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Jeep KJ 2005 Service Manual

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GROUP TAB LOCATOR

Introduction

0

Lubrication & Maintenance

2

Suspension

3

Differential & Driveline

5

Brakes

6

Clutch

7

Cooling

8A

Audio/Video

8B

Chime/Buzzer

8E

Electronic Control Modules

8F

Engine Systems

8G

Heated Systems

8H

Horn

8I

Ignition Control

8J

Instrument Cluster

8L

Lamps

8M

Message Systems

8N

Power Systems

8O

Restraints

8P

Speed Control

8Q

Vehicle Theft Security

8R

Wipers/Washers

8T

Navigation/Telecommunication

8W

Wiring

9

Engine

11

Exhaust System

13

Frame & Bumpers

14

Fuel System

19

Steering

21

Transmission and Transfer Case

22

Tires/Wheels

23

Body

24

Heating & Air Conditioning

25

Emissions Control

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

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Summary of Contents for Jeep KJ 2005

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Navigation/Telecommunication Wiring Engine...
Page 2: Fastener Usage
INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page FASTENER IDENTIFICATION TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 3 INTRODUCTION FASTENER IDENTIFICATION (Continued) BOLT MARKINGS AND TORQUES - U. S. CUSTOMARY Bolt Markings Grade 5 Grade 8 Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs 1/4 - 20 125* 1/4 - 28 150* 5/16 - 18 200* 270* 5/16 - 24 240* 300* 3/8 - 16...
Page 4 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 1 FASTENER STRENGTH...
Page 5: Introduction
INTRODUCTION FASTENER USAGE INTERNATIONAL SYMBOLS DESCRIPTION DESCRIPTION The graphic symbols illustrated in (Fig. 2) and the following International Control and Display Symbols DESCRIPTION Chart are used to identify various instrument con- trols. The symbols correspond to the controls and dis- WARNING: Use of an incorrect fastener may result plays that are located on the instrument panel.
Page 6: Introduction
INTRODUCTION METRIC SYSTEM (Continued) Fig. 3 METRIC CONVERSION CHART...
Page 7 INTRODUCTION METRIC SYSTEM (Continued) CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY TO GET in-lbs = Newton Meters N·m x 8.851 = in-lbs 0.11298 (N·m) ft-lbs = Newton Meters N·m = ft-lbs 1.3558 (N·m) 0.7376 Inches Hg (60° F) x 3.377 = Kilopascals (kPa) = Inches Hg...
Page 8 INTRODUCTION TORQUE REFERENCES (Continued) Fig. 4 TORQUE SPECIFICATIONS...
Page 9: Vehicle Identification Number
INTRODUCTION VEHICLE EMISSION CONTROL VEHICLE IDENTIFICATION INFORMATION (VECI) LABEL NUMBER DESCRIPTION DESCRIPTION All models have a Vehicle Emission Control Infor- The Vehicle Identification Number (VIN) plate is mation (VECI) Label. DaimlerChrysler permanently located on the lower left A-pillar and is visible attaches the label in the engine compartment (Fig.
Page 10: Vehicle Certification Label
CODE = DESCRIPTION Country of Origin 1 = Manufactured by DaimlerChrysler Corporation Make J = Jeep Vehicle Type 4 = MPV W/O Side Airbags. 8 = MPV With Side Airbags. Gross Vehicle Weight Rating F = 4001 - 5000 lbs.
Page 12: Lubrication & Maintenance
LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS MAINTENANCE SCHEDULES DESCRIPTION ......1 DESCRIPTION PARTS &...
Page 13 0 - 2 LUBRICATION & MAINTENANCE PARTS & LUBRICANT RECOMMENDATION (Continued) FLUID TYPES Body Component Fluid, Lubricant, and Genuine DESCRIPTION Part ENGINE OIL Hinges: Door & Hood Mopar Engine Oil WARNING: NEW OR USED ENGINE OIL CAN BE Swing Gate Mopar Multi-Purpose Lube NLGI IRRITATING TO THE SKIN.
Page 14 LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) SAE VISCOSITY GRADE CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. To assure of properly formulated engine oils, it is recommended that SAE Grade 10W-40 engine oils that meet Chrysler material standard MS-6395, be used in accordance to ACEA B3, B4 specification.
Page 15 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) This is normal. ATF+4 also has a unique odor that ENGINE COMPARTMENT RELATED SERVICE IS may change with age. Consequently, odor and color PERFORMED, PERSONAL INJURY CAN RESULT. cannot be used to indicate the fluid condition or the CAUTION: Use of Propylene Glycol based coolants need for a fluid change.
Page 16: Fluid Capacities
LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) must always be a minimum of 44 percent, year- FLUID CAPACITIES round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec- SPECIFICATIONS - FLUID CAPACITIES tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing DESCRIPTION...
Page 17: Maintenance Schedules
0 - 6 LUBRICATION & MAINTENANCE only when the level is at or below the ADD or MIN MAINTENANCE SCHEDULES mark. • Check the windshield washer solvent, add as DESCRIPTION required. Once a Month MAINTENANCE SCHEDULES - GASOLINE • Check the tire pressure and look for unusual ENGINES wear or damage.
Page 18 LUBRICATION & MAINTENANCE 0 - 7 MAINTENANCE SCHEDULES (Continued) Miles 3,000 6,000 9,000 12,000 15,000 (Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) Change the engine oil and engine oil filter, if not replaced at 3 months. Rotate the tires.
Page 19 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 48,000 51,000 54,000 57,000 60,000 (Kilometers) (77 000) (82 000) (86 000) (91 000) (96 000) Replace the ignition cables (2.4L Only). Inspect the brake linings. Drain and refill the front and rear axle fluid‡ Drain and refill the automatic transmission fluid, and replace main sump filter.
Page 20 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 93,000 96,000 99,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (163 000) (168 000) Change the engine oil and engine oil filter, if not replaced at 3 months. Rotate the tires.
Page 21 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Schedule “A” Miles 6,000 12,000 18,000 24,000 30,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) [Months] [12] [18] [24] [30] Change the engine oil and engine oil filter. Rotate the tires.
Page 22 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) Miles 84,000 90,000 96,000 102,000 (Kilometers) (134 000) (144 000) (154 000) (163 000) [Months] [84] [90] [96] [102] Change the engine oil and engine oil filter. Rotate the tires. Inspect the engine air filter element, and replace if necessary.
Page 23 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) MAINTENANCE SCHEDULES - DIESEL ENGINE Once a Month • Check the tire pressure and look for unusual There are two maintenance schedules that show wear or damage. the required service for your vehicle. •...
Page 24 LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) Miles 37,500 43,750 50,000 56,250 62,500 (Kilometers) (60 000) (70 000) (80 000) (90 000) (100 000) Change the engine oil and engine oil filter. Inspect the engine air filter element. Replace as necessary.
Page 25 0 - 14 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Schedule “A” Miles 12,500 25,000 37,500 50,000 (Kilometers) (20 000) (40 000) (60 000) (80 000) Change the engine oil and engine oil filter. Inspect the engine air filter element. Replace as nec- essary.
Page 26 LUBRICATION & MAINTENANCE 0 - 15 MAINTENANCE SCHEDULES (Continued) Once a Month At Each Oil Change • Check the tire pressure and look for unusual • Change the engine oil filter. • Inspect the exhaust system. wear or damage. • Inspect the battery, and clean and tighten the •...
Page 27 0 - 16 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Kilometers 120 000 132 000 144 000 156 000 (Miles) (75,000) (82,500) (90,000) (97,500) [Months] [60] [66] [72] [78] Replace the spark plugs. Inspect and replace the PCV valve, if necessary. Inspect the brake linings.
Page 28 LUBRICATION & MAINTENANCE 0 - 17 MAINTENANCE SCHEDULES (Continued) • Short trips of less than 16.2 km (10 miles). Schedule “B” • More than 50% of your driving is at sustained Follow schedule “B” if you usually operate your high speeds during hot weather, above 32°C (90°F). vehicle under one or more of the following conditions.
Page 29 0 - 18 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Kilometers 77 000 82 000 86 000 91 000 96 000 (Miles) (48,000) (51,000) (54,000) (57,000) (60,000) Replace the spark plugs. Inspect and replace the PCV valve, if neces- sary. Replace the ignition cables (2.4L Only). Inspect the brake linings.
Page 30 LUBRICATION & MAINTENANCE 0 - 19 MAINTENANCE SCHEDULES (Continued) Kilometers 149 000 154 000 158 000 163 000 168 000 (Miles) (93,000) (96,000) (99,000) (102,000) (105,000) Change the engine oil and engine oil filter. Rotate the tires. Inspect the engine air filter element, replace if necessary.
Page 31 0 - 20 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • More than 50% of your driving is at sustained Once a Month • Check the tire pressure and look for unusual high speeds during hot weather, above 32° C (90° F). •...
Page 32 LUBRICATION & MAINTENANCE 0 - 21 MAINTENANCE SCHEDULES (Continued) Kilometers 120 000 km 140 000 km 160 000 km 180 000 km Replace the engine air filter element. Replace the fuel filter/water separator unit. Flush and replace the engine coolant. Inspect the ball joints.
Page 33 0 - 22 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Kilometers 60 000 70 000 80 000 90 000 100 000 Change the engine oil and engine oil filter. Inspect the engine air filter element. Replace as necessary. Replace the engine air filter element. Replace the fuel filter/water separator unit.
Page 34: Suspension
When properly positioned, a floor jack can be used POINTS PROVIDED ARE FOR A COMPLETE VEHI- to lift a Jeep vehicle (Fig. 5). Support the vehicle in CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO- the raised position with jack stands at the front and NENT IS REMOVED FROM A VEHICLE, THE rear ends of the frame rails.
Page 35 A vehicle equipped with SAE approved wheel lift- clamp to battery positive (+) terminal. Connect type towing equipment can be used to tow Jeep vehi- BLACK jumper cable clamp to the engine as close to cles. When towing a 4WD vehicle using a wheel-lift the ground cable connection as possible (Fig.
Page 36 LUBRICATION & MAINTENANCE 0 - 25 TOWING (Continued) SAFETY PRECAUTIONS CAUTION: Do not use steering column lock to secure steering wheel during towing operation. CAUTION: The following safety precautions must be (6) Secure steering wheel in straight ahead posi- observed when towing a vehicle: tion with a clamp device designed for towing.
Page 37 0 - 26 LUBRICATION & MAINTENANCE TOWING (Continued) (3) Raise the front of the vehicle off the ground (1) Attach wheel lift device to rear wheels. and install tow dollies under front wheels. (2) Place the transmission in neutral. (4) Attach wheel lift device to rear wheels and (3) Raise the rear of the vehicle off the ground and raise vehicle to towing position.
Page 38 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page SUSPENSION WHEEL ALIGNMENT ..... . 3 DIAGNOSIS AND TESTING - SUSPENSION FRONT .
Page 39 2 - 2 SUSPENSION SUSPENSION (Continued) CONDITION POSSIBLE CAUSES CORRECTION VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires. DRIFTS FROM STRAIGHT 2. Brakes dragging. 2. Repair brake as necessary. AHEAD DIRECTION ON UNCROWNED ROAD 3. Weak or broken spring. 3.
Page 40 WHEEL ALIGNMENT 2 - 3 WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT STANDARD PROCEDURE - TOE DESCRIPTION ......3 ADJUSTMENT .
Page 41 2 - 4 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle (Fig. 1) STANDARD PROCEDURE STANDARD PROCEDURE - HEIGHT MEASUREMENT RIDE HEIGHT NOTE: The suspension is non-adjustable. The vehicle suspension height should be measured before performing wheel alignment procedure.
Page 42 WHEEL ALIGNMENT 2 - 5 WHEEL ALIGNMENT (Continued) (2) Loosen the tie rod jam nuts. Measure- Target Minimum Maximum ment NOTE: Each front wheel should be adjusted for Front Ride 66.5 mm 56.5 mm 76.5 mm one-half of the total toe position specification. This Height Z=996.8 - will ensure the steering wheel will be centered...
Page 43 2 - 6 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CAMBER SPECIFICATIONS Move both of the cam bolts together in or out. This ALIGNMENT will change the camber angle significantly and caster angle slightly. (Fig. 4) After adjustment is made tighten the cam bolt nuts NOTE: Specifications are in degrees.
Page 44 FRONT 2 - 7 FRONT TABLE OF CONTENTS page page FRONT REMOVAL ......13 DESCRIPTION .
Page 45 2 - 8 FRONT FRONT (Continued) WARNING WARNING: Suspension components with rubber bushings must be tightened with the vehicle at nor- mal ride height. It is important to have the springs supporting the weight of the vehicle when the fas- teners are torqued.
Page 46 FRONT 2 - 9 FRONT (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Stabilizer Bar Link Upper — Stabilizer Bar Link Lower — Hub/Bearing — Bolt Hub/Bearing — Halfshaft Nut Upper Ball Joint Nut — Lower Ball Joint Nut — Wheel Speed Sensor 13.5 —...
Page 47 2 - 10 FRONT NOTE: Extreme pressure lubrication must be used on BUSHINGS the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation REMOVAL during the removal and installation process. (2) Press the bushing out using special tools REMOVAL - STABILIZER BAR BUSHINGS 8858-1 (receiver), 8858-3 (driver) and 8839 with the (1) Raise vehicle on hoist.
Page 48 FRONT 2 - 11 BUSHINGS (Continued) Fig. 4 UPPER CONTROL ARM BUSHING REMOVAL Fig. 5 LOWER CONTROL ARM BUSHING - INSTALLATION 1 - 8830-3 (ADAPTER) 2 - 8830-2 (RECIEVER) 1 - 8858-5 DRIVER 3 - 8830-4 (DRIVER) 2 - 8858-6 RECEIVER 4 - 8838 (THREADED ROD) 3 - 8839 THREADED ROD INSTALLATION - LOWER CONTROL ARM...
Page 49 2 - 12 FRONT BUSHINGS (Continued) INSTALLATION - UPPER CONTROL ARM (3) Remove the caliper adapter (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BUSHINGS BRAKE CALIPERS - REMOVAL). NOTE: Extreme pressure lubrication must be used CAUTION: Never allow the disc brake caliper to on the threaded portions of the tool.
Page 50 FRONT 2 - 13 KNUCKLE (Continued) CAUTION: Never allow the disc brake caliper to LOWER BALL JOINT hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang DIAGNOSIS AND TESTING - LOWER BALL the caliper securely.
Page 51 2 - 14 FRONT LOWER BALL JOINT (Continued) (1) Install the ball joint into the steering knuckle and press in using special tools C-4212–F (press), 8859-3 (driver) and 6761 (receiver) (Fig. 10). Fig. 8 SUSPENSION IN THE CURB POSITION 1 - PRY BAR 2 - BALL JOINT 3 - DIAL INDICATOR Fig.
Page 52 FRONT 2 - 15 LOWER CONTROL ARM (Continued) (4) Remove the stabilizer link bolt at the lower (9) Perform a full wheel alignment (Refer to 2 - control arm. SUSPENSION/WHEEL ALIGNMENT - STANDARD (5) Remove the lower ball joint nut. PROCEDURE).
Page 53 2 - 16 FRONT SHOCK (Continued) INSTALLATION INSTALLATION - LEFT SIDE (1) Install the spring to the shock (if removed). (2) Install the shock assembly to the vehicle. (3) Install the four upper shock mounting nuts. Tighten the nuts to 108 N·m (80 ft.lbs.). (4) Install the clevis bracket at the shock.
Page 54 FRONT 2 - 17 SHOCK (Continued) (Refer to 2 - SUSPENSION/FRONT/STABILIZER (2) Install the shock mounting nut. Tighten the LINK - INSTALLATION). bolt to 41 N·m (30 ft.lbs.). (8) Install the right tire and wheel assembly. (3) Loosen the compressed spring. (Refer to 22 - TIRES/WHEELS/WHEELS - STAN- (4) Remove the shock assembly from the spring DARD PROCEDURE).
Page 55 2 - 18 FRONT CLEVIS BRACKET (Continued) (2) Raise the lower control arm to the lower ball STABILIZER LINK joint. (3) Install the nut to the lower ball joint. Tighten REMOVAL the nut to 81 N·m (60 ft.lbs.). (1) Raise and support the vehicle. (4) Install the clevis bracket to the lower control (2) Remove the tire and wheel assembly.
Page 56 FRONT 2 - 19 UPPER CONTROL ARM (Continued) (7) Remove the cruise control servo mounting nuts. (5) Install the air box (Refer to 9 - ENGINE/AIR (8) Remove the upper control arm rear bolt. INTAKE SYSTEM/AIR CLEANER ELEMENT - (9) Remove the upper control arm front bolt. INSTALLATION).
Page 57 2 - 20 REAR REAR TABLE OF CONTENTS page page REAR UPPER CONTROL ARM DESCRIPTION ......20 DESCRIPTION - UPPER SUSPENSION ARM, WARNING .
Page 58 REAR 2 - 21 REAR (Continued) WARNING supporting the weight of the vehicle when the fas- teners are torqued. If springs are not at their normal ride position, vehicle ride comfort will be affected WARNING: Suspension components with rubber and cause premature bushing wear. bushings must be tightened with the vehicle at nor- mal ride height.
Page 59 2 - 22 REAR REAR (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Suspension Arms Lower — Body/Axle Bracket Nut Control Arms to Control — Arm Bracket Suspension Arms Lower — Frame Bracket Nut Control Arm Bracket to — Rear Differential Rear Differential Damper —...
Page 60 REAR 2 - 23 SHOCK (Continued) INSTALLATION (1) Install the upper isolator (Fig. 3). (2) Install the lower isolator (Fig. 3). (3) Pull down on the axle and position the coil spring in the lower isolator. CAUTION: Ensure the spring is positioned on the lower isolator.
Page 61 2 - 24 REAR STABILIZER BAR UPPER BALL JOINT REMOVAL REMOVAL (1) Raise and support the vehicle. (1) Raise and support the vehicle. (2) Remove the stabilizer bar bolts from the lower (2) Support the rear axle with a hydraulic jack. suspension arm.
Page 62 REAR 2 - 25 UPPER BALL JOINT (Continued) INSTALLATION OPERATION - UPPER SUSPENSION ARM, (1) Install special tools C-4212F (press), 8861-1 BUSHINGS, AND BALL JOINT (receiver) and 8861-2 (driver) with the ball joint in The upper suspension arm provides fore/aft and place (Fig.
Page 63 2 - 26 REAR UPPER CONTROL ARM (Continued) Fig. 12 LOWER SUSPENSION ARM Fig. 11 BALL JOINT BRACKET 1 - AXLE BRACKET BOLT 1 - UPPER BALL JOINT 2 - LOWER CONTROL ARM 2 - SUPPORT BRACKET BOLTS 3 - BODY BRACKET BOLT (5) Remove the supports and lower the vehicle.
Page 64 REAR 2 - 27 BUSHINGS (Continued) (3) Install special tools 8862-4 (receiver), 8862-5 (spacer) and 8862-1 or 8862- 2 (driver) with the threaded rod 8839 and the bearing as shown (Fig. 13) Fig. 14 UPPER SUSPENSION ARM BUSHING - REMOVAL 1 - 8853-3 DRIVER 2 - 8860-1 RECEIVER Fig.
Page 65 2 - 28 REAR BUSHINGS (Continued) INSTALLATION - UPPER SUSPENSION ARM BUSHING NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation pro- cess.
Page 66: Differential & Driveline
DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . 1 FRONT AXLE - 186FIA .
Page 67: Brakes
3 - 2 PROPELLER SHAFT PROPELLER SHAFT (Continued) DRIVELINE VIBRATION 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.
Page 68 PROPELLER SHAFT 3 - 3 PROPELLER SHAFT (Continued) positions, the source of the vibration may not be pro- RUNOUT peller shaft. RUNOUT SPECIFICATIONS Front of Shaft 0.020 in. (0.50 mm) Center of Shaft 0.025 in. (0.63 mm) Rear of Shaft 0.020 in.
Page 69 3 - 4 PROPELLER SHAFT PROPELLER SHAFT (Continued) (5) Rotate propeller shaft 90 degrees and place inclinometer (2) (Fig. 5) on yoke bearing cap (1) or propeller shaft tube on C/V propeller shaft, parallel to the shaft. Center bubble in sight glass and record measurement.
Page 70 PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Front Shaft - Companion Flange Bolts Rear Shaft - Companion Flange Bolts SPECIAL TOOLS (3) Mark companion flanges (3) and C/V joints at the front (2) and rear of the propeller shaft for instal- lation reference.
Page 71 3 - 6 PROPELLER SHAFT SHAFT-PROPELLER FRONT (Continued) GAS ENGINES Fig. 10 TRANSFER CASE COMPANION FLANGE 1 - FLANGE BOLT Fig. 9 TRANSFER CASE COMPANION FLANGE 2 - COMPANION FLANGE 1 - FLANGE BOLT 2 - COMPANION FLANGE (4) Install rear C/V joint bolts (1) (Fig. 10) and tighten to 30 N·m (22 ft.
Page 72 PROPELLER SHAFT 3 - 7 SHAFT-PROPELLER REAR (Continued) (2) Mark a reference line (3) (Fig. 11) across com- INSTALLATION panion flanges (2) (4) and propeller shaft (1) for installation. Fig. 12 DUST BOOT CLAMP 1 - SLINGER 2 - BOOT 3 - AWL 4 - TRANSFER CASE Fig.
Page 73 3 - 8 PROPELLER SHAFT SHAFT-PROPELLER REAR (Continued) (3) Install companion flange bolts and tighten to 115 N·m (85 ft. lbs.). (4) Tighten dust boot (3) (Fig. 15) clamp (4) if equipped with Clamp C-4975A (1). UNIVERSAL JOINT-SINGLE CARDAN DISASSEMBLY - WITH SNAP RINGS Fig.
Page 74 PROPELLER SHAFT 3 - 9 UNIVERSAL JOINT-SINGLE CARDAN (Continued) CAUTION: If cross or bearing cap are not straight (1) Apply (EP) N.L.G.I. Grade 1 or 2 grease to during removal, the bearing cap will score the walls inside of yoke bores. (2) Position cross (1) (Fig.
Page 75 3 - 10 HALF SHAFT HALF SHAFT TABLE OF CONTENTS page page HALF SHAFT SPECIAL TOOLS ..... . . 12 CAUTION .
Page 76 HALF SHAFT 3 - 11 HALF SHAFT (Continued) (3) Remove stabilizer link (2) (Fig. 1) from stabi- (6) Pull out on the steering knuckle and push the lizer bar (1). half shaft out of the knuckle. (7) With a pry bar remove the half shaft from the axle.
Page 77 3 - 12 HALF SHAFT HALF SHAFT (Continued) NOTE: Seperate right half shaft from axle shaft in a (6) Align clevis (2) with knuckle. Install and vise if necessary and install axle shaft in the axle. tighten lower clevis bolt (3) to specifications (Fig. 5). (1) Apply a light coat of wheel bearing grease on the female splines of the inner C/V joint.
Page 78 HALF SHAFT 3 - 13 (5) Spread snap ring (1) and slide the joint off the JOINT/BOOT-C/V OUTER shaft (Fig. 8). REMOVAL Fig. 9 BEARING ACCESS Fig. 7 BOOT CLAMP LOCATIONS 1 - ALIGNMENT MARKS 1 - C/V HOUSING 2 - BEARING HUB 2 - CLAMP 3 - BEARING CAGE 3 - HALF SHAFT...
Page 79 3 - 14 HALF SHAFT JOINT/BOOT-C/V OUTER (Continued) (10) Remove ball (4) from the bearing cage (3) (Fig. (13) Turn inner race 90° in the cage and rotate the 10). inner race/hub out of the cage (Fig. 12). INSTALLATION Fig. 11 CAGE AND INNER RACE/HUB 1 - HOUSING Fig.
Page 80 HALF SHAFT 3 - 15 JOINT/BOOT-C/V OUTER (Continued) (4) Rotate inner race/hub in the cage (1) (Fig. 14). (6) Rotate cage 90° into the housing (1) (Fig. 16). (7) Apply lubricant included with replacement boot/joint to the ball races. Spread lubricant equally between all the races.
Page 81 3 - 16 HALF SHAFT JOINT/BOOT-C/V OUTER (Continued) (11) Push the joint onto the shaft until the snap ring (1) seats in the groove (3) (Fig. 18). Pull on the joint to verify the span ring has engaged. (12) Position boot on the joint in it’s original posi- tion.
Page 82 HALF SHAFT 3 - 17 JOINT/BOOT-C/V INNER (Continued) (4) Remove lubricant from housing (1) to expose (7) Remove spread inner race (1) snap ring (4) and the C/V snap ring (2) and remove snap ring (Fig. 21). remove race (1) from the shaft (3) (Fig. 23). (8) Remove boot from the shaft and discard.
Page 83 3 - 18 HALF SHAFT JOINT/BOOT-C/V INNER (Continued) INSTALLATION (4) Install the inner race (1) (Fig. 26) onto the shaft (3). Pull on the race to verify snap ring has engaged. Fig. 25 BEARING CAGE 1 - SHAFT Fig. 27 CAGE/INNER RACE 2 - CAGE 3 - SMALL DIAMETER 1 - CAGE...
Page 84 HALF SHAFT 3 - 19 JOINT/BOOT-C/V INNER (Continued) (7) Apply grease to the inner race and bearings (11) Slide the boot onto the C/V housing into it’s and install the bearings. original position. Ensure boot is not twisted and (8) Apply grease to the housing bore (4) (Fig. 28) remove any excess air.
Page 85 3 - 20 FRONT AXLE - 186FIA FRONT AXLE - 186FIA TABLE OF CONTENTS page page FRONT AXLE - 186FIA BEARING-AXLE DIAGNOSIS AND TESTING REMOVAL ......41 FRONT AXLE - 186FIA .
Page 86: Clutch
FRONT AXLE - 186FIA 3 - 21 FRONT AXLE - 186FIA (Continued) • Loose wheel lug nuts. • Transmission shift operation. • Worn U-joints/CV joint. • Loose engine/transmission/transfer case mounts. • Loose/broken springs. • Worn U-joints/CV joint. • Damaged axle shaft bearing(s). •...
Page 87 3 - 22 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 88 FRONT AXLE - 186FIA 3 - 23 FRONT AXLE - 186FIA (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage.
Page 89 3 - 24 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) REMOVAL (6) Remove stabilizer bar (1) links (2) from the lower control arms (Fig. 2). Fig. 3 LOWER CONTROL ARM 1 - FRONT CAM BOLT 2 - OUTER TIE ROD END 3 - LOWER BALL JOINT NUT 4 - LOWER CONTROL ARM 5 - REAR CAM BOLT...
Page 90 FRONT AXLE - 186FIA 3 - 25 FRONT AXLE - 186FIA (Continued) Fig. 5 DRAIN TROUGH Fig. 7 RIGHT AXLE BRACKET 1 - TROUGH 1 - RIGHT AXLE BRACKET 2 - MOUNTING NUT 2 - FRONT BRACKET BOLT 3 - REAR BRACKET BOLT NOTE: Right half shaft has a splined axle that may come out with the half shaft.
Page 91 3 - 26 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) (18) Remove bolt (2) from left rear axle bracket (1) frame mount (Fig. 8). (19) Lower axle and from vehicle. INSTALLATION Fig. 10 LEFT AXLE BRACKET 1 - LEFT REAR AXLE BRACKET 2 - BRACKET BOLT Fig.
Page 92 FRONT AXLE - 186FIA 3 - 27 FRONT AXLE - 186FIA (Continued) (16) Install skid plate. (17) Tighten clevis and stabilizer links bolts to specifications. (18) Check vehicle alignment. ADJUSTMENTS Fig. 12 LOWER CONTROL ARM 1 - FRONT CAM BOLT 2 - OUTER TIE ROD END 3 - LOWER BALL JOINT NUT 4 - LOWER CONTROL ARM...
Page 93 3 - 28 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0.001 +0.006...
Page 94 FRONT AXLE - 186FIA 3 - 29 FRONT AXLE - 186FIA (Continued) (4) Position Arbor Disc 6732 (2) (Fig. 16) and Arbor DIFFERENTIAL SIDE BEARING PRELOAD AND D-115-3 (3) into the housing bearing cradles. Install GEAR BACKLASH differential bearing caps on Arbor Discs and tighten bolts to 41 N·m (30 ft.
Page 95 3 - 30 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) PRELOAD SHIM SELECTION Fig. 20 BEARING CAP BOLTS 1 - BEARING CAPS 2 - HOUSING 3 - BOLTS Fig. 19 DUMMY SHIMS 1 - DUMMY SHIM 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE 4 - DUMMY BEARINGS NOTE: It is difficult to salvage the differential side...
Page 96 FRONT AXLE - 186FIA 3 - 31 FRONT AXLE - 186FIA (Continued) (8) With a dead-blow hammer (2) (Fig. 22), seat (12) Push and hold differential case to ring gear the differential dummy bearings to the ring gear (3) side of the housing (2) (Fig. 24) and record dial indi- side of the housing (1).
Page 97 3 - 32 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) Fig. 26 DIFFERENTIAL RING GEAR SIDE Fig. 27 RING GEAR BACKLASH 1 - DIAL INDICATOR 1 - DIAL INDICATOR 2 - PINION GEAR 2 - RING GEAR 3 - RING GEAR (6) Verify differential case and ring gear runout by the shim thickness required on the pinion side of the measuring ring to pinion gear backlash at eight loca-...
Page 98 FRONT AXLE - 186FIA 3 - 33 FRONT AXLE - 186FIA (Continued) GEAR CONTACT PATTERN NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered it is a 2 Axis cut gear. (1) Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth.
Page 99 3 - 34 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) Fig. 30 PATTERN INTERPRETATION (GEAR CUT 2 AXIS) Fig. 31 PINION ROTATING TORQUE 1 - PINION COMPANION FLANGE 2 - TORQUE WRENCH...
Page 100 FRONT AXLE - 186FIA 3 - 35 FRONT AXLE - 186FIA (Continued) TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Ring Gear Bolts 95-122 70-90 Differential Bearing Cap 54-67 39-50 Bolts Differential Cover Bolts 19-26 14-19 Pinion Nut 217-352 160-260 Left Axle Bracket Bolts Front Axle Bracket Bolts Right Axle Bracket Bolts...
Page 101 3 - 36 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) DUMMY BEARINGS D-348 REMOVER C-4307 PLUG SP-3289 INSTALLER C-4308 PULLER C-452 SPREADER W-129-B INSTALLER D-146 INSTALLER W-162-D REMOVER D-149 INSTALLER 6448...
Page 102 FRONT AXLE - 186FIA 3 - 37 FRONT AXLE - 186FIA (Continued) DUMMY SHIMS 8107 PINION DEPTH SET 6774 CUP 8109 SPANNER WRENCH 6958 REMOVER 8420A ADAPTER KIT 6987B INSTALLER 8681 REMOVER 7794-A...
Page 103 3 - 38 FRONT AXLE - 186FIA FRONT AXLE - 186FIA (Continued) COVER-DIFFERENTIAL REMOVAL PINION BLOCK 8804 Fig. 32 DRAIN PLUG 1 - LEFT FRONT AXLE BRACKET INSTALLER 8805 2 - DRAIN PLUG 3 - DIFFERENTIAL HOUSING (1) With vehicle in neutral, position vehicle on hoist.
Page 104 FRONT AXLE - 186FIA 3 - 39 COVER-DIFFERENTIAL (Continued) Fig. 35 APPLY SEALANT 1 - SEALANT 2 - DIFFERNTIAL COVER Fig. 33 DRAIN TROUGH 1 - TROUGH 2 - MOUNTING NUT Fig. 36 DIFFERENTIAL COVER Fig. 34 LEFT FRONT AXLE BRACKET 1 - COVER 1 - LEFT FRONT AXLE BRACKET 2 - VENT TUBE...
Page 105 3 - 40 FRONT AXLE - 186FIA SHAFT-AXLE REMOVAL Fig. 37 AXLE SHAFT PULLER 1 - SNAP RING GROVE 2 - SLID HAMMER THREADS Fig. 38 AXLE SHAFT SEAL 3 - REMOVER BLOCKS 1 - BEARING 4 - REMOVER COLLAR 2 - SEAL (1) With vehicle in neutral, position vehicle on SEAL-AXLE SHAFT...
Page 106 FRONT AXLE - 186FIA 3 - 41 SEAL-AXLE SHAFT (Continued) INSTALLATION Fig. 41 SHAFT BEARING REMOVER 1 - SHAFT BEARING Fig. 40 SEAL INSTALLER 2 - REMOVER 1 - INSTALLER 8806 2 - HANDLE C-4171 (1) Apply a light coat of lubricant on the lip of the shaft seal.
Page 107 3 - 42 FRONT AXLE - 186FIA SEAL-PINION REMOVAL Fig. 45 PINION FLANGE REMOVER 1 - SPANNER WRENCH 2 - REMOVER (8) Pry pinion seal out with a seal pick. Fig. 43 PINION ROTATING TORQUE 1 - PINION COMPANION FLANGE INSTALLATION 2 - TORQUE WRENCH (1) With vehicle in neutral, position vehicle on...
Page 108 FRONT AXLE - 186FIA 3 - 43 SEAL-PINION (Continued) CAUTION: Never loosen pinion nut to decrease pin- ion rotating torque and never exceed specified pre- load torque. Failure to follow these instructions will result in damage. (4) Rotate pinion a minimum of ten time and ver- ify pinion rotates smoothly.
Page 109 3 - 44 FRONT AXLE - 186FIA DIFFERENTIAL (Continued) (5) Position Spreader W-129-B (3) (Fig. 49) onto differential locating holes and install the safety hold- down clamps (2). Tighten spreader turnbuckle (4) fin- ger-tight. Fig. 51 DIFFERENTIAL CASE 1 - DIFFERENTIAL HOUSING 2 - DIFFERENTIAL CASE 3 - DIFFERENTIAL BEARINGS DISASSEMBLY...
Page 110 FRONT AXLE - 186FIA 3 - 45 DIFFERENTIAL (Continued) (3) Remove pinion gear mate shaft. (4) Rotate differential side gears (2) (Fig. 52) and remove pinion gears (3) and thrust washers (1). (5) Remove differential side gears and thrust washers. ASSEMBLY Fig.
Page 111 3 - 46 FRONT AXLE - 186FIA DIFFERENTIAL (Continued) (2) Install Pilot Stud C-3288-B to the left side of (7) Loosen turnbuckle (4) (Fig. 56) remove safety the differential housing. Attach Dial Indicator C-3339 clamp (2) and remove spreader (3). to pilot stud.
Page 112 FRONT AXLE - 186FIA 3 - 47 BEARING-DIFFERENTIAL CASE (Continued) INSTALLATION Fig. 59 RING GEAR 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER Fig. 58 DIFFERENTIAL CASE BEARINGS 1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER (1) Install differential case (2) (Fig.
Page 113 3 - 48 FRONT AXLE - 186FIA GEAR-PINION/RING (Continued) Fig. 61 PINION FLANGE REMOVER 1 - SPANNER WRENCH 2 - REMOVER (6) Remove pinion companion flange from pinion shaft with Spanner Wrench 6958 (1) (Fig. 61) and Remover C-452 (2). Fig.
Page 114 FRONT AXLE - 186FIA 3 - 49 GEAR-PINION/RING (Continued) (11) Remove rear pinion bearing from the pinion (4) (Fig. 66) with Puller/Press C-293-PA (1) and Adapters C-293-42 (3). Remove oil slinger/pinion depth shim from the pinion shaft and record thick- ness.
Page 115 3 - 50 FRONT AXLE - 186FIA GEAR-PINION/RING (Continued) Fig. 70 PINION FLANGE NUT 1 - SPANNER WRENCH 2 - PINION COMPANION FLANGE (9) Install pinion a new nut onto the pinion gear and tighten the nut to 216 N·m (160 ft. lbs.). Do not over-tighten.
Page 116 FRONT AXLE - 186FIA 3 - 51 GEAR-PINION/RING (Continued) (12) Rotate the pinion a minimum of ten times. Verify pinion (1) (Fig. 71) rotates smoothly and check rotating torque with an inch pound torque wrench (2). Pinion gear rotating torque is: •...
Page 117 3 - 52 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 TABLE OF CONTENTS page page REAR AXLE - 8 1/4 SEAL-PINION DIAGNOSIS AND TESTING ....52 REMOVAL .
Page 118 REAR AXLE - 8 1/4 3 - 53 REAR AXLE - 8 1/4 (Continued) • Missing drive shaft balance weight(s). DRIVELINE SNAP • Worn or out-of-balance wheels. A snap or clunk noise when the vehicle is shifted • Loose wheel lug nuts. into gear or the clutch engaged, can be caused by: •...
Page 119 3 - 54 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) Condition Possible Causes Correction Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Improper grade of lubricant. 2.
Page 120 REAR AXLE - 8 1/4 3 - 55 REAR AXLE - 8 1/4 (Continued) Condition Possible Causes Correction Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2. Check ring gear and pinion adjustment.
Page 121 3 - 56 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) INSTALLATION Fig. 3 SHOCK ABSORBER 1 - UPPER MOUNTING BOLT Fig. 5 LOWER SUSPENSION ARM 2 - LOWER MOUNTING BOLT 1 - AXLE BRACKET BOLT 2 - LOWER CONTROL ARM (9) Remove shock absorbers from axle brackets (2) 3 - BODY BRACKET BOLT (Fig.
Page 122 REAR AXLE - 8 1/4 3 - 57 REAR AXLE - 8 1/4 (Continued) ADJUSTMENTS Fig. 7 BALL JOINT PINCH BOLT Fig. 9 PINION ID NUMBERS 1 - UPPER BALL JOINT 2 - PINCH BOLT 1 - VARIANCE NUMBER 2 - SEQUENCE NUMBER (5) Install upper control arm ball joint (1) into axle Ring gear and pinion are supplied as matched sets.
Page 123 3 - 58 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) Compensation pinion depth variance number is negative, add that value to the required achieved with select shims (4). The shims are placed thickness of the depth shims. If the number is posi- behind the rear pinion bearing (Fig.
Page 124 REAR AXLE - 8 1/4 3 - 59 REAR AXLE - 8 1/4 (Continued) Fig. 13 GAUGE TOOLS IN HOUSING 1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK Fig. 11 PINION DEPTH GAUGE 1 - DIAL INDICATOR 2 - ARBOR 3 - PINION HEIGHT BLOCK...
Page 125 3 - 60 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft. lbs.) (7) Measure the ring gear backlash. The range of backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Page 126 REAR AXLE - 8 1/4 3 - 61 REAR AXLE - 8 1/4 (Continued) Decrease backlash by moving ring gear closer to the pinion gear using the adjusters. Fig. 17 RING GEAR IS TOO FAR AWAY 1 - COAST SIDE 2 - DRIVE SIDE Fig.
Page 127 3 - 62 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) Pinion gear is set too high. Decrease pinion height (3) If side gear clearances is no more than 0.005 by decreasing the pinion depth shim thickness (Fig. inch.
Page 128 REAR AXLE - 8 1/4 3 - 63 REAR AXLE - 8 1/4 (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 3.73, 4.10 Differential Case Flange Runout 0.076 mm (0.003 in.) Differential Case Clearance 0.12 mm (0.005 in.) Ring Gear Diameter 209.5 mm (8.25 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Page 129 3 - 64 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) DIAL INDICATOR C-3339 REMOVER C-4307 INSTALLER C-4308 INSTALLER C-4076-B ADJUSTMENT WRENCH C-4164 INSTALLER C-4340 REMOVER C-4345 HANDLE C-4171 PULLER C-452 INSTALLER C-4198...
Page 130 REAR AXLE - 8 1/4 3 - 65 REAR AXLE - 8 1/4 (Continued) HOLDER 6719A HANDLE C-4735 PINION GAUGE SET 6774 INSTALLER D-130 FIXTURE 8138 ADAPTER PLUG SP-3289 PINION BLOCK 8540 REMOVER 6310 ARBOR DISCS 8541 INSTALLER 6448...
