70-4)

K7
20
OR

3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2 1

K167
20
BR/YL

S127
(8W-70-3)

K167 K167 K167

20 20 20
BR/YL BR/YL BR/YL

K167
20
BR/YL 2
ENGINE
3
COOLANT
ENGINE
TEMPERATURE
OIL
SENSOR
PRESSURE
SENSOR 1

2 1 2
INTAKE
K6 AIR
20 TEMPERATURE
VT/OR SENSOR
1
S123 S133
(8W-70-4) (8W-70-3)

K6 K167
18 18
K7 K1 G60 VT/OR BR/YL K2 K21
18 18 18 18 18
OR DG/RD GY/YL TN/BK BK/RD

A17 C1 A27 C1 B23 C2 B31 C2 A4 C1 A16 C1 A15 C1

5V MANIFOLD ENGINE 5V SENSOR ENGINE INTAKE POWERTRAIN
SUPPLY ABSOLUTE OIL SUPPLY GROUND COOLANT AIR CONTROL
PRESSURE PRESSURE TEMPERATURE TEMPERATURE MODULE
SENSOR SENSOR SENSOR SENSOR
SIGNAL SIGNAL SIGNAL SIGNAL

TJI03007 J998W-5
8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM TJ
4.0L
S129
(8W-70-4)

K7
20
OR

3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2 1

K167
20
BR/YL

S127
(8W-70-3)

K167 K167 K167

20 20 20
BR/YL BR/YL BR/YL

S133
(8W-70-3)
K167
20
BR/YL 2
ENGINE
COOLANT
TEMPERATURE
SENSOR
1

3 2
ENGINE INTAKE
OIL AIR
PRESSURE TEMPERATURE
SENSOR SENSOR
2 1 1

K6
20
VT/OR

S123
(8W-70-4)
K7 K1 G60 K6 K167 K2 K21
18 18 18 18 18 18 18
OR DG/RD GY/YL VT/OR BR/YL TN/BK BK/RD

A17 C1 A27 C1 B23 C2 B31 C2 A4 C1 A16 C1 A15 C1

5V MANIFOLD ENGINE 5V SENSOR ENGINE INTAKE POWERTRAIN
SUPPLY ABSOLUTE OIL SUPPLY GROUND COOLANT AIR CONTROL
PRESSURE PRESSURE TEMPERATURE TEMPERATURE MODULE
SENSOR SENSOR SENSOR SENSOR
SIGNAL SIGNAL SIGNAL SIGNAL

J998W-5 TJI03008
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9

BATT A14 (8W-10-11)

B1 POWER
A1 AUTOMATIC DISTRIBUTION
FUSE
SHUT CENTER
DOWN (8W-10-2)
27
RELAY
10A (8W-30-2)
(8W-10-11)
A2 B2

F142 A142 A142

20 14 14
OR/DG DG/PK DG/PK
LEAK
OTHER DETECTION S101
(8W-10-11)
S107
(8W-10-11)
F142
20
F142 OR/DG
20
OR/DG 3 C180
1 C103 2
S124 FUSED LEAK
(8W-10-11) AUTOMATIC DETECTION
F142 SHUT DOWN PUMP
18 RELAY
OUTPUT
(EXCEPT BUILT-
OR/DG
F142 F142 UP-EXPORT)
18 18 (8W-30-11)
OR/DG OR/DG

4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 18 18 20
BR/YL BK BK BR/YL

S127 S132
(8W-70-3) (8W-15-6)
Z1
K167 14
20 BK
BR/YL
G105
(8W-15-6)
S133
(8W-70-3)
K41 K167 K141
18 18 18
BK/DG BR/YL TN/WT
A24 C1 A4 C1 A25 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
1/1 1/2 MODULE
SIGNAL SIGNAL

TJI03009 J998W-5
8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM TJ

VEHICLE
SPEED
VEHICLE SENSOR
SPEED
K7 SENSOR
SENSOR 5V
20 SIGNAL
S129 OR
GROUND SUPPLY
(8W-70-4) 2 1 3
3
THROTTLE K167
POSITION 20
SENSOR BR/YL

2 1
K167
20
K6 G7
BR/YL
20 20
VT/OR WT/OR
S127
(8W-70-3)
K167
20
BR/YL

S133
(8W-70-3)
8 C103 S123 S135
(8W-70-4)
K167
20
BR/YL G7
20
S147 WT/OR
(8W-70-3) K6
20
LHD RHD VT/OR
12 C103
K167 K167
20 18
BR/YL BR/YL G7
20
WT/OR
2
BATTERY 1 7
TEMPERATURE 5V ENGINE VEHICLE DAYTIME
SENSOR SUPPLY OIL SPEED RUNNING
PRESSURE SENSOR LAMP
SIGNAL
1 SENSOR MODULE
(8W-30-7) (8W-50-8)
(8W-30-8)
K7 K22 K118 K167 K6 G7
18 18 18 18 18 18
OR OR/DB PK/YL BR/YL VT/OR WT/OR

A17 C1 A23 C1 C15 C3 A4 C1 B31 C2 B27 C2

5V THROTTLE BATTERY SENSOR 5V VEHICLE POWERTRAIN
SUPPLY POSITION TEMPERATURE GROUND SUPPLY SPEED CONTROL
SENSOR SENSOR SENSOR MODULE
SIGNAL SIGNAL SIGNAL

J998W-5 TJI03010
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11

FROM
ST-RUN A21 (8W-10-9)
S101
FUSE (8W-10-11)
BLOCK
(8W-11-2)
FUSE
11
POWER
10A A1 DISTRIBUTION
(8W-11-8) FUSE CENTER
27 (8W-10-2)
31 10A
(8W-10-11)
A2
F12
20
RD/LG
F142
20
F10 C106 OR/DG
S102
(8W-11-8) S107
(8W-10-11)
F12
20 3 C180
F12
RD/LG F142
20
RD/LG 20
9 C103 OR/DG

F12 2
11 C110 LEAK
20 FUSED
RD/LG AUTOMATIC DETECTION
SHUT DOWN PUMP
F12 A
RELAY
20 TORQUE OUTPUT (EXCEPT
RD/LG CONVERTER BUILT-UP
CLUTCH LEAK LEAK -EXPORT)
DETECTION DETECTION
SOLENOID PUMP PUMP
B SOLENOID SWITCH
2 CONTROL SENSE
DUTY 3 4
CYCLE
EVAP/ K106 K105
PURGE IDLE 20 20
AIR WT/DG WT/OR
1 SOLENOID
IDLE IDLE IDLE IDLE CONTROL
K52 AIR AIR AIR AIR MOTOR
20 CONTROL CONTROL CONTROL CONTROL
PK/BK NO. 1 NO. 2 NO. 3 NO. 4
DRIVER DRIVER DRIVER DRIVER 2 1 C180
10 C110 4 3 2 1

K52 T23 K106 K105

18 18 K39 K60 K40 K59 18 18
PK/BK OR/LG 18 18 18 18 WT/DG WT/OR
GY/RD YL/BK BR/WT VT/BK

C20 C3 B11 C2 A19 C1 A10 C1 A11 C1 A20 C1 C10 C3 C14 C3

DUTY TRANSMISSION IDLE IDLE IDLE IDLE LEAK LEAK POWERTRAIN
CYCLE/ LOW/ AIR AIR AIR AIR DETECTION DETECTION CONTROL
EVAP OVERDRIVE CONTROL CONTROL CONTROL CONTROL PUMP PUMP MODULE
PURGE SOLENOID NO. 1 NO. 2 NO. 3 NO. 4 SOLENOID SWITCH
SOLENOID DRIVER DRIVER DRIVER DRIVER CONTROL SENSE
CONTROL

TJI03011 J998W-5
8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM TJ

C21 20 DB/OR A/C- GENERATOR

A/C
HEATER GENERATOR (8W-20-2)
2 2
SELECT CONTROL VOLTAGE FIELD
A/C A/C (8W-42-3) REGULATOR DRIVER
INPUT
LOW HIGH SIGNAL (+)
PRESSURE PRESSURE A C3 1 2
SWITCH SWITCH C90
1 1 20
LG
C22 C90
20 20 6 C170
DB/WT LG
C90 K72
2 1 C104 20 18
LG DG/OR
C90
C22 20 2 C103
18 LG
DB/WT
K72 K20
S103 18 18
(8W-42-4) DG/OR DG
C90
18
LG
C22 C3 C23 C3 C25 C3 B10 C2
A/C A/C VOLTAGE GENERATOR POWERTRAIN
SWITCH SELECT REGULATOR FIELD CONTROL
SENSE INPUT PARK/ SIGNAL DRIVER MODULE
NEUTRAL (+)
BRAKE POSITION POWER STEERING
SWITCH SWITCH PRESSURE
SENSE SENSE SWITCH SENSE
C24 C3 A6 C1 A12 C1
K29 T41 K10
18 18 18
WT/PK BR/LB DB/BR
D14 C108 S134
(8W-15-6) 2
K29 (8W-70-4) POWER
20 STEERING
WT/PK
PRESSURE
1 SWITCH
T41
BRAKE CIGAR 20 (2.5L)
1
LAMP LIGHTER/ BR/LB
SWITCH ACCESSORY A/T M/T
(8W-51-6)
GROUND RELAY
(8W-41-2) LHD RHD
2 5 3 C154
Z1 20BK 3 C154 Z1 MANUAL
LHD RHD
20 TRANSMISSION Z1 Z1
T41
BK JUMPER 20 18
20
Z1 BK BK
BR/LB
K29
20 1 C154
BK
20 Z1
WT/PK Z1 20
20 S304 BK
BK (8W-15-10)
Z1 2 S132
1 (8W-15-6)
BRAKE 16 PARK/ Z1
BRAKE BK
SWITCH SHIFT NEUTRAL 14
P/N
SENSE INTERLOCK POSITION BK
SOLENOID SWITCH
G300 (8W-21-2) G105
(8W-31-2)
(8W-15-9) (8W-15-6)
J998W-5 TJI03012
(8W-15-10)
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13

BATT A0 (8W-10-6)
POWER
A16 DISTRIBUTION
FUSE CENTER
20 (8W-10-2)
10A
(8W-10-15)
A15

M1
20 M1
PK/WT 20
PK/WT
D12 C108 HARD SOFT
M1 TOP TOP
20
PK/WT

2 B7 C203
TO TO
FUSED UNDERHOOD DOME SOUND
B(+) LAMP LAMP BAR
(8W-44-3) S204
(8W-10-15) AND DOME
M1 SOUND LAMP
20
PK/WT
BAR (8W-44-2)
DOME
16
LAMP
(8W-44-2) DATA
LINK
6 7 4 5 CONNECTOR
D20 D21 SENTRY
20 20 KEY
LG PK Z12 Z12
IMMOBILIZER 20 20
B10 MODULE
B8 C203 GROUND BK/LB BK/TN
4 (8W-30-14)
D20 D21 A6 C202 C4 C204
20 20
Z12 20BK/LB
LG PK Z12 Z12
E13 E14 C107 20 20
BK/LB BK/TN

E6 E9 C107
Z12 Z12
20 20
BK/LB BK/TN
11 10
C103

Z12 Z12
D20 D21 20 20
18 18 D21
BK/LB BK/TN
LG PK 20
PK
C29 C3 C27 C3 S130
SCI SCI POWERTRAIN (8W-15-6)
RECEIVE TRANSMIT/ CONTROL 3 C1
ISO SCI CONTROLLER Z12
MODULE 10
9141K TRANSMIT/ ANTI-LOCK
ISO BK/TN
BRAKE
9141K (8W-35-5)
G105
(8W-15-6)
TJI03013 J998W-5
8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM TJ

BATT A6 (8W-10-10) ST-RUN A21 (8W-10-9)

INSTRUMENT
CLUSTER FUSE
CCD CCD (8W-40-3) BLOCK
BUS BUS (8W-40-4) (8W-11-2)
(8W-40-5) FUSE FUSE
(-) (+)
(8W-40-7) 1 12
20A 10A
1 2 (8W-11-4) (8W-11-8)
C1 C1
21 32
F34
18
TN/BK
D2 D1
20 20
WT/BK VT/BR A11 C202
TWISTED DATA
F34 F15
PAIR 18 20
LINK
TN/BK DB CONNECTOR
(8W-30-13)
4 4
F34 FUSED HEADLAMP
DATA 20 B(+) SWITCH
LINK TN/BK (8W-50-2)
(8W-50-4) Z12
CONNECTOR 20
11 3 1 3 BK/LB
FUSED FUSED SENTRY
D2 D1 B(+) IGNITION KEY
20 20 SWITCH IMMOBILIZER
WT/BK VT/BR OUTPUT
(ST-RUN)
MODULE
CCD CCD
BUS BUS
B12 B11 (-) (+) GROUND GROUND
C203
5 6 2 4
Z12
D2 D1 D2 D1 20
20 TWISTED 20 20 TWISTED 20 BK/LB
WT/BK PAIR VT/BR WT/BK PAIR VT/BR
A6 C202
Z1
20
S302 BK
Z12
20
S303 BK/LB

D2 D1
20 20 E6 C107
LHD RHD
WT/BK VT/BR
11 C103
D5 D4 C108 TWISTED Z12
Z1
PAIR 20
TWISTED 20 S304 BK/LB
PAIR BK (8W-15-10)

D2 D1 Z1
18 18 16 S130
D2 D1
WT/BK VT/BR G302 BK (8W-15-6)
18 18
WT/BK VT/BR (8W-15-11) Z12
10
C28 C3 C30 C3 18 19 BK/TN
CCD CCD POWERTRAIN CCD CCD AIRBAG G300
BUS BUS CONTROL BUS BUS CONTROL (8W-15-10)
(-) (+) MODULE (-) (+) MODULE G105
(8W-43-3) (8W-15-6)

J998W-5 TJI03014
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15

POWERTRAIN
SPEED
CONTROL
CONTROL MODULE
SWITCH SENSOR
SIGNAL GROUND
C32 C3 A4 C1
B13 POWER
BATTERY K167
DISTRIBUTION
18 HORN
TEMPERATURE RELAY CENTER
BR/YL
SENSOR SENSOR (8W-41-3) (8W-10-2)
RETURN (8W-30-10) S133
2 (8W-70-3)
K167 B15
LHD RHD 20
BR/YL
K167 K167
20 18 8 C103
BR/YL BR/YL X3
V37
18 20
RD/LG RD/YL
S147
(8W-70-3)
K167
20
BR/YL (NOT E7 C107
USED)
D3 D3
C108

SPEED OTHER X3
CONTROL 20
D10 C108 RD/YL
V37 K167
20 20
RD/LG BR/YL

2 C2 3 C2 1 C2
CLOCKSPRING

HORN
SWITCH

LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 2 POD 1 2 3 POD
1 ON/OFF 1 RESUME/ACCEL
2 SET 2 CANCEL
3 COAST

TJI03015 J998W-5
8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM TJ

POWERTRAIN
SPEED SPEED SPEED CONTROL
CONTROL CONTROL CONTROL MODULE
VACUUM VENT ON/OFF BRAKE
SOLENOID SOLENOID SWITCH SWITCH
CONTROL CONTROL SENSE SENSE
C4 C3 C5 C3 C11 C3 C24 C3

BRAKE
V32 K29
18 18
SHIFT
BRAKE
YL/RD WT/PK SWITCH INTERLOCK
SENSE SOLENOID
V36 V35 (8W-31-2)
18 18 1
TN/RD LG/RD
K29
D1 D14
C108 20
WT/PK

V32
20 K29
YL/RD 20
WT/PK

3 1 5
BRAKE
1 2 3 LAMP
VEHICLE SWITCH
VACUUM VENT SPEED (8W-51-6)
SOLENOID SOLENOID CONTROL 4 2 6
SERVO

V30 Z1
20 20
DUMP
DB/RD BK CIGAR
SOLENOID LIGHTER/
ACCESSORY
GROUND RELAY
V30 E11 C107 (8W-41-2)
4 5
20
DB/RD
Z1
20
BK

Z1 LHD RHD
18
BK
Z1
20
BK
S106 Z1
(8W-15-2) 20 S304
BK (8W-15-10)
Z1
Z1 16
12 BK
BK

G300
G100 (8W-15-9)
(8W-15-2) (8W-15-10)
J998W-5 TJI03016
XY Z\[^]`_\acbed$fVgih!jlk hVhQk migonVmigibd$mqprhVs!hVbetuj Z\[^]`_\a?]3a

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ó*ôOõ)öôR÷TøU÷Tù úYûOüRø ó*ôOõ´öŠôR÷TøU÷Tù úYûOüRø
ý]þB
ÿ Š
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 !" I C
JK<L!<G"
ý]þB
ÿ  #$ %'&)(*þ+,-. #,-+-(,- /0!" I 
C
CK<L!<G"
1 2ƒÿy3 þ 4 25$f7þ 6 89;:<:,f7þ =?>'-+ ÿ =@!" &)($:k þB$-( 1 +B$:f þF<L!"
A4B$:<.CDAŠ# ý EF!" M4,) þ þÿN ( 1 ,-($k þ,-+!OP,-/NB$+Q<L!"
A4B$:<.-FDGA# ý E!" R, þSNB 1 ,;(UTV þf þ 1 +B$P V,;+G;($,- /@<L!"
A4B$:<{'ý +,-H!" R©þBÿ
($:<%Gf þ 1 ÿ
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8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM TJ

ST-RUN A21 (8W-10-9)

FUSE
BLOCK
(8W-11-2)
FUSE FUSE
11 10
10A 10A
(8W-11-8) (8W-11-8)

31 30
G5 20DB/WT
F12
20
RD/LG
A10 C202
G5
20
DB/WT G5
F10 C106
20
DB/WT

F12 2
20 8 C2
RD/LG
BRAKE INSTRUMENT
SHIFT CLUSTER
INTERLOCK 4WD (8W-40-5)
SOLENOID INDICATOR
S102
1
(8W-11-8)
F12 K29 5 C1
20 20
G107
RD/LG WT/PK
20
BK/RD

9 C103
D14 C108 K29
20 5 C170
WT/PK

F12 1 13 C103
20 BRAKE
RD/LG G107
LAMP 20
SWITCH BK/RD
(8W-51-6)
A A
TORQUE 2
TRANSFER
CONVERTER Z1 CASE
CIGAR
CLUTCH 20 SWITCH
BK LIGHTER/
SOLENOID
K29 ACCESSORY
B 18 RELAY B
GROUND
WT/PK (8W-41-2)
5
T23 Z1
18 20 Z1
OR/LG BK 20
BK
LHD RHD

B11 C2 C24 C3 S304 S132

POWERTRAIN Z1 (8W-15-10)
TRANSMISSION BRAKE 20 (8W-15-6)
Z1
LOW/ SWITCH CONTROL BK 16
OVERDRIVE SENSE Z1
MODULE BK 14
SOLENOID (8W-30-11) BK
(8W-30-12)

G300 G105
(8W-15-9) (8W-15-6)
J998W-5 (8W-15-10) TJI03102
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8W - 35 - 2 8W-35 ANTI-LOCK BRAKES TJ

FROM
RUN A22 (8W-10-8)
S146
FUSE (8W-35-3)
BLOCK A
(8W-11-2)
FUSE
7 B48
10A 20
(8W-11-7) RD/YL
BATT A0 (8W-10-6)
27
POWER
F20 DISTRIBUTION
20 A14 CENTER
VT/WT FUSE (8W-10-2)
21
F3 C106 10A
(8W-10-17)
A13
F20
20
VT/WT
19 20
S108
FUSE FUSE
(8W-11-7)
13 14
30A 40A
F20 (8W-10-17) (8W-10-17)
20 26 27
VT/WT
A20 B47 A10
14 14 12
C11 C10 RD/DB RD/LB RD/DG
ABS
C4 C2
SYSTEM
ABS
RELAY
PUMP
(IN PDC)
MOTOR
C13 C14 C12 RELAY
C6 C8 C3 (IN PDC)
B116 B120 Z1
B58 Z1 B47 B47 20 12 14
20 14 14 14 GY BR/WT BK
GY/LB BK RD/LB RD/LB
S110
S114 1
ABS
PUMP
M MOTOR
B47 B47
14 14
RD/LB RD/LB B120
2 12
Z1
BR/WT
12
B C
BK
S112
TO TO S106
HYDRAULIC HYDRAULIC (8W-15-2)
CONTROL CONTROL B120
UNIT UNIT 16
(8W-35-4) (8W-35-4) BR/WT
Z1
11 C2 7 C2 3 C2 12
ABS ABS ABS CONTROLLER BK
MAIN PUMP PUMP ANTI-LOCK
RELAY MOTOR MOTOR BRAKE G100
CONTROL RELAY RELAY (8W-15-2)
CONTROL OUTPUT
J998W-5 TJI03502
TJ 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3

RUN A22 (8W-10-8) ST-RUN A21 (8W-10-9)

FUSE
BLOCK
(8W-11-2)
FUSE FUSE
7 10
10A 10A
(8W-11-7) (8W-11-8)

27 30
F20 G5
20 20
VT/WT DB/WT G5
A10 C202 20
DB/WT
8 C2
F3 C106 INSTRUMENT
CLUSTER
ABS (8W-40-6)
WARNING
INDICATOR
F20
20
VT/WT
4 C2 2
B14 C203 FUSED BRAKE
D2 C108 IGNITION SHIFT
SWITCH INTERLOCK
S108 OUTPUT
(8W-11-7) B SOLENOID
(ST-RUN)
ABS (8W-31-2)
DIODE

A
S146

B48
20
RD/YL

A
B48
F20 TO 20
20 G19 RD/YL
VT/WT
POWER
20
LG/OR DISTRIBUTION
CENTER
(8W-35-2)
5 C1 1 C1 5 C2
FUSED ABS ABS CONTROLLER
IGNITION WARNING MAIN ANTI-LOCK
SWITCH INDICATOR RELAY BRAKE
OUTPUT DRIVER OUTPUT
(RUN) GROUND GROUND
13 C2 14 C2
Z22 Z22
16 16
BK/PK BK/PK

S109
(8W-15-2)
Z22
14
BK/PK

G101
(8W-15-2)
TJI03503 J998W-5
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES TJ

FROM FROM
S114 S114
(8W-35-2) (8W-35-2)
B C

B47 B47
14 14
RD/LB RD/LB

10 1
HYDRAULIC
CONTROL
UNIT

2 7 9 4 8 3

B251 B254 B243 B245 B248 B249

20 20 20 20 20 20
WT/BK DG/OR DG/BK WT/LG DG/WT WT/DG

4 C2 12 C2 8 C2 18 C2 6 C2 15 C2
REAR REAR LEFT LEFT RIGHT RIGHT CONTROLLER
INLET OUTLET FRONT FRONT FRONT FRONT ANTI-LOCK
VALVE VALVE OUTLET INLET OUTLET INLET BRAKE
CONTROL CONTROL VALVE VALVE VALVE VALVE
CONTROL CONTROL CONTROL CONTROL

J998W-5 TJI03504
TJ 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5

BATT A6 (8W-10-10)
FUSE
BLOCK
(8W-11-2)
FUSE
2
20A
(8W-11-4)

22
F32
18
PK/DB

5
BRAKE
LAMP
SWITCH DATA
(8W-51-6) LINK
6 CONNECTOR
(8W-30-13)
L50 7
18
WT/TN
D21
20
PK
POWERTRAIN
CONTROL
SCI MODULE
D9 C108 B10 C203 TRANSMIT (8W-30-13)
C27 C3
G SWITCH

D21 D21
20 18
PK PK

3 2 1 E14 C107

L50 B43 B41 B42 D21

18 20 20 20 20
WT/TN PK/OR YL/VT TN/WT PK

8 C1 2 C1 6 C1 7 C1 3 C1
BRAKE G-SWITCH G-SWITCH G-SWITCH SCI CONTROLLER
LAMP TEST NO. 1 NO. 2 TRANSMIT ANTI-LOCK
SWITCH SIGNAL SENSE SENSE BRAKE
OUTPUT

TJI03505 J998W-5
8W - 35 - 6 8W-35 ANTI-LOCK BRAKES TJ

LEFT RIGHT
REAR FRONT
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR

LEFT 1 2 2 1 RIGHT
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
B3 B4 B7 B6
18 18 18 18
1 2 LG/DB LG WT WT/DB 1 2

B8 B9 B1 B2
18 18 18 18
RD/DB RD YL/DB YL

C104 5 4 C103 C104

4 3 7 6

B3 B4 B7 B6 B1 B2
18 18 18 18 18 18
LG/DB LG WT WT/DB YL/DB YL

10 C2 9 C2 9 C1 10 C1 1 C2 2 C2 11 C1 12 C1
LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT CONTROLLER
FRONT FRONT REAR REAR FRONT FRONT REAR REAR ANTI-LOCK
WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL BRAKE
SPEED SPEED SPEED SPEED SPEED SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(-) (+) (-) (+) (+) (-) (-) (+)

J998W-5 TJI03506
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8W - 40 - 2 8W-40 INSTRUMENT CLUSTER TJ

BATT A0 (8W-10-6) ST-RUN A21 (8W-10-9)

POWER FUSE
A16 DISTRIBUTION BLOCK
FUSE CENTER FUSE (8W-11-2)
20 (8W-10-2) 10
10A 10A
(8W-10-15) (8W-11-8)
A15

30
M1
20
PK/WT G5
20
D12 C108 DB/WT
M1
20
PK/WT HARD SOFT
TOP TOP
A10 C202
2
FUSED UNDERHOOD
B (+) LAMP M1 M1 M1 G5
(8W-44-3) 20 20 20 20
PK/WT PK/WT PK/WT DB/WT

TO
B7 C203 DOME 2
LAMP FUSED BRAKE
AND IGNITION SHIFT
M1 SOUND SWITCH
20 INTERLOCK
BAR TO OUTPUT
PK/WT SOUND (ST-RUN)
SOLENOID
DOME (8W-31-2)
LAMP BAR
(8W-44-2) DOME
S204 LAMP
(8W-10-15) (8W-44-2)

M1 G5
20 20
PK/WT DB/WT

9 C2 8 C2
INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGNITION
SWITCH
OUTPUT
(ST-RUN)
GROUND

6 C2 9 C1
Z2 Z2
18 18
BK/LG BK/LG

G201
(8W-15-7)
(8W-15-8)
J998W-5 TJI04002
TJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3

BATT M1 (8W-10-15) ST-RUN G5 (8W-11-8)

INSTRUMENT
CLUSTER
VOLT OIL
METER SPEEDOMETER PRESSURE
GAUGE

FUSED VOLT FUSED SPEEDOMETER OIL

B(+) METER IGNITION CONTROL PRESSURE
CONTROL SWITCH GAUGE
OUTPUT CONTROL
(ST-RUN)
ENGINE
CCD CCD FUEL COOLANT
BUS BUS GAUGE TEMPERATURE TACHOMETER
(+) (-) CONTROL CONTROL CONTROL GROUND

