Page 1 GROUP TAB LOCATOR Lubrication & Maintenance Cooling Electronic Control Modules Engine Systems Ignition Control Engine Exhaust System Fuel System Steering - 2.7L - Diesel Transmission and Transfer Case Emissions Control - 2.7L Diesel Service Manual Comment Forms (Rear of Manual)
Page 2: Table Of Contents
LUBRICATION & MAINTENANCE 0a - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE DESCRIPTION - ENGINE OIL - DIESEL SPECIFICATIONS - FLUID CAPACITIES ..1 ENGINES ......6 INTERNATIONAL SYMBOLS OPERATION - AUTOMATIC TRANSMISSION DESCRIPTION...
Page 3: International Symbols
0a - 2 LUBRICATION & MAINTENANCE LUBRICATION & MAINTENANCE (Continued) DESCRIPTION SPECIFICATION REAR AXLE ± 0.3 L (1 oz.) 198 RBI (Model 35) 1.66 L (3.5 pts.)* 226 RBA (Model 44) 2.24 L (4.75 pts.)** * With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier.
Page 4: Description - Hoat Coolant
LUBRICATION & MAINTENANCE 0a - 3 FLUID TYPES (Continued) Use of 100 percent ethylene-glycol will cause for- CAUTION: Use of Propylene Glycol based coolants mation of additive deposits in the system, as the cor- is not recommended, as they provide less freeze rosion inhibitive additives in ethylene-glycol require protection and less corrosion protection.
Page 5: Engine Oil
0a - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) tion against freezing is provided with a 68 percent SAE VISCOSITY antifreeze concentration, which prevents freezing An SAE viscosity grade is used to specify the vis- down to -67.7°C (-90°F). A higher percentage will cosity of engine oil.
Page 6: Description - Engine Oil
LUBRICATION & MAINTENANCE 0a - 5 FLUID TYPES (Continued) DESCRIPTION - ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH.
Page 7: Description - Automatic Transmission Fluid - W5J400
0a - 6 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) condition. As the vehicle is driven, the ATF will begin additives must not be used. The use of transmission to look darker in color and may eventually become “sealers” should also be avoided, since they may brown.
Page 8: Lift Points
LUBRICATION & MAINTENANCE 0a - 7 LIFT POINTS STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS FLOOR JACK When properly positioned, a floor jack can be used to lift a WJ vehicle (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails.
Page 9: Emergency Tow Hooks
VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY. Some Jeep vehicles are equipped with front emer- gency tow hooks (Fig. 9). The tow hooks should be used for EMERGENCYpurposes only.
Page 10: Towing
LUBRICATION & MAINTENANCE 0a - 9 TWO-WHEEL-DRIVE VEHICLE TOWING TOWING DaimlerChrysler Corporation recommends that a vehicle be towed with the rear end lifted, whenever STANDARD PROCEDURE - TOWING possible. RECOMMENDATIONS A vehicle equipped with SAE approved wheel lift- WARNING: WHEN TOWING A DISABLED VEHICLE type towing equipment can be used to tow WJ vehi- AND THE DRIVE WHEELS ARE SECURED IN A cles.
Page 11 0a - 10 LUBRICATION & MAINTENANCE TOWING (Continued) (6) Turn the ignition switch to the OFF position to (5) Attach safety chains. Route chains so not to unlock the steering wheel. interfere with tail pipe when vehicle is lifted. (7) Secure steering wheel in straight ahead posi- (6) Turn the ignition switch to the OFF position to tion with a clamp device designed for towing.
Page 12 COOLING - 2.7L DIESEL 7a - 1 COOLING - 2.7L DIESEL TABLE OF CONTENTS page page COOLING - 2.7L DIESEL DIAGNOSIS AND TESTING - COOLING OPERATION—COOLING SYSTEM ... 1 SYSTEM ......2 DIAGNOSIS AND TESTING ACCESSORY DRIVE .
Page 13: Checks
7a - 2 COOLING - 2.7L DIESEL COOLING - 2.7L DIESEL (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATUREGAUGE 1. Vehicle is equipped with a heavy duty 1. None. System operating normaly. READS LOW cooling system.
Page 14: System
COOLING - 2.7L DIESEL 7a - 3 COOLING - 2.7L DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Heavy duty cooling system, extream 1. None. System operating normaly. READING INCONSISTENT cold ambient (outside) temperature or ( ERRATIC, CYCLES OR heater blower motor in high position.
Page 15 7a - 4 COOLING - 2.7L DIESEL COOLING - 2.7L DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER 1. Heavy duty cooling system, and 1. None. Normal condition. PERFORMANCE. GUAGE cooler ambient temperatures. MAY OR MAY NOT READ LOW. 2. Obstruction in heater hoses. 2.
Page 16: Diagnosis And Testing - Accessory Drive Belt
ACCESSORY DRIVE 7a - 5 ACCESSORY DRIVE TABLE OF CONTENTS page page DRIVE BELTS INSTALLATION ......7 DIAGNOSIS AND TESTING - ACCESSORY BELT TENSIONERS DRIVE BELT...
Page 17 7a - 6 ACCESSORY DRIVE DRIVE BELTS (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from has separated from belt body) pulley grooves. pulley grooves.
Page 18: Removal
ACCESSORY DRIVE 7a - 7 DRIVE BELTS (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE (Objectional squeal, squeek, 1. Incorrect belt tension 1. Inspect/Replace tensioner if or rumble is heard or felt while drive necessary belt is in operation) 2. Bearing noise 2.
Page 19: Belt Tensioners Description
7a - 8 ACCESSORY DRIVE DRIVE BELTS (Continued) BELT TENSIONERS DESCRIPTION CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Drive belts on all engines are equipped with a spring loaded automatic belt tensioner.
Page 20 ENGINE 7a - 9 ENGINE TABLE OF CONTENTS page page COOLANT WATER PUMP DESCRIPTION ......9 REMOVAL .
Page 21: Coolant Description
7a - 10 ENGINE COOLANT (Continued) glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-gly- col. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol.
Page 22: Standard Procedure Standard Procedure - Adding Additional Coolant
ENGINE 7a - 11 COOLANT (Continued) the result of a cylinder head gasket leak or crack in engine. Repair as necessary. If there is not an immediate pressure increase, pump the Pressure Tester. Do this until indicated pressure is within system range of 110 kPa (16 psi). Fluctuation of gauge pointer indicates compression or combustion leakage into cooling system.
Page 23: Standard Procedure - Draining Cooling System
7a - 12 ENGINE COOLANT (Continued) Year/100,000 Mile Formula (glycol base coolant with engine is cold. Coolant level in a warm engine corrosion inhibitors called HOAT, for Hybrid Organic will be higher due to thermal expansion. To Additive Technology) is recommended. This coolant purge the cooling system of all air, this heat up/cool offers the best engine cooling without corrosion when down cycle (adding coolant to cold engine) must be...
Page 24: Removal
ENGINE 7a - 13 COOLANT RECOVERY PRESSURE CONTAINER (Continued) - COOLING/ENGINE/RADIATOR PRESSURE CAP - (3) Partailly drain coolant system (Refer to 7 - DESCRIPTION) COOLING/ENGINE/COOLANT - STANDARD PRO- CEDURE). REMOVAL (4) Unplug coolant temperature sensor electrical connector. WARNING: DO NOT OPEN COOLING SYSTEM NOTE: Capture any residual coolant that may flow.
Page 25: Engine Coolant Thermostat Removal
7a - 14 ENGINE ENGINE COOLANT TEMP SENSOR (Continued) WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL- LEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
Page 26: Installation
ENGINE 7a - 15 WATER PUMP (Continued) (2) Remove engine cover (Refer to 9 - ENGINE - (8) Connect negative battery cable. REMOVAL). (9) Fill coolant system to proper level with the (3) Drain engine coolant (Refer to 7 - COOLING/ appropriate coolant mixture (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).
Page 27: Operation
7a - 16 ENGINE RADIATOR FAN (Continued) • Steering flow control valve HYDRAULIC FAN STRATEGY • Fan control valve The hydraulic radiator cooling fan is controlled by • Two stage G-rotor hydraulic drive the Electronic Control Module (ECM). A PWM (Pulse The hydraulic fan and drive are not serviceable.
Page 28: Removal
ENGINE 7a - 17 RADIATOR FAN (Continued) Fig. 8 HYDRAULIC FAN FLUID FLOW CIRCUIT 1 - POWER STEERING RESERVOIR 5 - HYDRAULIC FAN CONTROL SOLENOID 2 - POWER STEERING PUMP 6 - POWER STEERING OIL COOLER 3 - HYDRAULIC FAN DRIVE ASSEMBLY 7 - STEERING GEAR 4 - FAN BLADE NOTE: There is a steering flow control valve located...
Page 29: Installation
7a - 18 ENGINE RADIATOR FAN (Continued) Fig. 9 HYDRAULIC LINES/HOSES AND ELECTRICAL Fig. 11 FAN SHROUD MOUNTING BOLT LOCATIONS CONNECTOR 1 - FAN SHROUD UPPER MOUNTING BOLT LOCATIONS 2 - FAN SHROUD LOWER MOUNTING BOLT LOCATIONS 1 - LOW PRESSURE RETURN HOSE 2 - HIGH PRESSURE LINE (OUTLET) 3 - HIGH PRESSURE LINE (INLET) INSTALLATION...
Page 30: Radiator Pressure Cap Description
ENGINE 7a - 19 RADIATOR FAN (Continued) RADIATOR PRESSURE CAP DESCRIPTION all vehicle are equipped with a pressure cap (Fig. 13). This cap releases pressure at some point within a range of 124-to-145 kPa (18-to-21 psi). The pres- sure relief point (in pounds) is engraved on top of the The cooling system will operate at pressures slightly above atmospheric pressure.
Page 31: Operation
7a - 20 ENGINE RADIATOR PRESSURE CAP (Continued) OPERATION CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause A vent valve in the center of the cap will remain cooling system problems. A pressure cap that does shut as long as the cooling system is pressurized.
Page 32: Removal
ENGINE 7a - 21 RADIATOR (Continued) REMOVAL WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT. DO NOT OPEN COOL- ING SYSTEM UNLESS TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN APPROVED AND APPROPRIATELY MARKED CONTAINER.
Page 33: Installation
7a - 22 ENGINE RADIATOR (Continued) INSTALLATION NOTE: When ever the pressure line fittings are installed at the hydraulic fan drive, the O-rings must be replaced. CAUTION: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEMS HOSES. (5) Connect low pressure return hose at hydraulic USE ONLY THE TOOLS THAT ARE DESIGNED FOR fan.
Page 34 ELECTRONIC CONTROL MODULES 8Ea - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ENGINE CONTROL MODULE INSTALLATION ......4 DESCRIPTION .
Page 35: Procedure
8Ea - 2 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE (Continued) Normal Driving Modes ing (i.e. sensor grounds or 5-volt supply circuits). Refer to the appropriate schematic to identify shared Engine idle, warm-up, acceleration, deceleration circuits. Refer to the appropriate Diesel Powertrain and wide open throttle modes are controlled based on Diagnostic Manual for more information.
Page 36: Procedure
ELECTRONIC CONTROL MODULES 8Ea - 3 ENGINE CONTROL MODULE (Continued) STANDARD PROCEDURE - ECM/SKIM NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into PROGRAMMING - DIESEL SKIM, the SKIM must be replaced. NOTE: Before replacing the ECM for a failed driver, (6) Select YES to update VIN (the SKIM will learn control circuit or ground circuit, be sure to check...
Page 37 8Ea - 4 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE (Continued) hydraulic fluid within the transmission, by moving a sequence of four valves to make a shift occur. The W5J400 electronic transmission has a fully adaptive control system. The system performs its functions based on continuous real-time sensor feed- back information.
Page 38 ELECTRONIC CONTROL MODULES 8Ea - 5 TRANSMISSION CONTROL MODULE (Continued) lems. When a problem is sensed, the TCM stores a diagnostic trouble code (DTC). Some of these codes cause the transmission to go into Limp-In default mode. Some faults cause permanent Limp-In and others cause temporary Limp-In.
Page 39: Transfer Case
8Ea - 6 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • Trailer Operation, Loading. to confirm switch status. The PCM receives this • Engine Coolant Temperature. information and allows operation of the starter cir- • Cruise Control Operation. cuit. • Sporty Driving Style. N2 and N3 Speed Sensors •...
Page 40 ELECTRONIC CONTROL MODULES 8Ea - 7 TRANSMISSION CONTROL MODULE (Continued) • lateral acceleration (calculated by the TCM). pressure in order for shift member to apply. These • gear change frequency (how often the shift return springs have slightly different values. This occurs).
Page 41: Procedure
8Ea - 8 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • Transmission Control Module Replacement Controlled Limp-in Mode • Solenoid Pack Replacement When a failure does not require the TCM to shut • Clutch Plate and/or Seal Replacement down the solenoid supply, but the failure is severe •...
Page 42 ENGINE SYSTEMS 8Fa - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page CHARGING ....... 1 STARTING .
Page 43: Charging