Page 131 3 - 66 REAR AXLE - 8 1/4 COVER-DIFFERENTIAL REMOVAL (1) With vehicle in neutral, position vehicle on hoist. (2) Remove drain plug. (3) Remove cover bolts. (4) Remove cover and drain lubricant. INSTALLATION Fig. 26 LOCK SCREW 1 - PINION MATE SHAFT 2 - BEARING CAP BOLT 3 - ADJUSTER LOCK BOLT 4 - LOCK SCREW...
Page 132 REAR AXLE - 8 1/4 3 - 67 SHAFT-AXLE (Continued) INSTALLATION Fig. 29 AXLE SHAFT SEAL 1 - SEAL Fig. 28 LOCK SCREW 2 - AXLE TUBE 1 - PINION MATE SHAFT 2 - BEARING CAP BOLT 3 - ADJUSTER LOCK BOLT 4 - LOCK SCREW (1) Lubricate bearing bore and seal lip with gear lubricant.
Page 133 3 - 68 REAR AXLE - 8 1/4 (4) Insert bearing remover foot through BEARING-AXLE receiver (2) and bearing (1) (Fig. 32). REMOVAL Fig. 33 BEARING REMOVER ASSEMBLY 1 - NUT Fig. 31 BEARING RECEIVER 2 - BEARING 1 - RECEIVER 3 - RECEIVER 2 - AXLE BEARING 4 - SHAFT...
Page 134 REAR AXLE - 8 1/4 3 - 69 BEARING-AXLE (Continued) (2) Install axle shaft bearing with Installer C-4198 (1) and Handle C-4171 (2) (Fig. 34). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer.
Page 135 3 - 70 REAR AXLE - 8 1/4 SEAL-PINION (Continued) Fig. 37 COMPANION FLANGE PULLER Fig. 39 TIGHTENING PINION NUT 1 - COMPANION FLANGE 2 - PULLER 1 - DIFFERENTIAL HOUSING 2 - COMPANION FLANGE HOLDER 3 - TORQUE WRENCH Fig.
Page 136 REAR AXLE - 8 1/4 3 - 71 SEAL-PINION (Continued) CAUTION: Never loosen pinion nut to decrease pin- DIFFERENTIAL ion bearing rotating torque and never exceed spec- ified preload torque. Failure follow these REMOVAL instructions will result in damage. (10) If rotating torque is low use Holder 6719 to hold the companion flange and tighten pinion nut in 6.8 N·m (5 ft.
Page 137 3 - 72 REAR AXLE - 8 1/4 DIFFERENTIAL (Continued) (7) Loosen differential bearing cap bolts (2) (Fig. (1) Rotate one pinion gear (2) with thrust washer 43). (3) to the differential window (1) and remove gear and thrust washer (Fig. 45). Fig.
Page 138 REAR AXLE - 8 1/4 3 - 73 DIFFERENTIAL (Continued) ASSEMBLY (3) Install first pinion gear (3) with thrust washer into differential window (1) and side gears (2) (Fig. 49). Rotate pinion gear into the case. (4) Install remaining pinion gear and thrust washer.
Page 139 3 - 74 REAR AXLE - 8 1/4 extreme cases of differences of traction, the wheel DIFFERENTIAL-TRAC-LOK with the least traction may spin. OPERATION DIAGNOSIS AND TESTING DIFFERENTIAL-TRAC-LOK Fig. 52 Trac-lok™ Test-Typical 1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE 2 - TORQUE WRENCH The most common problem is a chatter noise when turning corners.
Page 140 REAR AXLE - 8 1/4 3 - 75 BEARING-DIFFERENTIAL CASE REMOVAL Fig. 54 Differential Bearing Installer 1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER GEAR-PINION/RING REMOVAL Fig. 53 DIFFERENTIAL BEARING PULLER 1 - PULLER 2 - ADAPTERS 3 - BEARING 4 - DIFFERENTIAL 5 - PLUG...
Page 141 3 - 76 REAR AXLE - 8 1/4 GEAR-PINION/RING (Continued) (2) Place differential case (1) in a vise with soft metal jaw. (3) Remove bolts holding ring gear (2) to differen- tial case. (4) Drive ring gear from differential case with a dead-blow hammer (3) (Fig.
Page 142 REAR AXLE - 8 1/4 3 - 77 GEAR-PINION/RING (Continued) (12) Remove collapsible spacer (1) from pinion (3) (Fig. 60). Fig. 59 REAR PINION BEARING CUP 1 - DRIVER 2 - HANDLE Fig. 61 REAR PINION BEARING PULLER (11) Remove rear bearing cup with Remover 1 - PULLER C-4307 (1) and Handle C-4171 (2) (Fig.
Page 143 3 - 78 REAR AXLE - 8 1/4 GEAR-PINION/RING (Continued) INSTALLATION Fig. 63 FRONT BEARING CUP 1 - INSTALLER 2 - HANDLE Fig. 62 REAR PINION BEARING CUP 1 - INSTALLER 2 - HANDLE NOTE: A pinion depth shim/oil baffle is placed between the rear pinion bearing cone and pinion gear.
Page 144 REAR AXLE - 8 1/4 3 - 79 GEAR-PINION/RING (Continued) Fig. 65 REAR PINION BEARING Fig. 66 COLLAPSIBLE PRELOAD SPACER 1 - PRESS 1 - COLLAPSIBLE SPACER 2 - INSTALLATION 2 - SHOULDER 3 - PINION GEAR 3 - PINION 4 - REAR PINION BEARING 4 - PINION DEPTH SHIM 5 - REAR BEARING...
Page 145 3 - 80 REAR AXLE - 8 1/4 GEAR-PINION/RING (Continued) Fig. 68 PINION ROTATION TORQUE Fig. 69 RING GEAR 1 - COMPANION FLANGE 2 - INCH POUND TORQUE WRENCH 1 - TORQUE WRENCH 2 - BOLTS (13) Check pinion (1) rotating torque with an inch 3 - RING GEAR 4 - DIFFERENTIAL CASE pound torque wrench (2) (Fig.
Page 146 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 147 5 - 2 BRAKES - BASE PEDAL SPECIFICATIONS DESCRIPTION ......22 BRAKE FLUID ......30 OPERATION .
Page 148 BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) WARNING the backing plates. Use multi-mileage grease or GE 661 or Dow 111 silicone grease on caliper slide pins to ensure proper operation. WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON- DIAGNOSIS AND TESTING - BASE BRAKE TAIN ASBESTOS FIBERS FROM AFTERMARKET LININGS.
Page 149 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) ROAD TESTING BRAKE DRAG Brake drag occurs when the lining is in constant (1) If complaint involved low brake pedal, pump contact with the rotor or drum. Drag can occur at one pedal and note if it comes back up to normal height.
Page 150 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) A common and frequently misdiagnosed pull condi- parked overnight or stored. This is primarily due to tion is where direction of pull changes after a few the formation of trace corrosion (light rust) on metal stops.
Page 151 5 - 6 BRAKES - BASE BRAKES - BASE (Continued) • Right Front Wheel Bleed only one brake component at a time in the • Left Front Wheel following sequence: • Master Cylinder (1) Remove reservoir filler caps and fill reservoir. •...
Page 152 BRAKES - BASE 5 - 7 BRAKES - BASE (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION Disc Brake Rotor Max. Thickness Variation BRAKE COMPONENTS Ventilated 0.015 mm (0.0006 in.) SPECIFICATIONS Front Disc Brake Rotor Max. Thickness Variation DESCRIPTION SPECIFICATION Solid 0.018 mm (0.0007 in.) Rear Disc Brake Rotor 288 x 28 mm (11.3 x...
Page 153: Brake Lines
5 - 8 BRAKES - BASE BRAKES - BASE (Continued) DIAGNOSIS AND TESTING - BRAKE LINE AND SPECIAL TOOLS HOSES BASE BRAKES Flexible rubber hose is used at both front and rear brakes and at the rear axle junction block. Inspect the hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle is in for service.
Page 154 BRAKES - BASE 5 - 9 BRAKE LINES (Continued) (8) Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flar- ing screw in recess of compression disc (Fig. 3). (9) Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool.
Page 155 5 - 10 BRAKES - BASE BRAKE LINES (Continued) (2) Remove the brake line (1) from the brake hose (1) Install prop rod on the brake pedal to keep inside the engine compartment by the front control pressure on the brake system. arm bolt (2) (Fig.
Page 156 BRAKES - BASE 5 - 11 BRAKE LINES (Continued) CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. (7) Remove the inboard and outboard pads. REMOVAL - REAR DISC BRAKE PADS Fig.
Page 157 5 - 12 BRAKES - BASE BRAKE PADS / SHOES (Continued) Fig. 11 BRAKE PAD RATTLE CLIP Fig. 12 BRAKE PAD RATTLE CLIP 1 - INBOARD BRAKE PAD 1 - INBOARD BRAKE PAD 2 - OUTBOARD BRAKE PAD 2 - OUTBOARD BRAKE PAD 3 - ANTI-RATTLE SPRING CLIP 3 - ANTI-RATTLE SPRING CLIP 4 - CALIPER ADAPTER...
Page 158 BRAKES - BASE 5 - 13 BRAKE PADS / SHOES (Continued) (10) Apply brakes several times to seat caliper pis- Fluid pressure applied to the piston is transmitted tons and brake shoes and obtain firm pedal. directly to the inboard brake shoe. This forces the (11) Top off master cylinder fluid level.
Page 159 5 - 14 BRAKES - BASE DISC BRAKE CALIPERS (Continued) REMOVAL FRONT Fig. 17 CALIPER MOUNTING 1 - BRAKE HOSE 2 - CALIPER MOUNTING BOLTS 3 - BANJO BOLT Fig. 16 DISC BRAKE CALIPER 1 - DISC BRAKE CALIPER 2 - CALIPER SLIDE MOUNTING BOLTS 3 - BRAKE HOSE 4 - BANJO BOLT 5 - CALIPER ADAPTER MOUNTING BOLT...
Page 160 BRAKES - BASE 5 - 15 DISC BRAKE CALIPERS (Continued) WARNING: NEVER ATTEMPT TO CATCH THE PIS- TON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY. Fig. 21 PISTON SEAL REMOVAL - TYPICAL 1 - REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL 2 - PISTON SEAL (7) Remove caliper mounting bolt bushings and boots (Fig.
Page 161 5 - 16 BRAKES - BASE DISC BRAKE CALIPERS (Continued) CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never inter- change phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
Page 162 BRAKES - BASE 5 - 17 DISC BRAKE CALIPERS (Continued) INSTALLATION FRONT Fig. 27 CALIPER PISTON INSTALLATION - TYPICAL 1 - PISTON 2 - BOOT Fig. 29 DISC BRAKE CALIPER 1 - DISC BRAKE CALIPER 2 - CALIPER SLIDE MOUNTING BOLTS 3 - BRAKE HOSE 4 - BANJO BOLT 5 - CALIPER ADAPTER MOUNTING BOLT...
Page 163 5 - 18 BRAKES - BASE DISC BRAKE CALIPERS (Continued) REAR (6) Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 31 N·m (23 ft. lbs.). (7) Remove the prop rod from the vehicle. (8) Bleed the base brake system, (Refer to 5 - BRAKES - STANDARD PROCEDURE) OR (Refer to 5 - BRAKES - STANDARD PROCEDURE).
Page 164 BRAKES - BASE 5 - 19 plunger approximately 25.4 mm (1 in.) inward from ROTORS the rotor edge. The dial indicator should be posi- tioned in the center of the rotor surface. Maximum DIAGNOSIS AND TESTING allowable rotor runout is 0.102 mm (0.004 in.). ROTOR THICKNESS VARIATION DIAGNOSIS AND TESTING - DISC BRAKE ROTOR...
Page 165 5 - 20 BRAKES - BASE ROTORS (Continued) causes the drum in hat rotor to exceed the maximum allowable diameter. STANDARD PROCEDURE STANDARD PROCEDURE - DISC BRAKE ROTOR The disc brake rotor can be machined if scored or worn. The lathe must machine both sides of the rotor simultaneously with dual cutter heads.
Page 166: Brake Junction Block
BRAKES - BASE 5 - 21 ROTORS (Continued) INSTALLATION FRONT Fig. 37 ROTOR 1 - CALIPER MOUNTING BOLTS 2 - ROTOR 3 - CALIPER Fig. 36 DISC BRAKE ROTOR BRAKE JUNCTION BLOCK 1 - DISC BRAKE ROTOR 2 - CALIPER ADAPTER 3 - DISC BRAKE CALIPER DESCRIPTION 4 - SHOES...
Page 167 5 - 22 BRAKES - BASE BRAKE JUNCTION BLOCK (Continued) REMOVAL (1) Install the junction block (2) on the mounting studs. (2) Install mounting nuts (3). Tighten to 14 N·m (125 in. lbs.). (3) Install brake lines to the junction block (2) and tighten to 20 N·m (180 in.
Page 168: Power Brake Booster
BRAKES - BASE 5 - 23 PEDAL (Continued) OPERATION (2) Remove the retainer clip securing the booster push rod (5) to pedal (4) (Fig. 42). (3) Remove the brake lamp switch, (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL). (4) Remove the nuts securing the pedal to the col- umn bracket.
Page 169 5 - 24 BRAKES - BASE POWER BRAKE BOOSTER (Continued) Two push rods are used in the booster. The pri- housing (4) is a one-way device that prevents vacuum mary push rod connects the booster to the brake leak back. pedal.
Page 170 BRAKES - BASE 5 - 25 POWER BRAKE BOOSTER (Continued) (3) Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. (4) Clamp hose shut between vacuum source and check valve. (5) Stop engine and observe vacuum gauge. (6) If vacuum drops more than one inch Hg (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty.
Page 171 5 - 26 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (7) Remove the brake light switch, (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL) (8) Remove retaining clip that secures booster push rod (2) to brake pedal (1) (Fig. 49). Fig.
Page 172 BRAKES - BASE 5 - 27 POWER BRAKE BOOSTER (Continued) (2) Install booster mounting nuts. Tighten nuts RIGHT HAND DRIVE (RHD) just enough to hold booster in place (Fig. 51). Fig. 52 BOOSTER PUSH ROD Fig. 53 BOOSTER MOUNTING 1 - BRAKE PEDAL 1 - BRAKE BOOSTER 2 - BOOSTER ROD (1) Align and position booster (1) on the dash...
Page 173 5 - 28 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (6) Install the knee blocker, (Refer to 23 - BODY/ (2) Stop engine and shift transmission into Neu- INSTRUMENT PANEL/KNEE BLOCKER - INSTAL- tral. LATION). (3) Pump brake pedal until all vacuum reserve in (7) If original master cylinder is being installed, booster is depleted.
Page 174 BRAKES - BASE 5 - 29 MASTER CYLINDER (Continued) Fig. 57 MASTER - TYPICAL 1 - BLEEDING TUBES 2 - RESERVOIR REMOVAL Fig. 55 Typical Booster Vacuum Test Connections 1 - TEE FITTING 2 - SHORT CONNECTING HOSE 3 - CHECK VALVE 4 - CHECK VALVE HOSE 5 - CLAMP TOOL 6 - INTAKE MANIFOLD...
Page 175 5 - 30 BRAKES - BASE MASTER CYLINDER (Continued) (7) If master cylinder reservoir requires service, rates into layers, there is mineral oil or other fluid (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ contamination of the brake fluid. FLUID RESERVOIR - REMOVAL). (Fig. 58) If brake fluid is contaminated, drain and thor- oughly flush system.
Page 176: Fluid Reservoir
BRAKES - BASE 5 - 31 FLUID (Continued) CAUTION: Never use any type of a petroleum-based SUPPORT PLATE fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle REMOVAL brake hydraulic system causing a failure of the (1) Remove wheel and tire assembly.
Page 177: Parking Brake
5 - 32 BRAKES - BASE SUPPORT PLATE (Continued) INSTALLATION Fig. 63 PARK BRAKE SHOES INSTALLED 1 - SUPPORT PLATE 2 - PARK BRAKE SHOES 3 - AXLE PARKING BRAKE DESCRIPTION Fig. 62 BRAKE SHOES The parking brake is a hand lever and cable oper- 1 - SUPPORT PLATE ated system used to apply the rear brakes.
Page 178 BRAKES - BASE 5 - 33 PARKING BRAKE (Continued) A parking brake switch is mounted on the parking CABLES brake lever and is actuated by movement of the lever. The switch, which is in circuit with the red REMOVAL warning light in the dash, will illuminate the warn- ing light whenever the parking brakes are applied.
Page 179 5 - 34 BRAKES - BASE CABLES (Continued) (2) Remove the rear seat (Refer to 23 - BODY/ INSTALLATION SEATS/SEAT - REMOVAL). (3) Pull the carpet forward far enough in the rear to gain access to the two parking brake cables thru the floor (Fig.
Page 180 BRAKES - BASE 5 - 35 CABLES (Continued) LEVER REMOVAL Fig. 71 MOUNTING BRACKETS 1 - PARK BRAKE CABLES 2 - CARPET (5) Lay the carpet (2) back down in the rear (Fig. Fig. 73 LOCK OUT CABLES 71). 1 - PARKING BRAKE HANDLE (6) Install the rear seat (Refer to 23 - BODY/ 2 - PUNCH 3 - CABLE GUIDE...
Page 181 5 - 36 BRAKES - BASE LEVER (Continued) (5) Remove the parking brake lever assembly (1) mounting bolts (Fig. 75). (6) Remove the lever assembly (1). INSTALLATION Fig. 75 LEVER MOUNT Fig. 76 BRAKE SHOES 1 - ELECTRICAL CONNECTOR 2 - PARK BRAKE LEVER ASSEMBLY 1 - SUPPORT PLATE 3 - CABLE 2 - PARK BRAKE SHOES...
Page 182 BRAKES - BASE 5 - 37 SHOES (Continued) (4) Remove the disc brake rotor, (Fig. 77), (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL). Fig. 79 BRAKE SHOES 1 - SUPPORT PLATE 2 - PARK BRAKE SHOES 3 - EQUALIZER Fig. 78 BRAKE SHOES 4 - SPRINGS 5 - HOLD DOWN CLIPS 1 - SUPPORT PLATE...
Page 183 5 - 38 BRAKES - BASE SHOES (Continued) INSTALLATION Fig. 81 Brake Adjustment 1 - STAR WHEEL 2 - LEVER 3 - BRAKE SHOE WEB 4 - SCREWDRIVER 5 - ADJUSTING TOOL 6 - ADJUSTER SPRING Fig. 80 BRAKE SHOES ADJUSTMENTS 1 - SUPPORT PLATE 2 - PARK BRAKE SHOES...
Page 184 BRAKES - BASE 5 - 39 SHOES (Continued) Fig. 83 MEASURING PARK BRAKE DRUM DIAMETER Fig. 82 Brake Adjustment the area in which the park brake shoes contact the 1 - STAR WHEEL surface of the brake drum. 2 - LEVER 3 - BRAKE SHOE WEB 4 - SCREWDRIVER 5 - ADJUSTING TOOL...
Page 185 5 - 40 BRAKES - BASE SHOES (Continued) (11) Install brake rotor on the axleshaft (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - INSTALLATION). (12) Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum.
Page 186 BRAKES - ABS 5 - 41 BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS INSTALLATION ......43 DESCRIPTION .
Page 187 5 - 42 BRAKES - ABS BRAKES - ABS (Continued) ELECTRONIC BRAKE DISTRIBUTION NOTE: An audible noise may be heard during the self-test. This noise should be considered normal. Upon entry into EBD the inlet valve for the rear brake circuit is switched on so that the fluid supply from the master cylinder is shut off.
Page 188 BRAKES - ABS 5 - 43 ELECTRICAL DESCRIPTION Three wheel speed sensors are used. The front sen- sors are mounted to the steering knuckles. The rear sensor is mounted at the top of the rear axle differ- ential carrier. Tone wheels are mounted to the out- board ends of the front axle shafts.
Page 189 5 - 44 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) (6) Install the disc brake rotor (3) (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION) (Fig. 2). (7) Install the disc brake caliper adapter. (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - INSTALLATION). (8) Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).
Page 190 BRAKES - ABS 5 - 45 HCU (HYDRAULIC CONTROL UNIT) (Continued) PRESSURE DECREASE (3) Pull up on the ABM harness connector release (4) (Fig. 5) and remove connector. The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sen- sor signals indicate high wheel slip at one or more wheels.
Page 191 5 - 46 BRAKES - ABS HCU (HYDRAULIC CONTROL UNIT) (Continued) (2) If the seals on the components are not new, they must be replaced. Each of the solenoid valve stem seals (1) must be replaced (Fig. 9); do not reuse solenoid valve stem seals.
Page 192 BRAKES - ABS 5 - 47 HCU (HYDRAULIC CONTROL UNIT) (Continued) Fig. 12 MK25E ABM MOUNTING SCREWS Fig. 13 ABM MOUNTING 1 - MOUNTING SCREWS 1 - BRAKE LINES 2 - ABM 2 - ABM UNIT 3 - MOUNTING NUTS (5) Install the four screws attaching the ABM mod- ule to the HCU (Fig.
Page 194 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH LINKAGE WARNING ......1 REMOVAL .
Page 195 6 - 2 CLUTCH CLUTCH (Continued) Road splash contamination is dirt/water entering A frequent cause of clutch cover distortion (and the clutch housing due to loose bolts, housing cracks. consequent misalignment) is improper bolt tighten- Driving through deep water puddles can force water/ ing.
Page 196 CLUTCH 6 - 3 CLUTCH (Continued) DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1. Normal wear. 1. Replace cover and disc. 2. Driver frequently rides (slips) the 2. Replace cover and disc. clutch. Results in rapid overheating and wear.
Page 197 6 - 4 CLUTCH CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc binds on input shaft 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub splines. during installation. splines if possible. Replace disc if necessary. 2. Input shaft splines rough, 2.
Page 198: Clutch Disc
CLUTCH 6 - 5 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Contact surface of release bearing 1. Clutch cover incorrect or release 1. Replace clutch cover and release damaged. fingers bent or distorted. bearing. 2. Release bearing defective or 2. Replace the release bearing. damaged.
Page 199 6 - 6 CLUTCH CLUTCH DISC (Continued) (6) Insert clutch alignment tool (3) through the clutch disc and into the pilot bearing. (7) Position clutch pressure plate (2) over disc and on the flywheel (1) (Fig. 2). (8) Install pressure plate bolts finger tight. CAUTION: Use only the factory bolts to mount the pressure plate.
Page 200 CLUTCH 6 - 7 CLUTCH RELEASE BEARING (Continued) (3) Inspect bearing slide surface of transmission front bearing retainer. Replace retainer if slide sur- face is scored, worn, or cracked. (4) Inspect release fork and fork pivot. Be sure pivot is secure and in good condition. Be sure fork is not distorted or worn.
Page 201 6 - 8 CLUTCH FLYWHEEL (Continued) The Dual Mass Flywheel (Fig. 6) is used on the PILOT BEARING 2.4L engine and 2.8L Diesel. The flywheel incorpo- rates the ring gear (5) around the outer circumfer- REMOVAL ence to mesh with the starter to permit engine (1) Remove transmission.
Page 202 CLUTCH 6 - 9 LINKAGE REMOVAL Fig. 9 CLUTCH PEDAL 1 - CYLINDER Fig. 8 SLAVE CYLINDER 2 - ACTUATOR SHAFT 3 - PEDAL PIN 1 - CLUTCH SLAVE CYLINDER 4 - ACTUATOR EYE 5 - CONNECTOR NOTE: The clutch master cylinder, slave cylinder and connecting line are serviced as an assembly only.
Page 203: Clutch Pedal
6 - 10 CLUTCH LINKAGE (Continued) (1) Tighten master cylinder reservoir cap to avoid CLUTCH PEDAL spills. (2) Position clutch linkage components in vehicle. REMOVAL Work connecting line and slave cylinder downward past engine and adjacent to clutch housing. (3) Position clutch master cylinder (1) on dash panel.
Page 204 CLUTCH 6 - 11 CLUTCH PEDAL (Continued) INSTALLATION OPERATION The clutch pedal position switch override relay, inhibits operation of the clutch pedal position switch when the vehicle transfer case is in the four wheel drive low-range position. This enables the starter motor to operate without depressing the clutch pedal, for off-road applications.
Page 205 6 - 12 CLUTCH the position switch when the vehicle transfer case is CLUTCH PEDAL POSITION in the four wheel drive low-range position. This SWITCH enables the starter motor to operate without depress- ing the clutch pedal, for off-road applications. If DESCRIPTION Diagnostic Trouble Codes (DTC’s) for the override relay or transfer case switch are stored, override...
Page 206: Cooling
COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING COOLING SYSTEM AERATION ... 12 DESCRIPTION STANDARD PROCEDURE 2.4L ENGINE ......1 DRAINING COOLING SYSTEM .
Page 207: Engine
7 - 2 COOLING COOLING (Continued) Fig. 1 Engine Cooling System 3.7L Engine 1 - LH CYL. HEAD 5 - RH BANK CYL. BLOCK 2 - AIR BLEED 6 - LH BANK CYL. BLOCK 3 - THERMOSTAT LOCATION 7 - COOLANT TEMP. SENSOR 4 - RH CYL.
Page 208 COOLING 7 - 3 COOLING (Continued) DESCRIPTION - HOSE CLAMPS hose clamp, only use constant tension clamp pliers designed to compress the hose clamp. The cooling system utilizes spring type hose clamps. If a spring type clamp replacement is neces- sary, replace with the original Mopar equipment DIAGNOSIS AND TESTING...
Page 209 7 - 4 COOLING COOLING (Continued) (2) RECENT SERVICE OR ACCIDENT REPAIR: Determine if any recent service has been per- formed on vehicle that may effect cooling system. This may be: • Engine adjustments (incorrect timing) • Slipping engine accessory drive belt(s) •...
Page 210 COOLING 7 - 5 COOLING (Continued) tem. However, there could be an internal leak that pressure is within system range of 110 kPa (16 psi). does not appear with normal system test pressure. If Fluctuation of gauge pointer indicates compression or it is certain that coolant is being lost and leaks can- combustion leakage into cooling system.
Page 211 7 - 6 COOLING COOLING (Continued) COOLING SYSTEM DIAGNOSIS CHART - GAS ENGINE COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to (Refer to 25 - EMIS- (DTC) been set indicating a stuck SIONS CONTROL - DESCRIP- open thermostat? TION) for On-Board Diagnostics...
Page 212 COOLING 7 - 7 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep 1. This may be a temporary condi- HIGH OR THE COOLANT WARN- hill is being climbed, vehicle is tion and repair is not necessary. ING LAMP ILLUMINATES.
Page 213 7 - 8 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 8. Incorrect coolant concentration 8. Check coolant. (Refer to 7 - COOLING/ENGINE/COOLANT - DESCRIPTION) for correct coolant/ water mixture ratio. 9. Fan installed backwards on vis- 9. Mount fan on drive correctly. cous drive.
Page 214: Exhaust System
COOLING 7 - 9 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READ- 1. During cold weather operation, 1. A normal condition. No correc- ING IS INCONSISTENT (FLUCTU- with the heater blower in the high tion is necessary. ATES, CYCLES OR IS ERRATIC) position, the gauge reading may drop slightly.
Page 215 7 - 10 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cool- 1. Pressure test and repair as nec- GROUND WITHOUT PRESSURE ing system hoses, water pump or essary. (Refer to 7 - COOLING - CAP BLOWOFF.
Page 216 COOLING 7 - 11 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER PERFOR- 1. Has a Diagnostic trouble Code 1. (Refer to 25 - EMISSIONS MANCE. THERMOSTAT FAILED IN (DTC) been set? CONTROL - DESCRIPTION) for OPEN POSITION correct procedures and replace thermostat if necessary 2.
Page 217 7 - 12 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION FAN RUNS ALL THE TIME 1. Fan control sensors inoperative. 1. Check for DTC’s. Verify sensor readings. 2. Fan control solenoid stuck on . 2. Check fan operation speeds. Refer to fan speed operation table. 3.
Page 218 COOLING 7 - 13 COOLING (Continued) REFILLING COOLING SYSTEM CHEMICAL CLEANING If visual inspection indicates the formation of (1) Tighten the radiator draincock and the cylinder sludge or scaly deposits, use a radiator cleaner block drain plug(s) (if removed). (Mopar Radiator Kleen or equivalent) before flushing. CAUTION: Failure to purge air from the cooling sys- This will soften scale and other deposits and aid the tem can result in an overheating condition and...
Page 219 7 - 14 COOLING COOLING (Continued) Install the thermostat and housing with a replace- DESCRIPTION N·m ment gasket (Refer to 7 - COOLING/ENGINE/EN- Lbs. Lbs. GINE COOLANT THERMOSTAT Cooling Fan Support Bolts 47.1 INSTALLATION). Connect the radiator hoses. Refill Block Heater Bolt the cooling system with the correct antifreeze/water mixture (Refer to 7 - COOLING - STANDARD PRO- 2.4L...
Page 220 COOLING 7 - 15 COOLING (Continued) SPECIAL TOOLS COOLING Pressure Tester 7700–A Pliers 6094 Coolant Refractometer 8286 RELEASE TOOL 8875A Adapter Pins 8346 Spanner Wrench 6958 with 8346 adapter pins...
Page 221 7 - 16 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE 3.7L ENGINE ......19 DIAGNOSIS AND TESTING - SERPENTINE DRIVE BELTS DRIVE BELT DIAGNOSIS .
Page 222 ACCESSORY DRIVE 7 - 17 ACCESSORY DRIVE (Continued) SERPENTINE DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (ONE OR MORE 1. Foreign objects imbedded in pul- 1. Remove foreign objects from RIBS HAS SEPARATED FROM ley grooves. pulley grooves. Replace belt. BELT BODY) 2.
Page 223: Belt Tensioners
7 - 18 ACCESSORY DRIVE ACCESSORY DRIVE (Continued) CONDITION POSSIBLE CAUSES CORRECTION BELT BROKEN (NOTE: IDEN- 1. Excessive tension. 1. Replace belt and automatic belt TIFY AND CORRECT PROBLEM tensioner. BEFORE NEW BELT IS 2. Incorrect belt. 2. Replace belt. INSTALLED) 3.
Page 224: Drive Belts
ACCESSORY DRIVE 7 - 19 BELT TENSIONERS (Continued) WARNING: BECAUSE OF HIGH SPRING TENSION, cover. Install the mounting nut on the stud. Tighten DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC stud to 41 N·m (30 ft. lbs.). (3) Install drive belt (Refer to 7 - COOLING/AC- TENSIONER.
Page 225 7 - 20 ACCESSORY DRIVE DRIVE BELTS (Continued) 3.7L ENGINE publication. If anything differs between these sche- matics and the Belt Routing Label, use the sche- matics on Belt Routing Label. This label is located NOTE: The belt routing schematics are published in the engine compartment.
Page 226 ACCESSORY DRIVE 7 - 21 DRIVE BELTS (Continued) matics on Belt Routing Label. This label is located in the engine compartment. Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt ten- sioner. (1) Check condition of all pulleys.
Page 227 7 - 22 ENGINE ENGINE TABLE OF CONTENTS page page COOLANT INSTALLATION DESCRIPTION 2.4L ENGINE ......31 HOAT COOLANT .
Page 228 ENGINE 7 - 23 DESCRIPTION - WATER PUMP BYPASS - 3.7L ....... . 42 3.7L .
Page 229 7 - 24 ENGINE COOLANT (Continued) Year/100,000 Mile Formula (glycol base coolant with of propylene-glycol can result in boil-over or freeze-up corrosion inhibitors called HOAT, for Hybrid Organic on a cooling system designed for ethylene-glycol. Pro- Additive Technology) is recommended. This coolant pylene glycol also has poorer heat transfer character- offers the best engine cooling without corrosion when istics than ethylene glycol.
Page 230 ENGINE 7 - 25 COOLANT RECOVERY CONTAINER (Continued) ated pressure. The bottle acts as a reserve coolant point in the system) and is forced out of the system source to keep air out of the system but must have a through the pressure cap.
Page 231: Engine Block Heater
7 - 26 ENGINE COOLANT RECOVERY CONTAINER (Continued) REMOVAL PRESSURE SYSTEM - 3.7L/2.8L DIESEL Fig. 2 COOLANT BOTTLE - NON-PRESSURE SYSTEM 1 - NUT 2 - OVERFLOW TUBE Fig. 1 COOLANT BOTTLE - PRESSURE SYSTEM 3 - COOLANT BOTTLE 4 - MOUNTING BRACKET 1 - PRESSURE CAP 5 - COOLANT BOTTLE TO RADIATOR HOSE 2 - COOLANT BOTTLE...
Page 232 ENGINE 7 - 27 ENGINE BLOCK HEATER (Continued) OPERATION The block heater element is submerged in the cool- ing system’s coolant. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the engine coolant. This pro- vides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures.
Page 233: Engine Coolant Temperature Sensor
7 - 28 ENGINE ENGINE COOLANT REMOVAL TEMPERATURE SENSOR 2.4L ENGINE The Engine Coolant Temperature (ECT) sensor is DESCRIPTION installed into a water jacket at left front of cylinder The Engine Coolant Temperature (ECT) sensor is head (Fig. 5). used to sense engine coolant temperature. The sensor protrudes into an engine water jacket.
Page 234 ENGINE 7 - 29 ENGINE COOLANT TEMPERATURE SENSOR (Continued) 3.7L ENGINE ENGINE COOLANT The Engine Coolant Temperature (ECT) sensor is THERMOSTAT installed into a water jacket at front of intake mani- fold near rear of generator (Fig. 6). DESCRIPTION WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING.
Page 235 7 - 30 ENGINE ENGINE COOLANT THERMOSTAT (Continued) The same thermostat is used for winter and sum- OPERATION mer seasons. An engine should not be operated with- The thermostat starts to open at 80°C (176°F). out a thermostat, except for servicing or testing. Above this temperature, coolant is allowed to flow to Operating without a thermostat causes other prob- the radiator.
Page 236: Hose Clamps
ENGINE 7 - 31 ENGINE COOLANT THERMOSTAT (Continued) 3.7L ENGINE (1) Clean mating areas of timing chain cover and thermostat housing. (2) Install thermostat (spring side down) into recessed machined groove on housing assembly. Make sure rubber seal locating tab is positioned in the cor- responding notch in the housing.
Page 237 7 - 32 ENGINE HOSE CLAMPS (Continued) Fig. 10 Thermostat and Thermostat Housing 1 - THERMOSTAT HOUSING 3 - THERMOSTAT AND GASKET 2 - THERMOSTAT LOCATION 4 - TIMING CHAIN COVER Fig. 12 Spring Clamp Size Location 1 - SPRING CLAMP SIZE LOCATION Fig.
Page 238 ENGINE 7 - 33 CAUTION: A number or letter is stamped into the RADIATOR tongue of constant tension clamps (Fig. 15). If replacement is necessary, use only an original DESCRIPTION equipment clamp with matching number or letter. All vehicles are equipped with a cross flow type radiator with plastic side tanks (Fig.
Page 239 7 - 34 ENGINE RADIATOR (Continued) CAUTION: When removing the radiator or A/C con- denser for any reason, note the location of all radi- ator-to-body and radiator-to-A/C condenser rubber air seals (Fig. 16). These are used at the top, bot- tom and sides of the radiator and A/C condenser.
Page 240: Radiator Pressure Cap
ENGINE 7 - 35 RADIATOR (Continued) INSTALLATION 2.4L ENGINE CAUTION: Before installing the radiator or A/C con- denser, be sure the radiator-to-body and radiator-to- A/C condenser rubber air seals are properly fastened to their original positions. These are used at the top, bottom and sides of the radiator and A/C condenser.
Page 241 7 - 36 ENGINE RADIATOR PRESSURE CAP (Continued) Fig. 19 Pressure Testing Radiator Pressure Cap - Fig. 20 Radiator Cooling Fan - Typical Typical 1 - RADIATOR 2 - ELECTRIC COOLING FAN CONNECTOR 1 - PRESSURE CAP 3 - FAN SHROUD 2 - TYPICAL COOLING SYSTEM PRESSURE TESTER 4 - 2 SPEED ELECTRIC COOLING FAN CLEANING...
Page 242 ENGINE 7 - 37 RADIATOR FAN - ELECTRIC (Continued) NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow cooling package, the viscous fan cannot be removed separate from the shroud. Both fan and shroud must be removed together. (1) Disconnect battery negative cable. (2) Using special tool 6958 spanner wrench and 8346 adapters, remove the viscous fan from the water pump (Fig.
Page 243 7 - 38 ENGINE RADIATOR FAN - ELECTRIC (Continued) INSTALLATION INSTALLATION NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow cooling package, the viscous fan cannot be installed separate from the shroud. Both fan and shroud must be installed together. (1) Gently lay viscous fan into shroud. (2) Install fan shroud assembly into the vehicle.
Page 244 ENGINE 7 - 39 RADIATOR - FAN - VISCOUS (Continued) (2) Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0° to 220° F). Insert thermometer through the hole in the shroud. Be sure that there is adequate clearance from the fan blades.
Page 245: Water Pump
7 - 40 ENGINE RADIATOR - FAN - VISCOUS (Continued) CAUTION: If fan blade assembly is replaced (3) Disconnect engine coolant temperature sensor. because of mechanical damage, water pump and (4) Disconnect heater supply hose. (5) Remove housing attaching bolts (Fig. 26). viscous fan drive should also be inspected.
Page 246 ENGINE 7 - 41 WATER PUMP (Continued) cated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley (Fig.
Page 247 7 - 42 ENGINE WATER PUMP (Continued) (10) Remove the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKET(S) - REMOVAL). (11) Remove timing belt idler pulley. (12) Hold camshaft sprocket with Special tool C-4687 and adaptor C-4687-1 while removing bolt. Remove both cam sprockets.
Page 248 ENGINE 7 - 43 WATER PUMP (Continued) Fig. 32 Water Pump Body 1 - IMPELLER 2 - WATER PUMP BODY Fig. 31 Automatic Belt Tensioner—3.7L 3 - O-RING LOCATING GROOVE 1 - AUTOMATIC TENSIONER (4) Install the timing belt rear cover (Refer to 9 - 2 - WATER PUMP PULLEY ENGINE/VALVE TIMING/TIMING BELT COVER(S) (11) Remove water pump and gasket.
Page 249 7 - 44 ENGINE WATER PUMP (Continued) (5) Relax tension from belt tensioner. Install drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/ DRIVE BELTS - INSTALLATION). CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction.
Page 250 TRANSMISSION 7 - 45 TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION TRANS COOLER STANDARD PROCEDURE - TRANSMISSION DESCRIPTION ......46 COOLER LINE QUICK CONNECT FITTING REMOVAL .
Page 251 7 - 46 TRANSMISSION TRANSMISSION (Continued) CONNECT will only snap over quick connect fitting when the transmission cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step #2. TRANS COOLER DESCRIPTION The automatic transmission cooler is located in the front of the condenser and behind the front fascia.
Page 252 AUDIO/VIDEO 8A - 1 AUDIO/VIDEO TABLE OF CONTENTS page page AUDIO/VIDEO INSTALLATION ......11 DESCRIPTION ......1 INSTRUMENT PANEL ANTENNA CABLE OPERATION .
Page 253 8A - 2 AUDIO/VIDEO AUDIO/VIDEO (Continued) • Speakers over the Programmable Communication Interface Certain functions and features of the audio system (PCI) bus network to control the radio volume up or rely upon resources shared with other electronic down, station seek up or down, preset station modules in the vehicle over the Programmable Com- advance, and mode advance functions.
Page 254 AUDIO/VIDEO 8A - 3 AUDIO/VIDEO (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if required. 4. Radio ground faulty. 4. Check for continuity between radio chassis and a known good ground. There should be continuity.