FUEL ENGINE TACHOMETER

GAUGE COOLANT
TEMPERATURE
GAUGE

2 C1 1 C1 DATA 6 C2 9 C1
LINK Z2 Z2
D1 D2
20 20 CONNECTOR 18 18
VT/BR WT/BK (8W-30-14) BK/LG BK/LG
ENGINE ENGINE
TWISTED 3 11 OIL OIL
PAIR D1 D2 PRESSURE PRESSURE G201
20 20 SENSOR (8W-15-7)
SIGNAL
SENSOR
VT/BR WT/BK (8W-15-8)
(8W-30-7)
2 (8W-30-8)

B12
B11 C203
VEHICLE FUEL
D1 D2 VEHICLE SPEED FUEL PUMP
20 TWISTED 20 SPEED LEVEL
SENSOR
SENSOR SENSOR
MODULE
VT/BR PAIR WT/BK
SIGNAL (8W-30-10) SIGNAL (8W-30-3)
3 3
S302 S303
(8W-30-14) (8W-30-14) G7 K226 ENGINE ENGINE
D1 D2 20 20 COOLANT COOLANT
WT/OR DB/LG TEMPERATURE TEMPERATURE
20 TWISTED 20
SENSOR
VT/BR PAIR WT/BK SENSOR
SIGNAL
(8W-30-7)
S135 6 C103 1 (8W-30-8)
D4 D5 C108
TWISTED (8W-30-10)
PAIR
G7 G60 K226 K2
D1 D2 18 18 18 18
18 18 WT/OR GY/YL DB/LG TN/BK
VT/BR WT/BK
C30 C3 C28 C3 B27 C2 B23 C2 C26 C3 A16 C1
CCD CCD VEHICLE ENGINE FUEL ENGINE POWERTRAIN
BUS BUS SPEED OIL LEVEL COOLANT CONTROL
(+) (-) SENSOR PRESSURE SENSOR TEMPERATURE MODULE
SIGNAL SENSOR SIGNAL SENSOR (8W-30-3)
SIGNAL SIGNAL (8W-30-7)
(8W-30-8)
(8W-30-10)
(8W-30-14)

TJI04003 J998W-5
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER TJ

BATT M1 (8W-10-15) ST-RUN G5 (8W-11-8)

INSTRUMENT
CLUSTER
AIRBAG LOW CHECK CHECK
WARNING FUEL ENGINE GAUGES
INDICATOR INDICATOR INDICATOR INDICATOR

FUSED AIRBAG FUSED LOW CHECK CHECK

B(+) WARNING IGNITION FUEL ENGINE GAUGES
INDICATOR SWITCH INDICATOR INDICATOR INDICATOR
SEAT
DRIVER OUTPUT DRIVER DRIVER DRIVER
CCD CCD BELT
(ST-RUN)
BUS BUS SWITCH
(+) (-) ODOMETER CONTROL TRIP RESET GROUND SENSE

TRIP
ODOMETER
ODOMETER/
RESET
TRIP
SWITCH
ODOMETER

2 C1 1 C1 6 C2 9 C1 10 C1
DATA
Z2 Z2 G10
LINK 18 18 20
D1 D2
20 20 CONNECTOR BK/LG BK/LG LG/RD
VT/BR WT/BK (8W-30-14)
3 11 G201 C3 C204
TWISTED (8W-15-7)
PAIR D1 D2 (8W-15-8)
20 20 LHD RHD
VT/BR WT/BK
G6 C322 6 C322

B12
B11 C203
G10
20
D1 D2
LG/RD
20 TWISTED 20
VT/BR PAIR WT/BK
1
SEAT
S303 BELT
(8W-30-14) SWITCH
S302
(8W-30-14) (EXCEPT LHD
D1 D2 BUILT-UP
20 20 TWISTED 2
VT/BR WT/BK PAIR -EXPORT)
D1 D2 Z1
TWISTED 18 18 20
PAIR VT/BR WT/BK BK

D4 C108 19 18 S309
D5
TWISTED CCD CCD AIRBAG (8W-15-11)
PAIR BUS BUS CONTROL Z1
(+) (-) MODULE 12
(8W-43-3) BK
D1 D2
18 18 LHD RHD
VT/BR WT/BK 5 C322
G5 C322
C30 C3 C28 C3
CCD CCD POWERTRAIN
BUS BUS CONTROL G302
(+) (-) MODULE (8W-15-11)
(8W-30-14)
J998W-5 TJI04004
TJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5

BATT M1 (8W-10-15) ST-RUN G5 (8W-11-8)

INSTRUMENT
CLUSTER
SENTRY SEAT UPSHIFT 4WD
KEY BELT INDICATOR INDICATOR
IMMOBILIZER WARNING
MODULE (M/T)
INDICATOR
INDICATOR

FUSED SENTRY FUSED SEAT UPSHIFT

B(+) KEY IGNITION BELT INDICATOR
IMMOBILIZER SWITCH WARNING DRIVER
MODULE OUTPUT INDICATOR (M/T)
INDICATOR (ST-RUN) DRIVER
CCD DRIVER CCD
BUS BUS
(+) (-) GROUND

2 C1 1 C1 6 C2 9 C1 5 C1
G107
Z2 Z2 20
DATA 18 18 BK/RD
D1 D2
LINK BK/LG BK/LG
20 20
VT/BR WT/BK CONNECTOR 5 C170
(8W-30-14)
G201
TWISTED 3 11 (8W-15-7)
PAIR (8W-15-8)
D1 D2 G107
20 20 20
VT/BR WT/BK BK/RD

B11 B12
C203 13 C103
D1 D2
20 TWISTED 20 G107
VT/BR WT/BK 20
PAIR BK/RD

A
S302 S303 TRANSFER
(8W-30-14) (8W-30-14) CASE
D1 D2 SWITCH
20 20 (8W-31-2)
VT/BR WT/BK
TWISTED B
PAIR
Z1
20
D4 D5 C108 BK
TWISTED
PAIR
S132
D1 D2 (8W-15-6)
18 18
VT/BR WT/BK Z1
14
C30 C3 C28 C3 BK
CCD CCD POWERTRAIN
BUS BUS CONTROL
(+) (-) MODULE G105
(8W-30-14) (8W-15-6)

TJI04005 J998W-5
8W - 40 - 6 8W-40 INSTRUMENT CLUSTER TJ

ST-RUN G5 (8W-11-8) BATT M1 (8W-10-15)

INSTRUMENT
CLUSTER
FUSED FUSED
BRAKE ABS IGNITION B(+)
WARNING WARNING SWITCH
INDICATOR INDICATOR OUTPUT
(ST-RUN)

GROUND

2 C2 4 C2 6 C2 9 C1
G99 G19
20 20 Z2 Z2
GY/WT LG/OR 18 18
BK/LG BK/LG
B14 C203
3 C170 OTHERS ABS
G201
(8W-15-7)
G99 D2 C108
(8W-15-8)
20
GY/WT

2 G19 G19 G19

BRAKE 20 20 20
WARNING LG/OR LG/OR LG/OR
INDICATOR
SWITCH
B 1 C1
D2 C108 ABS ABS ABS CONTROLLER
1 NOT WARNING DIODE WARNING ANTI-LOCK
USED INDICATOR (8W-35-3) INDICATOR BRAKE
G9
DRIVER DRIVER (8W-35-3)
20
GY/BK
F11 C106
G9 20 GY/BK
2
G9 IGNITION
20
GY/BK SWITCH
1 4 1 START
LHD RHD 2 RUN
2 0 3
0 OFF
G9 C322 9 C322 3 LOCK
1 4 ACC
(8W-10-9)
Z1
16
G9 BK
20
GY/BK S304
(8W-15-9)
Z1 (8W-15-10)
16
PARK BK
BRAKE
G300
SWITCH (8W-15-9)
(8W-15-10)

J998W-5 TJI04006
TJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7

BATT M1 (8W-10-15) ST-RUN G5 (8W-11-8)

INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGNITION
SWITCH
KEY-IN OUTPUT
CCD CCD IGNITION (ST-RUN)
BUS BUS SWITCH
(+) (-) GROUND SENSE

2 C1 1 C1 6 C2 9 C1 8 C1
Z2 Z2 G26 20LB
D1 D2 18 18
20 20 BK/LG BK/LG G26 20 LB
VT/BR WT/BK
5
G201 HEADLAMP B3 C203
(8W-15-7) SWITCH 2
(8W-15-8) 0 OFF KEY-IN
1 PARK SWITCH
DATA 0 1 2 2 HEAD
LINK (8W-50-3)
TWISTED
CONNECTOR
PAIR (8W-30-14) 6 1
G16 G16
3 11 20 20
D1 D2 BK/LB BK/LB
20 20
VT/BR WT/BK B4 C203

G16 20BK/LB
B12 3
B11 C203
PASSENGER DRIVER
DOOR DOOR DOOR
D1 D2
AJAR AJAR AJAR
20 TWISTED 20
SWITCH
VT/BR WT/BK SWITCH SWITCH
PAIR OUTPUT
(8W-44-4) (8W-44-4)
1 1
M23 M23
S302 S303 20 20
(8W-30-14) (8W-30-14) YL/BK YL/BK
D1 D2
20 TWISTED 20 4
VT/BR PAIR WT/BK FUSE
FUSE
BLOCK
4 (8W-11-2)
D4 D5 C108 10A
TWISTED (8W-11-5)
PAIR 24
LHD RHD
D1 D2
18 18 Z1 20BK
VT/BR WT/BK Z1
S304 20
C30 C3 C28 C3 (8W-15-9) BK
CCD CCD POWERTRAIN
Z1 16BK
BUS BUS CONTROL
(+) (-) MODULE
(8W-30-14)
G300
(8W-15-9)
TJI04007 J998W-5
(8W-15-10)
8W - 40 - 8 8W-40 INSTRUMENT CLUSTER TJ

BATT F34 (8W-11-4)

HEADLAMP
SWITCH
0 HEAD
1 PARK
0 1 2 3 4 5 2 HEAD
3 DOME
4 MAX
1 5 MIN
E1 (8W-50-2)
RUN F20 (8W-11-7) 18
REAR TN
WINDOW A3 C202
DEFOGGER 3
RELAY FUSE
D6 (IN PDC) BLOCK
FUSE (8W-11-2)
(8W-48-2)
3
10A
(8W-11-4)
C81
20
LB/WT 23

E2
20 E2
OR 20
2 C170 OR
A4 C202 1
FUSED PRNDL
S206 PANEL LAMP
(8W-11-4) LAMPS (8W-44-5)
C81
DIMMER
20
E2 SWITCH
LB/WT
20 SIGNAL
OR

BATT M1 (8W-10-15) ST-RUN G5 (8W-11-8)

3 C1 3 C2
INSTRUMENT
CLUSTER
FUSED REAR FUSED
B(+) WINDOW IGNITION CLUSTER
DEFOGGER SWITCH ILLUMINATION
REAR RELAY OUTPUT LAMPS
WINDOW CONTROL (ST-RUN)
DEFOGGER
SWITCH
SENSE GROUND

4 C1 6 C2 9 C1
C80
20
DB/LG Z2 Z2
18 18
BK/LG BK/LG
2
REAR REAR
WINDOW WINDOW
DEFOGGER DEFOGGER G201
SWITCH (8W-15-7)
SENSE
SWITCH
(8W-15-8)
(HARD TOP)
(8W-48-2)
J998W-5 TJI04008
TJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9

HEADLAMP
DIMMER
SWITCH DIMMER
HIGH SWITCH
BEAM (8W-50-2)
TURN
OUTPUT SIGNAL/
3 HAZARD
L3
SWITCH
14 LEFT RIGHT (8W-52-3)
RD/OR TURN TURN
SIGNAL SIGNAL
E4 C107 10 1
L3
16
RD/OR

S105 L61 L60

(8W-50-2) 18 18
GY TN
OTHER DRL

L3
16
L3
RD/OR
16
RD/OR
G34
18
RD/GY
B2 C203 B1 C203
4 1
HIGH DIMMER DAYTIME
BEAM SWITCH RUNNING
INDICATOR HIGH LAMP
DRIVER BEAM
OUTPUT
MODULE
(8W-50-8)

D7 C108
G34
16 G34 L61 L60
RD/GY 16 18 18
RD/GY GY TN
1
B5 C203 HIGH FOG LAMP
BEAM RELAY
INDICATOR NO. 2
G34 DRIVER
(EXCEPT
16
RD/GY
BUILT-UP
-EXPORT)
(8W-50-6)
5 C2 10 C2 6 C1
INSTRUMENT
HIGH LEFT RIGHT CLUSTER
BEAM TURN TURN
INDICATOR SIGNAL SIGNAL
INDICATOR INDICATOR

6 C2 9 C1
Z2 Z2
18 18
BK/LG BK/LG

G201
(8W-15-7)
TJI04009 (8W-15-8) J998W-5
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8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET TJ

BRAKE BATT A0 (8W-10-6)

LAMP POWER
SWITCH DISTRIBUTION
(8W-51-6) 11
GROUND CENTER
2 FUSE (8W-10-2)
BATT A1 (8W-10-9) 5
40A
IGNITION (8W-10-10)
4
SWITCH
1 START
2 RUN
1 4 0 OFF F30
3 LOCK 12
2 0 3
4 ACC RD/PK
(8W-10-9)
F1 C106
8

S307 S332
(8W-10-9) (8W-10-10)

A31 F30
14 12
BK/DG RD/PK

2 1
CIGAR
LIGHTER/
Z1 ACCESSORY
20 RELAY
BK
5 4
F22
12
Z1 WT/PK
20
19
BK
FUSE
FUSE
BLOCK
LHD RHD 19 (8W-11-2)
20A
(8W-11-10)
S304
(8W-15-10)
39
Z1 Z1 A9 C202
20 16
BK BK F38
16
LB
1
CIGAR
LIGHTER/
POWER
G300 F38
(8W-15-9) OUTLET
16
(8W-15-10) LB 3
Z1
SWITCH 16
AUXILIARY BK
POWER
(TAPED TO S207
HARNESS (8W-15-7)
IN FB T/O) (8W-15-8)
G200
(8W-15-7)
J998W-5 (8W-15-8) TJI04102
TJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3

BATT A0 (8W-10-6)
POWER
DISTRIBUTION
A21
CENTER
FUSE (8W-10-2)
17
20A
(8W-10-16)
A22

F31 F31
18 18
VT VT
B13 B11
HORN
RELAY
(IN PDC)

B15 B12
X2
X3 18
20 WT/RD
RD/YL
6 C110
X2
18
WT/RD

BUILT- EXCEPT BUILT-

E7 C107 UP-EXPORT UP-EXPORT

S115

X3
20 X2 X2
RD/YL 18 18
WT/RD WT/RD

1 1
HIGH LOW
NOTE NOTE
HORN HORN

1 C2 2 2
CLOCKSPRING
(8W-30-15) Z1 Z1
18 18
BK BK

S117
(8W-15-3)
HORN
SWITCH Z1
16
BK

G102
(8W-15-3)
TJI04103 J998W-5
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8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER TJ
HEATER ONLY
RUN A22 (8W-10-8) BATT A0 (8W-10-6)
FUSE POWER
BLOCK 17 DISTRIBUTION
FUSE (8W-11-2) FUSE CENTER
8 11 (8W-10-2)
10A 40A
(8W-11-7) 24 (8W-10-13)

28
A111
F24 12
20 RD/LB
RD/DG
F12 C106
A1 A12 C202
F24 20RD/DG

F24
F24 20 A111
20 RD/DG 12
RD/DG RD/LB

5 9 8
HVAC
BLOWER
UNIT
BLOWER MOTOR
M MOTOR RELAY

FROM
S206 BLEND
(8W-11-4) DOOR
M
ACTUATOR

E2
20
OR

2 3 4 7 6 1 10

C4 C5 C6 C7 C1 C36
16 16 14 12 12 20
1 TN LG/LB LB BR/TN DG DB/RD
4 C2 3 C2 D C1 C C1 B C1 A C1 E C1 B C3 2 C2
A/C-
HEATER
7 6 CONTROL
Z1
8 5 0 OFF
20
1 VENT
BK
2 HEAT
3 MIX
2 1 4 DEFROST
3
4 0 5 HIGH
6 M2
7 M1
8 LOW
5 C2 C C3 1 C2
3
Z1 Z1 Z1 Z11 Z11
20 12 20 20 G200
16
BK BK BK/WT BK/WT (8W-15-7)
BK
(8W-15-8)
LHD
S207 G202 G203
(8W-15-7) G200 RHD
(8W-15-7) (8W-15-7)
(8W-15-8) (8W-15-7) (8W-15-8) (8W-15-8)
J998W-5 (8W-15-8) TJI04202
TJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3

RUN A22 (8W-10-8) BATT A0 (8W-10-6)

FUSE POWER
BLOCK 17 DISTRIBUTION
FUSE (8W-11-2) FUSE CENTER
8 11 (8W-10-2)
10A 40A
(8W-11-7) 24 (8W-10-13)

28
F24 A111
20 12
RD/DG RD/LB
F12 C106
A1 A12 C202
F24 20RD/DG
F24 F24 A111
20 20 12
RD/DG RD/DG RD/LB

5 9 8
HVAC
BLOWER
UNIT
BLOWER MOTOR
M MOTOR RELAY

FROM BLEND
S206 M DOOR
(8W-11-4) ACTUATOR

E2
20
OR 2 3 4 7 6 1 10
C4 C5 C6 C7 C1 C36
16 16 14 12 12 20
TN LG/LB LB BR/TN DG DB/RD
1
4 C2 3 C2 D C1 C C1 B C1 A C1 E C1 B C3 2 C2
A/C-
9 8 HEATER
10 7 CONTROL
Z1
0 OFF
20
1 MAX
BK
2 NORM
3 3 3 3 VENT
4 2 4 2 4 2 4 HEAT
5 MIX
5 1 5 1 5 1 6 DEFROST
7 HIGH
6 0 6 0 6 0 8 M2
9 M1
10 LOW
5 C2 A C3 C C3 1 C2
Z1 C90 Z1 3 Z11 Z11 G200
20 FROM 20 12 20 20 (8W-15-7)
BK Z1 S103 LG BK BK/WT BK/WT (8W-15-8)
16
BK
(8W-42-4) 6 C170
S207 G202 G203
(8W-15-7) (8W-15-7) (8W-15-7)
(8W-15-8) LHD (8W-15-8)
(8W-15-8) G200
RHD
(8W-15-7)
TJI04203 J998W-5
(8W-15-8)
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER TJ

POWERTRAIN
A/C CONTROL
COMPRESSOR MODULE
A/C A/C CLUTCH (8W-30-3)
SWITCH SELECT RELAY (8W-30-12)
SENSE INPUT CONTROL
C22 C3 C23 C3 C1 C3 RUN A22 (8W-10-9)
C22 C90 C13 FUSE
18 18 18
DB/WT LG DB/OR BLOCK
FUSE (8W-11-2)
2 C104 7
C22 10A
20 (8W-11-7)
DB/WT
1
27
A/C
LOW F20
PRESSURE 20 BATT A0 (8W-10-6)
VT/WT
SWITCH POWER
2 F3 C106 DISTRIBUTION
A23
C21 F20 CENTER
20 20 FUSE (8W-10-2)
DB/OR VT/WT 16
10A
2 S108 (8W-10-16)
A24
A/C (8W-11-7)
HIGH F20 A17
PRESSURE 20 20
SWITCH VT/WT RD/GY
1 B8 B6
C90 A/C
20 COMPRESSOR
LG CLUTCH
1 C104 RELAY
C90 B10 B7 (IN PDC)
20 C3
LG 20
DB/BK
S103 14 C103
C3
C90 20
20 DB/BK
LG
1
6 C170 A/C
COMPRESSOR
A C3
CLUTCH
A/C
HEATER
3
4 2 CONTROL
0 OFF 2
5 1 1 MAX
2 NORM Z1
6 0 3 VENT 20
4 HEAT BK
5 MIX
C C3 6 DEFROST S132
Z1 (8W-15-6)
12 Z1
BK 14
BK
G202
(8W-15-7)
(8W-15-8)
G105
(8W-15-6)
J998W-5 TJI04204
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8W - 43 - 2 8W-43 AIRBAG SYSTEM TJ

ST-RUN A21 (8W-10-9) RUN A22 (8W-10-8)

FUSE
BLOCK
(8W-11-2)
FUSE FUSE
9 5
10A 10A
(8W-11-8) (8W-11-6)

29 25

F14 F23
18 18
LG/YL DB/YL

17 20
FUSED FUSED AIRBAG
IGNITION IGNITION CONTROL
SWITCH SWITCH MODULE
F14 OUTPUT OUTPUT
18 (ST-RUN) (RUN)
LG/YL

PASSENGER PASSENGER DRIVER DRIVER

AIRBAG SQUIB AIRBAG SQUIB AIRBAG AIRBAG
LINE 2 LINE 1 GROUND LINE 1 LINE 2
6 5 10 2 1
R144 R142
18 18
R43 R45
VT/YL BR/YL
18 18
BK/LB DG/LB
1 C1 2 C2 1 C2
TWISTED
PASSENGER PAIR
Z6
AIRBAG 18
ON/OFF BK/PK
SWITCH 2 C1 1 C1

CLOCKSPRING

FUSED
RESISTOR

R43 R45
18 18
BK/LB DG/LB
2 C1 4 C2 3 C2 G301
(8W-15-11)

R44 R42
18 18
Z6 DG/YL BK/YL
20 DRIVER DRIVER DRIVER
BK/PK A B
AIRBAG AIRBAG AIRBAG
PASSENGER PASSENGER PASSENGER LINE 1 LINE 2 SQUIB
G301 AIRBAG AIRBAG AIRBAG
(8W-15-11) LINE 2 LINE 1
J998W-5 TJI04302
TJ 8W-43 AIRBAG SYSTEM 8W - 43 - 3

ST-RUN A21 (8W-10-9)

AIRBAG FUSE
CONTROL BLOCK
(8W-11-2)
MODULE FUSE
10
CCD CCD 10A
BUS BUS (8W-11-8)
(-) (+)
30
18 19

G5
20
D2 D1 DB/WT G5
18 18 20
WT/BK VT/BR DB/WT
A10 C202
TWISTED
PAIR 2
G5 FUSED BRAKE
20 IGNITION SHIFT
DB/WT SWITCH INTERLOCK
OUTPUT
(ST-RUN)
SOLENOID
S303 S302 (8W-31-2)
(8W-30-14) (8W-30-14)
8 C2
D2 D1 INSTRUMENT
20 TWISTED 20 CLUSTER
WT/BK PAIR VT/BR DATA AIRBAG (8W-40-2)
LINK WARNING
INDICATOR
CONNECTOR
(8W-30-14)
3 11 AIRBAG
D1 D2 WARNING
20 20 CCD INDICATOR CCD
VT/BR WT/BK BUS DRIVER BUS
C203 (+) (-)
B12 B11

2 C1 1 C1

TWISTED
PAIR

D1 D2
20 20
VT/BR WT/BK

TJI04303 J998W-5
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8W - 44 - 2 8W-44 INTERIOR LIGHTING TJ

BATT A0 (8W-10-6)
POWER
A16 DISTRIBUTION
FUSE CENTER
20 (8W-10-2)
10A
A15 (8W-10-15)
M1
20
M1 HARD PK/WT SOFT
20 TOP TOP
PK/WT
LHD RHD 4 SPEAKER LHD 2 RHD 2
M1 H2 C323 2 C323 SYSTEM SPEAKER SYSTEM SPEAKER SYSTEM
D12 C108
20
PK/WT M1 M1 M1 M1
20 20 20 20
M1
PK/WT PK/WT PK/WT PK/WT
20
PK/WT 2 SPEAKER 4 SPEAKER
B SYSTEM SYSTEM
H2 C323 2 C323
B7 C203 LHD RHD NOT NOT
TO S313 USED USED
UNDERHOOD M1 H2 C323 2
C323
20
LAMP PK/WT
(8W-44-3) 8 C326
8 C331 3 C325
TO M1 3 C330
20
S204 PK/WT
M1
(8W-10-15) 20
PK/WT
DOME 1
LAMP SOUND
BAR
DOME
LAMP
M2 20YL
2
9 C331 M2
M2 20
18 YL
YL 4 C330
9 C326 4 C325

S314 LHD RHD

H3 C323 3 C323 NOT NOT
2 SPEAKER 4 SPEAKER USED USED
SYSTEM M2 SYSTEM H3 C323 3 C323
20 M2 M2 M2
YL 20 20 20
LHD RHD YL YL YL

H3 C323 3 C323 4 SPEAKER LHD 2 RHD 2 SPEAKER

SYSTEM SPEAKERSYSTEM SYSTEM
HARD SOFT
TOP M2 TOP
20
YL

TO
S301
(8W-44-4)
J998W-5 TJI04402
TJ 8W-44 INTERIOR LIGHTING 8W - 44 - 3

FROM
C108
(8W-44-2)
B

M1
20
PK/WT

2
UNDERHOOD
LAMP

MERCURY
SWITCH

BASE OTHER

Z1
18
BK

Z1
18 S106
BK (8W-15-2)

Z1
12
BK

G100 G100
(8W-15-2) (8W-15-2)

TJI04403 J998W-5
8W - 44 - 4 8W-44 INTERIOR LIGHTING TJ

BATT A0 (8W-10-6)
UNDERHOOD INSTRUMENT
POWER LAMP CLUSTER
A16 DISTRIBUTION KEY-IN
(8W-44-3) IGNITION (8W-40-7)
FUSE CENTER FUSED
B (+) SWITCH
20 (8W-10-2) SENSE
10A 2
A15 (8W-10-15)
M1 8 C1
M1 20
G26 20LB
20 PK/WT
PK/WT
G26 20LB
12 C108 5
HEADLAMP B3 C203
B7 C203
SWITCH
S204 HARD SOFT 0 OFF G26
(8W-10-15) FROM TOP TOP 1 PARK 20
M1 M1 DOME 0 2 HEAD LB
20 20 1 2
PK/WT PK/WT LAMP M1 M1 (8W-50-3)
AND 20 20
2
1 PK/WT PK/WT
SOUND 6 KEY-IN
BAR G16 SWITCH
LEFT TO TO 20
DOME
COURTESY LAMP DOME SOUND BK/LB
LAMP 1 LAMP BAR
(8W-44-2) B4 C203 1
AND DOME
A SOUND LAMP G16 20BK/LB
RIGHT G16
BAR (8W-44-2)
COURTESY M2 20
LAMP DOME BK/LB
20
YL LAMP
2 (8W-44-2)
S301
M2 M2 M2
2 20 20 20
YL YL YL
C5 C204 2 2 3
PASSENGER DRIVER
M2 M2 M2
20 20 20
DOOR DOOR
YL YL YL AJAR AJAR
SWITCH SWITCH
S202
1 1
M2 M23 M23
20 20 20
YL YL/BK YL/BK