8Fa - 2 CHARGING (11) Remove 2 lower generator mounting bolts GENERATOR (Fig. 2). Note lower bolts are slightly shorter than upper bolts. DESCRIPTION (12) Lower generator for removal. The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the genera- tor fails for any reason, the entire assembly must be replaced.
Page 44: Generator Decoupler Pulley Description
CHARGING 8Fa - 3 GENERATOR (Continued) (6) Install oil pan splash shield. Press in 2 clips (Fig. 3). (7) Lower vehicle. (8) Install 2 upper generator mounting bolts. Tighten all 4 mounting bolts (9) Tighten idler pulley bolt. (10) Install turbo intercooler hose (Fig. 1). (11) Install accessory drive belt by relieving ten- sion on belt tensioner.
Page 45: Diagnosis And Testing - Generator Decoupler
8Fa - 4 CHARGING GENERATOR DECOUPLER PULLEY (Continued) DIAGNOSIS AND TESTING - GENERATOR DECOUPLER CONDITION POSSIBLE CAUSES CORRECTION Does not drive generator Internal failure Replace decoupler (generator not charging) Noise coming from Internal failure Replace decoupler decoupler REMOVAL The generator decoupler is used only with certain engines.
Page 46 CHARGING 8Fa - 5 GENERATOR DECOUPLER PULLEY (Continued) Fig. 10 END OF GENERATOR SHAFT (SPLINED) 1 - GENERATOR SHAFT 2 - SPLINES Fig. 8 #8823 (VM.1048) TOOL AND INA DECOUPLER 1 - INA DECOUPLER 2 - TOOL #8823 (VM.1048) Fig. 11 DECOUPLER REMOVAL (INA-HEX) 1 - DEEP 10 MM SOCKET 2 - TOOL #8823 (VM.1048) Fig.
Page 47: Installation
8Fa - 6 CHARGING GENERATOR DECOUPLER PULLEY (Continued) Fig. 13 # 8433 TOOL AND LITENS DECOUPLER Fig. 12 DECOUPLER REMOVAL (INA-SPLINED) 1 - DRIVER 2 - TOOL #8823 (VM.1048) 3 - 17 MM WRENCH Litens Decoupler (1) Disconnect negative battery cable. (2) Remove generator and accessory drive belt.
Page 48 CHARGING 8Fa - 7 GENERATOR DECOUPLER PULLEY (Continued) (4) Do not use an adjustable, ratcheting “click type” torque wrench. Most “click type” wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counter-clockwise rotation (Fig.
Page 49 8Fa - 8 STARTING STARTING TABLE OF CONTENTS page page STARTING STARTER MOTOR SPECIFICATIONS REMOVAL - 2.7L DIESEL ....9 STARTER MOTOR - DIESEL .
Page 50: Starter Motor
STARTING 8Fa - 9 STARTER MOTOR REMOVAL - 2.7L DIESEL (1) Disconnect and isolate negative battery cable. (2) Raise and support vehicle. (3) Remove battery cable mounting nut and cable eyelet at starter solenoid battery terminal. (4) Remove 2 starter mounting bolts (Fig. 1). (5) Partially lower starter to gain access to sole- noid wire connector.
Page 52 IGNITION CONTROL 8Ia - 1 IGNITION CONTROL TABLE OF CONTENTS page page GLOW PLUG GLOW PLUG RELAY DESCRIPTION ......1 DESCRIPTION .
Page 53 8Ia - 2 IGNITION CONTROL GLOW PLUG (Continued) GLOW PLUG RELAY DESCRIPTION There are two glow plug relays. These relays are located in the Power Distribution Center (PDC) in the engine compartment. OPERATION When the ignition (key) switch is place in the ON position, a signal is sent to the ECM relating current engine coolant temperature.
Page 54 ENGINE 9a - 1 ENGINE TABLE OF CONTENTS page page ENGINE - 2.7L DIESEL REMOVAL ......24 DESCRIPTION INSTALLATION .
Page 55: Engine - 2.7L Diesel
9a - 2 ENGINE OIL PAN INSTALLATION ......47 REMOVAL ......41 TIMING BELT/CHAIN AND SPROCKETS INSTALLATION .
Page 56: Description - Engine Cover
ENGINE 9a - 3 ENGINE - 2.7L DIESEL (Continued) DESCRIPTION - ENGINE COVER sible difference between the individual cylinders is exceeded. Refer to cylinder leak down test. The engine cover is a black plastic cover used to (10) Remove compression tester and adapter from cover the top of the engine (Fig.
Page 57: Removal
9a - 4 ENGINE ENGINE - 2.7L DIESEL (Continued) (10) At normal operating temperature the oil pres- (17) Remove power steering resivior retaining sure must not drop below 3 bar (44 psi.). When bolts. engine speed is raised, oil pressure must rise with (18) Lift coolant module from vehicle (Refer to 7 - out delay and be no less than 3 bar (44 psi.) at 3000 COOLING/ENGINE/RADIATOR - REMOVAL).
Page 58: Removal - Engine Cover
ENGINE 9a - 5 ENGINE - 2.7L DIESEL (Continued) REMOVAL - ENGINE COVER (1) Firmly grasp front of cover and lift straight up to release cover from mounting ball studs (Fig. 3). Fig. 3 ENGINE COVER FRONT MOUNTS 1 - ENGINE COVER 2 - MOUNTING BALL STUDS Fig.
Page 59: Installation - Engine Cover
9a - 6 ENGINE ENGINE - 2.7L DIESEL (Continued) (25) Install turbocharger outlet to charge air (42) Fill engine oil to proper level. Refer to owners cooler. manual for specifications. (26) Install junction block bracket to compressor. (43) Connect negative battery cable. (27) Install air conditioning lines to compressor.
Page 60: Specifications - Torque Specifications
ENGINE 9a - 7 ENGINE - 2.7L DIESEL (Continued) SPECIFICATIONS - TORQUE SPECIFICATIONS 2.7L DIESEL DESCRIPTION N·m Ft. Lbs. In. Lbs. Crankcase Ventilation Screw-Air Charge Distribution Pipe to Air Charge Distribution Panel Cylinder Head 8m-Bolt- Cylinder Head to Timing Case Cover Bolt-Front Cover to Cylinder Head 12m-Bolt-Cylinder Head to Crankcase (3 stages, 60, 90°, 90°...
Page 61 9a - 8 ENGINE ENGINE - 2.7L DIESEL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Connection-Flange of Exhaust Manifold to Turbo Charger Connection-Turbo Charger to Front Catalytic Converter Charge Air Pipe/Charge Air Cooling Bolt-Charge Air Distribution Pipe Bolt-Inlet Port Shut Off Positioning Motor to Air Charge Distribution Pipe Bolt-Support to Charge Air Distribution Pipe Bolt-Support to Engine Bracket...
Page 62 ENGINE 9a - 9 ENGINE - 2.7L DIESEL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt-Oil-Water Heat Exchanger to Timing Cover Case Oil Level Pressure Bolt-Dip Stick Guide Tube to Cylinder Head Bolt-Oil Level Sensor to Oil Pan Coolant Pre- Heater Coolant Pre-Heater in Engine Block Engine Cooling General Bolt-Belt Pully to Coolant Pump...
Page 63 9a - 10 ENGINE ENGINE - 2.7L DIESEL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Timing Chain Tensioner to Timing Case Cover Camshaft Bolt-Camshaft Bearing Cap to Cylinder Head Bolt-Driver to Inlet Camshaft Common Rail Diesel Injection Bolt-Bango Bolt of Leak Oil Line to Rail Bolt-Bracket to High Pressure Pump Bolt-High Pressure Pump to Cylinder Head Bolt-Pre-delivery Pump to Top Cover of Cylinder...
Page 64: Special Tools
ENGINE 9a - 11 ENGINE - 2.7L DIESEL (Continued) SPECIAL TOOLS #8929 CAMSHAFT LOCKING PIN #8927 COMPRESSION TESTER ADAPTER #8931 TIMING CHAIN RETAINER #8928 FUEL PRESSURE TESTER...
Page 65 9a - 12 ENGINE ENGINE - 2.7L DIESEL (Continued) #8932 CRANKSHAFT LOCK #8937 SLIDE HAMMER #8936 FRONT CRANKSHAFT SEAL INSTALLER #8938 INJECTOR REMOVER...
Page 66 ENGINE 9a - 13 ENGINE - 2.7L DIESEL (Continued) #8940 VIBRATION DAMPER REMOVER #8944 REAR MAIN SEAL INSTALLER #8942 OIL JET INSTALLER #8945 ADAPTER CABLE...
Page 67 9a - 14 ENGINE ENGINE - 2.7L DIESEL (Continued) #8946 VALVE SERVICE TOOLS #8948 CHAIN SEPARATOR TOOL #8947 RIVET OPENER #8949 THRUST PIECE...
Page 68 ENGINE 9a - 15 ENGINE - 2.7L DIESEL (Continued) #8950 PRESSING SCREW #8952 ASSEMBLY INSERTS #8951 ASSEMBLY LINKS...
Page 69: Cylinder Head Standard Procedure Standard Procedure - Cylinder Head Bolt Inspection
9a - 16 ENGINE NOTE: camshaft housing Must CYLINDER HEAD machined. Basic bore of the camshaft bearings will be altered. STANDARD PROCEDURE (7) Machine cylinder head contact surface, if nec- essary. STANDARD PROCEDURE - CYLINDER HEAD (8) Measure cylinder head height (1) at point indi- BOLT INSPECTION cated, record stock removal (Fig.
Page 70: Removal
ENGINE 9a - 17 CYLINDER HEAD (Continued) (17) Remove timing chain tensioner(Refer to 9 - REMOVAL ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). REMOVAL - CYLINDER HEAD (18) Remove cylinder head front cover(Refer to 9 - (1) Disconnect negative battery cable. ENGINE/CYLINDER HEAD - REMOVAL).
Page 71: Removal - Cylinder Head Guide Rail
9a - 18 ENGINE CYLINDER HEAD (Continued) (5) Disconnect cooling fan power steering hose at (10) Remove bolts attaching front cover. power steering pump and set aside. NOTE: Lower portion of front cover is sealed with (6) Remove cylinder head cover (Refer to 9 - RTV sealant.
Page 72: Installation
ENGINE 9a - 19 CYLINDER HEAD (Continued) (2) Position piston of number 1 cylinder to ignition (3) Install M8 timing chain cover to cylinder head TDC. bolts (1A) (Fig. 8). Tighten to 20N·m (177 lbs.in.). (3) Remove engine cover. (Refer to 9 - ENGINE/ (4) Tighten M12 cylinder head bolts in numeric CYLINDER HEAD/CYLINDER HEAD COVER(S) - order starting with number 1 an additional 90°...
Page 73: Installation - Cylinder Head Front
9a - 20 ENGINE CYLINDER HEAD (Continued) BELT/CHAIN AND SPROCKETS - INSTALLATION) WARNING: NO FIRE, OPEN FLAMES OR SMOKING. Tighten to 80N·m (59 lbs.ft.). REMOVE SOURCES OF IGNITION FROM THE AREA. (18) Remove retaining lock for crankshaft/starter WEAR PROTECTIVE CLOTHING WHEN HANDLING ring gear.
Page 74: Cylinder Head Cover(S) Removal
ENGINE 9a - 21 CYLINDER HEAD (Continued) WARNING: US EXTREME CAUTION WHEN THE (4) Remove cylinder head cover (Refer to 9 - ENGINE IS OPERATING. DO NOT STAND IN A ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 75: Installation
9a - 22 ENGINE VALVE SPRINGS (Continued) WARNING: Suitably mark the valve and the position (11) Install camshafts and check basic position in the cylinder head before removal. Failure to do (Refer to 9 - ENGINE/CYLINDER HEAD/CAM- SHAFT(S) - INSTALLATION). so will result in improperly seated valves and pos- sible engine damage after reassembly.
Page 76: Camshaft(S)
ENGINE 9a - 23 VALVE SPRINGS (Continued) NOTE: Using tool, screw retaining fork into (5) Insert the locking pin through first camshaft threaded edge of cylinder head and position thrust bearing cap into the hole in the left inlet camshaft sprocket (Fig.
Page 77 9a - 24 ENGINE CAMSHAFT(S) (Continued) (7) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). (8) Install injectors (Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/FUEL INJECTOR - INSTALLA- TION). WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING.
Page 78: Installation
ENGINE 9a - 25 CAMSHAFT(S) (Continued) (10) Mark camshaft sprocket relative to timing INSTALLATION chain. (11) Unbolt camshaft sprocket from exhaust cam- CAUTION: The camshafts are sensitive to fractur- shaft. ing. Ensure they are installed free of stress. NOTE: Note the position of dowel pin for camshaft CAUTION: Pay attention to assignment of cam- sprocket alignment during reassembly.
Page 79: Engine Block Standard Procedure Standard Procedure - Replacing Engine Core And Oil Gallery Plugs
9a - 26 ENGINE CAMSHAFT(S) (Continued) (10) Inspect/Set basic position of camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - STANDARD PROCEDURE). (11) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). NOTE: Refer to the appropriate injector servicing procedures for cleaning of injectors and recesses.
Page 80: Standard Procedure - Measuring Cylinder Bores
ENGINE 9a - 27 ENGINE BLOCK (Continued) STANDARD PROCEDURE - MEASURING (3) Using the three measurment point, measure cylinder in the longitudinal and in the transverse CYLINDER BORES direction (Fig. 13). (4) Use the measurment and table below to group NOTE: This must be done with engine completely cylinder bores: disassembled.
Page 81: Crankshaft
9a - 28 ENGINE CAUTION: The crankshaft bearing caps are num- CRANKSHAFT bered consecutively, beginning with the first crank- shaft bearing cap at the front of the engine. STANDARD PROCEDURE - MEASURE Attention must be paid to the way crankshaft bear- CRANKSHAFT AND BLOCK JOURNALS ing caps fit.
Page 82: Crankshaft Oil Seal - Rear Removal
ENGINE 9a - 29 CRANKSHAFT (Continued) CAUTION: Oil grooves in the thrust washers must CRANKSHAFT OIL SEAL - point toward the thrust collars of the crankshaft. REAR CAUTION: Thrust washers in the bearing cap each REMOVAL have two retaining lugs as a anti-twist lock. This must be done with the transmission removed from the vehicle.
Page 83: Crankshaft Oil Seal - Front Removal
9a - 30 ENGINE CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 15 REAR MAIN SEAL/ADAPTER 1 - FLYWHEEL 6 - CRANKSHAFT 2 - FLYWHEEL BOLTS 7 - ALIGNMENT DOWELS 3 - SPECIAL TOOL 8944 8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT 4 - REAR CRANKSHAFT OIL SEAL 9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT...
Page 84: Installation
ENGINE 9a - 31 CRANKSHAFT OIL SEAL - FRONT (Continued) HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES. (7) Start the engine and inspect for leaks. FLYWHEEL REMOVAL (1) Remove transmission (Refer to 21 - TRANS- MISSION/TRANSAXLE/AUTOMATIC - W5J400 - REMOVAL).
Page 85: Installation