Page 255 8A - 4 AUDIO/VIDEO repair the open fused B(+) circuit to the battery as AMPLIFIER CHOKE AND required. RELAY (3) Disconnect the instrument panel wire harness connector from the amplifier choke and relay. Check DESCRIPTION for battery voltage at the fused B(+) circuit cavity of Vehicles equipped with the premium speaker pack- the instrument panel wire harness connector for the age have a amplifier choke and relay.
Page 256 AUDIO/VIDEO 8A - 5 AMPLIFIER CHOKE AND RELAY (Continued) (3) Disconnect the electrical harness connector conductor of the flexible primary antenna coaxial from the amplifier choke and relay (Fig. 1). cable. The braided outer shield of the antenna coax- (4) Remove mounting fasteners and amplifier ial cable is grounded through both the antenna body choke and relay (1).
Page 257 8A - 6 AUDIO/VIDEO ANTENNA BODY & CABLE (Continued) open antenna conductor. If OK, go to Test 3. If not OK, isolate and test each of the individual antenna conductor components. Replace only the faulty antenna conductor component. TEST 3 Test 3 checks the condition of the vehicle body ground connection.
Page 258 AUDIO/VIDEO 8A - 7 ANTENNA BODY & CABLE (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the assist handles on the right side of DOMESTIC the headliner (Refer to 23 - BODY/INTERIOR/AS- SIST HANDLE - REMOVAL). (3) Remove the right side visor (Refer to 23 - BODY/INTERIOR/SUN VISOR - REMOVAL).
Page 259 8A - 8 AUDIO/VIDEO ANTENNA BODY & CABLE (Continued) Fig. 4 ANTENNA CABLE EXPORT ANTENNA CABLE - SATELLITE RADIO WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, REMOVAL STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 260 AUDIO/VIDEO 8A - 9 ANTENNA CABLE - SATELLITE RADIO (Continued) (4) Install headliner (Refer to 23 - BODY/INTERI- OR/HEADLINER - INSTALLATION). (5) Connect battery negative cable. ANTENNA MODULE DESCRIPTION The antenna module is an electromagnetic circuit component designed to capture and enhance radio frequency signals in both the AM and FM broadcast bands.
Page 261 8A - 10 AUDIO/VIDEO ANTENNA MODULE (Continued) REMOVAL TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG WARNING: DISABLE AIRBAG SYSTEM SYSTEM. FAILURE TO TAKE THE PROPER PRE- BEFORE ATTEMPTING ANY STEERING WHEEL, CAUTIONS COULD RESULT IN ACCIDENTAL AIR- STEERING COLUMN, SEAT BELT TENSIONER, SIDE...
Page 262 AUDIO/VIDEO 8A - 11 ANTENNA-SATELLITE RADIO (Continued) Fig. 9 CD CHANGER INSTALLATION (1) Install the CD Changer to the vehicle. Fig. 8 SATELLITE ANTENNA (2) Install and tighten the mounting fasteners. (4) Install headliner (Refer to 23 - BODY/INTERI- (3) Connect the wire harness connector. OR/HEADLINER - INSTALLATION).
Page 263 8A - 12 AUDIO/VIDEO INSTRUMENT PANEL ANTENNA CABLE (Continued) TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 264 AUDIO/VIDEO 8A - 13 INSTRUMENT PANEL ANTENNA CABLE (Continued) INSTALLATION QUARTER GLASS INTEGRAL ANTENNA DOMESTIC DESCRIPTION WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER-...
Page 265 8A - 14 AUDIO/VIDEO QUARTER GLASS INTEGRAL ANTENNA (Continued) or equivalent (Refer to 8 - ELECTRICAL/HEATED INTERNATIONAL RADIO BROADCAST GLASS - STANDARD PROCEDURE). COUNTRY CODE STD. AMERICAN SAMOA RADIO (8AD) ANDORRA (8AE) DESCRIPTION ANGOLA (8AF) ANGUILLA (8HA) RADIO ANTARCTICA (8HB) Available radios include: •...
Page 266 AUDIO/VIDEO 8A - 15 RADIO (Continued) INTERNATIONAL RADIO BROADCAST INTERNATIONAL RADIO BROADCAST COUNTRY CODE STD. COUNTRY CODE STD. CAYMAN ISLANDS GERMANY (8CJ) (8BF) GHANA (8CK) CENTRAL AFRICAN GIBRALTAR (8CL) REPUBLIC (8BG) GREECE (8CP) CHAD (8BJ) GREENLAND (8CR) CHILE (8BK) GRENADA (8CS) CHINA MAINLAND (8BL) GUADELOUPE (8CT) COLOMBIA (8BM)
Page 267 8A - 16 AUDIO/VIDEO RADIO (Continued) INTERNATIONAL RADIO BROADCAST INTERNATIONAL RADIO BROADCAST COUNTRY CODE STD. COUNTRY CODE STD. MALAGASY/MADASGAR PUERTO RICO (8E9) (8DW) QATAR (8FA) MALAWI (8DX) ROMANIA (8FB) MALAYSIA (8DY) RUSSIA (8FE) MALDIVE (8DZ) RWANDA (8FD) MALI (8D1) SAO TOME (8FG) MALTA &...
Page 268 AUDIO/VIDEO 8A - 17 RADIO (Continued) INTERNATIONAL RADIO BROADCAST COUNTRY CODE STD. TUNISIA (8GG) TURKEY (8GH) TURKMENISTAN (8HV) TURKS & CAICAO ISLAND (8GJ) TUVALU (8CM) UGANDA (8GK) UKRAINE (8FC) UNITED ARAB EMIRATES (8GL) UNITED KINGDOM (8CN) Fig. 15 RADIO URUGUAY (8GN) UZBEKISTAN (8HW) VANUATU (8GP) VATICAN CITY (8GR)
Page 269 8A - 18 AUDIO/VIDEO RADIO NOISE SUPPRESSION COMPONENTS (Continued) on-board or external source of electromagnetic nents or circuits intended for use by, or in close energy. These electromagnetic energy sources can proximity to the audio system components or circuits. radiate electromagnetic signals through the air, or Preventing the reception of RFI and EMI is accom- conduct them through the vehicle electrical system.
Page 270 AUDIO/VIDEO 8A - 19 RADIO NOISE SUPPRESSION COMPONENTS (Continued) (3) Remove the retaining nut (2) from the plenum (Fig. 18). 2.5L ENGINE Fig. 21 ENGINE GROUND STRAP - 3.7L Fig. 19 ENGINE GROUND STRAP - 2.5L (1) Disconnect and isolate the battery negative cable.
Page 271 8A - 20 AUDIO/VIDEO RADIO NOISE SUPPRESSION COMPONENTS (Continued) (3) Connect the battery negative cable. RECEIVER-SATELLITE DESCRIPTION The satellite receiver is located behind the right rear quarter trim. OPERATION The satellite receiver module receives signals from the roof mounted antenna and processes this infor- mation before it is sent to the radio.
Page 272 AUDIO/VIDEO 8A - 21 REMOTE SWITCHES (Continued) OPERATION REMOTE RADIO SWITCH TEST TABLE The six switches in the two remote radio switch units normally open, resistor multiplexed Switch Switch Position Resistance momentary switches that are hard wired to the Body Right 1.210 Kilohms Volume Up...
Page 273 8A - 22 AUDIO/VIDEO REMOTE SWITCHES (Continued) REMOVAL DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- WARNING: DISABLE AIRBAG SYSTEM TEM CAPACITOR TO DISCHARGE BEFORE PER- BEFORE ATTEMPTING ANY STEERING WHEEL, FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 274 AUDIO/VIDEO 8A - 23 SPEAKER (Continued) nector repair procedures, details of wire harness an amplifier. disconnect wire harness connector at routing and retention, connector pin-out information output side of amplifier. Go to Step 4. and location views for the various wire harness con- (4) Check both the speaker feed (+) circuit and nectors, splices and grounds.
Page 275 8A - 24 AUDIO/VIDEO SPEAKER (Continued) (2) Remove the rear door trim panel (Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - REMOVAL). (3) Remove the speaker mounting fasteners (Fig. 29). (4) Remove the speaker (1) from the door and dis- connect the wire harness connector (3).
Page 276 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME WARNING SYSTEM DIAGNOSIS AND TESTING DESCRIPTION ......1 CHIME WARNING SYSTEM .
Page 277 8B - 2 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) Fig. 1 Chime Warning System 1 - ELECTROMECHANICAL INSTRUMENT CLUSTER • Compass Mini-Trip Computer Global Reset “Antilock Brake System (ABS)” indicator illumina- tion. This warning will only occur following comple- - The EMIC transducer will generate one short chime tion of the “ABS”...
Page 278 CHIME/BUZZER 8B - 3 CHIME WARNING SYSTEM (Continued) • Door Ajar Indicator Warning - On vehicles tailgate ajar input has changed from closed to not without an Electronic Vehicle Information Center closed, and from the PCM indicating that the vehicle (EVIC), the EMIC transducer will generate one short is moving.
Page 279 8B - 4 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) • No Airbag Indicator Message Warning - The indicator illumination. The chime will only occur a second time during the same ignition cycle if another EMIC transducer will generate one short chime and electronic message has been received from the PCM turn on the “Airbag”...
Page 280 CHIME/BUZZER 8B - 5 CHIME WARNING SYSTEM (Continued) wired inputs, and electronic message inputs received sensor, or instrument panel component diagnosis from other modules over the PCI data bus network to or service. Disconnect and isolate the battery neg- provide the chime warning system features. The ative (ground) cable, then wait two minutes for the internal programming of the EMIC determines the system capacitor to discharge before performing...
Page 282 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES DESCRIPTION - MODES OF OPERATION . . . 16 STANDARD PROCEDURE - PCM/SKREEM DESCRIPTION - 5 VOLT SUPPLIES ..19 PROGRAMMING .
Page 283 8E - 2 ELECTRONIC CONTROL MODULES ELECTRONIC CONTROL MODULES (Continued) (3) Replace all ignition keys and program them If ignition key programming is unsuccessful, the into the new SKREEM/WCM. scan tool will display one of the following error mes- sages: PROGRAMMING THE PCM/SKREEM •...
Page 284 ELECTRONIC CONTROL MODULES 8E - 3 ANTILOCK BRAKE MODULE (Continued) OPERATION The ABM voltage source is through the ignition switch in the RUN position. The ABM contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously.
Page 285 8E - 4 ELECTRONIC CONTROL MODULES ANTILOCK BRAKE MODULE (Continued) INSTALLATION NOTE: If the ABM module (1) is being replaced with a new ABM module it must be reprogrammed with the use of a scan tool. Fig. 6 ABM MOUNTING 1 - BRAKE LINES 2 - ABM UNIT 3 - MOUNTING NUTS...
Page 286: Body Control Module
ELECTRONIC CONTROL MODULES 8E - 5 BODY CONTROL MODULE DESCRIPTION Fig. 9 Body Control Module 1 - BODY CONTROL MODULE 2 - JB-BCM CONNECTOR 3 - CONNECTOR RECEPTACLE (2) Fig. 8 Body Control Module Location hard wired outputs and the transmission of elec- 1 - DRIVER DOOR tronic message outputs to other electronic modules in 2 - INSTRUMENT PANEL END BRACKET...
Page 287 8E - 6 ELECTRONIC CONTROL MODULES BODY CONTROL MODULE (Continued) • Electronic Pinion Factor - On vehicles with- • Fog Lamp Control - The BCM provides fog out the optional Antilock Brake System (ABS) the lamp control for front fog lamps (optional), and rear BCM provides a source voltage to the rear wheel fog lamps (in required markets only).
Page 288 ELECTRONIC CONTROL MODULES 8E - 7 BODY CONTROL MODULE (Continued) vide control of the power lock motors through outputs details on wire harness routing and retention, as well to the lock, unlock, and driver unlock relays. This as pin-out and location views for the various wire includes support for rolling door locks (also known as harness connectors, splices and grounds.
Page 289 8E - 8 ELECTRONIC CONTROL MODULES BODY CONTROL MODULE (Continued) • Door unlock relay control will store a Diagnostic Trouble Code (DTC) in elec- • Driver door unlock relay control tronic memory for any failure it detects. These DTCs • Flip-up glass release motor driver can be retrieved and diagnosed using a diagnostic •...
Page 290 ELECTRONIC CONTROL MODULES 8E - 9 BODY CONTROL MODULE (Continued) NOTE: Before replacing a Body Control Module DIAGNOSIS AND TESTING (BCM), use a diagnostic scan tool to retrieve the current settings for the many BCM programmable BODY CONTROL MODULE features including electronic pinion factor (tire size), cabin equalization curve (audio system archi- WARNING: To avoid personal injury or death, on tecture), country code and Remote Keyless Entry...
Page 291 8E - 10 ELECTRONIC CONTROL MODULES BODY CONTROL MODULE (Continued) INSTALLATION the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. Many of the electronic control modules in a vehicle WARNING: To avoid personal injury or death, on require information from the same sensing device.
Page 292: Data Link Connector
ELECTRONIC CONTROL MODULES 8E - 11 COMMUNICATION (Continued) • Cyclic Redundancy Check (CRC) Byte - This the only dominant node for the PCI data bus system. A standard node terminates the bus through an 11 byte is used to detect errors during a message trans- KW resistor and a 330 pF capacitor.
Page 293 8E - 12 ELECTRONIC CONTROL MODULES DATA LINK CONNECTOR (Continued) OPERATION The Data Link Connector (DLC) is an industry- standard 16-way connector that permits the connec- tion of a diagnostic scan tool to the Programmable Communications Interface (PCI) data bus for inter- facing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network within the vehi-...
Page 294 ELECTRONIC CONTROL MODULES 8E - 13 been met. The ECM compares input signal voltages ENGINE CONTROL MODULE- from each input device with specifications (the estab- DIESEL ENGINE lished high and low limits of the input range) that are programmed into it for that device. If the input DESCRIPTION voltage is not within the specifications and other trouble code criteria are met, a DTC will be stored in...
Page 295 8E - 14 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE-DIESEL ENGINE (Continued) identify problems. Although most subsytems of the ECM DIAGNOSTIC TROUBLE CODES engine control module are either directly or indirectly IMPORTANT NOTE: Before replacing the ECM monitored, there may be occasions when diagnostic for a failed driver, control circuit or ground circuit, be trouble codes are not immediately identified.
Page 296 ELECTRONIC CONTROL MODULES 8E - 15 ENGINE CONTROL MODULE-DIESEL ENGINE (Continued) (3) Select ENTER to update the VIN. The DRB (3) Select PCM REPLACED (GAS ENGINE). III will display the updated VIN. (4) Program the vehicle four-digit PIN into SKIM. (4) If the engine is equipped with air conditioning, (5) Select COUNTRY CODE and enter the correct the ECM A/C function must be enabled.
Page 297 8E - 16 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE-DIESEL ENGINE (Continued) REMOVAL POWERTRAIN CONTROL (1) Disconnect negative battery cable. MODULE (2) Disconnect ECM electrical connectors (Fig. 16). (3) Remove ECM bracket to inner fender retaining nuts (Fig. 16). DESCRIPTION (4) Remove ECM and bracket assembly from vehi- cle (Fig.
Page 298: Fuel System
ELECTRONIC CONTROL MODULES 8E - 17 POWERTRAIN CONTROL MODULE (Continued) • Idle Voltage is applied to the fuel injectors with the • Cruise ASD relay via the PCM. The PCM will then control • Acceleration the injection sequence and injector pulse width by •...
Page 299 8E - 18 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Battery voltage ACCELERATION MODE • Park/neutral switch (gear indicator signal—auto. This is an Open Loop mode. The PCM recognizes trans. only) an abrupt increase in throttle position or MAP pres- •...
Page 300: Steering
ELECTRONIC CONTROL MODULES 8E - 19 POWERTRAIN CONTROL MODULE (Continued) tional fuel. This is done by adjusting injector pulse The PCM receives input signals from various switches width. and sensors. Based on these inputs, the PCM regulates • The PCM adjusts ignition timing by turning the various engine and vehicle operations through different ground path to the coil(s) on and off.
Page 301 8E - 20 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) NOTE: PCM Outputs: Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in • A/C clutch relay the RUN or START position. This is referred to as •...
Page 302 ELECTRONIC CONTROL MODULES 8E - 21 POWERTRAIN CONTROL MODULE (Continued) INSTALLATION USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDEN- TIFICATION NUMBER (VIN) AND THE VEHI- CLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
Page 303 8E - 22 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) Some examples of indirect inputs to the TCM the CVI calculation because the TCM determines are: CVIs by monitoring how long it takes for a gear • Engine/Body Identification change to occur (Fig. 21). •...
Page 304 ELECTRONIC CONTROL MODULES 8E - 23 TRANSMISSION CONTROL MODULE (Continued) Certain mechanical problems within the input put Speed Sensors and wiring can cause these clutch assembly (broken return springs, out of posi- conditions. The following chart identifies the appro- tion snap rings, excessive clutch pack clearance, priate clutch volumes and when they are monitored/ improper assembly, etc.) can cause inadequate or out- updated:...
Page 305 8E - 24 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) Schedule Condition Expected Operation Oil temperature at start-up above – Normal operation (upshift, kick- 80° F downs, and coastdowns) – Full EMCC, no PEMCC except to engage FEMCC (except at closed throttle at speeds above 70-83 mph) Overheat...
Page 306 ELECTRONIC CONTROL MODULES 8E - 25 TRANSMISSION CONTROL MODULE (Continued) BATTERY FEED ues in the “Monitors” display. Gear ratio can be obtained by dividing the Input Speed Sensor value by A fused, direct battery feed to the TCM is used for the Output Speed Sensor value.
Page 307 8E - 26 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) Schedule Condition Expected Operation Extreme Cold Oil temperature below -16° F -Park, Reverse, Neutral and 1st and 3rd gear only in D position, 2nd gear only in Manual 2 or L -No EMCC Super Cold Oil temperature between -12°...
Page 308 ELECTRONIC CONTROL MODULES 8E - 27 TRANSMISSION CONTROL MODULE (Continued) Learn procedure can be performed to fine tune any shift quality. Although the UD CVI may not change, shifts which are particularly objectionable. shift quality should improve. (1) Start the vehicle engine and shift to drive. NOTE: It is not necessary to perform the complete (2) Move the vehicle forward to a speed of at least Drive Learn procedure every time the TCM is Quick...
Page 309 8E - 28 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) LEARN A SMOOTH 4-3 COASTDOWN AND PART LEARN A SMOOTH 4-5 UPSHIFT THROTTLE 4-3 KICKDOWN NOTE: The transmission oil temperature must be above 110°F (43°C). NOTE: The transmission oil temperature must be above 110°F (43°C).
Page 310 ELECTRONIC CONTROL MODULES 8E - 29 HEATED SEAT MODULE (Continued) tem functions and provide feedback of that diagnosis DIAGNOSIS AND TESTING - HEATED SEAT through the heated seat switch indicator lamps. MODULE The heated seat module cannot be repaired. If the If a heated seat fails to heat and one or both of the heated seat module is damaged or faulty, the entire indicator lamps on a heated seat switch flash, refer...
Page 311 8E - 30 ELECTRONIC CONTROL MODULES HEATED SEAT MODULE (Continued) (2) Back-probe the heated seat module wire har- LEFT SEAT HEATER INOPERATIVE ness connector (Fig. 24), do not disconnect. Check (1) If a heated seat heats but one or both indicator cavity #3 for battery voltage when the right heated lamps (LED’s) on the heated seat switch fail to illu- seat switch is turned “ON”, voltage should be...
Page 312 ELECTRONIC CONTROL MODULES 8E - 31 HEATED SEAT MODULE (Continued) NOT OK, repair the open or shorted 5v supply circuit as required. If OK check for continuity between the left heated seat cushion connector and control mod- ule connector on the temperature sensor input cir- cuit.
Page 314 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING SYSTEM .
Page 315 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) tery and an anchor point for the battery holddown and the battery to maintain its charge properly, all of hardware. the components that are used in these systems must For battery system maintenance schedules and perform within specifications.
Page 316 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 317 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 318 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
Page 319 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) INSPECTION certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH The following information details the recommended ratings that equal or exceed the original equipment inspection procedures for the battery and related specification for the vehicle being serviced.
Page 320 BATTERY SYSTEM 8F - 7 BATTERY (Continued) System for the proper charging system diagnosis and testing procedures. SPIRAL PLATE BATTERY - DIESEL ENGINE Vehicles equipped with a diesel engine utilize a spi- ral wound plate designed battery with recombination technology. This is a maintenance-free battery that is capable of delivering more power than a conventional battery.
Page 321 8F - 8 BATTERY SYSTEM BATTERY (Continued) the terminals of the battery, an electrochemical reac- TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY tion occurs. This reaction causes the battery to dis- MAY ARC INTERNALLY AND EXPLODE. PERSONAL charge electrical current from its terminals. As the INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
Page 322 BATTERY SYSTEM 8F - 9 BATTERY (Continued) • The temperature corrected specific gravity of the CAUTION: Battery electrolyte will bubble inside the battery electrolyte is less than 1.235. battery case during normal battery charging. Elec- • The battery open-circuit voltage is less than 12.4 trolyte boiling or being discharged from the battery volts.
Page 323 8F - 10 BATTERY SYSTEM BATTERY (Continued) very low at first. As the battery warms, it will accept a higher charging current rate (amperage). • Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time.
Page 324 BATTERY SYSTEM 8F - 11 BATTERY (Continued) WARNING: IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST- BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. CAUTION: Always disconnect and isolate the bat- tery negative cable before charging a battery.
Page 325 8F - 12 BATTERY SYSTEM BATTERY (Continued) discharged battery. Electrolyte is nearly pure water it is important that the battery be level and have a in a completely discharged battery. At first, the clean sight glass. Additional light may be required to charging current (amperage) will be low.
Page 326 BATTERY SYSTEM 8F - 13 BATTERY (Continued) refer to Diagnosis and Testing for alternate methods of determining the battery state-of-charge. Specific gravity is a comparison of the density of the battery electrolyte to the density of pure water. Pure water has a specific gravity of 1.000, and sulfu- ric acid has a specific gravity of 1.835.
Page 327 8F - 14 BATTERY SYSTEM BATTERY (Continued) when a hydrometer is not available, or for mainte- STANDARD PROCEDURE - IGNITION-OFF nance-free batteries with non-removable cell caps. DRAW TEST Before proceeding with this test, completely charge The term Ignition-Off Draw (IOD) identifies a nor- the battery (Refer to 8 - ELECTRICAL/BATTERY mal condition where power is being drained from the SYSTEM/BATTERY - STANDARD PROCEDURE).
Page 328 BATTERY SYSTEM 8F - 15 BATTERY (Continued) ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE Time Out? IOD After Time Module (If Yes, Interval And Wake-Up Input) 1 to 3 Radio milliamperes Audio Power up to 1 Amplifier milliampere 4.75 Body Control Module milliamperes (BCM) (max.)
Page 329 8F - 16 BATTERY SYSTEM BATTERY (Continued) STANDARD PROCEDURE - USING MICRO 420 is at the battery terminal. If the battery is not accessible, you may test using both the positive and BATTERY TESTER negative jumper posts. Select TESTING AT JUMPER POST when connecting to that location.
Page 330 BATTERY SYSTEM 8F - 17 BATTERY (Continued) REMOVAL (2) Reinstall the battery thermal guard onto the battery case. Refer to Thermal Guard for the proper (1) Turn the ignition switch to the Off position. Be battery thermal guard installation procedures. certain that all electrical accessories are turned off.
Page 331: Battery Cables
8F - 18 BATTERY SYSTEM BATTERY HOLDDOWN BATTERY CABLES DESCRIPTION DESCRIPTION The battery holddown hardware includes a plastic holddown bracket and retaining bolt. The battery holddown bracket meshes with the battery tray to secure the battery to the battery tray. When installing a battery into the battery tray, it is important that the holddown hardware is properly installed and that the fastener is tightened to the...
Page 332 BATTERY SYSTEM 8F - 19 BATTERY CABLES (Continued) ness routing and retention, as well as pin-out and you are reading the combined voltage drop in the location views for the various wire harness connec- battery positive cable terminal clamp-to-terminal tors, splices and grounds. post connection and the battery positive cable.
Page 333 8F - 20 BATTERY SYSTEM BATTERY CABLES (Continued) (2) Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the nega- tive lead of the voltmeter to the battery positive cable terminal clamp (Fig. 16). Rotate and hold the ignition switch in the Start position.
Page 334: Battery Tray
BATTERY SYSTEM 8F - 21 battery tray also provides the anchor point/s for the BATTERY TRAY battery holddown hardware. The battery tray and the battery holddown hardware combine to secure DESCRIPTION and stabilize the battery in the engine compartment, which prevents battery movement during vehicle operation.
Page 335 8F - 22 CHARGING SYSTEM CHARGING SYSTEM TABLE OF CONTENTS page page CHARGING SYSTEM OPERATION ......25 DESCRIPTION .
Page 336 CHARGING SYSTEM 8F - 23 CHARGING SYSTEM (Continued) • the voltmeter (if equipped) does not register form the following inspections before attaching the properly scan tool. • an undercharged or overcharged battery condi- (1) Inspect the battery condition. Refer to 8, Bat- tion occurs.
Page 337 8F - 24 CHARGING SYSTEM CHARGING SYSTEM (Continued) SPECIAL TOOLS The BTS is also used for OBD II diagnostics. Cer- tain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests).
Page 338 CHARGING SYSTEM 8F - 25 water pump will be rotating in the wrong direction if GENERATOR the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine DESCRIPTION compartment, or refer to Belt Schematics in Cooling The generator is belt-driven by the engine using a System.
Page 339 8F - 26 CHARGING SYSTEM GENERATOR (Continued) (2) 3.7L Engine: Position generator to engine and install 3 mounting bolts. Tighten 2 horizontal mount- ing bolts to specified torque. Tighten 1 verticle mounting bolt to specified torque. Refer to torque specifications. (3) Snap field wire connector into rear of genera- tor.
Page 340 CHARGING SYSTEM 8F - 27 GENERATOR DECOUPLER PULLEY (Continued) OPERATION Dry operation is used (no grease or lubricants). The decoupler is not temperature sensitive and also has a The generator decoupler is used only with low sensitivity to electrical load. The decoupler is a certain engines.
Page 341 8F - 28 CHARGING SYSTEM GENERATOR DECOUPLER PULLEY (Continued) INA Decoupler (1) Disconnect negative battery cable. (2) Remove generator and accessory drive belt. Refer to Generator Removal. (3) Position Special Tool #8823 (VM.1048) into decoupler (Fig. 8). (4) Determine if end of generator shaft is hex shaped (Fig.
Page 342 CHARGING SYSTEM 8F - 29 GENERATOR DECOUPLER PULLEY (Continued) (3) Position Special Tool #8433 (Fig. 13) into decoupler. Align to hex end of generator shaft. (4) The generator shaft uses conventional right- hand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clock- wise (Fig.
Page 343 8F - 30 CHARGING SYSTEM GENERATOR DECOUPLER PULLEY (Continued) INSTALLATION INA Decoupler (1) Thread decoupler pulley onto generator shaft by hand (right-hand threads). (2) Position Special Tool #8823 (VM.1048) into decoupler (Fig. 8). (3) Determine if end of generator shaft is hex shaped (Fig.
Page 344: Voltage Regulator
CHARGING SYSTEM 8F - 31 EVR circuitry monitors system line voltage (B+) and VOLTAGE REGULATOR battery temperature (refer to Battery Temperature Sensor for more information). It then determines a DESCRIPTION target charging voltage. If sensed battery voltage is The Electronic Voltage Regulator (EVR) is not a 0.5 volts or lower than the target voltage, the PCM separate component.
Page 345 8F - 32 STARTING SYSTEM STARTING SYSTEM TABLE OF CONTENTS page page STARTING SYSTEM REMOVAL ......40 DESCRIPTION .
Page 346 STARTING SYSTEM 8F - 33 STARTING SYSTEM (Continued) neutral position switch is installed in series between Once the engine starts, the overrunning clutch pro- the starter relay coil ground terminal and ground. tects the starter motor from damage by allowing the This normally open switch prevents the starter relay starter pinion gear to spin faster than the pinion from being energized and the starter motor from...
Page 347 8F - 34 STARTING SYSTEM STARTING SYSTEM (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER ENGAGES, 1. Starter ring gear faulty. 1. Refer to Starter Motor Removal and Installation. SPINS OUT BEFORE Remove starter motor to inspect starter ring gear. ENGINE STARTS.
Page 348 STARTING SYSTEM 8F - 35 STARTING SYSTEM (Continued) (d) If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Cir- cuit Test in this section. NOTE: A cold engine will increase starter current (amperage) draw reading, and reduce battery volt- age reading.
Page 349 8F - 36 STARTING SYSTEM STARTING SYSTEM (Continued) (1) Connect positive lead of voltmeter to negative battery cable terminal post. Connect negative lead of voltmeter to negative battery cable clamp (Fig. 2). Rotate and hold ignition switch in Start position. Observe voltmeter.
Page 350 STARTING SYSTEM 8F - 37 STARTING SYSTEM (Continued) (4) Connect voltmeter to measure between nega- tive battery terminal post and a good clean ground on engine block (Fig. 5). Rotate and hold ignition switch in Start position. Observe voltmeter. If read- ing is above 0.2 volt, clean and tighten negative bat- tery cable attachment on engine block.
Page 351 8F - 38 STARTING SYSTEM STARTING SYSTEM (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- for indications of physical damage and loose or cor- BAGS, DISABLE AIRBAG SYSTEM BEFORE roded wire harness connections. Clean corroded con- nections required. Refer Park/Neutral ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT Position Switch for park/neutral position switch DIAGNOSIS OR SERVICE.
Page 352: Starter Motor
STARTING SYSTEM 8F - 39 STARTING SYSTEM (Continued) STARTER MOTOR - GAS POWERED Starter Motor and Solenoid Manufacturer Mitsubishi Engine Application 2.4L / 3.7L Power Rating 1.4 Kilowatt (1.9 Horsepower) Voltage 12 Volts ** Number of Permanent Magnets Number of Brushes Drive Type Planetary Gear Reduction Free Running Test Voltage...
Page 353 8F - 40 STARTING SYSTEM STARTER MOTOR (Continued) (4) Check for continuity between solenoid terminal 3.7L V-6 and solenoid case (Fig. 8). There should be continuity. (1) Disconnect and isolate negative battery cable. If not OK, replace faulty starter motor assembly. (2) Raise and support vehicle.
Page 354: Starter Motor Relay
STARTING SYSTEM 8F - 41 STARTER MOTOR (Continued) (3) Install solenoid wire connector to solenoid ter- minal. (4) Lower vehicle. (5) Connect negative battery cable. 3.7L V-6 (1) Position front of starter towards rear of vehicle with solenoid position rotated until it is located below starter.
Page 355 8F - 42 STARTING SYSTEM STARTER MOTOR RELAY (Continued) When electromagnetic coil is de-energized, spring times. If OK, go to Step 2. If not OK, repair open cir- pressure returns movable contact to normally closed cuit to fused B(+) fuse in PDC as required. position.
Page 356 STARTING SYSTEM 8F - 43 STARTER MOTOR RELAY (Continued) REMOVAL The starter relay is located in the Power Distribu- tion Center (PDC) (Fig. 14). Refer to label on PDC cover for relay location. (1) Remove PDC cover. (2) Remove relay from PDC. (3) Check condition of relay terminals and PDC connector terminals for damage or corrosion.
Page 358 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEAT SYSTEM .
Page 359 8G - 2 HEATED GLASS HEATED GLASS (Continued) OPERATION The electric backlight (EBL) system is controlled by a momentary switch (Fig. 2) located in the A/C- heater control on the instrument panel. When the rear window defogger switch is pressed to the On position, the body control module (BCM) energizes the rear window defogger (EBL) relay, which then directs fused battery current through the relay and...
Page 360: Rear Window Defogger Relay
HEATED GLASS 8G - 3 HEATED GLASS (Continued) and fuses must be tight in their receptacles and all EBL relay is energized when the relay coil is pro- electrical connections must be secure. Refer to the vided a ground path by the control circuitry within appropriate wiring information for diagnosis and the body control module (BCM).
Page 361: Rear Window Defogger Switch
8G - 4 HEATED GLASS REAR WINDOW DEFOGGER RELAY (Continued) REMOVAL INSTALLATION WARNING: On vehicles equipped with airbags, dis- NOTE: Refer to the fuse and relay layout map on able the airbag system before attempting any steer- the inside of the junction block (JB) cover for EBL ing wheel, steering column, or instrument panel relay location.
Page 362 HEATED GLASS 8G - 5 REAR WINDOW DEFOGGER SWITCH (Continued) OPERATION (Fig. 7). There should be momentary continuity as the defogger switch is pressed, and then no continu- An LED indicator will illuminate when the rear ity. If OK, (Refer to 8 - ELECTRICAL/HEATED window defogger switch is activated.
Page 363 8G - 6 HEATED GLASS HEATED GLASS (Continued) Repair of the rear glass heating grid lines, bus (9) Allow the epoxy to cure 24 hours at room tem- bars or terminals can be accomplished using the perature, or carefully use a heat gun for fifteen min- Mopar Rear Window Defogger Repair Kit (Part utes.
Page 364 HEATED MIRRORS 8G - 7 HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS OPERATION ......7 DESCRIPTION .
Page 365 8G - 8 HEATED SEAT SYSTEM HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM DIAGNOSIS AND TESTING - PASSENGER DESCRIPTION ......8 HEATED SEAT SWITCH .
Page 366 HEATED SEAT SYSTEM 8G - 9 HEATED SEAT SYSTEM (Continued) ignition switch is turned back “ON” until a heated If the heated seat system failure is identified by seat switch is depressed again. flashing heated seat switch indicator lamps, go to the The heated seat module monitors inputs from the appropriate diagnosis and testing procedure in this heated seat sensors and the heated seat switches.
Page 367 8G - 10 HEATED SEAT SYSTEM DRIVER HEATED SEAT SWITCH (Continued) When the front of the switch rocker is fully depressed, the High position is selected and the high position LED indicator illuminates. When the rear of the switch rocker is fully depressed, the Low position is selected and the low position LED indicator illumi- nates.
Page 368 HEATED SEAT SYSTEM 8G - 11 DRIVER HEATED SEAT SWITCH (Continued) INSTALLATION Refer to Wiring Diagrams for complete heated seat system wiring diagrams. (1) Gently rock the switch back and forth in to its (1) If the problem being diagnosed involves a mounting location.
Page 369 8G - 12 HEATED SEAT SYSTEM PASSENGER HEATED SEAT SWITCH (Continued) NOTE: Any resistance values (ohms ) given in the and it is located on the seat cushion heating element following text are supplied using the automatic for all models. seat heating elements...
Page 370 HEATED SEAT SYSTEM 8G - 13 HEATED SEAT ELEMENT (Continued) SEAT BACK ELEMENT the temperature of the seat, and regulates the cur- rent flow to the seat heating elements accordingly. (1) Disconnect and isolate the battery negative cable. Disconnect the green heated seat back element DIAGNOSIS AND TESTING - HEATED SEAT wire harness connector from the power seat wire har- SENSOR...
Page 372 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM INSTALLATION ......2 DESCRIPTION .