3 4
HEADLAMP FUSE
SWITCH FUSE
BLOCK
0 OFF 4 (8W-11-2)
0 1 1 DOME 10A
(8W-50-3) (8W-11-5)

RHD LHD 24
Z1
Z1 Z1 20
16 16 BK
BK BK RHD LHD

S207 Z1 S304
(8W-15-8) 20 (8W-15-9)
Z1 Z1
16 BK 16
BK BK

G200 G200 G300 G300

(8W-15-8) (8W-15-7) (8W-15-10) (8W-15-9)
J998W-5 TJI04404
TJ 8W-44 INTERIOR LIGHTING 8W - 44 - 5

BATT F34 (8W-11-4)

HEADLAMP
SWITCH
0 OFF
1 PARK S206
0 1 2 HEAD (8W-11-4)
2 3 4 5
3 DOME
4 MAX
1 5 MIN E2 E2 E2 E2 E2 E2
(8W-50-2) 20 20 20 20 20 20
E1
OR OR OR OR OR OR
18
TN
A4
A3 C202
3
FUSE
BLOCK 1
FUSE (8W-11-2) FRONT
3 FOG
10A E2
(8W-11-4) 20 LAMP
OR SWITCH
23 (EXCEPT
4 BUILT-UP
-EXPORT)
(8W-50-7)

E2 4 4 C2
20 REAR A/C-
OR WINDOW HEATER
DEFOGGER CONTROL
SWITCH (8W-42-2)
(HARD TOP) (8W-42-3)
1 (8W-48-2)

1 4 3
5 C2
PRNDL REAR REAR
LAMP FOG WIPER/
LAMP WASHER
SWITCH SWITCH
(BUILT-UP (HARD TOP)
2 1 -EXPORT) 1 (8W-53-4)
(8W-51-7)
(8W-51-8)
Z1 Z1 Z1 Z1 Z1 Z1
20 20 20 18 20 20
BK BK BK BK/WT BK BK

S304 S207
(8W-15-9) (8W-15-7)
(8W-15-10) (8W-15-8)
Z1 Z1
16 16
BK BK

G300 G200
(8W-15-9) (8W-15-7)
(8W-15-10) (8W-15-8)
TJI04405 J998W-5
8W - 44 - 6 8W-44 INTERIOR LIGHTING TJ

BATT F34 (8W-11-4)

HEADLAMP
SWITCH
0 OFF
1 PARK
0 1 2 3 4 5 2 HEAD
3 DOME
4 MAX
1 5 MIN
E1 (8W-50-2)
18
TN

A3 C202

E1
18
TN

3
FUSE
BLOCK
FUSE (8W-11-2)
3
10A
(8W-11-4)

23
E2
20
E2
OR
20
OR
A4 C202

E2 TO
20
OR
PRNDL
LAMP
(8W-44-5)

S206
(8W-11-4)
E2
20
OR

3 C2
INSTRUMENT
E2
CLUSTER 20
(8W-40-8) OR

5 C1
RADIO
(8W-47-2)

6 C2
Z2
18
BK/LG

G201
(8W-15-7)
(8W-15-8)
J998W-5 TJI04406
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8W - 47 - 2 8W-47 AUDIO SYSTEM TJ

RUN-ACC A31 (8W-10-9) BATT A0 (8W-10-6)

FUSE POWER
BLOCK A16 DISTRIBUTION
FUSE FUSE (8W-11-2) FUSE CENTER
15 3 20 (8W-10-2)
10A 10A 10A
(8W-11-9) (8W-11-4) A15 (8W-10-15)

35 3 23

X12 E1 E2 M1
20 18 20 20
PK TN OR PK/WT

C10 C204 D12 C108

A3 C202

E1 M1 M1 M1
18 20 20 20
TN PK/WT PK/WT PK/WT

HARD SOFT
TOP TOP
BATT F34 (8W-11-4)
1 TO
HEADLAMP UNDERHOOD
SWITCH LAMP TO TO
0 OFF
(8W-44-3) DOME SOUND
1 HEAD LAMP BAR
1 0 2 PARK
2 4 5 4 MAX AND DOME
5 MIN SOUND LAMP
9 (8W-50-2) BAR (8W-44-2)
A4 C202 DOME
LAMP
(8W-44-2)
L7
18
BK/YL E2
20 B7 C203
OR RADIO
M1 ANTENNA
20
PK/WT
B6 C203 S206
(8W-11-4) S204
(8W-10-15)

X12 L7 E2 M1
20 18 20 20
PK BK/YL OR PK/WT

6 C1 4 C1 5 C1 7 C1
FUSED HEADLAMP FUSED FUSED ANTENNA RADIO
IGNITION SWITCH PANEL B (+)
SWITCH OUTPUT LAMPS
OUTPUT DIMMER
(RUN-ACC) SWITCH
SIGNAL

J998W-5 TJI04702
TJ 8W-47 AUDIO SYSTEM 8W - 47 - 3

2 2
LEFT RIGHT
REAR REAR
2 2
SPEAKER SPEAKER
(SOUND (SOUND
LEFT RIGHT
1 BAR) 1 BAR)
FRONT FRONT
SPEAKER SPEAKER
X57 X51 X58 X52
1 1 20 20 20 20
BR/LB BR/YL DB/PK DB/WT

1 2 5 6 C330

X57 X51 X58 X52

18 18 18 18
BR/LB BR/YL DB/PK DB/WT

1 2 5 6 C325

X58 X52
18 18
DB/PK DB/WT

LHD RHD
X57 X51
18 18
H10 H9
BR/LB BR/YL C323 10 9 C323

LHD RHD

H8 H7
C323 8 7 C323

X57 X51 X58 X52

18 18 18 18
BR/LB BR/YL DB/PK DB/WT

C12 C11 C14 C13 C204

X55 X53 X56 X54 X57 X51 X58 X52

18 18 18 18 18 18 18 18
BR/RD DG DB VT BR/LB BR/YL DB/PK DB/WT

2 C1 4 C2 3 C1 5 C2 6 C2 2 C2 7 C2 3 C2
LEFT LEFT RIGHT RIGHT LEFT LEFT RIGHT RIGHT RADIO
FRONT FRONT FRONT FRONT REAR REAR REAR REAR
SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (-) (+) (-) (+) (-) (+)

TJI04703 J998W-5
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:<;>=@?A:CBEDGF-B5;CHJILKNML; KEDPOMLQLQRDPB

S9TU7V2TWX WY Z\[]X S9TUŽVTWX WY Z\[]X

^_`@abdce^fhg\ijiiiiiiiiijiiiiiiiiijiiiiii2kmlonepkneq ƒ„‡ †‹{ˆ ‰Šz‘’Œ2ˆ…diiiiiiijiiiiiiiiijiiiiii2k@l“nepkneq
^_`@aArmsdcetu9vhgwiiiiiijiiiiiiiiiijiiiiii2kmlonepkneq ƒ„‡`m‰Š‘}_…da‡‰”vy_`m‰Ša‘xiiiijiiiiiiiiijiiiiii2k@l“nepkneq
^_`@aArmbdce^fhgxiiiiiiiijiiiiiiiiiijiiiiii2kmlonepkneq tz„•!a‘9u9†`m‰
‘}†–_‰Š†z‡<va‡‰Ša‘—iiiiiiijiiiiii2k@l“nepkneq
^_`@afyz{}|~iiiiiiiiijiiiiiiiiiijiiiiii2kmlonepkneq ˜aˆ‘2lo†‡z
•wu’a™ezšJš›a‘ijiiiiiiiiijiiiiii2k@l“nepkneq
 q€€iiiiijiiiiiiiiijiiiiiiiiiijiiiiii2kmlonepkneq ˜aˆ‘2lo†‡z
•wu’a™ezšJš›a‘9˜ayˆ@œLiiiiijiiiiii2k@l“nepkneq
9‚ €qiiiiijiiiiiiiiijiiiiiiiiiijiiiiii2kmlonepkneq ˜aˆ‘2lo†‡z
•wu’a™ezšJš›a‘9›•!†‰Š{}žwiiiijiiiiii2k@l“nepkneq
ƒ„yy_…d†‡ˆ‰Š†‹z‡Œˆ…dLiiijiiiiiiiiiijiiiiii2kmlonepkneq
8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER TJ

BATT A0 (8W-10-6) RUN A22 (8W-10-8)

POWER FUSE
21 DISTRIBUTION BLOCK
FUSE CENTER FUSE (8W-11-2)
15 (8W-10-2) 7
40A 10A
28 (8W-10-14) (8W-11-7)

A4 27
F20 20VT/WT
12
BK/PK
F3 C106
S108
D2 D4 (8W-11-7)
REAR
WINDOW
DEFOGGER
RELAY
D8 D6 (PDC)
C15
12
BK/WT
F8 C106
S320
LHD RHD
C15 C81
14 H1 C323 1 C323 20
BK/WT LB/WT
17
FUSE 1 C326
BLOCK
FROM FUSE (8W-11-2) 1 C331
S206 17
(8W-11-4) 10A C15 12BK/WT
(8W-11-9)
2 C170
C15
E2 12
20 37
GY
OR A5 C202
F81 REAR
20 WINDOW
DB/RD C81
DEFOGGER 20
4 3 (HARD LB/WT
REAR TOP)
ILLUMINATION WINDOW
LAMP INDICATOR Z1
LAMP DEFOGGER 3 C1
(HARD 12
TOP) SWITCH BK REAR INSTRUMENT
(HARD WINDOW CLUSTER
TOP) DEFOGGER (8W-40-8)
S400 RELAY
(8W-15-11) CONTROL
1 2
Z1
6 C331
20 6 C326
BK
S309 REAR
S207 (8W-15-11) WINDOW
(8W-15-7) LHD RHD DEFOGGER
Z1 (8W-15-8) C80
SWITCH
16 20 5 C322
G5 C322 SENSE
BK DB/LG
4 C1
G200 G302
(8W-15-7) (8W-15-11)
(8W-15-8)
J998W-5 TJI04802
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8W - 50 - 2 8W-50 FRONT LIGHTING TJ

BATT F34 BATT A3 DAYTIME

(8W-11-4) (8W-10-13)
3
FUSED
RUNNING
HEADLAMP B(+) LAMP
CIRCUIT SWITCH MODULE
OPTICAL
BREAKER 0 OFF HORN (8W-50-8)
24A 1 PARK FEED
2 HEAD
6
3 3 DOME
4 MAX
5 MIN L20
0 1 2 16
0 1 2
LG/WT
2 7
5 4 D8 C108
L2 L20
16 16
L20
1 9 LG LG/WT
16
A8 A2 LG/WT
C202
E1
18
L2 L20
TN
14 14
LG LG/WT
L2 2 4
A3 C202 16 HEADLAMP
LG DIMMER
E1 SWITCH
18 1 LOW
1 2 3
TN 2 HIGH
TO
3 FLASH
FUSE 1 3
16 (FB) L4 L3
TO (REAR FOG 14 14
FUSE LAMPS) VT/WT RD/OR
3 (FB) (8W-11-10)
E5 E4 C107
(8W-11-4) L3
L4
16 16
VT/WT RD/OR
DRL OTHER

S104 S105
(8W-50-8)
OTHER DRL

C110 1
5 4 L3
DIMMER SWITCH DAYTIME
S119 16
HIGH BEAM OUTPUT RUNNING
RD/OR
L4 HIGH BEAM LAMP
L4 L3 16RD/OR 16 INDICATOR DRIVER MODULE
16 VT/WT
VT/WT 4 (8W-50-8)
L3 G34 FOG
2 1 16 18 HIGH
RD/GY LAMP
LEFT RD/OR BEAM
1 2 INDICATOR
RELAY
HEADLAMP DRIVER NO. 2
3 RIGHT (EXCEPT
HEADLAMP D7 C108 1
Z1 G34 BUILT-UP
3 G34 16
20 16
-EXPORT)
Z1 RD/GY
BK RD/GY (8W-50-6)
18
S117 EXCEPT BUILT- BK BUILT-
UP-EXPORT UP-EXPORT
B5 C203
(8W-15-3)
Z1 5 C2
S150 INSTRUMENT
16 HIGH
(8W-15-5)
BK BEAM CLUSTER
INDICATOR (8W-40-9)
G102 G103 DRIVER
(8W-15-3) (8W-15-4)
J998W-5 (8W-15-5) TJI05002
TJ 8W-50 FRONT LIGHTING 8W - 50 - 3

INSTRUMENT
KEY-IN CLUSTER
IGNITION (8W-40-7)
SWITCH
SENSE
8 C1
G26
20
LB
FROM
S202
(8W-44-4) B3 C203

M2 G26
20 20
YL LB

3 5
HEADLAMP
SWITCH
0 OFF
1 PARK
0 1 2
2 HEAD
3 DOME
0 3

Z1 G16
16 20
BK BK/LB

RHD LHD
B4 C203

S207
(8W-15-8)
G16
20
Z1 Z1
BK/LB
16 16
BK BK

3
DRIVER DRIVER
Z1 DOOR DOOR
AJAR G16
16 AJAR 20
BK SWITCH
SENSE
SWITCH BK/LB
(8W-44-4)

G200
(8W-15-7) 1
(8W-15-8)
DRIVER KEY-IN
DOOR SWITCH
AJAR (8W-40-7)
SWITCH (8W-44-4)
SENSE

TJI05003 J998W-5
8W - 50 - 4 8W-50 FRONT LIGHTING TJ

INSTRUMENT BATT F34 TURN

(8W-11-4)
CLUSTER SIGNAL/
LEFT (8W-40-9) HEADLAMP RIGHT
TURN HAZARD
TURN SWITCH
TURN 1 PARK SIGNAL SWITCH
SIGNAL
SIGNAL/ 1 (8W-52-3)
2 HEAD
10 C2 LEFT 0 2
TURN HAZARD 1 3 OFF
L61 L60
SIGNAL SWITCH 18
18 (8W-52-3)
GY 10 TN
INSTRUMENT
9
FOG CLUSTER
HEAD-
LAMP RIGHT (8W-40-9)
LAMP
RELAY TURN
SWITCH
SIGNAL
OUTPUT NO. 2 L7
(EXCEPT 18 6 C1
3
BUILT-UP BK/YL L60
EXPORT) 18
L61 L7
(8W-50-6) TN
18 18
GY BK/YL
B2 C203 B6 B1 C203

L7 18BK/YL
C107 LHD RHD
E3 E1 E2

C110 G1 C322 1 C322

3 1 2
S118
(8W-70-2)
S141
2 S142 TO
LEFT
L7 SIDE 2 S310
18 RIGHT (8W-70-2)
MARKER
BK/YL 1 L60 L7 SIDE
LAMP 18 18
1 MARKER
(EXCEPT BUILT- TN BK/YL
L61 LAMP
18
UP-EXPORT) L7
18
(EXCEPT BUILT-
GY L7 L7
S143 BK/YL UP-EXPORT)
18 18
1 2 LEFT BK/YL BK/YL
FRONT S144
PARK/ 1
3 TURN RIGHT
CITY RIGHT
SIGNAL 1 1 2
FRONT
Z1 LAMP
18
LAMP LEFT 2 PARK/
(EXCEPT BUILT- (BUILT-UP
BK CITY TURN
UP-EXPORT) -EXPORT)
2 LAMP 3 SIGNAL
FRONT EXCEPT FRONT (BUILT-UP Z1 LAMP
FOG LAMPS FOG LAMPS -EXPORT) 18 (EXCEPT BUILT-
BK UP-EXPORT)
S122 Z1
(8W-15-3) 20 FRONT EXCEPT FRONT
BK FOG LAMPS FOG LAMPS
Z1 Z1
18 18 S125
BK BK
S150 (8W-15-4)
(8W-15-5)
S117 Z1
(8W-15-3) Z1
Z1 18 18
16 BK BK
BK

G102 G103
(8W-15-3) (8W-15-4)
J998W-5 (8W-15-5) TJI05004
TJ 8W-50 FRONT LIGHTING 8W - 50 - 5
BUILT-UP-EXPORT
BATT A3 (8W-10-13)
HEADLAMP
CIRCUIT SWITCH
16
BREAKER 0 OFF
FUSE 24A 1 PARK
BLOCK 2 HEAD
FUSE (8W-11-2)
16
10A
(8W-11-10)
0 1 2

36 L2 2
16 L2
L22
LG 16
20
LG/DG LG
A8 C202
S330
(8W-11-10) L2
14
L22 LG
20
LG/DG
L22 20LG/DG 2
D13 C108 HEADLAMP HEADLAMP
C9 C204 SWITCH DIMMER
L22
20 OUTPUT SWITCH
LG/DG (8W-50-2)
9 C110
L22
20
LG/DG

S151
S138 (8W-11-10)
L13 L13 L13
20 20 20
BR/YL BR/YL BR/YL
14 C110
L13
L22 20
20 BR/YL
LG/DG 1 C170 L22 L22
20 20
2 5 LG/DG LG/DG
HEADLAMP 2 1 2 1
LEVELING LEFT RIGHT
SWITCH HEADLAMP HEADLAMP
M LEVELING M LEVELING
MOTOR MOTOR
4 3 3
Z1 Z1 Z1
20 20 18
BK BK BK
LHD RHD
S117 S150
S207 (8W-15-3) (8W-15-5)
(8W-15-7) Z1 Z1
Z1 16
16 18
BK BK
BK
G102 G103
G200 G200 (8W-15-3) (8W-15-5)
(8W-15-7) (8W-15-8)
TJI05005 J998W-5
8W - 50 - 6 8W-50 FRONT LIGHTING TJ
FOG LAMPS
DIMMER HEADLAMP
SWITCH DIMMER
HIGH SWITCH BATT F34 (8W-11-4)
BEAM (8W-50-2)
OUTPUT HEADLAMP
3 SWITCH
0 OFF
L3 1 PARK
14 2 HEAD
RD/OR 0 2 3 DOME
1
4 MAX
E4 C107 5 MIN
3 4 5
(8W-50-2)
L3
16
RD/OR 9 1

S105
(8W-50-2)
L7 E1
L3 18 18
16 BK/YL TN
RD/OR

D7 C108
B6 C203 A3 C202
G34
16 G34
RD/GY 16
RD/GY
B5 C203 L7 E1
5 C2 18 18
HIGH INSTRUMENT BK/YL TN
G34 BEAM CLUSTER
16 INDICATOR (8W-40-9)
RD/GY DRIVER
1 3 3
FOG FUSE
LAMP BLOCK
RELAY FUSE (8W-11-2)
NO. 2 3
10A
2 4 (8W-11-4)

FUSE
23
BLOCK
Z1 FUSE (8W-11-2) L95
20 4 18 E2 E2
BK 10A DG/YL 20 20
(8W-11-5) OR OR

24 C1 C204 A4 C202
Z1
20 Z1 1
BK 20 L95 E2 FUSED PRNDL
BK 18 20 PANEL LAMP
DG/YL OR LAMPS (8W-44-5)
A DIMMER
S304 SWITCH
TO B C SIGNAL
(8W-15-9)
FOG
TO TO
LAMP Z1
16 FRONT S206
RELAY (8W-50-7)
BK FOG
NO. 1
(8W-50-7) LAMP
G300 SWITCH
(8W-50-7)
(8W-15-9)
J998W-5 TJI05006
TJ 8W-50 FRONT LIGHTING 8W - 50 - 7
FOG LAMPS
FROM FROM
C202 C204
(8W-50-6) (8W-50-6)
C B BATT A6 (8W-10-10)

FROM POWER
FOG E2 DISTRIBUTION
20 CENTER
LAMP OR
L95 A6
18 (8W-10-2)
RELAY FUSE
DG/YL 25
NO. 2 S206
(8W-50-6) (8W-11-4) 20A
(8W-10-16)
A A5
1 3
FRONT
FOG
LAMP F61
SWITCH 18
WT/OR

4 2 D6 C108

Z1
B13 C203
F61
20 18
BK L35
WT/OR
18
BR/WT
S207
(8W-15-7) 1 3
Z1 FOG
20 Z1
BK 16
LAMP
BK RELAY
NO. 1
2 5
G200
(8W-15-7) E10 C107
L39
18
LB
13 C110

S116
2 2
LEFT RIGHT
FOG FOG
1 LAMP 1 LAMP

S122 Z1
(8W-15-3) 18
BK
Z1
18
BK S125
(8W-15-4)
S117 Z1
(8W-15-3) 18
Z1 BK
16
BK G103
(8W-15-4)
G102
(8W-15-3)
TJI05007 J998W-5
8W - 50 - 8 8W-50 FRONT LIGHTING TJ
DRL
ST-RUN A21 (8W-10-9) VEHICLE
VEHICLE SPEED
SPEED
FUSE SENSOR SENSOR
BLOCK SIGNAL (8W-30-10)
(8W-11-2)
3
FUSE HEADLAMP
11 FUSED
B(+) SWITCH G7
10A 20
OPTICAL (8W-50-2)
(8W-11-8) WT/OR
HORN
FEED
31 S135
7
F12 L20 G7
20 16 18
G7
RD/LG LG/WT WT/OR
20
WT/OR
F10 C106 A2 C202
B27 C2
L20 14LG/WT
F12 POWERTRAIN
20 L20 4 12 C103 VEHICLE CONTROL
RD/LG 16 FUSED HEADLAMP SPEED
LG/WT B(+) DIMMER G7 SENSOR MODULE
OPTICAL 20 SIGNAL (8W-30-10)
SWITCH
S102 D8 C108 HORN (8W-50-2) WT/OR
(8W-11-8) FEED
5 6 7
FUSED FUSED VEHICLE DAYTIME
IGNITION B(+) SPEED RUNNING
SWITCH OPTICAL SENSOR LAMP
OUTPUT HORN SIGNAL
(ST-RUN) FEED
MODULE
DIMMER DIMMER
SWITCH SWITCH HIGH
HIGH LOW BEAM
BEAM BEAM INDICATOR
OUTPUT OUTPUT DRIVER GROUND
1 10 4 8
DIMMER DIMMER HEADLAMP
G34
SWITCH SWITCH DIMMER
18
HIGH LOW SWITCH RD/GY Z1
BEAM BEAM (8W-50-2)
18
OUTPUT OUTPUT
BK
3 1
D7 C108
L3 L3 L4 L4
16 14 14 16 G34
RD/OR RD/OR VT/WT VT/WT 16
RD/GY
S106
(8W-15-2)
E4 E5 C107 G34 16RD/GY
L3 L4
B5 C203
1 Z1
16 16 12
RD/OR VT/WT FOG BK
HIGH
G34
BEAM LAMP
S105 S104 16
INDICATOR RELAY
(8W-50-2) RD/GY
DRIVER NO. 2
4 C110 5 C110 (8W-50-6)
5 C2
L3 INSTRUMENT
16 S119 HIGH
RD/OR BEAM CLUSTER
L3 16RD/OR INDICATOR (8W-40-9)
1 2 1 2 DRIVER G100
(8W-15-2)
LEFT RIGHT
HEADLAMP HEADLAMP
(8W-50-2) (8W-50-2)
J998W-5 TJI05008
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-/.1032547698;:<6>=/?A@CBEDF?HGE@

IKJML*N'JOQPROQS TVUMWP IKJML¤N|JOQPROQS TVUMWP

XZY [A\]_^a`cb'Y de`f)gMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgih3jk]_lnm3]_o pq ¡ q ¢ o£gMggMgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_ pš ph
XZY [A\]_^a`cb'Y de`crHstvuw[AxygMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_o pq Ž{Y Š‡Y de`;¥,tdede{z,rHs)tuw[Ax¦gMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
XZzAY \{b|Y de`;r}s)tuw[Ax~gMgMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_ p€ Ž{Y Š‡Y de`;r}s)tuw[Ax§gMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_o pq pš ph
XZzAY \{rxt‚_uZƒ…„Mu†{zA‡ˆ[A\‰rˆ‡{„MˆtŠ‹gMgMggMgMgMgMgMgMg'h3jk]_lnm3]_€ b|{‚_uZb|t[A{„f3{Žb'Y de`¨gMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
Œ {„Mu†{zKŽtHx/‘ˆ’M„uw{Šcr“uwˆ`cb'Y de`/gMgMgMgMgMg'h3jk]_lnm3]_ p€ b|{‚_uZ™Z{YRz,b'Y de`V–af3f—{de© ‡ ˜igMgMgMgMgMg'h—j5]_lnm3]_o pq p pl p€
Œ tHY zKb|tHxuw{z•” –a[A[A{f—f3ˆz•˜*™Z{‡Y3˜~gMgMgMggMgMgMgMgMg'h3jk]_lnm3]_€ ª|YRzA\”¬«a{’uwzAYR‡nª|ˆf3tu†tˆ„‘r}s)tuw[Ax­gMgMggMgMgMgMgMg'h—j5]_lnm3]_o pq
Œ tzA[A’tuZXZzA{Y \{zKgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ª|ˆ…s){zAu†z®YRt„ Œ ˆ„uwzAˆ‡“‘ˆŠR’‡{¯gMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_€
Œ ˆ„Mu†zAˆ‡‡v{z–a„uwtv]vb'ˆ[A\‰XZzAY \M{ŽgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_ p€ ª|™Z«a¥Kbœb|Y de`°gMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
›|ˆb'Y de`cƒ…‡‡v’Mdet„YRuwtˆ„œgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ™Z{Y z,›'ˆ)b|Y de`¤gMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
›|ˆb'Y de`cƒ…„Št[AY uwˆzggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ™Z{Y z,›'ˆ)b|Y de`;™Z{‡vY3˜±gMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
›|’f—{Žoež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_ p€ ™Z{Y z,›'ˆ)b|Y de`;r}s)tuw[AxFgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
›|’f—{Žqež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ™ZtHxuZb|t[A{„f3{Žb'Y de`ggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š ph
›|’f—{Žež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ™ZtHxuZ™Z{YRz,b'Y de`V–af3f—{de© ‡ ˜‰gMgMgMgMg'h—j5]_lnm3]_o pq p pl p€
›|’f—{Žšež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_o pq ²³YRt‡ ”¬ru†ˆ`´” ²³’z®„‘rtv}„Y ‡nb'Y de`RfCgMgMggMgMgMgMgMg'h—j5]_lnm3]_o pl
›|’f—{‰m3€ež_›|XŸŽgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ²³YRt‡ ” ²³’MzA„‘rtH„Y ‡nb|YRde`Rf<gMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_q
›|’f—{ŽXZ‡ˆ[A\ ggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_o pq p p€ pš ph ²³’MzA„‘rtH„Y ‡ ”¬Y µ´Y zAŠcrHstvuw[Ax¤ggMgMgMgMgMg'h—j5]_lnm3]_o pq pl p€
¡ o ¢ ¢œgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š ph ¶Z{xt[A‡{Žr“`R{{Š Œ ˆ„Mu†zAˆ‡nr{z•·“ˆ‘gMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_€
¡ q ¢ ¢£gMggMgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_€ pš ph
8W - 51 - 2 8W-51 REAR LIGHTING TJ
EXCEPT BUILT-UP-EXPORT
RUN A22 (8W-10-8) BATT F34 (8W-11-4)
FUSE HEADLAMP
BLOCK SWITCH
(8W-11-2) 0 OFF
FUSE 1 PARK
0 1 2
7 2 HEAD
10A (8W-50-4)
(8W-11-7)
9
27 TURN
F20
LEFT RIGHT
SIGNAL/
20 L7
18 TURN TURN HAZARD
VT/WT
BK/YL SIGNAL SIGNAL SWITCH
F3 C106 (8W-52-2)
9 3
S108 B6 C203
(8W-11-7)
10 C104 L7
18
F20
BK/YL
20
VT/WT
A/T M/T E1 C107
L7
4 C154 4 C154 18 L7
F20 F20 BK/YL 18
18 18 L63 L62
BK/YL
VT/WT VT/WT 18 18
1 B DG/RD BR/RD
1 C110
PARK/ BACK-UP
NEUTRAL LAMP L7
G1 C322
POSITION SWITCH 18
SWITCH BK/YL
3 A
L1 L1
18 18
VT/BK VT/BK TO
C154 L7 S118
2 C154 2 18 (8W-70-2)
L1 L1 BK/YL
20 20
VT/BK VT/BK