9a - 32 ENGINE FLYWHEEL (Continued) INSTALLATION NOTE: A flex rod torque wrench must not be used in order to avoid angle errors when tightening to degrees. (1) Align flywheel and inner and outer washers with straight pin. Tighten bolts in two stages. 45N·m (33 lbs.
Page 86 ENGINE 9a - 33 PISTON & CONNECTING ROD (Continued) NOTE: If the maximum permissible diameter is CONNECTING ROD SPECIFICATIONS exceeded, grind off contact surface of connecting rod bearing cap by a Maximum of 0.02mm. Distance between middle connecting rod bore to 148.970 mm to 149.030 (3) Using a dial indicator, measure connecting rod connecting rod bushing...
Page 87: Standard Procedure - Measuring Piston Protrusion
9a - 34 ENGINE PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE - MEASURING REMOVAL PISTON PROTRUSION (1) Disconnect the negative battery cable. (2) Remove the engine (Refer to 9 - ENGINE - After replacing the pistons/connecting rods or REMOVAL). machining the engine block contact surface, it is then (3) Remove the cylinder head (Refer to 9 - necessary to measure the piston protrusion.
Page 88: Installation
ENGINE 9a - 35 PISTON & CONNECTING ROD (Continued) Fig. 21 PISTON AND CONNECTING ROD ASSEMBLY 1 - PISTON PIN CIRCLIP 5 - CONNECTING ROD CAP 2 - PISTON PIN 6 - CONNECTING ROD BOLTS 3 - PISTON ASSEMBLY 7 - ENGINE BLOCK 4 - CONNECTING ROD AND CAP ALIGNMENT MARKS (11) Remove the piston pin circle clip.
Page 89 9a - 36 ENGINE PISTON & CONNECTING ROD (Continued) (8) Install piston with arrow pointing in the direc- tion of travel (in the opposite direction to power flow) (the marking on the connecting rod should be point- ing toward the inlet side). (Fig. 23). (9) Clean and inspect the connecting rod bolts.
Page 90: Piston Rings
ENGINE 9a - 37 PISTON & CONNECTING ROD (Continued) (13) Install oil pump (Refer to 9 - ENGINE/LU- BRICATION/OIL PUMP - INSTALLATION). (14) Install engine oil pan and oil pan drain plug (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION). CAUTION: Install a cylinder head gasket of standard thickness or a cylinder head gasket of repair thick- ness depending on piston projection.
Page 91 9a - 38 ENGINE PISTON RINGS (Continued) (4) Place ring in the cylinder bore and push down with inverted piston to position near lower end of the ring travel. Measure ring gap with a feeler gauge fit- ting snugly between ring ends (Fig. 25). Fig.
Page 92: Vibration Damper Removal
ENGINE 9a - 39 NOTE: If grooves can be felt in the belt pulley/vibra- VIBRATION DAMPER tion damper during inspection, the pulley/damper must be replaced. REMOVAL (1) Disconnect negative battery cable. (6) Inspect hub at belt pulley/vibration damper for (2) Remove accessory drive belt (Refer to 7 - wear grooves.
Page 93: Operation
9a - 40 ENGINE VACUUM PUMP (Continued) OPERATION Vacuum pump output is transmitted to the Heater, Electronic, Vacuum, Air Conditioner (HEVAC) and speed control, systems through a supply hose. The hose is connected to an outlet port on the pump hous- ing and uses an in-line check valve to retain system vacuum when vehicle is not running.
Page 94: Oil Jet Description
ENGINE 9a - 41 OIL JET DESCRIPTION There are five oil jets installed in the engine block (Fig. 30). These oil jets are used to cool and lubricate the piston assemblies. Fig. 31 OIL JET INSTALLATION 1 - OIL JET INSTALLER #8942 2 - ENGINE BLOCK 3 - OIL JET (4) Remove engine cover (Refer to 9 - ENGINE -...
Page 95: Oil Pump Removal Removal
9a - 42 ENGINE OIL PUMP REMOVAL REMOVAL (1) Disconnect negative battery cable. (2) Remove oil pan (Refer to 9 - ENGINE/LUBRI- CATION/OIL PAN - REMOVAL). (3) Unbolt oil pump from crankcase. (4) Press chain tensioner off oil pump chain and remove oil pump (Fig.
Page 96: Installation - Oil Pump Chain
ENGINE 9a - 43 OIL PUMP (Continued) INSTALLATION - OIL PUMP CHAIN CAUTION: IT IS ESSENTIAL that the installation pro- cedure is followed exactly. Failure to do so will result in severe engine damage. (1) Connect old oil pump chain and new chain with temporary link, outer plate and locking element (Fig.
Page 97 9a - 44 ENGINE OIL PUMP (Continued) (5) Assemble riveting tool by attaching inserts. (Fig. 37). Fig. 38 INSTALLING RIVETING INSERTS INTO Fig. 37 INSTALLING ASSEMBLY INSERTS INTO RIVETING TOOL RIVETING TOOL 1 - SPECIAL TOOL #8947 1 - SPECIAL TOOL #8947 2 - SPECIAL TOOL #8949 2 - SPECIAL TOOL #8952 (16) Turn over tool moving assembly insert to the...
Page 98: Oil Cooler & Lines
ENGINE 9a - 45 OIL PUMP (Continued) (18) Tighten riveting tool spindle until it stops. NOTE: Collect any residual fluids that may flow. (19) Remove riveting tool, inspect riveting, rerivet (5) Drain engine coolant. if necessary (Fig. 40). (6) Remove fuel full-flow filter (Refer to 14 - FUEL (20) Repeat procedure for both rivets.
Page 99: Intake Manifold
9a - 46 ENGINE OIL COOLER & LINES (Continued) (13) Start engine and inspect for leaks. receives a PWM signal from the ECM for this pur- (14) Inspect engine oil level 2 minutes after turn- pose. A direct current motor pushes the adjusting ing engine off.
Page 100: Installation
ENGINE 9a - 47 TIMING CHAIN COVER (Continued) (12) Position piston of cylinder 1 to ignition TDC. Markings on the camshaft bearing cap must be aligned. (13) Install retaining lock for crankshaft/starter ring gear. (14) Remove timing chain tensioner (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN...
Page 101 9a - 48 ENGINE TIMING CHAIN COVER (Continued) (14) Install the AC compressor and reconnect elec- TIMING BELT/CHAIN AND trical connector. SPROCKETS (15) Install belt pulley onto power steering pump. (16) Apply sealant to lower portain of, and install, front cover to cylinder block. Tighten bolts to 20N·m REMOVAL (177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
Page 102 ENGINE 9a - 49 TIMING BELT/CHAIN AND SPROCKETS (Continued) REMOVAL - INTERMEDIATE GEAR (1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE - REMOVAL). WARNING: NO FIRE, FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL.
Page 103 9a - 50 ENGINE TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 46 SECURING TIMING CHAIN TO SPROCKET 1 - CAMSHAFT SPROCKET 2 - TIMING CHAIN 3 - TIE STRAPS 4 - RETAINING BOLTS Fig. 45 TIMING CHAIN TENSIONING RAIL 1 - TIMING CHAIN COVER 2 - TENSIONING RAIL 3 - BEARING PIN 4 - OIL PAN...
Page 104 ENGINE 9a - 51 TIMING BELT/CHAIN AND SPROCKETS (Continued) (15) Connect new timing chain and old timing chain with assembly link, assembly plate and locking element, and secure (Fig. 50) (Fig. 51). Fig. 48 SEPARATING TIMING CHAIN WITH SPECIAL TOOL #8948 1 - TIMING CHAIN Fig.
Page 105 9a - 52 ENGINE TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 51 TIMING CHAIN TEMPORARY LINK 1 - CYLINDER HEAD COVER 7 - TIMING CHAIN TENSIONER 2 - TIMING CHAIN TEMPORARY LINK 8 - VACUUM PUMP 3 - ALIGNMENT PINS 9 - LOW PRESSURE FUEL PUMP 4 - TOP GUIDE RAIL 10 - LOW PRESSURE PUMP MOUNTING BOLTS 5 - CYLINDER HEAD FRONT COVER...
Page 106: Installation - Timing Chain
ENGINE 9a - 53 TIMING BELT/CHAIN AND SPROCKETS (Continued) (12) Connect negative battery cable. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR WARNING: USE EXTREME CAUTION WHEN THE HANDS NEAR THE PULLEYS, BELTS OR FAN. DO ENGINE IS OPERATING.
Page 107 9a - 54 ENGINE TIMING BELT/CHAIN AND SPROCKETS (Continued) NOTE: Rotate engine at crankshaft only. DO NOT crank engine and DO NOT rotate engine backward (Fig. 52). NOTE: Draw out the end of old timing chain evenly as it becomes free, to the same extent that new tim- ing chain is drawn in (Fig.
Page 108 ENGINE 9a - 55 TIMING BELT/CHAIN AND SPROCKETS (Continued) NOTE: Ensure that the riveted link and riveting tool NOTE: The outer plate is held magnetically by rivet- are aligned. ing tool. (9) Press in new riveted link as far as the stop (13) Insert new outer plate into the moving assem- (Fig.
Page 109 9a - 56 ENGINE TIMING BELT/CHAIN AND SPROCKETS (Continued) (17) Remove riveting tool. (18) Turn over moving assembly insert (D8) to the riveting profile. (19) Position riveting tool exactly over middle of pin. (20) Tighten riveting tool spindle to end of travel. (21) Repeat procedure for both riveting pins (Fig.
Page 110: Timing Chain Tensioner
ENGINE 9a - 57 TIMING CHAIN TENSIONER REMOVAL (1) Disconnect negative battery cable. CAUTION: Rotate engine at crankshaft only. DO NOT rotate the engine with the bolt of the camshaft sprocket. DO NOT rotate the engine counter clock- wise. NOTE: Markings on the camshaft and camshaft bearing cap must be aligned.
Page 112 EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL 11a - 1 EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL TABLE OF CONTENTS page page EXHAUST SYSTEM AND TURBOCHARGER - INSTALLATION ......4 2.7L DIESEL CHARGE AIR COOLER AND PLUMBING DESCRIPTION - 2.7L DIESEL...
Page 113: Turbocharger System
11a - 2 EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL • Higher torque as a result of improved cylinder TURBOCHARGER SYSTEM charge. • Reduction in exhaust emissions as a result of an DESCRIPTION improvement in the air supply of the engine. •...
Page 114: Installation
EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL 11a - 3 TURBOCHARGER SYSTEM (Continued) INSTALLATION (1) Position and install the turbocharger on the lower support bracket. (2) Position exhaust down pipe to turbocharger and secure with clamp. (3) Reconnect turbocharger oil lines with new seals.
Page 115: Installation
11a - 4 EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL WASTEGATE (Continued) INSTALLATION REMOVAL - CHARGE AIR COOLER (1) Position and install waste gate solenoid onto WARNING: IF THE ENGINE WAS JUST TURNED bracket. OFF, THE AIR INTAKE SYSTEM TUBES MAY BE (2) Connect engine vacuum harness to waste gate HOT.
Page 116: Inspection
EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL 11a - 5 CHARGE AIR COOLER AND PLUMBING (Continued) (6) Rinse the cooler with hot soapy water to (2) Install cooling module (Refer to 7 - COOLING/ remove any remaining solvent. ENGINE/RADIATOR - INSTALLATION) (Refer to 7 - (7) Rinse thoroughly with clean water and blow COOLING/ENGINE/RADIATOR FAN - INSTALLA- dry with compressed air.
Page 118 FUEL SYSTEM 14a - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL INJECTION ......1 FUEL DELIVERY .
Page 119: Fuel Injection
14a - 2 FUEL INJECTION CAMSHAFT POSITION SENSOR (Continued) Fig. 1 CAMSHAFT POSITION SENSOR LOCATION 1 - CAMSHAFT POSITION (CMP) SENSOR 2 - CYLINDER HEAD COVER Fig. 2 SENSOR LOCATION 1 - CRANKSHAFT POSITION SENSOR (2) Remove engine cover (Refer to 9 - ENGINE - 2 - SWIRL ACTUATOR REMOVAL).
Page 120: Removal
FUEL INJECTION 14a - 3 FUEL PRESSURE SENSOR (Continued) Fig. 3 FUEL PRESSURE SENSOR 1 - FUEL PRESSURE ELECTRICAL CONNECTOR 3 - FUEL RAIL 2 - FUEL PRESSURE SENSOR REMOVAL SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRI- WARNING: NO SPARKS, OPEN FLAMES OR SMOK- ATELY MARKED CONTAINERS.
Page 121: Fuel Injector
14a - 4 FUEL INJECTION FUEL INJECTOR DESCRIPTION FUEL INJECTOR There are individual fuel injectors for all five cyl- inders. These fuel injectors are used to spray fuel into the combustion chamber (Fig. 4). Fig. 4 FUEL INJECTOR 1 - FUEL INJECTOR 2 - NOZZLE 3 - FUEL INLET FITTING 4 - ELECTRICAL CONNECTION...
Page 122: Standard Procedure - Cleaning Fuel Injectors
FUEL INJECTION 14a - 5 FUEL INJECTOR (Continued) The force exerted by the triggered solenoid now (1) Seal the injector holes inside the cylinder head exceeds that of the valve spring and the armature recesses. opens the bleed orifice. Almost immediately, the high- (2) Wipe out injector recesses with a non - woven level pick-up current is reduced to the lower holding cloth, then clean with a cylinder brush.
Page 123: Installation
14a - 6 FUEL INJECTION FUEL INJECTOR (Continued) NOTE: If injectors are tight, remove with extraction (1) Clean injectors and recesses (Refer to 14 - claw in place of tensioning claw. If extraction claw FUEL SYSTEM/FUEL INJECTION/FUEL INJEC- TOR - STANDARD PROCEDURE). contacts cylinder head cover, remove cylinder head cover.
Page 124: Fuel Rail Description
FUEL INJECTION 14a - 7 FUEL INJECTOR (Continued) (7) If injectors four and five were replaced NOTE: After removing lines, seal connections and raise engine back in position and install engine ensure cleanliness. mount through bolts. (5) Remove injector high pressure lines (Refer to (8) Install engine cover (Refer to 9 - ENGINE - 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES INSTALLATION).
Page 125: Operation
14a - 8 FUEL INJECTION FUEL RAIL (Continued) INSTALLATION WARNING: NO FIRE, FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CON- TAINERS.
Page 126: Fuel Pressure Solenoid Description