Page 373 8H - 2 HORN HORN SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION ONE HORN INOPERATIVE 1. Faulty horn. 1. Refer to horn for the proper diagnosis and testing procedures. Replace the horn or repair the open horn circuit, if required. HORN SOUNDS 1.
Page 374: Horn Switch
HORN 8H - 3 HORN RELAY (Continued) INSTALLATION (1) Locate proper connector, and press relay into position. (2) Install instrument panel end cap. (3) Connect battery negative cable. HORN SWITCH DESCRIPTION The horn switch is molded into the driver airbag. The horn switch can not be serviced separately.
Page 376 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL 2.8L TURBODIESEL ....10 DESCRIPTION ......1 GLOW PLUG OPERATION .
Page 377 8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) The Auto Shutdown (ASD) relay provides battery SPECIFICATIONS voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When SPECIFICATIONS - IGNITION TIMING the PCM breaks the contact, the energy in the coil Ignition timing is not adjustable on any primary transfers to the secondary causing a spark.
Page 378 IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 2.4L RE16MC (Champion #) 1.24 to 1.37 mm (0.048 to 0.053 in.) 3.7L V-6 ZFR6F - 11G (NGK #) 1.1 mm (0.042 in.) SPARK PLUG CABLE RESISTANCE - 2.4L MINIMUM MAXIMUM 250 Ohms Per Inch...
Page 379 8I - 4 IGNITION CONTROL AUTO SHUT DOWN RELAY DESCRIPTION - PCM OUTPUT The 5–pin, 12–volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION OPERATION - ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated.
Page 380 IGNITION CONTROL 8I - 5 AUTO SHUT DOWN RELAY (Continued) (4) Connect the ohmmeter between terminals 87 (3) Check condition of relay terminals and PDC and 30. The ohmmeter should not show continuity at connector terminals for damage or corrosion. Repair this time.
Page 381 8I - 6 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) 3.7L The camshaft position (CMP) sensor is mounted in the top of cylinder head cover/intake manifold at the The Camshaft Position Sensor (CMP) on the 3.7L rear of the engine (Fig. 7) (Fig. 8) The CMP sensor is 6–cylinder engine is bolted to the right-front side of a hall effect device that detects a notch on the rear of the right cylinder head (Fig.
Page 382 IGNITION CONTROL 8I - 7 CAMSHAFT POSITION SENSOR (Continued) signal generator. The signal from the CMP sensor is OPERATION used in conjunction with the Crankshaft Position Sensor (CKP) to differentiate between fuel injection 2.4L and spark events. It is also used to synchronize the The Camshaft Position Sensor (CMP) sensor con- fuel injectors with their respective cylinders.
Page 383 8I - 8 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) REMOVAL GAS ENGINES 2.4L The Camshaft Position Sensor (CMP) on the 2.4L 4-cylinder engine is bolted to the right-front side of the cylinder head (Fig. 11). Sensor position (depth) is adjustable. (1) Disconnect electrical connector at CMP sensor.
Page 384 IGNITION CONTROL 8I - 9 CAMSHAFT POSITION SENSOR (Continued) CAUTION: After tightening sensor mounting bolts, INSTALLATION recheck air gap and adjust as necessary. Retorque bolts. GAS ENGINES (6) Install upper timing belt cover and 3 bolts. 2.4L (7) Connect electrical connector to ECT sensor. The Camshaft Position Sensor (CMP) on the 2.4L (8) Connect electrical connector to CMP sensor.
Page 385: Glow Plug
8I - 10 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) 3.7L The Camshaft Position Sensor (CMP) on the 3.7L V-6 engine is bolted to the front/top of the right cyl- inder head. (1) Clean out machined hole in cylinder head. (2) Apply a small amount of engine oil to sensor o-ring.
Page 386 IGNITION CONTROL 8I - 11 GLOW PLUG (Continued) REMOVAL (1) Disconnect negative battery cable. (2) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL). (3) Disconnect glow plug electrical connectors (Fig. 19). NOTE: The intake manifold inlet tube must be removed to remove the cylinder # 3 glow plug (Fig.
Page 387 8I - 12 IGNITION CONTROL GLOW PLUG MODULE DESCRIPTION CAUTION: The glow plug system is a 7 volt system. DO NOT ATTEMPT to test the glow plug system with a 12V power source or damage will occur. Fig. 21 GLOW PLUG MODULE 1 - MASTER CYLINDER 2 - GLOW PLUG MODULE 3 - BATTERY...
Page 388: Ignition Coil
IGNITION CONTROL 8I - 13 GLOW PLUG MODULE (Continued) REMOVAL Fig. 23 IGNITION COIL - 2.4L 1 - IGNITION COIL Fig. 22 GLOW PLUG MODULE 2 - MOUNTING BOLTS (4) 1 - MASTER CYLINDER 2 - GLOW PLUG MODULE 3 - BATTERY (1) Disconnect the negative battery cable.
Page 389 8I - 14 IGNITION CONTROL IGNITION COIL (Continued) Because of coil design, spark plug cables (second- ary cables) are not used with the 3.7L engine. REMOVAL 2.4L (1) Disconnect electrical connector at rear of coil. (2) Remove all secondary cables from coil. (3) Remove 4 coil mounting bolts (Fig.
Page 390: Knock Sensor
IGNITION CONTROL 8I - 15 IGNITION COIL (Continued) (5) Carefully pull up coil from cylinder head open- (2) Install 4 mounting bolts. Refer to torque speci- ing with a slight twisting action. fications. (6) Remove coil from vehicle. (3) Install secondary cables. (4) Install electrical connector at rear of coil.
Page 391: Spark Plug
8I - 16 IGNITION CONTROL KNOCK SENSOR (Continued) Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maxi- mum authority that long term memory has over tim- ing retard can be calibrated.
Page 392 IGNITION CONTROL 8I - 17 SPARK PLUG (Continued) OPERATION To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tighten- ing spark plugs. This is especially true when plugs are equipped with tapered seats.
Page 393 8I - 18 IGNITION CONTROL SPARK PLUG (Continued) OIL OR ASH ENCRUSTED If one or more spark plugs are oil or oil ash encrusted (Fig. 31), evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig.
Page 394 IGNITION CONTROL 8I - 19 SPARK PLUG (Continued) CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode (Fig. 34). Spark plugs with this condition must be replaced.
Page 395 8I - 20 IGNITION CONTROL SPARK PLUG (Continued) 3.7L 3.7L Each individual spark plug is located under each Special care should be taken when installing spark ignition coil. Each individual ignition coil must be plugs into the cylinder head spark plug wells. Be removed to gain access to each spark plug.
Page 396 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER HIGH BEAM INDICATOR DESCRIPTION ......2 DESCRIPTION .
Page 397 8J - 2 INSTRUMENT CLUSTER OPERATION ......38 OPERATION ......40 TRANS TEMP INDICATOR WASHER FLUID INDICATOR DESCRIPTION...
Page 398 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) • Audible Warnings - The EMIC electronic cir- vehicle electrical system through a single dedicated take out and connector of the instrument panel wire cuit board is equipped with an audible tone trans- harness.
Page 399 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) • Rear Fog Lamp Indicator (with Rear Fog Each indicator in the EMIC, except the Cruise Lamps only) indicator located within the odometer/trip odometer • Seatbelt Indicator VFD unit, is illuminated by a dedicated Light Emit- •...
Page 400 INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) Hard wired circuitry connects the EMIC to the to an extreme position and the microprocessor can electrical system of the vehicle. These hard wired cir- sound a chime through the on-board audible tone cuits are integral to several wire harnesses, which transducer to provide distinct visual and audible are routed throughout the vehicle and retained by...
Page 401 8J - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) • “glass” - indicating the tailgate glass is ajar (on of the coils has a fixed current flowing through it to maintain a constant magnetic field strength. Current vehicles without the optional EVIC only). •...
Page 402 INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER (Continued) sages from the Powertrain Control Module (PCM); CLUSTER ILLUMINATION however, if the EMIC loses PCI data bus communica- The EMIC has several illumination lamps that pro- tion, the EMIC circuitry will automatically turn the vide cluster back lighting whenever the exterior MIL on until PCI data bus communication is lighting is turned On.
Page 403 8J - 8 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) INPUT AND OUTPUT CIRCUITS out information and location views for the various wire harness connectors, splices and grounds. HARD WIRED INPUTS If an individual hard wired gauge or indicator is inoperative, refer to the diagnosis and testing service The hard wired inputs to the EMIC include the fol- information for that specific gauge or indicator.
Page 404 INSTRUMENT CLUSTER 8J - 9 INSTRUMENT CLUSTER (Continued) the gauge needles at various calibration points, illu- CLUSTER ILLUMINATION DIAGNOSIS minate each of the segments in the Vacuum-Fluores- cent Display (VFD) unit, and turn all of the PCI data WARNING: To avoid personal injury or death, on bus message-controlled indicators on and off again.
Page 405 8J - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) CLUSTER BULB NOTE: This procedure applies to each of the incan- descent cluster illumination lamp and bulb holder units. (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument cluster from the instru- ment panel.
Page 406 INSTRUMENT CLUSTER 8J - 11 INSTRUMENT CLUSTER (Continued) NOTE: This procedure applies to each of the incan- descent cluster illumination lamp and bulb holder units. (1) Align the bulb holder and bulb with the keyed opening in the circuit board of the instrument cluster (Fig.
Page 407: Abs Indicator
8J - 12 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) (4) Reinstall the cluster bezel onto the instrument OPERATION panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ The ABS indicator gives an indication to the vehi- CLUSTER BEZEL - INSTALLATION). cle operator when the ABS system is faulty or inop- (5) Reconnect the battery negative cable.
Page 408 INSTRUMENT CLUSTER 8J - 13 ABS INDICATOR (Continued) Each time the ABS indicator fails to light due to an always be off when the ignition switch is in any posi- open or short in the cluster ABS indicator circuit, the tion except On or Start.
Page 409 8J - 14 INSTRUMENT CLUSTER ment cluster transistor. The instrument cluster will BRAKE/PARK BRAKE turn on the brake indicator for the following reasons: INDICATOR • Bulb Test - Each time the ignition switch is turned to the On position the brake indicator is illu- DESCRIPTION minated by the instrument cluster for about three seconds as a bulb test.
Page 410 INSTRUMENT CLUSTER 8J - 15 BRAKE/PARK BRAKE INDICATOR (Continued) is applied or not fully released. The brake fluid level OPERATION switch on the brake master cylinder reservoir pro- The charging indicator gives an indication to the vides a hard wired ground input to the instrument vehicle operator when the electrical system voltage is cluster circuitry through the red brake warning indi- too low or too high.
Page 411 8J - 16 INSTRUMENT CLUSTER CHARGING INDICATOR (Continued) instrument cluster circuitry that controls the indica- will turn on the coolant low indicator for the follow- tor, (Refer to 8 - ELECTRICAL/INSTRUMENT ing reasons: • Bulb Test - Each time the ignition switch is CLUSTER - DIAGNOSIS AND TESTING).
Page 412: Door Ajar Indicator
INSTRUMENT CLUSTER 8J - 17 until the ignition switch is turned to the Off position, CRUISE INDICATOR whichever occurs first. • Actuator Test - Each time the cluster is put DESCRIPTION through the actuator test, the cruise indicator will be turned on, then off again during the VFD portion of the test in order to confirm the functionality of the VFD and the cluster control circuitry.
Page 413: Engine Temperature Gauge
8J - 18 INSTRUMENT CLUSTER DOOR AJAR INDICATOR (Continued) OPERATION the door ajar indicator, a diagnostic scan tool is required. Refer to the appropriate diagnostic infor- The door ajar indicator gives an indication to the mation. vehicle operator that one or more of the passenger compartment doors may be open or not completely latched.
Page 414 INSTRUMENT CLUSTER 8J - 19 ENGINE TEMPERATURE GAUGE (Continued) The engine coolant temperature gauge is an air nostic scan tool is required. Refer to the appropriate core magnetic unit that receives battery current on diagnostic information. instrument cluster electronic circuit board through the fused ignition switch output (run-start) ETC INDICATOR...
Page 415: Front Fog Lamp Indicator
8J - 20 INSTRUMENT CLUSTER ETC INDICATOR (Continued) • Bulb Test - Each time the ignition switch is FRONT FOG LAMP INDICATOR turned to the On position the ETC indicator is illu- minated for about fifteen seconds. The entire bulb DESCRIPTION test is a function of the PCM.
Page 416: Fuel Gauge
INSTRUMENT CLUSTER 8J - 21 FRONT FOG LAMP INDICATOR (Continued) BCM indicating the front fog lamps are turned On, ter in daylight. When illuminated from behind by the the front fog lamp indicator will be illuminated. The panel lamps dimmer controlled cluster illumination indicator remains illuminated until the cluster lighting with the exterior lamps turned On, the white receives a front fog lamp-off message from the BCM.
Page 417 8J - 22 INSTRUMENT CLUSTER FUEL GAUGE (Continued) end of the gauge scale and the low fuel indicator is clear lens located on the lower edge of the tachome- illuminated immediately. This message would indi- ter gauge dial face of the cluster overlay. The dark cate that the fuel tank sending unit input to the lens over the VFD prevents the indicator from being PCM is a short circuit.
Page 418 INSTRUMENT CLUSTER 8J - 23 GATE AJAR INDICATOR (Continued) The BCM continually monitors the tailgate ajar (BCM) over the Programmable Communications switch to determine the status of the rear tailgate. Interface (PCI) data bus. The BCM then sends the proper gate ajar lamp-on The glass ajar indicator function of the Vacuum and lamp-off messages to the instrument cluster.
Page 419: High Beam Indicator
8J - 24 INSTRUMENT CLUSTER • Light Bar Lamps-On Message - This function HIGH BEAM INDICATOR of the high beam indicator applies only to vehicles equipped with the optional light bar lamps and man- DESCRIPTION ufactured for certain markets where it is required. Each time the cluster receives a light bar lamps-on message from the BCM indicating the light bar lamps are turned On, the high beam indicator will be...
Page 420 INSTRUMENT CLUSTER 8J - 25 LIGHT BAR LAMP INDICATOR (Continued) when the it is not illuminated. An amber or blue bar lamp indicator or the instrument cluster circuitry Light Emitting Diode (LED) behind the cutout in the that controls the indicator, (Refer to 8 - ELECTRI- opaque layer of the overlay causes the icon to appear CAL/INSTRUMENT CLUSTER - DIAGNOSIS AND in amber or blue through the translucent outer layer...
Page 421: Low Oil Pressure Indicator
8J - 26 INSTRUMENT CLUSTER LOW FUEL INDICATOR (Continued) turn on the low fuel indicator for the following rea- LOW OIL PRESSURE sons: INDICATOR • Bulb Test - Each time the ignition switch is turned to the On position the low fuel indicator is DESCRIPTION illuminated for about three seconds as a bulb test.
Page 422 INSTRUMENT CLUSTER 8J - 27 LOW OIL PRESSURE INDICATOR (Continued) • Engine Oil Pressure Low Message - Once the “Engine” in the opaque layer of the instrument clus- engine has been started (engine speed has been ter overlay. The dark outer layer of the overlay pre- greater than 450 rpm), each time the cluster receives vents the indicator from being clearly visible when it three consecutive messages from the PCM indicating...
Page 423 8J - 28 INSTRUMENT CLUSTER MALFUNCTION INDICATOR LAMP (MIL) (Continued) • Actuator Test - Each time the cluster is put information can be increased when the proper inputs through the actuator test, the MIL will be turned on, are provided to the instrument cluster, but the infor- then off again during the bulb check portion of the mation cannot be decreased.
Page 424: Overdrive Off Indicator
INSTRUMENT CLUSTER 8J - 29 ODOMETER (Continued) positions. The instrument cluster circuitry controls An overdrive off indicator is standard equipment the VFD and provides the following features: on all instrument clusters (Fig. 26). However, on • Odometer/Trip Odometer Display Toggling - vehicles not equipped with the optional overdrive Actuating the trip odometer reset switch button automatic transmission, this indicator is electroni-...
Page 425: Rear Fog Lamp Indicator
8J - 30 INSTRUMENT CLUSTER OVERDRIVE OFF INDICATOR (Continued) overdrive off lamp-off message from the PCM, or illumination lighting using the panel lamps dimmer until the ignition switch is turned to the Off position, control ring on the left control stalk of the multi- whichever occurs first.
Page 426 INSTRUMENT CLUSTER 8J - 31 • Seatbelt Reminder Function - Each time the SEATBELT INDICATOR cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indica- DESCRIPTION tor will be illuminated as a seatbelt reminder for about seven seconds, or until the ignition switch is turned to the Off position, whichever occurs first.
Page 427: Security Indicator
8J - 32 INSTRUMENT CLUSTER SEATBELT INDICATOR (Continued) For proper diagnosis of the seatbelt switch, the ment cluster below the speedometer and to the right ACM, the PCI data bus, or the electronic message of the fuel gauge. inputs to the instrument cluster that control the The security indicator consists of a small round seatbelt indicator, a diagnostic scan tool is required.
Page 428 INSTRUMENT CLUSTER 8J - 33 SECURITY INDICATOR (Continued) the security indicator will be illuminated. The indica- tor can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator Fig. 30 Part Time Indicator remains illuminated solid or continues to flash until tem, this indicator is electronically disabled.
Page 429 8J - 34 INSTRUMENT CLUSTER SHIFT INDICATOR (TRANSFER CASE) (Continued) function switch. The full time indicator is serviced as The instrument cluster must be electronically con- a unit with the instrument cluster. figured for the type of transfer case in the vehicle using a diagnostic scan tool in order to provide FOUR LOW MODE INDICATOR proper operation of the part time indicator.
Page 430 INSTRUMENT CLUSTER 8J - 35 SHIFT INDICATOR (TRANSFER CASE) (Continued) Module (PCM) over the Programmable Communica- lights when the transfer case is engaged in the “4 Lo” tions Interface (PCI) data bus. position. The instrument cluster must be electronically con- This indicator is controlled by a transistor on the figured for the type of transfer case in the vehicle instrument cluster circuit board based upon the clus-...
Page 431 8J - 36 INSTRUMENT CLUSTER The speedometer is an air core magnetic unit that SPEEDOMETER receives battery current on the instrument cluster electronic circuit board through the fused ignition DESCRIPTION switch output (run-start) circuit whenever the igni- tion switch is in the On or Start positions. The clus- ter is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position.
Page 432 INSTRUMENT CLUSTER 8J - 37 The tachometer is an air core magnetic unit that TACHOMETER receives battery current on the instrument cluster electronic circuit board through the fused ignition DESCRIPTION switch output (run-start) circuit whenever the igni- tion switch is in the On or Start positions. The clus- ter is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position.
Page 433 8J - 38 INSTRUMENT CLUSTER the TPM indicator for about three seconds as a bulb TIRE PRESSURE MONITOR test. INDICATOR • TPM Lamp-On Message - Each time the clus- ter receives a TPM lamp-on message from the DESCRIPTION SKREEM, the TPM indicator will be illuminated. The indicator remains illuminated until the cluster receives a TPM lamp-off message from the SKREEM or until the ignition switch is turned to the Off posi-...
Page 434: Turn Signal Indicator
INSTRUMENT CLUSTER 8J - 39 TRANS TEMP INDICATOR (Continued) edge of the instrument cluster, between the tachom- during the bulb check portion of the test to confirm eter and the speedometer. the functionality of the LED and the cluster control The transmission over-temperature indicator con- circuitry.
Page 435 8J - 40 INSTRUMENT CLUSTER TURN SIGNAL INDICATOR (Continued) indicator flashing) or hazard warning signals (both OPERATION left and right indicators flashing) have been selected The wait-to-start indicator gives an indication to and are operating. These indicators are controlled by the vehicle operator when the diesel engine glow two individual hard wired inputs from the combina- plugs are energized in their pre-heat operating mode.
Page 436 INSTRUMENT CLUSTER 8J - 41 washer fluid level low) the cluster applies an algo- WASHER FLUID INDICATOR rithm to ensure that the input is correct and not the result of fluid sloshing in the washer reservoir. The DESCRIPTION cluster tests the status of the circuit about seven mil- liseconds after the ignition switch is turned to the On position, and about once every second thereafter, then uses an internal counter to count up or down.
Page 437 8J - 42 INSTRUMENT CLUSTER WATER-IN-FUEL INDICATOR (Continued) located above the coolant temperature gauge and to instrument cluster transistor. The instrument cluster the right of the tachometer in the instrument cluster. will turn on the water-in-fuel indicator for the follow- The water-in-fuel indicator consists of a stencil-like ing reasons: •...
Page 438 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....73 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 439 8L - 2 LAMPS/LIGHTING - EXTERIOR INSTALLATION ......37 INSTALLATION HEADLAMP LEVELING SWITCH BULB ....... 54 DESCRIPTION .
Page 440 LAMPS/LIGHTING - EXTERIOR 8L - 3 • Rear Lamp Units - A standard equipment rear LAMPS/LIGHTING - EXTERIOR lamp unit is mounted to the rear of each quarter panel on either side of the tailgate opening. DESCRIPTION • Side Repeater Lamps - A side repeater lamp is The exterior lighting system for this model mounted to each front fender just behind the front includes the following exterior lamp units (Fig.
Page 441 8L - 4 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) Fig. 1 Exterior Lamps...
Page 442 LAMPS/LIGHTING - EXTERIOR 8L - 5 LAMPS/LIGHTING - EXTERIOR (Continued) 1 - LIGHT BAR LAMP (2 OR 4) 6 - FRONT SIDE MARKER LAMP UNIT (2) 2 - HEADLAMP UNIT (2) 7 - FRONT FOG LAMP (2) 3 - REPEATER LAMP UNIT (2) 8 - CENTER HIGH MOUNTED STOP LAMP UNIT 4 - FRONT POSITION LAMP (2) 9 - REAR LAMP UNIT...
Page 443 8L - 6 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) factory-installed heavy duty 7-way trailer tow con- base of the right D-pillar behind the quarter trim nector to a conventional 4-way light duty connector. panel. The Center High Mounted Stop Lamp Hard wired circuitry connects the exterior lighting (CHMSL) has a path to ground at all times through system components to the electrical system of the...
Page 444 LAMPS/LIGHTING - EXTERIOR 8L - 7 LAMPS/LIGHTING - EXTERIOR (Continued) relay output circuit. The BCM provides a battery voltage from a fuse in the Power Distribution Center saver (load shedding) feature for the front fog lamps, (PDC) through a relay (low beam, high beam, or which will turn these lamps off if they are left on for DRL) output circuit.
Page 445 8L - 8 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) The light bar lamps have a path to ground at all lamp switch integral to the left (lighting) control times through a take out and eyelet terminal of the stalk of the multi-function switch. The rear fog lamps instrument panel wire harness that is secured by a operate in concert with the front fog lamps.
Page 446 LAMPS/LIGHTING - EXTERIOR 8L - 9 LAMPS/LIGHTING - EXTERIOR (Continued) CAUTION: Do not contaminate the glass of halogen NOTE: A good ground is necessary for proper light- bulbs with fingerprints or allow contact with other ing operation. If a lighting problem is being diag- possibly oily surfaces.
Page 447 8L - 10 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) BACKUP LAMPS CONDITION POSSIBLE CAUSES CORRECTION BACKUP LAMP DOES NOT 1. Faulty or missing fuse. 1. Test and replace backup lamp fuse as ILLUMINATE required. 2. Faulty or missing bulb. 2.
Page 448 LAMPS/LIGHTING - EXTERIOR 8L - 11 LAMPS/LIGHTING - EXTERIOR (Continued) DAYTIME RUNNING LAMPS operate. If the headlamp high and low beams are also inoperative, diagnose and repair that problem NOTE: Before performing the following tests, deter- before attempting to repair the Daytime Running mine whether the headlamp low and high beams Lamps.
Page 449 8L - 12 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION FRONT FOG LAMPS DO NOT 1. Faulty supply circuit. 1. Test and repair shorted front fog lamp EXTINGUISH relay output circuit as required. 2. Faulty control circuit. 2.
Page 450 LAMPS/LIGHTING - EXTERIOR 8L - 13 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION BOTH LOW OR HIGH BEAM 1. Faulty or missing relay. 1. Test and replace low beam, high beam, HEADLAMPS DO NOT or DRL relay as required. (Note: Vehicles ILLUMINATE with a DRL relay do not use a high beam relay.
Page 451 8L - 14 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) HEADLAMP LEVELING park lamps are inoperative, diagnose and repair that problem before attempting to repair the Head- NOTE: Before performing the following tests, con- lamp Leveling System. firm whether the park lamps operate properly. If the CONDITION POSSIBLE CAUSES CORRECTION...
Page 452 LAMPS/LIGHTING - EXTERIOR 8L - 15 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO LIGHT BAR LAMPS 1. Faulty or missing fuse. 1. Test and replace light bar lamp fuse as ILLUMINATE required. 2. Faulty switch feed circuit. 2. Test and repair open fused B(+) circuit to light bar switch as required.
Page 453 8L - 16 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) PARK LAMPS CONDITION POSSIBLE CAUSES CORRECTION ONE OR SEVERAL, BUT NOT 1. Faulty or missing fuse. 1. Test and replace park lamp fuse as ALL LAMPS IN PARK LAMP required. CIRCUIT DO NOT ILLUMINATE 2.
Page 454 LAMPS/LIGHTING - EXTERIOR 8L - 17 LAMPS/LIGHTING - EXTERIOR (Continued) REAR FOG LAMPS CONDITION POSSIBLE CAUSES CORRECTION ONE REAR FOG LAMP DOES 1. Faulty or missing bulb. 1. Test and replace rear fog lamp bulb as NOT ILLUMINATE required. 2. Faulty ground circuit. 2.
Page 455 8L - 18 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) TURN SIGNAL LAMPS CONDITION POSSIBLE CAUSES CORRECTION ONE TURN SIGNAL LAMP 1. Faulty or missing bulb. 1. Test and replace turn signal bulb as DOES NOT ILLUMINATE required. 2. Faulty ground circuit. 2.
Page 456 LAMPS/LIGHTING - EXTERIOR 8L - 19 tacts whenever the reverse gear has been selected. BACKUP LAMP SWITCH The switch receives battery voltage through a fuse in the Junction Block (JB) whenever the ignition switch DESCRIPTION is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods.
Page 457 8L - 20 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) connector receptacle containing six terminal pins and The brake lamp switch can be diagnosed using con- featuring a Connector Position Assurance (CPA) lock. ventional diagnostic tools and methods. The switch is connected to the vehicle electrical sys- tem through a dedicated take out of the instrument DIAGNOSIS AND TESTING panel wire harness.
Page 458 LAMPS/LIGHTING - EXTERIOR 8L - 21 BRAKE LAMP SWITCH (Continued) switch locking collar with the keyed mounting hole in BRAKE LAMP SWITCH TESTS the switch mounting bracket. PLUNGER POSITION CONTINUITY BETWEEN (5) Pull the switch straight back from the keyed Released (Extended) Pins 1 &...
Page 459 8L - 22 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) to a final adjustment position and cannot be undone. (2) Remove the two screws that secure the Center If not performed properly the first time, a new brake High Mounted Stop Lamp (CHMSL) to the rear of lamp switch must be installed.
Page 460 LAMPS/LIGHTING - EXTERIOR 8L - 23 LAMP-HIGH MOUNTED STOP (Continued) LAMP OPERATION (1) Check to be certain that the two plastic nuts The combination flasher has the following inputs are properly positioned and in good condition on each and outputs: fused B(+), fused ignition switch output, side of the roof panel opening for the Center High right turn signal sense, left turn signal sense, and Mounted Stop Lamp (CHMSL) (Fig.
Page 461 8L - 24 LAMPS/LIGHTING - EXTERIOR DAYTIME RUNNING LAMP RELAY (Continued) horn (flash-to-pass) output of the multi-function switch through a high beam relay control circuit. • Control Output - The DRL relay supplies Pulse Width Modulated (PWM) battery voltage to the headlamp high beam filaments through the high beam relay output circuit.
Page 462: Fog Lamp Relay
LAMPS/LIGHTING - EXTERIOR 8L - 25 DAYTIME RUNNING LAMP RELAY (Continued) (4) Reinstall the trim onto the driver side outboard end of the instrument panel. (Refer to 23 - BODY/IN- STRUMENT PANEL/INSTRUMENT PANEL END CAP - INSTALLATION). (5) Reconnect the battery negative cable. FOG LAMP RELAY DESCRIPTION FRONT...
Page 463 8L - 26 LAMPS/LIGHTING - EXTERIOR FOG LAMP RELAY (Continued) coil is de-energized, spring pressure returns the mov- able contact back against the normally closed con- tact. The inputs and outputs of the front fog lamp relay include: • Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times.
Page 464: Front Fog Lamp
LAMPS/LIGHTING - EXTERIOR 8L - 27 FOG LAMP RELAY (Continued) • Coil Ground Terminal (85) - The coil ground terminal is connected to a control output of the pre- mium BCM through a rear fog lamp relay control cir- cuit. The BCM controls rear fog lamp operation by controlling a ground path through this circuit.
Page 465 8L - 28 LAMPS/LIGHTING - EXTERIOR FRONT FOG LAMP (Continued) (6) Pull the bulb straight out of the mounting flange on the back of the lens reflector. LAMP - GRILLE MOUNTED (1) Disconnect and isolate the battery negative cable. (2) Remove the grille panel from the front of the grille opening reinforcement.
Page 466 LAMPS/LIGHTING - EXTERIOR 8L - 29 FRONT FOG LAMP (Continued) (3) Disconnect the front fog lamp pigtail wire from (6) Reinstall the fog lamp into the grille opening the connector on the grille opening reinforcement. reinforcement. (Refer to 8 - ELECTRICAL/LAMPS/ (4) Remove the screw from the mounting bracket LIGHTING - EXTERIOR/FRONT FOG LAMP - that secures the fog lamp to the bracket on the top of...
Page 467 8L - 30 LAMPS/LIGHTING - EXTERIOR FRONT FOG LAMP (Continued) (7) Reinstall the grille panel onto the front of the ADJUSTMENTS grille opening reinforcement. (Refer to 23 - BODY/ EXTERIOR/GRILLE - INSTALLATION). FRONT FOG LAMP UNIT (8) Reconnect the battery negative cable. (9) Confirm proper front fog lamp alignment.
Page 468 LAMPS/LIGHTING - EXTERIOR 8L - 31 FRONT FOG LAMP (Continued) ment screen at the centerline of the vehicle. Sight along the centerline of the vehicle (from the rear of the vehicle forward) to verify the accuracy of the cen- terline placement. (3) Rock the vehicle from side-to-side three times to allow the suspension to stabilize, then jounce the front suspension three times by pushing downward...
Page 469: Hazard Switch
8L - 32 LAMPS/LIGHTING - EXTERIOR FRONT POSITION LAMP (Continued) HAZARD SWITCH DESCRIPTION Fig. 22 Front Position Lamp Bulb Remove/Install 1 - HEADLAMP HOUSING 2 - SOCKET 3 - BULB Fig. 23 Hazard Switch INSTALLATION - BULB 1 - HAZARD SWITCH BUTTON 2 - SCREW (1) CAUTION: Always use the correct bulb size and 3 - MOUNTING BRACKET TABS...
Page 470 LAMPS/LIGHTING - EXTERIOR 8L - 33 HAZARD SWITCH (Continued) switch circuitry, which includes a circuit board with relay controls the right lamps, while the other con- both the hazard switch and the electronic combina- trols the left. tion flasher circuitry. The circuitry of the combina- Because of active electronic elements within the tion flasher performs both the hazard flasher and the hazard switch module, it cannot be tested using con-...
Page 471 8L - 34 LAMPS/LIGHTING - EXTERIOR HAZARD SWITCH (Continued) (7) Reinstall the radio into the instrument panel. (Refer ELECTRICAL/AUDIO/RADIO INSTALLATION). (8) Reconnect the battery negative cable. HEADLAMP HIGH BEAM RELAY DESCRIPTION Fig. 24 Hazard Switch Remove/Install 1 - WIRE HARNESS CONNECTOR 2 - HAZARD SWITCH 3 - ALIGNMENT PIN (2) 4 - STANCHION (2)
Page 472 LAMPS/LIGHTING - EXTERIOR 8L - 35 HEADLAMP HIGH BEAM RELAY (Continued) the Body Control Module (BCM) to control a high ative (ground) cable, then wait two minutes for the current output to the headlamp high beam filaments. system capacitor to discharge before performing Within the relay are an electromagnetic coil, a mov- further diagnosis or service.
Page 473 8L - 36 LAMPS/LIGHTING - EXTERIOR HEADLAMP HIGH BEAM RELAY (Continued) INSTALLATION WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supple- mental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service.
Page 474 LAMPS/LIGHTING - EXTERIOR 8L - 37 HEADLAMP LEVELING MOTOR (Continued) headlamp leveling circuits and the leveling switch must be tested before considering motor replacement. REMOVAL NOTE: Headlamp leveling motors are integral to the headlamp unit only on vehicles manufactured for certain markets where...
Page 475: Headlamp Leveling Switch
8L - 38 LAMPS/LIGHTING - EXTERIOR OPERATION HEADLAMP LEVELING The headlamp leveling switch receives battery volt- SWITCH age on a fused park lamp relay output circuit from a fuse in the Junction Block (JB) whenever the park DESCRIPTION lamps relay is energized (the park lamps are turned On).
Page 476 LAMPS/LIGHTING - EXTERIOR 8L - 39 HEADLAMP LEVELING SWITCH (Continued) Fig. 31 Headlamp Leveling Switch Connector Receptacle (4) If the switch fails any of the resistance tests, replace the faulty headlamp leveling switch as required. Fig. 32 Headlamp Leveling Switch Remove/Install 1 - HEADLAMP LEVELING SWITCH REMOVAL 2 - UPPER LATCH TAB...
Page 477: Headlamp Unit
8L - 40 LAMPS/LIGHTING - EXTERIOR electromagnetic field is produced by the coil wind- HEADLAMP LOW BEAM RELAY ings. This field draws the movable contact point away from the normally closed contact, and holds it DESCRIPTION against the normally open contact. When the relay coil is de-energized, spring pressure returns the mov- able contact back against the normally closed con- tact.
Page 478 LAMPS/LIGHTING - EXTERIOR 8L - 41 HEADLAMP UNIT (Continued) Fig. 34 Headlamp Unit Remove/Install Fig. 36 Headlamp Unit - Export 1 - FENDER PANEL 1 - LEVELING MOTOR (IF EQUIPPED) 2 - HEADLAMP UNIT 2 - BOOT SEAL 3 - MOUNTING TAB (2) 3 - ADJUSTING SCREW 4 - MOUNTING PANEL 4 - LOCATOR TAB...
Page 479 8L - 42 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. (5) Pull the lock ring, socket, and bulb straight out of the keyed opening in the headlamp housing and up from behind the upper radiator crossmember (Fig.
Page 480 LAMPS/LIGHTING - EXTERIOR 8L - 43 HEADLAMP UNIT (Continued) may overheat and cause damage to the lamp, the socket and/or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces.