9 C104 S310
L1
(8W-70-2) G2 C322
20
VT/BK
G4 C322
F2 C106
S335
G3 C322
S311
L1 L7 L63 L63 L1 L7 L62
20 18 18 18 20 18 18
VT/BK BK/YL DG/RD DG/RD VT/BK BK/YL BR/RD
1 3 2 4 1 3 2
LEFT NOT RIGHT
TAIL/ REAR USED TAIL/ REAR
STOP/ LAMP STOP/ LAMP
BACK-UP BACK-UP
LAMP TURN ASSEMBLY LAMP TURN ASSEMBLY
SIGNAL SIGNAL
LAMP LAMP

J998W-5 TJI05102
TJ 8W-51 REAR LIGHTING 8W - 51 - 3
BUILT-UP-EXPORT
RUN A22 (8W-10-8) BATT F34 (8W-11-4)
FUSE HEADLAMP
BLOCK SWITCH
FUSE (8W-11-2) 0 OFF
7 1 PARK
0 1 2
10A 2 HEAD
(8W-11-7) (8W-50-4)

27 9
F3 C106 TURN
L7
SIGNAL/
S108 18 LEFT RIGHT
(8W-11-7) BK/YL TURN TURN HAZARD
10 C104 SIGNAL SIGNAL SWITCH
B6 C203 9 3 (8W-52-2)
F20
20
L7
VT/WT
18
A/T M/T BK/YL

4 C154 4 C154 E1 C107

F20 F20 L7
18 18 18
VT/WT VT/WT BK/YL
1 B L7
PARK/ BACK-UP 18 1 C110
BK/YL L63 L62
NEUTRAL LAMP 18 18
POSITION SWITCH TO DG/RD BR/RD
SWITCH S118
3 A (8W-70-2)

L1 L1 LHD RHD
18 18
VT/BK VT/BK G1 C322 1 C322

2 C154 2 C154 LHD RHD

L1 L1
20 20 L7
VT/BK VT/BK 18 G2 C322
BK/YL
2 C322

9 C104 S310
(8W-70-2)
L1 L7
20 18 LHD RHD
VT/BK BK/YL
F2 C106 G4 C322 4 C322
LHD RHD

G3 C322 L7
18
3 C322 L63
BK/YL
18
L62
DG/RD
18
S311 BR/RD
2 3 4 1 2 3 4 1
LEFT RIGHT
REAR REAR
TAIL/ TURN
BACK-UP
SIGNAL
LAMP BACK-UP TAIL/ TURN LAMP
LAMP STOP STOP SIGNAL
LAMP LAMP ASSEMBLY LAMP ASSEMBLY
LAMP LAMP

TJI05103 J998W-5
8W - 51 - 4 8W-51 REAR LIGHTING TJ

BATT A6 (8W-10-10)
FUSE
BLOCK
(8W-11-2)
FUSE
2
20A
(8W-11-4)

22
F32 CONTROLLER
18 BRAKE ANTI-LOCK
PK/DB LAMP
SWITCH
BRAKE
5
OUTPUT (8W-35-5)
BRAKE
LAMP
8 C1
SWITCH L50
(8W-51-6) 18
WT/TN
6

L50 18WT/TN L50

18
LHD EXCEPT WT/TN
BUILT-UP- BUILT-UP-
RHD EXPORT EXPORT D9 C108

7 C322 G7 C322 G7 C322

L50
18
EXCEPT L50
WT/TN
BUILT-UP- BUILT-UP- 18
EXPORT EXPORT WT/TN

S315
L50 L50
18 18
WT/TN WT/TN A
CENTER
3 HIGH TO
MOUNTED TURN
RIGHT STOP SIGNAL/
TAIL/STOP/TURN REAR LAMP HAZARD
SIGNAL LAMP LAMP SWITCH
ASSEMBLY (8W-51-5)
TAIL/STOP LAMP
Z1
18
BK

3 S309
(8W-15-11)
LEFT Z1
REAR 12
TAIL/STOP/TURN BK
SIGNAL LAMP LAMP
ASSEMBLY LHD RHD
TAIL/STOP LAMP
G5 C322 5 C322
EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
G302
(8W-15-11)
J998W-5 TJI05104
TJ 8W-51 REAR LIGHTING 8W - 51 - 5

FROM
C322
(8W-51-4)
A

L50
18
WT/TN

4 2
TURN
SIGNAL/
3 4
HAZARD
SWITCH
3 4 3 4 1 LEFT
2 RIGHT
3 NORMAL
4 HAZARD

1 2 1 2

9 1 10 3

L63 L62
18 18
DG/RD BR/RD

EXCEPT LHD EXCEPT LHD

BUILT-UP- BUILT-UP- BUILT-UP- BUILT-UP-
EXPORT EXPORT RHD EXPORT EXPORT RHD

G4 C322 G2 C322 2 C322

L63 G4 C322 4 C322 G2 C322
18
L62
DG/RD
18
S335 BR/RD
(8W-51-2)
L63 1
18
DG/RD
RIGHT
L63 TURN REAR
18 L63 L62 SIGNAL LAMP
2 DG/RD 18 18 LAMP ASSEMBLY
DG/RD BR/RD
LEFT (8W-51-3)
TAIL/
STOP/ REAR
TURN LAMP 4 2
SIGNAL ASSEMBLY RIGHT
LAMP (8W-51-2) NOT TAIL/
USED STOP/ REAR
TURN LAMP
1 SIGNAL ASSEMBLY
LAMP (8W-51-2)
LEFT
TURN REAR
SIGNAL LAMP
LAMP ASSEMBLY
(8W-51-3)
TJI05105 J998W-5
8W - 51 - 6 8W-51 REAR LIGHTING TJ

POWERTRAIN BATT A6 (8W-10-10)

SPEED CONTROL
CONTROL MODULE FUSE
ON/OFF BRAKE BLOCK
SWITCH SWITCH (8W-30-16)
FUSE (8W-11-2)
SENSE SENSE
BRAKE 2
C11 C3 C24 C3 SHIFT 20A
BRAKE (8W-11-4)
SWITCH INTERLOCK
V32 K29 SENSE SOLENOID
18 18 (8W-31-2) 22
1
YL/RD WT/PK
K29
20 F32
D1 D14
C108 WT/PK 18
PK/DB

V32 K29
20 20
YL/RD WT/PK

3 1 5
BRAKE
L50 18WT/TN
LAMP
SWITCH EXCEPT
LHD EXCEPT BUILT-UP BUILT-UP
BUILT-UP BUILT-UP -EXPORT -EXPORT
4 2 6 RHD -EXPORT -EXPORT

L50
G7 C322 S315
18 7 C322 G7 C322
WT/TN

Z1 L50
V30 20 18
20 BK CIGAR D9 C108 L50 WT/TN
DB/RD LIGHTER/ 18
L50 WT/TN CENTER
ACCESSORY 18 BRAKE
GROUND RELAY WT/TN LAMP HIGH
(8W-41-2) L50 SWITCH MOUNTED
E11 C107 5 18 OUTPUT
STOP
WT/TN
LAMP
LHD RHD 3 (8W-51-4)
Z1
V30 20 BRAKE RIGHT
20 BK L50 LAMP REAR
DB/RD 18 SWITCH LAMP
Z1 S304 WT/TN OUTPUT
(8W-15-10) ASSEMBLY
20 (8W-51-4)
BK Z1 3
16 8 C1
BK BRAKE CONTROLLER
LAMP ANTI-LOCK BRAKE LEFT
SWITCH BRAKE LAMP REAR
OUTPUT (8W-35-5) SWITCH LAMP
G300 OUTPUT
3 (8W-15-9) ASSEMBLY
(8W-15-10) (8W-51-4)
SPEED VEHICLE
CONTROL SPEED 2
BRAKE CONTROL BRAKE TURN
SWITCH SERVO LAMP SIGNAL/
OUTPUT SWITCH
(8W-30-16) HAZARD
OUTPUT
SWITCH
(8W-51-5)
J998W-5 TJI05106
TJ 8W-51 REAR LIGHTING 8W - 51 - 7
LHD BUILT-UP-EXPORT
BATT A3 (8W-10-13) BATT F34 (8W-11-4)
HEADLAMP
CIRCUIT SWITCH
BREAKER 0 OFF
HEADLAMP 24A 1 PARK
HEAD-
DIMMER 2 HEAD
SWITCH 3 MAX
LAMP
(8W-50-2) 4 MIN
SWITCH
OUTPUT (8W-50-2)
0 1 2 0 1 2
(8W-50-4)
2
2 4 3
L2
L2 16
14 LG 1 9
LG E1 L7
A8 C202 18 18
TN BK/YL
L2 16LG A3 C202 B6 C203
16 3
FUSE L7
S330 BLOCK 18
(8W-11-10) FUSE FUSE (8W-11-2) BK/YL
L22 L22 L22 16 3
20 20 20 10A 10A
LG/DG LG/DG LG/DG (8W-11-10) (8W-11-4)
5 1 E1 C107 L7
HEADLAMP HEADLAMP REAR 36 23 18
SWITCH SWITCH FOG 1 C110 BK/YL
E2
FUSED FUSED LAMP 20 E2
OUTPUT OUTPUT OR 20 L7
G1 C322
RELAY
OR 18
REAR
BK/YL L7
FOG REAR TO 18
LAMP FOG PRNDL A4 C202 BK/YL
RELAY LAMP
CONTROL FEED GROUND LAMP S206
(8W-44-5) (8W-11-4) TO S310
2 4 3
S118 (8W-70-2)
L95 L38 (8W-70-2)
18 20 G8 C322 L38 2 C329
DG/YL BR/WT 20
L38 20BR/WT BR/WT
S317
C1 C8 C204 Z1 1 C329
2 3 20 L7 L7
L38
REAR BK 18 18
18
FOG BR/WT BK/YL BK/YL
FOG
LAMP LAMP 1 1 1
INDICATOR SWITCH REAR LEFT RIGHT
FOG LICENSE LICENSE
Z1 20BK
LAMP LAMP LAMP
FOG 2 2 2
24
LAMP
ILLUMINATION FUSE S316
BLOCK 3 C329
FUSE (8W-11-2) Z1
1 4 4 S304 20
Z1 E2 10A (8W-15-9) BK
20 20 (8W-11-5)
BK OR S309
(8W-15-11)
S207 Z1 Z1
16 12
(8W-15-7)
BK BK
Z1 16BK G5 C322
G200 G300 G302
(8W-15-7) (8W-15-9) (8W-15-11)
TJI05107 J998W-5
8W - 51 - 8 8W-51 REAR LIGHTING TJ
RHD BUILT-UP-EXPORT
BATT A3 (8W-10-13) BATT F34 (8W-11-4)
HEADLAMP
CIRCUIT SWITCH
BREAKER 0 OFF
HEADLAMP 24A 1 PARK
HEAD-
DIMMER 2 HEAD
SWITCH 3 MAX
LAMP
(8W-50-2) 4 MIN
SWITCH
OUTPUT (8W-50-2)
0 1 2 0 1 2
(8W-50-4)
2
2 4 3
L2
L2 16
14 LG 1 9
LG E1 L7
A8 C202 18 18
TN BK/YL
L2 16LG
A3 C202 B6 C203
16 3
S330 FUSE L7
(8W-11-10) BLOCK 18
L22 L22 L22 FUSE FUSE (8W-11-2) BK/YL
20 20 20 16 3
LG/DG LG/DG LG/DG 10A 10A
5 1 (8W-11-10) (8W-11-4)
REAR E1 C107 L7
HEADLAMP HEADLAMP
SWITCH SWITCH FOG 36 23 18
FUSED FUSED 1 C110 BK/YL
LAMP E2
OUTPUT OUTPUT E2
RELAY 20
L7 1 C322
OR 20
OR 18
REAR BK/YL L7
FOG REAR TO 18
LAMP FOG PRNDL A4 C202 BK/YL
RELAY LAMP
CONTROL FEED GROUND LAMP S206
(8W-44-5) TO
2 4 3 (8W-11-4)
S118 S310
(8W-70-2) (8W-70-2)
L95 L38
18 20 8 C322 L38 2 C329
DG/YL BR/WT 20
L38 20BR/WT BR/WT
S317
C1 C8 C204 Z1 1 C329
2 3 20 L7 L7
L38
REAR BK 18 18
18
FOG BR/WT BK/YL BK/YL
FOG
LAMP LAMP 1 1 1
INDICATOR SWITCH REAR LEFT RIGHT
FOG LICENSE LICENSE
Z1 20BK
LAMP LAMP LAMP
FOG 2 2 2
24
LAMP
ILLUMINATION FUSE S316
BLOCK 3 C329
FUSE (8W-11-2) Z1
1 4 4 20
Z1 E2 10A BK
20 20 (8W-11-5)
BK OR S309
(8W-15-11)
S207 Z1
12
(8W-15-8)
BK
Z1 16BK 5 C322
G200 G300 G302
(8W-15-8) (8W-15-10) (8W-15-11)
J998W-5 TJI05108
*,+ -/.1032/465/798;:=<?> @A:ABDC!< -/.E0F2/4G0IH

È/É7ʗË/Ì7ÍFÎÐÏ9ÑÓÒFÔAÕCÑE֋×Ò

ØKÙMÚ*Û'ÙÜQÝRÜQÞ ßVàMáÝ ØKÙMÚ¤Û|ÙÜQÝRÜQÞ ßVàMáÝ

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8W - 52 - 2 8W-52 TURN SIGNALS TJ

RUN-ACC A31 (8W-10-9) BATT A0 (8W-10-6)

FUSE POWER
BLOCK 22 DISTRIBUTION
FUSE
(8W-11-2)
FUSE CENTER
13 9 (8W-10-2)
10A 20A
(8W-11-9) (8W-10-13) COMBINATION
15
FLASHER
33 COMBINATION COMBINATION
FLASHER FLASHER
L9 INPUT OUTPUT GROUND
16
BK/WT 6 2 4
Z1
20
BK
L5 L55 L32
20 D11 C108 16 16 S304
BK/GY RD/WT PK (8W-15-9)
L9 Z1 (8W-15-10)
16 16
BK/WT BK
G300
(8W-15-9)
5 6 11 4 2 (8W-15-10)
TURN
SIGNAL/
3 4 3 4
HAZARD
SWITCH
3 4 3 4 1 LEFT
2 RIGHT
3 NORMAL
4 HAZARD

1 2 1 2

9 1 10 3
L63 L62
EXCEPT LHD 18 EXCEPT LHD 18
BUILT-UP- BUILT-UP- DG/RD BUILT-UP- BUILT-UP- BR/RD
EXPORT EXPORT RHD EXPORT EXPORT RHD

G4 C322 G2 C322 2 C322

L63 G4 C322 4 C322 G2 C322
18
L62
DG/RD
18
S335 BR/RD
(8W-51-2) 1
L63 L62 RIGHT
L63 18 18
18 L63 TURN REAR
DG/RD BR/RD
DG/RD 18 SIGNAL LAMP
DG/RD LAMP ASSEMBLY
2 (8W-51-3)
1 4 2
LEFT
TAIL/
REAR LEFT NOT RIGHT
STOP/ TAIL/
LAMP TURN REAR USED STOP/ REAR
TURN
SIGNAL ASSEMBLY SIGNAL LAMP TURN LAMP
LAMP LAMP ASSEMBLY SIGNAL ASSEMBLY
(8W-51-2)
(8W-51-3) LAMP (8W-51-2)
J998W-5 TJI05202
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5 6 11 4 2
TURN
3 4 3 4 SIGNAL/
HAZARD
SWITCH
3 4 3 4
1 LEFT
2 RIGHT
3 NORMAL
4 HAZARD

1 2 1 2

9 1 10 3
L60 L61
18 18
TN GY

B1 B2 C203
L60 6 C1 10 C2 L61
18 18
TN RIGHT LEFT INSTRUMENT GY
TURN TURN CLUSTER
SIGNAL SIGNAL (8W-40-9)

E2 E3 C107
2 3 C110
L60 L61
18 EXCEPT 18 EXCEPT
BUILT- TN BUILT- GY BUILT-
BUILT-
UP-EXPORT UP-EXPORT UP-EXPORT
UP-EXPORT

S142 S141
2 2 LEFT
S142 RIGHT S141
SIDE SIDE
1
MARKER MARKER
1 LEFT
RIGHT 1 LAMP 1 LAMP
REPEATER
REPEATER LAMP 1 S143
S144 2 LEFT
2 LAMP 1 RIGHT L60 (8W-50-4)
18
(8W-50-4) FRONT L61 L7
FRONT L7 Z1 TURN 18 18
TN 18
TURN 18 3 SIGNAL
GY BK/YL
Z1 BK/YL
SIGNAL BK LEFT
18 3 LAMP 1 2
BK LAMP RIGHT FRONT
1 2
FRONT S122
(8W-15-3)
PARK/
S125 PARK/ TURN
(8W-15-5) TURN 3 SIGNAL
Z1
Z1 SIGNAL 18
18
3 LAMP
LAMP BK FRONT
BK FRONT OTHER FOG LAMPS
FOG LAMPS OTHER
S122
S150 S125 (8W-15-3)
(8W-15-5) (8W-15-4)

S117
(8W-15-3) Z1
Z1 18
18 Z1
BK
BK 16
BK
G103
(8W-15-4) G102
(8W-15-5) (8W-15-3)
TJI05203 J998W-5
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STANDARD
RUN-ACC A31 (8W-10-9)
FUSE
BLOCK
(8W-11-2)
FUSE
14
20A
(8W-11-9)

34
V6
18
PK/BK

S306

V6
18
PK/BK

5
WINDSHIELD
WIPER
SWITCH
0 OFF
0 2 0 2 0 3 1 LOW
1 1 2 HIGH
3 WASH

2 4 6 3
V10
18
BR
V6 V5 V3 V4
18 18 18 18
PK/BK DG/YL BR/WT RD/YL E8 C107
V10
18
1 2 5 6
BR
WINDSHIELD
4 WIPER 8 C110
3 MOTOR
M V10
1 PARK
18
2 RUN
1 2 BR
3 LOW
4 HIGH A
WINDSHIELD
WASHER
M PUMP
4
Z1 B
18
BK Z1
18
S304 BK
(8W-15-9)
(8W-15-10) S117
Z1 (8W-15-3)
16
Z1
BK
16
BK
G300
(8W-15-9)
(8W-15-10)
G102
(8W-15-3)
J998W-5 TJI05302
TJ 8W-53 WIPERS 8W - 53 - 3
INTERMITTENT
RUN-ACC A31 (8W-10-9)
FUSE
BLOCK
(8W-11-2)
FUSE
14
20A
(8W-11-9)

34
V6
18
PK/BK

S306
5
WINDSHIELD
WIPER
5 SWITCH
0 OFF
0 3 3 1 DELAY
0
2 LOW
1 2 1 2
6 3 HIGH
4 WASH
5 MIN
DELAY INTERNAL
6 MAX
LOGIC AND DELAY
RELAY RELAY
CONTROL
0 4

1 2 4 6 3
V5 V3 V4 V10
18 18 18 18
DG/YL BR/WT RD/YL BR
V6
18 E8 C107
PK/BK
8 C110
1 2 5 6
WINDSHIELD V10
4 18
3
WIPER BR
M MOTOR A
1 PARK
1 2 2 RUN WINDSHIELD
3 LOW WASHER
4 HIGH M PUMP

B
4
Z1
Z1 Z1 18
20 18 BK
BK BK
S117
S304 (8W-15-3)
(8W-15-9)
Z1 (8W-15-10) Z1
16 16
BK BK

G300 G102
(8W-15-9) (8W-15-3)
TJI05303 (8W-15-10) J998W-5
8W - 53 - 4 8W-53 WIPERS TJ
HARD TOP
BATT F34 (8W-11-4) RUN A22 (8W-10-8)
HEADLAMP REAR FUSE
SWITCH WIPER BLOCK
0 OFF MOTOR FUSE
(8W-11-2)
1 PARK M 1 PARK
0 2 HEAD 6
5 4 3 2 1 2 RUN 20A
3 DOME 1 2
4 MAX (8W-11-6)
1 5 MIN
E1 (8W-50-2) 26
3 1 2
18
V23
TN
18
A3 C202 V13 V23 Z1 BR/PK
3 18 18 16 LHD RHD
FUSE BK/LG BR/PK BK
BLOCK H4 C323 4 C323
FUSE (8W-11-2)
3 C331
3 V13 5 C326
10A 18
(8W-11-4) BR/LG 5 C331
3 C326 S401 S400
23 (8W-15-11)
LHD RHD V21 Z1
18 12
E2 E2 BR/PK BK
20 20 H5 C323 5 C323 4 C331
OR OR 6
4 6 C326
A4 C202 TO V23 Z1
E2 PRNDL 18 12
V13 BR/PK BK
20 LAMP
18 LHD RHD
OR (8W-44-5) S309
BR/LG
(8W-15-11)
G10 C322 10 C322
S206 C2 C204
(8W-11-4) V23 V23 Z1 Z1
18 18 18 12
E2 V13 BR/PK BR/PK BK BK
20 18 LHD RHD
OR BR/LG
C6 C204 5 C322
3 4 5 G5 C322
REAR
1 1 WIPER/
2 0 2 0
ILLUMINATION WASHER
Z1
LAMP SWITCH 12
0 OFF BK
1 WIPE
2 WASH G302
(8W-15-11)
1 2
B
V20 REAR
Z1 18 WASHER
18 VT/OR M PUMP
BK/WT
B9 C203
S207 V20
A
(8W-15-7) 18
(8W-15-8) VT/OR V20
Z1
16 18
LHD RHD VT/OR
BK
H6 C323 6 C323
G200
(8W-15-7)
J998W-5 (8W-15-8) TJI05304
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LEFT RADIO HEADLAMP

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EXCEPT BUILT-UP-EXPORT
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J998W-5 TJI07002
TJ 8W-70 SPLICE INFORMATION 8W - 70 - 3

OXYGEN MANIFOLD INTAKE

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TJI07003 J998W-5
8W - 70 - 4 8W-70 SPLICE INFORMATION TJ

POWERTRAIN VEHICLE ENGINE

CONTROL SPEED OIL
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8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS TJ

BLACK
1 2

CAV CIRCUIT FUNCTION

1 C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z1 20BK GROUND
A/C COMPRESSOR
CLUTCH

BLACK

A E CAV CIRCUIT FUNCTION

A C7 12BR/TN HIGH SPEED BLOWER MOTOR
B D M2 SPEED BLOWER MOTOR
B C6 14LB
C C C5 16LG/LB M1 SPEED BLOWER MOTOR
D C4 16TN LOW SPEED BLOWER MOTOR
A/C-HEATER
CONTROL - C1 E C1 12DG BLOWER MOTOR FEED

BLACK CAV CIRCUIT FUNCTION

1 Z11 20BK/WT GROUND
1 F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
5 1 2 C36 20DB/RD BLEND DOOR FEEDBACK SIGNAL
3 F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
3 Z11 20BK/WT GROUND
A/C-HEATER 4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
CONTROL - C2 5 Z1 20BK GROUND

BLACK

CAV CIRCUIT FUNCTION

A C A C90 20LG A/C SELECT INPUT
B C1 12DG BLOWER MOTOR FEED
C Z1 12BK GROUND
A/C-HEATER
CONTROL - C3

BLACK
1 2

CAV CIRCUIT FUNCTION

1 C90 20LG A/C SELECT INPUT
2 C21 20DB/OR A/C SWITCH SENSE
A/C HIGH
PRESSURE SWITCH
LHD
RHD

J998W-5 TJI08004
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5

GRAY
1 2

CAV CIRCUIT FUNCTION

1 C22 20DB/WT A/C SWITCH SENSE
A/C LOW 2 C21 20DB/OR A/C SWITCH SENSE
PRESSURE SWITCH

BLACK

A B CAV CIRCUIT FUNCTION

A B48 20RD/YL ABS MAIN RELAY OUTPUT
B G19 20LG/OR ABS WARNING INDICATOR DRIVER
ABS DIODE

BLACK

CAV CIRCUIT FUNCTION

1 B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT
2 Z1 12BK GROUND
2 1

ABS PUMP
MOTOR CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER AIRBAG LINE 2
2 R43 18BK/LB DRIVER AIRBAG LINE 1
3 - -
YELLOW 4 - -
5 R142 18BR/YL PASSENGER AIRBAG SQUIB LINE 1
6 R144 18VT/YL PASSENGER AIRBAG SQUIB LINE 2
7 - -
11 1
22 12 8 - -
9 - -
10 Z6 18BK/PK GROUND
11 - -
AIRBAG 12 - -
CONTROL - -
13
MODULE
14 - -
15 - -
16 - -
17 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (ST-RUN)
18 D2 18WT/BK CCD BUS(-)
19 D1 18VT/BR CCD BUS(+)
20 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
21 - -
22 - -
BLACK