FUEL INJECTION 14a - 9 MANIFOLD AIR FLOW (MAF) SENSOR (Continued) Fig. 10 FUEL PRESSURE SOLENOID 1 - INJECTION LINES 2 - FUEL RAIL 3 - FUEL RETURN LINE Fig. 9 MAF SENSOR LOCATION 4 - FUEL PRESSURE SOLENOID 1 - TURBOCHARGER 5 - OIL LINE 2 - MAF SENSOR 6 - SEALS...
Page 127: Installation - Fuel Pressure Solenoid
14a - 10 FUEL INJECTION FUEL PRESSURE SOLENOID (Continued) Fig. 11 FUEL PRESSURE SOLENOID OPERATION 1 - BALL SEAT 2 - SPRING FORCE 3 - MAGNETIC FORCE 4 - COIL 5 - FUEL PRESSURE SOLENOID 6 - HIGH PRESSURE FEED Fig.
Page 128: Operation
FUEL INJECTION 14a - 11 BOOST PRESSURE SENSOR (Continued) INTAKE AIR TEMPERATURE SENSOR DESCRIPTION This sensor is also used to monitor the intake air temperature (Fig. 14). Fig. 13 BOOST PRESSURE SENSOR LOCATION 1 - OIL FILTER CAP 2 - BOOST PRESSURE SENSOR OPERATION When the intake manifold pressure is low (high vacuum) sensor voltage output is 0.25-1.8 volts at the...
Page 129 14a - 12 FUEL DELIVERY FUEL DELIVERY TABLE OF CONTENTS page page FUEL DELIVERY OPERATION STANDARD PROCEDURE - BLEEDING AIR OPERATION ......13 FROM FUEL SYSTEM .
Page 130: Fuel Filter / Water Separator Description
FUEL DELIVERY 14a - 13 FUEL FILTER / WATER SEPARATOR (Continued) (1) Disconnect negative battery cable. (2) Insert a suitable hose into the fuel drain port in rear of filter, turn drain port counterclockwise and drain fuel into a suitable and appropriately marked container.
Page 131: Operation - Low Pressure Pump
14a - 14 FUEL DELIVERY FUEL PUMP (Continued) coming a spring force and allows excessive fuel to flow to the intake side of the low pressure pump. This diverted fuel flows into the return flow pipe through the fuel cooler back to the tank. As a result of this circulation, the fuel always remains relatively cool.
Page 132: Removal - Low Pressure Pump
FUEL DELIVERY 14a - 15 FUEL PUMP (Continued) Fig. 3 HIGH PRESSURE PUMP Fig. 4 VACUUM PUMP AND LOW PRESSURE FUEL PUMP ASSEMBLIES 1 - FUEL RETURN LINE 2 - FUEL LINE BRACKET 1 - VACUUM LINE 3 - HIGH PRESSURE PUMP 2 - FUEL OUTLET LINE 4 - O-RING 3 - FUEL FEED LINE...
Page 133: Installation - Low Pressure Pump
14a - 16 FUEL DELIVERY FUEL PUMP (Continued) (1) Position and secure the high pressure pump to INSTALLATION - LOW PRESSURE PUMP cylinder head (Fig. 3). Tighten bolts to 14 N·m (124 lbs. in.). WARNING: NO SPARKS, OPEN FLAMES OR SMOK- ING.
Page 134: Installation - High Pressure Lines
FUEL DELIVERY 14a - 17 FUEL LINES (Continued) CAUTION: DO NOT crimp or bend lines. INSTALLATION - HIGH PRESSURE LINES WARNING: NO SPARKS, OPEN FLAMES OR SMOK- NOTE: After removing injection lines, seal connec- ING. RISK OF POISONING FROM INHALING AND tions and ensure cleanliness.
Page 136 STEERING - 2.7L - DIESEL 19a - 1 STEERING - 2.7L - DIESEL TABLE OF CONTENTS page PUMP ........1 PUMP TABLE OF CONTENTS page...
Page 137 19a - 2 PUMP PUMP (Continued) INSTALLATION CAUTION: Power steering system fluid may be con- taminated with metal shavings, overheated or improper fluid. All fluid should be drained from the system. After any component replacement, system should be flushed and filled with Mopar Power Steering fluid, or equivalent.
Page 138 PUMP 19a - 3 RESERVOIR (Continued) (5) Install the intercooler outlet hose to the vehi- (2) Install the accessory drive belt on the power cle. steering pump pulley. Refer to Cooling System for the (6) Fill the reservoir and check the power steering procedure.
Page 139 19a - 4 PUMP HOSES (Continued) (6) Disconnect the high pressure hose from the power steering gear. (7) Remove the hose from the clipped position on the fan shroud. (8) Raise and support the vehicle. (9) Remove the metal skid plate. (10) Disconnect the high pressure hose from the hydraulic fan motor.
Page 140 PUMP 19a - 5 HOSES (Continued) INSTALLATION - RETURN HOSE - RESERVOIR INSTALLATION - 3/8 GEAR OUTLET HOSE TO THE HYDRAULIC FAN MODULE NOTE: Lubrication and a new o-ring must be used (1) Install the hose to the vehicle. when reinstalling. (2) Reconnect the rubber return hose to the hydraulic fan motor.
Page 142 TRANSMISSION AND TRANSFER CASE 21a - 1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page page AUTOMATIC TRANSMISSION - W5J400 FLUID AND FILTER DESCRIPTION ......2 DESCRIPTION .
Page 143 ..... . . 112 TRANSFER CASE - NV247 ... . . 138 • J = A transmission first used in a Jeep vehicle. AUTOMATIC TRANSMISSION - • 400 = A 4X4 transmission.
Page 144: Automatic Transmission - W5J400 Description
TRANSMISSION AND TRANSFER CASE 21a - 3 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 1 W5J400 Automatic Transmission 1 - TORQUE CONVERTER 11 - PARKING LOCK GEAR 2 - OIL PUMP 12 - INTERMEDIATE SHAFT 3 - DRIVESHAFT 13 - FREEWHEEL F2 4 - MULTI-DISC HOLDING CLUTCH B1 14 - REAR PLANETARY GEAR SET 5 - DRIVING CLUTCH K1...
Page 145: Operation
21a - 4 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) SHIFT GROUPS downshift safeguard to prevent over-revving the engine. The system offers the additional advantage of The hydraulic control components (including actua- flexible adaptation to different vehicle and engine tors) which are responsible for the pressure distribu- variants.
Page 146 TRANSMISSION AND TRANSFER CASE 21a - 5 AUTOMATIC TRANSMISSION - W5J400 (Continued) FIRST GEAR POWERFLOW the housing by the engaged multiple-disc holding clutch B2 (6), by the locked freewheel F2 (24) during Torque from the torque converter is increased via acceleration and by the engaged multiple-disc clutch the drive shaft (25) and all three planetary gearsets K3 (12) during deceleration.
Page 147 21a - 6 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 3 First Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 148 TRANSMISSION AND TRANSFER CASE 21a - 7 AUTOMATIC TRANSMISSION - W5J400 (Continued) Center Planetary Gear Set The annulus gear (10) is driven at the same speed as the rear planetary carrier (15) as a result of a mechanical connection. The sun gear (22) is held against the housing by the multiple-disc holding clutch B2 (6).
Page 149 21a - 8 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 5 Second Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 150 TRANSMISSION AND TRANSFER CASE 21a - 9 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 6 Third Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 151 21a - 10 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 7 Third Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 152 TRANSMISSION AND TRANSFER CASE 21a - 11 AUTOMATIC TRANSMISSION - W5J400 (Continued) FOURTH GEAR POWERFLOW Rear Planetary Gear Set The multiple-disc clutch K2 (9) is engaged and Speed and torque are not converted by the direct transfers the input speed of the drive shaft (25) to gear ratio of the 4th gear.
Page 153 21a - 12 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 9 Fourth Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 154 TRANSMISSION AND TRANSFER CASE 21a - 13 AUTOMATIC TRANSMISSION - W5J400 (Continued) FIFTH GEAR POWERFLOW the planetary carrier (15) via the annulus gear (10). The annulus gear (11) turns at a reduced speed due Torque from the torque converter is increased via to the mechanical connection with the front plane- the drive shaft (25) and all three planetary gearsets tary carrier (13).
Page 155 21a - 14 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 11 Fifth Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 156 TRANSMISSION AND TRANSFER CASE 21a - 15 AUTOMATIC TRANSMISSION - W5J400 (Continued) Center Planetary Gear Set The annulus gear (10) is held against the housing by the multiple-disc holding clutch B3 (5) via the mechanical connection to the planetary carrier (15). The sun gear (22) turns backwards due to the engaged multiple-disc clutch K3 (12).
Page 157 21a - 16 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 13 Reverse Gear Powerflow 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS...
Page 158 TRANSMISSION AND TRANSFER CASE 21a - 17 AUTOMATIC TRANSMISSION - W5J400 (Continued) Center Planetary Gear Set The annulus gear (10) is held against the housing by the multiple-disc holding clutch B3 (5) via the mechanical connection to the planetary carrier (15). The sun gear (22) turns backwards due to the engaged multiple-disc clutch K3 (12).
Page 159 21a - 18 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 15 Reverse Gear Powerflow - 4WD Low 1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER 2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER 3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR 4 - HOLDING CLUTCH B1...
Page 160 TRANSMISSION AND TRANSFER CASE 21a - 19 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 16 First Gear Engaged 1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE 2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1 3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1 4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE Shift Phase...
Page 161 21a - 20 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 17 Shift Phase 1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE 2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1 3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1 4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE Second Gear Engaged...
Page 162 TRANSMISSION AND TRANSFER CASE 21a - 21 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 18 Second Gear Engaged 1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE 2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1 3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1 4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE Gear Shift N to D (1st gear) - Engine Started...
Page 163: 1-2/4-5 Shift Solenoid
21a - 22 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 19 Engine Started 1 - HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE 2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE 3 - HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE 4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE...
Page 164: Holding Clutch B1
TRANSMISSION AND TRANSFER CASE 21a - 23 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 20 Activation Sequence 1 - HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE 2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE 3 - HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE 4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE...
Page 165: Diagnosis And Testing
21a - 24 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) • Mechanical malfunctions. sure shift valve (12) and the 3-4 command valve (13) • Electronic malfunctions. to the piston of multiple-disc holding clutch B2 (5). • Transfer case performance. Diagnosis of these problems should always begin DIAGNOSIS AND TESTING by checking the easily accessible variables: fluid level...
Page 166: Diagnosis And Testing - Road Testing
TRANSMISSION AND TRANSFER CASE 21a - 25 AUTOMATIC TRANSMISSION - W5J400 (Continued) VEHICLE IS DRIVABLE (c) If propeller shaft does not turn and transmis- sion is not noisy, perform hydraulic-pressure test to (1) Check for transmission fault codes using DRB determine if problem is hydraulic or mechanical.
Page 167 21a - 26 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) CONDITION POSSIBLE CAUSES CORRECTION LEVER IN P POSITION 1. No Vacuum Brake Booster After 1. Check Vacuum/ Tightness of BLOCKED (BRAKE Long Immobilization, Brake Pedal Brake Booster. ACTIVATED) Not Fully Applied/Hard Pedal.
Page 168 TRANSMISSION AND TRANSFER CASE 21a - 27 AUTOMATIC TRANSMISSION - W5J400 (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO UPSHIFT INTO 5TH 1. The Upshift 4-5 At Full Throttle or 1. Instruct Customer. GEAR WHEN FULL Kick Down Never Occurs Until THROTTLE OR KICK Reaching Cut Off Speed.
Page 169: Standard Procedure - Aluminum Thread Repair
21a - 28 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) CONDITION POSSIBLE CAUSES CORRECTION LEAKAGE AT THE AREA 1. Deformation O-Rings. 1. Replace O-Rings. OF THE ELECTRICAL 2. Deformation Adapter. 2.Replace Adaptor. PLUG TO THE 3. The Conductor Plate Is Not Fitted 3.
Page 170: Disassembly
TRANSMISSION AND TRANSFER CASE 21a - 29 AUTOMATIC TRANSMISSION - W5J400 (Continued) (25) Carefully work transmission and torque con- verter assembly rearward off engine block dowels. (26) Hold torque converter in place during trans- mission removal. (27) Lower transmission and remove assembly from under the vehicle.
Page 171 21a - 30 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 26 Remove Rear Output Shaft Retaining Ring - Typical 1 - RETAINING RING 2 - OUTPUT SHAFT BEARING Fig. 25 Remove Electrohydraulic Unit 1 - HEAT SHIELD 2 - ELECTROHYDRAULIC UNIT 3 - BOLT 4 - OIL FILTER...