Page 481 8L - 44 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT (7) The fuel tank should be Full. Add 2.94 kilo- - INSTALLATION). grams (6.5 pounds) of weight over the fuel tank for (7) Reconnect the battery negative cable. each estimated gallon of missing fuel.
Page 482: License Plate Lamp
LAMPS/LIGHTING - EXTERIOR 8L - 45 HEADLAMP UNIT (Continued) screen and tape a horizontal line on the wall at this (4) Repeat the adjustment procedure for the oppo- mark. This line will be used for up-and-down adjust- site headlamp. ment reference. (4) Measure the distance from the centerline of the LICENSE PLATE LAMP vehicle to the center of each headlamp being aligned.
Page 483 8L - 46 LAMPS/LIGHTING - EXTERIOR LICENSE PLATE LAMP (Continued) LAMP - NORTH AMERICA (1) Disconnect and isolate the battery negative cable. (2) Remove the two screws that secure the license plate lamp unit to the rear bumper fascia (Fig. 47). Fig.
Page 484 LAMPS/LIGHTING - EXTERIOR 8L - 47 LICENSE PLATE LAMP (Continued) (4) Insert the socket and bulb into the housing until the socket is firmly seated. (5) Rotate the socket clockwise about 30 degrees to lock it into place. (6) Swing the license plate bracket back against the spare tire (Fig.
Page 485 8L - 48 LAMPS/LIGHTING - EXTERIOR LAMP BAR (Continued) NOTE: The optional light bar includes either two or four lamps, depending upon the requirements in the market for which the vehicle is manufactured. Each lamp contains a single bulb. The service proce- dures for each of these bulbs is the same.
Page 486 LAMPS/LIGHTING - EXTERIOR 8L - 49 LAMP BAR (Continued) Fig. 51 Light Bar Lamp Tab Fig. 53 Light Bar Reinforcement Remove/Install 1 - BRACKET 1 - NUT & WASHER (4) 2 - LAMP 2 - JUMPER WIRE CONNECTOR 3 - REINFORCEMENT 3 - RIVET STUD (4) 4 - HOOK 4 - LIGHT BAR REINFORCEMENT...
Page 487 8L - 50 LAMPS/LIGHTING - EXTERIOR LAMP BAR (Continued) NOTE: The optional light bar includes either two or COVER four lamps, depending upon the requirements in the (1) Position the front edge of the light bar cover on market for which the vehicle is manufactured. Each the roof panel just ahead of the front edge of the lamp contains a single bulb.
Page 488 LAMPS/LIGHTING - EXTERIOR 8L - 51 LAMP BAR (Continued) ADJUSTMENTS LIGHT BAR LAMP VEHICLE PREPARATION FOR LIGHT BAR LAMP ALIGNMENT (1) Repair or replace any faulty or damaged com- ponents that could hinder proper lamp alignment. (2) Verify proper tire inflation. (3) Clean light bar lamp lenses.
Page 489 8L - 52 LAMPS/LIGHTING - EXTERIOR LAMP BAR SWITCH (Continued) active electronic elements. A connector receptacle is REMOVAL integral to the back of the switch housing, while a two integral latch features on the top and bottom of WARNING: To avoid personal injury or death, on the housing secure the switch in the instrument vehicles equipped with airbags, disable the supple- panel trim bezel.
Page 490 LAMPS/LIGHTING - EXTERIOR 8L - 53 LAMP BAR SWITCH (Continued) rock the bottom of the switch out through the face of (1) Turn the front wheels full lock toward the the bezel. same side of the vehicle as the lamp being serviced. (5) From the back of the trim bezel, depress the (2) Disconnect and isolate the battery negative two upper latch features on the switch housing and...
Page 491 8L - 54 LAMPS/LIGHTING - EXTERIOR MARKER LAMP (Continued) (3) Remove the four fasteners securing the front of INSTALLATION the adjacent right or left front fender wheel liner to the lower edge of the front bumper fascia and the BULB outboard surface of the frame rail ahead of the front wheel.
Page 492 LAMPS/LIGHTING - EXTERIOR 8L - 55 MARKER LAMP (Continued) (7) If the vehicle is so equipped, rotate the socket ing column shrouds are installed on the column, clockwise about 30 degrees to lock it into place. mounting tabs on the switch housing and the clock- (8) Reinstall the four fasteners securing the front spring are clamped to the lock housing by the same of the wheel liner to the lower edge of the fascia and...
Page 493 8L - 56 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) • Turn Signal Control - The left multi-function six terminal pins for the wiper control circuits of the switch. switch control stalk provides both momentary non- The multi-function switch cannot be adjusted or detent switching and detent switching with auto- repaired.
Page 494 LAMPS/LIGHTING - EXTERIOR 8L - 57 MULTI-FUNCTION SWITCH (Continued) LEFT CONTROL STALK responds by de-energizing its internal courtesy lamp driver circuit. The left (lighting) control stalk of the multi-func- • Interior Lamps On - The control ring on the tion switch operates as follows: •...
Page 495 8L - 58 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) gizing or de-energizing the park lamp relay in the high speed continuous front wiper mode. The multi- Junction Block (JB). function switch provides a resistor multiplexed out- • Rear Fog Lamps - For vehicles so equipped, put to the Body Control Module (BCM) on a front the control knob on the end of the multi-function wiper switch circuit, and the BCM responds by ener-...
Page 496 LAMPS/LIGHTING - EXTERIOR 8L - 59 MULTI-FUNCTION SWITCH (Continued) switch provides a battery voltage output to the rear further diagnosis or service. This is the only sure wiper motor on a rear wiper intermittent driver cir- way to disable the supplemental restraint system. cuit to signal the rear wiper motor to operate in the Failure to take the proper precautions could result intermittent wipe mode.
Page 497 8L - 60 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) MULTI-FUNCTION SWITCH TESTS EXTERIOR LIGHTING FUNCTIONS SWITCH POSITION CONNECTOR C-1 PINS RESISTANCE (OHMS) ±10% 4 & 5 3781 Park Lamps On 4 & 5 Headlamp Low Beams On 4 & 5 Rear Fog Lamps On 4 &...
Page 498 LAMPS/LIGHTING - EXTERIOR 8L - 61 MULTI-FUNCTION SWITCH (Continued) (4) If the switch fails any of the tests, replace the faulty multi-function switch as required. REMOVAL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supple- mental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact...
Page 499 8L - 62 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) (7) If the vehicle is equipped with the optional tilt operated by the park brake lever mechanism. The steering column, move the tilt steering column back switch is grounded through its mounting to the park to the fully raised position and move the tilt release brake lever mechanism and provides a ground input lever into the locked (up) position.
Page 500 LAMPS/LIGHTING - EXTERIOR 8L - 63 PARK BRAKE SWITCH (Continued) (2) Disconnect the instrument panel wire harness connector for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness con- nector for the instrument cluster.
Page 501 8L - 64 LAMPS/LIGHTING - EXTERIOR PARK BRAKE SWITCH (Continued) (4) Reinstall the console onto the floor panel trans- OPERATION mission tunnel. (Refer to 23 - BODY/INTERIOR/ The park lamp relay is an electromechanical FLOOR CONSOLE - INSTALLATION). switch that uses a low current input from the Body (5) Reconnect the battery negative cable.
Page 502 LAMPS/LIGHTING - EXTERIOR 8L - 65 PARK/TURN SIGNAL LAMP REMOVAL BULB Fig. 66 Front Park/Turn Signal Lamp Unit Remove/ Install 1 - LAMP 2 - FENDER FLARE 3 - SCREW 4 - FASCIA Fig. 65 Front Park/Turn Signal Lamp Bulb Remove/ Install 1 - LAMP 2 - SOCKET...
Page 503 8L - 66 LAMPS/LIGHTING - EXTERIOR PARK/TURN SIGNAL LAMP (Continued) for each bulb are the same, only the bulb sizes and INSTALLATION types may differ. (1) Disconnect and isolate the battery negative BULB cable. (2) Remove the rear lamp unit from the end of the CAUTION: Always use the correct bulb size and quarter panel.
Page 504 LAMPS/LIGHTING - EXTERIOR 8L - 67 REAR LAMP UNIT (Continued) LAMP (1) Install two new plastic grommets into the quar- ter panel (Fig. 69). (2) Position the rear lamp unit to the quarter panel. (3) Reconnect the wire harness connector to the lamp socket plate connector.
Page 505 8L - 68 LAMPS/LIGHTING - EXTERIOR REPEATER LAMP (Continued) INSTALLATION BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. NOTE: Side repeater lamps are used only on vehi- cles manufactured for certain markets where these lamps are required.
Page 506 LAMPS/LIGHTING - EXTERIOR 8L - 69 TRAILER TOW CONNECTOR (Continued) (2) Remove the four screws that secure the trailer tow connector to the bracket on the trailer hitch receiver (Fig. 72). Fig. 73 Trailer Tow Relays Fig. 72 Trailer Tow Connector Remove/Install 1 - RELAY CONNECTOR BANK 1 - HITCH RECEIVER 2 - REAR BODY WIRE HARNESS...
Page 507 8L - 70 LAMPS/LIGHTING - EXTERIOR TRAILER TOW RELAY (Continued) ergized, spring pressure returns the movable contact (2) Remove the trim from the right side quarter back against the normally closed contact. inner panel. (Refer to 23 - BODY/INTERIOR/QUAR- The inputs and outputs of the trailer tow relays TER TRIM PANEL - REMOVAL).
Page 508 LAMPS/LIGHTING - EXTERIOR 8L - 71 TRAILER TOW RELAY (Continued) CAUTION: Use proper precautions to protect your skin and the rear body wire harness from cuts or scrapes caused by contact with the sharp edges of the quarter inner panel sheet metal while servicing the trailer tow relay connector bank.
Page 509 8L - 72 LAMPS/LIGHTING - EXTERIOR TRAILER TOW WIRING (Continued) cushion of the vehicle when it is shipped from the OPERATION factory) that adapts the 7-pin trailer tow connector to When the multi-function switch control stalk is a standard, light-duty, 4-pin trailer tow connector. moved to a latched turn signal position, a turn signal Refer to the appropriate wiring information.
Page 510 LAMPS/LIGHTING - INTERIOR 8L - 73 LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR LAMP ......83 DESCRIPTION .
Page 511 8L - 74 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR (Continued) Fig. 1 Courtesy Lamps 1 - COURTESY LAMP (2) 4- REAR DOME/READING LAMP 2 - FRONT DOME/READING LAMP 5 - CARGO LAMP 3 - VANITY LAMP (2) • Vanity Lamps - Available single intensity van- incandescent bulbs or bulb/bulb holder units in this ity lamps are located on each side of a covered mirror vehicle include:...
Page 512 LAMPS/LIGHTING - INTERIOR 8L - 75 LAMPS/LIGHTING - INTERIOR (Continued) • Heater-Air Conditioner Control Illumina- grams, proper wire and connector repair procedures, tion Lamps - The heater-air conditioner control has further details on wire harness routing and reten- two replaceable control illumination bulb/bulb holder tion, as well as pin-out and location views for the units on its circuit board that are controlled by the various wire harness connectors, splices and grounds.
Page 513 8L - 76 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR (Continued) from all of the ajar switches. A hard wired input from trol ring of the multi-function switch is moved to the the courtesy lamp defeat switch in the optional cargo Parade Mode detent position, all of the VFD units lamp will cause the BCM to override normal courtesy are illuminated at their full intensity levels for...
Page 514 LAMPS/LIGHTING - INTERIOR 8L - 77 LAMPS/LIGHTING - INTERIOR (Continued) NOTE: A good ground is necessary for proper light- However, conventional diagnostic methods may not ing operation. If a lighting problem is being diag- prove conclusive in the diagnosis of the Body Control Module (BCM), the ElectroMechanical Instrument nosed that involves multiple symptoms, systems, or components, the problem can often be traced to a...
Page 515 8L - 78 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION A SINGLE LAMP IN THE 1. Faulty lamp switch. 1. Test and replace a faulty map/reading COURTESY LAMP CIRCUIT lamp switch, cargo lamp switch, or sunvisor DOES NOT EXTINGUISH (vanity lamp switch) as required.
Page 516 LAMPS/LIGHTING - INTERIOR 8L - 79 LAMPS/LIGHTING - INTERIOR (Continued) momentary leaf contact-type unit that is actuated by SPECIFICATIONS the flip-up glass latch mechanism. An integral dedi- cated connector receptacle on the flip-up glass latch LAMPS/LIGHTING - INTERIOR connects the flip-up glass ajar switch to the vehicle electrical system through the tailgate wire harness.
Page 517 8L - 80 LAMPS/LIGHTING - INTERIOR AJAR SWITCH (Continued) bus, and both the hard wired and electronic message Instrument Cluster (EMIC) over the Programmable inputs and outputs affected by the door ajar switch Communications Interface (PCI) data bus and uses inputs requires the use of a diagnostic scan tool.
Page 518 LAMPS/LIGHTING - INTERIOR 8L - 81 ASH RECEIVER LAMP (Continued) Fig. 2 Ash Receiver Lamp Bulb Fig. 3 Ash Receiver Lamp 1 - SOCKET 1 - CENTER BEZEL 2 - BULB 2 - ASH RECEIVER HOUSING 3 - HOOD 3 - ASH RECEIVER LAMP UNIT LAMP INSTALLATION BULB...
Page 519: Cargo Lamp
8L - 82 LAMPS/LIGHTING - INTERIOR ASH RECEIVER LAMP (Continued) LAMP WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supple- mental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service.
Page 520: Courtesy Lamp
LAMPS/LIGHTING - INTERIOR 8L - 83 CARGO LAMP (Continued) further diagnosis or service. This is the only sure INSTALLATION way to disable the supplemental restraint system. Failure to take the proper precautions could result BULB in accidental airbag deployment. (1) Disconnect and isolate the battery negative CAUTION: Always use the correct bulb size and cable.
Page 521: Dome Lamp
8L - 84 LAMPS/LIGHTING - INTERIOR COURTESY LAMP (Continued) (3) Align the lens with the courtesy lamp unit housing. (4) Support the lamp housing with one hand while firmly and evenly pushing the lens into the housing with the other hand, until the lens snaps into place. (5) Reconnect the battery negative cable.
Page 522 LAMPS/LIGHTING - INTERIOR 8L - 85 DOME LAMP (Continued) (4) Swing the lens outward until it is perpendicu- lar to the housing. (5) Pull the lens hinge/retainer end of the housing outward slightly from the headliner, then slide the exposed end of the housing away from the mounting hole far enough to disengage the fixed retainer on the notched end from the headliner.
Page 523 8L - 86 LAMPS/LIGHTING - INTERIOR ILLUMINATION LAMP REMOVAL BULB - CMTC CONTROL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supple- mental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service.
Page 524 LAMPS/LIGHTING - INTERIOR 8L - 87 ILLUMINATION LAMP (Continued) BULB - TRANSMISSION RANGE INDICATOR INSTALLATION WARNING: To avoid personal injury or death, on BULB - CMTC CONTROL vehicles equipped with airbags, disable the supple- mental restraint system before attempting any WARNING: To avoid personal injury or death, on steering wheel, steering column, airbag, occupant vehicles equipped with airbags, disable the supple-...
Page 525 8L - 88 LAMPS/LIGHTING - INTERIOR ILLUMINATION LAMP (Continued) BULB - A/C-HEAT CONTROL (1) Align the base of the bulb with the transmis- sion range indicator illumination lamp socket. (2) Push the bulb straight into the socket until the WARNING: To avoid personal injury or death, on base is firmly seated.
Page 526 LAMPS/LIGHTING - INTERIOR 8L - 89 VANITY LAMP (Continued) (4) Using small needle-nose pliers, carefully grasp INSTALLATION - BULB the bulb and pull the base out of the lamp socket (Fig. 14). CAUTION: Always use the correct bulb size and type for replacement.
Page 528 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE OPERATION ......10 DESCRIPTION .
Page 529 8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) the technician trying to find a problem with a over- head console component. Diagnostic logic is built into the overhead console mounted module to help the person trying to locate the problem by the most effi- cient means possible.
Page 530 MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) NOTE: If the compass functions, but accuracy is STANDARD PROCEDURE - COURTESY LAMP suspect, it may be necessary to perform a variation REPLACEMENT adjustment. This procedure allows the compass (1) Open hood, disconnect and isolate the negative unit to accommodate variations in the earth’s mag- battery cable.
Page 531 8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) NOTE: If the “CAL” message remains in the display, either there is excessive magnetism near the com- pass, or the unit is faulty. Repeat the calibration procedure one more time. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field.
Page 532 MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) locations, the difference between magnetic and geo- (6) Momentarily depress and release the Reset graphic north is great enough to cause the compass push button to enter the displayed zone number into to give false readings.
Page 533 8M - 6 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) Fig. 7 VARIANCE SETTINGS - EXPORT REGION (2) Depress and release the Menu push button. PROGRAMMABLE FEATURES • LANGUAGE? - The options include English, The first item in the programmable features menu list will appear in the EVIC display.
Page 534 MESSAGE SYSTEMS 8M - 7 OVERHEAD CONSOLE (Continued) Auto Door Unlock event will only occur once follow- mile increments (3200 to 9600 kilometers in 800 kilo- ing each Auto Door Lock event. meter increments). The default is 6000 miles (9600 •...
Page 535 8M - 8 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) (4) Install the overhead console retaining screw, REMOVAL located in the front of console near the windshield. Torque the screw to 1.2 N·m (10 in. lbs.). OVERHEAD CONSOLE - REMOVAL (5) Connect the negative battery cable. (1) Disconnect and isolate the negative battery cable.
Page 536 MESSAGE SYSTEMS 8M - 9 ELECTRONIC VEHICLE INFO CENTER (Continued) • Elapsed time - shows the accumulated igni- tion-on time since the last trip computer reset. • Service Mileage - shows the distance remain- ing until the next scheduled service interval. •...
Page 537 8M - 10 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) directly on the roof of the vehicle. Magnetic mounts ture display mode from any other mode. While in the for an antenna, a repair order hat, or a funeral pro- compass/temperature display mode,...
Page 538 MESSAGE SYSTEMS 8M - 11 ELECTRONIC VEHICLE INFO CENTER (Continued) If not OK, repair the shorted circuit or component as through the PCI data bus. This can result from one required and replace the faulty fuse. or more faulty electronic modules in the vehicle, or (5) Turn the ignition switch to the On position.
Page 539: Universal Transmitter
8M - 12 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) tems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote opera- tion. The universal transmitter is capable of operat- ing systems using either rolling code or non-rolling code technology.
Page 540 MESSAGE SYSTEMS 8M - 13 UNIVERSAL TRANSMITTER (Continued) and reverse - does not meet current U.S. federal safety standards. WARNING: Your motorized door or gate will open and close while you are programming. Do not pro- gram the universal transmitter if people or pets are in the path of the door or gate.
Page 541 8M - 14 MESSAGE SYSTEMS UNIVERSAL TRANSMITTER (Continued) NOTE: There are 30 seconds in which to initiate the correspond to a specific temperature. The PCM then next step. sends the proper ambient temperature messages to the EVIC over the PCI data bus. (7) Return to the vehicle and firmly press, hold for The thermometer function is supported by the two seconds and release the programmed Transmit-...
Page 542 MESSAGE SYSTEMS 8M - 15 AMBIENT TEMP SENSOR (Continued) nector. Check for continuity between the sensor (2) Remove the grille from the vehicle. return circuit cavity of the PCM wire harness connec- (3) Disconnect the ambient temperature sensor tor and a good ground. There should be no continuity. electrical connector.
Page 544 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER TOP - SUNROOF .
Page 545: Programming Additional Transmitters
8N - 2 POWER LOCKS POWER LOCKS (Continued) The rolling door lock feature can be disabled if the RKE transmitter Unlock button is depressed the desired. first time. The remaining doors and the tailgate This vehicle also offers several customer program- unlock when the button is depressed a second time mable features, which allows the selection of several within 5 seconds of the first unlock press.
Page 546 POWER LOCKS 8N - 3 POWER LOCKS (Continued) COMBINATION FLASHER RKE lock/unlock button under these conditions will result in a normal lock/unlock activation. This flasher can be energized by the BCM to flash After the key is removed from the Ignition Switch, all of the park/turn signal lamps as a optical alert for or the doors are closed, the power door locks will the RKE panic function and, if the Flash Lights with...
Page 547 8N - 4 POWER LOCKS POWER LOCKS (Continued) ing the proper messages on the PCI data bus, mitter, proceed to diagnosis of the power lock motor. and that the power lock motors are being sent (Refer to 8 - ELECTRICAL/POWER LOCKS/POWER the proper hard wired outputs by the relays for LOCK MOTOR - DIAGNOSIS AND TESTING).
Page 548 POWER LOCKS 8N - 5 DOOR LOCK / UNLOCK SWITCH (Continued) DOOR LOCK MOTOR DESCRIPTION The lock mechanisms are actuated by a reversible electric motor mounted within each door and tailgate. The power lock motors are integral to the door latch units.
Page 549 8N - 6 POWER LOCKS If a functioning transmitter is available, (Refer to 8 DOOR LOCK RELAY - ELECTRICAL/POWER LOCKS/KEYLESS ENTRY TRANSMITTER - STANDARD PROCEDURE) REMOVAL (1) Disconnect and isolate the battery negative DIAGNOSIS AND TESTING - REMOTE KEYLESS cable. ENTRY MODULE (2) Reach up under instrument panel and remove Refer to the proper Body Diagnostic Procedures...
Page 550: Remote Keyless Entry Transmitter
POWER LOCKS 8N - 7 To ENABLE the horn chirp feature, repeat the REMOTE KEYLESS ENTRY above procedure. TRANSMITTER OPTICAL CHIRP (FLASH) DISABLING / ENABLING DIAGNOSIS AND TESTING - REMOTE KEYLESS The optical chirp can be toggled using a DRB III ENTRY TRANSMITTER or by using the Remote Keyless Entry (RKE) trans- mitter.
Page 551 8N - 8 POWER LOCKS REMOTE KEYLESS ENTRY TRANSMITTER (Continued) (4) Press LOCK and UNLOCK buttons simulta- OPERATION neously for 1 second and release. The tailgate cylinder lock switch is actuated when (5) Press and release any button on the same the key is inserted in the lock cylinder and turned to transmitter and a chime will sound after successfully the unlock or lock position.
Page 552 POWER LOCKS 8N - 9 TAILGATE CYLINDER LOCK SWITCH (Continued) INSTALLATION (1) Position the tailgate cylinder lock switch onto the back of the lock cylinder with the wire harness oriented toward the bottom. (2) Position the washer over the switch. (3) Install the retainer clip onto the pin on the back of the tailgate lock cylinder.
Page 553 8N - 10 POWER MIRRORS POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS OPERATION ......12 DESCRIPTION .
Page 554 POWER MIRRORS 8N - 11 POWER MIRRORS (Continued) • Connect the other to a good body ground The automatic day/night mirror sensitivity cannot • Refer to the Mirror Motor Test Chart for proper be repaired or adjusted. If any component of this unit wire connections at the switch connector is inoperative or damaged, the entire automatic day/ night inside rear view mirror unit must be replaced.
Page 555 8N - 12 POWER MIRRORS AUTOMATIC DAY / NIGHT MIRROR (Continued) (4) Turn the ignition switch to the Off position. POWER FOLDAWAY MIRROR Check for continuity between the ground circuit cav- SWITCH - EXPORT ity of the overhead wire harness connector for the automatic day/night mirror and a good ground.
Page 556 POWER MIRRORS 8N - 13 POWER FOLDAWAY MIRROR SWITCH - EXPORT (Continued) DIAGNOSIS AND TESTING - POWER SWITCH POSITION CONTINUITY BETWEEN FOLDAWAY MIRROR SWITCH - EXPORT LEFT 5 AND 6 (1) Disconnect and isolate the battery negative 3 AND 10 cable.
Page 557 8N - 14 POWER MIRRORS POWER MIRROR SWITCH (Continued) SWITCH POSITION CONTINUITY BETWEEN RIGHT 5 AND 1 3 AND 6 MIRROR SELECT SWITCH IN RIGHT POSITION 5 AND 9 3 AND 6 DOWN 5 AND 6 3 AND 9 LEFT 5 AND 6 3 AND 10 RIGHT...
Page 558 POWER SEATS 8N - 15 POWER SEATS TABLE OF CONTENTS page page POWER SEATS OPERATION ......18 DESCRIPTION .
Page 559 8N - 16 POWER SEATS POWER SEATS (Continued) on wire harness routing and retention, as well as pin-out and location views for the various wire har- ness connectors, splices and grounds. OPERATION The power seat system receives battery current through a fuse in the Power Distribution Center (PDC) and a circuit breaker in the Junction Block, regardless of the ignition switch position.
Page 560 POWER SEATS 8N - 17 LEFT POWER SEAT SWITCH (Continued) No power seat switch should be held applied in any direction after the seat track has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload.
Page 561 8N - 18 POWER SEATS LEFT POWER SEAT SWITCH (Continued) switch to the inside of the outboard seat cushion side CENTER PIN 1 to 3 PIN 1 to 3 shield. SWITCH (8) Remove the power seat switch from the out- PIN 5 to 6 PIN 5 to 6 REARWARD...
Page 562 POWER SEATS 8N - 19 RIGHT POWER SEAT SWITCH (Continued) operates to move the seat track through its drive unit in the selected direction until the switch is released, or until the travel limit of the seat track is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts.
Page 563 8N - 20 POWER SEATS RIGHT POWER SEAT SWITCH (Continued) switch to the inside of the outboard seat cushion side CENTER PIN 1 to 3 PIN 1 to 3 shield. SWITCH (8) Remove the power seat switch from the out- PIN 5 to 6 PIN 5 to 6 REARWARD...
Page 564 POWER SEATS 8N - 21 POWER SEAT TRACK (Continued) SEAT TRACK MOTOR TEST SEAT SWITCH CONNECTOR CONNECT JUMPER SEAT ACTION B(+) B(–) LEFT SIDE RIGHT SIDE PIN 9 PIN 8 FRONT FRONT RISER UP RISER DOWN PIN 8 PIN 9 FRONT FRONT RISER...
Page 565 8N - 22 POWER TOP - SUNROOF POWER TOP - SUNROOF TABLE OF CONTENTS page page POWER TOP - SUNROOF STANDARD PROCEDURE - INITIALIZATION . 25 DESCRIPTION ......22 REMOVAL .
Page 566 POWER TOP - SUNROOF 8N - 23 POWER TOP - SUNROOF (Continued) Check the condition of the circuit protection and wire and connector repair procedures, details of wire inspect all wiring connector pins for proper engage- harness routing and retention, connector pin-out ment and continuity.
Page 567 8N - 24 POWER TOP - SUNROOF POWER TOP - SUNROOF (Continued) SYMPTOM POSSIBLE CAUSE CORRECTION Sunroof vents, but does not Binding cable or mechanism. Repair or replace binding cable as open. necessary. Inoperative sunroof OPEN circuit. Check the condition of the circuit, connections and wiring.
Page 568 POWER TOP - SUNROOF 8N - 25 MOTOR/MODULE - SUNROOF (Continued) STANDARD PROCEDURE - RE-INITIALIZATION STANDARD PROCEDURE STANDARD PROCEDURE - POWER SUNROOF NOTE: If for some reason the sunroof is not oper- ating normally it may be necessary to re-initialize TIMING the sunroof assembly.
Page 569 8N - 26 POWER TOP - SUNROOF MOTOR/MODULE - SUNROOF (Continued) • The glass panel has not reached its closed posi- (7) Remove headliner as necessary to gain access tion. to sunroof motor/module. (Refer to 23 - BODY/INTE- RIOR/HEADLINER - REMOVAL). NOTE: if the initialization procedure is not carried (8) Disconnect the motor/module wire harness con- out completely, it must be started over.
Page 570 POWER TOP - SUNROOF 8N - 27 rocker type switch for opening and closing the sun- SWITCH - SUNROOF roof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector DESCRIPTION will raise. If the button is pressed a second time the The power sunroof switch is a combination push- sunroof will stop in that position.
Page 571 8N - 28 POWER TOP - SUNROOF SWITCH - SUNROOF (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the overhead console from the head- liner (Refer to 8 - ELECTRICAL/OVERHEAD CON- SOLE - REMOVAL). (3) Disconnect the switch electrical connector. (4) To remove the switch from the overhead con- sole, push on the back of the switch until it comes free from the overhead console.
Page 572 POWER WINDOWS 8N - 29 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS WINDOW SWITCH DESCRIPTION ......29 DIAGNOSIS AND TESTING - WINDOW OPERATION .
Page 573 8N - 30 POWER WINDOWS POWER WINDOWS (Continued) When positive probe is connected the motor should SWITCH POSITION CONTINUITY BETWEEN rotate in one direction to either move window up or LEFT FRONT UP 10 AND 11 down. If window is all the way up or down the motor LEFT FRONT DOWN 10 AND 9 will grunt and the inner door panel will flex when...
Page 574 POWER WINDOWS 8N - 31 WINDOW SWITCH (Continued) allows the window to roll down and stop when the (2) Using a trim stick, gently pry the switch from switch is released. The second detent position actu- the console (Fig. 4). ates an integral express roll down relay that rolls the window down after the switch is released.
Page 576 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS SIDE ....... 30 DESCRIPTION .
Page 577 8O - 2 RESTRAINTS OPERATION ......53 OPERATION ......55 SEAT BELT TURNING LOOP ADJUSTER REMOVAL .
Page 578 RESTRAINTS 8O - 3 RESTRAINTS (Continued) Fig. 1 Supplemental Restraint System 1 - FRONT IMPACT SENSOR (2) 5 - AIRBAG CONTROL MODULE 2 - PASSENGER AIRBAG 6 - FRONT SEAT BELT TENSIONER (2) 3 - DRIVER AIRBAG 7 - SIDE IMPACT SENSOR (WITH SIDE CURTAIN AIRBAG ONLY - 4 - SEAT WEIGHT BLADDER &...
Page 579 8O - 4 RESTRAINTS RESTRAINTS (Continued) secured to the outboard side of the passenger side front seat cushion frame. • Clockspring - The clockspring is located near the top of the steering column, directly beneath the steering wheel. • Driver Airbag - The driver airbag is located in the center of the steering wheel, beneath the driver airbag trim cover.
Page 580 RESTRAINTS 8O - 5 RESTRAINTS (Continued) each inside roof side rail, and extends from the A-pil- sive restraints because the vehicle occupants are not lar to just beyond the C-pillar. The side curtain air- required to do anything to make them operate; how- bags are concealed above the headliner trim.
Page 581 8O - 6 RESTRAINTS RESTRAINTS (Continued) at the given speed. Actual times will vary somewhat, tion messages received from the OCM. This indicator depending upon the vehicle speed, impact angle, is illuminated whenever the passenger airbag and severity of the impact, and the type of collision. seat belt tensioner operation has been suppressed, When the ACM monitors a problem in any of the and is turned off whenever the seat is empty or when...
Page 582 RESTRAINTS 8O - 7 RESTRAINTS (Continued) WARNING: To avoid personal injury or death, on restraint system components must never vehicles equipped with airbags, disable the supple- replaced with any substitutes. These fasteners have mental restraint system before attempting any special coatings and are specifically designed for steering wheel, steering column, airbag, occupant the restraint system.
Page 583 8O - 8 RESTRAINTS RESTRAINTS (Continued) deployment. If the airbag unit is placed on a bench or On vehicles with an optional sunroof, the sunroof any other surface, the trim cover or airbag cushion drain tubes and hoses must be closely inspected fol- side of the unit should be face up to minimize move- lowing a side curtain airbag deployment.
Page 584 RESTRAINTS 8O - 9 RESTRAINTS (Continued) (2) Turn the ignition switch to the On position. Using the active DTC information, refer to the Air- (3) Using the scan tool, read and record the active bag Squib Status table to determine the status of (current) Diagnostic Trouble Code (DTC) data.
Page 585 8O - 10 RESTRAINTS RESTRAINTS (Continued) steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery neg- ative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service.
Page 586 RESTRAINTS 8O - 11 RESTRAINTS (Continued) (9) Turn the ignition switch to the Off position for to the bottom of the ACM housing with four screws about fifteen seconds, and then back to the On posi- to enclose and protect the internal electronic circuitry tion.
Page 587 8O - 12 RESTRAINTS AIRBAG CONTROL MODULE (Continued) detects a monitored system fault, it sets an active restraint system protection in case there is a loss of and stored Diagnostic Trouble Code (DTC) and sends battery current supply to the ACM during an impact. electronic messages to the EMIC over the PCI data Two sensors are contained within the ACM, an bus to turn on the airbag indicator.
Page 588 RESTRAINTS 8O - 13 AIRBAG CONTROL MODULE (Continued) REMOVAL (3) The ACM cover is secured to the ACM by a latch tab located on each side of the cover (Fig. 8). Gently pry both latch tabs away from the ACM far WARNING: To avoid personal injury or death, on enough to disengage the latches from the slots in the vehicles equipped with airbags, disable the supple-...
Page 589 8O - 14 RESTRAINTS AIRBAG CONTROL MODULE (Continued) CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then per- form the supplemental restraint verification test before replacing the other.
Page 590 RESTRAINTS 8O - 15 load changes, the circuitry of the belt tension sensor BELT TENSION SENSOR changes the output voltage of the sensor. The belt tension sensor receives a nominal five DESCRIPTION volts and a ground through dedicated hard wired cir- cuits from the OCM.
Page 591 8O - 16 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) Fig. 11 Child Restraint Anchor Locations 1 - LOWER ANCHOR (PROVIDED FOR REAR OUTBOARD 2 - TETHER ANCHOR (PROVIDED FOR REAR CENTER AND SEATING POSITIONS ONLY) OUTBOARD SEATING POSITIONS) Fig. 12 Child Tether Anchors Fig.
Page 592 RESTRAINTS 8O - 17 CHILD RESTRAINT ANCHOR (Continued) WARNING: To avoid personal injury or death, during housing near the top of the steering column behind and following any seat belt or child restraint anchor the steering wheel (Fig. 14). The clockspring consists of a flat, round molded plastic case with a stubby tail service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and...
Page 593 8O - 18 RESTRAINTS CLOCKSPRING (Continued) the steering column. (Refer to 8 - ELECTRICAL/RE- the clockspring tape to the movable steering compo- STRAINTS/CLOCKSPRING - STANDARD PROCE- nents so that the tape can operate within its DURE - CLOCKSPRING CENTERING). designed travel limits. However, if the clockspring is Two versions of the clockspring are used on this removed from the steering column or if the steering model, one is a seven circuit unit for vehicles not...
Page 594 RESTRAINTS 8O - 19 CLOCKSPRING (Continued) (2) Disconnect and isolate the battery negative cable. (3) Remove the driver airbag from the steering wheel. (Refer to 8 - ELECTRICAL/RESTRAINTS/ DRIVER AIRBAG - REMOVAL). (4) Disconnect the steering wheel wire harness connector from the upper clockspring connector receptacle.
Page 595 8O - 20 RESTRAINTS CLOCKSPRING (Continued) (10) Disconnect the two instrument panel wire NOTE: Before starting this procedure, be certain harness connectors for the clockspring from the two that the front wheels are in the straight-ahead posi- connector receptacles located below the steering col- tion.
Page 596: Curtain Airbag