CAV CIRCUIT FUNCTION

A B A L1 18VT/BK BACK-UP LAMP FEED
B F20 18VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)

BACK-UP
LAMP SWITCH
(M/T)
TJI08005 J998W-5
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS TJ

BLACK
CAV CIRCUIT FUNCTION
1 2 1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
BATTERY 2 K167 18BR/YL SENSOR GROUND
TEMPERATURE
SENSOR

GRAY CAV CIRCUIT FUNCTION

1 K29 20WT/PK BRAKE SWITCH SENSE
2 Z1 20BK GROUND
1 6 3 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
4 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
BRAKE LAMP 5 F32 18PK/DB FUSED B(+)
SWITCH 6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT

WHITE

CAV CIRCUIT FUNCTION

1 2 1 K29 20WT/PK BRAKE SWITCH SENSE
2 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
BRAKE SHIFT
INTERLOCK
SOLENOID

BLACK
CAV CIRCUIT FUNCTION
1 2 1 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
2 G99 20GY/WT RED BRAKE WARNING INDICATOR DRIVER
BRAKE WARNING
INDICATOR SWITCH

CAV CIRCUIT CAV CIRCUIT

1 F142 20OR/DG 1 F142 18OR/DG
2 K72 18DG/OR 2 K72 18DG/OR
3 A14 14RD/WT 3 A14 14RD/WT
BLACK 4 B6 18WT/DB 4 B6 18WT/DB
BLACK
5 B7 18WT 5 B7 18WT
6 K226 18DB/LG 1 7 6 K226 20DB/LG
7 1
7 A141 18DG/WT 7 A141 18DG/WT
14 8 8 14
8 K167 20BR/YL 8 K167 20BR/YL
9 F12 20RD/LG 9 F12 20RD/LG
C103 10 Z12 20BK/TN C103 10 Z12 20BK/TN
11 Z12 20BK/LB 11 Z12 20BK/LB
12 G7 20WT/OR 12 G7 20WT/OR
13 G107 20BK/RD 13 G107 20BK/RD
ABS
14 C3 20DB/BK 14 C3 20DB/BK
DRL
LHD
RHD
J998W-5 TJI08006
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7

CAV CIRCUIT CAV CIRCUIT

1 C90 20LG 1 C90 20LG
2 C22 18DB/WT 2 C22 20DB/WT
3 B4 18LG 3 B4 18LG
GREY 4 B3 18LG/DB 4 B3 18LG/DB
GREY
5 T41 20BR/LB 5 T41 20BR/LB
7 1 6 B2 18YL 1 7 6 B2 18YL
14 8 7 B1 18YL/DB 8 14 7 B1 18YL/DB
8 - 8 -
9 L1 20VT/BK 9 L1 20VT/BK
C104 10 F20 20VT/WT C104 10 F20 20VT/WT
(LHD) 11 F42 18DG/LG (LHD) 11 F42 18DG/LG
12 T40 12BR 12 T40 12BR
13 F15 20DB 13 F15 18DB
14 - 14 -

CAV CIRCUIT CAV CIRCUIT

1 C90 20LG 1 C90 20LG
BLACK BLACK
2 C22 18DB/WT 2 C22 20DB/WT
3 - 3 -
4 F42 18DG/LG 4 F42 18DG/LG
5 1 1 5
5 T41 20BR/LB 5 T41 20BR/LB
10 6 6 10
6 T40 12BR 6 T40 12BR
7 F15 20DB 7 F15 18DB
8 - 8 -
C104 C104
9 L1 20VT/BK 9 L1 20VT/BK
(RHD) (RHD)
10 F20 20VT/WT 10 F20 20VT/WT

CAV CIRCUIT CAV CIRCUIT

F1 F30 12RD/PK F1 F30 12RD/PK
F2 L1 20VT/BK F2 L1 20VT/BK
F3 F20 20VT/WT F3 F20 20VT/WT
F4 F15 20DB F4 F15 20DB
BLACK F5 A1 14RD BLACK F5 A1 14RD
F6 A2 12PK/BK F6 A2 12PK/BK
F1 F6 F6 F1
F7 A6 12RD/BK F7 A6 12RD/BK
F8 C15 12BK/WT F12 F7 F8 C15 12BK/WT
F7 F12
T141 14YL/RD
F9 T141 14YL/RD F9
C106 T141 14YL/RD
C106
F10 F12 20RD/LG F10 F12 20RD/LG
G9 20GY/BK
F11 G9 20GY/BK F11
G9 20GY/BK
F12 A111 12RD/LB F12 A111 12RD/LB

ABS

TJI08007 J998W-5
8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT CAV CIRCUIT

L7 18BK/YL
E1 L7 18BK/YL E1
L7 18BK/YL
E2 L60 18TN E2 L60 18TN
E3 L61 18GY E3 L61 18GY
YELLOW L3 16RD/OR YELLOW
E4 E4 L3 14RD/OR
E5 L4 16VT/WT E5 L4 14VT/WT
E1 E7 E6 Z12 20BK/LB E7 E1 E6 Z12 20BK/LB
E7 X3 20RD/YL E14 E8 E7 X3 20RD/YL
E8 E14 E8 V10 18BR E8 V10 18BR
E9 Z12 20BK/TN E9 Z12 20BK/TN
C107 C107
E10 L39 18LB E10 L39 18LB
E11 V30 20DB/RD E11 V30 20DB/RD
E12 - E12 -
E13 D20 18LG E13 D20 20LG
D21 18PK
E14 E14 D21 20PK
D21 20PK

CAV CIRCUIT CAV CIRCUIT

D1 V32 18YL/RD D1 V32 20YL/RD
G19 20LG/OR G19 20 LG/OR
D2 D2
BLUE G19 20LG/OR BLUE
D3 K167 20BR/YL D3 K167 20BR/YL
D1 D7 D4 D1 18VT/BR D4 D1 20VT/BR
D7 D1
D5 D2 18WT/BK D5 D2 20WT/BK
D14 D8
D8 D14 D6 F61 18WT/OR D6 F61 18WT/OR
G34 18RD/GY
D7 D7 G34 16RD/GY
L3 16RD/OR
C108 C108
D8 L20 16LG/WT D8 L20 16LG/WT
L50 18WT/TN
D9 L50 18WT/TN D9
L50 18WT/TN
D10 V37 18RD/LG D10 V37 20RD/LG
D11 L9 16BK/WT D11 L9 16BK/WT
M1 20PK/WT M1 20PK/WT
D12 D12
M1 20PK/WT M1 20PK/WT
D13 L22 20LG/DG D13 L22 20LG/DG
K29 20WT/PK
D14 K29 18WT/PK D14
K29 20WT/PK

DRL
EXCEPT DRL
LHD
SPEED CONTROL
FRONT FOG LAMPS
BUILT-UP-EXPORT
ABS

J998W-5 TJI08008
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9

CAV CIRCUIT CAV CIRCUIT

1 L7 18BK/YL 1 L7 18BK/YL
2 L60 18TN 2 L60 18TN
BLACK BLACK
3 L61 18GY 3 L61 18GY
4 L3 16RD/OR 4 L3 16RD/OR
5 L4 16VT/WT 5 L4 16VT/WT
7 1 6 X2 18WT/RD 1 7 6 X2 18WT/RD
14 8 7 - 8 14 7 -
8 V10 18BR 8 V10 18BR
9 L22 20LG/DG 9 L22 20LG/DG
C110 C110
10 K52 20PK/BK 10 K52 18PK/BK
11 F12 20RD/LG 11 F12 20RD/LG
12 - 12 -
13 L39 18LB 13 L39 18LB
14 L13 20BR/YL 14 L13 20BR/YL

BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 Z1 20BK 1 Z1 20BK
2 L1 20VT/BK 2 L1 18VT/BK
4 1 1 4 3 T41 20BR/LB
3 T41 20BR/LB
3 Z1 20BK
C154 4 F20 20VT/WT 4 F20 18VT/WT
C154

M/T
A/T
BUILT-UP-EXPORT
FRONT FOG LAMPS

TJI08009 J998W-5
8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT CAV CIRCUIT

LIGHT 1 L13 20BR/YL 1 L13 20BR/YL
GRAY 2 C81 20LB/WT BLACK 2 C81 20LB/WT
3 G99 20GY/WT 3 G99 20GY/WT
4 A3 14RD/WT 4 A3 14RD/WT
5 1 5 5
5 1 G107 20BK/RD G107 20BK/RD
6 C90 20LG 6 10 6 C90 20LG
10 6
7 - 7 -
8 - C170 8 -
C170 9 - 9 -
10 - 10 -

BLACK BLACK
2 1
CAV CIRCUIT 1 2 CAV CIRCUIT
1 K105 18WT/OR 1 K105 20WT/OR
2 K106 18WT/DG 2 K106 20WT/DG
3 3 F142 20OR/DG 3 F142 20OR/DG
3
C180
C180

CAV CIRCUIT CAV CIRCUIT

F24 20RD/DG
A1 A1 F24 20RD/DG
F24 20RD/DG
L20 16LG/WT
A2 L20 16LG/WT A2
L20 14LG/WT
A3 E1 18TN A3 E1 18TN
GRAY GRAY
A4 E2 20OR A4 E2 20OR
A1 A6 A5 F81 20DB/RD A5 F81 20DB/RD
A6 A1
Z12 20BK/LB
A6 Z12 20BK/LB A6
A7 A12 A12 A7 Z12 20BK/LB
A7 - A7 -
C202 C202 L2 14LG
A8 L2 16LG A8
L2 16LG
A9 F38 16LB A9 F38 16LB
A10 G5 20DB/WT A10 G5 20DB/WT
F34 18TN/BK
A11 F34 18TN/BK A11
F34 20TN/BK
A12 A111 12RD/LB A12 A111 12RD/LB

EXCEPT DRL
REAR FOG LAMP
DRL
BUILT-UP-EXPORT
HARDTOP

J998W-5 TJI08010
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11

CAV CIRCUIT CAV CIRCUIT

L60 18TN
B1 L60 18TN B1
L60 18TN
L61 18GY
B2 L61 18GY B2
L61 18GY
G26 20LB
B3 B3 G26 20LB
GREEN G26 20LB GREEN
G16 20BK/LB
B4 G16 20BK/LB B4
B1 B7 G16 20BK/LB
B7 B1
G34 16RD/GY
B5 G34 16RD/GY B14 B8 B5
B8 B14 G34 16RD/GY
L7 18BK/YL L7 18BK/YL
B6 C203 B6
C203 L7 18BK/YL L7 18BK/YL
B7 M1 20PK/WT B7 M1 20PK/WT
B8 D20 20LG B8 D20 20LG
B9 V20 18VT/OR B9 V20 18VT/OR
B10 D21 20PK B10 D21 20PK
D1 20VT/BR
B11 B11 D1 20VT/BR
D1 20VT/BR
D2 20WT/BK
B12 B12 D2 20WT/BK
D2 20WT/BK
B13 L35 18BR/WT B13 L35 18BR/WT
B14 G19 20LG/OR B14 G19 20LG/OR

CAV CIRCUIT CAV CIRCUIT

C1 L95 18DG/YL C1 L95 18DG/YL
C2 V13 18BR/LG C2 V13 18BR/LG
C3 G10 20LG/RD C3 G10 20LG/RD
RED C4 Z12 20BK/TN RED C4 Z12 20BK/TN
C5 M2 20YL C5 M2 20YL
C1 C7 C7 C1
C6 V23 18BR/PK C6 V23 18BR/PK
C7 - C14 C8 C7 -
C8 C14
L38 20BR/WT
C8 L38 20BR/WT C8
C204 C204 L38 20BR/WT
L22 20LG/DG
C9 L22 20LG/DG C9
L22 20LG/DG
C10 X12 20PK C10 X12 20PK
C11 X51 18BR/YL C11 X51 18BR/YL
C12 X57 18BR/LB C12 X57 18BR/LB
C13 X52 18DB/WT C13 X52 18DB/WT
C14 X58 18DB/PK C14 X58 18DB/PK

REAR FOG LAMPS

HARD TOP
FRONT FOG LAMPS
BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
LHD BUILT-UP-EXPORT
TJI08011 J998W-5
8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT CAV CIRCUIT

G1 L7 18BK/YL BLACK G1 L7 18BK/YL
BLACK
G2 L62 18BR/RD G2 L62 18BR/RD
G3 L1 20VT/BK G3 L1 20VT/BK
G1 G5 G5 G1
G4 L63 18DG/RD G4 L63 18DG/RD
G5 Z1 12BK G10 G6 G5 Z1 12BK
G6 G10
G6 G10 20LG/RD G6 G10 20LG/RD
C322 C322 L50 18WT/TN
G7 L50 18WT/TN G7
(LHD) (LHD) L50 18WT/TN
G8 L38 20BR/WT G8 L38 20BR/WT
G9 G9 20GY/BK G9 G9 20GY/BK
G10 V23 18BR/PK G10 V23 18BR/PK

CAV CIRCUIT CAV CIRCUIT

BLACK 1 L7 18BK/YL 1 L7 18BK/YL
2 L62 18BR/RD BLACK 2 L62 18BR/RD
3 L1 20VT/BK 3 L1 20VT/BK
5 1 4 L63 18DG/RD 1 5 4 L63 18DG/RD
10 6 5 Z1 12BK 6 10 5 Z1 12BK
6 G10 20LG/RD 6 G10 20LG/RD
7 L50 18WT/TN 7 L50 18WT/TN
C322 C322
8 L38 20BR/WT 8 L38 20BR/WT
(RHD) (RHD)
9 G9 20GY/BK 9 G9 20GY/BK
10 V23 18BR/PK 10 V23 18BR/PK

CAV CIRCUIT CAV CIRCUIT

H1 C15 12BK/WT H1 C15 12BK/WT
RED RED
H2 M1 20PK/WT H2 M1 20PK/WT
H3 M2 20YL H3 M2 20YL
H1 H5
H4 V23 18BR/PK H5 H1 H4 V23 18BR/PK
H5 V13 18BR/LG H10 H6 H5 V13 18BR/LG
H6 H10
H6 V20 18VT/OR H6 V20 18VT/OR
H7 X51 18BR/YL H7 X51 18BR/YL
C323 C323 H8 X57 18BR/LB
H8 X57 18BR/LB
(LHD) H9 X52 18DB/WT (LHD) H9 X52 18DB/WT
H10 X58 18DB/PK H10 X58 18DB/PK

HARD TOP
EXCEPT BUILT-UP-EXPORT
REAR FOG LAMP
4 SPEAKER SYSTEM
THE FEMALE SIDE OF C323 IS NOT PRESENT
IN SOFT-TOP 2 - SPEAKER SYSTEM VEHICLES
J998W-5 TJI08012
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13

CAV CIRCUIT CAV CIRCUIT

1 C15 12BK/WT 1 C15 12BK/WT
Lt GRAY 2 M1 20PK/WT 2 M1 20PK/WT
3 Lt GRAY
M2 20YL 3 M2 20YL
4 V23 18BR/PK 4 V23 18BR/PK
5 1 5 V13 18BR/LG 1 5 5 V13 18BR/LG
10 6 6 V20 18VT/OR 6 10 6 V20 18VT/OR
7 X51 18BR/YL 7 X51 18BR/YL
C323 8 X57 18BR/LB C323 8 X57 18BR/LB
(RHD) 9 X52 18DB/WT (RHD) 9 X52 18DB/WT
10 X58 18DB/PK 10 X58 18DB/PK

BLACK
WHITE CAV CIRCUIT CAV CIRCUIT
1 X57 18BR/LB 1 X57 18BR/LB
1 6 2 X51 18BR/YL 2 X51 18BR/YL
3 M1 20PK/WT 6 1 3 M1 20PK/WT
4 M2 20YL 4 M2 20YL
C325 5 X58 18DB/PK C325 5 X58 18DB/PK
(4 SPKR SYS)
6 X52 18DB/WT (4 SPKR SYS) 6 X52 18DB/WT

CAV CIRCUIT CAV CIRCUIT

BLACK 1 C15 12BK/WT 1 C15 12BK/WT
BLACK
2 - 2 -
3 V13 18BR/LG 3 V13 18BR/LG
4 V23 18BR/PK 1 5 4 V23 18BR/PK
5 1
5 V23 18BR/PK 6 10 5 V23 18BR/PK
10 6
6 Z1 12BK 6 Z1 12BK
7 - 7 -
C326 8 M1 20PK/WT C326 8 M1 20PK/WT
(HARD TOP) 9 M2 20YL (HARD TOP) 9 M2 18YL
10 - 10 -

4 SPEAKER SYSTEM
HARD TOP

THE MALE SIDE OF C323 IS NOT PRESENT

IN SOFT-TOP 2 - SPEAKER SYSTEM VEHICLES

TJI08013 J998W-5
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS TJ

BLACK BLACK

CAV CIRCUIT CAV CIRCUIT

1 2 2 1
1 L38 20BR/WT 1 L38 18BR/WT
3
2 L7 18BK/YL 2 L7 18BK/YL
3
3 Z1 20BK 3 Z1 20BK
C329 C329

BLACK
WHITE CAV CIRCUIT CAV CIRCUIT
1 X57 18BR/LB 1 X57 20BR/LB
1 6 2 X51 18BR/YL 2 X51 20BR/YL
3 M1 20PK/WT 6 1 3 M1 20PK/WT
4 M2 20YL 4 M2 20YL
C330 5 X58 18DB/PK C330 5 X58 20DB/PK
(4 SPKR SYS)
6 X52 18DB/WT (4 SPKR SYS) 6 X52 20DB/WT

CAV CIRCUIT CAV CIRCUIT

BLACK 1 C15 12BK/WT 1 C15 12BK/WT
BLACK
2 - 2 -
3 V13 18BR/LG 3 V13 18BK/LG
4 V23 18BR/PK 1 5 4 V23 18BR/PK
5 1
5 V23 18BR/PK 6 10 5 V23 18BR/PK
10 6
6 Z1 12BK 6 Z1 12BK
7 - 7 -
C331 8 M1 20PK/WT C331 8 M1 20PK/WT
(HARD TOP) 9 M2 18YL (HARD TOP) 9 M2 20YL
10 - 10 -

GRAY
CAV CIRCUIT FUNCTION
1 3
1 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
3 K7 20OR 5V SUPPLY
CAMSHAFT POSITION
SENSOR

J998W-5 TJI08014
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15

BLACK
1
CAV CIRCUIT FUNCTION
1 F30 12RD/PK FUSED B(+)
5 2 2 A31 14BK/DG IGNITION SWITCH OUTPUT (RUN-ACC)
3 - -
4 F22 12WT/PK CIGAR LIGHTER/ACCESSORY RELAY OUTPUT
4 Z1 20BK GROUND
5
CIGAR LIGHTER/ Z1 20BK GROUND
ACCESSORY RELAY
RED

2 1 CAV CIRCUIT FUNCTION

1 F38 16LB FUSED B (+)
2 - -
3 3 Z1 16BK GROUND
CIGAR LIGHTER/
POWER OUTLET

YELLOW

CAV CIRCUIT FUNCTION

2 1 1 R45 18DG/LB DRIVER AIRBAG LINE 2
2 R43 18BK/LB DRIVER AIRBAG LINE 1
CLOCKSPRING - C1

NATURAL CAV CIRCUIT FUNCTION

1 X3 20RD/YL HORN RELAY CONTROL
4 1 2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
3 K167 20BR/YL SENSOR GROUND
CLOCKSPRING - C2 4 - -

BLACK

1 2 CAV CIRCUIT FUNCTION

1 T141 14YL/RD FUSED IGNITION SWITCH OUTPUT (ST)
CLUTCH PEDAL 2 A41 14YL FUSED IGNITION SWITCH OUTPUT (ST)
POSITION SWITCH
(M/T)

BLACK CAV CIRCUIT FUNCTION

1 - -
2 L32 16PK COMBINATION FLASHER OUTPUT
3 2 1 3 - -
6 5 4 4 Z1 20BK GROUND
5 - -
9 8 7
6 L55 16RD/WT COMBINATION FLASHER INPUT
7 - -
COMBINATION 8 - -
FLASHER 9 - -

TJI08015 J998W-5
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT FUNCTION

1 G19 20LG/OR ABS WARNING INDICATOR DRIVER
GRAY 2 B43 20PK/OR G-SWITCH TEST SIGNAL
3 D21 20PK SCI TRANSMIT/ISO 9141K
1 5 4 - -
6 12 5 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
6 B41 20YL/VT G-SWITCH NO. 1 SENSE
CONTROLLER 7 B42 20TN/WT G-SWITCH NO. 2 SENSE
ANTI-LOCK 8 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
BRAKE - C1 9 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
10 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
11 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
12 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)

CAV CIRCUIT FUNCTION

1 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
2 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
3 B120 16BR/WT ABS PUMP MOTOR RELAY OUTPUT
4 B251 20WT/BK REAR INLET VALVE CONTROL
5 B48 20RD/YL ABS MAIN RELAY OUTPUT
GRAY
6 B248 20DG/WT RIGHT FRONT OUTLET VALVE CONTROL
7 B116 20GY ABS PUMP MOTOR RELAY CONTROL
1 8
9 18 8 B243 20DG/BK LEFT FRONT OUTLET VALVE CONTROL
9 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
CONTROLLER 10 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
ANTI-LOCK 11 B58 20GY/LB ABS MAIN RELAY CONTROL
BRAKE - C2 12 B254 20DG/OR REAR OUTLET VALVE CONTROL
13 Z22 16BK/PK GROUND
14 Z22 16BK/PK GROUND
15 B249 20WT/DG RIGHT FRONT INLET VALVE CONTROL
16 - -
17 - -
18 B245 20WT/LG LEFT FRONT INLET VALVE CONTROL

BLACK
CAV CIRCUIT FUNCTION
1 3 1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
3 K7 20OR 5V SUPPLY
CRANKSHAFT
POSITION
SENSOR

J998W-5 TJI08016
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17

CAV CIRCUIT FUNCTION

1 - -
2 - -
3 D1 20VT/BR CCD BUS(+)
4 Z12 20BK/LB GROUND
BLACK 5 Z12 20BK/TN GROUND
6 D20 20LG SCI RECEIVE
1 8 7 D21 20PK SCI TRANSMIT/ISO 9141K
9 16 8 - -
9 - -
DATA LINK 10 - -
CONNECTOR 11 D2 20WT/BK CCD BUS(-)
12 - -
13 - -
14 - -
15 - -
16 M1 20PK/WT FUSED B(+)

CAV CIRCUIT FUNCTION

1 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
BLACK
2 - -
5 1 3 - -
4 G34 18RD/GY HIGH BEAM INDICATOR DRIVER
5 F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (ST-RUN)
6 L20 16LG/WT FUSED B(+) OPTICAL HORN FEED
10 6
7 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL
DAYTIME RUNNING 8 Z1 18BK GROUND
LAMP MODULE 9 - -
(EXCEPT BUILT- 10 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
UP-EXPORT)

TJI08017 J998W-5
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS TJ

NATURAL
1
CAV CIRCUIT FUNCTION
1 M23 20YL/BK DOOR AJAR SWITCH OUTPUT
2 3 2 M2 20YL COURTESY LAMPS DRIVER
DRIVER DOOR 3 G16 20BK/LB DRIVER DOOR AJAR SWITCH SENSE
AJAR SWITCH

BLACK

2 1 CAV CIRCUIT FUNCTION

1 K52 20PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
2 F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (ST-RUN)
DUTY CYCLE
EVAP/PURGE
SOLENOID

BLACK
1 2

CAV CIRCUIT FUNCTION

1 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
ENGINE COOLANT
TEMPERATURE
SENSOR

BLACK

CAV CIRCUIT FUNCTION

3 1 1 K6 20VT/OR 5V SUPPLY
2 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
3 K167 20BR/YL SENSOR GROUND
ENGINE OIL
PRESSURE
SENSOR

J998W-5 TJI08018
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19

BLACK

CAV CIRCUIT FUNCTION

2 4 1
1 L35 18BR/WT FOG LAMP SWITCH OUTPUT
5 2 Z1 20BK GROUND
3 3 F61 18WT/OR FUSED B(+)
4 - -
FOG LAMP 5 L39 18LB FOG LAMP RELAY NO. 1 OUTPUT
RELAY NO. 1
(EXCEPT BUILT-
UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

2 4 1 1 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
5 Z1 20BK GROUND
2
3 Z1 20BK GROUND
3 L7 18BK/YL HEADLAMP SWITCH OUTPUT
FOG LAMP 4 L95 18DG/YL FOG LAMP RELAY OUTPUT
RELAY NO. 2 5 - -
(EXCEPT BUILT-
UP-EXPORT)

BLACK
CAV CIRCUIT FUNCTION
1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 L35 18BR/WT FOG LAMP SWITCH OUTPUT
12 3 4 3 L95 18DG/YL FOG LAMP RELAY OUTPUT
4 Z1 20BK GROUND
FRONT FOG
LAMP SWITCH
(EXCEPT BUILT-
UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

1 2 1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
FUEL INJECTOR NO. 1
(2.5L)

2 1 BLACK

CAV CIRCUIT FUNCTION

1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER

FUEL INJECTOR NO. 1

(4.0L)

TJI08019 J998W-5
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS TJ

BLACK

CAV CIRCUIT FUNCTION

1 2 1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJECTOR NO. 2 DRIVER

FUEL INJECTOR NO. 2

(2.5L)

2 1 BLACK

CAV CIRCUIT FUNCTION

1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJECTOR NO. 2 DRIVER

FUEL INJECTOR NO. 2

(4.0L)

BLACK

CAV CIRCUIT FUNCTION

1 2 1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER

FUEL INJECTOR NO. 3

(2.5L)

2 1 BLACK

CAV CIRCUIT FUNCTION

1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER

FUEL INJECTOR NO. 3

(4.0L)

BLACK

CAV CIRCUIT FUNCTION

1 2 1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER

FUEL INJECTOR NO. 4

(2.5L)

J998W-5 TJI08020
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21

2 1 BLACK

CAV CIRCUIT FUNCTION

1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER

FUEL INJECTOR NO. 4

(4.0L)

2 1 BLACK

CAV CIRCUIT FUNCTION

1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER

FUEL INJECTOR NO. 5

(4.0L)

2 1 BLACK

CAV CIRCUIT FUNCTION

1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K16 18LG/BK FUEL INJECTOR NO. 6 DRIVER

FUEL INJECTOR NO. 6

(4.0L)