Page 172 TRANSMISSION AND TRANSFER CASE 21a - 31 AUTOMATIC TRANSMISSION - W5J400 (Continued) (13) Assemble Puller, Size 5, 8903 (Fig. 27) and Bearing Puller Adapter 8904 onto the output shaft and output shaft bearing. (14) Remove the output shaft bearing (Fig. 28). Fig.
Page 173 21a - 32 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 29 Remove K1, K2, and K3 Clutches 1 - DRIVING CLUTCH K1 5 - THRUST WASHER 2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND DRIVE SHAFT 3 - DRIVING CLUTCH K3, OUTPUT SHAFT , AND CENTER AND 7 - TEFLON RINGS...
Page 174 TRANSMISSION AND TRANSFER CASE 21a - 33 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 30 Remove Holding Clutch B1 and Oil Pump 1 - BOLTS - M6X32 4 - BOLTS - M8X35 2 - CONVERTER HOUSING 5 - HOLDING CLUTCH B1 3 - INTERMEDIATE PLATE 6 - OIL PUMP...
Page 175: Assembly
21a - 34 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 31 Remove B2, B3, and Parking Gear 1 - SNAP-RING 5 - PARK GEAR 2 - HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING 3 - SPRING WASHER 7 - BOLTS - M8X60 4 - HOLDING CLUTCH B2 ASSEMBLY...
Page 176 TRANSMISSION AND TRANSFER CASE 21a - 35 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 32 Install B2, B3, and Parking Gear 1 - SNAP-RING 5 - PARK GEAR 2 - HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING 3 - SPRING WASHER 7 - BOLTS - M8X60 4 - HOLDING CLUTCH B2 Fig.
Page 177 21a - 36 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 35 Install Holding Clutch B1 and Oil Pump 1 - BOLTS - M6X32 4 - BOLTS - M8X35 2 - CONVERTER HOUSING 5 - HOLDING CLUTCH B1 3 - INTERMEDIATE PLATE 6 - OIL PUMP (12) Using grease, insert Teflon rings (7) (Fig.
Page 178 TRANSMISSION AND TRANSFER CASE 21a - 37 AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 37 Install K1, K2, and K3 Clutches 1 - DRIVING CLUTCH K1 5 - THRUST WASHER 2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND DRIVE SHAFT 3 - DRIVING CLUTCH K3, OUTPUT SHAFT , AND CENTER AND 7 - TEFLON RINGS...
Page 179 21a - 38 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) Fig. 38 Measure From Transmission Housing to Fig. 40 Install Rear Output Shaft Retaining Ring - Park Gear Typical 1 - PARALLEL REST 8906 1 - RETAINING RING 2 - PARK GEAR 2 - OUTPUT SHAFT BEARING Fig.
Page 180: Installation
TRANSMISSION AND TRANSFER CASE 21a - 39 AUTOMATIC TRANSMISSION - W5J400 (Continued) (5) Align torque converter to oil pump seal open- ing. (6) Insert torque converter hub into oil pump. (7) While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears.
Page 181 21a - 40 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) (14) Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
Page 182: Specifications - W5J400 Automatic Transmission
TRANSMISSION AND TRANSFER CASE 21a - 41 AUTOMATIC TRANSMISSION - W5J400 (Continued) SPECIFICATIONS - W5J400 AUTOMATIC COMPONENT METRIC (mm) TRANSMISSION B2 Clutch 4 Disc 1.9-2.3 GEAR RATIOS Clearance 5 Disc 2.0-2.4 B2 Clutch Snap-rings 2.9, 3.2, 3.5, 3.59:1 3.8, and 4.1 2.19:1 B3 Clutch Clearance 1.0-1.4...
Page 183: Special Tools - W5J400 Automatic Transmission
21a - 42 TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION - W5J400 (Continued) SPECIAL TOOLS - W5J400 AUTOMATIC TRANSMISSION Puller, Size 5 - 8903 Compressor, Multi-use Spring - 8900 Adapter, Bearing Puller - 8904 Tool, Pressing - 8901 Socket - 8905 Punch, Drift - 8902...
Page 184 TRANSMISSION AND TRANSFER CASE 21a - 43 AUTOMATIC TRANSMISSION - W5J400 (Continued) Parallel Rest - 8906 Tube, Filler - 8909 Pliers - 8907 Pump - 8910 Funnel - 8908...
Page 185: Brake Transmission Shift Interlock
21a - 44 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING - BRAKE BRAKE TRANSMISSION SHIFT TRANSMISSION SHIFT INTERLOCK INTERLOCK MECHANISM SYSTEM VERIFICATION DESCRIPTION (1) Verify that the key can only be removed in the The Brake Transmission Shifter/Ignition Interlock PARK position (BTSI), is a cable and solenoid operated system.
Page 186: Adjustments - Brake Transmission Shift Interlock
TRANSMISSION AND TRANSFER CASE 21a - 45 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued) DIAGNOSTIC CHART CONDITION POSSIBLE CAUSE CORRECTION KEY WILL NOT ROTATE TO THE 1. Misadjusted Park Lock cable. 1. Adjust Park Lock cable. (Refer to OFF/LOCK POSITION. 21 - TRANSMISSION AND TRANSFER CASE/AUTOMATIC TRANSMISSION/BRAKE TRANSMISSION SHIFT...
Page 187 21a - 46 TRANSMISSION AND TRANSFER CASE BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued) Fig. 47 Ignition Interlock Cable 1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY 2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE 3 - ADJUSTMENT CLIP (4) Shifting out of PARK should not be possible Engine starts must not be possible in any other gate while applying normal push-button force, and igni-...
Page 188: Driving Clutches Description
TRANSMISSION AND TRANSFER CASE 21a - 47 A multi-plate driving clutch consists of a number of DRIVING CLUTCHES internally toothed discs (4) on an internally toothed disc carrier and externally toothed discs (3) on an DESCRIPTION externally toothed disc carrier. Three multi-plate driving clutches (Fig.
Page 189: Operation
21a - 48 TRANSMISSION AND TRANSFER CASE DRIVING CLUTCHES (Continued) OPERATION annulus gear (16) of the front planetary gear set is locked with the annulus gear (11) of the center plan- The driving clutches (Fig. 49) produce a non-posi- etary gear set via the externally toothed disc carrier tive locking connection between two elements of a (13) and the center planetary carrier (10) on which planetary gear set or between one element from each...
Page 190 TRANSMISSION AND TRANSFER CASE 21a - 49 (4) Remove snap-ring (10) (Fig. 50). DRIVING CLUTCH K1 (5) Take out disc spring (7) and remove piston (6) by carefully blowing compressed air into the bore (A). DISASSEMBLY (6) Remove snap-ring (3) and take out front free- (1) Remove snap-ring (11) (Fig.
Page 191 21a - 50 TRANSMISSION AND TRANSFER CASE DRIVING CLUTCH K1 (Continued) ASSEMBLY (5) Insert snap-ring (10) (Fig. 51). After installing, check snap-ring for correct seat (1) Install piston (6) (Fig. 51) in the outer multi- ple-disc carrier (1). Check sealing rings (4 and 5), NOTE: Pay attention to sequence of discs.
Page 192 TRANSMISSION AND TRANSFER CASE 21a - 51 DRIVING CLUTCH K1 (Continued) (8) Measure the K1 clutch pack clearance. (a) Mount Pressing Tool 8901 (1) (Fig. 52) on outer multiple disc. (b) Using a lever press, compress pressing tool as far as the stop (then the marking ring is still visible, see small arrow).
Page 193 21a - 52 TRANSMISSION AND TRANSFER CASE DRIVING CLUTCH K2 (Continued) Fig. 54 Driving Clutch K2 Components 1 - K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR 9 - SPRING RETAINER 2 - THRUST BEARING 10 - SNAP-RING 3 - INPUT SHAFT AND K2 CLUTCH 11 - DISC SPRING 4 - PISTON OUTER SEAL RING 12 - MULTIPLE DISC PACK...
Page 194 TRANSMISSION AND TRANSFER CASE 21a - 53 DRIVING CLUTCH K2 (Continued) (3) Place Multi-use Spring Compressor 8900 (Fig. 57) on spring plate (9) and press until the groove of the snap-ring is exposed. (4) Insert snap-ring (10). (5) Insert disk spring (11). NOTE: Pay attention to sequence of discs.
Page 195 21a - 54 TRANSMISSION AND TRANSFER CASE DRIVING CLUTCH K2 (Continued) Fig. 56 Driving Clutch K2 Components 1 - K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR 9 - SPRING RETAINER 2 - THRUST BEARING 10 - SNAP-RING 3 - INPUT SHAFT AND K2 CLUTCH 11 - DISC SPRING 4 - PISTON OUTER SEAL RING 12 - MULTIPLE DISC PACK...
Page 196 TRANSMISSION AND TRANSFER CASE 21a - 55 DRIVING CLUTCH K2 (Continued) Fig. 59 Driving Clutch K2 Stack-up 1 - DISC SPRING 2 - OUTER MULTIPLE DISC - 1.8 MM 3 - OUTER MULTIPLE DISC - 2.8 MM 4 - OUTER MULTIPLE DISC - 4.0 MM 5 - K2 OUTER DISC CARRIER 6 - SNAP-RING Fig.
Page 197 21a - 56 TRANSMISSION AND TRANSFER CASE DRIVING CLUTCH K3 (Continued) Fig. 60 Driving Clutch K3 Components 1 - SNAP-RING 6 - PISTON 2 - MULTIPLE DISC PACK 7 - SEALING RING 3 - DISC SPRING 8 - OUTER DISC CARRIER 4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900 5 - SPRING PLATE...
Page 198: Description
TRANSMISSION AND TRANSFER CASE 21a - 57 DRIVING CLUTCH K3 (Continued) Fig. 62 Driving Clutch K3 Stack-up 1 - OUTER DISC CARRIER 2 - OUTER MULTIPLE DISC - 4.0 MM 3 - OUTER MULTIPLE DISC - 2.8 MM 4 - OUTER MULTIPLE DISC - 1.8 MM 5 - DISC SPRING 6 - PISTON 7 - FRICTION DISCS - 2.1 MM...
Page 199 21a - 58 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Shift Pressure (p-S) Overlap Pressure (p-Ü) The shift pressure is determined by the shift pres- The overlap pressure controls the shift component sure regulating solenoid valve and the shift pressure pressure reduction during a shift phase.
Page 200 TRANSMISSION AND TRANSFER CASE 21a - 59 ELECTROHYDRAULIC UNIT (Continued) Torque Converter Lockup Clutch Regulating Valve Overlap Regulating Valve The torque converter lock-up clutch regulating Each shift group is assigned one overlap regulating valve (Fig. 65) is located in the valve housing of the valve (Fig.
Page 201 21a - 60 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Fig. 67 Command Valve 1 - HOLDING CLUTCH B1 3 - 1-2/4-5 COMMAND VALVE 2 - DRIVING CLUTCH K1 Fig. 68 Holding Pressure Shift Valve 1 - HOLDING PRESSURE SHIFT VALVE Shift Pressure Shift Valve Lubrication Pressure Regulating Valve Each shift group possesses one shift pressure shift...
Page 202 TRANSMISSION AND TRANSFER CASE 21a - 61 ELECTROHYDRAULIC UNIT (Continued) Fig. 69 Shift Pressure Shift Valve 1 - 1-2/4-5 COMMAND VALVE 3 - HOLDING CLUTCH B1 2 - DRIVING CLUTCH K1 4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE Fig. 70 Lubrication Pressure Regulating Valve Fig.
Page 203: Operation
21a - 62 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Regulating Valve Pressure Regulating Valve OPERATION The regulating valve pressure regulating valve ELECTRICAL CONTROL UNIT (Fig. 72) is located in the valve housing of the elec- trohydraulic control module. It regulates the regulat- Signals from the transmission control module ing valve pressure (p-RV).
Page 204 TRANSMISSION AND TRANSFER CASE 21a - 63 ELECTROHYDRAULIC UNIT (Continued) HYDRAULIC CONTROL UNIT Working Pressure Regulating Valve (Operating Pressure) The working pressure (p-A) is regulated at the working pressure regulating valve (22) (Fig. 75) in relation to load (modulating pressure) and gear (K1 or K2 pressure).
Page 205 21a - 64 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Command Valve Shift Valve Holding Pressure When the end face is unpressurized (stationary The holding pressure shift valve (Fig. 79) is actu- phase), the working pressure is directed to the actu- ated by the pressures present at the end face in the ated shift element.
Page 206 TRANSMISSION AND TRANSFER CASE 21a - 65 ELECTROHYDRAULIC UNIT (Continued) Shift Pressure Shift Valve When the multiple-disc brake B1 (3) is activated, the working pressure (pa) is applied to the end face of the 1-2 / 4-5 shift pressure shift valve (4) (Fig. 80) via the command valve (1).
Page 207 21a - 66 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Shift Pressure Regulating Valve Shift Valve Pressure Regulating Valve The shift pressure is determined by the shift pres- The non-constant regulating valve pressure (p-RV) sure regulating solenoid valve and the shift pressure is regulated to a constant shift valve pressure (p-SV) regulating valve (3) (Fig.
Page 208 TRANSMISSION AND TRANSFER CASE 21a - 67 ELECTROHYDRAULIC UNIT (Continued) (5) Disconnect 13-pin plug connector (1) (Fig. 86). Turn bayonet lock of guide bushing (2) anti-clock- wise. Fig. 86 Remove Wiring Connector Plug 1 - PLUG CONNECTOR 2 - GUIDE BUSHING Fig.
Page 209 21a - 68 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Fig. 88 Electrical Unit Components Fig. 89 Shift Valve Group Locations 1 - SOLENOID CAP A - OPERATING AND LUBRICATING PRESSURE REGULATING VALVES AND 2-3 OVERLAP VALVE 2 - SOLENOID CAP B - 1-2/4-5 SHIFT GROUP AND SHIFT, SHIFT VALVE, AND 3 - BOLT - M6X32 REGULATING VALVE PRESSURE REGULATING VALVES...
Page 210 TRANSMISSION AND TRANSFER CASE 21a - 69 ELECTROHYDRAULIC UNIT (Continued) (15) Note the location of all check balls (1, 3, 4) (Fig. 93) and the central strainer (2) for re-installa- tion. Remove all check balls (1, 3, 4) and the central strainer (2).
Page 211: Assembly
21a - 70 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Fig. 94 Valve Body Components 1 - VALVE BODY 8 - SHIFT VALVE PRESSURE REGULATING VALVE 2 - 1-2/4-5 COMMAND VALVE 9 - B2 SHIFT VALVE 3 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE 10 - 2-3 HOLDING PRESSURE SHIFT VALVE 4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 11 - 2-3 COMMAND VALVE...