RESTRAINTS 8O - 21 clips. The pigtail harness is connected to a take out CURTAIN AIRBAG and connector of the body wire harness on the B-pil- lar, which connects the airbag unit to the Airbag DESCRIPTION Control Module (ACM). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, faulty, or in any way damaged.
Page 597 8O - 22 RESTRAINTS CURTAIN AIRBAG (Continued) Fig. 19 Side Curtain Airbag 1 - INFLATOR 5 - PIGTAIL WIRE RETAINER (3) 2 - MANIFOLD 6 - PUSH-IN FASTENER (4) 3 - CHANNEL 7 - BRACKET (3) 4 - TETHER WARNING: To avoid personal injury or death, on WARNING: To avoid personal injury or death, use vehicles equipped with airbags, disable the supple- extreme care to prevent any foreign material from...
Page 598 RESTRAINTS 8O - 23 CURTAIN AIRBAG (Continued) (7) Disengage the three side curtain airbag pigtail wire retainer clips from the B-pillar. (8) Remove the three screws that secure the side curtain airbag manifold tube brackets to the U-nuts in the roof rail (Fig. 22) and (Fig. 23). Fig.
Page 599 8O - 24 RESTRAINTS CURTAIN AIRBAG (Continued) Fig. 23 Side Curtain Airbag (Rear) Remove/Install 1 - ROOF PANEL 2 - SCREW (3) 3 - U-NUT (5) Fig. 24 Side Curtain Airbag Inflator Remove/Install 4 - PIGTAIL WIRE 5 - MANIFOLD 1 - U-NUT (5) 6 - C-PILLAR 2 - ROOF PANEL...
Page 600: Driver Airbag
All low or black-jacketed, two-wire pigtail harnesses of models have a bright silver Jeep logo applied to the the clockspring. center of the trim cover. Concealed beneath the...
Page 601 8O - 26 RESTRAINTS DRIVER AIRBAG (Continued) state before they are burned, but they are securely sealed within the airbag inflator. Typically, both ini- tiators are used and all potentially hazardous chem- icals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault;...
Page 602 RESTRAINTS 8O - 27 DRIVER AIRBAG (Continued) NOTE: The following procedure is for replacement (3) Pull the driver airbag away from the steering of a faulty or damaged driver airbag. If the airbag is wheel far enough to access the three electrical con- nections on the back of the airbag housing.
Page 603 8O - 28 RESTRAINTS DRIVER AIRBAG (Continued) pull the insulators straight out from the airbag infla- CEDURE - SERVICE AFTER A SUPPLEMENTAL tor to disconnect them from the connector recepta- RESTRAINT DEPLOYMENT). cles. (1) Position the driver airbag close enough to the (6) Remove the driver airbag from the steering steering wheel to reconnect the three electrical con- wheel.
Page 604 RESTRAINTS 8O - 29 IMPACT SENSOR (Continued) remotely from the impact sensor that is internal to the Airbag Control Module (ACM). Each side sensor is secured with a screw to the inner right or left B-pillar above the front seat belt retractor within the passenger compartment.
Page 605 8O - 30 RESTRAINTS IMPACT SENSOR (Continued) SIDE deploy the front supplemental restraints. If an impact sensor is accidentally dropped during ser- The side impact sensors are electronic accelerome- vice, the sensor must be scrapped and replaced ters that sense the rate of vehicle deceleration, which with a new unit.
Page 606 RESTRAINTS 8O - 31 IMPACT SENSOR (Continued) WARNING: To avoid personal injury or death, never INSTALLATION strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. FRONT The side impact sensor enables the system to deploy the side curtain supplemental restraints.
Page 607 8O - 32 RESTRAINTS IMPACT SENSOR (Continued) SIDE OCCUPANT CLASSIFICATION MODULE WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supple- DESCRIPTION mental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service.
Page 608 RESTRAINTS 8O - 33 OCCUPANT CLASSIFICATION MODULE (Continued) ponents of the passenger side front seat cushion Pre-programmed decision algorithms and OCS cal- including the cushion frame, springs, insulator pad, ibration allow the OCM microprocessor to determine seat weight bladder and pressure sensor, seat cush- when passenger airbag protection is appropriate ion foam, wiring harness and the OCM are a factory- based upon the seat cushion load as signaled by the...
Page 609 8O - 34 RESTRAINTS OCCUPANT CLASSIFICATION MODULE (Continued) REMOVAL Failure to take the proper precautions could result in accidental airbag deployment. A non-calibrated Occupant Classification Module (OCM) is the only component of the Occupant Clas- WARNING: To avoid personal injury or death on sification System (OCS) that is available for separate vehicles equipped with the Occupant Classification service replacement, as outlined in the procedures...
Page 610 RESTRAINTS 8O - 35 OCCUPANT CLASSIFICATION MODULE (Continued) unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle.
Page 611: Passenger Airbag
8O - 36 RESTRAINTS OCCUPANT CLASSIFICATION MODULE (Continued) CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then per- form the supplemental restraint verification test before replacing the other.
Page 612 RESTRAINTS 8O - 37 PASSENGER AIRBAG (Continued) mounting brackets that are fastened with screws to determined tear seam lines on the inside surface of the instrument panel structural support. the door and the door will pivot out of the way. Fol- The passenger airbag unit used in this model is a lowing a passenger airbag deployment, the airbag multistage unit that complies with revised federal...
Page 613 8O - 38 RESTRAINTS PASSENGER AIRBAG (Continued) NOTE: The following procedure is for replacement CAUTION: Do not pull on the instrument panel wire of a faulty or damaged passenger airbag. If the air- harness passenger airbag take outs or pry on the bag is faulty or damaged, but not deployed, review connector insulators to disengage the connectors the recommended procedures for handling non-de-...
Page 614 RESTRAINTS 8O - 39 PASSENGER AIRBAG (Continued) (3) Remove the passenger side bezel from the NOTE: The passenger airbag mounting brackets upper glove box opening of the instrument panel. cannot be repaired. They must be replaced if faulty (Refer to 23 - BODY/INSTRUMENT PANEL/IP PAS- or damaged, or if the passenger airbag has been SENGER SIDE BEZEL - REMOVAL).
Page 615 8O - 40 RESTRAINTS PASSENGER AIRBAG (Continued) WARNING: To avoid personal injury or death, use DOOR extreme care to prevent any foreign material from entering passenger airbag, becoming WARNING: To avoid personal injury or death on entrapped between the passenger airbag cushion vehicles equipped with airbags, disable the supple- and the passenger airbag door.
Page 616 RESTRAINTS 8O - 41 PASSENGER AIRBAG (Continued) BRACKETS WARNING: To avoid personal injury or death on vehicles equipped with airbags, disable the supple- mental restraint system before attempting any steering wheel, steering column, driver airbag, pas- senger airbag, occupant classification system, seat belt tensioner, front impact sensor, side impact sen- sor, side curtain airbag, or instrument panel compo- nent diagnosis or service.
Page 617 8O - 42 RESTRAINTS PASSENGER AIRBAG ON/OFF INDICATOR (Continued) • Bulb Test - Each time the ignition switch is diagnosis of the OCM, the ACM, the PCI data bus, or turned to the On position the passenger airbag on/off the electronic message inputs to the ACM that con- indicator is illuminated for about six seconds.
Page 618 RESTRAINTS 8O - 43 PASSENGER AIRBAG ON/OFF INDICATOR (Continued) snap feature of the end cap to the bottom of the grab handle. (5) Using hand pressure, push the upper edge of the end cap firmly and evenly over the top of the grab handle until the cap snaps into place.
Page 619 8O - 44 RESTRAINTS SEAT BELT BUCKLE (Continued) WARNING: To avoid personal injury or death, during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or dam- age.
Page 620 RESTRAINTS 8O - 45 SEAT BELT BUCKLE (Continued) REAR INSTALLATION WARNING: To avoid personal injury or death, during FRONT and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, WARNING: To avoid personal injury or death, on mounting hardware, retractors, tether straps, and vehicles equipped with airbags, disable the supple- anchors for proper installation, operation, or dam-...
Page 621 8O - 46 RESTRAINTS SEAT BELT BUCKLE (Continued) (6) On the driver side only, install and tighten the (3) Lower the rear seat belt buckle anchor over the two screws that secure the inboard seat cushion side stud on the rear floor panel. shield to the seat cushion frame.
Page 622 RESTRAINTS 8O - 47 SEAT BELT & RETRACTOR (Continued) NOTE: On vehicles equipped with the Occupant Classification System (OCS), the passenger side front seat belt and retractor unit includes a belt ten- sion sensor that is integral to the lower seat belt anchor, which is secured to the outboard side of the passenger side front seat cushion frame.
Page 623 8O - 48 RESTRAINTS SEAT BELT & RETRACTOR (Continued) (10) Remove the lower trim from the inside of the B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR LOWER TRIM - REMOVAL). (11) Disconnect the body wire harness connector from the seat belt tensioner pigtail wire connector. (12) Remove the screw that secures the lower retractor bracket to the B-pillar.
Page 624 RESTRAINTS 8O - 49 SEAT BELT & RETRACTOR (Continued) Fig. 50 Rear Outboard Seat Belt & Retractor Fig. 49 Rear Center Retractor Remove/Install Remove/Install 1 - REAR SEAT BACK PANEL 2 - SCREW (1) 1 - C-PILLAR 2 - QUARTER TRIM PANEL (12) Remove the rear center seat belt and retractor 3 - COVER 4 - SEAT BELT &...
Page 625 8O - 50 RESTRAINTS SEAT BELT & RETRACTOR (Continued) WARNING: To avoid personal injury or death, during (2) Install and tighten the screw that secures the and following any seat belt or child restraint anchor lower retractor bracket to the B-pillar. Tighten the screw to 43 N·m (32 ft.
Page 626 RESTRAINTS 8O - 51 SEAT BELT & RETRACTOR (Continued) REAR CENTER REAR OUTBOARD WARNING: To avoid personal injury or death, during WARNING: To avoid personal injury or death, during and following any seat belt or child restraint anchor and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and...
Page 627: Seat Belt Tensioner
8O - 52 RESTRAINTS indicator based upon the status of the driver side SEAT BELT SWITCH front seat belt switch. A spring-loaded plastic slide with a small, enclosed DESCRIPTION permanent magnet is integral to the buckle latch mechanism. When a seat belt tip-half is inserted and latched into the seat belt buckle, the slide is pushed downward and into close proximity of the Hall Effect Integrated Circuit (IC) chip within the buckle.
Page 628 RESTRAINTS 8O - 53 SEAT BELT TENSIONER (Continued) The seat belt tensioners are integral to the front seat pants by the seat belts during a frontal impact, fur- belt and retractor units, which are secured to the ther reducing the potential for occupant injuries. B-pillars on the right and left sides of the vehicle.
Page 629 8O - 54 RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER (Continued) (3) Remove the nut that secures the seat belt turn- WARNING: To avoid personal injury or death, during ing loop to the height adjuster stud on the upper and following any seat belt or child restraint anchor B-pillar.
Page 630 RESTRAINTS 8O - 55 SEAT WEIGHT SENSOR (Continued) passenger side front seat cushion of a vehicle equipped with the OCS including the cushion frame, springs, insulator pad, seat weight bladder and pres- sure sensor, seat cushion foam, wire harness and the OCM are serviced only as a factory-calibrated, assembled and tamper-evident unit.
Page 631 8O - 56 RESTRAINTS SEAT WEIGHT SENSOR (Continued) Once any of the original factory-installed compo- should any Supplemental Restraint System (SRS) or nents except the OCM have been replaced with the OCS component be modified or replaced with any service replacement package components, the OCM part except those which are specified for the partic- can only be serviced by replacing the entire passen- ular vehicle application in the DaimlerChrysler...
Page 632 RESTRAINTS 8O - 57 SEAT WEIGHT SENSOR (Continued) Once any of the original factory-installed compo- Do not use any prior year, subsequent year, sec- nents except the OCM have been replaced with the ondary or aftermarket seat trim covers. At no time service replacement package components, the OCM should any Supplemental Restraint System (SRS) or can only be serviced by replacing the entire passen-...
Page 634 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL REMOVAL ......4 DESCRIPTION .
Page 635 8P - 2 SPEED CONTROL SPEED CONTROL (Continued) A “tap down” feature is used to decelerate without should include attention to the speedometer. Speed- disengaging the speed control system. To decelerate ometer operation should be smooth and without flut- from an existing recorded target speed, momentarily ter at all speeds.
Page 636 SPEED CONTROL 8P - 3 CABLE DESCRIPTION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. OPERATION This cable causes the throttle control linkage to open or close the throttle valve in response to move- ment of the vacuum servo diaphragm.
Page 637 8P - 4 SPEED CONTROL CABLE (Continued) OPERATION The Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the dia- phragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assem- bly.
Page 638 SPEED CONTROL 8P - 5 SERVO (Continued) (4) Install servo-to-mounting bracket nuts and tighten. Refer to torque specifications. (5) Install servo mounting bracket-to-body nuts and tighten. Refer to torque specifications. (6) Connect vacuum line at servo. (7) Connect electrical connector at servo. (8) Connect servo cable to throttle body.
Page 639 8P - 6 SPEED CONTROL SWITCH (Continued) The previous disengagement conditions are pro- RESULT IN ACCIDENTAL DEPLOYMENT AND POS- grammed for added safety. SIBLE PERSONAL INJURY. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM’s RAM.
Page 640 SPEED CONTROL 8P - 7 VACUUM RESERVOIR (Continued) vacuum source. This check valve is used to trap with RHD (Right Hand Drive), this access panel is engine vacuum in the reservoir. On certain vehicle located at left end of instrument panel. applications, this reservoir is shared with the heat- ing/air-conditioning system.
Page 641 8P - 8 SPEED CONTROL VACUUM RESERVOIR (Continued) (1) Remove glovebox assembly. Access to reservoir testing or removal, remove glovebox assembly. Also vacuum line and fitting can now be made. remove fuse box access cover panel at end of instru- (2) Remove vacuum line at reservoir.
Page 642 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY STRIKER ......11 DESCRIPTION .
Page 643 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) Fig. 1 Vehicle Theft Security System 1 - SIREN MODULE 4 - SENTRY KEY REMOTE ENTRY MODULE 2 - HOOD AJAR SWITCH 5 - INTRUSION TRANSCEIVER MODULE 3 - BODY CONTROL MODULE tems respond by pulsing the horn and flashing ble deterrent, while retaining the flashing exterior certain exterior lamps.
Page 644 VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) • Combination Flasher - An electronic combina- engine from operating unless a valid electronically tion flasher is integral to the hazard switch located encoded key is detected in the ignition lock cylinder. in the center of the instrument panel above the The SKIS includes the following major components, radio.
Page 645 8Q - 4 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) In addition, in vehicles built for certain markets are locked while they are open using the power lock where the export premium version of the VTA is switch. Active arming occurs when the “Lock” button required, the BCM also exchanges electronic mes- on the RKE transmitter is depressed to lock the vehi- sages with the Intrusion Transceiver Module (ITM)
Page 646 VEHICLE THEFT SECURITY 8Q - 5 VEHICLE THEFT SECURITY (Continued) mode will also apply if the battery goes dead while VTA arming, while the security indicator is still the system is armed, and battery jump-starting is flashing rapidly. The VTA provides a single short attempted.
Page 647 8Q - 6 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) any stored DTC can be retrieved using a diagnostic However, conventional diagnostic methods may not scan tool. Refer to the appropriate diagnostic infor- prove conclusive in the diagnosis of the Body Control mation.
Page 648 VEHICLE THEFT SECURITY 8Q - 7 VEHICLE THEFT SECURITY (Continued) SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION SECURITY INDICATOR 1. Light-Emitting Diode (LED) 1. Perform the instrument cluster actuator test. FAILS TO LIGHT DURING faulty. (Refer to 8 - ELECTRICAL/INSTRUMENT BULB TEST CLUSTER - DIAGNOSIS AND TESTING - ACTUATOR TEST)..
Page 649 8Q - 8 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) SECURED ACCESS METHOD SKIS will immediately exit the Customer Learn pro- gramming mode. After the ignition is cycled the vehi- The Secured Access method applies to all vehicles. cle may be started using the newly programmed This method requires the use of a diagnostic scan valid Sentry Key.
Page 650 VEHICLE THEFT SECURITY 8Q - 9 HOOD AJAR SWITCH (Continued) hood inner reinforcement for any reason, it must be replaced with a new unit. OPERATION The hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the hood panel when the hood panel is closed and latched.
Page 651 8Q - 10 VEHICLE THEFT SECURITY HOOD AJAR SWITCH (Continued) Fig. 4 Hood Ajar Switch Remove/Install Fig. 5 Hood Ajar Switch Bracket Remove/Install 1 - INNER FENDER 1 - INNER FENDER 2 - SCREW (2) 2 - SCREW (2) 3 - BRACKET 3 - BRACKET 4 - HOOD AJAR SWITCH 4 - HOOD AJAR SWITCH...
Page 652 VEHICLE THEFT SECURITY 8Q - 11 HOOD AJAR SWITCH (Continued) UK SECURITY SYSTEM MODULE DESCRIPTION Fig. 7 Intrusion Transceiver Module Fig. 6 Hood Ajar Switch Striker Remove/Install 1 - ITM 1 - STRIKER 2 - HEADLINER 2 - TAB 3 - INNER HOOD REINFORCEMENT An Intrusion Transceiver Module (ITM) is part of 4 - RETAINER the export premium version of the Vehicle Theft...
Page 653 8Q - 12 VEHICLE THEFT SECURITY UK SECURITY SYSTEM MODULE (Continued) cover afford access to the two integral rear latches of the driver side lower edge of the instrument panel. the ITM for service removal (Fig. 8). The ITM also communicates with the alarm siren module over a dedicated serial bus circuit.
Page 654 VEHICLE THEFT SECURITY 8Q - 13 UK SECURITY SYSTEM MODULE (Continued) diagnosis of the ITM, the PCI data bus, or the elec- (3) Align the two front latch features of the ITM tronic message inputs to and outputs from the ITM. with the mounting bracket above the headliner (Fig.
Page 655 8Q - 14 VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE (Continued) The SKREEM also serves as the Remote Keyless Entry (RKE) and the Tire Pressure Monitor (TPM) RF receiver. (Refer to 8 - ELECTRICAL/POWER LOCKS - DESCRIPTION) or (Refer to 22 - TIRES/ WHEELS/TIRE PRESSURE MONITORING...
Page 656 VEHICLE THEFT SECURITY 8Q - 15 SENTRY KEY REMOTE ENTRY MODULE (Continued) invalid key; therefore, if no message is received from (2) If the vehicle is equipped with a tilt steering the SKREEM by the PCM, the engine will be dis- column, move the tilt steering column to the fully abled and the vehicle immobilized after two seconds lowered position and leave the tilt release lever in...
Page 657 8Q - 16 VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE (Continued) (9) Lift the multi-function switch upward off of the NOTE: If the Sentry Key REmote Entry Module upper steering column housing far enough to remove (SKREEM) is replaced with a new unit, a diagnostic the SKREEM antenna ring formation from between scan tool MUST be used to initialize the new the ignition key release button and the multi-func-...
Page 658 VEHICLE THEFT SECURITY 8Q - 17 SIREN (Continued) plates and nuts that fit into slotted holes at the top tion on the left inner fender shield in the engine com- and each side of the bracket. Two mounting holes in partment.
Page 659 8Q - 18 VEHICLE THEFT SECURITY SIREN (Continued) INSTALLATION programmed for operation of the RKE system, each new Sentry Key has a unique transponder identifica- (1) Position the alarm siren module onto the front tion code that is permanently programmed into it by extension of the right front wheel house panel (Fig.
Page 660 VEHICLE THEFT SECURITY 8Q - 19 TRANSPONDER KEY (Continued) transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information.
Page 662 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS INSTALLATION DESCRIPTION FRONT ......21 FRONT .
Page 663 8R - 2 WIPERS/WASHERS REMOVAL ......35 WIPER ON/OFF RELAY INSTALLATION ......36 DESCRIPTION .
Page 664 WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) • Body Control Module - The Body Control • Washer Pump/Motor - The reversible electric Module (BCM) is located on the Junction Block (JB) washer pump/motor unit is located in a dedicated under the driver side outboard end of the instrument hole on the lower outboard side of the washer reser- panel.
Page 665 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) Fig. 2 Rear Wiper & Washer System 1 - REAR WIPER MODULE 3 - REAR WIPER ARM & BLADE 2 - REAR WASHER NOZZLE 4 - PARK RAMP ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ screw to the tailgate outer panel to the right of the MULTI-FUNCTION SWITCH - DESCRIPTION).
Page 666 WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) • Washer Reservoir - The washer reservoir is Delay mode, the control knob also allows the vehicle concealed behind the right front wheel house splash operator to select from one of five intermittent wipe shield ahead of the right front wheel.
Page 667 8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) current through the normally open contacts of the interval to the new delay interval timing before the energized wiper on/off relay and the normally closed next wipe cycle occurs each time a longer delay inter- contacts of the de-energized wiper high/low relay to val is selected.
Page 668 WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) interval at which to de-energize the wiper on/off module through a fused B(+) circuit. The rear wiper relay to complete the wipe-after-wash mode cycle. module uses this fused B(+) input to park the rear wiper blade off of the rear flip-up glass if the ignition REAR switch is turned to the Off position while the rear...
Page 669 8R - 8 WIPERS/WASHERS WIPERS/WASHERS (Continued) WIPE-AFTER-WASH MODE However, conventional diagnostic methods may not prove conclusive in the diagnosis of the Body Control When the momentary Wash (before Off) position of Module (BCM), or the inputs to or outputs from the the control ring on the right (wiper) control stalk of BCM that provide front wiper and washer system the multi-function switch is selected, the multi-func-...
Page 670 WIPERS/WASHERS 8R - 9 WIPERS/WASHERS (Continued) (3) Check for battery voltage at the fused B(+) fuse (10) Reconnect the battery negative cable. Check (Fuse 17 - 15 ampere) in the JB. If OK, go to Step 4. for battery voltage at the fused B(+) circuit cavity of If not OK, repair the open fused B(+) circuit between the tailgate wire harness connector for the rear wiper the JB and the Power Distribution Center (PDC) as...
Page 671 8R - 10 WIPERS/WASHERS WIPERS/WASHERS (Continued) (2) Pull the right (wiper) control stalk of the multi- suggested to remove any deposits of salt or road film. function switch toward the steering wheel. Check The wiper blades, arms, and windshield glass should whether the front washer system is operating.
Page 672 WIPERS/WASHERS 8R - 11 WIPERS/WASHERS (Continued) only be cleaned using a sponge or soft cloth and windshield washer fluid, a mild detergent, or a non- abrasive cleaner. If the wiper blade continues to leave streaks, smears, hazing, or beading on the glass after thorough cleaning of the squeegees and the glass, the entire wiper blade assembly must be replaced.
Page 673 8R - 12 WIPERS/WASHERS WIPERS/WASHERS (Continued) (3) Once proper hinge action of the wiper arm is confirmed, check the hinge for proper spring tension. Remove the wiper blade from the wiper arm. Either place a small postal scale between the blade end of the wiper arm and the glass, or carefully lift the blade end of the arm away from the glass using a small fish scale.
Page 674 WIPERS/WASHERS 8R - 13 WIPERS/WASHERS (Continued) WASHER SYSTEM molded plastic body with a raised arrowhead molded into its center section that indicates the direction of washer system components should the flow through the valve, and three barbed hose inspected periodically, not just when washer perfor- nipples formed in a wye configuration on the outside mance problems are experienced.
Page 675: Rear Wiper Motor
8R - 14 WIPERS/WASHERS CHECK VALVE (Continued) nozzle hoses to the three barbed nipples of the front check valve. (3) Reinstall the cowl plenum cover/grille panel over the cowl plenum. (Refer to 23 - BODY/EXTERI- OR/COWL GRILLE - INSTALLATION). (4) Reinstall both front wiper arms onto the wiper pivots.
Page 676 WIPERS/WASHERS 8R - 15 REAR WIPER MOTOR (Continued) motor that is secured with screws through two rub- (2) Remove the rear wiper arm from the rear ber insulators to the tailgate inner panel. wiper motor output shaft. (Refer to 8 - ELECTRI- •...
Page 677 8R - 16 WIPERS/WASHERS REAR WIPER MOTOR (Continued) (9) From the outside of the tailgate, press the nut cover firmly and evenly over the rear wiper motor output shaft bezel using hand pressure until it snaps into place. (10) Reinstall the rear wiper arm onto the rear wiper motor output shaft.
Page 678 WIPERS/WASHERS 8R - 17 WASHER FLUID LEVEL SWITCH (Continued) nostic resistor is connected between the two switch (5) Remove the plastic push-in fasteners that terminals within the switch mounting flange. The secure the forward end of the front wheelhouse washer fluid level switch cannot be adjusted or splash shield to the inner fender panel and the front repaired.
Page 679 8R - 18 WIPERS/WASHERS WASHER FLUID LEVEL SWITCH (Continued) washer fluid level switch should be pointed down- The front washer plumbing consists of a small ward. diameter rubber hose that is routed from the barbed (3) Using hand pressure, press firmly and evenly outlet nipple of the reversible electric washer pump/ on the washer fluid level switch mounting flange motor unit on the washer reservoir and along the...
Page 680: Washer Nozzle
WIPERS/WASHERS 8R - 19 WASHER HOSES/TUBES (Continued) plastic washer hose fittings cannot be repaired. If headliner hose is glued to top of the headliner and these fittings are faulty or damaged, they must be routed along the right roof side rail to the rear of the replaced.
Page 681 8R - 20 WIPERS/WASHERS WASHER NOZZLE (Continued) The rear washer nozzle is a fluidic-type unit con- structed of molded plastic (Fig. 17). The nozzle is secured by a snap fit in a dedicated mounting hole located in the rear edge of the roof panel above the rear flip-up glass opening and to the right of the Center High Mounted Stop Lamp (CHMSL) unit.
Page 682 WIPERS/WASHERS 8R - 21 WASHER NOZZLE (Continued) (3) Remove the cowl plenum cover/grille panel from over the cowl plenum. (Refer to 23 - BODY/EX- TERIOR/COWL GRILLE - REMOVAL). (4) From the underside of the cowl plenum cover/ grille panel, disconnect the washer nozzle hose from the barbed nipple of the front washer nozzle (Fig.
Page 683 8R - 22 WIPERS/WASHERS WASHER NOZZLE (Continued) REAR The washer pump/motor unit (Fig. 20) is located on the top of a sump area of the washer reservoir, on the outboard side of the right front frame rail ahead NOTE: The rear washer nozzle latch feature is a one of the right front wheel house splash shield.
Page 684 WIPERS/WASHERS 8R - 23 WASHER PUMP/MOTOR (Continued) the pump housing. A diaphragm in this valve body controls which washer system plumbing receives the washer fluid being pressurized by the pump. When the pump is not operating the diaphragm is biased to close all washer fluid flow in the rear washer system and, in this way it also performs the function of the rear washer system check valve.
Page 685: Washer Reservoir
8R - 24 WIPERS/WASHERS WASHER PUMP/MOTOR (Continued) ple, and the hose in front of the pump is connected to with an integral bail strap and filler neck mounting the front (blue) nipple. bracket is labeled with an International Control and (8) Reposition the forward end of the front wheel- Display Symbol icon for “Windshield Washer.”...
Page 686 WIPERS/WASHERS 8R - 25 WASHER RESERVOIR (Continued) ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - REMOVAL). (5) Remove the blind rivet that secures the washer reservoir filler neck support bracket to the upper radiator crossmember (Fig. 23). Fig. 24 Washer Reservoir Connections 1 - CONNECTOR (2) 2 - WIRE HARNESS Fig.
Page 687 8R - 26 WIPERS/WASHERS WASHER RESERVOIR (Continued) (3) Raise the washer reservoir far enough to WIPER ARM engage the hook tab at the back of the reservoir into the slot in the right front frame rail. DESCRIPTION (4) Install and tighten the two screws that secure the reservoir to the right front frame rail.
Page 688 WIPERS/WASHERS 8R - 27 WIPER ARM (Continued) A wiper arm cannot be adjusted or repaired. If A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be damaged or faulty, the entire wiper arm unit must be replaced.
Page 689 8R - 28 WIPERS/WASHERS WIPER ARM (Continued) (5) Remove the front wiper arm pivot end from the REMOVAL wiper pivot shaft. FRONT REAR (1) Lift the front wiper arm to its over-center posi- (1) Lift the rear wiper arm pivot cover by lifting it tion to hold the wiper blade off of the glass and at the rear wiper motor output shaft end of the arm relieve the spring tension on the wiper arm to wiper...
Page 690 WIPERS/WASHERS 8R - 29 WIPER ARM (Continued) REAR NOTE: Always install the wiper arm and blade with the wiper motor in the Park position. (1) The rear wiper arm must be indexed to the motor output shaft with the rear wiper motor in the park position to be properly installed.
Page 691: Wiper Blade
8R - 30 WIPERS/WASHERS WIPER ARM (Continued) (4) Install and tighten the nut that secures the WIPER BLADE rear wiper arm to the rear wiper motor output shaft. Tighten the nut to 18 N·m (13 ft. lbs.). DESCRIPTION (5) Close the rear wiper arm pivot cover. (6) Lift the rear wiper arm support away from the park ramp, then place the wiper arm support in the FRONT...
Page 692 WIPERS/WASHERS 8R - 31 WIPER BLADE (Continued) All models have two 47.50 centimeter (18.70 inch) adjusted or repaired. If faulty, worn, or damaged the long front wiper blades with non-replaceable rubber entire wiper blade unit must be replaced. elements (squeegees). The wiper blades cannot be adjusted or repaired.
Page 693 8R - 32 WIPERS/WASHERS WIPER BLADE (Continued) wiper blade that is nearest to the rear wiper motor REMOVAL output shaft. (1) Disengage the rear wiper arm support from the FRONT rear wiper arm park ramp on the right side of the tailgate just below the rear flip-up glass.
Page 694 WIPERS/WASHERS 8R - 33 WIPER BLADE (Continued) (1) Lift the rear wiper arm support out of the tail gate park ramp. (2) Position the rear wiper blade near the hook for- mation on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the rear wiper motor output shaft.
Page 695 8R - 34 WIPERS/WASHERS WIPER HIGH/LOW RELAY (Continued) angular, molded plastic housing and is connected to brush of the front wiper motor through the front all of the required inputs and outputs by five integral wiper high/low relay low speed output circuit. There- male spade-type terminals that extend from the bot- fore, the wiper motor low speed brush can only be tom of the relay base.
Page 696 WIPERS/WASHERS 8R - 35 WIPER MODULE (Continued) welds near the center of the main member. A short nately closes the wiper park switch sense circuit to stamped steel tab that extends laterally from one ground or to battery current, depending upon the side of the mounting plate provides a mounting loca- position of the wipers on the glass.
Page 697 8R - 36 WIPERS/WASHERS WIPER MODULE (Continued) insulators from the weld studs on the bottom of the plenum panel. (9) Remove the front wiper module from the cowl plenum panel as a unit. INSTALLATION (1) Position the front wiper module to the cowl ple- num as a unit (Fig.
Page 698 WIPERS/WASHERS 8R - 37 WIPER ON/OFF RELAY (Continued) • Coil Battery Terminal - The coil battery ter- • Normally Closed Terminal - The normally minal (86) receives battery current at all times from closed terminal (87A) is connected to the wiper park a circuit breaker in the Junction Block (JB) through switch in the front wiper motor through the front a fused ignition switch output (run-acc) circuit.
Page 700 NAVIGATION/TELECOMMUNICATION 8T - 1 NAVIGATION/TELECOMMUNICATION TABLE OF CONTENTS page page NAVIGATION/TELECOMMUNICATION HANDS FREE MODULE DESCRIPTION ......1 REMOVAL .
Page 701 8T - 2 NAVIGATION/TELECOMMUNICATION HANDS FREE MODULE (Continued) INSTALLATION (1) Connect electrical harness connector. (2) Position module, and install mounting fasteners. (3) Install quarter trim panel (Refer to 23 - BODY/ INTERIOR/QUARTER TRIM PANEL - INSTALLA- TION). (4) Connect battery negative cable.
Page 702 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 AUDIO SYSTEM ..... 8W-47-1 COMPONENT INDEX .
Page 704 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 705 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 706 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 707 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 708 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) LHD ....Left Hand Drive Vehicles WIRE COLOR CODE CHART RHD ....Right Hand Drive Vehicles ATX .
Page 709 8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 710 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 711 8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 712 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (2) Connect the other lead of the voltmeter to the selected test point.
Page 713 8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). (2) Connect the other lead of the voltmeter to the other side of the switch, component or circuit.
Page 714 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 INSTALLATION CONNECTOR (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 715 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 716 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 717 8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 718 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 720 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... . 8W-42 Electric Brake Provision ....8W-54 A/C Low Pressure Switch .
Page 721 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Line Pressure Sensor ....8W-31 Side Impact Sensors ....8W-43 Low Beam Relay .
Page 722 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-25 Fuse 17 ......8W-10-22 A/C Compressor Clutch Relay .
Page 748 8W-12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ....8W-12-21 Horn Switch ......8W-12-9 A/C-Heater Control .
Page 784 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-8 Left Heated Seat Assembly ....8W-15-12 A/C Low Pressure Switch .
Page 806 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Airbag Control Module ....8W-18-4 Instrument Cluster ....8W-18-4 Anti-Lock Brake Module .