BLACK
CAV CIRCUIT FUNCTION
1 A141 18DG/WT FUEL PUMP RELAY OUTPUT
3 1 2 - -
3 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL
6 4 4 K167 20BR/YL SENSOR GROUND
5 - -
FUEL PUMP 6 Z1 18BK GROUND
MODULE

BLACK
CAV CIRCUIT FUNCTION
1 B42 20TN/WT G-SWITCH NO.2 SENSE
1 3 2 B41 20YL/VT G-SWITCH NO.1 SENSE
3 B43 20PK/OR G-SWITCH TEST SIGNAL
G SWITCH

BLACK

2 1 CAV CIRCUIT FUNCTION

1 K72 18DG/OR VOLTAGE REGULATOR SIGNAL
2 K20 18DG GENERATOR FIELD DRIVER (+)

GENERATOR

TJI08021 J998W-5
8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS TJ

BLACK
CAV CIRCUIT FUNCTION
1 L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT
4 1 2 L2 14LG HEADLAMP SWITCH OUTPUT
3 L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
HEADLAMP 4 L20 14LG/WT FUSED B(+) OPTICAL HORN FEED
DIMMER
SWITCH

WHITE
CAV CIRCUIT FUNCTION
1 - -
2 L22 20LG/DG HEADLAMP SWITCH FUSED OUTPUT
1 6
3 - -
4 Z1 20BK GROUND
HEADLAMP
5 L13 20BR/YL HEADLAMP ADJUST SIGNAL
LEVELING
6 - -
SWITCH
(BUILT-UP-EXPORT)

CAV CIRCUIT FUNCTION

6 BLACK
8 1 E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL
5 2 L2 16LG HEADLAMP SWITCH OUTPUT
7 3 M2 20YL COURTESY LAMPS DRIVER
4 9 4 F34 18TN/BK FUSED B(+)
2 5 G26 20LB KEY-IN IGNITION SWITCH SENSE
3 6 G16 20BK/LB DRIVER AJAR SWITCH SENSE
1 7 L20 16LG/WT FUSED B(+) OPTICAL HORN FEED
HEADLAMP 8 A3 14RD/WT FUSED B(+)
SWITCH 9 L7 18BK/YL HEADLAMP SWITCH OUTPUT

BLACK

2
CAV CIRCUIT FUNCTION
1 1 X2 18WT/RD HORN RELAY OUTPUT
2 Z1 18BK GROUND
HIGH NOTE
HORN

CAV CIRCUIT FUNCTION

1 Z11 20BK/WT GROUND
2 C4 16TN LOW SPEED BLOWER MOTOR
GRAY
3 C5 16LG/LB M1 SPEED BLOWER MOTOR
4 C6 14LB M2 SPEED BLOWER MOTOR
F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
5 1 5
F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
10 6 6 C36 20DB/RD BLEND DOOR FEEDBACK SIGNAL
7 C7 12BR/TN HIGH SPEED BLOWER MOTOR
8 A111 12RD/LB FUSED B(+)
HVAC
9 F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
UNIT
10 Z1 20BK GROUND

J998W-5 TJI08022
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23

CAV CIRCUIT FUNCTION

BLACK 1 B47 14RD/LB ABS SYSTEM RELAY OUTPUT
2 B251 20WT/BK REAR INLET VALVE CONTROL
3 B249 20WT/DG RIGHT FRONT INLET VALVE CONTROL
5 1 4 B245 20WT/LG LEFT FRONT INLET VALVE CONTROL
10 6 5 - -
6 - -
HYDRAULIC 7 B254 20DG/OR REAR OUTLET VALVE CONTROL
CONTROL 8 B248 20DG/WT RIGHT FRONT OUTLET VALVE CONTROL
UNIT 9 B243 20DG/BK LEFT FRONT OUTLET VALVE CONTROL
10 B47 14RD/LB ABS SYSTEM RELAY OUTPUT

BLACK
1 4
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
IDLE AIR
4 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
CONTROL MOTOR

GRAY

CAV CIRCUIT FUNCTION

1 2 1 F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K19 18GY IGNITION COIL NO. 1 DRIVER

IGNITION
COIL

CAV CIRCUIT FUNCTION

1 Z1 16BK GROUND
2 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
GRAY 3 A2 12PK/BK FUSED B(+)
4 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
5 1 5 - -
10 6 6 - -
7 A1 14RD FUSED B(+)
IGNITION 8 A31 14BK/DG IGNITION SWITCH OUTPUT (RUN-ACC)
SWITCH 9 A21 14DB IGNITION SWITCH OUTPUT (ST-RUN)
10 A41 14YL IGNITION SWITCH OUTPUT (ST)

TJI08023 J998W-5
8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT FUNCTION

GREEN 1 D2 20WT/BK CCD BUS(-)
2 D1 20VT/BR CCD BUS(+)
3 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
4 C80 20DB/LG REAR WINDOW DEFOGGER SWITCH SENSE
5 1 5 G107 20BK/RD 4WD SENSE
10 6 6 L60 18TN RIGHT TURN SIGNAL
7 - -
8 G26 20LB KEY-IN IGNITION SWITCH SENSE
INSTRUMENT 9 Z2 18BK/LG GROUND
CLUSTER - C1 10 G10 20LG/RD SEAT BELT SWITCH SENSE

CAV CIRCUIT FUNCTION

BLUE 1 - -
2 G99 20GY/WT RED BRAKE WARNING INDICATOR DRIVER
3 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
4 G19 20LG/OR ABS WARNING INDICATOR DRIVER
5 1 5 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
10 6 6 Z2 18BK/LG GROUND
7 - -
INSTRUMENT 8 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
CLUSTER - C2 9 M1 20PK/WT FUSED B(+)
10 L61 18GY LEFT TURN SIGNAL

GRAY
1 2
CAV CIRCUIT FUNCTION
1 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
INTAKE AIR
TEMPERATURE
SENSOR

GREEN

CAV CIRCUIT FUNCTION

2 1 1 G16 20BK/LB DRIVER AJAR SWITCH SENSE
2 G26 20LB KEY-IN IGNITION SWITCH SENSE
KEY-IN
SWITCH

HARD TOP

J998W-5 TJI08024
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25

BLACK
CAV CIRCUIT FUNCTION
1 - -
4 1
2 F142 20OR/DG FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT
3 K106 20WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K105 20WT/OR LEAK DETECTION PUMP SWITCH SENSE
LEAK
DETECTION PUMP
(EXCEPT BUILT-
UP-EXPORT)

BLACK
2 CAV CIRCUIT FUNCTION
1 1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
2 Z1 18BK GROUND
LEFT CITY
LAMP
(BUILT-UP-EXPORT)

BLACK

2 1 CAV CIRCUIT FUNCTION

1 M1 20PK/WT FUSED B(+)
2 M2 20YL COURTESY LAMPS DRIVER
LEFT
COURTESY LAMP

BLACK
CAV CIRCUIT FUNCTION
1 2 1 Z1 18BK GROUND
2 L39 18LB FOG LAMP RELAY NO. 1 OUTPUT
LEFT FOG
LAMP
(EXCEPT BUILT-UP
-EXPORT)

BLACK

3 CAV CIRCUIT FUNCTION

1
1 L61 18GY LEFT TURN SIGNAL
LEFT FRONT PARK/ 2 L7 18BK/YL HEADLAMP SWITCH OUTPUT
TURN SIGNAL LAMP 3 Z1 18BK GROUND
(EXCEPT BUILT-UP
-EXPORT)

BLACK
CAV CIRCUIT FUNCTION
1 2 1 X53 18DG LEFT FRONT SPEAKER (+)
2 X55 18BR/RD LEFT FRONT SPEAKER (-)
LEFT
FRONT SPEAKER

TJI08025 J998W-5
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS TJ

BLACK
CAV CIRCUIT FUNCTION
1 3
1 L61 18GY LEFT TURN SIGNAL
2 - -
LEFT FRONT
3 Z1 18BK GROUND
TURN SIGNAL LAMP
(BUILT-UP-EXPORT)

BLACK

2 1 CAV CIRCUIT FUNCTION

1 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
2 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT
WHEEL SPEED
SENSOR

BLACK
2
CAV CIRCUIT FUNCTION
L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
1 3 1
L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
2 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
3 Z1 20BK GROUND
LEFT HEADLAMP

BLACK

CAV CIRCUIT FUNCTION

1 3 1 L22 20LG/DG HEADLAMP SWITCH FUSED OUTPUT
2 L13 20BR/YL HEADLAMP ADJUST SIGNAL
3 Z1 20BK GROUND
LEFT HEADLAMP
LEVELING MOTOR
(BUILT-UP-EXPORT)

GRAY
1 2

CAV CIRCUIT FUNCTION

1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
2 Z1 20BK GROUND
LEFT LICENSE
LAMP
(BUILT-UP-EXPORT)

J998W-5 TJI08026
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27

BLACK
CAV CIRCUIT FUNCTION
L1 20VT/BK BACK-UP LAMP FEED
1
1 2 L63 18DG/RD LEFT TURN SIGNAL
L63 18DG/RD LEFT TURN SIGNAL
3 4 2
L1 20VT/BK BACK-UP LAMP FEED
L7 18BK/YL HEADLAMP SWITCH OUTPUT
3
LEFT REAR L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
LAMP ASSEMBLY 4 L7 18BK/YL HEADLAMP SWITCH OUTPUT

BLACK

CAV CIRCUIT FUNCTION

1 2 1 X51 20BR/YL LEFT REAR SPEAKER (+)
2 X57 20BR/LB LEFT REAR SPEAKER (-)
LEFT REAR
SPEAKER
(SOUND BAR)
BLACK

CAV CIRCUIT FUNCTION

1 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
2 1
2 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)

LEFT REAR
WHEEL SPEED
SENSOR
GRAY

2 CAV CIRCUIT FUNCTION

1 1 L61 18GY LEFT TURN SIGNAL
2 Z1 18BK GROUND
LEFT REPEATER
LAMP
(BUILT-UP-EXPORT)

GRAY

2 CAV CIRCUIT FUNCTION

1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
1 2 L61 18GY LEFT TURN SIGNAL

LEFT SIDE
MARKER LAMP
(EXCEPT BUILT-
UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

2
1 1 X2 18WT/RD HORN RELAY OUTPUT
2 Z1 18BK GROUND
LOW NOTE
HORN
(EXCEPT BUILT- EXCEPT BUILT-UP-EXPORT
UP-EXPORT)
BUILT-UP-EXPORT

TJI08027 J998W-5
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS TJ

BLACK

CAV CIRCUIT FUNCTION

1 3 1 K167 20BR/YL SENSOR GROUND
2 K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
MANIFOLD 3 K7 20OR 5V SUPPLY
ABSOLUTE
PRESSURE
SENSOR

GRAY

1 2 CAV CIRCUIT FUNCTION

1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 4
2 Z1 18BK GROUND
3 K167 20BR/YL SENSOR GROUND
OXYGEN SENSOR 4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
1/1 UPSTREAM

BLACK

1 2
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 4
2 Z1 18BK GROUND
3 K167 20BR/YL SENSOR GROUND
OXYGEN SENSOR 4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
1/2 DOWNSTREAM

CAV CIRCUIT FUNCTION

1 3 1 F20 18VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
2 T41 20BR/LB PARK/NEUTRAL POSITION SWITCH SENSE
PARK/NEUTRAL 3 L1 18VT/BK BACK-UP LAMP FEED
POSITION SWITCH
(A/T)

YELLOW

CAV CIRCUIT FUNCTION

A R44 18DG/YL PASSENGER AIRBAG LINE 2
A B
B R42 18BK/YL PASSENGER AIRBAG LINE 1

PASSENGER
AIRBAG

J998W-5 TJI08028
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29

LIGHT
GRAY
1 2
CAV CIRCUIT FUNCTION
1 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (ST-RUN)
2 Z6 20BK/PK GROUND

PASSENGER AIRBAG
ON/OFF SWITCH - C1

YELLOW
CAV CIRCUIT FUNCTION
1 R142 18BR/YL PASSENGER AIRBAG SQUIB LINE 1
1 4 2 R144 18VT/YL PASSENGER AIRBAG SQUIB LINE 2
3 R42 18BK/YL PASSENGER AIRBAG LINE 1
4 R44 18DG/YL PASSENGER AIRBAG LINE 2
PASSENGER AIRBAG
ON/OFF SWITCH - C2

1 BLACK

CAV CIRCUIT FUNCTION

1 M23 20YL/BK DOOR AJAR SWITCH OUTPUT
2
2 M2 20YL COURTESY LAMPS DRIVER
PASSENGER
DOOR AJAR
SWITCH

BLACK

CAV CIRCUIT FUNCTION

1 2 1 Z1 20BK GROUND
1 Z1 18BK GROUND
2 K10 18DB/BR POWER STEERING PRESSURE SWITCH SENSE
POWER STEERING
PRESSURE SWITCH
(2.5L)

LHD

RHD

TJI08029 J998W-5
8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT FUNCTION

A1 - -
A2 F15 18DB FUSED IGNITION SWITCH OUTPUT (ST-RUN)
A3 - -
A4 K167 18BR/YL SENSOR GROUND
A5 - -
A6 T41 18BR/LB PARK/NEUTRAL POSITION SWITCH SENSE
A7 K19 18GY IGNITION COIL NO. 1 DRIVER
BLACK
A8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
A9 - -
A10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 1 A11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
A12 K10 18DB/BR POWER STEERING PRESSURE SWITCH SENSE
32 22 A13 - -
A14 - -
A15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
A16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
POWERTRAIN
A17 K7 18OR 5V SUPPLY
CONTROL
A18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
MODULE - C1
A19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
A20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
A21 - -
A22 A14 14RD/WT FUSED B(+)
A23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
A24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
A25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
A26 - -
A27 K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
A28 - -
A29 - -
A30 - -
A31 Z12 14BK/TN GROUND
A32 Z12 14BK/TN GROUND

2.5L

J998W-5 TJI08030
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31

CAV CIRCUIT FUNCTION

B1 - -
B2 - -
B3 - -
B4 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
B5 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
B6 K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER
B7 - -
WHITE
B8 - -
B9 - -
B10 K20 18DG GENERATOR FIELD DRIVER (+)
11 1 B11 T23 18OR/LG TRANSMISSION LOW/OVERDRIVE SOLENOID
B12 K16 18LG/BK FUEL INJECTOR NO. 6 DRIVER
32 22
B13 - -
B14 - -
B15 K12 18TN FUEL INJECTOR NO. 2 DRIVER
B16 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
POWERTRAIN B17 - -
CONTROL B18 - -
MODULE - C2
B19 - -
B20 - -
B21 - -
B22 - -
B23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
B24 - -
B25 - -
B26 - -
B27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
B28 - -
B29 - -
B30 - -
B31 K6 18VT/OR 5V SUPPLY
B32 - -

4.0L

TJI08031 J998W-5
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS TJ

CAV CIRCUIT FUNCTION

C1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
C2 - -
C3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
C4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
C5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
C6 - -
C7 - -
C8 - -
GRAY C9 - -
C10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
C11 V32 18YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
C12 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT SENSE
11 1 C13 - -
32 22 C14 K105 18WT/OR LEAK DETECTION PUMP SWITCH SENSE
C15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
C16 - -
C17 - -
POWERTRAIN C18 - -
CONTROL C19 K31 18BR FUEL PUMP RELAY CONTROL
MODULE - C3 C20 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
C21 - -
C22 C22 18DB/WT A/C SWITCH SENSE
C23 C90 18LG A/C SELECT INPUT
C24 K29 18WT/PK BRAKE SWITCH SENSE
C25 K72 18DG/OR VOLTAGE REGULATOR SIGNAL
C26 K226 18DB/LG FUEL LEVEL SENSOR SIGNAL
C27 D21 18PK SCI TRANSMIT/ISO 9141K
C28 D2 18WT/BK CCD BUS(-)
C29 D20 18LG SCI RECEIVE
C30 D1 18VT/BR CCD BUS(+)
C31 - -
C32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL

BLACK

CAV CIRCUIT FUNCTION

1 2 1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 Z1 20BK GROUND

PRNDL LAMP

SPEED CONTROL

LEAK DETECTION

J998W-5 TJI08032
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33

CAV CIRCUIT FUNCTION

GRAY
1 - -
2 X55 18BR/RD LEFT FRONT SPEAKER(-)
7 1 3 X56 18DB RIGHT FRONT SPEAKER(-)
4 L7 18BK/YL HEADLAMP SWITCH OUTPUT
RADIO - C1 5 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
6 X12 20PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
7 M1 20PK/WT FUSED B(+)

CAV CIRCUIT FUNCTION

BLACK
1 - -
2 X51 18BR/YL LEFT REAR SPEAKER(+)
7 1 3 X52 18DB/WT RIGHT REAR SPEAKER(+)
4 X53 18DG LEFT FRONT SPEAKER(+)
RADIO - C2 5 X54 18VT RIGHT FRONT SPEAKER(+)
6 X57 18BR/LB LEFT REAR SPEAKER(-)
7 X58 18DB/PK RIGHT REAR SPEAKER(-)

BLACK

CAV CIRCUIT FUNCTION

1 2
1 L38 18BR/WT REAR FOG LAMP FEED -
REAR FOG LAMP 2 Z1 20BK GROUND
(BUILT-UP-EXPORT)

LIGHT GREEN
CAV CIRCUIT FUNCTION
5 1 2 1 L22 20LG/DG HEADLAMP SWITCH FUSED OUTPUT
3 2 L95 18DG/YL REAR FOG LAMP RELAY CONTROL
3 Z1 20BK GROUND
L38 20BR/WT REAR FOG LAMP FEED
4 4
L38 20BR/WT REAR FOG LAMP FEED
REAR FOG 5 L22 20LG/DG HEADLAMP SWITCH FUSED OUTPUT
LAMP RELAY
(BUILT-UP-EXPORT)

WHITE

CAV CIRCUIT FUNCTION

1 4
1 Z1 20BK GROUND
2 L95 18DG/YL REAR FOG LAMP RELAY CONTROL
3 L38 20BR/WT REAR FOG LAMP FEED
4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
REAR FOG
LAMP SWITCH
(BUILT-UP-EXPORT)
RHD

TJI08033 J998W-5
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS TJ

BLACK

CAV CIRCUIT FUNCTION

A B A V20 18VT/OR REAR WASHER MOTOR CONTROL
B Z1 18BK GROUND
REAR WASHER
PUMP
(HARD TOP)

GRAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
1 4 2 C80 20DB/LG REAR WINDOW DEFOGGER SWITCH SENSE
3 F81 20DB/RD FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
REAR WINDOW 4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
DEFOGGER
SWITCH
(HARD TOP)

BLACK
CAV CIRCUIT FUNCTION
1 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
3 1 2 Z1 16BK GROUND
3 V13 18BK/LG REAR WIPER MOTOR CONTROL

REAR WIPER
MOTOR
(HARD TOP)

WHITE
CAV CIRCUIT FUNCTION
1 Z1 18BK/WT GROUND
1 2 2 V20 18VT/OR REAR WASHER MOTOR CONTROL
3 6 3 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
4 V13 18BR/LG REAR WIPER MOTOR CONTROL
5 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
REAR WIPER/
6 - -
WASHER SWITCH
(HARD TOP)

J998W-5 TJI08034
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35

BLACK
CAV CIRCUIT FUNCTION
2 1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
1 2 Z1 20BK GROUND
RIGHT CITY
LAMP
(BUILT-UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

2 1 1 M1 20PK/WT FUSED B(+)
2 M2 20YL COURTESY LAMPS DRIVER
RIGHT
COURTESY
LAMP
BLACK

1 2 CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2 L39 18LB FOG LAMP RELAY NO. 1 OUTPUT

RIGHT FOG
LAMP
(EXCEPT BUILT-UP
-EXPORT)

BLACK
1 3
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
RIGHT FRONT PARK/ 2 L7 18BK/YL HEADLAMP SWITCH OUTPUT
TURN SIGNAL LAMP 3 Z1 18BK GROUND
(EXCEPT BUILT-UP
-EXPORT)

BLACK
CAV CIRCUIT FUNCTION
1 2 1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB RIGHT FRONT SPEAKER (-)
RIGHT FRONT
SPEAKER

BLACK
1 3
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
RIGHT FRONT TURN 2 - -
SIGNAL LAMP 3 Z1 18BK GROUND
(BUILT-UP-EXPORT)

TJI08035 J998W-5
8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS TJ

BLACK

CAV CIRCUIT FUNCTION

2 1
1 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT
WHEEL SPEED
SENSOR

2 BLACK

CAV CIRCUIT FUNCTION

1 3 1 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
2 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
3 Z1 18BK GROUND
RIGHT
HEADLAMP

BLACK

1 3 CAV CIRCUIT FUNCTION

1 L22 20LG/DG HEADLAMP SWITCH FUSED OUTPUT
2 L13 20BR/YL HEADLAMP ADJUST SIGNAL
RIGHT HEADLAMP
3 Z1 18BK GROUND
LEVELING MOTOR
(BUILT-UP-EXPORT)

GRAY
1 2

CAV CIRCUIT FUNCTION

1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
2 Z1 20BK GROUND
RIGHT LICENSE
LAMP
(BUILT-UP-EXPORT)

BLACK CAV CIRCUIT FUNCTION

L1 20VT/BK BACK-UP LAMP FEED
1
1 2 L62 18BR/RD RIGHT TURN SIGNAL
L62 18BR/RD RIGHT TURN SIGNAL
2
3 4 L1 20VT/BK BACK-UP LAMP FEED
L7 18BK/YL HEADLAMP SWITCH OUTPUT
3
L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
RIGHT REAR
LAMP ASSEMBLY L63 18DG/RD LEFT TURN SIGNAL
4
L7 18BK/YL HEADLAMP SWITCH OUTPUT

BLACK

CAV CIRCUIT FUNCTION

1 2 1 X52 20DB/WT RIGHT REAR SPEAKER (+)
2 X58 20DB/PK RIGHT REAR SPEAKER (-)
RIGHT REAR
SPEAKER
(SOUND BAR)
EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
J998W-5 TJI08036
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37

BLACK

CAV CIRCUIT FUNCTION

2 1
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT REAR
WHEEL SPEED
SENSOR

GRAY

2 CAV CIRCUIT FUNCTION

1 1 L60 18TN RIGHT TURN SIGNAL
2 Z1 18BK GROUND

RIGHT REPEATER
LAMP
(BUILT-UP-EXPORT)

GRAY

2 CAV CIRCUIT FUNCTION

1 1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
2 L60 18TN RIGHT TURN SIGNAL

RIGHT SIDE
MARKER LAMP
(EXCEPT BUILT-
UP-EXPORT)

BLACK
2 1
CAV CIRCUIT FUNCTION
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z1 20BK GROUND
SEAT BELT
SWITCH
(EXCEPT LHD BUILT-
-UP-EXPORT)

BLACK CAV CIRCUIT FUNCTION

1 F34 20TN/BK FUSED B(+)
2 Z1 20BK GROUND
1 6 3 F15 20DB FUSED IGNITION OUTPUT (ST-RUN)
4 Z12 20BK/LB GROUND
5 D2 20WT/BK CCD BUS(-)
SENTRY KEY
6 D1 20VT/BR CCD BUS(+)
IMMOBILIZER
MODULE

BLACK

CAV CIRCUIT FUNCTION

1 2
1 M1 20PK/WT FUSED B(+)
SOUND BAR 2 M2 20YL COURTESY LAMPS DRIVER
DOME LAMP

TJI08037 J998W-5
8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS TJ

NATURAL
1 3 CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
2 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
THROTTLE 3 K7 20OR 5V SUPPLY
POSITION
SENSOR

BLACK

CAV CIRCUIT FUNCTION

B A A F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (ST-RUN)
B T23 18OR/LG TRANSMISSION LOW/OVERDRIVE SOLENOID

TORQUE CONVERTOR
CLUTCH SOLENOID

BLACK

CAV CIRCUIT FUNCTION

A B A G107 20BK/RD 4WD SENSE
B Z1 20BK GROUND

TRANSFER
CASE SWITCH

CAV CIRCUIT FUNCTION

BLACK 1 L60 18TN RIGHT TURN SIGNAL
2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
3 L62 18BR/RD RIGHT TURN SIGNAL
4 L32 16PK COMBINATION FLASHER OUTPUT
6 1 5 L5 20BK/GY FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
11 7 6 L9 16BK/WT FUSED FLASHER FEED
7 - -
8 - -
TURN SIGNAL/ 9 L63 18DG/RD LEFT TURN SIGNAL
HAZARD SWITCH 10 L61 18GY LEFT TURN SIGNAL
11 L55 16RD/WT COMBINATION FLASHER INPUT

BLACK

CAV CIRCUIT FUNCTION

2 1
1 Z1 18BK GROUND
2 M1 20PK/WT FUSED B(+)
UNDERHOOD
LAMP

EXCEPT BUILT-UP-EXPORT
J998W-5 TJI08038
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39

BLACK CAV CIRCUIT FUNCTION

4 1 1 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z1 18BK GROUND

VEHICLE SPEED
CONTROL
SERVO

BLACK

CAV CIRCUIT FUNCTION

1 K6 20VT/OR 5V SUPPLY
3 1
2 K167 20BR/YL SENSOR GROUND
3 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL

VEHICLE SPEED
SENSOR

BLACK

CAV CIRCUIT FUNCTION

A B A V10 18BR WASHER PUMP CONTROL SWITCH OUTPUT
B Z1 18BK GROUND

WINDSHIELD
WASHER PUMP

BLACK
CAV CIRCUIT FUNCTION
1 V6 18PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V5 18DG/YL WIPER PARK SWITCH SENSE
3 1 3 - -
6 4 4 Z1 18BK GROUND
5 V3 18BR/WT LOW SPEED WIPER SWITCH OUTPUT
WINDSHIELD 6 V4 18RD/YL WIPER SWITCH HIGH SPEED OUTPUT
WIPER MOTOR

NATURAL
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 V5 18DG/YL WIPER PARK SWITCH SENSE
3 V10 18BR WASHER PUMP CONTROL SWITCH OUTPUT
6 1
4 V3 18BR/WT LOW SPEED WIPER SWITCH OUTPUT
5 V6 18PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
WINDSHIELD 6 V4 18RD/YL WIPER SWITCH HIGH SPEED OUTPUT
WIPER SWITCH