Page 212 TRANSMISSION AND TRANSFER CASE 21a - 71 ELECTROHYDRAULIC UNIT (Continued) Fig. 95 Valve Housing Components 1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE 2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE 4 - 3-4 HOLDING PRESSURE SHIFT VALVE...
Page 213 21a - 72 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) (2) Install all valves and springs from the valve (4) Install the screws to hold the side covers to the body (1) (Fig. 98). Check all valves for ease of move- valve body and valve housing.
Page 214 TRANSMISSION AND TRANSFER CASE 21a - 73 ELECTROHYDRAULIC UNIT (Continued) Fig. 99 Valve Housing Components 1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE 2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE 4 - 3-4 HOLDING PRESSURE SHIFT VALVE...
Page 215 21a - 74 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) (8) Install the valve housing (2) onto the valve (12) Install the electrohydraulic control module body (4) and sealing plate (3). (12) onto the shift plate (13) (Fig. 104). (9) Install the shift plate Torx bolts (1) (Fig. 102). (13) Bend the retaining lug on stiffening rib on Tighten the bolts to 8 N·m.
Page 216 TRANSMISSION AND TRANSFER CASE 21a - 75 ELECTROHYDRAULIC UNIT (Continued) INSTALLATION (1) Position the electrohydraulic unit in the trans- mission housing. (2) Insert selector valve (1) (Fig. 105) in driver of detent plate (2). When installing the electrohydraulic control module in the transmission housing, the plas- tic part of the selector valve (1) must engage in the driver of the detent plate (2).
Page 217: Description
21a - 76 TRANSMISSION AND TRANSFER CASE ELECTROHYDRAULIC UNIT (Continued) Fig. 108 Install Heat Shield 1 - SCREW 2 - HEAT SHIELD 3 - BOLT FLUID AND FILTER Fig. 109 Fluid Level Control 1 - GEARSET CHAMBER DESCRIPTION 2 - OIL GALLERY The oil level control (Fig.
Page 218 TRANSMISSION AND TRANSFER CASE 21a - 77 FLUID AND FILTER (Continued) DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: • adding incorrect fluid • failure to clean dipstick and fill tube when checking level •...
Page 219 21a - 78 TRANSMISSION AND TRANSFER CASE FLUID AND FILTER (Continued) (6) Warm up the transmission, wait at least 2 min- STANDARD PROCEDURE utes and check the oil level with the engine running. Push the Oil Dipstick 8863 in up to the stop and pull STANDARD PROCEDURE - CHECK OIL LEVEL out again, read off oil level, repeat if necessary.
Page 220 TRANSMISSION AND TRANSFER CASE 21a - 79 FLUID AND FILTER (Continued) Fig. 112 W5J400 Fill Level Chart Fig. 113 Dipstick Tube Cap Components Fig. 114 Remove Dipstick Tube Cap Lock 1 - LOCKING PIN 1 - LOCKING PIN 2 - TUBE CAP 2 - TUBE CAP 3 - DIPSTICK TUBE 3 - DIPSTICK TUBE...
Page 221 21a - 80 TRANSMISSION AND TRANSFER CASE OPERATION FREEWHEELING CLUTCH The freewheeling clutch (Fig. 116) optimizes indi- DESCRIPTION vidual gearshifts. They lock individual elements of a planetary gear set together or against the transmis- Freewheeling clutches (Fig. 115) are installed in sion housing in one direction of rotation to allow the the front planetary gear set between the sun gear torque to be transmitted.
Page 222 TRANSMISSION AND TRANSFER CASE 21a - 81 FREEWHEELING CLUTCH (Continued) DISASSEMBLY (1) Remove retaining ring (5) (Fig. 117) from hol- low shaft (1). (2) Remove rear sun gear (4) with the K3 inter- nally toothed disk carrier and rear freewheeling clutch F2 (3).
Page 223 21a - 82 TRANSMISSION AND TRANSFER CASE FREEWHEELING CLUTCH (Continued) (6) Check the anti-friction bearing (Fig. 118) in the ASSEMBLY rear planetary sun gear for damage. Replace as nec- (1) Press freewheeling clutch F2 (3) (Fig. 119) into essary. sun gear (4). (2) Install snap-ring (2) for freewheeling clutch.
Page 224 TRANSMISSION AND TRANSFER CASE 21a - 83 FREEWHEELING CLUTCH (Continued) Fig. 119 Freewheeling Clutch F2 1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR 2 - SNAP-RING 5 - RETAINING RING 3 - FREEWHEELING CLUTCH F2 6 - O-RINGS GEARSHIFT CABLE (3) With floor shift lever handle push-button not...
Page 225 21a - 84 TRANSMISSION AND TRANSFER CASE GEARSHIFT CABLE (Continued) REMOVAL (1) Shift transmission into PARK. (2) Raise vehicle. (3) Remove the shift cable eyelet from the trans- mission manual shift lever. (4) Remove shift cable from the cable support bracket.
Page 226: Description
TRANSMISSION AND TRANSFER CASE 21a - 85 GEARSHIFT CABLE (Continued) (13) Verify that the shift lever is in the PARK posi- (6) Verify transmission shift lever is in PARK tion. detent by moving lever fully rearward. Last rearward (14) Push and hold forward on the shifter handle detent is PARK position.
Page 227 21a - 86 TRANSMISSION AND TRANSFER CASE HOLDING CLUTCHES (Continued) Fig. 123 Holding Clutches 1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR 2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS 3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR 4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS...
Page 228 TRANSMISSION AND TRANSFER CASE 21a - 87 HOLDING CLUTCHES (Continued) Fig. 124 Holding Clutches 1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR 2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS 3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR 4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS...
Page 229 21a - 88 TRANSMISSION AND TRANSFER CASE HOLDING CLUTCH B1 DISASSEMBLY (1) Remove snap-ring (7) (Fig. 125). (2) Remove multiple-disc pack (6) and disc spring (5) from outer multiple-disc carrier. (3) Place the Multi-use Spring Compressor 8900 (8) (Fig. 125) on disc spring (3) and compress the spring until the snap-ring (4) is exposed.
Page 230 TRANSMISSION AND TRANSFER CASE 21a - 89 HOLDING CLUTCH B1 (Continued) ASSEMBLY (3) Insert disc spring (5) and multiple-disc pack (6) in the outer multiple-disc carrier. (1) Install piston (2) (Fig. 126) in outer multiple- (4) Insert snap-ring (7). disc carrier (1). Press in piston using the disc spring (3) and Multi-use Spring Compressor 8900 (8).
Page 231 21a - 90 TRANSMISSION AND TRANSFER CASE HOLDING CLUTCH B1 (Continued) (5) Measure B1 clutch clearance. (a) Mount Pressing Tool 8901 (1) (Fig. 127) on outer multiple disc. (b) Using a lever press (Fig. 127), compress pressing tool as far as the stop (then the marking ring is still visible, see small arrow).
Page 232 TRANSMISSION AND TRANSFER CASE 21a - 91 HOLDING CLUTCH B2 (Continued) Fig. 129 Holding Clutch B2 1 - SNAP-RING 9 - B3 PISTON SEALING RING 2 - MULTIPLE DISC PACK 10 - B2 PISTON 3 - DISC SPRING 11 - PISTON GUIDE SEALING RING 4 - B2 AND B3 PISTON GUIDE 12 - PISTON GUIDE SEALING RING 5 - O-RING...
Page 233 21a - 92 TRANSMISSION AND TRANSFER CASE HOLDING CLUTCH B2 (Continued) (6) Separate piston guide ring (13) and the B2 pis- (4) Insert piston guide ring (2) (Fig. 133). The ton (10) from the B3 piston (8) by blowing com- valve (1) in the piston guide ring must be on top.
Page 234 TRANSMISSION AND TRANSFER CASE 21a - 93 HOLDING CLUTCH B2 (Continued) Fig. 131 Holding Clutch B2 1 - SNAP-RING 9 - B3 PISTON SEALING RING 2 - MULTIPLE DISC PACK 10 - B2 PISTON 3 - DISC SPRING 11 - PISTON GUIDE SEALING RING 4 - B2 AND B3 PISTON GUIDE 12 - PISTON GUIDE SEALING RING 5 - O-RING...
Page 235 21a - 94 TRANSMISSION AND TRANSFER CASE HOLDING CLUTCH B2 (Continued) Fig. 132 Holding Clutch B2/B3 Seals 1 - PISTON GUIDE RING 4 - B3 PISTON SEALING RING 2 - PISTON GUIDE RING SEALING RING 5 - B3 PISTON/B2 OUTER DISC CARRIER 3 - PISTON GUIDE RING SEALING RING 6 - B3 PISTON SEALING RING...
Page 236: Operation
TRANSMISSION AND TRANSFER CASE 21a - 95 HOLDING CLUTCH B2 (Continued) Fig. 135 B2 Clutch Stack-up 1 - B2 OUTER DISC CARRIER 2 - FRICTION DISCS 3 - DISC SPRING 4 - B2 PISTON 5 - OUTER MULTIPLE DISC - 1.8 MM 6 - OUTER MULTIPLE DISC - 1.8 MM Fig.
Page 237: Operation
21a - 96 TRANSMISSION AND TRANSFER CASE INPUT SPEED SENSORS (Continued) OIL PUMP DESCRIPTION The oil pump (Fig. 138) (crescent-type pump) is installed in the torque converter casing behind the torque converter and is driven by the drive flange of the torque converter.
Page 238 TRANSMISSION AND TRANSFER CASE 21a - 97 OIL PUMP (Continued) (2) Remove the inner oil pump seal (1) (Fig. 141). (3) Replace the outer oil pump O-ring (2) (Fig. 141). Fig. 139 Oil Pump 1 - CRESCENT 2 - OIL PUMP 3 - EXTERNAL GEAR Fig.
Page 239: Removal
21a - 98 TRANSMISSION AND TRANSFER CASE OIL PUMP (Continued) (3) Lubricate pump gears and place in the pump PARK LOCK CABLE housing. Insert pump gear (1) (Fig. 143) so that the chamfer (arrow) points towards the pump housing. REMOVAL (1) Place the shifter in the PARK position.
Page 240 TRANSMISSION AND TRANSFER CASE 21a - 99 PARK LOCK CABLE (Continued) INSTALLATION NOTE: The gearshift cable must be secured into position and properly adjusted before the installa- tion of the Park Lock Cable. (1) Verify that the shifter is in the PARK position. (2) Push the park lock cable straight into the square mounting hole in the steering column until cable snaps in place.
Page 241 21a - 100 TRANSMISSION AND TRANSFER CASE PISTONS (Continued) PISTON TRAVEL The relationship between hydraulic lever and a mechanical lever is the same. With a mechanical lever it’s a weight-to-distance output rather than a pressure-to-area output. Using the same forces and areas as in the previous example, the smaller piston (Fig.
Page 242 TRANSMISSION AND TRANSFER CASE 21a - 101 PLANETARY GEARTRAIN DESCRIPTION Three planetary gear sets (Fig. 149) are used to produce the different gear ratios. These are located in the mechanical part of the transmission as the front, middle and rear planetary gear sets. Fig.
Page 243 21a - 102 TRANSMISSION AND TRANSFER CASE PLANETARY GEARTRAIN (Continued) Fig. 151 Output Shaft with Center and Rear Planetary Geartrain 1 - TEFLON RINGS 7 - DRIVING CLUTCH K3 2 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER 8 - THRUST WASHER 3 - NEEDLE BEARING 9 - AXIAL NEEDLE BEARING 4 - THRUST WASHER...
Page 244 TRANSMISSION AND TRANSFER CASE 21a - 103 PLANETARY GEARTRAIN (Continued) Fig. 152 Output Shaft with Center and Rear Planetary Geartrain 1 - TEFLON RINGS 7 - DRIVING CLUTCH K3 2 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER 8 - THRUST WASHER 3 - NEEDLE BEARING 9 - AXIAL NEEDLE BEARING 4 - THRUST WASHER...
Page 245: Shift Mechanism
21a - 104 TRANSMISSION AND TRANSFER CASE PLANETARY GEARTRAIN (Continued) • Manual fourth (4) (8) Inspect axial play (Fig. 153) between shim (10) • Manual third (3) and retaining ring (11). Check axial play S between • Manual second (2) shim (10) and retaining ring (1) using a feeler gauge.
Page 246 TRANSMISSION AND TRANSFER CASE 21a - 105 SHIFT MECHANISM (Continued) SLSA GREY CODE TABLE PARK REVERSE NEUTRAL PARK LOCKOUT SOLENOID The SLSA contains a park lockout solenoid. The park lockout solenoid is energized by the TCM when- ever the shift position is not PARK and vehicle speed is above 10 kph (6 mph).
Page 247 21a - 106 TRANSMISSION AND TRANSFER CASE SHIFT MECHANISM (Continued) Fig. 155 Ignition Interlock Cable 1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY 2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE 3 - ADJUSTMENT CLIP Fig. 156 Transfer Case Shift Cable 1 - CLIP 2 - SHIFTER 3 - TRANSFER CASE SHIFT LEVER PIN...
Page 248 TRANSMISSION AND TRANSFER CASE 21a - 107 SHIFT MECHANISM (Continued) INSTALLATION A solenoid is an electromechanical device that uses a magnetic force to perform work. It consists of a coil (1) Install shifter assembly onto the shifter assem- of wire, wrapped around a magnetic core made from bly studs on the floor pan.
Page 249 21a - 108 TRANSMISSION AND TRANSFER CASE SOLENOID (Continued) UPSHIFT/DOWNSHIFT SOLENOID VALVES MODULATING PRESSURE CONTROL SOLENOID The solenoid valves for upshifts and downshifts VALVE (Fig. 158) are located in the shell of the electric con- The modulating pressure control solenoid valve trol unit and pressed against the shift plate with a (Fig.
Page 250 TRANSMISSION AND TRANSFER CASE 21a - 109 SOLENOID (Continued) TORQUE CONVERTER LOCKUP CLUTCH PWM SHIFT PRESSURE CONTROL SOLENOID VALVE SOLENOID VALVE The shift pressure control solenoid valve (1) (Fig. 161) is located in the shell of the electric valve con- The torque converter lockup clutch PWM solenoid trol unit and pressed against the shift plate by a valve (1) (Fig.
Page 251 21a - 110 TRANSMISSION AND TRANSFER CASE SOLENOID (Continued) The plunger is made of a conductive material and MODULATING PRESSURE CONTROL SOLENOID accomplishes this movement by providing a path for VALVE the magnetic field to flow. By keeping the air gap The modulating pressure regulating solenoid valve between the plunger and the coil to the minimum (1) (Fig.