Page 812 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auto Shut Down Relay ....8W-20-2 Fusible Link ..... . 8W-20-2, 3 Battery .
Page 816 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Automatic Day/Night Mirror ... 8W-21-3 Ignition Switch ..... . 8W-21-2 Back-Up Lamp Switch .
Page 820 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch ....8W-30-33 Fuse 12 ......8W-30-32 A/C Compressor Clutch Relay .
Page 858 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Accelerator Pedal Position Sensor ..8W-31-11 Output Speed Sensor ....8W-31-6, 15 Automatic Day/Night Mirror .
Page 874 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Anti-Lock Brake Module ....8W-33-3 G202 ......8W-33-2 Body Control Module .
Page 880 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Anti-Lock Brake Module ..8W-35-2, 3, 4, 5 G202 ......8W-35-3 Body Control Module .
Page 886 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Body Control Module . . 8W-39-2, 3, 4, 5, 6, 7, 11, 12 Horn Relay ......8W-39-6 Clockspring .
Page 898 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Airbag Control Module ....8W-40-4, 7 G111 ......8W-40-3 Anti-Lock Brake Module .
Page 906 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Body Control Module ....8W-41-2 G202 ......8W-41-3 Cigar Lighter .
Page 910 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ... . . 8W-42-5, 7 Fuse 1 ......8W-42-3, 6 A/C Compressor Clutch Relay .
Page 918 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ..8W-43-2, 3, 4, 5 Left Curtain Airbag Squib 1 ... . 8W-43-3 Belt Tension Sensor .
Page 924 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Body Control Module ... . . 8W-44-2, 3, 4 Left Courtesy Lamp ....8W-44-2 Cargo Lamp .
Page 928 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page A/C-Heater Control ....8W-45-5 Junction Block ....8W-45-2, 3, 4, 7, 8 Anti-Lock Brake Module .
Page 938 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Antenna ......8W-47-2 Left Front Door Speaker .
Page 950 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C-Heater Control ....8W-48-2 G303 ......8W-48-2 Body Control Module .
Page 952 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Automatic Day/Night Mirror ..8W-49-2, 3, 4 G303 ......8W-49-2, 3 Back-Up Lamp Switch .
Page 958 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Body Control Module ..8W-50-2, 3, 8, 9, 15, 16 Left Front Park/Turn Signal Daytime Running Lamp Relay ..8W-50-2 Lamp .
Page 976 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Back-Up Lamp Switch ....8W-51-3 Instrument Cluster ....8W-51-4, 5 Body Control Module .
Page 982 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Body Control Module ....8W-52-2, 3 Junction Block ....8W-52-2, 3 Fuse 7 .
Page 990: Table Of Contents
8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Body Control Module ... . . 8W-53-2, 3, 4 Junction Block ....8W-53-2, 3, 4 Circuit Breaker No.
Page 996 8W-54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Back-Up Lamp Switch ....8W-54-3 Junction Block ....8W-54-2, 4, 5, 6 Body Control Module .
Page 1002 8W-55 NAVIGATION/TELECOMMUNICATIONS 8W - 55 - 1 8W-55 NAVIGATION/TELECOMMUNICATIONS Component Page Component Page Automatic Day/Night Mirror ... 8W-55-2 Hands Free Module ....8W-55-2, 3 Fuse 34 .
Page 1006 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Fuse 1 ......8W-60-2 Power Window Master Switch .
Page 1010 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Body Control Module ..8W-61-2, 3, 4, 5, 6, 7, 8 Left Rear Door Lock Motor/Ajar Door Lock Relay ....8W-61-3, 6 Switch .
Page 1018 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Automatic Day/Night Mirror ... 8W-62-4 G300 ......8W-62-3, 6 Defogger Relay .
Page 1024 8W-63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Circuit Breaker No. 3 ....8W-63-2, 3 Left Heated Seat Switch ....8W-63-5 Fuse 25 .
Page 1030: Component
8W-64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 32 ......8W-64-2 Power Sunroof Relay .
Page 1032 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S225 ....... 8W-50-3, 12 S103 .
Page 1042 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-5 C112 ......8W-80-26 A/C High Pressure Switch (Diesel) .
Page 1043: G202
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C315 (RHD Midline/Highline) ..8W-80-46 Engine Oil Pressure Switch (Gas) ..8W-80-64 C316 (Export) ..... . 8W-80-46 EVAP/Purge Solenoid (Gas) .
Page 1044: Component Page
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Left Front Impact Sensor ... . . 8W-80-82 Passenger Airbag Squib 1 ... . . 8W-80-94 Left Front Park/Turn Signal Lamp Passenger Airbag Squib 2 .
Page 1045: Right Rear Power Window Motor
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Right Rear Power Window Motor Trailer Tow Connector ....8W-80-114 (Premium) ..... 8W-80-109 Trailer Tow Left Turn Relay .
Page 1046 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 18DB/YL A/C CLUTCH RELAY OUTPUT Z939 18BK GROUND A/C HIGH PRESSURE SWITCH (DIESEL) - GRAY 2 WAY CIRCUIT FUNCTION C18 20DB A/C PRESSURE SIGNAL C21 18DB/OR A/C LOW PRESSURE SWITCH SIGNAL A/C LOW PRESSURE SWITCH - GRAY 2 WAY...
Page 1047 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS A/C-HEATER CONTROL C2 - 12 WAY CIRCUIT FUNCTION C35 20BR/OR MODE DOOR DRIVER (A) F302 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) C215 20LB REAR WINDOW DEFOGGER CONTROL Z945 18BK GROUND C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 6 WAY CIRCUIT...
Page 1048 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AIRBAG CONTROL MODULE C2 (ORC) - 32 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R1 20LB/BR (SAB)
Page 1049 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS ANTENNA MODULE C1 (EXPORT) - 2 WAY CIRCUIT FUNCTION Q39 16RD POWER SUNROOF RELAY OUTPUT ANTI-LOCK BRAKE MODULE - 47 WAY CIRCUIT FUNCTION A107 12BK/LB FUSED B(+) B22 18DG/YL (GAS) VEHICLE SPEED SIGNAL B15 20DG/WT BRAKE SWITCH SENSE F22 20PK/TN...
Page 1050 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AUTOMATIC DAY/NIGHT MIRROR C1 - 7 WAY CIRCUIT FUNCTION F942 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) Z13 20BK/WT GROUND L10 20RD BACK-UP LAMP FEED P112 20RD AUTO DAY/NIGHT MIRROR (+) P114 20RD AUTO DAY/NIGHT MIRROR (-) AUTOMATIC DAY/NIGHT MIRROR C2 (HANDS FREE) - 12 WAY CIRCUIT...
Page 1051 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BLEND DOOR ACTUATOR - WHITE 4 WAY CIRCUIT FUNCTION Z945 18BK GROUND C35 20LB/OR MODE DOOR DRIVER (A) F302 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) BLOWER MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C75 12DB/GY BLOWER MOTOR HIGH DRIVER...
Page 1052 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 BODY CONTROL MODULE C1 - GRAY 26 WAY CIRCUIT FUNCTION Z15 20BK/TN GROUND W27 20DB/BR REAR WIPER INTERMITTENT DRIVER G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SIGNAL G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE G70 20VT/LB (EXCEPT BASE)
Page 1053 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BOOST PRESSURE SOLENOID (DIESEL) - 2 WAY CIRCUIT FUNCTION K347 20BR/PK FUSED ASD RELAY OUTPUT X635 20BR/WT BOOST PRESSURE SOLENOID CONTROL BRAKE LAMP SWITCH - BLACK 6 WAY CIRCUIT FUNCTION A103 18GY/RD FUSED B(+) L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL...
Page 1054 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C100 (LHD) - (HEADLAMP AND DASH SIDE) CIRCUIT R79 20LB/VT R81 20LB/WT D21 20WT/GY (DIESEL A/T) D15 20BR/WT (GAS) D21 20WT/GY K304 20BR/DB (DIESEL) B20 20DG/OR Z11 20BK/LG W33 20BR/DG K400 20BR/VT (DIESEL) T6 20DG (A/T) V37 20VT (SPEED CONTROL) W20 20BR/YL...
Page 1055 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C100 (LHD) - (I/P SIDE) CIRCUIT B1 20DG/DB B2 20DG/LB N4 20DB/YL B22 20DG/YL K106 20VT/LB T26 20DG/OR K167 20BR/YL V38 20VT/OR K29 20WT/BR K23 20BR/WT L13 18WT/YL (EXPORT) G70 20VT/LB (EXCEPT BASE) Z11 20BK/LG K900 20DB/DG T141 20YL/OR...
Page 1056 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C100 (LHD) - (I/P SIDE) CIRCUIT G18 20PK/BK A100 14RD/VT N1 16DG/OR L43 18VT/DB (EXPORT) A904 14RD (LIGHTBAR) A106 12LB/RD A1 12RD A111 12DG/RD A916 12RD C100 (RHD) - (HEADLAMP AND DASH SIDE) CIRCUIT L33 18WT/LG L34 18WT/GY...
Page 1057 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C100 (RHD) - (HEADLAMP AND DASH SIDE) CIRCUIT D15 20BR/WT (GAS) D21 20WT/GY F20 20PK/GY B20 20DG/OR Z11 20BK/LG W33 20BR/DG K400 20BR/VT (DIESEL) T6 20DG (A/T) V37 20VT W20 20BR/YL B153 20DG/WT D25 20WT/VT K852 20BR/VT (DIESEL) X75 18GY/DG...
Page 1058 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C100 (RHD) - (I/P SIDE) CIRCUIT L43 18VT F1 20DB B22 18LG/YL L44 18VT/RD V55 16TN/RD D25 18YL/VT/BR V14 18RD/VT L13 18BR/YL G70 20BR/TN G11 20WT/BK K4 20BK/LB L50 18WT/TN L62 18BR/RD L63 18DG/RD V30 18DB/RD D20 20LG...
Page 1059 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C101 (2.4L) - BLACK (ENGINE SIDE) CIRCUIT K61 18YL/BK K961 18BR/VT K21 18BK/RD K2 18TN/BK K1 18DG/RD K22 18OR/DB F856 18YL/PK G60 18GY/YL F855 18OR/PK C101 (2.4L) - BLACK (INJECTOR SIDE) CIRCUIT K61 18YL/BK K961 18BR K21 18BK/RD...
Page 1060 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C102 (RHD) - (HEADLAMP AND DASH SIDE) CIRCUIT F512 18PK/OR A141 16DG/WT B1 18YL/DB B2 18YL K4 18BK/LB B12 18DG/OR K107 18OR K106 18WT/DG C104 - (INJECTOR SIDE) CIRCUIT T515 20YL/DB (A/T) F142 16PK/GY (EXCEPT EXPORT) G18 20OR/VT (EXPORT) C13 20LB/OR (DIESEL)
Page 1061 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C104 - (HEADLAMP AND DASH SIDE) CIRCUIT T515 20YL/DB G18 20OR/VT (DIESEL) F142 16PK/GY (GAS) C13 20LB/OR (DIESEL) A142 14RD/OR (GAS A/T) T141 20YL/OR (DIESEL M/T) T16 16YL/OR (GAS) D25 20WT/VT B15 20DG/WT (DIESEL) D16 20WT/OR (GAS) D64 20WT/LB (DIESEL) D65 20WT/LG (DIESEL)
Page 1062 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C105 (DIESEL) - (HEADLAMP AND DASH SIDE) CIRCUIT K342 20BR/WT D21 20WT/GY L10 20WT/GY G31 20VT/OR K167 20BR/YL F1 20PK/WT F26 20PK/OR V38 20VT/OR Z11 20BK/LG Z11 20BK/LG T6 20DG (A/T) K347 20BR/PK K302 20BR/WT C105 (GAS) - BLACK (ENGINE SIDE) CIRCUIT...
Page 1063 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C106 - BLACK (GOR SIDE) CIRCUIT Z932 16BK Z931 16BK K900 20DB/DG L77 18PK/RD (HEADLAMP LEVELING) G31 20VT/OR L43 18WT/DB L34 18WT/GY L33 18WT/LG L78 18WT/OR (HEADLAMP LEVELING) L44 18WT/TN L89 16WT/YL L13 18WT/YL C106 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT...
Page 1064 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C107 - (HEADLAMP AND DASH SIDE) CIRCUIT Z931 16BK L63 18WT/DG L77 18PK/RD C108 (GAS) - LT GREEN (BATTERY SIDE) CIRCUIT K52 18PK/BK K20 18DG Z142 18BK/WT T40 12BR K70 18VT/RD C108 (GAS) - LT GREEN (HEADLAMP AND DASH SIDE) CIRCUIT K52 18PK/BK...
Page 1065 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C109 - (HEADLAMP AND DASH SIDE) CIRCUIT Z932 16BK L62 18WT/OR L78 18WT/OR C110 (2.4L M/T) - BLACK (ENGINE SIDE) CIRCUIT F142 18OR/DG C3 18DB/BK Z246 18BK/GY K11 18WT/DB K12 18TN K13 18YL/WT K14 18LB/BR K44 18TN/YL K4 18BK/LB...
Page 1066 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C111 (DIESEL) - LT GRAY (ENGINE SIDE) CIRCUIT D16 20WT/OR (A/T) V37 20VT Z133 14BK/LG N112 20DB/OR A119 18RD/OR C20 20DB/YL C3 18DB/YL K852 20BR/VT T752 20DG/OR N117 20DB/WT X635 20BR/WT K391 20BR/YL C111 (DIESEL) - LT GRAY (HEADLAMP AND DASH SIDE) CIRCUIT...
Page 1067 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C112 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT K66 20DB/WT K125 16BR/DG K399 18BR/GY K299 18BR/OR D15 20BR/WT C113 (DIESEL) - (ENGINE SIDE) CIRCUIT FUNCTION A202 14RD/WT NO FUNCTION DEFINED A203 14RD/BR NO FUNCTION DEFINED A204 14RD/YL NO FUNCTION DEFINED...
Page 1068 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C114 - (HEADLAMP AND DASH SIDE) CIRCUIT K125 16BR/DG K347 20BR/PK D330 20WT/BR K330 20LB/BR Z133 14BK/LG C114 (DIESEL) - LT GRAY (BATTERY SIDE) CIRCUIT K154 10GY K104 10RD/WT C114 (DIESEL) - LT GRAY (GLOW PLUG ASSEMBLY SIDE) CIRCUIT F154 10GY...
Page 1069 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C117 (DIESEL) - (INJECTOR SIDE) CIRCUIT K303 20BR/OR K300 20BR K310 20BR/DG K330 20LB/BR D330 20WT/BR K301 20 BR/LG K345 14BR/RD K305 20BR/LB K854 20VT/BR A903 16RD (A/T) T26 20DG/OR (M/T) A993 16RD K29 20WT/BR T750 12YL/GY K400 20BR/VT...
Page 1070 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C201 - (INSTRUMENT PANEL SIDE) CIRCUIT Z9 16BK L63 18DG/RD K106 18WT/DG K107 18OR D25 18VT/YL D25 18YL/VT G75 20TN G72 18DG/OR G73 18LG/OR A141 16DG/WT L10 18BR/LG P100 18OR/BR C201 - (UNIBODY SIDE) CIRCUIT F23 18DB/YL X75 18DG...
Page 1071 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C201 - (UNIBODY SIDE) CIRCUIT B2 18YL Z9 16BK L63 18DG/RD K106 18WT/DG K107 18OR D25 18YL/VT/DB G75 20TN G72 18DG/OR G73 18LG/OR A141 16DG/WT L10 18BR/LG P100 18OR/BR C203 (RENEGADE) - (INSTRUMENT PANEL SIDE) CIRCUIT Z144 14BK...
Page 1072 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C300 (LHD) - (PASSENGER DOOR SIDE) CIRCUIT X58 18GY/OR X296 18LG/GY X208 18GY/DG X13 16LG/GY X52 18GY/DB X205 18GY/LG X298 18GY/LG Z514 16BK/LG C300 (RHD) - (PASSENGER DOOR SIDE) CIRCUIT X57 18DG/OR X295 18GY/DG X299 18GY/YL X13 16LG/GY...
Page 1073 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C300 (LHD) - (UNIBODY SIDE) CIRCUIT X58 18GY/OR X296 18LG/GY X208 18GY/DG X13 16LG/GY X52 18GY/DB X205 18GY/LG X298 18GY/LG Z514 16BK/LG C301 (RHD) - ORANGE (UNIBODY SIDE) CIRCUIT Q12 14OR/BR F982 20PK/YL P33 16TN/DB C16 20DB/GY P71 20TN/DG...
Page 1074 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C301 (RHD) - ORANGE (DRIVER DOOR SIDE) CIRCUIT Q12 14OR/BR F982 20PK/YL P33 16TN/DB C16 20DB/GY P71 20TN/DG P110 20LG/WT P37 20LG/TN X56 18GY/BR Q22 14OR/VT F302 20GY/PK P34 16TN/LB P75 20TN/LG P76 20TN/LB G74 20VT/WT Z998 20BK...
Page 1075 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C301 (LHD) - ORANGE (DRIVER DOOR SIDE) CIRCUIT Q11 14OR/LG F982 20PK/YL P33 16TN/DB C16 20DB/GY P72 20TN/GY P112 20TN/OR P37 20LG/TN X55 18DG/BR Q21 14OR/WT F302 20GY/PK P34 16TN/LB P74 20TN/OR P76 20TN/LB G75 20VT Z999 20BK...
Page 1076 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C302 (RHD PREMIUM) - ORANGE (DRIVER DOOR SIDE) CIRCUIT X58 18GY/OR X296 18LG/GY X208 18GY/DG X13 16LG/GY X52 18GY/DB X205 18GY/LG X298 18GY/LG Z514 16BK/LG C302 (LHD PREMIUM) - (DRIVER DOOR SIDE) CIRCUIT X57 18DG/OR X295 18GY/DG...
Page 1077 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C302 (RHD) - (UNIBODY SIDE) CIRCUIT X58 18GY/OR X296 18LG/GY X208 18GY/DG X13 16LG/GY X52 18GY/DB X205 18GY/LG X298 18GY/LG Z514 16BK/LG C303 (RHD EXCEPT BASE) - ORANGE (PASSEN- GER DOOR SIDE) CIRCUIT Q11 14OR/LG F982 20PK/YL...
Page 1078 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C303 (RHD) - ORANGE (UNIBODY SIDE) CIRCUIT Q11 14OR/LG F982 20PK/YL P33 16TN/DB C16 20DB/GY P71 20TN/DG P110 20LG/WT P37 20LG/TN X55 18DG/BR Q21 14OR/WT P35 16TN/YL P75 20TN/LG P76 20TN/LB G75 20VT Z999 20BK P99 20LG/LB P36 20TN/DB...
Page 1079 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C303 (LHD EXCEPT BASE) - ORANGE (PASSEN- GER DOOR SIDE) CIRCUIT Q12 14OR/BR F982 20PK/YL P33 16TN/DB C16 20DB/GY P72 20TN/GY P37 20LG/TN X56 18GY/BR Q22 14OR/VT P35 16TN/YL P74 20TN/OR P76 20TN/LB G74 20VT/WT Z998 20BK P36 20TN/DB...
Page 1080 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 C304 - BLUE (REAR DOOR SIDE) CIRCUIT Q14 16GY (POWER WINDOWS) P33 18OR/BK (POWER LOCKS) X58 18DB/OR (BASE AUDIO) X92 18TN/BK (PREMIUM AUDIO) Q24 16DG (POWER WINDOWS) P35 18OR/VT (POWER LOCKS) Z351 20BK/LG G76 20TN/YL X52 18DB/WT (BASE AUDIO) X94 18TN/VT (PREMIUM AUDIO)
Page 1081 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS C305 - BLUE (LEFT REAR DOOR SIDE) CIRCUIT Q13 16GY (MIDLINE/HIGHLINE) P33 18OR/BK (EXCEPT BASE) X57 18DB/OR (BASE) X91 18TN/BK (PREMIUM) Q23 16DG (MIDLINE/HIGHLINE) P35 18OR/VT (EXCEPT BASE) Z350 20BK/LG G74 20TN/WT X51 18DB/WT (BASE) X93 18TN/VT (PREMIUM) C307 - LT GRAY (UNIBODY SIDE)
Page 1082 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 C308 - LT GRAY (UNIBODY SIDE) CIRCUIT F85 16VT/WT (EXCEPT BASE) L10 18BR/LG M1 20PK M3 20PK/DB Z111 16BK (EXCEPT BASE) P112 18YL/LB (LHD) X75 18DG (EXCEPT BASE) F89 18OR/RD (TRAILER TOW EXCEPT BASE) F87 20WT/BK (EXCEPT BASE) M20 20BR (EXCEPT BASE)
Page 1083 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS C309 - (UNIBODY SIDE) CIRCUIT V21 20DB/RD P31 16PK/WT F70 18PK/BK P100 18OR/BR P101 20OR/PK G71 18VT/YL V22 20BR/YL P30 16OR/WT L77 18BK/YL G80 20YL/WT Z235 16BK G78 20TN/BK G910 20VT/BR C309 - (SPLITGATE SIDE) CIRCUIT V21 20DB/RD P31 16PK/WT...
Page 1084 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 C310 - LT GRAY (REAR LIGHTING SIDE) CIRCUIT L10 18BR/LG L77 18BR/YL L63 18DG/RD L38 18BR/WT (EXPORT) L50 18WT/TN Z151 18BK/WT Z151 18BK/WT L78 18DG/YL L62 18BR/RD C311 - LT GRAY (DRIVER SEAT SIDE) CIRCUIT R57 18LG/GY R57 18DG (HEATED SEATS)
Page 1085 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS C312 - LT GRAY (UNIBODY SIDE) CIRCUIT P86 20PK/BK F98 14RD/WT V23 20BR/PK P142 20TN/DB P134 20TN/LG P138 20VT/LG P140 20VT/BK C312 - LT GRAY (SEAT SIDE) CIRCUIT F37 20RD/LB (EXCEPT HEATED SEATS) P86 18PK/BK (HEATED SEATS) F98 14RD/WT (HEATED SEATS) V23 20BR/PK (HEATED SEATS)
Page 1086 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 C313 - BLACK (RIGHT SEAT SIDE) CIRCUIT D25 18WT/VT R57 18LG/GY Z105 18BK/LG R59 18LG/TN F37 18PK/LB F201 18LG/YL Z849 14BK/WT C314 (HEATED SEATS) - (SEAT SIDE) CIRCUIT P86 18LG/GY F98 18PK/YL F302 20BR/PK P142 20LG/TN P134 20LG/OR...
Page 1087 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS C315 (LHD MIDLINE/HIGHLINE) - (UNIBODY SIDE) CIRCUIT FUNCTION Q12 14OR/BR RIGHT FRONT WINDOW DRIVER UP Q22 14OR/WT RIGHT FRONT WINDOW DRIVER DOWN Q112 14OR/BR RIGHT REAR WINDOW DRIVER UP Q212 14OR/VT RIGHT REAR WINDOW DRIVER DOWN C315 (LHD MIDLINE/HIGHLINE) - (UNIBODY SIDE) CIRCUIT FUNCTION...
Page 1088 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 C318 - (LIGHT BAR SIDE) CIRCUIT Z144 10 L8 10WT/LT C318 - (LIGHTBAR JUMPER SIDE) CIRCUIT Z144 14 L8 WT/DG C320 (LHD) - ORANGE (DRIVER DOOR SIDE) CIRCUIT Q11 14OR/LG F982 20PK/YL P33 16TN/DB C16 20DB/GY P72 20TN/GY...
Page 1089 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS C320 (RHD) - ORANGE (DRIVER DOOR SIDE) CIRCUIT Q12 14OR/BR F982 20PK/YL P33 16TN/DB C16 20DB/GY P71 20TN/DG P110 20LG/WT P37 20LG/TN X56 18GY/BR Q22 14OR/VT F302 20GY/PK P34 16TN/LB P75 20TN/LG P76 20TN/LB G74 20VT/WT Z998 20BK...
Page 1090 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 C321 (LHD EXCEPT BASE) - ORANGE (PASSEN- GER DOOR SIDE) CIRCUIT Q12 14OR/BR F982 20PK/YL P33 16TN/DB C16 20DB/GY P72 20TN/GY P37 20LG/TN X56 18GY/BR Q22 14OR/VT P35 16TN/YL P74 20TN/OR P76 20TN/LB G74 20VT/WT Z998 20BK P36 20TN/DB...
Page 1091 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS C321 (RHD) - ORANGE (PASSENGER DOOR SIDE) CIRCUIT Q11 14OR/LG F982 20PK/YL P33 16TN/DB C16 20DB/GY P71 20TN/DG P110 20LG/WT P37 20LG/TN X55 18DG/BR Q21 14OR/WT P35 16TN/YL P75 20TN/LG P76 20TN/LB G75 20VT Z999 20BK P99 20LG/LB...
Page 1092 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 C328 - (UNIBODY SIDE) CIRCUIT L50C 18 WT/TN C15 12 DB/WT Z255 12 BK/WT C330 - (UNIBODY SIDE) CIRCUIT D508 20WT/GY (TPM) F22 20PK/TN (TPM) Z912 18BK C330 - (REAR FASCIA SIDE) CIRCUIT D508 20WT/GY F22 20PK/TN...
Page 1093 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS CAMSHAFT POSITION SENSOR (3.7L) - LT GRAY 3 WAY CIRCUIT FUNCTION K44 20DB/GY CMP SIGNAL K900 20DB/DG SENSOR GROUND F856 20YL/PK 5 VOLT SUPPLY CAMSHAFT POSITION SENSOR (DIESEL) - 3 WAY CIRCUIT FUNCTION K944 20BR/GY CAMSHAFT POSITION SENSOR GROUND...
Page 1094 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 CENTER HIGH MOUNTED STOP LAMP - WHITE 2 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z255 18RD GROUND CIGAR LIGHTER - 3 WAY CIRCUIT FUNCTION A207 16RD/LG (LHD) FUSED B(+) F307 16LB/PK (RHD) FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z940 16BK...
Page 1095 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS CLOCKSPRING C2 - YELLOW 4 WAY CIRCUIT FUNCTION R43 20LG/BR DRIVER SQUIB 1 LINE 1 R45 20LG/OR DRIVER SQUIB 1 LINE 2 R61 20LG/VT DRIVER SQUIB 2 LINE 1 R63 20LG/WT DRIVER SQUIB 2 LINE 2 CLOCKSPRING C3 - 6 WAY CIRCUIT FUNCTION...
Page 1096 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 COIL ON PLUG NO. 2 (3.7L) - BLACK 3 WAY CIRCUIT FUNCTION K85 16DB/YL COIL CONTROL NO. 2 A142 14RD/OR ASD RELAY OUTPUT COIL ON PLUG NO. 3 (3.7L) - BLACK 3 WAY CIRCUIT FUNCTION K93 16DB...
Page 1097 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS COIL ON PLUG NO. 6 (3.7L) - BLACK 3 WAY CIRCUIT FUNCTION K10 16DB/OR COIL CONTROL NO. 6 A142 14RD/OR ASD RELAY OUTPUT COIL RAIL (2.4L) - 3 WAY CIRCUIT FUNCTION K85 16DB/YL COIL CONTROL NO.
Page 1098 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 CRANKSHAFT POSITION SENSOR (3.7L) - BLACK 3 WAY CIRCUIT FUNCTION K24 20BR/LB CKP SIGNAL K900 20DB/DG SENSOR GROUND F855 20PK/YL 5 VOLT SUPPLY CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION K853 20DB/BR CRANKSHAFT POSITION SENSOR SIGNAL NO.
Page 1099 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS DOME LAMP (BASE) - 3 WAY CIRCUIT FUNCTION A908 18RD FUSED B(+) Z327 20RD GROUND DRIVER AIRBAG SQUIB 1 - GRAY 2 WAY CIRCUIT FUNCTION R43 20LG/BR DRIVER SQUIB 1 LINE 1 R45 20LG/OR DRIVER SQUIB 1 LINE 2 DRIVER AIRBAG SQUIB 2 - BLACK 2 WAY...
Page 1100 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 DRIVER POWER MIRROR (EXCEPT BASE) - WHITE 8 WAY CIRCUIT FUNCTION P71 20TN/DG (LHD) LEFT MIRROR UP DRIVER P72 20TN/GY (RHD) RIGHT MIRROR UP DRIVER P76 20TN/LB MIRROR COMMON DRIVER P75 20TN/LG (LHD) LEFT MIRROR LEFT DRIVER P74 20TN/OR (RHD) RIGHT MIRROR LEFT DRIVER...
Page 1101 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS ENGINE CONTROL MODULE C1 (DIESEL) - 96 WAY CIRCUIT FUNCTION K613 16GY/BR FUEL INJECTOR NO. 1 LOW-SIDE CONTROL K612 16YL/BR FUEL INJECTOR NO. 2 LOW-SIDE CONTROL K369 16BR/OR FUEL PRESSURE SOLENOID SUPPLY K156 20BR/YL FUEL TEMPERATURE SENSOR SIGNAL K156 20BR/YL (A/T)
Page 1102 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 ENGINE CONTROL MODULE C1 (DIESEL) - 96 WAY CIRCUIT FUNCTION K2 20VT/OR ECT SENSOR SIGNAL K68 20BR/LG INLET PRESSURE SENSOR SIGNAL K181 20BR/YL FUEL PRESSURE SENSOR SIGNAL K856 20BR/YL BOOST PRESSURE SENSOR 5 VOLT SUPPLY K957 20BR/OR MASS AIR FLOW SENSOR GROUND K37 20BR/OR...
Page 1103 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS ENGINE CONTROL MODULE C2 (DIESEL) - 58 WAY CIRCUIT FUNCTION K347 14BR/PK FUSED ASD RELAY OUTPUT Z131 14BK/DG GROUND K347 14BR/PK FUSED ASD RELAY OUTPUT Z131 14BK/DG GROUND K345 14BR/RD FUSED ASD RELAY OUTPUT Z131 14BK/DG GROUND C20 20DB/YL...
Page 1104 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 ENGINE COOLANT LEVEL SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION G18 20OR/VT LOW COOLANT FLUID LEVEL SENSE Z939 20BK GROUND ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K2 20VT/OR ECT SENSOR SIGNAL K900 20DB/DG SENSOR GROUND...
Page 1105 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS ENGINE OIL PRESSURE SWITCH (GAS) - 2 WAY CIRCUIT FUNCTION G6 20VT/GY ENGINE OIL PRESSURE SIGNAL EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K70 20DB/BR EVAP PURGE SOL SIGNAL K52 20DB/WT EVAP PURGE SOL CONTROL FLIP-UP GLASS RELEASE MOTOR - BLACK 2 WAY CIRCUIT...
Page 1106 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 FRONT CONTROL MODULE (DIESEL) - 24 WAY CIRCUIT FUNCTION D25 18WT/VT PCI BUS D21 20WT/GY SCI TRANSMIT (ECM) K302 20BR/WT ENGINE OIL PRESSURE SENSOR SIGNAL D65 20WT/LG CAN C BUS (+) D64 20WT/LB CAN C BUS (-) K303 20BR/OR WATER IN FUEL SENSOR SIGNAL...
Page 1107 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS FUEL HEATER (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION A993 16RD FUEL HEATER RELAY OUTPUT Z939 18BK GROUND FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K611 16OR/BR FUEL INJECTOR NO. 1 LOW-SIDE CONTROL K11 16BR/YL FUEL INJECTOR NO.
Page 1108 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 FUEL INJECTOR NO. 2 (GAS) - BLACK 2 WAY CIRCUIT FUNCTION F142 16PK/GY FUSED ASD RELAY OUTPUT K12 16BR/DB INJECTOR CONTROL NO. 2 FUEL INJECTOR NO. 3 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K613 16GY/BR...
Page 1109 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 4 (GAS) - BLACK 2 WAY CIRCUIT FUNCTION F142 16PK/GY FUSED ASD RELAY OUTPUT K14 16BR/TN INJECTOR CONTROL NO. 4 FUEL INJECTOR NO. 5 (3.7L) - BLACK 2 WAY CIRCUIT FUNCTION F142 16PK/GY...
Page 1110 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 FUEL PRESSURE SOLENOID (DIESEL) - 2 WAY CIRCUIT FUNCTION K370 16BR FUEL PRESSURE SOLENOID CONTROL K369 16BR/OR FUEL PRESSURE SOLENOID SUPPLY FUEL PUMP MODULE - 4 WAY CIRCUIT FUNCTION Z201 18BK (GAS) GROUND K300 20BR (DIESEL) SENSOR GROUND...
Page 1111 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS G202 - BLACK 14 WAY CIRCUIT FUNCTION Z945 18BK GROUND Z40 14BK GROUND Z120 20BK/WT (EXCEPT BASE) GROUND Z950 20BK (RHD) GROUND Z18 20BK/LB GROUND Z10 16BK/TN GROUND Z15 16BK/TN GROUND Z943 14BK GROUND Z944 16BK GROUND...
Page 1112 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 HANDS FREE MODULE C1 - 22 WAY CIRCUIT FUNCTION A908 18RD FUSED B(+) X722 20LB/DG MICROPHONE 2 IN(+) X730 20GY/YL VOICE RECOGNITION/PHONE SWITCH SIGNAL X712 20DG/LB MICROPHONE 1 IN(+) X792 20DG/YL MICROPHONE IN(-) X793 20DG/YL IGNITION RUN/ACC SIGNAL X835 20OR/GY...
Page 1113 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS HAZARD SWITCH/COMBINATION FLASHER - WHITE 10 WAY CIRCUIT FUNCTION A701 18BR/RD FUSED B(+) Z940 16BK GROUND L62 18WT/OR RIGHT TURN SIGNAL L91 18WT/DB HAZARD LAMP CONTROL L305 20WT/LB LEFT TURN SWITCH SENSE L63 18WT/DG LEFT TURN SIGNAL C115 20DB...
Page 1114 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 HIGH BEAM RELAY CIRCUIT FUNCTION INTERNAL FUSED B(+) INTERNAL FUSED B(+) INTERNAL HIGH BEAM RELAY CONTROL INTERNAL FRONT FOG LAMP RELAY OUTPUT...
Page 1115 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS HIGH NOTE HORN - 2 WAY CIRCUIT FUNCTION X2 18DG/OR HORN RELAY OUTPUT Z931 18BK GROUND HOOD AJAR SWITCH (EXCEPT BASE) - 2 WAY CIRCUIT FUNCTION G70 20VT/LB HOOD AJAR SWITCH SENSE Z932 20BK GROUND IDLE AIR CONTROL MOTOR - 2 WAY...
Page 1116 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 INPUT SPEED SENSOR (A/T) - BLACK 2 WAY CIRCUIT FUNCTION T52 20DG/WT INPUT SPEED SENSOR SIGNAL T13 20DG/VT SPEED SENSOR GROUND INSTRUMENT CLUSTER - BLACK 20 WAY CIRCUIT FUNCTION A908 18RD FUSED B(+) G69 20VT/WT VTSS INDICATOR DRIVER B25 20DG/WT...
Page 1117 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS INTAKE AIR TEMPERATURE/BOOST PRESSURE SENSOR (DIESEL) - 4 WAY CIRCUIT FUNCTION K656 20GY/BR SENSOR GROUND K21 20BR/WT IAT SENSOR SIGNAL K856 20BR/YL BOOST PRESSURE SENSOR 5 VOLT SUPPLY K37 20BR/OR BOOST PRESSURE SENSOR SIGNAL INTAKE PRESSURE SENSOR (DIESEL) - 3 WAY CIRCUIT FUNCTION...
Page 1118 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 JUNCTION BLOCK BODY CONTROL MODULE-JB - 26 WAY CIRCUIT FUNCTION X3 (PREMIUM) HORN RELAY CONTROL P334 DOOR UNLOCK RELAY CONTROL L779 PARK LAMP RELAY CONTROL L239 (RHD/LHD HIGHLINE) REAR FOG LAMP RELAY CONTROL P109 (EXCEPT BASE) DRIVER DOOR UNLOCK RELAY CONTROL C515...
Page 1119 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C1 - 42 WAY CIRCUIT FUNCTION F944 12PK/LG IGNITION SWITCH OUTPUT (RUN-START) E2 20OR/BR PANEL LAMPS DRIVER E2 20OR/BR PANEL LAMPS DRIVER X3 20DG/VT HORN RELAY CONTROL L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT A207 16RD/LG (LHD) FUSED B(+) E2 20OR.BR (LIGHT BAR)
Page 1120 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 JUNCTION BLOCK C2 - GRAY 42 WAY CIRCUIT FUNCTION F37 14PK/LB (MIDLINE/HIGHLINE) FUSED B(+) C15 12DB/WT REAR WINDOW DEFOGGER RELAY OUTPUT Q39 16OR/TN REAR WINDOW DEFOGGER RELAY OUTPUT F892 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) P37 20LG/TN DOOR LOCK SWITCH GROUND P33 16TN/DB...
Page 1121 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C3 - GRAY 42 WAY CIRCUIT FUNCTION A12 10RD/BR FUSED B(+) A912 10RD FUSED B(+) A906 12RD FUSED B(+) L44 18WT/TN FUSED RIGHT LOW BEAM OUTPUT L43 18WT/DB FUSED LEFT LOW BEAM OUTPUT F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) A5 16RD/VT...
Page 1122 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 KNOCK SENSOR (3.7L) - BLACK 4 WAY CIRCUIT FUNCTION K942 18BR/LG KNOCK SENSOR NO. 1 RETURN K42 20BR/OR KNOCK SENSOR NO. 1 SIGNAL K924 20PK/RD KNOCK SENSOR NO. 2 RETURN K242 20BR/WT KNOCK SENSOR NO.
Page 1123 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS LEFT FOG LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z931 16BK GROUND L89 16WT/YL FRONT FOG LAMP RELAY OUTPUT LEFT FRONT DOOR SPEAKER (BASE) - 3 WAY CIRCUIT FUNCTION X53 18DG LEFT FRONT SPEAKER (+) X55 18DG/BR LEFT FRONT SPEAKER (-) LEFT FRONT DOOR SPEAKER (PREMIUM) - 10 WAY...
Page 1124 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 LEFT FRONT PARK/TURN SIGNAL LAMP (EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L63 18WT/DG LEFT TURN SIGNAL Z931 16BK GROUND LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT EXPORT) - 3 WAY CIRCUIT FUNCTION L63 18WT/DG LEFT TURN SIGNAL L77 18PK/RD...
Page 1125 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS LEFT FRONT WHEEL SPEED SENSOR (ABS) - BLACK 2 WAY CIRCUIT FUNCTION B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP- LEFT HEADLAMP (EXCEPT EXPORT) - 3 WAY CIRCUIT FUNCTION L43 18WT/DB...
Page 1126 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 LEFT HEATED SEAT SWITCH (HIGHLINE) - BLACK 8 WAY CIRCUIT FUNCTION P137 20VT/DG LEFT SEAT LOW HEAT LED DRIVER P133 20TN/DG LEFT SEAT HEATER SWITCH MUX P139 20VT/WT LEFT SEAT HIGH HEAT LED DRIVER F302 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN) Z849 20BK/WT...
Page 1127 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS LEFT POWER SEAT MOTORS (MIDLINE/HIGHLINE) - BLACK 6 WAY CIRCUIT FUNCTION P11 14YL/WT DRIVER SEAT REAR UP DRIVER P13 14RD/WT DRIVER SEAT REAR DOWN DRIVER P19 14YL/LG DRIVER SEAT FRONT UP DRIVER P21 14RD/LG DRIVER SEAT FRONT DOWN DRIVER P17 14RD/LB...
Page 1128 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 LEFT REAR DOOR SPEAKER (PREMIUM) - 3 WAY CIRCUIT FUNCTION X206 18DG/LG AMPLIFIED LOW LEFT REAR SPEAKER (+) X20 20GY/WT RADIO CONTROL MUX LEFT REAR POWER WINDOW MOTOR (PREMIUM) - LT GRAY 2 WAY CIRCUIT FUNCTION Q211 16TN/LB...
Page 1129 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS LEFT SIDE MARKER LAMP (EXCEPT EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L77 18PK/RD FUSED PARK LAMP RELAY OUTPUT L77 18PK/RD FUSED PARK LAMP RELAY OUTPUT L77 18PK/RD FUSED PARK LAMP RELAY OUTPUT L63 18WT/DG LEFT TURN SIGNAL L63 18WT/DG...
Page 1130 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 LICENSE LAMP (EXCEPT EXPORT) - LT GRAY 2 WAY CIRCUIT FUNCTION L77 18PK/RD FUSED PARK LAMP RELAY OUTPUT Z934 20BK GROUND LICENSE LAMP (EXPORT) - 2 WAY CIRCUIT FUNCTION L77 18PK/RD FUSED PARK LAMP RELAY OUTPUT Z213 18BK/OR GROUND LIGHTBAR LAMP NO.
Page 1131 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS LIGHTBAR LAMP NO. 4 - 2 WAY CIRCUIT FUNCTION Z946 16BK GROUND L8 14WT/DG LIGHTBAR SWITCHED OUTPUT LIGHTBAR SWITCH (RENEGADE) - 8 WAY CIRCUIT FUNCTION A904 14RD FUSED B(+) L8 14WT/DG LIGHTBAR SWITCHED OUTPUT Z940 20BK GROUND F942 20PK/LG (EXCEPT EXPORT)
Page 1132 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 MASS AIR FLOW SENSOR (DIESEL) - 6 WAY CIRCUIT FUNCTION K811 20BR/OR MASS AIR FLOW SENSOR 5 VOLT SUPPLY F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) K957 20BR/OR MASS AIR FLOW SENSOR GROUND K157 20BR/OR MASS AIR FLOW 5 VOLT SUPPLY MULTI-FUNCTION SWITCH C1 - GRAY 10 WAY...
Page 1133 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS OCCUPANT CLASSIFICATION MODULE - 18 WAY CIRCUIT FUNCTION D105 20WT/OR SEAT BELT TENSION SENSOR SIGNAL Z105 18BK/LG GROUND R741 20LG/VT PASSENGER BLADDER PRESSURE SENSOR SIGNAL R740 20LG/OR PASSENGER BLADDER PRESSURE SENSOR POWER D25 20WT/VT PCI BUS F201 18LG/YL...
Page 1134 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 OXYGEN SENSOR 1/1 UPSTREAM (2.4L) - 4 WAY CIRCUIT FUNCTION K99 18BR/TN O2 1/1 HEATER CONTROL Z42 18BK/LG GROUND K902 20BR/DG O2 UPSTREAM RETURN K41 20DB/LB O2 1/1 SIGNAL OXYGEN SENSOR 1/1 UPSTREAM (3.7L) - BLACK 4 WAY CIRCUIT FUNCTION K99 18BR/TN...
Page 1135 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS OXYGEN SENSOR 2/2 DOWNSTREAM (3.7L) - NATURAL 4 WAY CIRCUIT FUNCTION K399 18BR/GY O2 2/2 HEATER CONTROL Z42 18BK/LG GROUND K904 20DB/DG O2 DOWNSTREAM RETURN K243 20BR O2 2/2 SIGNAL PASSENGER AIRBAG ON/OFF INDICATOR - 2 WAY CIRCUIT FUNCTION F942 20PK/LG...
Page 1136 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 PASSENGER DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - 4 WAY CIRCUIT FUNCTION G74 20VT/WT (LHD) RIGHT FRONT DOOR AJAR SWITCH SENSE G75 20VT/WT (RHD) LEFT FRONT DOOR AJAR SWITCH SENSE Z99 20BK GROUND P35 16TN/YL (LHD) UNLOCK RELAY OUTPUT...
Page 1137 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS POWER MIRROR SWITCH (EXCEPT BASE) - WHITE 10 WAY CIRCUIT FUNCTION P75 20TN/LG LEFT MIRROR LEFT DRIVER P71 20TN/LG LEFT MIRROR UP DRIVER Z999 20BK (LHD) GROUND Z998 20BK (RHD) GROUND P110 20LG/WT (RHD) FOLDING MIRROR RETURN F302 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
Page 1138 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 POWERTRAIN CONTROL MODULE C1 - BLACK/BLACK 38 WAY CIRCUIT FUNCTION Z130 16BK/BR GROUND C20 20DB/YL A/C SWITCH SENSE F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) B22 20DG/YL VEHICLE SPEED SIGNAL Z131 16BK/DG...
Page 1139 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C2 - BLACK/ORANGE 38 WAY CIRCUIT FUNCTION K10 16DB/OR (3.7L) COIL CONTROL NO. 6 K16 16DB/YL (3.7L) COIL CONTROL NO. 5 K15 16DB (3.7L) COIL CONTROL NO. 4 K58 16BR/VT (3.7L) INJECTOR CONTROL NO.
Page 1140 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 POWERTRAIN CONTROL MODULE C3 (3.7L) - BLACK/NATURAL 38 WAY CIRCUIT FUNCTION K342 20BR/WT ASD RELAY CONTROL N112 20DB/OR HIGH SPEED RAD FAN RELAY CONTROL V35 20VT/OR (EXCEPT BASE) S/C VENT CONTROL N201 20DB/LG LOW SPEED RAD FAN RELAY CONTROL V32 20VT/YL S/C POWER SUPPLY...
Page 1141 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C4 (3.7L A/T) - BLACK/GREEN 38 WAY CIRCUIT FUNCTION T60 18YL/GY OD SOLENOID CONTROL T59 18YL/LB UD SOLENOID CONTROL T19 18YL/DB 2-4 SOLENOID CONTROL T20 18DG/WT L/R SOLENOID CONTROL Z903 16BK GROUND Z903 16BK...
Page 1142 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 RADIATOR FAN MOTOR - 3 WAY CIRCUIT FUNCTION C23 12DG LOW SPEED RAD FAN RELAY OUTPUT Z212 12BK/OR GROUND C25 12YL HIGH SPEED RAD FAN RELAY OUTPUT RADIO C1 - 22 WAY CIRCUIT FUNCTION A908 18RD...
Page 1143 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS RADIO C3 (EXCEPT EXPORT) - 2 WAY CIRCUIT FUNCTION D5 20WT/OR RADIO ANTENNA CORE D931 20WT/YL RADIO ANTENNA SHIELD RADIO CHOKE (MIDLINE/PREMIUM) - GRAY 4 WAY CIRCUIT FUNCTION X1 16DG/BR ANTENNA RELAY OUTPUT X13 16LG/GY RADIO CHOKE OUTPUT A116 20YL/RD...