TJI08039 J998W-5
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Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
A/C BK At A/C 12 C103 BK Near T/O for 2, 3
Compressor Compressor Fuel Injector
Clutch Clutch NO. 6
A/C Heater BK Rear of Blower 17, 18 C104 (LHD) GY Rear of Engine 2
Control - C1 Motor Switch C104 (RHD) BK Rear of Engine 3
A/C Heater BK Rear of Lamp 17, 18 C106 (LHD) BK Left Kick Panel 2, 15
Control - C2
C106 (RHD) BK Right Kick 16
A/C Heater BK Rear of A/C 17, 18 Panel
Control - C3 Heater Control
C107 (LHD) YL Left Kick Panel 2, 15
Switch
C107 (RHD) YL Right Kick 16
A/C High BK On A/C 12
Panel
Pressure Switch Compressor
C108 (LHD) BL Left Kick Panel 2, 15
A/C Low GY Near T/O for N/S
Pressure Switch Powertrain C108 (RHD) BL Right Kick 16
Control Module Panel
ABS Diode BK Near T/O for 2 C110 BK Left Fender 3, 5
Controller Side Shield
Anti-Lock Brake C154 BK Top Right Side 11, 14
ABS Pump BK Left Side of 6 of Transmission
Motor Engine C170 LT Right Kick 2, 17,
Compartment GY/ Panel 18
Near Grommet BK
Airbag Control YL Front of Floor 15, 16, C180 BK Engine N/S
Module Pan Tunnel 19 Compartment
Back-up Lamp BK Right Side of 14 Left Side
Switch (M/T) Transmission C202 (LHD) GY Left Kick Panel 15, 17
Battery BK Under Battery 3, 4 C202 (RHD) GY Right Kick 16, 18
Temperature Tray Panel
Sensor
C203 (LHD) GN Left Kick Panel 15, 17
Brake Lamp GY Top of Brake 15, 16
C203 (RHD) GN Right Kick 16, 18
Switch Pedal Bracket
Panel
Brake Shift WT Near Steering 20
C204 (LHD) RD Left Kick Panel 15, 17
Interlock Column
Solenoid C204 (RHD) RD Right Kick 16, 18
Panel
Brake Warning BK On Brake 2, 3
Indicator Switch Master Cylinder C322 BK Left Kick Panel 15, 16,
22
C323 (LHD) RD Left Kick Panel 15, 22
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Connector Color Location Fig. Connector Color Location Fig.
Name/Number Name/Number
C323 (RHD) LT GY Left Kick Panel 16 Data Link BK Bottom Left of 17
C325 (4 Spkr WT/ Left Side of 22, 23 Connector Instrument
Sys) BK Sound Bar (LHD) Panel
C326 (Hard BK Left Rear 22, 23 Data Link BK Bottom Right of 18
Top) Quarter Panel Connector Instrument
(RHD) Panel
C329 (LHD) BK Left Side of 24
Rear Bumper Daytime BK Left Side of 4
Running Lamp Engine
C329 (RHD) BK Right Side of 25
Module (Except Compartment
Rear Bumper
Built-Up-Export)
C330 (4 Spkr WT/ Left Side of 22, 23
Driver Door Ajar NAT At 9A9 Pillar 15, 16
Sys) BK Sound Bar
Switch
C331 (Hard BK Left Rear 22, 23
Duty Cycle BK Left Fender 5
Top) Quarter Panel
Evap/Purge Side Shield
Camshaft GY Below 11 solenoid
Position Sensor Distributor
Engine Coolant BK On Thermostat 9, 10
Cigar Lighter/ BK Bottom of 15, 22 Temperature Housing
Accessory Instrument Sensor
Relay (LHD) Panel Near
Engine Oil BK Right Side of 11
Steering
Pressure Engine Block
Column
Sensor
Cigar Lighter/ BK Bottom of N/S
Fog Lamp BK Near Fuse 15
Accessory Instrument
Relay NO.1 Block T/O
Relay (RHD) Panel Near
(Except
Steering
Built-Up-Export)
Column
Fog Lamp BK Near Fuse 15
Cigar Lighter/ RD Rear of Cigar 17, 18
Relay NO.2 Block T/O
Power Outlet Lighter
(Except
Clockspring - YL Rear of 20 Built-Up-Export)
C1 Clockspring
Front Fog Lamp BK At Switch 17
Clockspring - NAT Rear of 20 Switch (Except
C2 Clockspring Built-Up-Export)
Clutch Pedal BK Top of Clutch 15, 16 Fuel Injector BK At Injector 9, 10
Position Switch Pedal Bracket NO.1
(M/T)
Fuel Injector BK At Injector 9, 10
Combination BK Bottom of 20 NO.2
Flasher Instrument
Fuel Injector BK At Injector 9, 10
Panel Near
NO.3
Steering
Column Fuel Injector BK At Injector 9, 10
NO.4
Controller GY Near Grommet 2, 19
Anti-Lock Brake Rear Left Side Fuel Injector BK At Injector 10
- C1 of Dash Panel NO.5
Controller GY Near Grommet 2, 19 Fuel Injector BK At Injector 10
Anti-Lock Brake Rear Left Side NO.6
- C2 of Dash Panel Fuel Pump BK Above Fuel 1
Crankshaft BK At Rear of 9, 10, Module Tank
Position Sensor Intake Manifold 13
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Connector Color Location Fig. Connector Color Location Fig.
Name/Number Name/Number
G100 Rear Center of 2, 3 G Switch BK Near T/O for 19
Engine Controller
Compartment Anti-Lock Brake
G101 Rear Center of 2 Generator BK Rear of 12
Engine Generator
Compartment Headlamp BK At Steering 20
G102 Left Radiator 5 Dimmer Switch Column Part of
Closure Panel Multifunction
G103 Right Radiator 1 Switch
Closure Panel Headlamp BK Right Side of 17, 18
G104 Rear of 12 Leveling Switch Instrument
Generator (Built-Up- Panel
Export)
G105 Right Rear of 12
Engine Block Headlamp BK Rear of Switch 17, 18
Switch
G106 Right Rear of 12
Engine Block High Note Horn BK Left Front 5
Fender Side
G107 Right Rear of 12
Shield
Engine Block
HVAC Unit GY Bottom Right of 21
G200 Right Rear of 17, 18
(LHD) Instrument
Instrument
Panel
Panel
HVAC Unit GY Bottom Left of 18
G201 Right Rear of 17, 18
(RHD) Instrument
Instrument
Panel
Panel
Hydraulic BK Left Side of 6
G202 (LHD) Right Rear of 21
Control Unit Engine
Instrument
Compartment
Panel
Idle Air Control BK Side of Throttle 9, 10
G202 (RHD) Left Rear of 18
Motor Body
Instrument
Panel Ignition Coil GY Near Generator 12
G203 (LHD) Right Rear of 21 Ignition Switch GY Rear of Ignition 20
Instrument Switch
Panel Instrument GN Rear of Cluster 17, 18
G203 (RHD) Left Rear of 18 Cluster - C1
Instrument Instrument BL Rear of Cluster 17, 18
Panel Cluster - C2
G300 (LHD) Left Kick Panel 15 Intake Air GY Rear of Intake 9, 10
G300 (RHD) Right Kick 16 Temperature Manifold
Panel Sensor
G301 (LHD) Right Kick 15 Key-In Switch GN At Key-In 20
Panel Switch
G301 (RHD) Left Kick Panel 16 Leak Detection BK Engine N/S
Pump (Except Compartment
G302 (LHD) Left Kick Panel 15
Built-Up-Export) Left Side
G302 (RHD) Right Kick 16
Left City Lamp BK At Lamp 5
Panel
(Built-Up-
Export)
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Connector Color Location Fig. Connector Color Location Fig.
Name/Number Name/Number
Left Courtesy BK Left Side of 17, 18 Low Note Horn BK Left Front 5
Lamp Instrument (Except Fender Side
Panel Built-Up-Export) Shield
Left Fog Lamp BK At Lamp N/S Manifold BK Side of Throttle 9, 10
(Except Absolute Body
Built-Up-Export) Pressure
Left Front BK At Lamp N/S Sensor
Park/Turn Oxygen Sensor GY On Front 9, 10
Signal Lamp 1/1 Upstream Exhaust Pipe
(Except Oxygen Sensor BK Rear of 14
Built-Up-Export) 1/2 Downstream Catalytic
Left Front BK At Speaker 17, 18 Converter
Speaker Park/Neutral BK Left of 11
Left Front Turn BK At Lamp N/S Position Switch Transmission
Signal Lamp (A/T)
(Built-Up- Passenger YL Rear of Airbag 15, 16,
Export) Airbag 18, 21
Left Front BK Left Side of 6 Passenger LT GY Near Fuse 15, 16
Wheel Speed Engine Airbag On/Off Block T/O
Sensor Compartment Switch - C1
Near Hydraulic
Passenger YL Near Fuse 15, 16
Control Unit
Airbag On/Off Block T/O
Left Headlamp BK Rear of Lamp 5 Switch - C2
Left Headlamp BK At Lamp 5 Passenger Door BK Near T/O for 15, 16
Leveling Motor Ajar Switch G301
(Built-Up-
Power Steering BK Near Power 9
Export)
Pressure Switch Steering Pump
Left License GY At Lamp 24, 25 (2.5L)
Lamp
Powertrain BK Left Rear of 3, 4
(Built-Up-
Control Module Engine
Export)
- C1 Compartment
Left Rear Lamp BK At Lamp 24, 25
Powertrain WT Left Rear of 3, 4
Assembly
Control Module Engine
Left Rear BK At Sound Bar N/S - C2 Compartment
Speaker (Sound
Powertrain GY Left Rear of 3, 4
Bar)
Control Module Engine
Left Rear Wheel BK Near Vehicle 1 - C3 Compartment
Speed Sensor Speed Sensor
PRNDL Lamp BK Rear of Lamp 15, 16
T/O
Radio - C1 GY Rear of Radio 17, 18
Left Repeater GY At Lamp N/S
Lamp Radio - C2 BK Rear of Radio 17, 18
(Built-Up- Rear Fog Lamp BK At Lamp 24, 25
Export) (Built-Up-
Left Side GY At Lamp N/S Export)
Marker Lamp Rear Fog Lamp LT GN Near Fuse N/S
(Except Relay Block T/O
Built-Up-Export) (Built-Up-
Export) (LHD)
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Connector Color Location Fig. Connector Color Location Fig.
Name/Number Name/Number
Rear Fog Lamp LT GN Near Fuse 16 Right License GY At Lamp 24, 25
Relay Block T/O Lamp
(Built-Up- (Built-Up-
Export) (RHD) Export)
Rear Fog Lamp WT At Switch 17, 18 Right Rear BK At Lamp 24, 25
Switch Lamp Assembly
(Built-Up- Right Rear BK At Sound Bar N/S
Export) Speaker (Sound
Rear Washer BK Under Washer 5 Bar)
Pump (Hard Fluid Reservoir Right Rear BK Near Vehicle 1
Top) Wheel Speed Speed Sensor
Rear Window GY Behind Rear 17, 18 Sensor T/O
Defogger Switch Window Right Repeater GY At Lamp 1
(Hard Top) Defogger Lamp
Switch (Built-Up-
Rear Wiper BK At Rear Wiper N/S Export)
Motor (Hard Motor Right Side GY At Lamp 1
Top) Marker Lamp
Rear Wiper/ WT Behind Rear 17, 18 (Except
Washer Switch Wiper/Washer Built-Up-Export)
(Hard Top) Switch Seat Belt Switch BK Near Park 22, 23
Right City Lamp BK At Lamp 1 (Except LHD Brake Switch
(Built-Up- Built-Up-Export) T/O
Export) Sentry Key BK At Immobilizer 15, 16
Right Courtesy BK Right Side of 18, 21 Immobilizer
Lamp Instrument Module
Panel Sound Bar BK At Sound Bar N/S
Right Fog Lamp BK At Lamp 1 Dome Lamp
(Except Throttle Position NAT Side of Throttle 9, 10
Built-Up-Export) Sensor Body
Right Front BK At Lamp 1 Torque BK Left Side of N/S
Park/Turn Converter Transmission
Signal Lamp Clutch Solenoid
(Except
Transfer Case BK Left Side of 14
Built-Up-Export)
Switch Transfer Case
Right Front BK At Speaker 18, 21
Turn Signal/ BK At Steering 20
Speaker
Hazard Switch Column Part of
Right Front Turn BK At Lamp 1 Multifunction
Signal Lamp Switch
(Built-Up-
Underhood BK Under Hood 2, 3
Export)
Lamp
Right Front BK Rear of Engine 13
Vehicle Speed BK Left Side of N/S
Wheel Speed
Control Servo Engine
Sensor
(LHD) Compartment
Right Headlamp BK Rear of Lamp 1
Vehicle Speed BK Right Side of N/S
Right Headlamp BK Near Lamp at 1 Control Servo Engine
Leveling Motor Motor (RHD) Compartment
(Built-Up-
Vehicle Speed BK Left Rear of 14
Export)
Sensor Transfer Case
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Connector Color Location Fig. Connector Color Location Fig.
Name/Number Name/Number
Windshield BK Under Washer 5 Windshield NAT At Steering 20
Washer Pump Fluid Reservoir Wiper Switch Column
Windshield BK Center of Cowl 7, 8
Wiper Motor Panel
 
 "!$#"%&(')+* ,  -.0/
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I
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N
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Fig. 1 Front End Wiring Connectors

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Fig. 2 Engine Compartment Connectors — Rear, LHD

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Fig. 3 Engine Compartment Connectors — Rear, RHD

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Fig. 4 Engine Compartment Connectors—LHD

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Fig. 5 Engine Compartment Connectors—Front Side

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Fig. 6 ABS Hydraulic Control Unit

Fig. 7 Windshield Wiper Motor—LHD

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Fig. 8 Windshield Wiper Motor—RHD

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Fig. 9 Engine Harness Connectors—2.5L Engine

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Fig. 10 Engine Harness Connectors—4.0L Engine

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Fig. 11 Engine and Automatic Transmission Connectors

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Fig. 12 Engine Grounds

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Fig. 13 Crankshaft Position Sensor and Right Front Wheel Speed Sensor
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Fig. 14 Transmission and Transfer Case Connectors

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Fig. 15 Dash Panel Connectors—LHD

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Fig. 16 Dash Panel Connectors—RHD

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Fig. 17 Instrument Panel Wiring Connectors—LHD

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Fig. 18 Instrument Panel Wiring Connectors—RHD

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Fig. 19 Airbag Control Module and Controller, Antilock Brakes—LHD

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Fig. 20 Steering Column Connectors

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Fig. 21 Instrument Panel Connectors—Right Side, LHD

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Fig. 22 Body Connectors—LHD

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Fig. 23 Rear Body Wiring Connectors—RHD

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Fig. 24 Rear Under Body Wiring Connectors—LHD

Fig. 25 Rear Under Body Wiring Connectors—RHD


 
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Splice Location Fig. Splice Location Fig.

Number Number
S101 Near T/O for Powertrain 2 S119 Left Side Radiator Closure 1
(LHD) Control Module Panel
S101 Near T/O for Power 3 S122 Near T/O for Left Front Turn N/S
(RHD) Distribution Center (Built-Up- Signal Lamp At Grommet
S102 Near T/O for G100 2, 3 Export)
S103 Near T/O for G101 2 S122 Near T/O for Left Front N/S
(LHD) (Except Park/Turn Signal Lamp
Built-Up-
S103 Near T/O for Battery 3
Export)
(RHD) Temperature Sensor
S123 Near T/O for G105 6
S104 Near T/O for C110 2
(LHD)
S105 Near Grommet on Left Side 2
S123 Near T/O for C103 N/S
(LHD) of Dash Panel
(2.5L)
S105 Near T/O for C110 3 (RHD)
(RHD)
S123 Near T/O for Fuel Injector 7
S106 Near T/O for Ground G100 2 (4.0L) NO. 6
S107 Near T/O for G101 2 (RHD)
S108 Near T/O for Underhood 2 S124 Near T/O for G105 6
(LHD) Lamp (LHD)
S108 Near T/O for C110 3 S124 Near T/O for C103 N/S
(RHD) (RHD)
S109 Near T/O for C103 and C104 2 S125 Near T/O for Right Front N/S
(Built-Up- Turn Signal Lamp At
S110 Near T/O for C103 and C104 2
Export) Grommet
S112 Near Controller Antilock 2
S125 Near T/O for Right Front N/S
Brake
(Except Park/Turn Signal Lamp At
S114 Near ABS Pump Motor T/O 2 Built-Up- Grommet
S115 Near T/O for Duty Cycle 1 Export)
(Except Evap/Purge Solenoid S126 Near T/Os for Fuel Injectors 6
Built-Up- (LHD)
Export)
S126 Near T/O for Fuel Injector 7
S116 Near T/O for High Note Horn 1 (2.5L) NO. 4
(Except (RHD)
Built-Up-
S126 Near T/O for Fuel Injector 7
Export)
(4.0L) NO. 6
S117 Near T/O for Windshield 1 (RHD)
Washer Pump Motor
S127 Near T/O for Idle Air Control 4, 5
S118 Near Left Headlamp T/O 1 Motor
%& '!()"'$* %&'
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Splice Location Fig. Splice Location Fig.
Number Number
S127 Between Fuel Injector NO. 2 5 S144 Near T/O for Right Front N/S
(2.5L) and Fuel Injector NO. 3 Park/Turn Signal Lamp
(RHD) S146 Near T/O for Powertrain 2
S128 Between Fuel Injector NO. 2 4, 5 Control Module
and Fuel Injector NO. 3 S147 Near T/O for Powertrain 2
S129 Near T/O for Fuel Injectors 6 (LHD) Control Module
(LHD) S147 Right Side of Engine 3
S129 Near T/O for C104 7 (RHD) Compartment Near Grommet
(RHD) S150 Near T/O for Right Headlamp 1
S130 Near T/O for Fuel Injectors 6 (Built-Up- Leveling Motor
(LHD) Export)
S130 Near T/O for C103 N/S S151 Near T/O for Left Headlamp 1
(RHD) (Built-Up- Ground
S131 Near T/O for ABS Pump 2 Export)
(LHD) Motor S202 Center Rear of Instrument 10, 11
S131 Near T/O for C110 3 Panel
(RHD) S204 Center Rear of Instrument 10, 11
S132 Near T/O for Oxygen Sensor 6, 7 Panel
1/2 Downstream S206 Center Rear of Instrument 10, 11
S133 Near T/O for G105 6 Panel
(LHD) S207 Near Cigar Lighter T/O 10, 11
S133 Near T/O For C104 7 S301 Near Grommeted T/O to 8
(RHD) (LHD) Windshield Wiper Motor
S134 Near T/O for Oxygen Sensor 6, 7 S301 Near T/O for Passenger 9
1/2 Downstream (RHD) Airbag
S135 Near T/O for Oxygen Sensor 6, 7 S302 Near Grommeted T/O for 8, 9
1/2 Downstream Windshield Wiper Motor
S136 In Battery Harness Near N/S S303 Near Grommeted T/O for 8, 9
PDC Windshield Wiper Motor
S138 Near T/O for Right Headlamp 1 S304 Near Grommeted T/O for 8, 9
(Built-Up- Leveling Motor Windshield Wiper Motor
Export) S306 Near T/O for Airbag Control 8, 9
S141 Near T/O for Left Front Turn N/S Module
(Built-Up- Signal Lamp S307 Near T/O for Airbag Control 8, 9
Export) Module
S141 Near T/O for Left Front N/S S309 Front of Left Rear Wheel 12, 13
(Except Park/Turn Signal Lamp Well
Built-Up-
S310 Left Rear Quarter Panel, 12, 13
Export)
Near Body Grommet
S142 Near T/O for Right Front N/S
S311 Near Left Tail Lamp 12, 13
(Built-Up- Turn Signal Lamp At
Connector
Export) Grommet
S313 Front of Left Rear Wheel 12, 13
S142 Near T/O for Right Front N/S
Well
(Except Park/Turn Signal Lamp at
Built-Up- Grommet S314 Front of Left Rear Wheel 12, 13
Export) Well
S143 Near T/O for Left Front N/S S315 Near Right Tail Lamp 12, 13
Park/Turn Signal Lamp Connetor
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Splice Location Fig. Splice Location Fig.
Number Number
S316 In T/O for Rear Fog Lamp 12, 13 S331 Near T/O for Airbag Control 8, 9
S317 Near T/O for Left License 12, 13 Module
Lamp S332 Near T/O for Cigar 8, 9
S320 Near T/O for 100 way 8 Lighter/Accessory Relay
(LHD) Connector S335 Near Left Tail Lamp 12
S320 Near Passenger Airbag 9 Connector
(RHD) On/Off Switch S400 Near T/O for Rear Window N/S
S330 In T/O for Fuse Block 8 Defogger Feed
(LHD) S401 Near T/O for Rear Window N/S
S330 Near Passenger Airbag 9 Defogger Feed
(RHD) On/Off Switch
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Fig. 1 Engine Compartment Splices—Front

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Fig. 2 Engine Compartment Splices—Rear,LHD

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Fig. 3 Engine Compartment Splices—Rear,RHD

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Fig. 4 Engine Wiring Splices—LHD

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Fig. 5 Engine Wiring Splices—RHD

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Fig. 6 Engine Wiring Splices—LHD

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Fig. 7 Engine Wiring Splices—RHD

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Fig. 8 Dash Panel Wiring Splices—LHD

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Fig. 10 Instrument Panel Wiring Splices—LHD

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Fig. 11 Instrument Panel Wiring Splices—RHD

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ENGINE
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¿ÀÂÁÃÅÄÇÆÈRÉ%ÆÄ ÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀËÊÍÌ ÄÇÆÈRÉ%ÆÄÅÐÉ ÑNÈRÆÒÓ,É ÓÔÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀ½Õ
ÌÀÂÎÃÅÄÇÆÈRÉ%ÆÄ ÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀ'ÁÇÏ ÓNÖ×Ñ,ÆÐÑØÐÙÓ,ÄÇØÚÉ Û,ÄÅÉ%ÆÜÍÒRØÝRÑÇÖÉ ÒRÆÞÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÅÊ

STANDARD SERVICE INFORMATION

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GENERAL INFORMATION HYDROSTATIC LOCK . . . . . . . . . . . . . . . ...... 4

ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . . . 4 MEASURING WITH PLASTIGAGE . . . . . . ...... 3
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 2 REPAIR DAMAGED OR WORN THREADS ...... 4
FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . . . 1 SERVICE ENGINE
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 2 ASSEMBLY (SHORT BLOCK) . . . . . . . . ...... 4
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CAUTION: DO NOT use engine or transmission oil,

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mineral spirits or kerosene.

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DIAGNOSIS AND TESTING ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 10

CYLINDER COMBUSTION PRESSURE GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 7
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . .. 8 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER COMPRESSION PRESSURE TEST .. 8 INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 8
ENGINE CYLINDER HEAD GASKET FAILURE SERVICE DIAGNOSIS—MECHANICAL . . . . . . . . 12
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 SERVICE DIAGNOSIS—PERFORMANCE . . . . . . 10
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . .. 9
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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

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x$.(*(*,3$!0|0"->$1?$UV2&)\4(*-1&)+)S<Sn&)+1yFHkLx4OKYx40=)&)KY,s,A0@g4(*(*"-<&)&,sB -1(*,*$O(*-
8282D1J1:<:<EE $)KL4-6?&FHMGFH&),*)N$=+4I(*MB (*&0CFH,*O,P&,P(*+=O(*Q&+-640#
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-6$88 > :<:Y)f ` $4==,*$(*)+#d,*eg$,a&),_$-1(*"UV,3!,*!1#d0@bh"-1UV)$$0=O2SV.-X)SV,*O$0c&gKY#%,*$+=#%00iB ,*-1!O,* $@b4#%40jSVS!4(*&$kLO0=- l

polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
UV(*$&KY-6-1-64I>$=!_I\(*$>$+&)-1,*)X-G(*!+=,3Un_?UVUV+&)#%,*-^&+&-m4m>$#%&)$(*"lH@TSV4U!-64IU!,*X4>$+UV+&),.#%-1-1l)$&4l
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seal.

2>$4I&O(*XK,ZY,*+$04I&0=2I#slR-1$+0,*So2$(*KY-6$B 4I0p>!$,*40#P(*$Uq&a(A@r4I0=SV),
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CAUTION: Do not exceed 20.6 kPa (3 psi).

SVO(*)Sb>$)kL)0‚p(*,*$0=-1$2ƒ$0Sb-1)$|kL4 2&,_?(*&),3,*)(*.UV,3)-6-1+,*-6B
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CONDITION POSSIBLE CAUSES CORRECTION

ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A,
Battery, for correct procedures. Check charging
system. Refer to Group 8C, Charging Systems,
for correct procedures.