Page 252 TRANSMISSION AND TRANSFER CASE 21a - 111 SOLENOID (Continued) TORQUE CONVERTER LOCKUP CLUTCH PWM SHIFT PRESSURE CONTROL SOLENOID VALVE SOLENOID VALVE The shift pressure regulating solenoid valve (1) (Fig. 165) assigns a proportional pressure to the cur- The torque converter lockup PWM solenoid (1) rent which is controlled by the TCM according to the (Fig.
Page 253 21a - 112 TRANSMISSION AND TRANSFER CASE TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT (Continued) manent magnet (3) is moved away from the dry-reed contact (4). The dry-reed contact (4) is opened. The TCM receives an electric signal. The circuit to the starter in the selector lever positions P and N is closed.
Page 254: Specifications
TRANSMISSION AND TRANSFER CASE 21a - 113 TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT (Continued) Refer to the Transmission Temperature Sensor TORQUE CONVERTER Specifications table (Fig. 170) for the relationship between transmission temperature, sensor voltage, DESCRIPTION and sensor resistance. The torque converter (Fig. 171) is a hydraulic device that couples the engine crankshaft to the transmission.
Page 255 21a - 114 TRANSMISSION AND TRANSFER CASE TORQUE CONVERTER (Continued) IMPELLER TURBINE The impeller (Fig. 172) is an integral part of the The turbine (Fig. 173) is the output, or driven, converter housing. The impeller consists of curved member of the converter. The turbine is mounted blades placed radially along the inside of the housing within the housing opposite the impeller, but is not on the transmission side of the converter.
Page 256 TRANSMISSION AND TRANSFER CASE 21a - 115 TORQUE CONVERTER (Continued) Fig. 173 Turbine 1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER 2 - ENGINE ROTATION 5 - ENGINE ROTATION 3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION STATOR The stator assembly (Fig.
Page 257 21a - 116 TRANSMISSION AND TRANSFER CASE TORQUE CONVERTER (Continued) Fig. 175 Stator Location Fig. 176 Torque Converter Lock-up Clutch 1 - STATOR 1 - TURBINE 2 - IMPELLER 2 - IMPELLER 3 - FLUID FLOW 3 - STATOR 4 - TURBINE 4 - INPUT SHAFT 5 - STATOR SHAFT TORQUE CONVERTER CLUTCH (TCC)
Page 258 TRANSMISSION AND TRANSFER CASE 21a - 117 TORQUE CONVERTER (Continued) STATOR Torque multiplication is achieved by locking the stator’s over-running clutch to its shaft (Fig. 177). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter- clockwise direction.
Page 259: Transfer Case - Nv247
21a - 118 TRANSMISSION AND TRANSFER CASE TORQUE CONVERTER (Continued) PARTIAL EMCC (3) Align torque converter to oil pump seal open- ing. Partial EMCC operation modulates the TCC Sole- (4) Insert torque converter hub into oil pump. noid (duty cycle) to obtain partial torque converter (5) While pushing torque converter inward, rotate clutch application.
Page 260 TRANSMISSION AND TRANSFER CASE 21a - 119 TRANSFER CASE - NV247 (Continued) (7) Disconnect the transfer case shift cable from the shifter arm (Fig. 182). Fig. 180 Front Driveshaft Retaining Bolts 1 - TRANSFER CASE 2 - FRONT DRIVESHAFT RETAINING BOLTS Fig.
Page 261 21a - 120 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) Fig. 185 Remove Damper 1 - DAMPER 2 - TRANSFER CASE (3) Install two bolts (Fig. 186) partially into the Fig. 183 Transmission Support Crossmember rear propellor shaft companion flange, 180° from Position and Orientation each other.
Page 262 TRANSMISSION AND TRANSFER CASE 21a - 121 TRANSFER CASE - NV247 (Continued) (10) Remove the screws holding the transfer case chain snubber (Fig. 190) to the rear transfer case half. Fig. 187 Remove Companion Flange 1 - TRANSFER CASE 2 - COMPANION FLANGE 3 - REMOVER C-452 Fig.
Page 263 21a - 122 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) Fig. 192 Disengage Oil Pump Tube From Oil Pump Fig. 194 Pick-up Tube O-ring Location 1 - OIL PUMP PICKUP TUBE 1 - OIL PUMP 2 - OIL PUMP 2 - O-RING NOTE: Note position of range lever so it can be re- installed correctly.
Page 264 TRANSMISSION AND TRANSFER CASE 21a - 123 TRANSFER CASE - NV247 (Continued) FRONT OUTPUT SHAFT AND DRIVE CHAIN (1) Remove rear output shaft drive gear snap-ring (Fig. 198). (2) Disengage drive gear (Fig. 199). Pry gear upward and off mainshaft as shown. (3) Remove front output shaft, drive chain and drive gear as assembly (Fig.
Page 265 21a - 124 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) (4) Remove front output shaft drive gear snap- ring. (Fig. 200) (5) Remove output shaft drive gear from front out- put shaft. (Fig. 201) Fig. 202 Remove Oil Pump Pickup Tube 1 - OIL PUMP PICKUP TUBE 2 - FRONT CASE HALF Fig.
Page 266 TRANSMISSION AND TRANSFER CASE 21a - 125 TRANSFER CASE - NV247 (Continued) (2) Remove shift rail from shift fork and transfer case housing. (3) Rotate range shift fork until it disengages from shift sector. (4) Remove mainshaft and shift fork from input gear pilot bearing.
Page 267 21a - 126 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) INPUT AND LOW RANGE GEAR (1) Remove snap-ring that retains input gear in low range gear (Fig. 207). (2) Remove retainer (Fig. 208). (3) Remove front tabbed thrust washer (Fig. 209). (4) Remove input gear (Fig.
Page 268 TRANSMISSION AND TRANSFER CASE 21a - 127 TRANSFER CASE - NV247 (Continued) Fig. 211 Rear Tabbed Thrust Washer Removal 1 - LOW RANGE GEAR 2 - REAR TABBED THRUST WASHER Examine the input gear carefully. Be sure the gear teeth and bearing surfaces are in good condition. Replace the gear if wear or damage is evident.
Page 269 21a - 128 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) Check condition of each transfer case bearing. Replace any bearing exhibiting signs of roughness, wear, or damage. ASSEMBLY Lubricate transfer case components with Mopar Transfer Case Lubricant or petroleum jelly (where indicated) during assembly.
Page 270 TRANSMISSION AND TRANSFER CASE 21a - 129 TRANSFER CASE - NV247 (Continued) Fig. 216 Front Output Seal Installation 1 - INSTALLER 6952-A 2 - TRANSFER CASE (7) Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 Fig.
Page 271 21a - 130 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) Fig. 220 Input Shaft Bearing Removal 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL C-4210 (12) Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing Fig.
Page 272 TRANSMISSION AND TRANSFER CASE 21a - 131 TRANSFER CASE - NV247 (Continued) Fig. 225 Sector O-Ring And Bushing Installation Fig. 223 Input/Low Range Gear Components 1 - SECTOR BUSHING 2 - O-RING 1 - SNAP-RING 2 - RETAINER PLATE 3 - INPUT GEAR 4 - LOW RANGE GEAR 5 - THRUST WASHERS Fig.
Page 273 21a - 132 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) (7) Install shift rail to shift range fork and trans- fer case housing. (8) Rotate shift sector to NEUTRAL position. (9) Install new O-ring on detent plug (Fig. 227). (10) Lubricate detent plunger with transfer case lubricant or light coat of petroleum jelly.
Page 274 TRANSMISSION AND TRANSFER CASE 21a - 133 TRANSFER CASE - NV247 (Continued) PROGRESSIVE COUPLING (1) Install progressive coupling (Fig. 233). (2) Install the progressive coupling thrust washer (Fig. 234) over the output shaft and against the cou- pling. (3) Install the progressive coupling snap-ring (Fig. 235) onto the output shaft.
Page 275 21a - 134 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) Fig. 235 Install Progressive Coupler Snap-ring Fig. 237 Install Oil Pump Snap-ring 1 - PROGRESSIVE COUPLING SNAP-RING 1 - OIL PUMP SNAP-RING 2 - PROGRESSIVE COUPLING 2 - OIL PUMP OIL PUMP (1) Install new O-ring on flanged end of oil pickup tube.
Page 276 TRANSMISSION AND TRANSFER CASE 21a - 135 TRANSFER CASE - NV247 (Continued) COMPANION FLANGE AND RANGE LEVER (1) Install range lever, washer and locknut on sec- tor shaft (Fig. 242). Tighten locknut to 27-34 N·m (20-25 ft. lbs.) torque. Fig. 239 Installing Case Magnet 1 - MAGNET Fig.
Page 277 21a - 136 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) INSTALLATION NOTE: If a replacement transfer case is being installed, be certain the counter weight is installed on the transfer case housing prior to installation. (1) Install the transfer case on the transmission. Torque the transfer case retaining nuts to 75 N·m (55 ft.
Page 278: Transfer Case - Nv247
TRANSMISSION AND TRANSFER CASE 21a - 137 TRANSFER CASE - NV247 (Continued) (5) Install the rear driveshaft. Torque the bolts to (6) Install the front driveshaft. Torque the bolts to 32 N·m (24 ft. lbs.). Be certain to install the drive- 32 N·m (24 ft.
Page 279 21a - 138 TRANSMISSION AND TRANSFER CASE TRANSFER CASE - NV247 (Continued) SPECIAL TOOLS TRANSFER CASE - NV247 Remover, Bearing - C-4210 Installer, Bearing - 5066 Remover, Bearing - L-4454 Installer, Seal - 6952-A Installer, Bearing - 6953 Cup, Installer - 8148 Installer, Seal - C-3995-A Installer, Bearing - 8128 Installer, Seal - 7884...
Page 280 EMISSIONS CONTROL - 2.7L DIESEL 25a - 1 EMISSIONS CONTROL - 2.7L DIESEL TABLE OF CONTENTS page page EMISSIONS CONTROL - 2.7L DIESEL EXHAUST GAS RECIRCULATION ... . 2 DESCRIPTION .
Page 281 25a - 2 EXHAUST GAS RECIRCULATION EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page page EXHAUST GAS RECIRCULATION REMOVAL ......3 DESCRIPTION .
Page 282 EXHAUST GAS RECIRCULATION 25a - 3 REMOVAL VALVE (1) Remove engine cover (Refer to 9 - ENGINE - DESCRIPTION REMOVAL). (2) Disconnect EGR valve vacuum line (Fig. 2). The egr valve is mounted to the intake manifold at (3) Remove EGR valve retaining bolts and EGR the left rear corner of the engine (Fig.
Page 283 25a - 4 EXHAUST GAS RECIRCULATION INSTALLATION SOLENOID (1) Position and install EGR solenoid onto bracket. DESCRIPTION (2) Connect engine vacuum harness to EGR sole- noid. The EGR solenoid is mounted in the left-rear of the (3) Connect EGR solenoid electrical connector. engine compartment (Fig.
Page 284 ON-BOARD DIAGNOSTICS 25a - 5 ON-BOARD DIAGNOSTICS TABLE OF CONTENTS page ON-BOARD DIAGNOSTICS DESCRIPTION - DIAGNOSTIC TROUBLE CODES ......5 ON-BOARD DIAGNOSTICS DESCRIPTION - DIAGNOSTIC TROUBLE CODES On the following pages, a list of DTC’s is provided...
Page 285 25a - 6 ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS (Continued) ENGINE CONTROL MODULE (ECM) - DRBIII CODES Generic Scan Tool Code DRB III Scan Tool Display P0070 Ambient Air Temperature Circuit Signal Voltage Too High Ambient Air Temperature Circuit Signal Voltage Too Low P0100 Mass Air Flow Sensor Signal Voltage Too High Mass Air Flow Sensor Signal Voltage Too Low...
Page 286 ON-BOARD DIAGNOSTICS 25a - 7 ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB III Scan Tool Display P0235 Boost Pressure Sensor Plausibility Boost Pressure Sensor Signal Voltage Too Low Boost Pressure Sensor Signal Voltage Too High Boost Pressure Sensor Signal Voltage Too High Or Low P0243 Boost Pressure EVM Short Circuit Boost Pressure EVM Open Circuit...
Page 287 25a - 8 ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB III Scan Tool Display P0579 Speed Control Switch Signal Too High Speed Control Switch Signal Too Low Speed Control Switch Plausibility Error P0606 ECM Recovery Flag ECM Redundant Monitoring ECM Gate Array Monitoring P0615 Starter Relay Circuit Short Circuit...
Page 288 ON-BOARD DIAGNOSTICS 25a - 9 ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB III Scan Tool Display P0703 Brake Switch Signal Plausibility Brake Switch Signal Plausibility After Initialization P0836 4 Wheel Drive Switch Signal Too Low 4 Wheel Drive Switch Signal Too High 4 Wheel Drive Switch Plausibility Error 2 4 Wheel Drive Switch Plausibility Error 1 P0850...
Page 289 25a - 10 ON-BOARD DIAGNOSTICS ON-BOARD DIAGNOSTICS (Continued) Generic Scan Tool Code DRB III Scan Tool Display P1608 A to D Monitoring, RAM Test Failure A to D Monitoring, Ground Connection to PPS Failure A to D Monitoring, Test Voltage Failure P1610 5 Voltage Supply Too High 5 Voltage Supply Too Low...
Page 290 SERVICE MANUAL COMMENTS What errors(s) have you found? ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ In order for us to assist you, please include as much details as possible when reporting an error Comments / Suggestions ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ □ □ Dealership Technician Retail Customer Dealer Code: Manual Title, Year, Number and Page: _________________________________________________...
Page 291 DaimlerChrysler Corporation Attn. Publications Dept. CIMS 486-02-70 800 Chrysler Drive Auburn Hills, MI 48326-2757...