Page 1144 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 103 REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B2 20DG/LB REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B1 20DG/DB REAR WHEEL SPEED SENSOR SIGNAL REAR WIPER MOTOR - BLACK 6 WAY CIRCUIT FUNCTION Z213 18BK/OR...
Page 1145 8W - 80 - 104 8W-80 CONNECTOR PIN-OUTS RIGHT DOOR LOCK SWITCH (EXCEPT BASE) - BLACK 4 WAY CIRCUIT FUNCTION P36 20TN/DB DOOR LOCK SWITCH MUX Z998 20BK GROUND F982 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) P37 20LG/TN DOOR LOCK SWITCH GROUND RIGHT FOG LAMP - BLACK 2 WAY CIRCUIT FUNCTION...
Page 1146 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 105 RIGHT FRONT IMPACT SENSOR - 2 WAY CIRCUIT FUNCTION R82 20WT/LB RIGHT FRONT IMPACT SENSOR GROUND R80 20VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL RIGHT FRONT PARK/TURN SIGNAL LAMP (EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L62 18WT/OR...
Page 1147 8W - 80 - 106 8W-80 CONNECTOR PIN-OUTS RIGHT FRONT POWER WINDOW MOTOR (MIDLINE/HIGHLINE) - LT GRAY 2 WAY CIRCUIT FUNCTION Q22 14OR/VT (LHD) PASSENGER FRONT WINDOW DRIVER DOWN Q22 14OR/VT (RHD) DRIVER FRONT WINDOW DRIVER DOWN Q12 14OR/BR (LHD) RIGHT FRONT WINDOW DRIVER UP Q12 14OR/BR (RHD) RIGHT FRONT WINDOW DRIVER UP...
Page 1148 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 107 RIGHT HEATED SEAT ASSEMBLY (HIGHLINE) - 4 WAY CIRCUIT FUNCTION F98 16RD/WT PASSENGER HEATED SEAT FEED Z849 16BK/WT GROUND P86 20PK/BK HEATED SEAT TEMPERATURE SENSOR SIGNAL P142 20TN/DB PASSENGER HEATED SEAT TEMPERATURE SENSOR GROUND RIGHT HEATED SEAT SWITCH (HIGHLINE) - BLACK 8 WAY CIRCUIT...
Page 1149 8W - 80 - 108 8W-80 CONNECTOR PIN-OUTS RIGHT POWER SEAT MOTORS (MIDLINE/HIGHLINE) - BLACK 6 WAY CIRCUIT FUNCTION P10 14YL/WT PASSENGER SEAT REAR UP DRIVER P12 14RD/WT PASSENGER SEAT REAR DOWN DRIVER P18 14YL/LG PASSENGER SEAT FRONT UP DRIVER P20 14RD/LG PASSENGER SEAT FRONT DOWN DRIVER P16 14RD/LB...
Page 1150 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 109 RIGHT REAR DOOR SPEAKER (PREMIUM) - 3 WAY CIRCUIT FUNCTION X205 18GY/LG AMPLIFIED LOW RIGHT REAR SPEAKER (+) X296 18LG/GY AMPLIFIED LOW RIGHT REAR SPEAKER (-) RIGHT REAR POWER WINDOW MOTOR (PREMIUM) - LT GRAY 2 WAY CIRCUIT FUNCTION Q212 16OR/VT...
Page 1151 8W - 80 - 110 8W-80 CONNECTOR PIN-OUTS RIGHT SIDE MARKER LAMP (EXCEPT EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT L62 18WT/OR RIGHT TURN SIGNAL L62 18WT/OR...
Page 1152 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 111 SATELLITE RECEIVER - 12 WAY CIRCUIT FUNCTION X41 20DG/WT AUDIO MUX LEFT Z515 20BK GROUND X112 20LG/GY IGNITION RUN/ACC SIGNAL X160 20GY/YL FUSED B(+) X40 20GY/WT AUDIO MUX RIGHT X140 20GY/OR SHIELD X235 20GY AUDIO RETURN D25 20WT/VT...
Page 1153 8W - 80 - 112 8W-80 CONNECTOR PIN-OUTS SIREN (EXPORT) - 3 WAY CIRCUIT FUNCTION Z932 20BK GROUND X75 18GY/DG SIREN SIGNAL CONTROL A908 20RD FUSED B(+) SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 18TN/RD S/C VACUUM CONTROL V35 18LG/RD S/C VENT CONTROL V30 18DB/RD...
Page 1154 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 113 TAILGATE CYLINDER LOCK SWITCH - LT GRAY 2 WAY CIRCUIT FUNCTION G910 20VT/BR TAILGATE SWITCH GROUND G71 20VT/OR TAILGATE CYLINDER LOCK SWITCH MUX TAILGATE FLIP-UP AJAR SWITCH - 2 WAY CIRCUIT FUNCTION G80 20VT/YL FLIP-UP GLASS AJAR SWITCH SENSE Z213 18BK/OR...
Page 1155 8W - 80 - 114 8W-80 CONNECTOR PIN-OUTS TRAILER TOW BRAKE LAMP RELAY - 5 WAY CIRCUIT FUNCTION A913 16RD FUSED B(+) Z933 14BK GROUND L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L651 16WT/LG TRAILER TOW BRAKE LAMP RELAY OUTPUT L76 16PK/RD TRAILER TOW BRAKE LAMP RELAY OUTPUT TRAILER TOW CONNECTOR - BLACK 10 WAY CIRCUIT...
Page 1156 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 115 TRAILER TOW RELAY CIRCUIT FUNCTION A100 14RD/VT FUSED B(+) Z933 14BK GROUND F302 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) A917 14RD TRAILER TOW RELAY OUTPUT TRAILER TOW RIGHT TURN RELAY - 5 WAY CIRCUIT FUNCTION L674 16LG...
Page 1157 8W - 80 - 116 8W-80 CONNECTOR PIN-OUTS TRANSMISSION CONTROL MODULE (2.8L) - BLACK 60 WAY CIRCUIT FUNCTION T1 20DG/LB TRS T1 SENSE T4 20DG/LB TRS T2 SENSE T3 20DG/DB TRS T3 SENSE K244 20BR/WT ENGINE RPM SIGNAL D21 20WT/GY SCI TRANSMIT (ECM) F26 20PK/OR FUSED IGNITION SWITCH OUTPUT (START)
Page 1158 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 117 TRANSMISSION RANGE SENSOR (42RLE) - 10 WAY CIRCUIT FUNCTION C115 20DB FUSED IGNITION SWITCH OUTPUT (RUN) T13 20DG/VT SPEED SENSOR GROUND T54 20DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL L10 20WT/GY BACK-UP LAMP FEED T1 20DG/LB TRS T1 SENSE T3 20DG/DB...
Page 1159 8W - 80 - 118 8W-80 CONNECTOR PIN-OUTS TRANSPONDER-TIRE PRESSURE-LEFT FRONT (EXCEPT 2.5L) - 6 WAY CIRCUIT FUNCTION F22 20PK/TN FUSED IGNITION SWITCH OUTPUT (RUN) D508 20WT/GY COM - LIN TIRE PRESSURE MONITOR LAN Z384 20BK GROUND Z384 20BK GROUND TRANSPONDER-TIRE PRESSURE-RIGHT FRONT (EXCEPT 2.5L) - 6 WAY CIRCUIT FUNCTION...
Page 1160 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 119 VARIABLE LINE PRESSURE SENSOR (3.7L) - 6 WAY CIRCUIT FUNCTION F856 20YL/PK 5 VOLT SUPPLY T38 20YL/BR LINE PRESSURE SENSOR SIGNAL K900 20DB/DG SENSOR GROUND T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT T140 20YL/GY MS SOLENOID CONTROL WASHER FLUID LEVEL SWITCH - 2 WAY CIRCUIT...
Page 1162 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 Connector, ground, and splice indexes are provided.
Page 1163 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Battery (Positive) Left Front Engine 32, 33 Compartment Battery (Negative) Left Front Engine 32, 33 Compartment Blend Door Actuator Behind Right Side of Instrument Panel Blower Motor Behind Right Side of Instrument Panel...
Page 1164 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C201 Behind Center of Instrument Panel C203 Left A-Pillar C300 (LHD) Left A-Pillar 41, 47 C300 (RHD) Right A-Pillar 45, 47 C301 (LHD) Left A-Pillar 41, 47 C301 (RHD) Right A-Pillar...
Page 1165 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Coil On Plug No.1 (3.7L) Left Side of Engine Near Fuel Injector No.1 Coil On Plug No.2 (3.7L) Right Side of Engine Near Fuel Injector No.2 Coil On Plug No.3 (3.7L) Left Side of Engine Near Fuel Injector No.3...
Page 1166 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Engine Oil Pressure Sensor (Diesel) Right Rear Side of Engine 18, 24 Engine Starter Motor Right Front Side of Engine Evap/Purge Solenoid At Solenoid Flip-Up Glass Release Motor In Tailgate Flip-Up Glass Release Switch...
Page 1167 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Idle Air Control Motor On Throttle Body Ignition Switch At Steering Column Input Speed Sensor Left Side of Transmission 5, 24 Instrument Cluster Rear of Cluster Intake Air Temperature Sensor Left Side of Intake Manifold Intake Pressure Sensor (Diesel) 3...
Page 1168 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Left Remote Radio Switch On Steering Wheel Left Side Impact Sensor 1 Left B-Pillar 41, 44 Left Side Marker Lamp Left Front Fender Left Side Repeater Lamp (Export) Left Front Fender Left Speed Control Switch On Steering Wheel...
Page 1169 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Passenger Door Lock Motor/Ajar In Passenger Door Switch (Except Base) Passenger Power Mirror Right Front Door Passenger Seat Belt Switch At Passenger Seat Passenger Seat Belt Tensioner Base of Right B- Pillar Power Distribution Center Left Engine Compartment...
Page 1170 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Right Headlamp (Export) Right Front Side of Engine Compartment Right Headlamp (Except Export) Right Front Side of Engine Compartment Right Heated Seat Assembly At Right Seat Right Heated Seat Switch At Right Seat Right Instrument Panel Speaker...
Page 1171 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Trailer Tow Circuit Breaker Right Quarter Panel Trailer Tow Connector At Trailer Hitch 55, 56 Trailer Tow Left Turn Relay Right Quarter Panel Trailer Tow Relay Right Quarter Panel Trailer Tow Right Turn Relay Right Quarter Panel...
Page 1172 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS GROUND NUMBER LOCATION FIG. G100 Left Side of Engine Compartment 8, 9, 14, 20 G101 (2.4L) Left Side of Engine Compartment G102 (A/T Gas) Left Rear Side of Engine Compartment G102 (Diesel) Left Rear Side of Engine Compartment G103 (3.7L)
Page 1173 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICES SPLICE NUMBER LOCATION FIG. S101 Near T/O to Power Distribution Center S102 In T/O for Power Distribution Center S103 (Diesel) In T/O for C100 S103 (Gas) Left Rear Engine Compartment S104 Rear Engine Compartment S105...
Page 1174 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S146 Near T/O for Right Front Park/Turn Signal Lamp S147 Front Lighting Harness S148 Front Lighting Harness S149 Front Lighting Harness S150 Right Side Engine Compartment S151 (2.4L) Near T/O for C110 11, 12...
Page 1175 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S200 Near T/O for C201 S201 Near T/O for Left Instrument Panel Lamp S202 Left Side Body Near G301 S204 Near T/O for Data Link Connector S205 In T/O for C100 S206...
Page 1176 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S317 Right Steering Wheel S318 (LHD) Near T/O for Left Instrument Panel Speaker S318 (RHD) Floor Near Right Front Door S319 (LHD) Near T/O for C201 S319 (RHD) Near T/O for Left Instrument Panel S322...
Page 1177 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE NUMBER LOCATION FIG. S369 Left Side Lightbar S370 Near T/O for Right Power Mirror S371 Near T/O for Right Door Lock Switch S372 Lower Front Engine Compartment S373 Right Front Lower Engine Compartment S377 (RHD) Near T/O for Right Door Lock Switch...
Page 1178 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1179 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1180 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1181 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1182 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1183 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1184 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1185 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1186 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 9 LEFT SIDE ENGINE COMPARTMENT, 3.7L Fig. 10 RIGHT SIDE ENGINE COMPARTMENT, 3.7L, RHD...
Page 1187 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1188 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1189 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1190 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1191 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1192 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 16 RIGHT REAR ENGINE COMPARTMENT, 2.4L Fig. 17 DIESEL ENGINE...
Page 1193 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 18 LOWER RIGHT FRONT DIESEL ENGINE...
Page 1194 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1195 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1196 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1197 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 22 FRONT DIESEL ENGINE...
Page 1198 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1199 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1200 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 25 TOP DIESEL ENGINE...
Page 1201 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1202 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 27 RIGHT SIDE ENGINE COMPARTMENT Fig. 28 RIGHT SIDE ENGINE COMPARTMENT, RHD...
Page 1203 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1204 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1205 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1206 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1207 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1208 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1209 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1210 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 49 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1211 8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1212 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 51 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 38 LEFT A POST...
Page 1213 8W - 91 - 52 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1214 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 53 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1215 8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 41 LEFT FRONT BODY, LHD...
Page 1216 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 55 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1217 8W - 91 - 56 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1218 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 57 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 44 LEFT FRONT BODY, RHD Fig. 45 RIGHT FRONT BODY, RHD...
Page 1219 8W - 91 - 58 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1220 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 59 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1221 8W - 91 - 60 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1222 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 61 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1223 8W - 91 - 62 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 50 RIGHT REAR BODY...
Page 1224 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 63 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1225 8W - 91 - 64 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1226 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 65 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1227 8W - 91 - 66 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1228 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 67 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 55 TRAILER TOW CONNECTORS...
Page 1229 8W - 91 - 68 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1230 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 69 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1232 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......6 DESCRIPTION .
Page 1233 8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION (Continued) cuits. The power distribution system can also prove up toward the knob exposing the heating element, useful for the sourcing of additional electrical circuits and the heating element extends from the housing that may be required to provide the electrical current toward the insulated contact in the bottom of the needed to operate accessories that the vehicle owner...
Page 1234 8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER OUTLET (Continued) (6) Connect the battery negative cable. Turn the reduce the normal IOD of the vehicle electrical sys- ignition switch to the Accessory or Run positions. tem during new vehicle transportation and pre-deliv- Check for battery voltage at the fused B(+) circuit ery storage to reduce battery depletion, while still cavity of the cigar lighter wire harness connector.
Page 1235 8W - 97 - 4 8W-97 POWER DISTRIBUTION built-in electrical connector. With the junction block JUNCTION BLOCK in its normal mounting location the body control module and remote keyless entry module are not DESCRIPTION accessible. The molded plastic junction block housing has two integral mounting bosses that are secured with two screws to the left instrument panel end bracket on left hand drive.
Page 1236 8W-97 POWER DISTRIBUTION 8W - 97 - 5 JUNCTION BLOCK (Continued) • Bent or distorted electrical circuit pins. • Incorrect size fuse installed in junction block fuse cavity. • Dark areas identifying a source of excess heat. • Defective fuse, relay or circuit breaker installed in junction block cavity.
Page 1237: Power Distribution Center
8W - 97 - 6 8W-97 POWER DISTRIBUTION JUNCTION BLOCK (Continued) INSTALLATION POWER DISTRIBUTION CENTER INSTALLATION - LHD DESCRIPTION NOTE: On vehicles equipped with a manual trans- All of the electrical current distributed throughout mission, it will be helpful to depress the clutch this vehicle is directed through the standard equip- pedal when installing the Junction Block under the ment Power Distribution Center (PDC).
Page 1238 8W-97 POWER DISTRIBUTION 8W - 97 - 7 POWER DISTRIBUTION CENTER (Continued) Distribution in Wiring Diagrams for the location of service replacement. The PDC cover can be simply complete PDC circuit diagrams. unlatched and removed from the PDC housing with- out the PDC being removed or disassembled.
Page 1239 8W - 97 - 8 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) PDC B+ TERMINAL MODULE unlatched and removed from the PDC housing with- out the PDC being removed or disassembled. Service REMOVAL of the remaining PDC components requires that the PDC be removed from its mounting and disassem- bled.
Page 1240 8W-97 POWER DISTRIBUTION 8W - 97 - 9 POWER DISTRIBUTION CENTER (Continued) (1) Remove the relay wedge from the PDC relay cassette to be removed. NOTE: It may be necessary to remove relay cas- settes that are not being serviced from the PDC housing in order to obtain sufficient clearance to access the faulty relay cassette.
Page 1241 8W - 97 - 10 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) RELAY CASSETTE INSTALLATION (1) Move the faulty PDC relay cassette with its wiring away from the bottom of the PDC housing far enough to allow the replacement relay cassette to be installed into the PDC.
Page 1242: Power Outlet
8W-97 POWER DISTRIBUTION 8W - 97 - 11 POWER DISTRIBUTION CENTER (Continued) downward until the mount latches fully engage the The power outlet receives battery voltage from a fuse mounting tabs on the stanchions. in the Junction Block at all times. (3) Install the two-holed eyelet of the battery wire While the power outlet is very similar to a cigar harness PDC take outs onto the two PDC B(+) termi-...
Page 1243 8W - 97 - 12 8W-97 POWER DISTRIBUTION POWER OUTLET (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the pro- tective cap from the power outlet receptacle base (Fig.
Page 1244 8W-97 POWER DISTRIBUTION 8W - 97 - 13 DIAGNOSIS AND TESTING - RELAY RELAY The relays are located in the junction block or DESCRIPTION power distribution center. For complete circuit dia- grams, refer to Wiring Diagrams. (1) Remove the relay from its mounting location. (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30.
Page 1245 8W - 97 - 14 8W-97 POWER DISTRIBUTION RELAY (Continued) REMOVAL OPERATION (1) Disconnect and isolate the negative battery A micro-relay is an electromechanical switch that cable. uses a low current input from one source to control a (2) Remove the relay by grasping it firmly and high current output to another device.
Page 1246 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE - 2.4L ......1 2.8L COMMON RAIL DIESEL ENGINE .
Page 1247 9 - 2 ENGINE - 2.4L HYDRAULIC LIFTERS REAR MOUNT DIAGNOSIS AND TESTING REMOVAL ......49 LASH ADJUSTER (TAPPET) NOISE INSTALLATION .
Page 1248 ENGINE - 2.4L 9 - 3 CLEANING ......62 INSTALLATION INSTALLATION BALANCE SHAFT TIMING .
Page 1249 9 - 4 ENGINE - 2.4L ENGINE - 2.4L (Continued) • Disconnect the fresh air hose (make-up air) at (3) Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnor- the cylinder head cover and plug or cap the nipple on mal firing indicators fouled, hot, oily, etc.
Page 1250 ENGINE - 2.4L 9 - 5 ENGINE - 2.4L (Continued) plug, bedplate to cylinder block mating surfaces ENGINE DIAGNOSIS and seal bore. See proper repair procedures for Engine diagnosis is helpful in determining the these items. causes of malfunctions not detected and remedied by (4) If no leaks are detected, pressurize the crank- routine maintenance.
Page 1251 9 - 6 ENGINE - 2.4L ENGINE - 2.4L (Continued) ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELEC- TRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1252 ENGINE - 2.4L 9 - 7 ENGINE - 2.4L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped 1. Clean plugs and set gap. plugs. 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 1253 9 - 8 ENGINE - 2.4L ENGINE - 2.4L (Continued) DIAGNOSIS AND TESTING - ENGINE MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION VALVETRAIN NOISE 1. High or low oil level in crank- 1. Check and correct engine oil case. level. 2. Thin or diluted oil. 2.
Page 1254 ENGINE - 2.4L 9 - 9 ENGINE - 2.4L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1255 9 - 10 ENGINE - 2.4L ENGINE - 2.4L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMIS- SIONS CONTROL/EVAPORATIVE EMISSIONS/PCV VALVE - DIAG- NOSIS AND TESTING) 2.
Page 1256 ENGINE - 2.4L 9 - 11 ENGINE - 2.4L (Continued) any fluid that may possibly be in the cylinder under this material will not properly cure. Always inspect pressure. the package for the expiration date before use. (4) With all spark plugs removed, rotate engine MOPAR GASKET MAKER is an anaerobic type crankshaft using a breaker bar and socket.
Page 1257 9 - 12 ENGINE - 2.4L ENGINE - 2.4L (Continued) ENGINE GASKET SURFACE PREPARATION MEASURING BEARING CLEARANCE USING PLASTIGAGE Engine crankshaft bearing clearances can be deter- mined by use of Plastigage or equivalent. The follow- ing is the recommended procedure for the use of Plastigage: Remove oil film from surface to be checked.
Page 1258 ENGINE - 2.4L 9 - 13 ENGINE - 2.4L (Continued) - ENGINE/ENGINE BLOCK/CONNECTING ROD (26) Secure the left and right engine wiring har- BEARINGS - STANDARD PROCEDURE) nesses away from engine. (27) Raise vehicle. REMOVAL - ENGINE ASSEMBLY (28) Disconnect oxygen sensor wiring. (29) Disconnect crankshaft position sensor.
Page 1259 9 - 14 ENGINE - 2.4L ENGINE - 2.4L (Continued) CAUTION: The structural cover requires a specific SPECIFICATIONS torque sequence. Failure to follow this sequence may cause severe damage to the cover. SPECIFICATIONS - 2.4L ENGINE GENERAL SPECIFICATIONS (11) Install the structural cover. (12) Install the exhaust pipe.
Page 1260 ENGINE - 2.4L 9 - 15 ENGINE - 2.4L (Continued) PISTONS PISTON RINGS DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Piston Diameter 87.456 - 3.4431 -3.4439 Ring Gap 87.474 mm Top Compres- 0.25 - 0.51 mm 0.0098 - 0.020 Clearance @ sion Ring 24.6 mm (0.551...
Page 1261 9 - 16 ENGINE - 2.4L ENGINE - 2.4L (Continued) CRANKSHAFT CAMSHAFT DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Connecting Rod 49.984 - 1.968 - 1.9685 Journal Diame- 25.976 - 1.022 - 1.023 Journal Diame- 50.000 mm ter No. 1 - 6 25.995 mm Bearing Clear- 0.025 - 0.065...
Page 1262 ENGINE - 2.4L 9 - 17 ENGINE - 2.4L (Continued) VALVE SEAT VALVES DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Angle 44.5 - 45° Face Angle - Intake and 44.5 - 45° Seat Diameter - 34.37 - 34.63 1.353 - 1.363 Exhaust Intake Head Diameter...
Page 1263 9 - 18 ENGINE - 2.4L ENGINE - 2.4L (Continued) VALVE STEM TO GUIDE CLEARANCE OIL PUMP DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Clearance Over 0.10 mm 0.004 in. Intake 0.048 - 0.066 0.0018 - 0.0025 Rotors (Max.) Cover Out-of- 0.025 mm 0.001 in.
Page 1264 ENGINE - 2.4L 9 - 19 ENGINE - 2.4L (Continued) SPECIFICATIONS - TORQUE DESCRIPTION N·m Lbs. Lbs. DESCRIPTION N·m Bolts, Engine Mounting (Refer to 9 ENGINE/ Lbs. Lbs. ENGINE MOUNTING) Bolts, Balance Shaft Car- Bolts, Exhaust Manifold rier to Block to Cylinder Head Fastener - Double Bolts, Exhaust Manifold...
Page 1265 9 - 20 ENGINE - 2.4L ENGINE - 2.4L (Continued) SPECIAL TOOLS 2.4L ENGINE Crankshaft Damper Installer 6792 Puller 1026 Valve Spring Compressor 8215 Crankshaft Damper Removal Insert 6827-A Camshaft Sprocket Holder 6847 Adaptor 8436 Camshaft Seal Remover C-4679-A Valve Spring Compressor MD-998772-A Camshaft Seal Installer MD-998306 Valve Spring Compressor Adapter 6779...
Page 1266 ENGINE - 2.4L 9 - 21 ENGINE - 2.4L (Continued) Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Cylinder Bore Gage C-119 Crankshaft Sprocket Remover 6793 Balance Shaft Sprocket Installer 6052 Crankshaft Sprocket Remover Insert C-4685-C2 Front Crankshaft Oil Seal Installer 6780 Crankshaft Seal Remover 6771 Combustion Leak Tester C-3685-A Oil Pressure Gauge C-3292...
Page 1267 9 - 22 ENGINE - 2.4L (9) Connect air intake duct. AIR CLEANER ELEMENT (10) Connect the mass airflow sensor connector REMOVAL - 2.4L Housing removal is not necessary for element (fil- CYLINDER HEAD ter) replacement. (1) Disconnect air intake duct at side of element DESCRIPTION cover.
Page 1268 ENGINE - 2.4L 9 - 23 CYLINDER HEAD (Continued) CHEMICAL TEST METHOD DIAGNOSIS AND TESTING Combustion leaks into the cooling system can also CYLINDER HEAD GASKET be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures A cylinder head gasket leak can be located between supplied with the tool kit.
Page 1269 9 - 24 ENGINE - 2.4L CYLINDER HEAD (Continued) CLEANING To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Page 1270 ENGINE - 2.4L 9 - 25 CYLINDER HEAD (Continued) (1) Before installing the bolts, the threads should (5) Install rocker arms. (Refer to 9 - ENGINE/ be coated with engine oil. CYLINDER HEAD/ROCKER ARMS - INSTALLA- (2) Position cylinder head gasket on engine block TION) (Fig.
Page 1271 9 - 26 ENGINE - 2.4L CAMSHAFT OIL SEAL(S) REMOVAL (1) Remove timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL) (2) Hold each camshaft sprocket with Special Tool 6847 while removing center bolt (Fig. 12). (3) Remove camshaft sprockets.
Page 1272 ENGINE - 2.4L 9 - 27 (6) If end play is excessive, check cylinder head CAMSHAFT(S) and camshaft for wear; replace as necessary. DESCRIPTION Both nodular iron camshafts have six bearing jour- nal surfaces and two cam lobes per cylinder (Fig. 15). Flanges at the rear journals control camshaft end play.
Page 1273 9 - 28 ENGINE - 2.4L CAMSHAFT(S) (Continued) Loosen the camshaft bearing cap attaching fasteners in sequence shown (Fig. 18) one camshaft at a time. CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider.
Page 1274 ENGINE - 2.4L 9 - 29 CAMSHAFT(S) (Continued) INSTALLATION NOTE: Replace spark plug well seals and bolt assemblies when installing a new cylinder head cover gasket. (1) Install new cylinder head cover gaskets and spark plug well seals (Fig. 22). Fig.
Page 1275 9 - 30 ENGINE - 2.4L CYLINDER HEAD COVER (Continued) CAUTION: Do not allow oil or solvents to contact (b) Tighten all bolts to 9.0 N·m (80 in. lbs.). the timing belt as they can deteriorate the rubber (c) Tighten all bolts to 12 N·m (105 in. lbs.). and cause tooth skipping.
Page 1276 ENGINE - 2.4L 9 - 31 INSPECTION VALVE SPRINGS (1) Whenever valves have been removed for inspec- tion, reconditioning or replacement, valve springs REMOVAL should be tested for correct tension. Discard the springs that do not meet specifications. The following REMOVAL - CYLINDER HEAD ON specifications apply to both intake and exhaust (1) Remove camshafts.
Page 1277 9 - 32 ENGINE - 2.4L VALVE SPRINGS (Continued) INSTALLATION - CYLINDER HEAD OFF Coat valve stems with clean engine oil and insert in cylinder head. Install new valve stem seals on all valves using a valve stem seal tool (Fig. 28). The valve stem seals should be pushed firmly and squarely over valve guide.
Page 1278 ENGINE - 2.4L 9 - 33 HYDRAULIC LIFTERS (Continued) REMOVAL ROCKER ARMS NOTE: This procedure is for in-vehicle service with REMOVAL camshafts installed. NOTE: This procedure is for in-vehicle service with (1) Remove cylinder head cover. (Refer to 9 - camshafts installed.
Page 1279 9 - 34 ENGINE - 2.4L ROCKER ARMS (Continued) INSPECTION Inspect the rocker arm for wear or damage (Fig. 32). Replace as necessary. Fig. 33 2.4L Cylinder Block and Bedplate - Typical 1 - CYLINDER BLOCK 2 - BEDPLATE Fig. 32 Rocker Arm - Typical piston pin about 14 mm (9/16 inch.) from the bottom of the skirt as shown in (Fig.
Page 1280 ENGINE - 2.4L 9 - 35 ENGINE BLOCK (Continued) Fig. 35 Piston Measurement - Typical 1 - PISTON DIAMETER 2 - 14 mm (0.551 in.) CYLINDER BORE HONING (1) Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped Fig.
Page 1281 9 - 36 ENGINE - 2.4L ENGINE BLOCK (Continued) CYLINDER BORE (2) Before installing the NEW bolts the threads should be oiled with clean engine oil. (3) Install each bolt finger tight then alternately NOTE: The cylinder bores should be measured at normal room temperature, 21°C (70°F).
Page 1282 ENGINE - 2.4L 9 - 37 CRANKSHAFT (Continued) (7) Remove the timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL) (8) Remove the oil pump. (Refer to 9 - ENGINE/ LUBRICATION/OIL PUMP - REMOVAL) (9) Remove balance shafts and housing assembly. (Refer to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT - REMOVAL) (10) Using a permanent ink or paint marker, iden-...
Page 1283 9 - 38 ENGINE - 2.4L CRANKSHAFT (Continued) Fig. 42 Bedplate Bolt Tightening Sequence INSPECTION The crankshaft journals should be checked for Fig. 44 Installing Main Bearing Upper Shell excessive wear, taper and scoring (Fig. 43). Limits of taper or out of round on any crankshaft journals 1 - LUBRICATION GROOVES 2 - OIL HOLES should within specitifications.
Page 1284 ENGINE - 2.4L 9 - 39 CRANKSHAFT (Continued) (14) Install the oil pump and pickup tube. (Refer ENGINE/LUBRICATION/OIL PUMP INSTALLATION) (15) Install the timing belt rear cover. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) (16) Install the timing belt. (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN...
Page 1285 9 - 40 ENGINE - 2.4L CRANKSHAFT MAIN BEARINGS (Continued) CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. Ensure that both cylinder block and bed- plate surfaces are clean. (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of anaerobic sealer Mopar Bed Plate Sealant to cyl- inder block as shown in (Fig.
Page 1286 ENGINE - 2.4L 9 - 41 CRANKSHAFT MAIN BEARINGS (Continued) • Step 2: Move crankshaft rearward to limits of CAUTION: Do not nick shaft seal surface or seal travel. bore. • Step 3: Then, move crankshaft forward to limits of travel. •...
Page 1287 9 - 42 ENGINE - 2.4L CRANKSHAFT OIL SEAL - FRONT (Continued) INSTALLATION (1) Install new seal by using Special Tool 6780 (Fig. 54). (2) Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover.
Page 1288 ENGINE - 2.4L 9 - 43 INSTALLATION CRANKSHAFT OIL SEAL - REAR CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit REMOVAL sand paper to prevent seal damage during installa- (1) Remove transmission. tion of new seal.
Page 1289 9 - 44 ENGINE - 2.4L CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 59 Crankshaft Seal and Special Tools 6926-2 & C-4171 1 - SPECIAL TOOL 6926–1 PILOT 2 - SEAL 3 - SPECIAL TOOL 6926–2 INSTALLER 4 - SPECIAL TOOL C-4171 Fig.
Page 1290 ENGINE - 2.4L 9 - 45 PISTON & CONNECTING ROD (Continued) (2) Remove oil pan. Scribe the cylinder number on the side of the rod and cap (Fig. 62) for identification. (3) Pistons have a directional stamping in the front half of the piston facing towards the front of engine.
Page 1291 9 - 46 ENGINE - 2.4L PISTON & CONNECTING ROD (Continued) (7) Before installing the NEW bolts the threads should be coated with clean engine oil. (8) Install each bolt finger tight than alternately torque each bolt to assemble the cap properly. CAUTION: Do not use a torque wrench for second part of last step.
Page 1292 ENGINE - 2.4L 9 - 47 PISTON RINGS (Continued) PISTON RINGS - INSTALLATION Fig. 69 Installing Side Rail - Typical 1 - SIDE RAIL END Fig. 68 Piston Ring Installation 1 - NO. 1 PISTON RING 2 - NO. 2 PISTON RING 3 - SIDE RAIL 4 - OIL RING 5 - SPACER EXPANDER...
Page 1293: Engine Mounting
9 - 48 ENGINE - 2.4L VIBRATION DAMPER REMOVAL (1) Remove accesory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) (2) Remove crankshaft damper bolt. (3) Remove damper using Special Tool 3-Jaw Puller 1026 and Insert 6827–A (Fig. 71). Fig.
Page 1294 ENGINE - 2.4L 9 - 49 FRONT MOUNT (Continued) INSTALLATION (2) Tighten the mount to engine bolts. (3) Loosely install the front engine mount through (1) Install the insulator mount assembly (Fig. bolt to the insulator. 73)and (Fig. 74). (4) Lower the engine. (5) Tighten the through bolt.
Page 1295 9 - 50 ENGINE - 2.4L REAR MOUNT (Continued) Fig. 75 TRANSMISSION MOUNT - 2.4L MANUAL Fig. 77 TRANSMISSION MOUNT - 3.7L 2WD AUTO TRANS TRANS 1 - TRANSMISSION MOUNT 1 - BOLT 2 - MOUNTING BOLT 2 - MOUNT Fig.
Page 1296 ENGINE - 2.4L 9 - 51 (5) After test is complete, remove test gauge and LUBRICATION fitting. (6) Install oil pressure switch and connector. (Refer DESCRIPTION to 9 - ENGINE/LUBRICATION/OIL PRESSURE The lubrication system is a full-flow filtration, SENSOR/SWITCH - INSTALLATION) pressure feed type.
Page 1297 9 - 52 ENGINE - 2.4L OIL (Continued) (2) Hoist and support vehicle on safety stands. Refer to Hoisting and Jacking Recommendations. (Refer to LUBRICATION & MAINTENANCE/HOIST- ING - STANDARD PROCEDURE) (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase drain.
Page 1298 ENGINE - 2.4L 9 - 53 OIL PAN (Continued) (15) Remove oil pan. OPERATION (16) Clean oil pan and all gasket surfaces. The oil pressure sensor uses three circuits. They are: • A 5 volt power supply from the Powertrain Con- INSTALLATION trol Module (PCM) (1) Install the oil pan gasket to the block.
Page 1299 9 - 54 ENGINE - 2.4L OIL PUMP (Continued) (6) Remove crankshaft key (Fig. 83). (3) Remove timing belt rear cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL). (4) Remove oil pan (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL).
Page 1300 ENGINE - 2.4L 9 - 55 OIL PUMP (Continued) (7) Remove oil pick-up tube. (8) Remove oil pump (Fig. 87) and front crankshaft seal. Fig. 88 Oil Pressure Relief Valve 1 - PLUG 2 - OIL PUMP BODY 3 - RELIEF VALVE 4 - SPRING Fig.
Page 1301 9 - 56 ENGINE - 2.4L OIL PUMP (Continued) INSPECTION (1) Inspect the mating surface of the oil pump. Surface should be smooth (Fig. 90). Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover sur- face (Fig.
Page 1302 ENGINE - 2.4L 9 - 57 OIL PUMP (Continued) INSTALLATION (1) Make sure all surfaces are clean and free of oil and dirt. (2) Apply Mopar Gasket Maker to oil pump as shown in (Fig. 94). Install O-ring into oil pump body discharge passage.
Page 1303 9 - 58 ENGINE - 2.4L INTAKE MANIFOLD REMOVAL REMOVAL DESCRIPTION (1) Disconnect negative cable from battery. The intake manifold is a two piece aluminum cast- (2) Disconnect connector from inlet air tempera- ing (Fig. 97) that attaches to the cylinder head with ture sensor.
Page 1304 ENGINE - 2.4L 9 - 59 INTAKE MANIFOLD (Continued) (8) Remove vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum res- ervoir (if equipped) at intake manifold fittings. (9) Disconnect throttle, speed control (if equipped), and transaxle control (if equipped) and cables from throttle lever and bracket.
Page 1305 9 - 60 ENGINE - 2.4L INTAKE MANIFOLD (Continued) (3) Install lower intake manifold support bracket bolts. • Bolts to intake 28 N·m (250 in. lbs.) • Bolt to engine block 54 N·m (40 ft. lbs.) (4) Connect the fuel line. (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY/QUICK CONNECT...

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