2. Corroded or loose battery 2. Clean/tighten suspect battery/starter

connections connections
3. Faulty starter or related 3. Check starting system. Refer to Group 8B,
circuit(s) Starting Systems, for correct diagnostics/
procedures
4. Siezed accessory drive 4. Remove accessory drive belt and attempt to
component start engine. If engine starts, repair/replace
siezed component.
5. Engine internal mechanical 5. Refer to Group 9, Engine, for correct
failure or hydro-static lock diagnostics/procedures

ENGINE CRANKS BUT 1. No spark 1. Check for spark. Refer to Group 8D, Ignition
WILL NOT START System, for correct procedures.
2. No fuel 2. Perform fuel pressure test, and if necessary,
inspect fuel injector(s) and driver circuits. Refer
to Group 14, Fuel System, for correct
procedures.
3. Low or no engine 3. Perform cylinder compression pressure test.
compression Refer to Group 9, Engine, for correct
procedures.
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CONDITION POSSIBLE CAUSES
ENGINE LOSS OF POWER 1. Worn or burned distributor
rotor
2. Worn distributor shaft
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 cables
12. Faulty ignition coil
ENGINE STALLS OR 1. Carbon build-up on throttle
ROUGH IDLE plate
2. Engine idle speed too low
3. Worn or incorrectly gapped
spark plugs
4. Worn or burned distributor
rotor
5. Spark plug cables defective or
crossed
6. Faulty coil
7. Intake manifold vacuum leak
8. EGR valve leaking or stuck
open
ENGINE MISSES ON 1. Worn or incorrectly gapped
ACCELERATION spark plugs
2. Spark plug cables defective or
crossed
3. Dirt in fuel system
4. Burned, warped or pitted
valves
5. Faulty coil
Öv×½Ø.Ù ×.Ö ÚsۆÜVÜ
CORRECTION
1. Install new distributor rotor
2. Remove and repair distributor (Refer to
group 8D, Ignition System
3. Clean plugs and set gap. (Refer to group
8D, Ignition System)
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
9. Install/Reface valves as necessary
10. Install new parts as necessary
11. Replace any cracked or shorted cables
12. Test and replace, as necessary (Refer to
Group 8D, ignition system)
1. Remove throttle body and de-carbon. (Refer
to Group 14 for correct procedures)
2. Check Idle Air Control circuit. (Refer to
Group 14, Fuel System)
3. Replace or clean and re-gap spark plugs
(Refer to group 8D, Ignition System)
4. Install new distributor rotor
5. Check for correct firing order or replace
spark plug cables. (Refer to Group 8D, Ignition
System for correct procedures.)
6. Test and replace, if necessary (Refer to
group 8D, Ignition System)
7. Inspect intake manifold gasket and vacuum
hoses. Replace if necessary (Refer to Group
11, Exhaust System & Intake Manifold)
8. Test and replace, if necessary (Refer to
group 25, Emission Control Systems)
1. Replace spark plugs or clean and set gap.
(Refer to group 8D, Ignition System)
2. Check Idle Air Control circuit. (Refer to
Group 14, Fuel System)
3. Clean fuel system
4. Install new valves
5. Test and replace as necessary (refer to
group 8D, Ignition System)
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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
3. Thin or diluted oil
4. Excessive main bearing
clearance
5. Excessive end play
6. Crankshaft main journal out of
round or worn
CORRECTION
1. Check for correct oil level. Adjust oil level by
draining or adding as needed
2. Change oil (Refer to Engine Oil Service in
this group)
3. Check engine oil level. If ok, Perform oil
pressure test. Refer to this group 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. (Refer to group 0,
Lubrication and Maintenance)
2. Check engine oil level. If ok, Perform oil
pressure test. Refer to this group for engine oil
pressure test/specifications
3. Change oil to correct viscosity. Refer to this
group for correct procedure/engine oil
specifications
4. 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. (Refer to group 0,
Lubrication and Maintenance)
2. Check engine oil level. If ok, Perform oil
pressure test. Refer to this group for engine oil
pressure test/specifications
3. Change oil to correct viscosity. Refer to this
group for correct procedure/engine oil
specifications
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
JK
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CONDITION POSSIBLE CAUSES
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. PCV 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
L#M%N'O M'L PQR S
CORRECTION
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 worn gears or oil pump assy
5. Change oil to correct viscosity. Refer to this
group for correct procedure/engine oil
specifications
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 group 25, Emission Control System
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
úûü ý þàÿ
 
 

2.5L ENGINE
g;hijlk

page page

DESCRIPTION AND OPERATION OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . 14 PISTONS AND CONNECTING RODS . . . . . . . . . 45
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 15 REAR MAIN OIL SEALS . . . . . . . . . . . . . . . . . . . 46
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . 15 ROCKER ARMS AND PUSH RODS . . . . . . . . . . 31
SERVICE PROCEDURES TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . 37
FITTING CONNECTING ROD BEARINGS . . . . . . 20 TIMING CASE COVER OIL SEAL . . . . . . . . . . . 36
FITTING CRANKSHAFT MAIN BEARINGS . . . . . 22 TIMING CHAIN AND SPROCKETS . . . . . . . . . . . 38
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . 17 VALVE SPRINGS AND OIL SEALS . . . . . . . . . . . 32
PISTON RING FITTING . . . . . . . . . . . . . . . . . . . 18 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 36
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 49
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 47
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 41 VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 47
CAMSHAFT PIN REPLACEMENT . . . . . . . . . . . . 40 CLEANING AND INSPECTION
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 41 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 50
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 33 ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . . 50
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 31 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 50
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26 ROCKER ARMS AND PUSH RODS . . . . . . . . . . 50
ENGINE MOUNTS—FRONT . . . . . . . . . . . . . . . . 25 SPECIFICATIONS
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . 25 2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EXHAUST MANIFOLD—2.5L ENGINE . . . . . . . . . 29 2.5L TORQUE SPECIFICATIONS . . . . . . . . . . . . 53
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 35 SPECIAL TOOLS
INTAKE MANIFOLD—2.5L ENGINE . . . . . . . . . . 29 2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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>;?Ž=2928A29A{05E765BUj>;A20123659767628360y36:;28<76<=362')728.)297-0B5 Plastigage
 58= =28360>;=KRT58A-‘T28<76>;=K’S>;00B>;=K  1<760‹*Q

“‡”–•_•_—T“c˜T™‹•$š@›‡”–œ4M—Tž‡›c™‹•$š@Ÿ~™˜T˜T™ •yš@“M¡_žM›˜

CRANKSHAFT JOURNAL CORRESPONDING CONNECTING ROD BEARING INSERT

Color Code Diameter Upper Insert Size Lower Insert Size

Yellow 53.2257-53.2079 mm Yellow - Standard Yellow - Standard

(2.0955-2.0948 in.)

Orange 53.2079 - 53.1901 mm Yellow - Standard Blue - Undersize

(2.0948 - 2.0941 in.) 0.025 mm (0.001 in.)

0.0178 mm (0.0014 in.)
Undersize

Blue 53.1901 - 53.1724 mm Blue - Undersize Blue - Undersize

(2.0941 - 2.0934 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)

0.0356 mm (0.0014 in.)
Undersize

Red 52.9717 - 52.9539 mm Red - Undersize Red - Undersize

(2.0855 - 2.0848 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
0.254 mm (0.010 in.)
Undersize

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Fig. 20 Bearing Insert Pairs

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).
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NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
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NOTE: DO NOT rotate the crankshaft. This will
ò…àAí3Ö)ßSÚ+Øß4í3Ý+Ø ÔŽ×3Ø9Ý+Ö)ØÕ$Ú+Õ$Ò3Ý+Ø Ùñ â$ê â$(ö +æ}æ ç~â$ê â$âá
cause the Plastigage to shift, resulting in an inaccu-
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rate reading. Plastigage must not be permitted to
Û)Ò3Ý+×kë•Õ4Ò?ßKò
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crumble. If brittle, obtain fresh stock.
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ç~õgÛ)Ü]êDögáëcêDîØévØÚԑàø÷.Ò?Ü]Û)Ò3ØJùôÞGØÝcÛvévÛvÝcÕ4ԎÛ)àÒ3Ówé~àÚԎ×3Ø &×3ØÿÝ+Ö)ØÕ$Ú+Õ$Ò3Ý+؏ò…àí?ÖvßÃԑ×?ØÒ Ù$Øÿâ$ê â *4ãá æ}æ ç~â$ê â$â/á 
ÞGÚ+àAÞGØAÚ
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CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
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CRANKSHAFT JOURNALS #1 - 4 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 - 63.4771mm
(2.4996 - 2.4991 in.) Blue- Undersize
Orange Yellow - Standard 0.025 mm (0.001 in.)
0.0127 mm (0.0005 in.)
Undersize
63.4771 - 63.4644 mm
(2.4991 - 2.4986 in.) Blue- Undersize Blue- Undersize
Blue 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0254 mm (0.001 in.)
Undersize
63.4644 - 63.4517 mm
(2.4986 - 2.4981 in.) Blue - Undersize Green - Undersize
Green 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
0.0381 mm (0.0015 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 #5 ONLY CORRESPONDING CRANKSHAFT 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 0.025 mm (0.001 in.)
0.0127 mm (0.0005 in.
Undersize
63.4619 - 63.4492 mm
(2.4985 - 2.4980 in.) Blue- Undersize Blue- Undersize
Blue 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0254 mm (0.001 in.)
Undersize
63.4492 - 63.4365 mm
(2.4980- 2.4975 in.) Blue - Undersize Green - Undersize
Green 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
0.0381 mm (0.0015 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
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zw~py ‚ {1y5„ƒD…my7ƒ8{ ‚ Dƒ y71„D‰Šy7…Ž

Fig. 34 Valve and Valve Components

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É*Ú"×8ÏÐÍIË1ÍIÎÉ1Ý2Þ+ÚØ Fig. 37 Fabricate Alignment Dowels
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NOTE: If valves, springs, or seals are to be inspect-
ed/replaced at this time, refer to Valves and Valve
Springs later in this section for proper procedures.

Fig. 38 Alignment Dowel Locations

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Fig. 36 Engine Cylinder Head Assembly CAUTION: Engine cylinder head bolts should be
øù+úû0ü¸ý(ýü(ûRø þfù reused only once. Replace the head bolts if they
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top of the bolt.





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bolt No.7 will be tightened to a lower torque than
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Fig. 39 Engine cylinder head Bolt Tightening
Sequence
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pump to turn in the opposite direction causing the
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gimE]Rajw
Fig. 54 Removing Main Bearing Caps and Lower Xb[ZI ggibet{h'b­kIbes©a`^gimEtInebe_x`}ˆ3mfbed
mfajˆqmEtrbqgi]^pIgi]}gh`
Inserts t·dfmfajˆ3`Rp:nedf]^t{”¶bqg²`^mfgihj`^plgh`¬p{]^ag]^plp{`^bepl]^Bgihj`
`^ajsšmfaj`^w
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Œ ]Rg`­ghj`­ˆ3mfbed mfajˆqmEt{begi]^p0p{`Rbeˆ3mfajs©_[w8Á
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Œ ® kµXYe‰²giwdfne_xw Z g]Rp{—e|j`^w
Fig. 55 Removing Upper Inserts Xrž[‰[Zyzaj_[gbedfda`z¯p{`Rbqp{kbqmfa0_[`^bedfw¼
`R`^p8gi]6¼
`^bep8‘}bemfa
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kIbemfalne`^bep{mfajs}|jvqv3`^p6mfaj_x`Rp{g_[w Xrž[Ž[Z\]`^p6gihj` ˜`^hmEtrdE`Rw
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ne`^bep{mfajs}t{bev3_xw ~e£²Œ ® kµXYe£²giwdfne_xw Z g]Rp{—e|j`^w
X‚[Zyzaj_[gibqdfdcgh`ƒkIbemEa„ne`^bep{mfajs…t{bevqX_†Z‡beajˆDdf]`^p Xrž[«[Z™mfdfd<gihj`¬]RmEd§v3bea½mfgih¢`Rajs©mfaj`¬]Rmfd<gi]¬gh`¬_xbe`
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X‰[ZŠ
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gNhji)klemNnomNpAqsrpAtju_mNnGnGm:u>rkApRvxwNyGzG{
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Fig. 56 Location of MoparT Gasket Maker

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Fig. 57 Crankshaft End Play Measurement õrQö P[ ÷ 
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Fig. 60 Oil Pan Sealer Locations

Fig. 58 Fabrication of Alignment Dowels

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Fig. 61 Position of 5/16 inch Oil Pan Bolts

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€  X* !N<="#;TLJ\kALM&' S;J$&;<=G8 &\…* € { X*
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.

‚ ƒ…„>w~xxw„P ui‚

X`/fg! 8' '…(&;'…"#D<="&hS†$|@ '  #;-G'&;$)pD!N 
U;"#' $<=;>!N)d* 6  >‡HG8&;' S!C&Y{Uˆ‰A<
X` bk%S*Š'G! * (&‹D;*
 fg! 8' '
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"8H>!N)d;S*
{ …' '
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&S! "#$ %;'S9 ;'*
03,/Œ3a+-Ž-ŒmiŽ-’‘3+-Ž-Ž-“a‘3a,/Ž-”’•-+--Œ
r
stiu
vFwQx Fig. 63 Stamped Connecting Rods and Caps
X`  £e&SLMi-9F $' =DS 'P o !(G&DQh%;o%X&<
X`/z3<M&g9  $|@ '  #;J;8$&S9 /* %' &&;q*
 z3<M&g9 &$)d;J<=!NKŠG8>!M"# 9 &;!N*
{ z3<M&g9 "#D! H&;#! *
– z3<M&g9  $|@ '  #;J;88* CAUTION: Ensure that the connecting rod bolts DO
_ c…&!  &kJ"8 !N&!—&(8jS <=(JG&: NOT scratch the crankshaft journals or cylinder
&<˜&%j! S&;)d*Š™—!NR #>;<=(&<=&S9  walls. Short pieces of rubber hose, slipped over the
 #C%X&<šS&;"I;I&;%i$|@ '  #;†LM' ' !N*Q™—! C rod bolts will provide protection during removal.
"#&;S;$ 9F$' &H&$&' ' $$D>! *
 € z3 !N—9 $' ;*
798;:< =?>A@?BDCFEHGJI EJC KML

NPO!Q RSUTPVTPWYX[ZWY\!]HTPV1V1T^] ZRYW`_baPc1d1ef(d1g1h1i1j

ÉXÊ;ÊqËÌiÍ Î ÏYÍ8ÐWÍÑ ÑNÒ ÑNÓÍÐÓpÔ#ÕÑ ÖWÓSÖÏYÔ#Ò ÑNÓ×ÐWÍÐØnÙX×ÐÚ

ÐÏ;ÙÓSÒ ÐÛTÜ×ØpÍÑNÑ ÏÝ=Þß Ò ÏÑiÕÔpÍ8ÐØpÓÖÜ×ÕÛ>ÖÓÖÏJÓS×;Ôh×;à­ÓÖÏ
Ù|á ß Ò ÐØ8ÏÜJÞ×;ÜÏÑMÉâ…Ò Û>ãPäå ËXã

Fig. 65 Rod and Piston Assembly Installation

É  Ë
~ÖÏÜ×;Ø  ×ÕÜXÐÍ8ß3ÒÑMÒ Ø#Ï;ÐÓSÒ àÒÏ;ØCØ8ÕÜÒ ÐÛRÓÖÏÏÐÛ>Ò ÐÏ


Ô#Ü×;Ø#ÕÙÓÒ ×ÐmÞNá1Í5Ù×;ß×;ÜXÚÙ×Ø#Ï;ØHÔ8Í8Ò ÐӆÝ=ÍÜY×;ÐIÓÖÏhÍ8Ø  ÍÚ
ÙÏÐÓ-ÙÖÏÏ C×܆Ù×ÕÐÓSÏ;Ü|ñMÏÒ ÛÖÓ-ÓS×SñMÍÜØkÓSÖÏTàßÍÐÛÏÉÜÏÍÜ|Ë
ÏÐØY×àÓÖÏkÙÜÍÐ dÑNÖÍàÓSã
QÖÏRÙ×ß ×ÜÙ×;Ø#ÏÑpÕÑNÏ;ØmÓ×kÒ ÐØ#Ò Ú
ÙÍÓSÏ  ×;ÕÜÐÍ߆ÑNÒ VÏÑÍÜÏHß Ò ÑNÓÏØlÒ Ð‡ÓÖÏ\í3×ÐÐÏ;ÙÓÒÐÛIÿ3×Ø
3ÏÍÜÒ ÐÛhâ…ÒÓÓÒÐÛRí3ÖÍ8ÜÓã
ÉXÊ 
Ë 1ÖÏ;Ð ÜÏ 8ÕÒÜÏ;Ø WÕÔ8Ô#ÏÜ¢ÍÐØ ß ×gñMÏ;Ü¢ÞÏÍÜÒ ÐÛ
Ò ÐÑNÏ;ÜÓц×à­Ø8ÒààÏÜXÏÐÓ~ÑNÒ VÏÑiÝ=ÍNá5ÞÏMÕÑNÏ;ØhÍ8ÑiÍpÔ#ÍÒ Ü—ÉÜÏ;àÏÜ
Ó×1í3×ÐÐÏ;ÙÓÒÐ۝ÿ3× Ø 3ÏÍÜÒ Ð۝â…ÒÓÓÒ Ð۝í3ÖÍÜÓ Ë?ã­ï ÑNÓÍÐÚ
Ø#ÍÜØWÑ Ò VÏUÒ ÐÑ ÏÜÓkÒÑYÑN×;Ý=ÏÓÒ Ý=ÏÑYÕÑNÏ;ØWÒ Ð7Ù×ÝMÞ8Ò ÐÍÓÒ ×Ð
ñMÒ ÓÖð Í ã òûBÝ=Ý É 8ã aÊUÒ ÐÙXÖîËmÕÐØ8ÏÜÑ Ò VϝÒÐÑNÏ;ÜÓ\Ó×
Fig. 64 Removal of Connecting Rod and Piston
Assembly
ÜÏØ8ÕÙÏÙß ÏÍÜÍÐÙ
Ï ã …Ê ökÝ=ݘ
É ã ûkÒ ÐÙÖËXã
æç è…é>ê~ëëêéPæ ìiç
ÉXÊ/Ëí3ß ÏÍÐ7ÓSÖÏUÙ|á ß Ò ÐØ#ÏÜHÞ×ÜÏ;ÑmÓSÖ×Ü×;ÕÛ>Öß áîã3ï—Ô#Ô#ß á’Í CAUTION: DO NOT intermix bearing caps. Each
ß Ò Û>ÖÓ
àÒ ß Ýð×;àeÙßÏ;ÍÐRÏ;ÐÛ>Ò Ðφ×Ò ß…Ó׆ÓSÖφÞ×ÜÏ;Ñ­ñMÒ ÓSÖhÍTÙß ÏÍÐ connecting rod and bearing cap are stamped with
ß Ò ÐÓÚàÜÏ;ÏÙXß×;ÓSÖã the cylinder number. The stamp is located on a
Éò ËógÐÑ ÓÍ8ß ßŸÓSÖÏôÔ#Ò ÑNÓ×;ÐõÜÒÐÛ>Ñ¢×;ÐõÓSÖÏôÔ#Ò ÑNÓ×;ÐÑ¢Ò à machined surface adjacent to the oil squirt hole
ÜÏ;Ý=×gÎ Ï;Ø#ã that faces the camshaft side of the cylinder block.
Éö Ë÷…ÕÞÜÒÙXÍ8ÓÏøÓSÖÏøÔ#Ò Ñ ÓS×;ÐùÍÐØúÜÒ ÐÛ>ÑBñMÒ ÓÖùÙß ÏÍÐ ÉXÊÊ/ËóSÐÑNÓÍßßÓÖÏUÙ×ÐÐÏÙÓÒ ÐÛnÜ×؟ÞÏ;Í8ÜXÒÐۇÙÍÔ#ÑmÍÐØ
ÏÐÛ>Ò ÐÏ×Ò ß ã Ò ÐÑNÏ;ÜÓÑMÒÐ\ÓÖÏÑNÍÝ=ÏÔ#×;ÑNÒ ÓÒ×;ÐÑMÍÑMÜÏÝ=×SÎ ÏØ8ã
CAUTION: Ensure that connecting rod bolts do not CAUTION: Verify that the oil squirt holes in the
scratch the crankshaft journals or cylinder walls. rods face the camshaft and that the arrows on the
Short pieces of rubber hose slipped over the con- pistons face the front of the engine.
necting rod bolts will provide protection during
ÉXÊ ö ËógÐÑ ÓSÍß ßjÓÖÏp×;Ò ßjÔ#ÍÐYÍÐØCÛ>ÍÑdÏÓÑ=ÍÑT×;ÕÓßÒ ÐÏ;Ø5Ò Ð
installation.
ÓÖÏÒÐÑNÓÍßß ÍÓÒ×;ÐHÔ8Ü×ÙÏ;Ø#ÕÜÏ;ã
Éû Ëü—Ñ ÏJÍÔ8ÒÑ Ó×ÐkÜÒ ÐÛ=Ù×Ý=Ô8ÜÏÑ ÑN×;ÜÓ×JÒ ÐÑ ÓSÍß ßeÓSÖÏJÙ×;ÐÚ ÉXÊ å Ë÷e×SñMÏÜ(ÓÖϗΠÏÖÒÙXßÏ;ã
ÐÏ;ÙÓSÒ ÐÛÜ×ØRÍ8ÐØkÔ#Ò Ñ ÓS×;Ð5ÍÑNÑ ÏÝ=Þß Ò ÏÑ(ÓSÖÜX×ÕÛ>ÖCÓSÖÏTÓ×ÔR×à ÉXÊ û ËógÐÑ ÓSÍß ß=ÓSÖÏ1ÏÐÛ>Ò ÐÏ1Ù|áFß ÒÐØ#ÏÜ\ÖÏÍØ (Ô#ÕÑ ÖBÜ×;Ø#Ñ 
ÓÖÏÙ|á ß Ò ÐØ#Ï;ÜJÞ×ÜÏ;ÑMÉâ…ÒÛãPäû ËXã Ü×Ù Ï;Ü-ÍÜÝ=Ñ FÞÜÒ Ø#Û>Ï;Ñ FÔ8Ò ÎF×ÓÑÍÐØÏ;ÐÛ>Ò ÐφÙ|áFßÒ ÐØ8ÏÜoÖÏÍØ
Éä Ëý3ÐÑ ÕÜÏ\ÓÖÏ\Í8ÜXÜ×gñú×ÐnÓÖÏ\Ô#Ò ÑNÓ×ÐnÓ×ÔUÔ#×;Ò ÐÓSÑÓ× Ù×gÎFÏÜ/ã
ÓÖÏàÜ×;ÐÓ×àjÓÖÏÏÐÛÒÐÏÉâeÒ Û>ãŠäûNË?ã ÉXÊ ä ËâeÒ ß ß
ÓÖÏÙÜÍÐ dÙÍ8Ñ Ï—ñMÒ ÓÖHÏ;ÐÛ>Ò ÐÏ×Ò ß ã
Éþ Ëÿ3ÍÒ ÑNÏÓÖϗΠÏÖÒÙß Ï;ã
É Ëý3ÍÙÖWÞÏÍÜÒ ÐÛ1Ò ÐÑNÏ;ÜÓpÒÑ5àÒ ÓÓÏØnÓ×YÒ ÓSÑ5ÜÏÑ Ô#Ï;ÙÓSÒ Î Ï

!"#%$"#&('*)!&(+-,."#+,
 ×;ÕÜÐÍß3Ó×T×ÞÓSÍÒ Ð5ÓSÖÏTÑ Ô#ÏÙÒ àÒÏ;ØÙß Ï;Í8ÜXÍ8ÐÙÏÞÏ;Ó ñJÏÏÐ5ÓÖÏ
ÞÏÍÜÒ ÐÛRÍÐØ5ÓÖÏ  ×ÕÜÐÍß ã­óSÐYÔ#Ü×;Ø#ÕÙÓÒ ×Ð ­ÓSÖÏÑNÏß Ï;ÙӗàÒ Ó /102 iì13FêQë
Ò Ñh×ÞÓSÍÒ ÐÏ;ØIÞ ánÕÑNÒ ÐÛÎ ÍÜÒ ×ÕÑ ÚÑNÒ VÏ;Ø QÙ×;ß×;ÜXÚÙ×Ø#Ï;ØIÞÏ;Í8Ü?Ú ÉXÊ/Ëÿ3ÏÝ=×SÎ Ï5ÓSÖÏ\àß áñMÖÏ;Ïßi×ÜRÙX×ÐîÎFÏÜÓÏÜRØ8ÜÒ ÎFÏ\Ô8ßÍÓÏã
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â…ÒÓÓÒ ÐÛRí3ÖÍÜÓã
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• ˆs…}
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è Ò#Ë è Ï-é.ÏpÐ è Ì(É.Ï

Fig. 66 Replacement of Rear Crankshaft Oil Seal
k
lnmpoq^rrsqotk uMl ’.ƒ}s‚Œê‚ƒƒ¯‡‚… • ˆsŒêª}s|ˆz~€å†
…ˆs”ë~€}쇈” • „~€zˆsŒ
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vw(x y{z|}-~€}D}‚ƒ „…†‚‡}-‚…}‚‰ˆs†Š~‹}D‡…‚ŒŽ‚†~
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„Œ~€zƒ1z~Jz‡ƒ}s‚Œ
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 ¬Œ|}s‡~ã†
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ˆ… • „…Œ}ªމ‡…‚‡}ªðˆs…‚…|}sª
flywheel mounting surface. If the lip is not posi- }‚ª
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Fig. 68 Measurement of Valve Seat Runout

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page page

DESCRIPTION AND OPERATION OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . 56 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 57 PISTONS AND CONNECTING RODS . . . . . . . . . . 86
OIL PUMP PRESSURE. . . . . . . . . . . . . . . . . . . . . 57 ROCKER ARMS AND PUSH RODS . . . . . . . . . . . 74
SERVICE PROCEDURES TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . . 78
FITTING CONNECTING ROD BEARINGS. . . . . . . 62 TIMING CASE COVER OIL SEAL . . . . . . . . . . . . . 88
FITTING CRANKSHAFT MAIN BEARINGS . . . . . . 64 TIMING CHAIN AND SPROCKETS . . . . . . . . . . . . 79
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . . 59 VALVE SPRINGS AND OIL SEALS . . . . . . . . . . . . 75
PISTON RING FITTING . . . . . . . . . . . . . . . . . . . . 60 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . 78
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 92
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 90
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . 82 VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . 89
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 84 CLEANING AND INSPECTION
CRANKSHAFT OIL SEALS—REAR. . . . . . . . . . . . 88 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 93
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 73 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 92
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 69 HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 92
ENGINE CYLINDER HEAD. . . . . . . . . . . . . . . . . . 75 ROCKER ARMS AND PUSH RODS . . . . . . . . . . . 92
ENGINE MOUNTS—FRONT. . . . . . . . . . . . . . . . . 68 SPECIFICATIONS
ENGINE MOUNT—REAR . . . . . . . . . . . . . . . . . . . 68 4.0L ENGINE SPECIFICATIONS . . . . . . . . . . . . . . 93
EXHAUST MANIFOLD—4.0L ENGINE . . . . . . . . . 73 4.0L TORQUE SPECIFICATIONS . . . . . . . . . . . . . 95
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 77 SPECIAL TOOLS
INTAKE MANIFOLD—4.0L ENGINE . . . . . . . . . . . 72 4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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Fig. 13 Connecting Rod Bearing Inspection

Fig. 16 Rod and Piston Assembly Installation

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Fig. 17 Measuring Bearing Clearance with

Plastigage
ìYíyîsîsï3ì-ð3ñjîžò]óYíyô¬õï3öYó-ñjîžò]÷Ûñ»ð3ð3ñøî×ò]ìùsöóð

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

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Fig. 19 Main Bearing Wear Patterns
NOTE: DO NOT rotate the crankshaft. This will
NOTE: If any of the crankshaft journals are scored, cause the Plastigage to shift, resulting in an inaccu-
remove the engine for crankshaft repair. rate reading. Plastigage must not be permitted to
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more than one bearing size as a pair.
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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 0.025 mm (0.001 in.)
0.0127 mm (0.0015 in.)
Undersize
63.4771 - 63.4644 mm
(2.4991 - 2.4986 in.) Blue - Undersize Blue - Undersize
Blue 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0254 mm (0.001 in.)
Undersize
63.4644 - 63.4517 mm
(2.4986 - 2.4981 in.) Blue - Undersize Green - Undersize
Green 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
0.0381 mm (0.0015 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
(2.4996 - 2.4991 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 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0254 mm (0.001 in.)
Undersize
63.4492 - 63.4365 mm
(2.4980 - 2.4975 in.) Blue - Undersize Green - Undersize
Green 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
0.0381 mm (0.0015 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
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Fig. 23 Left Front Engine Mount
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