Jeep 2002 WJ Service Manual

Lubrication & Maintenance

International Symbols

Parts & Lubricant Recommendation

Fluid Types

Fluid Fill/Check Locations

Maintenance Schedules Description

Lift Points

Jump Starting

Emergency Tow Hooks

Towing

Accessory Drive

Drive Belts

Belt Tensioners Description

Engine

Coolant Description

Coolant Recovery Pressure Container Description

Engine Coolant Temp Sensor Removal

Engine Coolant Thermostat Removal

Water Pump Removal

Radiator Fan Description

Radiator Pressure Cap Description

Lubrication &

Maintenance

Engine Systems

Generator Description

Generator Decoupler Pulley Description

Engine

Cylinder Head Cover(S) Removal

Valve Springs

Camshaft(S)

Engine Block Standard Procedure Standard Procedure - Replacing Engine Core and Oil Gallery Plugs

Crankshaft

Crankshaft Oil Seal - Rear Removal

Crankshaft Oil Seal - Front Removal

Flywheel Removal

Piston & Connecting Rod Description

Piston Rings

Vibration Damper Removal

Vacuum Pump Description

Oil Pan Removal

Oil Jet Description

Oil Pump Removal Removal

Oil Cooler & Lines

Intake Manifold

Timing Chain Cover

Timing Chain Tensioner

Exhaust System and Turbocharger - 2.7L Diesel

Exhaust System and Turbocharger - 2.7L Diesel

Wastegate

Charge Air Cooler and Plumbing Description

Fuel System

Camshaft Position Sensor

Crankshaft Position Sensor Description

Fuel Pressure Sensor Description

Fuel Rail Description

Fuel Injection

Manifold Air Flow (Maf) Sensor Description

Fuel Pressure Solenoid Description

Boost Pressure Sensor Description

Intake Air Temperature Sensor Description

Fuel Delivery

Fuel Pump

Fuel Lines

Transmission and Transfer Case

Table of Contents

2 2/4-5 Overlap Valve

4 2/4-5 Holding Pressure Shift Valve

Diagnosis and Testing - Brake Transmission Shift Interlock

Driving Clutch K1

Driving Clutches Description

Transfer Case - Nv247

Quick Links

Chapters

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Questions and answers

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Summary of Contents for Jeep 2002 WJ